Quality Towing Systems since 1974
Entire contents of manual must be read by owner
Owner's Manual
Welcome to the ROADMASTER family!
This manual has been prepared to acquaint you with the installation, operation, care and maintenance of your tow bar,
and to provide you with important safety information.
Read your owner’s manual cover to cover. Understand how to install and operate your tow bar, and carefully follow
the instructions and safety precautions.
Your tow bar has a one-year limited warranty. To qualify for your warranty, fill out and return the enclosed product
registration card within 30 days of purchase. As a bonus, we’ll extend your warranty to a total of two years at no
additional cost, if we receive the product registration card within 20 days of purchase.
We thank you for your patronage and greatly appreciate your discerning taste.
IMPORTANT NOTICE!
Safety Definitions
Statements in this manual identified as follows are of special significance:
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result in property
damage, serious personal injury, or even death.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in property damage, or minor or moderate personal injury.
CAUTION
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
NOTE
Refers to important information and is placed in italic
type. It is recommended that you take special notice of
these items.
Table of Contents
Safety definitions ................................... inside front cover
Safe towing practices ..................................................... 2-4
Installer’s safety checklist ............................................. 4-5
Installing the ‘quick-disconnect’ system...................... 6-8
Connecting and disconnecting
Connecting the tow bar ........................................... 8-11
Disconnecting the tow bar ......................................... 12
Wiring instructions
Wiring a four-wire system ..................................... 13-14
Your tow bar serial number…
…is located on a label on the inside of the driver’s side
tow bar arm. You will need this number when you fill out
your product registration card.
Write down the serial number in the space below and
retain for future reference.
Serial number:
Wiring a six-wire system ....................................... 14-15
Safety cables
How to use safety cables .......................................... 16
Proper installation of safety cables ..................... 17-18
Stay within the ‘Safe Zone’ ............................................ 19
Care and cleaning ........................................................... 20
Limited warranty .............................................................. 21
Tow bar components ......................................... back cover
WARNING
Read all instructions before installing the tow bar,
or before towing a vehicle. Failure to understand how
to properly install or operate the tow bar could result
in property damage, personal injury or even death.
1
Safe Towing Practices
To ensure your safety and that of your passengers, as
well as the safety of others on the road, follow these safe
towing practices at all times.
CAUTION
Do not back up the motorhome with the towed ve-
•
hicle attached.
Backing up with the towed vehicle attached will
cause the towed vehicle to “jackknife,” which will
damage the tow bar, the mounting bracket, the receiver hitch, the towed vehicle's front end, and/or the rear
of the motorhome. Backing up with the towed vehicle attached is the primary cause of tow bar damage
and will void the warranty.
Be sure the vehicle can be towed before taking it
•
on the road. Some vehicles must be equipped with a
transmission lube pump, an axle disconnect, driveline disconnect or free-wheeling hubs before they can be towed.
Failure to properly equip the vehicle will cause severe
damage to the transmission.
Check the vehicle manufacturer’s instructions for the
proper procedure(s) to prepare the vehicle for towing.
2
The tow bar must be within the ‘Safe Zone’ — no
•
more than three inches above level or four inches below
level. Towing with an out-of-level tow bar will cause significant wear and tear on the tow bar and mounting brackets, and on the towed vehicle’s suspension and frame.
(See the section titled “Stay within the ‘Safe Zone’” for
further information.)
The steering wheel must be unlocked and free to
•
turn when towing.
and equipment damage. Check the manufacturer's instructions for the proper towing procedure(s).
The towed vehicle and all its contents cannot ex-
•
ceed 6,000 pounds.
rated at a maximum of 6,000 pounds carrying capacity;
therefore the towed vehicle and all its contents cannot
exceed 6,000 pounds.
In addition, the receiver hitch, the safety cables, and
all supplementary towing equipment must be rated at no
less than the weight of the towed vehicle and all its contents.
The tow bar must be secured with linch pins (or
•
optional padlocks) before towing.
is secured to both vehicles with all appropriate pins (or
padlocks), the towed vehicle will detach.
Inspect the system before towing — check the
•
mounts, brackets, fasteners, bolts, wiring, the safety cables, and all other components each time before towing.
Failure to do so can cause severe tire
The Sterling All Terrain tow bar is
Unless the tow bar
continued on next page
Safe towing practices
continued from preceding page
Additionally, check the tow bar bracket every 3,000
miles — inspect for any fractures or cracks in the steel,
or any visible damage. Do not tow if the tow bar bracket
is damaged.
Additionally, check the torque on all bolts. (To find the
torque ratings, refer to the installation instructions for the
mounting bracket and the tow bar.)
Never tow a vehicle with one of a comparable
•
weight.
40 percent of the towing vehicle’s weight.
the towed vehicle to override the towing vehicle, resulting in “jackknifing,” “leapfrogging,” or “fishtailing.” Serious damage to both vehicles, as well as the towing system, could result.
•
motorhome as possible when releasing the tow bar
locking mechanisms.
able arms, or put any part of your body between the adjustable arms, when releasing the tow bar — always stand
to one side. Because the towed vehicle may jerk forward
when the locking mechanisms are released, face the
towed vehicle and stand as close to the back of the motorhome as possible before releasing the locking mechanisms, to keep from being hit by the towed vehicle.
