SERVICE BODY PRO-II. ASSEMBLY INSTRUCTIONS for : Parts: & (916) (800)

Transcription

1 ASSEMBLY INSTRUCTINS for : R-II SERVICE BDY arts: & _1.1 (916) (800) G Trade Center Drive Rancho Cordova, CA 95742

2 R II - SERVICE BDY 1 J 4 3 G I A M L 2 Q K U N U E W I 5 G I V R U = R U V 12_1.1

3 G (4 ea.) 1/2" x 2 1/2" Button ead Bolt (6 ea.) 1/2" x 1" ex Bolt A (4 ea.) 1/2" x 1 1/2" ex Bolt K (2 ea.) 3/8" x 3 1/2" Tap Bolt V (6 ea.) 3/8" x 1" Button ead Q (4 ea.) 5/16" x 3/4" Carriage Bolt (20 ea.) 1/2" SAE Flat Washer (6 ea.) 1/2" Lock Washer U (14 ea.) 3/8" SAE Flat Washer L (4 ea.) 5/16" Flat Washer I (8 ea.) R (8 ea.) M (4 ea.) 1/2" Jam Nut 3/8" Lock Nut 5/16" Lock Nut N (2 ea.) 3/8" Coupling Nut W (2 ea.) lastic Knob E (2 ea.) 3/8" Lock Washer 2012 KARG MASTER --SrvBody 12_1.1

4 SRV-BDY 12_1.1 BEFRE YU BEGIN, LEASE VERIFY TAT TIS RACK WILL FIT YUR SERVICE BDY. #1- Side Channel kit will fit an 8ft. body mounted on an extended cab chassis. Side Channel kit will fit an 8ft. body mounted on a standard cab chassis. Side Channel kit will fit a 9ft. body mounted on an extended cab chassis, or an 11 ft. body mounted on a standard cab chassis. Side Channel kit will fit a 9ft. body mounted on a standard cab chassis. #2- The "bulkhead" is the panel that is the front of the service body. Measure the distance from the top of the bulkhead to the top of the truck's cab. This distance should be in the range of 15" to 22". #3- Standard mounting is on rear panel. Check to ensure that the rear panel of the service body is free of taillights or other obstructions (inside or out) in the area where the rear legs of the rack bolt to the body. Consult sketch below: NTE: If it is not possible to attach the included rear leg mounts to your service body back panel because the panel is plastic or because the tail lights or box lock handle are in the way, please see TINAL MUNTING METDS on the back page. These options require accessory mount kit #70060 purchased separately. LBS. REAR MUNTS ATTACING AREA 7" VARIABLE EIGT ADJUSTMENT AREA 77.5" - 79" ALICATIN Swaged joint & holes Apply a healthy air tight bead of goop around every swaged joint as shown, to prevent moisture from leaking into and out of the joint. If this is not done properly, the inside surface of the tubes can rust and rusty water can leak out. Maintain this joint seal throughout the life of your rack. Smooth goop at swaged joint & holes

5 SRV-BDY 12_1.1 STE 1 #1 = Cover entire swedge joints with and join FRNT and REAR side channels together. Be sure the connecting plates overlap and bolt together with bolts Q, washers L and lock nuts M. M L Q STE 2 D #1= Slide REAR BAR on to 04 REAR SIDE BEAMS 06 D 06 #2= Fully insert LCK INS J J J completely to the bend of the pin. STE 3 #1= Cover entire swedged joint surfaces with, Slide FRNT CRSS BAR A, into FRNT SIDE BEAMS G 03 #2= BLT TGETER using G, & I. The allen wrench is included in the package.rear SIDE BEAMS A I

6 / W U STE 4 #1= Turn partially assembled rack upside down as shown. Cover entire swedged joint surfaces with, then insert the swedged end of each REAR leg, rope hooks facing outward, into the short tubes projecting from the bottom of the SIDE BEAMS. See recomomended "Support Tube" installation on following pages. SRV-BDY 12_1.1 #2= Bolt REAR LEGS and REAR BAR BRACE (as shown) K U N E #3= After determining your service body length, attach FRNT CRSS BAR to appropreate U Clips with bolts A, flat washer and jam nut I. NTE: 11 ft U-Clip will be on the model only. #4= Start bolt, with lock washer, flat washer, into ends of 4th CRSS BAR, position onto rack then with an open end 3/4" wrench, snug bolts on each side of the rack. I I G A U Clips B ft 11 ft (79010 model only)

