instructions—instrucciones—consignes

INSTRUCTIONS—INSTRUCCIONES—CONSIGNES
APPLICATION: 2009-2010 DODGE RAM 1500 WINCH TRAY /GRILLE
GUARD COMBO
PART # 40-93545, 45-93540
AUTOMOTIVE PRODUCTS, INC.
ITEM
QUANTITY
DESCRIPTION
1
1
WINCH TRAY
19MM SOCKET
2
1
GRILLE GUARD
19MM WRENCH
3,4
2
LOWER MOUNTING BRACKET ASSEMBLY (3) DRIVERS SIDE,
(4) PASSENGER SIDE
5/8” SOCKET
5,6
2
LOWER FRAME REINFORCEMENT BRACKET (5) DRIVERS SIDE,
(6) PASSENGER SIDE
5/8” WRENCH
7,8
2
LOWER TRAY MOUNTING BRACKET (7) DRIVERS SIDE, (8)
PASSENGER SIDE
RATCHET
9,10
2
TORQUE WRENCH
11,12
2
UPPER FRAME MOUNT ASSEMBLY (9) DRIVERS SIDE, (10) PASSENGER SIDE
LOWER GRILLE GUARD MOUNTNG BRACKET (11) DRIVERS
SIDE, (12) PASSENGER SIDE
13,14
2
UPPER GRILLE GUARD MOUNTING BRACKET (13) DRIVERS
SIDE, (14) PASSENGER SIDE
15
1
CROSS BAR ASSEMBLY
16
2
LOWER FRAME MOUNT
17
14
M12 X 40MM HEX HEAD BOLTS
18
14
M12 HEX NUTS
19
12
M12 X 37MM FLAT WASHERS
20
14
M12 LOCK WASHERS
21
16
M12 X 24MM FLAT WASHERS
22
28
M12 X 40MM HEX HEAD BOLT (YELLOW ZINC)
23
28
M12 HEX NUTS (YELLOW ZINC)
24
2
M12 X 100MM HEX HEAD BOLTS (YELLOW ZINC)
25
2
7/16 X 2” HEX HEAD BOLTS (YELLOW ZINC)
26
4
M12 X 25MM HEX HEAD BOLT (YELLOW ZINC)
27
2
M12 X 37MM FLAT WASHERS (YELLOW ZINC)
28
88
M12 X 24MM FLAT WASHERS (YELLOW ZINC)
29
32
M12 LOCK WASHERS (YELLOW ZINC)
30,31
2
M12 DRILLED AND TAPPED PLATE ( 30) DRIVERS SIDE, (31 )
PASSENGER SIDE
Westin Automotive Products, Inc.
5200 N. Irwindale Ave. Ste 220
Irwindale, Ca 91706
1
TOOLS NEEDED
Thank You for choosing Westin products
For additional installation assistance please call
Customer Service (800)793-7846
75-1029 rev a 08/20/10
1.
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19.
Remove contents from box. Verify that all parts listed are present and free from damage. Read installation instructions carefully before
attempting installation.
This product requires the removal of the factory tow hook assemblies (if equipped) and the lower bumper grille cover.
Locate the two main bumper brackets that attach to the front of the vehicle frame. Starting at the driver side, remove the two 18MM hex
bolts that secure the bumper to the frame. The metal tab above the inside bumper stud must be flattened with a hammer. Due to the shape,
the tab will not be completely flat. Only the drive side must be modified. ( fig 3)
Attach one lower frame mount (ITEM 16) to the bumper studs. Secure only the outside stud with a factory 18MM hex nut. Leave the
inside stud unsecured for a future part attachment. ( fig 4)
Repeat steps 3 & 4 for the passenger side.
Slide the driver side lower mounting bracket (ITEM 3) through the bumper opening so that the lower mounting bracket cradles the previously installed lower frame mount. Remove the bumper plastic valance and place the lower drivers side grille guard bracket ( ITEM 11)
on the outside of the previously placed brackets( NOTE: THE PLASTIC VALANCE MUST BE REMOVED OR TRIMMED TO
FIT THE LOWER GRILLE GUARD MOUNTING BRACKETS). Secure the two upright flanges and the lower grille guard mounting bracket with four M12 x 40MM hex bolts (ITEM 22), eight M12 flat washers (ITEM 28), four M12 lock washers (ITEM 29), and
four M12 hex nuts (ITEM 23). Do not fully tighten at this time. ( fig 5, 6, and 7)
Repeat step 6 for the passenger side lower mounting bracket ( ITEM 4) and passenger lower grille guard mounting bracket (ITEM 12) .
