Safe Fleet Prime Design AluRack AR-2002 User manual

Page 2 Packaging Contents
Page 3 Strip Nuts and Roller Bracket
Page 4 Crossbar Congurations
Page 5 Crossbar Installation
Page 6 Roller Installation
Page 7 Final Instructions
AR-2002 AluRack Crossbar Module, 59” Kit
PRIME DESIGN, A SAFE FLEET BRAND
Address: 580 Opperman Drive, Eagan, MN 55123 ▪ Toll Free: 1.8.PRIME.RACK
Fax: [phone] ▪ Email: inf[email protected] ▪ Website: www.primedesign.net
MODELS AVAILABLE:
AR-2002 (CLEAR ANODIZED)
AR-2002-BLK (BLACK ANODIZED)

Prime Design Limited Warranty. Seller’s sole and exclusive warranty (and Buyer’s sole and exclusive remedy and Seller’s entire liability for any breach thereof) with respect to the Goods is set forth in the Limited Warranty document available at primedesign.net/warranty-liability
(the “Prime Design Limited Warranty”).
▪ TM & © 2021 PRIME DESIGN. PROTECTED BY ONE OR MORE OF THE FOLLOWING PATENT NO.’s 6427889, 6764268, 6971563, 8991889, 9415726, 9506292, 9481313, 9776476, 9796340, 10470565, 10486608, 10501022 AND OTHER PATENTS PENDING
2
AR-2002 ASSEMBLY INSTRUCTIONS–PACKAGING CONTENTS
CONTENTS OVERVIEW
Anti-Seize (1X)
M8 Cap Head Bolt (18X)
Roller Spring (2X)
M8 Lock Washer (18X)
Roller Tube Pin (2X)
M8 Strip Nut (18X)
Roller Bracket (2X)
Crossbar and Roller Hardware ............................ (Qty 1)
AluRack Standard Crossbar ................................. (Qty 5)
With hardware, 59.00”
Clear or Black (BLK), Anodized
AluRack Roller Assembly ...................................... (Qty 1)
55.75”, with Caps
Clear or Black (BLK), Anodized
AluRack Heavy Duty Crossbar ............................. (Qty 3)
With hardware, 59.00”
Clear or Black (BLK), Anodized

Prime Design Limited Warranty. Seller’s sole and exclusive warranty (and Buyer’s sole and exclusive remedy and Seller’s entire liability for any breach thereof) with respect to the Goods is set forth in the Limited Warranty document available at primedesign.net/warranty-liability
(the “Prime Design Limited Warranty”).
▪ TM & © 2021 PRIME DESIGN. PROTECTED BY ONE OR MORE OF THE FOLLOWING PATENT NO.’s 6427889, 6764268, 6971563, 8991889, 9415726, 9506292, 9481313, 9776476, 9796340, 10470565, 10486608, 10501022 AND OTHER PATENTS PENDING
3
AR-2002 ASSEMBLY INSTRUCTIONS–CROSSBAR CONFIGURATIONS
1
2
STRIP NUT INSTALLATION
ROLLER BRACKETS
Install Roller Brackets into the rear most Strip Nuts, and
align ush against the rear end of the Side Rail as shown.
Torque Roller Bracket Bolts to 90 in-lbs.
Roller Bracket
Lock Washer
Cap Head Bolt

Prime Design Limited Warranty. Seller’s sole and exclusive warranty (and Buyer’s sole and exclusive remedy and Seller’s entire liability for any breach thereof) with respect to the Goods is set forth in the Limited Warranty document available at primedesign.net/warranty-liability
(the “Prime Design Limited Warranty”).
▪ TM & © 2021 PRIME DESIGN. PROTECTED BY ONE OR MORE OF THE FOLLOWING PATENT NO.’s 6427889, 6764268, 6971563, 8991889, 9415726, 9506292, 9481313, 9776476, 9796340, 10470565, 10486608, 10501022 AND OTHER PATENTS PENDING
4
Fig. 1
Fig. 2 | STD=STANDARD CROSSBAR | HD=HEAVY DUTY CROSSBAR
Roller
Rear Front
A
B
C
D
E
F
G
H
AR-2002 ASSEMBLY INSTRUCTIONS–CROSSBAR CONFIGURATIONS
CROSSBAR CONFIGURATIONS
Measurements are specied according to distances from the Side Rail rear ends. It is recommended to determine your Crossbar pattern
before installing them into your Strip Nuts to ensure proper order of use.
*The AluRack shown in Fig.1 is for Illustrative Purposes only, and your Conguration will vary. Refer to the table in Fig. 2–3 for your
product-specic Conguration.
3
* Side Rail Sizes vary according to customer sizing needs - See respective AR Side Rail Kit Manual to build your Side Rails.
** When mounting your AluRack, mounts must attach to the Heavy Duty Crossbars. Customer may adjust distances as needed.
*** Custom Rack Layouts: Maximum Bolt Spacing on Crossbars and Roller is 24.00”. Extra Heavy Duty Crossbars and Hardware
are available as needed-contact Sales and Service.
PRODUCT Crossbar
A
Crossbar
B
Crossbar
C
Crossbar
D
Crossbar
E
Crossbar
F
Crossbar
G
Crossbar
H
FRONT
SIDE RAIL
END
AR1916: Metris 2016 L2H1
126” Wheelbase, 76” Roof Height 5.00”
STD
20.00”
HD
35.00”
STD
50.00”
STD
65.00”
HD
80.00”
STD
95.00”
HD
Flush to
Front Side
Rail End
*112.00”
AR1929: Sprinter 2007+ L2H2
144” Wheelbase, 111” Roof Height 10.00”
HD
25.50”
STD
41.00”
STD
56.50”
HD
72.00”
STD
87.50”
STD
103.00”
HD
Flush to
Front Side
Rail End
*120.00”
AR1930 Sprinter 2007+ L3H2/L4H2
170” Wheelbase, 111” Roof Height 9.75”
HD
29.75”
STD
49.75”
STD
69.75”
HD
89.75”
STD
109.75”
STD
129.75”
HD
Flush to
Front Side
Rail End
*152.00”
Metris 2018 L3H1
135” Wheelbase, 76” Roof Height 3.75”
STD
20.00”
HD
36.25”
STD
52.50”
STD
68.75”
HD
85.00”
STD
101.25”
HD
Flush to
Front Side
Rail End
*120.00”

