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Oshkosh Corporation JERR-DAN HDL500/280 Installation Manual

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HEAVY DUTY WRECKER
HDL500/280 - 25 TON
HDL600/350 - 30 TON
INSTALLATION MANUAL
5-376-000061
Rev 00 - May 01, 2001
1080 Hykes Road
Greencastle, PA 17225
Phone (717) 597-7111
www.jerr-dan.com
© 2009 Jerr-Dan Corporation. All Rights Reserved.

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Summary of Contents for Oshkosh Corporation JERR-DAN HDL500/280

  • Page 1 HEAVY DUTY WRECKER HDL500/280 - 25 TON HDL600/350 - 30 TON INSTALLATION MANUAL 1080 Hykes Road Greencastle, PA 17225 Phone (717) 597-7111 www.jerr-dan.com 5-376-000061 Rev 00 - May 01, 2001 © 2009 Jerr-Dan Corporation. All Rights Reserved.
  • Page 2 DECIMAL EQUIVALENTS FRACTION 3 PLACES 2 PLACES FRACTION 3 PLACES 2 PLACES .016 0.397 33/64 .516 13.097 1/64 1/32 .031 0.794 17/32 .531 13.494 3/64 .047 1.191 35/64 .547 13.891 1/16 .062 1.588 9/16 .562 14.288 5/64 .078 1.984 37/64 .578 14.684 3/32...

  • Page 3: Table Of Contents

    HDL500/280 HDL600/350 INSTALLATION MANUAL Table of Contents Title Page PREFACE ............................3 Unpacking and Special Handling Instructions ................3 Tools/Special Equipment Needed ....................3 HDL500/280 Chassis Recommendations ...................4 HDL600/350 Chassis Recommendations ...................5 HDL500/280 Kit Disassembly .....................7 HDL600/350 Kit Disassembly .....................8 CHASSIS PREP ..........................9 Frame Cutoff - Single Rear Axle ....................10 Frame Cutoff - Tandem Rear Axle ....................11 INSTALLATION ..........................12...
  • Page 4 INSTALLATION MANUAL HDL500/280 HDL600/350 Table of Contents Title Page INSTALLATION (cont.) Wire Rope Installation (Optional Planetary Gear Winch) ............68 Mud Flap Installation .........................70 Paint Touch-Up .........................70 Decal Installation ........................71 CHECKOUT AND INSPECTION .....................72 APPENDIX ............................ A-1 RH Body Wiring Harness (Standard Short Body) ..............A-2 LH Body Wiring Harness (Standard Short Body) ..............

  • Page 5: Preface

    HDL500/280 HDL600/350 INSTALLATION MANUAL PREFACE This manual describes installation instructions Tools/Special Equipment Needed for the HDL500/280 and HDL600/350. Read these instructions thoroughly prior to starting Proper tools will ease the installation of your installation. Sketches are provided to give Jerr-Dan unit and insure proper installation. visual aid and may not look the same as what The following is a list of special tools and you are working with because of make of truck...

  • Page 6: Hdl500/280 Chassis Recommendations

    INSTALLATION MANUAL HDL500/280 HDL600/350 HDL500/280 CHASSIS RECOMMENDATIONS Single Axle Chassis Minimum G.V.W.R (Single Axle).................33,000 lbs. Minimum Front Axle G.A.W.R..................10,000 lbs. Minimum Rear Axle G.A.W.R..................23,000 lbs. Minimum C.A. (Cab to Axle) Dimension ................116” Minimum Resisting Bending Moment (R.B.M.) ...... (1.50 mil) per rail 1,500,000 in/lbs Minimum Frame Length behind Center Line of Axle ............

  • Page 7: Hdl600/350 Chassis Recommendations

    HDL500/280 HDL600/350 INSTALLATION MANUAL HDL500/280 CHASSIS RECOMMENDATIONS Tandem Axle Chassis Minimum G.V.W.R......................50,000 lbs. Minimum Front Axle G.A.W.R..................12,000 lbs. Minimum Rear Axle G.A.W.R..................38,000 lbs. Minimum C.B. (Cab to Bogie) Dimension ................90” Minimum Resisting Bending Moment (R.B.M.) ...... (2.25 mil) per rail 2,250,000 in/lbs Minimum Frame Length behind Center Line of Bogie ............
  • Page 8 INSTALLATION MANUAL HDL500/280 HDL600/350 TANDEM SPACING FRAME CUT-OFF “A” “B” 52” - 56” 64.31” 56” - 62” 65.19” Figure 2. Frame Clearance Requirements - Tandem Axle Rev. Date 05/2001 Page 6...

