Miller Vulcan 810 NYC Owner'S Manual Download

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I-0

Section I - SAFETY PRECAUTIONS (cont'd)

SAFETY TIPS

Don't rely on anti-theft steering

locks to secure the steering

wheel. Use a special steering

wheel clamping device. Rope is

commonly used to secure steering

wheels, but that is not as reliable

as devices designed for this

purpose.

Don't operate your wrecker's

engine faster than recommended.

excessive speeds can damage

hydraulic pumps, and winches.

Don't completely unwind all cable

from a winch while loaded. Keep

AT LEAST five wraps on the

drum.

Don't permit bystanders in the

area while performing recovery

work.

Summary of Contents for Vulcan 810 NYC

Page 1: ...CIFICATIONS subject to change without notice All ratings specified are based on structural factors only not vehicle capacities or capabilities Miller Industries Towing Equipment Inc 8503 Hilltop Drive...

Page 2: ...al theory regardless of whether the loss resulted from any general or particular requirement which MILLER knew or had reason to know about at the time of sale MILLER MAKES NO WARRANTY EXPRESS OR IMPLI...

Page 3: ...State and Local Regulations 2 Read Understand and Follow the Instructions in this Manual 3 Use Good Safe Work Practices in a Common Sense Way 4 Only have Authorized and Trained Operators running the W...

Page 4: ...ty county or state Miller Industries rejects any liability claim that may result from the incorrect or unlawful application of its equipment Section I SAFETY PRECAUTIONS I 1 thru I 18 Section II SPECI...

Page 5: ...SSEMBLY VI 12 VI 13 WHEEL LIFT ASSEMBLY VI 14 thru VI 17 RECOVERY BOOM WINCH HYDRAULICS VI 18 VI 19 WHEEL LIFT HYDRAULICS VI 20 VI 21 PUMP VALVE FILTER HYDRAULICS VI 22 VI 23 WINCH CLUTCH CONTROL VI 2...

Page 6: ...NOTES...

Page 7: ...ible for the failure of the wrecker or its accessories resulting from improper maintenance The danger from an automobile does not cease when it is disabled or wrecked Recovering and towing automobiles...

Page 8: ...READTHEMOUNTING OPERATING MAINTENANCEMANUALFOR WARNINGS AND PRECAUTIONS 2 NEVER TAKE ANYTHING FOR GRANTED DON T ASSUME THAT EVERYTHING ISALLRIGHTATTHE START OF WORK TODAY JUST BECAUSE EVERYTHING SEEME...

Page 9: ...ULATIONS PERTINENT TO THESE RATINGS SHALL ALWAYS BE CAREFULLY OBSERVED RATINGS SHOWN ARE BASED ON THE HYDRAULIC MECHANICAL OR STRUCTURAL DESIGN OF THE WRECKER RATHER THAN STABILITY IT IS ALWAYS UNSAFE...

Page 10: ...INTENANCE MANUAL WARNINGS AND PRECAUTIONS AND UNDERSTAND AND HAVE HAD EXPLAINED TO THEM BY THEIR EMPLOYER THE HAZARDS OF OPERATING THE WRECKER THEY MUST BE FAMILIAR WITH THE HAZARDS OF OPERATING AT A...

Page 11: ...e known Don t use winch cables with hooks attached by means of cable clips Use only cables with hooks attached by means of thimbles and machine swaged terminals USE CABLE CLIPS ONLY IN THE EVENT OF AN...

Page 12: ...next clip as near loop as thimble will permit Turn nuts on firm but do not tighten 3 Space additional clips as indicated so distance between clips is equal Tighten all nuts evenly and torque as speci...

Page 13: ...cables don t begin pulling without rechecking connections Make sure that all cables and snatch blocks are securely attached and cannot accidentally pull loose Alwaysusetwosafetychainswhen towing all v...

Page 14: ...with your wrecker without making absolutely sure that the winch drum clutch is FULLY engaged Don t attempt to recover heavy loads without first estimating the amount of pull that will be required Rig...

