3 Car Carrier - Jerr-Dan

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3 CAR CARRIER OPERATIONS AND MAINTENANCE MANUAL 13224 Fountainhead Plaza Hagerstown, MD 21742 Phone (717) 597-7111 www.jerr-dan.com FOREWORD This manual is intended…
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3 CAR CARRIER OPERATIONS AND MAINTENANCE MANUAL 13224 Fountainhead Plaza Hagerstown, MD 21742 Phone (717) 597-7111 www.jerr-dan.com FOREWORD This manual is intended to serve as a guide to the owner and operator in the safe operation and optimum performance of this Jerr-Dan equipment. Establishment of good operating habits and familiarity with the equipment and its capabilities combined with good judgement are essential. Before attempting to operate the unit carefully read all sections of this manual. TABLE OF CONTENTS Certification ...................................................................................... 0.1 Safety ............................................................................................... 1.1 Decal Group ..................................................................................... 1.5 Operation .......................................................................................... 2.1 Maintenance and Lubrication ........................................................... 3.1 Lubrication Chart .............................................................................. 3.3 Troubleshooting ................................................................................ 3.4 Rev. __________ 1 Date _________ 9/14 THIS PAGE INTENTIONALLY LEFT BLANK Rev. __________ Date _________ NOTICE MANUFACTURED BY: DATE OF MANUFACTURE_____mo. _____yr. INCOMPLETE VEHICLE MANUFACTURED BY: DATE INC. VEH. MFD. _____yr. _____mo. GVWR _______________________________ GAWR FRONT _____________________ with __________________________________tires, _____ rims, @ _____ psi cold _____________ GAWR INTERMEDIATE (1) ____________with __________________________________tires, _____ rims, @ _____ psi cold _____________ GAWR INTERMEDIATE (2) ____________with __________________________________tires, _____ rims, @ _____ psi cold _____________ GAWR REAR ______________________with __________________________________tires, _____ rims, @ _____ psi cold _____________ Conformity of the chassis-cab to Federal Motor Vehicle Safety Standards, which have been previously fully certified by the incomplete vehicle manufacturer or intermediate vehicle manufacture, has not been affected by final-stage manufacture. The vehicle has been completed in accordance with the prior manufacturer’s instructions, where applicable. This vehicle conforms to all other applicable Federal Motor Vehicle Safety Standards in effect in: _____mo. _____yr. VEHICLE IDENTIFICATION NUMBER: VEHICLE TYPE: ________________________ This certification sticker appears on every Jerr-Dan unit mounted on a new chassis and is required by law. Jerr-Dan Corporation will not certify any unit for a capacity greater than the chassis manufacturer’s specified rating. The capacity ratings of Jerr-Dan units do not imply that vehicles can be used without regard to gross vehicle weight ratings (GVWR) or gross axle rating limitations. The payload carrying capacity of any truck is determined by the GVWR of the cab chassis, the curb weight of the cab chassis and the weight of the body. It is important that you determine that your truck has satisfactory carrying capacity and axle ratings for your specific application. Jerr-Dan’s authorized sales representatives are available to assist you in this regard. 0.1 Rev. __________ Date _________ THIS PAGE INTENTIONALLY LEFT BLANK 0.2 Rev. __________ Date _________ SAFETY Safety is all-important when working with machinery. Accidents happen when established safety practices have been overlooked. Read and practice all safety points listed in this manual. Safety is the prime responsibility of the operator. 1. Read operating and loading instructions thoroughly. 