(44100B, 44101B, 44102B & 44103B) Place these instructions in the vehicle s glove box after installation is complete. Important: Please read these instructions carefully prior to installation. Check the contents of this kit before commencing fitment and report any discrepancies. Place these instructions in the vehicle s glove box after installation is complete. DO NOT use REB Eye bolt kit with Pioneer Alloy Tray Pioneer Eye Bolt Kit 43106 must be used instead Care Instruction: Wash vehicle roof prior to installing Rhino Pioneer Alloy Tray. Important Information Maximum carrying capacity: Refer vehicle manufacturer specifications, less weight of alloy tray below (includes leg kits): (44100B = 19.5kg, 44101B = 22.5kg, 44102B = 25kg, 44103B = 29.5kg) Recommendations: It is essential that all bolt connections be checked after driving a short distance when you first install your cross bars. Bolt connections should be checked again at regular intervals (probably once a week is enough, depending on road conditions, usage, loads and distances travelled). You should also check the alloy tray each time it is re-fitted. Make sure to fasten your load securely. Please ensure that all loads are evenly distributed and that the centre of gravity is kept as low as possible. Use only non-stretch fastening ropes or straps. Sensitivity to cross winds, behaviour in curves and braking. The handling characteristics of the vehicle, changes when you transport a load on the roof. For safety reasons, we recommend you exercise extreme care when transporting wind-resisting loads; special consideration must be taken into account when braking. Please remove cross bars when putting vehicle through an automatic car wash. Load Ratings: Maximum permissible load is set by the vehicle manufacturer less the weight of trays above (weights above include leg kits). When alloy trays are to be used in off-road conditions, please build a safety factor of 1.5 into this load limit. Although the alloy trays are tested and approved to AS1235-2000, Australian road conditions can be much more rigorous. However, increasing the number of mount points to the vehicle does not increase the vehicles maximum permissible roof loading. Note for Dealers and Fitters: It is your responsibility to ensure instructions are given to the end user or client. Rhino-Rack 3 Pike Street, Rydalmere, Document No: R074 NSW 2116, Australia. Prepared By: Nigel Greig Issue No: 11 (Ph) (02) 9638 4744 Authorised By: Chris Murty Issue Date: 28/08/2014 (Fax) (02) 9638 4822 These instructions remain the property of Rhinorack Australia Pty Ltd and may not be used or changed for any other purpose than intended. Page 1
Parts List Quantity Item Component Name Part No. 44100B 44101B 44102B 44103B 1 Pioneer Tray Assembly - 1 1 1 1 2 Crossbar A490/A491 2 2 2 2 3 Pioneer SXB Endcap M562 4 4 4 4 4 PVC Insert - 200mm R034 4 4 4 4 5 AT Locking Tab M136 6 8 6 8 6 AT Locking Tab Knob M137 6 8 6 8 7 M6 x 12mm Cap Screw B188 4 4 4 4 8 M6 Spring Washer W004 4 4 4 4 9 M6 x 16mm Flat Washer W031 4 4 4 4 10 Plate Nut N057 4 4 4 4 11 Rubber Buffer Strip - 125mm R011 4 4 4 4 12 Fitting Instructions R074 1 1 1 1 1 (44103B Shown) 11 6 5 3 2 4 8 7 9 10 Tools Required Electric Drill Tape Measure Pilot Drill (eg. 3mm) 8mm Drill Bit Stanley Knife or Cutters Rubber Mallet 5mm Security Allen Key (provided in kit) Page 2
1 Measure and Drill Sides of Alloy Tray Place the Pioneer alloy tray upside down in your work area. It may be advisable to sit the tray on top of the packing box to protect the tray from scratches. Refer to Appendix A for the appropriate measurements to suit your vehicle and tray size. Measure and mark the 4 drill locations on both sides of the Alloy Tray. Drill with a pilot hole and then drill an Ø8mm hole using a drill stop (as shown below). 37mm Drill Stop 8 mm Slots on top of tray indicate FRONT Drill depth stop. Round piece of wood or plastic of larger outer diameter than the hole being drilled. 8mm hole through centre. Page 3
