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DOING OUR BEST TO PROVIDE YOU THE BEST
TO W -IT
TI110 & TI110SB TOW DOLLY
OPERATORS MANUAL
08/03
RD20006, Rev 3
ASSEMBLY
CALIBRATION
OPERATION
REPLACEMENT PARTS
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
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IMPORTANT
We have discovered 1992 and newer model cars that are too wide in the body area to properly fit on a TI110 - 8' wide tow dolly
even though the front tire measurement is less than 70".
The 1992 and newer Oldsmobile 88 and 98 are in this category, there may be others. In addition to the standard measurement,
always follow weight limitations when using a Demco TOW-IT Tow Dolly.
TI100 - Standard Unit
3350 lbs. - Total Towed Vehicle Weight
WARNING: Exceeding weight limitations or not using a towing vehicle larger and at least 1,000 lbs. heavier
than the tow dolly and the towed vehicle combined can result in loss of towing vehicle control, separation of the tow
dolly from the towing vehicle, or separation of the towed vehicle from the tow dolly, causing severe personal injury,
death, or property damage.
CAUTION: All vehicles to be towed on Demco Tow Dollies must be towed with the front axle on the dolly.
TI110SB - Brake Unit
3500 lbs. - Total Towed Vehicle Weight
Table of Contents
General information............................................................................................................... 2
Safety Sign Locations ..........................................................................................................3
Bolt T orque ............................................................................................................................4
Safety and Maintenance .......................................................................................................4
T esting Lights........................................................................................................................5
Loading Instructions ........................................................................................................... 6-8
Limited Warranty ................................................................................................................... 9
Tow Dolly Parts List and Breakdown..................................................................................10-11
Assembly Instructions .......................................................................................................12-13
Surge Brake Assembly........................................................................................................ 14
Model DA66 Actuator Parts (replacemant only) ................................................................... 14
Model DA603 Actuator Parts ............................................................................................... 15
Model DA91 Actuator Parts (replacement only) ................................................................... 16
10î Brake Cluster Parts List and Breakdown .......................................................................17
Optional Winch..................................................................................................................... 18
Optional T ool Box ................................................................................................................. 18
Optional Spare Tire and Mount ............................................................................................ 18
Optional Wheel Jack ............................................................................................................ 19
Optional Deflector ................................................................................................................ 19
Optional Light Bar ................................................................................................................ 19
Tow Dolly Parts List and Breakdown..................................................................................16-17
Assembly Instructions .......................................................................................................18-19
"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
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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.
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SAFETY SIGN LOCATIONS
Types of safety sign and locations on Tow It are shown in illustration below. Good safety
requires that you familiarize yourself with various safety signs, type of warning, and particular
function related to that area, that requires your SAFETY AWARENESS.
3
4
SAFETY DECAL PARTS LIST
REF.
NO. PART NO. DESCRIPTION
1. 04508 Amber Reflector
2. 04804 Red Reflector
3. RD21007 Instructions
4. DD21016 Winch Operation
5. DA21001 Tire Pressure
2
5
1
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BOLT TORQUE
TORQUE DATA FOR STANDARD NUTS, BOLTS, AND CAP SCREWS.
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 T orque for Standard bolts *
Torque Specifications
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
cap screws 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
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10.9
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WARNING:
VEHICLE CONTROL, SEPARATION 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
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN LOSS OF TOWING
MAINTENANCE
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:
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 Tow-It. Leave some slack in the chain
to allow suspension movement.
Check to make sure that all lights are in proper working
order.
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 TI110 tires must be inflated to the recommended 35
PSI.
The TI110SB 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.
All vehicles mounted on the Tow-It must be mounted
with the front of the vehicle facing forward.
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.
while using the Tow-It.
before
securely at
Periodically check all bolts and nuts to ensure proper
tension or torque.
An occasional drop of oil may be required on the moving
parts of the tie down winches.
Grease the center pivot pin grease zerk every 1500
miles.
Grease the main frame platform skids every 1500 miles.
These grease zerks are readily accessible from under
the front tire stop main platform.
Grease the Sure Lube
TM
Hubs every 3,000 miles.
Use High Quality Bearing
Grease with Hand Operated
Grease Gun.
IMPORTANT LOADING INSTRUCTION
Check your wheel tie-down straps.
Your Tow-It 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 of your 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 of your
car and tire size.
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Thank you for Purchasing
Products.
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TESTING LIGHTS BEFORE USE
1. Check that the WHITE (ground) wire of the wiring harness
is connected to the Tow-It 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 Tow-It 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 and GREEN
wires have been reversed. Check the plug connection
under the tongue of the Tow-It 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. To allow the wheel platform to tilt back for loading:
1) Swing the bottom of the locking latch (C) toward the hitch
far enough to allow locking pin handle to be lifted.
Step 1. Secure ball coupler to 2" (3,500 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. Ensure that towed vehicle parking brake is fully
engaged, then release the tie-down straps. NOTE: Tie down
straps must be "quick -released" by grasping ratchet pawl and
ratchet handle simultaneously and pushing down sharply. This
process will permit easy removal of strap from winch.Remove
tie-down strap hook from its storage position at the rear of the
ramp. Lay the straps on the ground in front of the winches.
2) Pull locking pin toward the hitch as far as it will go. The wheel
platform will tilt back to allow loading.
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:
TI110 - 70" max. (outside to outside),
TI110SB 42" min. (inside to inside),
70" max. (body width)
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Step 5. 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 7. 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 TOW-IT.
Step 8. Be sure tie-down winch is centered with the tire before
tightening straps.
Step 6. Drive vehicle onto 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.
IMPORTANT: Lock the platform in position by pushing
locking pin toward platform. Push the handle down as far
as possible so locking latch holds it in a locked down
position.
