Jerr-Dan MPL40 Operation And Maintenance Manual Download Page 90

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Section III: Maintenance

Page 82

5-376-000086

REV. 4 - 07/10

HYDRAULIC CLUTCH PUMP

Problem

Cause

Solution

No oil flow from

a. No oil in reservoir

a. Fill hydraulic reservoir

pump

b. Pump not “primed”

b. Fill inlet hose from pump

end

c. Clutch not engaging

c. Check wiring/fuse

Pump will not build

a. Relief valve improperly set a. Adjust relief valve to manu-

or hold pressure

facturers specification

b. Relief valve stuck open

b. Remove, clean and reset

Pump is noisy -

a. Air in the system

a. See “Oil Foaming”

whines

b. Cavitation

b. Check Hoses, Reservoir

breather or strainer

Pump is noisy -

a. Belts are worn/loose

a. Inspect, adjust and/or

squeals

replace

b. System horsepower

b. Review application

demand exceeds belt
capacity

c. Clutch is slipping

c. Check voltage/ground

Pump ‘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 shaft

a. Damaged seal

a. Replace seal

seal

b. Damaged pump body

b. Replace pump body

Pump leaks at body

a. Damaged seal

a. Replace seal

section

b. Damaged pump body

b. Replace pump body

c. Body section bolt torque

c. Torque to specification

Pump leaks a

a. Loose fitting

a. Inspect and/or tighten

fittings

b. Damaged fitting

b. Replace fitting

c. Damaged pump body

c. Replace pump body

Pump is overheating

a. Low oil level

a. Fill hydraulic reservoir

b. Dirty oil

b. Replace oil and filter

c. Relief valve stuck open

c. Remove, clean and reset

d. Relief valve improperly set d. Adjust relief valve to manu-

facturers specification

e. Improper weight oil

e. Replace with correct oil

Oil foaming

a. Low oil lever

a. Fill hydraulic reservior

b. Improper oil

b. Fill with correct oil

Summary of Contents for MPL40

Page 1: ...5 376 000086 REV 4 07 10 2010 Jerr Dan Corporation All Rights Reserved MPL40 OPERATIONS AND MAINTENANCE MANUAL 35 00 1080 Hykes Road Greencastle PA17225 Phone 717 597 7111 www jerr dan com ...

Page 2: ...5 376 000086 REV 4 07 10 ...

Page 3: ...the equipment at all times and referred to whenever in doubt of proper operation Information contained in this manual reflects how this vehicle was built at the factory Modifications or additions by the distributor or owner are not re flected in this manual This manual does not include operation and maintenance information for the commercial chassis IHC Ford GM etc This information is provided by ...

Page 4: ...Road Greencastle PA17225 Additional or replacement manuals or replacement safety warning labels can be ordered by calling Jerr Dan Parts at 717 597 7111 Price and avail ability will be quoted at time of the request The material in this document is confidential and the property of Jerr Dan Corporation No part of this document may be photocopied reproduced or translated to another language without t...

Page 5: ...s 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 of responsibility for fulfillment of this warranty with respect to parts or components of all repairs alterations or replacements so made No claims for labor shall be considered unless authorized by...

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 repairs F Owner to be informed of C O D on parts if deemed necessary to assure return of defective parts for manufacturer s evaluation At this time the Manufacturer will ship as soon as practical the pa...

Page 7: ...Boom Single Line Boom Planetary Gear Winch 37 Wrecker Boom Dual Line Boom Worm Gear Winches 42 Tow Sling Optional 48 Motorcycle TowingAdapter Optional 58 Dolly Storage Optional 65 Dollies Optional 70 Section III Maintenance Maintenance and Lubrication 73 Oils and Greases 76 Wire Rope Handling and Inspection 77 Underlift Level Stop Assist System 79 Lubrication Points 80 Trouble Shooting 81 Hydrauli...

Page 8: ...5 376 000086 REV 4 07 10 Page iv THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 9: ... surrounding conditions such as the weather 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 use with your new Jerr Dan Recovery Vehicle Periodically inspect all straps for any signs of fatigue or damage Don t overlook the hooks be sure they have not been...

Page 10: ... alert personnel to hazardous operating 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 potentially hazardous situation exists and may result in a minor or moderate injury or property damage WARNING Identifies when a potentially hazardous situation ...

