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): (41100 = 24kg, 41101 = 27kg, 41102 = 30.5kg, 41103 = 34kg, 41104 = 38kg, 41107 = 33kg, 41108 = 33.5kg) (42100B = 19.5kg, 42101B = 22.5kg, 42102B = 25kg, 42103B = 29.5kg, 42104B = 32kg, 42105B = 40kg, 42107B = 27.5kg, 42108B = 28.5kg) 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: RS-393 NSW 2116, Australia. Prepared By: Nigel Greig Issue No: 17 (Ph) (02) 9638 4744 Authorised By: Gary England Issue Date: 19/12/2013 (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 Item Component Name Part No. Pioneer Tray, Pioneer Platform & Pioneer Tradie 41100 42100B 45100B 41101 42101B 45101B 41102 42102B 45102B 41103 42103B 45103B Quantity 41104 42104B 45104B 42105B 41107 42107B 45107B 1 Pioneer Tray Assembly - 1 1 1 1 1 1 1 1 2 Crossbar - 2 2 3 3 3 4 3 3 3 M8 x 20mm Dome Socket Screw B155 4 4 6 6 6 8 6 6 4 M8 Spring Washer W019 4 4 6 6 6 8 6 6 5 M8 Flat Washer OD17mm W020 4 4 6 6 6 8 6 6 6 M8 Flat Washer OD15 x 2.5mm - 4 4 6 6 6 8 6 6 7 M8 Channel Nut N003 4 4 6 6 6 8 6 6 12 5mm Security Allen Key H034 1 1 1 1 1 1 1 1 13 Locking Tab A523 6 8 9 12 12 16 9 12 14 M6 x 20mm Security Screw B062 6 8 9 12 12 16 9 12 15 M6 Spring Washer W004 6 8 9 12 12 16 9 12 16 M6 x OD16 Flat Washer W031 6 8 9 12 12 16 9 12 17 Fitting Instructions RS-393 1 1 1 1 1 1 1 1 41108 42108B 45108B Tools Required 1 (41104 Shown) 16 15 14 2 Tape Measure Rubber Mallet 16mm Ring Spanner Phillips Screwdriver 5mm Security Allen Key (provided in kit) 8 12 9 3 13 10 4 6 11 5 7 Page 2
Pioneer Tray, Pioneer Platform & Pioneer Tradie 1 Insert Crossbars Lay the tray upside down in your work area being careful not to scratch the alloy tray finish. Refer at rear of this document (or online www.rhinorack.com.au for the latest vehicle listings) and select the correct slots to suit your vehicle. Lower the crossbars into the tray as shown and rotate into position. Note: The front of the platform tray is identified by the slots in the top of the planks. Cut corners facing outside of tray Before Rotation 2 Crossbar sitting under bottom lip and aligned with slot. After Rotation Insert Hardware Place channel nut within the crossbar as shown below and rotate 90 degrees. Place clamp washer on top of the channel nut and slide both to the outside of the tray so they sit under the slot. Proceed to fit remaining hardware as shown but do not tighten at this stage. Repeat this process for both ends of each crossbars. M8 x OD15 Flat Washer Clamp Washer Channel Nut M8 Spring Washer M8 Flat Washer OD17 3 Centre Crossbars and Fix in Position Align crossbars so that the washer sits centred over the slot, you may need to tap the crossbar into position with a rubber mallet. Once the crossbar is in position tighten bolt with allen key provided. Washer Aligned with Slot Page 3
4 RL Leg Fitments Only - Remove Clamps If your fitment requires the use of RL legs remove the clamps from the legs as shown below. This makes positioning the tray on the vehicle much easier and ensures that the vehicle is not scratched by the metal clamps during fitment. Rubber Foot Assembled Leg Removed Clamps and Clamp Hardware 5 Fit Legs to Tray Fit the appropriate legs (as specified in Rhino Fit Guide) to the insertable crossbars previously fitted in step 1. Refer to the at back of this instruction for. Fasten each leg in this position making sure the channel nut rotates within the crossbar as shown below. Channel nut must rotate and sit within crossbar (Dim. A) RLCP Leg Fitment Shown Page 4
