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Table of contents for the manual
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Page 1
1 7-06 RD20010,Rev 6[...]
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Page 2
2 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 INFORMA TION 1. Unless otherwise specified, high-strength (grade 5) (3 radial-line head markings) hex head bolts are used throughout assembly of this piece of equip- ment. 2. Whenever the [...]
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Page 3
3 SAFETY T AKE NO TE! THIS SAFETY ALER T SYMBOL FOUND THR OUGHOUT THIS MANUAL IS USED T O CALL Y OUR A TTENTION T O INSTR UCTIONS INV O L VING Y OUR PERSONAL SAFETY AND THE SAFETY OF O THERS. F AILURE T O FOLLO W THESE INSTRUCTIONS CAN RESUL T IN INJUR Y OR DEA TH. THIS SYMBOL MEANS A TTENTION BECOME ALERT Y OUR SAFETY IS INV OL VED! SIGNAL W ORDS [...]
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Page 4
4 SAFETY SIGN CARE • Keep safety signs clean and legible at all times. • Replace safety signs that are missing or have become illegible. TIRE SAFETY • Failure to follow proper procedures when mounting a tire on a rim can produce an explosion which may result in serious injury or death. • Do not attempt to mount a tire unless you have proper[...]
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Page 5
5 BEFORE OPERA TION: • 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 [...]
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Page 6
6 FOLLO WING OPERA TION • Following operation, or when unhitching, stop towing vehicle, set parking brake, shut off engine and remove ignition key . • Store KK460SS in area away from human activity. • Do not permit children to play on or around stored KK460SS. • Make sure parked KK460SS is on hard, level surface. • Wheel chocks may be nee[...]
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Page 7
7 PERFORMING MAINTENANCE • Good maintenance is your responsibility . Poor maintenance is an in vitation to trouble . • Make sure there is plenty of v entilation. Nev er operate engine of towing v ehicle in a closed building. Exhaust fumes may cause asph yxiation. • Before wo rking on KK460SS, stop towing vehicle , set parking brake, turn off [...]
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Page 8
8 T o 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. WARNING REV 0 DD21019 PULL & LIFT TO FOLD RAMP Rev 0 DD21020 Read following information before hooking up, loading, using, unloading or unhooking Kar Kaddy to prevent property [...]
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Page 9
9 BOL T T ORQUE T ORQUE D A T A FOR ST AND ARD NUTS, BOL TS, AND CAPSCREWS. Tighten all bolts to torques specified in char t unless otherwise noted. Check tightness of bolts periodically , using bolt char t as guide . Replace hardware with same grade bolt. NOTE: Unless otherwise specified, high-strength Grade 5 hex bolts are used throughout assembl[...]
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Page 10
10 Tongue and Ramp Assembly Instructions 1. Place the main frame (#1) on blocks or some other sturdy support so that the frame rests approximately 8" - 10" off the ground. 2. 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 fra[...]
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Page 11
11 1. Install fender with fender backup plate (#1) and three 3/8” x 1-1/2” bolts (#2). Put 3/8” nylon lock nuts (#3) inside of fender and tighten. 2. Cut nylon wire tie from wiring to brake hose on main frame, (used for shipping purposes only). Fish the three wires from main unit through the hole in fender. Fender Assembly Instructions 3. On [...]
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Page 12
12 WIRING OF THE TOWING VEHICLE Connect wiring to towing vehicle, keeping in mind the color code indicated below. 1. Make certain towing vehicle lights are "OFF" . 2. Connect YELLOW wire to left turn signal and stop wire in the left rear of towing vehicle with the wire splicer (01883) supplied. 3. Connect GREEN wire to the right turn sign[...]
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Page 13
13 T ongue folding and storage 1. Pull retainer clip from bottom of tongue locking pin. Lift locking pin out of tongue pivot. NOTE: T ow Dolly m ust be empty and unhooked to perform any and all of these steps. Do not attempt while tow dolly is loaded or hooked up. 2. With tongue wheel jack turned to its lowest position, push/pull tongue to the left[...]
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Page 14
14 Folding Ramp Lock 1. Locate ramp locks at inside center of ramps . 2. Pull ramp lock straight out as f ar as it will go . 3. Lift ramp lock up as f ar as it will go and allow lock to slide in until it stops. 4. If lock has been pulled and lifted properly the ramp lock will e xtend out from it’ s holder . This will mean that the ramp is unlocke[...]
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Page 15
15 1. Pull ramp back as f ar as it will go . Bolt must be past notch before attempting the ne xt step . 2. Lift ramp until it is past center and resting on it stops. Folding Ramp IMPORT ANT: When taking this tow dolly out of storage it is v er y impor- tant to check all pins and retainers f or damage. If damage is f ound replace. Do not use damaged[...]
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Page 16
16 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./lbs. Lug Nuts - 120 ft./lbs. Check Lug Nut tension after the first[...]
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Page 17
17 Step 1. Secure ball coupler to 2" (5,000 lb. capacity) towing vehicle ball only. Make sure that the hitch and the hitch ball are in good condition and not rusted, loose or stripped. Recommended ball height is 18" to the top of the ball. Make sure hitch is locked down and secured with safety clip. Criss-cross safety chains under tongue [...]
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Page 18
18 Step 5. Grasp bed release handle on tongue and pull toward coupler. This releases the tilt bed to permit loading. 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 veh[...]
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Page 19
19 • 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 [...]
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Page 20
20 12" 12" C L BACK MEASUREMENT FRONT MEASUREMENT (1/32" to 1/16" less than back measurement) 18" Ground 1. Put a mark on each side of the locking clamp on the tie rod. 2. Loosen the locking nuts on each end of the tie rod and then the six bolts on the tie rod locking clamp. 3. Turn the tie rod whichever direction is needed[...]
