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 PARTS LIST: 1- LOWER RECEIVER (A) - Passenger side 1- LOWER RECEIVER (B) - Driver's side 1- FRONT BRACE (C) - Passenger side 1- FRONT BRACE (D) - Driver's side 1- CROSS BRACE (E) 1-800-669-9690 fax 360-735-9300 www.roadmasterinc.com KIT NO. 1510-3 070298 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 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, 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 Installation of of most most mounting mounting brackets brackets requires requires moderate moderate mechanical mechanical aptitude aptitude and and skills. skills. We We strongly strongly recommend recommend professional professional installation installation by by an an experienced experienced installer. installer. •• The The installer installer must must read read the the instructions instructions and and use use all all bolts bolts and and parts parts supplied. supplied. When When the the instructions instructions require require the the reuse reuse of of factory factory bolts, bolts, thread thread lock lock and/or and/or lock lock washers washers must must also also be be used. used. Failure Failure to 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. •• 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. •• Every Every 3,000 3,000 miles, miles, the the owner owner must must inspect inspect the the fasteners fasteners for for proper proper torque, torque, according according to to the the bolt bolt torque torque requirements requirements chart chart on on the the last last page page of of these these instructions. instructions. The The owner owner must must also also inspect inspect all all mounts mounts and and brackets brackets for for cracks cracks or or other other signs signs of of fatigue fatigue every every 3,000 3,000 miles. miles. Failure Failure to to do do so so could could result result in in loss loss of of the the towed towed vehicle. vehicle. •• The The owner owner must must check check the the vehicle vehicle manufacturer's manufacturer's instructions instructions for for the the proper proper procedure(s) procedure(s) to to prepare prepare the the vehicle vehicle for for towing. towing. Some Some vehicles vehicles must must be be equipped equipped with with aa transmission transmission lube lube pump, pump, an an axle axle disconnect, disconnect, drivdriveline eline disconnect disconnect or or free-wheeling free-wheeling hubs hubs before before they they can can be be towed. towed. Failure Failure to to properly properly equip equip the the vehicle vehicle will will cause cause severe severe damage damage to to the the transmistransmission. sion. •• IfIf running running changes changes were were made made by by the the vehicle vehicle manufacturer manufacturer after after this this bracket bracket was was designed, designed, some some bolts bolts or or other other fasteners fasteners in in the the included included hardhardware ware pack pack may may no no longer longer be be the the correct correct size. size. ItIt is is the the installer’s installer’s responresponsibility sibility to to verify verify that that the the bracket bracket is is securely securely fastened fastened to to the the vehicle, vehicle, and and fitted fitted with with the the correct correct hardware, hardware, to to account account for for these these changes. changes. Failure Failure to 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 is is 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. 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. 1510-3 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 mounting kit utilizes the E-A (Energy Absorbing) bumper mounts and the lower tie down plate mounting points. To gain access to the E-A mounts the bumper will have to be removed. This is accomplished by first removing the turn signals to expose the main mounting bolts behind them. The lower splash guard may have to be removed to gain access to the light harness. Remove the bolt and the two other bolts in the top corner on each side of the grill. Remove three additional 10mm bolts from the lower side splash guards and pull forward. 2. Remove the E-A units from the bumper mount towers and sandwich the upper braces (A&B) between the E-A units and the bumper mount, with the braces positioned as shown on the diagram. Bolt these in place using the 8 x 1.25 x 25mm bolts provided. Now, bolt the upper brace tabs (F&G) to braces A&B with ½” x 1½” bolts provided and adjust so that the tab fits flush against the side of the tower. Make sure the upper braces are lined up with each other before the next step. Note: set the face plate (E) on the braces to check if the inner holes line up and the face plate will sit level. Adjust if necessary, then remove it and go on to the next step. 3. Now use the upper braces as a template, drill two 7/16” holes in each bumper mount tower. Insert a 7/16” x 1½” bolt and flat washer into the holes from inside the tower. Tighten these bolts to the torque specifications. 4. Reinstall the bumper over the upper braces. 5. Now remove the lower tie down plates from the car and install the lower braces (C&D) using the original tie down plate bolts. Leave these bolts loose for now. Note: the lower splash panels will have to be trimmed slightly. 6. Now install the face plates (E) using ½” x 1½” bolts and flat washers. Align and tighten the bolts to torque specifications. 7. Install the tow bar according to the instructions provided with the tow bar. 8. Be sure to tighten ALL bolts according to the torque chart shown below. 070298 HARDWARE LIST: 4-8MM X 1.25 X 25MM BOLTS 4-8MM FENDER WASHERS 4-8MM LOCK WASHERS 4-7/16 X 1 ½” BOLTS 4-7/16” NUTS 4-7/16” FLAT WASHERS 4-7/16” LOCK WASHERS 10-1/2” X 1 ½” BOLTS 10-1/2” FLAT WASHERS 10-1/2” LOCK WASHERS 10-1/2” NUTS 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.