manual operación jerrdan hdr 7085

5-376-000094REV. 3 - 03/10

© 2010 Jerr-Dan Corporation. All Rights Reserved.

HDR 70/85WRECKER

OPERATIONS AND MAINTENANCEMANUAL

$35.00

1080 Hykes RoadGreencastle, PA 17225Phone (717) 597-7111

www.jerr-dan.com

5-376-000094REV. 3 - 03/10

© 2010 Jerr-Dan Corporation. All Rights Reserved.

FOREWORDThis manual serves as a guide for the owner and operator in the safe operationand optimum performance of your Jerr-Dan equipment.

For your safety, and the safety of others, you must• know the proper use of the equipment• use the equipment within its capability• develope consistent habits of proper use• use good judgement

Before attempting to operate the unit, carefully read all sections of thismanual.

Keep this manual with your equipment at all times. Refer to it if in doubt ofproper operation.

Information contained in this manual reflects how your Jerr-Dan equipmentwas built at the factory. Modifications or additions by the distributor orowner are not reflected in this manual.

This manual does not include operation and maintenance information forthe commercial chassis (International, Ford, GM, etc.). That information isprovided by the chassis manufacturer.

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

001001

VEHICLEIDENT. 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, com-plete and useful. All information contained in this manual is as accurate asknown at the time of publication and is subject to change, without notice, asa result of continuous product improvements. Jerr-Dan reserves the right toamend the information in this document at any time without prior notice.

Should you find inadequacies in the text, please send your comments to thefollowing address:

Jerr-Dan CorporationAttn: Technical Publications1080 Hykes RoadGreencastle, PA 17225

or by e-mail at [email protected].

Always keep this manual in your vehicle so the operator can study it asneeded before a recovery. Remember to replace the manual if lost.

Additional or replacement manuals or replacement safety warning labelscan be ordered by calling Jerr-Dan Parts at 717-597-7111.

The material in this document is the property of Jerr-Dan Corporation. Nopart of this document may be photocopied, reproduced or translated toanother language without the express written consent of Jerr-DanCorporation.

Patents Pending.

Jerr-Dan and the Jerr-Dan logo are registered trademarks and Run Hard isa service mark of Jerr-Dan Corporation, Greencastle, PA USA.

5-376-000094REV. 3 - 03/10

Page i

LIMITED WARRANTYManufacturer’s Warranty. Manufacturer’s sole warranty shall be the following, whichDistributor shall make on behalf of Manufacturer by conspicuous notice in writingaccompanying each contract or memorandum of sale:

1. Warranty. Jerr-Dan Corporation, (“Manufacturer”) warrants each new product madeby it to be free from defects in material or workmanship for one year from the date ofinitial sale, lease, rental, or other disposition of such product, and agrees only to repair orreplace at its own expense, f.o.b. the place or places of manufacture, at manufacturer’soption, 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 warrantyperiod and given a reasonable time to correct the defect. In no case, shall the warrantyextend to defects in materials, components, or services furnished by third parties. Defectscaused by chemical action, or the presence of abrasive materials and defects arisingfollowing the operation beyond rated capacity or the improper use or application of anyProducts shall not be considered defects within the scope of the foregoing warranty. If anyrepairs or alterations are made or any parts are replaced during the period covered by anywarranty above mentioned by other than an authorized Manufacturer’s Distributor inaccordance with authorized Manufacturer’s service manuals or with other than parts,accessories, or attachments authorized by Manufacturer for use in its products, customershall pay for all such repairs or parts without recourse against Manufacturer, and Manufacturershall be relieved of responsibility for fulfillment of this warranty with respect to parts orcomponents of all repairs, alterations or replacements so made. No claims for labor shallbe considered unless authorized by Manufacturer.

2. Disclaimer as to Consequential or Special Damages. Under no circumstancesshall 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 asa result of any defect in the product or in any correction or alteration thereof made orfurnished by Manufacturer or others. “Consequential” or “special damages” as used hereinincludes 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 manufacturingvariances and operational inefficiencies.

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

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

1080 Hykes RoadGreencastle, PA 17225

(717) 597-7111

WARRANTY

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5. Exclusive and Entire Warranty. The warranty constitutes Manufacturer’s entirewarranty as to the product and it is expressly agreed that the remedies of dealer and thoseclaiming under dealer as stated in this warranty are exclusive. Manufacturer does notassume (and has not authorized any other person to assume on its behalf) any otherwarranty or liability in connection with any product covered by this warranty.

MANUFACTURER EXPRESSLY DISCLAIMS ANY AND ALL OTHER WARRANTIES OFANY KIND WHATSOEVER AS TO THE PRODUCT FURNISHED HEREUNDER,INCLUDING BUT NOT LIMITED TO EXPRESS OR IMPLIED WARRANTIES AS TOMERCHANTABILITY, FITNESS FOR PARTICULAR PURPOSES SOLD, DESCRIPTIONOR QUALITY OF THE PRODUCT FURNISHED HEREUNDER.

6. Notice of Occurrence. This warranty shall be void if, upon the occurrence of anyincident involving any product made by Manufacturer, and resulting in any personal injuryor property damage, customer shall fail to notify Manufacturer within 24 hours of suchoccurrence or permit Manufacturer audit representatives to have immediate access tosuch product and to all records of and within the control of the customer and/or distributorrelating to the product and the occurrence.

7. Filing of Warranty Claim. Upon notifying the Manufacturer of a failure, theManufacturer or its representative will verbally authorize and confirm by letter the repairsto 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, 50% to assure return of defective parts.

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

The vehicle owner/dealer will complete the Request for Warranty form and the WarrantyReturn Tag marked “Return with Shipping Notice”. Both documents should be attached tothe shipping notice and returned to the Manufacturer by mail. The parts to be returned shallbe tagged with the Warranty Return Tag (more than one part pertaining to the samewarranty claim shall be identified with the same warranty claim number - see number onWarranty Return Tag). All parts under this claim shall be returned to the Manufacturer pre-paid for warranty evaluation.

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

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

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

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

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Section I: SafetySafety (General) ....................................................................... 1Ratings:HDR70/85 - 530........................................................... 4Ratings:HDR70/85 - 565........................................................... 8Safety Chains ........................................................................ 17Lift Safety .............................................................................. 18Boom Safety .......................................................................... 19Capacity/Rating Information Placards .................................... 26Safety Warning Labels ........................................................... 28

Section II: OperationUnder Lift ............................................................................... 33Spring Brackets ..................................................................... 36Frame Forks .......................................................................... 40Chain Forks (Optional) ........................................................... 42Chain Hook Adapters (Optional) ............................................. 45Heavy Duty Tire Lift (Optional) ................................................ 48Trailer 5th Wheel Plate and Pintle Hook Ball Hitch Adapter (Optional) ................................................... 55Rear Hydraulic Stabilizers ...................................................... 58Integral Spades ...................................................................... 60Outrigger Stabilizers ............................................................... 62Outrigger Spades ................................................................... 66Wrecker Boom Operation ....................................................... 68

Section III: MaintenanceMaintenance and Lubrication ................................................. 75Fastener Torque Specifications .............................................. 77Oils and Greases ................................................................... 78Wire Rope Handling and Inspection ....................................... 79Lubrication Points .................................................................. 81Trouble Shooting .................................................................... 83Hydraulic System .................................................................. 83P.T.O. Functioning Improperly ................................................ 84Hydraulic Pump ..................................................................... 84Winch Functioning Improperly ................................................ 85

Section IV: GlossaryGlossary ................................................................................ 87

TABLE OF CONTENTS

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5-376-000094REV. 3 - 03/10 Section I: Safety

Page 1

The safe operation of your HDR is your responsibility. Read this manual andthe truck manufacturer’s manual and thoroughly understand them. Youcan be held legally responsible for injuries or damage resulting from unsafeoperating practices.

The manufacturer’s recommendations for operating this wrecker can helpyou avoid unsafe practices and their bad consequences. Theserecommendations are contained in this manual.

Jerr-Dan Corporation is not responsible for the results of any unsafe practiceof wrecker operators or for the failure of the wrecker of its accessoriesresulting from improper maintenance.

The danger from a vehicle does not cease when it is disabled or wrecked.Recovering or towing vehicles can be dangerous too! The danger threatenswrecker operators and everyone else close by. As a wrecker operator youmust develop an awareness of the hazards involved. You must use everysafeguard within reason to prevent injuries.

For each step in operating your wrecker develop the habit of asking yourselfif it is safe to proceed. Carefully check all rigging before starting a heavy liftor pull.

We cannot warn you of all the possible dangers you will encounter, but wewill tell you of the most common hazards that we know about. We alsorecommend that you receive specialized and advanced training from aprofessional Towing and Recovery instructor before operating any recoveryequipment.

To alert personnel to hazardous operating practices, safety messages areused throughout the manual. Each safety message contains a safety alertsymbol and a signal word to identify the hazard's degree of seriousness.

CAUTION:Identifies when a potentially hazardous situation exists and mayresult in a minor or moderate injury or property damage.

SAFETY

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Section I: SafetyPage 2

DANGER:Identifies when an imminently hazardous situation exists and canresult in death or serious injury.

WARNING:Identifies when a potentially hazardous situation exists and couldresult in death or serious injury.


Page 3

WARNING

ONLY AUTHORIZED AND TRAINEDPERSONNEL SHOULD BE PERMITTED TO

OPERATE THIS WRECKER UNSUPERVISED.

IN ORDER TO BE SUFFICIENTLY TRAINED TO OPERATE THISWRECKER, A PERSON MUST HAVE, AS A MINIMUM, THEFOLLOWING QUALIFICATIONS:

1. SATISFACTORILY PERFORMED ALL WRECKERMANEUVERS AND FUNCTIONS UNDER THESUPERVISION OF FULLY TRAINED PERSONNEL.

2. HAVE COMPLETELY READ AND UNDERSTAND THEOPERATIONS, MAINTENANCE, AND PARTS,MANUAL(S) IN THEIR ENTIRETY FOR THIS WRECKER.

3. HAVE COMPLETELY READ ALL WARNINGS ANDPRECAUTIONS ON THIS WRECKER.

4. HAVE HAD EXPLAINED TO THEM THE HAZARDS OFMOVING THE PARTICULAR MATERIALS THEY WILL BELOADING OR UNLOADING.

5. UNDERSTAND THE HAZARDS OF OPERATING AT APARTICULAR JOB SITE, INCLUDING

... THE IMPORTANCE OF STAYING WELL CLEAR OFALL ELECTRICAL LINES,

... GIVING CONSIDERATION TO GROUNDCONDITIONS SUCH AS IRREGULAR CONTOURS,ICE, WATER, OR MUD,

... ANY OTHER CONDITIONS WHICH MAYINTERFERE WITH ORDINARY CAREFULOPERATION OF THIS WRECKER.

