$35.00 STANDARD DUTY CARRIER MEDIUM DUTY CARRIER HEAVY DUTY CARRIER OPERATIONS AND MAINTENANCE MANUAL 1080 Hykes Road Greencastle, PA 17225 Phone (717) 597-7111 www.jerr-dan.com 5-376-000097 REV. 1 - 12/08 © 2008 Jerr-Dan Corporation. All Rights Reserved.
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FOREWORD This manual serves as a guide for the owner and operator in the safe operation and 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 this manual. Keep this manual with your equipment at all times.
Jerr-Dan Corporation strives to provide information that is accurate, complete and useful. All information contained in this manual is as accurate as known at the time of publication and is subject to change, without notice, as a result of continuous product improvements. Jerr-Dan reserves the right to amend the information in this document at any time without prior notice.
WARRANTY 1080 Hykes Road Greencastle, PA 17225 (717) 597-7111 LIMITED WARRANTY Manufacturer’s Warranty. Manufacturer’s sole warranty shall be the following, which Distributor shall make on behalf of Manufacturer by conspicuous notice in writing accompanying each contract or memorandum of sale: 1. Warranty.
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.
1080 Hykes Road Greencastle, PA 17225 (717) 597-7111 LIMITED WARRANTY Coverage and Procedures Like our wheel lift and car carrier products, Jerr-Dan warranty programs are designed for the long haul. Whether you own a wheel lift 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 for wheel lifts and car carriers.
Procedures for warranty coverage: 1. Contact your selling distributor. 2. If necessary, contact Jerr-Dan for the distributor nearest you - Call 1-800-926-9666. 3. If necessary, Jerr-Dan may authorize repair by a qualified equipment service center. Under these arrangements, it will be necessary to obtain an estimate of repairs before any work is performed.
TABLE OF CONTENTS Section I: Safety Safety (General) ....................................................................... 1 Ratings: ................................................................................... 3 Standard Duty .................................................................... 3 Medium Duty ..................................................................... 6 Heavy Duty 10 Ton ............................................................. 8 Heavy Duty 15 Ton .....................
Section III: Maintenance Maintenance and Lubrication ................................................. 83 Fastener Torque Specifications .............................................. 85 Oils and Greases ................................................................... 86 Wire Rope Handling and Inspection ....................................... 87 Lubrication Points .................................................................. 89 Trouble Shooting ......................................................
SAFETY The safe operation of your Jerr-Dan Carrier is your responsibility. Read this manual and the truck manufacturer’s manual and thoroughly understand them. You can be held legally responsible for injuries or damage resulting from careless or unsafe operating practices. Our recommendations for operating your equipment can help you avoid unsafe practices and their bad consequences. These recommendations are contained in this manual.
that we know about. We also strongly recommend that you receive specialized and advanced training from a professional Towing and Recovery instructor before operating any recovery equipment. To alert personnel to hazardous operating practices, safety messages are used throughout the manual. Each safety message contains a safety alert symbol and a signal word to identify the hazard's degree of seriousness.
STANDARD DUTY CARRIER Includes the following Models: _ _NGAF - 5 Ton Pioneer Fixed Rail _ _NGADF - 5 Ton Pioneer Aluminum Dual Angle Fixed Rail _ _NGAR - 5 Ton Pioneer Aluminum Removable Rail _ _NGAT - 5 Ton Pioneer Aluminum Transporter _ _WSRB - 5 Ton Steel Rustler _ _RRSB - 5 Ton Steel B.I.C. _ _SLPB - 5 Ton Steel Shark _ _STRB - 5 Ton Steel B.I.C.
WIRE ROPE: (10,000 lb Winch) Working Limit Each Line ............................................... 5,828 lbs Nominal Breaking Strength ......................................... 20,400 lbs Construction .......................................... 6 x 25 EIPS RRL IWRC Diameter ....................................................................... 7/16 inch Standard Length .............................................................. 56 Feet TOW OPTION RATINGS: Lift Tow IRL Wheel Lift .......................
NOTE These ratings apply to the structural design of the Standard Duty Carrier only . They might 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 the towed vehicle load must not exceed the posted lift / towing ratings.
MEDIUM DUTY CARRIER Includes the following Models: _75T2B - 7.5 Ton Steel B.I.C. _75TRB - 7.5 Ton Steel B.I.C. Transporter DO NOT EXCEED THE FOLLOWING RATINGS: DECK RATING: ....................................................................... 15,000 lbs WINCH RATING: (Standard Ramsey Worm Gear) 1 Each Drum (Single Speed, Variable Control) ............... 10,000 lbs WINCH RATING: (Optional Ramsey Worm Gear) 1 Each Drum (Single Speed, Variable Control) ...............
1 SAE J706: Surface Vehicle Recommended Practices - Rating of Winches 2 SAE J2512: Surface Vehicle Recommended Practices - Towing Equipment Ratings and Practices MAXIMUM LIFTING CAPACITY - THE MAXIMUM LOAD THAT CAN BE LIFTED. GROSS COMBINED WEIGHT RATING (GCWR) - THE VALUE SPECIFIED BY THE VEHICLE MANUFACTURER AS GCW.
HEAVY DUTY CARRIER 10 TON Includes the following Models: _10T2B - 10 Ton Steel Wrangler _10TRB - 10 Ton Steel Transporter DO NOT EXCEED THE FOLLOWING RATINGS: DECK RATING: ....................................................................... 20,000 lbs WINCH RATING: (Standard Ramsey Worm Gear) 1 Each Drum (Single Speed, Variable Control) ............... 12,000 lbs WINCH RATING: (Optional Ramsey Worm Gear) 1 Each Drum (Single Speed, Variable Control) ...............
