Demco TI110SB User's Manual
Contents
1. 3 8 16UNC x 2 3 4 Hex Head Bolt gr 5 07176 3 8 16UNC Stover Lock Nut l p aN SS 05684 1 2 13UNC x 4 7 16 Hex Head Bolt gr 5 Fulton Le Y 8 02178 1 2 13UNC Nylon Insert Lock Nut 6000 Ib gt o e en NO e 05959 Push Rod Assembly coupler L lt yen we 05692 Damper Shock 05958 95 Rear Roller Spacer 05951 Emergency Lever 05955 95 Front Cover SB24700 2 Cable with S Hooks SB10555 Replacement S Hook ONLY 05960 5 16 18UNC x 1 2 Self Tapping Screw 05424 5 16 External Tooth Lock Washer 05693 95 Emergency Lever Spring 03876 Master Cylinder Cap 01076 1 4 20UNC x 3 4 Hex Head Bolt Gr 5 00057 1 4 Lock Washer 03564 95 Outer Case 05681 Replacement Master Cyl Gasket ONLY 5650 Composite Master Cylinder Kit w 09153 SB12098 1 8 pipe 3 16 inverted Flare Fitting 05695 1 4 Internal Tooth Lock Washer 05966 95 Rear Cover BH21004 Decal Preset Fasteners DA66 ACTUATOR PARTS REPLACEMENT ONLY 5398 Master Cylinder Repair Kit gasket 05681 included Lever Replacement Kit incl items wi 5398 Master Cylinder Repair Kit w gasket 5495 Coupler Repair Kit DA603 BRAKE ACTUATOR PARTS BREAKDOWN Components not sold separately 5695 Emergency Lock Cam Replacement Kit Hem 23 includes cable 10 ltem 10 is not included in 5696 1885 5398 Master Cylinder Repair Kit drum gasket 09153 included 5696 Coupler Repair Kit 2i lever lock ACTUATOR PARTSLIST Components not so2. Ibs Lay the bracing struts 29 out along the tow dolly tongue with the back end the end with the larger hole in it of the bracing strut toward the mainframe Loosely bolt the back of each bracing strut to the trailer frame as shown using 1 2 x 1 1 2 grade 5 bolt 30 flatwasher 37 pivot bushing 32 and locknut 33 Hold up the front end the end with the smaller hole of each bracing strut to the tongue align holes and secure with a two 5 8 x 1 1 4 epoxied bolt 34 Torque the 1 2 x 1 1 2 bolt with the pivot bushing to 75 ft Ibs 14 Attach the two 24 transport safety chains 35 to the two holes in the angle located under the tongue using two 7 16 x 1 1 4 grade 5 bolts 36 flatwashers 37 and locknuts 38 Torque bolts to 50 ft lbs WIRING OF THE TOWING VEHICLE Connect wiring to towing vehicle keeping in mind the color code indicated below 1 Make certain towing vehicle lights are OFF 2 Connect YELLOW wire to left turn signal and stop wire in the left rear of towing vehicle with the wire splicer 01883 X supplied 3 Connect GREEN wire to the right turn signal and stop wire 4 Connect BROWN wire to tail light wire 5 VERY IMPORTANT connect WHITE wire to frame body of towing vehicle This is the common ground and aclean metal to metal contact must be made CAUTION Many flashers for vehicle turn signals will not carry the additional load of TOW IT turn signals If normal o
3. mately 1 1 2 2 from the winch Refer to drawing on page 9 for following steps Attach Hub and Spindle Assembly 79 using 7 16 x 1 1 4 Fine Thread Bolts 20 and hex nuts Bolt the fenders 21 on using 3 8 x 1 1 2 gr 5 bolts 22 back up plates 23 and locknuts 24 in each fender Mount the fender with the light pocket to the rear Attach the white ground wire 25 the end with the eye loop on it under the center top bolt head it is advantageous to wire the fender lights prior to attaching the wheels Cut off stripped ends of the wiring harness cut off stripped end of the white ground wire The yellow brown wires must be run to the left tail light pocket The green brown wires must be run to the right tail light pocket Start at either fender pull the loom at the center of the fender downward and push the green brown or yellow brown wires upward through the loom until itcomes out the loom by the light pocket Push the white ground wire through the slit in the top of the loom in the fender trough and push the wire toward the light pocket 10 Make sure all three wires are coming out the fender wire loom Slide the rubber fender grommet over the wires and up close to the wire loom Push the hollow looped end of the loom hanger into the small hole under the fender pocket in the side of the fender Leave the holder open Pull the three wire pigtail wires through the hole in the fender pocket outward When wiring
4. must be bled manually proceed as follows Fill master cylinder with fluid Install bleeder hose on first wheel cylinder to be bled Have loose end of hose submerged in brake fluid in glass container to observe bubbling By loosening the bleeder screw located in the wheel cylinder one turn the system is open to the atmosphere through the passage drilled in the screw Pump actuator with long steady strokes The bleeding operation is completed when bubbles no longer rise to the surface of the fluid Be sure to close bleeder screw securely Repeat bleeding operation at each wheel cylinder During the bleeding process replenish the brake fluid so the level does not fall below the 1 2 full level in the master cylinder reservoir After bleeding is complete make sure master cylinder reser voir is filled and filler cap is securely in place After the bleeding operation has been completed apply pres sure to the system and check the whole brake system for leaks DA91 ACTUATOR PARTS BREAKDOWN 6000 2 Lever Lock Coupler zinc plated 1 2 13UNC x 4 Hex Head Bolt gr 5 1 2 13UNC Nylon Insert Lock Nut Front Shock Pin drop tube actuators Drop Tube Actuator Slider plated Damper Shock 3 Bolt Mount Outer Case plated 5 16 External Tooth Lock Washer 5 32 x 1 1 4 Cotter Pin Qty 3 w drop tube 3 32 Cable with hooks Replacement S Hooks ONLY Emergency Lever Spring plated 5 16 18UNC x 5 8 Hex Head Bolt gr 5 1 4 20UNC x 2 He