UNTRAINED OPERATORS SUBJECTTHEMSELVES AND OTHERS TO DEATH OR

SERIOUS INJURY AND MAY CAUSE SERIOUSDAMAGE TO PROPERTY.

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DO NOT EXCEED THE FOLLOWING RATINGS:

HDR70/85 - 530

Maximum Structural LimitsBoom Fully Elevated and Retracted over Rear ......... 170,000 lbs.

Maximum Rated LoadsBoom Fully Elevated and Retracted over Rear ......... 140,000 lbs.

BOOM RATING: (Two Stage Boom)SAE Rating - Boom elevated at 30° Angle1

Retracted ................................................................. 120,000 lbs.Extended.................................................................... 44,000 lbs.

BOOM RATING: (Optional Three Stage Boom)SAE Rating - Boom elevated at 30° Angle1

Retracted ................................................................. 120,000 lbs.Mid ............................................................................. 44,000 lbs.Extended.................................................................... 26,000 lbs.

WINCH RATING: (Option 1 - Dp Planetary Gear) 2

Each Drum (Two Speed, Variable Control) .................. 50,000 lbs.

WIRE ROPE:Working Limit Each Line ............................................ 16,800 lbs.Construction .................................................... 6 x 37 EIP IWRCDiameter ......................................................................... 3/4 inchStandard Length .............................................................250 Feet

WINCH RATING: (Option 2 - Dp Planetary Gear) 2Each Drum (Single Speed, Variable Control) .............. 60,000 lbs.

WIRE ROPE:Working Limit Each Line ............................................ 22,500 lbs.Construction .................................................. 6 x 36 EEIP IWRCDiameter ......................................................................... 7/8 inchStandard Length .............................................................245 Feet


Page 5

UNDER LIFT RATING:Full Retracted ........................................................... 53,000 lbs.3Full Extended ............................................................ 17,000 lbs.3

Tow Rating ................................................................. 80,000 lbs.

DRAG WINCH RATING: (Optional dp Planetary Gear) 2Each Drum (Single Speed, Variable Control) .............. 35,000 lbs.

WIRE ROPE: (Option 1)Working Limit Each Line ............................................ 22,500 lbs.Construction .................................................... 6 x 37 EIP IWRCDiameter ......................................................................... 7/8 inchStandard Length .............................................................220 Feet


HEAVY DUTY TIRE LIFT RATING (OPTION):Lifting Capacity (Each Arm) ..........................................7,000 lbs.Lifting Capacity (Total) ................................................. 14,000 lbs.Towing Capacity (Maximum)4 ...................................................................42,000 lbs.

SUPER HEAVY DUTY TIRE LIFT RATING (OPTION):Lifting Capacity (Each Arm) ........................................ 12,000 lbs.Lifting Capacity (Total) ................................................. 25,000 lbs.Towing Capacity (Maximum)4 ...................................................................42,000 lbs.

5th WHEEL PLATE (OPTION):Lifting Capacity ........................................................... 15,000 lbs.Towing Capacity .......................................................... 25,000 lbs.

PINTLE HOOK BALL HITCH (OPTION):2 in. Ball Hitch ................................................ 10,000 lbs. (GTW)Pintle Hook ..................................................... 16,000 lbs. (GTW)

GROSS TRAILER WEIGHT ...................... 3,000 Maximum Vertical Load

5-376-000094REV. 3 - 03/10


1 SAE J2512: Surface Vehicle Recommended Practices - TowingEquipment Ratings and Practices

2 SAE J706: Surface Vehicle Recommended Practices - Rating of Winches

3 Rating Using Axle And Spring Lift Tools

4 THE TOWING CAPACITY SHOULD NOT EXCEED THE GROSS COM-BINED WEIGHT RATING (GCWR) OF THE TOWING VEHICLE OR 42,000LBS. (GCW) GROSS COMBINED WEIGHT OF THE TOWED VEHICLE,WHICHEVER IS LOWER.

5 The Maximum Structural Limit and Maximum Rated Load are basedon lifting the load vertically directly over the rear with the swing lockengaged. The rear spades and outriggers must be properly set onfirm level surface. Proper rigging for the wire rope limits must beutilized. Lifting the Maximum Structural Limit may cause permanentdeformation of components.

MAXIMUM LIFTING CAPACITY - THE MAXIMUM LOAD THAT CAN BE LIFTED.

GROSS COMBINED WEIGHT RATING (GCWR) - THE VALUE SPECIFIED BY THE VEHICLEMANUFACTURER AS GCW.

GROSS TRAILER WEIGHT (GTW) - THE MAXIMUM TRAILER WEIGHT WITH LOAD.

GROSS COMBINED WEIGHT (GCW) - ACTUAL WEIGHT OF THE ENTIRE VEHICLE AT THEGROUND WITH TRAILER OR TRAILERS, INCLUDING VEHICLE EQUIPMENT, DRIVER, PAS-SENGER, FUEL AND PAYLOAD (EVERYTHING THAT MOVES WITH THE VEHICLE).


Page 7

NOTE

These ratings apply to the structural design of the HDR70/85 - 530 only . Theymight be limited by the axle rating and gross vehicle weight rating of the truckchassis.

The payload and towing capacity of any towing vehicle must meet thefollowing: • The actual payload on the towing vehicle must not exceed the posted

rating and 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 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 a towed vehicle load must bedistributed so that each axle’s GAWR (Gross Axle Weight Rating) is notexceeded.

• The total weight of the towing vehicle and towed vehicle (everythingthat 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 andperformance of the towing vehicle.

CHECK TRUCK MANUAL FOR SPECIFIC GVW & AXLE RATINGS. ALSO LOOKAT THE CERTIFICATION DECAL AFFIXED TO DRIVER’S SIDE DOOR JAMB, HINGEPILLAR OR LATCH POST AND THE STRUCTURAL CAPACITIES PLACARD ONTHE UNIT.

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HDR70/85 - 565

Maximum Structural LimitsBoom Fully Elevated and Retracted over Rear ......... 170,000 lbs.

Maximum Rated LoadsBoom Fully Elevated and Retracted over Rear ......... 140,000 lbs.

BOOM RATING: (Two Stage Boom) ........................................................SAE Rating - Boom elevated at 30° Angle1

Retracted ................................................................. 120,000 lbs.Extended.................................................................... 44,000 lbs.

BOOM RATING: (Optional Three Stage Boom)SAE Rating - Boom elevated at 30° Angle1

Retracted ................................................................. 120,000 lbs.Mid ............................................................................. 44,000 lbs.Extended.................................................................... 26,000 lbs.

WINCH RATING: (Option 1 - Dp Planetary Gear) 2

Each Drum (Two Speed, Variable Control) .................. 50,000 lbs.

WIRE ROPE:Working Limit Each Line ............................................ 16,800 lbs.Construction .................................................... 6 x 37 EIP IWRCDiameter ......................................................................... 3/4 inchStandard Length .............................................................250 Feet

WINCH RATING: (Option 2 - Dp Planetary Gear) 2Each Drum (Single Speed, Variable Control) .............. 60,000 lbs.

WIRE ROPE:Working Limit Each Line ............................................ 22,500 lbs.Construction ................................................ 6 x 36 EEIPS IWRCDiameter ......................................................................... 7/8 inchStandard Length .............................................................245 Feet


Page 9

UNDER LIFT RATING:Full Retracted ........................................................... 56,500 lbs.3Full Extended ............................................................ 17,600 lbs.3

Tow Rating ................................................................. 80,000 lbs.

DRAG WINCH RATING: (Optional dp Planetary Gear) 2Each Drum (Single Speed, Variable Control) .............. 35,000 lbs.



HEAVY DUTY TIRE LIFT RATING (OPTION):Lifting Capacity (Each Arm) ..........................................7,000 lbs.Lifting Capacity (Total) ................................................. 14,000 lbs.Towing Capacity (Maximum)4 ...................................................................42,000 lbs.

SUPER HEAVY DUTY TIRE LIFT RATING (OPTION):Lifting Capacity (Each Arm) ........................................ 12,000 lbs.Lifting Capacity (Total) ................................................. 25,000 lbs.Towing Capacity (Maximum)4 ...................................................................42,000 lbs.

5th WHEEL PLATE (OPTION):Lifting Capacity ........................................................... 15,000 lbs.Towing Capacity .......................................................... 25,000 lbs.

PINTLE HOOK BALL HITCH (OPTION):2 in. Ball Hitch ................................................ 10,000 lbs. (GTW)Pintle Hook ..................................................... 16,000 lbs. (GTW)

GROSS TRAILER WEIGHT ...................... 3,000 Maximum Vertical Load

5-376-000094REV. 3 - 03/10


1 SAE J2512: Surface Vehicle Recommended Practices - TowingEquipment Ratings and Practices

2 SAE J706: Surface Vehicle Recommended Practices - Rating of Winches

3 Rating Using Axle And Spring Lift Tools

4 THE TOWING CAPACITY SHOULD NOT EXCEED THE GROSS COM-BINED WEIGHT RATING (GCWR) OF THE TOWING VEHICLE OR 42,000LBS. (GCW) GROSS COMBINED WEIGHT OF THE TOWED VEHICLE,WHICHEVER IS LOWER.

5 The Maximum Structural Limit and Maximum Rated Load are basedon lifting the load vertically directly over the rear with the swing lockengaged. The rear spades and outriggers must be properly set onfirm level surface. Proper rigging for the wire rope limits must beutilized. Lifting the Maximum Structural Limit may cause permanentdeformation of components.

MAXIMUM LIFTING CAPACITY - THE MAXIMUM LOAD THAT CAN BE LIFTED.

GROSS COMBINED WEIGHT RATING (GCWR) - THE VALUE SPECIFIED BY THE VEHICLEMANUFACTURER AS GCW.


GROSS COMBINED WEIGHT (GCW) - ACTUAL WEIGHT OF THE ENTIRE VEHICLE AT THEGROUND WITH TRAILER OR TRAILERS, INCLUDING VEHICLE EQUIPMENT, DRIVER, PAS-SENGER, FUEL AND PAYLOAD (EVERYTHING THAT MOVES WITH THE VEHICLE).


