Roadmaster Sterling User manual

CONTENTS OF THIS
MANUAL MUST BE
READ BY OWNER
by R O A D M A S T E R
THE FINEST TOW BAR ON THE PLANET
Owner's Manual
IMPORTANT!

R O A D M A S T E R, I N C.
Congratulations on the purchase of your new STERLING™tow bar...and
THANK YOU. You have purchased the finest tow bar made...bar none! Quality materials,
computer technology and our reputation for craftsmanship have gone into each of our precision
folding tow bars. Each of our products is designed for safe, trouble-free towing. Your safety
is important to us. This booklet was written with your safety in mind.
Before using your tow bar, read this booklet. Understand how to install & maintain your
tow bar and carefully follow all the instructions and safety precautions. Remember, proper
installation and use of the product is the sole responsibility of the purchaser. Improper
installation, use or maintenance may result in personal injury, property damage or even
death.
A good time to inspect your mounting brackets is during your regular vehicle maintenance
check-ups such as an oil change, brake check or tire rotation. Don't forget to keep your tow
bar clean and lubricated on a regular basis. We offer a silicone spray specifically for this
purpose. Using our vinyl tow bar cover will help keep your tow bar free from dirt and road
grime assuring easy hook-up and operation. Safety cables are required by law in most
states. Follow our safety cable installation in this booklet.
To qualify for your Warranty you must completely fill out and return the enclosed
warranty registration card within (30) thirty days of purchase. As a bonus, we'll extend your
warranty to a total of two years at no additional cost. As a STERLING owner, rest assured you
have bought the finest tow bar on the planet. We thank you for your patronage and greatly
appreciate your discerning taste.

1
IMPORTANT
FILL OUT - TEAR OFF & MAIL WITHIN 30 DAYS TO QUALIFY FOR YOUR WARRANTY
AND TO RECEIVE YOUR FREE ONE YEAR EXTENSION.
Your warranty registration is an important record for ROADMASTER to keep in touch
with you. It also enables us to expedite any future claim, update or recall that may arise
concerning our products.
You must fill out & mail the warranty registration card within thirty (30) days from the date of
purchase to qualify for your warranty. If we receive your card within 30 days, we will extend
the coverage to a total of TWO (2) years at no extra charge.
YOUR TOW BAR SERIAL NUMBER IS ON A LABEL. YOU WILL
NEED THIS NUMBER WHEN YOU FILL OUT YOUR TOW BAR
WARRANTY INFORMATION.
RETAIN SERIAL NUMBER FOR FUTURE REFERENCE.
SERIAL NUMBER #
WARRANTY PROCEDURES
If you have any problems with this product, immediately contact ROADMASTER at 1-800-669-9690. If necessary, we
can direct you to your nearest warranty service center and make arrangements for any warranty repairs or replacements.
While under warranty, ROADMASTER will make arrangements for your product to be repaired or replaced . Do not
purchase replacement parts or pay for labor - you will not be reimbursed. See section titled “ROADMASTER
Limited Warranty” for specific details.
FREE EXTENDED WARRANTY
CAN'T LOCATE YOUR TOW BAR SERIAL NUMBER?
ROADMASTER
FREE BONUS
Serial Number
Located Here

