JD35IND HDUL HEAVY DUTY WRECKER PARTS · PDF fileWinch Installation DP25K & DP35K Planetary Winches ... JD35IND HDUL Heavy Duty Wrecker Parts Manual - Page 10 5-376-000158 Rev 0 SUBFRAME

JD35IND HDUL HEAVY DUTY WRECKER

PARTS MANUAL

5-376-000158Rev 0 - July 01, 2012 © 2012 Jerr-Dan Corporation. All Rights Reserved.

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

www.jerr-dan.com

JD35IND HDUL Heavy Duty Wrecker Parts Manual - Page 3 5-376-000158 Rev 0

This manual covers the following Jerr-Dan Models:

JD35IND HDUL - 35 Ton Independent HDUL

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

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

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

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

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

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

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

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

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

SERIAL NO.

MODEL NO.

MANUFACTURED BY:

JLG INDUSTRIES, INC.

1001127220-00

FOR:


THIS PAGE INTENTIONALLY LEFT BLANK


Subframe Installation (86" Body) ............................................................................................ 6 - 7Subframe Installation (146" Body)......................................................................................8 - 9Subframe Hydraulic Tubing ................................................................................................. 10 - 11Hydraulic Tank Installation ................................................................................................... 12 - 13Hydraulic Tank Assembly .................................................................................................... 14 - 15Rear Spade Installation ........................................................................................................ 16 - 17Rear Spade Tubing .............................................................................................................. 18 - 19Boom Installation - 2 Piece Boom ........................................................................................ 20 - 21Wrecker Boom Assembly - 2 Piece Boom .......................................................................... 22 - 23Winch Installation DP25K & DP35K Planetary Winches ..................................................... 24 - 25Boom Tube Assembly .......................................................................................................... 26 - 27Underlift Installation .............................................................................................................. 28 - 29Underlift Assembly - 53,000 LB (Standard) ....................................................................... 30 - 31Underlift Assembly - 56,500 LB (Optional) ......................................................................... 32 - 33Underlift Winch Installation .................................................................................................. 34 - 35Crosstube Installation .......................................................................................................... 36 - 37Underlift Tools - Frame Forks .............................................................................................. 38 - 39Underlift Tools - 14,000 LB Tire Lift .................................................................................... 40 - 41Underlift Tools - 25,000 LB Tire Lift .................................................................................... 42 - 43Underlift Tools - Fifth Wheel Attachment ............................................................................ 44 - 45Underlift Tools - Pintle Hook ................................................................................................. 46 - 47Rear Tail Plate Installation .................................................................................................... 48 - 49Controls - Control Valve Installation .................................................................................... 50 - 51Controls - Push-Pull Cables Installation - 6 & 14 Function ................................................. 52 - 53Controls - Push-Pull Cables Installation - 16 Function ....................................................... 54 - 55Controls - Control Valve Assembly - 3935000178 & 3935000180 ................................... 56 - 57Controls - Control Valve Assembly - 3935000218 ............................................................. 58 - 59Controls - 6 Function Non-Proportional Miratron ................................................................ 60 - 61Controls - 12 Function Non-Proportional Miratron .............................................................. 62 - 63Controls - 12 Function Proportional Miratron ..................................................................... 64 - 65Controls - Electrical Emergency Stop ................................................................................. 66 - 67Hydraulics - Supply-Pressure-Return....................... ....................................................... 68 - 69Hydraulics - Lines and Fittings ............................................................................................ 70 - 75Driver Side Hydraulic Pressure Gauges ............................................................................ 76 - 77Driver Side Hydraulic Pressure Gauges W/ Drag Winch Option ...................................... 78 - 79Driver & Passenger Side Winch Air Controls - DP 25K & 35K .......................................... 80 - 83Winch Electric Speed Controls - DP 25K & 35K ................................................................. 84 - 87Winch Electric 2-Speed Main & Drag Winch Controls ........................................................ 88 - 89Decals....................................................... ........................................................................ 90 - 91

INDEX DESCRIPTION PAGE


SUBFRAME INSTALLATION - 86” BODY

ITEM PART NO. DESCRIPTION QTY1 3868000277 Subframe 12 4706002262 Plate 23 4706002961 Plate 24 4706002490 Plate 25 4706002554 Plate 26 4062000688 Bar 27 7118221816 Capscrew, 0.75”-10NC x 2.25” 368 7660222308 Locknut, 0.75”-10NC 369 7118242050 Capscrew, 0.88”-9NC x 2.50” 6

10 7949000061 Washer, 0.88” ID 611 7660242308 Locknut, 0.88”-9NC 612 4062000269* Bar 213 4706002163* Plate 214 4706002555* Plate 215 4706002556* Plate 2

* Also Available In Shim Kit - 3577000118



1

2

3

4

5

6

7

7

7

8

8

8

9 10

11

12

13

14

15


1 3868000278 Subframe 12 4706002262 Plate 23 4706002961 Plate 24 4706002490 Plate 25 4706002554 Plate 26 4062000688 Bar 27 7118221816 Capscrew, 0.75”-10NC x 2.25” 368 7660222308 Locknut, 0.75”-10NC 369 7118242050 Capscrew, 0.88”-9NC x 2.50” 6

10 7949000061 Washer, 0.88” ID 611 7660242308 Locknut, 0.88”-9NC 612 3868000157 Subframe Weld Stand Alone 113 3274000011 Toolbox Clamp Weldment 414 7115182050 Capscrew, 0.50”-13NC x 2.50” 415 7660182301 Locknut, 0.50”-13NC 416 7950182052 Flatwasher, 0.50” ID 417 4062000269 Bar 218 4706002163 Plate 219 4706002555 Plate 220 4706002556 Plate 221 4705000705 Plate 4


ITEM PART NO. DESCRIPTION QTY




1

2

3

4

5

6

7

7

7

8

8

8

9 10

11

12

14

1315

16

21

17

18

19

20


SUBFRAME HYDRAULIC TUBING


1 7661000022 Nut, 0.31”-18NC 302 7115150850 Capscrew, 0.31”-18NC x 1.00” 163 7115150650 Capscrew, 0.31”-18NC x 0.75” 384 7912000282 Tube Assembly 15 7912000280 Tube Assembly 16 7209000024 Bushing, 0.62” ID x 1.31” 147 7950150000 Washer, 0.31” ID 548 7445101025 Bulkhead 49 7445121225 Bulkhead 2

10 7445080825 Bulkhead 211 7209000023 Bushing, 0.50” ID x 1.31” 612 7209000033 Bushing, #16 413 7661000027 Stacking Nut 1514 7007000036 Adapter 1515 7209000032 Bushing, #12 616 7912000281 Tube Assembly 117 7274000030 Clamping Unit 618 7912000287 Tube Assembly 219 7274000049 Clamp 520 7912000284 Tube Assembly 121 7912000288 Tube Assembly 222 7912000285 Tube Assembly 123 7912000289* Tube Assembly 224 7912000283 Tube Assembly 1

