Installation Instructions - Roadmaster Inc.

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Transcript

KIT# 1185-1
07/27/15
KS
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ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 360-896-0407 fax 360-735-9300 www.roadmasterinc.com
MOUNTING BRACKET KIT
INSTALLATION INSTRUCTIONS
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ITEM QTY NAME MATERIAL
1...........2...........12mm x 1.25 x 35mm BOLT ............................................................ 357002-00
2...........2...........12mm LOCK WASHER .................................................................... 355725-00
3...........2...........1/2" x 2" BOLT .................................................................................. 350097-00
4...........2...........1/2" LOCK WASHER ....................................................................... 350309-00
5...........2...........1/2" HEX NUT .................................................................................. 350258-00
6...........2...........3/8" x 4" BOLT .................................................................................. 350067-00
7...........4...........3/8" x 1 1/2" FENDER WASHER ..................................................... 350305-10
8...........2...........1/2" PLATE WASHER ...................................................................... 350351-00
9...........2...........3/8" LOCK WASHER ....................................................................... 350305-00
10.........2...........3/8" HEX NUT .................................................................................. 350254-00
11 .........2...........SAFETY CABLES 12" ...................................................................... 650648-12
12.........2...........3/8" QUICK LINK ............................................................................. 200008-00
13.........2...........5/8" PIN W/ CLIP.............................................................................. 357035-00
14.........2...........BACKING PLATE 3/16" x 2" x 2" .....................................................A-001066
15.........2...........BACKING PLATE 3/16" x 1 1/2" x 2 1/2" .........................................C-001405
16.........1...........DRIVER SIDE ARM .........................................................................C-001403
17.........1...........PASSENGER SIDE ARM.................................................................C-001404
18.........1...........DRIVER SIDE RECEIVER ...............................................................C-001502
19.........1...........PASSENGER SIDE RECEIVER ......................................................C-001503
KIT# 1185-1
07/27/15
KS
Fig.A
Fig.B
This is one of our XL series brackets, which allows the visible front portion of the bracket to be easily removed from
the front of the vehicle (Fig.A and Fig.B). The
bracket kit consists of a passenger and driver
side main receiver brace, two removable front
braces and a hardware pack. The main receiver braces mount to the frame rails and the tow
hooks, the removable front braces install in the
main receiver braces.
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.
MOUNTING BRACKET KIT
INSTALLATION INSTRUCTIONS
ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 360-896-0407 fax 360-735-9300 www.roadmasterinc.com
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 torqued 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
• 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 to do so could result in loss of the towed vehicle.
• Use Loctite® Red on all bolts used for mounting this bracket.
• Every 3,000 miles, the owner must inspect the fasteners for proper
torque, according to the bolt torque requirements chart on the last page
of these instructions. The owner must also inspect all mounts and
brackets for cracks or other signs of fatigue every 3,000 miles.
Failure to do so could result in loss of the towed vehicle.
• The owner must check the vehicle manufacturer's instructions for
the proper procedure(s) to prepare the vehicle for towing. Some
vehicles must be equipped with a transmission lube pump, an axle disconnect, driveline disconnect or free-wheeling hubs before they can be
towed. Failure to properly equip the vehicle will cause severe damage
to the transmission.
• If running changes were made by the vehicle manufacturer after this
bracket was designed, some bolts or other fasteners in the hardware
pack may no longer be the correct size. It is the installer’s responsibility to verify that the bracket is securely fastened to the vehicle and
fitted with the correct hardware to account for these changes. Failure to
securely fasten the bracket could result in loss of the towed vehicle.
• If the towed vehicle has been in an accident, it must be properly repaired before attaching the bracket. Do not install the bracket if any
structural frame damage is found. Failure to repair the damage could
result in the loss of the towed vehicle.
ROADMASTER Limited Warranty, including One-Year Conditional Warranty Text and Product Registration Card, in Carton.
• Roadmaster manufactures many styles of brackets. If your bracket
has removable arms, they must be removed before driving the
vehicle, unless the arms can be pinned or padlocked in place.
If not secured, the arms could vibrate out, resulting in non-warranty
damage or personal injury.
• Some motorhome chassis have such a tight turning radius that you can
damage your motorhome, towed vehicle, tow bar or bracket while turning
sharply. Before getting on the road, test your turning radius in an
empty parking lot. Turning too sharply could result in non-warranty
damage to towing system, motorhome and/or towed vehicle.
• Do not back up with the towed vehicle attached or non-warranty
damage will occur to your towing system, motorhome and/or towed
vehicle.
