Prorack K991 User manual

K991
Fitting Kit
EN Fitting Instructions for Basic Carrier CAUTION: Professional
installation only
x 2 x 1 x 1 x 4
x 4 x 1 x 4 x 4
x 8 x 1 x 4 x 4
Revision No: 3C 1

Fitting Kit K991
MAX kgs (lbs)
W/P WHD
Toyota
HiLux Double Cab, 4dr Ute 16-20 ZA 75 kgs (165 lbs) 100 kgs (220 lbs)
HiLux Double Cab, 4dr Ute 16-20 EU 75 kgs (165 lbs) 100 kgs (220 lbs)
HiLux Double Cab, 4dr Ute 20-+ EU 75 kgs (165 lbs) 100 kgs (220 lbs)
HiLux Double Cab, 4dr Ute 20-+ ZA 75 kgs (165 lbs) 100 kgs (220 lbs)
HiLux Double Cab, 4dr Ute Oct 15-Aug 20 AU 75 kgs (165 lbs) 100 kgs (220 lbs)
HiLux Double Cab, 4dr Ute Oct 15-Aug 20 NZ 75 kgs (165 lbs) 100 kgs (220 lbs)
HiLux Double Cab, 4dr Ute Sep 20-+ AU 75 kgs (165 lbs) 100 kgs (220 lbs)
HiLux Double Cab, 4dr Ute Sep 20-+ NZ 75 kgs (165 lbs) 100 kgs (220 lbs)
HiLux Extra Cab, 4dr Ute 16-20 EU 75 kgs (165 lbs) 100 kgs (220 lbs)
HiLux Extra Cab, 4dr Ute 16-20 ZA 75 kgs (165 lbs) 100 kgs (220 lbs)
HiLux Extra Cab, 4dr Ute 20-+ EU 75 kgs (165 lbs) 100 kgs (220 lbs)
HiLux Extra Cab, 4dr Ute 20-+ ZA 75 kgs (165 lbs) 100 kgs (220 lbs)
HiLux Extra Cab, 4dr Ute Oct 15-Aug 20 AU 75 kgs (165 lbs) 100 kgs (220 lbs)
HiLux Extra Cab, 4dr Ute Oct 15-Aug 20 NZ 75 kgs (165 lbs) 100 kgs (220 lbs)
HiLux Extra Cab, 4dr Ute Sep 20-+ AU 75 kgs (165 lbs) 100 kgs (220 lbs)
HiLux Extra Cab, 4dr Ute Sep 20-+ NZ 75 kgs (165 lbs) 100 kgs (220 lbs)
HiLux Single Cab, 2dr Ute 16-20 EU 35 kgs (77 lbs) 50 kgs (110 lbs)
HiLux Single Cab, 2dr Ute 16-20 ZA 35 kgs (77 lbs) 50 kgs (110 lbs)
HiLux Single Cab, 2dr Ute 20-+ EU 35 kgs (77 lbs) 50 kgs (110 lbs)
HiLux Single Cab, 2dr Ute 20-+ ZA 35 kgs (77 lbs) 50 kgs (110 lbs)
HiLux Single Cab, 2dr Ute Oct 15-Aug 20 AU 35 kgs (77 lbs) 50 kgs (110 lbs)
HiLux Single Cab, 2dr Ute Oct 15-Aug 20 NZ 35 kgs (77 lbs) 50 kgs (110 lbs)
HiLux Single Cab, 2dr Ute Sep 20-+ AU 35 kgs (77 lbs) 50 kgs (110 lbs)
HiLux Single Cab, 2dr Ute Sep 20-+ NZ 35 kgs (77 lbs) 50 kgs (110 lbs)
HSV
Silverado, 4dr Ute 19-+ AU 0 kgs (0 lbs) 0 kgs (0 lbs)
Silverado, 4dr Ute 19-+ NZ 0 kgs (0 lbs) 0 kgs (0 lbs)
2