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Page 21
21 MODEL D A91 A CTU A T OR P ARTS BREAKDO WN 5398 Master Cylinder Repair Kit (gasket included) 2 ” Lever Lock Coupler RATED AT 6000# not included REF. NO. PART NO. QTY. DESCRIPTION Model 91 ACTUATOR PARTS LIST 1. 09417 1 6000# 2" Lever Lock Coupler (zinc plated) 2. 01896 3 1/2"-13UNC x 4" Hex Head Bolt (gr.5) 3. 02178 3 1/2"-[...]
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Page 22
22 REF. PART NO. NO. QTY. DESCRIPTION BRAKE CLUSTER PARTS LIST - SB24429M - Left Hand Cluster (shown above) - SB24428M - Right Hand Cluster 1. SB23871 1 Back Plate Assembly 2. SB9254 2 Cover Plate - Adjusting Hole 3. SB10954 1 Brake Shoe Kit (includes 2 P rimary & 2 S econdary) 4. 04305 2 5/16"-18UNC-Gr5 x 1/2" Hex Hd Bolt 5. 05424 2 [...]
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Page 23
23 SURGE BRAKES P ARTS BREAKDO WN Please order replacement parts by PART NO. and DESCRIPTION. SURGE BRAKES FIELD SETUP PARTS LIST 1. 11968 1 6" Brake Line 2. 02034 1 45” Brake Hose 3. SB512 1 12” Brake Line 4. 05679 2 Brake Fitting 5. 11617 1 Male Coupler 6. 11618 1 Female Coupler 7. 11643 1 7" Brake Hose Swival Male/Solid Male 8. SB7[...]
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Page 24
24 KK460SS P ARTS BREAKDO WN 2 4 5 6 7 9 10 11 12 13 19 20 21 22 22 21 20 23 23 24 24 25 26 26 27 28 29 32 32 6 26 36 37 60 38 39 40 41 43 41 45 46 46 47 48 49 50 51 52 52 55 54 53 53 56 56 57 58 60 59 58 19 61 62 63 64 65 71 37 21 21 19 75 1 76[...]
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Page 25
25 1. 03528 2 Tie-down Strap assembly, Black 2. 5737 1 Right Fender Assembly with Lights 3. 5736 1 Left Fender Assembly with Lights 4. 04424-95 2 Fender Backing Plate 5. 00914 6 3/8”-16UNC x 1-1/2” Hex Head Bolt (gr.5) 6. 02592 18 3/8”-16UNC Nylon Lock Nut 7. 04165-80 1 Right Wheel Carrier 8. 04166-80 1 Left Wheel Carrier 9. 01732 4 1"I.[...]
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Page 26
26 KIT #5511 TILT-BED LATCH ASSEMBLY 5511 - Tilt-Bed Latch Kit 1*. 03434 1 5/16"-18 UNC x 4" Eye Bolt 2*. 04221 1 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 - Stain[...]
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Page 27
27 (not available) 5740 License Plate Mount and Light Cluster 5740 - License Plate Bracket and Light Assembly 1. 04505-95 1 License Plate and Light Cluster Bracket 2. 04176 2 1/4”-20UNC X 3/4” Carriage Bolt 3. 02214 2 #10 NC X 1/2” Slotted Truss Head Screw 4. 02163 1 Square License Plate Light w/Washer and Nut - 02164 - Clear License Plate Li[...]
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Page 28
28 Fender Assembly 1 2 2 2 2 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 REF. NO. PART NO. QTY. DESCRIPTION PARTS LIST 5736 - Left Fender Assembly 5737 - Right Fender Assembly 1. 01883 2 Wire Splicer 2. 04425 5 Tinnerman U-clamp 3. 04515 1 17-1/2” Wire Loom 4. 04643 2 9/16” x 5/8” Pop Rivet 5. 05443 1 Nylon Cable Hanger 6. 05447 1 4” Light Grommet[...]
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Page 29
29 OPTIONAL SP ARE TIRE and MOUNT P AR TS BREAKDO WN 3. 02193-30 1 Spare Tire Bracket 4. 02917 1 Stud Bolt (12mm x 1.5) 5. 02933 2 Wheel Nut (12mm) Chrome 6. 02759 2 3/8"-16UNC Square U-Bolt 7. 00059 2 3/8" Flatwasher 8. 02592 4 3/8"-16UNC Nylon Insert Locknut RKSTM 1 Spare Tire Mounting Bracket 1. N/A 1 ST205/75R 14"x"C&qu[...]
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Page 30
30 OPTIONAL LIGHT B AR P AR TS BREAKDO WN 1 11 11 13 13 1 2 8 9 8 12 1 7 9 9 8 6 8 9 1 14 15 16 10 3 4 4 5 COLOR CODE FOR WIRING HARNESS WHITE Ground BROWN Tail Lights, License Plate Lights, Light Cluster Bar & Clearance Lights YELLOW Left Turn and Stop GREEN Right Turn and Stop RKLB Kar Kaddy Light Bar (complete) REF. PART NO. NO. QTY. DESCRIP[...]
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Page 31
31 1. 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[...]
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Page 32
32 NO TES:[...]
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Page 33
33 How satisfied are you with our product? ❍❍ ❍ ❍ How satisfied are you with the dealership/distributor sales staff? ❍❍ ❍ ❍ Dealer/Distributor Name City State How satisfied are you with the compan y sales staff? ❍❍ ❍ ❍ How satisfied are you with the deliver y? ❍❍ ❍ ❍ Did you ha ve any contact with a Demco Representa [...]
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Page 34
34 P ostage Dethmers Manufacturing Company 4010 320th Street, Box 189 Boyden, Iowa 51234[...]
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35 NO TES:[...]
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Page 36
36 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[...]