Kargo Master 4A98L Manual

Kargo Master
Rancho Cordova, CA 95742
800-343-7486
[e-mail]
20210107R2 DATE: ________________
Instruction Guide
4A98L

Instructions –4A98L
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
1/2” Wrench and Socket
3/8” Wrench and Socket
9/16” Wrench and Socket
7/16” Wrench and Socket
Table of Contents
Parts ......................................................................................................................................................................... 2
Hardware................................................................................................................................................................. 3
Step 1 –Remove End Stops.................................................................................................................................... 5
Step 2 –Install Latch Assembly.............................................................................................................................. 5
Step 3 –Install Rear Bow Damper Mechanism..................................................................................................... 6
Step 4 –Install Dampers......................................................................................................................................... 7
Step 5 –Install Rear Wheels................................................................................................................................... 7
Step 6 –Install Rear Pan ......................................................................................................................................... 8
Step 7 –Install Front Pan Mechanism ................................................................................................................... 9
Step 8 –Install Front Wheels ............................................................................................................................... 10
Step 9 –Remove Bolts .......................................................................................................................................... 10
Step 10 –Install Front Pan.................................................................................................................................... 11
Step 11 –Attach Torque Tube .............................................................................................................................. 11
Step 12 –Install End Tube .................................................................................................................................... 12
Step 13 –Install Ladder Stops .............................................................................................................................. 13
Step 14 –Assemble Ladder Hooks....................................................................................................................... 14
Step 15 –Install Ladder Hooks............................................................................................................................. 14
Step 16 –Install Handle ........................................................................................................................................ 15
Before You Begin
Read all instructions prior to assembling or installing any Kargo Master product.
Always locate your installation locations prior to performing any work.
Have rack already installed on vehicle. This product is a driver side drop down addition.

Instructions –4A98L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 2
Parts

Instructions –4A98L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 3
Parts (Continued)
Hardware

Instructions –4A98L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 4
Hardware (Continued)

Instructions –4A98L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 5
DO NOT EXCEED MANUFACTURERS WEIGHT CAPACITY FOR ROOF
Step 1 –Remove End Stops
If installed, remove end stops on the drivers
side, at the end of each bow.
Repeat for both 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” lock nuts.

Instructions –4A98L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 6
Step 3 –Install Rear Bow Damper Mechanism
Mount damper mechanism to the underside of the rear bow in the location shown.
Use the existing 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.

Instructions –4A98L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 7
Step 4 –Install Dampers
Install dampers underneath the rear bow to the existing damper mount using clevis pin, two nylon
washers, a plastic spacer, and cotter pin. . The plastic spacer goes in between two dampers. The nylon
washers go between the dampers and the inside of the damper mount block. Be sure cotter pin is
correctly fastened.
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.
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.
**While placing the pan in the next steps, be sure the wheel caps DO NOT come off.**
Shown without cross
bow for clarity.

Instructions –4A98L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 8
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.

Instructions –4A98L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 9
Step 7 –Install Front Pan Mechanism
Mount the front mechanism to the underside of the front bow in the location shown. This mechanism
DOES NOT have the dampers.
Use the existing hardware found in the mechanism to mount.
Snug tighten, but allow movement.

Instructions –4A98L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 10
Step 8 –Install 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.

Instructions –4A98L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 11
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 bolts were previously removed.
Bolt together using hardware that was removed.
Snug tighten, but allow movement.
Step 11 –Attach Torque Tube
Bolt one end fo torque tube to front or rear bow using three 1/4" x 1” hex head bolts, six 1/4" flat
washers and three 1/4" lock nuts.
Repeat on opposite end.
TIGHTEN.

Instructions –4A98L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 12
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.

Instructions –4A98L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 13
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 one 3/8” x 1” hex head, two 3/8” flat washers and one 3/8” lock nut to install on the front bow.
TIGHTEN.

Instructions –4A98L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 14
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.

Instructions –4A98L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 15
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.
GO BACK AND TIGHTEN ALL HARDWARE.
YOUR INSTALLATION IS NOW COMPLETE.