CANOPY INSTALLATION INSTRUCTIONS Mitsubishi Triton MN ... Triton Fleet cp0096.pdf · Page 1 of 17...

6/03/13 of 17

CP0096

This Canopy is designed to suit the (4x2 & 4x4) GLX, GL-R and GLX-R Triton (Double Cab).Sports Bars MUST be removed and returned to Customer with all hardware components.

Cabin Guards MUST be removed and discarded, follow steps 28 to 38 at the end of this instructions.This Fitting Instruction where a Bed Liner is referred to, is based on -

Mitsubishi Motors Genuine Under Rail Bed Liner Accessory only.

RECOMMENDED TOOL LIST - (Not Supplied in Kit)• Loctite 243 thread locking liquid (IMPORTANT)• Phillips Head Screwdriver• Side Cutters• Sockets 10 & 13mm, Extension Bar and Driver• Spanners 10 & 13mm• Silicon Dispensing Gun• Non Acetic Silicon (Neutral Cure)• Spray Bottle (25% isopropyl Alcohol & 75% Water)• Torque Wrench - 0-20Nm• Non Permanent Marker

• Allen Keys• Masking Tape• Cleaning Cloths / Rags• Steel Rule and Tape Measure• Scissors (Sharp)• Knife (Sharp)• Squeegee• Drill & Ø5mm Drill Bit• Engineers Scribe• Rivet Gun for Stainless Steel Rivets• Centre punch

Clean Canopy with a milddetergent and water solution.

Do not use abrasivecleaners or solvents.Care Instructions:

PLEASE REFER TO PAGE 2, OF THIS INSTRUCTION FOR A LIST OF PARTS AND QUANTITIES.

PlPlacece these inststructions inin vevehicle’s gloveve bobox afafter ininstallllation is complplete

Installation Time: Approx. 60 Minutes

IMPORTANT!• Before unpacking canopy, install the rear spacers (CNPY0022LH/RH). See step A.• Read instructions carefully before installation.• It is strongly recommended that installation is conducted by an authorized dealer.• This product must be installed exactly as specified in these instructions. Failure to do so may result in improper fit and/or retention.• Recommend installation by 2 people. (4 people will be required to lift Canopy)

Mitsubishi Triton MN - Long Bed(MY09 Production Onwards)

CANOPYINSTALLATION INSTRUCTIONS

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CP0096

PARTS CHECK SHEET

CANOPY INSTALLATION INSTRUCTION

Clip spacer into the rear corner of the baserail. Once in place, bolt the spacer to the base rail as shown. (ref. diagram A).NOTE: LHS shown. Repeat for RHS.

A.

Diagram: A - ATTACH THE REAR SPACERS

1

3

CLIPSPACER

INTO POSITION 2

CanopyQty - 1

PARTS IN MAIN CARTON

Rail ExtrusionTub Stop(ALUM0038-5)Qty - 1

Fitting Kit(KIT033216)Qty - 1

Lock Keys(Attached toCanopy InternalRear Door Handle)Qty - 2

Strona Kit -Rail Clamps(CNPY0007)Qty - 6

Clear AbrasionTape Roll48mm Wide(TAPE0611-1)Qty - 1

Tape EPDM43005.5mx20mmx9mm(TAPE0412)Qty - 1

Screw M6x30Hex Head SS304(SCRW0824)Qty - 4

Screw M6x20Mushroom Head (SCRW0466)Qty - 2

M6 Flat WasherOD. 19mm(WASH0169)Qty - 10

M6 Spring Washer(WASH0103)Qty - 2

M6 Nyloc NutSS304(NUTS0016)Qty - 4

M6 Nut(NUTS0161)Qty - 2

Tape 4026 GHBWH12x1700mmx 1.14(TAPE0615)Qty - 1

Bulb Seal 70mmCut Length(MISC2600-1)Qty - 2

Vehicle Wiring Patch Harness(LOOM0018)Qty - 1

PARTS IN FITTING KIT (KIT033216)

PARTS IN VEHICLE WIRING PATCH HARNESS KIT (LOOM0018)

Cable Ties (3) Long, (2) ShortQty - 5

Adhesive Tie PadQty - 1

Rivet SS304ST-ST 6-6(FAST0505)Qty - 8

40mm RubberExtrusions(MISC0521-4)Qty - 6

Front Tub SpacerExtrusion(ALUM0038-6)Qty - 1

RustInhibitor

Alcohol Wipe(MISC0052)Qty - 3

Rear Spacer(CNPY0022LH)Qty - 1

Rear Spacer(CNPY0022RH)Qty - 1

AUTOMOTIVESURFACE CLEANER

IMPREGNATED WITH 70% ISOPROPYL ALCOHOL

For use in cleaning painted metal,glass and other vehicle surfaces.For external use only.Dispose of properly after use.

