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Jerr-Dan MPL-60 Operation And Safety Manual Download Page 54

Section 4 : Operation

4-16 

5376000278

Do not move the recovery vehicle with the outriggers/spades on the 
ground or damage to the recovery vehicle can occur.

CAUTION

Area must be clear of hands, feet and body when lowering the rear 
outrigger/spades.

WARNING

Do not use spades on pavement or concrete. Damage to the pavement 
or concrete may result.

CAUTION

Summary of Contents for MPL-60

Page 1: ...afety Manual Original Instructions Keep this manual with machine at all times MPL 60 WRECKER SN 0230011584 to Present including 0230010929 0230011078 0230011268 0230011269 and 0230011581 5376000278 No...

Page 2: ...ich are known to the State of California to cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service yo...

Page 3: ...Revision Log 5376000278 a REVISION LOG November 13 2023 A Original Issue of Manual...

Page 4: ...accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator Operators of this equipment must possess a valid applicable driver s license...

Page 5: ...will result in serious injury or death This decal will have a red background Indicates a potentially hazardous situation If not avoided could result in serious injury or death This decal will have an...

Page 6: ...re Jerr Dan product have been involved in an accident involving bodily injury or death of personnel or when substantial damage has occurred to personal property on the Jerr Dan product FOR Accident Re...

Page 7: ...afety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Jerr Dan To contact NHTSA yo...

Page 8: ...Read This First f 5376000278 THIS PAGE IS INTENTIONALLY LEFT BLANK...

Page 9: ...quipment 1 9 Weather Conditions 1 10 Vehicle Equipment Damage 1 10 Section 2 Pre Operation And Inspection 2 1 Pre Operation Check and Inspection 2 1 2 2 Decals 2 2 2 3 Walk Around Inspection 2 4 2 4 O...

Page 10: ...nance And Lubrication 6 2 6 3 Oils And Greases 6 3 6 4 Wire Rope Handling And Inspection 6 5 6 5 Wire Rope Installation 6 7 6 6 Underlift Level Stop 6 10 6 7 Lubrication Charts 6 11 Lubrication Points...

Page 11: ...ine until this manual has been read training is accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator There may be times your truc...

Page 12: ...e scope of its intended application set by Jerr Dan All operating personnel must be familiar with the emergency operation of the machine as specified in this manual Read understand and obey all applic...

Page 13: ...er 200KV to 350KV 20 6 Over 350KV to 500KV 25 8 Over 500KV to 750KV 35 11 Over 750KV to 1000KV 45 14 NOTE This requirement shall apply except where employer local or government regulations are more st...

Page 14: ...Position barricades if necessary Lower boom to stowed position prior to driving machine Be aware of height clearances when traveling Look out for and avoid other personnel machinery vehicles and obst...

Page 15: ...ad by letting out cable and inspect for damage Keep cables from contacting sharp objects Never wrap cables around objects Use appropriate chains straps to wrap around the vehicle to be recovered and a...

Page 16: ...assis Set parking brake and chock wheels of the recovery vehicle when connecting casualty vehicle Use two 2 safety chains and two 2 tie down chains or straps Release parking brake of casualty vehicle...

Page 17: ...recker boom to hoist personnel Never ride on boom hook load or any other device attached to wrecker boom or load line DO NOT carry riders outside the cab Riders could fall o the machine Do not climb o...

Page 18: ...the fuel tank or service the fuel system near an open flame sparks or smoking materials Engine fuel is flammable and can cause a fire and or explosion Hydraulic Fluid DO NOT attempt to repair or tigh...

Page 19: ...ated area Wear proper eye protection when servicing battery PERSONAL PROTECTIVE EQUIPMENT Use personal protective equipment when working on or around this vehicle Remove rings watches jewellery neckwe...

Page 20: ...ers many opportunities to inflict worse damage on the towed vehicle or even damage to the recovery vehicle Recovery operators should take great care to avoid this damage Follow these guidelines to re...

