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. BASEPLATE KIT ITEM QTY NAME MATERIAL mm x 1.5 x 75 mm BOLT mm LOCK WASHER mm FLAT WASHER /2" x 4" CARRIAGE BOLT /2" x 1 1/2" CARRIAGE BOLT /2" x 1 1/4" BOLT /2" LOCK WASHER /2" HEX NUT QUICK LINK SAFETY CABLE 8" /4" x 1 1/2" x 2 1/2" BACKING PLATE W/ ROUND HOLE...A " O.D. x WALL x 2 1/4" TUBE SPACER...A " O.D. x WALL x 1 1/2" TUBE SPACER...A " O.D. x WALL x 1 5/8" TUBE SPACER...A /4" x 1" x 3" BACKING PLATE W/ SQ. HOLE...A DRIVER SIDE REAR BRACE...C PASSENGER SIDE REAR BRACE...C DRIVER SIDE RECEIVER...C PASSENGER SIDE RECEIVER...C DRIVER SIDE ARM...C PASSENGER SIDE ARM...C ZIP TIE /4" x 3/4" SELF-TAPPING SCREW

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 Fig.B). The bracket consists of a main receiver brace, two removable front 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 the thread 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 Fig.E 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 two T24 Torx bolts attaching the grille the core support (Fig.C). 2. Push forward on two plastic clips located on either side of the hood latch (Fig.D) and pull up and forward remove the grille. 3. Remove two T27 Torx bolts attaching the fascia the core support (Fig.E). Fig.F Fig.G Fig.H 4. On each side, remove three T25 Torx bolts attaching the fender liner the fascia and one T25 Torx bolt attaching the fender liner the corner of the fascia (Fig.F). 5. Remove 16 T25 Torx bolts attaching the lower splash shield the fascia and fender liners (Fig.G). 6. Push down on two plastic clips in the center of the grille opening and pull forward on the fascia remove it (Fig.H). Disconnect the side marker lights. Fig.I Fig.J Fig.K 7. Pull forward remove the foam shock absorption pad (Fig.I). 8. On each side, remove the horn on the end of the frame rails by removing a 13mm (head) bolt (Fig.J driver's side). 9. Disconnect the ambient temperature sensor from the air deflecr (Fig.K).

4 Fig.L Fig.M Fig.N 10. Remove the air deflecr (Fig.L) and trim the lower half using the red line in Figure M as a reference. Replace the air deflecr. 11. Working on the driver's side, remove the upper and two lower 16mm (head) bolts from the bumper core (Fig.N). Fig.O Fig.P Fig.Q 12. Bolt the driver's side main receiver brace the end of the frame rail using the three provided 10mm x 1.5 x 70mm bolts, lock washers and flat washers. Note: place a 1-5/8" pipe spacer between the main receiver brace and the frame rail on each bolt (Fig.O). 13. Clamp the bumper core mounting points against the botm of the bumper (Fig.P) and tighten the bolt rque requirements found at the end of these instructions. 14. Cut off the stud marked in Figure Q. Fig.R Fig.S Fig.T 15. Fishwire the ½" x 1½" carriage bolt and ¼" x 1" x 3" backing plate through the large existing rear hole in the frame rail and out through the existing forward hole in the frame rail (Fig.R). 16. Place the driver's side rear brace over the bolt fishwired in the previous step. Bolt it in place using a ½" x 1" bolt, lock washer and nut (Fig.S). 17. Bolt the rear brace the main receiver brace. The inner hole uses a ½" x 1" bolt, lock washer and nut; the outer hole uses a ½" x 1" bolt and lock washer (Fig.T).

5 Fig.U Fig.V Fig.W 18. Utilizing the bumper core mounting point and pre-existing ½" holes in the main receiver brace as templates, drill through the main receiver brace and the bumper core with a 12" drill bit (Fig.U). 19. Place a 1" x 2¼" pipe spacer inside the bumper core (Fig.V). Place a ¼" x 1½" x 2½" backing plate over the bolt and bolt in place using a ½" lock washer and nut (Fig.W). Using the supplied ½" x 4" carriage bolt, bolt through the main receiver brace, botm of the bumper core, pipe spacer and the p of the bumper core. 20. Repeat steps 11 through 19 for the passenger side. Note: when repeating step 12 for the passenger side, the two lower mounting points on the front of the frame rail use a 1½" pipe spacer, and the upper mounting point uses a 1 5/8" pipe spacer. 21. Using the supplied zip tie, attach the ambient temperature sensor the wiring harness located across the front of the core support. Fig.X Fig.Y Fig.Z 22. The fascia will need be trimmed allow clearance for the main receiver braces. Remove the passenger side grille insert, and trim the rear of the grille opening using the red lines in Figure X as a guide. Trim the passenger side grille insert using the red lines in Figure Y as a guide. Note: use a small amount of contact adhesive hold the grille inserts in Fig.AA Fig.BB place after trimming. 23. Remove the driver's side grille insert, and trim the rear of the grille opening using the red lines in Figure Z as a guide. Trim the driver's side grille insert using the red lines in Figure AA as a guide. Figure BB shows how the driver's side grille opening should appear after trimming, when viewed from the back side of the fascia. Note: use a small amount of contact adhesive hold the grille inserts in place after trimming.

6 Fig.CC Fig.DD Fig.EE 24. On the driver's side only, use a pair of pliers bend flat one of the alignment tabs on the horn mount, then mount the horn the facry horn mount (Fig.CC). 25. Trim the inside edge of the horn mount on the passenger side only. Use the red line in Figure DD as a guide for trimming. Using the supplied ¾" self-tapping screw, attach the horn the bumper core flange. Fig.FF Fig.GG 26. Torque all bolts the bolt rque requirements found at the end of these instructions. 27. Hold the foam shock absorption pad in place and trim allow clearance for the upper (Fig.EE) and lower (Fig.FF) mounting points of the main receiver braces. 28. Reinstall the fascia, reversing steps 1 through Insert the removable front bracket arms in the front receiver braces, and twist each one 90 degrees lock. 30. Attach the 8" safety cables with the cable connecrs (Q-Links) the front of the receiver braces (Fig.GG). 31. Attach the ends of the safety cables the w vehicle's safety cables. 32. 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 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.