Demco KK370SB User Manual
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.
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
Tow Dolly safety guide ...........................................................................................................................................Page 3-10
Bolt Torque ................................................................................................................................................................ Page 11
Tongue & Ramp Installation ..................................................................................................................................... Page 12
Fender Assembly Installation .................................................................................................................................... Page 13
Safety, Maintenance, & Important Loading Instructions ..........................................................................................Page 14
Loading Angle Clearance Guide ............................................................................................................................... Page 14
Loading Instructions .............................................................................................................................................Page 15-17
Kar-Kaddy KK370SB Parts Breakdown and List ................................................................................................ Page 18-19
Winch Assembly ........................................................................................................................................................ Page 20
Latch Assembly ......................................................................................................................................................... Page 20
License Plate Bracket Assembly .............................................................................................................................. Page 21
Fender Assembly ...................................................................................................................................................... Page 21
Limited Warranty Information .................................................................................................................................... Page 22
DA91 Brake Actuator Parts Breakdown and List ..................................................................................................... Page 23
10" Self-Adjusting Brake Cluster Parts Breakdown and List ................................................................................... Page 24
Surge Brakes Parts Breakdown and List.................................................................................................................. Page 25
Testing Lights Before Use ......................................................................................................................................... Page 26
Wiring Diagram .......................................................................................................................................................... Page 26
Kar-Kaddy Toe-In Adjustment .................................................................................................................................. Page 27
Wheel Jack, Deflector, & Light Bar (optional) Parts Breakdown and List ............................................................... Page 28
Winch, Tool Box, & Spare Tire w/Mounting Bracket (optional) Parts Breakdown and List .................................... Page 31
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 between you, your dealer, or Dethmers Manufacturing
Company (DEMCO).
Page 2
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.
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.
!
THIS SYMBOL MEANS
-ATTENTION
-BECOME ALERT
-YOUR SAFETY IS INVOLVED!
SIGNAL WORDS
This manual uses the following signal words-DANGER, WARNING, and CAUTION-- with safety
messages. The appropriate signal word has been
selected using the following guidelines.
DANGER:
Indicates an imminently hazardous situation that,
if not avoided, will result in death or serious injury.
This signal word is to be limited to the most extreme
situations typically for tow dolly components which,
for functional purposes, cannot be guarded.
WARNING:
Indicates a potentially hazardous situation that, if
not avoided, could result in death or serious injury,
and includes hazards that are exposed when
guards are removed. It may also be used to alert
against unsafe practices.
CA UTION:
Indicates a potentially hazardous situation that, if
not avoided, ma y result in minor or moderate injury .
It may also be used to alert against unsafe
practices.
If you have questions not answered in this manual, or require additional copies, please contact your
dealer or Dethmers Mfg. Co., P.O. Box 189, 4010 320th Street, Boyden, IA 51234
ph: (712) 725-2311 Toll Free: 1-800-543-3626 Fax: (712) 725-2380 http://www .demco-products .com
Page 3
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. IF YOU HAVE
ANY QUESTIONS ABOUT THIS, DO NOT TOW. CONSULT YOUR DEALER OR CALL
DEMCO.
• Use a 2", 5000 lb. (or greater) capacity ball for a tow dolly without surge brakes and a 2", 6000
lb. (or greater) capacity ball for a tow dolly with surge brakes.
• Make sure towing vehicle’s parking brake is fully engaged before starting hookup, loading,
unloading, or unhooking of tow dolly.
• Do not load towed vehicle onto tow dolly until tow dolly is completely and properly hooked up
to towing vehicle and setting on a level surface.
• Tail lights and stop lights must be hooked up and operating properly at all times.
• Do not load a towed vehicle that exceeds weight or size limits of tow dolly.
• Always have someone safely guide you when driving towed vehicle onto tow dolly.
• Be sure tires of your towed vehicle and tow dolly are in good condition and inflated to proper
pressures. Tire pressure may increase during travel—do not bleed off extra pressure.
• Do not back up your towing vehicle when a tow dolly is attached. A tow dolly swivels both at
the coupler and at car platform. If you must back up, unload towed vehicle first, disconnect
tow dolly and move vehicle and tow dolly separately. Park where you can pull ahead when
leaving.
• Do not exceed 55 miles per hour, or any lower posted speed limit.
