Power Fist Steel Headache Rack

Introduction

The Headache Rack features a 2-inch wire screen designed to protect your cab window from damage caused by loose loads, without obstructing visibility.

Safety

General Warnings

WARNING! Read and understand all instructions before using this tool. Operators must follow basic precautions to reduce the risk of personal injury and/or equipment damage.

Keep this manual for safety warnings, precautions, operating, inspection, and maintenance instructions.

Hazard Definitions

• DANGER! Indicates an immediate and specific hazard that will result in severe personal injury or death if proper precautions are not taken.
• WARNING! Indicates a specific hazard or unsafe practice that could result in severe personal injury or death if proper precautions are not taken.
• CAUTION! Indicates a potentially hazardous situation that may result in minor or moderate injury if proper practices are not taken.
• NOTICE! Indicates a specific hazard or unsafe practice that will result in equipment or property damage, but not personal injury.

Work Area

1. Operate in a safe work environment. Keep your work area clean, well-lit, and free of distractions. Position lights to avoid working in shadows.
2. Keep individuals not wearing appropriate safety equipment away from the work area.
3. Store tools properly in a safe and dry location, out of the reach of children.

Personal Safety

WARNING! Wear personal protective equipment approved by the Canadian Standards Association (CSA) or American National Standards Institute (ANSI).

Personal Protective Equipment

1. Always wear impact safety goggles providing front and side eye protection, compliant with CSA Z94.3-07 or ANSI Z87.1 standards.
2. Wear an appropriate full-face shield in addition to safety goggles, as the work may create chips, abrasive, or particulate matter.
3. Wear gloves that offer protection based on work materials or to reduce tool vibration effects. Do not wear gloves if the tool could snag material and pull the hand into the tool.
4. Wear protective clothing designed for the work environment and tool.
5. Non-skid footwear is recommended for maintaining footing and balance.
6. Wear steel toe footwear or steel toe caps to prevent foot injuries from falling objects.
7. Wear an appropriately rated dust mask or respirator.

Personal Precautions

1. Control the tool, your movement, and the work environment to avoid personal injury or tool damage.
2. Do not operate any tool when tired or under the influence of drugs, alcohol, or medications.
3. Avoid wearing clothes or jewelry that can become entangled with moving parts. Keep long hair covered or bound.
4. Do not overreach when operating the tool. Proper footing and balance are essential for control in unexpected situations.

Specific Safety Precautions

WARNING! Do not let comfort or familiarity replace strict adherence to safety rules. Unsafe or incorrect use can cause serious personal injury.

1. Use the correct tool for the job; this tool is designed for a specific function. Do not modify or alter it, or use it for unintended purposes.
2. Do not use the tool if any parts are damaged, broken, or misplaced. Repair or replace parts. Check weld points for cracks or metal fatigue.
3. The rack is heavy. Seek assistance when carrying or lifting it during installation or assembly.
4. Check all bolts and connections for tightness daily. Tighten as necessary.

Unpacking

WARNING! Do not operate the tool if any part is missing. Replace missing parts before operation. Failure to do so may result in malfunction and personal injury.

Remove parts and accessories from packaging and inspect for damage. Ensure all items from the parts list are included.

Assembly & Installation

Numbered references in parentheses (#) refer to the included Parts List.

Installation requires drilling bolt holes into the truck bed rim to secure the rack. Verify there are no hidden wires or structures adjacent to the front pocket stakes.

1. Lay the rack (#2) flat with width adjustment slots (#13) facing up.
2. Insert side brackets (#3 and #11) into the rack. Bolt holes must be visible through width adjustment slots (#13). Refer to Parts Breakdown for orientation.
3. Slide an M12 lock washer (#10) over each of the four M12x30 flat hex bolts (#9). Screw two bolts into each side bracket. Do not fully tighten to allow for brace adjustment.
4. Insert end caps (#1) into the upright openings.
5. With assistance from another person, place the rack onto the truck. Have that person hold the rack in place during installation.
6. Extend the right side bracket beyond the truck wall.
7. Slide an M12 lock washer (#5) and an M12 flat washer (#6) over an M12x75 flat head hex bolt and insert it into the front slot of the side bracket.
8. Screw a U-clamp (#8) onto the bolt. Ensure the clamp flanges face upwards.
9. Lift the rack slightly and push the side bracket in until the U-clamp is above the truck's stake pocket hole. Align the U-clamp with the hole and lower the rack until seated.
10. Reach under the truck bed rim and turn the U-clamp 90°. Hold the clamp in position while tightening the bolt. Do not fully tighten yet.
11. Repeat steps 6 to 10 for the left bracket.
12. Center the rack between the brackets, then tighten the rack and clamp bolts with a wrench.
13. Use the second bracket bolt hole as a guide to drill a new bolt hole with a 1/2-inch cobalt twist bit. Repeat for the other bracket.
14. Slide an M12 lock washer (#5) and an M12 flat washer (#6) over an M12x75 flat hex bolt (#4). Insert this bolt through the new bolt hole created in step 13.
15. Position the flat bracket (#7) over the protruding bolt beneath the rim. Hold the bracket in place while screwing the bolt into it. Tighten with a wrench. Repeat for the other bracket.
16. Repeat steps 14 and 15 for the other side.
17. Recheck the tightness of all bolts to ensure the rack is properly installed.

Care & Maintenance

1. Maintain the tool with care. A tool in good condition is efficient, easier to control, and will have fewer problems.
2. Inspect tool components periodically. Repair or replace damaged or worn components using only identical replacement parts.
3. Ensure labels and nameplates remain intact as they contain important information. Contact Princess Auto Ltd. for replacements if unreadable or missing.

WARNING! Only qualified service personnel should repair the tool. Improperly repaired tools may pose a hazard to the user and others.

Troubleshooting

If the tool does not function properly or parts are missing, visit a Princess Auto Ltd. location for a solution. If unavailable, seek a qualified technician to service the tool.

Parts Breakdown

The following diagram illustrates the components of the Headache Rack:

[Diagram showing the rack assembly with numbered parts]

Parts List

Specifications