  • Page 9: Hdl500/280 Kit Disassembly

    HDL500/280 HDL600/350 INSTALLATION MANUAL 2. Disconnect the control rods between the HDL500/280 Kit Disassembly control stations and the hydraulic control The kit for the HDL500/280 contains five major valve. The best way to do this is to remove components: the Subframe and Booms, the two carriage bolts and locknuts from each LH Body, the RH Body, the Light Pylon, and control rod in the control station on both the...

  • Page 10: Hdl600/350 Kit Disassembly

    INSTALLATION MANUAL HDL500/280 HDL600/350 2. Operate all of the control handles to relieve HDL600/350 Kit Disassembly the pressure from the hydraulic system that The kit for the HDL600/350 contains five major may be present from testing at the factory. components: the Subframe and Booms, the Disconnect the hydraulic hoses at the LH Body, the RH Body, the Light Pylon, and control station control valve bulkhead on...

  • Page 11: Chassis Prep

    HDL500/280 HDL600/350 INSTALLATION MANUAL CHASSIS PREP Chassis preparation involves rear frame cutoff, FMVSS121 is constantly evolving with new and relocating and modifying components for requirements. It is your responsibility to keep installation of your Jerr-Dan unit. Different pace with these requirements, making sure factory options and truck modifications will that the modifications you make and warrant the modification of these instructions.

  • Page 12: Frame Cutoff - Single Rear Axle

    INSTALLATION MANUAL HDL500/280 HDL600/350 3. Cut the truck frame behind the centerline of Frame Cutoff - Single Rear Axle the rear axle as shown in Figure 3 and 1. Disconnect the wiring harness from the tail remove the extra after frame. lights and remove the tail lights.

  • Page 13: Frame Cutoff - Tandem Rear Axle

    HDL500/280 HDL600/350 INSTALLATION MANUAL 3. Cut the truck frame behind the centerline of Frame Cutoff - Tandem Rear Axle the tandem as shown in Figure 4 and 1. Disconnect the wiring harness from the tail remove the extra after frame. lights and remove the tail lights.

  • Page 14: Installation

    INSTALLATION MANUAL HDL500/280 HDL600/350 PTO Selection Running the pump dry will damage it. Always put the same type of transmission oil For manual transmissions, the factory supplied back in the transmission that you drained out, PTO is selected based on the data supplied on particularly if it is a new transmission.
  • Page 15 HDL500/280 HDL600/350 INSTALLATION MANUAL Figure 5. PTO Warning Labels Installation see if it stops rotating. Do not place any- torque is required to install the stud to the thing in or near the PTO opening while barrel or to the depth shown in the table the engine is running.
  • Page 16 INSTALLATION MANUAL HDL500/280 HDL600/350 grease may be placed on the gaskets/ 13. Install all the capscrews or stud nuts shims to help seal and to hold them in provided in the mounting kit. Torque all place during installation. Do not use a mounting bolts to the required torque as permanent sealant on gasket/shims be- specified in step 8.

  • Page 17: Pto Air Shift Control

    HDL500/280 HDL600/350 INSTALLATION MANUAL PTO Air Shift Control NOTE CAUTION A tight mounted PTO will cause under-cutting of gears and result in premature PTO failure, Air tank must be evacuated of all air before including gear or housing breakage. installing air circuit. 1.

  • Page 18: Pump Installation

    INSTALLATION MANUAL HDL500/280 HDL600/350 supported. Install the support strap to Pump Installation one of the extended studs on the back of Install the pump only after the PTO has been the pump and secure the other end to the checked for noise. transmission as shown in Figure 7.

  • Page 19: Switch Panel

    HDL500/280 HDL600/350 INSTALLATION MANUAL 3. Remove the switch panel and drill or saw a Switch Panel 1-1/4” hole in the center of the hole pattern 1. Find a suitable location for the switch panel. on the floor for the wiring harness. The recommended location for it is on the floor to the left or right of the driver’s seat.

