Kit# 2108-1 Mounting Bracket Kit Installation Instructions

Transcript

ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 1-800-669-9690 fax 360-735-9300 KIT# 2108-1 04/13/09 KS www.roadmasterinc.com R O A D M A S T E R , I N C. MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ITEM QTY NAME MATERIAL 1 ............... 2 ............... 5/8" x 2" BOLT ................................................. 350150-00 2 ............... 2 ............... 5/8" x 4 1/2" BOLT .......................................... 350159-00 3 ............... 2 ............... 5/8" PLATE WASHER ..................................... 350352-00 4 ............... 4 ............... 5/8" LOCK WASHER ....................................... 350313-00 5 ............... 4 ............... 5/8" HEX NUT ................................................... 350262-00 6 ............... 2 ............... 1/2" x 3" BOLT ................................................. 350101-00 7 ............... 2 ............... 1/2" FLAT WASHER ........................................ 350308-20 8 ............... 2 ............... 1/2" LOCK WASHER ....................................... 350309-00 9 ............... 2 ............... 1/2" HEX NUT ................................................... 350258-00 10 ............. 2 ............... DRAW PIN/SPRING PIN ................................. 357035-00 11 ............. 2 ............... QUICK LINK ...................................................... 200008-00 12 ............. 2 ............... SAFETY CABLES 8" ....................................... 500646-08 13 ............. 2 ............... BACKING PLATE WELDMENT ...................... C-000656 14 ............. 1 ............... DRIVER SIDE RECEIVER .............................. C-000654 15 ............. 1 ............... PASSENGER SIDE RECEIVER .................... C-000655 16 ............. 1 ............... DRIVER SIDE ARM ......................................... C-000652 FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN DEATH, PERSONAL INJURY OR PROPERTY 17 ............. 1 ............... PASSENGER SIDE ARM ............................... C-000653 DAMAGE MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 This bracket kit is one of our XL series, which is designed to be partly removable (Fig.A). The kit consists of the two main receiver braces, two front braces and a hardware pack. The main receivers utilize the front frame tie down loops and frame on each side as mounting points. Start by laying out the kit according to the hardware illustration. This will give you a visual idea of how the kit installs and also confirm that the kit components are present and accounted for. 1-800-669-9690 fax 360-735-9300 KIT# 2108-1 04/13/09 KS www.roadmasterinc.com Fig.A IMPORTANT: IMPORTANT: All All brackets brackets must must be be assembled assembled with with all all the the bolts bolts left left loose loose for for final final adjustment adjustment and and positioning positioning (before (before tightening) unless otherwise instructed. All bolts must be torqued for proper strength. If more than one tightening) unless otherwise instructed. All bolts must be torqued for proper strength. If more than one bolt bolt is is used used per per fastening fastening point, point, the the diagram diagram may may only only show show one. one. •• Use Use flat flat washers washers over over all all slotted slotted holes holes •• Use Use lock lock washers washers on on all all fasteners fasteners ROADMASTER ROADMASTER Limited Limited Warranty, Warranty, including including One-Year One-Year Conditional Conditional Warranty Warranty Text Text and and Product Product Registration Registration Card, Card, in in Carton. Carton. WARNING WARNING Failure Failure to to follow follow these these instructions instructions can can result result in in property property damage, damage, personal personal injury injury or or even even death. death. •• Installation Installation of of most most mounting mounting brackets brackets requires requires moderate moderate mechanimechanical cal aptitude aptitude and and skills. skills. We We strongly strongly recommend recommend professional professional installainstallation tion by by an an experienced experienced installer. installer. •• The The installer installer must must read read the the instructions instructions and and use use all all bolts bolts and and parts parts supplied. supplied. When to instructions fasten require the the reuse could factory in bolts, of supplied. Failure Failurethe to securely securely fasten the bracket bracket couldofresult result in loss loss of the thread lockvehicle. and/or lock washers must also be used. Failure to securely the towed towed vehicle. fasten could result in loss of the towed as vehicle. •• Do use this for fabrication, Do not notthe usebracket this document document for custom custom fabrication, as itit may may not not show show • Do all not use or this document components. for custom Custom fabrication, fabrication asor it may an not show to all parts parts or structural structural components. Custom fabrication or an attempt attempt to copy all parts this structural design components. could Custom in fabrication of or anvehicle. attempt to copy thisorbracket bracket design could result result in loss loss of the the towed towed vehicle. this bracket design could result inspect inand lossbrackets of thefasteners towed vehicle. •• copy Every 3,000 miles, the owner must the for proper The owner must inspect all mounts before each use • Every torque, 3,000 according miles, to the the bolt owner torque must requirements inspect the chart fasteners on the for lastproper page for cracks or other signs of