Page 11

NOTE

These ratings apply to the structural design of the HDR70/85 - 565 only . Theymight be limited by the axle rating and gross vehicle weight rating of the truckchassis.

The payload and towing capacity of any towing vehicle must meet thefollowing: • The actual payload on the towing vehicle must not exceed the posted

rating and 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 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 a towed vehicle load must bedistributed so that each axle’s GAWR (Gross Axle Weight Rating) is notexceeded.

• The total weight of the towing vehicle and towed vehicle (everythingthat 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 andperformance of the towing vehicle.

CHECK TRUCK MANUAL FOR SPECIFIC GVW & AXLE RATINGS. ALSO LOOKAT THE CERTIFICATION DECAL AFFIXED TO DRIVER’S SIDE DOOR JAMB, HINGEPILLAR OR LATCH POST AND THE STRUCTURAL CAPACITIES PLACARD ONTHE UNIT.

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LOAD CHART(Refer to the actual chart in your unit)

SAMPLE

74

9


Page 13

Certification Decal

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

Provided by the Final Stage Vehicle Manufacturer according to Title 49Part 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 notbeen properly maintained. Pay specialattention to the mounting bolts, andlubrication of moving parts.

• Don’t use rear spades on paved surfacesunless you are wil l ing to acceptresponsibility for damage to such surfaces.

• Don’t operate the wrecker’s engine faster thanrecommended. Excessive speeds candamage PTO, hydraulic pumps, and winches.

• Don’t lower the rear hydraulic stabilizers unlessthe area under them is clear. Pay particularattention to keeping this area clear.

• Don’t move the recovery vehicle while rearhydraulic stabilizers are extended. Damageis very likely to occur.

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


Page 15

• Don’t tow a vehicle that reduces the weighton the front wheels of the wrecker more than50 percent. (SAE J2512)

• Don’t travel with the PTO engaged. Damageto the recovery vehicle's transmission andhydraulic components will occur. Engage itonly while operating the controls.

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

• After you have hooked up a vehicle fortowing, don’t start the tow until you havedouble checked the hook-up, installed safetychains, and released the parking brakes ofthe towed vehicle.

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

• Never fold the boom up into storage positionwithout removing the towing adapters.

5-376-000094REV. 3 - 03/10


• Keep the underlift boom raised high enoughoff of the ground when roading to avoiddragging it over road surfaces.

• Don’t tow a vehicle on its drive wheels unlesssteps have been taken to protect i tstransmission and differential. Follow therecommendations of the vehicle manu-facturer. As an alternative, use a towingdolly.

• Never exceed the front and/or rear axleratings of your towing equipment.

• Never extend or retract an outrigger unless itis in full view from it's operating controls.

• Vehicle must be located on a firm levelsurface that will provide support for theoutrigger loading. Use caution when sittingup near overhanging banks or excavations.

• Don’t use outrigger spades on pavedsurfaces unless you are willing to acceptresponsibility for damage to such surfaces.


Page 17

SAFETY CHAINS AND TIE-DOWN CHAINS MUST BEUSED WHEN TOWING AND TRANSPORTING

Safety chains and tie-down chains are provided for use with your new Jerr-Dan Recovery Vehicle. Periodically inspect all chains for any signs of fatigueor damage. Don’t overlook the hooks; be sure they have not been bent ordeformed. If chain or hook damage is noted, they must be replaced beforebeing used. Do not use safety chains for recovery operations.

Many states require that the towed vehicle be secured to the wrecker bodywith 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 away as to damage brake lines or otherfunctional parts.

• Keep in mind that driving over bumps andhollows and around corners will tend totighten or loosen the chains.

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

• Always use two safety chains and two tie-downchains when towing all vehicles, regardless ofdistance.

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LIFT SAFETY

Careful consideration of the immediate surrounding conditions such as theweather, terrain, type or condition of the vehicle to be recovered and thecondition and experience of the operator is foremost to the safety andsuccess of the operation.

Your unit is unique. It not only can make lifts from level surfaces, our boomtilt feature allows pickup of vehicles that are parked on both inclines anddeclines.

• You should never make a lift or movementwhile close to or under the vehicle beinglifted!

• Don’t use towing forks that are not of propersize for the pickup requirements.

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

• Magnetic towing lights are required in manyareas and are always recommended for safetows.


Page 19

BOOM SAFETY

Your unit is equipped with a wrecker boom and the following safety proceduresmust be observed:

• Jog the winch control lever to be sure ofcomplete engagement of the clutch gearsbefore making a lift or pull.

• Never stand on or straddle a working wirerope.

• Take up the wire rope cable slowly and besure the hook is securely set.

• Be sure of your lift or pull and do not exceedthe working limit of the wire rope or hook.Rig to keep the estimated amount of pullwell within equipment ratings. Use wire ropebreaking strength ratings only for selectingreplacement wire rope.

5-376-000094REV. 3 - 03/10


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

• Never completely unwind wire rope from awinch while loaded. Always be sure that aminimum of five (5) wraps of wire rope are onthe drum at all times. (SAE J706)

• Never tie down the front end of your wreckerfor recovery work of heavy lifts. You willlikely damage the truck frame if you do.

• Never allow the wire rope to cross wrap(criss-cross) on the winch drum. Crushingof the wire rope can cause premature wirerope failure.

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

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


Page 21

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

• Never wrap the wire rope around frames orcross members. Use chains and hook thewire rope to the chains.

• Don’t use damaged wire ropes on yourwrecker. Become familiar with the varioustypes of wire rope damage and periodicallyinspect the entire wire rope for wear andcorrosion. Never use wire rope menders.Replace with similar rated wire rope andhooks.

• Be sure all brakes and locks are properlyset on the recovery vehicle.

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

• Death or Serious Injury can occur whenworking near power lines. Be sure that exactlocations of overhead power lines, and otherobstructions or hazards are known.

5-376-000094REV. 3 - 03/10


• Lubricate and maintain both the wire ropeand winch on regular intervals. (Seemaintenance charts.) Inspect the wire ropefor damage. Damaged, deformed or frayedwire rope should be replaced before use.

• Don’t continue to wind in wire rope after thehook is against the boom end.

• All boom placement functions should bemade with the winch wire ropes set in “freespool” to avoid over tensioning or breakingthe winch wire ropes.

• Avoid using the boom raise or boom upcontrol to lift a load. This causes unduestress and weight loading on the rear axle.Use the winch to lift the load.

• Caution should be taken when retractingor extending the boom extension whileunder load.

• After rigging wire ropes, don’t begin pullingwithout rechecking connections. Make surethat all wire ropes and snatch blocks aresecurely attached and cannot accidentlypull loose.


Page 23

• Don’t expect your wrecker to tow loads equalto the wrecker ratings. Wrecker ratings applyto loads imposed during recovery with thewrecker properly stabilized.

• Do not raise, lower, or move the boom nearpower lines. Hazardous voltage will causesevere injury or death.

• To avoid birdnesting and premature failure ofthe wire rope, always keep tension on the wirerope when winding or unwinding.

• Don’t exceed ratings of booms, wire ropes,snatch blocks, or winches. Stay withinnameplate ratings. Note that boom ratingsdecrease significantly as the boom isextended.

• Don’t drive with the wrecker boomextended.

• When making a pull to the side, always applyan equal load in the opposite direction of thepull to stabilize the wrecker.

5-376-000094REV. 3 - 03/10


• Know the load to be moved. DO NOTOVERLOAD!

• Do not drive without locking the slew lock.The boom may rotate unexpectedly.

• When swinging a load, watch out for centrifugalforce. As you swing a load this force willcause the load to swing away from the machineand may cause instability.

• Make sure vehicle is positioned in an areafree from overhead obstructions. KEEP ASAFE WORKING DISTANCE!

• Do not rotate or extend a load overanyone.

• All outrigger sections must be fully pinnedbefore starting recovery work to avoiddamage to outriggers and outrigger extensioncylinders.


Page 25

• Do not swing the wrecker boom withoutextending the outrigger stabilizers.

• Stay clear of rotating equipment to avoidcrushing injury.

5-376-000094REV. 3 - 03/10


CAPACITY/RATING INFORMATION PLACARDS

These placards provide information about carrier and vehicle ratings,capacities and load limits. You must stay within these ratings/capacitieswhen using the Jerr-Dan HDR. These placards must not be obliterated,removed or painted over. They are there to remind and protect the operator.(Not all placards are used on all units) If a placard becomes lost orunreadable, it should be replaced. Replacements are available through theService Parts Department.

MANUFACTURED BY:

JERR-DAN CORPORATION1080 HYKES ROADGREENCASTLE, PA 172251-800-926-9666

WORKING LIMIT

TYPE

SIZE

CABLE / WIRE ROPEFT.

LBS.

EACH DRUM

WINCH RATING (SAE J706)

LBS.

SERIAL NO.MODEL NO.

UNDERLIFTUNDERLIFT RATINGS (MAXIMUM)

RETRACTED

EXTENDED

LBS.

LBS.

WRECKER BOOMBOOM RATINGS (MAXIMUM)(SAE J2512 - BOOM AT 30° ANGLE

EXTENDED LBS.

RETRACTED LBS.

189

WARNINGREAD OPERATOR'S MANUAL AND FAMILIARIZE YOURSELFWITH THE OPERATION PRIOR TO USING THIS EQUIPMENT.

KNOW THE LOADS BEING MOVED.DO NOT EXCEED RATED CAPACITIES.

WARNINGALL RATINGS ARE BASED ON THE STRUCTURAL CAPACITY

OF ABOVE MODEL. ACTUAL TOWING AND RECOVERYCAPACITY MAY BE LIMITED BY THE CAPACITY OF

THE CHASSIS AND EQUIPMENT SELECTED.


Page 27

5-376-000094REV. 3 - 03/10


SAFETY WARNING LABELS

These safety warning labels describe hazards and what happens if youencounter them. Read each safety warning lable and figure out how to avoidthe hazard. These lables must not be obliterated, removed or painted over.They are there to remind and protect the operator. (Not all decals are usedon all units) If a decal becomes lost or unreadable, it should be replaced.Replacements are available through the Service Parts Department.


Page 29

WARNING

037

MOVING PARTSKEEP HANDS AND FEET CLEAR

OF THIS AREA

WARNING

139

HAVE YOU REVIEWED THE

OPERATOR'S PRE-TRANSPORT

CHECK LIST ON THE UNIT?