Rust InhibitorSatchel(MISC2776)Qty - 1

Primer Stick(MISC1365)Qty - 3

Cable Tie(FAST0254)Qty - 1

Vehicle WiringPatch Harness Kit(LOOM0018)Qty - 1

FittingInstruction(FIT-CP0096)Qty - 1

FittingInstruction

10mm

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CP0096

WIRING INSTALLATION


Open front and rear driver’s side doorsRemove and retain Front and Rear driver’s side scuff plates.Remove and retain ‘B’ Pillar trim.(ref. diagram 1).

Remove and retain driver’s lower dash cover and hardware as shown.Remove and retain driver’s side kick paneland hardware as shown.(ref. diagram 2).

1.

Diagram: 1 - REMOVE VEHICLE PARTS

2.


12

3

Unplug the brake pedal switch maleconnector from the brake pedal switchas shown.Remove and retain the bolt securing aconnector to the vehicle as shown.(ref. diagram 3).

3.


REMOVE AND RETAIN BOLT AND WASHER

under kick panel

2

REMOVE AND RETAINFRONT SCUFF PLATE

REMOVE AND RETAIN‘B’ PILLAR TRIM

REMOVE AND RETAINREAR SCUFF PLATE

DRIVER’S SIDE OFVEHICLE ONLY

REMOVEHARDWARE

3

REMOVEHARDWARE

REMOVEBRAKE PEDAL

SWITCH CONNECTOR

STEERINGCOLUMN

BRAKEPEDALARM

ACCELERATORPEDAL

1

REMOVEKICK PANEL

4

REMOVELOWER DASH COVER

2

1

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CP0096

WIRING INTALLATION

CANOPY INSTALLATION INSTRUCTIONCANOPY INSTALLATION INSTRUCTION

Using the vehicle wiring patch harnessfrom the hardware kit connect the femaleconnector to the brake pedal switch maleconnector as shown.Connect the male connector from the vehicle wiring patch harness back intothe brake pedal switch as shown.(ref. diagram 4).

4.

Diagram: 4 - CONNECT VEHICLE HARNESS

Diagram: 5 - CONNECT VEHICLE HARNESS

Route vehicle harness behind existingharness across to the kick panel and rundown to the front door scuff plates.Fit one (1) short cable tie to secure thevehicle harness to existing harness asshown. Trim excess tie with side cutters.Re-assemble the previously removedbolt and connector (from step 3) with thevehicle wiring patch harness eyelet terminaland secure to the vehicle as shownIMPORTANT: Be careful when tighteningto ensure wires are not stripped out ofthe eyelet terminal.(ref. diagram 5).

5.

VEHICLE WIRINGPATCH HARNESS

2

CONNECTBRAKE PEDAL HARNESS

CONNECTOR WITH VEHICLEHARNESS FEMALE CONNECTOR

1

CONNECTVEHICLE

HARNESS MALECONNECTOR

BACK INTO BRAKEPEDAL SWITCH

FEEDVEHICLE

HARNESS BEHINDEXISTING LOOMS

FITCABLE TIE

FITBOLT, EYELET

TERMINALAND CONNECTOR

21

Route vehicle harness from the front doorscuff plate to the rear door scuff plate,ensuring the harness sits between the‘B’ pillar sheetmetal and the seat belt asshown. (ref. diagram 6).

6.

