Demco Gravity Flow 450 Wagon User manual

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01-17
AG20023, Rev. 9

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WARNING: TO AVOID PERSONAL INJURY OR DEATH, OBSERVE THE FOLLOWING
INSTRUCTIONS:
Never overload the wagon. The rating of the GF450 gear is 30,000 lbs. or the rating of
the tires, whichever is less.
Ensure that anybody present is clear before applying power to any machinery used in
conjunction with the wagon box or when moving the box.
Never allow anyone in, near, or on the gravity box during the transporting, loading, or
unloading of grain. Moving grain is dangerous and can cause entrapment, resulting in
severe injury or death by suffocation.
Do not exceed 20 miles per hour when towing the wagon.
TABLE OF CONTENTS
General information, Warranty Policy & Registration & Table of Contents...........................2
For your safety................................................................................................................... 3-9
Safety Sign Locations.........................................................................................................10
Bolt Torque & Wheel Bearing Adjustment...........................................................................11
Running Gear Parts Breakdown.........................................................................................12
Running Gear Parts List and Assembly Instructions ..........................................................13
Brake Tongue Maintenance and Adjustment ......................................................................14
Brake Tongue Parts Breakdown and Parts List ..................................................................15
13” Brake Cluster Parts Breakdown and Parts List ............................................................16
Running Gear Brake Line Parts Breakdown, Parts List, and Assembly Instructions..........17
Brake System Maintenance and Repair .......................................................................... 18-19
Gravity Flow Box Parts Breakdown ....................................................................................20
Gravity Flow Box Assembly Instructions and Parts List......................................................21
Maintenance and General Operation .................................................................................22
Gravity Box to Running Gear Assembly Instructions and Parts List...................................22
Gravity Flow Light Kit Parts Breakdown, Parts List, and Wiring Schematic .......................23
Thank you for purchasing a Demco Gravity Flow Wagon. We feel you have made a wise choice and hope you are completely
satisfied with your new piece of equipment. Proper care and use will result in many years of service.
INTRODUCTION
GENERAL INFORMATION
1. Unless otherwise specified, high-strength (grade5)
(3 radial-line head markings) hex head bolts are used
throughout assembly of this piece of equipment.
2. Whenever the terms “LEFT” and “RIGHT” are used in
this manual it means from a position behind the wagon
box and facing forward.
3. When placing a parts order, refer to this manual for proper
part numbers and place order by PART NUMBER,
DESCRIPTION and COLOR.
4. Read the assembly instructionscarefully. Study the assembly
procedures and all illustrations before you begin assembly.
Note which parts are used in each step. This unit must
be assembled in the proper sequence or complications
will result.
WARRANTY POLICY, OPERATOR MANUALS & REGISTRATION
Go online to www.demco-products.com to review Demco warranty policies, operator manuals and register your Demco product.

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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 SAFETY OF OTHERS. FAILURE TO FOLLOW
THESE INSTRUCTIONS CAN RESULT IN INJURY OR DEATH!
THIS SYMBOL MEANS
ATTENTION
BECOME ALERT
YOUR SAFETY IS INVOLVED!
DANGER:
Indicates an imminently hazardous situation that,
if not avoided, will result in death or serious injury.
This signal word is to be limited to most extreme
situations typically for machine 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:
Indicates a potentially hazardous situation that,
if not avoided, may result in minor or moderate
injury. It may also be used to alert against unsafe
practices.
If you have questions not answered in this manual, require additional copies, or if your manual is
damaged, please contact your dealer or DEMCO, 4010 320th St., Boyden, IA 51234
ph: [phone] or Toll Free: 1-800-543-3626 Fax: [phone] or 1-800-845-6420
http://www.demco-products.com
SIGNAL WORDS:
This manual uses of the following signal words--
DANGER, WARNING, and CAUTION-- with safety
messages. The appropriate signal word has been
selected using the following guidelines.

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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.
In order to provide a better view, certain illustrations in your owners manual may show an
assembly with a safety shield removed. However, equipment should never be operated in
this condition. Keep all shields in place. If shield removal becomes necessary for repairs,
replace shield prior to use.
Replace any caution, warning, danger or instruction safety decal that is not readable or is
missing.
Do not attempt to operate this equipment under the influence of alcohol or drugs.
Review safety instructions with all users annually.
Operator should be a responsible adult. DO NOT ALLOW PERSONS TO OPERATE OR
ASSEMBLETHIS UNIT UNTILTHEY HAVE DEVELOPED ATHOROUGH UNDERSTANDING
OF SAFETY PRECAUTIONS AND HOW IT WORKS.
To prevent injury or death, use a tractor equipped with a roll over protective system (ROPS).
Do not paint over, remove, or deface any safety signs or warning decals on your equipment.
Observe all safety signs and practice instructions on them.
Never exceed limits of a piece of machinery. If its ability to do a job, or to do so safely is in
question DON’T TRY IT.
LIGHTING AND MARKING
It is the responsibility of customer to know lighting and marking requirements of local highway
authorities and to install and maintain equipment to provide compliance with regulations.
Add extra lights when transporting at night or during periods of limited visibility.
Lighting kits are available from your dealer or from manufacturer.