* For Use With Drag Winch Option


SUBFRAME HYDRAULIC TUBING

1

1

1

2

2

2

3

3

1

33

3

3

3

3

3

1

45

7

7

7

7

7

7

7

7

7

7

7

88

9

9

10

11

11

1813

13

13

14

14

2116

17

14

1717

17

17

17

17

17

17

17

19

19

19

22

20

23

23

24

6 116

6

15 126 11 6 6


HYDRAULIC TANK INSTALLATION


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


HYDRAULIC TANK INSTALLATION

6

4

5

7

2

3

1


HYDRAULIC TANK ASSEMBLY


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


HYDRAULIC TANK ASSEMBLY

1

2

3

4

5

6

7

8


REAR SPADE INSTALLATION


1 7115161250 Capscrew, 0.38”-16 NC x 1.50” 22 7950160161 Flatwasher, 0.38” I.D. 23 7660162601 Locknut, 0.38”-16 NC 24 3691000267 Pin 25 4706003716 Plate 26 7114140518 Capscrew, 0.25”-20 NC x 0.62” 87 7949000025 Lockwasher, 11MM ID 88 7950140153 Flatwasher, 0.25” ID 89 7320000006 Spade Cylinder Assembly 2

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


REAR SPADE INSTALLATION

5

15

6

10

14

1

11

23

4

9

9

17

16

23

1

4

578

678

12 13

1313

1213

1514

15

16

17 18

18

19

19


REAR SPADE TUBING


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

* Available In Hydraulic Tubing Kit - 7577000637


REAR SPADE TUBING

3

12

4 5

5

55

5

5

5

5

5

5

556

65

5

555

5

5

5


BOOM INSTALLATION - 2 PIECE BOOM


1 3170000183 Boom Assembly 12 7320000070 Lift Cylinder Assembly 23 3691000256 Pin 14 3691000255 Pin 45 7115181050 Capscrew, 0.50”-13NC x 1.25” 56 7950180000 Lockwasher, 0.59” ID 57 7950180161 Flat washer, 0.50” ID 58 4949000031* Shim, 0.63” Thick 2

4949000032* Shim, 0.93” Thick 29 7440030000 Fitting 3



BOOM INSTALLATION - 2 PIECE BOOM

1

2

2

3

4

4

4

4 5

5

5

5

5

6

6

6

6

67

7

7

7

7

8

9

9

9


WRECKER BOOM ASSEMBLY - 2 PIECE BOOM


1 3170000182 Base Section Boom Weldment 12 3170000148 Fly Section Boom Weldment 13 7320000031 Extension Cylinder Assembly 14 4691000323 Pin 15 7754000061 Retaining Ring 26 4691000208 Pin 17 7754000048 Retaining Ring 28 4679000163 Pad 19 7114140818 Capscrew, 0.25”-20NC x 1.00” 1

10 4679000162 Pad 111 4706002435 Plate 112 7950180153 Flatwasher, 0.50” ID 613 7115180850 Capscrew, 0.50”-13NC x 1.00” 614 4177000033 Brace 215 7115164450 Capscrew, 0.38”-16NC x 5.50” 216 7950160251 Flatwasher, 0.38” ID 417 7660161600 Locknut, 0.38”-16NC 218 4831000061 Spacer, 0.38” x 3.00” x 4.50” 219 4062000158 Bar 120 4831000064 Spacer, 1.50” x 0.515” x 0.50” 221 7115180750 Capscrew, 0.50”-13NC x 0.88” 222 7115181450 Capscrew, 0.50”-13NC x 1.75” 223 7950180000 Lockwasher, 0.59” ID 824 4679000168 Pad 225 4754000003 D-Ring 226 4691000243 Boom Nose Ring 227 7690142845 Pin 228 4706002856 Plate 229 7660142604 Locknut, 0.25”-20NC 1


WRECKER BOOM ASSEMBLY - 2 PIECE BOOM

1

2

3

45

67

8

9 10

11

12

12

12

13

13

14

14

1516

16

17 18

19

20

2122

2323

23

24

25

2627

28

29


WINCH INSTALLATION - DP25K & DP35K PLANETARY WINCHES


Winch Install DP 25K1 3636000068 Bracket, Winch Mount 12 7970000050 Winch, DP 25K - RH 13 7970000049 Winch, DP 25K - LH 14 7118181016 Capscrew, 0.50”-13NC x 1.25” 45 7660182301 Locknut, 0.50”-13NC 46 7118201616 Capscrew, 0.63”-11NC x 2.00” 167 7661000018 Nut, 0.63”-11NC 228 7118202016 Bolt, 0.63”-11NC x 2.50” 69 7440030000 Grease Fitting 2

10 7253000002 Grease Cap 211 7754000049 Retaining Ring, 3.50” Dia. 212 7754000048 Retaining Ring, 2.00” Dia. 213 3249000001 Cable Guide Weldment 214 7809000019 Sheave, 7.75” Dia. (0.63” Wire Rope) 215 4249000001 Cable Guide, 1.00” x 1.75” x 2.75” 416 3577000019 Sheave Shim Kit 117 3691000129 Pin 218 3249000010 Sheave Support Weldment 219 7115142050 Capscrew, 0.25”-20NC x 2.50” 420 7660141600 Locknut, 0.25”-20NC 421 7248000040 Wire Rope 0.63” x 200’ W/ 5T Hoist 1

7248000078 Wire Rope 0.63” x 200’ W/ 5T Swivel 17248000037 Wire Rope 0.63” x 250’ W/ 5T Hoist 17248000079 Wire Rope 0.63” x 250’ W/ 5T Swivel 1

Winch Install DP 35K1 3636000068 Bracket, Winch Mount 12 7970000067 Winch, DP 35K - RH 13 7970000066 Winch, DP 35K - LH 14 7118181016 Capscrew, 0.50”-13NC x 1.25” 45 7660182301 Locknut, 0.50”-13NC 46 7118201616 Capscrew, 0.63”-11NC x 2.00” 167 7661000018 Nut, 0.63”-11NC 228 7118202016 Bolt, 0.63”-11NC x 2.50” 69 7440030000 Grease Fitting 2

10 7253000002 Grease Cap 211 7754000049 Retaining Ring, 3.50” Dia. 212 7754000048+ Retaining Ring, 2.00” Dia. 2

7754000033* Retaining Ring, 1.50” Dia. 213 3249000001+ Cable Guide Weldment 2

3249000012* Cable Guide Weldment 214 7809000019+ Sheave, 7.75” Dia. (0.63” Wire Rope) 2

7809000006* Sheave, 8.00” Dia. (0.75” Wire Rope) 215 4249000001+ Cable Guide, 1.00” x 1.75” x 2.75” 4