  • Page 20: Main Wiring - Power Supply

    INSTALLATION MANUAL HDL500/280 HDL600/350 3. Connect one end of the wire to the battery Main Wiring - Power Supply and the other end to the circuit breaker post marked “BAT”. CAUTION 4. Using the remaining #4 GA welding wire, Avoid the risk of electrical shock. crimp wire end to one end of the wire and apply heat shrink tubing, and put wire into Before installing the circuit breaker and...

  • Page 21: Winch And Auxiliary Air Supply Installation

    HDL500/280 HDL600/350 INSTALLATION MANUAL Winch and Auxiliary Air Supply Installation Plug the small port of the valve with the 1/8” NPT brass plug supplied with the CAUTION valve. Air tank must be evacuated of all air before Install the 1/4” Tube x 1/4” NPT-90° installing air circuit.

  • Page 22: Subframe Installation - Hdl500/280 (Standard Short Body - 86" Ct/112" Ca)

    INSTALLATION MANUAL HDL500/280 HDL600/350 Subframe Installation - HDL500/280 NOTE (Standard Short Body - 86” CT/112” CA) Use clamps or a bottle jack and chains to pull 1. Set the subframe onto the truck frame and the subframe down to the chassis rails as position as shown in Figure 10.
  • Page 23 HDL500/280 HDL600/350 INSTALLATION MANUAL Figure 11. Subframe Mounting Plates Rev. Date 05/2001 Page 21...
  • Page 24 INSTALLATION MANUAL HDL500/280 HDL600/350 3. Layout and drill the hole pattern in the four subframe mounting plates as shown in WARNING Figure 11. If the truck chassis frame is narrower than the 4. Layout the position of the six loose sub- subframe and shims are used between the frame mounting plates as shown in Fig- chassis frame and the subframe mounting...
  • Page 25 HDL500/280 HDL600/350 INSTALLATION MANUAL 5. Weld the subframe mounting plates and 10. Clamp the subframe down onto the truck any required shims to the subframe as frame. Make sure that the subframe is shown in Figure 12 or Figure 13. down flat and tight to the truck frame.
  • Page 26 INSTALLATION MANUAL HDL500/280 HDL600/350 shown in Figure 14. Trim or modify the NOTE plate as required to fit your application. Leave approximately 1/4” space between To access the holes and mounting bolts in the the tie plate and the tail section. This will rear most mounting plates, remove the nylon allow any collection of road dirt, snow, rub plates from the spade housings.

  • Page 27: Subframe Installation - Hdl500/280 (Optional Long Body - 146" Ct/172" Ca)

    HDL500/280 HDL600/350 INSTALLATION MANUAL Subframe Installation - HDL500/280 NOTE (Optional Long Body - 146” CT/172” CA) Use clamps or a bottle jack and chains to pull 1. Set the subframe onto the truck frame and the subframe down to the chassis rails as position as shown in Figure 15.
  • Page 28 INSTALLATION MANUAL HDL500/280 HDL600/350 Figure 16. Subframe Mounting Plates Rev. Date 05/2001 Page 26...
  • Page 29 HDL500/280 HDL600/350 INSTALLATION MANUAL 3. Layout and drill the hole pattern in the four subframe mounting plates as shown in WARNING Figure 16. If the truck chassis frame is narrower than the 4. Layout the position of the six loose sub- subframe and shims are used between the frame mounting plates as shown in Fig- chassis frame and the subframe mounting...
  • Page 30 INSTALLATION MANUAL HDL500/280 HDL600/350 5. Weld the subframe mounting plates and 10. Clamp the subframe down onto the truck any required shims to the subframe as frame. Make sure that the subframe is shown in Figure 17 or Figure 18. down flat and tight to the truck frame.
  • Page 31 HDL500/280 HDL600/350 INSTALLATION MANUAL 13. Weld the tie plate into the back of the NOTE subframe. To access the holes and mounting bolts in the 14. Set the body front mounting frame onto rear most mounting plates, remove the nylon the truck frame and position as shown in rub plates from the spade housings.