7,000 lbs14,000 lbs80,000 lbs

THE TOWING CAPACITY SHOULD NOT EXCEEDTHE GROSS COMBINED WEIGHT RATING (GCWR)

OF THE TOWING VEHICLE OR THE 80,000 LB.STRUCTURAL CAPACITY OF THE TIRE LIFT,

WHICHEVER IS LOWER.

CAUTION

278278

THE BUS BAR GRID MUST BE SECUREDTO THE CROSS TUBE AT ALL TIMES

WITH THE RETAINING PINS.

THE BUS BAR GRID MUST BE SECUREDTO THE CROSS TUBE AT ALL TIMES

WITH THE RETAINING PINS.

TO AVOID DAMAGE TO THE WRECKER BODYTHE BUS BARS AND GRID TUBES MUST BE

IN THEIR OUTER MOST POSITIONS FORSTORAGE ON THE UNDER LIFT WHEN

FOLDED UP INTO THE TRAVEL POSITION

TO AVOID DAMAGE TO THE WRECKER BODYTHE BUS BARS AND GRID TUBES MUST BE

IN THEIR OUTER MOST POSITIONS FORSTORAGE ON THE UNDER LIFT WHEN

THE TRAVEL POSITION

5-376-000094REV. 3 - 03/10


WARNING

037

MOVING PARTSKEEP HANDS AND FEET CLEAR

OF THIS AREA

WARNINGWARNING

202202

ELECTRICAL HAZARDPOWER DISTRIBUTION PANEL

CAUTION

253

TO AVOID BIRDNESTING AND PREMATUREFAILURE OF THE WIRE ROPE

ALWAYS KEEP TENSION ON THEWIRE ROPE WHEN UNWINDING

A YS

WARNINGWARNING

262262

A MINIMUM OF 5 WRAPS OF CABLE MUST BE LEFT ON DRUMTO ACHIEVE RA TED LOAD. NOT TO BE USED IN THE MOVINGOR LIFTING OF PERSONS

A MINIMUM OF 5 WRAPS OF CABLE MUST BE LEFT ON DRUMTO ACHIEVE RA TED LOAD. NOT TO BE USED IN THE MOVINGOR LIFTING OF PERSONS

WARNINGWARNING

211211

TOWED VEHICLE MUST BE SECUREDTO CROSSBAR WHEN USING

FRAME FORKS AND SPRING HANGERS

TOWED VEHICLE MUST BE SECUREDTO CROSSBAR WHEN USING

FRAME FORKS AND SPRING HANGERS


Page 31

WARNING

122122

TOWED VEHICLE MUST BECONNECTED TO TOW TRUCK BODY

WITH SAFETY CHAINS

TOWED VEHICLE MUST BECONNECTED TO TOW TRUCK BODY

WITH SAFETY CHAINS

Hazardous voltage.Will cause severe

injury or death.

Hazardous voltage.Will cause severe

injury or death.

Do not raise, loweror move boom within

near power lines.

Do not raise, loweror move boom within

near power lines.203203

DANGERDANGER

WARNINGWARNING

580580

STAND CLEAR OF

OUTRIGGER/STABILIZERS

TO AVOID CRUSHING INJURY

5-376-000094REV. 3 - 03/10


5-376-000094REV. 3 - 03/10 Section II: Operation

Page 33

UNDER LIFT OPERATION

Your HDR is one of the most useful and efficient towing and recovery vehiclesavailable. It is hydraulically powered and careful consideration should begiven to the selection of commands. You can afford to work smart, thevehicle will do most of the work for you.

Follow these simple steps:

1. Turn on the safety and worklights. (Switches located onpanel on the floor beside thedriver’s seat.) If the remote handcontroller is going to be used theCONTROL switch must beturned “ON”.

2. Using the rear axle as a guide,position the recovery vehiclewithin nine (9) ft. of the subjectcasualty vehicle and as close tothe direction of the pull aspossible.

3. Place the recovery vehicle’stransmission gear selector intoneutral and set the parkingbrakes.

4. Engage the power take-off (PTO)by moving the control lever. SeePTO operator’s manual. NEVERTRAVEL WITH THE POWERTAKE-OFF CONTROLENGAGED. This could result indamage to the PTO unit and therecovery vehicle’s transmission.

OPERATION

5-376-000094REV. 3 - 03/10Section II: Operation

Page 34

5. Adjust the electronic or manual throttle control to elevate the enginespeed to approximately 1000-1200 R.P.M. of P.T.O. output shaft speedfor optimum performance.

CAUTION:Never exceed 1200 R.P.M. When your hook up is complete, resetthe engine idle to normal.

6. Confirm the recovery vehicle’s position in relation to the casualty vehicleto be towed. Nine (9) ft. is recommended. Reposition the recovery vehicleif necessary. Be sure the casualty vehicle is not in gear or park.Keep the brake set.

7. Using the tilt fuction, unfold theunder lift boom down until it is inthe horizontal position.

8. Lower the under lift boom toabout one (1) in. from the groundand swing the crossbar parallelto the casualty vehicle.


Page 35

9. Attach the lift receivers to thecrossbar by sliding them over theends of the crossbar. Install theretaining pin into the end of thecrossbar and secure with thesafety pin.

CAUTION:The retaining pins must be inplace during all towingapplications.

10. Adjust the lift receivers on thecrossbar to the desired positionand tighten the “T” handles tosecure the receivers on thecrossbar.

Various Positions for Lift Receiver Use


Page 36

SPRING BRACKETS

1. Insert the spring brackets intothe receivers that you put ontothe crossbar.

2. Extend the under lift boom underthe casualty vehicle so that thespring brackets are in the properposition for lifting. Make surethat the spring brackets areagainst the front part of thespring hanger as shown. At thesame time make sure you arenot attaching the springbrackets to any steeringcomponents.


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3. Raise the boom to lift thecasualty vehicle slightly.

4. Secure the casualty vehicle tothe spring brackets with theretaining pins and safety pins.

5. Secure the casualty vehicle tothe crossbar with chains and achain binder.

6. After securing the casualtyvehicle and before making thefinal lift, check to be sure thatthe casualty’s parking brake isreleased, the transmission is inneutral, and the wheels arestraight.

CAUTION:If vehicle to be towed is on a slope, do not release the brake untilthe load is secured.


Page 38

7. It is recommended that thesteering wheel be secured by asteering wheel strap for any frontor rear tow.

8. With the vehicle in neutral andthe parking brake released, youcan move the vehicle safely up,down, in or out. All of thesemovements are hydraulicallycontrolled.

9. Power retract the under lift untilthe casualty vehicle is aboutthree (3) to four (4) feet from theback of the recovery vehicle.Leave enough room to maneuveraround corners without cornerbinding or causing contactbetween the two (2) vehicles. Besure that the fly boom isextended at least four (4) in.from the middle boom sectionto ensure unobstructed cross-bar pivoting.

10. Raise the casualty vehicle into the final towing position observing the farend for sufficient ground clearance. It is possible to set the rear of a frontlifted vehicle completely onto the ground, causing damage. Take irregularroad surfaces into consideration. Observe the lift function from the sideand away from both vehicles if possible.

NOTE:When towing, the Underlift Boom should be as close to horizontalas possible. You will have better turning and manueveringcapabilities and it will prolong the life of your under lift and pivotpin.


Page 39

CAUTION:Always follow the chassis manufacturer's recommended proceduresfor towing. Remove drive lines and drive shafts as directed. Manyvehicles can be severely damaged unless these components areremoved prior to towing.

11. Be sure to maintain sufficient ground clearances with the bottom of thecasualty vehicle.

12. Attach the safety chains andauxiliary towing lights.

13. Hook-up and connect air andbraking systems.

14. If the remote hand controller wasused, turn the CONTROL switch“OFF”. (Switch is located onpanel on the floor.)

WARNING:Never fold the boom up into thestorage position withoutremoving the towing adaptersfrom the crossbar receivers.

CAUTION:The use of secondary tie-down chains is recommended. Install thetie-down chains between the axle or substantial chassis componentand the towbar.


Page 40

FRAME FORKS

1. Choose the frame forks that arebest suited to your needs andinsert them into the receivers onthe crossbar.

2. Extend the under lift boom underthe vehicle so that the frame forksare in the proper position forlifting. At the same time makesure you are not attaching theframe forks to any steeringcomponents.

3. Raise the boom to lift thecasualty slightly.

4. Secure the casualty vehicle tothe crossbar with chains and achain binder.

5. After securing the casualtyvehicle and before making thefinal lift, check to be sure thatthe casualty’s parking brake isreleased, the transmission is inneutral, and the wheels arestraight.

CAUTION:If vehicle to be towed is on aslope, do not release the brakeuntil the load is secured.



Page 41


8. Power retract the under lift until the casualty vehicle is about three (3) tofour (4) feet from the back of the recovery vehicle. Leave enough room tomaneuver around corners without corner binding or causing contactbetween the two (2) vehicles. Be sure that the fly boom is extendedat least four (4) in. from the middle boom section to ensureunobstructed cross-bar pivoting.

9. Raise the casualty vehicle into towing position observing the far end forsufficient ground clearance. It is possible to set the rear of a front liftedvehicle completely onto the ground, causing damage. Take irregularroad surfaces into consideration. Observe the lift function from the sideand away from both vehicles if possible.


10. Be sure to maintain sufficientground clearances with thebottom of the casualty vehicle.

11. Attach the safety chains andmagnetic towing lights.



Page 42


WARNING:Never fold the boom up into thestorage position withoutremoving the towing adaptersfrom the crossbar receivers.

CHAIN FORKS (OPTIONAL)

1. Insert the chain forks into thereceivers on the crossbar.

2. Extend the under lift boom up tothe casualty vehicle so that thechain forks are in the properposition for lifting.

3. Attach the hook-up chains to thecasualty vehicle. Hook thechains through the chain forksand secure any extra chain tothe hooks on the lift receivers.The use of wood blocks andrubber mats may be required toprotect the casualty vehicle.

4. Raise the boom to lift thecasualty vehicle slightly. At thesame time make sure that youare not going to damage anycomponents.


Page 43

5. Before making the final lift, checkto be sure that the casualty’sparking brake is released, thetransmission is in neutral, andthe wheels are straight.






Page 44

9. Raise the casualty vehicle intotowing position observing the farend for sufficient groundclearance. It is possible to setthe rear of a front lifted vehiclecompletely onto the ground,causing damage. Take irregularroad surfaces into consider-ation.