4249000002* Cable Guide, 1.00” x 0.81” x 2.75” 416 3577000019+ Sheave Shim Kit 1

4949000045* Washer, 5.00” OD x 1.53” ID 417 3691000129+ Pin 2

3691000169* Pin 218 3249000010+ Sheave Support Weldment 2

3249000011* Sheave Support Weldment 219 7115142050 Capscrew, 0.25”-20NC x 2.50” 420 7660141600 Locknut, 0.25”-20NC 421 7248000040+ Wire Rope, 0.63” x 200’ W/ 5T Hoist 1

7248000078+ Wire Rope, 0.63” x 200’ W/ 5T Swivel 17248000037+ Wire Rope, 0.63” x 250’ W/ 5T Hoist 17248000079+ Wire Rope, 0.63” x 250’ W/ 5T Swivel 17248000055* Wire Rope, 0.75” x 200’ W/ 7T Hoist 17248000080* Wire Rope, 0.75” x 200’ W/ 7T Swivel 1


* Denotes Parts Used In 3/4” (0.75”) Wire Cable Option+ Denotes Parts Used In 5/8” (0.63”)Wire Cable Option


WINCH INSTALLATION - DP25K & DP35K PLANETARY WINCHES

1

2

3

4

5

6

668

7

7

7

7

99

10 1011

11 12

12

13

13

14

14

1515

1515

16

16

16

17

17

9

918

18

19

19

20

20

21

21


BOOM TUBE ASSEMBLY

ITEM PART NO. DESCRIPTION QTY1 7912000239* Tube Assembly 22 7912000240* Tube Assembly 13 7912000241* Tube Assembly 14 4706002206 Plate 15 7115160850 Capscrew, 0.38”-16NC x 1.00” 46 7950160000 Lockwasher, 0.38” ID 47 7274000050 Clamp Assembly 68 7274000051 Clamp Assembly 4

* Available In Hydraulic Tubing Kit - 7577000661


BOOM TUBE ASSEMBLY

4 65

11

2

3

7

7

7

8

8

7

7

7


UNDERLIFT INSTALLATION


1 3507100001 Underlift Assembly - 53,000 LB (Standard) 13170000407 Underlift Assembly - 56,500 LB (Optional) 1

2 3170000423 Underlift Boom Weldment 13 7320000063 Lift Cylinder 14 7320000096 Tilt Cylinder - (Standard) 1

7320000097 Tilt Cylinder - (Optional) 15 4691000563 Pin 16 7118224450 Capscrew, 0.75”-10NC x 5.50” 17 7950220141 Flatwasher, 0.75” ID 48 7950220000 Washer, 0.75” ID 39 7660220230 Nut, 0.75”-16NF 1

10 7440030000 Grease Fitting 411 7253000002 Grease Fitting Cap 712 4691000484 Pin 113 4706004528 Plate 114 7118201650 Capscrew, 0.63”-11NC x 2.00” 415 7950200000 Lockwasher, 0.63” ID 516 7950200141 Flatwasher, 0.63” ID 517 7118201250 Capscrew, 0.63”-11NC x 1.50” 318 3691000231 Pin 119 7115220850 Capscrew, 0.75”-10NC x 1.00” 220 7440000000 Grease Fitting 321 3691000232 Pin 122 4691000290 Pin 123 7754000051 Retaining Ring 224 4691000291 Pin 125 7754000018 Retaining Ring 226 4679000127 Pad 427 7115161623 Capscrew, 0.38”-16NC x 2.00” 828 7189000017 Bumper 229 7262000025 Chain W/Latch Hook 230 7660202601 Locknut, 0.63”-11NC 231 3561000017 Hook Weldment 232 7115161450 Capscrew, 0.38”-16NC x 1.75” 433 7950160141 Flatwasher, 0.38” ID 4


UNDERLIFT INSTALLATION

1

2

3

4

5

67

78 9

1011

1011

1213

2011

2011

2011

1415

16

15 1617

18

19

19

7

78

821

2223

2425

26

2627

27

28

29

1730

3132 33


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


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

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


5

1

2

4

3

8

71

8181

91

91

7

7

61

67

7

018

6272

801

8 6272

6272

018

41

21

51

51

51

51

4151

51

9

3242

9

324241

6272

018

018

801

12 312252

2252

0211

2252

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


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


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

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

4679000293 Pad, 0.25 Thk 813 7114140518 Capscrew, 0.25”-20NC x 0.63” 814 4706005281 Plate 115 7661000019 U-Nut, 0.25”-20NC 416 7115140650 Capscrew, 0.25”-20NC x 0.75” 417 7950140000 Lockwasher, 0.25” ID 418 7440030000 Grease Fitting 1


6

1

2

4

3

31

41

6161

71

71

7

7

81

57

7

31

31

21

11 01

01

11

9

01

21

8

51

51

11 01

01

11 01

9

8

31

21

31

21

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


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

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

7248000079 Cable, 0.63” x 250’ w/Swivel Hook 17248000055 Cable, 0.75” x 200’ 17248000080 Cable, 0.75” x 200’ w/Swivel Hook 1

* Available in Cable Tie Back Assembly - 3249000038

UNDERLIFT WINCH INSTALLATION (OPTIONAL)



23 19

18

1819

2122

17

20 24

131315

14

6

7

10

10

9

8

5

16

11

12

11

12

23

4

4

2

3

1

UNDERLIFT WINCH INSTALLATION (OPTIONAL)


CROSSTUBE INSTALLATION


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

* Available in Shim Kit - 3577000018


2

3

1

4

5

6

7

CROSSTUBE INSTALLATION


UNDERLIFT TOOLS - FRAME FORKS


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

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


8

4

5

67

1

2 1

3

4

8

5

67

9

9

01

01

11

1121

21

21

21

UNDERLIFT TOOLS - FRAME FORKS

Item #13, not shown


UNDERLIFT TOOLS - 14,000 LB TIRE LIFT


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

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

7894000041* Strap, 2” Wide (Optional - Orange) 212 7894000028* Ratchet, 2” Wide Strap 413 3561000008* Hook, 2” Wide Strap 414 7330000550* Decal 215 7759000004* Rivet 816 7330000278* Decal 2

* Also available as - 2503550088


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61

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51

51





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

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

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


2

1

4

3

56

56

7

7

8

8

20

20

91

91

9

901

111101

3161

3161

4171

4171

5181

21



UNDERLIFT TOOLS - FIFTH WHEEL ATTACHMENT


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

* Also available as - 2503880033


2

5

4

3 7

8

8

6

6

1

7

UNDERLIFT TOOLS - FIFTH WHEEL ATTACHMENT


UNDERLIFT TOOLS - PINTLE HOOK


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

7056000004 Ball, 2.00” Dia 17056000005 Ball, 2.31” Dia 17056000006 Ball, 50mm Dia 1


1

23

4

UNDERLIFT TOOLS - PINTLE HOOK


REAR TAIL PLATE INSTALLATION


1 4706005772 Plate 22 7759000018 Rivet 12


REAR TAIL PLATE INSTALLATION

1

1

2

2


CONTROLS - CONTROL VALVE INSTALLATION


1 3935000199 Control Valve Assy - 9 Sect 3 Sol 24V 13935000200 Control Valve Assy - 9 Sect 7 Sol 24V 13935000201 Control Valve Assy - 9 Sect 9 Sol 24V 13935000178 Control Valve Assy - 9 Sect 7 Sol 12V 13935000180 Control Valve Assy - 9 Sect 3 Sol 12V 13935000179 Control Valve Assy - 9 Sect 9 Sol 12V 1

