Kit# 523137-1 Mounting Bracket Kit Installation Instructions

Transcript

ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 1-800-669-9690 fax 360-735-9300 www.roadmasterinc.com R O A D M A S T E R , I N C. MOUNTING BRACKET KIT KIT# 523137-1 09/18/09 INSTALLATION INSTRUCTIONS KS ITEM QTY NAME MATERIAL 1 ............... 5 ............... 1/2" x 1 1/2" BOLT ................................................................. 350095-00 2 ............... 2 ............... 1/2" x 1 1/2" CARRIAGE BOLT ............................................ 350625-00 3 ............... 7 ............... 1/2" LOCK WASHER ............................................................. 350309-00 4 ............... 7 ............... 1/2' HEX NUT .......................................................................... 350258-00 5 ............... 2 ............... 1/2" FLAT WASHER ............................................................... 350308-20 6 ............... 2 ............... QUICK LINK ............................................................................ 200008-00 7 ............... 2 ............... 8" SAFETY CABLE................................................................. 650646-08 8 ............... 2 ............... 1/4" X 1" x 2" SQUARE HOLE BACKING PLATE ............. A-000040 9 ............... 1 ............... 1/4" X 2" x 2" ROUND HOLE BACKING PLATE ............... A-001066 10 ............. 2 ............... 1/4" X 2" x 7" 2 HOLE BACKING PLATE ........................... A-001967 11 ............. 1 ............... MAIN RECEIVER .................................................................... C-001220 12 ............. 1 ............... DRIVER SIDE ARM ................................................................ C-001221 13 ............. 1 ............... PASSENGER SIDE ARM ...................................................... C-001222 FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN DEATH, PERSONAL INJURY OR PROPERTY DAMAGE MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 T 1-800-669-9690 his is one of our EZ series brackets, which allows the visible front portion of the brackets to be easily removed from the front of the vehicle (Fig.A and Fig.B). The bracket consists of a main receiver brace, two removable front braces and a hardware pack. The main receiver brace mounts to the subframe, bumper core and both 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. KIT# 523137-1 fax 360-735-9300 09/18/09 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. Failure to follow these instructions can result in property damage, personal injury or even death. • Do not use this document for custom fabrication, as it may not show all parts or structural components. Custom fabrication or an attempt to • Installation of most mounting brackets requires moderate mechanicopy this bracket designWe could resultrecommend in loss of the towed vehicle. cal aptitude and skills. strongly professional installaan experienced installer. • tion The by owner must inspect all mounts and brackets before each use for cracks or must otherread signs fatigue. Also, inspect fasteners for • The installer theofinstructions and use allthe bolts and parts proper torque, according to the bolt torque requirements chart on the supplied. supplied. Failure When the to securely instructions fasten require the bracket the reuse couldofresult factory in loss bolts, of last towed page. Failure dowashers so couldmust result in be lossused. of the towedtovehicle. the thread lockvehicle. and/or to lock also Failure securely fasten the could in loss of the towed vehicle. Thenot owner must checkresult the manufacturer's instructions forshow the •• Do usebracket this document for custom fabrication, as it may not proper procedure(s) to prepare the vehicle for towing. vehicles • Do all parts not use or structural this document components. for custom Custom fabrication, fabrication asor it Some may an attempt not show to must be or equipped with a could transmission pump, axle disconnect, copy all parts this bracket structural design components. result Custom inlube lossfabrication of the an towed or anvehicle. attempt to driveline disconnect or free-wheeling hubs they can be towed. bracket design could must result inspect in lossbefore of thefasteners towed vehicle. • copy Everythis 3,000 miles, the owner the for proper Failure to properly equip the vehicle will cause severe damage to the • Every torque,3,000 according miles, to the the bolt owner torque must requirements inspect thechart fasteners on thefor lastproper page transmission. of theseaccording torque, instructions. to the The boltowner torquemust requirements also inspect chart all on mounts the last page and • of The installer read instructions andinspect useevery all all bolts andmiles. parts brackets these instructions. for must cracks The or the other owner signs mustofalso fatigue 3,000 mounts and supplied. Failure to securely the bracket result in miles. loss of Failure brackets to for do so cracks could or result other infasten loss signs of of the fatigue towedcould vehicle. every 3,000 the towed vehicle. to do so could result in loss of the towed vehicle. • Failure The owner must check the vehicle manufacturer's instructions for If running were made by the vehicle manufacturer after this •• The the proper owner changes must procedure(s) check the to vehicle prepare manufacturer's the vehicle forinstructions towing. Some for bracket was designed, some bolts or the othervehicle fasteners in the included vehicles the proper must procedure(s) be equipped to with prepare a transmission lube for pump, towing. an axle Some dishardwaremust packbemay no longer the correct size. is thethey installer’s connect, vehicles driveline equipped disconnect with orbe afree-wheeling transmission hubs lubeItbefore