Jerr-Dan MPL40 Operation And Maintenance Manual
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Jerr-Dan MPL40 Operation And Maintenance Manual

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$35.00
MPL40
OPERATIONS AND MAINTENANCE
MANUAL
1080 Hykes Road
Greencastle, PA 17225
Phone (717) 597-7111
www.jerr-dan.com
© 2010 Jerr-Dan Corporation. All Rights Reserved.
5-376-000086
REV. 4 - 07/10

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  • Page 1 $35.00 MPL40 OPERATIONS AND MAINTENANCE MANUAL 1080 Hykes Road Greencastle, PA 17225 Phone (717) 597-7111 www.jerr-dan.com © 2010 Jerr-Dan Corporation. All Rights Reserved. 5-376-000086 REV. 4 - 07/10...
  • Page 2 5-376-000086 REV. 4 - 07/10...
  • Page 3 FOREWORD This manual is intended to serve as a guide to the owner and operator in the safe operation and optimum performance of this Jerr-Dan equipment. Establishment of good operating habits and familiarity with the equipment and its capabilities combined with good judgement are essential.
  • Page 4 Manufactured under one or more of the following patents: 5,575,606; 5,672,042; 5,697,741; 5,713,714; 5,722,810; 5,782,596; 5,839,755; and 6,315,515 B1 with other Patents Pending. Jerr-Dan and the Jerr-Dan logo are registered trademarks and Run Hard is a service mark of Jerr-Dan Corporation, Greencastle, PA. USA 5-376-000086...

  • Page 5: Limited Warranty

    Distributor shall make on behalf of Manufactuer by conspicuous notice in writing accompanying each contract or memorandum of sale: 1. Warranty. Jerr-Dan Corporation, ("Manufacturer") warrants each new product made by it to be free from defects in material or workmanship for one year from the date of initial sale, lease, rental, or other disposition of such product, and agrees only to repair or replace at its own expense, f.o.b.
  • Page 6 5. Exclusive and Entire Warranty. The warranty constitutes Manufacturer's entire warranty as to the product and it is expressly agreed that the remedies of dealer and those claiming under dealer as stated in this warranty are exclusive. Manufacturer does not assume (and has not authorized any other person to assume on its behalf) any other warranty or liability in connection with any product covered by this warranty.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Section I: Safety Safety (General) ............... 1 Ratings: MPL40 ............... 3 Safety Chains ................8 Lift Safety ................9 Boom Safety ................10 Sling Safety ................14 Safety Warning Decals ............16 Section II: Operation Wheel -Lift ................19 Tie-Down Straps ..............
  • Page 8 THIS PAGE INTENTIONALLY LEFT BLANK 5-376-000086 REV. 4 - 07/10 Page iv...
  • Page 9 SAFETY The safe operation of your MPL40 is your responsibility. Read this manual and the truck manufacturer’s manual and thoroughly understand them. You can be held legally responsible for injuries or damage resulting from unsafe operating practices. Our recommendations for operating your equipment can help you avoid unsafe practices and their bad consequences.
  • Page 10 operating any recovery equipment and that the Vehicle Manufacturers Towing Manual and/or American Automobile Association (AAA) Towing Manuals be used as a reference for operating safety methods. AAA address and phone number: THE AMERICAN AUTOMOBILE ASSOCIATION 1000 AAA Drive Heathrow, FL 32746-9970 (800)222-4357 To alert personnel to hazardous operating practices, safety messages are used throughout the manual.

  • Page 11: Ratings: Mpl40

    DO NOT EXCEED THE FOLLOWING RATINGS: MPL40 Underlift Rating ........4,000 lbs “L” Arm Tow 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.
  • Page 12 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...
  • Page 13 MFG BY:_______________________________________ ______________________________________________ DATE OF MFR:MO______________YR.______________ GVWR:_________________KG (_________________LB) GAWR-FRONT: ______________________KG (__________________LB) WITH____________________________________TIRES, ______________________RIMS,@______________KPA (___________________PSI) COLD__________________ GAWR-INTERMEDIATE(1): ______________________KG (__________________LB) WITH____________________________________TIRES, ______________________RIMS,@______________KPA (___________________PSI) COLD__________________ GAWR-INTERMEDIATE(2): ______________________KG (__________________LB) WITH____________________________________TIRES, ______________________RIMS,@______________KPA (___________________PSI) COLD__________________ GAWR-REAR: ______________________KG (__________________LB) WITH____________________________________TIRES, ______________________RIMS,@______________KPA (___________________PSI) COLD__________________ THIS VEHICLE HAS BEEN COMPLETED IN ACCORDANCE WITH THE PRIOR MANUFACTURERS' IVD, WHERE APPLICABLE.
  • Page 14 • Don’t use a recovery vehicle that has not been properly maintained. Pay special • Don’t operate the wrecker’s engine faster than • Don’t operate the wrecker’s engine faster than attention to the mounting bolts, and recommended. recommended. Excessive speeds can Excessive speeds can lubrication of moving parts.
  • Page 15 • Don’t tow a vehicle on its front wheels • Don’t tow a vehicle on its front wheels if unless the steering wheel is secured with they are damaged. the front wheels straight ahead. 5-376-000086 REV. 4 - 07/10 Section I: Safety Page 7...

