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Section 6 - Maintenance

6-15

5376000207

HYDRAULIC PUMP

Problem

Cause

Solution

Oil foaming

a. Air leaking into suction line

b. Wrong kind of oil

c. Oil level too low

a. Tighten all connections

b. Drain and refill with

non-foaming type of hydraulic
oil (See lube chart)
Replace filter

c. Refill to proper 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

Problem

Cause

Solution

Winch screeches
during operation

a. Insufficient lubrication

a. Lubricate per lube chart

Winch will not pull load
or take in wire rope

a. Free-spooling device

not engaged

b. Sheared keys or broken

coupling

c. Hydraulic pump worn

a. Engage

b. Inspect or replace

c. Inspect and replace

Free-spool device

a. No air pressure

b. Insufficient air pressure

c. Defective pressure switch

d. Leaking air line

a. Turn truck on

b. Allow truck to run

c. Inspect and replace

d. Inspect and replace

Содержание JERR-DAN 20NGADF6T-LP

Страница 1: ...Operation And Safety Manual Original Instructions Keep this manual with machine at all times STANDARD DUTY XLP CARRIER 5376000207 January 13 2020 SN 0220020309 to Present...

Страница 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...

Страница 3: ...Revision Log 5376000207 a REVISION LOG January 13 2020 A Original Issue of Manual...

Страница 4: ...raining is 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 drive...

Страница 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...

Страница 6: ...all instances where 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 produc...

Страница 7: ...s an investigation and if it finds that a safety 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...

Страница 8: ...Read This First f 5376000207 THIS PAGE IS INTENTIONALLY LEFT BLANK...

Страница 9: ...1 7 Tip Over Hazards 1 7 Chemical Hazards 1 8 Battery Hazards 1 9 Personal Protective Equipment 1 9 Weather Conditions 1 10 Vehicle Equipment Damage 1 10 Section 2 Pre Operation and Inspection 2 1 Pre...

Страница 10: ...ulic Failure Raising Lowering Extending Retracting Deck 5 1 5 2 Engine Failure Raising Lowering Extending Retracting Deck 5 2 Section 6 Maintenance 6 1 Introduction 6 1 6 2 Maintenance And Lubrication...

Страница 11: ...ehicle until this manual has been read training is accomplished and operation of the vehicle has been com pleted under the supervision of an experienced and qualified operator There may be times the v...

Страница 12: ...the manual Use the vehicle in a manner which is within the scope of its intended application set by Jerr Dan All operating personnel must be familiar with the emergency operation of the vehicle as spe...

Страница 13: ...inimum Approach Distance MAD chart One foot additional clearance is required for every additional 30 000 volts or less Minimum Approach Distance M A D Voltage Range Phases to Phase MINIMUM APPROACH DI...

Страница 14: ...uipment to avoid crushing injury Always use jack stands to support the deck and or towbar wheel lift before working underneath a lifted load Warn personnel not to work stand or walk under a raised dec...

Страница 15: ...ipment is secured at the front of the deck Do not rely on the winch to hold the load Stay to the side of the deck when winching Keep cables from contacting sharp objects Never wrap cables around objec...

Страница 16: ...ight Rating GVWR and Gross Combination Weight Rating GCWR as well as any federal or state roading regulation In addition be aware of your vehicle s overall loaded height to be sure that you are under...

Страница 17: ...ck is tilted NEVER drive equipment onto the deck Always use the winch to pull the equipment onto the deck DO NOT carry riders outside the cab Riders could fall off the vehicle NEVER allow riders in th...

Страница 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...

Страница 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...

Страница 20: ...ctions Keep a safe working distance from overhead power lines bridges road signs and other objects Do not use a vehicle that has not been properly maintained Make sure mounting bolts are tight and mov...

Страница 21: ...e deck is in the locked position before travelling Do not use vehicle as a ground when performing any welding operations Store L Arms when not in use NEVER drive with the L Arms in the wheel grids Use...

Страница 22: ...Section 1 General Safety Practices 1 12 5376000207 THIS PAGE IS INTENTIONALLY LEFT BLANK...

