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8-03
RD20005,Rev 3
DOING OUR BEST TO PROVIDE YOU THE BEST
KAR-KADDY
KK260 (8WIDE) & KK360 (8-1/2WIDE)
OPERATORS MANUAL
ASSEMBLY
READ complete manual CAREFULLY
CALIBRATION
BEFORE attempting operation.
OPERATION
REPLACEMENT PARTS
DEMCO Dethmers Mfg. Co. 4010 320th St. P.O. Box 189 Boyden, IA 51234
PH: (712) 725-2311 Toll Free: 1-800-543-3626 FAX: 1-800-845-6420
www.demco-products.com
Page 1
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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. When placing a parts order, refer to this manual for (3 radial-line head markings) hex head bolts are proper part numbers and place order by PART NO. used throughout assembly of this piece of equip- and DESCRIPTION. ment. 2. Whenever the terms "LEFT" and "
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BOLT TORQUE TORQUE DATA FOR STANDARD NUTS, BOLTS, AND CAPSCREWS. Tighten all bolts to torques specified in chart unless otherwise noted. Check tightness of bolts periodically, using bolt chart as guide. Replace hardware with same grade bolt. NOTE: Unless otherwise specified, high-strength Grade 5 hex bolts are used throughout assembly of equipment. Bolt Torque for Standard bolts * Torque Specifica- GRADE 2 GRADE 5 GRADE 8 A lb-ft (N.m) lb-ft (N.m) lb-ft (N.m) tions 1/4 6 (8) 9 (12) 12 (16) 5
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WARNING: FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN LOSS OF TOWING VEHICLE CONTROL, SEPERATION OF THE TOW DOLLY FROM THE TOWING VEHICLE, SEPERATION OF THE TOWED VEHICLE FROM THE TOW DOLLY, CAUSING SEVERE PERSONAL INJURY, DEATH, OR PROPERTY DAMAGE. SAFETY Rear Wheel Drive: Disconnect the towed vehicle driveshaft for rear wheel drive vehicles with automatic Safety is of utmost importance at all times. There are transmission. several items that must be checked each time before Fo
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TESTING LIGHTS BEFORE USE 1. Check that the WHITE (ground) wire of the wiring harness is connected to the Kar Kaddy frame and the WHITE (ground) wire is connected to the frame of the towing vehicle. 2. With headlights in "ON" position, the tail lights, the light cluster bar, the license plate light, and the clearance lights should be lighted. 3. Start engine and have someone depress brake pedal. Brake lights of tow dolly and towing vehicle should come "on" and "off" simultaneously with each appl
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Step 7. Drive vehicle onto the platform - front forward - until tires touch the wheel stops at the front of each side of the platform and the platform tilts to a flat position. Make sure the car is centered on the platform. Towed vehicle tires must fit in wheel troughs without overhanging sides. Engage towed vehicle parking brake. Shift loaded car into "park" and lock steering wheel with front tires in a straight position. If the car does not have a locking steering column the steering whe
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A B Step 13. TO UNLOAD towed vehicle. Make sure that plat- Step 10. Thread tie-down strap through the slotted tube on the form and vehicle are straight. Reinstall driveshaft. Ensure that tie-down winch. Pull approx. 6" of strap through this slot. towed vehicle parking brake is fully engaged, then unhook the Begin tightening strap making sure the tail becomes enclosed towed vehicle safety chains, and release the tie-down straps. by the strap coming over the tire. Tighten the straps ensuri
