ALR10011
- Easy
On/Off Ladder Rack
01/2001
Installation
Instructions:
Tailgater’s
“Easy On/Off Ladder Rack” system is to be assembled in various stages. It is
very important that key items are placed in proper order. PLEASE FOLLOW INSTRUCTIONS
CAREFULLY.
Tools:
To properly
assemble this rack, unit, you should have the following tools: ½” Wrench, 3/8”
drive ratchet, ½” socket, short extension, 3/8” hand drill, 3/8” drill bit,
rubber mallet, tape measure, and torque wrench.
*******SAFETY
FIRST********
Please follow
all safety procedures for lifting, eye protection and power tools operation.
**************************
Assembly Instructions: Before we begin the assembly, take a look at the fully
assembled rack shown below. This Rack has a full set of accessories; Ladder
Clamp, Beacon Bracket, Flip Ring Cone Holder, Ladder Hooks on curb side, and
Cable Tie for each ladder. It is very important that all Bolt Tracks that hold
these accessories be properly placed before you begin the general assembly.
The following page will show you where these bolt tracks are placed.
STAGE
1: First
open the shipping carton and check to see that all rack parts are there. This
page shows all rack component parts and all hardware (Nuts, Bolts & stuff) needed
to assemble the rack. We have carefully packed these items, however if you are
missing any pieces, call us at 1-800-424-LIDS. We can ship your items within
a few days of your call.
Tailgater has developed a unique Bolt Track system, the building blocks of the
rack. There are two Bolt Track sizes 1” long and 5 ¾” long. These Bolt Tracks
are little anchors that hold Hex Bolts and tie key areas of the rack together.
Placement of these Bolt Tracks in these key areas is very important and the
FIRST thing you must do. The Bolt Tracks simply slide inside the channel (see
fig. 1).
STAGE
2 CURB SIDE: You
are now ready to move on the second stage of assembly. This step applies to
the curb side of the rack only. Follow the diagram and attach the curb side
Rack Corner Plates to the Rack End Channels using the hardware shown (see fig.
2). Make sure the plates are straight with the top of the channel and tighten
all bolts to 20 ft. lb. Attach the Plastic Channel Covers, (48 ½” long), to
each Rack End Channel. You now have two Rack Ends with Plastic Covers and Corner
Plates at the curb side.
Next is the assembly of the curb side Rack Legs (see fig. 3). Follow the hardware
list and mount the legs to the corner plates. All of these bolts will be left
loose at this point to allow for adjustment of the legs. You will make one last
adjustment after the rack has been mounted, then tighten all bolts to 20 ft.
lb.
STAGE
3 STREET SIDE: This
step applies to the street side of the rack only. The street side corners are
molded brackets, known as Gater Corners. To install the Gater Corners, several
Molded Spacer Blocks must be slipped into the Rack Channels, (as shown below).
Mount the Gater Corner to the End Cross Channel (make sure the Molded Spacers
are inside the channel and positioned at the two top holes.) Attach thru using
5/16 x 2 ½” Carriage Bolts, 5/16 Flat Washers and 5/16 Nyloc Hex Nuts. Repeat
at the other street side End Cross Channel and move on to the Rack Leg mounting
before fully tightening bolts. (Recommend tighten to 18 ft. lb.) Next, mount
the legs to the Gater Corners. First insert the Rack Leg, with the two holes
at the top, between the Molded Corner Bracket (channel opening facing outward.)
Align the upper set of holes in the Rack Leg to the top holes in the Gater Corner.
Insert a Molded Spacer Block, align to hole and attach using the 5/16 x 2 ½”
Carriage Bolts, 5/16" Flat Washers, and 5/16" Hex Nuts. Repeat at all upper
hole locations for each Rack Leg and leave loose at this time. Now align the
lower holes of the Rack Leg to the slotted holes in the Molded Corner Bracket.
Place a Molded Lock Washer and attach using a 5/16 x 1 ¼” Carriage Bolt, 5/16"
Flat Washer and a 5/16" Hex Nut. Repeat at the other street side corners and
leave these bolts loose at this time allowing the Rack Legs to swing in the
slots. You will tighten all of these bolts after the rack is mounted.
STAGE
4:
Take a movement now to look at the two Rack Ends which you just assembled. Here
in stage four, turn the Rack Ends up side down and at the curb side Bolt Track,
(5 ¾”), mount the Gusset Plate with hardware indicated. Each Gusset Plate mounts
with three bolts. Adjust the Gusset Plate so it just touches the Corner Plate
(see fig. 4). The two Gusset Plates, one at each Rack End , must be mounted
so they face inward to the rack. Later we will mount the short Side Rail (curb
Side Rail) to these Gusset Plates.
