Demco Aluminator Self-Aligning Tow Bar User's Manual
Contents
1. 5 GRADE or CLASS value for bolts and cap screws are identified by their head markings CLASS 8 8 CLASS9 8 CLASS 10 9 A lb ft N m lb ft N m lb ft N m Bolt Torque for Standard bolts GRADE2 GRADE 5GRADE 8 lb ft N m Ib ft N m Ib ft N m s GRADE 2 GRADE 5 GRADE 8 me gt EA 6 CLASS 8 8 CLASS 9 8 CLASS 10 9 JOW 13 27 40 60 95 NOO SSE NN Page 12 SAFETY CABLE amp LIGHT CABLE INSTALLATION Step 1 Remove safety cables from box and coil a cable around each leg of the tow bar starting near the pivot point Install the light cable optional by placing the coil over the wire support rod Secure the cable with the cable anchor located on left connecting leg lock pin mount Remove 1 4 bolt place anchor over coil of cable and replace bolt This will prevent the cable from pulling off and becoming damaged HOOKING rad THE VEHICLE TO BE TOWED Step 2 Insert the lock pin block and sping into the A umina tor reciever tube and line up block with hole in tube Insert the Aluminator into a Class III or IV hitch Step 3 Insert locking pin with star washer through receiver on the block side and thread in pin until passes through Slide pin bushing over pin and into hitch receiver Tighten pin use 5 8 wrench and install lock on pin Step 4 Position the vehicle to be towed approx 24 behind the towing vehicle The vehicles do not have to be2. by PART NO and DESCRIPTION Page 21 OPTIONAL TOW BAR TO BASE PLATE LOCKING PINS PARTS LIST REF PART NO _NO DESCRIPTION 9523043 Tow Bar to Base Plate Locking Pin Set 1 5847 Tow Bar to Base Plate SingleLocking Pin Assembly 2 12431 Replacement Keys Please order replacement parts by PART NO and DESCRIPTION OPTIONAL 3 PIECE LOCKING PINS PARTS LIST NO __ NO DESCRIPTION 9523044 3 Piece Locking Pin Set Tow Bar to Base Plate SingleLocking Pin Assembly Tow Bar to Motor Home receiver Locking Pin Replacement Keys Please order replacement parts by PART NO and DESCRIPTION Page 22 DEMCO PRODUCTS Aluminator Tow Bar ORIGINAL PURCHASERS LIMITED WARRANTY 1 Extent and Duration of this Warranty Your Demco Aluminator has a Lifetime Limited warranty to be free from defects in materials and workmanship under normal use and service from date of purchase by the original first retail owner or until it is resold or transferred by the original owner Any part of the Demco Aluminator found in the judgement of the manufacturer to be defective in materials or workmanship will be repaired or replaced at the manufacturer s option without charge for parts or labor to the original owner Manufacturer and Warrantor of Tow Bar Dethmers Manufacturing Co 4010 320th Street P O Box 189 Boyden IA 51234 712 725 2311 Repair or Replacement Procedure If your Demco Tow Bar develops a defect durin
3. in straight alignment to complete the hook up Engage towed vehicle and towing vehicle parking brake Step 5 Slide and twist the legs into position to attach them to the baseplate on towed vehicle Secure to baseplate us ing the two attaching pins and 1 4 quick lock pin Attach safety cables see below Now connect the lighting cable between the towing vehicle and the towed vehicle lighting sys tem or optional light bar The coiled section of the cable will be stored on the support rod of the left connecting leg quick lock pin must be YES 7 closed properly Fold ring PIN MUST BE LOCKED of Quick Lock Pin to the side of the pin that allows ring to Snap against pin If you have folded its ring the wrong way it will not snap against pin Page 13 Step 6 Hook safety cables to chain anchor of baseplate Note Make sure safety clip is in working order Step 7 Leave the electrical cable storage pin circled above out for the locking procedure in step 6 When step 6 is com pleted position cable on storage rod leaving enough slack and insert pin Step 8 Once you are secured to the tow bar release towed vehicle parking brake and slowly back up the towed vehicle straight back until one leg latches Determine which leg latched by having an assistant tell you If you are by yourself put towed vehicle in neutral or park and apply parking brake Get out and check to see which leg latched You can tell this by w
4. to change or add to this warranty P O BOX 189 4010 320th St BOYDEN IA 51234 PH 712 725 2311 FAX 712 725 2380 TOLL FREE 1 800 54DEMCO 1 800 543 3626 www demco products com
