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. MOUNTING BRACKET KIT ITEM QTY NAME MATERIAL mm x 1.75 x 60 mm BOLT mm LOCK WASHER mm x 1.75 HEX NUT mm x 1.25 x 130 mm BOLT mm x 1.50 x 30 mm BOLT mm LOCK WASHER mm x 1.50 HEX NUT QUICK LINK SAFETY CABLE 8" " (25 mm) O.D. x WALL (5 mm) x 2 1/2" (63 mm) PIPE SPACER... A /2" (25 mm) x 1 3/4" (44 mm) CLIPPED PLATE WASHER... A /4" (6mm) x 1 1/2" (38mm) x 2 1/2" (63mm) BACKING PLATE W/ 1/2" (13mm) HOLE... A MAIN RECEIVER... C DRIVER SIDE ARM... C 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 and B). The bracket consists of a main receiver brace, two removable front braces, two center braces and a hardware pack. The main receiver brace mounts the frame rails and the bumper core. 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, and will also confirm that everything is present and accounted for. Fig.A Fig.B IMPORTANT: All brackets must be assembled with all the bolts left loose for final adjustment and positioning (before IMPORTANT: tightening) unless All brackets otherwise must instructed. be assembled All bolts with must all be the rqued bolts left for loose proper for strength. final adjustment If more than and one positioning bolt is used (before per tightening) fastening point, unless the otherwise diagram instructed. may only show All bolts one. must be rqued for proper strength. If more than one bolt is used per fastening point, the Use diagram flat may washers only over show all one. 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 and Product Registration Card, in Carn. ROADMASTER Limited Warranty, including One-Year Conditional Warranty Text and Product Registration Card, in Carn. Failure follow these instructions If the wed vehicle has been in an accident, it must be properly re- Failure can result follow in property these damage, instructions securely paired before fasten attaching the bracket the bracket. could result Do not in loss install of the the wed bracket if any WARNING can personal result injury property or even damage, death. structural frame damage is found. Failure repair the damage could WARNING If the wed vehicle has been in an accident, it must be properly re- personal injury or even death. paired result in before the loss attaching of the the wed bracket. Do not install the bracket if any Installation of most mounting brackets requires moderate mechanical aptitude of and most skills. mounting We strongly brackets recommend requires professional moderate mechani- installa- result damage in your the loss morhome, of the wed vehicle, w bar or bracket while turning cal tion aptitude by an experienced and skills. installer. We strongly recommend professional installa- Some sharply. morhome Before getting chassis on have the such road, a test tight your turning turning radius radius that you in can tion structural Some morhome frame damage chassis have is found. such Failure a tight turning repair radius the damage that you could can Installation The by installer an experienced must read installer. the instructions and use all bolts and parts damage empty parking your morhome, lot. Turning wed o vehicle, sharply w could bar or result bracket in non-warranty while turning The supplied. installer Failure must read securely the instructions fasten the bracket and use could all bolts result and in loss parts of sharply. damage Before wing getting system, on morhome the road, test and/or your wed turning radius in an supplied. the wed Failure When the securely do instructions so could fasten result require the in bracket loss the of reuse could the wed of result facry in loss bolts, of empty Do not parking back up lot. with Turning the wed o sharply vehicle could attached result or in non-warranty Do thread the not wed lock use and/or this document lock washers for cusm must also fabrication, be used. Failure as it may not securely show will occur your wing system, morhome Use Loctite Red on all bolts used for mounting this bracket. damage wing system, morhome and/or wed and/or wed fasten all parts the or bracket structural could components. result in loss Cusm of the wed or an attempt Do not use this document for cusm fabrication, as it may not show Do not back up with the wed vehicle attached or non-warranty Do copy not this use bracket this document design could for cusm result in fabrication, loss of the wed as it may not show The safety cables must connect the wing vehicle the all parts or structural components. Cusm fabrication or an attempt damage will occur your wing system, morhome and/or wed all The parts owner or structural must inspect components. all mounts Cusm and fabrication brackets before