Kargo Master 4A98L-Rev 1 User manual

Installation Guide
4A98L-Rev 1
Kargo Master
Rancho Cordova, CA 95742
800-343-7486
[e-mail]
DATE: ______________

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Installation Instructions –4A98L
*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 Mechanism ............................................................................. 7
Step 4 Install Dampers ................................................................................................................ 8
Step 5 Install Rear Wheels........................................................................................................... 9
Step 6 Install Rear Pan .............................................................................................................. 10
Step 7 Install Front Mechanism ................................................................................................ 11
Step 8 Install Front Wheels ....................................................................................................... 12
Step 9 Remove Bolts ................................................................................................................. 12
Step 10 Install Front Pan .......................................................................................................... 13
Step 11 Attach Torque Tube ..................................................................................................... 14
Step 12 Install End Tube............................................................................................................ 15
Step 13 Attach Ladder Stops .................................................................................................... 16
Step 14 Assemble Ladder Hook ................................................................................................ 17
Step 15 Install Ladder Hook ...................................................................................................... 17
Step 16 Install Handle ............................................................................................................... 18
Before You Begin
•Read all instructions.
•Have rack installed on vehicle. This product is a Driver Side drop down addition.

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Installation Instructions –4A98L
Parts

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Installation Instructions –4A98L
Parts Con’t

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Installation Instructions –4A98L
Hardware 1 of 2

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Installation Instructions –4A98L
Hardware 2 of 2

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Installation Instructions –4A98L
Step 1 –Remove Load Plates
•If installed, remove load plates on the
drivers side, at the end of each bow.
•Repeat on both front and rear bows.
Step 2 –Install Latch Assembly
•At the open end of the rear bow, mount latch
assembly in the squares shown.
•Use the 2nd 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.

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Installation Instructions –4A98L
Step 3 –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 nylon washers. The
nylon washers go on the inside of the bow.
•Snug Tighten, but allow movement.

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Installation Instructions –4A98L
Step 4 –Install Dampers
•Install dampers underneath the rear bow using the existing mount.
•Attach the end of damper to the existing 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
ends of both dampers. This is so you can use the handle to help compress the damper.
•Shown without cross bow for clarity.

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Installation Instructions –4A98L
Step 5 –Install Rear Wheels
•Install rear wheels.
•Slide wheel axle in the end of the rear bow.
•Place nylon washer in between the bow and the wheel.
•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**

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Installation Instructions –4A98L
Step 6 –Install Rear Pan
•Remove hardware from the installed damper
mechanism from step 3.
•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 use the front two bolts, leaving the
holes on the rear side empty as shown. The empty holes are for the handle installation.
•Snug Tighten, but allow movement.

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Installation Instructions –4A98L
Step 7 –Install Front Mechanism
•Mount the front mechanism to the under side of the front bow in the location shown. This
mechanism DOES NOT have the dampers.
•Use the exisiting hardware found in the mechanism to mount.
•Snug Tighten, but allow movement.

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Installation Instructions –4A98L
Step 8 –Front Wheels
•Install front wheels.
•Slide wheel axle in
the end of the front
bow.
•Place nylon washer
in between the bow
and the wheel.
•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 9 –Remove Bolts
•Remove hardware from the
previously installed mechanism
from step 7.

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Installation Instructions –4A98L
Step 10 –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.

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Installation Instructions –4A98L
Step 11 –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.
•TIGHTEN

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Installation Instructions –4A98L
Step 12 –Install End Tube
•Place end tube 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

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Installation Instructions –4A98L
Step 13 –Install Ladder Stops
•Bolt the ladder hook to both bows in the orientation shown.
•Be sure to have the flange of the hook line up with the slot on the bow.
•Use the existing hardware in the rear bow to attach the ladder stop to the rear bow.
•Use 3/8” x 1” hex head, two 3/8” flat washers and 3/8” nyloc nut to install on the front
bow.
TIGHTEN

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Installation Instructions –4A98L
Step 14 –Assemble Ladder Hooks
•Bolt ladder hook assembly to ladder hook
weldment as shown.
•Use 1/4" x 1" hex head, 1/4" lock washer and 1/4"
flat washer. This can be adjusted at a later time to
fit a variety of different ladder shapes and sizes.
Step 15 –Install Ladder Hooks
•At the location shown, use the hardware on the bows to install the ladder hooks.
•Loosen the nuts and slide the ladder hook into place in the orientation shown. Be sure the
washers are on the outside of the ladder hook.
•TIGHTEN

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Installation Instructions –4A98L
Step 16 –Install Handle
•Using the hardware
removed in step 4, insert
handle into swage on the
rear bow.
•Be sure to place sealant
along swage joint.
•TIGHTEN

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Installation Instructions –4A98L
GO BACK AND TIGHTEN ALL BOLTS FROM PREVIOUS STEPS
BE SURE ALL HARDWARE INCLUDING THE MOUNTING IS TIGHT.
YOUR INSTALLATION IS NOW COMPLETE