General Installation Information
Important Notes:
- Always check the Rhino-Rack website for the latest issue of these instructions.
- Refer to your specific vehicle fitting instructions to ensure roof racks are installed in correct locations.
- Verify all kit contents before commencing fitment and report any discrepancies.
- Keep these instructions in the vehicle's glove box after installation.
- Following these instructions is required for warranty validation.
Fit Time: Approximately 1 hour (for Pioneer Tray), 1.5 hours (for Jeep JK Backbone).
Carrying Capacity:
- Max System Load Capacity: Refer to Pioneer fit sheet (includes system weight).
- Vehicle Load Limit (VLL): Check vehicle owner's handbook. Always use the lower of the vehicle manufacturer's maximum roof allowance or the figure listed in these instructions.
- System Load Limit: Total permissible weight allowed on and attached to roof racks while the vehicle is in motion.
- Off Road: Defined as any driven path without a surface protection layer (tar/bitumen).
- Static Allowance: Total permissible weight allowed on and attached to roof racks while the vehicle is stationary.
Torque Settings: Unless stated otherwise:
- M6 fasteners: 4-5 Nm (3-4 lb/ft)
- M8 fasteners: 8-10 Nm (6-7.5 lb/ft)
- M10 fasteners: 16-18 Nm (12-13 lb/ft)
Warnings:
- Ensure the part number or kit is correct for your vehicle.
- Do not attempt to fit the rack system unless you fully understand these instructions. Direct any questions to the dealer where purchased.
- Extreme care must be taken in off-road conditions, as they can be more rigorous than tested standards (AS1235-2000 / ISO 11154).
- Roof racks must be removed before the vehicle undergoes an automatic car wash.
- For utility vehicles, avoid rigidly fixing loads to both cabin and canopy roof racks, as they move independently. Fix to either cabin or canopy racks only.
- Always fasten loads securely using non-stretch fastening ropes or straps.
- Vehicle handling characteristics change with roof loads; exercise extreme care with wind-resistant loads, especially during cornering and braking.
In-Service Maintenance Checks:
- Check all bolted connections after a short distance of initial installation.
- Check all bolted connections at regular intervals (weekly recommended, depending on usage).
- Check all bolted connections each time they are refitted.
Note for Dealers and Fitters: It is your responsibility to provide these fitting instructions to the end user. These instructions remain the property of Rhino-Rack Australia Pty. Ltd.
Pioneer Alloy Tray
Parts List:
- A x2
- B x2
- C x2
- D x2
- E x2
- F x2
- G (Quantity varies by model)
- H (Quantity varies by model)
- I (Quantity varies by model)
- J (Quantity varies by model)
- K (Quantity varies by model)
- L (Quantity varies by model)
- M (Quantity varies by model)
- N x1 (Torque Tool)
- O x1 (Phillips Bit)
- P x1 (8mm Socket)
Pioneer Tray Sizes:
