Rear Katerack Installation Instructions

Transcription

1 Rear Katerack Installation Instructions Ram Promaster City Frame Kit Part #: CRC V

2 IMPORTANT INSTALLATION STEPS ARE DENOTED USING A STOP SIGN. THESE STEPS MUST BE PERFORMED IN THE SPECIFIED ORDER TO ENSURE PROPER INSTALLATION AND MUST BE FOLLOWED IN ORDER TO MAINTAIN YOUR PRODUCT WARRANTY! CRITICAL INFORMATION PERTAINING TO USER AND/OR VEHICLE SAFETY IS DENOTED USING A CAUTION SIGN. SAFETY ITEMS MUST BE STRICTLY ADHERED TO IN ORDER TO ENSURE A SAFE WORKING ENVIRONMENT! WARNING THE USE OF DRILLS WITH INTEGRAL DRILL STOPS ALONG WITH PROPER INSPECTION FOR GAS TANK, GAS LINES, BRAKE LINES AND ELECTRICAL LINES PRIOR TO DRILLING ANY MOUNTING HOLES IS STRONGLY RECOMMENDED TO ENSURE THAT VEHICLE DAMAGE IS AVOIDED! THE USE OF AIR OR ELECTRIC IMPACT TOOLS FOR THE ASSEMBLY OF FASTENERS COULD CAUSE FASTENER FAILURE! THE USE OF NON STANDARD FASTENERS AND/OR DEVIATING FROM THE FASTENERS SPECIFIED IN THESE INSTRUCTIONS MAY VOID YOUR PRODUCT WARRANTY! ALL DRILLED HOLES IN THE VEHICLES SHOULD HAVE THE RAW METAL EDGES SEALED WITH A SELF ETCHING PRIMER TO RESIST CORROSION AND POTENTIAL FASTENER POINT FAILURE!

3 TOOL LIST Safety glasses MUST be worn at all times! TOOLS Drill Drill Bits Drill Stop Ratchet Wrench 3/8 1/2 Drill 10 Drift Punch Box End Wrench Rubber Mallet/ Steel Hammer 7/16 Socket; T40 TORX Bit with Misc. Extensions (Used in aligning bolt holes) 7/16 RECOMMENDED TOOLS: Inch-pound Torque Wrench Pneumatic Plus Nut Gun Impact Gun Leveling Gauge

4 Hardware: FAS NYLOCK NUT, 1/4-20 (QTY: 16) FAS SERRATED FLANGE BOLT, 1/4-20 X 3/4 (QTY: 16) FAS FLAT WASHER, 1/4 X 5/8 O.D. (QTY: 16) Step 1: Assemble Side Frame Subassemblies If pre-assembled from manufacturer proceed to Step 2. A. Assemble strut channels, angle, and baseplates into subassemblies. 1/4-20 hardware is used at all hole locations. Continually check that the frame is square during assembly. Baseplates have Curbside and Streetside callouts.

5 Hardware: FAS /4-20 HEX BOLT, 1.25 L (QTY: 6) FAS WASHER LOCK, 1/4 (QTY: 6) FAS FLAT WASHER, 1/4 X 5/8 O.D. (QTY: 6) FAS /4-20 PLUS NUT (QTY: 6) Step 2: Install Upper Mounting Brackets A. Drill through the (2) specified pilot holes on both the Curbside and Streetside using a 3/8 drill bit. Insert (2) 1/4-20 plus nuts into drilled out holes. Use drill stop when drilling into vehicle. Curbside Use rust blocker or any other form of rust protection spray on drilled out holes. Refer to page 7 on how to install plus nuts. Roadside

6 Step 2: Install Upper Mounting Brackets, CONT d. B. Fasten 1/4-20 hex bolts into the installed plus nuts. When fastening, make sure that upper mounting brackets are parallel with the floor of the vehicle. C. Mark the remaining (4) hole locations on both the Curbside and Streetside. Remove upper mounting brackets from their position and drill at the marked holes using a 3/8 drill bit. Insert (4) 1/4-20 plus nuts into drilled out holes. Upper mounting brackets have callouts for Streetside and Curbside. Use drill stop when drilling into vehicle. Use rust blocker or any other form of rust protection spray on drilled out holes. Refer to page 7 on how to install plus nuts. D. Now loosely fasten the upper mounting brackets into the plus nuts using 1/4-20 hex bolts. Include flat and lock washers when fastening FAS

