Page 1 Operation And Safety Manual Original Instructions Keep this manual with machine at all times. MPL-40 LIGHT DUTY WRECKER SN 0230011584 to Present including 0230010532, 0230010924 - 0230010930, 0230011032, 0230011121 - 0230011129, 0230011301 - 0230011319, and 0230011491 - 0230011510 5376000277 October 23, 2023...
Page 2 WARNING Operating, servicing and maintaining this vehicle or equipment can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle or equipment in a well-ventilated...
Page 3 Revision Log REVISION LOG October 23, 2023 - A - Original Issue of Manual. 5376000277...
Page 4 Read This First This manual provides Operational and Safety information for the Light Duty MPL-40 Wrecker. Read this manual and the Operation and Safety Manual provided with other equipment thoroughly prior to starting operation. This manual is a very important tool! Keep it with the machine at all times.
Page 5 Read This First HAZARD CLASSFICATION SYSTEM SAFETY ALERT SYSTEM AND SAFETY SIGNAL WORDS This is the Safety Alert Symbol. It is used to alert to the potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
Page 6 Jerr-Dan sends safety related bulletins to the owner of record of this machine. Contact Jerr-Dan to ensure that the current owner of records are updated and accurate.
Page 7 However, NHTSA cannot become involved in individual problems between you, your dealer, or Jerr-Dan. To contact NHTSA, you may call the Vehicle Safety Hotline toll-free at 1-888- 327-4236 (TTY: 1-800-424-9153);...
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Page 9: Table Of Contents
Table of Contents TABLE OF CONTENTS Revision Log Read This First Operator Qualiﬁ cations Modiﬁ cations Hazard Classﬁ cation System Safety Alert System and Safety Signal Words Reporting Safety Defects Table of Contents Section 1 - General Safety Practices General Pre-Operation Operator Training and Knowledge Electrical Hazards...
Page 10 6-15 P.T.O. Functioning Improperly 6-16 Hydraulic Pump 6-16 Hydraulic Pump 6-17 Winch Functioning Improperly 6-17 Remote Hand Controller 6-18 Section 7 - Speciﬁ cations Product Speciﬁ cations MPL-40 Truck Chassis Capacities Inspection, Maintenance and Repair Log Transfer Of Ownership 5376000277...
Page 11: Section 1 - General Safety Practices
If there are any questions with regard to safety, training, inspection, maintenance, application, and operation, please contact Jerr-Dan. WARNING Failure to comply with the safety precautions listed in this manual could result in machine damage, property damage, personal injury or death.
Page 12: Pre-Operation
• Use the machine in a manner which is within the scope of its intended application set by Jerr-Dan. • All operating personnel must be familiar with the emergency operation of the machine as speciﬁ...
Page 13 Section 1 - General Safety Practices • Always check for power lines before raising the boom. • Look up and use light to search for power lines in the dark. • Allow for machine movement and electrical line swaying. • Do not step oﬀ...
Page 14: Crush And Collision Hazards
Section 1 - General Safety Practices CRUSH AND COLLISION HAZARDS • Keep clear of all spades. • Always use jack stands to support the boom and/or underlift before working underneath a lifted load. • Warn personnel not to work, stand, or walk under a raised boom or underlift. Position barricades if necessary.
Page 15: Winch Cable / Falling Load Hazards
Section 1 - General Safety Practices WINCH CABLE / FALLING LOAD HAZARDS • Keep people away during operation. • Never exceed capacity of rigging or cable. • Never stand on or straddle cable. • Always keep a minimum of ﬁ ve (5) wraps of cable on winch drum. •...
Page 16: Uncontrolled Towed Load Hazards
Section 1 - General Safety Practices • Keep hands away from cable and drum during operation. • Never operate recovery equipment with people under load. • Jog winch clutch before pulling. Keep winch clutch engaged while the cable is loaded. •...
Page 17: Tip-Over Hazards
Section 1 - General Safety Practices • When towing a vehicle from the front or rear, ensure vehicle steering wheel is properly locked. • Tow casualty vehicle on undamaged wheels/tires only. • Retighten the tie-down straps during a tow as the tires settle into the grid from towing.
