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Safe Fleet PRIME DESIGN PCR-255 ARE4 Quick Start Manual

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PRIME DESIGN, A SAFE FLEET BRAND
Address: 580 Opperman Drive, Eagan, MN 55123 ▪ Toll Free: 1.8.PRIME.RACK
Fax: 651-552-1799 ▪ Email: info@primedesign.net ▪ Website: www.primedesign.net

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Summary of Contents for Safe Fleet PRIME DESIGN PCR-255 ARE4

  • Page 1 PRIME DESIGN, A SAFE FLEET BRAND Address: 580 Opperman Drive, Eagan, MN 55123 ▪ Toll Free: 1.8.PRIME.RACK Fax: 651-552-1799 ▪ Email: info@primedesign.net ▪ Website: www.primedesign.net...
  • Page 2 NOTE: Assemblies and parts shown in this manual are representative. Some items may appear differently than actual parts, assemblies, or components received. TABLE OF CONTENTS Page 2–7 ..............................Packaging Checklist Page 8–9 ............................Mounting Bracket Assembly Page 10–11 ......................Mounting Bracket to Crossbar Installation Page 12 ...............................Right Rotation Overview Page 13–16 ..................
  • Page 3 1—Rear Crossbar Rotation Assembly ....(Qty 1) Right Hand, with Left Hand Clamp Down 2—Front Crossbar Rotation Assembly ....(Qty 1) Right Hand, with Left Hand Clamp Down 3—Drive Shaft ............(Qty 1) Right Hand, Rear, 36.00” 4—Connecting Bar ..........(Qty 1) Left/Right Hand, 4.00’...
  • Page 4 8—Clamp Down Tube Kit ........(Qty 1) 84.00” with hardware 9—Z Post Assembly ..........(Qty 2) Padded, Adjustable, 7.25” Prime Design Limited Warranty. Seller’s sole and exclusive warranty (and Buyer’s sole and exclusive remedy and Seller’s entire liability for any breach thereof) with respect to the Goods is set forth in the Limited Warranty document available at primedesign.net/warranty-liability (the “Prime Design Limited Warranty”).
  • Page 5 10—UM Mounting Bracket ........(Qty 2) 5” x 6”, Vertical Mount 11—UM Mounting Bracket ........(Qty 2) 5” x 6”, QC Base Prime Design Limited Warranty. Seller’s sole and exclusive warranty (and Buyer’s sole and exclusive remedy and Seller’s entire liability for any breach thereof) with respect to the Goods is set forth in the Limited Warranty document available at primedesign.net/warranty-liability (the “Prime Design Limited Warranty”).
  • Page 6 HKT-8140 (Qty 1) 9.1—Bushing Assembly Lubricant ......(Qty 1) 9.2—M8 x 110MM Bolt Assy ........ (Qty 1) 9.4—BLT-6820-G ........... (Qty 4) 5/16 x 2.00” Bolt Assy 9.6—3/8 x 2.25” Bolt Assy ........(Qty 2) 9.7—1/4 x 1” Clevis Pin ........(Qty 1) 9.8—3/32 x .75”...
  • Page 7 HKT-8106 (Qty 1) 10.1—Drive Arm Bushing ........(Qty 2) 10.2—Drive Shaft Large Bushing, Celcon .... (Qty 2) 10.3—Drive Shaft Sealing Decals ...... (Qty 16) Prime Design Limited Warranty. Seller’s sole and exclusive warranty (and Buyer’s sole and exclusive remedy and Seller’s entire liability for any breach thereof) with respect to the Goods is set forth in the Limited Warranty document available at primedesign.net/warranty-liability (the “Prime Design Limited Warranty”).
  • Page 8 STEPS 1–3: ASSEMBLING THE BRT-8135 MOUNTING BRACKETS Step 1: Apply Anti-Seize Compound to all bolt threads. Step 2: Assemble Mounting Post to Mounting Foot as shown in Figure A. Step 3: Assemble Mounting Top U Bracket to Mounting Post as shown in Figure B. 45MM x M8 Figure A Figure B...
  • Page 9 STEPS 4–6: ASSEMBLING THE BRT-8134 MOUNTING BRACKETS Step 4: Apply Anti-Seize Compound to all bolt threads. Step 5: Assemble Mounting Post to Mounting Foot as shown in Figure C. Step 6: Assemble Mounting Top U Bracket to Mounting Post as shown in Figure D. 50MM x M8 45MM x M8 Figure C...
