PRORAC CONTRACTOR SERIES UNIVERSIAL STEEL TRUCK / CAP RACK INSTALLATION INSTRUCTIONS 1000 Lb. Capacity Bed Mount 750 Lb. Capacity Cap Mount Package Contents: Parts Hardware (4) Legs (12) 3/8-16 x 1-1/4 Hex Head Bolts (86) Flat Washers (4) Camper Plates (28) 3/8-16 x 2-3/4 Hex Head Bolts (13) 3/8 Split Lock Washers (2) Outer Crossbars (4) 3/8-16 x 4-1/2 Hex Head Bolts (36) 3/8-16 Nylon Insert Locknuts (2) Inner Crossbars (4) 3/8-16 x 5 Hex Head Bolts (12) 3/8-16 Nuts (2) Front Crossbar Adaptors (1) 3/8-16 Wing Nut (1) Middle Front Crossbar (1) Tube of Silicone (2) Front Rails (8) 2 Square End caps (2) Rear Rails (4) 1-3/4 Square End caps (2) Rear Rail Adaptors Before you begin: Do not carry more than 1000 pounds (454Kg) for leg mount or 750 pounds (340Kg) for cap mount of combined cargo and accessories on ProRac crossbars. Distribute loads evenly across both crossbar. ProRac cannot warranty loads that exceed this limit. Remove all components from the shipping carton and read the instructions thoroughly to familiarize yourself with the assembly sequence. Gather the following tools used to assemble and install the rack. 9/16 Socket and open end wrench 3/8 dia drill bit and drill Marker Tape measure Tape 1 of 16
Step 1 Locate legs on truck bed Locate on the truck bed where the front and rear legs will be positioned. The ideal positions for the legs are as far forward for the front legs and as far rearward for the back leg. You will need to have open access underneath the top of the bed surface for mounting the legs to the bed. Check for obstructions in mounting the legs to the truck bed such as stake pocket holes or limited access to the underside of the top surface of the bed. Check for function of tailgate or interference with the cab of the truck. Adjust as needed. The spacing between the centers of the bolt holes is 4-1/2. Place tape over the desired positions. Place a leg on top of the tape and position the leg to the desired location on the top surface. For best results, use a tape measure so each legs is positioned equally with the other side. Using a marker, mark the outline of the leg and the center of the two mounting holes onto the tape. Repeat for all legs 2 of 16
Step 2 Measure distances Truck Bed Mount Measure from driver side to passenger side on the inside marked edges of the tape where the legs where outline from step 1. See illustration below. Cap Plate Mount Measure from driver side to passenger side inside edges of the bed rail. See illustration below. Front truck leg or cap mount span = Rear truck leg or cap mount span = Measure the distance between the marked inside edges of the legs front to back and record the value below. Inside span between front and rear legs = From the measurements above Front cap bed mount span +12 = Rear cap bed mount span +12 = 3 of 16
Step 3 Crossbar assembly Crossbar width fit Because truck beds widths can taper front to back, each crossbar will be set specifically to match where it is mounted on the bed. The crossbar width will be 5-1/4 shorter than the length measured. Using the measurements from step 2, Front Legs span - 5-1/4 = Rear Legs span - 5-1/4 = Slide the 1-3/4 inner crossbar tube into the 2 out crossbar tube as shown until they measure the length from above. Temporarily secure the two crossbars together by wrapping tape around the end of the 2 outer crossbar and 1-3/4 inner crossbar. Using the 2 tube bolt holes as guides; mark the center of the holes using a center punch. Drill the holes marked with a 3/8 drill bit on both sides. Remove tape that was temporarily holding the two crossbars together. Align the bolt holes of both tubes. Apply a small bead of silicone around the bolt holes on the larger tube. Insert the 3/8-16 x 2-3/4 bolt with a flat washer through the crossbar. Secure the bolt with a flat washer and 3/8-16 nylon insert lock nut. Repeat for other bolt hole. Place the end caps on the ends of the crossbar. Apply silicone to the gap between the inner and outer crossbar to seal out water and reduce wind noise. Repeat step for other crossbar. 4 of 16
Step 4 Crossbar to leg assembly Note: Rail pass through tube on leg is not shown for exploded view clarity. You may mount to either the front side or rear side of the legs. Orientate the 1-3/4 tube as shown (note the holes are not centered on this end of the crossbar) Starting with the bottom hole first, insert the 3/8-16 x 4-1/2 bolt with a flat washer through the leg and 1-3/4 square crossbar. Secure the bolt with a flat washer and 3/8-16 nylon insert lock nut. Note the spacing between the washer fit is tight, it maybe necessary to adjust the washer centering so they will both fit flush on the legs and crossbars. Repeat for other bolt hole. Lightly tighten the hardware. Insert the 2 square end cap into the top of the leg. 5 of 16
Step 4 (continued) Crossbar to leg assembly Note: Rail pass through tube on leg is not shown for exploded view clarity. Orientate the 2 tube as shown (note the holes are not centered on this end of the crossbar) Starting with the bottom hole first, insert the 3/8-16 x 5 bolt with a flat washer through the leg and 2 square crossbar. Note the spacing between the washer fit is tight, it maybe necessary to adjust the washer centering so they will both fit flush on the legs and crossbars. Secure the bolt with a flat washer and 3/8-16 nylon insert lock nut. Repeat for other bolt hole. Insert the 2 square end cap into the top of the leg. Lightly tighten the hardware. 6 of 16
