BASEPLATE KIT INSTALLATION INSTRUCTIONS

Transcription

1 Item Qty. Length Width Name Part No mm... 10mm... 10mm x 1.5 x 30mm mm... 10mm FENDER WASHER mm... 10mm x 1.5 NUT mm... 10mm LOCK WASHER "... 1/2"... BOLT /2"... FLAT WASHER /2"... LOCKWASHER /2"... NUT SAFETY CABLES, 8,000 lb. rated CONNECTORS DRAW PIN/SPRING PIN "... 2"... 1/4" BACKING PLATE... A " HOLE TEMPLATE... A

2 Item Qty Name Assembly C MAIN BRACE WELDMENT C DRIVER SIDE ARM WELDMENT C PASSENGER SIDE ARM WELDMENT 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 torqued for proper strength. If more than one bolt is used per tightening) unless otherwise instructed. All bolts must be torqued 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 Carton. ROADMASTER Limited Warranty, including One-Year Conditional Warranty Text Product Registration Card, in Carton. Failure to follow these instructions Failure can result to follow in property these damage, instructions can result in property damage, WARNING personal injury or even 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 mechanical installation 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 to read do so the could instructions result in loss use of the all towed bolts parts supplied. When the instructions require the reuse of factory bolts, thread Use Loctite lock /or Red lock on all washers bolts used must for also mounting be used. this Failure bracket. to securely fasten Do not the use bracket this document could result for custom in loss of fabrication, the towed as it may not show Do all parts not use or structural this document components. for custom Custom fabrication, fabrication as or it may an attempt not show to all copy parts this or bracket structural design components. could result Custom in loss fabrication of the towed or an attempt to copy Every this 3,000 bracket miles, design the owner could result must inspect loss of the the fasteners towed for proper Every torque, 3,000 according miles, to the owner bolt torque must requirements inspect the chart fasteners on the for last proper page torque, of these according instructions. to the The bolt owner torque must requirements also inspect chart all on the mounts last page of brackets these instructions. for cracks The or other owner signs must of also fatigue inspect every all mounts 3,000 miles. brackets Failure to for do so cracks could or result other in loss signs of of the fatigue towed every 3,000 miles. Failure The owner to do must so could check result the vehicle in loss of manufacturer's the towed instructions for The the proper owner must procedure(s) check the to vehicle prepare manufacturer's the vehicle for instructions towing. Some for the vehicles proper must procedure(s) be equipped to with prepare a transmission the vehicle lube for pump, towing. an axle Some disconnect, must driveline be equipped disconnect with or a free-wheeling transmission hubs lube pump, before an they axle can dis- be vehicles connect, towed. Failure driveline to properly disconnect equip or free-wheeling the vehicle will hubs cause before severe they damage can be towed. the transmission. Failure to properly equip the vehicle will cause severe damage to If running the transmission. changes were made by the vehicle manufacturer after this If bracket running was changes designed, were some made bolts by or the other vehicle fasteners manufacturer in the hardware after this bracket pack may was no designed, longer be some the correct bolts size. or other It is fasteners the installer s the responsibility may to verify no longer that the be bracket the correct is securely size. It is fastened the installer s to the vehicle responsi- hardware pack bility fitted with to verify the correct that the hardware bracket is to securely account for fastened these changes. to the vehicle Failure to fitted securely with fasten the correct the bracket hardware could to account result in for loss these of the changes. towed Failure to securely fasten the bracket could result in loss of the towed If If the the towed towed vehicle has has been been in in an an accident, it it must must be be properly repairepaired before before attaching the the bracket. Do Do not not install install the the bracket if if any any structural frame frame damage is is found. found. Failure Failure to to repair repair the the damage could could re- result result in in the the loss loss of of the the towed towed Some Some motorhome chassis have have such such a tight tight turning turning radius radius that that you you can can damage your your motorhome, towed towed vehicle, tow tow bar bar or or bracket while while turning turning sharply. Before getting on on the the road, road, test test your your turning radius radius in in an an empty empty parking lot. lot. Turning too too sharply could could result result in in non-warranty damage to to towing towing system, motorhome /or /or towed towed Do Do not not back back up up with with the the towed towed vehicle attached or or non-warranty damage will will occur occur to to your your towing towing system, motorhome /or /or towed towed The The safety safety cables cables must must connect the the towing vehicle to to the the towed towed vehicle frame frame to to frame, frame, with with the the cables cables crossed, with with enough slack slack for for sharp sharp turns. turns. Refer Refer to to the the cable cable instructions for for proper proper routing. Failure Failure to to leave leave enough enough slack slack in in the the safety safety cables, cables, or or failure failure to to connect connect the the safety safety cables cables frame frame to to frame, frame, will will result result in in the the loss loss of of the the towed towed This This bracket bracket is is designed for for use use with with ROADMASTER tow tow bars bars ROADMASTER adaptors only. only. Using Using this this bracket with with other other brs, without an an approved ROADMASTER adaptor, may may result result in in non- nonwarranty damage or or injury. injury. Upon Upon final final installation, the the installer must must inspect the the bracket to to ensursure adequate clearance, particularly around around hoses, hoses, air air conditioner en- lines, lines, radiators, etc., etc., or or non-warranty damage to to the the towed towed vehicle vehicle will will result. result. This This bracket bracket is is only only warranteed for for the the original installation. Installing a used used bracket bracket on on another another vehicle vehicle is is not not recommended will will void void the the warranty.

