Demco KK460SS Utility Trailer User Manual
Contents
1. 9 7 A18 2 2 OO 5 2 49 2 0 0 7 0 9 Pg 2 Q 3 19 wi Y 6 7 17 TE 16 13 19 PARTS LIST REF NO PART NO DESCRIPTION 5736 Left Fender Assembly 5737 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 LED Tail Light Left Fender Assembly Right Fender Assembly Chrome LED Marker Base Mount Yellow LED 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 Please order replacement parts by PART NO and DESCRIPTION 01 ONO 2 5 1 2 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 2 2 28 OPTIONAL SPARE TIRE and MOUNT PARTS BREAKDOWN Drive in stud here for tire with rim 11574 115mm bolt circle All options may not mount on tow dolly simultaneously PARTS LIST 5734 1 Optional Spare Tire and Rim ST205 75R 14 x C ROWL RadialTire 6 x 14 Chrome Rim 115mm2. 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 lights 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 Kar Kaddy 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 16 Rear Wheel Drive Disconnect the 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 M
3. 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 Step 9 Be sure tie down winch is centered with the tire Make sure the tire is aligned to ascend onto the ramps before tightening straps 18 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 NOTE Be sure to tighten straps until each tire starts to flatten against tire stop 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 Step 11 Make sure the tie down strap is the correct size for the auto tire See page 4 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
4. 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 state to state NOTES 32 OCICS Dethmers Manufacturing Company 4010 320th Street Box 189 e 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 How satisfied are you with the dealership distributor sales staff Dealer Distributor Name City 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 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 What other products would you like to see DEMCO
5. UNLOAD towed vehicle Never unhook tow dolly coupler from towing vehicle before unloading todolly Make sure that platform and vehicle are straight Reinstall driveshaft Ensure that towed vehicle parking brake is fully engaged then unhook the towed vehicle safety chains 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 Grasp bed release handle on tongue and pull toward coupler This releases the tilt bed to permit unloading 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
6. for one complete axle only o A o e TANAH N e pd Ss Ss OD N Ph s 22 SURGE BRAKES PARTS BREAKDOWN Model 17 Brake Actuator SURGE BRAKES FIELD SETUP PARTS LIST SURGE BRAKES FACTORY SETUP PARTS LIST PART NO 11968 02034 SB512 05679 11617 11618 11643 SB7785 05960 SB541 02549 02032 SB7764 SB24429 SB24428 SB40929 04174 01863 12445 30 Please order replacement parts by PART NO and DESCRIPTION QTY HAH Aa Aa NAN AH WN ON AP DESCRIPTION 6 Brake Line 45 Brake Hose 12 Brake Line Brake Fitting Male Coupler Female Coupler 7 Brake Hose Swival Male Solid Male Brake Line Tee 5 16 x 1 2 Self threading Bolt 41 Brake Line Rubber Protector 12 Brake Hose Brake Line Clip Left Brake Cluster Right Brake Cluster 10 Brake Drum Retainer Washer Rubber Grommet Spring Return System REF NO PART NO 11968 02034 12449 N A N A N A SB7H67 SB7785 05960 SB541 02549 02032 SB7764 SB24429 SB24428 SB40929 04174 01863 12445 30 QTY ARP ONON a AH AH A CN HS DESCRIPTION 6 Brake Line 45 Brake Hose 15 Brake Line Brake Fitting Male Coupler Female Coupler 7 Brake Hose Swival Male Solid Female Brake Line Tee 5 16 x 1 2 Self threading Bolt 41 Brake Line Rubber Protector 12 Brake Hose Br
7. offer Comments Owner s Name Mailing Address City State Model Serial Purchase Date Owner s Signature Warranty Registration O O Ag RV Rental Brakes Marine Very Dissatisfied Dissatisfied O O If yes what improvement Very Satisfied Satisfied O O O O State O O O O YES NO O O YES NO YES NO YES NO YES NO O O Zip Code Please return to DETHMERS MFG CO By FAX or tri folding this form to the backside it is pre addressed Postage Dethmers Manufacturing Company 4010 320th Street Box 189 Boyden lowa 51234 NOTES 35 DETHMERS MFG COMPANY P O BOX 189 4010 320th St BOYDEN IA 51234 PH 712 725 2311 FAX 800 845 6420 TOLL FREE 1 800 54DEMCO 1 800 543 3626 www demco products com
