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5-376-000094
REV. 3 - 03/10

Section III: Maintnenace

Page 85

TROUBLESHOOTING

HYDRAULIC PUMP

Problem

Cause

Solution

Hydraulic oil leak

a. Defective shaft seal

a. Replace shaft seal

between P.T.O. and
pump
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

a. Engage

load or take in wire

not engaged

rope

b. Sheared keys or broken

b. Inspect or replace

coupling

c. Hydraulic pump worn

c. Inspect and replace

Free-spool device

a. No air pressure

a. Turn truck on

b. Insufficient air pressure

b. Allow truck to run

c. Defective pressure switch c. Inspect and replace
d. Leaking air line

d. Inspect and replace

Cable tensioner

a. No air pressure

a. Turn truck on

device non-functional b. Insufficient air pressure

b. Allow truck to run

c. Defective pressure switch c. Inspect and replace
d. Leaking air line

d. Inspect and replace

Cable speed shift

a. No air pressure

a. Turn truck on

nonfunctional

b. Insufficient air pressure

b. Allow truck to run

c. Defective pressure switch c. Inspect and replace
d. Leaking air line

d. Inspect and replace

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Содержание JERR-DAN HDR 70/85-530

Страница 1: ...10 2010 Jerr Dan Corporation All Rights Reserved HDR 70 85 WRECKER OPERATIONS AND MAINTENANCE MANUAL 35 00 1080 Hykes Road Greencastle PA17225 Phone 717 597 7111 www jerr dan com E a s t e r n W r e c...

Страница 2: ...E a s t e r n W r e c k e r S a l e s I n c...

Страница 3: ...ained in this manual reflects how your Jerr Dan equipment was built at the factory Modifications or additions by the distributor or owner are not reflected in this manual This manual does not include...

Страница 4: ...Road Greencastle PA17225 or by e mail at technicalpublications jerr dan com Always keep this manual in your vehicle so the operator can study it as needed before a recovery Remember to replace the man...

Страница 5: ...ments 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...

Страница 6: ...s 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...

Страница 7: ...48 Trailer 5th Wheel Plate and Pintle Hook Ball Hitch Adapter Optional 55 Rear Hydraulic Stabilizers 58 Integral Spades 60 Outrigger Stabilizers 62 Outrigger Spades 66 Wrecker Boom Operation 68 Secti...

Страница 8: ...5 376 000094 REV 3 03 10 Page iv THIS PAGE INTENTIONALLY LEFT BLANK E a s t e r n W r e c k e r S a l e s I n c...

Страница 9: ...everyone else close by As a wrecker operator you must develop an awareness of the hazards involved You must use every safeguard within reason to prevent injuries For each step in operating your wreck...

Страница 10: ...R Identifies when an imminently hazardous situation exists and can result in death or serious injury WARNING Identifies when a potentially hazardous situation exists and could result in death or serio...

Страница 11: ...ANUAL S INTHEIRENTIRETYFORTHISWRECKER 3 HAVE COMPLETELY READ ALL WARNINGS AND PRECAUTIONSONTHISWRECKER 4 HAVEHADEXPLAINEDTOTHEMTHEHAZARDSOF MOVINGTHEPARTICULARMATERIALSTHEYWILLBE LOADINGORUNLOADING 5...

Страница 12: ...onal Three Stage Boom SAE Rating Boom elevated at 30 Angle1 Retracted 120 000 lbs Mid 44 000 lbs Extended 26 000 lbs WINCH RATING Option 1 Dp Planetary Gear 2 Each Drum Two Speed Variable Control 50 0...

Страница 13: ...Construction 6 x 37 EIP IWRC Diameter 5 8 inch Standard Length 250 Feet HEAVY DUTY TIRE LIFT RATING OPTION Lifting Capacity Each Arm 7 000 lbs Lifting Capacity Total 14 000 lbs Towing Capacity Maximum...

Страница 14: ...directly over the rear with the swing lock engaged The rear spades and outriggers must be properly set on firm level surface Proper rigging for the wire rope limits must be utilized Lifting the Maxim...

