WARNING NOTICE CAUTION ASSEMBLY INSTRUCTIONS

Transcription

1 MODEL 284 EZ-GLIDE SYSTEM 10' HIGH CUBE VAN DRIVER SIDE ALUMINUM DROP DOWN LADDER RACK ATTENTION Read and understand all instructions and warnings before operating or using this product. WARNING This product is only intended and only safe for transporting ladders. It is the responsibility of the user to secure these materials to the rack before transporting. Ladders must be secured per ANSI standard A paragraph Ladder damage will occur from road shock and vehicle vibration if the ladder is not properly secured to the ladder rack. Bouncing and side to side motion of an improperly secured ladder will cause wear and weaken the ladder. Using a damaged ladder could lead to structural collapse resulting in serious injury or death. Place ladder in a raised position before transporting. Driving with rack in lowered position may cause serious injury or damage to vehicle, ladder, rack or persons. NOTICE Any modification or unintended use of this product shall immediately void all manufacturers warranties. Manufacturer disclaims all liability for injuries to persons or property resulting from any modification to, or unintended use of this product. CAUTION Never load your rack to exceed the safe capacity of your vehicle. Heavy loads when carried high can dangerously alter the center of gravity. Loads should be approximately centered front to rear. Failure to do this will cause damage to the vehicle roof. Long loads that extend out the rear of the vehicle will prevent the rear hatch from fully opening and cause damage if attempted. ASSEMBLY INSTRUCTIONS TOOLS REQUIRED Open or Box End Wrenches 9/16" - 1/2" - 7/16" 3/8" Drive Socket 9/16" - 1/2" - 7/16" 3/8" Drive Ratchet Phillips Screwdriver (Large) Needle Nose Pliers 3/8 Drive Torque Wrench (in. lbs.) Tape Measure Flat Screwdriver (Small) Electric Drill 5/16" Electric Drill Bit PARTS LIST See Page 2 Drive Shaft/Handle Assembly Lower Handle Section Upper Handle Section Cylinder Front Drive Tube Center Drive Tube Ladder Support Ladder Stop 4 -Mounting Bases 2 -Mounting Tubes 2 - Black Plastic Bushings 2 - White Plastic Bushings Tube E-6000 Sealant 15-1" Dia. Vinyl Hole Covers Front Cross-Member Assembly Rear Cross-Member Assembly 1 - Tube Loctite 290 Approximate assembly and Installation time: 120 min. per unit (2 hrs.) depending on van equipment and installer experience. IMPORTANT BEFORE YOU BEGIN Read these instructions and warnings completely before installation. HARDWARE KITS See Page 3 Check these kits to be sure the following parts are included. 1 HRR ROTATION KIT: 2 3/8-16 x 2-1/4" Hex Hd. Bolt 2 3/8-16 Nylon Lock Nut 7 3/8" Flat Washer 4 5/16-18 x 2" Hex Hd. Bolt 10 5/16-18 Nylon Lock Nut 16 5/16" Flat Washer 1 5/16-18 x 4-1/2" Hex Hd. Bolt 1 5/16-18 x 1" Hex Hd. Bolt 1 Aluminum Bushing 1 Clevis Pin (1") 1 Clevis Pin (1-1/2") 1 Cotter Pin 1 Bushing Lubricant Tube 2 5/16-18 x 2-1/2" Phillips Flat Hd. Screw 2 5/16-18 x 2-3/4" Hex Hd. Bolt 1 HRR ROOF BASE KIT: 4 5/16-18 x 4" Hex Hd. Bolt 8 5/16-18 x 1-1/4" Hex Hd. Bolt 12 5/16-18 Nylon Lock Nut 8 5/16" Flat Washer 8 5/16 Rubber Washer 8 1-1/2 Fender Washer 8 Rubber Pads 8 3/8 Flat Washer 1 Part No REV. E ECN /13

2 Front Cross-Member Assembly Rear Cross-Member Assembly Driveshaft/Handle Assembly Lower Handle Section Upper Handle Section Cylinder Front Drive Tube Center Drive Tube Ladder Support Ladder Stop Mounting Bases Qty. 4 Mounting Tubes Qty. 2 Black Plastic Bushings Qty. 2 White Plastic Bushings Qty

3 5/16-18 x 4-1/2" Hex Hd. Bolt FASTENER CHART 5/16-18 Nylon Lock Nut 5/16-18 x 4" Hex Hd. Bolt 3/8-16 Nylon Lock Nut 5/16-18 x 2-1/2" Phillips Flat Hd. Screw Cotter Pin 5/16" Flat Washer 5/16-18 x 2-3/4" Hex Hd. Bolt 5/16" Rubber Washer 3/8-16 x 2-1/4" Hex Hd. Bolt Clevis Pin (1") 3/8" Flat Washer 5/16-18 x 2" Hex Hd. Bolt Clevis Pin (1-1/2") 5/16-18 x 1-1/4" Hex Hd. Bolt 1-1/2" Fender Washer 5/16-18 x 1" Hex Hd. Bolt Aluminum Bushing 3