8. pivot With tongue wheel jack turned to its lowest position push pull tongue to the left Push pull tongue until it comes to a stop by the left fender It is recommended to place lock pin and retainer clip back in tongue pivot for storage 1 2 3 4 If lock has been pulled and lifted properly the Folding Ramp Lock NOTE Tow Dolly must be empty and unhooked to perform any and all of these steps Do not attempt while tow dolly is loaded or hooked up Locate ramp locks at inside center of ramps Pull ramp lock straight out as far as it will go Lift ramp lock up as far as it will go and allow lock to slide in until it stops ramp lock will extend out from its holder This will mean that the ramp is unlocked and ramp may be folded up Folding Ramp NOTE Tow Dolly must be empty and unhooked to perform any and all of these steps Do not attempt while tow dolly is loaded or hooked up Pull ramp back as far as it will go Bolt must be past notch before attempting the next step 2 Lift ramp until it is past center and resting on it stops IMPORTANT When taking this tow dolly out of storage it is very impor tant to check all pins and retainers for damage If damage is found replace Do not use damaged pins or retainers Make sure that tongue pin and retainer clip is replaced after tongue is folded back to the forward and locked position Fold ramps down as far as they will go and push forward un
9. x 3 4 Carriage Bolt 54 11967 95 1 5 8 13UNC x 5 1 4 Hex Head Bolt gr 5 Hinge Bol 55 11795 1 Pin 5 8 x 4 7 8 56 01898 4 7 16 14UNC x 1 1 4 Hex Head Bolt gr 5 57 00078 2 7 16 Lockwasher 58 00059 8 3 8 Flat Washer 59 1 2 7 16 14UNC Nylon Lock Nut 60 02383 4 36 Safety Chain 61 02288 95 1 Bolt on Handle 62 02189 1 Rubber Handle Grip 63 01338 1 1 2 12UNC x 4 1 2 lg Hex Head Bolt gr 5 64 01975 2 1 2 12UNC x 5 Ig Hex Head Bolt gr 5 65 1 11683 1 Wheel Jack 66 04369 2 Hub and Spindle 02917 Replacement 12mm x 1 50mm Stud Bolt 67 02210 8 7 16 20UNF x 1 1 4 Epoxy Bolt gr 8 68 11913 2 S1205 75R14 C Range Radial Tire 69 11574 2 Rim 14x 5 5 5 on 115mm B C 70 02933 10 Chrome Lug Nut 71 5607 1 DA91 Actuator 72 SB24428 1 10 Brake Cluster RH SB24429 1 10 Brake Cluster LH 73 SB40929 30 2 10 Brake Drum 74 4 4 Retainer Washer 75 11971 95 2 Nut Plate 76 12445 30 1 Spring Return System Please order replacement parts by PART NO and DESCRIPTION WINCH ASSEMBLY Left Winch 5432 Shown Right Winch 5433 Left Winch Assembly Right Winch Assembl 1 4 Flat Washer 1 4 20 UNC x 3 4 Hex Head Bolt Spring 1 4 20 UNC Nylon Insert Locknut Lock Pin w Cable 5 16 Flat Washer Black Vinyl Hand Grip 3 8 16 UNC x 3 4 Hex Head Bolt w Epoxy Winch Pawl Bushing
10. 1 00085 15 1 2 Flatwasher 22 1 01254 15 1 2 13UNC x 1 1 2 Hex Head Bolt gr 5 23 02747 96 2 Bracing Strut 24 03503 2 5 8 11UNC x 1 1 4 Epoxy Bolt gr 5 25 02434 1 5 8 13UNC x 4 1 2 Hex Head Bolt gr 5 26 02587 4 5 8 13UNC Nylon Lock Nut 27 6 2 5 8 11UNC x 2 3 4 Ig Hex Head Bolt gr 5 28 00477 11 5 8 Flatwasher 29 01729 30 1 Steering Stabilizer Shock 30 11553 80 1 Tie Rod Clamp Bottom 31 11554 80 1 Tie Rod Clamp Top 32 00907 6 3 8 16UNC x 1 Hex Head Bolt gr 5 33 02494 2 3 8 16UNC x 2 1 4 Hex Head Bolt gr 5 34 11659 91 12 Ramp Bushing 35 11529 96 2 Ramp 36 01718 95 1 Tie Rod Locking Pin 02189 1 Replacement Black Handle Grip for Locking Pin 37 00182 1 Hair pin 38 11540 96 1 KK460SS Main Frame 39 5740 1 License Plate Bracket Assembly 40 1 04771 80 1 Tie Rod 41 5179 1 Right Tie Rod End w Right Hand Threads 42 5178 1 Left Side Tie Rod End with Left Hand Threads 43 01905 1 9 16 18UNF Jam Nut w Right Hand Threads 44 1 01904 1 9 16 18UNF Jam Nut w Left Hand Threads 45 04773 96 2 Rear tire Stop 46 00523 4 3 8 16UNC x 1 1 4 Ig Hex Head Bolt gr 5 47 02243 1 Black Vinyl Hand Grip 48 11978 96 1 Rear Tongue Half 49 11969 96 1 Front Tongue Half 50 5433 1 Right Winch assembly 51 5432 1 Left Winch Assembly 52 02772 2 1 4 20UNC Nylon Lock Nut 53 04176 2 1 4 20UNC
11. 5762 Optional Deflector 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 091 09 RANNAN 30 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 Kar Kaddy 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 wi
12. 7 06 RD20010 Rev 6 Dethmers Manufacturing Company Kar Katdy CDSS WA oee eeo L 1 gt ee6e mS a eee 2 Se ee S 2 WA a o oe gOS 5 N gt P 5 Ee ASSEMBLY CALIBRATION OPERATION REPLACEMENT PARTS R 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 Morna aaa sana aaa setae e tale aes aa a A a aha aka cen loess Waa NE aa Na a Page 2 Safety YOU can Live With cc cccseeeecceceeeeecceeaeeseeseceeeeesessaeeassseeceeeeeseseuaaaaseeeeeeeeeessssaaaesesseeeeeeeees Page 3 7 Decak LOcCaUON sasak
