jd60ind heavy duty wrecker parts manual - … ton... · jd60ind heavy duty wrecker parts manual -...

JD60IND HEAVY DUTY WRECKER

PARTS MANUAL

5-376-000153Rev 0 - April 01, 2012 © 2012 Jerr-Dan Corporation. All Rights Reserved.

13224 Fountainhead PlazaHagerstown, MD 21742Phone (717) 597-7111

www.jerr-dan.com

JD60IND Heavy Duty Wrecker Parts Manual - 5-376-000153 Rev 0

This manual covers the following Jerr-Dan Models:

JD60IND - 60 Ton Independent

SERIAL NO.

MODEL NO.

MANUFACTURED BY:

JLG INDUSTRIES, INC.

1001127220-00

FOR:

Jerr-Dan Corporation strives to provide information that is accurate, complete and useful. Descriptions and illustrative material containedwithin this manual are as accurate as known at the time of publication and are subject to change, without notice, as a result of continuousproduct improvements. Jerr-Dan reserves the right to amend the information in this document at any time without prior notice.

Information contained in this manual reflects how this vehicle was built at the factory. Modifications or additions by the distributor or owner arenot reflected in this manual.

This parts manual does not include service parts information for the commercial chassis (IHC, Ford, GM, etc.).That information is provided by the chassis manufacturer.

When ordering parts, please refer to your unit’s Serial Number and Model Number. This information is be found on the aluminum tag riveted tothe inside of the driver’s side rear compartment of the main body.

Additional or replacement manuals can be ordered by calling Jerr-Dan Parts at 717-597-7111.Price and availability will be quoted at time of the request.

Please report comments and/or errors by contacting Jerr-Dan Corporation’s Technical Publications Department by e-mail [email protected] or by FAX on 717-485-7162.

Manufactured under one or more of the following patents: 5,575,606; 5,672,042; 5,697,741; 5,713,714; 5,722,810; 5,782,596; 5,839,775 and6,315,515 B1 with other Patents Pending.

Jerr-Dan and the Jerr-Dan logo are registered trademarks and Run Hard is a service mark of Jerr-Dan Corporation, Greencastle, PA USA.

The material in this document is confidential and the property of Jerr-Dan Corporation. No part of this document may be photocopied,reproduced or translated to another language without the express written consent of Jerr-Dan Corporation.


THIS PAGE INTENTIONALLY LEFT BLANK


Subframe Installation ............................................................................................................... 6 - 7Subframe Hydraulic Tubing ..................................................................................................... 8 - 9Hydraulic Tank Installation (Units Without Underlift Winch Option) ................................... 10 - 11Hydraulic Tank Assembly (Units Without Underlift Winch Option) .................................... 12 - 13Hydraulic Tank Installation (Units With Underlift Winch Option) ........................................ 14 - 15Hydraulic Tank Assembly (Units With Underlift Winch Option) ......................................... 16 - 17Rear Spade Installation ........................................................................................................ 18 - 19Rear Spade Tubing .............................................................................................................. 20 - 21Boom Installation - 2 Piece Boom ........................................................................................ 22 - 23Wrecker Boom Assembly - 2 Piece Boom .......................................................................... 24 - 25Winch Installation - 50K DP Planetary 2 Speed Gear Shift ................................................ 26 - 27Underlift Installation - Without Winch Option (Standard) ................................................... 28 - 29Underlift Installation - With Winch Option (Optional) .......................................................... 30 - 31Underlift Assembly - 53,000 LB - 3 Piece Boom (Standard) ............................................. 32 - 33Underlift Assembly - 56,500 LB - 3 Piece Boom (Optional) ............................................... 34 - 35Underlift Assembly - 56,500 LB - 4 Piece Boom (Optional) ............................................... 36 - 37Underlift Winch Installation (Optional) ................................................................................. 38 - 39Crosstube Installation .......................................................................................................... 40 - 41Underlift Tools - Frame Forks .............................................................................................. 42 - 43Underlift Tools - 14,000 LB Tire Lift .................................................................................... 44 - 45Underlift Tools - 25,000 LB Tire Lift .................................................................................... 46 - 47Underlift Tools - Fifth Wheel Attachment ............................................................................ 48 - 49Underlift Tools - Pintle Hook ................................................................................................. 50 - 51Rear Tail Plate Installation .................................................................................................... 52 - 53Tailboard D-Ring Installation ................................................................................................ 54 - 55Controls - Control Valve Installation - 6 Function & 14 Function ........................................ 56 - 57Controls - Control Valve Installation - 16 Function ............................................................. 58 - 59Controls - Push-Pull Cables Installation - 6 Function & 14 Function .................................. 60 - 61Controls - Push-Pull Cables Installation - 16 Function ........................................................ 62 - 63Controls - Control Valve Assembly - 6 Function & 14 Function ......................................... 64 - 65Controls - Control Valve Assembly - 16 Function .............................................................. 66 - 67Controls - 6 Function Non-Proportional Miratron ................................................................ 68 - 69Controls - 14 Function Non-Proportional Miratron .............................................................. 70 - 71Controls - 14 & 16 Function Proportional Miratron ............................................................. 72 - 73Controls - Electrical Emergency Stop ................................................................................. 74 - 75Hydraulics - Supply-Pressure-Return ................................................................................ 76 - 77Hydraulics - Lines and Fittings ............................................................................................ 78 - 85Driver Side Hydraulic Pressure Gauges - Without Underlift Winch Option (Standard) ... 86 - 87Driver Side Hydraulic Pressure Gauges - With Underlift Winch Option (Optional) .......... 88 - 89Passenger Side Winch Air Controls - 2 Spd Gear Shift .................................................... 90 - 91Driver & Passenger Side Winch Air Controls - DP 50K, 2 Spd Gear Shift ........................ 92 - 95Winch Electric Speed/Free Spool Controls - DP 50K, 2 Spd ............................................. 96 - 99Decals ................................................................................................................... 100 - 102

INDEX DESCRIPTION PAGE


SUBFRAME INSTALLATION

ITEM PART NO. DESCRIPTION QTY

1 3868000305 Subframe 12 4706002262 Plate 23 4706002261 Plate 24 4706002490 Plate 25 4706006016 Plate 26 7118221816 Capscrew, 0.75”-10NC x 2.25” 367 7660222308 Locknut, 0.75”-10NC 368 7118242050 Capscrew .88 -9NC x 2.50” 69 7949000061 Washer, 0.88” ID 6

10 7660242308 Locknut, 0.88”-9NC 611 4706002555 Plate 212 4062000268 Bar 213 4062000269 Bar 2


SUBFRAME INSTALLATION

1

2

3

45

6

6

6

7

7

7

89

10

11

12

13


SUBFRAME HYDRAULIC TUBING


1 7912000068 Tube Assembly 22 7912000069 Tube Assembly 23 7912000070 Tube Assembly 24 7912000041 Tube Assembly 65 7912000238* Tube Assembly 26 7274000030 Clamp 67 7274000049 Clamp 208 7209000024* Bushing, 0.62” ID 16

7209000024 Bushing, 0.62” ID 129 7209000032 Bushing, #12 Tube 6

10 7209000031 Bushing, #8 Tube 411 7209000033 Bushing, #16 Tube 412 7209000066 Bushing, #10 Tube 613 7661000022 Nut, 0.31”-18NC Stacking Head 1814 7661000027 Nut, Stacking 3015 7007000036 Adapter, 0.31”-18NC x 1.38” 2416 7950150000 Lockwasher, 0.31” ID 4817 7115150650 Capscrew, 0.31”-18NC x 0.75” 3218 7115150850 Capscrew, 0.31”-18NC x 1.00” 1619 7445080825 Fitting, Union Bulkhead 220 7445101025 Fitting, Union Bulkhead 421 7445121225 Fitting, Union Bulkhead 222 7443000209 Fitting 4

* Used With Drag Winch Option Only


12

35

45

6

66

6

7

77

7

7

7

7

6

66

7622

228

8911

10412

48 8

13

13

13

1314

14

14

14

15

15

16

16

16

16

1618

18

18

17

17

17

17 16

16

1920

21

SUBFRAME HYDRAULIC TUBING


HYDRAULIC TANK INSTALLATION - UNITS WITHOUT UNDERLIFT DRAG WINCH


1 3750000022 Hydraulic Tank Assembly 12 7115181850 Capscrew, 0.50”-13NC x 2.25” 43 7950180141 Flatwasher, 0.50” ID 44 7660182601 Locknut, 0.50”-13NC 45 7949000015 Washer, Head 46 7949000016 Washer, Tail 47 7636000006 Rubber Mount 4


2

5

4

3

7

5

6

1

7

2

3

2

3

57

57

46

46 4

6

2

3

HYDRAULIC TANK INSTALLATION - UNITS WITHOUT UNDERLIFT DRAG WINCH


HYDRAULIC TANK ASSEMBLY - 3750000022


1 3750000021 Hydraulic Tank 12 7183000002 Breather, Filler Cap 13 7470000003 Gauge, Sight 14 7701000025 Plug, Magnetic 15 7796000051 Gasket 16 4706002235 Plate 17 7115140650 Capscrew, 0.25”-25NC x 0.75” 128 7950140000 Lockwasher, 0.25” ID 129 7444120014 Plug 1

10 7444160011 Plug 2


4

9

1

5

2

01

3

6

7

8

01

HYDRAULIC TANK ASSEMBLY - 3750000022


1 3750000055 Hydraulic Tank Assembly 12 7115181850 Capscrew, 0.50”-13NC x 2.25” 43 7950180141 Flatwasher, 0.50” ID 44 7660182601 Locknut, 0.50”-13NC 45 7949000015 Washer, Head 46 7949000016 Washer, Tail 47 7636000006 Rubber Mount 4


HYDRAULIC TANK INSTALLATION - UNITS WITH UNDERLIFT DRAG WINCH


12

3

4

5

7

6

HYDRAULIC TANK INSTALLATION - UNITS WITH UNDERLIFT DRAG WINCH


1 3750000056 Hydraulic Tank 12 7470000003 Gauge, Sight 13 7701000025 Plug, Magnetic 14 7796000051 Gasket 15 4706002235 Plate 16 7790141253 Screw, 0.25”-20NC x 0.75” 127 7950140000 Lockwasher, 0.25” ID 128 7183000002 Breather, Filler Cap 1


HYDRAULIC TANK ASSEMBLY - 3750000055 - UNITS WITH UNDERLIFT DRAG WINCH


1

2

3

4

5

6

7

8

HYDRAULIC TANK ASSEMBLY - 3750000055 - UNITS WITH UNDERLIFT DRAG WINCH


REAR SPADE INSTALLATION


1 7115161250 Capscrew, 0.38”-16NC x 1.50” 22 7950160161 Flatwasher, 0.38” ID 23 7660162601 Locknut, 0.38”-16NC 24 3691000267 Pin 25 4706003716 Plate 26 7114140518 Capscrew, 0.25”-20NC x 0.63” 87 7949000025 Lockwasher, 11MM ID 88 7950140153 Flatwasher, 0.25” ID 89 7320000006 Spade Cylinder Assembly 2

10 3263000061 Channel, Spade - RH 111 3263000062 Channel, Spade - LH 112 4691000207 Pin 213 7754000033 Retaining Ring 414 4691000200 Pin 215 7754000008 Retaining Ring 416 3691000126 Pin 217 7691000019 Lynch Pin 218 3706000335 Spade Claw Plate 219 7440030000 Grease Fitting 2


