Demco Excalibar 3 User manual

TB20061, Rev 2
09/19
SELF-ALIGNING TOW BAR
Excalibar 3

Page 2 TB20061
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 dam-
age.
Warranty Policy, Operator Manuals & Registration
Go online to www.demco-products.com to review Demco warranty policies, operator manuals and register your Demco
product.
Introduction
TABLE OF CONTENTS
Warranty Policy, Operator Manuals & Registration..................................................................................................................... 2
Signal Words .................................................................................................................................................................................... 3
Equipment Safety Guidelines ........................................................................................................................................................ 3
Remember........................................................................................................................................................................................ 3
Lighting and Marking...................................................................................................................................................................... 3
SAFETY Sign Locations ................................................................................................................................................................... 4
Safety Sign Care............................................................................................................................................................................... 4
Before operation.............................................................................................................................................................................. 4
During Operation ............................................................................................................................................................................ 5
Highway and Transport Operations .............................................................................................................................................. 5
Following Operation ....................................................................................................................................................................... 5
Performing Maintenance................................................................................................................................................................ 6
Bolt Torque Data for Standard Nuts, Bolts, and Capscrews....................................................................................................... 7
Important Notice! ............................................................................................................................................................................ 8
Latch Disassembly ........................................................................................................................................................................... 9
Latch Reassembly ............................................................................................................................................................................ 9
Hooking Up the Vehicle to Be Towed......................................................................................................................................... 10
Unhooking the Towed Vehicle..................................................................................................................................................... 11
Receiver Parts Brteakdown........................................................................................................................................................... 12
Pivot Head Parts Brteakdown....................................................................................................................................................... 12
Connecting Leg Parts Breakdown ............................................................................................................................................... 13
Connecting Legs to Pivot Head Parts Breakdown..................................................................................................................... 14
Saftey Cables.................................................................................................................................................................................. 15
Safety Cable Extensions ............................................................................................................................................................... 15
4” or 6” Drop/Lift Receiver Hitch................................................................................................................................................. 16
Auxiliary Lighting Cable ............................................................................................................................................................... 16
3-Piece Locking Pins..................................................................................................................................................................... 17
Tow Bar to Base PLate Locking Pins............................................................................................................................................ 17
Light Bar.......................................................................................................................................................................................... 18

TB20061 Page 3
SAFETY
TAKE NOTE! THIS SAFETY ALERT SYMBOL FOUND THROUGHOUT THIS MANUAL IS USED TO CALL YOUR ATTENTION TO INSTRUCTIONS INVOLV-
ING 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!
Note use of following signal words DANGER, WARNING, and CAUTION with safety messages. Appropriate signal word for
each has been selected using following guidelines:
CAUTION:
Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may also be
used to alert against unsafe practices.
WARNING:
Indicates a potentially hazardous situation that, if not avoided, could result in serious injury or death, and includes haz-
ards that are exposed when guards are removed. It may also be used to alert against unsafe practices.
DANGER:
Indicates an imminently hazardous situation that, if not avoided, will result in serious injury or death. This signal word
is to be limited to the most extreme situations typically for tow bar components which, for functional purposes, cannot
be guarded.
If you have questions not answered in this manual, or require additional copies, please contact your dealer or Demco,
4010 320th Street, Boyden, IA 51234, ph: [phone] or [phone], Toll Free: 1-800-543-3626 Fax: (712)
725-2380, http://www.demco-products.com
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.
Replace any caution, warning, danger or instruction safety decal that is not readable or is missing. Location of such decals is indi-
cated in this booklet.
Do not attempt to operate this tow bar under the influence of alcohol or drugs.
Review safety instructions with all users.
Operator should be a responsible adult. DO NOT ALLOW PERSONS TO OPERATE OR ASSEMBLE THIS TOW BAR UNTIL THEY HAVE DEVELOPED A THOR-
OUGH UNDERSTANDING OF SAFETY PRECAUTIONS AND HOW IT WORKS.
Do not paint over, remove, or deface any safety signs or warning decals on your tow bar. Observe all safety signs and practice in-
structions on them.
Never exceed limits of a tow bar. If its ability to do a job safely is in question DON’T TRY IT.
SAFETY...You can live with it
It is the responsibility of owner to know lighting and marking requirements of local highway authorities and to install and maintain
equipment to provide compliance with regulations.
Light bar kits are available from your dealer or from manufacturer.
Your best assurance against accidents is a careful and responsible operator. If there is any portion of this manual or function you do
not understand, contact your local authorized dealer or manufacturer.
Safety Information
Lighting and Marking
Remember
Equipment Safety Guidelines
Signal Words

