ez hauler 3800 - sdpmfg.com

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.

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 Oshkosh Truck Corporation Company.

i

Contents Revisions .................................................................................................................................................... iii

Introduction 5 Safety ............................................................................................................................................................6 Daily Safety Inspection.................................................................................................................................7

Specifications 9 EZ Hauler 4100 Specifications .....................................................................................................................9 Geometric Configuration ............................................................................................................................11 Capacity Chart ............................................................................................................................................12 Recommended Spare Parts List ..................................................................................................................13 EZ Hauler 4100 Crane Assemblies, Grease Zerk Locations.......................................................................14

Parts 15 Parts Information ........................................................................................................................................16 Base and Mast Assemblies .........................................................................................................................18

Base & Mast Assembly (99903705)................................................................................................18 Gear Rotator (71056608) (Alternate configuration) ........................................................................20 Cylinder, Lower (51719040A) ........................................................................................................22 Valvebank Assembly (51719584, Drawing 99903708)...................................................................24 Valvebank (70733995) ....................................................................................................................25 Valve Bank Components (99904107) ..............................................................................................26 Valve, 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 Wiring Layout (77441178)..............................................................................................................52 Wiring Diagram (77441178) ...........................................................................................................53 Wiring Schematic (77441178).........................................................................................................54 Proportional Actuator System Specifications (77441178)...............................................................55 Light Switch Harness (77441179) ...................................................................................................57 Wiring Harness, Radio Remote (99903721-1) ................................................................................58 Wiring Schematic, Radio Remote (99903721-2) ............................................................................59

Miscellaneous .............................................................................................................................................60 Decal Placement (99903714)...........................................................................................................60 Retainer Frame, Auger (51719581).................................................................................................61

ii Contents

Swivel Assembly, Auger (51719582)..............................................................................................63

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

Contents iii

Revisions DATE LOCATION DESCRIPTION 20050809 ECN 9882 – UPDATES TO 99903705, 3706, 3707, 3715 BASED ON

PRE-PRODUCTION CHANGES. 20050909 99903706 ECN 9895 - ADDED CABLE GUIDES TO BOOM EXTENSIONS 20050919 51719583,

99903708 ECN 9891 - CHANGES PER PRODUCTION

41718922 ECN 9925 - CHANGE TO 41718922 99903705,

99903707 ECN 9897 - ADDED DRAWING REFERENCES

20051011 99903705, 707 ECN 9933 - ADDED OVERLOAD PROTECTION SYSTEM, THREADED MOUNTING HOLES IN MAST

20060221 51719583 ECN 10029 - CHANGE HOOK 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 DRAWING TO REV J.

20060831 MODEL CHANGE

ECN 10241 - CHANGED MODEL FROM 3500 TO 3800, UPDATED MANUAL AND CAPACITY CHART.

99903706, 99903715

ECN 10240 - DESIGN CHANGES

20061002 99904017 ECN 10269 - ADDED 99904017 20061024 99903715 ECN 10286 – UPDATE 99903715 TO REV . D. 20061120 99903706 UPDATE TO REV. K.

5

This manual includes parts, specifications, and installation information for your particular crane. It is your responsibility to maintain and operate this unit in a manner that will result in the safest working conditions possible.

Warranty of this unit will be void on any part of the unit subjected to misuse due to overloading, abuse, lack of maintenance and unauthorized modifications. No warranty - verbal, written or implied - other than the official, published IMT new machinery and equipment warranty will be valid with this unit. In addition, it is also the user’s responsibility to be aware of existing Federal, State and Local codes and regulations governing 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 and are defined as follows:

NOTE

A NOTE is used to either convey additional information or to provide further emphasis for a previous point.

CAUTION

A CAUTION is used when there is the very strong possibility of damage to the equipment or premature equipment failure.

WARNING

A WARNING is used when there is the potential for personal injury or death.

For optimum safety, treat this equipment with respect and service it regularly.

C H A P T E R 1

Introduction

6 EZ Hauler 4100 Manual Part # 99903718

Safety WARNING

KEEP CHILDREN, BY-STANDERS, AND PERSONS NOT REQUIRED IN THE OPERATION OF EQUIPMENT AT LEAST 10’-0” (3.05 m) FROM THE OUTERMOST RANGE OF THE CRANE.

CRANE OPERATION

Make sure the chassis is rated to withstand the crane weight and load moment. Know the position of the booms at all times while operating the crane. Eliminate swing by positioning the boom tip directly over the center of the load before lifting. Never drag a load. Check the safety of the load by first lifting the load barely off the ground. Stop all crane operation at a signal from anyone. When you rotate the crane, the load may change from being supported by the outriggers to

the vehicle suspension. Be cautious 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 refueling area. Install in the vehicle cab a portable fire extinguisher with a basic minimum extinguisher rating

of 10 BC and know how to use the fire extinguisher.

READ THE ENTIRE MANUAL BEFORE OPERATING THE CRANE.

Use this manual for reference and for training operators. This manual covers the basics of safe and correct operation of your crane. However, success and safety depends greatly upon the skill and caution of the person actually doing the work. Persons engaging in these procedures do so entirely at their own risk.

Chapter 1 Introduction 7

Daily Safety Inspection Using the Crane Log, IMT Manual No. 99900686, or the inspection checklist in the reference section of this manual, inspect the crane on a daily, weekly, and monthly basis. Use the following list as a guide when you are inspecting your unit at start-up and during operation:

1 Vehicle - Check oil level, battery, lights, brakes, and tires for inflation, pressure, cuts, and loose or missing wheel lugs.

2 Safety 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 Operation Placards and Safety Decals - Check for illegible or missing decals and placards. Refer to the decal section of this manual for more information on the required decals.

Replace or repair any items as needed prior to equipment operation.

9

In This Chapter EZ Hauler 4100 Specifications..................................9 Geometric Configuration ........................................... 11 Capacity Chart........................................................... 12 Recommended Spare Parts List ............................... 12 EZ Hauler 4100 Crane Assemblies, Grease Zerk Locations 14

EZ Hauler 4100 Specifications CRANE RATING * 30,000 ft-lb (4.1 ton-meters)

REACH (from centerline of rotation) 34'-4" (10.5 m) HYDRAULIC EXTENSIONS (3) 69.56" each (177 cm)

208.68" total (530 cm) MANUAL EXTENSION 66" (168 cm) LIFTING HEIGHT (from base of crane) 41' (12.5 m) CRANE WEIGHT 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 EXTENSION BOOMS (total time)

53.0" + 51.75" (135 cm + 131 cm)

61 seconds extension 40 seconds retraction

CYLINDERS BORE STROKE LOWER BOOM CYLINDER 5" (13 cm) 30.15" (77 cm) FIRST, SECOND, AND THIRD EXTENSION CYLINDER

2.5" (6 cm) 69.56" (177 cm)

C H A P T E R 2

Specifications


SYSTEM SPECIFICATIONS

ROTATION SYSTEM

Turntable bearing with an external worm gear driving an intermediate gear, powered by a high-torque hydraulic motor through a self-locking worm.

