Demco Kar-Kaddy SS User manual

1
6/17
RD20018,Rev 12

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 INFORMATION
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.
2. Whenever the terms “LEFT”and “RIGHT”are used
in this manual it means from a position behind the
Kar-Kaddy and facing forward.
3. When placing a parts order, refer to this manual for
proper part numbers and place order by PART NO.
and DESCRIPTION.
Introduction
To contact NHTSA, you may either call the
Auto Safety Hot line toll-free at
1-800-424-9393 (or 366-0129 in
Washington, D.C. area) or write to:
NHTSA,
U.S. Department of Transportation
Washington, D.C. 20590.
You can also obtain other information about
motor vehicle safety from the Hot line.
“Reporting Safety Defects”
If you believe that your vehicle has a defect
which could cause a crash or could cause injury or
death, you should immediately inform the National
Highway Traffic Safety Administration (NHTSA) in
addition to notifying Demco Manufacturing Company
(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
between you, your dealer, or (DEMCO).
TABLE OF CONTENTS
General Information ...............................................................................................................................Page 2
Tow Dolly Safety Guide........................................................................................................................Page 3-8
Decal Location........................................................................................................................................Page 9
Bolt Torque............................................................................................................................................Page 10
Tongue and Ramp Assembly................................................................................................................Page 11
Fender Assembly Instructions ..............................................................................................................Page 12
Wiring Diagram.....................................................................................................................................Page 13
Testing Lights........................................................................................................................................Page 13
Tongue Folding .....................................................................................................................................Page 14
Folding Ramps ................................................................................................................................Page 15-16
Loading Angle Clearance Guide...........................................................................................................Page 16
Safety, Maintenance, & Important Loading Instructions .......................................................................Page 17
Loading Instructions .....................................................................................................................Pages 18 -20
Toe-In Adjustment................................................................................................................................Page 21
Kar-Kaddy Breakdown Parts Assembly Instructions .....................................................................Page 22 - 23
DA91 Brake Actuator Parts Breakdown and List ..................................................................................Page 24
10” Disc Brake Parts Breakdown and List ............................................................................................Page 25
Brakes Line Parts Breakdown and List.................................................................................................Page 26
Winch & Tilt-Bed Parts Breakdown.......................................................................................................Page 27
Ramp Latch & License Plate Bracket Parts Breakdown.......................................................................Page 28
Fender Parts Breakdown......................................................................................................................Page 29
Spare Tire w/Mounting Bracket & Light Bar (optional) Parts Breakdown .............................................Page 30
Deflector (optional) Parts Breakdown...................................................................................................Page 31
WARRANTY POLICY, OPERATOR MANUALS & REGISTRATION
Go online to www.demco-products.com to review Demco warranty policies, operator manuals and register your Demco product.

3
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!
SIGNAL WORDS
This manual uses the following signal words--
DANGER, WARNING, and CAUTION-- with safety
messages. The appropriate signal word has been
selected using the following guidelines.
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 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:
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, or require additional copies, please contact your
dealer or Demco, 4010 320th Street, Boyden, IA 51234, ph: [phone]
Toll Free: 1-800-543-3626 Fax: [phone] http://www.demco-products.com

