RD20024, Rev 3
03/20
KAR KADDY 3
KK370SB
Page 1: ...RD20024 Rev 3 03 20 KAR KADDY 3 KK370SB ...
Page 2: ...ing Com pany 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 be tween you your dealer or DEMCO Manufacturing Company DEMCO TABLE OF CONTENTS General Information Page 2 Tow Dolly safety guide Page 4 8 Decal L...
Page 3: ...us injury This signal word is to be limited to the most extreme situations typically for tow dolly components which for functional purposes cannot be guarded WARNING Indicates a potentially hazardous situation that if not avoided could result in death or serious injury and includes hazards that are exposed when guards are removed It may also be used to alert against unsafe practices CAUTION Indica...
Page 4: ...vel do not bleed off extra pressure Do not back up your towing vehicle when a tow dolly is attached A tow dolly swivels both at the coupler and at car platform If you must back up unload towed vehicle first disconnect tow dolly and move vehicle and tow dolly separately Park where you can pull ahead when leaving Do not exceed 55 miles per hour or any lower posted speed limit Avoid sharp turns or sw...
Page 5: ...icle must weigh at least 1 000 lbs more than weight of vehicle in tow and tow dolly Suspension Your tow vehicle s rear springs must be of sufficient strength to support the added loaded tow dolly tongue weight while maintaining tow vehicle in approximately a level position If rear springs shock absorbers or struts are weak or broken they must be replaced In some cases it may be necessary to add he...
Page 6: ...s recommended maximum passenger cargo load must not be exceeded VEHICLE IN TOW Limitations Cautions 1 Vehicle in tow must not be wider than 76 inches at front doors to prevent damage to doors from contact with tow dolly fenders on turns 2 Vehicle in tow must weigh no more than 4 800 lbs Exceeding these limits may cause damage to tow dolly or vehicles Vehicle in tow tire tread must fit on ramps wit...
Page 7: ...speeds A road hazard that would be avoidable at 55 m p h can become unavoidable at 65 m p h If you drop any wheel s off the pavement don t attempt any sharp steering corrections Remain off the pavement decrease your speed until you have regained control then drive slowly back onto pavement Never Operate An Unstable Combination Instability swaying or whipping of a tow vehicle tow dolly combination ...
Page 8: ...er rough roads Turning Avoid U turns Avoid turning too sharply Turning too sharply may cause side of vehicle in tow to come in contact with rear of dolly fender and cause damage to both vehicles Pro Driving Tips Accidents occur more frequently at night with a tired driver exceeding recommended speed on a downgrade wet road or curve Don t attempt to drive straight through Be rested Slow down for do...
Page 9: ... 300 630 850 970 1310 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 Torque Specifications CLASS 8 8 CLASS ...
Page 10: ...ed 04 02 01 with no changes ordered 10 02 02 with no changes ordered 05 20 04 with no changes ordered 09 20 04 with no changes this file was ordered 03 03 05 this file was ordered 05 24 05 this file was ordered 08 09 05 this file was ordered 09 06 05 this decal was ordered 11 09 05 decal was ordered 11 28 05 decal was ordered 02 20 06 decal was ordered 04 05 06 decal was ordered 06 12 06 this deca...
Page 11: ...x 1 1 4 bolts will also go through the tilt bed ramps Torque 3 8 x 1 1 4 bolts to 35 ft lbs 8 Repeat steps 6 7 for other side 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 framechannelandpositionlatchontongueapproximately 3 from front of channel Clamp tongue to main fra...
Page 12: ... Make sure the Kar Kaddy logo on the flap faces the rear 4 Fish the three wires from the mainframe through the rear hole in the fender trough 5 Route wiring in through back of tail light housing on the bottom inside of housing Fish the three wire inside of housing The front marker light wires lay in the trough and route wires through back of tail light housing with main frame wires see red arrow 6...
Page 13: ...der wiring bullet connectors NOTE On the left side plug in the bullet plugs with white to white brown to black and yellow to red On the right side plug in bullet plugs with white to white brown to black and green to red 9 The front marker light male bullet connectors will plug into remaining female ports on the pigtail harness Black to black and white to white Coil pigtail harness inside of fender...
Page 14: ...ue Grease the king pin and tie rod end grease zerks every 2500 miles An occasional drop of oil may be required on the moving parts of the tie down winches A light film of oil should periodically be applied to steering stabilizer shaft to prevent rust NOTE Proper toe in is 1 32 This is preset at the factory The operator should periodically have the toe in checked and ad justed if needed at a qualif...
Page 15: ... clip on the front to a horizontal position and put license in the down position Turn the clip back so it rests against the back of the light bar to hold the license down and tighten wing nut License must be UP with the tow dolly empty 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...
Page 16: ...ing 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 transmissi...
Page 17: ...ng 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 A and ratchet handle B simulta neously 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 t...
Page 18: ...1UNC x 2 3 4 lg Hex Head Bolt gr 5 28 14100 1 5 8 Flatwasher 29 01729 30 1 Steering Stabilizer Shock 30 11553 81 1 Tie Rod Clamp Bottom 31 11554 81 1 Tie Rod Clamp Top 32 00907 12 3 8 16UNC x 1 Hex Head Bolt gr 5 33 02494 2 3 8 16UNC x 2 1 4 Hex Head Bolt gr 5 34 00967 9 1 2 13UNC x 1 1 4 Hex Head Bolt gr 5 35 04772 96 2 Ramp 36 01718 95 1 Tie Rod Locking Pin 02189 1 Replacement Black Handle Grip ...
Page 19: ...6 14 15 16 17 18 19 26 27 21 30 31 32 33 34 35 35 44 42 66 67 68 69 70 4 5 13 19 20 21 22 22 23 24 25 26 26 27 28 29 36 37 38 39 40 41 43 41 45 46 46 48 51 52 52 53 53 54 55 65 1 58 6 71 19 72 78 79 79 58 77 Parts Breakdown ...
Page 20: ... 00004 5 16 Flat Washer 2 2 00214 1 4 Flat Washer 2 3 01076 Bolt 1 4 20UNC x 3 4 Hex Head 1 4 01864 Spring 2 5 02772 1 4 20UNC Nylon Insert Locknut 2 6 03574 95 Ratchet Handle Plated w Hand Grip 1 7 03578 5 16 18UNC x 1 2 Socket Head Shoulder Bolt 1 8 05337 Safety Pin w Cable 1 9 05444 3 8 16UNC x 3 4 Hex Head Bolt w Epoxy 1 10 05449 Winch Pawl Bushing Stainless Steel 1 11 05450 Winch Pawl 1 12 11...
Page 21: ...0 95 LICENSE PLATE SUPPORT CLIP 1 3 02770 WING NUT 25NC NYLON INSERT 2 4 04176 BOLT CARRIAGE 25NC X 75 2 5 16239 3 LIGHT CLUSTER MAIN HOUSING 1 6 16240 3 LIGHT CLUSTER BOTTOM 1 7 16241 PUSH RIVET 188 4 8 16242 RUBBER GROMMET 1 15927 WIRING HARNESS w LED LIGHTS NOT SHOWN Please order replacement parts by PART NO and DESCRIPTION 1 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Fender Assembly ITEM PART...
Page 22: ...e 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 Afterthebleedingoperationhasbeencompleted applypressure to the system and check the whole brake system for leaks Model 91 ACTUATOR PARTS LIST 9 1 21 27 2 17 23 26 11 15 16 29 3 7 22 25 12 13 3...
Page 23: ...4798 1 90 Brake Fitting not shown 2 Bleeder Valve 2 Rubber Bushing 2 Stainless Steel Bushing 2 Stainless Steel Bolt PARTS LIST 3 1 Hub Assembly 5 4 Epoxy Bolt 6 9 10 8 2 7 ASSEMBLY 1 Begin by mounting the Hub Assembly and the Caliper Mounting Bracket 1 to the Forged Arm using the 6 7 16 Epoxied Bolts as shown 2 Now place the Rotor 2 onto the Hub Assembly as shown in the diagram 3 Make sure the Bra...
Page 24: ...ow 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 Afterthebleedingoperationhasbeencompleted applypressure to the system and check the whole brake system for leaks 1 12508 1 63 Brake Hose 2 01863 1 Rubber Grommet 3 13047 1 Rubber Grommet 4 12542 1 12 Brake Hose rubber 5 SB541 2 41 Brake...
Page 25: ...ess Please order replacement parts by PART NO and DESCRIPTION 2 TESTING LIGHTS BEFORE USE 1 Check that theWHITE 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 Star...
Page 26: ...the tie rod 7 Reassemble the rest of the Kar Kaddy unit Have the tongue in a hooked up position with the ball 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 Take the wheels off Find two 24 long bars these could be a level a square or a straight piece of iron bar Clamp one bar tight to the face of each hub with 12 extending f...
Page 27: ...LIPS HEAD 17 12 10184 SCREW 25 NC X 75 PHILLIPS HEAD 4 13 10185 SCREW 25 NC X 1 00 PHILLIPS HEAD 4 14 10186 T NUT 25 NC X 41 BARREL 23 15 11264 SCREW 25 NC X 1 50 PHILLIPS HEAD 2 16 11265 SPACER BUSHING 2 17 13731 81 UPRIGHT POST MOUNT 1 18 13732 81 SENTRY CROSSMEMBER TD MNT 1 19 17044 CAP PLUG 2 SQ X 10 14 GA 3 REV ECN DATE DFTM A 6654 3 4 2020 JK MIN MACHINE SURFACE 250 BREAK ALL SHARP EDGES BEN...
Page 28: ...Nylon Insert Locknut All options may not mount on tow dolly simultaneously OPTIONAL SPARE TIRE and MOUNT 1 13989 1 ST205 75R 14 x C BSW Radial Tire 2 09296 1 5 5 x 14 Rim PARTS LIST REF NO PART NO QTY DESCRIPTION 5965 1 Optional Spare Tire 5 1 2 4 3 7 6 All options may not mount on tow dolly simultaneously 3 02193 30 1 Spare Tire Bracket 4 02917 1 Stud Bolt 12mm x 1 5 5 02933 2 Wheel Nut 12mm Chro...