TOW OPTION RATINGS: Lift Tow IRL Wheel Lift (Standard) .......................... 3,000 lbs .... 7,500 lbs2 IRL Wheel Lift (Optional) ........................... 4,000 lbs .. 12,000 lbs2 IRL Wheel Lift (Optional) with T-37 Grids ... 4,000 lbs .... 8,000 lbs2 Towbar (Standard) ..................................... 3,500 lbs ..... 7,500 lbs Towbar (Optional) ...................................... 5,000 lbs .... 12,500 lbs Tow Hitch .................................................. 3,500 lbs .....
NOTE These ratings apply to the structural design of the Heavy Duty Carrier only . They might 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 the towed vehicle load must not exceed the posted lift / towing ratings.
HEAVY DUTY CARRIER 15 TON Includes the following Models: _15T2B - 15 Ton Steel Wrangler _15TRB - 15 Ton Steel Transporter DO NOT EXCEED THE FOLLOWING RATINGS: DECK RATING: ...................................................................... 30,000 lbs. WINCH RATING: (Standard Ramsey Worm Gear) 1 Each Drum (Single Speed, Variable Control) .............. 20,000 lbs. WIRE ROPE: Working Limit Each Line ............................................ 11,770 lbs. Nominal Breaking Strength ........................
1 SAE J706: Surface Vehicle Recommended Practices - Rating of Winches 2 SAE J2512: Surface Vehicle Recommended Practices - Towing Equipment Ratings and Practices MAXIMUM LIFTING CAPACITY - THE MAXIMUM LOAD THAT CAN BE LIFTED. GROSS COMBINED WEIGHT RATING (GCWR) - THE VALUE SPECIFIED BY THE VEHICLE MANUFACTURER AS GCW.
MFG BY:_______________________________________ ______________________________________________ DATE OF MFR:MO______________YR.
• Read operating and loading instructions thoroughly. • Don’t use a recovery vehicle that has not been properly maintained. Make sure mounting bolts are tight and moving parts are lubricated. • Become familiar with the loads that your unit can safely transport without exceeding the structural rating of the Jerr-Dan equipment or the gross axle weight ratings, gross vehicle weight rating, and the gross combined vehicle weight rating of your chassis. • Don’t operate the engine faster than recommended.
• NEVER exceed the front and/or rear axle ratings of your towing equipment. • Make sure you are clear of oncoming traffic. Driver side and passenger side controls are standard on your Jerr-Dan carrier. • NEVER exceed the rated capacity of the body or truck chassis and its components or use towbar/wheel lift without a vehicle on the deck. 5-376-000097 REV. 1 - 12/08 • Observe all CAUTION, WARNING, and DANGER decals. • Stay clear of equipment to avoid pinching injury.
• Make sure all brakes and locks are properly set on the recovery vehicle. • Stay to the side of the deck when winching. • Maintain winch cable/wire rope in good condition. Replace when worn, kinked or frayed. Do not use cable clamps. • Store L-Arms when not in use. NEVER DRIVE with L-Arms in the wheel grids. • Don't exceed the ratings. nameplate ratings. Stay within • Know the loads being moved. NEVER OVERLOAD! Section I: Safety Page 16 5-376-000097 REV.
• When loading or unloading the deck and operating the winch, make sure the area behind the load is clear of personnel and obstacles. • 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/wheel lift without a load on the deck. • Stay clear of equipment to avoid crushing injury. • Always put bumper on the ground to support the body and truck frame. • NEVER allow riders in the towed vehicle during lifting or transport.
• KEEP ALERT! Do not be distracted during any operating sequences. • NEVER work behind the truck with a vehicle on the deck unless the vehicle is secured at the front of the deck. (Do not rely on the winch to hold the load). • Read and follow towbar/ wheel lift instructions for proper towing. • NEVER exceed towbar/wheel lift ratings. Overloading can cause unsafe steering and braking conditions. • Always use both wheel straps on wheel lift towbar. • NEVER drive a vehicle onto the deck.
• Make sure deck is in the locked position before traveling. • Review the Operator's Pre-transport Checklist located on the headboard of the deck or in this manual each time before you move a vehicle. • Block up the deck before performing any service or maintenance work under the deck. • NEVER walk or climb on the deck surface. • NEVER winch from the side of the bed. Winch only from the rear with load centered and in line with the winch.
• Use separate safety chains from the towed vehicle to the subframe for standard towbar and wheel lift towbar. Always attach safety chains to the opposite side of the attaching point, crossing the chains under the towbar. Allow enough slack in the chains to maneuver around corners without binding. Section I: Safety Page 20 5-376-000097 REV.
CAPACITY/RATING INFORMATION PLACARDS These placards provide information about carrier and vehicle ratings, capacities and load limits. You must stay within these ratings/capacities when using the Jerr-Dan carrier. 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 or unreadable, it should be replaced. Replacements are available through the Service Parts Department.
SAFETY WARNING LABELS These safety warning labels describe hazards and what happens if you encounter them. Read each safety warning lable and figure out how to avoid the hazard. These lables must not be obliterated, removed or painted over. They are there to remind and protect the operator. (Not all decals are used on all units) If a decal becomes lost or unreadable, it should be replaced. Replacements are available through the Service Parts Department.
WARNING CAUTION AIR SUSPENSION MUST BE FULLY DEFLATED BEFORE TILTING DECK TO LOAD OR UNLOAD GUIDE BUSHING 176 WARNING DO NOT EXCEED TOW OPTION CAPACITIES. OVERLOADING MAY RESULT IN UNSAFE STEERING AND/OR BRAKING CONDITIONS. *TO ENGAGE WINCH: LIFT UP KNOB THEN RELEASE. OPERATE WINCH TO ENGAGE CLUTCH. *TO FREE SPOOL WINCH: RUN WINCH IN REVERSE (REEL OUT) UNTIL THE LOAD IS OFF THE CABLE. LIFT UP KNOB AND PULL OUT. LOCK IN PLACE. DO NOT FREE SPOOL UNDER LOAD.
