NB20008, Rev.1 03-01-04 MODEL NO. GR200B TOW DOLLY PARTS BREAKDOWN & LOADING INSTRUCTION READ complete manual CAREFULLY BEFORE attempting operation. OPERATION REPLACEMENT PARTS DEMCO Dethmers Mfg. Co. P.O. Box 189 4010 320th Street Boyden, IA 51234 PH: (712) 725-2311 or (712) 725-2302 Toll Free: 1-800-543-3626 FAX: (712) 725-2380 www.demco-products.com Page 1 This document is intended as a parts manual for use by the rental agency only. The rental customer, any rental agency using the tow dolly and any person assisting a rental customer with a hook-up, should refer to the current Budget instructions and instruction decals on proper use. The rental agency is responsible for the furnishing appropriate written instructions to the customer and for checking that all the decals are present and legible at the time of rental. 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 equipment. 3. When placing a parts order, refer to this manual for proper part numbers and place order by PART NO. and DESCRIPTION. 2. Whenever the terms "LEFT" and "RIGHT" are used in this manual it means from a position behind the Budget Tow Dolly and facing forward. Table of Contents Introduction and General Information ......................................................................2 Bolt Torque ..............................................................................................................3 Safety Sign Locations ........................................................................................... 4-5 Parts Breakdown .................................................................................................. 6-7 Replacement Kits ................................................................................................. 8-9 Page 2 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. Torque Specifications Torque figures indicated are valid for nongreased 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%. A 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 * GRADE or CLASS value for bolts and capscrews are identified by their head markings. A 6 7 8 GRADE-2 GRADE-5 GRADE-8 10 12 14 16 18 CLASS 8.8 CLASS 9.8 CLASS 10.9 20 22 10.9 9.8 8.8 24 Page 3 Bolt Torque for Standard bolts * GRADE 2 GRADE 5 GRADE 8 lb-ft (N.m) lb-ft (N.m) lb-ft 6 (8) 9 (12) 12 10 (13) 18 (25) 25 20 (27) 30 (40) 45 30 (40) 50 (70) 80 45 (60) 75 (100) 115 70 (95) 115 (155) 165 95 (130) 150 (200) 225 165 (225) 290 (390) 400 170 (230) 420 (570) 650 225 (300) 630 (850) 970 Bolt Torque for Metric bolts * CLASS 8.8 CLASS 9.8 lb-ft (N.m) lb-ft (N.m) 9 (13) 10 (14) 15 (21) 18 (24) 23 (31) 25 (34) 45 (61) 50 (68) 78 (106) 88 (118) 125 (169) 140 (189) 194 (263) 216 (293) 268 (363) --378 (513) --516 (699) --654 (886) --- (N.m) (16) (35) (60) (110) (155) (220) (300) (540) (880) (1310) CLASS 10.9 lb-ft (N.m) 13 (17) 21 (29) 31 (42) 61 (83) 106 (144) 170 (230) 263 (357) 364 (493) 515 (689) 702 (952) 890 (1206) SAFETY SIGN LOCATIONS A B C D E F G H I J K L Types of safety sign and locations on a Budget Tow Dolly are shown in the illustration below. Good safety requires that you familiarize yourself with various safety signs, type of warning, and particular function related to that area, that requires your SAFETY AWARENESS. SEE NEXT PAGE FOR SAFETY DECAL IDENTIFICATION A C I NB21004 DD21004 DA21001 ZA21004 NP21007 NB21003 NA21007 NB21005 NB21001 NP21007 Supplied Supplied L H K F Decals Budget Maximum Width Tire Pressure/Torque Do Not Back Up Tilt Bed Budget 55 MPH Speed Limit Budget Toll Free Decal Instruction Decal