4
TOW DOLLY USER GUIDE
WARNING: Read the following information completely before hooking up, loading, using
unloading or unhooking this Tow Dolly.
FAILURE TO FOLLOW THESE SAFETY INSTRUCTIONS
MAY LEAD TO DAMAGE TO PROPERTY, SEVERE PERSONAL INJURY, AND/OR DEATH.
• Readtowinginstructionsintowedvehicle’sowner’smanual.
• Readtowinginstructionsintowingvehicle’sowner’smanual.Becertainthatyourtowingvehiclehasthecapacity
to tow a tow dolly and towed vehicle combination. IF YOU HAVE ANY QUESTIONS ABOUT THIS, DO NOT TOW.
CONSULT YOUR DEALER OR CALL DEMCO.
• Usea2”,6000lb.(orgreater)capacityballforatowdolly.
• Makesuretowingvehicle’sparkingbrakeisfullyengagedbeforestartinghookup,loading,unloading,orunhookingof
tow dolly.
• Donotloadtowedvehicleontotowdollyuntiltowdollyiscompletelyandproperlyhookeduptotowingvehicleand
setting on a level surface.
• Taillightsandstoplightsmustbehookedupandoperatingproperlyatalltimes.
• Donotloadatowedvehiclethatexceedsweightorsizelimitsoftowdolly.
• Alwayshavesomeonesafelyguideyouwhendrivingtowedvehicleontotowdolly.
• Besuretiresofyourtowedvehicleandtowdollyareingoodconditionandinatedtoproperpressures.Tirepressure
may increase during travel—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swerves.
• Brakingdistanceincreaseswhenusingatowdolly.Usecautionandalwaysallowsufcient
distance for braking.
• Donottransportpassengersorcargoinvehiclebeingtowed.
• Donotunhooktowdollyfromtowingvehicleuntiltowedvehicleiscompletelyunloadedfromtowdolly.
• Allowonetow-vehicle/towdolly/vehicle-in-towlengthforeach10m.p.h.behindanothervehicle.
• ALWAYScheckthehitch,towdollyandvehicle-in-towateachstoptoinsurethatcoupling,chainsandtiedownequipment
remain tight and properly attached. Use tow dolly checklist as an aid.
• NEVERtowwithoutproperlyinstalledtirestrapsandsecuritychainsproperlyattachedtoframeorotherstructuralmember
of vehicle-in-tow.
• ALWAYSslowdown—40milesperhourorless—forcurves,wetorroughroads,anddowngrades.  On downgrades,
shift into a lower gear and allow engine to help hold speed down.
• ALWAYSberested.NEVERdrivewhenfatigued.
• AVOIDdrivingatnight.Nightdrivershavethreetimesthefatalityrateofdaydrivers.
• NEVERcontinuetooperateanunstable(swayingorwhipping)combination.Ifthisoccurs,slowlypullover,reducing
speed through your engine rather than braking. When stopped in an off the road location check hitch, tire straps, and
chains.
• NEVERpassonhillsorcurves.Bewareofcrosswindsandwindgustsfrompassingvehicles.
• NEVERtransportpassengersorcargointowedvehicle.
• ALWAYSloadvehicle-in-towfacingforward.NEVERbackontotowdolly.Formaximumstabilitysteeringaxlemustbe
on tow dolly.

5
• ALWAYSdisconnectdriveshaftofarearwheeldrive/frontenginevehicle-in-towatdifferentialtoavoidtransmission
damage. Secure disconnected parts.
• ALWAYSensurevehicle-in-towparkingbrakeisdisengagedbeforetowing.
• ALWAYSkeepchildren,pets,andbystandersclearofareawhileloadingandunloading.
THE MOST IMPORTANT PART - IS YOU
Will you read and follow these instructions on how to safely operate this DEMCO Tow Dolly?
If your answer is YES, we thank you for your attitude and believe your towing experience will be a safe and pleasant
one.
SAFETY CHECKLIST
While Stopped Check
• ThatHitchisTight
• ThatHitchBallisTight
• CouplerLeverLock
• AreTireTieDownStrapsTight
• AreHitchSafetyChainsandVehicle-in-TowFrameSecurityChainsProperlyAttached
• AreTirePressuresOK
• Vehicle-in-TowforWorkingLights
• AreDriveShaftandBatteryCableDisconnectedandSecuredIfRequiredWhen On the Road:
• ReduceSpeed
• ThinkAhead
• Allowforextralengthwhenturning
• AnticipateStops/BrakeEarly
• StopOftenforRest
• UseSafetyChecklistatEachStop
TOWING VEHICLE SIZE AND TOWING CAPACITY
Towing vehicle 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sufcient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 helper springs or air shocks to help
support weight properly. Poor wheel alignment, loose steering or worn suspension components can also adversely
affect vehicle handling and stability.
Sport Utility Vehicles
Exercise caution when towing with a sports utility (e.g., Jeep or Bronco) type vehicle. Some of these vehicles have a
higher than normal center of gravity, and a short wheelbase. This gives them different handling characteristics than
the average car or truck.
Tires
Tow dolly tires should be load range C tires inflated to 50 psi. These are COLD pressures, and will increase when tires
are hot from running. DO NOT bleed off this pressure increase. Incorrect tire pressure can adversely affect vehicle
handling and gas mileage.
Mirrors
State laws require vehicles towing a tow dolly to be equipped with mirrors on both sides. Inadequate side mirrors create
a hazard by limiting rearward vision. If your vehicle is not already so equipped, you should put right and left hand full
view, detachable mirrors on. Ask dealer if it has any available for rent if you do not want to purchase them.

