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ASSEMBLY INSTRUCTIONS
for :
PRO-III & IV
®
(916) 638-8703
• 11253- G Trade Center Drive • Rancho Cordova, CA 95742 •
(800) 343-7486
DON'T OVERLOAD YOUR VEHICLE!
LBS.
LBS.
@
@
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 OF 1700 LBS. MAY BE GREATER THAN YOUR
TRUCK'S GAWR OR GVWR CAPACITY, AND IS PROBABLY GREATER THAN THE WEIGHT THAT CAN BE
SAFELY CARRIED OVERHEAD.
100" = 3X lbs.
35" =
X lbs.
For TECHNICAL SUPPORT Call:
1.800.343.7486
HOURS: Monday- Friday 8:00 A.M. to 4:30 P.M. ( PACIFIC )
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PRO - III & IV
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1/2", 9/16", & 3/4"
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2004 KargoMaster-'Pro 3' _2.1
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A
(4 ea.)
1/2" x 3 1/2"
Hex Bolt
B
(2 ea.)
1/2" x 2 1/4"
Button Head Bolt
(2 ea.)
C
3/8" x 2 1/4"
Button Head
(8 ea.)
D
3/8" x 1 3/4"
Button Head
(2 ea.)
E
5/16" x 2 1/4"
Button Head Bolt
(8 ea.)
F
5/16" x 3/4"
Button Head Bolt
(4 ea.)
G
5/16" x 3/4"
Carriage Bolt
(4 ea.)
P
5/16" x 3/8"
Allen Head Set Screw
H
(10 ea.) 1/2" SAE Flat Washer
©2004 KARGO MASTER --Pro 3 _2.1
R
(2 ea.) 1/2" Rubber Washer
J
(18 ea.) 3/8" SAE Flat Washer
K
(14 ea.) 5/16" Flat Washer
L
(6 ea.)
1/2" Jam Nut
N
M
(10 ea.)
3/8" Lock Nut 5/16" Lock Nut
Shown Actual Size
Shown Actual Size
(14 ea.)
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Pro 3
STEP 1
#1 = Cover entire swedge joints with silicone
sealant and join FRONT and REAR side channels
together, there is a LEFT & RIGHT FRONT, with
the Right marked with a GREEN dot on the
overlapping plate. There is a RIGHT & LEFT
REAR. The leg cups angle outward. Be sure the
connecting plates overlap, and bolt together with
bolts G, washers K and lock nuts N.
STEP 2
#1 = Measure the inside of truck bed, from
tail gate to bulk head. Position the front
legs at approximately that distance from the
rear legs. Final positioning of the front legs
will follow in STEP 7.
BulkheadTailgate
N
K
N
K
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G
#2 = Slide the FRONT leg onto the front side
channel. There is a RIGHT & a LEFT.
Match to the correct side channel so that both
FRONT & REAR legs angle outward.
Insert the set screws P, but do not tighten yet.
#3 = Loosely attach the top CLAMP with
bolts F, washers K, and nuts N.
STEP 3
#1 = Cover entire swedge joints with
silicone sealant and attach the REAR LEGS
with bolts C, washers J, and nuts M.
Note: The distance between front & rear
legs will not be longer than the inside
measurements of the bed itself.
P
M
J
F
(RIGHT SIDE SHOWN)
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STEP 4
#1 = Cover entire swedge joints with
silicone sealant and insert the CENTER
CROSS BAR into the SIDE RAIL CUPS
and attach with bolts E, washers K and
lock nuts N.
E
Pro 3_1.2-’05
E
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K
STEP 5
#1 = Insert PLASTIC CAPS onto the rear
crossbar uprights, (the tall side of the tube).
Slide the REAR CROSS BAR into the REAR
LEG POSTS at the top, as shown.
STEP 6
B
#1 = Cover entire swedge joints with
silicone sealant and slide FRONT CROSS
BAR onto side rails and bolt together with
bolts B, rubber washer R, and jam nut L.
R
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STEP 7
#1 = Position the Front Mount Plates on the truck bed rail so that they are as far forward as possible,
but make sure inserted bolt A is at least
the truck bed rail so that the rear of the Mount Plate is even with the inside of the truck tail gate. Find the
pre-drilled hole in the footplate that is furthest from the leg and drill 3/8” hole through truck’s bed rail. You
must drill a second bolt hole through both the footplate and the truck’s bed rail. Locate this second hole as
close as possible to the front leg, but making sure you can access the end of the bolt underneath the truck’s
bed rail as necessary to put on the washer and nut.
NOTE: If it is not possible to locate a second hole close to the front leg, or if you would like to
mount your rack without drilling into your truck’s bed rail, please see OPTIONAL MOUNTING
METHODS on the last page of these instructions. These options require accessory mount kits
purchased separately.
1” clear of the cab of the truck.Position the Rear Mount Plates on
Pro 3
3"
8
#2 = Attach the Mount Plates on truck using either bolts D, washers J
and nuts M, or a combination of Clamps and Stake Pocket T bolts.
NOTE:
Mounting Plates so that one of the pre drilled holes in the Mount Plate is
over the truck’s stake pocket.
When using Stake Pocket T Bolts, it is convienient to locate the
#3 = Measure the distance, center to center, between the
FRONT and REAR U-BRACKETS. Adjust the distance between
the FRONT and REAR LEGS to match that measurement.
Then set the rack on the truck and attach the rear legs first with
bolts A, washers H, and nuts L.
L
J
M
H
D
J
A
H
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STEP 8
#1 = Make final adjustments and
attach front leg with bolts A,
washers H, and nut L.
Center rack on truck bed.
Pro 3
P
Tighten up the bolts on the crossbar and clamp
plates as well as the set screws P.
STEP 9
#1 = Attach the front SUPPORT
UPRIGHT where the 1” tube begins
to bend downward, then...
TIGHTEN DOWN EVERYTHING AND....
A
H
H
L
N
K
THAT’S IT!
You’re ready to LOAD & GO!
G
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Rack Mounting Bracket
Optional
T-nut
Footplate Pre-Drilled Holes
PRO 3
3"
8
A
Drill 1st hole in truck bedrail,
through pre-drilled hole in
the footplate, as shown.
TRUCKs’
BEDRAIL
A
Follow instruction that come with
your Stake Pocket T- Bolt Mounting Kit
#31560
OPTION
When it is not possible to locate a bolt close to the front leg, use our
optional Stake Pocket T- Bolt Kit #31560.
The T-nuts will go into the stake pocket to secure the footplate to bed
rail, along with the hole drilled into the trucks’ bed rail through the
pre-drilled hole in the footplate. Complete instructions come with the
kit.
(WITHOUT SEALANT)
PURCHASED SEPARATELY:
A
Optional Clamp-On Mount
NO DRILL clamp-on mounting
B
OPTION
This plan is the NO DRILL ANYTHING solution.
These clamps allow you to bolt down the footplates to the trucks’ bed
rail without having to drill any holes in your truck or the footplate.
This kit is #31580.
SILICONE
SEALANT
B
PURCHASED SEPARATELY:
Rusty Joint
Apply a healthy air tight bead of silicone around every swaged joint 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.
®
For TECHNICAL SUPPORT Call:
1.800.343.7486
HOURS: Monday- Friday 8:00 A.M. to 4:30 P.M. (PACIFIC)
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