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Jerr-Dan MPL Operation And Maintenance Manual

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$35.00
MPL
OPERATIONS AND MAINTENANCE
MANUAL
1080 Hykes Road
Greencastle, PA 17225
Phone (717) 597-7111
www.jerr-dan.com
© 2010 Jerr-Dan Corporation. All Rights Reserved.
5-376-000102
REV. 1 - 07/10

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  • Page 1 $35.00 OPERATIONS AND MAINTENANCE MANUAL 1080 Hykes Road Greencastle, PA 17225 Phone (717) 597-7111 www.jerr-dan.com © 2010 Jerr-Dan Corporation. All Rights Reserved. 5-376-000102 REV. 1 - 07/10...
  • Page 2 5-376-000102 REV. 1 - 07/10...
  • Page 3 FOREWORD This manual is intended to serve as a guide to the owner and operator in the safe operation and optimum performance of your Jerr-Dan equipment. Establishment of good operating habits and familiarity with your equipment and its capabilities combined with good judgement are essential.
  • Page 4 Manufactured under one or more of the following patents: 5,575,606; 5,672,042; 5,697,741; 5,713,714; 5,722,810; 5,782,596; 5,839,755; and 6,315,515 B1 with other Patents Pending. Jerr-Dan and the Jerr-Dan logo are registered trademarks and Run Hard is a service mark of Jerr-Dan Corporation, Greencastle, PA. USA 5-376-000102...
  • Page 5 Distributor shall make on behalf of Manufactuer by conspicuous notice in writing accompanying each contract or memorandum of sale: 1. Warranty. Jerr-Dan Corporation, ("Manufacturer") warrants each new product made by it to be free from defects in material or workmanship for one year from the date of initial sale, lease, rental, or other disposition of such product, and agrees only to repair or replace at its own expense, f.o.b.
  • 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: MPL ................3 Safety Chains ................7 Lift Safety ................8 Boom Safety ................9 Safety Warning Decals ............13 Section II: Operation Wheel -Lift ................15 Tie-Down Straps ..............21 Wheel Grid Spacers ...............
  • Page 8 THIS PAGE INTENTIONALLY LEFT BLANK 5-376-000102 REV. 1 - 07/10 Page iv...

  • Page 9: Section I: Safety

    SAFETY The safe operation of your MPL 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 Manual and/or American Automobile Association (AAA) Towing Manuals be used as a reference for operating safety methods. AAA address and phone number: THE AMERICAN AUTOMOBILE ASSOCIATION 1000 AAA Drive Heathrow, FL 32746-9970 (800)222-4357 To alert personnel to hazardous operating practices, safety messages are used throughout the manual.

  • Page 11: Ratings: Mpl

    Standard Length ..........75 Feet NOTE: These ratings apply to the structural design of the MPL only and may 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...
  • Page 12 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 13 • Don’t use a recovery vehicle that has not been properly maintained. Pay special • Don’t operate the wrecker’s engine faster than • Don’t operate the wrecker’s engine faster than attention to the mounting bolts, and recommended. recommended. Excessive speeds can Excessive speeds can lubrication of moving parts.
  • Page 14 • Don’t tow a vehicle on its front wheels • Don’t tow a vehicle on its front wheels if unless the steering wheel is secured with they are damaged. the front wheels straight ahead. 5-376-000102 REV. 1 - 07/10 Section I: Safety Page 6...

  • Page 15: Safety Chains

    SAFETY CHAINS MUST BE USED WHEN TOWING AND TRANSPORTING Safety 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. If chain or hook damage is noted, they must be replaced before being used.

  • Page 16: Lift Safety

    In addition, the intent of the design of this unit should be taken before the undertaking of its use. Your MPL is unique. It not only can make lifts from level surfaces, our boom tilt feature allows pickup of vehicles that are parked on both inclines and declines.

  • Page 17: Boom Safety

    BOOM SAFETY Your MPL is equipped with a recovery winch and the following safety procedures must be observed: • Take up the wire rope slowly and be sure • Jog the winch control lever to be sure of the hook is securely set.
  • Page 18 • 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 wire rope failure. • Never completely unwind wire rope from a •...
  • Page 19 • 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 20 • Avoid using the boom raise or boom up • All boom placement functions should be control to lift a load. This causes undue made with the winch wire ropes set in “free stress and weight loading on the rear axle. spool”...

  • Page 21: Safety Warning Decals

    SAFETY WARNING DECALS As an extra safety precaution, your MPL has specific safety and warning decals affixed to prominent locations. These decals must not be obliterated, removed or painted over. They are there to remind and protect the operator. SERIAL NO.
  • Page 22 An Oshkosh Truck Corporation Company GREENCASTLE, PENNSYLVANIA SERIAL NO. MODEL NO. VEHICLE IDENT. NO. MANUFACTURED BY MANUFACTURED BY JERR-DAN CORPORATION JERR-DAN CORPORATION MFG. UNDER ONE OR MORE MFG. UNDER ONE OR MORE OF THE FOLLOWING PATENTS: OF THE FOLLOWING PATENTS: 5,576,606 5,576,606...