13. AINTENANCE 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 Wheel This tow dolly comes equipped with chrome wheels To maintain a high gloss to the chrome clean and wax with a soft cloth regularly Do not use an abrasive to clean chrome this will cause scratches and this will lead to rust 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 on an 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 Tire too small This is not as obvious the basket will fit down over the tire ver
14. After bleeding is complete make sure master cylinder reservoir is filled and filler cap is securely in place Coupler Repair Kit Please order replacement parts by PART NO and DESCRIPTION After the bleeding operation has been completed apply pres sure to the system and check the whole brake system for leaks 21 10 SELF ADJUSTING BRAKE CLUSTER and DRUM PARTS BREAKDOWN W SY se BRAKE CLUSTER PARTS LIST REF PART NO N QTY DESCRIPTION B24429M Left Hand Cluster shown above 0 Right Hand Cluster SB23871 Back Plate Assembly SB9254 Cover Plate Adjusting Hole SB10954 Brake Shoe Kit includes 2 Primary amp 2 Secondary 04305 5 16 18UNC Gr5 x 1 2 Hex Hd Bolt 05424 5 16 External Tooth Washer SB9776 Wheel Cylinder Assembly Right SB9777 Wheel Cylinder Assembly Left 05431 Bleeder replacement SB9783 Push Rod SB24047 Adjusting Screw Assembly R for LEFT cluster SB24048 Adjusting Screw Assembly L for RIGHT cluster SB10958 Spring Shoe SB10961 95 Shoe Guide SB23937 Cable SB23936 Cable Guide SB23724 Spring Adjusting Screw 05415 95 Lever Right 05414 95 Lever Left SB10959 Pin Shoe Hold Down SB9789 Cup Shoe Hold Down 05983 Spring Shoe Hold Down 03380 Spring SB15845 1 Wheel Cylinder Repair Kit includes spring cup and boot 5840929 2 SB40929 10 Brake Drum Please order replacement parts by PART NO and DESCRIPTION Brake shoe kit can be ordered
15. Bolt Circle 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 BEN KK6TC Optional Spare Tire Cover Please order replacement parts by PART NO amp DESCRIPTION OPTIONAL TOOL BOX PARTS LIST Tool Box Small Hair Pin 2 3 8 16UNC x 3 Square U Bolt Please order replacement parts by PART NO and DESCRIPTION All options may not mount on tow dolly simultaneously 29 OPTIONAL LIGHT BAR PARTS BREAKDOWN gt LIGHT BAR PARTS LIST REF PART NO NO QTY DESCRIPTION Nylon Security Strap with hooks amp tightener 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 COLOR CODE FOR WIRING HARNESS WHITE round Hex Head Bolt BROWN Tail Lights License Plate Lights 3 4 arge Rea Lens Light Cluster Bar amp Clearance Lights YELLOW Left Turn and Stop Small Red Lens GREEN Right Turn and Stop aaa SO gt eae Clear Lens Please order replacement parts by PART NO and DESCRIPTION OPTIONAL DEFLECTOR OPTIONAL DEFLECTOR PARTS LIST REF PART NO NO 07 DESCRIPTION
16. Stainless Steel Winch Pawl Left Ratchet Pawl Arm 00214 01076 01864 02772 05337 00004 02243 05444 05449 05450 03572 95 Ol e O ao 03573 95 03574 95 03575 95 03576 95 Right Ratchet Pawl Arm Ratchet Handle Left Outer Ratchet Gear Right Outer Ratchet Gear 03666 03668 03578 01998 02002 5 16 x 1 1 4 Roll Pin 1 x 18 Gauge Machine Washer 5 16 18 UNC x 1 2 Socket Head Shoulder Bolt 5 16 Flat Washer Stainless Steel 1 4 Flat Washer Stainless Steel DO DO k ee e o d l KK ee REF PART NO NO QTY DESCRIPTION 5511 TitBedtatchkit 1 1 5 16 18 UNC x 4 Eye Bolt 03379 95 03435 03499 03382 95 03574 95 5 16 18 UNC x 2 1 2 Hex Head Bolt Gr 5 5 16 Flatwasher 5 16 18 UNC Hex Nut Latch Block Roll Pin 5 16 x 2 1 4 Latch Spring Stainless Steel Latch Handle Pivot Bushing Latch Handle SS 03381 95 03433 02802 00967 00085 00059 02178 Latch Catch Latch Cable 5 16 18 UNC Nylon Insert Locknut 1 2 13UNC x 1 1 4 lg Hex Head Bolt gr 5 1 2 Flatwasher 3 8 Flat Washer 1 2 13UNC Nylon Insert Locknut 05449 Spacer Bushing Stainless Steel 05444 3 8 16 UNC x 3 4 Epoxied Hex Bolt Gr 5 Please order replacement parts by PART NO and DESCRIPTION opi KIT 5511 TILT BED LATCH ASSEMBLY ed i N A Items inc