5

51

6

01

41

1

11

23

4

9

9

71

61

23

1

4

578

678

21 31

3131

2131

5141

51

61

71 81

81

91

91

REAR SPADE INSTALLATION


REAR SPADE TUBING


1 7912000245 Tube Assembly 12 7912000246 Tube Assembly 13 7912000247 Tube Assembly 14 7912000248 Tube Assembly 15 7274000050 Clamp 56 7274000064 Clamp 1


3

12

4 5

5

55

5

5

5

5

5

5

556

65

5

555

5

5

5

REAR SPADE TUBING


BOOM INSTALLATION - 2 PIECE BOOM


1 3170000136 Boom Assembly 12 3691000274 Pin 13 7754000059 Retaining Ring 14 7950180000 Lockwasher, 0.59” ID 45 3691000149 Pin 26 7115181850 Capscrew, 0.50”-13NC x 2.25” 27 7320000027 Lift Cylinder Assy w/o U/L Winch Option 2

7320000062 Lift Cylinder Assy w/ U/L Winch Option8 3691000148 Pin 29 7115181450 Capscrew, 0.50”-13NC x 1.75” 2

10 7440030000 Grease Fitting 411 4949000059* Shim, 0.062” Thick 2

4949000060* Shim, 0.125” Thick12 7253000002 Cap, Grease Fitting 413 4679000127 Pad 414 7115160623 Capscrew, 0.38”-16NC x 0.75” 8

* Available in Shim Kit - 3577000071


1

2

3

4

4

4

4

5

56

6

7

78

89

9

1012

1012

1012

1012

11

BOOM INSTALLATION - 2 PIECE BOOM


WRECKER BOOM ASSEMBLY - 2 PIECE BOOM


1 3170000133 Outer Boom Weldment 12 7754000055 Retaining Ring 43 4691000281 Pin 14 4679000140 Pin 25 7114140618 Capscrew, 0.25”-20NC x 0.75” 46 7950140000 Lockwasher, 0.25” ID 47 7320000028 Extension Cylinder Assembly 18 4062000273 Bar 29 7115141250 Capscrew, 0.25”-20NC x 1.50” 2

10 7660142600 Locknut, 0.25”-20NC 411 3170000135 Fly Boom Weld 112 4691000285 Pin 213 7440030000 Grease Fitting 414 4754000004 D-Ring 215 7690144840 Pin, Spring 216 4706002276 Plate 117 7115181450 Capscrew, 0.50”-13NC x 1.75” 318 7950180141 Flatwasher 319 4679000139 Pad 120 7786000005 Setscrew, 0.75”-16NF x 2.0” 1421 7660220230 Nut, 0.75”-16NF Hex Jam 1422 4691000280 Pin 123 4679000150 Pad 124 7114140818 Capscrew 0.25”-20 x 1.00” 225 4064000033 Bar 1426 4062000158 Bar 227 7115180850 Capscrew, 0.50”-13NC x 1.00” 428 7950180000 Lockwasher, 0.59” ID 429 4701000004 Keeper 14


1

23

4

56

7

8

89

910

10

10

11

1213

13

13

14

15

16

1718

1920

20

21

22

2324

25 2521

26

26

27

2728

28

29

29

WRECKER BOOM ASSEMBLY - 2 PIECE BOOM


WINCH INSTALLATION - 50K DP PLANETARY 2 SPEED GEAR SHIFT


1 7970000059 Winch 12 7970000060 Winch 13 4017000788 Angle - RH 14 4017000789 Angle - LH 15 4017000792 Angle 16 7118222816 Capscrew, 0.75”-10NC x 3.50” 167 7660222308 Locknut, 0.75”-10NC 248 7118221616 Capscrew, 0.75”-10NC x 2.00” 89 3249000008* Sheave Support Weldment 2

10 7754000059 Retaining Ring 211 7440030000 Grease Fitting 412 3249000035* Cable Guide Weldment 213 7809000004* Sheave 214 3691000151* Pin 215 7754000033* Retaining Ring 216 7115182650* Capscrew, 0.50”-13NC x 3.25” 617 7950180141* Flatwasher, 0.50” ID 1218 7660182601* Locknut, 0.50”-13NC 619 4831000104* Spacer 620 7248000135 Cable, 0.75” Dia x 250’ 2

7248000085 Cable, 0.75” Dia x 250’ w/Swivel Hook

* Available in Sheave Head Assembly - 3249000009


1

23

45

666

6

777

7

8

7

8

7

9

9

1010

11

11

12

12

13

1314

1415

15

11

11

16

16 1717

17

1718

18 19

19

20

20

WINCH INSTALLATION - 50K DP PLANETARY 2 SPEED GEAR SHIFT

Item #28, not shown


UNDERLIFT INSTALLATION - WITHOUT WINCH OPTION (STANDARD)


1 3170000408 Knee Boom Weldment 12 4691000284 Pin 13 7115183250 Capscrew, 0.50”-13NC x 4.00” 14 7950180161 Flatwasher, 0.50” ID 35 7320000024 Underlift Lift Cylinder Assembly 16 3691000251 Pin 17 7115220850 Capscrew, 0.75”-10NC x 1.00” 28 7950220141 Flatwasher, 0.75” ID 29 3691000152 Pin 1

10 7115180850 Capscrew, 0.50”-13NC x 1.00” 111 7320000096 U/L Tilt Cylinder Assembly UL530 1

7320000097 U/L Tilt Cylinder Assembly UL56512 3691000232 Pin 113 4691000290 Pin 114 7754000051 Retaining Ring 215 4691000291 Pin 116 7754000018 Retaining Ring 217 3507100001 Underlift Assembly UL530 1

3170000407 Underlift Assembly UL56518 4679000127 Pad 419 7115160623 Capscrew, 0.38”-16NC x 0.75” 820 7262000025 Chain 221 7115201250 Capscrew, 0.63-11NC x 1.50” 222 7660202601 Locknut, 0.63”-11NC 223 7189000017 Bumper 224 7440030000 Grease Fitting 525 7253000002 Grease Fitting 526 7660182601 Locknut, 0.50”-13NC 127 7950220000 Washer, 0.75” ID 228 3561000017 Hook Weldment Chain Guide 229 7115161450 Capscrew, 0.38”-16NC x 1.75” 430 7950160141 Flatwasher, 0.38” ID 4



31 4949000031* Washer, 4.50” OD x 2.12” ID x 0.063” 24949000032* Washer, 4.50” OD x 2.12” ID x 0.093” 2


1

2

34

4

26

5

6

77

8

8

27

27

9410

11

12

1314

1516

17

18

18

19

19

20

2122

232425

2425

28

2930

31

UNDERLIFT INSTALLATION - WITHOUT WINCH OPTION (STANDARD)


UNDERLIFT INSTALLATION - WITH WINCH OPTION (OPTIONAL)


1 3170000409 Knee Boom Weldment 12 4691000284 Pin 13 7115183250 Capscrew, 0.50”-13NC x 4.00” 14 7950180161 Flatwasher, 0.50” ID 35 7320000024 Underlift Lift Cylinder Assembly 16 3691000251 Pin 17 7115220850 Capscrew, 0.75”-10NC x 1.00” 28 7950220141 Flatwasher, 0.75” ID 29 3691000152 Pin 1

10 7115180850 Capscrew, 0.50”-13NC x 1.00” 111 7320000096 U/L Tilt Cylinder Assembly UL530 1

7320000097 U/L Tilt Cylinder Assembly UL56512 3691000232 Pin 113 4691000290 Pin 114 7754000051 Retaining Ring 215 4691000291 Pin 116 7754000018 Retaining Ring 217 3507100001 Underlift Assembly UL530 1

3170000407 Underlift Assembly UL56518 4679000127 Pad 419 7115160623 Capscrew, 0.38”-16NC x 0.75” 820 7262000025 Chain 221 7115201250 Capscrew, 0.63-11NC x 1.50” 222 7660202601 Locknut, 0.63”-11NC 223 7189000017 Bumper 224 7440030000 Grease Fitting 525 7253000002 Grease Fitting 526 7660182601 Locknut, 0.50”-13NC 127 7950220000 Washer, 0.75” ID 228 3561000017 Hook Weldment Chain Guide 229 7115161450 Capscrew, 0.38”-16NC x 1.75” 430 7950160141 Flatwasher, 0.38” ID 4



31 4949000031* Washer, 4.50” OD x 2.12” ID x 0.063” 24949000032* Washer, 4.50” OD x 2.12” ID x 0.093” 2


1

2

31

34

426

5

6

77

8

82727

910

4

11

12

1314

1516

17

18

1819

19

23

2425

2425

2425

28

2930

20

2122

UNDERLIFT INSTALLATION - WITH WINCH OPTION (OPTIONAL)


UNDERLIFT ASSEMBLY - 3507100001 - 53,000 LB - 3 PIECE BOOM (STANDARD)


1 3170000125 Base Section Boom Weldment 12 3170000124 Mid Section Boom Weldment 13 3170000123 Fly Section Boom Weldment 14 7320000026 Underlift Extension Cylinder Assembly 15 4691000292 Pin 16 4691000293 Pin 17 7754000043 Retaining Ring 48 4679000146 Pad 89 4679000147 Pad 2

10 7114140518 Capscrew, 0.25”-20NC x 0.63” 1011 4706002209 Plate 112 7108181050 Capscrew, 0.50”-20NF x 1.25” 613 4706002208 Plate 114 7108180850 Capscrew, 0.50”-20NF x 1.00” 615 7950180153 Flatwasher, 0.50” ID 1216 7440030000 Grease Fitting 117 4706002207 Plate 118 7115140650 Capscrew, 0.25”-20NC x 0.75” 419 7950140000 Lockwasher, 0.25” ID 420 4706002211 Plate 121 4706002210 Plate 122 4812000057 Shim, 14GA 223 4706003708 Plate 224 4706003709 Plate 225 4706003710 Plate 426 4706003717 Plate 827 4706003718 Plate 8


5

1

2

4

3

8

71

8181

91

91

7

7

61

67

7

018

6272

801

8 6272

6272

018

41

21

51

51

51

51

4151

51

9

3242

9

324241

6272

018

018

801

12 312252

2252

0211

2252

UNDERLIFT ASSEMBLY - 3507100001 - 53,000 LB - 3 PIECE BOOM (STANDARD)


UNDERLIFT ASSEMBLY - 3170000407 - 56,500 LB - 3 PIECE BOOM (OPTIONAL)


1 3170000400 Base Section Boom Weldment 12 3170000401 Mid Section Boom Weldment 13 3170000406 Fly Section Boom Weldment 14 7320000068 Underlift Extension Cylinder Assembly 15 4691000293 Pin 16 4691000321 Pin 17 7754000043 Retaining Ring 48 4706005262 Plate 29 4706005263 Plate 2

10 7108180850 Capscrew, 0.50”-20NF x 1.00” 1211 7950180000 Lockwasher, 0.50” ID 1212 4679000277 Pad, 0.38 Thk 8

4679000293 Pad, 0.25 Thk13 7114140518 Capscrew, 0.25”-20NC x 0.63” 814 4706005281 Plate 115 7661000019 U-Nut, 0.25”-20NC 416 7115140650 Capscrew, 0.25”-20NC x 0.75” 417 7950140000 Lockwasher, 0.25” ID 418 7440030000 Grease Fitting 1