Страница 23: ...re in cab 5 Walk Around Inspection See page 2 4 for details 6 Fluid Levels Check all fluids including hydraulic oil and winch gear case oil When adding fluids refer to Section 6 Maintenance and Lubric...

Страница 24: ...________________________ ______________________________________________ DATE OF MFR MO______________YR ______________ GVWR _________________KG _________________LB GAWR FRONT ______________________KG _...

Страница 25: ...YPE WORKING LOAD LIMIT LBS MODELNO SERIAL NO DECK CAPACITY BS WHEELLIFT LIFT CAPACITY LBS WHEELLIFT TOW CAPACITY LBS VIN C A IN GROSS VEHICLE LBS GVWR FRONTAXLE LBS GVWR REAR AXLE LBS GVWR LBS ON CARR...

Страница 26: ...A IN GROSS VEHICLE LBS GVWR FRONTAXLE LBS GVWR REAR AXLE LBS GVWR LBS ON CARRIER DECK LBS ON TOWBAR WHEELLIFT LOSS OF VEHICLE CONTROL WHICHCOULD RESULT IN SERIOUS BODILY INJURY OR DEATH CAN OCCURIF EF...

Страница 27: ...W CAPACITY LBS VIN C A IN GROSS VEHICLE LBS GVWR FRONTAXLE LBS GVWR REAR AXLE LBS GVWR LBS ON CARRIER DECK LBS ON TOWBAR WHEELLIFT LOSS OF VEHICLE CONTROL WHICHCOULD RESULT IN SERIOUS BODILY INJURY OR...

Страница 28: ...BOTH LH AND RH SIDES 7330000609 7330000060 IF EQUIPPED GREAS E R EQUIRE D GREAS E R EQUIRE D GREAS E R EQUIRE D 7330000684 7330000683 BOTH LH AND RH SIDES 7330000609 7330000060 IF EQUIPPED GREAS E R E...

Страница 29: ...9 REAR DOCK STABILIZER IF EQUIPPED TOW BAR WITH PINTLE HITCH OR BALL HITCH IF EQUIPPED 7330000684 7330000391 STABILIZER OPTIONS 7330000599 REAR DOCK STABILIZER WITH REESE HITCH IF EQUIPPED 7330000274...

Страница 30: ...ecurely fastened and no visible leaks or excessive wear exists in addition to any other criteria mentioned Inspect all structural members for cracks excessive corrosion and other damage FALL HAZARD Us...

Страница 31: ...mponents undamaged and operational b Secure 4 Hydraulic Tank a Hydraulic fluid level full b Hydraulic hoses undamaged not leaking 5 Toolbox Storage Compartment s a Components undamaged b Toolbox Stora...

Страница 32: ...ns secure 12 Controls a Components and switches undamaged b Hydraulic hoses and electric harnesses undamaged c Valve and hydraulic hoses not leaking 13 Winch Air Controls If Equipped a Components unda...

Страница 33: ...ge Boxes and Safety Chains a Chain Storage Boxes undamaged b Safety Chains are present c Safety Chains are undamaged 18 Winch a Hydraulic hoses undamaged not leaking b Gear oil level full 19 Wire Rope...

Страница 34: ...Take Off operation 5 Driver side and passenger side controlled functions all functions operate smoothly and the controls return to the Neutral Off position 6 Wireless remote control functions all fun...

Страница 35: ...sion to a hydraulic pump to provide hydraulic power to the carrier hydraulics The controls at the rear of the body on both the left hand side and right hand side control all of the carrier functions T...

Страница 36: ...2 5376000207 3 2 CONTROLS LEFT HAND SIDE CONTROL STATION 0 1000 20 00 30 00 4000 50 00 psi TOW OPT 652 675 W AGE WINCH FREE SPOOL 1 2 3 4 5 6 7 8 RIGHT HAND SIDE CONTROL STATION TOW OPT 653 676 W AGE...

Страница 37: ...Option In Out 7 Tow Option Control If Equipped Controls the Tow Option Up Down 8 Winch Free Spool Control If Equipped Controls the Winch Free Spool STABILIZER STABILIZER 0 1000 200 0 300 0 4000 50 00...

Страница 38: ...ON Button Turns ON the Hand Controller Power 3 Power Indicator Light Indicates that the Hand Controller is powered ON when Illuminated 4 Winch In Controls the wire rope winding function of the winch 5...

