3-04 NB20005, Rev.5

AT6000B, AT6000RG, & AT6000RS PARTS MANUAL AUTO TRANSPORT TRAILER

THIS MANUAL COVERS THE FOLLOWING YEARS AND UNIT NUMBERS

AT6000B YEAR 2000

-

1998 1997 1996 1995

-

UNIT NUMBER 375752 - 378616 040000 - 041891 8000 - 8499 7000 - 7149 6000 - 6149 5000 - 5499

AT6000RG/AT6000RS YEAR 2000 1999 1997 1996

-

UNIT NUMBER YEAR 360000 - 361999 1995 205100 - 205599 177500 - 177599 188851 - 188999 160519 - 160524 160557 - 160560 160616 - 160767 160672 - 160697

-

UNIT NUMBER 153763 - 153885 160000 - 160517 169341 - 169699

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

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

Important Information Weight and size limitations:

EXCLUSION OF WARRANTIES

Auto Transport

This product is warranted as provided by written agreement between Budget and the manufacturer. ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, ARE DISCLAIMED.

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

Interior platform dimensions Bed Length: 12 feet Maximum Bed Width: 79 inches Minimum Bed Width: 42 inches

"Reporting Safety Defects" If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Dethmers Manufacturing Company (DEMCO). If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Dethmers Manufac-

turing Company. To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0129 in Washington, D.C. area) or write to: NHTSA, U.S. Department of Transportation Washington, D.C. 20590. You can also obtain other information about motor vehicle safety from the Hotline.

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

Page 2

!

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 of warning, and the area or particular function related to that area, that requires your SAFETY AWARENESS.

M

L J O

B N D K

C

G I F

E

O

H

P

A REF. PART NO. NO. QTY. DESCRIPTION A. NP21010 1 Caution Actuator Spring B. BD21001 1 Attention Brake Actuator for Disc Brakes C. NR21021 1 Important Trailer Jack D. BH21003 1 Brakes On/Off E. NR21027 1 Do Not Remove Master Cylinder Cap F. BD21002 2 Unit Equipped with Disk Brakes G. DA21001 6 Bolt Torque and Tire Press. Spec. H. NR21023 1 Warning Cross Chains I. NR21017 1 Operateing Instructions J. NA21002 2 No Step K. NR21022 1 Safety Chain Attachment Location L. NR21010 1 Do Not Exceed 45 MPH M. NA21004 1 Width Requirments N. NR21015 1 Weight Specifications O. NA21003 2 Winch Operating Instructions P. BD21002 2 Equipped W/ Disc Brakes

Page 3

A. NP21010

E. NR21027

CAUTION

Do not remove master cylinder cap to check brake fluid.

Actuator is spring loaded. Use care when servicing or injury may occur. 10/99

SIGHT GLASS If sight glass ball is floating (full). If sight glass ball is not floating add untill ball floats.

NP21010

Use sight glass to determine brake fluid level. Only remove cap when adding fluid.

B. BD21001

ATTENTION

10/99

This brake actuator is specially designed for use with disc brakes ONLY. Any replacement of this unit MUST be of thesame design.

NR21027

F. BD21002

This Unit Equipped with DISC BRAKES 10/99

BD21002

10/99

BD21001

C. NR21021

G. DA21001

IMPORTANT

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

After securing trailer to ball on truck, PARKING JACK must be cranked up until

H. NR21023

WARNING

stopped and left in full up position for road travel. 10/98

To prevent serious injury or death.

NR21021

D. BH21003 BRAKES ON BRAKES OFF DO NOT TOW TOWABLE 10/99

Criss cross safety chains and attach to mounting loops on truck. Attach emergency brake actuator cable to one of these loops also.

BH21003

REV 1

Page 4

NR21023

L. NR21010

I. NR21017 OPERATING INSTRUCTIONS

DO NOT EXCEED

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

2.

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

3.

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

45 MPH

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

4. 5.

To extend ramp, pull release latch down, fully extend and lower ramp to ground. 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. Grasp ramp handle and slide ramp in until latch locks.