Page 11: ...RL IWRC Diameter 3 8 inch Standard Length 100 Feet 1 SAE J706 Surface Vehicle Recommended Practices Rating of Winches 2 SAE J2512 Surface Vehicle Recommended Practices Towing Equipment Ratings and Practices MAXIMUM LIFTING CAPACITY THE MAXIMUM LOAD THAT CAN BE LIFTED GROSS COMBINED WEIGHT RATING GCWR THE VALUE SPECIFIED BYTHE VEHICLE MANUFACTURERAS GCW GROSS COMBINED WEIGHT GCW ACTUALWEIGHTOF THE ...

Page 12: ... applicable the towed vehicle load must not exceed the GVWR Gross Vehicle Weight Rating of the towing vehicle The total weight of the towing vehicle and if applicable the towed vehicle load must be distributed so that each axle s GAWR Gross Axle Weight Rating is not exceeded The total weight of the towing vehicle and towed vehicle everything that moves with the towing vehicle must not exceed the G...

Page 13: ...______________________TIRES ______________________RIMS ______________KPA ___________________PSI COLD__________________ GAWR INTERMEDIATE 2 ______________________KG __________________LB WITH____________________________________TIRES ______________________RIMS ______________KPA ___________________PSI COLD__________________ GAWR REAR ______________________KG __________________LB WITH__________________...

Page 14: ...rcent 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 vehicle 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 Don t operate the wrecker s engine faste...

Page 15: ...Safety Page 7 5 376 000086 REV 4 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 are damaged ...

Page 16: ...rations 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 new JERR DAN Never attach the chain hooks in such a way as to damage brake lines or other functional parts Keep in mind that driving over bumps and hollows and around corners will tend to tighten or...

Page 17: ...dition the intent of the design of this unit should be taken before the undertaking of its use Your MPL40 is unique It not only can make lifts from level surfaces our boom tilt feature allows pickup of vehicles that are parked on both inclines and declines You should never make a lift or movement while close to or under the vehicle being lifted Always use jack stands to support the vehicle if it i...

Page 18: ...up 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 within equipment ratings Use wire rope breaking strength ratings only for selecting replacement wire rope BOOM SAFETY Your MPL40 is equipped with a recovery winch and the following safety procedures m...

Page 19: ...Never 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 Crushing of the wire rope can cause wire rope failure Never make a lift or pull with the wire rope attached to light gauge or sheet metal parts use the frame or major structural members Don t disengage t...

Page 20: ...on 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 wire rope and hooks Be sure all brakes and locks are properly set on the recovery vehicle Never under any circumstances use the winch or boom to lift people Lubricate and maintain both the wire rope an...

Page 21: ...pes 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 unless steps have been taken to protect its transmission and differential Follow the recommendations of the vehicle manu facturer As an alternative use a towing dolly To avoid birdnesting and premature ...

Page 22: ...l parts Be sure the chains and hooks are attached to frame members and not sheet metal Never make a front lift without unlatching the hood of the vehicle SLING SAFETY If your MPL40 is equipped with an optional tow sling certain safety precautions must be taken to ensure safe operation Consult the AAA Towing Manual for the make and model of the vehicle to be towed and observe the following safety p...

Page 23: ...embly round tube must never be higher than the attachment point on the rear of the MPL40 The rear stand off bar assembly acts as a pivot in the event of a sudden stop This will asure that the casualty vehicle will not catapult forward onto the deck of the recovery vehicle ...

Page 24: ... painted over They are there to remind and protect the operator CAUTION 034 CHECK HYDRAULIC FLUID LEVEL FILL ONLY WITH APPROVED FLUID SEE OPERATOR S MANUAL T WARNING 122 122 TOWED VEHICLE MUST BE CONNECTED TO TOW TRUCK BODY WITH SAFETY CHAINS TOWED VEHICLE MUST BE CONNECTED TO TOW TRUCK BODY WITH SAFETY CHAINS 546 AMINIMUMOF5WRAPSOFCABLEMUST BELEFTONWINCHDRUMTOACHIEVE RATEDLOAD DONOTUSEWINCHTOMOVE...

Page 25: ...OCCUR IF THE EFFECTIVE TRANSPORT LOAD IS EXCEEDED MAXIMUM EFFECTIVE TRANSPORT LOAD IS AFFECTED BY THE CHASSIS ON WHICH THE TOWING EQUIPMENT IS INSTALLED BEFORE ATTEMPTING TO USE THIS EQUIPMENT ON A CHASSIS OTHER THAN THAT SPECIFIED ABOVE CONTACT JERR DAN TO OBTAIN A REVISED RATING SAFETY IS NO ACCIDENT REVIEW OPERATOR S PRE TRANSPORT CHECKLIST IN THE OWNER S MANUAL EACH TIME YOU MOVE A VEHICLE FOL...