6
Engine and Transmission Cooling
Towing a loaded tow dolly can be quite demanding on engine and transmission cooling systems of tow vehicle,
especially if towing Iong distance or in hilly terrain. Be sure your cooling system is in top shape, and adequate for
towing anticipated load. Engine oil should be fresh and of maximum viscosity recommended for your particular
engine. Engine cooling may be enhanced by flushing system and installing fresh coolant. Automatic transmissions
may need an external oil cooler installed for unusually difficult or extended towing.
Engine and transmission heat increase as vehicle speed increases. To maintain proper cooling, do not exceed 55
m.p.h. regardless of engine size or load.
Hitch
Be certain that hitch and hitch ball are securely attached and that hitch ball is 2” in diameter. A minimum rating of
class III (6000 lbs) is required for both hitch and hitch ball.
Some sports utility vehicles are equipped with a bumper type hitch from the factory. DO NOT USE THESE HITCHES,
since bumper may not have sufficient structural capacity to handle the load. Equip your vehicle with a hitch attached
to the undercarriage of your vehicle.
Lights
Lights are required on tow dollies in every state. If your vehicle is not already equipped for tow dolly light hook-up, it
will be necessary to install connections now. Your dealer will let you know exactly what is needed for your particular
vehicle.
Tow Vehicle Loading
A loaded tow dolly tongue weight (approximately 200 lbs.) contributes to total cargo weight of tow vehicle. Tow vehicle
manufacturer’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 without overhanging sides. Tire tread width or body width of towed vehicle
must not exceed 76” maximum outside to outside and 42” minimum inside to inside.
Low hanging spoilers and air dams may be damaged by contact with tow dolly ramps when loading and unloading.
Be sure there is adequate clearance for these. If not, they must be removed before loading.
Vehicle-in-Tow Facing Forward
Vehicle-in-tow must always be facing forward (front wheels on tow dolly).
Transmission Damage to Towed Vehicles
When towing a rear axle driven front engine vehicle, the drive shaft must be disconnected to prevent transmission
damage. Simply placing transmission in neutral is not sufficient and will not prevent damage due to a lack of internal
lubrication. You must disconnect drive shaft at rear axle and tie or wire it up. The universal joint bearing caps must
be taped on to prevent loss of bearings. If you choose to remove drive shaft entirely, it may be necessary to cap
transmissiontailshafttopreventuidlossandpossiblefuturedamage.Consultyourvehicleowner’smanual.
Front wheel drive vehicles need not have drive shafts disconnected because the drive wheels are loaded on tow
dolly.
Towingdamagesmanyrearenginevehiclewithtransaxles.Consultowner’smanualfortowsuitability.