Diagram: 6 - ROUTING VEHICLE HARNESS

SEAT BELT

EXISTINGHARNESS

VEHICLEHARNESS

SEAT BELT

EXISTINGHARNESS

FRO

NT

DO

OR

OP

EN

ING

RE

AR

DO

OR

OP

EN

ING

VEHICLEHARNESS

SH

EE

T M

ETA

L

SH

EE

T M

ETA

L

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CP0096

WIRING INSTALLATION


Lift up drivers side rear floor carpet andremove and discard the existing plug in thefloor. Feed the vehicle harness downthrough the floor and fit the vehicle harnessplug into the sheetmetal.Important: Check under the vehicle thatplug is correctly located into the sheet-metal and fully seated to prevent waterentering the vehicle.Attach one (1) long cable tie to secure thevehicle harness to the top of the chassisrail as shown. Trim excess tie with sidecutters. (ref. diagram 7).

Replace driver’s side kick panel andhardware as shown.Replace driver’s lower dash cover andhardware as shown.NOTE: If scrivet broke during removal oflower dash cover, use the scrivet suppliedin the hardware kit. (ref. diagram 8).

7.

Diagram: 7 - ROUTING VEHICLE HARNESS

8.

Diagram: 8 - REPLACE VEHICLE PARTS

Replace driver’s side ‘B’ Pillar trim.Replace Front and Rear driver’s side scuffplates. (ref. diagram 9).

9.

Diagram: 9 - REPLACE VEHICLE PARTS

32

1

REPLACEFRONT SCUFF PLATE

REPLACE‘B’ PILLAR TRIM

REPLACEREAR SCUFF PLATE

DRIVER’S SIDE OFVEHICLE ONLY

REPLACEHARDWARE

2

REPLACEHARDWAREREPLACE

KICK PANEL

1

LIFT UPREAR FLOOR

CARPET

REPLACELOWER DASH COVER

3

4

1

REMOVE &DISCARDEXISTING

FLOOR PLUG

2

FEEDVEHICLE HARNESS& PLUG INTO HOLEUNDERNEATH VEHICLE

3

ENSUREPLUG IS FULLY SEATED

4

FIT CABLE TIE TOHARNESS & CHASSIS RAIL

5

CH

AS

SIS

RA

IL

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CP0096

TUB PREPARATION

If a Bed liner is installed use a medium sizepaint scraper to separate the front rail sealfrom the tub and completely remove the seal.Re-fit the seal and fit the rail extrusion tubstop (ALUM0035-5) between the front railand seal as shown.Measure and ensure the rail extrusion tubstop is centred in the tub. (ref. diagram 11).

11.

10.

Diagram: 11 - FIT RAIL EXTRUSION TUB STOP

Diagram: 10 - DISCONECT BRAKE LIGHT IN TAILGATE (GLX-R only)

SEPARATE & REMOVEFRONT RAIL SEAL

REMOVECOVER PANEL

1

1

RE-FITFRONT RAIL SEAL

2

BED LINER

BED LINER

RAIL EXTRUSIONTUB STOPFRONT RAIL

SEAL

FITRAIL EXTRUSION TUB STOP

3CENTRE

RAIL EXTRUSIONTUB STOP

4

=

VEHICLEFRONT RAIL

=

NOT SUPPLIED

FRONT TUB SPACER EXTRUSION

APPLYFIRM PRESSURE TO

ADHERE SILICON

FITFRONT TUB SPACER EXTRUSION

21

Apply a 10mm bead of silicon to the rail extrusion spacer along the back edge.Fit rail extrusion spacer to the front rail positioning it evenly between the side rails and align tub spacer extrusion slots with tub stop extrusion slots.Apply firm pressure rearward and down onthe front tub spacer extrusion along thelength to ensure maximum adhesion of thesilicon. (ref. diagram 12).

12.

Diagram: 12 - FIT RAIL EXTRUSION SPACER

SIILICON

SIILICON

3

23

FOR GLX-R MODELS ONLY.Disconnect the brake light in thetailgate to meet ADR requirements. Open tailgate and remove 8 Phillips screwsholding the cover panel.Disconect the brake light connector and secure the connector on the left hand side tothe tailgate using cable tie.Refit the cover panel to the tailgate.(ref. diagram 10).


DISCONNECTCONNECTORFIT

CABLE TIE

CP0096

6/03/13 of 17

TUB PREPARATIONMark, center punch and drill two 5.5mm holes through the spacer and front tub rail.Fit two rivets as shown. RHs shown, repeatfor LHS. (ref. diagram 13).

13.

