Assembly & Installa on Guide RB031-3: TRIPLE CROSSBAR KIT

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Amos Wilkinson
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PLEASE READ INSTRUCTIONS FULLY PRIOR TO INSTALLATION OF CROSSBAR KIT This instruction is to illustrate the recommended installation method for our Crossbar Kit, any deviation from this will be the

1 PLEASE READ INSTRUCTIONS FULLY PRIOR TO INSTALLATION OF CROSSBAR KIT This instruction is to illustrate the recommended installation method for our Crossbar Kit, any deviation from this will be the sole responsibility of whoever carries out the installation. PLEASE ENSURE THAT THE MANUFACTURERS MAXIMUM ROOF LOADING IS NOT EXCEEDED (Refer to vehicle handbook) REGULARLY INSPECT CROSSBARS AND FEET BRACKETS ENSURING ALL FIXINGS ARE SECURE PARTS LIST ILLUSTRATED RELATES TO COMPONENTS SUPPLIED WITHIN RB031-3 EACH PHASE OF THE INSTALLATION WILL ILLUSTRATE ITEMS REQUIRED SCALE OF ITEMS WILL VARY TO AID VISUAL IDENTIFICATION Ensure all the items listed are present, open each Fixing Kit Bag when instructed 1350mm CROSSBAR - x3 FIXING KIT 6 - x3 FIXING KIT TOOLS REQUIRED (Not included within kit) 13mm SPANNER - x2 TAPE MEASURE DRILL 5mm DRILL BIT FOOT BRACKET COVER - x6 LOCK KIT - x1 10mm DRILL BIT FIXING KIT EMPTY LOAD STOPS FOOT BRACKET - x6 SADDLE CLAMP - x6 P1 FOOT PACKER - x6 S1 FOOT GASKET - x6 LOAD STOP - x4 - x6 THE ABOVE DIAGRAM ILLUSTRATES COMPONENTS AS SUPPLIED IN A TRIPLE CROSSBAR KIT PACKAGE REF: a

2 Assembly & InstallaƟon Guide PHASE 1: REAR CROSSBAR INSTALLATION COMPLETE THE EIGHT PROCEDURES DETAILED AND MOVE ONTO PHASE 2. B INSTALLATION OF THE REAR CROSSBAR WILL BE COMPLETED AT A LATER STAGE ONE FIXING KIT 6 IS REQUIRED FOR THIS PHASE L1H2 L2H2 PLEASE CARRY OUT THE FOLLOWING PLEASE CARRY OUT THE FOLLOWING IDENTIFY DRILLING LOCATIONS FROM INSIDE VEHICLE IDENTIFY DRILLING LOCATIONS FROM INSIDE VEHICLE VISUAL CHECK OF WIRING HARNESS ROUTING IN ROOF VISUAL CHECK OF WIRING HARNESS ROUTING IN ROOF CAREFULLY REMOVE HEADLINER IF FITTED CAREFULLY REMOVE HEADLINER IF FITTED REPEAT PROCEDURE ON BOTH SIDES OF VEHICLE REPEAT PROCEDURE ON BOTH SIDES OF VEHICLE A L1H2: PLEASE CARRY OUT PROCEDURES LISTED ABOVE PRIOR TO COMMENCING INSTALLATION B L2H2: PLEASE CARRY OUT PROCEDURES LISTED ABOVE PRIOR TO COMMENCING INSTALLATION REAR ROOF BEAM TAP INTO POSITION TAP INTO POSITION USING APPROPRIATE TOOL 5mm LEAVE IN POSITION, PROCEED TO NEXT STAGE GA P! ONCE IN POSITION THERE MAY BE A GAP BETWEEN FIXING BOSS AND ROOF, THIS IS ACCEPTABLE DO NOT FORCE ANY FURTHER 1 2 LOCATE INTO REAR ROOF BEAM APERTURE INDICATED ABOVE. NOTE: PLEASE USE AN APPROPRIATE TOOL (IDEALLY RUBBER MALLET) USING AS A GUIDE, DRILL A IN THE VEHICLE ROOF. : ONCE PILOT HOLE HAS BEEN DRILLED LEAVE IN POSITION REF: a

