MPL-NGS WRECKER PARTS MANUAL

MPL-NGS Wrecker Parts Manual - 5-376-000117Rev 01 - 04/11

MPL-NGS WRECKER

PARTS MANUAL

5-376-000117Rev 01 - April 01, 2011 © 2011 Jerr-Dan Corporation. All Rights Reserved.

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

www.jerr-dan.com


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.).This parts information is provided by the chassis manufacturer.

When ordering parts, please refer to your unit’s Serial Number and Model Number. This information can be found on the aluminum tag rivetedto the inside of the driver’s side toolbox 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; 5,722,810; 5,782,596; 5,839,775 and 6,315,515 B1 with other PatentsPending.

Jerr-Dan and the Jerr-Dan logo are registered trademarks 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, repro-duced or translated to another language without the express written consent of Jerr-Dan Corporation.

This manual covers the following Jerr-Dan Model:

MPL-NGS Wrecker

SERIAL NO.

MODEL NO.

MANUFACTURED BY:

JLG INDUSTRIES, INC.

1001127220-00

FOR:

THIS PAGE INTENTIONALLY LEFT BLANK


Body - Complete ...................................................................................................................... 6 - 7Left Hand Body Assembly ....................................................................................................... 8 - 9Right Hand Body Assembly ................................................................................................. 10 - 11Subframe ........................................................................................................................ 12 - 13Hydraulic Reservior ............................................................................................................. 14 - 15Worm Gear Winch & Cable Roller Guide ............................................................................ 16 - 17Worm Gear Winch & Cable Sheave Guide ......................................................................... 18 - 19Worm Gear Winch - Cable Tensioner ................................................................................. 20 - 21Mud Flap ........................................................................................................................ 22 - 23Fender Flares ....................................................................................................................... 24 - 25Light Pylon - Deck Mounted ................................................................................................. 26 - 27Light Pylon - Toolbox Mounted ............................................................................................ 28 - 29Wrecker Boom ..................................................................................................................... 30 - 31Underlift Boom - Hydraulic Grid ........................................................................................... 32 - 33Hydraulic Wheel Lift Grid .................................................................................................... 34 - 39Underlift Level Stop .............................................................................................................. 40 - 41Wired Remote Control .......................................................................................................... 42 - 43Electrical Components - Body - Standard ........................................................................... 44 - 45Electrical Components - Pylon Lights / Tunnel Wiring ....................................................... 46 - 47Electrical Components - Anti-Stall Control Module (Ford V10 Gas Engine) ....................... 48 - 49Marker and Work Lights ...................................................................................................... 50 - 51Wireless Remote Control ..................................................................................................... 52 - 53Hydraulic Components - SPR / Hose Routing (Ford) ......................................................... 54 - 57Hydraulic Components - SPR / Hose Rounting (Dodge) .................................................... 58 - 61Hydraulic Components - HLF .............................................................................................. 62 - 63Hydraulic Components - Hydraulic Wheel Lift Grid ............................................................ 64 - 65Lightbar ........................................................................................................................ 66 - 67Switch Panels ...................................................................................................................... 68 - 69Chain and Straps ................................................................................................................. 70 - 71

Decals ........................................................................................................................ 72 - 73Tunnel Tool Compartment .................................................................................................... 74 - 75Bolt-On D-Rings ................................................................................................................... 76 - 77Jump Start Kit ........................................................................................................................ 78 - 79Fold Down Lightbar Bracket ............................................................................................... 80 - 81Ball Hitch Mounting Bracket ................................................................................................. 82 - 83Self-Loading Dolly ................................................................................................................ 84 - 85Motorcycle Adapter ............................................................................................................. 86 - 87Wheel Chocks ...................................................................................................................... 88 - 89Tow Sling ........................................................................................................................ 90 - 93Recovery Sheave ................................................................................................................ 94 - 95L-Arm Spacer Storage ......................................................................................................... 96 - 97Fuel Filler ........................................................................................................................ 98 - 99

INDEX DESCRIPTION PAGE

Fifth Wheel Attachment ................................................................................................... 100 - 101Gooseneck Attachment .................................................................................................. 102 - 103Pull-Out Drawer - Tunnel Toolbox .................................................................................. 104 - 105Stone Guard - Tunnel Toolbox ........................................................................................ 106 - 107Ford Diesel 08 Exhaust Alteration ................................................................................. 108 - 109Accessory Equipment ......................................................................................................110 - 111

DESCRIPTION PAGE


BODY - COMPLETE

ITEM PART NO. DESCRIPTION QTY1 3097000643 Body Assembly LH 12 3097000644 Body Assembly RH 13 4707000343 Coverplate, Front 14 4707000344 Coverplate, LH 15 4707000345 Coverplate, RH 16 4062000695 Bar 17 4090000010 Belt 28 4090000011 Belt 29 4632000058 Moulding 4

10 7585000023 Latch 111 7949000015 Washer 1212 7115181450 Capscrew, 0.50”-13NC x 1.75” 1613 7660182601 Lockwasher, 0.50”-13NC 1614 7950180153 Flatwasher, 0.50” ID 2015 7701000063 Plug 416 8632000002 Edge Trim 1.5 ft17 7661000029 J-Nut 418 7114150818 Caprscrew, 0.31”-18NC x 1.00” 419 7413000002 Nutsert, 0.25”-20NC 420 7114140618 Capscrew, 0.25”-20NC x 0.75” 221 4811001177 Coverplate 122 7950140000 Lockwasher, 0.25” ID 223 7115140650 Capscrew, 0.25”-20NC x 0.75” 224 7493000003 Rubber Grommet 1


BODY - COMPLETE

1

2

3

45

6

8

7

7

9

01

11

21

21

21

11

11

11

31

3131

31

31

41

41

41

41

1141

21

21

41

21

51

51 61

71

02

81

9132

91

12

22

42


LEFT HAND BODY ASSEMBLY

ITEM PART NO. DESCRIPTION QTY

1 3097000637 Deck Weld LH 12 3686000054 Door 13 7118160516 Capscrew, 0.38”-16NC x 0.62” 24 7660162301 Locknut, 0.38”-16NC 25 7585000012 Latch 16 7796000084 Gasket 17 7114080418 Capscrew, #8-32NC x 0.50” 48 7660082500 Locknut, #8-32NC 49 4632000050 Seal, Toolbox Door 1

10 7571000002 Taillight Housing 111 7413000013 Fastener 612 4178000746 Bracket 113 7115160850 Capscrew, 0.38”-16NC x 1.00” 314 7660162601 Locknut, 0.38”-16NC 315 7950160161 Flatwasher, 0.38” ID 616 4679000252 Mat 1


LEFT HAND BODY ASSEMBLY

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2

3

4

5 6

7

8

9

01

11

21

31

41

51

51

61



RIGHT HAND BODY ASSEMBLY

1 3097000638 Deck Weld LH 12 3686000054 Door 13 7118160516 Capscrew, 0.38”-16NC x 0.62” 24 7660162301 Locknut, 0.38”-16NC 25 7585000012 Latch 16 7796000084 Gasket 17 7114080418 Capscrew, #8-32NC x 0.50” 48 7660082500 Locknut, #8-32NC 49 4632000050 Seal, Toolbox Door 1

10 7571000002 Taillight Housing 111 7413000013 Fastener 612 4178000745 Bracket 113 7115160850 Capscrew, 0.38”-16NC x 1.00” 314 7660162601 Locknut, 0.38”-16NC 315 7950160161 Flatwasher, 0.38” ID 616 4679000252 Mat 1


RIGHT HAND BODY ASSEMBLY

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2

3

4

56

7

8

9

01

1121

31

41

51

51

61



Ford F-Series1 3868000288 Subframe Weld 12 Not Required3 4706005896 Plate 14 4706005897 Plate 15 Not Required6 Not required7 7115181650 Capscrew, 0.50”-13NC x 2.00” 208 7950180153 Flatwasher, 0.50” ID 209 7660182601 Locknut, 0.50”-13NC 20

10 4706004919 Plate

Ford F-Series with 19,000 lb GVWR1 3868000288 Subframe Weld 12 4706005898 Plate 23 4706005896 Plate 14 4706005897 Plate 15 Not Required6 Not required7 7115181650 Capscrew, 0.50”-13NC x 2.00” 208 7950180153 Flatwasher, 0.50” ID 209 7660182601 Locknut, 0.50”-13NC 20

10 4706004919 Plate 2

GM C3500 / 45001 3868000288 Subframe Weld 12 Not Required3 4706005897 Plate 14 4706005897 Plate 15 4706005634 Plate 26 4706005633 Plate 27 7115181650 Capscrew, 0.50”-13NC x 2.00” 208 7950180153 Flatwasher, 0.50” ID 209 7660182601 Locknut, 0.50”-13NC 20

10 4706004919 Plate 2

SUBFRAME


Dodge (60” CA)1 3868000288 Subframe Weld 12 Not Required3 4706005897 Plate 14 4706005897 Plate 15 4706005634 Plate 46 4706005633 Plate 47 7115181650 Capscrew, 0.50”-13NC x 2.00” 208 7950180153 Flatwasher, 0.50” ID 209 7660182601 Locknut, 0.50”-13NC 20

