Safe Fleet PRIME DESIGN PCR-255 ARE4 User manual

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

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
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PCR-255-ARE4 FULLY ASSEMBLED LADDER RACK ILLUSTRATION
TABLE OF CONTENTS
Page 2–7................................................................................................................................................... Packaging Checklist
Page 8–9......................................................................................................................................Mounting Bracket Assembly
Page 10–11 .......................................................................................................... Mounting Bracket to Crossbar Installation
Page 12 ...............................................................................................................................................Right Rotation Overview
Page 13–16 ......................................................................................... Right Rear Rotation Assembly-Drive Shaft Assembly
Page 17–18............................................................................Right Rear Rotation Assembly-Cylinder Assembly Installation
Page 19–21 .........................................................................................Right Front Rotation Assembly-Drive Shaft Assembly
Page 22 .............................................................................................. Right Rotation Assembly-Connecting Bar/Adjustment
Page 23 ................................................................................................................................Left Hand Clamp Down Overview
Page 24–28 ............................................................................................... Left Hand Clamp Down Handle Tube Installation
Page 29–30 ................................................................................................... Left Hand Rear Clamp Down Tube Installation
Page 31 .......................................................................................Left Hand Clamp Down Thumb Release Latch Installation
Page 32–34 ........................................................................................................ Left Hand Clamp Down Handle Installation
Page 35 ..........................................................................................................................Clamp Down Tube Splice Installation
Page 36–38 ...................................................................................................Left Hand Front Clamp Down Tube Installation
Page 39 ....................................................................................................................................Front Ladder Hook Installation
Page 40–41................................................................................................................................L Post and Z Post Installation
Page 42–43 ..................................................................................................................................... Mounting Rack to Vehicle
Page 44 ............................................................................................................................ Final Assembly-Drive Shaft Sealing
Page 45 ...........................................................................................................................Final Assembly-Cylinder Adjustment
Page 46–52 ...................................................................................................................Options And Accessories Installation
NOTE: Assemblies and parts shown in this
manual are representative. Some items
may appear differently than actual parts,
assemblies, or components received.

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
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4—Connecting Bar................................................. (Qty 1)
Left/Right Hand, 4.00’
6—Hydraulic Cylinder Assy.................................... (Qty 1)
5—Drive Shaft........................................................ (Qty 1)
Front, Right Hand, 35.75”
3—Drive Shaft........................................................ (Qty 1)
Right Hand, Rear, 36.00”
PCR-255-ARE4 PACKAGING CHECKLIST
1—Rear Crossbar Rotation Assembly................... (Qty 1)
Right Hand, with Left Hand Clamp Down
2—Front Crossbar Rotation Assembly.................. (Qty 1)
Right Hand, with Left Hand Clamp Down
7—L Post Assembly ............................................... (Qty 1)
9.25”

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
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PCR-255-ARE4 PACKAGING CHECKLIST
8—Clamp Down Tube Kit....................................... (Qty 1)
84.00” with hardware
9—Z Post Assembly ............................................... (Qty 2)
Padded, Adjustable, 7.25”

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
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PCR-255-ARE4 PACKAGING CHECKLIST
10—UM Mounting Bracket.................................... (Qty 2)
5” x 6”, Vertical Mount
11—UM Mounting Bracket ................................... (Qty 2)
5” x 6”, QC Base

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
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HKT-8140 (Qty 1)
9.6—3/8 x 2.25” Bolt Assy ................................... (Qty 2)
9.11—Anti-Seize..................................................... (Qty 1)
9.7—1/4 x 1” Clevis Pin........................................ (Qty 1)
9.8—3/32 x .75” Cotter Pin.................................. (Qty 1)
9.1—Bushing Assembly Lubricant........................ (Qty 1)
9.2—M8 x 110MM Bolt Assy ................................ (Qty 1)
9.4—BLT-6820-G ................................................... (Qty 4)
5/16 x 2.00” Bolt Assy
PCR-255-ARE4 PACKAGING CHECKLIST

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
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PCR-255-ARE4 PACKAGING CHECKLIST
10.3—Drive Shaft Sealing Decals ...................... (Qty 16)
10.2—Drive Shaft Large Bushing, Celcon............ (Qty 2)
10.1—Drive Arm Bushing ...................................... (Qty 2)
HKT-8106 (Qty 1)

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
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PCR-255-ARE4 MOUNTINGS–BRT-8135 MOUNTING ASSY
STEPS 1–3:
ASSEMBLING THE BRT-8135 MOUNTING BRACKETS
STEPS 1–3:
BRT-8135 MOUNTING BRACKETS
ASSEMBLY RESULTS
Step 1: Apply Anti-Seize Compound to all bolt threads.
Step 2: Assemble Mounting Post to Mounting Foot as
shown in Figure A.
Figure B
45MM x M8
Figure A 50MM x M8
Step 3: Assemble Mounting Top U Bracket to Mounting
Post as shown in Figure B.

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
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Figure DFigure C 50MM x M8 45MM x M8
PCR-255-ARE4 MOUNTINGS–BRT-8134 MOUNTING ASSY
STEPS 4–6:
ASSEMBLING THE BRT-8134 MOUNTING BRACKETS
STEPS 4–6:
BRT-8134 MOUNTING BRACKETS
ASSEMBLY RESULTS
Step 4: Apply Anti-Seize Compound to all bolt threads.
Step 5: Assemble Mounting Post to Mounting Foot as
shown in Figure C.
Step 6: Assemble Mounting Top U Bracket to Mounting
Post as shown in Figure D.

