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Oshkosh Corporation JERR-DAN HDR 70/85-530 Operation And Maintenance Manual

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OPERATIONS AND MAINTENANCE
5-376-000094
REV. 3 - 03/10
HDR 70/85
WRECKER
MANUAL
1080 Hykes Road
Greencastle, PA 17225
Phone (717) 597-7111
www.jerr-dan.com
© 2010 Jerr-Dan Corporation. All Rights Reserved.
$35.00

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  • Page 1 $35.00 HDR 70/85 WRECKER OPERATIONS AND MAINTENANCE MANUAL 1080 Hykes Road Greencastle, PA 17225 Phone (717) 597-7111 www.jerr-dan.com 5-376-000094 © 2010 Jerr-Dan Corporation. All Rights Reserved. REV. 3 - 03/10...
  • Page 3 FOREWORD This manual serves as a guide for the owner and operator in the safe operation and optimum performance of your Jerr-Dan equipment. For your safety, and the safety of others, you must • know the proper use of the equipment •...
  • Page 4 Jerr-Dan Corporation strives to provide information that is accurate, com- plete and useful. All information contained in this manual is as accurate as known at the time of publication and is subject to change, without notice, as a result of continuous product improvements. Jerr-Dan reserves the right to amend the information in this document at any time without prior notice.
  • Page 5 WARRANTY 1080 Hykes Road Greencastle, PA 17225 (717) 597-7111 LIMITED WARRANTY Manufacturer’s Warranty. Manufacturer’s sole warranty shall be the following, which Distributor shall make on behalf of Manufacturer by conspicuous notice in writing accompanying each contract or memorandum of sale: 1.
  • Page 6 5. Exclusive and Entire Warranty. The warranty constitutes Manufacturer’s entire warranty as to the product and it is expressly agreed that the remedies of dealer and those claiming under dealer as stated in this warranty are exclusive. Manufacturer does not assume (and has not authorized any other person to assume on its behalf) any other warranty or liability in connection with any product covered by this warranty.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Section I: Safety Safety (General) ............... 1 Ratings:HDR70/85 - 530 ............4 Ratings:HDR70/85 - 565 ............8 Safety Chains ................ 17 Lift Safety ................18 Boom Safety ................19 Capacity/Rating Information Placards ........26 Safety Warning Labels ............28 Section II: Operation Under Lift ................
  • Page 8 THIS PAGE INTENTIONALLY LEFT BLANK 5-376-000094 REV. 3 - 03/10 Page iv...

  • Page 9: Safety (General)

    SAFETY The safe operation of your HDR is your responsibility. Read this manual and the truck manufacturer’s manual and thoroughly understand them. You can be held legally responsible for injuries or damage resulting from unsafe operating practices. The manufacturer’s recommendations for operating this wrecker can help you avoid unsafe practices and their bad consequences.
  • Page 10 DANGER: 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 serious injury. 5-376-000094 REV. 3 - 03/10 Section I: Safety Page 2...
  • Page 11 WARNING ONLY AUTHORIZED AND TRAINED PERSONNEL SHOULD BE PERMITTED TO OPERATE THIS WRECKER UNSUPERVISED. IN ORDER TO BE SUFFICIENTLY TRAINED TO OPERATE THIS WRECKER, A PERSON MUST HAVE, AS A MINIMUM, THE FOLLOWING QUALIFICATIONS: 1. SATISFACTORILY PERFORMED ALL WRECKER MANEUVERS AND FUNCTIONS UNDER THE SUPERVISION OF FULLY TRAINED PERSONNEL.

