Manual # 99905829
EZ Hauler 3400LP
Effective September 2014
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 © 2014 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 Corporation Company.
i
Contents
Revisions ...................................................................................................................................................... ii
Introduction
3
Safety............................................................................................................................................................ 4
Daily Safety Inspection ................................................................................................................................ 5
Specifications
7
EZ Hauler 3400LP Specifications ................................................................................................................ 8
EZ Hauler 3400LP Geometric Configuration............................................................................................. 10
EZ Hauler Capacity .................................................................................................................................... 10
EZ Hauler 3400LP Recommended Spare Parts List................................................................................... 11
Crane Assemblies, Grease Zerk Locations ................................................................................................. 12
Parts
13
Parts Information ........................................................................................................................................ 14
Base & Mast Assembly (99905830)........................................................................................................... 16
Gear Rotator (71056608)............................................................................................................................ 18
Lower Cylinder (51722419) ....................................................................................................................... 19
Boom Assembly (99905730)...................................................................................................................... 20
Cylinder, Third Extension (51722432)....................................................................................................... 26
Top Feeder Tube Assembly (51722747) .................................................................................................... 27
Bottom Feeder Tube Assembly (51722909)............................................................................................... 28
Crane & Winch Assembly (99905831) ...................................................................................................... 29
Auger Retainer Frame (51722366) ............................................................................................................. 36
Light Switch Harness (77441179) .............................................................................................................. 37
Wiring Harness (77441356) ....................................................................................................................... 38
Cylinder, Extension (51722423) ................................................................................................................ 42
Cylinder, Extension (51722424) ................................................................................................................ 43
Winch Assembly (71570981) ..................................................................................................................... 44
Hydraulic Installation (99904827) ............................................................................................................. 45
Valve Bank Assembly (51722745) ............................................................................................................ 48
Valve Bank (70734456) ............................................................................................................................. 49
EZ Hauler 3400LP Decal Placement (95722759) ...................................................................................... 50
Crane Reference
51
Wire Rope Inspection & Replacement ....................................................................................................... 52
Hook Inspection ......................................................................................................................................... 53
Holding Valve Inspection ........................................................................................................................... 54
Inspection Checklist ................................................................................................................................... 54
Deficiency / Recommendation / Corrective Action Report ........................................................................ 59
Thread Torques .......................................................................................................................................... 61
Turntable Bearing Thread Tightening Sequence ........................................................................................ 62
ii
Contents
Revisions
DATE
LOCATION
DESCRIPTION
3
CHAPTER 1
Introduction
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, four means are used to draw the attention of personnel. They are
NOTEs, CAUTIONs and WARNINGs and DANGERs 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.
DANGER
Danger indicates an imminently hazardous
situation which, if not avoided, will result
in death or serious injury. Danger is used
in the most extreme situations.
4
EZ Hauler 3400LP Manual # 99905829
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 stabilizers 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
5
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.
7
CHAPTER 2
Specifications
In This Chapter
EZ Hauler 3400LP Specifications ..............................................8
EZ Hauler 3400LP Geometric Configuration ............................. 10
EZ Hauler Capacity ...................................................................10
EZ Hauler 3400LP Recommended Spare Parts List ................. 11
Crane Assemblies, Grease Zerk Locations ............................... 12
8
EZ Hauler 3400LP Manual # 99905829
EZ Hauler 3400LP Specifications
CRANE RATING *
24,000 ft-lb (3.3 ton-meters)
REACH (from centerline of rotation)
HYDRAULIC EXTENSIONS (3)
26'-0" (7.9 m)
56-1/8" each (142.5 cm)
168-3/8" total (427.5 cm)
MANUAL EXTENSION
Not applicable
LIFTING HEIGHT (from base of crane)
28'-5" (8.7 m)
CRANE WEIGHT
2,800 lb (1270 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
LOWER BOOM ELEVATION
Continuous
-10 to 80 degrees
STINGER
EXTENSION BOOMS
56-1/8" each
(142.5 cm each)
WINCH UP
60 seconds
16.3 seconds extension
11.4 seconds retraction
11.7 seconds extension
14.4 seconds retraction
21.8 seconds extension
13.1 seconds retraction
82 ft/min
CYLINDERS
LOWER BOOM CYLINDER
FIRST, SECOND, AND THIRD
EXTENSION CYLINDER
BORE
4" (10.2 cm)
2.5" (6 cm)
STROKE
30.06" (76.4 cm)
56-1/8" (142.5 cm)
Chapter 2 Specifications
9
SYSTEM SPECIFICATIONS
ROTATION SYSTEM
Turntable bearing with an external worm gear driving an intermediate gear, powered by a hightorque hydraulic motor through a self-locking worm.
