DEJANA Katerack User manual

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Rear Katerack Installation Instructions
Ford Transit Connect
Frame Kit Part #: CRC 10-1000-001
V1.0.07.17.18

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IMPORTANT INSTALLATION STEPS ARE DENOTED USING A STOP SIGN. THESE
STEPS MUST BE PERFORMED IN THE SPECIFIED ORDER TO ENSURE PROPER
INSTALLATION AND MUST BE FOLLOWED IN ORDER TO MAINTAIN YOUR
PRODUCT WARRANTY!
CRITICAL INFORMATION PERTAINING TO USER AND/OR VEHICLE SAFETY IS
DENOTED USING A CAUTION SIGN. SAFETY ITEMS MUST BE STRICTLY ADHERED
TO IN ORDER TO ENSURE A SAFE WORKING ENVIRONMENT!
WARNING
THE USE OF DRILLS WITH INTEGRAL DRILL STOPS ALONG WITH PROPER
INSPECTION FOR GAS TANK, GAS LINES, BRAKE LINES AND ELECTRICAL LINES
PRIOR TO DRILLING ANY MOUNTING HOLES IS STRONGLY RECOMMENDED TO
ENSURE THAT VEHICLE DAMAGE IS AVOIDED!
THE USE OF AIR OR ELECTRIC IMPACT TOOLS FOR THE ASSEMBLY
OF FASTENERS COULD CAUSE FASTENER FAILURE!
THE USE OF NON‐STANDARD FASTENERS AND/OR DEVIATING
FROM THE FASTENERS SPECIFIED IN THESE INSTRUCTIONS MAY
VOID YOUR PRODUCT WARRANTY!
ALL DRILLED HOLES IN THE VEHICLES SHOULD HAVE THE
RAW METAL EDGES SEALED WITH A SELF‐ETCHING
PRIMER TO RESIST CORROSION AND POTENTIAL
FASTENER POINT FAILURE!

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Katerack Installation Instructions –TOOL LIST
Safety glasses MUST be worn at all times!
TOOLS
Drill
Drill Bits
3/8” & 11/16”
Drill Stop
1/2”
Ratchet Wrench
Drill
7/16”, 3/4”, 10mm
Socket; 6mm, 5/16”
Allen Wrench Sockets;
T45 TORX Bit with
Misc. Extensions
10” Drift
Punch
(Used in
aligning bolt
holes)
Box End Wrench
7/16”, 3/4”, 10mm
Rubber Mallet/ Steel
Hammer
RECOMMENDED TOOLS:
Inch-pound Torque Wrench
Pneumatic Plus Nut Gun
Impact Gun
Leveling Gauge
1” Hole Saw

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Katerack Installation Instructions
Hardware:
FAS 37018
NYLOCK NUT,
1/4”-20 (QTY: 24)
FAS 19903
SERRATED FLANGE
BOLT, 1/4”-20 X
3/4” (QTY: 24)
FAS 33078
FLAT WASHER,
1/4” X 5/8”
O.D. (QTY: 24)
Step 1: Assemble Left/Right Side Frame Subassemblies
Notes:
If pre-assembled from manufacturer proceed to Step 2.
A.
Assemble strut channel, angles, and baseplates into street and curbside assemblies.
Continually check
that the frame is
square during
assembly.

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Katerack Installation Instructions
Hardware:
FAS 33221
FENDER WASHER
3/8” I.D. X 1.75”
O.D. (QTY: 2)
AUST EQFLATWASHER164
SPACER, 3/8” THICK,
1”O.D. X .4375” I.D.
(QTY: 10)
FAS 12319-01741
NUTSERT 1/2”-13,
LARGE FLANGE
(QTY: 2)
FAS 0154382
BTN HEAD CAP
M10-1.5 X
60MM (QTY: 2)
FAS 24130
BTN HEAD CAP
1/2”-13 X 2.5”L
(QTY: 2)
FAS 33012
FLAT WASHER,
1/2” X 1.375” O.D.
(QTY: 2)
Step 2: Side Frame Subassemblies into Transit
Notes:
A.
Remove D-rings from the floor of the vehicle.
B.
Pop off trim at the rear of the vehicle.
Trim should come off
easily.
C.
Lift up floor mat, and on both sides remove the foam padding and then the grommet
underneath of that.

