R O A D M A S T E R, I N C.

Transcription

1 R O A D M A S T E R, I N C. ITEM QTY NAME MATERIAL /2" x 1 1/4" BOLT /2" x 5 1/2" BOLT /2" NYLON LOCK NUT /2" x 2 3/4" BOLT /2" LOCK WASHER /2" NUT /2" x 3 1/2" BOLT QUICK LINK SAFETY CABLE 8" /4" x 1 1/2" x 2 1/2" BACKING PLATE... A /4" x 2" x 2" BACKING PLATE... A DRIVER SIDE BRACE... B PASSENGER SIDE BRACE... B MAIN RECEIVER... C FAILURE 1 TO... FOLLOW DRIVER THESE INSTRUCTIONS SIDE ARM... CAN RESULT IN DEATH, PERSONAL INJURY OR PROPERTY C DAMAGE PASSENGER SIDE ARM... C

2 This is one of our EZ2 series brackets, which allows the visible front portion of the bracket be easily removed from the front of the vehicle (Fig.A Fig.B). The bracket kit consists of a main receiver brace, two side braces, two removable front braces a hardware pack. The main receiver brace mounts the frame rails. The side braces mount the main receiver brace the frame rails. The removable front braces install in the main receiver brace. Before starting the installation, lay out the kit components in order, as they will be used. This will give you a visual idea of how the components work, will also confirm that everything is present accounted for. Fig.A Fig.B IMPORTANT: All brackets must be assembled with all the bolts left loose for final adjustment positioning (before IMPORTANT: All brackets must be assembled with all the bolts left loose for final adjustment positioning (before tightening) unless otherwise instructed. All bolts must be rqued for proper strength. If more than one bolt is used per 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. fastening point, the diagram may only show one. Use flat washers over all slotted holes Use lock washers on all fasteners Use flat washers over all slotted holes Use lock washers on all fasteners ROADMASTER Limited Warranty, including One-Year Conditional Warranty Text Product Registration Card, in Carn. ROADMASTER Limited Warranty, including One-Year Conditional Warranty Text Product Registration Card, in Carn. Failure follow these instructions Failure can result follow in property these damage, instructions can personal result injury property or even damage, WARNING death. personal injury or even death. Installation of most mounting brackets requires moderate mechani- Installation cal aptitude of most skills. mounting We strongly brackets recommend requires professional moderate mechani- installacation aptitude by an experienced skills. installer. We strongly recommend professional installation by an experienced installer. The installer must read the instructions use all bolts parts The supplied. installer Failure must read securely the instructions fasten the bracket use could all bolts result in loss parts of supplied. the wed Failure vehicle. 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 Do not Loctite lock vehicle. /or use this Red lock document on all washers bolts for cusm used must for also fabrication, mounting be used. this Failure as bracket. securely it may not show fasten all parts the bracket or structural could result components. in loss of Cusm the wed vehicle. Do not use this document for cusm fabrication, as or it may an attempt not show Do all copy parts not this use or bracket structural this document design components. could for cusm result Cusm in fabrication, loss fabrication of the wed as or it may an vehicle. attempt not show all copy parts The owner this or bracket structural must design components. inspect could all mounts result Cusm in loss fabrication brackets of the wed or an before vehicle. attempt each use copy this for cracks bracket or design other signs could of fatigue. result loss of Also, inspect the wed vehicle. Every 3,000 miles, the owner must inspect the fasteners the fasteners for proper for Every rque, proper 3,000 according rque, miles, according the bolt owner rque the must bolt requirements rque inspect requirements the chart fasteners on the chart for last proper on page the rque, of last these page. according instructions. Failure the do The bolt so owner could rque result must requirements in also loss inspect of chart the wed all on mounts the vehicle. last page of brackets these instructions. The owner for must cracks The check or other owner vehicle signs must manufacturer's of also fatigue inspect every all instructions 3,000 mounts miles. brackets for Failure the proper for do procedure(s) so cracks could or result other in prepare loss signs of of the fatigue wed vehicle vehicle. every 3,000 miles. for wing. Some Failure vehicles do must so could be equipped result with in loss of a transmission the wed vehicle. The owner must check the vehicle manufacturer's lube pump, instructions an axle dis- for The the connect, proper owner driveline must procedure(s) check disconnect the vehicle or prepare free-wheeling manufacturer's the vehicle hubs before instructions wing. they can Some for be vehicles the wed. proper Failure must procedure(s) be equipped properly equip with prepare a the transmission vehicle the vehicle will lube cause for pump, severe wing. an axle damage Some dis- vehicles connect, the transmission. must driveline be equipped disconnect with or free-wheeling transmission hubs lube before pump, they an axle can dis- be connect, driveline disconnect or free-wheeling hubs before they can be wed. wed. If running Failure Failure changes properly properly were equip