Prime Design Limited Warranty. Seller’s sole and exclusive warranty (and Buyer’s sole and exclusive remedy and Seller’s entire liability for any breach thereof) with respect to the Goods is set forth in the Limited Warranty document available at primedesign.net/warranty-liability
(the “Prime Design Limited Warranty”).
▪ TM & © 2021 PRIME DESIGN. PROTECTED BY ONE OR MORE OF THE FOLLOWING PATENT NO.’s 6427889, 6764268, 6971563, 8991889, 9415726, 9506292, 9481313, 9776476, 9796340, 10470565, 10486608, 10501022 AND OTHER PATENTS PENDING
5
AR-2002 ASSEMBLY INSTRUCTIONS–CROSSBAR INSTALLATION
RIGHT SIDE RAILS AND CROSSBARS
5Install the Crossbars according to your
conguration in the Strip Nuts as shown
and torque to 90 in-lbs.
LEFT SIDE RAILS AND CROSSBARS
4
NOTE: Rack shown is for Illustrative
Purposes only. The order and placement
of Standard Crossbars, Heavy Duty
Crossbars, and Roller will vary as shown
in Step 1, Fig. 2.
Install the Crossbars according to your
conguration in the Strip Nuts as shown
and torque to 90 in-lbs.

Prime Design Limited Warranty. Seller’s sole and exclusive warranty (and Buyer’s sole and exclusive remedy and Seller’s entire liability for any breach thereof) with respect to the Goods is set forth in the Limited Warranty document available at primedesign.net/warranty-liability
(the “Prime Design Limited Warranty”).
▪ TM & © 2021 PRIME DESIGN. PROTECTED BY ONE OR MORE OF THE FOLLOWING PATENT NO.’s 6427889, 6764268, 6971563, 8991889, 9415726, 9506292, 9481313, 9776476, 9796340, 10470565, 10486608, 10501022 AND OTHER PATENTS PENDING
6
AR-2002 ASSEMBLY INSTRUCTIONS–ROLLER INSTALLATION
6
7Insert the Roller Tube Pin on each side of the
Roller Tube into the Brackets as shown.
Insert the Roller Tube Pin
and Roller Tube Spring into
the Roller ends.
ROLLER ASSEMBLY
ROLLER INSTALLATION

Prime Design Limited Warranty. Seller’s sole and exclusive warranty (and Buyer’s sole and exclusive remedy and Seller’s entire liability for any breach thereof) with respect to the Goods is set forth in the Limited Warranty document available at primedesign.net/warranty-liability
(the “Prime Design Limited Warranty”).
▪ TM & © 2021 PRIME DESIGN. PROTECTED BY ONE OR MORE OF THE FOLLOWING PATENT NO.’s 6427889, 6764268, 6971563, 8991889, 9415726, 9506292, 9481313, 9776476, 9796340, 10470565, 10486608, 10501022 AND OTHER PATENTS PENDING
7
AR-2002 ASSEMBLY INSTRUCTIONS–PICKUP FINAL INSTRUCTIONS
FINAL INSTRUCTIONS FOR WORK VANS
Do not mount the AluRack to an FBM system at this time.
Refer to the respective FBM Assembly Manual(s) included with your chosen rack conguration features.
WARNING: Failure to position the AluRack as shown in your FBM
Assembly Manual may result in damage to the ladder rack.
INSTALLER NOTE: To purchase applicable features and accessories, please contact your authorized
distributor, or a Prime Design Sales & Service Representative.

USAM-AR2002-US01 Rev-A 0420