Holman 2HCS8C Pro Rack Kit Pro Rack Leg and Crossbar Rack Cap Rack Installation Guide

Holman 2HCS8C Pro Rack Kit Pro Rack Leg and Crossbar Rack Cap Rack

DON’T OVERLOAD YOUR VEHICLE

WEIGHT CARRIED ABOVE THE FLOOR OF THE TRUCK BED (E.G. ON AN OVERHEAD TRUCK RACK) WILL SIGNIFICANTLY INCREASE THE VEHICLE’S TENDENCY TO OVERTURN. ALWAYS KEEP HEAVY LOADS EVENLY DISTRIBUTED AND AS LOW AS POSSIBLE. IT IS IMPORTANT TO NOTE THAT THE KARGO MASTER RACK LOAD BEARING CAPACITY MAY BE GREATER THAN YOUR TRUCK’S GAWR OR GVWR CAPACITY, AND IS PROBABLY GREATER THAN THE WEIGHT THAT CAN BE SAFELY CARRIED OVERHEAD. RETIGHTEN ALL BOLTS AFTER FIRST USE, PERIODICALLY CHECK BOLTS FOR TIGHTNESS.

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.
A large area is required to assemble rack. Be sure to keep area clear of trip and fall hazards.

Tools Needed

Before You Begin

• Read all instructions prior to assembling or installing any Holman product.
• Always locate your installation locations prior to performing any work.
• ENSURE SAFETY WHILE INSTALLING OR DRILLING INTO VEHICLE.

Side Channel Parts List

OR
12102:101564
OR
12103:101579| SIDE CHANNEL FRONT PS RH| 1
2| | 12101: 101531
OR
12102:101568
OR
12103:101626| SIDE CHANNEL REAR PS RH| 1
3| | 12101 : 1 01530
OR
12102: 101565
OR
12103: 101580| SIDE CHANNEL FRONT DSLH| 1
4| | 12101: 101532
OR
12102:101569
OR
12103: 101627| SIDE CHANNEL REAR DSLH| 1
5| | 101572| EXTRA CROSSBAR| 2
6| | 12103:31 110|  |

Wind Deflector Hardware (18-31571)

Leg & Bar Kit Parts

OR
12003: 101658
OR
12007: 101681|  | 2
4| | 101200|  | 4
5| | 101669|  | 1
6| | 12001: 101656
OR
12003: 101661
OR
12007: 101684|  | 1
7| | 12001: 101655
OR
12003: 101660
OR
12007: 101683|  | 1
8| | 11-00133|  | 2
9| | 13-00844|  | 1
10| | 13-00843|  | 1
11| | 101170|  | 1
12| | 101415|  | 1
13| | 101404|  | 3
14|  | 18-12001|  | 1

Hardware

BUTTON HEAD CAP
SCREW| 4
4| | 94095| 3/8″-16 X 1-3/ 4″
BUTTON HEAD CAP
SCREW| 8
5| | 0123496| 3/8″ SPLIT LOCK
WASHER| 4
6| | 0159723| 3/8″ FLAT WASHER| 38
7| | 0169791| 3/8″-16 LOCK NUT| 9
8| | 37691| 3/8″-16 JAM
NYLOCK NUT| 10
9| | 11-00112| 3/8″-16 T-NUT| 4
10| | 11241379| 1/2-13 X 1-1/4″ HEX
HEAD BOLT| 4
11| |  | 1 /2″-13 X 1.25″ HEX
HEAD WITH
THREADLOCK| 4
12| | 42KD91| 1 /2″-13 X 3″ BUTTON
HEAD CAP SCREW| 2
13| | 1133626| 1/2″ LOCK WASHER| 8
---|---|---|---|---
14| | 11137086| 1 /2″ STEEL FLAT WASHER, NARROW PROFILE| 10
15| | 37695| 1 /2″-13 THIN LOCKING JAM NUT| 2
16| | 11241180| 5/16-H1E8A XD 1 B-1O/L4T” HEX| 4
17| | 21810| C5A/1R6R”I-A1G8 EX 3B/O4L”T| 8
18| | 33006| 5/16″ FLAT WASHER| 12
19| | 0169777| 5/16″-18 NYLOC| 8
20| | 11104019| 5/1N6Y-L18O FCLKA NNGUTE| 4
21|  | –| SELF LEVELING
ADHESIVE SEALANT| 1
22|  | –| HARDWARE KIT| 1

Extra Crossbar Parts List

Extra Crossbar Hardware

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.

Step 1 – 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.

• Apply sealant to both top and bottom swage joints.

• Insert rear side-channel swaged joints into front side-channel tubes until bolt holes in splice plates 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.

Step 2 – 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.
• 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 3 – Attach Wind Deflector

• Position wind deflector on front U-tube. The image shown below is approximately the best angle to start with.

• 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 4 – Attach Center Crossbar

• Position center crossbar approximately 1/2 the length of the truck bed from rear of side channels.
• Using two 3/8” x 1” carriage bolts, 3/8” flat washers, and 3/8” thin lock nuts, attach a mating clamp to each end of center crossbar.
• Lightly tighten 3/8” nuts on both sides.

Step 5 – Attach Front Legs and Front Crossbar

• Determine the approximate distance between front and back legs based upon the size of bed, size of truck cap, and length of truck cap side door.

• Position a front leg against the 2” lower tube on the side channel, with the leg at the distance measured from center of the rear leg. The rope hook should be to the outside, away from truck.