  • Page 10 STEPS 7–8: ATTACHING MOUNTING BRACKETS TO REAR CROSSBAR Step 7: Apply Anti-Seize Compound to all bolt threads. Step 8: Attach Mounting Bracket BRT-8134 to left side of Rear Crossbar, and BRT-8135 to right side of Rear Crossbar. Torque Nuts to 90 in-lb. STEPS 7–8: MOUNTING BRACKETS TO REAR CROSSBAR ATTACHMENT RESULTS...
  • Page 11 STEPS 9–10: ATTACHING MOUNTING BRACKETS TO FRONT CROSSBAR Step 9: Apply Anti-Seize Compound to all bolt threads. Step 10: Attach Mounting Bracket BRT-8134 to left side of Front Crossbar, and BRT-8135 to right side of Front Crossbar. Torque Nuts to 90 in-lb. STEPS 9–10: MOUNTING BRACKETS TO FRONT CROSSBAR ATTACHMENT RESULTS...
  • Page 12 RIGHT HAND ROTATION OVERVIEW Attention Installer! All Rotation Assembly Bolts must face inward to rack assembly with bolt heads facing outside the Rotations. Front Rotation Bolts face rearward, while Rear Rotation Bolts face forward. Failure to install fasteners as directed may result in potential interference damage to parts and/or assemblies.
  • Page 13 STEPS 11–12: INSTALLING THE RIGHT REAR ROTATION DRIVE SHAFT BUSHINGS Step 11: Insert the large black plastic bushing through the Crossbar as shown. Line up the bushing key to the Crossbar key cut. Step 12: Insert white plastic bushing through Drive Arm as shown.
  • Page 14 STEPS 13–14: INSERTING THE REAR DRIVE SHAFT Step 14: Insert Drive Shaft Rear through large Bushing and Drive Arm Bushing. Step 13: Lubricate OD of plastic Bushing using supplied lubricant (unless pre-lubricated). STEPS 13–14: REAR DRIVE SHAFT INSERTION RESULTS Prime Design Limited Warranty. Seller’s sole and exclusive warranty (and Buyer’s sole and exclusive remedy and Seller’s entire liability for any breach thereof) with respect to the Goods is set forth in the Limited Warranty document available at primedesign.net/warranty-liability (the “Prime Design Limited Warranty”).
  • Page 15 STEPS 15–16: DRIVE ARM BOLT ASSEMBLY INSTALLATION Step 15: Apply Anti-Seize to Bolt threads. Step 16: Install Bolt Assembly and torque to 90 in-lb STEPS 15–16: DRIVE ARM BOLT ASSEMBLY INSTALLATION RESULTS Prime Design Limited Warranty. Seller’s sole and exclusive warranty (and Buyer’s sole and exclusive remedy and Seller’s entire liability for any breach thereof) with respect to the Goods is set forth in the Limited Warranty document available at primedesign.net/warranty-liability (the “Prime Design Limited Warranty”).
  • Page 16 STEPS 17–18: INSTALLING THE THUMB RELEASE LATCH Step 17: Apply Anti-Seize to Bolt thread. Step 18: Slide Thumb Release Latch onto Drive Shaft and position so Latch catches handle in recess. Torque Bolt to 75 in-lb. STEPS 17–18: THUMB RELEASE LATCH INSTALLATION RESULTS Prime Design Limited Warranty.

  • Page 17: Cylinder Assembly

    STEPS 19–20: CYLINDER ASSEMBLY Step 19: Adjusting the Cylinder’s Flow Control screw by 1–½ turns left to default setting will release the Cylinder Rod making it easier to pull the rod toward the Drive Shaft’s Cylinder Lever during installation. Step 20 STEPS 19–20: CYLINDER ASSEMBLY RESULTS Prime Design Limited Warranty.
  • Page 18 STEPS 21–22: CYLINDER CLEVIS AND COTTER PIN INSTALLATION Step 21 Step 22 STEPS 21–22: CYLINDER CLEVIS AND COTTER PIN INSTALLATION RESULTS Prime Design Limited Warranty. Seller’s sole and exclusive warranty (and Buyer’s sole and exclusive remedy and Seller’s entire liability for any breach thereof) with respect to the Goods is set forth in the Limited Warranty document available at primedesign.net/warranty-liability (the “Prime Design Limited Warranty”).