  • Page 32: Subframe Installation - Hdl600/350 (Standard Short Body - 110" Ct/136" Ca)

    INSTALLATION MANUAL HDL500/280 HDL600/350 Subframe Installation - HDL600/350 NOTE (Standard Short Body - 110” CT/136” CA) Use clamps or a bottle jack and chains to pull 1. Set the subframe onto the truck frame and the subframe down to the chassis rails as position as shown in Figure 20.
  • Page 33 HDL500/280 HDL600/350 INSTALLATION MANUAL Figure 21. Subframe Mounting Plates Rev. Date 05/2001 Page 31...
  • Page 34 INSTALLATION MANUAL HDL500/280 HDL600/350 3. Layout and drill the hole pattern in the four subframe mounting plates as shown in WARNING Figure 21. If the truck chassis frame is narrower than the 4. Layout the position of the six loose sub- subframe and shims are used between the frame mounting plates as shown in Fig- chassis frame and the subframe mounting...
  • Page 35 HDL500/280 HDL600/350 INSTALLATION MANUAL 5. Weld the subframe mounting plates and 10. Clamp the subframe down onto the truck any required shims to the subframe as frame. Make sure that the subframe is shown in Figure 22 or Figure 23. down flat and tight to the truck frame.
  • Page 36 INSTALLATION MANUAL HDL500/280 HDL600/350 shown in Figure 14. Trim or modify the NOTE plate as required to fit your application. Leave approximately 1/4” space between To access the holes and mounting bolts in the the tie plate and the tail section. This will rear most mounting plates, remove the nylon allow any collection of road dirt, snow, rub plates from the spade housings.

  • Page 37: Subframe Installation - Hdl600/350 (Optional Long Body - 146" Ct)

    HDL500/280 HDL600/350 INSTALLATION MANUAL Subframe Installation - HDL600/350 NOTE (Optional Long Body - 146” CT) Use clamps or a bottle jack and chains to pull 1. Set the subframe onto the truck frame and the subframe down to the chassis rails as position as shown in Figure 25.
  • Page 38 INSTALLATION MANUAL HDL500/280 HDL600/350 Figure 26. Subframe Mounting Plates Rev. Date 05/2001 Page 36...
  • Page 39 HDL500/280 HDL600/350 INSTALLATION MANUAL 3. Layout and drill the hole pattern in the four subframe mounting plates as shown in WARNING Figure 26. If the truck chassis frame is narrower than the 4. Layout the position of the six loose sub- subframe and shims are used between the frame mounting plates as shown in Fig- chassis frame and the subframe mounting...
  • Page 40 INSTALLATION MANUAL HDL500/280 HDL600/350 5. Weld the subframe mounting plates and 10. Clamp the subframe down onto the truck any required shims to the subframe as frame. Make sure that the subframe is shown in Figure 27 or Figure 28. down flat and tight to the truck frame.
  • Page 41 HDL500/280 HDL600/350 INSTALLATION MANUAL 13. Weld the tie plate into the back of the NOTE subframe. To access the holes and mounting bolts in the 14. Set the body front mounting frame onto rear most mounting plates, remove the nylon the truck frame and position as shown in rub plates from the spade housings.

  • Page 42: Glad Hand Installation

    INSTALLATION MANUAL HDL500/280 HDL600/350 4. Connect the 1-1/2” suction hose to the Glad Hand Installation flanged fitting on the hydraulic pump and secure the flanged fitting. CAUTION 5. Connect the two 1/2” pressure hoses to the pump. Do not connect air lines to any point on the chassis except at points specifically intended for the use of Glad Hands.

  • Page 43: Hdl600/350 Hydraulic Hoses Supply/Pressure/Return

    HDL500/280 HDL600/350 INSTALLATION MANUAL Determine the length of suction hose are extended. Remember, there will be required to reach the connection on the more oil in the system when all the cylin- bottom of the hydraulic tank. Cut suction ders are extended. OIL EXPANDS hose to desired length.
  • Page 44 INSTALLATION MANUAL HDL500/280 HDL600/350 Figure 33. Pressure Hoses 10. Close the valve on the bottom of the hydraulic tank. The handle should be horizontal when the valve is closed. 11. Fill the hydraulic tank with approximately Figure 32. Hose Support Straps 55 gallons of Citgo A/W All Temp (or equivalent) hydraulic fluid.

  • Page 45: Body Installation - Hdl500/280 (Standard Short Body - 86" Ct/112" Ca)

    HDL500/280 HDL600/350 INSTALLATION MANUAL shown in Figure 34. Shims can be added Body Installation - HDL500/280 (Standard Short Body - 86” CT/112” CA) to the inside or outside body mount to shim the body in either direction as required. 1. Slide the LH body over the body mounts on the subframe.