Page 18: Chemical Hazards
DO NOT operate machine in an enclosed area without proper ventilation. • DO NOT operate the machine in hazardous environments unless approved for that purpose by Jerr-Dan and site owner. Sparks from the electrical system and the engine exhaust can cause an explosion. Flammable Fuel •...
Page 19: Battery Hazards
Section 1 - General Safety Practices BATTERY HAZARDS • Battery ﬂ uid is highly corrosive. Avoid contact with skin and clothing at all times. • Keep sparks, ﬂ ames, and lighted materials away from batteries. • Charge batteries only in a well ventilated area. •...
Page 20: Weather Conditions
Section 1 - General Safety Practices WEATHER CONDITIONS • Be aware of the wind conditions. Wind may cause load to swing or shifting of load. • If using in freezing conditions, you must be alert to possibility of ice forming on the device.
Page 21 Section 1 - General Safety Practices • Do not use machine as a ground when performing any welding operations. • Never tie-down the front of the recovery vehicle. This procedure may place excessive load on the chassis frame or other structural components leading to damage and costly repairs.
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Page 23: Section 2 - Pre-Operation And Inspection
See Section 3 - Controls and Indicators for more speciﬁ c operating instructions. WARNING If your MPL-40 does not operate properly, immediately bring machine to a stop, lower boom to ground and stop the engine. Determine cause and correct before continued use.
Page 24: Decals
CAPACITY MAY BE LIMITED BY THE CAPACITY OF THE CHASSIS AND EQUIPMENT SELECTED. MANUFACTURED BY: JLG INDUSTRIES, INC. FOR: 13224 Fountainhead Plaza Hagerstown, MD 21742 Phone (717) 597-7111 www.jerr-dan.com 1001132509-A 1001132509 CLOSE TILT CYLINDER LOCK-OUT VALVE BEFORE USING GRID RECOVERY SHEAVE. 7330000725 PROUDLY...
Page 25 Section 2 : Pre-operation and Inspection 7330000424 CAUTION TOW HITCH BRACKET MUST BE REMOVED BEFORE UNFOLDING THE BOOM DOWN FOR WHEEL GRID OPERATION CAUTION TOW HITCH BRACKET MUST BE REMOVED BEFORE UNFOLDING THE BOOM DOWN FOR WHEEL GRID OPERATION 7330000036 BOTH SIDES 7330000599 7330000036...
Page 26: Walk-Around Inspection
Section 2 : Pre-operation and Inspection WALK-AROUND INSPECTION NOTE: Complete all required maintenance before operating the unit. Begin your walk-around inspection at item 1, as noted below checking each item in sequence. INSPECTION NOTE: On all components, make sure there are no loose or missing parts, that they are securely fastened and no visible leaks or excessive wear exists in addition to any other criteria mentioned.
Page 27 Section 2 : Pre-operation and Inspection 1. Remote Controller (If equipped) Secure Undamaged and operational 2. Hydraulic Tank Hydraulic ﬂ uid level full Components undamaged Hydraulic hoses undamaged, not leaking 3. Toolbox/Storage Compartment Components undamaged Toolbox/Storage Compartment secure 4. Subframe Secure Components undamaged 5.
Page 28 Section 2 : Pre-operation and Inspection 8. Knee Boom/Underlift Knee Boom Pivot pin secure Cylinder pins secure Hydraulic hoses undamaged, not leaking Underlift pivot pin, secure Underlift tilt pivot pin, secure Check wear pads for presence of grease 9. Wheellift/Crossbar Crossbar pivot pin, secure Crossbar pivot pin, presence of grease Cylinder pins secure (If Equipped)
Page 29 Section 2 : Pre-operation and Inspection 13. Tow Sling (If equipped) (Not Shown) Components undamaged and operational Secure 14. Dollies (If equipped) (Not Shown) Components undamaged and operational Secure 5376000277...
Page 30: Operational Checks
Section 2 : Pre-operation and Inspection OPERATIONAL CHECKS OPERATIONAL CHECK When engine warms, perform an operational check: 1. Parking brake operation. 2. Horn and back-up alarm. Must be audible from inside operators cab with engine running. 3. Electric controlled hydraulic functions (if equipped) - all functions operate smoothly and the controls return to the “Neutral Oﬀ...
Page 31: Section 3 - Controls & Indicators
Your MPL-40 is supplied with various control options. Controls are provided at the rear of the unit along with various optional remote controllers. The wired remote controller or the wireless remote controllers should be found inside the cab of the vehicle.