4 REAR ROTATION ASSEMBLY 4

5 STEP 1 Slide a White Plastic Bushing (A) into the Pivot Arm (B) as shown. (A) (B) STEP 2 Use the supplied lubricant and coat the pre-assembled Black Plastic Bushing (A). Insert the Driveshaft/Handle Assembly (B) into the larger Black Plastic Bushing (C) in the Rear Cross-Member Assembly (D) and through the White Plastic Bushing in the Pivot Arm (Step 1) so that the black bushings are fully seated. (D) (A) (C) (B) STEP 3 Align holes in the Pivot Arm, White Plastic Bushing, and Rear Drive Tube. Install the 3/8-16 x 2-1/4" Fastener. Next install the 5/16-18 x 1" Fastener as shown. (2) 3/8" Flat Washer 3/8-16 Nylon Lock Nut * 3/8-16 x 2-1/4" Hex Hd. Bolt NOTE: Tighten all marked (*) fasteners to 200 in. lbs. 5/16-18 Nylon Lock Nut 5 (2) 5/16" Flat Washer 5/16-18 x 1" Hex Hd. Bolt 6

6 FRONT ROTATION ASSEMBLY 6 7

7 STEP 4 Slide a White Plastic Bushing (A) into the Pivot Arm (B) as shown. (A) (B) STEP 5 Use the supplied lubricant and coat the pre-assembled Black Plastic Bushing (A). Insert the Front Drive Tube (B) into the larger Black Plastic Bushing (C) in the Front Cross- Member Assembly (D) and through the White Plastic Bushing in the Pivot Arm (Step 4) so that the black bushings are fully seated. (B) (A) (C) (D) STEP 6 Align holes in the Pivot Arm, White Plastic Bushing, and Front Drive Tube. Install the 3/8-16 x 2-1/4" Fastener. * 3/8-16 x 2-1/4" Hex Hd. Bolt 3/8-16 Nylon Lock Nut NOTE: Tighten all marked (*) fasteners to 200 in. lbs. 7 (2) 3/8" Flat Washer 8

8 STEP 7 Place the Ladder Support (A) on top of the Connecting Tube (B) and install the 5/16-18 x 2-3/4" Fastener. 5/16-18 Nylon Lock Nut (A) (2) 5/16" Flat Washer (B) 5/16-18 x 2-3/4" Hex Hd. Bolt STEP 8 Place the Ladder Stop (A) on top of the Cross-Member (B) and install the 5/16-18 x 2-1/2" Fastener (Flat Hd. Screw). (A) 5/16-18 x 2-1/2" Flat Hd. Screw 5/16" Flat Washer 5/16-18 Nylon Lock Nut (B) 8 9

9 STEP 9 Insert Aluminum Bushing (A) into Rear Cross-Member (B). Attach back of Cylinder (C) to crossmember by installing 5/16-18 x 4-1/2" Fastener. NOTE: After installing Bolt, apply Loctite 290 to threads, then install the nut. CYLINDER INSTALLATION 5/16-18 Nylon Lock Nut (B) (A) (3) 3/8" Flat Washer (C) 5/16-18 x 4-1/2" Hex Hd. Bolt STEP 10 Attach front of Cylinder as shown. Bend over Cotter Pin after inserting it through Clevis Pin. Cotter Pin NOTE: Turn the Flow Control counter clockwise to release pressure. Adjust Flow Control Screw Per Instruction Decal On Handle Tube after final assembly and installation. Clevis Pin 9 10

10 STEP 11 Determine the length of rack you need. Front Pivot Arm USE THESE HOLES FOR DESIRED LENGTH Rear Pivot Arm 5' 6' 7' 8' FRONT TO REAR DRIVE TUBE ASSEMBLY STEP 12 Locate desired front to rear length (5' or 6' or 7' or 8') and install 5/16-18 x 2" Fasteners (Tighten fasteners to 200 in. lbs.) STEP 13 Cover any exposed holes on Front and Rear Drive Tubes with the 1" Dia. Vinyl Hole Covers STEP 14 Seal the ends of the Center Drive Tube, the four 5/16-18 Fasteners, and the two 3/8-16 Fasteners with the tube of sealant supplied. (4) 5/16-18 Nylon Lock Nut (4) 5/16-18 x 2" Hex Hd. Bolt (8) 5/16" Flat Washer 10 11

