Kit# 2109-1 Mounting Bracket Kit Installation Instructions

Transcript

ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 1-800-669-9690 03/23/09 KS fax 360-735-9300 www.roadmasterinc.com A S T E R , I N C. KIT# 2109-1 MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS M Item Qty. Length Width Description Part# 1 .............. 6 ............... 1 1/4" ....... 1/2" ........... 1/2" x 1 1/4" BOLT ...................... 350094-10 2 .............. 8 ................................. 1/2" ........... LOCK WASHER .......................... 350309-00 D 3 .............. 8 ................................. 1/2" ........... NUT ............................................. 350258-00 4 .............. 2 ............... 4 1/2" ....... 1/2" ........... 1/2" x 4 1/2" BOLT ...................... 350106-00 5 .............. 2 ................................. 1/2" ........... PLATE WASHER ........................ 350351-00 A 6 .............. 2 ............... 130mm .... 14mm ....... 14mm x 1.5 x130 BOLT .............. 357213-00 7 .............. 2 ................................. 14mm ....... LOCK WASHER .......................... 355740-00 8 .............. 2 ................................. 14mm ....... FENDER WASHER ..................... 355741-00 O 9 .............. 2 ............... 1 3/4" ....... 5/8" ........... 5/8" x1 3/4" BOLT ....................... 350149-00 10 ............ 2 ................................. 5/8" ........... FLAT WASHER ........................... 350348-00 11 ............ 2 ................................. 5/8" ........... LOCK WASHER .......................... 350313-00 R 12 ............ ................................. 5/8" ........... ............................................. 350262-00 FAILURE TO2FOLLOW THESE INSTRUCTIONS CANNUT RESULT IN DEATH, PERSONAL INJURY OR PROPERTY 13 ............ 2 ................................. 5/8" ........... DRAW PINS, SPRING PINS ...... 357035-00 14 ............ 2 .................................................... CABLE CONNECTOR ................ 200008-00 15 ............ 2 ............... 10" .............................. SAFETY CABLE ......................... 500646-10 DAMAGE MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 T his is one of our XL series brackets, which allows the visible front portion of the bracket to be easily removed from the front of the vehicle (Fig.A and Fig.B). The bracket kit consists of a main receiver brace, two side braces, two removable front braces and a hardware pack. The main receiver brace mounts to the subframe. The two side braces mount to the main receiver brace, the tow hooks and the frame rails. The removable front braces install in the main receiver brace. Before starting the installation, lay out the kit components in order, as they will be used. This will give you a visual idea of how the components work, and will also confirm that everything is present and accounted for. 1-800-669-9690 fax 360-735-9300 KIT# 2109-1 03/23/09 KS www.roadmasterinc.com Fig.A Fig.B 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 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 the to instructions fasten require the the reuse could factory in bolts, of supplied. Failure Failure 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 the bracket could result custom in loss of the towed as vehicle. not show •• Do Do not not use use this this document document for for custom fabrication, fabrication, as itit may may not 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 must result in loss of thefasteners towed vehicle. •• copy Every 3,000 miles, the owner the proper The owner must inspect all mountsinspect and brackets before for each use • Every torque, 3,000 according miles, to the the bolt owner torque must requirements inspect the chart fasteners on fasteners thefor lastproper page for cracks or other signs of fatigue. Also, inspect the 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 instructions. for cracks The orso other owner mustofin also fatigue inspect every all 3,000 mounts miles. and lastthese page. Failure to do couldsigns result loss of the towed vehicle. Failure to for brackets do so cracks could or result other in loss signs of of thefatigue towed vehicle. every 3,000 miles. • Failure The owner must check the vehicle manufacturer's instructions for to domust so could result in loss of the towed vehicle. • The owner check thetovehicle manufacturer's instructions for the proper procedure(s) prepare the vehicle for towing. Some • The the proper owner must procedure(s) check the to vehicle prepare manufacturer's the vehicle instructions towing. Some for vehicles must be equipped with a transmission lube for pump, an axle disvehicles the proper must procedure(s) be equipped to with prepare afree-wheeling transmission the vehicle lube for pump, towing. an axle Some disconnect, driveline disconnect or 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 to equipped 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. towed. Failure to properly equip the vehicle will cause severe damage • to If running changes were made by the vehicle manufacturer after this the transmission. • If running changes were made by or theother vehicle manufacturer after this bracket