ALUMINUM & STEEL CAR CARRIERS

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1 OWNER'S MANUAL ALUMINUM & STEEL CAR CARRIERS INSTALLATION, OPERATION, MAINTENANCE & PARTS NOTE: MANUAL including SPECIFICATIONS, subject to change without notice All ratings specified are based on structural factors only, not vehicle capacities or capabilities. Miller Industries Towing Equipment Inc Hilltop Drive Ooltewah, Tennessee FORM NO / 02 Phone (423) FAX (423) PRICE $25.00

2 This manual has been prepared for the owner and operators of CHALLENGER equipment. Its purpose, aside from operating and maintenance instructions, is to promote safety through the use of accepted operating procedures. Read all instructions thoroughly before operating the carrier. Also, contained in this manual is a parts section for your CHALLENGER equipment. Use of other than factory or factory-authorized parts will render the warranty void. LIMITED WARRANTY CHALLENGER warrants the original purchaser that each new CHALLENGER Carrier will be free from defects in material and workmanship for a peroid of one (1) year from the date of purchase. The purchaser must promptly notify CHALLENGER in writing of any failure in material or workmanship. In no event shall such notification be received by CHALLENGER later than 13 months from date of delivery. The obligation under this warranty, statutory or otherwise, is limited to the repair or replacement at our factory or at a point designated by us, of such part or parts as shall appear to us upon inspection to be defective in material or workmanship. New or remanufactured parts will be used for any replacement. This warranty does not obligate CHALLENGER to bear the cost of labor or transportation charges in connection with the replacement or repair of any parts found to be defective, nor shall it apply to a product upon which repairs or alterations have been made unless authorized by us. CHALLENGER shall in no event be liable for any incidental or consequential damages or contingent liabilities arising out of the failure of any parts or products to operate properly. NO IMPLIED, EXPRESS, OR STATUTORY WARRANTY OTHER THAN STATED HEREIN IS MADE OR AUTHORIZED TO BE MADE BY OR FOR US, INCLUDING BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. CHALLENGER makes no warranty, express or implied, as to finished products manufactured or supplied by another manufacturer or supplier by CHALLENGER to purchaser, including, but not limited to, any vehicle to which a CHALLENGER Carrier may be affixed or accessories or wire rope (cable), and expressly disclaims any implied warranties of merchantability or fitness for a particular purpose as to such equipment or products. This language shall in no way affect or diminish the rights of purchaser to rely on such warranties as are extended by such manufacturers or suppliers. CHALLENGER, whose policy is one of continuous improvement, reserves the right to improve its product through changes in design or materials as it may deem desirable without being obligated to incorporate such changes in products of prior manufacture. It is expressly understood that there is no implied warranty that CHALLENGER Carriers shall be fit for the purpose of lifting or moving persons or other improper use. This warranty is not transferable. Miller Industries Towing Equipment Inc Hilltop Drive Ooltewah, Tennessee SERIAL NUMBER Telephone (423)

3 Section VI - PARTS This Section is provided by the manufacturer for the purpose of ordering any component part of the Car Carrier that may be required when part replacement is necessary. Be certain to use only original equipment replacement parts for warranty purposes as well as for keeping your Car Carrier in its original state and optimum operating capacities. When ordering replacement or spare parts be sure to provide the following information to the manufacturer's Parts Department. 1. Manual Number & Date of Publication 2. Manual Page Number 3. Page Title 4. Reference Number of Part Desired 5. Part Number 6. Part Description 7. Quantity of Part Desired Providing this information will help ensure that the correct parts will be delivered to you in an expedient manner without delay. Should additional information be required for repair or replacement of certain components, contact your Car Carrier Manufacturer Authorized Representative. The Manufacturer reserves the right, without notice or obligation, to improve or modify their products, which may change the specifications, models and feature availability. VI-1

