RD20017 - Kar Kaddy 3 Operators Manual - Demco Products

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MODEL DA91 ACTUATOR PARTS BREAKDOWN8138175482 Master Cylinder Repair Kit(gasket included)**102523**16**121514141518263029205876 eZ-LatchCoupler RepairKit224928275672421191922133Model 91 ACTUATOR PARTS LIST2” eZ-Latch Coupler RATEDAT 10000#Bleeding the SystemThe first requirement for safe, sure hydraulic braking is the useof quality brake fluid. Use only DOT-3 or DOT-4 brake fluid froma sealed container.If pressure bleeding equipment is available, follow the manufacturer’sinstruction in bleeding the system.If system must be bled manually, proceed as follows: Fillmaster cylinder with fluid. Install bleeder hose on top bleederof first caliper to be bled.NOTE: always bleed brakes by using the top bleed screwon the caliper.Have loose end of hose submerged in brake fluid in glasscontainer to observe bubbling.By loosening the top bleeder screw located on the caliper oneturn, the system is open to the atmosphere through the passagedrilled in the screw. Pump actuator with long steady strokes.The bleeding operation is completed when bubbles no longerrise to the surface of the fluid. Be sure to close bleeder screwsecurely.Repeat bleeding operation at each caliper. During the bleedingprocess, replenish the brake fluid, so the level does not fallbelow the 1/2 full level in the master cylinder reservoir. Afterbleeding is complete, make sure master cylinder reservoir isfilled and filler cap is securely in place.After the bleeding operation has been completed, apply pressureto the system and check the whole brake system for leaks.Page 22REF.NO. PART NO. QTY. DESCRIPTION1. 12925 1 10000# 2” eZ-Latch Coupler2. 01896 3 1/2”-13UNC x 4” Hex Head Bolt (gr.5)3. 02178 3 1/2”-13UNC Nylon Insert Lock Nut4. 05426 1 Front Shock Pin (drop tube actuators)5. 11079-95 1 Drop Tube Actuator Slider (plated)6. SB12426 1 Damper/ Shock7. 11164-95 1 3 Bolt Mount Outer Case (plated)8. 05424 2 5/16” External Tooth Lock Washer9. 12557 1 Rue Cotter Pin for 5/8” Pin**10. 05408 1 Breakaway Cable Kit**12. 05693-95 1 Emergency Lever Spring (plated)13. 05961 2 5/16”-18UNC x 5/8” Hex Head Bolt (gr.5)14. 00618 4 1/4-20UNC x 2” Hex Head Bolt (gr.5)15. 00057 4 1/4” Lock Washer**16. 05951 1 Emergency Lever Assembly17. 03876 1 Master Cylinder Cap w/ Diaphragm & O-ring- 05849 1 O-Ring Only (not shown)18. 05977 1 Push Rod Assembly19. 00062 4 1/4”-20 UNC Hex Nut** 20. 09153 - Plastic Master Cyl. Gasket ONLY21. 11190 1 Master Cylinder22. 14798 1 90° Brake Fitting** 23. 03866-95 1 Lever Guide (plated)24. 05687 1 Master Cylinder Protective Boot25. 05986-95 1 Connecting Pin (plated)26. 10965 1 Upper Slider27. 10966 1 Lower Slider28. 10967 2 Side Spacers29. 12557 1 Master Cylinder Cap30. 12397 1 Rue Cotter Pin for 7/8” Pin- 8669113 - DA91 Actuator w/ 2” eZ-Latch Coupler- 6057 - DA91 Actuator without Coupler- 5401 - Lever Replacement Kit (incl. items w/**)- 5482 - Master Cyl. Replacement Kit (disc)- 5876 - eZ-Latch Coupler Repair KitPlease order replacement parts by PART NO. and DESCRIPTION
DISC BRAKE PARTS BREAKDOWN AND PARTS LISTHub Assembly510792146Epoxy Bolt38PARTS LISTASSEMBLY1. Begin by mounting the Hub Assembly andthe Caliper Mounting Bracket (#1) to theForged Arm using the (#6) 7/16” EpoxiedBolts (as shown).2. Now place the Rotor (#2) onto the HubAssembly as shown in the diagram.3. Make sure the Brake Pads (#4) arecorrectly placed in the Caliper (#3).4. Place Caliper (#3) over the Rotor (#2),and secure it to the Mounting Bracket(#1) using the Caliper Mounting Bolts (notshown).5. When mounting left caliper only, rotateelbow fitting 1/4 turn tighter (clockwise)to position elbow fitting correctly. Hookup Brake Hoses (#5) and replace the Rimand Tire.REF. PART reqdNO. NO. QTY. DESCRIPTION1. 13920-92 2 Caliper Mounting Plate2. 03927-92 2 Rotor3. 13825-92 2 Disc Brake Caliper Complete4. 13824 1 Brake Pads (for one complete axle)5. 05982 2 19” Brake Hose6. 02377 8 7/16”-20UNF Gr8 x 1-1/2” Epoxy Hex Hd Bolt7. 04369 2 Hub (5 on 115mm Bolt Circle)- 02917 - 12mm x 1-1/2” Replacement Stud Bolt8. 02933 10 12mm Lug Nut Chrome9. 09296 2 14x5.5” White Rim (115mm Bolt Circle)10 5965 2 Rim and Tire Assembly- 14179 - Kit Disc Brake Fitting (includes items listed below)11 14798 1 90° Brake Fitting (not shown)- - 2 Bleeder Valve- - 2 Rubber Bushing- - 2 Stainless Steel Bushing- - 2 Stainless Steel BoltPlease order replacement parts by PART NO. and DESCRIPTION.Page 23
Page 1 and 2: Page 18-14RD20017, Rev 4
Page 5 and 6: TOW DOLLY USER GUIDEWARNING: Read t
Page 8 and 9: Never transport any passengers or c
Page 10 and 11: ADecal LocationsGFHCBEEEBDWARNINGRe
Page 12 and 13: Tongue and Ramp Assembly Instructio
Page 14 and 15: Warning: Failure to follow these in
Page 16 and 17: Step 8. Place one tie-down strap ov
Page 18 and 19: REF. PARTNO. NO. QTY. DESCRIPTION1.
Page 20 and 21: WINCH ASSEMBLY512Left Winch 5432 (S
Page 24 and 25: SURGE BRAKES PARTS BREAKDOWN7651213
Page 27 and 28: 32171OPTIONAL WHEEL JACK- 11683 1 O
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RD20017 - Kar Kaddy 3 Operators Manual - Demco Products

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