Kargo Master 40983 User manual

40983 Parts List
Front Torque Tube Pivot Assy. Rear Torque Tube Pivot Assy.
Front Ladder Pan Assy. (1) Rear Ladder Pan Assy. (1)
Ladder Hook(2) Ladder Stop(2) Dampener Mnt Brkt(2) Roller(4) Axle(2) Dampener(2)
Torque Tube (1)
Ladder Pan Stiffener (1)
Handle Assy. (1) Handle Removable(1) _
1

40983 Installation Instructions
Step 1
Bolt “Dampener mounting bracket” underneath the crossbow (both front and rear) as shown below using 3/8”x3/4 Bolts with flat and lock washers.
Step 2
Bolt “Torque tube pivot Assy.” underneath the crossbow (both front and rear) as shown below using 3/8”x3/4 Bolts with flat and lock washers. Be sure to
have the 3 hole flanges facing each other (rear bow shown). You may need to detach the feet and lift the crossbow slightly to get into place.
Step 3
Attach the “Torque Tube” between the flanged plates on the “Torque Tube pivot Assy.” Using ¼”x7/8” bolts as shown below. Be sure the “Torque Tube
pivot Assy.” Are lined up prior to bolting them together. You can now re-attach the feet.
2

Step 4
Next attach the “Dampener” to the front and rear bow assembly. Make sure the “Torque Tube Pivot Assy.” is rotated so the cam is pointed
towards the center of the van. Attach the shaft end of the “Dampener” to the cam using the 5/16” pin, make sure the cotter pin is secure.
Now attach the body end to the “Dampener mounting Bracket” using the 5/16”x2 1/4” pin.
Step 5
Next install the “Axles” and “Rollers” at the end of both front and rear crossbow. The “Axle” just slides in and the “Rollers” slide
over the ends of the “Axle” as shown below. NOTE: There is NO latch on the “40983” like shown in this diagram.
3

Step 6
Next install the “Ladder Pan Assy.” Align cutouts in “Ladder Pan Assy.” with the “Rollers” and guide the arms onto the “Torque
Tube Pivot Assy.” As you lower the assembly onto the rollers. Insert 5/16”x 2” bolts with flat washer and nylock nuts through
arms and “Torque Tube Assy.” Make sure the “Rear Ladder Pan Assy.” is on the rear crossbow.
4

Step 7
Install handle assembly, use E6000 on 5/16”x 2” bolts to keep water out of the tube. Be sure handle will clear the back of the
van.
5

Step 8
Next attach the “Ladder Hooks” and “Ladder Stops”. Attach "Ladder Hooks" to ladder pans on 5/16” studs in desired location.
Attach "Ladder Stops" to coincide with "Ladder Hooks" by removing 3/8”x3/4” bolt and placing stop so the tab on the stop goes
into the corresponding slot. The first 4 pictures show the front hooks, the next 4 show the rear hook set in the “step ladder”
location. If you are using an extension ladder use the same location as the front bow.
6

Rear bow location for step ladder.
7

Step 9
Attach ladder pan stiffener, in the closed position, using 5/16”x5/8” bolts with lock and flat washers. Confirm that distance
between passenger side feet and driver side feet are still EXACTLY the same. Now you can tighten the feet for the front and rear
bow assembly. The installation is complete.
8

1


40983PartsList
  
FrontTorqueTubePivotAssy.RearTorqueTubePivotAssy.

FrontLadderPanAssy.(1)RearLadderPanAssy.(1)
     
LadderHook(2)LadderStop(2)DampenerMntBrkt(2)Roller(4)Axle(2)Dampener(2)


TorqueTube(1)

LadderPanStiffener(1)

HandleAssy.(1)

Tools Needed
8' Tape Measure 1/4" End Wrench
1/4" Socket 5/16" End Wrench
5/16" Socket Hamme
r
Hardware Pack
(b)
Qty 8 -
5/16" Flat Washer
( c)
Qty 4 -
5/16" Lock Washer
(d)
Qty 4 -
5/16"-18 Nyloc Nut
(e)
Qty 4 -
5/16"-18 x 5/8" Hex Bolt
(j)
Qty 6 -
1/4"-20 x 7/8" Fully Threaded Hex Bolt
(k)
Qty 12 -
1/4" Flat Washer
(l)
Qty 6 -
1/4"-20 Nyloc Nut
(m)
Qty 1-
E6000
(n)
Qty 4-
3/8" Nylon Washer
(p)
Qty 4
Nylon Spacer
40983 Harware List
For TECHNICAL SUPPORT Call: 800-343-7486 Monday - Friday 7:00 A.M. to 4:00 P.M (PST)

2



40983InstallationInstructions
Step1
Bolt“Dampenermountingbracket”underneaththecrossbow(bothfrontandrear)asshownbelowusing3/8”x3/4Boltswithflatandlockwashers.

