Ranger design 1525-FS User manual

INSTALLATION GUIDE
1525-FS Combination Ladder Rack
Express / Savana ( Aluminum )

QUICK START GUIDE
REQUIRED ITEMS
2
PERSONS
q1.1 Setup...............................................................................................................................................
q1.2 Ladder Rack Assembly....................................................................................................................
3 - 4
5 - 15
q2.1 Ladder Rack Installation..................................................................................................................
q2.2 Note.................................................................................................................................................
16 - 20
21
Phase 1 - Assembly
Phase 2 - Installation
NOTE: Use Sawhorses if possible, or use the box as a at protective surface on the ground or table.
qCordless Impact
qRatchet
qTape Measure
qMallet
qMarker
qLadder
qCutter
q1/2" Socket
qSawhorse ( Optional )
qBox
qKnife
q1/2" Wrench
q9/16" Socket

For technical support, contact us at 1-800-565-5321 1525-FS Installation Guide |REV. C2 | Page 3
PHASE 1 – ASSEMBLY
1.1 SETUP
1.1.1 Unpack components; compare with the bill of materials.
1.1.2 Verify all parts are present.
Item No. Description Qty.
10-149 Clamp Handle Support 2
10-411 Gutter Clip 4
10-545 Ski Plastic Plug 4
10-548 Hook Protector ( 4 - 3/8" L ) 2
10-447 “C” Foot 4
10-602 Insulator Pad 4
15-2583 Front Crossbow 2
15-2593 Rear Crossbow 1
15-3003 Ladder Clamp Hasp 2
15-3004 Ladder Clamp Rear Hook 2
15-3005 Ladder Clamp Bar ( Driver Side ) 1
15-3006 Ladder Clamp Bar ( Passenger Side ) 1
15-3010 Ski ( Left ) 1
15-3011 Ski ( Right ) 1
15-4290 Front Hook 2
94-1010 Assembly Fastener Kit 1
96-1014 Install Fastener Kit 1
BILL OF MATERIALS
15-300615-3005
15-259315-2583
15-3011
15-3010
15-3004 15-4290
15-3003
10-545
10-149
10-548
10-447
10-411
10-602

For technical support, contact us at 1-800-565-5321 1525-FS Installation Guide |REV. C2 | Page 4
94-1010 Fastener Kit Fastener Assembly
1.1.3 Fastener kits.
4×
#90-487 Carriage Bolt 5/16" × 3/4"
#98-123 Lock Washer
#94-105 Hex Nut
#98-117 Flat Washer
16×
#90-491 Carriage Bolt 5/16" × 1"
#98-123 Lock Washer
#94-105 Hex Nut
#98-117 Flat Washer
4×
#98-123 Lock Washer
#94-105 Hex Nut
#98-117 Flat Washer
2×
#90-491 Carriage Bolt 5/16" × 1"
#98-123 Lock Washer
#94-105 Hex Nut
#98-117 Flat Washer
#98-160 Spacer
# 90-487
4×
Carriage Bolt
5/16"-18 × 3/4"
SS304
# 90-491
18×
Carriage Bolt
5/16"-18 × 1"
SS304
# 98-117
Flat Washer
5/16", O.D 3/4"
SS18-8
26×
# 98-123
Lock Washer
Regular 5/16"
SS304
26×
# 94-105
Hex Nut
5/16"-18
SS316wax
26×
# 98-160 Spacer
SS18-8
2×
Fastener Assembly96-1014 Fastener Kit
# 98-109
Flat Washer
3/8"
SS304
4×
# 94-109
Lock Nut
3/8"
SS304wax
4×
# 90-327
Hex Bolt
3/8"-16 × 2-1/2"
SS304
4× 8×
#90-327 Hex Bolt 3/8" × 2-1/2"
#98-109 Flat Washer
#94-109 Lock Nut