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SAFETY SIGN CARE
• Keepsafetysignscleanandlegibleatalltimes.
• Replacesafetysignsthataremissingorhavebecomeillegible.
• 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thatinstallationareaiscleananddry.
• Decideonexactpositionbeforeyouremovebackingpaper.
• Removesmallestportionofsplitbackingpaper.
• Aligndecaloverspeciedareaandcarefullypresssmallportionwithexposedsticky 
backing in place.
• Slowly peel back remaining paper and carefully smooth remaining portion of decal into
place.
• Smallairpocketscanbepiercedwithapinandsmoothedoutusingpieceofdecal 
backing paper.
TIRE SAFETY
• Failuretofollowproperprocedureswhenmountingatireonarimcanproducean 
explosion which may result in a serious injury or death.
• Donotattempttomountatireunlessyouhaveproperequipmentandexperienceto 
do job.
• Inatingorservicingtirescanbedangerous.Wheneverpossible,trainedpersonnel 
should be called to service and/or mount tires.
• Alwaysorderandinstalltiresandwheelswithappropriatetypeandloadcapacitytomeet
or exceed anticipated weight to be placed on the equipment.
• NEVERexceed40psitireinationwhenusingtrucktiresongravityowwagons.
• Referto“TIREINFLATIONCHART”inyourownersmanualformaximumtirepressurefor
a Demco Grain Wagon.
REMEMBER
Your best assurance against accidents is a careful and responsible operator. If there is any
portion of this manual or function you do not understand, contact your local authorized dealer
or manufacturer.

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BEFORE OPERATION:
• CarefullystudyandunderstandthismanualandtheOwner’sManual.
• Donotwearloose-ttingclothingwhichmaycatchinmovingparts.
• Alwayswearprotectiveclothingandsubstantialshoes.
• Itisrecommendedthatsuitableprotectivehearingandeyeprotectionbeworn.
• Operatormaycomeincontactwithcertainmaterialswhichmayrequirespecicsafety
equipment relative to handling of such materials. (Examples: extremely dusty, molds,
fungus, bulk fertilizers, etc.)
• Keepwheelandlugnutstightenedtospeciedtorque.
• Assurethatagriculturalimplementtiresareinatedevenly.
• Giveunitavisualinspectionforanyloosebolts,wornparts,orcrackedwelds,andmake
necessary repairs. Follow maintenance safety instructions included in this manual.
• Besuretherearenotoolslyingonorinequipment
• Donotuseunituntilyouaresurethatareaisclear,especiallyaroundchildrenandanimals.
• Don’thurrylearningprocessortakeunitforgranted.Easeintoitandbecomefamiliar
with your new equipment.
• Practiceoperationofyourequipmentanditsattachments.Completelyfamiliarizeyourself
and other operators with its operation before using.
• Makesurethatbrakesareevenlyadjusted(ifequippedwithbrakes)
• UseatractorequippedwithRollOverProtectionSystem(ROPS)andfastenyourseatbelt
prior to starting the engine.
• ManufacturerdoesnotrecommendusageofatractorwiththeROPSremoved.
• Movetractorwheelstowidestrecommendedsettingstoincreasestability.
• Donotallowanyonetostandbetweentongueorhitchandtowingvehiclewhenbackingup
to equipment.
DURING OPERATION
• Bewareofbystanders,PARTICULARLYCHILDREN!Alwayslookaroundtomakesurethatit
is safe to start engine of towing vehicle or move unit.This is particularly important with higher
noise levels and quiet cabs, as you may not hear people shouting.
• NOPASSENGERSALLOWED-Donotcarrypassengersanywhereonorintractoror
equipment.
• Keephandsandclothingclearofmovingparts.
• Donotclean,lubricate,oradjustyourequipmentwhileitismoving.

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• Whenhaltingoperation,evenperiodically,settractorortowingvehiclesbrakes,disengage
PTO, shut off engine, and remove ignition key.
• Beespeciallyobservantofoperatingareaandterrain.Watchforholes,rocks,orother 
hidden hazards. Always inspect area prior to operation.
- DO NOT operate near edge of drop-off or banks.
- DO NOT operate on steep slopes as overturn may result.
- Operate up and down (not across) intermediate slopes. Avoid sudden starts and stops.
• Pickthemostlevelpossibleroutewhentransportingacrosselds.Avoidedgesofditches, 
gullies, and steep hillsides.
• Beextracarefulwhenworkingoninclines.
• Maneuvertractorortowingvehicleatsafespeeds.
• Avoidoverheadwiresorotherobstacles.Contactwithoverheadlinescouldcauseserious
injury or death.
• Avoidloosegravel,rocks,andholes;theycanbedangerousforequipmentoperationor
movement.
• Allowforunitlengthwhenmakingturns.
• Donotwalkorworkunderraisedcomponentsorattachmentsunlesssecurelypositionedand
blocked.
• Keepallbystanders,pets,andlivestockclearofworkarea.
• Operatetowingvehiclefromoperatorsseatonly.
• Neverstandalongsideofunitwithenginerunningorattempttostartengineand/oroperate 
machine while standing alongside of unit.
• Neverleaverunningequipmentunattended.
• Asaprecaution,alwaysrecheckhardwareonequipmentfollowingevery100hoursof 
operation. Correct all problems. Follow maintenance safety procedures.
FOLLOWING OPERATION
• Followingoperation,orwhenunhitching,stoptractorortowingvehicle,setbrakes,shutoff
engine and remove ignition key.
• Storeunitinanareaawayfromhumanactivity.
• Donotparkequipmentwhereitwillbeexposedtolivestockforlongperiodsoftime.Damage
and livestock injury could result.
• Donotpermitchildrentoplayonoraroundstoredunit.
• Makesureallparkedmachinesareonahard,levelsurfaceandengageallsafetydevices.
• Wheelchocksmaybeneededtopreventunitfromrolling.

