Holman 2SBS8R Pro Rack Kit Instruction Manual
- August 16, 2024
- Holman
Table of Contents
2SBS8R Pro Rack Kit
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Product Information
Specifications:
- Product Name: Pro Rack Service Body Rack
- Model Number: 20240123R2
- Manufacturer: Holman Rancho Cordova, CA 95742
- Contact: 800-343-7486, InstallationSupport@Holman.com
Product Usage Instructions
Warnings:
-
Always check for important vehicle components before
installation. -
Avoid exceeding the Gross Vehicle Weight Ratio (GVWR) or Gross
Axle Weight Ratio (GAWR). -
Do not use the rack with the rear crossbar removed.
-
Secure all payloads properly for safe transportation.
Before You Begin:
-
Ensure open space around the taillight and fliptop box
lid. -
Check the distance between the roof crown and mount
bracket. -
Mount the service body foot close to the rear body panel
corner.
Tools Needed:
- 1/2, 9/16, 3/4 Box Wrenches
- 7/32, 5/16 Allen Wrenches
- 11/32, 13/32 Drill Bits
- 1/2, 9/16, 3/4 Sockets and Wrench Drill
- Drill Bit Stop Collar
Sealant Application:
Proper sealant application is crucial to prevent water
penetration inside the rack. Follow manufacturer guidelines.
FAQ
Q: Can I exceed the weight limits provided by the
manufacturer?
A: It is not recommended to exceed the weight limits specified
by the manufacturer to ensure vehicle stability and safety.
Q: What should I do if I need technical support?
A: For technical support, contact
800-343-7486, Monday-Friday,
7AM – 4 PM (PST).
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Assembly and Installation
The Pro Rack Service Body Rack
20240123R2
Holman Rancho Cordova, CA 95742
800-343-7486
InstallationSupport@Holman.com
DATE: __
Instructions The PRO Service Body Rack
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM – 4 PM (PST)
Page 1
Instructions The PRO Service Body Rack
PLEASE READ ALL INSTRUCTIONS AND WARNINGS PRIOR TO ASSEMBLING, INSTALLING, AND
USING THIS PRODUCT.
WARNING
Always check for wires, fuel tanks and lines, brake lines and other important
vehicle functionality items prior to drilling and installing all products.
Too much weight will greatly reduce the stability of your vehicle. Holman
makes no representation or warranty as to the amount of weight your vehicle
can safely carry. For guidance, we recommend that you consult the vehicle
manufacturer. At no time should the weight of the vehicle, rack, driver,
passengers and cargo loaded on a Holman rack exceed either the Gross Vehicle
Weight Ratio (GVWR) or the Gross Axle Weight Ratio (GAWR) as specified by the
vehicle manufacturer.
Do not use your rack with the rear cross bar removed. Removal of rear crossbar
will affect structural integrity of the rack.
Secure all payloads properly for safe transportation.
Before You Begin
· Read all instructions carefully, and follow each step in proper sequence,
for ease and speed in assembling your Holman rack.
· The “bulkhead” is the panel at the front of the service body. Measure the
distance from the top of the bulkhead to the top of the truck’s cab. This
distance should be in the range of 15″ to 22″.
· PROPER SEALANT APPLICATION IS CRITICAL TO PREVENTING WATER PENETRATION
INSIDE THE RACK. Apply a healthy bead of sealant entirely around every swaged
joint and every bolt going through tubing. Improper sealing can lead to water
penetration and rust on inside surfaces.
· Standard mounting is on the rear panel. Check to ensure the rear panel of
the service body is free of taillights or other obstructions (inside or out)
in the area where the rear legs of the rack bolt to the body. Consult sketch
below.
o There must be open unobstructed space at least 1-3/4″ above taillight and
below fliptop box lid.
o There must be open unobstructed space at least 1-1/4″ to the left or right
of taillight.
o The distance between the crown of the roof plus 2-1/2″ to the top of the
mount bracket must be no greater than 24-1/2″. If the distance is greater than
24-1/2″, the optional 9″ extension kit (31520) is required.
o The service body foot must be mounted as close as possible to the vertical
exterior corner of the rear body panel. If mounting to the vertical exterior
corner of the rear body panel is not possible, the right and left service body
rear feet can be switched and the feet can be mounted as close as possible to
the vertical interior corner of the rear body panel.