10 4706004919 Plate 2

Dodge (84” CA)1 3868000288 Subframe Weld 12 Not Required3 4706005897 Plate 14 4706005897 Plate 15 Not Required6 4706005633 Plate 47 7115181650 Capscrew, 0.50”-13NC x 2.00” 208 7950180153 Flatwasher, 0.50” ID 209 7660182601 Locknut, 0.50”-13NC 20

10 4706004919 Plate 2


SUBFRAME

10

7

8

32

9

8

7

9

9

2

4

8

7

8

7

1

9

6

10

5

5

5

5

6

6


HYDRAULIC RESERVOIR


1 3750000061 Reservoir Assembly 12 7183000008* Filler Cap 13 7430000010* Tank Filter 14 7701000026* Magnetic Plug 15 7115181064 Carriage Bolt, 0.50”-13NC x 1.25” 46 7950180153 Flatwasher, 0.50” ID 47 7660182601 Locknut, 0.50”-13NC 4

* also available in Reservoir Assembly, P/N 3750000061


HYDRAULIC RESERVOIR

1

4

3

2

5

5

6

7

7

7

6

6


WORM GEAR WINCH & CABLE ROLLER GUIDE


1 7970000150+ Winch - 8,000 lb Worm Gear 12 7626000014 Orbit Motor 13 7115181250 Capscrew, 0.50”-13NC x 1.50” 24 7950180400 Lockwasher, 0.50” ID 25 3178000508 Bracket Weld 16 7115160850 Capscrew, 0.38”-16NC x 1.00” 27 7950160000 Lockwasher, 0.38” ID 88 7950160162 Flatwasher, 0.38” ID 89 7115161250 Capscrew, 0.38”-16NC x 1.50” 6

10 7115181450 Capscrew, 0.50”-13NC x 1.75” 411 7950180153 Flatwasher, 0.50” ID 812 3178000511* Bracket Weld 113 4912000325* Tube 214 4912000423* Tube 115 4691000568* Pin 216 4691000567* Pin 117 7754000022* Retaining Ring 618 7115181264 Carriage Bolt, 0.50”-13NC x 1.50” 419 7660182601 Locknut, 0.50”-13NC 420 7248000092 Winch cable, 0.38 dia x 75’ 1

+ Refer to manufacturer’s manual for winch parts list. * also available in Cable Guide Assembly, P/N 3249000039


WORM GEAR WINCH & CABLE ROLLER GUIDE

Item #20, Winch Cable, not shownStandard Cable Guide, shown

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2

3

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5

6

7

8

9

9

7

8

6

9

7

8

7

9

10

11

10

7

8

1314

15

17

1717

17

1717

18

11

19

16

12

For Tow Sling Cable Guide parts, refer to Tow Sling pageFor Recovery Sheave Cable Guide parts, refer to Recovery Sheave page


WORM GEAR WINCH & CABLE SHEAVE GUIDE


1 7970000150+ Winch - 8,000 lb Worm Gear 12 7626000014 Orbit Motor 13 7115181250 Capscrew, 0.50”-13NC x 1.50” 24 7950180400 Lockwasher, 0.50” ID 25 3178000508 Bracket Weld 16 7115160850 Capscrew, 0.38”-16NC x 1.00” 27 7950160000 Lockwasher, 0.38” ID 88 7950160162 Flatwasher, 0.38” ID 89 7115161250 Capscrew, 0.38”-16NC x 1.50” 6

10 7115181450 Capscrew, 0.50”-13NC x 1.75” 411 7950180153 Flatwasher, 0.50” ID 812 3170000490 Boom Sheave Weld 113 4178000876 Bracket 114 7115181464 Carriage Bolt, 0.50”-13NC x 1.75” 215 7115181264 Carriage Bolt, 0.50”-13NC x 1.50” 216 7660182601 Locknut, 0.50”-13NC 417 3512900006 Sheave Shupport Weld 118 3510900068 Cable Guide Weld 119 3691000002 Pin 120 7754000005 Retaining Ring 121 7809000001 Sheave 122 4209000019 Bushing 223 7754000006 Retaining Ring 124 7440030000 Grease Fitting 125 7248000092 Winch cable, 0.38 dia x 75’ 1

+ Refer to manufacturer’s manual for winch parts list.


WORM GEAR WINCH & CABLE SHEAVE GUIDE

12

3

4

67

8

87 9

9

7

8

11

01

5 41

31

02

7132

21

42

91

22

22

81

12

11

61

69

51

4151

9

Item #25, Winch Cable, not shown

For Tow Sling Cable Guide parts, refer to Tow Sling pageFor Recovery Sheave Cable Guide parts, refer to Recovery Sheave page



1 3017000003 Angle Weld LH 12 3017000002 Angle Weld RH 13 3706000099 Pressure Plate Weld 14 7843000004 Spring 25 7950180161 Flatwasher, 0.50” ID 46 7660182600 Locknut, 0.50”-13NC 27 7115161050 Capscrew, 0.38”-16NC x 1.25” 48 7950150161 Flatwasher, 0.31” ID 89 7660162601 Locknut, 0.38”-16NC 4

WORM GEAR WINCH - CABLE TENSIONER


1

2

3

4

4

5

5

5

5

6

6

7

7

88

8 8

99

WORM GEAR WINCH - CABLE TENSIONER


MUD FLAP


1 7638000003 Mud Flap 22 4706001123 Plate 23 7111151010 Capscrew, 0.31”-18NC x 1.25” 84 7950150161 Flatwasher, 0.31” ID 165 7950150000 Lockwasher, 0.31” ID 86 7660150000 Hex Nut, 0.31”-18NC 8


MUD FLAP

1

2

4

3

34

1

2 43

4

3

45

6

65

4


FENDER FLARES

ITEM PART NO. DESCRIPTION QTY1 7415000035 Fender Flare - 1.62” ( Chevy/GMC) 2

7415000036 Fender Flare - 3.50” (Ford & Dodge) 28495000001 Lip Guard (Other chassis as Required) 10ft

2 7115140650 Capscrew, 0.25”-20NC x 0.75” 183 7950140143 Flatwasher, 0.25” ID 184 7660142601 Locknut, 0.25”-20NC 18


FENDER FLARES

1

1

4

3

2


LIGHT PYLON - DECK MOUNTED


1 3509570121 Light Pylon Weld - 37” 13509570127 Light Pylon Weld - 34”

2 7796000101 Gasket 23 7949000058 Washer, 0.53” ID 44 7115181450 Capscrew, 0.50”-13NC x 1.75” 45 7950180161 Flatwasher, 0.50” ID 4


LIGHT PYLON - DECK MOUNTED

1

2

3

4

5


LIGHT PYLON - TOOLBOX MOUNTED


1 3509570106 Light Pylon Weld - 28” 13509570111 Light Pylon Weld - 41.50”

2 4263000689 Channel 13 4314000102 Cover (28” Pylon) 2

4314000103 Cover (41.50” Pylon)4 7796000091 Gasket 25 7115181650 Capscrew, 0.50”-13NC x 2.00” 46 7950180161 Flatwasher, 0.50” ID 87 7660182601 Locknut, 0.50”-13NC 48 7114140818 Capscrew, 0.25”-20NC x 1.00” 89 7950140143 Flatwasher, 0.25” ID 20

10 7413000002 Nutsert, 0.25”-20NC 811 7114140618 Capscrew, 0.25”-20NC x .75” 1212 7661000019 U-Nut, 0.25”-20NC 1213 7949000058 Washer, 0.53” ID 4


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2

3

4

4

5

6

5

6

6

7

6

77

6

89

8 9

8 9

01

01

01

0111

9

119

21

21

31

31

LIGHT PYLON - TOOLBOX MOUNTED


WRECKER BOOM


1 3170000446 Knee Boom Weld 12 7320000080 Cylinder Assembly 13 3691000280 Pin Weld 14 3691000278 Pin Weld 25 7115161050 Capscrew, 0.38”-16NC x 1.25” 26 7950160000 Lockwasher, 0.38” ID 37 7950160161 Flatwasher, 0.38” ID 38 7115160824 Capscrew, 0.38”-16NC x 1.00” 19 7082000044* Bearing 2

* also available in Knee Boom Weld, P/N 3170000446


WRECKER BOOM

1

2

3

4

4

5

6

7

5

678

6

7

99


UNDERLIFT BOOM - HYDRAULIC GRID

ITEM PART NO. DESCRIPTION QTY1 3170000415 Base Boom Weld 12 3170000346 Fly Boom Weld 13 7320000081 Cylinder Assembly 14 4691000278 Pin 25 4691000279 Pin 16 7115160824 Capscrew, 0.38”-16NC x 1.00” 37 7950160000 Lockwasher, 0.38” ID 38 7950160161 Flatwasher, 0.38” ID 39 4691000308 Pin 1

10 7754000056 Snap Ring 211 7082000043+ Bearing 212 7320000077* Cylinder Assembly 113 4691000307 Pin 114 7754000019 Retaining Ring 215 7209000030^ Bushing 116 4679000046 Wear Pad 117 4017001502 Angle 218 4679000213 Wear Pad 219 7785161274 Set Screw, 0.38”-16NC x .75” 420 7104150627 Capscrew, 0.31”-24NF x .75” 421 7950150000 Lockwasher, 0.31” ID 422 7950150161 Flatwasher, 0.31” ID 423 7189000023 Bumper 124 7114141018 Capscrew, 0.25”-20NC x 1.25” 225 7950140143 Flatwasher, 0.25” ID 426 7660142604 Locknut, 0.25”-20NC 2

