Miller Vulcan 810 NYC User manual

OWNER'S MANUAL
MODEL 810 NYC
INSTALLATION, OPERATION, MAINTENANCE & PARTS
NOTE: MANUAL including SPECIFICATIONS, subject to change without notice
All ratings specied are based on structural factors only,
not vehicle capacities or capabilities.
Miller Industries Towing Equipment Inc.
8503 Hilltop Drive FORM NO. 0501576
Ooltewah, Tennessee 37363 05 / 07
Phone [phone] • FAX [phone] PRICE $25.00

LIMITED WARRANTY
MILLERINDUSTRIESTOWING EQUIPMENT INC.,hereinafterreferredtoasMILLER,warrantstothe
original purchaser that each new MILLER wrecker or other MILLER products will be free from defects
in material and workmanship for a period of twelve (12) months from date placed in service, but in no
eventshallsuchwarrantyperiodexceedtwenty-four(24) months from date ofmanufactureby MILLER.
The purchaser must promptly notify MILLER in writing of any failure in material or workmanship. In no
event shall MILLER accept such notication later than twenty-four (24) months from date of delivery or
twelve (12) months from date placed in service, whichever is earlier.
MILLER's obligation under this warranty, statutory or otherwise, is limited to the repair or replacement
at the MILLER factory, or at a point designated by MILLER, of such part or parts as shall appear upon
inspection by MILLER to be defective in material or workmanship. New or remanufactured parts will
be used for any replacement at MILLER's option. This warranty is not transferable. This warranty does
not obligate MILLER to bear the cost of labor or transportation charges in connection with the repair
or replacement of any parts found to be defective, nor shall it apply to a product upon which repairs or
alterations have been made unless authorized by MILLER.
EXCEPTASEXPRESSLYSETFORTHINTHISWARRANTY,MILLERMAKESNOOTHERWARRANTY,
EXPRESS OR IMPLIED, AND HEREBY DISCLAIMS ALL OTHER WARRANTIES INCLUDING, BUT
NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE. MILLER shall in no event be liable for claimed downtime, claimed loss of
prots or goodwill, or any other special, incidental, indirect, or consequential damages concerning or
relating to any product or parts, whether based on negligence, strict liability, breach of contract, breach
of warranty, misrepresentation or any other legal 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 IMPLIED, AS TO THE FINISHED PRODUCTS
MANUFACTUREDORSUPPLIED BYANOTHER MANUFACTURERANDSUPPLIED BYMILLERTO
PURCHASER, including, but not limited to, any vehicle to which a MILLER product may be afxed or
anyaccessoriesorwirerope,andMILLEREXPRESSLYDISCLAIMSANYIMPLIEDWARRANTIESOF
MERCHANTABILITY OR FITNESS FORAPARTICULAR PURPOSE ASTO SUCH EQUIPMENT OR
PRODUCTS. This language shall in no way affector diminish the rights of the purchaser to rely on such
warranties as are extended by such manufacturers or suppliers. MILLER shall, to the extent permitted
under applicable law, pass on to the purchaser such manufacturer's or seller's warranty.
MILLER, whose policy is one of continuous improvement, reserves the right to improve its products
through changes in design or materials as it may deem desirable without being obligated to incorporate
suchchanges in productspreviouslysold.Thiswarranty is notintendedto cover orincludethe following
items, which are set forth by way of example and not limitation:
A. Normal deterioration of trim, paint, lettering, and appearance items due to wear or exposure to
weather, road conditions, road treatments, etc.
B. Any damage or defect due to accident, misuse, abuse, improper or unauthorized repairs, failure
to provide reasonable and necessary maintenance, or uses for which the equipment was not
designed or intended.
C. Alterations or modications that affect performance, operation or reliability.
D. Normal maintenance parts including, but not limited to, wear pads, bushings, wire rope, mud
aps, fenderettes, light bulbs, hydraulic oil, lters, and tow sling belts.
IT IS EXPRESSLY UNDERSTOOD THAT MILLER MAKES NO IMPLIED WARRANTY THAT MILLER
PRODUCTS SHALL BE FIT FOR THE PURPOSE OF LIFTING OR MOVING PEOPLE OR FORANY
OTHER IMPROPER USE.
SERIAL NUMBER
Miller Industries Towing Equipment Inc.
8503 Hilltop Drive
Ooltewah, Tennessee 37363
Telephone [phone]

i
OWNER, USER AND OPERATOR:
Miller Industries Towing Equipment Inc. appreciates your choice of
our wrecker for your application. Our number one priority is user
safety which is best achieved by our joint efforts. We feel that you
can make a major contribution to safety if you, as the equipment
owner and operator:
1. Comply with Federal, 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
Wrecker.
Also contained in this manual is a Parts Section for your Wrecker.
Use of other than Factory or Factory Authorized Parts will render the
Warranty void.
© 2007 MILLER INDUSTRIES TOWING EQUIPMENT INC.All rights reserved. Reproduction
or use, without express permission, of editorial or pictorial content, in any manner, is
prohibited.

