Demco KK260, KK360 User Manual

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DOING OUR BEST TO PROVIDE YOU THE BEST

KAR-KADDY

8-03

RD20005,Rev 3

KK260 (8

OPERATORS MANUAL

ASSEMBLY CALIBRATION OPERATION REPLACEMENT PARTS

WIDE) & KK360 (8-1/2 WIDE)

READ complete manual CAREFULLY

BEFORE attempting operation.

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

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.

2. Whenever the terms "LEFT" and "RIGHT" are used in this manual it means from a position behind

the

Kar-Kaddy and facing forward.

TABLE OF CONTENTS

General Information................................................................................................................ Page 2

Bolt Torque............................................................................................................................. Page 3

Safety, Maintenance, & Important Loading Instructions......................................................... Page 4

Testing Lights Before Use.................................................................................................... Pages 5

Loading Instructions ............................................................................................................ Page 5-7

Kar-Kaddy 260 and 360 Parts Breakdown and List ............................................................ Page 8-9

Kar-Kaddy 260 and 360 Parts List cont. .............................................................................. Page 10

Limited Warranty Information ............................................................................................... Page 11

DA66 Brake Actuator Parts Breakdown and List................................................................. Page 12

DA603 Brake Actuator Parts Breakdown and List............................................................... Page 13

DA91 Brake Actuator Parts Breakdown and List................................................................. Page 14

10" Self-Adjusting Brake Cluster Parts Breakdown and List ............................................... Page 15

Optional Surge Brakes Parts Breakdown and List .............................................................. Page 16

KK260 and KK360 Parts Assembly Instructions .......................................................... Pages 17-18

Wiring and Fender Assembly Instructions ........................................................................... Page 19

Kar-Kaddy Toe-In Adjustment.............................................................................................. Page 20

Wheel Jack, Deflector, & Light Bar (optional) Parts Breakdown and List ............................ Page 21

Winch, Tool Box, & Spare Tire w/Mounting Bracket (optional) Parts Breakdown and List .. Page 22

Notes.................................................................................................................................... Page 23

3. When placing a parts order, refer to this manual for proper part numbers and place order by PART NO.

and DESCRIPTION.

"Reporting Safety Defects"

If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Dethmers Manufacturing Company (DEMCO).

If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems be-

tween you, your dealer, or Dethmers Manufacturing Company (DEMCO).

To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0129 in Washington, D.C. area) or write to:

NHTSA, U.S. Department of Transportation Washington, D.C. 20590.

You can also obtain other information about motor vehicle safety from the Hotline.

Page 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

Torque figures indicated are valid for non-greased or non-oiled threads and heads unless otherwise specfied. Therefore, do not grease or oil bolts or capscrews unless otherwise specified in this manual. When using locking elements, increase torque values by 5%.

* GRADE or CLASS value for bolts and capscrews are identified by their head markings.

GRADE 2 GRADE 5 GRADE 8

A lb-ft (N.m) lb-ft (N.m) lb-ft (N.m)

1/4 6 (8) 9 (12) 12 (16)

5/16 10 (13) 18 (25) 25 (35)

3/8 20 (27) 30 (40) 45 (60)

7/16 30 (40) 50 (70) 80 (110)

1/2 45 (60) 75 (100) 115 (155)

9/16 70 (95) 115 (155) 165 (220)

5/8 95 (130) 150 (200) 225 (300) 3/4 165 (225) 290 (390) 400 (540) 7/8 170 (230) 420 (570) 650 (880)

1 225 (300) 630 (850) 970 (1310)

Bolt T orque for Metric bolts *

CLASS 8.8 CLASS 9.8 CLASS 10.9

A lb-ft (N.m) lb-ft (N.m) lb-ft (N.m)

6 9 (13) 10 (14) 13 (17) 7 15 (21) 18 (24) 21 (29)

8 23 (31) 25 (34) 31 (42) 10 45 (61) 50 (68) 61 (83) 12 78 (106) 88 (118) 1 06 (144) 14 125 (169) 140 (189) 170 (230) 16 194 (263) 216 (293) 263 (357) 18 268 (363) -- -- 364 (493) 20 378 (513) -- -- 515 (689) 22 516 (699) -- -- 702 (952) 24 654 (886) -- -- 890 (1206)

GRADE-2 GRADE-5 GRADE-8

CLASS 8.8 CLASS 9.8 CLASS 10.9

8.8

9.8

Page 3

10.9

WARNING:

Safety is of utmost importance at all times. There are several items that must be checked each time using and

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 the first 5 miles and

periodically thereafter. The ball hitch must latch securely around the ball and

the safety lock pin or lever must be in position to lock the hitch on the ball.

RECOMMENDED BALL HEIGHT: 18 inches to the top of the ball on the towing vehicle.

Hook the towed vehicle safety chains to the frame of the vehicle directly above the area where the chain is mounted on the Kar Kaddy. Leave some slack in the chain to allow suspension movement.

Check to make sure that all lights are in proper working order.

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

before

while using the Kar Kaddy.

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.

MAINTENANCE

Periodically check all bolts and nuts to insure proper tension or torque.

Grease the king pin and tie rod end grease zerks every 2500 miles.

An occasional drop of oil may be required on the moving parts of the tie down winches.

A light film of oil should periodically be applied to steering stabilizer arm to prevent rust.

NOTE: Proper toe-in is 1/32". This is preset at the factory.

The operator should periodically have the toe-in checked and adjusted if needed at a qualified alignment shop. Improper toe-in can result in irregular tire wear.

Examine the winches and straps, making sure they are in good conditon.

Be certain the safety lock pins are locking the strap winches.

Retighten straps over the tires after the first 5 miles and every 50 miles thereafter. Ensure that they are tight.

The KK260 tires must be inflated to the recommended 50 PSI.

The KK260SB, KK360 and KK360SB tires must be inflated to the recommended 50 PSI.

The strap on the optional tongue winch must be in good condition and should be stored neatly on winch when not in use.

NOTE: The winch strap must not be left connected to the towed vehicle after it is loaded and strapped down.

Make sure the optional light bar is fastened the rear of the towed vehicle.

The wires to the optional light bar should be run along the car and fastened so as not to damage the finish of the towed vehicle.