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Katerack Installation Instructions
Step 2: Side Frame Subassemblies into Transit, CONT’d.
Notes:
D.
Drill through hole where grommet was removed from using 11/16” drill bit.
E.
Insert nutsert in these drilled out holes by using a nut and a lock washer to fasten
nutsert to floor of vehicle.
Nutserts are installed
similarly to plus nuts,
found on page 9.
F.
Use drift punch to align and mark location to use hole saw on so that nutsert is able to
be accessed. Should be approximately 2.5” from back trim and 2.5” from line in floor.
Drill through location with 1” hole saw.
G.
On both sides of the vehicle, place (3) spacers at the rear most location that was drilled
through, and (2) spacers at the location the D-rings were removed.
A total of (10)
spacers should be
used.
H.
Place the Curbside and Roadside frame kit subassemblies into the proper side of the
vehicle and place them on top of the spacers.
I.
Fasten at the rear most location using FAS 24130 & FAS 33012 and at location closer to
the front use FAS 0154382 & FAS 33221, do not tighten fully to allow for adjustment.

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Katerack Installation Instructions
Hardware:
FAS 37018
NYLOCK NUT,
1/4”-20 (QTY: 8)
FAS 19903
SERRATED FLANGE
BOLT, 1/4”-20 X
3/4” (QTY: 8)
FAS 33078
FLAT WASHER,
1/4” X 5/8”
O.D. (QTY: 14)
FAS 0158980
HEX CAP SCREW
M6-1.0 X 40MM
(QTY: 6)
FAS 33618
WASHER
LOCK, 1/4”
(QTY: 6)
FAS 12319-
00883
M6 PLUS
NUT (QTY: 2)
FAS 10140021
TORX HEAD SCREW
3/8”-16 X 1.25”L
(QTY: 2)
Step 3: Install Upper Mounting Bracket to Side Frames
Notes:
A.
Begin loosely fastening the upper mounting brackets to the aluminum angles of the side
frames using serrated flange bolts.
Upper mounting
brackets have
callouts for
Streetside and
Curbside.
B.
Now loosely mount the upper mounting brackets into the pre-existing threaded holes in the
roof of the vehicle using (2) FAS 0158980 and (1) FAS 10140021.
3 of the 4 holes in
the mounting
bracket line up
with the previous
fastener
locations.
Include flat and
lock washers
when fastening
FAS 0158980

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Katerack Installation Instructions
Step 3: Install Upper Mounting Bracket to Side Frames, CONT’d.
Notes:
C.
Once upper mounting bracket is loosely tightened in the position where it lines up well, drill
through last available hole in mounting bracket with 3/8” drill bit. Once hole is drilled insert
M6 plus nut. Loosely fasten (1) FAS 0158980 into plus nut.
Use drill stop
when drilling into
vehicle.
Use rust blocker
or any other form
of rust protection
spray on drilled
out holes.
Include flat and
lock washers
when fastening
FAS 0158980.

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Katerack Installation Instructions
Step 3: Install Upper Mounting Bracket to Side Frames, CONT’d.
Notes:
Before drilling check all mounting locations to prevent penetration of:
Gas Lines, Gas Tanks, Break Lines, Wiring or any other vehicle structure.
There are 2 methods for installing the Plus Nuts: Manual & Automatic (They are both listed below)
D.
First Method: Manual
1. The Plus Nut is Pre-bulbed for easy installation.
2. The Plus Nut is pre-assembled with hex cap and hex bolt, and then inserted into
pre-drilled hole.
3. As the bolt is tightened the Plus Nut expands holding in place.
4. Full tightened Plus Nut provides reliable nut plate for fastening.
Second Method: Automatic (Requires Pneumatic Plus Nut Gun)
1. Thread Plus Nut onto Plus Nut Gun.
2. Screw Plus Nut into Hole.
3. When Plus Nut is fully tightened remove Plus Nut Gun.
1.
2.
3.
4.