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
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PCR-255-ARE4 MOUNTINGS–MOUNTING ASSY TO REAR CROSSBAR
STEPS 7–8:
ATTACHING MOUNTING BRACKETS
TO REAR CROSSBAR
STEPS 7–8:
MOUNTING BRACKETS TO REAR
CROSSBAR ATTACHMENT RESULTS
Step 7: Apply Anti-Seize Compound to all bolt threads.
Step 8: Attach Mounting Bracket BRT-8134 to left side of
Rear Crossbar, and BRT-8135 to right side of Rear Crossbar.
Torque Nuts to 90 in-lb.

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
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PCR-255-ARE4 MOUNTINGS–MOUNTING ASSY TO FRONT CROSSBAR
STEPS 9–10:
ATTACHING MOUNTING BRACKETS
TO FRONT CROSSBAR
STEPS 9–10:
MOUNTING BRACKETS TO FRONT
CROSSBAR ATTACHMENT RESULTS
Step 9: Apply Anti-Seize Compound to all bolt threads.
Step 10: Attach Mounting Bracket BRT-8134 to left side of
Front Crossbar, and BRT-8135 to right side of Front Crossbar.
Torque Nuts to 90 in-lb.

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
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RIGHT HAND ROTATION OVERVIEW
PCR-255-ARE4 RIGHT ROTATION–FULLY ASSEMBLED ILLUSTRATION
Attention Installer! All Rotation Assembly
Bolts must face inward to rack assembly
with bolt heads facing outside the Rotations.
Front Rotation Bolts face rearward, while
Rear Rotation Bolts face forward.
Failure to install fasteners as directed may
result in potential interference damage to
parts and/or assemblies.
Installer Note: Factory-installed Z Posts
require nal adjustments based upon
End User’s ladder rail dimensions.
Due to differing ladder manufacturer’s
specications: this nal adjustment may
need to be made by the End User.

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
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PCR-255-ARE4 RIGHT ROTATION ASSY–REAR DRIVE SHAFT BUSHINGS
Bushings in place
Step 11: Insert the large
black plastic bushing through
the Crossbar as shown. Line
up the bushing key to the
Crossbar key cut.
Step 12: Insert white plastic
bushing through Drive Arm
as shown. Line up bolt hole.
STEPS 11–12:
INSTALLING THE RIGHT REAR ROTATION DRIVE
SHAFT BUSHINGS
STEPS 11–12:
RIGHT REAR ROTATION DRIVE SHAFT
BUSHINGS INSTALLATION RESULTS

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
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PCR-255-ARE4 RIGHT ROTATION ASSY–REAR DRIVE SHAFT
STEPS 13–14:
INSERTING THE REAR DRIVE SHAFT
STEPS 13–14:
REAR DRIVE SHAFT INSERTION RESULTS
Step 14: Insert Drive Shaft
Rear through large Bushing
and Drive Arm Bushing.
Step 13: Lubricate OD of plastic
Bushing using supplied lubricant
(unless pre-lubricated).

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
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PCR-255-ARE4 RIGHT ROTATION ASSY–REAR DRIVE SHAFT/ARM BOLT
STEPS 15–16:
DRIVE ARM BOLT ASSEMBLY INSTALLATION
STEPS 15–16:
DRIVE ARM BOLT ASSEMBLY
INSTALLATION RESULTS
Step 15: Apply Anti-Seize to Bolt threads.
Step 16: Install Bolt Assembly and torque to 90 in-lb

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
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PCR-255-ARE4 RIGHT ROTATION ASSY–THUMB RELEASE LATCH
STEPS 17–18:
INSTALLING THE THUMB RELEASE LATCH
STEPS 17–18:
THUMB RELEASE LATCH INSTALLATION
RESULTS
Step 18: Slide Thumb Release Latch onto Drive
Shaft and position so Latch catches handle in
recess. Torque Bolt to 75 in-lb.
Step 17: Apply Anti-Seize to Bolt thread.

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
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PCR-255-ARE4 RIGHT ROTATION ASSY–CYLINDER ASSY
STEPS 19–20:
CYLINDER ASSEMBLY
STEPS 19–20:
CYLINDER ASSEMBLY RESULTS
Step 19: Adjusting the Cylinder’s Flow Control screw
by 1–½ turns left to default setting will release the
Cylinder Rod making it easier to pull the rod toward
the Drive Shaft’s Cylinder Lever during installation.
Step 20

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
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PCR-255-ARE4 RIGHT ROTATION ASSY–CYLINDER ASSY
STEPS 21–22:
CYLINDER CLEVIS AND COTTER PIN INSTALLATION
STEPS 21–22:
CYLINDER CLEVIS AND COTTER PIN
INSTALLATION RESULTS
Step 22
Step 21

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
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PCR-255-ARE4 RIGHT ROTATION ASSY–FRONT DRIVE SHAFT BUSHINGS
Bushings in place
Step 23: Insert the large
black plastic bushing through
the Crossbar as shown. Line
up the bushing key to the
Crossbar key cut.
STEPS 23–24:
INSTALLING THE RIGHT FRONT ROTATION DRIVE
SHAFT BUSHINGS
STEPS 23–24:
RIGHT FRONT ROTATION DRIVE SHAFT
BUSHINGS INSTALLATION RESULTS
Step 24: Insert white plastic bushing through
Drive Arm as shown. Line up bolt hole.

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
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PCR-255-ARE4 RIGHT ROTATION ASSY–FRONT DRIVE SHAFT
STEPS 25–26:
INSTALLING THE RIGHT FRONT ROTATION
DRIVE SHAFT BUSHINGS
STEPS 25–26:
RIGHT FRONT DRIVE SHAFT INSERTION RESULTS
Step 25: Lubricate OD of plastic
Bushing using supplied lubricant
(unless pre-lubricated).
Step 26: Insert Front Drive Shaft
through large Bushing and Drive
Arm Bushing.