Kit No. 157-1 12-16-99

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- MAIN BRACE (A) - Passenger side 1- MAIN BRACE (B) - Driver’s side 1-800-669-9690 fax 360-735-9300 www.roadmasterinc.com KIT NO. 157-1 12-16-99 IMPORTANT: All brackets must be assembled with all the bolts left loose for final adjustment and positioning (before tightening) IMPORTANT: All brackets must assembled all theforbolts left loose for final adjustment and positioning (before tightening) unless otherwise instructed. All be bolts must bewith torqued proper strength. If more than one bolt is used per fastening point, unless otherwise the diagram may instructed. only show All one.bolts must be torqued for proper strength. If more than one bolt is used per fastening point, the diagram may only show • Use one. flat washers over all slotted holes • Use lock washers on all fasteners • Use flat washers over all slotted holes • Use lock washers on all fasteners ROADMASTER Limited Warranty, including One-Year Conditional Warranty Text and Product Registration Card, in Carton. ROADMASTER Limited Warranty, including One-Year Conditional Warranty Text and Product Registration Card, in Carton. Failure to follow these instructions can result in property perFailure to follow these damage, instructions sonal injury even death. can result in or property damage, personal injury or even death. • Installation of most mounting brackets requires moderate mechanical • Installation ofskills. most mounting brackets requires moderate mechanical aptitude and We strongly recommend professional installation by • Installation of skills. most mounting brackets requires moderateinstallation mechanical aptitude and We strongly recommend professional by an experienced installer. aptitude and skills. We strongly recommend professional installation by an experienced installer. • an The installer must read the instructions and use all bolts and parts experienced installer. • supplied. The installer must the instructions use all bolts andthread parts When the read instructions require the and reuse of factory bolts, • The installer must the instructions andFailure use parts supplied. toread securely fasten couldallresult in and loss fasten of the lock and/orFailure lock washers must also the be bracket used. tobolts securely supplied. Failure securely fasten thetowed bracket could result in loss of the towed vehicle. the bracket could to result in loss of the vehicle. towed vehicle. • Do not use this document for custom fabrication, as it may not show all • Do notoruse this document for custom not show all parts structural components. Customfabrication, fabrication as or it anmay attempt to copy parts or structural fabrication an attempt to copy this bracket designcomponents. could result Custom in loss of the towedorvehicle. this bracket design could result in loss of the towed vehicle. • Every 3,000 miles, the owner must inspect the fasteners for proper • The owner must to inspect mounts and brackets before each use torque, according the boltall torque requirements chart on the last page of for cracks or other The signs of fatigue. Also,inspect inspect all themounts fasteners proper these instructions. owner must also andfor brackets torque, according to the boltoftorque requirements onFailure the lasttopage. for cracks or other signs fatigue every 3,000chart miles. do so Failure to do in soloss could in loss of the towed vehicle. could result of result the towed vehicle. •• The Theowner ownermust mustcheck checkthe thevehicle vehiclemanufacturer's manufacturer'sinstructions instructionsfor forthe the proper proper procedure(s) procedure(s) to to prepare prepare the the vehicle vehicle for for towing. towing. Some Some vehicles vehicles must mustbe beequipped equippedwith withaatransmission transmissionlube lubepump, pump,an anaxle axledisconnect, disconnect,drivdriveline eline disconnect disconnect or or free-wheeling free-wheeling hubs hubs before before they they can can be be towed. towed. Failure Failure to to properly properly equip equip the the vehicle vehicle will will cause cause severe severe damage damage to to the the transmistransmission. sion. •• IfIf running running changes changes were were made made by by the the vehicle vehicle manufacturer manufacturer after after this this bracket bracket was was designed, designed, some some bolts bolts or or other other fasteners fasteners in in the the included included hardhardware ware pack pack may may no no longer longer be be the the correct correct size. size. ItIt is is the the installer’s installer’s responresponsibility sibility to to verify verify that that the the bracket bracket isis securely securely fastened fastened to to the the vehicle, vehicle, and and fitted with the correct hardware, to account for these changes. Failure to WARNING WARNING fitted with the correct hardware, to account for these changes. Failure to securely fasten the bracket could result in loss of the towed vehicle. 