7
Passengers And Cargo Prohibited in the Vehicle-in-Tow
Never transport any passengers or cargo in towed vehicle. In addition to being illegal in most states, carrying passengers
in a towed vehicle exposes those passengers to risk of exhaust gas asphyxiation.
Lighting Requirements
Even though tow dollies have operating lights, law requires that a vehicle-in-tow be equipped with functioning stop,
turn and running lights. Detachable vehicle-in-tow towing lights can be purchased at many rental locations. They can
also be purchased at auto supply shops. Follow instructions carefully when installing.
TOW DOLLY HOOK UP
ALWAYS FOLLOW HOOK-UP, LOADING, AND UNLOADING INSTRUCTIONS ON FENDER DECALS OF TOW
DOLLY. IF YOUR TOW DOLLY DOES NOT HAVE INSTRUCTIONS OR IF THEY ARE ILLEGIBLE, ASK COMPANY
FOR A LEGIBLE COPY.
TOWING
55 Miles Per Hour Max.
All vehicle combinations have a speed beyond which adequate emergency control cannot be assured. Maximum
recommended speed for all tow dolly combinations is 55 m.p.h. under good road conditions. As road conditions
deteriorate you must reduce the maximum recommended speed.
Posted speed limit is usually the same for trucks and car-trailer combinations. Observe this limit even if it is less than
55 m.p.h.
Please do not be lulled into a false sense of security because your tow dolly tows easily at higher 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 at low speeds usually increases at higher speeds.
If combination begins to whip or sway, steer straight ahead, take your foot OFF the throttle, but do not brake until
combination has stabilized. Stop in an off the road location and check tow vehicle and tow dolly as soon as possible.
•Reviewallinstructionsandbesureyouhavecomplied.
• Checkthatvehicleontowdollyisloadedwithfrontwheelsontowdolly.Reloadifnecessary.
• Checkthatallchainsandtiedownequipmentremaintightandproperlyattached.
• Checkforpropertireinationallaroundcombination.
• Makesuretrunkorbedoftowingandtowedvehiclesarenotloadedwithcargo.
• Checkwheelbearingsandlugnutsonbothtowvehicleandtowdollytobesureawheelhasnotbecomeloose.
• Checktowvehicle’swheelalignment.
• Finally,besureyouarenotexceedingmaximumrecommendedspeed(55MPH).    
Check coupler and attachment to tow vehicle.•
If you have followed preceding instructions, any instability should be corrected. If situation persists, stop and call for
professional assistance from a tow truck operator.

8
BREAKDOWNS
Get Off The Road
Immediately park tow vehicle-tow dolly combination in a safe place completely off the highway. Get all occupants out
of vehicle and away from roadway.
If you must continue on the highway to reach a safe place off the road, turn on emergency flashers and proceed with
caution.
Do not hesitate to proceed on a flat tire if necessary to reach a safe place completely off the highway. Proceed slowly,
for road friction could ignite a flat tire and cause a fire.
Rough Roads
To prevent damage to tow vehicle or tow dolly, reduce speed when towing tow dolly over 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down-grades,wetroadsorcurves.Night
drivers have three times the fatality rate of day drivers. Avoid driving at night.
ACCIDENTS
Move all vehicles completely off the road.
Get everyone out of the vehicle and off the road. Call police.
Demco wants you
to have a safe towing experience.
Read these instructions carefully,
read fender decals on tow dolly,
and follow all instructions.

9
locked position
A. DD21018
B. DD21019 QTY. 1
C. DD21020 QTY. 2
D. DD21017 QTY. 4
E. RD21002 QTY. 1
Decal Location
F. DD21016 QTY. 2
PINCH POINT
REV 0 DD21018
A
B
C
D
D
D
D
F
E
F
F. RD21008 QTY. 2
CAUTION
Actuator is spring
loaded. Use care when
servicing or injury may
occur.
REV 1NP21010
ATTENTION
This brake actuator is
specially designed for
use with disc brakes
ONLY.
Any replacement of
this unit MUST be of
the same design.
REV 1 BD21001
ordered 01-22-01 with no changes
ordered 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 decal was ordered 08-07-06
ordered 09-27-06
ordered 11-06-07
ordered 07-08-08
BRAKES ON
DO NOT TOW
BRAKES OFF
TOWABLE
BH21003
G. NP21010 Qty. 1
H. BD21001 Qty. 1
I. BH21003 Qty 1
G
H
I
WINCH OPERATING INSTRUCTIONS
Rem o ve wi nch lo ck p i ns (A)fr om st rap w inc h es on f ron t of tow d ol ly.
Rele ase winch: Gr asp han dl e (B)squeez e tr igger (C)pu sh down and p ull all
exc e ss st r ap fr o m win c h. La y t ire s t rap t o o ut si de of t o w dol l y.
Tighten strap s: Plac e ti re straps o ver tires c enterin g st raps and wi nches to
tir es . W hil e t igh te nin g st r aps , pu ll cro s s str a ps fo r war d to e nsu re e v en ti g hte ni ng.
Tig hte n s tr ap s un t il ea ch ti re st a rt s t o fla tte n aga i ns t t ire s top . Aft er st r ap i s ti gh t ,
ins ert l ock p in an d mak e s ur e h and le is i n hor izo nta l pos iti on.
REV 2D D2101 6
B
C
A
Rev 1