MOTOR DISPLACEMENT 5.9 ci/rev MOUNTING FLANGE 2 bolt std: 3.25" dia. x 0.12 pilot, 0.535" dia. mounting holes on

4.18" dia. b. c. OUTPUT SHAFT 1" dia. straight with woodruff key and 1/4-2 threaded hole PORT TYPE 0.875-14 UNF-2B o-ring port, size 10. Accepts fittings for SAE

J1926. CASE DRAIN No case drain SPECIAL FEATURES High pressure shaft seal COLOR Gloss black

CYLINDER HOLDING VALVES

The base ends (extend sides) 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 a hose failure.

WINCH

The winch is powered by a hydraulic motor through a planetary gear with a mechanical brake. Only single line is permitted. The maximum single line capacity is 3800 lb. The winch is equipped with 1/2" diameter synthetic fiber rope.

HYDRAULIC SYSTEM

The six-section crane valvebank is operated by a radio remote control with a manual handle as a back-up system. The handle is stored behind the cover on the mast.

Chapter 2 Specifications 11

Geometric Configuration

28'-10"

5'-11"

41'

4'-4"

3'-4"

5'-8"

35'-7"

34'-4"


Capacity Chart

Crane manufactured exclusively forS.D.P. MANUFACTURING, INC.

byIOWA MOLD 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

4100lb

2800lb

1536lb

1129lb

900lb

600lb

6' 12' 15' 22' 27' 34'

41'MAX.REACH

5'-11"

80°

10°

Chapter 2 Specifications 13

Recommended Spare Parts List This spare parts list does not necessarily indicate that the items can be expected to fail in the course of a year. It is intended to provide the user with a stock of parts sufficient to keep the unit operating with minimal down-time waiting for parts. There may be parts failures not covered by this list. Parts not listed are considered not to be Critical or Normal Wear items during the first year of operations, and you will need to contact your 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 PAD 1 60030348 WEAR PAD 1 60030350 WEAR PAD 1 60123777 WEAR PAD 8 60125458 WEAR PAD 6 60127562 WEAR PAD 1 60127564 WEAR PAD 1 60127565 WEAR PAD 1 60127867 WEAR PAD 1 70142209 PIN 1 EXTENSION CYLINDER ASSEMBLY (41718922) 51744143 SEAL KIT 3 (1 KIT PER

CYLINDER) WINCH (71570781) 71411150 CABLE WEDGE 1 SEAL KIT 1


EZ Hauler 4100 Crane Assemblies, Grease Zerk Locations

12

3

4

56

LOWERCYLINDER

WORMGEAR

BASE

MAST

LOWERBOOM

EXTENSIONBOOMS(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

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


Parts Information GENERAL

This section contains the exploded parts drawings and accompanying parts lists for the assemblies used on this crane. These drawings are intended to be used in conjunction with the instructions found in the maintenance and repair manuals for this crane family. For optional equipment such as winches and remote controls, refer to the appropriate service manual.

WARNING

DO NOT ATTEMPT TO REPAIR ANY COMPONENT WITHOUT READING THE INFORMATION CONTAINED 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 correspondence, always include the serial number and model numbers. All inquiries should be addressed to:

S.D.P. Manufacturing 400 Industrial Drive Dunkirk, IN 47336 Telephone: 765-768-5000 Technical Support Fax: 765-768-5015

MODELNUMBER

SERIALNUMBER

MFGDATE

IOWA MOLD TOOLING CO., INC.BOX 189, GARNER, IA 50438-0189

Chapter 3 Parts 17

CYLINDER IDENTIFICATION

To insure proper replacement parts are received, it is necessary to specify the complete number/letter sequence for any part requested. Part numbers may be cross checked by comparing the stamped identification on the cylinder case (See figure below) against the information contained in the service manual. You must include the part number stamped on the cylinder case when ordering parts.

CYLINDERPART NUMBER

LOCATION

WELDMENT 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 model number of the unit.

2 Give the serial number of the unit.

3 Specify the complete part number. When ordering cylinder parts, or one of the main weldments, always give the stamped part number.

4 Give a complete description of the part.

5 Specify the quantity required.


Base and Mast Assemblies

Base & Mast Assembly (99903705)

5

33

9

10

6

8

9

32

383617

121

15

12

11

4

23

16

19

26

9

9

2829 31

30

30

3027

30

40

37

37

25

44

14,20,22 (4 plcs)

13,22 (4 PLCS)

GREASE ZERKPART OF ROTATOR(2 PLCS)

35(3 PLCS)

42(2 PLCS)

41 (2 PLCS)(USED TO FASTEN

SHIPPING BLOCKING)

USEANTI-SEEZ

USE BLUETHREAD LOCK

18,20(3 PLCS)(VB)

10mm NUT FROMVB HANDLE

REMOVE HANDLEAND 10mm NUT

TORQUE TO160 FT-LB

SECUREVB HANDLEHERE

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.

9,13-26,41-42) 1

Chapter 3 Parts 19

99903705 PARTS LIST 3. 51719584 VALVE BANK ASSEMBLY 1 4. 52719058 PIN WELDMENT 1 5. 52719438 MAST WLDMNT 1 6. 52719525 GEAR GUARD WLDMNT 1 7. 52719599 WLDMT-SWIVEL ADAPTER PLATE 1 8. 60128858 GEAR GUARD 1 9. 70034382 CAP-GREASE 5 10. 71056608 GEAR BOX-ROT WORM DRIVE

W/BASEPLATE 1

11. 71411199 TUBE ASM-HYD 0.38 X 11.38 LG ORFS/ORFS 2 BEND

1

12. 71411200 TUBE ASM-HYD 0.38 X 17.17LG ORFS/ORFS 2 BEND

1

13. 72060000 CAP SCR 1/4-20X1/2 HHGR5Z 4 14. 72060002 CAP SCR 1/4-20X3/4 HHGR5Z 4 15. 72060037 CAP SCR .31-18X 4.00 HH GR5 Z 2 16. 72060091 CAP SCR .50-13X 1.00 HH GR5 Z 1 17. 72060796 CAP SCR .50-13X 2.00 SH PLAIN 2 18. 72062104 NUT .25-20 HEX NYLOCK 3 19. 72062109 NUT .31-18 HEX NYLOCK 2 20. 72063001 WASHER .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-BULKHEAD 8MJIC/.50MPT 2 32. 72533613 ADPTR-M STR/M JIC 10 6 2 33. 72534418 ZERK-NPT .12 X 1.75 LG 1 34. 72601482 CAP SCR .62-11X 2.50 HH GR8 Z 16 35. 72601855 CAP SCR .25-20 4.50 SH PLAIN 3 36. 73051963 MOTOR-HYD 1 37. 73540134 VALVE - CBAL 1 38. 76393171 GASKET-WINCH 1 39. 91719508 HYDRAULIC FITTING KIT (INCL. 27-32) 1 40. HANDLE HANDLE FROM VALVE BANK REF 41. 72060158 CAP SCR 5/8-11X5 HHGR5Z 2 42. 72063007 WASHER 5/8 FLAT 2 43. 99903715 DRAWING-EZ HAULER PLUMBING DIAGRAM REF 44. 77041222 PRESSURE SWITCH 1

REV. C 20051011


Gear Rotator (71056608) (Alternate configuration)

4325

2421

20

2318

33

1119

1713

48

26,40,41

36,37,38

35 2214

9

15 12NOTSHOWN

39

3

6

21034

27,28,29

5

42

30

32

71056608 PARTS LIST (PARTS SHOWN ON DRAWING 99903804) ITEM PART # DESCRIPTION QUANTITY 2. 70055307 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 BUSHING, RED 1/8X1/4 1 15. 71412287 GREASE FITTING 1/8 NPT STRAIGHT 1 17. 70055309 BEARING, ROLL CUP 1

