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 140mm BOLT mm FENDER WASHER mmlock WASHER mm x 1.5 HEX NUT /2" x 5 1/2" BOLT /2 FLAT WASHER /2 LOCK WASHER /2 NUT DRAW PIN, SPRING PIN CABLE CONNECTOR SAFETY CABLE BEVELED WASHER BACKING PLATE WELDMENT... C MAIN BRACE... C DRIVER SIDE ARM WELDMENT... C PASSENGER SIDE ARM WELDMENT... C INSIDE BACKING PLATE... A OUTSIDE BACKING PLATE... A ZIP TIE 7" mm x 1.5 x 35 mm BOLT FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN DEATH, PERSONAL INJURY OR PROPERTY DAMAGE

2 This is one of our XL bracket series, which Fig.A allows the visible front portion of the bracket be easily removed from the front of the car by removing the front braces. The bracket kit consists of a receiver brace, two front braces, and a hardware pack. The rear receiver brace mounts the front of the frame and protrudes through the lower grill below the headlights. The bumper core is removed and replaced with the receiver brace. The front braces insert in the rear brace and pin in place. Before starting the installation, lay out the kit components as it is illustrated. This will give you a visual idea of how the components work and also confirm that everything is present and accounted for. 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 diagram Use flat may washers only show over 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, 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, death. structural frame is found. Failure repair the 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 structural structural Some morhome frame frame chassis is is have found. found. such Failure Failure a tight turning repair repair radius the the that you could could can Installation result in in your the the loss loss morhome, of of the the wed wed vehicle, w bar or bracket while turning cal tion aptitude by an experienced and skills. installer. We strongly recommend professional installa- 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 tion The by installer an experienced must read installer. the instructions and use all bolts and parts 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 The supplied. installer Failure must read securely the instructions fasten the bracket and use could all bolts result and in loss parts of sharply. sharply. Before Before wing getting getting system, on on morhome the the road, road, test test and/or your your wed turning turning radius radius in in an 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 empty Do not parking parking back up lot. lot. with Turning Turning the wed o o sharply sharply vehicle could could attached result result or in in non-warranty non-warranty the thread Do 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. 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 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. Failure leave enough slack in the safety cables, or failure connect for 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. Some warranty 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 warranty 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 Upon lines, final final radiars, installation, installation, etc., the the or non-warranty installer installer must must inspect inspect the the the bracket bracket wed vehicle ensure 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 this and 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 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 installer s responsi- will result. bracket on another vehicle is not recommended and will void bility 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 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 This the warranty. bracket bracket is is only only warranteed warranteed for for the the original original installation. installation. Installing Installing bility fitted with verify the correct that the hardware bracket is account securely for fastened these changes. the vehicle Failure and a used used bracket bracket on on another another vehicle vehicle is is not not recommended recommended and and will will void void fitted securely with fasten the correct the bracket hardware could account result in for loss these of the changes. wed Failure the the warranty. warranty.

3 Fig.B 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 the front fascia, starting with two 10mm (head) bolts located on the p near the inside corners of the headlights (Fig.B), then two plastic fasteners in the lower grille opening (Fig.C). Move the fender wells and remove three plastic fasteners in each fender well (Fig.D). Remove three 10mm (head) bolts from the botm of the fascia in front of the fender wells on each side, then remove three more across the botm of the fascia (Fig.E). Now, go the fascia fender joints and remove one plastic fastener in each side (Fig.F). Disconnect the foglights (Fig.G) and pull forward remove and set aside (Fig.H). Fig.E Fig.F Fig.G 2. Remove two plastic fasteners from the radiar air deflecrs on each side (Fig.I) and remove (Fig.J). 3. Remove the bumper core (four 13mm nuts, two on each side Fig.K,L). Note: retain the bumper core and attachment hardware so that it can be replaced if the bracket is ever removed. Fig.H Fig.I Fig.J 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 4. Now remove the tie down brackets (five 13mm head bolts) on each side (Fig.M), then remove the bumper core support brackets in front of the frame tubes (four 13mm head bolts) on each side (Fig.N). Note: The main receiver brace will replace all the parts removed in steps 3 and 4 except some of the bolts, which will be reused (Fig.O). Note: retain the bumper core attachment hardware so that it can be replaced if the bracket is ever removed. Fig.N Fig.O Fig.P 5. On both sides, using two of the bumper core mounting bolts you removed, bolt the 4½" x 3-5/8" backing plate the side of the frame (Fig.P). Note: due manufacturing variances, some vehicles may not be equipped with facry weld nuts. If this is the case, use the four supplied 10mm fender washers, lock washers and nuts instead of the weld nuts. Fig.Q Fig.R 6. Using the lower mounting points in the main receiver brace, bolt the main receiver brace the radiar support using the two 10mm x 1.5 x 35mm bolts, fender washers and lock washers (Fig.Q). Note: due manufacturing variances, some vehicles may not be equipped with facry weld nuts. Enlarge the hole in the botm of the frame and then use the four supplied 10mm fender washers, lock washers and nuts instead of the weld nuts (Fig.R). ROADMASTER, INC. reserves the right make changes at any time without notice in material, specification and models or discontinue models.

5 Fig.S Fig.T Fig.U 7. Bolt through the p front frame mounting holes, the outside backing plate and an inner backing plate with two 10mm x 1.5 x 140mm bolts, fender washers, lock washers and nuts on each side (Fig.S,T,U). Fig.V Fig.W Fig.X 8. Using the main receiver brace as a drill template, drill a 17/32" hole through the front of the frame on each side (Fig.V). 9. Bolt through these holes with a ½" x 5½" bolt, beveled backing plate, flat washer, lock washer and nut (Fig.W). 10. Align the brace, then rque all mounting bolts the specifications at the botm of these instructions. 11. Trim the front radiar air deflecrs as shown, then reinstall (Fig.X). Fig.Y Fig.Z Fig.AA 12. If the vehicle is equipped with an ambient temperature sensor, reattach it the main receiver brace using the two provided zip ties (Fig.Y). 13. If your vehicle is equipped with an extra chrome trim on the front of the fascia, the five plastic tabs on the inside of the fascia (Fig.Z) need be removed. Replace the five plastic tabs with two plastic pop rivets. Proceed the next step for further instruction. 14. Start by drilling a ¼" hole through the fascia and front of the trim piece (Fig.AA,BB). Fig.BB ROADMASTER, INC. reserves the right make changes at any time without notice in material, specification and models or discontinue models.

6 15. Now, attach the trim piece the fascia with the plastic pop rivets (Fig.CC). 16. Next, remove the plastic tabs; either cut or grind them off. 17. Once the trimming is done, reinstall the fascia, reversing step 1, with the exception of replacing the bumper core and the parts removed in step Install the front braces by inserting them in the front of the receivers and securing them in place with 5/8 draw pins and 1/8 spring pins (Fig.DD). 19. Mount the w bar according the w bar manufacturer s instructions. Install the 8 safety cables under the main receivers with the quick links provided. Attach the other end the w vehicle's safety cables and w bar. Fig.CC Fig.DD 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 s 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 and models or discontinue models.