| GH | Platform # | L x W (mm) | L x W (inches) | G | H | I | J | K | L | M |
|---|---|---|---|---|---|---|---|---|---|---|
| 52100 | 4 | 1528 x 1236 | 60' x 49' | 3 | 3 | 52 | 52 | 12 | 16 | 6 |
| 52101 | 5 | 1528 x 1376 | 60' x 54' | 3 | 3 | 62 | 62 | 12 | 16 | 6 |
| 52102 | 4 | 1928 x 1236 | 76' x 49' | 3 | 5 | 76 | 76 | 12 | 16 | 6 |
| 52103 | 5 | 1928 x 1376 | 76' x 54' | 5 | 5 | 90 | 90 | 12 | 16 | 6 |
| 52104 | 5 | 2128 x 1426 | 84' x 56' | 5 | 5 | 90 | 90 | 12 | 16 | N/A |
| 52105 | 5 | 2728 x 1465 | 107' x 58' | 5 | 6 | 104 | 104 | 12 | 16 | N/A |
| 52107 | 4 | 2128 x 1236 | 84' x 49' | 5 | 5 | 76 | 76 | 12 | 16 | N/A |
| 52108 | 5 | 1828 x 1426 | 72' x 56' | 5 | 5 | 90 | 90 | 12 | 16 | N/A |
| 52109 | 4 | 1328 x 1236 | 52' x 49' | 3 | 3 | 52 | 52 | 12 | 16 | N/A |
| 52110 | 5 | 1328 x 1376 | 52' x 54' | 3 | 3 | 62 | 62 | 12 | 16 | N/A |
| 52111 | 5 | 1328 x 1426 | 52' x 56' | 3 | 3 | 62 | 62 | 12 | 16 | N/A |
| 52112 | 2 | 928 x 1426 | 37' x 56' | 3 | 2 | 48 | 48 | 12 | 16 | N/A |
| 52113 | 5 | 1528 x 1426 | 60' x 56' | 3 | 3 | 90 | 90 | 12 | 16 | N/A |
| 52114 | 3 | 1228 x 952 | 48' x 37' | 1 | 1 | 22 | 22 | 12 | 16 | N/A |
| 52115 | 4 | 1478 x 1184 | 58' x 47' | 1 | 1 | 28 | 28 | 12 | 16 | N/A |
| 52119 | 5 | 2528 x 1586 | 100' x 62' | 6 | 6 | 104 | 104 | 12 | 16 | N/A |
| 52120 | 5 | 1528 x 1586 | 60' x 62' | 3 | 3 | 62 | 62 | 12 | 16 | N/A |
| 52121 | 5 | 1228 x 1426 | 48' x 56' | 3 | 3 | 62 | 62 | 12 | 16 | N/A |
Tools Required: T1 - Phillips head screwdriver. T2 - Power drill.
Assembly Steps:
- Step 1: Identify parts A (x2), B (x2), C (x2), D (x2), E (x2), F (x2).
- Step 2: Attach part F to part L using parts H (x3) and I (x12). Torque: 1-1.5 Nm (1.1 lb/ft).
- Step 3: Attach parts E (x2) and K (x3) using part O and tool T2.
- Step 4: Assemble parts E (x2), H (x4), and I (x16).
- Step 5: Assemble parts E (x2), H (x5), and I (x20).
- Step 6: Assemble parts E (x2), H (x6), and I (x24).
- Step 7: Assemble parts G (x4) and I (x4).
- Step 8: Assemble parts G (x4) and I (x16).
- Step 9: Assemble parts A (x2), I (x4), E (x2), and G (x4).
- Step 10: Assemble parts B (x2), E (x2), and G (x4).
- Step 11: Attach part J to part N using part P. Ensure a CLICK! sound. Torque: 6-8 Nm (4-6 lb/ft).
Vehicle Fitting Example: KIA Carnival Van Flush Rail 5 dr
- Pioneer Size: 52100
- Connector: RCL
- Height Added: 120.0 mm / 4.7 in
- Important Notes: RCP68-BK required. Fixed point factory mount.
- Region Availability: AUS (3), NZ (3), USA (2), CA (2), SA (2), UK (2), EU (2), ZA (2)
- Running Dates: 02/15 - (AUS, NZ)
- Underbar Spacing: A (-45.2 cm), B (0 cm), C (45.2 cm)
- Bar No. Dimension (cm): A (-45.2)
- Vehicle Load Limit (VLL): Up to 100 kg / 220.5 lbs *
- System Weight (SW): 19 kg / 41.2 lbs
- On-Road Cargo Allowance (OR): OR = VLL - SW
- Off-Road Cargo Allowance (OFR): OFR = OR / 1.5
- Note: Always check vehicle owner's handbook for maximum carrying capacity and use the lower figure. Load must be evenly distributed.
