S.D.P. EZ Hauler 4100 Manuel utilisateur

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.

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.

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.

CHAPTER 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.

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