Philips 37PFL9604H Universal Remote User Manual
Contents
1. Hex Head Bolt gr 5 3 8 16UNC Nylon Lock Nut Right Wheel Carrier Left Wheel Carrier 1 1 D x 1 1 4 0 D x 1 1 2 lg Bushing brnz King Pin 1 x 6 1 2 1 1 4 Dust Cap 1 1 D x 14 GA Narrow Rim Machine Washer Right Drop Axle Mount Left Drop Axle Mount King Pin Retainer Bolt 7 16 20UNF Center Punched Nut 7 16 20UNF x 1 1 2 Epoxy Bolt gr 8 7 16 20UNF Nylon Lock Nut 1 2 13UNC Nylon Lock Nut Pivot Bushing 1 2 Flatwasher 1 2 13UNC x 1 1 2 Hex Head Bolt gr 5 Bracing Strut 5 8 11UNC x 1 1 4 Epoxy Bolt gr 5 5 8 13UNC x 4 1 2 Hex Head Bolt gr 5 5 8 13UNC Nylon Lock Nut 5 8 11UNC x 2 3 4 Ig Hex Head Bolt gr 5 5 8 Flatwasher Steering Stabilizer Shock Tie Rod Clamp Bottom Tie Rod Clamp Top 3 8 16UNC x 1 Hex Head Bolt gr 5 3 8 16UNC x 2 1 4 Hex Head Bolt gr 5 1 2 13UNC x 1 1 4 Hex Head Bolt gr 5 Ramp Tie Rod Locking Pin Replacement Black Handle Grip for Locking Pin Hair pin KK370SB Main Frame License Plate Bracket Assembly Tie Rod Right Tie Rod End w Right Hand Threads Left Side Tie Rod End with Left Hand Threads 9 16 18UNF Jam Nut w Right Hand Threads 9 16 18UNF Jam Nut w Left Hand Threads Rear tire Stop 3 8 16UNC x 1 1 4 Ig Hex Head Bolt gr 5 Black Vinyl Hand Grip Tongue DA91 Actuator less coupler Right Winch assembly Left Winch Assembly 1 4 20UNC Nylon Lock Nut 1 4 20UNC x 3 4 Carriage Bolt 10 Brake Cluster RH 10 Brake Cluster LH2. NOTE Unless otherwise specified high strength Grade 5 hex bolts are used throughout assembly of equipment A Torque Specifications Torgue wheel nuts to 120 ft Ibs Torque figures indicated are valid for non greased or non oiled threads and heads unless otherwise specfied Therefore do not grease or oil bolts or capscrews unless otherwise specified in this manual When using locking elements increase torque values by 5 GRADE or CLASS value for bolts and capscrews are identified by their head markings E Bolt Torque for Standard bolts GRADE 2 GRADE 5 GRADE 8 A Ib ft N m lb ft N m Ib ft N m 1 4 6 8 9 12 12 16 5 16 10 13 18 25 25 35 3 8 20 27 30 40 45 60 7 16 30 40 50 70 80 110 1 2 45 60 75 100 115 155 9 16 70 95 115 155 165 220 5 8 95 130 150 200 225 300 3 4 165 225 290 390 400 540 7 8 170 230 420 570 650 880 1 225 300 630 850 970 1310 Bolt Torque for Metric bolts CLASS 8 8 CLASS 9 8 CLASS 10 9 A lb ft N m lb ft N m lb ft N m 6 9 13 10 14 13 17 7 15 21 18 24 21 29 8 23 31 25 34 31 42 10 45 61 50 68 61 83 12 78 106 88 118 106 144 14 125 169 140 189 170 230 16 194 263 216 293 263 357 18 268 363 364 493 20 378 513 515 689 22 516 699
3. 20 UNC x 1 Hex Hd Bolt Gr 5 00214 1 4 Flatwasher 05337 Lock Pin w Cable Please order replacement parts by PART NO and DESCRIPTION Left Winch Shown 3 4 5 6 7 8 9 Left Winch Shown aaa A fae 2 i i eee 2 1 i feneeeN 2 TILT BED LATCH ASSEMBLY REF PART NO NO QTY DESCRIPTION O ea 03434 5 1 er 18 UNC x 4 Eye Bolt s 04221 5 5 16 18 UNC x 2 1 2 Hex Head Bolt Gr 5 3 00004 1 5 16 Flatwasher 4 00007 1 5 16 18 UNC Hex Nut 5 03379 95 1 Latch Block 6 03435 1 Roll Pin 5 16 x 2 1 4 7 03499 1 Latch Spring Stainless Steel 8 03382 95 1 Latch Handle Pivot Bushing 9 03574 95 1 Latch Handle 10 03381 95 1 Latch Catch 11 03433 1 Latch Cable 12 02802 1 5 16 18 UNC Nylon Insert Locknut 13 00967 8 1 2 13UNC x 1 1 4 Ig Hex Head Bolt gr 5 KIT 5511 14 00085 1 1 2 Flatwasher TILT BED LATCH 15 1 00059 9 3 8 Flat Washer ASSEMBLY 16 02178 13 1 2 13UNC Nylon Insert Locknut 17 05449 1 Spacer Bushing Stainless Steel 18 05444 1 3 8 16 UNC x 3 4 Epoxied Hex Bolt Gr 5 Please order replacement parts by PART NO and DESCRIPTION Items included in 5511 kit Page 20 LICENSE PLATE BRACKET ASSEMBLY REF PART NO NO DESCRIPTION QTY 5806 m License Plate Bracket and Light Assembl 04505 95 License Plate and Light Cluster Bracket 04176 1 4 20UNC X 3 4 Carriage Bolt 02214 10 NC X
4. 702 952 24 654 886 890 1206 GRADE 2 GRADE 5 GRADE 8 J CLASS 8 8 CLASS 9 8 CLASS 10 9 N M N J J Page 11 Tongue and Ramp Assembly Instructions Place the main frame 1 on blocks or some other sturdy support so that the frame rests approximately 8 10 off the ground With an assistant place tongue assembly 2 into main frame channel and position latch on tongue approximately 3 from front of channel Clamp tongue to main frame and support front of tongue Locate the four bullet connectors extending out the back of the tongue and plug into the connector protruding from under the main frame channel Plug into the flat four connector by matching the colors Do not cross colors when making this connection Make sure that the two pigtails for the license plate bracket are out With an assistant mount the tongue assembly 2 to the front of the Kar Kaddy main frame and use a 5 8 x 4 1 2 grade 5 bolt 3 and lock nut 4 torque to 50 ft lbs Do not torque over 50 ft Ibs or bed will not tilt NOTE Brake line and wiring must be above bolt also coupler assembly must be ahead of bolt Do this by opening tongue about half way 5 Lay the bracing struts 5 out along the tow dolly tongue with the back end the end with the larger hole in it of the bracing strut toward the main frame Loosely bolt the back of each bracing strut to the trailer frame as shown using 1 2 x 1 1 2 grade 5 bolt 6 f
5. Left Tail Brake and Signal Light w Lenses Brown Jumper Wire Wire Holder metal Light Bar Framework Adjustable Light Bracket Right Tail Brake and Signal Light w Lenses 1 4 20UNC Nylon Insert Locknut 1 4 20UNC x 1 2 Hex Head Bolt Light Bar Z Bracket 3 Suction Cup w Bolt 13 Light Bar Wiring Harness new style 1 4 20UNC x 3 4 Hex Head Bolt Large Red Lens Small Red Lens Clear Lens Please order replacement parts by PART NO and DESCRIPTION Page 28 COLOR CODE FOR WIRING HARNESS Ground BROWN Tail Lights License Plate Lights Light Cluster Bar amp Clearance Lights YELLOW Left Turn and Stop GREEN Right Turn and Stop CO CHIE Dethmers Manufacturing Company 4010 320th Street e Box 189 Boyden lowa 51234 Toll Free 800 54DEMCO 800 543 3626 FAX 800 845 6420 www demco products com How satisfied are you with our product Warranty Registration Ag RV Rental Brakes Marine How satisfied are you with the company sales staff How satisfied are you with the delivery Did you have any contact with a Demco Representative If YES how satisfied were you would recommend this product to my family and friends Would you purchase again from DEMCO Since taking delivery have you been contacted by the dealer Did you have any problems with this DEMCO product Very Very Satisfied Satisfied Dissatisfied Dissatisfied O O O O How satisfied are you with the dealership distributor sales
6. plated 5 16 External Tooth Lock Washer 5 32 x 1 1 4 Cotter Pin Qty 3 w drop tube 3 32 Cable with hooks Replacement S Hooks ONLY Emergency Lever Spring plated 5 16 18UNC x 5 8 Hex Head Bolt gr 5 1 4 20UNC x 2 Hex Head Bolt gr 5 1 4 Lock Washer Emergency Lever Assembly Master Cylinder Cap w Diaphragm amp O ring O Ring Only not shown Push Rod Assembly 1 4 20 UNC Hex Nut Plastic Master Cyl Gasket ONLY Master Cylinder 018 Connector Orifice Drum Brakes Lever Guide plated Master Cylinder Protective Boot Connecting Pin plated Upper Slider Lower Slider Side Spacers 5401 Lever Replacement Kit incl items w 5650 Master Cyl Replacement Kit drum 5495 Coupler Repair Kit Please order replacement parts by PART NO and DESCRIPTION Page 23 10 SELF ADJUSTING BRAKE CLUSTER and DRUM PARTS BREAKDOWN Ga REF PART NO NO _ QTY DESCRIPTION SB24429 Left Hand Cluster shown above SB24428 Right Hand Cluster Back Plate Assembly NDH Hub Mounting Cover Plate Adjusting Hole Brake Shoe Kit includes 2 Primary amp 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 Ad