6 Fit Alloy Tray to Vehicle With a person on either side of the tray, lift the tray up and walk it over the vehicle from the rear. Lower the tray onto the vehicle making sure that the base of the legs locate within the fitment point for that vehicle.!! Note: For vehicles with tailgates that lift up, be sure to position the tray so that it clears the tailgate when fully open. 1 2 7 RLCP Leg/Crossbar Adjustment (if required) If any of the RLCP legs HAVE NOT dropped neatly into the recess in the top of the pads you will have to adjust the crossbar position. If the RLCP legs sit neatly within all of the pads you can proceed to the next step. If adjustment is required release the M8 dome bolt at the edge of the tray (shown below) with the allen key provided. Tap the crossbar until the leg drops into the recess in the top of the pad and re-tighten the M8 dome bolt. M8 Dome Bolt Crossbar Page 5
8 Fasten Legs to Vehicle Secure the tray to the vehicle by fastening each of the legs in position. Refer images below for the appropriate system being used on your vehicle: RL Leg Fitment Re-fit the clamp brackets and hardware previously removed in Step 10. Refer leg kit fitting instructions for details on fitting the clamps securely to the vehicle. Tip: You may need to place a finger behind the leg and hold the dowel nut in position. This will also allow you to rotate the dowel nut to align the thread. Leg Rubber Foot Metal Clamp Plastic Clamp Assembled Leg Flat Washer Spring Washer M6 x 35mm Security Screw RLCP & RLTP/RLTF Leg Fitment Tighten security screws to secure the legs to the vehicle as shown below. Security Screw Security Screw Page 6
9 Fit Locking Tabs Fit locking tabs to secure the planks to the crossbars. Use the the hardware shown below to fit the locking tabs to the cage nuts within the crossbars. All locking tabs are required to hold tray firmly in position. M6 x 20mm Security Screw M6 Spring Washer M6 x OD16 Flat Washer Locking Tab Cage Nut Fitted Locking Tab IMPORTANT! It is important that all roof racks and accessories are installed and attached correctly. Failure to follow correct attachment procedure could result in an accident, serious injury or death to others. The driver of the vehicle is responsible for securing the roof racks and accessories, checking the attachments, periodically checking bolt torque and visual inspection of all components for wear and damage. Do not attempt to fit the roof rack system or accessory to your vehicle unless you fully understand these fitting instructions. Please direct any questions regarding fitting to the dealer or retailer from where they were purchased. Page 7
PIONEER 41100 (1140 x 1400mm - Internal) PIONEER 42100B (1236 x 1528mm) PIONEER 45100B (1236 x 1528mm) F2 R2 Dim. A Dim. A Front Crossbar Rear Crossbar Approx. Overall Vehicle Make Model Front Slot Dim. A LHS Rear Slot Dim. A LHS Height Holden Colorado 4dr (08/08-05/12) Chevrolet Colorado Crew Cab (2004-2012) F2 - R2 - Holden Chevrolet Colorado 4dr (06/12 - on) S10 4dr (2013 - on) 175 mm - 180 mm - 1850 mm Isuzu D-Max 4dr (08/08-05/12) F2 - R2 - Isuzu D-Max 4dr (06/12 - on) 175 mm - 180 mm - 1850 mm Foton Tunland (06/12 - on) Refer Supplement Sheet Refer Supplement Sheet 1955 mm Grand Cherokee WK (02/11 - on) Jeep Grand Cherokee WK2 (2011 - on) Refer Supplement Sheet Refer Supplement Sheet Does not suit black roof rails Suzuki Grand Vitara 4dr (09/05 - on) Grand Vitara 4dr (2006 - on) F2 188 mm - R2 221 mm - 1820 mm Great Wall V240 4dr (07/09 - on) F2 - R2 - Great Wall X200/X240 5dr (04/11 - on) Refer Supplement Sheet Refer Supplement Sheet 1805 mm Hilux Dual Cab 4dr (04/05 - on) F2 - R2 - Ford Ranger 4dr PX (10/11 - on) F2 142 mm - R2 150 mm - 1890 mm Ford Ranger 4dr PK (04/09-08/11) Refer Supplement Sheet Refer Supplement Sheet 1840 mm Holden Rodeo 4dr RA (03/03-07/08) F2 - R2 - Holden Rodeo 4dr R9 (1998-02/03) F2 - - Ford Territory (04/04 - on) Refer Supplement Sheet Refer Supplement Sheet Mitsubishi Triton Dual Cab 4dr (11/96-06/06) F2 260 mm - R2 180 mm - 1830 mm Mitsubishi Triton Dual Cab 4dr (07/06 - on) F2 199 mm - R2 229 mm - Volkswagen Amarok 4dr (02/11 - on) Refer Supplement Sheet Refer Supplement Sheet Nissan X-Trail (10/07 - on) Refer Supplement Sheet Refer Supplement Sheet Page 8
PIONEER 41101 (1280 x 1400mm - Internal) PIONEER 42101B (1376 x 1528mm) PIONEER 45101B (1376 x 1528mm) R3 R2 Front Crossbar Rear Crossbar Approx. Overall Vehicle Make Model Front Slot Dim. A LHS Rear Slot Dim. A LHS Height Land Rover Nissan Discover 3 & 4 (04/05 - on) LR3 & LR4 (05 - on) Navara 4dr D40 (11/05 - on) Frontier (05 - on) - LHSPAIR - R2 - Range Rover Sport (08/05 - on) 170 mm - 182 mm - Volkswagen Amarok 4dr (02/11 - on) - R3 - Page 9
PIONEER 41102 (1140 x 1800mm - Internal) PIONEER 42102B (1236 x 1928mm) PIONEER 45102B (1236 x 1928mm) F2 M2 R2 M1 Front Crossbar Middle Crossbar Rear Crossbar Approx. Overall Vehicle Make Model Front Slot Dim. A LHS Mdle Slot Dim. A LHS Rear Slot Dim. A LHS Height Great Wall X200/X240 5dr (04/11 - on) Refer Supplement Sheet Refer Supplement Sheet Refer Supplement Sheet 1805 Mitsubishi Pajero NM - NP (05/00-10/06) Montero 4dr (2001-2006) 156 mm LHSPAIR M2 157 mm - 158 mm LHSPAIR 1948 Prado 120 5dr - M1 - - Prado 150 5dr F2 142 mm - M2 162 mm - R2 173 mm - Page 10
PIONEER 41103 (1280 x 1800mm - Internal) PIONEER 42103B (1376 x 1928mm) PIONEER 45103B (1376 x 1928mm) F2 M2 R2 M1 * 100 Series & LX470 with dust deflector fitted: 100 Series & LX470 with tailgates that lift up and are fitted with a dust deflector. New crossbar positions must be drilled 53mm back (towards rear of tray) from the centre of the slot positions detailed above. Drill Diameter 8.5mm holes in place of the slots. Front Crossbar Middle Crossbar Rear Crossbar Approx. Overall Vehicle Make Model Front Slot Dim. A LHS Middle Slot Dim. A LHS Rear Slot Dim. A LHS Height 90 Series Prado F2 148 mm - M1 156 mm - R2 162 mm LHS2PAIR Land Rover Lexus 100 Series Landcruiser * Landcruiser (1998-2007) * 200 Series Landcruiser Landcruiser (2008 - on) Discovery 3 & 4 (Factory Track Long) LR3 & LR4 (2005 - on) LX470 (05/98-03/08) * LX Series (1998-2007) * F2 - M2 - R2-194 mm - M1 204 mm - 214 mm - 2085 F2 - M1 - R2 - F2 - M2 - R2 - Lexus LX Series (2008 - on) 194 mm - M1 204 mm - 214 mm - 2085 Mitsubishi Pajero NH - NL (LWB) F2 150 mm LHSPAIR M1 155 mm - 157 mm - Mitsubishi Nissan Pajero NM - NP (LWB) Montero (2000-2006) Pathfinder 4dr (07/05 - on) Pathfinder 4dr (2005-2012) F2 227 mm LHSPAIR M2 226 mm - R2 231 mm LHSPAIR 1948 F2 178 mm LHSPAIR M2 180 mm - R2 202 mm LHSPAIR 1870 VW Transporter (08/04 - on) Refer Supplement Sheet Refer Supplement Sheet Refer Supplement Sheet Page 11
PIONEER 41104 (1330 x 2000mm - Internal) PIONEER 42104B (1426 x 2128mm) PIONEER 45104B (1426 x 2128mm) F2 M3 M2 R3 R2 F3 M1 * 100 Series & LX470 with dust deflector fitted: 100 Series & LX470 with tailgates that lift up and are fitted with a dust deflector. New crossbar positions must be drilled 53mm back (towards rear of tray) from the centre of the slot positions detailed above. Drill Diameter 8.5mm holes in place of the slots. Front Crossbar Middle Crossbar Rear Crossbar Approx. Overall Make Model Front Dim. A LHS Middle Dim. A LHS Rear Dim. A LHS Vehicle Slot Slot Slot Height LC 80 Series 