or an attempt each use copy this bracket design could result in loss of the wed frame frame, with the cables crossed, with enough slack copy for cracks this bracket or other design signs could of fatigue. result Also, loss inspect of the wed the fasteners for for sharp turns. Refer the cable instructions for proper routing. Every 3,000 miles, the owner must inspect the fasteners for proper The safety cables must connect the wing vehicle the wed Every proper 3,000 rque, miles, according owner the must bolt rque inspect requirements the fasteners chart for proper on the Failure leave enough slack in the safety cables, or failure connect rque, according the bolt rque requirements chart on the last page vehicle frame frame, with the cables crossed, with enough slack rque, last page. according Failure the do bolt so could rque result requirements in loss of chart the wed on the last page the safety cables frame frame, will result the loss of the wed of these instructions. The owner must also inspect all mounts and for sharp turns. Refer the cable instructions for proper routing. of The these owner instructions. must check The owner vehicle must manufacturer's also inspect instructions all mounts and brackets for cracks or other signs of fatigue every 3,000 miles. for Failure leave enough slack in the safety cables, or failure connect brackets the proper for procedure(s) cracks or other prepare signs of fatigue vehicle every for wing. 3,000 miles. Some This bracket is designed for use with ROADMASTER w bars Failure do so could result in loss of the wed the safety cables frame frame, will result in the loss of the wed and Failure vehicles must do so be could equipped result with in loss a transmission of the wed lube pump, an axle dis- ROADMASTER adaprs only. Using this bracket with other brands, The owner must check the vehicle manufacturer's instructions for The connect, owner driveline must check disconnect the vehicle or free-wheeling manufacturer's hubs before instructions they can for be without an approved ROADMASTER adapr, may result in non- the proper procedure(s) prepare the vehicle wing. Some This bracket is designed for use with ROADMASTER w bars and the wed. proper Failure procedure(s) properly equip prepare the vehicle the vehicle will cause for severe wing. damage Some warranty damage injury. vehicles must be equipped with a transmission lube pump, an axle disconnect, driveline disconnect or free-wheeling hubs before they can be without an approved ROADMASTER adapr, may result in non- en- ROADMASTER adaprs only. Using this bracket with other brands, vehicles the transmission. must be equipped with transmission lube pump, an axle dis- Upon final installation, the installer must inspect the bracket connect, If running driveline changes disconnect were made or free-wheeling by the vehicle hubs manufacturer before they after can this be sure adequate clearance, wed. Failure properly equip the vehicle will cause severe damage warranty damage or injury. particularly around hoses, air conditioner wed. bracket the transmission. Failure was designed, properly some equip bolts the or vehicle other will fasteners cause in severe the hardware damage Upon lines, final radiars, installation, etc., the or non-warranty installer must damage inspect the the bracket wed vehicle en- pack the may transmission. no longer be the correct size. It is the installer s responsi- will result. If running changes were made by the vehicle manufacturer after this sure adequate clearance, particularly around hoses, air conditioner If bility running verify changes that the were bracket made is by securely the vehicle fastened manufacturer the vehicle after and this This bracket is only warranteed for the original installation. Installing bracket was designed, some bolts or other fasteners in the hardware lines, radiars, etc., or non-warranty damage the wed vehicle bracket fitted with was the designed, correct hardware some bolts account or other for fasteners these changes. the hardware Failure a used pack may no longer be the correct size. It is the installer s 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- and This the warranty. bracket is only warranteed for the original installation. Installing bility fitted with verify the correct that the hardware bracket is account securely for fastened these changes. the vehicle Failure and a used bracket on another vehicle is not recommended and will void fitted securely with fasten the correct the bracket hardware could account result in for loss these of the changes. wed Failure the will result. bracket on another vehicle is not recommended and will void warranty.

