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INSTALLATION INSTRUCTIONS
Thank you for purchasing a DURACAP
Hard Truck Topper. Agri-Cover, Inc. proudly
™
manufactured this topper using superior quality materials and workmanship. With
proper care, your hard truck topper will provide years of service and enjoyment.
NOTICE TO INSTALLER: Even if familiar with product, read instructions prior to
installation as improvements may be made without notice. Always handle components
with care. If you have questions or problems, have serial number ready and call
customer service. When done, these instructions must be given to the consumer.
NOTICE TO CONSUMER: Before using this product, read operating, maintenance and
safety sections. Save these instructions for future reference.
FOR YOUR RECORDS
DATE PURCHASED:
WHERE PURCHASED:
SERIAL NUMBER:
(Located on side rail)
Questions? 888-568-3709
agricover.com
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Summary of Contents for aci DURACAP
- Page 1 INSTALLATION INSTRUCTIONS Thank you for purchasing a DURACAP Hard Truck Topper. Agri-Cover, Inc. proudly ™ manufactured this topper using superior quality materials and workmanship. With proper care, your hard truck topper will provide years of service and enjoyment. NOTICE TO INSTALLER: Even if familiar with product, read instructions prior to installation as improvements may be made without notice.
- Page 2 PREPARATION Unpack topper components and clean truck box if dirty. For additional installation assistance, go to duracaptoppers.com for install video. COMPONENTS TOOLS NEEDED • (4) Clamp plates • Ratchet with 1/4”, 3/8”, 7/16”, 1/2” and 9/16” sockets • Alignment plates (quantity varies) •...
- Page 3 PREPARATION IMPORTANT: Stake pockets must be open to install this product. If stake pockets are not present, refer to special instructions. NOTE: DURACAP Hard Truck Topper is a (2) person install. Hardware appearance ™ and components may vary. Corrosion resistant coating may cause hardware to thread firmly.
- Page 4 PARTS DIAGRAM Roof Rear angle bracket Side panel Trim Rear door support Rear panel Window...
- Page 5 Front panel Bows Support brackets Side brackets Side panel Bar hold downs Rear bar Side rails...
- Page 6 1: ASSEMBLING REAR PANEL IF NOT INSTALLING REAR WINDOW PROCEED TO STEP 1G Seal A. Clean and prepare flat work area. Place cloth, cardboard or tarp on work area to protect topper. B. Place rear panel on flat work area. Starting at top center of window, peel protective backing as you go.
- Page 7 1: ASSEMBLING REAR PANEL (Continued) G. Cut a 3-1/2” piece of flat seal. Center Seal and adhere seal on square hole side of rear door support. Flat seal shown in white for illustration purposes. Firmly press adhesive along flat seal. H.
- Page 8 1: ASSEMBLING REAR PANEL (Continued) NOTE: Strap goes on driver side. Extended bar hold down L. Center rear bar between holes on bottom of rear panel. Using (3) bar hold downs, with extended bar hold down in middle, insert extended bar hold down under latch and secure with 1/4”...
- Page 9 2: ASSEMBLING SIDE PANELS A. Place side panel on flat work area, then apply black sealant to corner openings. Black sealant B. Align holes in side bracket with holes in Carriage bolts with side panel lip. Insert (4) 1/4” x 3/4” carriage serrated flange nuts bolts, then secure with serrated flange nuts.
- Page 10 3: ASSEMBLING SIDE WINDOWS IF NOT INSTALLING SIDE WINDOWS Start seal here PROCEED TO STEP 4 A. Place window on flat work area. Starting at bottom center of window, peel protective backing as you go. Align and adhere bulb seal flush around inside lip of window, ensuring no gap at seam.
- Page 11 5: PREPPING ROOF A. Place pre-folded roof assembly on flat work area, unfold and apply black sealant to ends of all hinges. Ensure sealant fills hinge groove in the middle and tapers down on both sides. Any excess sealant will push out during tightening process (STEP 14: SQUARING TOPPER).
