Y Camper Shell Tracks, 37 Cross Bars. Y Camper Shell Tracks, 44 Cross Bars.

Transcription

1 Y Camper Shell Tracks, 37 Cross Bars. Y Camper Shell Tracks, 44 Cross Bars. Important: Parts List Please read these instructions carefully prior to installation. Please refer to your fitting instruction to ensure that the roof racks are installed in the correct locations. Check the contents of kit before commencing fitment and report any discrepancies. Place these instructions in the vehicle s glove box after installation is complete. Maximum carrying capacity: Refer to manufactures specifications. Item Component Name Qty Part No. 1 Track 63 RIGHT 1 A Track 63 LEFT 1 A a Sports Buffer Strip b Sports Cross Bar a Sports Buffer Strip b Sports Cross Bar Knob & M6 Nyloc Nut 12 M175/N013 6 Track End Cap (LEFT) 2 M176 7 Track End Cap (RIGHT) 2 M177 8 M6 Brass Hex Nut 4 N009 9a Track Wedge RIGHT 2 M024 9b Track Wedge LEFT 2 M g x ½ Screw 4 B M6 x 20mm Security Screw 4 B M6 x 16mm Security Screw 4 B M6 x 35mm T-Bolt 12 B M6 Spring Washer 4 W M6 x 12.5mm Flat Washer 4 W mm x 3mm O-ring 12 C Sports Leg (RIGHT) 2 M Sports Leg (LEFT) 2 M mm Security Allen Key 1 SecKey-S 20 Fitting Instruction 1 RR a,4a. 3b,4b a,9b Care Instruction: Thoroughly clean top of camper shell prior to fitting the Rhino Tracks. Tools Required; Allen key, provided in kit. Vacuum cleaner. Tape measure. Marking pen/pencil. Power or Battery drill. 3/16 drill bit. 1/4 drill bit. Phillips head screwdriver. Rubber mallet. Hacksaw. Small ruler. Page 1 of 7

2 1 Check inside of camper shell before marking track holes. Make sure knobs (item 5) have sufficient clearance and are not obstructed by strengthening ribs on the underside of the camper shell. Check for and avoid uneven mounting surface for knobs when positioning holes. 2 Position tracks as close as possible to the outside edge of the camper shell, without mounting onto curved surface of camper shell. This will ensure maximum strength. When positioning, ensure tracks are parallel and end of each track lines up. Track ends with cutouts to be placed at rear of the vehicle. Vertical face of track towards inside, curved face towards outside of vehicle. B C Curved face of track towards outside of vehicle. A A & A - equal. B & B - equal. C & C - equal. A REAR of vehicle B Track cutout at rear of camper shell. C 3 a. Mark a line on the camper shell at the end of tracks. Mark centre line of the C channel on both ends of each track. b. Move the track out slightly and use it as a straight edge to join the two centre line points. IMPORTANT: Re-check tracks are parallel before drilling, as this will effect the dimensions in Step 10. a. b. C channel. Page 2 of 7

3 4 a. Mark end holes (front & rear) 5/8 in from end of tracks. Six holes are to be drilled for each track. Spacing for T-bolt holes to be approximately 5 5/8. b. Drill holes through canopy using ¼ drill bit. c. Vacuum fibreglass particles from inside and top of camper shell. NOTE: Hole spacing determined by any obstruction on the underside of the camper shell. Refer Step 1. a. b. c. 5/8 Approx. 5 5/8 1st hole mark. Track end mark. 5 Remove back tape from foam on underside of tracks. 6 Install the rubber O-rings onto each T-bolt. Slide six T-bolts into the C channel of each track. 7 a. Install track end caps. b. Place tracks onto camper shell. Make sure track cut outs are placed towards rear of the camper shell. c. Double check that all T-bolts have o-rings fitted. a. b. c. Rear LEFT shown. Page 3 of 7

4 8 Gently Finger tighten T-bolts only at this stage. Once all have been started then tighten in the pattern as shown below. Ideally all knobs should be in line as shown. DO NOT OVER TIGHTEN a. Insert both support legs fully into the cross bars. A rubber mallet may be used to knock the legs in place. b. Fasten one leg only to the cross bars by inserting the self tapping screw into the underside of the cross bar. Determine Correct Cross Bar Length. 10 a. Measure Distance X. b. Subtract 5 7/16 from distance X. Mark distance Y on the cross bar from the fastened end. Distance X (inside lip of track). Distance Y. Distance Y = X - 5 7/16. Page 4 of 7

5 11 Remove the leg which is not fastened. Cut excess from that end. Leave this leg fastened. Cut. 12 Mark out, then drill a hole for the self tapping screw to fix the opposing leg in place. Drill through the underside of the cross bar only using a 3/16 drill bit. Repeat for each cross bar. Mark centre of the cross bar. = = 13/32 Drill Ø3/16 13 a. Insert the remaining support leg fully into the cross bar. A rubber mallet may be used to knock the leg in place. b. Fasten the leg to the cross bar by inserting the self tapping screw into the hole you drilled. 14 Insert cross bar buffer strips into the top of each cross bar. Trim the buffer strip to suit the length of the cross bars. Do not stretch the rubber. Page 5 of 7

6 15 Insert two brass hex nuts into the slot at rear of each track. Slide along to position. 16 Top view showing orientation of legs. Longer end of leg must point towards front of the vehicle. FRONT of Vehicle. 17 Track wedges are supplied to support the inside of the leg to suit varying camper shell angles. NOTE: Only use track wedge if the track angle is excessive after installation. NOTE: Only use the M6 x 20mm screws when using the track wedge. M6 x 20mm screw (track wedge only). M6 spring washer. M6 flat washer. With track wedge. Track wedge. LEFT Part No. M025. RIGHT Part No. M024. M6 x 16mm screw. M6 spring washer. M6 flat washer. Without track wedge. Page 6 of 7

7 18 As a guide the recommended rack spacing is apart. Assemble the M6 flat washer, M6 spring washer and M6 screw through the leg and into the brass hex nut in the track. Recommended tightening torque for the M6 screws is 30 lbf in. Measure each side to make sure legs and cross bars are parallel across the vehicle. Position of racks Important Information LOAD RATINGS: Maximum Carrying Capacity: Due to the varying thickness and strengths of camper shells Rhino-Rack cannot recommend a weight carrying capacity. Please refer to the camper shell manufacturer. 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 cross bars each time they are refitted. USE ONLY NON-STRETCH FASTENING ROPES OR STRAPS. 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. 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. Please refer to vehicle specific manual for load rating. When cross bars are to be used in extreme off road conditions please build a safety factor of 1.5 into the load rating. Although the roof racks are tested and approved to AS , Australian road conditions can be much more rigorous. However, increasing the number of cross bars does not increase the vehicles maximum permissible roof loading. Important note for dealers and fitters. Rhino-Rack cannot be held responsible for incorrect mounting of units or usage that exceeds production tolerance. If any of these fitting instructions are unclear to you, the fitter, please contact Rhino-Rack. It is your responsibility to ensure the instructions are given to the end user or client. Rhino-Rack 3 Pike Street, Rydalmere, NSW 2116, Australia. Document No: RR-234 (Ph) (02) Prepared By: Craig Jones Issue No: 01 (Fax) (02) Authorised By: Gary England Issue Date: 31/08/2009 These instructions remain the property of Rhino-Rack Australia Pty Ltd and may not be used or changed for any other purpose than intended. Page 7 of 7