seriess manual 408, 408a, 410, 410a, 512 series installation, operation, maintenance & parts...

OWNER'S MANUAL

408, 408A, 410, 410A, 512SERIES

INSTALLATION, OPERATION, MAINTENANCE & PARTS

NOTE: MANUAL including SPECIFICATIONS, subject to change without notice.All ratings specified are based on structural factors only,

not vehicle capacities or capabilities.

Carriers & Wreckers7320 W. Market Street

Mercer, PA 16137Phone (724) 981-7500 • FAX (724) 981-4425

Toll Free (800) 886-6400http://www.chevroninc.com

OWNER'S MANUAL

408, 408A, 410, 410A, 512SERIES

INSTALLATION, OPERATION, MAINTENANCE & PARTS

NOTE: MANUAL including SPECIFICATIONS, subject to change without notice.All ratings specified are based on structural factors only,

not vehicle capacities or capabilities.

Carriers & Wreckers7320 W. Market Street

Mercer, PA 16137Phone (724) 981-7500 • FAX (724) 981-4425

Toll Free (800) 886-6400http://www.chevroninc.com

Section V - PARTSDIRECT MOUNT PUMP - 18 GPM

REF PART # DESCRIPTION QPU

12

345

0320144SI4604-20 x 16S14603- 20 x 26F77620779A70909434

18 GPM , 1 IN.15 SPLINE SHAFT, SAE 4-BOLT FLANGE#16-45 M O-RING x 1-1/4 M NIPPLE#16 M O-RING x 1-1/4 NIPPLE1-1/4 O-RING PLUG 900598-20#16 M O-RING X 3/4 MJICPRESSURE TRANSDUCER (OPTIONAL)

111211

V-1

Section V - PARTS408, 408A & 512 BODY COMPONENTS

V-2

24

25

25


1 37558 PADDLE LATCH - ROTARY 12 5A221 TOOL BOX DOOR LANYARD - 21 INCH 23 5A310 TOOL BOX DOOR 14 5A316 TOOL BOX DOOR MOUNTING BLOCK 25 50340 WRECKER BODY 16 51141 STEEL REAR ACCESS COVER 17 51145 ALUMINUM REAR ACCESS COVER 18 53182L MUDFLAP MOUNTING BRACKET - LEFT 19 53182R MUDFLAP MOUNTING BRACKET - RIGHT 110 53250 MIDDLE MOUNTING BRACKET - 34 IN. FRAME 211 53263 FRONT MOUNTING BRACKET - 34 IN. FRAME 212 59140L TOW SLING MOUNTING BRACKET - LEFT 113 59140R TOW SLING MOUNTING BRACKET - RIGHT 114 59115 REAR REFLECTOR MOUNTING PLATE 215 7A165 CONTROL HANDLE 1616 7A211 CONTROL KNOB 1617 83425 5/8 JAM NUT 1618 84716 6-1/2 TON SHACKLE W/NUT & BOLT 219 92600R TAIL LIGHT 220 92650 TAIL LIGHT GROMMET 421 93100R SIDE MARKER LIGHT - RED 222 93150 MARKER LIGHT GROMMET - 2-1/2 IN. ROUND 223 93300R REFLECTOR - RED 224 95600 BACKUP LIGHT 225 A1040 MUDFLAP - 408 & 408A 2

A1045 MUDFLAP - 512 2

Section V - PARTS408, 408A & 512 BODY COMPONENTS

V-3

Section V - PARTS408, 408A & 410 RECOVERY BOOM COMPONENTS

V-4

Section V - PARTS408, 408A & 410 RECOVERY

BOOM COMPONENTS

V-5


1 60125 8-TON RECOVERY BOOM TWIN LINE 160115 8-TON RECOVERY BOOM SINGLE LINE 160145 10-TON RECOVERY BOOM TWIN LINE 1

2 613A1 PIN - BOOM EXTENSION CYLINDER BASE 13 613A2 PIN - BOOM EXTENSION CYLINDER ROD 14 61320 LIFT CYLINDER BASE MOUNT 15 61364 PULLEY PIN - 408 & 408A 1 OR 2