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HIGHWAY AND TRANSPORT OPERATIONS
• Adoptsafedrivingpractices:
- Keep brake pedals latched together at all times. NEVER USE INDEPENDENT
BRAKINGWITH MACHINE INTOW, LOSS OF CONTROL AND/OR UPSET OF UNIT
CAN RESULT.
- Always drive at a safe speed relative to local conditions, ensure that your speed is low
enough for an emergency stop. Keep speed to a minimum.
- Reduce speed prior to turns to avoid risk of overturning.
- Always keep tractor or towing vehicle in gear to provide engine braking when going
downhill. Do not coast.
- Do not drink and drive!
• Complywithstateandlocallawsgoverninghighwaysafetyandmovementoffarm
machinery on public roads.
• Useapprovedaccessorylighting,agsandnecessarywarningdevicestoprotectoperators
of other vehicles on highway during transport.Various safety lights and devices are available
from your dealer.
• Useofashingamberlightsisacceptableinmostlocalities.However,somelocalitiesprohibit
their use. Local laws should be checked for all highway lighting and marking requirements.
• Whendrivingtractorandequipmentonroadunder20m.p.h.(40kph)atnightorduringday,
use flashing amber warning lights and a slow moving vehicle (SMV) identification emblem.
• Planyourroutetoavoidheavytrafc.
• Beasafeandcourteousdriver.Alwaysyieldtooncomingtrafcinallsituations,including
narrow bridges, intersections, etc.
• Beobservantofbridgeloadratings.Donotcrossbridgesratedlowerthangrossweight
at which you are operating.
• SAFETYCHAINS:Ifequipmentisgoingtobetransportedonapublichighway,always
follow state and local regulations regarding safety chains and auxiliary lighting. Be sure
to check with local law enforcement agencies for your own particular regulations.
Only safety chains (not elastic or nylon/plastic tow straps) should be used to retain
connection between towing and towed machines in event of separation of primary attaching
system. Use a high strength, appropriately sized hitch pin with a mechanical retainer and
attach safety chains. Criss cross chains under tongue and secure to draw bar cage,
mounting loops, or bumper frame.

Page 9
• Watchforobstructionsoverheadandsidetosidewhiletransporting.
• Always operate equipment in a position to provide maximum visibility. Make allowances
for increased length and weight of equipment when making turns, stopping unit, etc.
• Goodmaintenanceisyourresponsibility.Poormaintenanceisaninvitationtotrouble.
• Makesurethereisplentyofventilation.Neveroperateengineoftowingvehiclein 
a closed building. Exhaust fumes may cause asphyxiation.
• Beforeworkingonthismachine,stoptowingvehicle,setbrakes,shutoffengine 
and remove ignition key.
• Alwaysusesafetysupportandblockwheels.Neveruseajacktosupportmachine.
• Alwaysusepropertoolsorequipmentforjobathand.
• Useextremecautionwhenmakingadjustments.
• Followtorquechartinownersmanualwhentighteningboltsandnuts.
• Neveruseyourhandstolocateahydraulicleakonattachments.Useasmallpieceof
cardboard or wood. Hydraulic fluid escaping under pressure can penetrate skin.
• Openingsinskinandminorcutsaresusceptibletoinfectionfromhydraulicuid.
Without immediate medical treatment, serious infection and reactions can occur.
• Whendisconnectinghydrauliclines,shutoffhydraulicsupplyandrelieveallhydraulic
pressure.
• Replaceallshieldsandguardsafterservicingandbeforemoving.
• Afterservicing,besurealltools,partsandserviceequipmentareremoved.
• Donotallowgreaseoroiltobuilduponanystepsorplatform.
• Whenreplacingbolts,refertoownersmanual.
• Refertobolttorquechartinownersmanualforheadidenticationmarking.
• Wherereplacementpartsarenecessaryforperiodicmaintenanceandservicing,
genuine factory replacement parts must be used to restore your equipment to original
specifications. Manufacturer will not claim responsibility for use of unapproved parts
or accessories and other damages as a result of their use.
• Ifequipmenthasbeenalteredinanywayfromoriginaldesign,manufacturerdoes 
not accept any liability for injury or warranty.
• Areextinguisherandrstaidkitshouldbekeptreadilyaccessiblewhileperforming
maintenance on this equipment
PERFORMING MAINTENANCE

Page 10
SAFETY SIGN LOCATIONS
The types of safety sign and locations on the equipment are shown in the illustration
below. Good safety requires that you familiarize yourself with the various safety signs,
the type of warning, and the area or particular function related to that area, that requires
your SAFETY AWARENESS.
Please order replacement parts by PART NO., DESCRIPTION and COLOR.
REF. PART
NO. NO. QTY. DESCRIPTION
1. 04508 5 Amber Reflector (2.75” x 1.75”)
2. 04804 5 Red Reflector (2.75” x 1.75”)
3. 07278 2 Conspicuity Tape, Reflective (18”)
4. AG21006 1 Wagon Safety Decal (5” x 8”)
5. AG21067 1 “Keep off Ladder” (3 7/8” x 3 7/8”)
6. AG21163 2 Large “Demco”, Charcoal
7. AG21164 2 Medium “Demco”, Charcoal
8. AG21192 1 Med. Stripes, Charcoal (left)
- AG21193 1 Med. Stripes, Charcoal (right)
DECAL PARTS LIST
3
2
2
2
2
3
7
9
CAUTION!
Do not exceed 20 MPH
when loaded.
09/99 AG21002
13.
14.
4.
12.
5.
11.
Decals are not shown to scale
1
41
1
1
1
56
8
7
9
10
14 14
11
12
13
2
9. AG21172 2 “450”, Charcoal
10. BH21003 1 Brake Lever Indicator, Red/Green
11. AG21002 1 “Caution, 20 MPH” (2” x 3 7/8”)
12. AG21070 1 “Attention: Don’t Turn Sharp” (2” x 4”)
13. AG21001 1 “Tire Load Rating” (4 1/2” x 6”)
14. AG21127 2 “Caution Check All Wheel Nuts”
REF. PART
NO. NO. QTY. DESCRIPTION
NOTICE!
Keep wheel lug nuts or bolts tightened to specified torque
IMPORTANT :
Always retorque wheels after first trip!
CAUTION:
Over inflation may result in damage to
running gear and box integrity.
REV 5 AG21001
650/750bu.
3/4”-16UNF Grade 8
T o rque to 400 ft. lbs.
450/550bu.
5/8”-18UNF Grade 8
T o rque to 225 ft. lbs.
Check tire pressure regularly .
365bu.
5/8”-18UNF Grade 5
T o rque to 150 ft. lbs.
Nut or Bolt T o rques
Tire Pressure for all 365/450/550/650/750
Bushel Gravity Flow W a gons
60 psi.