NOTE:When towing, the Underlift Boomshould be as close to horizontalas possible. You will havebetter turning and manueveringcapabilities and it will prolong thelife of your under lift and pivotpin.





WARNING:Never fold the boom up into the storage position without removingthe towing adapters from the crossbar receivers.


Page 45

CHAIN HOOK ADAPTERS

1. Slide the chain hook adaptersonto the crossbar.

2. Install the retaining pin from theback side of the crossbarthrough the adapter and cross-bar and install the hair pin.

3. Extend the under lift boom up tothe casualty vehicle so that thechain hook adapters are in theproper position for lifting.

4. Attach hook-up chains to thecasualty vehicle. Fasten thechains in the hooks on the endof the adapters and safety wrapthe chain around the bottom ofthe hook as shown. Secure theremaining chain.



Page 46

6. Before making the final lift, checkto be sure that the casualty’sparking brake is released, thetransmission is in neutral, andthe wheels are straight.






Page 47

10. Raise the casualty vehicle intotowing position observing the farend for sufficient groundclearance. It is possible to setthe rear of a front lifted vehiclecompletely onto the ground,causing damage. Take irregularroad surfaces into consider-ation.

NOTE:When towing, the Underlift Boomshould be as close to horizontalas possible. You will havebetter turning and manueveringcapabilities and it will prolong thelife of your under lift and pivotpin.






Page 48

HEAVY DUTY TIRE LIFT (OPTIONAL)

DO NOT EXCEED THE FOLLOWING RATINGS:HDTL SHDTL

Lifting Capacity (Each Arm) .......................... 7,000 lbs. ......... 12,000 lbs.Lifting Capacity (Total)2 ............................... 14,000 lbs. ......... 25,000 lbs.Towing Capacity (Maximum)1 ...................... 80,000 lbs. ......... 80,000 lbs.

1 THE TOWING CAPACITY SHOULD NOT EXCEED THE GROSS COMBINED WEIGHT RATING (GCWR) OF THE TOWING VEHICLE OR 42,000 LBS. (GCW) GROSS COMBINED WEIGHT OF THE TOWED VEHICLE, WHICHEVER IS LOWER.

2 MAXIMUM LIFTING CAPACITY - THE MAXIMUM LOAD THAT CAN BE LIFTED.

1. Slide the tire lift grid onto thecrossbar.

CAUTION:Make sure that the tire lift Gridis installed as shown with thewide flanged plate on top. Theflanges are marked with an "L"for left hand and an "R" for righthand.

2. Install the retaining pin from theback side of the crossbarthrough the grid and crossbarand secure with the pin. Thereare two width positions. One forwider front end lifts and one fornarrower rear end lifts.

WIDE

FLANGED

PLATE


Page 49

3. Insert the round tube into thedesired position in the grid.

4. Install the retaining pin andhairpin.

5. Retract the tube inward to theloading position.

6. Slide the arm weldment over theend of the grid and adjust to thedesired position for loading.


Page 50

7. Install the retaining pin throughthe grid and arm weldment andsecure with the pin.

8. Extend the under lift under thecasualty vehicle so that the armmakes contact with the front ofthe tires. At the same timemake sure that you are notgoing to damage any underbody components.

9. Using the pulling tool, extend theround tube to capture the backof the tire. After extending thetube, make sure that the flangededge of the tube is turned up toprevent the tire from sliding offthe end of the tube.

CAUTION:When lifting a vehicle that hasdual tires from the rear, onlyextend the round tube out tocapture the inside tire. Theflanged edge of the tube mustbe between the tires and turnedup to prevent the tire from slidingoff the end of the tube.


Page 51


11. Attach the hook end of the tie-down strap to the round tubebehind the tire. Pull the strap upand cover the tire and attach thehook on the ratchet end of thestrap to the arm in front of thetire.

12. Take up the slack in the strapby ratcheting the takeup spoolarm. Continue until the tires showsome compression.



Page 52

13. Always secure the steeringwheel with a steering wheel strapfor any front or rear tow.



16. Raise the casualty vehicle into towing position observing the far end forsufficient ground clearance. It is possible to set the rear of a front liftedvehicle completely onto the ground, causing damage. Take irregularroad surfaces into consideration.



Page 53





WARNING:Do not use the tire lift if the tire(s) of the casualty vehicle are flat orif there is damage to the wheels or suspension.

CAUTION:The tire lift and grid tubes must be in their outermost positions forstorage on the under lift when folded up in the travel position toavoid damage to the body.

CAUTION:Retighten the tie-down straps periodically during a tow as the tiressettle into the grid from towing.


Page 54

CAUTION:The use of secondary tie-down chains is recommended. Fit thesecondary tie-down chains to the axle (not to any part of thesuspension or body which will rise and fall with the suspension)arranged so as to hold the wheel down in the grid and prevent itfrom jumping up, forwards, or backwards. Use load binders asrequired.

CAUTION:The use of trailer brakes or secondary braking devices while towingis recommended.

CAUTION:Do not tow any vehicle without safety chains being installed.

CAUTION:Always follow the chassis manufacturer's recommended proceduresfor towing. Remove drive lines and drive shafts as directed. Manyvehicles can be severely damaged unless these components areremoved prior to towing.

CAUTION:All products are subject to age, wear and deterioation, all of whichcause a reduction in the products breaking strength capacity. It isrecommended that all products be regularly inspected. Any worn,deformed, misused or overloaded products should be replacedimmediately.


Page 55

TRAILER 5TH WHEEL PLATE AND PINTLE HOOK BALLHITCH ADAPTER (OPTIONAL)


5TH WHEEL PLATELIFTING CAPACITY ...................................... 15,000 lbs.TOWING CAPACITY ..................................... 25,000 lbs.

PINTLE HOOK BALL HITCH2 IN. BALL HITCH ......................................... 10,000 lbs. (GTW)PINTLE HOOK .............................................. 16,000 lbs. (GTW)GROSS TRAILER WEIGHT .......................... 3,000 lbs.MAXIMUM VERTICAL LOAD


1. Slide the 5th wheel plate adapteronto the crossbar pivot.

2. Install the keeper bracket downonto the crossbar pivot adapter.


Page 56

3. Install the retaining bolts thru thekeeper bracket and into theadapter. Tighten the retainingbolts.

4. Install the 5th wheel plate ontothe adapter with the attachingpin. Secure the attaching pin withthe linchpin.

5. Remove the king pin locking pinfrom the 5th wheel plate andposition the recovery vehicle infront of the casualty and in-linewith the king pin.

6. Extend the under lift up to theking pin.


Page 57

7. Engage the 5th wheel plate withthe king pin. Install the king pinlocking pin and linchpin.

8. Connect the air lines from therecovery vehicle to the casualtytrailer to release the trailerbrakes.

9. Raise the trailer jack stands.

10. Attach the safety chains.

CAUTION:If the trailer to be towed is on a slope, do not release the brakeuntil the load is secured.

CAUTION:Always install safety chains before towing any vehicle.


Page 58

REAR HYDRAULIC STABILIZERS

Your HDR is equipped with rear hydraulic stabilizers. The stabilizers servetwo purposes. First, they may be used as a chassis support when liftingheavy loads which would otherwise cause the front axle of the vehicle to liftoff the ground. Second, they can be used to provide a resistance to winchingforces. USE CAUTION AND GOOD JUDGEMENT!


1. Position the recovery vehicle asclose as possible to the work andset the parking brakes and placethe transmission in neutral.

2. Engage the power take-off(PTO). See PTO operator’sinstruction manual.

3. Adjust the electronic or manualthrottle control to elevate theengine speed to approximately1000-1200 R.P.M. of P.T.O.output shaft speed for optimumperformance.

CAUTION:Never exceed 1200 R.P.M.When your hook up is complete,reset the engine idle to normal.


Page 59

4. Using the control levers, lowerthe stabilizers to the ground. Thestabilizers work independentlyfrom each other so that they canbe used on uneven ground.

WARNING:Area should be clear of feet when lowering the rear stabilizers.

CAUTION:Do not move the recovery vehicle with the stabilizers on the groundor damage to the chassis can occur.


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INTEGRAL SPADES

1. Remove the safety pin andspade retaining pin.

2. Allow the integral spade to swingdown exposing the spadeblades.

3. Line up holes and insert spaderetaining pin and safety pin.


Page 61

NOTE:When the spade is on the ground the eye plate on the back side ofthe stabilizers can be used for the attachment of snatch blocks orto terminate the wire rope hook during winching operations.



CAUTION:Do not use spades on pavement or concrete. Damage to thepavement or concrete may result.


Page 62

OUTRIGGER STABILIZERS

Your HDR is equipped with hydraulic outrigger stabilizers. The stabilizersserve two purposes. First, they are used as a chassis support when liftingor pulling heavy loads over the sides of the truck which would otherwisecause the chassis to become unstable and possibly roll over. Second,they can be used to provide a resistance to winching forces. USE CAUTIONAND GOOD JUDGEMENT!



2. Engage the power take-off(PTO). See PTO operator’sinstruction manual.

3. Adjust the electronic or manualthrottle control to elevate theengine speed to approximately1000-1200 R.P.M. of P.T.O.output shaft speed for optimumperformance.



Page 63

4. Using the control levers, extendthe outriggers to the full extendedposition.

5. Retract the inner outriggersections about 1" to align thelocking pin holes.

6. Remove the outrigger pins fromthe storages compartments.Install the pins into the innersections of the outrigger andsecure with the retaining pins.

7. Retract the outer outriggersections about 1" to align thelocking pin holes.

8. Lower the outriggers slightly togain access to the pinninglocations at the upper, inboardends of the outriggers.

9. Install the pins into the outersections of the outriggers.


Page 64

10. Turn the pin to lock into the pininto position.

11. Lower the outriggers to theground. Raise the chassis to getthe tires off the groud. Level thechassis as required.



Page 65


NOTE:When the stabilizer is on the ground the "D Rings" on the ends ofthe stabilizers can be used for the attachment of snatch blocks orto terminate the wire rope hook during winching operations.

CAUTION:When using stabilizer pads on pavement or concrete, it is suggestedthat you use larger steel plates and pads to help distribute theheavy loads. Damage to the pavement or concrete may result.

WARNING:All outrigger sections must be pinned before starting recovery work.