7. 1 2 Slotted Truss Head Screw 02163 Square License Plate Light w Washer and Nut 02164 Clear License Plate Light Lens Only 02580 95 License Plate Clip 02770 1 4 20UNC Nylon Insert Wing Nut 01077 1 4 NC Serrated Lock Nut 00214 1 4 20UNC Flat Washer 04513 3 Cluster Light Bar Please order replacement parts by PART NO and DESCRIPTION FENDER ASSEMBLY 2 vir PARTS LIST REF NO PART NO QTY DESCRIPTION 2 Left Fender Assembly a i Right Fender Assembly Wire Splicer Tinnerman U clamp 17 1 2 Wire Loom 9 16 x 5 8 Pop Rivet Nylon Cable Hanger 4 Light Grommet Tail Light Wire Harness 4 Round Tail Light Left Fender Assembly Right Fender Assembly Black Marker Base Mount Yellow Marker Light 12 Wire Loom Front Marker Wiring Harness Amber Reflector Red Reflector 3 16 Washer Kar Kaddy Mud Flap 1 4 Nylon Lock Nut 1 4 Slotted Truss Head Bolt 1 4 Flat Washer OONDARONS Please order replacement parts by PART NO and DESCRIPTION Page 21 1 DEMCO PRODUCTS KAR KADDY ORIGINAL PURCHASER S LIMITED WARRANTY Extent and Duration of this Warranty Your Demco Kar Kaddy is warranted to be free from defects in materials and workmanship under normal use and service for a period of one year after date of purchase by the original first retail owner or until it is resold or transferred by the original owner Hubs used on the KK370SB
8. 10 Brake Drum 7 16 14UNC x 1 1 4 Hex Head Bolt gr 5 7 16 Lockwasher 3 8 Flat Washer 7 16 14UNC Nylon Lock Nut 36 Safety Chain Bolt on Handle Rubber Handle Grip 1 2 12UNC x 4 1 2 Ig Hex Head Bolt gr 5 1 2 12UNC x 5 Ig Hex Head Bolt gr 5 Retainer Washer Hub and Spindle Replacement 12mm x 1 50mm Stud Bolt 7 16 20UNF x 1 1 4 Epoxy Bolt gr 8 REF PART NO NO QTY DESCRIPTION 04826 T205 75R14 C Range Radial Tire 09296 Rim 14 x 5 5 5 on 115mm B C 02933 Chrome Lug Nut 04167 7 16 20UNF x 1 hex head bolt gr 8 04168 7 16 20UNF Nylon Lock Nut 12445 30 Spring Return System Please order replacement parts by PART NO and DESCRIPTION Page 18 WINCH ASSEMBLY To 6 DESCRIPTION ee eects Right Ratchet Winch Assembly Plated 03569 95 Ratchet Frame 03570 95 Left Spool Tube 03571 95 Right Spool Tube 03577 Heavy Duty External Snap Ring 03574 95 Ratchet Handle 03668 18 Ga Shim Washer 03575 95 Left Ratchet Gear 03576 95 Right Ratchet Gear 03666 5 16 x 1 1 4 Roll Pin 02243 Black Vinyl Hand Grip 05450 Winch Pawl 01864 Winch Pawl Spring SS 05449 Winch Pawl Bushing SS 00004 5 16 Flatwasher 05444 3 8 16 UNC x 3 4 Hex Bolt w epoxy Gr 5 03572 95 Left Ratchet Pawl Arm 03573 95 Right Ratchet Pawl Arm 03578 5 16 18 UNC x 1 2 Shoulder Screw 01998 5 16 Flatwasher SS 02002 1 4 Flatwasher SS 02772 1 4 20 UNC Nylon Locknut 04055 1 4
9. parts by PART NO and DESCRIPTION All options may not mount on tow dolly simultaneously OPTIONAL SPARE TIRE and MOUNT PARTS BREAKDOWN Drive in stud here for tire with rim 04173 100mm bolt circle RK4ST 1 Optional Spare Tire and Rim 1 N A 1 ST205 75R 14 x C BSW Radial Tire 2 09296 1 6 x 14 Rim 115mm Bolt Circle RKSTM 1 Spare Tire Mounting Bracket Spare Tire Bracket Stud Bolt 12mm x 1 5 2 Wheel Nut 12mm Chrome 2 3 8 16UNC Square U Bolt 2 3 8 Flatwasher 4 3 8 16UNC Nylon Insert Locknut Drive in stud here for 85 KK6TC Optional Spare Tire Cover ALET aM FO 2 Oe 3 Mit 1 2 j tire with rim 04366 115mm bolt circle Please order replacement parts by PART NO amp DESCRIP All options may not mount on tow dolly simultaneously Page 31 DETHMERS MFG COMPANY P O BOX 189 4010 320th St BOYDEN IA 51234 PH 712 725 2311 FAX 712 725 2380 TOLL FREE 1 800 54DEMCO 1 800 543 3626 www demco products com
10. staff O O O O Dealer Distributor Name City State O O O O O O YES NO O O O O YES NO YES NO YES NO YES NO O O O O If YES are you satisfied with the company s resolution of your problem Why did you purchase this product Please list the specific source of information prompting this purchase After purchasing this product do you see any needed product improvement If yes what improvement What other products would you like to see DEMCO offer Comments Owner s Name Mailing Address City State Model Serial Purchase Date Owner s Signature Zip Code Please return to DETHMERS MFG CO By FAX or tri folding this form to the backside it is pre addressed Dethmers Manufacturing Company 4010 320th Street Box 189 Boyden lowa 51234 Postage OPTIONAL WINCH PARTS LIST REF NO PART NO QTY DESCRIPTION Optional Winch Winch Mechanism 1400 capacity Replacement Handle Strap Assembly includes strap amp hook 3 8 16UNC x 3 Hex Hd Bolt gr 5 3 8 16UNC x 4 Hex Head Bolt gr 5 3 8 Flatwasher 3 8 16UNC Nylon Insert Locknut Please order replacement parts by PART NO and DESCRIPTION All options may not mount on tow dolly simultaneously OPTIONAL TOOL BOX PARTS LIST Tool Box Small Hair Pin 02742 30 2 Mounting Z Bracket 4 3 8 16UNC x 1 Hex Head Bolt gr 5 2 3 8 16UNC x 3 Square U Bolt Please order replacement
11. transmission For manual transmission Consult your vehicle owners manual for towing suitability with the drive shaft connected MAINTENANCE Periodically check all bolts and nuts to insure proper tension or torque Grease the king pin and tie rod end grease zerks every 2500 miles An occasional drop of oil may be required on the moving parts of the tie down winches A light film of oil should periodically be applied to steering stabilizer arm to prevent rust NOTE Proper toe in is 1 32 This is preset at the factory The operator should periodically have the toe in checked and adjusted if needed at a qualified alignment shop Improper toe in can result in irregular tire wear IMPORTANT LOADING INSTRUCTION Check your wheel tie down straps Your Kar Kaddy is equipped with custom made wheel tie down straps of a standard size that will fit most tires however if your tires are too large or too small you will want to exchange these new straps for the proper size straps 1 Tire too large This is very obvious the strap will not basket over the tire properly call us we will provide at NO Charge onan exchange basis the proper size strap You must return your new unused straps and provide us with the Make and Model car and the tire size 2 Tire too small This is not as obvious the basket will fit down over the tire very well the problems cannot be readily seen You must tighten the straps down solid and then check on the ins
12. which in the judgment of Warrantor are either incompat ible with the Demco Kar Kaddy or affect its operation perfor mance or durability This warranty does not cover 1 normal wear and tear 2 road film or gravel damage to paint 3 paint 4 rust damage 5 Any Demco Kar Kaddy that has been loaded in excess of the load capacity stated on the tow dolly identification label Warrantor has a policy of continuous product improvement We reserve the right to change or improve the design of any Demco Kar Kaddy model including but not limited to state of the art changes without assuming any obligation to modify any tow dolly previously manufactured Warrantor assumes no responsibility to the owner for loss of use of the tow dolly loss of time inconvenience or other damage consequential or otherwise including but not limited to expense for gasoline expense of transporting the tow dolly to the dealer and expense of returning the tow dolly mechanic s travel time telephone or telegram charges road service towing charges rental of another tow dolly during the time warranty repairs are being performed travel lodging loss or damage to personal property or loss of revenue or earnings Limitations of Implied Warranties All implied warranties if any expire and terminate upon expira tion of this warranty Some states do not allow limitation on how long an implied warranty lasts so this limitation may not apply to you