3 This bracket kit is one of our XL series, which is designed to be partly removable. The kit consists of a main receiver braces, two front braces a hardware pack. The main receiver brace mounts behind below the front bumper core to the front frame extensions the frame cross member just in front of the radiator. The front braces insert into the receiver brace on each side. Start by laying the kit out according to the illustration. This will give you a visual idea of how the kit installs also confirm that the kit components are present accounted for. Fig.A Fig.B 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 by removing the center splash panel located in front of the sway bar (Fig.C). Remove all the front fasteners in the fender well holding the splash panels to the front fender fascia (Fig.B). This should give you access to the back of the bumper fascia. 2. Remove the brush guard if the vehicle is so equipped (two bolts) on each side a fastener on each outer bar near the fender well (Fig.D). Fig.E Fig.F Fig.G 3. Unbolt the bumper on each side just forward of the fender well. These are cylindrical rubber isolation mounts accessible from the fender well (Fig.E). 4. Access the back of the bumper disconnect the fog light electrical connections as well as the vent tubes to each light (Fig.F). 5. Locate the washer bottle on the driver s side disconnect the headlight washer lines on the front pump. 6. Remove two nuts on each side of the aluminum frame extensions holding the steel bumper core (Fig.G). Pull forward set bumper aside. The entire front mounting area should now be exposed. All illustrations specifications contained herein are based on the latest information available at the time of publication approval. ROADMASTER, INC. reserves the right to make changes at any time without notice in material, specification models or to discontinue models.

4 Fig.H Fig.I Fig.J 7. Find four bolts holding the aluminum extensions the frame center brace to the front of the frame tubes. Unbolt these remove the Fig.K center brace the metric bolts. Ream the holes with a 17/32 drill bit through both sides of the frame tube. This will enlarge the holes slightly to fit the larger receiver mounting bolts. The brace will also replace the frame center brace (Fig.H). 8. Hold the brace to the bottom of the frame bolt through with four ½ x 5 bolts, flat washers, lock washers nuts. 9. Using the receiver brace center mount as a drill template, carefully drill a 17/32 hole up through the center frame member. Use caution in this area since it is close to the radiator. 10. Bolt through the cross member the brace using a ½ x5 bolt, flat washer, ¼" x 2" x 2" backing plate on top of the cross member, lock washer nut (Fig.H). 11. Torque the mounting bolts to the specifications below. 12. Using the included hole template, position as shown, mark cut holes in the bumper fascia to allow mounting the bumper over the receiver brace (Fig.I,J). Note: the large template outline, marked Top, Bottom Grille, is intended for positioning only, Use the inner outline to trim the fascia. 13. Bend the ends of the mesh grille back ½" on each end to fit between the braces (Fig.K) then fit the fascia reversing steps 4 through Reinstall the brush guard if present with the fresh 10mm x 1.5 x30mm bolts, fender washers, lock washers nuts provided. 15. Insert the front braces into the receiver tubes secure with 5/8 draw pins 1/8 spring pins. 16. Install the tow bar according to the manufacturer s instructions torque all mounting bolts to the specifications below. 17. Attach one end of the included 8 safety cables to the lower front hole in the side mounting plate on each side of the receiver brace with the included cable connectors. Connect the other end to the tow vehicle s safety cables the tow bar. 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 torque values represented below are intended as general guidelines. Torque requirements for specific applications may vary. Roadmaster does not warrant this information to 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. All illustrations specifications contained herein are based on the latest information available at the time of publication approval. ROADMASTER, INC. reserves the right to make changes at any time without notice in material, specification models or to discontinue models.

5 TOP This is the cut line Trim the fascia according to the dotted lines. GRILLE BOTTOM