Oshkosh Corporation JERR-DAN 20NGADF6T-LP Use and care manual

Operation And Safety
Manual
Original Instructions
Keep this manual with machine at all times.
STANDARD DUTY
XLP
CARRIER
5376000207
January 13, 2020
SN 0220020309 to Present

WARNING
Operating, servicing and maintaining this
vehicle or equipment can expose you to
chemicals including engine exhaust, carbon
monoxide, phthalates, and lead, which are
known to the State of California to cause
cancer and birth defects or other
reproductive harm. To minimize exposure,
avoid breathing exhaust, do not idle the
engine except as necessary, service your
vehicle or equipment in a well-ventilated
area and wear gloves or wash your hands
frequently when servicing. For more
information go to www.P65Warnings.ca.gov.

Revision Log
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REVISION LOG
January 13, 2020 - A - Original Issue of Manual.

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This manual provides Operational and Safety information for the Standard Duty XLP
Carrier. Read this manual and the Operation and Safety Manual provided with other
equipment thoroughly prior to starting operation.
This manual is a very important tool! Keep it with the machine at all times.
The purpose of this manual is to provide owners, users, and operators with the
precautions and operating procedures essential for the safe and proper machine
operation for its intended purpose.
Due to continuous product improvements, Jerr-Dan Corporation reserves the right to
make specification changes without prior notification. Contact Jerr-Dan Corporation
for updated information.
OPERATOR QUALIFICATIONS
The operator of the machine must not operate the machine until this manual has been
read, training is accomplished and operation of the machine has been completed
under the supervision of an experienced and qualified operator.
Operators of this equipment must possess a valid, applicable driver’s license, be
in good physical and mental condition, have normal reflexes and reaction time,
good vision and depth perception and normal hearing. Operator must not be using
medication which could impair abilities nor be under the influence of alcohol or any
other intoxicant during the work shift.
In addition, the operator must read, understand and comply with instructions
contained in the following material furnished with the equipment:
• This Operation & Safety Manual
• All instructional decals and plates
• Any optional equipment instructions furnished
• Commercial vehicle’s Operation & Maintenance Manuals
The operator must also read, understand and comply with all applicable Employer,
Industry and Governmental rules, standards and regulations.
MODIFICATIONS
Any modification to this machine must be approved by Jerr-Dan.

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HAZARD CLASSFICATION SYSTEM
SAFETY ALERT SYSTEM AND SAFETY SIGNAL WORDS
This is the Safety Alert Symbol. It is used to alert to the potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible injury or
death.
Indicates an imminently hazardous situation. If not avoided, will result in serious
injury or death. This decal will have a red background.
Indicates a potentially hazardous situation. If not avoided, could result in serious
injury or death. This decal will have an orange background.
Indicates a potentially hazardous situation. If not avoided, may result in minor or
moderate injury. It may also alert against unsafe practices. This decal will have a
yellow background.
Indicates information or a comply policy that relates directly or indirectly to the safety
of the personnel or protection of property.
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This product must comply with all safety related bulletins. Contact Jerr-Dan
Corporation or the local authorized representative for information regarding safety
bulletins which may have been issued for this product.
Jerr-Dan Corporation sends safety related bulletins to the owner of record of this
machine. Contact Jerr-Dan Corporation to ensure that the current owner of records
are updated and accurate.
Jerr-Dan Corporation must be notified immediately in all instances where Jerr-
Dan product have been involved in an accident involving bodily injury or death of
personnel or when substantial damage has occurred to personal property on the
Jerr-Dan product.
FOR:
• Accident Reporting and Product Safety Publications
• Current Owner Updates
• Questions Regarding Product Applications and Safety
• Standards and Regulations Compliance Information
• Questions Regarding Product Modifications
CONTACT:
Product Safety and Reliability Department
Jerr-Dan Corporation
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
or Your Local Jerr-Dan Office
In USA
Toll Free: 1-877-554-7233
Outside USA
Phone: [phone]
Fax: [phone]
E-mail
ProductSaf[email protected]