Page 26: ...Section I Safety Page 18 5 376 000086 REV 4 07 10 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 27: ... 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 on the dash panel 2 Position the truck within 9 ft of the subject vehicle and as close to the direction of the pull as possible 3 Set the truck s parking brakes and put the transmission in park or neu...

Page 28: ...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 R P M When your hook up is complete reset the engine idle to normal 5 Confirm the truck s position in relation to the vehicle to be towed Nine 9 feet is recommended Reposition the MPL40 if necessary Be s...

Page 29: ... will stop the underlift travel at a preset position 7 Next lower the underlift using the underlift down funtion on the hand controller The underlift level stop assist system will stop the underlift travel at a preset position about 1 1 2 to 2 from the ground NOTE To override either stop position simply release the control function and reactivate the same control function again to achieve further ...

Page 30: ...rms 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 making the actual lift check to be sure the towed vehicle s parking brake is released the transmission is in neutral and the wheels are straight NOTE If vehicle to be towed is on a slope do not rele...

Page 31: ...king 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 observing the far end for sufficient ground clearance It is possible to set the rear of a front lifted vehicle completely onto the ground causing damage Take irregular roadsurfaces into consideration Obs...

Page 32: ...ners 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 clearances with the bottom of the towed vehicle 19 Attach the safety chains and towing lights Safety chains should be crossed from one side of the recovery vehicle to the opposite side of the towed vehicle ...

Page 33: ...sembly 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 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 the amount of strap required to fit over the tire 2 Now pull on t...

Page 34: ...ed 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 the ten o clock and two o clock positions The choker strap should be across the center of the tire 2 Place the rear hook of the strap assembly into a hole on the back side of the grid arm Try to use th...

Page 35: ...t 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 ratchet is pulling down and forward on the loop over the tire 5 Raise the wheel grid to the tow ing position RE TIGHTEN THE RATCHET PERIODICALLY AS THE TIRE SETTLES IN GRID FROM TOWING NOTE Never tow a...

Page 36: ...ter 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 Close the grid arms around the tires to secure the towed vehicle Make sure that the arm is fully closed and in its over center locked position 3 Visually inspect the tire to grid contact before pro...

Page 37: ...railers requiring 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 towball hitch attachment from the toolbox 2 Install the towball hitch to the bottomontheunderliftboomusing the hitch pins 3 Secure the hitch pins with the linch pins ...

Page 38: ...4 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 Connect the trailer lights and attach safety chains ...

Page 39: ...ting Extended 6 000 lbs Retracted 16 000 lbs 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 100 Feet All ratings comply with SAE J2512 and SAE J706 Recommended Practice WARNING Do not exceed the working limit of the wire rope Use snatch blocks and multiple lines to reduce the load on the wire rope 1 Ch...

Page 40: ... are the best and most efficient 3 Set the brakes on your Jerr Dan unit 4 Unfold the under lift boom 5 If a heavy lift or pull is to be made additional lines may be necessary Always use more stabilizing lines than pull lines RIG FOR SAFETY The use of scotch blocks is also recommended 6 Unhook the wire rope cables from the top of the tow sling ...

Page 41: ...handle and turning the handle 90 The handle should remain in the free spool position Never turn this handle while the wire rope is under load This allows the wire rope to be pulled directly off the drum to the work 8 Position the boom head by using the boom up and down control lever and the boom in and out lever ...

Page 42: ...ose during the winching operation Slings and bridles are usually designed with hook clusters on them Most chassis manufacturer s provide tie down hooks and or slots in 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 10 Reengage the winch free spool by turning the ...

Page 43: ...oss on the drum Observe the path the work must travel for snags or obstructions which could stall the movement and overload the wire rope 13 Once the work is in the desired position apply the towed vehicles parking brake or use blocks or tie the work down if there is any question about stability Slowly reduce the wire rope tension After enough wire rope has been unwound you may remove the hookup ...

Page 44: ...ake this opportunity to do a visual inspection When you ve finished rewinding the wire rope be sure you don t overwind it Always wear safety glasses and gloves when doing recovery work or handling the wire rope Remember most wire rope failures are caused by cable crushing or the operator underestimating the pull or over estimating the wire rope strength ...

