Rhino-Rack Roof Bars Installation Instructions
Contents
1. ROOF BARS2. fitted to this vehicle should have no more than 35kgs loaded on them Caution 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 resistant loads Special consideration must be taken into account when cor nering and braking Please remove crossbars when putting vehicle through an automatic car wash Note for Dealers and Fitters It is your responsibility to ensure instructions are given to the end user or client Rhino 2500 Series Two Bar Heavy Duty System When these roof racks are to be used on a vehicle that is driven off sealed roads the manufacturer maximum roof load rating to be found in the vehicles User Manual should be halved Do not forget to subtract 5kg from your maximum carrying capacity due to the weight of the crossbars and legs 70kg load rating Urban road 35 kg load rating Off road 70kg 2 WARNING Important Load Carrying Instructions With utility vehicles the cabin and the canopy move independently Roofracks and vehicle can be damaged if the item transported is rigidly fixed at points on both the cabin and canopy Instead rigidly fix to either the cabin roofracks or the canopy roofracks Rhino 2500 Series Two Bar Heavy Duty System lace ES carrying Capacity R
3. 366 SUB0247 M366 SUB0247 1095mm 43 7 64 Volvo V70 5dr wagon 00 07 1260mm M366 SUB0247 M366 SUB0247 982mm 38 21 32 VEHICLE Date Crossbar Pad Clamp Pad Clamp Bar measurement HD Crossbar REAR RIGHT REAR LEFT arrow direction strip Length per side distance x Ford Falcon FPV FG 4dr sedan 2008 1375mm M366 SUB0247 M366 SUB0247 1095mm 43 7 64 Ford Falcon FPV FG 4dr sedan no rear bar 2008 N A Ford Falcon FPV FG utility no rear bar 2008 N A Volvo V70 5dr wagon 00 07 1260mm M366 SUB0247 M366 SUB0247 1028mm 40 15 32 Gr Measurement A CENTRE of door jamb to CENTRE arrow of leg foot plate Rhino Rack 2500 Series DK133 Measurement B CENTRE of Front leg foot plate arrow to CENTRE of Rear leg foot plate arrow Carrying capacity Roof rack is rated to 75kg Please refer to manufacturers handbook for your vehicles maximum roof load capacity Always use the lower of the two figures Gs VEHICLE Date Measurement A Measurement B Load rating includes racks 5kg 11lbs Ford Falcon FPV FG 4dr sedan 2008 220mm 8 21 32 750mm 29 17 32 75kg 165lbs Ford Falcon FPV FG 4dr sedan front bar only 2008 220mm 8 21 32 N A 38kg 84lbs Ford Falcon FPV FG utility front bar only 2008 150mm 5 29 32 N A 38kg 84lbs Volvo V70 5dr wagon 00 07 60mm 2 23 64 750mm 29 17 32 60kg 132lbs RHINO RACK CARGO CARRIERS
4. Rhino 2500 Series Two Bar Heavy Duty System Important 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 75kg 165lbs evenly distributed over crossbars Please refer to your vehicle manufacturers handbook and DK Specification sheet for maximum roof loading Always use the lower of the two figures Recommendations It is essential that all bolt connections be checked after driving a short distance when you first install your crossbars Bolt con nections 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 crossbars each time they are refitted 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 Load Ratings When these roof racks are to be used on a vehicle that is driven off sealed roads the manufacturer maximum roof load rating to be found in the vehicles User Manual should be halved For example if the vehicles maximum roof load rating is 70kgs sub tract 5kg weight of crossbar and legs these racks when
5. efer to DK specification sheet for maximum carrying capacity of your particular vehic le Item Component Name Qty Part No Rubber Buffer Strip Heavy Duty Cross Bar M8 Pivot Nut M8 x 50mm Security Bolt End Cap 2 2 4 N047 4 B154 4 M002 4 M315 4 M310 Leg Cover Plate 4 M324 M6 Channel Nut 4 N002 M6 Flat Washer 4 W031 4 4 4 2 4 1 4 4 1 Heavy Duty Cross Bar Adaptor Leg ON WD UN BPWHNY M6 Spring Washer W004 M6 x 25mm Security Screw B137 M312 M314 M311 SecKey L S365 S364 RR244 Front Cover Front Cover Key Foot Plate Security Allen Key 17 Leg Location Decals 18 Arrow Positioning Decals 19 Fitting Instruction Tools Required Security Allen key provided in kit Tape measure Pad amp clamp kit Rubber mallet available separately 4444 18 NOTE Refer to the DK kit specification sheet for correct placement Front amp Rear Left amp Right of the foot plate rubber L pad and metal strap Also refer for sizes to cut the bar measurement strips EN Attach hardware a Attach the heavy duty cross bar adaptor onto top of the l