Page 21: ...combinations allow for the PTO to be operated during travel Consult your specific PTO Operators Manual When using spades on pavement or concrete it is suggested that you use larger rubber or wood pads...

Page 22: ...Section 1 General Safety Practices 1 12 5376000278 THIS PAGE IS INTENTIONALLY LEFT BLANK...

Page 23: ...round Inspection See page 2 4 for details 6 Fluid Levels Check fluids including fuel hydraulic oil engine oil transmission fluid and coolant When adding fluids refer to Section 6 Maintenance and Lubri...

Page 24: ...phthalates and lead which are known to the state of California to cause cancer and birth defects or other reproduction harm To minimize exposure avoid breathing exhaust do not idle the engine except a...

Page 25: ...BOTH SIDES 7330000599 7330000609 7330000599 WARNIN G Operating servicing and maintaining this vehicle or equipment can expose you to chemicals including exhaust carbon monixide phthalates and lead whi...

Page 26: ...14 12 3 6 3 3 7 9 11 9 9 11 2 13 5 5 10 5 5 4 7 7 10 8 8 Begin your walk around inspection at item 1 as noted below checking each item in sequence INSPECTION NOTE On all components make sure there are...

Page 27: ...b Toolbox Storage Compartment secure 4 Subframe a Secure b Components undamaged 5 Electric Hydraulic Controls a Components undamaged and operational b Electric harnesses undamaged c Valve and hydrauli...

Page 28: ...om Underlift a Knee Boom Pivot pin secure b Cylinder pins secure c Hydraulic hoses undamaged not leaking d Underlift pivot pin secure e Underlift tilt pivot pin secure f Check wear pads for presence o...

Page 29: ...f grease c Wire Rope Hooks Undamaged d Wire Rope Hook Latches Undamaged and functional 14 Winch s a Hydraulic hoses undamaged not leaking b Gear oil level full 15 Dollies If equipped Not Shown a Compo...

Page 30: ...ke operation 2 Horn and back up alarm Must be audible from inside operators cab with engine running 3 Electric controlled hydraulic functions if equipped all functions operate smoothly and the control...

Page 31: ...mission to a hydraulic pump to provide hydraulic power to the wrecker hydraulics Your MPL 60 is supplied with various control options Controls are provided at the rear of the unit along with various o...

Page 32: ...In Out Controls the wire rope winding unwinding function of the LH winch 3 Right Hand Winch In Out Controls the wire rope winding unwinding function of the RH winch 4 Boom Out In Controls the boom ext...

Page 33: ...Winch In Out Controls the wire rope winding unwinding function of the LH winch 3 Right Hand Winch In Out Controls the wire rope winding unwinding function of the RH winch 4 Boom Out In Controls the b...

Page 34: ...Function Operated 2 Underlift Boom Up Down Controls the underlift boom raise lower functions 3 NOT USED 4 Underlift Boom Tilt Up Down Controls the underlift boom tilt raise lower functions 5 Underlif...

Page 35: ...the extend function of the underlift boom 3 Underlift Boom Down Controls the lowering function of the underlift boom 4 Underlift Boom Tilt Up Controls the tilt up function of the underlift boom 5 Unde...

Page 36: ...re rope unwinding functions of the Right Hand winch 5 Left Hand Winch In Controls the wire rope winding functions of the Left Hand winch 6 Left Hand Winch Out Controls the wire rope unwinding function...

Page 37: ...ound when transmiter is removed from the trans mitter holder with the ignition switch turned ON If Equipped 13 Underlift Boom Tilt Up Controls the tilt up functions of the underlift boom 14 Underlift...

Page 38: ...Section 3 Controls Indicators 3 8 5376000278 THIS PAGE IS INTENTIONALLY LEFT BLANK...

Page 39: ...rols for your MPL 60 are conveniently located at the rear corners of the truck body There are also a variety of optional wired and wireless handheld remote controllers that controls the MPL 60 functio...

