Prorack K544 User manual

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

Fitting Kit K544
MAX kgs (lbs)
W/P WHD
Toyota
Hilux Double Cab, 4dr Ute 05-12 EU 75 kgs (165 lbs) 100 kgs (220 lbs)
Hilux Double Cab, 4dr Ute 05-12 ZA 75 kgs (165 lbs) 100 kgs (220 lbs)
Hilux Double Cab, 4dr Ute 05-12 CN 75 kgs (165 lbs) 100 kgs (220 lbs)
Hilux Double Cab, 4dr Ute 12-+ NZ 75 kgs (165 lbs) 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 (165 lbs) 100 kgs (220 lbs)
Hilux DoubleCab, 4dr Truck 12-+ US 75 kgs (165 lbs) 100 kgs (220 lbs)
2

Fitting Kit EN
K544
Items you will require:
●Tape measure
Pen
Flat-head screwdriver
Craft knife
Side cutters or tin snips
Hammer
8mm (3/8") punch
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

Fitting 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

Fitting Kit EN
K544
●Press adjusting screw and pull crossbar
legs out. Refer to the crossbar instructions
for crossbar adjustment 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

Fitting Kit EN
K544
●Select plastic internal block (from fitting kit)
and insert into foot.
●Repeat for all legs.
●Fit rubber pads (supplied with fitting 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

Fitting Kit EN
K544
Permanent Mount Fitment
●Carefully cut 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

Fitting Kit EN
K544
●Unhook rubber ditch mould from plastic
retaining clip (A) and double sided tape (B).
Lift ditch mould up and out of the channel.
●Completely remove from the vehicle.
●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

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

Fitting Kit EN
K544
●Cut steel strip in centre using 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