•
The towed vehicle’s weight should never exceed
Towing a vehicle with one of similar weight will cause
Always stand to one side and as close to the
Never stand between the adjust-
Always use safety cables when towing. The safe-
ty cables, which are provided with the Sterling All Terrain, must connect the towed vehicle to the towing vehicle frame to frame.
If the safety cables are ever replaced, use only 6,000
pound or heavier rated safety cables.
Additionally, check to ensure that the safety cables
are the proper length. Refer to the sections titled “How
to use safety cables” and “Proper installation of safety
cables” for further information.
Check the motorhome turning radius. Some motor-
•
home chassis have such a tight turning radius that you
can damage your motorhome, towed vehicle, or tow bar
while turning too sharply. Before getting on the road with
your towed vehicle, you should test your turning radius
in an empty parking lot.
With the towed vehicle attached, have someone
watch as you slowly turn sharply to see whether you have
this potential problem. If you do, note how far you can
safely turn the motorhome’s steering wheel, and be sure
not to turn it further when towing. Damage that results
from turning too sharply is not covered by warranty.
Never use the tow bar to tow more than one ve-
•
In some states it is legal to have one vehicle tow-
hicle.
ing more than just one vehicle (for example, a truck which
is towing a trailer which is towing a boat). However, when
continued on next page
3
Safe towing practices
continued from preceding page
using a tow bar, never tow more than one vehicle, or nonwarranty damage or injury may result.
The tow bar stinger fits motorhome hitch receiv-
•
ers with 2-inch inner diameters.
receiver is a larger size, attach a 2-inch adaptor sleeve
(not supplied) to the hitch receiver.
Damage to the tow bar stinger or other components
of the tow bar, abnormal wear patterns on the towed
vehicle’s tires, as well as other, consequential damage
may result if an adaptor sleeve is not used.
Keep the tow bar clean and well-lubricated. As is
•
the case with most precision equipment, frequent cleaning and care results in better performance and longevity. Refer to the section titled “Care and cleaning” for further information.
WARNING
Failure to follow these instructions may cause
property damage, personal injury or even death.
4
If the motorhome hitch
Installer’s safety checklist
The following safety checklist is provided to the installer with the instructions for installing the Sterling All Terrain tow bar. It is repeated here for your information.
As a precaution, verify that all safety requirements
have been followed before towing the vehicle.
Stress to the owner that the tow bar must be with-
•
in the ‘Safe Zone’
level or four inches below level. Towing with an out-oflevel tow bar will cause significant wear and tear on the
tow bar and mounting brackets, and on the towed vehicle’s suspension and frame. (See the section titled “Stay
within the ‘Safe Zone’” for further information.)
Show the owner how to properly operate the tow
•
Familiarize yourself with the features of the tow bar.
bar.
Demonstrate them to the owner, and ask the owner to
connect and disconnect the tow bar and other components of the towing system, until the owner is comfortable with its operation.
Caution the owner to use a receiver hitch rated
•
higher than the actual weight of the towed vehicle.
The motorhome receiver hitch must have a minimum
capacity of no less than the weight of the towed vehicle
and all its contents.
(The Sterling All Terrain tow bar is rated at a maxi-
— no more than three inches above
continued on next page
Installer’s safety checklist
continued from preceding page
mum of 6,000 pounds carrying capacity; therefore ROADMASTER has used 6,000 pounds as a standard for rating the weight capacity of all supplementary towing equipment, as well as the towed vehicle and all its contents,
throughout this manual.)
The tow bar must be attached to a bracket which
•
is bolted to the towed vehicle’s frame or unibody.
order to be towed, virtually all vehicles require a tow bar
mounting bracket that is connected to the frame, unibody
or chassis and extends beyond the bumper.
Caution the owner to secure the tow bar with linch
•
pins (or optional padlocks) before towing.
tow bar is secured to both vehicles with all appropriate
pins (or padlocks), the towed vehicle will detach.
Advise the owner to use 6,000 pound or higher
•
rated safety cables.
cables are provided with the Sterling All Terrain; if the
safety cables are ever replaced, use only 6,000 pound or
heavier rated safety cables.
Read the instructions thoroughly before installing
•
the ‘quick-disconnect’ (‘QD’) system and its components.
the QD system is not properly aligned, centered and positioned on the towed vehicle, the tow bar will not be
centered on the towed vehicle, which may cause excessive tire wear and other consequential, non-warranty
The tow bar will be attached to the QD system. If
Six-thousand pound-rated safety
Unless the
In
damage.
The installer must be sure that the vehicle is suit-
•
able or adaptable for towing.
equipped with a transmission lube pump, an axle disconnect, driveline disconnect or free-wheeling hubs before
they can be towed. Failure to properly equip the vehicle
will cause severe damage to the transmission.
Check the manufacturer’s instructions for the proper
procedure(s) to prepare the vehicle for towing.
The installer must NOT use the tow bar as a
•
ground for welding.
frame’ of the tow bar will cause current to flow through
the locking spring, which will detemper the spring and
destroy the locking mechanism.
