0-11 RD20010,Rev 12 For serial number 04274 and higher 1
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.
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! warning: SIGNAL WORDS Note the use of the signal words DANGER, WARNING and CAUTION with the safety messages.
SAFETY...you can live with it 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.
• 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 small portion with exposed sticky backing in place.
• Secure emergency brake actuator cable to mounting loop on towing vehicle. • 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. • NO PASSENGERS ALLOWED- Do not carry passengers anywhere on or in towed unit. • When halting operation, even periodically, set towing vehicle parking brake, shut off engine, and remove ignition key.
• Local laws should be checked for all highway lighting and marking requirements. • Plan your route to avoid heavy traffic. • Be a safe and courteous driver. Always yield to oncoming traffic in all situations, including narrow bridges, intersections, etc. • Watch for obstructions overhead and to both sides while transporting. • Operate with maximum visibility at all times. Make allowances for increased length and weight of KK460SS when making turns and stopping.
Decal Location PINCH POINT REV 0 A. DD21018 D. DD21018 DD21017 QTY. 4 WARNING Read following information before hooking up, loading, using, unloading or unhooking Kar Kaddy to prevent property damage, serious injury , or death. Loading T owed V ehicle E 1. Assure towing vehicle and Kar Kaddy are straight, on level ground, and properly hooked up before loading towed vehicle. IMPORTANT DO’S & DON’TS Read towing instructions in towed vehicl e C owners manual . Use 2” 5000 lb.
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 * GRADE 2 GRADE 5 GRADE 8 Torque Specifications “A” lb-ft (N.m) lb-ft (N.m) lb-ft (N.
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 frame and support front of tongue. 3.
Fender Assembly Instructions 3. On the left side, plug in bullet plugs with white to white, black to brown and yellow to red. On the right side, plug white to white, black to brown and green to red. 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. 4. With a pliers, install two wire clamps on fender. From rear of fender lip, install one clamp at 5-1/2” and one at 8”. 2.
Wiring Diagram 1 2 PARTS LIST REF. NO. PART NO. QTY. DESCRIPTION 1. 2. 3. 11590 11591 01863 1 1 1 Tongue Wiring Harness Main Frame Wiring Harness Rubber Grommet (not shown) Please order replacement parts by PART NO. and DESCRIPTION. TESTING LIGHTS BEFORE USE 1. Make sure that the WHITE ground wire is connected to the frame of both the Kar Kaddy and the towing vehicle. 2.
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. 1. Pull retainer clip from bottom of tongue locking pin. Lift locking pin out of tongue pivot. 2. With tongue wheel jack turned to its lowest position, push/pull tongue to the left. 3. 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.
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. 1. Locate ramp locks at inside center of ramps. 2. Pull ramp lock straight out as far as it will go. 3. Lift ramp lock up as far 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 extend out from it’s 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. 1. 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 important to check all pins and retainers for damage. If damage is found replace. Do not use damaged pins or retainers.
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 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.
LOADING INSTRUCTIONS . 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 and secure to towing vehicle frame. Step 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 13. TO UNLOAD towed vehicle. Never unhook tow dolly coupler from towing vehicle, before unloading tow dolly. 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.
Kar-kaddy toe-in adjustment Back measurement Locking 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. 1. Put a mark on each side of the locking clamp on the tie rod. 2.
MODEL DA91 ACTUATOR PARTS BREAKDOWN 13 8 17 8 14 23 **16 **1215 5398 Master Cylinder Repair Kit (gasket included) **10 D 25 20 7 6 22 21 4 5876 eZ-Latch Coupler Repair Kit 29 26 2 18 15 30 E UD L C T IN O N 14 5 2 9 24 28 19 19 27 1 3 3 Model 91 ACTUATOR PARTS LIST REF. NO. PART NO. QTY. DESCRIPTION 1. 12925 1 10000# 2” eZ-Latch Coupler 2. 01896 3 1/2”-13UNC x 4” Hex Head Bolt (gr.5) 3. 02178 3 1/2”-13UNC Nylon Insert Lock Nut 4.
10” SELF-ADJUSTING BRAKE CLUSTER and DRUM PARTS BREAKDOWN 4 4 5 5 7 16 1 6 16 2 3 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. DESCRIPTION SB24429M Left Hand Cluster (shown above) SB24428M Right Hand Cluster 1. SB23871 1 Back Plate Assembly 2. SB9254 2 Cover Plate - Adjusting Hole 3. 07811 1 Brake Shoe Kit (includes 2 Primary & 2 Secondary) 4. 04305 2 5/16”-18UNC-Gr5 x 1/2” Hex Hd Bolt 5. 05424 2 5/16” External Tooth Washer 6.
