Jerr-Dan MPL40 Operation And Maintenance Manual

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5-376-000086 REV. 4 - 07/10

MPL40

OPERA TIONS AND MAINTENANCE

MANUAL

$35.00

1080 Hykes Road

Greencastle, P A 17225

Phone (717) 597-71 1 1

www.jerr-dan.com

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REV. 4 - 07/10

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FOREWORD

This manual is intended to serve as a guide to the owner and operator in the safe operation and optimum performance of this Jerr-Dan equipment.

Establishment of good operating habits and familiarity with the equipment and its capabilities combined with good judgement are essential.

Before attempting to operate the unit carefully read all sections of this manual. This manual is intended to serve as a guide to the owner and operator in the

safe operation and optimum performance of this Jerr-Dan equipment. This manual should be kept with the equipment at all times and referred to

whenever in doubt of proper operation. Information contained in this manual reflects how this vehicle was built at the

factory. Modifications or additions by the distributor or owner are not reflected in this manual.

This manual does not include operation and maintenance information for the commercial chassis (IHC, Ford, GM, etc.). This information is provided by the chassis manufacturer .

When inquiring about operation, maintenance or warranty, please refer to your equipment’s Sales Order Number , Serial Number and Model Number . This information can be found on the aluminum tag riveted inside the driver’s side toolbox on the back wall in the upper right corner .

001

VEHICLE

IDENT. NO.

MODEL NO.

SERIAL NO.

MANUFACTURED BY

GREENCASTLE, PENNSYLVANIA

An Oshkosh Truck Corporation Company

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Jerr-Dan Corporation strives to provide information that is accurate, complete 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. Should you find inadequacies in the text, please send your comments to the following address:

Jerr-Dan Corporation Attn: T echnical Publications 1080 Hykes Road Greencastle, P A 17225

Additional or replacement manuals or replacement safety warning labels can be ordered by calling Jerr-Dan Parts at 717-597-71 1 1. Price and availability will be quoted at time of the request.

The material in this document is confidential and the property of Jerr-Dan Corporation. No part of this document may be photocopied, reproduced or translated to another language without the express written consent of JerrDan Corporation.

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, P A. USA

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LIMITED WARRANTY

Manufacturer's Warranty. Manufacturer's sole warranty shall be the following, which

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. the place or places of manufacture, at manufacturer's option, any part or parts of the product found to be defective in material or workmanship, provided Manufacturer is notified of such defect or defects within the one year warranty period and given a reasonable time to correct the defect. In no case, shall the warranty extend to defects in materials, components, or services furnished by third parties. Defects caused by chemical action, or the presence of abrasive materials and defects arising following the operation beyond rated capacity or the improper use or application of any Products shall not be considered defects within the scope of the foregoing warranty. If any repairs or alterations are made or any parts are replaced during the period covered by any warranty above mentioned by other than an authorized Manufacturer's Distributor in accordance with authorized Manufactuerer's service manuals or with other than parts, accessories, or attachments 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 fulfillment of this warranty with respect to parts or components of all repairs, alterations or replacements so made. No claims for labor shall be considered unless authorized by Manufacturer.

2. Disclaimer as to Consequential or Special Damages. Under no circumstances shall Manufacturer be liable for any consequential or special damage which any person, firm, corporation, or other entity may suffer or claim to suffer or incur or claim to incur as a result of any defect in the product or in any correction or alteration thereof made or furnished by Manufacturer or others. "Consequential" or "special damages" as used herein includes but is not limited to costs of transportation, lost sales, lost orders, lost profits, lost income, increased overhead, labor and material costs and cost of manufacturing variances and operational inefficiencies.

3. Maximum Liability. The maximum liability of Manufacturer under the exclusive warranty set forth herein shall be the amount paid to Manufacturer by the vendor of the component with respect to the product to which such vendor warranty applies.

4. Limitation of Liability. The limitation of liability provisions herein shall apply to any and all claims or suits brought against Manufacturer, including any claim based upon negligence, breach of contract, breach of warranty, strict liability or any other theories upon which liability may be asserted against Manufacturer.

1080 Hykes Road

Greencastle, P A 17225

(717) 597-71 1 1

WARRANTY

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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.

MANUFACTURER EXPRESSLY DISCLAIMS ANY AND ALL OTHER WARRANTIES OF ANY KIND WHA TSOEVER AS T O THE PRODUCT FURNISHED HEREUNDER, INCLUDING BUT NOT LIMITED T O EXPRESS OR IMPLIED W ARRANTIES AS T O MERCHANT ABILITY, FITNESS FOR PARTICULAR PURPOSES SOLD, DESCRIPTION OR QUALITY OF THE PRODUCT FURNISHED HEREUNDER.

6. Notice of Occurrence. This warranty shall be void if, upon the occurrence of any incident involving any product made by Manufacturer, and resulting in any personal injury or property damage, customer shall fail to notify Manufacturer within 24 hous of such occurrence or permit Manufacturer audit representatives to have immediate access to such product and to all records of and within the control of the customer and/or distributor relating to the product and the occurrence.

7. Filing of Warranty Claim. Upon notifying the Manufacturer of a failure, the Manufacturer or its representative will verbally authorize and comfirm by letter the repairs to be made. Verbal authorization will require the following information:

A) Owner'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 repairs. F) Owner to be informed of C.O.D. on parts (if deemed necessary) to assure return of

defective parts for manufacturer’s evaluation.

At this time, the Manufacturer will ship as soon as practical the parts needed to make the repair. Included with the parts will be the invoice for the parts and a Request for Warranty form, with the Warranty Return Tags.

The vehicle owner/dealer will complete the Request for Warranty form and the Warranty Return Tag marked "Return with Shipping Notice." Both documents should be attached to the shippping notice and returned to the Manufacturer by mail. The parts to be returned shall be tagged with the Warranty Return Tag (more than one part pertaining to the same warranty claim shall be identified with the same warranty claim number - see number on Warranty Return Tag). All parts under this claim shall be returned to the Manufacturer prepaid for warranty evaluation.

Upon receiving the part or parts for warranty evaluation, the part will be inspected and tested. After being inspected and tested, the decision to honor or deny warranty claim shall be based on analysis of all available information.

When warranty is honored, the Manufacturer will reimburse the owner/dealer in the amount agreed to by both parties.

If warranty is denied, the owner and distributor will be notified in writing of the decision and a full explanation for the decision will be given.

8.Manufacturer may at any time amend the foregoing form of warranty without prior notice.

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TABLE OF CONTENTS

Section I: Safety

Safety (General).......................................................................1

Ratings: MPL40 .......................................................................3

Safety Chains ..........................................................................8

Lift Safety ................................................................................9

Boom Safety .......................................................................... 1 0

Sling Safety ........................................................................... 14

Safety Warning Decals .......................................................... 16

Section II: Operation

Wheel -Lift .............................................................................1 9

Tie-Down S traps.....................................................................25

Wheel Grid Sp acers ............................................................... 2 8

T owball Hitch Attachment.......................................................29

Wrecker Boom - Single Line Boom - Worm Gear Winch ....... 31

Wrecker Boom - Single Line Boom - Planetary Gear Winch ..3 7

Wrecker Boom - Dual Line Boom - Worm Gear Winches ...... 4 2

T ow Sling (Optional) ...............................................................48

Motorcycle T owing Adapter (Optional) .................................... 58

Dolly S torage (Optional) ......................................................... 65

Dollies (Optional) ...................................................................70

Section III: Maintenance

Maintenance and Lubrication ................................................. 73

Oils and Greases ................................................................... 76

Wire Rope Handling and Inspection ....................................... 77

Underlift Level S top Assist System ........................................ 79

Lubrication Points .................................................................. 80

Trouble Shooting ....................................................................81

Hydraulic System .................................................................. 81

Hydraulic Clutch Pump .......................................................... 82

P.T .O. Functioning Improperly ................................................83

Hydraulic Pump ..................................................................... 83

Winch Functioning Improperly................................................84

Section IV: Glossary

Glossary ................................................................................85

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Section I: Safety

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The safe operation of your MPL40 is your responsibility . Read this manual and the truck manufacturer’s manual and thoroughly understand them. Y ou can be held legally responsible for injuries or damage resulting from unsafe operating practices.