Page 45: ...ating Extended 6 000 lbs Retracted 16 000 lbs Winch Rating Warn Planetary Gear 9 000 lbs Wire Rope Working Limit 4 100 lbs Wire Rope Construction 6 x 25 EIPS RRL IWRC Wire Rope Size 3 8 inch x 100 Feet All ratings comply with SAE J2512 and SAE J706 Recommended Practice WARNING Do not exceed the working limit of the wire rope Use snatch blocks and multiple lines to reduce the load on the wire rope ...

Page 46: ... are the best and most efficient 3 Set the brakes on your Jerr Dan unit 4 Unfold the under lift boom 5 If a heavy lift or pull is to be made additional lines may be necessary Always use more stabilizing lines than pull lines RIG FOR SAFETY The use of scotch blocks is also recommended 6 Unhook the wire rope cables from the top of the tow sling ...

Page 47: ...d down control lever and the boom in and out lever 9 Attach the wire rope hook to a chain sling or bridle and hook securely to the work Be sure of this hook up you don 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 Slings and bridles are usually de...

Page 48: ...nch engagement by jogging the winch control Now slowly take up the slack in the wire rope 11 With the wire rope tight slowly wind it in observing both the work and the drum 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 ...

Page 49: ... use blocks or tie the work down if there is any question about stability Slowly reduce the wire rope tension After enough wire rope has been unwound you may remove the hookup 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 ve finished rewinding the wire rope be sure you don t overwind it Alw...

Page 50: ...ting Extended 6 000 lbs Retracted 16 000 lbs 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 100 Feet All ratings comply with SAE J2512 and SAE J706 Recommended Practice WARNING Do not exceed the working limit of the wire rope Use snatch blocks and multiple lines to reduce the load on the wire rope 1 Ch...

Page 51: ... are the best and most efficient 3 Set the brakes on your Jerr Dan unit 4 Unfold the under lift boom 5 If a heavy lift or pull is to be made additional lines may be necessary Always use more stabilizing lines than pull lines RIG FOR SAFETY The use of scotch blocks is also recommended 6 Unhook the wire rope cables from the top of the tow sling ...

Page 52: ...l Never pull this handle while the wire rope is under load Moving the boom head with the wire rope locked can result in damage to both the wire ropes and the boom Be sure both winches are free spooling This allows the wire rope to be pulled directly off the drum to the work Unwind enough wire rope to make the hook up being sure that a minimum of at least five 5 wraps of wire rope remains on the dr...

Page 53: ...s and bridles are usually designed with hook clusters on them Most chassis manufacturer s provide tie down hooks and or slots in 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 10 Re engage the winches by placing the free spool levers back to their original positi...

Page 54: ...oss 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 Once the work is in the desired position apply the towed vehicles parking brake or use blocks or tie the work down if there is any question about stability Slowly reduce the wire rope tension After enough wire rope has been unwound you may remove the hookup ...

Page 55: ...ull 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 ve finished rewinding the wire rope be sure you don t overwind it Always wear safety glasses and gloves when doing recovery work or handling the wire rope ...

Page 56: ...sport Speed Single Line Boom 4 000 lbs Dual Line Boom 4 000 lbs If your MPL40 is equipped with a towing sling consult the AAA Towing Manual for hook up 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 9 FT ...

Page 57: ...pins allowing the hold back bars to swing out of its retaining brackets on the sides of the boom 4 Rotate the CAM handles on the hold back bars 180 to the open position 5 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 ...

Page 58: ...dles on the hold back bars 180 to the close position Raise or lower the boom slightly until the cam locks on the tow sling hold bars snap into the closed position 8 Extend the wrecker boom and adjust the wire rope cable s to lift the top of the tow sling and tow sling straps Extend the boom to the yellow indicator mark on the inner boom section of the wrecker boom ...

Page 59: ... 9 Lower the boom to allow the tow sling head to raise out of it holder on the back side of the boom 10 Carefully extend and lower the wrecker boom to allow the tow sling head to rotate outward and down away from boom 11 Lower the tow sling to the ground ...

Page 60: ... to be towed far enough under so the vehicle will ride on the rubber belts 14 Attach hook up chains The chain J hooks must be secured firmly around the 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 parts of the vehicle ...

Page 61: ...r to get sufficient height to prevent any damage to body parts TheAAA Towing Manual will diagram this 17 Be sure the fuel tank is not in contact with the sling or towing mechanism The fuel tank must not support any weight whatsoever 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 t...

Page 62: ...he CAM handles on the hold back bars 180 to the closed position 21 Retract the boom slowly drawing the vehicle forward until the stand offs are fully retracted and the CAM handles retract to the closed position for traveling 22 Install safety chains and towing lights ...