Diagram: 13 - FIT RAIL EXTRUSION SPACER

Using alcohol wipes provided clean all toprail areas of the tub and wipe away residuewith a dry clean cloth. If heavy cleaning isrequired use Iso-Propyl alcohol and wipeaway residue with a dry clean cloth.Ensure no silicon is squeezed up by thefitting of the front tub spacer extrusion,if it is clean it off with IPA and a rag.Using priming stick (MISC1365) prime toprails of the tub where EPDM foam tapewill be applied in (step 15). Please do notprime too far over the sides of the toprails. Read (step 15) to understand wherethe foam tape is to be positioned anduse this as a guide for priming the area.Follow the instructions on the primingstick for optimum results.(ref. diagram 14).

14.

Diagram: 15 - MARK TUB RAILS FOR TAPE ALIGNMENT

(1) Open the rear tailgate.(2) Using non-permanent marker, measureand mark lines 5mm outboard from theinside edge of the side rails at intervals of150mm as shown.(3) Measure and mark lines 5mm rearwardfrom the front edge of the front tub spacerextrusion at intervals of 150mm as shown.(4) Mark a point on the side rails in line withthe back face of the sheetmetal flange.(5) Measure and mark a line 20mm forwardon the side rails and another line 10mmforward again.(6) Mark a point 20mm outboard on theside rails. (7) Mark a diagonal line as shown usingmarked lines and points. (ref. diagram 15 ).

15.

Diagram: 14 - VEHICLE SURFACE PREPARATION

OPEN VEHICLETAILGATE

TOP VIEW OFVEHICLE TUB

CABIN OF VEHICLE

1

2

5

6

3

SID

E R

AIL

SIDE RAIL

SHEETMETALFLANGE

TAILGATE

FRONT TUBSPACER

EXTRUSION

5mm

5mm

10mm20mm

20mm

SIDE RAIL

FRONT TUBSPACER

EXTRUSION

20m

m

20mm 15mm

47

1 2


Ø5mm

Rust

Inhibitor

(x8)

1 2

3 4

CP0096

6/03/13 of 17

TUB PREPARATION16.

NOT SUPPLIED

Diagram: 16 - INSTALL WATER SEALING TAPE

APPLYEPDM FOAM TAPEAROUND BED RAIL

TOP VIEW OFVEHICLE TUB

CA

BIN

OF

VEH

ICLE

TRIM TO 45°ALIGN TO MARKS

POSITIONEPDM FOAM TAPE

OVER THE EDGE OFTHE INSIDE RADIUS

ALONG THE SIDE RAILS

POSITIONEPDM FOAM TAPE

5mm REARWARD OFTHE EDGE OF THE

FRONT TUB SPACEREXTRUSION

ALONGSIDE RAILS

SILICON BEAD Ø5mmFOR LENGTH 150MM

INSIDE REAR EDGE OF TAPE

ALONGSIDE RAILS

FOAM TAPE MUST NOTPUCKER AROUND CORNERS

TRIM EXCESS TO 45° AND ALIGN TO MARKS

ALONGFRONT RAIL

WITH SPACER

5mm5mm

5mm150mm

TAILGATE OFVEHICLE

20mm10mm

5mm

SHEETMETALFLANGE

Ø5mmSILICON

BEAD

150mm


APPLY EPDM TAPE AS SHOWN

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CP0096

TUB PREPARATION

NOT SUPPLIED

With a clean cloth wipe down all areas ofthe internal front tub corners to besiliconed as shown. Spray areas to besiliconed with water, Do Not dry.Apply non-acetic silicon (neutral cure)(not supplied) to the top of the tub andspacer around the foam tape, inside thetub at the join between the front and sidepanels of the tub and between the tub andspacer as shown.Re-spray silicon with water and pushsilicon into gaps and clean up excesssilicon. Repeat process for the other sideof the vehicle.IMPORTANT: This step must be doneproperly to ensure the vehicle tub iswater sealed. (ref. diagram 17).

17.