  • Page 23: Section Ii: Operation

    OPERATION WHEEL-LIFT OPERATION Your MPL 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 24 5. Confirm the truck’s position in relation to the vehicle to be towed. Nine (9) feet is recommended. Reposition the MPL if necessary. Be sure the towed vehicle is not in gear or park. Keep the brake set.
  • Page 25 6. Using the hand controller, unfold the underlift using the tilt down function. The underlift level stop assist system will stop the underlift travel at a preset position. 7. Next, lower the underlift using the underlift down function on the hand controller.
  • Page 26 8. 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. There is no reason for the operator to get under the vehicle.
  • Page 27 13. Lift the vehicle high enough to allow the tires to clear the ground. Make sure that the grid is not in contact with any engine or body components. 14. Remove the tie down straps from tool boxes and attach the tie down straps.
  • Page 28 17. Power retract the grid boom until the towed 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 the two (2) vehicles. Be sure that the boom is extended least 4"...

  • Page 29: Tie-Down Straps

    TIE DOWN STRAPS The MPL 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 wheel lift grid. NEVER TOW A VEHICLE WITHOUT THE TIE DOWN STRAPS INSTALLED.
  • Page 30 3. To release the ratchet, simply pull on the locking bar, disengaging the teeth and raise the handle to the “free spool” position. INSTALLING THE TIE DOWN STRAP 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.
  • Page 31 3. Place the hook of the ratchet into one of the holes on the front side of the grid. Again, try to use the hole that is closest to the tire. NOTE: The hole on the outside of the grid can be used to hook the ratchet in if you need to clear body mouldings or wide tires.

  • Page 32: Wheel Grid Spacers

    WHEEL GRID SPACERS The MPL with the self loading grid is supplied with a set wheel grid spacers. They can be used to pick up a vehicle with small diameter tires or even a vehicle without wheels and tires. The following steps should be...

  • Page 33: Towball Hitch Attachment

    TOWBALL HITCH ATTACHMENT The MPL is supplied with a Towball Hitch attachment that will allow you to recover and tow trailers requiring a tow ball hookup. DO NO EXCEED THE FOLLOWING RATINGS: 1-7/8 in. Ball: ........ 5,000 lbs. (GTW)* 2 in. Ball: ........5,000 lbs. (GTW)* 2-5/16 in.
  • Page 34 4. Install the desired towball to the towball hitch. 5. Position the ball coupler over the ball and lock into place. CAUTION: Make sure that the ball and coupler are of the same matched size. 6. Connect the trailer lights and attach safety chains.

  • Page 35: Recovery Winch

    RECOVERY WINCH OPERATION The MPL 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. Winch Rating: (Ramsey Worm Gear) ....8,000 lbs.
  • Page 36 2. Position and align the truck to obtain as direct a pull as possible. Straight line pulls are the best and most efficient. 3. Set the brakes on your Jerr-Dan unit. The use of scotch blocks is also recommended. 4. Unfold the under lift boom.
  • Page 37 6. Pull the wire rope off of the winch spool and route it through the roller guide. Unwind enough wire rope to make the hook-up being sure that a minimum of at least five (5) wraps of wire rope remains on the drums.
  • Page 38 8. Jog the winch control until the handle retracts into the engaged position. Now slowly take up the slack in the wire rope. 11. With the wire rope tight, slowly wind it in, observing both the work and the drum. Be sure the wire rope strands do not cross wrap or criss-cross on the drum.
  • Page 39 13. Now slowly retrieve the wire rope, carefully winding the wire rope onto the drum. Many operators take this opportunity to do a visual inspection. When you’ve finished rewinding the wire rope, be sure you don’t overwind it. Always wear safety glasses and gloves when doing recovery work or handling the wire rope.

  • Page 40: Motorcycle Towing Adapter (Optional)

    MOTORCYCLE TOWING ADAPTER OPERATION (OPTIONAL) If your MPL is equipped with a motorcycle towing adapter follow these steps: 1. Lower the boom flat to the ground. 2. Extend the wheel lift at least 6”. 6 IN 3. Close the grid arms like you would if you were loading a vehicle.
  • Page 41 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 42 7. Adjust the upper and lower tire stops so that they will contact and restrain the front tire when loaded. 8. Align the motorcycle with wheel lift boom and ramp. 5-376-000102 REV. 1 - 07/10 Section II: Operation Page 34...
  • Page 43 9. Push the motorcycle up the ramp until the front wheel is resting in and against the tire stops in the front brackets. 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.
  • Page 44 12. After securing the front tire, extend the wheel lift under the rear tire of the motorcycle raising the rear tire of the motorcycle onto the ramp. 13. Tie down the rear of the motorcycle. Place the hook on one end of the “rear” strap into the hole on the front side of the grid.
  • Page 45 15. Tie the front of the motorcycle to the rear of the wrecker body. Attach the lasso style straps to each of the handle bars. 16. Place the hook on one end of the “front” strap to the loop of the lasso strap on the handle bars and place the hook on the other end to the rear of the wrecker...
  • Page 46 18. Attach towing lights. 19. Reverse the loading procedures to unload the motorcycle. 5-376-000102 REV. 1 - 07/10 Section II: Operation Page 38...