Page 66

OUTRIGGER SPADES

1. Swing down the spade pads.

3. Line up holes and insert spaderetaining pin and secure with thesafety pin.



Page 67


CAUTION:Do not use spades on pavement or concrete. Damage to thepavement or concrete may result.

CAUTION:All spades must be pinned in working position before startingrecovery work.


Page 68

WRECKER BOOM OPERATION

The wrecker boom is probably one of the most useful accessories on yourHDR. It allows the operator to perform lifting and retrieval tasks that cannotbe performed in any other way. Safe operation of the wrecker boom demandsknowledge of the controls and the boom functions. Review the boom safetysection of this manual and USE CAUTION AND GOOD JUDGEMENT!

Position the recovery vehicle to best take advantage of the leverage theboom affords. A vertical lift is the best and most efficient, so attempt toplace the boom over the work. This reduces the chance of the work breakingfree and swinging during the lift. Place the recovery vehicle as close aspossible to the work. A shorter boom extension will result in less rear axleloading. When pulling, align the recovery vehicle with the work so that thedirection of pull is in line with the length of the truck. Always use morestabilizing lines than pull lines. If the front wheels of the recovery vehicleraise completely from the ground,

Stop! And Re-Rig.

WARNING:Do not exceed the working limit of the wire rope. Use snatch blocksand multiple lines to reduce the load on the wire rope. Alwaysapply an equal load in the opposite direction of the pull to stabilizethe load.

DANGER:Do not swing the wrecker boom without extending the outrigger/stabilizers.

WARNING:Refer to load charts prior to performing any lifting or recovery work.


Page 69

WARNING:Stay clear of rotating equipment to avoid crushing injury.

When making a heavy lift or pull with the wrecker boom, the following stepsshould be taken:


2. Turn “ON” the CONTROL switchif the remote hand controller isgoing to be used.

3. Engage the power take-off(PTO). See PTO operator’sinstruction manual. Adjust theelectronic or manual throttlecontrol to elevate the enginespeed to approximately 1000-1200 rpm of P.T.O. output shaftspeed for optimum performance.


4. Confirm that the recovery vehicleis positioned properly and restson firm ground. The outriggers,stabilizers and spades can belowered to provide additionalsupport if necessary.


Page 70

5. Wearing gloves, unhook the wireropes from their stored position.Moving the boom head with thewire rope locked can result indamage to both the wire ropesand the boom.

6. If you are going to be making alift or pull off the corners or sidesof the truck, use the controls tounlock the slew pin to allow thewrecker boom to rotate .

DANGER:Do not swing the wrecker boomwithout extending the outrigger/stabilizers.

7. Using the winch control levers, unwind some wire rope from the winchesto relieve the pressure on the winch free-spool device.

8. Pull the winch free-spool knobs to the “out” position to set both boomwinches into the “free spool” mode.

9. Position the boom head by usingthe boom up, down, in, out andslew left and right levers asnecessary.


Page 71

10. Manually, “free-spool” enoughwire rope to make the hook-upbeing sure that a minimum of five(5) wraps remains on the cabledrums.

WARNING:Wear gloves to protect handsfrom wire ropes.

CAUTION:To avoid birdnesting and premature failure of the wire rope, alwayskeep tension on the wire rope when winding or unwinding.

11. Make the hook-up in such a way as to afford an even pull on both wireropes. Over stressing one wire rope can happen if care isn’t taken inhook placement.

12. If a heavy lift or pull is to be madeadditional cable lines may benecessary. Always use morestabilizing lines than pulllines. RIG FOR SAFETY.

13. DO NOT EXCEED THEWORKING LIMIT OF THE WIREROPE. When making a recoveryand pulling to the side, alwaysapply an equal or lesser load inthe opposite direction of the pullto stabilize the load.


Page 72

14. The use of snatch blocks andmultiple lines will allow you topull, stabilize the recoveryvehicle, and minimize deflectionof the wrecker boom.

15. Push the winch free-spool knobsto the in position to re-engagethe winch. Slowly take up theslack in the wire ropes. Inspectthe hook-up points for slippagebefore continuing the lift or pull.Manually control each winch toensure wire ropes are stressedevenly. As the wire rope isretrieved, be sure it doesn’t criss-cross on the spool.

WARNING:When swinging a load, watch out for centrifugal force. As youswing a load this force will cause the load to swing away from themachine and may cause instability.

DANGER:Do not swing the wrecker boom without extending the outrigger/stabilizers.


Page 73

16. Complete the lift or pull beingsure the work is placed in a stablelocation where it won’t slip or roll.If there is any question aboutstability, use blocks or tie thework down before removing wirerope and chains.

17. Using the winch controls, unwindenough wire rope to remove thehooks or chains and removethem carefully. Avoid straddlingthe wire rope.

18. Respool both wire ropes andtake this opportunity to inspectthem for damage. Keep tensionon the wire rope whilerespooling.

19. Retract and lower the boom tonormal horizontal position andcarefully snug up any loose wirerope.

CAUTION:Don’t stress the wire rope by overretrieving or tightening andexceeding the working limit. Overstressing the wire rope beyondits working limit can causedamage resulting in prematurewire rope failure.


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THIS PAGE INTENTIONALLY LEFT BLANK

5-376-000094REV. 3 - 03/10 Section III: Maintnenace

Page 75

MAINTENANCE AND LUBRICATION

Your HDR has been designed to give you excellent service and long life butlike all equipment, it requires proper and periodic maintenance. The truckchassis itself is on a maintenance schedule recommended by themanufacturer. Follow these guidelines and protect your vehicle warranty.There are a number of different lubricants used on your HDR. The followingLubricant Chart shows the proper lubricant and the most common brandsand specification which meet the requirements.

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

Inspect your vehicle and wheel lift system periodically for damage or evidenceof pending failure. Damaged or broken parts should be replaced immediately.Never operate the carrier or any of its components if they are defective oroperating improperly. The cause of any binding or leakage should bedetermined immediately and the problem promptly fixed.

Critical wear points on your HDR must be lubricated at regular intervals.Sliding surfaces are to be cleaned and coated with a heavy greaseperiodically. Cleaning every month is recommended for normal highwayoperations, but this frequency will vary appreciably with the type of service.Sliding on dirty wear surfaces will cause rapid wear. Fittings on linkagepivots should be greased with an anti-seize lubricate every two (2) months,again depending upon usage. The turntable bearing should be greased witha general purpose lithium based grease every two (2) months.The turntablegear should be greased with an open gear lubricant every two (2) months.The following chart and diagram shows the location of these points, andwhen and what type of lubricant to use.

Check the hydraulic oil level bi-monthly or after any leakage. A sight glasshas been provided on the hydraulic tank. The proper oil level is best checkedwith all cylinders fully retracted. Use a Super Premium Grade Multi-Viscosityhydraulic oil. (See Chart) (Automatic transmission fluid may be used in thehydraulic system if necessary.)

The hydraulic filters located on the return side of the hydraulic tank comeequipped with restriction indicator gauges. The gauge shows the conditionof the filter element. When the needle reaches the red band (25 psi), thefilter is starting to bypass and the element needs to be changed. Failure to

MAINTENANCE

5-376-000094REV. 3 - 03/10Section III: Maintenance

Page 76

change the filter element will result in premature wear and/or failure of anyor all of the hydraulic components.Only check gauge when hydraulicfluid is at operating temperature. Cold oil is more dense and willgive a false indicator gauge reading.

Cold temperatures can cause hydraulic oils to thicken and adversely affectthe hydraulic functions of your carrier. If this is the case, it will be necessaryto change the hydraulic oil to maintain maximum system efficiency. Ahydraulic oil such as Mobil DTE 11M or Conoco AW Hydraulic Fluid MV 32can be used to replace the factory installed oil or it can be added to thehydraulic oil in your factory system.

If a cylinder seal leaks, disassemble the cylinder and find the cause of theleak. Small scores caused by chips or contaminated fluid can usually beworked out with fine emery cloth to avoid repetition of the trouble. Wheneverany seal replacement is necessary, it is always advisable to replace allseals in that component. These seals are available in kits. Also, thoroughlyclean all components before reassembly.

The HDR and over components are mounted to the truck chassis by bolts.We recommend that these bolts be inspected within the first 30 days andinspected and retorqed every 90 days thereafter. Replace any broken ordamaged bolts immediately. Refer to chart on the following page.

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


Page 77

• All torque values shown are for bolts (cap screws) and nuts that are either zinc-plated or lubricated.

• Torques shown above apply only to screws and nuts used for assembly andinstallation of all carrier components, not to the chassis.

• Different torque values may be given in instructions for certain components due toshort thread engagement or low-strength internal threads.

• When nuts are used, tighten nuts to torques shown (screws or bolts should beheld but not turned). Always use a calibrated torque wrench.

• Retighten nuts of all mounting screws that secure the carrier and carrier-bodywithin 30 days after putting the vehicle into service. Thereafter, inspect andretorque such screws and nuts every 90 days and after each job that imposesextremely heavy loads on the equipment.

• Convert ft/lbs to Nm (Newton metres) by using the following formula:Multiply: by: to get:ft/lbs x 1.3558 = Nm (Newton metres)

FASTENER TORQUE SPECIFICATIONS


Page 78

OILS AND GREASES

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

Company Product

HYDRAULIC OILS

1. Chevron AW Hydraulic Oil MV2. Exxon Univis N323. Mobil DTE134. Texaco Rando HDZ-325. Shell Tellus Oil T 326. Citgo A/W All Temp7. Amoco Rycon Oil 328. Conoco AW Hydraulic Fluid MV 469. Mobil DTE11M

(for cold weather use)10. Conoco AW Hydraulic Fluid MV 32

(for cold weather use)

GREASES

1. Drydene HD Lithium EP22. Gulf Crown EP23. Amoco Amolith EP24. Shell Alvania EP25. Texaco Marfax EP26. Mobil Mobilux EP27. 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 forcold weather use)


Page 79

WIRE ROPE HANDLING AND INSPECTION

A new wire rope requires a break in period. Run the wire rope throughseveral 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 thewinch drum. A loose wire rope on the winch drum will cause crushing of thewire rope when heavy loads are applied.

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

WARNINGWARNINGWARNINGWARNINGWARNINGWire Rope WILL FAIL if worn-out, overloaded, damaged, improperlymaintained or abused.

Wire rope failure may cause serious injury or death!

Protect yourself and other:• 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 andREGULATIONS for INSPECTION REQUIREMENTS andREMOVAL CRITERIA.