Under no circumstances should the tow bar be
•
welded to the vehicle
mounting holes be altered. Any welding or altering of the
tow bar will void the owner's warranty.
Connecting a ground to the ‘A-
, nor should any of the pre-punched
Some vehicles must be
WARNING
Failure to follow these instructions may cause
property damage, personal injury or even death.
5
Installing the
‘quick-disconnect’ system
Your ROADMASTER tow bar is equipped with an exclusive “quick-disconnect” (or, “QD”) system. Before connecting the tow bar to the vehicle, first install the components of the QD system to the mounting bracket.
Note: the quick-disconnect system is not used with
ROADMASTER ‘MS’ or ‘MX’ series mounting brackets. If
the towed vehicle has MS or MX brackets, proceed to the
next section — “Connecting the tow bar.” The quick-disconnect system should be reserved, however, for subsequent vehicles which may not have these brackets.
Figure 1
Quick-disconnect parts list
(2) quick-disconnects
(parts A & B)
(2) cable anchors (E & F)
(2) safety plates (C)
All mounting hardware
6
vehicle
mounting
bracket
passenger side
quick-disconnect
A
vertical
pin
1. First, attach the quick-disconnects (“QDs,” parts “A”
and “B” in Figure 1) to the tow bar mounting brackets. Attach the QDs so that the vertical pin on each is pointing
up, as shown in Figure 1.
Attach part “A” on the passenger side, and part “B”
on the driver side. Use the supplied ½" x 1½" bolts, the
two safety plates (parts “C”), flat washers, lock washers
and nuts, as shown in Figure 1.
Both QDs have cable anchors — parts “E” and “F” in
Figure 1 — designed for safety cable attachment. Bolt
continued on next page
vertical
pin
driver side
vehicle
mounting
bracket
B
quick-disconnect
C
safety
plate
F
cable
anchor
safety
C
plate
quick-
disconnect
base
E
cable
anchor
disconnect
quick-
disconnect
base
quick-
crossbar
Installing the ‘quick-disconnect’ system
continued from preceding page
cable anchor “E” to part “A,” and cable anchor “F” to part
“B,” using the supplied ½" x 1" bolts and nuts.
Do not tighten any of the bolts — leave them loose
for now — they will be tightened later.
WARNING
Use all mounting hardware, the safety plates, and
the cable anchors. If all supplied materials are not
used, the quick-disconnects, the quick-disconnect
bases, or other components may vibrate loose, which
may cause property damage, personal injury or even
death.
vertical pin of
quick-disconnect
part “A”
vehicle
mounting
bracket
safety
plate
long safety
cable attachment
linch pin
short safety
cable attachment
top hole
of QD
base
Figure 2
QD
base
lower vertical
pin of QD base
CAUTION
The quick-disconnects must be centered on the
mounting brackets. If they are attached too far to the
left or the right, the tow bar will not be centered on
the towed vehicle, which will cause excessive tire
wear and other consequential, non-warranty damage.
2. Now, attach both quick-disconnect (“QD”) bases (and
the QD crossbar) by lowering them so that the vertical
pins of parts “A” and “B” extend upward through the top
holes of the QD bases (Figure 2). At the same time, be
certain the lower vertical pins of each QD base slide
through the lower holes on parts “A” and “B” (Figure 2).
3. Both linch pins must be inserted through the upper
holes in the vertical pins in parts “A” and “B,” as shown
in Figure 2.
Both linch pins must be locked. The rings (Figure 3)
are spring-loaded — they must be snapped over the pin,
as shown in Figure 3, with the curved side of the linch
pin touching the ring (as shown in Figure 4), in order to
keep the QD bases secure.
WARNING
Towing vibrations will force the linch pins out un-
continued on next page
7
Installing the ‘quick-disconnect’ system
continued from preceding page
less they are properly locked in place over the vertical pins on both quick-disconnects. Refer to Figures
3 and 4. Failure to install the linch pins properly will
result in tow bar malfunction, loss and damage to the
vehicle and property, personal injury or even death.
Connecting the tow bar
CAUTION
Use caution when handling the tow bar — if your
hands, fingers or any part of your body are caught between moving components, they can be pinched, cut
or otherwise injured.
4. Adjust the spacing of QDs “A” and “B” until the QD
bases slide on and off easily. Now, torque all bolts to 75
ft./lbs.
linch
8
pin
ring
flat side of
linch pin
curved side
of linch pin
touches ring
YES
PIN MUST BE
LOCKED
Figure 3
NO!
PIN WILL
VIBRATE
LOOSE
Figure 4
1. Follow the preceding section in this manual — “Install-
ing the ‘quick-disconnect’ system” — to attach the tow bar
quick-disconnects (“QDs”) and the QD bases.
Note: the quick-disconnect system is not used with
ROADMASTER ‘MS’ or ‘MX’ series mounting brackets. Instead, the tow bar is connected directly to the mounting
bracket with the base pins and linch pins.
With this exception, the instructions below apply.
2. Drive the vehicle within three or three-and-a-half feet
of the motorhome hitch receiver. The vehicle does not
have to be perfectly centered to the hitch receiver, just
close. Then, put the vehicle in gear (park), set the emergency brake and chock one of the wheels.
