HEAVY DUTY WRECKER BODY PARTS MANUAL - Jerr-Dan

HEAVY DUTY WRECKER BODY 

PARTS MANUAL 

13224 Fountainhead Plaza 

Hagerstown, MD 21742 

Phone (717) 597-7111 

www.jerr-dan.com 

5-376-000142 

Rev 0 - August 01, 2010 

© 2010 Jerr-Dan Corporation. All Rights Reserved.

This manual covers the following Jerr-Dan Models: 

JD25 - 25 Ton Integrated JD35 INT - 35 Ton Integrated JD50 - 50 Ton Independent 

JD30 - 30 Ton Integrated JD35HDULIND - 35 Ton HDUL Independent JD60 - 60 Ton Independent 

JD35IND - 35 Ton Independent JD50INT - 50 Ton Integrated 

Jerr-Dan Corporation strives to provide information that is accurate, complete and useful. Descriptions and illustrative material contained 

within this manual are as accurate as known at the time of publication and are subject to change, without notice, as a result of continuous 

product improvements. Jerr-Dan reserves the right to amend the information in this document at any time without prior notice. 

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

not reflected in this manual. 

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

That information is provided by the chassis manufacturer. 

When ordering parts, please refer to your unit’s Serial Number and Model Number. This information is be found on the aluminum tag riveted to 

the inside of the driver’s side rear compartment of the main body. 

FOR: 

MANUFACTURED BY: 

JLG INDUSTRIES, INC. 

SERIAL NO. 

MODEL NO. 

1001127220-00 

Additional or replacement manuals can be ordered by calling Jerr-Dan Parts at 717-597-7111. 

Price and availability will be quoted at time of the request. 

Please report comments and/or errors by contacting Jerr-Dan Corporation’s Technical Publications Department by e-mail at 

technicalpublications@jerr-dan.com or by FAX on 717-485-7162. 

Manufactured under one or more of the following patents: 5,575,606; 5,672,042; 5,697,741; 5,713,714; 5,722,810; 5,782,596; 5,839,775 and 

6,315,515 B1with other Patents Pending. 

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

The material in this document is confidential and the property of Jerr-Dan Corporation. No part of this document may be photocopied, 

reproduced or translated to another language without the express written consent of Jerr-Dan Corporation. 

Heavy Duty Wrecker Body Parts Manual - Page 3 5-376-000142 Rev 0

Heavy Duty Wrecker Body Parts Manual - Page 4 5-376-000142 Rev 0 

THIS PAGE INTENTIONALLY LEFT BLANK

INDEX 

DESCRIPTION 

PAGE 

Body Applications - 25 Ton and 30 Ton Single Axle with 112” CA Base ................................... 7 

Body Applications - 25 Ton and 30 Ton Single Axle with 86” CT Base ..................................... 8 

Body Applications - 35 Ton Tandem Axle with 110” CT Base .................................................... 9 

Body Applications - 35 Ton Tandem Axle with 146” CT Base .................................................. 10 

Body Applications - 35 Ton Tri-Axle with 146” Tri Base ........................................................... 11 

Body Applications - 50 Ton and 60 Ton Tandem Axle with 170” CT Base .............................. 12 

Body Applications - 50 Ton and 60 Ton Tri-Axle with 170” Tri Base ....................................... 13 

Body Installation - 112” CA/86” CT Base ............................................................................ 14 - 15 

Body Installation - 110” CT Base ......................................................................................... 16 - 17 



Body Panel Assembly - 112” CA Base ............................................................................... 22 - 23 

Body Panel Assembly - 86” CT Base ................................................................................. 24 - 25 

Body Panel Assembly - 146” CT Tandem Base .................................................................. 26 - 27 

Body Panel Assembly - 146” CT Tri-Axle Base ................................................................. 28 - 29 

Door and Hardware Assembly - 112” CA/86” CT Base .................................................... 30 - 31 

Door and Hardware Assembly - 146” CT Base ................................................................. 32 - 33 

Fender Flare Assembly - 112” CA Base ............................................................................. 34 - 35 

Fender Flare Assembly - 86” CT Base ............................................................................... 36 - 37 

Fender Flare Assembly - 136” CA Base ............................................................................. 38 - 39 

Fender Flare Assembly - 110” CT Base ............................................................................. 40 - 41 


Fender Flare Assembly - 146” CT Tri-Axle Base ............................................................... 44 - 45 


Fender Flare Assembly - 174” CT Tri-Axle Base ............................................................... 48 - 49 

Mudflap Installation .............................................................................................................. 50 - 51 

Tool Holder Bracket Installation ........................................................................................... 52 - 53 

Shelf Assembly .................................................................................................................... 54 - 55 

24” Tunnel Tool Compartment Installation ........................................................................... 56 - 57 

24” Tunnel Tool Compartment Panel Assembly .................................................................. 58 - 59 

24” Tunnel Tool Compartment Door and Hardware Assembly .......................................... 60 - 61 

24” Tunnel Tool Compartment Fender Flare Assembly ...................................................... 62 - 63 

24” 3/4 Height Tunnel Tool Compartment Installation ......................................................... 64 - 65 

24” 3/4 Height Tunnel Tool Compartment Panel Assembly ................................................ 66 - 67 

24” 3/4 Height Tunnel Tool Compartment Door and Hardware Assembly ........................ 68 - 69 

24” Counterweighted Tunnel Tool Compartment Installation ............................................. 70 - 71 

24” Counterweighted Tunnel Tool Compartment Panel Assembly .................................... 72 - 73 

24” Counterweighted Tunnel Tool Compartment Door and Hardware Assembly ............ 74 - 75 

49” Tunnel Tool Compartment Installation ........................................................................... 76 - 77 

49” Tunnel Tool Compartment Panel Assembly .................................................................. 78 - 79 

49” Counterweighted Tunnel Tool Compartment Installation ............................................. 80 - 81 

49” Counterweighted Tunnel Tool Compartment Panel Assembly .................................... 82 - 83 

49” Tunnel Tool Compartment Door and Hardware Assembly .......................................... 84 - 85 

49” Tunnel Tool Compartment Fender Flare Assembly ...................................................... 86 - 87 

24” Stand-A-Lone Tool Compartment Installation ............................................................... 88 - 89 

DESCRIPTION 

PAGE 

24” Stand-A-Lone Tool Compartment Panel Assembly - LH .............................................. 90 - 91 

24” Stand-A-Lone Tool Compartment Panel Assembly - RH .............................................. 92 - 93 

24” Stand-A-Lone Tool Compartment Door and Hardware Assembly - LH ...................... 94 - 95 

24” Stand-A-Lone Tool Compartment Door and Hardware Assembly - RH ..................... 96 - 97 

24” Stand-A-Lone Tool Compartment Fender Flare Assembly .......................................... 98 - 99 

24” Stand-A-Lone Tool Compartment Spacer Mounting Assembly - LH ...................... 100 - 101 

24” Stand-A-Lone Tool Compartment Spacer Mounting Assembly - RH ...................... 102 - 103 

24” Stand-A-Lone Tool Compartment Hanger Bracket Assembly - LH ........................ 104 - 105 

24” Stand-A-Lone Tool Compartment Shelf Installation - RH ........................................ 106 - 107 

24” 3/4 Height Stand-A-Lone Tool Compartment Installation ........................................ 108 - 109 

24” 3/4 Height Stand-A-Lone Tool Compartment Panel Assembly - LH .........................110 - 111 

24” 3/4 Height Stand-A-Lone Tool Compartment Panel Assembly - RH ........................ 112 - 113 

24” 3/4 Height Stand-A-Lone Tool Compartment Door and Hardware Assembly - LH 114 - 115 

24” 3/4 Height Stand-A-Lone Tool Compartment Door and Hardware Assembly - RH 116 - 117 

24” 3/4 Height Stand-A-Lone Tool Compartment Spacer Mounting Assembly - LH ..... 118 - 119 

24” 3/4 Height Stand-A-Lone Tool Compartment Spacer Mounting Assembly - RH .... 120 - 121 

24” 3/4 Height Stand-A-Lone Tool Compartment Hanger Bracket Assembly - LH ...... 122 - 123 

24” 3/4 Height Stand-A-Lone Tool Compartment Hanger Bracket Assembly - RH ...... 124 - 125 

49” Stand-A-Lone Tool Compartment Installation .......................................................... 126 - 127 

49” Stand-A-Lone Tool Compartment Panel Assembly - LH ......................................... 128 - 129 

49” Stand-A-Lone Tool Compartment Panel Assembly - RH ......................................... 130 - 131 

49” Stand-A-Lone Tool Compartment Door and Hardware Assembly - LH ................. 132 - 133 

49” Stand-A-Lone Tool Compartment Door and Hardware Assembly - RH ................ 134 - 135 

49” Stand-A-Lone Tool Compartment Fender Flare Assembly ..................................... 136 - 137 

49” Stand-A-Lone Tool Compartment Spacer Mounting Assembly - LH ..................... 138 - 139 

49” Stand-A-Lone Tool Compartment Spacer Mounting Assembly - RH ...................... 140 - 141 

49” 3/4 Height Stand-A-Lone Tool Compartment Installation ........................................ 142 - 143 

49” 3/4 Height Stand-A-Lone Tool Compartment Panel Assembly - LH ....................... 144 - 145 

49” 3/4 Height Stand-A-Lone Tool Compartment Panel Assembly - RH ....................... 146 - 147 

49” 3/4 Height Stand-A-Lone Tool Compartment Door and Hardware Assembly - LH 148 - 149 

49” 3/4 Height Stand-A-Lone Tool Compartment Door and Hardware Assembly - RH 150 - 151 

49” 3/4 Height Stand-A-Lone Tool Compartment Spacer Mounting Assembly - LH .... 152 - 153 

49” 3/4 Height Stand-A-Lone Tool Compartment Spacer Mounting Assembly - RH .... 154 - 155 

49” Tunnel Tool Compartment with Drawer Installation ................................................ 156 - 157 

49” Tunnel Tool Compartment with Drawer Panel Assembly ....................................... 158 - 159 

49” Tunnel Tool Compartment with Drawer Door and Hardware Assembly ............... 160 - 161 

49” Tunnel Tool Compartment with Drawer - Drawer Installation ............................... 162 - 163 

Headboard Installation - Body Mounted ......................................................................... 164 - 165 

Headboard Installation - Forward Mounted ................................................................... 166 - 167 

Upright Headboard Installation - Forward Mounted ...................................................... 168 - 169 

Headboard and Panel Assembly .................................................................................... 170 - 171 

Wing Light Bracket installation ....................................................................................... 172 - 173 

49” Toolbox Tray ............................................................................................................. 174 - 175 

49” Tunnel Tool Compartment Inside Drawer ................................................................ 176 - 177 

Slide Out Frame Fork Storage Board ............................................................................. 178 - 179 



INDEX 

DESCRIPTION 

PAGE 

Slide Out ToolBoard ........................................................................................................ 180 - 181 

Tire Lift Grid Storage Brackets for Body Compartments .............................................. 182 - 183 

Tire Lift Grid Storage Brackets for Tunnel Tool Compartments .................................... 184 - 185 

14K Tire Lift Storage Brackets for 49” Tunnel Tool Compartments ............................. 186 - 189 

25K Tire Lift Storage Brackets for 49” Tunnel Tool Compartments ............................. 190 - 193 

25K Tire Lift Storage Brackets for 24” Tunnel Tool Compartment & 24” Stand-A-Lone 

Tool Compartment ......................................................................................................... 194 - 195 

Bracket Assembly - 3178000460 .................................................................................. 196 - 197 

24” Tool Compartment Lighting ....................................................................................... 198 - 199 

49” Tool Compartment Lighting ....................................................................................... 200 - 201 

Body Wiring ................................................................................................................... 202 - 205 

Body Compartment Lighting ........................................................................................... 206 - 207 

Headboard Lighting ......................................................................................................... 208 - 209 

Incandescent Tail Lights .................................................................................................. 210 - 211 

LED Tail Lights ................................................................................................................. 212 - 213 

7-Way Trailer Towing Plug ............................................................................................. 214 - 215 

Glad Hands ................................................................................................................... 216 - 217 

Switch Panel - 9 Function .............................................................................................. 218 - 219 

Switch Panel - 9 Function with In-Cab Underlift Controls ............................................ 220 - 223 

Switch Panel - 8 Function Multiplex ............................................................................... 224 - 227 

Switch Panel - 8 Function Multiplex with Underlift Controls ......................................... 228 - 229 

Emergency Lightbar Installation ..................................................................................... 230 - 231 

Emergency Wing Lightbar Installation ............................................................................ 232 - 233 

Lower Hook-up Lights .................................................................................................... 234 - 235 

Upper Hook-up Lights ..................................................................................................... 236 - 237 

Upper Work Lights .......................................................................................................... 238 - 239 

Lower Hook-up Lights - Underlift Mounted ................................................................... 240 - 241 

Upper Work Lights - Wrecker Boom Mounted ............................................................... 242 - 243 

Under Body Marker Lights - 112” CA Base, 146” CT Base & 170” CT Base Bodies .. 244 - 245 

Under Body Marker Lights - 86” CT Base, 110” CT Base & 146” Tri & 170” Tri Base 

Bodies ................................................................................................................... 246 - 247 

Under Tool Compartment Marker Lights ......................................................................... 248 - 249 

Wide Body Maker Lights ................................................................................................. 250 - 251 

In Body Marker Lights ..................................................................................................... 252 - 253 

Mid Body marker Lights .................................................................................................. 254 - 255 

Rear View Video Camera Kit ......................................................................................... 256 - 257 

Winch View Camera Kit ................................................................................................. 258 - 259 

Hose Reel Installation ...................................................................................................... 260 - 261 

Under Body Battery Box ................................................................................................ 262 - 266