5. the pigtail into the tow dolly Page 12 Triple Wire Plug eum Wire A ens White Connector Be DES N White a White Ground Wire th 6 Fender Yellow or Green WIRING DIAGRAM FOR THE AU TO 11 12 13 TRANSPORT FENDER Yellow Brown or Green Brown COLOR CODE FOR WIRING HARNESS Ground Left Turn and Stop GREEN Right Turn and Stop harness at the fender pocket the wire ends SHOULD NOT be stripped Use the wire connectors to make all contacts Lay the wire in the connector pinch securely with a pliers closing the wire connector Splice the white wire of the pigtail to the white ground wire from the fender Splice the black wire to the brown wire Splice the green or yellow wire to the red wire of the pigtail The connections are made on the outside of the fender pocket and pushed into the fender pocket through the pocket hole Pull the wires back into the fender pocket and push the strain relief into the fender with the wire loom close to the clip Wrap the loom hanger tie around the wire loom and insert the peg into the fender Push the round rubber light seal 26 into the light pocket Be sure the lip is secured in the light housing Plug the pigtail into the fender light Push the round light 27 into the rubber seal until it snaps in firmly Wire the other fender in the same manner Attach the tire rim assembly to the mainframe Use the supplied lug nuts 28 and torque to 75 80 ft
6. 13UNC x 4 1 2 Hex Head Bolt gr 5 Handle 1 2 D Handle Grip 1 2 13UNC Nylon Insert Locknut 7 16 14UNC Nylon Insert Locknut NO DENI o ch ch P esch Tor Fulton 5000 Ib coupler Ww 5217 Coupler Repair Kit SNO OO CO MW PP VS W Part 07426 Hook Retainer Replacement Only e oe DE D Page 10 LEFTWINCHSHOWN Page 11 Genn esl ses TOW IT ASSEMBLY INSTRUCTIONS Place the mainframe on blocks or some other sturdy support so that the frame rests approximately 8 10 off the ground Attach the tilt bed ramps 7 as shown using three 7 16 x 1 grade 8 bolts 2 and lock nuts 3 on the top of each ramp and four 1 2 x 1 1 4 grade 5 bolts 4 flatwasher 5 and locknuts 6 two on each side of the ramp Torque the 7 16 bolts to 80 ft los and torque the 1 2 bolts to 75 ft Ibs Hold the tongue 7 up to the front of the tow dolly and locate the three bullet connectors extending out the back of the tongue and plugintothe connector pro truding from under the main frame channel Do not cross colors when making this connection Pigtail po or Nar L Bn Son NS x Mount the tongue to the front of the tow dolly using one 5 8 x 4 1 2 grade 5 bolt 8 and locknut 9 torque to 50 ft Ibs Do not torque over 50 ft Ibs or the bed will not tilt Make
7. 3 SB9254 SB10954 04305 05424 SB9776 SB9777 05431 SB9783 SB24047 SB24048 SB10958 _ B10961 95 SB23937 SB23936 SB23724 05414 95 05415 91 Right Hand Cluster Back Plate Assembly Cover Plate Adjusting Hole Brake Shoe Kit includes 2 Primary amp 2 Secondary 5 16 18UNC Gr5 x 1 2 Hex Hd Bolt 5 16 External Tooth Washer Wheel Cylinder Assembly Right Wheel Cylinder Assembly Left Bleeder replacement Push Rod Adjusting Screw Assembly R for LEFT cluster Adjusting Screw Assembly L for RIGHT cluster Spring Shoe Shoe Guide Cable Cable Guide Spring Adjusting Screw Lever Left Lever Right Pin Shoe Hold Down Cup Shoe Hold Down Spring Shoe Hold Down Spring Adjusting Screw Retainer Wheel Cylinder Repair Kit w spring cup amp boot 10i Hub Drum w bearings seals nuts amp dust cap SB15845 SB15545A SB15545 4 10 Brake Drum Please order replacement parts by PART NO and DESCRIPTION Brake shoe kit can be ordered for one complete axle only Page 16 pan notincladed See 2 2 E H ou 9 5495 Coupler Repair Kit 2i Lever Lock Coupler RATED AT 6000 BLEEDING THE SYSTEM The first requirement for safe sure hydraulic braking is the use of quality brake fluid Use only DOT 3 or DOT 4 brake fluid from a sealed container If pressure bleeding equipment is available follow the manufactureris instruction in bleeding the system If system
8. EMCO which could cause a crash or could cause injury or death you should immediately inform the National To contact NHTSA you may either call the Highway Traffic Safety Administration NHTSA in Auto Safety Hotline toll free at addition to notifying Dethmers Manufacturing Com 1 800 424 9393 or 366 0129 in pany DEMCO Washington D C area or write to If NHTSA receives similar complaints it may NHTSA open an investigation and if it finds that a safety U S Department of Transportation defect exists in a group of vehicles it may order a Washington D C 20590 recall and remedy campaign However NHTSA cannot become involved in individual problems be You can also obtain other information about tween you your dealer or Dethmers Manufacturing motor vehicle safety from the Hotline Page 2 SAFETY SIGN LOCATIONS Types of safety sign and locations on Tow It are shown in illustration below Good safety requires that you familiarize yourself with various safety signs type of warning and particular function related to that area that requires your SAFETY AWARENESS SAFETY DECAL PARTS LIST REF NO PART NO DESCRIPTION 04508 Amber Reflector 04804 Red Reflector RD21007 Instructions DD21016 Winch Operation DA21001 Tire Pressure Page 3 BOLT TORQUE TORQUE DATA FOR STANDARD NUTS BOLTS AND CAP SCREWS Tighten all bolts to torques specified in chart unless otherwise noted Check tightness of bolts perio