61368 PULLEY BOLT - 410 & 410A 26 61366 SWIVEL INSERT - 408 & 408A 1 OR 2

61369 SWIVEL INSERT - 410 & 410A 27 61370 CABLE FOLLOWER - 408 & 408A 1 OR 2

61379 CABLE FOLLOWER - 410 & 410A 28 61383 PIN - BOOM LIFT CYLINDER ROD 19 61384 PIN - BOOM LIFT CYLINDER BASE 110 61410 BOOM BEARING PAD 211 61412 BOOM BEARING CHANNEL 112 69120 PULLEY - 6 INCH 408 & 408A 1 OR 2

69125 PULLEY - 6 INCH 410 & 410A 213 71102L WINCH - 408 & 408A 0 OR 1

71105L WINCH - 410 & 410A 114 71102R WINCH - 408 & 408A 0 OR 1

71105R WINCH - 410 & 410A 115 72140 CYLINDER - BOOM LIFT 116 72150 CYLINDER - BOOM EXTENSION 117 81110 BOLT - 5/16 x 1 218 81117 BOLT - 5/16 x 7/8 219 82130 FLAT WASHER - 5/16 420 82510 FLAT WASHER - 3/4 - 408 & 408A 4 OR 8

82717 FLAT WASHER - 1 x 1.75 - 410 & 410A 821 86075E SNAP-RING .75 INCH EXTERNAL 2 OR 4

83610 NUT - 7/8 NYLON LOCK - 410 & 410A 222 86100I SNAP-RING 1.00 INCH INTERNAL 423 86125I SNAP-RING 1.25 INCH INTERNAL 424 86287E SNAP-RING 2.875 INCH EXTERNAL 1 OR 2

Section V - PARTS512 RECOVERY BOOM COMPONENTS

V-6


1 60164 TWIN LINE BOOM 12-1/2 INCH DRUM 160165 TWIN LINE BOOM 10 INCH DRUM 1

2 613A1 PIN - BOOM EXTENSION CYLINDER BASE 13 613A2 PIN - BOOM EXTENSION CYLINDER ROD 14 61320 LIFT CYLINDER BASE MOUNT 15 61368 PULLEY BOLT 26 61369 SWIVEL INSERT 27 61379 CABLE FOLLOWER 28 61383 PIN - BOOM LIFT CYLINDER ROD 19 61384 PIN - BOOM LIFT CYLINDER BASE 110 61410 BOOM BEARING PAD 111 61735 NYLATRON WEAR PAD 412 69125 PULLEY - 6 INCH 213 71105L WINCH SERIES 12 (10 INCH DRUM) 1

71106L WINCH SERIES 12 (12-1/2 INCH DRUM) 114 71105R WINCH SERIES 12 (10 INCH DRUM) 1

71106R WINCH SERIES 12 (12-1/2 INCH DRUM) 115 72141 CYLINDER - BOOM LIFT 116 72150 CYLINDER - BOOM EXTENSION 117 81117 BOLT - 5/16 x 7/8 218 82130 FLAT WASHER - 5/16 219 82717 FLAT WASHER - 1 x 1.75 820 83610 NUT - 7/8 NYLON LOCK 221 86100I SNAP-RING 1.00 INCH INTERNAL 422 86125I SNAP-RING 1.25 INCH INTERNAL 423 86287E SNAP-RING 2.875 INCH EXTERNAL 2

Section V - PARTS512 RECOVERY BOOM COMPONENTS

V-7

V-8

Section V - PARTS408 & 408A UNDERLIFT COMPONENTS

Section V - PARTS408 & 408A UNDERLIFT COMPONENTS

V-9


1 657701 STANCHION - 408 & 408A 12 65780 OUTER BOOM - 408 1

65790 OUTER BOOM - 408A 13 72190 LIFT CYLINDER - 408 & 408A 24 66709 PIVOT PIN - 1.480 x 22 15 66701 PIVOT MOUNTING BRACKET 26 65712 .980 x 7 SNAP-RING GROOVE PIN 27 65714 .980 x 4-5/8 ROD PIN 28 65715 1.230 x 9-1/4 SNAP-RING GROOVE ROD PIN 19 65716 1.230 x 12-1/4 SNAP-RING GROOVE BASE PIN 110 65753 NYLATRON WEAR PAD 1/2 x 2-1/2 111 65759 SPACER SHIM PLATE - 408 1