4 ALUMINUM BED ASSEMBLY VI-2

5 ALUMINUM BED ASSEMBLY CAR CARRIER 19' ALUMINUM WINCH ASSEMBLY SCREW, 1/2"-13 X 1-1/2" HEX HD CAP WINCH MOUNTING BRACKET SPACER WINCH BRACKET CAB PROTECTOR - 32" CAB PROTECTOR - 34" CAB PROTECTOR - 36" CAB PROTECTOR - 45" CAB PROTECTOR - 48" CAB PROTECTOR - 54" NUT, 1/2"-13 NYLON LOCK BEARING PAD STOP BAR BEARING PAD SCREW, 1/4"-20 X 5/8" BRASS WASHER, 1/2" FLAT PIN, LYNCH HOSE CLAMP GROMMET, LIGHT ASSEMBLY MOUNTING COVER PLATE (BOTTOM) SCREW, SELF-DRILLING CAP, END SCREW, DRIVE TRAY, HOSE (SPECIFY BODY LENGTH) CABLE ASSEMBLY, WINCH LIGHT ASSEMBLY, AMBER WIRE TIE BEARING PAD (SPECIFY BODY LENGTH) ANTI TILT PLATE FRONT REMOVABLE SIDE RAIL (19' CARRIER) CENTER REMOVABLE SIDE RAIL REAR REMOVABLE SIDE RAIL CAB PROTECTOR REINFORCEMENT PLATE SCREW, 1/2"-13 X 1-1/2" HEX HD CAP SCREW, 1/2"-13 X 4" HEX HD CAP VI-3

6 STEEL BED ASSEMBLY VI-4

7 STEEL BED ASSEMBLY CAR CARRIER 19' STEEL CAR CARRIER 21' STEEL WINCH ASSEMBLY SCREW, 1/2"-13 X 1-1/2" HEX HD CAP WINCH MOUNTING BRACKET SPACER, WINCH BRACKET CAB PROTECTOR - 32" CAB PROTECTOR - 34" CAB PROT0ECTOR - 36" CAB PROTECTOR - 45" CAB PROTECTOR - 48" CAB PROTECTOR - 54" NUT, 1/2"-13 NYLON LOCK SCREW, 1/4"-20 X 5/8" BRASS BEARING PAD SCREW, 1/2"-13 X 1-1/4" HEX HD CAP BEARING PAD SCREW, 1/4"-20 X 1" BRASS HOSE CLAMP NUT, 1/4"-20 NYLON LOCK COVER PLATE, BOTTOM SCREW, SELF-DRILLING LIGHT ASSEMBLY, AMBER WIRE TIE TRAY, HOSE (SPECIFY BODY LENGTH) SCREW, 1/2"-13 X 1-3/4" HEX HEAD CAP ANTI TILT PLATE FRONT REMOVABLE SIDE RAIL (19' CARRIER) CENTER REMOVABLE SIDE RAIL REAR REMOVABLE SIDE RAIL CABLE ASSEMBLY, WINCH FRONT REMOVABLE SIDE RAIL (21' CARRIER) PIN, LYNCH VI-5

8 MOUNTING & TILT FRAME ASSEMBLY (Continued on Page VI-8) VI-6

9 MOUNTING & TILT FRAME ASSEMBLY (Continued on Page VI-9) RESERVOIR ASSEMBLY GREASE FITTING SUB-FRAME, INDEPENDENT WHEEL LIFT SUB-FRAME, INDEPENDENT TOW BAR OIL TANK MTG. BRACKETS (SPECIFY FRAME WIDTH) PIN, PIVOT JUNCTION BOX PIN, LYNCH TAIL LIGHT (CHASSIS TAKE OFF) WORK LIGHT SHAFT, LIFT CYLINDER PIN, SAFETY WEAR PAD SCREW, 1/2"-13 X 1-3/4" HEX HD CAP SAFETY CHAIN WITH HOOKS 10' SNAP RING, 1-1/4" SOCKET, TOW LIGHT ILLUMINATOR, CONTROL PANEL ILLUMINATOR, LICENSE PLATE LIGHT, SEALED RED MARKER THROTTLE ASSEMBLY (25 FT.) PIN, ROLL VI-7