pump, an axle candisbe responsibility to properly verify that the bracket is securely fastened todamage the vetowed. connect, Failure driveline to disconnect equip or free-wheeling the vehicle will hubs cause before severe they can be hicle, fittedtowith the correct to account forsevere these changes. to towed. the and transmission. Failure properly equiphardware, the vehicle will cause damage Failure to securely fasten the bracket could result in loss of the towed the transmission. • to If running changes were made by the vehicle manufacturer after this vehicle. • If bracket running waschanges designed, were some made bolts byor theother vehicle fasteners manufacturer in the hardware after this • bracket If themay towed vehicle has in an mustinbethe properly repack was no designed, longer be some thebeen correct bolts size. or accident, other It is fasteners theit installer’s responsihardware pairedmay attaching the correct bracket. Do It not install the bracket if and any bility pack tobefore verify no longer that the be bracket the is securely size. is fastened the installer’s to the vehicle responsistructural frame is found. Failure to repair may fitted bility with to verify the correct thatdamage the hardware bracket to is account securely for fastened these changes. tothe thedamage vehicle Failure and to resultwith in the of bracket the towed vehicle. securely fitted fasten theloss correct the hardware could to account result infor loss these of the changes. towed Failure vehicle.to WARNING WARNING securely fasten the bracket could result in loss of the towed vehicle. motorhome chassis haveinsuch a tight turning radius you can •• IfSome the towed vehicle has been an accident, it must be that properly redamage your motorhome, towed vehicle, tow bar or bracket while turning paired before attaching the bracket. Do not install the bracket if any sharply. Before road, test your turning radius could in an structural frame damage found. Failure to the structural framegetting damageonis isthe found. Failure to repair repair the damage damage could emptyin Turning sharply could result in non-warranty result inparking the loss loss lot. of the the towedtoo vehicle. result the of towed vehicle. damage to towing chassis system,have motorhome and/or towed vehicle. Some motorhome such a a tight tight turning radius that you you can can •• Some motorhome chassis have such turning radius that • damage Do not your backmotorhome, up with the towed vehicle attached or non-warranty damage your motorhome, towed vehicle, tow bar bar or bracket bracket while turning turning towed vehicle, tow or while damage Before will occur to your towing system, motorhome sharply. getting on road, test turning radius in sharply. Before getting on the the road, test your your turning and/or radius towed in an an vehicle.parking empty empty parking lot. lot. Turning Turning too too sharply sharply could could result result in in non-warranty non-warranty damage to towing towing system, motorhome and/or towed vehicle. to motorhome vehicle. • damage The safety cablessystem, must connect theand/or towingtowed vehicle to the towed vehicle frameup to frame, with the cables crossed, with slack Do not back back up with the the towed vehicle attached or enough non-warranty •• Do not with towed vehicle attached or non-warranty for sharp to towing the cable instructions for proper damage willturns. occurRefer to your your towing system, motorhome and/orrouting. towed damage will occur to system, motorhome and/or towed Failure to leave enough slack in the safety cables, or failure to connect vehicle. vehicle. the safety cables frame toconnect frame, will result in the losstoofthe the towed •• The The safety safety cables cables must must connect the the towing towing vehicle vehicle to the towed towed vehicle. frame to frame, with the cables crossed, with enough slack vehicle vehicle frame to frame, with the cables crossed, with enough slack • for Thissharp bracket is designed withinstructions ROADMASTER tow bars and for sharp turns. Refer to tofor theuse cable instructions for proper proper routing. turns. Refer the cable for routing. ROADMASTER adaptorsslack only.in this bracket with other brands, Failure to leave leave enough enough slack inUsing the safety safety cables, or or failure to connect connect Failure to the cables, failure to without approved adaptor, may nonthe safety frame to in loss of the safetyancables cables frameROADMASTER to frame, frame, will will result result in the the lossresult of the theintowed towed warranty damage or injury. vehicle. vehicle. Uponbracket final installation, thefor installer must inspect the bracket to and en••• This is use ROADMASTER tow This bracket is designed designed for use with with ROADMASTER tow bars bars and sure adequate clearance, particularly around hoses, conditioner ROADMASTER adaptors only. only. Using this this bracket withair other brands, ROADMASTER adaptors Using bracket with other brands, lines, radiators, etc., ROADMASTER or non-warranty adaptor, damage to theresult towedin without an approved approved ROADMASTER adaptor, may result invehicle nonwithout an may nonwill result.damage warranty warranty damage or or injury. injury. This bracket is only warranteed for must the original installation. Installing ••• Upon final the inspect the to Upon final installation, installation, the installer installer must inspect the bracket bracket to enena used bracketclearance, on anotherparticularly vehicle is not recommended will void sure adequate around hoses, conditioner sure adequate clearance, particularly around hoses, air air and conditioner the warranty. lines, radiators, etc., etc., or or non-warranty non-warranty damage damage to to the the towed towed vehicle vehicle lines, radiators, will result. result. will This bracket bracket is is only only warranteed warranteed for for the the original original installation. installation. Installing Installing •• This a on is Failure follow vehicle these instructions can resultand in will a used used bracket bracket ontoanother another vehicle is not not recommended recommended and will void void the property damage, personal injury or even death. the warranty. warranty. WARNING KIT# 523137-1 MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. 