WARNING GUIDE BUSHING *TO ENGAGE WINCH: LIFT UP KNOB THEN RELEASE. OPERATE WINCH TO ENGAGE CLUTCH. *TO FREE SPOOL WINCH: RUN WINCH IN REVERSE (REEL OUT) UNTIL THE LOAD IS OFF THE CABLE. LIFT UP KNOB AND PULL OUT. LOCK IN PLACE. DO NOT FREE SPOOL UNDER LOAD. *BEFORE OPERATION: WINCH CLUTCH MUST BE COMPLETELY ENGAGED WITH GUIDE BUSHING POSITIONED AS SHOWN. 495 WARNING SAFETY PIN MUST BE INSTALLED WHILE TOWING. FULLY RETRACT BOOM FOR RATED CAPACITY.
OPERATION PLACARDS AND LABELS 649 STABILIZER 650 STABILIZER 651 5-376-000097 REV.
TOW OPT 652 TOW OPT 653 TOW OPT GRID ARMS 657 GRID ARMS TOW OPT 658 Section I: Safety Page 26 5-376-000097 REV.
ROLL TILT WINCH TOW OPT TOW OPT TOW OPT GRID ARMS CAUTION ALWAYS USE TIRE STRAPS TO RETAIN VEHICLE IN GRID SYSTEM. DO NOT RELY ON L-ARMS ALONE FOR VEHICLE TRANSPORT. OPERATION INSTRUCTIONS ALL OPERATORS SHOULD BE TRAINED AND UNDERSTAND THE OPERATOR'S MANUAL. ASSURE SAFETY OF ALL PERSONNEL. TILT ONLY WHEN DECAL ALIGNS WITH FIRST CONTROL HANDLE. CAUTION ALWAYS USE TIRE STRAPS TO RETAIN VEHICLE IN GRID SYSTEM. DO NOT RELY ON L-ARMS ALONE FOR VEHICLE TRANSPORT.
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OPERATION OPERATION The safe operation of your Jerr-Dan carrier is your responsibility. You can be held legally responsible for any injuries or damage caused by the unsafe operation of your equipment. If you follow our tested and proven procedure you will operate the equipment properly. Remember you alone are always responsible for your actions.
TILTING THE DECK/LOADING Follow these simple steps: 1. Turn on the safety and work lights. (Switches are located on the switch panel in the dash.) 0N 0N 0N 0N 0N BEACON LIGHT AUX WARN REAR FLOOD WORK LIGHT MASTER 2. Position the rear of the carrier about 12 feet from the vehicle you intend to load. Make sure the carrier is in line with the vehicle. 12 FT P R N 3. Place the carrier’s transmission gear selector into Neutral or Park and set the parking brakes.
AKE-OFF WER TAKE-OFF POWER OUT 4. Engage the power take-off (PTO). Refer to PTO operator’s manual. NEVER TRAVEL WITH THE POWER TAKE-OFF CONTROL ENGAGED. This could result in damage to the PTO unit and the recovery vehicle’s transmission. 5. Adjust the electronic or manual throttle control to set the engine speed to approximately 1000-1200 R.P.M. Refer to chassis operator’s manual for proper operation of the auxiliary throttle.
7. Raise the Rollback Control handle to slide the deck back. Align the arrow decal pointer on the side of the deck with the first control handle. Tilting the deck too soon may cause damage to the mechanical hold down. 8. Raise the Tilt Control handle to raise the front of the deck until the rear bumper rests firmly on the ground. 9. Raise the Rollback Control handle again to slide the deck back. Continue sliding the deck back until the approach plate makes firm contact with the ground.
WARNING: Maintain a minimum of five (5) wraps of wire rope/cable on the winch drum at all times. Also maintain a uniform wrap of wire rope/ cable on the drum to avoid crushing of the wire rope/cable. 11. Attach the wire rope/cable to the vehicle to be loaded. Always use V-straps or hook-up chains to attach the wire rope/cable to the vehicle. Refer to the AAA or vehicle manufacturer's towing manual for correct attachment points.
12. Re-engage the winch clutch. (See winch operation) 13. Slowly lower the Winch Control handle to remove any slack in the wire rope/cable. 14. Make sure the vehicle's parking brake is released and the transmission is in Neutral. NOTE: If the vehicle is parked on an incline, leave the parking brake partially engaged to prevent it from rolling forward on its own. 15. Slowly lower the Winch Control handle and begin winching the vehicle onto the deck and into the transport position.
CAUTION: Remain clear of the load while winching. Never walk between the winch and its load when the winch and wire rope/cable is under tension. 16. Secure the front of the vehicle. NEVER rely on the winch to hold the load. (See Securing Vehicle instructions) CAUTION: There is no need to access the vehicle once it is loaded on the deck. NEVER walk or climb on the deck surface. 17. Slowly raise the Winch Control handle to spool out some wire rope/cable to pre-load the tiedowns. 18.
19. Secure the rear of the vehicle. (See Securing Vehicle instructions) 20. Once the vehicle is secured from movement in all directions, lower the Tilt Control handle and lower the front of the deck to the subframe. 21. Lower the Rollback Control handle and move the deck completely forward until it engages the hold downs and into the transport position. WARNING: Always use tie downs at all four corners of the load.
WARNING: Always refer to the Operator's Pre-Transport Checklist located on the headboard of the deck before transporting. Make sure you have followed all of the items on the list. 22. Remove the wheel chocks from the carrier's rear tires. AKE-OFF TAKE-OFF OU 5-376-000097 REV. 1 - 12/08 IN 23. Disconnect the power take-off (PTO). Refer to PTO operator’s manual. NEVER TRAVEL WITH THE POWER TAKE-OFF CONTROL ENGAGED. This could result in damage to the PTO unit and the recovery vehicle’s transmission.