10 MUSTS FOR TOWING SAFETY
1. TOW BAR MUST BE LEVEL WITH THE MOTORHOME. DO NOT TOW IF TOW BAR IS OVER 6 INCHES
OFF LEVEL IN EITHER DIRECTION
Towing with an upward or downward slope of the tow bar puts undue strain on the tow bar and mounting brackets. Do not tow
if tow bar is over 6 inches off level (see page 17).
2. STEERING MUST BE UNLOCKED AND FREE TO TURN WHEN TOWING
Failure to do so can result in severe tire and equipment damage. Steering wheel must be free to turn when towing.
3. DRIVER MUST NOT BACK UP MOTORHOME WITH VEHICLE ATTACHED
Backing up with towed vehicle attached easily causes the vehicle to "jack-knife" and will damage the tow bar, mounting bracket,
hitch, the towed vehicle front end and/or rear of the motorhome. This is the primary cause of tow bar damage and will void the
warranty.
4. TOW BAR MUST BE SECURED WITH LINCH PINS AND/OR PADLOCKS BEFORE TOWING
Unless the tow bar is secured to both vehicles with all designated pins and/or padlocks, you will lose your towed vehicle.
5. OWNER MUST KEEP THE TOW BAR CLEAN AND WELL LUBRICATED
As is the case with most precision equipment, frequent cleaning and care results in prolonged service. Details for cleaning &
lubricating your STERLING tow bar are outlined in the section titled "Care and Cleaning" (page 18).
6. OWNER MUST INSPECT ALL MOUNTS, BRACKETS AND FASTENERS
Visually inspect ALL bolts, wiring, cables and metal components each time before you tow to avoid problems on the road. Check
brackets every 3,000 miles. Inspect for any fractures or cracks in the steel or any visible damage. Do not tow if damaged.
Check torque on all bolts. Refer to installation instructions for mounting brackets and tow bar for torque ratings.
7. OWNER MUST FILL OUT & MAIL THE WARRANTY REGISTRATION CARD
It is IMPORTANT that you send in a completely filled out registration card as soon as possible. The information is needed in
case we must contact you for updates, recalls and to verify your warranty.
2

3
CAUTION! NEVER BACK UP WHEN TOWING YOUR VEHICLE
Backing up while the towed vehicle is attached, will easily "jackknife" the vehicle being towed.
This will result in damage to the towed vehicle, hitch, tow bar assembly, and/or motorhome.
ROADMASTER, Inc assumes no responsibility for any damage that is caused by improper use.
Backing up with a towed vehicle is considered "improper use".
FAILURE TO FOLLOW INSTRUCTIONS MAY RESULT
IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH
8. OWNER MUST CHECK MANUFACTURER'S INSTRUCTIONS FOR TOWING
Some vehicles require a transmission lube pump, axle disconnect, driveline disconnect or free-wheeling hubs to tow without
damaging equipment. Failure to properly equip vehicle will result in severe damage to the transmission. Check manufacturer's
specifications for the proper procedure to prepare vehicle for towing. Be sure your vehicle is towable before taking it on the
road.
9. OWNER MUST NEVER TOW VEHICLE WITH A LIGHTER VEHICLE
Towing a vehicle equipped with a tow bar using a lighter weight vehicle will cause the rear vehicle to over-ride the front vehicle,
resulting in "jack-knifing", "leap-frogging", "fish-tailing" or other unsafe towing situation. Serious damage to both vehicles and
the towing system equipment could result.
10. OWNER MUST ALWAYS USE SAFETY CABLES OR CHAINS WHEN TOWING
A frame to frame safety cable hookup is legal in ALL states that require them.
11. OWNER MUST CHECK TURNING RADIUS OF MOTORHOME BEFORE TOWING.
Some motorhome chassis have such a tight turning radius that you can damage your motorhome, towed vehicle or tow bar while
turning 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 you as you slowly turn sharply to see if you have this potential problem.
Damage that results from turning to sharply is not covered by warranty.

