Kit No. 165-2

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 1-800-669-9690 PARTS LIST: 1- MAIN BRACE (A) - Passenger side 1- MAIN BRACE (B) - Driver's side 1- SIDE BRACE (C) - Passenger side 1- SIDE BRACE (D) - Driver's side 1- LOWER BRACE (E) - Passenger side 1- LOWER BRACE (F) - Driver's side fax 360-735-9300 www.roadmasterinc.com KIT NO. 165-2 112497 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 otherwise instructed. All bolts must be torqued for proper strength. If more than one bolt is used per unless otherwise instructed. All bolts must be torqued for proper strength. If more than one bolt is used 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 ofskills. most mounting brackets requires moderate mechanical aptitude and We strongly recommend professional installation by aptitude and skills. We strongly recommend professional installation by an experienced installer. an experienced installer. • The installer must read the instructions and use all bolts and parts • supplied. The installer must the instructions use all bolts andthread parts When the read instructions require the and reuse of factory bolts, supplied. to securely fasten could result in loss fasten of the lock and/orFailure lock washers must also the be bracket used. Failure to securely towed vehicle. the bracket could result in loss of the towed vehicle. •• Do not Do not use use this this document document for for custom custom fabrication, fabrication, as as it it may may not not show show all all 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 The owner inspect all mounts and brackets before for each use •• Every 3,000must miles, the owner must inspect the fasteners proper for cracks or othertosigns of fatigue. Also, inspect chart the fasteners forpage proper torque, according the bolt torque requirements on the last of torque, according The to the bolt torque requirements on the page. these instructions. owner must also inspect allchart mounts andlast brackets Failure to do could result loss ofevery the towed for cracks orso other signs ofinfatigue 3,000vehicle. miles. Failure to do so result must in loss of thethe towed vehicle. • could The owner check vehicle manufacturer's instructions for the proper procedure(s) to the prepare themanufacturer's vehicle for towing. Some vehicles • The owner must check vehicle instructions for the must beprocedure(s) equipped withto a transmission pump, axle disconnect, drivproper prepare the lube vehicle foran towing. Some vehicles eline disconnect free-wheeling hubslube before they towed. Failure must be equippedorwith a transmission pump, ancan axlebe disconnect, drivto properly equiporthe vehicle will hubs causebefore severethey damage the transmiseline disconnect free-wheeling can betotowed. Failure sion. to properly equip the vehicle will cause severe damage to the transmis• sion. If running changes were made by the vehicle manufacturer after this waschanges designed,were somemade bolts or fasteners in the included • bracket If running by other the vehicle manufacturer afterhardthis ware pack no longer be the correct size. It is theininstaller’s responbracket wasmay designed, some bolts or other fasteners the included hardsibility to verify that the bracket is securely to the vehicle, and ware pack may no longer be the correct size. fastened It is the installer’s responfitted with correct hardware, these changes. Failureand to sibility to the verify that the bracket to is account securelyfor fastened to the vehicle, •• •• •• •• •• •• •• 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 the towed towed vehicle vehicle has has been been in in an an accident, accident, it it must must be be properly properly repaired repaired If before attaching attaching the the bracket. bracket. Do Do not not install install the the bracket bracket if if any any structural structural before 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 a a 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 Before getting getting on on the the road, road, test test your your turning turning radius radius in in an an empty 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 damdamDo 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 veveThe hicle frame frame to to frame, frame, with with the the cables cables crossed, crossed, with with enough enough slack slack for for hicle 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 bracket is is designed designed for for use use with with ROADMASTER ROADMASTER tow tow bars bars and and ROADROADThis MASTER adaptors adaptors only. only. Using Using this this bracket bracket with with other other brands, brands, without without an an MASTER approved ROADMASTER ROADMASTER adaptor, adaptor, may may result result in in non-warranty non-warranty damage damage approved or injury. injury. or Upon final final installation, installation, the the installer installer must must inspect inspect the the bracket bracket to to ensure ensure Upon adequate clearance, clearance, particularly particularly around around hoses, hoses, air air conditioner conditioner lines, lines, adequate radiators, etc., etc., or or non-warranty non-warranty damage damage to to the the towed towed vehicle vehicle will will result. result. radiators, This bracket bracket is is only only warranteed warranteed for for the the original original installation. installation. Installing Installing This a used used bracket bracket on on another another vehicle vehicle is is not not recommended recommended and and will will void void the the a 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. 165-2 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 tow hook mounts in the front of the frame as a attachment point. Remove the tow hooks and stock bolts. If the vehicle is equipped with a skid pan, remove two bolts on each side from the bottom of the frame. Now, remove the tubular fender brace bolt on each side of the frame. Save the skid pan and brace bolts. 2. Enlarge the existing tow hood mount bolt holes slightly to accommodate the larger ½” bolts included in the kit hardware. 3. Working on one side at a time, fit the lower brace plate under the frame and under the side of the skid pan. Line up the holes in the lower brace plate with the reamed holes in the frame. 4. Fit a main brace through the air dam and into the front of the frame tube. Line up the two bottom holes in the brace with the enlarged holes in the frame and lower brace plate, then check the large slotted side hole in the frame and see if it lines up with the rear side mounting nut on the main brace. If it doesn’t line up, the frame hole will have to be enlarged. 5. Bolt through the lower brace plate and two enlarged tow hook mounting holes into the inserted main brace with the supplied ½” x 3” bolts and lock washers. 6. Pull the fender brace away from the frame slightly, hold the side brace to the side of the frame and bolt through the fender brace and side plate with a 10mm x 1.5 x 40mm bolt, lock washer and flat washer. Note: on ‘98 vehicles the fender brace has been eliminated. Using 1” x 2” backing plates and carriage bolts, fish wire them through the large slot on the outside of the frame and then through the brace. Finished with flat washers, lock washers, and nuts. Repeat step on the opposite side. 7. Bolt the bottom of the side brace to the bottom brace plate using ½” x 1½” bolts, flat washer, lock washers and nuts. 8. Now, bolt through the frame side hole with a ½” x 2” bolt, ½” plate washers and lock washer. Note: be sure to use a ¼” thick plate washer between the frame and the side brace as a spacer. 9. Repeat steps 3 through 8 for the remaining side. 10. Replace skid pan bolts if present. 11. Mount the bar according to the manufacturers instructions and align the braces. Once aligned tighten all bolts to the specifications below. HARDWARE LIST: 2-1/2” X 2” BOLTS 4-1/2” X 1 ½” BOLTS 4-1/2” X 3” BOLTS 14-1/2” FLAT WASHERS 4-1/2” PLATE WASHER 12-1/2” LOCK WASHERS 6-1/2” NUTS 2-10MM X 1.5 X 40MM BOLTS 2-10MM LOCK WASHERS 112497 2-10MM FENDER WASHER 2-1/2 x 1 ½ CARRIAGE BOLTS 2-1/4" x 1" x 2" SQ. HOLE BACKING PLATE 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. METRIC BOLTS STANDARD BOLTS Thread Size Grade 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.