AUTO TRANSPORT TRAILER

Page 1

DEMCO ï Dethmers Mfg. Co. ï 4010 320th St. ï P.O. Box 189 ï Boyden, IA 51234PH: (712) 725-2311 ï Toll Free: 1-800-543-3626 ï FAX: 1-800-845-6420

www.demco-products.com

3-04NB20005, Rev.5

AUTO TRANSPORT TRAILER

��

��

�� THIS MANUAL COVERS THE FOLLOWING YEARS AND UNIT NUMBERS

YEAR UNIT NUMBER2000 - 360000 - 3619991999 - 205100 - 2055991997 - 177500 - 1775991996 - 188851 - 188999

160519 - 160524160557 - 160560160616 - 160767160672 - 160697

YEAR UNIT NUMBER1995 - 153763 - 153885

160000 - 160517169341 - 169699

YEAR UNIT NUMBER2000 - 375752 - 378616

040000 - 0418911998 - 8000 - 84991997 - 7000 - 71491996 - 6000 - 61491995 - 5000 - 5499

AT6000RG/AT6000RSAT6000B

Page 2

Table of ContentsImporant Information ................................................................................................................................... 2Safety Sign Locations ................................................................................................................................. 3Bolt Torque .................................................................................................................................................4-6AT6000B, AT6000RS, & AT6000RG Auto Transport Front Half Parts Breakdown .......................................... 7AT6000B, AT6000RS, & AT6000RG Auto Transport Back Half Parts Breakdown ......................................... 8Wheel Carrier Parts Breakdown & List and Disc Brake Parts Breakdown and List ....................................... 9Brake Cluster & Drum Parts Breakdown and Parts List .............................................................................. 10New Style Drum & Disc Brake Actuator Parts Breakdown and Parts List ................................................... 11Electrical Diagram & Brake Line Parts Breakdown and Parts List ............................................................... 12Brake System Repair & Maintenance ......................................................................................................... 13Serial Number Tag & Decal Location ........................................................................................................... 14Safety & Maintenance Notes ...................................................................................................................... 15

IMPORTANT INFORMATION

This document is intended as a parts manual for use by the rental agency only. The rental customer, any rental agencyusing the AT6000B and any person assisting with hooking or loading the AT6000B, should refer to the rental agency'scurrent trailer systems guide and instructions and to the instruction decals for instruction on proper use. The rental agencyis responsible for furnishing appropriate written instructions to the customer and checking that all decals are present andlegible at the time of rental. Dethmers will be happy to assist with the composing of appropriate instructions.

EXCLUSION OF WARRANTIES

This product is warranted as provided by written agree-ment between Budget and the manufacturer. ALLOTHER WARRANTIES, EXPRESS OR IMPLIED, AREDISCLAIMED.

Transport weight empty.....................1925 lbs.Maximum weight of load....................4055 lbs.Maximum transport total weight.........5980 lbs.

Auto Transport

Interior platform dimensionsBed Length: 12 feetMaximum Bed Width: 79 inchesMinimum Bed Width: 42 inches

Important InformationWeight and size limitations:

"Reporting Safety Defects"turing Company.

To contact NHTSA, you may either call theAuto Safety Hotline toll-free at 1-800-424-9393 (or366-0129 in Washington, D.C. area) or write to:

NHTSA,U.S. Department of TransportationWashington, D.C. 20590.

You can also obtain other information aboutmotor vehicle safety from the Hotline.

If you believe that your vehicle has a defectwhich could cause a crash or could cause injury ordeath, you should immediately inform the NationalHighway Traffic Safety Administration (NHTSA) inaddition to notifying Dethmers Manufacturing Com-pany (DEMCO).

If NHTSA receives similar complaints, it mayopen an investigation, and if it finds that a safetydefect exists in a group of vehicles, it may order arecall and remedy campaign. However, NHTSAcannot become involved in individual problemsbetween you, your dealer, or Dethmers Manufac-

Page 3

! SAFETY SIGN LOCATIONS

The types of safety sign and locations on the equipment are shown in the illustration below.Good safety requires that you familiarize yourself with the various safety signs, the type ofwarning, and the area or particular function related to that area, that requires your SAFETYAWARENESS.

A

B

H

I

E

D

G

F

C

M

L

N

J

K

REF. PARTNO. NO. QTY. DESCRIPTIONA. NP21010 1 Caution Actuator SpringB. BD21001 1 Attention Brake Actuator for Disc BrakesC. NR21021 1 Important Trailer JackD. BH21003 1 Brakes On/OffE. NR21027 1 Do Not Remove Master Cylinder CapF. BD21002 2 Unit Equipped with Disk BrakesG. DA21001 6 Bolt Torque and Tire Press. Spec.H. NR21023 1 Warning Cross ChainsI. NR21017 1 Operateing InstructionsJ. NA21002 2 No StepK. NR21022 1 Safety Chain Attachment LocationL. NR21010 1 Do Not Exceed 45 MPHM. NA21004 1 Width RequirmentsN. NR21015 1 Weight SpecificationsO. NA21003 2 Winch Operating InstructionsP. BD21002 2 Equipped W/ Disc Brakes

O

O

P

Page 4

Keep wheel lug nuts or bolts tightened to specified torque.Maintain tire pressure at 50 P.S.I. cold 11/98 DA21001

G. DA21001

This Unit EquippedThis Unit EquippedThis Unit EquippedThis Unit EquippedThis Unit Equippedwith with with with with DISC BRAKESDISC BRAKESDISC BRAKESDISC BRAKESDISC BRAKES

BD2100210/99

BRAKES ONDO NOT TOW

BRAKES OFFTOWABLE

10/99 BH21003

Do not remove master cylindercap to check brake fluid.

