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. Item Qty. Description Part No /2" x 1 1/2" CARRIAGE BOLT /2" x 3" BOLT /2" LOCK WASHER /2" NUT DRAW PIN/SPRING PIN CABLE CONNECTOR " SAFETY CABLE /4" x 1 1/2" x 2" BACKING PLATE W/ SQUARE HOLE... A DRIVER SIDE ARM WELDMENT... C FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN DEATH, PERSONAL INJURY OR PROPERTY DAMAGE PASSENGER SIDE ARM WELDMENT... C /4" O.D. x 1 3/4" X.250 TUBE SPACER WITH HANDLE... C /2" x 3" THREADED BACKING PLATE... C MAIN RECEIVER BRACE WELDMENT... C

2 This is one of our XL series brackets, which allows visible front portion of brackets be easily removed from front of (Fig.A and Fig.B). The bracket kit consists of a ma receiver brace, two removable front bracket arms and a hardware pack. Bee startg stallation, lay out kit components order, as y will be used. This will give you a visual idea of how components work, and will also confirm that everythg is present and accounted. Fig.A Fig.B IMPORTANT: All brackets must be assembled with all bolts left loose fal adjustment and positiong (bee tighteng) unless orwise structed. All bolts must be rqued proper strength. If more than one bolt is used per fasteng pot, diagram may only show one. Use flat washers over all slotted holes Use lock washers on all fasteners ROADMASTER Limited Warranty, cludg One-Year Conditional Warranty Text and Product Registration Card, Carn. follow se structions can result property damage, WARNING personal jury or even death. Installation of most mountg brackets requires moderate mechanical aptitude and skills. We strongly recommend professional stallation by an experienced staller. The staller must read structions and use all bolts and parts supplied. When securely do structions so could fasten result require bracket loss of reuse could of result facry. loss bolts, of Use thread wed Loctite lock. and/or Red lock on all washers bolts used must also mountg be used. this bracket. securely fasten bracket could result loss of. Do not use this document cusm fabrication, as it it may not show Do all parts not use or structural this document components. cusm Cusm fabrication, fabrication as or it may an attempt not show all copy parts this or bracket structural design components. could result Cusm loss fabrication of or an. attempt copy The owner this bracket must design spect could all mounts result and loss brackets of bee. Every 3,000 miles, owner must spect fasteners each proper use Every rque, cracks 3,000 accordg miles, or signs bolt owner of rque fatigue. must requirements spect Also, spect chart fasteners on fasteners last proper page rque, of proper se accordg rque, structions. accordg The bolt owner rque bolt must requirements rque also requirements spect chart all on mounts chart last on page and of brackets last se page. structions. cracks do The or so or owner could signs result must of also fatigue loss spect of every wed all 3,000 mounts. miles. and brackets The owner do must so cracks could check or result or loss signs of manufacturer's of fatigue wed. every structions 3,000 miles. proper do procedure(s) so could result prepare loss of wed. The owner must check manufacturer's structions wg. Some The s proper owner must must procedure(s) be equipped check with prepare a transmission manufacturer's lube pump, structions wg. an axle Some disconnect, proper must drivele procedure(s) be equipped disconnect with or prepare a free-wheelg transmission hubs lube pump, bee wg. an y axle can Some dis- be s connect, wed. must drivele be equipped properly disconnect equip with or free-wheelg transmission will hubs lube cause bee pump, severe y an axle damage can dis- be connect, wed. transmission. drivele properly disconnect equip or free-wheelg will hubs cause bee severe y damage can be s wed. If runng transmission. changes properly were equip made by will manufacturer cause severe after damage this bracket transmission. If runng was changes designed, were some made bolts by or or fasteners manufacturer hardware after this If bracket pack runng may was no changes designed, longer be were some made correct bolts by size. or or It is fasteners manufacturer staller s responsi- hardware after this bracket pack bility may was