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Jerr-Dan MPL-NG Operation And Safety Manual

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Operation And Safety
Manual
Original Instructions
Keep this manual with machine at all times.
MPL-NG
LIGHT DUTY
WRECKER
SN 0230011755 to Present
Including 0230009801, 0230010717, 0230011072-0230011326,
0230011488-0230011512 & 0230011597-0230011611
5376000275
December 1, 2023

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Summary of Contents for Jerr-Dan MPL-NG

  • Page 1 Operation And Safety Manual Original Instructions Keep this manual with machine at all times. MPL-NG LIGHT DUTY WRECKER SN 0230011755 to Present Including 0230009801, 0230010717, 0230011072-0230011326, 0230011488-0230011512 & 0230011597-0230011611 5376000275 December 1, 2023...
  • Page 2 WARNING Operating, servicing and maintaining this vehicle or equipment can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which 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 your vehicle or equipment in a well-ventilated...
  • Page 3 Revision Log REVISION LOG December 1, 2023 - A - Original Issue of Manual. 5376000275...
  • Page 4 Read This First This manual provides Operational and Safety information for the Light Duty MPL-NG Wrecker. Read this manual and the Operation and Safety Manual provided with other equipment thoroughly prior to starting operation. This manual is a very important tool! Keep it with the machine at all times.
  • Page 5 Read This First HAZARD CLASSIFICATION SYSTEM SAFETY ALERT SYSTEM AND SAFETY SIGNAL WORDS WARNING OW0021 This is the Safety Alert Symbol. It is used to alert to the potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
  • Page 6 Jerr-Dan sends safety related bulletins to the owner of record of this machine. Contact Jerr-Dan to ensure that the current owner of records are updated and accurate.
  • Page 7 However, NHTSA cannot become involved in individual problems between you, your dealer, or Jerr-Dan. To contact NHTSA, you may call the Vehicle Safety Hotline toll-free at 1-888- 327-4236 (TTY: 1-800-424-9153);...
  • Page 8 Read This First THIS PAGE IS INTENTIONALLY LEFT BLANK 5376000275...

  • Page 9: Table Of Contents

    Table of Contents TABLE OF CONTENTS Revision Log Read This First Operator Qualifications Modifications Hazard Classification System Safety Alert System and Safety Signal Words Reporting Safety Defects Table of Contents Section 1 - General Safety Practices General Pre-Operation Operator Training and Knowledge Electrical Hazards Crush and Collision Hazards Winch Cable / Falling Load Hazards...
  • Page 10 Hydraulic System 6-15 P.T.O. Functioning Improperly 6-16 Hydraulic Pump 6-16 Hydraulic Pump 6-17 Winch Functioning Improperly 6-17 Remote Hand Controller 6-18 Section 7 - Specifications Product Specifications MPL-NG Truck Chassis Capacities Inspection, Maintenance and Repair Log Transfer Of Ownership 5376000253...

  • Page 11: Section 1 - General Safety Practices

    If there are any questions with regard to safety, training, inspection, maintenance, application, and operation, please contact Jerr-Dan. WARNING OW0021 Failure to comply with the safety precautions listed in this manual could result in machine damage, property damage, personal injury or death.

  • Page 12: Pre-Operation

    • Use the machine 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 machine as specified in this manual.
  • Page 13 Section 1 - General Safety Practices • Always check for power lines before raising the boom. • Look up and use light to search for power lines in the dark. • Allow for machine movement and electrical line swaying. • Do not step off or touch a charged vehicle.

  • Page 14: Crush And Collision Hazards

    Section 1 - General Safety Practices CRUSH AND COLLISION HAZARDS • Always use jack stands to support the boom and/or underlift before working underneath a lifted load. • Warn personnel not to work, stand, or walk under a raised boom or underlift. Position barricades if necessary.
  • Page 15 Section 1 - General Safety Practices • Always keep a minimum of five (5) wraps of cable on winch drum. • Keep tension on cable when unwinding. • Always stop operation before block contacts sheave. • If block contacts sheave, lower load by letting out cable and inspect for damage. •...