5. 1 08 TB20017 Rev 12 Aluminator SEIELIGDMMT VOM at ASSEMBLY CALIBRATION OPERATION REPLACEMENT PARTS R E A D complete manual CAREFULLY BEFORE attempting operation Doing Our Best To Provide You The Best A WARNING Exceeding weight limitations or not using a towing vehicle larger and at least 500 Ibs heavier than the tow bar and the towed vehicle combined can result in loss of towing vehicle control separation of the tow bar from the towing vehicle or separation of the towed vehicle from the tow bar causing severe personal injury death and or property damage TABLE OF CONTENTS Warranty Registration risers team O LGP AA O onan AA AEO 3 4 Safety Sign Location POZEW CE EA 5 TI FU Veep cic EEEE 6 Equipment Safety Guidlines amp Lighting and Marking c cccccecsseeceeeeeeeeeeeeeeceeeeesseeeeesseeeessaneeeeas 7 Safety Sign Care amp Before Operation ccccccccccssssceccseseeeeeaeeeeeeeseeeeeeesseeeeeeessaaeeeessaueeeessaaaeeessaages 8 During 8 Following Operation ccccccsseeccesseecceeceeceueeecsececseeeessueeeeseuecesseuseeseeeessageessenseesseneeeees 9 Highway and Transport Operations area RAJA GEA ep EEEAaoE A ALOC EO 9 10 PONOTMN MANENANCOZ Eni kolski AE OO ri at ECO CO AEO ati 10 Safety a d IV LIEN NAC ee ete AE A O ARE W A R 11 Tan ofelg e219 91 2 co rea ar EE E E OGG 12 POTO RECE EC EE EC CEE PCE EECC CY 12 Hooking up and Operating Instructions
6. A TION OF THE TOW BAR FROM THE TOWING VEHICLE SEPARATION OF THE TOWED VEHICLE FROM THE TOW BAR CAUSING SEVERE PERSONAL INJURY DEATH OR PROPERTY DAMAGE WARNING ADDITIONAL SAFETY ITEMS Safety is of utmost importance at all times To prevent per sonal injury or property damage observe the following e Before allowing anyone to hook up or operate the Aluminator be sure they have read and understand the proper operating procedure e This unit must be used with a Class III 5 000 Ib Hitch or higher e Be sure the steering components of the towed vehicle are properly aligned e The male receiver tube must fit snugly in the hitch receiver and the safety pin must be in position to lock the receiver and tube together e NOTE This unit can be backed up in moderate increments Any severe backwards cornering could result in damage to the Aluminator and or towed vehicle chassis e For automatic transmissions Consult your vehicle owners manual for towing suitability with the drive shaft connected Otherwise the towed vehicle will have to be equipped with a transmission pump or drive shaft discon nect e Be sure the SAFETY CABLES w retainers are hooked to both the towing and towed vehicles using the criss cross method e Do not load the towed vehicle with anything as you may exceed the towing capacity of the tow bar e Check to make sure that all lights are in proper working order e Make sure the optional light bar is
7. Insert the small hairpin into the lockpin inside the front yoke Cover your Aluminator and you are ready to drive your vehicle NOTE Picture shown in 90 degree position A uminator will also store in 45 degree position NOTE If you need to store your A uminator on the op posite side you must rotate the rear yoke 180 and rotate the legs clockwise into the storage position Page 15 PARTS BREAKDOWN Order No 9511007 REF PART REF PART NO QTY DESCRIPTION 6 Plastic Bearing Nyliner 2 O ring 1 862 I D x 103 Cross Section 1 Washer 782 ID Stainless Steel 2 4 DESCRIPTION Male Receiver with bushings Crosstube Bushing Only 3 4 10NC x 4 1 2 Hex Head Bolt Gr 5 3 4 10NC Nylon Insert Locknut Front Yoke Cable Tie Rear Yoke 9523042 Vinyl Storage Cover Optional not shown 5 32 x 1 1 2 lg Cotter Pin Yoke Washer Please order replacement parts by PART NO and DESCRIPTION Thrust Plate 3 4 16NF Hex Jam Nut Connecting Arm Bushing 1 3 4 Round Vented Caplug 1 2 13NC x 1 Hex Head Bolt Gr 5 Stop Washer Neoprene O Ring 1 8 x 1 1 4 OD Ear Washer Left Front Connecting Leg Right Front Connecting Leg Light Cable Anchor 1 4 20NC x 1 1 2 Hex Head Bolt Gr 5 1 4 20NC Nyon Insert Locknut Lanyard Cable 1 8 Small Hair Pin 5 32 x 3 4 Roll Pin Wire Support Lock Pawl Leg Seal Coil Spring Lock Collar Snap Ring Rear Connecting Leg Connec
