Jerr-Dan MPL40 User manual

5-376-000086
REV. 4 - 07/10 ©2010Jerr-DanCorporation.AllRightsReserved.
MPL40
OPERATIONS AND MAINTENANCE
MANUAL
$35.00
1080HykesRoad
Greencastle,PA17225
Phone[phone]
www.jerr-dan.com

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

5-376-000086
REV. 4 - 07/10 ©2010Jerr-DanCorporation.AllRightsReserved.
FOREWORD
Thismanualisintendedtoserve as a guide to the owner and operatorinthe
safeoperationandoptimum performance of thisJerr-Danequipment.
Establishment of good operating habits and familiarity with the equipment
and its capabilities combined with good judgement are essential.
Beforeattemptingtooperatetheunitcarefullyreadallsectionsofthismanual.
Thismanualisintendedtoserve as a guide to the owner and operatorinthe
safeoperationandoptimum performance of thisJerr-Danequipment.
This manual should be kept with the equipment at all times and referred to
wheneverin doubtofproperoperation.
Informationcontainedin thismanualreflectshowthis vehiclewasbuiltatthe
factory. Modifications or additions by the distributor or owner are not re-
flected in this manual.
Thismanual doesnotincludeoperation andmaintenanceinformationfor the
commercial chassis (IHC, Ford, GM, etc.). This information is provided by
thechassismanufacturer.
When inquiring about operation, maintenance or warranty, please refer to
yourequipment’sSalesOrder Number, Serial NumberandModel Number.
Thisinformationcanbefoundonthe aluminumtagrivetedinsidethe driver’s
side toolbox on the back wall in the upper right corner.
001
001
VEHICLE
IDENT. NO.
MODEL NO.
SERIAL NO.
MANUFACTURED BY
GREENCASTLE, PENNSYLVANIA
An Oshkosh Truck Corporation Company

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Jerr-Dan Corporation strives to provide information that is accurate, com-
plete and useful. All information contained in this manual is as accurate as
knownatthetimeof publication and is subject tochange,withoutnotice,as
aresultofcontinuousproductimprovements.Jerr-Danreservestherightto
amend the information in this document at any time without prior notice.
Shouldyoufindinadequaciesinthe text, please send your comments to the
followingaddress:
Jerr-DanCorporation
Attn: Technical Publications
1080HykesRoad
Greencastle,PA17225
Additional or replacement manuals or replacement safety warning labels
canbeordered by calling Jerr-DanPartsat 717-597-7111. Price andavail-
ability will be quoted at time of the request.
The material in this document is confidential and the property of Jerr-Dan
Corporation. Nopartof this document maybe photocopied, reproduced or
translatedto another language withoutthe express written consentof Jerr-
DanCorporation.
Manufactured under one or more of the following patents: 5,575,606;
5,672,042; 5,697,741; 5,713,714; 5,722,810; 5,782,596; 5,839,755; and
6,315,515B1 with other PatentsPending.
Jerr-Danand theJerr-Danlogoare registeredtrademarksandRun Hardisa
servicemarkofJerr-DanCorporation,Greencastle,PA. USA

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Pagei
LIMITED WARRANTY
Manufacturer's Warranty. Manufacturer's sole warranty shall be the following, which
Distributor shall make on behalf of Manufactuer by conspicuous notice in writing
accompanying each contract or memorandum of sale:
1. Warranty. Jerr-Dan Corporation, ("Manufacturer") warrants each new product made
by it to be free from defects in material or workmanship for one year from the date of
initial sale, lease, rental, or other disposition of such product, and agrees only to repair or
replace at its own expense, f.o.b. the place or places of manufacture, at manufacturer's
option, any part or parts of the product found to be defective in material or workmanship,
provided Manufacturer is notified of such defect or defects within the one year warranty
period and given a reasonable time to correct the defect. In no case, shall the warranty
extend to defects in materials, components, or services furnished by third parties. Defects
caused by chemical action, or the presence of abrasive materials and defects arising
following the operation beyond rated capacity or the improper use or application of any
Products shall not be considered defects within the scope of the foregoing warranty. If any
repairs or alterations are made or any parts are replaced during the period covered by any
warranty above mentioned by other than an authorized Manufacturer's Distributor in
accordance with authorized Manufactuerer's service manuals or with other than parts,
accessories, or attachments authorized by Manufacturer for use in its products, customer
shall pay for all such repairs or parts without recourse against Manufacturer, and Manufacturer
shall be relieved of responsibility for fulfillment of this warranty with respect to parts or
components of all repairs, alterations or replacements so made. No claims for labor shall
be considered unless authorized by Manufacturer.
2. Disclaimer as to Consequential or Special Damages. Under no circumstances
shall Manufacturer be liable for any consequential or special damage which any person,
firm, corporation, or other entity may suffer or claim to suffer or incur or claim to incur as
a result of any defect in the product or in any correction or alteration thereof made or
furnished by Manufacturer or others. "Consequential" or "special damages" as used herein
includes but is not limited to costs of transportation, lost sales, lost orders, lost profits,
lost income, increased overhead, labor and material costs and cost of manufacturing
variances and operational inefficiencies.
3. Maximum Liability. The maximum liability of Manufacturer under the exclusive
warranty set forth herein shall be the amount paid to Manufacturer by the vendor of the
component with respect to the product to which such vendor warranty applies.
4. Limitation of Liability. The limitation of liability provisions herein shall apply to
any and all claims or suits brought against Manufacturer, including any claim based upon
negligence, breach of contract, breach of warranty, strict liability or any other theories
upon which liability may be asserted against Manufacturer.
1080 Hykes Road
Greencastle, PA17225
[phone]
WARRANTY