verify no designed, longer that be bracket some correct bolts is securely size. or or It is fastened fasteners staller s responsibility pack fitted may with verify no longer correct that be hardware bracket correct is securely account size. It is fastened se staller s changes. responsi- and bility fitted securely with verify fasten correct that bracket hardware bracket could is account securely result fastened loss se of changes. wed. and fitted securely with fasten correct bracket hardware could account result loss se of changes. wed. hardware and securely If fasten bracket has been could result an accident, loss it of must be properly. re- If paired bee attachg has been bracket. an Do accident, not stall it must be bracket properly if any repaired structural bee frame attachg damage is bracket. found. Do not stall repair bracket damage if could any structural structural result frame frame loss damage damage of is is found. found.. repair repair damage damage could could result result Some morhome loss loss of of chassis wed have.. such a tight turng radius that you can Some Some damage morhome morhome your morhome, chassis chassis wed have have such such, a tight tight w turng turng bar or bracket radius radius that that while you you turng can can damage damage sharply. your your Bee morhome, morhome, gettg on wed wed,, road, test w w your bar bar or or turng bracket bracket radius while while turng turng an sharply. sharply. empty parkg Bee Bee gettg gettg lot. Turng on on o road, road, sharply test test could your your result turng turng radius radius non-warranty an an empty empty damage parkg parkg wg lot. lot. system, Turng Turng morhome o o sharply sharply and/or could could wed result result. non-warranty non-warranty damage Do not back wg up with system, morhome wed and/or attached wed. or non-warranty Do Do damage not not back back will occur up up with with your wed wg system, attached attached morhome or or and/or non-warranty non-warranty wed damage damage. will will occur occur your your wg wg system, system, morhome morhome and/or and/or wed wed. The safety cables must connect wg The The safety safety frame cables cables frame, must must with connect connect cables wg wg crossed, with enough wed slack sharp frame frame turns. frame, frame, Refer with with cables cables structions crossed, crossed, with with proper enough enough routg. slack slack sharp sharp leave turns. turns. enough Refer Refer slack cable cable safety structions structions cables, failure proper proper routg. routg. connect safety leave leave cables enough enough frame slack slack frame, will safety safety result cables, cables, or or loss failure failure of connect connect wed. safety safety cables cables frame frame frame, frame, will will result result loss loss of of wed. This bracket is designed use with ROADMASTER w bars and This This ROADMASTER bracket bracket is is designed designed adaprs only. use use Usg with with this ROADMASTER ROADMASTER bracket with or w w bars bars brands, ROADMASTER ROADMASTER without an approved adaprs adaprs ROADMASTER only. only. Usg Usg this this adapr, bracket bracket may with with result or or brands, brands, non- without without warranty an an damage approved approved or jury. ROADMASTER ROADMASTER adapr, adapr, may may result result nonwarranty Upon fal damage stallation, or jury. staller must spect bracket en- Upon non- Upon sure adequate fal fal stallation, stallation, clearance, particularly staller staller must must around spect spect hoses, air bracket bracket conditioner ensure ensure les, adequate adequate radiars, clearance, clearance, etc., or non-warranty particularly particularly around around damage hoses, hoses, air air wed conditioner conditioner les, les, will result. radiars, radiars, etc., etc., or or non-warranty non-warranty damage damage wed will This result. bracket is only warranteed origal stallation. Installg This This a used bracket bracket bracket is is only only anor warranteed warranteed is not origal origal recommended stallation. stallation. and Installg Installg will void a used used warranty. bracket bracket on on anor anor is is not not recommended recommended and and will will void void warranty. warranty.