Step 5 Rear leg subassembly On the rear legs, slide the 1-3/4 x 12 tube adaptor into the rail tube and align the bolt holes and secure with (2) 3/8-16 x 2-3/4 bolts, (4) flat washers and (2) 3/8-16 nylon insert lock nuts. Place 2 square end caps on the rear of the leg and top of leg. Repeat for other leg. Step 6 Rear Rail assembly Slide the 2 square tubing rear rail section onto the rear leg subassembly. Align the bolt holes and secure with (with (2) 3/8-16 x 2-3/4 bolts, (4) flat washers and (2) 3/8-16 nylon insert lock nuts. Repeat for other side. 7 of 16
Step 7 Front Rail assembly Slide the front rail through the front legs and line up the bolt holes for 10 length. If a shorter length is desired, slide the front rail into the rear rail to the desired position. Mark the holes. Remove front rail and drill holes. Reinsert the front rail into the rear and line up holes. Align the bolt holes and secure with (with (2) 3/8-16 x 2-3/4 bolts, (4) flat washers and (2) 3/8-16 nylon insert lock nuts. Seal the gap between the rails with silicone. Repeat for other side. Insert 1-3/4 square end caps into the front rails. 8 of 16
Step 7 Front leg to front rail assembly Slide the front legs on front rail. Adjust the span between the front and rear legs so the distance matches the measured spacing above. Temporarily secure the front legs to the rails with tape as shown. This will allow you to set the rack on the vehicle and adjust for final fit. Mount the middle crossbar to the front legs using hardware as used for mounting the rear crossbar to the rear legs. Adjust the legs to crossbar so the leg feet are flush with the ground. Tighten the crossbar to leg hardware. 9 of 16
Step 8 Front Crossbar assembly Loosely bolt one end of the front crossbar rail adaptor to a rail with (2) 3/8-16 x 2-3/4 bolts, (4) flat washers and (2) 3/8-16 nylon insert lock nuts.. Slide the front crossbar middle tube onto the front crossbar rail adaptor and push it so it is close to the front rail. Slide the other front crossbar rail adaptor into the front middle crossbar tube and then loosely bolt it to the front rail with (2) 3/8-16 x 2-3/4 bolts, (4) flat washers and (2) 3/8-16 nylon insert lock nuts. 10 of 16
Step 8 (continued) Front Crossbar assembly Center the front middle crossbar tube between the front rail crossbar adaptors. For best results, use a tape measure. Temporally secure the middle crossbar to front rail crossbar adaptors with tape. This will keep the middle crossbar in place while drilling holes to secure it to the rail adaptors. Tighten the hardware for the front rail adaptors. Locate the center of the front middle crossbar marked holes and use a center punch. Drill the 3/8 holes on both sides. Repeat for all holes. Secure with (4) 3/8-16 x 2-3/4 bolts, (8) flat washers and (4) 3/8-16 nylon insert lock nuts. and apply a small silicone bead around the bolt holes before putting on the flat washers. Remove the tape and seal the gap between the crossbars on both sides with silicone. 11 of 16
Step 9 Rack placement on bed CAP PLATES If using a cap plates, bolt the plate to the leg using (2) 3/8-16 x 1-1/4 bolts, (2) flat washer, (2) split lock washers and (2) 3/8-16 nuts. Repeat for remaining plates and legs. With an assistant place on the vehicle and align to desired position. Using the cap plate side bolt hole as a guide, drill a 3/8 hole through the truck bed side rail wall. Apply a small bead of silicone around the drilled hole. Bolt the plate to the truck bed with a 3/8-16 x 1-1/4 bolt, flat washer, split lock washer and 3/8-16 nut. Repeat for remaining cap plates. TRUCK BED MOUNT Drill out the holes marked on the tape with a 3/8 drill and remove tape from the truck bed. Apply a small bead of silicone around the drilled holes. With an assistant, lift the rack and place on the bed of the truck and align the bolt holes in the leg feet with the holes drilled in the bed. Loosely secure the legs to the bed with (2) 3/8-16 x 1-1/4 bolts, (2) flat washers, (2) split lock washers and (2) 3/8-16 nuts. 12 of 16
Step 10 Front Leg to front rail Remove the tape from the front leg rail pass through tubes and adjust the front legs so they are perpendicular to the rails. Check that the legs to crossbar assembly is square and tighten the hardware, starting with the crossbar bolts and then proceeding to the legs. Locate the center of the holes on the front legs rail pass through tube marked holes and use a center punch Drill a 3/8 holes on one side and insert a 3/8 bolt through the leg and into the rail to hold the leg to rail assembly in place and continue to drill the other (3) holes. Secure with hardware and apply silicone to the flat washers. Tighten the leg hardware. Repeat for other side. Seal the gap of the front rail and the rail pass through tubes with silicone. Check to make sure the crossbar is square to the upper portion of the legs. Adjust as needed and then tighten the hardware. Go around rack and check and tighten all hardware. 13 of 16
