Kargo Master 90001 User manual

Kargo Master
Rancho Cordova, CA 95742
800-343-7486
[e-mail]
20210922R1 DATE: ________________
Installation Guide
90001

Instructions –90001
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.
Too much weight will greatly reduce the stability of your vehicle. Kargo Master
makes no representation or warranty as to the amount of weight your vehicle can
safely carry. For guidance, we recommend that you consult the vehicle
manufacturer. AT NO TIME SHOULD THE WEIGHT OF THE VEHICLE, RACK, DRIVER,
PASSENGERS AND CARGO LOADED ON A KARGO MASTER RACK EXCEED EITHER THE
GROSS VEHICLE WEIGHT RATIO (GVWR) OR THE GROSS AXLE WEIGHT RATIO (GAWR)
AS SPECIFIED BY THE VEHICLE MANUFACTURER.
Do not use your rack with the rear cross bar removed. Removal of rear crossbar will
affect structural integrity of the rack.
Secure all payloads properly for safe transportation.
A large area is required to assemble rack. Be sure to keep area clear of trip and fall
hazards.
Before You Begin
Read all instructions prior to assembling or installing any Kargo Master product.
Follow each step in proper sequence, for ease and speed in assembling your Kargo Master rack.
PROPER SEALANT APPLICATION IS CRITICAL TO ENSURE SOLID ASSEMBLY, PREVENTING RATTLING, AND
WATER PENETRATION INSIDE THE RACK. Apply a healthy bead of sealant entirely around every swaged
joint and every bolt going through tubing. Improper sealing can lead to water penetration. Lack of
sealant and loose hardware can also lead to rattling.
Tools Needed
1/2”, 9/16”, 3/4” Sockets and Wrench
1/2”, 9/16”, 3/4” Box Wrenches
Rubber Mallet
5/16”*, 7/32” Hex Key Wrench
13/32” Drill Bit (optional)
Drill (optional)
*Included

Instructions –90001
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 2
Table of Contents
Before You Begin............................................................................................................................................... 1
Parts .................................................................................................................................................................. 3
Hardware (18-90001)........................................................................................................................................ 4
Hardware (18-00001GM).................................................................................................................................. 6
Hardware (18-90001M) .................................................................................................................................... 6
Sealant Application ........................................................................................................................................... 8
Installation Notes.............................................................................................................................................. 8
Step 1A –Install Feet –Standard Installation:.................................................................................................. 9
Step 1B –Permanent Installation: .................................................................................................................. 11
Step 2 –Assemble Side Channels ................................................................................................................... 11
Step 3 –Install Front Leg Assemblies.............................................................................................................. 12
Step 4 –Install Rear Legs ................................................................................................................................ 12
Step 5 –Attach Side Channel to Center Cross Tube....................................................................................... 13
Step 6 –Attach Front U-tube.......................................................................................................................... 13
Step 7 –Attach Front Rail Brackets ................................................................................................................ 13
Step 8 –Attach Rear Crossbar ........................................................................................................................ 14
Step 9 –Attach Rack to Feet........................................................................................................................... 14
Step 10 –Tighten Hardware in Order............................................................................................................. 15

Instructions –90001
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 3
Parts

Instructions –90001
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 4
Hardware (18-90001)

Instructions –90001
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 5
Hardware (18-90001) (Continued)

Instructions –90001
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 6
Hardware (18-00001GM)
Hardware (18-90001M)

Instructions –90001
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 7
TRUCK RACK EXPLODED VIEW

Instructions –90001
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 8
DO NOT EXCEED MANUFACTURERS WEIGHT CAPACITY FOR ROOF
Sealant Application
Proper sealant application is critical to preventing water penetration inside the rack
AND provides for a stable connection between parts.
Apply a healthy bead of sealant entirely around every swaged joint as shown. Improper sealing can lead
to water penetration.
Wipe any excess sealant off immediately with a plastic scraper or paper towel. Any smeared sealant can
be rubbed off as soon as sealant dries.
Maintain this seal throughout the life of your rack.
Installation Notes
There are 2 methods of installation.
(a) clamping the feet to the side of the bed with rail clamps and securing and bolting the feet to the stake
pockets;
OR
(b) drilling and permanently mounting through the side rails.

Instructions –90001
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 9
Step 1A –Install Feet –Standard Installation:
Position a footplate on the bedrail, as far forward as possible, with the inside of the bed is against the
downward flange on the foot.
Position a second footplate on the bedrail, with
the foot U-bracket saddle located near the rear
stake pocket.
If there are covers over the stake pockets, remove the covers. Some stake pockets are covered with solid
plastic. Bed rails should be cut to access.
Determine which pre-drilled hole falls over the stake pocket. For most trucks, the feet have been
designed to have at least one hole that will be near center of the stake pocket.
If the none of the pre-drilled holes fall over the stake pocket, mark and drill a 13/32” hole in the foot plate
that is approximately over the center of the stake pocket.
Front Foot Stake Pocket:
Put 3/8” x 2-1/2” button head screw with
3/8” lock washer and 3/8” washer through
footplate and start T-nut as shown.
Maneuver the T-nut inside the stake pocket, push
the footplate forward against the bulkhead, and
then snug tighten the T-nut up against the
underside of the truck bed rail. Be sure inside of
the bed is against downward flange on the foot.
LOOSELY tighten T-nut inside stake pocket.
Hole location example only.
Actual hole depends on
actual stake pocket location.
3/8” X 2-1/2”
Button Head Screw