SIGHT GLASS

If sight glass ball isfloating (full). If sightglass ball is notfloating add untillball floats.

Use sight glass to determine brakefluid level. Only remove cap whenadding fluid.

10/99 NR21027ATTENTIONThis brake actuator isspecially designed foruse with disc brakesONLY.Any replacement ofthis unit MUST be of

thesame design.10/99 BD21001

F. BD21002

E. NR21027

B. BD21001

D. BH21003

IMPORTANTAfter securing trailer

to ball on truck,

PARKING JACK must

be cranked up until

stopped and left in

full up position for

road travel.

10/98 NR21021

CAUTIONActuator is springloaded. Use care whenservicing or injury mayoccur.

10/99 NP21010

WARNING

Criss cross safety chains and attach tomounting loops on truck. Attach emergencybrake actuator cable to one of these loopsalso. REV 1 NR21023

To prevent serious injury or death.

A. NP21010

C.NR21021

H.NR21023

Page 5

NO STEPNO STEPNO STEPNO STEPNO STEP 12/99 NA21002

OPERATING INSTRUCTIONS

Read all instructions completely before use 1. Fully engage parking brake on truck. Secure ball coupler to a 2î- 6000 lb. rated ball on truck. Assure hitch and hitch ball are securely

attached to truck, in good condition, not rusted, loose or stripped. Criss-cross safety chains under tongue and secure to mounting

loops on truck. Secure emergency brake actuator cable to mounting loop on truck. Connect light wires to truck and check for proper

operation. Raise tongue jack fully before moving car carrier. 2. Car carrier must be completely and properly attached to truck, setting on level surface, before loading towed vehicle. Vehicle to be

loaded must have an outside tire width of not more than 79î and an inside width of not less than 42î and must not exceed 4055 lbs.

3. Remove winch lock pins from strap winches on front of car carrier. Release winch (grasp handle, squeeze trigger, then push down)

and pull all excess strap from winch. Lay tire strap to outside of car carrier.

4. To extend ramp, pull release latch down, fully extend and lower ramp to ground.

5. With someone safely guiding you, center vehicle to car carrier and slowly drive forward until tires touch front stops.

Do not back vehicle onto car carrier. Place towed vehicle in park (automatic) or in gear (manual) and set parking brake.

6. Place tire straps over tires centering straps and winches to tires. While tightening straps, pull cross straps forward to ensure even

tightening. Tighten straps until each tire starts to flatten against tire stop. After strap is tight, insert lock pin into winch.

7. Attach front and rear safety chains to towed vehicle axle or frame. Chains must not attach to or go over steering or brake parts of

towed vehicle.

8. Grasp ramp handle and slide ramp in until latch locks.

9. Release truckís parking brake and drive forward 100 feet. Stop and perform safety check. Check hitch, hitch ball, ball coupler, safety

chains, tire straps, bolts, ramps, and other items to ensure they are tight and in correct position. Check all lights to make sure they are

operating properly. Repeat safety check after first 5 miles and every 50 miles thereafter.

10. Unloading- Do not unhook car carrier from truck until towed vehicle is completely unloaded from car carrier.Fully engage parking brake on truck. Reverse procedure in this order: step 4, step 7, step 3, step 5 step 8. After completing

unloading procedures, secure safety chains and tie down straps in their original empty car carrier positions.

SAFETY

Perform safety check. Check hitch, hitch ball, ball coupler, safety chains, tire straps,

bolts, ramps, and other items to ensure they are tight and in correct position.

Check all lights to make sure they are operating properly. Car carrier tires must be

inflated to recommended P.S.I. . See decal on car carrier for correct pressure.

Tire pressure may increase during travel. Do not bleed off this increase in pressure.

Repeat safety check after first 5 miles and every 50 miles thereafter.

Do not exceed load capacity of car carrier. Car carriers may only be towed by

approved trucks with correct towing capacity. Weight of loaded trailer must not exceed

weight of towing vehicle. Do not exceed 45 M.P.H.

AT6000 SAT

09/98 NR21017

IMPORTANT INFORMATIONWeight and size limitations:

Car CarrierEmpty Weight ........................... 1925 lbs.Maximum Weight .................... 5980 lbs.Carrying Capacity ..................... 4055 lbs.