3. With the tow bar in the folded position (Figure 5), insert the stinger into the motorhome hitch receiver, and
attach the stinger to the hitch receiver with the hitch pin
and clip (Figure 5).
continued on next page
Connecting the tow bar
continued from preceding page
CAUTION
Attach the tow bar so that the locking mechanisms
Figure 5
©
Rotate both arms up,
until they are vertical.
folded position
Figure 6
tow bar in
release latch and
locking mechanisms point up
stinger
release
latch
clip
hitch pin
and the release latch are pointing up, as shown in
Figure 6. Components of the tow bar may be damaged
if the tow bar is attached with the release latch and/
or the locking mechanisms pointing down.
4. Hold both tow bar arms firmly, and rotate them up,
so that they are vertical, as shown in Figure 5.
WARNING
Never release the tow bar arms when they are in the
vertical position. The arms can fall and cause severe
personal injury.
5. Push the release latch
Figure 7
(Figure 5, Figure 7) forward,
to bring both arms down to a
horizontal position.
Standing to one side,
swing both arms away from
you. Then, align the holes in
the outermost arm with the
holes in one of the tabs on
the quick-disconnect base (Figure 8).
Attach the tow bar arm to the quick-disconnect base
with one of the included base pins (Figure 8). Lock the base
continued on next page
9
Connecting the tow bar
continued from preceding page
pin with a linch pin (Figure 9) or optional padlock.
The linch pin must be locked. The ring (Figure 9) is
spring-loaded — it must be snapped over the pin, as
shown in Figure 9, with the curved side of the linch pin
touching the ring (as shown in Figure 10), in order to keep
the base pin secure.
WARNING
Both tow bar arms must be attached to the quick-disconnect bases and locked with a linch pin. Towing vibrations will force the linch pins out unless they are
properly locked in place over the base pins on both
quick-disconnect bases, as shown in Figures 9 and 10.
Failure to properly install and lock both base pins will
result in the loss of the towed vehicle, which may cause
property damage, personal injury or even death.
6. Now, swing the other arm to the opposite side and
connect it in the same manner.
7. Attach the safety cables and plug in the electrical wir-
ing cord, according to the supplier’s instructions.
Before towing the vehicle, be sure the steering is unlocked, the transmission is in the proper setting, and the
emergency brake is released. Remove the wheel chock.
10
tow
bar
arm
quick-disconnect
base
base pin
inserted
c
Figure 8
quick-
disconnect
crossbar
quick-disconnect
base pin
to be inserted
base
tab
base
pin
c
linch
pin
Check the manufacturer’s specifications, the owner’s
manual, or talk to the installer for the proper towing
procedure(s) or requirement(s) for the vehicle to be towed.
WARNING
Do not tow the vehicle until the tow bar is attached
with all pins or padlocks. Unless the tow bar is secured to both vehicles with all appropriate pins or
padlocks, the vehicle will detach, which may cause
property damage, personal injury or even death.
continued on next page
Connecting the tow bar
continued from preceding page
When you drive away, steer briefly to the left and then
to the right, to extend, self-center and lock the tow bar.
Always stop at this time. Check the tow bar to ensure
that both arms are locked, before assuming highway
speed. Additionally, check the other components of your
towing system, to ensure that they are fully engaged.
WARNING
Do not tow a vehicle using tow bar mounting brackets, safety cables, or a hitch receiver rated less than
the actual weight of the towed vehicle.
If the brackets, safety cables, hitch receiver or any
supplementary towing equipment is not rated at the
weight of the towed vehicle and all its contents, it may
fail during towing, causing property damage, personal injury or even death.
WARNING
If the motorhome hitch receiver has an extension, do
not tow if the tow bar is more than three inches out of
level.
Receiver extensions cause the towing system to
swing much higher and lower than towing systems without extensions. This enlarged arc of motion creates excessive strain on the tow bar, brackets and frame, which
can cause the towing system to fail, causing property
damage, personal injury or even death.
Figure 9
The base
pins on
both arms
must be
installed
and
locked,
as illustrated.
YES
Both linch
pins must be
LOCKED.
NO!
The pin
will vibrate
loose.
linch
pin
ring
flat side of
linch pin
curved side
of linch pin
touches ring
Figure 10
11
Disconnecting the tow bar
1. Disconnecting the tow bar is essentially the reverse
of connecting it. First, always try to park on level ground,
with the towed vehicle in line with the motorhome. This
will eliminate most of the tension between the vehicles,
allowing for an easier disconnect.
2. Disconnect the electrical wiring harness, safety ca-
bles, and any other towing system accessories.
3. Lift the release handles on each tow bar arm (Fig-
ure 11) to release the locking mechanisms.
(Usually, one of the handles will require more pressure to release. This is the arm that has the majority of
the tension between the two vehicles.)
WARNING
Always put the towed vehicle in gear (park), set the
emergency brake and chock one of the wheels after
lifting the release handles, and before removing the
base pins. Failure to do so may result in a ‘runaway’
vehicle or may crush you between the towed vehicle
and the motorhome, causing property damage, personal injury or even death.
