08/03
RD20006, Rev 3
DOING OUR BEST TO PROVIDE YOU THE BEST
TOW-IT
TI110 & TI110SB TOW DOLLY
OPERATORS MANUAL
ASSEMBLY
READ complete manual CAREFULLY
BEFORE attempting operation.
CALIBRATION
OPERATION
REPLACEMENTPARTS
DEMCO • Dethmers Mfg. Co. • 4010 320th St. • P.O. Box 189 • Boyden, IA 51234
PH: (712) 725-2311 • Toll Free: 1-800-543-3626 • FAX: 1-800-845-6420
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SAFETY SIGN LOCATIONS
Types of safety sign and locations on Tow It are shown in illustration below. Good safety
requiresthatyoufamiliarizeyourselfwithvarioussafetysigns, typeof warning, and particular
function related to that area, that requires your SAFETY AWARENESS.
3
2
5
4
1
SAFETY DECAL PARTS LIST
REF.
NO. PART NO.
DESCRIPTION
1.
2.
04508
04804
Amber Reflector
Red Reflector
Instructions
Winch Operation
Tire Pressure
3. RD21007
4. DD21016
5. DA21001
Page 3
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BOLT TORQUE
TORQUE DATA FOR STANDARD NUTS, BOLTS, AND CAP SCREWS.
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.
Bolt Torque for Standard bolts *
GRADE 2
GRADE 5
GRADE 8
Torque Specifications
“A” lb-ft
1/4”
5/16” 10
3/8” 20
7/16” 30
1/2” 45
9/16” 70
5/8” 95
(N.m)
lb-ft
(N.m)
lb-ft
(N.m)
6
(8)
(13)
(27)
(40)
(60)
(95)
(130)
(225)
(230)
(300)
9
18
(12)
(25)
12
25
(16)
(35)
30
(40)
45
(60)
50
(70)
80
(110)
(155)
(220)
(300)
(540)
(880)
75
(100)
(155)
(200)
(390)
(570)
(850)
115
165
225
400
650
115
150
290
420
630
3/4” 165
7/8” 170
1”
225
970 (1310)
Bolt Torque for Metric bolts *
CLASS 8.8 CLASS 9.8 CLASS 10.9
“A” lb-ft
(N.m)
(13)
(21)
(31)
(61)
(106)
(169)
(263)
(363)
(513)
(699)
(886)
lb-ft
(N.m)
(14)
(24)
(34)
(68)
(118)
(189)
(293)
--
lb-ft
13
21
31
61
106
170
263
364
515
702
890
(N.m)
(17)
(29)
(42)
(83)
(144)
(230)
(357)
(493)
(689)
(952)
(1206)
6
9
10
18
25
50
88
140
216
--
7
15
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
cap screws unless otherwise specified
in this manual. When using locking
elements, increase torque values
by 5%.
8
23
10
12
14
16
18
20
22
24
45
78
125
194
268
378
516
654
--
--
--
--
--
--
*
GRADE or CLASS value for bolts
and capscrews are identified by their
head markings.
GRADE-2 GRADE-5
GRADE-8
CLASS 8.8 CLASS 9.8 CLASS 10.9
10.9
9.8
8.8
Page 4
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WARNING: FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN LOSS OF TOWING
VEHICLE CONTROL, SEPARATION OF THE TOW DOLLY FROM THE TOWING VEHICLE, SEPERATION OF THE
TOWED VEHICLE FROM THE TOW DOLLY, CAUSING SEVERE PERSONAL INJURY, DEATH, OR PROPERTY
DAMAGE.
SAFETY
MAINTENANCE
Safety is of utmost importance at all times. There are
several items that must be checked each time before
using and while using the Tow-It.
Periodically check all bolts and nuts to ensure proper
tension or torque.
An occasional drop of oil may be required on the moving
parts of the tie down winches.
Make sure all bolts are properly tightened and those
requiring a set torque are up to specifications:
Lug Nuts - 75 to 80 ft./lbs.
Check Lug Nut tension after the first 5 miles and
periodically thereafter.
Grease the center pivot pin grease zerk every 1500
miles.
Greasethemainframeplatformskidsevery1500miles.
These grease zerks are readily accessible from under
the front tire stop main platform.
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.
Grease the Sure LubeTM Hubs every 3,000 miles.
Hook the towed vehicle safety chains to the frame of the
vehicle directly above the area where the chain is
mounted on the Tow-It. Leave some slack in the chain
to allow suspension movement.
UseHighQualityBearing
Grease with HandOperated
GreaseGun.
Check to make sure that all lights are in proper working
order.
Examine the winches and straps, making sure they are
in good conditon.
Be certain the safety lock pins are locking the strap
winches.
IMPORTANT LOADING INSTRUCTION
Check your wheel tie-down straps.
Your Tow-It 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.
Retighten straps over the tires after the first 5 miles and
every 50 miles thereafter. Ensure that they are tight.
TheTI110tiresmustbeinflatedtotherecommended35
PSI.
TheTI110SBtiresmustbeinflatedtotherecommended
50 PSI.
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 of your car and the tire
size.
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.
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,exchangebasis,thepropersizestrap.
You must return your new unused straps and
provide us with the Make and Model of your
car and tire size.
Thewirestotheoptionallightbarshouldberunalongthe
car and fastened so as not to damage the finish of the
towed vehicle.
NOTE: This unit cannot be backed up when loaded.
All vehicles mounted on the Tow-It 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 con-
nected.
Thank you for Purchasing
Products.
Page 5
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TESTING LIGHTS BEFORE USE
1. Check that the WHITE (ground) wire of the wiring harness
is connected to the Tow-It frame and the WHITE (ground)
wire is connected to the frame of 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.
Step 3. To allow the wheel platform to tilt back for loading:
1) Swing the bottom of the locking latch (C) toward the hitch
far enough to allow locking pin handle to be lifted.
4. Turn left turn signal on. Left turn light of Tow-It and towing
vehicle should flash simultaneously. Should the turn
signal lights of the trailer function opposite to those of the
towingvehicle,itisprobablethattheYELLOWandGREEN
wires have been reversed. Check the plug connection
underthetongueoftheTow-Ittomakesurewirecolorsare
not crossed at that point. If plug connection is incorrect,
correctproblembyreversingyellowandgreenwireconnec-
tion on the towing vehicle.