Interior platform dimensions:Bed length: ............................... 12 feetMaximum Bed Width: ............... 79 inchesMinimum Bed Width: ................ 42 inches

I. NR21017

DO NOT EXCEED

45MPH

WHEN TOWING THIS TRAILER11/98 NR21010

EMPTYWEIGHT

MAXIMUMWEIGHT

CARRYINGCAPACITY

1925 LBS

5980 LBS

4055 LBS09/98 AT6000 SAT NR21015

IMPORTANTLoading oversized or undersized vehicles

may result in property damage

12/99 NA21004

42"79"

MIN. INSIDE TREAD WIDTH

MAX. OUTSIDE TREAD WIDTH

N. NR21015

L. NR21010

M. NA21004

��

Attach safety chainsand emergency brakeactuator cable tomounting loops ontruck.10/98 NR21022

K. NR21015

J. NA21002

WINCH OPERATING INSTRUCTIONS

Tire Size Limitations

Maximum Tire Size:17" tires ... Not Transportable16" tires ... 215R6015" tires ... 215R6014" tires ... 215R60

Minimum Tire Size:13" tires ... 165R7012" tires ... Not Transportable

B

C

A

Remove winch lock pins (A) from strap winches on front of car carrier.Release winch: Grasp handle (B) squeeze trigger (C) push down and pull all

excess strap from winch. Lay tire strap to outside of car carrier.Tighten straps: Place tire straps over tires centering straps and winches to

tires. While tightening straps, pull cross straps forward to ensure even tightening.Tighten straps until each tire starts to flatten against tire stop. After strap is tight,

insert lock pin into winch. 10/99 NA21003

O. NA21003

This Unit EquippedThis Unit EquippedThis Unit EquippedThis Unit EquippedThis Unit Equippedwith with with with with DISC BRAKESDISC BRAKESDISC BRAKESDISC BRAKESDISC BRAKES

BD2100210/98

P. Trailer sides BH21002 Qty. 2

Page 6

Checking Bolt Torque

Table shown below gives correct torque values for various bolts and capscrews.Tighten all bolts to torques specified in chart unless otherwise noted. Check tightness ofbolts periodically, using bolt chart as a guide. Replace hardware with same grade bolt.

NOTE: Unless otherwise specified, high-strength Grade 5 hex head bolts are used through-out assembly of this Ryder Auto Transport.

Torque Specifications

BOLT TORQUE!

GRADE-2 GRADE-5 GRADE-8

Torque figures indicated above are valid for non-greased or non-oiled threads and heads unless otherwisespecified. Therefore, do not grease or oil bolts or capscrews unless otherwise specified in this manual.When using locking elements, increase torque values by 5%.

* Torque value for bolts and capscrews are identified by their head markings.

Bolt Torque *

GRADE 2 GRADE 5 GRADE 8ì A î lb-ft (N.m) lb-ft (N.m) lb-ft (N.m)

1/4î 6 (8) 9 (12) 12 (16)5/16î 10 (13) 18 (25) 25 (35)3/8î 20 (27) 30 (40) 45 (60)

7/16î 30 (40) 50 (70) 80 (110)1/2î 45 (60) 75 (100) 115 (155)

9/16î 70 (95) 115 (155) 165 (220)5/8î 95 (130) 150 (200) 225 (300)3/4î 165 (225) 290 (390) 400 (540)7/8î 170 (230) 420 (570) 650 (880)1î 225 (300) 630 (850) 970 (1310)

Note: Torque Lug Nuts To 120 lb-ft

Page 7

78

10

23

22

212012

1922

16181712

131415

9

116

4 35

5

Left Winch Shown

1

2

24

25

26

27

30

29

33

38

31

29

6646

27

45

28

45

64

45

32

28

43

59

52

4661

28

51

4847

50

3755

5960

6160

56

5758

6561 606659

89 62

63

59

44

53 54

61

49 85

28

40

27

42

3739

27

8841

3427

37

36

28

28Torque to75 ft. lbs.

Torque to75 ft. lbs.

ACTUATOR(ref. no. 24) See page 11 for

parts breakdown and parts list.

28


29

29


2827

Torque to75 ft. lbs. 45

AT6000B, AT6000RS, & AT6000RGPARTS BREAKDOWN

46

59

61

90

91

92

REF.NUM. AT6000B QTY. AT6000RS QTY. AT6000RG QTY. DESCRIPTION1. 5433 1 5433 1 5433 1 Right Winch Assembly2. 5432 1 5432 1 5432 1 Left Winch Assembly3. 03569-95 1 03569-95 1 03569-95 1 Winch Frame4. 03570-95 1 03570-95 1 03570-95 1 Left Spool Tube- 03571-95 1 03571-95 1 03571-95 1 Right Spool Tube5. 03577 2 03577 2 03577 2 Heavy Duty External Snap Ring6. 03574-95 1 03574-95 1 03574-95 1 Winch Handle7. 03668 1 03668 1 03668 1 18 Ga. Shim Washer8. 03575-95 1 03575-95 1 03575-95 1 Left Ratchet Gear- 03576 1 03576 1 03576 1 Right Ratchet Gear9. 03666 1 03666 1 03666 1 5/16î x 1-1/4î Split Roll Pin

10. 02243 1 02243 1 02243 1 Rubber Winch Hand Grip11. 05450 1 05450 1 05450 1 Winch Pawl12. 01864 2 01864 2 01864 2 Winch Spring SS13. 05449 1 05449 1 05449 1 Winch Pawl Bushing SS14. not used - not used - 00004 1 5/16î Flat Washer15. 05444 1 05444 1 05444 1 3/8î-UNC x 3/4î Hex Head Bolt w/ epoxy16. 03572-95 1 03572-95 1 03572-95 1 Left Ratchet Catch- 03573-95 1 03573-95 1 03573-95 1 Right Ratchet Catch