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

10 7590140161 Flatwasher, 0.25” ID 2511 7661000006 Well Nut, 0.25”-20 NC 812 7796000012 Seal 8ft13 7660142601 Locknut, 0.25”-20NF 614 4706005591 Plate 115 4706002643 Plate 116 4679000171 Pad 117 4679000143 Pad, Rubber 118 4679000144 Pad, Rubber 119 7330000199 Decal 120 7330000262 Decal 121 7330000200 Decal 122 7330000253 Decal 123 7330000302 Decal 124 7330000304 Decal 125 7330000299 Decal 126 7330000300 Decal 127 7330000256 Decal 128 7330000257 Decal 129 4706005656 Panel 1


30 7413000002 Nutsert, 0.25”-20 NC 531 7950140000 Lockwasher, 0.25” ID 532 7114140618 Capscrew, 0.25”-20NC x 0.75” 533 4314000208 Coverplate 134 4314000209 Coverplate 135 7701000067 Plug, 0.50” 4


CONTROLS - CONTROL VALVE INSTALLATION

��

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��

��

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��OPERATOR'S PRE-TRANSPORT CHECKLIST

��

��

��

��

��

��

��

��

1

2

3

3

3

33

3

3 3

4

4 4

5

6

7

8

99

910

1010

10

10

11

12

13

13

14

15

1718

19 2021

2223 24 2526

2728

29

30

30

31

3132

32

33

34

10

10

35

16



1 3178000260 Bracket Weldment 12 2686000016 Panel Weldment 13 4706002746 Plate 14 4314000210 Coverplate 15 4706005594 Plate, LH Cable Bracket 16 4309000001 Coupling 37 4309000007 Coupling, Cable 68 4679000119 Pad 19 4679000131 Pad 1

10 4638000003 Brush 111 4411000113 Extrusion Brush Holder 112 7806000005 Shaft 113 7754000009 Retaining Ring 214 7551000034 Handle 915 7701000058 Plug, 0.31” 416 7248000053 Push-Pull Cable 917 7990000003 Yoke 918 7690141200 Pin 1819 7690000810 Pin 1820 7660140230 Nut, 0.25”-28NF 1821 7082000005 Bearing, 0.75” ID x 1.00” OD x 0.50” 222 7790141056 Screw, 0.25”-20NC x 0.63” 1323 7111140813 Screw, 0.25”-20NC x 1.00” 1024 7115140650 Capscrew, 0.25”-20NC x 0.75” 325 7115140850 Capscrew, 0.25”-20NC x 1.00” 326 7950140161 Flatwasher, 0.25” ID 2227 7660142601 Locknut, 0.25”-20NC 628 7661000006 Nut, 0.25”-20NC 1029 7115161050 Capscrew, 0.38”-16NC x 1.25” 430 7950160161 Flatwasher, 0.38” ID 831 7660162601 Locknut, 0.38”-16NC 432 7330000199 Decal 1


33 7330000262 Decal 134 7330000200 Decal 135 7330000253 Decal 136 7330000703 Decal 137 7330000702 Decal 138 7701000067 Plug, 0.50” 4

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


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

OPERATOR'S PRE-TRANSPORT CHECKLIST

��

��

��

��

��

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B

DETAIL B

A

DETAIL A

12

3

4

5

6

67

7

8

9

10

11

12

13

13

14

15

1617

18

18

1817

1919 18

19

1920

20

21

21

22

22

23

23

24

2526

26

26

26

2626

27

27

28

28

2930 30

31

32

33

34 35

36

37

38

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


CONTROLS - PUSH-PULL CABLES INSTALLATION - 16 FUNCTION

ITEM PART NO. DESCRIPTION QTY ITEM PART NO. DESCRIPTION QTY

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

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

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


A

DETAIL A

B

DETAIL B

1

2

3

14

5

6

78

910

10

11

1818

1213

415

15

16

16

1719

20

20

21

21

2122

22

22

2222

22

22

22

22

22

2223

23

23

24

24

2526

2627

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

CAUTION

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

199

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

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


200

CAUTION262

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

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

WARNING

WRK BMEXT

BOOMLIFT

FRONTWINCH

REARWINCH

LEFTSPADE

TUOTUO UP441

OUT UP

DNIN ININ DN442

DRAGWINCH

U/LLIFT

U/LEXTEND

U/LTILT

RIGHTSPADE

443

UP UPUP OUTOUT

DNINDNINDN444

FRONT WINCHFREESPOOL

RELEASED WHEN LIT737

REAR WINCHFREESPOOL


FRONT WINCH2-SPEED

HIGH SPEED WHEN LIT739

REAR WINCH2-SPEED


U/L WINCHFREESPOOL


U/L WINCH2-SPEED


28

29

30

31

32 33

34

35

36

36

37

3839

141516

4

15

16

CONTROLS - PUSH-PULL CABLES INSTALLATION - 16 FUNCTION


CONTROLS - CONTROL VALVE ASSEMBLY - 3935000178 & 3935000180

ITEM PART NO. DESCRIPTION QTY1 3177000060 Valve Mount Weldment 12 4706005657 Plate 13 3935000186 Valve Assembly - 6 Function Remote 1

3935000187 Valve Assembly - 12 Function Remote 14 7912000301* Tube Assembly 15 7912000302* Tube Assembly 16 7912000303* Tube Assembly 17 7912000304* Tube Assembly 18 7912000305* Tube Assembly 19 7912000306* Tube Assembly 2

10 7912000307* Tube Assembly 211 7912000308* Tube Assembly 612 7115152450 Capscrew, 0.31”-18NC x 3.00” 313 7660152601 Locknut, 0.31”-18NC 314 7950140161 Flatwasher, 0.31” ID 315 7445060625 Fitting, Union Bulkhead 116 7443000012 Tee 117 7445121225 Fitting, Union Bulkhead 218 7445161625 Fitting, Union Bulkhead 319 7445080825 Fitting, Union Bulkhead 1220 7445101025 Fitting, Union Bulkhead 421 7445081043 Adapter 1222 7445101043 Adapter 423 7445121243 Adapter 224 7443000211 Elbow 225 7445151243 Adapter 126 7912000309* Tube Assembly 627 7912000310* Tube Assembly 128 7445060645 Elbow 1