8. 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.

WHEN TOWING THIS TRAILER 11/98

NR21010

IMPORTANT INFORMATION

SAFETY

Weight and size limitations:

Car Carrier 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.

Empty Weight ........................... 1925 lbs. Maximum Weight .................... 5980 lbs. Carrying Capacity ..................... 4055 lbs.

M. NA21004

Interior platform dimensions: Bed length: ............................... 12 feet Maximum Bed Width: ............... 79 inches Minimum Bed Width: ................ 42 inches

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

IMPORTANT Loading oversized or undersized vehicles may result in property damage

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.

12/99 AT6000

NA21004

SAT

09/98

NR21017

J. NA21002

NO STEP 12/99

42" 79" MAX. OUTSIDE TREAD WIDTH MIN. INSIDE TREAD WIDTH

NA21002

K. NR21015

Loop

N. NR21015

Loop

Attach safety chains and emergency brake actuator cable to mounting loops on truck. 10/98

NR21022

EMPTY WEIGHT

1925 LBS

MAXIMUM WEIGHT

5980 LBS

CARRYING CAPACITY

4055 LBS

09/98

AT6000

SAT

NR21015

O. NA21003 WINCH OPERATING INSTRUCTIONS Tire Size Limitations

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

Maximum Tire Size: 17" tires ... Not Transportable 16" tires ... 215R60 15" tires ... 215R60 14" tires ... 215R60

This Unit Equipped with DISC BRAKES

Minimum Tire Size: 13" tires ... 165R70 12" tires ... Not Transportable

P. Trailer sides BH21002 Qty. 2

10/98

NA21003

Page 5

BD21002

!

BOLT TORQUE 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 of bolts 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 throughout assembly of this Ryder Auto Transport.

Torque Specifications Bolt Torque *

ìAî

GRADE 2 lb-ft (N.m)

GRADE 5 lb-ft (N.m)

GRADE 8 lb-ft (N.m)

1/4î 5/16î 3/8î 7/16î 1/2î 9/16î 5/8î 3/4î 7/8î 1î

6 10 20 30 45 70 95 165 170 225

9 18 30 50 75 115 150 290 420 630

12 25 45 80 115 165 225 400 650 970

(8) (13) (27) (40) (60) (95) (130) (225) (230) (300)

(12) (25) (40) (70) (100) (155) (200) (390) (570) (850)

(16) (35) (60) (110) (155) (220) (300) (540) (880) (1310)

Note: Torque Lug Nuts To 120 lb-ft

Torque figures indicated above are valid for non-greased or non-oiled threads and heads unless otherwise specified. Therefore, do not grease or oil bolts or capscrews unless otherwise specified in this manual. When using locking elements, increase torque values by 5%. * Torque value for bolts and capscrews are identified by their head markings. GRADE-2

Page 6

GRADE-5

GRADE-8

AT6000B, AT6000RS, & AT6000RG PARTS BREAKDOWN

59

51

63

61 43

61

45 53

54 89

62

52 29 66

28 28

47 48 49 45

55

85

90

29

Torque to 75 ft. lbs.

26 32 2

27 28

27

60 59

29

37

28 Torque to 75 ft. lbs.

59

44

45 1

65 59 66

61

46

46

64

61 60

46

50

56

42

59

58

92 27

24

28 38 40 41

91 27 29 30

22 31

Torque to 75 ft. lbs.

34

37 33 AT6000B 5433 5432 03569-95 03570-95 03571-95 03577 03574-95 03668 03575-95 03576 03666 02243 05450 01864 05449 not used 05444 03572-95 03573-95 03578 01998 02002 01076 00214 02772 05337 8619111 8659111 01338 00060 00085

10

28

27 28 Torque to 75 ft. lbs.

Torque to 75 ft. lbs.

REF. NUM. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.

23

88

39 37

ACTUATOR (ref. no. 24) See page 11 for parts breakdown and parts list.