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5. Exclusive and Entire Warranty. The warranty constitutes Manufacturer's entire
warranty as to the product and it is expressly agreed that the remedies of dealer and those
claiming under dealer as stated in this warranty are exclusive. Manufacturer does not
assume (and has not authorized any other person to assume on its behalf) any other
warranty or liability in connection with any product covered by this warranty.
MANUFACTURER EXPRESSLY DISCLAIMS ANY AND ALL OTHER WARRANTIES OF
ANY KIND WHATSOEVERAS TO THE PRODUCTFURNISHED HEREUNDER, INCLUDING
BUT NOT LIMITEDTO EXPRESS OR IMPLIED WARRANTIESAS TO MERCHANTABILITY,
FITNESS FOR PARTICULAR PURPOSES SOLD, DESCRIPTION OR QUALITY OF THE
PRODUCT FURNISHED HEREUNDER.
6. Notice of Occurrence. This warranty shall be void if, upon the occurrence of any
incident involving any product made by Manufacturer, and resulting in any personal injury
or property damage, customer shall fail to notify Manufacturer within 24 hous of such
occurrence or permit Manufacturer audit representatives to have immediate access to
such product and to all records of and within the control of the customer and/or distributor
relating to the product and the occurrence.
7. Filing of Warranty Claim. Upon notifying the Manufacturer of a failure, the
Manufacturer or its representative will verbally authorize and comfirm by letter the repairs
to be made. Verbal authorization will require the following information:
A) Owner's name and telephone number.
B) The dealer's name from whom it was purchased.
C) The Manufacturer's unit serial number.
D) Telephone number of the party making the repairs.
E) The part numbers needed to make repairs.
F) Owner to be informed of C.O.D. on parts (if deemed necessary) to assure return of
defective parts for manufacturer’s evaluation.
At this time, the Manufacturer will ship as soon as practical the parts needed to make the
repair. Included with the parts will be the invoice for the parts and a Request for Warranty
form, with the Warranty Return Tags.
The vehicle owner/dealer will complete the Request for Warranty form and the Warranty
Return Tag marked "Return with Shipping Notice." Both documents should be attached to
the shippping notice and returned to the Manufacturer by mail. The parts to be returned
shall be tagged with the Warranty Return Tag (more than one part pertaining to the same
warranty claim shall be identified with the same warranty claim number - see number on
Warranty Return Tag). All parts under this claim shall be returned to the Manufacturer pre-
paid for warranty evaluation.
Upon receiving the part or parts for warranty evaluation, the part will be inspected and
tested. After being inspected and tested, the decision to honor or deny warranty claim shall
be based on analysis of all available information.
When warranty is honored, the Manufacturer will reimburse the owner/dealer in the amount
agreed to by both parties.
If warranty is denied, the owner and distributor will be notified in writing of the decision and
a full explanation for the decision will be given.
8.Manufacturer may at any time amend the foregoing form of warranty without prior
notice.

