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- RECEIVER BRACE (A) - Passenger side 1- RECEIVER BRACE (B) - Driver's side 1- FRONT BRACE (C) - Passenger side 1- FRONT BRACE (D) - Driver's side 1-800-669-9690 fax 360-735-9300 www.roadmasterinc.com KIT NO. 2104-1 B A D C 8-27-02 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 otherwise instructed. All bolts must be torqued for proper strength. If more than one bolt is used per unless otherwise instructed. All bolts must be torqued for proper strength. If more than one bolt is used 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 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 of most brackets requires moderate mechanical aptitude and We strongly recommend professional installation by Installation ofskills. most mounting mounting brackets requires moderate mechanical aptitude and We an experienced installer. aptitude and skills. skills. We strongly strongly recommend recommend professional professional installation installation by by installer. an experienced experienced installer. • an The installer must read the instructions and use all bolts and parts •• supplied. The must the use all and parts When the read instructions require the and reuse of factory bolts, The installer installer must read the instructions instructions and use all bolts bolts andthread parts supplied. to fasten could in of lock and/orFailure lock washers must also the be bracket used. Failure to securely supplied. Failure to securely securely fasten the bracket could result result in loss lossfasten of the the towed vehicle. the bracket could result in loss of the towed vehicle. 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. •• Every 3,000 must miles,inspect the owner must inspect the fasteners proper The owner all mounts and brackets before for each use torque, according the bolt torque requirements on the last of for cracks or othertosigns of fatigue. Also, inspectchart the fasteners forpage proper these instructions. owner inspect allchart mounts andlast brackets torque, according The to the bolt must torquealso requirements on the page. for cracks or so other signs of in fatigue 3,000vehicle. miles. Failure to do so Failure to do could result loss ofevery the towed result must in losscheck of thethe towed vehicle. • could The owner vehicle manufacturer's instructions for the • The owner must check vehicle manufacturer's instructions for the proper procedure(s) tothe prepare the vehicle for towing. Some vehicles proper prepare the vehicle for an towing. Some vehicles must beprocedure(s) equipped withto a transmission lube pump, axle disconnect, drivmust equippedorwith a transmission lube pump, an can axlebe disconnect, driveline be disconnect free-wheeling hubs before they towed. Failure eline disconnect free-wheeling they can betotowed. Failure to properly equiporthe vehicle will hubs causebefore severe damage 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 • Ifbracket running the vehicle manufacturer afterhardthis waschanges designed,were somemade bolts by or other fasteners in the included bracket wasmay designed, some or other fasteners the included hardware pack no longer be bolts the correct size. It is theininstaller’s responware pack longer be the correct size. It is the installer’s responsibility to may verifynothat the bracket is securely fastened to the vehicle, and sibility to verify that the bracket to is account securely for fastened to the vehicle, and fitted with the correct hardware, these changes. Failure to WARNING WARNING 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 towed vehicle has been in an accident, it must be the towed vehicle has been in an accident, it must 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 bracket is designed for use with ROADMASTER This bracket is designed for use with 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. 2104-1 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 is one of our XL series brackets, which are partly removable. The kit consists of two receiver braces, two main braces and related hardware. The receivers utilize the tie down loops and main frame as attachment points. 2. Hold a receiver (passenger or driver side) so that the flat vertical plate is on the backside of the square tie down loop. Locate the 7/16” x 1-3/8” x 2½" special backing plate and situate it to the front of the square tie down loop so that it partially sits inside the loop. Secure the backing plate and receiver to the loop with a ½” x 2½” bolt, ½” lock washer and nut. Repeat this step on the other side. Note: two holes are provided to correctly line up the receiver brace with the front valence and the frame. Use the hole that lines the top of the reciever tube up with the bottom of the bumper valence and allows you to drill a ½" hole, through the side of the frame without interference. 3. Slide the main braces into the receivers and secure using the 5/8” draw pins and 1/8” spring pins. Make certain that the front clips are straight and even on front, and drill two 17/32” hole, through the entire frame on each side, taking extra care not to drill into any components on the inside of the frame. Insert two ½” x 3” bolts into the holes just drilled and two ½” flat washers, lock washers and nuts per bolt on the inside of the frame. 4. Torque all bolts to the torque chart below, and mount the tow bar according to the manufacturer's instructions. Hardware List 4-1/2” x 3” bolts 2-1/2” x 2-1/2” bolts 6-1/2” nuts 6-1/2” lock washers 4-1/2” flat washers 2-7/16” x 1-3/8” x 2-1/2” special backing plates 2-5/8” draw pins 2-1/8” spring pins 2-quick links 2-13” safety cables `8-27-02 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.