  • Page 16: Uncontrolled Towed Load Hazards

    Section 1 - General Safety Practices UNCONTROLLED TOWED LOAD HAZARDS • DO NOT exceed GAWR’s or GCWR of the chassis. • Set parking brake and chock wheels of the recovery vehicle when connecting casualty vehicle. • Use two (2) safety chains and two (2) tie-down chains or straps. •...

  • Page 17: Fall Hazards

    DO NOT operate machine in an enclosed area without proper ventilation. • DO NOT operate the machine in hazardous environments unless approved for that purpose by Jerr-Dan and site owner. Sparks from the electrical system and the engine exhaust can cause an explosion. Flammable Fuel OW0300 •...

  • Page 18: Battery Hazards

    Section 1 - General Safety Practices Hydraulic Fluid OW0950 • DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the engine is running or when the hydraulic system is under pressure. • Stop engine and relieve trapped pressure. Fluid in the hydraulic system is under pressure and can penetrate the skin.

  • Page 19: Weather Conditions

    Section 1 - General Safety Practices • Wear : Snug fitting and sturdy long-sleeve shirt and long pants. Avoid loose fitting clothes. Sturdy gloves. Approved eye protection. Steel toed boots. Approved head gear. Approved hearing protection. WEATHER CONDITIONS • Be aware of the wind conditions. Wind may cause load to swing or shifting of load.
  • Page 20 Section 1 - General Safety Practices • Never attach the chain hooks in such a way as to damage brake lines or other functional parts. • Ensure proper ground clearance of the underlift boom when travelling. Keep the underlift boom raised high enough off the ground when roading to avoid dragging it over road surfaces.

  • Page 21: Section 2 - Pre-Operation And Inspection

    See Section 3 - Controls and Indicators for more specific operating instructions. WARNING OW0021 If your MPL-NG does not operate properly, immediately bring machine to a stop, lower boom to ground and stop the engine. Determine cause and correct before continued use. 5376000253...

  • Page 22: Decals

    CAPACITY MAY BE LIMITED BY THE CAPACITY OF THE CHASSIS AND EQUIPMENT SELECTED. MANUFACTURED BY: JLG INDUSTRIES, INC. FOR: 13224 Fountainhead Plaza Hagerstown, MD 21742 Phone (717) 597-7111 www.jerr-dan.com 1001132509-A CAUTION PROUDLY MADE IN THE CHECK HYDRAULIC FLUID LEVEL FILL ONLY WITH APPROVED FLUID...
  • Page 23 Section 2 : Pre-operation and Inspection 7330000424 CAUTION TOW HITCH BRACKET MUST BE REMOVED BEFORE UNFOLDING THE BOOM DOWN FOR WHEEL GRID OPERATION CAUTION TOW HITCH BRACKET MUST BE REMOVED BEFORE UNFOLDING THE BOOM DOWN FOR WHEEL GRID OPERATION 7330000036 BOTH SIDES 7330000599 7330000036...

  • Page 24: Walk-Around Inspection

    Section 2 : Pre-operation and Inspection WALK-AROUND INSPECTION NOTE: Complete all required maintenance before operating the unit. Begin your walk-around inspection at item 1, as noted below checking each item in sequence. INSPECTION NOTE: On all components, make sure there are no loose or missing parts, that they are securely fastened and no visible leaks or excessive wear exists in addition to any other criteria mentioned.
  • Page 25 Section 2 : Pre-operation and Inspection 1. Remote Controller Secure Undamaged and operational 2. Hydraulic Tank Hydraulic fluid level full Components undamaged Hydraulic hoses undamaged, not leaking 3. Toolbox/Storage Compartment(s) Components undamaged Toolbox/Storage Compartment(s) secure 4. Subframe Secure Components undamaged 5.
  • Page 26 Section 2 : Pre-operation and Inspection 8. Wheellift/Crossbar Crossbar pivot pin, secure Crossbar pivot pin, presence of grease Cylinder pins secure (If Equipped) Hydraulic hoses undamaged, not leaking (If Equipped) Components undamaged Pins undamaged Presence of grease 9. Winch Sheave (If equipped) Check for presence of grease Pivot pin secure 10.