17. 03578 1 03578 1 03578 1 5/16î-18 UNC x 1/2î Shoulder Screw18. 01998 1 01998 1 01998 1 5/16î SS Flat Washer19. 02002 1 02002 1 02002 1 1/4î SS Flat Washer20. 01076 1 01076 1 01076 1 1/4î-20UNC x 3/4î lg. Gr. 5 Hex Head Bolt21. 00214 1 00214 1 00214 1 1/4î Flat Washer22. 02772 2 02772 2 02772 2 1/4î-20 UNC Nylon Insert locknut23. 05337 1 05337 1 05337 1 Clip with Cable24. 8619111 1 8619111 1 8619111 1 Disc Brake Actuator- 8659111 - 8659111 - 8659111 - Drum Brake Actuator

25. 01338 2 01338 2 01338 2 1/2î-13 UNC x 4-1/2î Bolt (Gr. 5)26. 00060 8 00060 8 00060 8 3/8î Lock Washer27. 00085 16 00085 16 00085 16 1/2" Flatwasher

Page 8

6761

59

68

69

69

64 66

71

73

742728

68

6566

72

7778

76

80

7945

46

46

60

6665

8448

49

61 59

75

AT6000B, AT6000RS, & AT6000RGPARTS BREAKDOWN

81

838228

Ramp Latch Assembly 87

86

49

49 4848

8475

License Plate Light Assembly

70

REF.NUM. AT6000B QTY. AT6000RS QTY. AT6000RG QTY. DESCRIPTION27. 00085 16 00085 16 00085 16 1/2" Flatwasher28. 02178 32 02178 28 02178 28 1/2"-13 UNC Nylon Insert Locknut29. 01254 22 01254 22 01254 22 1/2"- 13 UNC x 1-1/2" Lg. Hex Hd Bolt30. 04273 2 04273 2 04273 2 32" Safety Chain w/ S-Hook31. 03637-96 1 03637-96 1 03637-96 1 Tongue32. 03635-96 1 03635-96 1 09797-96 1 Trailer Bed33. 05580-96 1 05580-96 1 05580-96 1 Jack Foot - Galvanized34. 05582-95 1 05582-95 1 05582-95 1 1/2" x 11-1/2" Pin- ----- - ----- - ----- - ---------------------

36. 05581-95 1 05581-95 1 05581-95 1 1/2" x 8" Pin37. 00185 5 00185 5 00185 5 5/32" x 1" Cotter Pin38. 00191 1 00191 1 00191 1 3/16" x 1-1/2" Cotter Pin39. 05584-95 1 05584-95 1 05584-95 1 1/2" x 2-3/8" Pin40. 5539 1 5539 1 5539 1 Jack with Hardware41. 05587 1 05587 1 05587 1 1" Machine Washer 14 ga.42. 04508 4 04508 4 04508 4 Reflective Sticker (Yellow)43. not used - not used - 03638-96 2 Front Tire Stop44. 03643-30 2 03643-30 2 03643-30 2 Winch Mounting Plate45. 00907 18 00907 18 00907 4 3/8"-16 UNC x 1" Lg. Hex Hd Bolt46. 02592 30 02592 26 02592 30 3/8"-16 UNC Nylon Insert Lock Nut47. 04228 1 04228 1 04228 1 Registration Holder48. 04208 6 04208 6 04208 6 #10-24 UNC x 3/4" Lg. Round Hd Screw49. 02205 6 02205 6 02205 6 #10-24 UNC Nylon Insert Lock Nut

Page 9

Please order replacement parts by PART NO. and DESCRIPTION.

REF.NUM. AT6000B QTY. AT6000RS QTY. AT6000RG QTY. DESCRIPTION50. 03639-95 2 03639-95 2 03639-95 2 Auto Tie-Down Strap Rod51. 05898 2 05898 2 05898 2 3-Point Tie-Down Strap with Buckle52. 02729-95 2 02729-95 2 02729-95 2 Strap Buckle Only53. 00640 2 00640 4 not used - 1/2"-13 UNC Hex Jam Nut54. 03714 2 03714 2 03714 2 1/2"-13 UNC x 4" Full Thread Hex Head Bolt55. 03644-30 2 03644-30 2 03644-30 2 Axle

- 5464 - 5464 - 5464 - Fender Kit (includes Fender, Insert, & Fastners)56. 03901 1 03901 1 03901 1 Fender - Galvanized57. 07279 1 07279 1 07279 1 Fender Insert58. 05909 2 05909 2 05909 2 Fender Gusset59. 01076 40 01076 40 01076 40 1/4"-20 UNC x 3/4" Lg. Hex Hd Bolt60. 00214 46 00214 46 00214 46 1/4" Flat Washer61. 02772 40 02772 40 02772 40 1/4"-20 UNC Nylon Insert Lock Nut

62. 03640-30 2 03640-30 2 09796-96 2 Rear Light Pod63. 03641 1 03641 1 03641 1 3-Cluster Wire Guard64. see pg. 12 4 see pg. 12 4 09793 4 LED Yellow Lamp grommet style65. see pg. 12 7 see pg. 12 7 09794 7 LED Red Lamp grommet style

