The AR-2002 AluRack Crossbar Module, 59" Kit, is a roof rack system designed for vans, providing additional cargo capacity. This manual outlines the installation and configuration of the crossbar module, including components for both heavy-duty and standard crossbar setups, as well as a roller for easier loading and unloading.
Function Description:
The primary function of the AR-2002 AluRack Crossbar Module is to securely transport items on the roof of a van. It consists of multiple crossbars that attach to the vehicle's roof, creating a stable platform for various loads. The system is designed to distribute weight evenly and provide a robust solution for carrying equipment, materials, or other cargo that cannot fit inside the vehicle. The inclusion of a roller at the rear of the system facilitates the loading and unloading of longer or heavier items, allowing them to be slid onto the crossbars with less effort and reducing the risk of damage to the vehicle or cargo.
Important Technical Specifications:
The kit includes several key components with specific quantities and dimensions:
- AluRack Heavy Duty Crossbar: 3 units, each 53.00" long. These are designed for heavier loads and provide enhanced durability.
- AluRack Standard Crossbar: 5 units, each 53.00" long. These are suitable for general cargo and complement the heavy-duty crossbars.
- AluRack Roller Assembly: 1 unit, 49.75" long, with caps. This assembly is crucial for the loading and unloading feature.
- Crossbar and Roller Hardware: Includes various fasteners and brackets for assembly.
- M8 Strip Nut: 18 units
- M8 Lock Washer: 18 units
- M8 Cap Head Bolt: 18 units
- Roller Bracket: 2 units
- Roller Tube Pin: 2 units
- Roller Spring: 2 units
- Anti-Seize: 1 unit (for lubrication during assembly)
The crossbar configurations vary depending on the vehicle model and desired load capacity. The manual provides a detailed table for different van models (Metris 2016 L2H1, Sprinter 2007+ L2H2/L4H2, Sprinter 2007+ L3H2/L4H2, Metris 2018 L3H1) with specific measurements (A, B, C, D, E, F, G, H) for positioning the crossbars. These measurements are crucial for proper weight distribution and optimal performance. For instance, the AR1916 Metris 2016 L2H1 (126" Wheelbase, 76" Roof Height) uses a 5.00" A measurement for both standard and heavy-duty crossbars, while the AR1929 Sprinter 2007+ L2H2 (144" Wheelbase, 111" Roof Height) uses a 10.00" A measurement. The "Front Side Rail End" measurement, which indicates the distance from the front of the side rail to the first crossbar, also varies by model, ranging from 112.00" to 152.00".
The system is designed to accommodate different crossbar types (Standard and Heavy Duty) and allows for flexible configurations. The manual specifies that "Side Rail Sizes vary according to customer sizing needs – See respective AR Side Rail Kit Manual to build your Side Rails." This indicates that the side rails, which are not part of this specific module kit, are a prerequisite and their dimensions influence the overall setup.
Usage Features:
The AR-2002 AluRack Crossbar Module is designed for ease of use and versatility.
- Configurable Crossbar Placement: The system allows for custom placement of crossbars to suit different cargo types and sizes. The manual provides detailed instructions and a table to determine the correct spacing for various van models, ensuring optimal load distribution and stability. This flexibility is a key feature, enabling users to adapt the rack to their specific needs, whether transporting ladders, lumber, or other equipment.
- Roller for Easy Loading: The integrated roller assembly at the rear significantly simplifies the loading and unloading process. Users can slide long or heavy items onto the rack without needing to lift them completely, reducing physical strain and the risk of scratching the vehicle's paint. This is particularly beneficial for single-person operations.
- Durable Construction: The use of AluRack heavy-duty and standard crossbars, along with robust hardware, ensures the system's durability and ability to withstand various weather conditions and heavy loads. The components are designed for long-term reliability in commercial or personal use.
- Safety Guidelines: The manual emphasizes safety during installation and use. It includes warnings about proper torque settings for fasteners (60 in-lbs for strip nuts and roller brackets, 90 in-lbs for crossbar installation) and cautions against mounting the AluRack to an FBM system at the time of installation, as this may result in damage to the FBM system or cargo. It also advises consulting the respective FBM Assembly Manual(s) for chosen rack configuration features.
Maintenance Features:
While the manual primarily focuses on installation, it implicitly highlights aspects related to maintenance through its emphasis on proper assembly and component quality.
- Proper Installation for Longevity: Adhering to the specified torque settings for all fasteners (60 in-lbs for strip nuts and roller brackets, 90 in-lbs for crossbar installation) is crucial for the long-term integrity and safety of the rack system. Incorrectly tightened fasteners can lead to loosening, component failure, or even detachment of the cargo.
- Anti-Seize Application: The inclusion of anti-seize compound in the kit (1 unit) suggests its application during assembly to prevent corrosion and seizing of threaded components, particularly in outdoor environments. This is a proactive maintenance measure that ensures fasteners can be easily removed or adjusted in the future if needed.
- Regular Inspection: Although not explicitly detailed as a maintenance schedule, the nature of a roof rack system implies the need for regular visual inspections. Users should periodically check all fasteners for tightness, inspect crossbars and brackets for any signs of wear, damage, or corrosion, and ensure the roller assembly operates smoothly. Any damaged or worn components should be replaced promptly to maintain the safety and functionality of the rack.
- Component Replacement: The modular design of the system, with individual components like strip nuts, washers, bolts, and brackets, suggests that specific parts can be replaced if damaged, rather than requiring the replacement of the entire system. This contributes to the overall maintainability and cost-effectiveness of the rack over its lifespan. The manual also notes that "Please contact your authorized distributor, or a Prime Design Sales & Service Representative" for applicable parts and accessories, indicating support for component replacement.
In summary, the AR-2002 AluRack Crossbar Module, 59" Kit, is a robust and versatile roof rack solution designed for vans, offering enhanced cargo capacity and ease of use through its configurable crossbar system and integrated roller. Its technical specifications highlight a focus on durability and adaptability, while its usage and implicit maintenance features underscore its practical design for long-term, reliable performance.
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