• The safety cables must connect the towing vehicle to the towed
vehicle frame to frame, with the cables crossed, with enough slack
for sharp turns. Refer to the cable instructions for proper routing.
Failure to leave enough slack in the safety cables, or failure to connect
the safety cables frame to frame, will result in the loss of the towed
vehicle.
• This bracket is designed for use with ROADMASTER tow bars and
ROADMASTER adaptors only. Using this bracket with other brands,
without an approved ROADMASTER adaptor, may result in nonwarranty damage or injury.
• Do not use this document for custom fabrication, as it may not show
all parts or structural components. Custom fabrication or an attempt to
copy this bracket design could result in loss of the towed vehicle.
• Upon final installation, the installer must inspect the bracket to ensure adequate clearance, particularly around hoses, air conditioner
lines, radiators, etc., or non-warranty damage to the towed vehicle
will result.
• This bracket is only warranteed for the original installation. Installing
a used bracket on another vehicle is not recommended and will void
the warranty.
Failure to follow these instructions
can result in property damage,
personal injury or even death.WARNING
KIT# 1185-1
07/27/15
KS
Fig.C Fig.D Fig.E
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. Starting on the passenger side, remove four 14mm (head)
nuts attaching the bumper core to the frame rail (Fig.C). One is located on the inside of the vehicle (Fig.D). The remaining
three are located on the opposite side toward the outside of the vehicle (Fig.E). Note: due to manufacturing variances, the
nuts may be bolts instead.
Fig.G Fig.HFig.F
2. Next, place one of the main receiver braces over the studs you removed the nuts from in the previous step (Fig.F).
Now, replace the four nuts (Fig.G,H) and tighten to the torque specifications listed at the end of these instructions.
3. Using the supplied 12mm x 1.25 x 35mm bolt and lock washer, bolt through the lower side hole in the main receiver
brace and into the factory weld nut in the frame (Fig.I).
4. Now, bolt the main receiver brace to the tow hook. Place the 3/16" x 1½" x 2½" backing plate with spacer on the back
side of the tow hook. Bolt into place using the supplied ½" x 2" bolt, lock washer and nut (Fig.J).
Fig.I Fig.K
5. Using the upper hole in the side of the main receiver brace as a template, drill through the side of the frame rail using
a ½" drill (Fig.K). Note: use caution not to drill through any engine components which may be on the other side.
Fig.J
MOUNTING BRACKET KIT
INSTALLATION INSTRUCTIONS
ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 360-896-0407 fax 360-735-9300 www.roadmasterinc.com
'06-'07 Lexus GX470 and '06-'15 Toyota 4Runner
This bracket kit fits the 2006-2007 Lexus GX470, and 2006-2015 Toyota 4Runner models. Follow the instructions below
for the 2006-2007 Lexus GX470 and the 2006-2009 Toyota 4Runner; for 2010-2015 Toyota 4Runner installations, see the
separate section included in these instructions.
one on
this side
three on
this side inside location
outside location
backing plate
with spacer
KIT# 1185-1
07/27/15
KS
All illustrations and 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 and models or to discontinue models.
6. Now, bolt through the hole in the main receiver brace and the hole you drilled through the frame rail using a 3/8" x 4"
bolt, fender washer and plate washer (the fender washer goes on the outside of the main receiver brace, the plate washer
goes between the main receiver brace and the frame rail — Fig.L). Finish with a 3/16" x 2" x 2" backing plate and 3/8" flat
washer, lock washer and nut (on the opposite side of the frame rail — Fig.M).
7. Repeat steps 1 through 6 for the driver side of the vehicle.
8. Tighten all bolts to the torque specifications listed at the end of these instructions, starting with the 14mm (head) nuts.
9. Fit the removable front braces into the front receiver braces, and secure them in place with the supplied 5/8" draw
pins and spring pins (Fig.N).
10. Attach the 12" safety cables with the cable connectors (Q-Links) to the front of the receiver braces (Fig.N).
11. Attach the ends of the safety cables to the tow vehicle's safety cables and tow bar.
12. Install the tow bar to the mounting bracket according to the manufacturer's instructions.
Fig.M Fig.NFig.L
BOLT TORQUE REQUIREMENTS
METRIC BOLTS
Thread Size Grade Plated / Unplated
12mm-1.25 ........8.8 ............70 ft./lb. 65 ft./lb.
12mm-1.5 ..........8.8 ............66 ft./lb. 61 ft./lb.
12mm-1.75 ........8.8 ...........65 ft./lb. 60 ft./lb.