  • Page 27: Operational Checks

    Section 2 : Pre-operation and Inspection OPERATIONAL CHECKS OPERATIONAL CHECK When engine warms, perform an operational check: 1. Parking brake operation. 2. Horn and back-up alarm. Must be audible from inside operators cab with engine running. 3. Electric controlled hydraulic functions - all functions operate smoothly and the controls return to the “Neutral Off”...
  • Page 28 Section 2 : Pre-operation and Inspection THIS PAGE IS INTENTIONALLY LEFT BLANK 5376000253...

  • Page 29: Section 3 - Controls & Indicators

    Your MPL-NG is supplied with various optional remote controllers. The wired remote controller or the wireless remote controller should be found inside the cab of the vehicle.

  • Page 30: Function Wired Hand Controller (If Equipped)

    Section 3 - Controls & Indicators 10 FUNCTION WIRED HAND CONTROLLER (IF EQUIPPED) 1. Power/Function Indicator : “Red” - Power On/”Green” - Function Operated 2. Underlift Boom - Up/Down : Controls the underlift boom raise/ lower functions. Hydraulic Grid - Open/Close : Controls the hydraulic grid open/close functions.

  • Page 31: Function Wireless Hand Controller (If Equipped)

    Section 3 - Controls & Indicators 8 FUNCTION WIRELESS HAND CONTROLLER (IF EQUIPPED) LED1 LED2 LED3 LED4 LED5 TILT LIFT CLOSE OPEN ca7055 A-1 1. Underlift Boom Tilt – Down : Controls the tilt down function of the underlift boom. 2.
  • Page 32 Section 3 - Controls & Indicators THIS PAGE IS INTENTIONALLY LEFT BLANK 5376000253...

  • Page 33: Section 4 - Operation

    Section 4: Operation SECTION 4 - OPERATION Operating controls for your MPL-NG are conveniently located inside the cab of the truck using the wired remote controller. There is also an optional wireless handheld remote controller that controls all the MPL-NG functions.

  • Page 34: Underlift Operation - Hydraulic Grids

    Section 4 : Operation UNDERLIFT OPERATION - HYDRAULIC GRIDS 1. Turn on the safety and work lights. (Switches can be located the dash panel, in the headliner or in the floor mount.) 2. Position the truck within 9 ft. of the subject vehicle and as close to the direction of the pull as possible.
  • Page 35 6. Confirm the truck’s position in relation to the vehicle to be towed. Nine (9) feet is recommended. Reposition the MPL-NG if necessary. Be sure the towed vehicle is not in gear or park. Keep the brake set. 7. Using...
  • Page 36 Section 4 : Operation 8. Next, lower the underlift using the underlift down function on the hand controller. underlift level stop assist system will stop the underlift travel at a preset position about 1-1/2” to 2” from the ground. override either stop position,...
  • Page 37 Section 4: Operation If vehicle to be towed is on a slope, do not release the brake until the tie-down straps are installed. Observe the wheels in the grid for any slippage. 13. It is recommended that the steering wheel be secured by a steering wheel strap for any tow.
  • Page 38 Section 4 : Operation 17. Raise the vehicle into the final towing position observing the far end for sufficient ground clearance. It is possible to set the rear of a front lifted vehicle completely onto the ground, causing damage. Take irregular roadsurfaces into...

  • Page 39: Tie-Down Straps - Hydraulic Grids

    Section 4: Operation TIE-DOWN STRAPS - HYDRAULIC GRIDS The MPL-NG is supplied with a set of high strength polyester web tie- down straps. They are to be used to secure wheels of the towed vehicle to the underlift grid. NEVER TOW A VEHICLE WITHOUT THE TIE-DOWN STRAPS INSTALLED.
  • Page 40 Section 4 : Operation INSTALLING THE TIE-DOWN STRAPS 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 strap resting on the tire at the ten o’clock and two o’clock...
  • Page 41 Section 4: Operation 5. Raise the wheel grid to the towing position. Re-tighten ratchet periodically as the tire settles in the grid from towing. Never tow a vehicle without tire tie-down straps and safety chains installed. 6. Review Operator’s Pre-Transport Checklist before each tow. 5376000253...
  • Page 42 Section 4 : Operation WHEEL GRID SPACERS The MPL-NG with the self loading grid is supplied with a set of wheel grid spacers. They can be used to pick up a vehicle with small diameter tires or even a vehicle without wheels and tires.

