Kargo Master 4090L Manual
Instruction Guide
4090L
Kargo Master
Rancho Cordova, CA 95742
800-343-7486
CustomerService@KargoMaster.com
DATE: ______________
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Instructions –4090L
*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” Socket and Wrench
1/2” Socket and Wrench
8’ Tape Measure
Table of Contents
Parts List ................................................................................................................................... 2
Hardware .............................................................................................................................. 3-4
Rack Assembly
Step 1 –Load Plate ................................................................................................................ 5
Step 2 –L Bracket .................................................................................................................. 5
Step 3 –Mount Side Tube ..................................................................................................... 6
Step 4 –Install Clamp Tube ................................................................................................... 7
Step 5 –Mount Latch Assembly ............................................................................................ 8
Step 6 –Mount Handle .......................................................................................................... 8
Step 7 –Mount Ladder Stop .................................................................................................. 9
Step 8 –Bows to Feet ............................................................................................................ 9
Before You Begin
•Read all instructions. Find your vehicle roof rail mounting, prior to rack assembly.
•Assembly on top of vehicle is a more user friendly installation.
•Be sure to put E6000 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
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Instructions –4090L
Parts
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Instructions –4090L
Hardware 1 of 2
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Instructions –4090L
Hardware 2 of 2
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Instructions –4090L
Step 1 –Load Plate
•Bolt load plate (D) to one end of each bow (A).
•Use a 5/16” x 3/4" carriage bolt (1), 5/16” flat
washer (4) and a 5/16” nyloc (7).
•TIGHTEN. Skip if adding 40813.
Step 2 –Mount L Bracket
•Place L bracket (B) on top of installed bows in location and orientation shown.
•Bolt together using 3/8” x 1” carriage bolt (9), a 3/8” flat washer (11) and a 3/8” nyloc (12).
•Snug Tighten, but allow movement
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Instructions –4090L
Step 3 –Mount Side Tube
•Place side tube (C) on top of installed bows.
•The bend goes towards the front of the vehicle. Be sure to have orientation to your desire.
•Leave one square slot open at the rear of the side tube.
•Bolt side tube to bows using 5/16” x 2” carriage bolt (3), a 5/16” flat washer (4) and a 5/16”
nyloc (7).
•Snug Tighten, but allow movement.
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Instructions –4090L
Step 4 –Install Clamp Tube
•Place bushings (13) around clamp
tube in orientation shown.
•Insert clamp tube (F).
•Slide hangar bracket (E) around
tube.
•Bolt hangar bracket into place
using a 5/16” x 2” carriage bolt (3),
a 5/16” flat washer (4) and a 5/16”
nyloc (7).
•Slide bushings into L and hangar
bracket.
•Be sure the flange of the hangar
bracket is in the correct
orientation.
•Snug Tighten, but allow movement.
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Instructions –4090L
Step 5 –Mount Latch Assembly
•Bolt latch (G) at the rear of the mount tube (C) that was installed in Step 3 using a 5/16” x 2”
carriage bolt (2), 5/16” curved washer (6) and a 5/16” nyloc (7).
•TIGHTEN
Step 6 –Mount Handle
•Bolt handle to clamp tube using a 5/16” x 2-3/4” hex head (3), two 5/16” flat washers (4), two
5/16” nylon washers (5) and a 5/16” nyloc (7).
•The nylon washers fit in between the clamp tube and handle and at the bottom in between
the handle and the flat washer.
•TIGHTEN
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Instructions –4090L
Step 7 –Mount Ladder Stop to Bow
•Bolt ladder stop (J) to the front bow in
the orientation shown using a 3/8” x 1”
carriage bolt (9), a 3/8” flat washer (11)
and a 3/8” nyloc (12).
•Be sure the bracket is square to the bow.
•Adjust clamp on bracket to fit firmly
against your ladder.
•TIGHTEN
Step 8 –Bows to Feet
•Set assembled rack onto feet installed using separate mounting package.
•Bolt bow into feet using 3/8” x .3/4” hex head (8), 3/8” split lock washers (10) and 3/8” flat
washers (11).
•Adjust to square rack on vehicle. TIGHTEN.
SQUARE AND ALIGN RACK TO YOUR LIKING.
GO BACK AND ENSURE ALL HARDWARE IS TIGHT
Your installation is now complete.
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