Step 9. While tightening straps, pull cross strap forward to
ensure even tightening. 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.
(continue with Step 10 on following page)
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Step 10. Make sure the tie-down strap is the correct size for
the auto tire. The picture above shows a correct fitting strap.
See page 1 of this instruction for proper fit and exchange
instructions.
Step 11. Hook the towed vehicle safety chains to frame of
vehicle directly above the area where the chains are mounted
on the TOW-IT. Leave some slack in the chains to allow
suspension movement of the towed vehicle. Review the
safety points on page 1 before moving vehicles.
Step 13. To pull the TOW-IT empty, make sure tie-down
straps are tightened in the storage position, and towed
vehicle safety chains are wrapped up and hooked. Tie-
down winch handles should be left in a down position (horizontal) with safety pins in place when towing loaded or empty. DO
NOT ATTEMPT TO PULL TOW-IT 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
Tow-It or exceeding the width limit may result in damage to
both car and Tow-It.
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 TOW-IT MUST BE WITH THE
FRONT OF THE VEHICLE FACING FORWARD.
Step 12. TO UNLOAD towed vehicle. Make sure that plat-
form 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 and ratchet handle 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.
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 thereafter to
ensure they are tight and not rubbing or fraying.
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DEMCO PRODUCTS - TOW-IT Tow Dolly
ORIGINAL PURCHASERS LIMITED WARRANTY
1. Extent and Duration of this Warranty:
Your Demco Tow-It is warranted to be free from defects in
materials and workmanship under normal use and service for a
period of one year after date of purchase by the original (first)
retail owner, or until it is resold or transferred by the original
owner. Tires and lights are not included in this warranty.
Tires are warranted by the manufacturer against defects in
materials and workmanship, but not against road hazards.
Any part of the Demco Tow-It, except tires and lights, found in the
judgement of the manufacturer to be defective in materials or
workmanship will be repaired or replaced at the manufacturerís
option without charge for parts or labor to the original owner.
2. Manufacturer and Warrantor of Tow Dolly:
Dethmers Manufacturing Co.
4010 320th Street
P.O. Box 189
Boyden, IA 51234
(712) 725-2311
The manufacturer and warrantor of the tires has his name
permanently molded into the tires. Tire warranty questions and
claims can be taken directly to an authorized dealer of the tire
manufacturer.
3. Repair or Replacement Procedure:
If your Demco Tow-It develops a defect (except for tires or lights)
during the warranty period, promptly notify Dethmers Manufacturing Co. customer service department. Until such notice is
received, Warrantor will not be responsible for any repair or
replacement.
Upon receipt of notice from you, Warrantor will have a choice of
options in replacing any part it determines to be defective:
a) Warrantor may require you at your own expense to deliver
or ship the part to its factory or authorized dealer. Any
defective part will be repaired or replaced and returned to
you free of charge. Any part returned to Warrantor and
found not to be defective will be returned to you freight
collect with an explanation.
b) Warrantor may elect to ship a new part to its dealer to be
exchanged free of charge for the defective part returned
by you to the dealer.
c) Warrantor may elect to ship or deliver a replacement part
to your address.
Warranty claims on tires should be presented to a local authorized dealer of the tire manufacturer. Provide proof of purchase
when making a tire warranty claim.
4. Limitations on Warranty Coverage:
Coverage under this warranty will be effective only when a copy
of the original invoice, showing the date and location of purchase,
accompanies any claim for warranty.
Warrantor has no liability whatsoever and this warranty is null and void
if any Demco
negligence, misuse, accident or operated in any way contrary to the
operating and maintenance instructions as specified in the Demco
Ownerís Manual for that model tow dolly.
This warranty does not cover any tow dolly that has been altered
or modified so as to affect the tow dollyís operation, performance
or durability, or that has been modified to change the intended
use of the tow dolly.
Tow-It
has been misassembled or subjected to neglect,
This warranty does not cover:
1) normal wear and tear
2) road film or gravel damage to paint
3) paint
4) rust damage
5) Any Demco Tow-It that has been loaded in excess of the load
capacity stated on the tow dolly identification label.
Warrantor has a policy of continuous product improvement. We
reserve the right to change or improve the design of any Demco
Tow-It model, including but not limited to state of the art changes,
without assuming any obligation to modify any tow dolly previously manufactured.
Warrantor assumes no responsibility to the owner for loss of use
of the tow dolly, loss of time, inconvenience or other damage
consequential or otherwise, including, but not limited to expense for gasoline, expense of transporting the tow dolly to the
dealer and expense of returning the tow dolly, mechanicís
travel time, telephone or telegram charges, road service/towing
charges, rental of another tow dolly during the time warranty
repairs are being performed, travel, lodging, loss or damage to
personal property or loss of revenue or earnings.
5. Limitations of Implied Warranties:
All implied warranties, if any, expire and terminate upon expiration of this warranty. Some states do not allow limitation on
how long an implied warranty lasts, so this limitation may not
apply to you.
6. Limitation of Consequential Damages:
Warrantorís responsibility under this warranty extends solely to
repair or replacement of your Demco Tow-It and its component
parts.
Warrantor does not assume responsibility for, nor shall it be
liable for, any special, incidental or consequential damages.
Some states do not allow the exclusion or limitation on incidental or consequential damages, so the above exclusion or
limitation may not apply to you.
7. Use of Vehicle Identification Number (VIN):
The VIN is a 17 digit number located in the lower left corner of
the tow dolly identification label. The label is located on the left
side of the tow dolly frame. Be sure to include the VIN number
in all communications with Warrantor or its dealers concerning
the warranty.
8. Purchaserís Rights:
This warranty gives you specific legal rights, and you may also
have other rights which vary from state to state.