8. cle requires additional equipment such as a transmission lube pump free wheel hubs driveline disconnect or axle locks Failure to properly equip towed vehicle will result in severe damage to towed vehicle s transmission Be sure that towed vehicle s steering wheel is unlocked and free to turn Check manufacturer s specifications for the proper way to unlock steering wheel Be sure to check that receiver on towing vehicle is not inset to far When attaching a Demco towing product it is important that turning clearance is adequate A receiver that is inset to far on a towing vehicle will shorten turning radius Failure to check this may result in towing or towed vehicle to be damaged It may be necessary to install a receiver extension to allow for proper turning clearance BOLT TORQUE TORQUE DATA FOR STANDARD NUTS BOLTS AND CAPSCREWS A Tighten all bolts to torques specified in chart unless otherwise noted Check tightness of bolts periodically using bolt chart Torque Specifications Torque figures indicated are valid for non as guide Replace hardware with same grade bolt greased or non oiled threads and heads unless NOTE Unless otherwise specified high strength Grade 5 hex otherwise specified Therefore do not grease or bolts are used throughout assembly of equipment oil bolts or capscrews unless otherwise speci fied in this manual When using locking Bolt Torque for Metric bolts elements increase torque values by
9. d Capacity of Towing Hitch Towbar or Towing Vehicle DETHMERS MFG COMPANY 4010 320th St P O BOX 189 Patent numbers RE35 482 j BOYDEN IA 51234 5 887 497 5 957 477 CMeEO TOLL FREE 1 800 54DEMCO 1 800 543 3626 Patent pending www demco products com REV 2 TB21008 Important operator instructions To prevent serious injury or property damage follow these safety items Before operating read and follow operators manual Be sure SAFETY CABLES are attach to both towing and towed vehicles using criss cross method Replace all worm or damaged parts Be certain all attaching pins and safety pins are in place Check all attaching points after first 5miles and every 200 miles thereafter Check clearance between vehicles in turning situation 02 88 TB21004 Page 5 SAFETY TAKE NOTE THIS SAFETY ALERT SYMBOL FOUND THROUGHOUT THIS MANUAL IS USED TO CALL YOUR ATTENTION TO INSTRUCTIONS INVOLVING YOUR PERSONAL SAFETY AND SAFETY OF OTHERS FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN INJURY OR DEATH THIS SYMBOL MEANS ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED SIGNAL WORDS Note use of following signal words DANGER WARNING and CAUTION with safety messages Appropriate signal word for each has been selected using following guidelines DANGER Indicates an imminently hazardous situation that if not avoided will result in serious injury or death This signal word is to be limited to the m
10. essaaee aa aa aa aa wana aa aaa aaa aa aaaaa aa aaaaaazaaaaaziaaakaraaask ania 13 14 URDOOKNG WOW A OPORY 14 15 Aluminator Tow Bar Parts Breakdown ccccsesscescscssssecececererereecsvevevecevvereneevsvevaverevererenenen 16 17 Lock Collar Assembly amp Disassembly Instructions aan in A ON A EEE A A EA WAWA EO AE 18 Safety Cable Kit Parts BreakQOwn ccccccceccccccseseececeeeeeeseeeeeeeseeeeeeeseeueeeesseaeeeesseaeeeeseeaeeeeessages 19 Auxiliary Lighting Cable Kit Parts Breakdown ccccscccccsseeeeceeeeeeeeeeeesaeeeeesaeeeseaeeesseaeeesseeessaees 19 Optional Tow Bar Light Bar Parts BreakQOwn cccccsescecseseeeeeeeeeseeeeeeseeeeeseeeeseeeeessageeeesaeeeeeas 20 Optional Extended and Drop Lift Hitch Attachment eesaaa aaa aaa anawa aaa aaa aaaaaaaaaaaaawaazaaaaa ai 21 ORiona Loek nG PSA A E EEEE AE EO A EE 22 Warranty Statene Miess RA A Eo ER O ee o R 23 Page 2 CZ WEO 4010 320th Street e Box 189 e Boyden lowa 51234 Toll Free 800 54DEMCO 800 543 3626 e FAX 800 845 6420 www demco products com How satisfied are you with our product How satisfied are you with the dealership distributor sales staff Dealer Distributor Name City How satisfied are you with the company sales staff How satisfied are you with the delivery Did you have any contact with a Demco Representative If YES how satisfied were you would recommend this product to my family and friends Would you purchase a
