ROOF RACK CP0023 INSTALLATION … · page 2 of 13 11/01/11 parts check sheet egr roof racks parts in main carton parts in hardware kit parts in roof rack kit cp0023 roof rack front

Place these instructions in vehicle’s glove box after installation is complete

11/01/11Page 1 of 13

Installation Time:2 Hours (Approximately)

IMPORTANT!• Read instructions carefully before installation.• It is strongly recommended that installation is conducted by an authorised 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.

RECOMMENDED TOOL LIST - (Not Supplied in Kit)

• Socket Driver and Sockets - 10mm, 13mm & 17mm• Spanners - 10mm, 13mm & 17mm• Silicon Dispensing Gun• Non Acetic Silicon (Neutral Cure)• Torque Wrench - 0-10Nm• File / De-burring Tool• Non Permanent Marker / Metal Scribe• Cleaning Cloths / Rags• Steel Rule and Tape Measure• Drill and Ø3mm & Ø9mm Drill Bits• Ø20mm Hole Saw• 10mm Socket Drive Drill Attachment (for 14G Tek Screw)

ROOF RACKINSTALLATION INSTRUCTIONS

(FOR FITMENT TO EGR CANOPIES)

CP0023

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

Clean Roof Racks with a milddetergent and water solution.

Do not use abrasivecleaners or solvents.Care Instructions:

Roof Racks MaximumLoad to be carried

150Kg

150KgMAX.

Page 2 of 13 11/01/11

PARTS CHECK SHEET EGR ROOF RACKS

PARTS IN MAIN CARTON

PARTS IN HARDWARE KIT

PARTS IN ROOF RACK KIT

CP0023ROOF RACK

Front Bracket LHQty - 1

Front Bracket RHQty - 1

Rear Bracket LHQty - 1

Rear Bracket LHQty - 1

Internal Foam PadQty - 4

External FoamPad - AQty - 2

External FoamPad - BQty - 2

PedestalBracket - AQty - 2

PedestalBracket - BQty - 2

Roof Rack Extrusionwith Endcaps & Keys(RACK0005)Qty - 2

Centre TubeQty - 2

14G Tek ScrewQty - 8(8 Spares)

M8x25mmHex Head BoltQty - 4

M8 FlatWasherQty - 12

M8 SpringWasherQty - 8

M8 HexNutQty - 4


M6 LargeFlat WasherQty - 16


M6 HexNutQty - 2

M8 ThreadedBlockQty - 4


M6 ThreadedPlateQty - 6

Steel BushQty - 4

FittingInstruction


M10 FlatWasherQty - 8


M10 HexNutQty - 4

Fitting Instruction(FIT-CP0023)Qty - 1

Front Tube LHQty - 1

Front Tube RHQty - 1

Rear Tube LHQty - 1

Rear Tube RHQty - 1

Roof Rack KitQty - 1

Hardware KitQty - 1

11/01/11Page 3 of 13

CP0023ROOF RACK

Diagram: 3 - FIT FRONT BRACKETS

1.

2.

Diagram: 2 - REMOVE EXISTING HARDWARE

3.

Diagram: 1 - CLEAN INSTALLATION AREAS

Thoroughly clean and dry installationareas (canopy and inside of the tub)as shown. (ref. diagram1).

Open the rear tailgate and canopy rearwindow. Inside the canopy at the front ofthe tub remove the corner “L” bracketsand hardware as shown for both sidesof the vehicle.Retain hardware to secure the front brackets in the next step.Discard the “L” brackets. (ref. diagram2).

Position the front brackets LH and RH tothe location on the canopy rails where the“L” brackets were previously removed.Secure brackets to rails using hardwarepreviously removed as shown.Tighten to Torque 5Nm. (ref. diagram3).

10mm 10mm

10mm5Nm

10mm

REMOVE & DISCARD“L” BRACKETS

CANOPYFRONT RHCORNER

REMOVE & RETAINHARDWARE

CANOPYFRONT RHCORNER

REPLACEHARDWARE

FITFRONT BRACKETS

TORQUE TO 5Nm

11/01/11Page 4 of 13

Diagram: 6 - FIT FRONT TUBES

CP0023ROOF RACK

4.