TILTING THE DECK/UNLOADING Follow these simple steps: 1. Turn on the safety and work lights. (Switches are located on the switch panel in the dash.) 0N 0N 0N 0N 0N BEACON LIGHT AUX WARN REAR FLOOD WORK LIGHT MASTER 2. Position the rear of the carrier about 30 feet from the area where you intend to unload the vehicle. 30 FT P 3. Place the carrier’s transmission gear selector into Neutral or Park and set the parking brakes. R N D 4 2 1 Section II: Operation Page 38 5-376-000097 REV.
AKE-OFF WER TAKE-OFF POWER OUT 4. Engage the power take-off (PTO). Refer to PTO operator’s manual. NEVER TRAVEL WITH THE POWER TAKE-OFF CONTROL ENGAGED. This could result in damage to the PTO unit and the recovery vehicle’s transmission. 5. Adjust the electronic or manual throttle control to set the engine speed to approximately 1000-1200 R.P.M. Refer to chassis operator’s manual for proper operation of the auxiliary throttle.
7. Raise the Rollback Control handle to slide the deck back. Align the arrow decal pointer on the side of the deck with the first control handle. Tilting the deck too soon may cause damage to the mechanical hold down. 8. Raise the Tilt Control handle to raise the front of the deck until the rear bumper rests firmly on the ground. 9. Remove the tie-downs from the rear of the vehicle. CAUTION: NEVER walk or climb on the deck surface. 10. Raise the Rollback Control handle to slide the deck back.
11. Slowly lower the Winch Control handle to take-up any slack in the wire rope/cable to allow the front tie-downs to become slack and loose. 12. Remove the tie-downs from the front of the vehicle. CAUTION: NEVER walk or climb on the deck surface. 13. Raise the Winch Control handle and start unreeling the wire rope/ cable from the winch. Unreel enough of the wire rope/cable from the winch to allow the vehicle to roll/slide off of the carrier deck.
15. Remove the hook-up chains and wire rope/cable. 16. Lower the Winch Control handle and spool the wire rope/cable back onto the winch drum. Keep tension on the wire rope/cable so that the wire wraps properly on the winch spool to avoid birdnesting. 17. Lower the Rollback Control handle to move the deck forward. Align the arrow decal pointer on the side of the deck with the first control handle. Lowering the deck too late may cause damage to the mechanical hold down. 18.
19. Lower the Rollback Control handle and move the deck completely forward until it engages the hold downs and into the transport position. 20. Remove the wheel chocks from the carrier's rear tires. AKE-OFF TAKE-OFF OU 5-376-000097 REV. 1 - 12/08 IN 21. Disconnect the power take-off (PTO). Refer to PTO operator’s manual. NEVER TRAVEL WITH THE POWER TAKE-OFF CONTROL ENGAGED. This could result in damage to the PTO unit and the recovery vehicle’s transmission.
WINCH OPERATION - MANUAL REMOTE FREE-SPOOL Follow these simple steps to disengage the winch: 1. To disengage the winch clutch, raise the Winch Control handle to run the winch in the reverse (reel out) direction until the load is off the wire rope/cable. Never pull the free spool knob while the wire rope/cable is under load. Raise and lift the free spool knob and pull it toward you. 2. Then lower the knob and release. 3. Look to make sure that the free spool knob is locked in the free spool position.
Follow these simple steps to reengage the winch: 1. To re-engage the winch clutch, simply raise and lift the free spool knob and release. The free spool knob should spring back into the engaged position. Raise the Winch Control handle to run the winch in reverse (reel out) direction until the free spool snaps fully in position or until the winch drum starts turning. 2. Look to make sure that the free spool knob is locked in the engaged position.
WINCH OPERATION - AIR REMOTE FREE-SPOOL Follow these simple steps to disengage the winch: 1. To disengage the winch clutch, raise the Winch Control handle to run the winch in the reverse (reel out) direction until the load is off the wire rope/cable. Never move the free spool lever while the wire rope/cable is under load. 2. Move the free spool lever in the control station up into the free spool position. FR WINCH ENGAGE 675 3.
Follow these simple steps to reengage the winch: 1. To re-engage the winch clutch simply move the free spool lever in the control station down into the engage position. WINCH FREE SPOOL WI AGE 75 2. Raise the Winch Control handle to run the winch in reverse (reel out) direction until the winch drum starts turning. After the winch clutch is fully engaged, the winch is ready for winching. CAUTION: Do not attempt to pull a load unless the winch free spool is completely engaged. 5-376-000097 REV.
SECURING VEHICLE Each Standard Duty and Medium Duty Carrier is supplied with a set of high strength polyester web tie-down strap and chain assemblies. They are to be used to secure the vehicle to the carrier deck. NEVER TOW A VEHICLE WITHOUT TIE-DOWNS INSTALLED. For specialty equipment other than vehicles, the user assumes all responsibility for choosing and providing the proper tie-down devices. The tie-down strap and chain assembly is comprised of the following components: 1.
3. To release the ratchet, simply pull on the locking bar, disengaging the teeth and raise the handle to the “free spool” position. INSTALLING THE FRONT TIE-DOWN CHAINS 1. Using the RTJ hook cluster chains, insert the appropriate hook into the vehicle frame tie down hole or slot. Refer to the AAA or vehicle manufacturer's towing manual for the correct attachment points. 2. Insert the other end of the chain into the keyslot in the deck. Adjust the chain so that it is as tight as possible. 3.
