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Demco KK360 manual

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Table of contents for the manual

  • Page 1

    Page 1 OPERA T ORS MANUAL KK260 (8  WIDE ) & KK360 (8-1/2  WIDE ) KAR-KADDY DOING OUR BEST T O PROVIDE YOU THE BEST DEMCO  Dethmers Mfg. Co.  4010 320th St.  P .O. Box 189  Boyden, IA 51234 PH: (712) 725-2311  Toll Free: 1-800-543-3626  FAX: 1-800-845-6420 www.demco-products.com ASSEMBLY CALIBRATION OPERATION REPLACEMENT[...]

  • Page 2

    Page 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[...]

  • Page 3

    Page 3 BOL T TORQUE TORQUE DA T A FOR ST ANDARD NUTS, BOL TS, AND CAPSCREWS. T ighten 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. NOTE: Unless otherwise specified, high-strength Grade 5 hex bolts are used throughout assembly[...]

  • Page 4

    Page 4 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 - 75 to 80 ft./lbs. Check Lug Nut tension after [...]

  • Page 5

    Page 5 TESTING LIGHTS BEFORE USE 1. Check that the WHITE (ground) wire of the wiring harness is connected to the Kar Kaddy frame and the WHITE (ground) wire is connected to the frame of the towing vehicle. 2. With headlights in "ON" position, the tail lights, the light cluster bar, the license plate light, and the clearance lights should [...]

  • Page 6

    Page 6 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[...]

  • Page 7

    Page 7  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 th[...]

  • Page 8

    Page 8 Right Fender 1 2 45 45 34 35 43 37 38 42 48 49 49 40 41 39 44 46 47 53 86 46 47 52 52 10 100 54 54 55 55 56 56 57 58 35 58 51 42 36 66 82 2 5 81 80 78 51 89 90 90 103 104 33 109 110 111 112 113 114 108 107 106 105 100 99 98 *69 *69 *69 *69 72 75 63 62 65 75 46 88 61 60 KK260 (8'wide) and KK360 (8-1/2' wide) P ARTS BREAKDOWN 50 5217[...]

  • Page 9

    Page 9 KK6LBAS License Plate Mount and Light Cluster (not available) 25 25 24 26 26 27 29 30 30 31 31 32 84 27 27 78 79 77 75 76 51 74 55 42 85 73 130 *70 *70 *70 *70 104 109 115 103 64 68 67 93 94 95 102 Left Fender Left Winch Shown 15 14 13 10 9 4 12 19 20 20 22 16 18 17 23 21 7 6 12 11 8 3 5 1. 5432 1 Left Ratchet Winch Assembly (Plated) 2. 5433[...]

  • Page 10

    Page 10 REF. PART NO. NO. QTY. DESCRIPTION 29. 02580-95 1 License Plate Clip 30. 02770 2 1/4-20UNC Nylon Insert Wing Nut 31. 01077 2 1/4"-20UNC Serrated Locknut 32. 04513 1 Light Cluster 10. 02243 2 Black Vinyl Hand Grip 33. 01883 11 Electrical Wire Splicer 34. 01881 1 Trunk Connector 35. 04785 1 Front Half Trailer Wiring Harness 36. 04786 1 R[...]

  • Page 11

    Page 11 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. New Departure Hyatt Hubs used on the KK[...]

  • Page 12

    Page 12 Model DA66 ACTUA TOR P ARTS BREAKDOWN - 8606701 1 DA66 Brake Actuator complete (incl. ref. 1-25) - 5400 - Lever Replacement Kit (incl. items w/*) - 5398 - Master Cylinder Repair Kit w/ gasket - 5495 - Coupler Repair Kit ACTUATOR PARTS LIST Please order replacement parts by PART NO. and DESCRIPTION. REF. PART N O . N O . QTY. DE SCRIPTION 2 [...]

  • Page 13

    Page 13 5695 - Emergency Lock Cam Replacement Kit 20. ----- 1 7/16î-14UNC x 1 1/4î Hex Head Bolt (Gr. 5) 21 . ----- 1 7/16î-14UNC Lock Nut (Center Punch) 22. ----- 1 Emergency Catch Cam (black oxide finish) 23 . ----- 1 Pushrod Assembly (includes cable) 5696 - Coupler Repair Kit (2î lever lock) 5398 - Master Cylinder Repair Kit w/ gasket DA603 [...]