Page 15: ...n t tie down the front end of your wrecker for recovery work or heavy lifts You are apt to damage the truck frame if you do Don t exceed WORKING LIMIT ratings of cable Use breaking strength ratings on...

Page 16: ...nly used to secure steering wheels but that is not as reliable as devices designed for this purpose Don t operate your wrecker s engine faster than recommended excessive speeds can damage hydraulic pu...

Page 17: ...er you have hooked up a vehicle for towing don t start the tow until you have double checked the hook up installed safety chains and released the parking brakes of the towed vehicle When using a towin...

Page 18: ...cle on its front wheels unless the steering wheel is secured with the front wheels straight ahead Don t tow a vehicle on its front wheels if they are damaged Don t tow a vehicle on its drive wheels un...

Page 19: ...require both systems for safety You should use wheel straps plus safety chains with all wheel lifts The following illustrations show why Don t continue to wind in winch cable after the hook is agains...

Page 20: ...panic stop or minor collision may cause the vehicle to come loose Without straps crossing a railroad track may free the vehicle Without straps a pothole may cause the vehicle to come free Without stra...

Page 21: ...l lift if the crossbar is obstructed Without straps the vehicle may contact the ground and pull free if wheel lift hydraulics fail Without straps maneuvering in parking areas may twist the vehicle fre...

Page 22: ...vehicles regardless of distance A Always use two wheel straps when towing all vehicles regardless of distance To avoid such accidents use wheel straps plus safety chains You need both systems for saf...

Page 23: ...load for safe steering FAW unladen unloaded weight at front axle WB wheel base or distance between the center of the front axle to the center of the rear axle s OH overhang or distance from the center...

Page 24: ...I 18 Section I SAFETY PRECAUTIONS cont d SAFE TOWING Wheel base and overhang distances for tow slings and wheel lifts Wheel base and overhang distances for truck hitches and underlifts...

Page 25: ...nufacturer i e that person or company installing new equipment on a new chassis must certify the completed vehicle by obtaining completing and affixing to the door post on the drivers side of the vehi...

Page 26: ...ve a Serial Number Specification Label mounted on the outer boom The label will exhibit the Model Number Serial Number and Ratings See Figure 2 2 FIGURE 2 2 2 3 SPECIFICATIONS 810 NYC 8 ton independen...

Page 27: ...nter IPS Working line limit 3 500 lb c Boom Specifications Boom Rating at Boom Swivel Retracted 16 000 lbs Maximum Boom Elevation 38 2 4 SPECIFICATIONS Wheel Lift DESCRIPTION INCHES Retracted Distance...

Page 28: ...l Lift System 60 C A 86 Wide Modular Body Safety Chains in Tailboard Chain Pockets Safety Chain Pocket Guards Wheel Lift Ratchets Straps Drivers and Passenger Side Tool Compartments In Cab Wheel Lift...

Page 29: ...and is switched on by the clutch pump switch mounted in the truck cab See Figure 3 1 FIGURE 3 1 THE PUMP IS DESIGNED TO RUN ANY FUNCTION AT NORMAL IDLE SPEED DO NOT OVER REV ENGINE 3 3 The hand held...

Page 30: ...hand held control unit is clearly marked as to its functions and directions See Figure 3 2 FIGURE 3 2 3 5 The wrecker boom is elevated and extended by means of double acting cylinders The boom can be...

Page 31: ...L LEVEL IN WINCH BEFORE ANY OPERATION FILL TO PROPER LEVEL WITH REQUIRED GEAR LUBRICANT AS NEEDED REFER TO SECTION V MAINTENANCE FOR PROPER PROCEDURES 3 2 The switch panel mounted in the truck cab con...

Page 32: ...III Section III OPERATIONAL FUNCTIONS WRECKER cont d FIGURE 3 4 USE SAFETY CHAINS ON ALL TOWING AND LIFTING APPLICATIONS...

Page 33: ...FUNCTION AT NORMAL IDLE SPEED DO NOT OVER REV ENGINE 3A 3 The hand held control units are electrically switched on by the switch and the hydraulic pump is electrically engaged when any function switch...

