Ranger 1520-DH Installation Manual

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INSTALLATION GUIDE
1520-DH Single Clamp Ladder Rack
Sprinter Universal Wheelbase ( Aluminum )
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QUICK START GUIDE
Phase 1 - Assembly
q 1.1 Setup...............................................................................................................................................
q 1.2 Ladder Rack Assembly....................................................................................................................
Phase 2 - Installation
q 2.1 Mounting Tracks Preparation..........................................................................................................
q 2.2 Mounting Tracks Installation............................................................................................................
q 2.3 Ladder Rack Installation..................................................................................................................
q 2.4 Note.................................................................................................................................................
REQUIRED ITEMS
NOTE: Use Sawhorses if possible, or use the box as a at protective surface on the ground or table.
14 - 15 16 - 17 17 - 20 21
2
PERSONS
q Cordless Impact q Ratchet q Tape Measure q Mallet q Marker q Ladder q Cutter q 1/2" Socket q Sawhorse ( Optional ) q Box q Knife q 1/2" Wrench q Silicone
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PHASE 1 – ASSEMBLY
1.1 SETUP
1.1.1 Unpack components; compare with the bill of materials.
10-464
10-715
15-2044
15-2049
10-548
15-3004
15-3011
15-3003
15-3006
15-4290
10-149
10-545
10-725
1.1.2 Verify all parts are present.
BILL OF MATERIALS
Item No. Description Qty.
10-149 Clamp Handle Support 1
10-464 “V” Foot 4
10-545 Ski Plastic Plug 10
10-546 Track Plug Extrusion ( QTY in Inches ) 48
10-548 Hook Protector ( 4 - 3/8" L ) 1
10-715 Mounting Track 4
10-725 Support Plate 4
15-2044 Front Crossbow 1
15-2049 Rear Crossbow 1
15-3003 Ladder Clamp Hasp 1
15-3004 Ladder Clamp Rear Hook 1
15-3006 Ladder Clamp Bar ( Passenger Side ) 1
15-3011 Ski ( Right ) 1
15-4290 Front Hook 1
94-1005 Assembly Fastener Kit 1
96-1001 Install Fastener Kit 1
10-546
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1.1.3 Fastener kits.
94-1005 Fastener Kit Fastener Assembly
19×
23×
# 90-487
# 90-491
# 94-105
# 98-160
Carriage Bolt 5/16"-18 × 3/4" SS304
Carriage Bolt 5/16"-18 × 1" SS304
Hex Nut 5/16"-18 SS316wax
Spacer SS18-8
#90-487 Carriage Bolt 5/16" × 3/4"
#98-117 Flat Washer
#98-123 Lock Washer
#94-105 Hex Nut
18×
#90-491 Carriage Bolt 5/16" × 1"
#98-117 Flat Washer
#98-123 Lock Washer
#94-105 Hex Nut
#98-117 Flat Washer
#98-123 Lock Washer
23×
23×
#94-105 Hex Nut
Flat Washer
# 98-117
# 98-123
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5/16", O.D 3/4" SS18-8
Lock Washer Regular 5/16" SS304
#90-491 Carriage Bolt 5/16" × 1"
#98-160 Spacer
#98-117 Flat Washer
#98-123 Lock Washer
#94-105 Hex Nut
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16×
# 90-491
# 90-495
Carriage Bolt 5/16"-18 × 1" SS304
Carriage Bolt 5/16"-18 × 1-1/4" SS304
Fastener Assembly96-1001 Fastener Kit
16×
16×
# 94-105
# 94-116
# 98-109
# 98-117
# 98-123
Hex Nut 5/16"-18 SS316wax
Serrated Nut 5/16"-18 ZINC
Flat Washer SAE 3/8" SS304
Flat Washer 5/16", OD 3/4" SS18-8
Lock Washer 5/16" SS304
#90-491 Carriage Bolt 5/16" × 1"
#98-117 Flat Washer
#98-123 Lock Washer
#94-105 Hex Nut
16× ranger design tracks only
#90-495 Carriage Bolt 5/16" × 1-1/4"
#98-109 Flat Washer
#98-149 Neoprene Spacer
#94-116 Serrated Nut
Spacer
16×
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# 98-149
0.290" ID × 1.375" OD × 0.125" L NEOPRENE
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PHASE 1 – ASSEMBLY
1.2 LADDER RACK ASSEMBLY
1.2.1 Peel the backer off of the adhesive on the hook protector, then attach the hook protector
to the upper rear hook.