2. Become familiar with the loads that your unit can safely transport without exceeding the structural capacity of the Jerr-Dan equipment or the gross axle weight ratings, gross vehicle weight rating, and gross combined vehicle weight rating of your chassis. 3. Observe all warning decals. 4. Make sure you are clear of oncoming traffic. Dual controls (driver’s side and passenger’s side) are standard on your Jerr-Dan roll back. 5. Always put bumper on the ground to support the body and truck frame. 6. Never exceed the rated capacity of the body or truck chassis and it’s components or use a tow option without a vehicle on the deck. 1.1 Rev. __________ Date _________ 7. Never winch from the side of the bed. Winch only from the rear with load in line with the winch. Failure to do so can result in winch or wire rope damage. JERR-DAN DOES NOT RECOMMEND THE USE OF SIDE PULLING DEVICES. 8. Always try to winch from the center of the load. 9. Maintain winch cable in good condition. Replace when worn, kinked or frayed. Do not use cable clamps. 1.2 Rev. __________ Date _________ 10. When loading or unloading the deck and operating the winch, make certain the area behind the load is clear of personnel and obstacles. 11. Distribute load evenly on the deck. Do not concentrate the load on one section of the deck, to the rear of the truck axles, or use a tow option without a load on the deck. 12. Secure cargo to the deck at both the front and rear before the truck is driven. Do not rely on the winch as the only means of holding the load. 1.3 Rev. __________ Date _________ 13. Keep alert. Do not be distracted during any operating sequences. 14. Do not work behind truck with vehicle on deck unless vehicle is secured at front of deck. (Do not rely on winch.) 15. Read and follow wheel lift instructions for proper towing. 16. Do not exceed tow option ratings. Overloading can cause unsafe steering and braking conditions. 17. Always use both wheel straps on wheel lift. 18. Use separate safety chains from towed vehicle to subframe for tow options. Always attach safety chains to the opposite side of the attaching point, crossing chains under the tow option. Allow enough slack in the chains to maneuver around corners without binding. 19. Insure deck is in the locked position before traveling. 20. Review operator’s pre-transport checklist located on the headboard of the deck each time you move a vehicle. 21. Block up deck before performing any service or maintenance work under deck. 1.4 Rev. __________ Date _________ DECAL GROUP (STANDARD DECAL, LEFT SIDE) (STANDARD DECAL, RIGHT SIDE) (LUBRICATION CHART) 1.5 Rev. __________ 1 Date _________ 9/14 (WINCH) CAUTION MAINTAIN OIL LEVEL WITHIN 1/2 OF TOP OF SIGHT GAUGE WITH ALL CYLINDERS FULLY RETRACTED. TORQUE SIGHT GAUGE BOLTS: 8 FT-LBS MAX. 272-02 (HYDRAULIC OIL LEVEL) MANUF ACTURED JL G I NDUSTRIES, FOR: IDENT. NO. MODEL VERSION MANUFACTURED BY: JLG INDUSTRIES, INC. SERIAL BY : INC. NO. FOR: UNDER ONE OR MORE OF THE FOLLOWING PATENTS: MODEL NO. 1001 127221-00 5,133,633 5,575,606 5,697,741 5,722,810 5,951,235 6,231,294 B1 6,315,515 B1 6,336,783 B1 6,447,239 B2 7,264,305 B2 OTHER PATENTS PENDING 1001132766-A (SUBFRAME ID) 1.6 (SERIAL NUMBER) Rev. __________ 1 Date _________ 9/14 SLIDE DECK UNTIL ARROW ALIGNS WITH FIRST LEVER BEFORE TILITING (DECK ALIGNMENT) (TOW OPTION WARNING) (WHEEL LIFT WARNING) 1.7 Rev. __________ Date _________ CAUTION FULLY RETRACT TOW OPTION BOOM TO AVOID DAMAGE DURING OPERATION OF OTHER CARRIER FUNCTIONS. 165 (TOW OPTION WARNING) (CHECKLIST REMINDER) 1.8 Rev. __________ Date _________ (CHECKLIST) 1.9 Rev. __________ Date _________ 381 WINCH FREE SPOOL SYSTEM LOCATED UNDER MAIN DECK TO ENGAGE: LIFT UP KNOB THEN RELEASE. OPERATE WINCH TO LATCH IN. WARNING BEFORE OPERATION - WINCH CLUTCH MUST BE COMPLETELY ENGAGED WITH GUIDE BUSHING POSITIONED AS SHOWN TO DISENGAGE: LIFT UP KNOB AND PULL OUT. LOCK IN PLACE. (FREE-SPOOL OPERATION) (SLIDE PAD LUBRICATION) WARNING WINCH ORBIT MOTOR FITTINGS WILL INTERFERE WITH NYLON CABLE TRACK SYSTEM UPON INSTALLATION AND REMOVAL OF DECK. DO NOT INSTALL ORBIT MOTOR FITTINGS INTO ORBIT MOTOR TILL DECK IS SLID COMPLETELY ONTO SUBFRAME. REMOVE ORBIT MOTOR FITTINGS PRIOR TO REMOVING DECK FROM SUBFRAME. 