65758 NYLATRON SHIM PAD - 408A 112 65779 1/4 x 2-11/16 PHENOLIC WEAR STRIP 413 812A5 BOLT 3/8 x 500 BUTTON HEAD ALLEN 214 81710 BOLT 7/8 x 2.250 615 83611 NUT 7/8 NYLON LOCK 616 86100I-1 SNAP-RING 1.00 INCH INTERNAL 417 86100E-1 SNAP-RING 1.00 INCH EXTERNAL 418 86125E-1 SNAP-RING 1.25 INCH EXTERNAL 419 72188 POWER TILT CYLINDER 1

Section V - PARTS408 WHEEL LIFT COMPONENTS

(STANDARD)

V-10

Section V - PARTS408 WHEEL LIFT COMPONENTS

(STANDARD)

V-11


1 59231 L-ARM CHANNEL BRACKET 22 59232R L-ARM MOUNTING BRACKET - RIGHT 13 59232L L-ARM MOUNTING BRACKET - LEFT 14 64357 PIN - .980 x 5.875 15 65816 INNER BOOM 16 64355 WEAR PAD 17 65515 CROSSBAR WELDMENT 18 65228 YOKE SPRING 19 65435 CROSSBAR PIVOT PIN 110 65245 REMOVABLE PAN 211 65250R WHEEL RETAINER - RIGHT 112 65250L WHEEL RETAINER - LEFT 113 65265R WHEEL GRID - RIGHT 114 65265L WHEEL GRID - LEFT 115 65280A RATCHET 216 65285 WHEEL STRAP 217 812A5 BOLT 3/8 x 1/2 ROUND ALLEN HEAD 118 82210 WASHER 3/8 FLAT 119 84911 5/16 SAFETY SNAP PIN 220 84921 T-PIN WITH LANYARD 221 86100I SNAP-RING 1.00 INCH INTERNAL 2

Section V - PARTS408A WHEEL LIFT COMPONENTS

V-12

Section V - PARTS408A WHEEL LIFT COMPONENTS

V-13

REF PART # DESCRIPTION QPU1 658202 INNER TUBE 12 72192 EXTENSION CYLINDER 13 69726 HOSE TRACK 14 65621 NYLATRON WEAR PAD 15 65286 BASKET STRAP - AUTO 2

65287 BASKET STRAP - TRUCK 26 69325 DETENT BALL 27 69320 DETENT SPRING 28 64304R RUBBER GASKET 29 64304C HOSE CLAMP PLATE 210 643572 PIN .980 x 5-7/8 111 644002 AUTOGRIP CROSSBAR WELDMENT 112 720152L L-ARM CYLINDER - LEFT 113 720152R L-ARM CYLINDER - RIGHT 114 727162 L-ARM CYLINDER MOUNTING BLOCK 215 83520 NYLON LOCK NUT 3/4-16 UNF 416 644432 L-ARM CYLINDER MOUNTING PIN 217 644292 CROSSBAR GRAVEL GUARD 218 697402L WHEEL CHOCK - LEFT 119 697402R WHEEL CHOCK - RIGHT 120 644452 L-ARM PIVOT PIN 221 644352L L-ARM - LEFT 122 644352R L-ARM - RIGHT 123 87440 L-ARM CHAIN 4

81127 5/16 x 1-1/4 SHOULDER SHCS 1/4-20 UNC 483105 1/4-20 UNC NYLON LOCK NUT 4

24 64441 L-ARM CHAIN CLEVIS 483411 NYLON LOCK NUT 5/8-11 UNC 481126 5/16 x 1 SHOULDER SHCS 1/4-20 UNC 483105 1/4-20 UNC NYLON LOCK NUT 4