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REPORTING SAFETY DEFECTS
If you believe that your vehicle has a defect which could cause a crash
or could cause injury or death, you should immediately inform the National
Highway Tra󰀩c Safety Administration (NHTSA) in addition to notifying Jerr-
Dan Corporation.
If NHTSA receives similar complaints, it opens an investigation, and if it nds
that a safety defect exists in a group of vehicles, it may order a recall and
remedy campaign. However, NHTSA cannot become involved in individual
problems between you, your dealer, or Jerr-Dan Corporation.
To contact NHTSA, you may call the Vehicle Safety Hotline toll-free at 1-888-
327-4236 (TTY: 1-800-424-9153); go to http://www.safercar.gov; or write to:
Administrator
NHTSA
400 Seventh Street S.W.
Washington, DC 20590
You can also obtain other information about motor vehicle safety from http://
www.safercar.gov.

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THIS PAGE IS INTENTIONALLY LEFT BLANK

Table of Contents
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TABLE OF CONTENTS
Revision Log
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Operator Qualifications b
Modifications b
Hazard Classfication System c
Safety Alert System and Safety Signal Words c
Reporting Safety Defects e
Table of Contents
Section 1 - General Safety Practices
1.1 General 1-1
1.2 Pre-Operation 1-2
Operator Training and Knowledge 1-2
Electrical Hazards 1-3
Crush and Collision Hazards 1-4
Winch Cable / Falling Load Hazards 1-5
Uncontrolled Towed Load Hazards 1-6
Fall Hazards 1-7
Tip-Over Hazards 1-7
Chemical Hazards 1-8
Battery Hazards 1-9
Personal Protective Equipment 1-9
Weather Conditions 1-10
Vehicle Equipment Damage 1-10
Section 2 - Pre-Operation and Inspection
2.1 Pre-Operation Check And Inspection 2-1
2.2 Decals 2-2
2.3 Walk-Around Inspection 2-8
2.4 Operational Checks 2-12
Operational Check 2-12
Section 3 - Controls & Indicators
3.1 General 3-1
3.2 Controls 3-2
Left Hand - Side Control Station 3-2
Right Hand - Side Control Station 3-2
3.3 2 Function Wireless Hand Controller (If Equipped) 3-4
3.4 4 Function Wireless Hand Controller (If Equipped) 3-5
3.5 6 Function Wireless Hand Controller (If Equipped) 3-6
3.6 10 Function Wireless Hand Controller (If Equipped) 3-7

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Section 4 - Operation
4.1 Tilting the Deck/Loading 4-2
4.2 Tilting the Deck/Unloading 4-9
4.3 Winch Operation - Manual Free-Spool 4-15
4.4 Winch Operation - Air Remote Free-Spool 4-17
4.5 Securing vehicle 4-19
4.6 “IRL” Wheel Lift Operation 4-22
4.7 “L” Arm Grid Operation 4-29
4.8 “T37” Pivoting Grid Operation 4-31
4.9 Hydraulic Grid Operation 4-33
4.10 Tie-Down Straps - L-Arm Grid 4-34
4.11 Tie-Down Straps - “T37” Grid 4-36
4.12 Tie-Down Straps - Hydraulic Grid 4-38
Section 5 - Emergency Procedures
5.1 Electric/Hydraulic Failure
Raising/Lowering/Extending/Retracting Deck 5-1
5.2 Engine Failure
Raising/Lowering/Extending/Retracting Deck 5-2
Section 6 - Maintenance
6.1 Introduction 6-1
6.2 Maintenance And Lubrication 6-2
6.3 Oils And Greases 6-3
6.4 Wire Rope Handling And Inspection 6-5
6.5 Wire Rope Installation 6-7
6.6 Lubrication Chart 6-10
Lubrication Points 6-11
6.7 Trouble Shooting 6-13
Hydraulic System 6-13
P.T.O. Functioning Improperly 6-14
Hydraulic Pump 6-14
Hydraulic Pump 6-15
Winch Functioning Improperly 6-15
Remote Hand Controller 6-16
Section 7 - Specifications
7.1 Product Specifications 7-1
6Ton Standard Duty XLP Carrier Series 7-1
Truck Chassis 7-4
7.2 Capacities 7-5
Inspection, Maintenance and Repair Log
Transfer Of Ownership