9. Manual for that model tow dolly This warranty does not cover any tow dolly that has been altered or modified so as to affect the tow dollyis operation performance or durability or that has been modified to change the intended use of the tow dolly In addition the warranty does not extend to repairs made neces sary by normal use of parts accessories or other equipment which in the judgment of Warrantor are either incompatible with the Demco Tow lt or affect its operation performance or durabil ity Page 9 This warranty does not cover 1 normal wear and tear 2 road film or gravel damage to paint 3 paint 4 rust damage 5 Any Demco Tow ltthat has been loaded in excess of the load capacity stated on the tow dolly identification label Warrantor has a policy of continuous product improvement We reserve the right to change or improve the design of any Demco Tow lt model including but not limited to state of the art changes without assuming any obligation to modify any tow dolly previ ously manufactured Warrantor assumes no responsibility to the owner for loss of use of the tow dolly loss of time inconvenience or other damage consequential or otherwise including but not limited to ex pense for gasoline expense of transporting the tow dolly to the dealer and expense of returning the tow dolly mechanic s travel time telephone or telegram charges road service towing charges rental of another tow dolly during t
10. Manufac turing Co customer service department Until such notice is received Warrantor will not be responsible for any repair or replacement Upon receipt of notice from you Warrantor will have a choice of options in replacing any part it determines to be defective a Warrantor may require you at your own expense to deliver or ship the part to its factory or authorized dealer Any defective part will be repaired or replaced and returned to you free of charge Any part returned to Warrantor and found not to be defective will be returned to you freight collect with an explanation b Warrantor may elect to ship a new part to its dealer to be exchanged free of charge for the defective part returned by you to the dealer c Warrantor may elect to ship or deliver a replacement part to your address Warranty claims on tires should be presented to a local autho rized dealer of the tire manufacturer Provide proof of purchase when making a tire warranty claim Limitations on Warranty Coverage Coverage under this warranty will be effective only when a copy of the original invoice showing the date and location of purchase accompanies any claim for warranty Warrantor has no liability whatsoever and this warranty is null and void if any Demco Tow It has been misassembled or subjected to neglect negligence misuse accident or operated in any way contrary to the operating and maintenance instructions as specified in the Demco Owneris
11. ON KK10STB 1 Optional Spare Tire and Rim 1 04826 1 IST205 75R 14 x C BSW Radial Tire 2 04782 1 6 x 14 Rim 4 1 2 Bolt Circle Spare Tire Mounting Bracket 02193 25 Spare Tire Bracket 02917 Stud Bolt 12mm x 1 5 02933 Wheel Nut 12mm 02759 3 8 16UNC Square U Bolt 00059 3 8 Flatwasher n 02592 3 8 16UNC Nylon Insert Locknut Drive in stud here for tire with rim 04782 4 p KK6TC Optional Spare Tire Cover 1 2 bolt circle Please order replacement parts by PART NO 8 DESCRIPTION All options may not mount on tow dolly simultaneously Page 18 OPTIONAL WHEEL JACK WHEEL JACK PARTS LIST KK2WJ arty Optional Wheel Jack w hardware 02769 3 8 UNC x 4 Bolt Gr 5 00060 3 8 Lock Washer 00061 3 8 Hex Head Nut Please order replacement parts by PART NO and DESCRIPTION All options may not mount on tow dolly simultaneously OPTIONAL DEFLECTOR PARTS BREAKDOWN NQRi Q d e N Da a S OPTIONAL DEFLECTOR PARTS LIST KM Mi REF PART QTY So 3 Sa NO NO REQIiD DESCRIPTION Do 4 ALa g KK2DF Optional Deflector N 1 02592 4 3 8 16UNC Nylon Insert Lock Nut vi Si N 2 02759 2 3 8 16UNC Square U Bolt fits around 3 tube P IS NI 3 00161 95 2 Lock Handle offs Ne A 4 02054 25 1 Deflector Slide Mount gu e De af 5 00095 4 3 8 16UNC x 3 4 Ig Square Head Set Screw ra SS 6 02743 25 1 Deflector Upright P