Page 4 TB20061
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.
• Align decal over specified area and carefully press small portion with exposed sticky backing in place.
• Slowly peel back remaining paper and carefully smooth remaining portion of decal into place.
• Small air pockets can be pierced with a pin and smoothed out using piece of decal backing paper.
• Carefully study and understand this manual.
• Give tow bar a visual inspection for any loose bolts, worn parts, or cracked welds, and make necessary repairs. Follow mainte-
nance safety instructions included in this manual.
• Be sure there are no tools lying on tow bar, towing unit or towed vehicle.
• Do not use tow bar until you are sure that area is clear, especially around children and animals.
• Don’t hurry learning process or take tow bar for granted. Ease into it and become familiar with your new tow unit.
• Practice operation of your tow unit and its attachments. Completely familiarize yourself and other operators with its operation
before using.
• Securely attach to towing unit. Use an appropriately sized and rated hitch ball and/or a class III, class IV receiver and attach
safety cables.
• Criss cross safety cables under tow bar, secure to mounting loops on towing vehicle.
• Do not allow anyone to stand between vehicles when backing up.
• Make sure tow rating on towing unit is high enough for what it is towing.
• To prevent swaying of towed vehicle insure all tires are inflated to specifications. Failure to inflate tires evenly will result in
towed vehicle to pull unevenly.
Before operation
SAFETY Sign Locations
Types of safety sign and locations on the Excalibar 3 are shown in illustration below. Good safety requires that you fa-
miliarize yourself with various safety signs, type of warning, and particular function related to that area, that requires
your SAFETY AWARENESS. WARNING
CAUTION
Safety Information

TB20061 Page 5
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.
• Beware of bystanders, PARTICULARLY CHILDREN! Always look around to make sure it is safe to start engine of towing unit and mov-
ing towed vehicle. This is particularly important with higher noise levels, as you may not hear people shouting.
•NO PASSENGERS ALLOWED- Do not carry passengers anywhere on or in towed vehicle.
• When halting operation, even periodically, set towing unit’s parking brake, shut off engine, and remove ignition key.
• Be extra careful on inclines.
• MANEUVER TOWING UNIT AT SAFE SPEEDS.
• Avoid overhead wires or other obstacles. Contact with overhead lines could cause serious injury or death.
• Avoid loose gravel, rocks, and holes; they can be dangerous for unit operation or movement.
• Allow for unit length when making turns.
• Do not work under raised components or attachments unless securely positioned and blocked.
• Keep all bystanders and pets clear of work area.
• Operate towing unit from operators seat only.
• As a precaution, recheck hardware on tow bar every 200 miles, and correct all problems. Follow maintenance safety proce-
dures.
Following Operation
• Following operation, or when unhooking, stop towing vehicle, set parking brake, shut off engine and remove ignition key.
• Store tow bar in area away from human activity.
• Do not permit children to play on or around stored tow bar.
• Make sure parked vehicle is on hard, level surface.
• Wheel chocks may be needed to prevent vehicle from rolling.
Highway and Transport Operations
• Adopt safe driving practices:
- Always drive at safe speed relative to local conditions and ensure that your speed is low enough for an
emergency stop.
- 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.
• Watch for obstructions overhead and to both sides while towing vehicle.
• Operate with maximum visibility at all times. Make allowances for increased length and weight when making turns and stop-
ping.
Safety Information

