WeatherTech AlloyCover Quick start guide

Thank you for purchasing the AlloyCover™from WeatherTech®. Manufactured with

pride using superior quality materials and workmanship. With proper care, your cover

will provide years of service and enjoyment.

NOTICE TO INSTALLER: It is recommended instructions are read before installation,

even if familiar with cover. Improvements may be made without prior notice. Always

handle cover and components with care. If you have any problems or questions, have

serial number ready and call customer service. When done, this owner’s manual must

be given to the consumer.

NOTICE TO CONSUMER: Before using cover, read operating, maintenance, and safety

sections and save owner’s manual for future reference.

INSTALLATION INSTRUCTIONS AND OWNER’S MANUAL

Questions? (800) 441-6287

.com

1 MacNeil Ct, Bolingbrook, IL 60440

NOTE ON BED LINERS: With an under-the-rail drop-in bed liner, installation is possible

with minimal trim/cutting of bed liner at front corner of box and back by tailgate to allow

side rail to install properly. Considerable trim/cutting is required with an over-the-rail

drop-in bed liner.

NOTE: For additional protection against the elements, locate and seal miscellaneous

factory holes, crevices, stake pockets, etc. that may be on box (sealant not included).

NOTE: Rails may be contoured to follow the shape of the box.

Rail clamps

Unpack cover components and clean truck box if dirty.

COMPONENTS:

(1) Driver side rail

(1) Passenger side rail

(8) Clamps

(1) Pre-folded cover assembly

TOOLS NEEDED:

- 1/2" wrench

- Torque wrench with 1/2" socket

- Spring clamp - optional

- Tape measure or ruler

- Protective eyewear

- Marking pen

Left side rail

Front catch

towards front of box

Right

side rail

Latch on rear

panel

Cover assembly

Front of cover (closest to

cab) has storage

clip retainers

PREPARATION

PARTS DIAGRAM

2 3

NOTE: Some installs require special

instructions. Follow the special instructions

for rail attachment along with these

standard instructions.

A. Position side rail with weather strip

against inside lip of box and front

catch towards front of box. Push rail

forward until it touches front of box

Top of rail ﬂush with top

of box and touching front

of box

This surface of rail

should be level

Adjust

clamps up

or down until

rail is level

when tightened

STEP 1: INSTALLING COVER SIDE RAILS

Top of rail ﬂush

with top of box

Rear clamp Front

clamp

Middle clamps

Narrow leg

on inside

B. Ensure each half clamp has a wide

and narrow offset positioned at top

and bottom. Adjust top of rail ﬂush

with top of box, hold with assistance

of another person or spring clamp.

Install ﬁrst clamp as close to front

as possible and use 1/2" wrench to

tighten. IMPORTANT: To keep rail

secured on truck, ensure clamp teeth

engage grooves on rail, turn nut ﬁnger

tight, use wrench to ﬁnish tightening.

C. Check if the rail is level. If rail tilts

up, loosen clamp; lower it; engage

teeth; and retighten. If rail tilts down,

loosen clamp; raise it; engage teeth;

and retighten. For further leveling

capabilities, clamp assembly may be

rotated 180°.

D. With rail ﬂush with top of box, install

two middle clamps equally spaced

from front to rear. At rear of box,

place rear clamp as close to tailgate

as possible, always make sure teeth

engage grooves on rail. Repeat Step 1

to install rail on opposite side. When

done, make sure all clamps are

torqued to

20 ft-lbs.

Equally space middle clamps

between front and rear clamps

Wide Narrow

STEP 2: INSTALLING COVER

D. Unfold rear panel towards tailgate.

Hooks on rear panel will

automatically engage rear catch

on each side rail. Latches will

automatically engage each side

rail at rear of box.

NOTE: Make sure all latches fully

engage the side rails when

closing cover.

C. Unhook storage clips at front of

cover and unfold middle panel

towards tailgate. Hooks on middle

panel will automatically engage

middle catch on each side.

A. Lift folded cover above rails and place

leading edge of front panel on rails at

front of box. Hold rear edge of folded

cover 1" above rails and slide cover

hooks underneath front catch on

each side.

B. With cover hooks engaged underneath

front catches, lower cover and engage

latch in retainment bracket on

each side.

NOTE: Retainment brackets may be

loosened, adjusted and retightened

with a 7/16" wrench as needed.

