Demco KK460SS User Manual

7-06

RD20010,Rev 6

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

Safety, You can Live With.................................................................................................................... Page 3-7

Decal Location ........................................................................................................................................ Page 8

Bolt Torque ............................................................................................................................................. Page 9

Tongue and Ramp Assembly ............................................................................................................... Page 10

Fender Assembly .................................................................................................................................. Page 11

Wiring Diagram ..................................................................................................................................... Page 12

Testing Lights........................................................................................................................................ Page 12

Tongue Folding ..................................................................................................................................... Page 13

Folding Ramps................................................................................................................................. Page 14-15

Loading Angle Clearance Guide........................................................................................................... Page 15

Safety, Maintenance, & Important Loading Instructions ....................................................................... Page 16

Loading Instructions...................................................................................................................... Pages 17-19

Toe-In Adjustment................................................................................................................................ Page 20

DA91 Brake Actuator Parts Breakdown and List.................................................................................. Page 21

10" Self-Adjusting Brake Cluster Parts Breakdown and List ................................................................ Page 22

Brakes Line Parts Breakdown and List................................................................................................. Page 23

Kar-Kaddy Breakdown Parts Assembly Instructions .................................................................... Pages 24-25

Winch and Tilt-Bed Parts Breakdown................................................................................................... Page 26

Ramp Latch and License Plate Bracket Parts Breakdown ................................................................... Page 27

Fender Parts Breakdown ...................................................................................................................... Page 28

Winch, Tool Box, & Spare Tire w/Mounting Bracket (optional) Parts Breakdown and List .................. Page 29

Deflector, & Light Bar (optional) Parts Breakdown and List .................................................................. Page30

Product Warranty .................................................................................................................................. Page 31

Warranty Registration ...................................................................................................................... Page 33-34

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).

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.

SAFETY

T AKE 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

Note the use of the signal words DANGER, WARNING and

CAUTION with the safety messages . The appropriate signal

word for each has been selected using the following guidelines:

DANGER:

Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.

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 or 1-800-845-6420

http://www.demco-products.com

WARNING:

Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. It may also be used to alert against unsafe practices.

CA UTION:

Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury . It ma y also be used to alert against unsafe practices.

REMEMBER

Your best assurance against accidents is a careful and responsible operator. If there is any portion of this manual or method of operation you do not understand, contact your local authorized dealer or manufacturer.

SAFETY...YOU CAN LIVE WITH IT

EQUIPMENT SAFETY GUIDELINES

Every year many accidents occur which could have been avoided by a few seconds of thought and a more careful approach to handling equipment. You, the operator , can av oid many accidents by observing the following precautions in this section. To avoid personal injury, study the following precautions and insist those working with you, or you yourself, follow them.

Replace any caution, warning, danger or instruction safety decal that is not readable or is missing. Location of such decals is indicated in this booklet.

Do not attempt to operate this KK460SS under the influence of alcohol or drugs. Review the safety instructions with all users. Operator should be a responsible adult. DO NOT ALLOW PERSONS TO OPERATE OR ASSEMBLE THIS

UNIT UNTIL THEY HA VE DEVELOPED A THOROUGH UNDERST ANDING OF THE SAFETY PRECA UTIONS AND HOW IT WORKS.

Do not paint over , remov e, or def ace any safety signs or w arning decals on your KK460SS . Observe all safety signs and practice the instructions on them.

Never exceed the limits of a Kar Kaddy SS If its ability to do a job safely is in question

DON'T TRY IT.

LIGHTING AND MARKING

It is the responsibility of owner to know lighting and marking requirements of local highway authorities and to install and maintain equipment to provide compliance with regulations.

Light bar kits are available from your dealer or from manufacturer.

TIRE SAFETY

• Failure to follow proper procedures when mounting a tire on a rim can produce an explosion which may result in serious injury or death.

• Do not attempt to mount a tire unless you have proper equipment and experience to do the job.

• Inflating or servicing tires can be dangerous. Whenever possible, trained personnel should be called to

service and/or mount tires.

