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RHINO-RACK Isuzu Dmax Gen3 Backbone Mounting System

Rhino Rack RHINO-RACK Isuzu Dmax Gen3 Backbone Mounting System User manual

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  • What is the total static load limit for the Rhino-Rack Backbone system on the Isuzu DMax Gen3?
    What is the total dynamic load limit for on and off-road travel?
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    How do I properly install the Rhino-Rack Backbone system on an Isuzu DMax Gen3 with factory rails?
Document No: 520-RFI-00071
Issue No: 04
Issue Date: 06/06/2022
Important:
1. Check the Rhino-Rack website to ensure you have the latest issue of these instructions.
2. Please refer to your fitting instruction to ensure that the roof racks are installed in the correct locations.
3. Check the contents of kit before commencing fitment and report any discrepancies.
4. Place these instructions in the vehicle’s glove box after installation is complete.
5. These instructions must be followed for warranty to be upheld.
Fit Time: 3 hours
ISUZU MU-X Gen 2 Backbone
RIMB2
Rhino-Rack AUSTRALIA
22A Hanson Pl,
Eastern Creek, NSW, 2766
(02) 8846 1900
rhinorack.com.au
Rhino-Rack USA
Unit D, 2450 Airport Blvd,
Aurora, CO, 80011
877-744-6622
rhinorack.com
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kg / lbs kg / lbs kg / lbs
kg / lbs
kg / lbs kg / lbs kg / lbs kg / lbs
kg / lbs
kg / lbs
kg / lbs
kg / lbs
kg / lbs kg / lbs kg / lbs
kg / lbs
kg / lbs kg / lbs kg / lbs kg / lbs
kg / lbs
kg / lbs
kg / lbs
kg / lbs
Avoid point loads concentrated in the centre span.
Avoid point loads concentrated at the front or rear.
Distribute loads evenly and laterally as low as possible over the span.
Distribute loads evenly and longitudinally as low as possible over the span.
!
Exercise extreme care when transporting wind-resistant loads.
Special consideration must be taken when cornering and braking.
For additional Pioneer Vehicle Fitting Information
refer to your vehicle’s online supplement sheet.
Off-road conditions can be much more rigorous.
Extreme care must be taken on any driven path that does
not contain a surface protection layer (tar/bitumen).
VEHICLE
OWNER’S
MANUAL
ROOF LOAD
LIMIT
DYNAMIC LOAD LIMIT
X
VEHICLE HEIGHT ADDED (mm/in)
BAR NO. A B C D E F G
DIMENSION (CM)
SPACERS REQ’D
CONNECTOR BACKBONE BACKBONE BACKBONE
REAR
FRONT
+- CA E
BAR D
BAR B
UNDERBAR SPACING
REGION AUS NZ USA CA SA UK EU ZA
AVAILABILITY  
RUNNING
DATES 2015 - 2015 - - - - - - 2015 -
VEHICLE PIONEER CONNECTOR HEIGHT ADDED (mm/in)
XXX/XX
VEHICLE
NOTES - Do not operate sunroof
XXX Kg
XXX lbs
XX Kg
XX lbs
XXX Kg
XXX lbs
*VEHICLE
MANUFACTURER’S
ROOF LOAD LIMIT
OR
Max
kg
UP TO UP TO
VISIT THE ONLINE
CALCULATOR FOR
CURRENT SYSTEM
LOAD LIMIT DATA
TOTAL STATIC LOAD LIMIT: UP TO
DYNAMIC LOAD LIMIT (ON AND OFF-ROAD):
*USE THE VEHICLE MANUFACTURER’S MAXIMUM ROOF ALLOWANCE IF IT IS LOWER THAN THE FIGURE LISTED
CARGO SYSTEM WEIGHT
LOAD LIMIT
PIONEER VEHICLE FITTING INFORMATION
rhinorack.com
TAP HERE
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Surfboard Overhang < 600mm must be tied to the bonnet
Surfboard Overhang < 600mm must be tied to the bonnet
Do NOT obstruct windscreen camera sensors Warranty for roof rack system will
be void if the front of the kayak is not
secured to the bonnet
Long flexible loads must attach securely to rigid
support and be tied down to the bonnet
Surfboard Overhang > 600mm must be tied to the
bonnet
!
