Kit# 523143-1 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 M A S T E R , I N C. MOUNTING BRACKET KIT KIT# 523143-1 02/03/06 INSTALLATION INSTRUCTIONS RV Item Qty. Length Width Description Part # 1 ............... 2 ............... 140mm ..... 14mm ...... 14mm x 2.0 x 140 BOLT ..................................... 355910-00 D 2 ............... 2 .................................. 14mm ...... LOCK WASHER .................................................. 355740-00 3 ............... 1 ............... 1 1/2" ........ 1/2" .......... CARRIAGE BOLT ............................................... 350362-00 4 ............... 2 ............... 1 1/4" ........ 1/2" .......... BOLT ................................................................... 350094-10 A 5 ............... 2 ............... 6" .............. 1/2" .......... BOLT ................................................................... 350109-00 6 ............... 5 .................................. 1/2" .......... LOCK WASHER .................................................. 350309-00 7 ............... 5 .................................. 1/2" .......... NUT ..................................................................... 350258-00 O 8 ............... 2 .................................................... CABLE CONNECTOR ........................................ 200008-00 9 ............... 2 ............... 8" ................................ SAFETY CABLE .................................................. 500646-08 10 ............. 1 .................................................... MAIN RECEIVER BRACE WELDMENT ............. C-001371 R 11 FAILURE ............. 1TO.................................................... DRIVER SIDE ARM WELDMENT ....................... C-001372 FOLLOW THESE INSTRUCTIONS CAN RESULT IN DEATH, PERSONAL INJURY OR PROPERTY DAMAGE 12 ............. 1 .................................................... PASSENGER SIDE ARM WELDMENT .............. C-001373 13 ............. 1 .................................................... DRIVER SIDE UPPER PLATE ........................... B-000933 14 ............. 1 .................................................... PASSENGER SIDE UPPER PLATE .................. B-000934 15 ............. 1 .................................................... 1/4" x 1 1/4" x 3" BACKING PLATE .................... A-000691 MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 1-800-669-9690 KIT# 523143-1 fax 360-735-9300 02/03/06 RV www.roadmasterinc.com Fig.A T his is one of our EZ series brackets, which allows the visible front portion of the bracket to be rotated and easily removed from the front of the vehicle (Fig.A and Fig.B). The bracket kit consists of a main receiver brace, two tubular front braces and a hardware pack. The main receiver brace mounts to the subframe, radiator support and bumper core. The tubular front braces are inserted into the receiver braces and rotated 90 degrees to lock them in place. Before starting the installation, lay out the kit components in order. This will give you a visual idea of how the components work and will also confirm that everything is present and accounted for. Fig.B IMPORTANT: IMPORTANT: All brackets must must be assembled with all the bolts left loose for final adjustment and positioning (before tightening) unless otherwise instructed. All bolts must must be torqued for proper strength. If more than one bolt is used per fastening point, the diagram may only show 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 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 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 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 owner check thetovehicle manufacturer's instructions for the proper procedure(s) the towed 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. Failure to properly vehicle will manufacturer cause severe after damage • towed. If running changes were equip madethe by the vehicle this the transmission. • to 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 fasten the bracket could in loss itofmust the towed vehicle.re• securely If the towed vehicle has been in result an accident, 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 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 and/or and/or towed towed vehicle. vehicle. • damage Do not back up with the motorhome 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 damage or or injury. injury. • warranty Upon finaldamage 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 the warranty. warranty. KIT# 523143-1 MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. Fig.C 6110 NE 127th Ave. Vancouver, WA 98682 1-800-669-9690 Fig.D 02/03/06 RV 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. Start by removing eight plastic fasteners across the top of the radiator cover (Fig.C). Then, remove the radiator cover. 2. Next, remove the splash shield — remove nine plastic fasteners across the bottom of the splash shield (Fig.D), and two plastic fasteners at the bottom of each fender well. 3. Support the subframe (Fig.E). Fig.F 4. ing 5. the Fig.G Fig.H Now, remove the two 18mm (head) front subframe bolts (one on each side — Fig.F), as well as the bushcups. Next, fishwire the ¼" x 1¼" x 3" backing plate and the ½" x 1½" carriage bolt into the hole in the center of radiator support (Fig.G and Fig.H). Fig.I Fig.K Fig.J 6. At each side of the main receiver brace, thread one of the 14mm x 2.00 x 140mm bolts and lock washers through the pre-drilled hole and through one of the bushing cups you removed in step 4 (Fig.I). 7. Extend the fishwire from the center hole in the radiator support to the center mounting point on the main receiver brace (Fig.J). 8. Lift the main receiver brace into position, over the two front subframe mounts, and bolt the main receiver brace into place (Fig.K). Torque the two 14mm x 2.00 x 140mm bolts to the specifications at the bottom of these instructions. KIT# 523143-1 MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. Fig.L 6110 NE 127th Ave. Vancouver, WA 98682 1-800-669-9690 Fig.M 02/03/06 RV fax 360-735-9300 www.roadmasterinc.com Fig.N 9. Remove the fishwire from the center mounting point (Fig.L). Then, thread a ½" nut and lock washer over the ½" x 1½" carriage bolt, and tighten the nut and lock washer (Fig.M) to attach the main receiver brace to the radiator support at the center mounting point. 10. On each side, use the upper mounting point of the main receiver brace (the pre-drilled hole) as a template, and drill entirely through the bumper core (Fig.N). Fig.P Step 12 q Step 13 q Fig.O Fig.Q 11. Use the opening at the top of the grille to position the two L-brackets (each with two 9/16" holes) over the holes you drilled in step 10. Then, insert a ½" x 6" bolt through each L-bracket, the bumper core, and the main brace (Fig.O and Fig.P). 12. Thread a ½" lock washer and nut onto each bolt (Fig.Q). 13. Attach both backing plates to the main brace, using a ½" x 1¼" bolt, a ½" lock washer and a ½" nut on each side (Fig.Q). 14. Tighten all bolts to the specifications at the bottom of these instructions. 15. The splash shield can be discarded or reinstalled. If the splash shield is reinstalled, trim it to accommodate the main receiver brace — use the yellow marker line in Figure R as a reference. 16. Reinstall the radiator cover, which you removed in step 1. 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. MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 1-800-669-9690 KIT# 523143-1 02/03/06 RV fax 360-735-9300 www.roadmasterinc.com 17. Insert the tubular front braces into the main receiver brace, and twist 90 degrees to lock (Fig.S). Note: Remove the tubular front braces when not towing, unless a cross bar or tow bar is in place. Attach the safety cables with the cable connectors (Q-links) to the front of the tubular front braces (Fig.S). Attach the ends of the safety cables to the tow vehicle's safety cables and tow bar. 18. Install the tow bar to the mounting bracket according to the manufacturer's instructions. Fig.S 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.