Page 34: ...nd the claws are opened and closed by means of double acting hydraulic cylinders and can be operated under either LOAD or NO LOAD conditions 3A 6 The switch panel is mounted in the truck cab and contr...

Page 35: ...of the cable 3 500 lbs d DO NOT use the winch or cable for the lifting of people 4 3 PREPARING TO RECOVER VEHICLE a Position wrecker as near as possible to disabled vehicle to be recovered b Reduce t...

Page 36: ...fore operating any control handles observe the winch cables to make sure they are free and have sufficient slack to allow boom to extend If not pay out sufficient cable by either 1 or 2 1 Operate CABL...

Page 37: ...ecovery operation to reduce line load and increase pulling capacity The winch cable is then anchored in the ring at the end of the boom c After recovery operation is complete rewind winch cable on dru...

Page 38: ...NOTES...

Page 39: ...familiar with its controls components and load requirements before attempting any operation 4A 2 PREPARING TO LOAD VEHICLE a Align the Wheel Lift with the disabled vehicle to be towed See Figure 4A 1...

Page 40: ...ch pump ENGAGED THIS CAN CAUSE PUMP FAILURE DUE TO OVER SPEED AND OVERHEATING c Adjust engine speed to desired RPM recommended 1400 to 1500 using the electronic throttle control in cab of truck DO NOT...

Page 41: ...G INSTRUCTIONS WHEEL LIFT cont d 4A 3 VEHICLE HOOK UP cont d FIGURE 4A 2 b Extend Wheel Lift Boom to maximum stroke then retract boom approximately 3 by use of the WHEEL LIFT EXTEND IN OUT Control See...

Page 42: ...STRUCTIONS WHEEL LIFT cont d 4A 3 VEHICLE HOOK UP cont d c If disabled vehicle is equipped with small or flat tires it may be necessary to attach the small tire adapters to claws See Figures 4A 4 and...

Page 43: ...by either 1 or 2 1 Straight Approach Back the Wheel Lift until the crossbar is firmly against the tires of the vehicle to be towed See Figure 4A 6 FIGURE 4A 6 2 Angled Approach Back the Wheel Lift unt...

Page 44: ...cont d 4A 3 VEHICLE HOOK UP cont d FIGURE 4A 7 FIGURE 4A 8 e Engage claws to capture tires of vehicle to be towed using the CLAW OPEN CLOSE Control See Figure 4A 9 Ensure that both claws have fully c...

Page 45: ...HOWN IN FIGURE 4A 9 WITH TIRES CAGED f Check position of tires from left to right Tires should be centered on the wheel lift as much as possible On wide track vehicles such as vans this is critical On...

Page 46: ...cal On these vehicles the tires may hang over the claws one or two inches on each side This is permissible provided tire tie down straps are properly installed NOTE TOWING REAR WHEEL DRIVE VEHICLES WH...

Page 47: ...IE DOWN STRAPS AND SAFETY CHAINS ON ALL TOWING AND LIFTING APPLICATIONS 4A 4 TIE DOWN STRAP PROCEDURES a Using the BOOM UP DOWN Control raise the vehicle to the desired towing height b Lay the safety...

Page 48: ...GURE 4A 10 e With the strap pulled tight pass the chain between the two hooks welded to the front of the crossbar at an angle f Repeat tie down strap procedures on opposite side of vehicle 4A 5 SAFETY...

Page 49: ...OPERATING INSTRUCTIONS WHEEL LIFT cont d 4A 5 SAFETY CHAIN HOOK UP PROCEDURES cont d FIGURE 4A 11 b Loop free end of chain under crossbar and attach to vehicle to be towed See Figure 4A 12 4A 13 FIGUR...

Page 50: ...CTIONS WHEEL LIFT cont d 4A 5 SAFETY CHAIN HOOK UP PROCEDURES cont d FIGURE 4A 13 c The following are some suggested vehicle hook ups for safety chains See Figures 4A 14 thru 4A 17 or consult AAA towi...

Page 51: ...IVA 13 OPERATING INSTRUCTIONS WHEEL LIFT cont d 4A 5 SAFETY CHAIN HOOK UP PROCEDURES cont d FIGURE 4A 15 FIGURE 4A 16...

