MPL WRECKER PARTS MANUAL - Jerr-Dan Man… · MPL Wrecker Parts Manual - Page 2 5-376-000101 Rev 3....

MPL WRECKER

PARTS MANUAL

5-376-000101Rev 3 - January 01, 2008 © 2008 Jerr-Dan Corporation. All Rights Reserved.

1080 Hykes RoadGreencastle, PA 17225Phone (717) 597-7111

www.jerr-dan.com

MPL Wrecker Parts Manual - 5-376-000101 Rev 3.

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 Sales Order Number, Serial Number and Model Number. This information can be found on thealuminum tag riveted to 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 717-593-2362.

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 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, 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 Wrecker

001001

VEHICLEIDENT. NO.

MODEL NO.

SERIAL NO.

MANUFACTURED BY

GREENCASTLE, PENNSYLVANIA

An Oshkosh Truck Corporation Company


Body - Complete ...................................................................................................................... 4 - 5Left Hand Body Assembly ....................................................................................................... 6 - 7Right Hand Body Assembly ..................................................................................................... 8 - 9Subframe ........................................................................................................................ 10 - 11Hydraulic Reservior ............................................................................................................. 12 - 13Worm Gear Winch & Cable Guide ....................................................................................... 14 - 15Worm Gear Winch - Cable Tensioner ................................................................................. 16 - 17Mud Flap ........................................................................................................................ 18 - 19Fender Flares ....................................................................................................................... 20 - 21Light Pylon - Deck Mounted ................................................................................................. 22 - 23Light Pylon - Toolbox Mounted ............................................................................................ 24 - 25Wrecker Boom ..................................................................................................................... 26 - 27Underlift Boom - Hydraulic Grid ........................................................................................... 28 - 29Hydraulic Wheel Lift Grid .................................................................................................... 30 - 34Underlift Level Stop .............................................................................................................. 36 - 37Remote Controls .................................................................................................................. 38 - 39Wireless Remote Controls ................................................................................................... 40 - 41Hydraulic Components - Hose Routing / Mounting ............................................................. 42 - 43Hydraulic Components - Standard ...................................................................................... 44 - 45Hydraulic Components - Hydraulic Wheel Lift Grid ............................................................ 46 - 47Electrical Components - Body - Standard ........................................................................... 48 - 49Electrical Components - Pylon Lights / Tunnel Wiring ....................................................... 50 - 51Work Lights - Marker Lights ................................................................................................ 52 - 53Lightbar - Single / Dual ........................................................................................................ 54 - 55Switch Panels ...................................................................................................................... 56 - 57Chain and Straps ................................................................................................................. 58 - 59

Decals ........................................................................................................................ 60 - 61Wrecker Boom Tilt Cylinder Assembly ................................................................................ 62 - 63Underlift Boom Tilt Cylinder Assembly ................................................................................ 64 - 65Tunnel Toolbox ..................................................................................................................... 66 - 67Bolt-On D-Rings ................................................................................................................... 68 - 69Jump Start Kit ........................................................................................................................ 70 - 71Fold Down Lightbar Bracket ............................................................................................... 72 - 73Ball Hitch Mounting Bracket ................................................................................................. 74 - 75Self-Loading Dolly ................................................................................................................ 76 - 77Motorcycle Adapter ............................................................................................................. 78 - 79Tow Sling ........................................................................................................................ 80 - 83Recovery Sheave ................................................................................................................ 84 - 85L-Arm Spacer Storage ......................................................................................................... 86 - 87Stone Guard ........................................................................................................................ 88 - 89Ford Diesel 08 Exhaust Alteration ...................................................................................... 90 - 91

INDEX DESCRIPTION PAGE


BODY - COMPLETE

ITEM PART NO. DESCRIPTION QTY1 3097000595 Body Assembly LH 12 3097000596 Body Assembly RH 13 4314000159 Coverplate, Frt 14 3097000600 Mid Deck Weld, Rear 15 4314000160 Coverplate, LH 16 4314000161 Coverplate, RH 17 4314000158 Valve Cover, Front 18 4314000097 Coverplate, Front 19 4090000010 Pad 2