Page 40: ...of the pull as possible 3 Set the truck s parking brakes and put the transmission in park or neutral 4 Engage the Power Take O PTO or Clutch Pump and the hand controller using the Control switch in th...

Page 41: ...on to the vehicle to be towed Nine 9 feet is recommended Reposition the MPL 60 if necessary Be sure the towed vehicle is not in gear or park Keep the brake set 7 Using a hand controller or the manual...

Page 42: ...the grid width loosen the T handles on the front of the grid arms and pull out Be sure both grids are as close to the center of the boom as possible and wide enough to allow the L Arms to slide into...

Page 43: ...with the tires Then reset the locking pin by turning the Cam handle back to the original position The tires are now confined front and back Visually inspect the tire to grid contact before proceeding...

Page 44: ...ve the tie down straps from tool boxes and attach the tie down straps See Tie Down Strap instructions 18 With the straps in place the vehicleinneutralandtheparking brake released you can move the vehi...

Page 45: ...oom is extended at least 4 to ensure unobstructed crossbar pivoting 21 Be sure to maintain su cient clearances with the bottom of the towed vehicle 22 Attach the safety chains and towing lights Safety...

Page 46: ...RATCHET SPOOL MECHANISM 1 First set the spool into free spool This is done by pulling the lock bar out and swinging the handle upward until it rests in the free spool notch and then simply pulling out...

Page 47: ...ull the webbed strap out and form a loop which will wrap around the tire Be sure the loop is over a minimum of 1 3 of the tire 3 Take up the slack in the strap by ratcheting the take up spool arm Cont...

Page 48: ...n the T handles on the front of the grid arms and pull the grids out to the stops 3 Turn the T handle clockwise until the grid is released then remove the grid from the crossbar Do this on both sides...

Page 49: ...t attachments under the vehicle so that they are in the proper position for lifting 3 Now you may lift the vehicle slightly o the ground 4 Secure the vehicle to the wheel grid crossbar with straps and...

Page 50: ...ll hookup 1 Remove the towball hitch attachment from the toolbox 2 Use the bottom set of holes install the towball hitch to the bottom of the underlift boom using the hitch pins 3 Secure the hitch pin...

Page 51: ...Section 4 Operation 5376000278 4 13 6 Connect the trailer lights and attach safety chains 7 Review Operator s Pre Transport Checklist before each tow...

Page 52: ...be used to provide a resistance to winching forces 1 Position the recovery vehicle as close as possible to the work area Set the parking brakes place the transmission in neutral and chock the wheels 2...

Page 53: ...gral spade to swing down There are three positions that can be used 3 Line up holes and insert spade pin 2 and retaining pin 1 When the spade is on the ground the D Rings on the back side of the stabi...

Page 54: ...the outriggers spades on the ground or damage to the recovery vehicle can occur CAUTION Area must be clear of hands feet and body when lowering the rear outrigger spades WARNING Do not use spades on p...

Page 55: ...erate the winch e ectively care and thought must be given 1 Check the direction you wish the work to travel being sure there are no major obstacles in the way 2 Position and align the truck to obtain...

Page 56: ...ow sling 6 Set both boom winches into free spool using the disengagement levers Raise lift and pull out on the free spool lever handle Lower the free spool lever handle capturing the lever stop bar on...

Page 57: ...n chassis frames that may be able to be used as recovery attachment points Consult the Chassis Manufacturer s Towing Manual and or the American Automobile Association AAA Towing Manuals DO NOT EXCEED...

Page 58: ...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 11 Onc...

Page 59: ...and follow these steps 1 Position the truck within 9 ft of the subject vehicle and as close to the direction of the tow as possible 2 Unfold the underlift 3 Remove the wheel grid L Arms from their hol...

Page 60: ...tow sling lugs 6 Swing the hold back bars out toward the lower tow sling lugs on the back of the body Allow the hold back bars to extend as necessary 7 Rotate the CAM handles on the hold back bars 18...

