BASEPLATE KIT INSTALLATION INSTRUCTIONS. ROADMASTER, Inc NE 127th Ave. Vancouver, WA fax

Transcription

1 R O A D M A S T E R, I N C. BASEPLATE KIT Item Qty. Length Width Name Material mm... 10mm... 10mm x 1.5 x 85mm BOLT mm... LOCK WASHER mm... 10mm... 10mm x 1.5 x 30mm /2"... 7/16"... BOLT /16"... LOCK WASHER /16"... NUT /2"... 1/2"... BOLT "... 1/2"... BOLT /4"... 1/2"... CARRIAGE BOLT /2"... LOCK WASHER /2"... NUT FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN DEATH, PERSONAL INJURY OR PROPERTY DAMAGE DRAW PIN/SPRING PIN CABLE CONNECTOR "... 13" SAFETY CABLE

2 Item Qty Part No. Assembly C MAIN RECEIVER BRACE C DRIVER SIDE ARM BRACE C PASSENGER SIDE ARM BRACE C DRIVER SIDE INNER BUMPER BRACE C PASSENGER SIDE INNER BUMPER BRACE A " O.D. x 1 5/8" x.219 WALL TUBE A /4" x 1 1/2" x 2" SQ. HOLE BACKING PLATE C DRIVER SIDE LOWER CORE SUPPORT BRACE C PASSENGER SIDE LOWER CORE SUPPORT BRACE B MOTOR MOUNT CENTER BRACE B WIRE PLUG CONNECTOR BRACKET IMPORTANT: All brackets must be assembled with all the bolts left loose for final adjustment and positioning (before tightening) unless otherwise instructed. All bolts must be rqued for proper strength. If more than one bolt is used per fastening point, the diagram may only show one. Use flat washers over all slotted holes Use lock washers on all fasteners ROADMASTER Limited Warranty, including One-Year Conditional Warranty Text and Product Registration Card, in Carn. Failure follow these instructions can result in property damage, WARNING personal injury or even death. Installation of most mounting brackets requires moderate mechanical aptitude and skills. We strongly recommend professional installation by an experienced installer. The installer must read the instructions and use all bolts and parts supplied. Failure When the securely do instructions so could fasten result require the in bracket loss the of reuse could the wed of result facry vehicle. in loss bolts, of Use the thread wed Loctite lock vehicle. and/or Red lock on all washers bolts used must for also mounting be used. this Failure bracket. securely fasten the bracket could result in loss of the wed vehicle. Do not use this document for cusm fabrication, as it may not show Do all parts not use or structural this document components. for cusm Cusm fabrication, fabrication as or it may an attempt not show all copy parts this or bracket structural design components. could result Cusm in loss fabrication of the wed or an vehicle. attempt copy this The owner bracket must design inspect could all mounts result loss of and brackets the wed vehicle. Every 3,000 miles, the owner must inspect the fasteners before for each proper use Every rque, for cracks 3,000 according miles, other the signs bolt owner of rque fatigue. must requirements inspect Also, inspect the chart fasteners the on fasteners the for last proper page for rque, of proper these according rque, instructions. according the The bolt owner rque the bolt must requirements rque also requirements inspect chart all on mounts the chart last on page and the of brackets last these page. instructions. for Failure cracks do The or so other owner could signs result must of in also fatigue loss inspect of the every wed all 3,000 mounts vehicle. miles. and brackets Failure The owner for do must so cracks could or check result other the vehicle in loss signs of of manufacturer's the fatigue wed vehicle. every 3,000 miles. instructions for Failure the proper do so could procedure(s) result in loss of prepare the wed vehicle. The owner must check the vehicle manufacturer's the vehicle for instructions wing. Some for The the vehicles proper owner must must procedure(s) be equipped check the with vehicle prepare a transmission manufacturer's the vehicle lube for pump, instructions wing. an axle Some disconnect, proper must driveline procedure(s) be equipped disconnect with or prepare a free-wheeling transmission the vehicle hubs lube pump, before wing. an they axle can Some dis- be vehicles connect, wed. Failure must driveline be equipped properly disconnect equip with or free-wheeling the transmission vehicle will hubs lube cause before pump, severe they an axle damage can dis- be connect, wed. the transmission. Failure driveline properly disconnect equip or free-wheeling the vehicle will hubs cause before severe they damage can be wed. Failure properly equip the vehicle will cause severe damage for vehicles the If running the transmission. changes were made by the vehicle manufacturer after this bracket the transmission. If running was changes designed, were some made bolts by or the other vehicle fasteners manufacturer in the hardware after this If bracket pack running may was no changes designed, longer be were some the made correct bolts by size. or the other vehicle It is fasteners the manufacturer installer s the responsi- hardware after this bracket pack bility may was verify no designed, longer that the be bracket some the correct bolts is securely size. or other It is fastened fasteners the installer s the the vehicle responsibility