10 4090000011 Pad 211 7661000029 J-Nut, 0.31”-18NC 412 7114150818 Capscrew, 0.31”-18NC x 1.00” 413 7114140818 Capscrew, 0.25”-20NC x 1.00” 1814 7950140143 Flatwasher, 0.25” ID 1815 7585000023 Latch 116 7120000046 Screw, 0.25”-20NC x .75” 417 7115181450 Capscrew, 0.50”-13NC x 1.75” 1618 7950180153 Flatwasher, 0.50” ID 2419 7949000015 Head Washer, 0.50” ID 820 7660182601 Lockwasher, 0.50”-13NC 1621 7949000056 Nylon Washer, 0.25” ID 422 7661000002 Hex Nut, #10-24NC 2423 7413000002 Nutsert, 0.25”-20NC 1424 8632000002 Edge Trim 19 in25 4632000058 Edge Trim 426 7493000009 Marker Light Grommet 227 7590000048 Marker Light - Amber (IND) 2

7590000342 Marker Light - Amber (LED)28 7330000498 Reflector - Amber (use with INC only) 429 7590000130 Light, Backup 230 7590000128 Light, Stop-Tail-Turn (IND) 2

7590000301 Light, Stop-Tail-Turn (LED)

ITEM PART NO. DESCRIPTION QTY

31 7590000131 Light, Wrap Around (IND) 27590000302 Light, Wrap Around (LED)

32 7111100810 Capscrew, #10-24NC x 1.00” 2433 7796000012 Seal 150in


BODY - COMPLETE

See pages 6 through 9 for LH and RH Body parts

Item #33, Seal, not shown

1

2

34

6

5

7

8

10

10

9

9

11

11

11

12

12

31

32

22

26

27 28

28

1825 25

1817

19

17

13

14

23

23

1820

20

22

3032

22 29 32

1718

13

1421

1920

19 19

20

1820

15

16

16

2525

23

24

18

17

2726 28

19

17

23

13

14

3132

2230

32

22

29

32

22

1817

1321

17


LEFT HAND BODY ASSEMBLY (3097000595)


1 3097000597 Deck Weld LH 12 3811000033 Tailplate Weld LH 13 4811000819 Sheet LH 14 4314000091 Coverplate LH 15 4178000744 Bracket 16 4178000577 Bracket 17 4811000840 Sheet 18 3899000119 Toolbox Bond LH 19 4686000207 Door 1

10 4632000050 Seal, Toolbox Door 111 4811000823 Shelf 112 7555000012 Door Hinge 213 7585000019 Latch, LH 114 4062000569 Bar 115 4706003611 Plate 116 4178000746 Bracket 117 7571000001 Taillight Housing 118 7413000013 Fastener 819 7759000006 Rivet 220 7114161050 Capscrew, 0.38”-16NC x 1.25” 621 7114140818 Capscrew, 0.25”-20NC x 1.00” 1922 7949000056 Nylon Washer, 0.25” ID 1123 7950140161 Flatwasher, 0.25” ID 2224 7660142601 Locknut, 0.25”-20NC 1625 7950140000 Lockwasher, 0.25” ID 626 7950140143 Flatwasher, 0.25” ID 527 7413000002 Nutsert, 0.25”-20NC 328 7115140650 Capscrew, 0.25”-20NC x .75” 329 7115161050 Capscrew, 0.38”-16NC x 1.25” 2330 7950160161 Flatwasher, 0.38” ID 3331 7660162601 Locknut, 0.38”-16NC 1032 7950160000 Lockwasher, 0.38” ID 1333 4679000252 Mat 1


34 7796000012 Seal 54in


LEFT HAND BODY ASSEMBLY (3097000595)

Item #33, Mat, not shown Item #34, Seal, not shown

1

2

3 4

5

6

7

8

9

1011

12

13

1415

1929

30293230

31

3021

22

24

23

23

24

21

22

2020

21

26

30

29

293230

29

2423

3029

3031

27

3130

28 2523

17

18 18

23

24

212523

2221

2122

16

30

29



1 3097000598 Deck Weld RH 12 3811000034 Tailplate Weld RH 13 4811000820 Sheet RH 14 4314000092 Coverplate RH 15 4178000744 Bracket 16 4178000577 Bracket 17 4811000840 Sheet 18 3899000120 Toolbox Bond RH 19 4686000207 Door 1

10 4632000050 Seal, Toolbox Door 111 4811000823 Shelf 112 7555000012 Door Hinge 213 7585000020 Latch, RH 114 4062000569 Bar 115 4706003611 Plate 116 4178000745 Bracket 117 7571000001 Taillight Housing 118 7413000013 Fastener 819 7759000006 Rivet 220 7114161050 Capscrew, 0.38”-16NC x 1.25” 621 7114140818 Capscrew, 0.25”-20NC x 1.00” 1922 7949000056 Nylon Washer, 0.25” ID 1123 7950140161 Flatwasher, 0.25” ID 2224 7660142601 Locknut, 0.25”-20NC 1625 7950140000 Lockwasher, 0.25” ID 626 7950140143 Flatwasher, 0.25” ID 527 7413000002 Nutsert, 0.25”-20NC 328 7115140650 Capscrew, 0.25”-20NC x .75” 329 7115161050 Capscrew, 0.38”-16NC x 1.25” 2330 7950160161 Flatwasher, 0.38” ID 3331 7660162601 Locknut, 0.38”-16NC 1032 7950160000 Lockwasher, 0.38” ID 1333 4679000253 Mat 1

