S.D.P. EZ Hauler 4100 Manual Download Page 1

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Printed on 20 November, 2006

Manual Part # 99903718

EZ Hauler 4100

Revision Date 20061120

S.D.P. Manufacturing, Inc.

400 Industrial Drive

Dunkirk, IN 47336

Tel: 765-768-5000 FAX: 765-768-5015

Website: http://www.sdpmfg.com

Crane manufactured exclusively for S.D.P. MANUFACTURING, INC. by Iowa Mold Tooling Co.,
Inc.

No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any
form or by any means, electronic, mechanical, photocopying, recording or otherwise without the
prior written permission of Iowa Mold Tooling Co., Inc

Iowa Mold Tooling Co., Inc. is an Oshkosh Truck Corporation Company.

Summary of Contents for EZ Hauler 4100

Page 1: ...xclusively for S D P MANUFACTURING INC by Iowa Mold Tooling Co Inc Copyright 2006 Iowa Mold Tooling Co Inc All rights reserved No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Iowa Mold Tooling Co Inc Iowa Mold Tooling Co Inc is an O...

Page 2: ......

Page 3: ...alve Counterbalance 73540163 27 Boom Assemblies Cylinders 28 Boom Assembly 99903706 28 Mast Boom Assembly 99903707 35 Boom Tip Asembly 51719583 37 Cylinder Assembly Extension 41718922 39 Winch Planetary 71570781 40 Hydraulics 42 Hydraulic Layout 99903715 42 Hydraulic Schematic 99903702 45 Control Valve Cross Section Torques 47 EZ Hauler 4100 Control Valve Troubleshooting Guide 49 Electrical 52 Wir...

Page 4: ... Crane Reference 65 Wire Rope Inspection Replacement 65 Hook Inspection 66 Holding Valve Inspection 67 Inspection Checklist 68 Deficiency Recommendation Corrective Action Report 72 Thread Torques 74 Turntable Bearing Thread Tightening Sequence 76 ...

Page 5: ...OK FROM 70732870 TO 70732871 77441178 ECN 10036 INCREASE FUSE SIZE REMOVE DIODE FROM ELEC SYSTEM 20060302 71056608 ADDED GEAR ROTATOR COMPONENT PART NUMBERS 20060329 51719583 99903706 ECN 10077 ADDED AUGER SWIVEL STOP AND HARDWARE 20060502 99903706 41718922 ECN 10116 10077 CLAMP PLATE ON EXT CYL 20060721 51719040A 99903706 ECN 10143 ADD NOTE TO PAINT CYLINDER WHITE ECN 10137 UPDATE 99903706 DRAWIN...

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Page 7: ...ning the safe use and maintenance of this unit This crane was designed and built to meet the standards of ANSI ASSE A10 31 1995 Safety Requirements Definitions and Specifications for Digger Derricks Contact the American National Standards Institute www ansi org for more information Throughout this manual three means are used to draw the attention of personnel They are NOTEs CAUTIONs and WARNINGs a...

Page 8: ...utious as you rotate the crane because the springs on the carrier vehicle will respond differently to the load than the tires will Position the crane in its stowed position when not in use FIRE PRECAUTIONS To avoid fires Use safety type portable gasoline containers equipped with an automatic closing cap and flame arrester DO NOT refuel while the vehicle engine is running DO NOT smoke in a refuelin...

Page 9: ...ty Accessories Check for proper function oil levels leaks and malfunctions 3 Weldments Check visually for damage especially cracks or breaks in welds 4 Fasteners Check pins sheaves nuts and bolts for breakage excessive wear and tightness 5 Crane Hooks Check for the presence of a safety catch twists cracks or damage 6 Covers and Guards Check for missing or improperly maintained covers and guards 7 ...

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Page 11: ...T 2 470 lb 1120 kg MOUNTING SPACE REQUIRED crane base 21 x 21 53 3 cm x 53 3 cm Crane rating ft lb is the rated load lb multiplied by the respective distance ft from centerline of rotation with all extensions retracted and lower boom in horizontal position PERFORMANCE CHARACTERISTICS ROTATION 400 degrees 76 seconds LOWER BOOM ELEVATION 0 72 degrees 33 seconds extension 26 seconds retraction EXTENS...

Page 12: ...of the lower boom and extension cylinders are equipped with integral mounted counter balance valves to prevent sudden cylinder collapse in case of hose or other hydraulic failure The counter balance valves serve several functions These include 1 Holding valves 2 Speed control for the lowering function via which causes that function to be metered under load 3 Prevention of excessive oil loss during...

Page 13: ...Chapter 2 Specifications 11 Geometric Configuration 28 10 5 11 41 4 4 3 4 5 8 35 7 34 4 ...

