Kit No. 154-3 012899

Transcript

R 1-800-669-9690 O A D M A S T E R MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 PARTS LIST: 1- FRONT BRACE (A) - Passenger side 1- FRONT BRACE (B) - Driver's side 1- STABILIZER BAR (C) 1- SIDE BRACE (D) - Passenger side 1- SIDE BRACE (E) - Driver's side 1-800-669-9690 fax 360-735-9300 www.roadmasterinc.com KIT NO. 154-3 012899 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) tightening) unless unless otherwise otherwise instructed. instructed. All All bolts bolts must must be be torqued torqued for for proper proper strength. strength. IfIf more more than than one 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, perpersonal sonal injury injury or or even even death. death. • Installation of most mounting brackets requires moderate mechanical •• Installation of most brackets requires moderate mechanical Installation ofskills. most mounting mounting brackets requires moderate mechanical aptitude and We strongly recommend professional installation by aptitude and We aptitude and skills. skills. We strongly strongly recommend recommend professional professional installation installation by by an experienced installer. an experienced installer. installer. • an Theexperienced installer must read the instructions and use all bolts and parts •• The must read the and use all and parts The installer installer must the instructions instructions use all bolts bolts andthread parts supplied. When the read instructions require the and reuse of factory bolts, supplied. Failure to securely fasten the bracket could result in loss of supplied. to securely fasten could result in loss fasten of the the lock and/orFailure lock washers must also the be bracket used. Failure to securely towed vehicle. towed vehicle. the bracket could result in loss of the towed vehicle. • Do not use this document for custom fabrication, as it may not show all • Do not use this document for custom fabrication, as it may not show all parts or structural components. Custom fabrication or an attempt to copy parts or structural components. Custom fabrication or an attempt to copy this bracket design could result in loss of the towed vehicle. this bracket design could result in loss of the towed vehicle. • The owner must inspect all mounts and brackets before each use • Every 3,000 miles, the owner must inspect the fasteners for proper for cracks or other signs of fatigue. Also, inspect the fasteners for proper torque, according to the bolt torque requirements chart on the last page of torque, according to the bolt torque requirements chart on the last page. these instructions. The owner must also inspect all mounts and brackets Failure to do so could result in loss of the towed vehicle. for cracks or other signs of fatigue every 3,000 miles. Failure to do so • The owner check the vehicle manufacturer's instructions for the could resultmust in loss of the towed vehicle. proper procedure(s) to prepare the vehicle for towing. Some vehicles • The owner must check the vehicle manufacturer's instructions for the must be equipped with a transmission lube pump, an axle disconnect, drivproper procedure(s) to prepare the vehicle for towing. Some vehicles eline disconnect or free-wheeling hubs before they can be towed. Failure must be equipped with a transmission lube pump, an axle disconnect, drivto properly equip the vehicle will cause severe damage to the transmiseline disconnect or free-wheeling hubs before they can be towed. Failure sion. to properly equip the vehicle will cause severe damage to the transmis• Ifsion. running changes were made by the vehicle manufacturer after this bracket was designed, some bolts or other fasteners in the included hard• If running changes were made by the vehicle manufacturer after this ware pack may no longer be the correct size. It is the installer’s responbracket was designed, some bolts or other fasteners in the included hardsibility to verify that the bracket is securely fastened to the vehicle, and ware pack may no longer be the correct size. It is the installer’s responfitted with the correct hardware, to account for these changes. Failure to sibility to verify that the bracket is securely fastened to the vehicle, and fitted with the correct hardware, to account for these changes. Failure to securely securely fasten fasten the the bracket bracket could could result result in in loss loss of of the the towed towed vehicle. vehicle. •• IfIf the towed vehicle has been in an accident, it must be the towed vehicle has been in an accident, it must be properly properly repaired repaired before before attaching attaching the the bracket. bracket. Do Do not not install install the the bracket bracket ifif any any structural structural frame frame damage damage is is found. found. Failure Failure to to repair repair the the damage damage could could result result in in the the loss loss of of the the towed towed vehicle. vehicle. •• Some Some motorhome motorhome chassis chassis have have such such aa tight tight turning turning radius radius that that you you can can damage damage your