13. 4 06 RD20011 Rev 1 L manua ctun Dethmers Manufacturing Company Kar Kaddy 3 KKSIOSE ASSEMBLY CALIBRATION OPERATION REPLACEMENT PARTS R E A D complete manual CAREFULLY BEFORE attempting operation Doing Our Best To Provide You The Best Introduction Thank you for purchasing a Demco Kar Kaddy We feel you have made a wise choice and hope you are completely satisfied with your new piece of equipment GENERAL INFORMATION 1 Unless otherwise specified high strength grade 5 3 When placing a parts order refer to this manual for 3 radial line head markings hex head bolts are proper part numbers and place order by PART NO used throughout assembly of this piece of equip and DESCRIPTION ment 2 Whenever the terms LEFT and RIGHT are used in this manual it means from a position behind the Kar Kaddy and facing forward TABLE OF CONTENTS General MMO rmatiOny t22 22 tic eetese heals eth a cleat a tates Bie acme teen ee ea cea aca eek at da oe Page 2 Tow Dolly Safety Quid r E a a a espesadlan E E E R S Page 3 10 Bolt Torque nnn n a e a eile nla edhe eis eed deed ee Page 11 Tongue amp Ramp Installathon a cas sosedeges a EE ai e aaa a aa Eaa T araa Aaa tas Ae Er Aud aAa A Eaa aa aiaei iaia Page 12 Fender Assembly Installation iriiri a a a a a a aed ace Page 13 Safety Maintenance amp Important Loading Instructions 0 c cee eeceeseeeeeeeeeeeeceeeeseeeeeeaeeeeeeaeeeeeseeeea
14. Limitation of Consequential Damages Warrantor s responsibility under this warranty extends solely to repair or replacement of your Demco Kar Kaddy and its compo nent parts Warrantor does not assume responsibility for nor shall it be liable for any special incidental or consequential damages Some states do not allow the exclusion or limitation on inciden tal or consequential damages so the above exclusion or limitation may not apply to you Use of Vehicle Identification Number VIN The VIN is a 17 digit number located in the lower left corner of the tow dolly identification label The label is located on the left side of the tow dolly frame Be sure to include the VIN number in all communications with Warrantor or its dealers concerning the warranty Purchaser s Rights This warranty gives you specific legal rights and you may also have other rights which vary from Page 22 MODEL DA91 ACTUATOR PARTS BREAKDOWN 5398 Master Cylinder Repair Kit gasket included 8 5495 Coupler Repair Kit 2 Lever Lock Coupler RATED AT 6000 BLEEDING THE SYSTEM The first requirement for safe sure hydraulic braking is the use of quality brake fluid Use only DOT 3 or DOT 4 brake fluid from a sealed container If pressure bleeding equipment is available follow the manufacturer s instruction in bleeding the system If system must be bled manually proceed as follows Fill master cylinder with fluid Install bleed
15. are warranted for a period of three years after the date of purchase by the original first retail owner or until it s resold or transferred by the original owner Tires and lights are not included in this warranty Tires are warranted by the manufacturer against defects in materials and workmanship but not against road hazards Any part of the Demco Kar Kaddy except tires and lights found in the judgement of the manufacturer to be defective in materials or workmanship will be repaired or replaced at the manufacturer s option without charge for parts or labor to the original owner Manufacturer and Warrantor of Tow Dolly Dethmers Manufacturing Co 4010 320th Street P O Box 189 Boyden IA 51234 712 725 2311 The manufacturer and warrantor of the tires has his name molded into the tires Tire warranty questions and claims can be taken directly to an authorized dealer of the tire manufacturer Repair or Replacement Procedure If your Demco Kar Kaddy develops a defect except for tires or lights during the warranty period promptly notify Dethmers Manufacturing Co customer service department Until such notice is received Warrantor will not be responsible for any repair or replacement Upon receipt of notice from you Warrantor will have a choice of options in replacing any part it determines to be defective a Warrantor may require you at your own expense to deliver or ship the part to its factory or authorized deale
16. ark on each side of the locking clamp on the tie rod Loosen the locking nuts on each end of the tie rod and then the six bolts on the tie rod locking clamp Turn the tie rod whichever direction is needed until you have a front measurement of 1 32 to 1 16 less than the back measurement Hold the tie rod and tighten the locknuts on each end Measure again to make sure the toe in measurement has not moved Tighten the locking clamp bolts while holding clamp between the marks you previously put on the tie rod Reassemble the rest of the Kar Kaddy unit OPTIONAL WHEEL JACK WHEEL JACK PARTS LIST KK2WJ Optional Wheel Jack w hardware Please order replacement parts by PART NO and DESCRIPTION All options may not mount on tow dolly simultaneously OPTIONAL DEFLECTOR PARTS BREAKDOWN K OPTIONAL DEFLECTOR PARTS LIST REF PART NO NO QTY DESCRIPTION 02055 30 Deflector Framework 02592 3 8 16UNC Nylon Insert Lock Nut 02759 3 8 16UNC Square U Bolt fits around 3 tube 00161 95 Lock Handle 02054 30 Deflector Slide Mount 00095 3 8 16UNC x 3 4 Ig Square Head Set Screw 02743 30 Deflector Upright Post 02165 Deflector Lacing Cord 1 8 x 25 ft 11710 Deflector Fabric Please order replacement parts by PART NO and DESCRIPTION ne as ORDS Ol Pa hH MN AD 7 Ay a Ah INS LIGHT BAR PARTS LIST DESCRIPTION Kar Kaddy Light Bar complete Nylon Security Strap with hooks amp tightener
17. ctor B7785 3 16 Brake Line Tee By loosening the bleeder screw located in the wheel cylinder 13 SBD10 Have loose end of hose submerged in brake fluid in glass container to observe bubbling 4 3 4324 RAR OMNMDY H A PD Union Fitting one turn the system is open to the atmosphere through the 14 05960 5 16 x 1 2 Self Threading Bolt passage drilled in the screw Pump actuator with long steady 15 12445 30 Spring Return System strokes The bleeding operation is completed when bubbles 161 5B24429 Len eae Custer no longer rise to the surface of the fluid Be sure to close SB24428 K Right Brake Cluster bleeder Screw securely 17 SB40929 30 10 Brake Drum Repeat bleeding operation at each wheel cylinder During the Please order replacement parts by PART NO and DESCRIPTION bleeding process replenish the brake fluid so the level does not fall below the 1 2 full level in the master cylinder reservoir After bleeding is complete make sure master cylinder reser voir is filled and filler cap is securely in place After the bleeding operation has been completed apply pres sure to the system and check the whole brake system for leaks Page 25 Wiring Diagram PARTS LIST o PART NO am DESCRIPTION ae Tongue Wiring Harness Main Frame Wiring Harness Please order replacement parts by PART NO and DESCRIPTION TESTING LIGHTS BEFORE USE Check that the WHITE ground wire of the