  • Page 19 STEPS 23–24: INSTALLING THE RIGHT FRONT ROTATION DRIVE SHAFT BUSHINGS Step 23: Insert the large black plastic bushing through the Crossbar as shown. Line up the bushing key to the Crossbar key cut. Step 24: Insert white plastic bushing through Drive Arm as shown.
  • Page 20 STEPS 25–26: INSTALLING THE RIGHT FRONT ROTATION DRIVE SHAFT BUSHINGS Step 26: Insert Front Drive Shaft through large Bushing and Drive Arm Bushing. Step 25: Lubricate OD of plastic Bushing using supplied lubricant (unless pre-lubricated). STEPS 25–26: RIGHT FRONT DRIVE SHAFT INSERTION RESULTS Prime Design Limited Warranty.
  • Page 21 STEPS 27–28: DRIVE ARM TO DRIVE SHAFT ATTACHMENT Step 27: Apply Anti-Seize to Bolt threads. Step 28: Install Bolt Assembly and torque to 90 in-lb STEPS 27–28: DRIVE ARM TO DRIVE SHAFT ATTACHMENT RESULTS Prime Design Limited Warranty. Seller’s sole and exclusive warranty (and Buyer’s sole and exclusive remedy and Seller’s entire liability for any breach thereof) with respect to the Goods is set forth in the Limited Warranty document available at primedesign.net/warranty-liability (the “Prime Design Limited Warranty”).
  • Page 22 STEP 29: CONNECTING BAR ASSEMBLY Tighten all Connecting Bar Bolts to 90 in-lb. Step 29 Prime Design Limited Warranty. Seller’s sole and exclusive warranty (and Buyer’s sole and exclusive remedy and Seller’s entire liability for any breach thereof) with respect to the Goods is set forth in the Limited Warranty document available at primedesign.net/warranty-liability (the “Prime Design Limited Warranty”).
  • Page 23 LEFT HAND CLAMP DOWN OVERVIEW Prime Design Limited Warranty. Seller’s sole and exclusive warranty (and Buyer’s sole and exclusive remedy and Seller’s entire liability for any breach thereof) with respect to the Goods is set forth in the Limited Warranty document available at primedesign.net/warranty-liability (the “Prime Design Limited Warranty”).
  • Page 24 STEPS 30–31: INSTALLING THE LEFT REAR CLAMP DOWN HANDLE TUBE BRACKET Step 30: Apply Anti-Seize Compound to all bolt threads. Step 31: Locate the Clamp Down Handle Tube Bracket in appropriate Crossbar hole as shown. Install Bracket Bolt Assembly and torque to 90 in-lb. STEPS 30–31: LEFT REAR CLAMP DOWN HANDLE TUBE BRACKET INSTALLATION RESULTS...
  • Page 25 STEP 32: HANDLE TUBE INNER BUSHING INSTALLATION Step 32: Press Handle Tube Bushing into Handle Tube Bracket. STEP 32: HANDLE TUBE INNER BUSHING INSTALLATION RESULTS Prime Design Limited Warranty. Seller’s sole and exclusive warranty (and Buyer’s sole and exclusive remedy and Seller’s entire liability for any breach thereof) with respect to the Goods is set forth in the Limited Warranty document available at primedesign.net/warranty-liability (the “Prime Design Limited Warranty”).
  • Page 26 STEPS 33–34: INSTALLING THE CLAMP DOWN HANDLE TUBE ASSEMBLY Step 33: Apply Anti-Seize Compound to all bolt threads. Step 34: Assemble Clamp Down Rear Hook onto Handle Tube using supplied Bolt Assemblies. Torque to 90 in-lb STEPS 33–34: CLAMP DOWN HANDLE TUBE INSTALLATION RESULTS Prime Design Limited Warranty.
  • Page 27 STEP 35: CLAMP DOWN HANDLE TUBE COTTER PIN INSTALLATION Step 35: Slide Cotter Pin into Handle Tube as shown. STEP 35: CLAMP DOWN HANDLE TUBE COTTER PIN INSTALLATION RESULTS Prime Design Limited Warranty. Seller’s sole and exclusive warranty (and Buyer’s sole and exclusive remedy and Seller’s entire liability for any breach thereof) with respect to the Goods is set forth in the Limited Warranty document available at primedesign.net/warranty-liability (the “Prime Design Limited Warranty”).
