Kargo Master 40803 User Manual
40803 Parts List
Side Tube Assembly
Cross Bow
Item -001
Qty 2
Item -012
Qty 1
Support Angle
Item -014
QTY 1
Pad Bracket
Item -026
QTY 1
Gutter Mount
Item -041
QTY 4
Gutter Clamp
Item -044
QTY 4
Bracket Plate
Item -015
QTY 1
Tube Assembly
Item -016
QTY 1
Load Lock Plate
Item -025
QTY 2
Lock Box Assembly
Item -002
QTY 1
Clamp Pads
Item -034
QTY 2
For TECHNICAL SUPPORT Call: 800-343-7486
Handle
Item -002
QTY 1
E-6000
QTY 1
E-6000
40803 Hardware List
Tools Needed
8' Tape Measure
1/2 Socket
9/16 Socket
Component Pack
Qty 2
Flange Bushing
Item -013
Qty 2
5/16 ID Nylon Washer
Item -038
1/2 End Wrench
9/16 End Wrench
Hammer
Hardware Pack
(a)
Qty 11 3/8-16 x 1 Carriage Bolt
(c)
Qty 13 3/8-16 Nylock Nut
(b)
Qty 13 3/8 Flat Washer
(f)
Qty 4 5/16 x 3/4 Carriage Bolt
(k)
Qty 24 5/16 Flat Washer
(g)
Qty 1 5/16 x 2 3/4 Hex Bolt
(h)
Qty 15
5/16 Nylock Nut
(u)
Qty 5 5/16 x 1 1/2 Carriage
Bolt
(v)
Qty 6 5/16 x 1 3/4 Carriage
Bolt
(w)
Qty. 1 5/16 Nylock Jam Nut
For TECHNICAL SUPPORT Call: 800-343-7486 Monday - Friday 8:00 A.M to 4:30 P.M. (PST)
Approx
84"
DIAGRAM 1a
Approx
16"
Gutter Rail
Rear Door
Center Dimension
STEP 1
The first thing to decide is whether or not you will have the ability to lift and place the
entire assembled rack on the van. It will be easier to do the full assembly off the van.
But this will require 4 people, or a forklift, or a hoist. If not, you must assemble the rack
on top of the van.
When setting the cross bows in place on the van leave mounting clamp loose enough
for movement back and forth to align insertion of side tube assembly (-012).
Make (2) pencil marks
[Diagram 1a]
on gutter rail. One about 16" from rear of door
and one at 84". These will provide an approximate mount location for gutter mount
brackets (-041)
dimension. Insert mount (-041) into cross bow channel opening
[Diagram 6d]
. Now measure across gutters for approximate center
[Diagram 6c].
Insert 3/8
x 1 carriage bolt (a) from backside and through channel with 3/8 flat washer (b) and
3/8 nylock nut (c).
[Diagram 6d]
to correspond to gutter center measurement taken earlier. Hole "C" will
NOTE:
Choose hole "C"(FORD) or "D"(CHEVY) in bracket (-041) per
provide a maximum of 65" and a minimum of 59" (gutter centers). Hole "D" will provide
a maximum of 62 1/2" and a minimum of 57". Install all four (-041) brackets and leave
bolts loose for final adjustment on van.
If you are installing the rack yourself, place the bows and attached gutter mounts on
the van now.
DIAGRAM 6d
Max 65" / Min 59"
Max 62 1/4" / Min 57"
"C"
FORD
Gutter Mount
(-041)
"D"
CHEVY
Gutter Mount
(-041)
(b)
(c)
Cross Bow
(-001)
(a)
Channel
Opening
DIAGRAM 6c
Loading...