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Oshkosh JERR-DAN 19NGADF6T-LP 2024 Service Maintenance Manual

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Service & Maintenance Manual
Carriers
Light Duty, Medium Duty,
Heavy Duty, Multi-Car
5376000252
May 1, 2024 - Rev A
Copyright ©

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Summary of Contents for Oshkosh JERR-DAN 19NGADF6T-LP 2024

  • Page 1 Service & Maintenance Manual Carriers Light Duty, Medium Duty, Heavy Duty, Multi-Car 5376000252 May 1, 2024 - Rev A Copyright ©...

  • Page 3: Effectivity Page

    EFFECTIVITY PAGE DATE REVISION DESCRIPTION May 01, 2024 Original Issue of Manual Carriers 5376000252...
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  • Page 5: Read This First

    READ THIS FIRST Modifications Modifications to this truck may affect compliance with Industry Standards and/or Governmental Regulations. Any modification must be approved by JerrDan, LLC (Jerr-Dan). Information contained in this manual reflects how your Jerr-Dan equipment was built at the factory. Modifications or additions by the distributor or owner are not reflected in this manual.
  • Page 6 Heavy Duty Models: 410T2B-8 410TRB-8 415T2B 615TRB 410T2B-8W 410TRB-8W 415T2B-W 615TRBLP 610T2B-8 610TRB-8 415TRB 615TRBLP-W 610T2B-8W 610TRB-8W 415TRBLP 615TRB-W 810T2B-8 810TRB-8 415TRBLP-W 815T2B 810T2B-8W 810TRB-8W 415TRB-W 815T2B-W 3010T2B 3010TRB 615T2B 815TRB 3010T2B-W 3010TRB-W 615T2B-W 815TRBLP 815TRBLP-W Multi-Car Models: 28ALA3CB-LP 28ST3CB-LP 30ALA3CB-LP 30ST3CB-LP 28ALA3CB-W-LP...
  • Page 7 MANUF ACTURED B Y: JLG INDUSTRIES , INC. FOR: SERIAL NO. MODEL NO. 1001127221-00 KAF21200 MULTI-CAR LOCATION Additional or replacement manuals or replacement safety warning labels 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 Technical Publications Department by e-mail at technicalpublications@jerrdan.com.
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  • Page 9: Table Of Contents

    SECTION CONTENTS Page Section Subject EFFECTIVITY PAGE ........................... 3 READ THIS FIRST ............................5 SECTION 1 SAFETY ............................... 13 General ..........................13 Safety Information ......................13 Safety Hazards .........................14 Safety Decals........................15 Machine Verification ......................15 SECTION 2 GENERAL EQUIPMENT INFORMATION AND SPECIFICATIONS..........17 Specifications........................17 Fluids and Lubrication......................20 SECTION 3...
  • Page 10 Section Contents On-Demand Remote Throttle Installation................64 SECTION 7 HYDRAULICS............................. 67 General Information and Safety ..................67 Carrier Hydraulic System ....................68 Theories of Operation ......................69 Hydraulic Components ......................71 Torque Values ........................72 Hydraulic Troubleshooting Guide ..................73 Hydraulic Quick Test Procedures ..................75 Typical Winch Troubleshooting Guide .................76 Typical PTO/Pump Troubleshooting Guide ................77 SECTION 8 ELECTRICAL..............................
  • Page 11 Section Contents 10.3 Hydraulic Oil Reservoir ....................212 10.4 Hydraulic Cylinders ......................212 10.5 Hydraulic Valves......................212 10.6 Hose Carrier ........................213 10.7 Power Take Off........................ 214 Hydraulic Pump ........................215 10.8 10.9 Winch(s) ......................... 215 10.10 SRS - Side Recovery System ................... 215 SECTION 11 TORQUE / CONNECTION INFORMATION ..................217 11.1...
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  • Page 13: Safety

    SECTION 1 SAFETY GENERAL This Service Manual provides general directions for service and repair procedures. Following the procedures in this manual will help assure safety and equipment reliability. This section contains general safety precautions that must be observed during maintenance of this machine. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment.

  • Page 14: Safety Hazards

    Safety 1.2.1 Safety Alert System and Signal Words DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will re- sult in death or serious injury. WARNING WARNING indicates a potentially hazardous situation which, if not avoided, could re- sult in death or serious injury.

  • Page 15: Safety Decals

    Safety • Avoid pressure-washing electrical/electronic components. In the event pressure-washing the machine is needed, make sure the machine is powered off before pressure-washing. If pressure-washing areas containing electrical/electronic components, it is recommended a maximum pressure of 750 psi (52 bar) at a minimum distance of 12 in (30,5 cm) away from these components. If electrical/electronic components are sprayed, spraying must not be direct and spray for brief time periods to avoid heavy saturation.
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  • Page 17: General Equipment Information And Specifications

    SECTION 2 GENERAL EQUIPMENT INFORMATION AND SPECIFICATIONS SPECIFICATIONS 2.1.1 Hydraulic Cylinder and Winch Performance Note: Truck with no attachment or load, engine at 900–1000 R.P.M., hydraulic oil temperature is between 100°-130°F (38°-54°C), engine at operating temperature. A 10% variance above or below these ranges is still considered within normal operating parameters Approximate Times (Seconds) Function...
  • Page 18 General Equipment Information and Specifications 2.1.4 Pump Performance Specifications (Typical Standard Pump Performance - May vary based on exact model equipped.) Description Specifications Direct Mount Pump Muncie PKS1–11–02BSBB or Chelsea 3089113232 Pump Displacement 2.46 cu in 11 gpm Flow (@ 1000 RPM) Maximum Operation Pressure 3000 psi Rotation...
  • Page 19 General Equipment Information and Specifications Description Specifications Winch Assembly Ramsey Worm Gear (HDG-350R) Line Pull 10,000 lb Gear Ratio 30:1 Winch Assembly Ramsey Worm Gear (H-400R) Line Pull 12,000 lb Gear Ratio 29:1 Winch Assembly Ramsey Planetary Gear (HD-P10000) Line Pull 10,000 lb Gear Ratio 5.1:1...

  • Page 20: Fluids And Lubrication

    General Equipment Information and Specifications 2.1.7 Wire Rope Specifications Description Specifications 3/8 in Dia x 56 FT Construction 6x25 FW IWRC RRL Grade EIPS Finish Drawn Galvanized Nominal Breaking Strength 15,100 lb Working Load Limit 4,314 lb 7/16 in Dia x 56 FT Construction 6x25 FW IWRC RRL Grade...
  • Page 21 General Equipment Information and Specifications 3. Cold temperatures can cause hydraulic oils to thicken and adversely affect the functions of a carrier. If this is the case, it will be necessary to change the hydraulic oil to maintain maximum system efficiency. Note: Start-up of hydraulic system with oil temperatures below -15°F (-26°C) is not recommended.
  • Page 22 General Equipment Information and Specifications 3. While the unit is shut down, a good preventive maintenance measure is to perform a thorough inspection of all hydraulic components, lines, fittings, etc., as well as a functional check of each system, before placing the truck back in service. 4.
  • Page 23 General Equipment Information and Specifications 2.2.8 Carrier Lubrication Points Note: The following numbers correspond to those on the lubrication chart. 3. Winch Gear Case Lube Point(s) Fill Plug Lube Reference winch manufacturer’s manual Interval Check level every 250 hours or semi-annually Change every 1000 hours 6.
  • Page 24 General Equipment Information and Specifications Lube Point(s) Site Glass/Fill Cap Interval Check level every 100 hours or bi-monthly Change every 1000 hours 7. Hydraulic Reservoir Return Filter Lube Point(s) Replaceable Element Interval Change every 250 hours or semi-annually 2.2.9 Multi-Car Carrier Lubrication Schedule 50, 100, 250 and 1000 Hour The following lubrication chart is located on the driver’s side of the rear upper deck.
  • Page 25 General Equipment Information and Specifications 2.2.10 Multi-Car Carrier Lubrication Points Note: The following numbers correspond to those on the lubrication chart. 3. Winch Gear Case Fill Plug Lube Point(s) Lube Reference winch manufacturer’s manual Interval Check level every 250 hours or semi-annually Change every 1000 hours 6.
  • Page 26 General Equipment Information and Specifications Lube Point(s) Site Glass/Fill Cap Interval Check level every 100 hours or bi-monthly Change every 1000 hours 7. Hydraulic Reservoir Return Filter Lube Point(s) Replaceable Element Interval Change every 250 hours or semi-annually 2.2.11 SRS Lubrication Schedule 50, 100, 250 and 1000 Hour The following lubrication chart is located on the rear of the Side Recovery System frame.
  • Page 27 General Equipment Information and Specifications Carriers 5376000252...
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  • Page 29: Maintenance And Inspection Schedules

    SECTION 3 MAINTENANCE AND INSPECTION SCHEDULES EQUIPMENT PREPARATION, INSPECTION, AND MAINTENANCE This section provides the necessary information needed by those personnel that are responsible to place the truck in operation readiness and maintain its safe operating condition. For maximum service life and safe operation, ensure that all the necessary inspections and maintenance have been completed before placing the truck into service.
  • Page 30 Maintenance and Inspection Schedules 3.2.4 Components Removal and Installation 1. Use adjustable lifting devices, whenever possible, if mechanical assistance is required. All slings (chains, cables, etc.) should be parallel to each other and as near perpendicular as possible to top of part being lifted. 2.
  • Page 31 Maintenance and Inspection Schedules 3. The hydraulic filter located on the return side of the hydraulic tank comes equipped with a restriction indicator gauge. The gauge shows the condition of the filter element. When the needle reaches the red band (25 psi), the filter is starting to bypass and the element needs to be changed.

  • Page 32: Preventive Maintenance And Inspection Schedule

    Maintenance and Inspection Schedules PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE In conjunction with the specified inspections, maintenance shall be performed by a qualified Jerr-Dan equipment mechanic. Jerr- Dan recognizes a qualified Jerr-Dan equipment mechanic as a person who, by possession of a recognized degree, certificate, extensive knowledge, training, or experience, has successfully demonstrated the ability and proficiency to service, repair, and maintain the subject Jerr-Dan product model.

  • Page 33: Wheel Lift Inspection And Maintenance

    Maintenance and Inspection Schedules 3.5.3 "No-Lube" Maintenance-Free Pivot System Jerr-Dan carriers use a "No-Lube" maintenance-free pivot joint system. Most of the pivot joints utilize high-strength composite bearings with hardened and plated pins to reduce maintenance, down-time, and the cost of lubrication over the life of the product. There are however a few areas that still require some lubrication or maintenance.
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  • Page 35: Testing, Calibrations, And Special Procedures

    SECTION 4 TESTING, CALIBRATIONS, AND SPECIAL PROCEDURES SPECIAL TOOLS 4.1.1 Multimeter General This section contains basic electrical information and schematics for locating and correcting most electrical problems. If a problem develops which is not presented in this section or corrected by listed corrective actions, obtain technically qualified guidance before proceeding with any additional maintenance.
  • Page 36 Testing, Calibrations, and Special Procedures Voltage Measurement TH100007A • If meter is not auto ranging, set it to the correct range (Refer to multimeter’s operation manual) • Use firm contact with meter leads Resistance Measurement TH100008A • First test meter and leads by touching leads together. Resistance should read a short circuit (very low resistance) •...
  • Page 37 Testing, Calibrations, and Special Procedures Continuity Measurement TH100009A • Some meters require a separate button press to enable audible continuity testing • Circuit power must be turned OFF before testing continuity • Disconnect component from circuit before testing • Use firm contact with meter leads •...

