SIDE RECOVERY SYSTEM (WRECKER) PARTS MANUAL

Transcription

1 SIDE RECOVERY SYSTEM (WRECKER) PARTS MANUAL 1080 Hykes Road Greencastle, PA Phone (717) Rev 0 - May 01, Jerr-Dan Corporation. All Rights Reserved.

2 Wrecker Side Recovery System Parts Manual - Page Rev 0 This manual covers the following Jerr-Dan Models: SRS-W25S Side Recovery System (25,000 lb) SRS-W35S Side Recovery System (35,000 lb) Jerr-Dan Corporation strives to provide information that is accurate, complete and useful. Descriptions and illustrative material contained within this manual are as accurate as known at the time of publication and are subject to change, without notice, as a result of continuous product 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 are not 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 Sales Order Number, Serial Number and Model Number. This information is found on the aluminum tag riveted to the frame crossmember of the Side Recovery System as shown below: Additional or replacement manuals can be ordered by calling Jerr-Dan Parts at 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 at technicalpublications@jerr-dan.com or by FAX on 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.

3 INDEX DESCRIPTION PAGE Frame Stabilizer Pivoting Recovery Boom Planetary Gear Winch Sheave Assembly Hydraulic Components Manifold Valve Electrical Components Air Components Control Coverplate Tool Compartment Installation Tool Compartment - LH Tool Compartment - RH Carrier Bearing Bracket Rework Winch Cable Assembly Decals Wrecker Side Recovery System Parts Manual - Page Rev 0

4 Wrecker Side Recovery System Parts Manual - Page Rev 0 FRAME ITEM PART NO. DESCRIPTION QTY Frame Weld Spacer, 0.12 A/R Spacer, 0.06 A/R Spacer, 0.25 A/R Capscrew, NC x Locknut, NC 12

5 FRAME $ Wrecker Side Recovery System Parts Manual - Page Rev 0

6 Wrecker Side Recovery System Parts Manual - Page Rev 0 STABILIZER ITEM PART NO. DESCRIPTION QTY Inner Boom Weld Cylinder Assembly Spade Weld Pin Pin Retaining Ring Pin Pin Pin Weld Quick Pin Wear Pad Flatwasher, 0.44 ID Capscrew, NC x Washer Capscrew, NC x D-Ring Grease Fitting 6

7 STABILIZER % $ $ % % $ $ % $ $ ' & Wrecker Side Recovery System Parts Manual - Page Rev 0

8 Wrecker Side Recovery System Parts Manual - Page Rev 0 PIVOTING RECOVERY BOOM ITEM PART NO. DESCRIPTION QTY Swing Boom Weld Cylinder Assembly Pin Weld Pin Pin Flatwasher 0.50 ID Capscrew, NC x Retaining Ring Retaining Ring Grease Fitting 4

9 PIVOTING RECOVERY BOOM & ' & $ % ' % $ Wrecker Side Recovery System Parts Manual - Page Rev 0

10 Wrecker Side Recovery System Parts Manual - Page Rev 0 PLANETARY GEAR WINCH ITEM PART NO. DESCRIPTION QTY Winch - 25,000 lb Planetary Gear Winch - 35,000 lb Planetary Gear Sheave Support Weld Sheave Guide Weld Sheave Sheave Assembly Bracket Pin Weld Pin Weld Retaining Ring Retaining Ring Grease Fitting Spacer Flatwasher, 0.50 ID Capscrew, NC x Locknut, NC Capscrew, NC x Locknut, NC Capscrew, NC x Lockwasher, 0.38 ID Shim Shim 2 Refer to manufacturer s manual for winch parts list

11 PLANETARY GEAR WINCH $ ' & $ & ' % & % ' Item 22, Winch Cable, not shown Wrecker Side Recovery System Parts Manual - Page Rev 0

12 Wrecker Side Recovery System Parts Manual - Page Rev 0 SHEAVE ASSEMBLY ITEM PART NO. DESCRIPTION QTY Sheave Pivot Support Weld Roller Bearing Retaining Nut Lockwasher Locknut Sheave Pin Weld Grease Fitting Retaining Ring Capscrew, NC x Locknut, NC Plug Seal 2 Refer to manufacturer s manual for winch parts list