  • Page 12: Ratings:hdr70/85 - 530

    DO NOT EXCEED THE FOLLOWING RATINGS: HDR70/85 - 530 Maximum Structural Limits Boom Fully Elevated and Retracted over Rear ..170,000 lbs. Maximum Rated Loads Boom Fully Elevated and Retracted over Rear ..140,000 lbs. BOOM RATING: (Two Stage Boom) SAE Rating - Boom elevated at 30°...
  • Page 13 UNDER LIFT RATING: Full Retracted ............53,000 lbs. Full Extended ............17,000 lbs. Tow Rating ..............80,000 lbs. DRAG WINCH RATING: (Optional dp Planetary Gear) Each Drum (Single Speed, Variable Control) ....35,000 lbs. WIRE ROPE: (Option 1) Working Limit Each Line ..........22,500 lbs. Construction ............
  • Page 14 SAE J2512: Surface Vehicle Recommended Practices - Towing Equipment Ratings and Practices SAE J706: Surface Vehicle Recommended Practices - Rating of Winches Rating Using Axle And Spring Lift Tools THE TOWING CAPACITY SHOULD NOT EXCEED THE GROSS COM- BINED WEIGHT RATING (GCWR) OF THE TOWING VEHICLE OR 42,000 LBS.
  • Page 15 NOTE These ratings apply to the structural design of the HDR70/85 - 530 only . They might be limited by the axle rating and gross vehicle weight rating of the truck chassis. The payload and towing capacity of any towing vehicle must meet the following: •...

  • Page 16: Ratings:hdr70/85 - 565

    DO NOT EXCEED THE FOLLOWING RATINGS: HDR70/85 - 565 Maximum Structural Limits Boom Fully Elevated and Retracted over Rear ..170,000 lbs. Maximum Rated Loads Boom Fully Elevated and Retracted over Rear ..140,000 lbs. BOOM RATING: (Two Stage Boom) ............SAE Rating - Boom elevated at 30°...
  • Page 17 UNDER LIFT RATING: Full Retracted ............56,500 lbs. Full Extended ............17,600 lbs. Tow Rating ..............80,000 lbs. DRAG WINCH RATING: (Optional dp Planetary Gear) Each Drum (Single Speed, Variable Control) ....35,000 lbs. WIRE ROPE: (Option 1) Working Limit Each Line ..........22,500 lbs. Construction ............
  • Page 18 SAE J2512: Surface Vehicle Recommended Practices - Towing Equipment Ratings and Practices SAE J706: Surface Vehicle Recommended Practices - Rating of Winches Rating Using Axle And Spring Lift Tools THE TOWING CAPACITY SHOULD NOT EXCEED THE GROSS COM- BINED WEIGHT RATING (GCWR) OF THE TOWING VEHICLE OR 42,000 LBS.
  • Page 19 NOTE These ratings apply to the structural design of the HDR70/85 - 565 only . They might be limited by the axle rating and gross vehicle weight rating of the truck chassis. The payload and towing capacity of any towing vehicle must meet the following: •...
  • Page 20 LOAD CHART (Refer to the actual chart in your unit) 5-376-000094 REV. 3 - 03/10 Section I: Safety Page 12...
  • Page 21 MFG BY:_______________________________________ ______________________________________________ DATE OF MFR:MO______________YR.______________ GVWR:_________________KG (_________________LB) GAWR-FRONT: ______________________KG (__________________LB) WITH____________________________________TIRES, ______________________RIMS,@______________KPA (___________________PSI) COLD__________________ GAWR-INTERMEDIATE(1): ______________________KG (__________________LB) WITH____________________________________TIRES, ______________________RIMS,@______________KPA (___________________PSI) COLD__________________ GAWR-INTERMEDIATE(2): ______________________KG (__________________LB) WITH____________________________________TIRES, ______________________RIMS,@______________KPA (___________________PSI) COLD__________________ GAWR-REAR: ______________________KG (__________________LB) WITH____________________________________TIRES, ______________________RIMS,@______________KPA (___________________PSI) COLD__________________ THIS VEHICLE HAS BEEN COMPLETED IN ACCORDANCE WITH THE PRIOR MANUFACTURERS' IVD, WHERE APPLICABLE.
  • Page 22 • Don’t use a recovery vehicle that has not • Don’t lower the rear hydraulic stabilizers unless been properly maintained. Pay special the area under them is clear. Pay particular attention to the mounting bolts, and attention to keeping this area clear. lubrication of moving parts.
  • Page 23 • Don’t tow a vehicle that reduces the weight • After you have hooked up a vehicle for on the front wheels of the wrecker more than towing, don’t start the tow until you have 50 percent. (SAE J2512) double checked the hook-up, installed safety chains, and released the parking brakes of the towed vehicle.
  • Page 24 • Keep the underlift boom raised high enough • Never exceed the front and/or rear axle off of the ground when roading to avoid ratings of your towing equipment. dragging it over road surfaces. • Don’t tow a vehicle on its drive wheels unless •...

