Kit# 4415-1 Mounting Bracket Kit Installation Instructions

Transcript

ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 1-800-669-9690 fax 360-735-9300 KIT# 4415-1 08/24/07 KB 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 .......... 1/2" x 5 1/2" BOLT ............................................................................ 350108-00 2 ............... 4 .......... 1/2" x 1 1/2" BOLT ............................................................................ 350095-00 3 ............... 2 .......... 1/2" x 1 1/2" CARR. BOLT ............................................................... 350362-00 4 ............... 8 .......... 1/2" LOCK WASHER ........................................................................ 350309-00 5 ............... 4 .......... 1/2" HEX NUT ................................................................................... 350258-00 6 ............... 2 .......... 1/4" x 1 1/2" x 2" BACKING PLATE W/ 9/16" HOLE ......................... A-000122 7 ............... 2 .......... 5/8" x 3/16" x 2 1/2" CLIPPED PLATE WASHER .............................. A-001763 8 ............... 2 .......... 1 1/4" O.D. x 0.250 WALL x 5/8" PIPE SPACER .............................. A-001068 9 ............... 2 .......... 1/4" x 1 1/2" x 1 3/4" SQUARE HOLE BACKING PLATE ................. A-000196 10 ............. 4 .......... 1/4" x 1 1/2" x 2 1/2" THREADED BACKING PLATE W/ ROD ......... C-001572 11 ............. 2 .......... 5/8" DRAW PIN W/ CLIP .................................................................. 357035-00 12 ............. 2 .......... QUICK LINK ..................................................................................... 200008-00 FAILURE TO2 FOLLOW INSTRUCTIONS CAN RESULT IN DEATH, PERSONAL INJURY OR 500646-08 PROPERTY DAMAGE 13 ............. .......... 8"THESE SAFETY CABLE ........................................................................... 14 ............. 1 .......... DRIVER SIDE RECEIVER ................................................................. C-001573 15 ............. 1 .......... PASSENGER SIDE RECEIVER ........................................................ C-001574 16 ............. 1 .......... DRIVER SIDE ARM ............................................................................ C-001575 17 ............. 1 .......... PASSENGER SIDE ARM ................................................................. C-OO1576 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 passenger and driver side main receiver brace, two removable front bracket arms and a hardware pack. The main receiver braces mount to the bumper core and the lower sub frame; the removable front brackets install in the main receiver braces. 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# 4415-1 08/24/07 KB 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# 4415-1 MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. Fig.C 6110 NE 127th Ave. Vancouver, WA 98682 Fig.D 1-800-669-9690 08/24/07 KB 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 two plastic fasteners and two 10mm (head) bolts attaching the top of the fascia to the core support (Fig.C). 2. Next, remove three Phillips (head) screws attaching the fender liner to the fascia (Fig.D). Repeat for the other side. 3. Remove three plastic fasteners attaching the center splash shield to the core support (Fig.E). Fig.F 4. 5. 6. 7. Fig.G Fig.H Now, unplug the fog lights. Pull out and forward on both corners of the fascia to remove it (Fig.F). Remove the air deflectors on both sides by removing three plastic fasteners per side (Fig.G). On each side, remove one 13mm (head) bolt attaching the hood latch support to the core support (Fig.H). Fig.I Fig.J Fig.K 8. Starting on the passenger side, position one of the main receiver braces in place under the bumper core and over the hole you removed the 13mm (head) bolt from in step 7. Bolt through the existing hole in the end of the receiver tube, replacing the 13mm (head) bolt you removed in step 7 (Fig.I, J). 9. Fishwire the ½" x 1½" carriage bolt and ¼" x 1½" x 1¾" backing plate through the lower sub frame and existing hole in the main receiver brace (Fig.K). Finish with a lock washer and nut (Fig.L). 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# 4415-1 MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. Vancouver, WA 98682 1-800-669-9690 Lock washer & nut Fig.M KB fax 360-735-9300 www.roadmasterinc.com Fig.N q Fig.L 6110 NE 127th Ave. 08/24/07 q q Cut plate washer q Backing plate q Spacer Bolt 10. Place the ¼" x ½" x 2" backing plate over the ½" x 5½" bolt. Then, place the 1¼" x 5/8" pipe spacer and cut plate washer between the end of the frame rail and the main receiver brace. Now, bolt through the bottom of the frame rail, cut plate washer, pipe spacer and the main receiver brace. Finish with a lock washer and nut (Fig.M). 11. Using the two existing holes in the main receiver brace as templates for drilling, drill through the bottom of the bumper core (Fig.N). Fig.O Fig.P Fig.Q 12. Place the two ½" x 1½" x 2½" weld nut backing plates with attached wire inside the bumper core (Fig.O). Now, bolt through the main receiver brace, the holes you drilled in the bumper core and into the weld nut backing plates using the two ½" x 1½" bolts and lock washers (Fig.P). After both bolts are in place, use a pair of pliers to break off the attached wire. 13. Repeat step 8 through 12 for the driver side of the vehicle. 14. Torque all remain bolts to the torque specifications listed at the end of these instructions. Note: torque the 13mm (head) bolt in step 8 to 19ft./lbs. 15. On both sides, a portion of the plastic shock absorption pad on the back side of the fascia needs to be trimmed to allow clearance for the main receiver brace. Follow the yellow maker line in Figure Q for correct trimming. 16. Reassemble the fascia and fog lights, reversing steps 1 through 6. 17. Insert the removable front bracket arms into the front receiver braces, and secure them in place with the supplied 5/8" draw pins and spring pins (Fig.R). 18. Attach the 8" safety cables with the cable connectors (Q-Links) to the front of the receiver braces (Fig.R). 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. 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.R KIT# 4415-1 MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 1-800-669-9690 08/24/07 KB 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 ft./lb. ft./lb. ft./lb. ft./lb. 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.