18. driving at night Night drivers have three times the fatality rate of day drivers NEVER continue to operate an unstable swaying or whipping combination If this occurs slowly pull over reducing speed through your engine rather than braking When stopped in an off the road location check hitch tire straps and chains NEVER pass on hills or curves Beware of cross winds and wind gusts from passing vehicles NEVER transport passengers or cargo in towed vehicle ALWAYS load vehicle in tow facing forward NEVER back onto tow dolly For maximum stability steering axle must be on tow dolly ALWAYS disconnect drive shaft of a rear wheel drive front engine vehicle in tow at differential to avoid transmission damage Secure disconnected parts ALWAYS ensure vehicle in tow parking brake is disengaged before towing ALWAYS keep children pets and bystanders clear of area while loading and unloading THE MOST IMPORTANT PART IS YOU Will you read and follow these instructions on how to safely operate this Dethmers Tow Dolly If your answer is YES we thank you for your attitude and believe your towing experience will be a safe and pleasant one SAFETY CHECKLIST Wate Stopped Check That Hitch is Tight That Hitch Ball is Tight Coupler Lever Lock Are Tire Tie Down Straps Tight Are Hitch Safety Chains and Vehicle in Tow Frame Security Chains Properly Attached Are Tire Pressures OK Vehicle in Tow for Working Lights Are Drive Shaf
19. each wheel platform The short aai of the hook must face the rear ir of ue Kar Kaddy Step 9 Be sure tie down winch is centered with the tire before tightening straps Step 10 Thread tie down strap through the slotted tube on the tie down winch Pull approx 6 of strap through this slot Begin tightening strap making sure the tail becomes enclosed by the strap coming over the tire Tighten the straps ensuring that the strap fed through the slot binds between the shaft and the strap being wound onto the winch shaft While tightening straps pull cross strap forward to ensure even tightening After each strap is tight insert a safety pin in each winch Disengage towed vehicle parking brake Straps must be retightened after first 5 miles of travel Check straps every 50 miles thereafter to ensure they are tight and not rubbing or fraying Page 16 Step 11 Make sure the tie down strap is the correct size for the auto tire See page 11 of this instruction for proper fit and exchange instructions Step 12 Hook the towed vehicle safety chains to frame of vehicle directly above the area where the chains are mounted on the Kar Kaddy Leave some slack in the chains to allow suspension movement of the towed vehicle Step 13 TO UNLOAD towed vehicle Make sure that plat form and vehicle are straight Reinstall driveshaft Ensure that towed vehicle parking brake is fully engaged then unhook the towed vehicle safety chain
20. ead width or body width of towed vehicle must not exceed 76 max outside to outside 42 min inside to inside 78 max body width Step 5 Grasp bed release handle on tongue and pull toward coupler This releases the tilt bed to permit loading Page 15 Step 6 With someone safely guiding you slowly drive ve hicle onto platform FRONT FORWARD Any vehicle mounted on tow dolly must be mounted with front of the vehicle facing forward Drive the car forward until the tires touch the ramps Make sure the tire is aligned to ascend onto the ramps Step 7 Drive vehicle onto the platform front forward until tires touch the wheel stops at the front of each side of the platform and the platform tilts to a flat position Make sure the car is centered on the platform Towed vehicle tires must fit in wheel troughs without overhanging sides Engage towed vehicle parking brake Shift loaded car into park and lock steering wheel with front tires in a straight position If the car does not have a locking steering column the steering wheel must be tied securely with front tires in a straight position Rear Wheel Drive Disconnect towed vehicle driveshaft for rear wheel drive vehicles with automatic transmission For manual transmission Consult your vehicle owners manual for towing suitability with the drive shaft connected Step 8 Place one tie CIOWA strap over each tire nisi secure hooks to rods located at the rear of
21. er hose on first wheel cylinder to be bled Have loose end of hose submerged in brake fluid in glass container to observe bubbling By loosening the bleeder screw located in the wheel cylinder one turn the system is open to the atmosphere through the passage drilled in the screw Pump actuator with long steady strokes The bleeding operation is completed when bubbles no longer rise to the surface of the fluid Be sure to close bleeder screw securely Repeat bleeding operation at each wheel cylinder During the bleeding process replenish the brake fluid so the level does not fall below the 1 2 full level in the master cylinder reservoir After bleeding is complete make sure master cylinder reser voir is filled and filler cap is securely in place After the bleeding operation has been completed apply pres sure to the system and check the whole brake system for leaks REF NO PARTNO QTY 09417 01896 02178 05426 11079 95 SB12426 11164 95 05424 02363 05408 B10555 05693 95 05961 00618 00057 05951 03876 05849 05977 00062 09153 10616 B12098 03866 95 05687 05986 95 10965 10966 10967 e MEO O Model 91 ACTUATOR 8669111 PARTS LIST D S a a a O a a a O Hs a OOO a m a O DESCRIPTION 6000 2 Lever Lock Coupler zinc plated 1 2 13UNC x 4 Hex Head Bolt gr 5 1 2 13UNC Nylon Insert Lock Nut Front Shock Pin drop tube actuators Drop Tube Actuator Slider plated Damper Shock 3 Bolt Mount Outer Case
22. eseeeeaeeeeeaeteaetaeeeas Page 14 Loading Angle Clearance Guide wi i i c ccceiiseeen cece cede ete teed tees este estee a i eia Eei E a Eee a ia iee aA Page 14 Loading NSU NONS iaa r aa a adic aaa E catadusta cyeagsandegehenvecdnschavcecasecsuises aod sugitueesasanidedaspipezenaaess Page 15 17 Kar Kaddy KK370SB Parts Breakdown and List cecceeceeseseeeeeeeeeeeeeeeeeeaeeeeceeeeaeseeeaeseeecaeeeaeseeeaeeeeeeaeeneesateaas Page 18 19 Winch ASSOmbly ee E EE PE E E E E E TT Page 20 Latch Assembly araia eee A ene ee se E Page 20 License Plate Bracket AssemDly cccccesseseceeeseeeeseeeseeseneeesacecseesaneesanessenessaeneeeesegenseseesseneseceessaeeacenseeteneaneanensees Page 21 Fender ASSOMmbIy cress scccyeces svets cess sereesorensb even ee ee viioes a a aia aa a a ae deren Page 21 Limited Warranty Information cite sAecscascen araea a ni le ea ge cus ce aair anA pise EE aare bev ES Eaa Eae iai Page 22 DA91 Brake Actuator Parts Breakdown and List ec ceeeeeseeeeeeeeeeeeeeeeaeeseneeeaeeeeaeeseaeeeaeeesaeesaeeeaeeseaeeseeeseneeseeeeenes Page 23 10 Self Adjusting Brake Cluster Parts Breakdown and List c ccceeceeseeeeeeeeeeeeeeeeeaeeeeeeaeeeeesaeeeaeseeesaeeeeeeaeeeeeeaeees Page 24 Surge Brakes Parts Breakdown and LiSt ccceeceeseeeeeeeeeeeeeeeeeeecaeeeaeeeeeeaeeeeeseeeeaeeeeesaeseeesaeeeaeceaesaeseaseaeeeeeeaeeeeeeaeeeas Page 25 Testing Lights Betore Use as a4 itich sand leeds a sien eee axl naples agate ele