  • Page 43: Underlift Operation - Manual Grids

    Section 4: Operation UNDERLIFT OPERATION - MANUAL GRIDS 1. Turn on the safety and work lights. (Switches can be located the dash panel, in the headliner or in the floor mount.) 2. Position the truck within 9 ft. of the subject vehicle and as close to the direction of the pull as possible.
  • Page 44 6. Confirm the truck’s position in relation to the vehicle to be towed. Nine (9) feet is recommended. Reposition the MPL-NG if necessary. Be sure the towed vehicle is not in gear or park. Keep the brake set. 7. Using...
  • Page 45 Section 4: Operation 8. Next, lower the underlift using the underlift down function on the hand controller and swing the cross bar parallel to the tires. The underlift level stop assist system will stop the underlift travel at a preset position about 1-1/2”...
  • Page 46 Section 4 : Operation 11. Extend the underlift under the vehicle being sure that all under carriage parts are cleared and that the front portion of the grid is in contact with both tires. Lower the grid fully to the ground.
  • Page 47 Section 4: Operation If vehicle to be towed is on a slope, do not release the brake until the tie-down straps are installed. Observe the wheels in the grid for any slippage. 15. It is recommended that the steering wheel be secured by a steering wheel strap for any tow.
  • Page 48 Section 4 : Operation For the best towing and maneuverability the underlift boom should be as close to horizontal as possible. 20. Power retract the grid boom until the towed vehicle is about 3 to 4 feet from the back of the truck.

  • Page 49: Tie-Down Straps - Manual Grid

    Section 4: Operation TIE-DOWN STRAPS - MANUAL GRID The MPL-NG is supplied with a set of high strength polyester web tie-down straps. They are to be used to secure wheels of the towed vehicle to the underlift grid. WARNING OW0021 Never tow a vehicle without the tie-down straps installed.
  • Page 50 Section 4 : Operation INSTALLING THE TIE-DOWN STRAPS 1. With the vehicle lifted just barely off the ground, attach the strap to the L-Arm. Be sure the hook on the ratchet is securely seated in the L-Arm. 2. Set the ratchet spool in “free spool”...

  • Page 51: Towball Hitch Attachment

    Section 4: Operation TOWBALL HITCH ATTACHMENT The MPL-NG is supplied with a Towball Hitch attachment that will allow you to recover and tow trailers requiring a tow ball hookup. 1. Remove towball hitch attachment from the toolbox. 2. Use the bottom set of holes,...
  • Page 52 Section 4 : Operation 6. Connect the trailer lights and attach safety chains. 7. Review Operator’s Pre- Transport Checklist before each tow. 4-20 5376000253...

  • Page 53: Motorcycle Towing Adapter Operation (Optional)

    Section 4: Operation MOTORCYCLE TOWING ADAPTER OPERATION (OPTIONAL) The MPL-NG can be supplied with an optional motorcycle towing adapter that will allow you to recover and tow motorcycles. 1. Lower the boom flat to the ground. 2. Extend the underlift at least 6”.
  • Page 54 Section 4 : Operation 4. Hook the loading ramp onto the wheel grid and engage the rear hooks on the back side of the grid. 5. Completely retract the wheel grid for loading. 6. Attach the lower trough and vertical stop into the mounting bracket at the front of the boom with the pin and retaining pin.
  • Page 55 Section 4: Operation 7. Adjust the upper and lower tire stops so that they will contact and restrain the front tire when loaded. 8. Align motorcycle with underlift boom and ramp. 9. Push the motorcycle up the ramp until the front wheel is resting in and against the tire stops in the front brackets.
  • Page 56 Section 4 : Operation 10. Check front tire for fit with the upper and lower tire stops. When the motorcycle is rocked side to side the front tire 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...
  • Page 57 Section 4: Operation 14. Raise the underlift boom to the desired towing height. Care should be taken when lifting the boom. Do not try to level the underlift. straps may overtighten or become loose. 15. Tie the front of the motorcycle to the rear of the wrecker body.
  • Page 58 Section 4 : Operation 18. Attach towing lights. 19. Review Operator’s Pre- Transport Checklist before each tow. 4-26 5376000253...