6110 NE 127th Ave. Fig.C Vancouver, WA 98682 Fig.D 1-800-669-9690 09/18/09 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 majorFig.F ity of questions you may have can be answered within the text, and proper installation will ensure safe and secure travel. Now, begin plastic the installation by removing the four plastic fasteners at the top of the fastener fascia, attaching the fascia to the core support (Fig.C). 2. Then, on each side, remove a plastic fastener holding the fascia to the bumper core (Fig.D). 3. On each side, remove five 7mm screws attaching the fascia to the fender liner. Three of the screws are along the edge of the fender well; two are at the bottom edge of the fascia (Fig.E). Remove one plastic fastener (Fig.F) as well. 4. On each side, remove three 7mm screws attaching the fascia to the lower fender liner (Fig.F). 5. Also on each side, pull back the fender liner and remove one 10mm (head) bolt holding the fascia to the fender (Fig.G). Disconnect the fog lights, if the vehicle is so equipped (Fig.H). Then, pull the fascia out of the track, and pull forward on the fascia to remove it (Fig.I). q Fig.G Fig.H Fig.I 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# 523137-1 MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 1-800-669-9690 09/18/09 KS fax 360-735-9300 Fig.K www.roadmasterinc.com Fig.L Fig.J 6. Remove two plastic fasteners (on each side) holding each of the splash shields to the subframe (Fig.J), in order to gain access to the front subframe bolts. 7. Support the subframe (Fig.K). 8. On each side, remove one 21mm front subframe bolt (Fig.L). Fig.M Fig.N Fig.O q Bracket may contact AC line here. 9. Attach the main receiver brace to the subframe — position the main receiver brace so that the holes in the brace align with the holes for the subframe bolts you removed in the previous step (Fig.M). 10. Apply thread lock to the subframe bolts, then screw the two bolts back in place (Fig.N). Torque the bolts to the specifications at the bottom of these instructions. Note: on some models, the air conditioning lines may contact the top of the main receiver bracket, on the rear passenger side brace (Fig.O). If this is the case, once you have torqued the subframe bolts into place, use a pry bar or screwdriver to bend the air conditioning line approximately a half inch up to clear the rear passenger side brace. Fig.P Fig.Q Fig.R 11. Attach the main receiver brace to the bumper core — There are three attachment points along the bumper core, one in the center and one at each side. Begin with the center: Using the hole in the main receiver brace as a template, drill a 17/32" hole through the bumper core (Fig.P). 12. Put a ½" x 1½" bolt through the ¼" x 2" x 2" backing plate (9/16" hole, Fig.Q). From the inside of the bumper core, position the backing plate so that the bolt drops through the hole you drilled in the previous step (Fig.R). 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# 523137-1 MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 1-800-669-9690 09/18/09 KS fax 360-735-9300 www.roadmasterinc.com Fig.U Fig.S Fig.T 13. Thread a lock washer and nut onto the bolt to secure it in place (Fig.S). Torque to the specifications at the bottom of these instructions. 14. Now, attach the main receiver brace to each side of the bumper core — first, using the holes in the main receiver brace as a template, drill two 17/32" holes through one side of the bumper core (Fig.T). Slide one of the ¼" x 2" x 7" backing plates (9/16" hole) into the bumper core, and align the holes in the backing plate over the holes you just drilled. Drop two ½" x 1½" bolts through the holes in the backing plate (Fig.U). Fig.W Fig.X Fig.V 15. Thread a lock washer and nut onto each bolt to secure them in place (Fig.V). Torque to the specifications at the bottom of these instructions. Repeat for the other side. 16. Now, attach the main receiver brace to the frame rails — first, fishwire a ½" x 1½" carriage bolt and one of the ¼" x 1" x 2" backing plates (9/16" hole) through the square hole in one of the frame rails (Fig.W) and through the pre-drilled hole in the main receiver brace. 17. Attach the bolt to the main receiver brace with a ½" flat washer, a ½" lock washer and a nut (Fig.X). Torque the bolt to the specifications at the bottom of these instructions. Repeat for the other side. 18. Reattach both splash shields. In order to accommodate the main receiver brace, first trim a section of both splash shields. Use the white marker in Figure Y as a reference. 19. Before reattaching the fascia, trim three horizontal ribs from each side of the grille, as indicated in Figure Z. 20. Reinstall the fascia, reversing steps 1 through 5. Fig.Y Fig.Z 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. MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 1-800-669-9690 KIT# 523137-1 09/18/09 KS fax 360-735-9300 www.roadmasterinc.com 21. Insert the removable front braces into the main receiver brace, and twist them 90 degrees to lock. Attach the safety cables with the cable connectors (Q-Links) to the front of the receiver brace (Fig.AA). Attach the ends of the safety cables to the tow vehicle's safety cables and tow bar. 22. Install the tow bar to the mounting bracket according to the manufacturer's instructions. Fig.AA 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.