4-06 RD20011,Rev 1 Page 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 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. When placing a parts order, refer to this manual for proper part numbers and place order by PART NO. and DESCRIPTION. 2.
NOTE: This is one of a tow-manual set. The other manual is titled “Owner’s Manual” and contains technical information concerning the specific product that you purchased. Be sure to review both manuals. 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.
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.
• Allow one tow-vehicle/tow dolly/vehicle-in-tow length for each 10 m.p.h. behind another vehicle. • ALWAYS check the hitch, tow dolly and vehicle-in-tow at each stop to insure that coupling, chains and tie down equipment remain tight and properly attached. Use tow dolly checklist as an aid. • NEVER tow without properly installed tire straps and security chains properly attached to frame or other structural member of vehicle-in-tow.
When On the Road: • Reduce Speed • Think Ahead • Allow for extra length when turning • Anticipate Stops/Brake Early • Stop Often for Rest • Use Safety Checklist at Each Stop TOWING VEHICLE SIZE AND TOWING CAPACITY Towing vehicle must weigh at least 750 lbs. more than weight of vehicle-in-tow. Example: A 2,750 lb. car may tow no more than a 2,000 lb. car.
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.
Vehicle-in-Tow Facing Forward Vehicle-in-tow must always be facing forward (front wheels on tow dolly). Transmission Damage to Towed Vehicles When towing a rear axle driven front engine vehicle, the drive shaft must be disconnected to prevent transmission damage. Simply placing transmission in neutral is not sufficient and will not prevent damage due to a lack of internal lubrication. You must disconnect drive shaft at rear axle and tie or wire it up.
TOWING 55 Miles Per Hour All vehicle combinations have a speed beyond which adequate emergency control cannot be assured. Maximum recommended speed for all tow dolly combinations is 55 m.p.h. under good road conditions. As road conditions deteriorate you must reduce the maximum recommended speed. Posted speed limit is usually the same for trucks and car-trailer combinations. Observe this limit even if it is less than 55 m.p.h.
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.
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.
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. 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 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.
! 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.
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 9.
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 postion (horizontal) position with safety pins in place when towing loaded or empty. DO NOT ATTEMPT TO PULL KAR KADDY WITH WHEEL PLATFORM IN LOADING (tilted) POSITION.
KK370SB PARTS BREAKDOWN REF. NO. PART 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. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67.
1 4 5 41 35 46 45 41 46 43 13 40 53 2 27 33 32 39 53 35 26 31 28 29 27 19 22 36 38 52 26 26 58 6 30 6 6 37 72 19 71 21 52 34 42 44 25 48 15 22 18 47 23 21 20 16 19 17 14 3 24 51 8 66 55 68 65 54 67 70 69 Page 19
WINCH ASSEMBLY REF. NO. Left Winch Shown 21 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 18 10 8 19 3 18 20 14 16 17 15 12 10 11 13 3 2 9 1 4 5 7 6 Left Winch Shown PART NO. QTY.
LICENSE PLATE BRACKET ASSEMBLY REF. NO. 4 5 3 6 8 2 1. 2. 3. 4. 5. 6. 7. 8. 9. 6 2 3 1 9 7 PART NO. QTY.
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.
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 2” 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 9 10 17 18 17 15 14 17 BRAKE CLUSTER PARTS LIST REF. PART NO. NO. QTY. SB24429 SB24428 1. SB23871-80 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.
SURGE BRAKES PARTS BREAKDOWN 7 6 5 12 2 4 Model DA91 Brake Actuator 14 11 5 10 2 13 7 16 1 3 9 8 17 15 SURGE BRAKES PARTS LIST REF. NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. PART NO. SB566 01863 02746 SB7H67 SB541 SB7764 02032 02210 04174 SB5045 02549 SB7785 SBD10 05960 12445-30 BLEEDING THE SYSTEM QTY. 1 2 1 1 2 2 2 8 4 1 4 1 1 1 1 The first requirement for safe, sure hydraulic braking is the use of quality brake fluid.
Wiring Diagram 1 2 PARTS LIST REF. NO. PART NO. QTY. 1. 2. 11590 11591 1 1 DESCRIPTION Tongue Wiring Harness Main Frame Wiring Harness Please order replacement parts by PART NO. and DESCRIPTION. 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.
KAR-KADDY TOE-IN ADJUSTMENT BA CK LOCKING CLAMP FRONT MEASUREMENT (1/32" to 1/16" less than back measurement) ME AS UR EM EN T 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.
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. 5762 02055-30 02592 02759 00161-95 02054-30 00095 02743-30 02165 11710 QTY.
Warranty Registration Dethmers Manufacturing Company 4010 320th Street • Box 189 • Boyden, Iowa 51234 Toll Free 800-54DEMCO (800-543-3626) • FAX 800-845-6420 www.demco-products.
Postage Dethmers Manufacturing Company 4010 320th Street, Box 189 Boyden, Iowa 51234 Page 30
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.
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.