Winch Operating Unit Number Vehicle Identification Number (VIN) K B D 2 2 2 1 1 2 2 1 2 1 2 1 B E A F G I C J A. NB21004 Budget B. Budget REV 1 C. DD21004 Maximum Width ® IMPORTANT NB21004 loading oversized vehicles may result in property damage REV 1 DD21004 DA21001 Tire Pressure/Torque Keep wheel lug nuts or bolts tightened to specified torque. Maintain tire pressure at 50 P.S.I. cold REV 1 DA21001 Please order replacement parts by PART NO. and DESCRIPTION. Page 4 D. ZA21004 Do Not Back Up G. I. NA21007 55 MPH Speed Limit NB21001 Instruction Decal WARNING IMPORTANT DEEPS Do .H.P.M not back-up 55 IMPORTANT DO’S & DON’TS Read towing instructions in towed vehicle owners manual. Use 2” 5000 lb. (or greater) capacity ball for tow dolly. Assure truck parking brake is fully engaged before starting hookup, loading, unloading or unhooking tow dolly. REV 1 Always drive front wheels of towed vehicle onto tow dolly. Don’t load backwards. Tail lights and stop lights must be hooked up and operating properly at all times. NA21007 Don’t load towed vehicle that exceeds weight or size limits onto tow dolly. Always have someone safely guide you when driving towed vehicle onto tow dolly. Assure tires of towed vehicle and tow dolly are in good condition and properly inflated. Tire pressure may increase during travel, Don’t bleed off this increase in pressure. NB21005 Budget Decal Don’t back truck with tow dolly attached. Tow dolly swivels both at coupler and at car platform. If you must back up, unload towed vehicle first, disconnect tow dolly and move vehicle and tow dolly separately. Play it safe...park where you can pull ahead when leaving. Don’t exceed 45 M.P.H. or any lower posted speed limit. Braking distance increases when using tow dolly. Use caution and always allow sufficient braking distance. unit, property Avoid sharp turns or swerves. Descend hills in lower gear. Avoid sudden braking or lane changes when descending a hill. Don’t transport passengers or cargo in vehicle being towed. occur. 05/98 E. ZA21004 NP21007 Tilt Bed 1-800-749-8058 Spring loaded tilt-bed REV 1 F. • Compliance with towing restrictions as stated in towing vehicle owner’s manual or by manufacturer. • Towing vehicle having minimum of 5000 lb. hitch and hitch ball. Hitch ball must be 2”. Do not use any other size hitch ball. • Towing vehicle’s hitch being approximately 18 20 inches to top of hitch ball. Make sure that hitch and hitch ball are in good condition and not rusted, loose or stripped. Both hitch and hitch ball must be securely attached to towing vehicle. • Towing vehicle must be in good condition. • Towing vehicle having a current federal or state inspection where applicable, and complying with any applicable laws. • Assure all lights are properly hooked up and operating at all times. Load Weight and Size Limits Load weight is total weight of towed vehicle. Overloading tow dolly may cause serious injury or damage to both towed vehicle and tow dolly. Maximum Towed Vehicle Weight Do not back up this unit. Property damage may occur. NP21007 • Towing vehicle weight being substantially greater (at least 1000 lbs.) than weight of tow dolly and towed vehicle combined. 2. If disposition instructions have not been received 5 days after towing or repairs. Important 10/99 These responsibilities may include, but are not limited to: 1. If this equipment appears to be abandoned. Notice B A 2. Remove winch lock pins (A) from strap winches on front of tow dolly. RELEASE WINCH: Grasp handle (B) squeeze trigger (C) push down and pull all excess strap from winch. Lay tire strap to outside of tow dolly. A #3 3. Allow platform to tilt back for loading.1) Swing the bottom of locking latch (A) toward coupler far enough to allow locking pin handle to be lifted. 