ii
TABLE OF CONTENTS
The operator must read and understand
all instructions in this manual
before operating the wrecker.
It is assumed by Miller Industries that the Owner/Operator has thorough
knowledge of the accepted and lawful retrieval and towing methods as
dictated by his city, 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 - SPECIFICATIONS ...............................................II-1 thru II-4
Section III - OPERATIONAL FUNCTIONS
WRECKER ......................................................................III-1 thru III-4
WHEEL LIFT ..................................................................IIIA-1 & IIIA-2
Section IV - OPERATING INSTRUCTIONS
WRECKER .....................................................................IV-1 thru IV-3
WHEEL LIFT ........................................................... IVA-1 thru IVA-18
Section V - MAINTENANCE ................................................ V-1 thru V-9
Section Vl - PARTS
SUBFRAME ASSEMBLY ...............................................VI-2 thru VI-5

iii
TABLE OF CONTENTS (cont'd)
Section Vl - PARTS (cont'd)
BODYASSEMBLY .........................................................VI-6 thru VI-9
RECOVERY BOOM ASSEMBLY ...................................VI-10 & VI-11
WHEEL LIFT BOOM ASSEMBLY ..................................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-24
BOOM SWIVELASSEMBLY .......................................................VI-25
MISCELLANEOUS KIT PARTS .....................................VI-26 & VI-27
Section VII - SCHEMATICS
ELECTRICAL ...............................................................................VII-1
HYDRAULIC ROUTING ...................................................VII-2 & VII-3

NOTES

I-1
Section I - SAFETY PRECAUTIONS
Presented in the interest of safety for all wrecker operators.
NOTICE
You are obligated to operate your
wrecker safely. You can be held
legally responsible for injuries or
damages resulting from unsafe
operating practices.
The manufacturer's recommendations
for operating this wrecker can help
you avoid unsafe practices and their
bad consequences. These
recommendations are contained
in this manual.
Miller Industries is not responsible for
the results of any unsafe practice of
wrecker operators. Furthermore, the
division is not responsible 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 can
be dangerous, too! The danger threatens wrecker operators
and everyone close at hand. As a wrecker operator you must
develop an awareness of the hazards involved. You must use
every safeguard within reason to prevent injuries.
For each step in operating your wrecker develop the habit
of asking yourself if it is safe to proceed. Carefully check all
rigging (especially snatch blocks) before starting a heavy lift
or pull.
We cannot warn you of all the possible dangers you will
encounter. But we will tell you of the most common hazards
we know about. Learn them well.

I-2
Section I - SAFETY PRECAUTIONS (cont'd)
1.1 Improper use of this equipment can be dangerous! Incorrect operation
can result in bodily injury to the operator and bystanders. Therefore, a
thorough understanding of the "operating principles" and "operating
instructions" as found in this manual is essential.
1.2 Study each job to be done. Apply common sense judgment to assure
safety to yourself and bystanders.
1.3 Plan ahead. Work safely. Avoid accidental damage and injury. If an
accident or fire does occur, react quickly with the tools and skills at
hand.Know howto usea firstaid kit anda fireextinguisher -and where
to get assistance.
1.4 Read and understand the following instructions.
1. READTHEMOUNTING/OPERATING/MAINTENANCEMANUALFOR
WARNINGS AND PRECAUTIONS.
2. NEVER TAKE ANYTHING FOR GRANTED. DON'T ASSUME THAT
EVERYTHINGISALLRIGHTATTHESTARTOFWORKTODAYJUST
BECAUSE EVERYTHING SEEMED ALL RIGHT AT THE END OF
WORK YESTERDAY. BEFORE BEGINNING OPERATION,
THOROUGHLY INSPECT THE ENTIRE WRECKER TO BE SURE IT
IS IN GOOD OPERATING CONDITION.
3. VISUALLYINSPECTTHEWRECKERFOREVIDENCEOFPHYSICAL
DAMAGE,SUCHASCRACKING,BENDING,ORDEFORMATIONOF
PLATES OR WELDS. INSPECT CAREFULLY FOR CRACKING OR
FLAKINGOFPAINT,WHICHMAYINDICATEADANGEROUSCRACK
INTHESTRUCTUREBENEATH.DONOTOPERATEUNTILREPAIRS
ARE MADE.
4. LOOSE OR MISSING HARDWARE, BOLTS, NUTS, AND PINS
SHOULD BE PROPERLY TIGHTENED OR REPLACED WITH
MANUFACTURER'S SPECIFIED HARDWARE.
5. CHECK FOR FLUID LEAKS. HYDRAULIC SYSTEM LEAKS MUST
BECORRECTEDBEFORETHEWRECKERISOPERATED.INSPECT
ALL HYDRAULIC HOSES, ESPECIALLY THOSE WHICH FLEX