MOTOR DISPLACEMENT
MOUNTING FLANGE
OUTPUT SHAFT
PORT TYPE
CASE DRAIN
SPECIAL FEATURES
COLOR
5.9 ci/rev
2 bolt std: 3.25" dia. x 0.12 pilot, 0.535" dia. mounting holes on 4.18" dia.
b. c.
1" dia. straight with woodruff key and 1/4-2 threaded hole
0.875-14 UNF-2B o-ring port, size 10. Accepts fittings for SAE J1926.
No case drain
High pressure shaft seal
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 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 3400 lb. The winch is
equipped with 1/2" diameter synthetic fiber rope.
HYDRAULIC SYSTEM
The eight-section crane valvebank is operated by a radio remote control with a manual handle
as a back-up system. The system pressure is 2500 psi (172 bar) at 10 gpm (37.8 l/min).
10
EZ Hauler 3400LP Manual # 99905829
EZ Hauler 3400LP Geometric Configuration
4'-3"
32'-4"
5'-5"
26'-0"
EZ Hauler Capacity
Your equipment is designed for specific loads which are described on the capacity placard
mounted near the normal operator’s station. Exceeding the limits presented on the capacity
placard will create severe safety hazards and will shorten the life of your equipment. The
operator and other concerned personnel must know the load capacities of the equipment and
the weight of the load being lifted!
Refer to the load chart mounted on the unit for specific capacity information.
Chapter 2 Specifications
11
EZ Hauler 3400LP 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
BASE & MAST ASSEMBLY (99904779)
76393171
GASKET HYD MOTOR
LOWER CYLINDER (51722419)
9D161823
SEAL KIT- LOWER CYLINDER
BOOM ASSEMBLY (99905730)
60135201
SHIM
60135202
SHIM
60135203
SHIM
60135204
SHIM
60030353
WEAR PAD RND
60030398
WEAR PAD- STINGER
60030402
WEAR PAD
60030396
WEAR PAD
60030395
WEAR PAD
60030411
WEAR PAD
60030410
WEAR PAD- EXTENSION CYLINDER
60030082
SHEAVE
60030415
WEAR PAD, ROUND
60030399
WEAR PAD
60030404
GUIDE- FEEDER TUBES
60030397
WEAR PAD- STINGER
60030416
WEAR PAD, ROUND
60030417
WEAR PAD
60030418
WEAR PAD, ROUND
60030532
WEAR PAD
60030473
WEAR PAD
60030425
WEAR PAD
CRANE & WINCH ASSEMBLY (99904781)
60030475
WEAR PAD
60126691
ENERGY CHAIN
70034402
CLAMP- TUBE .62 OD
70034432
CLAMP- TUBE .50 OD
70144819
COVER PLATE
70143829
COVER PLATE
EXTENSION CYLINDERS (51722432 / 51722423 / 51722424)
91744176
SEAL KIT- EXTENSION CYLINDERS
FEEDER TUBE ASSEMBLIES (51722748 / 51722747 / 51722909)
51744195
SEAL KIT-FEEDER TUBES
QUANTITY
1
1
2
2
2
2
1
1
1
1
1
1
1
2
8
2
2
2
1
1
1
1
1
4
1
1
4
6
2
3
3
4
12
EZ Hauler 3400LP Manual # 99905829
Crane Assemblies, Grease Zerk Locations
EXTENSION BOOMS
(INTERNAL CYLINDERS)
LOWER
BOOM
6
MAST
2
1
4
WORM
GEAR
ITEM
1.
2.
3.
4.
5.
6.
7.