BODY APPLICATIONS 

25 Ton and 30 Ton 

Single Axle with 112” CA Base 

BACK OF CAB 

BACK OF CAB 

BACK OF CAB 

112.00 CA 

MAIN BODY 

118.00 REF 

CAB TO AXLE 

BACK OF CAB 

112.00 CA 

24.25 TOOL 


COMPARTMENT 

24.25 TOOL 

COMPARTMENT 

160.50 

167.00 REF 

CAB TO AXLE 

112.00 CA 


24.25 TOOL 

COMPARTMENT 

136.25 

142.25 REF 

CAB TO AXLE 

24.25 TOOL 

COMPARTMENT 

112.00 CA 


24.25 TOOL 

COMPARTMENT 

24.25 TOOL 

COMPARTMENT 

184.75 

191.25 REF 

CAB TO AXLE 




25 Ton and 30 Ton 

Tandem Axle with 86” CT Base 

BACK OF CAB 

BACK OF CAB 

BACK OF CAB 

86.00 CT 


24.25 TOOL 

COMPARTMENT 

110.25 

116.25 REF 

CAB TO TANDEM 

85.94 CT 


24.25 TOOL 

COMPARTMENT 

49.00 TOOL 

COMPARTMENT 

158.75 

164.75 REF 

CAB TO TANDEM 

86.00 CT 


24.25 TOOL 

COMPARTMENT 

48.50 TOOL 

48.50 TOOL 

COMPARTMENT 

COMPARTMENT 

207.25 

213.25 REF 

CAB TO TANDEM 

BACK OF CAB 

BACK OF CAB 

86.00 CT 


49.00 TOOL 

COMPARTMENT 

134.50 

140.50 REF 

CAB TO TANDEM 

86.00 CT 


49.00 TOOL 

49.00 TOOL 

COMPARTMENT 

COMPARTMENT 

183.00 

189.00 REF 

CAB TO TANDEM


35 Ton 


BACK OF CAB 

BACK OF CAB 

BACK OF CAB 

110.00 CT 


116.00 REF 

CAB TO TANDEM 

110.00 CT 


49.00 TOOL 

COMPARTMENT 

158.50 

164.50 REF 

CAB TO TANDEM 

110.00 CT 

49.00 TOOL MAIN BODY 

COMPARTMENT 

49.00 TOOL 

COMPARTMENT 

207.00 

213.00 REF 

CAB TO TANDEM 

BACK OF CAB 

BACK OF CAB 

110.00 CT 


24.25 TOOL 

COMPARTMENT 

134.25 

140.25 REF 

CAB TO TANDEM 

110.00 CT 


24.25 TOOLBOX 

49.00 TOOL 

COMPARTMENT 

182.75 

188.75 REF 

CAB TO TANDEM 




35 Ton 


BACK OF CAB 

BACK OF CAB 

146.00 CT 


152.00 REF 

CAB TO TANDEM 

146.00 CT 

24.25 TOOL 


COMPARTMENT 

49.00 TOOL 

COMPARTMENT 

219.25 

225.25 REF 

CAB TO TANDEM 

BACK OF CAB 

BACK OF CAB 

24.25 TOOL 

COMPARTMENT 

146.00 CT 


170.25 

176.25 REF 

CAB TO TANDEM 

49.00 TOOL 

COMPARTMENT 

49.00 TOOL 

COMPARTMENT 

244.00 

250.00 REF 

CAB TO TANDEM 

146.00 CT 


BACK OF CAB 

146.00 CT 

49.00 TOOL 


COMPATRMENT 

195.00 

201.00 REF 

CAB TO TANDEM


35 Ton 

Tri-Axle with 146” Tri Base 

BACK OF CAB 

BACK OF CAB 

146.00 CT 


152.00 REF 

CAB TO DRIVE TANDEM 

146.00 CT 


24.25 TOOL 

COMPARTMENT 

49.00 TOOL 

COMPARTMENT 

219.25 

225.25 REF 


BACK OF CAB 

BACK OF CAB 

146.00 CT 


24.25 TOOLBOX 

170.25 

176.25 REF 

CAB DRIVE TANDEM 

49.00 TOOL 

COMPARTMENT 

146.00 CT 


49.00 TOOL 

COMPARTMENT 

244.00 

250.00 REF 


BACK OF CAB 

146.00 CT 


49.00 TOOL 

COMPARTMENT 

195.00 

201.00 REF 





50 & 60 Ton 


BACK OF CAB 

BACK OF CAB 

170.00 CT 


176.00 REF 

CAB TO TANDEM 

49.00 TOOL 

COMPARTMENT 

219.00 

225.00 REF 

CAB TO TANDEM 

170.00 CT 


BACK OF CAB 

BACK OF CAB 

24.25 TOOL 

COMPARTMENT 

170.00 CT 


194.25 

200.25 REF 

CAB TO TANDEM 

49.00 TOOL 

COMPARTMENT 

24.25 TOOL 

COMPARTMENT 

243.25 

249.25 REF 

CAB TO TANDEM 

170.00 CT 

MAIN BODY


50 & 60 Ton 

Tri-Axle with 170” Tri Base 

BACK OF CAB 

BACK OF CAB 

170.00 CT 


176.00 REF 


49.00 TOOL 

COMPARTMENT 

170.00 CT 


219.00 

225.00 REF 


BACK OF CAB 

BACK OF CAB 

24.25 TOOL 

COMPARTMENT 

170.00 CT 


194.25 

200.25 REF 


24.25 TOOL 

COMPARTMENT 

49.00 TOOL 

COMPARTMENT 

170.00 CT 


243.25 

249.25 REF 




BODY INSTALLATION - 112” CA/86” CT BASE 

ITEM PART NO. DESCRIPTION QTY 

1 3097000229 LH Body Assembly 1 

112” CA Single Axle 

3097000223 LH Body Assembly 

86” CT, 52” Tandem Axle Spread 



2 3097000230 RH Body Assembly - 112” CA 1 

112” CA Single Axle 

3097000224 RH Body Assembly 




3 7636000007 Rubber Mount 4 

4 7949000017 Washer, Head 4 

5 7949000018 Washer, Tail 4 

6 7636000008 Rubber Mount 4 

7 7949000019 Washer, Snub Head 4 

8 7949000020 Washer, Snub Tail 4 

9 7115202850 Capscrew, 0.63”-11NC x 3.50” 4 

10 7950200161 Flatwasher, 0.63” ID 4 

11 7660200001 Nut, 0.63”-11NC 4 

12 7115223250 Capscrew, 0.75”-10NC x 4.00” 4 

13 7950220161 Flatwasher, 0.75” ID 4 

14 7660220001 Nut, 0.75”-10NC 4

BODY INSTALLATION - 112” CA/86” CT BASE 

12 

13 

4 

1 

2 

3 

9 

5 

14 

10 

6 

7 

8 

11 



BODY INSTALLATION - 110” CT BASE 






2 3097000213 RH Body Assembly 1 




3 7636000007 Rubber Mount 8 

4 7949000017 Washer, Head 8 

5 7949000018 Washer, Tail 8 

6 7636000008 Rubber Mount 4 



9 7115202850 Capscrew, 0.63”-11NC x 3.50” 4 

10 7950200161 Flatwasher, 0.63” ID 4 

11 7660200001 Nut, 0.63”-11NC 4 

12 7115223250 Capscrew, 0.75”-10NC x 4.00” 8 

13 7950220161 Flatwasher, 0.75” ID 8 

14 7660220001 Nut, 0.75”-10NC 8


12 

13 

4 

12 

13 

1 

2 

3 

5 

14 

4 

3 

5 

9 

10 

14 

7 

6 

8 

11 










146” CT, 52” Tri Axle Spread 











3 7636000007 Rubber Mount 4 

4 7949000017 Washer, Head 4 

5 7949000018 Washer, Tail 4 

6 7636000008 Rubber Mount 8 



9 7115202850 Capscrew, 0.63”-11NC x 3.50” 8 

10 7950200161 Flatwasher, 0.63” ID 8 

11 7660200001 Nut, 0.63”-11NC 8 

12 7115223250 Capscrew, 0.75”-10NC x 4.00” 4 

13 7950220161 Flatwasher, 0.75” ID 4 

14 7660220001 Nut, 0.75”-10NC 4


12 

1 

2 

13 

4 

3 

14 

5 

9 

10 

6 

7 

11 

8 

9 

10 

7 

6 

11 

8 





















3 7636000007 Rubber Mount 8 

4 7949000017 Washer, Head 8 

5 7949000018 Washer, Tail 8 

6 7636000008 Rubber Mount 8 



9 7115202850 Capscrew, 0.63”-11NC x 3.50” 8 

10 7950200161 Flatwasher, 0.63” ID 8 

11 7660200001 Nut, 0.63”-11NC 8 

12 7115223250 Capscrew, 0.75”-10NC x 4.00” 8 

13 7950220161 Flatwasher, 0.75” ID 8 

14 7660220001 Nut, 0.75”-10NC 8


12 

12 

13 

13 

1 

2 

4 

3 

5 

14 

4 

3 

5 

14 

9 

10 

7 

6 

9 

10 

8 

11 

7 

6 

8 

11 



BODY PANEL ASSEMBLY - 112” CA BASE 


1 3503080002 Body Bonding Assembly - LH 1 

3503080003 Body Bonding Assembly - RH 

2 7686000010 Front Cap Panel - LH 1 

7686000009 Front Cap Panel - RH 

3 4686000075 Single Wheel Well Panel - LH 1 

4686000076 Single Wheel Well Panel - RH 

4 7686000014 Tail Light Panel - LH 1 

7686000013 Tail Light Panel - RH 

5 7686000016 Logo Panel - LH 1 

7686000015 Logo Panel - RH 

6 7686000018 Rear Cap Panel - LH 1 

7686000017 Rear Cap Panel - RH 

7 7686000019 Filler Strip Panel 1 

8 7189000015 Bumper, 0.81” Dia x 0.13” Thk 5 

9 4636000031 Rubber Mount, 1.06 Dia x 0.36” Thk 16 

10 7790141251 Screw, Self Tapping - 0.25” Dia x 0.75” 26 

11 7950160163 Flatwasher, 0.38” ID 20 

12 7660160000 Nut, 0.38”-16NC 10 

13 4811000408 Sheet 2 

14 7949000022 Washer, Fender - 1.00 OD x 0.25” ID 29 

15 4679000120 Pad, Rubber - 0.12” Thk 23 

16 4679000122 Pad, Rubber - 0.38” Thk 5 


18 7796000078 Gasket 1.9Ft 

19 7790142051 Screw, Self Tapping - 0.25” Dia x 1.25 35 

20 7790100856 Screw, Self Tapping - #10 Dia x 0.50" 16 

21 7950160000 Lockwasher, 0.38” ID 2 

22 3017000026 Angle Bracket Weldment - LH 1 

3017000027 Angle Bracket Weldment - RH 

23 7114161050 Capscrew, 0.38”-16NC x 1.25” 2 

24 7115161250 Capscrew, 0.38”-16NC x 1.50” 8

BODY PANEL ASSEMBLY - 112” CA BASE 

2 

18 

15 

6 

5 

10 

19 

14 

19 

15 

20 

10 

7 

13 

23 

11 

17 

12 

11 

21 

11 

12 

10 

1 

9 

22 

8 

3 

11 

24 

1419 

19 

14 

9 

16 

4 

LH Body Shown 



BODY PANEL ASSEMBLY - 86” CT BASE 






3 4686000077 Tandem Wheel Well Panel - LH 1 

4686000078 Tandem Wheel Well Panel - RH 



5 7686000016 Logo Panel - LH 1 








11 4811000408 Sheet 2 


13 4679000120 Pad, Rubber - 0.12” Thk 23 

14 4679000122 Pad, Rubber - 0.38” Thk 5 


16 7796000078 Gasket 1.9Ft 


18 7790100856 Screw, Self Tapping - #10 Dia x 0.50" 16

BODY PANEL ASSEMBLY - 86” CT BASE 

2 

13 

16 

5 

10 

6 

13 

11 

18 

10 

17 

7 

1 

12 

3 

10 

17 

9 

15 

12 

17 

17 

12 

9 

8 

14 

4 

LH Body Shown 



BODY PANEL ASSEMBLY - 146” CT TANDEM BASE 






3 4686000089 Tandem Wheel Well Panel - LH 1 

4686000090 Tandem Wheel Well Panel - RH 



5 7686000016 Logo Panel - LH 1 


6 7686000025 Intermediate Cap Panel - LH 1 

7686000024 Intermediate Cap Panel - RH 






11 7590160161 Flatwasher, 0.38” ID 20 

12 7660160000 Nut, 0.38”-16NC 10 

13 4811000091 Sheet 1 


15 4679000120 Pad, Rubber - 0.12” Thk 31 

16 4679000122 Pad, Rubber - 0.38” Thk 5 


18 7796000078 Gasket 3.7Ft 



21 7950160000 Lockwasher, 0.38” ID 10 


23 3017000028 Angle Bracket Weldment - LH 1 

3017000029 Angle Bracket Weldment - RH 

24 7114161050 Capscrew, 0.38”-16NC x 1.25” 2 

25 4811000408 Sheet 2 

26 7115161250 Capscrew, 0.38”-16NC x 1.50” 10

BODY PANEL ASSEMBLY - 146” CT TANDEM BASE 

2 

18 

15 

6 

18 

5 

10 

19 

20 

25 

7 

13 

20 

8 

10 

24 

11 

11 

23 

21 

12 

26 

21 

11 

14 

1 

3 

11 

12 

19 

9 

17 

22 

4 

LH Body Shown 

9 

14 

19 14 

16 



BODY PANEL ASSEMBLY - 146” CT TRI-AXLE BASE 






3 4686000091 Tri-Axle Wheel Well Panel - LH 1 

4686000092 Tri-Axle Wheel Well Panel - RH 



5 7686000016 Logo Panel - LH 1 


6 7686000025 Intermediate Cap Panel - LH 1 

7686000024 Intermediate Cap Panel - RH 






11 4811000091 Sheet 1 


13 4679000120 Pad, Rubber - 0.12” Thk 31 

14 4679000122 Pad, Rubber - 0.38” Thk 5 


16 7796000078 Gasket 3.7Ft 




20 4811000408 Sheet 2

BODY PANEL ASSEMBLY - 146” CT TRI-AXLE BASE 

2 

16 

13 

6 

16 

10 

5 

11 

17 

18 

20 

7 

8 

18 

10 

17 

3 

1 

12 

9 

4 

15 

19 

12 17 

17 

12 

9 

14 

LH Body Shown 



DOOR AND HARDWARE ASSEMBLY - 112” CA/86” CT BASE 


1 4686000072 Door Panel - LH 1 

4686000073 Door Panel - RH 

2 4178000240 Bracket 1 

3 4686000074 Door Panel 2 

4 7555000002 Hinge 2 

5 4062000173 Bar 2 

6 4812000052 Shim 2 

7 3555000008 Front Hinge 2 

8 4062000174 Bar 2 

9 3555000007 Rear Hinge 2 

10 7595000005 Latch, 2 Stage Rotary 3 

11 7796000038 Gasket 3 

12 7585000009 Latch Striker 3 

13 4679000119 Pad, Rubber - LH 1 

4679000143 Pad, Rubber - RH 

14 4178000225 Bracket 3 

15 7178000023 Bracket, Ball Stud 5 

16 7843000020 Gas Spring - 6.00” Stroke 1 


18 7865000001 Ball Stud 5 

19 4632000012 Seal, Vertical Door 1 

20 4632000013 Seal, Horizontal Door 2 

21 7114140518 Capscrew, 0.25”-20NC x 0.62” 12 

22 7950100153 Flatwasher, 0.19” ID 12 

23 7660162604 Locknut, 0.38”-16NC 3 

24 7660102604 Locknut, #10-24NC 24 

25 7114100818 Capscrew, #10-24NC x 1.00” 12 

26 7949000074 Lockwasher, Serrated - 11mm ID 18 

27 7114140418 Capscrew, 0.25”-20NC x 0.50” 6 

28 7660152604 Locknut, 0.31”-18NC 7 

29 7114150650 Capscrew, 0.31”-18NC x 0.75” 2 

30 7114140818 Capscrew, 0.25”-20NC x 1.00” 4 

31 7114140650 Capscrew, 0.25”-20NC x 0.75” 8 

32 7660142604 Locknut, 0.25”-20NC 12 


33 7950140163 Flatwasher, 0.25” ID 22 

34 4679000131 Pad, Rubber - LH 1 

4679000144 Pad, Rubber - RH 

35 7114100418 Capscrew, #10-24NC x 0.50” 3 

36 7114100618 Capscrew, #10-24NC x 0.75” 12 

37 7660162604 Locknut, 0.38”-16NC 5 

38 4679000117 Pad, Rubber 1 

39 7950160163 Flatwasher, 0.38” ID 8 

40 4679000118 Pad, Rubber 1 

41 7114161050 Capscrew, 0.38”-16NC x 1.25” 6 

42 7950160143 Flatwasher, 0.38” ID 3 

43 7950160163 Flatwasher, 0.38” ID 3

DOOR AND HARDWARE ASSEMBLY - 112” CA/86” CT BASE 

28 

25 

1 

15 

2 

29 

35 

28 

18 

4 

16 

32 

42 

38 

10 

11 

26 

27 

32 

24 

13 

34 

19 

24 

4 

33 

30 

6 

5 

41 

39 

33 

37 

32 

24 

40 

3 

12 43 

14 

3 

23 

8 

15 

28 17 

18 

33 36 

7 

31 

21 

26 

22 28 

24 

18 

17 

15 

20 

LH Body Shown 

25 

10 

11 

9 

22 

36 

31 

33 

21 

26 



DOOR AND HARDWARE ASSEMBLY - 146” CT BASE 


1 4686000072 Door Panel - LH 1 

4686000073 Door Panel - RH 

2 4178000240 Bracket 1 

3 4686000074 Door Panel 3 

4 7555000002 Hinge 2 

5 4062000173 Bar 2 

6 4812000052 Shim 2 

7 3555000008 Front Hinge 2 

8 4062000174 Bar 2 

9 3555000007 Rear Hinge 4 


11 7796000038 Gasket 4 


13 7950161062 Flatwasher, 0.38” ID 4 

14 4178000225 Bracket 4 




18 7865000001 Ball Stud 7 


20 4632000013 Seal, Horizontal Door 3 

21 7114140518 Capscrew, 0.25”-20NC x 0.62” 18 

22 7950100153 Flatwasher, 0.19” ID 18 

23 7660162604 Locknut, 0.38”-16NC 4 

24 7660102604 Locknut, #10-24NC 34 

25 7114100818 Capscrew, #10-24NC x 1.00” 16 


27 7114140418 Capscrew, 0.25”-20NC x 0.50” 6 

28 7660152604 Locknut, 0.31”-18NC 9 

29 7114150650 Capscrew, 0.31”-18NC x 0.75” 2 

30 7114140818 Capscrew, 0.25”-20NC x 1.00” 4 

31 7114140650 Capscrew, 0.25”-20NC x 0.75” 12 

32 7660142604 Locknut, 0.25”-20NC 16 

33 7950140163 Flatwasher, 0.25” ID 26 


34 7950160163 Flatwasher, 0.38” ID 12 

35 7114100418 Capscrew, #10-24NC x 0.50” 3 

36 7114100618 Capscrew, #10-24NC x 0.75” 18 

37 7660162604 Locknut, 0.38”-16NC 7 

38 4679000117 Pad, Rubber 1 

39 4679000142 Pad, Rubber 1 

40 4679000118 Pad, Rubber 1 

41 7114161050 Capscrew, 0.38”-16NC x 1.25” 8 

42 7950160143 Flatwasher, 0.38” ID 3 

43 4679000119 Pad, Rubber - LH 1 

4679000143 Pad, Rubber - RH 

44 4679000131 Pad, Rubber - LH 1 

4679000144 Pad, Rubber - RH

DOOR AND HARDWARE ASSEMBLY - 146” CT BASE 

28 

25 

10 

11 

19 

25 

10 

1 

11 

40 

3 

24 

15 

12 

16 

4 

36 

18 

7 

8 

28 

2 

18 

32 

33 

4 6 5 

13 

14 

24 

29 

35 

27 

23 

7 

15 

17 

28 31 

33 

21 

26 

22 9 

25 

10 

33 

26 

33 

30 

41 

42 

42 

11 

3 

37 

24 

20 

32 

9 

25 

10 

11 

9 

12 

13 

23 

24 

3 

24 

41 

34 

14 

20 

9 

28 

38 

34 

37 

18 

17 

31 

33 

15 

36 

22 26 21 

20 

32 

39 

43 

24 

44 

LH Body Shown 



FENDER FLARE ASSEMBLY - 112” CA BASE 