pack fitted may with verify no the longer correct that the be hardware bracket the correct is securely account size. It for is fastened these installer s changes. the vehicle responsi- Failure and bility fitted securely with verify fasten the correct that the the bracket hardware bracket could is account securely result in for fastened loss these of the changes. wed the vehicle Failure vehicle. and fitted securely with fasten the correct the bracket hardware could account result in for loss these of the changes. wed Failure vehicle. hardware and securely fasten the bracket could result in loss of the wed vehicle. If the wed vehicle has been in an accident, it must be properly re- If paired the wed before vehicle attaching has the been bracket. in an Do accident, not install it must the be bracket properly if any repaired structural before frame attaching damage the is bracket. found. Do Failure not install repair the bracket damage if could any structural structural result in the frame frame loss damage damage of the wed is is found. found. vehicle. Failure Failure repair repair the the damage damage could could result result Some in in morhome the the loss loss of of chassis the the wed wed have vehicle. vehicle. such a tight turning radius that you can Some Some damage morhome morhome your morhome, chassis chassis wed have have such such vehicle, a tight tight w turning turning bar or bracket radius radius that that while you you turning can can damage damage sharply. your your Before morhome, morhome, getting on wed wed the vehicle, vehicle, road, test w w your bar bar or or turning bracket bracket radius while while turning turning an sharply. sharply. empty parking Before Before getting getting lot. Turning on on the the o road, road, sharply test test could your your result turning turning radius radius non-warranty in in an an empty empty damage parking parking wing lot. lot. system, Turning Turning morhome o o sharply sharply and/or could could wed result result vehicle. in in non-warranty non-warranty damage Do not back wing up with system, the morhome wed vehicle and/or attached wed vehicle. or non-warranty Do Do damage not not back back will occur up up with with your the the wed wed wing vehicle vehicle system, attached attached morhome or or and/or non-warranty non-warranty wed damage damage vehicle. will will occur occur your your wing wing system, system, morhome morhome and/or and/or wed wed vehicle. The safety cables must connect the wing vehicle the wed The The vehicle safety safety frame cables cables frame, must must with connect connect the cables the the wing wing crossed, vehicle vehicle with enough the the wed wed slack vehicle vehicle for sharp frame frame turns. frame, frame, Refer with with the the the cables cables instructions crossed, crossed, with with for proper enough enough routing. slack slack for for Failure sharp sharp leave turns. turns. enough Refer Refer slack the the in cable cable the safety instructions instructions cables, for for failure proper proper routing. routing. connect Failure Failure the safety leave leave cables enough enough frame slack slack frame, in in the the will safety safety result cables, cables, in the or or loss failure failure of the connect connect wed the the vehicle. safety safety cables cables frame frame frame, frame, will will result result in in the the loss loss of of the the wed wed vehicle. This bracket is designed for use with ROADMASTER w bars and This This ROADMASTER bracket bracket is is designed designed adaprs only. for for use use Using with with this ROADMASTER ROADMASTER bracket with other w w bars bars brands, ROADMASTER ROADMASTER without an approved adaprs adaprs ROADMASTER only. only. Using Using this this adapr, bracket bracket may with with result other other brands, brands, in non- without without warranty an an damage approved approved or injury. ROADMASTER ROADMASTER adapr, adapr, may may result result in in nonwarranty Upon final damage installation, or injury. the installer must inspect the bracket en- Upon non- Upon sure adequate final final installation, installation, clearance, the the particularly installer installer must must around inspect inspect hoses, the the air bracket bracket conditioner ensure ensure lines, adequate adequate radiars, clearance, clearance, etc., or non-warranty particularly particularly around around damage hoses, hoses, the air air wed conditioner conditioner vehicle lines, lines, will result. radiars, radiars, etc., etc., or or non-warranty non-warranty damage damage the the wed wed vehicle vehicle will This result. bracket is only warranteed for the original installation. Installing This This a used bracket bracket bracket is is only only another warranteed warranteed vehicle for for is the the not original original recommended installation. installation. and Installing Installing will void a the used used warranty. bracket bracket on on another another vehicle vehicle is is not not recommended recommended and and will will void void the the warranty. warranty.