2 Fit SXB Legs and Crossbars to Vehicle Refer to the fitting instructions provided with the SXB leg kit and proceed to fit the crossbars to the vehicles rails. Note: Refer to Appendix A in this document for the appropriate crossbar locations to suit your vehicle. 3 Cut and Insert Wind Strips Measure the gaps underneath the crossbar on either side of the legs and cut the wind strips to the appropriate size. Insert the wind strips as shown below. Wind Strip Wind Strip 4 Insert Endcaps into Crossbars Insert the endcaps into the ends of each crossbar as shown below. You may need to use a rubber mallot. Endcap 5 Insert Plate Nut into C Channel Insert a plate nut into each end of the crossbars sliding it over the lip on the endcap. Once inserted slide the plate nut back until it sits against the lip on the endcap. Fitted Position Lip Plate Nut Page 4
6 Slide Pioneer Tray onto Crossbars and Fit Hardware Slide the Pioneer Alloy Tray onto the crossbars from the side of the vehicle. The crossbars should sit within the tray. Align the holes (drilled in Step 1) with the channel nuts placed in the ends of the crossbars and fasten the tray in position with the hardware shown below. M6 x 12mm Cap Screw M6 Spring Washer M6 x 16mm Flat Washer (insert into tray first) 7 Fix Planks to Crossbars using Lock Tab Plates Place a lock tab plate in the cross bar between each Plank. Place the securing knob into the lock tab plate and rotate the Knob 90 with the allen key provided. Repeat till all Planks are secured to the cross bars. 8 Fit Buffer Strip to Remaining Exposed C Channel Measure and cut to size the rubber buffer strip to fill the remaining exposed C Channel within the crossbars. Push the buffer strip into the C Channel until completely inserted. Buffer Strip C Channel Page 5
Fitting Chart Pioneer 44100B (1528 x 1236mm) Dimension C Rear of Vehicle Vehicle Make Dimension C Approx. Overall Vehicle Height Holden Chevrolet Captiva (10/06 - on) Captiva (11-13) Captiva (06-13) 240 mm 800 mm 160 mm Opel Antara (07-13) Cherokee KJ (09/01-02/08) Jeep Cherokee KJ (02-07) Liberty (02-07) 185 mm 850 mm 75 mm Lexus RX Series (04/03 - on) 225 mm 750 mm 75 mm Challenger (12/09 - on) Nissan Montero Sport (09 - on) Pajero Dakar (09 - on) Pajero 5dr NS - NW (11/06 - on) Pajero Full 5dr (06 - on) Montero 5dr (06 - on) Pathfinder (07/05-10/13) Pathfinder (05-12) 125 mm 1050 mm 125 mm 185 mm 850 mm 60mm 185 mm 850 mm 120 mm Subaru XV (01/12 - on) 310 mm 780 mm Toyota Toyota Prado 120 5dr (03/03-11/09) Prado 120 5dr (03-09) Prado 150 5dr (11/09 - on) Prado 150 5dr (10-14) 185 mm 850 mm 60 mm 215 mm 850 mm 60 mm Page 6
Fitting Chart Pioneer 44101B (1528 x 1376mm) Dimension C Rear of Vehicle Make Model Dimension C Approx. Overall Vehicle Height Ford Wildtrack PX (10/11 - on) 273 mm 762 mm 115 mm 1915 mm Ford Explorer (2011 - on) Nth Am. 90 mm 1110 mm 190 mm 1840 mm ASX 5dr Wagon (07/10-7/12) Outlander Sport (11-13) RVR (11-14) 320 mm 740 mm 260 mm 1710 mm Pajero NM - NP LWB Montero (00-06) 185 mm 850 mm 120 mm Subaru Tribeca (12/07 - on) 185 mm 850 mm 80 mm 1785 mm Toyota Kluger (08/07 - on) Highlander (08 - on) 185 mm 850 mm 60 mm Page 7
Fitting Chart Pioneer 44102B (1928 x 1236mm) Dimension C Rear of Vehicle Make Model Dimension C Approx. Overall Vehicle Height Challenger PB (12/09 - on) 160 mm 1060 mm 100 mm Pajero NS - NW (11/06 - on) Pajero Sport (?? 09 - on) 190 mm 1200 mm 60 mm Toyota Land Cruiser Prado 120 5dr (03/03-11/09) 350 mm 900 mm 60 mm Toyota Land Cruiser Prado 150 5dr (11/09 - on) 390 mm 860 mm 60 mm Toyota Land Cruiser Prado 150 5dr (alt. position) 465 mm 860 mm 60 mm Page 8
Fitting Chart Pioneer 44103B (1928 x 1376mm) Dimension C Rear of Vehicle Make Model Dimension C Approx. Overall Vehicle Height Pajero NM - NP LWB Montero (00-06) 206 mm 1270 mm 60 mm Subaru Tribeca (12/07 - on) 385 mm 850 mm 80 mm 1795 mm Page 9