  • Page 28 STEP 36: HANDLE TUBE OUTER BUSHING INSTALLATION Step 36: Press Handle Tube Bushing Onto Handle Tube until it touches the Cotter Pin. STEP 36: HANDLE TUBE OUTER BUSHING INSTALLATION RESULTS Prime Design Limited Warranty. Seller’s sole and exclusive warranty (and Buyer’s sole and exclusive remedy and Seller’s entire liability for any breach thereof) with respect to the Goods is set forth in the Limited Warranty document available at primedesign.net/warranty-liability (the “Prime Design Limited Warranty”).
  • Page 29 STEP 37: INSTALLING THE LEFT REAR CLAMP DOWN TUBE Step 37: Slide the Rear Left Hand Clamp Down Tube onto the Handle Tube Assembly. STEP 37: LEFT REAR CLAMP DOWN TUBE INSTALLATION RESULTS Prime Design Limited Warranty. Seller’s sole and exclusive warranty (and Buyer’s sole and exclusive remedy and Seller’s entire liability for any breach thereof) with respect to the Goods is set forth in the Limited Warranty document available at primedesign.net/warranty-liability (the “Prime Design Limited Warranty”).
  • Page 30 STEPS 38–39: LEFT REAR CLAMP DOWN TUBE HARDWARE INSTALLATION Attention Installer: If installing the Convex Mirror Holder, skip to Steps 7-8 of the Options And Accessories section in this book for installation instructions, then proceed to Step 40. Step 38: Apply Anti-Seize to Bolt threads. Step 39: Attach Rear Clamp Down Tube to Crossbar using supplied hardware.
  • Page 31 STEPS 40–41: ATTACHING THE CLAMP DOWN HANDLE LATCH Step 40: Apply Anti-Seize to Bolt threads. Step 41: Attach Clamp Down Handle Latch using supplied bolt assembly. Torque Nut to 75 in-lb. STEPS 40–41: CLAMP DOWN HANDLE LATCH INSTALLATION RESULTS Prime Design Limited Warranty. Seller’s sole and exclusive warranty (and Buyer’s sole and exclusive remedy and Seller’s entire liability for any breach thereof) with respect to the Goods is set forth in the Limited Warranty document available at primedesign.net/warranty-liability (the “Prime Design Limited Warranty”).
  • Page 32 STEP 42: INSERTING THE HANDLE TUBE BALL ASSEMBLY Step 42: Press Handle Tube Ball Assembly into Handle Tube making sure to place with small Set Screw hole facing out. Hole must face outward. STEP 42: HANDLE TUBE BALL ASSEMBLY INSTALLATION RESULTS Prime Design Limited Warranty.
  • Page 33 STEP 43: CLAMP DOWN HANDLE INSTALLATION Step 43: Slide Clamp Down Handle into Tube Ball Assembly. Make sure to position hole at Handle ends with Set Screw hole in Ball Assembly. Align holes for Set Screw STEP 43: CLAMP DOWN HANDLE INSTALLATION RESULTS Prime Design Limited Warranty.
  • Page 34 STEP 44: INSTALLING THE TUBE BALL SET SCREW Step 44: Insert the Set Screw and tighten using Allen Head Wrench STEP 44: TUBE BALL SET SCREW INSTALLATION RESULTS Prime Design Limited Warranty. Seller’s sole and exclusive warranty (and Buyer’s sole and exclusive remedy and Seller’s entire liability for any breach thereof) with respect to the Goods is set forth in the Limited Warranty document available at primedesign.net/warranty-liability (the “Prime Design Limited Warranty”).
  • Page 35 STEP 45: CLAMP DOWN TUBE SPLICE INSTALLATION Step 45: Slide Clamp Down Tube Splice onto the Left Rear Clamp Down Tube. Do not tighten at this time. STEP 45: CLAMP DOWN TUBE SPLICE INSTALLATION RESULTS Prime Design Limited Warranty. Seller’s sole and exclusive warranty (and Buyer’s sole and exclusive remedy and Seller’s entire liability for any breach thereof) with respect to the Goods is set forth in the Limited Warranty document available at primedesign.net/warranty-liability (the “Prime Design Limited Warranty”).