  • Page 25: Safety Chains

    SAFETY CHAINS AND TIE-DOWN CHAINS MUST BE USED WHEN TOWING AND TRANSPORTING Safety chains and tie-down chains are provided for use with your new Jerr- Dan Recovery Vehicle. Periodically inspect all chains for any signs of fatigue or damage. Don’t overlook the hooks; be sure they have not been bent or deformed.

  • Page 26: Lift Safety

    LIFT SAFETY Careful consideration of the immediate 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. Your unit is unique.

  • Page 27: Boom Safety

    BOOM SAFETY Your unit is equipped with a wrecker boom and the following safety procedures must be observed: • Take up the wire rope cable slowly and be • Jog the winch control lever to be sure of sure the hook is securely set. complete engagement of the clutch gears before making a lift or pull.
  • Page 28 • Never lift or pull over or around a sharp obstacle. • Never allow the wire rope to cross wrap (criss-cross) on the winch drum. Crushing of the wire rope can cause premature wire rope failure. • Never completely unwind wire rope from a •...
  • Page 29 • Be sure all brakes and locks are properly • Don’t permit bystanders in the area while set on the recovery vehicle. performing recovery work. • Never wrap the wire rope around frames or • Never under any circumstances use the cross members.
  • Page 30 • Lubricate and maintain both the wire rope and winch on regular intervals. (See • Avoid using the boom raise or boom up maintenance charts.) Inspect the wire rope control to lift a load. This causes undue for damage. Damaged, deformed or frayed stress and weight loading on the rear axle.
  • Page 31 • Don’t expect your wrecker to tow loads equal • Don’t exceed ratings of booms, wire ropes, to the wrecker ratings. Wrecker ratings apply snatch blocks, or winches. Stay within to loads imposed during recovery with the nameplate ratings. Note that boom ratings decrease significantly as the boom is wrecker properly stabilized.
  • Page 32 • Know the load to be moved. DO NOT • Make sure vehicle is positioned in an area OVERLOAD! free from overhead obstructions. KEEP A SAFE WORKING DISTANCE! • Do not drive without locking the slew lock. • Do not rotate or extend a load over The boom may rotate unexpectedly.
  • Page 33 • Do not swing the wrecker boom without • Stay clear of rotating equipment to avoid extending the outrigger stabilizers. crushing injury. 5-376-000094 REV. 3 - 03/10 Section I: Safety Page 25...

  • Page 34: Capacity/Rating Information Placards

    CAPACITY/RATING INFORMATION PLACARDS These placards provide information about carrier and vehicle ratings, capacities and load limits. You must stay within these ratings/capacities when using the Jerr-Dan HDR. These placards must not be obliterated, removed or painted over. They are there to remind and protect the operator. (Not all placards are used on all units) If a placard becomes lost or unreadable, it should be replaced.
  • Page 35 5-376-000094 REV. 3 - 03/10 Section I: Safety Page 27...