66. see pg. 12 11 see pg. 12 11 05921 11 Rubber Grommet for 2" round light67. 03642 1 03642 1 03642 1 Front Wire Protector68. 04819 2 04819 2 04819 2 5/16" Rapid Link69. 05926 2 05926 2 05926 2 60" Auto Tie-Down Chain w/ hook70. see pg. 12 2 see pg. 12 2 see pg. 12 2 Oval Tail Light (stop, tail, turn)71. see pg. 12 2 see pg. 12 2 see pg. 12 2 Rubber Grommet for light72. 04804 4 04804 4 04804 4 Reflective Sticker (Red)73. 03647 2 03647 2 03647 2 Rubber Bumper74. 01897 4 01897 4 01897 4 1/2"-13 UNC x 3-1/2" Hex Hd Bolt75. 07734 1 07734 1 07734 1 License Plate Light Assembly76. 03636-96 2 03636-96 2 03636-96 2 Ramp77. 00082 4 00082 4 00082 4 3/8"-16UNC x 2-1/2" Lg. Hex Hd Bolt78. 04725 4 04725 4 04725 4 Ramp Roller Wheel with Bushing79. 03649-95 2 03649-95 2 03649-95 2 Ramp Stop Plate80. 03723 4 03723 4 03723 4 Ramp Pull-Out Strap81. 10126 2 10126 2 10126 2 Ramp Latch82. 10109 2 10109 2 10109 2 Double Torsion Spring83. 01975 2 01975 2 01975 2 1/2"-13 UNC x 5" Hex Hd Bolt84. 03848 1 03848 1 03848 1 License Plate Light Bracket85. 05049 2 not used - 05049 2 Pop Rivet (VIN Tag) (Qty's will vary w/ LED lights.)86. 02590 1 02590 1 02590 1 Grommet 1/4" ID X 7/16" OD X 1/4" Grip87. 02321 1 02321 1 02321 1 Grommet 1/4" ID X 7/16" OD X 1/8" Grip88. 03826 1 03826 1 03826 1 Grommet 3/4" ID X 1-7/16 OD X 1/4" Grip89. 04396 2 04396 2 04396 2 Grommet 11/16" ID X 1" OD X 3/16" Grip90. 00059 8 00059 8 00059 8 3/8î Flat Washer91. 07623-30 1 07623-30 1 07623-30 1 Spring Return System92. 04053 1 04053 1 04053 1 1/2î-13 UNC x 5-1/2î Bolt (Grd 5)

- 5296 - 5296 - 5296 - jack repair kit SQ(incl. Gears & pins) sidewind- 04866 1 04866 1 04866 1 Gear Cover (Wesbar only) sidewind- 5682 1 5682 1 5682 1 Handle Kit (Round Fulton Jack) topwind

Page 10

BRAKE CLUSTER PARTS BREAKDOWN

1

2

3

4

5

6

7

8



10


9

REF. PARTNO. NO. QTY. DESCRIPTION1. 02213 20 12mm Lug Nut2. 09296 4 14 x 5.5" White Rim (115mm Bolt Circle)3. SB40929 4 10" Brake Drum4. 02377 16 7/16"-20UNF Gr8 x 1-1/2 Epoxy Hex Hd Bolt5. 04369 4 New Departure Hub (5 on 115mm Bolt Circle)- 02917 - 12mm x 1-1/2" Replacement Stud Bolt6. SB24429 2 Left Hand Brake Cluster (see page 4 for parts breakdown)- SB24428 2 Right Hand Brake Cluster (not shown)7. 05900 4 Forged Arm8. 05933 4 5/8"-18UNF Nylon Insert Lock Nut9. 05932 4 5/8"-18UNF Gr5 x 3-3/4" Hex Head Bolt10. 03644-30 2 Axle


BRAKE CLUSTER PARTS LIST

DISC BRAKE PARTS BREAKDOWN

REF. PARTNO. NO. QTY. DESCRIPTION

PARTS LIST

1. 03930-30 4 Caliper Mounting Plate*2. 03933 8 Caliper Mounting Bolt*3. 03932 8 Caliper Mounting Bolt Protective Boot4. 03927 4 Rotor*5. 03929 2 Right Side Caliper includes items with *- 03928 2 Left Side Caliper w/ Brake Pads6. 03934 2 Brake Pads (for one complete axle)7. 03925 4 11-1/4" Brake Hose (not shown)8. 03926 4 Feeder Bolt*9. 03931 8 Brass Washer10. 02377 16 7/16"-20UNF Gr8 x 1-1/2 Epoxy Hex Hd Bolt11. 04369 4 New Departure Hub (5 on 115mm Bolt Circle)- 02917 - 12mm x 1-1/2" Replacement Stud Bolt

12. 05900 4 Forged Arm13. 05933 4 5/8"-18UNF Nylon Insert Lock Nut14. 05932 4 5/8"-18UNF Gr5 x 3-3/4" Hex Head Bolt15. 03644-30 2 Axle16. 10831 1 Bleeder Screw(replacement only)

1

2


4

5

6 3

89

ASSEMBLY1. Begin by mounting the Hub Assembly and the Caliper

Mounting Bracket (#1) to the Forged Arm using the 7/16"Epoxied Bolts (as shown).

2. Now place the Rotor (#4) onto the Hub Assembly as shownin the diagram.

3. Make sure the Brake Pads (#6) are correctly placed in theCaliper (#5).

4. Place Caliper (#5) over the Rotor (#4), and secure it to theMounting Bracket (#1) using the Caliper Mounting Bolts (#2)and Protective Boot (#3).