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TABLE OF CONTENTS
Section I: Safety
Safety(General).......................................................................1
Ratings:MPL40 .......................................................................3
SafetyChains ..........................................................................8
Lift Safety ................................................................................9
Boom Safety .......................................................................... 10
Sling Safety ...........................................................................14
SafetyWarning Decals .......................................................... 16
SectionII:Operation
Wheel-Lift .............................................................................19
Tie-DownStraps..................................................................... 25
Wheel Grid Spacers ...............................................................28
TowballHitchAttachment ....................................................... 29
Wrecker Boom - Single Line Boom - Worm Gear Winch .......31
Wrecker Boom - Single Line Boom - Planetary Gear Winch ..37
Wrecker Boom - Dual Line Boom - Worm Gear Winches ......42
Tow Sling (Optional) ............................................................... 48
MotorcycleTowingAdapter(Optional) ....................................58
DollyStorage(Optional) .........................................................65
Dollies(Optional) ...................................................................70
SectionIII:Maintenance
MaintenanceandLubrication .................................................73
Oilsand Greases ...................................................................76
WireRopeHandling and Inspection ....................................... 77
Underlift Level StopAssist System ........................................79
LubricationPoints ..................................................................80
TroubleShooting .................................................................... 81
Hydraulic System ..................................................................81
HydraulicClutch Pump .......................................................... 82
P.T.O. Functioning Improperly ................................................83
HydraulicPump .....................................................................83
WinchFunctioningImproperly................................................84
Section IV: Glossary
Glossary ................................................................................85

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THISPAGEINTENTIONALLYLEFTBLANK

Section I: Safety
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Thesafe operationof your MPL40 is your responsibility.Read this manual
andthetruckmanufacturer’smanual and thoroughly understandthem.You
canbeheldlegallyresponsiblefor injuries or damage resulting from unsafe
operatingpractices.
Our recommendations for operating your equipment can help you avoid
unsafe practices and their bad consequences. These recommendations
are contained in this manual.
Jerr-DanCorporation isnotresponsiblefor theresultsofanyunsafepractice
oftowoperatorsorforthefailureofyourequipmentoritsaccessoriesresulting
fromimproperuse or maintenance.
The danger from a vehicle continues after it is disabled or wrecked.
Recoveringortowing vehiclescanbedangeroustoo! Thedanger threatens
tow operators and everyone else close by. As a tow operator you must
developanawarenessofthehazardsinvolved. Youmustuseeverysafeguard
withinreasonto prevent injuries.
Carefulconsideration of the immediatesurrounding conditions such asthe
weather, terrain, type or condition of the vehicle to be recovered and the
condition and experience of the operator is foremost to the safety and
success of the operation.
Tie-downstrapsareprovidedforusewithyournewJerr-DanRecoveryVehicle.
Periodically inspect all straps for any signs of fatigue or damage. Don’t
overlookthehooks;be sure they have notbeenbentordeformed.Ifstrapor
hook damage is noted, they must be replaced before being used.
Wire rope cables wear out or can become damaged. Periodically inspect
the wire rope cable for any signs of fatigue or damage. Don’t overlook the
hooks; be sure they have not been bent or deformed. Refer to the Wire
Rope Handling and Inspection Section.
Foreachstepinoperatingyourequipmentdevelopthehabitofaskingyourself
"is it safe to proceed?" Carefully check your set up before starting a lift or
tow.
Becauserecoveriescanbesodifferent,wecannotwarnyouofallthepossible
dangersyouwill encounter, butwewilltellyou of themostcommonhazards
thatweknow about. We also recommendthatyou receive specialized and
advancedtrainingfromaprofessionalTowingandRecoveryinstructorbefore
SAFETY

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operatinganyrecoveryequipmentandthattheVehicleManufacturersTowing
Manualand/orAmericanAutomobileAssociation (AAA)Towing Manuals be
usedas a reference for operating safety methods.
AAA address and phone number:
THEAMERICANAUTOMOBILEASSOCIATION
1000AAADrive
Heathrow,FL 32746-9970
[phone]
To alert personnel to hazardous operating practices, safety messages are
usedthroughout the manual. Eachsafety message containsa safety alert
symbol and a signal word to identify the hazard's degree of seriousness.
CAUTION:
Identifies when a potentially hazardous situation exists and may
result in a minor or moderate injury or property damage.
WARNING:
Identifies when a potentially hazardous situation exists and could
result in death or serious injury.
DANGER:
Identifies when an imminently hazardous situation exists and can
result in death or serious injury.

