Transcript
ROADMASTER, Inc.
6110 NE 127th Ave.
Vancouver, WA 98682
1-800-669-9690
fax 360-735-9300
www.roadmasterinc.com
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MOUNTING BRACKET KIT KIT# 524413-1A 08/03/09 INSTALLATION INSTRUCTIONS KS
ITEM QTY NAME MATERIAL 1 ............... 6 ............... 1/2" x 1 3/4" BOLT ........................................................................................... 350096-00 2 ............... 4 ............... 1/2" FLAT WASHER ......................................................................................... 350308-00 3 ............... 6 ............... 1/2" LOCK WASHER ....................................................................................... 350309-00 4 ............... 4 ............... 1/2" HEX NUT ................................................................................................... 350258-00 5 ............... 4 ............... 7/16" x 1 3/4" BOLT ......................................................................................... 350075-00 6 ............... 2 ............... 7/16" FLAT WASHER ...................................................................................... 350306-00 7 ............... 4 ............... 7/16" LOCK WASHER ..................................................................................... 350307-00 8 ............... 2 ............... 1/4" x 1 1/2" SELF TAPPING SCREW .......................................................... 350092-00 9 ............... 2 ............... QUICK LINK ...................................................................................................... 200008-00 10 ............. 2 ............... SAFETY CABLE 8"........................................................................................... 500646-08 11 ............. 2 ............... 1" O.D. x 0.188 WALL x 5/8" PIPE SPACER .............................................. A-000156 12 ............. 2 ............... 1/4" x 1 1/4" x 5 3/4" BACKING PLATE ....................................................... A-001654 13 ............. 1 ............... DRIVER SIDE FRONT BRACE ...................................................................... B-000698 14 ............. 1 ............... PASSENGER SIDE FRONT BRACE ............................................................. B-000699 15 ............. 2 ............... 1/4" x 1 1/4" x 11 1/8" THREADED BACKING PLATE ............................... C-000096 16 ............. 2 ............... 1/4" x 1 1/2" x 2 1/2" THREADED BACKING PLATE W/ ROD ................ C-001572 17 ............. 1 ............... DRIVER SIDE RECEIVER .............................................................................. C-001604A 18 ............. 1 ............... PASSENGER SIDE RECEIVER ..................................................................... C-001605 FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN DEATH, PERSONAL INJURY OR PROPERTY DAMAGE 19 ............. 1 ............... DRIVER SIDE ARM .......................................................................................... C-001606 20 ............. 1 ............... PASSENGER SIDE ARM ................................................................................ C-001607
MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc.
6110 NE 127th Ave.
Vancouver, WA 98682
1-800-669-9690
KIT# 524413-1A
fax 360-735-9300
08/03/09 KS
www.roadmasterinc.com
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 two rear braces, two removable front braces and a hardware pack. The two rear braces mount to the frame rails and the main receiver braces. The removable front braces are inserted into the main receiver brace and rotated 90 degrees to lock them in place. 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.