Use only non-stretch fastening ropes
or straps to attach cargo to roof
racks
Loads must be tied down to
Platform, not around legs
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Racks must be
removed when vehicle
is put through an
automatic car wash.
Ensure sunroof will not collide
with roof rack system.
Ensure Ladder is
well supported on the
ground to support tent.
Take extreme caution
when climbing heights
above 1.2m/4ft.
Youtube.com/Rhinorackaustralia
!
!
!
rhinorack.com/
load-rating-calculator
rhinorack.com/roof
rhinorack.com/roof
LOAD RATING CALCULATOR
FIT MY VEHICLE
PIONEER
MANUFACTURER
MODEL
YEAR
BODY TYPE
SELECT YOUR VEHICLE
MANUFACTURER
MODEL
YEAR
BODY TYPE
SELECT YOUR VEHICLE
BAR NO. A B C D E F G
DIMENSION (CM) -54.5 0 52
SPACERS REQ’D
CONNECTOR BACKBONE BACKBONE
REAR
FRONT
+-
BA C
UNDERBAR SPACING
REGION AUS NZ USA CA SA UK EU ZA
AVAILABILITY     
RUNNING
DATES 02/11 - 02/11 - - - - 2011 - 2011 - 2011 -
VEHICLE PIONEER CONNECTOR HEIGHT ADDED (mm/in)
VOLKSWAGEN Amarok Dual Cab 2H Pickup/Ute Factory Mounts 4 dr 52100 RVAB1
VEHICLE
NOTES Requires Kit SP308 - Do not operate sunroof
96 Kg
212 lbs
24 Kg
53 lbs
120 Kg
265 lbs
*VEHICLE
MANUFACTURER’S
ROOF LOAD LIMIT
OR
Max
kg
UP TO UP TO
VISIT THE ONLINE
LOAD LIMIT
CALCULATOR FOR
CURRENT LOAD DATA
TOTAL
STATIC
LOAD LIMIT: UP TO 300 Kg / 661 lbs*
DYNAMIC LOAD LIMIT
(ON AND OFF-ROAD)
:
*USE THE VEHICLE MANUFACTURER’S MAXIMUM ROOF ALLOWANCE IF IT IS LOWER THAN THE FIGURE LISTED
PIONEER VEHICLE FITTING INFORMATION
rhinorack.com
EXAMPLE ONLY
System Weight
Total weight of the rack
system. (e.g. Crossbars,
Backbone, Platform)
Max
kg
Max System Load Capacity
Please ensure you use the vehicle
manufacturer’s maximum roof
allowance if it is lower than the
figure listed in the fitting chart/
supplement.
Vehicle Manufacturer’s
Load Limit
Total permissible weight
attached to the rack. This is
inclusive of the weight of the
rack system.
Max
kg
Cargo Load Limit
Total permissible weight
allowed on top, and attached
to the rack whilst the vehicle
is in motion.
Max
kg
Check the website and the vehicle owners hand book for your vehicle manufacturer’s maximum carrying capacity.
Load must be evenly distributed over the system.
Carrying Capacity
TAP HERE
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• All bolt connections should be checked after driving a short distance when you first install your roof racks.
• All bolted connections should be checked again at regular intervals (weekly is recommended, depending on road conditions,
usage, loads and distances travelled).
• All bolted connections should be checked each time they are re-fitted.
• Off-road conditions are more rigorous. Check all bolted connections and your load more regularly.
• Ensure that your vehicle manufacturer’s GVM, and gross axle weights are not exceeded (refer to vehicle owner’s manual).
