Jerr-Dan LIGHT DUTY User manual
•
•
•
Eastern Wrecker Sales Inc
•
•
•
TABLE OF CONTENTS
Warranty .......•..•.••.•...•..••..•................................................................... 0.1
Certification Notice 0.5
Safety ..........•....................................................................................... 1.0
Decal Group 1.5
Operalion ......•.................................•.................................................... 2.0
Maintenance and Lubrication .............••.•••...............•.•......................... 3.0
Lubrication Chart 3.2
Troubleshooting ...................••.....................................................•........ 3.3
Parts ..•..•••...............•.............•..•........................................................... 4.0
Rustler Deck .............•..•........................••.......................................... 4.2
Wrangler Lile Deck ...................................•...................................... 4.3
Viper Deck .......••...........................•...........•...•••.••..............•••............. 4.6-
Final Assembly Basic Unit 4.7
Dual Controls •.............•.•.•............................................................... 4.10
Hydraulic Towbar (1,500 lb.) .4.11
Hydraulic Towbar (with and without IRL) ....•..•............................... .4.14
Hydraulic Wheellift Towbar (with and without IRL) ................••....... 4.15
Lo-Profile Hydraulic Wheellift Towbar (with and without IRL) .4.16
Hydraulic Towbar Wheelgrid Assembly .4.19
Lo-Profile Hydraulic Towbar Wheel grid Assembly .4.22
Hydraulic Components •..•..............••.......•................•..................•... 4.23
Hydraulic Components Hydraulic Towbar •..................................... 4.26
Hydraulic Components Hydraulic Towbar wi1h IRL. .4.27
Ught and Wiring 4.30
Rollback Cylinder •..•....................................•...................•............... 4.32'
Tilt Cylinder .......•••...............................••...•••................................... 4.34
Towbar Cylinder 4.36-
Wheellift Towbar Cylinder 4.36
IRL Cylinder .....................•...................••....•................................... .4.40-
Winch Assembly (6,000 lb. Worm Gear) 4.42
Winch Assembly (6,000 ib. Planetary) 4.43
Dual Controls (ZOO) 4.46
Hydraulic Wheellift Towbar (ZOO) .........•........................................ 4.47
Hydraulic Towbar Wheelgrid Assembly (ZOD) 4.50
Hydraulic Components (ZOO) 4.51
RTL Cylinder (ZOO) 4.54
Wheellift Towbar Cylinder (ZOO) .4.55
Wheellift Cylinder (ZOO) ............................................•................... 4.56
Rev. __ 2
Date 11-15-97
Eastern Wrecker Sales Inc
•••
Eastern Wrecker Sales Inc
LIMITED WARRANTY
Coverage and Procedures
•
~
~R-~"t
~ "I.
-
,
•
..
~
~
..•
/'•••tnl1'~'
JBRR-DAN
lOBO Hykes Road Greencastle. PA 17225
(717) 597-7111
•
•
Like our wheel I~t and car carrier products, Jerr-Dan warranty
programs are designed lor the long haul.
Whether you own a wheel lilt or car carrier, you are assured that your
equipment is of the highest quality, and is covered under this limited
warranty,-
Our one-year unlimited mileage plan is offered lor wheel lilts and car
carriers. This warranty is designed for the most comprehensive protection
of your specific equipment.
WHEEL LIFT:
The Jerr-Dan one-year warranty covers material and workmanship
including the following:
I. Body
11. Substructure
III. Wheel lilt assembly
IV. Wrecker boom assembly
V. Winch and winch components (excluding cable)
VI. Hydraulics
VII. Electrical wiring assembly.
CAR CARRIERS:
The Jerr-Dan one-year warranty covers material and workmanship
including the following:
I. Deck
11.Winch and winch components (excluding cable)
III. Substructure
IV. Hydraulics
V. Electrical wiring assembly
Rev. 2
0.1 Dale 11.15-97
Eastern Wrecker Sales Inc
Procedures for warranty coverage:
1. Conlact Jerr-Dan for the distributor nearesl
you -
GaIl1-80D-926-
9666.