1 7415000008 Wheelwell Flare - LH 1 

7415000007 Wheelwell Flare - RH 

2 7111141050 Capscrew, 0.25”-20NC x 1.25” 5 

3 7950140151 Flatwasher, 0.25” ID 24 

4 7660142604 Locknut, 0.25”-20NC 12 

5 7415000032 Fender, Inner 6FT 


7 7280000020 Wire Clip 4 

8 7115142050 Capscrew, 0.25”-20NC x 2.50” 5 

9 4415000047 Flare, Body 1 

10 7415000014 Flare, Body Cap - LH 1 

7415000013 Flare, Body Cap - RH 

11 4831000068 Spacer 1 

12 7114141850 Capscrew, 0.25”-20NC x 2.25” 2


5 

10 

4 

3 

9 

3 

12 

3 

8 

6 7 

4 

3 

11 

3 2 

1 

4 

3 

LH Body Shown 



FENDER FLARE ASSEMBLY - 86” CT BASE 


1 4415000019 Wheelwell Flare, Rear - LH 1 

52” Tandem Axle Spread 

4415000017 Wheelwell Flare, Rear - RH 


4415000030 Wheelwell Flare, Rear - LH 




2 4415000018 Wheelwell Flare, Front - LH 1 


4415000016 Wheelwell Flare, Front - RH 


4415000029 Wheelwell Flare, Front - LH 




3 7415000010 Junction, Flare - 52” Tandem Axle Spread 1 

7415000011 Junction, Flare - 58” Tandem Axle Spread 1 



6 7111141050 Capscrew, 0.25”-20NC x 1.25” 10 

7 7114141850 Capscrew, 0.25”-20NC x 2.25” 3 

8 7950140151 Flatwasher, 0.25” ID 26 

9 7660142604 Locknut, 0.25”-20NC 13 

10 7494000022 Washer, Fender 1 

11 4679000148 Pad 1 


13 7280000020 Wire Clip 8 

14 4415000020 Flare, Body - 52” Tandem Axle Spread 1 

4415000031 Flare, Body - 58” Tandem Axle Spread 


7415000013 Flare, Body Cap - RH


4 

12 

4 

13 

15 

14 

9 

8 

2 

8 

7 

10 

5 

12 

13 

3 

11 

9 

8 

8 

6 

1 

LH Body Shown 





1 7415000008 Wheelwell Flare - LH 1 

7415000007 Wheelwell Flare - RH 

2 7111141050 Capscrew, 0.25”-20NC x 1.25” 5 

3 7950140151 Flatwasher, 0.25” ID 28 

4 7660142604 Locknut, 0.25”-20NC 14 



7 7280000020 Wire Clip 4 

8 7115142050 Capscrew, 0.25”-20NC x 2.50” 5 

9 4415000021 Flare, Body 1 



11 4831000068 Spacer 1 

12 7114141850 Capscrew, 0.25”-20NC x 2.25” 4


10 

5 

4 

3 

3 

9 

12 

11 

3 

8 

6 7 

4 

3 

3 

2 

4 

3 

1 






















7415000011 Junction, Flare - 58” Tandem Axle Spread 



6 7111141050 Capscrew, 0.25”-20NC x 1.25” 10 

7 7114141850 Capscrew, 0.25”-20NC x 2.25” 5 

8 7950140151 Flatwasher, 0.25” ID 30 

9 7660142604 Locknut, 0.25”-20NC 15 

10 7494000022 Washer, Fender 1 

11 4679000148 Pad 1 


13 7280000020 Wire Clip 8 




7415000013 Flare, Body Cap - RH


4 

15 

14 

12 

13 

4 

8 

7 

12 

13 

9 

8 

2 

10 

5 

3 

11 

9 

1 

8 

8 

6 

LH Body Shown 

























6 7111141050 Capscrew, 0.25”-20NC x 1.25” 10 

7 7950140151 Flatwasher, 0.25” ID 38 

8 7660142604 Locknut, 0.25”-20NC 19 

9 7494000022 Washer, Fender 1 

10 4679000148 Pad 1 


12 7280000020 Wire Clip 8 





15 7114141850 Capscrew, 0.25”-20NC x 2.25” 9 

16 4831000070 Spacer 1


4 

14 

11 

12 

4 

13 

16 

7 

15 

2 

7 

6 

9 

5 

11 

12 

8 

7 

7 

8 

7 

6 

3 

10 

8 

7 

1 

LH Body Shown 



FENDER FLARE ASSEMBLY - 146” CT TRI-AXLE BASE 



52” Tri-Axle Spread 















3 7415000010 Junction, Flare - 52” Tri-Axle Spread 2 

7415000011 Junction, Flare - 58” Tri-Axle Spread 



6 7111141050 Capscrew, 0.25”-20NC x 1.25” 16 

7 7950140151 Flatwasher, 0.25” ID 36 

8 7660142604 Locknut, 0.25”-20NC 18 


10 4679000148 Pad 2 

11 4415000043 Wheelwell Flare, Intermediate 1 


4415000044 Wheelwell Flare, Intermediate 



13 7280000020 Wire Clip 12 






16 7114141850 Capscrew, 0.25”-20NC x 2.25” 2


4 

12 

13 

4 

15 

14 

7 

16 

7 

6 

6 

12 

13 

4 

8 

7 

8 

7 

2 

8 

7 

3 

7 

10 

8 

11 

7 

3 

9 

5 

10 

7 

6 

1 

9 

5 

7 

6 

12 

13 

8 

7 

LH Body Shown 

























6 7111141050 Capscrew, 0.25”-20NC x 1.25” 10 

7 7950140151 Flatwasher, 0.25” ID 40 

8 7660142604 Locknut, 0.25”-20NC 26 


10 4679000148 Pad 1 


12 7280000020 Wire Clip 8 





15 7114141850 Capscrew, 0.25”-20NC x 2.25” 10 

16 4831000070 Spacer 1


14 

4 

11 

12 

4 

13 

8 

7 

16 

7 15 

7 

8 

2 

7 

6 

9 

5 

7 6 

11 12 

3 

10 

1 

8 

7 

LH Body Shown 





















3 7415000010 Junction, Flare - 52” Tri-Axle Spread 2 

7415000011 Junction, Flare - 58” Tri-Axle Spread 



6 7111141050 Capscrew, 0.25”-20NC x 1.25” 16 

7 7950140151 Flatwasher, 0.25” ID 38 

8 7660142604 Locknut, 0.25”-20NC 19 


10 4679000148 Pad 2 

11 4415000043 Wheelwell Flare, Intermediate 1 


4415000044 Wheelwell Flare, Intermediate 



13 7280000020 Wire Clip 12 






16 7114141850 Capscrew, 0.25”-20NC x 2.25” 3


4 

15 

12 

13 

4 

8 

7 

14 

2 

7 

16 

8 

7 

3 

10 

6 

7 

11 

7 

8 

3 

9 

5 

10 

7 

6 

9 

5 

12 13 

6 

7 

12 

13 

4 

8 

7 

1 



MUDFLAP INSTALLATION 


1 4178000242 Bracket 2 

2 4017000719 Angle 2 

3 4706001815 Plate 2 

4 7638000012 Mudflap 2 

5 7118151250 Capscrew, 0.31”-18NC x 1.50” 12 

6 7950150151 Flatwasher, 0.31” ID 40 

7 7660152604 Locknut, 0.31”-18NC 20 

8 7114150850 Capscrew, 0.31”-18NC x 1.00” 8

MUDFLAP INSTALLATION 

1 

7 

6 

6 8 

7 

6 

2 

3 

4 

6 

5 



TOOL HOLDER BRACKET INSTALLATION 


1 3178000222 Bracket Weldment - Base 1 

2 3178000221 Bracket Weldment - Intermediate 2 

3 3178000220 Bracket Weldment - Top 1 

4 7115160850 Capscrew, 0.38”-16NC x 1.00” 16 

5 7660160001 Nut, 0.38”-16NC 19 

6 7114161050 Capscrew, 0.38”-16NC x 1.25” 3 

7 4812000047 Shim 1

TOOL HOLDER BRACKET INSTALLATION 

7 

3 

5 

6 

4 

2 

4 

2 

4 

1 

4 5 



SHELF ASSEMBLY 


1 4811000142 Sheet 2 

2 4017000714 Angle 2 

3 4017000727 Angle 2 

4 7661000003 Rivnut, 0.38”-16NC 3 

5 7115160850 Capscrew, 0.38”-16NC x 1.00” 24 

6 7660160001 Nut, 0.38”-16NC 21 

7 7950160163 Flatwasher, 0.38” ID 21

SHELF ASSEMBLY 

5 

5 

7 

5 

7 

5 

7 

1 

7 

3 

6 

2 

6 6 

5 

6 

5 

7 

7 

1 

5 

7 

6 

2 

6 

3 

6 

4 

5 



24” TUNNEL TOOL COMPARTMENT INSTALLATION 


1 3911000067 Mount, Tube Weldment 1 

2 3274000011 Clamp Weldment 4 

3 7636000008 Rubber Mount 4 



6 7115202850 Capscrew, 0.63”-11NC x 3.50” 4 

7 7590200161 Flatwasher, 0.63” ID 4 

8 7660200001 Nut, 0.63”-11NC 4 

9 7115182050 Capscrew, 0.50”-13NC x 2.50” 4 

10 7660182301 Locknut, 0.50”-13NC 4 

11 7950180252 Flatwasher, 0.50” ID 4 

12 8632000011 Seal, Rubber “D” 12FT 

13 4705000705 Plate 4


12 

6 

7 

4 

9 

11 

3 

1 

5 

8 

13 

Toolbox Doors not Shown For Clarity 

10 

2 



24” TUNNEL TOOL COMPARTMENT PANEL ASSEMBLY 


1 3503740030 Bonding Assembly 1 

2 7686000008 Cap Panel 2 


4 4679000120 Pad, Rubber - 0.12” Thk 8 

5 7790141651 Screw, Self Tapping - 0.25” Dia x 1.00” 14


4 

2 

2 

5 

4 

3 

5 

1 

3 

5 



24” TUNNEL TOOL COMPARTMENT DOOR AND HARDWARE ASSEMBLY 


1 4686000072 Door Panel - LH 1 

2 4686000073 Door Panel - RH 1 

3 4811000135 Sheet 2 

4 7555000002 Hinge 4 

5 4812000052 Shim 4 


7 7114100418 Capscrew, #10-24NC x 0.50” 6 


9 4178000222 Bracket 2 

10 7796000038 Gasket 2 

11 7660152604 Locknut, 0.31”-18NC 7 



14 7865000001 Ball Stud 2 

15 4178000240 Bracket 2 

16 7114140850 Capscrew, 0.25”-20NC x 1.00” 4 


18 7114140818 Capscrew, 0.25”-20NC x 1.00” 8 

19 7660142604 Locknut, 0.25”-20NC 8 

20 7950140163 Flatwasher, 0.25 ID 20 

21 4679000115 Pad, Rubber 2 

22 4679000116 Pad, Rubber 1 

23 7114100818 Capscrew, #10-24NC x 1.00 8 

24 7660102604 Locknut, #10-24NC 8 

25 7114140418 Capscrew, 0.25”-20NC x 0.50” 12 

26 7950140503 Lockwasher, 0.25” ID 12 

27 7660162604 Locknut, 0.38”-16NC 2 

28 7950160163 Flatwasher, 0.38” ID 2 

29 7114150650 Capscrew, 0.31”-18NC x 0.75” 4 

30 7413000002 Nutsert, 0.25”-20 NC 4 


31 4178000229 Bracket 4 

32 7115181050 Capscrew, 0.50”-13NC x 1.25” 16 

33 7950180153 Flatwasher, 0.50” ID 16 

34 7660182301 Locknut, 0.50”-13NC 16 

35 4062000173 Bar 4 

36 4811000947 Sheet 4


2 

34 

31 

13 

11 

15 

11 

7 

29 

23 

1 

4 

14 

12 

36 

6 

10 

26 

25 

33 

32 

24 

17 

20 

35 

5 

4 

20 

18 

16 

20 

8 

28 

9 

27 30 

19 

3 

22 

21 



24” TUNNEL TOOL COMPARTMENT FENDER FLARE ASSEMBLY 


1 4415000045 Flare, Body 2 


3 7415000013 Flare, Body Cap - RH 2 

4 7114141850 Capscrew, 0.25”-20NC x 2.25” 6 

5 7950140151 Flatwasher, 0.25” ID 12 

6 7660142604 Locknut, 0.25”-20NC 6


3 

5 

4 

5 

6 

1 

2 



24” 3/4 HEIGHT TUNNEL TOOL COMPARTMENT INSTALLATION 




3 7636000008 Rubber Mount 4 



6 7115202850 Capscrew, 0.63”-11NC x 3.50” 4 

7 7950200161 Flatwasher, 0.63” ID 4 

8 7660200001 Nut, 0.63”-11NC 4 

9 7115182050 Capscrew, 0.50”-13NC x 2.50” 4 

10 7660182301 Locknut, 0.50”-13NC 4 

11 7950180252 Flatwasher, 0.50” ID 4 


13 4705000705 Plate 4

24” 3/4 HEIGHT TUNNEL TOOL COMPARTMENT INSTALLATION 

12 

7 

6 

4 

3 

9 

11 

1 

5 

8 

13 


10 

2 



24” 3/4 HEIGHT TUNNEL TOOL COMPARTMENT PANEL ASSEMBLY 



2 7686000008 Cap Panel 2 


4 4679000120 Pad, Rubber - 0.12” Thk 8 


24” 3/4 HEIGHT TUNNEL TOOL COMPARTMENT PANEL ASSEMBLY 

4 

2 

2 

5 

4 

3 

5 

1 

5 

3 



24” 3/4 HEIGHT TUNNEL TOOL COMPARTMENT DOOR AND HARDWARE ASSEMBLY 


1 4686000085 Door Panel - LH 1 

2 4686000086 Door Panel - RH 1 

3 4811000135 Sheet 2 

4 7555000002 Hinge 4 

5 4812000052 Shim 4 


7 7114100418 Capscrew, #10-24NC x 0.50” 6 


9 4178000222 Bracket 2 

10 7796000038 Gasket 2 

11 7660152604 Locknut, 0.31”-18NC 6 



14 7865000001 Ball Stud 2 

15 4178000250 Bracket 2 

16 7114140850 Capscrew, 0.25”-20NC x 1.00” 4 


18 7114140818 Capscrew, 0.25”-20NC x 1.00” 8 

19 7660142604 Locknut, 0.25”-20NC 8 

20 7950140163 Flatwasher, 0.25 ID 20 

21 4679000116 Pad, Rubber 1 

22 7114100818 Capscrew, #10-24NC x 1.00 8 

23 7660102604 Locknut, #10-24NC 8 

24 7114140418 Capscrew, 0.25”-20NC x 0.50” 12 

25 7950140503 Lockwasher, 0.25” ID 12 

26 7660162604 Locknut, 0.38”-16NC 2 

27 7114150650 Capscrew, 0.31”-18NC x 0.75” 4 

28 4178000229 Bracket 4 

29 7115181050 Capscrew, 0.50”-13NC x 1.25” 16 

30 7950180153 Flatwasher, 0.50” ID 16 


31 7660182301 Locknut, 0.50”-13NC 16 

32 7413000002 Nutsert, 0.25”-20NC 4 

33 7950160163 Flatwasher, 0.38” ID 2 

34 4679000115 Pad, Rubber 2 

35 4811000947 Sheet 4

24” 3/4 HEIGHT TUNNEL TOOL COMPARTMENT DOOR AND HARDWARE ASSEMBLY 

2 

31 

28 

11 

6 

10 

22 

1 

13 

4 

25 

7 

11 

15 

27 

14 

12 

24 

20 

19 

30 

29 

35 

23 

17 

18 

20 

8 

4 

5 

16 

33 

9 

26 

20 

32 

5 

3 

21 

34 



24” COUNTERWEIGHTED TUNNEL TOOL COMPARTMENT INSTALLATION 


1 3502740204 Counterweight Weldment - 2,000 lbs. 1 

3502740205 Counterweight Weldment - 3,000 lbs. 

2 4017001476 Angle 2 

3 7636000008 Rubber Mount 4 

4 7115203250 Capscrew, 0.63”-11NC x 4.00” 4 

5 7660200001 Nut, 0.63”-11NC 4 

6 7950200161 Flatwasher, 0.63” ID 4 



9 7118221816 Capscrew, 0.75”-10NC x 2.25” 4 

10 7660222308 Locknut, 0.75”-10NC 4 

11 3899000134 Toolbox Assembly 1


11 

6 

4 

8 

3 

7 

5 

1 

9 


10 

2 



24” COUNTERWEIGHTED TUNNEL TOOL COMPARTMENT PANEL ASSEMBLY 



2 7686000008 Cap Panel 2 


4 4679000120 Pad, Rubber - 0.12” Thk 8 



4 

2 

2 

5 

4 

3 

5 

1 

5 

3 



24” COUNTERWEIGHTED TUNNEL TOOL COMPARTMENT DOOR AND HARDWARE ASSEMBLY 


1 4686000072 Door Panel - LH 1 

2 4686000073 Door Panel - RH 1 

3 4811000135 Sheet 2 

4 7555000002 Hinge 4 

5 4812000052 Shim 4 


7 7114100418 Capscrew, #10-24NC x 0.50” 6 


9 4178000222 Bracket 2 

10 7796000038 Gasket 2 

11 7660152604 Locknut, 0.31”-18NC 7 



14 7865000001 Ball Stud 2 

15 4178000240 Bracket 2 

16 7114140850 Capscrew, 0.25”-20NC x 1.00” 4 


18 7114140818 Capscrew, 0.25”-20NC x 1.00” 8 

19 7660142604 Locknut, 0.25”-20NC 8 

20 7950140163 Flatwasher, 0.25 ID 20 

21 4679000115 Pad, Rubber 2 

22 4679000116 Pad, Rubber 1 

23 7114100818 Capscrew, #10-24NC x 1.00 8 

24 7660102604 Locknut, #10-24NC 8 

25 7114140418 Capscrew, 0.25”-20NC x 0.50” 12 

26 7950140503 Lockwasher, 0.25” ID 12 

27 7660162604 Locknut, 0.38”-16NC 2 

28 7950160163 Flatwasher, 0.38” ID 2 

29 7114150650 Capscrew, 0.31”-18NC x 0.75” 4 

30 7413000002 Nutsert, 0.25”-20 NC 4 


31 4178000229 Bracket 4 

32 7115181050 Capscrew, 0.50”-13NC x 1.25” 16 

33 7950180153 Flatwasher, 0.50” ID 16 

34 7660182301 Locknut, 0.50”-13NC 16 

35 4062000173 Bar 4 

36 4811000947 Sheet 4

24” COUNTERWEIGHTED TUNNEL TOOL COMPARTMENT DOOR AND HARDWARE ASSEMBLY 

2 

34 

31 

13 

11 

15 

11 

7 

29 

23 

1 

4 

14 

12 

36 

6 

10 

26 

25 

33 

32 

24 

17 

20 

35 

5 

4 

20 

18 

16 

20 

8 

28 

9 

27 30 

19 

3 

22 

21 







3 7636000008 Rubber Mount 6 



6 7115202850 Capscrew, 0.63”-11NC x 3.50” 6 

7 7590200161 Flatwasher, 0.63” ID 6 

8 7660200001 Nut, 0.63”-11NC 6 

9 7115182050 Capscrew, 0.50”-13NC x 2.50” 8 

10 7660182301 Locknut, 0.50”-13NC 8 

11 7950180252 Flatwasher, 0.50” ID 8 


13 4705000705 Plate 8


6 

7 

12 

4 

3 

9 

11 

1 

5 

8 


13 

10 

2 






3502740175 Bonding Assembly 

( For Forward Mounted Headboards) 

2 7686000050 Cap Panel 2 


4 4679000120 Pad, Rubber - 0.12” Thk 12 



2 

2 

4 

4 

3 

3 

5 

5 

1 

3 

3 





1 3502740200 Counterweight Weldment - 3,000 lbs. 1 




2 4017001476 Angle 4 

3 7636000008 Rubber Mount 6 

4 7115203250 Capscrew, 0.63”-11NC x 4.00” 6 

5 7660200001 Nut, 0.63”-11NC 6 

6 7950200161 Flatwasher, 0.63” ID 6 



9 7118221816 Capscrew, 0.75”-10NC x 2.25” 8 

10 7660222308 Locknut, 0.75”-10NC 8 

11 3503740041 Toolbox Assembly 1


6 

4 

8 

11 

3 

1 

7 

5 

2 


10 

9 






3503740046 Bonding Assembly 

( For Forward Mounted Headboards) 