Our recommendations for operating your equipment can help you avoid unsafe practices and their bad consequences. These recommendations are contained in this manual.

Jerr-Dan Corporation is not responsible for the results of any unsafe practice of tow operators or for the failure of your equipment or its accessories resulting from improper use or maintenance.

The danger from a vehicle continues after it is disabled or wrecked. Recovering or towing vehicles can be dangerous too! The danger threatens tow operators and everyone else close by. As a tow operator you must develop an awareness of the hazards involved. Y ou must use every safeguard within reason to prevent injuries.

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.

Tie-down straps are provided for use with your new Jerr-Dan Recovery V ehicle. Periodically inspect all straps for any signs of fatigue or damage. Don’t overlook the hooks; be sure they have not been bent or deformed. If strap or hook damage is noted, they must be replaced before being used.

Wire rope cables wear out or can become damaged. Periodically inspect the wire rope cable for any signs of fatigue or damage. Don’t overlook the hooks; be sure they have not been bent or deformed. Refer to the Wire

Rope Handling and Inspection Section.

For each step in operating your equipment develop the habit of asking yourself "is it safe to proceed?" Carefully check your set up before starting a lift or tow.

Because recoveries can be so different, we cannot warn you of all the possible dangers you will encounter , but we will tell you of the most common hazards that we know about. We also recommend that you receive specialized and advanced training from a professional T owing and Recovery instructor before

SAFETY

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operating any recovery equipment and that the V ehicle Manufacturers T owing Manual and/or American Automobile Association (AAA) T owing Manuals be used as a reference for operating safety methods.

AAA address and phone number:

THE AMERICAN AUTOMOBILE ASSOCIA TION

1000 AAA Drive

Heathrow, FL 32746-9970

(800)222-4357

T o alert personnel to hazardous operating practices, safety messages are used throughout the manual. Each safety message contains a safety alert symbol and a signal word to identify the hazard's degree of seriousness.

CAUTION:

Identifies when a potentially hazardous situation exists and may result in a minor or moderate injury or property damage.

W ARNING:

Identifies when a potentially hazardous situation exists and could result in death or serious injury .

DANGER:

Identifies when an imminently hazardous situation exists and can result in death or serious injury .

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DO NOT EXCEED THE FOLLOWING RA TINGS:

MPL40 Underlift Rating ....................................... 4,000 lbs “L” Arm

T ow Rating ..................................................................... 7,500 lbs.

Boom Rating: (Extended)...............................................6,000 lbs.

(Retracted) ............................................16,000 lbs.

Winch Rating: (Ramsey Worm Gear Winches)

.....................

8,000 lbs.

(Warn Planetary Gear Winch)

.........................

9,000 lbs.

Wire Rope:

Working Limit ................................................4,100 lbs.

Construction ............................ 6 x 25 EIPS RRL IWRC

Diameter ........................................................... 3/8 inch

S tandard Length ..............................................100 Feet

SAE J706: Surface V ehicle Recommended Practices - Rating of Winches

SAE J2512: Surface Vehicle Recommended Practices - Towing Equipment Ratings and Practices

MAXIMUM LIFTING CAP ACITY - THE MAXIMUM LOAD THA T CAN BE LIFTED. GROSS COMBINED WEIGHT RA TING (GCWR) - THE V ALUE SPECIFIED BY THE VEHICLE

MANUFACTURER AS GCW. GROSS COMBINED WEIGHT (GCW) - ACTUAL WEIGHT OF THE ENTIRE VEHICLE A T THE

GROUND WITH TRAILER OR TRAILERS, INCLUDING VEHICLE EQUIPMENT, DRIVER, PASSENGER, FUEL AND P A YLOAD (EVERYTHING THA T MOVES WITH THE VEHICLE).

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NOTE

These ratings apply to the structural design of the Standard Duty Carrier 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

following:

- The actual payload on the towing vehicle must not exceed the posted rating and, if applicable, the towed vehicle load must not exceed the posted lift / towing ratings.

- The total weight of the towing vehicle (cab chassis, body, payload, driver, passenger(s), tools, fuel, etc.) and, if applicable, the towed vehicle load must not exceed the GVWR (Gross Vehicle Weight Rating) of the towing vehicle.

- The total weight of the towing vehicle and, if applicable, the towed vehicle load must be distributed so that each axle’s GAWR (Gross Axle Weight Rating) is not exceeded.

- The total weight of the towing vehicle and towed vehicle (everything that moves with the towing vehicle) must not exceed the GCWR (Gross Combination Weight Rating) of the towing vehicle.

Staying within these ratings is necessary to maintain the safety and performance of the towing vehicle.

CHECK TRUCK MANUAL FOR SPECIFIC GVW & AXLE RATINGS. ALSO REFERENCE THE CERTIFICA TION DECAL AFFIXED T O DRIVER’S SIDE DOOR JAMB, HINGE PILLAR OR LA TCH POST AND THE S.T.A.R. PLACARD ON THE

DRIVER'S SIDE OF THE HEADBOARD.

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Certification Decal

Affixed to the Driver's Side DoorJam, Hinge Pillar or Latch Post

Provided by the Final St age Vehicle Manufacturer according to Title 49

Part 567 of the Code of Federal Regulations (CFR)

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__________________

MO._______________________YR._________________ VEHICLE IDENTIFICATION NUMBER: _______________________________________________ VEHICLE TYPE: _______________________________________________

THIS VEHICLE HAS BEEN COMPLETED IN ACCORDANCE WITH THE PRIOR MANUFACTURERS' IVD, WHERE APPLICABLE. THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDS, [AND BUMPER AND THEFT PREVENTION STANDARDS, IF APPLICABLE] IN EFFECT IN:

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• Don’t use a recovery vehicle that has not been properly maintained. Pay special attention to the mounting bolts, and lubrication of moving parts.

• Don’t operate the wrecker’s engine faster than recommended. Excessive speeds can damage PTO, hydraulic pumps, and winches.

• Don’t pick-up and tow a vehicle that reduces the weight on the front wheels of the wrecker more than 50 percent.

• Don’t travel with the PTO or Clutch Pump engaged. Damage to the trucks transmission, engine or hydraulic components will occur. Engage it only while operating the controls.

• After you have hooked up a vehicle for towing, don’t start the tow until you have double checked the hook-up, installed safety chains, and released the parking brakes of the towed vehicle.

• Don’t operate the wrecker’s engine faster than recommended. Excessive speeds can damage PTO, hydraulic pumps, and winches.

• Don’t rely on anti-theft steering locks to secure the steering wheel. Use a special steering wheel clamping device designed for this purpose.

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• Don’t tow a vehicle on its front wheels unless the steering wheel is secured with the front wheels straight ahead.

• Don’t tow a vehicle on its front wheels if they are damaged.

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SAFETY CHAINS MUST BE USED WHEN TOWING AND TRANSPORTING

Safety chains are provided for use with your new Jerr-Dan Recovery V ehicle. 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. Do not

use safety chains for recovery operations.

Many states 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.

• Never attach the chain hooks in such a way as to damage brake lines or other functional parts.