  • Page 14

    Page 14 MODEL DA91 ACTUA TOR P ARTS BREAKDOWN 5398 Master Cylinder Repair Kit (gasket included) 2î Lever Lock Coupler RATED AT 6000# not included REF. N O . PART NO. QTY. DE SCR IPTION 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"[...]

  • Page 15

    Page 15 4 4 5 5 7 16 2 2 1 16 3 8 6 10 10 18 17 13 REF. PART N O . N O. QTY. DESCRIPTION BRAKE CLUSTER PARTS LIST 11 12 9 15 17 14 17 18 17 - SB24429 - Left Hand Cluster (shown above) - SB24428 - Right Hand Cluster 1. SB23871 1 Back Plate Assembly - (NDH Hub Mounting) 2. SB9254 2 Cover Plate - Adjusting Hole 3. SB10954 1 Brake Shoe Kit (includes 2 [...]

  • Page 16

    Page 16 OPTIONAL SURGE BRAKES (KK260SB and KK360SB) P ARTS BREAKDOWN Model DA603 Brake Actuator 1 2 3 4 5 5 6 7 8 2 9 Please order replacement parts by PART NO. and DESCRIPTION. SURGE BRAKES PARTS LIST 1. SB587 1 87" Brake Line 2. 01863 2 Rubber Gommet 3. 02746 1 54" Protective Hose 4. SB7H67 1 7" Brake Hose (rubber) 5. SB536 2 36&qu[...]

  • Page 17

    Page 17 KK260 AND KK360 ASSEMBLY INSTRUCTIONS 1. Place the main frame on blocks or some other sturdy support so that the frame rests approximately 8" - 10" off the ground. Attach the tilt bed ramps (#1) as shown using four 1/2" x 1-1/4" grade 5 bolts (#4), flat washer (#5) and lock nuts (#6), two on each side of each ramp, and t[...]

  • Page 18

    Page 18 11. DO NOT MOVE THE TIE ROD LOCKING CLAMP FROM ITS FACTORY PRESET POSITION. GREASE TIE ROD ENDS BEFORE USING. NOTE: Tie rods are factory set and should not be readjusted. 12. Bolt on the steering stabilizer cylinder (#1) as shown using a 5/8" x 2-3/4" bolt (#2) coming up from the bottom, through a 5/8" flat washer (#3), throu[...]

  • Page 19

    Page 19 WIRING & FENDER ASSEMBLY INSTRUCTIONS NOTE: It is advantageous to wire the fender lights prior to attaching the wheels. 1. Cut off stripped ends of the wiring harness, cut off stripped ends of the front clearance light, and cut off the stripped end of the white ground wire. The yellow/brown wires must be run to the left tail light pocke[...]

  • Page 20

    Page 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 n[...]

  • Page 21

    Page 21 - KK2WJ 1 Optional Wheel Jack w/ hardware Please order replacement parts by PART NO. and DESCRIPTION. OPTIONAL WHEEL JACK WHEEL JACK PARTS LIST * All options may not mount on tow dolly simultaneously.* REF. PART NO. NO. QTY. DES CRIPTION KK2DF Optional Deflector 1. 02055-25 2 Deflector Framework 2. 02592 4 3/8"-16UNC Nylon Insert Lock [...]

  • Page 22

    Page 22 1. 00059 4 3/8" Flatwasher 2. 02592 8 3/8"-16UNC Nylon Insert Locknut 3. 01888-25 1 Tool Box 4. 00182 1 Small Hair Pin 5. 02742-25 2 Mounting "Z" Bracket 6. 00907 4 3/8"-16UNC x 1" Hex Head Bolt (gr.5) 7. 02759 2 3/8"-16UNC x 3" Square U-Bolt OPTIONAL WINCH KK2TB 1 Optional Tool Box OPTIONAL T OOL BOX[...]

  • Page 23

    Page 23 NOTES[...]

  • Page 24

    Page 24 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[...]