LOADING INSTRUCTIONS
Refer to load limits on inside of front cover.
2)Pulllockingpintowardthehitchasfarasitwillgo.Thewheel
platform will tilt back to allow loading.
Step 1. Secure ball coupler to 2" (3,500 lb. capacity) towing
vehicle ball only. Make sure that the hitch and the hitch ball
are in good condition and not rusted, loose or stripped.
Recommended ball height is 18" to the top of the ball.
Make sure hitch is locked down and secured with safety clip.
Criss-cross safety chains under tongue and secure to towing
vehicle frame.
Step 4. Before loading (and unloading) towed vehicle make
sureplatformandtowedvehicleareinstraightalignment. Tow
dollymustbecompletelyandproperlyhookeduptothetowing
vehicle. Towing vehicle must be larger and at least 1000
lbs. heavier than the tow dolly and towed vehicle com-
bined.
Step 2. Ensure that towed vehicle parking brake is fully
engaged, then release the tie-down straps. NOTE: Tie down
strapsmustbe"quick-released"bygraspingratchetpawland
ratchethandlesimultaneouslyandpushingdownsharply. This
process will permit easy removal of strap from winch.Remove
tie-down strap hook from its storage position at the rear of the
ramp. Lay the straps on the ground in front of the winches.
IMPORTANT: Tire tread width or body width of towed
vehicle must not exceed:
TI110
-
70" max. (outside to outside),
42" min. (inside to inside),
70" max. (body width)
TI110SB
Page 6
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Step 7. 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 TOW-IT.
Step 5. With someone safely guiding you, slowly drive ve-
hicleontoplatformFRONTFORWARD. (Anyvehiclemounted
on tow dolly must be mounted with front of the vehicle facing
forward.) Drivethecarforwarduntilthetirestouchtheramps.
Make sure the tire is aligned to ascend onto the ramps.
Step 8. Besuretie-downwinchiscenteredwiththetirebefore
tightening straps.
Step 6. Drive vehicle onto 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 position. If the car
does not have a locking steering column the steering wheel
must be tied securely with front tires in a straight position.
Step 9. While tightening straps, pull cross strap forward to
ensure even tightening. Tighten straps until each tire starts to
flattenagainsttirestop. Aftereachstrapistight, insertasafety
pin in each winch. Disengage towed vehicle parking brake.
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.
(continue with Step 10 on following page)
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.
IMPORTANT: Lock the platform in position by pushing
locking pin toward platform. Push the handle down as far
as possible so locking latch holds it in a locked down
position.
Page 7
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Step 10. Make sure the tie-down strap is the correct size for
the auto tire. The picture above shows a correct fitting strap.
See page 1 of this instruction for proper fit and exchange
instructions.
Step 13. To pull the TOW-IT empty, make sure tie-down
straps are tightened in the storage position, and towed
vehicle safety chains are wrapped up and hooked. Tie-
downwinchhandlesshouldbeleftinadownposition(horizon-
tal)withsafetypinsinplacewhentowingloadedorempty. DO
NOT ATTEMPT TO PULL TOW-IT 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.
Donotpackgoodsincarthatisbeingtowed. Overloadingthe
Tow-It or exceeding the width limit may result in damage to
both car and Tow-It.
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
transmisssion. For manual transmission, consult your
vehicle owners manual for towing suitability with the drive
shaft connected.
Step 11. Hook the towed vehicle safety chains to frame of
vehicle directly above the area where the chains are mounted
on the TOW-IT. Leave some slack in the chains to allow
suspension movement of the towed vehicle. Review the
safety points on page 1 before moving vehicles.
ALLVEHICLESMOUNTEDONTHETOW-ITMUSTBE WITHTHE
FRONTOFTHEVEHICLEFACINGFORWARD.
SAFETY
- Examine winches and straps to make sure they are in
goodcondition.
- Check wheel nuts every trip.
- Tiresmustbeinflatedtorecommendedpressurebytire
manufacturer.
- Be certain the safety lock pins lock the strap winches.
- Retightenthestrapsoverthetiresafterthefirst5miles
of travel. Check straps every 50 miles thereafter to
ensure they are tight and not rubbing or fraying.
Step 12. TO UNLOAD towed vehicle. Make sure that plat-
formandvehiclearestraight. Reinstalldriveshaft. Ensurethat
towed vehicle parking brake is fully engaged, then unhookthe
towed vehicle safety chains, and release the tie-down straps.
NOTE: Tiedownstrapsmustbe"quick-released"bygrasping
ratchet pawl and ratchet handle simultaneously and pushing
down sharply. This process will permit easy removal of strap
from winch.Swing the wheel platform locking latch handle
forward, towards the coupler. This will allow the platform to tilt
as you slowly drive off. Make sure the winch ratchet handles
arehorizontal.
Page 8
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DEMCO PRODUCTS - TOW-IT Tow Dolly
ORIGINAL PURCHASERS LIMITED WARRANTY
1. Extent and Duration of this Warranty:
This warranty does not cover:
Your Demco Tow-It is warranted to be free from defects in
materials and workmanship under normal use and service for a
period of one year after date of purchase by the original (first)
retail owner, or until it is resold or transferred by the original
owner. Tires and lights are not included in this warranty.
1) normal wear and tear
2) road film or gravel damage to paint
3) paint
4) rust damage
5) Any Demco Tow-It that has been loaded in excess of the load
capacity stated on the tow dolly identification label.
Tires are warranted by the manufacturer against defects in
materials and workmanship, but not against road hazards.
Warrantor has a policy of continuous product improvement. We
reserve the right to change or improve the design of any Demco
Tow-Itmodel, includingbutnotlimitedtostateoftheartchanges,
without assuming any obligation to modify any tow dolly previ-
ously manufactured.
Any part of the Demco Tow-It, except tires and lights, found in the
judgement of the manufacturer to be defective in materials or
workmanship will be repaired or replaced at the manufacturerís
option without charge for parts or labor to the original owner.