13 SHEAVE ASSEMBLY ' $ % & Item 22, Winch Cable, not shown Wrecker Side Recovery System Parts Manual - Page Rev 0

14 Wrecker Side Recovery System Parts Manual - Page Rev 0 HYDRAULIC COMPONENTS ITEM PART NO. DESCRIPTION QTY Valve Assembly Capscrew, NC x Flatwasher, 0.38 ID Locknut, NC Clamp Clamp Capscrew, NC x Capscrew, NC x Flatwasher, 0.31 ID Stacking Nut Locknut, NC Elbow Elbow Elbow Elbow 3

15 HYDRAULIC COMPONENTS $ $ ' & % ' % ' Wrecker Side Recovery System Parts Manual - Page Rev 0

16 Wrecker Side Recovery System Parts Manual - Page Rev 0 HYDRAULIC COMPONENTS ITEM PART NO. DESCRIPTION QTY Valve Assembly Elbow Adapter Tee Reducer Elbow Fitting Elbow Orfice Adapter Fitting Adpater Elbow Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Sleeve 1

17 HYDRAULIC COMPONENTS WINCH HOSE 0.25 HOSE PIVOTING RECOVERY BOOM HOSE 0.50 HOSE HOSE 0.38 HOSE 0.38 HOSE 0.38 HOSE HOSE HOSE RH STABILIZER LH STABILIZER PUMP 0.75 HOSE Item 24, Sleeve, not shown Wrecker Side Recovery System Parts Manual - Page Rev 0

18 Wrecker Side Recovery System Parts Manual - Page Rev 0 MANIFOLD VALVE ITEM PART NO. DESCRIPTION QTY Manifold Block Main Relief Solenoid Selector Valve Valve Valve Valve Adapter 1

19 MANIFOLD VALVE $ Wrecker Side Recovery System Parts Manual - Page Rev 0

20 Wrecker Side Recovery System Parts Manual - Page Rev 0 ELECTRICAL COMPONENTS ITEM PART NO. DESCRIPTION QTY Harness Wired Controller 8 Function Wireless Controller 8 Function Indicator Light Capscrew, 10-24NC x Locknut, 10-24NC Flatwasher, 10 ID Dust Cap Screw * Transmitter * Transmitter Rubber Boot * Transmitter Belt Clip * Receiver 1 * included in Wireless Controller 8 Function, P/N

21 BOOM LH RH LH SPADE UP DN IN OUT RH SPADE UP DN WINCH ELECTRICAL COMPONENTS WIRELESS REMOTE RECEIVER MOUNTED IN RH SIDE TOOLBOX RH SPADE DOWN LH SPADE DOWN BOOM RH LH CONTROL PANEL WINCH OUT 8 1 VALVE REF SEE HYD. SCHEM. VALVE SHOWN IN MOUNTED POSITION DIVERTER 9 4 WINCH IN BOOM LH LH SPADE UP + RH SPADE UP 12V BATTERY - 3 CONNECTORISPARTOFITEM1 MUST BE WIRED TO LIGHT (ITEM 4) RH CONTROL PANEL TRANSMITTER Wrecker Side Recovery System Parts Manual - Page Rev 0

22 Wrecker Side Recovery System Parts Manual - Page Rev 0 AIR COMPONENTS ITEM PART NO. DESCRIPTION QTY Tee Fitting Fitting Regulator Panel Nut Pressure Gauge Fitting Union Fitting Bushing Pressure Switch Valve Fitting Plug Fitting Tee Tubing 30 ft

23 1/8 NPT FREESPOOL - ENGAGE CABLE TENSIONER 1/4 AIR LINE 1/4 AIR LINE AIR COMPONENTS SRS RECOVERY WINCH 1/4 AIR LINE 1/4 AIR LINE 11 ) * /4 AIR LINE PRESSURE SWITCH REGULATEDAIR PLUG (FS) INCLUDED W/ ITEM 5 SECONDARY AIR SUPPLY 7 1/4 AIR LINE /4 AIR LINE 3/8 AIR LINE AIR TO WRECKER FUNCTIONS Wrecker Side Recovery System Parts Manual - Page Rev 0