25 64327 DETENT SCREW 226 644402 CROSSBAR PIVOT PIN 127 86250I RETAINING RING 2.50 INTERNAL 128 84921 5/8 T-PIN 2

Section V - PARTS512 UNDERLIFT COMPONENTS

V-14

Section V - PARTS512 UNDERLIFT COMPONENTS


1 667702 STANCHION 12 66780 OUTER BOOM 13 72105 LIFT CYLINDER 24 66709 PIVOT PIN - 1.480 x 22 25 66701 PIVOT MOUNTING BRACKETS 26 65718 .980 x 6-1/4 SNAP-RING GROOVE BASE PIN 27 65714 .980 x 4-5/8 ROD PIN 48 65715 1.230 x 9-1/2 SNAP-RING GROOVE ROD PIN 19 65716 1.230 x 12-1/4 SNAP-RING GROOVE BASE PIN 110 65612 NYLATRON WEAR PAD 1/2 x 2 x 3 211 65758 NYLATRON SHIM PAD 112 66779N 3/8 x 2-3/4 NYLATRON NSM WEAR STRIP 413 812A5 BOLT 3/8 x .500 BUTTON HEAD ALLEN 214 81710 BOLT 7/8 x 2.250 615 83611 NUT 7/8 NYLON LOCK 616 86100I SNAP-RING 1.00 INCH INTERNAL 417 86100E-1 SNAP-RING 1.00 INCH EXTERNAL 418 86125E-1 SNAP-RING 1.25 INCH EXTERNAL 419 72189 POWER TILT CYLINDER 1

V-15

Section V - PARTS512 WHEEL LIFT COMPONENTS AND HOOK-UP ATTACHMENTS

(STANDARD)

V-16

Section V - PARTS512 WHEEL LIFT COMPONENTS AND HOOK-UP ATTACHMENTS (STANDARD)

V-17


1 59235 L-ARM CHANNEL BRACKET 22 59236L L-ARM MOUNTING BRACKET - LEFT 13 5926R L-ARM MOUNTING BRACKET - RIGHT 14 64357 .980 x 5.875 PIN 15 65245 REMOVABLE PAN 26 65228 YOKE SPRING 17 66230 CROSSBAR EXTENSION - OPTIONAL 28 66245 CROSSBAR EXTENSION PIN - OPTIONAL 29 66430 CROSSBAR PIVOT PIN 110 66510 CROSSBAR WELDMENT 111 66815 INNER BOOM 112 66250L WHEEL RETAINER - LEFT 113 66250R WHEEL RETAINER - RIGHT 114 66260L WHEEL GRID - LEFT 115 66260R WHEEL GRID - RIGHT 116 665280A RATCHET 217 65285 WHEEL STRAP 218 66280 FRAME FORK HOLDER 219 66290 TWO INCH FRAME FORK 220 66300 THREE INCH FRAME FORK 2

66310 FOUR INCH FRAME FORK - OPTIONAL 221 66320 SPRING SHACKLE ADAPTOR 222 66330 ELEVATED FRAME FORK HOLDER 223 72196 EXTENSION CYLINDER 224 64355 WEAR PAD 225 84911 5/16 SAFETY SNAP PIN 226 84922 T-PIN WITH LANYARD - 3/4 x 3.50 227 84923 T-PIN - 3/4 x 6.50 228 86100I SNAP-RING 1.00 INCH INTERNAL 229 86200I SNAP-RING 2.00 INCH INTERNAL 2

Section V - PARTS512 WHEEL LIFT COMPONENTS AND HOOK-UP ATTACHMENTS (STANDARD)

V-17


1 59235 L-ARM CHANNEL BRACKET 22 59236L L-ARM MOUNTING BRACKET - LEFT 13 5926R L-ARM MOUNTING BRACKET - RIGHT 14 64357 .980 x 5.875 PIN 15 65245 REMOVABLE PAN 26 65228 YOKE SPRING 17 66230 CROSSBAR EXTENSION - OPTIONAL 28 66245 CROSSBAR EXTENSION PIN - OPTIONAL 29 66430 CROSSBAR PIVOT PIN 110 66510 CROSSBAR WELDMENT 111 66815 INNER BOOM 112 66250L WHEEL RETAINER - LEFT 113 66250R WHEEL RETAINER - RIGHT 114 66260L WHEEL GRID - LEFT 115 66260R WHEEL GRID - RIGHT 116 665280A RATCHET 217 65285 WHEEL STRAP 218 66280 FRAME FORK HOLDER 219 66290 TWO INCH FRAME FORK 220 66300 THREE INCH FRAME FORK 2