2 7686000050 Cap Panel 2 


4 4679000120 Pad, Rubber - 0.12” Thk 12 



2 

2 

4 

3 

4 

3 

5 

1 

5 

3 

3 





1 4686000133 Door Panel 1 


3 4811000355 Sheet 2 

4 7555000002 Hinge 8 

5 4812000052 Shim 16 

6 7595000011 Latch, “T” Handle 4 

7 7114100418 Capscrew, #10-24NC x 0.50” 28 

8 7585000016 Latch Roller 8 

9 4178000337 Bracket 8 

10 7796000031 Gasket 4 

11 7660152604 Locknut, 0.31”-18NC 12 



14 7865000001 Ball Stud 4 

15 4178000240 Bracket 4 

16 4811000335 Sheet 4 


18 7114140818 Capscrew, 0.25”-20NC x 1.00” 28 

19 7660142604 Locknut, 0.25”-20NC 16 

20 7950140163 Flatwasher, 0.25 ID 56 

21 4679000181 Pad, Rubber 2 

22 4679000188 Pad, Rubber 2 

23 7114100818 Capscrew, #10-24NC x 1.00 16 

24 7660102604 Locknut, #10-24NC 16 

25 7114140418 Capscrew, 0.25”-20NC x 0.50” 24 

26 7950140503 Lockwasher, 0.25” ID 24 

27 7831000040 Spacer 8 

28 4686000134 Door Panel 1 

29 7114150650 Capscrew, 0.31”-18NC x 0.75” 8 

30 4062000368 Bar 4 

31 4811000336 Sheet 8 

32 4811000337 Sheet 8 

33 7660140001 Nut, 0.25”-20NC 12 

34 4178000229 Bracket 4 


35 7115181050 Capscrew, 0.50”-13NC x 1.25” 16 

36 7950180153 Flatwasher, 0.50” ID 16 

37 7660182301 Locknut, 0.50”-13NC 16 

38 7690000810 Pin, Cotter 8 

39 7189000015 Bumper 8 

40 7114100318 Capscrew, #10-24NC x 0.38” 8 

41 4686000185 Door Panel 1 

42 4686000186 Door Panel 1 

43 4811000947 Sheet 4


13 

7 

11 

15 

11 

28 

37 

34 

38 

23 

42 

29 

14 

6 

27 

38 

10 

26 

4 

12 

25 

43 

32 

32 

9 

8 

31 

31 

7 

8 

9 

2 

24 

18 

5 

4 

20 

16 

30 

5 

20 

19 

20 

33 

18 

1 

36 

35 

21 

3 

22 

22 

17 

40 

41 

39 





1 4415000046 Flare, Body 2 



4 7114141850 Capscrew, 0.25”-20NC x 2.25” 8 

5 7950140151 Flatwasher, 0.25” ID 16 

6 7660142604 Locknut, 0.25”-20NC 8


3 

5 

4 

1 

6 

5 

2 



24” STAND-A-LONE TUNNEL TOOL COMPARTMENT INSTALLATION 


1 3868000157 Subframe Weldment 1 


3 7636000007 Rubber Mount 4 



6 7590220161 Flatwasher, 0.75” ID 4 

7 7115223250 Capscrew, 0.75”-10NC x 4.00” 4 

8 7660220001 Nut, 0.75”-10NC 4 

9 7115182050 Capscrew, 0.50”-13NC x 2.50” 4 

10 7660182301 Locknut, 0.50”-13NC 4 

11 7950180252 Flatwasher, 0.50” ID 4


9 

11 

6 

7 

4 

1 

3 

5 

8 

10 

2 




24” STAND-A-LONE TOOL COMPARTMENT PANEL ASSEMBLY - LH 


1 3502740071 Bonding Assembly - LH 1 

2 7686000008 Cap Panel 1 


4 4679000120 Pad, Rubber - 0.12” Thk 4 


6 4811000408 Sheet 1 

7 4811000091 Sheet 1 



2 

4 

5 

1 

7 

8 

8 

6 

5 

3 



24” STAND-A-LONE TOOL COMPARTMENT PANEL ASSEMBLY - RH 



2 7686000008 Cap Panel 1 


4 4679000120 Pad, Rubber - 0.12” Thk 4 


6 4811000408 Sheet 1 

7 4811000091 Sheet 1 



2 

4 

5 

1 

7 

8 

6 

8 

3 



24” STAND-A-LONE TOOL COMPARTMENT DOOR AND HARDWARE ASSEMBLY - LH 


1 4686000072 Door Panel - LH 1 

2 7114150650 Capscrew, 0.31”-18NC x 0.75” 2 

3 4811000135 Sheet 1 

4 7555000002 Hinge 2 

5 4812000052 Shim 2 


7 7114100418 Capscrew, #10-24NC x 0.50” 3 


9 4178000222 Bracket 1 

10 7796000038 Gasket 1 

11 7660152604 Locknut, 0.31”-18NC 3 



14 7865000001 Ball Stud 1 

15 4178000240 Bracket 1 

16 7114140850 Capscrew, 0.25”-20NC x 1.00” 2 


18 7114140818 Capscrew, 0.25”-20NC x 1.00” 4 

19 7660142604 Locknut, 0.25”-20NC 4 

20 7950140163 Flatwasher, 0.25 ID 10 

21 4679000115 Pad, Rubber 1 

22 4062000173 Bar 2 

23 7114100818 Capscrew, #10-24NC x 1.00 4 

24 7660102604 Locknut, #10-24NC 4 

25 7114140418 Capscrew, 0.25”-20NC x 0.50” 6 

26 7413000002 Nutsert, 0.25”-20 NC 2 

27 7660162604 Locknut, 0.38”-16NC 1 


29 7950160163 Flatwasher, 0.38” ID 1


11 

15 

11 

13 

2 

7 

14 

23 

1 

4 

28 

12 

6 

10 

25 

24 

18 

20 

4 

5 

16 

19 

20 

22 

20 

3 

17 

8 

29 

9 

27 

26 

21 



24” STAND-A-LONE TOOL COMPARTMENT DOOR AND HARDWARE ASSEMBLY - RH 


1 4686000073 Door Panel - RH 1 

2 7114150650 Capscrew, 0.31”-18NC x 0.75” 2 

3 4811000135 Sheet 1 

4 7555000002 Hinge 2 

5 4812000052 Shim 2 


7 7114100418 Capscrew, #10-24NC x 0.50” 3 


9 4178000222 Bracket 1 

10 7796000038 Gasket 1 

11 7660152604 Locknut, 0.31”-18NC 3 



14 7865000001 Ball Stud 1 

15 4178000240 Bracket 1 

16 7114140850 Capscrew, 0.25”-20NC x 1.00” 2 


18 7114140818 Capscrew, 0.25”-20NC x 1.00” 4 

19 7660142604 Locknut, 0.25”-20NC 4 

20 7950140163 Flatwasher, 0.25 ID 10 

21 4679000115 Pad, Rubber 1 

22 4062000173 Bar 2 

23 7114100818 Capscrew, #10-24NC x 1.00 4 

24 7660102604 Locknut, #10-24NC 4 

25 7114140418 Capscrew, 0.25”-20NC x 0.50” 6 

26 7413000002 Nutsert, 0.25”-20 NC 2 

27 7660162604 Locknut, 0.38”-16NC 1 


29 7950160163 Flatwasher, 0.38” ID 1


11 

11 

14 

2 

15 

12 

7 

13 

4 

3 

19 

20 

22 

5 

25 

28 

4 

20 

18 

1 

10 

6 

23 

16 

20 

17 

26 

27 

9 

29 

8 

24 

21 



24” STAND-A-LONE TOOL COMPARTMENT FENDER FLARE ASSEMBLY 


1 4415000045 Flare, Body 2 



4 7114141850 Capscrew, 0.25”-20NC x 2.25” 6 

5 7950140151 Flatwasher, 0.25” ID 12 

6 7660142604 Locknut, 0.25”-20NC 6


3 

1 

5 

4 

6 

5 

2 



24” STAND-A-LONE TOOL COMPARTMENT SPACER MOUNTNG ASSEMBLY - LH 


1 4679000136 Spacer Pad 2 


3 7115162250 Capscrew, 0.38”-16NC x 2.75” 6 

4 7950160163 Flatwasher, 0.38” ID 12 

5 7660160001 Nut, 0.38”-16NC 6 

6 4062000243 Bar 4


1 

6 

4 

3 

5 

4 

6 

2 



24” STAND-A-LONE TOOL COMPARTMENT SPACER MOUNTNG ASSEMBLY - RH 


1 4679000136 Spacer Pad 2 


3 7115162250 Capscrew, 0.38”-16NC x 2.75” 6 

4 7950160163 Flatwasher, 0.38” ID 12 

5 7660160001 Nut, 0.38”-16NC 6


3 

4 

1 

5 

2 

4 



24” STAND-A-LONE TOOL COMPARTMENT HANGER BRACKET ASSEMBLY - LH 


1 4178000270 Bracket 2 

2 7115181050 Capscrew, 0.50”-13NC x 1.25” 8 

3 7950180153 Flatwasher, 0.50” ID 8 

4 7660182301 Locknut, 0.50”-13NC 8

24” STAND-A-LONE TOOL COMPARTMENT HANGER BRACKET ASSEMBLY - LH 

3 

2 

1 

3 

2 

4 

1 

4 



24” STAND-A-LONE TOOL COMPARTMENT SHELF INSTALLATION - RH 


1 4811000217 Sheet 2 

2 4017000714 Angle 2 

3 4017000727 Angle 2 

4 7115160850 Capscrew, 0.38”-16NC x 1.00” 18 

5 7660160001 Nut, 0.38”-16NC 18 

4 7950160163 Flatwasher, 0.38” ID 18

24” STAND-A-LONE TOOL COMPARTMENT SHELF INSTALLATION - RH 

1 

6 

4 

2 

3 

4 

6 

1 

3 

2 

5 



24” 3/4 HEIGHT STAND-A-LONE TUNNEL TOOL COMPARTMENT INSTALLATION 




3 7636000007 Rubber Mount 4 



6 7590220161 Flatwasher, 0.75” ID 4 

7 7115223250 Capscrew, 0.75”-10NC x 4.00” 4 

8 7660220001 Nut, 0.75”-10NC 4 

9 7115182050 Capscrew, 0.50”-13NC x 2.50” 4 

10 7660182301 Locknut, 0.50”-13NC 4 

11 7950180252 Flatwasher, 0.50” ID 4

24” 3/4 HEIGHT STAND-A-LONE TUNNEL TOOL COMPARTMENT INSTALLATION 

9 

11 

1 

7 

6 

4 

3 

5 

8 

2 

10 




24” 3/4 STAND-A-LONE TOOL COMPARTMENT PANEL ASSEMBLY - LH 



2 7686000008 Cap Panel 1 


4 4679000121 Pad, Rubber - 0.25” Thk 4 


6 4811000091 Sheet 1 

7 4811000408 Sheet 1 


24” 3/4 STAND-A-LONE TOOL COMPARTMENT PANEL ASSEMBLY - LH 

2 

4 

5 

1 

6 

7 

8 

5 

8 

3 



24” 3/4 STAND-A-LONE TOOL COMPARTMENT PANEL ASSEMBLY - RH 


1 3502740103 Bonding Assembly - rH 1 

2 7686000008 Cap Panel 1 


4 4679000121 Pad, Rubber - 0.25” Thk 4 


6 4811000091 Sheet 1 

7 4811000408 Sheet 1 


24” 3/4 STAND-A-LONE TOOL COMPARTMENT PANEL ASSEMBLY - RH 

2 

4 

5 

1 

6 

8 

5 

8 

3 



24” 3/4 STAND-A-LONE TOOL COMPARTMENT DOOR AND HARDWARE ASSEMBLY - LH 


1 4686000085 Door Panel - LH 1 

2 7114150650 Capscrew, 0.31”-18NC x 0.75” 2 

3 4811000341 Sheet 1 

4 7555000002 Hinge 2 

5 4812000052 Shim 2 


7 7114100418 Capscrew, #10-24NC x 0.50” 3 


9 4178000222 Bracket 1 

10 7796000038 Gasket 1 

11 7660152604 Locknut, 0.31”-18NC 3 



14 7865000001 Ball Stud 1 

15 4178000240 Bracket 1 

16 7114140850 Capscrew, 0.25”-20NC x 1.00” 2 


18 7114140818 Capscrew, 0.25”-20NC x 1.00” 4 

19 7660142604 Locknut, 0.25”-20NC 4 

20 7950140163 Flatwasher, 0.25 ID 10 

21 4679000115 Pad, Rubber 1 

22 4062000173 Bar 2 

23 7114100818 Capscrew, #10-24NC x 1.00 4 

24 7660102604 Locknut, #10-24NC 4 

25 7114140418 Capscrew, 0.25”-20NC x 0.50” 6 

26 7413000002 Nutsert, 0.25”-20 NC 2 

27 7660162604 Locknut, 0.38”-16NC 1 


29 7346000067 Hole Plug 2

24” 3/4 STAND-A-LONE TOOL COMPARTMENT DOOR AND HARDWARE ASSEMBLY - LH 

11 

11 

6 

23 

1 

13 

15 

7 2 

14 

4 

12 

25 

10 

28 

19 

20 

22 

24 

4 

5 

17 

29 

18 

20 

16 

20 

8 

9 

27 

26 

3 

21 



24” 3/4 STAND-A-LONE TOOL COMPARTMENT DOOR AND HARDWARE ASSEMBLY - RH 


1 4686000086 Door Panel - RH 1 

2 7114150650 Capscrew, 0.31”-18NC x 0.75” 2 

3 4811000341 Sheet 1 

4 7555000002 Hinge 2 

5 4812000052 Shim 2 


7 7114100418 Capscrew, #10-24NC x 0.50” 3 


9 4178000222 Bracket 1 

10 7796000038 Gasket 1 

11 7660152604 Locknut, 0.31”-18NC 3 



14 7865000001 Ball Stud 1 

15 4178000240 Bracket 1 

16 7114140850 Capscrew, 0.25”-20NC x 1.00” 2 


18 7114140818 Capscrew, 0.25”-20NC x 1.00” 4 

19 7660142604 Locknut, 0.25”-20NC 4 

20 7950140163 Flatwasher, 0.25 ID 10 

21 4679000115 Pad, Rubber 1 

22 4062000173 Bar 2 

23 7114100818 Capscrew, #10-24NC x 1.00 4 

24 7660102604 Locknut, #10-24NC 4 

25 7114140418 Capscrew, 0.25”-20NC x 0.50” 6 

26 7413000002 Nutsert, 0.25”-20 NC 2 

27 7660162604 Locknut, 0.38”-16NC 1 


29 7346000067 Plug, Hole 1.38” Dia 2

24” 3/4 STAND-A-LONE TOOL COMPARTMENT DOOR AND HARDWARE ASSEMBLY - RH 

11 

11 

15 

13 

2 

7 

14 

1 

12 

19 

28 

4 

23 

6 

20 

22 

25 

10 

5 

4 

20 

24 

3 

18 

26 

27 

20 

9 

16 

8 

29 

17 

21 



24” 3/4 STAND-A-LONE TOOL COMPARTMENT SPACER MOUNTNG ASSEMBLY - LH 


1 4679000186 Spacer Pad 1 


3 7115162250 Capscrew, 0.38”-16NC x 2.75” 7 

4 7950160163 Flatwasher, 0.38” ID 14 

5 7660160001 Nut, 0.38”-16NC 7 

6 4062000374 Bar 2 

7 4679000187 Spacer Pad 1 

8 4062000375 Bar 1

24” 3/4 STAND-A-LONE TOOL COMPARTMENT SPACER MOUNTNG ASSEMBLY - LH 

5 

1 

6 

4 

3 

4 

6 

5 

2 

4 

3 

4 

8 

7 



24” 3/4 STAND-A-LONE TOOL COMPARTMENT SPACER MOUNTNG ASSEMBLY - RH 


1 4679000186 Spacer Pad 1 


3 7115162250 Capscrew, 0.38”-16NC x 2.75” 7 

4 7950160163 Flatwasher, 0.38” ID 14 

5 7660160001 Nut, 0.38”-16NC 7 

6 4062000374 Bar 2 

7 4679000187 Spacer Pad 1 

8 4062000375 Bar 1

24” 3/4 STAND-A-LONE TOOL COMPARTMENT SPACER MOUNTNG ASSEMBLY - RH 

3 

4 

6 

1 

6 

4 

5 

3 

4 

7 

2 

8 

4 

5 



24” 3/4 STAND-A-LONE TOOL COMPARTMENT HANGER BRACKET ASSEMBLY - LH 


1 4178000270 Bracket 2 

2 7115181050 Capscrew, 0.50”-13NC x 1.25” 8 

3 7950180153 Flatwasher, 0.50” ID 8 

4 7660182301 Locknut, 0.50”-13NC 8

24” 3/4 STAND-A-LONE TOOL COMPARTMENT HANGER BRACKET ASSEMBLY - LH 

2 

3 

1 

4 

3 

2 

4 

1 



24” 3/4 STAND-A-LONE TOOL COMPARTMENT HANGER BRACKET ASSEMBLY - RH 


1 4178000270 Bracket 2 

2 7115181050 Capscrew, 0.50”-13NC x 1.25” 8 

3 7950180153 Flatwasher, 0.50” ID 8 

4 7660182301 Locknut, 0.50”-13NC 8

24” 3/4 STAND-A-LONE TOOL COMPARTMENT HANGER BRACKET ASSEMBLY - RH 

3 

2 

1 

2 

3 

4 

1 

4 







3 7636000007 Rubber Mount 8 



6 7590220161 Flatwasher, 0.75” ID 8 

7 7115223250 Capscrew, 0.75”-10NC x 4.00” 8 

8 7660220001 Nut, 0.75”-10NC 8 

9 7115182050 Capscrew, 0.50”-13NC x 2.50” 8 

10 7660182301 Locknut, 0.50”-13NC 8 

11 7950180252 Flatwasher, 0.50” ID 8


9 

11 

4 

1 

7 

3 

6 

5 

8 

1 

2 

10 







2 7686000050 Cap Panel 1 


4 4679000120 Pad, Rubber - 0.12” Thk 6 



2 

4 

1 

5 

5 

3 





1 3502740116 Bonding Assembly - RH 1 

2 7686000050 Cap Panel 1 


4 4679000120 Pad, Rubber - 0.12” Thk 6 



2 

4 

1 

5 

5 

3 





1 4686000186 Door Panel 1 


3 4811000355 Sheet 1 

4 7555000002 Hinge 4 

5 4812000052 Shim 8 

6 7595000011 Latch, “T” Handle 2 

7 7114100418 Capscrew, #10-24NC x 0.50” 14 

8 7585000016 Latch Roller 4 

9 4178000337 Bracket 4 

10 7796000031 Gasket 2 

11 7660152604 Locknut, 0.31”-18NC 6 



14 7865000001 Ball Stud 2 

15 4178000240 Bracket 2 

16 4811000335 Sheet 2 


18 7114141018 Capscrew, 0.25”-20NC x 1.25” 14 

19 7660142604 Locknut, 0.25”-20NC 8 

20 7950140163 Flatwasher, 0.25 ID 22 

21 4679000181 Pad, Rubber 1 

22 4686000185 Door Panel 1 

23 7114100818 Capscrew, #10-24NC x 1.00 8 

24 7660102604 Locknut, #10-24NC 8 

25 7114140418 Capscrew, 0.25”-20NC x 0.50” 12 

26 7950140503 Lockwasher, 0.25” ID 12 

27 7831000040 Spacer 4 

28 7660182301 Locknut, 0.50”-13NC 8 

29 7114150650 Capscrew, 0.31”-18NC x 0.75” 4 

30 4062000368 Bar 2 

31 4811000336 Sheet 4 

32 4811000337 Sheet 4 

33 7660140001 Nut, 0.25”-20NC 6 

34 4178000341 Bracket 2 


35 7115181050 Capscrew, 0.50”-13NC x 1.25” 8 

36 7950180153 Flatwasher, 0.50” ID 8 

37 7690000810 Pin, Cotter 4 

38 7189000015 Bumper 4 

39 7114100318 Capscrew, #10-24NC x 0.38” 4


11 

28 

13 

7 

15 

29 

11 

34 

37 

23 

1 

4 

12 

14 

17 

37 

6 

27 

10 

31 

32 

9 

8 

31 

32 

9 

7 

7 

4 

26 

25 

5 5 

20 

18 

24 

16 

33 

21 

30 

2 

19 

20 

20 

18 

3 

22 

36 

35 

38 

39 





1 4686000133 Door Panel 1 


3 4811000355 Sheet 1 

4 7555000002 Hinge 4 

5 4812000052 Shim 8 

6 7595000011 Latch, “T” Handle 2 

7 7114100418 Capscrew, #10-24NC x 0.50” 14 

8 7585000016 Latch Roller 4 

9 4178000337 Bracket 4 

10 7796000031 Gasket 2 

11 7660152604 Locknut, 0.31”-18NC 6 



14 7865000001 Ball Stud 2 

15 4178000240 Bracket 2 

16 4811000335 Sheet 2 


18 7114141018 Capscrew, 0.25”-20NC x 1.25” 14 

19 7660142604 Locknut, 0.25”-20NC 8 

20 7950140163 Flatwasher, 0.25 ID 22 

21 4679000181 Pad, Rubber 1 

22 7686000134 Door Panel 1 

23 7114100818 Capscrew, #10-24NC x 1.00 8 

24 7660102604 Locknut, #10-24NC 8 

25 7114140418 Capscrew, 0.25”-20NC x 0.50” 12 

26 7950140503 Lockwasher, 0.25” ID 12 

27 7831000040 Spacer 4 

28 7660182301 Locknut, 0.50”-13NC 8 

29 7114150650 Capscrew, 0.31”-18NC x 0.75” 4 

30 4062000368 Bar 2 

31 4811000336 Sheet 4 

32 4811000337 Sheet 4 

33 7660140001 Nut, 0.25”-20NC 6 

34 4178000341 Bracket 2 


35 7115181050 Capscrew, 0.50”-13NC x 1.25” 8 

36 7950180153 Flatwasher, 0.50” ID 8 

37 7690000810 Pin, Cotter 4 

38 7189000015 Bumper 4 

39 7114100318 Capscrew, #10-24NC x 0.38” 4


28 

34 

11 

11 

15 

29 

7 

14 12 

13 

22 

23 

4 

37 

35 

36 

19 

20 

20 

5 

5 

33 

4 

25 

26 

20 

30 

18 

16 

24 

7 

31 

32 

9 

8 

10 

27 

6 

37 

1 

3 

39 

38 

18 

21 

2 

7 

8 

9 

31 

32 

17 





1 4415000046 Flare, Body 2 



4 7114141850 Capscrew, 0.25”-20NC x 2.25” 6 

5 7950140151 Flatwasher, 0.25” ID 12 

6 7660142604 Locknut, 0.25”-20NC 6


3 

1 

6 

5 

2 

5 

4 





1 4679000136 Spacer Pad 2 


3 7115162250 Capscrew, 0.38”-16NC x 2.75” 6 

4 7950160163 Flatwasher, 0.38” ID 12 

5 7660160001 Nut, 0.38”-16NC 6 

6 4062000243 Bar 2


2 

5 

4 

1 

6 

4 

3 

6 





1 4679000136 Spacer Pad 2 


3 7115162250 Capscrew, 0.38”-16NC x 2.75” 6 

4 7950160163 Flatwasher, 0.38” ID 12 

5 7660160001 Nut, 0.38”-16NC 6 

6 4062000243 Bar 2


2 

4 

6 

1 

4 

5 

3 

6 



49” 3/4 HEIGHT STAND-A-LONE TOOL COMPARTMENT INSTALLATION 




3 7636000007 Rubber Mount 8 



6 7590220161 Flatwasher, 0.75” ID 8 

7 7115223250 Capscrew, 0.75”-10NC x 4.00” 8 

8 7660220001 Nut, 0.75”-10NC 8 

9 7115182050 Capscrew, 0.50”-13NC x 2.50” 8 

10 7660182301 Locknut, 0.50”-13NC 8 

11 7950180252 Flatwasher, 0.50” ID 8

49” 3/4 HEIGHT STAND-A-LONE TOOL COMPARTMENT INSTALLATION 

9 

11 

1 

7 

4 

3 

6 

5 

8 

1 

2 

10 




49” 3/4 HEIGHT STAND-A-LONE TOOL COMPARTMENT PANEL ASSEMBLY - LH 



2 7686000050 Cap Panel 1 


4 4679000120 Pad, Rubber - 0.12” Thk 6 


49” 3/4 HEIGHT STAND-A-LONE TOOL COMPARTMENT PANEL ASSEMBLY - LH 

2 

4 

1 

5 

5 

3 

3 



49” 3/4 HEIGHT STAND-A-LONE TOOL COMPARTMENT PANEL ASSEMBLY - RH 



