Jerr-Dan MPL, Operation And Maintenance Manual

Page 1: ...5 376 000102 REV 1 07 10 2010 Jerr Dan Corporation All Rights Reserved MPL OPERATIONS AND MAINTENANCE MANUAL 35 00 1080 Hykes Road Greencastle PA17225 Phone 717 597 7111 www jerr dan com...

Page 2: ...5 376 000102 REV 1 07 10...

Page 3: ...tion Information contained in this manual reflects how your vehicle was built at the factory Modifications or additions by the distributor or owner are not reflected in this manual This manual does no...

Page 4: ...this manual in your vehicle so the operator can study it as needed before a recovery Remember to replace the manual if lost Additional or replacement manuals or replacement safety warning labels can...

Page 5: ...accessories or attachments authorized by Manufacturer for use in its products customer shall pay for all such repairs or parts without recourse against Manufacturer and Manufacturer shall be relieved...

Page 6: ...name and telephone number B The dealer s name from whom it was purchased C The Manufacturer s unit serial number D Telephone number of the party making the repairs E The part numbers needed to make re...

Page 7: ...chment 25 Recovery Winch 27 Motorcycle TowingAdapter Optional 32 Dolly Storage Optional 39 Dollies Optional 44 Section III Maintenance Maintenance and Lubrication 47 Oils and Greases 50 Wire Rope Hand...

Page 8: ...5 376 000102 REV 1 07 10 Page iv THIS PAGE INTENTIONALLY LEFT BLANK...

Page 9: ...eather terrain type or condition of the vehicle to be recovered and the condition and experience of the operator is foremost to the safety and success of the operation Tie down straps are provided for...

Page 10: ...g practices safety messages are used throughout the manual Each safety message contains a safety alert symbol and a signal word to identify the hazard s degree of seriousness CAUTION Identifies when a...

Page 11: ...icle load must not exceed the posted lift towing ratings The total weight of the towing vehicle cab chassis body payload driver passenger s tools fuel etc and if applicable the towed vehicle load must...

Page 12: ..._____________________TIRES ______________________RIMS ______________KPA ___________________PSI COLD__________________ GAWR INTERMEDIATE 2 ______________________KG __________________LB WITH____________...

Page 13: ...cent Don t travel with the PTO or Clutch Pump engaged Damage to the trucks transmission engine or hydraulic components will occur Engage it only while operating the controls After you have hooked up a...

Page 14: ...afety Page 6 5 376 000102 REV 1 07 10 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...

Page 15: ...ations Many states require that the towed vehicle be secured to the wrecker body with safety chains Check your local regulations and use your safety chains Safety chains are provided for use with your...

Page 16: ...dition the intent of the design of this unit should be taken before the undertaking of its use Your MPL is unique It not only can make lifts from level surfaces our boom tilt feature allows pickup of...

Page 17: ...p the wire rope slowly and be sure the hook is securely set Be sure of your lift or pull and do not exceed the working strength of the wire rope or hook Rig to keep the estimated amount of pull well w...

Page 18: ...ever tie down the front end of your wrecker for recovery work of heavy lifts You will likely damage the truck frame if you do Never allow the wire rope to cross wrap criss cross on the winch drum Crus...

Page 19: ...n your wrecker Become familiar with the various types of wire rope damage and periodically inspect the entire wire rope for wear and corrosion Never use wire rope menders Replace with similar rated wi...

Page 20: ...es don t begin pulling without rechecking connections Make sure that all wire ropes and snatch blocks are securely attached and cannot accidently pull loose Don t tow a vehicle on its drive wheels unl...

Page 21: ...HASSIS G A W R AND G V W R SPECIFICATIONS DO NOT EXCEED THE FOLLOWING WEIGHTS LBS AT FULL EXTENSION LBS AT 10 EXTENSION LOSS OF VEHICLE CONTROL WHICH COULD RESULT IN SERIOUS BODILY INJURY OR DEATH CAN...