17. T TRY IT LIGHTING AND MARKING It is the responsibility of owner to know lighting and marking requirements of local highway authorities and to install and maintain equipment to provide compliance with regulations Light bar kits are available from your dealer or from manufacturer A TIRE SAFETY e Failure to follow proper procedures when mounting a tire on a rim can produce an explosion which may result in serious injury or death e Do not attempt to mount a tire unless you have proper equipment and experience to do the job e Inflating or servicing tires can be dangerous Whenever possible trained personnel should be called to service and or mount tires e KK460SS tires must be inflated to recommended P S I See decal on KK460SS for correct pressure e Always order and install tires and wheels with appropriate type and load capacity to meet or exceed gross weight of unit A SAFETY SIGN CARE e Keep safety signs clean and legible at all times e Replace safety signs that are missing or have become illegible 4 Replacement parts that displayed a safety sign should also display current sign Safety signs are available from your distributor dealer parts department or factory How to install safety signs Be sure installation surface is clean and dry Decide on exact position before you remove backing paper Remove smallest portion of split backing paper Align decal over specified area and carefully press smal
18. a GS Ajaa 4 04 e a e Page 8 1 ag akak Mer Nga ab Jaa a E aa a Bg aaa aka anan ene acne atan Page 9 TOongusand Ramp ASSenbIy as isian aaa aana Tan SEN TTNG ates eaaie GAK a BN a ER NG a aa Page 10 PONGSEASSS MOY kani aia aaa ain saa aaa aan a ag ga bag aa an bed aba kad aa a a a ga aa naa a aa ah aka aa Page 11 MALING IAQKAIN kasasar a aaa a nag a nang anga ag aa ag kian ga Tabanan anan gas Page 12 Testing HJN aia naga aa ag aan aan ga aa gg a aa NAYA Da aaa a fone JANG TE aust aa KA aa aa a baa ata a aaa aaa a Page 12 OMICS Fold asana aa aa AN a AE EN a EN GAN a E A aa aa a an EEN aga a aa EE aaa a EN a a a aaa a a aaa a a gaga Page 13 ONG AN DS aaa aaa aa a na aaa a a ap A Sa ties cue ga AKA E 22022 aba a ag a aa aa aaa Page 14 15 Loading Angle Clearance Guide ss asas aaa a tours aaa e aaa a a aaa aba aa a daana a daana Bag a A agan Page 15 Safety Maintenance 4 Important Loading Instructions Page 16 EOAGING NS NONG raaa a ani gana baa a ba ENG a ANG EA Aa GEN a aaa Sa aos DANG aa NG Bag a aaa Ba a aa a an Pages 17 19 Toe ln Adjustment 4 4 4 4 4 44 Page 20 DA91 Brake Actuator Parts Breakdown and List Page 21 10 Self Adjusting Br
19. 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 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 Note the use of the signal words DANGER WARNING and CAUTION with the safety messages The appropriate signal word for each has been selected using the following guidelines DANGER Indicates an imminently hazardous situation that if not avoided will result in death or serious injury WARNING Indicates a potentially hazardous situation that if not avoided could result in death or serious injury 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 P O Box 189 4010 320th Street Boyden IA 4 ph 712 725 2311 Toll F
20. ake Cluster Parts Breakdown and List Page 22 Brakes Line Parts Breakdown and 8 Page 23 Kar Kaddy Breakdown Parts Assembly Instructions Pages 24 25 Winch and Tilt Bed Parts Breakdown Page 26 Ramp Latch and License Plate Bracket Parts Breakdown Page 27 Fender Pans Bre akGQOw in sa gua anan GA lan GA A Ba aa aa a a a banga a a a a a a a aa a aaa aa Page 28 Winch Tool Box amp Spare Tire w Mounting Bracket optional Parts Breakdown and List Page 29 Deflector amp Light Bar optional Parts Breakdown and List Page30 Product WV aa y rrsan AE E Page 31 Waranty 1120212110 saa aaa aaa a a a a Page 33 34 Reporting Safety Defects If you believe that your vehicle has a defect To contact NHTSA you may either call the which could cause a crash or could cause injury or Auto Safety Hotline toll free at death you should immediately inform the National 1 800 424 9393 or 366 0129 in Highway Traffic Safety Administration NHTSA in Washington D C area or write to addition to notifying Dethmers Manufacturing Com pany DEMCO NHTSA 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
21. ake Line Clip Left Brake Cluster Right Brake Cluster 10 Brake Drum Retainer Washer Rubber Grommet Spring Return System Please order replacement parts by PART NO and DESCRIPTION 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 Only use pressure bleeding equipment and follow the manufacturer s instruction in bleeding the system 9 7 s KK460SS PARTS BREAKDOWN 24 REF PART REF PART NO NO QTY DESCRIPTION NO NO QTY DESCRIPTION 1 03528 Tie down Strap assembly Black 11 1 01731 4 1 1 4 Dust Cap 2 5737 Right Fender Assembly with Lights 12 05587 2 1 1 D x 14 GA Narrow Rim Machine Washer 3 5736 Left Fender Assembly with Lights 13 11566 80 1 Right Drop Axle Mount 4 04424 95 Fender Backing Plate 14 11550 80 1 Left Drop Axle Mount 5 00914 3 8 16UNC x 1 1 2 Hex Head Bolt gr 5 15 1 11551 2 King Pin Retainer Bolt 6 02592 3 8 16UNC Nylon Lock Nut 16 03724 2 7 16 20UNF Center Punched Nut 7 04165 80 Right Wheel Carrier 17 02377 8 7 16 20UNF x 1 1 2 Epoxy Bolt gr 8 8 04166 80 Left Wheel Carrier 18 8 8 7 16 20UNF Nylon Lock Nut 9 01732 1 1 D x 1 1 4 0 D x 1 1 2 lg Bushing brnz 19 1 02178 18 1 2 13UNC Nylon Lock Nut 0 King Pin 1 x 6 1 2 20 02579 95 2 Pivot Bushing 2