Warrantor assumes no responsibility to the owner for loss of use
of the tow dolly, loss of time, inconvenience or other damage
consequential or otherwise, including, but not limited to ex-
pense for gasoline, expense of transporting the tow dolly to the
dealer and expense of returning the tow dolly, mechanicís
travel time, telephone or telegram charges, road service/towing
charges, rental of another tow dolly during the time warranty
repairs are being performed, travel, lodging, loss or damage to
personal property or loss of revenue or earnings.
2. Manufacturer and Warrantor of Tow Dolly:
Dethmers Manufacturing Co.
4010 320th Street
P.O. Box 189
Boyden, IA 51234
(712) 725-2311
The manufacturer and warrantor of the tires has his name
permanently molded into the tires. Tire warranty questions and
claims can be taken directly to an authorized dealer of the tire
manufacturer.
5. Limitations of Implied Warranties:
All implied warranties, if any, expire and terminate upon expi-
ration of this warranty. Some states do not allow limitation on
how long an implied warranty lasts, so this limitation may not
apply to you.
3. Repair or Replacement Procedure:
If your Demco Tow-It develops a defect (except for tires or lights)
during the warranty period, promptly notify Dethmers Manufac-
turing Co. customer service department. Until such notice is
received, Warrantor will not be responsible for any repair or
replacement.
6. Limitation of Consequential Damages:
Warrantorís responsibility under this warranty extends solely to
repair or replacement of your Demco Tow-It and its component
parts.
Upon receipt of notice from you, Warrantor will have a choice of
options in replacing any part it determines to be defective:
Warrantor does not assume responsibility for, nor shall it be
liable for, any special, incidental or consequential damages.
Some states do not allow the exclusion or limitation on inciden-
tal or consequential damages, so the above exclusion or
limitation may not apply to you.
a) Warrantor may require you at your own expense to deliver
or ship the part to its factory or authorized dealer. Any
defective part will be repaired or replaced and returned to
you free of charge. Any part returned to Warrantor and
found not to be defective will be returned to you freight
collect with an explanation.
7. Use of Vehicle Identification Number (VIN):
The VIN is a 17 digit number located in the lower left corner of
the tow dolly identification label. The label is located on the left
side of the tow dolly frame. Be sure to include the VIN number
in all communications with Warrantor or its dealers concerning
the warranty.
b) Warrantor may elect to ship a new part to its dealer to be
exchanged free of charge for the defective part returned
by you to the dealer.
8. Purchaserís Rights:
c) Warrantor may elect to ship or deliver a replacement part
This warranty gives you specific legal rights, and you may also
have other rights which vary from state to state.
to your address.
Warranty claims on tires should be presented to a local autho-
rized dealer of the tire manufacturer. Provide proof of purchase
when making a tire warranty claim.
9. Exclusive Warranty:
This is the only express warranty made by Dethmers Manufac-
turing Co. on your Demco Tow-It and no agent, employee, or
other person is allowed to change or add to this warranty.
4. Limitations on Warranty Coverage:
Coverage under this warranty will be effective only when a copy
of the original invoice, showing the date and location of purchase,
accompanies any claim for warranty.
Warrantorhasnoliabilitywhatsoeverandthiswarrantyisnullandvoid
ifanyDemcoTow-Ithasbeenmisassembledorsubjectedtoneglect,
negligence, misuse, accident or operated in any way contrary to the
operating and maintenance instructions as specified in the Demco
Ownerís Manual for that model tow dolly.
This warranty does not cover any tow dolly that has been altered
or modified so as to affect the tow dollyís operation, performance
or durability, or that has been modified to change the intended
use of the tow dolly.
In addition, the warranty does not extend to repairs made neces-
sary by normal use of parts, accessories or other equipment
which in the judgment of Warrantor, are either incompatible with
the Demco Tow-It, or affect its operation, performance or durabil-
ity.
Page 9
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REF.
QTY.
REF.
QTY.
NO. PART NO. REQíD
DESCRIPTION
NO. PART NO. REQíD
DESCRIPTION
1.
2.
5432
5433
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
2
1
1
1
Left Ratchet Winch Assembly (Plated)
Right Ratchet Winch Assembly (Plated)
Ratchet Frame
Left Spool Tube
Right Spool Tube
Heavy Duty External Snap Ring
Ratchet Handle
18 Ga. Shim Washer
Left Ratchet Gear
Right Ratchet Gear
5/16" x 1-1/4" Roll Pin
Black Vinyl Hand Grip
Winch Pawl
Winch Pawl Spring SS
Winch Pawl Bushing SS
5/16" Flatwasher
3/8"-16 UNC x 3/4" Hex Bolt w/epoxy Gr.5
Left Ratchet Pawl Arm
Right Ratchet Pawl Arm
5/16"-18 UNC x 1/2" Shoulder Screw
5/16" Flatwasher SS
63.
64.
65.
66.
67.
02298
05443
04944
04508
02316
2
2
2
2
2
2
6
2
2
2
2
1
2
4
2
-
2
8
1
1
1
1
2
6
2
22-1/2" Wire Protector
Cable Hanger - wire harness
Wire Strain Relief
Amber Fender Reflector
White Ground Wire
Back-Up Plate for fender
3/8"-16UNC x 1-1/2" Hex Head Bolt (gr.5)
Red Fender Reflector
3-way Plug Pigtail (tail light)
Rubber Mounting Grommet for light
Sealed Round Tail Light
3. 03569-95
4. 03570-95
-
03571-95
03577
5.
68. 04424-95
6. 03574-95
7. 03668
8. 03575-95
-
9.
10.
11.
12.
13.
14.
15.
69.
70.
71.
72.
73.
00914
04804
02313
05447
05446
03576-95
03666
02243
05450
01864
05449
00004
05444
74. 04781-26
Upper Half Mainframe
75.
76.
77.
-
03528
01674
02383
04194
3-point Tie-Down Strap w/J-Hook & buckle
1/4" Drive Type Grease Zerk
36" Safety Chain with hook
7/16" "S" Hook for safety chains
Rear Tire Stop
3/8"-16UNC x 1" Hex Head Bolt (gr.5)
1/2"-13UNC x 1" Epoxied Bolt (gr.5) w/zerk
1/2" Special Flatwasher
78. 04270-25
79.
