Kargo Master 4A95M User manual

Kargo Master
Rancho Cordova, CA 95742
800-343-7486
[e-mail]
20200921R1 DATE: __________________
Installation Guide
4A95M

Assembly Instructions –4A95M
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
9/16” Wrench and Socket
7/16” Wrench and Socket
1/2” Wrench and Socket
3/8” Wrench and Socket
5/16” Wrench and Socket
Phillips Driver
1/4" Drill
Table of Contents
Parts List........................................................................................................................................................... 2
Hardware.......................................................................................................................................................... 3
Step 1 –Identify Front and Rear Bows.............................................................................................................4
Step 2 –Determine if the Extension is Needed ............................................................................................... 4
Step 3 –Install Torque Tube Extension............................................................................................................5
Step 4 –Install Torque Tube ............................................................................................................................5
Step 5 –Install Ladder Pan Stiffeners .............................................................................................................. 7
Step 6 –Determine Ladder Stop Locations...................................................................................................... 8
Step 7 –Install Handle....................................................................................................................................10
Step 8 –Assemble Ladder Hooks...................................................................................................................10
Step 9 –Install Clips for Handle .....................................................................................................................11
Before You Begin
Read all instructions before assembling or installing any Kargo Master product.
Place sealant around all swage connections.
Keep the adjustment guide in vehicle at all times.
DO NOT EXCEED MANUFACTURERS WEIGHT CAPACITY FOR ROOF.
BE SURE TO ADJUST LADDER CLAMPS ACCORDINGLY TO FIRMLY SECURE LADDER TO RACK.
Mounting kit in NOT included and must be purchased separately.

Assembly Instructions –4A95M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 2
Parts List

Assembly Instructions –4A95M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 3
Hardware

Assembly Instructions –4A95M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 4
Step 1 –Identify Front and Rear Bows
Determine front and rear bow. The rear bow will have a dampening mechanism attached. Notice the
location of the triangular piece.
Step 2 –Determine if the Extension is Needed
Based upon the vehicle and ladder needs, the rack length can be extended 24-1/2” by adding the included
torque tube extension.
The distance center of bow to center of bow without the extension is approximately 71.5”.
The distance center of bow to center of bow with the extension is approximately 96”.
FRONT BOW
REAR BOW
SHOWN HERE WITH EXTENSION INSTALLED.

Assembly Instructions –4A95M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 5
Step 3 –Install Torque Tube Extension
If installation requires the torque tube extension, complete the following instruction. If NOT installing the
torque tube extension, skip to the next step.
Bolt the torque tube to the torque tube extension using a 1/4"-20 x 1” hex head bolt, two 1/4" flat
washers, and a 1/4"-20 lock nut at each location.
Repeat for second extension on opposite bow.
Step 4 –Install Torque Tube
Bolt the torque tube to the front and the rear bow using a 1/4" x 1” hex head bolt, two 1/4" flat washers
and a 1/4" lock nut at each of the 3 holes through triangular ends of torque tube and actuator on bow.
Repeat for second torque tube and extension on opposite side of rack.
Snug tighten but allow for movement. This hardware is best tighten after installation.
WITH EXTENSIONS

Assembly Instructions –4A95M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 6
FRONT CONNECTION
REAR CONNECTION
WITHOUT EXTENSIONS

Assembly Instructions –4A95M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 7
Step 5 –Install Ladder Pan Stiffeners
Using 3/8" x 3/4” hex heads, 3/8” lock washers and 3/8” flat washers, install ladder pan stiffener to the
ends of the bow pan assembly on each bow.
TIGHTEN.
Repeat on opposite side of rack.
FRONT BOW
REAR BOW

Assembly Instructions –4A95M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 8
Step 6 –Determine Ladder Stop Locations
NOTE: On side of each bow, there are two positions available for mounting the ladder stops and ladder
hooks based on the size and type of ladder. Ladder stops may be installed either further inboard or further
outboard, depending on the ladder to be used. It is best to determine the size and type of ladder prior to
installing the ladder stops and ladder hooks. The following are examples of a typical 8 foot stepladder and
10 foot extension ladder mounted on the drop down ladder rack.
The following are the two positions available on each bow.
POSITION 1
POSITION 2
EXTENSION LADDER:
BOTH AT POSITION 1
STEPLADDER: REAR
AT POSITION 1,
FRONT AT POSITION 2
4A95C SHOWN HERE
EXTENSION LADDER:
BOTH AT POSITION 2
STEPLADDER: REAR
AT POSITION 1,
FRONT AT POSITION 2

Assembly Instructions –4A95M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 9
Position 1
For each ladder hook in this position, place the ladder hook base around the threaded studs in the desired
location and tighten.
For the rear bow, remove the existing 3/8” x 1” hex head bolt, a 3/8” lock washer and a 3/8” flat washer.
For the front bow, use a 3/8” x 1” hex head bolt, 3/8” flat washer, and 3/8” lock nut from the hardware
kit.
Position the ladder stop near the ladder hook base, as shown, with the flange on ladder stop aligned with
the slot in the bow.
Install ladder stop and tighten.
Position 2
For each ladder hook in this position, place the ladder hook base around the threaded studs in the desired
location and tighten.
Position the ladder stop near the ladder hook base, as shown, with the flange on ladder stop aligned with
the slot in the bow.
Remove the existing 3/8” x 1” hex head bolt, a 3/8” lock washer and a 3/8” flat washer.
Bolt the ladder stop in place using the removed hardware in the orientation shown.
FRONT BOW POSITION 2
REAR BOW POSITION 1

Assembly Instructions –4A95M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 10
Step 7 –Install Handle
Remove the 5/16” flanged head screws, 5/16” washers, and 5/16” lock
nuts from rear bow as circled below.
Apply sealant to swaged ends of handles.
Use removed hardware to bolt handles into position as shown.
TIGHTEN.
Step 8 –Assemble Ladder Hooks
Install the ladder hooks on the
previously installed ladder hook
base using 1/4" x 1” hex head
bolts, 1/4" lock washers, and
1/4" flat washers in the desired
locations. The location is
dependent on the size of the
ladder used. Adjust so the ladder
hook fits the ladder as tight as
possible.
TIGHTEN.
Repeat for remaining 3 ladder
hook locations.

Assembly Instructions –4A95M
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 11
Step 9 –Install Clips for Handle
Locate a good mounting place to install the clips for the
handle. It is recommended to place at the rear of the van
on the rear panel of a shelf.
Place the clips on the handle. Place the handle against the
shelf in the desired location.
Mark the holes onto the shelf.
Drill the locations using a 1/4" drill.
Attach clip using a #10 x 5/8” pan head screw and #10 lock
nut.
Repeat for second clip.
TIGHTEN.
REFER TO MOUNTING KIT INSTRUCTIONS FOR INSTALLATION.
ASSEMBLY IS NOW COMPLETE.