• KK460SS tires must be inflated to recommended P.S.I. . See decal on KK460SS for correct pressure.

• Always order and install tires and wheels with appropriate type and load capacity to meet or exceed gross

weight of unit.

SAFETY SIGN CARE

• Keep safety signs clean and legible at all times.

• Replace safety signs that are missing or have become illegible.

• Replacement parts that displayed a safety sign should also display current sign.

• Safety signs are available from your distributor, dealer parts department, or factory.

How to install safety signs:

• Be sure installation surface is clean and dry.

• Decide on exact position before you remove backing paper.

• Remove smallest portion of split backing paper.

• Align decal over specified area and carefully press small portion with exposed sticky backing in place.

• Slowly peel back remaining paper and carefully smooth remaining portion of decal into place.

• Small air pockets can be pierced with a pin and smoothed out using piece of decal backing paper.

BEFORE OPERATION:

• Carefully study and understand this manual.

• Keep wheel and lug nuts tightened to specified torque.

• Assure tires are inflated evenly.

• Give unit a visual inspection for any loose bolts, worn parts, or cracked welds, and make necessary repairs.

Follow maintenance safety instructions included in this manual.

• Be sure there are no tools lying on or in KK460SS

• Do not use unit until you are sure that area is clear, especially around children and animals.

• Don't hurry learning process or take unit for granted. Ease into it and become familiar with your new KK460SS

• Practice operation of your KK460SS and its attachments. Completely familiarize yourself and other

operators with its operation before using.

• Make sure that brakes are evenly adjusted (if equipped with brakes)

• Securely attach to towing vehicle. Use an appropriately sized and rated hitch ball and attach safety chains.

• Do not allow anyone to stand between tongue or hitch and towing vehicle when backing up to unit.

• Make sure tow rating on vehicle is high enough for what it is towing.

DURING OPERATION

• SAFETY CHAIN - Always follow state and local regulations regarding safety chains and auxiliary lighting when towing. Be sure to check with local law enforcement agencies for your own particular regulations. Only safety chains (not elastic or nylon/plastic tow straps) should be used to retain connection between towing vehicle and towed unit in event of separation.

• Do not load towed vehicle with cargo. Towed vehicles exceeding weight limits will overload KK460SS and may cause serious injury and damage.

• Criss cross safety chains under tongue, secure to mounting loops on towing vehicle.

• Secure emergency brake actuator cable to mounting loop on towing vehicle.

• Beware of bystanders, PARTICULARLY CHILDREN! Always look around to make sure it is safe to start engine

of towing vehicle or move unit. This is particularly important with higher noise levels, as you may not hear people shouting.

• NO PASSENGERS ALLOWED- Do not carry passengers anywhere on or in towed unit.

• When halting operation, even periodically, set towing vehicle parking brake, shut off engine, and remove ignition

key.

• Be extra careful on inclines.

• MANEUVER TOWING VEHICLE AT SAFE SPEEDS. Do not exceed 55 M.P.H.

• Avoid overhead wires or other obstacles. Contact with overhead lines could cause serious injury or death.

• Avoid loose gravel, rocks, and holes; they can be dangerous for unit operation or movement.

• Allow for unit length when making turns.

• Do not work under raised components or attachments unless securely positioned and blocked.

• Keep all bystanders and pets clear of work area.

• Operate towing vehicle from operators seat only.

• As a precaution, recheck hardware on KK460SS every 50 miles, and correct all problems. Follow

maintenance safety procedures.

FOLLOWING OPERATION

• Following operation, or when unhitching, stop towing vehicle, set parking brake, shut off engine and remove ignition key.

• Store KK460SS in area away from human activity.

• Do not permit children to play on or around stored KK460SS.

• Make sure parked KK460SS is on hard, level surface.

• Wheel chocks may be needed to prevent unit from rolling.

HIGHW AY AND TRANSPORT OPERATIONS

• Adopt safe driving practices:

- Always drive at safe speed relative to local conditions and ensure that your speed is low enough for an emergency stop. Do not exceed 55 M.P.H.