BASE
LOWER
CYLINDER
7
5
3
LOCATION DESCRIPTION
INTERMEDIATE GEAR
WORM GEAR
TURNTABLE (ROTATE CRANE WHILE
GREASING)
LOWER CYLINDER (LOWER END)
LOWER CYLINDER (UPPER END)
SHEAVES
AUGER PIVOT
LUBRICANT
FREQUENCY
SHELL ALVANIA 2EP
OR
SHELL RETINAX "A"
WEEKLY
13
CHAPTER 3
Parts
In This Chapter
Parts Information.......................................................................14
Base & Mast Assembly (99905830) .......................................... 16
Gear Rotator (71056608) (Alternate configuration) ................... 18
Lower Cylinder (51722419) .......................................................19
Boom Assembly (99905730) .....................................................20
Cylinder, Third Extension (51722432) ....................................... 26
Top Feeder Tube Assembly (51722747) ................................... 27
Bottom Feeder Tube Assembly (51722909) .............................. 27
Crane & Winch Assembly (99905831) ...................................... 29
Auger Retainer Frame (51722366)............................................ 36
Light Switch Harness (77441179) ............................................. 37
Wiring Harness (77441356) ......................................................38
Cylinder, Extension (51722423) ................................................41
Cylinder, Extension (51722424) ................................................43
Winch Assembly (71570981) ....................................................44
Hydraulic Installation (99904827) ..............................................44
Valve Bank Assembly (51722745) ............................................ 48
Valve Bank (70734456).............................................................49
EZ Hauler 3400LP Decal Placement (95722759) ...................... 50
14
EZ Hauler 3400LP Manual # 99905829
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
IOWA MOLD TOOLING CO., INC.
BOX 189, GARNER, IA 50438-0189
MODEL
NUMBER
SERIAL
NUMBER
MFG
DATE
Chapter 3 Parts
15
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.
CYLINDER
PART NUMBER
LOCATION
WELDMENT IDENTIFICATION
Each of the major weldments - base, mast, inner boom, outer boom, extension boom and
stabilizer 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.
16
EZ Hauler 3400LP Manual # 99905829
Base & Mast Assembly (99905830)
3
17 TORQUE TO 143 FT-LB
13
3
TORQUE TO 143 FT-LB
17
34
11
35
27
15 21
18
18
21 15
1
7
19, 32
1
19, 32
BASE ASSEMBLY
6
19
BASE ASSEMBLY BOTTOM VIEW
18
19
21
1 32
32 1
14
25
20
2
10
25 20
8
24
25
22
16
20
12
26
26
12
1
5 2
24
2 5
24
22
16
LOWER BOOM ASSEMBLY
22
16
Chapter 3 Parts
17
4
29
TORQUE TO
160 FT-LB
9
23
12
MAST ASSEMBLY
TOP VIEW
28
4
31
31
30
33
30
MAST ASSEMBLY
31
33
30
33
VALVE BANK ASSEMBLY
MAST ASSEMBLY
NOTES (SEE REFERENCE NUMBER IN BOX):
1
2
3
4
CAP SCREWS (IMT # 72601864) USED ONLY FOR INSTALLING BASE ASSEMBLY TO SHIPPING BLOCK.
DISCARD AFTER USE.
USE ANTI-SEEZ ON PINS.
USE BLUE THREAD LOCKER.
APPLY RUST PREVENTATIVE TO BEARING RACK AND UNDERSIDE OF MAST.
99905830 PARTS LIST
ITEM
PART #
DESCRIPTION
KIT
QTY
ITEM
PART #
DESCRIPTION
KIT
QTY
1.
51722419
CYL-4.0/2.2 30.06S 49.69CC C
1
19.
72063007
WASHER .62 FLAT
2
2
2.
51722740
KIT-HRDW BASE & MASE EZ3000
1
20.
72063039
MACHY BUSHING 2.00X10 GA NR
2
3
3.
51722744
KIT-HYD ASM EZ3000
1
21.
72063049
WASHER .25 LOCK
2
8
4.
51722745
VALVE BANK ASM-8 SEC
1
22.
72063053
WASHER .50 LOCK
2
3
5.
52719058
PIN WELDMENT
2
23.
72063119
WASHER .62 FLAT ASTM F436
2
16
6.
52719525
GEAR GUARD WLDMNT
1
24.
72063132
WASHER .50 FLAT ASTM F436
2
3
7.
52719599
WLDMT-SWIVEL ADPTR PLATE
1
25.
72066136
RETAINING RING-EXT 2.00 HD
2
3
8.
52722362
PIN-TYPE MM 2.00X10.50 (9.69)
1
26.
72532775
ADPTR-M STR/M JIC 4 6
3
2
9.
52726127
MAST WLDMT EZ3000-EZ5000
1
27.
72533613
ADPTR-M STR/M JIC 10 6
3
2
10.
52726170
WLDMT-LOWER BOOM EZ3000
1
28.
72534418
ZERK-NPT .12 X 1.75 LG
2
1
11.