5. Hook up Brake Hoses and replace the Rim and Tire.

* Items included when ordering calipers #03928 or #03929 .Note Calipers will be marked (Right/Left) opposite to the

above parts list, and the way they are assembled on thetrailer. (Example: a caliper marked right will be used on theleft side of trailer (when looking at trailer from the rear.)

Epoxied Bolt

Hub Assembly

Forged Arm

11

10

12

14

13

15

Front of Trailer

Alignment Instructions whenReplacing Forged Hub Mounting Arm

The end view drawing at left of the trailer axle (ref.no. 10 above) and hub mount forging (ref. no. 7above) shows the location of the axle spline shaftdivot marks and the casting marks. These marksmust be aligned as shown at left.

Page 11

44

55 7

16

22

116

8

6


BRAKE CLUSTER PARTS LIST

- SB24429 - Left Hand Cluster (shown above)- SB24428 - Right Hand Cluster1. SB23871-30 1 Back Plate Assembly - (NDH Hub Mounting)2. SB9254 2 Cover Plate - Adjusting Hole3. SB10954 1 Brake Shoe Kit (includes 2 Primary & 2 Secondary)4. 04305 2 5/16"-18UNC-Gr5 x 1/2" Hex Hd Bolt5. 05424 2 5/16" External Tooth Washer6. SB9776 1 Wheel Cylinder Assembly - Right- SB9777 1 Wheel Cylinder Assembly - Left7. 05431 1 Bleeder - replacement8. SB9783 1 Push Rod9. SB24047 1 Adjusting Screw Assembly - "R" (for LEFT cluster)- SB24048 1 Adjusting Screw Assembly - "L" (for RIGHT cluster)

10. SB10958 2 Spring - Shoe11. SB10961-11 1 Shoe Guide12. SB23937 1 Cable13. SB23936 1 Cable Guide14. SB23724 1 Spring - Adjusting Screw15. 05415-95 1 Lever - Right- 05414-95 1 Lever - Left

16. SB10959 2 Pin - Shoe Hold Down17. SB9789 4 Cup Shoe Hold Down18. 05983 2 Spring - Shoe Hold Down19. 03880 1 Spring

Please order replacement parts by PART NO. and DESCRIPTION.Brake shoe kit can be ordered for one complete axle only.

- SB15845 1 Wheel Cylinder Repair Kit(includes spring, cup and boot)

- SB40929 4 10" Brake Drum

3

10" SELF-ADJUSTING BRAKE CLUSTER and DRUM PARTS BREAKDOWN

3

10

10

1817

10" BRAKE CLUSTER

10" BRAKE DRUM

13

11

12

9

15

17

14

1718

17

19

Page 12

ACTUATOR PARTS BREAKDOWN8619111 DISC BRAKES

8659111 DRUM BRAKES

5221Coupler Repair Kit

2î Ball Coupler RATEDAT 6000#

not included

30

REF.NO. PART NO. QTY. DESCRIPTION

Model 91 ACTUATOR PARTS LIST

1. 05432 1 6000# 2" Ball Coupler (zinc plated)2. 01896 3 1/2"-13UNC x 4" Hex Head Bolt (gr.5)3. 02178 5 1/2"-13UNC Nylon Insert Lock Nut4. 05426 1 Front Shock Pin (drop tube actuators)5. 11079-95 1 Drop Tube Actuator Slider6. SB12426 1 Damper/ Shock7. 11164-95 1 3 Bolt Mount Outer Case8. 05424 2 5/16" External Tooth Lock Washer9. 02363 3 5/32" x 1 1/4 Cotter Pin

**10. 05408 1 3/32" Cable with hooks11. SB10555 - Replacement S-Hooks ONLY

**12. 05693-95 1 Emergency Lever Spring13. 05961 2 5/16"-18UNC x 5/8" Hex Head Bolt (gr.5)14. 00618 4 1/4-20UNC x 2" Hex Head Bolt (gr.5)15. 00057 4 1/4" Lock Washer

**16. 05951 1 Emergency Lever17. 03876 1 Master Cylinder Cap w/ Diaphragm & O-ring- 05849 1 O-Ring Only (not shown)

18. 05977 1 Push Rod Assembly19. 00062 4 1/4î-20 UNC Hex Nut20. 09153 - Plastic Master Cyl. Gasket ONLY21. 5650 1 Master Cylinder incl. gasket (drum brakes)- 5672 - Master Cylinder incl. gasket (disc brakes)

22. SB12098 1 .018 Connector Orifice (Drum Brakes)- 05679 1 Inverted Flare Adapter (Disc Brakes)

23. 03866-95 1 Lever Guide24. 05687 1 Master Cylinder Protective Boot25. 05986-95 1 Connecting Pin26. 10965 1 Upper Slider27. 10966 1 Lower Slider28. 10967 2 Side Spacers29. 07623-30 1 Spring return system (Disc Brakes Only)30. 04053 2 1/2î-13 UNC x 5-1/2î Hex Head bolt31. 11720-95 2 Reenforcement Straps

- 5401 - Lever Replacement Kit (incl. items w/**)- 5221 - Coupler Repair Kit

30. 02920 - Thumb Lock ONLY

5398 Master CylinderRepair Kit (drum)

(gasket 09153 included)

23

**16

22

20

21

17

24

13

14

119

**10

6

4

3

2

7

5

15

1

8

Please order replacement parts by PART NO. and DESCRIPTION

2

8

9

14

15

18

19

25

26

27

28

28

**12

5482 Master CylinderRepair Kit (disc)

(gasket 09153 included)

Torque to75 FT lbs.