Page 11
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.
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 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.
GRADE-2 CLASS 8.8 CLASS 10.9
GRADE-5 GRADE-8
CLASS 9.8
8.8 9.8 10.9 A
Bolt Torque for Standard bolts *
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)
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) 106 (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)
Bolt Torque for Metric bolts *
Hub Initial Toque Final Torque
8 bolt 75 ft/ lbs 35 ft/lbs
Wheel Bearing Adjustment
Tighten castle or slotted hex nut to initial torque indicated on chart while turning hub in both1.
directions to insure all bearing surfaces are in contact.
Back nut off and repeat step #1.2.
Back nut off, do not allow hub to turn.3.
Tighten nut to final torque indicated on chart.4.
Install cotter pin, if needed loosen or tighten nut to the next closest locking slot.5.
Check hub for end play.6.
If end play can be felt, start over and readjust bearings. If end play is felt again, try readjusting7.
with a different castle or slotted hex nut.
The bearings are set correctly when no end play can be felt after adjustment.8.

Page 12
RUNNING GEAR PARTS BREAKDOWN
37
8
D
C
A
E
B
O
F
G
R
Q
P
L
M
N
T
J
K
S
H
V
Z
Z
W
W
XP
Y
8
3
4
6
75
9
28
25
29
13 1
16
17
2
27
30
25
26
34
35
33
32
22
18
20
8
3
4
6
75
9
13 1
16
17
2
23
14
15 12 1110*
39
36
40 38
38
39
39
19
24
31
I
U
AA
For Breakdown of Tongue
and Pivot Arm Assembly,
See Page 16.
21
21
21
41
41
Items #13, #16, and #17 are not
included in hub assembly 5691
Items #13, #16, and #17 are not
included in hub assembly 5691

Page 13
REF. PART
NO. NO. QTY. DESCRIPTION
RUNNING GEAR PARTS LIST AND ASSEMBLY INSTRUCTIONS
1. 01933 1 Dust Cap
2. 01937 1 Outer Cone Bearing (LM501349)
3. 01938 1 Outer Cup (LM501310)
4. ----- 1 8 Bolt Hub (W80-8) (NOT SOLD SEPARATELY)
5. 01942 1 Inner Cone Bearing (JLM506849)
6. 01943 1 Inner Cup (JL506810)
7. 01944 1 Oil Seal (CR27362)
8. 10971 8 5/8” UNF Flanged Wheel Nut
9. 10151 8 5/8”-18 UNF x 2-1/2” Stud Bolt (for W80-8 hub)
5691 4 Wheel Hub Assembly
11. 01948 2 1”-16UNF Left Hand Jam Nut
- 01949 2 1”-16 UNF Right Hand Jam Nut
12. 01950-30 2 Tie Rod (Black)
13. 00191 4 Cotter Pin .188 x 1.50
14. 01922 3 1 1/2” Hex Nut w/ Set Screw Hole
15. 01923 3 1/4” Socket Head Set Screw
16. 01934 4 1” Slotted Hex Nut f/ W80-8 spindle
17. 01936 4 2.25” Case Hardened Flat Washer
18. 01947-30 2 1.50” x 12.5” Spindle Mounting Pin (Black)
19. 01953-30 1 1.50” x 9.0” Pivot Arm Mounting Pin (Black)
20. 02046 2 Thrust Bearing
21. 04642 3 1/4” Grease Zerk
22. 10991-30 1 Front Bolster (Black) (includes zerk)
23. 10753-30 1 Left Front Spindle (Black) (includes zerk)
24. 10754-30 1 Right Front Spindle (Black) (includes zerk)
25. 00084 24 1/2” Lock Washer
26. 00152 8 1/2” NF Hex Nut
27. 02010 8 1/2”-20 UNF x 1.00” Hex Head Bolt Gr. 5
28. 03532 2 13” Brake Drum
29. 05031 16 1/2”-20 UNF x 1.25” Hex Head Bolt Gr. 5
30. 07910 1 13” Uni-Servo Left Brake Cluster
31. 07911 1 13” Uni-Servo Right Brake Cluster
32. 10992-30 1 Rear Bolster (Black)
33. 01135-30 1 4” OD Collar (Black)
34. 01336 1 5/8”-11 UNC x 5” Hex Head Bolt Gr. 5
35. 02587 1 5/8” NC Nylon Locknut
36. 10797-30 2 Turn Stop, Bolt on (Black)
37. 11291-15 4 22.5 x 13.5 8 Bolt Rim (Yellow)
- 11291-60 4 22.5 x 13.5 8 Bolt Rim (Charcoal)
38. 10443 2 Rubber Bumper
39. 02178 6 1/2” NC Nylon Locknut
40. 01254 4 1/2”-13UNC x 1 1/2” Hex Head Bolt Gr. 5
41. 09510 3 Spacer Bushing
INSTALLING THE TONGUE AND
THE LIFT ASSIST SPRING
1. Mount the Tongue (H) onto the pivot arm (R), fasten together using
one 1-1/2” Dia. x 8 5/8” bolt (J) and one 1-1/2” nut (K). Tighten just
enough to take out all slack and hold nut in place using one 1/4” x 1/4”
socket set screw (L).
2. Insert 1/2” x 7 1/2” Bolt (V) through tongue as shown using one 1/2”
Nylon Insert Locknut (X) and two 1/2” Flat Washers (W). Tighten
bolt until all slack is removed between the tongue and Pivot Arm
(R). Do not overtighten, the tongue should still move freely. Raise
the tongue and support on a stand.
3. Mount the Lift Assist Plate (Q) onto the top of the Pivot Arm (R) using
two 5/8” x 2” Bolts (S) and two 5/8” Nylon Insert Locknuts (T).
4. Attach the Lift Assist Springs (M) to the Lift Assist Plate (Q) by
threading the two 1/2” x 6” Full Thread Bolts (N) with two 1/2” Hex
Nuts (AA) and two 1/2”Lock washers (O) into the threaded insert in
the springs (M). Tighten the bolts to remove any slack. Remove the
stand and adjust the tongue height using the two 1/2” x 6” bolts.
5. Mount the Turn Stop Plates (Y) to the Front Bolster (B) using four 1/2”
x 1 1/4” Bolts (I) and four 1/2” Nylon Insert Locknuts (T).
ADJUSTING THE TIE RODS FOR ALIGNMENT
1. Alignment is preset at the factory.To check alignment, theTie Rods
(P) should be adjusted to have 1/4” to 3/8” toe in (measured at
tire bead edge of rim). When this adjustment is made, the tongue
must be aligned with the reach pipe. Be sure both wheels toe in
equally.
1. Slide Front Bolster Reach Tube (B) into Rear Bolster ReceiverTube
(C).Slide on Lock Collar (A) until holes line up and bolt together using
one 5/8” x 5” Bolt (D) and one 5/8” Nylon Locknut (E).
2. Mount the Tire and Rim (F) to the front and rear bolster using
thirty-two 5/8” FlangedWheel Nuts (G), and thirty-two 5/8” x 2-1/2”
Stud Bolts.
TIGHTEN ALL BOLTS (SEE TORQUE CHART ON PAGE 4.)
MOUNTING THE WHEELS, AND ASSEMBLING
THE FRONT AND REAR BOLSTER FRAMES
Please order replacement parts by PART NO., DESCRIPTION and
COLOR.
ASSEMBLY INSTRUCTIONS
PARTS LIST
*10. 5182 2 Tie Rod End w/ Left Hand Threads
*10. 5183 2 Tie Rod End w/ Right Hand Threads
* This kit includes tie rod ends (specify left or right hand threads),
grease zerk, rubber cup, cotter pin, castle nut, and flat washers.