11. f alcohol or drugs Review safety instructions with all users Operator should be a responsible adult DO NOT ALLOW PERSONS TO OPERATE OR ASSEMBLE THIS TOW BAR UNTIL THEY HAVE DEVELOPED A THOROUGH UNDERSTANDING OF SAFETY PRECAUTIONS AND HOW IT WORKS Do not paint over remove or deface any safety signs or warning decals on your tow bar Observe all safety signs and practice instructions on them Never exceed limits of a tow bar If its ability to do a job safely is in question DON T TRY IT A LIGHTING AND MARKING It is the responsibility of owner to know lighting and marking requirements of local highway authorities and to install and maintain equipment to provide compliance with regulations Light bar kits are available from your dealer or from manufacturer Page 7 4 SAFETY SIGN CARE Keep safety signs clean and legible at all times Replace safety signs that are missing or have become illegible Replacement parts that displayed a safety sign should also display current sign Safety signs are available from your distributor dealer parts department or factory How to install safety signs Be sure installation surface is clean and dry Decide on exact position before you remove backing paper Remove smallest portion of split backing paper Align decal over specified area and carefully press small portion with exposed sticky backing in place Slowly peel back remaining paper and carefully smooth remaining portio
12. fastened securely at the rear of the towed vehicle S MAINTENANCE Periodically check all bolts and nuts to ensure proper tension or torque Check all pivot points for wear or breakage Replace any worn or damaged parts with O E M parts only An occasional spray of lubricant may be required inside the Lock Collar of the extending legs DO NOT lubricate any of the pivot points of the Alumina tor These are self lubricating washers and your towbar could lose its self supporting ability Keep the A uminator covered when stored on or off the towing vehicle If the Lock Collars become limited in their movement they may require disassembly using the instructions provided on page 18 Make sure all bolts are properly tightened and those requiring a set torque are up to specifications Center Horizontal Pivot Bolt 40 ft Ibs Front Vertical Pivot Bolt 75 ft lbs This bolt can be tightened to a torque range of 60 ft lbs 100 ft lbs for the ease of maneuverability Rear Horizontal Pivot Bolt 60 75 ft lbs See diagram on Page 13 Thank you for Purchasing DORA Products Must have cable anchors or a place o connect cable to frame A TOW BAR Ee roel Tow Bar positioning should be parallel to road surface or within 3 in either direction Page 11 Important Notice Be sure towed vehicle is suitable or adaptable for towing A few models are not towable Be sure to check if towed vehi
13. g the war ranty period promptly notify Dethmers Manufacturing 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 autho rized 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 Limitations on Warranty Coverage Coverage under this warranty will be valid only if the cus tomer warranty card is returned by the original pur chaser within 30 days of purchase Coverage under this warranty will be effective only whena copy ofthe 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 Bar has been misassembled or subjected to neglect negligence misuse accident or operated in any way contrary to the operating and main tenance instruc
14. gain from DEMCO Since taking delivery have you been contacted by the dealer Did you have any problems with this DEMCO product If YES are you satisfied with the company s resolution of your problem Why did you purchase this product Please list the specific source of information prompting this purchase After purchasing this product do you see any needed product improvement What other products would you like to see DEMCO offer Comments Owner s Name Mailing Address City State Model Serial Purchase Date Owner s Signature Warranty Registration Very Satisfied O O YES YES YES YES YES O Zip Code Satisfied O O NO NO NO NO Please return to DEMCO By FAX or tri folding this form to the backside it is pre addressed State Ag RV Rental Brakes Marine Dissatisfied O O If yes what improvement Very Dissatisfied O O Demco 4010 320th Street Box 189 Boyden lowa 51234 Postage SAFETY SIGN LOCATIONS Types of safety sign and locations on the Aluminator 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 A WARNING EMER Rating 6500 b Capacity 2 Receiver hitch with proper weight rating required To Prevent Serious Injury Or Death ZEE Do Not Excee