9

29

Page 13

AT6000RS, AT6000RG, & AT6000BBRAKE LINE SYSTEM

RED 3-CLUSTERCLEARANCE LIGHTS

LICENSEPLATELIGHT

1

4

4 AMBERMARKERS

2

4

4

3REDMARKERS

35

RIGHTTAIL

LIGHT

33

3

LEFTTAIL

LIGHT

56

3REDMARKERS

3

REF. INCAND. L.E.D LightNO. PART NO. PART NO. QTY. DESCRIPTION

1. 07261 07931 1 Main Wiring Harness2. 07262 07932 1 Front Marker Wire Harness3. 05919 07934 7 Sealed Red Lamp - Clearance & Marker4. 05920 07935 4 Sealed Yellow Lamp-Clearance & Marker5. 03651 07933 2 Sealed Oval Tail Light - Stop, Tail, Turn6. 07734 07734 1 License Lamp7. 03838 03838 1 Trunk Connector- 05921 - 11 2" Rubber Grommet- 03652 - 2 Oval Light Grommet- 01883 01883 2 Electrical Wire Splicer (not shown)- NHT11 NHT11 8 Plastic Wire Tie (not shown)

ELECTRICAL WIRING DIAGRAM PARTS LIST

ELECTRICAL WIRING DIAGRAM


7

AMBERMARKERS

NOTE: Incandescent lightswill not interchange with L.E.Dlights and harness.


72.000

GROUND

12

16

17

18


12. SB508 3 8" Brake Line13. SB541 1 41" Brake Line14. SB572 2 72" Brake Line15. 07913 1 128" Armored Brake Line (inside tongue)16. SB10H136 4 10" Rubber Brake Hose (drum brakes)- 03925 4 Rubber Brake Hose (disc brakes)

17. 00496 4 1-1/8" O.D. x 5/8" I.D. x 14 Ga. Washer18. SB7764 4 Retainer Clip19. SB7785 2 .188î Brake Tee- NTH11 8 Nylon Hose Tie (Brake Lines & Wiring)

PARTS LIST

17

18 16

1317

18

14

14

17

18 16

15

12

Galfan Brake Lines

12

1916

19

Page 14

until you start to get a little drag on the wheel. Do not overtighten the adjusting nut. You can not back the nut offunless you hold the adjusting lever away from the nutwhile turning it back.ALWAYS ROTATE DRUM IN DIRECTION OFFORWARD ROTATION ONLY.

Brake Drum MaintenanceBrake drums must be reground if abnormal wear is found,

such as brake shoe hitting brake drum once lining isgone, rivets hitting brake drums and/or brake drumsout of round. NOTE: Maximum diameter allowed10.060"

Brake Rotor MaintenanceBrake rotors, if worn, may be reground to minimum

thickness of .995 before needing to be replaced.

Actuator Installation The Model 91 is completely assembled and ready to bolt into

place.

1. Bolt the actuator to a 3" square tongue with three 1/2" x 4-1/2" bolts (gr.5) and nylon insert lock nuts. Tighten bolts to 75ft. lbs. torque.

2. Attach brake line to master cylinder outlet. Make sure allconnections are tight.

3. Fill the master cylinder from a sealed container of DOT 3 or4 brake fluid. A pressure type brake bleeder may be used.If one is not available, you can bleed the system manually asfollows.

4. After the master cylinder has been filled, remove the flatspring behind the emergency lever. Pull forward on the leverto pump the master cylinder. Use short strokes until bubblingstops in the master cylinder.

Bleed the rear axle first. Install bleeder hose on the bleedervalve on the first wheel with other end of the hose in a clearcontainer partially filled with brake fluid.

Backplate Installation (Drum Brakes)Place the backplate between spindle flange, and swingarm. In mounting the brake, be sure the hydraulic wheelcylinder is at the top. Brakes are also marked asìRIGHTî and ìLEFTî. The brake designated as ìLEFTîtravels on the driverís side of the road.

Brake Line InstallationUse care in forming tubing to avoid sharp bends or kinks.Use double flare steel tubing to assure tight leakproofconnections. This must be done by a certified brakeshop. Anchor all hydraulic lines at two foot intervals toprevent chafing and vibration. Use hydraulic rubberhose at points of flexing. Anchor hose ends to avoidstress on tubing.

Brake Adjustment (Drum Brakes)Before removing the ground stand jacks, adjust thebrakes. Self adjusting brakes must be adjusted the firsttime only to assure having brakes the first few times theyare applied. Insert a brake adjusting tool or a screwdriver into the slotted hole. With the handle up and the bitdown and against the adjusting nut, pull down on thehandle. While spinning the wheel adjust the cog wheel up

RIGHT (Double Flare)

WRONG

Brake System Repair & Maintenance(INSTRUCTIONS FOR UNITS WITH DISC BRAKES AND DRUM BRAKES AS THEY APPLY)

WARNINGDEALERS, RENTAL AGENCIES, OR DISTRIBUTORS MUST REVIEW THESEINSTRUCTIONS WITH THE ULTIMATE USER. FAILURE TO FOLLOW THESEINSTRUCTIONS, OR FAILURE TO PROPERLY MAINTAIN BRAKES AFTER INSTAL-LATION, CAN RESULT IN LOSS OF BRAKING ACTION. THIS CAN CAUSEPERSONAL INJURY, DEATH OR PROPERTY DAMAGE. ONLY PROFESSIONALMECHANICS SHOULD INSTALL BRAKE COMPONENTS. HAVE YOUR BRAKESINSPECTED BY A PROFESSIONAL MECHANIC A MINIMUM OF ONCE A YEARAFTER INSTALLATION.

