Demco KK260, KK360 User Manual
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
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.
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
87
5217
117
46
120
116
for
Fulton
5000 lb.
coupler
55
118
119
55
42
not included
Coupler Repair Kit
126
123
124
127
129
122
125
KIT #5511
TILT-BED LATCH
ASSEMBLY
53
99
47
100
86
63
46
98
75
59
61
60
Right Fender
113
106
114
108
62
65
54
55
56
105
*69
107
42
33
112
*69
104
110
111
109
90
103
89
51
90
51
58
88
57
80
78
*69
*69
66
72
81
46
75
82
2
83
5
34
45
37
35
42
38
44
45
Part# 07426
Hook Retainer
Replacement Only
43
46
47
71
2
48
39
52
49
35
10
52
41
40
49
1
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)
36
58
50
56
55
54
100
Page 8
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