Insert the driver side M12 drilled & tapped plate (ITEM 30) through the top opening of the driver side tow hook tower. Make sure the
holes on the plate align with the holes on the inside of the tower. (fig 8, and 9)
Attach the driver side upper frame mount (ITEM 9) to the inside of the driver frame rail. Align the lower hole on the most forward flange
onto the lower inside bumper stud. Secure with the Factory 18MM hex nut. Secure only the top rear slot in the upper frame mount to the
installed M12 drilled & tapped plate with one M12 x 25mm hex bolts (ITEM 26), two M12 flat washers (ITEM 28)(TWO STACKED
PER BOLT), and one M12 lock washers (ITEM 29). The top hole at the most front flange is unused in most cases. If the vehicle front
bumper has a top mounting stud, the bracket can be secured with such. Do not fully tighten at this time (fig 10)
Repeat steps 8 & 9 to attach the passenger side upper frame mount (ITEM 9). (fig 11, and 12)
Attach the driver side lower frame reinforcement bracket (ITEM 5) to the bottom of the tow hook tower and lower mounting bracket.
Secure to the tow hook tower with one 7/16” x 2” hex bolt (ITEM 25), one M12 large O.D. flat washer (ITEM 27), and one M12 lock
washer (ITEM 29). Secure to the lower mounting bracket with two M12 x 40MM hex bolts (ITEM 22), four M12 flat washers (ITEM
28), two M12 lock washers (ITEM 29), and two M12 hex nuts (ITEM 23). Secure to the upper frame mount lower rear slot with one M12
x 25MM hex bolt (ITEM 26), two M12 flat washers (ITEM 28)(TWO STACKED PER BOLT), and one M12 lock washer (ITEM 29).
Do not fully tighten at this time. ( fig 13, and 14)
Repeat step 11 for the passenger side lower frame reinforcement bracket (ITEM 6). (fig 15)
From below the vehicle, attach the cross bar assembly (ITEM 15) the attachment flanges on each upper frame mount. Secure with two
M12 x 100MM hex bolts (ITEM 24), four M12 flat washers (ITEM 28), two M12 lock washers (ITEM 29), and two M12 hex nuts
(ITEM 23). Do not fully tighten at this time. ( fig 16, and 17)
Insert each lower tray mounting bracket (ITEM 7, 8) from behind the bumper and through the bumper opening. Each bracket mount to
the inside flange of the cross bar assembly. Secure to the cross bar with four M12 x 40MM hex bolts (ITEM 22), eight M12 flat washers
(ITEM 28), four M12 lock washers (ITEM 29), and four M12 hex nuts (ITEM 23) for each bracket. Do not fully tighten at this time.( fig
18, and 19)
At this time attach the winch tray assembly (ITEM 1) to the mounting brackets. Secure the winch tray to the lower center brackets with
four M12 x 40MM hex bolts (ITEM 22), eight M12 flat washers (ITEM 28), four M12 lock washers (ITEM 29), and four M12 hex nuts
(ITEM 23). Secure the bottom two slots on each side mounting bracket with two M12 x 40MM hex bolts (ITEM 22), four M12 flat washers (ITEM 28), two M12 lock washers (ITEM 29), and two M12 hex nuts (ITEM 23). Secure the side flanges and the upper grille guard
mounting brackets to the side mounting brackets with six M12 x 40MM hex bolts (ITEM 17), twelve M12 flat washers (ITEM 21), six
M12 lock washers (ITEM 20), and six M12 hex nuts (ITEM 18). (fig 20, 21, and 22)
With help align the grille guard with the upper and lower grille guard mounting brackets, the upper grille guard mounting brackets go
inside the uprights of the grille guard and attach with two M12 x 40MM hex head bolts (ITEM 17), two M12 lock washers ( ITEM 20),
four M12 flat washers (ITEM 21), and two M12 hex nuts (ITEM 18). Do not fully tighten at this time. (fig 23, and 24)
Attach the grille guard to the lower mounting brackets with six M12 x 40MM hex head bolts (ITEM 17), six M12 lock washers (ITEM
20), twelve M12 flat washers (ITEM 19), and 6 M12 hex nuts (ITEM 18). Do not fully tighten at this time. (fig 25)
Install a winch to the tray to the manufacturers specific instructions
Align all brackets and winch tray as desired and tighten all fasteners. Tighten the four 18MM bumper hex nuts to 45-50 lbs-ft, tighten
M12 fasteners to 40-45 lbs-ft, and tighten 7/16” fasteners to 30-35 lbs-ft.