equip made the the by the vehicle vehicle vehicle will will manufacturer cause severe cause severe after damage damage this bracket the transmission. was designed, some bolts or other fasteners in the hardware pack the transmission. If running may no changes longer be were the made correct by size. the vehicle It is the manufacturer installer s responsi- after this If bracket bility running was verify changes designed, that the were bracket some made bolts is by securely or the other vehicle fastened fasteners manufacturer in the the vehicle hardware after this bracket pack fitted may with was no the designed, longer correct be hardware some the correct bolts account size. or other It for is fasteners these installer s changes. the responsibility pack securely may verify fasten no longer that the the bracket be bracket the correct could is securely result size. It in is fastened loss the of installer s the wed the vehicle responsi- vehicle. bility fitted with verify the correct that the hardware bracket is account securely for fastened these changes. the vehicle Failure fitted securely with fasten the correct the bracket hardware could account result in for loss these of the changes. wed Failure vehicle. hardware Failure If the wed vehicle has been in an accident, it must be properly repaired before attaching the bracket. Do not install the bracket if any If structural the wed frame vehicle damage has been is found. in an Failure accident, repair it must the be damage properly could repaired result in before the loss attaching of the the wed bracket. vehicle. Do not install the bracket if any structural securely fasten the bracket could result in loss of the wed vehicle. structural Some morhome frame frame damage damage chassis is is have found. found. such Failure Failure a tight turning repair repair radius the the damage damage that you could could can result result damage in in your the the loss loss morhome, of of the the wed wed wed vehicle. vehicle. vehicle, w bar or bracket while turning Some Some sharply. morhome morhome Before getting chassis chassis on have have the such such road, a test tight tight your turning turning turning radius radius radius that that you you in can can damage damage empty parking your your morhome, morhome, lot. Turning wed wed o vehicle, vehicle, sharply w w could bar bar or or result bracket bracket in non-warranty while while turning turning sharply. sharply. damage Before Before wing getting getting system, on on morhome the the road, road, test test /or your your wed turning turning vehicle. radius radius in in an an empty Do not parking back up lot. with Turning the wed o sharply vehicle could attached result or in non-warranty damage will wing occur system, your morhome wing system, /or morhome wed vehicle. /or wed Do Do vehicle. not not back back up up with with the the wed wed vehicle vehicle attached attached or or non-warranty non-warranty damage The safety will cables occur must your connect wing system, the wing morhome vehicle /or the wed vehicle. frame frame, with the cables crossed, with enough slack The The for sharp safety safety turns. cables cables Refer must must connect connect the cable the the instructions wing wing vehicle vehicle for proper the the routing. wed wed vehicle vehicle Failure frame frame leave enough frame, frame, slack with with the the in the cables cables safety crossed, crossed, cables, or with with failure enough enough connect slack slack for for the sharp sharp safety turns. turns. cables Refer Refer frame the the frame, cable cable will instructions instructions result the for for loss proper proper of the routing. routing. wed Failure Failure vehicle. leave leave enough enough slack slack in in the the safety safety cables, cables, or or failure failure connect connect the This safety bracket cables is designed frame for frame, use with will result ROADMASTER in the loss w of the bars wed vehicle. ROADMASTER adaprs only. Using this bracket with other brs, This This without bracket bracket an approved is is designed designed ROADMASTER for for use use with with ROADMASTER ROADMASTER adapr, may result w w bars bars in non- ROADMASTER ROADMASTER warranty damage adaprs adaprs injury. only. only. Using Using this this bracket bracket with with other other brs, brs, without Upon final an installation, approved the ROADMASTER installer must adapr, inspect may the result bracket in nonwarrantsure adequate damage clearance, or injury. particularly around hoses, air conditioner Upon en- Upon lines, final final radiars, installation, installation, etc., the the or non-warranty installer installer must must damage inspect inspect the the bracket bracket wed vehicle ensure ensure will result. adequate adequate clearance, clearance, particularly particularly around around hoses, hoses, air air conditioner conditioner lines, This bracket radiars, is only etc., warranteed or non-warranty for the damage original installation. the wed Installing vehicle will a used result. bracket on another vehicle is not recommended will void This This the warranty. bracket bracket is is only only warranteed warranteed for for the the original original installation. installation. Installing Installing a used used bracket bracket on on another another vehicle vehicle is is not not recommended recommended will will void void the the warranty. warranty.