Page 63: ...n the event of a sudden stop This will assure that the towed vehicle will not catapult forward onto the deck of the MPL40 23 After the tow is complete reverse the procedures to unload the vehicle 24 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 25 Rotate the CAM handles on the hold back bars 180 to...

Page 64: ...hold back bars at the rear of the body 27 Swing the hold back bars in toward the tow sling storage brackets on the side of the boom Allow the hold back bars to retract as necessary 28 Connect the hold back bars to the tow sling storage brackets using the pins that you removed earlier ...

Page 65: ...ction II Operation Page 57 5 376 000086 REV 4 07 10 29 Rotate the CAM handles on the hold back bars 180 to the closed position 30 Retract the wrecker boom snug up the wire rope s and fold up the underlift ...

Page 66: ...CYCLE TOWING ADAPTER OPERATION OPTIONAL If your MPL40 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 grid arms like you would if you were loading a vehicle 6 IN ...

Page 67: ...he 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 bracket at the front of the boom with the pin and retaining pin ...

Page 68: ...on II Operation Page 60 5 376 000086 REV 4 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 and ramp ...

Page 69: ...re 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 in the towing adapter strap the front tire to the wheel lift boom Place the hooks of the middle wheel straps over the end of the boom top plate and run the other ends of the straps thru the front ti...

Page 70: ... 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 other side 14 Raise the underlift boom to the desired towing height CAUTION Care should be taken when lifting the boom Do not try to level the underlift The straps may overtighten or become loose ...

Page 71: ...p 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 safety chains to prevent the wheel grid from pivoting during travel Loop the end of the safety chain around the grid and secure with the grab hook Remove the slack in the chain and secure the chain in th...

Page 72: ...Section II Operation Page 64 5 376 000086 REV 4 07 10 18 Attach towing lights 19 Reverse the loading procedures to unload the motorcycle ...

Page 73: ...AGE OPERATION OPTIONAL If your MPL40 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 have 2 Open dolly the retaining latch by pulling the top toward you ...

Page 74: ...assemblies the axle cross tube rails and the pry bar jack bar 5 Load dollies See Dolly Operation instructions 6 Afterloading the dollies place the pry bar jack bar back into the storage bracket by inserting the end of the bar with the ring around it thru the cutout in the front bracket Allow the other end of the bar to rest on the rear bracket ...

Page 75: ...ts 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 axle cross tube rails back into the storage bracket by inserting the tab on the end of the axle tube into the cutout in the storage bracket ...

Page 76: ...6 REV 4 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 assemblies back into the storage brackets ...

Page 77: ... REV 4 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 retaining bolts and wing nuts or pad locks ...

Page 78: ...ires 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 trip assemblies freedom of movement while lifting vehicle 6 Engage ratchet assemblies to prevent injury and damage to the operator and vehicle in case pry bar slips from hand 7 Insert pry bar into pr...

Page 79: ...To 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 vehicle to drop Repeat this step on the other dolly and then remove the axles from the dollies USE CARE WHEN RELEASING OR UNLOCKING THE CAM BAR AS IT CAN MOVE SUDDENLYAND WITH FORCE CAUSING INJURY J...

Page 80: ...Section II Operation Page 72 5 376 000086 REV 4 07 10 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 81: ...t of the pivot joints utilize high strength 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 some lubrication or maintenance Sliding surfaces should be cleaned periodiacally The following chart and diagram shows the location of these points and when ...

Page 82: ...rom high strength aluminum which has been carefully assembled and polished in our factory To keep it clean and free of dirt use any non abrasive soap or detergent recommended for automotive finishes Use a soft cloth or sponge and finish with a thorough rinsing Drying with a soft cloth or chamois will prevent spotting or streaking A coat of automotive wax is recommended The MPL40 is mounted to the ...

Page 83: ...hey 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 accessible screws and nuts for proper tightness Converting ft lbs to Nm Newton metres can be accomplished by using the following Multiply by to get ft lbs x 1 3558 Nm Newton metres S D N U O P T O O F S ...

Page 84: ...us 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 HD Lithium EP2 2 Gulf Crown EP2 3 Amoco Amolith EP2 4 Shell Alvania EP2 5 Texaco Marfax EP2 6 Mobil Mobilux EP2 7 Sunoco Prestige EP2 WINCHAND GEAR LUBE 1 Phillips 140 wt EP Gear Lube 93301 or approved ...