330 (ORBIT MOTOR FITTINGS WARNING) 1.10 Rev. __________ Date _________ MANUFACTURED BY: JLG INDUSTRIES, INC. FOR: 13224 Fountainhead Plaza Hagerstown, MD 21742 Phone (717) 597-7111 www.jerr-dan.com MODELNUMBER: SERIAL NUMBER: STRUCTURAL CAPACITIES* MAIN DECK CAPACITY: LBS.* UPPER DECK CAPACITY: LBS.* WHEELLIFT/TOWBAR LIFT CAPACITY: (FULL EXTENSION) LBS.* WHEELLIFT/TOWBAR TOW CAPACITY: LBS.* HITCH OPTION TONGUE CAPACITY: (FULL RETRACTION) LBS.* HITCH OPTION TONGUE CAPACITY: LBS.* *PLEASE READ THE FOLLOWING IN ORDER TO ENSURE SAFE AND CORRECT USE OF THE EQUIPMENT. DO NOT EXCEED THE ABOVE STRUCTURAL RATINGS. THE MAXIMUM EFFECTIVE TRANSPORT LOAD MAY BE LIMITED BY THE GAWR, GVWR OR GCWR OF THE TRUCK CHASSIS. THE MAXIMUM EFFECTIVE TRANSPORT LOAD MAY BE LIMITED BY THE RATINGS OF ANY TOW IMPLEMENTS, ATTACHMENTS, OR ACCESSORIES BEING USED. WHEN SUPPLIED, THE SAFETY LOCKING PIN MUST BE IN PLACE DURING TRANSPORT TO ACHIEVE THE RATINGS LISTED ABOVE. SAFETY IS NO ACCIDENT. REVIEW OPERATOR'S PRE-TRANSPORT CHECKLIST ON VEHICLE AND IN THE OWNERS MANUAL EACH TIME YOU MOVE A VEHICLE. FOLLOW ALL INSTRUCTIONS ON CONTROLS AND UNIT. 1001132765-A (STRUCTURAL RATING PLACARD) 1.11 Rev. __________ 1 Date _________ 9/14 THIS PAGE INTENTIONALLY LEFT BLANK 1.12 Rev. __________ Date _________ OPERATION A. Controls The operating controls for the Jerr-Dan equipment are conveniently located on both the driver’s and passenger’s side. All operators must be trained and understand the contents of the operator’s manual before operating any controls. Assure adequate operating clearance and the safety of all personnel before operating the rollback equipment. 3 5 7 9 6 4 8 10 The following controls are provided: 1. Power-take-off (in truck cab) 2. Auxiliary engine throttle control (in truck cab) 3. Rollback control (first handle in control station) 4. Tilt control, lower deck (second handle in control station) 5. Winch control, lower deck front winch (third handle in control station) 6. Winch control, lower deck rear winch (fourth handle in control station) 7. Tilt control, upper deck (fifth handle in control station) 8. Winch control, upper deck (sixth handle in control station) 9. Tow option/Stabilizer, up/down (seventh handle in control station) 10. Tow option, in/out (eigth handle in control station) W R W W T I I I I N B L C C H O W O T W A N N L H T S T T I O L L C B A I R L T T H O P T OPERATING INSTRUCTIONS ALL OPERATORS SHOULD BE TRAINED AND COMPLY WITH ALL LOAD RATINGS. UNDERSTAND THE OPERATOR'S MANUAL. CAPACITY LOADS MUST BE UNIFORMLY DISTRIBUTED. ASSURE SAFETY OF ALL PERSONNEL. TILT ONLY WHEN DECAL ALIGNS WITH ADEQUATELY SECURE ALL LOADS. FIRST CONTROL HANDLE. ASSURE ENGAGEMENT OF WINCH DRUM. DO NOT OPERATE IF DAMAGED OR DEFECTIVE. ASSURE PROPER MAINTENANCE. DISENGAGE PTO BEFORE ENGAGING TRANSMISSION. USE SAFETY CHAINS FROM SUBFRAME TO TOWED VEHICLE. 343 B. Loading the Deck 1. Position Park the truck with the rear of the deck approximately 12 feet from the object to be loaded and in line with that object. CAUTION: The unit should always be loaded and unloaded on level and stable ground. 1 12 FT. 2.1 Rev. __________ Date _________ 1a. Set the parking brake. 1b. With the engine running, engage the PTO per instructions in the truck cab or in the PTO Operating Manual. 1c. Set the auxiliary throttle. After operating the unit several times, one will establish a feel for the optimum speed. DO NOT OVERSPEED. 2. Roll Raise the rollback handle and the deck will slide back. Roll the deck rearward approximately 12 inches to clear the mechanical hold downs at the front of the frame. A decal is provided on the rubrail to aid in determining the amount to roll. Align the decal pointer with the roll (first) control handle. 2 SLIDE DECK UNTIL ARROW ALIGNS WITH FIRST LEVER BEFORE TILITING 3. Tilt Raise the tilt control lever, raising the forward end of the deck until the rear bumper rests firmly on the ground. 