9. Exclusive Warranty:
This is the only express warranty made by Dethmers Manufacturing Co. on your Demco Tow-It and no agent, employee, or
other person is allowed to change or add to this warranty.
In addition, the warranty does not extend to repairs made necessary by normal use of parts, accessories or other equipment
which in the judgment of Warrantor, are either incompatible with
the Demco Tow-It, or affect its operation, performance or durability.
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REF. QTY.
NO. PART NO. REQíD DESCRIPTION
1. 5432 1 Left Ratchet Winch Assembly (Plated)
2. 5433 1 Right Ratchet Winch Assembly (Plated)
3. 03569-95 1 Ratchet Frame
4. 03570-95 1 Left Spool Tube
- 03571-95 1 Right Spool Tube
5. 03577 1 Heavy Duty External Snap Ring
6. 03574-95 1 Ratchet Handle
7. 03668 1 18 Ga. Shim Washer
8. 03575-95 1 Left Ratchet Gear
- 03576-95 1 Right Ratchet Gear
9. 03666 1 5/16" x 1-1/4" Roll Pin
10. 02243 1 Black Vinyl Hand Grip
11. 05450 1 Winch Pawl
12. 01864 2 Winch Pawl Spring SS
13. 05449 1 Winch Pawl Bushing SS
14. 00004 1 5/16" Flatwasher
15. 05444 1 3/8"-16 UNC x 3/4" Hex Bolt w/epoxy Gr.5
16. 03572-95 1 Left Ratchet Pawl Arm
- 03573-95 1 Right Ratchet Pawl Arm
17. 03578 1 5/16"-18 UNC x 1/2" Shoulder Screw
18. 01998 1 5/16" Flatwasher SS
19. 02002 1 1/4" Flatwasher SS
20. 02772 2 1/4"-20 UNC Nylon Locknut
21. 01076 1 1/4"-20 UNC x 3/4" Hex Hd. Bolt Gr.5
22. 00214 1 1/4" Flatwasher
23. 05337 1 Lock Pin w/Cable
24. 01883 9 Electrical Wire Splicer
25. 01881 1 Trunk Connector
26. 04785 1 Front Half Trailer Wiring Harness
27. 04786 1 Rear Half Trailer Wiring Harness
28. 01863 2 5/8" Grommet
29. 04496 1 Lever Lock Coupler (5,000 lb.)
- 01855 1 Safety Lock Pin for coupler
30. 01338 2 1/2"-13UNC x 4-1/2" Hex Head Bolt (gr.5)
31. 02288-95 1 Handle
32. 02189 1 1/2" I.D. Handle Grip
33. 02178 1 2 1/2"-13UNC Nylon Insert Locknut
34. 02771 2 7/16"-14UNC Nylon Insert Locknut
35. 01853 2 24" Safety Chain with Hook
- 04194 - 7/16" "S" Hook for safety chains
36. 00059 12 3/8" Flatwasher
37. 01898 4 7/16"-14UNC x 1-1/4" Hex Head Bolt (gr.5)
38. 04792-26 1 Tongue
39. 02587 1 5/8"-11UNC Nylon Insert Locknut
40. 02434 1 5/8"-11UNC x 4-1/2" Hex Head Bolt (gr.5)
41. 03503 2 5/8"-11 UNC x 1-1/4" Hex Hd. Epoxied Bolt
42. 02747-25 2 Bracing Strut
43. 01254 2 1/2-13UNC x 1-1/2" Hex Head Bolt (gr.5)
44. 00085 11 1/2" Flatwasher
45. 02579-95 2 Pivot Bushing
46. 04825 1 3/8" I.D. x 1/2" O.D. Grommet
47. 02574-95 1 Lock Pin (Tongue)
48. 02583 1 3/16" x 1-1/4" Roll Pin
49. 04780-26 1 Undercarriage (09533-26 for TI110SB)
50. 02209 8 7/16"-20UNF Hex Nut (gr.8)
51. 02377 8 7/16"-20UNF x 1-1/2" Epoxied Bolt (gr.8)
52. 04782 2 14 x 6 rim (5 on 4-1/2" BC)
53. 01725 1 0 1/2"-20UNF Chrome Lug Nut
54. 04826 2 ST205/75R14 "C" Range BW Radial Tire
55. 04323-25 2 Tilt Bed Ramp
56. 00967 8 1/2"-13UNC x 1-1/4" Hex Head Bolt (gr.5)
57. 04168 6 7/16"-20UNF Nylon Insert Locknut
58. 04167 6 7/16"-20UNF x 1" Hex Head Bolt (gr.8)
59. 02592 1 4 3/8"-16UNC Nylon Insert Locknut
60. 05358 1 Left Fender (w/ wire protector & gr. wire)
61. 05357 1 Right Fender (w/ wire protector & gr. wire)
62. 04425 4 Tinnerman Fender Clamp
REF. QTY.
