Jerr-Dan LIGHT DUTY, Operation, Maintenance And Parts Manual

Page 1: ...DUTY OPERATIONS MAINTENANCE AND PARTS MANUAL lBRR DAN 1m Oshkosh Corporation Company 1080 Hykes Road Greencastle PA 17225 Phone 717 597 7111 www jerr dan com 7 50 E a s t e r n W r e c k e r S a l e s...

Page 2: ...Eastern W recker Sales Inc...

Page 3: ...Wheelgrid Assembly 4 19 Lo Profile Hydraulic Towbar Wheel grid Assembly 4 22 Hydraulic Components 4 23 Hydraulic Components Hydraulic Towbar 4 26 Hydraulic Components Hydraulic Towbar wi1h IRL 4 27 Ug...

Page 4: ...Eastern Wrecker Sales Inc...

Page 5: ...iers This warranty is designed for the most comprehensive protection of your specific equipment WHEEL LIFT The Jerr Dan one year warranty covers material and workmanship including the following I Body...

Page 6: ...e PA 17225 Be sure to include your daytime phone number 3 Authorization lor repairs under this limited warranty will be provided by telephone within 24 hours of receipl of valid warranly claims 4 This...

Page 7: ...ctlJ er s s vice manuals or with other than parts ac c sorils Of allacrm rts authorized by Mam llaeturer lor use In Its products aJSlomer shall pay ler all such repairs or parts without r8OOUl S8 agai...

Page 8: ...blM B The d8a1er nama from whom it was C The Menufacturat ri MriaJ nlmb r D Taleophonltrunber of party making the repairs E The part runbeB nelKled to mBka pai F Owner to be lnformMf of C O D on palla...

Page 9: ...ety SlanclardsIn effect lit __ mo __ yr VEHICLE IDENTIFICATIONNUMBER VEHiClE TYPE _ I This certificaUon sticker appears on every JerT Oan unit mounled on 8 new c tlassls and Is required by law Jan Dan...

Page 10: ...Eastern Wrecker Sales Inc...

Page 11: ...T A A placard located on the headboard 01the deck and become famDiar with the loads that your unit can salely transport 3 Observe all waming decals 4 Make sure you are clear 01 oncoming traffic Dual...

Page 12: ...rom the rear with load in line of winch 8 Always try to winch from the center 01the load 9 Maintain winch cable In good condition Replace when worn kinked or frayed Do not use cable clamps 1 1 Rev _ O...

Page 13: ...nly on the deck Do not concentrate the load on one section of the deck to the rear of the truck axles or use tow bar wheel lift without a load on the deck l 12 Secure cargo to the deck at both the Iro...

Page 14: ...5 Read and follow tow bar instructions for proper towing 16 Do not exceed tow bar wheellift ratings Overloading can cause unsafe steering and braking conditions 17 Always use both wheel straps on whee...

Page 15: ...ling 20 Review operato s pre transport checklist located on the headboard 01 the deck each time you move a vehicle 21 Block up deck before performing any service or maintenance work under deck Rev _ 1...

Page 16: ...L _ _ r l _ T _ e o z I ill m m m d b E 1moL j EREI DAN Iorr l Il __ e r STANDARD DECAL LEFT SIDE t u e onofriOWl f JERR DAN _ r r _ _ I _ _ _ n _f _ _ _m _ CH ll ltoVlM s RR DAN DlClmnlllOIU IllEATES...

Page 17: ...RAULIC OIL LEVEL SERIAL NUMBER MAN Jl C1UREO 6 1 JS UU Vlll C I CA lLI rlNN t I 1 H ll 1 NO S L NO O Jll NO MANUFACTURED BY JERR DAN CORPORATION MFG UNDER ONE OR MORE OF THE FOLLOWING PATENTS 3 430 79...