Chapter 3 Parts 21

71056608 PARTS LIST (PARTS SHOWN ON DRAWING 99903804) ITEM PART # DESCRIPTION QUANTITY 18. 71412288 RING, GREASE 1 19. 70055310 BEARING, ROLL CONE 1 20. 70055311 BEARING, ROLL CUP 1 21. 70055312 BEARING, ROLL CONE 1 22. 71056614 GEAR, WORM 1 23. 71056615 PINION, OUTPUT 1 24. 71412289 SPACER, WASHER 1 25. 71412290 HOUSING 1 26. 71412291 COVER 1 27. 76029615 SHIM, WORM 0.010 BROWN 2 28. 76029616 SHIM, 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 3 41. 76029614 SHIM, COVER 0.020 YELLOW ALUMINUM 2 42. 71412296 MTR ADAPTER 1 43. 76396849 SEAL, FACE 1 REF 70734049 SHIM KIT (INCL. 27-30,35-38,40,41) 1 REF 94396846 SEAL KIT (INCL. 10,32,43) 1

REV. 20060302


Cylinder, Lower (51719040A)

A

A

B

515

93171118

16210 6 1219 7 812

13 1413

18

9

SECTION A-ASCALE 1/2

45.02" CLOSED - 80.05" OPEN30.15" STROKE

DRILL #15 X 0.188" DEEP HOLE.PRESS IN PIN # 60125699.

DETAIL BSCALE 1:1

NOTES: 1 CYLINDER OPERATING PRESSURE: 3000 PSI. CYLINDER TEST PRESSURE: 3500 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 HOLDING VALVE SEALS, NYLON LOCK RING, CAST IRON PISTON RINGS, AND ROD STINGER THREADS.

7 PAINT DU PONT N00006 WHITE OR EQUIVALENT.

Chapter 3 Parts 23

51719040A PARTS LIST ITEM PART # DESCRIPTION QUANTITY 1. 51744139 SEAL KIT (INCL:4, 8, 11-19) 1 2. 52719041 CASE ASSEMBLY 1 3. 52719042 ROD ASSEMBLY 1 4. 60125699 PIN 1 5. 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


Valvebank Assembly (51719584, Drawing 99903708)

2

5

7

6

1

4 (4 PLCS)

3 (6 PLCS)

REMOVE HANDLEAND NUT IF ATTACHED -SEE 99903705

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

Chapter 3 Parts 25

Valvebank (70733995) Drawing not available at time of printing.


Valve Bank Components (99904107) 9

8

3

7

210

5

11

12

1

6

4

13

4

4

4

99904107 PARTS LIST ITEM PART # DESCRIPTION QUANTITY 1. 70734167 HANDLE-VALVE BANK, MANUAL 1 2. 73540230 VALVE-SECT MID INLET VALVE BANK 1 3. 73540229 VALVE-SECT AUGER 1 4. 73540227 VALVE-SECT VALVE BANK 4 5. 73540237 COMPENSATOR INLET VALVE BANK 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-SEAL O-RING VB AUGER SEC 1 17. 73540232 VALVE PROP 1 18. 73540235 VALVE-SOLENOID W/COIL 1 19. 94744155 KIT-SEAL O-RING INLET INTERFACE 1 NEW 20060929

Chapter 3 Parts 27

Valve, Counterbalance (73540163) 4,5 4 4

3

PRESSURESWITCH PORTSAE #6 ORB,PLUGGED

SAE #6ORB PORT(3 PLCS)

SAE #6ORB PORT

24

CYL R CYL ESWT

R E

ø0.344 THRU(2 PLCS)

PRESSURE FIXED:2500 PSI HOLDING

THIS IS A THERMAL RELIEF VALVE.ACTUAL CRACKING PRESSURERANGE 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


Boom Assemblies & Cylinders

Boom Assembly (99903706)

Chapter 3 Parts 29

99903706 COMPONENT PLACEMENT

A

B

412

74

17 55

16

22

30

31

32

13

14

15

2222

22

5

18 6464

6

7

8

20

20

20

51 63

5163

85

865163

6351

6355

5163

6351

6355

4 6412 64

74

53

10

84INSTALL AUGERMOUNT ASSEMBLYTO 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)



26

8178

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.)

Chapter 3 Parts 31


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.


99903706 TUBING ASSEMBLY

42 4139

40

24

24

23

72

797743 4424

1111

8788

89

87

33

2

7882

7836

78

37

77

25

47,58,62(2 PLCS)

55,63(4 PLCS)

47(2)61(2)

61(2)

58(2) 73 (3 PLCS)

52,63(4 PLCS)

54,59,67(2 PLCS)(USED TO FASTEN LANYARD DOWN)

66,72(2 PLCS)

56,62

50,69(2 PLCS)

56,62(2 PLCS)

56,62(2 PLCS)

56,62(2 PLCS)

99903706 PARTS LIST ITEM PART # DESCRIPTION QUANTITY 1. 41718922 CYL 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. 60010351 SPRING-"T" PIN 2 13. 60030342 WEAR PAD-RC 0.44 X 5.25 X 7.875 1 14. 60030343 WEAR PAD-RC 0.38 X 5.25 X 6.88 1 15. 60030344 WEAR PAD-RC 0.38 X 5.88 X 6.25 1 16. 60030345 WEAR PAD-RC 0.38 X 4.875 X 5.25 1

Chapter 3 Parts 33

99903706 PARTS LIST 17. 60030348 ROLLER-BOOM 1 18. 60030350 WEAR PAD CHANNEL 1.25 X 0.38 X .19 X 8.00 1 19. 60030352 WEAR PAD-RC 1.00 X 1.25 X 3.00 1 20. 60030353 WEAR PAD-RND 2.00 DIA X 1.00 DIA X 1.00 6 21. 60105544 PLATE-ANGLE PLASTIC 2 22. 60123777 WEAR PAD-RND 2.00 DIA 8 23. 60126637 TUBING CLAMP 0.63 X 2.27 3 24. 60126646 TUBING CLAMP - 1.25 X 6.13 3 25. 60126682 PIN-TYPE A Ø1.50 X 6.75 (6.06) 1 26. 60126683 PIN-TYPE A Ø1.50 X 4.07 (3.43) 1 27. 60126684 PIN-TYPE A Ø1.50 X 7.75 (7.09) 1 28. 60126687 SPACER TUBE Ø1.75 X 3.19 1 29. 60126691 ENERGY CHAIN ASM EZHAULER III 1 30. 60127562 WEAR PAD 4.13 X 9.00 1 31. 60127564 WEAR PAD 5.50 X 7.00 1 32. 60127565 WEAR PAD 6.50 X 7.00 1 33. 60127867 WEAR PAD- 2.00X 3.00X 3.00 UHMW 1 34. 60128905 TRUNNION 1.25 X 6.88 1 35. 60128956 PIN CYLINDER PIVOT 1 36. 71411197 TUBE ASM-HYD .38 X 13.85 ORFS/ORFS 4 BEND 1 37. 71411198 TUBE ASM-HYD .38 X 60.46 ORFS/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 14.66LG ORFS/ORFS 6 -6 1 45. 71570781 WINCH 1 46. 72060004 CAP SCR .25-20X 1.00 HH GR5 Z 1 47. 72060037 CAP SCR .31-18X 4.00 HH GR5 Z 4 48. 72060046 CAP SCR .38-16X 1.00 HH GR5 Z 2 49. 72060047 CAP SCR .38-16X 1.25 HH GR5 Z 2 50. 72060049 CAP SCR .38-16X 1.75 HH GR5 Z 2 51. 72060094 CAP SCR .50-13X 1.75 HH GR5 Z 9 52. 72060095 CAP SCR .50-13X 2.00 HH GR5 Z 8 53. 72060104 CAP SCR .50-13X 6.50 HH GR5 Z 1 54. 72060668 CAP SCR #10-32X .50 SH PLAIN 2 55. 72062080 NUT .50-13 HEX NYLOCK 15 56. 72062103 NUT .38-16 HEX NYLOCK 15 57. 72062106 NUT 10-24 HEX NYLOCK 6 58. 72062109 NUT .31-18 HEX NYLOCK 4 59. 72063000 WASHER .19 W FLAT ANSI B27.2Z 8 60. 72063001 WASHER .25 FLAT 3 61. 72063002 WASHER .31 FLAT 4 62. 72063003 WASHER .38 FLAT 21