10 MOUNTING & TILT FRAME ASSEMBLY (Continued from Page VI-6) VI-8

11 MOUNTING & TILT FRAME ASSEMBLY (Continued from Page VI-7) TOOL BOX EXTENSION STAND (WHEN NEEDED) MUD FLAP BAR, MUD FLAP BRACKET, MUD FLAP MOUNTING SCREW, 3/8"-16 X 1-1/4" HEX HD CAP SCREW, 3/8"-16 X 3/4" HEX HD CAP NUT, 3/8"-16 HEX NYLOK PIN, EXTEND CYLINDER CABLE TIE CLAMP, INSULATED WIRE SCREW, 3/8"-16 X 2-1/2" HEX HD CAP BACK-UP ALARM TOOL BOX MOUNTING BRACKET GREASE FITTING, CLAMP, INSULATED WIRE DECAL, CONTROL STATION (L.H.) DECAL, CONTROL STATION (R.H.) TAIL LAMP HOUSING, LEFT TAIL LAMP HOUSING, RIGHT CHAIN, 12" SASH L-ARM STORAGE TUBE BRACKET NUT, 1/2"-13 NYLON LOCK VI-9

12 HYDRAULICS (Continued on Page VI-12) VI-10

13 HYDRAULICS (Continued on Page VI-13) ELBOW, 1/2" MJ X 1/4" MP X TEE, 3/8" MJ X 3/8" MJ X 1/4" MP HOSE, ASSEMBLY CONNECTOR, 3/8" MJ X 1/4" MP HOSE ASSEMBLY, 54" (W/L EXT CYLINDER) HOSE ASSEMBLY, 14" (BED LIFT CYLINDER) VALVE, BED TILT CYLINDER LOCK HOSE ASSEMBLY, 128" (BED EXT CYLINDER) HOSE ASSEMBLY, 21" (BED LIFT CYLINDER) ORIFICE TEE HOSE ASSEMBLY, 52" (BED EXT. CYLINDER) CYLINDER, BED LIFT HOSE ASSEMBLY, 137" (BED LIFT LOCK VLV) CYLINDER, 108" STROKE BED EXTEND HOSE ASSEMBLY, 204" (WINCH MOTOR) ELBOW, 3/8" MJ X 1/2" MP X SKUFF JACKET HOSE BARB, 3/4" HOSE X 3/4" MP HOSE BARB, 1" HOSE X 1" MP CLAMP, 1" HOSE FILTER ASSEMBLY 22 1 REF. PTO CONNECTOR ELBOW, 1" X 90 STREET CONNECTOR, 1/2 MJ X 1/2" MB HOSE ASSEMBLY, 150" (VALVE TO PUMP) HOSE ASSEMBLY, 91" HI-PRESSURE HOSE, 192" RETURN FILTER TO CONTROL VALVE CONNECTOR, 3/8" MJ X 1/2" MB SWIVEL, 3/4" MB X 3/4" FPX PIPE VI-11

14 HYDRAULICS (Continued from Page VI-10) VI-12

15 HYDRAULICS (Continued from Page VI-11) CONNECTOR, 5/8" SAE X 1/2" JIC STRAIGHT VALVE, 5 SPOOL CONTROL PLUG, 1/2" SQ HD BLACK RESERVOIR OIL TANK TOP CAP CONNECTOR, 3/8" MJ X 3/8" MB STRAIGHT CYLINDER, WHEEL LIFT HYDRAULIC EXTEND CLAMP, 3"-4" HOLDING VALVE RETAINER ELBOW, 3/8" MJ X 3/8" MP X HOSE ASSEMBLY, 18" (W/L HOLDING VALVE TO TEE) CYLINDER, 8-1/4" STROKE WHEEL LIFT TILT VALVE, WHEEL LIFT CYLINDER HOLDING ELBOW, 3/8" JIC X 3/8" NPT X TEE, 1/4" FP X 1/4" FP X 1/4" MALE RUN HOSE ASSEMBLY, 18" (W/L CYL. TO W/L HOLDING VALVE) SCREW, 1/4"-20 X 2-1/4" RD HD SLOTTED NUT, 1/4"-20 HEX FLAT WASHER, 1/4" LOCK WASHER, 1/4" HELICAL BRACKET, W/L HOLDING VALVE MOUNTING MOTOR, WINCH SCREW, 1/2"-13 X 1-1/4" SOCKET HD CAP SWIVEL, 90 BENT TUBE ELBOW, 90, 6MJ-4MP90L HOSE, 1" DIA. SUCTION PUMP TO RESERVOIR PTO PUMP, HIGH PRESSURE HYDRAULIC VI-13

