KK460SS
7-06
RD20010,Rev 6
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
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.
2
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.
3
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.
4
• 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.
5
• 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.
6
• 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
7
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.
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.
C
B
#2
A
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
#3
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
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
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
#4
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
F
F
C
E
D
A
B
D
D
D
PULL & LIFT
TO
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
B
C
A
F. DD21016 QTY. 2
8
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
9
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
5
10
3”
13
7
9
12
7
11
8
7
6
9
2
14
10
1
Connector
5
4
67
3
8
12
7
6
6
6
9
10
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.
5
1
2
6
3
7
4
11
Loading...