99903706 PARTS LIST 63. 72063005 WASHER .50 FLAT 32 64. 72063027 MACHY BUSHING .62X14 GA NR 4 65. 72063035 MACHY BUSHING 1.25X10 GA NR 2 66. 72063037 MACHY BUSHING 1.50X10 GA NR 6 67. 72063047 WASHER #10 LOCK 2 68. 72063049 WASHER .25 LOCK 3 69. 72063051 WASHER .38 LOCK 2 70. 72063053 WASHER .50 LOCK 3 71. 72066129 RETAINING RING-EXT 1.25 HD 2 72. 72066132 RETAINING RING-EXT 1.50 HD 6 73. REF HAIR PIN .12 (PART OF 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. 52719708 CABLE GUIDE BOOM 3RD EXT WLDMT 1 85. 52719707 CABLE GUIDE BOOM 2ND EXT WLDMT 1 86. 52719706 CABLE GUIDE BOOM 1ST EXT WLDMT 1 87. 72066125 RETAINING RING-EXT 1.00 HD 2 88. 52720148 LATCH-BOOM EXTENSION 1 89. 60129864 PIN 1 REV. K 20061120

Chapter 3 Parts 35

Mast - Boom Assembly (99903707)

3

2

4

13

14

19 20

9,12

9,12

7,8�(4 PLCS)

7(2 PLCS)

17(2 PLCS) 18

(2 PLCS)16(2 PLCS)

8(2 PLCS)

5,8 (4 PLCS)USE BLUE LOCKTITE

6,10,11

USE NEVER-SEEZ

USE NEVER-SEEZ

6,10,11

USE BLUE LOCKTITE

E-CHAIN TRACK,E-CHAIN, AND TUBINGREMOVED FROM VIEWFOR CLARITY

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 .50 LOCK 2 11. 72063132 WASHER .50 FLAT ASTM F436 2 12. 72066136 RETAINING RING-EXT 2.00 HD 2


99903707 PARTS LIST 13. BOOMS BOOM ASSEMBLY - SEE 99903706 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

Chapter 3 Parts 37

Boom Tip Asembly (51719583)

3

11

7

92 5

6

16

14

8

10,13,15(2 PLCS)

12 (2 PLCS)

4


51719583 PARTS LIST ITEM PART # DESCRIPTION QUANTITY 1. 51719421 HARDWARE KIT-BOOM TIP & TAIL (INCL. 9-

16) 1

2. 52704255 PIN-TYPE T .75X 1.88 1 3. 52719033 TAIL WELDMENT (WAS 52719026) 1 4. 52719688 BOOM TIP WELDMENT (WAS 52719026) 1 5. 60030082 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 WASHER .38 LOCK 2 16. 72066145 HAIR PIN .19 ZINC 1 REV. C 20060329

Chapter 3 Parts 39

Cylinder Assembly, Extension (41718922)

4

9

1

3

5

4

9

10

11

11

10 7

2

6

8

8

12

89.31"96.81"

7.5"

41718922 PARTS LIST ITEM PART # DESCRIPTION QUANTITY 1. 51718920 CYL-2.50/1.50 69.56S 91.19CC C 1 2. 51719289 CYL-2.50/1.50 69.56S 91.19 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 WELDMENT, EXT CYL CLAMP BRACE 2

REV. C 20060502


Winch, Planetary (71570781)

71570781 PARTS LIST ITEM PART # DESCRIPTION QUANTITY 1. BEARING SUPPORT ENDPLATE 1 2. BRAKE CYLINDER ENDPLATE 1 3. CABLE DRUM 1

Chapter 3 Parts 41

71570781 PARTS LIST 4. TIEPLATE 2 5. CAPSCREW 8 6. LOCK WASHER 8 7. SIGHT GAUGE 1 8. OIL SEAL (PART OF #54) 1 9. 71411143 BALL BEARING 1 10. OIL SEAL (PART OF #54) 1 11. 71411144 BALL BEARING 1 12. OUTPUT PLANET CARRIER 1 13. OUTPUT PLANET GEAR 3 14. OUTPUT PLANET GEAR SHAFT 3 15. 71411145 ROLLER BEARING 3 16. THRUST RACE 6 17. ROLL PIN 3 27. 71411146 SPRING 8 28. SPRING LOCATOR 1 29. BRAKE COUPLING 1 30. SNAP RING 1 31. SPRING PLATE 1 32. BRAKE PISTON SEAL (PART OF #54) 1 33. BRAKE PISTON SPACER 2 34. 71411147 FRICTION DISC 8 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 WEDGE 1 54. 94744136 SEAL KIT - WINCH (INCL. 8,10,32,36,37,46) REF 94396840 SEAL KIT - MOTOR REF

WINCH SPECIFICATIONS MOTOR DISP: 13.9 CI/REV MOTOR EFFICIENCY: 0.68 DRUM DIAMETER 6.75" MOTOR SUP 1.5 GPM FLANGE DIAMETER 11" RATIO 5 WIDTH 7.28" WINCH EFFICIENCY 0.95 PRESSURE 2451 PSI HP INPUT 14.3 FLOW 10 GPM RPW INPUT 141 RPM D/d 14.5:1


Hydraulics

Hydraulic Layout (99903715)

Chapter 3 Parts 43

AUGER

INLET LIFTEXT

WINCHAUX

ROTATE

TP

NOTE:

1 For valve bank fittings, see 99903708. Route items #25 (2), 26 (2), 31, and 33 through item #54-hose sleeve. 99903715 PARTS LIST ITEM PART # DESCRIPTION QUANTITY 1. 51719584 VALVE BANK ASSEMBLY 1 2. 91719508 HYDRAULIC FITTING KIT (INCL. 4-23) 1 3. 51719422 HOSE KIT (INCL. 24-40) 1 4. 72053760 ELBOW-M STR/90/M JIC 6 6 2 5. 72533430 ADPTR-MPT/M JIC .50 8 BLKHD 2 6. 72533119 COUPLER-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 JIC XLG 8 8 1 21. 72053777 ELBOW-M STR/45/M JIC 8 8 1 22. 72534423 PLUG-JIC HEX HD STL .56 THD 2 23. 72534424 PLUG-JIC HEX HD STL .88 THD 2 24. 51396739 HOSE-FF .50 X 126.00 OAL (8-8) 2 25. 51396740 HOSE-FZ .50 X 42.00 OAL (8-8) 2