2. If there is not an aulhorized Jerr-Dan warranty service center
I •
nearby, find a convenient, qual~ied non-Jerr-Dan service center and
send in their estimate of repair cost before any work is pertonned
to:
Jerr-Dan Corporation
A Subsidiary
01
Durakon Industries, Inc.
Warranty Department
1080 Hykes Road
Greencastle, PA 17225
Be sure to include your daytime phone number.
3. Authorization lor repairs under this limited warranty will be provided
by telephone within 24 hours of receipl of valid warranly claims.
*4. This outlines the Jerr-Dan One-Year Warranty Plan. For exact
coverages, please consult your limited warranty and/or vehicle
I
service contract. Coverage dollS nol include damages caused by
excessive abuse or consequential damages resu~ing from the lack •
of proper service, maintenance or need for repairs. All plans begin
at original retail purchase date.
•
Rev. 2
0.2
Date 11-15-97
Eastern Wrecker Sales Inc
•
~J'I.-b
,)~+'I.
• I
~ .to
- OJ"
~I,
J-~
.•.•-0.\'
JEREl-DAN
Subsidiary of Durakon Induslries, Inc
10aO Hykes Road Greencastle, PA 17225
(717) 597.7111
•
•
LIMITED WARRANTY
W.nufllCturer'. Warranly. ManufactLl'Br's sole warranty shall be the following, w~ch Distributor
shaD make on behalf at Manufach •• , by conspicuous notice
ill
wr1ting accempanying each
eormaet
Of
memaandLl'n of
sale:
1. W.rranty. Jerf.Dan Corporatial.
rManufad~«") W8Jlants
each new product made by it
to be If. from defects in mat.iar Of
wakmarcship
fa cne
year
Irom
the
dale of
imial sale.,
lease,
rent •• or othef disposition 01 such
product
and agrees only 10 repair or replace at its own
expense, I.O-b. tile place or places of manu\'act •••.e, at manufaclurer's opIion, any part
Of
parts of
the producllCU'ld to be delectiw in matarial or
workmanship.
provided
ManutactU'8l'
Is notified
01
such defect or
defedS
within the one
year
warrantY period and ~n I
rBilsonabie
time to
conect the defect.
In
no case. shaA the warranty extend 10
defedS
in materials, c:omponenl.s, or
services
bristled
by
ttird
perties. Detects caused
by
dlemica! action. or the presence
ol
abrasive materials and delects arising following the operation beyond rated capacity or the
imprcper use or application
01
any Products shall not be oonsidefed defects within lhe seope 01
the loregcing warrWlty. If any repairs or alterations are made Of any parts at. replaced durirg the
period covered by any warranty &bow mentioned
by
other than an authorized Manurach .•.••..s
DistrbJtor in accordan09 with authotized MlWlUfactlJ'er's s.vice manuals or with other than parts,
ac:c.sorils, Of allacrm.-rts authorized by
Mam.llaeturer lor
use In Its
products. aJSlomer
shall
pay ler all such repairs. or parts without
r8OOUl'S8
against
Manu1acll.J'er,
and
Maratfllchl'el'
shall
be re&8Y9d ot ,esponsibility for hJfillmenI 01 this wananty with respect 10 pans
Of oorTlponarrtS
of
all repairs, alt.-ations or rll'lac:ernenlS so
made.
No daims for labor shal be
c:onsIdeted unless
._eel
by
M_.e .
2.
Dlac"hn.r •• to CDn.~uantlal or Spacial lhimav••.
Under no circunstances
shall
Mll'lufaclu'. be liable Icr any consequential or special damage wtict\ any
p61'son. finn.
COt'porBlion.or olhar entity may
suff.
or daim to
sutt.
or
inl:::u'IX
dBim 10 incur as 8 result 01any
dB1ed in the pradud or in
afToJ
corTKtion or alt.alion thereof
mad.
or
funished
by
Manuf8C1l1'er
or at"s. 'ConHqUlnti.r or 'special dl.mages' as used herein
indlJdes
but is not limited to costs
oIliatspJIbiliCll,
lost sales.