2) Swing locking pin handle upward, then pull toward coupler as far as it will go. Wheel platform will tilt back to allow loading. 4. Before loading (and unloading) towed vehicle make sure platform and towed vehicle are in straight alignment. Don’t load towed vehicle onto tow dolly until completely and properly hooked up to towing vehicle and setting on level surface. 5. With someone safely guiding you, center vehicle to tow dolly. Slowly drive vehicle forward, until tires touch wheel stops at front of platform. DO NOT BACK VEHICLE ONTO TOW DOLLY. Assure that towed vehicle is centered on tow dolly platform and tires fit in wheel pans without hanging over sides. 6. Place towed vehicle in park (low gear if it has standard transmission), engage parking brake, shut off engine, remove ignition key, lock steering wheel of towed vehicle with tires in a straight forward position. If towed vehicle does not have a locking steering column, steering wheel must be securely tied. #7 IMPORTANT INFORMATION Operator Responsibilities Operator assumes all risks inherent in operation, use, or possession of a Budget tow dolly. Towing a vehicle is operators responsibility and it is the operator who must ensure that weight and size limits of tow dolly will not be exceeded by vehicle being towed. Any injury or damage that results from improper use or exceeding weight or size limits is sole responsibility of operator. Towing Vehicle Requirements may C #2 Don’t unhook tow dolly from towing vehicle until towed vehicle is completely unloaded from tow dolly. CALL TOLL FREE damage Loading Towed Vehicle 1. Assure towing vehicle and tow dolly are straight, on level ground, and properly hooked up before loading towed vehicle. Don’t load towed vehicle onto tow dolly until tow dolly is completely and properly hooked up to truck and setting on level surface. TIMIL H. this Read following information before hooking up, loading, using, unloading or unhooking tow dolly to prevent property damage, serious injury, or death. This tow dolly may only be used with a Budget truck that is equipped with a 2”, 5000 lb. capacity ball. Most Budget trucks are equipped to tow Budgets’ tow dollies. Each truck has a maximum towing capacity decal on the rear, next to tow hitch assembly. Check the towing capacity decal to be sure it has correct capacity for your needs, or ask your Budget representative for assistance. FWD vehicles: 3300 lbs. AWD, 4WD, RWD vehicles: 3600 lbs. Size limit is overall width. Towed vehicle exceeding size limit will obstruct platform’s turning action when towing and could damage towed vehicle’s tires and fenders. 76” max. (outside to outside) 42” min. (inside to inside) IMPORTANT: Chains must not attach to or go over steering or brake parts. Leave enough slack in chains for suspension movement. Check tire straps after first 5 miles of travel and every 50 miles thereafter to ensure they are tight and not rubbing or fraying on suspension components of towed vehicle. 8. If towed vehicle is rear wheel or four wheel drive, disconnect drive shaft. (Simply placing transmission in neutral is not sufficient to prevent damage to transmission). You must disconnect drive shaft at rear axle and remove it. With the drive shaft removed it will be necessary to cap the transmission tail shaft to prevent transmission fluid loss. Rear engine/transaxle vehicle cannot be towed with tow dolly. (All vehicles loaded on tow dolly must be loaded with front of vehicle facing forward). Consult your vehicle owner’s manual to help determine if and how your vehicle is suitable to be towed. 