Diagram: 17 - APPLY SILICON

BED LINER FITTEDBED LINER NOT FITTED

EPDM FOAMTAPE

FRONT TUBSPACER EXTRUSION

BED LINER

APPLYNON ACETIC

SILICON(NEUTRAL CURE)

EPDM FOAMTAPE

APPLYNON ACETIC SILICON

(NEUTRAL CURE)

FRO

NT

TUB

SPA

CE

R E

XTR

US

ION

FRONT TUB STOP

NOT SUPPLIED

CLEANCANOPY FRONT

1

With a clean cloth wipe down all areas tobe siliconed as shown. Spray areas to besiliconed with water, Do Not dry.Apply non-acetic silicon (neutral cure)(not supplied) to the top of the tub andspacer around the foam tape and downthe front side of the tub between the tuband the cabin, and down at least the depthof the return of the front tub spacerextrusion, from the top of the tub and pushsilicon into gaps. Repeat process for theother side of the vehicle.IMPORTANT: This step must be doneproperly to ensure the vehicle tub iswater sealed. (ref. diagram 18).

18.

Diagram: 18 - APPLY SILICON

Diagram: 19 - PREPARE CANOPY

Clean front of canopy including the frontwindow.Using non-permanent marker, measureand mark lines 5mm rearward from thejoint between the sheetmetal and plastictrim for each side of the vehicle as shown.(ref. diagram 19).

19.

2 5mmSH

EE

TME

TAL

SID

E R

AIL

PLASTICTRIM

MARK A LINE

TOP VIEW OF TUB FRONT CORNER

FRONT TUBSPACER

EPDM FOAMTAPE

VEHIC

LE CABIN

APPLYNON ACETIC

SILICON(NEUTRAL CURE)


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CP0096

TUB PREPARATIONTwo people are required for this step.First tape the wiring harness to the RHside window with masking tape.Position the canopy onto the vehicletub carefully.IMPORTANT: Ensure canopy is placedfully forward on the tub in one action.DO NOT slide the canopy on the EPDMfoam tape, as this can damage thefoam tape (break the water seal).Remove masking tape and feed canopyharness down between tub and cabin (righthand side of vehicle) so it is accessibleunder the vehicle on the outside of thechassis rail. (ref. diagram 20).

20.

Diagram: 20 - FIT CANOPY TO TUB

DO NOT SLIDE CANOPYON EPDM FOAM TAPE

2 FITCANOPY TO

VEHICLE

1 TAPEWIRING HARNESS

TO RH SIDE WINDOW

3FEED

CANOPY HARNESSBETWEEN TUB AND

CABIN DOWN TOCHASSIS RAIL

HARNESS

ALIGN FRONT OF CANOPY

WITH 5MM MARK0mm

1020

3040

5060

7080

90

21.

+70Kg

Diagram: 21 - SECURE FRONT TUB STOP RAIL

Align the front of the canopy with the 5mm lines as shown.Secure previously installed front rail tubstop extrusion (ALUM0043-2) to thecanopy front base rail spacer using four (4) M6 bolts (SCRW0824), M6 flat washers and M6 nyloc nuts as shown.IMPORTANT! Tighten middle bolts beforethe outer bolts. Torque to 7Nm. (ref. diagram 21).

10mm

TIGHTEN ALL BOLTS TO TORQUE 7Nm

7Nm

10mm


DISASSEMBLE4 CLAMPS

1

FITREMAINING CLAMPS

APPLYLOCTITE 243 TO BOLTS

23

TIGHTEN2 - REAR CLAMPSTORQUE TO 9Nm

4TIGHTEN

2 - FRONT CLAMPSTORQUE TO 9Nm

5TIGHTEN

2 - MIDDLE CLAMPSTORQUE TO 9Nm

9Nm

13mm

13mm

Fit the clamps to the holes in the canopy base rails by fitting the top L clamp downthrough the hole in the rail and sliding the lower U clamp along the side rail over the rubber extrusion.IMPORTANT! Apply Loctite 243 threadlock compound (not supplied), alongthe thread on the bolts.Secure the clamps with the bolts andwashers as shown. Tighten the rear clamps first, then the frontclamps and finally the middle clamps, allto Torque 9Nm. (ref. diagram 22).

22.

Diagram: 22 - FIT REMAINING CLAMPS AND TIGHTEN ALL

20mm

LOCTITE243

2

2

1

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CP0096

CANOPY ATTACHMENT

CLEARABRASION

TAPE

TRIMEXCESS CLEARABRASION TAPE

3

REMOVEMASKING TAPE

CANOPY NOT SHOWN FOR CLARITY

5

SQUEEGEE OUTEXCESS SOLUTION

BUBBLES

41

25% ISOPROPYLALCOHOL

75% WATER

APPLYCLEAR

ABRASION TAPE

ALIGNBOTTOM EDGE

OF CLEAR ABRASIONTAPE WITH TOP EDGE

OF MASKING TAPE

2

23.