23. h a safe place off the road turn on emergency flashers and proceed with caution Do not hesitate to proceed on a flat tire if necessary to reach a safe place completely off the highway Proceed slowly for road friction could ignite a flat tire and cause a fire Rough Roads To prevent damage to tow vehicle or tow dolly reduce speed when towing tow dolly over rough roads Turning Avoid U turns Avoid turning too sharply Turning too sharply may cause side of vehicle in tow to come in contact with rear of dolly fender and cause damage to both vehicles Pro Driving Tips Accidents occur more frequently at night with a tired driver exceeding recommended speed on a downgrade wet road or curve Don t attempt to drive straight through Be rested Slow down for down grades wet roads or curves Night drivers have three times the fatality rate of day drivers Avoid driving at night ACCIDENTS Move all vehicles completely off the road Get everyone out of the vehicle and off the road Call police Dethmers Manufacturing Company wants you to have a safe towing experience Read these instructions carefully read fender decals on tow dolly and follow all instructions Page 10 BOLT TORQUE TORQUE DATA FOR STANDARD NUTS BOLTS AND CAPSCREWS Tighten all bolts to torques specified in chart unless otherwise noted Check tightness of bolts periodically using bolt chart as guide Replace hardware with same grade bolt
24. he wire splicer 01883 supplied Connect GREEN wire to the right turn signal and stop wire Connect BROWN wire to tail light wire VERY IMPORTANT connect WHITE wire to frame body of towing vehicle This is the common ground andaclean metal to metal contact must be made CAUTION Many flashers for vehicle turn signals will not carry the additional load of Kar Kaddy turn signals If normal operation does not occur when connected to the Kar Kaddy a heavy duty replacement flasher may be obtained through auto parts outlets Page 26 KAR KADDY TOE IN ADJUSTMENT FRONT MEASUREMENT amp 7a 1 32 to 1 16 less than back measurement Pr MEL MEASURING THE TOE IN Have the tongue in a hooked up position with the ball coupler 18 off the ground Jack up the axle just enough to allow you to take the wheels off and put blocks under the axle Take the wheels off Find two 24 long bars these could be a level a square or a straight piece of iron bar Clamp one bar tight to the face of each hub with 12 extending forward and backward of the center of the spindle The bars must be parallel to the platform the car sits on Measure across the back end of the bars and then across the front end The front measurement should be 1 32 to 1 16 less than the back measurement If the unit needs to be adjusted this must be done by adjusting the tie rod Page 27 TOE IN ADJUSTMENT Put a m
25. ide of the tire and be sure the strap when tightened does not come in contact with any metal that may cause wear or cutting such as strut mounts If there is contact you need a smaller strap call us we will provide on a NO Charge exchange basis the proper size strap You must return your new unused straps and provide us with the Make and Model car and tire size Thank you for Purchasing Products LOADING INSTRUCTIONS Step 1 Secure ba 6 000 Ib capacity towing vehicle ball only Make sure that the hitch and the hitch ball are in good condition and not rusted loose or stripped Make sure hitch is locked down and secured with safety clip Criss cross safety chains under tongue and secure to towing vehicle frame Step 4 Before loading and unloading towed vehicle make sure platform and towed vehicle are in straight alignment Tow dolly must be completely and properly hooked up to the towing vehicle Step 2 Remove black locking pin BEFORE loading vehicle onto the Kar Kaddy The removal of the locking pin allows Auto Steer to operate When towing the dolly empty this pin must be in place Step 3 Loosen wing nut on back of license plate holder turn the clip on the front to a horizontal position and put license in the down position Turn the clip back so it rests against the back of the light bar to hold the license down and tighten wing nut License must be UP with the tow dolly empty Tire tr
26. justing Screw Lever Right Lever Left Pin Shoe Hold Down Cup Shoe Hold Down 05983 Spring Shoe Hold Down 03380 Spring SB15845 1 Wheel Cylinder Repair Kit includes spring cup and boot SB40929 30 2 10 Brake Drum Please order replacement parts by PART NO and DESCRIPTION Brake shoe kit can be ordered for one complete axle only SB9254 SB10954 04305 05424 SB9776 SB9777 05431 SB9783 SB24047 SB24048 SB10958 SB10961 95 B23937 B23936 B23724 05415 95 05414 95 B10959 SB9789 o Cao OP Cae PMpPANMH HH 3232 ap m aan O O Page 24 SURGE BRAKES PARTS BREAKDOWN Model DA91 Brake Actuator SURGE BRAKES PARTS LIST BLEEDING THE SYSTEM The first requirement for safe sure hydraulic braking is the use of quality brake fluid Use only DOT 3 or DOT 4 brake fluid from a sealed container REF PART NO NO QTY DESCRIPTION SB566 66 Brake Line 01863 Rubber Gommet 02746 54 Protective Hose If pressure bleeding equipment is available follow the SB7H67 7 Brake Hose rubber manufacturer s instruction in bleeding the system SB541 41 Brake Line SB7764 Rubber Brake Line Clip If system must be bled manually proceed as follows Fill 02032 12 Brake Hose rubber master cylinder with fluid Install bleeder hose on first wheel 02210 7 16 20UNF x 1 1 4 Epoxied Bolt gr 8 cylinder to be bled 04174 12mm Retainer Washer 2 per drum SB5045 4 1 2 Brake Line 02549 Rubber Prote
27. latwasher 7 pivot bushing 8 and locknut 9 Hold up the front end the end with the smaller hole of each bracing strut to the tongue and secure with two 5 8 x 1 1 4 epoxied hex head bolts 10 Torque the 1 2 x 1 1 2 bolt with the pivot bushing to 75 ft lbs Torque the two 5 8 x 1 1 4 epoxied hex head bolts to 100 ft Ibs Attach the tilt bed ramps 11 as shown using four 1 2 x 1 1 4 grade 5 bolts 12 flat washer 7 and lock nuts 9 two on each side of each ramp and then three 7 16 x 1 grade 8 bolts 13 and lock nuts 14 on the top of each ramp Torque 7 16 bolts to 80 ft lbs and torque 1 2 bolts to 75 ft Ibs Attach rear tire stop 15 as shown using two 3 8 x 1 1 4 grade 5 bolts 16 flat washers 17 and lock nuts 118 These 3 8 x 1 1 4 bolts will also go through the tilt bed ramps Torque 3 8 x 1 1 4 bolts to 35 ft Ibs 8 Repeat steps 6 7 for other side Page 12 Fender Assembly Instructions 1 Install fender with fender backup plate 1 and three 3 8 3 On the left side plug in bullet plugs with white to white x 1 1 2 bolts 2 Put 3 8 nylon lock nuts 3 inside of black to brown and yellow to red On the right side plug fender and tighten white to white black to brown and green to red 4 With a pliers install two wire clamps on fender From rear 2 Cutnylon wire tie from wiring to brake hose on main frame of fender lip i