Page 14: ...LD TOOLING CO INC Single part line lifting ONLY All outriggers must be extended and set firmly on ground and machine leveled before crane operation Capacities shown in pounds for FULL 360 degree work zone REACH FROM CENTERLINE OF ROTATION 4100 lb 2800 lb 1536 lb 1129 lb 900 lb 600 lb 6 12 15 22 27 34 41 MAX REACH 5 11 80 10 ...

Page 15: ...r distributor or manufacturer for availability ASSEMBLY NAME PART COMPONENT PART DESCRIPTION QUANTITY BASE MAST ASSEMBLY 99903705 73051963 HYDRAULIC MOTOR 1 LOWER CYLINDER 51719040A 51744139 SEAL KIT 1 BOOM ASSEMBLY 99903706 41719025 E CHAIN KIT 1 52719329 RESTRAINING PIN WELDMENT 3 60030342 WEAR PAD 1 60030343 WEAR PAD 1 60030344 WEAR PAD 1 60030345 WEAR PAD 1 60030346 WEAR PAD 1 60030347 WEAR PA...

Page 16: ... LOWER CYLINDER WORM GEAR BASE MAST LOWER BOOM EXTENSION BOOMS INTERNAL CYLINDERS ITEM LOCATION DESCRIPTION LUBRICANT FREQUENCY 1 INTERMEDIATE GEAR 2 WORM GEAR 3 TURNTABLE ROTATE CRANE WHILE GREASING 4 LOWER CYLINDER LOWER END 5 LOWER CYLINDER UPPER END 6 SHEAVE SHELL ALVANIA 2EP OR SHELL RETINAX A WEEKLY ...

Page 17: ...15 In This Chapter Parts Information 16 Base and Mast Assemblies 18 Boom Assemblies Cylinders 28 Hydraulics 42 Electrical 52 Miscellaneous 60 C H A P T E R 3 Parts ...

Page 18: ...TAINED IN THE REPAIR SECTION PAY PARTICULAR ATTENTION TO STATEMENTS MARKED WARNING CAUTION OR NOTE IN THAT SECTION FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN DAMAGE TO THE EQUIPMENT PERSONAL INJURY OR DEATH CRANE IDENTIFICATION Every crane has an identification placard see figure attached to the mast When ordering parts communicating warranty information or referring to the unit in co...

Page 19: ...ELDMENT IDENTIFICATION Each of the major weldments base mast inner boom outer boom extension boom and outrigger weldments bear a stamped part number Any time a major weldment is replaced you must specify the complete part number as stamped on the weldment The locations of the part numbers are shown in the Crane Reference Section ORDERING REPAIR PARTS When ordering replacement parts 1 Give the mode...

Page 20: ...4 PLCS GREASE ZERK PART OF ROTATOR 2 PLCS 35 3 PLCS 42 2 PLCS 41 2 PLCS USED TO FASTEN SHIPPING BLOCKING USE ANTI SEEZ USE BLUE THREAD LOCK 18 20 3 PLCS VB 10mm NUT FROM VB HANDLE REMOVE HANDLE AND 10mm NUT TORQUE TO 160 FT LB SECURE VB HANDLE HERE JAM NUT PART OF 39 24 34 16 PLCS 99903705 PARTS LIST ITEM PART DESCRIPTION QUANTITY 1 51719040A CYLINDER 1 2 51719567 HARDWARE KIT BASE MAST ASM INCL 9...

Page 21: ...ASHER 25 FLAT 7 21 72063002 WASHER 31 FLAT 4 22 72063049 WASHER 25 LOCK 8 23 72063053 WASHER 50 LOCK 1 24 72063119 WASHER 62 FLAT ASTM F436 16 25 72063132 WASHER 50 FLAT ASTM F436 1 26 72066136 RETAINING RING EXT 2 00 HD 1 27 72532355 ADPTR M STR M JIC 6 6 2 28 72532997 COUPLER DISC 50FLSHFAC MALE 1 29 72533119 COUPLER DISC 50 14FPT FF3718 1 30 72533186 ADPTR M FACE M STR 6 6 4 31 72533430 UNION B...

Page 22: ... BEARING ROLL CUP 2 3 70055308 BEARING ROLL CONE 2 4 71412279 3 8 16X1 1 4 12 PT CBB GR8 8 5 71412280 CAP SCR 1 2 13X1 HH SHIPPING ONLY 2 6 71412281 CAP SCR 1 2 13X1 1 4 HH PLATE GR5 2 8 71412282 PLUG PIPE 1 8 HEX SUN 1 9 71412283 VENT PLUG 1 10 76396847 SEAL OIL 1 11 71412284 PLUG THREADED 1 4 28 1 12 70034484 CAP GREASE FIT PLASTIC COVER 2 13 71412285 GREASE FITTING 1 4 28 STRAIGHT 1 14 71412286...