  • Page 38: Testing Procedures

    Testing, Calibrations, and Special Procedures 4.1.2 Threadlocking Compound Description Jerr-Dan PN Loctite® ND Industries 0100011 ™ Vibra-TITE ™ Medium Strength (Blue) 1001095650 ™ Vibra-TITE ™ Medium Strength (Blue) 0100019 ™ Vibra-TITE ™ High Strength (Red) 0100071 ™ Vibra-TITE ™ Medium - High Strength (Red) Note: Loctite®...
  • Page 39 Testing, Calibrations, and Special Procedures 5. Install pressure gauge hose assembly (Jerr-Dan P/N 3470000003) to the adapter fitting on the cylinder. Connect the ball valve assembly (Jerr-Dan P/N 3935000172) to the pressure gauge hose assembly and also to the cylinder pressure port hose (from control valve).
  • Page 40 Testing, Calibrations, and Special Procedures 18. Start truck - Engage PTO and check for any leaks and for correct operation. 4.2.2 IRL Tow Option Drift Down Analysis The Tow Option IRL (Raise/Lower) System used on Jerr-Dan Rollback Carriers is considered a redundant system, which means in order for the tow option to drift down, two separate failures must occur simultaneously such as: •...
  • Page 41 Testing, Calibrations, and Special Procedures 3. Remove the new cartridge and reinstall old cartridge in valve "A" of cylinder "A" and proceed with test #4. 4. Lower the tow option so it is resting on the ground. Disengage the PTO and relieve the hydraulic pressure from the IRL lift cylinders by raising and lowering the IRL function control handle.
  • Page 42 Testing, Calibrations, and Special Procedures 4.2.3 Cylinder Pressure Checking Checking Cylinder Pressure Attach a digital or an analog 4000 psi (276 bar) gauge to test port on hydraulic pump to check system pressure. Adjusting Cylinder Pressure If a hydraulic cylinder pressure is greater than main control valve pressure, increase main control valve pressure by adjusting the main relief.

  • Page 43: Calibration Procedures

    Testing, Calibrations, and Special Procedures CALIBRATION PROCEDURES 4.3.1 Manual Winch Free Spool Adjustment The purpose of the Winch Free-Spool device is to allow for the operator to engage and disengage the winch free spool from the ground at the side of the carrier deck. It may be installed on either the drivers side, LH side, or both sides of the carrier deck. If the free spool device isn’t working correctly, there are a few things to check: 1.
  • Page 44 Testing, Calibrations, and Special Procedures 6. Check the free spool rod(s) locking sleeve(s) and spring pin(s). Adjust the free spool rod(s) to balljoint(s) connections, if necessary. Replace any broken, missing or worn parts, if necessary. JD000071A 4.3.2 Air Operated Winch Free Spool Adjustment The purpose of the Air Operated Winch Free-Spool device is to allow for the operator to engage and disengage the winch free spool from the ground at the control stations of the carrier deck subframe controls.
  • Page 45 Testing, Calibrations, and Special Procedures 4. Check the operation of the air switches at the control stations. Adjust the system air pressure, if necessary. Replace any broken, missing or worn parts, if necessary. 4.3.3 Remote Linear Actuator Adjustment The linear actuator is attached to the control linkage operating rods to provide radio control to operate functions. The actuator uses 12 volt DC to operate.

  • Page 46: Special Procedures

    Testing, Calibrations, and Special Procedures 2. Check the linkage connection(s) of the actuator to the control rod(s). 3. Check the linkage connection(s) of the actuator to the control station. DO NOT TRY TO DISASSEMBLE LINEAR ACTUATOR! The linear actuator has no serviceable parts inside. If you suspect that you have a defective linear actuator. Follow these guidelines: 1.
  • Page 47 Testing, Calibrations, and Special Procedures 4.4.2 Hydraulic Oil Reservoir The hydraulic reservoir is located behind the cab of the truck mounted to the frame rail. It is usually mounted on the driver side, LH side, but may be mounted on the passenger side, RH side. Hydraulic Oil Reservoir Draining 1.
  • Page 48 Testing, Calibrations, and Special Procedures 1. Park the truck on a firm, level surface. Engage the park brake, place the transmission in (N) Neutral, ensure PTO is disengaged, and turn the engine OFF. 2. Actuate any of the control handles up and down to relieve any residual pressure from the lines. 3.
  • Page 49 Testing, Calibrations, and Special Procedures 4.4.4 Spool Operated Hydraulic Control Valve Spool operated hydraulic control valves may build up debris, dirt, and/or corrosion under the spring cap. This may cause slower operation of that hydraulic function even when the control handle is fully actuated. It is recommended to annually remove the spring caps on the valve section (usually the opposite side from the spool end clevis) and clean the cap and the items under the cap, to remove any build up.
  • Page 50 Testing, Calibrations, and Special Procedures 4.4.5 Husco Relief Valve Adjustment and Troubleshooting 5376000252 Carriers...
  • Page 51 Testing, Calibrations, and Special Procedures Carriers 5376000252...
  • Page 52 Testing, Calibrations, and Special Procedures 5376000252 Carriers...
  • Page 53 Testing, Calibrations, and Special Procedures 4.4.6 Hydraulic Circuits This section covers the hydraulic circuits and includes listings for all hydraulic function pressures and where and how to check those pressures. Electrical and hydraulic functions are often related. Verify that the electrical components of the circuit are functioning properly whenever troubleshooting the hydraulic circuit.
  • Page 54 Testing, Calibrations, and Special Procedures 4.4.8 Pressure Specifications Main Control Note: Service information not available at time of publication. 4.4.9 Automatic Throttle-Up Control The Auto Throttle-Up is an option which utilizes a pressure switch to supply a signal to a pre-programmed International, Freightliner or Hino Chassis.
  • Page 55 Testing, Calibrations, and Special Procedures E TENDER FITTING HOSE & FITTING TO PRESSURE GAUGE IN CONTROL TEE FITTING HOOD CONTROL VALVE INLET/OUTLET SECTION PRESSURE HARNESS, SEE CHASSIS CHECK PORT SPECIFIC INSTRUCTIONS PRESSURE SWITCH RED WIRE TO PRESSURE WITH FUSE SWITCH TO BATTERY SEE INSTRUCTIONS TO PRESSURE...
  • Page 56 Testing, Calibrations, and Special Procedures 4.4.10 Linear Actuator Jerr-Dan offers an Electrical Linear Actuator, which can be used to operate most manual hydraulic control valve functions. The linear actuator is attached to the control linkage operating rods to provide radio control to operate functions. The actuator uses 12 volt DC to operate.
  • Page 57 Testing, Calibrations, and Special Procedures Carriers 5376000252...
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  • Page 59: Body And Paint

    SECTION 5 BODY AND PAINT BODY MAINTENANCE 5.1.1 Aluminum Carrier Deck General Cleaning and Care The deck and/or rails of your carrier may have been built from high strength aluminum which has been carefully assembled and polished in our factory. To keep it clean and free of dirt, use any non-abrasive soap or detergent recommended for automotive finishes.
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  • Page 61: Remote Control Systems

    SECTION 6 REMOTE CONTROL SYSTEMS AUTOMATED REMOTE MECHANISM “ARM” (LINEAR ACTUATOR) The “ARM” Control-100 System is an “add-on” system to provide Remote Control capability for the hydraulic valve control function(s). It is used in conjunction with a conventional manual control valve assembly with 0.25" – 0.312" Spool Travel. The desired control function(s) is powered by an Electric Actuator which is attached to the control assembly and handle linkage.

  • Page 62: Miratron Remote System

    Remote Control Systems MIRATRON REMOTE SYSTEM 6.2.1 Miratron Remote System Operation Using the remote control 1. Press the green button on the transmitter. The red LED will flash to indicate that the transmitter is on. 2. Press the yellow function keys to operate remote functions. 3.
  • Page 63 Remote Control Systems 1. Remove transmitter from protective rubber boot. Slide the battery compartment cover latch to open the battery compartment. 3. Replace battery and reassemble. Transmitter replacement (2 and 4 function) In the event the transmitter is lost, stolen, or damaged, the receiver must be programmed to the replacement transmitter. To program a new transmitter, follow these steps: 1.

  • Page 64: On-Demand Remote Throttle Installation

    Remote Control Systems Remedy Problem Install new battery. Make sure receiver is powered. Transmitter not working. LED on or blinking. Check receiver fuse. Make sure transmitter is in range of receiver. Make sure transmitter and receiver are matched. Check receiver antenna and cable for loose connections or damage. Poor range.
  • Page 65 Remote Control Systems E TENDER FITTING HOSE & FITTING TO PRESSURE GAUGE IN CONTROL TEE FITTING HOOD CONTROL VALVE INLET/OUTLET SECTION PRESSURE HARNESS, SEE CHASSIS CHECK PORT SPECIFIC INSTRUCTIONS PRESSURE SWITCH RED WIRE TO PRESSURE WITH FUSE SWITCH TO BATTERY SEE INSTRUCTIONS TO PRESSURE SWITCH...
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  • Page 67: Hydraulics

    SECTION 7 HYDRAULICS GENERAL INFORMATION AND SAFETY 7.1.1 General Information and Safety This section covers the hydraulic circuits and includes listings for all hydraulic function pressures, as well as where and how to check those pressures. Electrical and hydraulic functions are often related. Verify that electrical components of the circuit are functioning properly whenever troubleshooting the hydraulic circuit.

  • Page 68: Carrier Hydraulic System

    Hydraulics 4. Loose fittings, faulty o-rings or seals, trapped oil, leaks, system opened for service, etc., can cause air in the system. Determine what is causing air to enter the system and correct it. Bleed air from the system. WARNING DO NOT service the equipment without following all safety precautions as outlined in Section 1, “Safety”, of this manual.

  • Page 69: Theories Of Operation

    Hydraulics 3. An open center directional manually and/or electrically controlled valve to direct fluid to hydraulic cylinders and/or hydraulic motors and back to the tank. 4. One double-acting hydraulic cylinder that rolls the carrier bed back and forth. 5. Two double-acting cylinders in tandem that tilt the carrier bed(s) up and down. 6.
  • Page 70 Hydraulics 7.3.4 Valves Manual Control Valves When force is applied to a handle/lever a circuit is activated, the spool is shifted and the corresponding work port opens to permit oil flow to the component in the selected circuit, with the opposite work port opening to reservoir. Once the force is relieved from the handle/lever (control returned to neutral), the valve spool returns to neutral (center) and oil flow is then directed through the valve body and returns to reservoir.

  • Page 71: Hydraulic Components

    Hydraulics an aerial lift device can have multiple control stations. Generally there is one in the platform and one at the base that controls the boom functions. Orifice Valves Orifice valve is a type of flow metering throttling device which can measure all single-phase fluid. Flow Control Valve The flow control valve is located on the top of the holding valve on the tilt cylinder.