Страница 15: ...d vehicle 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 G...

Страница 16: ...onal Three Stage Boom SAE Rating Boom elevated at 30 Angle1 Retracted 120 000 lbs Mid 44 000 lbs Extended 26 000 lbs WINCH RATING Option 1 Dp Planetary Gear 2 Each Drum Two Speed Variable Control 50 0...

Страница 17: ...Construction 6 x 37 EIP IWRC Diameter 5 8 inch Standard Length 250 Feet HEAVY DUTY TIRE LIFT RATING OPTION Lifting Capacity Each Arm 7 000 lbs Lifting Capacity Total 14 000 lbs Towing Capacity Maximum...

Страница 18: ...y directly over the rear with the swing lock engaged The rear spades and outriggers must be properly set on firm level surface Proper rigging for the wire rope limits must be utilized Lifting the Maxi...

Страница 19: ...d vehicle 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 G...

Страница 20: ...5 376 000094 REV 3 03 10 Section I Safety Page 12 LOAD CHART Refer to the actual chart in your unit S A M P L E 749 E a s t e r n W r e c k e r S a l e s I n c...

Страница 21: ...TIRES ______________________RIMS ______________KPA ___________________PSI COLD__________________ GAWR INTERMEDIATE 2 ______________________KG __________________LB WITH_________________________________...

Страница 22: ...wrecker s engine faster than recommended Excessive speeds can damage PTO hydraulic pumps and winches Don t lower the rear hydraulic stabilizers unless the area under them is clear Pay particular atte...

Страница 23: ...ting the controls Don t tow a vehicle on its front wheels unless the steering wheel is secured with the front wheels straight ahead After you have hooked up a vehicle for towing don t start the tow un...

Страница 24: ...As an alternative use a towing dolly Never exceed the front and or rear axle ratings of your towing equipment Never extend or retract an outrigger unless it is in full view from it s operating contro...

Страница 25: ...ates 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...

Страница 26: ...t 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 u...

Страница 27: ...rs before making a lift or pull Never stand on or straddle a working wire rope Take up the wire rope cable slowly and be sure the hook is securely set Be sure of your lift or pull and do not exceed th...

Страница 28: ...ont 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 rop...

Страница 29: ...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 pro...

Страница 30: ...ith the winch wire ropes set in free spool to avoid over tensioning or breaking the winch wire ropes Avoid using the boom raise or boom up control to lift a load This causes undue stress and weight lo...

Страница 31: ...or death To avoid birdnesting and premature failure of the wire rope always keep tension on the wire rope when winding or unwinding Don t exceed ratings of booms wire ropes snatch blocks or winches St...

Страница 32: ...wing a load this force will cause the load to swing away from the machine and may cause instability Make sure vehicle is positioned in an area free from overhead obstructions KEEP A SAFE WORKING DISTA...

Страница 33: ...REV 3 03 10 Section I Safety Page 25 Do not swing the wrecker boom without extending the outrigger stabilizers Stay clear of rotating equipment to avoid crushing injury E a s t e r n W r e c k e r S a...

Страница 34: ...nt MANUFACTURED BY JERR DAN CORPORATION 1080 HYKES ROAD GREENCASTLE PA 17225 1 800 926 9666 WORKING LIMIT TYPE SIZE CABLE WIRE ROPE FT LBS EACH DRUM WINCH RATING SAE J706 LBS SERIAL NO MODEL NO UNDERL...

Страница 35: ...5 376 000094 REV 3 03 10 Section I Safety Page 27 E a s t e r n W r e c k e r S a l e s I n c...

Страница 36: ...y warning lable and figure out how to avoid the hazard These lables must not be obliterated removed or painted over They are there to remind and protect the operator Not all decals are used on all uni...

Страница 37: ...ICHEVER IS LOWER CAUTION 278 278 THE BUS BAR GRID MUST BE SECURED TO THE CROSS TUBE AT ALL TIMES WITH THE RETAINING PINS THE BUS BAR GRID MUST BE SECURED TO THE CROSS TUBE AT ALL TIMES WITH THE RETAIN...