6

1

2

4

3

31

41

6161

71

71

7

7

81

57

7

31

31

21

11 01

01

11

9

01

21

8

51

51

11 01

01

11 01

9

8

31

21

31

21




1 3170000379 Fly Section Boom Weld 12 3170000380 2nd Stage Boom Weld 13 3170000178 3rd Stage Boom Weld 14 3710000179 Base Section Boom Weld 15 7320000038 Underlift Extension Cylinder Assembly 16 4691000293 Pin 17 4691000321 Pin 18 7754000043 Retaining Ring 49 3178000273 Bracket LH 3

10 3178000275 Bracket RH 311 4679000170 Pad 612 7108180850 Capscrew, 0.50” - 20NF x 1.00” 1213 7950180153 Flatwasher, 0.50” ID 1214 4679000146 Pad 12

4679000254 Pad 1215 7114140518 Capscrew, 0.25” - 20NC x 0.62” 1216 4706002428 Plate 117 7661000019 U-Nut 0.25” 418 7115140650 Capscrew, 0.25” - 20NC x 0.75” 419 7950140000 Lockwasher, 0.25” ID 420 7440030000 Fitting 0.25” - 28NF 1



1

2

3

4

5

6

7

8

8

8

8

9

9

9

10

10

10

11

11

11

11

12

12

12

12

12

12

13

13

13

13

13

13

14

14

14

14

14

14

14

15

15

15

15

16

2017

17

1818

19

19



UNDERLIFT WINCH INSTALLATION (OPTIONAL)


1 7970000079 Winch 12 7118201616 Capscrew, 0.63”-11NC x 2.00” 43 7118202016 Bolt, 0.63” x 2.50” 44 7661000018 Nut, 0.63”-11NC 85 3249000015 Sheave Support Weldment 16 3249000012 Cable Guide Weldment 17 7809000006 Sheave 18 3691000169 Pin Weldment 19 7754000058 Retaining Ring 1

10 4949000045 Washer 211 7440030000 Fitting, 0.25”-28NF 212 7253000002 Grease Fitting 213 4949000002 Cable Guide 214 7115142050 Capscrew, 0.25”-20NC x 2.50” 215 7660142604 Locknut, 0.25”-20NC 216 7754000049 Retaining Ring 117 3912000034* Tube Weldment 118 7189000014* Spring 219 4831000115* Spacer 220 7120000053* Bolt, 0.50”-132UNC x 10.00” 121 7115181250* Capscrew, 0.50”-13NC x 1.50” 422 7950180150* Flatwasher, 0.50” ID 423 7660182601* Locknut, 0.50”-13NC 524 7248000037 Cable, 0.63” x 250’ 1

7248000079 Cable, 0.63” x 250’ w/Swivel Hook7248000055 Cable, 0.75” x 200’7248000080 Cable, 0.75” x 200’ w/Swivel Hook

* Available in Cable Tie Back Assembly - 3249000038


12

4

3

4

5

6

7

8

910

10

1112

1112

131314

15

16

17

18

1819

19

20

212223

23

24

UNDERLIFT WINCH INSTALLATION (OPTIONAL)


CROSSTUBE INSTALLATION


1 3913000094 Crosstube Weldment 12 4691000242 Pin 13 7754000042 Retaining Ring 14 7440300000 Grease Fitting 15 7209000022 Bushing 16 4949000041* Washer, 0.125” Thk 17 4949000042* Washer, 0.63” Thk 2



2

3

1

4

5

6

7

CROSSTUBE INSTALLATION


UNDERLIFT TOOLS - FRAME FORKS


1 3007000004 Adapter, Chain Hook 22 7007000056 Adapter, Frame Fork - RH 13 7007000055 Adapter, Frame Fork - LH 14 3178000226 Spring Lift Bracket 25 7454000006 Fork, 3.00” Short 26 7454000005 Fork, 3.00” Medium 27 7454000003 Fork, 4.50” Medium 28 7454000004 Fork, 4.50” Long 29 3551000036 T-Handle 2

10 7691000022 Pin 211 7691000020 Hairpin 212 7691000021 Hitch Pin 213 7262000026 Chain, Tie-Down 2


8

4

5

67

1

2 1

3

4

8

5

67

9

9

01

01

11

1121

21

21

21

UNDERLIFT TOOLS - FRAME FORKS

Item #13, not shown


UNDERLIFT TOOLS - 14,000 LB TIRE LIFT


1 3484000048* Tire Lift Grid - RH 12 3484000049* Tire Lift Grid - LH 13 3020000120* Tire Lift Arm Weldment - RH 14 3020000119* Tire Lift Arm Weldment - LH 15 3912000038* Tire Lift Tube Weldment 26 7691000026* Hitch Pin 27 4691000274* Pin 28 7691000020* Hairpin 29 7691000021 Hitch Pin 2

10 4561000012* Hook, Pull 111 7894000037* Strap, 2” Wide (Standard - Yellow) 2

7894000041* Strap, 2” Wide (Optional - Orange)12 7894000028* Ratchet, 2” Wide Strap 413 3561000008* Hook, 2” Wide Strap 414 7330000550* Decal 215 7759000004* Rivet 816 7330000278* Decal 2

* Also available as - 2503550088


1

2

3

4

5

5

6

6

7

8

7

8

9

9

01

11

21

31

21

31

41

61

61

41

51

51





1 3484000072^ Tire Lift Grid - LH 12 3484000073^ Tire Lift Grid - RH 13 3020000119^ Tire Lift Arm Weldment - LH 14 3020000120^ Tire Lift Arm Weldment - RH 15 3912000038^ Tire Lift Tube Weldment - 23” Long 26 3912000033^ Tire Lift Tube Weldment - 27.5” Long 27 4691000274^ Pin 28 7691000020^ Hairpin 29 7330000278^ Decal 2

10 7330000550^ Decal 211 7759000004^ Rivet 812 4561000012^ Hook, Pull 113 3561000015* Hook, 3” Wide Strap 414 7894000060* Ratchet, 3” Wide Strap 415 7894000057* Strap, 3” Wide 216 3561000008^ Hook, 2” Wide Strap 417 7894000028^ Ratchet, 2” Wide Strap 418 7894000037^ Strap, 2” Wide 219 7691000021 Hitch Pin 220 7691000026^ Hitch Pin 2

^ Also available as - 2502880300 * Available in Strap Kit - 7577000368


2

1

4

3

56

56

7

7

8

8

20

20

91

91

9

901

111101

3161

3161

4171

4171

5181

21



UNDERLIFT TOOLS - FIFTH WHEEL ATTACHMENT


1 3178000240* Bracket Weldment 12 3178000499* Bracket, Fifth Wheel Weldment 13 3706000080* Plate Weldment 14 3691000144* Pin 15 3691000145* Pin 16 7118267250* Capscrew, 1.00”-8NC x 9.00” 27 7120000036* Capscrew, 0.75”-10NC x 3.25” 28 7691000025* Pin 2

* Also available as - 2503880033


2

5

4

3 7

8

8

6

6

1

7

UNDERLIFT TOOLS - FIFTH WHEEL ATTACHMENT


UNDERLIFT TOOLS - PINTLE HOOK

1 7561000020 Hitch, Pintle Hook with 2” Dia. Ball 12 7118181250 Capscrew, 0.50”-13NC x 1.50” 43 7950180000 Lockwasher, 0.50” ID 44 7056000003 Ball, 1.88” Dia 1

7056000004 Ball, 2.00” Dia7056000005 Ball, 2.31” Dia7056000006 Ball, 50mm Dia



1

23

4

UNDERLIFT TOOLS - PINTLE HOOK


REAR TAIL PLATE INSTALLATION


1 4706006008 Plate - LH 12 4706006009 Plate - RH 13 7759000018 Rivet 8


1

2

3

3

REAR TAIL PLATE INSTALLATION


TAILBOARD D-RING INSTALLATION


1 4754000004 D-Ring 22 3691000176 Pin 23 7950160000 Lockwasher, 0.38” ID 24 7115160650 Capscrew, 0.38”-16NC x 0.75” 25 7440030000 Grease Fitting 26 4949000055 Washer 27 7691000047 Lynch Pin 2


5

8

2

1

1

2

3

4

7

5

6

6

7

3

4

TAILBOARD D-RING INSTALLATION


CONTROLS - CONTROL VALVE INSTALLATION - 6 FUNCTION & 14 FUNCTION


1 3935000180 Control Valve Assy - 6 Function Remote 13935000178 Control Valve Assy - 14 Function Remote

2 7115162850 Capscrew, 0.38”-16NC x 3.50” 43 7950160161 Flatwasher, 0.38” ID 324 7660162601 Locknut, 0.38”-16NC 135 4706005589 Plate 16 7115161450 Capscrew, 0.38”-16NC x 1.75” 37 7115161050 Capscrew, 0.38”-16NC x 1.25” 68 7660160000 Nut, 0.38”-16NC 39 7115140850 Capscrew, 0.25”-20NC x 1.00” 14

10 7590140161 Flatwasher, 0.25” ID 2511 7661000006 Well Nut, 0.25”-20 NC 812 7796000012 Seal 8ft13 7660142601 Locknut, 0.25”-20NC 614 4706005591 Plate 115 4706002643 Plate 116 7701000058 Plug 417 4679000143 Pad, Rubber 118 4679000144 Pad, Rubber 119 7330000199 Decal 120 7330000262 Decal 121 7330000200 Decal 122 7330000253 Decal 123 7330000302 Decal 124 7330000304 Decal 125 7330000299 Decal 126 7330000300 Decal 127 7330000256 Decal 128 7330000257 Decal 129 4706005656 Panel 130 7413000002 Nutsert, 0.25”-20NC 531 7950140000 Lockwasher, 0.25” ID 532 7114140618 Capscrew, 0.25”-20NC x 0.75” 533 4314000208 Coverplate 1


34 4314000209 Coverplate 135 7701000067 Plug 4


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��OPERATOR'S PRE-TRANSPORT CHECKLIST

��

��

��

��

��

��

��

��

1

2

3

3

3

33

3

3 3

4

4 4

5

6

7

8

99

910

1010

10

10

11

12

13

13

14

15

1718

19 2021

2223 24 2526

2728

29

30

30

31

3132

32

33

34

10

10

35

16

CONTROLS - CONTROL VALVE INSTALLATION - 6 FUNCTION & 14 FUNCTION


CONTROLS - CONTROL VALVE INSTALLATION - 16 FUNCTION


1 3935000218 Control Valve Assy 12 7115162850 Capscrew, 0.38”-16NC x 3.50” 43 7950160161 Flatwasher, 0.38” ID 324 7660162601 Locknut, 0.38”-16NC 135 4706005589 Plate 16 4314000209 Coverplate 17 4314000208 Coverplate 18 7115161450 Capscrew, 0.38”-16NC x 1.75” 39 7115161050 Capscrew, 0.38”-16NC x 1.25” 6

10 7660160000 Nut, 0.38”-16NC 311 7115140850 Capscrew, 0.25”-20NC x 1.00” 1412 7950140161 Flatwasher, 0.25” ID 2513 7661000006 Well Nut, 0.25”-20NC 814 7796000012 Seal 8ft15 7660142601 Locknut, 0.25”-20NC 616 4706005627 Plate 117 4706002643 Plate 118 4679000143 Pad, Rubber 119 4679000144 Pad, Rubber 120 4706005629 Plate 121 7330000199 Decal 122 7330000262 Decal 123 7330000200 Decal 124 7330000253 Decal 125 7330000434 Decal 126 7330000435 Decal 127 7330000299 Decal 128 7330000300 Decal 129 7330000256 Decal 130 7330000257 Decal 131 7114140618 Capscrew, 0.25”-20NC x 0.75” 532 7413000002 Nutsert, 0.25”-20NC 533 7950140000 Lockwasher, 0.25” ID 534 7701000058 Plug 3


35 7701000067 Plug 3


12

3

3

3

33

3

33

4

44

5

10

12

11

11

1215

6

7

89

1215

1112

1312

14

1617

1819

DN IN300

IN

OUTOUT

BOOMLIFT

WRK BMEXT

FRONTWINCH

UP299

UNTRAINED OPERATORS SUBJECT THEMSELVES AND OTHERS TO DEATHOR SERIOUS INJURY AND MAY CAUSE SERIOUS DAMAGE TO PROPERTY.

