Kargo Master PRO-III User manual

ASSEMBLY INSTRUCTIONS
for :
PRO-III & IV
Parts: 80000, 80020, & 90000
®
• 11253- G Trade Center Drive • Rancho Cordova, CA 95742 •
[phone]
[phone]
v _4.1

Q
A
1/2", 9/16", & 3/4"
PRO-III & IV
ALL MODELS FOR
TRUCKS WITHOUT SHELLS
V
R
C
J
HA
H
L
F
K
N
F
K
N
B
H
L
N
99
788
3
1
2
G
O
O
P
G
O
O
P
G
O
O
P
777
©2011 KARGO MASTER-Pro3&4 _4.1
E
G
KN
KM
4
1010

2011 KargoMaster-'Pro 3 & 4' _4.1
E(2 ea.)
5/16" x 2 1/4"
Button Head Bolt
F(8 ea.)
5/16" x 3/4"
Button Head Bolt
H
AG
JK
(14 ea.) 1/2" SAE Flat Washer (22 ea.) 3/8" SAE Flat Washer
U
(4 ea.) 3/8" Lock Washer (14 ea.) 5/16" Flat Washer
(4 ea.)
L(6 ea.) M(10 ea.) N(14 ea.)
(4 ea.)
1/2" x 3 1/2"
Hex Bolt
5/16" x 3/4"
Carriage Bolt
1/2" Jam Nut 3/8" Lock Nut 5/16" Lock Nut
D(8 ea.)
3/8" x 1 3/4"
Button Head
C(2 ea.)
3/8" x 2 1/4"
Button Head
T(2 ea.)
3/8" x 16 x 2 1/2"
Button Head Bolt
B(2 ea.)
1/2" x 2 1/4"
Button Head Bolt
S(6 ea.)
1/2" x 13 x 2 1/2"
Button Head Bolt
P(4 ea.)
5/16" x 3/8"
Allen Head Set Screw
Q(2 ea.)
3/8” T Nut
R(6 ea.)
Bed Rail
Clamps
(yellow zinc plated, grade 5) (yellow zinc plated, grade 5)
(yellow zinc plated, grade 5)

Pro3&4_4.1
#1=
STEP 1
T
R
Q
S
TRUCKs’
BEDRAIL
Front
Stake
Pocket
T-nut
Bed Rail Clamp
FOOTPLATE
(front)
Position FRONT FOOTPLATES on the truck bedrail, as far
forward as possible. Determine which pre-drilled hole (if any) falls over
the stake pocket. If none of the pre-drilled holes fall over the stake
pocket, mark and drill a hole in the foot plate that is approximately over
the center of the stake pocket. Put bolt T through FOOTPLATE and start T Nut Q
as shown. Maneuver T Nut Q inside the stake pocket, push the FOOTPLATE forward
against the bulkhead, and tighten the T nut up against the underside of the
truck bed rail. Secure the rear of the front FOOTPLATE to the bedrail using
Bolt S and Bed Rail Clamp R as shown.
Note: If you prefer to mount the FOOTPLATES by drilling through the truck
bedrail, locate the FOOTPLATES as per above, and attach using included
fasteners D,K & M . We recommend using the pre-drilled hole at the rear
of the FOOTPLATES. You will have to locate and drill a second hole in the
FOOTPLATE, get as close to the leg as possible. Be sure you can access the nut.
TRUCK
CAB

Pro3&4_4.1
#1=
STEP 2
Position the REAR FOOTPLATES against the bedrail.
Secure the rear of the front FOOTPLATE to the bedrail usingBolt S and Bed
Rail Clamp R as shown.
Note: If you prefer to mount the FOOTPLATES by drilling 3/8" holes through
the truck bedrail, locate the FOOTPLATES as per above, and attach using
included fasteners D, K, & M. We recommend using the pre-drilled hole at
the rear of the FOOTPLATES. You will have to locate and drill a second 3/8"
hole in the FOOTPLATE, as close to the leg as possible (loosely).