Page 18: ...RESPONDING BDOM LUGS PRIOR TO LEAVING LOADING SITE WHEEL LIFT WARNING a WARNING i VEHICLE MUST BE SECURED TO WHEEl GRID USING BOTH TIE DOWN STRAPS PRIOR TO lEAVING lOADING SITE WHEEL LIFT WARNING WARN...

Page 19: ...Eastern W recker Sales Inc...

Page 20: ...Eastern W recker Sales Inc...

Page 21: ...Ollbackcontrol first handle In control box 4 Tilt control second handle In control box 5 Winch control third handle In control box 6 Tow bar Extend Retract fourth handle In control box 7 Tow bar Raise...

Page 22: ...pointer with the red control handle 2 I Q Ag j 4 Roll Raisethe roll handle and the deck will slide back Continue this operal on until the approach plate of the deck has contacted the ground Make sure...

Page 23: ...e is not intended to tie down load Always winch load onto deck never drive a vehicle onto the tilted deck Make sure that the load is side to side centered Remain clear of load when winching onto deck...

Page 24: ...It completely C Operating the Winch 1 Raise the winch control handle to power unreel the cable while a second person keeps the cable taut NOTE II a one man operation exists disengage the spool and un...

Page 25: ...pproximately 12 feet fror desired position of vehicle being unloaded ta Set the parking brake I b With the engine running engage the PTO per instructions in th truck cab Ie Set the auxiliary throllie...

Page 26: ...plate has contacted the ground Make sure that the rear bumper and the approach plate are both in firm contact with the ground before unloading There should be an equal weight distribution between the...

Page 27: ...bar straps arE used it may be necessary to shorten them by wrapping therr around the hitch bar and reconnecting chain 5 6 Level the main deck and check for adequate wheel clearancE under towed vehicl...

Page 28: ...racted CAUTION Always use safety pin while tow bar is being used to prevent damage to vehicles in the event of a hydraulic failure CAUTION The tow bar option is designed for the transport of a second...

Page 29: ...bout 1 1 2 from the ground and swing the cross bar parallel to the tires 2 Set the truck s parking brakes 3 Confirm the truck s position In relation to the vehicle to be towed Three 3 to four 4 feet i...

Page 30: ...r carriage parts are cleared and that the front portion of the grid is in contact with both tires Lower the grid fully to the ground There I no reason for the operator t get under the vehicle 9 Visual...

Page 31: ...ulically controlled 11 After securing the grid arm around the towed vehicles tires and before making the actual lift check to be sure the towed vehicle s parking brake Is released the transmission is...

Page 32: ...adsurfaces into consideration Observe the lift function from the side and away from both vehicles If possible 17 Power retract the grid boom until the towed vehicle is about 3 to 4 feetlrom the back 0...

Page 33: ...straps USING THE RACHET SPOOL MECHANISM 1 First the spool must be set into free spoo This is done by pulling the lock bar out and swinging the handle upward until It rests In the free spool notch and...

Page 34: ...rid to the towing position RE TIGHTEN THE RACHET PERIODICAL LY AS TIRE SETTLES IN GRID FROM TOWING 1 With the vehicle lifted just barely off the ground attach the strap to the wheel grid Be sure the r...

Page 35: ...ny leaJcage Use 5W20 Dual Renge hl d aullc 011 AulomaUc transmission nuld may be used In tile hydraulic system necessary The proper 011level Is best checked by roiling 1Ile deck back enough to gain ao...

Page 36: ...II prevent spoiling or straaJdng To help keep lila surface clean III pro1ect Iha Inlsh fiom minor scratches or abrasion and to ladutale later cleaning a coat of non abraslve liquid or paste wax such a...

Page 37: ...lIll Tl T mJNIIEJl lUBE llPG WIICIt BE llPG I SUD B1OCKS COAl llPG PlVlI1 LUBE llPG l VN vtSPOOLS 1WIl 0I EMG1MEOll O 0 WODDSlRlP COAl 01 7 lIOTOUlJ COAL MI G my I If fD IlESERVOIR Ct tK 1 11 f UII Bl...