3 PHASE 1: REAR CROSSBAR INSTALLATION REAR ROOF BEAM TAP INTO POSITION 5mm LEAVE IN POSITION, PROCEED TO NEXT STAGE GAP! 3 4 LOCATE INTO REAR ROOF BEAM APERTURE INDICATED ABOVE. NOTE: PLEASE USE AN APPROPRIATE TOOL (IDEALLY RUBBER MALLET) ONCE IN POSITION THERE MAY BE A GAP BETWEEN FIXING BOSS AND ROOF, THIS IS ACCEPTABLE DO NOT FORCE ANY FURTHER USING AS A GUIDE, DRILL A IN THE VEHICLE ROOF. : ONCE PILOT HOLE HAS BEEN DRILLED LEAVE IN POSITION 10mm 15mm ENSURE A STOP IS USED ON THE DRILL SET TO 15mm FK1 FK3 P1 PACKER S1 GASKET 5 TOUCH-UP PAINT IT IS ADVISABLE TO TREAT EXPOSED METAL WITH TOUCH-UP PAINT A: DRILL OUT EACH TO 10mm, LOCATIONS INDICATED. B: IT IS ADVISABLE TO TREAT ALL EXPOSED METAL AT EACH DRILLED HOLE WITH TOUCH-UP PAINT. 6 ATTACH FOOT BRACKET ONTO VEHICLE AS SHOWN AT LOCATION INDICATED. NOTE: FEET BRACKETS ARE IDENTICAL SO CAN BE FITTED EITHER SIDE OF VEHICLE. FEET BRACKETS CAN BE FITTED EITHER SIDE ENSURE PACKERS ARE LOCATED AS SHOWN REF: a

4 PHASE 1: REAR CROSSBAR INSTALLATION FK1 FK5 FK3 P1 PACKER FK2 S1 GASKET 7 ATTACH FOOT BRACKET ONTO VEHICLE AS SHOWN AT LOCATION INDICATED. ENSURE PACKERS ARE LOCATED AS SHOWN 8 REPEAT ON BOTH SIDES OF VEHICLE A: LOCATE CROSSBAR INTO EACH FOOT BRACKET ENSURING CROSSBAR SLOT IS AT THE TOP. B: POSITION SADDLE CLAMP AS SHOWN AND ONTO FOOT BRACKET. REF: a

5 Assembly & InstallaƟon Guide PHASE 2: FRONT CROSSBAR INSTALLATION COMPLETE THE EIGHT PROCEDURES DETAILED IN PHASE 2 AND MOVE ONTO PHASE 3. B INSTALLATION OF THE FRONT CROSSBAR WILL BE COMPLETED AT A LATER STAGE ONE FIXING KIT 6 IS REQUIRED FOR THIS PHASE L1H2 L2H2 PLEASE CARRY OUT THE FOLLOWING PLEASE CARRY OUT THE FOLLOWING IDENTIFY DRILLING LOCATIONS FROM INSIDE VEHICLE IDENTIFY DRILLING LOCATIONS FROM INSIDE VEHICLE VISUAL CHECK OF WIRING HARNESS ROUTING IN ROOF VISUAL CHECK OF WIRING HARNESS ROUTING IN ROOF CAREFULLY REMOVE HEADLINER IF FITTED CAREFULLY REMOVE HEADLINER IF FITTED REPEAT PROCEDURE ON BOTH SIDES OF VEHICLE REPEAT PROCEDURE ON BOTH SIDES OF VEHICLE A L1H2: PLEASE CARRY OUT PROCEDURES LISTED ABOVE PRIOR TO COMMENCING INSTALLATION B L2H2: PLEASE CARRY OUT PROCEDURES LISTED ABOVE PRIOR TO COMMENCING INSTALLATION FRONT ROOF BEAM TAP INTO POSITION TAP INTO POSITION USING APPROPRIATE TOOL 5mm LEAVE IN POSITION, PROCEED TO NEXT STAGE GA P! ONCE IN POSITION THERE MAY BE A GAP BETWEEN FIXING BOSS AND ROOF, THIS IS ACCEPTABLE DO NOT FORCE ANY FURTHER 1 2 LOCATE INTO FRONT ROOF BEAM APERTURE INDICATED ABOVE. NOTE: PLEASE USE AN APPROPRIATE TOOL (IDEALLY RUBBER MALLET) USING AS A GUIDE, DRILL A IN THE VEHICLE ROOF. : ONCE PILOT HOLE HAS BEEN DRILLED LEAVE IN POSITION REF: a