INSTALLER MUSTS FOR SAFETY
1. INSTALLER MUST SHOW OWNER HOW TO PROPERLY OPERATE THE TOW BAR.
Instruct Owner to read and follow instructions in Owner's Manual before using tow bar. Carefully read
the section “Hook-up Instructions” and familiarize yourself with the features of the tow
bar. Demonstrate it and have the owner do a few “practice runs”. You not only impress your customer
with your thoroughness, but will start your customer off on a safer and happier towing experience.
2. INSTALLER MUST CAUTION OWNER TO USE A HITCH OR RECEIVER FOR THE
MOTORHOME THAT IS RATED HIGHER THAN THE ACTUAL WEIGHT OF YOUR VEHICLE
INCLUDING ALL OF ITS CONTENTS.
3. INSTALLER MUST CAUTION OWNER TO SECURE TOW BAR TO BOTH VEHICLES WITH
DESIGNATED PINS AND/OR PADLOCKS.
Unless all the pins are used to secure the tow bar to both vehicles, the owner will lose his
towed vehicle.
4.
INSTALLER MUST BOLT THE STERLING QD BASE TO A MOUNTING BRACKET
ATTACHED TO THE TOWED VEHICLE’S FRAME OR UNIBODY.
The STERLING tow bar is designed as a bolt-on device only. Virtually all vehicles require a mounting
bracket assembly that is connected safely to the frame, unibody or chassis and extends beyond the
bumper. Using a mounting bracket kit designed by ROADMASTER takes the burden of doubt out of
the installer’s hands. Under no circumstances should the tow bar be welded to the vehicle, nor
should any of the pre-punched mounting holes be altered. In fact, any welding or altering of the
tow bar will void the Owner’s Warranty.
The following "Musts for Safety" are provided to your installer with the installation instructions for
the STERLING. It is repeated here for your information. As a precautionary measure, verify that
you or the installer have followed all safety requirements before towing your vehicle.
4

5. INSTALLER MUST ADVISE OWNER TO USE 6,000 LB. OR HIGHER RATED SAFETY CABLES
Frame to frame safety cables are legal in ALL states.
6. INSTALLER MUST STRESS IMPORTANCE OF OWNER SENDING IN WARRANTY CARD
New owners are to be urged to mail their Warranty Registration Card as soon as possible. This will
enable ROADMASTER to expedite any claim or update important information concerning their
STERLING tow bar.
7.
INSTALLER MUST READ INSTRUCTIONS THOROUGHLY BEFORE MOUNTING THE TOW BAR
Proper mounting of the tow bar is of critical importance. Proper centering and height positioning of the
tow bar will give the owner a safe, dependable and trouble-free towing system.
8. INSTALLER MUST BE SURE THE VEHICLE IS SUITABLE OR ADAPTABLE FOR TOWING
Not all vehicles can be safely towed as manufactured. A few models are not towable under any
conditions and others with automatic transmissions require additional equipment such as a transmission
lube pump, axle lock, driveline disconnect or free-wheeling hubs to make them towable. Failure to
properly equip the towed vehicle will result in severe damage to the transmission. Also, the steering
wheel MUST be unlocked for towing. Check manufacturer’s specifications for the proper way to unlock
the steering wheel.
FAILURE TO FOLLOW INSTRUCTIONS MAY RESULT
IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH 5

6
Use caution when operating the tow bar to be sure that your hands, fingers or any
part of your body does not get caught between any moving components. Doing
so can result in pinching, crushing or cutting causing severe personal injury.
RELEASE
HANDLE
QD BASE
TABS
TABS
LINCH
PINS
BASE PIN
HITCH PIN
RELEASE
LATCH
RETAINING BOLT
SAFETY CHAN-
NEL
HOOK-UP INSTRUCTIONS
SAFETY CHAN-
NEL
CLIP

7
STEP 3
Follow Installation Instructions (in separate envelope) to
mount STERLING Quick Disconnect Base
STEP 1
STEP 2
STEP 4
With the STERLING tow bar in the folded position (Fig.1), insert it into
the motorhome’s receiver and secure with Hitch Pin & Clip.
Firmly hold both tow bar arms and rotate them so that they are
vertical as shown in Figure 2. WARNING: Never let go of the arms when
they are in the vertical position. The arms can fall and cause severe
injury if any part of your body is in the way.
Push the Release Latch forward to bring both arms down
to a horizontal position (Fig. 3). Swing both arms away from you
aligning the outermost arm with the tabs on the Quick-Disconnect
Base. Using the included Base pin, attach the arm and secure with
linch pin or optional padlock.
Fig. 1
Fig. 2
Tow Bar Arm
Base Pin
Tabs
Base Pin
Linch Pin
QUICK-DISCONNECT
BASE
Fig. 3