24.

With the canopy rear door closed, applya length of masking tape to the reartailgate, level with the bottom edge ofthe canopy rear door sash, when viewedfrom the rear horizontal position as shown.This will assist in positioning the clearabrasion tape applied to the top of thetailgate in the next step. (ref. diagram 23).

Using a solution of 25% isopropyl alcoholand 75% water in a spray bottle (not -supplied) Thoroughly spray along the topof the tailgate. Remove liner from clearabrasion tape. Working from one end witha 5mm overhang, place liner on the tailgate. Trim excess tape leaving a 5mm overhangat both ends of the tailgate.When in position use a squeegee to pushout any excess water solution and bubbles.Using a sharp knife or scissors, trim tape to end of tailgate.You may need to squeegee a few times.When finished the tape is virtuallyinvisible. To ensure a good finish please take carean do not rush this step. Remove maskingtape. (ref. diagram 24).Diagram: 24 - APPLY ABRASION TAPE

Diagram: 23- APPLY MASKING TAPE


TAILGATE

REARDOOR SASH

MASKINGTAPE

REAR WINDOW

APPLYMASKING TAPETO TAILGATE

1

(Optional): Recommended for ‘Off Road’vehicle use (with no bed liner fitted).Mark and drill eight (8) Ø5mm holes intothe front rail tub stop and tub rail usingdimension’s as shown.Rivets must secure to raised formon tub.Apply rust inhibitor to all drilled holes inthe tub sheetmetal.Secure with eight (8) stainless steel rivetsas shown. (ref. diagram 25).

25.

Diagram: 25 - (OPTIONAL) SECURE FRONT TUB STOP RAIL

RAISED FORMON TUB

175 175 175 175175 3535 175

BOTTOM GROOVEON FRONT RAIL TUB STOP

Ø5mmRust

Inhibitor

(x8)1 2 3 4

CP0096

6/03/13 of 17

CANOPY ATTACHMENT

CHECKCANOPY LAMP

WORKS

CHECKBRAKE LIGHTS

WORK

Two people are required to check thecanopy brake light is operational afterdepressing the brake pedal.Then open the rear window and checkthat the internal canopy lamp is operatingcorrectly when switched to the ’ON’position only.(ref. diagram 27).

27.

Diagram: 27 - CHECK BRAKE LIGHTS AND CANOPY LIGHT

Feed the canopy harness along thechassis rail.If there is excess length on the vehicleharness, loop the harness near theconnector as shown and secure it to thechassis rail with one (1) long cable tie.Connect the canopy harness connector tothe vehicle harness connector as shown.Attach one (1) long cable tie to the canopyharness near the connector, to secure it tothe chassis rail as shown.Trim excess ties with side cutters.IMPORTANT: Wiring harnesses shouldbe positioned away from the exhaustsystem side. Preferably place it on thetop side of the chassis rail.(ref. diagram 26).

26.

Diagram: 26 - CONNECT VEHICLE & CANOPY HARNESSES

Using alcohol wipe provided in the kit,clean the driver’s side top corner of thetub as shown, and wipe away residuewith a dry clean cloth.Remove tape liner from adhesive tie padand position on the tub in area previouslycleaned as shown. Apply pressure toensure maximum adhesion.

28.

Diagram: 28 - FIT ADHESIVE TIE PAD AND CABLE TIE

CONNECTCANOPY HARNESS TO VEHICLE HARNESS

1

FIT TWO (2) CABLE TIES2

CHASSIS RAIL

Fit one short cable tie through theadhesive tie pad previously fitted to thefront of the tub and secure the canopywiring harness. Trim excess tiewith side cutters. (ref. diagram 28).

CABIN

TUB

FITCABLE TIE

CANOPY

FITADHESIVE

TIE PAD

2

3

1


6/03/13 of 17

CP0096

Secure the sacrificial grinding plate (notsupplied in kit) to the tub rail by coveringit with masking tape as shown.Repeat process for the other side of thevehicle. (ref. diagram 31).

