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. Length Width Description Part# /2"... 1/2"...BOLT /2"... 1/2"...BOLT /2"...LOCK WASHER /2"...NUT /2"...FLAT WASHER /2"...PLATE WASHER... A mm... 8mm...8mm x 1.25 x 25mm BOLT mm...LOCK WASHER mm... FENDER WASHER mm... 10mm...10mm x 1.25 x 80mm BOLT mm...LOCK WASHER mm...FLAT WASHER mm... 12mm...12mm x 1.25 x 8mm0 BOLT mm...LOCK WASHER mm...FLAT WASHER /8"...DRAW PIN / SPRING PIN CONNECTOR "... 10" SAFETY CABLES ZIP TIES BLACK DRIVER SIDE LOWER BRACE WELDMENT... C PASSENGER SIDE LOWER BRACE WELDMENT... C MAIN RECEIVER BRACE WELDMENT... C DRIVER SIDE ARM WELDMENT... C PASSENGER SIDE ARM WELDMENT... C SPACER TUBE WELDMENT WITH HANDLE... C /2" TUBE SPACER... A FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN DEATH, PERSONAL INJURY OR PROPERTY DAMAGE

2 This is one of our XL 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 kit consists of a main receiver brace, two lower braces and a hardware pack. The main receiver brace mounts the frame rail. The two lower braces mount the main receiver brace and the frame. The removable front braces install in the main receiver brace. Bee 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. Fig.A Fig.B IMPORTANT: All brackets must be assembled with all the bolts left loose final adjustment and positioning (bee tightening) unless otherwise instructed. All bolts must be rqued proper strength. If 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 of result facry vehicle. in in loss bolts, of Use the thread wed Loctite lock vehicle. and/or Red lock on all washers bolts used must also mounting be used. this Failure bracket. securely fasten the bracket could result in loss of vehicle. 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Every 3,000 miles, the owner must inspect the fasteners each proper use Every rque, cracks 3,000 according or miles, other the signs bolt owner of rque fatigue. must requirements inspect Also, inspect the chart fasteners the on the fasteners last proper page 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. Failure cracks do The or so other owner could signs must result of also in fatigue loss inspect of every the all wed 3,000 mounts vehicle. miles. and brackets Failure The owner do must so cracks could check or result other in vehicle loss signs of manufacturer's of the fatigue wed vehicle. every instructions 3,000 miles. Failure the proper do procedure(s) so could result in prepare loss of vehicle vehicle. The owner must check the vehicle manufacturer's instructions wing. Some The the vehicles proper owner must must procedure(s) be check equipped the with vehicle prepare a transmission manufacturer's the vehicle lube pump, instructions wing. an axle Some disconnect, proper must vehicles the driveline procedure(s) be equipped disconnect with prepare or a free-wheeling transmission the vehicle hubs lube pump, bee wing. an they axle can Some disconnect, be vehicles wed. Failure must driveline be equipped properly disconnect equip with or free-wheeling the transmission vehicle will hubs lube cause bee 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 bee severe they damage can be wed. If running the transmission. Failure changes properly were equip made the by vehicle the vehicle will cause manufacturer severe after damage 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 were be some the made correct bolts by or size. the other vehicle It is fasteners the manufacturer installer s in the responsi- hardware after this bracket pack bility may was verify no designed, longer that the be some the bracket correct bolts is securely size. or other It is fastened fasteners the installer s the the vehicle responsibility pack fitted may hardware and with verify no the longer correct that the be hardware bracket the correct is securely account size. 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Failure Failure repair repair the the damage damage could could result result Some in in morhome the the loss loss of of chassis the 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 Bee 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 Bee Bee getting getting lot. 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The safety cables must connect the wing vehicle 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 wed slack vehicle vehicle sharp frame frame turns. frame, frame, Refer with with the the the cables cables instructions crossed, crossed, with with proper enough enough routing. slack slack Failure sharp sharp leave turns. turns. enough Refer Refer slack the the in cable cable the safety instructions instructions cables, 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 wed vehicle. vehicle. This bracket is designed use with ROADMASTER w bars and This This ROADMASTER bracket bracket is is designed designed adaprs only. use use Using with with this ROADMASTER ROADMASTER bracket with other w w bars bars brands, and 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 nonwarranty Upon final damage damage installation, or or injury. injury. the installer must inspect the bracket en- Upon Upon sure adequate final final installation, installation, clearance, the the installer installer particularly must must around inspect inspect hoses, the the bracket bracket air conditioner ensure ensure lines, adequate adequate radiars, clearance, clearance, etc., or particularly particularly non-warranty 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 wed vehicle vehicle will will This result. result. bracket is only warranteed the original installation. Installing This This a used bracket bracket bracket is is only only another warranteed warranteed vehicle 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 Fig.C Fig.D Fig.E 1. Important: please use all supplied bolts and parts and read all instructions carefully bee 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 15 plastic fasteners remove the radiar cover (Fig.C). 2. On both sides, remove one Phillips screw that attaches the fascia the fender liner (Fig.D). 3. On both sides, remove two 10mm (head) bolts attaching the lower fascia the splash shield (Fig.E). Fig.F Fig.G Fig.H 4. On the lower front of the fascia, there are three plastic fasteners attaching the fascia the splash shield. Remove the two outside fasteners (Fig.F). 5. If your vehicle is equipped with fog lights carefully pull out the fascia and unplug them (Fig.G). Then, remove the fascia by pulling out and ward on both corners (Fig.H). 6. To remove the headlights, remove four 10mm (head) bolts. One is located on the p of the headlight (Fig.J) and two are located on the botm inside edge of the headlight bracket (Fig.I). The fourth one is located on the outside corner of the headlight bracket (Fig.I). Next, remove one plastic fastener on p of the headlight (Fig. J), and one Phillips screw (Fig.I) on the outside corner of the headlight bracket. Repeat the other side. 3 of the 10mm (head) bolts Plastic fastener 10mm (head) bolt Fig.I Phillips screw Fig.J All illustrations and specifications contained herein are based on the latest inmation 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.