was designed, some bolts fasteners in the hardware • If bracket running was changes designed, were some bolts bysize. or theother vehicle in the responsihardware after this pack may no longer be themade correct It isfasteners themanufacturer installer’s pack bracket no designed, longer be bracket some the correct bolts size. or other It isfastened fasteners the installer’s thevehicle responsihardware bilitymay to was verify that the is securely tointhe and bility pack to verify no that the be bracket the correct is size. It for is fastened the installer’s to the vehicle responsiand fitted may with the longer correct hardware to securely account these changes. Failure to fitted bility with to verify the correct that hardware bracket to is account securely fastened these changes. to towed the vehicle Failure and to securely fasten thethe bracket could result infor loss of the vehicle. securely fitted withfasten the correct the bracket hardware could to account result infor loss these of the changes. towed Failure vehicle.to securely fasten the bracket could result in loss of the towed vehicle. • If the towed vehicle has been in an accident, it must be properly re• Ifpaired the towed hasthe been in an Do accident, it must properly rebeforevehicle attaching bracket. not install thebe bracket if any paired before attaching theisbracket. not to install any structural frame damage found. Do Failure 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, tow turning 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 the vehicle, 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 resultvehicle. in non-warranty non-warranty damageparking to towing damage to to towing towing system, system, motorhome motorhome and/or and/or towed towed vehicle. vehicle. damage • Do not back up with the towed vehicle attached or non-warranty Do not back back up with with the towed towed vehicle attached or and/or non-warranty •• Do not up the or non-warranty damage will occur to your towing vehicle system, attached motorhome 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 to The safety cables mustwith connect the towing towing vehicle to the the towed towed vehicle frame to frame, the cables crossed, with enough slack vehicle frame to the cables crossed, enough slack vehicle frame to frame, frame, with thecable cables crossed, with with enough slack for sharp turns. Refer with to the instructions for proper routing. for sharp turns. Refer slack to the thein cable cable instructions forfailure proper routing. for sharp turns. Refer to instructions for proper Failure to leave enough the safety cables, or to routing. connect Failure to leave leave enough slack in the thewill safety cables, or loss failure to connect Failure to enough in safety cables, or failure connect the safety cables frameslack to frame, result in the of to the 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 adaptors only. Using Using this thisadaptor, bracketmay with result other brands, brands, ROADMASTER adaptors only. bracket with other without an approved ROADMASTER in nonwithout an approved ROADMASTER adaptor, adaptor, may may result result in in nonnonwithout approved ROADMASTER warrantyan damage or injury. warranty warranty damage damage or or injury. injury. • Upon final installation, the installer must inspect the bracket to en•• Upon final the installer inspect the bracket to Upon final installation, installation, the particularly installer must must inspect the air bracket to enensure adequate clearance, around hoses, conditioner sure clearance, particularly hoses, conditioner sure adequate clearance, particularly around around hoses, airtowed conditioner lines,adequate radiators, etc., or non-warranty 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 isthe the original installation. Installing •• This bracket is warranteed for original installation. a used bracket on another vehicle not recommended and Installing 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 warranty. the warranty. KIT# 2109-1 MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. Fig.C 6110 NE 127th Ave. Vancouver, WA 98682 1-800-669-9690 Fig.D 03/23/09 KS fax 360-735-9300 www.roadmasterinc.com Fig.E 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 by removing the radiator overflow bottle (The overflow bottle will obstruct an attachment in a later step.) — first, remove the cap and pull out the hose (Fig.C). Then, lift the bottle straight up and away (Fig.D). 2. Next, on each side, remove four plastic fasteners holding the lower fender liner to the fascia (Fig.E). Fig.F Fig.G Fig.H 3. Remove four plastic fasteners Fig.I Fig.J toward the front of the center splash shield (Fig.F), and four 10mm (head) bolts toward the rear of the center splash shield (Fig.G). Then, remove the center splash shield (Fig.H). 4. Support the subframe (Fig.I). 5. On each side, remove a 19mm (head) subframe bolt, and the bushing cup (Fig.J). For '05-'06 Kia Spectra EX and LX and '05 to '09 Kia Spectra 5 models, proceed to step 9 in these instructions. For 2007 to 2009 Kia Spectra EX and LX models only If the vehicle is a 2007 Kia Spectra EX or LX model, the fascia will require trimming to allow for clearance of the braces. Follow steps 6 through 8 below. If the vehicle is not a 2007 to 2009 Kia Spectra EX or LX model, proceed to step 9 in these instructions. 