• Avoid sharp turns or swerves.
• Braking distance increases when using a tow dolly. Use caution and always allow sufficient
distance for braking.
• Do not transport passengers or cargo in vehicle being towed.
• Do not unhook tow dolly from towing vehicle until towed vehicle is completely unloaded from
tow dolly.
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• 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.
• ALWAYS slow down—40 miles per hour or less—for curves, wet or rough roads, and
downgrades. On downgrades, shift into a lower gear and allow engine to help hold speed
down.
• ALWAYS be rested. NEVER drive when fatigued.
• AVOID driving at night. Night drivers have three times the fatality rate of day drivers.
• NEVER continue to operate an unstable (swaying or whipping) combination. If this occurs,
slowly pull over, reducing speed through your engine rather than braking. When stopped in
an off the road location check hitch, tire straps, and chains.
• NEVER pass on hills or curves. Beware of cross winds and wind gusts from passing vehicles.
• NEVER transport passengers or cargo in towed vehicle.
• ALWAYS load vehicle-in-tow facing forward. NEVER back onto tow dolly. For maximum
stability steering axle must be on tow dolly.
• 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.
THE MOST IMPORTANT PART - IS YOU
Will you read and follow these instructions on how to safely operate this Dethmers Tow
Dolly?
If your answer is YES, we thank you for your attitude and believe your towing experience
will be a safe and pleasant one.
SAFETY CHECKLIST
While Stopped Check
• That Hitch is Tight
• That Hitch Ball is Tight
• Coupler Lever Lock
• Are Tire Tie Down Straps Tight
• Are Hitch Safety Chains and Vehicle-in-Tow Frame Security Chains Properly Attached
• Are Tire Pressures OK
• Vehicle-in-Tow for Working Lights
• Are Drive Shaft and Battery Cable Disconnected and Secured If Required
Page 5
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.
Suspension
Your tow vehicle’s rear springs must be of sufficient strength to support the added loaded tow
dolly tongue weight while maintaining tow vehicle in approximately a level position. If rear springs,
shock absorbers, or struts, are weak or broken, they must be replaced. In some cases, it may be
necessary to add helper springs or air shocks to help support weight properly. Poor wheel
alignment, loose steering or worn suspension components can also adversely affect vehicle
handling and stability.
Sport Utility Vehicles
Exercise caution when towing with a sports utility (e.g., Jeep or Bronco) type vehicle. Some of
these vehicles have a higher than normal center of gravity, and a short wheelbase. This gives them
different handling characteristics than the average car or truck.
Tires
You must increase pressure in rear tires of tow vehicle to accommodate extra weight of tow dolly.
When cold, inflate rear tires to approximately 6 pounds above their normal operating pressure, but
DO NOT exceed pressure limit molded into tire sidewall. Normal pressure should be maintained
in tow vehicle’s front tires.
Tow dolly tires should be inflated to pressure recommended on operational decal on fender (45
or 50 psi). These are COLD pressures, and will increase when tires are hot from running. DO NOT
bleed off this pressure increase. Incorrect tire pressure can adversely affect vehicle handling and
gas mileage.
Mirrors
State laws require vehicles towing a tow dolly to be equipped with mirrors on both sides.
Inadequate side mirrors create a hazard by limiting rearward vision. If your vehicle is not already
so equipped, you should put right and left hand full view, detachable mirrors on. Ask dealer if it has
any available for rent if you do not want to purchase them.
Page 6
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. Automatic transmissions may
need an external oil cooler installed for unusually difficult or extended towing.
Engine and transmission heat increase as vehicle speed increases. To maintain proper
cooling, do not exceed 55 m.p.h. regardless of engine size or load.
Hitch
Be certain that hitch and hitch ball are securely attached and that hitch ball is 2" in diameter. A
minimum rating of class II (3500 lbs) is required for both hitch and hitch ball.
Some sports utility vehicles are equipped with a bumper type hitch from the factory. DO NOT
USE THESE HITCHES, since bumper may not have sufficient structural capacity to handle the
load. Equip your vehicle with a hitch attached to the undercarriage of your vehicle.
Lights
Lights are required on tow dollies in every state. If your vehicle is not already equipped for tow dolly
light hook-up, it will be necessary to install connections now. Your dealer will let you know exactly
what is needed for your particular vehicle.
