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 /2" x 6 1/2" BOLT /2" x 4 1/2" BOLT /2" PLATE WASHER... A /2" LOCK WASHER /2" HEX NUT /4" x 3/4" SELF TAPPING SCREW FAILURE... TO FOLLOW MAIN THESE RECEIVER INSTRUCTIONS... CAN RESULT IN DEATH, PERSONAL INJURY OR PROPERTY C DAMAGE DRIVER SIDE ARM... C PASSENGER SIDE ARM... C

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 consists of a main receiver brace, two removable front braces and a hardware pack. The main receiver brace mounts the frame rails. 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 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. 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 loss bolts, of Use the thread wed Loctite lock vehicle. and/or Red lock on all washers bolts used must for also mounting be used. this Failure bracket. securely fasten the bracket could result in loss of vehicle. Do not use this document for cusm fabrication, as it may not show Do all parts not use or structural this document components. for cusm Cusm fabrication, fabrication as or it may an attempt not show all copy parts this or bracket structural design components. could result Cusm in loss fabrication of or an vehicle. attempt The copy this owner bracket must design inspect could all mounts result loss of and brackets vehicle. Every 3,000 miles, the owner must inspect the fasteners before for each proper use for Every rque, cracks 3,000 according miles, other the signs bolt owner of rque fatigue. must requirements inspect Also, inspect the chart fasteners the on fasteners the for last proper page for proper rque, of these rque, according 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 last of brackets these page. instructions. for Failure cracks do The or so other owner could signs result must of in also fatigue loss inspect of the every wed all 3,000 mounts vehicle. miles. and brackets The Failure owner for do must so cracks could or check result other the vehicle in loss signs of of manufacturer's the fatigue wed vehicle. every 3,000 miles. instructions for the Failure proper do so could procedure(s) result in loss of prepare vehicle. The owner must check the vehicle manufacturer's the vehicle for instructions wing. Some for vehicles The the proper owner must must procedure(s) be equipped check the with vehicle prepare a transmission manufacturer's the vehicle lube for pump, instructions wing. an axle Some disconnect, vehicles the proper must driveline procedure(s) be equipped disconnect with or prepare a free-wheeling transmission the vehicle hubs lube before pump, wing. they an axle can Some dis- be for wed. vehicles connect, Failure must driveline be equipped properly disconnect equip with or free-wheeling the transmission vehicle will hubs lube cause before 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 before severe they damage can be wed. Failure properly equip the vehicle will cause severe damage If running the transmission. changes were made by the vehicle manufacturer after 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 pack bracket running may was no changes designed, longer be were some the made correct bolts by size. or the other vehicle It is fasteners the manufacturer installer s the responsi- hardware after this bility bracket pack may was verify no designed, longer that the be bracket some the correct bolts is securely size. or other It is fastened fasteners the installer s the the vehicle responsibility pack may with verify the no longer correct that the be hardware bracket the correct is account securely size. It for is fastened these installer s changes. the vehicle responsi- Failure and hardware and fitted securely bility fitted with verify fasten the correct that the the bracket hardware bracket could is account securely result in for fastened loss these of the changes. wed the vehicle Failure vehicle. and fitted securely with fasten the correct the bracket hardware could account result in for loss these of the changes. wed Failure vehicle. If securely fasten vehicle the bracket has been could in an result accident, in loss it of must be properly vehicle. re- paired If before vehicle attaching has the been bracket. in an Do accident, not install it must the be bracket properly if any repaired structural before frame attaching damage the is bracket. found. Failure Do not install repair the bracket damage if could any structural result structural in the frame frame loss of damage damage is is found. found. vehicle. Failure Failure repair repair the the damage damage could could Some result result 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 while that that you you turning can can damage sharply. damage your your Before 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. empty sharply. parking Before Before getting getting lot. Turning on on the the o road, road, sharply test test could your your result turning turning non-warranty radius radius in in an an empty damage empty parking parking wing lot. lot. system, Turning Turning morhome o o sharply sharply and/or could could wed result result vehicle. in in non-warranty non-warranty damage Do not back wing up with system, the morhome wed vehicle and/or attached wed vehicle. or non-warranty Do damage Do not not back back will occur up up with with your the wed wing vehicle vehicle system, attached attached morhome or or and/or non-warranty non-warranty wed damage vehicle. damage will will occur occur your your wing wing system, system, morhome morhome and/or and/or wed wed vehicle. The safety cables must connect the wing vehicle The vehicle The 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 for vehicle sharp frame frame turns. frame, frame, Refer with with the the the cables cables instructions crossed, crossed, with with for proper enough enough routing. slack slack for Failure for sharp sharp leave turns. turns. enough Refer Refer slack the the in cable cable the safety instructions instructions cables, or for for failure proper proper connect routing. routing. Failure the Failure 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 vehicle. the safety safety cables cables frame frame frame, frame, will will result result in in the the loss loss of of the wed This vehicle. bracket is designed for use with ROADMASTER w bars and This This ROADMASTER bracket bracket is is adaprs designed designed only. for for use use Using with with this ROADMASTER ROADMASTER bracket with other w w bars bars brands, ROADMASTER without ROADMASTER 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 warranty without an an damage approved approved or injury. ROADMASTER ROADMASTER adapr, adapr, may may result result in in nonwarranty final damage installation, or injury. the installer must inspect the bracket en- Upon non- Upon Upon sure adequate final final installation, installation, clearance, the the particularly installer installer must must around inspect inspect hoses, the the air bracket bracket conditioner ensure lines, sure adequate en- adequate radiars, clearance, clearance, etc., or non-warranty particularly particularly around around damage hoses, hoses, the air air wed conditioner conditioner vehicle lines, will lines, result. radiars, radiars, etc., etc., or or non-warranty non-warranty damage damage the wed vehicle vehicle will This result. bracket is only warranteed for the original installation. Installing This a This used bracket bracket bracket is is only only another warranteed warranteed vehicle for for 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 T30 bolt Fig.E T20 bolt 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. Remove four T25 Torx bolts attaching the p of the grille the core support (Fig.C). Lift up on the grille remove it. 2. On both sides, remove two Torx bolts attaching the center grille the core support. The p bolt is T30 and the botm is T20 (Fig.D). 3. Pull forward on the outside edge of the center grille remove it (Fig.E). T45 bolts Fig.F Fig.G ambient temperature sensor Fig.H T20 bolts 4. Remove two T45 Torx bolts attaching the botm of the grille opening the bumper core (Fig.F). 5. Remove four T20 Torx bolts attaching the license plate holder the fascia (Fig.F), then disconnect the ambient temperature sensor from the back of the license plate holder (Fig.G). 6. Remove two 13mm (head) bolts attaching the fascia the front of the bumper (Fig.G). 7. On both sides, remove three plastic fasteners attaching the fender liner the side of the fascia and fender junction (Fig.H). Fig.I Fig.J Fig.K 8. On both sides, remove two plastic fasteners attaching the fender liner the botm of the fascia (Fig.I). 9. Disconnect the fog lights, if the vehicle is so equipped. Then, pull forward on the fascia remove it (Fig.J). 10. On the passenger's side, remove two 10mm plastic nuts attaching the electrical box the frame rail (Fig.K).