RIGHT HAND BODY ASSEMBLY (3097000596)


34 7796000012 Seal 54in


RIGHT HAND BODY ASSEMBLY (3097000596)

Item #33, Mat, not shown Item #34, Seal, not shown

12

3

4

5

7

6

8

9

10

11

12

12

13

2122

2423

1415

19

2122

29

3032

20

20

3029

3031

232421

26

30 29 32

30

2930

3031

2730

31

2825 23

16

29

30

17

18

18

2122

21

2324

212523



1 3868000288 Subframe Weld 12 4706004919 Plate 23 4706004950 Plate (Ford) 2

4706004999 Plate (Chevy)4 4705000665 Plate (Ford 19,000 lb) 25 7115181650 Capscrew, 0.50”-13NC x 2.00” 126 7950180153 Flatwasher, 0.50” ID 127 7660182601 Locknut, 0.50”-13NC 12

SUBFRAME


SUBFRAME

1

2

2

4

3

4

3

5

6

5

6

5

6

56

5

6

56

5

6

5

77

7


HYDRAULIC RESERVOIR


1 3750000061 Reservoir Weldment 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


HYDRAULIC RESERVOIR

1

4

3

25

5

6

7

7

76

6


WORM GEAR WINCH & CABLE 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 GUIDE

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

1

2

3

4

5

67

8

9

97

8

6

9

78

7

9

10

11

10

78

1314

15

17

1717

17

1717

18

11

19

16

For Tow Sling Cable Guide parts, refer to Tow Sling 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 - 19” long 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 7415000021 Fender (narrow) 2

7415000023 Fender (wide)2 7114150850 Capscrew, 0.31”-18NC x 1.00” 223 7950150000 Lockwasher, 0.31” ID 224 7949000055 Fender Washer, 0.38” ID 225 7661000029 J-Nut, 0.31”-18NC 22


FENDER FLARES

1

2

3

4

5

5

1

5

2

3

4


LIGHT PYLON - DECK MOUNTED


1 3509570103 Light Pylon Weld - 37” 13509570113 Light Pylon Weld - 50”

2 4263000689 Channel 13 4706005002 Plate (37” Pylon) 2

4314000125 Plate (50” Pylon)4 7796000091 Gasket 25 7949000058 Washer, 0.53” ID 46 7115181450 Capscrew, 0.50”-13NC x 1.75” 47 7950180161 Flatwasher, 0.50” ID 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 12


1

2

3

4

4

6

7

6

7

8 9

8 9 89

10

10

10

911

5

5

8

11

12

12

LIGHT PYLON - DECK MOUNTED

37” Pylon shown


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


1

2

3

4

4

5

6

5

6

6

7

6

77

6

89

8 9

8 9

01

01

01

01119

119

21

21

31

31

LIGHT PYLON - TOOLBOX MOUNTED

28” Pylon shown


WRECKER BOOM


1 3170000446 Knee Boom Weld 12 3320000224 Cylinder Assembly 13 3691000258 Pin Weld 14 3691000242 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 7082000030* 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 3320000225 Cylinder Assembly 14 4691000242 Pin 25 4691000236 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 7082000029+ 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


UNDERLIFT BOOM - HYDRAULIC GRID

1

2

4

5

4

67

8

6

7

8

67

8

910

10 11

11 12

13

14

16

17

18

18

17

19

19

2021

22

1514

2625

2524

23


HYDRAULIC WHEEL LIFT GRID


1 4691000198^ Pin 12 4949000047^ Washer, 2.84” ID 23 7754000024^ Retaining Ring 14 3484000068^ 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 4691000497^ Pin 2

10 3592000052^ Link Weld 211 3592000051^ Link Weld 212 4706003497^ Plate 213 7754000022^ Retaining Ring 414 7785140870^ Set Screw, 0.25”-20NC x .50” 215 7440030000^ Grease Fitting 116 7701000007^ Plug Button 117 3691000230^ Pin Weld 218 3020000116^ Arm Weld LH 119 3020000117^ Arm Weld RH 120 8411080091^ L-Arm Spacer 221 7082000027# Bearing 422 7082000026*+ Bearing 1023 4314000076^ 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 3020000116 & 3020000117* quantity of 1 also available in each of Arm Weldments, P/N 3020000116 & 3020000117