80.
81. 02578-95
82.
83.
84. 5341-26
85.
86.
16. 03572-95
-
00907
05570
03573-95
03578
01998
02002
02772
01076
00214
05337
17.
18.
19.
20.
21.
22.
23.
02584
04083
3/16" x 3/4" Roll Pin
1/4" Flatwasher SS
1-3/4" O.D. Bronze Bushing
SureLubeTM Hub and Spindle Assembly
3/8” External Tooth Washer
7/16” Lock Washer
1/4"-20 UNC Nylon Locknut
1/4"-20 UNC x 3/4" Hex Hd. Bolt Gr.5
1/4" Flatwasher
04499
00078
Lock Pin w/Cable
-
5341
01747
01743
01744
01745
01748
02264
02265
02266
02267
00116
04789
2
1
1
1
1
1
1
1
1
1
1
1
5
1
Sure LubeTM Hub Assembly
Hub
Grease Seal (NOK AD 2548 E)
Inner Cup (L68111)
Inner Cone Bearing (L68149)
Outer Cup (L44610)
Outer Cone Bearing (L44643)
Hardened Tongue Washer
13/16”-20 UNF Jam Nut
Retainer Adjustment Washer for Jam Nut
5/32" x 1-1/2" Cotter Pin
Sure Lube Dust Cap
24.
25.
26.
27.
28.
29.
-
01883
01881
04785
04786
01863
04496
01855
01338
9
1
1
1
2
1
1
2
1
1
Electrical Wire Splicer
Trunk Connector
89.
90.
91.
92.
93.
94.
95.
96.
97.
98.
99.
Front Half Trailer Wiring Harness
Rear Half Trailer Wiring Harness
5/8" Grommet
Lever Lock Coupler (5,000 lb.)
Safety Lock Pin for coupler
1/2"-13UNC x 4-1/2" Hex Head Bolt (gr.5)
Handle
30.
31. 02288-95
32.
33.
34.
35.
-
02189
02178
02771
01853
04194
00059
01898
1/2" I.D. Handle Grip
12 1/2"-13UNC Nylon Insert Locknut
2
2
-
7/16"-14UNC Nylon Insert Locknut
24" Safety Chain with Hook
7/16" "S" Hook for safety chains
100. 01746
101. 04790-26
1/2"-20UNF x 1-5/8" lg. Stud Bolt
Spindle
Please order replacement parts by PART NO. and DESCRIPTION.
36.
37.
12 3/8" Flatwasher
4
1
1
1
2
2
2
7/16"-14UNC x 1-1/4" Hex Head Bolt (gr.5)
Tongue
5/8"-11UNC Nylon Insert Locknut
5/8"-11UNC x 4-1/2" Hex Head Bolt (gr.5)
5/8"-11 UNC x 1-1/4" Hex Hd. Epoxied Bolt
Bracing Strut
38. 04792-26
39.
40.
41.
02587
02434
03503
42. 02747-25
43.
44.
not included
01254
00085
1/2-13UNC x 1-1/2" Hex Head Bolt (gr.5)
11 1/2" Flatwasher
45. 02579-95
46. 04825
47. 02574-95
48. 02583
49. 04780-26
2
1
1
1
1
8
8
2
Pivot Bushing
3/8" I.D. x 1/2" O.D. Grommet
Lock Pin (Tongue)
for
Fulton
5000 lb.
coupler
33
29
3/16" x 1-1/4" Roll Pin
Undercarriage (09533-26 for TI110SB)
7/16"-20UNF Hex Nut (gr.8)
7/16"-20UNF x 1-1/2" Epoxied Bolt (gr.8)
14 x 6 rim (5 on 4-1/2" BC)
50.
51.
52.
53.
54.
02209
02377
04782
01725
04826
5217
Coupler Repair Kit
38
26
10 1/2"-20UNF Chrome Lug Nut
28
2
2
8
6
6
ST205/75R14 "C" Range BW Radial Tire
Tilt Bed Ramp
1/2"-13UNC x 1-1/4" Hex Head Bolt (gr.5)
7/16"-20UNF Nylon Insert Locknut
7/16"-20UNF x 1" Hex Head Bolt (gr.8)
24
55. 04323-25
25
56.
57.
58.
59.
60.
61.
62.
00967
04168
04167
02592
05358
05357
04425
34
36
35
14 3/8"-16UNC Nylon Insert Locknut
Part# 07426
Hook Retainer
Replacement Only
37
1
1
4
Left Fender (w/ wire protector & gr. wire)
Right Fender (w/ wire protector & gr. wire)
Tinnerman Fender Clamp
35
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LEFTWINCHSHOWN
23
20
12
22
21
10
5
3
20
19
16
75
6
18
17
12
13
4
14
15
11
80
44
9
7
8
36
81
83
79
2
74
78
86
36
37
59
72
73
77
66
71
61
65
64
62
63
1
62
67
68
69
59
84
73
72
69
71
68
60
70
49
85
82
76
33
43
44
46
58
40
45
55
57
33
28
44
42
48
59
56
54
26
27
47
84
41
50
43
44
45
33
52
51
41
101
42
32
31
5341
TM
Sure Lube Hub Assembly
53
90
100
91
30
89
92
93
94
98
97
95
96
99
Page 11
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TOW-IT ASSEMBLY INSTRUCTIONS
1
2
16
8
17
3
9
6
5
18
4
13
10
19
7
14
20
15
12
11
1. Place the mainframe on blocks or some other sturdy support
so that the frame rests approximately 8"-10" off the ground.
Attach the tilt bed ramps (#1) as shown using three 7/16" x 1"
grade 8 bolts (#2) and lock nuts (#3) on the top of each ramp
and four 1/2" x 1-1/4" grade 5 bolts (#4), flatwasher (#5) and
locknuts (#6) (two on each side of the ramp). Torque the 7/16"
bolts to 80 ft. lbs. and torque the 1/2" bolts to 75 ft. lbs.
6. When assembling the tie-down strap to the tow dolly winch,
make sure the tie-down strap does not contain any twists and
the overlaps are to the inside. Weave the front of the tie-down
strap through the openings in the buckle. The buckle should
be approximately 8" from the end of the strap. Thread the strap
endthroughthewinchslot. Bringthestrapupandthreaditback
through the buckle again. The buckle should be approxi-
mately 1-1/2" - 2" from the winch.