31.

Diagram: 31 - SECURE GRINDING PLATE

SECURESACRIFICIAL GRINDING

PLATE WITH TAPE

Using cardboard cut from the canopycarton, cut and place a piece inside thetub on the floor as a protection mat whileinstalling the canop. Place a piece betweenthe tub and cabin as a protection sheetwhile removing the cabin guard.(ref. diagram 29).

29.

Apply 200mm lengths of overlappingmasking tape to the top and side of thetub rail, up to and around the cabin guardas shown.Recommended: Fit a 2mm thick steelplate as a sacrificial grinding plate (Notsupplied in kit), next to the cabin guardas shown, repeat process for the otherside of the vehicle. (ref. diagram 30).

30.

Diagram: 30 - SECURE GRINDING PLATE

FITTAPE

RECOMMENDEDFIT SACRIFICIALGRINDING PLATE

1

2

Diagram: 29 - PROTECT VEHICLE SURFACES

POSITIONCARDBOARD

TUB AND CABINPROTECTION MATS

CABIN GUARD

CABIN GUARD REMOVAL


CP0096

6/03/13 of 17

Insert a suitable protective timber boardof adequate thickness between thecardboard and cabin guard as shown.IMPORTANT: To avoid accidentaldamage to the vehicle, the timber boardMUST be used when ever cutting of thecabin guard is undertaken.(ref. diagram 32).

IMPORTANT: Ensure that the vehicle’s(paint work, glass, etc...) is adequatelyprotected before removing the cabinguard.Using a medium sized angle grinder,partially cut through the rear and sidefaces of the LH outer cabin guard bar,taking care not to damage vehiclesurfaces.Repeat process for the RH side of thevehicle, ensuring the protective timberboard is repositioned behind the RH outercabin guard bar. (ref. diagram 33).

32.

Diagram: 32 - PROTECT VEHICLE SURFACES

33.

Diagram: 33 - REMOVAL OF CABIN GUARD

PARTIALLY CUT THROUGHOUTER CABIN GUARD BARS

INSERTTIMBER BOARD

IMPORTANT: Ensure the protectivetimber board is repositioned behind each of the centre support bars beforecutting.Using a medium sized angle grinder,completely cut through the three (3)centre support bars at the base, flush tothe front tub rail, taking care not todamage vehicle surfaces. (ref. diagram 34).

34.


1

2

INSERTTIMBER BOARD

COMPLETELY CUT THROUGHCENTRE SUPPORT BARS

CABIN GUARD REMOVAL


6/03/13 of 17

CP0096

IMPORTANT: Ensure the protectivetimber board is repositioned behind the outer cabin guard bars beforecutting.Two people are required to completethis step, one person will need tosupport the cabin guard and prevent itfrom damaging the vehicle while theother person finishes cutting throughthe cabin guard bars completely.Using a medium sized angle grinder,completely cut through the LH and RHouter cabin guard bars, flush to thegrinding plates.Carefully remove cabin guard fromvehicle and discard. (ref. diagram 35).

IMPORTANT: Ensure the protectivetimber board is repositioned to each bar location before cutting.Take care to prevent damage to vehicle.Using a medium sized angle grinder,carefully cut away any remaining metalnot flush with the tub rail.Remove sacrificial grinding plates andall masking tape. (ref. diagram 36).

35.


36.

Diagram: 36 - PREPARE VEHICLE SURFACES

1

2

SUPPORTCABIN GUARD

COMPLETELY CUT THROUGHOUTER CABIN GUARD BARS

1

2

GRINDAWAY ANY REMAINING

METAL NOT FLUSHWITH THE TUB

REMOVEGRINDING PLATES

& TAPE

Using a file / de-burring tool, remove allburrs and sharp edges from cabin guardand tub rail surfaces previously cut withthe angle grinder. (ref. diagram 37).

37.

Diagram: 37 - PREPARE VEHICLE SURFACES

DEBURRALL SURFACES AROUNDCUT CABIN GUARD BARS

CABIN GUARD REMOVAL


Using a suitable metal primer, paint overand completely cover all bare metalsurfaces previously cut and deburred.(ref. diagram 39).