Страница 39: ...dicates that the Hand Controller is powered ON when Illuminated 4 Winch In Controls the wire rope winding function of the winch 5 Winch Out Controls the wire rope unwinding function of the winch 6 Opt...

Страница 40: ...Controller is powered ON when Illuminated 4 Optional Specified by Customer Controls Option 5 Optional Specified by Customer Controls Option 6 Optional Specified by Customer Controls Option 7 Optional...

Страница 41: ...ols the roll back function of the deck 6 Deck Tilt Down Controls the tilt down function of the deck 7 Deck Tilt Up Controls the tilt up function of the deck 8 Winch In Controls the wire rope winding f...

Страница 42: ...Section 3 Controls Indicators 3 8 5376000207 THIS PAGE IS INTENTIONALLY LEFT BLANK...

Страница 43: ...d on the left hand side Another set of controls are located on the right hand side There is also a wireless handheld remote controller that controls all the carrier functions Do not use the wireless r...

Страница 44: ...d any work lights as necessary Switches are located on the switch panel in the dash 2 Position the rear of the carrier deck about 12 feet from the equipment you intend to load Make sure the vehicle is...

Страница 45: ...hassis operator s manual for proper operation of the auxiliary throttle If your chassis is equipped with the remote throttle up option from the chassis manufacturer there is no need to set the throttl...

Страница 46: ...and the approach plate are both in firm contact with the ground before loading so there is equal weight distribution between the rear bumper and the end of the deck 10 Next unreel enough of the wire r...

Страница 47: ...Re engage the winch clutch See Winch Operation Sections 4 3 and 4 4 13 Slowly operate the Winch Control to remove any slack in the wire rope cable Maintain a minimum of five 5 wraps of wire rope cable...

Страница 48: ...winch to hold the load Properly chock the equipment s wheels to prevent it from rolling until the wire rope cable is under tension Always winch the equipment onto the deck Never drive equipment onto t...

Страница 49: ...ward Align the arrow decal pointer on the side of the deck with the deck control switch in the control panel 19 Secure the equipment to the rear of the deck 20 Once the equipment is secured from movem...

Страница 50: ...sport Checklist located on the headboard of the deck before transporting Make sure you have followed all of the items on the list Always use approved tie downs per the equipment manufacturer s instruc...

Страница 51: ...load the equipment P P R R N N 4 4 2 2 1 1 D D 3 Place the carrier s transmission gear selector into Neutral or Park and set the parking brakes OUT OUT P PO OWER WER T TAKE OFF AKE OFF 4 Engage the po...

Страница 52: ...lly increase when any of the carrier hydraulic functions are operated Never exceed 1200 R P M When your hook up is complete reset the engine idle to normal 6 Block the carrier s rear tires with wheel...

Страница 53: ...ear bumper and the approach plate are both in firm contact with the ground before loading so there is equal weight distribution between the rear bumper and the end of the deck 11 Slowly operate the Wi...

Страница 54: ...to allow the equipment to roll slide off of the carrier deck 14 Set the equipment s parking brake and put the transmission into Park if equipped 15 Remove the hook up chains and wire rope cable Mainta...

Страница 55: ...l to avoid birdnesting 17 Slide the deck forward Align the arrow decal pointer on the side of the deck with the deck control switch in the control station 18 Lower the front of the deck to the subfram...

Страница 56: ...rom the carrier s rear tires T TAKE OFF AKE OFF IN IN OU OU 21 Disconnect the power take off PTO Refer to PTO operator s manual NEVER TRAVEL WITH THE POWER TAKE OFF CONTROL ENGAGED This could result i...

Страница 57: ...er the knob and release 3 Look to make sure that the free spool knob is locked in the free spool position The winch clutch is now disengaged and the wire rope cable may be pulled off by hand Always we...

Страница 58: ...nd release The free spool knob should spring back into the engaged position Raise the Winch Control handle to run the winch in reverse reel out direction until the free spool snaps fully in position o...

Страница 59: ...inch in the forward reel in direction to disengage the clutch The winch clutch is now disengaged and the wire rope cable may be pulled out by hand Never move the free spool lever while the wire rope c...