  • Page 59: Gooseneck Towball Towing Adapter Operation (Optional)

    Section 4: Operation GOOSENECK TOWBALL TOWING ADAPTER OPERATION (OPTIONAL) The MPL-NG can be supplied with an optional gooseneck towing adapter that will allow you to recover and tow gooseneck trailers requiring a tow ball hookup. 1. Remove the gooseneck towball adapter attachment from the toolbox.

  • Page 60: Gooseneck Fifth Wheel Towing Adapter Operation (Optional)

    Section 4 : Operation GOOSENECK FIFTH WHEEL TOWING ADAPTER OPERATION (OPTIONAL) The MPL-NG can be supplied with an optional gooseneck towing adapter that will allow you to recover and tow gooseneck trailers requiring a fifth wheel hookup. 1. Remove the gooseneck fifth wheel adapter attachment from the toolbox.

  • Page 61: Recovery Winch Operation (Optional)

    Section 4: Operation RECOVERY WINCH OPERATION (OPTIONAL) The MPL-NG recovery winch is an extremely effective tool in recovery or retrieval prior to lifting and towing. To operate the winch effectively, care and thought must be given. 1. Check the direction you wish...
  • Page 62 Section 4 : Operation 5. Disengage the winch “free- spool” by pulling out on the “T” handle and turning the handle 90°. The handle should remain in the “free-spool” position. This allows the wire rope to be pulled directly off the drum to the work.
  • Page 63 Section 4: Operation 7. Attach the wire rope hook to a chain sling, or bridle and hook securely to the work. Be sure of this hook up; you don’t want it breaking loose during the pull. (See the safety sections earlier in this manual).
  • Page 64 Section 4 : Operation 10. With the wire rope tight, slowly wind it in, observing both the work and the drum. Inspect the hook-up points for slippage before continuing the lift or pull. Be sure the wire rope strands do not cross wrap or criss-cross on the drum.

  • Page 65: Grid Mounted Recovery Sheave Operation (Optional)

    GRID MOUNTED RECOVERY SHEAVE OPERATION (OPTIONAL) The MPL-NG can be supplied with an optional Grid Mounted Recovery Sheave that is an extremely effective tool in recovery or retrieval prior to lifting and towing. To operate effectively, care and thought must be given.
  • Page 66 Section 4 : Operation 5. Install the grid recovery sheave onto the back side of the grid crossbar and secure with the pins (1) and hair pins (2). 6. Remove the wire rope retaining pin from the grid recovery sheave. 7.
  • Page 67 Section 4: Operation 10. OPEN the underlift lockout valve located on the tilt/fold cylinder on the back side of the knee boom. 11. Raise and fold your underlift into the travel position. 4-35 5376000253...
  • Page 68 THIS PAGE IS INTENTIONALLY LEFT BLANK...

  • Page 69: Section 5 - Emergency Procedures

    Section 5 : Emergency Procedures SECTION 5 - EMERGENCY PROCEDURES LOWERING OF THE WRECKER BOOM In the event of total loss of engine power or hydraulic pump failure with an elevated boom, Contact a local Authorized Distributor for specific instructions. Secure the vehicle using the following procedures: 1.

  • Page 70: Raising/Lowering/Retracting/Folding/Tilting The Underlift Boom

    Section 5 : Emergency Procedures RAISING/LOWERING/RETRACTING/FOLDING/TILT ING THE UNDERLIFT BOOM In the event of total loss of engine power or hydraulic pump failure with an elevated boom, Contact a local Authorized Distributor for specific instructions. Secure the vehicle using the following procedures: 1.
  • Page 71 Section 5 : Emergency Procedures MANUAL OVER HYDRAULIC OVERRIDE OPERATION In the event of loss of electric control system, the manual override can be utilized. 1. Locate the hydraulic control valve access panel at the front of the body. 2. Remove the access plate by turning the thumb latch and lifting the panel out of the body.
  • Page 72 THIS PAGE IS INTENTIONALLY LEFT BLANK...