28. lded into tire sidewall Normal pressure should be maintained in tow vehicle s front tires Tow dolly tires should be inflated to pressure recommended on operational decal on fender 45 or 50 psi These are COLD pressures and will increase when tires are hot from running DO NOT bleed off this pressure increase Incorrect tire pressure can adversely affect vehicle handling and gas mileage Mirrors State laws require vehicles towing a tow dolly to be equipped with mirrors on both sides Inadequate side mirrors create a hazard by limiting rearward vision If your vehicle is not already so equipped you should put right and left hand full view detachable mirrors on Ask dealer if it has any available for rent if you do not want to purchase them Page 6 A Engine and Transmission Coolin Towing a loaded tow dolly can be quite demanding on engine and transmission cooling systems of tow vehicle especially if towing long distance or in hilly terrain Be sure your cooling system is in top shape and adequate for towing anticipated load Engine oil should be fresh and of maximum viscosity recommended for your particular engine Engine cooling may be enhanced by flushing system and installing fresh coolant Automatic transmissions may need an external oil cooler installed for unusually difficult or extended towing Engine and transmission heat increase as vehicle speed increases To maintain proper cooling do not exceed 55 m p h regardless
29. nstall one clamp at 5 1 2 and one at 8 used for shipping purposes only Fish the three wires from main unit through the hole in fender 5 Mount the mud flaps 4 to the inside back of the fender using two 1 4 x 3 4 truss head bolts 5 with flat washers 6 and lock nuts 7 Make sure the Kar Kaddy logo on the flap faces the rear Page 13 A WARNING FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN LOSS OF TOWING VEHICLE CONTROL SEPERATION OF THE TOW DOLLY FROM THE TOWING VEHICLE SEPERATION OF THE TOWED VEHICLE FROM THE TOW DOLLY CAUSING SEVERE PERSONAL INJURY DEATH OR PROPERTY DAMAGE Ak SAFETY Safety is of utmost importance at all times There are several items that must be checked each time before using and while using the Kar Kaddy Make sure all bolts are properly tightened and those requiring a set torque are up to specifications Tie Rod Castle Nut 75 ft Ibs Lug Nuts 120 ft lbs Check Lug Nut tension after the first 5 miles and periodically thereafter The ball hitch must latch securely around the ball and the safety lock pin or lever must be in position to lock the hitch on the ball RECOMMENDED BALL HEIGHT 18 inches to the top of the ball on the towing vehicle Hook the towed vehicle safety chains to the frame of the vehicle directly above the area where the chain is mounted on the Kar Kaddy Leave some slack in the chain to allow suspension movement Check to make sure that all ligh
30. of engine size or load Hitch Be certain that hitch and hitch ball are securely attached and that hitch ball is 2 in diameter A minimum rating of class II 3500 lbs is required for both hitch and hitch ball Some sports utility vehicles are equipped with a bumper type hitch from the factory DO NOT USE THESE HITCHES since bumper may not have sufficient structural capacity to handle the load Equip your vehicle with a hitch attached to the undercarriage of your vehicle Lights Lights are required on tow dollies in every state If your vehicle is not already equipped for tow dolly light hook up it will be necessary to install connections now Your dealer will let you know exactly what is needed for your particular vehicle Tow Vehicle Loading A loaded tow dolly tongue weight approximately 200 Ibs contributes to total cargo weight of tow vehicle Tow vehicle manufacturer s recommended maximum passenger cargo load must not be exceeded VEHICLE IN TOW Limitations Cautions 1 Vehicle in tow must Not be wider than 76 inches at front doors to prevent damage to doors from contact with tow dolly fenders on turns 2 Vehicle in tow must Weigh no more than 4 400 lbs Exceeding these limits may cause damage to tow dolly or vehicles Vehicle in tow tire tread must fit on ramps without overhanging sides Track width distance from left front tire center to right front tire center must be between 49 and 59 inches Low hanging s
31. owing suitability with the drive shaft connected ALL VEHICLES MOUNTED ON THE KAR KADDY MUST BE WITH THE FRONT OF THE VEHICLE FACING FORWARD AX SAFETY Examine winches and straps to make sure they are in good condition Check wheel nuts every trip Tires must be inflated to recommended pressure by tire manufacturer Be certain the safety lock pins lock the strap winches Retighten the straps over the tires after the first 5 miles of travel Check straps every 50 miles therafter to ensure they are tight and not rubbing or fraying Page 17 REF PART NO NO QTY 03528 5809 5808 04424 95 00914 02592 04165 81 04166 81 01732 11588 01731 05587 11566 81 11550 81 11551 03724 02377 04168 02178 02579 95 00085 01254 02747 96 03503 02434 02587 02696 00477 01729 35 11553 81 11554 81 00907 02494 00967 04772 96 01718 95 02189 00182 11933 81 5806 04771 81 5179 5178 01905 01904 04773 96 00523 02243 07077 81 09417 5433 5432 02772 04176 B24428 B24429 SB40929 30 01898 00078 00059 02771 02383 04017 95 02189 01338 01975 04174 04369 02917 02210 OnmnNMNMN A NMANAAAGRANM AN N ayo au NANA RBNONANAHANMNMNAHAAAAANMABRAB AAA AHA PONMHAAH ANA AND Cor KK370SB PARTS BREAKDOWN DESCRIPTION Tie down Strap assembly Black Right Fender Assembly with Lights Left Fender Assembly with Lights Fender Backing Plate 3 8 16UNC x 1 1 2
32. poilers and air dams may be damaged by contact with tow dolly ramps when loading and unloading Be sure there is adequate clearance for these If not they must be removed before loading Page 7 Vehicle in Tow Facing Forward Vehicle in tow must always be facing forward front wheels on tow dolly Transmission Damage to Towed Vehicles When towing a rear axle driven front engine vehicle the drive shaft must be disconnected to prevent transmission damage Simply placing transmission in neutral is not sufficient and will not prevent damage due to a lack of internal lubrication You must disconnect drive shaft at rear axle and tie or wire it up The universal joint bearing caps must be taped on to prevent loss of bearings If you choose to remove drive shaft entirely it may be necessary to cap transmission tail shaft to prevent fluid loss and possible future damage Consult your vehicle owner s manual Front wheel drive vehicles need not have drive shafts disconnected because the drive wheels are loaded on tow dolly Towing damages many rear engine vehicle with transaxles Consult owner s manual for tow suitability Passengers And Cargo Prohibited in the Vehicle in Tow Never transport any passengers or cargo in towed vehicle In addition to being illegal in most states carrying passengers in a towed vehicle exposes those passengers to risk of exhaust gas asphyxiation Lighting Requirements Even though tow dollies ha