For technical support, contact us at 1-800-565-5321 1525-FS Installation Guide |REV. C2 | Page 5
PHASE 1 – ASSEMBLY
1.2 LADDER RACK ASSEMBLY
1.2.1 Peel the backer off of the adhesive on the hook protector, then attach the hook protector
to the upper rear hook.
1.2.2 Attach the rear hooks to the ladder clamps, with the pre-assembled hardware on the pivot bars.
TOOLS
qKnife
REMOVE
TOOLS
qCordless Impact
q1/2" Socket
q1/2" Wrench
#90-225 Hex Bolt
5/16" - 18 × 2" SS304
#98-117 Flat Washer
#98-117 Flat Washer
#94-111 Lock Nut
HARDWARE USED
4× hardware is pre-assembled.
2×

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1.2.3 Slide carriage bolts on the bottom face of the crossbows.
First Front crossbow
• Slide 2 pcs. of 1" carriage bolts.
DRIVER SIDE
4×
#90-491 Hex Bolt
5/16" × 1" SS304
Rear crossbow
• Slide 2 pcs. of 3/4" carriage bolts.
• Slide 2 pcs. of 1" carriage bolts.
HARDWARE USED
2×
#90-487 Carriage Bolt
5/16" × 3/4" SS304
PASSENGER SIDE
4×
#90-491 Hex Bolt
5/16" × 1" SS304
Rear crossbow
• Slide 2 pcs. of 3/4" carriage bolts.
• Slide 2 pcs. of 1" carriage bolts.
First Front crossbow
• Slide 2 pcs. of 1" carriage bolts.
HARDWARE USED
2×
#90-487 Carriage Bolt
5/16" × 3/4" SS304
TIPS: Use tape to keep the bolts from sliding off.
NOTE: The track plug must be removed from the underneath of the crossbows, and reinstalled after
the feet have been installed in the nal position.

For technical support, contact us at 1-800-565-5321 1525-FS Installation Guide |REV. C2 | Page 7
HARDWARE USED
8× hand-tighten the nuts.
Carriage bolts are already on
the crossbows.
#98-123 Lock Washer
#98-117 Flat Washer
#94-105 Hex Nut
1.2.4 Install the feet on the rst Front, and Rear Crossbows.

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1.2.5 Fasten the left and right ladder clamp assemblies to the Rear Crossbow.
HARDWARE USED
4×
Carriage bolts are already on
the crossbows.
#98-123 Lock Washer
#98-117 Flat Washer
#94-105 Hex Nut
TOOLS
qCordless Impact q1/2" Socket
qTape Measure qMarker
12 - 3/4"

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Tighten the nuts just to hold the front
hook for adjustment.
HARDWARE USED
4× hardware is pre-assembled.
#98-123 Lock Washer
#98-117 Flat Washer
#90-491 Carriage Bolt 5/16" × 1"
#94-105 Hex Nut
TOOLS
qMarker
qCutter
1.2.6 • Pull out the 14.5" track plug on the passenger side of the rst front crossbow and
the driver side of the adjustable front crossbow.
• Loosen the pre-assembled hardware on the front hooks and slide the hooks onto the
front crossbows to the position shown below.
• Cut the track plug, then attach it back to the crossbows.
8.5"

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1.2.7 Install the left and right Skis to the end brackets of the front crossbow.
HARDWARE USED
4×
Carriage bolts are already on
the ski.
#98-123 Lock Washer
#98-117 Flat Washer
#94-105 Hex Nut
TOOLS
qCordless Impact
q1/2" Socket

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Tighten the nuts just to hold the 2nd
front crossbow for adjustment.
HARDWARE USED
4× hand-tighten the nuts.
#98-123 Lock Washer
#98-117 Flat Washer
#90-491 Carriage Bolt 5/16" × 1"
#94-105 Hex Nut
TOOLS
qMarker
qCutter
1.2.8 Install the adjustable front crossbow to the left and right Skis.

For technical support, contact us at 1-800-565-5321 1525-FS Installation Guide |REV. C2 | Page 12
HARDWARE USED
4× hand-tighten the nuts.
#98-123 Lock Washer
#98-117 Flat Washer
#90-491 Carriage Bolt 5/16" × 1"
#94-105 Hex Nut
1.2.9 After assembling the third crossbow attach the third crossbow to the skis.
NOTE: If you have a third crossbow, stop here and open the third crossbow box and follow the installation
guide to assemble the third crossbow.
THIRD CROSSBOW
NOTE: Don’t do this step if you don’t have the third crossbow.
Use the assembly fastener kit of the
third crossbow.