Page 23: ...HIM WORM 0 0075 CLEAR 2 29 76029617 SHIM WORM 0 005 BLUE 3 30 76029618 SHIM WORM 0 020 YELLOW 2 32 76396848 O RING 1 33 71412292 CAP GEAR 1 34 71412293 CAP WORM 1 35 71412294 SCREW 6 32X3 8 HWHTR 8 36 76029610 SHIM GEAR 0 0075 NAT ALUMINUM 4 37 76029611 SHIM GEAR 0 005 BLUE ALUMINUM 4 38 76029612 SHIM GEAR 0 003 GREEN ALUMINUM 4 39 71412295 WORM GROUND 1 40 76029613 SHIM COVER 0 005 BLUE ALUMINUM ...

Page 24: ...0 PSI 2 TORQUE PISTON TO 400 500 FT LB 3 TORQUE HEAD GLAND TO 300 400 FT LB 4 REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS DISASSEMBLED THIS WILL REDUCE FUTURE DOWNTIME 5 APPLY REGULAR GRADE ANTI SEIZE AND LUBRICATING COMPOUND TO THREADS ON CYLINDER HEAD ONLY KEEP AWAY FROM ALL SEALS 6 APPLY LUBRIPLATE NO 630 2 MEDIUM HEAVY MULTI PURPOSE LUBRICANT TO ALL PISTON HEAD GLAND AND HO...

Page 25: ...60127499 HEAD 1 6 60127500 PISTON 1 7 60127542 STOP TUBE 1 8 6A025025 WAFER LOCK 1 9 72053508 ZERK NPT 12 2 10 72062304 COLLAR LOCK 1 11 76396605 SEAL ROD 1 12 76396606 WEAR RING PISTON 2 13 76396608 BACKUP RING 2 14 7Q072226 O RING 1 15 7Q072350 O RING 1 16 7Q10P350 BACKUP RING 1 17 7R14P025 ROD WIPER 1 18 7T2NX427 WEAR RING ROD 2 19 7T66P500 PISTON SEAL DYNAMIC 1 REV A 20060721 ...

Page 26: ...9903705 99903708 PARTS LIST ITEM PART DESCRIPTION QUANTITY 1 70733995 VALVE BANK 1 2 72532351 ADPTR M STR M JIC 4 4 1 3 72532355 ADPTR M STR M JIC 6 6 6 4 72532357 ADPTR M STR M JIC 6 8 4 5 72532359 ADPTR M STR M JIC 10 8 2 6 72532362 ADPTR M STR M JIC 10 10 2 7 72533682 ELBOW M JIC F JIC SW 10 10 1 8 93719600 HARDWARE KIT VB INCL 2 7 1 NEW 20050919 ...

Page 27: ...Chapter 3 Parts 25 Valvebank 70733995 Drawing not available at time of printing ...

Page 28: ... 1 6 73540236 VALVE PRESSURE REDUCING 1 7 73540238 VALVE PRESSURE COMPENSATOR 1 8 73540240 KIT INTERFACE ADAPTER SERVO PISTON 1 9 77441221 COIL SOLENOID 1 10 73540231 RELIEF VALVE 1 11 73540233 VALVE PROP MLT MODULE W VALVES 5 12 73540239 KIT INTERFACE ADAPTER SERVO PISTON 5 13 73540228 VALVE SECTION WINCH 1 14 94744153 KIT SEAL O RING 5 15 73540234 VALVE PROP MLT AUGER W VALVES 1 16 94744154 KIT ...

Page 29: ...6 ORB PORT 2 4 CYL R CYL E SWT R E ø0 344 THRU 2 PLCS PRESSURE FIXED 2500 PSI HOLDING THIS IS A THERMAL RELIEF VALVE ACTUAL CRACKING PRESSURE RANGE FROM 3500 TO 4000 PSI 73540163 PARTS LIST ITEM PART DESCRIPTION QUANTITY 1 VALVE BODY 1 2 COUNTERBALANCE VALVE 1 3 PLUG SAE 6 1 4 PLUG SAE 4 4 5 ORIFICE REMOVABLE 1 NEW 20050912 ...

Page 30: ...28 EZ Hauler 4100 Manual Part 99903718 Boom Assemblies Cylinders BoomAssembly 99903706 ...