In service maintenance checks
Torque Settings:
Unless stated otherwise in these
instructions, all fasteners should be
set to the following torque settings:
4-5Nm 8-10Nm 16-18Nm
3-4lbs/ft 6-7.5lbs/ft 12-13lbs/ft
M6 M8 M10
4-5Nm
3-4lbs/ft
M6 8-10Nm
6-7.5lbs/ft
M8 16-18Nm
12-13lbs/ft
M10
4-5Nm
3-4lbs/ft
M6 8-10Nm
6-7.5lbs/ft
M8 16-18Nm
12-13lbs/ft
M10
Note for Dealers and Fitters
It is your responsibility to ensure these fitting instructions are given to the end user or client. These instructions remain the property
of Rhino-Rack Australia Pty. Ltd. and may not be used or changed for any other purpose than intended.
x2
Cx16
F
x6
J
x6
Kx6
Lx1
M
x4
D
x10
G
x10
E
x1
Hx6
I
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Tools Required:
T1 - 12mm Socket + Ratchet
T2 - Trim tool
T3 - Cleaning Rag
T4 - Masking Tape
T5 - Flathead Screwdriver
T6 - 6mm Allen Key
T7 - 4mm Allen Key
T8 - Caulking Gun with Butyl Mastic
T9 - Measuring Tape
T10 - Black Felt Tip Marker
T11 - Scissors
T12 - 13mm Spanner
Parts List
Backbone Left
Backbone Right
M8 x 20mm Hex Head Flanged
Bolt (For 4XXXX Pioneer only)
M8 x 20 Button Head Cap
Screw
M8 x 17mm Flat Washer
M8 Spring Washer
5mm Ball End Allen Key
M8 x 24mm Flat Washer
(For 4XXXX Pioneer only)
M8 Channel Nut
(For 4XXXX Pioneer only)
Instruction
1.25m Ditch Rubber
Pioneer NG Bolt Kit
(For 5XXXX Pioneer only)
x1
A
x1
B
M8 x 10mm Grub Screw
For Factory Rail Variants, complete Steps - and -
For Bare Roof Variant, complete Steps -
CONTENTS:
1
10
149c
26
26
1
1b 1c
1a
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Remove rail end covers, using a clean rag to protect ditch and roof.
Note: Pull tool upwards to remove, DO NOT pry downwards and
lever off roof or windscreen, as this may damage the vehicle. Fully insert tool between
plastic cap and sealing rubber
up to the internal clip.
FRONT
WINDSCREEN
!!
T2
T2
T3
FACTORY RAIL REMOVAL (For Bare Roof Variant, skip to Step )
10
3
2
6
4
7
5
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Use masking tape to protect edge then remove the
two middle rail covers. .
Remove entire rail by lifting vertically.
Note: Store rail, rail hardware and rail covers in a safe place.
Remove front factory ditch rubber piece. Clean roof ditch area.
Loosen socket head cap screws fully.
Note: Unthreaded screws will be retained
in the rail and cannot be fully removed.
T4
TOP VIEW TOP VIEW
T5 T6
T3
FRONT
WINDSCREEN
T1
Remove hardware underneath front and rear rail cover.
9
9a 9b
9c
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T8
WINDSCREEN
C
Insert grub screw into front-most mounting hole only.
SIDE VIEW
CROSS SECTION
C
C
T7
Thread until flush with
surface of inner skin.
T8
Seal grub screw, and
the hole in the upper
roof skin above the grub
screw.
Ensure the top of the
hole is completely sealed
Ensure threads, gaps between roof
skins, and the hole in the top roof
sheet are completely filled/sealed.
Top roof skin
!
!
11
10
12
BARE ROOF VARIANT (For Factory Rail Variant, skip to Step )
14
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Remove factory ditch rubber.
Peel off any remaining ditch rubber tape.
Locate circular indents in the ditch.
NOTE:
Do NOT remove infill
from the front-most hole.
Use a screwdriver to dig out a circular
hole through the factory infill on
each mounting location.
5 per side.
FRONT
WINDSCREEN
T5
13
14
15
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Clean roof ditch area. T3
FRONT
T10 T9
Mark dimensions onto ditch surface, measuring from the edge of the rear plastic cover.