TOOLS
q Knife
REMOVE
1.2.2 Attach the rear hook to the ladder clamp, with the pre-assembled hardware on the pivot bar.
TOOLS
q Cordless Impact q 1/2" Socket q 1/2" Wrench
HARDWARE USED
hardware is pre-assembled.
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#90-225 Hex Bolt 5/16" - 18 × 2" SS304
#98-117 Flat Washer
#98-117 Flat Washer
#94-111 Lock Nut
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1.2.3 Slide carriage bolts on the bottom face of the crossbows.
NOTE: The track plug must be removed from the underneath of the front crossbow, and reinstalled
after the feet have been installed in the nal position.
TIPS: Use tape to keep the bolts from sliding off.
• Slide 4 pcs. of 1" carriage bolts.
• Slide 4 pcs. of 1" carriage bolts.
HARDWARE USED
DRIVER SIDE
Front crossbow
Rear crossbow
PASSENGER SIDE
Front crossbow
• Slide 4 pcs. of 1" carriage bolts.
Rear crossbow
• Slide 2 pcs. of 3/4" carriage bolts.
• Slide 4 pcs. of 1" carriage bolts.
HARDWARE USED
#90-487 Carriage Bolt 5/16" × 3/4" SS304
#90-491 Carriage Bolt 5/16" × 1" SS304
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#90-491 Hex Bolt 5/16" × 1" SS304
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1.2.4 Install the feet on the Front, and Rear Crossbows.
HARDWARE USED
16× hand-tighten the nuts.
Carriage bolts are already on the crossbows.
#98-117 Flat Washer
#98-123 Lock Washer
#94-105 Hex Nut
1.2.5 Fasten the Ladder Clamp assemblies to the Rear Crossbow.
12-3/4"
TOOLS
q Cordless Impact q 1/2" Socket q Tape Measure q Marker
HARDWARE USED
Carriage bolts are already on the crossbows.
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#98-117 Flat Washer
#98-123 Lock Washer
#94-105 Hex Nut
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1.2.6 • Pull out the 14.5" track plug on the passenger side of the front crossbow.
• Loosen the pre-assembled hardware on the front hook and slide the hook onto the passenger side of the front crossbow to the position shown below.
• Cut the track plug, then attach it back to the crossbow.
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8.5"
Tighten the nuts just to hold the front hook for adjustment.
TOOLS
q Marker
HARDWARE USED
hardware is pre-assembled.
#90-491 Carriage Bolt 5/16" × 1"
#98-117 Flat Washer
#98-123 Lock Washer
#94-105 Hex Nut
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1.2.7 Install the front crossbow to the ski.
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TOOLS
q Cordless Impact q 1/2" Socket
HARDWARE USED
Carriage bolts are already on the ski.
#98-117 Flat Washer
#98-123 Lock Washer
#94-105 Hex Nut
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1.2.8 Loosen the pre-assembled hardware on the ladder clamp hasp, slide the hasp on the ski to the position shown below, and tighten the nuts.
15 - 1/2"
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TOOLS
q Cordless Impact q 1/2" Socket q Tape Measure q Marker
HARDWARE USED
hardware is pre-assembled.
#90-487 Carriage Bolt 5/16" × 3/4"
#98-117 Flat Washer
#98-123 Lock Washer
#94-105 Hex Nut
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1.2.9 Slide 3pcs. of carriage bolts on the rear end of the ski, then attach end plugs on both ends of the ski.
end plug
end plug
end plug
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TOOLS
q Mallet
HARDWARE USED
#90-491 Carriage Bolt 5/16" × 1" SS304
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1.2.10 Install the Rear Crossbow to the ski with the clamp handle support, aligning the rear surface of the crossbow bracket to the rear surface of the ski.
TOOLS
q Cordless Impact q 1/2" Socket
HARDWARE USED
Carriage bolts are already on the ski.
#98-117 Flat Washer
#98-123 Lock Washer
#94-105 Hex Nut
Carriage bolts are already on the ski.
#98-160 Spacer
#98-117 Flat Washer
#98-123 Lock Washer
#94-105 Hex Nut
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PHASE 2 – INSTALLATION
2.1 MOUNTING TRACKS PREPARATION
2.1.1 Mounting tracks preparation for regular distance.
Ranger Design Tracks
Regular
Slide bolts on top and bottom side of the mounting tracks, then attach the end caps on both ends of the mounting tracks.