Fitting Kit K991
X
A B C 1 2 3
HiLux Double Cab, 4dr Ute 16-20 (ZA) -125mm 620mm - 885mm 880mm -
-4 -15/16ths" 24 7/16ths" - 34 13/16ths" 34 5/8ths" -
HiLux Double Cab, 4dr Ute 16-20 (EU) -125mm 620mm - 885mm 880mm -
-4 -15/16ths" 24 7/16ths" - 34 13/16ths" 34 5/8ths" -
HiLux Double Cab, 4dr Ute 20-+ (EU) -125mm 620mm - 885mm 880mm -
-4 -15/16ths" 24 7/16ths" - 34 13/16ths" 34 5/8ths" -
HiLux Double Cab, 4dr Ute 20-+ (ZA) -125mm 620mm - 885mm 880mm -
-4 -15/16ths" 24 7/16ths" - 34 13/16ths" 34 5/8ths" -
HiLux Double Cab, 4dr Ute Oct 15-Aug 20 (AU) -125mm 620mm - 885mm 880mm -
-4 -15/16ths" 24 7/16ths" - 34 13/16ths" 34 5/8ths" -
HiLux Double Cab, 4dr Ute Oct 15-Aug 20 (NZ) -125mm 620mm - 885mm 880mm -
-4 -15/16ths" 24 7/16ths" - 34 13/16ths" 34 5/8ths" -
HiLux Double Cab, 4dr Ute Sep 20-+ (AU) -125mm 620mm - 885mm 880mm -
-4 -15/16ths" 24 7/16ths" - 34 13/16ths" 34 5/8ths" -
HiLux Double Cab, 4dr Ute Sep 20-+ (NZ) -125mm 620mm - 885mm 880mm -
-4 -15/16ths" 24 7/16ths" - 34 13/16ths" 34 5/8ths" -
HiLux Extra Cab, 4dr Ute 16-20 (EU) -350mm 300mm - 885mm 885mm -
-13 -3/4ths" 11 13/16ths" - 34 13/16ths" 34 13/16ths" -
HiLux Extra Cab, 4dr Ute 16-20 (ZA) -350mm 300mm - 885mm 885mm -
-13 -3/4ths" 11 13/16ths" - 34 13/16ths" 34 13/16ths" -
HiLux Extra Cab, 4dr Ute 20-+ (EU) -350mm 300mm - 885mm 885mm -
-13 -3/4ths" 11 13/16ths" - 34 13/16ths" 34 13/16ths" -
HiLux Extra Cab, 4dr Ute 20-+ (ZA) -350mm 300mm - 885mm 885mm -
-13 -3/4ths" 11 13/16ths" - 34 13/16ths" 34 13/16ths" -
HiLux Extra Cab, 4dr Ute Oct 15-Aug 20 (AU) -350mm 300mm - 885mm 885mm -
-13 -3/4ths" 11 13/16ths" - 34 13/16ths" 34 13/16ths" -
HiLux Extra Cab, 4dr Ute Oct 15-Aug 20 (NZ) -350mm 300mm - 885mm 885mm -
-13 -3/4ths" 11 13/16ths" - 34 13/16ths" 34 13/16ths" -
HiLux Extra Cab, 4dr Ute Sep 20-+ (AU) -350mm 300mm - 885mm 885mm -
-13 -3/4ths" 11 13/16ths" - 34 13/16ths" 34 13/16ths" -
3

Fitting Kit K991
HiLux Extra Cab, 4dr Ute Sep 20-+ (NZ) -350mm 300mm - 885mm 885mm -
-13 -3/4ths" 11 13/16ths" - 34 13/16ths" 34 13/16ths" -
HiLux Single Cab, 2dr Ute 16-20 (EU) -200mm - - 885mm - -
-7 -7/8ths" - - 34 13/16ths" - -
HiLux Single Cab, 2dr Ute 16-20 (ZA) -200mm - - 885mm - -
-7 -7/8ths" - - 34 13/16ths" - -
HiLux Single Cab, 2dr Ute 20-+ (EU) -200mm - - 885mm - -
-7 -7/8ths" - - 34 13/16ths" - -
HiLux Single Cab, 2dr Ute 20-+ (ZA) -200mm - - 885mm - -
-7 -7/8ths" - - 34 13/16ths" - -
HiLux Single Cab, 2dr Ute Oct 15-Aug 20 (AU) -200mm - - 885mm - -
-7 -7/8ths" - - 34 13/16ths" - -
HiLux Single Cab, 2dr Ute Oct 15-Aug 20 (NZ) -200mm - - 885mm - -
-7 -7/8ths" - - 34 13/16ths" - -
HiLux Single Cab, 2dr Ute Sep 20-+ (AU) -200mm - - 885mm - -
-7 -7/8ths" - - 34 13/16ths" - -
HiLux Single Cab, 2dr Ute Sep 20-+ (NZ) -200mm - - 885mm - -
-7 -7/8ths" - - 34 13/16ths" - -
Silverado, 4dr Ute 19-+ (AU) -300mm 500mm - 1055mm 1070mm -
-11 -13/16ths" 19 11/16ths" - 41 9/16ths" 42 1/8ths" -
Silverado, 4dr Ute 19-+ (NZ) -300mm 500mm - 1055mm 1070mm -
-11 -13/16ths" 19 11/16ths" - 41 9/16ths" 42 1/8ths" -
4