INSTALLING THE REAR TIE DOWN STRAPS 1. Using the RTJ hook cluster straps and ratchet spool mechanisms, insert the appropriate hook into the vehicle frame tie down hole or slot. Refer to the AAA or vehicle manufacturer's towing manual for the correct attachment points. 2. Insert the chain on the end of the ratchet into the keyslot in the deck. Adjust the chain so that it is as tight as possible. Using the ratchet, tighten the tie down strap. 3. Repeat for the other side.
"IRL" (INDEPENDENT RAISE/LOWER) WHEEL LIFT OPERATION The optional wheel lift allows a second vehicle to be towed damage free on its own suspension by utilizing a wheel grid. The wheel lift cross bar may also be used as a conventional tow bar for badly damaged or heavier vehicles. Refer to the AAA or vehicle manufacturer's towing manual for the correct towing procedures and attachment points.
1. Turn on the safety and work lights. (Switches are located on the switch panel in the dash.) 0N 0N 0N 0N 0N BEACON LIGHT AUX WARN REAR FLOOD WORK LIGHT MASTER 2. Position the rear of the carrier about 4 feet from the vehicle you intend to load. Make sure you are in line with the vehicle. 4 FT 3. Place the carrier’s transmission gear selector into Neutral or Park and set the parking brakes. P R N D 4 2 1 AKE-OFF WER TAKE-OFF POWER OUT 4. Engage the power take-off (PTO).
5. Adjust the electronic or manual throttle control to set the engine speed to approximately 1000-1200 R.P.M. Refer to chassis operator’s manual for proper operation of the auxiliary throttle. If your chassis is equipped with the remote throttle up option from the chassis manufacturer there is no need to set the throttle up control in the cab because the throttle will automatically increase when any of the carrier hydraulic functions are operated. CAUTION: NEVER exceed 1400 R.P.M.
8. Raise the Tow Option Extend/ Retract Control handle to extend the wheel lift under the vehicle. Make sure all undercarriage parts are cleared and that the ramp portion of the of grid is in contact with the tires. 9. Load the vehicle onto the wheel lift. (See Wheel Grid instructions) 10. Raise the Tow Option Raise/Lower Control handle to raise the wheel lift until the vehicle's tires have cleared the ground. 11. Install tie-down straps to secure the wheels in the grid.
12. Place the vehicle's transmission in Neutral and release the parking brake. Make sure that the wheels are straight and install a steering wheel strap. It is recommended that the steering wheel be secured by a steering wheel strap for any tow. 13. Raise the Tow Option Raise/Lower Control handle to raise the wheel lift until the vehicle is in the final towing position. 14. Make sure that the far end of the vehicle has enough ground clearance.
15. Lower the Tow Option Extend/ Retract Control handle to retract the wheel lift until the vehicle is about 3 to 4 feet from the back of the truck. Leave enough room to maneuver around corners without corner binding or causing contact between the (2) vehicles. Be sure that the boom is extended adequately to ensure unobstructed crossbar pivoting. 16. Be sure to maintain sufficient clearances with the bottom of the vehicle. 17. Attach the safety chains and magnetic towing lights.
WARNING: Properly secure the vehicle to the wheel grid using tie-down straps. Tie-down straps should be tightened periodically during the tow as the tires settle into the grid from towing. WARNING: Properly secure the vehicle using safety chains from the vehicle to the carrier subframe. WARNING: The wheel lift is designed to transport a second vehicle. Never tow a vehicle on the wheel lift without a vehicle on the deck. Unsafe braking and steering conditions may result.
"ZOD" (ZERO DEGREE) WHEEL LIFT OPERATION The optional wheel lift allows a second vehicle to be towed damage free on its own suspension by utilizing a wheel grid. The wheel lift cross bar may also be used as a conventional tow bar for badly damaged or heavier vehicles. Refer to the AAA or vehicle manufacturer's towing manual for the correct towing procedures and attachment points.
1. Turn on the safety and work lights. (Switches are located on the switch panel in the dash.) 0N 0N 0N 0N 0N BEACON LIGHT AUX WARN REAR FLOOD WORK LIGHT MASTER 2. Position the rear of the carrier about 4 feet from the vehicle you intend to load. Make sure you are in line with the vehicle. 4 FT 3. Place the carrier’s transmission gear selector into Neutral or Park and set the parking brakes. P R N D 4 2 1 AKE-OFF WER TAKE-OFF POWER OUT 5-376-000097 REV. 1 - 12/08 4.
5. Adjust the electronic or manual throttle control to set the engine speed to approximately 1000-1200 R.P.M. Refer to chassis operator’s manual for proper operation of the auxiliary throttle. If your chassis is equipped with the remote throttle up option from the chassis manufacturer there is no need to set the throttle up control in the cab because the throttle will automatically increase when any of the carrier hydraulic functions are operated. CAUTION: NEVER exceed 1400 R.P.M.
8. Lower the Tow Option Raise/ Lower Control handle to lower the back end of the wheel lift to about 1-1/2" from the ground so that it will clear the underside of the vehicle when the wheel lift boom is extended. 9. Raise the Tow Option Extend/ Retract Control handle to extend the wheel lift under the vehicle. Make sure all undercarriage parts are cleared and that the ramp portion of the of grid is in contact with the tires. 10. Load the vehicle onto the wheel lift. (See Wheel Grid instructions) 11.
12. Install tie-down straps to secure the wheels in the grid. (See TieDown Straps instructions) 13. Place the vehicle's transmission in Neutral and release the parking brake. Make sure that the wheels are straight and install a steering wheel strap. It is recommended that the steering wheel be secured by a steering wheel strap for any tow. 14. Raise both of the Tow Option Raise/Lower Control handles to raise the wheel lift until the vehicle is in the final towing position.