2 7686000050 Cap Panel 1 


4 4679000120 Pad, Rubber - 0.12” Thk 6 


49” 3/4 HEIGHT STAND-A-LONE TOOL COMPARTMENT PANEL ASSEMBLY - RH 

2 

4 

1 

5 

5 

3 

3 



49” 3/4 HEIGHT STAND-A-LONE TOOL COMPARTMENT DOOR AND HARDWARE ASSEMBLY - LH 


1 4686000187 Door Panel 1 


3 4811000332 Sheet 1 

4 7555000002 Hinge 2 

5 4812000052 Shim 6 

6 7585000011 Latch, “T” Handle 2 

7 7114100418 Capscrew, #10-24NC x 0.50” 14 

8 7585000010 Latch Roller 4 

9 4178000334 Bracket 4 

10 7796000031 Gasket 2 

11 7660152604 Locknut, 0.31”-18NC 6 



14 7865000001 Ball Stud 2 

15 4178000240 Bracket 2 

16 4811000335 Sheet 2 


18 7114141018 Capscrew, 0.25”-20NC x 1.25” 14 

19 7660142604 Locknut, 0.25”-20NC 4 

20 7950140163 Flatwasher, 0.25 ID 18 

21 4679000181 Pad, Rubber 1 

22 4686000188 Door Panel 1 

23 7114100818 Capscrew, #10-24NC x 1.00 8 

24 7660102604 Locknut, #10-24NC 8 

25 7114140418 Capscrew, 0.25”-20NC x 0.50” 12 

26 7950140503 Lockwasher, 0.25” ID 12 

27 7831000040 Spacer 4 

28 7660182301 Locknut, 0.50”-13NC 8 

29 7114150650 Capscrew, 0.31”-18NC x 0.75” 4 

30 4062000368 Bar 2 

31 4811000336 Sheet 4 

32 4811000337 Sheet 4 

33 7660140001 Nut, 0.25”-20NC 6 

34 4178000341 Bracket 2 


35 7115181050 Capscrew, 0.50”-13NC x 1.25” 8 

36 7950180153 Flatwasher, 0.50” ID 8 

37 7690000810 Pin, Cotter 4 

38 7189000015 Bumper 3 

39 7114100318 Capscrew, #10-24NC x 0.38” 4 

40 7843000026 Gas Spring - 5.50” Stroke 1

49” 3/4 HEIGHT STAND-A-LONE TOOL COMPARTMENT DOOR AND HARDWARE ASSEMBLY - LH 

11 

28 

37 

6 

37 

27 

9 

8 

8 

23 

31 

32 

31 

32 

9 

10 

7 

7 

22 

24 

2 

15 

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7 

29 11 

20 

14 5 19 

12 FRONT 

40 REAR 

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41 

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4 5 25 

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18 33 

21 30 

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18 

38 

34 

1 

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35 

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39 



49” 3/4 HEIGHT STAND-A-LONE TOOL COMPARTMENT DOOR AND HARDWARE ASSEMBLY - RH 


1 4686000166 Door Panel 1 


3 4811000332 Sheet 1 

4 7555000002 Hinge 2 

5 4812000052 Shim 6 

6 7585000011 Latch, “T” Handle 2 

7 7114100418 Capscrew, #10-24NC x 0.50” 14 

8 7585000010 Latch Roller 4 

9 4178000334 Bracket 4 

10 7796000031 Gasket 2 

11 7660152604 Locknut, 0.31”-18NC 6 



14 7865000001 Ball Stud 2 

15 4178000240 Bracket 2 

16 4811000335 Sheet 2 


18 7114141018 Capscrew, 0.25”-20NC x 1.25” 14 

19 7660142604 Locknut, 0.25”-20NC 4 

20 7950140163 Flatwasher, 0.25 ID 18 

21 4679000181 Pad, Rubber 1 

22 4686000167 Door Panel 1 

23 7114100818 Capscrew, #10-24NC x 1.00 8 

24 7660102604 Locknut, #10-24NC 8 

25 7114140418 Capscrew, 0.25”-20NC x 0.50” 12 

26 7950140503 Lockwasher, 0.25” ID 12 

27 7831000040 Spacer 4 

28 7660182301 Locknut, 0.50”-13NC 8 

29 7114150650 Capscrew, 0.31”-18NC x 0.75” 4 

30 4062000368 Bar 2 

31 4811000336 Sheet 4 

32 4811000337 Sheet 4 

33 7660140001 Nut, 0.25”-20NC 6 

34 4178000341 Bracket 2 


35 7115181050 Capscrew, 0.50”-13NC x 1.25” 8 

36 7950180153 Flatwasher, 0.50” ID 8 

37 7690000810 Pin, Cotter 4 

38 7189000015 Bumper 3 

39 7114100318 Capscrew, #10-24NC x 0.38” 4 

40 7843000026 Gas Spring - 5.50” Stroke 1

49” 3/4 HEIGHT STAND-A-LONE TOOL COMPARTMENT DOOR AND HARDWARE ASSEMBLY - RH 

28 

34 

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5 26 

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17 



49” 3/4 HEIGHT STAND-A-LONE TOOL COMPARTMENT SPACER MOUNTNG ASSEMBLY - LH 


1 4679000136 Spacer Pad 2 


3 7115162250 Capscrew, 0.38”-16NC x 2.75” 6 

4 7950160163 Flatwasher, 0.38” ID 12 

5 7660160001 Nut, 0.38”-16NC 6 

6 4062000243 Bar 2

49” 3/4 HEIGHT STAND-A-LONE TOOL COMPARTMENT SPACER MOUNTNG ASSEMBLY - LH 

2 

5 4 

1 

6 

4 

3 

6 



49” 3/4 HEIGHT STAND-A-LONE TOOL COMPARTMENT SPACER MOUNTNG ASSEMBLY - RH 


1 4679000136 Spacer Pad 2 


3 7115162250 Capscrew, 0.38”-16NC x 2.75” 6 

4 7950160163 Flatwasher, 0.38” ID 12 

5 7660160001 Nut, 0.38”-16NC 6 

6 4062000243 Bar 2

49” 3/4 HEIGHT STAND-A-LONE TOOL COMPARTMENT SPACER MOUNTNG ASSEMBLY - RH 

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6 

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4 

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3 

6 



49” TUNNEL TOOL COMPARTMENT WITH DRAWER INSTALLATION 




3 7636000008 Rubber Mount 6 



6 7115202850 Capscrew, 0.63”-11NC x 3.50” 6 

7 7590200161 Flatwasher, 0.63” ID 6 

8 7660200001 Nut, 0.63”-11NC 6 

9 7115182050 Capscrew, 0.50”-13NC x 2.50” 8 

10 7660182301 Locknut, 0.50”-13NC 8 

11 7950180252 Flatwasher, 0.50” ID 8 


13 4705000705 Plate 8

49” TUNNEL TOOL COMPARTMENT WITH DRAWER INSTALLATION 

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6 

12 

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4 

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11 

5 

8 

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49” TUNNEL TOOL COMPARTMENT WITH DRAWER PANEL ASSEMBLY 



2 7686000008 Cap Panel 2 

3 4679000120 Pad, Rubber - 0.12” Thk 12 


49” TUNNEL TOOL COMPARTMENT WITH DRAWER PANEL ASSEMBLY 

2 

2 

3 

3 

4 

1 



49” TUNNEL TOOL COMPARTMENT WITH DRAWER DOOR AND HARDWARE ASSEMBLY 


1 4686000166 Door Panel 1 


3 4811000332 Sheet 2 

4 7555000002 Hinge 8 

5 4812000052 Shim 16 

6 7595000011 Latch, “T” Handle 4 

7 7114100418 Capscrew, #10-24NC x 0.50” 28 

8 7585000010 Latch Roller 8 

9 4178000334 Bracket 8 

10 7796000031 Gasket 4 

11 7660152604 Locknut, 0.31”-18NC 12 



14 7865000001 Ball Stud 4 

15 4178000240 Bracket 4 

16 4811000335 Sheet 4 


18 7114140818 Capscrew, 0.25”-20NC x 1.00” 28 

19 7660142604 Locknut, 0.25”-20NC 16 

20 7950140163 Flatwasher, 0.25 ID 56 

21 4679000181 Pad, Rubber 2 

22 4679000188 Pad, Rubber 2 

23 7114100818 Capscrew, #10-24NC x 1.00 16 

24 7660102604 Locknut, #10-24NC 16 

25 7114140418 Capscrew, 0.25”-20NC x 0.50” 24 

26 7950140503 Lockwasher, 0.25” ID 24 

27 7831000040 Spacer 8 

28 7690000810 Pin, Cotter 8 

29 7114150650 Capscrew, 0.31”-18NC x 0.75” 8 

30 4062000368 Bar 4 

31 4811000336 Sheet 8 

32 4811000337 Sheet 8 

33 7660140001 Nut, 0.25”-20NC 12 

34 7189000015 Bumper 6 



36 4686000167 Door Panel 1 

37 7114100318 Capscrew, #10-24NC x 0.38” 8 

38 4686000187 Door Panel 1 

39 4686000188 Door Panel 1

49” TUNNEL TOOL COMPARTMENT WITH DRAWER DOOR AND HARDWARE ASSEMBLY 

11 

15 

11 

39 

28 

23 

6 

10 

36 

13 

4 

7 

29 

14 

12 FRONT 

35 REAR 

27 

26 

25 

31 

38 

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32 

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9 

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49” TUNNEL TOOL COMPARTMENT WITH DRAWER - DRAWER INSTALLATION 


1 3502740134 Drawer Weldment 1 

2 7821000003 Slide 2 

3 7114100518 Capscrew, #10-24NC x 0.63” 16 

4 7950100103 Flatwasher, #10 ID 36 

5 7660102604 Locknut, #10-24NC 36 

6 7114100523 Capscrew, #10-24NC x 0.63” 20 

7 7686000059 Panel, Drawer 2 




11 4679000156 Pad, Wear 4 

12 7114100323 Capscrew, #10-24NC x 0.38” 4 

13 7585000011 Latch, “T” Handle 2 

14 7796000031 Gasket 2 

15 7114100818 Capscrew, #10-24NC x 1.00” 8 

16 7660102604 Locknut, #10-24NC 8 

17 4811000391 Sheet 2 

18 7759000008 Rivet, 0.25” Dia 10 

19 4706003145 Plate 2 

20 7114140850 Capscrew, 0.25”-20NC x 1.00” 4 

21 7950140143 Flatwasher, 0.25” ID 24 

22 7660142604 Locknut, 0.25”-20NC 12 

23 4415000050 Flare, Body 2 



26 7114141850 Capscrew, 0.25”-20NC x 2.25” 8 

27 4679000207 Pad, Rubber 2

49” TUNNEL TOOL COMPARTMENT WITH DRAWER - DRAWER INSTALLATION 

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25 



HEADBOARD INSTALLATION - BODY MOUNTED 


1 3241000078 Headboard and Panel Assembly - 28.93” 1 

3241000080 Headboard and Panel Assembly - 38.93” 


2 3178000242 Bracket Weldment - LH 1 

3 3178000243 Bracket Weldment - RH 1 

4 7115181250 Capscrew, 0.50”-13NC x 1.50” 12 

5 7660182601 Locknut, 0.50”-13NC 16 

6 7950180161 Flatwasher, 0.50” ID 24 

7 7636000009 Rubber Mount 4 


9 7115182850 Capscrew, 0.50”-13NC x 3.50” 4

HEADBOARD INSTALLATION - BODY MOUNTED 

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HEADBOARD INSTALLATION - FORWARD MOUNTED 





2 7115181850 Capscrew, 0.50”-13NC x 2.25” 4 

3 7950180153 Flatwasher, 0.50” ID 4 

4 4679000121 Pad, Rubber - 0.25” Thk 4 

5 7949000012 Washer, Rubber 4 

6 7949000016 Washer, Tail 4 

7 7660182601 Locknut, 0.50”-13NC 4

HEADBOARD INSTALLATION - FORWARD MOUNTED 

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2 

3 

4 

5 

6 

7 



UPRIGHT HEADBOARD INSTALLATION - FORWARD MOUNTED 




2 7115181850 Capscrew, 0.50”-13NC x 2.25” 4 

3 7950180153 Flatwasher, 0.50” ID 4 

4 4679000121 Pad, Rubber - 0.25” Thk 4 

5 7949000012 Washer, Rubber 4 

6 7949000016 Washer, Tail 4 

7 7660182601 Locknut, 0.50”-13NC 4

UPRIGHT HEADBOARD INSTALLATION - FORWARD MOUNTED 

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2 

3 

4 

5 

6 

7 



HEADBOARD AND PANEL ASSEMBLY 


1 3241000077 Headboard Bonding Assembly - 28.93” 1 

3241000079 Headboard Bonding Assembly - 38.93” 

3241000121 Headboard Bonding Assembly - 44.93” 

3241000204 Headboard Bonding Assy - 39.00” Upright 

3241000206 Headboard Bonding Assy - 45.00” Upright 

2 4707000106 Plate - LH - 28.93” 1 

4707000108 Plate - LH - 38.93” 

4707000194 Plate - LH - 44.93” 

4707000305 Plate - LH - 39.00” Upright 

4707000290 Plate - LH - 45.00” Upright 

3 4707000107 Plate - RH - 28.93” 1 

4707000109 Plate - RH - 38.93” 

4707000195 Plate - RH - 44.93” 

4707000306 Plate - RH - 39.00” Upright 

4707000291 Plate - RH - 45.00” Upright 

4 4707000105 Plate 1 

5 7759000008 Rivet, 0.25” Dia 26 

6 7661000019 U-Nut, 0.25”-20NC 8 

7 7114140518 Capscrew, 0.25”-20NC x 0.63” 8 

8 7701000057 Plug, Hole 0.63” Dia 2 

9 7701000056 Plug, Hole 0.44” Dia 4

HEADBOARD AND PANEL ASSEMBLY 

1 

9 8 

9 

6 

4 

7 

9 

8 

9 

5 

2 

3 



WING LIGHT BRACKET INSTALLATION 


1 3178000404 Wing Light Bracket - LH 1 

2 3178000405 Wing Light Bracket - RH 1 

3 4706002570 Plate 2 

4 4706002569 Plate 2 

5 4707000129 Plate - LH 1 

6 4707000130 Plate - RH 8 

7 7114161050 Capscrew, 0.38”-16NC x 1.25” 4 

8 7950160163 Flatwasher, 0.38” ID 4 

9 7660161603 Locknut, 0.38”-16NC 4 

10 7661000029 J-Nut, 0.31”-18NC 12 

11 7114150618 Capscrew, 0.31”-18NC x 0.75” 12

WING LIGHT BRACKET INSTALLATION 

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3 

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4 

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49” TOOLBOX TRAY 


1 3502740137 Tray 1 

2 4017001129 Angle 2 

3 4679000198 Pad 8 

4 7105100323 Capscrew, #10-32NC x 0.38” 16 

5 7759000011 Rivet, 0.25” Dia 6

49” TOOLBOX TRAY 

4 

3 

2 

5 

1 

2 

3 

4 



49” TUNNEL TOOL COMPARTMENT INSIDE DRAWER 


1 3502740229 Drawer Weldment 1 

2 4178000377 Bracket 2 

3 4811000403 Sheet 2 

4 7821000001 Slide 2 

5 7114100518 Capscrew, #10-24NC x 0.63” 10 

6 7950100103 Flatwasher, #10 ID 18 

7 7660102604 Locknut, #10-24NC 18 

8 7114100523 Capscrew, #10-24NC x 0.63” 8 

9 4706003228 Plate 2 

10 7114140850 Capscrew, 0.25”-20NC x 1.00” 14 

11 7950140163 Flatwasher, 0.25” ID 20 

12 7759000011 Rivet, 0.25” Dia 16 

13 7660142604 Locknut, 0.25”-20NC 14 

14 4763000184 Rod 2 

15 4811000407 Sheet 1 

16 4679000209 Pad, Rubber - 0.19” Thk 1 

17 4679000210 Pad, Rubber - 0.19” Thk 1 

18 7413000002 Nutsert, 0.25”-20 NC 4 

19 7949000022 Washer, Fender - 1.00 OD x 0.25” ID` 8

49” TUNNEL TOOL COMPARTMENT INSIDE DRAWER 

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16 

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LH shown, RH similiar 



SLIDE OUT FRAME FORK STORAGE BOARD 


1 3706000393 Sliding Plate Assembly 1 

2 7821000009 Slide 1 

3 4178000900 Bracket 2 

4 3178000570 Bracket, Upper Front 1 

5 3178000570 Bracket, Upper Rear 1 

6 4411000206 Track 4 

7 4263000941 Channel 1 

8 4679000323 Pad, Slide 2 

9 4017001727 Angle 2 

10 4706006251 Plate 4 

11 7115151050 Capscrew, 0.31”-18NC x 1.25” 16 

12 7950160163 Flatwasher, 0.38” ID 32 

13 7660162604 Locknut, 0.38”-16NC 16 

14 7114140823 Capscrew, 0.25”-20NC x 1.00” 16 

15 7950140143 Flatwasher, 0.25” ID 24 

16 7660142604 Locknut, 0.25”-20NC 20 

17 7114140423 Capscrew, 0.25”-20NC x 0.50” 5 

18 7114140850 Capscrew, 0.25”-20NC x 1.00” 4 

19 7115182050 Capscrew, 0.25”-20NC x 2.50” 2 

20 7950180143 Flatwasher, 0.50” ID 4 

21 7660182601 Locknut, 0.50”-13NC 2 

22 3706000394* Sliding Plate Weldment 1 

23 3178000569* Bracket 8 

24 4178000884* Bracket 1 

25 4062000741* Bar 1 

26 3178000579* Bracket 1 

27 4178000888* Bracket 1 

28 7115161250* Capscrew, 0.38”-16NC x 1.50” 18 

29 7950160143* Flatwasher, 0.38” ID 36 

30 7660162604* Locknut, 0.38”-16NC 18 

* Also available in 3706000393

SLIDE OUT FRAME FORK STORAGE BOARD 

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SLIDE OUT TOOLBOARD 


1 3706000396 Sliding Plate Assembly 1 

2 7821000009 Slide 1 

3 4178000900 Bracket 2 

4 3178000570 Bracket, Upper Front 1 

5 3178000570 Bracket, Upper Rear 1 

6 4411000206 Track 4 

7 4263000941 Channel 1 

8 4679000323 Pad, Slide 2 

9 4017001727 Angle 2 

10 4706006251 Plate 4 

11 7115151050 Capscrew, 0.31”-18NC x 1.25” 16 

12 7950160163 Flatwasher, 0.38” ID 32 

13 7660162604 Locknut, 0.38”-16NC 16 

14 7114140823 Capscrew, 0.25”-20NC x 1.00” 16 

15 7950140143 Flatwasher, 0.25” ID 24 

16 7660142604 Locknut, 0.25”-20NC 20 

17 7114140423 Capscrew, 0.25”-20NC x 0.50” 5 

18 7114140850 Capscrew, 0.25”-20NC x 1.00” 4 

19 7115182050 Capscrew, 0.25”-20NC x 2.50” 2 

20 7950180143 Flatwasher, 0.50” ID 4 

21 7660182601 Locknut, 0.50”-13NC 2

SLIDE OUT TOOLBOARD 

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TIRE LIFT GRID STORAGE BRACKETS FOR BODY COMPARTMENTS 


1 3178000460 Bracket Assembly 1 

2 4062000600 Bar 2 

3 7115161250 Capscrew, 0.38”-16NC x 1.50” 10 

4 7950140163 Flatwasher, 0.38” ID 20 

5 7660162604 Locknut, 0.38”-16NC 10 

6 4062000615 Bar 2

TIRE LIFT GRID STORAGE BRACKETS FOR BODY COMPARTMENTS 

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TIRE LIFT GRID STORAGE BRACKETS FOR TUNNEL TOOL COMPARTMENTS 



2 4178000660 Bracket 1 

3 4017001493 Angle 1 

4 7114140850 Capscrew, 0.25”-20NC x 1.00” 2 

5 7950140163 Flatwasher, 0.25” ID 2 

6 7413000002 Nutsert, 0.25”-20 NC 2 

7 7114161050 Capscrew, 0.38”-16NC x 1.25” 8 

8 7950160163 Flatwasher, 0.38” ID 24 

9 7413000003 Nutsert, 0.38”-16 NC 4 

10 7660162604 Locknut, 0.38”-16NC 10 

11 7115161250 Capscrew, 0.38”-16NC x 1.50” 6 

12 4062000615 Bar 2

TIRE LIFT GRID STORAGE BRACKETS FOR TUNNEL TOOL COMPARTMENTS 

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14K TIRE LIFT STORAGE BRACKETS FOR 49” TUNNEL TOOL COMPARTMENTS 



2 4178000660 Bracket 1 

3 4017001493 Angle 1 

4 7114140850 Capscrew, 0.25”-20NC x 1.00” 2 

5 7950140163 Flatwasher, 0.25” ID 2 

6 7413000002 Nutsert, 0.25”-20 NC 2 

7 7114161050 Capscrew, 0.38”-16NC x 1.25” 25 

8 7950160163 Flatwasher, 0.38” ID 41 

9 7413000003 Nutsert, 0.38”-16 NC 21 

10 7660162604 Locknut, 0.38”-16NC 10 

11 7115161250 Capscrew, 0.38”-16NC x 1.50” 6 

12 4062000615 Bar 2 

13 4017001549 Angle 1 

14 4178000715 Bracket 2 

15 3178000513 Bracket Weldment 1 

16 7950160000 Lockwasher, 0.38” ID 21 

17 4178000678 Bracket 1 

18 4178000720 Bracket 1


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THIS PAGE INTENTIONALLY LEFT BLANK 