199

ONLY AUTHORIZED AND TRAINED PERSONNEL SHOULD BEPERMITTED TO OPERATE THIS WRECKER UNSUPERVISED.

WARNING

262

A MINIMUM OF 5 WRAPS OF CABLE MUST BE LEFTON DRUM TO ACHIEVE RATED LOAD.

NOT TO BE USED IN THE MOVING OR LIFTING OF PERSONS.

WARNINGOPERATOR'S PRE-TRANSPORT CHECKLIST

200

CAUTION

253

TO AVOID BIRDNESTING AND PREMATUREFAILURE OF THE WIRE ROPE ALWAYS KEEPTENSION ON WIRE ROPE WHEN UNWINDING

CAUTION

IN DN NDND435

INDN IN

WINCHDRAG

OUT

LEFTSPADE

OUT

U/LEXT

UPOUT

U/LLIFT

UP UP

U/LTILT

UP

RIGHTSPADE

434

REARWINCH

256

PRESSUREREAR VALVE

FRONT WINCHFREESPOOL

RELEASED WHEN LIT737

REAR WINCHFREESPOOL


FRONT WINCH2-SPEED

HIGH SPEED WHEN LIT739

REAR WINCH2-SPEED


U/L WINCHFREESPOOL


U/L WINCH2-SPEED


PRESSUREFRONT VALVE

257

21 2223

2425 26 2728

29 30

1233 31

32

20

34

35

12

CONTROLS - CONTROL VALVE INSTALLATION - 16 FUNCTION


CONTROLS - PUSH-PULL CABLES INSTALLATION - 6 FUNCTION & 14 FUNCTION


1 3178000260 Bracket Weldment 12 3686000016 Panel Weldment 13 4706002746 Plate 14 4314000210 Coverplate 15 4706005594 Plate 16 4309000001 Coupling - 6 Function Remote 3

4309000001 Coupling - 14 Function Remote 77 4309000007 Coupling - 6 Function Remote 6

4309000007 Coupling - 14 Function Remote 28 4679000119 Pad 19 4679000131 Pad 1

10 4638000003 Brush 111 4411000113 Extrusion, Brush Holder 112 7806000005 Shaft 113 7754000009 Retaining Ring 214 7551000034 Handle 915 7701000058 Plug 416 7248000068 Push-Pull Cable - 14 Function Remote 917 7990000003 Yoke 918 7690141200 Clevis Pin 1819 7690000810 Cotter Pin 1820 7660140230 Nut, 0.25”-28NF 1821 7082000005 Bearing 222 7790141056 Screw, 0.25”-20NC x 0.63” 1323 71111140813 Screw, 0.25”-20NC x 1.00” 1024 7115140650 Capscrew, 0.25”-20NC x 0.75” 325 7115140850 Capscrew, 0.25”-20NC x 1.00” 326 7950140161 Flatwasher, 0.25” ID 2227 7660142601 Locknut, 0.25”-20NC 628 7661000006 Well Nut, 0.25”-20NC 1029 7115161050 Capscrew, 0.38”-16NC x 1.25” 430 7950160161 Flatwasher, 0.38” ID 831 7660162601 Locknut, 0.38”-16NC 432 7330000199 Decal 1


33 7330000262 Decal 134 7330000200 Decal 135 7330000253 Decal 136 7330000703 Decal 137 7330000702 Decal 138 7701000067 Plug 4


��

��

��

��

��

��

��

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REVIEW THIS CHECKLIST BEFORE EACH TOW. FAILURE TO F OLLOW CHECKLISTCOULD CREATE A DANGEROUS CONDITION FOR YOU, OTHER MOTORISTS ANDPEDESTRIANS, AND MIGHT RESULT IN SERIOUS INJURY OR DEATH.

OPERATOR'S PRE-TRANSPORT CHECKLIST

��

��

��

��

��

��

B

DETAIL B

A

DETAIL A

12

3

4

5

6

67

7

8

9

10

11

12

13

13

14

15

1617

18

18

1817

1919 18

19

1920

20

21

21

22

22

23

23

24

2526

26

26

26

2626

27

27

28

28

2930 30

31

32

33

34 35

36

37

38

CONTROLS - PUSH-PULL CABLES INSTALLATION - 6 FUNCTION & 14 FUNCTION

Push-Pull Cable Installation for 12 Function Remote Controller shown


CONTROLS - PUSH-PULL CABLES INSTALLATION - 16 FUNCTION


1 3178000343 Plate, RH Cable Bracket 12 4706003848 Plate 13 4706005628 Plate 14 4309000001 Coupling 85 4679000119 Pad 16 4679000131 Pad 17 4638000003 Brush 18 4411000113 Extrusion, Brush Holder 19 7806000005 Shaft 1

10 7754000009 Retaining Ring 211 7551000033 Handle 1012 4309000007 Coupling 213 7248000068 Push-Pull Cable 1014 7990000003 Yoke 1015 7690141200 Clevis Pin 2016 7690000810 Cotter Pin 2017 7660140230 Nut, 0.25”-28NF 2018 7082000005 Bearing 219 7790141056 Screw, Self Tapping - 0.25”-20NC x 0.63” 320 7115140650 Capscrew, 0.25”-20NC x 0.75” 621 7115140850 Capscrew, 0.25”-20NC x 1.00” 922 7950140161 Flatwasher, 0.25” ID 3123 7660142601 Locknut, 0.25”-20NC 924 7661000006 Well Nut, 0.25”-20NC 625 7115161050 Capscrew, 0.38”-16NC x 1.25” 426 7950160161 Flatwasher, 0.38” ID 827 7660162601 Locknut, 0.38”-16NC 428 7330000199 Decal 129 7330000262 Decal 130 7330000200 Decal 131 7330000253 Decal 132 7330000441 Decal 133 7330000442 Decal 134 7330000443 Decal 1


35 7330000444 Decal 136 4314000211 Plate 137 7413000002 Nutsert, 0.25”-20NC 138 7950140000 Lockwasher, 0.25” ID 139 7114140618 Capscrew, 0.25”-20NC 1


A

DETAIL A

B

DETAIL B

1

2

3

14

5

6

78

910

10

11

1818

1213

415

15

16

16

1719

20

20

21

21

2122

22

22

2222

22

22

22

22

22

2223

23

23

24

24

2526

2627


CAUTION


199


WARNINGREVIEW THIS CHECKLIST BEFORE EACH TOW. FAILURE TO FOLLOW CHECKLISTCOULD CREATE A DANGEROUS CONDITION FOR YOU, OTHER MOTORISTS ANDPEDESTRIANS, AND MIGHT RESULT IN SERIOUS INJURY OR DEATH.


200

CAUTION262



WARNING

WRK BMEXT

BOOMLIFT

FRONTWINCH

REARWINCH

LEFTSPADE

TUOTUO UP441

OUT UP

DNIN ININ DN442

DRAGWINCH

U/LLIFT

U/LEXTEND

U/LTILT

RIGHTSPADE

443

UP UPUP OUTOUT

DNINDNINDN444



REAR WINCHFREESPOOL


FRONT WINCH2-SPEED


REAR WINCH2-SPEED


U/L WINCHFREESPOOL


U/L WINCH2-SPEED


28

29

30

31

32 33

34

35

36

36

37

3839

141516

4

15

16

CONTROLS - PUSH-PULL CABLES INSTALLATION - 16 FUNCTION

Push-Pull Cable Installation for 12 Function Remote Controller shown


CONTROLS - CONTROL VALVE ASSEMBLY - 3935000178 & 3935000180


1 3177000060 Valve Mount Weldment 12 4706005592 Plate 13 3935000185 Valve Assembly - 6 Function Remote 1

7935000304 Valve Assembly - 14 Function Remote4 7912000301* Tube Assembly 15 7912000302* Tube Assembly 16 7912000303* Tube Assembly 17 7912000304* Tube Assembly 18 7912000305* Tube Assembly 19 7912000306* Tube Assembly 2

10 7912000307* Tube Assembly 211 7912000308* Tube Assembly 612 7115152450 Capscrew, 0.31”-18NC x 3.00” 313 7660152601 Locknut, 0.31”-18NC 314 7950140161 Flatwasher, 0.31” ID 315 7445060625 Fitting, Union Bulkhead 116 7443000012 Tee 117 7445121225 Fitting, Union Bulkhead 218 7445161625 Fitting, Union Bulkhead 319 7445080825 Fitting, Union Bulkhead 1420 7445101025 Fitting, Union Bulkhead 421 7445081043 Adapter 1422 7445101043 Adapter 423 7445121243 Adapter 224 7443000211 Elbow 225 7445151243 Adapter 126 7912000309* Tube Assembly 727 7912000310* Tube Assembly 128 7445060645 Elbow 1

* Available in Hydraulic Tubing Kit - 7577000668


1

23

4

5

6

7

8

99

1010

11 26

2712

13

14

15

16

1717

18

18

18

19

19

1919

2021

21

2121

2222

23

23

24

24

25

28

CONTROLS - CONTROL VALVE ASSEMBLY - 3935000178 & 3935000180



1 3177000060 Valve Mount Weldment 12 4706005626 Control Closure 13 7935000374 Valve Assembly 14 7912000301* Tube Assembly 15 7912000302* Tube Assembly 16 7912000303* Tube Assembly 17 7912000304* Tube Assembly 18 7912000305* Tube Assembly 19 7912000306* Tube Assembly 3

10 7912000307* Tube Assembly 311 7912000308* Tube Assembly 712 7115152450 Capscrew, 0.31”-18NC x 3.00” 313 7660152601 Locknut, 0.31”-18NC 314 7950140161 Flatwasher, 0.31” ID 315 7445060625 Fitting, Union Bulkhead 116 7443000012 Tee 117 7445121225 Fitting, Union Bulkhead 218 7445161625 Fitting, Union Bulkhead 319 7445080825 Fitting, Union Bulkhead 1420 7445101025 Fitting, Union Bulkhead 621 7445081043 Adapter 1422 7445101043 Adapter 623 7445121243 Adapter 224 7443000211 Elbow 225 7445151243 Adapter 126 7912000309* Tube Assembly 727 7912000310* Tube Assembly 128 7445060645 Elbow 1

* Available in Hydraulic Tubing Kit - 7577000670

CONTROLS - CONTROL VALVE ASSEMBLY - 3935000218


1

23

4

5

6

7

8

99

9

10

10

1011

1111

26

26

26

27

12

13

14

15

16

1717

18

18

1819

19

19

1919

19

20

2020

20

21

21

21

21

21

21

22 22

22

23

23

24

24

25

28

CONTROLS - CONTROL VALVE ASSEMBLY - 3935000218


CONTROLS - 6 FUNCTION NON-PROPORTIONAL MIRATRON


1 7295000146 Antenna 12 7552000383 Harness 13 7552000148 Harness 14 7493000014 Grommet 25 7493000011 Grommet 16 7740000001 Relay, 40 Amp 17 7457000011 Relay, 40 Amp 18 7346000068 Dust Cap 19 7114100518 Capscrew, #10-24NC x 0.63” 4