10
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 as-
sembly of equipment.
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)
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 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 *
Torque Lug Nuts to 120 FT/LBS
GRADE-2 CLASS 8.8 CLASS 10.9
GRADE-5 GRADE-8
CLASS 9.8
8.8 9.8 10.9 A
Torque 11MM caliper bolts to 40 ft/lbs

11
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
approximately3”fromfront
of channel. Clamp tongue
to main frame and support
front of tongue.
3. Locate the four bullet con-
nectors extending out the back of the tongue and plug into
the connector protruding from under the main frame channel.
Plug into the flat four connector by matching the colors. Do
not cross colors when making this connection. Make sure
that the two pigtails for the license plate bracket are out.
4. Using the open end of a 9/16” wrench to support the back
of the male coupler, (as shown below) push drip free quick
couplers together.NOTE:When pushing the male connector
into the female connector, the female knurl collar will snap
towards male connector automatically, locking the connec-
tion.
5. With an assistant, mount the tongue assembly (#2) to the
front of the Kar Kaddy main frame and use a 5/8” x 4-1/2”
grade 5 bolt (#3) and lock nut (#4)(torque to 50 ft. lbs). Do
not torque over 50 ft. lbs. or bed will not tilt.
NOTE: Brake line and wiring must be above bolt also
coupler assembly must be ahead of bolt. Do this by opening
tongue about half way.
6. Lay the bracing struts (#5) out along the tow dolly tongue
with the back end (the end with the larger hole in it) of the
bracing strut toward the main frame. Loosely bolt the back
of each bracing strut to the trailer frame as shown using
1/2” x 1-1/2” grade 5 bolt (#6), flatwasher (#7), pivot bush-
ing (#8) and locknut (#9). Hold up the front end (the end
with the smaller hole) of each bracing strut to the tongue
and secure with two 5/8” x 1-1/4” epoxied hex head bolts
(#10) and nut plate (#14). Torque the 1/2” x 1-1/2” bolt with
the pivot bushing to 75 ft. lbs. Torque the two 5/8” x 1-1/4”
epoxied hex head bolts to 100 ft. lbs.
7. On the main unit, pull ramp latch (#11) out and up in unlatched
position.
8. Use four 1/2” x 1-1/2” bolts (#6), 1/2” flat washers (#7) and
yellow plated bushings (#12) and place in the front slotted
hole and the rear slotted hole on both sides of ramp (#13).
Use four 1/2” nylon lock nuts (#9) and snug these bolts so
they can slide up and down in slot.
9. Place ramp (#13) in main frame (#1). Front bolts and bush-
ings go in front open slot of ramp mount. Lift ramp up and
push forward until rear bolts and bushings go into rear half
slot.
10. Engage Ramp latch (#11) and move ramp around so latch
can engage through ramp. With the use of two clamps, se-
cure ramp to main frame. Install the remaining 1/2” x 1-1/2”
bolts (#6), flatwashers (#7), yellow bushings (#12), and nylon
lock nuts (#9) into the remaining slotted holes.
11. Tighten all six bolts. Pull and lift ramp latch (#11) and pull
ramp back and fold up. If ramp is too tight when pulling back,
reclamp ramp as in previous step and loosen bolts so ramp
lowers away from main frame. Tighten bolts and retry.
12. Repeat steps 7-11 for other side.
Connector
1
2
3
4
5
5
6
7
8
9
9
678
10
10
6
66
7
7
7
9
11
12
12
13
Male Coupler
Connecting Drip Free Quick Coupler
brake couplers.
Female Coupler
9/16 Wrench
3” 14

