Kargo Master 80070 User Manual

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Page 1

ASSEMBLY INSTRUCTIONS

for :

80070 TOP MOUNT

CAMPER SHELL

and TRANSIT CONNECT

RACK

TMCS_3:1

(916) 638-8703

• 11261 Trade Center Drive • Rancho Cordova, CA 95742 •

(800) 343-7486

• www.kargomaster.com •

Page 2

ASSEMBLY INSTRUCTIONS

Read all instructions carefully and follow each step in proper sequence for ease and speed in assembling your KARGO-MASTER RACK. See below for nuts and bolts diagram.

80070 Top Mount Camper Shell & Transit Connect Rack

Camper

Transit

WARNING!

WE RECOMMEND THAT YOU NOT EXCEED 200 LBS. OF EVENLY

SPACED CARGO. TOO MUCH WEIGHT COULD DAMAGE YOUR CAMPER SHELL. KARGO MASTER MAKES NO REPRESENTATION OR WARRANTY AS TO THE AMOUNT OF WEIGHT THAT CAN BE CARRIED SAFELY BY OR WITHOUT DAMAGING YOUR SHELL. FOR GUIDANCE, WE RECOMMEND THAT YOU CONSULT THE CAMPER SHELL MANUFACTURER.

1111

NOTE:

Shaded numbers ( ) in this view correspond to instruction steps in this assembly package.

DRILLING HOLES IN THE CAMPER SHELL ROOF MAY VOID THE WARRANTY. WE RECOMMEND THAT YOU HAVE AN AUTHORIZED CAMPER SHELL DEALER DRILL AND MOUNT THE RACK FOOT PLATES.

SECURE ALL CARGO PROPERLY FOR SAFE TRANSPORTATION.

2012 KargoMaster-TMCS-3:1

Page 3

(4 ea.)

1/2" x 2 1/4"

Button Head Bolt

(4 ea.)

1/2" Nyloc Jam Nut

(4 ea.) Mounting Bracket Spacers

(16 ea.)

5/16" x 1"

Carriage Bolt

(8 ea.)

5/16" x 3/4"

Button Head Bolt

(8 ea.)

5/16" Lock Washer

(4 ea.)

3/8" x 4" Hex Bolt

80070 Bolt Kit

(32 ea.)

5/16" Flat Washer

(24 ea.)

5/16" Lock Nut

(4 ea.)

M8 x 32

(8 ea.)

5/16" x 1 1/4"

Button Head Bolt

(4 ea.)

1/2" SAE Flat Washer

(8 ea.)

3/8" SAE Flat Washer

(4 ea.)

3/8" Lock Nut

Page 4

TMCS_3:1

GOOP APPLICATION

Apply a healthy air tight bead of goop

around every swaged joint as shown, to

prevent moisture from leaking into and out

of the joint. If this is not done properly, the

inside surface of the tubes can rust and

rusty water can leak out. Maintain this

joint seal throughout the life of your rack.

Swaged joint & holes

GOOP

Smooth goop at swaged joint & holes

GOOP

STEP 1

#1 = Cover entire swedge joints with

goop and slide FRONT U- BAR onto side rails and bolt together with bolts jam nut

A, and

STEP 2

#1 = Cover entire swedge joints with

goop and slide REAR U- BAR onto side rails and bolt together with bolts jam nut

A, and

Page 5

CAMPER SHELL ONLY - Transit Connect skip to STEP 8

TMCS_3:1

STEP 3

#1 = Position rear cross bar behind the ½” button head

A that attaches the rear U bar to the side channel.

bolt Loosely bolt clamp plates together with bolts and lock nuts

#2 = With the camper shell rear door fully opened, measure the distance from the open rear door to the front most point of the camper shell roof, where you will be locating the front mounting plates. See diagram in STEP 5.

#3 = Position the front cross bar so that the distance from the rear U bar to the front cross bar is as per the measurement above. The objective is to locate the front foot as far forward on the camper shell roof as possible, but at the same time making sure that the opened camper shell rear door will not hit the rear U bar. See diagram in STEP together with bolts

E, washer I and lock nuts J.

**(Camper Shell ONLY)

E, washer I

5. Loosely bolt clamp plates

STEP 4

#1 = There are 8 mounting feet in your box. There are

4 identical feet (these are the taller ones with the three holed flange on the bottom). These will be used for Camper Shell installation. Find these now.

#2 = Position the Camper Shell feet into the slider brackets on the cross bars.

#3 = Place the spacer N inside the mounting brackets. Loosely bolt the feet to slider brackets using bolts

K, washers L and lock nuts M.

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TMCS_3:1

STEP 5

**(Camper Shell ONLY)

#1 = Place a rubber roof pad under each foot flange, align the holes, and temporarily secure it in place with tape. Do not tape over the holes.

#2 = Carefully place the assembled rack onto the top of the camper shell and position it centered side to side. Examine the underside of your camper shell to see if the manufacture has molded any reinforcement pads into the roof. If so, position the feet so that the mount bolts will go through the pads. If not, we recommend that you consult the camper shell manufacture for optimal foot location. Typically, the front feet should be as far forward as possible, the rear feet should be as far back as possible, and all feet should to the outer most shoulder of the shell. When the rack has been positioned as described above, BE SURE that the there is at least 2” clearance between the rear U-bar and the fully opened rear camper shell door. BE SURE that the INSIDE backing plate will be clear of any obstacles inside the camper shell roof. After final positioning, tighten down the cross bar clamps.

