MOUNTING BRACKET KIT INSTALLATION

MOUNTING BRACKET KIT INSTALLATION
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MOUNTING BRACKET KIT
INSTALLATION INSTRUCTIONS
ROADMASTER, Inc.
6110 NE 127th Ave.
Vancouver, WA 98682
PARTS LIST:
1- FRONT BRACE (A) - Passenger side
1- FRONT BRACE (B) - Driver’s side
1- MAIN BRACE (C) - Passenger side
1- MAIN BRACE (D) - Driver’s side
1-800-669-9690
fax 360-735-9300
www.roadmasterinc.com
KIT NO. 199-5
07/18/07
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
ROADMASTER Limited Warranty, including One-Year Conditional Warranty Text and Product Registration Card, in Carton.
WARNING
Failure to follow these instructions
can result in property damage, 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 to do so could result in loss of the towed vehicle.
• Use Loctite® Red on all bolts used for mounting this bracket.
• 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.
• 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.
• 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 non-warranty damage
or injury.
• 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.
R
1-800-669-9690
O
A
D
M
A
S
T
E
R
MOUNTING BRACKET KIT
INSTALLATION INSTRUCTIONS
ROADMASTER, Inc.
6110 NE 127th Ave.
Vancouver, WA 98682
1-800-669-9690
fax 360-735-9300
www.roadmasterinc.com
KIT NO. 199-5
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. This bracket kit is one of our XL series, which is designed to be partly
removable. The kit consists of two main receiver braces, front braces and a hardware pack. The main receiver braces mount
below the front bumper fascia to the front frame tubes and frame cross member. 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 and
also confirm that the kit components are present and accounted for.
2. To gain access to the mounting area, remove the front grille and bumper.
3. Locate the front tow hooks in the frame tubes and remove. The front of the receiver braces will utilize this mounting area.
Note: retain the front tow hooks and attachment hardware for replacement if the bracket is ever removed.
4. Insert a ¼” x 3” x 3” backing plate in the front of each frame tube so that the hole lines up with the existing hole in the bottom
of each frame tube. The hole in the backing plate is closer to the front of the plate then the back, install with the front forward.
Hold a receiver brace to the bottom of the front frame tube and bolt in place using two ½” nuts and lock washers. Install the
remaining receiver brace then tighten to hold the positioning.
5. Bolt through the sides of the receiver braces and frame tubes with ½” x 1¼” bolts, flat washers, lock washers and nuts. Be
sure to use flat washers on the inside of the frame tubes. Note: due to manufacturing variances, the frame holes may need to
be enlarged using a die grinder.
6. Install the front braces and pin in position. Check the front alignment across the mounting face, adjust if needed then tighten
all mounting bolts to maintain alignment.
7. Using the receiver braces as drilling templates, drill a 17/32” hole through each side of the front frame cross member.
8. Bolt through the frame cross member and receiver braces on each side with a ½” x 1½” carriage bolt, ¼” x 1½” x 2½” sq.
holed backing plate, lock washer and nut. Be sure to use the backing plate inside the subframe. A large access hole in the
front of the subframe on each side will provide the needed access.
9. Torque all mounting bolts to the specifications below.
10. Remove the front braces from the receiver tubes and reinstall the bumper and grille. Note: some models may have plastic
inserts around the tow hooks, trim or remove these plastic inserts.
11. Install the front braces and secure with 5/8” draw pins and 1/8” spring pins.
12. Install the tow bar according to the manufacturer’s instructions and torque all mounting bolts to the specifications below.
13. Attach one end of the included 10” safety cables to the 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 and the tow bar.
Note: if the bracket is so equipped, the holes in the alignment tabs which are welded to the arms and main receiver braces
are for padlocks only. Under no circumstances should you bolt the alignment tabs together. Bolting the alignment tabs together
may result in non-warranty damage to the bracket.
07/18/07
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 and disclaims all liability for any claims or damages which may result from its use.
METRIC BOLTS
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.
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.
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.
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.
R
1-800-669-9690
O
A
D
M
A
S
T
E
R
MOUNTING BRACKET KIT
INSTALLATION INSTRUCTIONS
ROADMASTER, Inc.
6110 NE 127th Ave.
Vancouver, WA 98682
1-800-669-9690
fax 360-735-9300
www.roadmasterinc.com
KIT NO. 199-5
Hardware Kit
2- ½” x 1-1/2” carriage bolts
4- ½” x 1-1/4” bolts
2- ¼” x 1-1/2” x 2-1/2” sq. hole backing plates
8- ½” lock washers
8- ½” nuts
2- 10” safety cables, 8,000 lb. rated
2- cable connectors
2- 5/8” draw pins
2- 1/8” spring pins
2- ¼” x 3 x 3 backing plates
4- flat washers
07/18/07
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 and disclaims all liability for any claims or damages which may result from its use.
METRIC BOLTS
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.
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.
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.
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.
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