Page 14
DISASSEMBLY AND REASSEMBLY
1. The brake tongue is preassembled and adjusted at the factory:
Do Not Disassemble or Attempt to Adjust The
Tongue Push-Rod Assembly (#37)
To disassemble the tongue: (refer to illustration on page 16)
A. Remove 1/2” bolts (#44) , remove stop block (#10), and pull
male tongue (#20) out of female tongue (#38).
B. Remove 1/2” bolt (#28), pin (#33), and spacer (#34)
C. Remove set screw (#12) from adjustment spud (#25b),
unthread and remove adjustment spud (#25b).
D. Remove push-off assembly (#36), pin (#35), two shocks
(#40), and two springs (#32).
E. To remove tongue push-rod assembly (#37), master cylinder
(#29), emergency lever (#31), pin (#46), spring (#18), and
guide (#14), refer to section a&b of “Servicing the
Emergency Lever” on this page.
To reassemble the tongue: (refer to illustration on page 16)
A. Replace 2 shocks (#40) into yoke (#36), with pin (35).
B. Place 2 springs (#32), onto shaft of push-off assembly (#36),
and insert shaft into female tongue (#38), through hole in
plate (shown in exploded view).
C. Thread adjustment spud (#25b) onto rear threaded portion of
push-rod assembly (#36), until the 2 springs (#32) compress
to a length of 6-1/2”. Install and tighten set screw (#12),
using Locktite, into one of the threaded holes of the
spud (25b).
D. Insert pin (#33) into hole in tongue, through 1 shock (#40),
through the spacer (#34), and through the other shock (#40)
and tongue. Install and tighten 1/2” bolt, lock washer, and
washer (#28, 3, 4).
E. Install master cylinder (#29), (refer to c-f of “Servicing
Emergency Lever” section on this page).
F. Thread adjust spud (25a) onto front threaded portion of push-
rod assembly (#36). Insert male tongue (#20), (with latch
installed as shown), into female tongue (#38). Install stop
block (#10), using 1/2” bolts and lock washers (#44, #3). Pull
male tongue (#20) forward to latched position and adjust
spud (#25a) until there is a 7/16” gap between spud (#25a)
and rear stop surface of male tongue (#20) see arrow.
G. Tighten set screw (#24), using Locktite, into hole in
spud (#23a).
2. Connect and tighten all brake lines. (Brake lines are shown on
page 18.)
3. Fill the Master Cylinder (#29) with DOT 3 or 4 brake fluid.
4. Bleed the brake system using a pressure-type brake bleeder or
manually, as follows:
A. Remove the two Self-Tapping Screws (#13) and Lock
washers (#17) that hold the Lever Guide (#14) and the flat
Emergency Lever Spring (#18).Remove the Lever Guide and
the Emergency Lever Spring. Using short strokes, pull
forward on the Emergency Lever (#31), pumping the Master
Cylinder until the brake fluid within the Master Cylinder stops
bubbling.
DEMCO BRAKE TONGUE MAINTENANCE AND ADJUSTMENT
Review all of the following instructions before installation and use of the hydraulic brake tongue. Dealers
or Distributors must review these instructions with the ultimate user. Failure to follow these instructions, or failure to properly
maintain the braking system after installation, can result in loss of braking action which could cause severe property damage,
personal injury and/or death.
CAUTION
WARNING
B. Attach a bleeder hose to the bleeder valve on one of the
wheels (always begin with wheel farthest from the master
cylinder and move toward it). Immerse the other end of the
hose into a clean, transparent container partially filled with
brake fluid. Loosen the bleeder valve one turn and, watching
the hose in the transparent container, use the Emergency
Lever to pump the Master Cylinder as long as air bubbles
continue to leave the hose. When the repeat the process
until all the brakes have been bled. (Note: Check the fluid
level in the Master Cylinder frequently while bleeding the
brakes (every 4 or 5 strokes). Refill as necessary to keep
the level above half full.)
5. Once bleeding is completed, refill the Master Cylinder and attach
the Cap (#15) securely. Replace Emergency Lever Spring, Lever
Guide, with Lock Washers and Self-Tapping Screws.
6. Test the brakes by pulling the Emergency Lever (#31) forward
until it locks into its first detent position. (The lever should be ap-
proximately straight up.) Attempt to rotate the wheels in a forward
direction. If any of the wheels rotate, the brakes must be adjusted
on that wheel. To adjust the brakes, release the Emergency Lever
from its locked position and set the wheel brake adjustment up
2 or 3 notches (refer to instructions on page 12). Repeat the test
procedure as necessary.
MAINTENANCE
1. Frequently check the brake fluid level. (Fluid must be approved,
clean and uncontaminated.)
2. Inspect the brake tongue and brakes and replace bent, worn or
damaged parts.
3. Be constantly aware of the system’s braking quality and make
periodic checks. Consult a certified brake specialist to make the
necessary adjustments and/or repairs. Failure to do so could result
in loss of braking.
SERVICING THE EMERGENCY LEVER
If the Emergency Lever (#31) of the tongue is applied, it can be
disengaged by using a screwdriver to lift upward on the front of the
flat Emergency Lever Spring (#18) while pulling the lever forward
until it releases. A thorough inspection of the Emergency Lever,
Emergency Lever Spring, and the Chain with S-Hooks is required
and all damaged parts must be replaced as follows:
A. Remove the Master Cylinder (#29) and the Push Plate Assembly
(#37). Be careful not to get dirt into the Master Cylinder. (A new
Master Cylinder Gasket (#30) should be used when reinstalling.)
B. Remove the Safety Chain from the Emergency Lever (#31), Emer-
gency Lever Guide (#14), and flat Emergency Lever Spring (#18),
then pull the lever out of the tongue (#38) from the bottom.
C. Install the new Emergency Lever from the bottom of tongue and
up through the slot in the tongue. Attach the new Emergency Lever
Spring, and the Emergency Lever Guide.
D. Install a new Master Cylinder Gasket to the Master Cylinder and
put the Push Plate Assembly and Master Cylinder back into the
inside of the tongue.
E. Squeeze shut the S-Hook of the Emergency Chain (#22) onto the
Emergency Lever (#31).
F. Add adequate brake fluid to the Master Cylinder and bleed the
brake system per instructions 4-6 in the disassembly and reas-
sembly section.