4 Fig.L measure Fig.M Fig.N electrical box remounted 11. After removing the electrical box, cut the remaining two studs from the side of the frame rail. Using the two supplied ¼" x ¾" self-tapping screws, remount the electrical box the botm of the headlight support (Fig.L). 12. Slide the main receiver brace over the botm of the frame rails until the botm inside plate of the brace lies flush with the botm of the frame rails. 13. Slide the main receiver brace forward and measure from the back of the bumper core the brace. This measurement must be 2½" (Fig.M). Once it has been positioned, clamp the main receiver brace the frame rail (Fig.M). 14. Using the pre-drilled holes in the main receiver brace as a template, drill four ½" holes on each side of the brace. The pre-drilled holes are on the botm, both sides and the p. While drilling, keep a piece of scrap metal on the opposite side of the frame rail protect the engine components. Note: keep the drill as straight as possible. If the holes aren't straight, the plate washers in Step 15 may need be trimmed with a metal grinder, shear or saw. Fig.O front holes Fig.P Fig.Q license plate rim template 15. Bolt the main receiver brace the frame rails using the four supplied ½" x 6½" bolts, plate washers, lock washers and nuts. The plate washers must be on the p side of the frame rail (Fig.O). Torque the bolts the specifications listed at the end of these instructions. 16. Using the pre-drilled holes in the main receiver brace as a template, drill ½" holes through the two side holes in the frame rail on each side (Fig.P). While drilling, keep a piece of scrap metal on the opposite side of the frame rail protect the engine components. Note: a 90-degree angle drill will be required drill these holes (Fig.P). Bolt the main receiver brace the frame rails using the supplied ½" x 4½" bolts. 17. Cut out the template provided on the last page of these instructions and align it with the edge of the license plate rim on the fascia (Fig.Q). Using a marker, trace out the rectangular opening and trim (Fig.Q). 18. Reassemble the fascia by reversing steps 1 through 9. Tighten all bolts the rque specifications listed at the end of these instructions. All illustrations and specifications contained herein are based on the latest information 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 19. Insert the removable front bracket arms in the front receiver braces, and secure them in place with the supplied 5/8" draw pins and spring pins. 20. Install the w bar the mounting bracket according the manufacturer's instructions. Note: this bracket does not use short safety cables. It requires 10,000-pound rated safety cables that attach the main receiver brace on the wing vehicle. 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/ 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 information 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.

6 Template for fascia trimming