3 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 by removing one plastic fastener and three 10mm (head) bolts attaching the p of the fascia the core support (Fig.C). Fig.E Fig.F 2. On each side, remove one plastic fastener attaching the corner of the fascia the fender (Fig.D). 3. Remove five 10mm (head) bolts attaching the botm of the fascia the fender liners and radiar support. Note: two are located on either side of the vehicle (Fig.E) and one is in the center. 4. Pull out and forward on the corners of the fascia remove it (Fig.F). 5. Remove two air deflecrs attached by three plastic fasteners on each side. Note: two are located on the core support, and one is located on the bumper core (Fig.G). Fig.G

4 Fig.H Fig.I 6. On each side, remove four 14mm (head) bolts attaching the bumper core the frame rails (Fig.H). 7. Remove one plastic fastener attaching the horn wiring the radiar support (Fig.I). Loosen the 12mm (head) bolt on the horn bracket, and relocate it the outside of the radiar support. Tighten the bolt (Fig.J). Fig.J Fig.K 8. Place the bumper core upside down on the ground. Place the main receiver brace on the bumper core (Fig.K). 9. Using one of the supplied 10mm x 1.25 x 130mm bolts, lock washers and 63mm pipe spacers, place a lock washer over the bolt and run the bolt through the main receiver brace, pipe spacer and the bumper core mounting hole. Repeat this process for each of the remaining three holes (Fig.L). Note: these bolts will replace the four lower facry bolts. Fig.L

5 Fig.M Fig.N 10. Lift the main receiver brace and bumper core in place and bolt it on each side by replacing the two upper facry bolts you removed from each side in step 6 (Fig.M). Tighten all eight bolts the bolt rque requirements found at the end of these instructions. 11. The lower mounting point should be lined up with the pre-existing hole in the radiar support. Place the supplied 10mm x 1.5 x 30mm bolt through the ¼" x 1½" x 2½" backing plate (Fig.N). Now, place the bolt through the radiar support and main receiver brace. Finish with a 10mm lock washer and 10mm x 1.5 nut. Note: due manufacturing variances, the holes in the radiar support may need be enlarged (Fig.O). Fig.O Fig.P 12. Locate the center point of the two outside 50mm holes in the face of the bumper. Drill a 12mm hole through the weld seam. Note: this should line up with the hole in the upper mounting point in the main receiver brace (Fig.P and Q). Fig.Q

6 Fig.R Fig.S 13. Working on one side at a time, place a ½" clipped plate washer over a 12mm x 1.75 x 60mm bolt. Bolt through the bumper core the main receiver brace. Finish with a 12mm lock washer and 12mm x 1.75 nut (Fig.R and S). Repeat for the opposite side of the Tighten all remaining bolts the bolt rque requirements found at the end of this document. Fig.T Fig.U 14. Trim the air deflecrs using the yellow lines in Figure T as a guide for trimming. 15. Trim the fascia grille inserts using the yellow lines in Figure U as a guide for trimming the driver's side. Use the yellow lines in Figure V as a guide for trimming the passenger side. 16. Reassemble the fascia, reversing steps Insert the removable front bracket arms in the front receiver braces, and twist each one 90 degrees lock. 18. Attach the 8" safety cables with the cable connecrs (Q-Links) the front of the receiver braces. 19. Attach the ends of the safety cables the w vehicle's safety cables. 20. Install the w bar the mounting bracket according the manufacturer's instructions. Fig.V

7 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. STANDARD BOLTS Thread Size Grade Torque 5/ nt./mt. 3/ nt./mt. 7/ nt./mt. 1/ nt./mt. 5/ nt./mt. METRIC BOLTS Thread Size Grade Plated / Unplated 8mm nt./mt./ 25 nt./mt. 8mm nt./mt./ 25 nt./mt. 10mm nt./mt./ 49 nt./mt. 10mm nt./mt./ 48 nt./mt. METRIC BOLTS Thread Size... Grade... Plated / Unplated 12mm nt./mt./ 89 nt./mt 12mm nt./mt./ 83 nt./mt 12mm nt./mt./ 82 nt./mt 14mm nt./mt./ 132 nt./mt