9. RELEASE PARKING BRAKE ON TOWED VEHICLE . Ensure that steering wheel is locked in straight forward position, remove ignition keys and lock doors of towed vehicle. 10. Release parking brake on towing vehicle and drive forward 100 feet. Stop and perform safety check. Check hitch, hitch ball, ball coupler, safety chains, tire straps, bolts and other items to ensure they are tight and in correct position. Check all lights to make sure they are operating properly. Repeat safety check after first 5 miles and every 50 miles thereafter. Do not exceed 45 M.P.H. NOTE: Do not unhook tow dolly from towing vehicle until towed vehicle is completely unloaded from tow dolly. INSTRUCTIONS Tow Dolly Hook-Up Unloading Towed Vehicle 1. Assure towing vehicle parking brake is fully engaged. 2. Loosen coupler lock, place coupler of tow dolly over 2” hitch ball on towing vehicle. Assure coupler is fully seated on ball, then completely tighten coupler lock. Pull up on tow dolly tongue to assure it is properly secured. NOTE: Assure that hitch and hitch ball are in good condition and not rusted, loose or stripped. Both hitch and hitch ball must be securely attached to towing vehicle. 3. Connect tow dolly wire harness to connector on truck and check lights for proper operation. 4. Criss cross safety chains under tongue and attach to mounting loops on truck. Allow some slack in chains for movement during turning. Failure to follow these instructions could result in serious injury or death. REV 1 7. Assure that platform is locked in transport position by reversing illustration #3. Place tire straps over tires centering straps and winches to tires, avoiding contact with suspension components. While tightening straps, pull cross straps forward to ensure even tightening. Tighten straps until each tire starts to flatten against tire stop. After strap is tight and with ratchet handle in down (horizontal) position insert lock pin through hole in ratchet pawl arm and ratchet frame, then attach retainer clip. Hook safety chains to frame of towed vehicle directly above area where chains are mounted on tow dolly. 1. Assure towing vehicle and tow dolly are straight, on level ground, and properly hooked up before unloading towed vehicle. 2. Fully engage parking brake of towing and towed vehicles. 3. If removed, reinstall drive shaft of towed vehicle. 4. Straps may be “quick released” by removing lock pin, grasping ratchet pawl and ratchet handle simultaneously and pushing down sharply. This process will permit easy removal of strap from winch as shown in illustration #2 5. Remove tire straps and safety chains from towed vehicle. Also release platform as shown in illustration #3. 6. Release parking brake of towed vehicle and slowly back towed vehicle off tow dolly. 7. On level ground check the transmission fluid level of towed vehicle. Fluid may have leaked out during towing. 