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MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc.
6110 NE 127th Ave.
Vancouver, WA 98682
PARTS LIST: 1- MAIN RECEIVER (A) 1- FRONT BRACE (B) - Passenger's side 1- FRONT BRACE (C) - Driver's side 1- REAR BRACE (D) - Passenger's side 1- REAR BRACE (E) - Driver's side
1-800-669-9690
fax 360-735-9300
www.roadmasterinc.com
KIT NO. 909-1
7/27/99
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) IMPORTANT: 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, unless the diagram diagram may may only only show show one. one. the 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 •• Use 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. ROADMASTER
WARNING
Failure to to follow follow these these instructions instructions Failure can result result in in property property damage, damage, perpercan sonal injury injury or or even even death. death. sonal
• 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 the use and parts 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, supplied. Failure to fasten could in supplied. Failure to securely securely fasten the bracket could result result in loss loss of of the the lock and/or lock washers must alsothe bebracket used. Failure to securely fasten towed vehicle. towed vehicle. the bracket could result in loss of the towed vehicle. •• Do Do not not use use this this document document for for custom custom fabrication, fabrication, as as itit may may not not show show all all parts parts or or structural structural components. components. Custom Custom fabrication fabrication or or an an attempt attempt to to copy copy this this bracket bracket design design could could result result in in loss loss of of the the towed towed vehicle. vehicle. •• The owner inspect all mounts and brackets before each use Every 3,000must miles, the owner must inspect the fasteners for proper for cracks or otherto signs of fatigue. inspect the fasteners for page proper torque, according the bolt torque Also, requirements chart on the last of torque, according to theowner bolt torque requirements on the page. these instructions. The must also inspect allchart mounts andlast 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 thetowed vehicle manufacturer's instructions for the could resultmust in loss of the vehicle. procedure(s) to the prepare themanufacturer's vehicle for towing. Some vehicles • proper The owner must check vehicle instructions for the must be procedure(s) equipped with to a transmission pump, axle disconnect, drivproper prepare thelube vehicle foran towing. Some vehicles eline orwith free-wheeling hubslube before theyancan bedisconnect, towed. Failure must disconnect be equipped a transmission pump, axle drivto properly equip or thefree-wheeling vehicle will cause severethey damage to towed. the transmiseline disconnect hubs before can be 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 was changes designed,were somemade bolts or fasteners in the included hard• bracket If running byother the vehicle manufacturer after this ware pack may no longer be the correct size. It is the in installer’s responbracket was designed, some bolts or other fasteners 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 correct hardware, these changes. Failureand to sibility to the verify that the brackettoisaccount securelyfor fastened to the vehicle,
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 the towed towed vehicle vehicle has has been been in in an an accident, accident, itit must must be 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 towing system, system, motorhome motorhome and/or and/or towed towed vehicle. 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 hicle frame frame to to frame, frame, with with the the cables cables crossed, crossed, with with enough 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 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 cables 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. •• This This bracket bracket isis designed designed for for use use with with ROADMASTER ROADMASTER tow tow bars bars and and ROADROADMASTER MASTER adaptors adaptors only. only. Using Using this this bracket bracket with with other other brands, brands, without without an an approved approved ROADMASTER ROADMASTER adaptor, adaptor, may may result result in in non-warranty non-warranty damage damage or or injury. 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.
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1-800-669-9690
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A
D
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A
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T
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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. 909-1 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 is one of our XL Series with removable front braces. The main receiver brace is designed to mount between the the bottom front tie down loops. It also attaches to the bottom of the frame on each side with two additional mounting braces. Remove two small splash panels located on each side of the frame. 2. Position the main receiver brace between the tie down plates. Now, bolt through the tie down loops on each side with a ½" x 2" bolt, plate washer, lock washer and nut. Be sure to use the plate washer on outside of the tie down loop. Tighten the bolts until the brace stays in position. 3. Bolt the rear braces to the receiver brace as illustrated using two ½" x 1½" bolts, flat washers,lock washers and nuts on each side. 4. Insert the two front braces into the receivers and pin with the supplied 5/8" draw pins and 1/8" spring pins. 5. Check the brace for alignment then tighten the side bolts and the rear brace bolts on each side. The rear braces should be flat against the bottom of the frame on each side with the mounting hole centered on the frame. The front braces mounting surface should vertical. 6. Now, drill a ½" hole through the top and bottom of the frame on each side using the rear braces as a template. Note: check the top of the frame — if ABS brake lines are present, protect and reposition slightly, if necessary. Some models may require removal of the air cleaner plenum for access. 7. Bolt through the frame on each side using the supplied ½" x 5" bolts, ¼" x 2" x 3" backing plates, lock washers and nuts. Note: be sure to use the backing plates on the top of the frame. 8. Trim the small splash panels to fit and reinstall. 9. Mount the tow bar according to the manufacturer’s instructions and torque all bolts to the specifications below. 10. Attach the supplied 19" safety cables to the receivers and the tow vehicle's cables. Hardware: 2- 1/2" x 2" bolts
2- 1/2" plate washers
2- cable connectors
4- 1/2" x 1-1/2" bolts
4- 1/2" flat washers
2- 19" safety cables
2- 1/2" x 5" bolts
2- 1/4" x 2" x 3" backing plates
8- 1/2 nuts
2- 5/8" draw pins
8- 1/2" lock washers
2- 1/8" spring pins
7/27/99
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.