6. eg Push to snap in place b Locate the M6 x 25mm security screw spring washer and flat washer through top of the leg and fasten to the M6 channel nut Do not tighten at this stage c Make sure the M8 pivot is correctly located as shown below Va Angled face of pivot nut faces out Rhino 2500 Series Two Bar Heavy Duty System A Attach pad to foot plate Centre tube End tabs Clip the rubber pad onto the foot plate Pad centre tube and end tabs must fully locate into the foot plate Note Certain rubber pad sets have a DK supplement sheet to show correct orientation Centre tube pushes through End tabs clip in Attach foot plate to leg Clip the foot plate onto base of the leg with the arrow facing In or Out according to your vehicle listed in the DK specification sheet Diagram at left shows arrow facing Out DK spec sheet Foot Plate Arrow Dir OUT example only Crossbar rubber Push the cross bar rubber buffer strip into top of the bar Attach cross bar a Locate leg with channel nut into cross bar b Turn to locate the channel nut to sit across the bar K ZA a G S Channel nut must sit across the bar Rhino 2500 Series Two Bar Heavy Duty System 6 Measurement between legs Accurat
7. ely measure between the legs to set the correct distance Refer to DK specification sheet for vehicle specific distance Also set equal cross bar over hang Tighten M6 security screw to 4 5 Nm 35 44 Ibf in HD Cross Bar DK spec sheet distance x Measure to edge 894mm 35 13 64 K N of heavy duty cross bar adaptor Leg location decals Stick the leg position labels inside the leg The labels are used to easily identify front and rear cross bars if they are removed from vehicle Refer layout below RL REAR LEFT LW 8 Position roof racks Place racks onto the vehicle roof Refer to DK specification sheet for correct positioning of your roof racks A Measure forward from a centre line of where the front and rear doors meet close B Measure back to set distance between cross bars A and B measurements are to be in line with arrow in centre of foot plate 8 Rhino 2500 Series Two Bar Heavy Duty System 9 Positioning decals Stick the white arrow decals in line with foot plate arrows onto the body work inside the door jamb This marks reference points for future use when racks are removed and then replaced Po N ARS 10 Attach clamps a Hook t
8. he lower part of the metal clamp in at the top of the door jamb underneath any rubber seals that may be present Fasten the M8 bolt to the pivot nut in the leg b Bolts must be tensioned evenly on each side of the vehicle to avoid pulling the rack to one side Do not tighten one side at a time Tighten M8 bolt to 12 14 Nm 106 123 Ibf in Refer to DK instruction for correct clamp and pad combination for front and rear of vehicle c Knock end caps into end of cross bars A rubber mallet may be used L Front cover key ee Attach front cover Insert the two lugs on left side of front cover into the leg Use key provided to turn lock barrel to the open position O Engage locking tab into leg Turn to close C ra s GAN ESS SY Rhino Rack 2500 Series DK133 FRONT VEHICLE Date Crossbar Pad Clamp Pad Clamp Bar measurement HD Crossbar FRONT RIGHT FRONT LEFT arrow direction strip Length per side distance x Ford Falcon FPV FG 4dr sedan 2008 1375mm M366 SUB0247 M366 SUB0247 1095mm 43 7 64 Ford Falcon FPV FG 4dr sedan single front bar 2008 1375mm M366 SUB0247 M366 SUB0247 1095mm 43 7 64 Ford Falcon FPV FG utility single front bar 2008 1375mm M
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