33. r Any defective part will be repaired or replaced and returned to you free of charge Any part returned to Warrantor and found not to be defective will be returned to you freight collect with an explanation b Warrantor may elect to ship a new part to its dealer to be exchanged free of charge for the defective part returned by you to the dealer c Warrantor may elect to ship or deliver a replacement part to your address Warranty claims on tires should be presented to a local autho rized dealer of the tire manufacturer Provide proof of purchase when making a tire warranty claim Limitations on Warranty Coverage Coverage under this warranty will be effective only when a copy of the original invoice showing the date and location of purchase accompanies any claim for warranty Warrantor has no liability whatsoever and this warranty is null and void if any Demco Kar Kaddy has been misassembled or subjected to neglect negligence misuse accident or operated in any way contrary to the operating and maintenance instructions as specified in the Demco Owner s Manual for that model tow dolly This warranty does not cover any tow dolly that has been altered or modified so as to affect the tow dolly s operation performance or durability or that has been modified to change the intended use of the tow dolly In addition the warranty does not extend to repairs made necessary by normal use of parts accessories or other equip ment
34. re in good condition and inflated to proper pressures Tire pressure may increase during travel do not bleed off extra pressure Do not back up your towing vehicle when a tow dolly is attached A tow dolly swivels both at the coupler and at car platform If you must back up unload towed vehicle first disconnect tow dolly and move vehicle and tow dolly separately Park where you can pull ahead when leaving Do not exceed 55 miles per hour or any lower posted speed limit Avoid sharp turns or swerves Braking distance increases when using a tow dolly Use caution and always allow sufficient distance for braking Do not transport passengers or cargo in vehicle being towed Do not unhook tow dolly from towing vehicle until towed vehicle is completely unloaded from tow dolly Page 4 Allow one tow vehicle tow dolly vehicle in tow length for each 10 m p h behind another vehicle ALWAYS check the hitch tow dolly and vehicle in tow at each stop to insure that coupling chains and tie down equipment remain tight and properly attached Use tow dolly checklist as an aid NEVER tow without properly installed tire straps and security chains properly attached to frame or other structural member of vehicle in tow ALWAYS slow down 40 miles per hour or less for curves wet or rough roads and downgrades On downgrades shift into a lower gear and allow engine to help hold speed down ALWAYS be rested NEVER drive when fatigued AVOID
35. s and release the tie down straps NOTE Tie down straps must be quick released by grasping ratchet pawl A and ratchet handle B simultaneously and pushing down sharply This process will permit easy removal of strap from winch Swing the wheel platform locking latch handle forward towards the coupler This will allow the platform to tilt as you slowly drive off Make sure the winch ratchet handles are horizontal Replace the Auto Steer locking pin for towing empty Step 14 To pull the Kar Kaddy empty make sure Auto Steer LOCKING PIN IS IN PLACE and towing vehicle safety chains are up and hooked Tie down winch handles should be left in a down postion horizontal position with safety pins in place when towing loaded or empty DO NOT ATTEMPT TO PULL KAR KADDY WITH WHEEL PLAT FORM IN LOADING tilted POSITION DAMAGE PREVENTION Check your vehicle manual or registration for vehicle weight Towing vehicle must be larger and at least 1 000 Ibs heavier than the towed vehicle and tow dolly combined Do not pack goods in car that is being towed Overloading the Kar Kaddy or exceeding the width limit may result in damage to both car and Kar Kaddy REAR WHEEL DRIVE PRECAUTIONS Disconnect towed vehicle driveshaft for rear wheel drive vehicles with automatic transmission Simply placing trans mission in neutral is not sufficient to prevent damage to transmisssion For manual transmission Consult your vehicle owners manual for t
36. s Manual and contains technical information concerning the specific product that you purchased Be sure to review both manuals SAFETY TAKE NOTE THIS SAFETY ALERT SYMBOL FOUND THROUGHOUT THIS MANUAL IS USED TO CALL YOUR ATTENTION TO INSTRUCTIONS INVOLVING YOUR PERSONAL SAFETY AND THE SAFETY OF OTHERS FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN INJURY OR DEATH THIS SYMBOL MEANS ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED SIGNAL WORDS This manual uses the following signal words DANGER WARNING and CAUTION with safety messages The appropriate signal word has been selected using the following guidelines DANGER Indicates an imminently hazardous situation that if not avoided will result in death or serious injury This signal word is to be limited to the most extreme situations typically for tow dolly components which for functional purposes cannot be guarded WARNING Indicates a potentially hazardous situation that if not avoided could result in death or serious injury and includes hazards that are exposed when guards are removed It may also be used to alert against unsafe practices CAUTION Indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury It may also be used to alert against unsafe practices If you have questions not answered in this manual or require additional copies please contact your dealer or Dethmers Mfg Co PO Bo
37. s as Page 26 Wiring Diagrarn nih att ais tet ee Pee nd ete ee eis Sagi eisai eed Page 26 Kar Kaddy TLoe In AGjustrme nts a a e Secs cess cha aa E casacas legate E decddcck pabedburadiadss toaseaaseas SA A EA EEE Page 27 Wheel Jack Deflector amp Light Bar optional Parts Breakdown and List 00 0 eeeeeeseeeseeeeeeeeeeeteaeeeeeeeeeeeteneeeaeeees Page 28 Winch Tool Box amp Spare Tire w Mounting Bracket optional Parts Breakdown and List eceseeeeeeereeteees Page 31 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 Com pany DEMCO NHTSA 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 U S Department of Transportation If NHTSA receives similar complaints it may Washington D C 20590 open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a You can also obtain other information about recall and remedy campaign However NHTSA motor vehicle safety from the Hotline cannot become involved in individual problems be tween you your dealer or Dethmers Manufacturing Company DEMCO NOTE This is one of atow manual set The other manual is titled Owner
38. t and Battery Cable Disconnected and Secured If Required Page 5 When On the Road e Reduce Speed e Think Ahead e Allow for extra length when turning e Anticipate Stops Brake Early e Stop Often for Rest e Use Safety Checklist at Each Stop TOWING VEHICLE SIZE AND TOWING CAPACITY Towing vehicle must weigh at least 750 lbs more than weight of vehicle in tow Example A 2 750 lb car may tow no more than a 2 000 Ib car Suspension Your tow vehicle s rear springs must be of sufficient strength to support the added loaded tow dolly tongue weight while maintaining tow vehicle in approximately a level position If rear springs shock absorbers or struts are weak or broken they must be replaced In some cases it may be necessary to add helper springs or air shocks to help support weight properly Poor wheel alignment loose steering or worn suspension components can also adversely affect vehicle handling and stability Sport Utility Vehicles Exercise caution when towing with a sports utility e g Jeep or Bronco type vehicle Some of these vehicles have a higher than normal center of gravity and a short wheelbase This gives them different handling characteristics than the average car or truck Tires You must increase pressure in rear tires of tow vehicle to accommodate extra weight of tow dolly When cold inflate rear tires to approximately 6 pounds above their normal operating pressure but DO NOT exceed pressure limit mo