Страница 38: ...WARNING WARNING 262 262 A MINIMUM OF 5 WRAPS OF CABLE MUST BE LEFT ON DRUM TO ACHIEVE RA TED LOAD NOT TO BE USED IN THE MOVING OR LIFTING OF PERSONS A MINIMUM OF 5 WRAPS OF CABLE MUST BE LEFT ON DRUM...

Страница 39: ...ITH SAFETY CHAINS Hazardous voltage Will cause severe injury or death Hazardous voltage Will cause severe injury or death Do not raise lower or move boom within near power lines Do not raise lower or...

Страница 40: ...5 376 000094 REV 3 03 10 Section I Safety Page 32 E a s t e r n W r e c k e r S a l e s I n c...

Страница 41: ...the driver s seat If the remote hand controller is going to be used the CONTROL switch must be turned ON 2 Using the rear axle as a guide position the recovery vehicle within nine 9 ft of the subject...

Страница 42: ...e to normal 6 Confirm the recovery vehicle s position in relation to the casualty vehicle to be towed Nine 9 ft is recommended Reposition the recovery vehicle if necessary Be sure the casualty vehicle...

Страница 43: ...ing pin into the end of the crossbar and secure with the safety pin CAUTION The retaining pins must be in place during all towing applications 10 Adjust the lift receivers on the crossbar to the desir...

Страница 44: ...xtend the under lift boom under the casualty vehicle so that the spring brackets are in the proper position for lifting Make sure that the spring brackets are against the front part of the spring hang...

Страница 45: ...cure the casualty vehicle to the crossbar with chains and a chain binder 6 After securing the casualty vehicle and before making the final lift check to be sure that the casualty s parking brake is re...

Страница 46: ...etween the two 2 vehicles Be sure that the fly boom is extended at least four 4 in from the middle boom section to ensure unobstructed cross bar pivoting 10 Raise the casualty vehicle into the final t...

Страница 47: ...casualty vehicle 12 Attach the safety chains and auxiliary towing lights 13 Hook up and connect air and braking systems 14 If the remote hand controller was used turn the CONTROL switch OFF Switch is...

Страница 48: ...ponents 3 Raise the boom to lift the casualty slightly 4 Secure the casualty vehicle to the crossbar with chains and a chain binder 5 After securing the casualty vehicle and before making the final li...

Страница 49: ...pivoting 9 Raise the casualty vehicle into 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 cau...

Страница 50: ...on the crossbar 2 Extend the under lift boom up to the casualty vehicle so that the chain forks are in the proper position for lifting 3 Attach the hook up chains to the casualty vehicle Hook the cha...

Страница 51: ...ront or rear tow 7 With the vehicle in neutral and the parking brake released you can move the vehicle safely up down in or out All of these movements are hydraulically controlled 8 Power retract the...

Страница 52: ...u will have better turning and manuevering capabilities and it will prolong the life of your under lift and pivot pin 10 Be sure to maintain sufficient ground clearances with the bottom of the casualt...

Страница 53: ...om up to the casualty vehicle so that the chain hook adapters are in the proper position for lifting 4 Attach hook up chains to the casualty vehicle Fasten the chains in the hooks on the end of the ad...

Страница 54: ...ront or rear tow 8 With the vehicle in neutral and the parking brake released you can move the vehicle safely up down in or out All of these movements are hydraulically controlled 9 Power retract the...

Страница 55: ...Underlift Boom should be as close to horizontal as possible You will have better turning and manuevering capabilities and it will prolong the life of your under lift and pivot pin 11 Be sure to mainta...

Страница 56: ...ED WEIGHT OF THE TOWED VEHICLE WHICHEVER IS LOWER 2 MAXIMUM LIFTING CAPACITY THE MAXIMUM LOAD THAT CAN BE LIFTED 1 Slide the tire lift grid onto the crossbar CAUTION Make sure that the tire lift Grid...