60128858
GEAR GUARD 6025 SII
1
29.
72601482
CAP SCR .62-11X2.50 HH GR8 Z
2
16
12.
70034382
CAP-GREASE PRO20 GC-RED
13.
71056608
GEAR BOX-ROT WORM DRIVE
14.
7206001
CAP SCR .25-20 X .62 HH GR5 Z
15.
7206002
16.
2
3
30.
72601797
WASHER-LCOK 8MM
2
3
1
31.
72601799
WASHER-FLAT M 8
2
3
2
4
32.
72601854
CAP SCR .62-11 X 5.50 HH GR8 Z
2
2
CAP SCR .25-20 X .75 HH GR5 Z
2
4
33.
72602040
CAP SCR M 8-1.25X25 HHZ
2
3
72060091
CAP SCR .50-13 X 1.00 HH GR5 Z
2
3
34.
73051963
MOTOR-ROTATION LSHT
1
17.
72060796
CAP SCR .50-13 X 2.00 SH PLAIN
2
2
35.
76393171
GASKET-WINCH TUL01 40147
1
18.
72063001
WASHER .25 FLAT
2
8
NEW 20140620
18
EZ Hauler 3400LP Manual # 99905829
Gear Rotator (71056608)
25
43
21
20
24
22
35
32
9
14
15
12
NOT
SHOWN
26,40,41
23
8
18
11
17
19
4
36,37,38
13
33
2
10
34
6
27,28,29
3
39
30
42
5
71056608 PARTS LIST (PARTS SHOWN ON DRAWING 99903804)
ITEM
PART #
DESCRIPTION
PART #
DESCRIPTION
PART #
DESCRIPTION
2.
3.
70055307
70055308
BEARING, ROLL CUP
BEARING, ROLL CONE
2
2
18.
19.
71412288
70055310
RING, GREASE
BEARING, ROLL CONE
1
1
33.
34.
71412292
71412293
1
1
4.
71412279
3/8-16X1/4 12 PT CBB GR8
8
20.
70055311
BEARING, ROLL CUP
1
35.
71412294
5.
71412280
2
21.
70055312
BEARING, ROLL CONE
1
36.
76029610
6.
71412281
2
22.
71056614
GEAR, WORM
1
37.
76029611
CAP, GEAR
CAP, WORM
SCREW, 6-32X3/8"
HWHTR
SHIM, GEAR 0.0075 NAT
ALUMINUM
SHIM, GEAR 0.005 BLUE
ALUMINUM
SHIM, GEAR 0.003
GREEN ALUMINUM
WORM, GROUND
SHIM, COVER 0.005
BLUE ALUMINUM
SHIM, COVER 0.020
YELLOW ALUMINUM
MTR ADAPTER
CAP SC ½-13X1 HH
(SHIPPING ONLY
CAP SCR ½-13X1-1/4 HH
PLATE GR5
QTY ITEM
QTY ITEM
8.
71412282
PLUG, PIPE 1/8” HEX SUN
1
23.
71056615
PINION, OUTPUT
1
38.
76029612
9.
71412283
VENT PLUG
1
24.
71412289
SPACER, WASHER
1
39.
71412295
10.
76396847
SEAL, OIL
1
25.
71412290
HOUSING
1
40.
76029613
QTY
8
4
4
4
1
3
11.
71412284
PLUG, THREADED ¼-28
1
26.
71412291
COVER
1
41.
76029614
12.
70034484
2
27.
76029615
SHIM, WORM 0.010 BRWN
2
42.
71412296
13.
71412285
CAP, GREASE FIT
GREASE FITTING ¼-28
STRAIGHT
1
28.
76029616
SHIM, WORM .0075 CLEAR
2
43.
76396849
SEAL, FACE
1
1
1
14.
71412286
15.
71412287
17.
70055309
BUSHING, RED 1/8X1/4
GREASE FITTING 1/8 NPT
STRAIGHT
BEARING, ROLL CUP
1
29.
76029617
1
30.
76029618
1
32.