22. 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 towing suitability with the drive shaft connected ALL VEHICLES MOUNTED ON THE KAR KADDY MUST BE WITH THE FRONT OF THE VEHICLE FACING FORWARD ASAFETY 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 there after to ensure they are tight and not rubbing or fraying KAR KADDY TOE IN ADJUSTMENT 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 Brake Drum 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 me
23. ardware with same grade bolt NOTE Unless otherwise specified high strength Grade 5 hex bolts are used throughout assembly of equipment Bolt Torque for Standard bolts GRADE 2 GRADE 5 GRADE 8 A lb ft N m lb ft N m lb ft Nam Torque Specifications A Torque Lug Nuts to 120 FT LBS OWN oo SS 1 2 2 3 CLASS 8 8 CLASS9 8 CLASS 10 9 A lb ft N m lb ft N m lb ft N m Torque figures indicated 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 GRADE or CLASS value for bolts and capscrews are identified by their head markings GRADE 2 GRADE 5 GRADE 8 ap e CO gs z I CLASS 8 8 CLASS 9 8 CLASS 10 9 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 matchin
24. asurement 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 20 TOE IN ADJUSTMENT Puta mark 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 MODEL DA91 ACTUATOR PARTS BREAKDOWN oy 5398 Master Cylinder Repair Kit 2 5696 Coupler Repair Kit Model 91 ACTUATOR PARTS LIST REF NO PARTNO QTY 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 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 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 ri
25. ccept any liability for injury or warranty e A fire extinguisher and first aid kit should be kept readily accessible while performing maintenance on this KK460SS PINCH POINT REV 0 DD21018 A DD21018 4 6 To prevent serious injury or death Make sure tongue is in forward locked position with locking pin and retainer clip properly installed before hooking up or loading REV 0 DD21019 B DD21019 QTY 1 F RD21008 QTY 2 PULL amp LIFT TO FOLD RAMP Rev 0 DD21020 C DD21020 QTY 2 Decal Location D DD21017 QTY 4 Loading Towed Vehicle e WINCH OPERATING INSTRUCTIONS Remove winch lock pins A from strap winches on front of tow dolly Release winch Grasp handle B squeeze trigger C push down and pull all excess strap from winch Lay tire strap to outside of tow dolly 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 REV1 DD21016 DD21016 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 h
26. er 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 31 to neglect negligence misuse accident or operated in any way contrary to the operating and maintenance instructions as speci fied 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 perfor mance 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 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 or galvanizing 3 paint or galvanizing 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 t
27. g the colors Do not cross colors when making this connection Make sure that the two pigtails for the license plate bracket are out Using the open end of a 9 16 wrench to support the back of the male coupler as shown below push drip free quick couplers together Factory setup units will not havequick couplers 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 lbs 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 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 Connecting Drip Free Quick Coupler brake couplers Not needed for factory setup units Female Coupler 10 11 of each bracing strut to the trailer frame as shown using 1 2 x 1 1 2 grade 5 bolt 6 flatwasher 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 and nut plate 14 Torque the 1 2 x 1 1 2 bolt with the pivot bushing to 75 ft Ibs Torque the two 5 8 x 1 1 4 epoxied hex head bolts to 100 ft Ibs On the main unit p
28. he 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 ex pense 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 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
