8-03 RD20005,Rev 3 DOING OUR BEST TO PROVIDE YOU THE BEST KAR-KADDY KK260 (8WIDE) & KK360 (8-1/2 WIDE) OPERATORS MANUAL READ complete manual CAREFULLY BEFORE attempting operation. ASSEMBLY CALIBRATION OPERATION REPLACEMENT PARTS 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.
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 3. When placing a parts order, refer to this manual for proper part numbers and place order by PART NO. and DESCRIPTION. 1. Unless otherwise specified, high-strength (grade 5) (3 radial-line head markings) hex head bolts are used throughout assembly of this piece of equipment. 2.
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. NOTE: Unless otherwise specified, high-strength Grade 5 hex bolts are used throughout assembly of equipment. Bolt Torque for Standard bolts * Torque Specifications A GRADE 2 lb-ft (N.m) GRADE 5 lb-ft (N.m) GRADE 8 lb-ft (N.
! 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. 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.
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 be lighted. 3. 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. 4.
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.
A B 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.
KK260 (8'wide) and KK360 (8-1/2' wide) PARTS BREAKDOWN 128 104 126 125 121 124 33 127 87 129 117 55 46 118 109 110 112 98 122 116 120 119 106 99 KIT #5511 TILT-BED LATCH ASSEMBLY 55 42 103 Right Fender 123 111 113 107 114 105 100 *69 *69 75 *69 108 90 46 75 89 63 *69 90 59 72 65 88 62 not included 61 60 for Fulton 5000 lb.
t (no le) ilab a av 84 27 29 26 25 30 30 25 26 24 32 31 KK6LBAS License Plate Mount 31 and Light Cluster 27 27 Left Winch Shown 130 20 23 12 10 78 21 5 76 85 51 74 55 73 *70 103 104 109 115 102 93 28 67 64 68 6 *70 91 92 Left Fender 3 8 *70 87 16 4 7 5 18 11 9 *70 3 12 14 13 15 42 77 79 22 17 75 19 20 94 95 Page 9 REF. NO. PART NO. QTY. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
REF. NO. PART NO. QTY. DESCRIPTION 29. 02580-95 30. 02770 31. 01077 32. 04513 1 2 2 1 License Plate Clip 1/4-20UNC Nylon Insert Wing Nut 1/4"-20UNC Serrated Locknut Light Cluster 10. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. *69. *70. 71. 72. 73. 74. 75. 76. 77. 78. 79. 80. 81.
DEMCO PRODUCTS - KAR KADDY ORIGINAL PURCHASERíS LIMITED WARRANTY 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.
Model DA66 ACTUATOR PARTS BREAKDOWN 18 15 14 19 16 19 13 25 20 17 20 12 21 2 10 10 22 8 11 9 7 2 24 7 5 23 6 4 1 6 2 3 2 ACTUATOR PARTS LIST REF. PART NO. NO. 8606701 for 6000 lb. coupler 5495 Coupler Repair Kit 1. 07599-95 2. SB23278 3. 05957-95 4. 02166 5. 07176 6. 05684 7. 02178 8. 05959 9. 05692 10. 05958-95 11. *05951 12. 05955-95 13. *SB24700 14. SB10555 15. 05960 16. 05424 17. *05693-95 18. 03876 19. 01076 20. 00057 21. 03564-95 22. 05681 23. 05680 24. SB12098 25.
DA603 BRAKE ACTUATOR PARTS BREAKDOWN Components not sold separately 7 20 22 23 4 21 1 20 5695 Emergency Lock Cam Replacement Kit 15 Item #23 includes cable 16 22 14 21 11 23 11 8 3 5 9 2 18 6 2 17 10a 10 13 Item #10 is not included in 5696 12 12 18 5398 Master Cylinder Repair Kit (drum) (gasket included) 5696 Coupler Repair Kit (2î lever lock) **Components not sold separately** ACTUATOR PARTS LIST REF. NO. PART NO. QTY.
MODEL DA91 ACTUATOR PARTS BREAKDOWN 13 8 8 23 17 **12 **10 **16 5398 Master Cylinder Repair Kit (gasket included) 14 14 15 15 18 25 9 11 26 not included 6 20 9 7 22 28 21 4 5 19 5495 Coupler Repair Kit 24 2 9 19 28 2 27 1 3 2î 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.
10" SELF-ADJUSTING BRAKE CLUSTER and DRUM PARTS BREAKDOWN 4 4 5 5 7 16 1 6 16 3 2 2 8 11 13 10 12 3 19 10 9 17 18 17 15 14 17 BRAKE CLUSTER PARTS LIST REF. PART NO. NO. QTY. SB24429 SB24428 1. SB23871 1 2. SB9254 2 3. SB10954 1 4. 04305 2 5. 05424 2 6. SB9776 1 SB9777 1 7. 05431 1 8. SB9783 1 9. SB24047 1 SB24048 1 10. SB10958 2 11. SB10961-95 1 12. SB23937 1 13. SB23936 1 14. SB23724 1 15. 05415-95 1 05414-95 1 16. SB10959 2 17. SB9789 4 18. 05983 2 19.
OPTIONAL SURGE BRAKES (KK260SB and KK360SB) PARTS BREAKDOWN 5 12 11 2 4 7 5 6 Model DA603 Brake Actuator 1 2 13 3 9 10 8 14 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. NO. PART NO. 1. 2. 3. 4. 5. 5. 6. 7. 8. 9. 10. 11. 12. SB587 01863 02746 SB7H67 SB536 SB540 SB7764 QTY.
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 then three 7/16" x 1" grade 8 bolts (#2) and lock nuts (#3) on the top of each ramp. Torque 7/16" bolts to 80 ft. lbs. and torque 1/2" bolts to 75 ft. lbs. 2.
11. DO NOT MOVE THE TIE ROD LOCKING CLAMP FROM ITS FACTORY PRESET POSITION. GREASE TIE ROD ENDS BEFORE USING. 1-1/4" 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), through cylinder end and into threaded ear on the Kar Kaddy main frame. Snug bolt up, then tighten putting 3/16" squeeze on the rubber of the cylinder end.
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 pocket. The green/brown wires must be run to the right tail light pocket.
KAR-KADDY TOE-IN ADJUSTMENT BA CK ME AS UR EM EN LOCKING T CLAMP FRONT MEASUREMENT (1/32" to 1/16" less than back measurement) 12" 12" CL 18" nd ou Gr 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.
OPTIONAL WHEEL JACK WHEEL JACK PARTS LIST - KK2WJ 1 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 8 9 6 OPTIONAL DEFLECTOR PARTS LIST REF. NO. PART NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. KK2DF 02055-25 02592 02759 00161-95 02054-25 00095 02743-25 02165 02161 QTY.
OPTIONAL WINCH 5 PARTS LIST REF. NO. PART NO. QTY. 3 6 7 1 1. 3. 4. 5. 6. 7. 4 KK2W 04620 04621 01738 02207 02769 00059 02592 1 1 1 1 2 2 3 DESCRIPTION Optional Winch Winch Mechanism (1400 capacity) Replacement Handle Strap Assembly (includes strap & 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.
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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.