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM – 4 PM (PST)
Page 2
Instructions The PRO Service Body Rack
Tools Needed
1/2″ 9/16″, 3/4″ Box Wrenches 7/32″, 5/16″ Allen Wrenches
11/32″, 13/32″ Drill Bits
1/2″, 9/16″, 3/4″ Sockets and Wrench Drill
Drill Bit Stop Collar
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM – 4 PM (PST)
Page 3
Instructions The PRO Service Body Rack
Table of Contents
Leg and Bar Kit Parts ………………………………………………………………………………………………………. 5 Leg and Bar
Kit Parts (Continued) ……………………………………………………………………………………… 6 Forklift Loadable
Side Channel Parts List……………………………………………………………………………. 6 Wind Deflector
Hardware (18-31571) …………………………………………………………………………………. 6 Extra Crossbar Parts
(31110) ……………………………………………………………………………………………. 7 Standard Side Channel Parts
List………………………………………………………………………………………. 7 Hardware Kit
…………………………………………………………………………………………………………………… 8 Hardware (Continued)
……………………………………………………………………………………………………… 9 Extra Crossbar Hardware
(18-31110)……………………………………………………………………………….. 10 Sealant Application
………………………………………………………………………………………………………… 10 Step 1 Measure Service Body and
Truck ……………………………………………………………………….. 11 Step 2 Install Front Leg Angle Mount
…………………………………………………………………………….. 11 Step 3 Install Bulkhead Bracing
…………………………………………………………………………………….. 12 Step 4 Assemble Front Leg
Assembly……………………………………………………………………………. 13 Step 5 Join Side Channels
…………………………………………………………………………………………… 13 Step 6 Attach Wind
Deflector………………………………………………………………………………………… 14 Step 7 Attach Front
Tube……………………………………………………………………………………………… 14 Step 8 Attach Center Crossbar
……………………………………………………………………………………… 14
Step 8A Forklift Loadable Side Channels………………………………………………………………….. 14 Step
8B Standard Side Channels ……………………………………………………………………………. 15 Step 10 Attach
Rear Take-out Bar…………………………………………………………………………………. 15 Step 10 Attach Rear
Legs…………………………………………………………………………………………….. 16 Step 11 Attach Front Legs
……………………………………………………………………………………………. 16 Step 12 Install Foot to
Rack………………………………………………………………………………………….. 17 Step 13 Install Rack onto
Service Body………………………………………………………………………….. 18 Step 14 Install Support
Arm………………………………………………………………………………………….. 19 Step 15 Install Extra Crossbar
(extended and crew cab kits only)………………………………………. 20 Step 16 Tighten
Hardware ……………………………………………………………………………………………. 20 Step 17 Take-out Bar
Adjustment………………………………………………………………………………….. 20 Step 18 Adjust Wind Deflector
………………………………………………………………………………………. 21 Using Rear Take-out Bar Position
Lock…………………………………………………………………………….. 21
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM – 4 PM (PST)
Page 4
Leg and Bar Kit Parts
Instructions The PRO Service Body Rack
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM – 4 PM (PST)
Page 5
Leg and Bar Kit Parts (Continued)
Instructions The PRO Service Body Rack
Forklift Loadable Side Channel Parts List
Wind Deflector Hardware (18-31571)
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM – 4 PM (PST)
Page 6
Extra Crossbar Parts (31110)
Instructions The PRO Service Body Rack
Standard Side Channel Parts List
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM – 4 PM (PST)
Page 7
Hardware Kit
Instructions The PRO Service Body Rack
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM – 4 PM (PST)
Page 8
Hardware (Continued)
Instructions The PRO Service Body Rack
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM – 4 PM (PST)
Page 9
Instructions The PRO Service Body Rack Extra Crossbar Hardware (18-31110)
Sealant Application
Proper sealant application is critical to preventing water penetration inside
the rack.
· Apply a healthy bead of sealant around every swaged joint as shown. Improper
sealing can lead to water penetration and rust on inside surfaces.
· Wipe any excess sealant off immediately with a plastic scraper or paper
towel. Any smeared sealant can be rubbed off as soon as sealant dries.
· Maintain this seal throughout the life of your rack.
· Repeat process for opposite side.
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM – 4 PM (PST)
Page 10
Instructions The PRO Service Body Rack Step 1 Measure Service Body and
Truck
· Measure distance between inside of service body bulkhead to rear of service
body. · Measure and record height from bulkhead to top of vehicle. · Crossbars
will need to be 2-1/2″ or more above the roof.