29. ing vehicle from operators seat only e As a precaution recheck hardware on KK460SS every 50 miles and correct all problems Follow maintenance safety procedures FOLLOWING OPERATION e Following operation or when unhitching stop towing vehicle set parking brake shut off engine and remove ignition key e Store KK460SS in area away from human activity e Do not permit children to play on or around stored KK460SS e Make sure parked KK460SS is on hard level surface e Wheel chocks may be needed to prevent unit from rolling HIGHWAY AND TRANSPORT OPERATIONS e Adopt safe driving practices Always drive at safe speed relative to local conditions and ensure that your speed is low enough for an emergency stop Do not exceed 55 M P H Reduce speed prior to turns to avoid risk of overturning Always keep towing vehicle in gear to provide engine braking when going downhill Do not coast Do not drink and drive e Comply with state and local laws governing highway safety 6 e Local laws should be checked for all highway lighting and marking requirements e Plan your route to avoid heavy traffic e Bea safe and courteous driver Always yield to oncoming traffic in all situations including narrow bridges intersections etc e Watch for obstructions overhead and to both sides while transporting e Operate with maximum visibility at all times Make allowances for increased length and weight of KK460SS when making tu
30. l portion with exposed sticky backing in place Slowly peel back remaining paper and carefully smooth remaining portion of decal into place Small air pockets can be pierced with a pin and smoothed out using piece of decal backing paper BEFORE OPERATION Carefully study and understand this manual Keep wheel and lug nuts tightened to specified torque Assure tires are inflated evenly Give unit a visual inspection for any loose bolts worn parts or cracked welds and make necessary repairs Follow maintenance safety instructions included in this manual Be sure there are no tools lying on or in KK460SS Do not use unit until you are sure that area is clear especially around children and animals Don t hurry learning process or take unit for granted Ease into it and become familiar with your new KK460SS Practice operation of your KK460SS and its attachments Completely familiarize yourself and other operators with its operation before using Make sure that brakes are evenly adjusted if equipped with brakes Securely attach to towing vehicle Use an appropriately sized and rated hitch ball and attach safety chains Do not allow anyone to stand between tongue or hitch and towing vehicle when backing up to unit Make sure tow rating on vehicle is high enough for what it is towing A DURING OPERATION SAFETY CHAIN Always follow state and local regulations regarding safety chains and auxiliary lighting when towing Be sure to check with
31. local law enforcement agencies for your own particular regulations Only safety chains not elastic or nylon plastic tow straps should be used to retain connection between towing vehicle and towed unit in event of separation Do not load towed vehicle with cargo Towed vehicles exceeding weight limits will overload KK460SS and may cause serious injury and damage e Criss cross safety chains under tongue secure to mounting loops on towing vehicle e Secure emergency brake actuator cable to mounting loop on towing vehicle e Beware of bystanders PARTICULARLY CHILDREN Always look around to make sure it is safe to start engine of towing vehicle or move unit This is particularly important with higher noise levels as you may not hear people shouting e NO PASSENGERS ALLOWED Do not carry passengers anywhere on or in towed unit e When halting operation even periodically set towing vehicle parking brake shut off engine and remove ignition key e Be extra careful on inclines e MANEUVER TOWING VEHICLE AT SAFE SPEEDS Do not exceed 55 M P H e Avoid overhead wires or other obstacles Contact with overhead lines could cause serious injury or death e Avoid loose gravel rocks and holes they can be dangerous for unit operation or movement e Allow for unit length when making turns e Do not work under raised components or attachments unless securely positioned and blocked e Keep all bystanders and pets clear of work area e Operate tow