For technical support, contact us at 1-800-565-5321 1525-FS Installation Guide |REV. C2 | Page 13
1.2.10 Loosen the pre-assembled hardware on the ladder clamp hasps, slide the hasps on the ski to the
position shown below, and tighten the nuts.
THIRD CROSSBOW
15 - 1/2"
HARDWARE USED
4× hardware is pre-assembled.
#98-123 Lock Washer
#98-117 Flat Washer
#90-487 Carriage Bolt 5/16" × 3/4"
#94-105 Hex Nut
TOOLS
qCordless Impact
q1/2" Socket
qTape Measure
qMarker

For technical support, contact us at 1-800-565-5321 1525-FS Installation Guide |REV. C2 | Page 14
1.2.11 Slide 3pcs. of carriage bolts on the rear end of the each ski, then attach end plugs on
both ends of the skis.
end plug
end plug
THIRD CROSSBOW
HARDWARE USED
6×
#90-491 Carriage Bolt
5/16" × 1" SS304
TOOLS
qMallet
end plug

For technical support, contact us at 1-800-565-5321 1525-FS Installation Guide |REV. C2 | Page 15
TOOLS
qCordless Impact
q1/2" Socket
HARDWARE USED
4×
#98-123 Lock Washer
#98-117 Flat Washer
#94-105 Hex Nut
2×
#98-123 Lock Washer
#98-160 Spacer
#98-117 Flat Washer
#94-105 Hex Nut
Carriage bolts are already on
the ski.
Carriage bolts are already on
the ski.
THIRD CROSSBOW
1.2.12 Install the Rear Crossbow to the skis with the clamp handle supports, aligning the rear surface of the
crossbow brackets to the rear surface of the skis.

For technical support, contact us at 1-800-565-5321 1525-FS Installation Guide |REV. C2 | Page 16
PHASE 2 – INSTALLATION
2.1 LADDER RACK INSTALLATION
NOTE: If you do not have a hoist, lift the ladder rack onto the roof manually.
Ladder Rack
2.1.1 Position the Ladder Rack ( minimum two persons ) on the roof, so that the feet sit in the gutters.

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2.1.2 While making sure the crossbows are parallel to each other, place the rack in the appropriate position,
then attach all the feet to the roof.
#90-327 Hex Bolt 3/8" × 2-1/2"
#98-109 Flat Washer
#94-109 Lock Nut
TOOLS
qCordless Impact
q9/16" Socket
HARDWARE USED
4×
GUTTER CLIP
INSULATOR PAD
THIRD CROSSBOW
NOTE: •If you have a third crossbow, center the third crossbow between the front and rear crossbows.
• Use the third crossbow install faster kit for the third crossbow feet installation.

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THIRD CROSSBOW
2.1.3 Center the crossbows on the vehicle, then tighten all the feet to the crossbows.
TOOLS
qRatchet
q1/2" Socket
NOTE: If you have a third crossbow, center the third crossbow between the front and rear crossbows.

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2.1.4 Ladder Rack adjustment for extention ladder.
1"
TOOLS
qCordless Impact
q1/2" Socket
front hook
rear hook
NOTE: The ladder cannot extend beyond the rear bumper of the vehicle.
When the rear hook touches the ladder,
the handle should be 1" below the ladder
clamp hasp.
Now adjust the front hook to be snug against
the ladder rung and tighten the bolts on the
front crossbow.
THIRD CROSSBOW

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2.1.5 Ladder Rack adjustment for stepladder.
NOTE: • The same procedure applies to the hook located on the adjustable front crossbow. The position
of the adjustable front crossbow must be adjusted according to the length of the stepladder.
•The ladder cannot extend beyond the rear bumper of the vehicle.
NOTE: Make sure all the bolts are
tightened after adjusting.
The inner ladder side support must
be adjusted according to the width
of the step ladder.
Be sure that the extrusion of the
step ladder is on the ladder side
support.
IMPORTANT: • After installation is complete, cut the track plug underneath the crossbows to ll all the
unused space.
• Place the ladder rack warning label on a visible area, recommended on a partition.
THIRD CROSSBOW