7 Step 2: Install Upper Mounting Brackets, CONT d. Before drilling check all mounting locations to prevent penetration of: Gas Lines, Gas Tanks, Break Lines, Wiring or any other vehicle structure. There are 2 methods for installing the Plus Nuts: Manual & Automatic (They are both listed below) C. First Method: Manual The Plus Nut is Pre-bulbed for easy installation. 2. The Plus Nut is pre-assembled with hex cap and hex bolt, then inserted into predrilled hole. 3. As the bolt is tightened the Plus Nut expands holding in place. 4. Full tightened Plus Nut provides reliable nut plate for fastening. Second Method: Automatic (Requires Pneumatic Plus Nut Gun) 1. Thread Plus Nut onto Plus Nut Gun. 2. Screw Plus Nut into Hole. 3. When Plus Nut is fully tightened remove Plus Nut Gun.

8 Step 3: Mount Frame Kit to the Floor A. Remove the (4) truss head bolts and D-rings from the floor on both the Curbside and Streetside of the vehicle using a T40 Torx bit. B. Place frame kit subassemblies into the vehicle on their respective sides. Lineup the baseplates with the OEM holes in the vehicle and use the same D-ring and truss head bolt you removed from the floor to fasten the baseplates to the vehicles floor. Baseplates have callouts for Streetside and Curbside.

9 Hardware: FAS NYLOCK NUT, 1/4-20 (QTY: 8) FAS SERRATED FLANGE BOLT, 1/4-20 X 3/4 (QTY: 8) FAS FLAT WASHER, 1/4 X 5/8 O.D. (QTY: 8) Step 4: Mount Frame Kit to Upper Mounting Brackets A. Begin loosely fastening the upper mounting brackets to the aluminum angles of the side frames using 1/4-20 bolts.

10 Step 4: Mount Frame Kit to Upper Mounting Brackets, CONT d. IMPORTANT! SQUARE UP THE FRAME KIT AND MAINTAIN IN BETWEEN THE STRUTS IN BOTH THE CURBSIDE AND ROADSIDE, AS WELL AS AT THE TOP AND BOTTOM OF THE STRUTS B. Before you begin the installation of the drawers, check that the frame is square by using a level gauge and eyeing that the frame kit is square. The frame kit should have the dimensions shown below. Once frame kit is fully square, tighten all bolts. Loosen bolts at baseplates if necessary to get these dimensions.

11 Hardware: AUST MBH 1179 A01 STRUT NUT INSERT (QTY 4, per drawer) Step 5: Drawer Installation A. Insert the Strut Nut assemblies into the strut channel at the exact same height and snug down ¼ -20 hex bolts with wrench. B. Extend drawer fully to the locked out position. Using the (4) #10-32 Pan Head Screws supplied with strut nut, securely attach slide to inserts. Align all 4 Strut Nut inserts vertically. One bolt at each strut nut kit at each vertical strut C. Place Drawer back to the closed position (at your desired shelf height) and tighten the ¼ -20 hex bolts to 100 in-lbs. To adjust the shelving height, loosen ¼ -20 hex bolts. Moving drawer parallel to floor with a second person to keep level. D. Repeat steps A, B, and C for each additional drawer you wish to add.

12 Bill of Material ITEM NO. PART NUMBER DESCRIPTION QTY. 1 AUS TB STRUT CHANNEL, L 4 2 CRF UPPER FRAME ANGLE 2 3 CRF BASEPLATE, CS 1 4 CRF BASEPLATE, RS 1 5 CRF TOP ATTACHMENT BRACE, CS 1 6 CRF TOP ATTACHMENT BRACE, RS 1 7 CRC REAR KATERACK DRAWER TBD 8 FAS SERRATED FLANGE BOLT, 1/4-20 X 3/ FAS FLAT WASHER, 1/4 X 5/8 O.D FAS NYLOCK NUT, 1/ FAS WASHER, LOCK, 1/4" 6 12 FAS /4-20 HEX BOLT, 1.25 L 6 13 FAS /4-20 PLUS NUT 6 14 AUST MBH 1179 A01 STRUT NUT INSERT (4 PER DRAWER) TBD

13 Technical Drawing

14 Inspection Dimensions