- Page 12 7: APPLYING BULKHEAD SEAL NOTE: With a spray-in bed liner, better Clean top adhesion is possible by smoothing surface of bulkhead and applying an adhesion promoter. A. Ensure bulkhead is clean, wipe top surface with alcohol pad (if needed wash and dry surface first).
- Page 13 8: INSTALLING SIDE RAILS IMPORTANT: Stake pockets must be Tie loose ends open to install this product. If stake in a knot pockets are not present, refer to special instructions. Alignment A. Loop cord around extended threads on plates clamp plate, add alignment plates equally, (quantity then tie knot at top of cord.
- Page 14 9: ASSEMBLING TOPPER A. Place front panel, side panels and rear Front panel angle bracket on flat work area. B. Attach side panel to front panel with 1/4” x 3/4” carriage bolts and serrated flange nuts, Side panels leaving finger tight. C.
- Page 15 10: INSTALLING ROOF A. Refold roof assembly and set on top of Leave these frame towards the front. Unfold roof and align two open large holes in roof with large holes in topper frame. Starting with the smaller square holes near each corner insert 1/4”...
- Page 16 10: INSTALLING ROOF (Continued) NOTE: Some roofs may taper, bar lengths Support bracket will vary with a tapered roof. Start with the longest bar at widest point and work to smallest. E. Insert bow into support bracket. On opposite side, raise bow into place and repeat support bracket installation.
- Page 17 12: ATTACHING REAR PANEL IF INSTALLING RACK PROCEED TO Rear angle DURACAP TRUCK TOPPER RACK ™ bracket hinge INSTRUCTIONS A. Slide rear panel hinge into rear angle bracket hinge. Rear panel hinge B. Ensure both sides are flush, then secure...
- Page 18 13: SQUARING TOPPER IMPORTANT: All bolts should be finger tight unless instructed otherwise. A. Ensure lip of front panel is flush with inside edge of bulkhead. Front panel Bulkhead B. Ensure edge of side rails are flush with inside edge of bed cap at front clamping locations, then tighten clamps.
- Page 19 13: SQUARING TOPPER (Continued) E. Starting at one corner, tighten serrated flange nut at top holding rear angle bracket to side bracket. Serrated F. Repeat on opposite side. flange nut NOTE: Check for square and adjust as needed. Tip: Hold pressure one way while tightening if necessary.
- Page 20 13: SQUARING TOPPER (Continued) N. Starting at front, tighten outside 3/8” nylock flange nuts on both sides, then inside 3/8” nylock flange nuts on both sides. O. Repeat Step 13N at rear. P. Wipe excess black sealant from topper. Inside bolt Outside bolt second first...
- Page 21 14: APPLYING FRONT PASS THROUGH SEAL (Continued) C. Wipe top and sides of cab window with alcohol pad. Seal starting point D. Starting at one lower corner, apply “J” seal to cab window with a continuous piece along sides and top of opening to opposite lower corner.
- Page 22 SAFETY INFORMATION • Do not place object(s) on topper at any time without DURACAP Truck Topper Rack ™ installed. • Only use support bracket tie downs to secure cargo. Do not use the topper’s framework to tie down cargo. • Always secure cargo to avoid shifting and damaging topper or its parts.
- Page 23 TIPS FOR A LONGER LASTING TOPPER • Ensure topper is properly latched. • Always remove foreign substances from topper. • Clean windows of debris by spraying with water before cleaning to avoid scratching windows. Do not use squeegee to clean windows. •...
- Page 24 MANUFACTURER’S LIMITED WARRANTY Agri-Cover, Inc. extends the following three (3) year Limited Warranty for the DURACAP ™ QUEST Hard Truck Topper, DURACAP JOURNEY Hard Truck Topper and DURACAP ™ ™ ™ ™ EXPLORE Hard Truck Topper: ™ Agri-Cover, Inc. warrants a period of three (3) years from the date of manufacture that...
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