Ranger design C10-PC User manual

INSTALLATION GUIDE
C10-PC CONTOURED PARTITION
Promaster City ( Perforated Window, Steel )

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QUICK START GUIDE
REQUIRED ITEMS
2
PERSONS
qCordless Impact
qCordless Drill
qKnife or Cutter
qMallet
qPhilips Screw Driver
qPlusnut Tool
qRatchet
q1/2" Socket
q7/16" Socket
q10mm Socket
q13mm Socket
qT30 Torque Bit
qT40 Torque Bit
q9/16" Wrench
q1" Holesaw
q1.1 Setup....................................................................................................................................................
q1.1.1 Unpack components; compare with the bill of materials................................................................
q1.1.2 Verify all parts are present...............................................................................................................
q1.1.3 Identify the assembly and installation fastener bags......................................................................
q1.2 Partition Assembly................................................................................................................................
q1.2.1 Remove all the PVC from all the parts, then attach the upper panel to the lower panel................
q1.2.2 Attach the edge trims on these locations.......................................................................................
q1.2.3 Attach both wings to the upper and lower panels..........................................................................
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6
6
Phase 1 - Assembly
q2.1 Tips on how to attach a plusnut..........................................................................................................
q2.1.1 Attach plusnut using plusnut gun...................................................................................................
q2.1.2 Attach plusnut using Ranger plusnut tool......................................................................................
q2.2 Vehicle preparation..............................................................................................................................
q2.2.1 Removing handle............................................................................................................................
q2.2.2 Removing overhead plastic............................................................................................................
q2.2.3 Driver and passenger sides preparation.........................................................................................
q2.2.4 Ceiling and oor preparation..........................................................................................................
q2.3 Contoured partition installation...........................................................................................................
q2.3.1 Attach the oor bracket in the van.................................................................................................
q2.3.2 Lift the assembled partition in the van, then bolt both sides of the partition in the van................
q2.3.3 Attach the upper panel in the van, then attach the lower panel to the oor bracket.....................
q2.3.4 Apply the warning label on the upper panel...................................................................................
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Phase 2 - Installation

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PHASE 1 – ASSEMBLY
1.1 SETUP
1.1.2 Verify all parts are present.
Item No. Description Qty.
30-060 Lower Panel 1
30-062 Passenger Side Wing 1
30-063 Driver Side Wing 1
30-064 Floor Bracket 1
30-065 Upper Panel 1
30-500 Edge Trim ( QTY in Inches ) 8
79-907 Warning Label 1
94-3010 Assembly Fastener Bag 1
96-3012 Installation Fastener Bag 1
1.1.1 Unpack components; compare with the bill of materials.
30-063
30-065
30-062
30-500
30-060
30-064
79-907

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1.1.3 Identify the Assembly and Installation fastener bags.
Assembly Fastener Bag Hardware Assembly
Hardware AssemblyInstallation Fastener Bag
13× # 98-112
Flat Washer
1/4", 3/4" OD
ZINC
Flat Washer
5/16", 7/8" OD
ZINC
# 98-116
8×
# 98-118
Lock Washer
Regular 1/4"
ZINC
13×
Hex Bolt
1/4"-20 × 1-1/4"
GR-5 ZINC
# 90-118
5×
Spacer
0.375" ID, × 1.0" OD × 0.25" L
NYLON
# 98-157
24×
# 98-122
Lock Washer
Regular 5/16"
ZINC
8×
# 90-668
8× Hex Bolt
M8-1.25 × 40 CL 8.8 DIN
933 BLACK OXIDE
# 94-130 Plusnut .250
5×
8× Hex Bolt
M6-1.0 × 40 CL 12.9 DIN
933 BLACK OXIDE
# 90-836
# 98-158
Retaining Washer
M16 ( 1/4")
NYLON
8×
#98-158 Retaining Washer
#90-668 Hex Bolt M8 × 40
#98-122 Lock Washer
#98-116 Flat Washer
8×
#90-118 Hex Bolt 1/4" × 1-1/4"
#98-118 Lock Washer
#98-112 Flat Washer
#94-130 Plusnut .250
5×
#90-836 Hex Bolt M6 " × 40
#98-118 Lock Washer
#98-112 Flat Washer
#98-157 Spacers ( 3 )
8×
# 94-116
Serrated Nut
5/16"-18
ZINC
25×
# 98-116
Flat Washer
5/16", 7/8" OD
ZINC
25×
# 90-200
Hex Bolt
5/16"-18 × 1/2"
GR-5 ZINC
25×
25×
#90-200 Hex Bolt 5/16" × 1/2"
#98-116 Flat Washer
#94-116 Serrated Nut

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PHASE 1 – ASSEMBLY
1.2 PARTITION ASSEMBLY
1.2.1 Remove all the PVC from all the parts, then attach the upper panel to the lower panel.
HARDWARE USED
7×
TOOLS
qCordless Impact
q1/2" Socket
#90-200 Hex Bolt 5/16" × 1/2"
#98-116 Flat Washer
#94-116 Serrated Nut