+ also available in Base Boom Weld, P/N 3020000415^ also available in Fly Boom Weld, P/N 3170000346* Service Seal Kit, P/N 9577820242


UNDERLIFT BOOM - HYDRAULIC GRID

1

2

3 4

5

4

67

8

6

7

8

67

8

901

01 11

1121

31

41

61

71

81

8171

91

91

0212

22

32

5141

62


HYDRAULIC WHEEL LIFT GRID


1 4691000198^ Pin 12 4949000047^ Washer, 2.84” ID 23 7754000024^ Retaining Ring 14 3484000078^ Grid Weld 15 7320000064^ Cylinder Assembly 26 3691000229^ Pin Weld 47 7115151023^ Capscrew, 0.31”-18NC x 1.25” 68 7660152601^ Locknut, 0.31”-18NC 69 part of item #5

10 3592000052^ Link Weld 211 3592000051^ Link Weld 212 4706003497^ Plate 213 7754000022^ Retaining Ring 414 part of item #515 7440030000^ Grease Fitting 116 7701000007^ Plug Button 117 3691000230^ Pin Weld 218 3020000124^ Arm Weld LH 119 3020000125^ Arm Weld RH 120 8411080091^ L-Arm Spacer 221 7082000027# Bearing 422 7082000026*+ Bearing 1023 4314000189^ Coverplate 224 7114140518^ Capscrew, 0.25”-20NC x .62” 425 7785140400^ Set Screw, 0.25”-20NC x .25” 226 7274000086^ Clamp Half 427 7274000039^ Clamp Cover 228 7115151250^ Capscrew, 0.31”-18NC x 1.50” 429 7950160000^ Lockwasher, 0.38” ID 230 4619000013^ Hydraulic Manifold 131 7912000184^ Tube Assembly 432 7445040443^ Adapter 4


33 4064000052^ Bar 134 4831000095^ Spacer 135 7843000037^ Compression Spring 136 7786000009^ Set Screw, 0.75”-16NF x 1.50” 137 4706004066 Plate LH 138 4706004067 Plate RH 139 7189000019 Rubber Bumper 240 7114140618 Capscrew, 0.25”-20NC x .75” 241 7950140143 Flatwasher, 0.25” ID 1842 7114140427 Capscrew, 0.25”-20NC x .50” 443 3619000001 Manifold Weld 244 7445040445 Elbow 445 7115140850 Capscrew, 0.25”-20NC x 1.00” 446 7660142604 Locknut, 0.25”-20NC 1247 7592000004 Swivel Link 248 7843000031 Extension Spring 249 4706003501 Plate 250 7719000004 Roller 251 7691000040 Clevis Pin 252 7691000042 Cotter Pin 253 7912000174 Tube Assembly 254 7274000073 Hose Clamp 855 7950160153 Flatwasher, 0.38” ID 256 7660162604 Locknut, 0.38”-16NC 2

# also available in Arm Weldments, P/N 3020000124 & 3020000125* quantity of 1 also available in each of Arm Weldments, P/N 3020000124 & 3020000125

+ quantity of 8 also available in Link Weldments, P/N 3592000052^ also available in Grid Assembly, P/N 3484000079


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2

2

3

4

66

7

8

7

11

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13

13

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5 22

9

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10



17

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8

18

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2728

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2829

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4141

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43 44

44

45

45

4146

47

48

4950

51

52

53

5441

46

54

41

46

54

5556



UNDERLIFT LEVEL STOP


1 4178000709 Bracket 12 4178000705 Bracket 13 7870000126 Proxi Switch 24 7346000261 Controller 15 7552000367 Lift Cyl Switch to Controller Harness 16 7552000368 Tilt Cyl Switch to Controller Harness 17 7114100618 Capscrew, #10-24NC x 0.75” 28 7114100818 Capscrew, #10-24NC x 1.00” 29 7114100518 Capscrew, #10-24NC x 0.63” 4

10 7950100003 Lockwasher, 0.19” ID 411 7950100103 Flatwasher, 0.19” ID 812 7950100163 Flatwasher, 0.19” ID 813 7661000056 Weld Nut, #10-24NC 214 7660102604 Locknut, #10-24NC 415 7894000042 Tie Strap 416 5526000553 Tie Strap 1017 7894000004 Tie Strap 3


UNDERLIFT LEVEL STOP

Items #16 & #17, Tie Straps, not shown 2 of item #15, Tie Strap, not shown

SSENRAH ETOMER

4

5

6

3

TFIL MOOBREDNILYC

TLIT L/WEDNILYC R

3

47

41

2

31

51

513

9

0111

1141

1

8

9

3

0111

811

21

3121

11


WIRED REMOTE CONTROL


1 7552000365 Control Valve to Subframe Harness 12 7295000062 Hand Controller - 8 function (w/o winch) 1

7295000061 Hand Controller - 10 function(w/ winch)3 4706003402 Plate 14 7790100856 Screw, #10 x 0.50” 35 7740000003 Relay 16 7345001710 Tab 27 7345001714 Terminal 18 7345221702 Terminal 19 7346000039 Tubing 12in

10 8977500100 Wire #16 ga 36in11 8597650002 Wire Loom 36in12 7870000092 Toggle Switch 113 7560000004 Switch Boot 114 7935000364 Valve Dump with Relief (PTO Units Only)


WIRED REMOTE CONTROL

30

85

86

87

CAB - SUBFRAME HARNESS

AB

CD

EFA

BC

DE

F

ABCDEF

TO SWITCH

PANEL

WINCH IN

GRID OPEN

UNLOADER

VALVE

CONTROLS

BOOM TILT DN

BOOM LIFT DN

BOOM IN

RED

BOOM OUT

BOOM LIFT UP

BOOM TILT UP

GRID CLOSE

WINCH OUT

C

O

N

T

R

O

L

V

A

L

V

E

12V IGNITION

10 A

CLUTCH PUMP

12V BATTERY

+

-

1

2

3

4

5

4

FUSE HOLDER

SUPPLIED WITH

CLUTCH PUMP

6

9

9

6

9

10

11

7

9

7

910

11

8

9

12

13

A

A

VIEW A-A

12

13

B B

UNLOADER

VALVE BANK

CONTROL HARNESS

7-552-000365

VIEW B-B14


ELECTRICAL COMPONENTS - BODY - STANDARD


1 7552000292 Cab to Subframe Harness 12 7552000416 LH Body Harness 13 7552000417 RH Body Harness 14 7457000004 Circuit Breaker - 50 amp 15 7792000001 Screw, #10 x .75” 26 8977530200 Wire 10ga 36in7 8597650002 Convoluted Wire Loom 36in8 7345211902 Terminal 19 7345221902 Terminal 1

10 7346000039 Heat Shrink Tubing 24in11 7111141050 Capscrew, 0.25”-20NC x 1.25” 412 7950140141 Flatwasher, 0.25” ID 613 7660142600 Locknut, 0.25”-20NC 414 7577000194 Wiring Connector Kit - Chassis 115 7291000010 4-Way Receptacle 116 7111140613 Capscrew, 0.25”-20NC x .75” 217 7950140000 Lockwasher, 0.25” ID 218 7413000002 Nutsert, 0.25”-20NC 219 7894000042 Tie Strap 3220 7011000003 Back-up Alarm 121 7796000096 Gasket 1


Item #19, Tie Strap, not shown.

ELECTRICAL COMPONENTS - BODY - STANDARD

AF EGH

A EFGH

F EGH

CBA

BC A

YRETTAB V21

+

-

LORTNOC2 NOCAEB1 NOCAEB

NAD-RREJ

KROWPU

KROWND

A B C D EA B C D E

E D C B A

F

E

G

HH

G

E

F

YRETTAB V21

+

-

A

B A

BA

B

A

B A

BA

B

A

LIATED

11

469

81

1

4111

2

3

02

61

51

7181

12

112131

2131

2131

01 75

01

NOLYP OTSSENRAH

LORTNOC OTSSENRAH


ELECTRICAL COMPONENTS - PYLON / TUNNEL TOOL COMPARTMENT WIRING


1 1 7552000293 Harness (body mounted pylon) 17552000295 Harness (tunnel mounted pylon)

2 7346000039 Heat Shrink Tubing 10 in3 7894000042 Tie Strap (body mounted pylon) 6

7894000042 Tie Strap (tunnel mounted pylon) 34 5526000553 Tie Strap (body mounted pylon) 2

5526000553 Tie Strap (tunnel mounted pylon) 85 7590000274 Dome Light (tunnel mounted pylon) 26 7790100856 Screw, #10 x .50” (tunnel mounted pylon) 47 7661000047 Nylon Nut, #8 (tunnel mounted pylon) 48 7870000115 Pin Switch (tunnel mounted pylon) 29 7413000013 Fastener (tunnel mounted pylon) 2

10 7493000011 Grommet (tunnel mounted pylon) 1


ELECTRICAL COMPONENTS - PYLON / TUNNEL TOOL COMPARTMENT WIRING

Item #3, Tie Strap, not shownItem #4, Tie Strap, not shown

AB

AB

A BA B

NOLYP THGIL DETNUOM YDOB

NOLYP THGIL DETNUOM NEMTRAPMOC LOOT LENNUT

1

EMARFBUS-BAC OTSSENRAH

EMARFBUS-BAC OTSSENRAH

1

01

1

85 5 867

67

99

2

2


ELECTRICAL COMPONENTS - ANTI-STALL CONTROL MODULE (FORD V10 GAS ENGINE)