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 could result in loss of the towed as vehicle. Do not the usebracket this document document for custom custom fabrication, it may may not not show show •• Do not use this for fabrication, as it • 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 of or anvehicle. attempt to copy thisorbracket bracket design could result result in loss lossfabrication 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, thesetorque, according instructions. to the The bolt torque must requirements alsorequirements inspect chart all on mounts the lastonpage and proper according toowner the bolt torque chart the brackets of for cracks The orso other owner mustof also fatigue every all 3,000 mounts miles. and lastthese page.instructions. Failure to do couldsigns result in lossinspect 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. • The owner must check the vehicle manufacturer's instructions for to domust so could result in loss of the towed vehicle. • Failure The owner check the for the proper procedure(s) tovehicle preparemanufacturer's the vehicle forinstructions 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 before for pump, towing. an axle Some disconnect, driveline disconnect or hubs 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 • If running changes were made by the vehicle manufacturer after this the transmission. • to If running were made byor theother vehicle manufacturer after this bracket waschanges 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 is fasteners themanufacturer installer’s pack bracket no designed, longer be bracket some the correct bolts size. or other It is fasteners the installer’s responsihardware bility may to was verify that the is securely fastened to in thethe vehicle and bility pack to verify no longer that the be bracket the correct is account securely size. It for is fastened the installer’s to the vehicle responsiand fitted may with the correct hardware to 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 the the 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 rethe towed • If hasthe been in anDo accident, it must properly repaired beforevehicle attaching bracket. not install the be bracket if any paired before attaching theisbracket. Do not to install any structural frame damage found. Failure repairthe thebracket damageifcould structural damage is Failure structural frame damage is found. found. Failure to to repair repair the the damage damage could could result in theframe loss 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 chassistowed have such such a tight tight turning radius while that you you can •• Some motorhome chassis have a radius that can damage your motorhome, vehicle, tow turning bar or bracket turning damage your motorhome, towed vehicle, towyour bar or orturning bracketradius 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 radius sharply.parking Before getting getting on the the road, testcould yourresult turning radius in in an an empty lot. Turning tooroad, sharply in non-warranty empty lot. Turning too could result in empty parking lot. Turning too sharply sharply couldtowed resultvehicle. in non-warranty non-warranty damageparking to towing system, motorhome and/or 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 not back back up with with the towed towed vehicle attached or and/or non-warranty •• Do 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 cables must connect the vehicle to The safety 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. Referslack to the the cable instructions forfailure proper routing. for sharp turns. Refer to instructions for proper routing. Failure to leave enough in cable the safety cables, or to connect Failure to leave leave enough slack in the thewill safety cables, orloss failure to connect Failure to enough in safety cables, failure the safety cables frameslack to frame, result in theor of to theconnect towed the the safety 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 designed for with ROADMASTER tow and This bracket is is adaptors designed only. for use use with ROADMASTER tow bars bars and ROADMASTER Using this bracket with other brands, ROADMASTER adaptors only. Using Using this this bracketmay with result other brands, brands, ROADMASTER adaptors only. bracket with other without an approved ROADMASTER adaptor, 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 conditioner sure adequate clearance, particularly around around hoses, air conditioner lines,adequate radiators, etc., or non-warranty damagehoses, to theair towed 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 foristhe the original installation. Installing •• This bracket is warranteed for installation. a used bracket on another vehicle notoriginal recommended and Installing will void a bracket a used used bracket on on another another vehicle vehicle is is not not recommended recommended and and will will void void the warranty. the warranty. the warranty.
MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc.
Fig.C
6110 NE 127th Ave.
Vancouver, WA 98682
Fig.D
1-800-669-9690
KIT# 524413-1A 08/03/09 KS
fax 360-735-9300
www.roadmasterinc.com
Fig.E 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. Remove four plastic fasteners attaching the top of the fascia to the bumper core (Fig.C). 2. Pull forward on the grille to remove it (Fig.D). 3. Remove two plastic fasteners attaching the fascia to the core support (Fig.E). On both sides, remove two plastic fasteners and two 10mm screws attaching the fender liner to the fascia (Fig.F). Fig.F
Fig.G
Fig.H
4. Remove three plastic fasteners attaching the center splash shield to the radiator support (Fig.G). 5. Pull out and forward on the fascia to remove it (Fig.H). Note: if the vehicle is equipped with fog lights, remove one plastic fastener attaching the harness to the back of the fascia; then, unplug the fog lights. Fig.K
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Fig.J
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nut
bolts
q
Fig.I
6. Remove the foam shock absorption pad by drilling out two metal pop rivets (Fig.I). Note: the shock absorption pad will not be replaced. Retain it in case the bracket is ever removed. 7. Remove the air deflectors by removing the four plastic fasteners attaching them to the bumper core (Fig.J). Note: the air deflectors and fasteners will not be replaced. Retain them in case the bracket is ever removed. Remove one 10mm (head) nut and two 10mm (head) bolts attaching the water bottle to the side of the frame rail (Fig.K).
MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc.
6110 NE 127th Ave.
Fig.L
Vancouver, WA 98682
1-800-669-9690
Fig.M
KIT# 524413-1A 08/03/09 KS
fax 360-735-9300
www.roadmasterinc.com
Fig.N
q
backing plate bolted down
8. On both sides, use a die grinder to enlarge two existing holes in the frame rail to ½" (Fig.L). 9. Starting with the driver's side, and using the holes enlarged in the previous step, place two ½" x 1¾" bolts through the ¼" x 1¼" x 5¾" backing plate (Fig.M). Place the rear mounting points of the rear brace over the bolts and secure the brace using a ½" lock washer, flat washer and nut. Note: only the slotted hole uses the flat washer. Repeat for the passenger side. Figure N shows the secured bolts, plate, washer and nuts from the inside of the driver's side frame rail. Note: you may need to bend the passenger side horn bracket slightly downward with a pair of pliers to allow for the clearance of the rear brace. Fig.O
Fig.P
Fig.Q
1-5/8" 28½"
10. On both sides, clamp the front of the main receiver braces to the bottom of the bumper core (Fig.O). Now, insert the bracket arms into the front of the main receiver braces. 11. To ensure the bracket is centered on the car, make certain that the attachment points for the quickdisconnects will be 28½" from center to center (Fig.P). From the edge of the main receiver brace to the outer edge of the bumper core, the measurement should be 1-5/8" (Fig.Q). On both sides, using the predrilled holes in the main receiver braces as templates, drill two ½" holes through the bumper core (Fig.R).
Fig.R
Fig.S
Place a ¼" x 1¼" x 11-1/8" backing plate inside the bumper core (Fig.S). Secure the outer bolts into place using a 7/16" x 1¾" bolt and lock washer. On both sides, place a backing plate over the inside mounting point on the main receiver brace. Bolt through the backing plate, brace and bumper core and into the nutted backing plate using a 7/16" x 1¾" bolt, flat washer and lock washer.
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.
Fig.T
6110 NE 127th Ave.
Vancouver, WA 98682
1-800-669-9690
Fig.U
stud
08/03/09 KS
fax 360-735-9300
www.roadmasterinc.com
Fig.V
q
q wire
KIT# 524413-1A
12. On both sides, use the attached wire to place the ¼" x 1½" x 2½" backing plate into the bumper core. Then, bolt through the front backing plate, bumper core and into the inside backing plate using the supplied ½" x 1¾" bolt, lock washer and nut (Fig.T). Using a pair of pliers, break the wire off from the backing plate inside the bumper core. 13. Tighten all bolts to the bolt torque requirements found at the end of these instructions. On the passenger side, using a cut-off wheel, remove the stud at the rear of the washer bottle (Fig.U). 14. On the passenger side, replace the top 10mm (head) bolt removed in step 9. On the two lower mounting holes, place a 1" x 5/8" pipe spacer between the washer bottle and frame rail (Fig.V) and secure it in place using two ¼" x 1½" self-tapping screws (Fig.W). Fig.W
Fig.X
15. On both sides, trim the foglight housing, using the white lines in Figure X as a reference for trimming. 16. Hold the fascia in place and trim it on both sides to fit the arms of the receiver braces. Use the yellow lines in Figure Y as a general reference for trimming. The trimmed fascia should easily accommodate the front of the receiver braces (Fig.Z). 17. Reinstall the fascia by reversing steps 1 through 6. Insert the removable front braces into the main receiver brace and twist 90 degrees to lock.
Fig.Y
Fig.Z
18. Attach the 8" safety cables with the cable connectors (Q-Links) to the front of the receiver braces. Attach the ends of the safety cables to the tow vehicle's safety cables and tow bar 19. 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.
MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc.
6110 NE 127th Ave.
Vancouver, WA 98682
1-800-669-9690
KIT# 524413-1A 08/03/09 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
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.
