Allen Sports ZN540 User manual

WARNING: Bikes or rack falling in road can cause serious accidents resulting in bodily injury—do not use rack on any
vehicle on which it can not be properly mounted as described in this instruction sheet.
•Rack should only be used on vehicles with 2” receiver hitches.
•NEVER use on trailers or front of vehicles.
•Bikes must be tied to rack using tie-downs, or additional straps if necessary.
•Check periodically during use that all bolts and pins are tight, and that rack and bicycles are secure.
•Never carry more than 4 bikes (max capacity 140 LB/ 35 lb per bike)- no tandems, mopeds, or recumbents. Car
tail lights must remain visible.
•Drive conservatively, especially over bumps. Never use off-road.
• Do not use if any part of the rack is damaged, worn, or missing. Contact R. A. Allen Co., Inc. for replacement
parts.
CAUTION: Use Allen ZN540 only in accordance with local
motor vehicle and traffic regulations.
• Install rack and load bicycles only at a safe distance away
from moving traffic.
• Make sure that all of rack and bicycles are kept at a safe distance
from road and hot exhaust.
• Only operate vehicle with rack in an upright, locked position.
• Bicycles should never extend beyond sides of vehicle.
• Remove rack from car, or fold carry arms down when not in use.
•INSERT LOWER PORTION OF RR POST INTO
HITCH INSERT SO THAT THE HOLES AT THE
BOTTOM OF EACH PART LINE UP.
•INSERT THE 3/8” X 3” BOLT THROUGH THE HOLE,
AND THREAD 1—3/8” LOCK NUT ONTO THE END
OF THE BOLT.
•PIVOT THE RR POST INTO THE UPRIGHT
POSITION, SO THAT THE UPPER HOLES LINE UP.
INSERT THE QR CLIP THROUGH THESE HOLES,
AND SECURE THE WIRE RETAINER CLIP.
•TIGHTEN NUT AND BOLT FIRMLY USING TWO
WRENCHES.
• INSERT CARRY ARM ASSEMBLY
INTO UPPER PORTION OF RR POST,
LINING UP THE HOLES IN EACH
PART.
• INSERT THE 3/8” X 2 1/2”BOLTS
THROUGH EACH HOLE, AND
THREAD 1—3/8” LOCK NUT ONTO
THE END OF THE BOLTS.
•TIGHTEN NUT AND BOLT FIRMLY
USING TWO WRENCHES.
NOTE: UPON COMPLETION,
BOTH PARTS SHOULD BE
FIRMLY JOINED TOGETHER.
IMPORTANT:
WHEN RACK IS IN AN
UPRIGHT POSITION,WIRE
RETAINER ON QR CLIP
SHOULD ALWAYS BE IN A
CLOSED POSITION TO KEEP
RACK FROM FALLING OVER
DURING USE.
CARRY ARM ASSEMBLY
TOOLS REQUIRED: 2—9/16” WRENCH & 2—3/4” WRENCH;
OR 2—ADJUSTABLE WRENCHES
PARTES:
HITCH INSERT W/
FILLER PLATES
ZN540 BOX SHOULD CONTAIN THE
FOLLOWING ITEMS:
1-
CARRY ARM
ASSEMBLY
1-
1—HARDWARE KIT,
CONTAINING:
2—3/8” X 2 1/2” BOLT
1—3/8” X 3” BOLT
4—3/8” LOCK NUT
1—1/2” LOCK NUT
1—1/2” NO-WOBBLE BOLT
RR POST
1-
A. ASSEMBLING RACK:
B.
STEP 1 STEP 2
3/8” X 2 1/2”
BOLT
RR POST
QR CLIP
3/8” X 3”
BOLT HITCH
INSERT
3/8” LOCK
NUT
MODEL ZN540
INSTRUCTIONS
ENGLISH - PAGE 1
PRODUCT REGISTRATION:
MAKE SURE TO REGISTER YOUR PURCHASE AT
http://allensportsusa.com/about/product-registration
TO QUALIFY FOR PRODUCT WARRANTY AND TO
RECEIVE IMPORTANT PRODUCT NOTIFICATIONS

INSTALLING RACK ONTO VEHICLE:
• WITH ARMS IN FOLDED POSITION,
INSERT RACK INTO RECEIVER HITCH.
LINE UP HOLE IN THE BASE WITH HOLE
OF RECEIVER HITCH.