Tow Vehicle Loading
A loaded tow dolly tongue weight (approximately 200 lbs.) contributes to total cargo weight of tow
vehicle. Tow vehicle manufacturer’s recommended maximum passenger/cargo load must not be
exceeded.
VEHICLE-IN-TOW
Limitations/Cautions
1. Vehicle-in-tow must Not be wider than 76 inches at front doors to prevent damage to doors from
contact with tow dolly fenders on turns.
2. Vehicle-in-tow must Weigh no more than 4,400 lbs.
Exceeding these limits may cause damage to tow dolly or vehicles.
Vehicle-in-tow tire tread must fit on ramps without overhanging sides. Track width (distance from
left front tire center to right front tire center) must be between 49 and 59 inches.
Low hanging spoilers and air dams may be damaged by contact with tow dolly ramps when loading
and unloading. Be sure there is adequate clearance for these. If not, they must be removed before
loading.
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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. The universal joint bearing caps must be taped on to prevent loss of bearings.
If you choose to remove drive shaft entirely, it may be necessary to cap transmission tail shaft to
prevent fluid loss and possible future damage. Consult your vehicle owner’s manual.
Front wheel drive vehicles need not have drive shafts disconnected because the drive wheels
are loaded on tow dolly.
Towing damages many rear engine vehicle with transaxles. Consult owner’s manual for tow
suitability.
Passengers And Cargo Prohibited in the Vehicle-in-Tow
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. Follow
instructions carefully when installing.
TOW DOLLY HOOK UP
Double Check
After rental company has “hooked up” your tow dolly, it is wise for you to double-check
connections both before and during trip.
ALWAYS FOLLOW HOOK-UP, LOADING, AND UNLOADING INSTRUCTIONS ON FENDER
DECALS OF TOW DOLLY. IF YOUR TOW DOLLY DOES NOT HAVE INSTRUCTIONS OR IF
THEY ARE ILLEGIBLE, ASK COMPANY FOR A LEGIBLE COPY.
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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.
Please do not be lulled into a false sense of security because your tow dolly tows easily at higher
speeds. A road hazard that would be avoidable at 55 m.p.h. can become unavoidable at 65 m.p.h.
If you drop any wheel(s) off the pavement, don’t attempt any sharp steering corrections.
Remain off the pavement, decrease your speed until you have regained control, then drive
slowly back onto pavement.
Never Operate An Unstable Combination
Instability (swaying or whipping) of a tow vehicle/ tow dolly combination at low speeds usually
increases at higher speeds. If combination begins to whip or sway, steer straight ahead, take your
foot OFF the throttle, but do not brake until combination has stabilized. Stop in an off the road
location and check tow vehicle and tow dolly as soon as possible.
• Review all instructions and be sure you have complied.
• Check that vehicle on tow dolly is loaded with front wheels on tow dolly. Reload if necessary.
• Check that all chains and tie down equipment remain tight and properly attached.
• Check for proper tire inflation all around combination.
• Make sure trunk or bed of towing and towed vehicles are not loaded with cargo.
• Check wheel bearings and lug nuts on both tow vehicle and tow dolly to be sure a wheel has
not become loose.
• Check tow vehicle’s wheel alignment.
• Finally, be sure you are not exceeding maximum recommended speed (55 MPH).
If you have followed preceding instructions, any instability should be corrected. If situation
persists, stop and call for professional assistance from a tow truck operator.
Page 9
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.
Rough Roads
To prevent damage to tow vehicle or tow dolly, reduce speed when towing tow dolly over rough
roads.
Turning
Avoid U-turns. Avoid turning too sharply. Turning too sharply may cause side of vehicle-intow to come in contact with rear of dolly fender and cause damage to both vehicles.
“Pro” Driving Tips
Accidents occur more frequently at night with a tired driver exceeding recommended speed on
a downgrade, wet road, or curve. Don’t attempt to drive “straight through.” Be rested. Slow down
for down-grades, wet roads or curves. Night drivers have three times the fatality rate of day drivers.
Avoid driving at night.
ACCIDENTS
Move all vehicles completely off the road.
Get everyone out of the vehicle and off the road. Call police.
Dethmers Manufacturing Company wants you
to have a safe towing experience.
Read these instructions carefully,
read fender decals on tow dolly,
and follow all instructions.
Page 10
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