Jeep JK 2dr Backbone - RJKB2
Fit Time: 1.5 Hours
Maximum Carrying Capacity:
- On Road Cargo Allowance: 95 kg / 209 lbs
- Off Road Cargo Allowance: 63 kg / 138 lbs
- Static Allowance: 240 kg / 530 lbs
- Roof Allowance: 100 kg / 220 lbs
- Rack Weight: 5 kg / 11 lbs
Definitions:
- Off Road: Any driven path not on sealed (tarred/bitumen) and maintained surfaces.
- Roof Allowance: Total permissible weight attached to the roof, including the rack system.
- Cargo Allowance: Total permissible weight on and attached to roof racks while the vehicle is in motion.
- Static Allowance: Total permissible weight on and attached to roof racks while the vehicle is stationary.
Important Information:
- Refer to your vehicle manufacturer's handbook for maximum carrying capacity. Always use the lower of the two figures.
- Load must be evenly distributed over the entire Pioneer system.
- Weight of roof rack accessories is included in cargo allowance.
Torque Settings: Unless stated otherwise:
- M6: 4-5 Nm (3-4 lb/ft)
- M8: 8-10 Nm (6-7.5 lb/ft)
- M10: 16-18 Nm (12-13 lb/ft)
Warnings:
- Check Part No. and/or Kit is correct for your vehicle.
- Do not attempt to fit unless you fully understand these instructions; direct questions to the dealer.
- Use only non-stretch fastening ropes or straps.
- Vehicle handling changes with roof loads; exercise extreme care with wind-resistant loads, especially during cornering and braking.
- Extreme care must be taken in off-road conditions.
Recommendations:
- Essential to check all bolt connections after a short distance of initial installation.
- Check bolt connections at regular intervals (weekly recommended).
- Check roof racks each time they are refitted.
- Always fasten loads securely, ensure even distribution, and keep the center of gravity low and within rack extents.
Note for Dealers and Fitters:
Parts List:
| Item | Component Name | Qty | Qty RL | Part No. | Item | Component Name | Qty | Part No. |
|---|---|---|---|---|---|---|---|---|
| 1 | Rear Bracket | 2 | 1 | CA1274 | 6 | M8 Nyloc Nut Black | 4 | N043 |
| 2 | Middle Bracket | 2 | 2 | CA1275 | 7 | M8 Flat Washer Black | 8 | CA1068 |
| 3 | Internal Support Vertical Front | 2 | CA1358 | 8a | Bracket Fixture Plate Front | 2 | CA1325 | |
| 4 | Internal Support Vertical Rear | 2 | CA1280 | 8b | Bracket Fixture Plate Rear | 2 | CA1282 | |
| 5 | Internal Support Base | 11 | CA1324 | 9 | M6 x 30 Socket HD Bolt Black | 8 | B211 | |
| 10 | M8 Spring Washer Black | 4 | B020-Blk | 11 | M8x20 Hex Setscrew Black | 4 | B020-Blk | |
| 12 | M6 Flat Washer Black | 10 | W054-Blk | 13a | M6 x 30 Socket HD Bolt Black | 2 | B210 | |
| 13b | O-ring Middle Bracket Foam | 2 | C347 | 14 | Bracket O Foam L | 2 | CA1284 | |
| 15 | Bracket O Foam S | 4 | CA1285 | 16 | Bracket Foam Square | 2 | CA1286 | |
| 17 | M6 Nyloc Nut Blk | 2 | CA1287 | 18 | 4mm Allen Key | 10 | N069 | |
| 19 | 5mm Allen Key | 1 | H001 | 20 | 5mm Allen Key | 1 | H002 | |
| 21 | End Bracket Rear Foam | 2 | R438 | 22 | (Not specified) | 1 | - |
Tools Required: 10mm Spanner, Support Stands, 13mm Spanner, Drill, Tape Measure, 3.0mm Drill Bit, Marker Pen, 6.5mm Drill Bit, 4mm Allen Key (supplied), 5mm Allen Key (supplied).