Step2
Only“RearTorquetubepivotAssy.”underneaththerearcrossbowasshownbelowusing3/8”x3/4Boltswithflatandlockwashers.Besuretohavethe3
holeflangesfacingeachother(rearbowshown).Youmayneedtodetachthefeetandliftthecrossbowslightlytogetintoplace.


Step3
“FrontTorquetubepivotAssy.”underneaththefrontcrossbowasshownbelowusing3/8”x3/4Boltswithflatandlockwashers.Next
attach theBarlinkageendtothebowusingthe3/8”x4.5”HexHeadBoltwithflatwashersandnylonwasherinbetweenthebowandthe
barlinkage.Besuretohavethe3holeflangesfacingeachother(frontbowshown).Youmayneedtodetachthefeetandliftthecrossbow
slightlytogetintoplace.


3




Step4
Attachthe“TorqueTube”betweentheflangedplatesonthe“TorqueTubepivotAssy.”Using¼”x7/8”boltsasshownbelow.Besurethe“TorqueTube
pivotAssy.”Arelineduppriortoboltingthemtogether.Youcannowre‐attachthefeet. 









(
j
)

(
k
)

(
l
)

NylonSpacer
BetweenBarLinkage

4

Step5
Nextattachthe“Dampener”totherearbowassembly.Makesurethe“TorqueTubePivotAssy.”isrotatedsothecamispointedtowards
thecenterofthevan.Attachtheshaftendofthe“Dampener”tothecamusingthe5/16”pin,makesurethecotterpinissecure.Now
attachthebodyendtothe“DampenermountingBracket”usingthe5/16”x21/4”pin,sandwichthenylonspacer(p)tosecurethe
dampenerinthemiddleofthebracket.

Step6
Attachtheshaftendofthe“Dampener”tothecamusingthe5/16”pin,makesurethecotterpinissecure.Nowattachthebodyendofthe
dampenertothe“DampenermountingBracket”usingthe5/16”x21/4”pin,makesurethecotterpinissecure.


REARVIEW
NylonSpacer
Dampener

5

Step6
Nextinstallthe“Axles”and“Rollers”attheendofbothfrontandrearcrossbow.The“Axle”justslidesinandthe“Rollers”slide
overtheendsofthe“Axle”asshownbelow.NOTE:ThereisNOlatchonthe“40983”likeshowninthisdiagram.

6

Step7
Nextinstallthe“LadderPanAssy.”Aligncutoutsin“LadderPanAssy.”withthe“Rollers”andguidethearmsontothe“Torque
TubePivotAssy.”Asyoulowertheassemblyontotherollers.Insert5/16”x2”boltswithflatwasherandnylocknutsthrough
armsand“TorqueTubeAssy.”Makesurethe“RearLadderPanAssy.”isontherearcrossbow.


(
n
)

(
n
)


6


Step8
Installhandleassembly,useE6000on5/16”x2”boltstokeepwateroutofthetube.Besurehandlewillclearthebackofthevan.



7

Step9
Nextattachthe“LadderHooks”and“LadderStops”.Attach"LadderHooks"toladderpanson5/16”studsindesiredlocation.
Attach"LadderStops"tocoincidewith"LadderHooks"byremoving3/8”x3/4”boltandplacingstopsothetabonthestopgoes
intothecorrespondingslot.Thefirst4picturesshowthefronthooks,thenext4showtherearhooksetinthe“stepladder”
location.Ifyouareusinganextensionladderusethesamelocationasthefrontbow.








8

Rearbowlocationforstepladder.











9

Step10
Attachladderpanstiffener,intheclosedposition,using5/16”x5/8”bolts(e)withlockwashers(c)andflatwashers(b).Confirm
thatdistancebetweenpassengersidefeetanddriversidefeetarestillEXACTLYthesame.Nowyoucantightenthefeetforthe
frontandrearbowassembly.Theinstallationiscomplete.