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Installing the Tilt-A-Topper kit.

                                           

  Tilt-A-Topper Kit

Installation Instructions

For GS-2000 and GS-4000

 

Before you begin installation confirm that you have the correct size kit by following these simple instructions:

*Measure the outside width of the truck cap including any moldings.

A=____ inches

*Measure the inside width of the truck between the box flanges.

 B=____inches

*Subtract B from A  

A-B=____

 

2 1/4” - 4” use kit “A”

4 3/4”- 6 1/2” use kit “B”

6 1/2”- 8 3/16” use kit “C”

 

 

Parts List For GS-2000                                        

1-LF/RR arm assembly                                                         

2-LR/RR arm assemblies

1-RF/LR arm assembly                                                         

1-locking upper hinge w/ key                                                   

1-nonlocking upper hinge                                                     

 2-lower hinges                                                                         

2-butt hinges                                                                            

4-“Z” backer plates                                                              

1-foam hinge pad                                                                 

1-roll rubber seal                                                                 

1-roll adhesive tape

1-roll adhesive tape                                                                 

2-arm rests                                                                              

1-fastener package                                                                    

1-instruction book

 

 

Parts List For GS-4000

2-LR/RR arm assemblies

2-RF/LR arm assemblies

2-locking upper hinges w/ key

2-nonlocking upper hinges

4-lower hinges

4-“Z” backer plate

1-foam hinge pad

1-roll rubber seal      

4-arm rests

1-fastener package

1-instruction book

 

Required For Installation

2 people

Scissors 

Adhesive Cleaner (3M or similar)  

Wrenches- 3/8, ½, 7/16, 9/16, ¾”   

Drill and ¼” drill bit  

Sharp knife or razor

Phillips screw driver 

Putty knife or similar  

Carpet piece of similar                                                         

Straight edge (for GS-2000 kits)                                                                       

                                                                                                           

                                        

 

Warning- Never attempt to open both sides of a GS-4000 kit at the same time. One side must be closed and locked at all times. Any attempt to open both sides at the same time may result in personal injury and/or damage to the truck, truck cap, or Tilt-A-Topper Kit.

Warning- Never attempt to drive with the truck cap in the up position. Doing so could result in damage to the truck, truck cap, and Tilt-A-Topper Kit.

 

Installation Instructions- GS-4000 and GS-2000

Step #1

Lay truck cap upside down on a pad, ie. carpet. Use a putty knife or similar to remove old weather stripping. Clean with a solvent cleaner that leaves no oily residue. (Aluminum truck caps-see “Trouble Shooting #1).

Step #2

Choose a location for mounting the hinges (between 6-12 inches from the ends of both truck cap and the truck) making sure there are no obstructions such as stake pockets at you chosen location.

Step #3

Place the upper hinges onto the truck cap base rails at chosen location. NOTE: GS-4000 kit one locking and one non-locking upper hinge on each side with the locking ones at the rear of the cap. GS-2000 kit locking and non-locking upper hinges on the side that you wish to open, with the locking one at the rear of the cap. Mount the upper hinges to the truck cap base rail. Hold each hinge firmly against the truck cap, drill and install with ¼” and 1 ½” truss head screws, ¼” washers, lock washers, and nuts. GS-2000 kits continue to step #4. GS-4000 kits continue to step #5.

Step #4 GS-2000 kits only

Mount butt hinges flush with the outside edge of the truck cap in the location chosen, on the side that you want to hinge. Same fasteners as above.

Step #5

Apply the double faced tape to the truck cap base rails. First across the front, then down both side rails (stay approximately 2” in from the outside edges). It needs to be in approximately 2” from the outside edge of the truck cap to the tape on the side rails. Run it right over the hinges. Overlap the tape in the front corners. Press it down firmly! Separate and remove the backing.

Step #6

Place the rubber seal material onto the tape as shown. NOTE: The short end should be sticking up. Drill ¼” holes through the seal material and the truck cap base rail, once on each at the rear, twice on each side (near the hinges), and 3 times across the front (once in the middle and once in each corner where the seal material overlaps. Insert the plastic puch anchors firmly. NOTE: GS- 2000 kits may need to trim around the butt hinge pins using a scissor so that the hinge will close.