Page 52: ...SAFETY CHAIN HOOK UP PROCEDURES cont d FIGURE 4A 17 d After attaching the safety chains to the vehicle pull the chain tight under the crossbar and seat chain firmly in the outermost hook welded to the...

Page 53: ...th the bottom of the tailgate See Figure 4A 19 FIGURE 4A 19 MAKE SURE THAT CHAIN LINKS ARE FIXED SECURELY IN CHAIN CADDY KEYHOLE SLOTS f Raise vehicle to desired height for towing Retract boom pulling...

Page 54: ...IVE ADDITIONAL TURNING ABILITY CURBS SHOULD BE CROSSED AT A 45 DEGREE ANGLE WHEN TOWING FROM REAR AXLES SECURE STEERING WHEEL OF VEHICLE DO NOT RELY ON THE STEERING WHEEL LOCKING DEVICE DO NOT TOW ON...

Page 55: ...the event of a sudden stop follow the procedures below for reasons of safety in towing 1 Pull off the roadway and check safety straps to make certain they are tightened securely 2 If safety straps are...

Page 56: ...retract wheel lift boom and raise wheel lift to the fold position f Raise wrecker boom to obtain sufficient clearance between wheel lift and ground when driving Disengage hydraulic pump by switching c...

Page 57: ...are a Before checking oil level in reservoir wipe away all dirt grease and grime around filter cap before removing it Make certain that all containers funnels and pouring spouts are absolutely clean b...

Page 58: ...essary Vibration and stress may loosen even properly torqued bolts e Lubricate all grease fittings on the Wrecker and Wheel Lift including 1 Winch 2 Cylinder Pivot Bearings 3 Cross Bar Pivot 4 Boom Sl...

Page 59: ...Standard Stanogear 5 6 Texaco Maropa 5 c Grease Synthetic Fortified such as Drydene SFG d Oil for miscellaneous bearing surfaces SAE 30 e Cable Oil SAE 30 or special cable lubricant NOTE THERE IS NO P...

Page 60: ...supplier for information regarding specific temperature requirements 5 6 LUBRICATION 1 Cable Use oil or approved cable lubricant 2 Winch Oil Level Fill to oil plug level inside of housing with SAE 14...

Page 61: ...V Section V MAINTENANCE cont d MAINTENANCE RECORD DATE MECHANIC WEEKLY MONTHLY QUARTERLY SERVICE PERFORMED IMPORTANT HYDRAULIC HOSES AND CABLES SHOULD BE INSPECTED WEEKLY FOR SIGNS OF ABRASION...

Page 62: ...V Section V MAINTENANCE cont d MAINTENANCE RECORD DATE MECHANIC WEEKLY MONTHLY QUARTERLY SERVICE PERFORMED IMPORTANT HYDRAULIC HOSES AND CABLES SHOULD BE INSPECTED WEEKLY FOR SIGNS OF ABRASION...

Page 63: ...V Section V MAINTENANCE cont d MAINTENANCE RECORD DATE MECHANIC WEEKLY MONTHLY QUARTERLY SERVICE PERFORMED IMPORTANT HYDRAULIC HOSES AND CABLES SHOULD BE INSPECTED WEEKLY FOR SIGNS OF ABRASION...

Page 64: ...V Section V MAINTENANCE cont d MAINTENANCE RECORD DATE MECHANIC WEEKLY MONTHLY QUARTERLY SERVICE PERFORMED IMPORTANT HYDRAULIC HOSES AND CABLES SHOULD BE INSPECTED WEEKLY FOR SIGNS OF ABRASION...

Page 65: ...V Section V MAINTENANCE cont d MAINTENANCE RECORD DATE MECHANIC WEEKLY MONTHLY QUARTERLY SERVICE PERFORMED IMPORTANT HYDRAULIC HOSES AND CABLES SHOULD BE INSPECTED WEEKLY FOR SIGNS OF ABRASION...

Page 66: ...NOTES...