Page 6 TB20061
• Good maintenance is your responsibility. Poor maintenance is an invitation to trouble.
• Make sure there is plenty of ventilation. Never operate engine of towing unit in a closed building. Exhaust fumes may cause
asphyxiation.
• Before working on tow bar, stop towing vehicle, set parking brake, turn off engine and remove ignition key.
• Always use proper tools or equipment for job at hand.
• Use extreme caution when making adjustments.
• Follow torque chart in this manual when tightening bolts and nuts.
• After servicing, be sure all tools, parts and service equipment are removed.
• Do not allow grease or oil to build up.
• When replacing bolts, refer to owners manual.
• Refer to bolt torque chart for head identification marking.
• Where replacement parts are necessary for periodic maintenance and servicing, genuine factory replacement parts must be used
to restore your tow unit to original specifications. Manufacturer will not claim responsibility for use of unapproved parts and/or
accessories or other damages as a result of their use.
• If tow unit has been altered in any way from original design, manufacturer does not accept any liability for injury or warranty.
• A fire extinguisher and first aid kit should be kept readily accessible while performing maintenance on this tow bar.
• Any disassembly of the Excalibar 3 must be performed by an authorized dealer or sent back to Demco for repair and maintenance.
Performing Maintenance
Safety Information

TB20061 Page 7
Bolt Torque for Metric bolts *
CLASS 8.8 CLASS 9.8 CLASS 10.9
“A” lb-ft (N.m) lb-ft (N.m) lb-ft (N.m)
6 9 (13) 10 (14) 13 (17)
7 15 (21) 18 (24) 21 (29)
8 23 (31) 25 (34) 31 (42)
10 45 (61) 50 (68) 61 (83)
12 78 (106) 88 (118) 106 (144)
14 125 (169) 140 (189) 170 (230)
16 194 (263) 216 (293) 263 (357)
18 268 (363) -- -- 364 (493)
20 378 (513) -- -- 515 (689)
22 516 (699) -- -- 702 (952)
24 654 (886) -- -- 890 (1206)
Bolt Torque Data for Standard Nuts, Bolts, and Capscrews
Tighten all bolts to torques specified in chart unless otherwise noted. Check tightness of bolts periodically, using bolt chart as
guide. Replace hardware with same grade bolt.
NOTE: Unless otherwise specified, high-strength Grade 5 hex bolts are used throughout assembly of equipment.
Torque figures indicated are valid for non-greased or non-oiled threads and heads unless otherwise specified.Therefore, do not grease
or oil bolts or capscrews unless otherwise specified in this manual. When using locking elements, increase torque values by 5%.
* GRADE or CLASS value for bolts and capscrews are identified by their head markings.
GRADE 2 GRADE 5 GRADE 8
“A” lb-ft (N.m) lb-ft (N.m) lb-ft (N.m)
1/4” 6 (8) 9 (12) 12 (16)
5/16” 10 (13) 18 (25) 25 (35)
3/8” 20 (27) 30 (40) 45 (60)
7/16” 30 (40) 50 (70) 80 (110)
1/2” 45 (60) 75 (100) 115 (155)
9/16” 70 (95) 115 (155) 165 (220)
5/8” 95 (130) 150 (200) 225 (300)
3/4” 165 (225) 290 (390) 400 (540)
7/8” 170 (230) 420 (570) 650 (880)
1” 225 (300) 630 (850) 970 (1310)
Torque all 1/4” button head screws to 6 ft/lbs and apply Blue
R
to threads.
GRADE-2 CLASS 8.8 CLASS 10.9
GRADE-5 GRADE-8
CLASS 9.8
8.8 9.8 10.9 A
Bolt Torque
Bolt Torque for Standard bolts *