Step #7

Cut the adhesive backed foam material into 4 equal lengths and apply to the bottom sides of all lower hinges. GS-2000 kits also apply foam material to the butt hinges where it will sit on the truck. Pre-assemble the lower hinges, 3/8” carriage bolt, 3/8” nut, 3/8 washer, “Z” backer plate, lower hinge, 3/8” lock washer, 3/8” nut. Place onto the truck box rail in chosen location. Using tape measure, locate them to line up with the upper hinges. DO NOT TIGHTEN AT THIS TIME.

Step #8

Open lock levers on all upper hinges, and place the truck cap onto the truck, making sure that the curls on the lower hinges go up inside each of the nylon housings. (GS-2000 kits be careful to place the butt hinge down around the truck box rail first, then lower housings onto lower hinge curls). Center the truck cap from side to side. Close the tailgate and the truck cap door and check for seal. You can slide the truck cap forward and backward for optimum placement. Not center each of the lower hinges inside the nylon housings.

 

Step #9

Turn adjuster screws into the lower hinge until they touch the truck box rail. Use ¼” by ½”, ¼” by ¾”, or ¼” by 1” Truss Head Screws. (whichever is shortest but will still reach the rail).

Step#10

Push in on, and hold the head of the carriage bolt against the truck, turn the inside 3/8” nut with the lock washer (nut closest to you) until it JUST TOUCHES the lower hinge. Now tighten the outside 3/8” nut with flat washer (the one up underneath) towards you until the lower hinge assembly feels secure. Use a 9/16” wrench, and DO NOT ALLOW THE CARRAIGE BOLT TO TURN! It is important that the head of the carriage bolt is against the truck box wall. GS-4000 kits-tighten all four before continuing to step #12. GS-2000 kits-tighten both, them continue to step # 11. NOTE: All “B” and “C” kits (check the box label on outside of box) need additional 3/8” nut installed onto the carriage bolt. Snug tightly.

Step #11 GS-2000 kits only

Install and tighten butt hinges as shown, 3/8” by 2” bolt, 3/8” flat washer, 3/8” lock nut.

Step #12

Slide the 1”flat rubber caps into the arm rests. Do not cover the holes. Install onto arms as shown using the shortest remaining ¼” truss head screws, ¼” lock washers and ¼” nuts. Tighten only slightly. Lock washer and nut will be on the face side of the arm.

Step #13

Place arm assemblies in corners specified on the face of the adjuster disc (left is divers side). Install arm assemblies onto the upper and lower bolts by swinging the offset swivel blocks UP and sliding them. Arm rest must go between truck and truck cap rails. NOTE: Label on the adjuster disc must face the outside of the truck, and the threaded arm must by the bottom arm. If the threaded arm is on the top simply uncross the arms. (See Trouble Shooting #2). Install 3/8” flat washer and 3/8” locknut. Tighten, then back them off ¼ turn. Install all arms before continuing.

Step # 14

Push down on nylon housings and close all lock levers.

Step #15

Tighten the 3/8 locking nut on the threaded arms as follows. Rear nut first, to touch the swivel block, then add one full turn. Then front nut tight to swivel block, then back off ¼ trun. Make sure the arm rests are flat on the truck box rail and tighten them.

Step #16

Make sure that the arm rests sit flat onto the truck box rail and tighten them using a Phillips screwdriver and a 3/8” wrench.

Step #17

Open lock levers on one side and lift truck cap to full raised position. Turn adjusting disc until the spring hook makes contact with spring leg. ( You may have to help it past the first leg). Turn adjusting disc 3-5 holes past the anchor hole for aluminum caps, and 5-10 holes for fiberglass cps. Install ½” by 5/16” cap screw with lock washer. For more or less assistance simple turn the adjuster disc one or two holes either way until you have the assistance that you require. The truck cap should open and close evenly and stay in the up position by itself. Sometimes the rear arm may need to be slightly tighter than the front arm because of door weight. Close truck cap, shut lock levers, and repeat Step #16 for the other side (GS-4000 only). GS-2000 continue to step #18.

 

Step #18

Using a scissors, with the truck cap closed, make a small snip in the rubber seal, on either side of the lower hinges. Lift the truck cap and cut ¾” into the seal, where you made the snips. This will allow the seal to come down around the hinges and provide a better seal.

Step #19

Lubricate all springs and pivot points.

Step#20

Cap off bolt ends with 3/8” rubber caps. If you wish, you can cut off the excess bolt length first.