3 4. Roll Raise the roll handle and the deck will slide back. Continue this operation until the approach plate of the deck has contacted the ground. Make sure that the rear bumper and the approach plate are both in firm contact with the ground before loading. There should be an equal weight distribution between the rear bumper and the end of the deck. 4 5. Winch Winch the load onto the deck. Refer to the Winch Operation Manual for specific winch operation procedures. 5 2.2 Rev. __________ Date _________ 5a. Raise the winch control handle to power unreel the winch cable while a second person keeps the cable taut or disengages the winch clutch and free spool the cable. (See the Winch Operation Manual for proper clutch disengagement prodecures) 5b. Engage the winch clutch if the winch cable was free spooled. Raise the winch handle (unreel the cable)until the winch clutch fully engages. Ensure that the winch clutch is fully engaged before putting a load on the winch. 5c. Attach the winch cable to the load. The winch cable should be attached as close to the center of the load as possible. It may be necessary to use a “V” chain or other implement to attach the winch cable to the load. 5d. Lower the Winch control handle to wind the cable onto the winch drum and pull the load onto the deck. CAUTION: Never disengage the winch clutch when the winch is under load. CAUTION: Always maintain a minimum of 5 wraps of cable on the winch drum. CAUTION: Always winch load onto deck, NEVER drive equipment onto the tilted deck. CAUTION: Always maintain a uniform wrap of cable on the drum. “Nesting” of the winch cable may cause damage or premature wear of the winch cable. CAUTION: Remember that cables break, winches fail, and hooks become disengaged. DO NOT WORK BELOW THE LOAD! CAUTION: Replace worn or damaged cables. Always wear gloves when handling cable. DO NOT USE CABLE CLAMPS. CAUTION: The winch cable should remain attached to the load and taut. 6. Secure Load Once the load is positioned on the deck secure it from movement in all directions. Set the parking brake or use wheel chocks if applicable. 2.3 Rev. __________ Date _________ 7. Roll Lower the roll control handle to roll the deck forward until the deck is in the proper position for tilting. The deck is in the proper position for tilting when the decal pointer is aligned with or just behind the roll (first) control handle. 7 8. Tilt Lower the tilt control handle to lower the front of the deck until the deck lays flat on the slide pads on the hold down. NOTE: Tilting deck when fully forward will cause damage to the hold downs. 8 9. Roll Lower the roll control handle to roll the deck forward until it is in the full forward position and under the hold downs. 9 10. Secure Load All loads must be secured from movement in all directions using safety tiedowns. Jerr-Dan provides straps and chains suitable for securing most vehicles to the deck. Vehicles should be secured at all four corners using safety tie-downs. Set brakes (if a vehicle) and use wheel blocks and tiedowns for safe transport. Refer to the AAA or vehicle manufacturers towing manual for correct attachment points. CAUTION: Use safety tie-downs to secure the load against rearward motion. Leave the winch cable attatched to the load and taut, but do not rely on the winch cable to secure the load. 11. Disconnect PTO Return the engine to normal idle speed and disengage the PTO before engaging the transmission. Driving the truck with the PTO engaged will cause overspeeding. Overspeeding of the PTO and/or pump will greatly shorten their life and can cause damage to the PTO, pump, and transmission. Rev. __________ Date _________ 2.4 C. Unloading the Deck 1. Position Park the truck with the rear of the deck approximately 12 feet from desired position of vehicle being unloaded. 1a. Set the parking brake. 1b. With the engine running, engage the PTO per instructions in the truck cab. 1c. Set the auxiliary throttle. After operating the unit several times one will establish a feel for the optimum speed. DO NOT OVERSPEED. 