Page 8 TB20061
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. Check manufacturer’s specifications for the proper
way to unlock steering wheel.
Be sure to check that receiver on towing vehicle is not inset to far. When attaching a Demco towing product it is important
that turning clearance is adequate. A receiver that is inset to far on a towing vehicle will shorten turning radius. Failure
to check this may result in towing or towed vehicle to be damaged. It may be necessary to install a receiver extension to
allow for proper turning clearance.
WARNING: ADDITIONAL SAFETY ITEMS
Safety is of utmost importance at all times. To prevent personal
injury or property damage, observe the following.
• Before allowing anyone to hook up or operate the Excalibar 3, be
sure they have read and understand the proper operating procedure.
• This unit must be used with a Class III, 5,000 lb. Hitch or higher.
• 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: Any severe backwards cornering could result in damage to the
Excalibar 3 and/or towed vehicle chassis.
• 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 crisscross 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 at the rear of
the towed vehicle.
• Do not use coiled safety cables with this tow bar, always use straight
Demco safety cables.
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
latch trigger area of the extending legs.
DO NOT lubricate any of the pivot points of the Excalibar 3
These are self-lubricating washers and your tow bar could
lose its self-supporting ability.
Keep the Excalibar 3 covered when stored on or off the tow-
ing vehicle.
If the Excalibar 3 needs servicing, only an authorized dealer
can service it or it can sent to Demco for servicing.
Make sure all bolts are properly tightened and those requir-
ing a set torque are up to specifications.
CAUTION: Tow Bar must be inserted directly into tow vehicle
receiver hitch or into an approved rise drop receiver only!
Tow Bar should never be inserted into a receiver extension,
bike rack, storage rack, motorcycle rack, or any other device
that extends the tow bar away from the tow vehicle.
Thank you for Purchasing Products.
Tow Bar positioning
should be parallel to
road surface or within 3”
in either direction
Must have cable anchors or
a place to connect cable to
frame
TOW BAR
Important Notice

TB20061 Page 9
Latch Disassembly
You may leave the Excalibar 3 in the hitch receiver or take
it out and work on it on a work bench.
Latch Reassembly
NOTE: Apply Blue
R
to all fasteners and torque
fasteners according the torque chart on page 7.
Torque the 1/4” button head screws to 6 ft/lbs.
1. Collapse the connecting leg all the way in,With a straight
screwdriver, remove two E-clips from latch assembly
pins and remove pins.
3. Slide connecting leg shaft so you can see latch washer
through latch opening, and inspect latch sear washer
through slot in rail tube, for dirt, wear or damage.
5. Clean shaft and connecting leg assembly, replace worn
or damaged parts. Repeat process for other connect-
ing leg. NOTE: Keeping matching side together for
reassembly.
1. Reinstall connecting leg shaft and push shaft all the
way in to reinstall latch assembly. Install latch as an as-
sembly, put pin on bottom latch sear hole first and the
latch trigger handle second. Hold the trigger handle
down like you are releasing the latch to aid in getting
the 5/16” pin in. Be sure to install e-clips on pins.
2. Reassemble the rest of the tow bar in reverse order as
the disassembly.
4. If sear washer has excessive dirt or wear, the shaft will
need to removed. Remove connecting clevis from
shaft, note location of washers. Remove eight fasten-
ers from receiver end of connecting leg and slide rail
tube off of front clevis adaptor and slide shaft out of
tube.
2. Remove trigger latch, latch sear and spring from bottom
side of latch housing. Clean and inspect parts for wear
and damage. Replace worn & damaged parts.
Latch Maintenance Instructions