Page 38: ...gaugo dons b Broken reDelspring b Inspect and replace Valvo handk sslick Insufflclanllubrlcation a Lubricala par ka chart Iig1t or frozen b Brokan cenlorlng spmg or b Inspect cIoan or raplaca clogged...

Page 39: ...eil filter C ChJan or reptace d Restriction In Iuetion line d Remcwe Pump _ DO long to a Low on supply a FlU10proper level respond Ol sis 10 reo b _ relief valve pres b ReGelto correcI selling u pOnd...

Page 40: ...Eastern W recker Sales Inc...

Page 41: ...ll your nearest Jerr Dan Distributor or call 800 876 1415 for further information Give Sales Order No Serial No and Model No along with part number and description of part 4 0 Rev Date j E a s t e r n...

Page 42: ...ad C pscrew 2 Aluminum Decks Only 18 7660162301 Flanged Locknut 2 AluminumDocks Only 19 4706000989 Plate Aluminum Decks Only 2 20 3178000136 Bracket Weldment 1 21 48060000112 Shah 2 22 7754000022 Rota...

Page 43: ...w 6 o o o C b m C D co 1I l I l o E a s t e r n W r e c k e r S a l e s I n c...

Page 44: ...WRANGLER UTE DECK 34 33 J 35 34 32 1 31 36 h 37 29 Ir 38 41 39 40 375 0000B3 REV O 13 21 14 4 1 20 23 21 Rov _ Ooto _ Eastern W recker Sales Inc...

Page 45: ...Asssmbly 2 22 7391000003 Klik Pin 2 23 7254000002 End Cap 4 24 711816 025 Bolt 16 25 7269000002 Post 8 26 7 1116 051 Bolt 10 27 40620000024 Retaining Plate 10 28 7660162100 Wing Nut 10 29 7111141407...

Page 46: ...9 Plata Aluminum Decks Only 2 20 3178000136 Bracket Wektment 1 21 48060000 II Shalt 2 22 77S4000022 Retaining Ring 8 23 4806000014 Shalt 1 24 4806000015 Shalt 1 25 4912000087 Roner Tube 2 26 720900001...

Page 47: ...w 6 o o o c m 6 0 0 I I o 6 m 4 m o m E a s t e r n W r e c k e r S a l e s I n c...

Page 48: ...N w a o o o o b n c a 0 N r D N N E a s t e r n W r e c k e r S a l e s I n c...

Page 49: ...d 5crow 9 7860160000 Look Woohor 9 7660160000 Ha Nut 8 3655184002 8recket I 7690000009 ClearanoeUgh Red 4 Stop Turn Tall Lamp 2 7590000011 Work Light 2 7690000007 80r Light 1 7780141066 Sall Tepplng S...

Page 50: ...4 9 Aev l Date 07 01 95 Eastern W recker Sales Inc...

Page 51: ...0 Y 11 41 if I j _ I J I 27 I 1 30 20 I 26 21 IV x J Y i0 I 28 lf Ob 1 i 5 34 _ 2 b A I 1 7 14 6 J 11 33 32 1y3128 o 34 3 29 207 j _ 2 1 7 h r ft22 23 27 6 24 25 26 12 cz 15 14 6 376 000073 REV 3 4 10...

Page 52: ...4 I w II o o o o i G G III II C 7 r I L E a s t e r n W r e c k e r S a l e s I n c...

Page 53: ...151250 Hex Head Capscrew 1 9 7950150161 Flat Washer 1 10 7660152600 Locknut 1 11 4691000042 Pin 1 12 7440030000 Grease Rtting 1 13 3556000006 Tow Hitch 1 14 3691000026 Hitch Pin 1 15 7660261630 Locknu...