12. ONN EE 2 AMEN SION eet Lu EE 3 POL iere IT 4 Safety and Maintenance aaa e eaaaatttaaaaaaaaaeaaettootoooooeaeseosrooooooooooseoaosesreoosonooon 4 L SAYO Biel e avanti etik tk te a a a t at n vet kt l ko e n el n kal pt ou a ou a a 5 KO AA ANS WO ie 6 8 ETE ON Waranty a a a ta ek ik ap n ot n ie e et n te ok e e en ee eee pr ea be pon ni 9 Tow Dolly Parts List and Breakdown cccccceccceeceeseeceeeeseeeeeeeeessaeeeeeeeessseaeeeeeessaagseeees 10 11 PS S MIDI AN Ce 12 13 Surge Brake Assembly scccssccscsagececocssnetasesansscnedeceasslacwsaresactacsauesenbudessanndeeuaansssenecstecdonseteasanede 14 Model DA66 Actuator Parts replacemant only ccccccseeeeeceeecaeeeeeeeeeeseeeeeeeeeeseaeeeeeeesaaees 14 Model DA603 Actuator Parts ccccccccssssssceeeceeeeeeeeeecseneeeeeeseeeeseeeesssaueesessseagseeseesssaaeess 15 Model DA91 Actuator Parts replacement only cccceecceeeseeeeeeeeeeseeeceeeeeeeaseaeeeeeaeeeeeenaees 16 107 Brake Cluster Parts List and Breakdown 17 Optional VI ANNO EE 18 Optional THOU e 18 Optional Spare Tire and Mount EE 18 Optional VAG JAK ese se kanb pakie ooo pali tk fe one kaka non pitie E on bo re es kabin ken aa a 19 6 e jile gre RE e EE 19 Qpuonal LIN E 19 Tow Dolly Parts List and Breakdown cccsssscccccseeeeeececcceeeeeececcessuaeeeeeessueeeeeeesssaneeeees 16 17 Assembly le Cer 18 19 Reporting Safety Defects If you believe that your vehicle has a defect Company D
13. Paseo oe Dethmers Manufacturing Company DOING OUR BEST TO PROVIDE YOU THE BEST 08 03 RD20006 Rev 3 OPERATORS MANUAL ASSEMBLY READ complete manual CAREFULLY CALIBRATION BEFORE attempting operation OPERATION REPLACEMENT PARTS DEMCO Dethmers Mfg Co 4010 320th St P O Box 189 Boyden IA 51234 PH 712 725 2311 Toll Free 1 800 543 3626 FAX 1 800 845 6420 www demco products com IMPORTANT We have discovered 1992 and newer model cars that are too wide in the body area to properly fit on a T1110 8 wide tow dolly even though the front tire measurement is less than 70 The 1992 and newer Oldsmobile 88 and 98 are in this category there may be others In addition to the standard measurement always follow weight limitations when using a Demco TOW IT Tow Dolly T1100 Standard Unit TI110SB Brake Unit l 3350 Ibs Total Towed Vehicle Weight 3500 Ibs Total Towed Vehicle Weight WARNING Exceeding weight limitations or not using a towing vehicle larger and at least 1 000 lbs heavier than the tow dolly and the towed vehicle combined can result in loss of towing vehicle control separation of the tow dolly from the towing vehicle or separation of the towed vehicle from the tow dolly causing severe personal injury death or property damage CAUTION All vehicles to be towed on Demco Tow Dollies must be towed with the front axle on the dolly Table of Contents General ANLO ANA W
14. This is not as obvious The basket will fit down over the tire very well the problems cannot be readily seen You must tighten the straps down solid and then check on the inside of the tire and be sure the strap when tightened does not come in contact with any metal that may cause wear or cutting such as strut mounts If there is contact you need a smaller strap call us we will provide on a NO Charge exchange basis the proper size strap You must return your new unused straps and provide us with the Make and Model of your Car and tire size Thank you for Purchasing Products TESTING LIGHTS BEFORE USE 1 Checkthatthe WHITE ground wire ofthe wiring harness IS connected to the Tow lt frame and the WHITE ground wire is connected to the frame of the towing vehicle 2 With headlights in ON position the tail lights the light cluster bar the license plate light and the clearance lights should be lighted 3 Start engine and have someone depress brake pedal Brake lights of tow dolly and towing vehicle should come on and off simultaneously with each application 4 Turnleftturn signal on Leftturn light of Tow lt and towing vehicle should flash simultaneously Should the turn signal lights of the trailer function opposite to those of the towing vehicle itis probable thatthe YELLOWand GREEN wires have been reversed Check the plug connection under the tongue of the Tow ltto make sure wire colors are not crossed at that poi
15. change or add to this warranty REF QTY NO PART NO REQiD DESCRIPTION d 5432 1 Left Ratchet Winch Assembly Plated 2 5433 Right Ratchet Winch Assembly Plated Ratchet Frame Left Spool Tube Right Spool Tube Heavy Duty External Snap Ring Ratchet Handle 18 Ga Shim Washer Left Ratchet Gear Right Ratchet Gear 5 16 x 1 1 4 Roll Pin Black Vinyl Hand Grip Winch Pawl 2 Winch Pawl Spring SS Winch Pawl Bushing SS 5 16 Flatwasher 3 8 16 UNC x 3 4 Hex Bolt w epoxy Gr 5 Left Ratchet Pawl Arm Right Ratchet Pawl Arm 5 16 18 UNC x 1 2 Shoulder Screw 5 16 Flatwasher SS 1 4 Flatwasher SS 1 4 20 UNC Nylon Locknut 1 4 20 UNC x 3 4 Hex Hd Bolt Gr 5 1 4 Flatwasher Lock Pin w Cable REF QTY NO PARTNO REQiD DESCRIPTION 2 22 1 2 Wire Protector 2 Cable Hanger wire harness 2 Wire Strain Relief 2 Amber Fender Reflector 2 White Ground Wire 2 Back Up Plate for fender 6 3 8 16UNC x 1 1 2 Hex Head Bolt gr 5 2 Red Fender Reflector 2 3 way Plug Pigtail tail light 2 Rubber Mounting Grommet for light 2 Sealed Round Tail Light Upper Half Mainframe 2 3 point Tie Down Strap w J Hook amp buckle 1 4 Drive Type Grease Zerk St sch st st st sch st eck eck sch J eh 1 2 13UNC x 1 Epoxied Bolt gr 5 w zerk 1 2 Special Flatwasher 3 16 x 3 4 Roll Pin 1 3 4 O D Bronze Bushing a N sch eck eck eck eck sch eck sch Electrical Wire Splicer Trunk Connector F