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KK260 (8'wide) and KK360 (8-1/2' wide) PARTS BREAKDOWN 104 128 126 103 125 Right Fender 123 121 124 33 127 87 109 129 117 110 98 55 112 46 122 118 120 111 116 113 119 106 107 99 114 105 *69 KIT #5511 100 *69 75 *69 55 TILT-BED LATCH 108 90 ASSEMBLY 46 42 89 63 75 *69 90 72 65 59 88 62 not included 61 25 81 60 51 for Fulton 80 5000 lb. 78 coupler 53 54 66 46 82 86 42 58 5217 55 47 Coupler Repair Kit 51 56 57 83 52 2 58 49 36 50 37 42 35 56 38 10 54 48 55 52 41 49 39 43 35 1 34 40 44 45 46 47 DECA
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84 27 29 30 26 25 30 25 26 24 32 31 KK6LBAS 27 License Plate Mount 27 and Light Cluster 31 Left Winch Shown 130 20 23 12 10 20 5 22 78 19 21 5 16 76 17 75 18 85 12 13 14 3 4 15 11 6 42 7 51 77 9 74 79 *70 8 3 55 *70 REF. PART NO. NO. QTY. DESCRIPTION *70 1. 5432 1 Left Ratchet Winch Assembly (Plated) 2. 5433 1 Right Ratchet Winch Assembly (Plated) 73 87 *70 3. 03569-95 1 Ratchet Frame 92 91 4. 03570-95 1 Left Spool Tube - 03571-95 1 Right Spool Tube 5. 03577 1 Heavy Duty External Snap Ring 6. 03
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REF. PART REF. PART NO. NO. QTY. DESCRIPTION NO. NO. QTY. DESCRIPTION 29. 02580-95 1 License Plate Clip 82. 01718-95 1 Locking Pin 30. 02770 2 1/4-20UNC Nylon Insert Wing Nut - 02189 1 Black Handle Grip 31. 01077 2 1/4"-20UNC Serrated Locknut 83. 00182 1 Small Hair Pin 32. 04513 1 Light Cluster 84. 03528 2 Tie Down Strap w/J-Hook 85. 04503-25 2 Tilt Bed Ramp (KK260 - 8' wide) 10. 02243 2 Black Vinyl Hand Grip - 04772-25 2 Tilt Bed Ramp (KK360 - 8-1/2' wide) 33. 01883 11 Electrical Wire Splicer 8
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DEMCO PRODUCTS - KAR KADDY ORIGINAL PURCHASERíS LIMITED WARRANTY 1. Extent and Duration of this Warranty: Your Demco Kar Kaddy is warranted to be free from defects in In addition, the warranty does not extend to repairs made materials and workmanship under normal use and service for a necessary by normal use of parts, accessories or other equip- period of one year after date of purchase by the original (first) ment which in the judgment of Warrantor, are either incompat- retail owner, or until i
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Model DA66 ACTUATOR PARTS BREAKDOWN 18 15 14 19 16 19 25 20 17 13 20 12 21 2 10 10 22 8 11 7 9 2 24 7 5 23 6 4 1 2 6 3 2 ACTUATOR PARTS LIST REF. PART NO. NO. QTY. DESCRIPTION - 8606701 1 DA66 Brake Actuator complete (incl. ref. 1-25) 1. 07599-95 1 6000# 2" Ball Coupler 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" Stover Lock Nut 6. 05684 2 1/2"-13UNC x 4-1/2" Hex Head Bolt (gr.5) 7. 02178 2 1/2"-13UNC Nylon Insert Loc
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DA603 BRAKE ACTUATOR PARTS BREAKDOWN Components not 7 sold separately 20 22 4 23 21 1 20 5695 Emergency Lock Cam 15 Replacement Kit Item #23 includes cable 16 22 14 21 11 23 11 8 3 9 5 2 18 6 2 17 10 10a 13 Item #10 is not 12 included in 5696 12 18 5398 Master Cylinder Repair Kit (drum) (gasket included) 5696 Coupler Repair Kit (2î lever lock) ACTUATOR PARTS LIST **Components not sold separately** REF. NO. PART NO. QTY. DESCRIPTION - 8606301 - Plated Actuator f/ drum brakes 1. 00057 4 1/4î Lock