• Keep in mind that driving over bumps and hollows and around corners will tend to tighten or loosen the chains.

• Check that the chain does not become over tensioned when raising the towed vehicle to the towing position or during the towing operation.

• Always use two safety chains when towing all vehicles, regardless of distance.

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LIFT SAFETY

Your MPL40 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.

• You should never make a lift or movement while close to or under the vehicle being lifted!

• Always use jack stands to support the vehicle if it is necessary to work under it.

• Towing lights are required in many areas and are always recommended for safe tows.

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• Jog the winch control lever to be sure of complete engagement of the clutch gears before making a lift or pull.

• Never stand on or straddle a working wire rope.

• Take up the wire rope slowly and be sure the hook is securely set.

• Be sure of your lift or pull and do not exceed the working strength of the wire rope or hook. Rig to keep the estimated amount of pull well within equipment ratings. Use wire rope breaking strength ratings only for selecting replacement wire rope.

BOOM SAFETY

Your MPL40 is equipped with a recovery winch and the following safety procedures must be observed:

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• Never lift or pull over or around a sharp obstacle.

• Never completely unwind wire rope from a winch while loaded. Always be sure that a minimum of five (5) wraps of wire rope are on the drum at all times.

• Never tie down the front 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 rope can cause wire rope failure.

• Never make a lift or pull with the wire rope attached to light gauge or sheet metal parts; use the frame or major structural members.

• Don’t disengage the winch drum clutch while the wire rope is loaded.

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• Don’t permit bystanders in the area while performing recovery work.

• Never wrap the wire rope around frames or cross members. Use chains and hook the wire rope to the chains.

• Don’t use damaged wire ropes on your wrecker. Become familiar with the various types 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 properly set on the recovery vehicle.

• Never under any circumstances use the winch or boom to lift people!

• Lubricate and maintain both the wire rope and winch on regular intervals. (See maintenance charts.)

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• All boom placement functions should be made with 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 loading on the rear axle. Use the winch to lift the load.

• After rigging wire ropes, don’t begin pulling without rechecking connections. Make sure that all wire ropes and snatch blocks are securely attached and cannot accidently pull loose.

• Don’t tow a vehicle on its drive wheels unless steps have been taken to protect its transmission and differential. Follow the recommendations of the vehicle manufacturer. As an alternative, use a towing dolly.

• To avoid birdnesting and premature failure of the wire rope, always keep tension on the wire rope when unwinding.

• Don’t exceed ratings of booms, wire ropes, snatch blocks, or winches. Stay within nameplate ratings.

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• Hook up and make the lift in strict accordance with AAA’s instructions.

• Never attach the chain hooks in such a way as to damage brake lines or other functional parts.

• Be sure the chains and hooks are attached to frame members and not sheet metal.

• Never make a front lift without unlatching the hood of the vehicle.

SLING SAFETY

If your MPL40 is equipped with an optional tow sling certain safety precautions must be taken to ensure safe operation. Consult the AAA Towing Manual for the make and model of the vehicle to be towed and observe the following safety procedures:

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• The bottom anchor assembly (round tube) must never be higher than the attachment point on the rear of the MPL40. The rear stand off bar assembly acts as a pivot in the event of a sudden stop. This will asure that the casualty vehicle will not catapult forward onto the deck of the recovery vehicle.

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CAUTION

424

TOWHITCHBRACKET

MUST BE REMOVED

BEFORE UNFOLDING

THEBOOMDOWNFOR

WHEEL GRID OPERATION

TOW HITCH BRACKET

MUST BE REMOVED

BEFORE UNFOLDING

THE BOOM DOWN FOR

WHEEL GRID OPERATION

SAFETY WARNING DECALS

As an extra safety precaution, your MPL40 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 .

CAUTION

034

CHECK HYDRAULIC FLUID LEVEL

FILL ONLY WITH APPROVED FLUID

(SEE OPERATOR'S MANUAL)

WARNING

122

TOWED VEHICLE MUST BE

CONNECTED TO TOW TRUCK BODY

WITH SAFETY CHAINS

TOWED VEHICLE MUST BE

CONNECTED TO TOW TRUCK BODY

WITH SAFETY CHAINS

546

A MINIMUM OF 5 WRAPS OF CABLE MUST BE LEFT

N WINCH DRUM TO ACHIEVE

RATED L

OAD.

DO NOT USE WINCH TO MOVE OR LIFT

PERSONS.

WARNIN

WARNING

036

VEHICLE MUST BE SECURED TO WHEEL

GRID USING BOTH TIE DOWN STRAPS

PRIOR

TO LEAVING LOADING

SITE

VEHICLE MUST BE SECURED TO WHEEL

GRID USING BOTH TIE DOWN STRAPS

PRIOR

TO VING LOADING

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BODY NO: SERIAL NO: TOW RATING: LBS. (MAXIMUM)

UNDER LIFT NO:

UNDER LIFT CAPACITY: LBS. *

VIN C.A. IN.

* NOTE: LIFT CAPACITY INDICATES THE STRUCTURAL CAPACITY OF THE LIFT MECHANISM, NOT THE MAXIMUM EFFECTIVE TRANSPORT LOAD.

REAR AXLE WEIGHT RATING (GAWR): LBS.

TRUCK CHASSIS INFORMATION

THE MAXIMUM EFFECTIVE TRANSPORT LOAD OF

THIS UNIT BASED ON TRUCK CHASSIS

G.A.W.R. AND G.V.W.R SPECIFICATIONS

DO NOT EXCEED THE FOLLOWING WEIGHTS

LBS. AT FULL EXTENSION LBS. AT 10” EXTENSION

LOSS OF VEHICLE CONTROL, WHICH COULD RESULT

IN SERIOUS BODILY INJURY OR DEATH, CAN OCCUR

IF THE EFFECTIVE TRANSPORT LOAD IS EXCEEDED.

MAXIMUM EFFECTIVE TRANSPORT LOAD IS AFFECTED BY THE CHASSIS

ON WHICH THE TOWING EQUIPMENT IS INSTALLED. BEFORE

ATTEMPTING TO USE THIS EQUIPMENT ON A CHASSIS OTHER THAN

THAT SPECIFIED ABOVE, CONTACT JERR-DAN TO OBTAIN

A REVISED RATING.

SAFETY IS NO ACCIDENT.

REVIEW OPERATOR’S PRE-TRANSPORT CHECKLIST IN THE OWNER’S

MANUAL EACH TIME YOU MOVE A VEHICLE. FOLLOW ALL

INSTRUCTIONS ON CONTROLS AND UNIT.

JERR-DAN CORPORATION

307

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 move boom within

near power lines.

203

DANGER

WARNING

037

MOVING PARTS

KEEP HANDS AND FEET CLEAR

OF THIS AREA

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Section II: Operation

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WHEEL-LIFT OPERATION

Your MPL40 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.

Follow these simple steps:

1. Turn on the safety and work lights. (Switches located on the dash panel).

2. Position the truck within 9 ft. of the subject vehicle and as close to the direction of the pull as possible.

3. Set the truck’s parking brakes and put the transmission in park or neutral.

9 FT

OPERATION

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4. Engage the Power-Take-Off (PTO) or Clutch Pump and the hand controller using the “Control” switch in the switch panel. Most trucks will automatically throttle up when the parking brake is set and the transmission is park or neutral. NEVER TRAVEL WITH

THE POWER-TAKE-OFF or CLUTCH PUMP CONTROL ENGAGED. This could result in

damage to the PTO or Clutch Pump unit and the truck transmission.

CAUTION:

Never exceed 1,500 R.P.M. When your hook up is complete, reset the engine idle to normal.