Page 31: ... 31 32 13 14 15 22 22 22 5 18 64 64 6 7 8 20 20 20 51 63 51 63 85 86 51 63 63 51 63 55 5163 63 51 63 55 4 64 12 64 74 53 10 84 INSTALL AUGER MOUNT ASSEMBLY TO TIP OF BOOM 6 AS SHOWN DETAIL A 60 68 80 2 PLCS 76 2 23 56 62 2 PLCS 38 2 PCS 55 2 63 2 DETAIL B 2 PLCS 21 56 62 64 2 ...

Page 32: ...99903706 COMPONENT PLACEMENT 26 81 78 34 28 35 27 19 1 47 61 69 67 73 2 PLCS 66 72 2 PLCS 67 73 2 PLCS 52 71 3 PLCS NOTE 1 INSERT 35 PIN THROUGH 34 TRUNNION PIN CYLINDER 1 WITH 27 THROUGH 28 SPACER BOOM EARS NOT SHOWN IN DRAWING FOR CLARITY ...

Page 33: ...06 COMPONENT PLACEMENT 9 29 59 57 45 81 6 PLCS 49 62 2 PLCS 57 2 PLCS 55 63 4 PLCS 56 2 PLCS 59 4 PLCS 56 62 2 PLCS 52 63 4 PLCS 75 2 PLCS 48 62 2 PLCS NOTE 1 INSTALL AUGER HOSES INTO E CHAIN BEFORE INSTALLING E CHAIN INTO TRAY ...

Page 34: ...YL ASM 2 5 1 5 139 12S 96 81CC C DUAL 1 2 41718924A CYL 2 50 1 50 69 56S 6 06CC C 1 3 51719566 KIT HRDW BOOM ASM INCL 46 72 74 80 81 1 4 52070138 PIN WLDMT 2 5 52718909 LOWER BOOM WELDMENT 1 6 52718912 FIRST EXT WELDMENT 1 7 52718914 SECOND EXT WELDMENT 1 8 52718916 THIRD EXT WELDMENT 1 9 52719018 E CHAIN TRAY WELDMENT 1 10 52720189 WLDMNT SLIDING COLLAR 1 11 60129111 PIN TYPE N 75 X 9 25 3 12 600...

Page 35: ...ORFS 4 BEND 1 38 71411213 TUBE ASM 0 063 OD X 0 063W X 14 12LG MJIC MJIC 2 39 71411216 TUBE ASM 0 63 OD X 0 063W X 89 02 LG MJIC MJIC 1 40 71411217 TUBE ASM 0 63 OD X 0 063W X 90 43LG MJIC MJIC 1 41 71411218 TUBE ASM 0 63OD X 0 063W X 60 22L MJIC 1 42 71411219 TUBE ASM 0 63OD X 0 063W X 60 33LG MJI 1 43 71411549 TUBE ASM HYD 0 38OD X 17 32LG ORFS ORFS 6 6 1 44 71411550 TUBE ASM HYD 0 38OD X 14 66L...

Page 36: ... ITEM 11 3 74 72066185 COTTER PIN 16X1 00 PLAIN 2 75 72532362 ADPTR M STR M JIC 10 10 2 76 72532675 CAP JIC STL 75 THD 2 77 72533163 ELBOW M STR 90 M FACE 6 6 3 78 72533186 ADPTR M FACE M STR 6 6 3 79 72534414 ELBOW MSTR 90 M FACE XLG 6 6 2 80 72601410 CAP SCR 25 20X 75 BTNHD ZC 2 81 72601744 CAP SCR 10 24X1 00 SH 6 82 73540163 VALVE CBAL 10 GPM 7 1 1 83 91719508 HYD FITTING KIT INCL 75 79 1 84 52...

Page 37: ... 99903707 PARTS LIST ITEM PART DESCRIPTION QUANTITY 1 51719566 HARDWARE KIT BOOM ASM INCL 5 10 12 1 2 52719056 PIN WELDMENT 1 3 52719058 PIN WELDMENT 1 4 60128886 COVER VALVE BANK 1 5 72060004 CAP SCR 25 20X 1 00 HH GR5 Z 4 6 72060091 CAP SCR 50 13X 1 00 HH GR5 Z 2 7 72062104 NUT 25 20 HEX NYLOCK WAS 4 6 8 72063001 WASHER 25 FLAT WAS 8 10 9 72063039 MACHY BUSHING 2 00X10 GA NR 2 10 72063053 WASHER...

Page 38: ...6 REF 14 MAST MAST ASSEMBLY SEE 99903705 REF 15 99903715 DRAWING EZ HAULER REF 16 72060002 CAP SCR 1 4 20 X 3 4 HHGR5Z 2 17 72601726 NUT 6 32 HEX NYLOC 2 18 72601725 SCR MACH 6 32 1 2LG RDH PHILPS 2 19 51718913 CABLE ASSEMBLY E STOP SWITCH 1 20 51719826 CABLE ASSEMBLY HOP ALARM 1 REV C 20051011 ...