4. Put the towed vehicle in gear (park), set the emer-
gency brake, and chock one of the wheels.
Figure 11
5. Remove the base pins and store the tow bar on the
motorhome by reversing the connection procedure (under “Connecting the tow bar”).
ROADMASTER recommends replacing at least one
of the linch pins with a padlock (part number 301, 302 or
308) to prevent accidental release or theft.
Failure to follow these instructions may cause
property damage, personal injury or even death.
©
WARNING
Pull up on the release
handle to release the
locking mechanism.
12
Wiring instructions
3
1
Figure 12
The Sterling All Terrain tow bar comes equipped with a
fully-wired motorhome-to-towed vehicle electrical cord —
simply plug the cord into the sockets on the motorhome
and the towed vehicle.
If you should need to rewire the plugs and sockets,
follow the instructions below for a four-wire system, or the
instructions on pages 14 and 15 for a six-wire system.
Wiring the plug for a four-wire system
1. Insert the end of the electrical cord through one of the
cable guides.
2. Wire the plug to match your vehicle, or follow Figure
12. Apply a silicone sealant to the wires where they attach
to the plug — this will help prevent damage from moisture
and corrosion.
Wiring the sockets for a four-wire system
1. Find a suitable location to install one of the electrical
sockets on the front of the towed vehicle, in reach of the
existing four-wire harness.
2. Loosen the set screw at the back of the socket, and
push the inner connector out the front. Now, run the fourwire electrical cord through the back of the housing.
3. Loosen all of the set screws on the side of the socket, and connect the wires to the back of the socket, as
continued on next page
front of
plug on
4-wire
cord
4
Socket Pin Wire
Number Color Motorhome Towed Vehicle
1 ............... Yellow......... Left turn / Stop ........ Left turn / Stop
2 ............... White ..........Ground ...................... Ground
3 ............... Red .............Right turn / Stop ..... Right turn / Stop
4 ............... Black........... Taillight ..................... Taillight
2
Figure 13
13
front of
4-wire
socket
on towed
vehicle and
24
Socket Wire
Pin Number Color Motorhome Towed Vehicle
1 ............... Yellow......... Left turn / Stop ........ Left turn / Stop
2 ............... White ..........Ground ...................... Ground
3 ............... Green.......... Right turn / Stop ..... Right turn / Stop
4 ............... Brown .........Taillight ..................... Taillight
motorhome
13
Wiring instructions — four-wire system
continued from preceding page
shown in Figure 13. Or, wire the socket to match the existing wiring on the motorhome.
4. Tighten all the set screws, and check each wire to
ensure that it is secure. Apply a clear silicone sealant
around each wire entry and set screw indentation — this
will help weatherproof the socket and secure the set
screws.
5. If the motorhome does not have the correct wiring
socket already, you can replace it with the new socket
for the four-wire cord, and connect the appropriate wires
to the new socket, according to Figure 13.
6. Now, connect the four-wire electrical cord to the motorhome and to the towed vehicle. Test the towed vehicle’s turn signals, tail lights and brake lights to ensure
they mimic the motorhome’s.
WARNING
If the plugs and sockets are not properly wired, the
electrical connection will not function, and the towed
vehicle’s turn signals and brake lights will not mimic
those of the motorhome.
Drivers behind the towed vehicle will not be alerted by turn signals or brake lights, which may result
in a traffic accident, causing property damage, person-
14
al injury or even death.
Wiring the plug for a six-wire system
1. Insert the end of the electrical cord through one of the
cable guides.
2. Wire the plug to match your vehicle, or follow Figure
14. Apply a silicone sealant to the wires where they attach
to the plug. This will help prevent damage from moisture
and corrosion.
Wiring the sockets for a six-wire system
1. Find a suitable location to install one of the electrical
sockets on the front of the towed vehicle, in reach of the
existing six-wire harness.
2. Remove the protective boot on the back of the socket, loosen the set screw, and push the inner connector out
the front. Now, run the six-wire electrical cord through the
back of the protective boot and the housing.
3. Loosen all of the set screws on the side of the socket, and connect the wires to the back of the socket, as
shown in Figure 15. Or, wire the socket to match the existing wiring on the motorhome.
4. Tighten all the set screws, and check each wire to
ensure that it is secure. Apply a clear silicone sealant
around each wire entry and set screw indentation — this
will help weatherproof the socket and secure the set
screws. Replace the protective boot.
continued on next page
Wiring instructions — six-wire system
continued from preceding page
5. If your motorhome does not have the correct wiring
socket already, you can replace it with the new socket
for the six-wire cord, and connect the appropriate wires
to the new socket, according to Figure 15.
6. Now, connect the six-wire electrical cord to the motorhome and to the towed vehicle. Test the towed vehicle’s turn signals, tail lights and brake lights to ensure
they mimic the motorhome’s.
WARNING
If the plugs and sockets are not properly wired, the
electrical connection will not function, and the towed
vehicle’s turn signals and brake lights will not mimic
those of the motorhome.
Drivers behind the towed vehicle will not be alerted by turn signals or brake lights, which may result
in a traffic accident, causing property damage, personal injury or even death.
