Marlon Xplore pro ii sxs User manual

Marlon Xplore Pro II SxS Deck

Owner’s Manual

Assembly & Installation

Instructions

2850lbs load max on deck

2500lbs load max on ramps

Marlon Recreational Products

www.marlonproducts.com

1-800-663-7367

IMPORTANT READ ENTIRE MANUAL BEFORE YOU USE THIS UNIT

The directions, if not followed, could result in the personal injury, loss of life or damage or

destruction of equipment.

READ AND UNDERSTAND ALL INSTRUCTIONS BEFORE INSTALLING OR USING PRODUCT

•NEVER allow anyone unfamiliar with the Operating instructions to use this product;

•Read and understand all instructions provided by the manufacturer of the product(s) that this

ramp and deck will be used with;

•Marlon Recreational Products is not responsible for accidents, occurrence, injuries and loss to or

of any person or property wherever which arises as a result of Purchaser’s alteration, modification,

assembly, reassembly or installation of this product except as instructed;

•Ensure UTV Deck is properly secured to the vehicle before loading UTV: It is recommended

that operator inspect anchor points before loading & unloading UTV;

•Use caution when loading or unloading your equipment or vehicle: it is recommended that

operators use appropriate safety gear while loading and unloading UTV, set parking brake and chock

tires of the loading vehicle to prevent movement while loading & unloading, it is also recommended

operators load/unload with a winch, never stand between UTV and deck while loading, do not operate

vehicle or UTV under the influence of drugs or alcohol;

•Do not exceed the rated capacity of the ramps which is 2500 lbs evenly distributed when one

end of the ramp is elevated 48”;

•Do not exceed the rated capacity of the UTV Deck which is 2850 lbs evenly distributed;

•Operator should frequently inspect; ramp assembly for weld cracks, ensure hook bolts are

properly torqued; ensure deck tie downs and truck box anchor points are properly secured and in good

working order; deck assembly bolts are properly torqued. 85ft-lbs.

Installation

1. Position deck evenly between wheel wells of truck box, and tightly to the front of the truck box.

2. Drill and install bolt down kit anchors as per instructions.

Disclaimer:

There is an inherent risk involved in the loading, transport and unloading of any vehicle onto these

DECKS. Marlon Recreational Products assumes no liability whatsoever for damage or injury incurred

during the use of this product.

Warning

DECK INSTALLATION AND USE

Deck must be securely anchored to the vehicle with bolt down kit supplied with deck according to

installation instructions.

Inspect weekly for loose connection to truck.

Deck is approximately 360lbs; it is the operator’s responsibility to ensure that the deck and load must

not exceed the vehicle GVW. Maximum deck load, evenly spaced, is 2850lbs, skewed loads reduce

capacity. Ensure front and rear of load is securely attached to the deck prior to vehicle start-up.

Under no circumstance can the deck, load on the deck, and load in the rest of the vehicle exceed Gross

Vehicle Weight (GVW) of the vehicle.

The ramp is designed to load a UTV with one end elevated a minimum of 48” with a maximum capacity

of 2500lbs. This transfer the weight through the side supports to the ground. The ramp is not designed

to be used in a horizontal position like a bridge.

NARROW TRAILS:

Snagging the deck on low hanging branches, obstacles, garage doors will damage the deck and truck. It

will also damage whatever it comes in contact with. Go slow, do not cut corners, know your limitations.

DOWNHILL USE:

The Deck and load ads to the GVW of the truck. Do not exceed vehicle GVW.

SIDE HILL USE & CORNERING:

Travelling alongside slope is dangerous and should be avoided. If you must travel along a side slope, be

aware that with the load on the deck, the vehicles center of gravity is higher and therefore more

unstable. This applies for cornering as well. SLOW DOWN

•Check Deck to truck mounting anchors before every use with a load;

•Check Deck to truck mounting anchors weekly whether loaded or not;

•Ramp safety pins must be used when vehicle is in motion;

•Check deck frame for loose connections, broken welds or unusual sway in deck;

•When rounding turns, Slow Down and do not cut corners;

•Go slow over uneven terrain;

•Go slow downhill and ensure that the load vehicle can stop the combined vehicle load weight;

•Confirm GVW is less than the rated capacity of the load vehicle;

•Ensure the load is fastened securely to the deck at both the front and rear of the load.