Page 39: ...Chapter 3 Parts 37 Boom TipAsembly 51719583 3 11 7 9 2 5 6 16 14 8 10 13 15 2 PLCS 12 2 PLCS 4 ...

Page 40: ...0030082 SHEAVE 7 00 NYLON W BEARING 1 6 60030349 WEAR PAD RC 2 00 X 3 00 X 6 00 1 7 70034382 CAP GREASE PRO20 GC RED 1 8 70732871 HOOK SWVL W LATCH WAS 71073035 70732870 1 9 72053508 ZERK NPT 12 1 10 72060048 CAP SCR 38 16X 1 50 HH GR5 Z 2 11 72060096 CAP SCR 50 13X 2 50 HH GR5 Z 2 12 72062080 NUT 50 13 HEX NYLOCK 2 13 72063003 WASHER 38 FLAT 2 14 72063030 MACHY BUSHING 75X10 GA NR 1 15 72063051 W...

Page 41: ... 19 CC C 1 3 60126613 CLAMP BOTTOM PLATE DUAL CYL 1 4 60126614 CLAMP PLATE TOP DUAL CYL 2 5 60127866 CLAMP PLATE 1 00 X 2 09 X 9 50 1 6 71411195 TUBE ASM HYD 73 51LG ORFS ORFS 4 BEND 1 7 71411196 TUBE ASM HYD 85 29LG ORFS ORFS 4 BEND 1 8 72062335 CAP SCR 44 14X 3 00 SH GR5 Z 4 9 72063004 WASHER 44 FLAT 4 10 72533163 ELBOW M STR 90 M FACE 6 6 2 11 72533186 ADPTR M FACE M STR 6 6 2 12 52720292 WELDM...

Page 42: ...40 EZ Hauler 4100 Manual Part 99903718 Winch Planetary 71570781 71570781 PARTS LIST ITEM PART DESCRIPTION QUANTITY 1 BEARING SUPPORT ENDPLATE 1 2 BRAKE CYLINDER ENDPLATE 1 3 CABLE DRUM 1 ...

Page 43: ... 35 71411148 STEEL DISC 9 36 O RING PART OF 54 1 37 O RING PART OF 54 1 38 MOTOR ADAPTER 1 39 BRAKE VALVE BLOCK 1 40 71734007 COUNTERBALANCE VALVE CARTRIDGE 2 41 SUN GEAR 1 42 71411149 VENT PLUG 1 43 TUBE ASSEMBLY 1 44 CAPSCREW 4 45 ELBOW FITTING 2 46 O RING PART OF 54 2 47 CAPSCREW 8 48 LOCK WASHER 8 49 73511057 HYDRAULIC MOTOR 1 50 CAP SCREW 2 51 LOCK WASHER 2 52 SNAP RING 1 53 71411150 CABLE WE...

Page 44: ...42 EZ Hauler 4100 Manual Part 99903718 Hydraulics Hydraulic Layout 99903715 ...

Page 45: ...OUPLER DISC 50 14FPT FF3718 1 7 72532997 COUPLER DISC 50FLSHFAC MALE 1 8 72533613 ADPTR M STR M JIC 10 6 2 10 72533163 ELBOW M STR 90 M FACE 6 6 3 12 72533186 ADPTR M FACE M STR 6 6 7 13 72532699 ELBOW M STR 90 M JIC 6 4 1 14 72532355 ADPTR M STR M JIC 6 6 2 15 72532362 ADPTR M STR M JIC 10 10 1 17 72532678 PLUG JIC HEX HD STL 44 THD 1 18 72532675 CAP JIC STL 75 THD 2 20 72532666 ELBOW M STR 90 M ...

Page 46: ...51396758 HOSE FJ 38 X 53 00 OAL 6 6 1 36 51396759 HOSE FZ 38 X 42 00 OAL 10 10 1 37 51396969 HOSE FJ 50 X 10 00 OAL 10 10 WAS 51396959 2 40 51394218 HOSE FJ 25 X 35 00 OAL 4 4 1 45 71411213 TUBE ASM 0 063 OD X 0 063W X 14 12LG MJIC MJIC 2 46 71411216 TUBE ASM 0 63 OD X 0 063W X 89 02 LG MJIC MJIC 1 47 71411217 TUBE ASM 0 63 OD X 0 063W X 90 43LG MJIC MJIC 1 48 71411218 TUBE ASM 0 63OD X 0 063W X 7...

Page 47: ...Chapter 3 Parts 45 Hydraulic Schematic 99903702 ...