2. Hold the tongue (#7) up to
(Refer to drawing on page 9 for following steps)
7. Attach Hub and Spindle Assembly (#19) using 7/16" x 1-1/4"
Fine Thread Bolts (#20) and hex nuts.
Pigtail
the front of the tow dolly and
locate the three bullet
connectors extending out
the back of the tongue and
plugintotheconnector pro-
truding from under the main-
Brown
Yellow
Green
Brown/Yellow
Brown/Green
8. Bolt the fenders (#21) on using 3/8" x 1-1/2" gr. 5 bolts (#22),
back-up plates (#23) and locknuts (#24) in each fender. Mount
the fender with the light pocket to the rear. Attach the white
ground wire (#25) (the end with the eye loop on it) under the
center top bolt head.
frame channel. Do not cross colors when making this
connection.
3. Mount the tongue to the front of the tow dolly using one 5/8"
x 4-1/2" grade 5 bolt (#8) and locknut(#9) (torque to 50 ft. lbs.).
Do not torque over 50 ft. lbs. or the bed will not tilt. Make sure
the tongue latch is in the latched position to the tilt bed.
NOTE: It is advantageous to wire the fender lights prior to
attaching the wheels.
9. Cut off stripped ends of the wiring harness, cut off stripped end
of the white ground wire. The yellow/brown wires must be run
to the left tail light pocket. The green/brown wires must be run
to the right tail light pocket. Start at either fender, pull the loom
at the center of the fender downward and push the green/
brown (or yellow/brown) wires upward through the loom until
itcomesouttheloombythelightpocket. Pushthewhiteground
wire through the slit in the top of the loom in the fender trough
and push the wire toward the light pocket.
4. Secure the coupler (#10) and lift handle (#11) to the front end
of the tongue with two 1/2" x 4-1/2" gr.5 bolts (#12) and
locknuts (#13) . The white ground wire (#14) is attached under
the head of the second bolt attaching the coupler. (It is very
importantthatagoodgroundismade). Torquethelocknuts
to 75 - 80 ft. lbs. Tap a rubber grip (#15) onto the handle with
a rubber hammer or a wooden mallet.
10. Make sure all three wires are coming out the fender wire loom.
Slide the rubber fender grommet over the wires and up close
to the wire loom.
5. Remove the 7/16" x 1-1/4" bolt (#16), flatwasher, and locknut
from the outer front panel of each wheel platform tire stop.
Slide the tie-down winch (#17) into the channel at the front of
the wheel platforms as shown. Note that #17 is the left winch.
The ratchet handles are to the outside of each winch and
ratchet springs are to the top. Attach two 36" towed vehicle
safety chains (#18). Secure one chain to each wheel platform
tire stop with the 7/16" x 1-1/4" bolt (#16) , flatwasher and
locknut.
Push the hollow looped end of the loom hanger into the small
hole under the fender pocket in the side of the fender. Leave
the holder open.
Pull the three wire pigtail wires through the hole in the fender
pocket outward. When wiring the pigtail into the tow dolly
Page 12
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COLOR CODE FOR WIRING HARNESS
21
WHITE
Ground
BROWN
Tail Lights and License Plate Light
YELLOW Left Turn and Stop
GREEN
Right Turn and Stop
23
22
25
24
27
21
Triple Wire Plug
fromLight
26
22
Wire
Connector
23
White
Red
25
White
Black
White Ground Wire to
Fender
32
31
33
Brown
30
Yellow or
Green
29
WIRING DIAGRAM FOR THE AUTO
TRANSPORT FENDER
34
24
Yellow/Brownor
Green/Brown
29
34
38
28
35
36
37
35
14. Attach the two 24" transport safety chains (#35) to the two
holes in the angle located under the tongue using two 7/16"
x 1-1/4" grade 5 bolts (#36), flatwashers (#37), and locknuts
(#38). Torque bolts to 50 ft. lbs.
harness at the fender pocket, the wire ends SHOULD NOT be
stripped. Use the wire connectors to make all contacts. Lay
the wire in the connector, pinch securely with a pliers, closing
the wire connector. Splice the white wire of the pigtail to the
white ground wire from the fender. Splice the black wire to the
brown wire. Splice the green (or yellow) wire to the red wire
of the pigtail. The connections are made on the outside of the
fender pocket and pushed into the fender pocket through the
pocket hole. Pull the wires back into the fender pocket and
push the strain relief into the fender with the wire loom close
to the clip. Wrap the loom hanger tie around the wire loom and
insert the peg into the fender.
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 X) supplied.
11. Push the round rubber light seal (#26) into the light pocket.
Be sure the lip is secured in the light housing. Plug the pigtail
into the fender light. Push the round light (#27) into the rubber
seal until it snaps in firmly. Wire the other fender in the same
manner.
3. Connect GREEN wire to the right turn signal and
stop wire.
12. Attach the tire/rim assembly to the mainframe. Use the
supplied lug nuts (#28) and torque to 75 - 80 ft. lbs.
4. Connect BROWN wire to tail light wire.
13. Lay the bracing struts (#29) out along the tow dolly tongue
with the back end (the end with the larger hole in it) of the
bracing strut toward the mainframe. Loosely bolt the back of
each bracing strut to the trailer frame as shown using 1/2" x
1-1/2" grade 5 bolt (#30), flatwasher (#31), pivot bushing
(#32) and locknut (#33). Hold up the front end (the end with
the smaller hole) of each bracing strut to the tongue, align
holes and secure with a two 5/8" x 1-1/4" epoxied bolt (#34).
Torque the 1/2" x 1-1/2" bolt with the pivot bushing to 75 ft. lbs.
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 TOW-IT turn
signals. If normal operation does not occur when
connected to the TOW-IT, a heavy duty replace-
ment flasher may be obtained through auto parts
outlets.
Page 13
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11
SURGE BRAKE ASSEMBLY
NOTE: When installing DA603
onto Tow It be sure to pull
brake line out of tongue and
fasten it to the Actuator. Then
slide the Actuator , brake
line, and lift handle onto
tongue and attach with
12
11
10
21
9
8
7
11
12
11
supplied fasteners.