20

21 18 17

12 14 13 15

11

9

8

19

12 5

16 4

6

22

5

AT6000RS QTY. AT6000RG QTY. 5433 1 5433 1 5432 1 5432 1 03569-95 1 03569-95 1 03570-95 1 03570-95 1 03571-95 1 03571-95 1 03577 2 03577 2 03574-95 1 03574-95 1 03668 1 03668 1 03575-95 1 03575-95 1 03576 1 03576 1 03666 1 03666 1 02243 1 02243 1 05450 1 05450 1 01864 2 01864 2 05449 1 05449 1 not used 00004 1 05444 1 05444 1 03572-95 1 03572-95 1 03573-95 1 03573-95 1 03578 1 03578 1 01998 1 01998 1 02002 1 02002 1 01076 1 01076 1 00214 1 00214 1 02772 2 02772 2 05337 1 05337 1 8619111 1 8619111 1 8659111 8659111 01338 2 01338 2 00060 8 00060 8 00085 16 00085 16

Page 7

3

7

Left Winch Shown

36 QTY. 1 1 1 1 1 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 2 1 1 2 8 16

45

57

27 28

25

DESCRIPTION Right Winch Assembly Left Winch Assembly Winch Frame Left Spool Tube Right Spool Tube Heavy Duty External Snap Ring Winch Handle 18 Ga. Shim Washer Left Ratchet Gear Right Ratchet Gear 5/16î x 1-1/4î Split Roll Pin Rubber Winch Hand Grip Winch Pawl Winch Spring SS Winch Pawl Bushing SS 5/16î Flat Washer 3/8î-UNC x 3/4î Hex Head Bolt w/ epoxy Left Ratchet Catch Right Ratchet Catch 5/16î-18 UNC x 1/2î Shoulder Screw 5/16î SS Flat Washer 1/4î SS Flat Washer 1/4î-20UNC x 3/4î lg. Gr. 5 Hex Head Bolt 1/4î Flat Washer 1/4î-20 UNC Nylon Insert locknut Clip with Cable Disc Brake Actuator Drum Brake Actuator 1/2î-13 UNC x 4-1/2î Bolt (Gr. 5) 3/8î Lock Washer 1/2" Flatwasher

60 61

61 67

AT6000B, AT6000RS, & AT6000RG PARTS BREAKDOWN

59

68

69 64

66 69 68

71 70

28

73

66 65

27 74

49 66 48

72

81

75

84

65

License Plate Light Assembly 83 28

78

82

Ramp Latch Assembly

45

75

86

77

84

79 46

87 49 76

49

48 48

46

80 60 61 REF. NUM. 27. 28. 29. 30. 31. 32. 33. 34. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49.

AT6000B 00085 02178 01254 04273 03637-96 03635-96 05580-96 05582-95 ----05581-95 00185 00191 05584-95 5539 05587 04508 not used 03643-30 00907 02592 04228 04208 02205

QTY. 16 32 22 2 1 1 1 1 1 5 1 1 1 1 4 2 18 30 1 6 6

AT6000RS QTY. AT6000RG QTY. 00085 16 00085 16 02178 28 02178 28 01254 22 01254 22 04273 2 04273 2 03637-96 1 03637-96 1 03635-96 1 09797-96 1 05580-96 1 05580-96 1 05582-95 1 05582-95 1 --------05581-95 1 05581-95 1 00185 5 00185 5 00191 1 00191 1 05584-95 1 05584-95 1 5539 1 5539 1 05587 1 05587 1 04508 4 04508 4 not used 03638-96 2 03643-30 2 03643-30 2 00907 18 00907 4 02592 26 02592 30 04228 1 04228 1 04208 6 04208 6 02205 6 02205 6

Page 8

59

DESCRIPTION 1/2" Flatwasher 1/2"-13 UNC Nylon Insert Locknut 1/2"- 13 UNC x 1-1/2" Lg. Hex Hd Bolt 32" Safety Chain w/ S-Hook Tongue Trailer Bed Jack Foot - Galvanized 1/2" x 11-1/2" Pin --------------------1/2" x 8" Pin 5/32" x 1" Cotter Pin 3/16" x 1-1/2" Cotter Pin 1/2" x 2-3/8" Pin Jack with Hardware 1" Machine Washer 14 ga. Reflective Sticker (Yellow) Front Tire Stop Winch Mounting Plate 3/8"-16 UNC x 1" Lg. Hex Hd Bolt 3/8"-16 UNC Nylon Insert Lock Nut Registration Holder #10-24 UNC x 3/4" Lg. Round Hd Screw #10-24 UNC Nylon Insert Lock Nut

REF. NUM. 50. 51. 52. 53. 54. 55.