MEASURE INSIDE DISTANCE BETWEEN BULKHEAD AND REAR PANEL
MEASURE
Cut Away View of Bulkhead
Step 2 Install Front Leg Angle Mount
· Set front leg angle mount on top of the bulkhead, with flat face towards the
rear. · Center angle mount side-to-side. · Mark location of holes in angle
mount onto bulkhead.
MARK MARK
CENTER
· Remove front leg angle mount. · Using a 13/32″ drill bit, drill a hole in
the top of the bulkhead where marked.
Be sure drilling location is clear of wires, fuel tanks and lines, brake lines
and other important vehicle functionality items.
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM – 4 PM (PST)
Page 11
Instructions The PRO Service Body Rack
· Using one 3/8″ button head screw, two 3/8″ washers, and one 3/8″ lock nut,
install angle mount to service body bulkhead.
Step 3 Install Bulkhead Bracing
We recommend the following additional bracing be added to the service body bulkhead to support the truck rack. Some service bodies are not structurally designed to support loads upon the bulkhead without additional bracing.
· Place the corner support against the inside of the bulkhead, against the top
right side of the bulkhead flange or rail. The support should be touching
three service body panels.
· Mark the location of the three holes against the bulkhead and the two holes
to the service body interior sidewall.
· Repeat for the opposite side.
MARK BULKHEAD
MARK
MARK
MARK MARK
· Using an 11/32″ drill bit, drill a hole in each location marked.
Be sure drilling location is clear of wires, fuel lines, brake lines and other important vehicle functionality items. Use a drill bit stop collar.
· Apply some sealant around each hole drilled into side compartment.
· Using one 5/16″ bolt, two 5/16″ washers, and one 5/16″ lock nut for each hole drilled, attach the corner support to the service body.
· Repeat on opposite side.
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM – 4 PM (PST)
Page 12
Instructions The PRO Service Body Rack
Step 4 Assemble Front Leg Assembly
· Insert telescoping leg into leg assembly.
· Position leg so the bottom of telescoping leg is AT LEAST 1/2″ more than the
height between service body bulkhead and roof peak measured earlier.
· Align holes and LOOSELY fasten each leg to the leg assembly using a 1/2″ x
3-1/4″ button head screw, two flat washers, and 1/2″ jam nut. For most
installations, it is best to install bolts facing inward.
BULKHEAD TO ROOF
MEASUREMENT + 1/2″
Step 5 Join Side Channels
· Unpack side channels from box. Lay flattened box on ground and use for
scratch protection while building rack. Be sure you have correct front and
rear side channels paired.
Standard Side Channels
Forklift Loadable Side Channels
· Apply sealant to top and bottom swage joints.
· Insert rear side-channel swaged joints into middle side-channel tubes until
splice plates holes align.
· Insert front side-channel swaged joints into middle side-channel tubes until
splice plate holes align.
· Using 5/16″ x 3/4″ carriage bolts, 5/16″ washers, and 5/16″ lock nuts,
securely fasten channels together.
· Remove excess sealant.
· Repeat process for opposite side.
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM – 4 PM (PST)
Page 13
Instructions The PRO Service Body Rack
Step 6 Attach Wind Deflector
· Position wind deflector on front U-tube.
· Insert wind deflector straps into slots on rear of wind deflector.
· Using #10 x 3/4″ screws and #10 washers, bolt through top of wind deflector
into press-in nuts on wind deflector straps.
· Tighten.
Step 7 Attach Front Tube
· Apply sealant to front side-channel swaged joint.
· Insert front side-channel swaged joint into front tube until bolt holes in
tube and side-channel align.
· Apply sealant around top hole. · Loosely fasten front tube to side channel
using
1/2″ x 3″ partially threaded button head screw, 1/2″ washer, and 1/2″ lock
nut. · Remove excess sealant.
· Repeat process on opposite side.
Step 8 Attach Center Crossbar Step 8A Forklift Loadable Side Channels
· Using two 3/8″ x 1″ carriage bolts, 3/8″ flat washers, and 3/8″ thin lock
nuts, LOOSELY attach the center crossbar to the crossbar support.
· Repeat on opposite side of rack.
· Snug tighten.
For Technical Support Call:
800-343-7486, Monday-Friday, 7AM – 4 PM
(PST)
Forklift Loadable Side Channels
Page 14
Instructions The PRO Service Body Rack
Step 8B Standard Side Channels
· Position center crossbar, mid-way between the front and rear crossbars,
against the lower 2″ side channel tubes.