NOTE: This unit cannot be backed up, when loaded or

with the steering lock pin removed. All vehicles mounted on the Kar Kaddy must be mounted with the front of the vehicle facing forward.

securely at

IMPORTANT LOADING INSTRUCTION

Check your wheel tie-down straps.

Your Kar Kaddy is equipped with custom made wheel tie-down straps of a standard size that will fit most tires, however if your tires are too large or too small you will want to exchange these new straps for the proper size straps.

1. Tire too large - This is very obvious the strap

will not basket over the tire properly, call us, we will provide at NO Charge on an exchange basis, the proper size strap. You must return your new unused straps and provide us with the Make and Model car and the tire size.

2. Tire too small - This is not as obvious, the

basket will fit down over the tire very well, the problems cannot be readily seen. You must tighten the straps down solid and then check on the inside of the tire and be sure the strap, when tightened does not come in contact with any metal that may cause wear or cutting such as strut mounts. If there is contact, you need a smaller strap, call us, we will provide on a NO Charge, exchange basis, the proper size strap. You must return your new unused straps and provide us with the Make and Model car and tire size.

Thank you for Purchasing

Page 4

Products.

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. Turn left turn signal on. Left turn light of Kar Kaddy and

towing vehicle should flash simultaneously. Should the turn signal lights of the trailer function opposite to those of the towing vehicle, it is probable that the YELLOW (Driver side) and GREEN (Passenger side) wires have been reversed. Check the plug connection under the tongue of the Kar Kaddy to make sure wire colors are not crossed at that point. If plug connection is incorrect, correct problem by reversing yellow and green wire connection on the towing vehicle.

LOADING INSTRUCTIONS

Refer to load limits on inside of front cover.

Step 3. Loosen wing nut on back of license plate holder, turn the clip on the front to a horizontal position and put license in the "down" position. Turn the clip back so it rests against the back of the light bar to hold the license down and tighten wing nut.

(License must be "UP" with the tow dolly empty).

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 2. Remove black locking pin BEFORE loading vehicle onto the Kar Kaddy. The removal of the locking pin allows "Auto Steer" to operate. When towing the dolly empty, this pin must be in place.

Step 4. Before loading (and unloading) towed vehicle make sure platform and towed vehicle are in straight alignment. Tow dolly must be completely and properly hooked up to the towing vehicle. Towing vehicle must be larger and at least 1000

lbs. heavier than the tow dolly and towed vehicle combined.

IMPORTANT: Tire tread width or body width of towed

vehicle must not exceed:

KK260 - 70" max. (outside to outside),

42" min. (inside to inside), 72" max. (body width).

KK360 - 76" max. (outside to outside),

42" min. (inside to inside), 78" max. (body width).

Page 5

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 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. If the car does not have a locking steering column the steering wheel must be tied securely with front tires in a straight position.

Rear Wheel Drive: Disconnect 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.

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 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 9. Be sure tie-down winch is centered with the tire before tightening straps.

Page 6

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.

NOTE: Be sure to tighten straps until each tire starts to flatten against tire stop. After each strap is tight, insert a

safety pin in each winch. Disengage towed vehicle parking brake.

Straps must be retightened after first 5 miles of travel. Check straps every 50 miles thereafter to ensure they are tight and not rubbing or fraying.

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 13. TO UNLOAD towed vehicle. 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. This process will permit easy removal of strap from winch.Swing the wheel platform locking latch handle forward, towards the coupler. This will allow the platform to tilt as you slowly drive off. Make sure the winch ratchet handles are horizontal. Replace the "Auto Steer" locking pin (for towing empty).

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.

DAMAGE PREVENTION

Check your vehicle manual or registration for vehicle weight. Towing vehicle must be larger and at least 1,000 lbs. heavier than the towed vehicle and tow dolly combined.

Do not pack goods in car that is being towed. Overloading the Kar Kaddy or exceeding the width limit may result in damage to both car and Kar Kaddy.

Step 12. Hook the towed vehicle safety chains to frame of vehicle directly above the area where the chains are mounted on the Kar Kaddy. Leave some slack in the chains to allow suspension movement of the towed vehicle.

Page 7

REAR WHEEL DRIVE PRECAUTIONS

Disconnect towed vehicle driveshaft for rear wheel drive vehicles with automatic transmission. Simply placing transmission in neutral is not sufficient to prevent damage to transmisssion. For manual transmission: Consult your vehicle owners manual for towing suitability with the drive shaft connected.

ALL VEHICLES MOUNTED ON THE KAR KADDY MUST BE WITH THE FRONT OF THE VEHICLE FACING FORWARD.

SAFETY

 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 therafter to ensure they are tight and not rubbing or fraying.

KK260 (8'wide) and KK360 (8-1/2' wide) PARTS BREAKDOWN

128

121

5217

117

120

116

for Fulton 5000 lb. coupler

118

119

not included

Coupler Repair Kit

126

123

124

127

129

122

125

KIT #5511

TILT-BED LATCH

ASSEMBLY

100

Right Fender

113

106

114

108

105

*69

107

112

*69

104

110

111

109

103

*69

46 75

Part# 07426 Hook Retainer Replacement Only

DECALS

DECAL

NO. QTY. DESCRIPTION

RD21002 1 Instruction Decal RD21003 - 5 ft. Gold Striping (for fenders) RD21001 DA21005 - Check Wheel Nuts & 50 Psi. C Range BSW

ZA21003 1 VIN

4 Kar Kaddy Decal (brown)

(KK360, KK260SB, KK360SB)

100

Page 8

(not available)

130

Left Fender

115

102

109

104

103

KK6LBAS

License Plate Mount

and Light Cluster

*70

Left Winch Shown

REF. PART

NO. NO. QTY. DESCRIPTION

1. 5432 1 Left Ratchet Winch Assembly (Plated)

2. 5433 1 Right Ratchet Winch Assembly (Plated)