5. Confirm the truck’s position in relation to the vehicle to be towed. Nine (9) feet is recommended. Reposition the MPL40 if necessary. Be sure the towed

vehicle is not in gear or park. Keep the brake set.

9 FT

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6. Using the hand controller or manual controls located at the rear of the body, 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 funtion on the hand controller . The underlift level stop assist system will stop the underlift travel at a preset position about 1-1/2" to 2” from the ground.

NOTE:

To override either stop position, simply release the control function and reactivate the same control function again to achieve further travel of the underlift.

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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.

9. Visually inspect the tire to grid contact before proceeding.

10. Close the grid arms around the tires to secure the towed vehicle.

Make sure that the arm is fully closed and in its over center locked position.

11. After securing the grid arms around the towed vehicles tires and before making the actual lift, check to be sure the towed vehicle’s parking brake is released, the transmission is in neutral, and the wheels are straight.

NOTE:

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.

12. It is recommended that the steering wheel be secured by a steering wheel strap for any tow.

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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. (See Tie-Down

Strap instructions).

15. With the straps in place, 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 by the hand controller .

16. 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 consideration. Observe the lift function from the side and away from both vehicles if possible.

NOTE:

For the best towing and maneuverability the boom should be as close to horizontal as possible.

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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 at least 4" to ensure unobstructed crossbar pivoting.

18. Be sure to maintain sufficient clearances with the bottom of the towed vehicle.

19. Attach the safety chains and towing lights. Safety chains

should be crossed from one side of the recovery vehicle to the opposite side of the towed vehicle.

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TIE DOWN STRAPS

The MPL40 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 INST ALLED.

The tie down strap assembly is comprised of 2 basic components:

1. The S trap/Hook Assembly

2. The Ratchet S pool Mechanism

The following steps should be followed to properly install the tie down straps:

USING THE RATCHET SPOOL MECHANISM

1. First the spool must be set into “free spool”. This is done by pulling the lock bar out and swinging the handle upward until it rests in the free spool notch and then simply pulling out the amount of strap required to fit over the tire.

2. Now pull on the lock bar and move it downward until it engages the ratchet teeth on the take up spool. By pushing and pulling the handle up and down, the strap will be wound onto the spool.

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3. T o 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. Put the loop over the tire as shown with the strap resting on the tire at the ten o’clock and two o’clock positions. The choker strap should be across the center of the tire.

2. Place the rear hook of the strap assembly into a hole on the back side of the grid arm. Try to use the hole that is closest to the tire.

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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.

4. Take up the slack in the strap by ratcheting the takeup spool arm. Continue until the tires show some compression. Notice that

the strap in the ratchet is pulling down and forward on the loop over the tire.

5. Raise the wheel grid to the towing position. RE-TIGHTEN THE

RATCHET PERIODICALLY AS THE TIRE SETTLES IN GRID FROM TOWING.

NOTE:

Never tow a vehicle without tire tie-down straps and safety chains installed.

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WHEEL GRID SPACERS

The MPL40 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 followed to properly install the wheel grid spacers:

1. Slide the back side of the wheel spacer over the wheel grid arm.

2. Close the grid arms around the tires to secure the towed vehicle.

Make sure that the arm is fully closed and in its over center locked position.

3. Visually inspect the tire to grid contact before proceeding.

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TOWBALL HITCH ATTACHMENT

The MPL40 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 RA TINGS:

1-7/8 in. Ball:................................5,000 lbs. (GTW)*

2 in. Ball: .....................................5,000 lbs. (GTW)*

2-5/16 in. Ball:..............................7,500 lbs. (GTW)*

50 MM Ball: .................................5,000 lbs. (GTW)*

* Gross T ongue W eight

1. Remove the towball hitch attachment from the toolbox.

2. Install the towball hitch to the bottom on the underlift boom using the hitch pins.

3. Secure the hitch pins with the linch pins.

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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.

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WRECKER BOOM OPERATION SINGLE LINE BOOM - WORM GEAR WINCH

The MPL40 wrecker boom is an extremely effective tool in recovery or retrieval prior to lifting and towing. To operate the wrecker boom effectively, care and thought must be given.

Boom Rating: (Extended) .....................................6,000 lbs.

(Retracted) ..................................16,000 lbs.

Winch Rating: (Ramsey Worm Gear)...................8,000 lbs.

Wire Rope Working Limit: ....................................4,100 lbs.

Wire Rope Construction: ................ 6 x 25 EIPS RRL IWRC

Wire Rope Size:.................................... 3/8 inch x 100 Feet

*All ratings comply with SAE J2512 and SAE J706 Recommended Practice

WARNING:

Do not exceed the working limit of the wire rope. Use snatch blocks and multiple lines to reduce the load on the wire rope.

1. Check the direction you wish the work to travel, being sure there are no major obstacles in the way.

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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.

4. Unfold the under lift boom.

5. If a heavy lift or pull is to be made additional lines may be necessary. Always use more stabilizing lines than pull lines. RIG FOR SAFETY. The use of scotch blocks is also recommended.

6. Unhook the wire rope cables from the top of the tow sling.

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7. Disengage the winch “free-spool” by pulling out on the “T” handle and turning the handle 90°. The handle should remain in the “freespool” position. Never turn this

handle while the wire rope is under load! This allows the wire

rope to be pulled directly off the drum to the work.

8. Position the boom head by using the boom up and down control lever and the boom in and out lever .

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9. 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). Do not connect to thin or loose body panels or components that could break loose during the winching operation. Slings and bridles are usually designed with hook clusters on them. Most chassis manufacturer’s provide tie-down hooks and/or slots in chassis frames that may be able to be used as recovery attachment points. (Consult the Chassis Manufacturer’s Towing Manual and/or the American Automobile Association (AAA) Towing Manuals.)

10. Reengage the winch “free-spool” by turning the handle back 90°.

11. Jog the winch control until the handle retracts into the engaged position. Now slowly take up the slack in the wire rope.

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12. 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. Observe the path the work must travel for snags or obstructions which could stall the movement and overload the wire rope.

13. Once the work is in the desired position, apply the towed vehicles parking brake or use blocks or tie the work down if there is any question about stability. Slowly reduce the wire rope tension. After enough wire rope has been unwound, you may remove the hookup.

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14. 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.

Remember, most wire rope failures are caused by cable crushing or the operator underestimating the pull or over estimating the wire rope strength.

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WRECKER BOOM OPERATION SINGLE LINE BOOM - PLANETARY GEAR WINCH

The MPL40 wrecker boom is an extremely effective tool in recovery or retrieval prior to lifting and towing. To operate the wrecker boom effectively, care and thought must be given.

Boom Rating: (Extended) .....................................6,000 lbs.

(Retracted) ..................................16,000 lbs.

Winch Rating: (Warn Planetary Gear) ..................9,000 lbs.

Wire Rope Working Limit: ....................................4,100 lbs.

Wire Rope Construction: ................ 6 x 25 EIPS RRL IWRC

Wire Rope Size:.................................... 3/8 inch x 100 Feet

*All ratings comply with SAE J2512 and SAE J706 Recommended Practice

WARNING:

Do not exceed the working limit of the wire rope. Use snatch blocks and multiple lines to reduce the load on the wire rope.

1. Check the direction you wish the work to travel, being sure there are no major obstacles in the way.

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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.

4. Unfold the under lift boom.

5. If a heavy lift or pull is to be made additional lines may be necessary. Always use more stabilizing lines than pull lines. RIG FOR SAFETY. The use of scotch blocks is also recommended.

6. Unhook the wire rope cables from the top of the tow sling.

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7. Release the free spooling lever on the winch by pushing down on the spring steel latch plate and turning the handle 180°. Never

turn this handle while the wire rope is under load! This allows

the wire rope to be pulled directly off the drum to the work. 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.