6 PHASE 2: FRONT CROSSBAR INSTALLATION FRONT ROOF BEAM TAP INTO POSITION 5mm LEAVE IN POSITION, PROCEED TO NEXT STAGE GAP! 3 4 LOCATE INTO FRONT ROOF BEAM APERTURE INDICATED ABOVE. NOTE: PLEASE USE AN APPROPRIATE TOOL (IDEALLY RUBBER MALLET) ONCE IN POSITION THERE MAY BE A GAP BETWEEN FIXING BOSS AND ROOF, THIS IS ACCEPTABLE DO NOT FORCE ANY FURTHER USING AS A GUIDE, DRILL A IN THE VEHICLE ROOF. : ONCE PILOT HOLE HAS BEEN DRILLED LEAVE IN POSITION 10mm 15mm ENSURE A STOP IS USED ON THE DRILL SET TO 15mm FK1 FK3 P1 PACKER S1 GASKET 5 TOUCH-UP PAINT IT IS ADVISABLE TO TREAT EXPOSED METAL WITH TOUCH-UP PAINT A: DRILL OUT EACH TO 10mm, LOCATIONS INDICATED. B: IT IS ADVISABLE TO TREAT ALL EXPOSED METAL AT EACH DRILLED HOLE WITH TOUCH-UP PAINT. 6 ATTACH FOOT BRACKET ONTO VEHICLE AS SHOWN AT LOCATION INDICATED. NOTE: FEET BRACKETS ARE IDENTICAL SO CAN BE FITTED EITHER SIDE OF VEHICLE. FEET BRACKETS CAN BE FITTED EITHER SIDE ENSURE PACKERS ARE LOCATED AS SHOWN REF: a

7 PHASE 2: FRONT CROSSBAR INSTALLATION FK1 FK5 FK3 P1 PACKER FK2 S1 GASKET 7 ATTACH FOOT BRACKET ONTO VEHICLE AS SHOWN AT LOCATION INDICATED. ENSURE PACKERS ARE LOCATED AS SHOWN 8 REPEAT ON BOTH SIDES OF VEHICLE A: LOCATE CROSSBAR INTO EACH FOOT BRACKET ENSURING CROSSBAR SLOT IS AT THE TOP. B: POSITION SADDLE CLAMP AS SHOWN AND ONTO FOOT BRACKET. REF: a