66310 FOUR INCH FRAME FORK - OPTIONAL 221 66320 SPRING SHACKLE ADAPTOR 222 66330 ELEVATED FRAME FORK HOLDER 223 72196 EXTENSION CYLINDER 224 64355 WEAR PAD 225 84911 5/16 SAFETY SNAP PIN 226 84922 T-PIN WITH LANYARD - 3/4 x 3.50 227 84923 T-PIN - 3/4 x 6.50 228 86100I SNAP-RING 1.00 INCH INTERNAL 229 86200I SNAP-RING 2.00 INCH INTERNAL 2

V-18

Section V - PARTSPIVOT WHEEL GRIDS AND L-ARMS4 - SERIES


1 659811L PIVOT WHEEL GRID-LEFT 12 659811R PIVOT WHEEL GRID-RIGHT 13 659820L PIVOT L-ARM RECEIVER GROUP-LEFT 14 659820R PIVOT L-ARM RECEIVER GROUP-RIGHT 15 659822 L-ARM RECEIVER CASTING PIVOT PIN 16 659830L LEFT ALUMINUM L-ARM 17 659830R RIGHT ALUMINUM L-ARM 18 AA009G RUBBER TENSION STRAP WITH S-HOOK 29 65286 BASKET STRAP-CAR 2

65287 BASKET STRAP-TRUCK 2

V-18

Section V - PARTSPIVOT WHEEL GRIDS AND L-ARMS4 - SERIES


1 659811L PIVOT WHEEL GRID-LEFT 12 659811R PIVOT WHEEL GRID-RIGHT 13 659820L PIVOT L-ARM RECEIVER GROUP-LEFT 14 659820R PIVOT L-ARM RECEIVER GROUP-RIGHT 15 659822 L-ARM RECEIVER CASTING PIVOT PIN 16 659830L LEFT ALUMINUM L-ARM 17 659830R RIGHT ALUMINUM L-ARM 18 AA009G RUBBER TENSION STRAP WITH S-HOOK 29 65286 BASKET STRAP-CAR 2

65287 BASKET STRAP-TRUCK 2

V-19

Section V - PARTSPIVOT L-ARM RECEIVER GROUP 4-SERIES(OPTIONAL)


1 659820L PIVOT L-ARM RECEIVER GROUP-LEFT 1659820R PIVOT L-ARM RECEIVER GROUP-RIGHT (SHOWN) 1

2 659821L PIVOT L-ARM RECEIVER CASTING-LEFT 1659821R PIVOT L-ARM RECEIVER CASTING-RIGHT (SHOWN) 1

3 659822 L--ARM RECEIVER CASTING PIVOT PIN 14 659826 PIVOT LOCK PIN 15 659827 LANYARD 16 85016 RIVET 17 81225 FLAT HEAD SOCKET CAP SCREW 3/8-16 UNC X 1/2 18 81226 TAPERED SOCKET CAP SCREW 1/2-13 UNC X 1/2 19 659824 7/8 CAM PIN 110 89100 CAM PIN SPRING 111 659825 T-HANDLE 112 84675 ROLL PIN 3/16 X 1 1

V-19

Section V - PARTSPIVOT L-ARM RECEIVER GROUP 4-SERIES(OPTIONAL)


1 659820L PIVOT L-ARM RECEIVER GROUP-LEFT 1659820R PIVOT L-ARM RECEIVER GROUP-RIGHT (SHOWN) 1

2 659821L PIVOT L-ARM RECEIVER CASTING-LEFT 1659821R PIVOT L-ARM RECEIVER CASTING-RIGHT (SHOWN) 1

3 659822 L--ARM RECEIVER CASTING PIVOT PIN 14 659826 PIVOT LOCK PIN 15 659827 LANYARD 16 85016 RIVET 17 81225 FLAT HEAD SOCKET CAP SCREW 3/8-16 UNC X 1/2 18 81226 TAPERED SOCKET CAP SCREW 1/2-13 UNC X 1/2 19 659824 7/8 CAM PIN 110 89100 CAM PIN SPRING 111 659825 T-HANDLE 112 84675 ROLL PIN 3/16 X 1 1