16 WHEEL LIFT & TIRE RESTRAINT ASSEMBLY VI-14

17 WHEEL LIFT & TIRE RESTRAINT ASSEMBLY GREASE FITTING BEARING PAD BEARING PAD SPRING, PLUNGER PIN "T" HANDLE DETENT BALL PIPE PLUG DETENT SPRING "O" RING SCREW, 3/8"-16 X 1-1/4" HEX HD CAP SCREW, 3/8"-16 X 2-1/2" HEX HD CAP SCREW, 3/8"-16 X 1" CUP POINT ALLEN HD NUT, 3/8"-16 HEX NYLOK NUT, 3/8"-16 HEX JAM ROLL PIN, 5/32" X 1" SCREW, 3/8"-16 X 3/4" BUTTON ALLEN HD DECAL, SAFETY CHAIN WARNING SHAFT, INNER TUBE CYLINDER SLIDER, PAD SHAFT, EXTEND CYLINDER PIVOT PIN PIN, PLUNGER PIN, CROSSBEAM PIVOT WASHER, 1" O.D. X 3/8" I.D. FLAT SHAFT, PIN ASSEMBLY, UPPER BOOM SHAFT, LIFT CYLINDER TIRE RESTRAINT, LEFT TIRE RESTRAINT, RIGHT " NYLON POLY COAT STRAP "L" ARM RECEIVER WELDMENT, LEFT "L" ARM RECEIVER WELDMENT, RIGHT OUTER BOOM INNER BOOM INNER CROSSTUBE WELDMENT 35 2 HD0125 SPRING PIN, 5/32" X 1-3/8" 36 2 HD1203 SPRING, PLUNGER PIN 37 2 RB0296 PIN, PLUNGER PULL LOCK 38 2 RB0357 HANDLE, PULL GRIP VI-15

18 CONTROL & CROSSROD ASSEMBLY VI-16

19 CONTROL & CROSSROD ASSEMBLY SPOOL CONTROL VALVE BRACKET, CONTROL HANDLE REAR, OUTER CONTROL HANDLE REAR, INNER CONTROL HANDLE FWD, INNER CONTROL HANDLE FWD, OUTER CONTROL HANDLE KNOB, BALL KNOB KNOB, "IN-OUT" RED (CABLE) NUT, 3/8"-16 JAM COTTER PIN, 1/16" X 3/4" CONTROL HANDLE PIVOT ROD CLEVIS PIN, 5/16" DIA. X 1" WASHER, 5/16" FLAT SCREW, 3/8"-16 X 3/4" HEX HD LOCK WASHER, 3/8" HELICAL NUT, 3/8"-16 NYLON LOCK NUT, 3/8"-TINNERMAN "J" CONTROL ROD LINK VALVE SHIFTER CONTROL HANDLE, CENTER COTTER PIN, 1/8" X 3/4" SCREW, 3/8"-16 X 4" HEX HD CONTROL ROD LINK, ANTI-TILT SPRING, ANTI-RATTLE VI-17

20 HYDRAULIC WINCH VI-18

21 HYDRAULIC WINCH LEVER KEY SCREW KEY SHAFT CLUTCH HOUSING YOKE SCREW BUSHING SCREW SPRING BALL CLUTCH SPACER DRUM PLUG HOUSING PLUG REDUCER DRAG BRAKE SPRING SCREW CAP GASKET BEARING WORM SCREW CAP ADAPTER SEAL 30* 2 -- KEY 31* 1 -- SHAFT 32* 2 -- KEY HUB GEAR WASHER SCREW GASKET COVER SCREW COUPLING *SPECIFY WINCH SERIAL NUMBER WHEN ORDERING VI-19

