Roadmaster Sterling All Terrain User manual

Owner's Manual
Entire contents of manual must be read by owner
Quality Towing Systems since 1974

IMPORTANT NOTICE!
Safety Definitions
Statements in this manual identified as follows are of special significance:
WARNING indicates a potentially hazardous situa-
tion which, if not avoided, could result in property
damage, serious personal injury, or even death.
CAUTION indicates a potentially hazardous situa-
tion which, if not avoided, may result in property dam-
age, or minor or moderate personal injury.
CAUTION used without the safety alert symbol in-
dicates 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.
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.
WARNING
CAUTION
CAUTION

1
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
Table of Contents
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.
WARNING

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.
•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 receiv-
er hitch, the towed vehicle's front end, and/or the rear
of the motorhome. Backing up with the towed vehi-
cle 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 dis-
connect 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.
•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 sig-
nificant wear and tear on the tow bar and mounting brack-
ets, 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. Failure to do so can cause severe tire
and equipment damage. Check the manufacturer's in-
structions for the proper towing procedure(s).
•The towed vehicle and all its contents cannot ex-
ceed 6,000 pounds. The Sterling All Terrain tow bar is
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 con-
tents.
•The tow bar must be secured with linch pins (or
optional padlocks) before towing. Unless the tow bar
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 ca-
bles, and all other components each time before towing.
continued on next page
Safe Towing Practices
2
CAUTION

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. The towed vehicle’s weight should never exceed
40 percent of the towing vehicle’s weight.
Towing a vehicle with one of similar weight will cause
the towed vehicle to override the towing vehicle, result-
ing in “jackknifing,” “leapfrogging,” or “fishtailing.” Seri-
ous damage to both vehicles, as well as the towing sys-
tem, could result.
•Always stand to one side and as close to the
motorhome as possible when releasing the tow bar
locking mechanisms. Never stand between the adjust-
able arms, or put any part of your body between the ad-
justable 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 mo-
torhome as possible before releasing the locking mech-
anisms, to keep from being hit by the towed vehicle.
•Always use safety cables when towing. The safe-
ty cables, which are provided with the Sterling All Ter-
rain, must connect the towed vehicle to the towing vehi-
cle 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-
hicle. In some states it is legal to have one vehicle tow-
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 non-
warranty damage or injury may result.
•The tow bar stinger fits motorhome hitch receiv-
ers with 2-inch inner diameters. If the motorhome hitch
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 clean-
ing and care results in better performance and longevi-
ty. Refer to the section titled “Care and cleaning” for fur-
ther information.
Failure to follow these instructions may cause
property damage, personal injury or even death.
Installer’s safety checklist
The following safety checklist is provided to the install-
er with the instructions for installing the Sterling All Ter-
rain 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’ — 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 vehi-
cle’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
bar. Familiarize yourself with the features of the tow bar.
Demonstrate them to the owner, and ask the owner to
connect and disconnect the tow bar and other compo-
nents of the towing system, until the owner is comfort-
able 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-
continued on next page
4
WARNING

damage.
•The installer must be sure that the vehicle is suit-
able or adaptable for towing. Some vehicles must be
equipped with a transmission lube pump, an axle discon-
nect, 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. Connecting a ground to the ‘A-
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, nor should any of the pre-punched
mounting holes be altered. Any welding or altering of the
tow bar will void the owner's warranty.
Failure to follow these instructions may cause
property damage, personal injury or even death.
Installer’s safety checklist
continued from preceding page
mum of 6,000 pounds carrying capacity; therefore ROAD-
MASTER has used 6,000 pounds as a standard for rat-
ing the weight capacity of all supplementary towing equip-
ment, 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. In
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. Unless the
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. Six-thousand pound-rated safety
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 compo-
nents. The tow bar will be attached to the QD system. If
the QD system is not properly aligned, centered and po-
sitioned on the towed vehicle, the tow bar will not be
centered on the towed vehicle, which may cause exces-
sive tire wear and other consequential, non-warranty 5
WARNING

Installing the
‘quick-disconnect’ system
A
safety
plate
quick-
disconnect
base
vehicle
mounting
bracket
vehicle
mounting
bracket
safety
plate
Quick-disconnect parts list
(2) quick-disconnects
(parts A & B)
(2) cable anchors (E & F)
(2) safety plates (C)
All mounting hardware
Figure 1 vertical
pin
cable
anchor
cable
anchor
passenger side
quick-disconnect
vertical
pin
E
C
C
B
F
driver side
quick-disconnect
6
1. First, attach the quick-disconnects (“QDs,” parts “A”
and “B” in Figure 1) to the tow bar mounting brackets. At-
tach 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
quick-
disconnect
base
quick-
disconnect
crossbar
Your ROADMASTER tow bar is equipped with an ex-
clusive “quick-disconnect” (or, “QD”) system. Before con-
necting the tow bar to the vehicle, first install the com-
ponents 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-dis-
connect system should be reserved, however, for subse-
quent vehicles which may not have these brackets.