15. Make sure that the far end of the vehicle has enough ground clearance. It is possible to set the rear of a front lifted vehicle completely on the ground. Take irregular road surfaces into consideration. Make sure that there are no under body components of the vehicle in contact with the L-Arms or wheel grid device. Readjust if necessary. 16. Lower the Tow Option Extend/ Retract control handle to retract the wheel lift until the vehicle is about 3 to 4 feet from the back of the truck.
19. Remove the wheel chocks from the carrier's rear tires. AKE-OFF TAKE-OFF OU IN 20. Disconnect the power take-off (PTO). Refer to PTO operator’s manual. NEVER TRAVEL WITH THE POWER TAKE-OFF CONTROL ENGAGED. This could result in damage to the PTO unit and the recovery vehicle’s transmission. 21. Use the reverse order for unloading. WARNING: Properly secure the vehicle to the wheel grid using tie-down straps.
WARNING: The wheel lift is designed to transport a second vehicle. Never tow a vehicle on the wheel lift without a vehicle on the deck. Unsafe braking and steering conditions may result. CAUTION: After unloading the vehicle, fully retract the wheel lift boom before operating any deck functions. CAUTION: Always store the L-Arms in the storage location provided when not in use. Do not store the L-Arms in the wheel grids.
"L" ARM GRID OPERATION 1. Set the grid width as required for the casualty vehicle to be towed. "T" HANDLE 2. To set the grid width, loosen the "T" handles on the front of the grid arms and pull out. Be sure both grids are as close to the center of the boom as possible, and wide enough to allow the LArms to slide into their channels. Tighten the "T" handles to secure the grids. 3. Retract the "Cam" handle locking pin on the grid by turning it 180°. It should remain in the open position.
4. Extend the lift arm under the casualty vehicle. Make sure that all under carriage parts are cleared and that the front portion of the grid is in contact with both tires. Lower the grid fully to the ground. There is no reason for the operator to get under the casualty vehicle. 5. Visually inspect the tire to grid contact before proceeding. 6. Take the L-Arms and slide them into the channels on the side of the grid.
"T37" PIVOTING GRID OPERATION 1. Set the grid width as required for the casualty vehicle to be towed. 2. To set the grid width, loosen the "T" handles on the front of the grid arms and pull out. Be sure both grids are as close to the center of the boom as possible, and wide enough to allow the wheel restraints to fit into their receivers. Tighten the "T" handles to secure the grids. "T" HANDLE WHEEL RESTRAINT RECEIVER 3.
4. Extend the lift arm under the casualty vehicle. Make sure that all under carriage parts are cleared and that the front portion of the grid is in contact with both tires. Lower the grid fully to the ground. There is no reason for the operator to get under the casualty vehicle. 5. Visually inspect the tire to grid contact before proceeding. WHEEL RESTRAINT 6. Take the wheel restraints and place them into their receivers on the side of the grid.
HYDRAULIC GRID OPERATION 1. Lower the grid arms open/close control handle to unfold and open the arms for loading. 2. Extend the lift arm under the casualty vehicle being sure that all under carriage parts are cleared and that the front portion of the grid is in contact with both tires. Lower the grid fully to the ground. Never get under the casualty vehicle. 3. Visually inspect the tire to grid contact before proceeding. 4.
TIE-DOWN STRAPS - L-ARM GRID The L-Arm grid is supplied with a set of high-strength polyester web tiedown straps. They are to be used to secure wheels of the towed vehicle to the wheel lift grid. NEVER TOW A VEHICLE WITHOUT THE TIE-DOWN STRAPS INSTALLED. The tie-down strap assembly is comprised of 2 basic components: 1. (2) The Strap/Hook Assemblies 2. (2) The Ratchet Spool Mechanisms Follow these steps to properly install the tie-down straps: USING THE RATCHET SPOOL MECHANISM 1.
3. To release the ratchet, simply pull on the locking bar, disengaging the teeth and raise the handle to the “free spool” position. INSTALLING THE TIE DOWN STRAPS 1. With the vehicle lifted just barely off the ground, attach the strap to the L-Arm. Be sure the hook on the ratchet is securely seated in the L-Arm. 2. Set the ratchet spool in "free spool" position and pull the webbed strap out and form a loop which will wrap around the tire. Be sure the loop is over a minimum of 1/3 of the tire.
3. Take up the slack in the strap by ratcheting the take-up spool arm. Continue until the tires show some compression. Repeat for other side. 4. Raise the wheel grid to the towing position. RE-TIGHTEN THE RATCHET PERIODICALLY AS THE TIRE SETTLES IN GRID FROM TOWING. NOTE: Never tow a vehicle without tire tie-down straps and safety chains installed. 5-376-000097 REV.
TIE-DOWN STRAPS - "T37" PIVOTING GRID The "T37" pivoting grid is supplied with a set of high-strength polyester web tie-down straps. They are to be used to secure wheels of the towed vehicle to the wheel lift grid. NEVER TOW A VEHICLE WITHOUT THE TIE-DOWN STRAPS INSTALLED. The tie-down strap assembly is comprised of 2 basic components: 1. (2) The Strap/Hook Assemblies 2. (2) The Ratchet Spool Mechanisms Follow these steps to properly install the tie-down straps: USING THE RATCHET SPOOL MECHANISM 1.
3. To release the ratchet, simply pull on the locking bar, disengaging the teeth and raise the handle to the “free spool” position. INSTALLING THE TIE-DOWN STRAPS 1. With the vehicle lifted just barely off the ground, attach the strap to the wheel restraints. Be sure the hook on the ratchet is securely seated in the wheel restraint. 2. Set the ratchet spool in "free spool" position and pull the webbed strap out and form a loop which will wrap around the tire.