Page 48: ...AE 10 A B 1 2 BSPP SAE 10 PPG Tp Mls Mp 9 16 UNF SAE 4 MANUAL AUGER 15 0 5 GPM 1000 PSI ELECTRIC 4 0 0 3 0 GPM 1000 PSI 15 1 0 LPM 70 BAR MANUAL 5 0 0 5 GPM 1000 PSI 19 2 LPM 70 BAR SECTION B STACKABLE DIRECTIONAL CONTROL VALVE SYSTEM FOR CRANE FUNCTIONS OPERATION SECTION B CONTROL CONFIGURATION LOAD SENSING INDIVIDUALLY PRESSURE COMPENSATED ELEMENTS WITH MANUAL LEVERS AND ELECTRO HYDRAULIC PROPOR...

Page 49: ...rts 47 Control Valve Cross Section Torques CP2 COMPENSATOR TORQUE 30 FT LB TYP LOAD SENSE SHUTTLE ADAPTER MOUNTING BOLTS TORQUE 45 60 IN LB TYP ADAPTER PROPORTIONAL ACTUATOR ELECTRICAL CONNECTOR PROP VALVE 2 PLACES ...

Page 50: ...NG VALVE TORQUE 30 FT LB 18 FT LB VS RELIEF VALVE CP3 BYPASS COMPENSATOR 70 90 IN LB 18 FT LB CP2 COMPENSATOR MOUNTING BOLTS PROPORTIONAL DRIVER FOR CONTROL VALVE MOUNTING BOLTS TORQUE 25 30 IN LB TYP ELECTRICAL CONNECTOR TYP 6 PLACES AUGER MID INLET SECTION LIFT BOOM EXTEND WINCH AUXILIARY ROTATION CP2 RPM PPG MP B1 A1 MLS P T TP ...

Page 51: ...alve actuator uses two proportional flow control valves along with a Hall Effect position transducer and onboard electronics to precisely control spool position The input signal is a voltage signal with neutral at 2 5 volts The mid inlet contains a bypass compensator CP3 a load sense orifice a compensator decompression orifice a pilot relief valve VS that controls the inlet compensator a pressure ...

Page 52: ... not increase when the function is operated clean or replace the function load sense shuttle 1 Check the control disable solenoid valve EV9 for power during function operation If there is no power to the EV9 solenoid valve during winch operation check the radio controller and electrical system 2 Check the valve section 4 pin connector Pins 1 2 and 3 for proper function See the Control Requirements...

Page 53: ...the adapter bolts to 45 60 in lb 7 Torque the auger CP2 compensator bolts to 90 100 in lb These torques are reflected on the Control Valve Cross Section Torques on page 47 drawing WARNING Over torquing cartridges can cause valves to malfunction Under torquing cartridge can result in valves loosening with time Over torquing coil nuts can permanently damage valves NOTE Contamination may cause failur...

Page 54: ...8 Electrical Wiring Layout 77441178 FORWARD FLOOD LIGHT J5 J6 W1 W2 LEFT FLOOD LIGHT RIGHT FLOOD LIGHT J4 FLOOD LIGHT SWITCH J3 E STOP J2 ALARM J7 J1 RECEIVER R1 RELAY W5 W4 W3 B A W3 W4 W5 HORN PWR NO HOP SWITCH NC SWITCH PWR COM PRES SW ...

Page 55: ...GND B FRONT FLOOD PWR A FRONT FLOOD GND B RADIO POWER A RADIO VALVE GND 2 LIGHT CONTROL 3 PRESSURE SWITCH INPUT 4 HORN GROUND A HORN POWER B HORN POWER W3 HOP SWITCH W4 SWITCH PWR W5 F1 SPLICE A SPLICE B SPLICE A SPLICE A SPLICE C SPLICE C SPLICE A SPLICE C 30 86 87a 85 87 R1 SPLICE B A LIGHT SWITCH B LIGHT SWITCH J3 J2 A E STOP B RADIO POWER ...

Page 56: ...N ADJUST DITHER GENERATOR PID ANALOG CONTROLLER INPUT RANGE ALARM DETECTION SUPPLY RANGE ALARM DETECTION 5 V EXTERNAL 5 V INTERNAL DC DC A STROKE GAIN ADJUSTMENT B STROKE GAIN ADJUST TR2 TR3 1 2 3 4 MAXIMUM STROKE FW VALVE STROKE 2 25V 2 75V MIN FW 0 25V MAX BW 0 9V 4 1V MAX FW 4 75V 0 MIN BW MAXIMUM STROKE BW DRIVING VOLTAGE 1 12 VOLTS 2 GROUND 3 CONTROL SIGNAL 4 FLOOD LIGHT CONTROL 1 12 VOLTS 2 ...

