Kargo Master 4080L Manual

Instruction Guide
4080L
Kargo Master
Rancho Cordova, CA 95742
800-343-7486
[e-mail]
20210629R6 DATE: ______________

For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 1
Instructions –4080L
* 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
13mm Socket and Wrench
10mm Socket and Wrench
5mm Allen Hex
9/16” Socket and Wrench
7/16” Socket and Wrench
1/2” Socket and Wrench
Table of Contents
Parts List ..............................................................................................................................2
Assembly Hardware .............................................................................................................3
Install Hardware ................................................................................................................4-5
Roof Rail Mounting
Promaster City ...................................................................................................................6
NV200/City Express ...........................................................................................................7
Transit Connect ..................................................................................................................8
Rack Assembly
Step 1 –Mount Feet to Rails...............................................................................................9
Step 2 –Install Feet to Bows.............................................................................................10
Step 3 –Attach End Stops.................................................................................................12
Step 4 –Mount Side Tube ................................................................................................11
Step 5 –Mount Angle Bracket ..........................................................................................12
Step 6 –Mount Handle ....................................................................................................14
Step 7 –Mount Latch .......................................................................................................14
Step 8 –Mount Ladder Stop ............................................................................................15
Before You Begin
Read all instructions prior to assembling or installing any Kargo Master product.
Install the vehicle roof mounting rail prior to rack assembly.
Be sure to put sealant around all threads entering cargo area and between the rubber
spacer and roof of vehicle to prevent water from leaking into cargo area.
DO NOT EXCEED MANUFACTURERS WEIGHT CAPACITY FOR ROOF
BE SURE TO ADJUST LADDER CLAMPS ACCORDINGLY TO SECURE LADDER FIRMLY TO
RACK. To adjust, refer to Clamp and Lock adjustment guide.

For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 2
Instructions –4080L
Parts

For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 3
Instructions –4080L
Hardware (18-40800)

For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 4
Instructions –4080L
Hardware (18-4080L)

For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 5
Instructions –4080L
Hardware (18-4080L) (Continued)

For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 6
Instructions –4080L
DO NOT EXCEED MANUFACTURERS WEIGHT CAPACITY FOR ROOF
Promaster City Installation
Locate 6 mounting locations
shown on roof of van.
Install mounting rail as shown
using M6 x 22mm bolts, 1/4” lock
washers, and 1/4” flat washers.
In most installs, the rail upright is
to the outside of the van.
Be sure to put rubber washer between the mounting rail and the roof to ensure sealing.
Place sealant on and around threads to seal roof. (Passenger side shown)
FRONT EXPLODED
MID EXPLODED
REAR EXPLODED
FRONT TIGHTENED
MID TIGHTENED
REAR TIGHTENED

For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 7
Instructions –4080L
DO NOT EXCEED MANUFACTURERS WEIGHT CAPACITY FOR ROOF
NV200/City Express Installation
Locate 4 mounting locations shown on
roof of van.
Install mounting rail as shown using
M8 x 25mm bolts, 5/16” lock washers
and 5/16” flat washers.
In most installs, the rail upright is to
the outside of the van.
Mount rail so there is about 1” from the rear door opening.
Be sure to put rubber washer between the mounting rail and the roof to ensure sealing.
Place sealant on and around threads to seal roof. (Passenger side shown)
Note: Additional M8 x 20mm flat head screws are provided if mounting of feet interferes with
bolts.
FRONT EXPLODED
REAR EXPLODED
FRONT TIGHTENED
REAR TIGHTENED