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DO NOT EXCEED THE FOLLOWING RATINGS:
MPL40UnderliftRating .......................................4,000 lbs “L”Arm2
Tow Rating ..................................................................... 7,500 lbs.2
Boom Rating: (Extended)...............................................6,000 lbs.
(Retracted) ............................................16,000 lbs.
Winch Rating: (Ramsey Worm Gear Winches)1 ..................... 8,000 lbs.
(Warn Planetary Gear Winch)1 ......................... 9,000 lbs.
WireRope:
Working Limit ................................................4,100 lbs.
Construction ............................ 6 x 25 EIPS RRL IWRC
Diameter ...........................................................3/8inch
StandardLength ..............................................100Feet
1SAEJ706:SurfaceVehicleRecommendedPractices-RatingofWinches
2SAEJ2512: Surface Vehicle Recommended Practices -Towing
Equipment Ratings and Practices
MAXIMUM LIFTING CAPACITY -THE MAXIMUM LOADTHAT CANBE LIFTED.
GROSSCOMBINED WEIGHT RATING (GCWR)-THEVALUE SPECIFIEDBYTHEVEHICLE
MANUFACTURERASGCW.
GROSSCOMBINED WEIGHT (GCW)-ACTUALWEIGHTOFTHEENTIREVEHICLEAT THE
GROUNDWITHTRAILERORTRAILERS,INCLUDINGVEHICLEEQUIPMENT,DRIVER,PAS-
SENGER,FUELANDPAYLOAD(EVERYTHINGTHATMOVESWITHTHEVEHICLE).

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NOTE
These ratings apply to the structural design of the Standard Duty Carrier only
and may be limited by the axle rating and gross vehicle weight rating of the truck
chassis.
The payload and towing capacity of any towing vehicle must meet the
following:
- The actual payload on the towing vehicle must not exceed the posted
rating and, if applicable, the towed vehicle load must not exceed
the posted lift / towing ratings.
- The total weight of the towing vehicle (cab chassis, body, payload,
driver, passenger(s), tools, fuel, etc.) and, if applicable, the towed
vehicle load must not exceed the GVWR (Gross Vehicle Weight Rating)
of the towing vehicle.
- The total weight of the towing vehicle and, if applicable, the towed
vehicle load must be distributed so that each axle’s GAWR (Gross Axle
Weight Rating) is not exceeded.
- The total weight of the towing vehicle and towed vehicle (everything
that moves with the towing vehicle) must not exceed the GCWR
(Gross Combination Weight Rating) of the towing vehicle.
Staying within these ratings is necessary to maintain the safety and
performance of the towing vehicle.
CHECK TRUCK MANUAL FOR SPECIFIC GVW & AXLE RATINGS. ALSO
REFERENCETHECERTIFICATIONDECALAFFIXEDTODRIVER’SSIDEDOOR
JAMB,HINGEPILLAR ORLATCH POSTANDTHES.T.A.R.PLACARD ONTHE
DRIVER'SSIDEOFTHEHEADBOARD.

Section I: Safety
Page5
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Certification Decal
Affixedto the Driver's Side DoorJam, Hinge Pillar or Latch Post
Providedby the Final StageVehicleManufacturer according toTitle 49
Part567 of the Codeof Federal Regulations (CFR)
MFG BY:_______________________________________
______________________________________________
DATE OF MFR:MO______________YR.______________
GVWR:_________________KG (_________________LB)
GAWR-FRONT:
______________________KG (__________________LB)
WITH____________________________________TIRES,
______________________RIMS,@______________KPA
(___________________PSI) COLD__________________
GAWR-INTERMEDIATE(1):
______________________KG (__________________LB)
WITH____________________________________TIRES,
______________________RIMS,@______________KPA
(___________________PSI) COLD__________________
GAWR-INTERMEDIATE(2):
______________________KG (__________________LB)
WITH____________________________________TIRES,
______________________RIMS,@______________KPA
(___________________PSI) COLD__________________
GAWR-REAR:
______________________KG (__________________LB)
WITH____________________________________TIRES,
______________________RIMS,@______________KPA
(___________________PSI) COLD__________________
MO._______________________YR._________________
VEHICLE IDENTIFICATION NUMBER:
_______________________________________________
VEHICLE TYPE:
_______________________________________________
THIS VEHICLE HAS BEEN COMPLETED IN ACCORDANCE WITH
THE PRIOR MANUFACTURERS' IVD, WHERE APPLICABLE.
THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL
MOTOR VEHICLE SAFETY STANDARDS, [AND BUMPER AND
THEFT PREVENTION STANDARDS, IF APPLICABLE] IN EFFECT IN:

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• Don’t use a recovery vehicle that has not
been properly maintained. Pay special
attention to the mounting bolts, and
lubrication of moving parts.
• Don’toperate the wrecker’s engine faster than
recommended. Excessive speeds can
damage PTO, hydraulic pumps, and winches.
• Don’t pick-up and tow a vehicle that reduces
the weight on the front wheels of the wrecker
more than 50 percent.
• Don’t travel with the PTO or Clutch Pump
engaged. Damage to the trucks transmission,
engine or hydraulic components will occur.
Engage it only while operating the controls.
• After you have hooked up a vehicle for
towing, don’t start the tow until you have
double checked the hook-up, installed safety
chains, and released the parking brakes of
the towed vehicle.
• Don’toperate the wrecker’s engine faster than
recommended. Excessive speeds can
damage PTO, hydraulic pumps, and winches.
• Don’trely on anti-theft steering locks to secure
the steering wheel. Use a special steering
wheel clamping device designed for this
purpose.

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

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SAFETY CHAINS MUST BE USED WHEN TOWING
AND TRANSPORTING
SafetychainsareprovidedforusewithyournewJerr-DanRecoveryVehicle.
Periodically inspect all chains for any signs of fatigue or damage. Don’t
overlookthehooks; besuretheyhavenot been bentordeformed.Ifchain or
hook damage is noted, they must be replaced before being used. Do not
use safety chains for recovery operations.
Manystates require thatthe towed vehicle be secured to the wrecker body
withsafetychains. Check yourlocalregulationsanduseyour safety chains.
Safetychains are provided foruse with yournew JERR-DAN.
• Never attach the chain hooks in such a
way as to damage brake lines or other
functional parts.
• Keep in mind that driving over bumps and
hollows and around corners will tend to
tighten or loosen the chains.
• Check that the chain does not become over
tensioned when raising the towed vehicle to the
towing position or during the towing operation.
• Always use two safety chains when towing all
vehicles, regardless of distance.

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LIFT SAFETY
Carefulconsideration of the immediatesurrounding conditions such asthe
weather, terrain, type or condition of the vehicle to be recovered and the
condition and experience of the operator is foremost to the safety and
success of the operation. In addition, the intent of the design of this unit
should be taken before the undertaking of its use.
Your MPL40 is unique. It not only can make lifts from level surfaces, our
boom tilt feature allows pickup of vehicles that are parked on both inclines
anddeclines.
• You should never make a lift or movement
while close to or under the vehicle being
lifted!
• Always use jack stands to support the vehicle
if it is necessary to work under it.
• Towing lights are required in many areas and are always recommended for safe
tows.

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• Jog the winch control lever to be sure of
complete engagement of the clutch gears
before making a lift or pull.
• Never stand on or straddle a working wire
rope.
• Take up the wire rope slowly and be sure
the hook is securely set.
• Be sure of your lift or pull and do not exceed
the working strength of the wire rope or hook.
Rig to keep the estimated amount of pull
well within equipment ratings. Use wire rope
breaking strength ratings only for selecting
replacement wire rope.
BOOM SAFETY
Your MPL40 is equipped with a recovery winch and the following safety
proceduresmustbeobserved:

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• Neverliftorpull over or around a sharp obstacle.
• Never completely unwind wire rope from a
winch while loaded. Always be sure that a
minimum of five (5) wraps of wire rope are on
the drum at all times.
• Never tie down the front end of your wrecker
for recovery work of heavy lifts. You will
likely damage the truck frame if you do.
• Never allow the wire rope to cross wrap
(criss-cross) on the winch drum. Crushing
of the wire rope can cause wire rope failure.
• Never make a lift or pull with the wire rope
attached to light gauge or sheet metal parts;
use the frame or major structural members.
• Don’t disengage the winch drum clutch while
the wire rope is loaded.

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• Don’t permit bystanders in the area while
performing recovery work.
• Never wrap the wire rope around frames or
cross members. Use chains and hook the
wire rope to the chains.
• Don’t use damaged wire ropes on your
wrecker. Become familiar with the various
types of wire rope damage and periodically
inspect the entire wire rope for wear and
corrosion. Never use wire rope menders.
Replace with similar rated wire rope and
hooks.
• Be sure all brakes and locks are properly
set on the recovery vehicle.
• Never under any circumstances use the
winch or boom to lift people!
• Lubricate and maintain both the wire rope
and winch on regular intervals. (See
maintenance charts.)