Page 80

It is good practice , where the equipment is consistently in use, to give therope a certain length of service, several hundred hours, several weeks ormonths and then renew the rope regardless of it's condition. This methodeliminates 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 furtheruse of the wire rope would constitute a safety hazard.

There are certain points along any given rope which should be given moreattention than others, since some areas will be subjected to greater stresses,forces, and hazards. Some of these areas include at the winch drum, at theboom sheaves and at the end attachments.

All products are subject to age, wear and deterioration, all of which cause areduction in the products breaking strength capacity.

Probably the most common sign of rope deterioration and approaching failureis broken wires. Inspection criteria are specific as to the number of brokenwires allowable under various circumstances. It is important that a diligentsearch be made for broken wires, particularly in critical areas. Inspection ofwire rope ends should include hooks and thimbles.

Replace any wire ropes that have been abraded, crushed, kinked or twisted.

Wire rope should be routinely cleaned monthly of any and all debris. Gritand gravel can quickly reduce a wire ropes life. A wire rope should be welllubricated so that it can act and perform as it was designed. Lubricationkeeps a wire rope flexible and free from rust.

Consult the manufacturer or your local distributor for the proper replacementwire rope.


Page 81

HDR70/85 - 530LUBRICATION POINTS

The following lubrication charts are located inside the tool box door on thedriver’s side of the HDR body.

643

INTERVAL

(HOURS)

REF

NO.IDENTIFICATION SERVICE LUBRICANT

NO. OF

POINTS

WEEKLY 1 CABLE OIL ENGINE OIL 5

2 WINCH GEAR BOX CHECK 5

3 NYLATRON PADS COAT 4

4WINCH CASE

BREATHERSCHECK 5

5 BOOM PIVOT LUBE NEVER-SEEZ 1

6WRECKER BOOM

LIFT CYLINDERLUBE NEVER-SEEZ 4

7 BASE/MID BOOM LUBE MPG 10

8 "D" - RING LUBE MPG 12

9 SHEAVE HEAD LUBE MPG 5

10 SHEAVE PIN LUBE MPG 5

11UNDERLIFT

LIFT BOOMLUBE MPG 2

12UNDERLIFT

LIFT CYLINDERLUBE MPG 2

13UNDERLIFT

TILIT CYLINDERLUBE MPG 2

14UNDERLIFT

PIVOTLUBE MPG 3

15UNDERLIFT

EXTEND CYLINDERLUBE MPG 1

16CROSSTUBE

PIVOTLUBE MPG 1

17SPADE

EXTEND CYLINDERLUBE MPG 4

18SPADE CLAW

PIVOTLUBE MPG 2

19HYDRAULIC

RESERVOIRCHECK 1

20CONTROL VALVE

HANDLESCLEAN & OIL ENGINE OIL ALL

21 CAM LOCK LUBE MPG 4

22TURNTABLE

BEARINGLUBE

MOBILUX

EP24

23TURNTABLE

GEARLUBE

MOBITAC

375 NC1

24HYDRAULIC

FILTERCHANGE 3

25 MAGNETIC PLUG CLEAN & OIL 1

26TURNTABLE

GEAR DRIVECHECK 1

LUBRICATION CHART

MPG

50 OR

EVERY TWO

MONTHS

1000

OR

YEARLY

100

OR

MONTHLY

50 OR

TWICE

A MONTH


Page 82

HDR70/85 - 530LUBRICATION POINTS

1

2

3

45

6

6

89

10

11

12

13

14

15

17

17

18

LU

BR

ICA

TIO

N C

HA

RT

16

7

23

22

9

21

19 24

25

26

NOTES:

1: USE DUAL RANGE HYDRAULIC FLUID 5W20 (AUTOMATIC

TRANSMISSION FLUID CAN BE SUBSTITUTED IF NECESSARY)

2: USE GREASE GUN WITH NEEDLE NOSE ADAPTER TO SQUIRT

GREASE ONTO TOP AND BOTTOM OF BOOM INTERIOR WHERE WEAR PADS RUN

3: ROTATE BEARING WHILE APPLYING GREASE TO ALL (4) GREASE FITTINGS

4: OPTIONAL EQUIPMENT

NOTE:3

NOTE:2

NOTE:1

88

1

10

10

9

8

2

4

2

4

NOTE:4

NOTE:4

NOTE:4

NOTE:4

NOTE:4

NOTE:4

NOTE:4

NOTE:4

NOTE:4

NOTE:4


Page 83

TROUBLE SHOOTING

You probably won’t require anything but preventive maintenance to keepyour HDR running, however, the following chart should help you isolate andcorrect minor problems if they occur with use. Any service work on thehydraulic 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 level and fill with thespecified oil

c. Blocked or restricted hose c. Inspect: remove blockaged. Dirty hydraulic oil d. Drain, flush and refill with

clean oil, replace filtere. Hydraulic pump worn e. Rebuild or replacef . Frozen hydraulic lines f . Thaw and remove water

Valve handle sticks a. Insufficient lubrication a. Lubricate per lube charttight or frozen

b. Broken centering spring b. Inspect, clean or replaceor clogged with foreignmaterial

Valve leaks a. Defective seals a. Inspect and replaceCylinder leaks a. Defective seals or rods a. Inspect and replaceErratic cylinder a. Air in the system a. Cycle hydraulic system 10 tofunction 15 times to remove air

b. Defective pump (pulsating) b. Replace if necessaryRemote hand a. Electric power turned off a. Turn on CONTROL powercontroller fails to switch in cabrespond b. Discharged battery b. Charge battery

c. Defective battery c. Replaced. Emergency - Off switch d. Release/pull switch on

depressed transmitter


Page 84

TROUBLESHOOTING

P.T.O. FUNCTIONING IMPROPERLY

Problem Cause Solution Cable tight or frozen a. Cable kinked or bent a. Straighten or replace

b. Cable and PTO connection b. Inspect and adjustnot adjusted properly

c. Mounting bracket nuts are c. Loosen if necessaryover tightened at P.T.O.

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 P.T.O. a. P.T.O. backlash too tight a. Shims must be added(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 PTO connection a. Inspect and adjust or disengage not adjusted properly

b. Defective shifter cover b.Inspect and replace

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 filterd. Restriction in suction line d. Clean out and removee. Pump worn e. Repair or replace

Pump slow or fails a. Low oil supply a. Fill to proper level to respond b. Cold Thick Oil b. Drain and refill with a low

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

relief valve filterb. Using too light oil b. Drain and refill with clean oilc. Dirty oil c. Drain, flush and refill with

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

Oil foaming a. Air leaking into suction line a. Tighten all connectionsb. Wrong kind of oil b. Drain and refill with

non-foaming type of hydraulicoil (See lube chart)Replace filter

c. Oil level too low c. Refill to proper level


Page 85

TROUBLESHOOTING

HYDRAULIC PUMP

Problem Cause Solution Hydraulic oil leak a. Defective shaft seal a. Replace shaft seal between P.T.O. and pump Pump leaks at front a. Defective seals a. Replace seals and rear covers

WINCH FUNCTIONING IMPROPERLY

Problem Cause SolutionWinch screeches a. Insufficient lubrication a. Lubricate per lube chartduring operationWinch will not pull a. Free-spooling device a. Engageload or take in wire not engagedrope

b. Sheared keys or broken b. Inspect or replacecoupling

c. Hydraulic pump worn c. Inspect and replace Free-spool device a. No air pressure a. Turn truck on

b. Insufficient air pressure b. Allow truck to runc. Defective pressure switch c. Inspect and replaced. Leaking air line d. Inspect and replace

Cable tensioner a. No air pressure a. Turn truck ondevice non-functional b. Insufficient air pressure b. Allow truck to run

c. Defective pressure switch c. Inspect and replaced. Leaking air line d. Inspect and replace

Cable speed shift a. No air pressure a. Turn truck onnonfunctional b. Insufficient air pressure b. Allow truck to run

c. Defective pressure switch c. Inspect and replaced. Leaking air line d. Inspect and replace


Page 86

TROUBLESHOOTING

BOOM SLEW FUNCTIONING IMPROPERLY

Problem Cause SolutionBoom will not a. Slew locking pin engaged a. Disengage locking pinrotate b. Swing brake control valve b. Inspect: remove blockage

clogged with foreignmaterial

c. Faulty swing brake control c. Replacevalve

Slew locking pin will a. No air pressure a. Turn truck onnot engage b. Insufficient air pressure b. Allow truck to run

c. Defective pressure switch c. Inspect and replaced. Leaking air line d. Inspect and replacee. Defective air cylinder e. Inspect and replacef . Jammed locking pin f . Inspect and replaceg. Ice buildup on pin and/or g. Thaw

air cylinder Slew locking pin will a. No air pressure a. Turn truck on not disengage b. Insufficient air pressure b. Allow truck to run

c. Defective pressure switch c. Inspect and replaced. Leaking air line d. Inspect and replacee. Defective air cylinder e. Inspect and replacef. Jammed locking pin f . Inspect and replaceg. Ice buildup on pin and/or g. Thaw

air cylinder Slew lock indicator a. Limit switch out of a. Inspect: adjust light stays illuminated adjustment

b. Ice buildup on limit switch b. Thawc. Defective limit switch c. Inspect and replaced. Locking pin is not d. Disengage locking pin

disengagede. Electrical circuit wiring e. Check/repair electrical wiring

problem circuit Slew lock indicator a. Limit switch out of a. Inspect: adjust light will not illuminate adjustment

b. Ice buildup on limit switch b. Thawc. Defective limit switch c. Inspect and replaced. Locking pin is not d. Engage locking pin

engagede. Electrical circuit wiring e. Check/repair electrical wiring

problem circuitf . Defective controls f . Check, repair or replace

compartment dooractivation switch

g. Indicator light burned out g. Repair or replace

5-376-000094REV. 3 - 03/10 Section IV: Glossary

Page 87

AAnchoring 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 toassist the tow truck's brakes in retarding or stopping both vehicles.

Auxiliary Equipment - Equipment that is not necessary to perform the basicfunction of the primary equipment.

Auxiliary Towing Lights - Stop, tail, and turn signal lights attached to the trailingend of the towed vehicle and operated as part of the towing vehicle lightingsystem.

BBending 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 thatcarries the load.

Body Hinge - The attachment mechanism connecting the body to the hinge pinat 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 linethrough the boom pivot and center of sheave.

Boom Head - The structural member at one end of the boom which can swiveland support the load lifted through the sheave and sheave support device.