3 This is one of our XL series brackets, which allows the visible front portion of the brackets be easily removed from the front of the vehicle (Fig.A). The bracket kit consists of a main receiver brace, front braces and a hardware pack. The rear receiver brace mounts the front and side of the frame and protrudes through the lower grill below the bumper. The front braces insert in the rear brace and pin in place. Before starting the installation, lay out the kit components as illustrated. This will give you a visual idea of how the components work and also confirm that everything is present and accounted for. Fig.A Fig.B Fig.C Fig.D 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. Begin by removing the front fascia and headlights starting with the headlights. Remove three screws (10mm head) from each headlight (Fig.B), pull forward then disconnect and set aside (Fig.C,D). Remove two bolts (10mm) the p of the fascia between the headlights (Fig.E). Remove two screws (8mm head) in each fascia fender junction (Fig.F) then two phillips head screws in each fender well (Fig.G). Fig.E Fig.F Fig.G 2. Remove a remaining 8mm (head) bolt in the fascia fender junction on each side (Fig.H), then move the botm of the fascia and remove five plastic fasteners (Fig.I,J). Fig.H Fig.I Fig.J

4 Fig.K Fig.L Fig.M 3. Pull the sides of the fascia out (Fig.K), then pull forward remove (Fig.L). 4. Locate the radiar coolant reservoir on the drivers side and remove three 10mm (head) mounting bolts (Fig.M,N,O). Leave the reservoir hanging and save the bolts for reinstallation. Also, pull the wiring harness loose from the frame help with access (Fig.O). Fig.N Fig.O Fig.P 5. Some models are equipped with an extra guard between the fascia and the radiar. If the vehicle is so equipped, this will need be removed. Remove three 10mm (head) bolts (Fig.P) and three plastic fasteners (Fig.Q) remove the guard. The ambient temperature sensor needs be temporarily removed as well (Fig.R-S ) Fig.Q Fig.R Fig.S 6. Move the center engine mount and remove two side bolts. Leave the center bolts in place (Fig.T). 7. Bolt the lower mor mount center plate and 1 5/8" spacers over the engine mount with two 10mm x 1.50 x 85mm bolts and lock washers (Fig.U). 8. Find the ambient air sensor located on the botm of the bumper core and relocate it clear the receiver brace (Fig.V). All illustrations and specifications contained herein are based on the latest information available at the time of publication approval. ROADMASTER, INC. reserves the right make changes at any time without notice in material, specification and models or discontinue models.