8 Assembly & InstallaƟon Guide PHASE 3: MID CROSSBAR INSTALLATION COMPLETE THE EIGHT PROCEDURES DETAILED IN PHASE 3 AND MOVE ONTO PHASE 4. B INSTALLATION OF THE MID CROSSBAR WILL BE COMPLETED AT A LATER STAGE ONE FIXING KIT 6 IS REQUIRED FOR THIS PHASE L1H2 L2H2 PLEASE CARRY OUT THE FOLLOWING PLEASE CARRY OUT THE FOLLOWING IDENTIFY DRILLING LOCATIONS FROM INSIDE VEHICLE IDENTIFY DRILLING LOCATIONS FROM INSIDE VEHICLE VISUAL CHECK OF WIRING HARNESS ROUTING IN ROOF VISUAL CHECK OF WIRING HARNESS ROUTING IN ROOF CAREFULLY REMOVE HEADLINER IF FITTED CAREFULLY REMOVE HEADLINER IF FITTED REPEAT PROCEDURE ON BOTH SIDES OF VEHICLE REPEAT PROCEDURE ON BOTH SIDES OF VEHICLE A L1H2: PLEASE CARRY OUT PROCEDURES LISTED ABOVE PRIOR TO COMMENCING INSTALLATION B L2H2: PLEASE CARRY OUT PROCEDURES LISTED ABOVE PRIOR TO COMMENCING INSTALLATION MID ROOF BEAM TAP INTO POSITION TAP INTO POSITION USING APPROPRIATE TOOL 5mm LEAVE IN POSITION, PROCEED TO NEXT STAGE GA P! ONCE IN POSITION THERE MAY BE A GAP BETWEEN FIXING BOSS AND ROOF, THIS IS ACCEPTABLE DO NOT FORCE ANY FURTHER 1 2 LOCATE INTO MID ROOF BEAM APERTURE INDICATED ABOVE. NOTE: PLEASE USE AN APPROPRIATE TOOL (IDEALLY RUBBER MALLET) USING AS A GUIDE, DRILL A IN THE VEHICLE ROOF. : ONCE PILOT HOLE HAS BEEN DRILLED LEAVE IN POSITION REF: a

9 PHASE 3: MID CROSSBAR INSTALLATION MID ROOF BEAM TAP INTO POSITION 5mm LEAVE IN POSITION, PROCEED TO NEXT STAGE GAP! 3 4 LOCATE INTO MID ROOF BEAM APERTURE INDICATED ABOVE. NOTE: PLEASE USE AN APPROPRIATE TOOL (IDEALLY RUBBER MALLET) ONCE IN POSITION THERE MAY BE A GAP BETWEEN FIXING BOSS AND ROOF, THIS IS ACCEPTABLE DO NOT FORCE ANY FURTHER USING AS A GUIDE, DRILL A IN THE VEHICLE ROOF. : ONCE PILOT HOLE HAS BEEN DRILLED LEAVE IN POSITION 10mm 15mm ENSURE A STOP IS USED ON THE DRILL SET TO 15mm FK1 FK3 P1 PACKER S1 GASKET 5 TOUCH-UP PAINT IT IS ADVISABLE TO TREAT EXPOSED METAL WITH TOUCH-UP PAINT A: DRILL OUT EACH TO 10mm, LOCATIONS INDICATED. B: IT IS ADVISABLE TO TREAT ALL EXPOSED METAL AT EACH DRILLED HOLE WITH TOUCH-UP PAINT. 6 ATTACH FOOT BRACKET ONTO VEHICLE AS SHOWN AT LOCATION INDICATED. NOTE: FEET BRACKETS ARE IDENTICAL SO CAN BE FITTED EITHER SIDE OF VEHICLE. FEET BRACKETS CAN BE FITTED EITHER SIDE ENSURE PACKERS ARE LOCATED AS SHOWN REF: a

10 PHASE 3: MID CROSSBAR INSTALLATION FK1 FK5 FK3 P1 PACKER FK2 S1 GASKET 7 ATTACH FOOT BRACKET ONTO VEHICLE AS SHOWN AT LOCATION INDICATED. ENSURE PACKERS ARE LOCATED AS SHOWN 8 REPEAT ON BOTH SIDES OF VEHICLE A: LOCATE CROSSBAR INTO EACH FOOT BRACKET ENSURING CROSSBAR SLOT IS AT THE TOP. B: POSITION SADDLE CLAMP AS SHOWN AND ONTO FOOT BRACKET. REF: a