  • Page 46: Body Installation - Hdl500/280 (Optional Long Body - 146" Ct/172" Ca)

    INSTALLATION MANUAL HDL500/280 HDL600/350 side to the LH side. Adjust the body Body Installation - HDL500/280 (Optional Long Body - 146” CT/172” CA) accordingly by installing shim washers between the body and the body mounts as 1. Slide the LH body over the body mounts on shown in Figure 35.

  • Page 47: Body Installation - Hdl600/350 (Standard Short Body - 110" Ct/136" Ca)

    HDL500/280 HDL600/350 INSTALLATION MANUAL Body Installation - HDL600/350 (Standard Short Body - 110” CT/136” CA) 1. Slide the LH body over the body mounts on the subframe. 2. Secure the front of the body to the subframe using 3/4” x 4” capscrews, flatwashers, and nuts.

  • Page 48: Body Installation - Hdl600/350 (Optional Long Body - 146" Ct)

    INSTALLATION MANUAL HDL500/280 HDL600/350 Body Installation - HDL600/350 (Optional Long Body - 146” CT) 1. Slide the LH body over the body mounts on the subframe. 2. Secure the front of the body to the subframe using 3/4” x 4” capscrews, flatwashers, and nuts.

  • Page 49: Single Toolbox Installation

    HDL500/280 HDL600/350 INSTALLATION MANUAL Single Toolbox Installation BODY STYLE “A” HDL500/280 2.38” The toolboxes with your kit are shipped with Standard Short - 86” CT/112” CA the mounting frames attached. Before the HDL500/280 toolboxes can be installed, the mounting 2.75” Optional Long - 146”...
  • Page 50 INSTALLATION MANUAL HDL500/280 HDL600/350 Drill one 3/4” hole through the front the 11. Check the height alignment of the toolbox body as shown in Figure 39. caps with the body caps. Adjust the height of toolbox caps by adding and Install the toolbox onto the toolbox frame removing isolator pads as required.

  • Page 51: Multiple Toolbox Installation

    HDL500/280 HDL600/350 INSTALLATION MANUAL 3. Center the toolbox frame left to right across Multiple Toolbox Installations the truck frame. The toolboxes with your kit are shipped with the mounting frames attached. Before the 4. Install the toolbox frame to the truck frame toolboxes can be installed, the mounting using the clamps and 1/2”...
  • Page 52 INSTALLATION MANUAL HDL500/280 HDL600/350 Check the height alignment of the toolbox 12. Hold the cap in position and using the with the previously installed toolbox. holes in the top of the toolbox as a Adjust the toolbox accordingly by template, drill 3/16” pilot holes into the installing shim washers between the cap panels for self-tapping screws.

  • Page 53: Light Pylon Installation

    HDL500/280 HDL600/350 INSTALLATION MANUAL Light Pylon Installation Body Flare Installation 1. Set pylon onto the pylon mounts on the The body flares for your HDL500/280 and body. HDL600/350 have been partially installed at the factory. 2. Secure the pylon to the mounts using four 1/2”...
  • Page 54 INSTALLATION MANUAL HDL500/280 HDL600/350 Position the top edge of the under-door 10. The body flares have factory caps on both panel to the line that you marked on the ends that you can not use. Use a hack toolbox and temporarily clamp into saw to cut off the capped ends of the position.

  • Page 55: Body Lights And Wiring Installation - Hdl500/280

    HDL500/280 HDL600/350 INSTALLATION MANUAL 18. Secure the body flare using 1/4” x 2-1/4” Connect the RH Body wiring harness, capscrews, flatwashers, and locknuts as Jerr-Dan Part Number 7552000090, to shown in Figure 45. the connections marked “Right Body Harness” and “Ground”. Connect the Remote Control wiring harness, Jerr-Dan Part Number 7552000130, to the connection marked...
  • Page 56 INSTALLATION MANUAL HDL500/280 HDL600/350 14. Connect the Light Control harness to the SOLENOID VALVE WIRING connections marked “MAIN SWITCH Circuit Color Function PANEL”, “SWITCH PANEL FEED” and “MARKER OUT” as shown in Figure 47 White Ground and Table 3. White/Black U/L Retract SWITCH PANEL WIRING Tilt Down...
  • Page 57 HDL500/280 HDL600/350 INSTALLATION MANUAL 16. Connect the OEM wiring harness to the 21. Route each harness through the 3/4” hole power distribution panel as shown in in the front upper corner of the body and Figure 48. into the toolboxes. The harnesses have enough wire to connect three add-on 17.

