-08 TB20017,Rev.
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 .........................................................................................................
Warranty Registration 4010 320th Street • Box 189 • Boyden, Iowa 51234 Toll Free 800-54DEMCO (800-543-3626) • FAX 800-845-6420 www.demco-products.
Postage Demco 4010 320th Street, Box 189 Boyden, Iowa 51234 Page 4
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 WARNING To Prevent Serious Injury Or Death: Do Not Exceed Capacity of Towing Hitch, Towbar, or Towing Vehicle DETHMERS MFG.
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.
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.
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.
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 damage.
- 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.
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 vehicle’s transmission. Be sure that towed vehicle’s 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.
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 6. Hook safety cables to chain anchor of baseplate. Note: Make sure safety clip is in working order. Red Stripe Step 7.
Step 4. ward. Now fold both legs together and push them up- Step 5. Rotate them counter-clockwise into the storage position. The unit is self supportive in this position. Insert the small hairpin into the lockpin inside the front yoke. Cover your 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.
PARTS BREAKDOWN Order No. 9511007 REF. NO. 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. PART NO.
39 CROSS SECTIONAL VIEW OF ASSEMBLED FLEX- JOINT 36 34 Yoke Washers 35 Pivot Bushing Ear Washers Inner Sleeve Crosstube Bushing 34 Right Connecting Arm 75 ft/lbs. 33 37 60 ft/lbs. 40 40 ft/lbs. Left Connecting Arm O-Ring 36 35 40 34 33 37 49 25 PAT. PEND. 22 46 28 46 47 29 34 32 31 30 50 21 19 26 28 27 DECALS ORDER NO. 23 24 TB21009 11959 TB21004 TB21008 QTY.
LOCK COLLAR MAINTENANCE INSTRUCTIONS 4 3 13 5 12 6 11 14 7 10 5 8 2 9 11 15 15 1 DISASSEMBLY: REASSEMBLY: 1. 1. Leave Aluminator®on towing vehicle or clamp hitch tube in heavy-duty vise. 2. With a screw driver, pry up on bottom of release handle (#13) ear to to remove handle. Remove bellows boot 2. (#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 Collar in the release position. 3.
SAFETY CABLES (STANDARD FOR AluminatorTM & REQUIRED FOR TOWING) 1 PARTS LIST REF. PART NO. NO. QTY. 1 9523003 1. 07230 2 DESCRIPTION Safety Cable Kit (complete) 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 lighting kit.
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 9 8 14 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. 1. 2. 3. 4. 5. 6. 7. 8.
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. 07498-81 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. QTY.
OPTIONAL TOW-BAR TO BASE PLATE LOCKING PINS 1 2 PARTS LIST REF. PART NO. NO. 9523043 1. 5847 2. 12431 DESCRIPTION Tow-Bar to Base Plate Locking Pin Set Tow-Bar to Base Plate SingleLocking Pin Assembly Replacement Keys Please order replacement parts by PART NO. and DESCRIPTION. OPTIONAL 3-PIECE LOCKING PINS 2 3 1 PARTS LIST REF. PART P NO. NO. 3 9523044 9 95 1. 5847 2. 5846 3.
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.
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.