5 Fig.T Fig.U Fig.V 9. Remove two 15mm carriage bolts and nuts from the bumper core mounts on each side (Fig.W,X). 10. Mount the inner bumper braces in the bumper core on each side with two supplied 10mm x 1.5 x 30mm bolts using the original shoulder nuts (Fig.Y). Leave loose for now. 11. Mount the main receiver brace on the mor mount center plate with two 7/16" x 1½" bolts lock washers and nuts. Be sure and mount the wiring connecr plate on these bolts also (Fig.Z). Fig.W Fig.X Fig.Y 12. Now tighten the mounting bolts in sequence starting with the lower mor mount plate bolts (Fig.AA). Push the bumper core up (Fig.BB) and then tighten it (Fig.CC). Align the main receiver brace under the bumper core with the rear of the brace against the frame, and tighten the upper mor mount center plate bolts hold the receiver brace in position (Fig.DD). Fig.Z Fig.AA Fig.BB Fig.CC Fig.DD

6 Fig.EE Fig.FF Fig.GG 13. Using the lower receiver brace as a guide, drill a 17/32" hole through the botm of the bumper core on each side (Fig.EE), then bolt through the receiver brace, bumper core and inner braces with ½" x 1¼" bolts, lock washers and nuts. Tighten these bolts (Fig.FF). Fig.HH Fig.II Fig.JJ 14. Referencing Figure GG, the screwdriver points a access hole on the inside of the driver side frame beside the coolant reservoir dismounted in step 4. Push the reservoir away from the frame insert a 1½" x 2" backing plate and ½" x 1½" carriage bolt in the existing hole in the botm of the frame. Now, do the same thing on the passenger side but access the existing hole through a hole on the outside of the frame (Fig.HH). Align these core support braces with the existing hole in the back of the frame and tighten. 15. Moving the front of the frame use two front mounting holes on each side of the receiver brace as a guide drill two 7/16" holes through the front of the frame on each side (Fig.II). Now, go the rear of the frame and using the core support braces as a guide, drill additional p holes in the back of the frame on each side (Fig.JJ). 16. Bolt through the receiver brace, frame and rear core supports with two ½" x 5" bolts, lock washers and nuts on each side (Fig.KK,LL). 17. Now rque all the mounting bolts the specifications below, then replace the radiar reservoir bolts removed in step 4. Fig.KK Fig.LL All illustrations and specifications contained herein are based on the latest information available at the time of publication approval. ROADMASTER, INC. reserves the right make changes at any time without notice in material, specification and models or discontinue models.

7 Fig.MM Fig.NN Fig.OO 18. Trim the lower center of the fascia as shown then reinstall reversing steps 1 through 3 (Fig.MM). 19. Insert the front braces in the receivers and secure with 5/8" draw pins and 3/16" spring pins (Fig.NN). 20. Mount the w bar according the w bar manufacturer s instructions. Install the 13 safety cables on the main receiver cross bar with quick links provided (Fig.OO). Attach the other end the w vehicle's safety cables and w bar. STANDARD BOLTS Thread Size Grade Torque 5/ ft./lb. 3/ ft./lb. 7/ ft./lb. 1/ ft./lb. 5/ ft./lb. BOLT TORQUE REQUIREMENTS Note: The rque values represented below are intended as general guidelines. Torque requirements for specific applications may vary. Roadmaster does not warrant this information be accurate for all applications and disclaims all liability for any claims or damages which may result from its use. METRIC BOLTS Thread Size Grade Plated / Unplated 8mm ft./lb. 18 ft./lb. 8mm ft./lb. 18 ft./lb. 10mm ft./lb. 36 ft./lb. 10mm ft./lb. 35 ft./lb. METRIC BOLTS Thread Size Grade Plated / Unplated 12mm ft./lb. 65 ft./lb. 12mm ft./lb. 61 ft./lb. 12mm ft./lb. 60 ft./lb. 14mm ft./lb. 97 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 make changes at any time without notice in material, specification and models or discontinue models.