5
2
6
Socket Pin Wire
Number Color Motorhome Towed Vehicle
1 ............... Red .............Brake light ................ Brake light
2 ............... Black........... Auxiliary .................... Auxiliary
3 ............... Green.......... Right turn ................. Right turn
4 ............... Brown .........Taillight ..................... Taillight
5 ............... White ..........Ground ...................... Ground
6 ............... Yellow......... Left turn .................... Left turn
1
4
Figure 14
front of
plug on
6-wire
cord
3
4
1
3
Socket Pin Wire
Number Color Motorhome Towed Vehicle
1 ............... Red .............Brake light ................ Brake light
2 ............... Black........... Auxiliary .................... Auxiliary
3 ............... Green.......... Right turn ................. Right turn
4 ............... Brown .........Taillight ..................... Taillight
5 ............... White ..........Ground ...................... Ground
6 ............... Yellow......... Left turn .................... Left turn
2
5
6
Figure 15
front of
6-wire
socket
on towed
vehicle and
motorhome
15
How to use safety cables
Safety cables are an integral part of your towing system. They are a secondary safety device, required by law
in many states. This section, and the following section,
will acquaint you with how to use them properly.
The safety cables must connect the towing vehicle
•
to the towed vehicle, frame to frame.
The safety cables must be rated at 6,000 pounds
•
weight capacity per pair, or higher. This is the maximum
weight capacity of the tow bar — the towed vehicle and
all its contents cannot exceed 6,000 pounds.
Pull the safety cables so that all the slack is at the
•
motorhome. Make sure there is enough slack in the
cables at the motorhome to allow for sharp turns — if
there is not enough slack, the towing system will be severely damaged when the motorhome turns a sharp corner.
The safety cables must be the correct length…
•
Make sure the cables are not too short — if you use
•
a receiver hitch extension or other equipment that extends the distance between the towed vehicle and the
motorhome, the standard cables may be too short. If the
cables are too short, the towing system will be severely
damaged when the motorhome turns a sharp corner.
16
(Twelve-inch safety cable extensions, part number
910648-12, are available from ROADMASTER.)
Make sure the cables are not too long — the cables
•
should not hang down to the extent they may catch on
obstructions, or drag on the ground. This much slack
could cause damage to the towing system, the towed
vehicle, or the motorhome.
If the cables are too long, wrap the excess cable
around the tow bar to take up the slack. Make sure there
is enough slack in the cables at the motorhome to
allow for sharp turns.
Damage caused by using safety cables of an
incorrect length is not covered under warranty.
Always cross the cables under the hitch receiver, as
•
shown in Figure 16 under “Proper installation of safety
cables.” In the unlikely event the tow bar separates from
the motorhome, crossing the cables will help prevent the
tow bar from dragging on the ground, which can cause
the tow bar to “pole vault” the towed vehicle.
Some ROADMASTER tow bar mounting kits with
•
removable arms use two safety cables on each side. If
two sets of safety cables are required, both must be
used. This is required by law. Refer to “Proper installation of safety cables” for further information.
WARNING
Failure to follow these instructions may cause
property damage, personal injury or even death.
Figure 16
short
safety
cable
Use quick links for
easy attachment and
removal of cables
.
Connect each long safety
cable to the slot in the
cable anchor.
Proper installation
of safety cables
Some ROADMASTER tow bar mounting brackets with
removable arms, such as the ones in Figures 16 and 17,
use both a long safety cable and a short safety cable on
each side.
Each long safety cable runs from the towing vehicle
to a cable anchor. Connect each long safety cable to a
cable anchor by inserting it through the top of the slot in
the cable anchor bracket and dragging it down.
Both ends of the short safety cables are connected
The built-in cable
guides will help
prevent the safety
cables and 12-volt
electrical cord from
being damaged.
long
safety
cables
electrical
cord
Cross the safety cables under the hitch
and stinger. This helps prevent the tow bar
from hitting the road and “pole vaulting” if the
tow bar separates from the hitch receiver.
Connect the
snap hooks
to the loops
on hitch or
frame.
by quick links. One quick link is attached to the mounting bracket and one is attached to the cable anchor.
Unscrew the nuts on each quick link to connect the
safety cable loops. Finger-tighten the nuts firmly, until the
loop is completely closed, to secure the attachment.
Do not substitute carabiners or other devices for the
quick links — the quick links are rated at 6,000 pounds
carrying capacity; carabiners or other devices are not.
Only ROADMASTER bracket kits with removable arms
have these short safety cables. Other bracket kits are
continued on next page
17
Proper installation of safety cables
continued from preceding page
bolted directly to the frame of the towed vehicle and do
not require short safety cables.
If your ROADMASTER bracket kit contains short safety
cables, refer to the installation instructions for complete
information.
WARNING
The safety cables must be carefully routed so that
they cannot become pinched, frayed, scraped or otherwise damaged, and so they will not drag when going over dips or low spots.
Do not use the cables if they show any signs of
wear or damage — immediately discontinue towing
and replace the cables.
Failure to follow these instructions will result in ca-
ble failure, which may cause property damage, personal injury or even death.