3. 03569-95 1 Ratchet Frame

4. 03570-95 1 Left Spool Tube

- 03571-95 1 Right Spool Tube

5. 03577 1 Heavy Duty External Snap Ring

6. 03574-95 1 Ratchet Handle

7. 03668 1 18 Ga. Shim Washer

8. 03575-95 1 Left Ratchet Gear

- 03576-95 1 Right Ratchet Gear

9. 03666 1 5/16" x 1-1/4" Roll Pin

10. 02243 1 Black Vinyl Hand Grip

11. 05450 1 Winch Pawl

12. 01864 2 Winch Pawl Spring SS

13. 05449 1 Winch Pawl Bushing SS

14. 00059 1 3/8" Flatwasher

15. 05444 1 3/8"-16 UNC x 3/4" Hex Bolt w/epoxy Gr.5

16. 03572-95 1 Left Ratchet Pawl Arm

- 03573-95 1 Right Ratchet Pawl Arm

17. 03578 1 5/16"-18 UNC x 1/2" Shoulder Screw

18. 01998 1 5/16" Flatwasher SS

19. 02002 1 1/4" Flatwasher SS

20. 02772 2 1/4"-20 UNC Nylon Locknut

21. 04055 1 1/4"-20 UNC x 1" Hex Hd. Bolt Gr.5

22. 00214 1 1/4" Flatwasher

23. 05337 1 Lock Pin w/Cable

- 5192 License Plate Light and Light Cluster

24. 04505-25 1 License Plate and Light Cluster Bracket

25. 04176 4 1/4"-20UNC x 3/4" Carriage Bolt

26. 02519 2 1/4"-20UNC x 1/2" Slotted Truss Head Bolt

27. 02163 1 Square License Plate Light w/washer and nut

- 02164 - Clear License Plate Light LENS ONLY

Page 9

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 Rear Half Trailer Wiring Harness

37. 01855 1 Safety Lock Pin

38. 04496 1 5000 lb. Ball Coupler (lever lock)

39. 02288-95 1 Bolt on Handle

- 04017-95 1 Bolt on Handle (used with brakes)

40. 01338 2 1/2"-13UNC x 4-1/2" Hex Head Bolt (gr.5)

- 01975 2 1/2"-13UNC x 5" Hex Hd. Bolt (gr.5) (used w/ brakes)

41. 02189 1 1/2" I.D. Rubber Handle Grip

42. 02178 13 1/2"-13UNC Nylon Insert Locknut

43. 01863 1 5/8" Grommet for wiring harness

44. 02771 2 7/16"-14UNC Nylon Insert Locknut

45. 01853 2 24" Transport Safety Chain w/ Hook

- 02383 2 36î Transport Chain w/ Hook (used w/ brakes)

46. 00059 9 3/8" Flat Washer

47. 01898 4 7/16"-14UNC x 1-1/4" Hex Head Bolt (gr.5)

48. 07077-26 1 Kar Kaddy Tongue

49. 03503 2

50. 02434 1 5/8"-13UNC x 4-1/2" Hex Head Bolt (gr.5)

51. 02587 3 5/8"-13UNC Nylon Insert Locknut

52. 02747-25 2 Bracing Strut

53. 02383 2 36" Safety Chain

54. 02579-95 2 Pivot Bushing

55. 00085 12 1/2" Flatwasher

56. 01254 2 1/2"-13UNC x 1-1/2" Hex Head Bolt (gr.5)

57. 04815 2 Grommet

58. 02772 8 1/4"-20UNC Nylon Insert Locknut

59. 04642 2 Grease Zerk

60. 01731 4 1-1/4" Dust Cap

61. 01734 2 1" dia. x 6-1/2" lg. King Pin

62. 01732 4 1"I.D. x 1-1/4"O.D. x 1-1/2"lg. Bushing (brnz)

63. 04165-26 1 Right Wheel Carrier

64. 04166-26 1 Left Wheel Carrier

- 04642 4 1/4"-28UNF Grease Zerk

65. 05587 2 1" I.D.x 14 GA Narrow Rim Machine Washer

66. 07075-26 1 KK260 Main Frame (8' wide)

- 07076-26 1 KK360 Main Frame (8-1/2' wide)

- 09528-26 1 KK260SB Main Frame (8' wide)

- 09529-26 1 KK360SB Main Frame (8-1/2' wide)

67. 04369 2 Hub and Spindle (115mm B.C.)

- 02917 - Replacement 12mm x 1.5 Stud Bolt

68. 02210 8 7/16"-20UNF x 1-1/4" grade 8 Epoxied Bolt

*69. 5179 1 Right Tie Rod End w\Right Hand Threads *70. 5178 1 Left Side Tie Rod End with Left Hand Threads

71. 07426 4 Rubber Hook Retainer

72. 01905 1 9/16"-18UNF Jam Nut w/Right Hand Threads

73. 01904 1 9/16"-18UNF Jam Nut w/Left Hand Threads

74. 01869-26 1 Tie Rod (KK260 - 8' wide)

- 04771-26 1 Tie Rod (KK360 - 8-1/2" wide)

75. 02592 16 3/8"-16UNC Nylon Insert Locknut

76. 01871-26 1 Tie Rod Shock and Stop Mount Back-up Plate

77. 01870-26 1 Tie Rod Shock and Stop Mounting Clamp

78. 02696 2 5/8"-11UNC x 2-3/4" lg. Hex Head Bolt (gr.5)

79. 00907 6 3/8"-16UNC x 1" Hex Head Bolt (gr.5)

80. 00477 1 5/8" Flatwasher

81. 01729-26 1 Steering Stabilizer Cylinder

5/8"-11 UNC x 1-1/4" Epoxied Hex Hd Bolt (gr.5)

REF. PART

NO. NO. QTY. DESCRIPTION

82. 01718-95 1 Locking Pin

- 02189 1 Black Handle Grip

83. 00182 1 Small Hair Pin

84. 03528 2 Tie Down Strap w/J-Hook

85. 04503-25 2 Tilt Bed Ramp (KK260 - 8' wide)

- 04772-25 2 Tilt Bed Ramp (KK360 - 8-1/2' wide)

86. 00078 2 7/16" Lockwasher

87. 00967 8 1/2"-13UNC x 1-1/4" lg. Hex Head Bolt (gr.5)

88. 04167 6 7/16"-20UNF x 1" lg. Hex Head Bolt (gr.8)

89. 04171-25 2 Rear Tire Stop (KK260 - 8' wide)

- 04773-25 2 Rear tire Stop (KK360 - 8-1/2' wide)

90. 00523 4 3/8"-16UNC x 1-1/4" lg. Hex Head Bolt (gr.5)

91. 00789 2 3/8"-16UNC x 3/8" lg. Hex Socket Set Screw

92. 01930 2 3/8"-16UNC x 1/4" lg. Hex Socket Set Screw

93. 04941 2

- 04826 2 ST205/75R14 "C"Range BSW Radial Tire

94. 04367 2 Rim (6 x 14) (serial # 19001 & later)