16. dically using bolt chart as guide Replace hardware with same grade bolt NOTE Unless otherwise specified high strength Grade 5 hex bolts are used throughout assembly of equipment Bolt Torque for Standard bolts nn GRADE 2 GRADE 5 GRADE 8 Torque Specifications A pn Nm In Nm Ip Nm 1 4 12 16 5 16 25 3 8 45 7 16 80 1 2 115 9 16 165 5 8 225 3 4 400 7 3 650 1 970 AN AN APA ee OND OWN w CLASS 8 8 CLASS 9 8 CLASS 10 9 A Ib ft Wm lb ft N m Ib ft N m Torque figures indicated are valid for non greased or non oiled threads and heads unless otherwise specified Therefore do not grease or oil bolts or cap screws unless otherwise specified in this manual When using locking elements increase torque values by 5 GRADE or CLASS value for bolts and capscrews are identified by their head markings 7 GRADE 2 GRADE 5 GRADE 8 ap a Dei 8 I CLASS 8 8 CLASS 9 8 CLASS 10 9 Page 4 4 WARNING FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN LOSS OF TOWING VEHICLE CONTROL SEPARATION OF THE TOW DOLLY FROM THE TOWING VEHICLE SEPERATION OF THE TOWED VEHICLE FROM THE TOW DOLLY CAUSING SEVERE PERSONAL INJURY DEATH OR PROPERTY DAMAGE SAFETY Safety is of utmost importance at all times There are several items that must be checked each time before using and while using the Tow lt Make sure all bolts are properly tightened and those requiring a se
17. ed at the rear of each wheel platform The short side of the hook must face the rear of the TOW IT E fe a 4 d Yen Step 9 While tightening straps pull cross strap forward to ensure even tightening Tighten straps until each tire starts to flatten against tire stop After each strap is tight insert a safety pin in each winch Disengage towed vehicle parking brake Straps must be retightened after first 5 miles of travel Check straps every 50 miles thereafter to ensure they are tight and not rubbing or fraying continue with Step 10 on following page Page 7 Step 10 Make sure the tie down strap is the correct size for the auto tire The picture above shows a correct fitting strap See page 1 of this instruction for proper fit and exchange instructions Step 11 Hook the towed vehicle safety chains to frame of vehicle directly above the area where the chains are mounted on the TOW IT Leave some slack in the chains to allow suspension movement of the towed vehicle Review the safety points on page 1 before moving vehicles Step 12 TO UNLOAD towed vehicle Make sure that plat form and vehicle are straight Reinstall driveshaft Ensure that towed vehicle parking brake Is fully engaged then unhook the towed vehicle safety chains and release the tie down straps Tie down straps must be quick released by grasping ratchet pawl and ratchet handle simultaneously and pushing down sharply This process wil
18. en loaded All vehicles mounted on the Tow lt must be mounted with the front of the vehicle facing forward Rear Wheel Drive Disconnect the towed vehicle driveshaft for rear wheel drive vehicles with automatic transmission For manual transmission Consult your vehicle owners E for towing suitability with the drive shaft con nected Page 5 MAINTENANCE Periodically check all bolts and nuts to ensure proper tension or torque An occasional drop of oil may be required on the moving parts of the tie down winches Grease the center pivot pin grease zerk every 1500 miles Grease the main frame platform skids every 1500 miles These grease zerks are readily accessible from under the front tire stop main platform Grease the Sure Lube Hubs every 3 000 miles Use High Quality Bearing Grease with Hand Operated Grease Gun IMPORTANT LOADING INSTRUCTION Check your wheel tie down straps Your Tow lt is equipped with custom made wheel tie down straps of a standard size that will fit most tires however if your tires are too large or too small you will want to exchange these new straps for the proper size straps 1 Tire too large This is very obvious The strap will not basket over the tire properly call us we will provide at NO Charge on an exchange basis the proper size strap You must return your new unused straps and provide us with the Make and Model of your car and the tire size 2 Tire too small
19. he time warranty repairs are being performed travel lodging loss or damage to personal property or loss of revenue or earnings Limitations of Implied Warranties All implied warranties if any expire and terminate upon expi ration of this warranty Some states do not allow limitation on how long an implied warranty lasts so this limitation may not apply to you Limitation of Consequential Damages Warrantoris responsibility under this warranty extends solely to repair or replacement of your Demco Tow lt and its component parts Warrantor does not assume responsibility for nor shall it be liable for any special incidental or consequential damages Some states do not allow the exclusion or limitation on inciden tal or consequential damages so the above exclusion or limitation may not apply to you Use of Vehicle Identification Number VIN The VIN is a 17 digit number located in the lower left corner of the tow dolly identification label The label is located on the left side of the tow dolly frame Be sure to include the VIN number in all communications with Warrantor or its dealers concerning the warranty Purchaser s Rights This warranty gives you specific legal rights and you may also have other rights which vary from state to state Exclusive Warranty This is the only express warranty made by Dethmers Manufac turing Co on your Demco Tow lt and no agent employee or other person is allowed to