2
75-1029 rev a 08/20/10
FIGURE 1
FIGURE 2
FLATTEN FRAME TAB
LOCATION OF 18MM
FACTORY NUTS
3
FIGURE 3
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LEAVE INSIDE STUDS UNSECURED AT
THIS STEP
FIGURE 4
FIGURE 5
FIGURE 6
4
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FIGURE 7
ALIGN HOLES
FIGURE 8
FIGURE 9
FACTORY 18MM NUT
26
28
28
29
FIGURE 10
5
FIGURE 11
75-1029 rev a 08/20/10
FACTORY 18MM NUT
26
28
28
29
FIGURE 12
25
26
28
27
29
28
FIGURE 13
29
26
22
22
28
28
29
23
28
28
28
29
25
27
29
28
29
23
FIGURE 15
FIGURE 14
FIGURE 16
6
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24
28
28
29
23
FIGURE 17
FIGURE 18
22
28
28
29
23
FIGURE 19
7
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FIGURE 20
22
28
28
23
29
FIGURE 21
17
20
21
21
18
FIGURE 22
8
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FIGURE 23
17
20
21
21
18
FIGURE 24
17
20
19
19
18
FIGURE 25
9
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AUTOMOTIVE PRODUCTS, INC.
Irwindale, California
WARNINGS & NOTICES
FOR THE INSTALLATION OF
MAX WINCH TRAY & SPORTSMAN—WINCH MOUNTS
NOTICE
Westin Max Winch Trays are designed to accommodate a winch bolt pattern of 10” X 4.5”. Closely
follow all Westin Installation Instructions for the proper installation of product. Improper installation can result in death, serious injury, and/or product and vehicle damage. In the operation of
these products, it is imperative to observe precautions for your personal safety and the safety of
others.
WARNING
Failure to follow these instructions could lead to death, personal injury, and / or property damage.
FASTENERS:
All Westin supplied fasteners must be utilized and installed in accordance with the installation instructions
and apply torque to the specifications as defined. DOUBLE CHECK ALL FASTENERS BEFORE
PRODUCT USE TO ENSURE PROPER FUNCTION AND SAFETY.
DRILLING:
Most Westin products do not require drilling for installation. If drilling is defined as required, use caution
when drilling a vehicle.
FAILURE TO REVIEW AN AREA TO BE DRILLED MAY RESULT IN
PERSONAL INJURY AND OR INJURY TO OTHERS AS WELL AS VEHICLE DAMAGE.
EYE PROTECTION:
ALWAYS WEAR SAFETY GLASSES OR GOGLES DURING THE INSTALLATION PROCESS TO
AVOID PERSONAL INJURY.
TOW HOOKS—TOW ATTACHMENT:
During product use, Tow Straps, Tow Cables, and Tow Hooks must only be attached to the Westin Tow
Hook Loops as attached to the Max Winch Tray, (sold separately). DO NOT ATTACH TO ANY OTHER
AREA OR SERIOUS PERSONAL INJURY OR INJURY TO OTHERS MAY OCCUR.
WINCH SIZING & MAX WINCH TRAY CAPACITY:
The Max Winch Tray is designed for a maximum Winch size rating of 12,000 Lbs. Use of Winch size ratings above this limit will void the Westin warranty and MAY RESULT IN PERSONAL INJURY AND OR
INJURY TO OTHERS AS WELL AS VEHICLE DAMAGE.
Westin Automotive Products, Inc.
5200 N. Irwindale Ave. Ste 220
Irwindale, CA 91706
10
Thank You for choosing Westin products
For additional installation assistance please call 1
-800-345-8476
Customer Service (800)793-7846
75-1029 rev a 08/20/10
AUTOMOTIVE PRODUCTS, INC.
Irwindale, California
AVISOS Y ADVERTENCIAS
PARA LA INTALACIÓN DE
LA BANDEJA DE TORNO MAX Y MONTAJES DE LA BANDEJA SPORTSMAN
AVISO
Las bandejas de torno Westin Max estan diseñadas para caber a un diseño de perno de torno de
10” X 4.5”. Siga de cerca todas las instrucciones de instalación Westin para la instalación
adecuada del producto. La intalación inadecuada podria ocacionarle la muerte, leciones severas, y
o daño al producto y el vehiculo. Para la el funcionamiento de este producto, es imprescindible observar precauciones para su propia seguridad y para la seguridad de otros.
ADVERTENCIA
No seguir estas instrucciones podria llevarlo a la muerte, sufrir una leción personal, y o daño a la
propiedad.
SUJETADORES:
Todos los sujetadores suministrados Westin deben ser utilizados e instalados de acuerdo a las instrucciones de instalación y aplicar la torsión como lo define las especificasiones.PARA ASEGURARSE DEL FUNCIONAMIENTO Y SEGURIDAD ADECUADA HAGA UNA COMPARACIÓN MINUCIOSA A TODOS LOS SUJETADORES ANTES DE UTILIZAR EL PRODUCTO.