10 7660102604 Locknut, #10-24NC 411 3314000010 Coverplate 212 7950140161 Flatwasher, 0.25” ID 813 7660142601 Locknut, 0.25”-20NC 414 7111140613 Screw, 0.25”-20NC x 0.75” 415 5526000553 Tie Strap 516 7701000007 Plug 117 7701000032 Plug 118 7346000039 Tubing, Heat Shrink 12in19 7661000023 Locknut, #10-32NF 220 7790100856 Screw, Self Tapping - #10 Dia x 0.50" 321 7493000020 Grommet 1


AB

C

ABC

ABC

AUX 2

AUX 1

O/R LIGHTS

BODY MARKERS

CABINET RH

CABINET LH

RIGHT TURN

LEFT TURN

CONTROL

MARKER

FLOOD #2

FLOOD #1

BEACON #2

BEACON #1

SWITCHPANEL

OUTOUT

OUT OUT

OUTIN OUT

G

W

M

BB

AUX 3AUX 3

BACK-UP

IN OUT

IN

RHLH

BEACON 1AUX

AUXHOT 2

AUX 3

O/R LIGHTS

BODY MARKERS

AAC

CONTROL

GROUND

SDD

AUXHOT 1

BEACON 1AUX

AUX 2

Y

P

V

T

A

C

H

EE

F

CC

PAT REWOP SWITCH PANEL

AA

TURN SIGNAL

OUT

IN

I

BB

B

X

J

S

LEFT BODY

HARNESS

RD

FF

U

O

E

LIGHT BAR

M

Q

W

MAIN

HARNESS

L

G

K

N

HARNESS

RIGHT BODY

Z

IN

MARKER

GROUND

DD

RELAY

10 A

1

11

2

2

2

3

3

3

4

4

5

6

7

8

901

11

11213141

51

61

71

81

02

12

91

91





1 7295000124 Remote Controller 12 7552000364 Harness 13 7552000148 Harness 14 7493000014 Grommet 25 7493000011 Grommet 16 7346000029 In-Line Fuse Holder 17 7457000008 Fuse - 10 Amp 18 7345001714 Electrical Terminal 29 7346000039 Tubing, Heat Shrink 12in

10 7661000023 Locknut, #10-32NF 211 7740000001 Relay, 40 Amp 112 7457000006 Fuse - 15 Amp 113 7894000042 Tie Strap 214 7115141250 Capscrew, 0.25”-20NC x 1.50” 215 7950140161 Flatwasher, 0.25” ID 1216 7660142600 Locknut, 0.25”-20NC 617 3314000010 Coverplate 218 7115140650 Capscrew, 0.25”-20NC x 0.75” 419 7701000007 Plug 120 5526000553 Tie Strap 5


AB

C

ABC

AUX 2

AUX 1

O/R LIGHTS

BODY MARKERS

CABINET RH

CABINET LH

RIGHT TURN

LEFT TURN

CONTROL

MARKER

FLOOD #2

FLOOD #1

BEACON #2

BEACON #1

SWITCHPANEL

OUTOUT

OUT OUT

OUTIN OUT

G

W

M

BB

AUX 3AUX 3

BACK-UP

IN OUT

IN

RHLH

BEACON 1AUX

AUXHOT 2

AUX 3

O/R LIGHTS

BODY MARKERS

AAC

CONTROL

GROUND

SDD

AUXHOT 1

BEACON 1AUX

AUX 2

Y

P

V

T

A

C

H

EE

F

CC


AA

TURN SIGNAL

OUT

IN

I

BB

B

X

J

S

LEFT BODY

HARNESS

RD

FF

U

O

E

LIGHT BAR

M

Q

W

MAIN

HARNESS

L

G

K

N

HARNESS

RIGHT BODY

Z

IN

MARKER

GROUND

DD

RELAY

10 A

A01

1

1

1

2

2

2

3

3

3

4

4 5

367

898

9

9

01

01

11

21

31

415161

516181

71

71

91


Item #20, not shown


CONTROLS - 14 & 16 FUNCTION PROPORTIONAL MIRATRON


1 7295000148 Remote Controller 12 7295000146 Antenna 13 7552000441 Harness 14 7552000148 Harness 15 7493000014 Grommet 26 7493000011 Grommet 17 7346000039 Tubing, Heat Shrink 12in8 7740000001 Relay, 40 Amp 19 7457000006 Fuse - 15 Amp 1

10 7894000004 Tie Strap 111 8632000012 Trim 30in12 4178000699 Bracket 113 7950140161 Flatwasher, 0.25” ID 1214 7660142601 Locknut, 0.25”-20NC 1015 7111140813 Screw, 0.25-20N x 1.00” 416 7120000047 Screw, #4-40NC x 0.63” 217 7660040000 Nut, #4-40NC 218 3314000010 Coverplate 219 7111140613 Screw, 0.25”-20NC x 0.75” 420 7115141250 Capscrew, 0.25”-20NC x 1.50” 221 7493000020 Grommet 222 5526000553 Tie Strap 523 7114100518 Capscrew, #10-24NC x 0.63” 424 7660102604 Locknut, #10-24NC 425 7790100856 Screw, 0.25”-20NC x 0.75” 626 7661000023 Locknut, #10-32NF 227 7075000006 Battery 328 7075000003 Battery 1


AB

C

ABC

AUX 2

AUX 1

O/R LIGHTS

BODY MARKERS

CABINET RH

CABINET LH

RIGHT TURN

LEFT TURN

CONTROL

MARKER

FLOOD #2

FLOOD #1

BEACON #2

BEACON #1

SWITCHPANEL

OUTOUT

OUT OUT

OUTIN OUT

G

W

M

BB

AUX 3AUX 3

BACK-UP

IN OUT

IN

RHLH

BEACON 1AUX

AUXHOT 2

AUX 3

O/R LIGHTS

BODY MARKERS

AAC

CONTROL

GROUND

SDD

AUXHOT 1

BEACON 1AUX

AUX 2

Y

P

V

T

A

C

H

EE

F

CC


AA

TURN SIGNAL

OUT

IN

I

BB

B

X

J

S

LEFT BODY

HARNESS

RD

FF

U

O

E

LIGHT BAR

M

Q

W

MAIN

HARNESS

L

G

K

N

HARNESS

RIGHT BODY

Z

IN

MARKER

GROUND

DD

RELAY

15 A

ABC

ABC

1

2

12

1

34

3

4 12

5

5

6

4

7

8

9

11

21314151

31410261

71 8181

314191

12

22

3242

52

62

62

CONTROLS - 14 & 16 FUNCTION PROPORTIONAL MIRATRON

Items #20, #27 and #28, not shown


CONTROLS - ELECTRICAL EMERGENCY STOP


1 8977010103 Wire, 16GA. - 2 Conductor 40ft2 7346000094 Electrical Connector 13 7346000035 Electrical Terminal 24 7346000037 Seal, Cable 65 7346000087 Electrical Connector 26 7346000099 Electrical Terminal 47 8977500100 Wire, 16GA. Black 3in8 7870000128 Switch, Emergency Pushbutton 29 7870000128 Switch, Emergency Contact Block 2

10 7345001704 Electrical Terminal 311 7346000039 Tubing, Heat Shrink 6in12 7330000755 Decal 213 5526000553 Tie Strap 1


22

12

22

21

EMERGENCYSTOP

557

1

234

789

456

1

0111

0111

1

89

89

21

CONTROLS - ELECTRICAL EMERGENCY STOP

Item #13, not shown


HYDRAULICS - SUPPLY-PRESSURE-RETURN


1 7650100137 Pipe Nipple 12 7444121050 Reducer 13 7635000116 Valve, Ball 14 7444121271 Elbow 15 7443000130 Fitting 16 7274000028 Clamp 17 See Note 1 Hose - Supply 18 7443000222 Fitting 19 7577000213 Split Flange 1

10 7724000044 Pump 111 7115181050 Capscrew, 0.50”-13NC x 1.25” 212 7950180000 Lockwasher, 0.50” ID 213 7445121645 Elbow 214 See Note 1 Hose - Pressure 215 7430000010 Filter, Tank 116 4706003844 Plate 517 7274000071 Clamp 518 7274000040 Clamp 1019 7115140850 Capscrew, 0.25”-20NC x 1.00” 1020 7950140152 Flatwasher, 0.25” ID 1021 7660142601 Locknut, 0.25”-20NC 1022 7115181250 Capscrew, 0.50”-13NC x 1.50” 523 7660000011 Locknut, 0.50”-13NC 524 4178000248 Bracket 1

Note 1: Varies depending on chassis, transmission and PTO type. Consult factory for part numbers.


PMUP

SISSAHC FO TNORF

KNAT

CILUARDYH FO WEIV EDISEMARFBUS NO DLOFINAM

TROPPUS EMARF PYT

51

1

23

456

7

89

01

1121

31 41

41

12

2232

9102

81

61

71

HYDRAULICS - SUPPLY-PRESSURE-RETURN

Item #24, not shown


HYDRAULICS - LINES AND FITTINGS


1 7470000004 Gauge, Pressure 22 7790060676 Screw, #6 x 0.38” 63 7445040421 Fitting 24 7443000207 Reducer 15 7445040443 Adapter 16 7445060643 Adapter 117 7443000109 Adapter - 2 Piece Wrecker Boom 4

7443000109 Adapter - 3 Piece Wrecker Boom 28 7274000063 Clamp 29 7445060219 Adapter 1

10 7430000004 Filter Assembly 211 7443000150 Adapter 212 7470000002 Gauge, Filter 213 7443000213 Tee 114 7445161672 Elbow 115 7445161622 Union - 3 Piece Wrecker Boom 216 7445161620 Elbow 217 7445080822 Union 218 7445080837 Union 219 7445080843 Adapter 420 7445060645 Elbow 121 4619000006 Manifold 122 7115161650 Capscrew, 0.38”-16NC x 2.00” 223 7950160000 Lockwasher, 0.38” ID 224 7445101032 Fitting 425 7445100843 Adapter 426 7445080825 Union 427 7443000479 Adapter - 3 Piece Wrecker Boom 228 4819000008 Sleeve 229 7894000004 Tie Strap 630 4567113028* Hose Assembly 131 4567112024* Hose Assembly 132 4569133027* Hose Assembly 133 4569132030* Hose Assembly 234 4569133032* Hose Assembly 1


35 4570000138* Hose Assembly 236 4570000301* Hose Assembly 237 4570000313* Hose Assembly 138 4569182025* Hose Assembly 139 4567183040* Hose Assembly 140 4569183054* Hose Assembly 141 4567182029* Hose Assembly 142 4567182024* Hose Assembly 143 4569173038* Hose Assembly 144 4569173026* Hose Assembly 145 4569143028* Hose Assembly 146 4569142025* Hose Assembly 147 4567133032* Hose Assembly 148 4567132031* Hose Assembly 149 4567132043* Hose Assembly 450 4570000244* Hose Assembly 151 4570000245* Hose Assembly 152 4570000246* Hose Assembly 153 4570000247* Hose Assembly 154 4570000166* Hose Assembly 155 4570000192* Hose Assembly 156 4570000174* Hose Assembly 157 4570000173* Hose Assembly 158 4570000248* Hose Assembly 159 4570000180* Hose Assembly 160 4569132034* Hose Assembly 261 4569133035* Hose Assembly 262 4570000177* Hose Assembly 163 4570000176* Hose Assembly 164 4570000167* Hose Assembly 265 4567120017* Hose Assembly 266 4569133029* Hose Assembly 167 4569132028* Hose Assembly 168 4569163024* Hose Assembly 169 4569162024* Hose Assembly 1