- Reduce speed prior to turns to avoid risk of overturning.

- Always keep towing vehicle in gear to provide engine braking when going downhill. Do not coast.

- Do not drink and drive!

• Comply with state and local laws governing highway safety.

• Local laws should be checked for all highway lighting and marking requirements.

• Plan your route to avoid heavy traffic.

• Be a safe and courteous driver. Always yield to oncoming traffic in all situations, including narrow bridges,

intersections, etc.

• Watch for obstructions overhead and to both sides while transporting.

• Operate with maximum visibility at all times. Make allowances for increased length and weight of KK460SS when

making turns and stopping.

PERFORMING MAINTENANCE

• Good maintenance is your responsibility. Poor maintenance is an invitation to trouble.

• Make sure there is plenty of ventilation. Never operate engine of towing vehicle in a closed

building. Exhaust fumes may cause asphyxiation.

• Before working on KK460SS, stop towing vehicle, set parking brake, tur n off engine and remove ignition key.

• Always block wheels and never use a jack as sole support.

• Always use proper tools or equipment for job at hand.

• Use extreme caution when making adjustments.

• Follow torque chart in this manual when tightening bolts and nuts.

• Openings in skin and minor cuts are susceptible to infection from brake fluid.

Without immediate medical treatment, serious infection and reactions can occur.

• After servicing, be sure all tools, par ts and service equipment are removed.

• Do not allow grease or oil to build up on any step or platform.

• When replacing bolts, refer to owners manual for proper size and grade.

• Refer to bolt torque chart for head identification marking.

• Where replacement parts are necessar y for periodic maintenance and servicing, genuine factor y replacement

parts must be used to restore your KK460SS to original specifications. Manufacturer will not claim responsibility for use of unapproved parts and/or accessories or other damages as a result of their use.

• If KK460SS has been altered in any way from original design, manufacturer does not accept any liability for injury or warranty.

• A fire extinguisher and first aid kit should be kept readily accessible while perf orming maintenance on this KK460SS

PINCH POINT

REV 0 DD21018

A. DD21018

WARNING

To prevent serious injury or death.

Make sure tongue is in forward locked position with locking pin and retainer clip properly installed before hooking up or loading.

REV 0 DD21019

B. DD21019 QTY. 1

F. RD21008 QTY. 2

Decal Location

D. DD21017 QTY. 4

Loading Towed VehicleE

WARNING

Read towing instructions in towed vehicle owners manual. Use 2” 5000 lb. (or greater) capacity ball for Kar Kaddy without surge brakes and 2” 6000 lb. (or greater) capacity ball for Kar Kaddy with surge brakes. Assure towing vehicle parking brake is fully engaged before starting hookup, loading, unloading or unhooking Kar Kaddy. Don’t load towed vehicle onto Kar Kaddy until Kar Kaddy is completely and properly hooked up to towing vehicle and setting on level surface. Always drive front wheels of towed vehicle onto Kar Kaddy. Don’t load backwards. Tail lights and stop lights must be hooked up and operating properly at all times. Don’t load towed vehicle that exceeds weight or size limits onto Kar Kaddy. Always have someone safely guide you when driving towed vehicle onto Kar Kaddy. Assure tires of towed vehicle and Kar Kaddy are in good condition and properly inflated. Tire pressure may increase during travel, Do not bleed off this increase in pressure. Don’t back towing vehicle with Kar Kaddy attached. Kar Kaddy swivels both at coupler and at car platform. If you must back up, unload towed vehicle first, disconnect Kar Kaddy and move vehicle and Kar Kaddy separately. Play it safe... park where you can pull ahead when leaving. Braking distance increases when using Kar Kaddy. Use caution and always allow sufficient braking distance. Avoid sharp turns or swerves. Descend hills in lower gear. Avoid sudden braking or lane changes when descending a hill. Don’t transport passengers or cargo in vehicle being towed. Don’t unhook Kar Kaddy from towing vehicle until towed vehicle is completely unloaded from Kar Kaddy.