Page 15
PARTS LIST
1. 00057 4 1/4” Lock Washer
2. 00083 2 1/2” NC Hex Nut
3. 00084 3 1/2” Lock Washer
4. 00085 5 1/2” Flat Washer
5. 00290 2 5/8”-11UNC x 2” Hex Head Bolt Gr. 5
6. 00306-30 2 Tongue Lift Assist Spring w/ Insert (Black)
7. 00545 2 1/2”-13 UNC x 6” Hex Head Bolt (Full Thread)
8. 01158-95 1 Hitch Spring (Plated)
9. 01159-95 1 Hitch Lock Pin (Plated)
10. 01160-30 1 Male Tongue Stop Plate (Black)
11. 01922 1 1 1/2”-12 UNF Hex Nut w/ Set Screw Hole
12. 01923 3 1/4” NC x 1/4” Socket Head Set Screw
13. 02196 2 5/16” NC x 3/4” Hex Head Bolt, Thread Cutting
14. 03866-95 1 Emergency Lever Guide (Plated)
15. 03876 1 3-Tab Fill Cap w/ Diaphram & O-Ring
- 03877 - Diaphram Replacement
- 05849 - O-Ring Replacement
16. 10823 1 1/2”-13 UNC x 7.5” Hex Head Bolt Gr. 5
17. 05424 2 5/16” External Tooth Lock Washer
18. 05693-95 1 Safety Lever Spring (Plated)
19. 07876 2 1/8” x 1 1/4” Cotter Pin
20. 12224-30 1 Tongue Hitch, Male Half (Black)
21. 09297-30 1 Tongue Latch (Black)
22. 09309 1 72” Actuator Chain/Hook Assembly
23. 09317 1 1/2” NC x 2” Eye Bolt w/ Nut
24. 09326-30 1 Lift Assist Bracket
25. 09337 2 Adjustment Spud (a & b)
26. 10748-30 1 Tongue Pull Bolt (Black)
27. 01076 4 1/4”-20 UNC x 3/4” Hex Head Bolt Gr. 5
28. 04795 1 1/2”-13 UNC x 1” Hex Head Bolt Gr. 5
29. 5650 1 Master Cylinder w/ Gasket 09153
30. 09153 - Master Cylinder Gasket (included in 5650)
31. 05951 1 Emergency Lever
REF. PART
NO. NO. QTY. DESCRIPTION
Please order replacement parts by PART NO., DESCRIPTION,
and COLOR.
5398 Master Cylinder Repair Kit
THIS PLATE IS WELDED INTO TONGUE (#38)
- SHOWN SEPARATE FOR CLARITY
32. 05952 2 Spring f/ Plunger Assembly
33. 09301 1 Rear Shock Pin
34. 09302 1 Spacer f/ Rear Shock Pin
35. 09303 1 Front Shock Pin
36. 09304 1 Push Off Assembly
37. 09306 1 Push Plate Assembly
38. 10747-30 1 Tongue Hitch, Female Half (Black)
39. SB12099 1 Connector Orifice (.031)
40. SB12426 2 Damper
41. 10749-30 1 Pivot Arm (Black)
42. 02587 2 5/8” NC Nylon Insert Locknut
43. 02178 1 1/2” NC Nylon Insert Locknut
44. 01253 2 1/2”-13 UNC x 2” Hex Head Bolt Gr. 5
45. 04642 2 1/4”-28 UNF Grease Zerk
46. 05694 1 Groove Pin (included in 05951)
47. 05687 1 Master Cylinder Protective Boot
48. 05395 1 45° Grease Zerk
49. 01951 2 Bronze Bushing
50. 12557 1 Master Cylinder Cap
REF. PART
NO. NO. QTY. DESCRIPTION
47
KIT NUMBERS
BRAKE TONGUE PARTS BREAKDOWN
USE LOCKTITE
ON SET SCREW
- 5398 - Master Cylinder Repair Kit w/gasket
USE LOCKTITE
ON SET SCREW
SOLD AS
ASSEMBLY
ONLY
1
27
15
13
17
18
14
31
46
22
45
11
12
4
43
26
49
41
5
4
16
38
23 30
39
29
47
28
3
4
44
3
10
37
21
20
8
9
19 25A
12
MALE
TONGUE
STOP
36 35
32
32
25B
12
34
33
40
49
6
2
24
42
4
7
48
45° ZERK
LOCATED ON
OPPOSITE SIDE
OF THIS GUSSET
50