3
5
23
6
4
13
14
15
16
18
19
16
25
17
1
20
22
24
2
13. 04791-26
2
6
6
6
4
2
2
1
1
3
3
1
-
Spindle w/Brake Flange
BRAKE LINES PARTS LIST
14.
15.
02209
00078
7/16"-20UNF Hex Nut (Gr.8)
7/16" Lockwasher
REF.
QTY.
NO. PART NO. REQíD.
DESCRIPTION
16. SB8798
7/16"-20UNF x 1-1/8" Knurled Shoulder Bolt
3/8" Flatwasher
17.
18.
19.
00059
00060
00907
1.
2.
3.
4.
5.
02189
02383
SB587
01863
02746
1
2
1
1
1
1
1
1
1
1
4
2
Handle Grip
3/8" Lockwasher
36" Safety Chain
80" Brake Line
3/8"-16UNC x 1" Hex Head Bolt (Gr.5)
Handle
20. 02288-95
21. SB7785
5/8" Rubber Grommet
54" Protective Hose
Tongue
Tee, Brass
22.
23.
01338
02178
1/2” -13 UNC x 4-1/2” Hex Head Bolt, Gr. 5
1/2” -13 UNC Nylon Insert Locknut
Model DA603 plated drum brake Actutator
Gr. 8 Stud (Replacement only)
6. 04792-26
7.
8.
9.
10.
11.
12.
SB7H66
00496
7" Brake Hose
24. 8606301
5/8” x 14 Ga. Machine Washer
Retaining Clip
25.
10415
SB15545
SB23715
SB23714
SB7764
SB512
02549
-
-
-
4
-
10" Brake Drum
12" Brake Line
Rubber Brake Line Protector
44" Brake Line
Left Hand Cluster
Right Hand Cluster
SB544
-
DA66 ACTUATOR PARTS (REPLACEMENT ONLY)
ACTUATOR PARTS LIST
REF. PART QTY.
NO.
NO. REQíD.
DESCRIPTION
5398 Master Cylinder Repair Kit
-
8606701
1
Brake Actuator complete (incl. ref. 1-24)
(gasket 05681 included)
18
19
1. 07599-95
2. SB23278
3. 05957-95
4.
5.
6.
7.
8.
9.
10. 05958-95
11*. 05951
12. 05955-95
13*. SB24700
14. SB10555
1
6000# 2" Ball Coupler (Fulton)
Roller
Front Roller Spacer
3/8"-16UNC x 2-3/4" Hex Head Bolt (gr.5)
3/8"-16UNC Stover Lock Nut
1/2"-13UNC x 4-7/16" Hex Head Bolt (gr.5)
1/2"-13UNC Nylon Insert Lock Nut
Push Rod Assembly
Damper/ Shock
Rear Roller Spacer
Emergency Lever
Front Cover
5495 Coupler Repair Kit
15
16
17
4
1
1
1
2
2
1
1
2
1
1
1
2
2
2
1
1
4
2
1
1
1
1
2
1
1
14
19
02166
07176
05684
02178
05959
05692
25
not included
13
25
for
26
20
Fulton
6000 lb.
coupler
20
21
12
2' Cable with S-Hooks
Replacement S-Hook ONLY
5/16"-18UNC x 1/2" Self-Tapping Screw
5/16" External Tooth Lock Washer
Emergency Lever Spring
Master Cylinder Cap
1/4-20UNC x 3/4" Hex Head Bolt Gr 5
1/4" Lock Washer
Outer Case
Replacement Master Cyl. Gasket ONLY
Composite Master Cylinder Kit w/ 09153
1/8" pipe - 3/16" inverted Flare Fitting
1/4” Internal Tooth Lock Washer
Rear Cover
2
10
15.
16.
05960
05424
10
2
22
17*. 05693-95
9
27
8
18.
19.
20.
03876
01076
00057
7
11
24
7
21. 03564-95
22.
23.
24. SB12098
25. 05695
26. 05966-95
27. BH21004
5
05681
5650
23
1
6
6
Decal, “Preset Fasteners”
4
2
-
-
-
5400
5398
5495
-
-
-
Lever Replacement Kit (incl. items w/*)
Master Cylinder Repair Kit w/ gasket
Coupler Repair Kit
3
2
Page 14
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DA603 BRAKEACTUATOR PARTS BREAKDOWN
Components not
sold separately
7
20
22
4
1
23
21
20
5695 Emergency Lock Cam
Replacement Kit
15
Item #23
includes cable
16
22
14
21
11
23
11
8
3
9
5
2
2
18
6
17
10
10a
13
Item #10 is not
12
included in 5696
12
18
5398 Master Cylinder Repair Kit (drum)
(gasket 09153 included)
5696 Coupler Repair Kit
(2î lever lock)
**Components not sold separately**
ACTUATOR PARTS LIST
REF.
NO. PART NO. QTY.
DESCRIPTION
-
8606301
-
Plated Actuator f/ drum brakes
REPLACEMENT KITS
(components not sold separately)
1.
2.
3.
4.
00057
00062
00179
00618
4
4
1
4
1
1
1
1
1
1
-
2
2
2
1
1
2
1
1
1/4î Lock Washer
1/4î-20 UNC Hex Nut
3/8î-16 UNC Lock Nut (Center Punch)
1/4"-20UNC x 2" Hex Head Bolt (Gr.5)
.018 Connector Orifice (Drum Brakes)
3/8î-16UNC x 3î Hex Head Bolt (Gr. 5)
3 Tab Fill Cap w/ Diaphram & O-Ring
Master Cylinder Gasket (incl. in 10616 & 11190)
Composite Master Cylinder (drum)
Coupler/Inner Slider (plated)
Coupler/Inner Slider w/ Lever Lock Assy.
Top Plastic Slider
5695
-----
-
1
1
1
1
-
Emergency Lock Cam Replacement Kit
7/16î-14UNC x 1 1/4î Hex Head Bolt (Gr. 5)
7/16î-14UNC Lock Nut (Center Punch)
Emergency Catch Cam (black oxide finish)
Pushrod Assembly (includes cable)
Coupler Repair Kit (2î lever lock)
5. SB12098
20.