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Katerack Installation Instructions
Hardware:
AUST MBH‐1179‐A01
STRUT NUT INSERT
(QTY 4, per drawer)
Step 4: Drawer Installation
Notes:
A.
Before you begin the installation of the drawers, check that the frame is square by using a level gauge
and eyeing that the frame kit is square. The frame kit should have the dimensions shown below. Once
frame kit is fully square, tighten all bolts.
IMPORTANT!
BEFORE MOUNTING DRAWERS, SQUARE UP THE FRAME KIT AND
MAINTAIN 44.375” IN BETWEEN THE STRUTS IN BOTH THE FRONT AND THE
REAR, AS WELL AS AT THE TOP AND BOTTOM OF THE STRUTS

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Katerack Installation Instructions
Step 4: Drawer Installation, CONT’d
Notes:
B.
Insert the Strut Nut assemblies into the strut channel at the exact same
height and snug down ¼”-20 hex bolts with wrench.
Align all 4 Strut Nut inserts
vertically.
C.
Extend drawer fully to the locked out position. Using the (4) Pan Head
Screws supplied with strut nut, securely attach slide to inserts.
One bolt at each strut nut kit at
each vertical strut.
D.
Place Drawer back to the closed position (at your desired shelf height) and
tighten the ¼”-20 hex bolts to 80 in-lbs.
To adjust the shelving height,
loosen 1/4”-20 hex bolts.
Moving drawer parallel to floor
with a second person to keep
level.
E.
Repeat steps B, C, and D for each additional drawer you wish to add.

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Katerack Installation Instructions –Bill of Material
ITEM
NO.
PART NUMBER
DESCRIPTION
QTY.
1
CRF 10-1100-001
BASEPLATE, KATERACK, C/S
1
2
CRF 10-1100-003
BASEPLATE CONNECTOR, KATERACK, C/S
1
3
CRF 10-5400-002
STRUT CHANNEL, 41.75”L
4
4
CRF 10-5400-001
ALM ANGLE, 2” X 2” X .125”, 35.125”L
2
5
CRF 10-1100-005
TOP ATTACHMENT BRACE, C/S
1
6
CRF 10-1100-002
BASEPLATE, KATERACK, R/S
1
7
CRF 10-1100-004
BASEPLATE CONNECTOR, KATERACK, R/S
1
8
CRF 10-1100-006
TOP ATTACHMENT BRACE, R/S
1
9
FAS 19903
SERRATED FLANGE BOLT, 1/4”-20 X 3/4”
32
10
FAS 33078
FLAT WASHER, 1/4” X 5/8” O.D.
38
11
FAS 37018
NYLOCK NUT, 1/4”-20
32
12
FAS 33618
WASHER LOCK, 1/4”
6
13
FAS 0158980
HEX CAP SCREW M6-1.0 X 40MM
6
14
FAS 33221
FENDER WASHER 3/8” I.D. X 1.75” O.D.
2
15
FAS 0154382
BTN HEAD CAP M10-1.5 X 60MM
2
16
FAS 10140021
TRUSS HEAD SCREW 3/8”-16 X 1.25”L
2
17
FAS 12319-01741
NUTSERT 1/2”-13, LARGE FLANGE
2
18
FAS 33012
FLAT WASHER, 1/2” X 1.375” O.D.
2
19
FAS 24130
BTN HEAD CAP 1/2”-13 X 2.5”L
2
20
FAS 12319-00883
M6 PLUS NUT
2
21
AUST EQFLATWASHER164
SPACER, 3/8” THICK, 1”O.D. X .4375” I.D
10
22
AUST MBH‐1179‐A01
STRUT NUT INSERT (4 PER DRAWER)
TBD
23
CRC 01‐2100‐001
REAR KATERACK DRAWER
TBD

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Katerack Installation Instructions –Technical Drawing

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Katerack Installation Instructions –Inspection Dimensions