01-04 TB20017,Rev.6 DOING OUR BEST TO PROVIDE YOU THE BEST ALUMINATOR TM SELF-ALIGNING TOW BAR OPERATORS MANUAL READ complete manual CAREFULLY BEFORE attempting operation. ASSEMBLY CALIBRATION 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.
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 Safety, Sing Location .........................................................................................................
SAFETY SIGN LOCATIONS Types of safety sign and locations on the Aluminator ô 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.
WARNING: FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN LOSS OF TOWING VEHICLE CONTROL, SEPARATION 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 personal injury or property damage, observe the following. Periodically check all bolts and nuts to ensure proper tension or torque.
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 vehicleís transmission. Be sure that towed vehicleís steering wheel is unlocked and free to turn.
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.
Step 7. 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 by which leg has green stripe shown by lock collar.
PARTS BREAKDOWN Order No. 9511007 REF. NO. PART NO. QTY. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45.
CROSS SECTIONAL VIEW OF ASSEMBLED FLEX- JOINT 39 36 Pivot Bushing Ear Washers Yoke Washers 34 Inner Sleeve Crosstube Bushing 35 Right Connecting Arm 34 75 ft/lbs. 37 60 ft/lbs. 40 40 ft/lbs. Left Connecting Arm O-Ring 36 35 40 34 41 33 34 31 47 PAT. PEND. 25 46 28 37 29 30 32 46 22 21 19 26 28 27 18 DECALS ORDER NO. TB21009 09869 TB21004 TB21008 23 24 QTY.
LOCK COLLAR MAINTENANCE INSTRUCTIONS Lock Pawl Figure A O-Rings Spring Plastic Bearing Front Connecting Leg Tube Snap Ring Shaft Seal 4 Rear Leg 3 Collar 5 Plastic Bearing 6 7 9 11 8 2 5 10 11 1 DISASSEMBLY: Figure B 1. Leave AluminatorÆon towing vehicle or clamp hitch tube in heavy-duty vise. REASSEMBLY: 1. Reinstall o-rings (#10) on outer tube. (Note location in 2. Pull back the Lock Collar (#6) and push the Rear Leg (#7) Figure A) approximately halfway in.
SAFETY CABLES (STANDARD FOR AluminatorTM & REQUIRED FOR TOWING) 1 2 PARTS LIST REF. PART NO. NO. QTY. 1 9523003 1. 07230 2 2. 07426 - DESCRIPTION Safety Cable Kit (complete) Coiled Safety Cable w/Hooks Safety Hook Retainer (Replacement Only) 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.
OPTIONAL LIGHT BAR (KKLB) PARTS BREAKDOWN COLOR CODE FOR WIRING HARNESS WHITE Ground BROWN Tail Lights, License Plate Lights, Light Cluster Bar & Clearance Lights YELLOW Left Turn and Stop GREEN Right Turn and Stop 7 6 1 8 14 9 8 8 1 2 9 9 4 8 3 5 15 8 9 16 4 12 13 13 1 10 8 11 1 11 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. LIGHT BAR PARTS LIST REF. PART NO. NO. QTY. KKLB 1. 2. 3. 4. 5. 6.
DEMCO PRODUCTS - AluminatorTM Tow Bar ORIGINAL PURCHASERS LIMITED WARRANTY 1. Extent and Duration of this Warranty: Your Demco AluminatorTM 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.
OPTIONAL 3-1/2" EXTENDED MALE RECEIVER TUBE PARTS BREAKDOWN 3 To rqu eT o1 20 ft/l bs . 2 1 2 PARTS LIST REF. PART NO. NO. QTY. 9523008 1. 10174-81 1 2. 03808 2 3. 02961 1 DESCRIPTION 3-1/2" Extended Male Receiver (complete) Extended Receiver Tube 3-1/2" with bushings Cross Tube Bushing 3/4"-10UNC Nylon Insert Locknut Please order replacement parts by PART NO. and DESCRIPTION. OPTIONAL DROP/LIFT RECEIVER HITCH PARTS BREAKDOWN 3 2 1 To rqu eT o1 20 ft/l bs . 2 PARTS LIST REF. PART NO. NO.
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DETHMERS MFG. COMPANY P.O. BOX 189 4010 320th St., BOYDEN, IA. 51234 PH: (712) 725-2311 or (712) 725-2302 FAX: (712) 725-2380 TOLL FREE: 1-800-54DEMCO (1-800-543-3626) www.demco-products.