WARNING
If the quick links are not completely tightened, with
the loop closed, the safety cables may detach. In the
event of a towing system failure, the towed vehicle
will detach, which may cause property damage, personal injury or even death.
WARNING
If your towing system requires two sets of safety
cables, always use both the long and the short safety cables. Connect them as shown in Figures 16 and
17. Otherwise, in the event of a towing system failure,
the towed vehicle will detach, which may cause property damage, personal injury or even death.
Figure 17
portion of
mounting bracket
bolted to
vehicle frame
18
quick link
connecting nut
quickdisconnect
short safety cable
quick link
attached to
cable anchor
tow bar arm
long
safety
cable
Stay within the ‘Safe Zone’
Towing with a motorhome-mounted tow bar which has
an upward or downward slope puts undue strain on the
entire towing system. For that reason, do not tow if the
tow bar is not within the ‘Safe Zone' — no more than
three inches above level or four inches below level.
Towing a vehicle with a tow bar that is not within the
Safe Zone will result in significant wear and tear on the
tow bar and brackets, significant wear and tear on the
vehicle's suspension and frame, and the eventual failure
of the towing system.
To determine if the tow bar is within the Safe Zone —
first, connect the motorhome and towed vehicle on level
ground.
Next, measure the distance from the center of the motorhome receiver down to the ground. Then, measure the
distance from the center of one of the base pins down to
the ground.
Compare these two
measurements. To be
within the Safe Zone,
they cannot be more
than three inches
apart if the base pin
is above the motorhome hitch receiver,
or four inches apart if
STAY WITHIN THE ‘SAFE ZONE’
the base pin is below the motorhome hitch receiver.
If the tow bar is not within the Safe Zone, you must purchase a hitch accessory to raise or lower the hitch receiver. ROADMASTER has three accessories available — HiLow Hitches, Hi-Low Drops, and Dual Hitch Receivers —
which will raise or lower the hitch receiver from two to 10
inches, depending on the model.
Towing with the tow bar more than three inches above
level or four inches below level will void the ROADMASTER warranty.
WARNING
Failure to follow these instructions may cause
property damage, personal injury or even death.
19
Care and cleaning
As is the case with most precision equipment, frequent cleaning
and care results in better performance and longevity. Use the following guidelines to keep your tow bar clean and well-lubricated.
Always clean the tow bar before lubricating. Use a water-soluble cleaner such as Voom RV (part number 9911) — it does an exceptional job of breaking down road film, dirt and grease.
With one tow bar arm raised, spray a liberal amount of cleaner
at the top of the inner/outer arm assembly (Figure 18). Then flex
the tow bar arm up and down to flush dirt and debris out the bottom of the assembly. Repeat, if necessary, until the arm is clean.
Repeat for the other arm.
CAUTION
Do not use petroleum-based products to clean or lubricate
the tow bar. Petroleum will attract dirt and dust, which will
impede the operation of the sliding arms and/or other components. Certain petroleum products may also corrode non-metallic components.
Damage caused by using a petroleum-based product to
clean or lubricate the tow bar is not covered under warranty.
After cleaning the tow bar, wipe any remaining cleaner away.
Now that you have a clean, dry tow bar, use a dry silicone aerosol, such as LubeMaster (part number 747), to lubricate the tow bar
— spray a liberal amount of the silicone into all moving parts. LubeMaster sprays on wet, then dries in 30 seconds. After the lubricant
has dried, flex the tow bar components, to work the lubricant in.
To lubricate the locking mechanisms, lift and remove the rubber
caps (Figure 19) and spray silicone lubricant inside. Move the release handles (FIgure 11) up and down to work the lubricant in.
Replace the rubber caps.
CAUTION
Always clean the locking
mechanisms, as described
above, before lubricating
them. Silicone coats and
covers in a thin layer. If it is
not removed, it will reduce
the clearance for the locking mechanisms, preventing
proper operation.
Extended storage — be-
fore storing your tow bar for
an extended period of time,
be sure to clean and lubricate
it as above. Store the tow bar
in its cover, to protect it from
the elements.
Note: to remove scratches
and restore luster on the
stainless steel arms, we suggest that you use extra fine
(0000) steel wool, 3M “Scotch
Brite” (fine pad) or a similar
product.
Figure 18
Spray at
this point.
Figure 19
Lift the
rubber
cap.
20
Limited Warranty
1. WARRANTY
1a. WARRANTY OF CONFORMITY AT TIME OF SALE
ROADMASTER, Inc. warrants that at the time of sale of this product it will be
free from defects in material and manufacture and will conform to ROADMASTER’S
specifications for the product.
1b.
CONDITIONAL ONE-YEAR WARRANTY
In addition to the preceding time-of-sale warranty, if the product registration card
is completely and accurately filled out and mailed to ROADMASTER within thirty (30)
days of purchase, ROADMASTER will provide an additional warranty that for a period of one year after sale the product will remain in good working order, PROVIDED
THAT the product is installed and maintained in accordance with ROADMASTER’S
instructions and is not subjected to: (a) alteration or unauthorized repairs or repairs
by anyone other than ROADMASTER or a ROADMASTER-authorized service center,
(b) misuse, abuse, commercial use, or improper maintenance, (c) Acts of God (including without limitation hurricanes, tornadoes, floods, or other severe weather or
natural phenomena), (d) failures due to products not supplied by ROADMASTER, or
(e) other treatments, uses, or installations for which the product was not intended.