Page 10 TB20061
Tow Bar Instructions
Step 5. Slide and twist the legs into position to attach them
to the baseplate on towed vehicle. Secure to baseplate using
the two attaching pins and 1/4” quick-lock pins. Attach safety
cables. 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. Towing vehicle must be larger and at least 500 lbs.heavier than the
towed vehicle and tow bar combined.
Step 1. Out of the box, the Excalibar 3 tow bar is setup for the
recommended positions for the safety cables and light wire stor-
age rod. These can be positioned to new areas to fit your setup
by loosening the screw on the retaining rings and sliding them
off the rail and relocating to a new position and tighten screw.
Install the light cable (optional) by placing the coil over the wire
support rod. Secure the cable with the cable locking hair pin.
Hooking Up the Vehicle to Be Towed
Refer to load limits on inside of front cover.
Step 4. Position the vehicle to be towed approx. 24” be-
hind the towing vehicle. Perform a tow bar check, look for any
loose fasteners, condition of safety cables, excessive move-
ment in connecting leg shaft when the shaft is extended and
locked. If any excessive movement or loose fasteners, the tow
bar will need to be serviced before towing. The vehicles do
not have to be in straight alignment to complete the hook-up.
Engage towed vehicle and towing vehicle parking brake.
Step 2. Insert the lock pin block and spring into the Excalibar
3 receiver tube and line up block with hole in tube. Insert the
Excalibar 3 into a Class III or IV hitch. Caution: Tow Bar must
be inserted directly into tow vehicle receiver hitch or into an ap-
proved rise drop receiver only! Tow Bar should never be insert-
ed into a receiver extension, bike rack, storage rack, motorcycle
rack, or any other device that extends the tow bar away from the
tow vehicle.
Step 6. Hook safety cables to chain anchor of baseplate.
Note: Make sure safety clip is in working order.
Step 7. Leave the electrical cable storage pin (circled above) out
for the locking procedure in step 6. When step 6 is completed,
position cable on storage rod leaving enough slack, and insert
pin.
Step 3. Insert receiver pin through receiver until pin passes
through. Secure pin with the Receiver hair pin. Crisscross safety
cables underneath pivot assembly and attach to chain anchors
on towing vehicle. Do not use coiled safety cables with this tow
bar, always use straight Demco safety cables.
quick-lock pin must be
closed properly. Fold ring of Quick-Lock
Pin to the side of the pin that allows ring
to snap against pin. If you have folded
its ring the wrong way it will not snap
against pin.

TB20061 Page 11
Tow Bar Instructions
Step 3. Remove pins that attach tow bar to towed vehicle.
will remain in position. Slide the extendable legs back into tube.
Position electrical cable on storage rod and insert pin to prevent
cable from sliding off.
Step 4. Now take the bottom leg and lift up high enough for
storage pin to clear under storage plate. Turn leg under storage
and push leg down so pin locks into plate. Repeat for top leg.
NOTE: Your can store in three storage positions, both arms left,
both arms right and one arm left and one arm right.
Step 8. Once you are secured to the tow bar, release towed ve-
hicle parking brake, and slowly back up the towed vehicle straight
back until one leg latches. Determine which leg latched by hav-
ing 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. To latch the second leg, turn the top of
towed vehicle’s steering wheel into the direction of the leg that
first latched, and slowly back up again. This will latch the second
leg. Once both legs are latched, straighten wheels on towed ve-
hicle, shut vehicle off. Adjust tow bar receiver head so the vertical
bolt is perpendicular to the baseplate height of towed vehicle.
Tighten the 1/2” bolts on each side of joint head to 85 ft/lbs. If manual
transmission, shift to neutral, unlock steering wheel and make
sure parking brake is released. Note: For four wheel drive units, shift
transfer case into neutral also. Reminder: Consult vehicle’s manufac-
turer for towing suitability of manual or automatic transmission
vehicles.
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 ve-
hicle.
Step 2. Use the latch trigger handle to release the connect-
ing legs between the two vehicles by pressing down on the latch
trigger handle.
NOTE: The Excalibar 3 comes with a 1-1/2” off-set receiver
that can be flipped to help level the tow bar with the towed ve-
hicle. The receiver is in the down position from factory, to change
to the lower position, remove both 1/2” bolts and washer from
side of receiver joint head. Remove the 3/4” nut and bolt, slide
receiver out of receiver joint head and flip receiver into the down
position. Slide receiver back into the receiver joint head and rein-
stall the fasteners.
Up Position Down Position