3 1. Important: please use all supplied bolts and parts and read all structions carefully bee begng this stallation. The majority of questions you may have can be answered with text, and proper stallation will ensure safe and secure travel. Now, beg stallation by removg six plastic fasteners along p of fascia (Fig.C). 2. Remove seven 7mm (head) bolts connectg splash shield lower fascia (Fig.D). 3. Remove four plastic fasteners one on each side attachg splash shield radiar support (Fig.E), and one on each side attachg center air deflecr outside air deflecrs (Fig.F). Then, remove center splash shield (Fig.G). Fig.D Fig.E Fig.C Fig.G Fig.F Fig.H 4. Remove four plastic fasteners from each outer splash shield (Fig.H), allowg outer splash shields be moved out of way. 5. From behd fascia, remove 10mm head bolt connectg fender fascia. This bolt is close where headlight, fascia and fender tersect. Figure I shows location of driver side bolt. Repeat or side. Fig.I ROADMASTER, INC. reserves right make changes at any time without notice material, specification and models or discontue models.

4 10mm bolt Fig.J plastic fastener 7mm bolt Fig.K Fig.L plastic fastener 6. Then, from outside of each fender well, remove three plastic fasteners, one 7mm (head) bolt, and one 10mm head bolt (Fig.J). 7. Disconnect fog lights, if is so equipped (Fig.K). 8. Pull down and ward remove fascia (Fig.L) Fig.M Fig.O Fig.N 9. Trim both driver's side and passenger side air deflecrs Start by cuttg away sections marked with an 'X' Figures M and N. Once ma receiver brace is bolted place, trim air deflecrs fit, as shown Figure O. Fig.Q Fig.R Fig.P 10. On each side, remove one plastic fastener holdg air deflecr radiar support (Fig.P). 11. Support subframe (Fig.Q). 12. On each side, remove a 21mm (head) bolt from subframe (Fig.R). ROADMASTER, INC. reserves right make changes at any time without notice material, specification and models or discontue models.

5 Fig.S Fig.T first center layer Fig.U 13. Position ma receiver brace so that pre-drilled holes at rear of brace are between subframe and frame recement. Now, align ma receiver brace with holes 21mm subframe bolts previous step. 14. Apply Loctite one of 21mm (head) subframe bolts, bolt through frame recement, ma receiver brace and subframe (Fig.S). Repeat or side and rque bolts specifications at botm of se structions. 15. Usg pre-drilled hole ma receiver brace as a template, drill a 17/32" hole through botm of bumper core (Fig. T) and through first center layer (Fig.U). Repeat or side. Fig.V Fig.W Fig.X nutted backg plate bolt & lock washer 16. Usg attached wire, position one of supplied 1¼" x 1¾" pipe spacers bumper core (Fig.V) and directly over one of holes you drilled precedg step. 17. From botm of bumper core, fit one of supplied ½" x 3" bolts and ½" lock washers through ma receiver brace, pipe spacer and first center layer of bumper core (Fig.W). From back of bumper core, fit one of supplied 1½" x 3" nutted backg plates over first center layer of bumper core (Fig.W) and over bolt. Thread bolt backg plate, n rque specifications at botm of se structions. Repeat or side. 18. Once bolts are tightened, break wires off with a pair of pliers, eir through each end of bumper core (Fig.X), or through one of access holes at front of bumper core. 19. Usg pre-drilled hole ma receiver brace (Fig.Y) as a template, drill a 17/32" hole through frame rail (Fig.Z). Repeat or side. Fig.Y Fig.Z ROADMASTER, INC. reserves right make changes at any time without notice material, specification and models or discontue models.

6 Fig.AA Fig.BB Fig.CC 20. Then, fishwire one of supplied ½" x 1½" carriage bolts and 1½" x 2" backg plates through square openg frame rail (Fig.AA, Fig.BB) and through one of holes you drilled precedg step. Thread a ½" lock washer and nut over bolt (Fig.CC), and rque bolt specifications at end of se structions. Repeat or side. Fig.DD Fig.EE Fig.FF 21. Replace plastic fasteners holdg air deflecrs radiar support, which you removed step Bee restallg fascia, trim section below grill shown Figure DD, on both sides. Then, remove a section of p horizontal rib from grille, on both driver side and passenger side, as shown Figure EE. 23. Restall fascia and center splash shield by reversg steps 1 through Fit front bracket arms front receiver braces, and secure m place with supplied 5/8" draw ps and sprg ps. 25. Attach 8" safety cables with cable connecrs (Q-Lks) front of receiver braces (Fig.FF). 26. Attach ends of safety cables w 's safety cables and w bar. 27. Install w bar mountg bracket accordg manufacturer's structions. BOLT TORQUE REQUIREMENTS Note: The rque values represented below are tended as general guideles. Torque requirements specific applications may vary. Roadmaster does not warrant this mation 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. ROADMASTER, INC. reserves right make changes at any time without notice material, specification and models or discontue models.