  • Page 36: Safety Warning Labels

    SAFETY WARNING LABELS These safety warning labels describe hazards and what happens if you encounter them. Read each safety 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 units) If a decal becomes lost or unreadable, it should be replaced.
  • Page 37 WARNING HAVE YOU REVIEWED THE OPERATOR'S PRE-TRANSPORT CHECK LIST ON THE UNIT? 7,000 lbs 14,000 lbs 80,000 lbs THE TOWING CAPACITY SHOULD NOT EXCEED THE GROSS COMBINED WEIGHT RATING (GCWR) OF THE TOWING VEHICLE OR THE 80,000 LB. STRUCTURAL CAPACITY OF THE TIRE LIFT, WHICHEVER IS LOWER.
  • Page 38 WARNING MOVING PARTS KEEP HANDS AND FEET CLEAR OF THIS AREA CAUTION TO AVOID BIRDNESTING AND PREMATURE FAILURE OF THE WIRE ROPE ALWAYS KEEP TENSION ON THE WIRE ROPE WHEN UNWINDING WARNING WARNING ELECTRICAL HAZARD POWER DISTRIBUTION PANEL WARNING WARNING A MINIMUM OF 5 WRAPS OF CABLE MUST BE LEFT ON DRUM A MINIMUM OF 5 WRAPS OF CABLE MUST BE LEFT ON DRUM TO ACHIEVE...
  • Page 39 WARNING TOWED VEHICLE MUST BE TOWED VEHICLE MUST BE CONNECTED TO TOW TRUCK BODY CONNECTED TO TOW TRUCK BODY WITH SAFETY CHAINS WITH SAFETY CHAINS DANGER DANGER Hazardous voltage. Hazardous voltage. Will cause severe Will cause severe injury or death. injury or death.
  • Page 40 5-376-000094 REV. 3 - 03/10 Section I: Safety Page 32...

  • Page 41: Section Ii: Operation

    OPERATION UNDER LIFT OPERATION Your HDR is one of the most useful and efficient towing and recovery vehicles available. It is hydraulically powered and careful consideration should be given to the selection of commands. You can afford to work smart, the vehicle will do most of the work for you.
  • Page 42 5. Adjust the electronic or manual throttle control to elevate the engine speed to approximately 1000-1200 R.P.M. of P.T.O. output shaft speed for optimum performance. CAUTION: Never exceed 1200 R.P.M. When your hook up is complete, reset the engine idle to normal. 6.
  • Page 43 9. Attach the lift receivers to the crossbar by sliding them over the ends of the crossbar. Install the retaining pin into the end of the crossbar and secure with the safety pin. CAUTION: The retaining pins must be in place during towing...

  • Page 44: Spring Brackets

    SPRING BRACKETS 1. Insert the spring brackets into the receivers that you put onto the crossbar. 2. Extend 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 hanger as shown.
  • Page 45 3. Raise the boom to lift the casualty vehicle slightly. 4. Secure the casualty vehicle to the spring brackets with the retaining pins and safety pins. 5. Secure the casualty vehicle to the crossbar with chains and a chain binder. 6.
  • Page 46 7. It is recommended that the steering wheel be secured by a steering wheel strap for any front 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.
  • Page 47 CAUTION: Always follow the chassis manufacturer's recommended procedures for towing. Remove drive lines and drive shafts as directed. Many vehicles can be severely damaged unless these components are removed prior to towing. 11. Be sure to maintain sufficient ground clearances with the bottom of the casualty vehicle.

  • Page 48: Frame Forks

    FRAME FORKS 1. Choose the frame forks that are best suited to your needs and insert them into the receivers on the crossbar. 2. Extend the under lift boom under the vehicle so that the frame forks are in the proper position for lifting.
  • Page 49 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 under lift until the casualty vehicle is about three (3) to four (4) feet from the back of the recovery vehicle.