Page 61: ...w the tow sling head to raise out of it holder on the back side of the boom 10 Remove the tow sling head from the back of the boom carefully and allow it to rotate outward and downward away for the bo...

Page 62: ...he axle or the frame of the towed vehicle When fastening the J hook be sure that it is attached to the towed vehicle in such a manner as to prevent any damage to the brake lines or other functional pa...

Page 63: ...e sling or towing mechanism 18 Raise the vehicle using the wrecker boom winches Read the safety and operating instructions for the boom and winches beforehand The vehicle should be raised until the wh...

Page 64: ...Pre Transport Checklist before each tow 25 After the tow is complete reverse the procedures to unload the vehicle 26 Remove the wheel grid L Arms from their holders 27 Rotate the CAM handles on the ho...

Page 65: ...0278 4 27 28 With the vehicle unloaded and the tow sling extended use the underlift fold function to bring the tow sling head back up into its storage position 29 Remove the pins from the hold back ba...

Page 66: ...oward the tow sling storage brackets on the side of the boom Allow the hold back bars to retract as necessary 32 Connect the hold back bars to the tow sling storage brackets using the pins that you re...

Page 67: ...re with an elevated boom Contact a local Authorized Distributor for specific instructions Secure the vehicle using the following procedures 1 Clear the area around the unit of all personnel 2 Engage t...

Page 68: ...lure with an elevated boom Contact a local Authorized Distributor for specific instructions Secure the vehicle using the following procedures 1 Clear the area around the unit of all personnel 2 Engage...

Page 69: ...E CLUTCH PUMP OVERRIDE SWITCH IF EQUIPPED DIAGNOSTIC PLUG CAB UL TILT UL EXTEND HYD GRID LH WINCH RH WINCH BOOM LIFT BOOM EXTEND N D N D N D N D OUT CLS OUT OUT OUT P U P U P U P U IN OPN IN IN IN LH...

Page 70: ...s and use manual override tool to engage override function of the solenoid A small pick tool or mini slotted screw driver may also be used to carefully engage override function 2 When using the manual...

Page 71: ...th a hose or flexible tube for best results When performing maintenance that requires accessing the top of the truck use only an approved ladder Use only safe practices when maintaining this equipment...

Page 72: ...ated on the return side of the hydraulic tank comes equipped with restriction indicator gauges The gauge shows the condition of the filter element When the needle reaches the red band 25 psi the filte...

Page 73: ...is N46 5 Mobil Mobilfluid 424 6 Texaco Rando HD 46 7 Kendall AW 46 8 Citgo Mystik AW 46 9 Amoco AW 46 10 Conoco Super 11 Mobil DTE10 Excel 32 for cold weather use below 20 F 12 Conoco AW Hydraulic Flu...

Page 74: ...r approved equivalent WIRE ROPE 1 CRC Chain and Wire Rope Lubricant or other approved deep penetrating equivalent 2 Jet Lube WLD Chain and Wire Rope Lubricant or other approved deep penetrating equiva...

Page 75: ...which has been idle for a period of a month or more should be given a thorough inspection before it is put back into service All inspections should be the responsibility of and performed by an appoint...

Page 76: ...thly of any and all debris Grit and gravel can quickly reduce a wire ropes life A wire rope should be well lubricated so that it can act and perform as it was designed Lubrication keeps a wire rope fl...

Page 77: ...taut The Wrong Way To Unreel If a reel of wire rope is laid on its flange with its axis vertical to the floor and the rope unreeled by throwing o the turns spirals will occur and kinks are likely to...

Page 78: ...be attached at the correct location on a flat or smooth faced drum so that the rope will spool evenly with the turns lying snugly against each other in even layers If wire rope is wound on a smooth fa...

Page 79: ...grooved drum will wear just as quickly as an improperly installed rope on a smooth drum If a wire rope is poorly wound and as a result jumps the grooves it will be crushed and cut under operating loa...

