Excali-Bar®

OWNERS MANUAL

ASSEMBLY

CALIBRATION

OPERATION

REPLACEMENT PARTS

READ complete manual CAREFULLY

BEFORE attempting operation.

DEMCO • 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

SELF-ALIGNING TOW BAR

TB20001,Rev.4

Excali-Bar

WARNING:

Exceeding weight limitations or not using a towing vehicle larger and at least 1,000 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.

- DO NOT use worn or damaged cables.

- Examine pivot points and latch collars to make sure

they are in good working condition. Check after first 5

miles and every 200 miles thereafter.

- Be certain the safety lock pins lock the clevis pins.

- Keep fingers away from pivot points to prevent

personal injury.

Check clearance between vehicles in a turning situation.

SAFETY

INDEX

Maintenance and Safety ...................................................................................................... Page 1

Operating Instructions ..................................................................................................... Pages 2-3

Excali-Bar

Tow Bar Parts List ......................................................................................... Page 4

Excali-Bar

Tow Bar Parts Breakdown ............................................................................. Page 5

Lock Collar Assembly & Disassembly Instructions ............................................................... Page 6

Safety Cable Kit Parts Breakdown ....................................................................................... Page 7

Auxiliary Lighting Cable Kit Parts Breakdown....................................................................... Page 7

Optional Tow Bar Light Bar Parts Breakdown ...................................................................... Page 8

Warranty Statement ............................................................................................................. Page 9

Optional Extended and Drop/Lift Hitch Attachments ...................................................... Back Page

ADDITIONAL SAFETY ITEMS

Safety is of utmost importance at all times. There are

several items that must be checked each time before

using and while using the Excali-Bar

Before allowing anyone to hook up or operate the

Excali-Bar

, be sure they have read and understand the

proper operating procedure.

This unit must be used with a Class III, 5,000 lb. Hitch.

Be sure the steering components of the towed vehicle

are properly aligned.

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.

NOTE: This unit can be backed up in moderate incre-

ments. Any severe backwards cornering could result in

damage to the Excali-Bar

and/or towed vehicle chas-

sis.

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

disconnect.

Be sure the SAFETY CABLES w/retainers are hooked

to both the towing and towed vehicles using the criss-

cross method.

Do not load the towed vehicle with anything as you may

exceed the towing capacity of the tow bar.

Check to make sure that all lights are in proper working

order.

Make sure the optional light bar is fastened securely

the rear of the towed vehicle.

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.

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 Excali-

Bar

These are self-lubricating washers and your towbar

could lose its self-supporting ability.

Keep the Excali-Bar

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 6.

Make sure all bolts are properly tightened and those

requiring a set torque are up to specifications:

Center Horizontal Pivot Bolt - 40 ft./lbs.

Front Vertical Pivot Bolt - 120 ft./lbs.

(This bolt can be tightened to a torque range of 75 ft./lbs

- 130 ft./lbs for the ease of maneuverability)

Rear Horizontal Pivot Bolt - 60 ft./lbs.

(See diagram on Page 5)

Thank you for Purchasing

Products.

BASE PLATE RECOMMENDATIONS

Must have cable

anchors or a place

to connect cable to

frame

Tow Bar positioning

should be parallel to

road surface or within 6"

in either direction

22" - 26"

Center

Step 4. Slide and twist the legs into position to attach them

to the baseplate. Secure to baseplate using the two attaching

pins and 1/4" Quick-Lock Pin. Towing vehicle must be

larger and at least 1000 lbs. heavier than the towed

vehicle.

Step 3. Extend legs by pulling the Lock Collar back over the

green stripe, which releases the locking mechanism, and

slide the rear legs outward.

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

Refer to load limits on inside of front cover.

Step 1. Insert the Excali-Bar

into a Class III (5,000 lb.) hitch.

Make sure the receiver tube of the tow bar is secured with a

hitch pin supplied with your Excali-Bar

. Criss Cross cables

underneath pivot assembly and attach safety cables near

receiver of towing vehicle.Secure with rubber retainers.

Step 2. Position the vehicle to be towed approx. 24" behind

the towing vehicle. The vehicles do not have to be in straight

alignment to complete the hook-up. Engage towed vehicle

and towing vehicle parking brake.