2 4178000660 Bracket 1 

3 4017001493 Angle 1 

4 7114140850 Capscrew, 0.25”-20NC x 1.00” 2 

5 7950140163 Flatwasher, 0.25” ID 2 

6 7413000002 Nutsert, 0.25”-20 NC 2 

7 7114161050 Capscrew, 0.38”-16NC x 1.25” 29 

8 7950160163 Flatwasher, 0.38” ID 45 

9 7413000003 Nutsert, 0.38”-16 NC 25 

10 7660162604 Locknut, 0.38”-16NC 10 

11 7115161250 Capscrew, 0.38”-16NC x 1.50” 6 

12 4062000615 Bar 2 

13 4017001549 Angle 1 

14 4178000715 Bracket 2 


16 4178000761 Bracket 1 

17 4178000678 Bracket 1 

18 4178000720 Bracket 1 

19 7950160000 Lockwasher, 0.38” ID 25 

20 7115181050 Capscrew, 0.50”-13NC x 1.25” 4 

21 7950180153 Flatwasher, 0.50” ID 1 

22 76601823011 Locknut, 0.50”-13NC 4


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25K TIRE LIFT STORAGE BRACKETS FOR 24” TUNNEL TOOL COMPARTMENT & 24” STAND-A-LONE 

TOOL COMPARTMENT 



2 7115161850 Capscrew, 0.38”-16NC x 1.00” 30 

3 7950160000 Lockwasher, 0.38” ID 30 

4 7950160163 Flatwasher, 0.38” ID 36 

5 7413000003 Nutsert, 0.38”-16 NC 30 

6 7660162604 Locknut, 0.38”-16NC 30 

7 7115161250 Capscrew, 0.38”-16NC x 1.50” 6 

8 4062000615 Bar 2 

9 4017001549 Angle 1 


11 4178000761 Bracket 1 

12 4178000760 Bracket 1 

13 4178000756 Bracket 1 

14 4811001110 Sheet 1 

15 4017001581 Angle 2 

16 7115221250 Capscrew, 0.75”-10NC x 1.50” 1 

17 7950220141 Flatwasher, 0.75” ID 2 

18 7660222601 Locknut, 0.75”-10NC 1 

19 8632000018 Trim 3Ft

25K TIRE LIFT STORAGE BRACKETS FOR 24” TUNNEL TOOL COMPARTMENT & 24” STAND-A-LONE 

TOOL COMPARTMENT 

12 

2 

2 

3 

3 

4 

4 

14 

19 

16 

17 

5 

13 

19 

17 

18 

5 

5 

10 

11 

5 

2 

3 

4 

3 

4 

3 

5 

10 

2 

2 

3 

9 

2 

4 

4 

3 

2 

8 

6 

15 

2 

4 

5 

15 

5 

1 

3 

4 

5 4 

5 

2 

3 

7 

4 



BRACKET ASSEMBLY - 3178000460 



2 3911000065 Tube Weldment - LH 1 

3 3911000066 Tube Weldment - RH 1 

4 4691000543 Pin 1 

5 7754000022 Retaining Ring, 0.75” Dia 2 

6 4691000186 Pin 2 

7 4254000005 Cap 2 

8 7843000006 Spring 2 

9 4763000184 Rod 2 

10 7440030000 Grease Fitting 2 

11 7189000007 Rubber Bumper 4

BRACKET ASSEMBLY - 3178000460 

10 

2 

6 

9 

7 

8 

3 

5 

1 

11 

4 

5 



24” TOOL COMPARTMENT LIGHTING 


1 7590000094 Light w/ Switch, 12V 2 



A 

A 

1 

1 

1 

2 

VIEW A-A 





1 7590000094 Light w/ Switch, 12V 4 



A 

A 

2 

1 

VIEW A-A 



BODY WIRING 


1 7552000090 Harness, Body - RH 1 

86”/110” 112” Base Bodies 

7552000123 Harness, Body - RH 

146”/174” Base Bodies 

2 7552000146 Harness, Body - LH 1 

86”/110” 112” Base Bodies 

7552000124 Harness, Body - LH 


3 7457000011 Fuse, 10 Amp 3 

4 7457000006 Fuse, 15 Amp 1 

5 7457000012 Fuse, 20 Amp 6 

6 7114140650 Capscrew, 0.25”-20NC x 0.75” 2 

7 7661000023 Locknut, #10-32NF 10 

8 7115151650 Capscrew, 0.31”-18NC x 0.75” 2 

9 7870000044 Power Distribution Panel 1 

10 7115101411 Screw, #10-24NC x 1.75” 4 

11 7661000002 Locknut, #10-24NC 4 

12 4346000003 Junction Box 1 

86”/110” 112” Base Bodies 

4346000004 Junction Box 


13 7493000014 Grommet 9 

14 7950140143 Flatwasher, 0.25” ID 4 

15 7660142604 Locknut, 0.25”-20NC 6 

16 7493000011 Grommet 1 

17 7345242202 Electrical Terminal 1 


19 7978000011 Cable, Red #4 25ft 

20 8597650001 Wire Loom 25ft 

21 7114100618 Capscrew, #10-24NC x 0.75” 8 

22 7274000036 Clamp 8 

23 7660102604 Locknut, #10-24NC 8 

24 7894000031 Tie Strap 4 




27 7120000033 Thumb Screw, #10-32 NC x 0.75” 4 


29 7950150000 Lockwasher, 0.31” ID 1 

30 7950150163 Flatwasher, 0.31” ID 3 

31 7120000035 Capscrew, .031”-18NC x 0.50” 1 

32 7949000053 Washer 1 

33 7660152604 Locknut, 0.31”-18NC 1


13 

D 

D 

1 

16 

W 

9BL 

RH STOP/TURN/TAIL 

CIRCUIT 

6BL 

2BL 

16W 

15B 

16W 

15B 

16W 

6BL 

2BL 

16W 

17 

8 

30 

3 

19W 

3 LICENSE PLATE / 

CHASSIS GROUND 

CIRCUIT 

19 

20 

OEM HARNESS 

19 

20 

A 

B 

B 

A 

13 

+ 

12V BATTERY 

- 

18 

18 

C 

C 

2 

LH STOP/TURN/TAIL 

CIRCUIT 

CABINET LIGHT 

CIRCUIT - TYP 4 PLCS 

8BL 

15 

W 

15W 

15B 

15W 

1BL 

4BL 

15W 

1BL 

4BL 

15W 

15B 

G 

CIRCUIT 

COLOR 

FUNCTION 

1BL 

2BL 

4BL 

BROWN 

BROWN 

YELLOW 

MARKER/TAIL 

MARKER/TAIL 

LH STOP/TURN 

13 

13 

6BL 

GREEN 

RH STOP/TURN 

8BL 

WHITE/BLACK 

LH COMPARTMENT LIGHT 

9BL 

WHITE/BLACK 

RH COMPARTMENT LIGHT 

13B 

BLUE 

FLOOD #2 

15B 

15W 

16W 

BLACK 

WHITE 

WHITE 

BACK-UP 

GRND, LH BODY 

GRND, RH BODY 

13 

19W 

BLACK 

GRND, CHASSIS 

VIEW A-A 

INNER LH BODY PANEL REF 




14 

6 

14 

15 

F 

F 

10 

11 

12 

27 

21 

22 

23 

SECTION B-B 

VIEW C-C 

E 

22 

23 

25 

E 

24 

24 

25 

24 

25 

21 

SECTION D-D SECTION E-E VIEW F-F

LEFT BODY 

HARNESS 

RIGHT BODY 

HARNESS 

IN 

MARKER 

OUT 

LEFT TURN 

IN 

OUT 

RIGHT TURN 

IN 

OUT 

BACK-UP 

IN 

OUT 

A 

EE 

C 

D 

E 

F 

G 

H 

I 

J 

K 

L 

M 

N 

O 

P 

20A 

15A 

2OA 

2OA 

B 

FF 

Q 

R 

S 

T 

U 

V 

W 

X 

Y 

Z 

AA 

BB 

CC 

DD 

1OA 

10A 

2OA 

2OA 

1OA 

2OA 


HARNESS 


HARNESS 

IN 

MARKER 

OUT 

LEFT TURN 

IN 

OUT 

RIGHT TURN 

IN 

OUT 

BACK-UP 

IN 

OUT 


8 

28 

29 

30 

1BL 4BL 15B 

16 

16 

29 

13B 8BL 

OEM HARNESS 

15W 

26 

2 2 

8 

28 

JUNCTION BOX 

WIRING CIRCUIT 

OEM HARNESS 

H 1 

JUNCTION BOX 

WIRING CIRCUIT 

1 H 

30 

1BL 4BL 15B 

13B 8BL 

15W 

13B 

2BL 

13B 

2BL 

9BL 

6BL 

9BL 

6BL 

16W 

15B 

16W 

15B 

19W, 

BLACK, 

GND 

19W, 

BLACK, 

GND 

GND 

H 

DETAIL G 

POWER DISTRIBUTION PANEL INSTALLATION 

FOR 150-174"CT (2-507-330012) 

13 

VIEW H-H 

H 

DETAIL G 

POWER DISTRIBUTION PANEL INSTALLATION FOR 

90-116" CT (2-506-330019) 

GND 

26 

13 

VIEW H-H 

FUSE 

A 

B 

C 

D 

E 

F 

G 

H 

AMP 

20 AMP 

15 AMP 

20 AMP 

20 AMP 

9 

31 

32 

3 

15 

14 

6 

14 

I 

J 

K 

L 

M 

N 

O 

P 

Q 

R 

S 

T 

U 

V 

W 

X 

Y 

Z 

AA 

BB 

CC 

DD 

EE 

FF 

10 AMP 

10 AMP 

20 AMP 

20 AMP 

10 AMP 

20 AMP 

4 

5 

MARKER 

LEFT S/T 

RIGHT S/ T 

MARKER 

OU 

IN 

T 

LEFT S/T 

OU 

IN 

T 

RIGHT S/T 

OU 

IN 

T 

BACK-UP 

OU 

IN 

T 

GROUND 

7 

12 

9 

15 

14 

12 

6 



BODY COMPARTMENT LIGHTING 


1 7870000043 Circuit Breaker, 150 Amp 1 

2 7114140650 Capscrew, 0.25”-20NC x 0.75” 2 

3 7950140143 Flatwasher, 0.25” ID 2 

4 7660142604 Locknut, 0.25”-20NC 2 

5 7740000001 Relay, 40 Amp 3 

6 7590000094 Light w/ Switch, 12V - 86” Body 8 

7590000094 Light w/ Switch, 12V - 110” Body 8 





86” Body 

7790100856 Screw, Self Tapping - #10 Dia x 0.50" 32 

110” Body 


112” Body 


146” Body 


174” Body 

8 7590000105 Light, License Plate 1 

9 7178000025 Bracket, License Plate 1 

10 7345001704 Electrical Terminal - 86” Body 9 

7345001704 Electrical Terminal - 110” Body 9 




11 7346000039 Tubing, Heat Shrink - 86” Body 18in 

7346000039 Tubing, Heat Shrink - 110” Body 18in 



7346000039 Tubing, Heat Shrink - 174” Body 26in

A 

EE 

C 

D 

E 

F 

G 

H 

I 

J 

K 

L 

M 

N 

O 

P 

B 

Q 

FF 

R 

S 

T 

U 

V 

W 

X 

Y 

Z 

AA 

BB 

CC 

DD 

BODY COMPARTMENT LIGHTING 

6 

A 

A 

1 

B 

B 

C 

C 

+ 

12V BATTERY 

- 

2 

3 

4 

10 

11 

8 

7 

9 

5 

MARKER 

20A 

1OA 

10A 

2OA 

MARKER 

IN OUT 

LEFT S/T 

LEFT 

S/T 

RIGHT 

S/ T 

15A 

2OA 

2OA 

IN OUT 

2OA 

RIGHT S/T 

IN OUT 

6 

1OA 

2OA 

BACK-UP 

IN OUT 

GROUND 

SECTION A-A 

VIEW C-C 

VIEW B-B 

Long Body Shown 



HEADBOARD LIGHTING 


1 7590000095 Light, Oval Amber Incandescent - 12V 4 

7590000109 Light, Oval Amber Incandescent - 24V 

7590000300 Light, Oval Amber LED - 12V 

7590000371 Light, Oval Clear LED - 12V 

2 7590000127 Light, 4” Dome - 12V 2 

7590000134 Light, 4” Dome - 24V 

3 7493000002 Grommet 2 

4 7493000003 Grommet 1 

5 7661000023 Locknut, #10-32NF 2 

6 7552000125 Harness 1 

7 7493000014 Grommet 2 

8 7457000006 Fuse, 15 Amp 1 

9 7457000011 Fuse, 10 Amp 1 

10 7493000026 Grommet 4

HEADBOARD LIGHTING 

9 

1 

8 

9 

1 

5 

3 

3 

A 

EE 

B 

Q 

FF 

R 

MARKER 

2 

C 

S 

T 

U 

15A 

OUT 

2 

D 

E 

F 

V 

W 

1 

9 

G 

H 

I 

J 

K 

X 

Y 

Z 

AA 

BB 

CC 

7 

6 

L 

DD 

1 

9 

M 

N 

O 

P 

GROUND 

7B, BROWN, MARKER 

WHITE, GROUND 

4 



INCANDESCENT TAIL LIGHTS 


1 7590000204 Light, STT - RH 2 

2 7590000205 Light, STT - LH 2 

3 7114101210 Screw, #10-24NC x 1.55” 16 

4 7661000024 U-Nut, #10-24NC 16 

5 7188000001 Bulb, STT 4 

6 7188000002 Bulb, Back-up 4

INCANDESCENT TAIL LIGHTS 

4 

5 

1 

6 

3 

4 

5 

2 

6 

2 

4 

6 

5 

4 

3 

6 

5 

3 

3 

1 

Items #14, #15 and #16, not shown 



LED TAIL LIGHTS 


1 3178000520 Bracket - Steel 4 

3175000524 Bracket - Stainless Steel 

2 4062000668 Bar 4 

3 7552000376 Harness 2 

4 7590000284 Light, Oval Red 6 

7590000370 Light, Oval Clear 

5 7590000317 Light, Oval Back-up 2 

6 7590000304 Light, Round Red w/ Grommet 8 

7590000372 Light, Round Clear w/ Grommet 

7 7493000026 Grommet 8 

8 7552000379 Harness 2 

9 7346000039 Tubing, Heat Shrink 30in 

10 8632000026 Trim 14ft 

11 7114100818 Capscrew, #10-24NC x 1.00” 8 

12 7950100163 Flatwasher, #10 ID 16 

13 7660102604 Locknut, #10-24NC 8 

14 5526000553 Tie Strap 4 

15 7552000418 Harness 1 

16 7330000821 Decal, Reflective (For Clear Lens Only) 4

LED TAIL LIGHTS 

4 

6 

6 

BODY HARNESS REF 

4 

2 

11 

12 

6 

1 

10 

4 

9 

3 

6 

2 

11 

12 

12 

6 

BODY 

HARNESS 

REF 

6 

5 

4 

7 

13 

1 

7 

4 

9 

8 

7 

10 

7 

4 

6 

12 

5 

Items #14, #15 and #16, not shown 

13 

6 



7-WAY TRAILER TOWING PLUG 


1 7346000055 Electrical, 7-Way Connector 1 

2 7346000078 Electrical, 7-Way Connector Boot 1 

3 7115150864 Bolt, 0.31”-18NC x 1.00” Carrage 2 

4 7950150163 Flatwasher, 0.31” ID 2 

5 7660152604 Locknut, 0.31”-18NC 2

7-WAY TRAILER TOWING PLUG 

1 

A 

2 

3 

4 

A 

5 

OEM TRAILER 

TOWING 

HARNESS 

SUBFRAME 

LH WEAR TOWER / SPADE 

HOUSING, REF 

GROUND (WHITE) 

CLEARANCE (BLACK) 

SIDE MARKER, ID LAMPS 

2 

1 

6 

TAIL LAMPS (BROWN) 

LICENSE PLATE LAMP 

LH TURN (YELLOW) 

HAZARD LAMPS 

3 

7 

4 

5 

RH TURN (GREEN) 

HAZARD LAMPS 

STOP LAMPS (RED) 

BRAKE ANTI-LOCK 

VIEW A-A 

REAR VIEW OF 7-WAY 



GLAD HANDS 


1 7312000015 Fitting, Glad Hand - Emergency 1 

2 7312000016 Fitting, Glad Hand - Service 1 

3 7446502518 Fitting, Bulkhead 2 

4 7446382506 Fitting, Connector 4 

5 7565000014 Airline, Tubing 0.38 OD * 

6 7443000148 Fttting, Bushing 2 

7 7443000146 Fitting, Elbow 2 

8 7443000145 Fttting, Bushing 2 

9 7577000145 Kit, Gland Hand Seal 1 

10 7330000208 Decal, Service Air 1 

11 7330000209 Decal, Supply Air 1 

* Varies by chassis length

GLAD HANDS 

TRUCK CAB, 

REF 

2 

AUX AIR 

1 

8 

7 

6 

4 

5 

4 

3 

1 

A 

(BLUE 

SUPPLY AIR SERVICE AIR 

( RED) 9 

9 ) 

2 

11 

10 

5 

GLAD HAND 

MOUNTING PLATE, 

REF 

A 

VIEW A-A 



SWITCH PANEL - 9 FUNCTION 


1 7870000075 Switch Panel, 9 Function 1 

2 7552000092 Harness 1 

3 7493000003 Grommet 1 

4 7493000011 Grommet 2 





9 7661000023 Lockwasher, #10-32NF 6 

10 7457000023 Fuse, 20 Amp Maxi 2 


12 7950140143 Flatwasher, 0.25” ID 6 

13 7457000012 Fuse, 20 Amp 3 




17 4811001208 Cover Plate 2 

18 7114100618 Capscrew, #10-24NC x 0.75” 8 

19 7660102604 Locknut, #10-24NC 8

A 

EE 

C 

D 

E 

F 

G 

H 

I 

J 

K 

L 

M 

N 

O 

P 

20A 

20A 

20A 

B 

FF 

Q 

R 

S 

T 

U 

V 

W 

X 

Y 

Z 

AA 

BB 

CC 

DD 

REAR WINCH 

FREESPOOL 

RELEASED WHEN LIT 

738 

U/L WINCH 

FREESPOOL 


741 

256 

REAR WINCH 

2-SPEED 

HIGH SPEED WHEN LIT 

740 

U/L WINCH 

2-SPEED 


831 

ONLY AUTHORIZED AND TRAINED PERSONNEL SHOULD BE 

PERMITTED TO OPERATE THIS WRECKER UNSUPERVISED. 

UNTRAINED OPERATORS SUBJECT THEMSELVES AND OTHERS TO DEATH 

OR SERIOUS INJURY AND MAY CAUSE SERIOUS DAMAGE TO PROPERTY. 

DN 

OUT 

IN 

199 

DN 

OUT 

IN 

OPERATOR'S PRE-TRANSPORT CHECKLIST 

UP 

DN 

UP 

DN 

OUT 

IN 

434 

435 

200 

OUT 

IN 

A MINIM UM OF 5 WRAPS OF CABLE MUST BE LEFT 

ON DRUM TO ACHIEVE RATED LOAD. 