Page 54: ...Rat Washer 1 11 7440000200 Grease FItting 45 1 12 3691000097 Pin Weldment 1 13 7691000001 Hair Pin 1 14 7291000003 Female Rec eptac le 1 15 7111140613 Truss Head Sc rew 2 16 7950140161 Rat Washer 2 1...

Page 55: ...J1 w N N e I I I o L __j J1 N o r N w N C D CD c o o o o CD n m F E a s t e r n W r e c k e r S a l e s I n c...

Page 56: ...a 3 o 1 1 t li I I 10 I uo z 5 Q 3 c C 10 C l l 1 N III III to a o t w a o o o o n t n E a s t e r n W r e c k e r S a l e s I n c...

Page 57: ...1000019 7115171050 7660172600 7262000020 3913000043 4495000007 Description Outer Tube Weldment Tow Bar Cylinder Inner Tube Weldment Pin Weldment Retaining Ring Pin Weldment Pin Weldment Hex Head Capsc...

Page 58: ...50140152 7661000019 7115171050 7660172600 7262000020 3913000043 4495000007 Description Outer Tube Weldment Tow Bar Cylinder Inner Tube Weldment Pin Weldment Retaining Ring Pin Weldment Pin Weldment He...

Page 59: ...6 o o o CIl i 6 N W r N N w N o E a s t e r n W r e c k e r S a l e s I n c...

Page 60: ..._ N w a N o o g C l o J 17 I iii l If I I i i J t 1 __ l III e E a s t e r n W r e c k e r S a l e s I n c...

Page 61: ...7440030000 3551000026 4691000188 7843000006 4254000006 4763000184 Description Qty Hitch Pin 2 TIe Down Strap 2 L Arm 2 R H Grid Weldment 1 L H Grid Weldment 1 Anchor Bracket 2 Button Head Capscrew 2...

Page 62: ...001 7118182418 7950180153 7660181630 4120000011 3500880062 7440030000 3551000026 4691000188 7843000006 4254000006 4763000184 Description Oty Hitch Pin 2 TIe Down Strap 2 L Arm 2 R H Grid Weldment 1 L...

Page 63: ...U1 a en W __ l l U1 en C1 c C1 g o g Ol D m E a s t e r n W r e c k e r S a l e s I n c...

Page 64: ...HYDRAULIC COMPONENTS 6 7 ROLLBACK CYL 1 18 23 24 22 WINCH 13 14 21 19 15 4 16 R TILT CYL 7 7 17 2 5 10 10 9 Rev _ Date 6 376 000079 REV 3 4 23 Eastern W recker Sales Inc...

Page 65: ...3 Straight Adapter 4 12 7445060637 Tee 2 13 7470000002 Gauge 1 14 7430000003 Filter Assembly 1 15 7431000001 Filter Element 1 16 Fitting 17 Return Hose 1 18 Suction Hose 1 19 Pressure Hose 1 20 Fittin...

Page 66: ...er 6 12 7445060637 Tee 2 13 4567122040 Towbar Supply Hose 2 14 7470000002 Gauge 1 15 7430000003 Riter Assembly 1 16 7431000001 Riter Element 1 17 Fining 18 Return Hose 1 19 Suction Hose 1 20 Pressure...

Page 67: ...I I 20 5 7 7 8 I I I I 2 24 25 I I L TILT 9 P17 tF bbbdJ T1LTVA OV i KOUT 0 I I 21 1 19 7 4 WINCH I l I I llj f 33 I 7 32 27 R T II T CYL 14 15 30 31 33 7t41T WK 1817 16 V 34 Y W L TOWBAI EXT 22 23 1...

Page 68: ...o W L TOWBAR EXT 2 ROLLBACK CYL 7_ 7 J 24 _ 5 6 8 13 37 1 I qCIEt o W L TOWBAR LIFT L TILT CYL 25 TILT LOCKOUT I 23 VALVE 3 10 I I I I 7_______ 1 4 WINCH I I 3 12 14 7 7 36 I 31 R TILT CYL 18 19 34 22...