NO. PART NO. REQíD DESCRIPTION
63. 02298 2 22-1/2" Wire Protector
64. 05443 2 Cable Hanger - wire harness
65. 04944 2 Wire Strain Relief
66. 04508 2 Amber Fender Reflector
67. 02316 2 White Ground Wire
68. 04424-95 2 Back-Up Plate for fender
69. 00914 6 3/8"-16UNC x 1-1/2" Hex Head Bolt (gr.5)
70. 04804 2 Red Fender Reflector
71. 02313 2 3-way Plug Pigtail (tail light)
72. 05447 2 Rubber Mounting Grommet for light
73. 05446 2 Sealed Round Tail Light
74. 04781-26 1 Upper Half Mainframe
75. 03528 2 3-point Tie-Down Strap w/J-Hook & buckle
76. 01674 4 1/4" Drive Type Grease Zerk
77. 02383 2 36" Safety Chain with hook
- 04194 - 7/16" "S" Hook for safety chains
78. 04270-25 2 Rear Tire Stop
79. 00907 8 3/8"-16UNC x 1" Hex Head Bolt (gr.5)
80. 05570 1 1/2"-13UNC x 1" Epoxied Bolt (gr.5) w/zerk
81. 02578-95 1 1/2" Special Flatwasher
82. 02584 1 3/16" x 3/4" Roll Pin
83. 04083 1 1-3/4" O.D. Bronze Bushing
84. 5341-26 2 SureLube
TM
Hub and Spindle Assembly
85. 04499 6 3/8 External Tooth Washer
86. 00078 2 7/16 Lock Washer
TM
- 5341 2 Sure Lube
Hub Assembly
89. 01747 1 Hub
90. 01743 1 Grease Seal (NOK AD 2548 E)
91. 01744 1 Inner Cup (L68111)
92. 01745 1 Inner Cone Bearing (L68149)
93. 01748 1 Outer Cup (L44610)
94. 02264 1 Outer Cone Bearing (L44643)
95. 02265 1 Hardened Tongue Washer
96. 02266 1 13/16-20 UNF Jam Nut
97. 02267 1 Retainer Adjustment Washer for Jam Nut
98. 00116 1 5/32" x 1-1/2" Cotter Pin
99. 04789 1 Sure Lube Dust Cap
100. 01746 5 1/2"-20UNF x 1-5/8" lg. Stud Bolt
101. 04790-26 1 Spindle
Please order replacement parts by PART NO. and DESCRIPTION.
not included
for
Fulton
5000 lb.
33
coupler
5217
29
Coupler Repair Kit
26
28
24
25
Part# 07426
35
34
36
Hook Retainer
Replacement Only
35
38
37
Page 10
Page 11
LEFT WINCH SHOWN
23
20
16
13
12
6
21
11
8
22
17
18
7
10
75
14
80
44
81
2
83
36
15
9
79
19
4
20
12
5
3
31
30
41
66
42
77
32
37
84
45
86
44
47
36
59
43
33
48
41
101
72
61
65
64
40
76
67
62
62
63
68
69
5341
Sure LubeTM Hub Assembly
90
92
100
91
89
93
94
49
26
42
71
95
96
73
98
97
27
82
28
99
43
44
1
74
46
45
69
68
Page 11
33
59
60
50
85
58
59
78
51
57
70
84
33
71
44
72
56
73
55
54
52
53
Page 12
TOW-IT ASSEMBLY INSTRUCTIONS
1
16
17
8
18
13
10
14
7
15
11
12
1. Place the mainframe on blocks or some other sturdy support
so that the frame rests approximately 8"-10" off the ground.
Attach the tilt bed ramps (#1) as shown using three 7/16" x 1"
grade 8 bolts (#2) and lock nuts (#3) on the top of each ramp
and four 1/2" x 1-1/4" grade 5 bolts (#4), flatwasher (#5) and
locknuts (#6) (two on each side of the ramp). Torque the 7/16"
bolts to 80 ft. lbs. and torque the 1/2" bolts to 75 ft. lbs.
2. Hold the tongue (#7) up to
the front of the tow dolly and
locate the three bullet
connectors extending out
the back of the tongue and
plug into the connector pro-
Brown
Yellow
Green
Pigtail
Brown/Yellow
Brown/Green
truding from under the mainframe channel. Do not cross colors when making this
connection.
2
9
3
6
5
4
19
20
6. When assembling the tie-down strap to the tow dolly winch,
make sure the tie-down strap does not contain any twists and
the overlaps are to the inside. Weave the front of the tie-down
strap through the openings in the buckle. The buckle should
be approximately 8" from the end of the strap. Thread the strap
end through the winch slot. Bring the strap up and thread it back
through the buckle again. The buckle should be approximately 1-1/2" - 2" from the winch.
(Refer to drawing on page 9 for following steps)
7. Attach Hub and Spindle Assembly (#19) using 7/16" x 1-1/4"
Fine Thread Bolts (#20) and hex nuts.
8. Bolt the fenders (#21) on using 3/8" x 1-1/2" gr. 5 bolts (#22),
back-up plates (#23) and locknuts (#24) in each fender. Mount
the fender with the light pocket to the rear. Attach the white
ground wire (#25) (the end with the eye loop on it) under the
center top bolt head.
3. Mount the tongue to the front of the tow dolly using one 5/8"
x 4-1/2" grade 5 bolt (#8) and locknut(#9) (torque to 50 ft. lbs.).
Do not torque over 50 ft. lbs. or the bed will not tilt. Make sure
the tongue latch is in the latched position to the tilt bed.
4. Secure the coupler (#10) and lift handle (#11) to the front end
of the tongue with two 1/2" x 4-1/2" gr.5 bolts (#12) and
locknuts (#13) . The white ground wire (#14) is attached under
the head of the second bolt attaching the coupler. (It is very
important that a good ground is made). Torque the locknuts
to 75 - 80 ft. lbs. Tap a rubber grip (#15) onto the handle with
a rubber hammer or a wooden mallet.
5. Remove the 7/16" x 1-1/4" bolt (#16), flatwasher, and locknut
from the outer front panel of each wheel platform tire stop.
Slide the tie-down winch (#17) into the channel at the front of
the wheel platforms as shown. Note that #17 is the left winch.
The ratchet handles are to the outside of each winch and
ratchet springs are to the top. Attach two 36" towed vehicle
safety chains (#18). Secure one chain to each wheel platform
tire stop with the 7/16" x 1-1/4" bolt (#16) , flatwasher and
locknut.