8. Store safety chains and straps in their storage position on each side. NB21001 NB21005 9. Return platform to locked transport position by reversing illustration #3. NB21003 Budget J. NP21007 Winch Operating WINCH OPERATING INSTRUCTIONS Remove winch lock pins (A) from strap winches on front of tow dolly. Release winch: Grasp handle (B) squeeze trigger (C) push down and pull all excess strap from winch. Lay tire strap to outside of tow dolly. Tighten straps: Place tire straps over tires centering straps and winches to tires. While tightening straps, pull cross straps forward to ensure even tightening. Tighten straps until each tire starts to flatten against tire stop. After strap is tight, insert lock pin into winch. B C A REV 1 REV 0 NB21003 Please order replacement parts by PART NO. and DESCRIPTION. Page 5 DD21016 PARTS LIST REF. NO. PART NO. QTY. 1. 2. 3. 4. 5. 6. 7. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 43. 44. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 65. 66. 67. 68. 69. *70. 5432 5433 5680 5681 03526 00914 04424-95 11779 11780 03724 03525 11202-96 03662-95 03665-95 02213 04826 09296 02210 02917 04369 11203-30 11204-30 00205 02771 02578-95 00698-95 03370 00638 02961 02383 05898 05892-95 02209 00907 02178 00059 07167-95 07274 11201-96 00348 02729-95 01338 01853 01898 07228 07079 03394-96 04050 00085 01254 02579-95 07166 02434 02587 05055 01863 11212-96 03500 00078 02592 5221 05432 03503 1 1 1 1 2 4 2 8 2 20 20 2 1 1 10 2 2 8 2 1 1 12 10 1 1 1 1 1 2 2 4 8 8 7 10 1 1 1 1 2 2 6 1 1 2 4 3 2 2 1 1 1 1 3 1 4 2 14 1 2 DESCRIPTION Left Ratchet Winch Assembly (see page 12) Right Ratchet Winch Assembly (see page 12) Right Fender Assembly (see page 13) Left Fender Assembly (see page 13) 3/8-16 UNC x 1-1/2 Flat Head Hex Socket Bolt 3/8-16 UNC x 1-1/2 Hex Head Bolt Back-up Plate for Fender 1/4-20 UNC x .75î Flat Phillips Hd Self Threading Screw 1/2î Wear Plate (four hole) 7/16-20 UNF Hex Punch Locknut 7/16-20 UNF x 3/4 Hex Head Bolt Gr. 8 Ramp Left Upright Wire Protector Tube Right Upright Wire Protector Tube 12 mm Lug Nut ST205/75R 14 x {C Radial Tire 14 x 5. Wheel (Rim Only) 7/16-20 UNF x 1-1/4 Epoxied Hex Head Bolt Gr. 8 Replacement 12mm x 1.5 x 30mm Long Stud Bolt Hub Assembly (5 on 115mm Bolt Circle) Left Axle Right Axle 7/16 Flatwasher 7/16-14 UNC Nylon Insert Locknut Metal Pivot Washer Top Pivot Bushing UHMV Pivot Washer 3/4-10 UNC x 6 Hex Head Bolt Gr.5 3/4-10 UNC Nylon Insert Locknut 36 Safety Chain Assembly Strap Assembly (Buckle Included) Tie Down Strap Bracket 7/16 UNF Nut 3/8-16 UNC x 1 Hex Head Bolt Gr. 5 1/2-13 UNC Nylon Insert Locknut 3/8 Flat Washer Spring Sleeve 54 Breakaway Harness Top Platform 1/2-13 UNC x 2-1/4 Hex Head Bolt Gr. 5 Replacement Buckle only 1/2-13 UNC x 4-1/2 Hex Head Bolt Gr. 5 24 Safety Chain Assembly 7/16-14 UNC x 1-1/4 Hex Head Bolt Gr. 5 Wiring Harness (Front Half) Wiring Harness (Rear Half) Bracing Strut (8-3 wide unit) 7/16-14 UNC x 1-1/2 Hex Head Bolt Gr. 5 1/2 Flat Washer 1/2-13 UNC x 1-1/2 Hex Head Bolt Gr. 5 Pivot Bushing Tilt Bed Spring 5/8-11 UNC x 4-1/2 Hex Head Bolt Gr. 5 5/8-11 UNC Nylon Insert Locknut 2 Ball 5/8 Grommet Undercarriage 1/2-13 UNC x 1 Socket Head Set Screw 7/16 Lock Washer 3/8-16 UNC Nylon Insert Locknut Coupler Repair Kit Coupler 5/8 x 1-1/4 Epoxied Hex Bolt (Included in kit #5675) 39 66 49 Refer to Page 12 for com- plete Winch Breakdown 2 49 39 33 3 5 6 24 10 38 not included 56 54 68 52 5221 Coupler Repair Kit 70 38 69 * Item #70 is included in Kit #5675 (see page 12) Please order replacement parts by PART NO. and DESCRIPTION. 50 61 41 47 26 39 48 plete Tongue Breakdown 49 48 Page 6 Refer to Page 12 for com- 55 BUDGET TOW DOLLY PARTS BREAKDOWN MODEL NO. GR200B 5676 44 34 60 27 53 BOLT-ON "BOLT-ACTION" ASSEMBLY 30 35 53 28 26 71 73 29 37 43 35 67 72 Bolts (#53), Washers (#39), and Nuts (#26) are shown for reference only and are not included in Kit 5676 54 46 26 1 49 66 39 *71. *72. *73. 