32. luded in 5511 kit 26 RAMP LATCH ASSEMBLY REF PART NO NO QTY DESCRIPTION gi ere etre ni AA NA 11622 95 5 16 18 UNC Latch Rod 00007 00004 5 16 18 UNC Hex Nut 5 16 Flatwasher 3 8 Flatwasher Latch Block Threaded Bushing Latch Spring Stainless Steel 1 2 Narrow Machine Washer Handle Knob 00059 11570 95 11623 95 03499 02384 11621 i st st 0 oo Ni REON Please order replacement parts by PART NO and DESCRIPTION LICENSE PLATE BRACKET ASSEMBLY REF PART NO NO QTY DESCRIPTION Mi 5740 Ei 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 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 02205 10 NC Nylon Lock Nut 00214 1 4 20UNC Flat Washer 11687 3 Cluster Light Bar Only No Lights 11688 Red LED Lighi 11655 3 Cluster LED Wiring Harness 11616 Gromment 5 8 OD x 3 8 x 1 8 Thick 5765 3 Cluster LED Light Assembly Included Please order replacement parts by PART NO and DESCRIPTION NN 5 6 7 8 9 k GU NNl 10 License Plate Mount z and Light Cluster 27 Fender Assembly
33. n straight alignment Tow dolly must be completely and properly hooked up to the towing vehicle Step 4 Before loading and unloading Over all width of towed vehicle must not exceed 76 max outside to outside 42 min inside to inside 78 max body width 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 Ifthe 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 5 Grasp bed release handle on tongue and pull toward coupler This releases the tilt bed to permit loading Step 8 Place one tie down strap over each tire and secure hooks to rods located at the rear of each wheel platform The short side of the hook must face the rear of the Kar Kaddy a Step 6 With someone safely guiding you slowly drive ve hicle onto platform FRONT
34. ng 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 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 bleeder 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 WW NNa RAP RS SS N 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
35. onnect BROWN wire to tail light wire on and off simultaneously with each application 1 Turn left turn signal on Left turn light of Kar Kaddy and towing vehicle should flash simultaneously If turn signal 2 light of the trailer function opposite to those of the towing l vehicle itis probable that the YELLOW Driver side and supplied GREEN Passenger side wires have been reversed Check the plug connection under the tongue of the Kar 3 Ci Kaddy to make sure wire colors are not crossed at that wire point If wires are crossed change them to match color for color 4 5 Whit Aas COLOR CODE FOR WIRING HARNESS WHITE VERY IMPORTANT connect WHITE wire to frame body of towing vehicle This isthe 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 BROWN Tail Lights License Plate Lights Light Cluster Bar amp Clearance Lights YELLOW Left Turn and Stoo GREEN Right Turn and Stop 12 Tongue folding and storage NOTE Tow Dolly must be empty and unhooked to perform any and all of these steps Do not attempt while tow dolly is loaded or hooked up Pull retainer clip from bottom of tongue locking pin Lift locking pin out of tongue
36. ree 1 800 543 3626 Fax 712 725 2380 or 1 800 845 6420 http www demco products com A REMEMBER Your best assurance against accidents is a careful and responsible operator If there is any portion of this manual or method of operation you do not understand contact your local authorized dealer or manufacturer SAFETY YOU CAN LIVE WITH IT A EQUIPMENT SAFETY GUIDELINES Every year many accidents occur which could have been avoided by a few seconds of thought and a more careful approach to handling equipment You the operator can avoid many accidents by observing the following precautions in this section To avoid personal injury study the following precautions and insist those working with you or you yourself follow them Replace any caution warning danger or instruction safety decal that is not readable or is missing Location of such decals is indicated in this booklet Do not attempt to operate this KK460SS under the influence of alcohol or drugs Review the safety instructions with all users Operator should be a responsible adult DO NOT ALLOW PERSONS TO OPERATE OR ASSEMBLE THIS UNIT UNTIL THEY HAVE DEVELOPED A THOROUGH UNDERSTANDING OF THE SAFETY PRECAUTIONS AND HOW IT WORKS Do not paint over remove or deface any safety signs or warning decals on your KK460SS Observe all safety signs and practice the instructions on them Never exceed the limits of a Kar Kaddy SS If its ability to do a job safely is in question DON