20. l permit easy removal of strap from winch Swing the wheel platform locking latch handle forward towards the coupler This will allow the platform to tilt as you slowly drive off Make sure the winch ratchet handles are horizontal straps are tightened in the storage position and towed vehicle safety chains are wrapped up and hooked Tie down winch handles should be leftin a down position horizon tal with safety pins in place when towing loaded or empty DO NOT ATTEMPT TO PULL TOW IT WITH WHEEL PLAT FORM IN LOADING tilted POSITION DAMAGE PREVENTION Check your vehicle manual or registration for vehicle weight Towing vehicle must be larger and at least 1 000 Ibs heavier than the towed vehicle and tow dolly combined Do not pack goods in car that is being towed Overloading the Tow lt or exceeding the width limit may result in damage to both car and Tow lt REAR WHEEL DRIVE PRECAUTIONS Disconnect towed vehicle driveshaft for rear wheel drive vehicles with automatic transmission Simply placing trans mission in neutral is not sufficient to prevent damage to transmisssion For manual transmission consult your vehicle owners manual for towing suitability with the drive shaft connected Examine winches and straps to make sure they are in good condition Check wheel nuts every trip Tires mustbe inflated to recommended pressure by tire manufacturer Becertain the safety lock pins lock the strap winches Retighten
21. ld separately REF NO PART NO QTY DESCRIPTION 8606301 Plated Actuator f drum brakes Fa en n n 1 47 Lock Washer REPLACEMENT KITS 1 41 20 UNG Hex Nut components not sold separately 3 81 16 UNC Lock Nut Center Punch 1 4 20UNC x 2 Hex Head Bolt Gr 5 018 Connector Orifice Drum Brakes 3 8i 16UNC x 3i Hex Head Bolt Gr 5 3 Tab Fill Cap w Diaphram amp O Ring Master Cylinder Gasket incl in 10616 amp 11190 Composite Master Cylinder drum Coupler Inner Slider plated Coupler Inner Slider w Lever Lock Assy Top Plastic Slider Bottom Plastic Slider Shock Spacer plated Rear Shock Pin plated Outer Case plated External Snap Ring Damper Protective Boot incl in 10616 amp 5398 00057 00062 00179 00618 SB12098 02207 03876 09153 10616 11367 95 5698 11368 11369 11371 95 11389 95 11390 95 11401 SB12426 05687 7 16 14UNC x 1 1 47 Hex Head Bolt Gr 5 7 16i 14UNC Lock Nut Center Punch Emergency Catch Cam black oxide finish 1 2 3 4 Sie 6 7 8 9 5696 Coupler Repair Kit 2 lever lock 5398 Master Cylinder Repair Kit drum Please order replacement parts by PART NO and DESCRIPTION Naa MAM MI sch sch zc ck fH HR HE Page 15 10i BRAKE CLUSTER PARTS LIST Left Side Breakdown REF PART QTY NO _ NO REQiD a SB23715 DESCRIPTION Left Hand Cluster shown above 0 ee 7 gt E SB23714 SB24636
22. must be completely and properly hooked up to the towing vehicle Towing vehicle must be larger and at least 1000 lbs heavier than the tow dolly and towed vehicle com bined IMPORTANT Tire tread width or body width of towed vehicle must not exceed 71110 70 max outside to outside TI110SB 42 min inside to inside 70 max body width Page 6 Step 5 With someone safely guiding you slowly drive ve hicle onto platform FRONT FORWARD Any vehicle mounted on tow dolly must be mounted with front of the vehicle facing forward Drive the car forward until the tires touch the ramps Make sure the tire is aligned to ascend onto the ramps wr fe Step 6 Drive vehicle onto platform until tires touch the wheel stops at the front of each side of the platform and the platform tilts to a flat position Make sure the car is centered on the platform Towed vehicle tires must fit in wheel troughs without overhanging sides Engage towed vehicle parking brake Shift loaded car into park and lock steering wheel with front tires in a straight position If the car does not have a locking steering column the steering wheel must be tied securely with front tires in a straight position Rear Wheel Drive Disconnect towed vehicle driveshaft for rear wheel drive vehicles with automatic transmission For manual transmission Consult your vehicle owners manual for towing suitability with the drive shaft connected hooks to rods locat