  • Page 16: Safety Chains

    SAFETY CHAINS MUST BE USED WHEN TOWING AND TRANSPORTING Safety chains are provided for use with your new Jerr-Dan Recovery Vehicle. Periodically inspect all chains for any signs of fatigue or damage. Don’t overlook the hooks; be sure they have not been bent or deformed. If chain or hook damage is noted, they must be replaced before being used.

  • Page 17: Lift Safety

    In addition, the intent of the design of this unit should be taken before the undertaking of its use. 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.

  • Page 18: Boom Safety

    BOOM SAFETY Your MPL40 is equipped with a recovery winch and the following safety procedures must be observed: • Take up the wire rope slowly and be sure • Jog the winch control lever to be sure of the hook is securely set.
  • Page 19 • Never lift or pull over or around a sharp obstacle. • Never allow the wire rope to cross wrap (criss-cross) on the winch drum. Crushing of the wire rope can cause wire rope failure. • Never completely unwind wire rope from a •...
  • Page 20 • Be sure all brakes and locks are properly • Don’t permit bystanders in the area while set on the recovery vehicle. performing recovery work. • Never wrap the wire rope around frames or • Never under any circumstances use the cross members.
  • Page 21 • Avoid using the boom raise or boom up • All boom placement functions should be control to lift a load. This causes undue made with the winch wire ropes set in “free stress and weight loading on the rear axle. spool”...

  • Page 22: Sling Safety

    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: •...
  • Page 23 • 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.

  • Page 24: Safety Warning Decals

    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. WARNING...
  • Page 25 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.
  • Page 26 THIS PAGE INTENTIONALLY LEFT BLANK 5-376-000086 REV. 4 - 07/10 Section I: Safety Page 18...
  • Page 27 OPERATION 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.
  • Page 28 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.
  • Page 29 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.
  • Page 30 8. Extend the underlift under the vehicle being sure that all under carriage parts are cleared and that the front portion of the grid is in contact with both tires. Lower the grid fully to the ground. There is no reason for the operator to get under the vehicle.
  • Page 31 13. Lift the vehicle high enough to allow the tires to clear the ground. Make sure that the grid is not in contact with any engine or body components. 14. Remove the tie down straps from tool boxes and attach the tie down straps.
  • Page 32 17. Power retract the grid boom until the towed vehicle is about 3 to 4 feet from the back of the truck. Leave enough room to maneuver around corners without corner binding or causing contact between the two (2) vehicles. Be sure that the boom is extended least 4"...

  • Page 33: Tie-Down Straps

    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 INSTALLED.
  • Page 34 3. To release the ratchet, simply pull on the locking bar, disengaging the teeth and raise the handle to the “free spool” position. INSTALLING THE TIE DOWN STRAP 1. With the vehicle lifted just barely off the ground, insert the end of the strap through the sewn loop on the other end of the strap to form a loop.
  • Page 35 3. Place the hook of the ratchet into one of the holes on the front side of the grid. Again, try to use the hole that is closest to the tire. NOTE: The hole on the outside of the grid can be used to hook the ratchet in if you need to clear body mouldings or wide tires.

  • Page 36: Wheel Grid Spacers

    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...