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SECTION 1 - GENERAL SAFETY PRACTICES
1.1 GENERAL
This section outlines the necessary precautions for proper and safe vehicle operation
and maintenance. For proper vehicle, it is mandatory that a daily routine is established
based on the content of this manual. A maintenance program, using the information
provided in this manual must also be established by a qualified person and followed
to ensure the vehicle is safe to operate.
The owner/user/operator of the vehicle must not operate the vehicle until this manual
has been read, training is accomplished, and operation of the vehicle has been com-
pleted under the supervision of an experienced and qualified operator.
There may be times the vehicle may be exposed to direct contact with the public such
as parades, charitable fundraisers, etc. Before allowing anyone other than a trained
and experienced company employee near your vehicle, consult with the company
safety officer and plan for safety.
If there are any questions with regard to safety, training, inspection, maintenance,
application, and operation, please contact Jerr-Dan Corporation.
Failure to comply with the safety precautions listed in this manual could result in
vehicle damage, property damage, personal injury or death.
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1.2 PRE-OPERATION
OPERATOR TRAINING AND KNOWLEDGE
• Read and understand this manual before operating the vehicle.
• Do not operate this vehicle until complete training is performed by authorized
persons.
• Only authorized and qualified personnel can operate the vehicle.
• Read, understand, and obey all DANGERS, WARNINGS, CAUTIONS, and
operating instructions on the vehicle and in the manual.
• Use the vehicle in a manner which is within the scope of its intended application
set by Jerr-Dan.
• All operating personnel must be familiar with the emergency operation of the
vehicle as specified in this manual.
• Read, understand, and obey all applicable employer, local, and government
regulations as they pertain to the operation of the vehicle.
• Become familiar with the loads that your unit can safely transport without
exceeding the structural rating of the Jerr-Dan unit or the gross axle weight
ratings (GAWR), gross vehicle weight rating (GVWR), and the gross combined
vehicle weight rating (GCWR) of your chassis.

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ELECTRICAL HAZARDS
• This vehicle is not insulated and does not provide protection from contact or being
near electrical current. This includes lightning and lightning strikes.
• NEVER operate the vehicle in an area where overhead power lines, overhead
or underground cables, or other power sources may exist without ensuring the
appropriate power utility company de-energizes the lines.
• Always check for power lines before raising the deck.
• Look up and use light to search for power lines in the dark.
• Allow for vehicle movement and electrical line swaying.
• Do not step off or touch a charged vehicle.
• Maintain a clearance of at least 10 ft (3m) between any part of the vehicle from
any electrical line or apparatus carrying up to 50,000 volts. Refer to the Minimum
Approach Distance (MAD) chart. One foot additional clearance is required for
every additional 30,000 volts or less.
Minimum Approach Distance (M.A.D.)
Voltage Range
(Phases to Phase)
MINIMUM APPROACH DISTANCE
in Feet (Meters)
0 to 50KV 10 (3)
Over 50KV to 200KV 15 (5)
Over 200KV to 350KV 20 (6)
Over 350KV to 500KV 25 (8)
Over 500KV to 750KV 35 (11)
Over 750KV to 1000KV 45 (14)
NOTE: This requirement shall apply except where employer, local
or government regulations are more stringent.
• The minimum approach distance may be reduced if insulating barriers are
installed to prevent contact, and the barriers are rated for the voltage of the line
being guarded. These barriers shall not be part of (or attached to) the truck. The
minimum approach distance shall be reduced to a distance within the designed
working dimensions of the insulating barrier. This determination shall be made
by a qualified person in accordance with the employer, local, or governmental
requirements for work practices near energized equipment.