* Available in Hydraulic Tubing Kit - 7577000668


1

2 3

4

5

6

7

8

9 9

01

01

11

1162

62

72

21

3141

51

61

71 71

81

81

8191

9191

91

02

0212

12

1212

22 2232

3242

42

52

82

CONTROLS - CONTROL VALVE ASSEMBLY - 3935000178 & 3935000180



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

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

* Available in Hydraulic Tubing Kit - 7577000670

CONTROLS - CONTROL VALVE ASSEMBLY - 3935000218


1

23

4

5

6

7

8

99

9

10

10

1011

1111

26

26

26

27

12

13

14

15

16

1717

18

18

1819

19

19

1919

19

20

2020

20

21

21

21

21

21

21

22 22

22

23

23

24

24

25

28

CONTROLS - CONTROL VALVE ASSEMBLY - 3935000218


CONTROLS - 6 FUNCTION NON-PROPORTIONAL MIRATRON


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

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


AB

C

ABC

ABC

AUX 2

AUX 1

O/R LIGHTS

BODY MARKERS

CABINET RH

CABINET LH

RIGHT TURN

LEFT TURN

CONTROL

MARKER

FLOOD #2

FLOOD #1

BEACON #2

BEACON #1

SWITCHPANEL

OUTOUT

OUT OUT

OUTIN OUT

G

W

M

BB

AUX 3AUX 3

BACK-UP

IN OUT

IN

RHLH

BEACON 1AUX

AUXHOT 2

AUX 3

O/R LIGHTS

BODY MARKERS

AAC

CONTROL

GROUND

SDD

AUXHOT 1

BEACON 1AUX

AUX 2

Y

P

V

T

A

C

H

EE

F

CC

PAT REWOP SWITCH PANEL

AA

TURN SIGNAL

OUT

IN

I

BB

B

X

J

S

LEFT BODY

HARNESS

RD

FF

U

O

E

LIGHT BAR

M

Q

W

MAIN

HARNESS

L

G

K

N

HARNESS

RIGHT BODY

Z

IN

MARKER

GROUND

DD

RELAY

10 A

1

11

2

2

2

3

3

3

4

4

5

6

7

8

901

11

11213141

51

61

71

81

02

12

91

91





1 7295000124 Remote Controller 12 7552000371 Harness 13 7552000148 Harness 14 7493000014 Grommet 25 7493000011 Grommet 16 7346000029 In-Line Fuse Holder 17 7457000008 Fuse - 10 Amp 18 7345001714 Electrical Terminal 29 7346000039 Tubing, Heat Shrink 12in

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


AB

C

ABC

AUX 2

AUX 1

O/R LIGHTS

BODY MARKERS

CABINET RH

CABINET LH

RIGHT TURN

LEFT TURN

CONTROL

MARKER

FLOOD #2

FLOOD #1

BEACON #2

BEACON #1

SWITCHPANEL

OUTOUT

OUT OUT

OUTIN OUT

G

W

M

BB

AUX 3AUX 3

BACK-UP

IN OUT

IN

RHLH

BEACON 1AUX

AUXHOT 2

AUX 3

O/R LIGHTS

BODY MARKERS

AAC

CONTROL

GROUND

SDD

AUXHOT 1

BEACON 1AUX

AUX 2

Y

P

V

T

A

C

H

EE

F

CC


AA

TURN SIGNAL

OUT

IN

I

BB

B

X

J

S

LEFT BODY

HARNESS

RD

FF

U

O

E

LIGHT BAR

M

Q

W

MAIN

HARNESS

L

G

K

N

HARNESS

RIGHT BODY

Z

IN

MARKER

GROUND

DD

RELAY

10 A

A01

1

1

1

2

2

2

3

3

3

4

4 5

367

898

9

9

01

01

11

21

31

415161

516181

71

71

91


Item #20, not shown


CONTROLS - 12 FUNCTION PROPORTIONAL MIRATRON


1 7295000148 Remote Controller 12 7295000146 Antenna 13 7552000433 Harness 14 7552000148 Harness 15 7493000014 Grommet 26 7493000011 Grommet 17 7346000039 Tubing, Heat Shrink 12in8 7740000001 Relay, 40 Amp 19 7457000006 Fuse - 15 Amp 1

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


AB

C

ABC

AUX 2

AUX 1

O/R LIGHTS

BODY MARKERS

CABINET RH

CABINET LH

RIGHT TURN

LEFT TURN

CONTROL

MARKER

FLOOD #2

FLOOD #1

BEACON #2

BEACON #1

SWITCHPANEL

OUTOUT

OUT OUT

OUTIN OUT

G

W

M

BB

AUX 3AUX 3

BACK-UP

IN OUT

IN

RHLH

BEACON 1AUX

AUXHOT 2

AUX 3

O/R LIGHTS

BODY MARKERS

AAC

CONTROL

GROUND

SDD

AUXHOT 1

BEACON 1AUX

AUX 2

Y

P

V

T

A

C

H

EE

F

CC


AA

TURN SIGNAL

OUT

IN

I

BB

B

X

J

S

LEFT BODY

HARNESS

RD

FF

U

O

E

LIGHT BAR

M

Q

W

MAIN

HARNESS

L

G

K

N

HARNESS

RIGHT BODY

Z

IN

MARKER

GROUND

DD

RELAY

15 A

ABC

ABC

1

2

12

1

34

3

4 12

5

5

6

4

7

8

9

11

21314151

31410261

71 8181

314191

12

22

3242

52

62

62

CONTROLS - 12 FUNCTION PROPORTIONAL MIRATRON

Items #10, #20, #27 and #28, not shown


CONTROLS - ELECTRICAL EMERGENCY STOP


1 8977010103 Wire, 16GA. - 2 Conductor 40ft2 7346000094 Electrical Connector 13 7346000035 Electrical Terminal 24 7346000037 Seal, Cable 65 7346000087 Electrical Connector 26 7346000099 Electrical Terminal 47 8977500100 Wire, 16GA. Black 3in8 7870000128 Switch, Emergency Pushbutton 29 7870000129 Switch, Emergency Contact Block 2

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


22

12

22

21

EMERGENCYSTOP

557

1

234

789

456

1

0111

0111

1

89

89

21

CONTROLS - ELECTRICAL EMERGENCY STOP

Item #13, not shown


HYDRAULICS - SUPPLY-PRESSURE-RETURN


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

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

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


PMUP

SISSAHC FO TNORF

KNAT

CILUARDYH FO WEIV EDISEMARFBUS NO DLOFINAM

TROPPUS EMARF PYT

51

1

23

456

7

89

01

1121

31 41

41

12

2232

9102

81

61

71

HYDRAULICS - SUPPLY-PRESSURE-RETURN

Item #24, not shown


HYDRAULICS - LINES AND FITTINGSITEM PART NO. DESCRIPTION QTY

1 7445040443 Adapter 12 7443000207 Reducer 13 7443000213 Fitting 14 7445161672 Fitting 15 7445080825 Union 46 7443000109 Adapter 67 7445060643 Adapter 138 7445060645 Elbow 19 7445100843 Adapter 4