Page 12 TB20061
4
7
2
1
8
3
6
9
5
US Patent #’s - 6,764,092, 6,612,604, 6,502,847,
7,837,216, 8,573,630 & 8,573,629
Torque to 85 ft/lbs
Parts Breakdown
2
8
6
5
7
3
4
1
ITEM # PART # DESCRIPTION Qty
100084 .50 LOCKWASHER 2
200085 .50 FLAT WASHER 2
300967 BOLT .50NC X 1.25 GR5 HEX 2
402961 .75NC NYLON INSERT LOCK NUT 1
507248 RECEIVER PIN 1
607251 HAIRPIN, RECEIVER PIN 1
713169 RECEIVER JOINT 1
813297 BOLT, .75 NC X 3.75 W/ 2.50 SHANK 1
913570 TOW BAR RECEIVER, 1.5 DROP/RISE 1
10 13168 CROSSTUBE BUSHING, NYLATRON 2
Please order replacement parts by PART NO. and DESCRIPTION.
ITEM # PART # DESCRIPTION Qty
101964 BOLT .75NC X 7.00 GR5 HEX 1
202534 WASHER, MACHINE, .75 X 14GA 1
302961 .75NC NYLON INSERT LOCK NUT 1
413171 ALUMINUM CLEVIS 2
513228 FLANGED BUSHING, .75 ID 4
613571 SPRING, COMPRESSION 2
713589 STORAGE PLATE, SPRING LOADED 2
813590 SPACER 1
Please order replacement parts by PART NO. and DESCRIPTION.
Torque to 150 ft/lbs
Receiver Parts Brteakdown
Pivot Head Parts Brteakdown

TB20061 Page 13
8
9
6
22
3
4
7
11
13
15
12
2
17
5
21
18
2016
1
19
14
10
PART # Qty DESCRIPTION
TB21039 2 Excalibar 3 Decal
TB21038 1 User Instruction Decal
TB21040 1 Warning Do Not Exceed Weight Limits &
Manufacturers Patent / Hitch Rating Decal
Please order replacement parts by PART NO. and DESCRIPTION.
DECALS
BeforeTowing, perform a tow bar safety check,look
for any loose fasteners, condition of safety cables,
excessive movement in connecting leg shaft when
the shaft is extended and locked. If any excessive
movement or loose fasteners are found, the tow
bar will need to be serviced before towing.
If tow bar needs servicing, please bring it to an au-
thorized dealer or send it to Demco.
Parts Breakdown
Connecting Leg Parts Breakdown
ITEM # PART # DESCRIPTION Qty
100182 HAIR PIN, .120 WIRE X 2.375 1
202178 NUT, .50NC LOCK, NY. INSERT 2
302397 LYNCH PIN 2
403805 WIRE SUPPORT ROD 1
503809 CLEVIS SPACER WASHER 4
603878 ATTACHING PIN 2
707223 ROLL PIN, .156 X .75 1
813176 TRIGGER HANDLE 2
913179 COMPRESSION SPRING 2
10 13227 PLASTIC BUSHING, .50 ID X .75 LG 2
11 13249 CLEVIS GROOVED PIN, .313 X 1.25, SS 4
12 13250 RETAINING RING F/ .313 SHAFT 4
13 13431 STORAGE PIN 2
14 13432 RETAINING E-CLIP, SS F/ .25 SHAFT 2
15 13527 CONNECTING CLEVIS F/INDEP.ARM TB 2
16 13561 SCREW, BUTTON SOCKET HD, .313NC X .5 SS 16
17 13859 LATCH SEAR 2
18 15352 BOLT .50NC X 2.75 W/1.75 SHANK 2
19 15712 CONNECTING LEG SHAFT 2
20 16702 CONNECTING LEG TUBE, LEFT 1
21 16703 CONNECTING LEG TUBE, RIGHT 1
22 16704 FRONT ADAPTOR 2
Please order replacement parts by PART NO. and DESCRIPTION.