12
Fender Assembly Instructions
Fish the three wires from the mainframe through the1.
rear hole in the fender trough.
Route wiring in through back of tail light housing on the2.
bottom inside of housing. Fish the three wire inside
of housing. NOTE: If fender is equipped with a front
marker light, lay wires in trough and route wires through
back of tail light housing with main frame wires (see red
arrow).
Pull all wire from light hole in housing and install the3.
snapper hose clip approximately 1-1/2” back from end
of wire shielding. Squeeze snapper clip tight with pliers.
Push wires back into housing and finish routing wires in4.
wire trough of fender and attach cable hanger. Install
two metal wire clips using pliers. Place one clip 5-1/2”
from rear of fender and one 8” from rear of fender (see
red arrow).
Install rubber grommet (with notch in grommet to the5.
top) and attach 3 wire pigtail harness to fender wiring
(bullet connectors). NOTE: On the left side, plug in
the bullet plugs with white to white, black to brown and
yellow to red. On the right side, plug in bullet plugs with
white to white, black to brown and green to red.
If equipped with front marker light, attach wires using6.
wire splicers, black to black or black to brown depend-
ing on which pigail harness and white to white onto the
3 wire pigtail harness. Coil pigtail harness inside of
fender housing and plug into 4” round light. Push light
into grommet with plug in to the top aligned with notch in
grommet.

13
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.
3. Connect GREEN wire to the right turn signal and stop
wire.
4. Connect BROWN wire to tail light wire.
5. VERY IMPORTANT - connect WHITE wire to frame body
of towing vehicle. This is the common ground, and a clean
metal - to - metal contact must be made.
CAUTION: Many flashers for vehicle turn signals will
not carry the additional load of Kar Kaddy turn signals.
If normal operation does not occur when connected to
the Kar Kaddy, a heavy duty replacement flasher may be
obtained through auto parts outlets.
WHITE Ground
BROWN Tail Lights, License Plate Lights,
Light Cluster Bar & Clearance Lights
YELLOW Left Turn and Stop
GREEN Right Turn and Stop
COLOR CODE FOR WIRING HARNESS
1
REF.
NO. PART NO. QTY. DESCRIPTION
PARTS LIST
1. 11590 1 Tongue Wiring Harness
2. 14762 1 Main Frame Wiring Harness
3. 01863 1 Rubber Grommet (not shown)
Please order replacement parts by PART NO. and DESCRIPTION.
2
Wiring Diagram
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
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 application.
4. Turn left turn signal on. Left turn light of Kar Kaddy and
towing vehicle should flash simultaneously. If turn signal
light of the trailer function opposite to those of the towing
vehicle, it is probable that the YELLOW (Driver side) and
GREEN (Passenger side) wires have been reversed.
Check the plug connection under the tongue of the Kar
Kaddy to make sure wire colors are not crossed at that
point. If wires are crossed change them to match color
for color.
White
Yellow
Green
Brown
White
Brown
Yellow
Green

14
Tongue folding and storage
1. Pull retainer clip from bottom of tongue locking
pin. Lift locking pin out of tongue pivot.
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.
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.

15
Folding Ramp Lock
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 up.
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.

16
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.
Folding Ramp
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. Make sure that
tongue pin and retainer clip is replaced after tongue is folded back
to the forward and locked position. Fold ramps down as far as they
will go and push forward until you hear or see retainer handles snap
into their locked positions. Check to make sure they all fully seated.
Make sure that all pins and locking devices are double checked
before returning this unit to service.
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.
Loading Angle Clearance Guide
IMPORTANT:
Using this guideline will reduce the chance of the towed ve-
hicles air dam, or bottom of facia from interfering with tow dolly
platform and/or tire stop. “X” must be less than 4.3 x “Y”.
Example: If Ymeasures 5”
4.3 x 5 = 21.5
X must measure less than 21.5”
NOTE: User’s responsibility for checking clearance. If
“Y” is less than 3.5”, interference may occur.
Kar-Kaddy SS Loading Angle = 13.1°