Pro3&4_4.1
G
N
K
G
OO
P
F
P
NK
(RIGHT SIDE SHOWN)
STEP 3
STEP 4
#1 = Cover entire swedge joints with goop
sealant and join FRONT and REAR side channels
together. There is a RIGHT & LEFT REAR. The
leg cups angle outward. Be sure the connecting
plates overlap, and loosely bolt together with bolts
G, washers K and lock nuts N.
#2 = Slide the FRONT leg onto the front side channel.
There is a RIGHT & a LEFT. Match to the correct side
channel so that both FRONT & REAR legs angle outward.
Position distance to match same as above. Insert the set
screws P, but do not tighten yet.
#3 = Loosely attach the top CLAMP with
bolts F, washers K, and nuts N.
#1 = Cover entire swedge joints with goop
sealant and attach the REAR LEGS with
bolts C, washers J, and nuts M.
Note: The distance between front & rear
legs will not be longer than the inside
measurements of the bed itself.
STEP 5
G
O
O
P
C
J
M
GOOP APPLICATION
Apply a healthy air tight bead of goop
around every swaged joint as shown, to
prevent moisture from leaking into and out
of the joint. If this is not done properly, the
inside surface of the tubes can rust and
rusty water can leak out. Maintain this
joint seal throughout the life of your rack.
Swaged joint & holes
Smooth goop at swaged joint & holes
GOOP
GOOP
#1 = Measure the center to center measurement
between the front and rear footplate saddles.
Final positioning of the front legs will follow.
Bulkhead (front) Tailgate (rear)

Pro3&4_4.1
E
N
K
STEP 6
#1 = Cover entire swedge joints with goop
sealant and insert the CENTER CROSS
BAR into the SIDE RAIL CUPS and attach
with bolts E, washers K and lock nuts N.
#1 = Insert PLASTIC CAPS onto the rear
crossbar uprights, (the tall side of the tube).
Slide the REAR CROSS BAR into the REAR
LEG POSTS at the top, as shown.
STEP 8
#1 = Cover entire swedge joints with
goop sealant and slide FRONT CROSS
BAR onto side rails and bolt together with
bolts B, flat washer H, and jam nut L.
GO
O
P
STEP 7
B
H
L
G
O
OP

Pro3&4_4.1
STEP 9
STEP 10
P
#1 = Lift rake onto truck and make
final adjustments and attach front
and rear legs with bolts A, washers
H, and nut L.
Center rack on truck bed.
Tighten up the bolts on the crossbar and clamp
plates as well as the set screws P.
#1 = Attach the front SUPPORT
UPRIGHT where the 1” tube begins
to bend downward, then...
TIGHTEN DOWN EVERYTHING AND....
THAT’S IT!
You’re ready to LOAD & GO!
NK
G
LH
HA

INSIDE BED WALL
#2= Center RACK over bed and tighten FRONT
MOUNT BOLTS. On REAR MOUNT BOLTS be sure
LOCK PINS slide IN & OUT smoothly and freely
before tightening the rear BOLTS.
J
©2011 KARGO MASTER --'Pro3'_4.1
THAT'S IT!
You're ready to
use and enjoy your
KARGO MASTER
TRUCK RACK!
#1= Tighten down ALL NUTS AND BOLTS, except LEG FOOTPLATES and CENTER CROSS BAR .
DO NOT OVER TIGHTEN ON DOUBLE WALL BED CONSTRUCTION, AS THIS MAY DEFORM THE
SHEET METAL OF THE PICKUP BED!
3/8"
3"
8
(OPTIONAL
BED SUPPORT)
STEP 11
#4= Modern truck beds are made from thin steel with
limited load bearing capacity. Approximately 75% of
the rack load is carried by the front legs. Because the
rack is wider at the bottom than the top, overhead
loads tend to push the bed walls down and apart.
If you expect to carry heavy loads,
we strongly suggest that you purchase
and install OPTIONAL BED SUPPORTS
as shown below.
C
#3= Snug bolts in CENTER CROSS BAR .
C
Pro3&4_4.1

100" = 3X lbs.
35" = X lbs.
@
@
O
V
E
R
T
U
R
N
F
O
R
C
E
For TECHNICAL SUPPORT Call:
1.800.343.7486
HOURS: Monday- Friday 8:00 A.M. to 4:30 P.M. ( PACIFIC )
WEIGHT CARRIED ABOVE THE FLOOR OF THE TRUCK BED (E.G. ON AN OVERHEAD TRUCK RACK)
WILL SIGNIFICANTLY INCREASE THE VEHICLE'S TENDENCY TO OVERTURN. ALWAYS KEEP
HEAVY LOADS EVENLY DISTRIBUTED AND AS LOW AS POSSIBLE. IT IS IMPORTANT TO NOTE THAT
THE KARGO MASTER RACK LOAD BEARING CAPACITY OF 1700 LBS. MAY BE GREATER THAN YOUR
TRUCK'S GAWR OR GVWR CAPACITY, AND IS PROBABLY GREATER THAN THE WEIGHT THAT CAN BE
SAFELY CARRIED OVERHEAD.
LBS.
LBS.
DON'T OVERLOAD YOUR VEHICLE!