  • Page 50: Chain Forks (Optional)

    13. If the remote hand controller was used, turn the CONTROL switch “OFF”. (Switch is located on panel on the floor.) WARNING: Never fold the boom up into the storage position without removing the towing adapters from the crossbar receivers. CHAIN FORKS (OPTIONAL) 1.
  • Page 51 5. Before making the final lift, check to be sure that the casualty’s parking brake is released, the transmission is in neutral, and the wheels are straight. CAUTION: If vehicle to be towed is on a slope, do not release the brake until the load is secured.
  • Page 52 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, causing damage. Take irregular road surfaces into consider-ation. NOTE: When towing, the Underlift Boom should be as close to horizontal...

  • Page 53: Chain Hook Adapters (Optional)

    CHAIN HOOK ADAPTERS 1. Slide the chain hook adapters onto the crossbar. 2. Install the retaining pin from the back side of the crossbar through the adapter and cross- bar and install the hair pin. 3. Extend the under lift boom up to the casualty vehicle so that the chain hook adapters are in the proper position for lifting.
  • Page 54 6. Before making the final lift, check to be sure that the casualty’s parking brake is released, the transmission is in neutral, and the wheels are straight. CAUTION: If vehicle to be towed is on a slope, do not release the brake until the load is secured.
  • Page 55 10. 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, causing damage. Take irregular road surfaces into consider-ation. NOTE: When towing, the Underlift Boom should be as close to horizontal...

  • Page 56: Heavy Duty Tire Lift (Optional)

    HEAVY DUTY TIRE LIFT (OPTIONAL) DO NOT EXCEED THE FOLLOWING RATINGS: HDTL SHDTL Lifting Capacity (Each Arm) ......7,000 lbs..12,000 lbs. Lifting Capacity (Total) ....... 14,000 lbs..25,000 lbs. Towing Capacity (Maximum) ...... 80,000 lbs..80,000 lbs. THE TOWING CAPACITY SHOULD NOT EXCEED THE GROSS COMBINED WEIGHT RATING (GCWR) OF THE TOWING VEHICLE OR 42,000 LBS.
  • Page 57 3. Insert the round 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 desired position for loading.
  • Page 58 7. Install the retaining pin through the grid and arm weldment and secure with the pin. 8. Extend the under lift under the casualty vehicle so that the arm makes contact with the front of the tires. At the same time make sure that you are not going to damage any under body components.
  • Page 59 10. Raise the boom to lift the casualty vehicle slightly. At the same time make sure that you are not going to damage any components. 11. Attach the hook end of the tie- down 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...
  • Page 60 13. Always secure the steering wheel with a steering wheel strap for any front or rear tow. 14. 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.
  • Page 61 17. Be sure to maintain sufficient ground clearances with the bottom of the casualty vehicle. 18. Attach the safety chains and auxiliary towing lights. 19. Hook-up and connect air and braking systems. 20. If the remote hand controller was used, turn the CONTROL switch “OFF”.
  • Page 62 CAUTION: The use of secondary tie-down chains is recommended. Fit the secondary tie-down chains to the axle (not to any part of the suspension or body which will rise and fall with the suspension) arranged so as to hold the wheel down in the grid and prevent it from jumping up, forwards, or backwards.

  • Page 63: Trailer 5Th Wheel Plate And Pintle Hook Ball Hitch Adapter (Optional)

    TRAILER 5TH WHEEL PLATE AND PINTLE HOOK BALL HITCH ADAPTER (OPTIONAL) DO NOT EXCEED THE FOLLOWING RATINGS: 5TH WHEEL PLATE LIFTING CAPACITY ........15,000 lbs. TOWING CAPACITY ........25,000 lbs. PINTLE HOOK BALL HITCH 2 IN. BALL HITCH ......... 10,000 lbs. (GTW) PINTLE HOOK ..........
  • Page 64 3. Install the retaining bolts thru the keeper bracket and into the adapter. Tighten the retaining bolts. 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 recovery vehicle in front of the casualty and in-line...
  • Page 65 7. Engage the 5th wheel plate with the king pin. Install the king pin locking pin and linchpin. 8. Connect the air lines from the recovery vehicle to the casualty trailer to release the trailer brakes. 9. Raise the trailer jack stands. 10.