Page 57: ...ANGE NEUTRAL 2 5 VOLTS 0 1 VOLTS AT REST 0 5 VOLTS TOTAL DEAD ZONE NEUTRAL TO MAX STROKE A 4 1 VOLTS DO NOT EXCEED 4 75 VOLTS NEUTRAL TO MAX STROKE B 0 9 VOLTS DO NOT DROP BELOW 0 25 VOLTS 10 AMP FAST TYPE FUSE MUST BE USED FOR 1 POWER SOURCE WHERE CONTROL DOES NOT PROVIDE PROTECTION HYDRAULIC SPECIFICATIONS MAXIMUM SUPPLY PRESSURE 508 PSI 35 BAR MINIMUM SUPPLY PRESSURE 174 PSI 12 BAR MAXIMUM BACK...

Page 58: ...LOW GREEN 2 POWER SOURCE BROWN 3 CONTROL SIGNAL BLACK 4 5 V VOLTAGE SUPPLY TO THE REMOTE CONTROL POTENTIOMETER ADJUSTING TRIMMERS GREEN LED NEUTRAL POSITION T1 NEUTRAL POS ADJ TRIMMER PART A REMOTE CONTROL POTENTIOMETER CHARACTERISTICS CONFIGURATION 3 PIN OHMIC RESISTANCE 1K 5K 10K OHM ELEC POWER RATING 0 25 WATTS OUTPUT VOLTAGE 95 98 OF VIN ADJ TRIMMERS LED ...

Page 59: ...CH 1 2 3 LOCATOR CODE J1 PACKARD 12015792 TERM 12124580 SEAL 12015323 CAVITY COLOR GA PRINT LABEL TO CON SPLC CAVITY A RED 16 LIGHT SWITCH TO S1 2 B RED 16 LIGHT SWITCH TO S1 3 LOCATOR CODE S1 EATON SWITCH 8510K9 CAVITY COLOR GA PRINT LABEL TO CON SPLC CAVITY 2 RED 16 LIGHT SWITCH TO J1 A 3 RED 16 LIGHT SWITCH TO J1 B NEW 20050719 ...

Page 60: ...58 EZ Hauler 4100 Manual Part 99903718 Wiring Harness Radio Remote 99903721 1 J1 J2 J4 J3 J6 J7 J5 EXTEND BOOM AUGER EV9 WINCH AUX ROTATE R1 R2 P1 P2 R3 ...

Page 61: ...Chapter 3 Parts 59 Wiring Schematic Radio Remote 99903721 2 ...

Page 62: ...CRANE SAFETY 1 1 4 70396735 CAPACITY PLACARD 4 4 5 70396736 DECAL CONTROLS 1 1 7 70396748 DECAL DANGER ELECTROCUTION 4 4 8 70396749 DECAL AUGER 6 6 9 70396750 DECAL CAUTION MOVE AUGER PINS 4 4 10 70396751 DECAL CRANE 4 4 95719357 DECAL KIT TELE COMMON SHEET INCL IN KIT REQ D ON CRANE 11 70391612 DECAL GREASE WEEKLY LEFT 9 AS NEEDED 12 70391613 DECAL GREASE WEEKLY RIGHT 6 AS NEEDED 13 70392399 DECA...

Page 63: ...Chapter 3 Parts 61 Retainer Frame Auger 51719581 7 4 3 5 17 19 8 6 2 PLACES 14 18 11 17 4 PLACES 17 19 2 PLCS 16 10 2 PLCS 13 2 PLCS ...

Page 64: ...2 2 6 70034382 CAP GREASE 2 7 71731799 PIN T QUICK RLSE 1 8 72053508 ZERK NPT 12 2 10 72060188 CAP SCR 75 10X 3 50 HH GR5 Z PART OF 1 2 11 72060622 SCR MACH 10 32X 50 RDH PART OF 1 1 13 72062114 NUT 75 10 HEX NYLOCK PART OF 1 2 14 72063000 WASHER 19 W FLAT ANSI B27 2Z PART OF 1 1 16 72063008 WASHER 75 FLAT PART OF 1 4 17 72063034 MACHY BUSHING 1 00X10 GA NR PART OF 1 8 18 72063047 WASHER 10 LOCK P...

Page 65: ...CR 50 13X 1 00 HH GR5 Z PART OF 1 2 7 72060668 CAP SCR 10 32X 50 SH PLAIN PART OF 1 1 8 72063000 WASHER 19 W FLAT ANSI B27 2Z PART OF 1 1 9 72063035 MACHY BUSHING 1 25X10 GA NR PART OF 1 1 10 72063037 MACHY BUSHING 1 50X10 GA NR PART OF 1 1 11 72063047 WASHER 10 LOCK PART OF 1 1 12 72063053 WASHER 50 LOCK PART OF 1 2 13 72063132 WASHER 50 FLAT ASTM F436 PART OF 1 2 14 72066084 RETAINING RING EXT 1...