21.
22.
23.
6.
7.
8.
9.
02207
03876
09153
10616
-----
-----
-----
10. 11367-95
5696
5398
10a.
11.
12.
5698
11368
11369
-
Master Cylinder Repair Kit (drum)
Bottom Plastic Slider
Shock Spacer (plated)
13. 11371-95
14. 11389-95
15. 11390-95
16.
17. SB12426
18. 05687
Please order replacement parts by PART NO. and DESCRIPTION.
Rear Shock Pin (plated)
Outer Case (plated)
11401
External Snap Ring
Damper
Protective Boot (incl. in 10616 & 5398)
Page 15
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10î BRAKE CLUSTER PARTS LIST
4
7
5
1
16
Left Side Breakdown
6
16
3
2
2
8
11
13
10
12
19
18
9
10
17
15
17
14
17
18
17
10" BRAKE CLUSTER PARTS LIST
REF. PART QTY.
NO.
NO. REQíD.
DESCRIPTION
-
-
SB23715
SB23714
-
-
Left Hand Cluster (shown above)
Right Hand Cluster
1. SB24636-30 1 Back Plate Assembly
2.
3.
4.
5.
6.
-
7.
8.
9.
-
SB9254
SB10954
04305
2
1
2
2
1
1
1
1
1
1
2
Cover Plate - Adjusting Hole
Brake Shoe Kit (includes 2 Primary & 2 Secondary)
5/16"-18UNC-Gr5 x 1/2" Hex Hd Bolt
5/16" External Tooth Washer
Wheel Cylinder Assembly - Right
Wheel Cylinder Assembly - Left
Bleeder - replacement
05424
SB9776
SB9777
05431
SB9783
SB24047
SB24048
Push Rod
Adjusting Screw Assembly - "R" (for LEFT cluster)
Adjusting Screw Assembly - "L" (for RIGHT cluster)
Spring - Shoe
10. SB10958
11. SB10961-95 1 Shoe Guide
12. SB23937
13. SB23936
14. SB23724
15. 05414-95
1
1
1
1
1
2
4
2
1
Cable
Cable Guide
Spring Adjusting Screw
Lever - Left
Lever - Right
Pin - Shoe Hold Down
Cup Shoe Hold Down
Spring - Shoe Hold Down
Spring - Adjusting Screw Retainer
-
05415-91
16. SB10959
17.
18.
19.
SB9789
05983
03880
-
-
SB15845
SB15545A
1
Wheel Cylinder Repair Kit (w/ spring, cup, & boot)
10î Hub/Drum (w/ bearings, seals, nuts, & dust cap)
-
SB15545
4
10" Brake Drum
Please order replacement parts by PART NO. and DESCRIPTION.
Brake shoe kit can be ordered for one complete axle only.
Page 16
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MODEL DA91 ACTUATOR PARTS BREAKDOWN
13
8
8
23
17
**12
18
**10
14
15
14
15
**16
5398 Master Cylinder Repair Kit
(gasket 05681 included)
25
9
11
26
notincluded
20
6
9
7
22
28
21
4
5
19
5495
Coupler Repair Kit
24
19
28
2
9
2
1
27
Model 91 ACTUATOR PARTS LIST
REF.
NO. PART NO. QTY.
1.
2.
3.
4.
5.
6.
7.
8.
DESCRIPTION
3
09417
01896
02178
1
3
3
1
1
1
1
2
2
1
-
1
2
4
4
1
1
1
1
4
-
6000# 2" Lever Lock Coupler (zinc plated)
1/2"-13UNC x 4" Hex Head Bolt (gr.5)
1/2"-13UNC Nylon Insert Lock Nut
Front Shock Pin (drop tube actuators)
Drop Tube Actuator Slider (plated)
Damper/ Shock
3 Bolt Mount Outer Case (plated)
5/16" External Tooth Lock Washer
5/32" x 1 1/4 Cotter Pin(Qty 3 w/drop tube)
3/32" Cable with hooks
Replacement S-Hooks ONLY
Emergency Lever Spring (plated)
5/16"-18UNC x 5/8" Hex Head Bolt (gr.5)
1/4-20UNC x 2" Hex Head Bolt (gr.5)
1/4" Lock Washer
Emergency Lever Assembly
Master Cylinder Cap w/ Diaphragm & O-ring
O-Ring Only (not shown)
Push Rod Assembly
1/4”-20 UNC Hex Nut
Plastic Master Cyl. Gasket ONLY
Master Cylinder
Master Cylinder
.018 Connector Orifice (Drum Brakes)
Inverted Flare Adapter (Disc Brakes)
Lever Guide (plated)
Master Cylinder Protective Boot
Connecting Pin (plated)
2î Lever Lock Coupler
RATEDAT6000#
05426
11079-95
SB12426
11164-95
05424
02363
05408
BLEEDING THE SYSTEM
The first requirement for safe, sure hydraulic braking is the use
of quality brake fluid. Use only DOT-3 or DOT-4 brake fluid from
a sealed container.
9.
**10.
11.
SB10555
**12. 05693-95
If pressure bleeding equipment is available, follow the
manufacturerís instruction in bleeding the system.
13.
14.
15.
**16.
17.
-
18.
19.
20.
21.
-
05961
00618
00057
05951
03876
05849
05977
00062
09153
10616
11190
SB12098
05679
03866-95
05687
05986-95
10965
10966
10967
If system must be bled manually, proceed as follows: Fill
master cylinder with fluid. Install bleeder hose on first wheel
cylinder to be bled.
Have loose end of hose submerged in brake fluid in glass
container to observe bubbling.
By loosening the bleeder screw located in the wheel cylinder
one turn, the system is open to the atmosphere through the
passage drilled in the screw. Pump actuator with long steady
strokes. The bleeding operation is completed when bubbles
no longer rise to the surface of the fluid. Be sure to close
bleeder screw securely.
1
-
22.
-
1
1
1
1
1
1
1
2
23.
24.
25.
26.
27.
28.
Repeat bleeding operation at each wheel cylinder. During the
bleeding process, replenish the brake fluid, so the level does
not fall below the 1/2 full level in the master cylinder reservoir.