  • Page 66: Rear Hydraulic Stabilizers

    REAR HYDRAULIC STABILIZERS Your HDR is equipped with rear hydraulic stabilizers. The stabilizers serve two purposes. First, they may be used as a chassis support when lifting heavy loads which would otherwise cause the front axle of the vehicle to lift off the ground.
  • Page 67 4. Using the control levers, lower the stabilizers to the ground. The 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 vehicle with the stabilizers on the ground or damage to the chassis can occur.

  • Page 68: Integral Spades

    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 pin. 5-376-000094 REV. 3 - 03/10 Section II: Operation Page 60...
  • Page 69 NOTE: When the spade is on the ground the eye plate on the back side of the stabilizers can be used for the attachment of snatch blocks 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 the ground or damage to the chassis can occur.

  • Page 70: Outrigger Stabilizers

    OUTRIGGER STABILIZERS Your HDR is equipped with hydraulic outrigger stabilizers. The stabilizers serve two purposes. First, they are used as a chassis support when lifting or pulling heavy loads over the sides of the truck which would otherwise cause the chassis to become unstable and possibly roll over. Second, they can be used to provide a resistance to winching forces.
  • Page 71 4. Using the control levers, extend the outriggers to the full extended position. 5. Retract the inner outrigger sections about 1" to align the locking pin holes. 6. Remove the outrigger pins from the storages compartments. Install the pins into the inner sections of the outrigger and secure with the retaining pins.
  • Page 72 10. Turn the pin 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 lowering the rear stabilizers. 5-376-000094 REV.
  • Page 73 CAUTION: Do not move the recovery vehicle with the stabilizers on the ground or damage to the chassis can occur. NOTE: When the stabilizer is on the ground the "D Rings" on the ends of the stabilizers can be used for the attachment of snatch blocks or to terminate the wire rope hook during winching operations.

  • Page 74: Outrigger Spades

    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 stabilizers. 5-376-000094 REV. 3 - 03/10 Section II: Operation Page 66...
  • Page 75 CAUTION: Do not move the recovery vehicle 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 in working position before starting recovery work.

  • Page 76: Wrecker Boom Operation

    WRECKER BOOM OPERATION The wrecker boom is probably one of the most useful accessories on your HDR. It allows the operator to perform lifting and retrieval tasks that cannot be performed in any other way. Safe operation of the wrecker boom demands knowledge of the controls and the boom functions.
  • Page 77 WARNING: Stay clear of rotating equipment to avoid crushing injury. When making a heavy lift or pull with the wrecker boom, the following steps should be taken: 1. Position the recovery vehicle as close as possible to the work and set the parking brakes and place the transmission in neutral.
  • Page 78 5. Wearing gloves, unhook the wire ropes from their stored position. Moving the boom head with the wire rope locked can result in damage to both the wire ropes and the boom. 6. If you are going to be making a lift or pull off the corners or sides of the truck, use the controls to unlock the slew pin to allow the...
  • Page 79 10. Manually, “free-spool” enough wire rope to make the hook-up being sure that a minimum of five (5) wraps remains on the cable drums. WARNING: Wear gloves to protect hands from wire ropes. CAUTION: To avoid birdnesting and premature failure of the wire rope, always keep tension on the wire rope when winding or unwinding.
  • Page 80 14. The use of snatch blocks and multiple lines will allow you to pull, stabilize the recovery vehicle, and minimize deflection of the wrecker boom. 15. Push the winch free-spool knobs to the in position to re-engage the winch. Slowly take up the slack in the wire ropes.
  • Page 81 16. Complete the lift or pull being sure the work is placed in a stable location where it won’t slip or roll. If there is any question about stability, use blocks or tie the work down before removing wire rope and chains. 17.
  • Page 82 THIS PAGE INTENTIONALLY LEFT BLANK 5-376-000094 REV. 3 - 03/10 Section II: Operation Page 74...