Section V - PARTS4 SERIES BOOM END SWIVEL


1 61366 BOOM END SWIVEL 12 69120 PULLEY - 6 INCH 13 61370 CABLE FOLLOWER 14 61364 PIN .750 x 3-1/8 15 86287E RETAINING RING 2-7/8 EXTERNAL 16 86075E RETAINING RING 3/4 EXTERNAL 27 82510 FLAT WASHER 3/4 X 1-1/2 x .120 28 82511 FLAT WASHER 3/4 X 1-1/2 x .060 2

V-20



1 61366 BOOM END SWIVEL 12 69120 PULLEY - 6 INCH 13 61370 CABLE FOLLOWER 14 61364 PIN .750 x 3-1/8 15 86287E RETAINING RING 2-7/8 EXTERNAL 16 86075E RETAINING RING 3/4 EXTERNAL 27 82510 FLAT WASHER 3/4 X 1-1/2 x .120 28 82511 FLAT WASHER 3/4 X 1-1/2 x .060 2

V-20

V-21



1 61369 BOOM END SWIVEL 12 69125 PULLEY - 6 INCH 13 61379 CABLE FOLLOWER 14 61368 PIN .980 x 3-5/8 15 86287E RETAINING RING 2-7/8 EXTERNAL 16 83611 NYLON LOCK NUT 7/8-9 17 82710 FLAT WASHER 1.00 X 1-1/2 x .120 28 82718 FLAT WASHER 1.00 X 1-1/2 x .060 2

V-21



1 61369 BOOM END SWIVEL 12 69125 PULLEY - 6 INCH 13 61379 CABLE FOLLOWER 14 61368 PIN .980 x 3-5/8 15 86287E RETAINING RING 2-7/8 EXTERNAL 16 83611 NYLON LOCK NUT 7/8-9 17 82710 FLAT WASHER 1.00 X 1-1/2 x .120 28 82718 FLAT WASHER 1.00 X 1-1/2 x .060 2

V-22

Section V - PARTSPINTLE HITCH GROUP


66370G PINTLE HITCH GROUP 11 66370W PINTLE HITCH WELDMENT 12 A3020 TOW BALL PINTLE HITCH 13 66378 RETAINING PIN 24 812A6 3/8 X 5/8 BUTTON HEAD BOLT 4

5A220 LANYARD 25 81428 BOLT 1/2-13 X 1.25 GRADE 8 2

SECURE WITH LOCTITE6 81449 BOLT 1/2-13 X 2.5 GRADE 8 27 83312 NUT NYLOK 1/2-13 2

V-22

Section V - PARTSPINTLE HITCH GROUP


66370G PINTLE HITCH GROUP 11 66370W PINTLE HITCH WELDMENT 12 A3020 TOW BALL PINTLE HITCH 13 66378 RETAINING PIN 24 812A6 3/8 X 5/8 BUTTON HEAD BOLT 4

5A220 LANYARD 25 81428 BOLT 1/2-13 X 1.25 GRADE 8 2

SECURE WITH LOCTITE6 81449 BOLT 1/2-13 X 2.5 GRADE 8 27 83312 NUT NYLOK 1/2-13 2

Section V - PARTS24 IN. STEEL TUNNEL BOX GROUP


122224

54845245484024546585485155465754863

24 INCH STEEL TUNNEL BOX WELDMENT24 INCH TUNNEL BOX DOORROTARY PADDLE LATCHTUNNEL BOX MOUNTING BRACKEGASKET - PADDLE LATCHTUNNEL BOX DOOR HINGE MOUNT

123456

V-23

Section V - PARTS24 IN. STEEL TUNNEL BOX GROUP


122224

54845245484024546585485155465754863

24 INCH STEEL TUNNEL BOX WELDMENT24 INCH TUNNEL BOX DOORROTARY PADDLE LATCHTUNNEL BOX MOUNTING BRACKEGASKET - PADDLE LATCHTUNNEL BOX DOOR HINGE MOUNT

123456

V-23

seriess manual 408, 408a, 410, 410a, 512 series installation, operation, maintenance & parts...

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