+ quantity of 8 also available in Link Weldments, P/N 3592000052^ also available in Grid Assembly, P/N 3484000069


1

2

2

3

4

66

7

8

7

11

12

13

13

14

16

15

5 22

9

22

22

10



17

17

7

8

7

8

18

19

21

21

22

20

20



4

23

23

24

24

25

25

26

26

26

26

2728

27

28

2829

2829

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36

35

34



37

38

39

39

40

41

40

4141

42

41

42

42

41

43 44

44

45

45

4146

47

48

4950

51

52

53

5441

46

54

41

46

54

5556



THIS PAGE INTENTIONALLY LEFT BLANK


UNDER LIFT LEVEL STOP


1 4178000709 Bracket 12 4178000705 Bracket 13 7870000126 Proxi Switch 24 7346000218 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


UNDER LIFT LEVEL STOP

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

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


REMOTE CONTROLS


1 7552000365 Control Valve to Subframe Harness 12 7295000061 Hand Controller 13 4706003402 Plate 14 7790100856 Screw, #10 x 0.50” 35 7740000003 Relay 16 7345001710 Tab 27 7345001714 Terminal 18 7345221702 Terminal 19 7346000039 Tubing 1

10 8977500100 Wire #16 ga 36in11 8597650002 Wire Loom 36in12 7345001747 Fastener 113 7870000092 Toggle Switch 114 7560000004 Switch Boot 1


REMOTE CONTROLS

30

85

86

87

CAB - SUBFRAME HARNESS

ABC

DEFABCD

EF

ABCDEF

TO SWITCH PANEL

WINCH INGRID OPEN

UNLOADERVALVECONTROLS

BOOM TILT DNBOOM LIFT DNBOOM IN

RED

BOOM OUTBOOM LIFT UPBOOM TILT UPGRID CLOSEWINCH OUT

CONTROL

VALVE

12V IGNITION

10 A

CLUTCH PUMP

12V BATTERY

+

-

1

2

34

54

FUSE HOLDERSUPPLIED WITHCLUTCH PUMP

69

912

69

1011

79

7910

11

89

1314


WIRELESS REMOTE CONTROLS


1 7295000117 Wireless Controller 10 Func 12 4636000038 Mounting Plate 13 7114100518 Capscrew, #10-24NC x 0.62” 44 7660102604 Locknut, #10-24NC 45 7552000386 Controller to 5 Sect Valve Harness 16 5526000553 Tie Strap 57 9295310046* Transmitter 18 9295310029* Rubber Boot 19 9295310030* Belt Clip 1

10 7075000003 Battery, 9V 111 9295310050* Receiver 1

* included in Wireless Controller 10 Func, P/N 7295000117


12

3

3

4

4 EXISTING FRONTMOUNTING HARDWARE OF THE HYDRAULIC OIL RESERVOIR

CAB - SUBFRAME HARNESS

ABCDEFABCDEF

ABCDEF

ABCDEF ABCDEF

SUBFRAME - REMOTE HARNESS

111

34

2

5

OPEN

CLOSE

(TRANSMITTER)

789

1

10

WIRELESS REMOTE CONTROLS

Item #6, Tie Strap, not shown


HYDRAULIC COMPONENTS - HOSE ROUTING / MOUNTING


1 See Note 1 PTO 12 See Note 1 Pump, Fittings and Mtg Hardware 13 4567632141 Hose Assembly (60” CA) 1

4567632166 Hose Assembly (84” CA)4 4570000308 Hose (60” CA) 1

4570000309 Hose (84” CA)5 7443000013 Fitting 16 7274000002 Clamp 27 4570000307 Hose 18 7443000374 Fitting 19 7274000047 Clamp 4

10 4570000306 Hose 111 7443000319 Fitting 112 7430000003 Filter Assembly 113 7431000001^ Filter Element 114 7443000066 Fitting 115 7470000002 Gauge 116 4178000719 Bracket 117 7114140518 Capscrew, 0.25”-20NC x 0.63” 218 7950140003 Lockwasher, 0.25” ID 219 7950140143 Flatwasher, 0.25” ID 220 7115181064 Carriage Bolt, 0.50”-13NC x 1.25” 121 7950180161 Flatwasher, 0.50” ID 122 7660182601 Locknut, 0.50”-13NC 123 7274000105 Clamp 724 7274000042 Clamp 625 7274000076 Cast Frame Clamp 226 7785152420 Set Screw, 0.31”-18NC x 1.50” 227 7115151050 Capscrew, 0.31”-18NC x 1.25” 528 7950150161 Flatwasher, 0.31” ID 1229 7660152601 Locknut, 0.31”-18NC 1130 7115150864 Carriage Bolt, 0.31”-18NC x 1.00” 2