Страница 57: ...tube into the desired position in the grid 4 Install the retaining pin and hairpin 5 Retract the tube inward to the loading position 6 Slide the arm weldment over the end of the grid and adjust to the...

Страница 58: ...components 9 Using the pulling tool extend the round tube to capture the back of the tire After extending the tube make sure that the flanged edge of the tube is turned up to prevent the tire from sl...

Страница 59: ...own strap to the round tube behind the tire Pull the strap up and cover the tire and attach the hook on the ratchet end of the strap to the arm in front of the tire 12 Take up the slack in the strap b...

Страница 60: ...t corner binding or causing contact between the two 2 vehicles Be sure that the fly boom is extended at least four 4 in from the middle boom section to ensure unobstructed cross bar pivoting 16 Raise...

Страница 61: ...L switch OFF Switch is located on panel on the floor WARNING Do not use the tire lift if the tire s of the casualty vehicle are flat or if there is damage to the wheels or suspension CAUTION The tire...

Страница 62: ...es while towing is recommended CAUTION Do not tow any vehicle without safety chains being installed CAUTION Always follow the chassis manufacturer s recommended procedures for towing Remove drive line...

Страница 63: ...lbs TOWING CAPACITY 25 000 lbs PINTLE HOOK BALL HITCH 2 IN BALL HITCH 10 000 lbs GTW PINTLE HOOK 16 000 lbs GTW GROSS TRAILER WEIGHT 3 000 lbs MAXIMUM VERTICAL LOAD GROSS TRAILER WEIGHT GTW THE MAXIM...

Страница 64: ...olts 4 Install the 5th wheel plate onto the adapter with the attaching pin Secure the attaching pin with the linchpin 5 Remove the king pin locking pin from the 5th wheel plate and position the recove...

Страница 65: ...e air lines from the recovery vehicle to the casualty trailer to release the trailer brakes 9 Raise the trailer jack stands 10 Attach the safety chains CAUTION If the trailer to be towed is on a slope...

Страница 66: ...nching forces USE CAUTIONAND GOOD JUDGEMENT Follow these simple steps 1 Position the recovery vehicle as close as possible to the work and set the parking brakes and place the transmission in neutral...

Страница 67: ...he stabilizers work independently from each other so that they can be used on uneven ground WARNING Area should be clear of feet when lowering the rear stabilizers CAUTION Do not move the recovery veh...

Страница 68: ...Page 60 INTEGRAL SPADES 1 Remove the safety pin and spade retaining pin 2 Allow the integral spade to swing down exposing the spade blades 3 Line up holes and insert spade retaining pin and safety pi...

Страница 69: ...s or to terminate the wire rope hook during winching operations WARNING Area should be clear of feet when lowering the rear stabilizers CAUTION Do not move the recovery vehicle with the stabilizers on...

Страница 70: ...a resistance to winching forces USE CAUTION AND GOOD JUDGEMENT Follow these simple steps 1 Position the recovery vehicle as close as possible to the work and set the parking brakes and place the trans...

Страница 71: ...er pins from the storages compartments Install the pins into the inner sections of the outrigger and secure with the retaining pins 7 Retract the outer outrigger sections about 1 to align the locking...

Страница 72: ...to lock into the pin into position 11 Lower the outriggers to the ground Raise the chassis to get the tires off the groud Level the chassis as required WARNING Area should be clear of feet when lower...

Страница 73: ...tabilizers can be used for the attachment of snatch blocks or to terminate the wire rope hook during winching operations CAUTION When using stabilizer pads on pavement or concrete it is suggested that...

Страница 74: ...Page 66 OUTRIGGER SPADES 1 Swing down the spade pads 3 Line up holes and insert spade retaining pin and secure with the safety pin WARNING Area should be clear of feet when lowering the rear stabilize...

Страница 75: ...with the stabilizers on the ground or damage to the chassis can occur CAUTION Do not use spades on pavement or concrete Damage to the pavement or concrete may result CAUTION All spades must be pinned...