fatigue. Also, inspect the fasteners for of torque, theseaccording instructions. to the The bolt owner torque must requirements alsorequirements inspect chart all on mounts the laston page and proper torque, according to the bolt torque chart the brackets of these instructions. for cracks The or so other owner signs must inspect 3,000 mounts miles. and last page. Failure to do could resultofalso infatigue loss of every the all towed vehicle. Failure to for domust so cracks could or result other in loss signs ofmanufacturer's of thefatigue towed vehicle. every 3,000 miles. • brackets The owner check the vehicle instructions for to domust so could result inprepare loss of the vehicle. • Failure The check thetovehicle manufacturer's instructions for the owner proper procedure(s) the towed vehicle for towing. Some • The the proper owner must procedure(s) the to vehicle prepare manufacturer's the vehicle instructions towing. Some for vehicles must be check equipped with a transmission lubefor pump, an axle disvehicles the proper must procedure(s) be equipped to with prepare transmission the vehicle lube for pump, towing. an axle Some disconnect, driveline disconnect orafree-wheeling hubs before they can be connect, vehicles must driveline be disconnect with or afree-wheeling transmission hubs lube before pump, they an axle candisbe towed. Failure toequipped properly equip the vehicle will cause severe damage towed. connect, Failure driveline to properly disconnect equip or free-wheeling the vehicle will hubs cause before severe theydamage can be to the transmission. to the transmission. Failure to properly will cause severe after damage • towed. If running changes wereequip madethe by vehicle the vehicle manufacturer this the transmission. • to Ifbracket running changes were made by or theother vehicle manufacturer after this was designed, some bolts fasteners in the hardware • If bracket running was changes designed, bolts byor theother vehicle manufacturer in the responsihardware after this pack may no longer were be some themade correct size. It isfasteners the installer’s pack bracket no designed, longer be some the correct bolts size. or other It isfastened fasteners the installer’s thevehicle responsihardware bilitymay towas verify that the bracket is securely tointhe and bility pack to verify no that the be bracket the correct is size. It is fastened the installer’s to the vehicle responsiand fittedmay with thelonger correct hardware to securely account for these changes. Failure to fitted bility with to verify the correct that hardware bracket to is account securely fastened these changes. to the vehicle Failure and to securely fasten thethe bracket could result infor loss of the towed vehicle. securely fitted withfasten the correct the bracket hardware could to account result infor loss these of the changes. towed Failure vehicle.to fasten the bracket could in loss of the towed vehicle.re• securely If the towed vehicle has been in result an accident, it must be properly • Ifpaired the towed hasthe been in an Do accident, it must properly rebeforevehicle attaching bracket. not install thebe bracket if any paired before attaching the is bracket. not install any structural frame damage found. Do Failure to repairthe thebracket damageifcould structural frame is Failure structural frame damage is found. found. Failure to to repair repair the the damage damage could could result in the loss damage of the towed vehicle. result in in the the loss loss of of the the towed towed vehicle. vehicle. result • Some motorhome chassis have such a tight turning radius that you can Some motorhome chassis towed have such such a tight tight turning radius that that you can •• Some motorhome chassis have a radius can damage your motorhome, vehicle, towturning bar or bracket whileyou turning damage your motorhome, towed vehicle, tow your bar or orturning bracket radius while turning turning damage motorhome, towed tow bar bracket while sharply. your Before getting on thevehicle, road, test in an sharply. Before on test your turning in sharply. Before getting getting on the the road, testcould your result turning radius in an an empty parking lot. Turning tooroad, sharply in radius non-warranty empty lot. Turning too could result in empty parking lot.system, Turningmotorhome too sharply sharplyand/or couldtowed result vehicle. in non-warranty non-warranty damageparking to towing damage to to towing towing system, system, motorhome and/or and/or towed towed vehicle. vehicle. • damage Do not back up with themotorhome towed vehicle attached or non-warranty Do not back back up with with the towed towed vehicle attached or non-warranty non-warranty •• Do not up the or damage will occur to your towing vehicle system,attached motorhome and/or towed damage will occur occur to to your your towing towing system, system, motorhome motorhome and/or and/or towed towed damage vehicle. will vehicle. • vehicle. The safety cables must connect the towing vehicle to the towed •• The safety cables must connect the vehicle the The safety cables mustwith connect the towing towing vehicle to the towed towed vehicle frame to frame, the cables crossed, with to enough slack vehicle frame to the cables crossed, enough slack vehicle frame to frame, frame, with thecable cables crossed, with with enoughrouting. slack for sharp turns. Refer with to the instructions for proper for sharp turns.enough Refer slack to the theincable cable instructions forfailure proper routing. for sharp turns. Refer to instructions for proper Failure to leave the safety cables, or to routing. connect Failure to leave leave enough slack in the the will safety cables, or loss failure tothe connect Failure