42” min.

good condition and not rusted, loose or stripped. Both hitch and hitch ball must be securely attached to towing vehicle.

under tongue and attach to mounting loops on towing vehicle. If Kar Kaddy is equipped with brakes attach emergency brake cable to one of these loops. Allow some slack in chains and cable for movement during turning. Failure to follow these instructions could result in serious injury or death.

1.Assure towing vehicle and Kar Kaddy are straight, on level ground, and properly hooked up before loading towed vehicle.

2.Remove winch lock pins (A) from strap winches on front of Kar Kaddy. RELEASE WINCH: Grasp handle (B) squeeze trigger (C) push down and pull all excess strap from winch. Lay tire strap to outside of Kar Kaddy.

3. Remove STEERING LOCK PIN before loading vehicle onto Kar Kaddy to allow AUTO STEER

WHEN KAR KADDY IS EMPTY, THIS

to operate. PIN MUST BE REINSERTED

4. Loosen wing nut on back of license plate holder, turn clip on front to horizontal position and put license in “down” position. Turn clip back so it rests against back of light to hold license “down” and tighten wing nut. (License must be “up” with Kar Kaddy empty).

5. Grasp bed release handle on tongue and pull toward coupler. This releases tilt bed.

6. Before loading (and unloading) towed vehicle make sure platform and towed vehicle are in straight alignment. Don’t load towed vehicle onto KAR KADDY until completely and properly hooked up to towing vehicle and setting on level surface.

7.With someone safely guiding you, center vehicle to Kar Kaddy. Slowly drive vehicle forward, until tires touch wheel stops at front of platform. DO NOT BACK VEHICLE ONTO KAR KADDY. Assure that towed vehicle is centered on Kar Kaddy platform and tires fit in wheel pans without hanging over sides.

8.Place towed vehicle in park (low gear if it has standard transmission), engage parking brake, shut off engine, remove ignition key, lock steering wheel of towed vehicle with tires in a straight forward position. If towed vehicle does not have a locking steering column, steering wheel must be securely tied.

9.Place tire straps over tires centering straps and winches to tires, avoiding contact with suspension components. Short side of hook must face rear of Kar Kaddy. While tightening straps, pull cross straps forward to ensure even tightening. Tighten straps until each tire starts to flatten against tire stop. After strap is tight and with ratchet handle in down (horizontal) position insert lock pin through hole in ratchet pawl arm

and ratchet frame then attach retainer

clip.

Hook safety chains to frame of towed vehicle directly above area where chains are mounted on Kar Kaddy. IMPORTANT: Chains must not attach to or go over steering or brake parts. Leave enough slack in chains for suspension movement. Check tire straps after first 5 miles of travel and every 50 miles thereafter to ensure they are tight and not rubbing or fraying on suspension components of towed vehicle.

10. If towed vehicle is rear wheel or four wheel drive, disconnect drive shaft. (Simply placing transmission in neutral is not sufficient to prevent damage to transmission). You must disconnect drive shaft at rear axle and remove it. With the drive shaft removed it will be necessary to cap the transmission tail shaft to prevent transmission fluid loss. Rear engine/transaxle vehicle cannot be towed with Kar Kaddy. (All vehicles loaded on Kar Kaddy must be loaded with front of vehicle facing forward). Consult your vehicle owner’s manual to help determine if and how your vehicle is suitable to be towed. RELEASE

PARKING BRAKE ON TOWED VEHICLE.

11. Ensure that steering wheel is locked in straight forward position, remove ignition keys and lock doors of towed vehicle.

12. Release parking brake on towing vehicle and drive forward 100 feet. Stop and perform safety check. Check hitch, hitch ball, ball coupler, safety chains, tire straps, bolts and other items to ensure they are tight and in correct position. Check all lights to make sure they are operating properly. Repeat safety check after first 5 miles and every 50 miles thereafter. NOTE: Do not unhook Kar Kaddy from towing vehicle until towed vehicle is completely unloaded from Kar Kaddy.

Unloading Towed Vehicle

1.Assure towing vehicle and Kar Kaddy are straight, on level ground, and properly hooked up before unloading towed vehicle.