  • Page 36 STEPS 46–47: INSTALLING THE FRONT CLAMP DOWN TUBE Step 46: Slide the Front Clamp Down Tube into the Tube Splice. Step 47: Once Front Clamp Down Tube has been inserted into the Tube Splice Assembly, rotate Clamp Down Tube Horn upward to align Tube mounting tangs with Crossbar bolt holes.
  • Page 37 STEPS 48–49: LEFT FRONT CLAMP DOWN TUBE HARDWARE INSTALLATION Step 48: Apply Anti-Seize to Bolt threads. Step 49: Attach Front Clamp Down Tube to Crossbar using supplied hardware. Torque to 90 in-lb. STEPS 48–49: LEFT FRONT CLAMP DOWN TUBE HARDWARE INSTALLATION RESULTS Prime Design Limited Warranty.
  • Page 38 STEP 50: TUBE SPLICE ASSEMBLY Step 50: Torque the Tube Splice Nuts to 90 in-lbs. STEP 50: TUBE SPLICE ASSEMBLY RESULTS Prime Design Limited Warranty. Seller’s sole and exclusive warranty (and Buyer’s sole and exclusive remedy and Seller’s entire liability for any breach thereof) with respect to the Goods is set forth in the Limited Warranty document available at primedesign.net/warranty-liability (the “Prime Design Limited Warranty”).
  • Page 39 STEPS 51–52: ADJUSTABLE LADDER BAR FRONT HOOK INSTALLATION Attention Installer: If installing the optional Adjustable Ladder Bar, skip to Steps 1-4 of the Options And Accessories section in this book for installation instructions, then proceed to Step 53. Step 51: Apply Anti-Seize to Bolt threads. Step 52: Attach Front Ladder Hook to Front Crossbar using supplied hardware.
  • Page 40 STEPS 53–54: FRONT AND REAR L POST INSTALLATION Step 53: Apply Anti-Seize to Bolt threads. Step 54: Attach L Posts to Crossbars using supplied hardware. Torque Nuts to 90 in-lb. STEPS 53–54: FRONT AND REAR L POST INSTALLATION RESULTS Prime Design Limited Warranty. Seller’s sole and exclusive warranty (and Buyer’s sole and exclusive remedy and Seller’s entire liability for any breach thereof) with respect to the Goods is set forth in the Limited Warranty document available at primedesign.net/warranty-liability (the “Prime Design Limited Warranty”).
  • Page 41 STEPS 55–56: FRONT AND REAR Z POST INSTALLATION Step 55: Apply Anti-Seize to Bolt threads. Step 56: Attach Z Posts to Rotation Uppers using supplied hardware. Torque Nuts to 90 in-lb. STEPS 55–56: FRONT AND REAR Z POST INSTALLATION RESULTS Prime Design Limited Warranty.

  • Page 42: Mounting Holes

    STEPS 57–58: 41.86" DRILLING TRUCK CAP MOUNTING HOLES Step 57: Place Ladder Rack squarely on the vehicle’s Cap, and fit to the Cap’s internal mounting plates if installed. Step 58: Leaving Rack in place and using a P, 21/64, or 8.25MM sized drill bit, drill all the way through the Truck Cap’s shell and internal mounting plates.
  • Page 43 STEPS 59–60: MOUNTING RACK TO VEHICLE Step 59: Apply Anti-Seize to Bolt threads. Step 60: Lift and place assembled Rack to truck cap roof using supplied hardware. Torque Nuts to 100 in-lb. STEPS 59–60: RACK TO VEHICLE MOUNTING RESULTS Prime Design Limited Warranty. Seller’s sole and exclusive warranty (and Buyer’s sole and exclusive remedy and Seller’s entire liability for any breach thereof) with respect to the Goods is set forth in the Limited Warranty document available at primedesign.net/warranty-liability (the “Prime Design Limited Warranty”).
  • Page 44 STEPS 61–63: SEALING THE DRIVE SHAFTS Step 61: Apply Sealing Decals to cover all open unused holes on Drive Shaft. Step 61 Step 62A: Clean both the Rear and Front Drive Shaft to remove residual assembly lubricant. Step 62B: Apply Silicone caulk (not supplied) to joints on both sides of the Connecting Bar.