5.

Diagram: 5 - ASSEMBLE FRONT TUBES

Diagram: 4 - FIT REAR BRACKETS

Position the rear brackets LH and RH onthe canopy rails aligning to the slotsin rails as shown.Secure clamp brackets to rails using (2) M8x25mm bolts, M8 spring washers(4) M8 flat washers and (2) M8 hex nuts(per side) as shown.Tighten to Torque 6Nm. (ref. diagram4).

Orient one centre tube so the foam padon the brackets is facing up and thebrackets are coming out towards you.Slide the front tube LH assy into the LHside of the centre tube and the front tubeRH into the RH side of the centre tubeas shown. (ref. diagram5).

6. Fit the front tubes into the vehicle andposition the tube brackets to the outsideof the front brackets.For the single hole at the front of thefront bracket, loosely secure each sidewith (1) M6x20 hex head bolt, M6 Springwasher, (2) M6 flat washers and (1) M6hex nut as shown.For the two holes at the rear of the frontbracket, loosely secure each side with(2) M6x20 hex head bolts, M6 Springwashers, M6 flat washers and M6 hexnuts as shown.Rotate the centre tube so the brackets arelocated against the canopy roof as shown.Finger Tighten only, Do Not Torque.(ref. diagram6).

6Nm

13mm

13mm

TORQUE TO 6Nm

REARBRACKET

M8 HEXNUTM8x25

BOLT

M8 FLATWASHER

M8 SPRINGWASHER

CANOPYSIDE RAIL FIT

REAR BRACKETS

FRONT ASSYCANOPY HIDDEN FOR CLARITY

FITFRONT TUBE LH

FRONTTUBE LH

M6x20 HEX HEAD BOLT (3 PER SIDE)

M6 HEX NUT(1 PER SIDE)

M6 FLAT WASHER(4 PER SIDE)

M6 SPRING WASHER(3 PER SIDE)

FRONTTUBE RH

CENTRETUBE

ORIENTCENTRE TUBE

FITFRONT TUBE RH

FRONT BRACKETS

3

1

2

M6 THREADED PLATE (2 PER SIDE)

11/01/11Page 5 of 13

CP0023ROOF RACK

Diagram: 9 - ALIGN TUBE ASEMBLIES & MARK HOLES

FITREAR TUBE LH

ORIENTCENTRE TUBE

FITREAR TUBE RH

3

1

2

7.

Diagram: 7 - ASSEMBLE REAR TUBES

8.

Diagram: 8 - FIT REAR TUBES

Orient the other centre tube so the foampad on the brackets is facing up and thebrackets are pointing away from you.Slide the rear tube LH into the LH sideof the centre tube and the rear tube RHinto the RH side of the centre tube asshown. (ref. diagram7).

Fit the rear tubes into the vehicle andposition the tube brackets to the outsideof the rear brackets.Loosely secure each side with (4) M6x20hex head bolts, M6 Spring washers,M6 flat washers and (2) M6 threadedplates as shown.Rotate the centre tube so the brackets arelocated against the canopy roof as shown.Finger Tighten only, Do Not Torque.(ref. diagram8).

9. Check that the centre tube brackets are evenly positioned inside canopy roof,front and rear.Adjust the centre tube’s so they areparallel across the canopy, by measuringfrom a flat surface at the front of thecanopy, back to each bracket as shown.Recheck alignment across the vehicle andmark the centre of the (4) bracket slotsas shown. (ref. diagram9).

0mm 10 20 30 40 50 60 70 80 90

REAR ASSYCANOPY HIDDEN FOR CLARITY

VIEW FROMINSIDE

CANOPY

FRONT OF VEHICLE

ALIGNLEFT TO RIGHT

1

ALIGNFRONT TO BACK

2

B

A

C

A

B

C

REAR TUBE LH

M6x20 HEX HEAD BOLT(4 PER SIDE)

M6 THREADED PLATE (2 PER SIDE)

M6 FLAT WASHER( PER SIDE)

M6 SPRING WASHER(4 PER SIDE)

REAR TUBE RHCENTRETUBE

REAR BRACKETS

11/01/11Page 6 of 13

CP0023ROOF RACK

0mm 10 20 30 40 50 60 70 80 90

FRONT OF VEHICLE

A A

B

C C

B

VIEW FROMINSIDE

CANOPY

VIEW FROMINSIDE

CANOPY

Ø3mm

Diagram: 12 - RE-CHECK HOLE POSITIONS

0mm 10 20 30 40 50 60 70 80 90

ROTATETUBES

2

RE-CHECKHOLE ALIGNMENT POSITIONS

3

LOOSENM6 BOLTS

1

10.