• Hook two of the side channel clamps into the slots on the head of the leg assembly.

• Using a 5/16” x 1” hex bolt, 5/16” flat washer, and 5/16” flanged lock nut, LOOSELY fasten each clamp to the head of the leg.

• Repeat for second front leg on opposite side.

Step 6 – Attach Center Crossbar

• Using two 1/2″ x 1-1/4” hex head bolts, 1/2″ lock washers, and 1/2″ flat washers, fasten the front crossbar to the front feet.

Step 7 – Attach Rear Take-out Bar

• 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.
• Repeat on opposite side.

Step 8 – Attach Mounts

• Remove your camper shell from truck. Note whether or not there is a ridge on the bottom of your shell.

• Carefully insert the square tubing of the left supported mounting plate into the square tubing of the right supported mounting plate.

• Using 1/2” x 1-1/4”” hex bolts WITH PRE-APPLIED THREADLOCK, 1/2″ lock washers and 1/2” flat washers, bolt the supported mounting plates to the bottom of the front legs.

• Snug tighten but allow movement.

• Using 1/2” x 1-1/4”” hex bolts WITH PRE-APPLIED THREAD LOCK, 1/2″ lock washers, and 1/2” flat washers, bolt the rear mounting plates to the bottom of the back legs.

• Snug tighten but allow movement.

Step 9 – Mount Installation Preparation

• Position the rack on the truck as far forward as possible, with mounting plate tongue over the front bulkhead of the truck bed.

• Center the rack left to right on truck bed.

• Slide the front mount plates apart so that they are flush against opposite sides of the truck bed.

• Measure the inside dimension of the mount plates just above the support bar, and the outside dimension of the ridges (if any) on the bottom of your shell.

• It may be necessary to notch this ridge to avoid interference with the mount plates, or you may want to notch the ridge front and back so that the mount plates can be slid in towards the center of the truck to minimize overhang.

Bolt-through Mounting

• Make certain that the mount plates are square and flat horizontal with the bed rail.
• With the mount plates in their final position, locate and mark two optimal bolt hole locations on the top of each mount plate. The bolts should be located as far apart as possible, with clear access to the bolts, washers, and nuts underneath the truck’s bedrail.

Stake Pocket Mounting

If the inside of your truck bed has a double wall and it is not possible to locate a bolt on the mounting plate nearest the leg, we recommend using our accessory STAKE POCKET T-NUTS to provide an ADDITIONAL attachment point.

• If the stake pocket is covered by plastic, remove plastic cap or cut out plastic.

• Locate center of stake pocket and mark location on top of mounting plate.

• With the front mount plates in position, mark the through bolt hole in the inner support arm.

• Remove rack from the truck.

• Remove the rear mounting plates and front support arm from rack.

• Punch hole centers in the locations that you have marked.

• CHECK TWICE – DRILL ONCE!

• Drill 3/8″ holes in the mount plates and the inner support arm.

• Bolt the support arms together using a 3/8” x 2-1/2” hex bolt, two 3/8” flat washers, and a 3/8” lock nut.

• Tighten.

Step 10 – Mount Installation

• Set the mount plates back on the truck, in exactly the same location that they were before. Make certain each mount plate is square with the bed rail and dead horizontal. We recommend that you clamp each mount plate in position before drilling through truck’s bed rail.

• CHECK TWICE – DRILL ONCE!

• Drill through the bed using the holes in mount plates as guides.

• If using the stake pocket installation, screw the 3/8” x 1-3/4” cap screw, with 3/8” lock washer and 3/8” flat washer, through drilled hole and then into t-nut.

• Insert the 3/8” t-nut into the stake pocket hole.

• With the front foot at the correct distance, snug tighten the 3/8” x 2-1/2” button head screw until the t-nut is bound beneath metal stake pocket hole.

• Using 3/8” x 1-3/4” cap screws, 3/8” flat washers, and 3/8” lock nuts, bolt the mounting plates to the bed.

• Snug tighten but allow for movement. DO NOT TIGHTEN until all mounting bolts have been installed. It may be helpful to set the rack on the mounts to verify fitment before tightening hardware.

• Once mounts in correct position, TIGHTEN ALL MOUNTING HARDWARE.

Step 11 – Install Shell and Rack

• Apply adhesive foam tape (NOT INCLUDED) between the footplates and camper shell, along the bed rail, and along the top of the bulkhead, to seal the gaps.
• Attach the camper shell to the truck.
• Place the rack on the mount plates and center side-to-side.
• Using previously removed 1/2” x 1” hex bolts, 1/2” lock washers, and 1/2” flat washers, bolt the rack to the mounting plates.
• Adjust each rear leg slightly side to side to ensure that the lock pins in the removable rear bar slide in and out easily.
• Tighten ALL bolts.

Step 12 – 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.
• Snug tighten but allow for movement.
• Install 3/8” set screw into telescoping crossbars.
• Tighten.

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.

GO BACK AND TIGHTEN ALL HARDWARE.
If cordless impact wrench was used to assemble, retighten all hardware using wrenches and sockets.
INSTALLATION AND ASSEMBLY ARE COMPLETE.

Customer Support

Holman
Rancho Cordova, CA 95742
800-343-7486
InstallationSupport@Holman.com

Read User Manual Online (PDF format)

Download This Manual (PDF format)

Download this manual  >>