Page 32: In-Body Controls
Section 3 - Controls & Indicators IN-BODY CONTROLS - LEFT HAND 1. Left Hand Winch - In/Out : Controls the wire rope winding/ unwinding function of the LH winch. 2. Right Hand Winch - In/Out : Controls the wire rope winding/ unwinding function of the RH winch 3.
Page 33 Section 3 - Controls & Indicators IN-BODY CONTROLS - RIGHT HAND 1. Left Hand Winch - In/Out : Controls the wire rope winding/ unwinding function of the LH winch. 2. Right Hand Winch - In/Out : Controls the wire rope winding/ unwinding function of the RH winch 3.
Page 34: Function Wired Hand Controller (If Equipped)
Section 3 - Controls & Indicators 10 FUNCTION WIRED HAND CONTROLLER (IF EQUIPPED) 1. Power/Function Indicator : “Red” - Power On/”Green” - Function Operated 2. Underlift Boom - Raise/Lower : Controls the underlift boom raise/ lower functions. Hydraulic Grid - Open/Close : Controls the hydraulic grid open/close functions.
Page 35: Function Wireless Hand Controller (If Equipped)
Section 3 - Controls & Indicators 8 FUNCTION WIRELESS HAND CONTROLLER (IF EQUIPPED) LED1 LED2 LED3 LED4 LED5 TILT LIFT CLOSE OPEN ca7055 A-1 1. Underlift Boom Tilt – Down : Controls the tilt down function of the underlift boom. 2.
Page 36 Section 3 - Controls & Indicators 14 FUNCTION WIRELESS HAND CONTROLLER (IF EQUIPPED) ON/OFF LED3 Charge indication LED2 LED4 Radio Link active (flashing) - LED1 LED5 - Low battery indication TILT LIFT BOOM EXT LH WINCH RH WINCH CLOSE OPEN ca7056 A-2 1.
Page 37 Section 3 - Controls & Indicators 13. Underlift Boom Tilt – Up : Controls the tilt up functions of the underlift boom 14. Underlift Boom Tilt – Down : Controls the tilt down functions of the underlift boom NOTE: Audible alarm will sound when transmiter is removed from the trans- mitter holder with the ignition switch turned“ON”.
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Page 39: Section 4 - Operation
Section 4: Operation SECTION 4 - OPERATION The standard operating controls for your MPL-40 are conveniently located at the rear corners of the truck body. There are also a variety of optional wired and wireless handheld remote controllers that controls the MPL-40 functions.
Page 40: Underlift Operation - Hydraulic Grids
Section 4 : Operation UNDERLIFT OPERATION - HYDRAULIC GRIDS 1. Turn on the safety and work lights. (Switches can be located the dash panel, in the headliner or in the ﬂ oor mount.) 2. Position the truck within 9 ft. of the subject vehicle and as close to the direction of the pull as possible.
Page 41 6. Conﬁ rm the truck’s position in relation to the vehicle to be towed. Nine (9) feet is recommended. Reposition the MPL-40 if necessary. Be sure the towed vehicle is not in gear or park. Keep the brake set. 7. Using the hand controller or...
Page 42 Section 4 : Operation 8. Next, lower the underlift using the underlift down function on the hand controller. underlift level stop assist system will stop the underlift travel at a preset position about 1-1/2” to 2” from the ground. override either stop position,...
Page 43 Section 4: Operation 11. 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. 12. 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...
Page 44 Section 4 : Operation 17. Raise the vehicle into the ﬁ nal towing position observing the far end for suﬃ cient ground clearance. It is possible to set the rear of a front lifted vehicle completely onto the ground, causing damage. Take irregular roadsurfaces into...
Page 45: Tie-Down Straps - Hydraulic Grids
Section 4: Operation TIE-DOWN STRAPS - HYDRAULIC GRIDS The MPL-40 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 grid. NEVER TOW A VEHICLE WITHOUT THE TIE-DOWN STRAPS INSTALLED.
Page 46 Section 4 : Operation INSTALLING THE TIE-DOWN STRAPS 1. With the vehicle lifted just barely oﬀ the ground, insert the end of the strap through the sewn loop on the other end of the strap to form a loop. Put the loop over the tire as shown with the strap resting on the tire at the ten o’clock and two o’clock...
Page 47 Section 4: Operation 5. Raise the wheel grid to the towing position. Re-tighten ratchet periodically as the tire settles in the grid from towing. Never tow a vehicle without tire tie-down straps and safety chains installed. 5376000277...