1 7552000292 Anti-Stall Control Module Harness 12 3295000003 Anti-Stall Control Module 13 7935000361 Proportional Dump Valve 14 7274000040 Clamp 15 7114060810 Capscrew, #6-32NC x 1.00” 16 7950100163 Flatwasher, #10 ID 17 7660062604 Locknut, #6-32NC 18 8977010400 Wire, #16 GA Yellow 2ft9 7345001710 Terminal 1

10 7345001714 Terminal 211 7346000039 Heat Shrink Tubing 6in


ELECTRICAL COMPONENTS - ANTI-STALL CONTROL MODULE (FORD V10 GAS ENGINE)

9

11

8

AB

C

BROWN/BLACK

WHITE/RED

RED/WHITE

AB

CBROWN/BLACK

RED/WHITE

WHITE/RED

WHITE YELLOW

WHITE/RED

BROWN/BLACK

BROWN/BLACK

COIL -

AB

C

AB

C

CAB - SUBFRAME HARNESS REFCONTROL HARNESS REF

YELLOW

WHITE/REDWHITE/BLUE3.3 OHM 50W

BRN/BLK

WHT/YEL

WHT/RED

TACH

A A

TO AUXILARY TACHOMETER CIRCUIT

BLUE WIRE UNDER DASH BOARD,

ABOVE EMERGENCY BRAKE PEDAL

VIEW A-ALOCATED UNDER HOOD

OF CHASSIS CAB.

BBRN/BLK

WHT/YEL

WHT/RED

TACH

DETAIL B-B

10

11

10

11

2

2

3

INSTALL ITEM #3 INTO

THE RVI PORT ON

CONTROL VALVE

4

5

6

7

2

1


MARKER AND WORK LIGHTS


1 7493000029 Grommet 42 7590000380 Stop/Tail/Turn Light (Incandescent) 2

7590000381 Stop/Tail/Turn Light (LED)3 7590000379 Backup Light 24 7493000009 Grommet 25 7590000047 Marker Light - Red (Incandescent) 2

7590000238 Marker Light - Red (LED)6 7590000207 Light Mount 27 7493000009 Pop Rivet 48 7590000385 Marker Light - Amber (Incandescent) 2

7590000339 Marker Light - Amber (LED)9 7178000025 License Plate Bracket 1

10 7590000105 License Plate Light 111 7590000193 DOT ID Light (incandecsent) 1

7590000316 DOT ID Light (LED)12 7950140143 Flatwasher, 0.25” ID 213 7114141018 Capscrew, 0.25”-20NC x 1.25” 214 7660142601 Locknut, 0.25”-20NC 215 4178000784 Bracket 216 7590000185 Lower Work Light 217 7590000144 Upper Work Light 218 7949000015 Washer 219 7552000404 Harness (LED lights only) 220 7759000006 Pop Rivet (LED lights only) 4


6

8

019

5

4

1

2

1

3

61

*

*

81

71

11

3121

51

41

31

2141

61

7

02

91

MARKER AND WORK LIGHTS

* - existing hardware from body


WIRELESS REMOTE CONTROL


1 7295000116 Wireless Controller 8 Function, 1 (w/o winch)

7295000117 Wireless Controller 10 Function, (w/ winch)

2 4636000038 Mounting Plate 13 7114100518 Capscrew, #10-24NC x 0.62” 44 7660102604 Locknut, #10-24NC 45 7552000384 Controller to 4 Sect Valve Harness, 1

(w/o winch)7552000386 Controller to 5 Section Valve Harness,

(w/ winch)6 5526000553 Tie Strap 57 9295310045^ Transmitter, 8 Function (w/o winch) 1

9295310046* Transmitter, 10 Function (w/ winch)8 9295310029*^ Rubber Boot 19 9295310030*^ Belt Clip 1

10 7075000003 Battery, 9V 111 9295310049^ Receiver, 8 Function (w/o winch) 1

9295310050* Receiver, 10 Function (w/ winch)

* included in Wireless Controller 10 Func, P/N 7295000116 ^ included in Wireless Controller 8 Function, P/N 7295000117


1

2

3

3

4

4 EXISTING FRONT

MOUNTING

HARDWARE OF THE

HYDRAULIC OIL

RESERVOIR

CAB - SUBFRAME HARNESS

ABCDEFABCDEF

ABCDEF

ABCDEF ABCDEF

SUBFRAME - REMOTE HARNESS

1

11

3

4

2

5

OPEN

CLOSE

(TRANSMITTER)

7

8

9

1

10

WIRELESS REMOTE CONTROL

Item #6, Tie Strap, not shown10 Function Remote Shown


HYDRAULIC COMPONENTS - SPR / HOSE ROUTING (FORD)


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

1 7430000003 Filter Assembly 12 4178000719 Bracket 13 7114140650 Capscrew, 0.25”-20NC x 0.75” 24 7950140003 Lockwasher, 0.25” ID 25 7950140143 Flatwasher, 0.25” ID 26 7115181064 Carriage Bolt, 0.50”-13NC x 1.25” 17 7950180161 Flatwasher, 0.50” ID 18 7660182601 Locknut, 0.50”-13NC 19 7443000066 Fitting 1

10 7470000002 Gauge 111 7443000319 Fitting 112 7443000374 Fitting 113 7274000122 Clamp 414 4570000345 Hose - Return 115 4570000344 Hose - Return 116 See Note 1 Hose - Pressure 117 See Note 1 Hose - Supply 118 7443000013 Barb Fitting 119 7274000002 Clamp 220 7274000076 Cast Frame Clamp 321 7785152420 Set Screw, 0.31”-18NC x 1.50” 322 7115151050 Capscrew, 0.31”-18NC x 1.25” 623 7950150161 Flatwasher, 0.31” ID 1324 7660152601 Locknut, 0.31”-18NC 1325 7274000105 Clamp 726 7274000042 Clamp 727 7115150864 Carriage Bolt, 0.31”-18NC x 1.00” 228 7443000426 Barb Fitting 129 7445081246 Fitting 130 7819000013 Sleeve 431 7660150000 Nut, 0.31”-18NC 532 7274000071 Clamp 333 7431000001^ Filter Element 1

^ Also available in Filter Assembly, P/N 7430000003



0212

22

52

6222

62

FER SECALP 2-PYT

52

22

12 02

121

01

81

61

71

51

41

11

A

D

BC

31

31

3

16

2

A

A

9

13

13

31

31

91

52

723242

"A" TNIOP PMALC "B" TNIOP PMALCFER SECALP 1-PYT FER SECALP 2-PYT FER SECALP 1-PYT

"C" TNIOP PMALC "D" TNIOP PMALC

3242

423242

42

45

78

A-A NOITCES33



A

BCDE

02 03

ELDDIM OT SESOH ERUCESTSAC GNISU TNUOM YDOB

)02# METI( PMALC

22

6182

7191

0271 0261

61

71 91HCTULC EICNUM ROTANETLA ELGNIS DROF 8002SAG ROF LACIPYT .NWOHS NOITALLATSNI PMUP

.SNOITALLATSNI ROTANETLA LAUD DNA

B LIATED

A LIATED

C LIATED D LIATED3242

1222421323

92

92

82

122242526213

1222425213

8191


HYDRAULIC COMPONENTS - SPR / HOSE ROUTING (DODGE)


1 7430000003 Filter Assembly 12 4178000719 Bracket 13 7114140650 Capscrew, 0.25”-20NC x 0.75” 24 7950140003 Lockwasher, 0.25” ID 25 7950140143 Flatwasher, 0.25” ID 26 7115181064 Carriage Bolt, 0.50”-13NC x 1.25” 17 7950180161 Flatwasher, 0.50” ID 18 7660182601 Locknut, 0.50”-13NC 19 7443000066 Fitting 1

10 7470000002 Gauge 111 7443000319 Fitting 112 7443000374 Fitting 113 7274000122 Clamp 414 4570000345 Hose - Return 115 4570000344 Hose - Return 116 See Note 1 Hose - Pressure 117 See Note 1 Hose - Supply 118 7443000412 Elbow Barb 119 7274000002 Clamp 220 7274000076 Cast Frame Clamp 421 7785152420 Set Screw, 0.31”-18NC x 1.50” 422 7115151050 Capscrew, 0.31”-18NC x 1.25” 623 7950150161 Flatwasher, 0.31” ID 724 7660152601 Locknut, 0.31”-18NC 1325 7274000105 Clamp 526 7274000042 Clamp 727 7115150864 Carriage Bolt, 0.31”-18NC x 1.00” 328 4706003844 Plate 129 7443000013 Fitting 430 7660150000 Nut, 0.31”-18NC 431 7274000071 Clamp 132 7431000001^ Filter Element 1

^ Also available in Filter Assembly, P/N 7430000003Note 1: Varies depending on chassis, transmission and PTO type. Consult factory for part numbers.



