Kit No. 3103-1 05/22/03

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 fax 360-735-9300 PARTS LIST: 1- MAIN BRACE (A) - Passenger side 1- MAIN BRACE (B) - Driver's side 1- FRONT BRACE (C) - Passenger side 1- FRONT BRACE (D) - Driver's side www.roadmasterinc.com KIT NO. 3103-1 B A D C 05/22/03 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 can result to follow in property these damage, instructions percan sonal result injury in or property even death. 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 musttoread the fasten instructions and use boltsin and parts supplied. securely couldallresult loss fasten of the lock and/orFailure lock washers must also the be bracket used. Failure to securely 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. • 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. • 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 page of for cracks or other signs of fatigue. Also, inspect the fasteners for proper these instructions. The owner must also inspect all mounts and brackets torque, according to the bolt torque requirements chart on the last page. for cracks or other signs of fatigue every 3,000 miles. Failure to do so Failure to do so could result in loss of the towed vehicle. could result in loss of the towed vehicle. • The owner must check the vehicle manufacturer's instructions for the • The owner must check the vehicle manufacturer's instructions for the proper procedure(s) to prepare the 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 be equipped with a transmission lube pump, an axle disconnect, driveline disconnect or free-wheeling hubs before they can be towed. Failure eline disconnect or free-wheeling hubs before they can be towed. Failure to properly equip the vehicle will cause severe damage to 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 • If running changes were made by the vehicle manufacturer after this bracket was designed, some bolts or other fasteners in the included hardbracket was designed, some bolts or other fasteners in the included hardware pack may no longer be the correct size. It is the installer’s responware pack may no longer be the correct size. It is the installer’s responsibility to verify that the bracket is securely fastened to the vehicle, and 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 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, towed vehicle, tow bar or bracket while turning sharply. Before getting on the road, test your turning radius in an 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 to the cable instructions for proper routing. Failure 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 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 ROADMASTER adaptor, may result in non-warranty damage or injury. 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 clearance, particularly around hoses, air conditioner lines, 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 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. 3103-1 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 consists of two rear main braces, two front braces and a hardware pack. The main receiver braces mount behind and below the front bumper to the front engine and suspension sub frame. Start by laying the kit out according to the illustration. This will give you a visual idea of how the kit installs and also confirm that the kit components are present and accounted for. The lower air deflector will have to be trimmed to fit later after the bracket kit is fully installed. 2. Working on one side at a time, locate the front main A frame suspension bolt and remove. Note: this is a suspension bolt so don’t move the vehicle once it has been removed. 3. Take a ¼” x 2½” x 6” backing plate and a ½” x 1½” carriage bolt and insert through the open side of the sub frame into the existing slotted hole in the bottom of the frame. 4. Hold the passenger side brace to the bottom of the subframe and bolt to the bottom of the sub frame using a ½” nut and lock washer. 5. Bolt through the side mount with the suspension bolt removed in step two. Leave loose at this time. 6. Take the special ¼” x 2” x 6½” backing plates and slide them over the top of the sub frame channel. Note be sure to slide them under any tubing present. If necessary, displace the tubing upward enough to clear the backing plate. Center holes are provided for the plastic tubing holders. Insert two ½” x 4½” bolts through the backing plate into the brace and bolt using ½” nuts and lock washers. 7. Put the specially formed flat U bolt over the rear of the sub frame as illustrated and bolt in place using ½” flat washers, lock washers and nuts. 8. Repeat steps 2 through 7 for the passenger side brace. 9. Torque all mounting bolts to the specifications below. 10. Trim the lower air dam to fit. 11. Install the tow bar according to the manufacturer’s instructions. Hardware 4- ½” x 4-1/2” bolts 1- ¼” x 1 1/4” x 4” Bolted backing plate (Drivers Side) 1- ¼” x 1 1/4” x 7” Bolted backing plate (Passenger Side) 2- ½” x 1 ½” carriage bolts 2- 1/2" x 2 1/2" x 6" Backing plates 2- 1/2" x 2" x 6 1/2" Backing plates 10- ½” lock washers 10- ½” nuts 4- ½” flat washers 2- 10” safety cables 2- Cable connectors 2- 5/8” draw pins 2- 1/8” spring pins 05/22/03 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.