This warranty extends only to the first retail purchaser-consumer of the product and
is not transferable.
EXTENDED WARRANTY PERIOD: If ROADMASTER receives the product reg-
istration card, completely and accurately filled out, within twenty (20) days of purchase, ROADMASTER will enlarge the one-year warranty period in the preceding
paragraph to a period of two years.
2.
DISCLAIMER OF OTHER WARRANTIES
The preceding warranties are the exclusive and sole express warranties given
by ROADMASTER. They supersede any prior, contrary or additional representations,
whether oral or written. No agent, representative, dealer or employee has the authority to alter or increase the obligations or limitations of this warranty. Any implied
warranties, including the WARRANTY OF MERCHANTABILITY and any WARRANTY
OF FITNESS FOR A PARTICULAR PURPOSE, are limited in duration to thirty days
or the term of the applicable express warranty provided above, whichever is longer.
Some states do not allow limitations on how long an implied warranty lasts, so
the above limitation may not apply to you.
3.
EXCLUSIVE REMEDY FOR ANY NONCONFORMITIES
If during the applicable Warranty Period, the product does not conform to the pre-
ceding Warranties, notify ROADMASTER as provided below, and within a reasonable
time ROADMASTER will provide, at its option, one of the following: (1) replacement
components for any nonconforming or defective product or components or (2) the percentage of the purchase price for the nonconforming product equal to the percentage of the Warranty Period remaining when ROADMASTER is notified of the nonconformity. ROADMASTER will, at its option, (a) use new and/or reconditioned parts
in performing warranty repairs and making replacement products, (b) use parts or
products of original or improved design in the repair or replacement. If ROADMASTER
repairs or replaces a product, its warranty continues for the remaining portion of the
original Warranty Period or 60 days from the date of the return shipment to the customer, whichever is greater. All replaced products and all parts removed from repaired
products become the property of ROADMASTER. ROADMASTER will not provide,
and will not be liable for, labor, costs of removal or reinstallation of components,
disposal, shipping, freight, taxes, or other incidental charges.
THESE REMEDIES ARE THE EXCLUSIVE AND SOLE REMEDIES FOR ANY
BREACH OF WARRANTY.
For any breach of warranty, the Owner must telephone ROADMASTER at 1-800669-9690 within thirty (30) days after discovering the nonconformity. Do not return
any product without first calling ROADMASTER and getting a return authorization
number. Returned products must include the return authorization number and a copy
of the original invoice, bill or other proof of the date of purchase. The date of purchase must coincide with the original warranty registration card on file. ROADMASTER will authorize (a) shipment of the product to ROADMASTER or (b) repair or replacement at the nearest warranty service center—in both cases with shipping at your
expense. Do not purchase replacement parts or pay for repair labor—you will not be
reimbursed. Compliance with the requirements of this paragraph is a condition to
coverage under the Warranty: if these requirements are not complied with, ROADMASTER will have no obligation to provide any remedy for any breach of warranty.
4.
DISCLAIMER OF INCIDENTAL AND CONSEQUENTIAL DAMAGES
IN NO EVENT SHALL ROADMASTER BE LIABLE FOR ANY INCIDENTAL, SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES, WHETHER RESULTING FROM
NONDELIVERY OR FROM THE USE, MISUSE OR INABILITY TO USE THE PRODUCT OR FROM DEFECTS IN THE PRODUCT.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you.
5.
APPLICABLE LAW
This Warranty will be interpreted, construed, and enforced in all respects in accordance with the laws of the State of Oregon, without reference to its choice of law
rules. The U.N. Convention on Contracts for the International Sale of Goods will not
apply to this Warranty.
6.
SEVERABILITY
If any provision of this warranty is found to be invalid or unenforceable, then the
remainder shall have full force and effect, and the invalid provision shall be partially
enforced to the maximum extent permitted by law to effectuate the purpose of the
agreement.
7.
ADDRESS FOR NOTICES TO ROADMASTER
ROADMASTER, Inc., 5602 N.E. Skyport Way, Portland, OR 97218
This warranty gives you specific legal rights, and you may also have other rights
which vary from State to State.
21
quickdisconnect
(QD) 222
QD linch pins (2)
910024
crossbar
067
quick-
disconnect (QD)
222
swivel
ear
910661
lock cap
200460-00
inner/outer arm assembly,
driver’s side
910656
release latch
(patent no. 6,619,686)
and stinger assembly
910019-40
QD base pin
with chain (2)
910029
cable anchors (2)
910653
release handle
750600
inner/outer arm assembly,
passenger’s side
910657
Quality Towing Systems since 1974
ROADMASTER, Inc. • 5602 N.E. Skyport Way • Portland, OR 97218 • 800-669-9690 • Fax 503-288-8900 • www.roadmasterinc.com
© 2007 ROADMASTER, Inc. All Rights Reserved 853326-01 05/2007
hitch pin
& clip
910027
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