A

A

FER SECALP 2-PYT"A" TNIOP PMALC "B" TNIOP PMALC

FER SECALP 1-PYT FER SECALP 2-PYT FER SECALP 1-PYT"C" TNIOP PMALC "D" TNIOP PMALC

A-A NOITCES1

21

01

81

61

71

51

41

11

A

D

B

C

31

31

931 31

91

0212

22

52

62

32

62

62

5203

72

52723242

324203

4242

3242

3

16

2

45

78

23



A

B C D E

B LIATEDA LIATED

C LIATEDD LIATED

E LIATED

92

71

61

02

61

91

122242526203

2202324292

12223242526282

32426272

32426272

71

8191



1 7935000311 Valve Assembly 17935000363 Valve Assembly (Ford V10 Gas Engines

with Anti-Stall Control)2 7115150850 Capscrew, 0.31”-18NC x 1.00” 43 7950150000 Lockwasher, 0.31” ID 44 7950150161 Flatwasher 85 7445080845 Elbow 16 7443000435 Fitting 17 7443000436 Fitting 18 7445060643 Adapter 29 7935000308 Counterbalance Valve 1

10 7114151650 Capscrew, 0.31”-18NC x 2.00” 411 7660152601 Locknut, 0.31”-18NC 412 4567120056 Hose Assembly 213 7445060645 Elbow 614 7445060647 Tee 215 7912000080 Tube Assembly 116 7912000291 Tube Assembly 117 4567120087 Hose Assembly 218 7912000292 Tube Assembly 119 7912000078 Tube Assembly 120 4567120118 Hose Assembly 221 7445060625 Fitting 422 4570000305 Hose 223 4567120112 Hose Assembly 224 7570000304 Hose 225 7445040443 Adapter 226 7443000114 Plug 127 4570000343 Hose (w/ winch) 2

Not Required (w/o winch)28 7445081045 Elbow (w/ winch) 2

Not Required (w/o winch)

HYDRAULIC COMPONENTS - HLF


29 4819000008 Hose Sleeve 130 7445060843 Adapter (w/ winch) 10

7445060843 Adapter (w/o winch) 831 7935000354 Counterbalance Valve 132 4495000011 Guard 133 Not Required (w/ winch)

7443000048 Plug (w/o winch) 234 7819000005 Sleeve 3 in35 5526000553 Tie Strap 3


HYDRAULIC COMPONENTS - HLF

iItem #29, Hose Sleeve, not shownItem #34, Sleeve, not shownItem #35, Tie Strap, not shown

GR

ID, P

OR

T B4

TILT

, PO

RT

B3

LIFT

, PO

RT

B2

EXT,

PO

RT

B1

TILT

, PO

RT

A3

LIFT

, PO

RT

A2

EXT,

PO

RT

A1

GR

ID, P

OR

T A

4

WIN

CH

, PO

RT

A5W

INC

H, P

OR

T B5

NRUTERFER

ERUSSERPFER

12

3

12

3

- STENOPMOC CILUARDYH OT REFERDIRG TFIL LEEHW CILUARDYH

PMUPFER

RHCNIW FE

REDNILYC TFILECNEREFER REDNILYC TLIT

ECNEREFER

REDNILYC TXEECNEREFER

82

82

72

72

21

21 41 3151

01411

93131 61

02

5

76

1

03 02

32

32 12

12

42

42

52

52 62

12

12

22

2201

411

3113

9131

8

417181

31

71

23

234

8

33


HYDRAULIC COMPONENTS - HYDRAULIC WHEEL LIFT GRID


1 4570000210 Hose Assembly 22 7445040445 Elbow 63 4570000211 Hose Assembly 24 4570000212 Hose Assembly 2


HYDRAULIC COMPONENTS - HYDRAULIC WHEEL LIFT GRID

RH GRIDCYLINDER

1

1

2

2

2

2

2

2

3

3

4

4

LH GRIDCYLINDER

TOP TUBE

TOP TUBE

CROSSBARMANIFOLD

U/L BASE BOOMMANIFOLD

U/L BASE BOOMMANIFOLD

SEE HYDRAULICCOMPONENTS -STANDARD


LIGHTBAR


1 7590000307 Lightbar, Amber (Std) 17590000395 Lightbar, Amber (LED) 17590000336 Lightbar, Amber (Strobe) 1

2 4178000402 Bracket 23 7115181050 Capscrew, 0.50”-13NC x 1.25” 24 7660182601 Locknut, 0.50”-13NC 2


LIGHTBAR

1

2

2

3

4

4

3

1

1

1

1

1

1


SWITCH PANELS

ITEM PART NO. DESCRIPTION QTY1 4178000403 Bracket - 1 Function Switch Panel 12 7870000083 Switch 13 7870000113 Switch Panel - 3 Function, Mini In-Dash 14 7870000100 Switch Panel - 3 Function, In-Dash 15 7870000106 Switch Panel - 5 Function, In-Dash 16 7870000053 Switch Panel - 3 Function, Under-Dash 17 7870000063 Switch Panel - 5 Function, Under-Dash 18 7870000089 Switch Panel - 5 Function 19 7870000134 Switch Panel - 5 Function, Under-Dash 1

10 7870000137 Switch Panel - 5 Function, Under-Dash 1


SWITCH PANELS

NOCAEB DOOLF .XUA

OTPDEGAGNE

O

NOCAEB DOOLF .XUA

O O

OTPDEGAGNE

O

NOCAEB

O O

DOOLF .XUA

O

.XUA

O

.XUA

OTPDEGAGNE

NOCAEB DOOLF .XUA .XUA.XUA

LORTNOC2 NOCAEB1 NOCAEB KROWND

KROWPU

.XUADOOLFNOCAEB

OTPDEGAGNE

3

4 5

876

21

.XUA.XUA

DEGAGNEOTP

DOOLF .XUANOCAEB

DEGAGNEOTP

DOOLF 1.XUA

NOCAEB

9 01


CHAIN AND STRAPS

ITEM PART NO. DESCRIPTION QTY1 7894000061* Tire Tie-Down Strap 22 7894000059* Tire Tie-Down Strap Choker 23 7894000028* Tire Tie-Down Strap Ratchet 24 7561000024* Tire Ratchet Hook 25 7894000034 Wheel Lift Tire Strap 26 7262000040 Wheel Lift Chain 27 7115181050 Capscrew, 0.50”-13NC x 1.25” 28 7660182601 Locknut, 0.50”-13NC 29 7894000065+ Tie-Down Strap (Motorcycle) 2

10 7894000064+ Front Tire Tie-Down Strap (Motorcycle) 111 7894000066+ Rear Tie-Down Strap (Motorcycle) 212 7894000067+ Front Tie-Down Strap (Motorcycle) 2

+ also available in Tie-Down Kit Motorcycle, P/N 7577000375* also available in Wheel Lift Tie-Down Strap & Ratchet Kit, P/N 7577000367


CHAIN AND STRAPS

CHAIN BOXES ON SIDES OF KNEE BOOM

1

3

4

5

6

678

9

2

10

11

12


DECALS

ITEM PART NO. DESCRIPTION QTY1 7330000546 Decal - Winch Cable Wrap 12 7330000717 Decal - Patent 13 7330000034 Decal - Wheel Lift 14 7330000534 Decal - Jerr-Dan Logo 25 7330000287 Decal - Serial-Model Number -Rating 16 7330000307 Decal - Placard 17 7330000001 Serial Number Tag 18 7759000004 Pop Rivet 129 7330000697 Decal - Lubrication 1

10 7330000143 Decal - Made In The USA 111 7330000138 Decal - Wheel Lift Checklist 112 7330000139 Decal - Checklist Reminder 113 7330000122 Decal - Wheel Lift Polycarbonate 214 7330000699 Decal - Manual Valve Operation 115 7330000424 Decal - Tow Hitch 116 7330000036 Decal - Secure Vehicle 117 7330000599 Decal - Moving Parts 218 7330000609 Decal - Grease Required 119 7330000716 Decal - Lock-Out Valve (Tow Sling) 1

7330000725 Decal - Lock-Out Valve (Recovery Sheave)20 7300000630 Decal - Control Switches (Ford) 1


DECALS

546

WARNINGA MINIMUM OF 5 WRAPS OF CABLE MUSTBE LEFT ON WINCH DRUM TO ACHIEVERATED LOAD.DO NOT USE WINCH TO MOVE OR LIFTPERSONS.

:VEHICLE ON WHEEL LIFT - CHECKLIST

:VEHICLE ON TOW SLINGS - CHECKLIST

PRE-TRANSPORT CHECKLISTOPERATOR'S

REVIEW THIS CHECKLIST BEFORE EACH TOW. FAILURE TOFOLLOW CHECKLIST COULD CREATE A DANGEROUS CONDITIONFOR YOU, OTHER MOTORISTS AND PEDESTRIANS, AND MIGHT

RESULT IN SERIOUS INJURY OR DEATH.

HEED ALL WARNINGS ON EQUIPMENT AND CONTROLS.