NOTE: It i s advantageous to wire the fender lights prior to
attaching the wheels.
9. Cut off stripped ends of the wiring harness, cut off stripped end
of the white ground wire. The yellow/brown wires must be run
to the left tail light pocket. The green/brown wires must be run
to the right tail light pocket. Start at either fender, pull the loom
at the center of the fender downward and push the green/
brown (or yellow/brown) wires upward through the loom until
it comes out the loom by the light pocket. Push the white ground
wire through the slit in the top of the loom in the fender trough
and push the wire toward the light pocket.
10. Make sure all three wires are coming out the fender wire loom.
Slide the rubber fender grommet over the wires and up close
to the wire loom.
Push the hollow looped end of the loom hanger into the small
hole under the fender pocket in the side of the fender. Leave
the holder open.
Pull the three wire pigtail wires through the hole in the fender
pocket outward. When wiring the pigtail into the tow dolly
Page 12
Page 13
Triple Wire Plug
from Light
White
Red
Black
Brown
Yellow or
Green
WIRING DIAGRAM FOR THE AUTO
TRANSPORT FENDER
Wire
Connector
White
White Ground Wire to
Yellow/Brown or
Green/Brown
Fender
24
33
34
21
29
25
32
23
31
22
30
34
COLOR CODE FOR WIRING HARNESS
WHITE Ground
BROWN Tail Lights and License Plate Light
YELLOW Left Turn and Stop
GREEN Right Turn and Stop
27
26
29
25
22
21
23
24
35
harness at the fender pocket, the wire ends SHOULD NOT be
stripped. Use the wire connectors to make all contacts. Lay
the wire in the connector, pinch securely with a pliers, closing
the wire connector. Splice the white wire of the pigtail to the
white ground wire from the fender. Splice the black wire to the
brown wire. Splice the green (or yellow) wire to the red wire
of the pigtail. The connections are made on the outside of the
fender pocket and pushed into the fender pocket through the
pocket hole. Pull the wires back into the fender pocket and
push the strain relief into the fender with the wire loom close
to the clip. Wrap the loom hanger tie around the wire loom and
insert the peg into the fender.
11. Push the round rubber light seal (#26) into the light pocket.
Be sure the lip is secured in the light housing. Plug the pigtail
into the fender light. Push the round light (#27) into the rubber
seal until it snaps in firmly. Wire the other fender in the same
manner.
12. Attach the tire/rim assembly to the mainframe. Use the
supplied lug nuts (#28) and torque to 75 - 80 ft. lbs.
38
35
37
36
28
14. Attach the two 24" transport safety chains (#35) to the two
holes in the angle located under the tongue using two 7/16"
x 1-1/4" grade 5 bolts (#36), flatwashers (#37), and locknuts
(#38). Torque bolts to 50 ft. lbs.
WIRING OF THE TOWING VEHICLE
Connect wiring to towing vehicle, keeping in mind the
color code indicated below.
1. Make certain towing vehicle lights are "OFF".
2. Connect YELLOW wire to left turn signal and stop
wire in the left rear of towing vehicle with the wire
splicer (01883 X) supplied.
3. Connect GREEN wire to the right turn signal and
stop wire.
4. Connect BROWN wire to tail light wire.
13. Lay the bracing struts (#29) out along the tow dolly tongue
with the back end (the end with the larger hole in it) of the
bracing strut toward the mainframe. Loosely bolt the back of
each bracing strut to the trailer frame as shown using 1/2" x
1-1/2" grade 5 bolt (#30), flatwasher (#31), pivot bushing
(#32) and locknut (#33). Hold up the front end (the end with
the smaller hole) of each bracing strut to the tongue, align
holes and secure with a two 5/8" x 1-1/4" epoxied bolt (#34).
Torque the 1/2" x 1-1/2" bolt with the pivot bushing to 75 ft. lbs.
5. VERY IMPORTANT - connect WHITE wire to frame
body of towing vehicle. This is the common ground,
and a clean metal - to - metal contact must be made.
CAUTION: Many flashers for vehicle turn signals
will not carry the additional load of TOW-IT turn
signals. If normal operation does not occur when
connected to the TOW-IT, a heavy duty replacement flasher may be obtained through auto parts
outlets.
Page 13
Page 14
NOTE: When installing DA603
onto T ow It be sure to pull
brake line out of tongue and
fasten it to the Actuator . Then
slide the Actuator , brake
line, and lift handle onto
tongue and attach with
supplied fasteners.
23
4
6
20
11
SURGE BRAKE ASSEMBLY
12
11
5
3
1
10
9
8
21
7
11
12
14
15
11
16
13
17
16
18
19
25
24
2
22
BRAKE LINES PARTS LIST
REF. QTY.
NO. PART NO. REQíD. DESCRIPTION
1. 02189 1 Handle Grip
2. 02383 2 36" Safety Chain
3. SB587 1 80" Brake Line
4. 01863 1 5/8" Rubber Grommet
5. 02746 1 54" Protective Hose
6. 04792-26 1 Tongue
7. SB7H66 1 7" Brake Hose
8. 00496 1 5/8 x 14 Ga. Machine Washer
9. SB7764 1 Retaining Clip
10. SB512 1 12" Brake Line
11. 02549 4 Rubber Brake Line Protector
12. SB544 2 44" Brake Line
DA66 ACTUATOR PARTS (REPLACEMENT ONLY)
5398 Master Cylinder Repair Kit
(gasket 05681 included)
5495 Coupler Repair Kit
not included
for
Fulton
6000 lb.