Removable rear cross bar option. The rear crossbar can be removed or pivot out of the way when loading tall upright cargo into the truck bed. Removal To remove the rear crossbar - unbolt the crossbar from the leg on both sides. NOTE: Always have the crossbar secured with all bolts on both ends when using the vehicle. Pivoting crossbar Note! This feature should only be used when a load is not carried on the crossbars. If a load is going to be carried on the crossbars, all four bolts must be used to secure the crossbar to the legs! To change the rack for pivoting the rear crossbar, remove the hardware holding the rear crossbar in place. On the end with the 1-3/4 inner crossbar, use a 4-1/2 bolt with flat washer and slide them through the upper hole of the leg. Place a flat washer on the 4-1/2 bolt and move it to so it contacts the leg. Place the crossbar onto the bolt and slide towards the leg. Secure the crossbar to the leg using a flat washer and nylon insert lock nut. Tighten the nut and bolt enough so the crossbar can be rotated around the bolt but not binding. 14 of 16
Removable rear cross bar pivot continued. On the end with the 2 outer crossbar, use a 5 bolt with flat washer and slide them through the upper hole of the leg. Place the crossbar onto the bolt and slide towards the leg. Secure the crossbar to the leg using a flat washer, split lock washer and wing nut. Tighten the wing nut enough to flatten the split lock washer. NOTE: Always check so make sure the wing nut is tight before and during use. If the wing nut loosens, replace by removing the split lock washer and use a 3/8-16 nylon insert lock nut. NOTE: Always have the crossbar secured on both ends when using the vehicle. 15 of 16
Customer Limited Warranty and Standard Return Policy Hauler Racks, Inc. offers to preferred customers a special limited warranty. It is our goal to provide effective service for any warranty or standard return. This statement of warranty and return policy is divided into two sections: Warranty Returns of Defective Product and Standard Returns of Unused Product. Warranty Returns of Defective Product Hauler Racks, Inc. will repair or replace, at its option and without charge, any properly installed Hauler component that fails due to defect in material or workmanship up to 30 days from the initial registered consumer purchase. All of our aluminum product line is guaranteed not to rust or corrode for 1 year. Proof of Purchase must be provided for warranty to be honored. Loads should never exceed 1/3 of your vehicle s manufacturer s total load capacity. Loads should never extend more than 1 foot on either end of rack. This warranty is void if any damage to the product is due to misuse, abuse, neglect, accident, improper installation, or any uses contrary to the instructions accompanying the product. The warranty is also void if racks are altered in any manner. The racks have been load tested for the racks capacity to hold loads when not on a vehicle. Hauler Racks, Inc. does not warranty load capacities. As the factory has no way of knowing if the product was properly assembled, installed, used according to instructions, or if loads were secured properly. This warranty covers the cost of the defective component and not the cost of removal, installation or other incidental charges unless other arrangements have been made with Hauler Racks. This warranty gives you specific legal rights and you may have other rights which vary from state to state. All warranty claims must receive a Return Authorization number from Hauler Racks, Inc. BEFORE the product is returned to the Company. Please follow this procedure: 1. Call Hauler at 800-843-5445 to request a Return Authorization number. You will need to provide the following information Specific nature of the defect Product installation date Product part number Original sales invoice number 2. When a replacement or repair strategy is determined, a Return Authorization number will be assigned to the claim. 3. A replacement invoice and shipping document will be generated at Hauler Racks to initiate any replacement product. Replacement product will be sent according to standard shipping cycles. 4. The purchaser is responsible for packing and return shipping of the product. The RETURN AUTHORIZATION NUMBER MUST BE CLEARLY MARKED ON THE OUTSIDE OF THE PACKAGE. Unmarked packages will be refused. Any product damage that occurs during the shipping is not covered under warranty. The purchaser must pursue claims for shipping damage with the shipping center. 5. The purchaser is responsible for payment of both the original product invoice and the replacement invoice according to established credit terms. 6. Upon receipt of the returned product, Hauler Racks will review the claim for warranty conformance. If the claim meets warranty criteria, a credit for the original invoice amount will be posted to the purchaser s account and a credit memo will be mailed. If the claim does not meet warranty criteria, the purchaser will receive a statement detailing reasons for partial credit or denial. At the purchaser s option, denied product may be returned to the purchaser. Standard Returns of Unused Product Unused product may be eligible for return to Hauler Racks, Inc. Follow the procedure described in the section on Warranty Returns to receive an Authorization Number. Returned product which is less than 6 (six) months old is subject to a 20% restocking fee. Returned product which is more than 6 (six) months old may not be eligible for return or may incur additional restocking charges. HMIS37 Steel Truck / Cap Rack 2009 Hauler Racks, Inc. Revised 5-12-2009 16 of 16