Kargo Master 4A95L User manual

Installation Guide
4A95L
Kargo Master
Rancho Cordova, CA 95742
800-343-7486
[e-mail]
DATE: ______________

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Installation Instructions –4A95L
*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
7/16”Wrench and Socket
3/8” Wrench and Socket
1/2” Wrench and Socket
9/16” Wrench and Socket
Tape Measure
Table of Contents
Parts List .................................................................................................................................. 2-3
Hardware List ............................................................................................................................. 4
Step 1 Determine Bows .............................................................................................................. 5
Step 2 Pan Mount ....................................................................................................................... 6
Step 3 Determine if EXT is needed ............................................................................................. 6
Step 4 Install Torque Tube ......................................................................................................... 7
Step 5 Install Cross Tube ............................................................................................................ 8
Step 6 Install Latch ..................................................................................................................... 9
Step 7 Install Handle ................................................................................................................. 10
Step 8 Install Ladder Stops ....................................................................................................... 11
Step 9 Assemble Ladder Hooks ................................................................................................ 12
Step 10 Install Ladder Hooks .................................................................................................... 12
Before You Begin
•Read all instructions.
•Have mount kit installed on vehicle.
•NEVER EXCEED MANUFACTURERS ROOF WEIGHT RATING.
•Place BH-821 around all tube connections to ensure water does not get inside of rack.

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Installation Instructions –4A95L
Parts

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Installation Instructions –4A95L
Parts Continued
HARDWARE

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Installation Instructions –4A95L
HARDWARE

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Installation Instructions –4A95L
Step 1 –Determine Bows
•Determine front and rear bow. The triangular piece should be facing eachother on each
bow.
Front Bow
Rear Bow

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Installation Instructions –4A95L
Step 2 –Pan Mount
•Be sure mount kit is installed on vehicle.
•Set front and rear bow asm on mounting feet as shown.
•Place a foam block from the packaging to hold the bow in the up position in order to
access the mounting slots.
•Leave loose until the the rack is assembled.
•Repeat on both ends of bow.
**Feet and bow design vaires from rack to rack. The installation is the same.**
Step 3 –Determine if Extension is Needed
•Measure between the two bows as shown. If distance is approximately 84.5”, the
extension will be needed.
•If the distance between the two bows is approximately 60”, the EXT piece is not needed.

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Installation Instructions –4A95L
Step 4 –Install Torque Tube
•If EXT is needed, Assemble EXT to long torque tube.
•If EXT is not needed, Only use long torque tube.
•Bolt torque tube to front and rear bow using 1/4"-20 x 1” Hex Head bolt, two 1/4" flat
washers and 1/4"-20 nyloc nut at each location.

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Installation Instructions –4A95L
Step 5 –Install Cross Tube
•Insert crosstube as
shown. Bolt to the end of
both pans using 3/8” x
3/4" Hex Head bolts,
3/8” flat washers and
3/8”nyloc nuts.
•Repeat at front and rear
on the ends of both bows.
•BE SURE TO USE THE 3/4" long bolts.
TIGHTEN

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Installation Instructions –4A95L
Step 6 –Install Latch
•Move rear pan assembly out of the way to expose the end of the crossmember.
•Bolt latch assembly to end of crossmember using 5/16” x 1" carriage bolts, 5/16” flat
washers and 5/16”nyloc nuts.
•Shown without pan for clarity.
•Repeat on both ends of rear
bow.
•TIGHTEN

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Installation Instructions –4A95L
Step 7 –Install Handle
•Place handle in orientaion
shown. Attach handle to the
rear pan using existing 5/16”
hardware.
•Repeat at both ends of rear
bow.
•Place BH-821 around tube
connection.
•TIGHTEN

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Installation Instructions –4A95L
Step 8 –Ladder Stop
•Attach ladder
stop to both
front and rear
bow. Be sure
the flange of
the ladder stop
is aligned with
the cut out in
the bows.
•In the front
bow, bolt in
place using
3/8” x 1" hex
head bolt, two
3/8” flat
washers and a
3/8” nyloc nut.
•In the rear
bow, bolt in
place using
3/8” x 1" hex
head bolt and a
3/8” flat
washer.
**Be sure to
use the longer
of the 3/8” hex
head bolts**
•Repeat at both
sides of each
bow.
•TIGHTEN

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Installation Instructions –4A95L
Step 9 –Assemble Ladder Hooks
•Bolt ladder hook
ASM to ladder
hook weldment
as shown.
•Use 1/4" x 1" hex
head and 1/4" flat
washer. This can
be adjusted later.
•TIGHTEN
Step 10 –Install Ladder Hooks
•Using the hardware and
installed pem studs on
both bows, loosen nuts
and slide ladder hook
assembly into place.
•TIGHTEN

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Installation Instructions –4A95L
GO BACK AND TIGHTEN ALL BOLTS FROM PREVIOUS STEPS, BE SURE
HARDWARE IN MOUNTING IS TIGHT.
YOUR INSTALLATION IS NOW COMPLETE