Kargo Master 4A873 Manual

Instruction Guide
4A873
Kargo Master
Rancho Cordova, CA 95742
800-343-7486
[e-mail]
DATE: ______________

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Instructions –4A873
*PLEASE READ ALL INSTRUCTIONS AND WARNINGS PRIOR TO ASSEMBLING,
INSTALLING, AND USING THIS PRODUCT*
Warning
Always check for wires, fuel tanks and lines, brake lines and other important vehicle
functionality items prior to drilling and installing all products.
Tools Needed
13mm Socket and Wrench
10mm Socket and Wrench
5mm Allen Hex
5/32” Allen Hex
7/16” Socket and Wrench
1/2” Socket and Wrench
9/16" Socket and Wrench
Table of Contents
Parts List ................................................................................................................................... 2
Assembly Hardware .............................................................................................................. 3-4
Install Hardware ....................................................................................................................... 5
Roof Rail Mounting
Promaster City ....................................................................................................................... 6
NV200/City Express ............................................................................................................... 7
Transit Connect ..................................................................................................................... 8
Rack Assembly
Step 1 –Assembly of Foot ..................................................................................................... 9
Step 2 –Ladder Stops ............................................................................................................ 9
Step 3 –Mount to Rails ....................................................................................................... 10
Step 4 –Assemble Side Tube ............................................................................................... 10
Step 5 –Mount Side Tube ................................................................................................... 11
Step 6 –Clamp Tube ............................................................................................................ 12
Step 7 –Handle ................................................................................................................... 13
Step 8 –Latch Assembly ...................................................................................................... 14
Step 9 –Ladder Hook .......................................................................................................... 14
Step 10 –Ladder Hook to Bracket ....................................................................................... 15
Step 11 –Ladder Hook Bracket to Bow ............................................................................... 15
Before You Begin
•Read all instructions. Find your vehicle roof rail mounting prior to rack assembly.
•Be sure to put E6000 sealant around all threads entering cargo area and between the
rubber spacer and roof of vehicle to prevent water from leaking into cargo area.
•DO NOT EXCEED MANUFACTURERS WEIGHT CAPACITY FOR ROOF

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Instructions –4A873
Parts

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Instructions –4A873
Assembly Hardware

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Instructions –4A873
Assembly Hardware (con’t)

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Instructions –4A873
Installation Hardware

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Instructions –4A873
DO NOT EXCEED MANUFACTURERS WEIGHT CAPACITY FOR ROOF
Promaster City Installation
•Locate 6 mounting locations
shown on roof of van.
•Install “Top Rail” as shown using
M6x20mm bolts with lock
washers and flat washers.
•Be sure to put rubber washer
between the “Top Rail” and the roof to ensure sealing.
•Place E6000 on and around threads to seal roof. (Passenger side shown)
Front EXP
Mid EXP
Rear EXP
Front Tighten
Mid Tighten
Rear Tighten

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Instructions –4A873
DO NOT EXCEED MANUFACTURERS WEIGHT CAPACITY FOR ROOF
NV200/City Express Installation
•Locate 4 mounting locations
shown on roof of van.
•Install “Top Rail” as shown using
M8x25mm bolts with lock
washers and flat washers.
•Mount rail so there is about 1”
from the rear door opening.
•Be sure to put rubber washer between the “Top Rail” and the roof to ensure sealing.
•Place E6000 on and around threads to seal roof. (Passenger side shown)
Front EXP
Rear EXP
Front Tighten
Rear Tighten

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Instructions –4A873
DO NOT EXCEED MANUFACTURERS WEIGHT CAPACITY FOR ROOF
Transit Connect Installation
•Locate 4 mounting locations
shown on roof of van.
•Be sure to put rubber washer
between the “Top Rail” and the
roof to ensure sealing.
•Mount rail so there is about 1”
from the rear door opening.
•Install “Top Rail” as shown using M8x25mm bolts and flat washers on the outside. Use the
fender washer and nylock nut on the inside of the van.
•Place E6000 on and around threads to seal roof. (Passenger side shown)
Front EXP
Rear EXP
Front Tighten
Rear Tighten

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Instructions –4A873
Assembly Instructions
Step 1 –Assembly of Foot
•Measure width between previously installed rails.
•On the cross bows, use the slots that correspond to the measured distance between rails.
•Bolt feet to bows as shown, DO NOT TIGHTEN at this point.
•Feet can be installed as shown or reverse depending on how you mounted the rail.
•Use a 3/8" x .75" hex head bolt, 3/8" lock washers and a 3/8" flat washer to bolt foot to
crossmember.
Step 2 –Ladder Stops
•Bolt ladder hooks to one end of each bow.
•Use a 5/16” carriage bolt, 5/16” washers
and a 5/16” nylock.
•TIGHTEN

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Instructions –4A873
Step 3 –Mount to Rails
•Place both bows on top of installed rails.
•Have the ladder hooks on the driver side of vehicle.
•Snug Tighten, but allow movement
Step 4 –Assemble Side Tube
•Bolt side bar to side support bar using .25 x 1.5 button head, .25 washer and a .25 nylock.
•Place some E6000 in and around the connection.
•TIGHTEN

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Instructions –4A873
Step 5 –Mount Side Tube
•Place side tube on top of installed bows.
•Have the bend towards the front of the vehicle as shown.
•Mount rotation bar plate to tube as shown.
•Leave one square slot open at the rear.
•Bolt together using 5/16 x 1.75 carriage bolt, a 5/16 flat washer and a 5/16 nylock.
•Insert tube caps in both ends of the tube.
•Snug Tighten, but allow movement

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Instructions –4A873
Step 6 –Clamp Tube
•Place clamp and lock L bracket on top of installed bows.
•Insert plastic bushings into the clamp and lock L bracket and the rotation bar plate installed in
Step 5, with flange towards each other and to the inside as shown.
•Insert clamp tube into both plastic bushings.

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Instructions –4A873
•Bolt clamp and lock L bracket to bows using 3/8 x 1 carriage bolt, 3/8 flat washer and a 3/8
nylock as shown. (This view shown without clamp tube)
•TIGHTEN
Step 7 –Handle
•Bolt handle to clamp tube using a 5/16 x 2.75 hex head, two 5/16” flat washers, 5/16 nylon
washer and 5/16 a nylock. The nylon washer goes in between the clamp tube and handle.
•TIGHTEN

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Instructions –4A873
Step 8 –Latch Assembly
•Bolt latch to the rear of the mount tube that was installed in Step 5 using 5/16 x 1.75 carriage
bolt, 5/16 curved washer and a 5/16 nylock.
•TIGHTEN
Step 9 –Ladder Hook
•Bolt ladder hook to the clamp tube in the orientation shown using a 3/8 flat washer and a 3/8
nylock.
•Snug Tighten, but allow movement.
•Final location will be determined once ladder is placed on rack.

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Instructions –4A873
Step 10 –Ladder Hook to Bracket
•Bolt ladder hook to the ladder hook bracket in the orientation shown using a 3/8 flat washer
and a 3/8 nylock.
•Snug Tighten, but allow movement.
•Final location will be determined once ladder is placed on rack.
Step 11 –Ladder Hook Bracket to Bow
•Bolt ladder hook bracket to
the bow in the orientation
shown using a 3/8 x 1
carriage bolt, a 3/8 flat
washer and a 3/8 nylock.
Be sure the bracket is
square to the bow.
•TIGHTEN
GO BACK AND ENSURE ALL HARDWARE IS TIGHT
Your installation is now complete.