your motorhome, motorhome, towed towed vehicle, vehicle, tow tow bar bar or or bracket bracket while while turning turning sharply. sharply. Before Before getting getting on on the the road, road, test test your your turning turning radius radius in in an an empty empty parking parking lot. lot. Turning Turning too too sharply sharply could could result result in in non-warranty non-warranty damage damage to to towing system, motorhome and/or towed vehicle. towing system, motorhome and/or towed vehicle. •• Do Do not not back back up up with with the the towed towed vehicle vehicle attached attached or or non-warranty non-warranty damdamage age will will occur occur to to your your towing towing system, system, motorhome motorhome and/or and/or towed towed vehicle. vehicle. •• The The safety safety cables cables must must connect connect the the towing towing vehicle vehicle to to the the towed towed vevehicle frame to frame, with the cables crossed, with enough hicle frame to frame, with the cables crossed, with enough slack slack for for sharp sharp turns. turns. Refer Refer to to the the cable cable instructions instructions for for proper proper routing. routing. Failure Failure to to leave enough slack in the safety cables, or failure to connect the safety leave enough slack in the safety cables, or failure to connect the safety cables frame to frame, will result in the loss of the towed vehicle. cables frame to frame, will result in the loss of the towed vehicle. •• This This bracket bracket is is designed designed for for use use with with ROADMASTER ROADMASTER tow tow bars bars and and ROADROADMASTER adaptors only. Using this bracket with other brands, MASTER adaptors only. Using this bracket with other brands, without without an an approved approved ROADMASTER ROADMASTER adaptor, adaptor, may may result result in in non-warranty non-warranty damage damage or injury. or injury. •• Upon Upon final final installation, installation, the the installer installer must must inspect inspect the the bracket bracket to to ensure ensure adequate adequate clearance, clearance, particularly particularly around around hoses, hoses, air air conditioner conditioner lines, lines, radiators, radiators, etc., etc., or or non-warranty non-warranty damage damage to to the the towed towed vehicle vehicle will will result. result. •• This This bracket bracket is is only only warranteed warranteed for for the the original original installation. installation. Installing Installing aa used used bracket bracket on on another another vehicle vehicle is is not not recommended recommended and and will will void void the the warranty. warranty. R 1-800-669-9690 O A D M A S T E R MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 1-800-669-9690 fax 360-735-9300 www.roadmasterinc.com KIT NO. 154-3 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. This bracket assembly utilizes the lower frame, subframe, stabilizer bar mount as attachment points. Remove the lower plastic air dam located under the bumper. It will be necessary to trim and refit later. Work on one side at a time, starting with the passenger side. 2. Remove the top stabilizer bar mounting bolts from the stabilizer mounting bracket. Hold the lower main brace in position with the rear mounting tab over the top of the stabilizer mounting bracket. Reinstall the stabilizer bar mounting bolt through the braces rear mounting tab. 3. Now, find the large subframe mount bolt near the front and above the brace. Remove this bolt and reinstall through the side brace mounting tab. Be sure to install as illustrated. Bolt the side brace to the main brace using the supplied ½” x 1½” bolts, flat washers, lock washers and nut. 4. Locate the existing holes in the subframe that line up with the two holes in the rear lower brace extension. A ¼” x 1½” x 3½” nutted backing plate will have to be fishwired through the hollow front of the subframe and lined up with the ½” holes in the brace extension. Once the backing plate is inserted, it can be held in place with a finger through a nearby access hole in the sub frame. Bolt through the lower brace extension and sub frame using the supplied ½” x 1½” bolts, flat washers, and lock washers. 5. Repeat steps 2, 3 and 4 to install the driver side main and side brace with the following exception. After fish wiring the nutted backing plate into position and bolting through the one available hole in the subframe, swing the backing plate to one side for clearance and drill a ½” hole through the sub frame using the existing hole in the lower brace extension as a template. 6. Bolt the center brace between the lower braces using two ½” x 1½” bolts, flat washers, lock washers and nuts. 7. Align the main braces so they are parallel and level with each other, then tighten all bolts to the torque specifications below. 8. Mount the tow bar according to the manufacturer’s instructions. HARDWARE LIST: 8-1/2” X 1 ½” BOLTS 8-1/2” LOCK WASHERS 10-1/2” FLAT WASHERS 4-1/2” NUTS 2-1/4” X 1 ½” X 3 ½” NUTTED BACKING PLATES 012899 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.