coupler
7
7
5
1
2
13
12
2
10
8
9
6
4
6
23
14
10
2
11
17
16
15
27
20
21
20
18
19
19
25
25
23
Page 14
13. 04791-26 2 Spindle w/Brake Flange
14. 02209 6 7/16"-20UNF Hex Nut (Gr.8)
15. 00078 6 7/16" Lockwasher
16. SB8798 6 7/16"-20UNF x 1-1/8" Knurled Shoulder Bolt
17. 00059 4 3/8" Flatwasher
18. 00060 2 3/8" Lockwasher
19. 00907 2 3/8"-16UNC x 1" Hex Head Bolt (Gr.5)
20. 02288-95 1 Handle
21. SB7785 1 Tee, Brass
22. 01338 3 1/2 -13 UNC x 4-1/2 Hex Head Bolt, Gr. 5
23. 02178 3 1/2 -13 UNC Nylon Insert Locknut
24. 8606301 1 Model DA603 plated drum brake Actutator
25. 10415 - Gr. 8 Stud (Replacement only)
- SB15545 4 10" Brake Drum
- SB23715 - Left Hand Cluster
- SB23714 - Right Hand Cluster
ACTUATOR PARTS LIST
REF. PART QTY.
NO. NO . REQíD. DESCRIPTION
- 8606701 1 Brake Actuator complete (incl. ref. 1-24)
1. 07599-95 1 6000# 2" Ball Coupler (Fulton)
2. SB23278 4 Roller
3. 05957-95 1 Front Roller Spacer
4. 02166 1 3/8"-16UNC x 2-3/4" Hex Head Bolt (gr.5)
5. 07176 1 3/8"-16UNC Stover Lock Nut
6. 05684 2 1/2"-13UNC x 4-7/16" Hex Head Bolt (gr.5)
26
7. 02178 2 1/2"-13UNC Nylon Insert Lock Nut
8. 05959 1 Push Rod Assembly
9. 05692 1 Damper/ Shock
10. 05958-95 2 Rear Roller Spacer
11*. 05951 1 Emergency Lever
12. 05955-95 1 Front Cover
13*. SB24700 1 2' Cable with S-Hooks
14. SB10555 2 Replacement S-Hook ONLY
15. 05960 2 5/16"-18UNC x 1/2" Self-Tapping Screw
16. 05424 2 5/16" External Tooth Lock Washer
22
17*. 05693-95 1 Emergency Lever Spring
18. 03876 1 Master Cylinder Cap
19. 01076 4 1/4-20UNC x 3/4" Hex Head Bolt Gr 5
24
20. 00057 2 1/4" Lock Washer
21. 03564-95 1 Outer Case
22. 05681 1 Replacement Master Cyl. Gasket ONLY
23. 5650 1 Composite Master Cylinder Kit w/ 09153
24. SB12098 1 1/8" pipe - 3/16" inverted Flare Fitting
25. 05695 2 1/4 Internal Tooth Lock Washer
26. 05966-95 1 Rear Cover
27. BH21004 1 Decal, Preset Fasteners
- 5400 - Lever Replacement Kit (incl. items w/*)
- 5398 - Master Cylinder Repair Kit w/ gasket
- 5495 - Coupler Repair Kit
Page 15
DA603 BRAKE ACTUA TOR P ARTS BREAKDOWN
Components not
sold separately
23
5695 Emergency Lock Cam
Replacement Kit
3
10a
21
13
20
22
11
11
17
12
Item #23
includes cable
23
6
12
18
22
9
7
4
1
20
15
16
14
21
8
5
2
2
10
Item #10 is not
included in 5696
18
5398 Master Cylinder Repair Kit (drum)
(gasket 09153 included)
ACTUATOR PARTS LIST
REF.
NO. PART NO. QTY. DESCRIPTION
- 8606301 - Plated Actuator f/ drum brakes
1. 00057 4 1/4î Lock Washer
2. 00062 4 1/4î-20 UNC Hex Nut
3. 00179 1 3/8î-16 UNC Lock Nut (Center Punch)
4. 00618 4 1/4"-20UNC x 2" Hex Head Bolt (Gr.5)
5. SB12098 1 .018 Connector Orifice (Drum Brakes)
6. 02207 1 3/8î-16UNC x 3î Hex Head Bolt (Gr. 5)
7. 03876 1 3 Tab Fill Cap w/ Diaphram & O-Ring
8. 09153 1 Master Cylinder Gasket
9. 10616 1 Composite Master Cylinder (drum)
10. 11367-95 1 Coupler/Inner Slider (plated)
10a. 5698 - Coupler/Inner Slider w/ Lever Lock Assy.
11. 11368 2 Top Plastic Slider
12. 11369 2 Bottom Plastic Slider
13. 11371-95 2 Shock Spacer (plated)
14. 11389-95 1 Rear Shock Pin (plated)
15. 11390-95 1 Outer Case (plated)
16. 11401 2 External Snap Ring
17. SB12426 1 Damper
18. 05687 1 Protective Boot (incl. in 10616 & 5398)
(incl. in 10616 & 11190)
5696 Coupler Repair Kit
(2î lever lock)
**Components not sold separately**
REPLACEMENT KITS
(components not sold separately)
5695 - Emergency Lock Cam Replacement Kit
20. ----- 1 7/16î-14UNC x 1 1/4î Hex Head Bolt (Gr. 5)
21. ----- 1 7/16î-14UNC Lock Nut (Center Punch)
22. ----- 1 Emergency Catch Cam (black oxide finish)
23. ----- 1 Pushrod Assembly (includes cable)
5696 - Coupler Repair Kit (2î lever lock)
5398 - Master Cylinder Repair Kit (drum)
Please order replacement parts by PART NO. and DESCRIPTION.