CAUTION

TRUCK TO TOWED VEHICLE?ARE BOTH SAFETY CHAINS ATTACHED FROM TOWING

POSSIBLE TO OBTAIN MAXIMUM WEIGHT DISTRIBUTION?IS THE WHEEL LIFT RETRACTED AS CLOSE AS

INSURE UNOBSTRUCTED CROSSBAR PIVOTING?IS THE WHEEL LIFT EXTENDED AT LEAST 4" TO

VEHICLE?ARE AUXILIARY TOWING LIGHTS ATTACHED TO TOWED

VEHICLE?IS THERE SUFFICIENT GROUND CLEARANCE FOR TOWED

THE FRAME OF THE TOWED VEHICLE?ARE CHAINS SECURED FIRMLY AROUND THE AXLE OR

BOTTOM BAR ASSEMBLY?SAFETY WRAPPED ON EACH SIDE OF THE SLINGARE CHAINS SECURELY FASTENED IN THE HOOKS AND

TRUCK TO TOWED VEHICLE?ARE BOTH SAFETY CHAINS ATTACHED FROM TOWING

VEHICLE?IS THERE SUFFICIENT GROUND CLEARANCE FOR TOWED

POSITION TO PREVENT RIDING UP?IS TOW SLING ASSEMBLY IN A BELOW HORIZONTAL

VEHICLE?ARE AUXILIARY TOWING LIGHTS ATTACHED TO TOWED

DO NOT OVERLOAD YOUR VEHICLE?

AND TIGHTENED DOWN ON TOWED VEHICLE?ARE BOTH WHEEL LIFT TIE DOWN STRAPS INSTALLED

ACCIDENT.RESULT FROM AN OVERLOAD AND CAN CAUSE A SERIOUSEXCESSIVELY LIGHT. LOSS OF VEHICLE CONTROL CANBOUNCES EXCESSIVELY OR IF STEERING FEELSIF YOU NOTICE FRONT END OF TRUCK FEELS LIGHT ORUNIT. STOP VEHICLE AT ONCE AND REARRANGE LOADDO NOT OVERLOAD. SEE LOAD RATING PLACARD ON

138

DO YOU HAVE TURNING CLEARANCE FOR TOWED VEHICLE?

122

TOWED VEHICLE MUST BECONNECTED TO TOW TRUCK BODY

WITH SAFETY CHAINS

WARNING

TOW RATING: LBS. (MAXIMUM)

LBS. AT 10" EXTENSION

307

LBS. AT FULL EXTENSION

UNDER LIFT CAPACITY: LBS.

THE MAXIMUM EFFECTIVE TRANSPORT LOAD OFTHIS UNIT BASED ON TRUCK CHASSIS

G.A.W.R. AND G.V.W.R. SPECIFICATIONS

SERIAL NO:

DO NOT EXCEED THE FOLLOWING WEIGHTS

*

BODY NO: UNDER LIFT NO:

TRUCK CHASSIS INFORMATION

VIN.: C.A.: IN.

REAR AXLE WEIGHT RATING (GAWR): LBS.

LOSS OF VEHICLE CONTROL, WHICH COULD RESULTIN SERIOUS BODILY INJURY OR DEATH, CAN OCCURIF THE EFFECTIVE TRANSPORT LOAD IS EXCEEDED.

MAXIMUM EFFECTIVE TRANSPORT LOAD IS AFFECTED BY THE CHASSISON WHICH THE TOWING EQUIPMENT IS INSTALLED. BEFORE

ATTEMPTING TO USE THIS EQUIPMENT ON A CHASSIS OTHER THANTHAT SPECIFIED ABOVE, CONTACT JERR-DAN TO OBTAIN

A REVISED RATING.

SAFETY IS NO ACCIDENT.REVIEW OPERATOR'S PRE-TRANSPORT CHECKLIST IN THE OWNER'S

MANUAL EACH TIME YOU MOVE A VEHICLE. FOLLOW ALLINSTRUCTIONS ON CONTROLS AND UNIT.

* NOTE: LIFT CAPACITY INDICATES THESTRUCTURAL CAPACITY OF THE LIFT MECHANISM,NOT THE MAXIMUM EFFECTIVE TRANSPORT LOAD.

RETRACTED LBS.

ALL RATINGS ARE BASED ON THE STRUCTURAL CAPACITYOF ABOVE MODEL. ACTUAL TOWING AND RECOVERYCAPACITY MAY BE LIMITED BY THE CAPACITY OF

THE CHASSIS AND EQUIPMENT SELECTED.

WARNING

READ OPERATOR'S MANUAL AND FAMILIARIZE YOURSELFWITH THE OPERATION PRIOR TO USING THIS EQUIPMENT.

KNOW THE LOADS BEING MOVED.DO NOT EXCEED RATED CAPACITIES.

WORKING LOAD LIMIT LBS.

SIZE FT.

UNDER LIFT RATINGS (MAXIMUM)

287

WARNING

TYPE

EXTENDED LBS.

SAE J706 LBS.

SERIAL NO.MODEL NO.

WINCH RATING:

WIRE ROPE:

1-800-926-9666GREENCASTLE, PA 172251080 HYKES ROADJERR-DAN CORPORATION

MANUFACTURED BY:

SECTION A-A

1

3MPGLUBEROLLER PINS G

G

1MPGLUBEPIVOT PIN F

F

H

1---CHANGEHYD FILTERH

ANNUALLYSEMI-250 OR

SELF LOADING

GRID

C

A

B

D

E

** CONSULT WINCH MANUAL FOR PROPER GRADE AND TYPE

(AUTOMATIC TRANSMISSION FLUID MAY BE SUBSTITUTED IF NECESSARY) * INDICATES SUPER PREMIUM GRADE MULTI-VISCOSITY HYDRAULIC OIL

MPG INDICATES MULTI-PURPOSE GREASE

NO LUBRICATION IS REQUIRED

"MAINTENANCE FREE DESIGN"

GREASELESS PIVOT JOINTS.SYSTEM IS EQUIPPED WITH

THE SUBFRAME AND WHEEL-LIFT

1

12

ENGINE OILMPG

OILCOAT

WIRE ROPEBOOM FLY

BA

1***

CHECKCHECK

WINCH GEAR BOXHYD RESERVOIR

E C

DRAIN/FILL **WINCH GEAR BOX E11

---*

CLEANDRAIN/FILL

MAGNETIC PLUGHYD RESERVOIR

D C

MONTHLYBI-

100 OR

YEARLY1000 OR

NOTICE

NO. OFPOINTS

LUBRICANTSERVICEIDENTIFICATIONREFNO.

INTERVAL(HOURS)

50 ORMONTHLY

697

LUBRICATION CHART

WHEEL LIFT SYSTEM

CAUTIONCHECK HYDRAULIC FLUID LEVEL

FILL ONLY WITH APPROVED FLUID(SEE OPERATOR'S MANUAL)

5,576,606 5,722,8106,290,450 6,315,515 B16,527,495 B2

MANUFACTURED BYJERR-DAN CORPORATION

414

OTHER PATENTS PENDING

OF THE FOLLOWING PATENTS:MFG. UNDER ONE OR MORE

PROUDLYMADEIN THE

USA

A

A

OVERRIDESWITCH

MANUAL VALVE OPERATION

WINCH

GRID

BOOM

TILT

BOOM

LIFT

BOOM

OUT

IN OP DN DN IN

OUT CL UP UP OUT

TO OPERATE VALVE MANUALLY: FLIP OVERRIDE SWITCHAND PRESS BUTTON ON SECTION END TO BE OPERATED

CAB

699

78

10

2

39

11

13

14

58

6

14

MANUFACTURED BY

SERIAL NO.

MODEL NO.

IDENT. NO.VEHICLE

GREENCASTLE, PENNSYLVANIA

001

TOW BALL HITCH

15

DRIVER SIDE BODYDRIVER SIDE TOOLBOX DOOR

UNDERSIDE OF VALVE BANK COVER

1617 1718

WHEELLIFT GRIDCAB DASHBOARD

WARNING

12

CAUTIONCLOSE TILT CYLINDER LOCK-OUT VALVEBEFORE LIFTING WITH THE TOW SLINGOR USING GRID RECOVERY SHEAVE.19

LORTNOCNOCAEBLOWERWORKLIGHTS

UPPERWORKLIGHTS

20

CAB SWITCH PANEL


TUNNEL TOOL COMPARTMENT


1 3899000121 Tunnel Toolbox Weld 12 4636000041 Toolbox Mount 13 7636000005 Rubber Mount 44 7949000013 Washer, Head 85 7115182850 Capscrew, 0.50”-13NC x 3.50” 46 7950180153 Flatwasher, 0.50” ID 8

7590180153 Flatwasher, 0.50” ID 10 (Chevy/GMC C3500)

7 7660182601 Locknut, 0.50”-13NC 87660182601 Locknut, 0.50”-13NC 6

(Chevy/GMC C3500)8 7115181864 Capscrew, 0.50”-13NC x 2.25” Carriage 4

7115181864 Capscrew, 0.50”-13NC x 2.25” Carriage 2 (Chevy/GMC C3500)

9 4686000208 Panel, Door 210 4632000053 Seal Door 211 7585000019 Latch, LH 112 7585000020 Latch, RH 113 7555000012 Door Hinge 414 7114140818 Capscrew, 0.25”-20NC x 1.00” 1615 7949000056 Nylon Washer 1616 7950140161 Flatwasher, 0.25” ID 1617 7660142601 Locknut, 0.25”-20NC 1618 4062000569 Bar 219 4178000848 Bracket 220 7114080618 Capscrew, #8-32NC x 0.75” 421 4679000249 Pad 222 4679000250 Pad 123 7493000009 Marker Light Grommet 424 7590000048 Marker Light - Amber (INC) 2