14mm-2.0 ..........8.8 .........104 ft./lb. 97 ft./lb.
METRIC BOLTS
Thread Size Grade Plated / Unplated
8mm-1.0 ............8.8 ............20 ft./lb. 18 ft./lb.
8mm-1.25 .........8.8 ............19 ft./lb. 18 ft./lb.
10mm-1.25 ........8.8 ...........38 ft./lb. 36 ft./lb.
10mm-1.5 ..........8.8 ...........37 ft./lb. 35 ft./lb.
STANDARD BOLTS
Thread Size Grade Torque
5/16..................... 5 ........................... 13 ft./lb.
3/8....................... 5 ........................... 23 ft./lb.
7/16..................... 5 ........................... 37 ft./lb.
1/2....................... 5 ........................... 56 ft./lb.
5/8....................... 5 ......................... 150 ft./lb.
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 and disclaims all liability for any claims or damages which may result from its use.
MOUNTING BRACKET KIT
INSTALLATION INSTRUCTIONS
ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 360-896-0407 fax 360-735-9300 www.roadmasterinc.com
outside of
frame rail
KIT# 1185-1
07/27/15
KS
MOUNTING BRACKET KIT
INSTALLATION INSTRUCTIONS
ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 360-896-0407 fax 360-735-9300 www.roadmasterinc.com
1. Remove four plastic fasteners attaching the air intake ducting to the rock guard (Fig.A)
2. Remove five 10mm (head) bolts attaching the center splash shield to the bottom of the fascia, and three 10mm (head)
bolts attaching the center splash shield to the rock guard (Fig.B). Note: due to manufacturing variances, there may be
three 10mm (head) bolts in the back and two in the front, along with one plastic fastener.
Fig.A Fig.B
Fig.D
3. On each side, remove four 10mm (head) bolts attaching the outer splash shield to the bottom of the fascia (Fig.C —
driver's side).
4. On each side, remove four 14mm (head) bolts attaching the bumper core to the frame rail.
5. Complete steps 2 through 8 in the main installation instructions and then return to step 6 in this supplement.
6. Now, trim the rear splash shield using the yellow lines in Figure D as a guide for trimming.
Fig.C
All illustrations and 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 and models or to discontinue models.
Supplemental Instructions for '06-'07 Lexus GX470 and '06-'15 Toyota 4Runner
KIT# 1185-1
07/27/15
KS
Fig.G
MOUNTING BRACKET KIT
INSTALLATION INSTRUCTIONS
ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 360-896-0407 fax 360-735-9300 www.roadmasterinc.com
7. If your center splash shield looks like Figure
E: use the yellow lines as a guide for trimming. If your
center splash shield looks like Figure F: use the yellow
lines as a guide for trimming.
8. Trim the fascia using the yellow lines in Figure G as a
guide for trimming.
9. Fit the removable front braces into the front receiver
braces, and secure them in place with the supplied 5/8"
draw pins and spring pins.
10. Attach the 12" safety cables with the cable connectors (Q-Links) to the front of the receiver braces.
11. Attach the ends of the safety cables to the tow vehicle's safety cables and tow bar.
12. Install the tow bar to the mounting bracket according
to the manufacturer's 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 to make changes at any time without notice in material, specification and models or to discontinue models.
BOLT TORQUE REQUIREMENTS
METRIC BOLTS
Thread Size Grade Plated / Unplated
12mm-1.25 ........8.8 ............70 ft./lb. 65 ft./lb.
12mm-1.5 ..........8.8 ............66 ft./lb. 61 ft./lb.
12mm-1.75 ........8.8 ...........65 ft./lb. 60 ft./lb.
14mm-2.0 ..........8.8 .........104 ft./lb. 97 ft./lb.
METRIC BOLTS
Thread Size Grade Plated / Unplated
8mm-1.0 ............8.8 ............20 ft./lb. 18 ft./lb.
8mm-1.25 .........8.8 ............19 ft./lb. 18 ft./lb.
10mm-1.25 ........8.8 ...........38 ft./lb. 36 ft./lb.
10mm-1.5 ..........8.8 ...........37 ft./lb. 35 ft./lb.
STANDARD BOLTS
Thread Size Grade Torque
5/16..................... 5 ........................... 13 ft./lb.
3/8....................... 5 ........................... 23 ft./lb.
7/16..................... 5 ........................... 37 ft./lb.
1/2....................... 5 ........................... 56 ft./lb.
5/8....................... 5 ......................... 150 ft./lb.
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 and disclaims all liability for any claims or damages which may result from its use.
Fig.FFig.E

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