I-3
Section I - SAFETY PRECAUTIONS (cont'd)
OR MOVE IN SERVICE, AND REPLACE IF NECESSARY. SECURE
ALL CAPS AND FILLER PLUGS FOR ALL SYSTEMS.
6. YOUR CLOTHING SHOULD BE RELATIVELY CLOSEFITTING.
7. ALWAYSWEARPROTECTIVEITEMSSUCHASSAFETYGLASSES,
GLOVES, REFLECTIVE CLOTHING AND SAFETY SHOES.
8. BEFORE OPERATING THE BOOM, REFER TO THE BOOM
CAPACITY LABELS ON THE BOOMAND INSIDE OF THE DOOR OF
THE CAB AND IN THE SPECIFICATION SECTION OF YOUR
OPERATING MANUAL. FOR CHASSIS CAPACITYCONSULT YOUR
TRUCK DEALER. NEVER EXCEED MANUFACTURER'S LOAD
RATING. THE STIPULATIONS PERTINENT TO THESE RATINGS
SHALLALWAYS BE CAREFULLY OBSERVED.
RATINGS SHOWN ARE BASED ON THE HYDRAULIC,
MECHANICAL, OR STRUCTURAL DESIGN OF THE WRECKER
RATHER THAN STABILITY. IT IS ALWAYS UNSAFE TO APPLY ANY
LOAD WHICH IS GREATER THAN RATED LOAD SHOWN ON THE
DATA PLATE.
9. DO NOT USE THIS EQUIPMENT EXCEPT ON SOLID, LEVEL
SURFACEWITHSTABILIZERSPROPERLYEXTENDEDANDTRUCK
BRAKES LOCKED.
10. OPERATE ALL CONTROLS SLOWLY AND SMOOTHLY TO AVOID
DAMAGE TO WRECKER OR INJURY TO PERSONNEL.
11. DO NOT OPERATE, WALK OR STAND BENEATH BOOM OR A
SUSPENDED LOAD.
12. NEVER LIFT LOAD OVERANYONE.
13. DO NOT USE BOOM TO LIFT PEOPLE.
14. KEEP LOAD WITHIN ONE FOOT OF THE GROUND WHENEVER
POSSIBLE.
15. FOR TRAVEL, BOOM MUST BE IN STOWED POSITIONAND P.T.O.
DISENGAGED.

I-4
Section I - SAFETY PRECAUTIONS (cont'd)
ONLY AUTHORIZED AND TRAINED PERSONNEL
SHOULD BE PERMITTED TO OPERATE THIS WRECKER
UNSUPERVISED.
TRAINED PERSONNELARE THOSE WHO HAVE WORKED
UNDER EXPERIENCED SUPERVISIONAND HAVE
PERFORMED ALL WRECKER MANEUVERS, HAVE READ
THE MOUNTING, OPERATING AND MAINTENANCE
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 ATA SITE WHERE ELECTRIC
POWER LINES, IRREGULAR GROUND CONTOUR,
WATER, ICE, MUD, OR OTHER CONDITIONS CAN
INTERFERE WITH ORDINARY CAREFUL OPERATION OF
THIS WRECKER.
AN UNTRAINED OPERATOR SUBJECTS HIMSELF AND
OTHERS TO DEATH OR SERIOUS INJURY.
USE SAFETY CHAINS ON ALL TOWING
AND LIFTING APPLICATIONS!