and locked as shown in this photo.
Failure to properly secure pins will
result in loss of towed vehicle.
IMPORTANT:
Base Pins
Must Be Installed
FAILURE TO FOLLOW INSTRUCTIONS MAY RESULT IN
PROPERTY DAMAGE, PERSONAL INJURY OR DEATH
STEP 6
8
STEP 5
Now, swing the other arm to the opposite side and connect in the same manner. Before continuing make sure
your vehicle is prepared for towing as per the manufacturer's instructions. In particular make sure:
a. Your steering wheel is in the unlocked position so it can freely move
b. The transmission is in the correct gear for towing
c. The emergency brake is released
d. You've connected your safety cables and wiring
Now slowly pull away in the motorhome. Your tow bar will self center and the AUTOWLOK Sys-
tem will "SNAP" into position as you drive away. Visually verify that the locks have engaged before
taking your trip.
TIP:If the STERLING arm does not automatically lock when you pull the motorhome ahead, try turning the mo-
torhome left, then right as you drive away. This will pull each arm in the necessary direction to engage the locking
mechanism.

To disconnect the STERLING:
a. IMPORTANT! Set your towed vehicle's
emergency brake and put your vehicle in
Park when un-hooking. Otherwise the towed
vehicle will roll-away when tow bar and
safety cables are removed.
b. Disconnect your safety cables and wiring.
c. Lift the release handles to unlock the arms.
This will normally relieve tension on the
Base Pin.
d. Remove the Base Pins and store the
STERLING on the motorhome by reversing
the hook-up procedure.
DISCONNECT INSTRUCTIONS
IF YOU ARE EXPERIENCING ANY DIFFICULTY IN RELEASING THE LOCKING MECHANISM
ON YOUR STERLING, TRY THE FOLLOWING:
Turn the steering wheel in the towed vehicle so the front tires are parallel to the motorhome as
shown in Figure A and Figure B. Note that it is not necessary for the car to be parallel with the
motorhome, only the car’s front tires. This procedure should alleviate the tension on the
locking mechanism allowing it to release more easily. If you are still having difficulty, then have
someone get in the car (with the car running) and turn the steering wheel all the way left then right
while you lift on the release handle. The locking mechanism should disengage.
CAUTION: Do not use any type of leverage tool to assist with lifting of the Sterling Release Handle.
Doing so will damage the locking mechanism, and is not covered by warranty.
9

Wiring the Plug.
1. Insert the end of the wiring cord through the safety channels. See illustration on page 12.
2. Wire the plug to match your vehicle or follow Figure A below. Apply silicone sealant to the wires where they
attach to the plug. This will prevent moisture and corrosion and help assure a trouble free wiring system.
Wiring the Sockets.
• Find a suitable location to install one of the electrical sockets on the front of the towed vehicle in reach of the
existing 4-wire harness.
• Remove the screw on the back of the electrical socket. Push the inner connector out of the front. Now run the
4-wire through the back of the housing.
SOCKET WIRE MOTORHOME CAR
PIN# COLOR
2 WHITE Ground Ground
4 BLACK Tail light Tail light
1 YELLOW Left turn / Stop Left turn / Stop
3 RED Right turn / Stop Right turn / Stop
3
4
1
2
Front of Plug on Cord
Fig. A
WIRING INSTRUCTIONS
10

