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1-08
TB20017,Rev.12
Page 1
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WARNING: Exceeding weight limitations or not using a towing vehicle larger and at least 500 lbs. 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 .........................................................................................
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Ag ❍ RV ❍ Warranty Registration Rental ❍ Brakes ❍ 4010 320th Street • Box 189 • Boyden, Iowa 51234 Marine ❍ Toll Free 800-54DEMCO (800-543-3626) • FAX 800-845-6420 www.demco-products.com Very Very Satisfied Dissatisfied Satisfied Dissatisfied How satisfied are you with our product? ❍❍ ❍ ❍ How satisfied are you with the dealership/distributor sales staff? ❍❍ ❍ ❍ Dealer/Distributor Name City State
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Postage Demco 4010 320th Street, Box 189 Boyden, Iowa 51234 Page 4
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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. WARNING Rating - 6500 lb. Capacity 2" Receiver hitch with proper weight rating required To Prevent Serious Injury Or Death: WARNING Do Not Exceed Capacity of Towing Hitch, Towbar, or
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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: WARNING, and CAUTION with safety messages. Indicates a potentially hazardous situation that, if Appropriate signal wor
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SAFETY...YOU CAN LIVE WITH IT 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
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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. • Al
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DURING OPERATION • 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. • Do not load towed vehicle with cargo. Towed vehicles exceeding weight limits will overload tow bar and may cause serious injury and da
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- 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 traffi c. • Be a safe and courteous driver. Always yield to oncoming traffi c in all situations, including narrow bridges, i
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WARNING: FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN LOSS OF TOWING VEHICLE CONTROL, SEPARA- 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 MAINTENANCE Safety is of utmost importance at all times. To prevent per- Periodically check all bolts and nuts to ensure proper sonal injury or property damage, observe the following. tension or torque. • Befor
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Important Notice! Be sure towed vehicle is suitable or adaptable for towing. A few models are not towable! Be sure to check if towed vehicle 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 specifi cations for the proper way to un
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SAFETY CABLE & 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 UP THE VEHICLE TO BE TO
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UNHOOKING THE TOWED VEHICLE Step 1. Begin unhooking your unit by fi rst 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 6. Hook safety cables to chain anchor of baseplate. Note: Make sure safety clip is in working order. Red Stripe Step 7. Leave the electrical cable storage pin (circled above) S
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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. Insert the small hairpin into the lockpin inside the front yoke. Cover your TM Aluminator and you are ready to drive your vehicle. TM NOTE: Picture shown in 90 degree position. Aluminator will also store in 45 degree position. TM NOTE: If you need to store your Aluminator on the op- posite side you must rotate the r
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PARTS BREAKDOWN Order No. 9511007 REF. PART REF. PART NO. NO. QTY. DESCRIPTION NO. NO. QTY. DESCRIPTION 1. 03796-81 1 Male Receiver with bushings 46. 09343 6 Plastic Bearing (Nyliner) 2. 03808 2 Crosstube Bushing Only 47. 10117 2 O-ring 1.862 I.D. x .103 Cross Section 3. 07161-95 2 3/4”-10NC x 4-1/2” Hex Head Bolt (Gr.5) 48. 11770 1 Washer, .782 ID, Stainless Steel 4. 02961 2 3/4”-10NC Nylon Insert Locknut 49. 11825 2 Protective Bellows Boot 5. 09386-89 1 Front Yoke 50. 11874 4
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39 CROSS SECTIONAL VIEW OF ASSEMBLED FLEX- JOINT 36 34 Pivot Bushing Ear Washers Inner Sleeve Yoke Washers 35 Crosstube Right Bushing Connecting Arm 34 75 ft/lbs. 33 40 37 40 ft/lbs. Left Connecting Arm O-Ring 36 35 40 39 34 33 34 31 32 37 49 30 29 47 46 25 PAT. PEND. 46 28 50 22 21 19 26 28 27 DECALS ORDER 23 NO. QTY. DESCRIPTION TB21009 2 Aluminator Decal 11959 2 Safety Latch Stripe (Red) 24 TB21004 1 User Instruction Decal TB21008 1 Warning Do Not Exceed Weight Limits & 1 Manufac
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LOCK COLLAR MAINTENANCE INSTRUCTIONS 4 3 13 5 12 6 5 11 7 10 8 14 2 9 11 15 15 1 REASSEMBLY: DISASSEMBLY: ® 1. Reinstall o-ring (#10) on outer tube. Lubricate only the 1. Leave Aluminator on towing vehicle or clamp hitch tube o-ring with a lite coat of copper anti-seize (included with in heavy-duty vise. ® Aluminator Part number 10173). (Note location in Figure 2. With a screw driver, pry up on bottom of release handle A) (#13) ear to to remove handle. Remove bellows boot 2. Slide r
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SAFETY CABLES TM (STANDARD FOR Aluminator & REQUIRED FOR TOWING) 1 PARTS LIST REF. PART 1 NO. NO. QTY. DESCRIPTION 9523003 Safety Cable Kit (complete) 1. 07230 2 Coiled Safety Cable w/Hooks Please order replacement parts by PART NO. and DESCRIPTION. AUXILIARY LIGHTING CABLE (OPTIONAL) NOTE: To be used with optional Light Bar, the ends will have to be cut off light bar harness. This end will then need to be wired to the receptacle of the auxiliary Possible mounting li
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OPTIONAL LIGHT BAR (KKLB) PARTS BREAKDOWN COLOR CODE FOR WIRING HARNESS WHITE Ground BROWN Tail Lights, License Plate Lights, 7 Light Cluster Bar & Clearance Lights 1 6 YELLOW Left Turn and Stop GREEN Right Turn and Stop 8 14 8 9 8 1 2 9 9 4 8 3 5 15 8 4 16 9 12 13 13 1 10 8 1 11 11 NOTE: The wires to the optional light bar should be run along the car and fastened so as not to damage the fi nish of the towed vehicle. LIGHT BAR PARTS LIST REF. PART NO. NO. QTY. DESCRIPTION TM KKLB Alumin