Page 48 Section 4 : Operation WHEEL GRID SPACERS The MPL-40 with the hydraulic 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.
Page 49: Underlift Operation - Manual Grids
Section 4: Operation UNDERLIFT OPERATION - MANUAL GRIDS 1. Turn on the safety and work lights. (Switches can be located the dash panel, in the headliner or in the ﬂ oor mount.) 2. Position the truck within 9 ft. of the subject vehicle and as close to the direction of the pull as possible.
Page 50 6. Conﬁ rm the truck’s position in relation to the vehicle to be towed. Nine (9) feet is recommended. Reposition the MPL-40 if necessary. Be sure the towed vehicle is not in gear or park. Keep the brake set. 7. Using the hand controller or...
Page 51 Section 4: Operation 8. Next, lower the underlift using the underlift down function on the hand controller and swing the cross bar parallel to the tires. The underlift level stop assist system will stop the underlift travel at a preset position about 1-1/2”...
Page 52 Section 4 : Operation 11. Extend the underlift under the vehicle being sure that all under carriage parts are cleared and that the front portion of the grid is in contact with both tires. Lower the grid fully to the ground.
Page 53 Section 4: Operation If vehicle to be towed is on a slope, do not release the brake until the tie-down straps are installed. Observe the wheels in the grid for any slippage. 15. It is recommended that the steering wheel be secured by a steering wheel strap for any tow.
Page 54 Section 4 : Operation For the best towing and maneuverability the underlift boom should be as close to horizontal as possible. 20. Power retract the grid boom until the towed vehicle is about 3 to 4 feet from the back of the truck.
Page 55: Tie-Down Straps - Manual Grid
Section 4: Operation TIE-DOWN STRAPS - MANUAL GRID The MPL-40 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 grid. WARNING Never tow a vehicle without the tie-down straps installed.
Page 56 Section 4 : Operation INSTALLING THE TIE-DOWN STRAPS 1. With the vehicle lifted just barely oﬀ the ground, attach the strap to the L-Arm. Be sure the hook on the ratchet is securely seated in the L-Arm. 2. Set the ratchet spool in “free spool”...
Page 57: Towball Hitch Attachment
Section 4: Operation TOWBALL HITCH ATTACHMENT The MPL-40 is supplied with a Towball Hitch attachment that will allow you to recover and tow trailers requiring a tow ball hookup. 1. Remove towball hitch attachment from the toolbox. 2. Use the bottom set of holes,...
Page 58 Section 4 : Operation 6. Connect the trailer lights and attach safety chains. 4-20 5376000277...
Page 59: Motorcycle Towing Adapter Operation (Optional)
Section 4: Operation MOTORCYCLE TOWING ADAPTER OPERATION (OPTIONAL) The MPL-40 can be supplied with an optional motorcycle towing adapter that will allow you to recover and tow motorcycles. 1. Lower the boom ﬂ at to the ground. 2. Extend the wheel grid at least 6”.
Page 60 Section 4 : Operation 4. Hook the loading ramp onto the wheel grid and engage the rear hooks on the back side of the grid. 5. Completely retract the wheel grid for loading. 6. Attach the lower trough and vertical stop into the mounting bracket at the front of the boom with the pin and retaining pin.
Page 61 Section 4: Operation 7. Adjust the upper and lower tire stops so that they will contact and restrain the front tire when loaded. 8. Align motorcycle with underlift boom and ramp. 9. Push the motorcycle up the ramp until the front wheel is resting in and against the tire stops in the front brackets.
Page 62 Section 4 : Operation 10. Check front tire for ﬁ t 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...
Page 63 Section 4: Operation 14. Raise the underlift boom to the desired towing height. Care should be taken when lifting the boom. Do not try to level the underlift. straps may overtighten or become loose. 15. Tie the front of the motorcycle to the rear of the wrecker body.
Page 64 Section 4 : Operation 18. Attach towing lights. 4-26 5376000277...
Page 65: Gooseneck Towball Towing Adapter Operation (Optional)