95. 02933 10 Chrome Lug Nut

- 5333 1 LH Fender Assembly (qtyís below are for 1 fender)

- 5334 1 RH Fender Assembly (qtyís below are for 1 fender)

28. 00214 3 1/4" Flatwasher

97. 05356 1 Left Fender

98. 05355 1 Right Fender

- 4 Stainless Steel Ground Strap

99. 04508 1 Amber Fender Reflective Decal

100. 04498 1 Front Fender Light with lead wire

101. 01769 1 Kar Kaddy Mud Flap

102. 05338 2 1/4"-20UNC x 3/4" lg. Brown Sltd Truss Bolt

103. 05446 1 4-1/2" Enclosed Round Tail Light

104. 05447 1 Rubber Grommet for 05446 Light

105. 04424-95 1 Fender Back-up Plate

106. 02316 1 White Ground Wire

107. 00914 3 3/8"-16UNC x 1-1/2" lg. Hex Head Bolt (gr.5)

108. 04499 3 3/8" I.D. External Tooth Lockwasher

109. 02313 1 3-Way Plug Pigtail (tail light)

110. 04944 1 5/8" Grommet (thin wall)

111. 05443 1 Cable Hanger - wire harness

112. 02298 1 22-1/2" Wire Protector Loom

113. 04425 4 Tinnerman Fender Clamp

114. 04515 1 17-1/2" Wire Protector Loom

115. 04804 1 Red Fender Reflective Decal

116. 05449 1 Spacer Bushing - Stainless Steel

117. 05444 1 3/8"-16 UNC x 3/4" Epoxied Hex Bolt (Gr 5)

118. 03382-95 1 Latch Handle Pivot Bushing

119. 03574-95 1 Latch Handle

120. 03434 1 5/16"-18 UNC x 5-1/4" Eye Bolt

121. 04221 1 5/16"-18 UNC x 2-1/2 Hex Head Bolt (Gr 5)

122. 02802 1 5/16-18 UNC Nylon Insert Locknut

123. 03381-95 1 Latch Catch

124. 00007 1 5/16"-18 UNC Hex Nut

125. 03379-95 1 Latch Block

126. 03435 1 Roll Pin (5/16" x 2-1/4")

127. 03499 1 Latch Spring - Stainless Steel

128. 03433 1 Latch Cable

129. 00004 1 5/16" Flatwasher

130. 04168 6 7/16"-20UNF Nylon Insert Locknut

- CMO8021 12 oz. Buckskin Touch-up Paint (Aerosol)

- IC8633 12 oz. Brown Touch-up Paint (Aarosol)

P195/75R14 "B" Range BSW Radial Tire (KK260)

(KK360,KK260SB,KK360SB)

* Indicates this kit includes appropri-

ate tie rod end (left or right hand threads), grease zerk, rubber cup, cotter pin and castle nut.

Page 10

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. New Departure Hyatt Hubs used on the KK260 and KK360 are warranted for a period of three years after the date of purchase by the original (first) retail owner or until itís resold or transferred by the original owner. Tires and lights are not included in this warranty.

Tires are warranted by the manufacturer against defects in materials and workmanship, but not against road hazards.

Any part of the Demco Kar Kaddy, except tires and lights, found, in the judgement of the manufacturer to be defective in materials or workmanship will be repaired or replaced at the manufacturerís option without charge for parts or labor to the original owner.

2. Manufacturer and Warrantor of Tow Dolly:

Dethmers Manufacturing Co. 4010 320th Street P.O. Box 189 Boyden, IA 51234 (712) 725-2311

The manufacturer and warrantor of the tires has his name permanently molded into the tires. Tire warranty questions and claims can be taken directly to an authorized dealer of the tire manufacturer.

3. Repair or Replacement Procedure:

If your Demco Kar Kaddy develops a defect (except for tires or lights) during the warranty period, promptly notify Dethmers Manufacturing Co. customer service department. Until such notice is received, Warrantor will not be responsible for any repair or replacement.

Upon receipt of notice from you, Warrantor will have a choice of options in replacing any part it determines to be defective:

a) Warrantor may require you at your own expense to deliver

or ship the part to its factory or authorized dealer. Any defective part will be repaired or replaced and returned to you free of charge. Any part returned to Warrantor and found not to be defective will be returned to you freight collect with an explanation.

b) Warrantor may elect to ship a new part to its dealer to be

exchanged free of charge for the defective part returned by you to the dealer.

c) Warrantor may elect to ship or deliver a replacement part

to your address.

Warranty claims on tires should be presented to a local authorized dealer of the tire manufacturer. Provide proof of purchase when making a tire warranty claim.

In addition, the warranty does not extend to repairs made necessary by normal use of parts, accessories or other equipment which in the judgment of Warrantor, are either incompatible with the Demco Kar Kaddy, or affect its operation, performance or durability.

This warranty does not cover:

1) normal wear and tear

2) road film or gravel damage to paint

3) paint

4) rust damage

5) Any Demco Kar Kaddy that has been loaded in excess of the load capacity stated on the tow dolly identification label.

Warrantor has a policy of continuous product improvement. We reserve the right to change or improve the design of any Demco Kar Kaddy model, including but not limited to state of the art changes, without assuming any obligation to modify any tow dolly previously manufactured.

Warrantor assumes no responsibility to the owner for loss of use of the tow dolly, loss of time, inconvenience or other damage consequential or otherwise, including, but not limited to expense for gasoline, expense of transporting the tow dolly to the dealer and expense of returning the tow dolly, mechanicís travel time, telephone or telegram charges, road service/towing charges, rental of another tow dolly during the time warranty repairs are being performed, travel, lodging, loss or damage to personal property or loss of revenue or earnings.

5. Limitations of Implied Warranties:

All implied warranties, if any, expire and terminate upon expiration of this warranty. Some states do not allow limitation on how long an implied warranty lasts, so this limitation may not apply to you.

6. Limitation of Consequential Damages:

Warrantorís responsibility under this warranty extends solely to repair or replacement of your Demco Kar Kaddy and its component parts. Warrantor does not assume responsibility for, nor shall it be liable for, any special, incidental or consequential damages. Some states do not allow the exclusion or limitation on incidental or consequential damages, so the above exclusion or limitation may not apply to you.