• Check fastening during every stop.

ASSEMBLY INSTRUCTION’S

*YOU SHOULD HAVE THE FOLLOWING IN THE

HARDWARE KIT PROVIDED*

QTY / SIZE / LENGTH / DESCRIPTION / DECK LOCATION

24 1/2” 3 1/4”Hex Head Bolts SS Deck Ramps/Braces

6 1/2”5 1/2”Hex Head Bolt SS Deck Ramps/Braces

32 1/2”N/A Nylock Nut Deck Ramps/Braces

64 1/2” N/A Flat Washers Deck Ramps/Braces

2 1/4" N/A Spring Pins Ramp Hold Downs

Install Kit

4 - 3/4” x 2 1/2” Carriage Bolt

4 - 1/2” Washers

4 - Threaded Backing Plates

DECK ASSEMBLY INSTRUCTIONS

Note do not tighten any nuts until all bolts are in place.

1. Start by standing the front and back leg assemblies upright.

2. Choose either the 53” (shortbox Truck) or the 65” (longbox Truck) crossmembers, bolt into

place on the u-channel located near the bottom of the leg assembles, using 3 1/4” bolt, washers

and Nyloc nuts. You will be left with the 2 crossmembers that you don’t use. Keep them as you

may change truck bed lengths and they will fit the new truck if you switch from a short box to

long box truck, or vice versa.

3. Bolt in the centers brace that supports the ramps with 3 1/4” bolt, washers and Nyloc nuts.

4. Bolt down the deck ramp sections to the leg assembles. Using the 3 1/4” bolts for the 4 outer

holes then using the 5” bolt for the 4 inner holes, along with the washers, and Nyloc nuts.

5. Now you can install the 2 front tire cradles using 4 -3 1/4”bolts per cradle.

6. Now install the 2 side bars using the 7 –3 1/3”bolts per side.

7. Now install the winch mount plate bar with 2 –3 ¼” and 2 –5 ½” bolts

8. Now you can tighten all nuts, starting from the lowest to the highest. All nuts are to be

tightened and torqued to 45ft lbs.

9. Slide Ramps in center, narrow ramp on top of wider ramp and pin into place.

CONGRADULATIONS

Finished Product

INSTALLATION INSTRUCTIONS:

SXS Deck is rated for 2850lbs and loading Ramp 2500lbs

All decks come with serial numbers located on the lower rear leg.

1. Remove the ramp from the deck to lighten the deck’s weight.

2. With the assistance of 2-3 others, lift the deck into the back of the truck (approx. weight is 300

lbs without the ramps)

3. Square the deck in the truck box –be mindful that most truck boxes are not square and will

taper in the rear. Usually align center of deck to center of cab rear window.

4. Drill a pilot hole through the center of the deck leg mounting hole, and the truck box –be

careful to not drill through any fuel lines.

5. Providing that a pilot hole has clearance underneath the truck, follow the pilot hole with a ½

drill bit.

6. Install a 1/2” zinc flat washer (the smaller flat washer) onto a 1/2” x 4” zinc plated grade 8

bolt. Thread the bolt through the deck leg, and truck box.

7. On the underside of the truck, install the 1/2” lock washer & backing plate onto the bolt

8. Repeat steps 5-8 on other 3 deck legs.

9. Reinstall the ramps and secure with the spring pins.

Congrats your New Side by Side Deck is ready to Load

www.marlonproducts.com

Marlon Recreational Products

Proudly serving you from:

Chilliwack, BC Office 1-800-663-7367

Stony Plain, AB Office 1-855-962-5500

St. Andrews, MB Office 1-855-885-9150

Tacoma, WA Office 1-866-930-9411

Load Instructions with Vehicle Power

1. Set parking brake and chock tires of the loading vehicle to prevent movement while

loading & unloading, never stand between UTV and deck while loading, do not

operate vehicle or UTV under the influence of drugs or alcohol.

2. Remove ramps from deck, make sure the ramp hooks are securely engaged on the

rear load bars of the deck.