2.Fully engage parking brake of towing and towed vehicles.

3.If removed, reinstall drive shaft of towed vehicle.

4.Straps may be “quick released” by removing locking pin, grasping ratchet pawl and ratchet handle simultaneously and pushing down sharply. This process will permit easy removal of strap from winch.

5.Remove tire straps and safety chains from towed vehicle. Also release tilt bed as shown in illustration #5.

6.Release parking brake of towed vehicle and slowly back towed vehicle off Kar Kaddy.

7.On level ground check the transmission fluid level of towed vehicle. Fluid may have leaked out during towing.

8.Store safety chains and straps in their storage position on each side.

9.Return tilt bed to locked position and reinsert steering lock pin. As shown in illustration #3

Read following information before hooking up, loading, using, unloading or unhooking Kar Kaddy to prevent property damage, serious injury, or death.

IMPORTANT DO’S & DON’TS

IMPORTANT INFORMATION

Customer Responsibilities

Customer assumes all risks inherent in operation, use, or possession of Kar Kaddy. Towing a vehicle is owners responsibility and it is the owner who must ensure that weight and size limits of Kar Kaddy will not be exceeded by vehicle being towed. Any injury or damage that results from improper use or exceeding weight or size limits is sole responsibility of owner.

Towing Vehicle Requirements

Owner assumes all responsibility for towing vehicle’s fitness and suitability to perform towing task in safe, legal, and reliable manner. These responsibilities may include, but are not limited to:



Towing vehicle weight being substantially





greater (at least 1000 lbs.) than weight of Kar Kaddy and towed vehicle combined.

Compliance with towing restrictions as stated



by towing vehicle owner’s manual or manufacturer.



Towing vehicle having minimum of 5000 lb. hitch and hitch ball for Kar Kaddy without surge brakes, or 6000 lb. hitch and hitch ball for Kar Kaddy with surge brakes. Hitch ball must be 2”. Do not use any other size hitch ball.



Towing vehicle’s hitch being approximately 18 inches to top of hitch ball. Make sure that hitch and hitch ball are in good condition and not rusted, loose or stripped. Both hitch and hitch ball must be securely attached to towing vehicle.



Towing vehicle must be in good condition.



Towing vehicle having a current federal or state inspection where applicable, and complying

with any applicable laws.



Assure all lights are properly hooked up and

operating at all times.

Load Weight and Size Limits

Load weight is total weight of towed vehicle. Overloading Kar Kaddy may cause serious injury or damage to both towed vehicle and Kar Kaddy.

Maximum Towed Vehicle Weight.

KK260 KK260SB KK360 KK360SB 4400 lbs. 4700 lbs. 4400lbs. 4700lbs.

Size limit is overall width. Towed vehicle exceeding size limit will obstruct platform’s turning action when towing and could damage towed vehicle’s tires and fenders.

KK260: 70” max.

KK360 76” max.

INSTRUCTIONS

Kar Kaddy Hook-Up

1.Assure towing vehicle parking brake is fully engaged.

2.Loosen coupler lock, place coupler of Kar

Kaddy over 2” hitch ball on towing vehicle. Assure coupler is fully seated on ball then completely tighten coupler lock. Pull up on Kar Kaddy tongue to assure it is properly secured. NOTE: Assure that hitch and hitch ball are in

3.Connect Kar Kaddy wire harness to connector on towing vehicle and check lights for proper operation.

4. Criss cross safety chains

REV 1 RD21002

E. RD21002 QTY. 1

PULL & LIFT

FOLD RAMP

Rev 0 DD21020

C. DD21020 QTY. 2

Remove winch lock pins (A) from strap winches on front of tow dolly. Release winch: Grasp handle (B) squeeze trigger (C) push down and pull all

excess strap from winch. Lay tire strap to outside of tow dolly. Tighten straps: Place tire straps over tires centering straps and winches to tires. While tightening straps, pull cross straps forward to ensure even tightening. Tighten straps until each tire starts to flatten against tire stop. After strap is tight, insert lock pin into winch.