2“

DIAGRAM #1

Feet Flange

Fiberglass

Camper Shell

( inside )

Rack

Cross Beam

Rubber

Roof Pad

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TMCS_3:1

STEP 6

**(Camper Shell ONLY)

NOTE: Be sure that the INSIDE backing plate will be clear of any obstacles inside the camper shell roof.

#1 = With the rack properly positioned, mark the

TWO outer holes (not the middle hole) on the foot flange where the through bolts will go through. See diagram.

WARNING!

• DRILLING HOLES IN THE CAMPER SHELL ROOF MAY VOID THE WARRANTY. WE RECOMMEND THAT YOU HAVE AN AUTHORIZED CAMPER SHELL DEALER DRILL AND MOUNT THE RACK FOOTPLATES.

#2 = Remove the rack from the roof. CAREFULLY drill a small pilot hole through the shell. With a 5/16 bit, drill up from inside, about half way through the fiberglass. From outside, drill down to finish the hole.

STEP 7

#1 = CAREFULLY lift each foot one at a

time, remove the tape, and reposition the rubber roof pad so that the holes are aligned.

#2 = Secure each foot flange, outside rubber roof pad, inside rubber roof pad, and inside backing plate using through bolts flat washers have really long arms, this is a two man job.

I, and lock nuts J. Unless you

**(Camper Shell ONLY)

DIAGRAM #2

Fiberglass

Camper Shell

Foot

( inside )

Rubber

Roof Pad

Inside Roof

Clamp Plate

Inside Rubber

Backing Pad

Foot

Foot Flange

Rubber

Backing Plate

( inside )

Tighten down all nuts & bolts and THAT'S IT! You are now ready to use your rack.

Page 8

STEP 8

Ford Transit Connect

Rear Cross Bar

TMCS_3:1

#1 = Position centerline of rear crossbar about 36” forward of centerline of rear U-bar. Securely bolt clamp plates together with bolts E, flat washers I, and lock nuts J.

#2 = Position centerline of front crossbar about 39” forward of centerline of rear crossbar. Loosely bolt clamp plates together with bolts E, flat washer I and lock nuts J.

36”

39”

Page 9

Ford Transit Connect, con’t

STEP 9

#1 = There are 8 mounting feet in your box,

SEE NEXT PAGE FOR DETAILS. There are 4 feet (these are the shorter ones with no flange and a single hole in the bottom) that will be used for Transit Connect installation. NOTE: The front feet (these are the shortest ones, are angled to conform with the contour of the front of the roof. There is a left and a right front foot. See diagram next page. Find these now.

TMCS_3:1

#2 = Position the Transit Connect feet into the slider brackets on the cross bars.

#3 = Place the spacer N inside the mounting

brackets. Loosely bolt the feet to slider brackets using bolts

#4 = The Transit Connect has factory threaded

bosses on the roof. No need to drill holes in the roof. These bosses have a threaded button with a rubber washer. Remove the factory button and washer.

#5 = There are 4 rubber pads in the box. Align the middle hole of the pad with the middle hole in the Transit Connect foot. Cut off the ends of the pads to match the width of the Transit Connect foot. Position the pads over the threaded bosses.

K, washers L and lock nuts M.

Rear Pad

Front Pad

#6 = Carefully position the rack onto the roof. Align the holes in the feet with the holes in the rubber pads with the bosses. Loosely attach the rear feet to the roof with M8 x 32 button head bolt, flat washer and lock washer. Adjust the front cross bar as necessary. To align the front feet. Securely attach the front feet to the roof with M8 x 32 button head bolt, flat washer and lock washer. Tighten rear feet.

Tighten down all nuts & bolts and

THAT'S IT! You are now ready to use your rack.

CAUTION! DO NOT OVERLOAD YOUR TRANSIT CONNECT.

Page 10

► Use these feet to mount to a Transit Connect.

► Cut the rubber pad to fit foot.

Front Drivers Side

Taller in Front

Front Passenger Side

Taller in Front

Rears’

Page 11

Ensure all nuts & bolts are tighten down and THAT'S IT! You are now ready to use your rack.

TMCS_3:1

DON'T OVERLOAD YOUR VEHICLE!

100" = X3 lbs.

.SBL

SBL

WEIGHT CARRIED ABOVE THE FLOOR OF THE TRUCK BED (E.G. ON AN OVERHEAD TRUCK RACK) WILL SIGNIFICANTLY INCREASE THE VEHICLE'S TENDENCY TO OVERTURN. ALWAYS KEEP HEAVY LOADS EVENLY DISTRIBUTED AND AS LOW AS POSSIBLE. IT IS IMPORTANT TO NOTE THAT THE KARGO MASTER RACK LOAD BEARING CAPACITY MAY BE GREATER THAN YOUR TRUCK'S GAWR OR GVWR CAPACITY, AND IS PROBABLY GREATER THAN THE WEIGHT THAT CAN BE SAFELY CARRIED OVERHEAD.

35" =

lbs.