39. trol then drive slowly back onto pavement Never Operate An Unstable Combination Instability swaying or whipping of a tow vehicle tow dolly combination at low speeds usually increases at higher speeds If combination begins to whip or sway steer straight ahead take your foot OFF the throttle but do not brake until combination has stabilized Stop in an off the road location and check tow vehicle and tow dolly as soon as possible e Review all instructions and be sure you have complied e Check that vehicle on tow dolly is loaded with front wheels on tow dolly Reload if necessary e Check that all chains and tie down equipment remain tight and properly attached e Check for proper tire inflation all around combination e Make sure trunk or bed of towing and towed vehicles are not loaded with cargo e Check wheel bearings and lug nuts on both tow vehicle and tow dolly to be sure a wheel has not become loose e Check tow vehicle s wheel alignment e Finally be sure you are not exceeding maximum recommended speed 55 MPH If you have followed preceding instructions any instability should be corrected If situation persists stop and call for professional assistance from a tow truck operator Page 9 p gt BREAKDOWNS Get Off The Road Immediately park tow vehicle tow dolly combination in a safe place completely off the highway Get all occupants out of vehicle and away from roadway If you must continue on the highway to reac
40. ts are in proper working order Examine the winches and straps making sure they are in good conditon Be certain the safety lock pins are locking the strap winches Retighten straps over the tires after the first 5 miles and every 50 miles thereafter Ensure that they are tight The tires must be inflated to the recommended 50 PSI The strap on the optional tongue winch must be in good condition and should be stored neatly on winch when not in use NOTE The winch strap must not be left connected to the towed vehicle after it is loaded and strapped down Make sure the optional light bar is fastened securely at the rear of the towed vehicle The wires to the optional light bar should be run along the car and fastened so as not to damage the finish of the towed vehicle NOTE This unit cannot be backed up when loaded or with the steering lock pin removed All vehicles mounted on the Kar Kaddy must be mounted with the front of the vehicle facing forward Loading Angle Clearance Guide NOTE User s responsibility for checking clearance IMPORTANT Using this guideline will reduce the chance of the towed ve hicles air dam or bottom of facia from interfering with tow dolly platform and or tire stop X must be less than 3 1 2 x yy lf Y measures 6 3 1 2 x6 21 X must measure less than 21 Example Rear Wheel Drive Disconnect the towed vehicle driveshaft for rear wheel drive vehicles with automatic
41. ve operating lights law requires that a vehicle in tow be equipped with functioning stop turn and running lights Detachable vehicle in tow towing lights can be purchased at many rental locations They can also be purchased at auto supply shops Follow instructions carefully when installing TOW DOLLY HOOK UP Double Check After rental company has hooked up your tow dolly it is wise for you to double check connections both before and during trip ALWAYS FOLLOW HOOK UP LOADING AND UNLOADING INSTRUCTIONS ON FENDER DECALS OF TOW DOLLY IF YOUR TOW DOLLY DOES NOT HAVE INSTRUCTIONS OR IF THEY ARE ILLEGIBLE ASK COMPANY FOR A LEGIBLE COPY Page 8 A TOWING 55 Miles Per Hour All vehicle combinations have a speed beyond which adequate emergency control cannot be assured Maximum recommended speed for all tow dolly combinations is 55 m p h under good road conditions As road conditions deteriorate you must reduce the maximum recommended speed Posted speed limit is usually the same for trucks and car trailer combinations Observe this limit even if it is less than 55 m p h Please do not be lulled into a false sense of security because your tow dolly tows easily at higher speeds A road hazard that would be avoidable at 55 m p h can become unavoidable at 65 m p h If you drop any wheel s off the pavement don t attempt any sharp steering corrections Remain off the pavement decrease your speed until you have regained con
42. wiring harness is connected to the Kar Kaddy frame and the WHITE ground wire is connected to the frame of the towing vehicle With headlights in ON position the tail lights the light cluster bar the license plate light and the clearance lights should be lighted Start engine and have someone depress brake pedal Brake lights of tow dolly and towing vehicle should come on and off simultaneously with each application Turn left turn signal on Left turn light of Kar Kaddy and towing vehicle should flash simultaneously Should the turn signal lights of the trailer function opposite to those of the towing vehicle it is probable that the YELLOW Driver side and GREEN Passenger side wires have been reversed Check the plug connection under the tongue of the Kar Kaddy to make sure wire colors are not crossed at that point If plug connection is incorrect correct problem by reversing yellow and green wire connection on the towing vehicle COLOR CODE FOR WIRING HARNESS Ground BROWN Tail Lights License Plate Lights Light Cluster Bar amp Clearance Lights YELLOW Left Turn and Stop GREEN Right Turn and Stop ay m Lj i N WIRING OF THE TOWING VEHICLE Connect wiring to towing vehicle keeping in mind the color code indicated below 1 2 Make certain towing vehicle lights are OFF Connect YELLOW wire to left turn signal and stop wire in the left rear of towing vehicle with t
43. x 189 4010 320th Street Boyden IA 51234 ph 712 725 2311 Toll Free 1 800 543 3626 Fax 712 725 2380 http www demco products com Page 3 TOW DOLLY USER GUIDE A WARNING Read the following information completely before hooking up loading using unloading or unhooking this Tow Dolly A FAILURE TO FOLLOW THESE SAFETY INSTRUCTIONS MAY LEAD TO DAMAGE TO PROPERTY SEVERE PERSONAL INJURY AND OR DEATH Read towing instructions in towed vehicle s owner s manual Read towing instructions in towing vehicle s owner s manual Be certain that your towing vehicle has the capacity to tow a tow dolly and towed vehicle combination IF YOU HAVE ANY QUESTIONS ABOUT THIS DO NOT TOW CONSULT YOUR DEALER OR CALL DEMCO Use a 2 5000 Ib or greater capacity ball for a tow dolly without surge brakes and a 2 6000 lb or greater capacity ball for a tow dolly with surge brakes Make sure towing vehicle s parking brake is fully engaged before starting hookup loading unloading or unhooking of tow dolly Do not load towed vehicle onto tow dolly until tow dolly is completely and properly hooked up to towing vehicle and setting on a level surface Tail lights and stop lights must be hooked up and operating properly at all times Do not load a towed vehicle that exceeds weight or size limits of tow dolly Always have someone safely guide you when driving towed vehicle onto tow dolly Be sure tires of your towed vehicle and tow dolly a
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