3. Take up the slack in the strap by ratcheting the take-up spool arm. Continue until the tires show some compression. Repeat for other side. 4. Raise the wheel grid to the towing position. RE-TIGHTEN THE RATCHET PERIODICALLY AS THE TIRE SETTLES IN GRID FROM TOWING. NOTE: Never tow a vehicle without tire tie-down straps and safety chains installed. Section II: Operation Page 76 5-376-000097 REV.
TIE-DOWN STRAPS - HYDRAULIC GRID The hydraulic grid is supplied with a set of high-strength polyester web tiedown straps. They are to be used to secure the wheels of the towed vehicle to the wheel grid. NEVER TOW A VEHICLE WITHOUT THE TIE-DOWN STRAPS INSTALLED. The tie-down strap assembly is comprised of 2 basic components: 1. (2) The Strap/Hook Assemblies 2. (2) The Ratchet Spool Mechanisms Follow these steps to properly install the tie-down straps: USING THE RATCHET SPOOL MECHANISM 1.
3. To release the ratchet, simply pull on the locking bar, disengaging the teeth and raise the handle to the “free spool” position. INSTALLING THE TIE-DOWN STRAPS 1. With the vehicle lifted just barely off the ground, insert the end of the strap through the sewn loop on the other end of the strap to form a loop. Put the loop over the tire as shown with the strap resting on the tire at the ten o’clock and two o’clock positions. Place the choker strap across the center of the tire. 2.
3. Place the ratchet hook of the strap assembly into a hole on the front side of the grid arm. Use the hole that is closest to the tire. 4. Take up the slack in the strap by ratcheting the take-up spool arm. Continue until the tires show some compression. Repeat for other side. 5. Raise the wheel grid to the towing position. RE-TIGHTEN THE RATCHET PERIODICALLY AS THE TIRE SETTLES IN GRID FROM TOWING. NOTE: Never tow a vehicle without tire tie-down straps and safety chains installed. 5-376-000097 REV.
HAND HELD WIRELESS REMOTE The hand held wireless remote controller is an option available for any or all of your carriers hydraulic functions. Single Function Controller Multi Function Controller Follow these simple steps to operate the controller: 1. With the trucks engine running and the PTO engaged, press the green button on the hand controller to turn the power on to the hand controller. The red light on the controller will illuminate and flash. Section II: Operation Page 80 5-376-000097 REV.
2. Depress the appropriate yellow button on the hand controller for the desired funtion(s). The red light will stop flashing whenever a function is being operated. 3. To turn off the power to the hand controller, simply press the red button. The red light will stop illuminating. 5-376-000097 REV.
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MAINTENANCE MAINTENANCE AND LUBRICATION Your Jerr-Dan carrier has been designed to give you excellent service and long life, but like all equipment, it requires proper and periodic maintenance. The truck chassis itself is on a maintenance schedule recommended by the manufacturer. Follow these guidelines and protect your vehicle warranty. There are a number of different lubricants used on your carrier.
fluid is at operating temperature. Cold oil is more dense and will give a false indicator gauge reading. Cold temperatures can cause hydraulic oils to thicken and adversely affect the hydraulic functions of your carrier. If this is the case, it will be necessary to change the hydraulic oil to maintain maximum system efficiency.
FASTENER TORQUE SPECIFICATIONS • • • • • • All torque values shown are for bolts (cap screws) and nuts that are either zincplated or lubricated. Torques shown above apply only to screws and nuts used for assembly and installation of all carrier components, not to the chassis. Different torque values may be given in instructions for certain components due to short thread engagement or low-strength internal threads.
OILS AND GREASES The following oils and greases are suitable for use with your Jerr-Dan Carrier. Company Product HYDRAULIC OILS 1. 2. 3. 4. 5. 6. 7. 8. 9. Chevron Exxon Mobil Texaco Shell Citgo Amoco Conoco Mobil AW Hydraulic Oil MV Univis N32 DTE13 Rando DHZ-32 Tellus Oil T 32 A/W All Temp Rycon Oil 32 AW Hydraulic Fluid MV 46 DTE11M (for cold weather use) 10. Conoco AW Hydraulic Fluid MV 32 (for cold weather use) GREASES 1. Drydene 2. Gulf 3. Amoco 4. Shell 5. Texaco 6. Mobil 7.
WIRE ROPE HANDLING AND INSPECTION WARNING Wire Rope WILL FAIL if worn-out, overloaded, damaged, improperly maintained 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.
It is good practice , where the equipment is consistently in use, to give the rope a certain length of service, several hundred hours, several weeks or months and then renew the rope regardless of it's condition. This method eliminates the risk of fatigue causing rope failure. Any deterioration, resulting in a suspected loss of original rope strength, should be carefully examined and a determination made as to whether further use of the wire rope would constitute a safety hazard.
5-376-000097 REV. 1 - 12/08 Section III: Maintenance Page 89 7 2 3 4 5 DO NOT GREASE SLIDE PADS CHART COVERS ONLY BODY COMPONENTS * INDICATES DUAL RANGE HYD.
TROUBLE SHOOTING You probably won’t require anything but preventive maintenance to keep your Carrier running, however, the following chart will help you isolate and correct minor problems if they occur with use. Any service work on the hydraulic system should be performed by qualified mechanics. For a more comprehensive trouble shooting guide refer to Jerr-Dan’s “Hydraulic Troubleshooting Guide”, part number 5-377-000013, which is available through the Service Parts Department.
HYDRAULIC CLUTCH PUMP Problem No oil flow from pump Cause a. No oil in reservoir b. Pump not “primed” c. Clutch not engaging Pump will not build or hold pressure a. Relief valve improperly set b. Relief valve stuck open Solution a. Fill hydraulic reservoir b. Fill inlet hose from pump end c. Check wiring/fuse a. Adjust relief valve to manufacturers specification b. Remove, clean and reset Pump is noisy whines a. Air in the system b. Cavitation a. See “Oil Foaming” b.