Diagram: 10 - LOOSEN TUBES & RE-CHECK HOLES

11.

Diagram: 11 - PILOT DRILL HOLES

When holes are marked loosen all M6 boltsfinger tightened in steps 6 and 8, androtate centre tube down away from the roofas shown, to gain access to drill holes incanopy roof.Before drilling re-check position andalignment of all (4) hole positions marked.(ref. diagram10).

From inside the canopy carefully drill the(4) holes with Ø3mm pilot drill.(ref. diagram11).

12. IMPORTANT: Before proceeding ensureyou spend some time to recheck the(4) hole positions across the vehicleand down the length of the vehicle. This will ensure the pedestal bracketson the top of the canopy will sit in lineand parallel to the canopy and vehicle.(ref. diagram12).

11/01/11Page 7 of 13

15.

Diagram: 15 - RE-ORIENT TUBES & FIT STEEL BUSHES

CP0023ROOF RACK

Re-orient tube assembly and rotatecentre tube back up to the roof.Finger tighten all M6 bolts previouslyloosened in step 10.Fit the (4) steel bushes into the (4) Ø20mmdrilled holes. (ref. diagram15).IMPORTANT: If the steel bushes are verytight to fit, ream the holes out graduallyuntil the steel bushes are a neat fit.

REMOVETAPE LINERS

FITINTERNAL FOAM

PADS

CENTRE TUBESFRONT

REAR

1

2

FRONT OF VEHICLE

FITSTEEL BUSHES

RE-ORIENTTUBES

1

FITINTERNAL

FOAM PADS

1 14.

Diagram: 14 - APPLY FOAM PADS TO CENTRE TUBE

Remove tape liners from all (4) internalfoam pads, and fit to the centre tubebrackets as shown.(ref. diagram14).

Ø20mm1

2

VIEW FROMTOP OF

CANOPY

13.

Diagram: 13 - DRILL HOLES AND DEBURR

Carefully re-drill the (4) holes with aØ20mm hole saw. Remove all burrs and sharp edges.(ref. diagram13).

VIEW FROMINSIDE

CANOPY

CANOPY HIDDEN FOR CLARITY

2

11/01/11Page 8 of 13

16.

17.

Diagram: 17 - FIT THREADED BLOCKS TO PEDESTAL’S

18.

Diagram: 18 - REMOVE END CAPS FROM ROOF RACKS

Diagram: 16 - FIT FOAM PADS TO PEDESTAL BRACKETS

CP0023ROOF RACK

Trial fit the external foam pads A & B tothe pedestal bracket’s A & B (with the tapeliner against the bottom of the brackets).Check you have the correct gasket byensuring the holes line up.When correct, remove the tape liner fromthe foam pads and adhere to the pedestalbracket’s as shown. (ref. diagram16).(Pedestal bracket ID’s A & B are stamped on the base plate)

Loosely fit (1) M8 threaded block to eachof the (4) pedestal brackets using (1)M8x20 hex head bolt, M8 spring washerand M8 flat washer as shown.Leave Loose, Do Not tighten at this stage.(ref. diagram17).

Using keys supplied remove and retain allend caps from the roof rack extrusions asshown. (ref. diagram18).

TRIAL FITEXTERNAL FOAM

PADS A & BENSURING HOLES ALIGN

PEDESTAL BRACKET - A

PEDESTAL BRACKET

PEDESTAL BRACKET - B

1

FITEXTERNAL FOAM

PADS A & B

3

REMOVETAPE LINERS

M8 THREADEDBLOCK

M8x20mm HEXHEAD BOLT

M8 SPRINGWASHER

M8 FLATWASHER

2

REMOVEEND CAPS

ASSEMBLEDPEDESTAL BRACKET& THREADED BLOCK

11/01/11Page 9 of 13

CP0023ROOF RACK

19.