17
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./lbs.
Lug Nuts - 120 ft./lbs.
Check Lug Nut tension after the first 5 miles and periodi-
cally thereafter.
The ball hitch must latch securely around the ball and the
safety lock pin or lever must be in position to lock the hitch
on the ball.
RECOMMENDED BALL HEIGHT: 18 inches to the top of
the ball on the towing vehicle.
Hook the towed vehicle safety chains to the frame of the
vehicle directly above the area where the chain is mounted
on the Kar Kaddy. Leave some slack in the chain to allow
suspension movement.
Check to make sure that all lights are in proper working
order.
Examine the winches and straps, making sure they are in
good condition.
Be certain the safety lock pins are locking the strap winch-
es.
Retighten straps over the tires after the first 5 miles and every
50 miles thereafter. Ensure that they are tight.
The Kar-Kaddy tires must be inflated to the recommended
50 PSI.
The strap on the optional tongue winch must be in good
condition and should be stored neatly on winch when not
in use.
NOTE: The winch strap must not be left connected to the
towed vehicle after it is loaded and strapped down.
Make sure the optional light bar is fastened securely at the
rear of the towed vehicle.
The wires to the optional light bar should be run along the
car and fastened so as not to damage the finish of the towed
vehicle.
NOTE: This unit cannot be backed up, when loaded or with
the steering lock pin removed.
All vehicles mounted on the Kar Kaddy must be mounted
with the front of the vehicle facing forward.
Rear Wheel Drive: Disconnect the towed vehicle driveshaft for
rear wheel drive vehicles with automatic transmission.
For manual transmission: Consult your vehicle owners manual
for towing suitability with the drive shaft connected.
MAINTENANCE
Periodically check all bolts and nuts to insure proper tension
or torque.
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 sta-
bilizer arm to prevent rust.
NOTE: Proper toe-in is 1/32”. This is preset at the fac-
tory.
The operator should periodically have the toe-in checked and
adjusted if needed at a qualified alignment shop. Improper toe-
in can result in irregular tire wear.
Wheel:
This tow dolly comes equipped with chrome wheels. To main-
tain a high gloss to the chrome, clean and wax with a soft
cloth regularly. Do not use an abrasive to clean chrome, this
will cause scratches and this will lead to rust.
IMPORTANT LOADING INSTRUCTION
Check your wheel tie-down straps.
Your Kar Kaddy is equipped with custom made wheel tie-down
straps of a standard size that will fit most tires, however if your
tires are too large or too small you will want to exchange these
new straps for the proper size straps.
1. Tire too large - This is very obvious the strap will not
basket over the tire properly, call us, we will provide at
NO Charge on an exchange basis, the proper size strap.
You must return your new unused straps and provide us
with the Make and Model car and the tire size.
2. Tire too small - This is not as obvious, the basket will
fit down over the tire very well, the problems cannot be
readily seen. You must tighten the straps down solid and
then check on the inside of the tire and be sure the strap,
when tightened does not come in contact with any metal
that may cause wear or cutting such as strut mounts. If
there is contact, you need a smaller strap, call us, we
will provide on a NO Charge, exchange basis, the proper
size strap. You must return your new unused straps and
provide us with the Make and Model car and tire size.
Thank you for Purchasing Products.
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.

18
Step 1. Secure ball coupler to 2” (6,000 lb. capacity) tow-
ing 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. Criss-cross safety cables
under tongue and secure to towing vehicle frame.
LOADING INSTRUCTIONS
.
Step 3. Loosen wing nut on back of license plate holder, turn
the 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 2. Remove black locking pin BEFORE loading vehicle
onto the Kar Kaddy. The removal of the locking pin allows
“Auto Steer” to operate. When towing the dolly empty, this
pin must be in place.
IMPORTANT: Over all width of towed vehicle must not
exceed:
76” max. (outside to outside),
42” min. (inside to inside),
76” max. (body width).
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 to the
towing vehicle. Towing vehicle must be larger and at least
1000 lbs. heavier than the tow dolly and towed vehicle
combined.