11 VEHICLE MOUNTING PROCEDURE 11

12 Unit will need to be placed on roof in a position where the handle will be between 3" - 6" behind van. There are a few preliminary steps you need to take to make sure you use the correct holes in mounting base. THIS RACK WAS DESIGNED TO FIT VANS WITH ROOF RIBS SPACED 24" APART. IF YOUR VAN DOES NOT HAVE THIS SPACING, YOU MUST SUPPLY PROPER REINFORCEMENT ON IN- SIDE OF VEHICLE. Might have to flip ends to get needed dimension Large holes Roof Ribs STEP 15 Place a Mounting Base up on roof with the two large holes facing up. These two holes will be used to mount to the roof ribs. One of the three small holes will be used to mount the rotation kit to the Mounting Base. Mounting Base Small holes 22-1/2" /2" STEP 16 Line up large holes so they are centered on roof ribs closest to the back of the van. To get proper handle clearance of 3" to 6" from the back of van, you will need to locate one of the small holes so that it is between 22-1/2" to 25-1/2" from hole to back of the van (See Illustration). It may be necessary to rotate mounting base so a small hole is in that range. 3" - 6" Back of van (2) 5/16-18 x 4" Hex Hd. Bolt Mounting Tube STEP 17 After you have found the correct small hole, remove Mounting Base from roof and attach rear end of Rotation Kit to the Mounting Bases using 5/16-18 x 4" long Hex Hd. Bolt. Flat Washer and Nylon Lock Nut will mount through large hole on bottom, onto bolt. (2) 3/8 Flat Washer (2) 5/16-18 Nylon Lock Nut 12 (2) Mounting Base 13

13 STEP 18 Determine what small hole to mount Front Rotation with after lining Mounting Base up with Roof Ribs toward front of van. Attach Front Rotation Assembly to the Mounting Bases with 5/16-18 x 4" Hex Hd. Bolts. Flat Washer and Nylon Lock Nut will mount through large hole on bottom onto bolt. (2) 5/16-18 x 4" Hex Hd. Bolt Mounting Tube (2) 3/8 Flat Washer (2) Mounting Base (2) 5/16-18 Nylon Lock Nut STEP 19 WITH HELP! Place entire unit on vehicle in desired position. Check to verify that the Handle clears the rear of the van

14 STEP 20 (4 Places) With unit centered side to side, mark the holes in the Mounting base (A). Move the unit out of the way enough to drill the 5/16" dia. holes. Reposition unit and secure to the van roof with the 5/16-18 x 1-1/4" Fasteners. CAUTION To keep debris out of your eyes when drilling, always wear protective eyewear. NOTE: Seal the top of the bolts that go through the roof with the sealant that is supplied. (8) 5/16-18 x 1-1/4" Hex Hd. Bolt (8) 5/16" Flat Washer (8) 5/16 Rubber Washer (A) (8) Mounting Pad-Rubber Roof Rib (8) 5/16-18 Nylon Lock Nut (8) 1-1/2" OD Fender Washer STEP 21 Assemble Upper Handle Section to Lower Handle Section, Snap into position at a convenient height. Handle is removable and should not stay on rack when vehicle is in motion. Store Handle inside vehicle when transporting. Insert Handle Assembly into rack and turn clockwise to lock into place. To remove from rack, push up, turn counterclockwise, and pull. adjust to desired length and snap into place

15 FINAL ASSEMBLY 15

16 LADDER & CYLINDER ADJUSTMENTS STEP 22 Using the handle rotate rack to the down position. Because the ladder rack is not under the load of a ladder, you may have to pull the front and rear rotation assemblies down by hand after moving the handle to the down position. STEP 23 Actuating the release mechanism on the rear slide down, lower the assembly. Place the ladder onto the ladder rack and raise only the rear slide down to the upper position. Do not rotate the rack to the up position at this time. RELEASE CAUTION Once the release lever is pushed, you must support the full weight of the ladder and the ladder slide. UP DOWN HANDLE ROTATION LADDER STOP RELEASE LADDER SUPPORT UP REAR SLIDE DOWN STEP 25 Adjust the flow control screw on the cylinder per the instruction decal on the drive shaft handle tube until the ladder operates smoothly as you rotate the ladder up and down. DOWN 16 STEP 24 With the side of the ladder sitting on the ladder support of the rear slide down assembly in the up position, adjust the ladder stop so that it is approximately 1/4" above the ladder and tighten the fastener firmly.

17 REPLACEMENT PARTS All Replacement Parts Include Mounting Hardware ID# PART NUMBER DESCRIPTION USE WITH QUANTITY Drivers side rear slide down 284, Hydraulic Cylinder All Models Except Ladder Stop All Models Except Ladder Support All Models Except Bushing Kit All Models Except Driver side drive shaft for high roof vehicles 283, 284, 286, Handle for high roof racks 280, 281, 282, 283, 284, 285, 286, Moounting base for hi-cube vans 281, 282, 283, Mounting tube for hi-cube vans 281, 282, 283, Front Drive Tube Upper Handle Section Center Drive Tube Lower Handle Section Driveshaft/Handle Assembly 8 9