Ranger design 1525-M User manual

INSTALLATION GUIDE
1525-M Combination Ladder Rack
RAM Cargo Van ( Aluminum )

QUICK START GUIDE
REQUIRED ITEMS
2
PERSONS
q1.1 Setup...............................................................................................................................................
q1.2 Ladder Rack Assembly....................................................................................................................
3 - 5
6 - 14
Phase 1 - Assembly
NOTE: Use Sawhorses if possible, or use the box as a at protective surface on the ground or table.
Phase 2 - Installation
q2.1 Mounting Tracks Installation............................................................................................................
q2.2 Ladder Rack Installation..................................................................................................................
q2.3 Note.................................................................................................................................................
15 - 17
18 - 22
23
qCordless Impact
qRatchet
qTape Measure
qMallet
qMarker
qLadder
qCutter
q1/2" Socket
qSawhorse ( Optional )
qBox
qKnife
q1/2" Wrench
q7/16" Socket
qPlusnut Tool
qSilicone

For technical support, contact us at 1-800-565-5321 1525-M Installation Guide |REV. D3 | 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
10-545 Ski Plastic Plug 4
10-548 Hook Protector ( 4 - 3/8" L ) 2
10-710 Mounting Track 2
10-728 Installation Plate 2
10-4460 “C” Foot 4
15-2581 Front Crossbow 2
15-2591 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
15-3012 Ski ( Left ) 1
15-3013 Ski ( Right ) 1
15-4290 Front Hook 2
94-1010 Assembly Fastener Kit 1
96-1012 Install Fastener Kit 1
BILL OF MATERIALS
15-300615-3005
15-259115-2581
15-3013
15-3012
15-3004 15-4290
15-3003 10-545
10-149
10-548
10-728
10-4460
10-710

For technical support, contact us at 1-800-565-5321 1525-M Installation Guide |REV. D3 | 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×

For technical support, contact us at 1-800-565-5321 1525-M Installation Guide |REV. D3 | Page 5
Fastener Assembly96-1012 Fastener Kit
# 90-209
Hex Bolt
5/16"-18 × 1"
SS304
8×
4× # 90-217
Hex Bolt
5/16"-18 × 1-1/2"
SS304
# 98-117
16×
Flat Washer
5/16", O.D. 3/4"
SS18-8
8× # 98-113
Flat Washer
1/4", O.D. 5/8"
SS18-8
8× # 98-119
Lock Washer
1/4"
SS304
8× # 98-123
Lock Washer
5/16"
SS304
8× # 94-150 Channel Nut
5/16"
# 90-115
8×
Hex Bolt
1/4"-20 × 1"
SS304
8× Plusnut .250
# 94-130
4× # 94-111
Lock Nut
5/16"
SS304wax
8×
8×
#90-209 Hex Bolt 5/16" × 1"
#98-123 Lock Washer
#98-117 Flat Washer
#94-150 Channel Nut
#94-130 Plusnut .250
#90-115 Hex Bolt 1/4" × 1"
#98-119 Lock Washer
#98-113 Flat Washer
4×
#90-217 Hex Bolt 5/16" × 1-1/2"
#98-117 Flat Washer
#98-117 Flat Washer
#94-111 Lock Nut

For technical support, contact us at 1-800-565-5321 1525-M Installation Guide |REV. D3 | Page 6
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×

For technical support, contact us at 1-800-565-5321 1525-M Installation Guide |REV. D3 | Page 7
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 front crossbow, and reinstalled
after the feet have been installed in the nal position.

For technical support, contact us at 1-800-565-5321 1525-M Installation Guide |REV. D3 | Page 8
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.

For technical support, contact us at 1-800-565-5321 1525-M Installation Guide |REV. D3 | Page 9
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"

For technical support, contact us at 1-800-565-5321 1525-M Installation Guide |REV. D3 | Page 10
8.5"
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.