11
SOCKET WIRE MOTORHOME CAR
PIN# COLOR
2 WHITE Ground Ground
4 BROWN Tail light Tail light
1 YELLOW Left turn / Stop Left turn / Stop
3 GREEN Right turn / Stop Right turn / Stop
1
2
3
4
• Be sure to tighten all set screws and check each wire to see if it is secure. Use some clear silcone seal
around each wire entry and set screw indentation. This will help to weather proof the socket and secure
the set screws. Replace the protective boot.
• If your coach does not have the correct wiring socket already, you can replace it with the new socket for
the 4 wire cord and connect the appropriate wires to the new socket according to the diagram.
• Now connect the 4-wire cord to the coach and towed vehicle. Test the lights for proper operation.
• 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 the diagram below or wire the socket to match the existing wiring on the motorhome.
Fig. B
Front of Socket on Towed Vehicle and Motorhome

12
SAFETY CABLES INSTRUCTIONS
A
Cable Anchors
Figure 1
Safety Channels
Route the safety cables through the safety channels by inserting the small end of the
cable through the safety channel toward the towed car. Repeat for opposite side.
Installation of Cables
WARNING: USE ONLY 6,000 LB. (or higher) RATED SAFETY CABLES
Figure 2
Cable Anchors
Double back the end of the safety cable through the channel to store. The wiring cable
will fit inside the space created when the arms are folded together.
Storing the Safety Cables and Wiring

13
2. Always cross cables under the hitch as shown in Figure 3. In the event of hitch
failure, the crossed cables may help support the tow bar preventing it from
pole-vaulting the towed vehicle.
Cables must
be crossed.
Route safety cables
through channels.
Figure 3
Short cables
How to Use Safety Cables
1. Connect the cables to the anchor bracket by inserting the cables through the
anchor bracket and dragging down (Figure 2). If your baseplate has short cables
on the car, attach them to holes "A" (Figure 1) with a Quick-link (not included).
Quick-link

14
Motorhome
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
5. Safety cables are rated at 6000 lbs. per pair. Your vehicle and all of its contents cannot
exceed 6000 lbs.
Pull the safety cables so that all of the slack is at the motorhome.
IMPORTANT!: Cables too short: Make sure there is enough slack in the cables at the
motorhome to allow for sharp turns. If you have a hitch extension or other equipment that
extends the distance between your towed car and motorhome the standard cables may be
too short. Failure to use long enough cables will result in severe non-warranty damage to the
towing system when turning sharp corners. If you require longer cables, contact Roadmaster,
to custom make longer cables for your needs.
IMPORTANT!: Cables too long: On some hook-ups, the cables may be too long, and may
allow the cables to hang too low. The cables will drag when traveling through dips and low
spots resulting in non-warranty damage. If your cables are too long, you will need to wrap
the excess cable around the bar to take up the slack. REMEMBER TO LEAVE ENOUGH
SLACK FOR TURNING SHARP CORNERS!
4. If you are connecting the Sterling to a ROADMASTER bracket that has removable arms,
then you MUST use the short safety cables (that came with your brackets) to connect
between the Cable Anchor and the portion of your mounting bracket that is permanently
bolted to your towed car. This is required by law. You may lose your car if you do not
properly use the safetly short cables.
3.

15
• DO NOT TOW YOUR VEHICLE UNTIL TOW BAR IS SECURE WITH ALL PINS AND/
OR LOCKS. Unless your tow bar is secured to both vehicles with all designated
pins and/or padlocks, YOU WILL LOSE YOUR TOWED VEHICLE.
• SAFETY CABLES MUST CONNECT THE TOWING VEHICLE TO THE TOWED VEHICLE FRAME
TO FRAME.
• DO NOT TOW A VEHICLE USING TOW BAR, SAFETY CABLES, MOUNTING BRACKETS OR
A HITCH RECEIVER RATED LESS THAN THE ACTUAL WEIGHT OF YOUR VEHICLE.
WARNING
• USE CAUTION WHEN OPERATING THE TOW BAR TO BE SURE THAT YOUR HANDS,
FINGERS OR ANY PART OF YOUR BODY DOES NOT GET CAUGHT BETWEEN ANY
MOVING COMPONENTS. DOING SO CAN RESULT IN PINCHING, CRUSHING OR
CUTTING CAUSING SEVERE PERSONAL INJURY.
•NEVER HEAT, BEND OR WELD STERLING TOW BAR OR IT WILL WEAKEN METALS
RESULTING IN NON-WARRANTY FAILURE.
•TOWED VEHICLE MUST HAVE EMERGENCY BRAKE SET & VEHICLE IN PARK WHEN
HOOKING OR UN-HOOKING THE TOWED VEHICLE FROM MOTORHOME. FAILURE TO
DO SO WILL CAUSE THE TOWED VEHICLE TO ROLL AWAY.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