GLOSSARY OF TERMS

5-376-000094REV. 3 - 03/10Section IV: Glossary

Page 88

Boom Length - The straight line distance from center of the revolving base to thecenter of the boom head.

Brakes - Parking - A system used to hold a stopped machine in a stationaryposition.

Brakes - Service - A primary brake system used for retarding and stopping thetruck.

Bumper - DOT - A bumper designed to provide rear-end protection that meetsthe requirements of FMCSR 393.86.

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

CCA (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, wouldbalance vertically, horizontally, and laterally.

CT (Cab to Tandem) - The distance from the back of the truck cab to a pointmidway between the tandem axles.

Cable - Steel wire rope used for pulling.

Car Carrier - Vehicles equipped to transport other vehicles mounted on a flatplatform and/or with an additional assembly attached to the rear to facilitatetowing 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 thatmight result in minor injury or property damage.


Page 89

Certification Label - Required by Public Law 89-563, which states that a motorvehicle or item of motor vehicle equipment complies with all applicableFederal Motor Vehicle Safety Standards (FMVSS) in effect on the date ofmanufacture.

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 runninggear, but lacking a body or load-carrying structure.

Completed Vehicle - A vehicle that requires no further manufacturing operationsto perform its intended function, other than minor finishing operations suchas painting.

Component - Any part 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 awheel-lift or underlift for attaching towing accessories.

Curb Side - The right or passenger side of the vehicle when viewed from therear, opposite side from ROADSIDE.

Curb Weight - The weight of a vehicle in operational status, with all standardand commonly installed equipment and the fuel tank(s) filled to capacity.

Cylinder - A device which converts fluid power into a linear mechanical force andmotion usually consisting of a movable piston and piston rod within a cylinderbore.

DDANGER - 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 thetowed vehicle.


Page 90

DOT (Department of Transportation) - A federal agency dealing with regulationsconcerning both the manufacture and operation of motor vehicles and motorvehicle equipment. See NHTSA.

Driveline - The driveshaft and associated joints.

Drum - Any spool on which are wrapped ropes used in machine operation.

EExtend Cylinder - Cylinders used to extend or retract boom structures.

FFilter- 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 suchmanufacturing operations on an incomplete vehicle that it becomes acompleted (end-user) vehicle.

FMVSS (Federal Motor Vehicle Safety Standards) - Regulations promulgatedby NHTSA under Public Law 89-563, which are mandatory and must becomplied with when motor vehicles or items of motor vehicle equipment aremanufactured 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 chassisframe as modified for body installation.

Frame Lift - See Underlift.

Frame Section Modulus - The engineering term that indicates the relativestrength of frames as it relates to shape. It takes into account frame depth,flange width, and material thickness. All other things being equal, the framewith 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 onthe end of the wire rope while the winch is stationary. The drum isdisconnected (declutched) from its powertrain during this operation.


Page 91

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 tooutside behind the cab.

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

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

GCWR (Gross Combination Weight Rating) - Represents the entire weight of avehicle on the ground with a trailer or trailers including vehicle, equipment,driver, fuel, and payload (everything that moves with the vehicle.) Grosscombination weights published represent maximum allowed.

Grab Hook - For use with chains and some tow-sling hookups.

Grid - A device that attaches to the lift bar for engaging the tires of a towed vehicle.

GVWR (Gross Vehicle 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 themaximum loaded weight of a single vehicle including all equipment, fuel,body, payload, driver, etc.

HHeadboard - Structure on which an emergency light bar is mounted.

Hook-up Chains - Length of chain used to connect a recovery vehicle to a casualtyvehicle.

Horizontal Center of Gravity (HCG) - The point at which half of the gross weightis forward and half is aft.

Hydraulic Control Valve - A mechanical device to divert or control the flow of fluidin a hydraulic system.

Hydraulic Hose - Flexible oil lines used to transmit fluid.


Page 92

Hydraulic Oil - Fluid used in operation of hydraulic systems.

Hydraulic Relief Valve - A mechanical device used to limit the pressure in ahydraulic circuit.

IIncomplete Vehicle - As assemblage consisting, as a minimum, of a frame and

chassis structure, powertrain, steering system, suspension system andbraking system to the extent that those systems are to be part of the completevehicle 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 asa complete unit.

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

LL-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 awheel-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 localordinances.


Page 93

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-loadengine speed, with specified lagging diameter.

Line Speed - Speed in feet per minute of a single rope, based on full load enginespeed with specified lagging diameter.

MMarker 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 andcargo.

Motor - A rotary motion device which changes hydraulic energy into mechanicalenergy.

Motor Vehicle Safety Standards - See FMVSS.

Mud Flap - Splash-Deflecting shields at rear of wheel.

NNHTSA (National Highway Traffic Safety Administration) - The federal agency

responsible for promulgating and insuring compliance of regulations dealingwith the manufacture and certification of motor vehicles or items of motorvehicle equipment. See DOT.

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

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

Overall Vehicle Height - Distance from the ground to the highest point on thevehicle with equipment in stowed position.


Page 94

Overall Vehicle Width - The design dimension ot the widest part of the vehicle,exclusive of signal lamps, outside rearview mirrors, flexible fenderextensions, and mud flaps, determined with doors and windows closedand the wheel in the straight ahead position.

Overhang - The horizontal distance for the centerline of a single rear axle orcenter point of a tandem rear axle to a point where the vertical component isimposed.

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

computed by subtracting the completed weight of the vehicle (includingdriver 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 toauxiliary equipment. Power takeoffs can be mounted on either a main orauxiliary transmission. Front mounted and flywheel mounted power takeoffsare also used in various applications.

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

RRating - 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 ortowed.

Recovery Vehicle - Vehicle to retrieve and if necessary lift and tow other vehicles.

Resisting Bending Moment (RBM) - A calculation used to compare frames ofdifferent section modulus and of different material. It is the product of thesection modulus times the yield strength of the frame material.


Page 95

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 rollingon wheels.

Rollback - See Car Carrier

Rope - See Wire Rope

Rub Rail - Member running longitudinally providing rub service on side of body.

SSAE - Society of Automotive Engineers.

Safety Chain(s) - Used to connect the towing and towed vehicle as a secondarycoupling system to prevent separation of a vehicle trailer, converter dolly, ortowed vehicle, should the primary coupling become detached.

Safety Wrap - Wrapping the tow chain(s) around the grab hooks of the tow barinboard of chain.

Scotch Blocks - A device used to prevent chassis movement.

Serial Number - An identification number stamped on a metal plate by thepassenger car, van, or truck manufacturer (see VIN), or the towing equipmentmanufacturer, and placed on chassis, body, or components for identificationpurposes.

Sheave - A wheel grooved for a wire rope to transfer power.

Shipping Weight - The dry weight of a complete truck with all standard equipmentincluding grease and oil but without and fuel or coolant.

Side Rail - Horizontal extensions of the body sides, either sheet or tubular metal.

Slew - A rotating super structure about a vertical axis.

Snatch Block - A single or multiple pulley used to reduce line tension or changecable direction.

Spacer Blocks - Used in conjunction with wood beams to provide additionalclearance between the tow bar, chains, and the body of the casualty vehicle.


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Spade - One or more ground penetrating devices designed primarily, whenused, 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 downto the ground for improved stability.

Steering Wheel Securing Device - Used to secure front wheels in lieu of standardsteering column lock.

Stroke - The length of travel of a cylinder rod or piston.

Suction Line - A tubular connection line to convey fluid between a reservoir ortank and the inlet of a hydraulic pump.

Supply Tank - An oil reservoir used in the hydraulic system.

Swivel Head - See Boom Head.

TT-Hook - Attachment device used for towing.

Tail Plate - Rearmost part of the towing vehicle body.

Tail Swing - Clearance distance from center of rotation to the extreme rearextension of the revolving superstructure.

Tie-Down Assemblies - Device(s) used to restrain cargo or vehicles (i.e., strap,bridle, chain, or cable.)

Tie-Down Chains - Chains used to restrain cargo or vehicles.

Tilt Cylinder - Cylinders used to change the attitude of a structure or body.

Tire Clearance - Necessary space between tires and the nearest component toallow operation of truck without damage to tires.

Tire Lift - A device used for towing vehicles by lifting one end of the towed vehicleby the wheels.

Tow - Act of transporting a vehicle form one point to another by a second vehicle.

Towed Vehicle - The vehicle being towed.


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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 loadsupported on rubber straps.

Tow Vehicle - Vehicle used to lift-tow other vehicles.

Towing Light/Bar - See Auxiliary Towing Lights.

Trailer 5th Wheel Plate - A plate attached to a tow truck-lifting device that captivatesthe kingpin on trailers allowing a trailer to be towed in the same manner asintended by the trailer manufacturer.

UUnderlift - A device used for towing vehicles by lifting one end of the towed

vehicle from under the axle or structural member.

Unloaded Vehicle Weight - The weight of a vehicle with maximum capacity of allfluids necessary for operation of the vehicle, but without cargo or occupants.Also referred to as curb weight.

VValve - A device which controls fluid flow direction, pressure, or flow rate.

VIN (Vehicle Identification Number) - The number assigned to a vehicle by themanufacturer primarily for registration purposes. It may consist of numerals,letters, or a combination thereof.

WWARNING - A signal word used when a potentially hazardous situation exists

and could result in death or serious injury.

Weight Distribution - The portion of total weight of the vehicle on each axle.


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Wheel Arm - A device that attaches to the lift bar for engaging the tires of a towedvehicle.

Wheelbase - Horizontal dimension from centerline of front axle to the effectivecenterline of the rear axle(s).

Wheel Chock - A device used to prevent chassis movement.

Wheel Fork - See Wheel Arm.

Wheel-Lift - A device used for towing vehicles by lifting one end of the towedvehicle by the wheels.

Wheel Securing Device - A strap or mechanical device, when attached to the lift-bar, which limits the potential for separation of the towed vehicle from theunderlift, during operating conditions.

Wheel Straps - Used to tie down wheels of the towed vehicle when using wheel-lift, car carrier, or dolly towing equipment to limit the potential for separationof the towed vehicle from the towing apparatus.

Winch - A device for winding and unwinding cable.

Wire Rope - See Cable

Working Load Limit - Minimum breaking strength divided by the factor of safety.

Wrap - A single coil of wire rope wound on a drum.

Wrecker - See Tow Vehicle, or Recovery Vehicle.

manual operación jerrdan hdr 7085

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