99903715 PARTS LIST 26. 51396741 HOSE-FJ .50 X 42.00 OAL (8-8) 2 27. 51396742 HOSE-FJ .50 X 40.00 OAL (8-8) 1 28. 51396743 HOSE-FZ .50 X 40.00 OAL (8-8) 1 29. 51396744 HOSE-FJ .62 X 42.00 0AL (10-10) 1 30. 51396745 HOSE-FJ .38 X 37.00 OAL (6-6) 1 31. 51396746 HOSE-FJ .38 X 56.00 OAL (8-6) 1 32. 51396755 HOSE-FZ .38 X 37.00 OAL (6-6) 1 33. 51396756 HOSE-FZ .38 X 56.00 OAL (8-6) 1 34. 51396757 HOSE-FZ .38 X 55.00 OAL (6-6) 1 35. 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 71.72L MJIC-FJIC 1 49. 71411219 TUBE ASM - 0.63OD X 0.063W X 68.95LG MJIC-FJIC 1 50. 71411549 TUBE ASM-HYD 0.38ODX 17.32LG ORFS/ORFS 1 51. 71411550 TUBE ASM-HYD 0.38ODX 14.65LG ORFS/ORFS 1 54. 60350105 HOSE SLEEVE, WRAP AROUND 1 REV. D 20061024

Chapter 3 Parts 45

Hydraulic Schematic (99903702)


SECTION A: HI-FLOW DIRECTIONAL VALVE SECTION FOR AUGER OPERATION

SECTION A CONTROL CONFIGURATION: CLOSED CENTER / LOAD SENSING / INDIVIDUALLY PRESSURE COMPENSATED ELEMENT WITH MANUAL LEVERS AND ELECTRO-HYDRAULIC PROPORTIONAL ACTUATORS. HYDRAULIC CHARACTERISTICS: MAX INLET FLOW: 60 L/MIN MAXIMUM CONTROLLED FLOW AT PORTS: A1/B1: 13.2 GPM (50 LPM) MAX OPERATING PRESSURE: 3625 PSI (250 BAR) PORT SIZES: P,T: 7/8 UNF (SAE #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 PROPORTIONAL ACTUATORS. HYDRAULIC CHARACTERISTICS: MAX INLET FLOW: 60 L/MIN MAXIMUM CONTROLLED FLOW AT PORTS: A1/B1: 27 L/MIN MAX OPERATING PRESSURE: 3625 PSI (250 BAR) PORT SIZES: A,B: 3/8" BSPP (SAE #6) ELECTRIC: 4.0 +/- 0 GPM @ 1000 PSI MANUAL: 5 +/- 0.5 GPM @ 1000 PSI

Chapter 3 Parts 47

Control Valve Cross Section & Torques

CP2 COMPENSATORTORQUE - 30 FT-LB (TYP) LOAD SENSE

SHUTTLE ADAPTERMOUNTING BOLTSTORQUE - 45-60 IN-LB (TYP)

ADAPTER

PROPORTIONALACTUATOR

ELECTRICALCONNECTOR

PROP. VALVE(2 PLACES)


EV9 - SOLENOID VALVECARTRIDGE TORQUE - 30 FT-LBCOIL NUT TORQUE - 15-45 IN-LB

RPM - PRESSURE REDUCING VALVETORQUE - 30 FT-LB

18 FT-LB

VS-RELIEF VALVECP3 - BYPASS COMPENSATOR

70 - 90 IN-LB

18 FT-LB

CP2 COMPENSATORMOUNTING BOLTS

PROPORTIONALDRIVER FOR

CONTROL VALVE

MOUNTING BOLTSTORQUE - 25-30 IN-LB (TYP)

ELECTRICALCONNECTOR(TYP. 6 PLACES)

AUGERMID-INLETSECTION

LIFT BOOMEXTENDWINCH

AUXILIARYROTATION

CP2RPM

PPG

MP

B1

A1MLS

P

T

TP

Chapter 3 Parts 49

EZ Hauler 4100 Control Valve Troubleshooting Guide Theory of Operation – The control valve for the EZ Hauler 4100 includes three sections:

1 Mid-inlet section

2 To the right of the mid-inlet section:

1. Five 4-GPM four-way, three-position valve sections.

2. These five valve sections control Boom Lift, Boom Extend, Winch, Auxiliary, and Rotation

3 To the left of the mid-inlet section:

1. One 13-GPM four-way three-position valve section

2. This section controls the Auger function

To the left of the Auger Section is an end section containing an inlet gage port (MP), a pilot pressure gage port (PPG) and two mounting holes. All valve sections are individually pressure compensated. The 4 GPM sections use a screw in cartridge pressure compensator set at 290 PSI. The 13 GPM section uses a slip-in compensator that is also set at 290 PSI. All valve sections are electro-hydraulically operated with a lever type manual override. Each electro-hydraulic valve 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 reducing valve (RPM) set at 290 PSI to supply pressure to the proportional flow control valves and a control disable solenoid valve (EV9) that interrupts pressure to the proportional valves. The bypass compensator is controlled by the individual valve sections through a load sense shuttle logic. A cartridge shuttle is located in each valve section.

Control Requirements - Each electro-hydraulic valve actuator has a four-pin connector. Pin call-outs are included in the following chart.

PIN NUMBER DESIGNATION COMMENT 1 Power 9 to 30 volts with E-stop enabled. 0 volts with E-stop

disabled. 2 Ground 3 Signal Neutral - 2.5 +/- 0.1 Volts

Maximum Stroke A - 4.1 Volts (DO NOT exceed 4.75 Volts) Maximum Stroke B - 0.9 Volts (DO NOT drop below 0.25 Volts)

4 5 Volts Out Not used


The control disable solenoid valve (EV9) requires a nominal 12 volt signal to enable operation of all functions. Voltage should be 0 volts when disabled. Manual operation of the control valve does not require the control disable solenoid valve to be energized.

General Troubleshooting

Before beginning to troubleshoot the crane hydraulics, verify that the manual selector valve is in the crane position, that controls are enabled and that the engine is running. All six control valve functions have the same general internal configuration and share the same inlet valving. The initial diagnostic procedure applies to all six valve sections. It is followed by individual diagnostic procedures for functions that contain additional valving (I.E. counterbalance valves, pilot operated check valves, etc). FUNCTION / ISSUE ACTION ALL

1. Check and/or adjust main relief valve setting at port MP located on the far left side of the manifold. (Pressure setting - 2500 psi -0/+100 psi) The relief valve is located in the mid-inlet section. 2. Check if any other functions operate manually. If no functions operate manually, a. Check/clean load sense orifice b. Check inlet compensator (CP3) for contamination. Clean or replace. c. Diagnose lower hydraulics.

Operate valve section with manual lever. If function does NOT operate using manual lever:

3. Check load sense pressure at port MLS in the mid-inlet section. If the pressure does 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 section for required values. If pins do not have proper values, check the radio controller and electrical system.

Function will not operate in either direction.