Assembly Steps:
- Step 1: Remove the vehicle's hard top and place it on a stable, safe working area. Remove hardware from inside the hard top.
- Step 2a: Assemble the Support Struts (parts associated with 8a, 8b) using M8 security screws, M8 spring washers, and M8 flat washers. Finger tighten. Ensure correct left/right orientation and front/rear placement based on flange length and hole proximity.
- Step 2b: Attach items 8a,b to the arms using an M8 washer and M8 Nyloc nut. Finger tighten.
- Step 3: Repeat the process for the opposing support strut.
- Step 4: Align the REAR bracket with the REAR of the hard top, ensuring it sits flush with the contour.
- Step 5: Spot mark the bracket position on the hard top, ensuring accuracy and marking the center of each hole. The bracket should align with the upper lip of the small channel on the hard top's side.
- Step 6: Align the FRONT Bracket 35mm back from where the hard top meets the rubber seal at the front of the canopy.
- Step 7: Spot mark the FRONT bracket position.
- Step 8: Using a 6.5mm drill bit, drill all marked holes. Angle the drill to ensure perpendicularity to the roof.
- Step 9: Fit corresponding foam pads (remove protective strip first) to the FRONT bracket.
- Step 10: Fit corresponding foam pads to the REAR bracket. Repeat steps 4-10 for the opposing side of the hard top.
- Step 11: With assistance, set the assembly on the inside of the hard top. The Support Struts will slot onto the hard top studs.
- Step 12: With assistance, move to the outside of the hard top. Place the REAR Bracket in position. Insert M6 counter sunk screws from the inside, fastening with M6 black flat washers and M6 Nyloc nuts. Hold nuts with a 10mm spanner while tightening from the outside with a 4mm Allen key. Repeat for the FRONT Bracket.
- Step 13: With the REAR Bracket secure, drill the top fixture point with a 6.5mm (1/4") bit. Use an M6 socket HD bolt with an O-ring, an M6 flat washer, and an M6 nyloc nut to fix the bracket.
- Step 14: Tighten the supports with a 5mm Allen key. The top of the supports may require a 13mm spanner. Repeat steps 11-14 for the opposing side.
- Step 15: Place the hard top back onto the Jeep. Replace hardware removed in step 1 on both sides of the inner hard top.
- Step 16: Attach Vortex Crossbars (Front Bar, Rear Bar) to the assembled backbone.
- Step 17: Adjust crossbar overhang to be equal on both sides. Tighten M6 crossbar bolts and M6 security screws to 3-4 Nm (2-3 lb/ft).
- Step 18: Insert vortex rubber and end caps into all crossbars.
- Step 19: Measure the under-bar slot length on each side of the leg. Cut under-bar strips to fill the gaps. Re-check all fasteners are secure.
RCL, RCH 2,4,6 Kits
Important: Please read these instructions carefully before installation. Check the Rhino-Rack website for the latest version. Ensure roof racks are installed in the correct locations and check kit contents. Place instructions in the vehicle's glove box after installation.
Maximum Load Carrying Capacity: Up to 100 kg / 220 lbs (including rack system). Always use the lower figure from the vehicle manufacturer's handbook. Load must be evenly distributed.
Warnings:
- Do not attempt to fit unless you fully understand these instructions; direct questions to the dealer.
- Use only non-stretch fastening ropes or straps.
- Vehicle handling characteristics change with roof loads; exercise extreme care with wind-resistant loads, especially during cornering and braking.
- Off-road use requires a safety factor of 1.5 (maximum permissible off-road load is 66 kg / 145 lbs). Extreme care is needed in off-road conditions.
- Rack systems must be removed before using an automatic car wash.
- With utility vehicles, avoid rigidly fixing loads to both cabin and canopy roof racks. Fix to either cabin or canopy racks only.
- Paddle/Surfboards should be fixed to the front of the vehicle.
Recommendations:
- Check all bolt connections after initial installation and at regular intervals (weekly recommended).
- Check roof racks each time they are refitted.
