Ironman4x4 SLIDE-AWAY

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Summary

Product Preparation

Parts List

Lists all components included in the kit for the tonneau cover.

Tools Required

Details the necessary tools for performing the installation.

Bolt Tension Chart

Provides torque specifications for various bolt sizes.

Installation Guide

Initial Checks and Unpacking

Verify vehicle compatibility, unpack, and organize components.

Vehicle Tub Preparation

Remove sports bar if necessary and clean the ute tub surfaces.

Track Assembly and Adjustment

Install rubber covers and adjust the sliding cover clutch.

Attaching and Securing Tracks

Align, attach, and secure the side tracks to the drum assembly.

Installing Top Cover and Mounting

Fit the top cover, lift assembly onto vehicle, and attach tub brackets.

Drain Tube Installation

Install the drain tubes to the tracks and drum assembly.

Operation and Wiring

Wiring and Power Routing

Guides on routing power cables and connecting optional components.

Clutch Operation

Instructions for manual and remote clutch engagement/disengagement.

Remote Controller Functions

Explains the functions of each button on the remote controller.

Maintenance

Cleaning and Lubrication

Recommendations for regular cleaning and lubrication for smooth operation.

The Ironman 4x4 Slide-Away Roll Away Hard Tonneau is a retractable hard tonneau cover designed for ute tubs, providing security and weather protection for cargo. This installation guide outlines the steps for fitting the tonneau cover and provides essential information on its operation and maintenance.

Function Description:

The Slide-Away Tonneau Cover is an electrically operated, roll-away hard cover that retracts into a drum assembly located at the front of the ute tub. It offers a secure and weather-resistant enclosure for the cargo area. The cover is operated via a remote control, allowing for easy opening and closing. It also features a manual disengagement option for situations where remote control operation is not possible or desired. An optional in-car activation button can be connected for additional convenience. The cover includes an integrated tub interior light with adjustable brightness settings, also controlled by the remote.

Important Technical Specifications:

The installation process involves various fasteners and components, with specific torque requirements for certain bolts. The Bolt Tension Chart provides the following specifications for different bolt sizes (Grade 8.8):

M6 x 1: 10.5 Nm (7.7 ft/lb)
M8 x 1.25: 25 Nm (18 ft/lb)
M10 x 1.25: 49 Nm (36 ft/lb)
M12 x 1.25: 88 Nm (64 ft/lb)
M14 x 1.5: 140 Nm (103 ft/lb)

The system is designed to prevent water and dust ingress into the cargo area, although the manufacturer notes that they cannot be held accountable for pre-existing holes and gaps in the factory tub. Drain tubes are installed to manage any water that might enter the system. Wiring for the electrical operation requires routing power cables, and a 20mm diameter hole is recommended for vehicles without existing access points, with a strong emphasis on corrosion proofing. The remote control uses a CR2016 battery.

Usage Features:

Remote Control Operation: The tonneau cover is primarily operated using a remote control with dedicated buttons for:
- Close Tonneau Cover: Initiates closing from a static state or stops closing if in operation.
- Open Tonneau Cover: Initiates opening from a static state or stops opening if in operation.
- Turn Off Tub Interior Light: Turns off the integrated tub light.
- Turn On Tub Interior Light: Turns on the tub light and cycles through three brightness levels with successive presses.
- An LED indicator light on the remote confirms button presses.
Manual Disengagement (Clutch Operation): In cases where remote operation is not feasible, the cover can be manually disengaged. This involves:
1. Removing a clutch protection plate by undoing two screws with a 5mm hex key.
2. Rotating a clutch screw counterclockwise 3-4 times with a flat-bladed screwdriver, allowing the cover to be operated by hand.
Clutch Engagement (for Remote Operation): To re-enable remote control, the clutch screw must be rotated clockwise until it is tight, and the protection plate reinstalled.
Optional In-Car Button: An additional button can be installed inside the cabin for activating the Slide-Away, providing an alternative to the remote control.
Positioning Bar: An aluminium positioning bar (A4) is supplied to help keep the tracks square during installation and can be left in place at the end of the tub.

Maintenance Features:

Regular Cleaning and Lubrication: To ensure quiet and smooth operation, the rail tracks and main drum assembly should be regularly cleaned and lubricated. This is recommended every 3 months, 6,000 km, or after use in muddy, sandy, or dusty conditions.
Lubricant Type: Only silicone oil-type lubricants should be used. Petroleum-based lubricants and sticky greases should be avoided as they can damage rubber components and attract dust/dirt. Spray lubes with PTFE (Teflon) are recommended when regularly applied, wiped, and reapplied.
Cleaning Tracks: Lubricant should be applied to a rag and used to wipe the inside of the rail tracks, the underside of the sweep seal, and the top of the wear strip. This process should be repeated until all dust is removed. A high-pressure water gun can be used if necessary, followed by re-lubrication.
Cleaning Drum Assembly: The clutch should be disengaged, and the cover extended far enough to access the canister. Lubricant should be applied to a rag and used to wipe the inside of the main drum and all components within the canister.
Drain Tube Maintenance: Ensure the drain tubes are clear of any debris or blockages.
Water Jet Precaution: When cleaning, avoid directly aiming high-pressure water jets at the motor, ECU, or connectors. Necessary waterproof protection should be applied to connectors and plugs.
Remote Control Battery Replacement: If the remote control signal indicator light weakens or the button indicator light fails, the CR2016 battery should be replaced.
General Care: The Slide-Away should be washed and cared for in the same manner as the vehicle's finish, as a lack of proper cleaning and maintenance can negatively impact its operation and lifespan.