15. ghting Cable w recpt NOTE Forreplacementparts callorig 9523009 9523004 amp Towed Vehicle Tail Light Wiring Diode Kit inal manufacturer or DEMCO 9523010 Towed Vehicle Tail Light Wiring Diode Kit Only at 1 800 543 3626 9523011 9523006 amp Towed Vehicle Tail Light Wiring Diode Kit Please order replacement parts by PART NO and DESCRIPTION Page 19 NOTE The wires to the optional light bar should be run along the car and fastened so as not to damage the finish of the towed vehicle ESO O RR LIGHT BAR PARTS LIST DESCRIPTION Aluminator Light Bar complete Nylon Security Strap with hooks 4 tightener Left Tail Brake and Signal Light w Lenses 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 3 Suction Cup w Bolt 13 Light Bar Wiring Harness new style 1 4 20UNC x 3 4 Hex Head Bolt Large Red Lens Small Red Lens Clear Lens Please order replacement parts by PART NO and DESCRIPTION 2 1 1 4 1 2 1 10 6 2 4 1 4 PARTS BREAKDOWN COLOR CODE FOR WIRING HARNESS WHITE YELLOW BROWN Tail Lights License Plate Lights Light Cluster Bar amp Clearance Lights Left Turn and Stop GREEN Right Turn and Stop Page 20 TESTING LIGHTS BEFORE USE With headlights in ON position the tail lig
16. hich leg no longer has red stripe showing To latch the second leg turn the top of towed vehicle s steering wheel into the direction of the leg that first latched and slowly back up again This will latch the second leg Once both legs are latched straighten wheels on towed vehicle shut vehicle off If manual transmission shift to neutral unlock steering wheel and make sure parking brake is released For four wheel drive units shift transfer case into neutral also Consult vehicle s manufacturer for towing Suitability of manual or automatic transmission vehicles UNHOOKING THE TOWED VEHICLE Step 1 Begin unhooking your unit by first applying both vehicle parking brakes and unhook your lighting and safety cables Failure to have parking brakes applied could allow towed vehicle to roll forward This could result in limited space between towing vehicle and towed vehicle Step 2 Use the Lock Collar Release lever to relieve any pressure in the connecting legs between the two vehicles by lifting up on handle Step 3 Remove pins that attach tow bar to towed vehicle Aluminator will remain in position Slide the extendable legs back into tube Position electrical cable on storage rod and insert pin to prevent cable from sliding off Page 14 Step 4 Now fold both legs together and push them up ward Step 5 Rotate them counter clockwise into the storage po sition The unit is self supportive in this position
17. hts and the clearance lights should be lighted Start engine and have someone depress brake pedal Brake lights of the light bar and towing vehicle should come on and off simultaneously with each applica tion Turn left turn signal on Left turn light of light bar and tow ing vehicle should flash simultaneously Should the turn signal lights of the light bar function opposite to those of the towing vehicle it is probable that the YELLOW and GREEN wires have been reversed Check the plug con nections to make sure wire colors are not crossed at any point If plug connection is incorrect correct problem by reversing yellow and green wire connection on the towing vehicle OPTIONAL 3 1 2 EXTENDED MALE RECEIVER TUBE PARTS BREAKDOWN PARTS LIST REF PART NO NO QTY 9523008 1 07498 81 1 Extended Receiver Tube 3 1 2 with bushings 2 03808 2 Cross Tube Bushing 3 02961 1 3 4 10UNC Nylon Insert Locknut Please order replacement parts by PART NO and DESCRIPTION DESCRIPTION 3 1 2 Extended Male Receiver complete OPTIONAL DROP LIFT RECEIVER HITCH PARTS BREAKDOWN PARTS LIST REF PART NO NO QTY 9523038 9523039 DESCRIPTION 6 Drop Lift Receiver Hitch complete 3 Drop Lift Receiver Hitch complete 6 Drop Lift Receiver Tube Shown with bushings 3 Drop Lift Receiver Tube with bushings 3 4 10 UNC Nylon Insert Locknut Please order replacement parts