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Do not maneuver vehicle or personnel inside prohibited zone (MAD). Assume all
electrical parts and wiring are energized unless known otherwise
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CRUSH AND COLLISION HAZARDS
• Ensure to stay clear of oncoming traffic. Driver side and passenger side controls
are standard on your Jerr-Dan carrier.
• Keep clear of rear stabilizer
• Stay clear of equipment to avoid crushing injury.
• Always use jack stands to support the deck and/or towbar/wheel-lift before
working underneath a lifted load.
• Warn personnel not to work, stand, or walk under a raised deck. Position
barricades if necessary.
• Set parking brake and chock wheels of the recovery vehicle when connecting
equipment.
• KEEP ALERT! Avoid distractions during any operating sequences.
• Be aware of height clearances when travelling.
• Look out for and avoid other personnel, machinery, vehicles and obstructions in
the area when driving the truck. Use a spotter if you do not have a clear view.

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When opening tool compartments:
• Loose items may shift during transport. Properly secure items when not in use
• Ensure all tool compartment doors are properly closed prior to transport.
WINCH CABLE / FALLING LOAD HAZARDS
• Keep people away during operation.
• Never exceed capacity of rigging or cable.
• Never stand on or straddle cable.
• Always keep a minimum of five (5) wraps of cable on winch drum.
• Keep tension on cable when unwinding.
• NEVER work behind the truck with equipment on the deck unless the equipment
is secured at the front of the deck. (Do not rely on the winch to hold the load).
• Stay to the side of the deck when winching.
• Keep cables from contacting sharp objects.
• Never wrap cables around objects. Use appropriate chains/straps to wrap around
the equipment to be transported, and attach the cable hook to the chain/straps.
• Never allow the cable to cross over itself when wrapping on the drum.
• NEVER winch from the side of the bed. Winch only from the rear with load
centered and in line with the winch. Failure to do so can result in winch or wire
rope damage and/or bodily injury. Never use the deck winch for side pulling.
• Never use damaged cable. Never use cable menders. Replace damaged cable
with cable and hooks of equal or greater rating.

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• Keep hands away from cable and drum during operation.
• Block up the deck before performing any service or maintenance work under the
deck. Jog winch clutch before pulling. Keep winch clutch engaged while the cable
is loaded.
• Approved head gear must be worn during recovery operations.
UNCONTROLLED TOWED LOAD HAZARDS
• Always know the weight distribution of your load and ensure you are within your
truck’s Gross Axle Weight Rating (GAWR), Gross Vehicle Weight Rating (GVWR)
and Gross Combination Weight Rating (GCWR) as well as any federal or state
roading regulation. In addition, be aware of your vehicle’s overall loaded height to
be sure that you are under the federal bridge law height of 13 feet 6 inches.
• DO NOT exceed GAWR or GCWR of the chassis.
• Use two (2) safety chains and four (4) tie down chains.
• Check chain tension periodically while in transit.
• Always retract towbar as close as possible.
• Ensure safety chains are properly attached from tow vehicle to towed equipment.
• After you have placed equipment on the carrier for towing, do not start the
tow until tie-down straps and chains have been installed per the equipment’s
recommended tie-down points.