3. Line up ramps to match your machines tire width.

4. Wear your helmet and use your seatbelt.

5. Install the moveable ladder to the driver’s side of deck using the spring pin provided

(This is a must as it will keep the ladder from possible rotating and causing vehicle or

bodily harm). Place it in front of the Marlon side decal (this is so you can get out of

the vehicle once you park).

6. Start vehicle and put it in low range 4x4 mode.

7. Climb ramps at a slow steady pace (high speed not needed or recommended).

8. You will feel the front of the machine drop slightly once the front tires roll into the

front tire cradle.

9. You’re there apply the brakes and put the vehicle in park.

10. If you have a winch on your vehicle or mounted on the deck, hook it to the winch

mount point and snug up the tension on the cable.

11. Dismount the vehicle using the movable ladder.

12. Move the movable ladder to the front tire location on the driver’s side, install with

spring pin.

13. Climb ladder with 1 tire tiedown strap in hand. Lock the adjustable anchor end into

the supertrac that is installed on the deck. Loop the lasso end of the strap over the tire

at the 10-2 position. If the supertrac is mounted on an angle look at it as if you were

looking at a clock and the anchor point would be 6:00, that will always put the lasso

in the right position. Tighten the lasso by pulling the end of the strap until the lasso

and ratchet mechanism look like the picture below. Then tighten the lasso by using

the ratchet level, tighten until strap depresses into tire approx. 1 inch. Make sure the

D ring is centered as close as possible, this may take loosening the strap a couple time

and adjusting. Once its centered and the strap is tightened, tie the remaining strap

end up in such a way that is not able to flap in the wind. As this can damage the

finish on the wheel and or the deck

14. Repeat steps 12 and 13 on the remaining 3 tires.(remember to install the spring pin

when using the movable ladder, this is imperative to the strength of the mounting

positions)

15. Place the removable ladder in the holder on the deck, close the tailgate and you’re

ready to hit the road.

Unload Instructions with Vehicle Power

1. Remove ramps from deck mount and securely engage onto the rear load bar of the deck.

Align with tire width of vehicle.

2. Use the movable ladder to undo and remove all 4 tire tiedowns as well as winch hook from

winch brace. (remember to install the spring pin when using the movable ladder, this is

imperative to the strength of the mounting positions)

3. Enter vehicle, close door, apply seat belt, press on the brake start vehicle. Place in reverse and

start to back off slowly. Watch to make sure your tires are lined up when transitioning from the

deck to the ramps. This is easier to achieve with another person helping spot you (but not

necessary)

4. Continue down ramps until vehicle is completely on the ground. Place vehicle in park.

5. Place ramps back on the deck and pin in place with spring pin. Place movable ladder back in

holding position on the deck.

Your Unloaded

Load With Winch

1. Set parking brake and chock tires of the loading vehicle to prevent movement while

loading & unloading, never stand between UTV and deck while loading, do not operate

vehicle or UTV under the influence of drugs or alcohol.

2. Remove ramps from deck, make sure the ramp hooks are securely engaged on the rear

load bars of the deck.

3. Line up ramps to match your machines tire width.

4. Wear your helmet and use your seatbelt. If inside vehicle. Not required if using a

remote operated winch.

5. Install the moveable ladder to the driver’s side of deck using the spring pin. Place it in

front of the Marlon side decal (this is so you can get out of the vehicle once you park).

(remember to install the spring pin when using the movable ladder, this is imperative to

the strength of the mounting positions)

6. Attach winch cable hook to the winch brace on the top of the deck or attach winch

cable hook from the winch mounted on the deck to a secure pull position on the vehicle.

7. Make sure vehicle is in neutral and tires are aligned with ramps.

8. Guide vehicle tires on to the load ramps until the rear tires are on the ramps, continue

to load vehicle with winch power until the front tires are secure in the front tire cradle

(do not over tighten the winch. Just put enough tension on the cable to keep the vehicle

touching the front support braces on the tire cradle).

9. You’re there apply the brakes and put the vehicle in park.

10. Dismount the vehicle using the movable ladder.

11. Move the movable ladder to the front tire location on the driver’s side, install with

spring pin.

12. Climb ladder with 1 tire tiedown strap in hand. Lock the adjustable anchor end into