  • Page 72: Torque Values

    Hydraulics TORQUE VALUES 7.5.1 Cylinder Torque Specifications Tilt Cylinder Note: Service information not available at time of publication. Roll Cylinder Note: Service information not available at time of publication. IRL Wheel Lift Boom Lift Cylinder Note: Service information not available at time of publication. IRL Wheel Lift Boom Extend Cylinder Note: Service information not available at time of publication.

  • Page 73: Hydraulic Troubleshooting Guide

    Hydraulics HYDRAULIC TROUBLESHOOTING GUIDE Remedy Problem Possible Causes 1a. PTO/Clutch pump not engaged. 1a. Follow proper procedure to engage PTO. (Type or chassis specific). Check troubleshooting guide in PTO/clutch pump owner's manual. 1b. Clutch shift PTO slipping. 1b. Check transmission or other hydraulic fluid line that supplies pressure to engage/ hold PTO clutch.
  • Page 74 Hydraulics Remedy Problem Possible Causes 4. Spool end spring cap on main control valve 4. Remove spring cap and clean out any build up contaminated and/or corrosion. Lubricate and reinstall. 5. Internal leak in the cylinder. 5. See cylinder internal leak test procedure. •...

  • Page 75: Hydraulic Quick Test Procedures

    Hydraulics Remedy Problem Possible Causes 8. Tilt drifts by itself without handle activation. 1. See problems 6-3, 6-4, 6-5, 6-7, 6-8. 1. See problems 6-3, 6-4, 6-5, 6-7, 6-8.. 1a. See quick test procedure 1. 1a. See quick test procedure 1. 1b.

  • Page 76: Typical Winch Troubleshooting Guide

    Hydraulics 7.7.2 Procedures 1. Identify the function that has the problem. Determine if it is only in one direction or both. a. One Direction Only i. Switch the hoses within that section. If the problem moves to the other direction, the problem is in the valve section.

  • Page 77: Typical Pto/Pump Troubleshooting Guide

    Hydraulics 7.8.2 Ramsey Planetary Gear Winch Note: This is a typical Ramsey Planetary Gear Winch troubleshooting guide - Refer to the winch manual supplied with your car- rier for your specific model needs. Remedy Problem Possible Causes 1. Winch not mounted squarely, causing end bearings 1.
  • Page 78 Hydraulics Remedy Problem Possible Causes 3. PTO is noisy - clicking. 1. Nicked or damaged gear tooth. 1. Replace damaged gear. 1. Dirt under seal. 1. Replace seal. Examine PTO shaft for scoring. 2. Damaged seal or bearing cover. 2. Replace seal or bearing cover. 4.
  • Page 79 Hydraulics Remedy Problem Possible Causes 1. Improper connection to Ford wiring. 1. Muncie blue wire w/yellow stripe must connect with Ford blue w/yellow stripe. Muncie white wire must connect with Ford white w/blue. See installation instruction manual. 1. PTO will not engage. 2.
  • Page 80 Hydraulics Remedy Problem Possible Causes 1. Hydraulic or air lines connected to wrong ports on 1. Re-route lines. valve control. 5. PTO will not disengage. 2. Faulty air or hydraulic valve. 2. Repair or replace valve. 3. Misadjusted drag brake. 3.
  • Page 81 Hydraulics Remedy Problem Possible Causes 3. Damaged pump body. 3. Replace body section. 1. Low oil level. 1. Fill reservoir with approved fluid. 2. Reservoir too small. 2. Increase reservoir size. 3. Dirty oil. 3. Replace oil and filter. 4. Relief valve stuck open. 4.
  • Page 82 Hydraulics Remedy Problem Possible Causes 2c. Check for kinked or collapsed inlet hose. 2d. Check for clogged reservoir breather or strainer. 3. PTO Noise 3. Confirm noise is not coming from PTO. Separate pump from PTO. Be sure it is tied up to not cause any damage.

  • Page 83: Electrical

    SECTION 8 ELECTRICAL CARRIER ELECTRICAL SYSTEM OVERVIEW The electrical system used for the Rollback Carrier is a 12 volt DC two wire system. This means each wiring harness has a ground conductor and power conductor. The marker lights are LED (light emitting diode) as standard equipment. Power is supplied through a 50 amp manual reset circuit breaker located near vehicle battery.
  • Page 84 Electrical Application The following is general guidance for the application of dielectric grease in a connector system. • Use dielectric grease in a tube for larger connection points or apply with a syringe for small connectors. • Apply dielectric grease to plug/male connector housing which typically contains sockets contact/female terminals. •...
  • Page 85 Electrical Mini Fit Sr. This connector system is typically used on control modules at Jerr-Dan. Follow the general guidance for installation. Carriers 5376000252...
  • Page 86 Electrical DIN Connectors This connector is typically used on hydraulic valves. Follow the installation instructions. Exceptions Some waterproof connector applications do benefit from dielectric grease, and some non waterproof connectors do not benefit from dielectric grease. In the exceptions below, we have found dielectric grease is not needed for some applications, and in some cases can interfere with the intended connection.

  • Page 87: Electrical Connectors

    Electrical ELECTRICAL CONNECTORS Carriers 5376000252...
  • Page 88 Electrical 5376000252 Carriers...

  • Page 89: Electrical Component Terminology

    Electrical ELECTRICAL COMPONENT TERMINOLOGY To understand the safety, operation, and service information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the electrical components of the machine. The following illustration identifies the components that are referred to throughout this section.
  • Page 90 Electrical 8.6.3 Electrical Troubleshooting Guide Remedy Problem Possible Causes 1. All marker lights out. 1. Main circuit breaker tripped. 1. Reset circuit breaker. Check for short circuit. 1. Bad light. 1. Replace with a good pretested light. 2. One marker light out. 2.
  • Page 91 Electrical Taillight Converter Troubleshooting Guide The Taillight Converter is designed to allow additional lighting to be added without adding extra electrical loads to the vehicle's lighting circuits. It converts independent stop and turn inputs circuits to common stop/turn outputs. The Taillight Converter has internal "loading resistors"...
  • Page 92 Electrical 5376000252 Carriers...