Page 67: ...anufacturer s Parts Department 1 Manual Number Date of Publication 2 Manual Page Number 3 Page Title 4 Reference Number of Part Desired 5 Part Number 6 Part Description 7 Quantity of Part Desired Prov...

Page 68: ...VI Section VI PARTS cont d SUBFRAME ASSEMBLY...

Page 69: ...X 1 1 2 FL HD SKT 13 2 805040011 VERTICAL BOOM GUIDE PAD 23299002 BODY INSTALL NEW YORK CITY 14 6 0306680 RUBBER T MOUNT LTI 20203 15 2 0307114 RUBBER MOUNT TBA 20103 16 4 SCREW 3 8 16 X 1 1 4 HEX HD...

Page 70: ...VI Section VI PARTS cont d SUBFRAME ASSEMBLY cont d...

Page 71: ...HD CAP 38 14 NUT 1 4 20 NYLOK HEX 39 5 NUT 3 8 16 NYLOK HEX 40 4 NUT 1 2 13 NYLOK HEX 41 4 WASHER 1 4 FLAT 42 5 WASHER 3 8 FLAT 43 1 LOCKWASHER 3 8 HELICAL 44 4 WASHER 1 2 FLAT 45 3 0806854 PIN WELDME...

Page 72: ...VI Section VI PARTS cont d BODY ASSEMBLY...

Page 73: ...MUD FLAP BRACKET CS 16 1 810031100 LH INSIDE SKIRT WELDMENT 17 1 810038100 RH INSIDE SKIRT WELDMENT 18 2 0307996 MUD FLAP BLANK 19 2 804500001 MUD FLAP BACK UP STRIP 810033000 TAIL LIGHT GUARD KIT 20...

Page 74: ...VI Section VI PARTS cont d BODY ASSEMBLY cont d...

Page 75: ...307963 BALL STUD 46 1 23297601 COVER PLATE 810 NYC 47 1 23297627 DEAD BOLT STRIKER PLATE 810 NYC 48 1 23298610 RH BODY WELDMENT 810 NYC 49 1 23298640 DOOR WELDMENT 810 NYC 50 1 23298650 CHAIN BAR WELD...

Page 76: ...VI 10 Section VI PARTS cont d RECOVERY BOOM ASSEMBLY...

Page 77: ...WASHER 1 2 HELICAL 16 4 WASHER 1 2 FLAT 17 1 0705499 SHAFT UPPER SPADE 18 1 0703137 SHAFT 19 2 0717674 SHIM PAD SPACER 20 2 9031088 SLIDE PAD 3 8 X 1 X 6 UHMW 21 2 9053713 FLANGE BEARING 1 1 2 I D 22...

Page 78: ...VI 12 Section VI PARTS cont d WHEEL LIFT BOOM ASSEMBLY...

Page 79: ...5 10 LOCKWASHER 1 4 HELICAL 16 2 SHIM WASHER 5 8 ID X 1 OD X 02 THK 17 1 SHIM WASHER 1 1 2 ID X 2 1 8 OD X 125 THK 18 3 WASHER 3 8 FLAT 19 3 LOCKWASHER 3 8 HELICAL 20 3 WASHER 1 2 FLAT 21 2 WASHER 5 8...

Page 80: ...VI 14 Section VI PARTS cont d WHEEL LIFT ASSEMBLY...

Page 81: ...UM BRONZE 9 2 SCREW 1 4 20 X 5 8 HEX HD CAP 10 1 SCREW 5 16 18 X 1 HEX HD CAP 11 4 SCREW 3 8 16 X 1 1 4 FL HD SKT 12 1 SCREW 3 8 16 X 1 1 2 HEX SKT SET 13 1 SCREW 3 8 16 X 5 8 SKT HD SUNK 14 1 SCREW 3...

Page 82: ...VI 16 Section VI PARTS cont d WHEEL LIFT ASSEMBLY cont d...

Page 83: ...38 1 0803911 L ARM WELDMENT LEFT 39 1 0803912 L ARM WELDMENT RIGHT 40 1 0803928 INNER BOOM WELDMENT 41 1 0806980 CROSSBAR WELDMENT EXPRESS 42 1 0806981 PIVOT PIN WELDMENT 43 2 0806982 PIN WELDMENT L A...