Page 69: ...0 Towbar Base Hose 1 14 7445060643 Straight Adapter 3 15 7445060672 900 Elbow 2 16 4567122043 Towbar Lift Hose 2 17 7443000030 Tee 2 18 7470000002 Gauge 1 19 7430000003 Filter Assembly 1 20 7431000001...

Page 70: ...7950140161 Flat Washer 2 12 7590000012 Light 2 13 7552000005 Wiring Harness 1 14 7552000007 Wiring Harness Units 1 without Emergency Lights 7552000006 Wiring Harness Units 1 with Emergency Lights 15...

Page 71: ...LIGHTS AND WIRING Eastern W recker Sales Inc...

Page 72: ...N w 0 It o o o o It Il Il 0 0 7 7 7 U I I _ D I_ I U1 I X 111 D IMlt 1 I I II I I 111 _ w I I Q L __J v n I I I I L I L I E a s t e r n W r e c k e r S a l e s I n c...

Page 73: ...000 7796000008 7754000002 7660262031 7755334609 7755224609 7754000026 Description Barrel I A 102 381 Rod A 109 501 Piston Head Ring Wear Ring Wear Seal Piston Seal Rod 0 Ring 0 Ring Seal Rod Wiper Rin...

Page 74: ...eal Piston T 1 8 7796000024 Seal Rod 1 9 7755224000 0 Ring 1 10 7755334000 0 Ring 1 11 7796000008 Seal Rod Wiper 1 12 7754000002 Ring Retaining 1 13 7660262031 Locknut 1 14 7440000000 Fining Grease 1...

Page 75: ...U1 to U1 o U1 D m C Il CD _ r 7 r 7 Jl j 1 7 I _ i i Wi Jl QS 1 I _ 1 QJ I 1 en w 1 1 I enl _ Jl al 1 1 fJ _ 1 I lJ 0 1 1 1 o 1 L L L Eastern W recker Sales Inc...

Page 76: ...Ql a o Eastern W recker Sales Inc...

Page 77: ...754000025 Ring Retaining 1 Available only in service kit 7577250023 PARTS LIST TOW BAR CYLINDER 3320000020 Ref No Part No Description Qty 1 3071000020 Barrel 1 2 3763000035 Rod 1 3 4698000007 Piston 1...

Page 78: ...96000008 7754000002 7754000003 7754000004 7660262031 7755334609 7755224609 7754000026 Description Barrel Rod Piston Head Seal Piston T 0 Ring 0 Ring Seal Rod Seal Rod Wiper Ring Retaining Ring Wear Ri...

Page 79: ...N r il_ w 0 i V1 _Y J w i Id _ N i 0 _ _ I I1l L__ Jl 1 Jl L L _____ 1 _ I C U 01 II S Eastern Wrecker Sales Inc...

Page 80: ...ell ell co a c Cll M w a M It o 8 It M It Eastern Wrecker Sales Inc...

Page 81: ...0024 7755224000 7755334000 7796000008 7754000002 7660262031 7440000200 7440000000 7755334609 7755224609 7754000026 Description Barrel Rod Piston Head Ring Wear Ring Wear Seal Piston T Seal Rod 0 Ring...

Page 82: ...19 414045 Copscrow 1 4 2ONCx718 LG 4 20 414279 Copscrow 318 16NCx314 LG 2 21 414282 Cop crow 318 16NCxl 1 4 LG 6 22 414842 Copscrow 114 20NCxl 314 LG 4 23 414952 Capsc rew 1 2 13NCxl 112 LG 2 24 41603...

Page 83: ...C rJ 10 10 Cll E 0_ z 0 It i CtI tI 5 m Cl5 mill r E a s t e r n W r e c k e r S a l e s I n c...

Page 84: ...WINCH ASSEMBLY 8000 PLANETARY GEAR 4 43 Rev Dale Eastern W recker Sales Inc...