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

262 

TO AVOI D BIRDNESTING AND PREMATURE 

FAILURE OF THE WIRE ROPE ALWAYS KEEP 

TENSION ON WIRE ROPE WHEN UNWINDING 

253 

UP 

DN 

OUT 

IN 

299 

300 

FRONT WINCH 

FREESPOOL 


737 

FRONT WINCH 

2-SPEED 


739 

SWITCH PANEL - 9 FUNCTION 

11 

12 

1 

2 

5 

18 GA RED 

8 

16 

CIRCUIT 

14Y 

13Y 

12Y 

11Y 

10Y 

10G 

6G 

5G 

4G 

7B 

2R 

1R 

LIGHT SUPPLIED W/ 

SWITCH PANEL, REF 

10 AMP FUSE 

SUPPLIED 

W/ PTO 

14 

16 

COLOR 

YELLOW/BLK 

BLUE/BLK 

BLUE 

ORANGE 

GREY 

RED/BLK 

RED/YELLOW 

RED/WHT 

WHITE/BLK 

BROWN 

RED 

RED 

AUX 

AUX 

2 

1 

CABINET 

CABINET 

CONTROL 

FLOODS 

FLOODS 

BEACON 

BEACON 

1R 

2R 

PTO 

2 

1 

2 

1 

7B 

GROUND 

CONTROLS 

FLOOD 

FLOOD 

BEACON 

BEACON 

AUX 

CABINET 

AUX 

CABINET 

SWITCH 

POWER 

POWER 

15 

16 

FUNCTION 

TO 

TO 

#1 

#2 

#2 

#1 

#2 

#1 

SWITCH 

SWITCH 

SWITCH 

SWITCH 

PANEL 

SWITCH 

SWITCH 

18 GA 

WHITE 

SWITCH 

SWITCH 

SWITCH 

SWITCH 

SWITCH 

ID 

PANEL 

PANEL 

14 

16 

6 

5G 

10G 

6G 

4G 

14Y 

13Y 

12Y 

11Y 

10Y 

10 

7 

13 

TO SENDING 

UNIT ON PTO 

30 MAXI 

30 MAXI 

AUX 

HOT 

MARKER 

AUX 

HOT 

OUT 

AUX 

HOT 

MAIN 

SWITCH 

SWITCH 

PANEL 

FEED 

PANEL 

SWITCH 

PANEL 

FEED 

2 

3 4 

5G 

13Y 

6G 

10G 

14Y 

4G 

10Y 

11Y 

12Y 

7B 

1R 

2R 

PRESSURE 

REAR VALVE 

WARNING 

U/L 

TILT 

UP 

U/L 

EXT 

U/L 

LIFT 

UP 

DRAG 

WINCH 

RIGHT 

SPADE 

CAUTION 

LEFT 

SPADE 

REAR 

WINCH 

WRK BM 

EXT 

CAUTION 

BOOM 

LIFT 

WARNING 

FRONT 

WINCH 

257 

PRESSURE 

FRONT VALVE 

17 

18 

19 

9 9 



SWITCH PANEL - 9 FUNCTION WITH IN-CAB UNDERLIFT CONTROLS 


1 7870000058 Switch Panel, 9 Function 1 

2 7552000092 Harness 1 

3 7493000003 Grommet 2 






9 7552000395 Harness 1 


11 7950140143 Flatwasher, 0.25” ID 4 

12 7493000011 Grommet 1 

13 7457000023 Fuse, 20 Amp Maxi 2 

14 7661000023 Lockwasher, #10-32NF 3 

15 7493000014 Grommet 1

I 

FOLD/UP 

FOLD/DN 

IN OUT 

UP DOWN 

AUX 2 

AUX 1 

R 

FLOOD 

FLOOD 


DETAIL 

CIRCUIT 

COLOR 

FUNCTION 

14Y 

YELLOW/BLK 

CONTROLS SWITCH 

13Y 

BLUE/BLK 

FLOOD #2 SWITCH 

12Y 

BLUE 

FLOOD #1 SWITCH 

11Y 

ORANGE 

BEACON #2 SWITCH 

10Y 

GREY 

BEACON #1 SWITCH 

10G 

RED/BLK 

AUX #1 SWITCH 

6G 

RED/YELLOW 

CABINET SWITCH 

5G 

RED/WHT 

AUX #2 SWITCH 

4G 

WHITE/BLK 

CABINET SWITCH 

7B 

BROWN 

SWITCH PANEL ID 

2R 

RED 

POWER TO SWITCH PANEL 

1R 

CIRCUIT 

7B 

RED 

COLOR 

BROWN/WHT 

POWER TO SWITCH PANEL 

FUNCTION 

PILOT PRESS 

10 

11 

9 

6B 

5B 

4B 

LT BLUE/BLK 

LT GREEN/BLK 

BLUE/BLK 

U/L BOOM IN 

TILT DOWN 

BOOM DOWN 

1 

3B 

LT BLUE 

U/L BOOM OUT 

ON OFF 

ON OFF 

ON OFF 

ON OFF 

ON OFF 

ON OFF 

ON OFF 

ON OFF 

ON OFF 

2B 

LT GREEN 

TILT UP 

CABINET 

CABINET 

CONTROL 

BEACON 

BEACON 

1B 

BLUE 

BOOM UP 

JUNCTION 

BOX, REF 

DETAIL 

SEE SHEET 2 OF 2 

2 

DETAIL 

13 

A 

EE 

20 MAXI 

20 MAXI 

B 

FF 

Q 

R 

S 

T 

MARKER 

OUT 

MAIN 

SWITCH PANEL 

LH BODY SIDE PANEL 

REF 

15 

9 

1B, 

2B, 

3B, 

4B, 

5B, 

BLUE 

LT GREEN 

LT BLUE 

BLUE/BLK 

LT GREEN/BL 

REMOTE CONTROL HARNESS 

REF 

1B, 

2B, 

3B, 

4B, 

5B, 

BLUE 

LT GREEN 

LT BLUE 

BLUE/BLK 

LT GREEN/BLK 

C 

U 

D 

V 

6B, 

LT BLUE/BLK 

6B, 

LT BLUE/BLK 

E 

W 

F 

G 

H 

X 

Y 

SWITCH 

PANEL 

FEED 

SWITCH 

PANEL 

FEED 

5G 

13Y 

10Y 

7B, 

BROWN/WHT 

7B, BROWN/WHT 

Z 

J 

K 

AA 

BB 

CC 

6G 

14Y 

11Y 

DETAIL 

L 

M 

DD 

10G 

4G 

12Y 

N 

O 

P 

7B 

12 

14 

1R 

2R 

DETAIL 

SECTION 


7B, BROWN/WHT 

4B, BLUE/BLK 

1B, BLUE 

3B, LT BLUE 

6B, LT BLUE/BLK 

5B, LT GRN/BLK 

2B, LT GREEN 

AUX 2 

AUX 1 

CABINET 

CABINET 

CONTROL 

GROUND, 16GA 

MARKER, 16GA 

CIRCUIT 1, 12GA 





POWER, 12GA RED 

POWER, 12GA RED 

AUX 2 

AUX 1 

CABINET 

CABINET 

CONTROL 

FLOOD 

FLOOD 

BEACON 

BEACON 

CIRCUIT 6 , 12GA 




7B, BROWN 

5G, RED/WHT 

10G, RED/BLK 

6G, RED/YELLOW 

4G, WHT/BLK 

14Y, YELLOW/BLK 

1R, RED 

13Y, BLUE/BLK 

12Y, BLUE 

11Y, ORANGE 

10Y, GREY 

2R, RED, POWER 

AUX 2 

AUX 1 



3 2 

5 

6 

1 

4 

5 

5 

6 

5 

7 

5 

7 

DETAIL 

5 

7 

PTO LIGHT 

SUPPLIED W/ 

SWITCH PANEL 

18GA BROWN 

WIRE 

10 AMP FUSE 

SUPPLIED W/ 

PTO 

PT 

O 

DETAIL 

2R, 

RED, 

POWER 

5 

7 

1 

DETAIL 

5 

6 

5 

8 

5 

8 

5 

8 

3 

9 

5 

DETAIL




SWITCH PANEL - 8 FUNCTION MULTIPLEX 


1 7552000455 Harness 1 

2 7552000456 Harness 1 

3 7552000457 Harness 2 

4 7552000460 Harness 1 

5 4686000253 Panel 1 

4686000292 Panel (Peterbilt Chassis Only) 

6 4686000254 Panel 1 

3686000062 Panel Weldment, Overhead 

(Peterbilt Chassis Only) 

7 7114100418 Capscrew, #10-24NC x 0.50” 20 

7114100418 Capscrew, #10-24NC x 0.50” 20 



(Non Peterbilt Chassis) 

9 7660142301 Locknut, 0.25”-20NC 4 

10 7950100103 Flatwasher, #10 ID 16 

7590100103 Flatwasher, #10 ID 20 


11 7950140143 Flatwasher, 0.25” ID 4 

12 7661000024 U-Nut, #10-24NC 4 

13 7493000022 Grommet 3 

14 8977510200 Wire, 14GA. Red 25Ft 

15 8597650002 Wire Loom 25Ft 



18 7661000002 Locknut, #10-24NC 3 

19 7740000001 Relay, 40 Amp 1 

20 7457000019 Fuse, 5 Amp 1 

21 7660102604 Locknut, #10-24NC 12 

7660102604 Locknut, #10-24NC 16 


22 4811001208 Sheet, Cover Plate 1 



23 7870000155* Switch Panel 1 

24 7870000156* Switch Panel 1 

25 7870000157* Switch Panel 1 

26 7346000276* Electrical Terminator Plug 1 

27 7346000277* Electrical Terminator Plug 1 

28 7295000138* Controller, Switch Panel 1 

* Available in Switch Panel Kit - 7577000025

SW 8 SW 7 SW 6 SW 5 

BEA CON 1 FLOOD 1 CO NT RO L AUX 1 

SW 4 SW 3 SW 2 SW 1 

BEA CON 2 FLOOD 2 CAB IN ET AUX 2 

SW 8 SW 7 SW 6 

BEAC ON 1 FLOOD 1 C ON TROL 

SW 4 SW 3 

BEAC ON 2 FLOOD 2 

SW 5 

AUX 1 

SW 2 SW 1 

CAB INET 

AUX 2 

7 

8 

9 

4 

5 

6 

BEACON 1 

AUX 

1 

2 

3 

AUX 

HOT 1 

BEACON 1 

BEACON 2 

FLOOD 1 

FLOOD 2 

CONTROL 

AUX 1 

CABINET 

AUX 2 

SW 

5 SW 

6 SW 

7 SW 8 

AUX 

1 CONTR OL 

FLOOD 1 BEAC ON 1 

SW 

1 SW 

2 SW 

3 SW 4 

AUX 2 CAB IN ET FLOOD 2 BEAC ON 2 

SW 8 SW 7 SW 6 

BEA CON 1 FLOOD 1 C ONTR OL 

SW 4 SW 3 

BEA CON 2 FLOOD 2 

SW 5 

AUX 1 

SW 2 SW 1 

CAB INE T AUX 2 

BEACON 1 

BEACON 2 

BEACON 1 

BEACON 2 

FLOOD 1 

FLOOD 2 

FLOOD 1 

FLOOD 2 

CONTROL 

AUX 1 

CABINET 

AUX 2 

CONTROL 

AUX 1 

CABINET 

AUX 2 


17 

25 

23 

4 

3 

23 13 

17 

1 4 

4 

28 

9 

2 

24 

17 

25 

BEACON #1 

FLOOD #1 

BEACON #2 

POWER 

A 

TAP 

B 

J 

K 

POWER 

TAP 


HARNESS 


MAIN 

SWITCH PANEL 

LIGHT BAR 

28 

2 

27 

MARKER 

FLOOD #2 

L 

M 

N 

HARNESS 

MARKER 

HARNESS 

BODY MARKERS 

EE 

FF 

O 

IGNITION HOT 

LEFT TURN 

CONTROL 

RIGHT TURN 

CABINET LH 

CABINET RH 

BODY MARKERS 

AUX 1 

O/R LIGHTS 

AUX 2 

19 

C 

D 

E 

F 

G 

H 

I 

AUX 3 

BEACON 1 

AUX 

14 

15 

20 

P 

Q 

R 

S 

T 

U 

V 

W 

X 

Y 

Z 

AA 

BB 

CC 

DD 

5A 

IN OUT 

M O/R LIGHTS 

TURN SIGNAL SWITCH 

AUX 2 

LH RH 

PANEL 

IN IN OUT OUT 

C AA 

BACK-UP 

IN 

IN 

AUX 3 

OUT 

BB 

GROUND 

OUT 

W 

OUT 

DD 

GROUND 

OUT 

S 

16 

17 

18 

18 

18 

23 

1 

26 

3 

24 

Body shown is for reference only 




7 

10 

12 

6 

23 

5 

7 

10 

21 

6 

23 

PETERBILT 335 HEADLINER MOUNT. 

22 

7 

10 

12 

8 

11 

7 

10 

21 

CAB FLOOR MOUNT 

7 

10 

21 

24 

7 

10 

21 

25 

CONTROL STATIONS




SWITCH PANEL - 8 FUNCTION MULTIPLEX WITH UNDERLIFT CONTROLS 


1 7870000158 Switch Panel - Integrated Underlift Units 1 

7870000160 Switch Panel - Independent Underlift Units 

2 7552000458 Harness 1 

3 7114100418 Capscrew, #10-24NC x 0.50” 4 

4 7950100103 Flatwasher, #10 ID 4 

5 7660102604 Locknut, #10-24NC 4

SWITCH PANEL - 8 FUNCTION MULTIPLEX WITH UNDERLIFT CONTROLS 

1 

PETERBILT 335 HEADLINER MOUNT 

3 

4 

5 

2 

TO LIGHTING SWITCH PANELS 

IN REAR CONTROL STATIONS 

1 

EXISTING LIGHTING 

SWITCH PANEL 

BEACON 1 

FLOOD 1 

CONTROL 

AUX 1 

TILT DN 

LIFT DN 

EXT OUT 

WB LIFT DN 

BEACON 2 

FLOOD 2 

CABINET 

AUX 2 

TILT UP 

LIFT UP 

EXT IN 

WB LIFT UP 



EMERGENCY LIGHTBAR INSTALLATION 


1 7590000396 Lightbar - LED 1 

2 4178000234 Bracket 2 

3 7115161250 Capscrew, 0.38-16NC x 1.50” 8 

4 7660162604 Locknut, 0.38”-16NC 8 

5 7950160163 Flatwasher, 0.38” ID 16 

6 7493000011 Grommet 1 

7 7457000023 Fuse, 20 Amp Maxi 1 

8 7457000012 Fuse, 20 Amp 1 

9 7457000019 Fuse, 5 Amp 3 

10 7740000001 Relay, 40 Amp 1

EMERGENCY LIGHTBAR INSTALLATION 

1 

3 

5 

10 

2 

3 

5 

2 

6 

7 

BEACON 

#1 

20 MAXI 

A 

EE 

B 

Q 

FF 

R 

S 5A 

LIGHTBAR 

HARNESS 

9 

T 

C 

U 5A 

D 

V 

E 

W 5A 

F 

G 

X 20A 

H 

I 

J 

K 

Y 

Z 

AA 

BB 

CC 

8 

L 

DD 

5 

M 

N 

O 

4 

P 

5 

4 

Lightbar mounting hardware is supplied with lightbar 



EMERGENCY WING LIGHTBAR INSTALLATION 


1 7590000398 Lightbar - LED 2 

7590000310 Lightbar - Halogen 

7590000310 Lightbar - Strobe 

2 7457000023 Fuse, 20 Amp Maxi 1 

3 7740000001 Relay, 40 Amp 1 

4 4178000402 Bracket 4 

5 7660182601 Locknut, 0.50”-13NC 4 

6 7115181450 Capscrew, 0.50-13NC x 1.75” 4

EMERGENCY WING LIGHTBAR INSTALLATION 

1 

3 

2 

BEACON 

#2 

LIGHTBAR 

6 

A 

EE 

20 MAXI 

B 

Q 

FF 

R 

S 

T 

HARNESS 

4 

6 

1 

C 

D 

E 

F 

G 

H 

I 

U 

V 

W 

X 

Y 

Z 

AA 

4 

J 

K 

L 

M 

N 

BB 

CC 

DD 

O 

P 

5 

Lightbar mounting hardware is supplied with lightbar 

LED Lightbar shown 



LOWER HOOK-UP LIGHTS 


1 7590000089 Light 2 

2 7740000001 Relay, 40 Amp 1 

3 7457000012 Fuse, 20 Amp 1 

4 7274000026 Clamp 6 

5 8597650002 Wire Loom 2Ft

A 

B 

LOWER HOOK-UP LIGHTS 

R H BODY HARNESS 

MOUNTING HARDWARE 

INCLUDED WITH LIGHT 

1 

A 

B 

A 

B 

5 

1 

A 

B 

L H BODY HARNESS 

SECTION A - A 

STANDARD LOWER HOOK-UP LIGHTS 

1 

TRUCK FRAME 

FLOOD 

#2 

A 

B 

MOUNTING HARDWARE 


Q 

A 

B 

EE 

FF 

R 

A 

B 

S 

2 

C 

D 

E 

F 

G 

H 

I 

J 

K 

L 

M 

N 

O 

T 

U 

V 

W 

X 

Y 20A 

Z 

AA 

BB 

CC 

DD 

3 

POWER DISTRIBUTION 

PANEL 

6 

7 5 

8 

SECTION B - B 

1 

STANDARD / DELUXE LOWER HOOK-UP LIGHTS 

P 

RELAY AND FUSE REQUIREMENTS 

Item #4, not shown 



UPPER HOOK-UP LIGHTS 


1 7590000096 Light 2 

7590000126 Light w/ Switch 

2 7740000001 Relay, 40 Amp 1 

3 7457000012 Fuse, 20 Amp 1 

4 8597650002 Wire Loom 1Ft 

5 7120000028 Screw, #10-30NF x 1.00” 8 

6 7661000023 Lockwasher, #10-32NF ID 10 

7 7345211702 Electrical Terminal 2

A 

EE 

C 

D 

E 

F 

G 

H 

I 

J 

K 

L 

M 

N 

O 

P 

B 

Q 

FF 

R 

S 

T 

U 

V 

W 

X 

Y 

Z 

AA 

BB 

CC 

DD 

UPPER HOOK-UP LIGHTS 

R H BODY HARNESS 

TYP RH & LH BODY 

4 

1 

1 

A 

A 

1 

SECTION A - A 

STANDARD UPPER HOOK-UP LIGHTS 

NOTE: MOUNTING 

HARDWARE IS 


TYP RH & LH BODY 

4 

1 

5 

L H BODY HARNESS 

6 

FLOOD 

#2 

7 

2 3 

20A 

RELAY AND FUSE REQUIREMENTS 

POWER DISTRIBUTION 

PANEL 

SECTION A - A 

DELUXE UPPER HOOK-UP LIGHTS 



UPPER WORK LIGHTS 


1 7590000096 Light 2 

7590000144 Light 


3 7346000075 Electrical Connector 1 

4 8597650002 Wire Loom 12Ft 

5 7457000012 Fuse, 20 Amp 1 

6 7740000001 Relay, 40 Amp 1 

7 7978000020 Wire, 14GA. Blue 12Ft 

8 7978000021 Wire, 14GA. White 12Ft 

9 5526000553 Tie Strap 5

UPPER WORK LIGHTS 

8 

4 

7 

2 2 

1 

1 

1 

1 

WING LIGHT MOUNTED 

LIGHT PYLON MOUNTED 

6 

4"x6" HALOGEN WORK LIGHT 

MTG HARDWARE INCLUDED 

FLOOD 

#1 

A 

B 

LIGHTBAR 

6" DIA WORK LIGHT 

MTG HARDWARE INCLUDED 

HARNESS 

Q 

EE 

FF 

R 

S 

C 

D 

E 

F 

G 

T 

U 

V 

W 

X 20A 

5 

3 

H 

Y 

I 

Z 

AA 

J 

BB 

K 

CC 

L 

M 

N 

O 

DD 

GROUND 

5G 3BL 

10B 5BL 

P 

17W 11B 7BL 

12B, BLUE, FLOOD #1 

WHITE, 

GROUND 




LOWER HOOK-UP LIGHTS - UNDERLIFT MOUNTED 


JD25, JD30INT, JD35IND JD35INT 

1 7590000350 Light 1 

2 7552000401 Harness 1 




6 8977010300 Wire, 16GA. White 6in 

7 7346000039 Tubing, Heat Shrink 1Ft 

8 7740000001 Relay, 40 Amp 1 

9 7457000019 Fuse, 5 Amp 1 

10 7330000715 Decal 1 

11 7894000010 Tie Strap 12 



14 7346000037 Seal, Cable 2 

15 7346000234 Lock, Sealed 1 

JD35HDULIND, JD50, JD50INT JD60 

1 7590000144 Light 1 

2 7552000401 Harness 1 






8 7740000001 Relay, 40 Amp 1 

9 7457000019 Fuse, 5 Amp 1 

10 7330000715 Decal 1 

11 7894000010 Tie Strap 12 



14 7346000119 Seal, Cable 2 

15 8597650002 Wire Loom 6in

UL 

LIGHT 

5A 

MAIN 

SWITCH 

PANEL 

HAND CONTROLLER 

FUNCTION 


SWITCH 

RELAY #6 

FUSE Z 

REMOTE 

CONTROL 

USE 

US 

USE 

USE 

A 

HAND 

HAND 

SWITCH 

PANEL 

FEED 

CONTROLLER 

CONTROLLER 

SWITCH 

PANEL 

FEED 

USE 

F 

AUX 2 

SWITCHED 

HOT 

LOWER HOOK-UP LIGHTS - UNDERLIFT MOUNTED 

1 

A 

EE 

C 

D 

E 

F 

G 

H 

I 

J 

B 

Q 

FF 

R 

S 

T 

U 

V 

W 

X 

Y 

Z 

AA 

BB 

FLOOD 

4 

5 

4 

5 

6 

SWITCH PANEL 

HARNESS REF 

FLOOD 

GROUND 

2 

K 

CC 

L 

DD 

M 

N 

O 

P 

AUX 

HOT 

FUSE 

I 

GROUND 

8 9 

3 

7 

MAIN 

2 

BEACON 

RELAY 

FUSE 

FLOOD 

RELAY 

FUSE 

#1 

#1 

A 

#1 

#3 

X 

BEACON 

RELAY 

FUSE 

FLOOD 

RELAY 

FUSE 

#2 

#2 

B 

#2 

#4 

Y 

A 

POWER 

30A MAXI 

TAP 

30A MAXI 

B 

REF: 