11 ADJUST PHASE 4: COMPLETION OF CROSSBAR KIT INSTALLATION EQUAL BOTH SIDES ANY STRAIGHT EDGE ADJUST SADDLE CLAMP TO ACHIEVE LEVEL CROSSBARS 1 SECURE FASTENERS PRIOR TO CENTRALISING CROSSBAR M8: TIGHTEN TO 12Nm A:, SECURE ALL FEET BRACKET FASTENERS TO THE TORQUE SETTING GIVEN ABOVE. B: ADJUST EACH CROSSBAR TO ENSURE THEY ARE CENTRAL AND ACHIEVE AN EQUAL DISTANCE EACH SIDE OF SADDLE CLAMP. 2 ENSURE ALL CROSSBAR ASSEMBLIES ARE LEVEL USE A STRAIGHT EDGE THAT SPANS ALL CROSSBARS ALL M8 FASTENERS: TIGHTEN TO 12Nm A: USING A STRAIGHT EDGE THAT SPANS ALL CROSSBARS, ADJUST SADDLE CLAMPS TO ENSURE CROSSBARS ARE LEVEL. B:, SECURE ALL SADDLE CLAMP FASTENERS TO THE TORQUE SETTING GIVEN ABOVE. ENSURE TAB IS LOCATED AS SHOWN HERE ROTATE LOCK BARREL 90º ANTI-CLOCKWISE TO LOCK 3 INSERT A LOCK BARREL INTO EACH FOOT BRACKET COVER LOCATE A LOCK BARREL INTO EACH FOOT BRACKET COVER, ENSURE TAB IS LOCATED AS DETAILED. 4 A: LOCATE FOOT BRACKET COVER ONTO EACH FOOT BRACKET ASSEMBLY AS SHOWN. B: ROTATE LOCK BARREL 90º ANTI-CLOCKWISE TO LOCK IN POSITION AND REMOVE KEY. REMOVE KEY AND REPEAT ON ALL REMAINING FEET BRACKETS REF: a

12 LSN2: LOAD STOP KIT (1 PAIR) LOAD STOP KIT (1 PAIR) INSTALLATION PLEASE READ FULLY PRIOR TO INSTALLATION This instruction illustrates the recommended installation method for our Load Stops, any deviation from this will be the sole responsibility of whoever carries out the installation. USING THE TYPICAL INSTALLATION METHOD SHOWN, LOAD STOPS CAN BE LOCATED AS DESIRED ON ANY VAN SUPPLIES CROSSBAR THESE LOAD STOPS ARE NOT DESIGNED TO SECURE LOADS, PLEASE ENSURE ANY LOAD IS SECURE PRIOR TO ANY MOVEMENT OF VEHICLE TYPICALLY LOAD STOPS ARE LOCATED ON THE FRONT AND REAR CROSSBARS, TWO ON EACH LOCATE LOAD STOP KNOB LOCATE M8 x 35mm SET ASSEMBLY COMPLETE ONE LOAD STOP KIT CONTAINS: SCALE MAY VARY TO AID VISUAL IDENTIFICATION 1 A - ENSURING LOAD STOP KNOB IS IN CORRECT ORIENTATION LOCATE AS SHOWN. B - LOCATE M8 x 35mm SET THROUGH LOAD STOP KNOB AND INTO LOAD STOP. 2 LOCATE x2 LOCK NUTS INTO DESIRED CROSSBAR AS SHOWN ABOVE LOAD STOP - x2 LOAD STOP KNOB - x2 SET TO DESIRED WIDTH / LOCATION M8 x 35mm SET - x2 LOCK NUT - x2 3 ALIGN LOAD STOP ASSEMBLIES WITH LOCK NUTS AND, THESE CAN BE LOCATED AT ANY POINT ALONG CROSSBAR AND IMAGE ABOVE IS USED FOR ILLUSTRATION PURPOSE ONLY. 4 A - LOCATE LOAD STOPS TO DESIRED WIDTH / LOCATION. B -, TIGHTEN FASTENERS AND ENSURE ALL LOAD STOPS ARE SECURE. LSN2 - LOAD STOP KIT REF: a

Assembly & Installa on Guide RB091-3: TRIPLE CROSSBAR KIT

Assembly & Installa on Guide RB091-3: TRIPLE CROSSBAR KIT PLEASE READ INSTRUCTIONS FULLY PRIOR TO INSTALLATION OF CROSSBAR KIT This instruction is to illustrate the recommended installation method for our Crossbar Kit, any deviation from this will be the sole