19
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. 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 posi-
tion. 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 transmission: Consult your vehicle owners
manual for towing suitability with the drive shaft connected.
Step 8. Place one tie-down strap over each tire and secure
hooks to rods located at the rear of each wheel platform. The
short side of the hook must face the rear of the Kar Kaddy.
Step 9. Be sure tie-down winch is centered with the tire
before tightening straps.
Step 6. With someone safely guiding you, slowly
drive vehicle onto platform FRONT FORWARD. (Any vehicle
mounted on tow dolly must be mounted with front of the
vehicle facing forward.) Drive the car forward until the tires
touch the ramps. Make sure the tire is aligned to ascend
onto the ramps.

20
•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 winch-
es.
•Retighten the straps over the tires after the first 5 miles
of travel. Check straps every 50 miles there after to
ensure they are tight and not rubbing or fraying.
Step 10. Thread tie-down strap through the slotted tube on
the tie-down winch. Pull approx. 6” of strap through this slot.
Begin tightening strap making sure the tail becomes enclosed
by the strap coming over the tire. Tighten the straps ensuring
that the strap fed through the slot binds between the shaft and
the strap being wound onto the winch shaft. While tightening
straps, pull cross strap forward to ensure even tightening.
NOTE: Be sure to tighten straps until each tire starts to
flatten against tire stop. After each strap is tight, insert a
safety pin in each winch.
Step 14. To pull the Kar Kaddy empty, make sure“Auto-
Steer” LOCKING PIN IS IN PLACE and towing vehicle
safety chains are up and hooked. Tie-down winch handles
should be left in a down position (horizontal position) with
safety pins in place when towing loaded or empty. DO NOT
ATTEMPT TO PULL KAR KADDY WITH WHEEL PLAT-
FORM IN LOADING (tilted) POSITION.
DAMAGE PREVENTION
Check your vehicle manual or registration for vehicle weight.
Towing vehicle must be larger and at least 1,000 lbs. heavier
than the towed vehicle and tow dolly combined.
Do not pack goods in car that is being towed. Overloading
the Kar Kaddy or exceeding the width limit may result in
damage to both car and Kar Kaddy.
REAR WHEEL DRIVE PRECAUTIONS
Disconnect towed vehicle driveshaft for rear wheel drive
vehicles with automatic transmission. Simply placing trans-
mission in neutral is not sufficient to prevent damage to
transmission.
For manualtransmission: Consultyourvehicle ownersmanual
for towing suitability with the drive shaft connected.
ALLVEHICLES MOUNTED ONTHE KAR KADDY MUST BE WITH
THE FRONT OF THE VEHICLE FACING FORWARD.
Step 12. Hook the towed vehicle safety chains to frame of
vehicle directly above the area where the chains are mounted
on the Kar Kaddy. Leave some slack in the chains to allow
suspension movement of the towed vehicle. Disengage
towed vehicle parking brake.
Step 11. Make sure the tie-down strap is the correct size for
the auto tire. See page 4 of this instruction for proper fit and
exchange instructions.
Step 13. TO UNLOAD towed vehicle. Never unhook tow
dolly coupler from towing vehicle, before unloading tow
dolly. Make sure that platform and vehicle are straight. Re-
install driveshaft. Ensure that towed vehicle parking 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) simultaneously and pushing down sharply.
This process will permit easy removal of strap from winch.
Grasp bed release handle on tongue and pull toward cou-
pler. This releases the tilt bed to permit unloading. This will
allow the platform to tilt as you slowly drive off. Make sure
the winch ratchet handles are horizontal. Replace the “Auto
Steer” locking pin (for towing empty).
SAFETY
A
B
Straps must be retightened after first 5 miles of travel. Check
straps every 50 miles thereafter to ensure they are tight and
not rubbing or fraying.