· Using two 3/8″ x 1″ carriage bolts, 3/8″ flat washers, and 3/8″ thin lock
nuts, LOOSELY fasten the MTG bracket clamp around the lower tube on each side.
Install carriage bolts with heads towards vehicle center.
· Repeat on opposite side of rack.
· Snug tighten.
Standard Side Channels
Step 9 Attach Rear Take-out Bar
NOTE: The rear take-out bar can be installed to open in either direction. One end is bolted and the other side is pinned.
· On the side to be bolted, slide end into rear side-channel receiver. Be sure the second lock-down hole in the end is towards the front of the vehicle.
· Using 3/8″ x 2-1/2″ hex head, two 3/8″ washers, and a 3/8″ lock nut, bolt
the rear take-out bar to
the receiver.
Lock Down Hole
· On opposite side, insert 3/8″ lock pin.
Step 9A FORKLIFT LOADABLE RACKS:
IF YOU EXPERIENCE DIFFICULTY PINNING REAR TAKE-OUT BAR INTO SIDE CHANNEL
RECEIVER, it may be necessary to install one or two spacers between the center
crossbar and crossbar support.
· Remove bolts fastening center crossbar to ONE of the side channel supports.
· Insert a spacer between the center crossbar and the crossbar support.
· Tighten hardware.
· Check pin alignment. If second spacer is required, install spacer on the
side opposite the previously installed spacer.
For Technical Support Call:
800-343-7486, Monday-Friday, 7AM – 4 PM
(PST)
Spacer
Page 15
Instructions The PRO Service Body Rack
Step 10 Attach Rear Legs
· Flip rack upside down. · Apply sealant to swaged joint on one leg and around
holes in leg cup. · Orient leg correctly with side
channel, with rope hook away from center of rack, and then insert leg into leg
cup until holes in leg and leg cup align. · Loosely fasten leg to leg cup
using, one 3/8″ x 2-1/2″ hex head bolt, two 3/8″ washers, and one 3/8″ lock
nut. Be sure to apply sealant around bolt between each washer and leg cup as
you assemble. · Remove excess sealant. · Repeat process on opposite side. ·
Tighten hex head bolt until legs are solidly fastened (up to 35 ft-lb.)
Step 11 Attach Front Legs
· Place strapping bracket against the 2″ diameter tube on the side channel. ·
Position the rear side of each strapping bracket 2-3/4″ less than the distance
measured earlier
from the absolute rear of rack.
2-3/4″ LESS THAN INSIDE BULKHEAD TO REAR DISTANCE
· Hook two of the side channel clamps into the slots on the head of the
strapping bracket.
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM – 4 PM (PST)
Page 16
Instructions The PRO Service Body Rack
· Using a 5/16″ x 1-1/4″ hex bolt, a 5/16″ lock washer, and 5/16″ flanged lock
nut, LOOSELY fasten each clamp to the head of
the leg.
5/16″ x 1-1/4″ hex bolts
· Using 1/2″ x 1-1/4″ hex head screws, 1/2″ lock washers, 1/2″ flat washers,
secure the front leg assembly to the crossbar strapping bracket.
· Repeat for opposite side. · Snug tighten but allow for movement.
Step 12 Install Foot to Rack
Depending on the model of service body the rack is installed on, it may be
necessary to install the rear feet pointed inwards instead of the typical rear
foot installation pointed outwards.
FEET DIRECTED OUTSIDE
FEET DIRECTED INSIDE
Also depending on the model of service body the rack is installed on, it may
be necessary to install
the 3″ leg extension prior to installing the rear feet. If the service body
has flip-open top lid door, then the extension is most likely necessary.
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM – 4 PM (PST)
Page 17
If NOT installing the 3″ extension:
· Using one 1/2″ x 1-1/4″ hex head bolt, one 1/2″ lock washer, and one 1/2″
washer, loosely install the rear foot to the rear leg.
· Snug tighten but allow for movement.
· Repeat on the opposite side.
Instructions The PRO Service Body Rack
If installing using the 3″ leg extensions (or optional 9″ leg extensions):
· Using one 1/2″ x 4-1/2″ hex head bolt, one 1/2″ lock washer, and one 1/2″
washer, loosely install the rear foot and the 3″ extension to the rear leg.
· Snug tighten but allow for movement.
· Repeat on the opposite side.