PERFORACIÓN:
La mayoria de los productos Westin no se le require perforación para la intalación. Si se le difine perforar como requisito, tenga precaución al
perforar un vehiculo. NO REVISAR UNA AREÁ QUE TENGA QUE PERFORAR PODRIA OCACIONARLE UNA LECION PERSONAL Y O
LECIONES A OTRS A LO IGUAL QUE DAÑO AL VEHICULO.
PROTECCIÓN OCULAR:
SIEMPRE UTILIZE LENTES PROTECTORES DURANTE EL PROCESO DE INSTALACIÓN PARA EVITAR LECIONES PERSONALES.
GANCHOS DE REMOLQUE—ACCESORIO DE REMOLQUE:
Durante el uso del producto, correas de remolque, cables de remolque, y ganchos de remolque solo deben de ir sujetados a los lazos del
gancho de remolque Westin mientras sujetados a la bandeja de torno Max, (se vende por separado).NO SUJETE A NINGUNA OTRA
AREA POR QUE LE PUEDE OCACIONAR LESIONES PERSONALES SEVERAS O LECIONES A OTROS.
CALIBRADO DE TORNO Y CAPACIDADA DE LA BANDEJA DE TORNO:
La bandeja de torno Max esta diseñada para un grado de tamaño de torno maximo de 12,000 Lbs. El de un torno de grado superior a este
limite le anulara la garantia Westin y LE PODRIA OCACIONAR LECIONES PERSONALES O LECIONES A OTROS A LO IGUAL QUE
DAÑOS AL VEHICULO.
11
75-1029 rev a 08/20/10
AUTOMOTIVE PRODUCTS, INC.
Irwindale, California
MISES EN GARDE & NOTICES
POUR L’INSTALLATION DE
PLATINE DE TREUIL MAX & SPORTSMAN— SUPPORTS DE
TREUIL
NOTICE
Les platines de treuil Max de Westin sont conçues pour s’adapter à un modèle de treuil à boulon
de 10” X 4.5”. Suivre soigneusement toutes les instructions d'installation Westin pour une installation correcte du produit. Une installation incorrecte peut conduire à la mort, à de sérieuses blessures et/ou des dégâts au produit et au véhicule. Pendant le fonctionnement de ces produits, il est
impératif d'observer des précautions pour votre sécurité personnelle et la sécurité d’autrui.
MISE EN GARDE
Le non-respect de ces instructions pourrait conduire à la mort, à des blessures personnelles et / ou des dommages matériels.
FIXATIONS :
Toutes les fixations Westin fournies doivent être utilisées et installées conformément aux instructions d’installation et les spécifications des
couples de serrage doivent être appliquées comme défini. VERIFIER ET REVERIFIER TOUTES LES FIXATIONS AVANT L’UTILISATION
DU PRODUIT POUR S’ASSURER DE SON BON FONCTIONNEMENT ET DE SA SECURITE.
PERCAGE :
La plupart des produits Westin ne nécessitent pas de perçage pour l'installation. Si le perçage est nécessaire, faire preuve de prudence lors
du perçage d’un véhicule.
LE NON-RESPECT DE PASSER EN REVUE UN ENDROIT A ETRE PERCE PEUT CONDUIRE A DES
BLESSURES PERSONNELLES ET OU DES BLESSURES A AUTRUI AINSI QU’A DES DEGATS AU VEHICULE.
PROTECTION DES YEUX :
TOUJOURS PORTER DES LUNETTES DE PROTECTION OU DE SECURITE DURANT L’INSTALLATION POUR EVITER DES BLESSURES PERSONNELLES.
CROCHETS DE REMORQUAGE — ACCESSOIRE DE REMORQUAGE :
Pendant l'utilisation du produit, les sangles de remorquage, les câbles de remorquage et les crochets de remorquage doivent uniquement être
fixés aux boucles de crochet de remorquage Westin tel que fixés à la platine de treuil Max (vendue séparément). NE PAS FIXER A UN AUTRE ENDROIT OU DES BLESSURES PERSONNELLES SERIEUSES OU DES BLESSURES A AUTRUI POURRAIENT SE PRODUIRE.
DIMENSION DE TREUIL & CAPACITE PLATINE DE TREUIL MAX :
La platine de treuil Max est conçue pour une taille maximale de treuil de 12’000 livres. L'utilisation de taille de treuil supérieure à cette limite
annulera la garantie Westin et POURRAIT CONDUIRE A DES BLESSURES PERSONNELLES ET OU DES BLESSURES A AUTRUI AINSI
QU’A DES DEGATS AU VEHICULE.
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