4 Fig.K Fig.L Fig.M 7. Remove the ambient temperature sensor (Fig.K). 8. Remove three 12mm (head) bolts remove the bumper core (Fig.L). 9. Now, remove two 10mm bolts remove the air box from the driver's side. 10. Remove three 10mm screws that attach the washer bottle the vehicle. (Note: when removing the washer bottle, either drain the fluid in a container or plug the fitting). Two of the screws are located at the botm of the washer bottle (Fig. M); one is at the neck of the bottle. Fig.N Fig.O Fig.P Pipe spacer 11. Now, slide the main receiver brace in the frame rails (Fig.N). 12. Using the supplied 8mm x 1.25 x 25mm bolt, fender washer and lock washer, bolt in the existing bumper core weld nut on the p of the frame rail (Fig.O). Repeat the other side. 13. Starting with the rear mounting point on the frame rail, insert the supplied 1¼" x 2½" pipe spacer with the attached wire in the frame rail and slide it back align with the existing hole (Fig.P). Bolt through the frame, pipe spacer and the main brace using a ½" x 4½" bolt, plate washers, lock washer and nut. (Note: the plate washers go on the inside and the outside of the frame rails). Repeat the other side. 14. Once the pipe spacers are in place, cut or twist off the attached wire. All illustrations and specifications contained herein are based on the latest inmation 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.Q Fig.R Fig.S 15. Using the rear hole in the main receiver brace as a template, drill a ½" hole in the p of the frame rail (Fig.Q). Repeat the other side. 16. Using the supplied ½" x 1½" bolt, bolt through the hole in the main receiver brace and frame rail which you drilled in the previous step. Finish with a ½" plate washer, lock washer and nut (Fig.R). Repeat the other side. 17. Tighten all bolts the rque specifications listed at the end of these instructions. 18. On the passenger's side remove the retainer clip holding the air cooling line the core support. Bend the air cooling line out of the way (Fig.S). Fig.T Fig.U Fig.V 19. Using the hole in the frame rail as a template, drill through the outside of the frame rail and in the main brace with a ½" drill bit (Fig.T). Repeat the other side. 20. Bolt through the end of the frame rail using a ½" x 4½" bolt, 1¼" x 2½" pipe spacer, two flat washers, lock washer and nut (Fig.U). Repeat the other side. 21. Next, remove the 14mm bolt attaching the frame brace the core support on the passenger's side (Fig.V). 22. Bolt the lower brace the main receiver brace using two ½" x 1- ½" bolts, lock washers and nuts (Fig.W). Fig.W

6 Fig.X Fig.Y Fig.Z Bolt 23. Now, bolt the lower brace the core support using a 10mm x 1.25 x 80mm bolt, flat washer and nut (Fig.X). 24. Repeat steps 21 through 23 the other side. Note: the driver's side bolt attaching the frame brace the core support is a 17mm (head) bolt and is being replaced by a 12mm x 1.25 x 80mm bolt. 25. Tighten all remaining bolts the rque specifications listed at the end of these instructions. 26. Secure the ambient temperature sensor you removed in step 7 the main receiver brace with the provided zip tie (Fig.Y). 27. Reattach the washer bottle, air box, headlights, fascia and the radiar cover, reversing steps 1 through Fit the front bracket arms in the front receiver braces, and secure them in place with the supplied 5/8" draw pins and spring pins. 29. Attach the 10" safety cables with the cable connecrs (Q-Links) the front of the receiver braces (Fig.Z). 30. Attach the ends of the safety cables the w vehicle's safety cables and w bar. 31. Install the w bar the mounting bracket according the manufacturer's instructions. BOLT TORQUE REQUIREMENTS Note: The rque values represented below are intended as general guidelines. Torque requirements specific applications may vary. Roadmaster does not warrant this inmation be accurate all applications and disclaims all liability any claims or damages which may result from its use. STANDARD BOLTS Thread Size Grade Torque 5/ ft./lb. 3/ ft./lb. 7/ ft./lb. 1/ ft./lb. 5/ ft./lb. 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 inmation 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.