Diagram: 19 - FIT ROOF RACK EXTRUSIONS, REPLACE END CAPS

Carefully slide the M8 threaded blocks &pedestal bracket assemblies into the roofrack extrusion ensuring brackets ‘A’ and ‘B’are oriented as shown.Repeat process for the other roof rack.IMPORTANT: Take care to avoidscratching the roof rack extrusion andpedestal brackets.Replace the end caps ensuring they arelocked back in place with the keys.(ref. diagram19).3

1

2

2

20.

Diagram: 20 - FIT M10 BOLTS & APPLY SILICON

21.

Diagram: 21 - FIT PEDESTAL BRACKETS / EXTRUSIONS TO CANOPY

Complete step 20 then step 21 for the rearpedestal brackets.Then repeat the process for the frontpedestal brackets.Two people are required for this step.One person to fit and hold the M10 bolts,spring washers and flat washers from insidethe canopy.The second person to apply a bead of non-acetic silicon (not supplied) to the top of thecanopy around the M10 bolt thread, andaround the previously fitted steel bush, asshown.IMPORTANT: Ensure there is acontinuous bead of silicon all aroundthe steel bush and M10 bolt thread toprevent water entering the canopy.Ensure the silicon contacts the M10 boltthread all around.(ref. diagram20).

One person continues holding the M10 bolts,while the second person carefully positionsthe pedestal brackets and extrusion on topof the canopy aligning the holes with theM10 bolts as shown,(Bracket A to the Front RH & Rear LH side, Bracket B to the Front LH & Rear RH side).Secure each bracket to the M10 bolt witha M10 hex nut as shown.Tighten to Torque 7Nm, ensure thepedestal brackets sit parallel across thecanopy and do not rotate when tightening.(ref. diagram21).

NOT SUPPLIED

APPLYBEAD OF SILICON

AROUND STEEL BUSH

APPLYBEAD OF SILICON

AROUND M10 BOLT

FRONT OF VEHICLEVIEW FROM TOP OF CANOPY

7Nm

17mm

17mm

FITPEDESTAL BRACKETS

A

A

B

B

1

2

3

M10 FLATWASHER

M10 SPRINGWASHER

M10x40 HEXHEAD BOLT

A

AB

B

PEDESTALBRACKET

ROOF RACKEXTRUSIONM10 HEX NUT

M10 FLATWASHERS

B

11/01/11Page 10 of 13

CP0023ROOF RACK

22.

Diagram: 22 - SECURE ROOF RACKS

Measure and adjust the roof rack extrusionsso they are evenly positioned on thepedestal brackets as shown.Tighten the (4) M8 hex head bolts securingthe roof rack extrusions to the pedestalbrackets. Tighten to Torque 6Nm, ensurethe extrusion remain parallel across thecanopy and the pedestal brackets donot rotate when tightening.(ref. diagram22).

==

6Nm

13mm

13mm

24.

Diagram: 24 - PILOT DRILL TUBE ASSEMBLIES

Using the (4) holes in each of the top tubeassemblies as a guide, drill (8) Ø3mm pilotholes into the tubes as shown, through oneside only.IMPORTANT: DO NOT DRILL THROUGHBOTH SIDES OF THE TUBE.(ref. diagram24).

Ø3mm

23.

Diagram: 23 - TIGHTEN TUBE ASSY M6 BOLTS

Tighten all the M6 hex head bolts securingthe tube assemblies to the brackets.Tighten to Torque 5Nm. (ref. diagram23).

5Nm

10mm

10mm

TIGHTENALL M6 BOLTSTORQUE 5Nm

11/01/11Page 11 of 13

CP0023ROOF RACK

FittingInstructions

26.

Diagram: 26 - CLEAN VEHICLE & HANDOVER TO CUSTOMER

Clean the Tub, Canopy, Roof Racks andvehicle thoroughly ensuring all drill swarfis removed.PLACE FITTING INSTRUCTIONSIN THE CUSTOMERS LOG BOOK,AND ENSURE PAGE 12 OF THESEINSTRUCTIONS ARE DISCUSSEDWITH THE CUSTOMER AND A COPYGIVEN TO THE CUSTOMER.(ref. diagram26).