Page 22: ...kosh Truck Corporation Company WARNING WARNING 139 HAVE YOU REVIEWED THE OPERATOR S PRE TRANSPORT CHECK LIST ON THE UNIT MANUFACTURED BY JERR DAN CORPORATION MFG UNDER ONE OR MORE OF THE FOLLOWING PAT...

Page 23: ...should be given to the selection of commands You can afford to work smart the vehicle will do most of the work for you Follow these simple steps 1 Turn on the safety and work lights Switches located...

Page 24: ...is park or neutral NEVER TRAVEL WITH THE POWER TAKE OFF or CLUTCH PUMP CONTROL ENGAGED This could result in damage to the PTO or Clutch Pump unit and the truck transmission CAUTION Never exceed 1 500...

Page 25: ...avel at a preset position 7 Next lower the underlift using the underlift down function on the hand controller The underlift level stop assist system will stop the underlift travel at a preset position...

Page 26: ...ms around the tires to secure the towed vehicle Make sure that the arm is fully closed and in its over center locked position 11 After securing the grid arms around the towed vehicles tires and before...

Page 27: ...ing brake released you can move the vehicle safely up down in or out All of these movements are hydraulically controlled by the hand controller 16 Raise the vehicle into the final towing position obse...

Page 28: ...ers without corner binding or causing contact between the two 2 vehicles Be sure that the boom is extended at least 4 to ensure unobstructed crossbar pivoting 18 Be sure to maintain sufficient clearan...

Page 29: ...mbly 2 The Ratchet Spool Mechanism The following steps should be followed to properly install the tie down straps USING THE RATCHET SPOOL MECHANISM 1 First the spool must be set into free spool This i...

Page 30: ...d just barely off the ground insert the end of the strap through the sewn loop on the other end of the strap to form a loop Put the loop over the tire as shown with the strap resting on the tire at th...

Page 31: ...in if you need to clear body mouldings or wide tires 4 Take up the slack in the strap by ratcheting the takeup spool arm Continue until the tires show some compression Notice that the strap in the ra...

Page 32: ...r tires or even a vehicle without wheels and tires The following steps should be followed to properly install the wheel grid spacers 1 Slide the back side of the wheel spacer over the wheel grid arm 2...

Page 33: ...g a tow ball hookup DO NO EXCEED THE FOLLOWING RATINGS 1 7 8 in Ball 5 000 lbs GTW 2 in Ball 5 000 lbs GTW 2 5 16 in Ball 7 500 lbs GTW 50 MM Ball 5 000 lbs GTW Gross Tongue Weight 1 Remove the towbal...

Page 34: ...07 10 4 Install the desired towball to the towball hitch 5 Position the ball coupler over the ball and lock into place CAUTION Make sure that the ball and coupler are of the same matched size 6 Conne...

Page 35: ...Winch Rating Ramsey Worm Gear 8 000 lbs Wire Rope Working Limit 4 100 lbs Wire Rope Construction 6 x 25 EIPS RRL IWRC Wire Rope Size 3 8 inch x 75 Feet All ratings comply with SAE J2512 and SAE J706 R...

Page 36: ...t the brakes on your Jerr Dan unit The use of scotch blocks is also recommended 4 Unfold the under lift boom 5 Disengage the winch free spool by pulling out on the T handle and turning the handle 90 T...

Page 37: ...n t want it breaking loose during the pull See the safety sections earlier in this manual Do not connect to thin or loose body panels or components that could break loose during the winching operation...

Page 38: ...Be sure the wire rope strands do not cross wrap or criss cross on the drum Observe the path the work must travel for snags or obstructions which could stall the movement and overload the wire rope 12...

Page 39: ...ll or over estimating the wire rope strength 13 Now slowly retrieve the wire rope carefully winding the wire rope onto the drum Many operators take this opportunity to do a visual inspection When you...