 

Trouble Shooting Guide

 

                                                                  

1. Problem

The aluminum angle on the front of                          

my truck cap will hit the rear window                                   

molding of the truck

 

1. Solution

 Remove the aluminum drip rail and replace the screws only

 

2. Problem

One arm assembly seems incorrect                                        

or seems to be labeled incorrectly                                          

 

2. Solution

One arm has crossed over the other during shipping. Simply uncross them

 

3. Problem

 Lower hinge not tight or comes loose                                   

                                                                                               

3.Solution

See Step #10-it is important that the lower hinge be tightened according to directions.

May be drilled and bolted.

 

 4. Problem

Lower hinges seem too short. Won’t move out far enough to work 

 

4.Solution

Wrong size kit for this application- Call factory

 

5. Problem

Lifting assembly squeaks                                                       

 

5. Solution

Lubricate springs and all pivot points                                                

 

 

6. Problem

Difficulty with key                                                                

 

6. Solution

Lubricate the lock

 

 

7. Problem

 Difficult to lift                                                                      

 

7. Solution

Increase lifting tension-see step #16

 

 8. Problem

Arms are loose, rattle and/or fall down below truck box rail.           

 

8. Solution

See Step #15-by loosening the front nut first, the rear nut can raise or lower the lifting arm assembly by

adjusting it forward or backward

 

9. Problem

 Lifting arm assembly hits the pickup box rail when opening or closing       

 

9. Solution

With the truck cap open 6-10 inches, grasp the spring assembly and push  it inward slightly.

Repeat if necessary

 

 10. Problem

The truck cap is flimsy and unstable                                      

 

10.Solution

Usually an older aluminum truck cap. Check for broken welds at the corners and repair is necessary

 

11. Problem

Truck cap base rail bends upward when the truck cap is closed.      

 

11.Solution

 Usually a heavy fiberglass cap with Very thin aluminum base rails. Suggest reinforcing with aluminum, steel angle, or hardwood.

 

 

 

Parts List Only

  1. Upper hinge assembly
  2. Key (GS-2000 one, GS-4000 two)
  3. ¼” by 1 ½” Truss head screws
  4. ¼” nuts
  5. ¼” lock washers
  6. ¼” flat washers
  7. Lower hinge
  8. Adjuster screws ¼” by ½”, ¾” or 1” Truss head
  9. Z backer plate
  10. 3/8” carriage bolt
  11. 3/8” nut
  12. 3/8” flat washer
  13. 3/8” lock washer
  14. 3/8” nut (B and C kits only)
  15. 3/8” lock nuts
  16. Lifting arm assembly
  17. ¾” adjuster
  18. Anchor bolt 5/16”
  19. 5/16” lock washer
  20. Arm rest with rubber cap
  21. ¼” by ¾” Truss head Screw
  22. Butt hinge (GS-2000 kits only)

 

 

 Warranty and Limitationor Liability

 

Your Tilt-A-Topper kit is warranted for a period of twelve (12) months from the date of purchase to be free from defects in material and workmanship under correct use, normal operating conditions, and proper application. Seller obligation under this warranty shall be limited to the repair or exchange, at Sellers option, F.O.P. Sellers factory, of any Tilt-A-Topper Kit or part which proves to be defective as provided herein. Seller reserves the right to either inspect the product at Buyers location or require it to be returned to the factory for inspection. The above warranty does not extend to goods damaged, or subject to accident, abuse, or misuse after shipment from Sellers factory, nor to goods altered or repaired by anyone other than authorized CEL representatives.

            Seller makes no express warranties other then those which are specifically described herein. Any description of the goods sold here under, including any referenced to Buyers specifications and any descriptions in catalogs, circulars, and other written material published by the Seller is for the sole purpose of identifying such goods and shall not create an express warranty that the goods shall conform to such description. Any sample or model is for the illustrative purposes only and shall not create any express warrant that the goods shall conform to the sample or model. Buyer is solely responsible for determining the suitability of goods sold hereunder for use by buyer.

 

          This warranty is expressly in lieu of all other warranties expressed or implied. There are no implied warranties of merchantability or fitness for a particular purpose. This warranty states sellers entire and exclusive liability and buyers exclusive remedy for any claim for damages in connection with the sale or furnishings of CEI products, their design, suitability for use, installation or operation, or for any claimed defects therein. Seller will in no event be liable for any incidental or consequential damages whatsoever, nor for any sum in excess of the price received for the goods for which liability is claimed




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