Kargo Master 4A96M User manual

Kargo Master
Rancho Cordova, CA 95742
800-343-7486
[e-mail]
20191112R1 DATE: __________________
Installation Guide
4A96M

Instructions –4A96M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 1
*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
9/16” Wrench and Socket
7/16” Wrench and Socket
Table of Contents
Parts List............................................................................................................................................................ 2
Hardware .......................................................................................................................................................... 4
Step 1 ─Remove Load Plates and Install Bumpers........................................................................................... 6
Step 2 ─Assemble Front Bow Mechanism ....................................................................................................... 7
Step 3 –Install Front Wheels ............................................................................................................................ 7
Step 4 –Install Front Bow ................................................................................................................................. 8
Step 5 –Install Damper Mount....................................................................................................................... 10
Step 6 –Install Damper Assembly .................................................................................................................. 11
Step 7 –Install Rear Wheels ........................................................................................................................... 13
Step 8 –Install Rear Pan ................................................................................................................................. 13
Step 9 –Install Torque Tube ........................................................................................................................... 15
Step 10 –Install End Tube............................................................................................................................... 17
Step 11 –Install Ladder Clamps and Stops ..................................................................................................... 18
Step 12 –Install Ladder Hooks........................................................................................................................ 20
Step 13 –Attach Dampers .............................................................................................................................. 20
Before You Begin
•Read all instructions.
•Have ladder rack installed on vehicle.
•Place sealant around all swage connections.
•DO NOT EXCEED MANUFACTURERS WEIGHT CAPACITY FOR ROOF.
•BE SURE TO ADJUST LADDER CLAMPS ACCORDINGLY TO FIRMLY SECURE LADDER TO RACK.
•KEEP THE ADJUSTMENT GUIDE IN VEHICLE AT ALL TIMES.

Instructions –4A96M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 2
Parts List

Instructions –4A96M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 3

Instructions –4A96M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 4
Hardware

Instructions –4A96M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 5

Instructions –4A96M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 6
Step 1 ─Remove Load Plates and Install Bumpers
•If installed, at the end of each bow, opposite from the pan mechanism, remove the load
plates as shown.
•Push the rubber bumper into the larger round hole in the location shown.
•Repeat on both bows.

Instructions –4A96M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 7
Step 2 ─Assemble Front Bow Mechanism
•On the underside of the front bow, install the front torque tube assembly using the pre-
assembled 3/8” hardware in the location shown.
Step 3 –Install Front Wheels
•Slide the axle into the end of the front bow.
•Place a nylon washer and a wheel on each end of the axle as shown.
•While installing the pan, be sure the wheels stay in position.

Instructions –4A96M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 8
Step 4 –Install Front Bow
•Remove the hardware from the arms in the pan.
•Rotate the pan and place over the previously installed wheels. Position the pan so it is
parallel with the bow.

Instructions –4A96M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 9
•Place the arms around the tube from the front bow mechanism. Replace the hardware to
attach the pan to the front bow mechanism.

Instructions –4A96M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 10
Step 5 –Install Damper Mount
•On the underside of the rear bow, install the damper mount in the location and
orientation shown using the pre-assembled 3/8” hardware.

Instructions –4A96M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 11
Step 6 –Install Damper Assembly
•Along the rear bow, install the damper assembly using the pre-assembled 3/8” hardware
in the location shown.

Instructions –4A96M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 12
•Attach the damper cantilever mechanism to the bow using the pre-assembled hardware
as shown. Be sure to keep the nylon washers in the correct locations. One goes in
between the two damper mounts and one in between each damper mount and the bow.
(picture shown below is without the bow)

Instructions –4A96M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 13
Step 7 –Install Rear Wheels
•Slide the axle into the end of the rear bow.
•Place a nylon washer and a wheel on each end of the axle as shown.
•While installing the pan, be sure the wheels stay in position.
Step 8 –Install Rear Pan
•Remove the hardware from the arms in the pan.
•Rotate the pan and place over the previously installed wheels. Position the pan so it is
parallel with the bow.

Instructions –4A96M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 14
•Place the arms around the tube from the front bow mechanism.
•Insert handle assembly into the rear of the damper mechanism.
•Replace the hardware to attach the pan and handle assembly to the rear bow
mechanism.

Instructions –4A96M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 15
Step 9 –Install Torque Tube
•Look at the passenger side of the rack. Notice if the extension on the torque tube is being
used.
•If the extension is needed, assemble the extension to the torque tube the same way the
torque tube attaches to the bows.
•If the extension is NOT needed, use only the torque tube as shown below.

Instructions –4A96M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 16
•Bolt the torque tube to the front and the 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 the extension is used, bolt
together using the same method.

Instructions –4A96M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 17
Step 10 –Install End Tube
•Attach the end tube to the end of both bows using 3/8” x 3/4” hex head bolts, 3/8” split
lock washers and 3/8” flat washers in the orientation shown.
•Repeat at the end of both bows.
Front Bow Shown Below

Instructions –4A96M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 18
Step 11 –Install Ladder Clamps and Stops
•Determine the location the ladder bow and stop will need to be installed.
Location of ladder clamps and stops for standard extension ladders shown below.
(Both towards the end of the bow)
Location of ladder clamps and stops for standard step ladders shown below.
(Front bow in the low position, rear bow in the upper position)

Instructions –4A96M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 19
•On the front bow, position the ladder stop in the desired location.
•Bolt the ladder stop in place using a 3/8” x 1” hex head bolt, two 3/8” flat washer and a
3/8” nyloc nut in the orientation shown. Be sure the slot of the ladder stop aligns with
the slot in the bow.
•Place the ladder hook base around the threaded studs near the ladder stop and attach
using 5/16” flat washers and 5/16” nyloc nuts.
•On the rear bow, position the ladder stop in the desired location.
•Bolt the ladder stop in place using 3/8” x 1” hex head bolt, 3/8” split lock washer and a
3/8” flat washer in the orientation shown. Be sure the slot of the ladder stop aligns with
the slot in the bow.
•Place the ladder hook base around the threaded studs near the ladder stop and attach
using 5/16” flat washers and 5/16” nyloc nuts.