Page 85: ...equires 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 the winch drum Aloose wire rope on the winch drum will cause crushing of the wire rope when heavy loads are applied All wire rope in continuous service should be observed during normal operation and v...

Page 86: ...e 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 of rope deterioration and approaching failure is broken wires Inspection criteria are specific as to the number of broken wires allowable under various circumstances It is important that a diligent s...

Page 87: ...derlift Level Stop Assist system follow these steps MPL40 1 To change the tilt stop move the sensor on the underlift boom base up to lower the boom and down to raise the boom as shown below 2 To change the boom stop move the sensor on the boom lift cylinder up to raise the boom and down to lower the boom as shown below BOOM LIFT CYLINDER REF MOVE SENSOR UPWARD TO RAISE UNDERLIFT DOWN WARD TO LOWER...

Page 88: ...Section III Maintenance Page 80 5 376 000086 REV 4 07 10 LUBRICATION POINTS The following lubrication chart is located inside the tool box lid on the driver s side of the MPL40 body ...

Page 89: ...lter 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 with foreign material b Low Amperage Voltage b Check Amperage Voltage at Solenoid Valve leaks a Defective seals a Replace Cylinder leaks a Defective seals or rods a Inspect and replace b Dirty or De...

Page 90: ...mp 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 shaft a Damaged seal a Replace seal seal b Damaged pump body b Replace pump body Pump leaks at body a Damaged seal a Replace seal section b Damaged pump body b Replace pump body c Body section bolt ...

Page 91: ...d 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 Fill to proper level Cavitation b Heavy oil b Fill with proper oil See chart c Dirty oil filter c Replace filter d Restriction in suction line d Clean out and remove e Pump worn e Repair or replace Pump...

Page 92: ...ls 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 WINCH FUNCTIONING IMPROPERLY Problem Cause Solution Winch screeches a Insufficient lubrication a Lubricate per lube chart during operation Winch will not pull a Free spooling device not a Engage load o...

Page 93: ...e 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 on a drum Body The structure mounted on a chassis cab or that portion of the vehicle that carries the load Body Hinge The attachment mechanism connecting the body to the hinge pin at the pivot axis ab...

Page 94: ... 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 cab to a point midway between the tandem axles Cable Steel wire rope used for pulling Car Carrier Vehicles equipped to transport other vehicles mounted on a flat platform and or with an additional as...

Page 95: ... 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 to the boom of a wheel lift or underlift for attaching towing accessories Curb Side The right or passenger side of the vehicle when viewed from the rear opposite side from ROADSIDE Curb Weight The we...

Page 96: ...ted 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 which either the upper or lower equipment is located Frame Cutoff Centerline of rear axle s to the rearmost point of the chassis frame as modified for body installation Frame Lift See Underlift Frame Sec...

Page 97: ... 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 Weight Rating The maximum total vehicle rated capacity measured at the tire ground interface as rated by the chassis manufacturer GVW Gross Vehicle Weight Value specified by the manufacturer as the max...

Page 98: ...The 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 towing recovery L L Arm See Wheel Arm Layer All wraps of the same diameter on a drum Lift Bar A traverse horizontally pivoting member attached to the boom of a wheel lift or underlift for attaching t...

Page 99: ...go 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 Highway Traffic Safety Administration The federal agency responsible for promulgating and insuring compliance of regulations dealing with the manufacture and certification of motor vehicles or items of mo...

Page 100: ...uck 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 transmission Front mounted and flywheel mounted power takeoffs are also used in various applications Push Bumper Device used to push a vehicle sometimes equipped with a rubber face R Rating The specifie...

Page 101: ... 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 VIN or the towing equipment manufacturer and placed on chassis body or components for identification purposes Sheave A wheel grooved for a wire rope to transfer power Shipping Weight The dry weight o...

Page 102: ... 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 center of rotation to the extreme rear extension of the revolving superstructure Tie Down Assemblies Device s used to restrain cargo or vehicles i e strap bridle chain or cable Tie Down Chains Chains used...

Page 103: ... 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 with maximum capacity of all fluids necessary for operation of the vehicle but without cargo or occupants Also referred to as curb weight V Valve A device which controls fluid flow direction pressure...

Page 104: ... 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 Straps Used to tie down wheels of the towed vehicle when using wheel lift car carrier or dolly towing equipment to limit the potential for separation of the towed vehicle from the towing apparatus Winch...

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Jerr-Dan MPL40, Operation And Maintenance Manual

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