1051orders. lost
profits.
lost in:::ome,
increased OV8l'head, labor and
material costs end cost
of
rnantA'actucingvariances and qlOfational
inefficiencies.
3. Mulmum Liability. The mllXimtnl liability of
ManufBClll'al' undet It.
exclusive
warranty
set
fr;rth netan
shallbe
the
am(U'ltpaid to
Manulacttl'.
by thevendor01the ~nl with
rasped
10 the product 10 which
s.ueh
vendOf warranty
applies.
4. LlmtiMion 01 LIability. The limitation of liability provisions hefein shall apply to any and
ell c1Bims or suits brought againsl Manu1actlJ'9l'. including any daim based upon negligence,
breach 01conlract, breach ~ warranty. s1rid liability or any olher theories ~n which liability may
be asserted against ManufaetlJ'er •
Rev. 2
0.3
Dale 11-15.97
Eastern Wrecker Sales Inc
5. EKlu8lv. and EntIN Warnntr. The wam.nt)' eonsaitutN MWIl,acturer' • .,t1re""""" lIS
to the product and k
It
expr.aatyo agtMd
hlI
h r.mecles
d
dealer and those ~
&rider
climer
88 Blated~ INs wamriy.,.
exdUlive.
Mar"dacturtf cbM
noll
aaatm.
(and
t.
not.uIhoriDd
enr
oIhtr ptreon to
assOO'It
on ttl
behalf)
In'f
other wamr.nty Of
liabiity
in ••••••
",tioI.
VIft1h
8tf/
pfOdld
covered
by
Ilia wananIV.
MANUFACTURER ~ Y DISClAIMS
AI«
AND AU. OTHER wARIWITES OF
my
KNl
WHATSOEVER AS TOTHE PRODUCT FURNISHED HEREUNOER, INClUDING BUT NOT UMITED
TO EXPRESS OR IMl'lIEll WARRANTIES AS TO MERCHANTAIIIUTY. FITNESS FOR
PARTICULAR PURPOSES SOlD. DESCRIPTION OR CUAlITY OF THE PROOUCT FURNISHED
HEREUNDER.
•• Noue.
0'
Occurnnce. TtU WIll1Wlt';'IhaII b. vokt II, ~ the oocun--=- ci In)'
IncIdtnI
InvoMng
lint
produd made
by
u.nutaeturer, and,.wtlng In arJf pereonllllr$JrV
Of
Prq:lMty d.mage,
cusklmer ahaI tail 10 notify Manufadu"If wit!W1 2. h::JUls of lIUCh
oc:cun"'"
Of permit
M.nufllCkirw
audit
r.NlftaUvM
10 have
In'lfMciate
lM:lCeSSto such
product
and
to
aU
reocwda
cf and witNn the
contrd ci
the cus&amer and/or
cklI'ibi.*H'
r.taIing 10
fie product
and till
ClCCU1WICe.
7, fUlng of Warrantr Claim. Upon notifying !hi Manufadt.nf d • falh.•.•• Ihe Manufw::lurw or
Ib rtpleMnte!tve 'NIl velbaly euttoize and con&nn by
lea" •.••
f'peIra 10 b. made.
V-.baI
euthorizadon will
r.,.
IN: tollowlng
I""""tlon:
A) Owrwr's name and t81ephcne ntnblM'.
B) The d8a1er'. nama from whom
it
was ~
C) The Menufacturat.
ri
MriaJ
nlmb.r.
D) Taleophonltrunber of'" party making the repairs.
E) The part runbeB nelKled to
mBka
.-.pai•.•.
F) Owner to be lnformMf of C.O.D. on
palla,
50% 10
U8l.I'e
retum of
dtf~
parts.
Allhi. lime, tht
Manuf.cturlf
wiDsNp •• eoon 8!1 practlCIIIIhe parts neldtd 10
mea
Ihe c.pair.