If the function operates normally using the manual lever, but does not operate electro-hydraulically : 3. If values are correct for EV9 solenoid valve and Pins 1,2, and 3:

a. Check the pilot pressure to the proportional valves at port PPG, located on the far left side of the manifold. (290 psi when the EV9 is powered; 0 psi when the EV9 is de-energized. b. If there is no pressure at PPG when the EV9 is energized: i. Check/replace the EV9 coil (approximately 6 Ohms). ii. Clean/replace the EV9 solenoid valve. c. Clean the valve section proportional valves. Verify free spool movement by gently pushing on the spool through the nose of the cartridge. d. Replace the proportional driver valve section.

WINCH Winch will not operate in either direction.

1. Check winch counterbalance valve, shuttle valve, and PO check valve for contamination. Clean or replace.

BOOM EXTEND Extend cylinders will not retract. 1. Check extend counterbalance valves for contamination. Clean or replace. BOOM LIFT Boom lift cylinder will not retract. 1. Check boom lift counterbalance valve for contamination. Clean or replace.

Chapter 3 Parts 51

NOTES: If a valve must be replaced, torque the new valve with the following installation torques: 1 Torque valves CP3, RPM, VS, EV9, and CP2 with an installation torque of 30 ft-lb.

2 Torque the coil nut used on valve EV9 to 15-45 in-lb.

3 Torque the valve tie bolts to 45 -60 in-lb.

4 Torque the proportional driver for the control valve to 25-30 in-lb.

5 Torque the manual lever retaining bolts to 70-90 in-lb.

6 Torque 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 failure in any hydraulic system. Avoid introducing any contamination into your hydraulic system during the assembly procedures. Plug all ports and cavities of the manifold and cylinders while other work is being performed during assembly.


Electrical

Wiring Layout (77441178)

FORWARDFLOODLIGHT

J5

J6

W1 W2

LEFTFLOODLIGHT

RIGHTFLOODLIGHT

J4

FLOODLIGHTSWITCH

J3

E-STOP

J2

ALARM

J7

J1

RECEIVER

R1 RELAY

W5 W4W3

B A

W3

W4

W5

HORN PWR (NO)

HOP SWITCH(NC)

SWITCH PWR (COM)

PRES SW

Chapter 3 Parts 53

Wiring Diagram (77441178)

J6

J4

J5

J1

W1

W2

POWER AGROUND B

LEFT FLOOD PWR ALEFT FLOOD GND B

RIGHT FLOOD PWR ARIGHT FLOOD GND B

FRONT FLOOD PWR AFRONT FLOOD GND B

RADIO POWER ARADIO/VALVE GND 2

LIGHT CONTROL 3PRESSURE SWITCH INPUT 4

HORN GROUND AHORN POWER B

HORN POWER W3HOP SWITCH W4SWITCH PWR W5

F1

SPLICE A

SPLICE BSPLICE ASPLICE A

SPLICE C

SPLICE C

SPLICE A

SPLICE C30

86

87a

85

87

R1

SPLICE B

A LIGHT SWITCHB LIGHT SWITCH

J3

J2A E-STOPB RADIO POWER


Wiring Schematic (77441178)

PRESSUREREDUCING VALVE

RPMTp Pp

VBAVPB

SP

TP

DIRECTIONALCONTROL VALVE

+5V

A: 2.5 - 0.9VB: 2.5 - 4.1V

VARIABLEINPUT SIGNAL

ELECTRO-HYDRAULICACTUATOR

REMOTECONTROLLEVER

POWER SOURCE(9-30 VOLTS)

A B

ELECTRO-HYDRAULICPROPORTIONAL CONTROL ACTUATOR

M

(34 kOHMS)INPUTSIGNALSTAGE

5 VEXTERNAL

DUALPWM DRIVER

HALL EFFECTPOS. TRANSDUCER

INPUT STAGE

TR1NEUTRALPOSITIONADJUST.

DITHERGENERATOR

PIDANALOGCONTROLLERINPUT

RANGEALARMDETECTION

SUPPLYRANGEALARMDETECTION

5 V EXTERNAL

5 V INTERNALDC

DC A STROKEGAIN

ADJUSTMENT

B STROKEGAIN

ADJUST.

TR2 TR312

3

4

MAXIMUM STROKE FW

VALVESTROKE

2.25V 2.75V

MIN FW0.25V

MAXBW0.9V

4.1VMAXFW

4.75V

0

MINBW

MAXIMUM STROKE BW

DRIVINGVOLTAGE

1: +12 VOLTS2: GROUND3: CONTROL SIGNAL4: FLOOD LIGHT CONTROL

1: +12 VOLTS2: GROUND3: CONTROL SIGNAL4: FLOOD LIGHT CONTROL

AUGER EV9 LIFT BOOMEXTEND WINCHAUXIL-

IARY ROTATION

2 2 2 2 2 2 2

1 3 1 1 3 1 3 1 3 1 3 1 3

15 AMPFUSE

15 AMPFUSE

RADIOE-STOP

85

30

8687a87

OVERLOADSYSTEM

4 1

2

RADIORECEIVER

Chapter 3 Parts 55

Proportional Actuator System Specifications (77441178) The electro-hydraulic proportional actuator has closed-loop position control of the valve spool stroke and integrated hydraulics.

ELECTRICAL SPECIFICATIONS SUPPLY VOLTAGE 9-30 VDC MAXIMUM CURRENT DRAW

750 MA / SECTION

MAXIMUM POWER ABSORPTION

8 WATTS

INPUT IMPEDANCE 40 K OHM VOLTAGE CONTROL RANGE

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 PRESSURE

22 PSI (1.5 BAR)

PILOT FLOW REQUIREMENT

0.05 GPM (0.2 LPM)

OIL TEMPERATURE RANGE

- 4 - + 203 ° F (-20 - + 95 ° C)

OIL VISCOSITY RANGE 3 cSt - 650 cSt FILTRATION 18/15 (ISO 4406)


PROPORTIONAL ACTUATOR SYSTEM DRAWING A

4-PIN CONNECTOR

4-PIN CONNECTION DIAGRAMA

VIEW A

2

1

3

4BLUE 1 (+) POWER SOURCEYELLOW/GREEN 2 (-) POWER SOURCEBROWN 3 CONTROL SIGNALBLACK 4 +5 V VOLTAGE SUPPLY

TO THE REMOTE CONTROLPOTENTIOMETER

ADJUSTING TRIMMERSGREEN LED: NEUTRAL POSITIONT1: NEUTRAL POS. ADJ. TRIMMER

PART A

REMOTE CONTROL POTENTIOMETER CHARACTERISTICS

CONFIGURATION: 3-PINOHMIC RESISTANCE: 1K / 5K / 10K OHMELEC. POWER RATING: 0.25 WATTSOUTPUT VOLTAGE: 95-98% OF VIN

ADJ.TRIMMERS

LED

Chapter 3 Parts 57

Light Switch Harness (77441179)

J1

J1

J1 S1

S1

S1

LIGHT SWITCH ALIGHT SWITCH B

1) N/C2) LIGHT SWITCH3) LIGHT SWITCH

123

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


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

Chapter 3 Parts 59

Wiring Schematic, Radio Remote (99903721-2)


Miscellaneous

Decal Placement (99903714)

4(1),5

13,14

1112

16 (THIS SIDE)17 (OTHER SIDE)

11

9

9

10 8

8

101215

NOTES: 1 EACH KIT, PART NUMBERS 95719436 AND 95719347, COMES AS A PURCHASED ASSEMBLY. THE ITEMS

INDICATED ARE INCLUDED WITH THE KIT. ONE OF EACH KIT IS REQUIRED PER CRANE.