23. nt If plug connection is incorrect correct problem by reversing yellow and green wire connec tion on the towing vehicle LOADING INSTRUCTIONS Refer to load limits on inside of front cover Step 1 Secure ball coupler to 2 3 500 Ib capacity towing vehicle ball only Make sure that the hitch and the hitch ball are in good condition and not rusted loose or stripped Recommended ball height is 18 to the top of the ball Make sure hitch is locked down and secured with safety clip Criss cross safety chains under tongue and secure to towing vehicle frame Ee E F age Lo d BZ Step 2 Ensure that towed vehicle parking brake is fully engaged then release the tie down straps NOTE Tie down straps must be quick released by grasping ratchet pawl and ratchet handle simultaneously and pushing down sharply This process will permit easy removal of strap from winch Remove tie down strap hook from its storage position at the rear of the ramp Lay the straps on the ground in front of the winches Step 3 To allow the wheel platform to tilt back for loading 1 Swing the bottom of the locking latch C toward the hitch far enough to allow locking pin handle to be lifted ZS i 2 Pull locking pin toward the hitch as far as it willgo The wheel platform will tilt back to allow loading Step 4 Before loading and unloading towed vehicle make sure platform and towed vehicle are in straight alignment Tow dolly
24. ost SO T 02165 1 Deflector Lacing Cord 1 8 x 25 ft 8 02161 1 Deflector Fabric 9 02055 25 2 Deflector Framework Please order replacement parts by PART NO and DESCRIPTION REF PART QTY NO _ NO REQiD Nylon Security Strap with hooks 8 tightener 01857 Left Tail Brake and Signal Light w Lenses 01773 Brown Jumper Wire Wire Holder metal Light Bar Framework Adjustable Light Bracket Right Tail Brake and Signal Light w Lenses 1 4 20UNC Nylon Insert Locknut 1 4 20UNC x 1 2 Hex Head Bolt Light Bar Z Bracket COLOR CODE FOR WIRING HARNESS 3 Suction Cup w Bolt 13 WHITE Light Bar Wiring Harness new style EI VE AYE BROWN Tail Lights License Plate Lights Light Cluster Bar amp Clearance Lights Large Red Lens YELLOW Left Turn and Stop Please order replacement parts by PART NO and DESCRIPTION GREEN Right Turn and Stop 01912 Small Red Lens Page 19 AA gt OC Ee Page 20
25. peration does not occur when connected to the TOW IT a heavy duty replace ment flasher may be obtained through auto parts outlets Page 13 NOTE When installing DA603 K onto Tow it be sure to pull N lt brake line out of tongue and slide the Actuator brake EE line and lift handle ono tongue and attach with supplied fasteners 25 a y ki f f pA A MI 04791 26 2 Spindle w Brake Flange 02209 6 7 16 20UNF Hex Nut Gr 8 00078 6 7 16 Lockwasher SB8798 6 7 16 20UNF x 1 1 8 Knurled Shoulder Bolt Handle Grip 00059 4 3 8 Flatwasher 02383 36 Safety Chain 00060 2 3 8 Lockwasher SB587 80 Brake Line 00907 2 3 8 16UNC x 1 Hex Head Bolt Gr 5 01863 5 8 Rubber Grommet 02288 95 1 Handle 02746 54 Protective Hose SB7785 1 Tee Brass 04792 26 Tongue 01338 3 1 2 13 UNC x 4 1 2 Hex Head Bolt Gr 5 SB7H66 7 Brake Hose 02178 3 1 2 13 UNC Nylon Insert Locknut 00496 5 8 x 14 Ga Machine Washer 24 8606301 1 Model DA603 plated drum brake Actutator SB7764 Retaining Clip 25 1 10415 Repl SB512 12 Brake Line SB15545 4 10 Brake Drum Rubber Brake Line Protector SB23715 Left Hand Cluster B 44 Brake Li SB23714 Right Hand Cluster ACTUATOR PARTS LIST REF PART QTY NO REQiD DESCRIPTION 8606701 1 Brake Actuator complete incl ref 1 24 07599 95 6000 2 Ball Coupler Fulton SB23278 Roller 05957 95 Front Roller Spacer 02166
26. ront Half Trailer Wiring Harness Rear Half Trailer Wiring Harness 01747 Hub 01743 Grease Seal NOK AD 2548 E 01744 Inner Cup L68111 01745 Inner Cone Bearing L68149 01748 Outer Cup L44610 02264 Outer Cone Bearing L44643 02265 Hardened Tongue Washer 02266 13 16 20 UNF Jam Nut 02267 Retainer Adjustment Washer for Jam Nut 00116 5 32 x 1 1 2 Cotter Pin 04789 Sure Lube Dust Cap 24 Safety Chain with Hook 01746 1 2 20UNF x 1 5 8 Ig Stud Bolt 7 16 S Hook for safety chains E SE 3 8 Flatwasher Please order replacement parts by PART NO and DESCRIPTION 7 16 14UNC x 1 1 4 Hex Head Bolt or bi Tongue 5 8 11UNC Nylon Insert Locknut 5 8 11UNC x 4 1 2 Hex Head Bolt gr 5 5 8 11 UNC x 1 1 4 Hex Hd Epoxied Boll Bracing Strut 1 2 13UNC x 1 1 2 Hex Head Bolt gr 5 1 2 Flatwasher Pivot Bushing 3 8 l D x 1 2 O D Grommet Lock Pin Tongue 3 16 x 1 1 4 Roll Pin Undercarriage 09533 26 for TI110SB 7 16 20UNF Hex Nut gr 8 7 16 20UNF x 1 1 2 Epoxied Bolt gr 8 14 x 6 rim 5 on 4 1 2 BC 1 2 ZOUNF Chrome Lug Nut ST205 75R14 C Range BW Radial Tire Tilt Bed Ramp 1 2 13UNC x 1 1 4 Hex Head Bolt gr 5 7 16 20UNF Nylon Insert Locknut 7 16 20UNF x 1 Hex Head Bolt gr 8 3 8 16UNC Nylon Insert Locknut Left Fender w wire protector amp gr wire Right Fender w wire protector amp gr wire 4 Tinnerman Fender Clamp Lever Lock Coupler 5 000 Ib Safety Lock Pin for coupler 1 2