AT6000B 03639-95 05898 02729-95 00640 03714 03644-30

QTY. 2 2 2 2 2 2

AT6000RS QTY. AT6000RG QTY. 03639-95 2 03639-95 2 05898 2 05898 2 02729-95 2 02729-95 2 00640 4 not used 03714 2 03714 2 03644-30 2 03644-30 2

DESCRIPTION Auto Tie-Down Strap Rod 3-Point Tie-Down Strap with Buckle Strap Buckle Only 1/2"-13 UNC Hex Jam Nut 1/2"-13 UNC x 4" Full Thread Hex Head Bolt Axle

56. 57. 58. 59. 60. 61.

5464 03901 07279 05909 01076 00214 02772

1 1 2 40 46 40

5464 03901 07279 05909 01076 00214 02772

1 1 2 40 46 40

5464 03901 07279 05909 01076 00214 02772

1 1 2 40 46 40

Fender Kit (includes Fender, Insert, & Fastners) Fender - Galvanized Fender Insert Fender Gusset 1/4"-20 UNC x 3/4" Lg. Hex Hd Bolt 1/4" Flat Washer 1/4"-20 UNC Nylon Insert Lock Nut

62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 79. 80. 81. 82. 83. 84. 85. 86. 87. 88. 89. 90. 91. 92.

03640-30 03641 see pg. 12 see pg. 12 see pg. 12 03642 04819 05926 see pg. 12 see pg. 12 04804 03647 01897 07734 03636-96 00082 04725 03649-95 03723 10126 10109 01975 03848 05049 02590 02321 03826 04396 00059 07623-30 04053

2 1 4 7 11 1 2 2 2 2 4 2 4 1 2 4 4 2 4 2 2 2 1 2 1 1 1 2 8 1 1

03640-30 03641 see pg. 12 see pg. 12 see pg. 12 03642 04819 05926 see pg. 12 see pg. 12 04804 03647 01897 07734 03636-96 00082 04725 03649-95 03723 10126 10109 01975 03848 not used 02590 02321 03826 04396 00059 07623-30 04053

2 1 4 7 11 1 2 2 2 2 4 2 4 1 2 4 4 2 4 2 2 2 1 1 1 1 2 8 1 1

09796-96 03641 09793 09794 05921 03642 04819 05926 see pg. 12 see pg. 12 04804 03647 01897 07734 03636-96 00082 04725 03649-95 03723 10126 10109 01975 03848 05049 02590 02321 03826 04396 00059 07623-30 04053

2 1 4 7 11 1 2 2 2 2 4 2 4 1 2 4 4 2 4 2 2 2 1 2 1 1 1 2 8 1 1

Rear Light Pod 3-Cluster Wire Guard LED Yellow Lamp grommet style LED Red Lamp grommet style Rubber Grommet for 2" round light Front Wire Protector 5/16" Rapid Link 60" Auto Tie-Down Chain w/ hook Oval Tail Light (stop, tail, turn) Rubber Grommet for light Reflective Sticker (Red) Rubber Bumper 1/2"-13 UNC x 3-1/2" Hex Hd Bolt License Plate Light Assembly Ramp 3/8"-16UNC x 2-1/2" Lg. Hex Hd Bolt Ramp Roller Wheel with Bushing Ramp Stop Plate Ramp Pull-Out Strap Ramp Latch Double Torsion Spring 1/2"-13 UNC x 5" Hex Hd Bolt License Plate Light Bracket Pop Rivet (VIN Tag) (Qty's will vary w/ LED lights.) Grommet 1/4" ID X 7/16" OD X 1/4" Grip Grommet 1/4" ID X 7/16" OD X 1/8" Grip Grommet 3/4" ID X 1-7/16 OD X 1/4" Grip Grommet 11/16" ID X 1" OD X 3/16" Grip 3/8î Flat Washer Spring Return System 1/2î-13 UNC x 5-1/2î Bolt (Grd 5)