  • Page 45 STEP 64: ADJUSTING THE CYLINDER FLOW CONTROL Step 64: Attention End User! To achieve Cylinder final setting, adjust the Cylinder Flow Control Screw to allow approximately 3 seconds time for the ladder to glide down when operating the loaded Ladder Rack. Repeat for Left Side Rotation. Prime Design Limited Warranty.

  • Page 46: Options And Accessories

    OPTIONS AND ACCESSORIES NOTE: Assemblies and parts shown in this manual are representative. Some items may appear differently than actual parts, assemblies, or components received. OPTIONAL ACCESSORIES Page 45–47 .............................. Packaging Checklist Page 48–49 ............................Adjustable Ladder Bar Page 50 ................................Mirror Holder Page 51.................................Convex Mirror Prime Design Limited Warranty.
  • Page 47 1—ALB-8094 ..Adjustable Ladder Bar Assy, 94.25” ASZ-0101 ............(Qty 1) CDR-3112 ............(Qty 1) CDR-1115 ............(Qty 1) BLC-6865-M8 ........... (Qty 2) BLT-6864-M8 ........... (Qty 6) ALB-2033 ............(Qty 1) ALB-2045 ............(Qty 1) 2—ACM-8022 ....Mirror Holder Mounting, LH, 22” ASZ-0101 ............
  • Page 48 STEPS 1–2: ADJUSTABLE LADDER BAR INSTALLATION Step 1: Apply Anti-Seize to Bolt threads. Step 2: Attach Front and Rear halves of the Adjustable Ladder Bar using supplied Bolt Assemblies. Torque to 90 in-lb. STEPS 1–2: ADJUSTABLE LADDER BAR INSTALLATION RESULTS Prime Design Limited Warranty.
  • Page 49 STEPS 3–4: ADJUSTABLE LADDER BAR INSTALLATION Step 3: Apply Anti-Seize to Bolt threads. Step 4: Attach Ladder Bar into Crossbars using supplied Bolt Assemblies. Torque Bolts to 90 in-lb. STEPS 3–4: ADJUSTABLE LADDER BAR INSTALLATION RESULTS Prime Design Limited Warranty. Seller’s sole and exclusive warranty (and Buyer’s sole and exclusive remedy and Seller’s entire liability for any breach thereof) with respect to the Goods is set forth in the Limited Warranty document available at primedesign.net/warranty-liability (the “Prime Design Limited Warranty”).
  • Page 50 STEPS 5–6: ADJUSTABLE LADDER BAR INSTALLATION Step 5: Apply Anti-Seize to Bolt threads. Step 6: Install Adjustable Ladder Bar Front Hook using supplied Bolt Assemblies. Position for ladder, then torque to 90 in-lb. STEPS 5–6: ADJUSTABLE LADDER BAR INSTALLATION RESULTS Prime Design Limited Warranty.
  • Page 51 STEPS 7–8: CONVEX MIRROR HOLDER INSTALLATION Step 7: Apply Anti-Seize to Bolt threads. Step 8: Attach Convex Mirror Holder to Rear Crossbar using supplied Bolt Assemblies. Torque Bolts to 90 in-lb. STEPS 7–8: CONVEX MIRROR HOLDER INSTALLATION RESULTS Prime Design Limited Warranty. Seller’s sole and exclusive warranty (and Buyer’s sole and exclusive remedy and Seller’s entire liability for any breach thereof) with respect to the Goods is set forth in the Limited Warranty document available at primedesign.net/warranty-liability (the “Prime Design Limited Warranty”).
  • Page 52 STEPS 9–10: CONVEX MIRROR INSTALLATION Step 9: Apply Anti-Seize to Bolt threads. Step 10: Attach Convex Mirror to Holder with supplied hardware. Torque bolt to 72 in-lb. STEPS 9–10: CONVEX MIRROR INSTALLATION RESULTS Prime Design Limited Warranty. Seller’s sole and exclusive warranty (and Buyer’s sole and exclusive remedy and Seller’s entire liability for any breach thereof) with respect to the Goods is set forth in the Limited Warranty document available at primedesign.net/warranty-liability (the “Prime Design Limited Warranty”).
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