  • Page 93: Removal/Installation

    SECTION 9 REMOVAL/INSTALLATION CARRIER DECK COMPONENTS WARNING DO NOT service the truck without following all safety precautions as outlined in the Section 1, “Safety” of this manual. 9.1.1 Carrier Deck Removal Carrier Deck Hose Track Removal 1. Roll the deck rearward until it clears the hold down and tilt the deck up as far as possible. Support the deck in this position using a cylinder safety prop or similar device to keep it from lowering.
  • Page 94 Removal/Installation 5. Remove the orbit motor fittings in the winch orbit motor as shown in Figure. 6. Remove the hoses from the deck beam by removing 5/16 in. dia. flatwashers, 5/16 in. dia. locknuts, double pipe clamps from the capscrews welded to the main deck beam as shown in Figure. ELECTRICAL HARNESS 5/16 in.
  • Page 95 Removal/Installation 2. Remove the 1 in. dia. locknut from the end of the roll cylinder rod. 1.0 in. DIA. LOCKNUT ROLL CYLINDER DECK BRACKET JD000292A ROLL CYLINDER 3. Using a crane or an overhead remove the deck from the subframe by sliding it rearward.. 9.1.2 Carrier Deck Installation Carrier Deck Roll Cylinder Adjustment...
  • Page 96 Removal/Installation 3. To adjust the roll cylinder bracket, first determine the amount the bracket is required to be moved. Take the measurement from step 2 and subtract 2-1/2 in. This is how much the bracket needs to be moved rearward. To relate this dimensional value to the number of holes, divide the distance to be moved by 1.34 and round down to the nearest whole number.
  • Page 97 Removal/Installation 11.25 in. GAP 21 ft. DECK 144 in. CA 34 in. CUTOFF DECK WITH ROLL CYLINDER BRACKET IN FORWARD MOST (SHIPPED) POSITION 3.19 in. GAP 21 ft. DECK 144 in. CA 34 in. CUTOFF DECK WITH ROLL CYLINDER BRACKET IN RELOCATED (MOVE 6 HOLES REARWARD) POSITION KAF14671 Figure 2.
  • Page 98 Removal/Installation Figure 3. Deck Roll Cylinder Adjustment - Light, Medium and Heavy Duty Units Figure 4. Deck Roll Cylinder Bracket Alternate Position 9.1.3 Removable Side Rails Optional Tubular Steel Rail Removal 1. Remove the capscrew (13) from the underside of deck at stack pocket post as shown Figure, “Optional Tubular Steel Rails”, page 99 Figure, “Optional Tubular Steel Rails Variations”, page...
  • Page 99 Removal/Installation 3. Remove the rail(s). Note: Two rails per side are shown in Figure. Some decks may have three rails per side. Figure 5. Optional Tubular Steel Rails Carriers 5376000252...
  • Page 100 Removal/Installation Figure 6. Optional Tubular Steel Rails Variations Optional Tubular Steel Rail Installation 1. Position and place rails (10, 11, if required, and 12) into the stack pockets in the deck rail. 2. Install capscrew (13) from the underside of deck at stack pocket post as shown in Figure, “Optional Tubular Steel Rails”, page Figure, “Optional Tubular Steel Rails Variations”, page 100.
  • Page 101 Removal/Installation Figure 7. Standard Aluminum Blade Rails Standard Aluminum Blade Rail Installation 1. Position and align bracket (8A)with hole in deck rail. 2. Install two capscrews (8C), flatwashers (8D) and nuts (8E) in the bracket (8A) 3. Position and place rail (7A) into the stack pockets in the deck rail. 4.
  • Page 102 Removal/Installation Figure 8. Optional Aluminum Blade Rails Optional Aluminum Blade Rail Installation 1. Insert rail(s) into the deck stack pockets. 2. Insert the capscrew (5) from the underside of deck at stack pocket post as shown in Figure, “Optional Aluminum Blade Rails”, page 102.
  • Page 103 Removal/Installation 3. Repeat for each stack pocket post. 9.1.4 Deck Hold Downs Deck Hold Down Removal Light Duty (XLP-6) and 22 ft./24 ft. Medium Duty (XLP-8.5) Models 1. Remove two 1/2 in. dia. x 2 in. long capscrews, 1/2 in. dia. flatwashers and 1/2 in. dia. flanged locknuts securing the hold down to the truck frame.
  • Page 104 Removal/Installation 3. Drill two 33/64 in. dia. holes through the chassis frame using the holes in the angle as a template. Secure the front end of the hold down to the chassis frame using two 1/2 in. dia. x 2 in. long capscrews, 1/2 in. dia. flatwashers and 1/2 in. dia. flanged locknuts.
  • Page 105 Removal/Installation Figure 9. Hold Down Installation (XLP-6 and XLP-8.5) Light Duty (XLP-6) — Isuzu Carriers 5376000252...
  • Page 106 Removal/Installation 1. Position the hold down on top of the chassis frame as shown in Figure, “Hold Down Installation (XLP-6 Isuzu)”, page 107 making sure it is centered and square to the chassis frame and tightly clamp in position. Note: Hold down to be centered on and parallel with truck frame within 1/16 in. maximum. 2.
  • Page 107 Removal/Installation Figure 10. Hold Down Installation (XLP-6 Isuzu) Light Duty (XLP-6) — Hino 1. Position the hold down on top of the chassis frame as shown in Figure, “Hold Down Installation (XLP-6 Hino)”, page 108 making sure it is centered and square to the chassis frame and tightly clamp in position. Note: Hold down to be centered on and parallel with truck frame within 1/16 in.
  • Page 108 Removal/Installation 4. Repeat steps 2 through 3 for the opposite side. 5. Remove any clamps used to secure the hold down to the chassis frame. Note: The angles should be positioned in the front if possible. If there is an interference with chassis components, the angles and clamps can be reversed.
  • Page 109 Removal/Installation 3. Use angle plate as a template and drill two 0.516 in. dia. holes through the chassis frame as shown in Section A-A of Figure, “Hold Down Installation – 26 ft./28 ft./30 ft. Medium Duty (XLP-8.5) Models and Multi-Car Models”, page 110.
  • Page 110 Removal/Installation Figure 12. Hold Down Installation – 26 ft./28 ft./30 ft. Medium Duty (XLP-8.5) Models and Multi-Car Models Heavy Duty Models 5376000252 Carriers...
  • Page 111 Removal/Installation 1. Position the hold down on top of the chassis frame as shown in Figure, “Hold Down Installation and (26 ft./28 ft./30 ft. Medium Duty and Heavy Duty)”, page 112 making sure it is centered and square to the chassis frame and tightly clamp in position. Note: Hold down to be centered on and parallel with truck frame within 1/16 in.
  • Page 112 Removal/Installation Figure 13. Hold Down Installation and (26 ft./28 ft./30 ft. Medium Duty and Heavy Duty) Hold Down Slide Pad Installation Light Duty (XLP-6) and Medium Duty (XLP-8.5) Models 1. Position slide pads on top of chassis frame and as close to the hold down as possible. 2.
  • Page 113 Removal/Installation Figure 14. Hold Down Slide Pad Installation (XLP-6 and XLP-8.5) Light Duty (XLP-6) Models — Ford F550/600 with Frame Reinforcement 1. Position slide pads on top of chassis frame and rubber pads as close to the hold down as possible. Carriers 5376000252...
  • Page 114 Removal/Installation 2. Cut the rubber pad at areas where the frame rivets are. See Figure, “Hold Down Slide Pad Installation Ford F550/600 with Frame Reinforcement - XLP Units”, page 114. 3. Secure each slide pad to the chassis frame using four clamps and four 3/8 in. dia. x 1-3/4 in. long square head screws and 3/ 8 in.
  • Page 115 Removal/Installation Figure 16. Hold Down Slide Pad Installation Ford F550/600 without Frame Reinforcement - XLP Units Light Duty (XLP-6) Models —Dodge 1. Position slide pads on top of chassis frame and rubber pads as close to the hold down as possible. 2.
  • Page 116 Removal/Installation Figure 17. Hold Down Slide Pad Installation Dodge 5500 - XLP Units Light Duty (XLP-6) — Isuzu 1. Position slide pads on top of chassis frame and as close to the hold down as possible. 2. Secure each slide pad to the chassis frame using three clamps and three 3/8 in. dia. x 1-3/4 in. long square head screws and 3/8 in.
  • Page 117 Removal/Installation 3. Repeat to remove all fourteen slide pads. Carriers 5376000252...
  • Page 118 Removal/Installation JD000291A Figure 18. Deck Slide Pads — (XLP-6) 5376000252 Carriers...
  • Page 119 Removal/Installation Slide Pad Installation — (XLP-6) 1. Position and align slide pad to the subframe mounting holes as shown in Figure, “Deck Slide Pads — (XLP-6)”., page 118. 2. Using three flathead capscrews (2), and locknuts (3), secure the slide pad to the subframe. 3.
  • Page 120 Removal/Installation 1. Position and align slide pad to the subframe mounting holes as shown in Figure, “Deck Slide Pads — (XLP-8.5)”, page 119 2. Using three flathead capscrews (2), and locknuts (3), secure the slide pad to the subframe. 3. Repeat to install all fourteen slide pads. Slide Pad Removal —...
  • Page 121 Removal/Installation 2. Using three flathead capscrews (2), and locknuts (3), secure the slide pad to the subframe. 3. Repeat to install all sixteen slide pads. 9.1.6 Approach Tip Rollers Approach Tip Rollers Removal 1. Park the truck on a firm, level surface, level the truck, fully retract the deck, retract wheel lift boom, place the transmission in NEUTRAL, engage the park brake and shut the engine OFF.
  • Page 122 Removal/Installation 9.1.7 Extrusion Keyslots Extrusion Keyslot Removal 1. Remove four flat head capscrews (3), flatwashers (5) and locknuts (4). See Figure. 2. Remove the keyslot plate (2) from the extruded deck panel. 3. Repeat as necessary. Extrusion Keyslot Installation 1. Thoroughly clean the bottom of the deck panel extrusion (1) mounting surface area of burrs, dirt etc.. 2.
  • Page 123 Removal/Installation 8. Remove capscrew (29) and retaining washer (30) from the end of the pin (8) at the upper end of the rear stabilizer pivot and retain. See Figure, “Rear Dock Stabilizer”, page 124. 9. Remove capscrew (9) and nut (11) securing pin (8) in the subframe trunnion pivot and retain. 10.
  • Page 124 Removal/Installation Figure 21. Rear Dock Stabilizer 5376000252 Carriers...
  • Page 125 Removal/Installation Rear Dock Stabilizer Installation 1. Park the truck on a firm, level surface, level the truck, fully lower the deck, retract wheel lift boom, retract the rear dock stabilizer, place the transmission in NEUTRAL, engage the park brake and shut the engine OFF. 2.
  • Page 126 Removal/Installation 24. Connect the short 90° end of one of the 0.38” dia. x 50” long hydraulic hoses (1) to the 90° fitting installed in the “V” port of the counterbalance valve of the LH lift cylinder (11). Torque to 23 ft lbs (31 Nm). 25.

  • Page 127: Wheel Lift

    Removal/Installation Figure 22. Hydraulic Lines and Fittings — Rear Dock Stabilizer WHEEL LIFT 9.2.1 Manual Wheel Lift Pivot Tube/Wheel Grid Manual Wheel Lift Pivot Tube/Wheel Grid Removal 1. Remove the snap ring on the bottom of the pivot pin. 2. Remove the pivot pin from the wheel lift cross tube and wheel lift boom nose. 3.
  • Page 128 Removal/Installation 5. Slide the wheel lift cross tube onto the wheel lift boom nose making sure the wear washers stay in place. 6. Install the pivot pin through the wheel lift cross tube and wheel lift boom nose. Line up the two flat edges of the pivot pin with those in the wheel lift cross tube as shown in Figure.
  • Page 129 Removal/Installation 4. Partially screw in the two bolts that secure the detent plate to the wheel lift crosstube. Pull the detent plate toward the wheel lift crosstube and away from the pivot pin hole just enough to allow insertion of the pivot pin. See Figure. 5.
  • Page 130 Removal/Installation 10. Install the snap rings on the bottom and top of the pivot pin. 11. Connect two hydraulic lines. Torque hose end fitting to 14 lb-ft/19Nm. 12. Install the two hose clamps, capscrews and flatwashers onto the wheel lift boom nose. 5376000252 Carriers...
  • Page 131 Removal/Installation 13. Loosen the in the two bolts, that secure the detent plate to the wheel lift crosstube, allowing the detent plate to move away from the wheel lift crosstube and toward the flat on the end of the fly boom nose. With the bolts loosened, rotate the crossbar 90°...
  • Page 132 Removal/Installation 1. Park the truck on a firm, level surface, level the truck, fully lower the deck, retract wheel lift boom, place the transmission in NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel. 3.
  • Page 133 Removal/Installation Carriers 5376000252...
  • Page 134 Removal/Installation Level Stop System Adjustment The underlift level stop assist system is factory set to stop the underlift travel at a preset position about 1-1/2” to 2” from the ground. To override stop position, simply release the control function and reactivate the same control function again to achieve further travel of the underlift.
  • Page 135 Removal/Installation 2. Remove the six (three per bumper tube) 1/2 in. dia. x 1-1/4 in. long carriage bolts, two (one per bumper tube) 1/2 in. dia. x 2 in. long carriage bolts and 1/2 in. dia. locknuts and remove the rear bumper tubes and chain boxes from the subframe. Rear Bumper Tube Adjustment and Installation 1.
  • Page 136 Removal/Installation 9.2.5 IRL Wheel Lift Link IRL Wheel Lift Link Removal 1. Use a jack or stand to support the link end of the wheel lift . 2. Remove the two 3/8 in. dia. x 1-1/2 in. long capscrews and 3/8 in. dia. locknuts holding the shaft keepers in the link arm pins. 3.

  • Page 137: Hydraulic Filter

    Removal/Installation HYDRAULIC FILTER The hydraulic filter located on the return side of the hydraulic tank comes equipped with restriction indicator gauges. The gauge shows the condition of the filter element. When the needle reaches the red band (25 psi), the filter is starting to bypass and the element needs to be changed.

  • Page 138: Hydraulic Oil Reservoir

    Removal/Installation 9.3.1 Hydraulic Filter Removal 1. Park the truck on a firm, level surface, level the truck, fully lower the deck, retract wheel lift boom, place the transmission in NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel. 3.
  • Page 139 Removal/Installation ART_2750000008 Standard Hydraulic Oil Reservoir Installation Note: Ensure the reservoir internal is completely dry before refilling. 1. Place the new hydraulic oil reservoir into its original orientation. 2. Secure the hydraulic oil reservoir to the frame with the previous mounting hardware. 3.
  • Page 140 Removal/Installation 5. Check the hydraulic oil reservoir for leaks. 6. Start truck and check all hydraulic functions for proper operation. Check for any hydraulic oil leaks. Shut truck OFF and check hydraulic oil level. If oil is warm, oil level should be visible in the gauge window. Add hydraulic oil if necessary. 7.
  • Page 141 Removal/Installation Carriers 5376000252...

  • Page 142: Hydraulic Cylinders

    Removal/Installation HYDRAULIC CYLINDERS 9.5.1 General Cylinder Instructions General Cylinder Removal 1. Remove any load from the truck. Park the truck on a firm level surface and fully retract the deck. Allow sufficient work space around the hydraulic cylinder being removed. Support the boom if the lift/lower cylinder is being removed. Place the transmission in (N) NEUTRAL, engage the park brake, shut the engine OFF and chock wheels.
  • Page 143 Removal/Installation The main control valve assembly (A) consists of working sections with their own valve assemblies, each providing a specific hydraulic function. Those functions are: Standard Deck Roll Tilt Winch Dual Winch Option Roll Tilt Winch Winch Stabilizer Option Roll Tilt Winch Stabilizer...