-

5296 04866 5682

1 1

5296 04866 5682

1 1

5296 04866 5682

1 1

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

Please order replacement parts by PART NO. and DESCRIPTION.

Page 9

BRAKE CLUSTER PARTS BREAKDOWN BRAKE CLUSTER PARTS LIST REF. NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

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

Torque to 150 ft. lbs.

9

7

10

6 8

5

Please order replacement parts by PART NO. and DESCRIPTION.

3

Alignment Instructions when Replacing Forged Hub Mounting Arm

4

Front of Trailer

Torque to 80 ft. lbs.

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

2 1 Torque to 120 ft. lbs.

DISC BRAKE PARTS BREAKDOWN PARTS LIST ASSEMBLY REF. PART NO. NO. QTY. DESCRIPTION 1. 03930-30 4 Caliper Mounting Plate *2. 03933 8 Caliper Mounting Bolt *3. 03932 8 Caliper Mounting Bolt Protective Boot 4. 03927 4 Rotor *5. 03929 2 Right Side Caliper includes items with * 03928 2 Left Side Caliper w/ Brake Pads 6. 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 Washer 10. 02377 16 7/16"-20UNF Gr8 x 1-1/2 Epoxy Hex Hd Bolt 11. 04369 4 New Departure Hub (5 on 115mm Bolt Circle) 02917 12mm x 1-1/2" Replacement Stud Bolt 12. 05900 4 Forged Arm 13. 05933 4 5/8"-18UNF Nylon Insert Lock Nut 14. 05932 4 5/8"-18UNF Gr5 x 3-3/4" Hex Head Bolt 15. 03644-30 2 Axle 16. 10831 1 Bleeder Screw(replacement only) Please order replacement parts by PART NO. and DESCRIPTION. * 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 the trailer. (Example: a caliper marked right will be used on the left side of trailer (when looking at trailer from the rear.)

1. 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 shown in the diagram. 3. Make sure the Brake Pads (#6) are correctly placed in the Caliper (#5). 4. Place Caliper (#5) over the Rotor (#4), and secure it to the Mounting Bracket (#1) using the Caliper Mounting Bolts (#2) and Protective Boot (#3). 5. Hook up Brake Hoses and replace the Rim and Tire.

14 15 12

13

Forged Arm 2

Hub Assembly 11

3

6 1

4

lt Bo d ie ox Ep

9

10

Page 10

5

8

10" SELF-ADJUSTING BRAKE CLUSTER and DRUM PARTS BREAKDOWN 4

4

5

5

7

16

1

6

16

3

2 2 8

11 13 10 12 3 19 10

9

17 18 17

15 14

BRAKE CLUSTER PARTS LIST REF. PART NO. NO. QTY. SB24429 SB24428 1. SB23871-30 1 2. SB9254 2 3. SB10954 1 4. 04305 2 5. 05424 2 6. SB9776 1 SB9777 1 7. 05431 1 8. SB9783 1 9. SB24047 1 SB24048 1 10. SB10958 2 11. SB10961-11 1 12. SB23937 1 13. SB23936 1 14. SB23724 1 15. 05415-95 1 05414-95 1 16. SB10959 2 17. SB9789 4 18. 05983 2 19. 03880 1