  • Page 73: Section 6 - Maintenance

    Section 6 - Maintenance SECTION 6 - MAINTENANCE INTRODUCTION Service the product in accordance with the maintenance schedule on the following pages. Wear all the protective clothing and personal safety devices issued to you or called for by job conditions. DO NOT wear loose clothing or jewelry that can get caught on controls or moving parts.

  • Page 74: Maintenance And Lubrication

    Section 6 - Maintenance MAINTENANCE AND LUBRICATION 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 vehicle. The following Lubricant Chart shows the proper lubricant and the most common brands and specification which meet the requirements.

  • Page 75: Oils And Greases

    Section 6 - Maintenance OILS AND GREASES The following oils and greases are suitable for use with the Jerr-Dan Vehicle. Company Product HYDRAULIC OILS 1. Shell Spirax S4 TXM 2. Shell Tellus S2 VX 32 3. Chevron Clarity AW 46 4.
  • Page 76 Section 6 - Maintenance Company Product WINCH 1. Mobil SAE 75W-90 Synthetic Gear Lube (or approved equivalent) WIRE ROPE 1. CRC Chain and Wire Rope Lubricant (or other approved deep penetrating equivalent) 2. Jet-Lube WLD - Chain and Wire Rope Lubricant (or other approved deep penetrating equivalent) 3.

  • Page 77: Wire Rope Handling And Inspection

    Section 6 - Maintenance WIRE ROPE HANDLING AND INSPECTION WARNING OW0021 Wire Rope WILL FAIL if worn-out, overloaded, misused, damaged, improperly maintained or abused. Wire rope failure may cause serious injury or death! Protect yourself and others: • NEVER USE wire rope that is WORN-OUT, DAMAGED or ABUSED. •...
  • Page 78 Section 6 - Maintenance Replace any wire ropes that have been abraded, crushed, kinked or twisted. Wire rope should be routinely cleaned monthly of any and all debris. Grit and gravel can quickly reduce a wire rope’s life. A wire rope should be well lubricated so that it can act and perform as it was designed.

  • Page 79: Wire Rope Installation

    Section 6 - Maintenance WIRE ROPE INSTALLATION Proper Unreeling Procedures Wire rope can be permanently damaged by improper unreeling or uncoiling practices. The majority of wire rope performance problems start here. Improper unreeling practices lead to premature rope replacement, hoisting problems and rope failure. Place the payout reel as far away from the boom tip as is practical, moving away from the chassis.
  • Page 80 Section 6 - Maintenance Drum Winding When wire rope is wound onto a sheave or drum, it should bend in the manner in which it was originally wound. This will avoid causing a reverse bend in the rope. Always wind wire rope from the top of the one reel onto the top of the other. Also acceptable, but less so, is re-reeling from the bottom of one reel to the bottom of another.
  • Page 81 Section 6 - Maintenance Keep Wraps Tight The end of the rope must be securely and evenly attached to the drum anchorage point by the method recommended by the equipment manufacturer. At least five wraps of wire rope must remain on the drum as dead wraps when the rope is unwound during normal operations.

  • Page 82: Underlift Level Stop

    Section 6 - Maintenance UNDERLIFT LEVEL STOP To change or adjust the factory set positions of the Underlift Level Stop Assist Sys- tem, follow theses stops: 1. To change the tilt stop, move the sensor on the underlift boom base up, to lower the boom, and down to raise the boom as shown below.

  • Page 83: Lubrication Charts

    Section 6 - Maintenance LUBRICATION CHARTS One of the following lubrication charts is located inside the door of the tool compart- ment on the driver’s side of the body. Standard “NO LUBE” Greaseless Subframe System: 6-11 5376000253...
  • Page 84 Section 6 - Maintenance Optional “Lubricated” Greased Subframe System: 6-12 5376000253...