  • Page 58: Body Lights And Wiring Installation - Hdl600/350

    INSTALLATION MANUAL HDL500/280 HDL600/350 25. Install the rubber lower hook-up lights to Route the harnesses through the “A” the rear of the angled plate welded into framed recovery boom mount and across the end of the truck frame. the subframe to the LH side of the body. 26.
  • Page 59 HDL500/280 HDL600/350 INSTALLATION MANUAL REMOTE CONTROL WIRING SWITCH PANEL WIRING Circuit Color Function Circuit Color Function Black 12V Function Brown Illumination Not Used Panel Power Green Not Used Panel Power White Ground Table 5. Light Control Wiring Table 4. Valve Wiring 11.
  • Page 60 INSTALLATION MANUAL HDL500/280 HDL600/350 14. Crimp wire end onto wire and apply heat 18. Connect the harnesses to the interior shrink tubing. toolbox lights using butt connectors and heat shrink tubing and grounding the ring 15. Connect wire to the connection marked terminals to the light mounting screws.

  • Page 61: Pylon Lights And Wiring Installation

    HDL500/280 HDL600/350 INSTALLATION MANUAL 24. Connect lights to the wiring harnesses. using four 5/16” x 1” carriage bolts, flatwashers, lockwashers, and acorn nuts 25. Connect the pigtail from the RH body as shown in Figure 53. harness to the license plate light using a butt connector and heat shrink tubing.
  • Page 62 INSTALLATION MANUAL HDL500/280 HDL600/350 10. Insert the connector on the blue wire from PYLON LIGHTS WIRING the light pylon wiring harness into the the Circuit Color Function top center position in the connector on the light bar harness as shown in Figure 54. Brown Marker 11.

  • Page 63: Winch Free-Spool Air Installation (Standard Worm Gear Winches)

    HDL500/280 HDL600/350 INSTALLATION MANUAL Uncoil the 1/4” air line tubing that is tied Winch Free-Spool Air Installation (Standard Worm Gear Winches) up at the winches. Tag the ends of the air lines with tape and identify as “front” and Remove the cover plate from the RH con- “rear”...

  • Page 64: Winch Free-Spool/Cable Tensioner Air Installation (Optional Planetary Gear Winches)

    INSTALLATION MANUAL HDL500/280 HDL600/350 Uncoil the 1/4” air line tubing that is tied Winch Free-Spool/Cable Tensioner Air up at the winches. Tag the ends of the air Installation (Optional Planetary Gear Winches) lines with tape and identify as “front” and “rear”...

  • Page 65: Auxiliary Air Installation

    HDL500/280 HDL600/350 INSTALLATION MANUAL Auxiliary Air Installation Hydraulic System Pressure Gauge Installation - HDL500/280 Find the 3/8” air line tubing that you connected earlier and ran back the truck Find two 1/4” hose assemblies in your kit. frame to the rear axle(s). The hose assemblies can be identified by the tape and markings on the end of each Route the 3/8”...
  • Page 66 INSTALLATION MANUAL HDL500/280 HDL600/350 Carefully remove the caps from the tee Connect the 90º end of the 53” hose fittings at the subframe manifold. See assembly to the tee that is closest to the Figure 58. driver’s side. Connect the 90º end of the 50” hose assembly to the tee that is closest to the to the passenger’s side.

  • Page 67: Paint Specifications (Primed Units)

    HDL500/280 HDL600/350 INSTALLATION MANUAL 5. All surfaces not to be painted, such as, Paint Specifications (Primed Unit) chromed and/or plated parts, exposed To ensure delivery of a quality finished product unconnected electrical terminals, hydraulic meeting our customer expectations, the cylinder rods and rod seal lips, previously following guidelines are provided and must be painted surfaces, rubber parts, etc., must followed by the painter/paint subcontractor.
  • Page 68 INSTALLATION MANUAL HDL500/280 HDL600/350 10. A final coat (barrier coat) of primer-sealer the epoxy and/or acrylic urethane must be applied over all surfaces. The materials recommended in this procedure barrier coat will serve two significant have been proven effective. purposes. First and primarily it serves as a protective barrier between the original 11.
  • Page 69 HDL500/280 HDL600/350 INSTALLATION MANUAL 13. Alternately, a two stage urethane system adjusted or positioned so that the body may be used if specified, or if a two tone panel and/or compartment door surface finish scheme is being applied, the appro- temperatures will not exceed 140 priate base coat color(s) and clear coat degrees F.