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CP0096

Remove all timber boards and cardboardprotection mats from the vehicle.Retain cardboard tub floor protection matfor use later during the fitment.Using compressed air, completely blowout all metal filings, swarf etc... in the tubfloor. (ref. diagram 38).

38.

Diagram: 38 - CLEAN VEHICLE SURFACES

39.

Diagram: 39 - PRIME VEHICLE SURFACES

1 REMOVETIMER BOARDS& CARDBOARD

PROTECTION MATS

2

CABIN GUARD REMOVAL

KEY IDENTIFICATION CODE

1234

CANOPY

Please write the key identification code in the boxes above,and retain this copy with the vehicle service history.

Replacement keys can be purchased from your local dealer.


CP0096

6/03/13 of 17

WARNING! - SAFETY!• Do Not use the canopy as a passenger compartment.• Do Not operate/drive vehicle with fold up windows or rear door open. They must be closed when vehicle is in motion.• Do Not store or transport volatile materials, such as solvents, chemicals or liquids as fumes may accumulate inside canopy. Do Not allow solvents, chemicals or oils to come in contact with the canopy. If this should occur clean the canopy immediately with a mild detergent and water solution.• Do not stand/sit or rest heavy objects on Canopy.• Do not fill volatile liquid containers while inside canopy such as fuel cans.• VEHICLES FITTED WITH A BED LINER: Static electricity can cause fire when fuel is pumped into ungrounded fuel containers or equipment (e.g.: motorcycles, chain saws etc..). Do Not fill fuel containers or equipment within the vehicle tray as static electricity can cause fuel to ignite, resulting in damage, injury or death. To avoid electricity build-up, place fuel container or equipment on the ground before filling.

MaintenanceOnly use mild detergents or wax polish. Do Not use abrasive compounds on painted or plastic finishedcanopy surfaces.The gas struts are self lubricating and should only be cleaned with a damp cloth, when regularly cleaningthe vehicle. Premature seal failure will result if solvents or lubricants are used to clean struts.Gas struts must be orientated as installed, cylinder (wide end) to canopy and rod (narrow end) to glass.Lightly coat the door and window rubber assemblies with a silicon spray after cleaning periodically.Only locks and lock recesses are to be lubricated with Graphite Powder.Vaseline may be used on the rotary catches on the rear door.DO NOT use any other lubricants or oils. Using alternative products will VOID Warranty.Check canopy attachment brackets every 1000 Km.If removed, bolts must have LOCTITE 243 re-applied and be re-tightened on refitting to specified values.CHECK regularly that all screws and fasteners holding windows and doors are tight.The rear tailgate protection tape must be replaced periodically to minimize paint scuffing caused by the canopy rear door opening and closing.For sliding windows use a silicon based Non-Aerosol lubricant or a dry film lubricant or LY70 lubricant or 3Mwindow channel dresser lubricant sparingly.

DO NOT use CRC, WD40 or petroleum based lubricants on sliding windows.

Warranty TermsEGR warrants that the ABS Canopy will be free from defects in material and workmanship for a period of three (3) years from the retail date ofpurchase. The gas struts are warranted for one (1) year from the retail date of purchase.This warranty only applies to the original purchaser and is nontransferable. Warranty must be claimed with original sales receipt for proof of purchase.

ExclusionsThis warranty does not cover failure due to neglect, improper installation, including any modifications to installation hardware, alterations, additionof non genuine equipment, abuse, accident, normal wear and tear, lack of maintenance, misuse, and exposure to chemicals that are not safe forplastics or hardware components. Incidental or consequential damage or loss of contents due to use, neglect, lack of maintenance, misuse of EGR Canopy is sole responsibility ofthe vehicle owner and operator. Paint wear to the vehicle bed can happen with any Canopy and is the sole responsibility of the vehicle owner.Paint damage to your vehicle is not covered under this warranty.

DisclaimerIn the event that your EGR Canopy is found to be defective under the terms of this warranty, it is at the discretion of EGR to repair or replace thedefective part. Transportation costs and labour are not associated with this warranty claim.

OWNERS MANUAL SUPPLEMENTIMPORTANT: PLACE THIS PAGE IN THE CUSTOMER’S

VEHICLE SERVICE BOOK.

CANOPY INSTALLATION INSTRUCTIONS Mitsubishi Triton MN ... Triton Fleet cp0096.pdf · Page 1 of 17...

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