Page 14 TB20061
2
3
1
6
5
4
Torque to 40-50 ft/lbs
or when legs self-support
ITEM # PART # DESCRIPTION Qty
102178 NUT, .50NC LOCK, NY. INSERT 2
213212 RAIL CLIP HOLDER 4
313213 SCREW, SOCKET HD, #8-32 X .625 SS 4
413273 SAFETY CABLE 54” 2
513305 BOLT, .50NC X 2.38 W/1.75 SHANK SS 2
613317 CLEVIS SPACER WASHER 4
Please order replacement parts by PART NO. and DESCRIPTION.
Connecting Legs to Pivot Head Parts Breakdown
Parts Breakdown

TB20061 Page 15
1
1
2
1
ITEM # PART # DESCRIPTION Qty
9523051 54”Safety Cable Kit (complete)
9523055 64”Safety Cable Kit (complete) Optional
1. 13273 Straight Safety Cable w/Hooks 54” 2
1. 13507 Straight Safety Cable w/Hooks 64” 2
Please order replacement parts by PART NO. and DESCRIPTION.
ITEM # PART # DESCRIPTION Qty
9523064 12”Safety Cable Extension Kit
9523065 18”Safety Cable Extension Kit
1. 13779 Safety Cable Extension12” 2
2. 13780 Safety Cable Extension 18” 2
Please order replacement parts by PART NO. and DESCRIPTION.
Tow Bar Options
Saftey Cables
Safety Cable Extensions

Page 16 TB20061
PART # DESCRIPTION
9523060 6” Drop/Lift Receiver Hitch (complete)
9523059 4” Drop/Lift Receiver Hitch (complete)
Please order replacement parts by PART NO. and DESCRIPTION.
PARTS LIST
PART # DESCRIPTION
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
9523054 7 to 6-WayAuxiliary Coiled Lighting Cable w/recpt.
Please order replacement parts by PART NO. and DESCRIPTION.
AVAILABLE WIRING KITS
NOTE: For replacement parts, call original manufac-
turer 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.
Tow Bar Options
4” or 6” Drop/Lift Receiver Hitch
Auxiliary Lighting Cable

TB20061 Page 17
ITEM # PART # DESCRIPTION
9523067 Tow-Bar to Base Plate Locking Pin Set
1. 14054 Tow-Bar to Base Plate Single Locking Pin Assembly
Please order replacement parts by PART NO. and DESCRIPTION.
PARTS LIST
1
ITEM # PART # DESCRIPTION
9523068 3-Piece Locking Pin Set
1. 14054 Tow-Bar to Base Plate Single Locking Pin Assembly
2. 14047 Tow-Bar to Motor Home receiver Locking Pin
Please order replacement parts by PART NO. and DESCRIPTION.
PARTS LIST
2
1
Tow Bar Options
Tow Bar to Base PLate Locking Pins
3-Piece Locking Pins

Page 18 TB20061
ITEM # PART # DESCRIPTION Qty
KKLB
Excalibar 3 Light Bar (complete)
1. 01772 Nylon Security Strap with hooks & tightener 2
2. 01857 Left Tail/ Brake and Signal Light w/Lenses 1
3. 01773 Brown Jumper Wire 1
4. 01886 Wire Holder (metal) 4
5. 02385 Light Bar Framework 1
6. 02386 Adjustable Light Bracket 2
7. 01856 Right Tail/ Brake and Signal Light w/Lenses 1
8. 02772 1/4”-20UNC Nylon Insert Locknut 10
9. 00092 1/4”-20UNC x 1/2” Hex Head Bolt 6
10. 01777 Light Bar “Z” Bracket 2
11. 01778 3” Suction Cup w/Bolt (#13) 4
12. 02198 Light Bar Wiring Harness (new style) 1
13. 00068 1/4”-20UNC x 3/4” Hex Head Bolt 4
14. 01911 Large Red Lens -
15. 01912 Small Red Lens -
16. 01890 Clear Lens -
Please order replacement parts by PART NO. and DESCRIPTION.
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 Ground
BROWN Tail Lights, License Plate Lights,
Light Cluster Bar & Clearance Lights
YELLOW Left Turn and Stop
GREEN Right Turn and Stop
1
12
1
1
6
7
8
8
8
9
9
9
8
12 13 13
11
11
8
16
15
14
9
8
4
4
3
5
10
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.
Tow Bar Options
PARTS LIST
Light Bar

TB20061 Page 19