Page 66: ......

Page 67: ...iencies shown below shall be removed and replaced immediately a Corrosion can be cause for replacement Any development of corrosion must be noted and monitored closely b When there are either three broken wires in one strand or a total of six broken wires in all strands in any one rope lay c When flat spots on the outer wires appear and those outside wires are less than 2 3 the thickness of the un...

Page 68: ...d or twist exceeding 10 from the plane of the unbent hook Increased Throat Opening HOOK WITHOUT LATCH An increase in throat opening exceeding 15 Or as recommended by the manufacturer HOOK WITH LATCH An increase of the dimension between a fully opened latch and the tip section of the hook exceeding 8 Or as recommended by the manufacturer b WEAR If wear exceeds 10 of the original sectional dimension...

Page 69: ...on of distortion wear cracks nicks or gouges are present unless a qualified person authorizes their use Or as recommended by the manufacturer Holding Valve Inspection The cylinders are equipped with holding valves that prevent sudden movement of the cylinder rods in the event of a hydraulic hose or other hydraulic component failure The valve is checked in the following manner 1 With a full rated l...

Page 70: ...If operation exceeds 20 cycles per hour inspection frequency should be increased accordingly Consult Operator Service Manual for additional inspection items service bulletins and other information Before inspecting and operating crane crane must be set up away from power lines and leveled with outriggers fully extended DAILY D Before each day of operation those items designated with a D must be in...

Page 71: ... and determine cause and severity of hazard D 11 Remote Ctrl Operate remote control devices to check for proper operation D 12 Electrical Operate all lights alarms etc to check for proper operation D 13 Anti 2 Block Operate anti 2 block device to check for proper operation D 14 Other Per customer requirements D 15 Other Per customer requirements M 16 Daily All daily inspection items M 17 Cylinders...

Page 72: ...ces for wear cracks corrosion and distortion 52 Rotation bearing s 53 Inner boom pivot pin s and retainer s 54 Outer boom pivot pin s and retainer s 55 Inner boom cylinder pin s and retainer s 56 Outer boom cylinder pin s and retainer s 57 Extension cylinder pin s and retainer s 58 Jib boom pin s and retainer s 59 Jib cylinder pin s and retainer s 60 Jib extension cylinder pin s and retainer s 61 ...

Page 73: ...arities Q 90 Hyd Filters Hydraulic filters for replacement per maintenance schedule A 91 Daily All daily inspection items A 92 Monthly All monthly inspection items A 93 Quarterly All quarterly inspection items A 94 Hyd Sys Hydraulic fluid change per maintenance schedule A 95 Controls Control valve calibration for correct pressure relief valve settings A 96 Valves Safety valve calibration for corre...

Page 74: ... for corrective actions Corrective action for a particular recommendation depends on the facts in each situation c Corrective actions CA repairs adjustments parts replacement etc are to be performed by a qualified person in accordance with all manufacturer s recommendations specifications and requirements NOTE Deficiencies X listed must be followed by the corresponding corrective action taken CA X...

Page 75: ...Chapter 4 Crane Reference 73 X R CA ITEM EXPLANATION DATE CORRECTED ...

Page 76: ...pounds To convert to inch pounds multiply by 12 4 Torque values specified are for bolts with residual oils or no special lubricants applied If special lubricants of high stress ability such as Never Seez compound graphite and oil molybdenum disulphite collodial copper or white lead are applied multiply the torque values in the charts by the factor 90 The use of Loctite does not affect the torque v...

Page 77: ... PLATED FT LB 5 16 18 0 3125 17 13 25 18 3 8 16 0 375 31 23 44 33 7 16 14 0 4375 49 37 70 52 1 2 13 0 5 75 57 105 80 9 16 12 0 5625 110 82 155 115 5 8 11 0 625 150 115 220 160 3 4 10 0 75 265 200 375 280 7 8 9 0 875 395 295 605 455 1 8 1 590 445 910 680 1 1 8 7 1 125 795 595 1290 965 1 1 4 7 1 25 1120 840 1815 1360 1 3 8 6 1 375 1470 1100 2380 1780 1 1 2 6 1 5 1950 1460 3160 2370 ...

Page 78: ...to apply to the size of capscrew used 2 Follow the tightening sequence shown in the diagram Note that the quantity of capscrews may differ from the diagram but the sequence must follow the criss cross pattern as shown in the diagram 3 Torque all capscrews to approximately 40 of the specified torque value by following the sequence EXAMPLE 40 x 265 FT LB 106 FT LB EXAMPLE METRIC 40 x 36 KG M 14 4 KG...

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