Section 4: Operation GOOSENECK TOWBALL TOWING ADAPTER OPERATION (OPTIONAL) The MPL-40 can be supplied with an optional gooseneck towing adapter that will allow you to recover and tow gooseneck trailers requiring a towball hookup. 1. Remove the gooseneck towball adapter attachment from the toolbox.
Page 66: Gooseneck Fifth Wheel Towing Adapter Operation (Optional)
Section 4 : Operation GOOSENECK FIFTH WHEEL TOWING ADAPTER OPERATION (OPTIONAL) The MPL-40 can be supplied with an optional gooseneck towing adapter that will allow you to recover and tow gooseneck trailers requiring a ﬁ fth wheel hookup. 1. Remove the gooseneck ﬁ fth wheel adapter attachment from the toolbox.
Page 67: Wrecker Boom Operation - Dual Line Boom
Section 4: Operation WRECKER BOOM OPERATION - DUAL LINE BOOM The MPL-40 wrecker boom is an extremely eﬀ ective tool in recovery or retrieval prior to lifting and towing. To operate the winch eﬀ ectively, care and thought must be given.
Page 68 Section 4 : Operation 5. Unhook the wire rope cables from the top of the tow sling. 6. 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...
Page 69 Section 4: Operation 7. Position the boom head by using the boom up and down control lever and the boom in and out lever Always wear gloves when handling wire rope/cable. 8. Attach the wire rope hook to a chain sling, or bridle and hook securely to the work.
Page 70 Section 4 : Operation 10. With the wire rope tight, slowly wind it in, observing both the work and the drum. Inspect the hook-up points for slippage before continuing the lift or pull. Be sure the wire rope strands do not cross wrap or criss-cross on the drum.
Page 71: Grid Mounted Recovery Sheave Operation (Optional)
GRID MOUNTED RECOVERY SHEAVE OPERATION (OPTIONAL) The MPL-40 can be supplied with an optional Grid Mounted Recovery Sheave that is an extremely eﬀ ective tool in recovery or retrieval prior to lifting and towing. To operate eﬀ ectively, care and thought must be given.
Page 72 Section 4 : Operation 5. Install the grid recovery sheave onto the back side of the grid crossbar and secure with the pins (1) and hair pins (2). 6. Remove the wire rope retaining pin from the grid recovery sheave. 7.
Page 73 Section 4: Operation 10. OPEN the underlift lockout valve located on the tilt/fold cylinder on the back side of the knee boom. 11. Raise and fold your underlift into the travel position. 5376000277 4-35...
Page 74: Tow Sling Operation (Optional)
Section 4 : Operation 4.11 TOW SLING OPERATION (OPTIONAL) If your MPL40 is equipped with a towing sling, consult the AAA Towing Manual for hook up and follow these steps: 1. Position the truck within 9 ft. of the subject vehicle and as close to the direction of the tow as possible.
Page 75 Section 4: Operation 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.
Page 76 Section 4 : Operation 8. Extend the wrecker boom and adjust the wire rope cable(s) to lift the top of the tow sling and tow sling straps. 9. Lower the boom to allow the tow sling head to raise out of it holder on the back side of the boom.
Page 77 Section 4: Operation 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.
Page 78 Section 4 : Operation 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 suﬃ cient height to prevent any damage to body parts. The AAA Towing Manual will diagram this.
Page 79 Section 4: Operation 22. Install safety chains and towing lights 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.
Page 80 Section 4 : Operation 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.
Page 81: Spade Foot Attachment (Optional)
Section 4: Operation 4.12 SPADE FOOT ATTACHMENT (OPTIONAL) The MPL-40 can be supplied with an optional spade foot attachment that will allow you stabilize the MPL-40 against movement and make heavier pulls with your wrecker boom. 1. Remove spade foot attachment from the toolbox.
Page 82 Section 4 : Operation CAUTION Do not use spades on pavement or concrete. Damage to the pavement or concrete may result. When the spade is on the ground the eye plate on the back side of the spade can be used for the attachment of snatch blocks or to terminate the wire rope hook during winching operations.
Page 83: Section 5 - Emergency Procedures