7590000342 Marker Light - Amber (LED)


25 3274000007 Clamp Weldment 426 7796000078 Moulding 12.5ft27 4812000108 Shim 428 4812000107 Shim 429 4706005869 Plate 4

4706005869 Plate 2 (Chevy/GMC C3500)

30 7115161250 Capscrew, 0.38”-16NC x 1.50” 127115161250 Capscrew, 0.38”-16NC x 1.50” 10

(Chevy/GMC C3500)31 7660162301 Locknut, 0.38”-16NC 12

7660162301 Locknut, 0.38”-16NC 10 (Chevy/GMC C3500)

32 4831000121 Spacer 2 (Chevy/GMC C3500)

33 4706005880 Plate 2 (Chevy/GMC C3500)

34 7120000075 Capscrew, M14-20 x 35 2 (Chevy/GMC C3500)

35 7949000019 Washer, Snub Head 2 (Chevy/GMC C3500)

36 7950200000 Flatwasher, 0.63” ID 2 (Chevy/GMC C3500)

37 4705000705 Plate 138 4178000849 Bracket, LH 139 4178000850 Bracket, RH 140 7114100618 Capscrew, #10-24NC x 0.75” 441 7950100003 Lockwasher, #10 ID 442 7660082604 Locknut, #8-32NC 4


Item #26, Moulding, not shown

1

2

3

33

3

44

4

4

4 4

4

5

5

6 6

6

77

76

6

6

8

8

9

9

10

10

11

12

13

13

13

13

14

14

14

14

15

15

15

15

15

1516

16

16

16

17

17

18

18

21

2122

23

23

23

23

24

24

25

C3500 CHASSIS ONLY

27 28

29

29

31

31

30

34

36

35

28

324

3

5

6

30

33

31

7

6

4

372 REF

41

40

39

1920

42

1920

42

41 40

38

TUNNEL TOOL COMPARTMENT


BOLT-ON D-RINGS


1 4263000705 Channel 22 3754000004 D-Ring Weld 23 4691000541 Pin 24 7754000022 Retaining Ring 45 7440030000 Grease Fitting 2


BOLT-ON D-RINGS

Left side body shown. Typical both sides.

1

23

4

4

5



1 7002000386 Jump Start Plug (IHC) 17002000385 Jump Start Plug (Ford & Chevy)

2 4178000372 Bracket (Ford) 14178000202 Bracket (Chevy)

3 4178000203 Bracket (Chevy) 14 7110140605 Capscrew, 0.25”-20NC x 0.75” 1

(Ford & Chevy)5 7950140161 Flatwasher, 0.25” ID (Ford) 1

7950140161 Flatwasher, 0.25” ID (IHC) 27950140161 Flatwasher, 0.25” ID (Chevy) 3

6 7660142600 Locknut, 0.25”-20NC (Ford & Chevy) 17660142600 Locknut, 0.25”-20NC (IHC) 2

7 7115141450 Capscrew, 0.25”-20NC x 1.75” (IHC) 18 7115141650 Capscrew, 0.25”-20NC x 2.00” (IHC) 19 7660140000 Hex Nut, 0.25”-20NC (IHC) 1

7660140000 Hex Nut, 0.25”-20NC (Chevy) 210 7111140850 Capscrew, 0.25”-20NC x 1.00” (Chevy) 211 7115181050 Capscrew, 0.50”-13NC x 1.25” (Chevy) 112 7950180153 Flatwasher, 0.50” ID (Chevy) 113 7660180000 Hex Nut, 0.50”-13NC (Chevy) 1

JUMP START KIT


JUMP START KIT

1

23

1

21

1

1

EXISTING BUMPERMOUNTING HARDWARE

54

6

54

6

57

658

6

9

FORD FRONT BUMPER

IHC FRONT BUMPER

CHEVY FRONT BUMPER

510

9

111213


FOLD DOWN LIGHTBAR BRACKET


1 3178000443 Fold Down Bracket - Bottom 12 3178000444 Fold Down Bracket - Top 23 4090000012 Belt 24 7690144800 Clevis Pin 25 7690000810 Cotter Pin 26 7585000001 Draw Latch 27 7115161250 Capscrew, 0.38”-16NC x 1.50” 88 7950160161 Flatwasher, 0.38” ID 89 7660162601 Locknut, 0.38”-16NC 8

10 7114100518 Capscrew, #10-24NC x .62” 411 7950100103 Flatwasher, 0.19 ID 412 7660102604 Locknut, #10-24NC 413 4178000402 Bracket 414 7115180950 Capscrew, 0.50”-13NC x 1.12” 415 7950180252 Flatwasher, 0.50” ID 416 7660182601 Lockwasher, 0.50”-13NC 417 7115150664 Carriage Bolt, 0.31”-18NC x .75” 818 7660152601 Lockwasher, 0.31” ID 8


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1

2

2

33

5

45

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6

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7

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11

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13

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1415

14

16

17

18

17

14

14

17

18

16

4

15

Standard Lightbar shown

FOLD DOWN LIGHTBAR BRACKET


BALL HITCH MOUNTING BRACKET


1 3178000507 Bracket Weld 12 3691000195 Pin Weld 23 7691000027 Pin Linch 24 7056000007 Ball (1.88” dia) 1

7056000008 Ball (2.00” dia)7056000009 Ball (2.31” dia)


BALL HITCH MOUNTING BRACKET

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2

2

3

4

4

3


SELF-LOADING DOLLY


1 4178000654 Bracket 22 4178000655 Bracket LH 13 4178000656 Bracket RH 14 7283000004 Collar 15 4706005244 Plate 26 Not Required7 7660162100 Wingnut, 0.38”-16NC 28 7114161050 Capscrew, 0.38”-16NC x 1.25” 169 7660162604 Locknut, 0.38”-16NC 14

10 7950160163 Flatwasher, 0.38” ID 2011 7949000055 Fender Washer 812 7002000022 Dollies - Self-Loading (Steel Axle) 1

7002000380 Dollies - Self-Loading (Aluminum Axle)


SELF-LOADING DOLLY

21

21

4

21

911

8

01

1

01

9

01

9

9 2

5

7

018

8

01

3


MOTORCYCLE ADAPTER

ITEM PART NO. DESCRIPTION QTY1 3178000470 Bracket Weld - Rear Ramp 12 2178000468 Bracket Weld - Lower 13 4263000710 Channel 14 3178000469 Bracket Weld - Tire Stop 15 4178000636 Bracket 26 4178000639 Bracket 17 4691000547 Pin 18 4679000275 Pad 19 7790161253 Screw, 0.38”-16NC x .75” 2

10 7115161064 Carriage Bolt, 0.38”-16NC x 1.25” 411 7950160161 Flatwasher, 0.38” ID 412 7660162601 Locknut, 0.38”-16NC 413 7691000047 Pin Linch 214 7819000012 Compression Sleeve 415 4248000002 Wire Rope 116 4248000003 Wire Rope 117 7120000052 Eye Bolt, 0.50”-13NC x 1.50” 2


MOTORCYCLE ADAPTER

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4

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7

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9

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11

12

1211

13

13

14

14

14

15 16

14

1

3L H & R H SIDETAILPLATES

17

17

ITEM #17 NOT INCLUDED IFUNIT SUPPLIED WITH D-RING

OR TOW SLING OPTIONS


WHEEL CHOCKS

ITEM PART NO. DESCRIPTION QTY1 7002000120 Wheel Chock 22 3636000012 Mount Weld 23 4949000016 Flatwasher, 0.41” ID 24 7660162100 Wing Nut, 0.38”-16NC 25 7111161250 Capscrew, 0.38”-16NC x 1.50” 86 7950160161 Flatwasher, 0.38” ID 167 7660162601 Locknut, 0.38”-16NC 88 4706005553 Plate 2


WHEEL CHOCKS

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1

2

2

3

4

4

3

5

66

5

5

66

5

8

8

6

77

6

6

7



1 4178000621 Bracket 22 3309000007 U-Joint Weld 23 7115223806 Shoulder Bolt, 0.63”-11NC x 4.75” 24 7660202601 Locknut, 0.63”-11NC 65 7822000003 Sling Belt 26 4706005679 Plate 27 7115161050 Capscrew, 0.38”-16NC x 1.25” 68 7950160000 Lockwasher, 0.38” ID 69 7950160141 Flatwasher, 0.38” ID 18

10 3500800077 Sling Anchor Head Weld 111 7701000003 Plug 412 3912000046 Sling Strap Mount Weld 213 4706005678 Plate 214 7691000077 Hitch Pin 415 7115161450 Capscrew, 0.38”-16NC x 1.75” 616 7660162601 Locknut, 0.38”-16NC 1017 7440300000 Grease Fitting 718 3500800078 Sling Head Assembly 119 3912000045 Sling End Cap Weld 220 3020000007 Hold Back Arm Assembly 221 7691000053 Hitch Pin 222 4254000006* Rod Cap 223 4763000184* Rod 224 7843000006* Compression Spring 225 4691000188* Pin 226 4706005748 Plate 127 7105223250 Capscrew, 0.75”-16NF x 4.00” 228 7661000017 Locknut, 0.75”-16NC 229 7189000023 Bumper 130 7114140818 Capscrew, 0.25”-20NC x 1.00” 231 7950140143 Flatwasher, 0.25” ID 232 7660142604 Locknut, 0.25”-20NC 233 4178000733 L H Bracket 1


