Jerr-Dan MPL40 Use and care manual

Operation And Safety

Manual

Original Instructions

Keep this manual with machine at all times.

MPL-40

LIGHT DUTY

WRECKER

5376000277

October 23, 2023

SN 0230011584 to Present

including 0230010532, 0230010924 - 0230010930, 0230011032,

0230011121 - 0230011129, 0230011301 - 0230011319, and

0230011491 - 0230011510

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

5376000277 a

REVISION LOG

October 23, 2023 - A - Original Issue of Manual.

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b 5376000277

This manual provides Operational and Safety information for the Light Duty MPL-40

Wrecker. 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, LLC (Jerr-Dan) reserves the

right to make speciﬁcation changes without prior notiﬁcation. Contact Jerr-Dan 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 or the

local authorized representative for information regarding safety bulletins which may

have been issued for this product.

Jerr-Dan sends safety related bulletins to the owner of record of this machine. Contact

Jerr-Dan to ensure that the current owner of records are updated and accurate.

Jerr-Dan 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

13224 Fountainhead Plaza

Hagerstown, MD 21742

USA

or Your Local Jerr-Dan Oﬃce

In USA

Toll Free: 1-877-554-7233

Outside USA

Phone: 240-420-2661

Fax: 301-745-3713

E-mail

[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 Traﬃc Safety Administration (NHTSA) in addition to notifying Jerr-

Dan.

If NHTSA receives similar complaints, it opens an investigation, and if it ﬁnds

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.

To contact NHTSA, you may call the Vehicle Safety Hotline toll-free at 1-888-

327-4236 (TTY: 1-800-424-9153); go to https://www.nhtsa.gov/about-nhtsa/

contact-us; or write to:

Administrator

NHTSA

1200 New Jersey Avenue SE.

West Building

Washington, DC 20590

You can also obtain other information about motor vehicle safety from

https://www.nhtsa.gov/campaign/safercargov?redirect-safercar-sitewide.

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THIS PAGE IS INTENTIONALLY LEFT BLANK

Table of Contents

5376000277 i

TABLE OF CONTENTS

Revision Log

Read This First

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 1-2

Crush and Collision Hazards 1-4

Winch Cable / Falling Load Hazards 1-5

Uncontrolled Towed Load Hazards 1-6

Tip-Over Hazards 1-7

Fall 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 2-4

2.4 Operational Checks 2-8

Operational Check 2-8

Section 3 - Controls & Indicators

3.1 General 3-1

3.2 In-Body Controls 3-2

3.4 10 Function Wired Hand Controller (If Equipped) 3-4

3.5 8 Function Wireless Hand Controller (If Equipped) 3-5

3.6 14 Function Wireless Hand Controller (If Equipped) 3-6

Section 4 - Operation

4.1 Underlift Operation - Hydraulic Grids 4-2

4.2 Tie-down Straps - Hydraulic Grids 4-7

4.3 Underlift Operation - Manual Grids 4-11

4.4 Tie-Down Straps - Manual Grid 4-17

4.5 Towball Hitch Attachment 4-19

4.6 Motorcycle Towing Adapter Operation (Optional) 4-21

4.7 Gooseneck Towball Towing Adapter Operation (Optional) 4-27

Table of Contents

ii 5376000277

4.8 Gooseneck Fifth Wheel Towing Adapter Operation (Optional) 4-28

4.9 Wrecker Boom Operation - Dual Line Boom 4-29

4.10 Grid Mounted Recovery Sheave Operation (Optional) 4-33

4.11 Tow Sling Operation (Optional) 4-36

4.12 Spade Foot Attachment (Optional) 4-43

Section 5 - Emergency Procedures

5.1 Lowering of the Wrecker Boom 5-1

5.2 Raising/Lowering/Retracting/Folding/Tilting the Underlift Boom...........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 Underlift Level Stop 6-10

6.7 Lubrication Charts 6-11

Lubrication Points 6-13

6.8 Trouble Shooting 6-15

Hydraulic System 6-15

P.T.O. Functioning Improperly 6-16

Hydraulic Pump 6-16

Hydraulic Pump 6-17

Winch Functioning Improperly 6-17

Remote Hand Controller 6-18

Section 7 - Speciﬁcations

7.1 Product Speciﬁcations 7-1

MPL-40 7-1

Truck Chassis 7-3

7.2 Capacities 7-4

Inspection, Maintenance and Repair Log

Transfer Of Ownership

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