Rear Front
HARDWARE USED
top
#90-491 Carriage Bolt 5/16" × 1" SS304
bottom
HARDWARE USED
top
#90-491 Carriage Bolt 5/16" × 1" SS304
bottom
#90-495 Hex Bolt 5/16" × 1 - 1/4" SS304
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#90-495 Hex Bolt 5/16" × 1 - 1/4" SS304
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2.1.2 Mounting tracks preparation for extended distance.
Ranger Design Tracks
Extended
Slide bolts on top and bottom side of the mounting tracks, then attach the end caps on both ends of the mounting tracks.
Rear Front
HARDWARE USED
top
#90-487 Carriage Bolt 5/16" × 3/4" SS304
bottom
HARDWARE USED
top
#90-487 Carriage Bolt 5/16" × 3/4" SS304
bottom
#90-495 Hex Bolt 5/16" × 1 - 1/4" SS304
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#90-495 Hex Bolt 5/16" × 1 - 1/4" SS304
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PHASE 2 – INSTALLATION
2.2 MOUNTING TRACKS INSTALLATION
Ranger Design Tracks
2.2.1 • Remove the plugs on the roof holes, then apply a bead of silicone around each hole.
• Put at washers and neoprene spacers on the bottom bolts, then cut the plug extrusion into 8 pieces of 6" and attach one piece on both ends of the mounting tracks.
• Align the bottom bolts to the roof holes, then install the mounting tracks onto the roof.
Regular
14×
TOOLS
q Cordless Impact q 1/2" Socket
"
6
#90-495 Carriage Bolt 5/16" × 1-1/4"
#98-109 Flat Washer
#98-149 Neoprene Spacer
#94-116 Serrated Nut
q Knife
Extended
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16×
TOOLS
q Cordless Impact q 1/2" Socket
"
6
#90-495 Carriage Bolt 5/16" × 1-1/4"
#98-109 Flat Washer
#98-149 Neoprene Spacer
#94-116 Serrated Nut
q Knife
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With OEM Tracks
2.2.2 Put bolts on the 2 middle holes of the support plates, then slide the plates on the ends
of the OEM mounting tracks.
FASTENERS USED
#90-491 Carriage Bolt 5/16" × 1"
PHASE 2 – INSTALLATION
2.3 LADDER RACK INSTALLATION
2.3.1 Position the Ladder Rack ( minimum two persons ) on the vehicle so that the feet are on the tracks.
NOTE: If you do not have a hoist, lift the ladder rack onto the roof manually.
Ladder Rack
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2.3.2 While making sure the crossbows are parallel to each other, slide the rack to the appropriate position, then attach all the “V” feet to the mounting tracks.
distance < foot to end of track >
distance < A >
distance < B >
distance < A >
TOOLS
q Ratchet q 1/2" Socket q Tape Measure
distance < B >
With OEM TracksRanger Design Tracks
FASTENERS USED
Carriage bolts are already on the tracks or plates
#98-117 Flat Washer
#98-123 Lock Washer
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#94-105 Hex Nut
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2.3.3 Center the crossbows on the vehicle, then tighten all the “V” feet to the crossbows.
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TOOLS
q Ratchet q 1/2" Socket
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2.3.4 Ladder Rack adjustment.
NOTE: The ladder cannot extend beyond the rear bumper of the vehicle.
IMPORTANT: • After installation is complete, cut the track plug underneath the front crossbow to ll all the
unused space.
• Place the ladder rack warning label on a visible area, recommended on a partition.
When the rear hook touches the ladder, the handle should be 1" below the ladder clamp hasp.
rear hook
1"
Now adjust the front hook to be snug against the ladder rung and tighten the bolts on the front crossbow.
TOOLS
q Cordless Impact q 1/2" Socket
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front hook
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PHASE 2 – INSTALLATION
2.4 NOTE
2.4.1 If the handle is interfering with the door or roof of the vehicle, the handle can
be installed in an alternate position.
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If the handle is interfering with the door or roof of the vehicle, disassemble the handle, then assemble it in an alternate position as shown.
Handle
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“You have successfully installed your
1520-DH Ladder Rack
Thank you for doing business with us.”
For any feedback or suggestions you may have, please contact: cs@rangerdesign.com
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