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


HYDRAULIC COMPONENTS - HOSE ROUTING / MOUNTING

TYPICAL HOSE ROUTING / MOUNTING

1 222

2

43

56

7

89

9

9

9

11

121314

1516

10

1817

19

2120

22

2323

2324

24

25

252926

2926

2928

30

2928

2827

29

2827

29



1 7935000311 Valve Assembly 12 7115150650 Capscrew, 0.31”-18NC x 0.75” 43 7950150000 Lockwasher, 0.31” ID 44 7950150161 Flatwasher 85 7445080845 Elbow 16 7443000435 Fitting 17 7443000436 Fitting 18 7445060643 Adapter 129 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 4570000303 Hose 228 7445081045 Elbow 229 4819000008 Hose Sleeve 130 7935000354 Counterbalance Valve 1

HYDRAULIC COMPONENTS - STANDARD


HYDRAULIC COMPONENTS - STANDARD

Item #29, Hose Sleeve, not shown

GR

ID,

B4

TIL

T, B

3

LIF

T,

B2

EX

T,

B1

TIL

T, A

3

LIF

T, A

2

EX

T,

A1

GR

ID,

A4

WIN

CH

, A5

WIN

CH

, B5

12

3

12

3

PRESSURE

BOOM LIFT

UNDER LIFT TILT

1

23

5

6

7

8 8

8

8

8

9

30

10411

411

1012

13

13

13

13

13

13

14

14 15

16

17

18

19

20

20 21

21 22

22

23

23 21

21

24

24

25

25 26

27

27

28

28

WINCH

UNDER LIFT EXTEND

SEE HYDRAULIC COMPONENTS -HYDRAULIC WHEEL LIFT GRID

CONTROLVALVE

4 RETURN

12

17


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


ELECTRICAL COMPONENTS - BODY - STANDARD


1 7552000292 Cab to Subframe Harness 12 7457000004 Circuit Breaker - 50 amp 13 7792000001 Screw, #10 x .75” 24 8977530200 Wire 10ga 36in5 8597650002 Convoluted Wire Loom 36in6 7345211902 Terminal 17 7345221902 Terminal 18 7346000039 Heat Shrink Tubing 24in9 7111141050 Capscrew, 0.25”-20NC x 1.25” 4

10 7950140141 Flatwasher, 0.25” ID 611 7660142600 Locknut, 0.25”-20NC 412 7552000290 LH Body Harness 113 7552000291 RH Body Harness 114 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 7011000003 Back-up Alarm 120 7894000042 Tie Strap 2521 7870000115 Pin Switch 222 7590000273 Dome Light 223 7790100856 Screw, #10 x .50” 424 7661000047 Nylon Nut, #8 4


Item #20, Tie Strap, not shown.

ELECTRICAL COMPONENTS - BODY - STANDARD

ABC

AB

A

B

ABC

A

B

A

B

A

B

12V BATTERY

+

-

BEACON 1 BEACON 2 CONTROLWORKUP

WORKDN

AB

AB

BA

BA

1

2

3

54

68

87

91011

14

109

11

SWITCH PANEL

CHASSIS HARNESS

13

12

222324

19

109

11

18

151617

21

22 2423 21


ELECTRICAL COMPONENTS - PYLON LIGHTS / TUNNEL WIRING


1 7552000293 Headboard Harness (Headboard only) 17552000295 Headboard/Tunnel Harness (Hdbd & Tunl)

2 7346000039 Heat Shrink Tubing 6in3 7894000042 Tie Strap (Headboard only) 1

7894000042 Tie Strap (Headboard & Tunnel) 34 5526000553 Tie Strap (Headboard only) 1

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

10 7493000011 Grommet 1


ELECTRICAL COMPONENTS - PYLON LIGHTS / TUNNEL WIRING

LIGHT PYLON - BODY

1

2

LICENSE PLATE LIGHT

CAB-SUBFRAMEHARNESS

1

2

CAB-SUBFRAMEHARNESS

LICENSE PLATE LIGHT

LIGHT PYLON -TUNNEL TOOLBOX

567

89

10

98 5

76

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


WORK LIGHTS - MARKER LIGHTS


1 7590000144 Work Light 22 7590000095 Marker Light - Amber (Std) 2

7590000300 Marker Light - Amber (LED)3 7493000026 Marker Light Grommet 24 7590000193 ID Marker Light - Amber (Std) 1

(Dual 22” Lightbar)7590000316 ID Marker Light - Amber (LED)