34 4178000734 R H Bracket 135 7115161064 Carriage Bolt, 0.38”-16NC 436 7950160161 Flatwasher, 0.38” ID 437 7935000345 Valve 138 7445060698 Fitting 139 7445060646 Elbow 140 7912000315 Tube Assembly 141 3178000523 Bracket Weld 142 7115221650 Capscrew, 0.75”-10NC x .50” 243 7950220141 Flatwasher, 0.75” ID 444 7660222601 Locknut, 0.75”-10NC 445 7115222050 Capscrew, 0.75”-10NC x 2.50” 246 7115181250 Capscrew, 0.50”-13NC x 1.50” 247 7950180141 Flatwasher, 0.50” ID 448 7660182601 Locknut, 0.50”-13NC 449 4178000741 Bracket 150 7115181450 Capscrew, 0.50”-13NC x 1.75” 251 4706005700 Plate 152 3170000358 Boom Nose Weld - Single 153 3249000033 Sheave Support Weld 154 7082000031# Bearing 255 7754000018 Retaining Ring 156 7809000013 Sheave 157 7082000032 Bearing 158 4691000513 Pin 159 7754000006 Retaining Ring 160 4811000760+ Sheet 261 4706004852+ Plate 162 4706004851+ Plate 263 7115141664+ Carriage Bolt, 0.25”-20NC x 2.00” 364 7950140153+ Flatwasher, 0.25” ID 365 7660142604+ Locknut, 0.25”-20NC 366 7115202050 Capscrew, 0.63”-11NC x 2.50” 467 7950200141 Flatwasher, 0.63” ID 468 3249000041 Cross Bar Sheave Assembly 1

* also available in Arm Weld Outer Tube, P/N 3020000005# also available in Boom Nose Weld - Single, P/N 3170000358+ also available in Cable Guide Assembly, P/N 3249000034

TOW SLING


TOW SLING

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1

2

23

4

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5

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6

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8

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9

0111

1121

21

31

31

41

4141

41

51

51

9

9

9

9

61

61

71

71

71

71

86

SEE RECOVERY SHEAVE FOR PARTS


TOW SLING

91

11

41

41

02

12

71

71

71

72

927262

1303

23

81

02

11

8291

41

41

4363

61

53

32

22

5242

12 7133

6163

53

04

9373

83


TOW SLING

14

24

2434

34

44

44

54

34

64

74

5484

05

74

84

94

15

25 35454555

657585

95

95

06

06

16

26

2636

46

46

56

6676

4


RECOVERY SHEAVE

ITEM PART NO. DESCRIPTION QTY1 3249000040* Sheave Weld 12 7809000013* Sheave 13 7082000032* Bearing 14 4691000572* Pin 15 7754000006* Retaining Ring 26 3691000195* Pin Weld 27 7691000027* Linch Pin 28 7691000053* Hitch Pin 19 3178000533 Bracket Weld 1

10 7115222050 Capscrew, 0.75”-10NC x 2.50” 211 7115221650 Capscrew, 0.75”-10NC x 2.00” 212 7950220141 Flatwasher, 0.75” ID 413 7660222601 Locknut, 0.75”-10NC 414 7115181250 Capscrew, 0.50”-13NC x 1.50” 215 7950180141 Flatwasher, 0.50” ID 216 7660182601 Locknut, 0.50”-13NC 617 3178000511# Bracket Weld 118 4912000325# Tube 219 4912000423# Tube 120 4691000568# Pin 221 4691000567# Pin 122 7754000022# Retaining Ring 623 7115181264# Carriage Bolt, 0.50”-13NC x 1.50” 424 7950180153 Flatwasher, 0.50” ID 425 7935000345 Valve 126 7445060698 Fitting 127 7445060646 Elbow 128 7912000315 Tube Assembly 1

* also available in Cross Bar Sheave Assembly , P/N 3249000041# also available in Cable Guide Assembly, P/N 3249000039


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3

45

5

6

6

77

8

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12

12

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19

2020

2122

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26

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28

RECOVERY SHEAVE


L-ARM SPACER STORAGE

ITEM PART NO. DESCRIPTION QTY1 4178000721 Bracket 12 7115140550 Capscrew, 0.25”-20NC x 0.63” 43 7950140000 Lockwasher, 0.25” ID 44 7950140161 Flatwasher, 0.25” ID 45 7413000002 Nutsert, 0.25”-20NC 4


L-ARM SPACER STORAGE

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2

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2

3

4


FUEL FILLER

ITEM PART NO. DESCRIPTION QTY1 7449000019 Fuel Bezel 12 7796000100 Gasket 13 7950100151 Flatwasher, 0.19” ID 44 4533000415 Fuel Hose (Ford) 1

7570000027 Fuel Hose (GMC, diesel)7570000028 Fuel Hose (GMC, gas)7570000037 Fuel Hose (Dodge)

5 4533000415 Bracket 16 7115161050 Capscrew, 0.38”-16NC x 1.25” 17 7950160141 Flatwasher, 0.38” ID 18 7660162601 Locknut, 0.38”-16NC 19 5526000553 Tie Strap 8

10 7570000021 Vent Hose (GMC) 6 ft7570000036 Vent Hose (Dodge)

11 7443000354 Fitting (GMC, gas) 2


FUEL FILLER

4

5

6 7 8

12

3*

* - nuts included with fuel bezel Not all items shown because of chassis variation


FIFTH WHEEL ATTACHMENT

ITEM PART NO. DESCRIPTION QTY1 3178000543 Bracket 12 4912000432 Tube 23 4017001612 Angle 14 3178000562 Bracket 15 3691000144 Pin 16 3691000145 Pin 17 7118225250 Capscrew, 0.75”-10NC x 6.50” 48 7661000069 Locknut, 0.75”-10NC 49 7691000025 Snap Pin 2


FIFTH WHEEL ATTACHMENT

46

9

9

5

77

7

1

22

38

8

8


GOOSENECK ATTACHMENT

ITEM PART NO. DESCRIPTION QTY1 3178000543 Bracket 12 4912000432 Tube 23 4017001612 Angle 14 3178000560 Bracket 15 3691000144 Pin 16 7056000011 2-5/16” Dia Ball w/ Nut 17 7118225250 Capscrew, 0.75”-10NC x 6.50” 48 7661000069 Locknut, 0.75”-10NC 49 7691000025 Snap Pin 1


GOOSENECK ATTACHMENT

4

6

9

5

77

7

1

22

38

8

8


PULL-OUT DRAWER - TUNNEL TOOLBOX

ITEM PART NO. DESCRIPTION QTY1 4811001178 Sheet 12 4811001179 Sheet 13 7821000006 Slide 1pr4 7114100618 Capscrew, #10-24NC x 0.75” 345 7950100103 Flatwasher, #10 ID 686 7660102601 Locknut, #10-24NC 347 4706005865 Plate 28 4706005864 Plate 29 7114100618 Capscrew, 0.25”-20NC x 1.25” 4

10 7950140141 Flatwasher, 0.25” ID 811 7660142601 Locknut, 0.25”-24NC 412 4763000184 Rod 213 7115161250 Capscrew, 0.38”-16NC x 1.50” 414 7950160153 Flatwasher, 0.38” ID 815 7949000015 Washer 216 7660162601 Locknut, 0.38”-16NC 417 4679000361 Pad 1


PULL-OUT DRAWER - TUNNEL TOOLBOX

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2

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3

4

6

5

5

5

17

5 6

1313

13

13

14

1414

14

14

14

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16

16

16

16

15

15

14

12

4

78

9

10

5

10 11


STONE GUARD - TUNNEL TOOLBOX

ITEM PART NO. DESCRIPTION QTY1 4706005881 Plate LH (Stainless Steel) 1

4707000346 Plate LH (Aluminum Diamond)2 4706005882 Plate RH (Stainless Steel) 1

4707000347 Plate RH (Aluminum Diamond)3 7114100618 Capscrew, #10-24NC x 0.75” 184 7950100103 Flatwasher, #10 ID 185 7660102604 Locknut, #10-24NC 18


STONE GUARD - TUNNEL TOOLBOX

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1

3

4

5

3

4

5

3

3

4

5

4

5


ITEM PART NO. DESCRIPTION QTY1 7696000069 Elbow Pipe 1

FORD DIESEL 08 EXHAUST ALTERATION


1

EXISTING DIFFUSER USED

FORD DIESEL 08 EXHAUST ALTERATION


ACCESSORY EQUIPMENT


1 5525000752 Magnetic Tow Lights 12 7002000449 Suction Mounted Tow Lights 13 7002000448 Wheel Chock 14 7002000404 Fire Extinguisher 15 7002000285 Reflective Triangles 16 7002000521 Remote Control Transmitter Holder 17 7002000447 Valve Stem Extension Kit 18 7002000217 Simulators - N6670 1

7002000353 Simulators - N66807002000518 Simulators - ND19077002000322 Simulators -NF197002000494 Simulators - NF237002000461 Simulators - NF257002000411 Simulators - NH48607002000210 Simulators - NH509727002000396 Simulators - NH84947002000238 Simulators - NH8495


ACCESSORY EQUIPMENT

1 2 3

4

7

8 BAC EDISNI DETACOL

65

5376000117- 1

MPL-NGS WRECKER PARTS MANUAL

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Transcript of MPL-NGS WRECKER PARTS MANUAL