18. n of decal into place Small air pockets can be pierced with a pin and smoothed out using piece of decal backing paper REMEMBER Your best assurance against accidents is a careful and responsible operator If there is any portion of this manual or function you do not understand contact your local authorized dealer or manufacturer BEFORE OPERATION Carefully study and understand this manual Give tow bar a visual inspection for any loose bolts worn parts or cracked welds and make necessary repairs Follow maintenance safety instructions included in this manual Be sure there are no tools lying on tow bar towing unit or towed vehicle Do not use tow bar until you are sure that area is clear especially around children and animals Don t hurry learning process or take tow bar for granted Ease into it and become familiar with your new tow unit Practice operation of your tow unit and its attachments Completely familiarize yourself and other operators with its operation before using Securely attach to towing unit Use an appropriately sized and rated hitch ball and or a Class Ill class IV receiver and attach safety cables Criss cross safety cables under tow bar secure to mounting loops on towing vehicle Do not allow anyone to stand between vehicles when backing up Make sure tow rating on towing unit is high enough for what it is towing To prevent swaying of towed vehicle insure all tires are inflated to specifica
19. ollar in the release position Remove the snap ring 8 While holding Lock Collar pull rear connecting leg outward to the latch position and collar will then slide off outer tube and hang on rear leg Inside of lock collar 6 can be cleaned at this time Lock pawls 11 can be removed at this time for cleaning by pushing rear leg 7 back into outer tube about 1 this will push lock pawls out for removal If not removing shaft go to step 7 For shaft removal or o ring replacement Remove caplugs 1 from the Front Connecting Leg Tube 2 and unbolt Connecting Clevis 3 from Rear Connecting Leg 7 by removing the 1 2 x 3 bolts 4 washers 5 and locknuts 12 Remove Lock Collar 6 Lock Spring 9 and O ring 10 Slide out Rear Leg be careful not to damage the shaft seal Clean o ring groove area and oval hole in outer tube and lock pawls Inspect all parts for excessive wear Reassemble this leg If shaft not removed go to step 3 of reassembly Repeat steps for other side RE 1 10 Page 18 P CY 4 ASSEMBLY Reinstall o ring 10 on outer tube Lubricate only the o ring with a lite coat of copper anti seize included with Aluminator Part number 10173 Note location in Figure A Slide rear leg into front connecting leg tube being carefull not to damage shaft seal see Figure A A slight twisting motion will aid in the installation Slide the rear leg in untill the shaf
20. ost extreme situations typically for tow bar components which for functional purposes cannot be guarded WARNING Indicates a potentially hazardous situation that if not avoided could result in serious injury or death and includes hazards that are exposed when guards are removed It may also be used to alert against unsafe practices CAUTION Indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury It may also be used to alert against unsafe practices If you have questions not answered in this manual or require additional copies please contact your dealer or Dethmers Mfg Co P O Box 189 4010 320th Street Boyden IA 51234 ph 712 725 2311 or 712 725 2302 Toll Free 1 800 543 3626 Fax 712 725 2380 http www demco products com Page 6 A SAFETY YOU CAN LIVE WITH IT A EQUIPMENT SAFETY GUIDELINES Every year many accidents occur which could have been avoided by a few seconds of thought and a more careful approach to handling equipment You the operator can avoid many accidents by observing and following precautions in this section To avoid personal injury study following precautions and insist those working with you or you yourself follow them Replace any caution warning danger or instruction safety decal that is not readable or is missing Location of such decals is indicated in this booklet Do not attempt to operate this tow bar under the influence o