(Dual 22” Lightbar)5 7114141018 Capscrew, 0.25”-20NC x 1.25” 2

(Dual 22” Lightbar)6 7950140143 Flatwasher, 0.25” ID 2

(Dual 22” Lightbar)7 7660142601 Locknut, 0.25”-20NC 2

(Dual 22” Lightbar)8 7590000105 License Plate Light 19 7178000025 License Plate Bracket 1

10 7590000185 Worklight 211 7346000039 Heat Shrink Tubing (Upper wrk Lt) 6in12 7894000010 Tie Strap (Pylon Marker Lights) 2

7894000042 Tie Strap (License Plate Light) 15526000553 Tie Strap (License Plate Light) 1

13 5525000752 Magnetic Tow Lights 1


WORK LIGHTS - MARKER LIGHTS

Item #11, Heat Shrink Tubing, not shownItem #12, Cable Ties, not shownItem #13, Magnetic Tow Lights, not shown

1

1

23

23

4

5

6

56

8

9

8

7

7

10

10


LIGHTBAR - SINGLE / DUAL


1 7590000307 Lightbar, Amber (Std) (58” Lightbar) 17590000312 Lightbar, Amber (LED) (58” Lightbar) 17590000336 Lightbar, Amber (Strobe) (58” Lightbar) 17590000309 Lightbar, Amber (Std) (Dual 22” Lightbar) 27590000332 Lightbar, Amber (Strobe) (22” Lightbar) 2

2 4178000402 Bracket (58” Lightbar) 24178000402 Bracket (Dual 22” Lightbar) 4

3 7115181050 Capscrew, 0.50”-13NC x 1.25” 2 (58” Lightbar)

7115181050 Capscrew, 0.50”-13NC x 1.25” 4 (Dual 22” Lightbar)

4 7660182601 Locknut, 0.50”-13NC (58” Lightbar) 27660182601 Locknut, 0.50”-13NC (Dual 22” Lightbar) 4

5 7346000039 Heat Shrink Tubing 6in6 4706005001 Plate (Dual 22” Lightbar) 27 7701000032 Hole Plug (Dual 22”Lightbar) 18 7345001914 Terminal (Dual 22” Lightbar) 19 8977030300 Wire, #12 ga (Dual 22” Lightbar) 6in

10 7346000097 Connector (Dual 22” Lightbar) 111 7346000102 Terminal (Dual 22” Lightbar) 212 7346000103 Wire Seal (Dual 22” Lightbar) 213 7346000100 Terminal (Dual 22” Lightbar) 114 7346000101 Wire Seal (Dual 22” Lightbar) 115 7346000108 Connector Lock (Dual 22” Lightbar) 1


1

2

2

1

1

3

4

4

3

1

1

1

1

1

1

B

C

A(RED)

(RED)

(WHT)RED

BLACK

BLACK

RED

1

1

(LH LIGHTBAR HARNESS)

(RH LIGHTBAR HARNESS)9 8

5

7

1112131415

2 2

22

3

1

1

4

46

4

6

3

1

13

1

1

3

1

1

10

Item #5, Heat Shrink Tubing, not shown

LIGHTBAR - SINGLE / DUAL


SWITCH PANELS

ITEM PART NO. DESCRIPTION QTY1 4178000403 Bracket - 1 Function Switch Panel 12 7870000083 Switch 13 7870000053 Switch Panel - 3 Function, Under Dash 14 7870000063 Switch Panel - 5 Function, Under Dash 15 7870000089 Switch Panel - 5 Function 16 7870000117 Switch Panel - 6 Function, In-Dash 1


SWITCH PANELS

O

BEACON FLOOD AUX.

O O

PTOENGAGED

O

BEACON

O O

FLOOD AUX.

O

AUX.

O

AUX.

PTOENGAGED

BEACON 1 BEACON 2 CONTROLWORKDN

WORKUP BEACON 1 BEACON 2 AUXWORK

DNWORK

UP CONTROL

5

4

3

21

6


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 7330000414 Decal - Self LoaderPatent 13 7330000034 Decal - Wheel Lift 14 7330000433 Jerr-Dan Nameplate 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 7330000037 Decal - Moving Parts 218 7330000609 Decal - Grease Required 119 7330000716 Decal - Lock-Out valve (Tow Sling only) 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

TOTOWEWED VED VEHIHICLCLE MUE MUSTST BECONNECTED TO TO TOW TRW TRUCUCK BOK BODYDY

WIWITHTH S SAFETY CHCHAIAINSNS

WARNING

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

RETRACTED LBS.