For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 8
Instructions –4080L
DO NOT EXCEED MANUFACTURERS WEIGHT CAPACITY FOR ROOF
Transit Connect Installation
Locate 4 mounting locations shown
on roof of van.
Be sure to put rubber washer
between the mounting rail and the
roof to ensure sealing.
In most installs, the rail upright is to
the outside of the van.
Mount rail so there is about 1” from the rear door opening.
Install mounting rail as shown using M8 x 25mm bolts, 5/16” flat washers on the outside.
Use the fender washer and 5/16” lock nut on the inside of the van.
Place sealant on and around threads to seal roof. (Passenger side shown)
Note: Additional M8 x 20mm flat head screws are provided if mounting of feet interferes with
bolts.
FRONT
EXPLODED
REAR
EXPLODED
FRONT TIGHTENED
REAR TIGHTENED

For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 9
Instructions –4080L
Assembly Instructions
Step 1 –Mount Feet to Rails
Bolt the feet to the rails in the location and orientation shown using 5/16” x 1” hex head,
two 5/16” flat washers and a 5/16” lock nut.
Snug tighten, but allow movement.

For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 10
Instructions –4080L
Step 2 –Install Feet to Bows
Place the bows and center on top of the previously installed feet. The same slot should be
used at both ends of the bows.
Use a 3/8” x 3/4" hex head bolt, 3/8” lock washers and a 3/8” flat washer to bolt the foot to
the cross member.
DO NOT TIGHTEN. Snug tighten, but allow movement.

For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 11
Instructions –4080L
Step 3 –Attach End Stops
NOTE: Skip this step if adding driver-side ladder rack.
On each bow, attach an end plate to the driver side using 5/16” carriage bolts,
5/16” washers and 5/16” lock nuts.
TIGHTEN.
Step 4 –Mount Side Tube
Assemble the side
tube.
Place sealant around
the connection of the
two tubes.
While still malleable,
place the side tube
assembly on top of
the installed bows.
Have the bend
towards the front and
outside of the vehicle
as shown.

For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 12
Instructions –4080L
Mount an end plate at the rear of the tube as shown.
Leave one square slot open at the rear of the side tube.
Bolt to the front and rear bow using 5/16” x 2” carriage bolt, a 5/16” flat washer and a
5/16” lock nut.
Snug tighten, but allow movement.
Step 5 –Mount Angle Bracket
Place the angle bracket on top of the installed bows with the long flange towards the center
of the vehicle. Do NOT install any hardware.

For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 13
Instructions –4080L
Insert plastic bushings into the angle bracket and the ladder stop installed in Step 4, with the
large flanges of the bushings towards each other and to the inside of the brackets as shown.
Insert the
clamp tube
into the
previously
installed
bushings in
the
prientation
shown.
Bolt the angle bracket to
the front and rear bow
using 3/8” x 1” carriage
bolts, 3/8” flat washers and
a 3/8” lock nuts as shown.
Be sure the bushings
CANNOT come out.
TIGHTEN.

For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 14
Instructions –4080L
Step 6 –Mount Handle
Bolt the handle to the clamp tube using a 3/8” x 3” hex head, a 3/8” flat washer, 3/8” nylon
washer, a 3/8” curved washer and a 3/8” lock nut. The nylon washer goes in between the
clamp tube and the handle. The curved washer fits the contour of the tube on the handle.
TIGHTEN, but do not over tighten.
Step 7 –Mount Latch
Bolt the latch to the round tube installed in Step 4 through the vacant slot using 5/16” x 2”
carriage bolt, 5/16” flat washer and a 5/16” lock nut.
TIGHTEN.

For Technical Support Call: 800-343-7486, Monday-Friday, 7AM - 4 PM (PST) Page 15
Instructions –4080L
Step 8 –Mount Ladder Stop
Bolt the ladder stop to the front bow in the orientation shown using two 3/8” x 1” carriage
bolts, two 3/8” flat washers and two 3/8” lock nuts.
Adjust clamp on bracket to fit firmly against your ladder.
TIGHTEN.
*Shown without some parts for clarity*
After installation, adjust clamps to fit firmly against the ladder.
GO BACK AND ENSURE ALL HARDWARE IS TIGHT
INSTALLATION IS NOW COMPLETE.