Witter ZX404 User manual

Torque Range 0-220 Nm
24mm x 1
Tools required for initial assembly:
+
x 2
CYCLE CARRIER SYSTEMS
ASSEMBLY AND USER INSTRUCTIONS v2
ZX404 Cycle Carrier
4x
ASSEMBLY AND USER INSTRUCTIONS v2
GB
Whenever this product is used the following information must be taken into
consideration:
The cycle carrier is a safe product IF used correctly, whereas if it is used incorrectly
it can cause damage to you, your vehicle and anyone driving behind you.
Rear cycle carrier
for mounting onto
a ange type towbar.
ATTENTION – SAFETY REQUIREMENTS
-The correct installation and use of this cycle carrier is the sole responsibility of the user.
-Weight and maximum capacity of “ZX404” bike racks:
Cycle carrier weight 19.6kg (excluding base plate) MAX cycle weight 20 kg
- 4 bikes, max. total capacity 65 kg
-Never exceed the vehicle manufacturer’s static nose weight.
-Never use an automatic car wash system when the carrier is mounted.
-The combined weight of the bike rack and the load must never exceed the permitted capacity.
-Remove from the transported bikes children’s seats, transport baskets, rain covers or other
elements that could get lost or increase the air resistance.
-The bike rack is only suitable for transporting bicycles.
-Before leaving, check that the rear lights of the vehicle and carrier function correctly.
-Ensure that the bike rack is fitted correctly on the cycle carrier base plate and that the bikes are
secured as instructed.
-When on the road, respect the highway code speed limits and pay attention to
the road conditions to prevent jolts.
-Be aware that the loaded bike rack may change the driving characteristics of the car while
braking, during windy conditions and whilst cornering.
-To avoid damage, if the boot lid is equipped with an automatic opening function,
use this function with care.
-Check all the bike rack fixing elements after a short while, then at regular intervals whilst on
your journey.
-Take care when reversing and parking because of the greater length of the car.
-Check the distance between the bike rack, the bikes and the exhaust pipe(s) to avoid heat
damage.
-To increase road safety and to reduce fuel consumption, remove the bike rack when not in use.
-Modifications to the bike rack and its components are not permitted.
-Immediately replace any worn or damaged parts using only original spare parts.
-The bike rack can be cleaned using warm water and/or car shampoo.
-Store the bike rack in dry conditions at moderate temperatures.
-The manufacturer is not responsible for damage caused by improper use of this product, nor for
any objection made by the competent authorities with regard to the highway code.
-The manufacturer shall only be responsible for manufacturing defects in the bike rack and
accessory components.
km/h
110
Supplied.
24 mm

page 15
x 8
x 2 x 8
x 8
M6 x 55 M6 x 30 M5 x 40
x 3 x 2
M16 x 60
x 6
x 2
A
C
DE
F
GH
page 2
J
I
K
L
M
Nx 4
LB x 1
RP x 5
P
Self
Tapper
x 4
ST
Tilt Latch play adjustment.
The cycle carrier has been designed with an adjustment
feature to minimise any play within the tilt mechanism.
These adjusters are set at the factory.
However over time, it maybe necessary to re-adjust to
ensure continued optimum performance from your
cycle carrier. If adjustment is required it is very
important that it is carried out correctly.
IMPORTANT!
The play adjustment screws should only be used to remove the gap between
the carrier stop rubber and the platform, do not over extend this as it will
prevent the latch on the tilt mechanism from engaging fully into the latch
receiver.
The handle and latch should operate smoothly and the latch should be able
to click securely back into its engaged position.
If this is not the case, then the adjustment screws may have been over extended
and should be backed o to allow full smooth latch operation.
Maintenance:
It is important to maintain the cycle carrier in a safe condition for use.
Periodically check the carrier and ensure the bolts and xtures are tight.
If the tilt mechanism becomes sti to operate it is important to apply a
silicone based grease to the sliding parts of the mechanism.
M6 x 75
B
Platform
Adjustment
screws
Base
x 1
x 16
Carefully remove cover.
Fully engage the latch into the receiver (Green position).
If the platform has excessive play, carefully adjust the screws half a turn at a time to
remove most of the play.
Note: Leave a little play in, so the latch can freely move into the receiver.
Do not over extend as the
platform will raise and the
latch mechanism will not
engage properly.
Gap
New reduced gap
1-2mm
AD

2.
1.
Remove and discard the M16 bolts,
washers and nuts.
Note: Always use new M16 bolts,
washers and nuts.
page 3
Check towbar nose weight limit ( S - Vertical Static Mass ) -
Never exceed this limit, the sum of the carrier and bikes must be
less weight than
this limit.
? KG
Vehicle Handbook
page 14
M5 x 40
x 3
M16 x 60
x 2
To tilt the bike rack rst support with your hands while you push the release
handle with your foot.
To avoid injury or damage, this operation of tilting the bike rack should be carried
out with assistance.
To close the bike rack lift until the release handle and mechanism click and engage
securely in the transit position.
The Tilt mechanism indicator must show Green before you commence
your journey.
transit positionrelease position
CARE MUST BE TAKEN WHEN TILTING THE CARRIER - WATCH YOUR HEAD AND FINGERS!
How to release cycle clamp arms with ratchet levers:
First push the release lever outwards, then pull out the strap.
Red Tilt mechanism Green
indicator