150mm
90mm
270mm
808mm
1338mm
REAR
Cut Ditch Rubber to the dimensions specified.
467mm
100mm
62mm
No.1
D
No. 3
D
No. 2
D
REAR
460mm
460mm
350mm
No. 5
D
No. 4
D
No. 6
D
FRONT
T11
16
17
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Position the trimmed Ditch Rubber strips next to the ditch, and cross check each corresponding dimension.
Adhere the ditch rubber strips with the markings made
in Step . Refer window below for the front rubber
position.
No.1No. 2No. 3No. 4No. 5No. 6
DDDDDD
No.1No. 2No. 3No. 4No. 5No. 6
DDDDDD
FRONT REAR
Butt ditch rubber No.6 up to
windscreen trim. Press forwards
lightly whilst applying.
Ditch rubber No.1
tucks underneath
rear plastic cover
approximately
10mm.
Approx.
10mm
14
CENTRE OF VEHICLE
Peel off backing
to adhere.
Note ditch rubber orientation:
REAR
18
19
20
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Seal all the exposed roof holes with Butyl Mastic REAR
FRONT
SIDE VIEW
CROSS SECTION
Ensure threads, gaps between roof
skins, and the hole in the top roof
sheet are completely filled/sealed.
!
Assemble and start each screw on the middle three legs.
E
E
H
H
E
F
F
F
G
G
G
Place hardware into front and rear backbone
legs.
Two people then required to carefully
lower the backbone into the front and rear
mounting holes
x3
x3
x3
x3
x3
T8
T8
Top roof skin
21
22
23
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8-10Nm
6-7.5LB/FT
Repeat Steps to to opposite side of vehicle.
Ensure backbones are securely
positioned and fastened before
attaching Pioneer Tray.
1 21
Incrementally tighten all hardware starting with front three screws, and finishing with rear two screws.
H
!!
1.
2.
View Fitting Chart
EXAMPLE ONLY
Bar 1
Bar 2
Bar 3
PLATFORM INSTALLATION
rhinorack.com/roof
BAR NO. A B C D E F G
DIMENSION (CM) -54.5 0 52
SPACERS REQ’D
CONNECTOR BACKBONE BACKBONE
REAR
FRONT
+-
BA C
UNDERBAR SPACING
REGION AUS NZ USA CA SA UK EU ZA
AVAILABILITY       
RUNNING
DATES 02/11 - 02/11 - - - - 2011 - 2011 - 2011 -
VEHICLE PIONEER CONNECTOR HEIGHT ADDED (mm/in)
VOLKSWAGEN Amarok Dual Cab 2H Pickup/Ute Factory Mounts 4 dr 52100 RVAB1
VEHICLE
NOTES Requires Kit SP308 - Do not operate sunroof
96 Kg
212 lbs
24 Kg
53 lbs
120 Kg
265 lbs
*VEHICLE
MANUFACTURER’S
ROOF LOAD LIMIT
OR
Max
kg
UP TO UP TO
VISIT THE ONLINE
LOAD LIMIT
CALCULATOR FOR
CURRENT LOAD DATA
TOTAL
STATIC
LOAD LIMIT: UP TO 300 Kg / 661 lbs*
DYNAMIC LOAD LIMIT
(ON AND OFF-ROAD)
:
*USE THE VEHICLE MANUFACTURER’S MAXIMUM ROOF ALLOWANCE IF IT IS LOWER THAN THE FIGURE LISTED
PIONEER VEHICLE FITTING INFORMATION
rhinorack.com
For 5XXXX Series Platform
x6
J
I
24
25
26
Page 15 of 15
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For 5XXXX Series Platform
For 4XXXX Series Platform
F
K
I
I
J
L
15-20Nm
11-15LB/FT
T12
For 4XXXX Series Platform
T12
8-10Nm
6-7.5LB/FT
Pioneer underbar
Ensure channel nut has
rotated within Pioneer
underbar and is fixing
Pioneer securely.
!!
L
/