BOOM RATINGS (MAXIMUM)EXTENDED LBS.

SAE J2512

ALL RATINGS ARE BASED ON THE STRUCTURALCAPACITY OF ABOVE MODEL. ACTUAL TOWINGAND RECOVERY CAPACITY MAY BE LIMITED BY

THE CAPACITY OF THE CHASSIS AND

WARNING

READ OPERATOR'S MANUAL AND FAMILIARIZEYOURSELF WITH THE OPERATION PRIOR TO USINGTHIS EQUIPMENT. KNOW THE LOADS BEING MOVED.

DO NOT EXCEED RATED CAPACITIES.

WORKING LOAD LIMIT LBS.

SIZE FT.

UNDER LIFT RATING (MAXIMUM)

500

WARNING

TYPE

LBS.

SAE J706

SERIAL NO.MODEL NO.

WINCH RATING:

WIRE ROPE:

EQUIPMENT SELECTED.

EACH DRUM LBS.

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

MANUFACTURED BY:

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.

VIEW A-A

1

3MPGLUBEROLLER PINS G

G

1MPGLUBEPIVOT PIN F

F

H

1---CHANGEHYD FILTERH

ANNUALLY

SEMI-

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 E

1

1

---*

CLEAN

DRAIN/FILL

MAGNETIC PLUG

HYD RESERVOIR

D

C

MONTHLY

BI-

100 OR

YEARLY

1000 OR

NONOTITICECE

NO. OF

POINTSLUBRICANTSERVICEIDENTIFICATIONREF

NO.

INTERVAL

(HOURS)

50 OR

MONTHLY

697

LUBRICATION CHART

WHEEL LIFT SYSTEM

CAUTIONCHCHECK ECK HYDHYDRAULRAULIC FIC FLUILUID LED LEVELVELFILFILL ONL ONLY LY WITHWITH APP APPROVROVED FED FLUILUID

(SEE(SEE OP OPERATERATOR'SOR'S MA MANUALNUAL)

MODEL NO.

IDENT. NO.VEHICLE

PROUDLYMADEIN THE

USA

DRIVER SIDETOOLBOX DOOR

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

UNDERSIDE OFVALVE BANK

COVER

A

A

LH SIDE KNEE BOOM

DRIVER'SSIDE

BODYFRONTRUBRAIL

LH SIDE BODY

CAB DASHBOARD

WARNING

TOW BALL HITCH

CAUTION

1617 1718

HYRAULIC GRIDWHEEL LIFT

12

34

5

6

8

78

9

10

11

12

14

15

(Both Sides)

13(Both Sides)CAUTION

CLOSLOSE TILE TILT CYLT CYLININDERDER LOCKOCK-O-OUT VAUT VALVELVEBEFOREORE L LIFTIFTINING WG WITH T THE TO TOW W SLISLINGNGOROR U USINSING G GRIGRID D RECRECOVOVERYERY S SHEAHEAVEVE.

19



1 3071000208 Barrel Weld 12 3763000183 Rod Weld 13 4698000008* Piston 14 7754000011* # Wear Ring 25 7796000065* # Piston Locking “T” Seal 16 7755226000* # “O” Ring 17 7755226609* # Back-Up Ring 28 4553000009^ Head 19 7755342000^ # “O” Ring 1

10 7755342609^ # Back-Up Ring 111 7754000012^ # Wear Ring 112 7796000025^ # Rod Seal 113 7796000011^ # Rod Wiper Seal 114 7754000013 # Retaining Ring 115 7754000028 # Retaining Ring 116 7661000035 Locknut 117 7082000029 Bearing 4

* included in Piston Assembly, P/N 3698000002^ included in Head Assembly, P/N 3553000012# available only in Service Kit #7577250026

WRECKER BOOM TILT CYLINDER ASSEMBLY - P/N 3320000224


WRECKER BOOM TILT CYLINDER ASSEMBLY - P/N 3320000224

1 23 4 45 86 7 9 1011 12 1314 151617 17


UNDERLIFT BOOM TILT CYLINDER ASSEMBLY - P/N 3320000225


1 3071000209 Barrel Weld 12 3763000184 Rod Weld 13 4698000008* Piston 14 7754000011* # Wear Ring 25 7796000065* # Piston Locking “T” Seal 16 7755226000* # “O” Ring 17 7755226609* # Back-Up Ring 28 4553000009^ Head 19 7755342000^ # “O” Ring 1