6. Pull out and forward to remove the fascia. 7. Using the yellow lines in Figure K as a reference, trim the fascia to allow for clearance of the side brace, as shown in Figure L. Fig.K q trim line for receiver brace q trim line for side brace MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. 6110 NE 127th Ave. 8. Using the yellow lines in Figure K as a reference, trim the fascia to allow for clearance of the receiver brace, as shown in Figure M. Vancouver, WA 98682 1-800-669-9690 fax 360-735-9300 KIT# 2109-1 03/23/09 KS www.roadmasterinc.com Fig.L Fig.M Fig.O Fig.P This completes the fascia trimming on the 2007 to 2009 Kia Spectra EX and LX models. Now, proceed to the following step to finish the installation of the bracket . Fig.N 9. Next, place the two bushing cups over the pre-drilled holes at each end of the main receiver brace (Fig.N). Then, slide a 14mm lock washer and flat washer over both of the supplied 14mm x 1.5 x 130mm bolts, and slide the bolts through the main receiver brace and the bushing cups (Fig.N). Apply thread lock to the bolts. 10. Move the main receiver brace under the subframe, and align the two 14mm x 1.5 x 30mm bolts to the holes for the factory subframe bolts you removed in step 5. Tighten both of the bolts, only enough to hold the main receiver brace in position. For the 2005 to 2009 Spectra 5 model: If the vehicle is equipped with a front spoiler the spoiler will need to be trimmed. This will allow for clearence of the receiver, arm and end plate. This will need to be done before you can tighten the main receiver brace. Refer to Figure O and use the yellow marker line as a guide for trimming. Repeat for the other side. Figure P shows the driver side subframe attachment. Leave the subframe support in place. Center the main receiver brace between the tow hooks (Fig.Q). 11. Before attaching the side braces, trim a small portion of the lower fascia (Fig.R, circled) on each side, to allow clearance. Trim and then test-fit the side braces, until you have trimmed enough material. (The braces will fit only one side of the vehicle — the welded pipe spacers at the top will fit against the frame rails.) 12. The side braces are bolted to the main receiver brace, to the tow hooks, and also to the frame rails. First, attach them to the main receiver brace, through the three pre-drilled holes at each end of the main receiver brace (Fig.R). Use three of the supplied ½" x 1¼" bolts, lock washers and nuts for each brace. Figure S shows the three passenger-side bolts in place. Finger-tighten only at this time. 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. KIT# 2109-1 MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 1-800-669-9690 Fig.R KS fax 360-735-9300 www.roadmasterinc.com Fig.S Tow hook First 3 attachment points q Main receiver brace q q q q Fig.Q 03/23/09 13. Now, attach the side braces to the tow hooks — for each side, position one of the supplied 5/8" flat washers between the side brace and the tow hook, so that the hole in the washer aligns to the pre-drilled hole in the side brace. Now, position one of the supplied 5/8" cut plate washers next to the tow hook, so that it aligns over the same hole (Fig.T). Bolt through the side brace and the tow hook with one of the supplied 5/8" x 1¾" bolts, lock washers and nuts. Figure Q shows the passenger side attachment. Finger-tighten only at this time. 14. Now, attach one of the side braces to the frame rail — the top hole in each side brace aligns to an existing hole through both sides of the frame rail. From the outside of the frame rail, slide one of the supplied ½" x 4½" bolts through the side brace and both sides of the frame rail. From the inside of the frame rail, secure the bolt with a ½" cut plate washer, lock washer and nut. Tighten the bolt from the inside, using a ratchet or air ratchet. Repeat for the other side. 15. Starting with the subframe bolts, torque all bolts to the specifications at the bottom of these instructions. 16. Reassemble the center splash shield, the lower fender liners, and the radiator overflow bottle by reversing steps 1 through 3. Note: the two plastic fasteners on the outside of the center splash shield will not be replaced. Note: in order to accommodate the side braces, it will be necessary to trim a small portion of both lower fender liners. Refer to Figure U. 17. Fit the front bracket arms into the front receiver braces, and secure them in place with the supplied 5/8" draw pins and spring pins (Fig.V). 18. Attach the 10" safety cables with the cable connectors (Q-Links) to the front of the receiver braces (Fig.V). 19. Attach the ends of the safety cables to the tow vehicle's safety cables and tow bar. 20. Install the tow bar to the mounting bracket according to the manufacturer's instructions. Cut plate washer Fig.U Fig.V q q Fig.T Tow hook 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. KIT# 2109-1 MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 1-800-669-9690 03/23/09 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. ....... 66 ft./lb. ...... 65 ft./lb. .... 104 ft./lb. 65 61 60 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.