*FUSE C: LH CABINET LIGHTS 

*FUSE CC: RH CABINET LIGHTS 

*FUSE BB: AUX #3, LIGHTBAR 

LEFT BODY RIGHT BODY 

HARNESS 

HARNESS 

SWITCH 

LIGHT 

HARNESS 

PANEL 

BAR 

12 

13 

14 

15 

1 

10 

MARKER 

RELAY #5 

FUSES: 

D - POST 

Q - LH BODY 

R - RH BODY 

S - HDBOARD 

LEFT S/T 

RELAY #7 

FUSES: 

E - POST 

T - LH BODY 

U - LGHTBAR 

CONTROLS: 

REMOTE 

RIGHT 

RELAY 

S/T 

#8 

FUSES: 

F - POST 

V - RH BODY 

W - LGHTBAR 

WB LIGHTS 

RELAY #12 

FUSE 

FUSE 

N 

UL LIGHTS 

RELAY #14 

O 

EE 

C* 

D 

E 

F 

G 

H 

I 

J 

K 

L 

M 

N 

O 

P 

20A MAXI 

2OA 

15A 

2OA 

2OA 

2OA 

2OA 

2OA 

10A 

5A 

20A MAXI 

FF 

Q 

R 

S 

T 

U 

V 

W 

X 

Y 

Z 

AA 

BB* 

CC* 

DD 

FUSE 

Z 

1OA 

10A 

20A 

2OA 

2OA 

2OA 

2OA 

2OA 

20A 

15A 

1OA 

2OA 

2OA 

20A 

AUX 

HOT 

FUSE 

I 

IN 

LEFT 

IN 

RIGHT 

IN 

IN 

AUX 

HOT 

FUSE 

H 

MARKER 

OUT 

F 

D 

TURN 

OUT 

F E 

E 

TURN 

OUT 

F 

F 

BACK-UP 

OUT 

F 

A 

AUX 

HOT 

FUSE 

G 

FUNCTION 

FUSE 

EE 

SWITCH 

F 

F 

GROUND 

FUSE 

DD 




UPPER WORK LIGHTS - WRECKER BOOM MOUNTED 


1 7590000144 Light 3 

2 3178000501 Bracket 1 

3 4314000152 Coverplate 1 

4 4695000026 Pipe 1 

5 7552000303 Harness 1 

6 7274000095 Clamp 6 

7 7661000024 U-Nut, #10-24NC 4 

8 7114100618 Capscrew, #10-24NC x 0.75” 4 

9 7443000399 Fitting 1 

10 7443000400 Nut, Fitting 1 





15 7740000001 Relay, 40 Amp 1 

16 7457000006 Fuse, 15 Amp 1 


18 7330000715 Decal 1 



21 7346000037 Seal, Wire 6

RELAY #6 

FUSE Z 

REMOTE 

CONTROL 

AUX 

HOT 

AUX 

HOT 

USE 

US 

USE 

USE 

A 

AUX 

HOT 

HAND 

HAND 

SWITCH 

PANEL 

FEED 

FUSE 

EE 

CONTROLLER 

CONTROLLER 

SWITCH 

PANEL 

FEED 

USE 

F 

AUX 2 

SWITCHED 

HOT 

FUSE 

DD 

WB 

LIGHTS 

15A 

MAIN 

SWITCH 

PANEL 


FUNCTION 


SWITCH 

A 

A 

B 

B 

UPPER WORK LIGHTS - WRECKER BOOM MOUNTED 

6 

6 

6 

6 

6 

12Y 

FLOOD 

(BLUE) 

6 

BEACON 

RELAY 

FLOOD 

RELAY 

FUSE 

MARKER 

RELAY #5 

FUSES: 

D - POST 

Q - LH BODY 

R - RH BODY 

S - HDBOARD 

LEFT S/T 

RELAY #7 

18 

FUSE 

#1 

#1 

A 

#1 

#3 

X 

FUSES: 

E - POST 

T - LH BODY 

U - LGHTBAR 

BEACON 

RELAY 

FUSE 

FLOOD 

RELAY 

FUSE 

CONTROLS: 

REMOTE 

RIGHT 

RELAY 

#2 

#4 

Y 

S/T 

#8 

#2 

#2 

B 

FUSES: 

F - POST 

V - RH BODY 

W - LGHTBAR 

WB LIGHTS 

RELAY #12 

FUSE 

FUSE 

N 

UL LIGHTS 

RELAY #14 

O 

A 

EE 

C* 

D 

E 

F 

G 

H 

I 

J 

K 

L 

M 

N 

O 

P 

POWER 

30A MAXI 

20A MAXI 

2OA 

15A 

2OA 

2OA 

2OA 

2OA 

2OA 

10A 

5A 

TAP 

30A MAXI 

20A MAXI 

B 

FF 

REF: 

*FUSE C: LH CABINET LIGHTS 

*FUSE CC: RH CABINET LIGHTS 

*FUSE BB: AUX #3, LIGHTBAR 


Q 

R 

S 

T 

U 

V 

W 

X 

Y 

Z 

AA 

BB* 

CC* 

DD 

HARNESS 

FUSE 

Z 

1OA 

10A 

20A 

2OA 

2OA 

2OA 

2OA 

2OA 

20A 

15A 

1OA 

2OA 

2OA 

20A 

FUSE 

I 

HARNESS 

IN 

LEFT 

IN 

RIGHT 

IN 

IN 

FUSE 

H 

MARKER 

OUT 

F 

D 

TURN 

OUT 

F E 

E 

TURN 

OUT 

F 

F 

BACK-UP 

OUT 

F 

A 

FUSE 

G 

MAIN 

SWITCH 

LIGHT 

HARNESS 

FUNCTION 

SWITCH 

BAR 

F 

F 

GROUND 

PANEL 

15 

16 

A 

EE 

C 

D 

E 

F 

G 

H 

I 

J 

K 

L 

M 

N 

O 

P 

B 

Q 

FF 

R 

S 

T 

U 

V 

W 

X 

Y 

Z 

AA 

BB 

CC 

DD 

AUX 

HOT 

FUSE 

I 

GROUND 

FLOOD 

GROUND 

11 

12 

13 

11 

12 

14 

17 

5 

B A 

19 

20 

21 

4 10 7 

9 

8 

3 

2 

1 

1 

1 



UNDER BODY MARKER LIGHTS - 112” CA BASE, 146” CT BASE &170” CT BASE BODIES 


112” CA Base, 146” CT Base Bodies 

1 4811000673 Sheet - 73” 2 

2 4706003236 Plate - LH 2 

3 4706003237 Plate - RH 2 


5 7894000042 Tie Strap 18 

6 7552000246 Harness 2 

7 7552000244 Harness 2 

8 7590000265 Light, Oval Amber Halogen 6 

7590000262 Light, Oval Amber LED 

7590000358 Light, Oval Clear LED 

9 7114080418 Capscrew, #8-32NC x 0.50” 12 

10 7660082500 Locknut, #8-32NC 12 

11 7346000030 Tubing, Heat Shrink 2 

12 7457000011 Fuse, 10 Amp 1 

170” CT Base Body 

1 4811001080 Sheet - 96” 2 

2 4706003236 Plate - LH 2 

3 4706003237 Plate - RH 2 


5 7894000042 Tie Strap 20 

6 7552000246 Harness 2 

7 7552000244 Harness 4 




9 7114080418 Capscrew, #8-32NC x 0.50” 16 

10 7660082500 Locknut, #8-32NC 16 


12 7457000011 Fuse, 10 Amp 1

B 

A 

UNDER BODY MARKER LIGHTS - 112” CA BASE, 146” CT BASE &170” CT BASE BODIES 

12 

C 

D 

FUSE 

MARKER 

IN OUT 

FUSE 

D 

2 

E 

F 

G 

H 

1 

I 

GROUND 

7B 

BLACK 

2 

7W 

WHITE 

1 

B 

A 

B 

A 

6 

4 

10 

3 

9 

8 

3 

7 

5 

8 

4 

1 




UNDER BODY MARKER LIGHTS - 86” CT BASE, 110” CT BASE, 146” TRI & 170” TRI BASE BODIES 


86” CT Base, 146” TRI Base Bodies 

1 4811000670 Sheet - 24” 2 

2 4706003236 Plate - LH 2 

3 4706003237 Plate - RH 2 


5 7894000042 Tie Strap 10 

6 7552000246 Harness 2 

7 7552000244 Harness 2 




9 7114080418 Capscrew, #8-32NC x 0.50” 4 

10 7660082500 Locknut, #8-32NC 4 


12 7457000011 Fuse, 10 Amp 1 

110” CT Base, 174” TRI Base Bodies 

1 4811000672 Sheet - 48” 2 

2 4706003236 Plate - LH 2 

3 4706003237 Plate - RH 2 


5 7894000042 Tie Strap 14 

6 7552000246 Harness 2 

7 7552000244 Harness 4 




9 7114080418 Capscrew, #8-32NC x 0.50” 8 

10 7660082500 Locknut, #8-32NC 8 


12 7457000011 Fuse, 10 Amp 1

B 

A 

UNDER BODY MARKER LIGHTS - 86” CT BASE, 110” CT BASE, 146” TRI & 170” TRI BASE BODIES 

12 

C 

D FUSE 

E 

F 

G 

H 

I 

MARKER 

IN OUT 

FUSE 

D 

2 

GROUND 

7B BLACK 

7W WHITE 

2 

1 

B 

A 

B 

A 

1 

10 

3 

6 

4 

9 

8 

4 

3 

7 

5 

8 

1 




UNDER TOOL COMPARTMENT MARKER LIGHTS 


1 Tool Compartment - 24” 

1 4811000670 Sheet - 24” 2 

2 4706003236 Plate - LH 2 

3 4706003237 Plate - RH 2 


5 7894000042 Tie Strap 10 

6 7552000244 Harness 2 




8 7114080418 Capscrew, #8-32NC x 0.50” 4 

9 7660082500 Locknut, #8-32NC 4 



3 Tool Compartments - 72” 

1 4811000673 Sheet - 72” 2 

2 4706003236 Plate - LH 2 

3 4706003237 Plate - RH 2 


5 7894000042 Tie Strap 18 

6 7552000244 Harness 2 




8 7114080418 Capscrew, #8-32NC x 0.50” 12 

9 7660082500 Locknut, #8-32NC 12 



1 4811000672 Sheet - 48” 

2 4706003236 Plate - LH 2 

3 4706003237 Plate - RH 2 


5 7894000042 Tie Strap 14 

6 7552000244 Harness 2 




8 7114080418 Capscrew, #8-32NC x 0.50” 8 

9 7660082500 Locknut, #8-32NC 8 



1 4811001080 Sheet - 96” 2 

2 4706003236 Plate - LH 2 

3 4706003237 Plate - RH 2 


5 7894000042 Tie Strap 20 

6 7552000244 Harness 2 




8 7114080418 Capscrew, #8-32NC x 0.50” 16 

9 7660082500 Locknut, #8-32NC 16 

10 7346000030 Tubing, Heat Shrink 2

B 

A 

UNDER TOOL COMPARTMENT MARKER LIGHTS 

2 

2 

2 

1 

1 

1 

2 

1 

9 

3 

4 

3 

8 

7 

3 

6 

5 

7 

4 

3 

1 




WIDE BODY MARKER LIGHTS 


1 7590000104 Light, Oval Amber 2 

2 7346000076 Gasket 2 

3 7346000077 Guard 2 

4 7114100610 Screw, #10-24NC x 0.75” 8 

5 7661000002 Locknut, #10-24NC 8 

6 7493000017 Grommet 2 


8 7346000039 Tubing, Heat Shrink 6in

WIDE BODY MARKER LIGHTS 

7 

8 

1 

2 

3 

3 

4 

1 

1 

2 

3 

5 2 6 



IN BODY MARKER LIGHTS 


112” CA Base, 86” CT Base Bodies 

1 7552000406 Harness 2 




3 7590000295 Light, Oval Red Halogen 2 

7590000282 Light, Oval Red LED 



5 7894000042 Tie Strap 24 

6 7493000021 Grommet 2 

7 7493000011 Grommet 2 

146” CT Base Bodies 

1 7552000406 Harness 2 




3 7590000295 Light, Oval Red Halogen 4 

7590000282 Light, Oval Red LED 



5 7894000042 Tie Strap 44 

6 7493000021 Grommet 2 

7 7493000011 Grommet 4

IN BODY MARKER LIGHTS 

7 

1 

A 

6 

1 

A 

1 

VIEW A-A 

2 

4 

2 

4 

5 2 3 

4 4 




MID BODY MARKER LIGHTS 


1 7590000095 Light, Oval Amber Incandescent - 12V 2 

7590000300 Light, Oval Amber led - 12V 

2 7493000028 Gromet 2 

3 7178000045 Bracket 2 

4 7790141651 Screw, Self Tapping - 0.25” Dia x 1.00" 4 

5 8977010103 Wire, 16GA. - 2 Conductor 20ft 




MID BODY MARKER LIGHTS 

4 

1 

2 

3 

3 

2 

1 

4 

5 


HARNESS HARNESS 

7 

8 

MARKER 

IN 

OUT 

6 

7 

5 

GND 

L H SIDE SHOWN 

5 

POWER DISTRIBUTION PANEL 

8 

7 




REAR VIEW VIDEO CAMERA KIT 


1 7002000524 Video Camera Kit 1 

2 3178000535 Bracket 1 

3 5525000537 Wire, 16GA. - 3 Conductor 30Ft 




REAR VIEW VIDEO CAMERA KIT 

1 

(MONITOR) 

2 

1 

(EXTENSION CABLE) 

1 

(INPUT CABLE) 

4 

5 

3 

5 

6 

(CAMERA) 

1 



WINCH VIEW VIDEO CAMERA KIT 


1 7002000524 Video Camera Kit 1 

2 4178000839 Bracket 1 

3 7114140818 Capscrew, 0.25”-20NC x 1.00” 2 

4 7660142604 Locknut, 0.25”-20NC 2 

5 7274000053 Clamp 1 

6 8977010300 Wire, 16GA. White 15Ft 

7 8977500100 Wire, 16GA. Black 15Ft 

8 8597650002 Wire Loom 15Ft 




WINCH VIEW VIDEO CAMERA KIT 

(CAMERA) 

1 

A 

A 

2 

3 

4 

5 

SECTION A-A 

1 

(MONITOR) 

1 

(INPUT CABLE) 

1 

(EXTENSION CABLE) 

1 

(CAMERA) 

9 

10 

6 

7 

8 

10 

11 



HOSE REEL INSTALLATION 


1 4706005755 Plate 1 

2 7732000003 Hose Reel 1 

3 7118171050 Capscrew, 0.44”-14NC x 1.25” 8 

4 7950170142 Flatwasher, 0.44” ID 8 

5 7660172601 Locknut, 0.44”-14NC 8 

6 7768000007 Roller Guide 1 

7 7114140618 Capscrew, 0.25”-20NC x 0.75” 4 

8 7660142604 Locknut, 0.25”-20NC 4 

9 7445080801 Fitting, Adapter 1 

10 7443000457 Fitting, Elbow 1 

11 7935000356 Valve, Pressure Protection 1 

12 7445080855 Fitting, Tee 1 

13 7446100832 Fitting 2 

14 7565000015 Airline, Tubing 0.63 OD 25ft 

15 7935000357 Valve 1 

16 7446100836 Fitting, Elbow 2 

17 7312000030 Coupling, Quick-Connect 2 

18 7330000724 Decal 1 

19 4811001138 Sheet 1 

20 7759000020 Rivet, 0.19” Dia 2 

21 7444040254 Fitting, Reducer 1 

22 4178000777 Bracket 1 

23 7679000008 Pad 3 

24 7330000733 Decal 1 

25 7330000732 Decal 1

HOSE REEL INSTALLATION 

6 

7 

8 

9 

AIR HOSE REEL 

SHUT-OFF 

CLOSE 

OPEN 

20 

18 

19 

25 

2 

24 

15 

1 

SECONDARY 

AIR SUPPLY 

! CAUTION ! 

AIR TANK MUST BE EVACUATED BEFORE 

INSTALLING AIR CIRCUIT 

9 

21 

13 

16 

2 

3 

4 

5 

17 

23 

2 

3 

4 

5 

10 

11 

12 

13 

14 

15 

14 

16 



UNDER BODY BATTERY BOX 


1 3175000003 Box Assembly 1 

2 2178000033 Battery Tray 1 

3 4062000593 Bar 1 

4 4062000595 Bar - 24” Tunnel Tool Compartment 1 

4062000594 Bar - 49” Tunnel Tool Compartment 

5 7115151050 Capscrew, 0.31”-18NC x 1.25” 11 

24” Tunnel Tool Compartment 

7115151050 Capscrew, 0.31”-18NC x 1.25” 10 


6 7950150163 Flatwasher, 0.31” ID 22 


7950150163 Flatwasher, 0.31” ID 20 


7 7660152604 Locknut, 0.31”-18NC 11 


7660152604 Locknut, 0.31”-18NC 10 


8 4062000596 Bar 4 

9 4679000272 Pad 3 

10 8632000018 Trim 1ft 

11 7691000018 Safety Pin 2 

12 7118161026 Capscrew, 0.38”-16NC x 1.25” 9 

13 7950160163 Flatwasher, 0.38” ID 9 

14 7660162604 Locknut, 0.38”-16NC 9 

15 7114150850 Capscrew, 0.31”-18NC x 1.00” 8 

16 7950150163 Flatwasher, 0.31” ID 8 

17 7660152604 Locknut, 0.31”-18NC 8 

18 3811000039 Drawer 1 

19 4090000017 Belt 3 

20 4707000293 Plate 1 

21 8892040001 Tape, Double Face 10in 

22 3178000456 Bracket 1 

23 3178000457 Bracket 1 

24 4763000377 Rod, Threaded 4 


25 7950140143 Flatwasher, 0.24” ID 12 

26 7950140003 Lockwasher, 0.25” ID 4 

27 7660140000 Nut, 0.25”-20NC 8 

28 7660142604 Locknut, 0.25”-20NC 4 

29 4017001451 Angle 2 

30 3811000038 Batery Box 1


5 

6 

7 

4 

2 2 

8 

5 

6 

7 

4 

5 

6 

7 

5 

6 

7 

1 

5 

6 

3 

1 

1 

18 

18 

UNDER BODY BATTERY BOX MOUNTED AT 

24" TUNNEL TOOLBOX 

UNDER BODY BATTERY BOX MOUNTED AT 

TUNNEL TOOLBOX 

49" 




29 

17 

12 

9 

17 

19 

19 

15 

11 

16 

10 

8 

30 

16 

15 

11 

13 

14 

18 

20 

21


28 

23 

28 

25 

25 

28 

25 

24 

24 

25 

22 

27 

27 

27 

25 

BATTERIES 

25 

26 

27 

25 

26 

27 

25 

26 

27 



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HEAVY DUTY WRECKER BODY PARTS MANUAL - Jerr-Dan

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