17 18

DESCRIPTION Left Hand Cluster (shown above) Right Hand Cluster Back Plate Assembly - (NDH Hub Mounting) Cover Plate - Adjusting Hole Brake Shoe Kit (includes 2 Primary & 2 Secondary) 5/16"-18UNC-Gr5 x 1/2" Hex Hd Bolt 5/16" External Tooth Washer Wheel Cylinder Assembly - Right Wheel Cylinder Assembly - Left Bleeder - replacement Push Rod Adjusting Screw Assembly - "R" (for LEFT cluster) Adjusting Screw Assembly - "L" (for RIGHT cluster) Spring - Shoe Shoe Guide Cable Cable Guide Spring - Adjusting Screw Lever - Right Lever - Left Pin - Shoe Hold Down Cup Shoe Hold Down Spring - Shoe Hold Down Spring

-

SB15845

1

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

-

SB40929

4

10" Brake Drum

17

10" BRAKE DRUM

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

10" BRAKE CLUSTER Page 11

ACTUATOR PARTS BREAKDOWN 8619111 DISC BRAKES 13 8659111 DRUM BRAKES 8 23

8 17

**12 14 **10

**16

14

18

15

15

25 9 11 9 26

2î Ball Coupler RATED AT 6000# 4

7 22

6

28

21 24

5 28

Torque to 75 FT lbs.

2

20

19

9 27

2 1 3

29

Model 91 ACTUATOR PARTS LIST REF. NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. **10. 11. **12. 13. 14. 15. **16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.

PART NO. 05432 01896 02178 05426 11079-95 SB12426 11164-95 05424 02363 05408 SB10555 05693-95 05961 00618 00057 05951 03876 05849 05977 00062 09153 5650 5672 SB12098 05679 03866-95 05687 05986-95 10965 10966 10967 07623-30 04053 11720-95

30.

5401 5221 02920

QTY. DESCRIPTION 1 6000# 2" Ball Coupler (zinc plated) 3 1/2"-13UNC x 4" Hex Head Bolt (gr.5) 5 1/2"-13UNC Nylon Insert Lock Nut 1 Front Shock Pin (drop tube actuators) 1 Drop Tube Actuator Slider 1 Damper/ Shock 1 3 Bolt Mount Outer Case 2 5/16" External Tooth Lock Washer 3 5/32" x 1 1/4 Cotter Pin 1 3/32" Cable with hooks Replacement S-Hooks ONLY 1 Emergency Lever Spring 2 5/16"-18UNC x 5/8" Hex Head Bolt (gr.5) 4 1/4-20UNC x 2" Hex Head Bolt (gr.5) 4 1/4" Lock Washer 1 Emergency Lever 1 Master Cylinder Cap w/ Diaphragm & O-ring 1 O-Ring Only (not shown) 1 Push Rod Assembly 4 1/4î-20 UNC Hex Nut Plastic Master Cyl. Gasket ONLY 1 Master Cylinder incl. gasket (drum brakes) Master Cylinder incl. gasket (disc brakes) 1 .018 Connector Orifice (Drum Brakes) 1 Inverted Flare Adapter (Disc Brakes) 1 Lever Guide 1 Master Cylinder Protective Boot 1 Connecting Pin 1 Upper Slider 1 Lower Slider 2 Side Spacers 1 Spring return system (Disc Brakes Only) 2 1/2î-13 UNC x 5-1/2î Hex Head bolt 2 Reenforcement Straps -

Lever Replacement Kit (incl. items w/**) Coupler Repair Kit Thumb Lock ONLY

Please order replacement parts by PART NO. and DESCRIPTION

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not included

5398 Master Cylinder Repair Kit (drum) (gasket 09153 included)

30

5221 Coupler Repair Kit

5482 Master Cylinder Repair Kit (disc) (gasket 09153 included)

ELECTRICAL WIRING DIAGRAM RED MARKERS

3

AMBER MARKERS

4

3

1

6

5

LICENSE PLATE LIGHT

4

GROUND

LEFT TAIL LIGHT

3

2

RED 3-CLUSTER CLEARANCE LIGHTS3

3

7

72.000

NOTE: Incandescent lights will not interchange with L.E.D lights and harness.

RIGHT TAIL LIGHT

5

3 RED MARKERS

4

3

4

AMBER MARKERS

ELECTRICAL WIRING DIAGRAM PARTS LIST REF. INCAND. NO. PART NO.