  • Page 144: Hose Carrier

    Removal/Installation 10. Remove the control valve. Main Control Valve Installation 1. Position the main control valve up to the control station channel, aligning with the holes in the end sections of the main control valve. 2. Using four capscrews, flatwashers and lock nuts, secure the control valve to the control station channel. 3.
  • Page 145 Removal/Installation 2. Remove the end of the cable track from the mounting plate on the under side of the deck by removing two #10 x 2 in. long capscrews and #10 locknuts as shown in Figure. DECK CABLE TRACK MOUNTING PLATE CABLE TRACK (2) #10 x 2 in.
  • Page 146 Removal/Installation 6. Remove the hoses to the deck beam by removing 5/16 in. dia. flatwashers, 5/16 in. dia. locknuts, double pipe clamps from the capscrews welded to the main deck beam as shown in Figure. ELECTRICAL HARNESS 5/16 in. DIA. x 3/4 in. LG CAPSCREW J-CLAMP 5/16 in.
  • Page 147 Removal/Installation 3. Secure the loose end of the cable track to the mounting plate on the under side of the deck using two #10 x 2 in. long capscrews and #10 locknuts as shown in Figure. DECK CABLE TRACK MOUNTING PLATE CABLE TRACK (2) #10 x 2 in.

  • Page 148: Storage

    Removal/Installation 7. Secure the hoses to the deck beam using 5/16 in. dia. flatwashers, 5/16 in. dia. locknuts and double pipe clamps and the capscrews welded to the main deck beam as shown in Figure. ELECTRICAL HARNESS 5/16 in. DIA. x 3/4 in. LG CAPSCREW J-CLAMP 5/16 in.
  • Page 149 Removal/Installation Standard Toolbox Installation 1. Position the toolbox on the bottom side of the mounting brackets as shown. 2. Secure using four (two per bracket) 1/2 in. dia. x 1-1/2 in. long capscrews and 1/2 in. dia. locknuts. 9.8.2 Standard Basket Standard Basket Removal 1.
  • Page 150 Removal/Installation Standard Basket Installation 1. Position the basket on the top side of the mounting brackets as shown. 2. Secure using four (two per bracket) 5/16 in. dia. x 1in. long capscrews, 5/16 in. dia. flatwashers and 5/16 in. dia. locknuts. 9.8.3 Standard Toolbox Stowage Tray Standard Toolbox Stowage Tray Removal...

  • Page 151: Hydraulic Pump

    Removal/Installation Standard Toolbox Stowage Tray Installation 1. Position the tray on top of the toolbox as shown. 2. Secure the tray to the mounting plates using 3/8 in. dia. x 1-1/8 in. long capscrews, 5/16 in. flatwashers and 3/8 in. locknuts. HYDRAULIC PUMP Hydraulic Pump Removal 1.

  • Page 152: Headboard

    Removal/Installation 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel. 3. Allow the system fluids to cool. 4. Properly disconnect the battery. Refer to Section, “Battery”,, page 158, for procedure. 5. Thoroughly clean the pump and surrounding area, including all hoses, fittings and electrical connections before proceeding. Note: Cap all hoses as you remove them to prevent unnecessary fluid spillage.
  • Page 153 Removal/Installation 9.11.2 Deluxe Deck Mounted Headboard Deluxe Deck Mounted Headboard Removal 1. Remove the winch free spool components keeping all the parts except the Z bracket on the 8,000 lb and 10,000 lb winches for later use. See Section 9.13.4, page 184.
  • Page 154 Removal/Installation 4. Position and align the headboard on the headboard mounting surface of the deck. 5. Using four capscrews, flatwashers and two hex nuts secure the headboard to the deck. 6. If equipped with a light bar or headboard work lights, connect the wiring harness located under the deck on the passenger side.
  • Page 155 Removal/Installation 3. Remove the twelve capscrews and washers securing the cover to the headboard. See Figure. 4. Remove the four capscrews, eight flatwashers and four hex nuts securing the headboard to the deck. Remove the headboard. Adjustable Deck Mounted Headboard Installation 1.
  • Page 156 Removal/Installation 9.11.4 Stationary Fixed Headboard Stationary Fixed Headboard Removal 1. If equipped with a light bar or headboard work lights, disconnect the wiring harness located under the deck on the passenger side. 2. Remove the eight (four each side) 1/2 in. dia. x 2 in. long capscrews, 5/8 on. flatwashers and 5/8 in. dia. flanged locknuts securing the headboard and base frame to the chassis frame.
  • Page 157 Removal/Installation 2. Center the stationary headboard from side to side and insert shims as required between the chassis frame and the stationary headboard mounting plate. Square the stationary headboard to the chassis frame and clamp into place. 3. Using the headboard base as a template, drill eight (four each side) 9/16 in. dia. holes through the chassis frame. 4.

  • Page 158: Electrical Components

    Removal/Installation 5. Remove any clamps used to secure the stationary headboard to the chassis frame. 6. If equipped with a light bar or headboard work lights, connect the wiring harness located under the deck on the passenger side. 9.12 ELECTRICAL COMPONENTS 9.12.1 Battery Note: Eye protection is recommended before disconnecting or connecting the battery.
  • Page 159 Removal/Installation 9.12.2 Dash Switches Switch Removal 1. Park the truck on a firm, level surface, level the truck,fully lower and retract the deck, place the transmission in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel. 3.
  • Page 160 Removal/Installation OEM Supplied Back-Up Camera Removal — International CV515, Chevy 5500HD/6500HD 1. Remove any j-clips or zip ties securing the camera wiring harness as shown in Figure. 2. Remove two #10 self-drilling screws securing the camera bracket to the subframe crossmember. 5376000252 Carriers...
  • Page 161 Removal/Installation 3. Remove the camera bracket and camera harness. OEM Supplied Back-Up Camera Installation — International CV515, Chevy 5500HD/6500HD 1. Layout the camera bracket as shown in Figure. 2. Using the bracket as a template, drill two holes for #10 self-drilling screws. 3.
  • Page 162 Removal/Installation 5376000252 Carriers...
  • Page 163 Removal/Installation 9.12.4 Back-Up Alarm The back-up alarm is located at the rear of the truck and will automatically sound when the transmission is in (R) REVERSE. The back-up alarm must not sound when the transmission is in (N) NEUTRAL or (F) FORWARD. With the ignition key switch in the RUN position, the back-up alarm should sound when the transmission is shifted into (R) REVERSE.
  • Page 164 Removal/Installation 2. Place one lightbar mounting bracket over the carriage bolts and install two 5/16 in. dia. locknuts. 3. Position the bracket approximately 8-1/2 in. from the end of the lightbar and hand tighten the locknut to keep the bracket from sliding.
  • Page 165 Removal/Installation 9.12.6 R.A.I.L. — Rear Awareness Indicator Lights ™ R.A.I.L. Lights Removal 1. Remove any tie straps securing the R.A.I.L. system wiring harness to existing wiring harnesses as required. 2. Locate the wire bundle under the front of the deck that connects the subframe wiring harness to the headboard lights wiring harness.
  • Page 166 Removal/Installation 5. Connect the (3) three wire connector that connects the headboard lights wiring harness to the subframe wiring harness. See Figure “Wiring Schematic”, page 166. Figure 23. Wiring Schematic 6. Remove outer grommet and the marker light from the light bracket on the deck side rail. See Figure “Light Installation”, page 166.
  • Page 167 Removal/Installation 7. Disconnect the marker light and pass marker light harness pigtail through hole in the deck side rail. 8. Disconnect the flashing light connector from the R.A.I.L. system wiring harness. 9. Repeat procedures to finish removing the remaining lights. 10.
  • Page 168 Removal/Installation 9. Firmly press on the light bracket to make sure there is full contact of the adhesive tape with the rubrail surface. 10. Insert grommet through outside hole in the light bracket and install the grommet into the inside hole so that it is securely holding the light bracket and rubrail together.
  • Page 169 Removal/Installation 3. For heavy duty carrier which uses top mount headboard work light, secure one work light mounting bracket to the top side of the upper headboard tube using one 1/2 in. dia. x 1 in. long capscrew, 1/2 in. dia. flatwasher and 19/32 in. lockwasher. Repeat for the opposite end as shown in Figure.
  • Page 170 Removal/Installation 5376000252 Carriers...

  • Page 171: Winch Wire Rope

    Removal/Installation 9.13 WINCH WIRE ROPE WARNING Wire rope WILL FAIL if worn-out, overloaded, misused, damaged, improperly main- tained, or abused. Wire rope failure may cause serious injury or death! Protect yourself and others: • NEVER USE wire rope that is WORN-OUT, DAMAGED, or ABUSED. •...
  • Page 172 Removal/Installation • The Right Way To Uncoil. There is only one correct way to uncoil wire rope. One person must hold the end of the rope while a second person rolls the coil along the floor, backing away. The rope is allowed to uncoil naturally with the lay, without spiraling or twisting.
  • Page 173 Removal/Installation A simple method of determining how a wire rope should be started on a drum is shown above. The observer stands behind the drum with the rope coming towards them. Using the right hand for right-lay wire rope and the left hand for left-lay wire rope, the clenched fist denotes the drum with the extended index finger representing the oncoming rope.