10 7790060676 Screw, #6 x 0.38” 611 7445080837 Union 212 7445060672 Elbow 213 7445161620 Elbow 214 7430000004 Filter Assembly, Oil 215 7443000150 Adapter 216 7470000002 Gauge, Oil 217 7445040421 Fitting 218 7470000004 Gauge 219 7474000040 Clamp 420 7115141050 Capscrew, 0.25”-20NC x 1.25” 421 7950140161 Flatwasher, 0.25” ID 822 7660142601 Locknut, 0.25”-20NC 423 7445060219 Adapter 124 7274000063 Clamp 125 7445101032 Fitting 626 4619000006 Manifold 127 7115161650 Capscrew, 0.38”-16NC x 2.00” 228 7950160000 Lockwasher, 0.38” ID 229 4570000245* Hose Assembly 230 4570000246* Hose Assembly 231 4569162038* Hose Assembly 132 4569163038* Hose Assembly 133 4569162029* Hose Assembly 134 4569163029* Hose Assembly 135 4569132035* Hose Assembly 136 4569173042* Hose Assembly 1

ITEM PART NO. DESCRIPTION QTY37 4569133035* Hose Assembly 138 4569173035* Hose Assembly 139 4567132041* Hose Assembly 140 4569183055* Hose Assembly 141 4567133041* Hose Assembly 142 4567182028* Hose Assembly 143 4567183040* Hose Assembly 144 4569132032* Hose Assembly 145 4567133032* Hose Assembly 146 4569132038* Hose Assembly 147 4569133038* Hose Assembly 148 4570000138* Hose Assembly 249 4570000301* Hose Assembly 250 4570000192* Hose Assembly 151 4570000166* Hose Assembly 152 4569132019* Hose Assembly 253 4569133020* Hose Assembly 254 4567120017* Hose Assembly 255 4570000271* Hose Assembly 256 4567112025* Hose Assembly 157 4567113031* Hose Assembly 158 4567132019* Hose Assembly 459 4567152052* Hose Assembly 460 4570000260* Hose Assembly 261 4569180022* Hose Assembly 162 4569180026* Hose Assembly 163 4570000329* Hose Assembly 1


HYDRAULICS - LINES AND FITTINGS


64 4567152024# Hose Assembly 165 4567152018# Hose Assembly 166 4570000106# Hose Assembly 167 4570000107# Hose Assembly 168 4570000335^ Hose Assembly 1

4570000302+ Hose Assembly 169 4570000336^ Hose Assembly 1

4570000176+ Hose Assembly 170 4569163042- Hose Assembly 171 4569162042- Hose Assembly 172 4569162027- Hose Assembly 173 4569162030- Hose Assembly 1

* Available in Hydraulic Tubing Kit - 7577000662 # Available in Hydraulic Tubing Kit - 7577000648 ̂ Available in Hydraulic Tubing Kit - 7577000664+ Available in Hydraulic Tubing Kit - 7577000665 - Available in Hydraulic Tubing Kit - 7577000663


VIEW A

1.0 HOSE

1.0 HOSE

DRAG WINCH, OUTDRAG WINCH, IN

RETURN, INLET / MID-INLET

REAR WINCH, OUT

FRONT WINCH, OUT

WRKR BOOM EXT, OUTWRKR BOOM EXT, IN

REAR WINCH, IN

FRONT WINCH, IN

PRESSURE, MID-INLET

PRESSURE, INLET

RETURN, OUTLET

DN IN NIND DN INDN IN

WINCHREAR

LIFTWRK BM

EXTWRK BM

SPADELEFT

SPADERIGHT

UP UPUP OUT OUT

WINCHFRONT

EXTU/L

TILTU/L

UP OUTOUT

"A" PORT

"B" PORT

PRESSURE TO "B"

PRESSURE TO "A"

TT

P

PRESSURE TO "A"

PRESSURE TO "B"

LIFTU/L

DN

UP

IN

WINCHDRAG

OUT

SEE SHT 3

3/8 HOSE3/8 HOSE

3/8 HOSE3/8 HOSE

3/8 HOSE3/8 HOSE

3/8 HOSE3/8 HOSE

R SPADE

L SPADE

RET

EXT

EXT

RET

P

SEE SHT 2

5/8 HOSE5/8 HOSE

5/8 HOSE5/8 HOSE

3/8 HOSE3/8 HOSE

5/8 HOSE5/8 HOSE

3/4 HOSE

3/4 HOSE

1.0 HOSE

A

A

6

7

7

6

2

17

1810

1

34

49

48

48

49

47 46

44 45

40

56

57

4263

4338

36

35 37

3334

31 32

7170




RETEXT

WRK BM LIFT

WRK BM LIFT RETEXT

U/L LIFT

RET

EXT

V1 ("B")

5/8

HO

SE

5/8

HO

SE

U/L TILT

.50 TUBE

.50 TUBE

.50 TUBE

.50 TUBE

RET

EXT

.38

HO

SE.3

8 H

OSE

UL

TILT

, DN

UL

EXT,

OU

T

UL

TILT

, UP

UL

EXT,

IN

DRAG WINCH, INDRAG WINCH, OUT

1/2

HO

SE

1/2

HO

SE

SEE SHT 1

1/2

HO

SE

1/2

HO

SE

1/2

HO

SE

1/2

HO

SE

3/8 HOSE3/8 HOSE

3/8 HOSE3/8 HOSE

UL

LIFT

, UP

UL

LIFT

, DN

3/8 HOSE

3/8 HOSE

3/8 HOSE

3/8 HOSE

3/8 HOSE

3/8 HOSE

DRAG WINCH, INDRAG WINCH, OUT

#10 #10

UL

LIFT

, UP

UL

LIFT

, DN

DN INDN IN DN INDN IN

WINCHREAR

LIFTWRK BM

EXTWRK BM

SPADELEFT

SPADERIGHT

UP UPUP OUT OUT

WINCHFRONT

EXTU/L

TILTU/L

UP OUTOUT

"A" PORT

"B" PORT

PRESSURE TO "B"

PRESSURE TO "A"

TT

P

PRESSURE TO "A"

PRESSURE TO "B"