Страница 60: ...simply move the free spool lever in the control station down into the engage position 2 Run the winch in reverse reel out direction until the winch drum starts turning After the winch clutch is fully...

Страница 61: ...ly is comprised of the following components 1 2 RTJ Hook Cluster Chains 2 2 RTJ Hook Cluster Straps 3 2 Ratchet Spool Mechanisms Follow these steps to properly install the tie down strap and chain ass...

Страница 62: ...THE FRONT TIE DOWN CHAINS 1 Using the RTJ hook cluster chains insert the appropriate hook into the vehicle frame tie down hole or slot Refer to the AAA or vehicle manufacturer s towing manual for the...

Страница 63: ...hole or slot Refer to the AAA or vehicle manufacturer s towing manual for the correct attachment points 2 Insert the chain on the end of the ratchet into the keyslot in the deck Adjust the chain so t...

Страница 64: ...ry Switches are located on the switch panel in the dash 4 FT 2 Position the rear of the carrier about 4 feet from the vehicle you intend to load Make sure you are in line with the vehicle to tow Becau...

Страница 65: ...th the remote throttle up option from the chassis manufacturer there is no need to set the throttle up control in the cab because the throttle will automatically increase when any of the carrier hydra...

Страница 66: ...nded 8 Raise the Tow Option Extend Retract Control handle to extend the wheel lift under the vehicle Make sure all undercarriage parts are cleared and that the ramp portion of the of grid is in contac...

Страница 67: ...ace the vehicle s transmission in Neutral and release the parking brake Make sure that the wheels are straight and install a steering wheel strap It is recommended that the steering wheel be secured b...

Страница 68: ...rol handle to retract the wheel lift until the vehicle is about 3 to 4 feet from the back of the truck Leave enough room to maneuver around corners without corner binding or causing contact between th...

Страница 69: ...amage to the PTO unit and the recovery vehicle s transmission Properly secure the vehicle using safety chains from the vehicle to the carrier subframe Properly secure the vehicle to the wheel grid usi...

Страница 70: ...5376000207 Always store the L Arms in the storage location provided when not in use Do not store the L Arms in the wheel grids After unloading the vehicle fully retract the wheel lift boom before oper...

Страница 71: ...sible and wide enough to allow the L Arms to slide into their channels Tighten the T handles to secure the grids 3 Retract the Cam handle locking pin on the grid by turning it 180 It should remain in...

Страница 72: ...them into the channels on the side of the grid Make sure that they are resting snugly against the tires with the L Arms in close contact with the tires Then reset the locking pin by turning the Cam h...

Страница 73: ...hten the T handles to secure the grids 3 Pivot the wheel restraint receivers on the end of the grid arms outward by lifting up on the receiver Rotate the Cam handles on the receivers 180 to the open p...

Страница 74: ...the holes The tires are now confined front and back 7 Pivot the receivers and wheel restraints inline with the tires Make any adjustments to the wheel restraints making sure that you clear body and u...

Страница 75: ...s are cleared and that the front portion of the grid is in contact with both tires Lower the grid fully to the ground 3 Visually inspect the tire to grid contact before proceeding 4 Lower the grid arm...

Страница 76: ...HE 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...

Страница 77: ...pull 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 Con...

Страница 78: ...ING THE 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 pul...

Страница 79: ...sition and pull 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 sp...

Страница 80: ...llow these steps to properly install the tie down straps INSTALLING THE RATCHET SPOOL MECHANISM 1 First set the spool into free spool This is done by pulling the lock bar out and swinging the handle u...

Страница 81: ...RAPS 1 With the vehicle lifted 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 st...

Страница 82: ...sest to the tire 4 Take up the slack in the strap by ratcheting the take up spool arm Continue until the tires show some compression Repeat for other side 5 Raise the wheel grid to the towing position...

Страница 83: ...s can be operated manually 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...

Страница 84: ...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 the parking brake Place t...

Страница 85: ...nnel with 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 eq...

Страница 86: ...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...

Страница 87: ...24 4 Texaco Rando HD 46 5 Kendall AW 46 6 Citgo Mystik AW 46 7 Amoco AW 46 8 Conoco Super 9 Mobil DTE10 Excel 32 for cold weather use below 20 F 10 Conoco AW Hydraulic Fluid MV 32 for cold weather use...