10 7755342609^ # Back-Up Ring 111 7754000012^ # Wear Ring 112 7796000025^ # Rod Seal 113 7796000011^ # Rod Wiper Seal 114 7754000013# Retaining Ring 115 7754000028# Retaining Ring 116 7661000035 Locknut 117 7082000029 Bearing 4

* included in Piston Assembly, P/N 3698000002^ included in Head Assembly, P/N 3553000012# available only in Service Kit #7577250026


UNDERLIFT BOOM TILT CYLINDER ASSEMBLY - P/N 3320000225

1 23 4 45 86 7 9 1011 12 1314 151617 17


TUNNEL TOOLBOX


1 3899000121 Tunnel Toolbox Weld 12 4017000674 Angle 23 7636000005 Rubber Mount 44 7949000013 Washer, Head 45 7949000012 Washer, Tail 46 7115182650 Capscrew, 0.50”-13NC x 3.25” 47 7950180153 Flatwasher, 0.50” ID 88 7660182601 Locknut, 0.50”-13NC 89 7115181650 Capscrew, 0.50”-13NC x 2.00” 4

10 4686000208 Panel, Door 211 4632000053 Seal Door 212 7585000019 Latch, LH 113 7585000020 Latch, RH 114 7555000012 Door Hinge 415 7114140818 Capscrew, 0.25”-20NC x 1.00” 1616 7949000056 Nylon Washer 1617 7950140161 Flatwasher, 0.25” ID 1618 7660142601 Locknut, 0.25”-20NC 1619 4062000569 Bar 220 4706003611 Plate 221 7759000006 Pop Rivet 422 4679000249 Pad 223 4679000250 Pad 124 7493000009 Marker Light Grommet 425 7590000048 Marker Light - Amber (IND) 2

7590000342 Marker Light - Amber (LED)26 7330000498 Reflector - Amber (use with INC only) 427 7632046140 Moulding 140in


1

2

2

3

5

6

7

8

97

8

67

97

8

85

493

97

01

11

21

01

11

31

41

41

41

41

51

61

7181 51

61

51

61

5161

7181

5161

9102

12

4

9102

12

22

22

32

42

42

425262

62

6252

TUNNEL TOOLBOX

Item #27, Moulding, not shown


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 13 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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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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SELF-LOADING DOLLY


1 4178000654 Bracket 22 4178000655 Bracket LH 13 4178000656 Bracket RH 14 4706005244 Plate 25 7283000004 Collar 16 7114161050 Capscrew, 0.38”-16NC x 1.25” 27 7660162604 Locknut, 0.38”-16NC 28 7950160163 Flatwasher, 0.38” ID 169 7120000024 Capscrew, 0.38”-16NC x 1.00” 2

10 7660162100 Wingnut, 0.38”-16NC 211 7002000022 Dollies - Self-Loading (Steel Axle) 112 7950160000 Lockwasher, 0.38” ID 12


SELF-LOADING DOLLY

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68

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812

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128

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11


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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1

3L H & R H SIDETAILPLATES

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ITEM #17 NOT INCLUDED IFUNIT SUPPLIED WITH D-RING

OR TOW SLING OPTIONS



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 918 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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86 SEE RECOVERY SHEAVE FOR PARTS


TOW SLING

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TOW SLING

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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 2


RECOVERY SHEAVE

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L-ARM SPACER STORAGE

ITEM PART NO. DESCRIPTION QTY1 3178000721 Bracket 12 7115140850 Capscrew, 0.25”-20NC x 1.00” 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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STONE GUARD

ITEM PART NO. DESCRIPTION QTY1 4706005533 Plate LH (Stainless Steel) 1

4707000314 Plate LH (Aluminum Diamond)2 4706005534 Plate RH (Stainless Steel) 1

4707000315 Plate RH (Aluminum Diamond)3 7114140818 Capscrew, 0.25”-20NC x 1.00” 124 7950140141 Flatwasher, 0.25” ID 125 7660142600 Locknut, 0.25”-20NC 12


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STONE GUARD


ITEM PART NO. DESCRIPTION QTY1 7696000069 Elbow Pipe 1

FORD DIESEL 08 EXHAUST ALTERATION


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EXISTING DIFFUSER USED

FORD DIESEL 08 EXHAUST ALTERATION


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MPL WRECKER PARTS MANUAL - Jerr-Dan Man… · MPL Wrecker Parts Manual - Page 2 5-376-000101 Rev 3....

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