24 Wrecker Side Recovery System Parts Manual - Page Rev 0 CONTROL COVERPLATE ITEM PART NO. DESCRIPTION QTY Coverplate Coverplate Capscrew, NC x Lockwasher, 0.25 ID Flatwasher, 0.25 ID Nutsert Plug Coverplate Coverplate Flatwasher, 0.38 ID Lockwasher, 0.38 ID Capscrew, NC x

25 CONTROL COVERPLATE RH TOOLBOX COVERPLATES WITH TOOL COMPARTMENTS COVERPLATES WITHOUT TOOL COMPARTMENTS 7 2 LH TOOLBOX Wrecker Side Recovery System Parts Manual - Page Rev 0

26 Wrecker Side Recovery System Parts Manual - Page Rev 0 TOOL COMPARTMENT INSTALLATION ITEM PART NO. DESCRIPTION QTY Tool Compartment Assembly - LH Tool Compartment Assembly - RH Mount Weld - RH Mount Weld - LH Capscrew, NC x Flatwasher, 0.50 ID Locknut, NC Rubber Mount Washer Washer Capscrew, NC x Flatwasher, 0.62 ID Nut, NC Spacer Rubber Moulding 12 ft

27 TOOL COMPARTMENT INSTALLATION ITEM 15, MOULDING NOT SHOWN Wrecker Side Recovery System Parts Manual - Page Rev 0

28 Wrecker Side Recovery System Parts Manual - Page Rev 0 TOOL COMPARTMENT - LH ITEM PART NO. DESCRIPTION QTY Panel - Door Capscrew, NC x Sheet Hinge Shim Latch Capscrew, 10-24NC x Striker Bracket Gasket Locknut, NC Shock Bracket Stud Brakcet Capscrew, NC x Door Seal Capscrew NC x Locknut, NC Flatwasher, 0.25 ID Pad Bar Capscrew, 10-24NC x Nut, 10-24NC Capscrew, NC x Nutsert, NC Locknut, NC Lockwasher, 11MM Flatwasher, 0.38 ID Bracket Capscrew, NC x ITEM PART NO. DESCRIPTION QTY Flatwasher, 0.50 ID Locknut, NC Flatwasher, 0.31 ID Plug Panel - Top Panel - Filler Pad Screw Sheet U-Nut Capscrew, NC x Tool Compartment Bond 1

29 TOOL COMPARTMENT - LH DETAIL A A Wrecker Side Recovery System Parts Manual - Page Rev 0

30 Wrecker Side Recovery System Parts Manual - Page Rev 0 TOOL COMPARTMENT - RH ITEM PART NO. DESCRIPTION QTY Panel - Door Capscrew, NC x Sheet Hinge Shim Latch Capscrew, 10-24NC x Striker Bracket Gasket Locknut, NC Shock Bracket Stud Brakcet Capscrew, NC x Door Seal Capscrew NC x Locknut, NC Flatwasher, 0.25 ID Pad Bar Capscrew, 10-24NC x Nut, 10-24NC Capscrew, NC x Nutsert, NC Locknut, NC Lockwasher, 11MM Flatwasher, 0.38 ID Bracket Bracket 1 ITEM PART NO. DESCRIPTION QTY Capscrew, NC x Flatwasher, 0.50 ID Locknut, NC Flatwasher, 0.31 ID Panel - Top Panel - Filler Pad Screw Sheet Coverplate Bond Tool Compartment Bond 1

31 TOOL COMPARTMENT - RH $ & ' $ % ' ' $ $ % % & & ' & % % Wrecker Side Recovery System Parts Manual - Page Rev 0

32 Wrecker Side Recovery System Parts Manual - Page Rev 0 CARRIER BEARING BRACKET REWORK ITEM PART NO. DESCRIPTION QTY Bracket Angle Channel Capscrew, NC x Flatwasher, 0.50 ID Locknut, NC 12

33 CARRIER BEARING BRACKET REWORK * * * 1 * - Hardware from Frame Installation * Wrecker Side Recovery System Parts Manual - Page Rev 0