(Continued on Page 3)

SAFETY CABLE & LIGHT CABLE INSTALLATION

Step 3. Remove pins that attach tow bar to towed vehicle.

Excali-Bar

will remain in position. Now release Lock Collars

and slide the extendable legs back into tube. You must rotate

the attaching clevis 90° for the leg to latch in the storage

position.

Step 4. Now fold both legs together and push them upward.

Step 5. Rotate them counter-clockwise into the storage posi-

tion. The unit is self supportive in this position. Insert the small

hairpin into the lockpin inside the front yoke. Cover your

Excali-Bar

and you are ready to drive your vehicle.

NOTE: If you need to store your Excali-Bar

on the oppo-

site side you must rotate the rear yoke 180° and rotate the

legs clockwise into the storage position.

Step 5. Once you are secured to the tow bar, release towed

vehicle parking brake, shift transmission into neutral and

unlock the steering wheel. NOTE: For four-wheel drive units

the transfer unit must be shifted into neutral also. Reminder:

Consult your vehicles manufacturer for towing suitability.

Attach Safety Cables w/rubber retainers to the baseplate

on towed vehicle

Drive the towing vehicle straight forward

approx. 20 feet until the vehicles are in alignment. Look to see

if green indicator stripes are showing on both Lock Collars. If

they are not, drive straight forward a few more feet then

examine again. Repeat procedure until securely latched.

Alternative Method: If vehicles are in alignment you can

back-up towed vehicle to latch legs. If this fails to latch legs

use above method.

Step 6. Now connect the lighting cable between the towing

vehicle and the towed vehicle lighting system or optional light bar.

The coiled section of the cable will be stored on the support rod

of the left connecting leg. The cotter pin in the end of the

support rod can be used to keep any excess cable from sliding

off.

REMINDER: The transmission must be in neutral and the

steering must be unlocked to allow the front wheels to

"Track" and disengage the parking brake of the towed

vehicle.

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 Tool to relieve any

pressure in the connecting legs between the two vehicles.

Green Stripe

REF. PART

NO. NO. QTY. DESCRIPTION

1. 03796 X 1 Male Receiver

2. 03808 X 2 Crosstube Bushing

3. 07161 X 2 3/4"-10UNC x 4-1/2" Hex Head Bolt (Gr.5)

4. 02961 X 2 3/4"-10UNC Nylon Insert Locknut

5. 03798 X 1Front Yoke

6. 03799 X 1Rear Yoke

7. 07162 X 1 3/4"-16UNF x 2-1/2" Hex Head Bolt (Gr.5)

8. 00116 X 1 5/32" x 1-1/2" lg. Cotter Pin

9. 03806 X 2 Yoke Washer

10. 03797 X 1 Thrust Plate

11. 07218 X 1 3/4"-16UNF Hex Jam Nut

12. 03810 X 1 Connecting Arm Bushing

13. 05645 X 2 1-3/4" Round Caplug

14. 04795 X 2 1/2"-13UNC x 1" Hex Head Bolt(Gr.5)

15. 00084 X 2 1/2" Lockwasher

16. 03804 X 2 Stop Washer

17. 01516 X 1 1/8" x 1-1/4" OD x 1" ID O-Ring

18. 03807 X 4 Ear Washer

19. 07696 X 1 Left Front Connecting Leg

20. 07697 X 1 Right Front Connecting Leg

21. 07221 X 1 Light Cable Anchor

22. 00879 X 1 1/4"-20UNC x 1-3/4" Hex Head Bolt (Gr.5)

23. 02772 X 1 1/4"-20UNC Nyon Insert Locknut

24. 07222 X 1 Lanyard Cables

25. 00182 X 2 1/8" Small Hair Pin

26. 07223 X 1 5/32" x 3/4" Roll Pin

27. 03805 X 1 Wire Support

28. 03871 X 4 Lock Pawl

29. 07224 X 2 Leg Seal

30. 03872 X 2 Coil Spring

31. 07695 X 2 Lock Collar

32. 03873 X 2 Snap Ring

33. 07694 X 2 Rear Connecting Leg

34. 03809 X 4 Connecting Clevis Washer

35. 03803 X 2 Connecting Clevis

36. 07164 X 2 1/2"-13UNC x 3" Hex Head Bolt (Gr.5)

37. 02178 X 4 1/2"-13UNC Nylon Insert Locknut

38. 07275 X 2 3/4" 14 Ga. NR Machine Washer

39. 03878 X 2 Attaching Pin

40. 02397 X 2 1/4" Quick Pin

41. 03870 X 1 Lock Collar Release Tool w/Grip

42. 02243 X 2 Black Handle Grip

43. 07248 X 1 Receiver Pin

44. 07245 X 1 Offset Hairpin

45. 07225 X 1 Split Ring

- 9523002 - Vinyl Storage Cover (Optional-not shown)

PARTS BREAKDOWN

Order No. 9511004

Please order replacement parts by PART NO. and DESCRIPTION.