Step 13 Install Rack onto Service Body
· Lift rack and set legs onto front leg angle mount.
· Loosely fasten front leg angle mount onto legs using two 1/2″ x 1-1/4″ hex
bolts, two 1/2″ lock washers, and two 1/2″ washers.
· Block, support, or hold rack in place, with side channels level to the
service body.
· Verify clearance above vehicle cab is as recommended on Page 2. If clearance
needs adjustment, remove rack and adjust height of front legs as necessary.
· Position rack with rear feet against rear of service body.
· Position rear feet as close to upper corner and edges of the rear body panel
as possible. Be sure clearance is available inside rear panel of service for
3/8″ washers and nuts.
NOTE: If feet are reversed, position rear feet as far towards center and as
close to vertical interior corner of the rear body panel as possible.
· Mark location of holes in rear feet onto service body.
MARK
MARK
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM – 4 PM (PST)
Page 18
Instructions The PRO Service Body Rack
· Move feet out of the way.
· Using 13/32″ drill bit, drill holes in rear of service body where marked.
Be sure drilling location is clear of wires, fuel lines, brake lines and other
important vehicle functionality items. Use a drill bit stop collar.
· Apply some sealant around each hole drilled into side compartment.
· Using three 3/8″ x 1″ button head screws, 3/8″ washers, and 3/8″ lock nuts
for each side, securely fasten rear feet to rear of service body.
Service body shown cut away for clarity.
Step 14 Install Support Arm
· Remove 1/2″ lock nut and washer from ONLY one leg on side of rack.
· Position lower end of support arm against inside of service body. If
necessary, support arm may need to be moved to opposite side of front leg.
· Position support arm to as close to 45 degrees as possible while still
allowing clearance for 3/8″ washer and lock nut inside service body side
panel. Be sure to allow clearance for flip top door if present.
· Mark location of hole in support arm onto service body side panel.
· Using 13/32″ drill bit, drill holes through side panel of service body where
marked.
Be sure drilling location is clear of wires, fuel lines, brake lines and other
important vehicle functionality items. Use a drill bit stop collar.
· Apply some sealant around the hole.
· Using one 3/8″ button head screw, two 3/8″ washers, and one 3/8″ lock nut,
attach support arm to service body side panel.
· Snug tighten but allow for movement.
· Repeat for opposite side.
45°
Service body shown cut away for clarity.
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM – 4 PM (PST)
Page 19
Instructions The PRO Service Body Rack
Step 15 Install Extra Crossbar (extended and crew cab kits only)
· Using 3/8″ x 1″ carriage bolts, 3/8″ washers, and 3/8″ thin lock nuts, bolt
each end of extra crossbar to bottom tube of side channels.
· Tighten.
· Using 3/8″ set screw, tighten telescoping crossbars.
Step 16 Tighten Hardware
TIGHTEN FROM FRONT TO BACK.
TIGHTEN FROM TOP TO BOTTOM.
· From front to back, with lock pin installed in rear take-out bar, tighten
all side channel and upper front leg screws and bolts.
· Tighten front leg and crossbar hardware. · Tighten mounting hardware. ·
Securely fasten all foot screws and support arm screws. · Tighten center
crossbar. · Ensure all hardware is tightened.
Step 17 Take-out Bar Adjustment
· Verify rear crossbar lock-pin pulls in and out easily. If necessary, loosen
center crossbar hardware, then slide rear crossbar hard left then right about
10 times to get lock-pins to seat properly.
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM – 4 PM (PST)
Page 20
Instructions The PRO Service Body Rack
Step 18 Adjust Wind Deflector
The best angle for the wind deflector will depend on the vehicle the rack is
installed on. Small angle adjustments can make a big difference. The image
shown is approximately the best angle to start with.
Using Rear Take-out Bar Position Lock
The rear take-out bar is able to be locked in an open position.
DO NOT DRIVE VEHICLE WITH REAR TAKE-OUT BAR IN OPEN POSITION!
· Remove the pin from the rear take-out bar. · Open the bar fully. · Align the
hole and notch in take-out bar receiver.
· Insert the pin in the hole and lock the pin in the lock position.
Align notch and hole
GO BACK AND TIGHTEN ALL HARDWARE. If cordless impact wrench was used to
assemble, tighten all
hardware using wrenches and sockets.
INSTALLATION AND ASSEMBLY ARE COMPLETE.
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM – 4 PM (PST)
Page 21