16
SAFE
ZONE
3"
LEVEL
FAILURE TO FOLLOW ANY ONE OF THESE WARNINGS MAY RESULT
IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH
3"
DO NOT TOW IF STERLING IS OVER 3 INCHES
OUT OF LEVEL. See Caution on next page.
Towing with an upward or downward slope of the tow bar puts undue strain on the tow bar and
mounting brackets. DO NOT TOW if the STERLING is over 3 inches out of level as shown.
To determine if your bar is at a safe angle:
a. Connect motorhome and car on level ground.
b. Measure from the ground to the center of the motorhome's receiver.
c. Measure from the ground to the center of the base pin.
d. Compare these two measurements. If they are more than 3" apart,
you will need to use a Receiver Drop. This will increase or decrease the height of
the motorhome's receiver. ROADMASTER manufactures several receiver drops in
various heights to accommodate various out of level situations.
CENTER
OF RE-
CEIVER
NOT SAFE
NOT SAFE
CENTER
OF BASE
PIN
CENTER
OF BASE
PIN

17
If you use any kind of receiver extension, the tow bar MUST be no more than 3
inches out of level. DO NOT TOW IF STERLING IS MORE THAN 3 INCHES OUT
OF LEVEL while using receiver extension. Extensions cause the towing system
to swing much higher and lower when traveling in and out of dips. The enlarged
arc of motion creates many problems:
1) Excessive strain on the tow bar, brackets and frame. Using extensions
with an out of level tow bar can cause the towing system to fail and
result in the loss of your towed vehicle.
2) Excessive suspension and tire wear on the towed vehicle.
3) Swaying and poor towing characteristics of the towed vehicle.
Towing more than 3 inches out of level while using extensions will voidROADMAS-
TER's warranty.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
CAUTION!

CARE & CLEANING
18
®
®
®
®
®
®
®
®
TIP: Keeping the Base Pins clean and lubricated will help ease the disconnect process. Use Silicone
over the entire surface of the tow bar to help preserve the nish.
Your tow bar requires regular cleaning and lubricating to assure long term trouble free
operation. Use the following guidelines when maintaining your tow bar:
Always clean the bar before lubricating. Use Roadmaster’s Voom! to clean the bar. It does
an exceptional job of breaking down road film, dirt and grease. Spray a liberal amount on the tow
bar, then operate the tow bar to work the cleaner into all of the moving parts. Spray cleaner into
the lock housing access hole (directly under the lock mechanism) and activate the lock several
times to work it in. Once you’ve cleaned the bar and wiped off the residue, extend the bar such
that the cleaner can drain out of the arms. Wipe any remaining cleaner away before lubricating.
Now that you have a clean, dry tow bar. Spray a liberal amount of Sil-
icone over the entire tow bar. Note: DO NOT SPRAY ANY SILICONE
DIRECTLY INTO THE LOCK HOUSING OR THE LOCK HOUSING
ACCESS HOLE! Silicone coats/covers in a thin layer. If you spray sili-
cone inside the lock housing, it reduces the clearance for the locking
mechanism preventing proper operation.
Proper cleaning and lubrication of the tow bar will prevent
corrosion on your tow bar and provide smooth operation.