8. Position the boom head by using the boom up and down control lever and the boom in and out lever .

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10. Re-engage the winch drive by pushing down on the spring steel latch plate and turning the handle 180°. Confirm winch engagement by jogging the winch control. 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. Observe the path the work must travel for snags or obstructions which could stall the movement and overload the wire rope.

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Remember, most wire rope failures are caused by cable crushing or the operator underestimating the pull or over estimating the wire rope strength.

12. Once the work is in the desired position, apply the towed vehicles parking brake or use blocks or tie the work down if there is any question about stability. Slowly reduce the wire rope tension. After enough wire rope has been unwound, you may remove the hookup.

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.

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WRECKER BOOM OPERATION DUAL LINE BOOM - WORM GEAR WINCHES

The MPL40 wrecker boom is an extremely effective tool in recovery or retrieval prior to lifting and towing. To operate the wrecker boom effectively, care and thought must be given.

Boom Rating: (Extended) .....................................6,000 lbs.

(Retracted) ..................................16,000 lbs.

Winch Rating: (Ramsey Worm Gear)...................8,000 lbs.

Wire Rope Working Limit: ....................................4,100 lbs.

Wire Rope Construction: ................ 6 x 25 EIPS RRL IWRC

Wire Rope Size:.................................... 3/8 inch x 100 Feet

*All ratings comply with SAE J2512 and SAE J706 Recommended Practice

WARNING:

Do not exceed the working limit of the wire rope. Use snatch blocks and multiple lines to reduce the load on the wire rope.

1. Check the direction you wish the work to travel, being sure there are no major obstacles in the way.

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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.

4. Unfold the under lift boom.

5. If a heavy lift or pull is to be made additional lines may be necessary. Always use more stabilizing lines than pull lines. RIG FOR SAFETY. The use of scotch blocks is also recommended.

6. Unhook the wire rope cables from the top of the tow sling.

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7. Set both boom winches into “free spool” using the disengagement levers. Raise, lift, and pull out on the free-spool lever handle. Lower the free-spool lever handle capturing the lever stop bar on the outside of the bracket locking the winch in free-spool. Never pull

this handle while the wire rope is under load! Moving the

boom head with the wire rope locked can result in damage to both the wire ropes and the boom. Be sure both winches are free spooling. This allows the wire rope to be pulled directly off the drum to the work. 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.

8. Position the boom head by using the boom up and down control lever and the boom in and out lever .

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10. Re-engage the winches by placing the free-spool levers back to their original position. Confirm winch engagement by jogging the winch controls. Now slowly take up the slack in the wire rope. Inspect the hookup points for slippage before continuing the lift or pull.

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12.Once the work is in the desired position, apply the towed vehicles parking brake or use blocks or tie the work down if there is any question about stability. Slowly reduce the wire rope tension. After enough wire rope has been unwound, you may remove the hookup.

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Remember, most wire rope failures are caused by cable crushing or the operator underestimating the pull or over estimating the wire rope strength.

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TOW SLING OPERATION (OPTIONAL)

Sling Rating: (50 M.P.H. Transport S peed)

Single Line Boom................................... 4,000 lbs.

Dual Line Boom...................................... 4,000 lbs.

If your MPL40 is equipped with a towing sling, consult the AAA T owing Manual for hook up and follow these step s:

1. Position the truck within 9 ft. of the subject vehicle and as close to the direction of the tow as possible.

2. Unfold the underlift.

9 FT

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3. Remove the tow sling hold back bar retaining pins allowing the hold back bars to swing out of its retaining brackets on the sides of the boom.

4. Rotate the “CAM” handles on the hold back bars 180° to the open position.

5. Swing the hold back bars out toward the lower tow sling lugs on the back of the body. Allow the hold back bars to extend as necessary.

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6. Connect the hold back bars to the tow sling lugs using the pins that you removed earlier .

7. Rotate the “CAM” handles on the hold back bars 180° to the close position. Raise or lower the boom slightly until the cam locks on the tow sling hold bars snap into the closed position.

8. Extend the wrecker boom and adjust the wire rope cable(s) to lift the top of the tow sling and tow sling straps. Extend the boom to the yellow indicator mark on the inner boom section of the wrecker boom.

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9. Lower the boom to allow the tow sling head to raise out of it holder on the back side of the boom.

10. Carefully extend and lower the wrecker boom to allow the tow sling head to rotate outward and down away from boom.

11. Lower the tow sling to the ground.

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12. Rotate the “CAM” handles on the hold back bars 180° to the open position.

13. Maneuver the sling under the vehicle to be towed, far enough under so the vehicle will ride on the rubber belts.

14. Attach hook-up chains. The chain J hooks must be secured firmly around the axle or the frame of the towed vehicle. When fastening the J hook, be sure that it is attached to the towed vehicle in such a manner as to prevent any damage to the brake lines or other functional parts of the vehicle.

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15. With the chain securely fastened in the hook on each side of the bottom bar assembly, the chain should then be wrapped around the bottom bar. Secure the remaining chain to the hook at the top of the tow sling.

16. Using the tow sling with late model vehicles, it may be necessary to use spacer blocks or a cross beam in order to get sufficient height to prevent any damage to body parts. The AAA T owing Manual will diagram this.

17. Be sure the fuel tank is not in contact with the sling or towing mechanism. The fuel tank must

not support any weight whatsoever.

18. Raise the vehicle using the wrecker boom winches. (Read the safety and operating instructions for the boom and winches beforehand.) The vehicle should be raised until the wheels are a minimum of ten inches off the ground. Observe the opposite end of the vehicle for ground clearance.

19 . Be sure that both wire ropes are

retracted with equal tension.

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20. Rotate the “CAM” handles on the hold back bars 180° to the closed position.

21. Retract the boom slowly drawing the vehicle forward until the stand offs are fully retracted and the “CAM” handles retract to the closed position for traveling.

22 .Install safety chains and towing

lights.

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CAUTION:

The Bottom Anchor Assembly (round tube) must never be higher than the attachment point on the rear of the truck. The Stand Off Bar Assembly acts as a pivot in the event of a sudden stop. This will assure that the towed vehicle will not catapult forward onto the deck of the MPL40.

23. After the tow is complete, reverse the procedures to unload the vehicle.

24. With the vehicle unloaded and the tow sling extended, use the underlift fold function to bring the tow sling head back up into its storage position.

25. Rotate the “CAM” handles on the hold back bars 180° to the open position.

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26. Remove the pins from the hold back bars at the rear of the body .

27. Swing the hold back bars in toward the tow sling storage brackets on the side of the boom. Allow the hold back bars to retract as necessary .

28. Connect the hold back bars to the tow sling storage brackets using the pins that you removed earlier.

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29. Rotate the “CAM” handles on the hold back bars 180° to the closed position.

30.Retract the wrecker boom, snug up the wire rope(s) and fold up the underlift.

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MOTORCYCLE TOWING ADAPTER OPERATION (OPTIONAL)

If your MPL40 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”.

3. Close the grid arms like you would if you were loading a vehicle.

6 IN

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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.

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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.

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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. If the front tire is not clamped in the stops, back the motorcycle off and readjust the stops as necessary.

1 1. With the motorcycle stable in the

towing adapter , strap the front tire to the wheel lift boom. Place the hooks of the “middle” wheel straps over the end of the boom top plate and run the other ends of the straps thru the front tire. Insert the lose end of the wheel strap into the ratchet on the end other strap and tighten.

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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. Place the other hook onto the motorcycle and tighten. Repeat for the other side.

