Kargo Master 4A96L Manual

Kargo Master
Rancho Cordova, CA 95742
800-343-7486
[e-mail]
20210107R2 DATE: ________________
Instruction Guide
4A96L

Instructions –4A96L
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
1/2” Wrench and Socket
3/8” Wrench and Socket
9/16” Wrench and Socket
7/16” Wrench and Socket
Table of Contents
Parts ......................................................................................................................................................................... 2
Hardware................................................................................................................................................................. 3
Step 1 –Remove End Stops.................................................................................................................................... 5
Step 2 –Install Latch Assembly.............................................................................................................................. 5
Step 3 –Install Rear Bow Damper Mount ............................................................................................................. 6
Step 4 –Install Rear Bow Damper Mechanism..................................................................................................... 7
Step 5 –Install Dampers......................................................................................................................................... 8
Step 6 –Install Rear Wheels................................................................................................................................... 9
Step 7 –Install Rear Pan ......................................................................................................................................... 9
Step 8 –Install Front Pan Mechanism ................................................................................................................. 11
Step 9 –Assemble Front Wheels ......................................................................................................................... 12
Step 10 –Remove Bolts........................................................................................................................................ 12
Step 11 –Install Front Pan.................................................................................................................................... 13
Step 12 –Install Front Bow Ladder Stop ............................................................................................................. 14
Step 13 –Determine if Extension is Required..................................................................................................... 14
Step 14 –Attach Torque Tube ............................................................................................................................. 15
Step 15 –Install End Tube .................................................................................................................................... 15
Step 16 –Assemble Ladder Hooks....................................................................................................................... 16
Step 17 –Install Ladder Hooks............................................................................................................................. 17
Step 18 –Install Handle ........................................................................................................................................ 18
Before You Begin
Read all instructions prior to assembling or installing any Kargo Master product.
Always locate your installation locations prior to performing any work.
Have rack already installed on vehicle. This product is a driver side drop down addition.

Instructions –4A96L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 2
Parts

Instructions –4A96L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 3
Parts (Continued)
Hardware

Instructions –4A96L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 4
Hardware (Continued)

Instructions –4A96L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 5
DO NOT EXCEED MANUFACTURERS WEIGHT CAPACITY FOR ROOF
Step 1 –Remove End Stops
If installed, remove end stops at the end of each bow, opposite from the
passenger side pan mechanism.
Repeat for both bows.
Step 2 –Install Latch Assembly
At the end of the rear bow, mount latch assembly
in the squares shown.
Use the 3rd set of square holes from the end of the
bow.
Mount using two 5/16” x 1” carriage bolts, two
5/16” flat washers and two 5/16” lock nuts.

Instructions –4A96L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 6
Step 3 –Install Rear Bow Damper Mount
Mount damper mount to the underside of the rear bow in the location shown.
Mount the ladder stop on the top side of bow.
When installing the ladder stop, be sure to use the longer, 3/8” x 1” hex head bolt, a 3/8” lock washer and
3/8” flat washer.
At the other location, fasten using 3/8” x 3/4” hex head bolt, 3/8” lock washer and 3/8” flat washer.
Snug tighten, but allow movement.

Instructions –4A96L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 7
Step 4 –Install Rear Bow Damper Mechanism
Mount damper mechanism to the underside of the rear bow in the location shown.
Use the existing hardware found in the damper mechanism to mount.
While using the 3/8” x 4-1/2” hex head bolt. Be sure not to lose the nylon washers.
Snug tighten, but allow movement.
3/8” Nylon Washers

Instructions –4A96L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 8
Step 5 –Install Dampers
Install the end of damper to the damper mount using clevis pin, two nylon washers, a plastic spacer and a
cotter pin in the orientation shown. The plastic spacer goes in between two dampers. The nylon washers
go between the dampers and the inside of the damper mount block. Be sure cotter pin is correctly
fastened.
In some situations, one may need to wait until handle assembly is installed to attach both ends of the
dampers. This is so you can use the handle to help adjust the damper.
Shown without cross member
for clarity.

Instructions –4A96L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 9
Step 6 –Install Rear Wheels
Slide wheel axle in the end of the rear bow.
Place a wheel on each end of the axle.
While placing the pan on the next step, be sure the wheel caps DO NOT come off.
Step 7 –Install Rear Pan
Remove hardware from the installed damper
mechanism from step 4.

Instructions –4A96L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 10
Place rear pan on top of wheels and bow. Be sure the wheel caps DID NOT come off.
Align the arms from the pan with the holes in the damper mechanism where the bolts were previously
removed.
Bolt together using previously removed hardware. Only mount the front two bolts, leaving the holes to
the rear as shown empty. The empty holes are for the handle installation.
Snug tighten, but allow movement.

Instructions –4A96L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 11
Step 8 –Install Front Pan Mechanism
Mount mechanism to the underside of the front bow in the location shown. This is the mechanism that
DOES NOT have the dampers.
Use the existing hardware found in the mechanism to mount.
Snug tighten, but allow movement.

Instructions –4A96L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 12
Step 9 –Assemble Front Wheels
Install wheel assembly. Slide wheel axle in the end of the front bow. Place a wheel on each end of the
axle.
While placing the pan on the following steps, be sure the wheel caps DO NOT come off.
Step 10 –Remove Bolts
Remove 5/16” x 2” hex head bolts,
5/16” flat washers, and 5/16” lock
nuts from the previously installed
mechanism from Step 8.

Instructions –4A96L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 13
Step 11 –Install Front Pan
Place front pan on top of wheels and bow. Be sure the wheel caps DID NOT come off.
Align the arms from the pan with the holes from the mechanism where the bolts were previously
removed.
Bolt together using hardware that was removed.
Snug tighten, but allow movement.

Instructions –4A96L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 14
Step 12 –Install Front Bow Ladder Stop
Bolt ladder hook to the front bow in the orientation shown.
Be sure to have the flange of the hook line up with the slot on the bow.
TIGHTEN.
Step 13 –Determine if Extension is Required
Determine if the extension will be needed. Look at the passenger side of rack.

Instructions –4A96L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 15
Step 14 –Attach Torque Tube
Bolt one end of torque tube to front or rear bow using three 1/4" x 1” hex head bolts, six 1/4" flat
washers and three 1/4" lock nuts.
Repeat on opposite end.
If the extension is needed, follow these same instructions to attach torque tube to extension.
TIGHTEN.
Step 15 –Install End Tube
Assemble end tube and place at the end of each bow.

Instructions –4A96L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 16
Bolt into place using 3/8” x 3/4" hex head, 3/8” lock washer and 3/8” flat washer.
Repeat at front and rear bow.
TIGHTEN.
Step 16 –Assemble Ladder Hooks
Bolt ladder hook to ladder hook base using a 1/4" x 3/4" hex head,
1/4” lock washer, and 1/4" flat washer. Ladder hook height can be
adjusted later.

Instructions –4A96L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 17
Step 17 –Install Ladder Hooks
Using the hardware and installed studs on the bows, loosen the nuts and slide ladder hook into place. Be
sure the washers are on the outside of the ladder hook.
TIGHTEN.

Instructions –4A96L
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 18
Step 18 –Install Handle
Using the hardware removed in Step 3, insert handle into swage on the rear bow.
Be sure to place sealant along swage joint.
TIGHTEN.
GO BACK AND TIGHTEN ALL BOLTS FROM PREVIOUS STEPS.
BE SURE HARDWARE IN MOUNTING IS TIGHT.
YOUR INSTALLATION IS NOW COMPLETE.