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MODEL DA91 ACTUATOR PARTS BREAKDOWN 13 8 8 23 17 **12 18 **10 14 14 15 15 **16 5398 Master Cylinder Repair Kit (gasket included) 25 9 11 26 not included 20 6 9 7 22 28 21 4 5 19 5495 24 Coupler Repair Kit 19 28 2 9 2 27 Model 91 ACTUATOR PARTS LIST 1 REF. NO. PART NO. QTY. DESCRIPTION 3 1. 09417 1 6000# 2" Lever Lock Coupler (zinc plated) 2. 01896 3 1/2"-13UNC x 4" Hex Head Bolt (gr.5) 2î Lever Lock Coupler 3. 02178 3 1/2"-13UNC Nylon Insert Lock Nut RATED AT 6000# 4. 05426 1 Front Shock Pin (dr
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10" SELF-ADJUSTING BRAKE CLUSTER and DRUM PARTS BREAKDOWN 4 4 5 5 7 16 1 6 3 16 2 2 8 11 13 10 12 3 19 9 10 17 18 17 15 14 17 18 17 BRAKE CLUSTER PARTS LIST REF. PART NO. NO. QTY. DESCRIPTION - SB24429 - Left Hand Cluster (shown above) - SB24428 - Right Hand Cluster 1. SB23871 1 Back Plate Assembly - (NDH Hub Mounting) 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 Too
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OPTIONAL SURGE BRAKES (KK260SB and KK360SB) PARTS BREAKDOWN 5 12 11 2 4 7 5 6 Model DA603 13 1 Brake Actuator 2 3 9 10 8 14 SURGE BRAKES PARTS LIST 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. REF. PART If pressure bleeding equipment is available, follow the NO. NO. QTY. DESCRIPTION manufacturerís instruction in bleeding the system. 1. SB587 1 87" Brake Line 2. 01863 2 R
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KK260 AND KK360 ASSEMBLY INSTRUCTIONS 1. Place the main frame on blocks or some other sturdy 6. Lay the bracing struts (#23) out along the tow dolly tongue support so that the frame rests approximately 8" - 10" off with the back end (the end with the larger hole in it) of the the ground. Attach the tilt bed ramps (#1) as shown using bracing strut toward the mainframe. Loosely bolt the back four 1/2" x 1-1/4" grade 5 bolts (#4), flat washer (#5) and of each bracing strut to the trailer frame as
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11. DO NOT MOVE THE TIE ROD LOCKING CLAMP FROM ITS FACTORY PRESET POSITION. GREASE TIE ROD ENDS BEFORE USING. 1-1/4" NOTE: Tie rods are factory set and should not be readjusted. 12. Bolt on the steering stabilizer cylinder (#1) as shown using a 5/8" x 2-3/4" bolt (#2) coming up from the bottom, through a 5/8" flat washer (#3), through cylinder end and into threaded ear on the Kar Kaddy main frame. Snug bolt up, then tighten putting 3/16" squeeze on the rubber of the cylinder end. The final g
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WIRING & FENDER 4. Pull the black and white wire from the pigtail through the hole in the fender pocket outward. Splice the white wire ASSEMBLY INSTRUCTIONS to the white wire coming out the loom. Splice the black wire to the brown wire. Splice the green (or yellow) wire NOTE: It is advantageous to wire the fender lights to the red wire of the pigtail. Make the connections on the prior to attaching the wheels. outside of the fender pocket, then push the connectors and wires back into the fe
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BACK MEASUREMENT KAR-KADDY TOE-IN ADJUSTMENT LOCKING CLAMP FRONT MEASUREMENT (1/32" to 1/16" less than back measurement) 12" 12" C L 18" MEASURING THE TOE-IN TOE-IN ADJUSTMENT Have the tongue in a hooked-up position with the ball 1. Put a mark on each side of the locking clamp on the coupler 18" off the ground. Jack up the axle just enough to tie rod. allow you to take the wheels off and put blocks under the axle. Take the wheels off. 2. Loosen the locking nuts on each end of the tie rod an