14. Raise the underlift boom to the desired towing height.

CAUTION:

Care should be taken when lifting the boom. Do not try to level the underlift. The straps may overtighten or become loose.

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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 body and tighten with the ratchet. Repeat for the other side.

17. Use the wheel lift safety chains to prevent the wheel grid from pivoting during travel. Loop the end of the safety chain around the grid and secure with the grab hook. Remove the slack in the chain and secure the chain in the keyslot of the chain box.

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18 . Attach towing lights.

19. Reverse the loading procedures to unload the motorcycle.

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DOLLY STORAGE OPERATION (OPTIONAL)

If your MPL40 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.

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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. Afterloading the dollies, place the pry bar/jack bar back into the storage bracket by inserting the end of the bar with the ring around it thru the cutout in the front bracket. Allow the other end of the bar to rest on the rear bracket.

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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.

10. Place the axle cross tube rails back into the storage bracket by inserting the tab on the end of the axle tube into the cutout in the storage bracket.

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1 1. 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.

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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.

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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.

1. Extend telescopic cross rails by first depressing spring-loaded plunger and sliding inner (male) tube until plunger locks into the hole that matches the width of vehicle to be towed.

2. Place cross rails on ground, fore and aft of vehicle’s tires.

3. Place dolly in the fully collapsed position with the dolly tires closest to each other .

4. Set rail ends into dolly pockets, adjusting for the size of vehicle’s tires, positioning rails as close as possible to tires.

5. Make sure safety locks are disengaged, allowing trip assemblies freedom of movement while lifting vehicle.

6. Engage ratchet assemblies to prevent injury and damage to the operator and vehicle in case pry bar slips from hand.

7. Insert pry bar into pry bar pocket.

8. Swing outer end of pry bar in an arc until trip assembly rises then locks spindle assembly in the down position. Do not release pry

bar until spindle assembly is locked down.

9. Repeat this action for all four (4) assemblies. Dolly is now raised.

10 . After dolly is in the raised position, engage safety locks over trip

assemblies to prevent releasing while vehicle is in tow .

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11. 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 A TTEMPTING A TOW.

T o unload the vehicle, stand clear of both the vehicle and the dollies and slip the chain link off of the cam bar. Carefully slide the jack handle over the cam bar and slowly lift the handle allowing the vehicle to drop. Repeat this step on the other dolly and then remove the axles from the dollies.

USE CARE WHEN RELEASING OR UNLOCKING THE CAM BAR AS IT CAN MOVE SUDDENL Y AND WITH FORCE, CAUSING INJURY. JERRDAN ASSUMES NO LIABILITY FOR THE USE OR MISUSE OF THESE DOLLIES OR ANY DAMAGE CAUSED BY THEM.

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THIS P AGE INTENTIONALL Y LEFT BLANK

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MAINTENANCE AND LUBRICATION

Y our MPL40 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 MPL40 and the following chart details the proper lubricant and the most common brands and specification which meet the requirements.

Use only safe practices when maintaining this equipment. Always shut off the engine before reaching into pinch areas.

Inspect the vehicle and underlift system periodically for damage or evidence of pending failure. Damaged or broken parts should be replaced immediately . Never operate a machine which is known to be defective or operating improperly. The cause of any binding or leakage should be determined immediately and the problem promptly fixed.

Y our MPL40 has Jerr-Dans “No-Lube” maintenance-free pivot joint system. Most of the pivot joints utilize high strength composite bearings with hardened and plated pins to drastically reduce maintenance, down-time and the cost of lubrication over the life of the product. There are however a few areas that still require some lubrication or maintenance. Sliding surfaces should be cleaned periodiacally. The following chart and diagram shows the location of these points, and when and what type of lubricant to use.

Check the hydraulic oil level bi-monthly or after any leakage. The proper oil level is best checked with all cylinders fully retracted. The hydraulic oil should just cover the bottom of the screen in the oil filler neck of the hydraulic tank. Use a Super Premium Grade Multi-Viscosity hydraulic oil. (See Chart) (Automatic transmission fluid may be used in the hydraulic system if necessary.)

The hydraulic filter located on the return side of the hydraulic tank comes equipped with a restriction indicator gauge. This gauge shows the operator the condition of the filter element. When the needle reaches the red band (25 psi), the filter is starting to bypass and the element needs to be changed. Failure to change the element will result in premature wear and/or failure of any or all of the hydraulic components. Check gauges when the hydraulic

MAINTENANCE

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fluid is at operating temperatures. Cold oil is more dense and will give a false indicator gauge reading.

If a cylinder seal leaks, disassemble the cylinder and ascertain the cause of the leak. Small scores caused by chips or contaminated 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. These seals are available in kits. Also, thoroughly clean all components before reassembly .

The body of your Jerr-Dan has been built from high strength aluminum which has been carefully assembled and polished in our factory . To keep it clean and free of dirt use any non-abrasive soap or detergent recommended for automotive finishes. Use a soft cloth or sponge and finish with a thorough rinsing. Drying with a soft cloth or chamois will prevent spotting or streaking. A coat of automotive wax is recommended.

The MPL40 is mounted to the truck chassis by bolts. These bolts are torqued at the factory to 70 ft. lbs. The MPL40 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. Your truck is equipped with winches and the winch mounting bolts should be regularly inspected and tightened if necessary. Replace any broken or damaged bolts immediately .

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· All torque values shown are for bolts (cap screws) and nuts that are either zincplated 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.

· When nuts are used, tighten nuts to torques shown (screws or bolts should be held but not turned).

· Retighten nuts of all mounting screws that secure the wrecker and wrecker-body within two weeks after they are first installed on the vehicle. Thereafter, inspect such screws and nuts visually once every month and after each job imposing extremely heavy loads on the equipment. Periodically recheck all accessible screws and nuts for proper tightness.

· Converting ft/lbs to Nm (Newton metres) can be accomplished by using the following:

Multiply: by: to get: ft/lbs x 1.3558 = Nm (Newton metres)

)SDNUOP-TOOF(SEUQROTGNINETHGIT

STUNDNASWERCSROF

EZIS

)MM(SEHCNI

2EDARG5EDARG8EDARG

)053.6(4/16801

)839.7(61/5014191

)525.9(8/3717233

)211.11(61/7825406

)007.21(2/1548609

)882

.41(61/936001021

)578.51(8/509531081

)050.91(4/3541032013

)522.22(8/7541083005

)004.52(102207506

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OILS AND GREASES

The following oils and greases are suitable for use with your Jerr-Dan.

Company Product

HYDRAULIC OILS

1. Chevron A W Hydraulic Oil MV

2. Exxon Univis N32

3. Mobil DTE13

4. Texaco Rando DHZ-32

5. Shell T ellus Oil T 32

6. Citgo A/W All T emp

7. Amoco Rycon Oil 32

8. Conoco AW Hydraulic Fluid MV 46

9. Mobil DTE11M

(for cold weather use)

10. Conoco A W Hydraulic Fluid MV 32

(for cold weather use)

GREASES

1. Drydene HD Lithium EP2

2. Gulf Crown EP2

3. Amoco Amolith EP2

4. Shell Alvania EP2

5. Texaco Marfax EP2

6. Mobil Mobilux EP2

7. Sunoco Prestige EP2

WINCH AND GEAR LUBE

1. Phillips 140 wt. EP Gear Lube 93301

(or approved equivalent)

2. Mobil Mobil SCH624

(or approved equivalent for cold weather use)

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WIRE ROPE HANDLING AND INSPECTION

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.

• NEVER USE wire rope that is WORN-OUT, DAMAGED or ABUSED.

• NEVER OVERLOAD a wire rope.