to enough in safety cables, or failure connect the safety cables frameslack to frame, result in the of to towed the safety the safety cables cables frame frame to to frame, frame, will will result result in in the the loss loss of of the the towed towed vehicle. vehicle. • vehicle. This bracket is designed for use with ROADMASTER tow bars and •• This bracket for with ROADMASTER tow and This bracket is is designed designed for use use withthis ROADMASTER tow bars bars and ROADMASTER adaptors only. Using bracket with other brands, ROADMASTER adaptorsROADMASTER only. Using Using this thisadaptor, bracket may with result other brands, brands, ROADMASTER adaptors only. bracket with other without an approved in nonwithout andamage approved ROADMASTER adaptor, adaptor, may may result result in in nonnonwithout approved ROADMASTER warrantyan or injury. warranty damage or or injury. injury. • warranty Upon finaldamage installation, the installer must inspect the bracket to en•• Upon final the must inspect the to Upon final installation, installation, the installer installer must inspect the bracket bracket to enensure adequate clearance, particularly around hoses, air conditioner sure clearance, hoses, conditioner sure adequate clearance, particularly around hoses, airtowed conditioner lines,adequate radiators, etc., or particularly non-warrantyaround damage to theair vehicle lines, radiators, etc., etc., or or non-warranty non-warranty damage damage to to the the towed towed vehicle vehicle lines, radiators, will result. will result. result. • will This bracket is only warranteed for the original installation. Installing This bracket is only only warranteed for is thenot original installation. Installing •• This bracket is warranteed for the original installation. a used bracket on another vehicle recommended andInstalling will void a used bracket athe used bracket on on another another vehicle vehicle is is not not recommended recommended and and will will void void warranty. the the warranty. warranty. MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. 6110 NE 127th Ave. Fig.B Vancouver, WA 98682 1-800-669-9690 fax 360-735-9300 KIT# 2108-1 04/13/09 KS www.roadmasterinc.com Fig.C Fig.D 1. Important: please use all supplied bolts and parts and read all instructions carefully before beginning this installation. The majority of questions you may have can be answered within the text, and proper installation will ensure safe and secure travel. Now, begin the installation. For 2007 to 2008 models: you will need to trim the fascia to access the tow hooks. Use the white lines in Figure B as a guide for trimming. All other models: proceed to step 2. 2. Locate the front tie down loops on the front of the frame (Fig.C). Working on one side at a time, hold a receiver brace against the side of the frame behind and under the tie down loop. Bolt through the lower side mounting hole with a 5/8" x 4½" bolt, plate washer, lock washer and nut. This will hold the brace in position (Fig.D,E). Fig.E Fig.F Fig.G 2. Bolt through the top of the brace and the frame with a ½" x 3" bolt, flat washer, lock washer and nut (Fig.F). Note: each side will use a different top hole; make certain to bolt through the frame hole that lines up. 3. Bolt through the front of the brace, the tow loop and the spacer backing plate with a 5/8" x 2" bolt, lock washer and nut (Fig.G). 4. Repeat steps 2 through 4 for the remaining side (Fig.G). 5. Align the braces and tighten the bolts to the torque specifications found at the end of this document. 6. I n s e r t t h e f r o n t b r a c e s i n t h e receiver braces and secure with 5/8" draw pins and 1/8" spring pins (Fig.H). Fig.G 7. U s e t h e c a b l e c o n n e c t o r s t o connect the 8" safety cables to the receiver braces. Attach the ends to the tow vehicle's safety cables. All illustrations and specifications contained herein are based on the latest information available at the time of publication approval. ROADMASTER, INC. reserves the right to make changes at any time without notice in material, specification and models or to discontinue models. Fig.H KIT# 2108-1 MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 1-800-669-9690 04/13/09 KS fax 360-735-9300 www.roadmasterinc.com BOLT TORQUE REQUIREMENTS Note: The torque values represented below are intended as general guidelines. Torque requirements for specific applications may vary. Roadmaster does not warrant this information to be accurate for all applications and disclaims all liability for any claims or damages which may result from its use. STANDARD BOLTS Thread Size Grade METRIC BOLTS Torque 5/16 ................... 5 ......................... 13 3/8 ...................... 5 ......................... 23 7/16 ................... 5 ........................ 37 1/2 ...................... 5 ........................ 56 5/8 ...................... 5 ...................... 150 ft./lb. ft./lb. ft./lb. ft./lb. ft./lb. Thread Size Grade 8mm-1.0 ......... 8mm-1.25 ....... 10mm-1.25 ..... 10mm-1.5 ....... 8.8 8.8 8.8 8.8 METRIC BOLTS Plated / Unplated ...... 20 ft./lb. ...... 19 ft./lb. ..... 38 ft./lb. ..... 37 ft./lb. 18 18 36 35 ft./lb. ft./lb. ft./lb. ft./lb. Thread Size Grade 12mm-1.25 ..... 12mm-1.5 ....... 12mm-1.75 ..... 14mm-2.0 ....... 8.8 8.8 8.8 8.8 Plated / Unplated ...... 70 ft./lb. 65 ...... 66 ft./lb. 61 ..... 65 ft./lb. 60 ... 104 ft./lb. 97 All illustrations and specifications contained herein are based on the latest information available at the time of publication approval. ROADMASTER, INC. reserves the right to make changes at any time without notice in material, specification and models or to discontinue models. ft./lb. ft./lb. ft./lb. ft./lb.