7 Recommended support installation. In the front of the service body, lace corner support ( ) into corner as shown. The bracket should be touching 3 panels of the service body. Mark the 3 holes parallel with the cab and the two holes on the side box. Drill with 5/16" drill. *Be sure not to drill into anything on the backside of the marked holes* Bolt corner support to service body using 5/16" hardware. For each drilled hole, use one 5/16" x 1" ex ead bolt, two 5/16" flat washers and a 5/16" Nyloc nut. Start with the two holes into the side box as shown. assenger Side

8 We recommend installing support tube ( ) to the front legs directly behind the cab of the vehicle. If front legs already bolted to top assembly, replace 1/2" x 2.5" Button head bolt with a 1/2" x 3.25" bolt. Along with bolt, use two 1/2" flat washers and a 1/2" Nyloc Nut. **In some cases, support tube will go on the other side of front leg than what is shown** D NT TIGTEN

9 Approximately align your tube at a 45 degree angle. Mark through the bottom hole of the support tube into the side of your service body. Be sure you can access the back side of where the hole was marked. Make sure nothing important is behind marked hole. Drill a 3/8" hole through the service body. Bolt bottom of support tube to service body using a 3/8" x 1" Button ead, two 3/8" flat washers and a 3/8" Nyloc Nut. Repeat on both sides. Tighten all bolts.

10 STE 5 SRV-BDY 12_1.1 #1= #2= Set rack on the service body, with the "bulkhead angle iron mounting bracket" centered between the boxes and pushed forward against the bulkhead. Bring the rack approximately level, and support the rear with clamps, blocks, or forklift. Bolt the bulkhead mounting bracket to bulkhead using bolts V, flat washers U and lock nuts R. ush the rack forward in the mounting bracket slots so that the rear leg mount plates are firmly against the rear of the service body boxes and position the mounts so that the rack is level and centered. Before drilling holes in the service body, check to ensure that the CRSS BAR is about 3" higher that the truck cab. Drill holes with a 3/8" drill bit through the back of the boxes and attach the rear mounting plates with button head bolts V, flat washers U and lock nuts R. Bolt the legs (loosely) to mounting plates with bolts, lock washers and flat washers. Tighten down ALL bolts except bolts. #3= The lock pins (J) securing the removable rear cross bar (D) will not slide in and out easily unless the holes are aligned. Move each rear leg left or right in the slot to ensure proper alignment. Tighten bolts. Tighten down all nuts & bolts and TAT'S IT! You are now ready to use your rack.

11 A B LBS. TIN TIN A URCASED SEARATELY: URCASED SEARATELY: When it is not possible to attach the included rear leg mounts to the back panel of your service body, an alternative is to mount the rear legs on top of the box. This works for Stahl bodies and all other service bodies with side opening boxes. In order to do this, you must purchase our accessory mount kit #70050 that includes shorter rear legs and a small mount plate that enable you to bolt the legs to the top of the box. WIT TIS MUNT, TERE IS N IEGT ADJUSTMENT. 1 1/2 B When it is not possible to attach the included rear leg mounts to the back panel of your service body in the ATTACING AREA as shown on page 1, an alternative is to mount the rear legs below the box lid and above the tail light/box lock. This works on all service bodies that do not have plastic back panels. In order to do this, you must purchase our accessory mount kit #70050 that include shorter legs and horizontal angle iron mount brackets (1 1/2 total height) that will fit below the box lid and above the obstruction. WIT TIS MUNT, TERE IS N EIGT ADJUSTMENT. DN'T VERLAD YUR VEICLE! 12_ " = X3 lbs. VERTURN FRCE LBS. 35" = x1 lbs. WEIGT CARRIED ABVE TE FLR F TE TRUCK BED (E.G. N AN VEREAD TRUCK RACK) WILL SIGNIFICANTLY INCREASE TE VEICLE'S TENDENCY T VERTURN. ALWAYS KEE EAVY LADS EVENLY DISTRIBUTED AND AS LW AS SSIBLE. IT IS IMRTANT T NTE TAT TE KARG MASTER RACK LAD BEARING CAACITY F 1700 LBS. MAY BE GREATER TAN YUR TRUCK'S GAWR R GVWR CAACITY, AND IS RBABLY GREATER TAN TE WEIGT TAT CAN BE SAFELY CARRIED VEREAD. For TECNICAL SURT Call: URS: Monday- Friday 8:00 A.M. to 4:30.M. ( ACIFIC )