- Fasten loads securely, ensure even distribution, and keep the center of gravity low and within rack extents.
Note for Dealers and Fitters: It is your responsibility to ensure these fitting instructions are given to the end user.
Parts List:
RCL (37mm)
| Item | Component Name | Kit Qty (2) | Kit Qty (4) | Kit Qty (6) | Part No. |
|---|---|---|---|---|---|
| 1 | Locking Leg Cover (37mm) | 2 | 4 | 6 | M810 |
| 2 | Locking Leg Base (37mm) | 2 | 4 | 6 | M813 |
| 3 | Key Barrel | 2 | 4 | 6 | CA1339 |
| 4 | Key | 1 | 2 | 2 | H034 |
| 5 | Allen Key | 1 | 1 | 1 | B054 |
| 6 | M6 x 20mm Socket Head Screw | 2 | 4 | 6 | W004 |
| 7 | M6 Spring Washer | 2 | 4 | 6 | W031 |
| 8 | M6 x 16mm Flat Washer | 2 | 4 | 6 | N035A |
| 9 | M6 Nut 30mm x 25mm | 2 | 4 | 6 | R1182 |
| 10 | Instructions | 1 | 1 | 1 | - |
RCH (52mm)
| Item | Component Name | Kit Qty (2) | Kit Qty (4) | Kit Qty (6) | Part No. |
|---|---|---|---|---|---|
| 10 | Locking Leg Cover (52mm) | 2 | 4 | 6 | M812 |
| 11 | Locking Leg (52mm) | 2 | 4 | 6 | M811 |
| 3 | Key Barrel | 2 | 4 | 6 | CA1339 |
| 4 | Key | 1 | 2 | 2 | H021 |
| 5 | Allen Key | 1 | 1 | 1 | B054 |
| 6 | M6 x 20mm Socket Head Screw | 2 | 4 | 6 | W004 |
| 7 | M6 Spring Washer | 2 | 4 | 6 | W031 |
| 8 | M6 x 16mm Flat Washer | 2 | 4 | 6 | N035A |
| 9 | M6 Nut 30mm x 25mm | 2 | 4 | 6 | R1182 |
| 10 | Instructions | 1 | 1 | 1 | - |
Assembly Steps:
- Step 1: Use the provided Metal Key to unlock and remove the Cover Plate. Remove the Allen Key from its storage position.
- Step 2: Insert M6 hardware (M6 Nut, M6 Spring Washer, M6 Flat Washer, M6 x 20mm Socket Screw) as shown. Finger tighten only.
- Step 3: Slide the assembled legs into the Crossbars. Insert Vortex Rubber, cut to length as required.
- Step 4: Fix the Crossbars to the vehicle-specific Base Kit using the provided Allen Key. (Note: In some installations, it may be required to fit the leg to the base first).
- Step 5: Ensure the Crossbars have equal overhang. Tighten the M6 Leg Hardware with the Allen Key.
- Step 6: Insert the Underbar Strips into the slots either side of the installed Leg. Cut to length as required.
- Step 7: Insert the Crossbar End Caps and lock in place. Replace the Allen Key and Leg Cover. Lock the Leg Cover Plate with the key. Ensure all fixtures are secure before use.
Fitting to Heavy Duty Crossbars and Pioneer Trays/Platforms:
- To fit Legs to Heavy Duty Crossbars, Pioneer QMHD05 must be purchased separately. Install the Spacer Kit then the HD Crossbars using M6 Channel Nuts and M6x30 Socket HD Cap Screws.
- To fit Legs to Pioneer Trays/Platforms positioned wide on a vehicle, QMPS10 must be purchased separately. Install the Spacer Kit then the Tray/Platform using M6 Channel Nuts and M6x35 Socket HD Cap Screws.
- Check all fixtures are secure before use.
Rhino-Rack offers a wide range of roof racks and cargo carriers. Visit the Rhino-Rack website for more information.