PTO FUNCTIONING IMPROPERLY Problem Cable tight or frozen Cause Solution a. Cable kinked or bent b. Cable and PTO connection not adjusted properly c. Mounting bracket nuts are over tightened at PTO a. Straighten or replace b. Inspect and adjust Rattling noise in PTO a. PTO backlash too loose (Consult PTO Manual) a. Shims must be removed Howling Noise in PTO a. PTO backlash too tight (Consult PTO Manual) a. Shims must be added c. Loosen if necessary Gear oil leak between a.
HYDRAULIC PUMP - con’t Problem Oil foaming Cause a. Air leaking into suction line b. Wrong kind of oil Solution c. Oil level too low a. Tighten all connections b. Drain and refill with non-foaming type of hydraulic oil (See lube chart) Replace filter c. Refill to proper level Hydraulic oil leak between PTO and pump a. Defective shaft seal a. Replace shaft seal Clutch Pump leaks at Pulley Shaft a. Defective Shaft Seals b. Hydraulic Supply/Return lines connected incorrectly a.
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GLOSSARY OF TERMS A Anchoring Device - Used to attach cable ends, snatch blocks, safety chains, and tie-down assemblies to the towing vehicle. Approach Angle - Angle between the plane of the platform and the ground. Attachment - Any device that can be added to a basic unit or assembly. Auxiliary Braking Device - A device which attaches to the disabled vehicle to assist the tow truck's brakes in retarding or stopping both vehicles.
Boom Length - The straight line distance from center of the revolving base to the center of the boom head. Brakes - Parking - A system used to hold a stopped machine in a stationary position. Brakes - Service - A primary brake system used for retarding and stopping the truck. Bumper - DOT - A bumper designed to provide rear-end protection that meets the requirements of FMCSR 393.86. Bus Bar Grid - A device used for towing vehicles by lifting one end of the towed vehicle by the wheels.
Certification Label - Required by Public Law 89-563, which states that a motor vehicle or item of motor vehicle equipment complies with all applicable Federal Motor Vehicle Safety Standards (FMVSS) in effect on the date of manufacture. Chain Assemblies - Chain with all hardware and coupling devices. Chassis Cab - A vehicle consisting of a chassis upon which is mounted a cab; capable of being driven by the addition of wheel or other items of running gear, but lacking a body or load-carrying structure.
DOT (Department of Transportation) - A federal agency dealing with regulations concerning both the manufacture and operation of motor vehicles and motor vehicle equipment. See NHTSA. Driveline - The driveshaft and associated joints. Drum - Any spool on which are wrapped ropes used in machine operation. E Extend Cylinder - Cylinders used to extend or retract boom structures. F Filter- A device whose primary function is the retention by a porous media of insoluble contaminants from a fluid.
Forks - A device attached to the lift bar for lifting a vehicle by the tires, axle, frame, or structural member. May be classified as chain, axle, or frame forks. FW (Frame Width) - The overall width of the chassis frame measured outside to outside behind the cab. G GAWR (Gross Axle Weight Rating) - The value specified by the manufacturer as the load-carrying capacity of a single-axle system as measured at the tire-roadway interface.
Hydraulic Oil - Fluid used in operation of hydraulic systems. Hydraulic Relief Valve - A mechanical device used to limit the pressure in a hydraulic circuit. I Incomplete Vehicle - As assemblage consisting, as a minimum, of a frame and chassis structure, powertrain, steering system, suspension system and braking system to the extent that those systems are to be part of the complete vehicle that requires further manufacturing operations.
Light Pylon - Structure on which an emergency light bar is mounted. Line Pull - The maximum wire rope pull, in pounds, at the drum, at full-load engine speed, with specified lagging diameter. Line Speed - Speed in feet per minute of a single rope, based on full load engine speed with specified lagging diameter. M Marker 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 and cargo.
Overall Vehicle Width - The design dimension ot the widest part of the vehicle, exclusive of signal lamps, outside rearview mirrors, flexible fender extensions, and mud flaps, determined with doors and windows closed and the wheel in the straight ahead position. Overhang - The horizontal distance for the centerline of a single rear axle or center point of a tandem rear axle to a point where the vertical component is imposed. P Payload - The weight of the commodity being hauled.
Roadside - The left or driver's side of the vehicle when viewed from the rear, opposite side from Curbside. Rolling Resistance - The restraining forces contributed to the load when rolling on wheels. Rollback - See Car Carrier Rope - See Wire Rope Rub Rail - Member running longitudinally providing rub service on side of body. S SAE - Society of Automotive Engineers.
Spade - One or more ground penetrating devices designed primarily, when used, to stabilize rearward chassis movement. Stabilizers - A hydraulic or manually operated leg device (i.e., outboard legs, outriggers, or jack legs) attached to trucks to give additional support down to the ground for improved stability. Steering Wheel Securing Device - Used to secure front wheels in lieu of standard steering column lock. Stroke - The length of travel of a cylinder rod or piston.
Towing - See Tow. Tow Bar - A device for positioning a towed vehicle behind a towing vehicle. Tow Chain - Length of chain used to connect the sling with the towed vehicle. Tow Sling - A device used for lifting and towing vehicles with a partial load supported on rubber straps. Tow Vehicle - Vehicle used to lift-tow other vehicles. Towing Light/Bar - See Auxiliary Towing Lights.
Wheel Arm - A device that attaches to the lift bar for engaging the tires of a towed vehicle. Wheelbase - Horizontal dimension from centerline of front axle to the effective centerline of the rear axle(s). Wheel Chock - A device used to prevent chassis movement. Wheel Fork - See Wheel Arm. Wheel-Lift - A device used for towing vehicles by lifting one end of the towed vehicle by the wheels.