7. Use of Vehicle Identification Number (VIN):

The VIN is a 17 digit number located in the lower left corner of the tow dolly identification label. The label is located on the left side of the tow dolly frame. Be sure to include the VIN number in all communications with Warrantor or its dealers concerning the warranty.

8. Purchaserís Rights:

This warranty gives you specific legal rights, and you may also have other rights which vary from

4. Limitations on Warranty Coverage:

Coverage under this warranty will be effective only when a copy of the original invoice, showing the date and location of purchase, accompanies any claim for warranty.

Warrantor has no liability whatsoever and this warranty is null and void if any Demco Kar Kaddy has been misassembled or subjected to neglect, negligence, misuse, accident or operated in any way contrary to the operating and maintenance instructions as specified in the Demco Ownerís Manual for that model tow dolly.

This warranty does not cover any tow dolly that has been altered or modified so as to affect the tow dollyís operation, performance or durability, or that has been modified to change the intended use of the tow dolly.

Page 11

Model DA66 ACTUATOR PARTS BREAKDOWN

for 6000 lb. coupler

5495

Coupler Repair Kit

5398 Master Cylinder Repair Kit

(gasket included)

ACTUATOR PARTS LIST

REF. PART

NO. NO. QTY. DESCRIPTION

- 8606701 1 DA66 Brake Actuator complete (incl. ref. 1-25)

1. 07599-95 1 6000# 2" Ball Coupler

2. SB23278 4 Roller

3. 05957-95 1 Front Roller Spacer

4. 02166 1 3/8"-16UNC x 2-3/4" Hex Head Bolt (gr.5)

5. 07176 1 3/8" Stover Lock Nut

6. 05684 2 1/2"-13UNC x 4-1/2" Hex Head Bolt (gr.5)

7. 02178 2 1/2"-13UNC Nylon Insert Lock Nut

8. 05959 1 Push Rod Assembly

9. 05692 1 Damper/ Shock

10. 05958-95 2 Rear Roller Spacer

11. *05951 1 Emergency Lever

12. 05955-95 1 Front Cover

13. *SB24700 1 2' Cable with S-Hooks

14. SB10555 2 Replacement S-Hook ONLY

15. 05960 2 5/16"-18UNC x 1/2" Self-Tapping Screw

16. 05424 2 5/16" External Tooth Lock Washer

17. *05693-95 1 Emergency Lever Spring

18. 03876 1 Master Cylinder Cap w/ diaphragm & O-ring

19. 01076 4 1/4-20UNC x 3/4" Hex Head Bolt

20. 00057 4 1/4" Lock Washer

21. 03564-95 1 Outer Case

22. 05681 1 Replacement Master Cyl. Gasket ONLY

23. 05680 1 Master Cylinder with gasket 05681 X

24. SB12098 1 1/8" pipe - 3/6" inverted Flare Fitting

25. 05966-95 1 Back Cover

- 5400 - Lever Replacement Kit (incl. items w/*)

- 5398 - Master Cylinder Repair Kit w/ gasket

- 5495 - Coupler Repair Kit

Please order replacement parts by PART NO. and DESCRIPTION.

Page 12

DA603 BRAKE ACTUA TOR P ARTS BREAKDOWN

Components not

sold separately

5695 Emergency Lock Cam

Replacement Kit

10a

Item #23 includes cable

4 1

Item #10 is not included in 5696

5398 Master Cylinder Repair Kit (drum)

(gasket included)

ACTUATOR PARTS LIST

REF.

NO. PART NO. QTY. DESCRIPTION

- 8606301 - Plated Actuator f/ drum brakes

1. 00057 4 1/4î Lock Washer

2. 00062 4 1/4î-20 UNC Hex Nut

3. 00179 1 3/8î-16 UNC Lock Nut (Center Punch)

4. 00618 4 1/4"-20UNC x 2" Hex Head Bolt (Gr.5)

5. SB12098 1 .018 Connector Orifice (Drum Brakes)

6. 02207 1 3/8î-16UNC x 3î Hex Head Bolt (Gr. 5)

7. 03876 1 3 Tab Fill Cap w/ Diaphram & O-Ring

8. 09153 1 Master Cylinder Gasket

9. 10616 1 Composite Master Cylinder (drum)

10. 11367-95 1 Coupler/Inner Slider (plated)

10a. 5698 - Coupler/Inner Slider w/ Lever Lock Assy.

11. 11368 2 Top Plastic Slider

12. 11369 2 Bottom Plastic Slider

13. 11371-95 2 Shock Spacer (plated)

14. 11389-95 1 Rear Shock Pin (plated)

15. 11390-95 1 Outer Case (plated)

16. 11401 2 External Snap Ring

17. SB12426 1 Damper

18. 05687 1 Protective Boot (incl. in 10616 & 5398)

(incl. in 10616 & 11190)

5696 Coupler Repair Kit

(2î lever lock)

**Components not sold separately**

REPLACEMENT KITS

(components not sold separately)

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

Please order replacement parts by PART NO. and DESCRIPTION.

Page 13

MODEL DA91 ACTUATOR PARTS BREAKDOWN

**12

**10

5398 Master Cylinder Repair Kit

(gasket included)

not included

5495

Coupler Repair Kit

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.

If pressure bleeding equipment is available, follow the manufacturerís instruction in bleeding the system.

If system must be bled manually, proceed as follows: Fill master cylinder with fluid. Install bleeder hose on first wheel cylinder to be bled.

Have loose end of hose submerged in brake fluid in glass container to observe bubbling.

By loosening the bleeder screw located in the wheel cylinder one turn, the system is open to the atmosphere through the passage drilled in the screw. Pump actuator with long steady strokes. The bleeding operation is completed when bubbles no longer rise to the surface of the fluid. Be sure to close

bleeder screw securely.

Repeat bleeding operation at each wheel cylinder. During the bleeding process, replenish the brake fluid, so the level does not fall below the 1/2 full level in the master cylinder reservoir. After bleeding is complete, make sure master cylinder reservoir is filled and filler cap is securely in place.

After the bleeding operation has been completed, apply pressure to the system and check the whole brake system for leaks.

**16

Model 91 ACTUATOR PARTS LIST

REF.