1d. Partially release bindings of the load but maintain restraint against movement of the load in any direction. 12'+ 1 LENGTH 2. Roll Raise the rollback handle and the deck will slide back. Roll the deck rearward approximately 12 inches to clear the mechanical hold downs at the front of the frame. A decal is provided on the rubrail to aid in determining the amount to roll. Align the decal pointer with the roll (first) control handle. 2 SLIDE DECK UNTIL ARROW ALIGNS WITH FIRST LEVER BEFORE TILITING 3. Tilt Raise the tilt control handle, raising the forward end of the deck until the rear bumper rests firmly on the ground. 3 2.5 Rev. __________ Date _________ 4. Roll Raise the roll handle and the deck will slide back. Continue this operation until the approach plate has contacted the ground.Make sure that the rear bumper and the approach plate are both in firm contact with the ground before unloading. There should be an equal weight distribution between the rear bumper and the end of the deck. 4 5. Winch Winch the load off of the deck. Refer to the Winch Operation Manual for specific winch operation procedures. 5 5a. Ensure that the winch cable is securely attached to the load and is taut. Ensure that the winch clutch is fully engaged (the winch is NOT in free spool mode.) 5b. Remove all equipment used to secure the load to the deck (excluding the winch cable). Release brakes of the load (if applicable). 5c. Raise the winch control to power unreel the cable from the drum, lowering the load from the deck. 5d. Secure the load on the ground Remove the winch cable from the lod and store the cable. CAUTION: Never disengage the winch clutch when the winch is under load. CAUTION: Always maintain a minimum of 5 wraps of cable on the winch drum. CAUTION: Always winch load off of the deck, NEVER drive equipment on the tilted deck. 2.6 Rev. __________ Date _________ CAUTION: Always maintain a uniform wrap of cable on the drum. “Nesting” of the winch cable may cause damager or premature wear of the winch cable. CAUTION: Remember that cables break,winches fail,and hooks become disengaged. DON’T WORK BELOW THE LOAD! CAUTION: Replace worn or damaged cables. Always wear gloves when handling cable. DO NOT USE CABLE CLAMPS! D. LOADING THE OVERCAB DECK 1. POSITION Position the truck with the rear of the deck approximately 12 feet from the object to be loaded and in line with that object. CAUTION: The unit should always be loaded and unloaded on level and stable ground. 1 12 FT. 1a. Set the parking brake. 1b. With the engine running, engage the PTO per instructions in the truck cab or in the PTO Operating Manual. 1c. Set the auxiliary throttle. After operating the unit several times, one will establish a feel for the optimum speed. DO NOT OVERSPEED. 2. Roll Raise the rollback handle (first lever) and the deck will slide back. Roll the deck rearward approximately 12 inches to clear the mechanical hold downs at the front of the frame. A decal is provided on the rubrail to aid in determining the amount to roll. Align the decal pointer with the roll (first) control handle. 2 SLIDE DECK UNTIL ARROW ALIGNS WITH FIRST LEVER BEFORE TILITING 2.7 Rev. __________ Date _________ 3. Tilt Raise the tilt control lever (second lever), raising the forward end of the deck until the rear bumper rests firmly on the ground. 3 4. Roll Raise the roll handle (first lever) and the deck will slide back. Continue this operation until the approach plate of the deck has contacted the ground. Make sure that the rear bumper and the approach plate are both in firm contact with the ground before loading. There should be an equal weight distribution between the rear bumper and the end of the deck. 4 5. Tilt (upper deck) Raise the tilt control lever (fifth lever) for the upper deck. This will raise the front end of the upper deck, raise fully. Free-spool the upper winch and hook up to the equipment to be loaded. 5 **Note that tilting the upper deck will leave a gap between the upper and lower decks. 6. Winch
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