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 fax 360-735-9300 PARTS LIST: 1- FRONT BRACE (A) - Passenger side 1- FRONT BRACE (B) - Driver's side www.roadmasterinc.com KIT NO. 415-1 A OPTIONAL B 7-23-97 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 instructed. All bolts must be torqued for 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 one. 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 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 to follow these instructions can result in property damage, percan result in property damage, personal injury or even death. sonal injury or even death. • Installation of most mounting brackets requires moderate mechanical Installation ofskills. mostmounting mounting brackets requires moderate mechanical aptitude and We strongly recommend professional installation by •• Installation of most brackets requires moderate mechanical aptitude and skills. skills. We strongly strongly recommend recommend professional professional installation installation by by an experienced installer. aptitude and We an experienced installer. experienced 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. When theread instructions require theand reuse of all factory bolts, •• The must the use and parts 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 supplied. Failure to fasten could in towed vehicle. the bracket could result in loss of the towed vehicle. towed vehicle. Donot notuse usethis thisdocument documentfor forcustom customfabrication, fabrication,as asititmay maynot notshow showall all ••Do 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 Every 3,000must miles, the owner must inspect the fasteners for proper •• The owner inspect all mounts and brackets before each use torque, according the bolt torque Also, requirements chart on the last of for cracks or other to signs of fatigue. inspect the fasteners for page proper these instructions. The must also inspect all mounts andlast brackets torque, according to theowner bolt torque requirements chart on the page. for cracks 3,000vehicle. miles. Failure to do so Failure to doorsoother couldsigns resultofinfatigue loss of every the towed could resultmust in loss of the vehicle. • The owner check thetowed vehicle manufacturer's instructions for the • proper The owner must check the vehicle instructions for the procedure(s) to prepare themanufacturer's vehicle for towing. Some vehicles proper prepare thelube vehicle forantowing. Some vehicles must be procedure(s) equipped with to a transmission pump, axle disconnect, drivmust disconnect be equipped a transmission pump, axle driveline orwith free-wheeling hubslube before theyancan bedisconnect, towed. Failure eline disconnect hubs before can be Failure to properly equip or thefree-wheeling vehicle will cause severethey damage to towed. the transmisto properly equip the vehicle will cause severe damage to the transmission. • Ifsion. running changes were made by the vehicle manufacturer after this • bracket If running byother the vehicle manufacturer after this was changes designed,were somemade bolts or fasteners in the included hardbracket was designed, some bolts or other fasteners the included hardware pack may no longer be the correct size. It is the in installer’s responware pack may no be the correct size.fastened It is the to installer’s responsibility to verify thatlonger the bracket is securely the vehicle, and sibility to the verify that the brackettoisaccount securelyforfastened to the vehicle, fitted with correct hardware, these changes. Failureand to WARNING WARNING 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 towed vehicle has been in an accident, it must be properly repaired • If the towed vehicle has been in an accident, it must be properly repaired beforeattaching attachingthe thebracket. bracket.Do Donot notinstall installthe thebracket bracketififany anystructural 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 aa 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 Beforegetting gettingon onthe theroad, road,test testyour yourturning turningradius radiusin inan anempty 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 damdam•• Do 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 veve•• The 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 is designed for use with ROADMASTER tow bars andROADROAD• This bracket is designed for use with ROADMASTER tow bars and MASTERadaptors adaptorsonly. only.Using Usingthis thisbracket bracketwith withother otherbrands, brands,without withoutan an MASTER approvedROADMASTER ROADMASTERadaptor, adaptor,may mayresult resultin innon-warranty non-warrantydamage 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 used bracket bracket on on another another vehicle vehicle isis not not recommended recommended and and will will void void the the aa used 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. 415-1 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. These brackets mount to the underneath and to the outside of the frame on each side. Begin by locating the reinforcement tab located on the bottom of the frame. If it is held on with a small screw, remove the screw and tab. If welded on, leave intact as it will not interfere with the installation. 2. Locate a ½” x 1½” carriage bolt and a ¼” x 1” x 2” square hole backing plate in the hardware kit. Fish wire the bolt and backing plate through the forward most hole in the outside of the frame and down into the hole in the bottom of the frame. Hold the respective brace (A or B) up to the ½” bolts and secure to the bottom tab in the brace with a ½” lock washer and nut. 3. Bolt through the upper most tab in the brace and through the frame with a ½” x 1¾” bolt, with a clipped plate washer, lock washer and nut on the inside of the frame. Note: there may be a suspension bolt which may block this hole in the frame. If so, remove this bolt, bolt through the brace as instructed above, then reinstall suspension bolt. When this bolt is tight, it will lay against the flat of the nut previously installed. 4. Repeat steps 1 through 3 on the other side. Make certain that there is a center to center distance of 27” and 30” at the front holes of the braces (where the tow bar will eventually mount) and torque the four bolts to the torque chart below. 5. Using the braces as templates, drill through the two holes in the side of the brace and through the frame. A majority of the hole may be there already, so drill enough to be able to put a ½” bolt through the hole. It may be difficult to drill a straight hole due to limited space, but drill as straight as possible. Place a ¼” x 2” x 7” backing plate to the inside of the frame with a oval hole to the rear. Bolt through the main brace, frame and backing plate with a ½” x 3 ½” bolt with a lock washer and nut on the front bolt, a lock washer, flat washer and nut on the rear bolt. SPECIAL NOTE: on models with air conditioning, the ½” x 3½” bolt would hit the a/c pulley if inserted into the rear hole. For models with a/c, there is an optional ¼” x 2” x 3” backing plate included in the kit. Insert the ½” x 3½” bolt into the front hole of the brace on the passenger side and the optional backing plate to the inside of the frame, then install a lock washer and nut onto the bolt. This will leave three bolt holding the passenger side and four bolts holding the drivers side. 6. Torque all of the bolts to the torque chart below, then mount the tow bar according to the manufacturers instructions. HARDWARE LIST: 2-1/2” X 1 ¾” BOLTS 2-1/2” X 1 ½” CARRIAGE BOLTS 4-1/2” X 3 ½” BOLT 8-1/2” NUTS 8-1/2” LOCK WASHERS 2-1/2” FLAT WASHERS 2-1/2” CLIPPED PLATE WASHER 2-1/4” X 1” X 2” BACKING PLATE 2-1/4” X 2” X 7” BACKING PLATE 1-1/4” X 2 X 3” OPTIONAL BACKING PLATE 7-23-97 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.