RD20017 - Kar Kaddy 3 Operators Manual - Demco Products

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SURGE BRAKES PARTS BREAKDOWN7651213Model DA91Brake Actuator31241157161714981510REF. PARTNO. NO. QTY. DESCRIPTION1. 12508 1 63” Brake Hose2. 01863 1 Rubber Grommet3. 13047 1 Rubber Grommet4. 12542 1 12” Brake Hose (rubber)5. SB541 2 41” Brake Line6. SB7764 2 Rubber Brake Line Clip7. 05982 2 19” Brake Hose (rubber)8. 02210 8 7/16”-20UNF x 1-1/4” Epoxy Bolt (gr.8)9. 04174 4 12mm Retainer Washer (2 per drum)10. 12445-30 1 Spring Return System11. 02549 4 Rubber Protector12. SB7785 1 3/16” Brake Line Tee13. 05960 1 5/16” x 1/2” Self-Threading Bolt14. 13825-92 2 Brake Caliper15. 03927-92 2 10” Brake Rotor16. 13920-92 2 Caliper Mount17. 14486 4 Caliper Mounting Bolt SSPlease order replacement parts by PART NO. and DESCRIPTION.Spring Return SystemSlide spring return system (#10) into tongue tube, secure theactuator and lift handle to the front end of the tongue withtwo 1/2” x 5-1/2” gr.5 bolts, one 1/2” x 4-1/2” gr.5 bolt, andlocknuts.NOTE: The spring return system has a small nut wedged inthe spring area for pre-load installation. Do not remove nut.Nut will automatically drop out during first braking period.SURGE BRAKES PARTS LISTPage 24Bleeding 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.
Wiring DiagramFender WiringOn the left side, plug in bullet plugs with white to white,black to brown and yellow to red. On the right side, plugwhite to white, black to brown and green to red.12PARTS LISTREF.NO. PART NO. QTY. DESCRIPTION1. 11590 1 Tongue Wiring Harness2. 11591 1 Main Frame Wiring HarnessPlease order replacement parts by PART NO. and DESCRIPTION.TESTING LIGHTS BEFORE USE1. Check that the WHITE (ground) wire of the wiring harnessis connected to the Kar Kaddy frame and the WHITE(ground) wire is connected to the frame of the towingvehicle.2. With headlights in “ON” position, the tail lights, the lightcluster bar, the license plate light, and the clearance lightsshould 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 andtowing vehicle should flash simultaneously. Should theturn signal lights of the trailer function opposite to thoseof the towing vehicle, it is probable that the YELLOW(Driver side) and GREEN (Passenger side) wires havebeen reversed. Check the plug connection under thetongue of the Kar Kaddy to make sure wire colors arenot crossed at that point. If plug connection is incorrect,correct problem by reversing yellow and green wire connectionon the towing vehicle.COLOR CODE FOR WIRING HARNESSWHITE GroundBROWN Tail Lights, License Plate Lights,Light Cluster Bar & Clearance LightsYELLOW Left Turn and StopGREEN Right Turn and StopPage 25WIRING OF THE TOWING VEHICLEConnect wiring to towing vehicle, keeping in mind the colorcode indicated below.1. Make certain towing vehicle lights are “OFF”.2. Connect YELLOW wire to left turn signal and stop wire inthe left rear of towing vehicle with the wire splicer (01883)supplied.3. Connect GREEN wire to the right turn signal and stopwire.4. Connect BROWN wire to tail light wire.5. VERY IMPORTANT - connect WHITE wire to frame bodyof towing vehicle. This is the common ground, and a cleanmetal - to - metal contact must be made.CAUTION: Many flashers for vehicle turn signals willnot carry the additional load of Kar Kaddy turn signals.If normal operation does not occur when connected tothe Kar Kaddy, a heavy duty replacement flasher may beobtained through auto parts outlets.
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 22 and 23: MODEL DA91 ACTUATOR PARTS BREAKDOWN
Page 27 and 28: 32171OPTIONAL WHEEL JACK- 11683 1 O
Page 29 and 30: Page 29
Page 31 and 32: Page 31

RD20017 - Kar Kaddy 3 Operators Manual - Demco Products

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