LIFTU/L

DN

UP

IN

WINCHDRAG

OUT

RET

EXTU/L EXT

P

V2 ("A")CABLE IN

UL DRAG WINCHOVER WOUNDCW - CABLE IN

VIEW A

7 7

26

2728

7

7

8

7

5

5 5

59

9

6

7

7

6

11

11

39

41 73 72

50 51

29 29 30 30

55

55

68

69

52 53

52 53

58

58

58

58



WRK BM EXT EXTRET

3/8

HO

SE3/

8 H

OSE

SEE SHT 1

PORT A

PORT B

PORT A

PORT B

#16

#16

SEE SHT 11.0 HOSE

1.0 HOSE

1.0 NPT

1.0 NPT

OIL TANKREF

RETURN, INLET / MID-INLET

RETURN, OUTLET

VIEW A

PILOT DRAIN

3/8 HOSE

VIEW B-B

19 20

2122

7

712

9 25

259

12

24

1516

23

13

14

60

60

59 59

5959

64 65

66 67

63

61

62





DRIVER SIDE HYDRAULIC PRESSURE GAUGES


1 7443000026 Tee 22 4567110141 Hose Assembly 23 7445040421 Fitting 24 7470000004 Gauge, Pressure 25 7790060676 Screw, #6 x 0.38” 66 7330000257 Decal - Pressure Front Valve 17 7330000256 Decal - Pressure Rear Valve 18 4178000858 Bracket 19 7413000002 Nutsert, 0.25”-20 NC 2

10 7950140161 Flatwasher, 0.25” ID 211 7950140000 Lockwasher, 0.25” ID 212 7114140618 Capscrew, 0.25”-20NC x 0.75” 2


DRIVER SIDE HYDRAULIC PRESSURE GAUGES

P

T

P

T

T

PRESSUREFRONT VALVE

PRESSUREREAR VALVE

"B" PORT

"A" PORT

1

1

2

2

3

345

45

8

7 6

A

A

VIEW A-A

8

9101112


DRIVER SIDE HYDRAULIC PRESSURE GAUGES W/ DRAG WINCH OPTION

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

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



DRIVER SIDE HYDRAULIC PRESSURE GAUGES W/ DRAG WINCH OPTION

256

PRESSUREREAR VALVE

257

PRESSUREFRONT VALVE

1

1

22

33

45

45

6 8

7

10121314

91011


DRIVER & PASSENGER SIDE WINCH AIR CONTROLS - DP 25K & 35K

ITEM PART NO. DESCRIPTION QTY1 7443000154 Bushing 12 7443000155 Elbow 13 7443000156 Nipple 14 7935000120 Valve, Pressure Protection 15 7443000152 Plug 56 7443000139 Elbow 57 7443000175 Fitting 28 7565000014 Airline, Tubing 0.38 OD 25ft9 7446502518 Fitting, Bulkhead 1

10 7312000017 Coupling 111 7565000016 Airline, Tubing 0.25 OD 150ft12 7443000178 Union 1513 7443000329 Fitting 414 7443000173 Elbow 1215 7935000351 Valve, Air 416 7295000029 Air Regulator 117 7470000006 Gauge, Air Pressure 118 7443000174 Tee 119 7443000146 Elbow 120 4619000005 Manifold 121 7115142450 Capscrew, 0.25”-20NC x 3.00” 222 7660142601 Locknut, 0.25”-20NC 223 7950140161 Flatwasher, 0.25” ID 424 7443000287 Tee 225 7443000243 Fitting, Bulkhead 226 7444020014 Plug 428 7330000737 Decal - Front Winch Freespool 229 7330000738 Decal - Rear Winch Freespool 230 7330000741 Decal - U/L Winch Freespool 231 7443000448 Fitting 1



! CAUTION !AIR TANK MUST BE EVACUATED BEFORE

INSTALLING AIR CIRCUIT

1/4NPT

1/2 NPT

SECONDARYAIR SUPPLY

1/4 NPT

PLUG (FS)INCLUDED W/ ITEM 4

1/8NPT

1/8NPT

1/4NPT

1/4NPT

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F. TENSIONER

F. FREESPOOL

R. FREESPOOLF. 2-SPEED

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

TO WRECKER BOOM

TO U/L

R. TENSIONER

R. FREESPOOL

F. FREESPOOL R. FREESPOOL

F. 2-SPEED R. 2-SPEED

U/L FREESPOOL

F. FREESPOOL R. FREESPOOL

F. 2-SPEED R. 2-SPEED

U/L FREESPOOL

#1

#2

#3

#4

#5 #9

#10

#11

#12

#13

#8

#2

#3

#4

#5 #9

#10

#11

#12

#13

#8

#14

#15

#16

#17 #18

#6

#7

#2

#3

#4

#5

#8

#9

#10

#11

#12

#13

#2

#3

#4

#5

#8

#9

#10

#11

#12

#13

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F. FREESPOOL

#4

#5#1

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R. FREESPOOL

#10

#11#1

ALTERNATE RH BODY SCHEMATIC(WORM OPTION)

RH BODYSCHEMATIC

LH BODYSCHEMATIC

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1

2 3 4 7

5 6 11

17

19

1816

6

11

12 12

32 11 20 212223

136

26 6

1414

14 15 11

12 12

15

15

1514

14

14

14

11 11

8

7 9

10

8

12 1225

24

13

2413

15

15

1511

5

5

5

514

1414

145

155

5

514

14

14

1111

14

11

151514 14

1414

18

11



F. TENSIONERF. FREESPOOL

R. TENSIONERR. FREESPOOL

WRECKER BOOM - DP 25K WINCHES - DP 35K WINCHES

#14

#16

#6

#7

11 12

11 12

NOTE: THESE FITTINGSAND AIRLINE SUPPLIEDWITH WINCH ASSEMBLYTYP- BOTH WINCHES

6

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U/L WINCH2-SPEED

741

U/L WINCHFREESPOOL

RELEASED WHEN LIT

REAR WINCH2-SPEED


FRONT WINCH2-SPEED


REAR WINCHFREESPOOL


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RELEASED WHEN LIT

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740HIGH SPEED WHEN LIT

REAR WINCH2-SPEED

738RELEASED WHEN LIT

REAR WINCHFREESPOOL

739HIGH SPEED WHEN LIT

FRONT WINCH2-SPEED

737RELEASED WHEN LIT


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


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2931

3328

30

DECAL INSTALLATION30-60 TON, 8-10 SECT VALVES

DECAL INSTALLATION25-60 TON, 8 & 9 SECT VALVES

RH CONTROL STATION

LH CONTROL STATION

2830

29 31

U/L FREESPOOLU/L TENSIONER

U/L DRAG - DP 35K WINCH

#7

#18

14

18

1412 11




WINCH ELECTRIC SPEED/FREE SPOOL CONTROLS - DP 25K & 35K


1 7870000136 Pressure Switch 22 7590000364 Light 43 7346000039 Tubing, Heat Shrink 6in4 7552000414 Harness 15 7552000415 Harness 16 7457000019 Fuse, 5 Amp 1