  • Page 83: Section Iii: Maintenance Maintenance And Lubrication

    MAINTENANCE MAINTENANCE AND LUBRICATION Your HDR has been designed to give you excellent service and long life but like all equipment, it requires proper and periodic maintenance. The truck chassis itself is on a maintenance schedule recommended by the manufacturer. Follow these guidelines and protect your vehicle warranty. There are a number of different lubricants used on your HDR.
  • Page 84 change the filter element will result in premature wear and/or failure of any or all of the hydraulic components.Only check gauge when hydraulic fluid is at operating temperature. Cold oil is more dense and will give a false indicator gauge reading. Cold temperatures can cause hydraulic oils to thicken and adversely affect the hydraulic functions of your carrier.

  • Page 85: Fastener Torque Specifications

    FASTENER TORQUE SPECIFICATIONS • All torque values shown are for bolts (cap screws) and nuts that are either zinc- plated or lubricated. • Torques shown above apply only to screws and nuts used for assembly and installation of all carrier components, not to the chassis. •...

  • Page 86: Oils And Greases

    OILS AND GREASES The following oils and greases are suitable for use with your Jerr-Dan Carrier. Company Product HYDRAULIC OILS 1. Chevron AW Hydraulic Oil MV 2. Exxon Univis N32 3. Mobil DTE13 4. Texaco Rando HDZ-32 5. Shell Tellus Oil T 32 6.

  • Page 87: Wire Rope Handling And Inspection

    WIRE ROPE HANDLING AND INSPECTION WARNING WARNING WARNING WARNING WARNING Wire Rope WILL FAIL if worn-out, overloaded, damaged, improperly maintained or abused. Wire rope failure may cause serious injury or death! Protect yourself and other: • ALWAYS INSPECT wire rope for WEAR, DAMAGE or ABUSE BEFORE USE.
  • Page 88 It is good practice , where the equipment is consistently in use, to give the rope a certain length of service, several hundred hours, several weeks or months and then renew the rope regardless of it's condition. This method eliminates the risk of fatigue causing rope failure. Any deterioration, resulting in a suspected loss of original rope strength, should be carefully examined and a determination made as to whether further use of the wire rope would constitute a safety hazard.

  • Page 89: Lubrication Points

    HDR70/85 - 530 LUBRICATION POINTS The following lubrication charts are located inside the tool box door on the driver’s side of the HDR body. LUBRICATION CHART INTERVAL NO. OF IDENTIFICATION SERVICE LUBRICANT (HOURS) POINTS WEEKLY CABLE ENGINE OIL WINCH GEAR BOX CHECK NYLATRON PADS COAT...
  • Page 90 HDR70/85 - 530 LUBRICATION POINTS 5-376-000094 REV. 3 - 03/10 Section III: Maintenance Page 82...

  • Page 91: Trouble Shooting

    TROUBLE SHOOTING You probably won’t require anything but preventive maintenance to keep your HDR running, however, the following chart should help you isolate and correct minor problems if they occur with use. Any service work on the hydraulic system should be performed by qualified mechanics. HYDRAULIC SYSTEM Problem Cause...

  • Page 92: P.t.o. Functioning Improperly

    TROUBLESHOOTING P.T.O. FUNCTIONING IMPROPERLY Problem Cause Solution Cable tight or frozen a. Cable kinked or bent a. Straighten or replace b. Cable and PTO connection b. Inspect and adjust not adjusted properly c. Mounting bracket nuts are c. Loosen if necessary over tightened at P.T.O.

  • Page 93: Winch Functioning Improperly

    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.
  • Page 94 TROUBLESHOOTING BOOM SLEW FUNCTIONING IMPROPERLY Problem Cause Solution Boom will not a. Slew locking pin engaged a. Disengage locking pin rotate b. Swing brake control valve b. Inspect: remove blockage clogged with foreign material c. Faulty swing brake control c. Replace valve Slew locking pin will a.