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TOOLS
qMallet
qCutter
1.2.2 Attach the edge trims on these locations.
1.2.3 Attach both wings to the upper and lower panels.
TOOLS
qCordless Impact
q1/2" Socket
HARDWARE USED
12×
#90-200 Hex Bolt 5/16" × 1/2"
#98-116 Flat Washer
#94-116 Serrated Nut

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PHASE 2 – INSTALLATION
2.1 TIPS ON HOW TO ATTACH A PLUSNUT
FORWARD REVERSE
TIPS: Put the plusnut on the plusnut gun, then attach the plusnut in the hole by turning the gun forward until the
plusnut locks, then remove the gun by turning in reverse.
2.1.1 Attach the plusnut using the plusnut gun.
2.1.2 Attach the plusnut using the 6490 plusnut tool.
6490 HARDWARE USED
Flat washer 1/4"
Flat washer 1/4" BS × 3/4" OD
TOOLS
qCordless Impact
q7/16" Socket
q9/16" Wrench
TIPS STEP 1:
Assemble the 6490 plusnut tool with the hardware needed,
plusnut and the 9/16" wrench as shown.
FORWARD REVERSE
TIPS STEP 2:
Attach the plusnut in the hole by turning
the bolt forward using an impact with a
7/16" socket until the plusnut locks, then
remove the bolt by turning the impact in
reverse.
NOTE: The hardware used for the 6490 plusnut tool is not included in the fastener bag.
The 6490 plusnut tool can be ordered separately upon demand at no charge.

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NOTE: If you are installing a Contoured Partition and your Promaster City is supplied with an oversized sliding
door handle, this handle must be removed in order for the door to close properly.
PHASE 2 – INSTALLATION
2.2 VEHICLE PREPARATION
2.2.1 Removing handle.
Detach the plastic bracket on the cable from the
metal part of the handle, then slide the cable
across the channel and pop out.
Tape or roll the cable.
TOOLS
qCordless Impact or Ratchet
qPhilips Screw Driver
qT30 Torque Bit
Separate the two halves of the handle exposing the
two bolts at the top by removing the small philips
screws and the bolt at the bottom.
NOTE: Pulling the cable unlocked the
door.

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NOTE: There are two types of covers.
( White Covers - Without OEM partition, and Black Covers - With OEM partition )
2.2.2 Removing overhead plastic.
NOTE: Do these on both sides of the van.
For the white cover, remove the two
screws on the side and bolt on the front.
TOOLS
qCordless Impact or Ratchet
qPhilips Screw Driver
q7/16" Socket
NOTE: Do these on both sides of the van.
For the black cover, remove the screw on
the side and bolt on the front.
TOOLS
qCordless Impact or Ratchet
qPhilips Screw Driver
q7/16" Socket

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2.2.3 Driver and passenger sides preparation.
Pull back the plastic cover, then cut a 1"
square from the plastic cover to uncover
the threaded holes or drill the plastic cover
using 1" holesaw.
TOOLS
qCordless Drill
qKnife
q1" Holesaw

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TOOLS
qPlusnut Tool
# 94-130
Plusnut .250
HARDWARE USED
5×
NOTE: Enlarge these holes if the plusnuts don't t, using 3/8" drill bit or step drill.
2.2.4 Ceiling and oor preparation.
Attach plusnut on these 5 holes.
Remove plastic caps and the two D-rings from vehicle oor, then verify if
the threads are in good condition.
TOOLS
qCordless Impact
qT40 Torque Bit

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2.3.1 Attach the oor bracket in the van.
PHASE 2 – INSTALLATION
2.3 CONTOURED PARTITION INSTALLATION
HARDWARE USED
8×
TOOLS
qCordless Impact
q13mm Socket
#90-668 Hex Bolt M8 × 40
#98-122 Lock Washer
#98-116 Flat Washer

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TOOLS
qCordless Impact
q10mm Socket
2.3.2 Lift the assembled partition in the van, then bolt both sides of the partition in the van.
HARDWARE USED
8×
#90-836 Hex Bolt M6 " × 40
#98-118 Lock Washer
#98-112 Flat Washer
#98-157 Spacers ( 3 )
#98-158 Retaining Washer

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TOOLS
qCordless Impact
q1/2" Socket
HARDWARE USED
6×
TOOLS
qCordless Impact
q7/16" Socket
2.3.3 Attach the upper panel in the van, then attach the lower panel to the oor bracket.
HARDWARE USED
5×
#90-118 Hex Bolt 1/4" × 1-1/4"
#98-118 Lock Washer
#98-112 Flat Washer
#90-200 Hex Bolt 5/16" × 1/2"
#98-116 Flat Washer
#94-116 Serrated Nut

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NOTE: Put the warning label in a place
where it’s easy to see.
2.3.4 Apply the warning label on the upper panel.

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“Congratulations, you have successfully installed your
Contoured Partition!
Thank you for doing business with us.”