Inner Sleeve

Right

Connecting Arm

Left

Connecting Arm

O-Ring

Pivot Bushing

Crosstube

Bushing

CROSS SECTIONAL VIEW OF ASSEMBLED FLEX- JOINT

Ear Washers

Yoke Washers

40 ft/lbs.

60 ft/lbs.

120 ft/lbs.

PAT. PEND.

LOCK COLLAR MAINTENANCE INSTRUCTIONS

DISASSEMBLY:

1. Leave Excali-Bar

on towing vehicle or clamp hitch tube in

heavy-duty vise.

2. 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. Remove the snap-ring (#8).

4. While holding Lock Collar, pull rear connecting leg out-

ward to the latch position and collar will release com-

pletely. NOTE: Lock Pawls can be removed at this time for

cleaning and lock collar (#6) can be pulled forward and

inside of lock collar cleaned. NOTE: For extensive

cleaning or shaft removal; Remove caplugs (#1) from

the Front Connecting Leg Tube (#2) and unbolt Connect-

ing Clevis (#3) from Rear Connecting Leg (#7) by remov-

ing the 1/2" x 3" bolts (#4), washers (#5) and locknuts.

5. Remove Lock Collar (#6) and Lock Spring (#9).

6. Remove the two square lock pawls (#10) from the tube

insert and slide out Rear Leg, be careful not to damage the

shaft seal.

7. Clean and inspect all parts for excessive wear.

Lubricate all moving parts with a light coat of lubricant.

8. Reassemble this leg, repeat steps for other side.

REASSEMBLY:

1. If Rear Leg (#7) was removed, slide it into Front Connect-

ing Leg Tube (#2) being careful not to damage shaft seal.

A slight twisting motion will aid in the installation. Slide the

rear leg in until the first shaft groove matches up with the

square pawl holes.

2. Reinstall the caplug (#1).

3. Replace the two square lock pawls (#10) into the tube

insert.

4. 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 Connect-

ing Leg.

5. Pull Lock Collar back and slide the rear leg in approxi-

mately halfway. This will hold the Lock Collar in the

release position.

6. Replace the snap-ring (#8).

7. Slide the rear leg (#7) in the rest of the way. This will cause

the Lock Collar (#6) to snap into the locked position.

8. 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.

SAFETY CABLES

(STANDARD FOR Excali-Bar

& REQUIRED FOR TOWING)

Possible mounting

location for lighting

receptacle in vehicle

air dam.

AUXILIARY LIGHTING CABLE

(OPTIONAL)

1. 07230 X 2 Coiled Safety Cable w/Hooks

2. 07426 X 4 Safety Hook Retainer (Plastic)

9523003 Safety Cable Kit (complete)

REF. PART

NO. NO. QTY. DESCRIPTION

PARTS LIST

9523004 4-WayAuxiliary Coiled Lighting Cable w/recpt.

9523006 6-WayAuxiliary Coiled Lighting Cable w/recpt.

9523009

9523004 & Towed Vehicle Tail Light Wiring/Diode Kit

9523010 Towed Vehicle Tail Light Wiring/Diode Kit Only

9523011

9523006 & Towed Vehicle Tail Light Wiring/Diode Kit

ORDER

NO. DESCRIPTION

AVAILABLE WIRING KITS

Please order replacement parts by PART NO. and DESCRIPTION.

NOTE: For replacement parts, call

original manufacturer or

DEMCO at 1-800-543-3626

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.

KKLB

Excali-Bar

Light Bar (complete)

REF. PART

NO. NO. QTY. DESCRIPTION

LIGHT BAR PARTS LIST

Please order replacement parts by PART NO. and DESCRIPTION.