Irduded wilh the parts willbe !he Invoica tor 1ha parts and • FMquat tor Warranly form, with the
Wasrarly Retum Tegs.
The vehlde OMMrldlaNr wiI compIet.1he Re<past lor
WarrlU"Ily
Iorm and the Wamny RItUm TIG
rnatbd -R.tum wilh SNpping
Notict;.-
80tl
docunents should be a1IBchad10the
m~
i'dcI
and
returned to !he Matdaclur",
by
mail. The parte to
b.
relumed
shill
be tagged with the Warrwttt
Rltwn Tag (mot.1han one pert pertaIrq to fl. sam. wenWllydan shd be Idenlililld with •• same
waJTBfIty
daim
mmbilr-fMl'
nN"
on
WarrIr'ltY Return Tag).
NJ paIb
WldIlf INs
cWm •••
be
,.turned to d'\e Uanufacturer
pt'.pakt
for
W8IJlIf'Ity walualion.
Upon raceivlng the pert
Ofparb
for
~ty
waiLmlion, the pert
will
be
mp.cted
11M limed. Aft.
bIIng
Insped~
and lest.c:l, the
deds&on
to honor or deny
W8IJWIty
dtIm
shall be
baed
on -wyais
01 all availabl.
lnIonnabon.
When warranty is
hcr1I:nd.
the Manufadurer.
wiI
(I"mbur~ Ihe
ownecldMler
in the
.mowlt agrMd
10 by
both
partI •••
" warranty Ia denied, the owner and diatribtJlOf will be
noIiMd
in wribng
cI fie
dKision and a
flAl
'lI;llanabon fOf the decision
MIl
b.
given.
a.
~urer may at e.rrt
tim.
amend the Ioregoinll form of
WilflWlty
wilhoUl prtor notlc ••
Rev. 2
•
•
•
0.4
Date 11-15-97
Eastern Wrecker Sales Inc
•
•
•
NOTICE
MANUFACTUREDBY:
DATE OF MANUFACTURE __ mo.----Yf.
I/ICOMPLETE VEHICLE MANUFACTUREDBY:
DATE
11'1:.
VEH. MFD. __ mo. ----Yf •
GVWR
GAWR FROm with
tires.
___ oms, 0 __ psi cold
GAWA ItfTERMEDIATE
(1)
with
tires,
___ rims, C __ psi cold
GAWR ItfTEAMEDIATE
(2)
with
Dres,
___ oms, 0 __ psi cold
GAWA REAR with
II"",
___ oms. 0 __ psi cold
Confortrdy
d
tile ci'<lSSis-cabto Federal Motor
VeI*:le Safety stanclards,which have been previ-
ously ILly Ce<1rledby Ille I~e velll::le
manuf~er
ex'h1ermedia!e vehCIe manufaeturet,
has not been anect~oo by lreI-s1age rnanulac-
lt'e. The velll::le has been ~eted In accor.
dB..:e with the prior mand..:tlle(s Insln.c1lons.
where appfcable. 1JlIs vehl:te conI~
10
aI
OIher applicable Federal MOIor Ve_ Safety
SlanclardsIn effect lit
__ mo. __ yr.
VEHICLE IDENTIFICATIONNUMBER:
VEHiClE TYPE:
•. _: I.
This certificaUon sticker appears on every -
JerT.Oan
unit mounled on 8 new
c:tlassls
and Is
required
by
law. Jan-Dan Corporation will not certity any unll for 8 capacity
great.r than
lhe
chassis manufacl •• er's specified rating. The capacity ratings of Jerr-Oan
unh.
do not Imply that
vehlel •• can be used w"haul regard to gross vehlel. weight ratings (OVWR) or gros. axle
rating IIm1tM1ons •
Tho
payload canylng eapacity
01
any lruck is dalennined by Ih. GVWR of the cab chassis. lhe
curl>
weight
01
the cab chassis and tho weight ollhe body. Ills Impolianl thai you d8lennlno lhal
your truck has satisfactory carrying capacity and axle ratings for your speclfk appDcatlon. Jarr-
Dan's authorized sales representatives are available to assist you tn thls regard.