  • Page 174: Winch And Winch Options

    Removal/Installation 3. Carefully operate with the winch in the ‘reel in’ direction, keeping tension on the end of the cable. Spool all the cable onto the winch drum, taking care to form neatly wrapped layers. Ramsey Planetary Gear Winch 1. Unwind the winch cable by rolling it out along the ground to prevent kinking. Securely wrap the end of the cable opposite the hook with plastic or similar tape to prevent fraying.
  • Page 175 Removal/Installation 8. Remove one 1/2 in dia. x 2–1/4” long capscrew (4), three 1/2 in dia. x 1–3/4” long capscrews (5), four 1/2 in dia. flatwashers (7) and four 1/2 in dia. locknuts (6) securing the winch frame to the deck. See Figure, “Winch Installation —...
  • Page 176 Removal/Installation 3. Using one 1/2 in dia. x 2–1/4” long capscrew (4), three 1/2 in dia. x 1–3/4” long capscrews (5), four 1/2 in dia. flatwashers (7) and four 1/2 in dia. locknuts (6), secure the winch frame to the deck. See Figure, “Winch Installation —...
  • Page 177 Removal/Installation Figure 27. Winch Installation — 12,000 lb and 15,000 lb — Standard Winch Installation — 12,000 lb and 15,000 lb — Standard 1. Thoroughly clean the winch and surrounding area before proceeding. 2. Position and align the winch and frame to the winch frame mounting holes in the deck. 3.
  • Page 178 Removal/Installation 4. Properly disconnect the battery. Refer to Section, “Battery”,, page 158, for procedure. 5. Thoroughly clean the winch, orbit and surrounding area, including all hoses, and fittings before proceeding. 6. Remove the winch orbit motor. See Section, “Orbit Motor”, page 182.
  • Page 179 Removal/Installation Figure 28. Winch Installation — 8,000 lb — Standard Multi-Car, Dual Lower Winch Installation — 8,000 lb — Standard Multi-Car, Dual Lower 1. Thoroughly clean the winch and surrounding area before proceeding. 2. Position and align the winch and frame to the winch frame mounting holes in the deck. Carriers 5376000252...
  • Page 180 Removal/Installation 3. Using four 1/2 in dia. x 2–1/4” long capscrews (5), four 1/2 in dia. flatwashers (7)and four 1/2 in dia. locknuts (6) secure the winch frame to the deck. See Figure, “ Winch Installation — 8,000 lb — Standard Multi-Car, Dual Lower”, page 179 4.
  • Page 181 Removal/Installation Figure 29. Winch Installation — 8,000 lb — Standard Multi-Car, Upper Winch Installation — 8,000 lb — Standard Multi-Car, Upper 1. Thoroughly clean the winch and surrounding area before proceeding. 2. Position and align the winch and frame to the winch frame mounting holes in the deck. Carriers 5376000252...
  • Page 182 Removal/Installation 3. Using four 1/2 in dia. x 1–3/4” long capscrews (4), four 1/2 in dia. locknuts (5), and two plates (1), secure the winch frame to the deck. See Figure, “ Winch Installation — 8,000 lb — Standard Multi-Car, Upper”, page 181.
  • Page 183 Removal/Installation Figure 30. Winch Cable Roller Guide/Tensioner Plate Winch Cable Roller Guide/Tensioner Plate Installation 1. Thoroughly clean the winch cable roller guide/tensioner plate assembly, winch and surrounding area before proceeding. 2. Position and align the winch cable roller guide/tensioner plate assembly to the holes in the winch frame. See Figure, “Winch Cable Roller Guide/Tensioner Plate”, page 183.
  • Page 184 Removal/Installation 9.14.4 Free Spool Mechanism Single Manual Free Spool Mechanism Removal — Deck Mounted 1. Thoroughly clean the free spool mechanism assembly, winch and surrounding area before proceeding. 2. Remove clevis pin and hair pin (9) and washer (22) securing the free spool lever (15) to the winch clutch. See Figure, “Single Manual Free Spool Mechanism —...
  • Page 185 Removal/Installation Figure 31. Single Manual Free Spool Mechanism — Deck Mounted Single Manual Free Spool Mechanism Removal — Headboard Mounted 1. Thoroughly clean the free spool mechanism assembly, winch and surrounding area before proceeding. Carriers 5376000252...
  • Page 186 Removal/Installation 2. Remove clevis pin and hair pin (8) and washer (21) securing the free spool lever (13) to the winch clutch. See Figure, “Single Manual Free Spool Mechanism — Headboard Mounted”, page 187. 3. Remove one capscrew, flatwasher, and locknut securing the winch to the deck along with two 1–1/2 in dia. washers (15), one bushing (12), and one 1/2 in dia.
  • Page 187 Removal/Installation Figure 32. Single Manual Free Spool Mechanism — Headboard Mounted Dual Manual Free Spool Mechanism Removal — Deck Mounted 1. Thoroughly clean the free spool mechanism assembly, winch and surrounding area before proceeding. Carriers 5376000252...
  • Page 188 Removal/Installation 2. Remove clevis pin and hair pin (9) and washer (22) securing the free spool lever (15) to the winch clutch. See Figure, “Single Manual Free Spool Mechanism — Deck Mounted”, page 185. 3. Remove one capscrew, flatwasher, and locknut securing the winch to the deck along with two 1–1/2 in dia. washers (16), one bushing (14), and one 1/2 in dia.
  • Page 189 Removal/Installation Figure 33. Dual Manual Free Spool Mechanism — Deck Mounted Carriers 5376000252...
  • Page 190 Removal/Installation Dual Manual Free Spool Mechanism Removal — Headboard Mounted 1. Thoroughly clean the free spool mechanism assembly, winch and surrounding area before proceeding. 2. Remove clevis pin and hair pin (8) and washer (21) securing the free spool lever (13) to the winch clutch. See Figure, “Single Manual Free Spool Mechanism —...
  • Page 191 Removal/Installation Figure 34. Dual Manual Free Spool Mechanism — Headboard Mounted Carriers 5376000252...
  • Page 192 Removal/Installation Remote Air Free Spool Mechanism Removal 1. Park the truck on a firm, level surface, level the truck, fully lower the deck, retract wheel lift boom, place the transmission in NEUTRAL, engage the park brake and shut the engine OFF. 2.
  • Page 193 Removal/Installation Figure 35. Remote Air Free Spool Mechanism 9.14.5 Winch Cover Plates Winch Cover Plate Removal Carriers 5376000252...
  • Page 194 Removal/Installation 1. Thoroughly clean the winch cover plates and surrounding area before proceeding. 2. Remove six 3/8 in dia. x 1– 1/2” long capscrews (3), six 5/16 in dia. flatwashers (4), and six 3/8 in dia. locknuts from each cover plate (1) securing the cover plates to the deck. See Figure, “Winch Cover Plates”, page 194.
  • Page 195 Removal/Installation 2. For aluminum decks only, position and align four shims (2) to the holes in the deck mounting surface. For steel decks only, position and align two shims (2) to the holes in the deck mounting surface. See Figure, “Winch Cover Plates”, page 194.
  • Page 196 Removal/Installation Figure 37. Sliding Winch Sliding Winch Installation 1. Park the truck on a firm, level surface, level the truck, fully lower the deck, retract wheel lift boom, place the transmission in NEUTRAL, engage the park brake and shut the engine OFF. 2.
  • Page 197 Removal/Installation 7. Install the two 90° elbows into the adapter fittings installed in the winch assembly. 8. Install the two .50” dia. hydraulic hoses into the two 90° fittings that you installed in the winch assembly. 9. Connect the two (2) .50” dia. hydraulic hoses to the existing winch hoses in the hose track system. 10.

  • Page 198: Control Station

    Removal/Installation Figure 38. Sliding Winch w/ Air Free Spool 9.15 CONTROL STATION Control Station Removal 5376000252 Carriers...
  • Page 199 Removal/Installation 1. Park the truck on a firm, level surface, level the truck, fully lower the deck, retract wheel lift boom, place the transmission in NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel. 3.

  • Page 200: Srs - Side Recovery System

    Removal/Installation 9.16 SRS - SIDE RECOVERY SYSTEM SRS — Side Recovery System Removal 1. Park the truck on a firm, level surface, level the truck, place the transmission in NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel. 3.
  • Page 201 Removal/Installation 5. Thoroughly clean the SRS, SRS controls, and surrounding area, including all hoses and fittings before proceeding. 6. Label, disconnect and cap the hydraulic hoses attached to the control valve. Refer to Figure, “Hydraulic Supply, Pressure and Return Hoses”, page 201.
  • Page 202 Removal/Installation Figure 40. Remote Controls Harness 5376000252 Carriers...
  • Page 203 Removal/Installation Figure 41. Light Bar Carriers 5376000252...
  • Page 204 Removal/Installation Figure 42. Work Lights 5376000252 Carriers...
  • Page 205 Removal/Installation Figure 43. SRS SRS — Side Recovery System Installation 1. Park the truck on a firm, level surface, level the truck, place the transmission in NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel. 3.

  • Page 206: Mud Flaps

    Removal/Installation 9.17 MUD FLAPS 9.17.1 Mud Flaps — General Mud Flap Removal 1. Remove the four 5/16 in. dia. x 1 in. long carriage bolts and 5/16 in. dia. locknuts securing the mud flap to the angle as shown in Figure. 2.
  • Page 207 Removal/Installation 9.17.2 Mud Flaps — Ford Diesel Only Mud Flap Removal 1. Remove the four 5/16 in. dia. x 1 in. long carriage bolts and 5/16 in. dia. locknuts securing the mud flap to the angle as shown in Figure. 2.
  • Page 208 Removal/Installation 9.17.3 Mud Flaps — Hino/Isuzu NQR and NRR Mud Flap Removal 1. Remove the four 5/16 in. dia. x 1 in. long carriage bolts and 5/16 in. dia. locknuts securing the mud flap to the angle as shown in Figure. 2.
  • Page 209 Removal/Installation Carriers 5376000252...
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  • Page 211: Disassembly/Assembly

    SECTION 10 DISASSEMBLY/ASSEMBLY 10.1 CARRIER DECK 10.1.1 Deck Deck Disassembly Note: Service information not available at time of publication. Deck Assembly Note: Service information not available at time of publication. 10.1.2 Approach Tip Rollers Approach Tip Rollers Disassembly 1. Remove the approach tip roller. Refer to” Approach Tip Roller Removal” in Section 9.1.6., page 121 2.

  • Page 212: Wheel Lift

    Disassembly/Assembly 4. Using an arbor of the correct size, carefully press each bearing into the approach tip roller bracket. 5. Position and align the roller with the holes in the approach tip bracket. 6. Insert the roller pin into the approach tip roller bracket and roller. 7.

  • Page 213: Hose Carrier

    Disassembly/Assembly 10.5.3 Counterbalance Valve Note: Service information not available at time of publication. 10.6 HOSE CARRIER Hose Carrier Track Disassembly Note: Refer to Section 9, page 144 for Hose Carrier Removal to remove the hose carrier before attempting to disassemble it.. Note: Service information not available at time of publication.

  • Page 214: Power Take Off

    Disassembly/Assembly 5. Secure Hose Assembly (3) and (4) to Plate (1) using Clamp (6), Clamp Cover (7), Bolt (8), Washer (9), and Locknut (10) 6. Secure Plate (11) to Plate (1) using two Bolts (12) and Locknut (13). 10.7 POWER TAKE OFF 10.7.1 Gear Driven Note: Service information not available at time of publication.

  • Page 215: Hydraulic Pump

    Disassembly/Assembly 10.8 PUMP 10.8.1 Gear Pump Note: Service information not available at time of publication. 10.8.2 Clutch Pump Note: Service information not available at time of publication. 10.9 WINCH(S) 10.9.1 Worm Gear Note: Service information not available at time of publication. 10.9.2 Planetary Gear Note: Service information not available at time of publication.
  • Page 216 This Page is intentionally left blank...