05/90-03/98) F3 146 mm - M3 148 mm - R3 153 mm LHSPAIR 90 Series Prado (07/96-02/03) F3 172 mm - M3 180 mm - R3 186 mm LHS2PAIR LC 100 Series (03/98-10/07) * Landcruiser (1998-2007) * LC 200 Series (11/07 - on) Landcruiser (2008 - on) F2 - M2 - R2 - - M1 - - 76 Series Wagon (03/07 - on) F3 - M3 - R2-75 Series Troopcarrier (85-99) F3 130 mm - M3 130 mm - 130 mm - 78 Series Troopcarrier (01/99 - on) F3 130 mm - M3 130 mm - R2 130 mm - Land Rover Discovery 3 & 4 (04/05 - on) LR3 & LR4 (2005 - on) FJ Cruiser (03/11 - on) FJ Cruiser (2006 - on) Refer Supplement Sheet Refer Supplement Sheet Refer Supplement Sheet 1945 Refer Supplement Sheet Refer Supplement Sheet Refer Supplement Sheet Hyundai i-load (02/08 - on) F3 LHSPAIR M3 - LHSPAIR Jeep JK 4DR Wranger fitted with OUT4X4 Heavy Hauler (02/11 - on) Refer Supplement Sheet Refer Supplement Sheet Refer Supplement Sheet 1950 Land Rover Discovery 1&2 (03/91-03/05) F3 PLHSPAIR M3 PLHSPAIR PLHSPAIR Lexus LX470 (05/98-03/08) * LX Series (1998-2007) * F2 - M2 - R2 - Lexus LX Series (2008 - on) - M1 - - Nissan Patrol GU (12/97 - on) F3 163 mm LHSPAIR M3 168 mm - R3 168 mm - VW Transporter (08/04 - on) Refer Supplement Sheet Refer Supplement Sheet Refer Supplement Sheet Page 12
PIONEER 42105B (1465 x 2728mm) F2 MF2 M2 R2 M M1 Front Crossbar Middle-Front Crossbar Middle Crossbar Rear Crossbar Approx. Overall Vehicle Make Model Front Slot Dim. A LHS MF Slot Dim. A LHS Middle Slot Dim. A LHS Rear Slot Dim. A LHS Height 78 Series Troopcarrier (01/99 - on) Fit on Vehicle - M 130 mm - M2 130 mm - R2 130 mm - Land Rover Defender 110 (03/93 - on) Defender 110 (1993-1994) F2 140 mm - MF2 140 mm - M1 140 mm - 140 mm - Volkswagen Transporter (08/04 - on) Refer Supplement Sheet Refer Supplement Sheet Refer Supplement Sheet Refer Supplement Sheet Dim. A Dim. A Page 13
PIONEER 41107 (1140 x 2000mm - Internal) PIONEER 42107B (1236 x 2128mm) PIONEER 45107B (1236 x 2128mm) F5 F3 F2 F4 M4 M3 M2 M1 R4 R3 R2 Dim. A Dim. A * 100 Series & LX470 (with dust deflector fitted): 100 Series & LX470 with tailgates that lift up and are fitted with a dust deflector. New crossbar positions must be drilled 53mm back (towards rear of tray) from the centre of the slot positions detailed above. Drill Diameter 8.5mm holes in place of the slots. Front Crossbar Miffle-Front Crossbar Middle Crossbar Rear Crossbar 4th Crossbar Kit Required Make Model Front Slot Dim. A LHS Mid-Fr Slot Dim. A LHS Middle Slot Dim. A LHS Rear Slot Dim. A LHS (43126) Lexus LC 100 Series (03/98-10/07) * Landcruiser (1998-2007) * LC 200 Series (11/07 - on) Landcruiser (2008 - on) LX470 (05/98-03/08) * LX Series (1998-2007) * F2 97 mm PLHSPAIR - - - M4 110 mm PLHSPAIR R2 125 mm PLHSPAIR - F5 115 mm PLHS2 (Cut) 125 mm PLHSPAIR (Cut) M2 135 mm LHSPAIR 145 mm LHSPAIR Yes F2 97 mm PLHSPAIR - - - M4 110 mm PLHSPAIR R2 125 mm PLHSPAIR - Lexus LX Series (2008 - on) F5 115 mm PLHSPAIR (Cut) 125 mm PLHSPAIR (Cut) M2 135 mm LHSPAIR 145 mm LHSPAIR Yes Prado 120 5dr (03/03-11/09) F4 148 mm - - - - M1 177 mm - R3 193 mm - - Prado 150 5dr (11/09 - on) F4 142 mm - - - - M3 162 mm - R4 173 mm - - FJ Cruiser (03/11 - on) FJ Cruiser (2006 - on) Refer Supplement Sheet - - - Refer Supplement Sheet Refer Supplement Sheet - Page 14
PIONEER 41108 (1330 x 1700mm - Internal) PIONEER 42108B (1426 x 1828mm) PIONEER 45108B (1426 x 1828mm) M1 Front Crossbar Middle Crossbar Rear Crossbar Approx. Overall Make Model Front Dim. A LHS Middle Dim. A LHS Rear Dim. A LHS Vehicle Slot Slot Slot Height Jeep JK 4DR Wranger fitted with OUT4X4 Heavy Hauler (02/11 - on) PLHSPAIR M1 PLHSPAIR PLHSPAIR 1950 Page 15