Page 85: ...k Hsg Relief Fitting Motor Hvdraulic For Model with CounterbelencB Valve Motor Hvdraulic 1 For Model without Counterbalance Valve O Ring 1 Quad Ring 2 O Ring 1 Reducer 1 Pipe Plug 2 Spirol Pin 1 Plug...

Page 86: ...ding 2 15 7590000087 Light 2 16 7690151200 Clevis Pin 18 17 7690021610 Cotler Pin 18 18 4763000123 Control Rod 18 19 3763000050 Control Rod 18 20 3551000013 Handle Weldment 2 21 3551000001 Handle Weld...

Page 87: ...RTL DUAL CONTROLS 10 19 9 J 11 16 l i1 I n I p I 14 11 21 Rev 2 Date 11 16 97 4 46 Eastern W recker Sales Inc...

Page 88: ...350011HYDRAULIC WHEEL LIFT TOW BAR WITH InL ZOO 28 1J I 27 4 47 22 21 Rev 2 Date 11 16 97 Eastern W recker Sales Inc...

Page 89: ...691000073 Pin Weldment 2 24 7118151250 Capscrew 4 25 7950150161 Flat Washer 4 26 7660152601 Lock Nut 4 27 4811000030 Back Plate 2 28 7115140850 Capscrew 8 29 4062000108 Bar 4 30 7950140152 Flat Washer...

Page 90: ...7118182418 Bullon Head Capscrew 2 8 7950180153 Flat Washer 2 9 7660181630 Hex Locknu 2 10 4691000103 Pin 1 11 3913000054 Pivot Pin 1 12 7440030000 Grease Fitting 2 13 3551000026 T Handle 2 14 46910001...

Page 91: ...E C II C r n III II m m II 6 III III m III N o g 1 1 1 1 61 o II So CD c E a s t e r n W r e c k e r S a l e s I n c...

Page 92: ...l i5 0 l N 0 lI a c S 0 C N 1 CIl l z w Z Q rj E 0 J 0 I c II Q J c 0 i li1 0 E a s t e r n W r e c k e r S a l e s I n c...

Page 93: ...35000125 Tilt Lockout Valve 1 22 7443000030 Tee 2 23 4567122034 Tilt Supply Hose 1 24 4570000064 Tilt Supp Hose 1 25 4567122034 Tow Bar ift Hose 2 26 7445041043 Straight Adapter 2 27 7445040219 Straig...

Page 94: ...Wear 1 7 7796000044 Seal Piston T 1 8 7796000045 Seal Roel 1 9 7755222000 llQ Ring 1 10 7755330000 O Ring 1 11 7796000046 Seal Roel Wiper 1 12 7754000051 Ring Retaining 2 13 7660262031 Locknut 1 14 74...

Page 95: ...o JJ ll Eastern W recker Sales Inc...

Page 96: ...2 l a 0 Eastern W recker Sales Inc...

Page 97: ...55222000 0 Ring 1 7 7755330000 0 Ring 1 8 7796000045 Seal Rod 1 9 7796000046 Seal Rod Wiper 1 10 7754000051 Ring Retaining 2 11 7754000053 Ring Wear 2 12 7754000054 Ring Wear 1 13 7660262031 Locknut 1...

Page 98: ...7755334000 0 Ring 1 8 7796000024 Seal Rod 1 9 7796000008 Seal Rod Wiper 1 10 7754000002 Ring Retaining 1 11 7754000003 Ring Wear 2 12 7754000004 Ring Wear 1 13 7660262031 Locknut 1 14 7755334609 Ring...

Page 99: ...Eastern W recker Sales Inc...

Page 100: ...lBElR DAN An Oshkosh Corporation Company 1080 Hykes Road Greencastle PA 17225 Phone 717 597 7111 www jerr dan com BC KE Part Number 5 376 000023 Rev 2 E a s t e r n W r e c k e r S a l e s I n c...