Holman 80160 Manual

Holman
Rancho Cordova, CA 95742
800-343-7486
[e-mail]
20220312R1 DATE: ________________
Instruction Guide
80160

Instructions –80160
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 1
*PLEASE READ ALL INSTRUCTIONS AND WARNINGS PRIOR TO ASSEMBLING, INSTALLING,
AND USING THIS PRODUCT. *
Warning
DO NOT EXCEED MANUFACTURERS WEIGHT CAPACITY FOR ROOF.
Tools Needed
7/16”, 1/2”, 9/16” Sockets and Wrench
7/16”, 1/2”, 9/16” Box Wrenches
#2 Philips Screwdriver
5/32”, 5/16” Allen Hex Wrenches
Table of Contents
Parts .................................................................................................................................................................. 2
Hardware (18-80160)........................................................................................................................................ 3
Hardware (18-8000S-RB) .................................................................................................................................. 4
Step 1 –Assemble Side Channels ..................................................................................................................... 5
Step 2 –Attach Wind Deflector to Front Crossbar ........................................................................................... 5
Step 3 –Install Crossbars To Feet ..................................................................................................................... 6
Step 4 –Attach Side Channels to Crossbars ..................................................................................................... 7
Step 5 –Attach Front Crossbar......................................................................................................................... 7
Step 6 –Attach Roller Bar to Roller Bar Brackets ............................................................................................. 8
Roller Bar Alternate Positions........................................................................................................................... 9
Before You Begin
Read all instructions prior to assembling or installing any product.
Always locate your installation locations prior to performing any work.
Be sure to put sealant around all threads entering cargo area and between the rubber spacer and roof of
vehicle to prevent water from leaking into cargo area.
HAVE THE MOUNTING KIT INSTALLED TO VEHICLE PRIOR TO INSTALLING THIS RACK.

Instructions –80160
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 2
Parts

Instructions –80160
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 3
Hardware (18-80160)

Instructions –80160
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 4
Hardware (18-8000S-RB)

Instructions –80160
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 5
DO NOT EXCEED MANUFACTURERS WEIGHT CAPACITY FOR ROOF.
Step 1 –Assemble Side Channels
Push ends of front side channel onto swaged ends of center side
channel.
Using a 1/4” x 1-1/2” button head bolt and 1/4” flanged lock nut, bolt
through upper side channel tubes.
Using a 1/2” x 2-1/4” button head bolt, 1/2” flat washer, and
1/2” locking jam nut, bolt through lower side channel tubes.
Repeat for rear side
channel.
Repeat for opposite side
channel.
Tighten the
bolts going
through top
and bottom
side-channel
tubes.
Step 2 –Attach Wind Deflector to Front Crossbar
Insert wind deflector clamp-retainer into cutout in wind
deflector.
Hold wind deflector in position with angled edge aimed
towards front of vehicle.
1/2” x 2-1/4”
button head
cap screw
1/4” x 1-1/2”
button head
cap screw

Instructions –80160
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 6
Fasten a #10 x 3/4” pan head screw through the
wind deflector into the press nut in the clamp.
Repeat for remaining two clamps.
Tighten.
Step 3 –Install Crossbars To Feet
NOTE: HARDWARE TO ATTACH CROSSBARS TO FEET IS INCLUDED IN MOUNTING KIT.
Set crossbar onto feet. Mounting feet may be installed into either upper or lower slots, based upon
clearance required for vehicle.
Center crossbar right-to-left with feet and vehicle.
Using 3/8” x 1” hex head bolts, 3/8” lock nuts, and 3/8” flat washers provided with mounting kit, bolt
crossbar to feet.
Tighten but allow movement.
Repeat for all remaining crossbars.
Center rack on vehicle.

Instructions –80160
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 7
Step 4 –Attach Side Channels to Crossbars
Set side channel into round cutout in crossbars in
desired position.
Although rack position may be adjusted later, it is
recommended to determine the front-to-back
position of the rack at this point.
Insert a side channel clamp into cutout in each
crossbar with interior diameter facing upward.
For each side channel clamp, use a
5/16” x 1”carriage bolt and 5/16” flanged lock nut
to bolt side channel clamp to crossbar.
LOOSELY tighten.
Step 5 –Attach Front Crossbar
Push front crossbar onto swaged end of front side
channel. Be sure to align holes in both and be sure flat
face of wind deflector is on top.
Using a 1/2” x 2-1/2” button head cap screw, 1/2” flat
washer, and 1/2” locking jam nut, bolt through front side
channel and front
crossbar.
Tighten.
Repeat for opposite
side.
1/2” x 2-1/2”
button head
cap screw

Instructions –80160
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 8
Step 6 –Attach Roller Bar to Roller Bar Brackets
Note: The center roller bar mounting position is best for load
bearing. Several positions are provided to accommodate
different loading positions.
Using a 3/8” x 1-1/2” hex head bolt, bolt through the
following and into the end of the roller bar.
oa 3/8” oversized steel flat washer,
onylon plastic washer,
onylon bushing,
osteel bracket end of rack, and
oa flanged bushing,
Be sure flanged bushing is inside steel bracket ad facing
outward, away from center of roller bar.
LOOSELY tighten hardware.
Repeat for opposite side.
Be sure the rear brackets are perpendicular to the roller
bar.
Be sure the rear roller bar is hanging off the rear of the vehicle enough so that when placing a ladder on
the rack, it does not come into contact with the rear of the vehicle.
90 DEGREES

Instructions –80160
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 9
Check that the rack is square to the vehicle and mounts.
GO BACK AND TIGHTEN ALL HARDWARE.
INSTALLATION AND ASSEMBLY ARE COMPLETE.
Roller Bar Alternate Positions
Note: The center mounting position of the roller bar is recommended for maximum load bearing
applications. Several locations are provided to accommodate different loading positions but at lower load
accommodation.