Page 16
1
2
3
4
5
6
7
8
9
10
10
10
10
11
11
12
12
13
14
15
15
2
13” UNI-SERVO BRAKE CLUSTER PARTS BREAKDOWN
BRAKE CLUSTER PARTS LIST
REF. PART
NO. NO. QTY. DESCRIPTION
- 07910 - Left Hand Cluster
- 07911 - Right Hand Cluster (shown above)
1. 03529-80 1 Back Plate Assembly (Black)
2. 5509 1 Shoe Assembly
3. SB9776M 1 Wheel Cylinder Assembly - Right
- SB9777M 1 Wheel Cylinder Assembly - Left (not shown)
4. SB9783 1 Push Rod
5. SB9254 2 Adjusting Hole Grommet
6. 05961 2 5/16”-18UNC x 5/8” Hex Head Bolt Gr. 5
7. 05424 2 5/16” External Tooth Washer
8. 05431 1 Bleeder - Replacement
9. SB10961-95 1 Shoe Guide
10. SB9789 4 Cup - Shoe Hold Down
11. 05983 2 Spring - Shoe Hold Down
12. SB9786 2 Spring - Shoe
13. SB23324 1 Adjusting Screw Assembly
14. SB24765 1 Spring - Adjusting Screw
15. SB9788 2 #6 Hold Down Pin
- SB15845 1 Wheel Cylinder Repair Kit
(includes spring, cup and boot)
Please order replacement parts by PART NO. and DESCRIPTION.
BRAKE CLUSTER PARTS LIST

Page 17
RUNNING GEAR BRAKE LINE PARTS BREAKDOWN
1. Assemble the running gear.
2. Mount the Rear Brass Tee (#6) onto the bolt welded to the top
of the rear bolster frame using one 5/16” nylon insert locknut
(#8).
3. Next attach the 52” Rubber Line (#2) to the orifice fitting on
the master cylinder.
4. Attach the 52” Rubber Brake Hose (#2) to the 72” Steel Brake
Line (#4), and bend the 72” Steel Line (#4) around the front
bolster frame to fit (as shown).
NOTE: When bending steel lines, form around a 3/4” diameter
pin. Be careful not to make the bend too sharp or line failure
will occur.
5. Assemble 44” Rear Steel Lines (#5) to the brake cluster first.
Then bend around the top of the rear bolster frame and attach
to the Rear BrassTee (#6) as shown. Now attach 30”Steel Line
(#3) to center of outlet on Brass Tee (#6) along reach pipe.
REF. PART
NO. NO. QTY. DESCRIPTION
BRAKE LINE PARTS LIST
1. SB12099 1 Orifice Connector (.031) for Master Cyl.
2. 05979 1 #6 X 52” Rubber Brake Line
3. SB530 1 3/16” X 30” Steel Brake Line
4. SB572 1 3/16” X 72” Steel Brake Line
5. SB544 2 3/16” X 44” Steel Brake Line
6. SB7785 1 Brake Line Tee Fitting
7. SB13H66 1 #6 X 13” Rubber Brake Line
8. 02802 1 5/16”-18 UNC Nylon Insert Locknut
9. 02549 12 Rubber Protector (for steel lines)
10. SBD10 1 Fitting Union .188 Female
6. Assemble 13”Rubber Line (#7) between the 30”Steel Line (#3),
and the 72” Steel Front Brake Line (#4) allowing some slack.
7. Put Rubber Line Protectors (#9) around steel lines at clips and
bend clips down.
Please order replacement parts by PART NO. and DESCRIPTION
9
4
7
35
5
8
6
2
1
9
9
10

