Mounting Bracket Kit Installation Instructions

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- FACE PLATE (A) 1- MAIN BRACE (B) - Passenger side 1- MAIN BRACE (C) - Driver's side 1- LOWER BRACE (D) - Driver's side 1- LOWER BRACE (E) - Passenger side fax 360-735-9300 www.roadmasterinc.com KIT NO. 506-1 120297 IMPORTANT: IMPORTANT: All brackets must must be assembled with all the bolts left loose for final adjustment and positioning (before tightening) unless otherwise instructed. All bolts must must be torqued for proper strength. If more than one bolt is used per fastening point, the diagram may only show 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 Limited Warranty, including One-Year Conditional Warranty Text and Product Registration Card, in Carton. WARNING Failure to follow these instructions can result in property damage, personal injury or even death. • 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 experienced installer. installer. • an The installer must read the instructions and use all bolts and parts The installer installer must read the instructions instructions and use all bolts bolts andthread parts •• supplied. The must the use all and parts When the read instructions require the and reuse of factory bolts, supplied. to fasten could in of supplied. Failure to securely securely fasten the bracket could result result in loss loss fasten of the the lock and/orFailure lock washers must also the be bracket used. Failure to securely 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 it it 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 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 so could result in loss of the towed vehicle. for cracks or other signs of fatigue every 3,000 miles. Failure to do so • could The owner check vehicle manufacturer's instructions for the result must in loss of thethe towed vehicle. 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 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 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. 506-1 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 assembly utilizes the E-A (Energy Absorption) unit mountings and the lower tie downs on each side. In order to access the E-A units, the front bumper will have to be removed. Do this by removing the two bolts, one on each side, which holds the bumper to the E-A units. Reach inside the fender well and squeeze the plastic bumper retainers with pliers until they pull free and save them. Unplug the turn signals, pull the bumper straight out and set aside. 2. Remove the four 8mm x 25 bolts holding the E-A units to the front of the car and discard. Hold the respective brace (B or C) to the car over the E-A unit mounting holes, then set the E-A units over the top of the brace. Bolt through the E-A unit, brace and into the frame with the 8mm x 1.25 x 35mm bolts, lock washers and flat washers. Hand tighten only at this time. 3. Temporarily install the face plate (A) onto the two braces and bolt using the four ½” x 1½” bolts, flat washers and nuts. Align the braces so that they are even across and tighten the bolts. Torque the 8mm bolts installed earlier according to the chart below. Remove the face plate and reinstall the bumper. Note: some plastic may need to be trimmed in order to reinstall bumper. Reinstall plastic bumper retainers and reconnect turn signal wires. 4. Mount the side braces (C and D) to the outsides of the tie downs and bolt through the brace and tie down with the ½” x 1½” bolts, clipped plate washers, lock washers and nuts, making certain that the ½” clipped plate washer is to the inside of the tie down. Set the face plate on top of the two main braces, then swing the side braces up to the main braces and bolt through the face plate, main braces and side braces with the ½” x 1½” bolts, flat washers, lock washers and nuts. 5. Torque all bolts according to the chart below and mount the tow bar directly to the face plate according to the manufacturer’s instructions. 120297 Hardware List 6- ½” x 1-1/2” bolts 4- ½” flat washers 6- ½” lock washers 6- ½” nuts 2- ½” clipped plate washers 4- 8mm x 1.25 x 35 bolts 4- 8mm flat washers 4- 8mm lock washers 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.