2-04 TB20001,Rev.10 DOING OUR BEST TO PROVIDE YOU THE BEST Excali-Bar ® 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 Table of Contents .............................................................................................................
SAFETY SIGN LOCATIONS ® Types of safety sign and locations on the Excalibar 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 - 8000 lb. Capacity 2î 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.
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: in 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. HOOKING UP THE VEHICLE TO BE TOWED Step 4.
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.
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.
CROSS SECTIONAL VIEW OF ASSEMBLED FLEX- JOINT Yoke Washers Pivot Bushing Ear Washers Inner Sleeve Crosstube Bushing Right Connecting Arm 60 ft/lbs. 120 ft/lbs. 39 36 40 ft/lbs. 34 35 34 Left Connecting Arm O-Ring 37 33 40 36 35 40 39 34 41 34 33 PAT. PEND. 31 25 46 28 29 37 30 32 22 18 26 21 19 28 27 DECALS 18 23 24 45 ORDER NO. QTY.
LOCK COLLAR MAINTENANCE INSTRUCTIONS Figure A Lock Pawl O-Rings Spring Snap Ring Shaft Seal 4 Front Connecting Leg Tube Rear Leg 3 5 Collar 6 7 9 11 8 2 5 10 11 1 Figure B Æ Leave Excali-Bar on towing vehicle or clamp hitch tube in heavy-duty vise. REASSEMBLY: Pull back the Lock Collar (#6) and push the Rear Leg (#7) 1. Reinstall o-rings (#10) on outer tube. (Note location in approximately halfway in. This will hold the Lock Collar in Figure A) the release position. 2.
SAFETY CABLES (STANDARD FOR Excali-BarÆ & 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. 1. 2. 3. 4. 5. 6. 7. 8.
DEMCO PRODUCTS - Excali-BarÆ Tow Bar ORIGINAL PURCHASERS LIMITED WARRANTY 1. Extent and Duration of this Warranty: Your Demco Excali-BarÆ 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. 9523028 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.