2 PLACE ITEMS 1, 2, 3, 7, AND 18 AT OR NEAR THE REMOTE CONTROL STORAGE POINT ON THE CARRIER VEHICLE. 95719436 DECAL KIT - EZ HAULER III INCL. IN KIT REQ’D ON CRANE 1. 70392863 DECAL-DANGER HOISTING PERSONNEL 4 4 2. 70392864 DECAL-DANGER OUTRG STAND CLEAR 4 4 3. 70396614 DECAL-DANGER, 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 DECAL-LUBRICATE WORM 1 1 14. 70392524 DECAL-ROTATE CRANE WHILE GREAS 1 1 70394166 DECAL-INSTR FOR MNL OPERATION 1 0 15. 70394443 DECAL-DANGER FREEFALLING BOOMS 1 1 70395090 DECAL-GREASE WORM DRIVE BRNGS 1 0 70395670 DECAL-CAUTION DOWN HAUL WT 2 0 16. 71391522 DECAL-ANGLE INDICATOR RH 1 1 17. 71391523 DECAL-ANGLE INDICATOR LH 1 1 18. 70392213 DECAL-CAUTION DONT WASH/WAX 1 1

NEW RELEASE 20050620

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)


51719581 PARTS LIST ITEM PART # DESCRIPTION QUANTITY1. 51719555 HARDWARE KIT-AUGER RETAINER FRAME 1 2. 52719019 RETAINER FRAME WELDMENT 1 3. 52719418 WELDMENT-RELEASE HANDLE 1 4. 60126635 YOKE/CLASP 10.25 x 7.88 1 5. 60126636 PIN Ø1.0 x 2.62 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 (PART OF #1) 1 19. 72066125 RETAINING RING-EXT 1.00 HD (PART OF #1) 4

NEW 20050718

Chapter 3 Parts 63

Swivel Assembly, Auger (51719582)

4

3

2

1510

5

16

6,12,13 (2 PLCS)

7,8,11

9,14

51719582 PARTS LIST ITEM PART # DESCRIPTION QUANTITY 1. 51719556 HARDWARE KIT-AUGER SWIVEL 1 2. 52719022 PIN WELDMENT 1 3. 52719030 SWIVEL WELDMENT 1 4. 52719055 PIN WELDMENT 1 5. 52719328 RESTRAINING PIN WELDMENT 1 6. 72060091 CAP SCR .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 1.25 STD (PART OF #1) 1 15. 72066132 RETAINING RING-EXT 1.50 HD (PART OF #1) 1 16. 72066143 HAIR PIN .12 (PART OF #1) 1

NEW 20050718

65

In This Chapter 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

Wire Rope Inspection & Replacement Wire rope with any of the deficiencies 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 unworn outer wire.

d When there is a decrease of diameter indicating a core failure.

C H A P T E R 4

Crane Reference


e When kinking, crushing, birdcaging or other distortion occurs.

f When there is noticeable heat damage (discoloration) of the rope by any means.

g When the diameter is reduced from nominal size by 1/32" or more.

h If a broken wire protrudes or loops out from the core of the rope.

Hook Inspection Hooks having any of the listed deficiencies shall be removed from service unless a qualified person approves their continued use and initiates corrective action. Hooks approved for continued use shall be subjected to periodic inspection.

a DISTORTION

Bending / Twisting

A bend 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. (Or as recommended by the manufacturer).

c CRACKS, NICKS, GOUGES

Repair of cracks, nicks, and gouges shall be carried out by a designated person by grinding longitudinally, following the contour of the hook, provided that no dimension is reduced more than 10% of its original value. (Or as recommended by the manufacturer). (A qualified person may authorize continued use if the reduced area is not critical).

d LATCH

Chapter 4 Crane Reference 67

Engagement, Damage & Malfunction

If a latch becomes inoperative because of wear or deformation, and is required for the service involved, it shall be replaced or repaired before the hook is put back into service. If the latch fails to fully close the throat opening, the hook shall be removed from service or “moused” until repairs are made.

e HOOK ATTACHMENTS & SECURING MEANS

If any indication 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 load, extend the cylinder in question and kill the engine.

2 Operate the control valve to retract the cylinder. If the cylinder “creeps”, replace the holding valve. If the cylinder does not “creep”, the valve is serviceable.


Inspection Checklist NOTICE:

The user of this form is responsible for determining that these inspections satisfy all applicable regulatory requirements.

OWNER/COMPANY:

TYPE OF INSPECTION (circle one):

CONTACT PERSON: DAILY MONTHLY QUARTERLY ANNUAL

CRANE MAKE & MODEL: DATE INSPECTED:

CRANE SERIAL NUMBER: HOURMETER READING (if applicable):

UNIT I.D. NUMBER:

INSPECTED BY (print):

LOCATION OF UNIT: SIGNATURE OF INSPECTOR:

TYPE OF INSPECTION NOTES: Daily and monthly inspections are to be performed by a “designated” person, who has been selected or assigned by the employer or the employer’s representative as being competent to perform specific duties. Quarterly and annual inspections are to be performed by a “qualified” person who, by possession of a recognized degree in an applicable field or certificate of professional standing, or who, by extensive knowledge, training and experience has successfully demonstrated the ability to solve or resolve problems related to the subject matter and work. One hour of normal crane operation assumes 20 complete cycles per hour. 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 inspected. This inspection need not be recorded unless a deficiency (8 ) is found. If the end user chooses to record all daily inspections and those daily inspections include the monthly inspection requirements, there would be no need for a separate monthly inspection. MONTHLY (M): Monthly inspections or 100 hours of normal operation (which ever comes first) includes all daily inspections plus items designated with an (M). This inspection must be recorded. QUARTERLY (Q): Every three to four months or 300 hours of normal operation (which ever comes first) includes all daily and monthly inspection items plus items designated with a (Q). This inspection must be recorded. ANNUAL (A): Each year or 1200 hours of normal operation (which ever comes first) includes all items on this form which encompasses daily, monthly and quarterly inspections plus those items designated by (A). This inspection must be recorded.


INSPECTION CHECKLIST STATUS KEY: S = Satisfactory R = Recommendation (should be considered for corrective action) X = Deficient (must be corrected prior to operation) NA = Not Applicable

FREQUENCY ITEM KEY INSPECTION DESCRIPTION STATUS (S,R,X,NA)

D 1 Labels All load charts, safety & warning labels, and control labels are present and legible.

D 2 Crane Check all safety devices for proper operation. D 3 Controls Control mechanisms for proper operation of all functions, leaks and

cracks.

D 4 Station Control and operator's station for dirt, contamination by lubricants, and foreign material.

D 5 Hydraulic System

Hydraulic system (hoses, tubes, fittings) for leakage and proper oil level.

D 6 Hook Presence and proper operation of hook safety latches. D 7 Rope Proper reeving of wire rope on sheaves and winch drum. D 8 Pins Proper engagement of all connecting pins and pin retaining devices. D 9 General Overall observation of crane for damaged or missing parts, cracked

welds, and presence of safety covers.

D 10 Operation During operation, observe crane for abnormal performance, unusual wear (loose pins, wire rope damage, etc.). If observed, discontinue use 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 Visual inspection of cylinders for leakage at rod, fittings, and welds.