  • Page 95: Glossary

    GLOSSARY OF TERMS Anchoring Device - Used to attach cable ends, snatch blocks, safety chains, and tie-down assemblies to the towing vehicle. Approach Angle - Angle between the plane of the platform and the ground. Attachment - Any device that can be added to a basic unit or assembly. Auxiliary Braking Device - A device which attaches to the disabled vehicle to assist the tow truck's brakes in retarding or stopping both vehicles.
  • Page 96 Boom Length - The straight line distance from center of the revolving base to the center of the boom head. Brakes - Parking - A system used to hold a stopped machine in a stationary position. Brakes - Service - A primary brake system used for retarding and stopping the truck.
  • Page 97 Certification Label - Required by Public Law 89-563, which states that a motor vehicle or item of motor vehicle equipment complies with all applicable Federal Motor Vehicle Safety Standards (FMVSS) in effect on the date of manufacture. Chain Assemblies - Chain with all hardware and coupling devices. Chassis Cab - A vehicle consisting of a chassis upon which is mounted a cab;...
  • Page 98 DOT (Department of Transportation) - A federal agency dealing with regulations concerning both the manufacture and operation of motor vehicles and motor vehicle equipment. See NHTSA. Driveline - The driveshaft and associated joints. Drum - Any spool on which are wrapped ropes used in machine operation. Extend Cylinder - Cylinders used to extend or retract boom structures.
  • Page 99 Forks - A device attached to the lift bar for lifting a vehicle by the tires, axle, frame, or structural member. May be classified as chain, axle, or frame forks. FW (Frame Width) - The overall width of the chassis frame measured outside to outside behind the cab.

  • Page 100: Section Iv: Glossary

    Hydraulic Oil - Fluid used in operation of hydraulic systems. Hydraulic Relief Valve - A mechanical device used to limit the pressure in a hydraulic circuit. Incomplete Vehicle - As assemblage consisting, as a minimum, of a frame and chassis structure, powertrain, steering system, suspension system and braking system to the extent that those systems are to be part of the complete vehicle that requires further manufacturing operations.
  • Page 101 Light Pylon - Structure on which an emergency light bar is mounted. Line Pull - The maximum wire rope pull, in pounds, at the drum, at full-load engine speed, with specified lagging diameter. Line Speed - Speed in feet per minute of a single rope, based on full load engine speed with specified lagging diameter.
  • Page 102 Overall Vehicle Width - The design dimension ot the widest part of the vehicle, exclusive of signal lamps, outside rearview mirrors, flexible fender extensions, and mud flaps, determined with doors and windows closed and the wheel in the straight ahead position. Overhang - The horizontal distance for the centerline of a single rear axle or center point of a tandem rear axle to a point where the vertical component is imposed.
  • Page 103 Roadside - The left or driver's side of the vehicle when viewed from the rear, opposite side from Curbside. Rolling Resistance - The restraining forces contributed to the load when rolling on wheels. Rollback - See Car Carrier Rope - See Wire Rope Rub Rail - Member running longitudinally providing rub service on side of body.
  • Page 104 Spade - One or more ground penetrating devices designed primarily, when used, to stabilize rearward chassis movement. Stabilizers - A hydraulic or manually operated leg device (i.e., outboard legs, outriggers, or jack legs) attached to trucks to give additional support down to the ground for improved stability.
  • Page 105 Towing - See Tow. Tow Bar - A device for positioning a towed vehicle behind a towing vehicle. Tow Chain - Length of chain used to connect the sling with the towed vehicle. Tow Sling - A device used for lifting and towing vehicles with a partial load supported on rubber straps.
  • Page 106 Wheel Arm - A device that attaches to the lift bar for engaging the tires of a towed vehicle. Wheelbase - Horizontal dimension from centerline of front axle to the effective centerline of the rear axle(s). Wheel Chock - A device used to prevent chassis movement. Wheel Fork - See Wheel Arm.

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