Page 15
Page 16
10î BRAKE CLUSTER PARTS LIST
4
5
16
7
16
1
Left Side Breakdown
6
2
2
8
13
19
3
11
10
12
9
10
17
15
18
17
14
17
18
17
10" BRAKE CLUSTER PARTS LIST
REF. PART QTY.
NO. NO . REQíD. DESCRIPTION
- SB23715 - Left Hand Cluster (shown above)
- SB23714 - Right Hand Cluster
1. SB24636-30 1 Back Plate Assembly
2. SB9254 2 Cover Plate - Adjusting Hole
3. SB10954 1 Brake Shoe Kit (includes 2 Primary & 2 Secondary)
4. 04305 2 5/16"-18UNC-Gr5 x 1/2" Hex Hd Bolt
5. 05424 2 5/16" External Tooth Washer
6. SB9776 1 Wheel Cylinder Assembly - Right
- SB9777 1 Wheel Cylinder Assembly - Left
7. 05431 1 Bleeder - replacement
8. SB9783 1 Push Rod
9. SB24047 1 Adjusting Screw Assembly - "R" (for LEFT cluster)
- SB24048 1 Adjusting Screw Assembly - "L" (for RIGHT cluster)
10. SB10958 2 Spring - Shoe
11. SB10961-95 1 Shoe Guide
12. SB23937 1 Cable
13. SB23936 1 Cable Guide
14. SB23724 1 Spring Adjusting Screw
15. 05414-95 1 Lever - Left
- 05415-91 1 Lever - Right
16. SB10959 2 Pin - Shoe Hold Down
17. SB9789 4 Cup Shoe Hold Down
18. 05983 2 Spring - Shoe Hold Down
19. 03880 1 Spring - Adjusting Screw Retainer
- SB15845 1 Wheel Cylinder Repair Kit (w/ spring, cup, & boot)
- SB15545A 10î Hub/Drum (w/ bearings, seals, nuts, & dust cap)
- SB15545 4 10" Brake Drum
Please order replacement parts by PART NO. and DESCRIPTION.
Brake shoe kit can be ordered for one complete axle only.
Page 16
Page 17
MODEL DA91 ACTUATOR PARTS BREAKDOWN
8
23
**12
**10
13
8
14
17
14
18
5398 Master Cylinder Repair Kit
(gasket 05681 included)
11
not included
28
4
5495
Coupler Repair Kit
2
9
2
1
3
2î Lever Lock Coupler
RATED AT 6000#
BLEEDING THE SYSTEM
The first requirement for safe, sure hydraulic braking is the use
of quality brake fluid. Use only DOT-3 or DOT-4 brake fluid from
a sealed container.
If pressure bleeding equipment is available, follow the
manufacturerís instruction in bleeding the system.
If system must be bled manually, proceed as follows: Fill
master cylinder with fluid. Install bleeder hose on first wheel
cylinder to be bled.
Have loose end of hose submerged in brake fluid in glass
container to observe bubbling.
By loosening the bleeder screw located in the wheel cylinder
one turn, the system is open to the atmosphere through the
passage drilled in the screw. Pump actuator with long steady
strokes. The bleeding operation is completed when bubbles
no longer rise to the surface of the fluid. Be sure to close
bleeder screw securely.
Repeat bleeding operation at each wheel cylinder. During the
bleeding process, replenish the brake fluid, so the level does
not fall below the 1/2 full level in the master cylinder reservoir.
After bleeding is complete, make sure master cylinder reservoir is filled and filler cap is securely in place.
After the bleeding operation has been completed, apply pressure to the system and check the whole brake system for leaks.
28
27
**16
15
15
25
9
26
6
7
9
20
21
5
24
19
Model 91 ACTUATOR PARTS LIST
REF.
NO. PART NO. QTY. DESCRIPTION
1. 09417 1 6000# 2" Lever Lock Coupler (zinc plated)
2. 01896 3 1/2"-13UNC x 4" Hex Head Bolt (gr.5)
3. 02178 3 1/2"-13UNC Nylon Insert Lock Nut
4. 05426 1 Front Shock Pin (drop tube actuators)
5. 11079-95 1 Drop Tube Actuator Slider (plated)
6. SB12426 1 Damper/ Shock
7. 11164-95 1 3 Bolt Mount Outer Case (plated)
8. 05424 2 5/16" External Tooth Lock Washer
9. 02363 2 5/32" x 1 1/4 Cotter Pin(Qty 3 w/drop tube)
**10. 05408 1 3/32" Cable with hooks
11. SB10555 - Replacement S-Hooks ONLY
**12. 05693-95 1 Emergency Lever Spring (plated)
13. 05961 2 5/16"-18UNC x 5/8" Hex Head Bolt (gr.5)
14. 00618 4 1/4-20UNC x 2" Hex Head Bolt (gr.5)
15. 00057 4 1/4" Lock Washer
**16. 05951 1 Emergency Lever Assembly
17. 03876 1 Master Cylinder Cap w/ Diaphragm & O-ring
- 05849 1 O-Ring Only (not shown)
18. 05977 1 Push Rod Assembly
19. 00062 4 1/4-20 UNC Hex Nut
20. 09153 - Plastic Master Cyl. Gasket ONLY
21. 10616 1 Master Cylinder
- 11190 - Master Cylinder
22. SB12098 1 .018 Connector Orifice (Drum Brakes)
- 05679 1 Inverted Flare Adapter (Disc Brakes)
23. 03866-95 1 Lever Guide (plated)
24. 05687 1 Master Cylinder Protective Boot
25. 05986-95 1 Connecting Pin (plated)
26. 10965 1 Upper Slider
27. 10966 1 Lower Slider
28. 10967 2 Side Spacers
- 5401 - Lever Replacement Kit (incl. items w/**)
- 5650 - Master Cyl. Replacement Kit (drum)
- 5495 - Coupler Repair Kit
Please order replacement parts by PART NO. and DESCRIPTION
22
19
Page 17
Page 18
OPTIONAL WINCH
4
PARTS LIST
REF. QTY.