SURGE BRAKES PARTS BREAKDOWN 12 11 10 10 9 7 1 4 3 6 8 9 10 5 3 10 1 2 16 15 13 14 Model DA91 Brake Actuator SURGE BRAKES PARTS LIST REF. NO. PART NO. QTY. 1. 13047 2. 12508 3. 05679 4. 11617 5. 11618 6. 11643 7. SB7785 8. 05960 9. SB541 10. 02549 11. 02032 12. SB7764 13. SB24429M -- SB24428M 14. SB40929 15. 04174 16.
KK460SS PARTS BREAKDOWN 2 1 4 5 41 6 46 45 7 41 46 43 13 9 10 39 11 60 57 79 26 28 58 20 21 19 36 38 52 26 22 53 29 27 56 40 53 12 37 50 23 52 24 75 54 6 25 48 55 22 47 23 19 71 21 37 49 24 26 19 51 76 59 78 56 77 21 61 62 32 32 63 65 64 24 21 20
REF. NO. PART NO. QTY. 1. 03528 2 2. 5983 1 3. 5982 1 4. 04424-95 2 5. 00914 6 6. 02592 18 7. 12560-81 1 8. 12559-81 1 9. 01732 4 10. 11588 2 11. 01731 4 12. 05587 2 REF. NO. DESCRIPTION 33 35 32 3 31 34 21 22 19 26 34 30 6 6 7 21 22 42 34 44 21 15 18 19 16 22 17 14 3 8 66 73 74 DESCRIPTION 13. 35652-81 1 Right Drop Axle & Wheel Carrier Assembly 14. 35651-81 1 Left Drop Axle& wheel Carrier Assembly 15. 11551 2 King Pin Retainer Bolt 16.
WINCH ASSEMBLY 5 1 Left Winch 5432 (Shown) Right Winch 5433 2 3 11 7 4 18 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
RAMP LATCH ASSEMBLY REF. NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 5 1 4 3 5763 11622-95 00007 00004 00059 11570-95 11623-95 03499 02384 11621 1 2 1 1 1 1 1 1 1 DESCRIPTION Ramp Latch Kit 5/16”-18 UNC Latch Rod 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 Please order replacement parts by PART NO. and DESCRIPTION. 6 2 PART NO. QTY. 2 7 8 9 LICENSE PLATE BRACKET ASSEMBLY ) ble a l i va ta REF.
Fender Assembly 8 6 1 7 9 17 2 2 2 5 2 14 2 18 12 16 3 10 11 15 13 4 PARTS LIST REF. NO. PART NO. QTY. DESCRIPTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
OPTIONAL SPARE TIRE and MOUNT PARTS BREAKDOWN Drive in stud here for tire with rim #11574 (115mm bolt circle). PARTS LIST 1 4 6 - 5968 1 Optional Spare Tire and Rim 1. 2. 13989 11574 1 1 ST205/75R 14”x”C” ROWL Radial Tire RKSTM 1 Spare Tire Mounting Bracket 1 1 2 2 2 4 Spare Tire Bracket Stud Bolt (12mm x 1.5) Wheel Nut (12mm) Chrome 3/8”-16UNC Square U-Bolt 3/8” Flatwasher 3/8”-16UNC Nylon Insert Locknut 3 7 3. 02193-30 4. 02917 5. 02933 6. 02759 7. 00059 8.
OPTIONAL LIGHT BAR PARTS BREAKDOWN 7 6 REF. PART NO. NO. QTY. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 8 1 LIGHT BAR PARTS LIST 9 DESCRIPTION 1 KKLB Kar Kaddy Light Bar (complete) 01772 2 Nylon Security Strap with hooks & tightener 01857 1 Left Tail/ Brake and Signal Light w/Lenses 01773 1 Brown Jumper Wire 01886 4 Wire Holder (metal) 02385-50 1 Light Bar Framework 02386.
DEMCO PRODUCTS - KAR KADDY ORIGINAL PURCHASER’S 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.
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Ag RV Rental Brakes Marine Warranty Registration 4010 320th Street • Box 189 • Boyden, Iowa 51234 Toll Free 800-54DEMCO (800-543-3626) • FAX 800-845-6420 www.demco-products.
Postage Demco 4010 320th Street, Box 189 Boyden, Iowa 51234 34
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4010 320th St. P.O. Box 189, BOYDEN, IA. 51234 PH: (712) 725-2311 FAX: (800) 845-6420 TOLL FREE: 1-800-54DEMCO (1-800-543-3626) www.demco-products.
