Kargo Master 4A96L User manual

Installation Guide
4A96L
Kargo Master
Rancho Cordova, CA 95742
800-343-7486
[e-mail]
DATE: ______________

For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 1
Installation Instructions –4A96L
*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
1/2”Wrench and Socket
3/8” Wrench and Socket
9/16” Wrench and Socket
7/16” Wrench and Socket
Table of Contents
Parts List .................................................................................................................................. 2-3
Hardware List .......................................................................................................................... 4-5
Step 1 Remove Load Plates ........................................................................................................ 6
Step 2 Install Latch Assembly ..................................................................................................... 6
Step 3 Install Rear Bow Damper Mount ..................................................................................... 7
Step 4 Install Rear Bow Damper Mechanism .............................................................................. 8
Step 5 Install Dampers ................................................................................................................ 9
Step 6 Wheel Assembly (Rear bow) .......................................................................................... 10
Step 7 Install Rear Pan .............................................................................................................. 11
Step 8 Install Front Pan Mechanism ......................................................................................... 12
Step 9 Wheel Assembly (Front bow) ........................................................................................ 13
Step 10 Remove Bolts ............................................................................................................... 13
Step 11 Install Front Pan .......................................................................................................... 14
Step 12 Install Front Bow Ladder Stop...................................................................................... 15
Step 13 Determine if EXT is needed ......................................................................................... 15
Step 14 Attach Torque Tube .................................................................................................... 16
Step 15 Install End Tube............................................................................................................ 17
Step 16 Assemble Ladder Hook ................................................................................................ 18
Step 17 Install Ladder Hook ...................................................................................................... 18
Step 18 Install Handle ............................................................................................................... 19
Before You Begin
•Read all instructions.
•Have Rack installed on vehicle. This is a Driver Side drop down addition.

For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 2
Installation Instructions –4A96L
Parts

For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 3
Installation Instructions –4A96L
Parts Con’t

For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 4
Installation Instructions –4A96L
Hardware 1 of 2

For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 5
Installation Instructions –4A96L
Hardware 2 of 2

For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 6
Installation Instructions –4A96L
Step 1 –Load Plates
•If installed, remove load plates at the end of each bow,
opposite from the passenger side pan mechanism.
•Repeat on both bows.
Step 2 –Install Latch Assembly
•At the end of the rear bow, mount latch assembly in the
squares shown.
•Use the 3rd set of square holes from the end of the bow.
•Mount using two 5/16” x 1” carriage bolts, two 5/16” flat
washers and two 5/16” nyloc nuts.

For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 7
Installation Instructions –4A96L
Step 3 –Rear Bow Damper Mount
•Mount damper mount to the under side of the rear bow in the location shown.
•Mount the ladder stop on the top side of bow.
•When installing the ladder stop, be sure to use the longer, 3/8” x 1” hex head bolt. Use
3/8” lock washer and 3/8” flat washer.
•At the other location, fasten using 3/8” x 3/4” hex head bolt, 3/8” lock washer and 3/8” flat
washer.
•Snug Tighten, but allow movement.

For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 8
Installation Instructions –4A96L
Step 4 –Install Rear Bow Damper Mechanism
•Mount damper mechanism to the under side of the rear bow in the location shown.
•Use the exisiting hardware found in the damper mechanism to mount.
•While using the 3/8” x 4-1/2” hex head bolt. Be sure to not lose the pre-assembled nylon
washers.
•Snug Tighten, but allow movement.

For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 9
Installation Instructions –4A96L
Step 5 –Install Dampers
•Install dampers in orientation shown.
•Install the end of damper to the damper mount using 2-1/4” pin, cotter pin and plastic
spacer in orientation shown. The plastic spacer goes in between two dampers.
•In some situations, one may need to wait until handle assembly is installed to attach both
sides of the dampers. This is so you can use the handle to help adjust the damper.
•Use cotter pin to ensure dampers stay in place.
•Shown without crossmember for clarity.

For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 10
Installation Instructions –4A96L
Step 6 –Wheel Assembly
•Install wheel assembly. Slide wheel axle in the end of the rear bow. Place a wheel on each
end of the axle. Cap the wheel with wheel stopper.
**While placing the pan on the next step, Be sure the wheel caps DO NOT come off**

For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 11
Installation Instructions –4A96L
Step 7 –Install Rear Pan
•Remove hardware from the installed damper
mechanism from step 4.
•Place rear pan on top of wheels and bow. Be sure the wheel caps DID NOT come off.
•Align the arms from the pan with the holes in the damper mechanism where the bolts were
previously removed.
•Bolt together using hardware that was removed, only mount the front two bolts, leaving
the holes to the rear as shown empty. The empty holes is for the handle installation.
•Snug Tighten, but allow movement.

For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 12
Installation Instructions –4A96L
Step 8 –Install Front Pan Mechanism
•Mount mechanism to the under side of the front bow in the location shown. This is the
mechanism that DOES NOT have the dampers.
•Use the exisiting hardware found in the mechanism to mount.
•Snug Tighten, but allow movement.

For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 13
Installation Instructions –4A96L
Step 9 –Wheel Assembly
•Install wheel
assembly. Slide
wheel axle in the
end of the front
bow. Place a wheel
on each end of the
axle. Cap the wheel
with wheel stopper.
**While placing the pan on the next step, Be sure the wheel caps DO NOT come off**
Step 10 –Remove Bolts
•Remove hardware from the
previously installed mechanism
from step 8.

For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 14
Installation Instructions –4A96L
Step 11 –Install Front Pan
•Place front pan on top of wheels and bow. Be sure the wheel caps DID NOT come off.
•Align the arms from the pan with the holes from the mechanism where the bolts were
previously removed.
•Bolt together using hardware that was removed.
•Snug Tighten, but allow movement.

For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 15
Installation Instructions –4A96L
Step 12 –Front Bow Ladder Stop
•Bolt ladder hook to the front bow in the orientation shown.
•Be sure to have the flange of the hook line up with the slot
on the bow.
•TIGHTEN
Step 13 –Determine if EXT is needed
•Determine if EXT will be needed. Look at the passenger side of rack.

For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 16
Installation Instructions –4A96L
Step 14 –Attach 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.
•If EXT is needed, follow same instructions to attach torque tube to EXT.
•TIGHTEN
**These pictures show using the EXT**

For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 17
Installation Instructions –4A96L
Step 15 –Install End Tube
•Assemble end tube and place at the end of each bow.
•Bolt into place using 3/8”x 3/4" hex head, 3/8”lock washer and 3/8”flat washer.
•Repeat at front and rear bow.
•TIGHTEN

For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 18
Installation Instructions –4A96L
Step 16 –Assemble Ladder Hooks
•Bolt ladder hook ASM to ladder hook weldment as shown.
•Use 1/4" x 3/4" hex head and 1/4" flat washer. This can be adjusted later.
Step 17 –Install Ladder Hooks
•Using the hardware and installed studs on the bows, loosen the nuts and slide ladder hook
into place. Be sure the washers are on the outside of the ladder hook.
•TIGHTEN

For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 19
Installation Instructions –4A96L
Step 18 –Install Handle
•Using the hardware
removed in step 4, insert
handle into swage on the
rear bow.
•Be sure to place BH-821
sealant along swage joint.
•TIGHTEN