  • Page 37: Towball Hitch Attachment

    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 RATINGS: 1-7/8 in. Ball: ........ 5,000 lbs. (GTW)* 2 in. Ball: ........5,000 lbs. (GTW)* 2-5/16 in.
  • Page 38 4. Install the desired towball to the towball hitch. 5. Position the ball coupler over the ball and lock into place. CAUTION: Make sure that the ball and coupler are of the same matched size. 6. Connect the trailer lights and attach safety chains.
  • Page 39 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.
  • Page 40 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...
  • Page 41 7. Disengage the winch “free-spool” by pulling out on the “T” handle and turning the handle 90°. The handle should remain in the “free- spool” position. 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.
  • Page 42 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...
  • Page 43 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.
  • Page 44 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.
  • Page 45 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.
  • Page 46 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...
  • Page 47 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.
  • Page 48 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.
  • Page 49 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.
  • Page 50 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.
  • Page 51 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...
  • Page 52 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.
  • Page 53 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...
  • Page 54 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.
  • Page 55 13. Now slowly retrieve the wire rope, carefully winding the wire rope onto the drum. Many operators take this opportunity to do a visual inspection. When you’ve finished rewinding the wire rope, be sure you don’t overwind it. Always wear safety glasses and gloves when doing recovery work or handling the wire rope.
  • Page 56 Single Line Boom ........4,000 lbs. Dual Line Boom ........4,000 lbs. 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.
  • Page 57 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.
  • Page 58 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.
  • Page 59 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.
  • Page 60 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.
  • Page 61 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.
  • Page 62 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.
  • Page 63 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.
  • Page 64 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.
  • Page 65 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. 5-376-000086 REV. 4 - 07/10 Section II: Operation Page 57...
  • Page 66 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”. 6 IN 3. Close the grid arms like you would if you were loading a vehicle.
  • Page 67 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 68 7. Adjust the upper and lower tire stops so that they will contact and restrain the front tire when loaded. 8. Align the motorcycle with wheel lift boom and ramp. 5-376-000086 REV. 4 - 07/10 Section II: Operation Page 60...
  • Page 69 9. Push the motorcycle up the ramp until the front wheel is resting in and against the tire stops in the front brackets. 10. Check front tire for fit with the upper and lower tire stops. When the motorcycle is rocked side to side the front tire should feel solid in the tire stops and centered in the trough.
  • Page 70 12. After securing the front tire, extend the wheel lift under the rear tire of the motorcycle raising the rear tire of the motorcycle onto the ramp. 13. Tie down the rear of the motorcycle. Place the hook on one end of the “rear” strap into the hole on the front side of the grid.
  • Page 71 15. Tie the front of the motorcycle to the rear of the wrecker body. Attach the lasso style straps to each of the handle bars. 16. Place the hook on one end of the “front” strap to the loop of the lasso strap on the handle bars and place the hook on the other end to the rear of the wrecker...
  • Page 72 18. Attach towing lights. 19. Reverse the loading procedures to unload the motorcycle. 5-376-000086 REV. 4 - 07/10 Section II: Operation Page 64...
  • Page 73 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.
  • Page 74 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...
  • Page 75 7. Close the dolly latch by pushing the top away from you. 8. Install the retaining bolts and wing nuts or pad locks. 9. After using the dollies, store them back on the deck in basically the reverse order. Remove the retaining bolts and wing nuts or pad locks and open the latch.
  • Page 76 11. The axle cross tube rails need to be stored with the wheel ramp plates turned in and up. 12. Allow the axle cross tube rails to hang from the bracket by the tab. 13. Place the dolly wheel assemblies back into the storage brackets.
  • Page 77 14. The tab on the storage bracket should be placed through the dolly pocket of the dolly wheel assembly. 15. Close the dolly retaining latch by pushing the top away from you. 16. Install the retaining bolts and wing nuts or pad locks. 5-376-000086 REV.
  • Page 78 DOLLY OPERATION (OPTIONAL) Specifications: Dolly Capacity: ..........2,360 lbs. Tire/Wheel: ..........4.80 x 4.00/8Tire Axle: ............ 2 1/2 Sq. Tube Max. Speed: ............ 50 M.P.H. The Quick Loading Dolly is simple to use once the principles of the unit are understood.
  • Page 79 Safety tie-down straps should be used to secure dolly to vehicle in case of rough road. Dolly is now ready for towing. BE SURE EACH WHEEL IS SECURELY HELD IN ITS DOLLY AND INSPECT THE GROUND CLEARANCE OF THE VEHICLE BEFORE ATTEMPTING A TOW.
  • Page 80 THIS PAGE INTENTIONALLY LEFT BLANK 5-376-000086 REV. 4 - 07/10 Section II: Operation Page 72...

  • Page 81: Maintenance And Lubrication

    MAINTENANCE MAINTENANCE AND LUBRICATION Your 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.
  • Page 82 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.
  • Page 83 · All torque values shown are for bolts (cap screws) and nuts that are either zinc- plated or lubricated. · Torques shown above apply to screws and nuts used for assembly and installation of all wrecker components. · Different torque values may be given in instructions for certain components due to short thread engagement or low-strength internal threads.

  • Page 84: Oils And Greases

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

  • Page 85: Wire Rope Handling And Inspection

    WIRE ROPE HANDLING AND INSPECTION WARNING Wire Rope WILL FAIL if worn-out, overloaded, misused, damaged, improperly maintained or abused. Wire rope failure may cause serious injury or death! Protect yourself and others: • ALWAYS INSPECT wire rope for WEAR, DAMAGE or ABUSE BEFORE USE.
  • Page 86 It is good practice , where the equipment is consistently in use, to give the rope a certain length of service, several hundred hours, several weeks or months and then renew the rope regardless of it's condition. This method eliminates the risk of fatigue causing rope failure. Any deterioration, resulting in a suspected loss of original rope strength, should be carefully examined and a determination made as to whether further use of the wire rope would constitute a safety hazard.