I-5
Section I - SAFETY PRECAUTIONS (cont'd)
SAFETY TIPS
Death or serious injury can
occur when working near
power lines.
Learn - beforehand - as
much about your working
area as possible. Be sure
that exact locations of
overhead power lines, and
other obstructions or
hazards are 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
EMERGENCY FIELD
TEMPORARY REPAIR.
Use at least three clips spaced
3-4 inches apart and reduce the
cable working limit by 20%.
U-bolt of the clip should never be
around the live or long end of the
cable. Replace clips as soon as
possible with swaged cable
termination.

I-6
Section I - SAFETY PRECAUTIONS (cont'd)
SAFETY TIPS
Proper technique for using wire rope clips.
USECABLE CLIPSONLYINTHE EVENTOFANEMERGENCYFIELD
TEMPORARY REPAIR.
RIGHT
WAY
WRONG
WAY
1. Turn back rope length specified in the chart. Apply first clip so U-bolt
isnolessthanthesaddlewidthfromthedeadend.Tightennutsevenly
and torque as specified.
2. Apply next clip as near loop as thimble will permit. Turn nuts on firm,
but do not tighten.
3. Spaceadditionalclipsasindicatedsodistancebetweenclipsisequal.
Tighten all nuts evenly and torque as specified.
4. Apply the initial load and retighten all nuts to recommended torque.
Inspect periodically and retighten as needed to the recommended
torque.
CLIP MINIMUM AMOUNT OF ROPE TORQUE
SIZE NUMBER TO TURN BACK IN FT.LBS.
(INCHES) OF CLIPS IN INCHES
3/8 2 6 1/2 45
7/16 2 7 65
1/2 3 11 1/2 65
9/16 3 12 95
5/8 3 12 95
3/4 4 18 130
This table is based on Crosby-Laughlin.

I-7
Section I - SAFETY PRECAUTIONS (cont'd)
SAFETY TIPS
Don't use a wrecker that has
not been properly maintained.
Pay special attention to wrecker
mounting bolts, cable condition,
and lubrication of moving parts.
After rigging 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 vehicles, regardless of
distance.
Don't use damaged cables on
your wrecker. Become familiar
with the various types of cable
damage and carefully inspect all
cables being used in a recovery
operation before starting to pull.

I-8
Section I - SAFETY PRECAUTIONS (cont'd)
SAFETY TIPS
Don't expect your wrecker to tow
loads equal to the wrecker rating.
Wrecker ratings apply to loads
imposed during recovery, with the
wrecker properly stabilized.
Don't pull a load 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
amountofpullthatwillberequired.
Rig to keep the estimated amount
of pull well within equipment
ratings.
Don't exceed ratings of booms,
cables, snatch blocks, or winches.
Stay within nameplate ratings.
Note that boom ratings decrease
significantly as a boom is
extended.

I-9
Section I - SAFETY PRECAUTIONS (cont'd)
SAFETY TIPS
Don't disengage the winch drum
clutch while the winch cable is
loaded.
Don'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 only for selecting
replacement cable.
Don't get under a raised vehicle or
load unless it has adequate safety
blocks in place.

I-10
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.

I-11
Section I - SAFETY PRECAUTIONS (cont'd)
SAFETY TIPS
Don't travel with the wrecker
Clutch pump engaged. Engage it
only while operating the wrecker
controls.
Afteryouhavehookedupavehicle
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 towing dolly, don't
exceed the speed recommended
for the dolly.
Don't tow a vehicle that reduces
the weight on the front wheels
of your wrecker more than 40
percent.

I-12
Section I - SAFETY PRECAUTIONS (cont'd)
SAFETY TIPS
Don't tow a vehicle at night without
proper signal lights on the towed
vehicle and the wrecker.
Don't tow a vehicle 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 unless steps have been
taken to protect its transmission
and differential. Follow the
recommendations of the vehicle
manufacturer. As an alternative,
use a towing dolly.

I-13
Section I - SAFETY PRECAUTIONS (cont'd)
SAFETY TIPS
STRAPS PLUS SAFETY CHAINS
Wheel lifts 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 against the
boom end.
Don't use wrecker flashing lights
except under conditions permitted
by law.

I-14
Section I - SAFETY PRECAUTIONS (cont'd)
SAFETY TIPS
Without straps, a 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 straps, the towed vehicle
may bounce free when crossing a
speed bump or dip.