After bleeding is complete, make sure master cylinder reser-
voir is filled and filler cap is securely in place.
Upper Slider
Lower Slider
Side Spacers
-
-
-
5401
5650
5495
-
-
-
Lever Replacement Kit (incl. items w/**)
Master Cyl. Replacement Kit (drum)
Coupler Repair Kit
After the bleeding operation has been completed, apply pres-
sure to the system and check the whole brake system for leaks.
Please order replacement parts by PART NO. and DESCRIPTION
Page 17
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OPTIONAL WINCH
4
PARTS LIST
REF.
QTY.
NO. PART NO. REQíD.
DESCRIPTION
2
KK2W
1
Optional Winch
5
6
1.
-
2.
3.
4.
5.
6.
04620
04621
01738
02207
02769
00059
02592
1
-
1
1
2
2
3
Winch Mechanism (1400 capacity)
ReplacementHandle
Strap Assembly (includes strap & hook)
3/8"-18UNC x 3" Hex Hd. Bolt (gr.5)
3/8"-16UNC x 4" Hex Head Bolt (gr.5)
3/8" Flatwasher
1
3
3/8"-16UNC Nylon Insert Locknut
Please order replacement parts by PART NO. and DESCRIPTION.
* All options may not mount on tow dolly simultaneously.*
6
OPTIONAL TOOL BOX
7
PARTS LIST
7
KK2TB QTY. Optional Tool Box
1.
2.
00059
02592
4
8
1
1
2
4
2
3/8" Flatwasher
3/8"-16UNC Nylon Insert Locknut
Tool Box
Small Hair Pin
Mounting "Z" Bracket
3/8"-16UNC x 1" Hex Head Bolt (gr.5)
3/8"-16UNC x 3" Square U-Bolt
3. 01888-25
4. 00182
5. 02717-25
6.
7.
2
2
00907
02759
1
6
Please order replacement parts by PART NO. and DESCRIPTION.
4
5
* All options may not mount on tow dolly simultaneously.*
3
OPTIONAL SPARE TIRE and MOUNT PARTS BREAKDOWN
REF.
QTY.
NO. PART NO. REQíD.
DESCRIPTION
4
-
KK10STB
1
Optional Spare Tire and Rim
6
1.
2.
04826
04782
1
1
ST205/75R 14"x"C" BSW Radial Tire
6" x 14" Rim 4-1/2" Bolt Circle
KK6STM
1
Spare Tire Mounting Bracket
3. 02193-25
1
1
2
2
2
4
Spare Tire Bracket
Stud Bolt (12mm x 1.5)
Wheel Nut (12mm)
3/8"-16UNC Square U-Bolt
3/8" Flatwasher
3/8"-16UNC Nylon Insert Locknut
4.
5.
6.
7.
8.
02917
02933
02759
00059
02592
3
2
7
1
8
Drive in stud here for
tire with rim #04782 (4-
1/2" bolt circle)
5
-
KK6TC
Optional Spare Tire Cover
Please order replacement parts by PART NO. & DESCRIPTION.
* All options may not mount on tow dolly simultaneously.*
Page 18
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OPTIONAL WHEEL JACK
WHEEL JACK PARTS LIST
KK2WJ QTY. Optional Wheel Jack w/ hardware
3
2
-
1.
2.
3.
02769
00060
00061
4
4
4
3/8” UNC x 4” Bolt, Gr. 5
3/8” Lock Washer
3/8” Hex Head Nut
3
2
Please order replacement parts by PART NO. and DESCRIPTION.
1
* All options may not mount on tow dolly simultaneously.*
OPTIONAL DEFLECTOR PARTS BREAKDOWN
7
8
5
OPTIONAL DEFLECTOR PARTS LIST
3
REF.
NO.
PART
NO.
QTY.
REQíD. DESCRIPTION
4
9
KK2DF
02592
02759
00161-95
02054-25
00095
02743-25
02165
Optional Deflector
1.
2.
3.
4.
5.
6.
7.
8.
4
2
2
1
4
1
1
1
3/8"-16UNC Nylon Insert Lock Nut
3/8"-16UNC Square U-Bolt (fits around 3" tube)
Lock Handle
Deflector Slide Mount
3/8"-16UNC x 3/4" lg. Square Head Set Screw
Deflector Upright Post
3
6
Deflector Lacing Cord (1/8" x 25 ft.)
Deflector Fabric
1
02161
9.
02055-25
2
Deflector Framework
Please order replacement parts by PART NO. and DESCRIPTION.
2
OPTIONAL LIGHT BAR (KKLB) PARTS BREAKDOWN
7
6
8
1
14
9
8
2
9
9
4
1
3
8
LIGHT BAR PARTS LIST
5
REF. PART QTY.
15
NO. NO. REQíD.
DESCRIPTION
8
9
KKLB
Kar Kaddy Light Bar (complete)
1
1. 01772
2. 01857
3. 01773
4. 01886
2
1
1
4
Nylon Security Strap with hooks & tightener
Left Tail/ Brake and Signal Light w/Lenses
Brown Jumper Wire
12
13
13
10
1
Wire Holder (metal)
5. 02385-25 1 Light Bar Framework
6. 02386-25 2 Adjustable Light Bracket
11
11
7. 01856
8. 02772 10 1/4"-20UNC Nylon Insert Locknut
9. 00092 1/4"-20UNC x 1/2" Hex Head Bolt
10. 01777-25 2 Light Bar "Z" Bracket
1
Right Tail/ Brake and Signal Light w/Lenses
6
COLOR CODE FOR WIRING HARNESS
WHITE Ground
BROWN Tail Lights, License Plate Lights,
Light Cluster Bar & Clearance Lights
YELLOW Left Turn and Stop
GREEN Right Turn and Stop
11. 01778
12. 02198
13. 00068
14. 01911
15. 01912
4
1
4
-
3" Suction Cup w/Bolt (#13)
Light Bar Wiring Harness (new style)
1/4"-20UNC x 3/4" Hex Head Bolt
Large Red Lens
-
Small Red Lens
Please order replacement parts by PART NO. and DESCRIPTION.
Page 19
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Page 20
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