34 Wrecker Side Recovery System Parts Manual - Page Rev 0 WINCH CABLE ASSEMBLY ITEM PART NO. DESCRIPTION QTY Cable Assembly - SRS-W25S Standard Winch Cable, 0.62 Dia x Hook - 5 Ton - Standard Hook Shackle Cable Assembly - SRS-W35S Standard Winch Cable, 0.62 Dia x Hook - 5 Ton - Standard Hook Shackle Cable Assembely - SRS-W35S Optional Winch Cable, 0.75 Dia x Hook - 5 Ton - Standard Hook Shackle 1

35 WINCH CABLE ASSEMBLY Wrecker Side Recovery System Parts Manual - Page Rev 0

36 Wrecker Side Recovery System Parts Manual - Page Rev 0 DECALS ITEM PART NO. DESCRIPTION QTY Decal - Pinch Point Decal - Moving Parts Decal - Stabilizer / Outrigger Decal - Remote Control Decal - Free Spool Decal - Winch Decal - Winch Cable Decal - Valve Manual Override Decal - Air Regulator Decal - Lubrication Chart Decal - Winch Oil Decal - Serial, Model, VIN, Rating Pop Rivet, 0.12 Dia 4

37 STAND CLEAR OF OUTRIGGERS/STABILIZERS TO AVOID CRUSHING INJURY 580 MOVING PARTS KEEP HANDS AND FEET CLEAR OF THIS AREA SRS-W35S LUBRICATION CHART LUBRICATION ID No. IDENTIFICATION SERVICE LUBRICATION INTERV AL 2 VENDOR SPECIFIED SEE 1 WINCH GEAR CASE LUBE DRAIN & FILL BREAK-I N PERI OD NO TE SEE WEEKLY 2 WIRE ROPE ASSEMBLY LUBRICATE NO TE HOURS 3 PADS, WEAR /STEEL COAT MPG OR WINCH GEAR CASE SEMI-MONTHLY 4 CHECK - BREATHER /PLUGS 5 CYLINDER, BOOM FLIP LUBRICATE MPG 6 CYLINDER, SPADE EXTEND LUBRICATE MPG 5 7 SWIVEL,BOOM SHEAVE HEAD LUBRICATE MPG 100 HO URS 8 PIN, SHEAV E LUBRICATE MP G 8 OR 9 D-RING LUBRICATE MPG MONTHLY 10 BEARING LUBRICATE MPG SEE 6 1 WINCH GEAR CASE LUBE CHECK LEVEL NO TE HOURS 9 SEE OR 1 WINCH GEAR CASE LUBE DRAIN & FILL NO TE 1 9 VENDOR SPECIFIED HEAVY DUTY MULTI-PURPOSE EP LITHIUM COMPLEX NLGI No. 2 MPG GREASE. PREMIUM BRAND LUBRICANT WITH PENETRATING OILAND RUST LUBRICANT INHIBITOR. 10 NOTES: 1.) REFER TO WINCH OPERATING /MAINTENANCE MANUAL FOR RECOMMENDED GEAR LUBRICANT FOR SPECIFIED AMBIENT TEMPERATURE RANGE. 2.) USE PREMIUM BRAND LUBRICANT SPECIFICALLY DESIGNED FOR WIRE ROPE LUBRICATION. FOLLOW WIRE ROPE SUPPLIER /MANUFACTURERS' RECOMMENDATION. 719 JERR-DAN'S DP 25/35 WINCHES ARE SUPPLIED WITH SYNGEAR G-32 W/ GL5 ADDITIVE PACKAGE FROM FACTORY. TO AVOID BIRDNESTING AND PREMATURE FAILURE OF THE WIRE ROPE ALWAYS KEEP TENSION ON WIRE ROPE WHEN UNWINDING A MINIMUM OF 5 WRAPS OF CABLE MUST BE LEFT ON DRUM TO ACHIEVE RATED LOAD. NOT TO BE USED IN THE MOVING OR LIFTING OF PERSONS. 