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 Special ols needed: Cut-off wheel or disc grinder ITEM QTY NAME MATERIAL /2" x 6 1/2" BOLT /2" x 5" BOLT /2" x 1 1/2" BOLT /2" LOCK WASHER /2" HEX NUT DRAW PIN W/ CLIP QUICK LINK SAFETY CABLE 8" /4" x 2" x 2" RD. HOLE BACKING PLATE... A /4" x 1 1/2" x 1 3/4" RD. HOLE BACKING PLATE... A DRIVER SIDE BRACE... C PASSENGER SIDE BRACE... C MAIN RECEIVER... C DRIVER SIDE ARM... C PASSENGER SIDE ARM... C

2 This bracket kit is one of our XL series, which allows the visible front portion of the brackets be easily removed (Fig.A Fig.B). The kit consists of the main receiver brace, removable front braces a hardware pack. The main receiver brace mounts the front frame bumper core on each side. The removable front braces insert in the receivers on each side are secured with draw pins. 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 Do Use the thread wed 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 rque, according 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 the no 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 have is is 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 cables turns. turns. frame Refer Refer frame, the the 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 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. Remove two 10mm screws four plastic fasteners attaching the p of the fascia the core support (Fig.C). Fig.E Fig.F 2. On each side, remove three 5.5mm screws one plastic fastener attaching the fender liner the fascia (Fig.D). 3. Remove three plastic fasteners attacing the botm of the fascia the radiar support (Fig.E). 4. Remove two plastic fasteners attaching the fascia the bumper core just above the lower grille (Fig.F). Fig.G 5. Disconnect the fog lights, if the vehicle is so equipped. 6. Pull out forward remove the fascia (Fig.G). ROADMASTER, INC. reserves the right make changes at any time without notice in material, specification models or discontinue models.

4 BASEPLATE KIT Fig.H Fig.I 7. On each side, remove four 13mm (head) bolts attaching the bumper core the end of the frame rail (Fig.H). 8. On each side, remove a plastic fastener attaching the air deflecrs the bumper core (Fig.I). Fig.J Fig.K 9. On each side, use a sharp 3/8" drill bit drill out the two spot welds attaching the bumper core the end of the frame rail (Fig.J driver's side). 10. Remove the bumper core. It will not be replaced. Note: retain the bumper core so that it can be replaced if the Fig.L bracket is ever removed. 11. On each side, use a cut-off wheel or disc grinder trim the radiar support. Use the green lines in Figure K (driver's side) as a guide for trimming. 12. On each side, use the four supplied ½" x 1½" bolts lock washers bolt the passenger driver's side welded tube braces the main receiver brace. Leave the bolts completely loose for now (Fig.L). Note: the welded tube will be used for attachment in step 16. ROADMASTER, INC. reserves the right make changes at any time without notice in material, specification models or discontinue models.

5 Fig.M Fig.N 13. Set the main receiver brace over the ends of the frame rails so the rear braces slip in the frame rails (Fig.M driver's side). Replace the eight bumper core bolts you removed in step 7. Note: use thread lock on the bolts. 14. On each side, tighten the bumper core bolts the bolt rque requirements found at the end of this document. Now, tighten the ½" bolts the bolt rque requirements. 15. Working on the driver's side only, bolt through the lower rear mounting point of the main receiver brace subframe using a ½" x 5" bolt. Place a ¼" x 2" x 2" backing plate on the p side of the subframe. Finish with a ½" lock washer nut (Fig.N). Note: due manufacturing variances, the pre-existing hole may need be enlarged. Fig.O Fig.P 2-1/16" 2-7/8" 16. Measure 2-7/8" from the back surface of the end of the frame rail 2-1/16" from the p surface of the frame. Where the two intersect (Fig.O driver's side), mark a hole, using a ½" drill bit, drill a hole through the outside of the frame rail, pass through the welded tube, through the inside frame rail. Place a ¼" x 1½" x 1¾" backing plate over a ½" x 6½" bolt. Thread the bolt through the hole you just drilled in another ¼" x 1½" x 1¾" backing plate on the outer edge of the inside frame rail. Finish with a ½" lock washer nut (Fig.P). 17. Repeat steps for the passenger side. Tighten all bolts the bolt rque requirements found at the end of this document. ROADMASTER, INC. reserves the right make changes at any time without notice in material, specification models or discontinue models.

6 Fig.Q Fig.R 18. On each side, measure 1¼" from the side of the grille opening remove a 1" x 2¾" piece from the p of the grille. Trim the four outside horizontal ribs one vertical rib from the grille. Use the red lines in Figure Q (driver's side) as a guide for trimming. 19. Reassemble the fascia, reversing steps 1 through Insert the removable front bracket arms in the front receiver braces, secure them in place with the supplied 5/8" draw pins spring pins. 21. Attach the 8" safety cables with the cable connecrs (Q-Links) the front of the receiver braces (Fig.R). 22. Attach the ends of the safety cables the w vehicle's safety cables. 23. 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. ROADMASTER, INC. reserves the right make changes at any time without notice in material, specification models or discontinue models.