1. 2. 3. 4. 5. 6. 7. -

07261 07262 05919 05920 03651 07734 03838 05921 03652 01883 NHT11

L.E.D Light PART NO. QTY.

07931 07932 07934 07935 07933 07734 03838 01883 NHT11

DESCRIPTION

1 1 7 4 2 1 1 11 2 2 8

Main Wiring Harness Front Marker Wire Harness Sealed Red Lamp - Clearance & Marker Sealed Yellow Lamp-Clearance & Marker Sealed Oval Tail Light - Stop, Tail, Turn License Lamp Trunk Connector 2" Rubber Grommet Oval Light Grommet Electrical Wire Splicer (not shown) Plastic Wire Tie (not shown)

Please order replacement parts by PART NO. and DESCRIPTION.

AT6000RS, AT6000RG, & AT6000B BRAKE LINE SYSTEM

15

Galfan Brake Lines 17 14

18

16 17

12 19 12 18

14

REF. PART NO. NO. 12. SB508 13. SB541 14. SB572 15. 07913 16. SB10H136 03925 17. 00496 18. SB7764 19. SB7785 NTH11

13 17 16 12 18

18

19 17 16

16

PARTS LIST

QTY. DESCRIPTION 3 8" Brake Line 1 41" Brake Line 2 72" Brake Line 1 128" Armored Brake Line (inside tongue) 4 10" Rubber Brake Hose (drum brakes) 4 Rubber Brake Hose (disc brakes) 4 1-1/8" O.D. x 5/8" I.D. x 14 Ga. Washer 4 Retainer Clip 2 .188î Brake Tee 8 Nylon Hose Tie (Brake Lines & Wiring)

Please order replacement parts by PART NO. and DESCRIPTION.

Page 13

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

! WARNING DEALERS, RENTAL AGENCIES, OR DISTRIBUTORS MUST REVIEW THESE INSTRUCTIONS WITH THE ULTIMATE USER. FAILURE TO FOLLOW THESE INSTRUCTIONS, OR FAILURE TO PROPERLY MAINTAIN BRAKES AFTER INSTALLATION, CAN RESULT IN LOSS OF BRAKING ACTION. THIS CAN CAUSE PERSONAL INJURY, DEATH OR PROPERTY DAMAGE. ONLY PROFESSIONAL MECHANICS SHOULD INSTALL BRAKE COMPONENTS. HAVE YOUR BRAKES INSPECTED BY A PROFESSIONAL MECHANIC A MINIMUM OF ONCE A YEAR AFTER INSTALLATION. Backplate Installation (Drum Brakes) Place the backplate between spindle flange, and swing arm. In mounting the brake, be sure the hydraulic wheel cylinder is at the top. Brakes are also marked as ìRIGHTî and ìLEFTî. The brake designated as ìLEFTî travels on the driverís side of the road.

until you start to get a little drag on the wheel. Do not over tighten the adjusting nut. You can not back the nut off unless you hold the adjusting lever away from the nut while turning it back.

ALWAYS ROTATE DRUM IN DIRECTION OF FORWARD ROTATION ONLY.

Brake Line Installation

Brake Drum Maintenance

Use care in forming tubing to avoid sharp bends or kinks. Brake drums must be reground if abnormal wear is found, Use double flare steel tubing to assure tight leakproof such as brake shoe hitting brake drum once lining is connections. This must be done by a certified brake gone, rivets hitting brake drums and/or brake drums shop. Anchor all hydraulic lines at two foot intervals to out of round. NOTE: Maximum diameter allowed prevent chafing and vibration. Use hydraulic rubber 10.060" hose at points of flexing. Anchor hose ends to avoid stress on tubing.

Brake Rotor Maintenance

Brake rotors, if worn, may be reground to minimum thickness of .995 before needing to be replaced.

Actuator Installation WRONG

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 75 ft. lbs. torque. 2. Attach brake line to master cylinder outlet. Make sure all connections are tight.