Rev. 2
0.5
Dale 11-15-97
Eastern Wrecker Sales Inc
•• •
Eastern Wrecker Sales Inc
•
•
•
SAFETY
Salety is all-important when working with machinery. Accidents
happen when established salety practices have been overlooked.
Read and practice all safety points listed in this manual. salety is
the I riMe responsibility 01 the operator.
1. Read operating and loading instructions thoroughly.
2. Review the Sale Towing Application Rating (S.T .A.A.) placard
located on the headboard 01the deck, and become famDiar with
the loads that your unit can salely transport.
3. Observe all waming decals.
4. Make sure you are. clear 01 oncoming traffic. Dual controls
(driver's side and passenger's side) are standard on all Jerr-
Dan roll back units.
5. Always put bumper on the ground to support the body and truck
frame .
-~
...••...
6. Never exceed the rated capacity 01 the body or truck chassis 01
use tow bar/wheel lift without a vehicle on the deck .
Aev. _
1.0
Date _
Eastern Wrecker Sales Inc
7. Never winch from the side 01the bed. Winch only from the rear
with load in line of winch.
8. Always try to winch from the center 01the load.
9. Maintain winch cable In good condition. Replace when worn,
kinked or frayed. Do not use cable clamps.
•
•
•
1.1
Rev. _
Oalo _
Eastern Wrecker Sales Inc
10. When loading or unloading the deck and operating the winch, make
certain the area behind the load is clear of personnel and obstacles .
o
•
•••
o
\
11. Distribute load evenly on the deck. Do not concentrate the load on
one section of the deck, to the rear of the truck axles, or use tow
bar/wheel lift without a load on the deck .
•
l
•
12. Secure cargo to the deck at both the Iront and rear belore the truck
is driven. Do not rely on the winch as the only means
01
holding
the load •
'.
Rev, _
1.2
Da1e _
Eastern Wrecker Sales Inc
13. Keep alert. Do not be distracted during any operating sequences .
~,
-=.
1"
•
•
•
14. Do not work behind truck with vehicle on deck unless vehicle Is
secured at front of deck. (Do not rely on winch.)
15. Read and follow tow bar instructions for proper towing.
16. Do not exceed tow bar/wheellift ratings. Overloading can cause •
unsafe steering and braking conditions.
17. Always use both wheel straps on wheel lift tow bar.
"I'
•
18. Use separate safety chains from towed vehicle to subframe for
standard low bar and wheel lift tow bar.
Rev. _
1.3
Date _
Eastern Wrecker Sales Inc
•
•
•
19. Insure deck is in the locked position before traveling.
20. Review operato~s pre-transport checklist located on the headboard
01
the deck each time you move a vehicle.
21. Block up deck before performing any service or maintenance work
under deck .
Rev. _
1.4
Date _
Eastern Wrecker Sales Inc
DECAL GROUP
(STANDARD DECAL, RIGHT SIDE)
"'ERR-DAN
(LOGO)
•
•=~'"T.;~
If'_
._--_
.
•r::=r.::.:r.=..
.
-.,
_......••....
-.
.
.:a.:.~
.
_.•... _.••.
..-
.
. U't:*-=."'..:e:':,
~ EO! 'Ii
.<:'>. m
!it
!;
I •. ;: ~
~
~
'
-~
~ ~
@'
-'BRR-DAN
\~
111
~
l......l:ii
• ::a&C.oa;:.-=:.:..r=. -
.
_""""
•....
_.
.I"'_"_~o
--
. __ .1- .
~
"0
~
~
QPE~ATING INSTRUCTIONS
•
'IL~.-
._-_
.
•:==r.::.:::l..
.
-.
............•.. _
.
.==T~
.--"--_~
.e-~o;.:::-..:z:
:I.) .
~~
~,
ill
mmm
d.b-
~ ~ E>1moL
~ j
-'EREI-DAN
.
~~
..
.;-.:.~
.