21. p all bystanders and pets clear of work area e Operate towing unit from operators seat only e As a precaution recheck hardware on tow bar every 200 miles and correct all problems Follow maintenance safety procedures AX FOLLOWING OPERATION e Following operation or when unhooking stop towing vehicle set parking brake shut off engine and remove ignition key e Store tow bar in area away from human activity e Do not permit children to play on or around stored tow bar e Make sure parked vehicle is on hard level surface e Wheel chocks may be needed to prevent vehicle from rolling HIGHWAY AND TRANSPORT OPERATIONS e Adopt safe driving practices Always drive at safe speed relative to local conditions and ensure that your speed is low enough for an emergency stop Page 9 A Reduce speed prior to turns to avoid risk of overturning Always keep towing unit in gear to provide engine braking when going downhill Do not coast Do not drink and drive Comply with state and local laws governing highway safety Local laws should be checked for all highway lighting and marking requirements Plan your route to avoid heavy traffic Be a safe and courteous driver Always yield to oncoming traffic in all situations including narrow bridges intersections etc Watch for obstructions overhead and to both sides while towing vehicle Operate with maximum visibility at all times Make allowances for increased length and
22. rtow bar during the 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 expiration 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 Warrantor s responsibility under this warranty extends solely to repair or replacement of your Demco Tow Bar 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 incidental or consequential damages so the above exclusion or limitation may not apply to you Use of Serial Number Identification SN The SN is a 6 digit number located on the tow bar identi fication label The label is located on the bottom side of the tow bar rear yoke Be sure to include the SN num ber in all communications with Warrantor or its dealers concerning the warranty Serial No 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 Manufacturing Co on your Demco Tow Bar and no agent employee or other person is allowed
23. t groove matchess up with the square pawl holes Replace the two lock pawls 11 into the tube insert Replace Lock Spring 9 and Lock Collar 6 NOTE The smaller end of the tapered lock spring 9 must be against the Lock Insert part of the Front Connecting Leg Pull Lock Collar back and slide the rear leg in approximately halfway This will hold the Lock Collar in the release posi tion Replace the snap ring 8 Replace rubber bellows boot 14 to lock collar 6 with nylon ties 15 Reattach Connecting Clevis 3 on Rear Connecting Leg 7 with the 1 2 x 3 bolts 4 washers 5 and locknuts Tighten bolts until clevises are just snug Reinstall the caplug 1 Reattach release handle 13 by tapping on with a rubber mallet SAFETY CABLES STANDARD FOR Aluminator amp REQUIRED FOR TOWING PARTS LIST REF PART NO NO QTY DESCRIPTION 9523003 Safety Cable Kit complete 07230 Coiled Safety Cable w Hooks Please order replacement parts by PART NO and DESCRIPTION AUXILIARY LIGHTING CABLE OPTIONAL 3 NOTE To be used with optional L Light Bar the ends will have to be cut off light bar harness This end willthen need to be wired to the receptacle ofthe auxiliary lighting kit Possible mounting location for lighting receptacle in vehicle air dam AVAILABLE WIRING KITS DESCRIPTION 9523004 4 WayAuxiliary Coiled Lighting Cable w recpt 9523006 6 WayAuxiliary Coiled Li
24. ting Clevis Washer Connecting Clevis 1 2 13NC x 3 Hex Head Bolt Gr 5 1 2 13NC Nylon Insert Locknut 3 4 21 Ga NR Machine Washer SS Attaching Pin 1 4 Quick Pin Lock Collar Release Tool w Grip Black Handle Grip Only Lock Pin F Reciever Rplacement Key Split Ring Please order replacement parts by PART NO and DESCRIPTION Protective Bellows Boot oppor p p pia p pEEF Bees _ nh PID ome fp fom b CROSS SECTIONAL VIEW OF ASSEMBLED FLEX JOINT Pivot Bushing Inner Sleeve Crosstube Right Bushing Connecting Arm 75 ft lbs RAWA Mee E KALE TEER dh 1 B 7 e Left Connecting Arm O Ring Da PEND A Ros O 22 21 af 27 DECALS 8 23 7 DESCRIPTION TB21009 Aluminator Decal 11959 Safety Latch Stripe Red 24 TB21004 User Instruction Decal TB21008 Warning Do Not Exceed Weight Limits amp Manufacturers Patent Hitch Rating Decal Q Please order replacement parts by PART NO and DESCRIPTION 45 25 Page 17 LOCK COLLAR MAINTENANCE INSTRUCTIONS DISASSEMBLY 1 2 Leave Aluminator on towing vehicle or clamp hitch tube in heavy duty vise With a screw driver pry up on bottom of release handle 13 ear to to remove handle Remove bellows boot 14 from lock collar 6 and slide bellow boot back Pull back the Lock Collar 6 and push the Rear Leg 7 approximately halfway in This will hold the Lock C