27. sure the tongue latch is in the latched position to the tilt bed Secure the coupler 70 and lift handle 77 to the front end of the tongue with two 1 2 x 4 1 2 gr 5 bolts 12 and locknuts 73 The white ground wire 74 is attached under the head of the second bolt attaching the coupler It is very important that a good ground is made Torque the locknuts to 75 80 ft Ibs Tap a rubber grip 15 onto the handle with a rubber hammer or a wooden mallet Remove the 7 16 x 1 1 4 bolt 76 flatwasher and locknut from the outer front panel of each wheel platform tire stop Slide the tie down winch 17 into the channel at the front of the wheel platforms as shown Note that 17 is the left winch The ratchet handles are to the outside of each winch and ratchet springs are to the top Attach two 36 towed vehicle safety chains 18 Secure one chain to each wheel platform tire stop with the 7 16 x 1 1 4 bolt 76 flatwasher and locknut _ Brown Yellow Brown Green NOTE 9 When assembling the tie down strap to the tow dolly winch make sure the tie down strap does not contain any twists and the overlaps are to the inside Weave the front of the tie down strap through the openings in the buckle The buckle should be approximately 8 from the end of the strap Thread the strap end through the winch slot Bring the strap up and thread it back through the buckle again The buckle should be approxi
28. t torque are up to specifications Lug Nuts 75 to 80 ft Ibs Check Lug Nut tension after the first 5 miles and periodically thereafter The ball hitch must latch securely around the ball and the safety lock pin or lever must be in position to lock the hitch on the ball RECOMMENDED BALL HEIGHT 18 inches to the top of the ball on the towing vehicle Hook the towed vehicle safety chains to the frame of the vehicle directly above the area where the chain is mounted on the Tow lt Leave some slack in the chain to allow suspension movement eka to make sure that all lights are in proper working order Examine the winches and straps making sure they are in good conditon Be certain the safety lock pins are locking the strap winches Retighten straps over the tires after the first5 miles and every 50 miles thereafter Ensure that they are tight ma T1110 tires must be inflated to the recommended 35 ee 10SB tires must be inflated to the recommended The strap on the optional tongue winch must be in good condition and should be stored neatly on winch when not in use NOTE The winch strap must not be left connected to the towed vehicle after it is loaded and strapped down Make sure the optional light bar is fastened securely at the rear of the towed vehicle The wires to the optional light bar should be on d the car and fastened so as not to damage the finish of the towed vehicle NOTE This unit cannot be backed up wh
29. the straps over the tires after the first 5 miles of travel Check straps every 50 miles thereafter to ensure they are tight and not rubbing or fraying Page 8 DEMCO PRODUCTS TOW IT Tow Dolly ORIGINAL PURCHASERS LIMITED WARRANTY 1 Extent and Duration of this Warranty Your Demco Tow lt is warranted to be free from defects in materials and workmanship under normal use and service for a period of one year after date of purchase by the original first retail owner or until it is resold or transferred by the original owner Tires and lights are not included in this warranty Tires are warranted by the manufacturer against defects in materials and workmanship but not against road hazards Any part of the Demco Tow lt except tires and lights found in the judgement of the manufacturer to be defective in materials or workmanship will be repaired or replaced at the manufactureris option without charge for parts or labor to the original owner Manufacturer and Warrantor of Tow Dolly Dethmers Manufacturing Co 4010 320th Street P O Box 189 Boyden IA 51234 712 725 2311 The manufacturer and warrantor of the tires has his name permanently molded into the tires Tire warranty questions and claims can be taken directly to an authorized dealer of the tire manufacturer Repair or Replacement Procedure lf your Demco Tow lt develops a defect except for tires or lights during the warranty period promptly notify Dethmers
30. x Head Bolt gr 5 1 4 Lock Washer Emergency Lever Assembly Master Cylinder Cap w Diaphragm amp O ring O Ring Only not shown Push Rod Assembly 1 4 20 UNC Hex Nut Plastic Master Cyl Gasket ONLY Master Cylinder Master Cylinder 018 Connector Orifice Drum Brakes Inverted Flare Adapter Disc Brakes Lever Guide plated Master Cylinder Protective Boot Connecting Pin plated Upper Slider Lower Slider Side Spacers 5401 Lever Replacement Kit incl items w 5650 Master Cyl Replacement Kit drum 5495 Coupler Repair Kit Please order replacement parts by PART NO and DESCRIPTION Page 17 OPTIONAL WINCH PARTS LIST REF QTY NO PART NO REQiD DESCRIPTION Optional Winch Winch Mechanism 1400 capacity Replacement Handle Strap Assembly includes strap amp hook 3 8 18UNC x 3 Hex Hd Bolt gr 5 3 8 16UNC x 4 Hex Head Bolt gr 5 3 8 Flatwasher 3 8 16UNC Nylon Insert Locknut Please order replacement parts by PART NO and DESCRIPTION All options may not mount on tow dolly simultaneously OPTIONAL TOOL BOX PARTS LIST 3 8 Flatwasher 3 8 16UNC Nylon Insert Locknut Tool Box Small Hair Pin Mounting Z Bracket 4 3 8 16UNC x 1 Hex Head Bolt gr 5 2 3 8 16UNC x 3 Square U Bolt Please order replacement parts by PART NO and DESCRIPTION All options may not mount on tow dolly simultaneously REF QTY NO PART NO REGQID DESCRIPTI
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