3/8”

FIT14G TEK SCREWS

25.

Diagram: 25 - SECURE TUBE ASSEMBLIES TOGETHER

Using the Ø3mm pilot holes as a guidesecure the tube assemblies with (8)14G tek screws as shown. (ref. diagram25).

WARNING! - SAFETY!• Total Load to be carried on EGR Roof Rack system is 150Kg Maximum.• Loads must be distributed as evenly as possible across EGR Roof Rack system, and the loads centre of gravity to be kept as low as possible. Narrow and Heavy loads (example: metal tubes) must be positioned over or near the Roof Rack Mounting Brackets attached to the vehicle roof. • Loads that over-hang the ends of the Roof Racks must conform to any relevant laws and must be adequately secured.• All loads must be firmly and independently secured, to both Front and Rear Roof Rack Extrusions.• Loads must be secured using suitable straps or similar tightening devices.• After loading, recheck the security of the load and Roof Racks reguarly throughout the journey.• Elastic straps with securing hooks must not be used.• Where surfboards are carried (or similar items that may produce high lifting forces), they must not be carried side by side, but stacked one upon the other and secured independently to Front and Rear Roof Rack Extrusions using straps or other methods capable of with-standing the lifting forces.• Where specialised accessories are available to carry or secure loads (example bicycle carriers), it is recommended that are used, and must be installed correctly.• The handling characteristics of a vehicle will change when a carrier system (Roof Racks) is fitted, and especially when it is loaded (in particular cross wind sensitivity, handling on bends and braking). Driving techniques should be altered to allow for these changes, reducing speed especially on bends, and allow for longer braking distances.

Maintenance• Only use mild detergents or wax polish.• Do Not use abrasive compounds on painted or plastic finished Roof Rack surfaces.• Roof Racks and any accessories, straps or other tightening devices must be maintained and kept in good working order.• Reguarly check and tighten Roof Rack attachment hardware to specified values, (if required).• If Roof racks are removed, all bolts must be re-tightened on refitting to specified values.

Warranty TermsEGR warrants that the Roof Racks will be free from defects in material and workmanship for a period of three (3) years 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 Roof Racks is sole responsibility ofthe vehicle owner and operator.Our products are sold as Roof Rack Systems and not a Roll Bar. In the event of a collision or rollover, the vehicle and any persons or objects travellingin the rear of the vehicle will not be protected by this product. The manufacturer assumes no liability for injury, loss, incidental or consequential damagesin the event of a collision or rollover.DisclaimerIn the event that your EGR Roof Racks are found to be defective under the terms of this warranty, it is at the discretion of EGR to repair or replacethe defective part. Transportation costs and labour are not associated with this warranty claim.

(Subject to vehicle manufacturer’s recommendations)

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

VEHICLE SERVICE BOOK.

11/01/11Page 12 of 13

CP0023ROOF RACK

Dealer Name:

Model:

Order Date:

Required By:

Canopy Colour

Roof Rack Checklist - Details of rectifications required: KEY No. :

Vehicle Damage Check: Detail:

Dealer Code:

Stock No:

Order No:

Vin No:

1. Cleanliness of vehicle,canopy & roof racks

2. Silicon applied to top of canopy around bush spacer & M10 Bolt Thread

3. EPDM foam tape pads adhered to internal and external brackets

4. All end caps locked onto roof rack extrusions with the keys supplied

5. Roof rack end cap keys handed over to the Customer

6. Roof Racks positioned evenly on the vehicle.

7. All M6 Bolts tightened to Torque 5Nm



10. Clean up of work area

11. Comment

Record Roof Rack Serial Number: Checked By:

Vehicle Type:

Vehicle received and Checked by Dealer Staff:

Fitted By:

INSTALLATION CHECKLIST

CP0023ROOF RACK

11/01/11Page 13 of 13

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ROOF RACK CP0023 INSTALLATION … · page 2 of 13 11/01/11 parts check sheet egr roof racks parts in main carton parts in hardware kit parts in roof rack kit cp0023 roof rack front