--
-"'"
...
-..
• :&.Iorr.:l'!Il'\ .•.•••"""~
.__--e;r~
(STANDARD DECAL, LEFT SIDE)
t)
u.-.e.onofriOWl'f
-
•
-
-
-
••
JERR-DAN"
-
•
-
-
•
•••
•
_.
•
.:;r~:r••
_.
"
.-
•
_.
•
,
.
,
....
•• ••
•
•
-••
••
•
,
•••••
-
••
•
•
-- •• ••
•
• I'
--
_
..
_.
••
.
,
--
-
•
•
•
-
-
••
•
_
..
-
-
.
n
.-
••
••
•
•
--
•••
••
•
•
•••••
•••
••
•
• ~_f
••
••
•
•
•
--
-
~.*
••
•
-_
.
-,.
_.
. _m
-
•
"----
-
••
_.
CH&ll.ltoVlM
.s£RR-DAN
DlClmnlllOIU
•
•
--
--
.• IllEATESDJlLIWIil trnl R.1d'. a
-
•
..
-
_
.•
AlJTt)lMIGRDD"".Il,mhtU1lIl.~
--
-
'0
IIJDttS untUIUS( GJOSI_ r.RoIMTtWll
(LUBRICATION CHART)
Rev. _
1.5
O3le _
Eastern Wrecker Sales Inc
•
A
WARNING
5 WRAPS MIN. OF CABLE MUST BE
LEFT ON DRUM TO ACHIEVE
RATED LOAD.
NOT TO BE USED IN THE MOVING
OR LIFTING OF PERSONS.
'02
(WINCH)
CAUTION
OILUVEl.13H AI"-
wmt
CY~DERS
FULLY RETRACTED)
MlIST 8E UAINTAINED
-
(HYDRAULIC OIL LEVEL)
...
(SERIAL NUMBER)
MAN:Jl""'C1UREO
6'1'
~ JS:UU
Vlll""
<~'"',.~~~
C~I!"'CA\lLI rlNN\~t.'I.""1.
~
H" ~ll
,:.)(,,1 NO
S!~L.,; NO
,.'O:.Jll NO
MANUFACTURED BY
JERR.DAN CORPORATION
MFG. UNDER ONE OR MORE
OF THE FOLLOWING PATENTS:
3,430,792 4,239,275
3,450,282 4,353,597
4,368,002
OTHER PATENTS PENDING
•
(PATENT)
•
SLIDE DECK UNTIL
ARROW AUGNS WITH
REO HYD. LEVER
BEFORE TILTING
(DECK ALIGNMENT)
Rev. _
1.6
Date _
Eastern Wrecker Sales Inc
097
-
6
WARNING
6
DO NOT EXCEED
WHEELLI FT/TOWBAR
CAPACITIES AS
OVERLOADING MAY RESULT
IN AN UNSAFE STEERING
AND/OR BRAKING
CONDITION.
6
CAUTION
6
INSTALL
WHEELLIFT/TOWBAR SAFETY
PINS THROUGH HOLES IN
REAR BUMPER ANGLES AND
CORRESPONDING BDOM
LUGS PRIOR TO LEAVING
LOADING SITE.
(WHEEL LIFT WARNING)
a
WARNING
/!i
VEHICLE MUST BE SECURED
TO WHEEl GRID USING BOTH TIE DOWN
STRAPS PRIOR TO lEAVING lOADING SITE .
.
"
-
(WHEEL LIFT WARNING)
~ WARNING ~
FUlLY RETRACT WHEELLIFT
OR TOWBAR BOOlA BEFORE
SLIlING DECK REARWARD.
OTHERWISE DAUAaE COULD
OCCUR TO DECK BEAUS OR
HYDRAULIC CYLINDER ROD.
16.
-
(WHEEL LIFT WARNING)
1.7
•
•
•
Rev. _
Date _
Eastern Wrecker Sales Inc
•• •
Eastern Wrecker Sales Inc
•
••
Eastern Wrecker Sales Inc
Table of contents