!

Page 15

MAINTENANCE1. Before towing check sight gauge to be sure master cylinder is full of brake fluid and check lines for leaks. Inspect

the actuator for bent or worn parts. Replace parts if necessary. Make sure the actuator mounting bolts are tight.

2. Check brake pad lining. Replace brake pads if necessary. (If lining is an 1/8" or less)

3. Inspect the tamper evidence cable on actuator. If cut or removed, the cap has been removed, and the systemshould be inspected for contamination.

4. A film of clean grease on the ball will extend ball and coupler life.

5. Periodically check braking quality, as described above. Failure to do so will result in loss of braking.

6. If units are used in corrosive conditions the actuator and wheels should be washed out with high pressure water.When actuator parts are dry, oil all moving parts.

8. Connect the emergency cable snap hook to towingvehicle. It should be hooked long enough so it will onlypull after coupler comes unhooked, but before safetychains are tight.

9. If the emergency brake lever is accidentally appliedwhile unhitching, release the lever by pulling it for-ward and with a screwdriver lift up the front of the flatspring until it releases the lever. Many times theseparts are damaged when this happens. An inspectionof the lever, flat spring, and cable with snap hooks isrequired and any damaged parts must be replaced.

Replacing The Emergency Lever

Step one: In order to replace the emergency lever youmust remove the master cylinder and the push rod.(Be careful - Do not get dirt into the master cylinder.)

Step two: Remove the lever guide and flat spring. Takethe S-hook off the lever, take the lever out from theinside.

Step three: Install the new lever from the inside and upthrough the slot. Replace the new flat spring and thelever guide. Replace the push rod and master cylin-der and new gasket.

Step four: Take the new cable, route it through the chainlink on the top roller cover and fasten the S-hook to thelever by squeezing the hook shut with a pliers. Checkthe master cylinder and fill with DOT 3 or 4 brake fluid.

Step five: Rebleed brake system.

10. Sway controls that restrict actuator movement can-not be used.

Loosen the bleeder valve one turn and pump themaster cylinder until the air bubbles stop coming out ofthe hose in the glass container, then close the bleedervalve and repeat the process on the other wheels.(Watch the fluid level in the master cylinder and refill solevel does not fall below 1/2 full.) Refill master cylinderevery 4 or 5 strokes.

5. After bleeding is completed, refill the master cylinderand put the filler cap on securely . Replace the flatspring behind the emergency lever.

To test the brakes use a wrench or vise grip and clamponto the top of the emergency lever to lengthen it. Pulllever forward until lever locks on the first click. Thelever should be approximately straight up and down.Now try to rotate each of the four wheels in a forwardrotation. You should not be able to rotate the wheelsforward. If you can, then release the emergency leverby wedging a screwdriver under the flat spring behindthe lever and set each wheel brake adjustment up 2 or3 notches. Then repeat the test procedeure.

Hitching The Trailer

6. The 2" Fulton coupler will accept a 2" ball only. Be sureball and hitch rating is equal to or greater than thetrailer GVWR. Put the coupler over the ball makingsure the ball clamp is in the correct position to retainthe ball. Tighten the hand wheel, or latch the lever tosecure the ball. Make sure that you release the handwheel lock in order to turn the wheel loose. If not it mustbe repaired.

7. Connect safety chains to towing vehicle using a criss-cross pattern.

Page 16

SAFETY & MAINTENANCESafety is of utmost importance at all times. The following are several items that should be checked eachtime before using and while using the Auto Transport. Failure to observe this warning could result insevere injuy, death, or property damage.

1. Make sure all bolts are properly tightened.

2. Make sure that the hitch and hitch ball are in good condition and not rusted, loose or stripped. Boththe hitch and hitch ball must be securely attached to the truck. The ball coupler must latch securelyaround the ball and the safety ball clamp must be in position to lock the hitch on the ball.RECOMMENDED LOADED BALL HEIGHT: 20 inches to the top of the towing vehicle ball.

3. Criss-cross the safety chains under the auto transport tongue and secure to safety chain mountingloops on truck.

4. The snap hook on the actuator must be hooked to the safety chain mounting loops, by the ball, on therear bumper of the truck.

5. Check to make sure that all lights are in proper working order.

6. The auto transport tires should be inflated to the recommended 50 PSI. Tire pressure may increaseduring travel - do not bleed off this increase pressure.

7. Check to make sure ramps are stored and secured in the transport position.

8. Periodically check brakes for proper operation.

Front die-cut serial number .

Rear die-cut serial number VIN number tag (ZN21003) is located inside the auto

transport on the front bulkhead.

Location of Metal Serial Number Tag

Location of Die-Cut Serial Number Decals

!

Documents

AUTO TRANSPORT TRAILER