Front catch

both sides

Front cover hook

both sides

Latch

both sides

Unhook storage

clips both sides

Latches will engage side

rails at rear of box

Retainment

bracket

both sides

4 5

PROBLEM

Gap between cover

and tailgate

Rails set too high (Refer to Step 1C)

Top of tailgate hits cover when

attempting to close

Rails set too low at rear of cover, raise

rails at rear of box until cover no longer

interferes with tailgate operation (Refer to

Step 1C)

Latch doesn’t engage Check side rails for height and level. (Refer

to Step 1) Inspect latches for jammed or

broken parts

Cover is not parallel with rails With cover installed on box, loosen

hardware on both retainment

brackets (DO NOT REMOVE HARDWARE).

Unfold cover to closed position and square

up with box. Carefully fold cover back to

open position and retighten retainment

bracket hardware.

Seal on edge of cover is not sealing

tight against top of box

Rail set too high (Refer to Step 1C)

TROUBLESHOOTING

SOLUTION

IMPORTANT: To avoid any damage or

misalignment of hinge points, close cover in

a smooth, ﬂuid manner.

C. Unfold rear panel towards tailgate.

Make sure all latches engage side rails

when closing cover then close tailgate.

B. Unfold middle panel

towards tailgate.

CLOSING TRI-FOLD COVER

A. Unhook storage clips on

both sides.

6 7

IMPORTANT: To avoid any damage or

misalignment of hinge points, open cover in

a smooth, ﬂuid manner.

B. Fold middle panel on top of

front panel.

OPENING TRI-FOLD COVER

C. Securely fasten storage clips on both

sides to store the cover.

A. Open tailgate, lightly pull synthetic

cord to release latch. Fold rear

panel on top of middle panel.

A. With cover completely open and storage clips secured, pull synthetic cord on front

panel and lift rear of cover up 1" above rails (Figure 1).

B. Slide cover back to disengage hooks then lift to remove (Figure 2).

REMOVAL AND REINSTALL OF COVER

A. Place leading edge of front panel on rails at front of box. Hold rear edge of folded cover

1" above rails (Figure 1) and slide cover hooks underneath front catch on each side

(Figure 2).

B. Lower cover and engage latch in retainment bracket on each side (Figure 1). Ensure

hooks are engaged by gently lifting corners of cover.

REMOVE COVER

REINSTALL COVER

Rear

Figure 1 Figure 2

Front

8 9

• Keep cover closed when not in use, avoid storing cover in its folded position for long

periods of time.

• Make sure cover is properly latched while traveling and before entering automatic

drive-through car washes.

• When cleaning, for best results use mild liquid soap and water. Never clean with

petroleum or citrus based products.

• Avoid allowing cargo to rub against cover while transporting, whether in open or closed

position.

TIPS FOR A LONGER LASTING COVER

• Inspection and much of the maintenance can be done by the operator. It may be

necessary to review the installation and operating instructions.

• Periodically check and/or retighten clamps as needed.

• Periodically check synthetic cord to ensure latches fully engage side rails.

• Periodically inspect the cover assembly and the condition of all parts. Check for loose

bolts and parts, tighten if needed. Test the operation to ensure that the parts are

functioning properly and that the cover is in top operational condition.

• If latch has been damaged, replace with new one.

NOTE: Inspection and/or maintenance should also be performed anytime a malfunction

is observed or suspected. If you need assistance inspecting and/or servicing your cover,

or if you want to order a replacement part, call the customer service number on the back

page. Always use original equipment replacement parts for your cover.

INSPECTION AND MAINTENANCE

• Do not tow vehicle backwards with cover on your truck.

• Do not cover cargo that is higher than the cover.

• Do not place object(s) on or against the cover or its framework at any time.

• Always secure cargo so it cannot shift and damage the cover or its parts.

• Remove any snow or debris from top of cover before folding cover.

• Do not use the cover’s framework to tie down cargo.

• Never stand, sit or ride on the cover or allow others to do so.

• The cover does not eliminate moisture and dust from entering the truck box. Special

wrappings or packaging of the cargo may be necessary.

• Due to poor ventilation, if you allow a pet/animal in the box, leave cover open. Do not

allow people or animals to occupy box with the cover closed.

• Use caution when operating cover in windy conditions.

• Always make sure all latches fully engage side rails prior to driving with cover in

closed position.

• Keep cover completely closed or completely open & secured with storage clips when

traveling. Do not attempt to drive with the rear panel in the partially open position.

• Keep cover closed when going through automatic car washes.

• Keep hands and ﬁngers away from all pinch points.

• Never use latch rope to lift or fold cover.

SAFETY INFORMATION

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