5
6
1
6
3
2
NO. PART NO. REQíD. DESCRIPTION
KK2W 1 Optional Winch
1. 04620 1 Winch Mechanism (1400 capacity)
- 04621 - Replacement Handle
2. 01738 1 Strap Assembly (includes strap & hook)
3. 02207 1 3/8"-18UNC x 3" Hex Hd. Bolt (gr.5)
4. 02769 2 3/8"-16UNC x 4" Hex Head Bolt (gr.5)
5. 00059 2 3/8" Flatwasher
6. 02592 3 3/8"-16UNC Nylon Insert Locknut
Please order replacement parts by PART NO. and DESCRIPTION.
* All options may not mount on tow dolly simultaneously.*
OPTIONAL TOOL BOX
PARTS LIST
KK2TB QTY. Optional Tool Box
1. 00059 4 3/8" Flatwasher
2. 02592 8 3/8"-16UNC Nylon Insert Locknut
3. 01888-25 1 Tool Box
4. 00182 1 Small Hair Pin
5. 02717-25 2 Mounting "Z" Bracket
6. 00907 4 3/8"-16UNC x 1" Hex Head Bolt (gr.5)
7. 02759 2 3/8"-16UNC x 3" Square U-Bolt
Please order replacement parts by PART NO. and DESCRIPTION.
* All options may not mount on tow dolly simultaneously.*
OPTIONAL SPARE TIRE and MOUNT PARTS BREAKDOWN
4
6
7
7
2
6
5
REF. QTY.
NO. PART NO. REQíD. DESCRIPTION
- KK10STB 1 Optional Spare Tire and Rim
1. 04826 1 ST205/75R 14"x"C" BSW Radial Tire
2. 04782 1 6" x 14" Rim 4-1/2" Bolt Circle
1
4
3
2
3
7
Drive in stud here for
tire with rim #04782 (4-
1/2" bolt circle)
8
2
1
5
* All options may not mount on tow dolly simultaneously.*
KK6STM 1 Spare Tire Mounting Bracket
3. 02193-25 1 Spare Tire Bracket
4. 02917 1 Stud Bolt (12mm x 1.5)
5. 02933 2 Wheel Nut (12mm)
6. 02759 2 3/8"-16UNC Square U-Bolt
7. 00059 2 3/8" Flatwasher
8. 02592 4 3/8"-16UNC Nylon Insert Locknut
- KK6TC Optional Spare Tire Cover
Please order replacement parts by PART NO. & DESCRIPTION.
Page 18
Page 19
OPTIONAL WHEEL JACK
3
2
3
2
- KK2WJ QTY. Optional Wheel Jack w/ hardware
1. 02769 4 3/8 UNC x 4 Bolt, Gr. 5
2. 00060 4 3/8 Lock Washer
WHEEL JACK PARTS LIST
3. 00061 4 3/8 Hex Head Nut
Please order replacement parts by PART NO. and DESCRIPTION.
1
* All options may not mount on tow dolly simultaneously.*
OPTIONAL DEFLECTOR PARTS BREAKDOWN
REF. PART QTY.
NO. NO. REQíD. DESCRIPTION
1. 02592 4 3/8"-16UNC Nylon Insert Lock Nut
2. 02759 2 3/8"-16UNC Square U-Bolt (fits around 3" tube)
3. 00161-95 2 Lock Handle
4. 02054-25 1 Deflector Slide Mount
5. 00095 4 3/8"-16UNC x 3/4" lg. Square Head Set Screw
6. 02743-25 1 Deflector Upright Post
7. 02165 1 Deflector Lacing Cord (1/8" x 25 ft.)
8. 02161 1 Deflector Fabric
9. 02055-25 2 Deflector Framework
Please order replacement parts by PART NO. and DESCRIPTION.
OPTIONAL DEFLECTOR PARTS LIST
KK2DF Optional Deflector
7
8
6
1
5
3
4
3
9
OPTIONAL LIGHT BAR (KKLB) PARTS BREAKDOWN
LIGHT BAR PARTS LIST
REF. PART QTY.
NO. NO. REQíD. DESCRIPTION
KKLB Kar Kaddy Light Bar (complete)
1. 01772 2 Nylon Security Strap with hooks & tightener
2. 01857 1 Left Tail/ Brake and Signal Light w/Lenses
3. 01773 1 Brown Jumper Wire
4. 01886 4 Wire Holder (metal)
5. 02385-25 1 Light Bar Framework
6. 02386-25 2 Adjustable Light Bracket
7. 01856 1 Right Tail/ Brake and Signal Light w/Lenses
8. 02772 10 1/4"-20UNC Nylon Insert Locknut
9. 00092 6 1/4"-20UNC x 1/2" Hex Head Bolt
10. 01777-25 2 Light Bar "Z" Bracket
11. 01778 4 3" Suction Cup w/Bolt (#13)
12. 02198 1 Light Bar Wiring Harness (new style)
13. 00068 4 1/4"-20UNC x 3/4" Hex Head Bolt
14. 01911 - Large Red Lens
15. 01912 - Small Red Lens
Please order replacement parts by PART NO. and DESCRIPTION.
2
6
1
8
9
8
9
1
4
8
12
7
14
9
8
5
9
1
13
10
11
2
3
15
13
1
11
COLOR CODE FOR WIRING HARNESS
WHITE Ground
BROWN Tail Lights, License Plate Lights,
Light Cluster Bar & Clearance Lights
YELLOW Left Turn and Stop
GREEN Right Turn and Stop
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