• INFORM YOURSELF: Read and understand manufacturer's literature or "Wire Rope and Sling Safety Bulletin".

• REFER TO APPLICABLE CODES, STANDARDS and REGULATIONS for INSPECTION REQUIREMENTS and REMOVAL CRITERIA.

WARNING

A new wire rope requires a break in period. Run the wire rope through several cycles at low speeds gradually increasing the load on the wire rope. Make sure that the wraps of the wire rope are tight and evenly wound on the winch drum. A loose wire rope on the winch drum will cause crushing of the wire rope when heavy loads are applied.

All wire rope in continuous service should be observed during normal operation and visually inspected on a weekly basis. A complete and thorough inspection of all ropes in use must be made at least once a month and all rope which has been idle for a period of a month or more should be given a thorough inspection before it is put back into service. All inspections should be the responsibility of and performed by an appointed competent person with the training and experience to look for deterioration of the wire rope.

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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.

There are certain points along any given rope which should be given more attention than others, since some areas will be subjected to greater stresses, forces, and hazards. Some of these areas include at the winch drum, at the boom sheaves and at 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 and approaching failure is broken wires. Inspection criteria are specific as to the number of broken wires allowable under various circumstances. It is important that a diligent search be made for broken wires, particularly in critical areas. Inspection of wire rope ends should include hooks and thimbles.

Any wire ropes that have been abraded, crushed, kinked or twisted should be replaced.

Wire rope should be routinely cleaned of any and all debris. Grit and gravel can quickly reduce a wire ropes life. A wire rope should be well lubricated so that it can act and perform as it was designed. Lubrication keeps a wire rope flexible and free from rust.

Consult the manufacturer or your local distributor for the proper replacement wire rope.

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KNEE BOOM REF

MOVE SENSOR UPWARD TO LOWER UNDERLIFT GRID; DOWNWARD TO RAISE UNDERLIFT GRID

NOTE: A GAP OF .125-.1875 MUST BE MAINTAINED BETWEEN THE SENSOR AND THE BASE BOOM SIDE PLATE. INTERMITTENT OPERATION WILL OCCUR IF THE GAP IS NOT MAINTAINED.

To change or adjust the factory set positions of the Underlift Level Stop Assist system, follow these steps:

MPL40

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 .

2. To change the boom stop, move the sensor on the boom lift cylinder up, to raise the boom, and down to lower the boom as shown below .

BOOM LIFT CYLINDER REF

MOVE SENSOR UPWARD TO

RAISE UNDERLIFT; DOWN-

WARD TO LOWER UNDERLIFT

NOTE: A GAP OF .125-.1875 MUST BE MAINTAINED BETWEEN THE SENSOR AND THE DOUBLER PLATE. INTERMITTENT OPERATION WILL OCCUR IF THE GAP IS NOT MAINTAINED.

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LUBRICATION POINTS

The following lubrication chart is located inside the tool box lid on the driver’s side of the MPL40 body .

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TROUBLE SHOOTING

Y ou probably won’t require anything but preventive maintenance to keep your MPL40 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 Solution

Slow operation a. Low engine RPM a. Speed up engine

b. Low oil level b. Check dipstick and fill with

the specified oil

c. Blocked or restricted c. Inspect: remove blockage

hoses

d. Dirty hydraulic oil d. Drain, flush and refill with

clean oil, replace filter

e. Hydraulic pump worn e. Rebuild or replace f. Clutch Pump belt slipping f. Tighten or Replace belt

Valve Solenoid(s) a. Broken centering spring a. Inspect, clean or replace sticking or frozen or clogged with foreign

material

b. Low Amperage/Voltage b. Check Amperage/Voltage

at Solenoid Valve leaks a. Defective seals a. Replace Cylinder leaks a. Defective seals or rods a. Inspect and replace

b. Dirty or Defective b. Clean or Replace

CounterBalance Valve CounterBalance Valve Erratic cylinder a. Air in the system a. Cycle hydraulic system 10

function to 15 times to remove air

b. Defective pump b. Replace if necessary

(pulsating) Remote hand a. Electric power turned off a. Turn on CONTROL power

controller fails to switch in cab respond b. Not plugged in b. Check plug connection

c. Faulty Remote Hand c. Use Manual Controls Controller at Rear of Body

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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

end

c. Clutch not engaging c. Check wiring/fuse

Pump will not build a. Relief valve improperly set a. Adjust relief valve to manuor hold pressure facturers specification

b. Relief valve stuck open b. Remove, clean and reset

Pump is noisy - a. Air in the system a. See “Oil Foaming” whines b.Cavitation b. Check Hoses, Reservoir

breather or strainer

Pump is noisy - a. Belts are worn/loose a. Inspect, adjust and/or squeals replace

b. System horsepower b. Review application

demand exceeds belt capacity

c. Clutch is slipping c. Check voltage/ground

Pump ‘throws” belts a. Engine and pump pulley a. Check installation

alignment

b. System horsepower b. Review application

demand exceeds belt capacity

c. High-speed engagement c. Reduce start-up RPM

Pump leaks at shaft a. Damaged seal a. Replace seal seal b. Damaged pump body b. Replace pump body

Pump leaks at body a. Damaged seal a. Replace seal section b. Damaged pump body b. Replace pump body

c. Body section bolt torque c. Torque to specification

Pump leaks a a. Loose fitting a. Inspect and/or tighten fittings b. Damaged fitting b. Replace fitting

c. Damaged pump body c. Replace pump body

Pump is overheating a. Low oil level a. Fill hydraulic reservoir

b. Dirty oil b. Replace oil and filter c. Relief valve stuck open c . Remove, clean and reset d. Relief valve improperly set d. Adjust relief valve to manu-

facturers specification

e. Improper weight oil e. Replace with correct oil

Oil foaming a. Low oil lever a. Fill hydraulic reservior

b. Improper oil b. Fill with correct oil

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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. Rattling noise in a. P.T.O. backlash too loose a. Shims must be removed

P.T .O . (Consult P.T .O. Manual) Howling Noise in a. P.T.O. backlash too tight a. Shims must be added

P.T .O . (Consult P.T .O. Manual) Gear oil leak between a. Defective shaft seal a. Remove and replace

P.T.O. and pump P.T.O. will not engage a. Cable and P.T.O. connec- a. Inspect and adjust

or disengage tion not adjusted properly

b. Defective shifter cover b. Inspect and replace

plate

HYDRAULIC 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 suction line d. Clean out and remove e. Pump worn e. Repair or replace

Pump/Clutch Pump a. Low oil supply a. Fill to proper level slow or fails to b. Worn or Loose Belt(s) b. Tighten or Replace Belt(s) respond

Oil heating up a. Foreign material lodged in a. Inspect and remove/

relief valve replace filter

b. Using too light oil b. Drain and refill with clean

oil c. Dirty oil c . Drain, flush and refill with

clean oil/replace filter d. Oil level too low d. Fill to proper level e. Pump worn (slippage) e. Repair or replace

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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. Refill to proper level

Hydraulic oil leak a. Defective shaft seal a. Replace shaft seal between P.T.O. and pump

Clutch Pump leaks at a. Defective Shaft Seals a. Replace seals or Pump Pulley Shaft b. Hydraulic Supply/Return b. Check hydraulic line

lines connected incorrectly connections

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 not a. Engage load or take in cable engaged

b. Sheared keys or broken b. Inspect or replace

coupling c. Hydraulic pump worn c. Inspect and replace d. Insufficient pump d. Check hydraulic pump

pressure and hydraulic fluid level e. Overload e. Install snatch block in the

rigging line

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Section IV: Glossary

Page 85

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.

Auxiliary Equipment - Equipment that is not necessary to perform the basic

function of the primary equipment.

