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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. WARRANTY POLICY & REGISTRATION Go online to www.demco-products.com to review Demco warranty policies and register your Demco product. GENERAL INFORMATION 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. 3.
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 This manual uses the following signal words-DANGER, WARNING, and CAUTION-- with safety messages.
TOW DOLLY USER GUIDE WARNING: Read the following information completely before hooking up, loading, using unloading or unhooking this Tow Dolly. FAILURE TO FOLLOW THESE SAFETY INSTRUCTIONS MAY LEAD TO DAMAGE TO PROPERTY, SEVERE PERSONAL INJURY, AND/OR DEATH. • Read towing instructions in towed vehicle’s owner’s manual. • Read towing instructions in towing vehicle’s owner’s manual. Be certain that your towing vehicle has the capacity to tow a tow dolly and towed vehicle combination.
• ALWAYS disconnect drive shaft of a rear wheel drive/front engine vehicle-in-tow at differential to avoid transmission damage. Secure disconnected parts. • ALWAYS ensure vehicle-in-tow parking brake is disengaged before towing. • ALWAYS keep children, pets, and bystanders clear of area while loading and unloading.
Engine and Transmission Cooling Towing a loaded tow dolly can be quite demanding on engine and transmission cooling systems of tow vehicle, especially if towing Iong distance or in hilly terrain. Be sure your cooling system is in top shape, and adequate for towing anticipated load. Engine oil should be fresh and of maximum viscosity recommended for your particular engine. Engine cooling may be enhanced by flushing system and installing fresh coolant.
Never transport any passengers or cargo in towed vehicle. In addition to being illegal in most states, carrying passengers in a towed vehicle exposes those passengers to risk of exhaust gas asphyxiation. Lighting Requirements Even though tow dollies have operating lights, law requires that a vehicle-in-tow be equipped with functioning stop, turn and running lights. Detachable vehicle-in-tow towing lights can be purchased at many rental locations. They can also be purchased at auto supply shops.
BREAKDOWNS Get Off The Road Immediately park tow vehicle-tow dolly combination in a safe place completely off the highway. Get all occupants out of vehicle and away from roadway. If you must continue on the highway to reach a safe place off the road, turn on emergency flashers and proceed with caution. Do not hesitate to proceed on a flat tire if necessary to reach a safe place completely off the highway. Proceed slowly, for road friction could ignite a flat tire and cause a fire.
Decal Locations F G A C H B E E B E D 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 * Torque Specifications GRADE 2 GRADE 5 GRADE 8 “A” lb-ft (N.m) lb-ft (N.m) lb-ft (N.
Tongue and Ramp Assembly Instructions 5. 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 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).
Fender Assembly Instructions 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. 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. 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. 4.
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.
LOADING INSTRUCTIONS Step 1. Secure ball coupler to 2” (6,000 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. Before loading (and unloading) towed vehicle make sure platform and towed vehicle are in straight alignment.
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. Step 6. With someone safely guiding you, slowly drive vehicle onto platform FRONT 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. Make sure the tire is aligned to ascend onto the ramps. Step 7.
Step 11. Make sure the tie-down strap is the correct size for the auto tire. See page 11 of this instruction for proper fit and exchange instructions. Step 14. To pull the Kar Kaddy empty, make sure “AutoSteer” LOCKING PIN IS IN PLACE and towing vehicle safety chains are up and hooked. Tie-down winch handles should be left in a down position (horizontal) position with safety pins in place when towing loaded or empty. DO NOT ATTEMPTTO PULL KAR KADDY WITH WHEEL PLATFORM IN LOADING (tilted) POSITION.
KK370SB PARTS BREAKDOWN REF. NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. PART NO.
1 4 5 41 35 46 45 41 46 43 13 40 53 27 39 26 22 35 29 27 52 32 53 31 28 79 19 33 38 26 79 36 26 58 6 30 6 6 37 71 52 48 77 23 21 42 44 15 22 47 21 34 25 72 19 20 18 16 19 17 14 3 24 51 8 54 78 66 55 65 68 67 70 69 Page 19
WINCH ASSEMBLY 5 1 3 11 7 4 18 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
LICENSE PLATE BRACKET ASSEMBLY ) ble aila v ta REF. NO. 5740 1. 04505-95 2. 04176 3. 02214 4. 02163 02164 5. 02580-95 6. 02770 7. 02205 8. 00214 9. 11687* 10. 11688* 11655* 11616 5765 (no 4 6 6 2 2 3 5 8 3 9 10 10 1 7 5740 10 License Plate Mount 4 7 PART NO. QTY.
MODEL DA91 ACTUATOR PARTS BREAKDOWN 13 8 17 8 14 23 **16 **1215 5482 Master Cylinder Repair Kit (gasket included) **10 7 , 12 (' 15 30 29 26 5876 eZ-Latch Coupler Repair Kit 2 18 25 8' / 1& 14 20 7 6 22 21 4 5 2 9 24 28 19 19 27 1 3 3 Model 91 ACTUATOR PARTS LIST 2” eZ-Latch Coupler RATED AT 10000# 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.
DISC BRAKE PARTS BREAKDOWN AND PARTS LIST Hub Assembly 7 10 9 5 1 2 4 6 xy po lt Bo E 3 8 PARTS LIST REF. NO. ASSEMBLY 1. Begin by mounting the Hub Assembly and the Caliper Mounting Bracket (#1) to the Forged Arm using the (#6) 7/16” Epoxied Bolts (as shown). 2. Now place the Rotor (#2) onto the Hub Assembly as shown in the diagram. 3. Make sure the Brake Pads (#4) are correctly placed in the Caliper (#3). 4.
SURGE BRAKES PARTS BREAKDOWN 7 6 5 12 2 4 Model DA91 Brake Actuator 13 11 5 3 17 7 16 14 9 1 8 15 10 SURGE BRAKES PARTS LIST REF. NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. PART NO. 12508 01863 13047 12542 SB541 SB7764 05982 02210 04174 12445-30 02549 SB7785 05960 13825-92 03927-92 13920-92 14486 Bleeding the System QTY.
Wiring Diagram Fender Wiring 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 2 PARTS LIST REF. NO. PART NO. QTY. DESCRIPTION 1. 2. 11590 11591 1 1 Tongue Wiring Harness Main Frame Wiring Harness Please order replacement parts by PART NO. and DESCRIPTION. TESTING LIGHTS BEFORE USE 1.
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 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 2 3 11683 1. 02769 2. 00060 3. 00061 4. 03646 5. 14542-95 6. 03129 7. 13303 * All options may not mount on tow dolly simultaneously.* 7 1 1 1 Optional Wheel Jack w/ hardware 4 3/8”-16 UNC x 4 Hex Head Bolt 4 3/8” Lock Washer 4 3/8”-16 UNC Hex Nut 1 Replacement Wheel only 1 Wheel Bushing for replacement only 1 Jack 1 Cap Please order replacement parts by PART NO. and DESCRIPTION.
OPTIONAL WINCH 5 PARTS LIST REF. NO. PART NO. QTY. DESCRIPTION 3 6 1. 3. 4. 5. 6. 7. 7 1 4 KK2W 04620 04621 01738 02207 02769 00059 02592 1 1 1 1 2 2 3 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.
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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 Go online to www.demco-products.com for Demco warranty policies & product registration.