7.
! Attach packer plate if using bottom
holes.
! Do not attach packer plate if using
top holes.
page 13page 4
To gain sucient clearance
to open the tail-gate whilst
the carrier is tilted, lower the
carrier by using the upper
holes in the base plate.
Secure wheels into the wheel locators by feeding the strap into the buckle
and pulling down until tight. Note: To release the strap push in the strap
retainer lever on the buckle.
How to operate ratchet straps and ratchet cycle arm clamps:
IMPORTANT:
Ensure the strap is routed
through the side aperture
into the ratchet buckle.
Continue to pump lever until the strap is tight against the cycle tube.
How to Tension cycle clamp arms with ratchet levers:
Push strap into
ratchet buckle.
Lift lever
Do not force lever !
On smaller diameter frames, take care that
the rubber protector does not interfere with
the operation of the ratchet system.
It maybe necessary to trim the rubber
to suit your frame size in this case.
Trim this area to
reduce length.
Do not over tighten !

IMPORTANT! ENSURE THE M16 NUTS ARE TIGHTENED FULLY (214Nm).
Note: Ensure that the
cable to the socket is
not stressed or pulled too tight.
Note: Discard removed bolts,washers
and nuts from electrical socket.
Use the new longer bolts
and Nyloc nuts provided.
214Nm
page 12 page 5
bike 1
bike 2
bike 3
Cycle Support Frame.
bike 4
bike 1 bikes 3 & 4

9. Positioning and xing the bikes on the carrier.
Bike 1:
Place the biggest/heaviest bike on the carrier rst, closest to the vehicle.
Position the wheels into the tyre locators and attach the shortest clamp arm
from the cycle support frame around the bike frame.
Secure the wheels in the locators using the straps. Pull down on the strap
until tight.
Bike 2:
Fits in the second set of locators with the medium clamp arm attached
to the bike frame.
Secure the wheels in the locators using the straps. Pull down on the strap
until tight.
Bike 3:
Fits in the third set of locators with the long clamp arm attached to the
bike frame.
Secure the wheels in the locators using the straps. Pull down on the strap
until tight.
Bike 4:
Fits in the outer locators (this should be the smallest/lightest bike) using the
bike to bike clamp arm attached to the bike frame from the previous
bike frame.
Ensure the adaptor is positioned
correctly for both the plug and socket.
K
Check all xtures
and bolts!
M
L
J
Attach the 13 pin plug into the vehicle 13 pin electrical socket.
If your vehicle is tted with a 7 pin socket,
use a 13 to 7 pin adaptor (supplied) to
convert the cycle carrier 13 pin plug.
IMPORTANT: Check light function!
page 6page 11
+
IMPORTANT! Safety pins MUST be inserted and closed fully.
Lift up cycle support arm.
Position and tighten retaining
thumb screws.
Slot groove onto pin whilst hooking over rear of
base plate to hold carrier in position.
3.
I
I
8.
IMPORTANT! Check Safety pins are inserted and closed fully.
I

Carefully route the lighting board cable and secure to the framework with cable ties.
It is important that the cable is not trapped or stretched and is tted to allow for the
tilt mechanism to tilt and slide without interference from the cable or without
damaging the cable.
Ensure that the cable does not hang
so as to catch the oor whilst driving. page 10 page 7
Slide 2 bolts into the “T” channel to the positions shown.
A A
A
Note:You may need to tilt the platform to gain
better access to some of the bolts underneath.
Mount the lighting board to the carrier using bolts .
x 2
M6 x 75
B
Secure the lightboard
to the carrier with bolts
“B” placing a washer at
the top and bottom.
B
Tighten the Nyloc
nut to 4 Nm.
Push the plastic end caps into the cycle rails .
Cable tie points
Mount the 4 rails, secure with the washer and nut underneath the sub-frame.
Do not over tighten!
4.

page 8page 9
Position the 8 wheel locators appropriate to the cycle sizes to be tted.
Outward position for adult (medium/large) cycles.
Inward facing position for very small cycles.
Slide the wheel holder onto the rail, locate bolt into the channel underneath.
Align the square section of the bolt with the rail cut out.
C
5.
Push the 13 pin plug through the centre hole.
Self
Tapper
x 4
ST P
Route wires into the cable lower channels.
Ensure wires are not trapped !
Mount number plate frame using screws .
ST
Support
Frame
Tube
Support
Frame
Tube
Attach the clamp arms to the carrier support frame.
Place nut within the Thumb nut wheel. Push nut in tight to prevent
the nut falling out on approach to the clamp xture bolt.
Attach the protective rubber to the clamp arms as shown. Ensure the rubber
does not impede the safe operation of the ratchet system.
KL
J
When tting the
actual number
plate do not screw
through the back-
plate where the
lighting cable may
get damaged.
Ensure the Thumb nut and bolt are seated properly, do not over tighten.
6.
7.
RP