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7-06
RD20010,Rev 6
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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SAFETY TAKE NOTE! THIS SAFETY ALERT SYMBOL FOUND THROUGHOUT THIS MANUAL IS USED TO CALL YOUR ATTENTION TO INSTRUCTIONS INVOLVING YOUR PERSONAL SAFETY AND THE SAFETY OF OTHERS. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN INJURY OR DEATH. THIS SYMBOL MEANS ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED! WARNING: SIGNAL WORDS Note the use of the signal words DANGER, WARNING and Indicates a potentially hazardous situation that, if not avoided, CAUTION with the safety messages. The appropri
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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 avoid 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 r
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• 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 pape
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• 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 igni
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• 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 m
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Decal Location PINCH POINT REV 0 DD21018 D. DD21017 QTY. 4 A. DD21018 Loading Towed VehicleE WARNING 1. Assure towing vehicle and Kar Kaddy are Read following information before hooking up, straight, on level ground, and properly loading, using, unloading or unhooking Kar hooked up before loading towed vehicle. Kaddy to prevent property damage, serious injury, or death. IMPORTANT DO’S & DON’TS Read towing instructions in towed vehicle owners manual. C Use 2” 5000 lb. (or greater) capacity ball f
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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 * GRADE 2 GRADE 5 GRADE 8 Torque Specifications “A” lb-ft (N.m) lb-ft (N.m) lb-ft (N.m) 1/4” 6 (8) 9 (12) 12 (16) 5/1
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Tongue and Ramp Assembly Instructions 1. Place the main frame (#1) on blocks or some other sturdy of each bracing strut to the trailer frame as shown using 1/ support so that the frame rests approximately 8" - 10" off 2" x 1-1/2" grade 5 bolt (#6), flatwasher (#7), pivot bushing the ground. (#8) and locknut (#9). Hold up the front end (the end with the smaller hole) of each bracing strut to the tongue and 2. With an assistant, place secure with two 5/8" x 1-1/4" epoxied hex head bolts (#10) ton
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Fender Assembly Instructions 3. On the left side, plug in bullet plugs with white to white, 1. Install fender with fender backup plate (#1) and three 3/8” black to brown and yellow to red. On the right side, plug x 1-1/2” bolts (#2). Put 3/8” nylon lock nuts (#3) inside of white to white, black to brown and green to red. fender and tighten. 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”. 2. Cut nylon wire tie from wiring
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Wiring Diagram 1 2 PARTS LIST REF. NO. PART NO. QTY. DESCRIPTION 1. 11590 1 Tongue Wiring Harness 2. 11591 1 Main Frame Wiring Harness 3. 01863 1 Rubber Grommet (not shown) Please order replacement parts by PART NO. and DESCRIPTION. TESTING LIGHTS BEFORE USE 1. Make sure that the WHITE ground wire is connected to the frame of both the Kar Kaddy and the towing vehicle. 2. With headlights in "ON" position, the tail lights, the light cluster bar, the license plate light, and the clearance lights WI
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Tongue folding and storage NOTE: Tow Dolly must be empty and unhooked to perform any and all of these steps. Do not attempt while tow dolly is loaded or hooked up. 1. Pull retainer clip from bottom of tongue locking pin. Lift locking pin out of tongue pivot. 2. With tongue wheel jack turned to its lowest position, push/pull tongue to the left. 3. Push/pull tongue until it comes to a stop by the left fender. It is recommended to place lock pin and retainer clip back in tongue pivot for storage. 1
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Folding Ramp Lock NOTE: Tow Dolly must be empty and unhooked to perform any and all of these steps. Do not attempt while tow dolly is loaded or hooked up. 1. Locate ramp locks at inside center of ramps. 2. Pull ramp lock straight out as far as it will go. 3. Lift ramp lock up as far as it will go and allow lock to slide in until it stops. 4. If lock has been pulled and lifted properly the ramp lock will extend out from it’s holder. This will mean that the ramp is unlocked and ramp may be folded
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Folding Ramp NOTE: Tow Dolly must be empty and unhooked to perform any and all of these steps. Do not attempt while tow dolly is loaded or hooked up. 1. Pull ramp back as far as it will go. Bolt must be past notch before attempting the next step. 2. Lift ramp until it is past center and resting on it stops. IMPORTANT: When taking this tow dolly out of storage it is very impor- tant to check all pins and retainers for damage. If damage is found replace. Do not use damaged pins or retainers. Ma
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WARNING: FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN LOSS OF TOWING VEHICLE CONTROL, SEPARATION ! OF THE TOW DOLLY FROM THE TOWING VEHICLE, SEPARATION 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 transmission. Safety is of utmost importance at all times. There are several For manual transmission: Consult your vehicle
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LOADING INSTRUCTIONS . Step 1. Secure ball coupler to 2" (5,000 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 4. Before loading (and unloading) towed vehicle make sure platform and towed vehicle are in strai
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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. Never unhook tow Step 10. Thread tie-down strap through the slotted tube on dolly coupler from towing vehicle, before unloading the tie-down winch. Pull approx. 6" of strap through this slot. todolly. Make sure that platform and vehicle are straight. Begin tightening strap making sure the tail becomes enclosed Reinstall driveshaft. Ensure that towed vehicle parking brake by the strap coming over the tire. Tighten the straps ensuring is fully engaged,
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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 tie rod. coupler 18" off the ground. Jack up the axle just enough to allow you to take the wheels off and put blocks under the axle. 2. Loosen the locking nuts on each end of the tie rod and Take the wheels off