  • Page 217: Torque / Connection Information

    SECTION 11 TORQUE / CONNECTION INFORMATION 11.1 HYDRAULIC FITTINGS 11.1.1 Tapered Thread Types NPTF = national tapered fuel (Dry Seal) per SAE J476/J512 BSPT = British standard pipe tapered per ISO7-1 11.1.2 Straight Thread Types, Tube and Hose Connections JIC = 37° flare per SAE J514 SAE = 45°...
  • Page 218 Torque / Connection Information MBTL = metric flareless bite type fitting, pressure rating L(medium) per ISO 8434, DIN 2353 MBTS = metric flareless bite type fitting, pressure rating S (high) per ISO 8434, DIN 2353 BH = bulkhead connection – JIC, ORFS, MBTL, or MBTS types 11.1.3 Straight Thread Types, Port Connections ORB = o-ring boss per SAE J1926, ISO 11926...
  • Page 219 Torque / Connection Information 11.1.4 Flange Connection Types FL61 = code 61 flange per SAE J518, ISO 6162 FL62 = code 62 flange per SAE J518, ISO 6162 11.1.5 Tightening Methods Torque = Application of a twisting force to the applicable connection by use of a precise measurement instrument (i. e. torque wrench).
  • Page 220 Torque / Connection Information 4. Take care to identify the material of parts to apply the correct torque values. a. Verify the material designation in the table headings. b. If specifications are given only for steel fittings and components, the values for alternate materials shall be as follows: Aluminum and Brass- reduce steel values by 35%;...
  • Page 221 Torque / Connection Information TYPE/FITTING IDENTIFICATION Turns From Finger Tight Thread Size ØA* (TFFT)** Material Dash Size (UNF) (in) (mm) 1/8 - 27 0.40 10.24 2 to 3 1/4 - 18 0.54 13.61 2 to 3 3/8 - 18 0.67 17.05 2 to 3 STEEL, ALUMINUM,...
  • Page 222 Torque / Connection Information 5. Rotate male fitting the number of turns as per below mention table. Note: TFFT values provided in below table are applicable for the following material configurations: a. Steel fittings with steel mating components. b. Steel fittings with aluminum or brass mating components. c.
  • Page 223 Torque / Connection Information 2. Align tube to fitting and start threads by hand. NOTICE The torque method should NOT be used on lubricated or oily fittings. No lubrication or sealant is required. The lubrication would cause increased clamping force and cause fitting damage.
  • Page 224 Torque / Connection Information 37° Flare (JIC) Thread - Aluminum Brass Torque TYPE/FITTING IDENTIFICATION Flats From Wrench Resist- [Ft-Lb] [Nm] Thread Size ØA* ØB* Dash ance (F.F.W.R) Material Size (UNF) (in) (mm) (in) (mm) – 5/16-24 0.28 7.00 0.31 7.75 –...
  • Page 225 Torque / Connection Information 3. Tighten fitting by hand until hand tight. NOTICE The torque method should NOT be used on lubricated or oily fittings. No lubrication or sealant is required. The lubrication would cause increased clamping force and cause fitting damage. Torque fitting to value listed in below table while using the Double Wrench Method outlined in this section.
  • Page 226 Torque / Connection Information ALUMINUM BRASS TYPE/FITTING IDENTIFICATION TORQUE Turns From Fin- Thread [Ft-Lb] [Nm] ØA* ØB* ger Tight (TFFT) Dash Size Material Size (UNF) (in) (mm) (in) (mm) 7/16-20 0.39 9.90 0.44 11.10 1/4 to 1/2 ALUMINUM/ BRASS FITTINGS 5/8-18 0.56 14.30...
  • Page 227 Torque / Connection Information O-ring Face Seal (ORFS) TYPE/FITTING IDENTIFICATION TORQUE Thread [Ft-Lb] [Nm] ØA* ØB* Size Swivel & Material Tube Nuts Hose Ends Size (UNF) (in) (mm) (in) (mm) 9/16-18 0.51 13.00 0.56 14.20 1/4 to 1/2 1/2 to 3/4 11/16-16 0.63 15.90...
  • Page 228 Torque / Connection Information 11.1.13 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS) NOTICE A non-square tube end can cause improperly seated fittings and leakage. 6. Inspect the components to ensure free of contamination, external damage, rust, splits, dirt, foreign matter, or burrs. Ensure tube end is visibly square.
  • Page 229 Torque / Connection Information DIN 24° CONE (MBTL and MBTS) DIN 24° CONE FLARELESS BITE FITTING (WITH OR WITHOUT O-RING) TYPE/FITTING IDENTIFICATION Torque Tube Thread M ØA* ØB* ØD* Flats From O.D. Size [Ft-Lb] [Nm] Type Wrench Resist- Material ance (F.F.W.R)** (mm) (Metric) (mm)
  • Page 230 Torque / Connection Information 11.1.14 Assembly Instructions for Bulkhead (BH) Fittings 1. Ensure threads and surface are free of rust, weld and brazing splatter, splits, burrs or other foreign material. If necessary replace fitting or adapter. 2. Remove the locknut from the bulkhead assembly. 3.
  • Page 231 Torque / Connection Information TYPE/FITTING IDENTIFICATION FASTENING JAM NUT FOR BULKHEAD CONNECTORS Torque Thread Size Type [Ft-Lb] [Nm] Material Dash Size (UNF) 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12 Bulkhead Fittings (BH) - METRIC TYPE/FITTING IDENTIFICATION FASTENING JAM NUT FOR BULKHEAD CONNECTORS Torque Connecting Thread M...
  • Page 232 Torque / Connection Information TYPE/FITTING IDENTIFICATION FASTENING JAM NUT FOR BULKHEAD CONNECTORS Torque Connecting Thread M Tube O.D. Size Type [Ft-Lb] [Nm] Material (mm) (metric) M22 x 1.5 M24 x 1.5 M30 x 2 M36 x 2 M42 x 2 M52 x 2 11.1.15 Assembly Instructions for O-Ring Boss (ORB) Fittings...
  • Page 233 Torque / Connection Information O-ring Boss (ORB) - Table 1 of 6 HEX TYPE PLUGS & STUD ENDS WITH 37° (JIC) OR L SERIES DIN TYPE/FITTING IDENTIFICATION (MBTL) OPPOSITE END Torque Thread Size ØA* Dash [Ft-Lb] [Nm] Material Size (UNF) (in) (mm) (85)
  • Page 234 Torque / Connection Information HEX TYPE PLUGS & STUD ENDS WITH 37° (JIC) OR L SERIES DIN TYPE/FITTING IDENTIFICATION (MBTL) OPPOSITE END Torque Thread Size ØA* Dash [Ft-Lb] [Nm] Material Size (UNF) (in) (mm) 13/16-12 1.19 30.10 15/16-12 1.31 33.30 15/8-12 1.63 41.30...
  • Page 235 Torque / Connection Information STUD ENDS WITH (ORFS) OR S ERIES DIN (MBTS) OPPOSITE TYPE/FITTING IDENTIFICATION Torque Thread Size [Ft-Lb] [Nm] Material Dash Size (UNF) (in) (mm) – – – – – – 5/16-24 0.31 7.93 – – – – –...
  • Page 236 Torque / Connection Information O-ring Boss (ORB) - Table 3 of 6 ADJUSTABLE STUD END WITH 37° (JIC) OR L SERIES DIN (MBTL) OP- TYPE/FITTING IDENTIFICATION POSITE END Torque Thread Size ØA* [Ft-Lb] [Nm] Material Dash Size (UNF) (in) (mm) (85) (90) (94)
  • Page 237 Torque / Connection Information ADJUSTABLE STUD END WITH 37° (JIC) OR L SERIES DIN (MBTL) OP- TYPE/FITTING IDENTIFICATION POSITE END Torque Thread Size ØA* [Ft-Lb] [Nm] Material Dash Size (UNF) (in) (mm) 1 5/16-12 1.31 33.30 1 5/8-12 1.63 41.30 1 7/8-12 1.87 47.60...
  • Page 238 Torque / Connection Information ADJUSTABLE STUD END WITH (ORFS) OR S SERIES DIN (MBTS) OP- TYPE/FITTING IDENTIFICATION POSITE END Torque Thread Size ØA* Dash [Ft-Lb] [Nm] Material Size (UNF) (in) (mm) – – – – – – 5/16-24 0.31 7.93 –...
  • Page 239 Torque / Connection Information TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS Torque Thread ØA* Size [Ft-Lb] [Nm] Material Dash Size (UNF) (in) (mm) 15/16-12 1.31 33.30 15/8-12 1.63 41.30 17/8-12 1.87 47.60 21/2-12 2.50 63.50 TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS Torque Thread ØA* Size [Ft-Lb]...
  • Page 240 Torque / Connection Information TYPE/FITTING IDENTIFICATION ZERO LEAK GOLD® HOLLOW HEX PLUGS Torque Thread ØA* Size [Ft-Lb] [Nm] Material Dash Size (UNF) (in) (mm) 5/16-24 0.31 7.93 3/8-24 0.37 9.52 7/16-20 0.44 11.11 1/2-20 0.50 12.70 9/16-18 0.56 14.28 STEEL FITTINGS 3/4-16 0.75 19.10...
  • Page 241 Torque / Connection Information TYPE/FITTING IDENTIFICATION ZERO LEAK GOLD 8 HOLLOW HEX PLUGS Torque Thread ØA* Size [Ft-Lb] [Nm] Material Dash Size (UNF) (in) (mm) 21/2-12 2.50 63.50 Note: * ØA Thread OD dimension for reference only. **Removal Torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque.
  • Page 242 Torque / Connection Information Metric Flat Face Port (MFF) L Series - Table 1 of 3 FORM A (SEALING WASHER) STUD ENDS WITH FORM B (CUTTING FACE) STUD ENDS WITH 37° TYPE/FITTING IDENTIFICATION 37° (JIC) or L SERIES DIN (MBTL) OPPOSITE (JIC) OR L SERIES DIN (MBTL) OPPOSITE END Torque Torque...
  • Page 243 Torque / Connection Information FORM A (SEALING WASHER) STUD ENDS WITH FORM B (CUTTING FACE) STUD ENDS WITH 37° TYPE/FITTING IDENTIFICATION 37° (JIC) or L SERIES DIN (MBTL) OPPOSITE (JIC) OR L SERIES DIN (MBTL) OPPOSITE END Torque Torque Thread M Connecting Size Tube O.D...
  • Page 244 Torque / Connection Information FORM G/H (O-RING W/ RETAINING RING)STUD FORM E (EOLASTIC SEALING RING) STUD ENDS ENDS & ADJUSTABLE STUD ENDS WITH 37° TYPE/FITTING IDENTIFICATION WITH 37° (JIC) OR L SERIES DIN (MBTL) OPPO- (JIC) OR L SERIES DIN (MBTL)OPPOSITE END SITE END Torque Torque...
  • Page 245 Torque / Connection Information Carriers 5376000252...
  • Page 246 Torque / Connection Information 5376000252 Carriers...
  • Page 247 Torque / Connection Information Metric Flat Face Port (MFF) S Series - Table 1 of 3 FORM B (CUTTING FACE) STUD ENDS WITH FORM A (SEALING WASHER) STUD ENDS WITH TYPE/FITTING IDENTIFICATION (ORFS) OR S SERIES DIN (MBTS) OPPOSITE (ORFS) OR S SERIES DIN (MBTS) OPPOSITE END Torque Torque ThreadM...
  • Page 248 Torque / Connection Information FORM B (CUTTING FACE) STUD ENDS WITH FORM A (SEALING WASHER) STUD ENDS WITH TYPE/FITTING IDENTIFICATION (ORFS) OR S SERIES DIN (MBTS) OPPOSITE (ORFS) OR S SERIES DIN (MBTS) OPPOSITE END Torque Torque ThreadM Connecting Size Tube O.D.
  • Page 249 Torque / Connection Information FORM E (EOLASTIC SEALING RING) STUD ENDS AND FORM G/H (O-RING W/ RETAINING RING)STUD HEX TYPE PLUGS WITH (ORFS) OR S SERIES DIN ENDS & ADJUSTABLE STUD ENDS WITH (ORFS) OR TYPE/FITTING IDENTIFICATION (MBTS) OPPOSITE END S SERIES DIN (MBTS)OPPOSITE END Torque Torque...
  • Page 250 Torque / Connection Information 5376000252 Carriers...
  • Page 251 Torque / Connection Information Carriers 5376000252...
  • Page 252 Torque / Connection Information 11.1.17 Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends 1. Inspect components to ensure that male and female threads and surfaces are free of rust, splits, dirt, foreign matter, or burrs. 2. If O-ring is not pre-installed, install proper size, taking care not to damage it. Refer to Section —...
  • Page 253 Torque / Connection Information STUD ENDS WITH 37° (JIC) OR L SERIES DIN STUD ENDS WITH (ORFS) OR S SERIES DIN TYPE/FITTING IDENTIFICATION (MBTL) OPPOSITE END (MBTS) OPPOSITE END Torque Torque Thread M Connecting Size Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm] Material (metric)
  • Page 254 Torque / Connection Information 11.1.18 Assembly instructions for Adjustable Port End (BSPP) Fittings 1. Inspect components to ensure that male and female threads and surfaces are free of rust, splits, dirt, foreign matter, or burrs. 2. If O-ring is not pre-installed, install proper size, taking care not to damage it. Refer to Section —...
  • Page 255 Torque / Connection Information British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3 FORM A**(SEALING WASHER) STUD ENDS WITH FORM B** (CUTTING FACE) STUD ENDS WITH 37° TYPE/FITTING IDENTIFICATION 37° (JIC) or L SERIES DIN (MBTL) OPPOSITE END (JIC) OR L SERIES DIN (MBTL)OPPOSITE END Torque Torque...
  • Page 256 Torque / Connection Information FORM A**(SEALING WASHER) STUD ENDS WITH FORM B** (CUTTING FACE) STUD ENDS WITH 37° TYPE/FITTING IDENTIFICATION 37° (JIC) or L SERIES DIN (MBTL) OPPOSITE END (JIC) OR L SERIES DIN (MBTL)OPPOSITE END Torque Torque Connecting BSPP Tube O.D.
  • Page 257 Torque / Connection Information FORM G/H*** (0-RING W/ RETAINING RING) STUD FORM E*(EOLASTIC SEALING RING) STUD ENDS ENDS & ADJUSTABLE STUD ENDS WITH 37° (JIC) TYPE/FITTING IDENTIFICATION WITH 37° (JIC) ORL SERIES DIN (MBTL) OPPO- ORL SERIES DIN (MBTL) OPPOSITE END SITE END Torque Torque...
  • Page 258 Torque / Connection Information 5376000252 Carriers...
  • Page 259 Torque / Connection Information Carriers 5376000252...
  • Page 260 Torque / Connection Information British Standard Parallel Pipe Port (BSPP) S Series - Table 1 of 3 FORM A** (SEALING WASHER) STUD ENDS WITH FORM B** (CUTTING FACE) STUD ENDS WITH TYPE/FITTING IDENTIFICATION (ORFS) ORS SERIES DIN (MBTS) OPPOSITE END (ORFS) ORS SERIES DIN (MBTS) OPPOSITE END Torque Torque...
  • Page 261 Torque / Connection Information FORM A** (SEALING WASHER) STUD ENDS WITH FORM B** (CUTTING FACE) STUD ENDS WITH (ORFS) TYPE/FITTING IDENTIFICATION (ORFS) ORS SERIES DIN (MBTS) OPPOSITE END ORS SERIES DIN (MBTS) OPPOSITE END Torque Torque Connect- BSPP ing Tube [Ft-Lb] [Nm] [Ft-Lb]...
  • Page 262 Torque / Connection Information FORM E* (EOLASTIC SEALING RING) STUD ENDS FORM G/H*** (Q-RING W/ RETAINING RING) STUD AND HEX TYPE PLUGS WITH (ORFS) or S SERIES ENDS & ADJUSTABLE STUD ENDS WITH (ORFS) TYPE/FITTING IDENTIFICATION DIN (MBTS) OPPOSITE END ORS SERIES DIN (MBTS) OPPOSITE END Torque Torque...
  • Page 263 Torque / Connection Information Carriers 5376000252...
  • Page 264 Torque / Connection Information 5376000252 Carriers...
  • Page 265 Torque / Connection Information 11.1.19 Assembly Instructions for Flange Connections: (FL61 and FL62) 1. Make sure sealing surfaces are free of rust, splits, scratches, dirt, foreign matter, or burrs. 2. Pre-lubricate the O-ring with Hydraulic Oil. 3. Position flange and clamp halves. 4.
  • Page 266 Torque / Connection Information 5376000252 Carriers...
  • Page 267 Torque / Connection Information Carriers 5376000252...
  • Page 268 Torque / Connection Information 5376000252 Carriers...
  • Page 269 Torque / Connection Information Carriers 5376000252...
  • Page 270 Torque / Connection Information 11.1.20 Double Wrench Method To prevent undesired hose or connector rotation, two wrenches must be used; one torque wrench and one backup wrench. If two wrenches are not used, inadvertent component rotation may occur which absorbs torque and causes improper joint load and leads to leaks.
  • Page 271 Torque / Connection Information 2. TFFT (Turns from Finger Tight Method) a. Tighten the swivel nut to the mating fitting until no lateral movement of the swivel nut can be detected; finger tight condition. b. Mark a dot on one of the swivel hex nut flats and another dot in line on the connecting tube adapter. c.