• INSERT NO-WOBBLE BOLT INTO HOLE,
MAKING SURE THAT THE SHOULDER OF
THE BOLT COMES AGAINST RECEIVER
RACK INSIDE OF HITCH.
• TIGHTEN FIRMLY USING TWO - 3/4”
WRENCHES. THERE SHOULD NOT BE
ANY MOVEMENT OF THE RACK INSIDE
OF THE HITCH WHEN DONE.
C.
D.
LOADING BICYCLES ON RACK:
E.
MODEL ZN540 SHOULD ONLY BE USED ON 2” RECEIVER HITCHES
INSTALLED ON AUTOMOBILES. NEVER USE THIS RACK ON A TRAILER.
FOLDING UP CARRY ARMS:
1. REMOVE ALL LOOSE ITEMS FROM BICYCLES (PUMPS, BAGS, ETC.), AND CHECK THAT ALL QUICK RELEASE HUBS ARE TIGHT.
2. LOAD FIRST BICYCLE WITH ITS CHAIN AND GEARS FACING AWAY FROM RACK. MAKE SURE THAT BICYCLES DO NOT COME IN
CONTACT WITH VEHICLE.
3. LOAD SUBSEQUENT BICYCLES IN ALTERNATING DIRECTIONS. FOR BEST WEIGHT DISTRIBUTION, LOAD HEAVIEST BICYCLES
FIRST, WITH LIGHTER BICYCLES ON THE OUTSIDE. ADD PADDING BETWEEN BICYCLE CONTACT POINTS, IF NECESSARY.
4. AFTER BICYCLES ARE LOADED, CHECK THAT ENTIRE RACK IS SECURE AND THAT NO-WOBBLE BOLT IS TIGHT, AND THAT THE
RACK IS STILL FIRMLY IN PLACE. VISION OUT OF REAR WINDOW MAY BE RESTRICTED—USE SIDE MIRRORS ACCORDINGLY
WHEN BACKING UP.
SPECIAL NOTE ON INSTALLING WOMEN’S STYLE FRAMES:
PLACE ONE CARRY ARM UNDER FRONT TOP TUBE. WITH THE OTHER CARRY ARM, ROTATE TIE-DOWN CRADLE, AND PLACE CARRY IN SPACE BEHIND SEAT
TUBE AND BELOW REAR DOWN-STAY. THE ALLEN 900B ADAPTOR BAR IS ALSO RECOMMENDED FOR THIS APPLICATION.
SECURING BIKES TO RACK:
F. ALL BIKES MUST BE SECURELY TIED TO RACK. USE INDIVIDUAL
TIE-DOWN STRAPS, OR ADDITIONAL STRAPS IF NECESSARY.
4. USE 70” STRAP (NOT
INCLUDED) TO PULL ALL
BICYCLES TOGETHER
AROUND BOTTOM BRACKETS.
STRAP SHOULD ALSO
SECURE WHEELS.
1. PLACE BICYCLE IN CRADLE. 2. THREAD STRAPS. 3. PULL STRAP TIGHT.
•TO FOLD UP CARRY ARMS,
REMOVE THE QR CLIP FROM
THE CARRY ARM ASSEMBLY,
AND SWING CARRY ARMS
INTO UPRIGHT POSITION.
•RE-INSTALL THE QR CLIP,
MAKING SURE TO PROPERLY
CLOSE THE WIRE RETAINER
ON THE QR CLIP.
•IMPORTNANT: WIRE RETAINER
MUST BE FULLY CLOSED TO KEEP
THE CARRY ARMS IN AN UPRIGHT
POSITION DURING USE. PLEASE
SEE DRAWING IN STEP 2 ON
PAGE 1.
ROTATE ARMS INTO
UPRIGHT POSITION
QR CLIP
NO-WOBBLE
BOLT
LOCK NUT
ALLEN LIFETIME WARRANTY:
IF AN ALLEN BIKE RACK IS FOUND TO HAVE A DEFECT IN
WORKMANSHIP OR MATERIAL OVER THE LIFETIME OF THE
ORIGINAL PURCHASER, ALLEN WILL REPAIR OR REPLACE
THE RACK FREE OF CHARGE. THE WARRANTY DOES NOT
COVER DAMAGE OR WEAR WHICH OCCURS AS A RESULT OF
DAY TO DAY USE OR GENERAL WEAR AND TEAR.
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VERO BEACH, FL 32963, USA
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MODEL ZN540
INSTRUCTIONS
ENGLISH - PAGE 2