Page 80: ...D MOVE DOWNWARD TO RAISE UNDERLIFT GRID NOTE A GAP OF 125 1875 MUST BE MAINTAINED BETWEEN THE SENSOR AND THE BASE BOOM SIDE PLATE INTERMITTENT OPERATION WILL OCCUR IF THE GAP IS NOT MAINTAINED BOOM LI...

Page 81: ...CATION IS REQUIRED MPG INDICATES MULTI PURPOSE GREASE INDICATES SUPER PREMIUM GRADE MULTI VISCOSITY HYDRAULIC OIL AUTOMATIC TRANSMISSION FLUID MAY BE SUBSTITUTED IF NECESSARY CONSULT WINCH MANUAL FOR...

Page 82: ...E OIL 3 1 OR 2 1 OR 2 1 OR 2 MPG INDICATES MULTI PURPOSE GREASE INDICATES SUPER PREMIUM GRADE MULTI VISCOSITY HYDRAULIC OIL AUTOMATIC TRANSMISSION FLUID MAY BE SUBSTITUTED IF NECESSARY CONSULT WINCH M...

Page 83: ...hown on the lubrication charts on Pages 6 11 and 6 12 C Hydraulic Reservoir Oil Level Lube Point s Fill Cap Interval Check level every 100 hours or bi monthly Change every 1000 hours F Hydraulic Reser...

Page 84: ...Section 6 Maintenance 6 14 5376000278 E Winch Gear Case Lube Point s Fill Plug Lube Reference winch manufacturer s manual Interval Check level every 100 hours or bi monthly Change every 1000 hours...

Page 85: ...up engine b Check level and fill with the specified oil c Inspect remove blockage d Drain flush and refill with clean oil replace filter e Rebuild or replace f Thaw and remove water Valve leaks a Defe...

Page 86: ...lectrical wiring problem circuit b Repair or replace c Replace fuse HYDRAULIC PUMP Problem Cause Solution Pump noisy Cavitation a Low oil supply b Thick oil c Dirty oil filter d Restriction in suction...

Page 87: ...er level Hydraulic oil leak between P T O and pump a Defective shaft seal a Replace shaft seal Pump leaks at front and rear covers a Defective seals a Replace seals WINCH FUNCTIONING IMPROPERLY Proble...

Page 88: ...n cab or control station b Replace Battery c Check connection d Check receiver power input e Make sure transmitter is in range of receiver f Make sure transmitter and receiver are matched Poor Range a...

Page 89: ...it Each Line 5 800 lbs Construction 6 x 25 EIPS RRL IWRC Diameter 7 16 inch Standard Length 101 Feet WINCH RATING Optional Worm Gear 12 000 lbs 2 WIRE ROPE Working Limit Each Line 5 800 lbs Constructi...

Page 90: ...eet the following The actual payload on the towing vehicle must not exceed the posted rating and the towed vehicle load must not exceed the posted lift towing ratings The total weight of the towing ve...

Page 91: ..._____________________________TIRES ______________________RIMS ______________KPA ___________________PSI COLD__________________ GAWR INTERMEDIATE 2 ______________________KG __________________LB WITH____...

Page 92: ...TO System 8 gpm 1000 RPM System Flow Clutch Pump System 7 gpm 1000 RPM System Capacity 15 gal Reservoir Capacity 9 gal Type of Oil PTO System Ambient Temperature Above 20 F Shell Spirax S4 TXM Ambient...

Page 93: ...Inspection Maintenance and Repair Log Serial Number Date Comments...

Page 94: ...Inspection Maintenance and Repair Log Date Comments...

Page 95: ...o provide Jerr Dan with updated information with regard to the current ownership of Jerr Dan products Please return com pleted form to the Jerr Dan Product Safety Reliability Department via fac simile...

Page 96: ...THIS PAGE IS INTENTIONALLY LEFT BLANK...

Page 97: ......

Page 98: ...www jerrdan com 13224 Fountainhead Plaza Hagerstown MD 21742 Phone 717 597 7111 Phone 800 926 9666...

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