ABCDEF

ABCDEF

FUSEAA

POWER TAP

BEACON #1

BEACON #2

FLOOD #2

CONTROL

MARKER

FLOOD #1

LEFT TURN

BOOM UP

W/L TILT UP

W/L TILT DOWN

BOOM DOWN

RIGHT TURN

W/L EXTEND

W/L RETRACT

MAIN

SWITCH PANEL

LIGHT BAR

HARNESS

LEFT BODY

HARNESS

RIGHT BODY

HARNESS

HAND CONTROLLER

HAND CONTROLLER

FUNCTION

SWITCH

GROUND

MARKER

LEFT TURN

RIGHT TURN

BACK-UP

IN OUT

IN OUT

IN OUT

IN OUT

POWER TAP

A B

EE FF

C

D

E

F

G

H

I

J

K

L

M

N

O

P

X

Y

Z

AA

BB

CC

DD

Q

R

S

T

U

V

W

AUXHOT

AUXHOT

AUXHOT

SWITCHPANELFEED

FUSEZ

FUSEH

FUSEI

FUSEG

FUSEDD

FUSEFFFUSE

F

FUSEE

FUSED

AUX 2SWITCHED

HOT

SWITCHEDAIR

CONTROL

FUSEEE

SWITCHPANELFEED

5

#34 WHITE - GROUND

#33 BLACK - AUX HOT

6

5

4

5

4

A

A

B B

C C

D D

DIST PANELVIEW A-A


BA BA BA BA

BA BA BA BA

BA

BA

F WINCH2-SPEED

RED

BLACK

#36 LT BLUE

#34 WHITE

R WINCH2-SPEED

RED

BLACK

#38 LT GREEN

#34 WHITE

F WINCHFREE SPOOL

R WINCHFREE SPOOL

UL WINCHFREE SPOOL

RED

BLACK

#35 BLUE

#34 WHITE

RED

BLACK

#37 GREEN

#34 WHITE

RED

BLACK

#39 YELLOW

#34 WHITE

F WINCHFREE SPOOL

F WINCH2-SPEED

R WINCHFREE SPOOL

F WINCH2-SPEED

UL WINCHFREE SPOOL

1

PRESSURE SWITCHCONNECTIONS

VIEW B-BLH CONTROL STATION

VIEW C-C

CONTINUEDIN VIEW C-C

STOW UNUSEDCONNECTORS FRONT CONTROL PANEL

LH - SIDE REF

3 2

4

4

CONTINUEDIN VIEW B-B




UL WINCHFREE SPOOL

R WINCHFREE SPOOL

R WINCH2-SPEED

RED

BLACK

RED

BLACK

RED

BLACK

#37 GREEN

#34 WHITE

#38 LT GREEN

#34 WHITE

#39 YELLOW

#34 WHITE

F WINCH2-SPEED

RED

BLACK

RED

BLACK

#35 BLUE

#34 WHITE

#36 LT BLUE

WHITE

F WINCHFREE SPOOL

REAR CONTROL PANELRH SIDE REF

FRONT CONTROL PANELRH SIDE REF

3

2

5

2

3

3

RH CONTROL STATIONVIEW D-D


WINCH ELECTRIC 2-SPEED MAIN & DRAG CONTROLS


1 7345211702 Terminal 52 7346000039 Tubing 23 7346000029 Fuse Holder 24 7345001714 Terminal 235 8977510200 Wire 14GA - Red 75ft6 8594100002 Wire Loom, 0.25” Black 175ft7 7457000011 Fuse, 10 AMP 18 7457000019 Fuse, 5 AMP 19 7346000264 Connector 1

10 7345001710 Tab 1811 7870000145 Toggle Switch 612 7590000364 LED Light 613 7330000739 Decal, Front Winch 214 7330000740 Decal, Rear Winch 215 7330000831 Decal, U/L Winch 216 7346000273 Terminal 617 7346000274 Connector 318 7346000275 Wedge Lock 319 8977010103 Wire, 16 GA 100ft


AAUX 2

AUX 1

O/R LIGHTS

BODY MARKERS

CABINET RH

CABINET LH

RIGHT TURN

LEFT TURN

CONTROL

MARKER

FLOOD #2

FLOOD #1

BEACON #2

BEACON #1

SWITCHPANEL

OUTOUT

OUT OUT

OUTIN OUT

G

W

M

BB

AUX 3AUX 3

BACK-UP

IN OUT

IN

RHLH

BEACON 1AUX

AUXHOT 2

AUX 3

O/R LIGHTS

BODY MARKERS

AAC

CONTROL

GROUND

SDD

AUXHOT 1

BEACON 1AUX

AUX 2

Y

P

V

T

A

C

H

EE

F

CC

POWER TAP SSWITCH PANEL

AA

TURN SIGNAL

OUT

IN

I

BB

B

X

J

S

LEFT BODY

HARNESS

RD

FF

U

O

E

LIGHT BAR

M

Q

W

MAIN

HARNESS

L

G

K

N

HARNESS

RIGHT BODY

Z

IN

MARKER

DD

RELAY

10 A

U/L WINCH2-SPEED


FRONT WINCH2-SPEED


REAR WINCH2-SPEED


U/L WINCH2-SPEED


FRONT WINCH2-SPEED


REAR WINCH2-SPEED


10A

5A

2 1

DEUTSCHDT04-2S

2 1

DEUTSCHDT04-2S

2 1

DEUTSCHDT04-2S

24

161718

161718

56

56

619 6

19

56

161718

24

37

12

12

38

24 5

6

619

619

619

619

619

619 6

19619 6

19

619

619

619

210

210

210

210

210

210

210

11 11 11

1111

11

9 13

13 14

14 15

15

5

12 12 12

121212

56

24

24

24

24

24

24

24

24

24

BOOM WINCHES U/L WINCH

WINCH ELECTRIC 2-SPEED MAIN & DRAG CONTROLS


DECALS


1 7330000211 Decal - Safety Chains 12 7330000122 Decal - Wheel Lift 23 7330000599 Decal - Moving Parts 24 7330000193 Decal - Wheel Lift 25 7330000202 Decal - Shock Warning 16 7330000203 Decal - Shock Warning 27 7330000034 Decal - Wheel Lift 18 7330000108 Decal - Jerr-Dan Nameplate 29 7330000294 Decal - Jerr-Dan (Red) 2

10 7330000270 Decal - Lubrication 111 7330000610 Decal - Lubrication 112 1001132328 Decal - Serial No./Load Rating 113 7330000143 Decal - Made In The USA 114 7759000004 Pop Rivet 1015 1001132346 Decal - Patent 116 7330000426 Decal - Fuse Panel Schematic 117 7330000208 Decal - Service Air 118 7330000209 Decal - Supply Air 119 7330000210 Decal - Auxiliary Air 120 7330000139 Decal - Checklist Reminder 1


DECALS

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VIEW A-A

HYDRAULIC TANKLOOKING FROM REAR

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VIEW B-B

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VIEW C-C

ITEM #20LOCATEDINSIDE THECAB.

A

A

B

B

C

C

13

7

5 16

11

10

89

6

3

2

1

4

4

19

1718

121414

15



5376000158- 0

Documents

JD35IND HDUL HEAVY DUTY WRECKER PARTS · PDF fileWinch Installation DP25K & DP35K Planetary Winches ... JD35IND HDUL Heavy Duty Wrecker Parts Manual - Page 10 5-376-000158 Rev 0 SUBFRAME