NO. PART NO. QTY. DESCRIPTION

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"-13UNC Nylon Insert Lock Nut

4. 05426 1 Front Shock Pin (drop tube actuators)

5. 11079-95 1 Drop Tube Actuator Slider (plated)

6. SB12426 1 Damper/ Shock

7. 11164-95 1 3 Bolt Mount Outer Case (plated)

8. 05424 2 5/16" External Tooth Lock Washer

9. 02363 2 5/32" x 1 1/4 Cotter Pin(Qty 3 w/drop tube)

**10. 05408 1 3/32" Cable with hooks

11. SB10555 - Replacement S-Hooks ONLY

**12. 05693-95 1 Emergency Lever Spring (plated)

13. 05961 2 5/16"-18UNC x 5/8" Hex Head Bolt (gr.5)

14. 00618 4 1/4-20UNC x 2" Hex Head Bolt (gr.5)

15. 00057 4 1/4" Lock Washer

**16. 05951 1 Emergency Lever Assembly

17. 03876 1 Master Cylinder Cap w/ Diaphragm & O-ring

- 05849 1 O-Ring Only (not shown)

18. 05977 1 Push Rod Assembly

19. 00062 4 1/4-20 UNC Hex Nut

20. 09153 - Plastic Master Cyl. Gasket ONLY

21. 10616 1 Master Cylinder

- 11190 - Master Cylinder

22. SB12098 1 .018 Connector Orifice (Drum Brakes)

23. 03866-95 1 Lever Guide (plated)

24. 05687 1 Master Cylinder Protective Boot

25. 05986-95 1 Connecting Pin (plated)

26. 10965 1 Upper Slider

27. 10966 1 Lower Slider

28. 10967 2 Side Spacers

- 5401 - Lever Replacement Kit (incl. items w/**)

- 5650 - Master Cyl. Replacement Kit (drum)

- 5495 - Coupler Repair Kit

Please order replacement parts by PART NO. and DESCRIPTION

Page 14

10" SELF-ADJUSTING BRAKE CLUSTER and DRUM PARTS BREAKDOWN

BRAKE CLUSTER PARTS LIST

REF. PART

NO. NO. QTY. DESCRIPTION

- 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 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. SB9776 1 Wheel Cylinder Assembly - Right

- SB9777 1 Wheel Cylinder Assembly - Left

7. 05431 1 Bleeder - replacement

8. SB9783 1 Push Rod

9. SB24047 1 Adjusting Screw Assembly - "R" (for LEFT cluster)

- SB24048 1 Adjusting Screw Assembly - "L" (for RIGHT cluster)

10. SB10958 2 Spring - Shoe

11. SB10961-95 1 Shoe Guide

12. SB23937 1 Cable

13. SB23936 1 Cable Guide

14. SB23724 1 Spring - Adjusting Screw

15. 05415-95 1 Lever - Right

- 05414-95 1 Lever - Left

16. SB10959 2 Pin - Shoe Hold Down

17. SB9789 4 Cup Shoe Hold Down

18. 05983 2 Spring - Shoe Hold Down

19. 03380 1 Spring

- SB15845 1 Wheel Cylinder Repair Kit

- SB40929 2 10" Brake Drum

Please order replacement parts by PART NO. and DESCRIPTION.

Brake shoe kit can be ordered for one complete axle only.

(includes spring, cup and boot)

Page 15

OPTIONAL SURGE BRAKES (KK260SB and KK360SB) PARTS BREAKDOWN

Model DA603

Brake Actuator

SURGE BRAKES PARTS LIST

REF. PART

NO. NO. QTY. DESCRIPTION

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" Brake Line (KK260SB)

5. SB540 2 40" Brake Line (KK360SB)

6. SB7764 2 Rubber Brake Line Clip

SB10H136

8. 02210 8 7/16"-20UNF x 1-1/4" Epoxied Bolt (gr.8)

9. 04174 4 12mm Retainer Washer (2 per drum)

10. 00496 2 Machine Washer

11. 02549 4 Rubber Protector

12. SB7785 1 3/16 Brake Line Tee

13. SB24429 - Left Brake Cluster

-- SB24428 - Right Brake Cluster

14. SB15545 - 10î Brake Drum

Please order replacement parts by PART NO. and DESCRIPTION.

2 10" Brake Hose (rubber)

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.

If pressure bleeding equipment is available, follow the manufacturerís instruction in bleeding the system.

If system must be bled manually, proceed as follows: Fill master cylinder with fluid. Install bleeder hose on first wheel cylinder to be bled.

Have loose end of hose submerged in brake fluid in glass container to observe bubbling.

bleeder screw securely.

After the bleeding operation has been completed, apply pressure to the system and check the whole brake system for leaks.

Page 16

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. Attach rear tire stop (#7) as shown using two 3/8" x 1-1/4" grade 5 bolts (#8), flat washers (#9) and lock nuts (#10). These 3/8" x 1-1/4" bolts will also go through the tilt bed ramps. Torque 3/8" x 1-1/4" bolts to 35 ft. lbs.

3. Hold tongue up to front of trailer and locate the three bullet connectors extending out the back of the tongue

Brown Yellow Green

and plug into the connector protruding from under the main frame channel. Do not cross colors when making this connection. See drawing above. Make sure the the pigtail for the license plate bracket is out.

4. Mount the tongue (#11) to the front of the Kar Kaddy mainframe using a 5/8" x 4-1/2" grade 5 bolt (#12) and lock nut (#13)(torque to 50 ft. lbs). Do not torque over 50 ft. lbs. or bed will not tilt.

5. Mount the latch handle (#14) to the mounting plate using the 1/2" x 1-1/4" grade 5 bolt (#15), two 1/2" flatwashers (#16), bushing (#17), and 1/2" locknut (#18). Put stainless steel bushing (#19) into latch cable (#20) and secure to handle using 3/8" x 3/4" grade 5 bolt (#21) and 5/16" flatwasher (#22). Adjust latch so cable is snug by loosening bolt and nut and sliding handle forward or back.