722 REMOTE CONTROL 721 SRS WINCH FREE SPOOL RELEASED WHEN LIT (WINCH IN FREEWHEEL MODE) MANUFACTURED BY SERIAL NO. MODEL NO. STRUCTURAL CAPACITY: LBS. IDENT. NO. WINCH RATING: LBS. WIRE ROPE LBS. WORKING LIMIT: DO NOT EXCEED THE ABOVE STRUCTURAL RATINGS CAPACITIES. SAFETY IS NO ACCIDENT. FOLLOW ALL INSTRUCTIONS ON CONTROLS AND UNIT. PATENT PENDING PINCH HAZARDS AND MOVING PARTS KEEP CLEAR OF THIS AREA PINCH HAZARDS AND MOVING PARTS KEEP CLEAR OF THIS AREA PINCH HAZARDS AND MOVING PARTS KEEP CLEAR OF THIS AREA PINCH HAZARDS AND MOVING PARTS KEEP CLEAR OF THIS AREA SRS WINCH FREE SPOOL 721 RELEASED WHEN LIT (WINCH IN FREEWHEEL MODE) REMOVE COVER FOR MANUAL VALVE OPERATION: 1. DEPRESS AND HOLD SELECTOR VALVE BUTTON 2. DEPRESS AND HOLD FUNCTION BUTTON FOR SELECTED FUNCTION SELECTOR VALVE TO AVOID BIRDNESTING AND PREMATURE FAILURE OF THE WIRE ROPE ALWAYS KEEP TENSION ON WIRE ROPE WHEN UNWINDING 722 REMOTE CONTROL A MINIMUM OF 5 WRAPS OF CABLE MUST BE LEFT ON DRUM TO ACHIEVE RATED LOAD. NOT TO BE USED IN THE MOVING OR LIFTING OF PERSONS. PULL RING TO UNLOCK 730 AIR TENSIONER INCREASE PRESSURE SETTING: PSI 720 STAND CLEAR OF OUTRIGGERS/STABILIZERS TO AVOID CRUSHING INJURY 580 MOVING PARTS KEEP HANDS AND FEET CLEAR OF THIS AREA SRS WINCH 721 FREE SPOOL RELEASED WHEN LIT (WINCH IN FREEWHEEL MODE) 722 REMOTE CONTROL MANUFACTURED BY SERIAL NO. MODEL NO. STRUCTURAL CAPACITY: LBS. IDENT. NO. WIRE ROPE WINCH RATING: LBS. LBS. WORKING LIMIT: DO NOT EXCEED THE ABOVE STRUCTURAL RATINGS CAPACITIES. SAFETY IS NO ACCIDENT. FOLLOW ALL INSTRUCTIONS ON CONTROLS AND UNIT. PATENT PENDING 710 A MINIMUM OF 5 WRAPS OF CABLE MUST BE LEFT ON DRUM TO ACHIEVE RATED LOAD. NOT TO BE USED IN THE MOVING OR LIFTING OF PERSONS. TO AVOID BIRDNESTING AND PREMATURE FAILURE OF THE WIRE ROPE ALWAYS KEEP TENSION ON WIRE ROPE WHEN UNWINDING 722 REMOTE CONTROL SRS WINCH FREE SPOOL 721 RELEASED WHEN LIT (WINCH IN FREEWHEEL MODE) PULL RING TO UNLOCK AIR TENSIONER INCREASE PRESSURE SETTING: PSI A MINIMUM OF 5 WRAPS OF CABLE MUST BE LEFT ON DRUM TO ACHIEVE RATED LOAD. NOT TO BE USED IN THE MOVING OR LIFTING OF PERSONS. TO AVOID BIRDNESTING AND PREMATURE FAILURE OF THE WIRE ROPE ALWAYS KEEP TENSION ON WIRE ROPE WHEN UNWINDING 720 DECALS WARNING WARNING CAUTION WARNING CAUTION WARNING WINCH IN WINCH OUT BOOM LH BOOM RH LH SPADE UP LH SPADE DOWN RH SPADE UP RH SPADE DOWN WARNING CAUTION WARNING CAUTION 9 3 WARNING WARNING WARNING WARNING WARNING WARNING LH CONTROL PANEL RH CONTROL PANEL WITH TOOL COMPARTMENTS WITHOUT TOOL COMPARTMENTS Wrecker Side Recovery System Parts Manual - Page Rev 0

38 Wrecker Side Recovery System Parts Manual - Page Rev 0 THIS PAGE INTENTIONALLY LEFT BLANK