25. tions Failure to inflate tires evenly will result in towed vehicle to pull unevenly Page 8 A DURING OPERATION e Always follow state and local regulations regarding auxiliary lighting when towing Be sure to check with local law enforcement agencies for your own particular regulations Only safety cables not elastic or nylon plastic tow straps should be used to retain connection between towing unit and towed vehicle in event of separation e Do not load towed vehicle with cargo Towed vehicles exceeding weight limits will overload tow bar and may cause serious injury and damage e Beware of bystanders PARTICULARLY CHILDREN Always look around to make sure it is safe to start engine of towing unit and moving towed vehicle This is particularly important with higher noise levels as you may not hear people shouting e NO PASSENGERS ALLOWED Do not carry passengers anywhere on or in towed vehicle e When halting operation even periodically set towing unit s parking brake shut off engine and remove ignition key e Be extra careful on inclines e MANEUVER TOWING UNIT AT SAFE SPEEDS e Avoid overhead wires or other obstacles Contact with overhead lines could cause serious injury or death e Avoid loose gravel rocks and holes they can be dangerous for unit operation or movement e Allow for unit length when making turns e Do not work under raised components or attachments unless securely positioned and blocked e Kee
26. tions as specified in the Demco Owners Manual for that model tow bar This warranty does not cover any tow bar that has been altered or modified so as to affect the tow bar s operation performance or durability or that has been modified to change the intended use of the tow bar Page 23 In addition the warranty does not extend to repairs made necessary by normal use of parts accessories or other equipment which in the judgment of Warrantor are either incompatible with the Demco Tow Bar or affect its opera tion performance or durability 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 Bar that has been loaded in excess of the load capacity stated on the tow bar identification label Warrantor has a policy of continuous product improvement We reserve the right to change or improve the design of any Demco Tow Bar model including but not limited to state of the art changes without assuming any obligation to modify any tow bar previously manufactured Warrantor assumes no responsibility to the owner for loss of use of the tow bar loss of time inconvenience or other damage consequential or otherwise including but not limited to expense for gasoline expense of transporting the tow bar to the dealer and expense of returning the tow bar mechanic s travel time telephone or telegram charges road service towing charges rental of anothe
27. weight when making turns and stopping PERFORMING MAINTENANCE Good maintenance is your responsibility Poor maintenance is an invitation to trouble Make sure there is plenty of ventilation Never operate engine of towing unit in a closed building Exhaust fumes may cause asphyxiation Before working on tow bar stop towing vehicle set parking brake turn off engine and remove ignition key Always use proper tools or equipment for job at hand Use extreme caution when making adjustments Follow torque chart in this manual when tightening bolts and nuts After servicing be sure all tools parts and service equipment are removed Do not allow grease or oil to build up When replacing bolts refer to owners manual Refer to bolt torque chart for head identification marking Where replacement parts are necessary for periodic maintenance and servicing genuine factory replacement parts must be used to restore your tow unit to original specifications Manufacturer will not claim responsibility for use of unapproved parts and or accessories or other damages as a result of their use If tow unit has been altered in any way from original design manufacturer does not accept any liability for injury or warranty A fire extinguisher and first aid kit should be kept readily accessible while performing maintenance on this tow bar Page 10 L WARNING FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN LOSS OF TOWING VEHICLE CONTROL SEPAR
Download Pdf Manuals
Related Search