Prorack K544, Fitting Instructions Manual

Page 1: ...K544 Fitting Kit EN Fitting Instructions for Basic Carrier x 1 x 4 x 4 x 8 x 8 x 4 x 4 x 4 Revision No 3C 1 ...

Page 2: ... 100 kgs 220 lbs Hilux Double Cab 4dr Ute 12 EU 75 kgs 165 lbs 100 kgs 220 lbs Hilux Double Cab 4dr Ute 12 ZA 75 kgs 165 lbs 100 kgs 220 lbs Hilux Double Cab 4dr Ute May 05 12 NZ 75 kgs 165 lbs 100 kgs 220 lbs Hilux Double Cab 4dr Ute May 05 Aug 11 AU 75 kgs 165 lbs 100 kgs 220 lbs Hilux Double Cab 4dr Ute Sep 11 AU 75 kgs 165 lbs 100 kgs 220 lbs Hilux DoubleCab Mexico 4dr Truck 05 11 US 75 kgs 16...

Page 3: ...h Cordless drill Depth stop Vacuum cleaner Rust inhibitor Small paint brush Neutral cure silicon sealant Rivet gun Attention Attaches with riveted mounts under rubber ditch mould Professional installation advised First Time Installation Remove parts from inside the package and check Contact your dealer if any parts are missing or damaged 3 ...

Page 4: ... Kit EN K544 This kit fits type A B C and D These instructions show type A crossbar fitted They also apply to type B C and D Use keys to remove covers Use hex screwdriver to reverse adjusting screw 10 turns 4 ...

Page 5: ...ent method Ensure each end of the crossbar is adjusted equally Adjust crossbar in or out to suit vehicle Please check the front of this manual for information relating specifically to your vehicle Remove plastic clamp block by gripping bar leg with fingers and push firmly with thumbs until clamp block drops out behind leg 5 ...

Page 6: ...kit to foot Pad may vary in shape to that shown Make sure the pad fits into the holes underneath the foot RECOMMENDED POSITION DUE TO AIRBAGS IN ROOF Front above centre door pillar as shown Rear 700mm 27 1 2 rearwards from centre door pillar Apply masking tape to vehicle roof in all four positions Mark reference point on masking tape with a pen 6 ...

Page 7: ...t tape to seperate ditch mould from roof Repeat for all four positions Ditch mould held at each end by A Plastic retaining clip B Double sided tape Apply protective tape as shown Carefully remove ditch mould at the front position with flat head screwdriver 7 ...

Page 8: ...icle The rubber ditch mould is to be re installed on the vehicle later Line up the centre hole in the mounting block with the marked reference points Wrap tape around rubber ditch mould to mark end position of mount Turn rubber ditch mould over Place on a workbench From the bottom cut 3 4 of the way through the rubber ditch mould as shown Blade should contact steel strip 8 ...

Page 9: ...Fitting Kit EN K544 Carefully cut rubber ditch mould between faces along steel strip A Top face B Bottom face A Top B Bottom C Steel strip D Removed excess Check fit 9 ...

Page 10: ...ng side cutters Lift and cut steel strip at each end Remove cut peices of steel strip Repeat for all four positions Turn rubber ditch mould over Punch 8mm 3 8 hole through top of rubber ditch mould centered on mark as shown Remove excess from hole 10 ...

Page 11: ...ole in the mounting block with the marked reference points Lightly mark position of outside holes of the mounting block in the roof channel CAUTION Maximum depth 7mm Use 7mm drillstop over supplied 4 9mm drill bit Drill two outside holes at marked positions 11 ...

Page 12: ...Fitting Kit EN K544 Vacuum and clean swarf from channel Treat holes to prevent corrosion Apply neutral cure silicon sealant in and around drilled holes 12 ...

Page 13: ...Fitting Kit EN K544 Install rivets through permanent mount blocks Rivet into place Fit plastic plugs to permanent mount blocks over rivet heads Assemble as shown 13 ...

Page 14: ...ing Kit EN K544 A Double sided tape Apply as shown at both ends of the roof Re install rubber ditch mould in roof channel Remove all masking tape Ensure the hole in rubber ditch mould lines up with mount 14 ...

Page 15: ...Fitting Kit EN K544 Place crossbar on vehicle Tighten the plastic knob Ensure the plastic knob is in the position shown when fully tightened 15 ...

Page 16: ...g screw to 5 Nm 3 7 ft lb hand tight Check crossbar is securely attached to the vehicle Use keys to fit and lock covers CAUTION Recheck all fasteners immediately after a load is applied to the crossbars Regularly check screws are tight 16 ...

Page 17: ...cle manufacturers roof load rating if it is lower than the maximum load capacity specified in the fitting instructions Loads should not overhang the sides of the product and be evenly distributed with the lowest possible centre of gravity Long loads should be secured with non elastic straps to the front and rear of the vehicle Objects with pointed ends e g ski poles should be carried with the poin...

Page 18: ...fitted Lubricate locks and adjusting screws at regular intervals Remove the products from the vehicle when not in use Make sure all loose parts are stored safely Yakima Australia Pty Ltd 17 Hinkler Court Brendale QLD 4500 AUSTRALIA www whispbar com www whispbar com au www whispbar co nz www whispbar co uk www whispbar co za www whispbar eu www whispbar ca 18 ...

Page 19: ...he warranty cover defects loss or damage resulting from accidents unlawful use of the vehicle or defects inconsistencies in the vehicle on which the product or component is fitted Liability for direct indirect special punitive incidental exemplary contractual or consequential damage or loss arising from defects faulty materials or design omissions or negligence or workmanship in the product or its...

Page 20: ...h those instructions and of returning the product to Yakima or the Prorack dealer will be borne by you Following receipt of the product and purchase invoice or receipt Yakima or the Prorack dealer must inspect the product to determine whether the claim falls within the warranty If 4 1 the claim falls within the warranty Yakima will remedy any defects in materials or workmanship becoming apparent d...