Pigtail

Brown/Yellow

Brown/Green

6. Lay the bracing struts (#23) out along the tow dolly tongue with the back end (the end with the larger hole in it) of the bracing strut toward the mainframe. Loosely bolt the back of each bracing strut to the trailer frame as shown using 1/2" x 1-1/2" grade 5 bolt (#24), flatwasher (#25), pivot bushing (#26) and locknut (#27). Hold up the front end (the end with the smaller hole) of each bracing strut to the tongue and secure with two 5/8" x 1-1/4" epoxied hex head bolts (#28). Torque the 1/2" x 1-1/2" bolt with the pivot bushing to 75 ft. lbs. Torque the two 5/8" x 1-1/4" epoxied hex head bolts to 100 ft. lbs.

7. Remove the 7/16" x 1-1/4" bolt (#29), flat washer (#30), and lock washer (#31) from the front of each wheel platform tire stop. Slide the tie-down winches into the channel at the

front of the wheel platforms as shown. The ratchet handles are to the outside of each winch and ratchet springs are to the top. Attach two towed vehicle safety chains (#32, 36"

long). Secure one chain to each wheel platform tire stop

and replace flat washer, lock washer and 7/16" x 1-1/4" bolt.

8. Attach each hub and spindle assembly (#33) as shown using four 7/16" x 1-1/4" grade 8 epoxied bolts (#34). (Torque to 80 ft. lbs.)

9. Secure the hitch coupler (#35) and the lift handle (#36) to the front end of the tongue (#11) with two 1/2" x 4-1/2" grade 5 bolts (#37) and lock nuts (#38). The white ground wire is attached under the head of the rear bolt attaching the hitch coupler. (It is very important that a good ground is made). Torque the lock nuts to 75 - 80 ft. lbs. Tap the rubber grip (#39) onto the handle with a rubber hammer or a wooden mallet.

10. Attach the two 24" long transport safety chains (#40) to the two holes located in the tongue rest using two 7/16" x 11/4" grade 5 bolts (#41), flat washers (#42) and lock nuts (#43). Torque bolts to 50 ft. lbs.

Latch Handle

Installation

36" Chain

24" Chain

Green/Brown

Wires

Page 17

Connector

Yellow/Brown

Wires

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), 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. The final gap between the flat washer and the threaded ear is 1-1/4". Lock in place with a 5/8" lock nut (#4). Extend cylinder and attach the other end of the cylinder to the tie rod locking clamp using a 5/8" x 2-3/4" bolt and lock nut. Align locking clamp and tow dolly frame ear, slide in black handle locking pin (#5) and secure with hair pin (#6).

The "auto steer" feature is locked.

NOTE: If installed properly there should be a 1-1/4" gap

between the flat washer and the threaded ear as shown in

Figure A.

NOTE: A light film of oil should be applied to retractable

shaft of steering stabilizer cylinder to prevent rust from forming. If Kar Kaddy sets idle for extended periods of time, turn wheels of tow dolly so that the shaft is fully retracted to prevent rust.

1-1/4"

Figure A

13. Mount the license plate bracket (#7) to the frame as shown

using 1/4" x 3/4" carriage bolts (#8) and lock nuts (#9). Plug pigtail into license plate light. Install license plate and license plate clip (#29) as shown on the top of page 17.

14. Bolt the fenders (#10) on as shown using 3/8" x 1-1/2" grade 5 bolts (#11), back-up plates (#12) and lock nuts (#13) in each fender. Mount the fender with the light pocket to the rear. The 3/8" I.D. external star washer (#14) mounts

between fender inner frame and main frame mounting plate to ensure a good ground. Attach the white ground wire (the

end with the eye loop on it) under the center top bolt head.

White

Ground Wire

Grease Zerk

The tie rod and locking clamp is shown unattached to the Kar

Kaddy for illustration purposes

only. The tie rod is shipped as-

sembled for you.

Tie Rod Locking Clamp

Grease Zerk

Page 18

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. Starting at either fender, pull the loom downward from the center of the fender and push the green/brown (or yellow/brown) wires upward through the loom until it comes out by the light pocket. Push the white ground wire through the slit in the top of the loom in the fender trough toward the light pocket.

2. Push the brown clearance light wire through the loom on the front of the fender until it comes out the loom in the center of the fender, then push the brown wire through the slit in the top of the back loom and toward the light pocket until it comes out the loom. Mount the amber clearance light to the front of the fender using the stainless steel grounding strap (attached to the steel frame inside the fender)SEE BELOW, then a 1/4" flat washer and lock nut. Make sure the wire runs through the recess in the back of the light so it doesn't get pinched when tightening the mounting nut.

4. Pull the black and white wire from the pigtail through the hole in the fender pocket outward. Splice the white wire to the white wire coming out the loom. Splice the black wire to the brown wire. Splice the green (or yellow) wire to the red wire of the pigtail. Make the connections on the outside of the fender pocket, then push the connectors and wires back into the fender pocket. Push the grommet into the fender with the wire loom close to the grommet. Wrap the loom hanger tie around the wire loom and insert the peg into fender.

Triple Wire Plug

from Light

Brown

Wire

Connector

White

White Ground Wire to

Brown

Jumper

Yellow/Brown or

Green/Brown

Fender

Brown Jumper

to Front

Clearance

Light

Black

White

Red

Yellow or

Green

WIRING DIAGRAM FOR THE

TOW DOLLY FENDER

5. Push the round rubber light seal into the light pocket. Be

sure the lip is secured in the light housing. Plug the pigtail into the fender light. Push the round light into the rubber seal until it snaps in firmly. Wire the other fender in the same manner.

Inside of fender with grounding

strap attached.

3. When wiring the pigtail into the tow dolly harness at the

fender pocket, the wire ends should NOT be stripped. Use the wire connectors to make all contacts. Lay the wire in the connector, pinch securely with a pliers, close the wire connector.

Push the hollow looped end of the fender wireloom hanger into the small hole under the fender pocket on the side of the fender. Leave the holder open.

Make sure all four wires are coming out the fender wire loom. Slide the rubber fender grommet over the wires and up close to the wire loom. Splice the brown clearance fender light and tow dolly brown wire together. Make sure the connector is far enough from the loom to allow you to push the connector into the hole in the fender pocket later.

COLOR CODE FOR WIRING HARNESS

WHITE Ground BROWN Tail Lights, License Plate Lights,

Light Cluster Bar & Clearance Lights

YELLOW Left Turn and Stop GREEN Right Turn and Stop

6. Mount the mud flaps to the inside back of the fender using

two 1/4" x 3/4" brown colored truss head bolts with flat washers and lock nuts. Make sure the Kar Kaddy logo on the flap faces the rear.