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 repaired • Ifbefore the towed vehicle been Do in an it must be properly repaired attaching thehas bracket. notaccident, install the bracket if any structural before thefound. bracket. Do not thedamage bracket could if anyresult structural frame attaching damage is Failure to install repair the in the frame is found. loss ofdamage the towed vehicle.Failure to repair the damage could result in the loss of the towed vehicle. • Some motorhome chassis have such a tight turning radius that you can • Some motorhome chassis towed have such a tight radius that can damage your motorhome, vehicle, tow turning bar or bracket whileyou turning damage your motorhome, vehicle, tow bar or bracket sharply. Before getting ontowed the road, test your turning radiuswhile in anturning empty sharply. gettingtoo on sharply the road, test result your turning radius indamage an empty parkingBefore lot. Turning could in non-warranty to parking lot. Turning too sharply could result in non-warranty damage to towing system, motorhome and/or towed vehicle. towing system, motorhome and/or towed vehicle. • Do not back up with the towed vehicle attached or non-warranty dam• Do towed vehicle attachedand/or or non-warranty damagenot willback occurup towith your the towing system, motorhome towed vehicle. age will occur to your towing system, motorhome and/or towed vehicle. • The safety cables must connect the towing vehicle to the towed ve• The must connect the towing vehicle the towed hiclesafety framecables to frame, with the cables crossed, with to enough slackvefor hicle frame, the cables crossed, with enough sharpframe turns.toRefer to with the cable instructions for proper routing. slack Failurefor to sharp turns. Refer proper routing. Failure to leave enough slacktointhe thecable safetyinstructions cables, or for failure to connect the safety leave slack in the or failure connect the safety cablesenough frame to frame, willsafety result cables, in the loss of the to towed vehicle. cables frame to frame, will result in the loss of the towed vehicle. • This bracket is designed for use with ROADMASTER tow bars and ROAD• This bracket is designed for usethis withbracket ROADMASTER tow bars and ROADMASTER adaptors only. Using with other brands, without an MASTER only. Using this bracket with other brands, without an approvedadaptors ROADMASTER adaptor, may result in non-warranty damage approved or injury. ROADMASTER adaptor, may result in non-warranty damage or injury. • Upon final installation, the installer must inspect the bracket to ensure • Upon final installation, installer around must inspect to ensure adequate clearance, the particularly hoses,the air bracket conditioner lines, adequate particularlydamage aroundtohoses, air conditioner lines, radiators,clearance, etc., or non-warranty the towed vehicle will result. radiators, etc., or non-warranty damage to the towed vehicle will result. • This bracket is only warranteed for the original installation. Installing • This bracket is on only warranteed original installation. a used bracket another vehiclefor is the not recommended and willInstalling void the awarranty. used bracket on another vehicle is not recommended and will void the 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. 157-1 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 kit utilizes the main frame and lower energy absorption unit mount as attachment points. Remove the lower outer gravel guards and loosen the front fender well splash panels on both sides to gain access to these areas. 2. Find the bumper energy absorption mounts on the front of the frame and remove the two lower bolts on each mount. Take a 3/8” drill bit and enlarge these holes. This can be done from the rear of the flange by drilling at a slight angle. 3. Hold a brace in position with the front bar mounting clip pointing toward the center of the car. The front mounting plate should be in front of the energy absorption unit and the rear mounting tabs should be snug against the bottom and side of the main frame. Bolt through the brace mounting plate and two lower energy absorption mounting holes using the 3/8” x 1½” bolts. Use the supplied flat washers over the mounting plate holes and finish with lock washers and nuts. 4. Follow step three for the remaining side. 5. At this point, check the alignment of the braces to each other. Make sure the front mounting clips are aligned to each other and are level. If they aren’t loosen your bolts and adjust as needed. 6. Hold or clamp the rear of the braces in position and using the braces as a template, drill three ½” holes, two through the bottom and one through the side of each main frame. 7. Now, fish wire a ¼” x 1½” x 6” bolted backing plate through a large access hole located near the front plate through a large access hole located near the front and underneath each frame and into the lower pre-drilled holes. Finish with ½” nuts and lock washers. Do this for each side. Note: see the included fish wire sheet. 8. Fish wire the remaining ¼” x 1½” x 2½” bolted backing plate through the same access hole and into the remaining side holes. Finish with ½” nuts and lock washers. 9. Mount the tow bar according to the manufacturers instructions and torque all bolts to the specifications shown below. HARDWARE LIST: 4-3/8” X 1 ½” BOLTS 4-3/8” NUTS 8-3/8” FLAT WASHERS 4-3/8” LOCK WASHERS 6-1/2” NUTS 6-1/2” LOCK WASHERS 2-1/4” X 1 ½” X 6” BACKING PLATES WITH BOLTS 2-1/4” X 1 ½” X 2 ½” BACKING PLATES WITH BOLTS 12-16-99 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.