For technical support, contact us at 1-800-565-5321 1525-M Installation Guide |REV. D3 | Page 11
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

For technical support, contact us at 1-800-565-5321 1525-M Installation Guide |REV. D3 | Page 12
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
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-M Installation Guide |REV. D3 | Page 13
1.2.9 Loosen the pre-assembled hardware on the ladder clamp hasps, slide the hasps on the skis to the
position shown below, and tighten the nuts.
1.2.10 Slide 3pcs. of carriage bolts on the rear end of the each ski, then attach end plugs on
both ends of the skis.
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
HARDWARE USED
6×
#90-491 Carriage Bolt
5/16" × 1" SS304
TOOLS
qMallet
end plug
end plug
end plug
15 - 1/2"

For technical support, contact us at 1-800-565-5321 1525-M Installation Guide |REV. D3 | Page 14
1.2.11 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.
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.

For technical support, contact us at 1-800-565-5321 1525-M Installation Guide |REV. D3 | Page 15
52-5/8"
48"
10"
PHASE 2 – INSTALLATION
2.1 MOUNTING TRACKS INSTALLATION
2.1.1 Position and align the tracks, 10" from the windshield, 52-5/8" outside tracks in the front and 48"
outside tracks to the rear of the vehicle, then mark all 12 holes from the mounting tracks to the
roof.
10"
TOOLS
qMarker
qTape Measure

For technical support, contact us at 1-800-565-5321 1525-M Installation Guide |REV. D3 | Page 16
2.1.2 • Drill all marks by 3/8" dia. The 5th hole from the rear will be drilled through to the sliding door opening.
• Apply a bead of silicone around each hole.
• Attach plusnuts in the 2nd, 3rd, 4th and 6th holes.
1st
1st
2nd
2nd
3rd
3rd
4th
4th
5th
5th
6th
6th
5th holes
6th
4th
3rd
2nd
TOOLS
qPlusnut Tool
# 94-130
Plusnut .250
HARDWARE USED
8×

For technical support, contact us at 1-800-565-5321 1525-M Installation Guide |REV. D3 | Page 17
FRONT
NOTE: The ends of the mounting tracks with the half-circles go to the front of the vehicle.
2.1.3 Apply bead of silicone around each plusnut holes, then install the mounting track to the vehicle.
2nd, 3rd, 4th and 6th holes
5th holes
Install the installation
plate inside between the
roof and the headliner.
NOTE: be sure there’s a
bead of silicone
around the hole.
1st holes
TOOLS
qCordless Impact
q1/2" Socket
q1/2" Wrench
TOOLS
qCordless Impact
q1/2" Socket
q1/2" Wrench
TOOLS
qCordless Impact
q7/16" Socket
#90-217 Hex Bolt 5/16" × 1-1/2"
#98-117 Flat Washer
#98-117 Flat Washer
#94-111 Lock Nut
HARDWARE USED
2×
#90-217 Hex Bolt 5/16" × 1-1/2"
#98-117 Flat Washer
#98-117 Flat Washer
#94-111 Lock Nut
HARDWARE USED
2×
#90-115 Hex Bolt 1/4" × 1"
#98-119 Lock Washer
#98-113 Flat Washer
HARDWARE USED
8×
Plusnuts are already on the roof.

For technical support, contact us at 1-800-565-5321 1525-M Installation Guide |REV. D3 | Page 18
PHASE 2 – INSTALLATION
2.2 LADDER RACK INSTALLATION
2.2.1 Position the Ladder Rack ( minimum two persons ) on the vehicle so that the feet are on the tracks.
NOTE: If you do not have a hoist, lift the ladder rack onto the roof manually.
Ladder Rack

For technical support, contact us at 1-800-565-5321 1525-M Installation Guide |REV. D3 | Page 19
2.2.2 • While making sure the crossbows are parallel to each other, slide the rack to the appropriate position,
then attach all the “C” feet to the mounting tracks.
• Tighten the bolts that attach the foot plate to the ladder rack leg.
distance < A >
distance < B >
distance < B >
distance < foot to end of track >
distance < A >
TOOLS
qRatchet
q1/2" Socket
qTape Measure
FASTENERS USED
8×
#90-209 Hex Bolt 5/16" × 1"
#98-123 Lock Washer
#98-117 Flat Washer
#94-150 Channel Nut

For technical support, contact us at 1-800-565-5321 1525-M Installation Guide |REV. D3 | Page 20
2.2.3 Center the crossbows on the vehicle, then tighten all the “C” feet to the crossbows.
TOOLS
qRatchet
q1/2" Socket