3 Fig.C Fig.D Fig.E 1. Important: please use all supplied bolts parts read all instructions carefully before beginning this installation. The majority of questions you may have can be answered within the text, proper installation will ensure safe secure travel. Now, begin the installation. Start by removing the four plastic fasteners that attach the fascia the core support (Fig.C). 2. On each side, remove one Phillips head screw attaching the splash shield the fascia (Fig.D). 3. On each side, remove one plastic fastener attaching the splash shield the corner of the fascia (Fig.E). Fig.F Fig.G Fig.H 4. Remove two more plastic fasteners attaching the splash shield the radiar support (Fig.F). 5. One each side, remove one Phillips head screw attaching the fascia the corner of the fender (Fig.G). 6. Now, remove the fascia by pulling out forward on both corners of the fascia (Fig.H). Disconnect the fog lights, if the vehicle is so equipped. 7. Remove the plastic cover inside the engine compartment on the driver side, next the headlight (Fig.I) 8. For both sides, remove the headlights by removing four 10mm (head) bolts per side. Three are located along the inside edge of the engine compartment (Fig.J). The fourth one in located on the outside rear corner (Fig.K). Remove both headlights disconnect three electrical plugs per side. Fig.I Fig.J All illustrations 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 models or discontinue models.

4 Fig.K Fig.L Fig.M 9. Temporarily remove the washer bottle by removing one plastic fastener from inside the engine compartment (Fig.L) two 10mm bolts on the side of the frame rail (Fig.M). Fig.N Fig.O Fig.P 10. Using a wire or zip tie, attach the washer bottle the side of the vehicle (Fig.N). 11. Remove the foam shock absorption pad from the bumper core by pulling forward on it. This will not be reinstalled. 12. Next, remove the bumper core by removing two 12mm bolts from the driver side (Fig.O) three 12mm bolts from the passenger side (Fig.P). The bumper core will not be reinstalled. Note: retain the bumper core attachment hardware in case the bracket is ever removed from the vehicle. 13. Place the main receiver brace over the ends of both frame rails (Fig.Q). Bolt in place using the bumper core bolts you removed in the previous step (Fig.R). Note: use thread lock on these bolts. Fig.Q Fig.R Fig.S 14. Starting on the driver side, measure 2¾" from the end of the frame rail wards the rear of the vehicle mark the location. Now, drill a hole direct center in the p of the frame rail at the 2¾" mark (Fig.S). 15. Insert the supplied ½" x 5½" bolt through the ¼" x 1½" x 2½" backing plate. Insert the bolt backing plate through the hole you drilled in the frame rail in the previous step in the existing hole in the botm of the frame rail (Fig.T,U). All illustrations 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 models or discontinue models.

5 Fig.T Fig.U Fig.V 16. Set the side brace in place over the bolt from step 15 (Fig.U). Bolt through the p hole using a ½" x 1¼" bolt lock washer. Use a ½" x 1¼" bolt, lock washer nut on the botm hole (Fig.V). Do not tighten. 17. Now, place a ½" nylock nut on the bolt you installed in step Before you can install the passenger side brace, relocate the horn allow clearance for the side brace: Loosen the 12mm (head) bolt rotate the horn about 20 degrees ward the front of the vehicle retighten the bolt (Fig.W). 19. The ground connecr next the horn (Fig.X) needs be temporarily disconnected. This will make installing the ½" flat washer nylock nut for the passenger side easier. Fig.W Ground connecr Fig.X Fig.Y 20. Repeat steps 14 through 18 for the passenger side of the vehicle. For step 16 on the passenger side, refer Figure Y for correct placement. Fig.Z 21. Now, tighten all the bolts the rque specifications listed at the end of these instructions. 22. Starting on the driver side, use the hole in the side brace as a template for drilling (Fig.Z). Before drilling, check make certain you will not drill in any engine components on the other side. For the driver's side only, drill through the side of the frame rail bolt through the main receiver brace, two spacer plates the frame rail using the ½" x 3½" bolt, place the ¼" x 2" x 2½" backing plate on the inside of the frame rail finish with a ½" nylock nut (Fig.AA). For the passenger side, drill through the side of the frame rail bolt in place using a ½" x 2¾" bolt, ¼" x 1½" x 2½" backing plate a ½" nyloc nut on the inside of the frame. Tighten the rque specifications listed at the end of these instructions. Fig.AA

6 Air flow duct Upper air vent Air flow duct Fig.CC trimmed Upper air vent Fig.DD Fig.BB 23. The back side of the fascia will need be trimmed allow clearance for the main receiver brace. On the driver's side, trim off the upper air flow duct (Fig.BB) trim the upper air vent next it (Fig.BB, CC). Use the yellow marker lines as guides for correct trimming. 24. For the passenger side trimming of the fascia, trim the upper air Fig.EE vent. Use the yellow marker line in Figure DD as a guide for correct trimming. 25. Reinstall the fascia, headlights washer bottle, reversing steps 1 through Insert the removable front braces in the main receiver brace, twist them 90 degrees lock. Attach the safety cables with the cable connecrs (Q-Links) the front of the receiver brace (Fig.EE). Attach the ends of the safety cables the w vehicle's safety cables w bar. 27. Install the w bar the mounting bracket according the manufacturer's instructions. 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 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 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 models or discontinue models.