STAGE
5: Installation
is now half complete. Now begin stage five. Place the long Side Rail (street
side) and place it channel side up and get ready to attach it to the two molded
Gater Corners. Before proceeding, mount the short Side Rail (curb side) to the
Gusset Plates. Two 5/16” x 3” Carriage Bolts attach each plate and hold the
rail in place. Tighten these bolts to 20 ft. lb. And move to the street side
long Side Rail. This rail mounts to the Gater Corners with 5 ¾” Bolt Tracks
at either end. There should be 2” from the rail end to the edge of the Gater
Corner (see fig. 5). Now tighten these bolts to 20 ft. lb.
STAGE
6: The
next step involves the Center Cross Channel. Leave the rack up side down for
easier installation. The Center Cross Channel ties the two Side Rails together
and provides a mounting base for the Cable Bracket (long). Attach the Long Cable
Bracket to the 45° bend in the Bracket (see fig. 6). The Cable must be resting
at the bend in the Bracket, then tighten. Now mount the Bracket to the Cross
Channel using a 5 ¾” Bolt Track (see fig. 7). Before you tighten the nuts, attach
the Bracket to the side of channel, step form fits into the channel, attach
the 1” Bolt Track in the side channel, mount it there, but leave it loose at
this time. At the other end of the channel, mount the 5 ¾” Bolt Track in the
long Side Channel (see fig. 8). Leave room on the Bolt Track to mount the other
Cable and Bracket (short) (see fig. 9). Now make the final adjustment of the
Center Cross Channel (see fig. 10) and tighten all bolts to 20-ft. lb.
STAGE
7: The
next step is to attach the Gater Feet (molded “U” brackets) to the ends of the
Rack Legs (see fig. 11). First, insert a Molded Spacer Block in the Rack Leg.
Then align holes and insert a 5/16 x 2 1/2” Carriage Bolt. Secure bolt with
a 5/16” Flat Washer and 5/16” Nyloc Hex Nut. Repeat at other four Rack Legs,
remember to leave all bolts loose until final mounting when we will tighten
bolts to 18 ft. lb.
STAGE
8: You
can now turn the rack over and mount the Plastic Protection Covers, one 41”
long, to the Center Cross Channel and one 18” long, Plastic Cover at each end
of the curb Side Rail (see fig. 12). If installed correctly, the long Side Rail
should be on the street side.
Accessories:
At the cab
end, street side, you will be mounting a Dual Beacon Bracket. At the tailgate
end, street side, you will be mounting a Ladder Clamp. At the Center Cross Channel
you will mount the Ladder Side Bar Bracket. The following figures will show
you how these accessories mount.
See figure 13 for mounting the Dual Beacon Bracket. See figure 14 for mounting
the Ladder Clamp and see figure 15 to mount the Ladder Side Bar Bracket.
Next, lift the rack on to the truck bed or Lid Assembly unit with the help of
two other people. It is best to have three people, one at each front Rack Leg
and one at rear. Walk the rack up to the truck and locate the Gater Feet to
the predrilled holes. Now adjust the rack side to side until the rack is level
or looks straight to your eye. Tighten all leg bolts to 20 ft. lb.
STAGE 9: The two major items to mount to the curb side and probably the most
innovative part of the rack are the Hook Assemblies. Place a single Spring Nut
in the top of each curb side Rack Leg (see fig. 17). Slip the Hook Assembly
in place and adjust the Spring Nut to align to the upper hole. Now, slide the
1” Bolt Track up the Rack Leg, place a 5/16 x 1 ¼” Hex Bolt in the track and
attach to the lower hole on the Hook Assembly. Check to see that the Spring
Nut is still visible through the upper hole, then tighten the lower bolt. Lastly
place a drop of Loctite® on the leading threads of a 5/16-x 1” Hex Bolt and
run it in to the Spring Nut. Repeat this task on the other Rack Leg and tighten
all bolts to 20 ft. lb. A Plastic Cover mounts to the channel covering the upper
mount. Simply peel and stick the adhesive strip on the Plastic Cover after tightening
all bolts (see fig. 18).
The final accessory is the Flip Ring Cone Holder. This device mounts to the
rear, street side Rack Leg. Attach the lower Cone Bracket to the leg using a
1” Bolt Track in the Rack Leg, 5/16 x 1 ¼” Hex Bolt, Flat Washer and Hex Nut
(see fig. 19). Now mount the Cone Stop Bracket using the 5/16 Spring Nut and
5/16 x 1” Hex Bolt with Flat Washer. Then place the two brass bushings in the
Gater Corner and mount the Flip Ring. This Ring will hold up to three safety
cones and lays flat when not in use.
FINAL STAGE: Inspect entire rack and accessories. Make one last check on each
bolt. Be sure to tighten all bots to 20 ft. lb. For technical support call Tailgater
at 1-800-424-LIDS. Enjoy Your New Easy On Off Ladder Rack.
Suggested Rack Layout for Optimal Performance:
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