Страница 88: ...Section 6 Maintenance 6 4 5376000207 Company Product WIRE ROPE Mobile Motor Oil or other approved deep penetrating equivalent...

Страница 89: ...h 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 appointed c...

Страница 90: ...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...

Страница 91: ...y 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 off the turns spirals will occur and kinks are likely to form in the rope...

Страница 92: ...t the rope will spool evenly with the turns lying snugly against each other in even layers If wire rope is wound on a smooth face drum in the wrong direction the turns in the first layer of rope will...

Страница 93: ...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...

Страница 94: ...R DRAIN FILL DRAIN FILL 1 1 LUBRICATION CHART CHART COVERS ONLY BODY COMPONENTS INDICATES DUAL RANGE HYD FLUID 5 W 20 AUTO TRANS FLUID MAY BE SUBSTITUTED IF NECESSARY CONSULT WINCH MANUAL FOR PROPER G...

Страница 95: ...ion chart on Page 6 10 1 Winch Gear Case Lube Point s Fill Plug Lube Reference winch manufacturer s manual Interval Check level every 250 hours or semi annually Change every 1000 hours 6 Hydraulic Res...

Страница 96: ...Section 6 Maintenance 6 12 5376000207 7 Hydraulic Reservoir Return Filter Lube Point s Replaceable Element Interval Check level every 250 hours or semi annually...

Страница 97: ...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 Defect...

Страница 98: ...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...

Страница 99: ...mp leaks at front and rear covers a Defective seals a Replace seals WINCH FUNCTIONING IMPROPERLY Problem Cause Solution Winch screeches during operation a Insufficient lubrication a Lubricate per lube...

Страница 100: ...harged Battery b Receiver power turned off c Out of range d Communication error a Replace Battery b Check receiver power input c Make sure transmitter is in range of receiver d Make sure transmitter a...

Страница 101: ...1SRRD6T LP 22SRRD6T LP 20SRRD6T W LP 21SRRD6T W LP 22SRRD6T W LP OPERATING SPECIFICATIONS AND PERFORMANCE DATA DO NOT EXCEED THE FOLLOWING RATINGS DECK RATING 12 000 lb WINCH RATING Ramsey Worm Gear 1...

Страница 102: ...1 2 Reese Receiver on Rear Stabailizer 1 200 lbs 12 000 lbs Hydraulic Towbar with Pintle Hook Mounting on Rear Stabailizer 3 500 lbs 12 000 lbs 2 Reese Hitch Receiver 500 lbs 5 000 lbs 2 1 2 Reese Hi...

Страница 103: ...ehicle load must not exceed the GVWR Gross Vehicle Weight Rating of the towing vehicle The total weight of the towing vehicle and a towed vehicle load must be distributed so that each axle s GAWR Gros...

Страница 104: ..._______________________________TIRES ______________________RIMS ______________KPA ___________________PSI COLD__________________ GAWR INTERMEDIATE 2 ______________________KG __________________LB WITH__...

Страница 105: ...00207 7 5 7 2 CAPACITIES Hydraulic System Operating Pressure 2500 psi System Flow 18 gpm System Capacity 14 gal Reservoir Capacity 12 gal Type of Oil 0 to 104 F 20 to 40 C Mobilfluid 424 40 to 0 F 40...

Страница 106: ...Section VII Specifications 7 6 5376000207 THIS PAGE IS INTENTIONALLY LEFT BLANK...

Страница 107: ...Inspection Maintenance and Repair Log Serial Number Date Comments...

Страница 108: ...Inspection Maintenance and Repair Log Date Comments...

Страница 109: ...to provide Jerr Dan with updated information with regard to the current ownership of Jerr Dan products Please return completed form to the Jerr Dan Product Safety Reliability Department via facsimile...

Страница 110: ...THIS PAGE IS INTENTIONALLY LEFT BLANK...

Страница 111: ......

Страница 112: ...www jerr dan com 5376000207 13224 Fountainhead Plaza Hagerstown MD 21742 Phone 717 597 7111 Phone 800 926 9666...

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