  • Page 70: Wire Rope Installation (Standard Worm Gear Winch)

    INSTALLATION MANUAL HDL500/280 HDL600/350 WIRE ROPE INSTALLATION WARNING Wear gloves to protect hands from the wire ropes. Do not put your fingers between the wire rope and the winch drum. CAUTION Winches are filled with oil at the factory. Check for proper level before installing cable. Wire Rope Installation Wire Rope Installation (Standard Worm Gear Winch)
  • Page 71 HDL500/280 HDL600/350 INSTALLATION MANUAL Rev. Date 05/2001 Page 69...
  • Page 72 INSTALLATION MANUAL HDL500/280 HDL600/350 Mud Flap Installation Paint Touch-Up 1. Temporarily position the mud flap and mud After completing all instructions and flap angle as shown in Figure 60. installations to this point, it is a good practice to touch-up any painted surfaces which may 2.
  • Page 73 HDL500/280 HDL600/350 INSTALLATION MANUAL Decal Installation 1. Install the decals as shown in Figure 61 Item Description and Table 7. Made in USA Jerr-Dan (Logo) NOTE Circle “J” (Logo) Make sure surfaces are clean before installing decals. Checklist Reminder Decal Jerr-Dan (Die-Cast Logo) 2.
  • Page 74 INSTALLATION MANUAL HDL500/280 HDL600/350 CHECKOUT AND INSPECTION As with any product, the safety, quality, and problems. We have a tendency to pay more reliability depends on the quality of attention to the more obvious details. One workmanship and the attention paid to details. must train themselves to look beyond the The most important details are those obvious to recognize potential problems.
  • Page 75 Notes...
  • Page 76 Notes...
  • Page 77 HDL500/280 HDL600/350 INSTALLATION MANUAL APPENDIX Appendix Rev. Date 05/2001 Page A-1...
  • Page 78 INSTALLATION MANUAL HDL500/280 HDL600/350 Rev. Date 05/2001 Page A-2 Appendix...
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  • Page 80 INSTALLATION MANUAL HDL500/280 HDL600/350 Rev. Date 05/2001 Page A-4 Appendix...
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  • Page 82 INSTALLATION MANUAL HDL500/280 HDL600/350 Rev. Date 05/2001 Page A-6 Appendix...
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  • Page 94 INSTALLATION MANUAL HDL500/280 HDL600/350 Rev. Date 05/2001 Page A-18 Appendix...
  • Page 95 HDL500/280 HDL600/350 INSTALLATION MANUAL PROPER CARE AND INSTALLATION OF WIRE ROPE UNREELING AND UNCOILING RE-REELING Wire rope is shipped in cut lengths, either in coils or on When re-reeling wire rope from a horizontally supported reels. Great care should be taken when the rope is re- reel to a drum it is preferable for the rope to travel from the moved from the shipping package since it can be per- top of the reel to the top of the drum;...
  • Page 96 INSTALLATION MANUAL HDL500/280 HDL600/350 PROCEDURES FOR TIGHTENING 37° JIC SWIVEL FEMALE NUTS WHEN A TORQUE WRENCH CANNOT BE USED 1. Check the 37° flare and flare seat for defects that might cause leakage. 2. Lubricate the connection with oil or hydraulic fluid. 3.
  • Page 97 Notes...
  • Page 98 Notes...
  • Page 99 TIGHTENING TORQUES (FOOT - POUNDS) FOR SCREWS AND NUTS SIZE INCHES (MM) GRADE 2 GRADE 5 GRADE 8 1/4 (6.350) 5/16 (7.938) 3/8 (9.525) 7/16 (11.112) 1/2 (12.700) 9/16 (14.288) 5/8 (15.875) 3/4 (19.050) 7/8 (22.225) 1 (25.400) · All torque values shown are for bolts (cap screws) and nuts that are either zinc-plated or lubricated.

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Jerr-dan hdl600/350

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