Page 40: ...CYCLE TOWING ADAPTER OPERATION OPTIONAL If your MPL is equipped with a motorcycle towing adapter follow these steps 1 Lower the boom flat to the ground 2 Extend the wheel lift at least 6 3 Close the g...

Page 41: ...e loading ramp onto the wheel grid and engage the rear hooks on the back side of the grid 5 Completely retract the wheel grid for loading 6 Attach the lower trough and vertical stop into the mounting...

Page 42: ...n II Operation Page 34 5 376 000102 REV 1 07 10 7 Adjust the upper and lower tire stops so that they will contact and restrain the front tire when loaded 8 Align the motorcycle with wheel lift boom an...

Page 43: ...e should feel solid in the tire stops and centered in the trough If the front tire is not clamped in the stops back the motorcycle off and readjust the stops as necessary 11 With the motorcycle stable...

Page 44: ...ramp 13 Tie down the rear of the motorcycle Place the hook on one end of the rear strap into the hole on the front side of the grid Place the other hook onto the motorcycle and tighten Repeat for the...

Page 45: ...to the loop of the lasso strap on the handle bars and place the hook on the other end to the rear of the wrecker body and tighten with the ratchet Repeat for the other side 17 Use the wheel lift safe...

Page 46: ...Section II Operation Page 38 5 376 000102 REV 1 07 10 18 Attach towing lights 19 Reverse the loading procedures to unload the motorcycle...

Page 47: ...AGE OPERATION OPTIONAL If your MPL is equipped with a towing dolly follow these steps for dolly removal and storage 1 Remove the retaining bolts and wing nuts or pad locks which ever your unit may hav...

Page 48: ...semblies the axle cross tube rails and the pry bar jack bar 5 Load dollies See Dolly Operation instructions 6 After loading the dollies place the pry bar jack bar back into the storage bracket by inse...

Page 49: ...s and wing nuts or pad locks 9 After using the dollies store them back on the deck in basically the reverse order Remove the retaining bolts and wing nuts or pad locks and open the latch 10 Place the...

Page 50: ...REV 1 07 10 11 The axle cross tube rails need to be stored with the wheel ramp plates turned in and up 12 Allow the axle cross tube rails to hang from the bracket by the tab 13 Place the dolly wheel...

Page 51: ...REV 1 07 10 14 The tab on the storage bracket should be placed through the dolly pocket of the dolly wheel assembly 15 Close the dolly retaining latch by pushing the top away from you 16 Install the r...

Page 52: ...res closest to each other 4 Set rail ends into dolly pockets adjusting for the size of vehicle s tires positioning rails as close as possible to tires 5 Make sure safety locks are disengaged allowing...

Page 53: ...o unload the vehicle stand clear of both the vehicle and the dollies and slip the chain link off of the cam bar Carefully slide the jack handle over the cam bar and slowly lift the handle allowing the...

Page 54: ...Section II Operation Page 46 5 376 000102 REV 1 07 10 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 55: ...composite bearings with hardened and plated pins to drastically reduce maintenance down time and the cost of lubrication over the life of the product There are however a few areas that still require...

Page 56: ...component These seals are available in kits Also thoroughly clean all components before reassembly The body of your Jerr Dan has been built from high strength aluminum which has been carefully assembl...

Page 57: ...ey are first installed on the vehicle Thereafter inspect such screws and nuts visually once every month and after each job imposing extremely heavy loads on the equipment Periodically recheck all acce...

Page 58: ...llus Oil T 32 6 Citgo A W All Temp 7 Amoco Rycon Oil 32 8 Conoco AW Hydraulic Fluid MV 46 9 Mobil DTE11M for cold weather use 10 Conoco AW Hydraulic Fluid MV 32 for cold weather use GREASES 1 Drydene...

Page 59: ...quires a break in period Run the wire rope through several cycles at low speeds gradually increasing the load on the wire rope Make sure that the wraps of the wire rope are tight and evenly wound on t...