Auxiliary T owing Lights - S top, tail, and turn signal light s att ached to the trailing

end of the towed vehicle and operated as part of the towing vehicle lighting system.

Bending 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 structure mounted on a chassis cab or that portion of the vehicle that

carries the load.

Body Hinge - The attachment mechanism connecting the body to the hinge pin

at the pivot axis about which the body rotates into the tilt position.

Body Subframe - Another term for body understructure or mounting frame. Body Weight - Unmounted weight of a body with applicable options. Boom - The structure member that supports the load. Boom Angle - The boom angle is measured between a horizontal line and a line

through the boom pivot and center of sheave.

Boom Head - The structural member at one end of the boom which can swivel

and support the load lifted through the sheave and sheave support device.

GLOSSARY OF TERMS

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Section IV: Glossary

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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.

Bumper - DOT - A bumper designed to provide rear-end protection that meets

the requirements of FMCSR 393.86.

Bus Bar Grid - A device used for towing vehicles by lifting one end of the towed

vehicle by the wheels.

CA (Cab to Axle) - The distance from the back of the truck cab to the center of the

rear axle.

CG (Center of Gravity) - The point at which the weight of the chassis, 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 between the tandem axles.

Cable - Steel wire rope used for pulling. Car Carrier - Vehicles equipped to transport other vehicles mounted on a flat

platform and/or with an additional assembly attached to the rear to facilitate towing a second vehicle. These units are also known as slidebacks, rollbacks, transporting equipment carriers and flatbeds. See Carrier.

Carrier - A platform body with a winch for loading. Casualty Vehicle - The damaged or disabled vehicle. Capacity - The load that a machine can lift at any given point. CAUTION - A signal word used when a potentially hazardous situation exists that

might result in minor injury or property damage.

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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;

capable of being driven by the addition of wheel or other items of running gear, but lacking a body or load-carrying structure.

Completed Vehicle - A vehicle that requires no further manufacturing operations

to perform its intended function, other than minor finishing operations such as painting.

Component - Any p art of an assembly on a machine when referred to individually . Control - 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-lift or underlift for attaching towing accessories.

Curb Side - The right or passenger side of the vehicle when viewed from the

rear, opposite side from ROADSIDE.

Curb Weight - The weight of a vehicle in operational status, with all standard

and commonly installed equipment and the fuel tank(s) filled to capacity.

Cylinder - A device which converts fluid power into a linear mechanical force and

motion usually consisting of a movable piston and piston rod within a cylinder bore.

DANGER - A signal word used when an imminently hazardous situation exists

that can result in death or serious injury.

Disabled Vehicle - Any vehicle that cannot operate under its own power. Dolly - A four-wheeled carriage used in towing to support the trailing end of the

towed vehicle.

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DOT (Department of T ransportation) - 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.

Filter- A device whose primary function is the retention by a porous media of

insoluble contaminants from a fluid.

Final Stage Manufacturer - A person, firm, or corporation who performs such

manufacturing operations on an incomplete vehicle that it becomes a completed (end-user) vehicle.

FMVSS (Federal Motor Vehicle Safety Standards) - Regulations promulgated

by NHTSA under Public 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 lower equipment is located. Frame Cutoff - Centerline of rear axle(s) to the rearmost point of the chassis

frame as modified for body installation.

Frame Lift - See Underlift. Frame Section Modulus - The engineering term that indicates the relative

strength of frames as it relates to shape. It takes into account frame depth, flange width, and material thickness. All other things being equal, the frame with the largest section modulus will have the greatest strength and stiffness, i.e., the ability to more effectively resist deflection under load.

Free Spool - The operation of unspooling wire rope from a drum by pulling on

the end of the wire rope while the winch is stationary. The drum is disconnected (declutched) from its powertrain during this operation.

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Section IV: Glossary

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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.

GAWR (Gross Axle Weight Rating) - The value specified by the manufacturer as

the load-carrying capacity of a single-axle system as measured at the tire-roadway interface.

GCWR (Gross Combination Weight Rating) - Represents the entire weight of a

vehicle on the ground with a trailer or trailers including vehicle, equipment, driver, fuel, and payload (everything that moves with the vehicle.) Gross combination weights published represent maximum allowed.

Grab Hook - For use with chains and some tow-sling hookups. Grid - A device that att aches to the lift bar for engaging the tires of a towed vehicle. GVWR (Gross V ehicle Weight Rating) - The maximum total vehicle rated capacity ,

measured at the tire ground interface, as rated by the chassis manufacturer .

GVW (Gross Vehicle Weight) - Value specified by the manufacturer as the

maximum loaded weight of a single vehicle including all equipment, fuel, body , payload, driver , etc.

Headboard - Structure on which an emergency light bar is mounted. Hook-up Chains - Length of chain used to connect a recovery vehicle to a casualty

vehicle.

Horizontal Center of Gravity (HCG) - The point at which half of the gross weight

is forward and half is aft.

Hydraulic Control V alve - A mechanical device to divert or control the flow of fluid

in a hydraulic system.

Hydraulic Hose - Flexible oil lines used to transmit fluid.

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Section IV: Glossary

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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.

Independent - The Wrecker Boom and Underlift Boom are separate

(independent) from each other.

Integrated - The Wrecker Boom and Underlift Boom are combined together as

a complete unit.

J-Hook - Attachment device used for towing/recovery.

L-Arm - See Wheel Arm Layer - All wraps of the same diameter on a drum. Lift Bar - A traverse horizontally pivoting member attached to the boom of a

wheel-lift or underlift for attaching towing accessories.

Lift Cylinder - Cylinders used to raise or lower boom structures. Lift Forks - See Forks. Lifting Capacity - The load that a machine can lift at any given point. Lift Tow Rating - Maximum Steering Towing Load. Light Bar (Emergency) - An array of lamps used in accordance with local

ordinances.

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Section IV: Glossary

Page 91

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 - S peed in feet per minute of a single rope, based on full load engine

speed with specified lagging diameter.

Marker Lights - Small amber and red lights attached to bodies to indicate

overall clearance at night.

Maximum Loaded Vehicle Weight - The sum of curb weight, passengers and

cargo.

Motor - A rotary motion device which changes hydraulic energy into mechanical

energy.

Motor V ehicle Safety St andards - See FMVSS. Mud Flap - Splash-Deflecting shields at rear of wheel.

NHTSA (National Highway T raffic Safety Administration) - The federal agency

responsible for promulgating and insuring compliance of regulations dealing with the manufacture and certification of motor vehicles or items of motor vehicle equipment. See DOT.

Outriggers - A beam type device attached to frame of a truck or rubber tired

carrier , to provide maximum stability by reducing load on tires and increasing width of operating base.

Overall Vehicle Height - Distance from the ground to the highest point on the

vehicle with equipment in stowed position.

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Section IV: Glossary

Page 92

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.

Payload - The weight of the commodity being hauled. Payload capacity is

computed by subtracting the completed weight of the vehicle (including driver and passengers) from the GVWR.

Pintle Hook - Hook mounted on a truck or semitrailer used 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 mounted and flywheel mounted power takeoffs are also used in various applications.

Push Bumper - Device used to push a vehicle, sometimes equipped with a

rubber face.

Rating - The specified design operating limit of a device. Rear Jack - One or more devices designed, when used, to stabilize chassis.

Recovery - Act of moving a vehicle to a position from which it can be driven or

towed.

Recovery V ehicle - Vehicle to retrieve and if necessary lif t and tow other vehicles. Resisting Bending Moment (RBM) - A calculation used to compare frames of

different section modulus and of different material. It is the product of the section modulus times the yield strength of the frame material.

Jerr-Dan MPL40 Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual