5-376-000102REV. 1 - 07/10
© 2010 Jerr-Dan Corporation. All Rights Reserved.
MPL
OPERATIONS AND MAINTENANCE
MANUAL
$35.00
1080 Hykes Road
Greencastle, PA 17225
Phone (717) 597-7111
www.jerr-dan.com
Страница 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...
Страница 2: ...5 376 000102 REV 1 07 10...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 8: ...5 376 000102 REV 1 07 10 Page iv THIS PAGE INTENTIONALLY LEFT BLANK...
Страница 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...
Страница 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...
Страница 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...
Страница 12: ..._____________________TIRES ______________________RIMS ______________KPA ___________________PSI COLD__________________ GAWR INTERMEDIATE 2 ______________________KG __________________LB WITH____________...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 54: ...Section II Operation Page 46 5 376 000102 REV 1 07 10 THIS PAGE INTENTIONALLY LEFT BLANK...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