Damage to rod and case.

M 18 Valves Holding valves for proper operation. M 19 Valves Control valves for leaks at fittings and between stations. M 20 Valves Control valve linkages for wear, smoothness of operation, and

tightness of fasteners.

M 21 General Bent, broken, or significantly rusted/corroded parts. M 22 Electrical Electrical systems for presence of dirt, moisture, and frayed wires. M 23 Structure All structural members for damage. M 24 Welds All welds for breaks and cracks. M 25 Pins All pins for proper installation and condition. M 26 Hardware All bolts, fasteners and retaining rings for tightness, wear and

corrosion.

M 27 Wear Pads Presence of wear pads. M 28 Pump &

Motor Hydraulic pumps and motors for leakage at fittings, seals, and between sections.

M 29 PTO Transmission/PTO for leakage, abnormal vibration, and noise. M 30 Hyd Fluid Quality of hydraulic fluid and presence of water.



M 31 Hyd Lines Hoses & tubes for leakage, abrasion damage, blistering, cracking, deterioration, fitting leakage, and secured properly.

M 32 Hook Load hook for abnormal throat distance, twist, wear, and cracks. M 33 Rope Condition of load line. M 34 Manual Presence of operator's manual with unit. M 35 Other Q 36 Daily All daily inspection items. Q 37 Monthly All monthly inspection items. Q 38 Extensions Condition of wear pads. Q 39 Rotation Sys Rotation bearing for proper torque of all accessible mounting bolts. Q 40 Hardware Base mounting bolts for proper torque. Q 41 Structure All structural members for deformation, cracks and corrosion. 42 • Base 43 • Outrigger beams and legs 44 • Mast 45 • Inner Boom 46 • Outer Boom 47 • Extension(s) 48 • Jib boom 49 • Jib extension(s) 50 • Other Q 51 Hardware Pins, bearing, shafts, gears, rollers, and locking devices 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 • Boom tip attachment 62 • Other Q 63 Hyd Lines Hoses, fittings and tubing for proper routing, leakage, blistering,

deformation and excessive abrasion.

64 • Pressure line(s) from pump to control valve 65 • Return line(s) from control valve to reservoir 66 • Suction line(s) from reservoir to pump 67 • Pressure line(s) from control valve to each function 68 • Load holding valve pipe(s) and hose(s) 69 • Other Q 70 Pumps,

PTO's & Motors

Pumps, PTO's & motors for loose bolts/fasteners, leaks, noise, vibration, loss of performance, heating & excess pressure.

71 • Winch motor(s) 72 • Rotation motor(s) 73 • Other Q 74 Valves Hydraulic valves for cracks, spool return to neutral, sticking spools,

proper relief valve setting, relief valve failure.

75 • Main control valve



76 • Load holding valve(s) 77 • Outrigger or auxiliary control valve(s) 78 • Other valves (per customer requirements) 79 • Other (per customer requirements) Q 80 Cylinders Hydraulic cylinders for drifting, rod seal leakage and leakage at welds.

Rods for nicks, scores and dents. Case for damage. Case and rod ends for damage and abnormal wear.

81 • Outrigger cylinder(s) 82 • Inner boom cylinder(s) 83 • Outer boom cylinder(s) 84 • Extension cylinder(s) 85 • Rotation cylinder(s) 86 • Jib lift cylinder(s) 87 • Jib extension cylinder(s) 88 • Other (per customer requirements) Q 89 Winch Winch, sheaves and drums for damage, abnormal wear, abrasions

and other irregularities.

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 correct pressure & relief valve settings. A 97 Valves Valves for failure to maintain correct settings. A 98 Rotation Sys Rotation drive system for proper backlash clearance & abnormal wear,

deformation and cracks.

A 99 Lubrication Gear oil change in rotation drive system per maintenance schedule. A 100 Hardware Check tightness of all fasteners and bolts, using torque specifications

on component drawings or torque chart.

A 101 Wear Pads Wear pads for excessive wear. A 102 Loadline Loadline for proper attachment to drum.


Deficiency / Recommendation / Corrective Action Report

DATE: OWNER: UNIT I.D. NUMBER:

GUIDELINES

a A deficiency (X) may constitute a hazard. Deficiency must be corrected and/or faulty parts replaced before resuming operation.

b Recommendations (R) should be considered 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 = DEFICIENCY R = RECOMMENDATION CA = CORRECTIVE ACTION TAKEN

X,R,CA ITEM # EXPLANATION DATE CORRECTED


X,R,CA ITEM # EXPLANATION DATE CORRECTED


Thread Torques WARNING

Anytime a gear-bearing bolt is removed, it must be replaced with a new bolt of the identical grade and size. Once a bolt has been torqued to 75% of its proof load and then removed, the torque coefficient may no longer be the same as when the bolt was new thus giving indeterminate clamp loads after torquing. Failure to replace gear-bearing bolts may result in bolt failure due to metal fatigue, causing serious injury or DEATH.

When using the torque data in the torque charts, the following rules should be observed.

1 Bolt manufacturer’s particular specifications should be consulted when provided.

2 Flat washers of equal strength must be used.

3 All torque measurements are given in foot-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 values.

FINE THREAD TORQUE CHART (ENGLISH) TIGHTENING TORQUE

SAE J429GRADE 5

SAE J429GRADE 8

SIZE (DIA-TPI)

BOLT DIA. (INCHES) PLAIN (FT-

LB) PLATED (FT-LB)

PLAIN (FT-LB)

PLATED (FT-LB)

5/16-24 0.3125 19 14 27 20 3/8-24 0.375 35 26 49 35 7/16-20 0.4375 55 41 78 58 1/2-20 0.5 90 64 120 90 9/16-18 0.5625 120 90 170 130 5/8-18 0.625 170 130 240 180 3/4-16 0.75 300 225 420 315 7/8-11 0.875 445 325 670 500 1-12 1 645 485 995 745 1 1/8-12 1.125 890 670 1445 1085 1 1/4-12 1.25 1240 930 2010 1510 1 3/8-12 1.375 1675 1255 2710 2035 1 1/2-12 1.5 2195 1645 3560 2670


COARSE THREAD TORQUE CHART (ENGLISH) TIGHTENING TORQUE

SAE J429GRADE 5

SAE J429GRADE 8

SIZE (DIA-TPI)

BOLT DIA. (INCHES) PLAIN (FT-

LB) PLATED (FT-LB)

PLAIN (FT-LB)

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


Turntable Bearing Thread Tightening Sequence Refer to the turntable bearing thread tightening diagram below for proper tightening/torqueing sequence of the turntable bearing to the crane base and crane mast. The total quantity of cap screws varies dependent on crane model.

Number 1 can be assigned toany capscrew if the sequenceremains the same in referenceto number 1.

WARNING

TIGHTENING PROCEDURE

1 Refer to the Torque Data Chart to determine the proper torque value 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-M)

4 Repeat Step 3, but torqueing all capscrews to 75% of the specified torque value. Continue to follow the tightening sequence.

(EXAMPLE: .75 x 265 FT-LB = 199 FT-LB)

(EXAMPLE-METRIC: .75 x 36 KG-M = 27 KG-M)

5 Using the proper sequence, torque all capscrews to the listed torque value as determined from the Torque Data Chart.

ez hauler 3800 - sdpmfg.com

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