  • Page 47: Dolly Storage (Optional)

    DOLLY STORAGE OPERATION (OPTIONAL) If your MPL is equipped with a towing dolly, follow these steps for dolly removal and storage: 1. Remove the retaining bolts and wing nuts or pad locks, which ever your unit may have. 2. Open dolly the retaining latch by pulling the top toward you.
  • Page 48 3. After you have the latch open, the dolly is free to be removed. 4. Remove the dolly wheel assemblies, the axle cross tube rails and the pry bar/jack bar. 5. Load dollies. (See Dolly Operation instructions). 6. After loading the dollies, place the pry bar/jack bar back into the storage bracket by inserting the end of the bar with the ring around...
  • Page 49 7. Close the dolly latch by pushing the top away from you. 8. Install the retaining bolts and wing nuts or pad locks. 9. After using the dollies, store them back on the deck in basically the reverse order. Remove the retaining bolts and wing nuts or pad locks and open the latch.
  • Page 50 11. The axle cross tube rails need to be stored with the wheel ramp plates turned in and up. 12. Allow the axle cross tube rails to hang from the bracket by the tab. 13. Place the dolly wheel assemblies back into the storage brackets.
  • Page 51 14. The tab on the storage bracket should be placed through the dolly pocket of the dolly wheel assembly. 15. Close the dolly retaining latch by pushing the top away from you. 16. Install the retaining bolts and wing nuts or pad locks. 5-376-000102 REV.

  • Page 52: Dollies (Optional)

    DOLLY OPERATION (OPTIONAL) Specifications: Dolly Capacity: ..........2,360 lbs. Tire/Wheel: ..........4.80 x 4.00/8Tire Axle: ............ 2 1/2 Sq. Tube Max. Speed: ............ 50 M.P.H. The Quick Loading Dolly is simple to use once the principles of the unit are understood.
  • Page 53 Safety tie-down straps should be used to secure dolly to vehicle in case of rough road. Dolly is now ready for towing. BE SURE EACH WHEEL IS SECURELY HELD IN ITS DOLLY AND INSPECT THE GROUND CLEARANCE OF THE VEHICLE BEFORE ATTEMPTING A TOW.
  • Page 54 THIS PAGE INTENTIONALLY LEFT BLANK 5-376-000102 REV. 1 - 07/10 Section II: Operation Page 46...

  • Page 55: Section Iii: Maintenance

    MAINTENANCE MAINTENANCE AND LUBRICATION Your MPL 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.
  • Page 56 The MPL is mounted to the truck chassis by bolts. These bolts are torqued at the factory to 70 ft. lbs. The MPL aluminum body is mounted to the subframe by bolts. These bolts are torqued at the factory to 70 ft. lbs. We recommend periodic inspection and retorquing of these bolts.
  • Page 57 · All torque values shown are for bolts (cap screws) and nuts that are either zinc- plated or lubricated. · Torques shown above apply to screws and nuts used for assembly and installation of all wrecker components. · Different torque values may be given in instructions for certain components due to short thread engagement or low-strength internal threads.

  • Page 58: 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 DHZ-32 5. Shell Tellus Oil T 32 6.

  • Page 59: Wire Rope Handling And Inspection

    WIRE ROPE HANDLING AND INSPECTION WARNING 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: • ALWAYS INSPECT wire rope for WEAR, DAMAGE or ABUSE BEFORE USE.
  • Page 60 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 61: Underlift Level Stop Assist System

    To change or adjust the factory set positions of the Underlift Level Stop Assist system, follow these steps: 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. MOVE SENSOR UPWARD TO LOWER UNDERLIFT GRID;...

  • Page 62: Lubrication Points

    LUBRICATION POINTS The following lubrication chart is located inside the tool box lid on the driver’s side of the MPL body. 5-376-000102 REV. 1 - 07/10 Section III: Maintenance Page 54...

  • Page 63: Trouble Shooting

    TROUBLE SHOOTING You probably won’t require anything but preventive maintenance to keep your MPL 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 64: Hydraulic Clutch Pump

    HYDRAULIC CLUTCH PUMP Problem Cause Solution No oil flow from a. No oil in reservoir a. Fill hydraulic reservoir pump b. Pump not “primed” b. Fill inlet hose from pump c. Clutch not engaging c. Check wiring/fuse Pump will not build a.

  • Page 65: P.t.o. Functioning Improperly

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

  • Page 66: Winch Functioning Improperly

    HYDRAULIC PUMP - con’t 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. Oil level too low c.

  • Page 67: Section Iv: 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 68 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 69 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 70 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 71 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 72 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 73 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 74 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 75 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 76 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 77 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 78 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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