Page 84: ...VI 18 Section VI PARTS cont d RECOVERY BOOM WINCH HYDRAULICS...

Page 85: ...RUN 6 0302510 CONNECTOR 6MJ 6MBL 7 0302584 HOSE ASSEMBLY 50 LONG 8 0307097 HYDRAULIC MOTOR PARKER 9 0307460 ELBOW 6MJ 6MB90 10 0307575 LIFT CYLINDER 11 0307633 HOSE ASSEMBLY 46 LONG 12 0307839 EXTEND...

Page 86: ...VI 20 Section VI PARTS cont d WHEEL LIFT HYDRAULICS...

Page 87: ...NG L ARM 7 1 0303860 HOSE ASSEMBLY 10 3 4 8 1 0303861 HOSE ASSEMBLY 17 9 2 0307042 ORIFICE CONNECTOR 6MJ 6MBR 3 64 10 1 0307840 CYLINDER WHEEL LIFT LIFT 11 1 0307841 CYLINDER WHEEL LIFT FOLD 12 1 0307...

Page 88: ...VI 22 Section VI PARTS cont d PUMP VALVE FILTER HYDRAULICS...

Page 89: ...L VALVE SOLENOID 8 SPOOL 8 1 0310033 ELBOW 8MJ 12MP45 9 1 0702540 SUCTION HOSE 12 FT 1 ID 10 1 810770020 HOSE ASSEMBLY 150 11 1 HC1335 PIPE NIPPLE 1 CLOSED THR NOT SHOWN 23298500 HYDRAULIC TANK ASSEMB...

Page 90: ...DJUSTABLE YOKE 4 1 SCREW 5 16 18 X 1 2 SQ HD SET 5 1 SCREW 3 8 16 X 1 HEX HD CAP 6 1 SCREW 3 8 16 X 2 1 2 HEX HD CAP 7 1 NUT 3 8 16 HEX JAM 8 2 LOCKWASHER 3 8 HELICAL 9 1 CLEVIS PIN 1 2 X 1 1 2 10 1 C...

Page 91: ...D NUMBER DESCRIPTION 805180000 SHEAVE HOUSING ASSEMBLY 1 3 0300113 GREASE FITTING 1 4 28 STRAIGHT 2 2 9056098 RETAINING RING EXT 1 NOM HVY DUTY 3 1 804181500 SHEAVE HOUSING CASTING 4 1 805180001 SHEAV...

Page 92: ...3299810 LH DOLLY BRACKET ASSEMBLY 17 1 23299811 RH DOLLY BRACKET ASSEMBLY 18 1 23299900 PYLON KIT NYC 19 2 174002274 5 LB FIRE EXTINGUISHER 20 11 174016080 RUBBER REAR FENDERFLAIRS UNDE 21 1 806073000...

Page 93: ...K NYC 41 1 23298811 RH DOLLY SUPPORT WELD T 42 1 23298821 RH DOLLY HOLDER WELD T 43 1 23298830 DOLLY LATCH PLATE WELD T 810033000 KIT TAIL LIGHT GUARD 44 4 0400084 1 4 20X1 5 HHCS 45 8 3 8 16X1 HHCS 4...

Page 94: ...NOTES...

Page 95: ...N BRAKE BLACK MARKER LIGHT RED WORK SPOT LIGHT YELLOW LEFT TURN BRAKE BLUE BACKUP LIGHT NOTE HARNESS PROVIDED IS A COMPLETELY SEALED SYSTEM ANY OTHER FUNCTIONS MUST ORIGINATE FROM JUNCTION BOX BREAKIN...

Page 96: ...VII Section VII SCHEMATICS 810 NYC HYDRAULICS...

Page 97: ...VII Section VII SCHEMATICS 810 NYC HYDRAULICS...

Page 98: ...NOTES...

Page 99: ...NOTES...

Page 100: ...Miller Industries Towing Equipment Inc 8503 Hilltop Drive Ooltewah Tennessee 37363 423 238 7227 www millerind com...

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