Страница 76: ...ing free and swinging during the lift Place the recovery vehicle as close as possible to the work A shorter boom extension will result in less rear axle loading When pulling align the recovery vehicle...

Страница 77: ...hand controller is going to be used 3 Engage the power take off PTO See PTO operator s instruction manual Adjust the electronic or manual throttle control to elevate the engine speed to approximately...

Страница 78: ...rols to unlock the slew pin to allow the wrecker boom to rotate DANGER Do not swing the wrecker boom without extending the outrigger stabilizers 7 Using the winch control levers unwind some wire rope...

Страница 79: ...r unwinding 11 Make the hook up in such a way as to afford an even pull on both wire ropes Over stressing one wire rope can happen if care isn t taken in hook placement 12 If a heavy lift or pull is t...

Страница 80: ...pes Inspect the hook up points for slippage before continuing the lift or pull Manually control each winch to ensure wire ropes are stressed evenly As the wire rope is retrieved be sure it doesn t cri...

Страница 81: ...hains and remove them carefully Avoid straddling the wire rope 18 Respool both wire ropes and take this opportunity to inspect them for damage Keep tension on the wire rope while respooling 19 Retract...

Страница 82: ...5 376 000094 REV 3 03 10 Section II Operation Page 74 THIS PAGE INTENTIONALLY LEFT BLANK E a s t e r n W r e c k e r S a l e s I n c...

Страница 83: ...and coated with a heavy grease periodically Cleaning every month is recommended for normal highway operations but this frequency will vary appreciably with the type of service Sliding on dirty wear s...

Страница 84: ...nated fluid can usually be worked out with fine emery cloth to avoid repetition of the trouble Whenever any seal replacement is necessary it is always advisable to replace all seals in that component...

Страница 85: ...ternal threads When nuts are used tighten nuts to torques shown screws or bolts should be held but not turned Always use a calibrated torque wrench Retighten nuts of all mounting screws that secure th...

Страница 86: ...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...

Страница 87: ...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 competent person...

Страница 88: ...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...

Страница 89: ...E MPG 5 10 SHEAVE PIN LUBE MPG 5 11 UNDERLIFT LIFT BOOM LUBE MPG 2 12 UNDERLIFT LIFT CYLINDER LUBE MPG 2 13 UNDERLIFT TILIT CYLINDER LUBE MPG 2 14 UNDERLIFT PIVOT LUBE MPG 3 15 UNDERLIFT EXTEND CYLIND...

Страница 90: ...0 AUTOMATIC TRANSMISSION FLUID CAN BE SUBSTITUTED IF NECESSARY 2 USE GREASE GUN WITH NEEDLE NOSE ADAPTER TO SQUIRT GREASE ONTO TOP AND BOTTOM OF BOOM INTERIOR WHERE WEAR PADS RUN 3 ROTATE BEARING WHIL...

Страница 91: ...ilter e Hydraulic pump worn e Rebuild or replace f Frozen hydraulic lines f Thaw and remove water Valve handle sticks a Insufficient lubrication a Lubricate per lube chart tight or frozen b Broken cen...

Страница 92: ...DRAULIC 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 suct...

Страница 93: ...nspect or replace coupling c Hydraulic pump worn c Inspect and replace Free spool device a No air pressure a Turn truck on b Insufficient air pressure b Allow truck to run c Defective pressure switch...

Страница 94: ...essure switch c Inspect and replace d Leaking air line d Inspect and replace e Defective air cylinder e Inspect and replace f Jammed locking pin f Inspect and replace g Ice buildup on pin and or g Tha...

Страница 95: ...ding 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 stru...

Страница 96: ...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...

Страница 97: ...l 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...

Страница 98: ...ic 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...

Страница 99: ...ximum 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 maximu...

Страница 100: ...derlift 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 Ar...

Страница 101: ...n 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 Admi...

Страница 102: ...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 mounte...

Страница 103: ...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 equi...

Страница 104: ...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 e...

Страница 105: ...er 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...

Страница 106: ...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 w...

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