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
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Parts

Instructions –90001
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Hardware (18-90001)

Instructions –90001
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Hardware (18-90001) (Continued)

Instructions –90001
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Hardware (18-00001GM)
Hardware (18-90001M)

Instructions –90001
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TRUCK RACK EXPLODED VIEW

Instructions –90001
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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
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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

Instructions –90001
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Rear Foot Stake Pocket - Ford and Chevy:
Remove taillight. A T15 Torx wrench is supplied to
remove Chevy taillights.
On the rear foot only, insert the 3/8” x 8” button
head screw through the hole in the rear slotted
channel and the hole in the bottom of the rear
stake pocket.
Install the 3/8” fender washer and 3/8” lock nut
onto the 3/8” x 8” button head screw.
Loosely tighten.
Rear Foot All Vehicles:
Insert a 1/2” x 2-1/2” button
head screw with 1/2” lock
washer, through saddle
bushings inside of foot, into a
rail clamp, as shown.
Pressing foot tight against
inside of bed rail, position rail
clamp beneath bedrail, clear
of any obstacles.
Snug tighten bolt, clamping
foot to bed rail hold the front
footplate in position.
Repeat for other side.
STAKE POCKET CUT AWAY VIEW
REAR PASSENGER-SIDE FOOT
FRONT PASSENGER-SIDE FOOT
1/2” X 2-1/2” Button
Head Screws

Instructions –90001
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Step 1B –Permanent Installation:
Position front footplate on the truck bedrail, as far forward as possible, as per above.
Position a rear footplate on the bedrail, with the foot U-bracket saddle located near the rear stake pocket.
Locate the best hole in the footplate for drilling through the bed rail. We recommend using the hole
farthest from the foot U-bracket saddle and another hole nearer the U-bracket saddle.
Using a 13/32” drill bit, drill
through the bed rails in the
location of the holes
selected.
Using a 3/8” x 1-3/4” button
head screw, bolt through foot
and bed, into a 3/8” washer
and 3/8” jam nut.
Snug tighten.
Repeat for opposite side.
Step 2 –Assemble Side Channels
Apply sealant entirely around each swaged joint.
Push rear side channel into front side channel until
holes in gussets align.
Using 5/16” x 3/4” hex head bolts, 5/16” washers, and
5/16” lock nuts, bolt front side channel to rear side
channel.
TIGHTEN hardware.
Remove excess sealant.
Repeat for second front and rear sided channels.
Be sure screws are
directed downward.
5/16” x 3/4” Hex Head Bolts
3/8” X 1-3/4” Button
Head Screws

Instructions –90001
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 12
Step 3 –Install Front Leg Assemblies
Measure center to center distance between
U-brackets on front and rear feet.
Slide front leg LH DS over the LH DS front
side-channel bottom-tube. Be sure the legs are
angled in the same direction.
Position front let assembly at the distance
measured.
LOOSELY TIGHTEN 3/8” set screws into threaded holes
in side channel.
Repeat for opposite RH PS front leg and side channel.
Using 5/16” x 3/4” hex head bolts, 5/16” washers, and
5/16” lock nuts, LOOSELY bolt front leg clamp bracket to
front leg assembly. DO NOT TIGHTEN.
Repeat for opposite side.
Step 4 –Install Rear Legs
Apply sealant entirely around each swaged joint.
Slide leg into rear side channel until holes in leg and
side channel align.
Using 3/8” x 2-1/2”hex head bolt, 3/8” flat washers,
and 3/8” lock nut, LOOSELY bolt leg to side channel.
Remove excess sealant.
Repeat for opposite side.
5/16” x 3/4”
Hex Head Bolts
3/8” x 2-1/2”
Hex Head Bolts

Instructions –90001
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Step 5 –Attach Side Channel to Center
Cross Tube
Apply sealant entirely around a swaged joint
on center cross tube.
Insert swaged joint into receiver tube on front
leg assembly until holes in both align.
Apply sealant into holes in leg assembly.
Using 5/16” x 2-1/2” hex head bolt,
5/16” washers, and 5/16” lock nut, LOOSELY
bolt the cross tube to the leg assembly.
Remove excess sealant.
Repeat for other side.
Step 6 –Attach Front U-tube
Apply sealant entirely around swaged joints on BOTH of the front side channels.
Insert swaged joints of both side channels into U-tube until holes on both sides align.
Using 1/2” x 2-3/4” button head screws, 1/2” washers, and 1/2” jam nuts, LOOSELY bolt the U-tube to the
side channels.
Remove excess sealant.
Step 7 –Attach Front Rail Brackets
Hold two front rail brackets on either side of the front
side channel just before the point where the top rail
bends.
Using 5/16” x 1” carriage bolts, 5/16” washers, and
5/16” lock nuts, bolt the two front rail brackets
together, clamping the side channel between. Be sure
carriage bolt are facing outwards.
Tighten.
Repeat for opposite side.
5/16” x 2-1/2”
Hex Head Bolts
1/2” x 2-3/4” Button
Head Screws
5/16” x 1”
Carriage Bolts

Instructions –90001
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 14
Step 8 –Attach Rear Crossbar
Using a rubber mallet, tap a plastic cap into the top of
the tube at each end of the rear crossbar. Be sure to
install the cap in the tall end of the tube, as shown.
Insert a plastic crossbar insert into one end of rear
crossbar. Be sure insert is oriented as shown.
Rotate plastic crossbar insert so slots align with holes in
crossbar.
Slide rear crossbar simultaneously onto receiver tubes on
both rear side channel until holes in crossbar and side
channel align.
Insert pin through holes in rear crossbar. Lock pin in place by hooking
wire lock over opposite end of pin.
Step 9 –Attach Rack to Feet
Lift rack and set legs into foot saddles.
Using 1/2” x 3-3/4” hex head bolts,
1/2” flat washers, and 1/2” jam nut,
LOOSELY bolt the feet to the foot
U-bracket saddles. DO NOT TIGHTEN.
THESE BOLT ARE LAST TO BE
TIGHTENED.
1/2” X 3-3/4”
Hex Head Bolts

Instructions –90001
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 15
Step 10 –Tighten Hardware in Order
1. Holding feet against the inside of the bed rails, tighten hardware to
secure the feet to the bed rails.
2. Starting at the FRONT and TOP, tighten side channel hardware.
3. Tighten leg hardware.
4. Check that rack is centered side-to-side on vehicle.
5. Holding legs in position, tighten 1/2” hardware connecting rack to
U-bracket saddle on feet.
GO BACK AND CHECK THAT ALL HARDWARE IS TIGHTENED.
INSTALLATION AND ASSEMBLY ARE COMPLETE.
CENTER LEFT & RIGHT

Instructions –90001
For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 16