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• Place the 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 towbar without a load on the deck.
• NEVER exceed towbar ratings. Overloading can cause unsafe steering and
braking conditions.
• Secure equipment to the deck at both the front and rear before the vehicle is
driven. NEVER rely on the winch as the only means of holding the load.
• Always use both wheel straps on wheel lift towbar.
FALL HAZARDS
• NEVER walk or climb on the deck surface when the deck is tilted.
• NEVER drive equipment onto the deck. Always use the winch to pull the
equipment onto the deck.
• DO NOT carry riders outside the cab. Riders could fall off the vehicle.
• NEVER allow riders in the towed equipment during lifting or transport.
• Only use approved ladders and grab handles and steps provided on the left side
of the vehicle when accessing the deck. Always maintain 3-point contact, using
two hands and one foot or two feet and one hand, when mounting or dismounting.
These surfaces can become slippery, ensure to keep them and footwear clean
and free of debris.
TIP-OVER HAZARDS
• Set up on firm surface only.
• Deploy rear bumper onto proper firm surface.
• Ensure truck is level prior to any operations.
• Make sure that equipment load is centered side to side.

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CHEMICAL HAZARDS
Exhaust Fumes
• DO NOT operate vehicle in an enclosed area without proper ventilation.
• DO NOT operate the vehicle in hazardous environments unless approved for that
purpose by Jerr-Dan and site owner. Sparks from the electrical system and the
engine exhaust can cause an explosion.
Flammable Fuel
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• DO NOT fill the fuel tank or service the fuel system near an open flame, sparks
or smoking materials. Engine fuel is flammable and can cause a fire and/or
explosion.
Hydraulic Fluid
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• DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the
engine is running or when the hydraulic system is under pressure.
• Stop engine and relieve trapped pressure. Fluid in the hydraulic system is under
pressure and can penetrate the skin.
• DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to
search for leaks. Wear gloves to protect hands from spraying fluid.

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BATTERY HAZARDS
• Battery fluid is highly corrosive. Avoid contact with skin and clothing at all times.
• Keep sparks, flames, and lighted materials away from batteries.
• Charge batteries only in a well ventilated area.
• Wear proper eye protection when servicing battery.
PERSONAL PROTECTIVE EQUIPMENT
• Use personal protective equipment when working on or around this vehicle.
• Remove rings, watches, jewellery, neckwear or other items that can catch in
equipment.
• Wear :
o Snug fitting and sturdy long-sleeve shirt and long pants. Avoid loose fitting
clothes.
o Sturdy gloves.
o Approved eye protection.
o Steel toed boots.
o Approved head gear.
o Approved hearing protection.

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WEATHER CONDITIONS
• Be aware of the wind conditions. Wind may cause load to swing or shifting of
load.
• If using in freezing conditions, you must be alert to possibility of ice forming on
the device. Use caution when extending and retracting winch cables, towbar, and
stabilizer. In addition use caution when opening/closing body panels
• Hydraulic cylinders are subject to thermal expansion and contraction. This may
result in changes to the deck, stabilizer and/or towbar position while the vehicle
is stationary. Factors affecting thermal movement can include the length of time
the vehicle is stationary, hydraulic oil temperature, and ambient air temperature.
VEHICLE EQUIPMENT DAMAGE
• Ensure vehicle is positioned in an area free from overhead obstructions. Keep a
safe working distance from overhead power lines, bridges, road signs and other
objects.
• Do not use a vehicle that has not been properly maintained. Make sure mounting
bolts are tight and moving parts are lubricated.
• Do not tow a vehicle on its drive wheels unless steps have been taken to protect
its transmission and differential. Follow the recommendations of the vehicle
manufacturer.
• Never attach the chain hooks in such a way as to damage brake lines or other
functional parts.
• Make sure all brakes and locks are properly set on the recovery vehicle.
• Do not operate the engine faster than recommended. Excessive speeds can
damage PTO, hydraulic pumps, and winches.
• Deck approach tip and subframe bumper may damage paved surfaces.
• NEVER drive a vehicle onto the deck. Always use the winch to pull the vehicle
onto the deck.
• Do not travel with the PTO engaged. Damage to the vehicle transmission and
hydraulic components will occur. Engage the PTO only when operating the
hydraulic controls.