  • Page 272: Torque Charts

    Torque / Connection Information 11.2 TORQUE CHARTS 11.2.1 SAE Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Tensile Clamp Torque Torque Torque Torque Stress Area Load (Dry) Lubricated (Loctite® 242™ or (Loctite®...
  • Page 273 Torque / Connection Information Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Tensile Clamp Torque Torque Torque Torque Stress Area Load (Dry) Lubricated (Loctite® 242™ or (Loctite® 262™ or Vi- Size Bolt Dia 271™...
  • Page 274 Torque / Connection Information SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Tensile Torque Torque Torque Stress Clamp Area (Loctite® 242™ or 271™ or (Loctite® 262™ or Vibra- Size Bolt Dia (Dry or Loctite®...
  • Page 275 Torque / Connection Information Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Tensile Torque Torque Torque Stress Clamp Area (Loctite® 242™ or 271™ or (Loctite® 262™ or Vibra- Size Bolt Dia (Dry or Loctite®...
  • Page 276 Torque / Connection Information SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 5 BOLTS & GRADE 2 NUTS Tensile Clamp Torque Torque Torque Stress Area Load (Loctite® 242™ or 271™ or (Loctite® 262™ or Vibra- Size Bolt Dia (Dry)
  • Page 277 Torque / Connection Information Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 5 BOLTS & GRADE 2 NUTS Tensile Clamp Torque Torque Torque Stress Area Load (Loctite® 242™ or 271™ or (Loctite® 262™ or Vibra- Size Bolt Dia (Dry) Vibra-TITE™...
  • Page 278 Torque / Connection Information SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Tensile Torque Torque Torque Stress Clamp Area (Loctite® 242™ or 271™ or (Loctite® 262™ or Vibra- Size Bolt Dia (Dry or Loctite®...
  • Page 279 Torque / Connection Information Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Tensile Torque Torque Torque Stress Clamp Area (Loctite® 242™ or 271™ or (Loctite® 262™ or Vibra- Size Bolt Dia (Dry or Loctite®...
  • Page 280 Torque / Connection Information SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SOCKET HEAD CAP SCREWS Tensile Clamp Torque Torque Torque Stress Load Area See Note (Dry) K=0.17 (Loctite® 242™ or 271™ or (Loctite® 262™ or Vibra- Size Bolt Dia Vibra-TITE™...
  • Page 281 Torque / Connection Information Values for Magni Coating Fasteners (Ref 4150701) SOCKET HEAD CAP SCREWS Tensile Clamp Torque Torque Torque Stress Load Area See Note (Dry) K=0.17 (Loctite® 242™ or 271™ or (Loctite® 262™ or Vibra- Size Bolt Dia Vibra-TITE™ 111 or 140) or TITE™...
  • Page 282 Torque / Connection Information SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* SOCKET HEAD CAP SCREWS Tensile Clamp Torque Torque Torque Stress Load Area See Note (Dry) K=0.17 (Loctite® 242™ or 271™ or (Loctite® 262™ or Vibra- Size Bolt Dia Vibra-TITE™...
  • Page 283 Torque / Connection Information Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* SOCKET HEAD CAP SCREWS Tensile Clamp Torque Torque Torque Stress Load Area See Note (Dry) K=0.17 (Loctite® 242™ or 271™ or (Loctite® 262™ or Vibra- Size Bolt Dia Vibra-TITE™...
  • Page 284 Torque / Connection Information 11.2.2 Metric Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Tensile Clamp Torque Torque Torque Stress Load Area See Note 4 (Dry or Loctite® 263™) (Loctite®...
  • Page 285 Torque / Connection Information Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Tensile Clamp Torque Torque Torque Stress Load Area See Note 4 (Dry or Loctite® 263™) (Loctite® 262™ or (Loctite®...
  • Page 286 Torque / Connection Information Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 10.9 METRIC (HEX HEAD) BOLTS, CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5* Torque Torque Clamp Load Torque (Lube or Loctite® (Loctite® 262™ or Tensile Stress Size Pitch...
  • Page 287 Torque / Connection Information Values for Magni Coated Fasteners (Ref 4150701)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Torque Torque Clamp Load Torque (Lube or Loctite® 242™or (Loctite® 262™ or Tensile Stress Size Pitch See Note 4 (Dry or Loctite®...
  • Page 288 Torque / Connection Information Values for Magni Coated Fasteners (Ref 4150701)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Torque Torque Clamp Load Torque (Lube or Loctite® 242™or (Loctite® 262™ or Tensile Stress Size Pitch See Note 4 (Dry or Loctite®...
  • Page 289 Torque / Connection Information Values for Magni Coated Fasteners (Ref 4150701)* CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS, CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE* Torque Torque Clamp Load Torque (Lube or Loctite® (Loctite® 262™ or Tensile Stress Size Pitch...
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  • Page 291: Schematics

    SECTION 12 SCHEMATICS Carriers 5376000252...

  • Page 292: Hydraulic Symbols

    Schematics 12.1 HYDRAULIC SYMBOLS 5376000252 Carriers...
  • Page 293 Schematics Carriers 5376000252...

  • Page 294: Hydraulic Schematics

    Schematics 12.2 HYDRAULIC SCHEMATICS 12.2.1 Light Duty, Medium Duty, Heavy Duty Carriers 5376000252 Carriers...
  • Page 295 Schematics Carriers 5376000252...
  • Page 296 Schematics 5376000252 Carriers...
  • Page 297 Schematics Carriers 5376000252...
  • Page 298 Schematics 5376000252 Carriers...
  • Page 299 Schematics Carriers 5376000252...
  • Page 300 Schematics 5376000252 Carriers...
  • Page 301 Schematics Carriers 5376000252...
  • Page 302 Schematics 5376000252 Carriers...
  • Page 303 Schematics 12.2.2 Multi-Car Carriers Carriers 5376000252...
  • Page 304 Schematics 5376000252 Carriers...
  • Page 305 Schematics Carriers 5376000252...
  • Page 306 Schematics 5376000252 Carriers...

  • Page 307: Electrical Symbols

    Schematics 12.3 ELECTRICAL SYMBOLS Typical Single Element Marker Light Typical LED Motor Back-Up Alarm Circuit Breaker Chassis Ground Carriers 5376000252...

  • Page 308: Electrical Schematics

    Schematics 12.4 ELECTRICAL SCHEMATICS 12.4.1 Light Duty, Medium Duty, Heavy Duty Carriers 5376000252 Carriers...
  • Page 309 Schematics Carriers 5376000252...
  • Page 310 Schematics 12.4.2 Multi-Car Carriers 5376000252 Carriers...
  • Page 311 Blank page...
  • Page 312 13224 Fountainhead Plaza Hagerstown, MD 21742 (717) 597-7111 (Corporate) (800) 926–9666 (Customer Support) www.jerrdan.com...

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