Page 18
Brake System Repair & Maintenance
DEALERS, OR DISTRIBUTORS MUST REVIEWTHESE
INSTRUCTIONS WITH THE ULTIMATE USER. FAILURE TO
FOLLOW THESE INSTRUCTIONS, OR FAILURE TO PROPERLY MAINTAIN BRAKES
AFTER INSTALLATION, CAN RESULT IN LOSS OF BRAKING ACTION. THIS CAN
CAUSE PERSONAL INJURY, DEATH OR PROPERTY DAMAGE. ONLY PROFES-
SIONAL MECHANICS SHOULD INSTALL BRAKE COMPONENTS. HAVE YOUR
BRAKES INSPECTED BY A PROFESSIONAL MECHANIC A MINIMUM OF ONCE A
YEAR AFTER INSTALLATION.
Backplate Installation
Mount the backplate to the spindle flange. In mount-
ing the brake, be sure the hydraulic wheel cylinder is
at the top. Brakes are also marked as “RIGHT” and
“LEFT”. The brake designated as “LEFT” travels on
the driver’s side of the road.
Brake Line Installation
Use care in forming tubing to avoid sharp bends or
kinks. Use double flare steel tubing to assure tight
leakproof connections. This must be done by a cer-
tified brake shop. Anchor all hydraulic lines at two
foot intervals to prevent chafing and vibration. Use
hydraulic rubber hose at points of flexing. Anchor
hose ends to avoid stress on tubing.
Brake Adjustment
Before removing the ground stand jacks, adjust the brakes.
Uni-servo brakes must be adjusted periodically to assure
having brakes when they are applied. Insert a brake
adjusting tool or a screwdriver into the slotted hole.With the
handle up and the bit down and against the adjusting nut,
pull down on the handle. While spinning the wheel adjust
the cog wheel up until you cannot rotate the wheel forward.
Then back off the adjusting wheel twenty notches.
ALWAYS ROTATE DRUM IN DIRECTION OF
FORWARD ROTATION ONLY.
Brake Drum Maintenance
Brake drums must be reground if abnormal wear
is found, such as brake shoe hitting brake drum
once lining is gone, rivets hitting brake drums and
or brake drums out of round. NOTE: Maximum
diameter allowed 13.060”
Brake Setup
1. Attach brake line to master cylinder outlet. Make sure
all connections are tight.
2.Fill the master cylinder from a sealed container of DOT 3
or 4 brake fluid. A pressure type brake bleeder may be
used. If one is not available, you can bleed the system
manually as follows.
3. After the master cylinder has been filled, remove the
flat spring behind the emergency lever. Pull forward on
the lever to pump the master cylinder. Use short strokes
until bubbling stops in the master cylinder.
Bleed the rear axle first.Install bleeder hose on the bleeder
valve on the first wheel with other end of the hose in a
clear container partially filled with brake fluid.
RIGHT (Double Flare)
WRONG
WARNING

Page 19
Hitching The Wagon
5. Be sure Pin and hitch rating is equal to or greater than
the wagon GVWR.
6. Connect the emergency chain hook to towing vehicle.
7. If the emergency brake lever is accidentally applied
while unhitching, release the lever by pulling it forward
and with a screwdriver lift up the front of the flat spring
until it releases the lever. Many times these parts are
damaged when this happens. An inspection of the
lever, flat spring, and chain with S-hooks is required
and any damaged parts must be replaced.
Loosen the bleeder valve one turn and pump the master
cylinder until the air bubbles stop coming out of the
hose in the glass container, then close the bleeder
valve and repeat the process on the other wheels.
(Watch the fluid level in the master cylinder and refill so
level does not fall below 1/2 full).Refill master cylinder
every 4 or 5 strokes. Dispose of contaminated brake
fluid according to local regulations.
4.After bleeding is completed, refill the master cylinder
and put the filler cap on securely . Replace the flat
spring behind the emergency lever.
To test the brakes use a wrench or vise grip and clamp
onto the top of the emergency lever to lengthen it. Pull
lever forward until lever locks on the second click.The
lever should be approximately straight up and down.
Now try to rotate each wheel in a forward rotation.You
should not be able to rotate the wheels forward. If you
can, then release the emergency lever by wedging a
screwdriver under the flat spring behind the lever and
set each wheel brake adjustment up 2 or 3 notches.
Then repeat the test procedure.
MAINTENANCE
1. Before towing check to be sure master cylinder is full of brake fluid and check lines for leaks. Inspect the
actuator for bent or worn parts. Replace parts if necessary. Make sure the actuator mounting bolts are tight.
2. Periodically check braking quality, as described above. Failure to do so can result in loss of braking.
3. If units are used in corrosive conditions the actuator and wheels should be washed out with high pressure
water. When actuator parts are dry, oil all moving parts.
Replacing The Emergency Lever
Step one: Remove the lever guide and flat spring. Take the S-hook off the lever, take the lever out from
the inside.
Step two: Install the new lever from the inside and up through the slot. Replace the new flat spring and the
lever guide. Replace the push rod and master cylinder and new gasket.
Step three: Take the new chain and fasten the S-hook to the lever by squeezing the hook shut with a pliers.
Check the master cylinder and fill with DOT 3 or 4 brake fluid.
Step four: Re-bleed brake system.

Page 20
450 BUSHEL WAGON PARTS BREAKDOWN
Door Lift Assembly Breakdown
Part #5757-30
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See Door Lift
Assembly
Breakdown
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