Section 5 : Emergency Procedures SECTION 5 - EMERGENCY PROCEDURES LOWERING OF THE WRECKER BOOM In the event of total loss of engine power or hydraulic pump failure with an elevated boom, Contact a local Authorized Distributor for speciﬁ c instructions. Secure the vehicle using the following procedures: 1.
Page 84: Raising/Lowering/Retracting/Folding/Tilting The Underlift Boom
Section 5 : Emergency Procedures RAISING/LOWERING/RETRACTING/FOLDING/TILTING THE UNDERLIFT BOOM In the event of total loss of engine power or hydraulic pump failure with an elevated boom, Contact a local Authorized Distributor for speciﬁ c instructions. Secure the vehicle using the following procedures: 1.
Page 85 Section 6 - Maintenance SECTION 6 - MAINTENANCE INTRODUCTION Service the product in accordance with the maintenance schedule on the following pages. Wear all the protective clothing and personal safety devices issued to you or called for by job conditions. DO NOT wear loose clothing or jewelry that can get caught on controls or moving parts.
Page 86: Maintenance And Lubrication
Section 6 - Maintenance MAINTENANCE AND LUBRICATION The truck chassis itself is on a maintenance schedule recommended by the manufacturer. Follow these guidelines and protect your vehicle warranty. There are a number of diﬀ erent lubricants used on your vehicle. The following Lubricant Chart shows the proper lubricant and the most common brands and speciﬁ...
Page 87: Oils And Greases
Section 6 - Maintenance OILS AND GREASES The following oils and greases are suitable for use with the Jerr-Dan Vehicle. Company Product HYDRAULIC OILS 1. Shell Spirax S4 TXM 2. Shell Tellus S2 VX 32 3. Chevron Clarity AW 46 4.
Page 88 Section 6 - Maintenance Company Product WINCH 1. Mobil SAE 75W-90 Synthetic Gear Lube (or approved equivalent) WIRE ROPE 1. CRC Chain and Wire Rope Lubricant (or other approved deep penetrating equivalent) 2. Jet-Lube WLD - Chain and Wire Rope Lubricant (or other approved deep penetrating equivalent) 3.
Page 89: Wire Rope Handling And Inspection
Section 6 - Maintenance 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: • NEVER USE wire rope that is WORN-OUT, DAMAGED or ABUSED. •...
Page 90 Section 6 - Maintenance Replace any wire ropes that have been abraded, crushed, kinked or twisted. Wire rope should be routinely cleaned monthly of any and all debris. Grit and gravel can quickly reduce a wire ropes life. A wire rope should be well lubricated so that it can act and perform as it was designed.
Page 91: Wire Rope Installation
Section 6 - Maintenance WIRE ROPE INSTALLATION Proper Unreeling Procedures Wire rope can be permanently damaged by improper unreeling or uncoiling practices. The majority of wire rope performance problems start here. Improper unreeling practices lead to premature rope replacement, hoisting problems and rope failure. Place the payout reel as far away from the boom tip as is practical, moving away from the chassis.
Page 92 Section 6 - Maintenance Drum Winding When wire rope is wound onto a sheave or drum, it should bend in the manner in which it was originally wound. This will avoid causing a reverse bend in the rope. Always wind wire rope from the top of the one reel onto the top of the other. Also acceptable, but less so, is re-reeling from the bottom of one reel to the bottom of another.
Page 93 Section 6 - Maintenance Keep Wraps Tight The end of the rope must be securely and evenly attached to the drum anchorage point by the method recommended by the equipment manufacturer. At least ﬁ ve wraps of wire rope must remain on the drum as dead wraps when the rope is unwound during normal operations.
Page 94: Underlift Level Stop
Section 6 - Maintenance UNDERLIFT LEVEL STOP To change or adjust the factory set positions of the Underlift Level Stop Assist Sys- tem, follow theses stops: 1. To change the tilt stop, move the sensor on the underlift boom base up, to lower the boom, and down to raise the boom as shown below.
Page 95: Lubrication Charts
Section 6 - Maintenance LUBRICATION CHARTS One of the following lubrication charts is located inside the door of the tool compart- ment on the driver’s side of the body. Standard “NO LUBE” Greaseless Subframe System: 5376000277 6-11...
Page 96 Section 6 - Maintenance Optional “Lubricated” Greased Subframe System: 6-12 5376000277...
Page 97: Lubrication Points
Section 6 - Maintenance LUBRICATION POINTS Note: The following numbers correspond to those shown on the lubrication charts on Pages 6-11 and 6-12. C. Hydraulic Reservoir Oil Level Lube Point(s) – Fill Cap Interval – Check level every 100 hours or bi-monthly Change every 1000 hours F.
Page 98 Section 6 - Maintenance E. Winch Gear Case Lube Point(s) – Fill Plug Lube – Reference winch manufacturer’s manual. Interval – Check level every 100 hours or bi-monthly Change every 1000 hours 6-14 5376000277...
Page 99: Trouble Shooting
Section 6 - Maintenance TROUBLE SHOOTING You probably won’t require anything but preventive maintenance to keep your Jerr- Dan running, however, the following chart should help you isolate and correct minor problems if they occur with use. Any service work on the hydraulic system should be performed by qualiﬁ...
Page 100: P.t.o. Functioning Improperly
Section 6 - Maintenance P.T.O. FUNCTIONING IMPROPERLY Problem Cause Solution Intermittent operation a. Poor Electrical connection a. Check electrical connections Rattling noise in P.T.O. a. P.T.O. backlash too loose a. Shims must be removed (Consult P.T.O. Manual) Howling noise in a.
Page 101: Winch Functioning Improperly
Section 6 - Maintenance HYDRAULIC PUMP Problem Cause Solution Oil foaming a. Air leaking into suction line a. Tighten all connections b. Wrong kind of oil b. Drain and reﬁ ll with non-foaming type of hydraulic oil (See lube chart) Replace ﬁ...
Page 102: Remote Hand Controller
Section 6 - Maintenance REMOTE HAND CONTROLLER Problem Cause Solution Transmitter not a. Electric power turned oﬀ a. Turn on CONTROL power working. switch in cab or control station b. Discharged Battery b. Replace Battery c. Plug In Connection c. Check connection d.
Page 103: Section 7 - Specifications
Section 7 : Speciﬁ cations SECTION 7 - SPECIFICATIONS PRODUCT SPECIFICATIONS MPL-40 OPERATING SPECIFICATIONS AND PERFORMANCE DATA DO NOT EXCEED THE FOLLOWING RATINGS: BOOM RATING: (SAE J2512 Rating) Extended (Boom elevated at 30° Angle .........6,000 lbs. Retracted ..................16,000 lbs.
Page 104 Section 7 : Speciﬁ cations MAXIMUM LIFTING CAPACITY - THE MAXIMUM LOAD THAT CAN BE LIFTED. GROSS COMBINED WEIGHT RATING (GCWR) - THE VALUE SPECIFIED BY THE VEHICLE MANUFACTURER AS GCW. GROSS TRAILER WEIGHT (GTW) - THE MAXIMUM TRAILER WEIGHT WITH LOAD.
Page 105: Truck Chassis
Section 7 : Speciﬁ cations TRUCK CHASSIS OPERATING SPECIFICATIONS AND PERFORMANCE DATA Refer to Final Stage Vehicle Manufacturer Label aﬃ xed to the Driver’s Side Door Jam, Hinge Pillar or Latch Post of the cab chassis and the chassis manufacturer’s manual.
Page 106: Capacities
Section 7 : Speciﬁ cations CAPACITIES Hydraulic System Operating Pressure ................3000 psi max. System Flow (PTO System) ............8 gpm @ 1000 RPM System Flow (Clutch Pump System) .........7 gpm @ 1000 RPM System Capacity .................... 15 gal Reservoir Capacity ....................9 gal Type of Oil (PTO System) Ambient Temperature Above 20°...
Page 107: Inspection, Maintenance And Repair Log
Inspection, Maintenance and Repair Log Serial Number Date Comments...
Page 108 Inspection, Maintenance and Repair Log Date Comments...
Page 109: Transfer Of Ownership
Please use this form to provide Jerr-Dan with updated information with regard to the current ownership of Jerr-Dan products. Please return com- pleted form to the Jerr-Dan Product Safety & Reliability Department via fac- simile or mail to address as speciﬁ...
Page 110 THIS PAGE IS INTENTIONALLY LEFT BLANK...
Page 112 13224 Fountainhead Plaza Hagerstown, MD 21742 Phone (717) 597-7111 Phone (800) 926-9666 www.jerrdan.com...

Jerr-Dan MPL-40 Operation And Safety Manual

Table of Contents

Section 1 - General Safety Practices

Section 2 - Pre-Operation and Inspection

Section 3 - Controls & Indicators

Section 4 - Operation

Section 5 - Emergency Procedures

Raising/Lowering/Retracting/Folding/Tilting the Underlift Boom

Section 6 - Maintenance

Section 7 - Specifications

Inspection, Maintenance and Repair Log

Transfer of Ownership

Quick Links

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Summary of Contents for Jerr-Dan MPL-40

Table of Contents