70 4569163034* Hose Assembly 171 4569162034* Hose Assembly 172 4569130046* Hose Assembly 273 4569160046* Hose Assembly 474 4567160048* Hose Assembly 475 4570000165* Hose Assembly 276 4567152033* Hose Assembly 177 4567152032* Hose Assembly 178 4567152066* Hose Assembly 179 4567152060* Hose Assembly 180 4570000177+ Hose Assembly - UL530 Underlift 1

4570000336^ Hose Assembly - UL565 Underlift 181 4570000176+ Hose Assembly - UL530 Underlift 1

4570000335^ Hose Assembly - UL565 Underlift 182 4567152033< Hose Assembly - Gear Shift Winch 1

4567152025> Hose Assembly - Motor Shift Winch 183 4567152032< Hose Assembly - Gear Shift Winch 1



4567152054> Hose Assembly - Motor Shift Winch 1

* Available in Hydraulic Hose Kit - 7577000599 +Available in Hydraulic Hose Kit - 7577000640 ^ Available in Hydraulic Hose Kit - 7577000641 <Available in Hydraulic Hose Kit - 7577000574 >Available in Hydraulic Hose Kit - 7577000573 #Available in Hydraulic Hose Kit - 7577000639 =Available in Hydraulic Hose Kit - 7577000600 ~Available in Hydraulic Hose Kit - 7577000601


86 4567182029# Hose Assembly - w/o Drag Winch 14569180038= Hose Assembly - w/1 Spd Drag Winch 14569180038~ Hose Assembly - w/2 Spd Drag Winch 1





91 4569162044= Hose Assembly - w/1 SpdDrag Winch 14569162044~ Hose Assembly - w/2 Spd Drag Winch 1

92 4569163044= Hose Assembly - w/1 Spd Drag Winch 14569163044~ Hose Assembly - w/2 Spd Drag Winch 1




1.00 1.00

"B" PORT

"A" PORT

1.00 1.00

PRESSURE TO "A"

PRESSURE TO "B"

RET

EXT

EXT

RET#6

#6LH SPADE

RH SPADEPRESSURE FRONT

PRESSURE REAR0.75

0.75

U/L TILT - DOWN

DRAG WINCH - OUTDRAG WINCH - IN

WRKR BOOM LIFT - UP

WRKR BOOM LIFT - DOWN

R WINCH - OUTR WINCH - INF WINCH - OUTF WINCH - IN

WRKR BOOM EXT - OUT

WRKR BOOM EXT - IN

RETURN, OUTLET

RETURN, INLET/MID-INLET

PRESSURE, MID-INLET

PRESSURE, INLET

0.62

0.62

0.62

0.62

0.62

0.75

0.75

WRK BOOM EXT IN

WRK BOOM EXT OUT0.62

0.62

0.62

0.62

0.62

0.62

F WINCH OUTF WINCH IN

R WINCH INR WINCH OUT

U/L EXT INU/L EXT OUTU/L TILT DNU/L TILT UP

A

A

VIEW A-ABODY

P

T

P

T

T

UP OUTPUPU OUT

INDN DNDNIN

OUTOUT UP

DNIN IN

PRESSURE TO "A"

PRESSURE TO "B"

UP OUT

DN IN

DRAGWINCH

U/LLIFT

U/L EXT - OUTU/L EXT - IN

U/L TILT - UP

0.62

0.62

DRAG WINCH INDRAG WINCH OUT

0.50 WRK BOOM LIFT UP

0.50 WRK BOOM LIFT DN

0.62

RETURN REAR

RETURN FRONT

0.62

0.62

PILOT DRAIN

FRONTWINCH

BOOMLIFT

WRK BMEXT

REARWINCH

LEFTSPADE

RIGHTSPADE

U/LEXT

U/LTILT

7

6

35

36

33

343332

35

366

7

434446 40

40 45

3938

13

14

37

8

31

312

5

1

2

3

304




DRAG WINCH OUTDRAG WINCH IN

0.62

0.62

0.62

0.62

PRESSURE FRONT

PRESSURE REAR0.75

0.75

0.62

0.62

0.62

0.62

0.62

0.62

0.75

0.75

WRK BOOM EXT IN


0.62

0.62

0.62

0.62

0.62



A

A

EXT

RET#6

#6

#6

#6

RET

EXT

U/L TILTU

/L E

XT

U/L TILT - DOWN


WRKR BOOM LIFT - UP



WRKR BOOM EXT - OUT

WRKR BOOM EXT - IN

RETURN, OUTLET


PRESSURE, MID-INLET

PRESSURE, INLET

VIEW A-ABODY


U/L TILT - UP

PRESSURE TO "A"

PRESSURE TO "B"

P

T

P

T

T

UP OUTPUPU OUT

INDN DNDNIN

OUTOUT UP

DNIN IN

PRESSURE TO "A"

PRESSURE TO "B"

UP OUT

DN IN

DRAGWINCH

U/LLIFT

"B" PORT

"A" PORT

WRK BOOM LIFT UP0.50

WRK BOOM LIFT DN0.50 0.50

RETURN FRONT

RETURN REAR

U/L EXT IN

U/L EXT OUT

U/L TILT DN

U/L TILT UP

EXT

RET#6 U/L LIFT

0.50

0.50

0.50

0.50

0.50

0.50

0.50

0.50

1.00

1.00

1.00

1.00

0.50

#8

FRONTWINCH

BOOMLIFT

WRK BMEXT

REARWINCH

LEFTSPADE

RIGHTSPADE

U/LEXT

U/LTILT

6 6

65

65

6

6

21 2223

64

64

6

6

80

81

20

6

54

55

60

6126

2658

59 26

56

57

61

605657

5859

5051

52535554


A

A

WRKR BOOM - EXTWRKR BOOM - RET

F WINCH - OUTF WINCH - INR WINCH - OUTR WINCH - IN

F WINCH - OUTF WINCH - IN

R WINCH - OUTR WINCH - IN

WRK

R B

OO

M E

XTEX

T

RET

#6

B

B

VIEW B-B

C

CVIEW C-C

D DE E

PRESSURE TO "A"

PRESSURE TO "B"

P

T

P

T

T

��

��

��

UP OU

T

UP

UPOU

T

INDN

DN

DNIN

��

��

��

OUTOU

TUP

DNIN IN

PRESSURE TO "A"

PRESSURE TO "B"

��

��

UP OU

T

DN IN

DRAGWINCH

U/LLIFT

"B" PORT

"A" PORT

U/L EXT OUTU/L TILT DNU/L TILT UP

U/L EXT IN

1.00 1.00

1.00 1.00

PRESSURE FRONT

PRESSURE REAR0.75

0.75

0.62

0.62

0.62

0.62

0.62

0.75

0.75

WRK BOOM EXT IN


0.62

0.62

0.62

0.62

0.62

F WINCH OUT

F WINCH IN

R WINCH IN

R WINCH OUT0.62

0.62




0.62

RETURN REAR

RETURN FRONT

0.62

0.62U/L TILT - DOWN


WRKR BOOM LIFT - UP



WRKR BOOM EXT - OUT

WRKR BOOM EXT - IN

RETURN, OUTLET


PRESSURE, MID-INLET

PRESSURE, INLET

VIEW A-ABODY


U/L TILT - UP

REAR WINCHUNDER WOUNDCCW - CABLE IN

FRONT WINCHOVER WOUNDCW - CABLE IN

#8 #8

VIEW D-D VIEW E-EFRONT WINCH PORTS

GEAR SHIFT 2 SPDREAR WINCH PORTSGEAR SHIFT 2 SPD

CABLE IN - V2

CABLE OUT - V1 CABLE IN - V1

CABLE OUT - V2

FRONT WINCH PORTSMOTOR SHIFT 2 SPD

REAR WINCH PORTSMOTOR SHIFT 2 SPD

CABLE OUT - V2

CABLE IN - V1

CABLE IN - V2

CABLE OUT - V1

VIEW D-D VIEW E-E

7 (2-PIECE WRECKER BOOM)27 (3-PIECE WRECKER BOOM)

7575

25

8283

848525

74

24

75

74

72

2829

73

72

71

7069

6867

66

82

83

82

83

84

85

84

85



HYDRAULIC

RESERVOIR

1.00 1.00

1.00 1.00

PRESSURE FRONT

PRESSURE REAR0.75

0.75

U/L TILT - DOWN


WRKR BOOM LIFT - UP



WRKR BOOM EXT - OUT

WRKR BOOM EXT - IN

RETURN, OUTLET


PRESSURE, MID-INLET

PRESSURE, INLET

WRK BOOM EXT IN


0.62

0.62

0.62

0.62

0.62




A

A

VIEW A-A

BODY


U/L TILT - UP

0.62

0.62




RETURN REAR

RETURN FRONT

0.62

0.62

HYDRAULIC

RESERVOIR

1.00 1.00

1.00 1.00

PRESSURE FRONT

PRESSURE REAR0.75

0.75

U/L TILT - DOWN


WRKR BOOM LIFT - UP



WRKR BOOM EXT - OUT

WRKR BOOM EXT - IN

RETURN, OUTLET


PRESSURE, MID-INLET

PRESSURE, INLET

WRK BOOM EXT IN


0.62

0.62

0.62

0.62

0.62




A

A

VIEW A-A

BODY


U/L TILT - UP

0.62

0.62




RETURN REAR

RETURN FRONT

0.62

0.62

PILOT DRAIN

PILO

T D

RAI

N

RETURN W/ODRAG WINCH

RETURN W/DRAG WINCH

1211

10

9

16

37

86

87

15

86 87

37

16

16

9

1011

12



1.00 1.00

1.00 1.00

PRESSURE FRONT

PRESSURE REAR0.75

0.75

0.62

0.62

0.62

0.62

0.62

0.75

0.75

WRK BOOM EXT IN


0.62

0.62

0.62

0.62

0.62




A

A

0.62

0.62




0.62

RETURN REAR

RETURN FRONT

W/B LIFT

RET

EXT#8

RET

EXT#8

W/B LIFT

0.62

0.62

PILOT DRAIN

1.00 1.00

1.00 1.00

PRESSURE FRONT

PRESSURE REAR0.75

0.75

0.62

0.62

0.62

0.62

0.62

0.75

0.75

WRK BOOM EXT IN


0.62

0.62

0.62

0.62

0.62




A

A

0.62

0.62




0.62

RETURN REAR

RETURN FRONT

W/B LIFT

RET

EXT#8

RET

EXT#8

W/B LIFT

0.62

0.62

PILOT DRAIN

U/L TILT - DOWN


WRKR BOOM LIFT - UP



WRKR BOOM EXT - OUT

WRKR BOOM EXT - IN

RETURN, OUTLET


PRESSURE, MID-INLET

PRESSURE, INLET

VIEW A-ABODY


U/L TILT - UP

1990

1888

1990

19

90

18

89

89

88

19

19

18

19

19

18

90

90

90

88

89

88

89

17



A

A

PRESSURE TO "A"

PRESSURE TO "B"