  • Page 87: Underlift Level Stop Assist System

    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.

  • Page 88: Lubrication Points

    LUBRICATION POINTS The following lubrication chart is located inside the tool box lid on the driver’s side of the MPL40 body. 5-376-000086 REV. 4 - 07/10 Section III: Maintenance Page 80...

  • Page 89: Trouble Shooting

    TROUBLE SHOOTING You 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.

  • Page 90: Hydraulic Clutch Pump

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

  • Page 91: P.t.o. Functioning Improperly

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

  • Page 92: Winch Functioning Improperly

    HYDRAULIC PUMP - con’t Problem Cause Solution Oil foaming a. Air leaking into suction line a. Tighten all connections b. Wrong kind of oil b. Drain and refill with non-foaming type of hydraulic oil (See lube chart) Replace filter c. Oil level too low c.
  • Page 93 GLOSSARY OF TERMS Anchoring Device - Used to attach cable ends, snatch blocks, safety chains, and tie-down assemblies to the towing vehicle. Approach Angle - Angle between the plane of the platform and the ground. Attachment - Any device that can be added to a basic unit or assembly. Auxiliary Braking Device - A device which attaches to the disabled vehicle to assist the tow truck's brakes in retarding or stopping both vehicles.
  • Page 94 Boom Length - The straight line distance from center of the revolving base to the center of the boom head. Brakes - Parking - A system used to hold a stopped machine in a stationary position. Brakes - Service - A primary brake system used for retarding and stopping the truck.
  • Page 95 Certification Label - Required by Public Law 89-563, which states that a motor vehicle or item of motor vehicle equipment complies with all applicable Federal Motor Vehicle Safety Standards (FMVSS) in effect on the date of manufacture. Chain Assemblies - Chain with all hardware and coupling devices. Chassis Cab - A vehicle consisting of a chassis upon which is mounted a cab;...
  • Page 96 DOT (Department of Transportation) - A federal agency dealing with regulations concerning both the manufacture and operation of motor vehicles and motor vehicle equipment. See NHTSA. Driveline - The driveshaft and associated joints. Drum - Any spool on which are wrapped ropes used in machine operation. Extend Cylinder - Cylinders used to extend or retract boom structures.
  • Page 97 Forks - A device attached to the lift bar for lifting a vehicle by the tires, axle, frame, or structural member. May be classified as chain, axle, or frame forks. FW (Frame Width) - The overall width of the chassis frame measured outside to outside behind the cab.
  • Page 98 Hydraulic Oil - Fluid used in operation of hydraulic systems. Hydraulic Relief Valve - A mechanical device used to limit the pressure in a hydraulic circuit. Incomplete Vehicle - As assemblage consisting, as a minimum, of a frame and chassis structure, powertrain, steering system, suspension system and braking system to the extent that those systems are to be part of the complete vehicle that requires further manufacturing operations.
  • Page 99 Light Pylon - Structure on which an emergency light bar is mounted. Line Pull - The maximum wire rope pull, in pounds, at the drum, at full-load engine speed, with specified lagging diameter. Line Speed - Speed in feet per minute of a single rope, based on full load engine speed with specified lagging diameter.
  • Page 100 Overall Vehicle Width - The design dimension ot the widest part of the vehicle, exclusive of signal lamps, outside rearview mirrors, flexible fender extensions, and mud flaps, determined with doors and windows closed and the wheel in the straight ahead position. Overhang - The horizontal distance for the centerline of a single rear axle or center point of a tandem rear axle to a point where the vertical component is imposed.
  • Page 101 Roadside - The left or driver's side of the vehicle when viewed from the rear, opposite side from Curbside. Rolling Resistance - The restraining forces contributed to the load when rolling on wheels. Rollback - See Car Carrier Rope - See Wire Rope Rub Rail - Member running longitudinally providing rub service on side of body.
  • Page 102 Spade - One or more ground penetrating devices designed primarily, when used, to stabilize rearward chassis movement. Stabilizers - A hydraulic or manually operated leg device (i.e., outboard legs, outriggers, or jack legs) attached to trucks to give additional support down to the ground for improved stability.
  • Page 103 Towing - See Tow. Tow Bar - A device for positioning a towed vehicle behind a towing vehicle. Tow Chain - Length of chain used to connect the sling with the towed vehicle. Tow Sling - A device used for lifting and towing vehicles with a partial load supported on rubber straps.
  • Page 104 Wheel Arm - A device that attaches to the lift bar for engaging the tires of a towed vehicle. Wheelbase - Horizontal dimension from centerline of front axle to the effective centerline of the rear axle(s). Wheel Chock - A device used to prevent chassis movement. Wheel Fork - See Wheel Arm.

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