7. Attach the wheels to the main frame. Use the supplied lug nuts (#4) and torque to 75 - 80 ft. lbs.

WIRING OF THE TOWING VEHICLE

Connect wiring to towing vehicle, keeping in mind the color code indicated below.

1. Make certain towing vehicle lights are "OFF".

2. Connect YELLOW wire to left turn signal and stop wire in

the left rear of towing vehicle with the wire splicer (01883) supplied.

3. Connect GREEN wire to the right turn signal and stop wire.

4. Connect BROWN wire to tail light wire.

5. VERY IMPORTANT - connect WHITE wire to frame body

of towing vehicle. This is the common ground, and a clean metal - to - metal contact must be made.

CAUTION: Many flashers for vehicle turn signals will not

carry the additional load of Kar Kaddy turn signals. If normal operation does not occur when connected to the Kar Kaddy, a heavy duty replacement flasher may be obtained through auto parts outlets.

Page 19

KAR-KADDY TOE-IN ADJUSTMENT

FRONT MEASUREMENT

(1/32" to 1/16" less than back measurement)

BACK MEASUREMENT

LOCKING

CLAMP

12"

18"

Ground

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. Clamp one bar tight to the face of each hub with 12" extending forward and backward of the center of the spindle. The bars must be parallel to the platform the car sits on. Measure across the back end of the bars and then across the front end. The front measurement should be 1/32" to 1/16" less than the back measurement. If the unit needs to be adjusted, this must be done by adjusting the tie rod.

12"

TOE-IN ADJUSTMENT

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 needed until you have a front measurement of 1/32" to 1/16" less than the back measurement.

4. Hold the tie rod and tighten the locknuts on each end.

5. Measure again to make sure the toe-in measurement has

not moved.

6. Tighten the locking clamp bolts while holding clamp between the marks you previously put on the tie rod.

7. Reassemble the rest of the Kar Kaddy unit.

Page 20

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

REF. PART

NO. NO . QTY. DESCRIPTION

KK2DF Optional Deflector

1. 02055-25 2 Deflector Framework

2. 02592 4 3/8"-16UNC Nylon Insert Lock Nut

3. 02759 2 3/8"-16UNC Square U-Bolt (fits around 3" tube)

4. 00161-95 2 Lock Handle

5. 02054-25 1 Deflector Slide Mount

6. 00095 4 3/8"-16UNC x 3/4" lg. Square Head Set Screw

7. 02743-25 1 Deflector Upright Post

8. 02165 1 Deflector Lacing Cord (1/8" x 25 ft.)

9. 02161 1 Deflector Fabric

Please order replacement parts by PART NO. and DESCRIPTION.

OPTIONAL LIGHT BAR (KKLB) PARTS BREAKDOWN

OPTIONAL DEFLECTOR PARTS LIST

REF. PART

NO. NO. QTY. DESCRIPTION

KKLB Kar Kaddy Light Bar (complete)

1. 01772 2 Nylon Security Strap with hooks & tightener

2. 01857 1 Left Tail/ Brake and Signal Light w/Lenses

3. 01773 1 Brown Jumper Wire

4. 01886 4 Wire Holder (metal)

5. 02385-25 1 Light Bar Framework

6. 02386.25 2 Adjustable Light Bracket

7. 01856 1 Right Tail/ Brake and Signal Light w/Lenses

8. 02772 10 1/4"-20UNC Nylon Insert Locknut

9. 00092 6 1/4"-20UNC x 1/2" Hex Head Bolt

10. 01777-25 2 Light Bar "Z" Bracket

11. 01778 4 3" Suction Cup w/Bolt (#13)

12. 02198 1 Light Bar Wiring Harness (new style)

13. 00068 4 1/4"-20UNC x 3/4" Hex Head Bolt

14. 01911 - Large Red Lens

15. 01912 - Small Red Lens

16. 01890 - Clear Lens

Please order replacement parts by PART NO. and DESCRIPTION.

LIGHT BAR PARTS LIST

Page 21

COLOR CODE FOR WIRING HARNESS

WHITE Ground BROWN Tail Lights, License Plate Lights,

Light Cluster Bar & Clearance Lights

YELLOW Left Turn and Stop GREEN Right Turn and Stop

OPTIONAL WINCH

PARTS LIST

REF.

NO. PART NO. QTY. DESCRIPTION

KK2W 1 Optional Winch

1. 04620 1 Winch Mechanism (1400 capacity)

- 04621 - Replacement Handle

3. 01738 1 Strap Assembly (includes strap & hook)

4. 02207 1 3/8"-16UNC x 3" Hex Hd. Bolt (gr.5)

5. 02769 2 3/8"-16UNC x 4" Hex Head Bolt (gr.5)

6. 00059 2 3/8" Flatwasher

7. 02592 3 3/8"-16UNC Nylon Insert Locknut

Please order replacement parts by PART NO. and DESCRIPTION.

* All options may not mount on tow dolly simultaneously.*

OPTIONAL TOOL BOX

PARTS LIST

KK2TB 1 Optional Tool Box

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

Please order replacement parts by PART NO. and DESCRIPTION.

* All options may not mount on tow dolly simultaneously.*

OPTIONAL SPARE TIRE and MOUNT PARTS BREAKDOWN

Drive in stud here for tire with rim #04173 X

(100mm bolt circle).

- KK8STBR 1 Optional Spare Tire and Rim

1. N/A 1 ST205/75R 14"x"C" BSW Radial Tire

2. 04367 1 6" x 14" Rim 115mm Bolt Circle

Drive in stud here for

tire with rim #04366

(115mm bolt circle).

* All options may not mount on tow dolly simultaneously.*

Page 22

KK6STM 1 Spare Tire Mounting Bracket

3. 02193-25 1 Spare Tire Bracket

4. 02917 1 Stud Bolt (12mm x 1.5)

5. 02933 2 Wheel Nut (12mm) Chrome

6. 02759 2 3/8"-16UNC Square U-Bolt

7. 00059 2 3/8" Flatwasher

8. 02592 4 3/8"-16UNC Nylon Insert Locknut

- KK6TC Optional Spare Tire Cover

Please order replacement parts by PART NO. & DESCRIP-

NOTES

Page 23

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

Page 24

Demco KK260, KK360 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual