Instruction/ maintenance manual of the product KK460SS Demco
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1 7-06 RD20010,Rev 6.
2 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 INFORMA TION 1. Unless otherwise specified, high-strength (grade 5) (3 radial-line head markings) hex head bolts are used throughout assembly of this piece of equip- ment.
3 SAFETY T AKE NO TE! THIS SAFETY ALER T SYMBOL FOUND THR OUGHOUT THIS MANUAL IS USED T O CALL Y OUR A TTENTION T O INSTR UCTIONS INV O L VING Y OUR PERSONAL SAFETY AND THE SAFETY OF O THERS. F AILURE T O FOLLO W THESE INSTRUCTIONS CAN RESUL T IN INJUR Y OR DEA TH.
4 SAFETY SIGN CARE • Keep safety signs clean and legible at all times. • Replace safety signs that are missing or have become illegible. 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.
5 BEFORE OPERA TION: • 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.
6 FOLLO WING OPERA TION • 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.
7 PERFORMING MAINTENANCE • Good maintenance is your responsibility . Poor maintenance is an in vitation to trouble . • Make sure there is plenty of v entilation. Nev er operate engine of towing v ehicle in a closed building. Exhaust fumes may cause asph yxiation.
8 T o 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.
9 BOL T T ORQUE T ORQUE D A T A FOR ST AND ARD NUTS, BOL TS, AND CAPSCREWS. Tighten all bolts to torques specified in char t unless otherwise noted. Check tightness of bolts periodically , using bolt char t as guide . Replace hardware with same grade bolt.
10 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.
11 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.
12 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) supplied.
13 T ongue folding and storage 1. Pull retainer clip from bottom of tongue locking pin. Lift locking pin out of tongue pivot. NOTE: T ow Dolly m ust be empty and unhooked to perform any and all of these steps. Do not attempt while tow dolly is loaded or hooked up.
14 Folding Ramp Lock 1. Locate ramp locks at inside center of ramps . 2. Pull ramp lock straight out as f ar as it will go . 3. Lift ramp lock up as f ar 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 e xtend out from it’ s holder .
15 1. Pull ramp back as f ar as it will go . Bolt must be past notch before attempting the ne xt step . 2. Lift ramp until it is past center and resting on it stops. Folding Ramp IMPORT ANT: When taking this tow dolly out of storage it is v er y impor- tant to check all pins and retainers f or damage.
16 SAFETY Safety is of utmost importance at all times. There are several items that must be checked each time before using and while using the Kar Kaddy. Make sure all bolts are properly tightened and those requiring a set torque are up to specifications: Tie Rod Castle Nut - 75 ft.
17 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.
18 Step 5. Grasp bed release handle on tongue and pull toward coupler. This releases the tilt bed to permit loading. 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.
19 • 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.
20 12" 12" C L BACK MEASUREMENT FRONT MEASUREMENT (1/32" to 1/16" less than back measurement) 18" Ground 1. Put a mark on each side of the locking clamp on the tie rod. 2. Loosen the locking nuts on each end of the tie rod and then the six bolts on the tie rod locking clamp.
21 MODEL D A91 A CTU A T OR P ARTS BREAKDO WN 5398 Master Cylinder Repair Kit (gasket included) 2 ” Lever Lock Coupler RATED AT 6000# not included REF. NO. PART NO. QTY. DESCRIPTION Model 91 ACTUATOR PARTS LIST 1. 09417 1 6000# 2" Lever Lock Coupler (zinc plated) 2.
22 REF. PART NO. NO. QTY. DESCRIPTION BRAKE CLUSTER PARTS LIST - SB24429M - Left Hand Cluster (shown above) - SB24428M - Right Hand Cluster 1. SB23871 1 Back Plate Assembly 2. SB9254 2 Cover Plate - Adjusting Hole 3. SB10954 1 Brake Shoe Kit (includes 2 P rimary & 2 S econdary) 4.
23 SURGE BRAKES P ARTS BREAKDO WN Please order replacement parts by PART NO. and DESCRIPTION. SURGE BRAKES FIELD SETUP PARTS LIST 1. 11968 1 6" Brake Line 2. 02034 1 45” Brake Hose 3. SB512 1 12” Brake Line 4. 05679 2 Brake Fitting 5. 11617 1 Male Coupler 6.
24 KK460SS P ARTS BREAKDO WN 2 4 5 6 7 9 10 11 12 13 19 20 21 22 22 21 20 23 23 24 24 25 26 26 27 28 29 32 32 6 26 36 37 60 38 39 40 41 43 41 45 46 46 47 48 49 50 51 52 52 55 54 53 53 56 56 57 58 60 5.
25 1. 03528 2 Tie-down Strap assembly, Black 2. 5737 1 Right Fender Assembly with Lights 3. 5736 1 Left Fender Assembly with Lights 4. 04424-95 2 Fender Backing Plate 5. 00914 6 3/8”-16UNC x 1-1/2” Hex Head Bolt (gr.5) 6. 02592 18 3/8”-16UNC Nylon Lock Nut 7.
26 KIT #5511 TILT-BED LATCH ASSEMBLY 5511 - Tilt-Bed Latch Kit 1*. 03434 1 5/16"-18 UNC x 4" Eye Bolt 2*. 04221 1 5/16"-18 UNC x 2-1/2 Hex Head Bolt (Gr 5) 3*. 00004 1 5/16" Flatwasher 4*. 00007 1 5/16"-18 UNC Hex Nut 5*. 03379-95 1 Latch Block 6*.
27 (not available) 5740 License Plate Mount and Light Cluster 5740 - License Plate Bracket and Light Assembly 1. 04505-95 1 License Plate and Light Cluster Bracket 2. 04176 2 1/4”-20UNC X 3/4” Carriage Bolt 3. 02214 2 #10 NC X 1/2” Slotted Truss Head Screw 4.
28 Fender Assembly 1 2 2 2 2 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 REF. NO. PART NO. QTY. DESCRIPTION PARTS LIST 5736 - Left Fender Assembly 5737 - Right Fender Assembly 1. 01883 2 Wire Splicer 2. 04425 5 Tinnerman U-clamp 3. 04515 1 17-1/2” Wire Loom 4.
29 OPTIONAL SP ARE TIRE and MOUNT P AR TS BREAKDO WN 3. 02193-30 1 Spare Tire Bracket 4. 02917 1 Stud Bolt (12mm x 1.5) 5. 02933 2 Wheel Nut (12mm) Chrome 6. 02759 2 3/8"-16UNC Square U-Bolt 7. 00059 2 3/8" Flatwasher 8. 02592 4 3/8"-16UNC Nylon Insert Locknut RKSTM 1 Spare Tire Mounting Bracket 1.
30 OPTIONAL LIGHT B AR P AR TS BREAKDO WN 1 11 11 13 13 1 2 8 9 8 12 1 7 9 9 8 6 8 9 1 14 15 16 10 3 4 4 5 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 RKLB Kar Kaddy Light Bar (complete) REF.
31 1. Extent and Duration of this Warranty: Your Demco Kar Kaddy 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.
32 NO TES:.
33 How satisfied are you with our product? ❍❍ ❍ ❍ How satisfied are you with the dealership/distributor sales staff? ❍❍ ❍ ❍ Dealer/Distributor Name City State How satisfied are you wit.
34 P ostage Dethmers Manufacturing Company 4010 320th Street, Box 189 Boyden, Iowa 51234.
35 NO TES:.
36 DETHMERS MFG. COMPANY P.O. BOX 189 4010 320th St., BOYDEN, IA. 51234 PH: (712) 725-2311 FAX: (800) 845-6420 TOLL FREE: 1-800-54DEMCO (1-800-543-3626) www.
An important point after buying a device Demco KK460SS (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Demco KK460SS yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Demco KK460SS - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Demco KK460SS you will learn all the available features of the product, as well as information on its operation. The information that you get Demco KK460SS will certainly help you make a decision on the purchase.
If you already are a holder of Demco KK460SS, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Demco KK460SS.
However, one of the most important roles played by the user manual is to help in solving problems with Demco KK460SS. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Demco KK460SS along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