P

T

P

T

T

UP OUTPUPU OUT

INDN DNDNIN

OUTOUT UP

DNIN IN

PRESSURE TO "A"

PRESSURE TO "B"

UP OUT

DN IN

DRAGWINCH

U/LLIFT

"B" PORT

"A" PORT


U/L EXT IN

1.00 1.00

1.00 1.00

PRESSURE FRONT

PRESSURE REAR0.75

0.75

0.62

0.62

0.62

0.62

0.62

0.75

0.75

WRK BOOM EXT IN


0.62

0.62

0.62

0.62

0.62



0.62

0.62

DRAG WINCH IN

DRAG WINCH OUT



0.62

RETURN REAR

RETURN FRONT

0.62

0.62

U/L TILT - DOWN


WRKR BOOM LIFT - UP



WRKR BOOM EXT - OUT

WRKR BOOM EXT - IN

RETURN, OUTLET


PRESSURE, MID-INLET

PRESSURE, INLET

VIEW A-A

BODY


U/L TILT - UP

#8

1 - SPEEDDRAG WINCHOVER WOUNDCW - CABLE IN

A

A

PRESSURE TO "A"

PRESSURE TO "B"

P

T

P

T

T

UP OUTPUPU OUT

INDN DNDNIN

OUTOUT UP

DNIN IN

PRESSURE TO "A"

PRESSURE TO "B"

UP OUT

DN IN

DRAGWINCH

U/LLIFT

"B" PORT

"A" PORT


U/L EXT IN

1.00 1.00

1.00 1.00

PRESSURE FRONT

PRESSURE REAR0.75

0.75

0.62

0.62

0.62

0.62

0.62

0.75

0.75

WRK BOOM EXT IN


0.62

0.62

0.62

0.62

0.62



0.62

0.62

DRAG WINCH IN

DRAG WINCH OUT



0.62

RETURN REAR

RETURN FRONT

0.62

0.62

F F

2 - SPEEDDRAG WINCHOVER WOUNDCW - CABLE IN

#8

VIEW F-FDRAG WINCH PORTS

2 - SPEED

CAB

CABLE IN - V1 CABLE OUT - V2

CABLE IN - V2 CABLE OUT - V1

U/LTILT

U/LEXT

RIGHTSPADE

LEFTSPADE

REARWINCH

WRK BMEXT

BOOMLIFT

FRONTWINCH

U/LTILT

U/LEXT

RIGHTSPADE

LEFTSPADE

REARWINCH

WRK BMEXT

BOOMLIFT

FRONTWINCH

91

92

2593 94

2593

94

9394

9192



DRIVER SIDE HYDRAULIC PRESSURE GAUGES - WITHOUT UNDERLIFT WINCH (STANDARD)


1 7443000026 Tee 22 4567110141 Hose Assembly 23 7445040421 Fitting 24 7470000004 Gauge, Pressure 25 7790060676 Screw, #6 x 0.38” 66 7330000257 Decal - Pressure Front Valve 17 7330000256 Decal - Pressure Rear Valve 18 4706005127 Plate 1


DRIVER SIDE HYDRAULIC PRESSURE GAUGES - WITHOUT UNDERLIFT WINCH (STANDARD)

PRESSUREFRONT VALVE

652652

PRESSUREREAR VALVE

PASSENGER SIDE GAUGEPASSENGER SIDE GAUGE

1

1

2

2

33

45

45

8

PASSENGER SIDECONTROL VALVE

6

7


DRIVER SIDE HYDRAULIC PRESSURE GAUGES - WITH UNDERLIFT WINCH (OPTIONAL)


1 7443000026 Tee 22 4567110141 Hose Assembly 23 7445040421 Fitting 24 7470000004 Gauge, Pressure 25 7790060676 Screw, #6 x 0.38” 66 7330000257 Decal - Pressure Front Valve 17 7330000256 Decal - Pressure Rear Valve 18 4314000215 Coverplate 19 7115140850 Capscrew, 0.25”-20NC x 1.00” 1

10 7950140161 Flatwasher, 0.25” ID 211 7661000006 Nut, Well 212 7114140618 Capscrew, 0.25”-20NC x 0.75” 113 7413000002 Nutsert, 0.25”-20NC 114 7950140000 Lockwasher, 0.25” ID 1


DRIVER SIDE HYDRAULIC PRESSURE GAUGES - WITH UNDERLIFT WINCH (OPTIONAL)

256

PRESSUREREAR VALVE

257

PRESSUREFRONT VALVE

1

1

22

33

45

45

6 8

7

10121314

91011


PASSENGER SIDE WINCH AIR CONTROLS - 2 SPD GEAR SHIFT

1 7443000154 Bushing 12 7443000155 Elbow 13 7443000156 Nipple 24 7443000152 Plug 15 7443000139 Elbow 86 7935000120 Valve, Pressure Protection 17 7443000175 Fitting 28 7295000029 Air Regulator 19 7443000066 Fitting 1

10 7470000006 Gauge, Air Pressure 111 7444020013 Plug 212 7443000173 Elbow 1013 7446502518 Fitting, Bulkhead 114 7312000017 Coupling 115 7443000176 Fitting 216 7443000174 Tee 217 7565000016 Airline, Tubing 0.25 OD 150ft18 7565000014 Airline, Tubing 0.38 OD 25ft19 7443000149 Bushing 120 7443000178 Union 621 7935000136 Valve, Air 422 4619000005 Manifold 123 7660142601 Locknut, 0.25”-20NC 224 7115142450 Capscrew, 0.25”-20NC x 3.00” 225 7950140161 Flatwasher, 0.25” ID 426 7443000270 Tee 127 4811001135 Sheet 128 7114140518 Capscrew, 0.25”-20NC x 0.62” 429 7660142604 Locknut, 0.25”-20NC 430 7330000840 Decal - Front Winch Freespool 131 7330000841 Decal - Rear Winch Freespool 132 7330000842 Decal - Front Winch 2 Speed 133 7330000843 Decal - Rear Winch 2 Speed 1



PASSENGER SIDE WINCH AIR CONTROLS - 2 SPD GEAR SHIFT

F. 2-SPEED

R. 2-SPEED

IN

EXTCYL

F. FREESPOOL

R. FREESPOOL

IN

EXTCYL

F. F

RE

ESPO

OL

F. 2

-SPE

ED

R. F

RE

ESPO

OL

R. 2

-SPE

ED

IN

EXTCYL! CAUTION !

2 SPEED

F. TENSIONER

R. TENSIONER

F. 2-SPEED

R. 2-SPEED

F. FREESPOOL

R. FREESPOOL

F. TENSIONER

R. TENSIONER

IN

EXTCYL

FRONT WINCH REAR WINCH

FREESPOOL

REGULATOR SETTING40-50 PSI

REAR WINCHREF

FRONT WINCHREF

SECONDARYAIR SUPPLY

AIR TANK MUST BEEVACUATED BEFORE

INSTALLING AIR CIRCUIT

1

2

34 5 17

7 186

10

919

18

12 21

18

121221

11

5

2425

2325

223826

29

713 28

14

2827

20 16

12

5

15

21 215

OUTOUT

BOOMLIFT

WRK BMEXT

FRONTWINCH

UP299

REAR WINCH2-SPEED

PULL - HIGH SPEED843

FRONT WINCH2-SPEED

PULL - HIGH SPEED842841

REAR WINCHFREESPOOL

PULL TO RELEASE840

IN DN NDND435

INDN IN


PULL TO RELEASE

PRESSUREFRONT VALVE

257

WINCHDRAG

OUT

LEFTSPADE

OUT

U/LEXT

UPOUT

U/LLIFT

UP UP

U/LTILT

UP

RIGHTSPADE

434

REARWINCH

DN IN300

IN

253


CAUTION


200

CAUTION


199


WARNING

262



WARNING

256

PRESSUREREAR VALVE

17

RH SIDE CONTROL COVERPLATE

30 32

31

33


DRIVER & PASSENGER SIDE WINCH AIR CONTROLS - DP 50K, 2 SPD GEAR SHIFT


1 7443000154 Bushing 12 7443000155 Elbow 13 7443000156 Nipple 14 7935000120 Valve, Pressure Protection 15 7443000152 Plug 116 7443000139 Elbow 87 7443000175 Fitting 28 7565000014 Airline, Tubing 0.38 OD 25ft9 7446502518 Fitting, Bulkhead 1

10 7312000017 Coupling 111 7565000016 Airline, Tubing 0.25 OD 300ft12 7443000178 Union 3113 7443000329 Fitting 814 7443000173 Elbow 3415 7935000351 Valve, Air 1016 7295000029 Air Regulator 117 7470000006 Gauge, Air Pressure 118 7443000174 Tee 419 7443000146 Elbow 120 4619000005 Manifold 121 7115142450 Capscrew, 0.25”-20NC x 3.00” 222 7660142601 Locknut, 0.25”-20NC 223 7950140161 Flatwasher, 0.25” ID 424 7443000287 Tee 525 7443000243 Fitting, Bulkhead 526 7444020014 Plug 227 7443000176 Fitting 228 7330000737 Decal - Front Winch Freespool 229 7330000738 Decal - Rear Winch Freespool 230 7330000739 Decal - Front Winch 2 Speed 231 7330000740 Decal - Rear Winch 2 Speed 232 7661000041 Nut, Panel 133 7330000741 Decal - U/L Winch Freespool 234 7443000448 Fitting 1



! CAUTION !AIR TANK MUST BE EVACUATED BEFORE

INSTALLING AIR CIRCUIT

1/4NPT

1/2 NPT

SECONDARYAIR SUPPLY

1/4 NPT

PLUG (FS)INCLUDED W/ ITEM 4

1/8NPT

1/8NPT

1/4NPT

1/4NPT

IN "1" OUT "2"WITH SWITCH INSHOWN POSITION 4

12

5

3 1/8NPT

7-935-351


12

5

3 1/8NPT

7-935-351


12

5

3 1/8NPT

7-935-351


12

5

3 1/8NPT

7-935-351

F. TENSIONER

F. FREESPOOL

R. FREESPOOLF. 2-SPEED

R. 2-SPEED U/L FREESPOOLU/L TENSIONER

TO WRECKER BOOM

TO U/L

R. TENSIONER

R. FREESPOOL

LOOPSEERF .RLOOPSEERF .F

DEEPS-2 .RDEEPS-2 .F

U/L FREESPOOL

LOOPSEERF .RLOOPSEERF .F

DEEPS-2 .RDEEPS-2 .F

U/L FREESPOOL

#1

#2

#3

#4

#5 #9

#10

#11

#12

#13

#8

#2

#3

#4

#5 #9

#10

#11

#12

#13

#8

#14

#15

#16

#17 #18

#6

#7

#2

#3

#4

#5

#8

#9

#10

#11

#12

#13

#2

#3

#4

#5

#8

#9

#10

#11

#12

#13

RH BODYSCHEMATIC

LH BODYSCHEMATIC


12

5

3 1/8NPT

7-935-351

2

4

7-935-351

1/8NPT

IN "1" OUT "2"WITH SWITCH INSHOWN POSITION

315

2

4

7-935-351

1/8NPT


315

2

4

7-935-351

1/8NPT


315

2

4

7-935-351

1/8NPT


315

2

4

7-935-351

1/8NPT


315

AT REAR TAILBOARD

1

2 3 4 7

5 6 11

17

19

1816

6

11

12 12

34 11 20 212223

136

26 6

1414

14 15 11

12 12

15

15

1514

14

14

14

11 11

8

7 9

10

8

12 1225

24

13

2413

15

15

1511

5

5

5

514

1414

145

155

5

514

14

14

1111

14

11

32


11

12 1814

6 27

14

18

1412 11

F. TENSIONERR. TENSIONER

F. FREESPOOL

R. FREESPOOLF. 2-SPEED

R. 2-SPEED

WRECKER BOOM - DP 50K WINCHES

#14

#16

#7

#6

#15

#17

U/L FREESPOOLU/L TENSIONER

U/L DRAG - DP 35K WINCH

#7

#18




OUTOUT

BOOMLIFT

WRK BMEXT

FRONTWINCH

UP299


U/L WINCH2-SPEED

741

U/L WINCHFREESPOOL

RELEASED WHEN LIT

REAR WINCH2-SPEED


FRONT WINCH2-SPEED


REAR WINCHFREESPOOL


IN DN NDND435

INDN IN


RELEASED WHEN LIT

256

PRESSUREREAR VALVE

PRESSUREFRONT VALVE

257

WINCHDRAG

OUT

LEFTSPADE

OUT

U/LEXT

UPOUT

U/LLIFT

UP UP

U/LTILT

UP

RIGHTSPADE

434

REARWINCH

DN IN300

IN

253


CAUTION


200

CAUTION


199


WARNING

262



WARNING

2931

28

30

DECAL INSTALLATIONUNITS WITH AND WITHOUT U/L DRAG WINCH

RH CONTROL STATION

740HIGH SPEED WHEN LIT

REAR WINCH2-SPEED

738RELEASED WHEN LIT

REAR WINCHFREESPOOL


FRONT WINCH2-SPEED




199


WARNING

BOOMLIFT

DNIN DNDN

REARWINCH

DN

RIGHTSPADE

LEFTSPADE

IN

U/LTILT

FRONTWINCH

IN

U/LEXT

INDN

U/LLIFT

WRK BMEXT

xxx

UPPUTUO UPOUT UP OUT OUT UP

262



WARNING

REVIEW THIS CHECKLIST BEFORE EACH TOW. FAILURE TO FOLLOW CHECKLISTCOULD CREATE A DANGEROUS CONDITION FOR YOU, OTHER MOTORISTS ANDPEDESTRIANS, AND MIGHT RESULT IN SERIOUS INJURY OR DEATH.


200

CAUTION


CAUTION

DECAL INSTALLATIONUNITS WITHOUT U/L DRAG WINCH

LH CONTROL STATION

2830

29 31


U/L WINCH2-SPEED


U/L WINCHFREESPOOL


REAR WINCH2-SPEED


FRONT WINCH2-SPEED


REAR WINCHFREESPOOL



DNINDNINDN444

DRAGWINCH

U/LLIFT

U/LEXTEND

U/LTILT

RIGHTSPADE

443

UP UPUP OUTOUT

DNIN ININ DN442

WRK BMEXT

BOOMLIFT

FRONTWINCH

REARWINCH

LEFTSPADE

TUOTUO UP441

OUT UP

262



WARNINGREVIEW THIS CHECKLIST BEFORE EACH TOW. FAILURE TO FOLLOW CHECKLISTCOULD CREATE A DANGEROUS CONDITION FOR YOU, OTHER MOTORISTS ANDPEDESTRIANS, AND MIGHT RESULT IN SERIOUS INJURY OR DEATH.


200

CAUTION


199


WARNING


CAUTION28

30

29

31

DECAL INSTALLATIONUNITS WITH U/L DRAG WINCH

LH CONTROL STATION

33

33


WINCH ELECTRIC SPEED/FREE SPOOL CONTROLS - DP 50K, 2 SPD


1 7870000136 Pressure Switch 52 7590000364 Light 103 7346000039 Tubing, Heat Shrink 15in4 7552000414 Harness 15 7552000415 Harness 16 7457000019 Fuse, 5 Amp 1


ABCDEF

ABCDEF

FUSEAA

POWER TAP

BEACON #1

BEACON #2

FLOOD #2

CONTROL

MARKER

FLOOD #1

LEFT TURN

BOOM UP

W/L TILT UP

W/L TILT DOWN

BOOM DOWN

RIGHT TURN

W/L EXTEND

W/L RETRACT

MAIN

SWITCH PANEL

LIGHT BAR

HARNESS

LEFT BODY

HARNESS

RIGHT BODY

HARNESS

HAND CONTROLLER

HAND CONTROLLER

FUNCTION

SWITCH

GROUND

MARKER

LEFT TURN

RIGHT TURN

BACK-UP

IN OUT

IN OUT

IN OUT

IN OUT

POWER TAP

A B

EE FF

C

D

E

F

G

H

I

J

K

L

M

N

O

P

X

Y

Z

AA

BB

CC

DD

Q

R

S

T

U

V

W

AUXHOT

AUXHOT

AUXHOT

SWITCHPANELFEED

FUSEZ

FUSEH

FUSEI

FUSEG

FUSEDD

FUSEFFFUSE

F

FUSEE

FUSED

AUX 2SWITCHED

HOT

SWITCHEDAIR

CONTROL

FUSEEE

SWITCHPANELFEED

5

#34 WHITE - GROUND

#33 BLACK - AUX HOT

6

5

4

5

4

A

A

B B

C C

D D

DIST PANELVIEW A-A



BA BA BA BA

BA BA BA BA

BA

BA

F WINCH2-SPEED

RED

BLACK

#36 LT BLUE

#34 WHITE

R WINCH2-SPEED

RED

BLACK

#38 LT GREEN

#34 WHITE

F WINCHFREE SPOOL

R WINCHFREE SPOOL

UL WINCHFREE SPOOL

RED

BLACK

#35 BLUE

#34 WHITE

RED

BLACK

#37 GREEN

#34 WHITE

RED

BLACK

#39 YELLOW

#34 WHITE

F WINCHFREE SPOOL

F WINCH2-SPEED

R WINCHFREE SPOOL

F WINCH2-SPEED

UL WINCHFREE SPOOL

1

PRESSURE SWITCHCONNECTIONS

VIEW B-BLH CONTROL STATION

VIEW C-C

CONTINUEDIN VIEW C-C

STOW UNUSEDCONNECTORS FRONT CONTROL PANEL

LH - SIDE REF

3 2

4

4

CONTINUEDIN VIEW B-B




UL WINCHFREE SPOOL

R WINCHFREE SPOOL

R WINCH2-SPEED

RED

BLACK

RED

BLACK

RED

BLACK

#37 GREEN

#34 WHITE

#38 LT GREEN

#34 WHITE

#39 YELLOW

#34 WHITE

F WINCH2-SPEED

RED

BLACK

RED

BLACK

#35 BLUE

#34 WHITE

#36 LT BLUE

WHITE

F WINCHFREE SPOOL

REAR CONTROL PANELRH SIDE REF

FRONT CONTROL PANELRH SIDE REF

3

2

5

2

3

3

RH CONTROL STATIONVIEW D-D


DECALS


1 7330000034 Decal - Wheel Lift 12 7330000037 Decal - Moving Parts Polycarb 23 7330000108 Decal - Jerr-Dan Nameplate 24 7330000122 Decal - Wheel Lift 25 7330000143 Decal - Made in the USA 16 7330000717 Decal - Patent 17 7330000189 Decal - Serial Number/Rating Placard 18 7330000193 Decal - Wheel Lift 29 7330000197 Decal - Jerr-Dan (Red) 2

7330000533 Decal - Jerr-Dan (White) 210 7330000202 Decal - Shock Warning 111 7330000208 Decal - Service Air 112 7330000209 Decal - Supply Air 113 7330000210 Decal - Auxiliary Air 114 7330000211 Decal - Safety Chains 115 7330000483 Decal - HDL1200/530, Red 2

7330000536 Decal - HDL1200/530, White7330000484 Decal - HDL1200/565, Red7330000537 Decal - HDL1200/565, White

16 7330000487 Decal - 60 Ton Boom Rating 217 7330000449 Decal - 50 Ton Boom Rating 218 7330000486 Decal - 37 Ton Boom Rating 219 7330000485 Decal - 24 Ton Boom Rating 220 7330000268 Decal - 22 Ton Boom Rating 221 7330000269 Decal - Lubrication 122 7330000270 Decal - Lubrication Chart 123 7330000426 Decal - Fuse Panel 124 7330000004 Pop Rivet 1025 7330000139 Decal - Checklist Reminder 126 7330000203 Decal - Shock Warning 2


DECALS

Item #25 not shown

DANGER

ELECTRICAL HAZARDPOWER DISTRIBUTION PANEL

202

WARNING

MAIN

SWITCH PANEL

LIGHT BAR

HARNESS

LEFT BODY

HARNESS

RIGHT BODY

HARNESS

HAND CONTROLLER

HAND CONTROLLER

FUNCTION

SWITCH

GROUND

MARKER

LEFT TURN

RIGHT TURN

BACK-UP

IN OUT

IN OUT

IN OUT

IN OUT

POWER TAP

A B

EE FF

C*

D

E

F

G

H

I

X

Y

Z

AA

BB*

CC*

DD

Q

R

S

T

U

V

W

30A MAXI

30A MAXI

20A MAXI

20A MAXI

2OA

15A

2OA

2OA

2OA

2OA

2OA

1OA

10A

20A

2OA

2OA

2OA

2OA

2OA

20A

15A

1OA

2OA

2OA

20A

REF:*FUSE C: LH CABINET LIGHTS*FUSE CC: RH CABINET LIGHTS*FUSE BB: AUX #3, LIGHTBAR

FUSEAA

BEACON #1RELAY #1

FUSE A

AUXHOT

AUXHOT

AUXHOT

BEACON #2RELAY #2

FUSE B

SWITCHPANELFEED

FUSEZ

FLOOD #1RELAY #3

FUSE X

FUSEH

FUSEI

FLOOD #2RELAY #4

FUSE Y

FUSEG

FUSEDD

CONTROLS:REMOTERELAY #6

FUSE Z

FUSEFFFUSE

F

MARKERRELAY #5

FUSES:D - POSTQ - LH BODYR - RH BODYS - HDBOARD

FUSEE

FUSED

AUX 2SWITCHED

HOT

REMOTECONTROL

FUSEEE

SWITCHPANELFEED

LEFT S/TRELAY #7

FUSES:E - POSTT - LH BODYU - LGHTBAR

RIGHT S/TRELAY #8

FUSES:F - POSTV - RH BODYW - LGHTBAR

KEEP C LEAR O F THIS AREA

PINCH HAZARD SAND MO VING PARTS

WARNING

A

A

B

B

USA

VIEW A-A

CAUTIONHYD FLUID LEVEL

HYDRAULIC TANKLOOKING FROM REAR

SERVICE AIRSUPPLY AIR

AUX AIR

! WARNING !SPADE ! WARNING !

SPADE

AUX AIR

SUPPLY SERVICE

122

TOWED VEHICLE MUST BECONNECTED TO TOW TRUCK BODY

WITH SAFETY CHAINS

WARNING

122

TOWED VEHICLE MUST BECONNECTED TO TOW TRUCK BODY

WITH SAFETY CHAINS

WARNING

VIEW B-B

C

C

PATENTNUMBERS

171

SERIALRATING

PATENTNUMBERS

171

SERIALRATING

VIEW C-C

51

23

10

22

21 3 915

26

2

624

724

8

14

4

12 11

13


DECALS

60 TON 2-PIECE WRECKER BOOM FLY

20 18 17 1619

5376000153- 0

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