37. rns and stopping PERFORMING MAINTENANCE e Good maintenance is your responsibility Poor maintenance is an invitation to trouble e Make sure there is plenty of ventilation Never operate engine of towing vehicle in a closed building Exhaust fumes may cause asphyxiation e Before working on KK460SS stop towing vehicle set parking brake turn off engine and remove ignition key e Always block wheels and never use a jack as sole support e Always use proper tools or equipment for job at hand e Use extreme caution when making adjustments e Follow torque chart in this manual when tightening bolts and nuts e Openings in skin and minor cuts are susceptible to infection from brake fluid Without immediate medical treatment serious infection and reactions can occur e After servicing be sure all tools parts and service equipment are removed e Do not allow grease or oil to build up on any step or platform e When replacing bolts refer to owners manual for proper size and grade e Refer to bolt torque chart for head identification marking e Where replacement parts are necessary for periodic maintenance and servicing genuine factory replacement parts must be used to restore your KK460SS to original specifications Manufacturer will not claim responsibility for use of unapproved parts and or accessories or other damages as a result of their use e If KK460SS has been altered in any way from original design manufacturer does not a
38. rom rear 2 Cutnylon wire tie from wiring to brake hose on main frame of fender lip install 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 11 Green Wiring Diagram PARTS LIST DESCRIPTION REF NO PART NO QTY 11590 11591 01863 1 2 3 Please order replacement parts by PART NO and DESCRIPTION TESTING LIGHTS BEFORE USE Make sure that the WHITE ground wire is connected to the frame of both the Kar Kaddy and 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 1 Tongue Wiring Harness 1 Main Frame Wiring Harness 1 Rubber Grommet not shown WIRING OF THE TOWING VEHICLE Connect wiring to towing vehicle keeping in mind the color code indicated below 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 the wire splicer 01883 Connect GREEN wire to the right turn signal and stop C
39. thout 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 permanently 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 dealer 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 manufactur
40. til you hear or see retainer handles snap into their locked positions Check to make sure they all fully seated Make sure that all pins and locking devices are double checked before returning this unit to service Loading Angle Clearance Guide NOTE User s responsibility for checking clearance IMPORTANT Using this guideline will reduce the chance of the towed vehicles 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 Y i Example If Y measures 6 3 1 2 x6 21 X must measure less than 21 A WARNING FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN LOSS OF TOWING VEHICLE CONTROL SEPARATION OF THE TOW DOLLY FROM THE TOWING VEHICLE SEPARATION OF THE TOWED VEHICLE FROM THE TOW DOLLY CAUSING SEVERE PERSONAL INJURY DEATH OR PROPERTY DAMAGE 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 20 777 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
41. ull ramp latch 11 out and up in unlatched position Use four 1 2 x 1 1 2 bolts 6 1 2 flat washers 7 and yellow plated bushings 12 and place in the front slotted hole and the rear slotted hole on both sides of ramp 13 Use four 1 2 nylon lock nuts 9 and snug these bolts so they can slide up and down in slot Place ramp 13 in main frame 1 Front bolts and bushings go in front open slot of ramp mount Lift ramp up and push forward until rear bolts and bushings go into rear half slot Engage Ramp latch 11 and move ramp around so latch can engage through ramp With the use of two clamps secure ramp to main frame Install the remaining 1 2 x 1 1 2 bolts 6 flatwashers 7 yellow bushings 12 and nylon lock nuts 9 into the remaining slotted holes Tighten all six bolts Pull and lift ramp latch 11 and pull ramp back and fold up If ramp is too tight when pulling back reclamp ramp as in previous step and loosen bolts so ramp lowers away from main frame Tighten bolts and retry 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 F
42. y well the problems cannot be readily seen You must tighten the straps down solid and then check on the inside 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 ball coupler to 2 5 000 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 1 1 4 ai ry 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 17 towed vehicle make sure platform and towed vehicle are i
Download Pdf Manuals
Related Search