22 CYLINDERS BED EXTEND CYLINDER (COMPLETE) SEAL KIT BED TILT CYLINDER (COMPLETE) SEAL KIT VI-20

23 CYLINDERS HYDRAULIC CYLINDER, EXTEND (COMPLETE) SEAL KIT, EXTEND CYLINDER HYDRAULIC CYLINDER, LIFT (COMPLETE) SEAL KIT, LIFT CYLINDER VI-21

24 OPTIONAL EQUIPMENT CABLE ROLLER ASSEMBLY CABLE ROLLER ASSEMBLY CABLE ROLLER GUIDE WELD MENTSCREW, 1/2"-13 X 1-1/4" HEX HEAD NUT, 1/2"-13 NYLON LOCK VI-22

25 OPTIONAL EQUIPMENT WINCH CLUTCH CONTROL SPRING, COMPRESSION GREASE FITTING "T" HANDLE ADJUSTING YOKE SCREW, 5/16"-18 X 1/2" SQ HD SET SCREW, 3/8"-16 X 1" HEX HD CAP SCREW, 3/8"-16 X 2-1/2" HEX HD CAP NUT, 3/8"-16 NYLON LOCK NUT, 3/8"-16 JAM WASHER, 1/2" FLAT PIN, 1/2" DIA. X 1-1/2" CLEVIS PIN, 1/8" X 1-1/4" COTTER PIN, 5/32" X 1" LG. ROLL MOUNTING CHANNEL CONTROL ROD, SINGLE WINCH WELDMENT, BELL CRANK VI-23

26 OPTIONAL EQUIPMENT LIGHTING ACCESSORIES WRECKER SPECIAL LIGHT "T" BOLT ADAPTER RUBBER CUSHION NUT, 3/8"-16 NYLON LOCK SPOTLIGHT WITH GASKET SCREW, #10-24 X 1" MACHINE NUT, #10 NYLON LOCK WASHER, #10 LOCK VI-24

27 OPTIONAL EQUIPMENT INDEPENDENT TOW BAR ASSEMBLY TOW BAR ASSEMBLY (COMPLETE) SNAP RING, 3/4" SHAFT, TOW BAR PIVOT, PIN W/KEEPER TUBE, TOW BAR OUTER PIN, CYLINDER SHAFT, EXTEND CYLINDER CYLINDER, TOW BAR DECAL, SAFETY CHAIN WARNING GUARD, TOW BAR BUMPER CROSSTUBE, TOW BAR GREASE FITTING PIN, TOW BAR PIVOT NUT SNAP RING, 1-1/4" TUBE, TOW BAR INNER CYLINDER, TOW BAR EXTEND VI-25

28 OPTIONAL EQUIPMENT FIXED TOW BAR ASSEMBLY TOW BAR ASSEMBLY (COMPLETE) GREASE FITTING SNAP RING, 3/4" SNAP RING, 1-1/4" GUARD, TOW BAR BUMPER CYLINDER, TOW BAR EXTEND NUT DECAL, SAFETY CHAIN WARNING SHAFT, EXTEND CYLINDER TUBE, TOW BAR INNER PIN, TOW BAR PIVOT CROSSTUBE, TOW BAR TUBE, TOW BAR OUTER VI-26

29 OPTIONAL EQUIPMENT TOW BAR CYLINDER TOW BAR CYLINDER (COMPLETE) SEAL KIT VI-27

30 OPTIONAL EQUIPMENT TOW SLING CHAIN KEEPER, LEFT CHAIN KEEPER, RIGHT TOW SLING BELT BELT RETAINER SCREW, 5/16"-18 X 1-1/4" SELF-TAPPING CARRIAGE BOLT, 3/8"-16 X 1-1/4" GRIP PLATE NUT, 3/8"-16 NYLON LOCK "J" HOOK ASSEMBLY VI-28

31 NOTES

32 Miller Industries Towing Equipment Inc Hilltop Drive Ooltewah, Tennessee (423)

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