  • Page 85: Lubrication Points

    Section 6 - Maintenance LUBRICATION POINTS Note: The following numbers correspond to those shown on the lubrication chart on Page 6-11 or 6-12. C. Hydraulic Reservoir Oil Level Lube Point(s) – Fill Cap Interval – Check level every 100 hours or bi-monthly Change every 1000 hours I.
  • Page 86 Section 6 - Maintenance E. Winch Gear Case Lube Point(s) – Fill Plug Lube – Reference winch manufacturer’s manual. Interval – Check level every 100 hours or bi-monthly Change every 1000 hours 6-14 5376000253...

  • Page 87: Trouble Shooting

    Section 6 - Maintenance TROUBLE SHOOTING You probably won’t require anything but preventive maintenance to keep your Jerr- Dan 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.

  • Page 88: P.t.o. Functioning Improperly

    Section 6 - Maintenance P.T.O. FUNCTIONING IMPROPERLY Problem Cause Solution Intermittent operation a. Poor Electrical connection a. Check electrical connections Rattling noise in P.T.O. a. P.T.O. backlash too loose a. Shims must be removed (Consult P.T.O. Manual) Howling noise in a.

  • Page 89: Winch Functioning Improperly

    Section 6 - Maintenance HYDRAULIC PUMP Problem Cause Solution Oil foaming a. Air leaking into suction line a. Tighten all connections b. Wrong kind of oil b. Drain and refill with non-foaming type of hydraulic oil (See lube chart) Replace filter c.

  • Page 90: Remote Hand Controller

    Section 6 - Maintenance REMOTE HAND CONTROLLER Problem Cause Solution Transmitter not a. Electric power turned off a. Turn on CONTROL power working. switch in cab or control station b. Discharged Battery b. Replace Battery c. Check connection c. Plug In Connection d.

  • Page 91: Section 7 - Specifications

    Section 7 : Specifications SECTION 7 - SPECIFICATIONS PRODUCT SPECIFICATIONS MPL-NG OPERATING SPECIFICATIONS AND PERFORMANCE DATA DO NOT EXCEED THE FOLLOWING RATINGS: BOOM RATING: SAE J2512 Rating - Boom elevated at 30° Angle ........8,000 lbs. WINCH RATING: (Standard Worm Gear) ..........8,000 lbs.
  • Page 92 Section 7 : Specifications SAE J2512: Surface Vehicle Recommended Practices - Towing Equipment Ratings and Practices SAE J706: Surface Vehicle Recommended Practices - Rating of Winches MAXIMUM LIFTING CAPACITY - THE MAXIMUM LOAD THAT CAN BE LIFTED. GROSS COMBINED WEIGHT RATING (GCWR) - THE VALUE SPECIFIED BY THE VEHICLE MANUFACTURER AS GCW.

  • Page 93: Truck Chassis

    Section 7 : Specifications TRUCK CHASSIS OPERATING SPECIFICATIONS AND PERFORMANCE DATA Refer to Final Stage Vehicle Manufacturer Label affixed to the Driver’s Side Door Jam, Hinge Pillar or Latch Post of the cab chassis and the chassis manufacturer’s manual. MFG BY:_______________________________________ ______________________________________________ DATE OF MFR:MO______________YR.______________ GVWR:_________________KG (_________________LB)

  • Page 94: Capacities

    Section 7 : Specifications CAPACITIES Hydraulic System Operating Pressure ................3000 psi max. System Flow (PTO System) ............8 gpm @ 1000 RPM System Flow (Clutch Pump System) .........7 gpm @ 1000 RPM System Capacity .................... 15 gal Reservoir Capacity ....................9 gal Type of Oil (PTO System) Ambient Temperature Above 20°...

  • Page 95: Inspection, Maintenance And Repair Log

    Inspection, Maintenance and Repair Log Serial Number Date Comments...
  • Page 96 Inspection, Maintenance and Repair Log Date Comments...

  • Page 97: Transfer Of Ownership

    Please use this form to provide Jerr-Dan with updated information with regard to the current ownership of Jerr-Dan products. Please return com- pleted form to the Jerr-Dan Product Safety & Reliability Department via fac- simile or mail to address as specified below.
  • Page 98 THIS PAGE IS INTENTIONALLY LEFT BLANK...
  • Page 100 13224 Fountainhead Plaza Hagerstown, MD 21742 Phone (717) 597-7111 Phone (800) 926-9666 www.jerrdan.com...

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