Page 60: ...boom sheaves and at the end attachments All products are subject to age wear and deterioration all of which cause a reduction in the products breaking strength capacity Probably the most common sign...

Page 61: ...NDERLIFT DOWN WARD TO LOWER UNDERLIFT NOTE A GAP OF 125 1875 MUST BE MAINTAINED BETWEEN THE SENSOR AND THE DOUBLER PLATE INTERMITTENT OPERATION WILL OCCUR IF THE GAP IS NOT MAINTAINED To change or adj...

Page 62: ...Section III Maintenance Page 54 5 376 000102 REV 1 07 10 LUBRICATION POINTS The following lubrication chart is located inside the tool box lid on the driver s side of the MPL body...

Page 63: ...er e Hydraulic pump worn e Rebuild or replace f Clutch Pump belt slipping f Tighten or Replace belt Valve Solenoid s a Broken centering spring a Inspect clean or replace sticking or frozen or clogged...

Page 64: ...p throws belts a Engine and pump pulley a Check installation alignment b System horsepower b Review application demand exceeds belt capacity c High speed engagement c Reduce start up RPM Pump leaks at...

Page 65: ...P T O connec a Inspect and adjust or disengage tion not adjusted properly b Defective shifter cover b Inspect and replace plate HYDRAULIC PUMP Problem Cause Solution Pump noisy a Low oil supply a Fil...

Page 66: ...s a Replace seals or Pump Pulley Shaft b Hydraulic Supply Return b Check hydraulic line lines connected incorrectly connections Pump leaks at front a Defective seals a Replace seals and rear covers WI...

Page 67: ...lighting system B Bending Moment The force times the distance from a reference point to the point the force is applied causing bending Bird Nesting The tangling and intertwining of wraps and layers o...

Page 68: ...weight of the chassis body equipment and payload if collectively or individually supported would balance vertically horizontally and laterally CT Cab to Tandem The distance from the back of the truck...

Page 69: ...to individually Control A device used to control the functions of a unit Control Lever A device for imparting motion into a control linkage Crossbar A transverse horizontally pivoting member attached...

Page 70: ...ed by NHTSA under Public Law 89 563 which are mandatory and must be complied with when motor vehicles or items of motor vehicle equipment are manufactured and certified thereto Frame Structure on whic...

Page 71: ...published represent maximum allowed Grab Hook For use with chains and some tow sling hookups Grid A device that attaches to the lift bar for engaging the tires of a towed vehicle GVWR Gross Vehicle We...

Page 72: ...he Wrecker Boom and Underlift Boom are separate independent from each other Integrated The Wrecker Boom and Underlift Boom are combined together as a complete unit J J Hook Attachment device used for...

Page 73: ...o Motor A rotary motion device which changes hydraulic energy into mechanical energy Motor Vehicle Safety Standards See FMVSS Mud Flap Splash Deflecting shields at rear of wheel N NHTSA National Highw...

Page 74: ...ck or semitrailer used to couple a full trailer PTO Power Takeoff Mechanical device used to transmit engine power to auxiliary equipment Power takeoffs can be mounted on either a main or auxiliary tra...

Page 75: ...the tow bar inboard of chain Scotch Blocks A device used to prevent chassis movement Serial Number An identification number stamped on a metal plate by the passenger car van or truck manufacturer see...

Page 76: ...reservoir used in the hydraulic system Swivel Head See Boom Head T T Hook Attachment device used for towing Tail Plate Rearmost part of the towing vehicle body Tail Swing Clearance distance from cente...

Page 77: ...the trailer manufacturer U Underlift A device used for towing vehicles by lifting one end of the towed vehicle from under the axle or structural member Unloaded Vehicle Weight The weight of a vehicle...

Page 78: ...Wheel Securing Device A strap or mechanical device when attached to the lift bar which limits the potential for separation of the towed vehicle from the underlift during operating conditions Wheel Str...