5676 07088-95 02574-95 03099 1 1 1 39 39 26 26 Bolt-On "Bolt-Action" Latch Assembly Bolt-On "Bolt Action" bracket "Bolt Action" Latch Pin 3/16" x 1" Roll Pin * Included in Kit # 5676 7 Please order replacement parts by PART NO. and DESCRIPTION. 67 51 13 15 9 38 11 4 25 12 67 7 11 12 62 47 38 58 40 59 61 57 32 51 5 47 6 50 55 54 56 14 38 36 65 21 52 70 22 17 23 20 COLOR CODE FOR WIRING HARNESS WHITE Ground BROWN Tail Lights YELLOW Left Turn and Stop Red on Fender GREEN Right Turn and Stop Red on Fender 16 18 Page 7 WINCH AND TONGUE BREAKDOWN 11 11 2 1 1 8 8 5 4 17 9 6 6 5 9 10 20 7 3 21 16 12 12 19 21 15 1. 2. 3*. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16*. 17. 18. 19*. 20*. 21*. - 5433 00214 01076 01864 01998 02002 02772 03569-95 03573-95 03577 03578 05337 03571-95 03576-95 03666 03668 00004 02243 03574-95 05444 05449 05450 5227 15 Right Winch 5433 13 1 1 2 1 1 2 1 1 2 1 1 1 1 1 1 2 1 1 1 1 1 - 7 18 3 16 19 14 9 4 18 3 3 9 17 10 20 2 14 1. 2. 3*. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16*. 17. 18. 19*. 20*. 21*. - Right Winch Assembly 1/4Flat Washer 1/4-20 UNC x 3/4 Hex Head Bolt Spring 5/16 Flat Washer (Stainless Steel) 1/4 Flat Washer (Stainless Steel) 1/4-20 UNC Nylon Insert Locknut Winch Frame (Plated) Right Ratchet Pawl Arm (Plated) Snap Ring 5/16-18 UNC x 1/2 Socket Head Shoulder Bolt Lock Pin w/ Cable Right Spool Tube Right Outer Ratchet Gear 5/16 x 1-1/4 Roll Pin 1 x 18 Gauge Machine Washer 5/16 Flat Washer Black Vinyl Hand Grip Ratchet Handle (Plated) 3/8-16 UNC x 3/4 Hex Head Bolt w/ Epoxy Winch Pawl Bushing (Stainless Steel) Winch Pawl Repair Kit (*included in kit) 13 5432 00214 01076 01864 01998 02002 02772 03569-95 03572-95 03577 03578 05337 03570-95 03575-95 03666 03668 00004 02243 03574-95 05444 05449 05450 5227 1 1 2 1 1 2 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 - Left Winch 5432 Right Winch Assembly 1/4 Flat Washer 1/4-20 UNC x 3/4 Hex Head Bolt Spring 5/16 Flat Washer (Stainless Steel) 1/4 Flat Washer (Stainless Steel) 1/4-20 UNC Nylon Insert Locknut Winch Frame (Plated) Left Ratchet Pawl Arm (Plated) Snap Ring 5/16-18 UNC x 1/2 Socket Head Shoulder Bolt Lock Pin w/ Cable Left Spool Tube Left Outer Ratchet Gear 5/16 x 1-1/4 Roll Pin 1 x 18 Gauge Machine Washer 5/16 Flat Washer Black Vinyl Hand Grip Ratchet Handle (Plated) 3/8-16 UNC x 3/4 Hex Head Bolt w/ Epoxy Winch Pawl Bushing (Stainless Steel) Winch Pawl Repair Kit (*included in kit) 6 1 1 3 2 5 6 4 4 1. 2. 3. 4. 5. 6. Page 8 5675 02178 11205-96 05432 01338 05893-95 03503 2 1 1 2 1 2 Tongue Assembly 1/2-13UNC Nylon Insert Locknut Tongue (Budget) Coupler (Lever Lock) 1/2-13UNC x 4-1/2 Hex Head Bolt (gr.5) Lift Handle 5/8-11 UNC x 1-1/4 Hex Hd. Epoxied Bolt FENDER BREAKDOWN Right Fender Assembly 5680 5 6 3 2 4 4 1 3 1. 2. 3. 4. 5. 6. 5680 10872 11207 11206 04425 05447 11209 1 1 1 2 1 1 Right Fender Assembly Wire Protector (Expandable) Right Poly Fender 3-Wire Pigtail Harness Wire Retaining Clip Rubber Mounting Grommet 4î LED Sealed Round Taillight Left Fender Assembly 5681 11 12 9 8 10 10 7 9 7. 8. 9. 10. 11. 12. 5681 10872 11208 11206 04425 05447 11209 1 1 1 2 1 1 Left Fender Assembly Wire Protector (Expandable) Left Poly Fender 3-Wire Pigtail Harness Wire Retaining Clip Rubber Mounting Grommet 4î LED Sealed Round Taillight Page 9 Page 10 Page 11 DETHMERS MFG. COMPANY P.O. BOX 189 4010 320th St., BOYDEN, IA. 51234 PH: (712) 725-2311 FAX: (712) 725-2380 TOLL FREE: 1-800-54DEMCO (1-800-543-3626) www.demco-products.com Page 12
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