REV 1 DD21016

WINCH OPERATING INSTRUCTIONS

F. DD21016 QTY. 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 char t 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 Lug Nuts to 120 FT/LBS

Torque figures indicated are valid for non-greased or non-oiled threads and heads unless otherwise specified. 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 Torque 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) 106 (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

10.9

Tongue and Ramp Assembly Instructions

1. Place the main frame (#1) on blocks or some other sturdy

support so that the frame rests approximately 8" - 10" off the ground.

2. With an assistant, place tongue assembly (#2) into main frame channel and position latch on tongue approximately 3” from front of channel. Clamp tongue to main frame and support front of tongue.

3. Locate the four bullet connectors extending out the back of the tongue and plug into the connector protruding from under the main frame channel. Plug into the flat four connector by matching the colors. Do not cross colors when making this connection. Make sure that the two pigtails for the license plate bracket are out.

4. Using the open end of a 9/16” wrench to support the back of the male coupler, (as shown below) push drip free quick couplers together. (Factory setup units will not havequick couplers)

5. With an assistant, mount the tongue assembly (#2) to the front of the Kar Kaddy main frame and use a 5/8" x 4-1/2" grade 5 bolt (#3) and lock nut (#4)(torque to 50 ft. lbs). Do not torque over 50 ft. lbs. or bed will not tilt. NOTE: Brake line and wiring must be above bolt also coupler assembly must be ahead of bolt. Do this by opening tongue about half way.

6. Lay the bracing struts (#5) out along the tow dolly tongue with the back end (the end with the larger hole in it) of the bracing strut toward the main frame. Loosely bolt the back

of each bracing strut to the trailer frame as shown using 1/ 2" x 1-1/2" grade 5 bolt (#6), flatwasher (#7), pivot bushing (#8) and locknut (#9). 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 (#10) and nut plate (#14). 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. On the main unit, pull ramp latch (#11) out and up in unlatched position.

8. Use four 1/2” x 1-1/2” bolts (#6), 1/2” flat washers (#7) and yellow plated bushings (#12) and place in the front slotted hole and the rear slotted hole on both sides of ramp (#13). Use four 1/2” nylon lock nuts (#9) and snug these bolts so they can slide up and down in slot.

9. Place ramp (#13) in main frame (#1). Front bolts and bushings go in front open slot of ramp mount. Lift ramp up and push forward until rear bolts and bushings go into rear half slot.

10. Engage Ramp latch (#11) and move ramp around so latch can engage through ramp. With the use of two clamps, secure ramp to main frame. Install the remaining 1/2” x 1-1/2” bolts (#6), flatwashers (#7), yellow bushings (#12), and nylon lock nuts (#9) into the remaining slotted holes.

11. Tighten all six bolts. Pull and lift ramp latch (#11) and pull ramp back and fold up. If ramp is too tight when pulling back, reclamp ramp as in previous step and loosen bolts so ramp lowers away from main frame. Tighten bolts and retry.

12. Repeat steps 7-11 for other side.

Connecting Drip Free Quick Coupler

brake couplers.

Not needed for factory setup units.

Female Coupler

Male Coupler

9/16 Wrench

3”

8 7

Connector

12 7

Fender Assembly Instructions

1. Install fender with fender backup plate (#1) and three 3/8”

x 1-1/2” bolts (#2). Put 3/8” nylon lock nuts (#3) inside of fender and tighten.

2. Cut nylon wire tie from wiring to brake hose on main frame, (used for shipping purposes only). Fish the three wires from main unit through the hole in fender.

3. On the left side, plug in bullet plugs with white to white, black to brown and yellow to red. On the right side, plug white to white, black to brown and green to red.

4. With a pliers, install two wire clamps on fender. From rear of fender lip, install one clamp at 5-1/2” and one at 8”.

5. Mount the mud flaps (#4) to the inside back of the fender using two 1/4" x 3/4" truss head bolts (#5) with flat washers (#6) and lock nuts (#7). Make sure the Kar Kaddy logo on the flap faces the rear.

+ 25 hidden pages