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.
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.
7
safety
plate
vertical pin of
quick-disconnect
part “A”
linch pin
QD
base
Figure 2
vehicle
mounting
bracket
long safety
cable attachment short safety
cable attachment
lower vertical
pin of QD base
top hole
of QD
base
WARNING
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.
Towing vibrations will force the linch pins out un-
continued on next page
CAUTION
WARNING

Installing the ‘quick-disconnect’ system
continued from preceding page
less they are properly locked in place over the verti-
cal 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.
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.
Connecting the tow bar
Use caution when handling the tow bar — if your
hands, fingers or any part of your body are caught be-
tween moving components, they can be pinched, cut
or otherwise injured.
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. In-
stead, 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 emer-
gency brake and chock one of the wheels.
3. With the tow bar in the folded position (Figure 5), in-
sert 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
NO!
PIN WILL
VIBRATE
LOOSE
YES
PIN MUST BE
LOCKED
Figure 3
CAUTION
8
Figure 4
flat side of
linch pin
curved side
of linch pin
touches ring
ring
linch
pin

Figure 5
hitch pin
stinger
©
Rotate both arms up,
until they are vertical. release
latch clip
9
release latch and
locking mechanisms point up
Figure 6
Connecting the tow bar
continued from preceding page
Attach the tow bar so that the locking mechanisms
tow bar in
folded position
CAUTION
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.
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 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
WARNING
Figure 7

Figure 8
10
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.
Both tow bar arms must be attached to the quick-dis-
connect bases and locked with a linch pin. Towing vi-
brations 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 un-
locked, the transmission is in the proper setting, and the
emergency brake is released. Remove the wheel chock.
tow
bar
arm
base pin
inserted
base pin
to be inserted
quick-
disconnect
crossbar
base
pin
tab
c
c
linch
pin
quick-disconnect
base
quick-disconnect
base
WARNING
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.
Do not tow the vehicle until the tow bar is attached
with all pins or padlocks. Unless the tow bar is se-
cured 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
WARNING

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.
Do not tow a vehicle using tow bar mounting brack-
ets, 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
WARNING
WARNING
fail during towing, causing property damage, person-
al injury or even death.
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 with-
out extensions. This enlarged arc of motion creates ex-
cessive 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 illus-
trated.
NO!
The pin
will vibrate
loose.
YES
Both linch
pins must be
LOCKED.
ring
linch
pin
Figure 10
flat side of
linch pin
curved side
of linch pin
touches ring 11

12
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 pres-
sure to release. This is the arm that has the majority of
the tension between the two vehicles.)
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, per-
sonal injury or even death.
4. Put the towed vehicle in gear (park), set the emer-
gency brake, and chock one of the wheels.
Pull up on the release
handle to release the
locking mechanism.
Figure 11
5. Remove the base pins and store the tow bar on the
motorhome by reversing the connection procedure (un-
der “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
WARNING
©

13
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 four-
wire electrical cord through the back of the housing.
3. Loosen all of the set screws on the side of the sock-
et, and connect the wires to the back of the socket, as
continued on next page
Wiring instructions 3
4
1
2
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
front of
plug on
4-wire
cord
Figure 12
13
24
front of
4-wire
socket
on towed
vehicle and
motorhome
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
Figure 13

14
Wiring instructions — four-wire system
continued from preceding page
shown in Figure 13. Or, wire the socket to match the ex-
isting 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 mo-
torhome and to the towed vehicle. Test the towed vehi-
cle’s turn signals, tail lights and brake lights to ensure
they mimic the motorhome’s.
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 alert-
ed by turn signals or brake lights, which may result
in a traffic accident, causing property damage, person-
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 sock-
et, 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 sock-
et, and connect the wires to the back of the socket, as
shown in Figure 15. Or, wire the socket to match the ex-
isting 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
WARNING

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 mo-
torhome and to the towed vehicle. Test the towed vehi-
cle’s turn signals, tail lights and brake lights to ensure
they mimic the motorhome’s.
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 alert-
ed by turn signals or brake lights, which may result
in a traffic accident, causing property damage, person-
al injury or even death.
15
5
6
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
front of
plug on
6-wire
cord
2
4
3
15
6
4
2
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
front of
6-wire
socket
on towed
vehicle and
motorhome
Figure 14
Figure 15
WARNING

How to use safety cables
16
Safety cables are an integral part of your towing sys-
tem. 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 se-
verely damaged when the motorhome turns a sharp cor-
ner.
•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 ex-
tends 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.
(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 installa-
tion of safety cables” for further information.
Failure to follow these instructions may cause
property damage, personal injury or even death.
WARNING

Proper installation
of safety cables
Connect the
snap hooks
to the loops
on hitch or
frame.
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.
Use quick links for
easy attachment and
removal of cables.
short
safety
cable
electrical
cord
The built-in cable
guides will help
prevent the safety
cables and 12-volt
electrical cord from
being damaged.
Figure 16
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
by quick links. One quick link is attached to the mount-
ing 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
long
safety
cables
Connect each long safety
cable to the slot in the
cable anchor.
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.
The safety cables must be carefully routed so that
they cannot become pinched, frayed, scraped or oth-
erwise damaged, and so they will not drag when go-
ing 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-
18
ble failure, which may cause property damage, per-
sonal injury or even death.
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, per-
sonal injury or even death.
If your towing system requires two sets of safety
cables, always use both the long and the short safe-
ty 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 prop-
erty damage, personal injury or even death.
WARNING
WARNING
Figure 17
quick link
short safety cable
quick link
attached to
cable anchor
tow bar arm
portion of
mounting bracket
bolted to
vehicle frame
quick-
disconnect
connecting nut
WARNING
long
safety
cable