1. 01772 X 2 Nylon Security Strap with hooks & tightener

2. 01857 X 1 Left Tail/ Brake and Signal Light w/Lenses

3. 01773 X 1 Brown Jumper Wire

4. 01886 X 4 Wire Holder (metal)

5. 02385 X 1 Light Bar Framework

6. 02386 X 2 Adjustable Light Bracket

7. 01856 X 1 Right Tail/ Brake and Signal Light w/Lenses

8. 02772 X 10 1/4"-20UNC Nylon Insert Locknut

9. 00092 X 6 1/4"-20UNC x 1/2" Hex Head Bolt

10. 01777 X 2 Light Bar "Z" Bracket

11. 01778 X 4 3" Suction Cup w/Bolt (#13)

12. 02198 X 1 Light Bar Wiring Harness (new style)

13. 00068 X 4 1/4"-20UNC x 3/4" Hex Head Bolt

14. 01911 X - Large Red Lens

15. 01912 X - Small Red Lens

16. 01890 X - Clear Lens

OPTIONAL LIGHT BAR (KKLB) PARTS BREAKDOWN

TESTING LIGHTS BEFORE USE

1. With headlights in "ON" position, the tail lights and the

clearance lights should be lighted.

2. 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.

3. Turn left turn signal on. Left turn light of light bar and towing

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

connections 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.

COLOR CODE FOR WIRING HARNESS

WHITE

BROWN

YELLOW

GREEN

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.

1. Extent and Duration of this Warranty:

Your Demco Excali-Bar

is warranted to be free from

defects in materials and workmanship under normal use

and service for a period of one year after 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

Excali-Bar

found in the judgement of the manufacturer to

be defective in materials or workmanship will be re-

paired or replaced at the manufacturer’s option without

charge for parts or labor to the original owner.

2. Manufacturer and Warrantor of Tow Bar:

Dethmers Manufacturing Co.

4010 320th Street

P.O. Box 189

Boyden, IA 51234

(712) 725-2311

3. Repair or Replacement Procedure:

If your Demco Tow Bar develops a defect during the

warranty 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 authorized

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.

4. Limitations on Warranty Coverage:

Coverage under this warranty will be valid only if the

customer warranty card is returned by the original

purchaser within 30 days of purchase.

Coverage under this warranty will be effective only when

a copy of the 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 mainte-

nance instructions as specified in the Demco Owner’s

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.

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 improve-

ment. 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 another tow bar

during the time warranty repairs are being performed,

travel, lodging, loss or damage to personal property or

loss of revenue or earnings.

5. 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.

6. 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.

7. Use of Serial Number Identification (SN):

The SN is a 6 digit number located on the tow bar

identification label. The label is located on the bottom side

of the tow bar rear yoke. Be sure to include the SN number

in all communications with Warrantor or its dealers

concerning the warranty.

Serial No.________________________

8. Purchaser’s Rights:

This warranty gives you specific legal rights, and you may

also have other rights which vary from state to state.

9. 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 to change or add to

this warranty.

DEMCO PRODUCTS - Excali-Bar

Tow Bar

ORIGINAL PURCHASERS LIMITED WARRANTY

OPTIONAL 3-1/2" EXTENDED MALE RECEIVER TUBE

PARTS BREAKDOWN

9523008 3-1/2" Extended Male Receiver Tube

REF. PART

NO. NO. QTY. DESCRIPTION

PARTS LIST

1. 07448 X 1 Extended Receiver Tube (3-1/2")

2. 03808 X 2 Cross Tube Bushing

3. 02961 X 1 3/4"-10UNC Nylon Insert Locknut

Please order replacement parts by PART NO. and DESCRIPTION.

que

0ft/l

que

0ft/l

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)

9523007 6" Drop/Lift Receiver Hitch (complete)

REF. PART

NO. NO. QTY. DESCRIPTION

PARTS LIST

1. 07480 X 1 6” Drop/Lift Receiver Tube

- 09281 X 1 3” Drop/Lift Receiver Tube

2. 03808 X 2 Cross Tube Bushing

3. 02961 X 1 3/4"-10 UNC Nylon Insert Locknut

Please order replacement parts by PART NO. and DESCRIPTION.

9523020 3" Drop/Lift Receiver Hitch (complete)

OPTIONAL DROP/LIFT RECEIVER HITCH

PARTS BREAKDOWN