RIGHT (Double Flare) Brake Adjustment (Drum Brakes)

3. Fill the master cylinder from a sealed container of DOT 3 or 4 brake fluid. A pressure type brake bleeder may be used. If one is not available, you can bleed the system manually as follows.

Before removing the ground stand jacks, adjust the brakes. Self adjusting brakes must be adjusted the first 4. After the master cylinder has been filled, remove the flat spring behind the emergency lever. Pull forward on the lever time only to assure having brakes the first few times they to pump the master cylinder. Use short strokes until bubbling are applied. Insert a brake adjusting tool or a screw stops in the master cylinder. driver into the slotted hole. With the handle up and the bit down and against the adjusting nut, pull down on the Bleed the rear axle first. Install bleeder hose on the bleeder handle. While spinning the wheel adjust the cog wheel up valve on the first wheel with other end of the hose in a clear container partially filled with brake fluid.

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Loosen the bleeder valve one turn and pump the 8. Connect the emergency cable snap hook to towing vehicle. It should be hooked long enough so it will only master cylinder until the air bubbles stop coming out of pull after coupler comes unhooked, but before safety the hose in the glass container, then close the bleeder chains are tight. valve and repeat the process on the other wheels. (Watch the fluid level in the master cylinder and refill so level does not fall below 1/2 full.) Refill master cylinder 9. If the emergency brake lever is accidentally applied while unhitching, release the lever by pulling it forevery 4 or 5 strokes. ward and with a screwdriver lift up the front of the flat 5. After bleeding is completed, refill the master cylinder spring until it releases the lever. Many times these and put the filler cap on securely . Replace the flat parts are damaged when this happens. An inspection spring behind the emergency lever. of the lever, flat spring, and cable with snap hooks is required and any damaged parts must be replaced. To test the brakes use a wrench or vise grip and clamp onto the top of the emergency lever to lengthen it. Pull Replacing The Emergency Lever lever forward until lever locks on the first click. The lever should be approximately straight up and down. Now try to rotate each of the four wheels in a forward Step one: In order to replace the emergency lever you must remove the master cylinder and the push rod. rotation. You should not be able to rotate the wheels (Be careful - Do not get dirt into the master cylinder.) forward. If you can, then release the emergency lever by wedging a screwdriver under the flat spring behind Step two: Remove the lever guide and flat spring. Take the lever and set each wheel brake adjustment up 2 or the S-hook off the lever, take the lever out from the 3 notches. Then repeat the test procedeure. inside. Step three: Install the new lever from the inside and up through the slot. Replace the new flat spring and the lever guide. Replace the push rod and master cylin6. The 2" Fulton coupler will accept a 2" ball only. Be sure der and new gasket. ball and hitch rating is equal to or greater than the trailer GVWR. Put the coupler over the ball making Step four: Take the new cable, route it through the chain sure the ball clamp is in the correct position to retain link on the top roller cover and fasten the S-hook to the the ball. Tighten the hand wheel, or latch the lever to lever by squeezing the hook shut with a pliers. Check secure the ball. Make sure that you release the hand the master cylinder and fill with DOT 3 or 4 brake fluid. wheel lock in order to turn the wheel loose. If not it must Step five: Rebleed brake system. be repaired.

Hitching The Trailer

7. Connect safety chains to towing vehicle using a crisscross pattern.

10. Sway controls that restrict actuator movement cannot be used.

MAINTENANCE 1. 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 system should 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.

Page 15

Location of Metal Serial Number Tag

Rear die-cut serial number VIN number tag (ZN21003) is located inside the auto transport on the front bulkhead.

Location of Die-Cut Serial Number Decals

Front die-cut serial number .

!

SAFETY & MAINTENANCE

Safety is of utmost importance at all times. The following are several items that should be checked each time before using and while using the Auto Transport. Failure to observe this warning could result in severe 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. Both the hitch and hitch ball must be securely attached to the truck. The ball coupler must latch securely around 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 mounting loops on truck.

4. The snap hook on the actuator must be hooked to the safety chain mounting loops, by the ball, on the rear 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 increase during 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.

Page 16