Kit No. 160-2 12-02-97

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- FACE PLATE (C) - Passenger side 1-800-669-9690 fax 360-735-9300 www.roadmasterinc.com KIT NO. 160-2 12-02-97 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 instructed. All bolts must be torqued for proper strength. If more than one bolt is used per fastening point, the diagram may only show one. 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 Failure to follow these damage, instructions can result in property percan result in or property damage, personal injury even death. sonal injury or even death. • Installation of most mounting brackets requires moderate mechanical Installation ofskills. mostmounting mounting brackets requires moderate mechanical aptitude and We strongly recommend professional installation by •• Installation of most brackets requires moderate mechanical aptitude and skills. skills. We strongly strongly recommend recommend professional professional installation installation by by an experienced installer. aptitude and We an experienced installer. • an The installer must read the instructions and use all bolts and parts experienced installer. The installer installer must read the instructions instructions and use all bolts bolts andthread parts supplied. When theread instructions require theand reuse of all factory bolts, •• The must the use and parts supplied. Failure to securely fasten the bracket could result in loss of the lock and/or lock washers must also be used. Failure to securely fasten supplied. Failure to securely fasten the bracket could result in loss of the towed vehicle. the bracket could result in loss of the towed vehicle. towed vehicle. Donot notuse usethis thisdocument documentfor forcustom customfabrication, fabrication,as asititmay maynot notshow showall all ••Do parts or or structural structural components. components. Custom Custom fabrication fabrication or or an an attempt attempt to to copy copy parts this bracket bracket design design could could result result in in loss loss of of the the towed towed vehicle. vehicle. this • Every 3,000 miles, the owner must inspect the fasteners for proper • The owner must inspect all mounts and brackets before each use torque, according to the bolt torque requirements chart on the last of for cracks or other signs of fatigue. Also, inspect the fasteners for page proper these instructions. The must also inspect all mounts andlast brackets torque, according to theowner bolt torque requirements chart on the page. for cracks 3,000vehicle. miles. Failure to do so Failure to doorsoother couldsigns resultofinfatigue loss of every the towed could result in loss of the towed vehicle. • The owner must check the vehicle manufacturer's instructions for the • proper The owner must check the vehicle instructions for the procedure(s) to prepare themanufacturer's vehicle for towing. Some vehicles proper procedure(s) to prepare the vehicle for towing. Some vehicles must be equipped with a transmission lube pump, an axle disconnect, drivmust disconnect be equipped a transmission pump, axle driveline orwith free-wheeling hubslube before theyancan bedisconnect, towed. Failure eline disconnect hubs before can be Failure to properly equip or thefree-wheeling vehicle will cause severethey damage to towed. the transmisto properly equip the vehicle will cause severe damage to the transmission. sion. • If running changes were made by the vehicle manufacturer after this • bracket If running byother the vehicle manufacturer after this was changes designed,were somemade bolts or fasteners in the included hardbracket was designed, some bolts or other fasteners the included hardware pack may no longer be the correct size. It is the in installer’s responware pack may no be the correct size.fastened It is the to installer’s responsibility to verify thatlonger the bracket is securely the vehicle, and sibility to the verify that the brackettoisaccount securelyforfastened to the vehicle, fitted with correct hardware, these changes. Failureand to WARNING WARNING fitted with the correct hardware, to account for these changes. Failure to securely fasten fasten the the bracket bracket could could result result in in loss loss of of the the towed towed vehicle. vehicle. securely • If the towed vehicle has been in an accident, it must be properly repaired • If the towed vehicle has been in an accident, it must be properly repaired before attaching the bracket. Do not install the bracket if any structural before attaching the bracket. Do not install the bracket if any structural 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 frame loss of of the the towed towed vehicle. vehicle. loss Some motorhome motorhome chassis chassis have have such such aa tight tight turning turning radius radius that that you you can can •• Some damage your your motorhome, motorhome, towed towed vehicle, vehicle, tow tow bar bar or or bracket bracket while while turning turning damage sharply.Before Beforegetting gettingon onthe theroad, road,test testyour yourturning turningradius radiusin inan anempty empty sharply. parking lot. lot. Turning Turning too too sharply sharply could could result result in in non-warranty non-warranty damage damage to to parking towing system, system, motorhome motorhome and/or and/or towed towed vehicle. vehicle. towing Do not not back back up up with with the the towed towed vehicle vehicle attached attached or or non-warranty non-warranty damdam•• Do age will will occur occur to to your your towing towing system, system, motorhome motorhome and/or and/or towed towed vehicle. vehicle. age The safety safety cables cables must must connect connect the the towing towing vehicle vehicle to to the the towed towed veve•• The hicle frame to frame, with the cables crossed, with enough slack for hicle frame to frame, with the cables crossed, with enough slack for sharp turns. turns. Refer Refer to to the the cable cable instructions instructions for for proper proper routing. routing. Failure Failure to to sharp leave enough enough slack slack in in the the safety safety cables, cables, or or failure failure to to connect connect the the safety safety leave 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. cables • This bracket is designed for use with ROADMASTER tow bars andROADROAD• This bracket is designed for use with ROADMASTER tow bars and MASTER adaptors only. Using this bracket with other brands, without an MASTER adaptors only. Using this bracket with other brands, without an approvedROADMASTER ROADMASTERadaptor, adaptor,may mayresult resultin innon-warranty non-warrantydamage damage approved or injury. injury. or • Upon final installation, installation, the the installer installer must must inspect inspect the the bracket bracket to to ensure ensure • Upon final adequate clearance, clearance, particularly particularly around around hoses, hoses, air air conditioner conditioner lines, lines, adequate radiators, etc., or non-warranty damage to the towed vehicle will result. radiators, etc., or non-warranty damage to the towed vehicle will result. This bracket bracket is is only only warranteed warranteed for for the the original original installation. installation. Installing Installing •• This used bracket bracket on on another another vehicle vehicle isis not not recommended recommended and and will will void void the the aa used 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. 160-2 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 front bumper and frame as the primary mounting points. Prepare the car for mounting the main braces by removing the plastic graves deflector from under the bumper. Then look under the bumper and locate the 2nd and 3rd bolt from both ends of the bumper. Remove these four bolts. 2. Hold a brace in position under the bumper and positioned on the frame. Look for the hole in the side of the frame that lines up with the braces rear side mounting tab. Fish wire a ½” x 1½” carriage bolt and a 2½” x 2” x ¼” backing plate into the rear holes. Bolt using the supplied ½” lock washers and nuts. 3. Follow the same procedure for the remaining side. 4. Mount the bar according to the manufacturer’s instructions and align the braces. Tighten the mounting bolts at this point. . 5. Each brace should have two remaining mounting tabs with holes. Use these tabs as templates to drill 9/16” holes in the bottom of each frame rail. Fish wire a ½” x 1½” carriage bolt and a 2½” x 2” x ¼” backing plate into the front most hole on each side and a ½” x 1½” carriage bolt and 2” x 1 ½” x ¼” backing plate into the rear holes. Bolt using the supplied ½” lock washers and nuts. 6. Do a final alignment and tighten all bolts to the torque specifications below. Trim the gravel deflector to fit and reinstall. HARDWARE LIST: 4- 2 ½” x 2” x ¼” backing plates 2- 2” x 1 ½” x ¼” backing plates 4- 8mm x 1.25 x 40mm bolts 4- 8mm lock washers 4- 8mm flat washers 10- 1 ½” x ½” carriage bolts 10- 1/2” nuts 4- 1/2” flat washers 10- 1/2” lock washers 12-02-97 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.