Fitting Kit EN
K991
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.
5

Fitting Kit EN
K991
First Time Installation
●Remove parts from inside the package and
check. Contact your dealer if any parts are
missing or damaged.
●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.
6

Fitting Kit EN
K991
●Use hex screwdriver to reverse adjusting
screw 10 turns.
●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.
7

Fitting Kit EN
K991
●Remove plastic clamp block by gripping bar
leg with fingers and push firmly with
thumbs until clamp block drops out behind
leg.
●Select plastic internal block (from fitting kit)
and insert into foot.
●Repeat for all legs.
●CAUTION:
●RECOMMENDED POSITION DUE TO
AIRBAGS IN ROOF:
●Please check the front of this manual for
information relating specifically to your
vehicle.
●Apply masking tape to vehicle roof in all
four positions.
●Mark reference point on masking tape with
a pen.
8

Fitting Kit EN
K991
Permanent Mount Fitment
●Carefully cut tape to seperate ditch mould
from roof.
●Repeat for all four positions.
●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.
●Ditch mould held at each end by:
●Front:
●Plastic retaining clip
●Rear:
●Double sided tape
9

Fitting Kit EN
K991
●Apply protective tape as shown.
●Carefully remove ditch mould at the front
position with flat-head screwdriver.
●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.
●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.
10

Fitting Kit EN
K991
●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.
11

Fitting Kit EN
K991
●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.
12

Fitting Kit EN
K991
●Removed excess
●Position as shown.
●Line up the centre hole in the mounting
block with the marked reference points.
●Lightly mark position of outside holes of the
mounting block in the roof channel.
13

Fitting Kit EN
K991
●Note:
●Assemble as shown.
●CAUTION:
●RECOMMENDED POSITION DUE TO
AIRBAGS IN ROOF:
●Please check the front of this manual for
information relating specifically to your
vehicle.
●CAUTION: Maximum depth 8mm.
Use 8mm drillstop over supplied 4.9mm
drill bit.
Drill two outside holes at marked positions.
●Vacuum and clean swarf from channel.
14

Fitting Kit EN
K991
●Treat holes to prevent corrosion.
●Apply neutral cure silicon sealant in and
around drilled holes.
●Install rivets through permanent mount
blocks.
●Rivet into place.
15

Fitting Kit EN
K991
●Apply as shown.
●Rear:
●Double sided tape
●Re-install rubber ditch mould in roof
channel.
Remove all masking tape.
●Ensure the hole in rubber ditch mould lines
up with mount.
16

Fitting Kit EN
K991
●Select grubscrews and screw into the
vehicle's fixed points.
●Do not over tighten.
●Repeat for all four positions.
●Fit nut to grubscrew.
●Refer to the underside of the pad for the
part number.
17

Fitting Kit EN
K991
●It is important to put the pads in the correct
position on the vehicle.
●Letters refer to the pad part numbers and
position.
●Pad Part Number:
A = 244
B = 293
C = 294
●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.
●Place crossbar foot over grubscrews.
18

Fitting Kit EN
K991
●Tighten the plastic knob.
●Ensure the plastic knob is in the position
shown when fully tightened.
●Tighten adjusting screw to 2 Nm (1.5 ft lb)
hand tight.
19

Fitting Kit EN
K991
●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.
20