76396848
SHIM, WORM .005 BLUE
SHIM, WORM .020
YELLOW
O-RING
3
REF
70734049
SHIM KIT (INCL. 27-30,3538,40,41)
2
REF
94396846
SEAL KIT (INCL. 10,32,43)
1
REV 2060302
2
1
Chapter 3 Parts
19
Lower Cylinder (51722419)
49.69" CLOSED - 79.75" OPEN
30.06" STROKE
19
2
7
A
A
10.38"
16
5 14
9
6
17 14
6 8 3
15 10 11 13 15 4
2
12
7.38"
SECTION A-A
30.31"
NOTES:
1 TO REDUCE DOWNTIME, REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS
DISASSEMBLED. NOTE: YOUR SEAL KIT INCLUDES A WAFER LOCK. IF YOUR CYLINDER IS STAMPED
WITH A NOTE: "IMT P/N 51722423 AND JI REV. _ MONTH/DAY/YEAR" ON THE CASE, DO NOT INSTALL
THE WAFER LOCK WITH THE OTHER SEALS.
2 DRILL #15 HOLE 3/16" DEEP. PRESS IN ITEM #7, 60125699.
51722419 CYLINDER DATA
EXTENDED
RETRACTED
CASE
ROD
DRY WEIGHT
TEST PRESSURE
OPERATING PRESSURE
PORTS
CYLINDER TUBE BURST PRESSURE
TORQUES
12.57 IN², 1.64 GAL
3.98 IN², 0.52 GAL
ø4.5" OD x 4" BORE X 44.44" LONG
ø2.25" X 45.81
146 LB
3400LP PSI
2500 PSI
SAE #4 O-RING BOSS (0.438-20 UNF-2B)
8,333 PSI
PISTON TO ROD: 710-740 FT-LB
HEAD GLAND TO CYLINDER: 450 FT-LB
FIRST STAGE EXTENSION ASSEMBLY (99905730-6) PARTS LIST
ITEM
PART #
DESCRIPTION
KIT
QTY
ITEM
PART #
DESCRIPTION
KIT
QTY
1.
9D161823
SEAL KIT
#20
1
11.
7Q10P342
BACK-UP RING 3.62 BORE 4 O.D.
0.07 THK
#1
1
2.
52722420
ROD ASSEMBLY
#20
1
12.
7R14P022
ROD WIPER-TYPE D 2.25 ROD
#1
1
3.
52722421
CASE ASSEMBLY
#20
1
13.
7R546022
U-CUP LOADED 2.25X2.75X.38 "B
#1
1
4.
6HD40022
HEAD
#20
1
14.
7T2N4040
WEAR RING - PISTON 4.00 O.D. X
.50 W
#1
2
5.
6ID40143
PISTON
#20
1
15.
7T2NX625
WEAR RING-ROD 2.25 IDX0.75
#1
2
6.
60136600
STOP TUBE
#20
2
16.
7T61N143
LOCK RING-NYLON 1.43
#1
1
7.
60125699
PIN - LOCK
#1
1
17.
7T66P040
PISTON SEAL DYNAMIC 4.00"
#1
1
8.
7Q072153
O-RING - 3.5 X 3.69 0.09 70
#1
1
18.
73054999
VALVE-COUNTERBALANCE
#3
1
9.
7Q072342
O-RING - 3.62 X 4 0.19 70
#1
1
19.
77041845
10.
9D161823
SEAL KIT
#20
1
20.
51722419A
REV B 20110125
SWITCH-PRESSURE
1
CYLINDER
1
20
EZ Hauler 3400LP Manual # 99905829
Boom Assembly (99905730)
Stinger Assembly (99905730-2)
15
2
1
STINGER ASSEMBLY
GUIDE TUBE
52
13
51
49
41
9
22
51
47
44
58
8
52
47
38
36
58
56
49
3
8
38
53
36
13
STINGER ASSEMBLY
NOTES (SEE REFERENCE NUMBER IN BOX):
1
2
3/8-16 JAM NUT
ITEM #13, FEEDER TUBE GUIDE, SHOWN FOR CLARITY, IS MOUNTED INSIDE THE BOOM. NOTE THE
LOCATION OF THE JAM NUT.
STINGER ASSEMBLY (99905730-2) PARTS LIST
ITEM
PART #
DESCRIPTION
KIT
QTY
KIT
QTY
41.
72060052
CAP SCR .38-16X2.50 HH GR5 Z
7
2
1
44.
72062103
NUT .38-16 HEX NYLOCK
7
1
KIT-HRDW BOOM ASM EZ3000
1
47.
72063030
MACHY BUSHING .75X10 GA NR
7
2
PIN-TYPE T .75 X 1.88
2
49.
72063051
WASHER .38 LOCK
7
18
52722328
BOOM ASM – STINGER EZ3000
1
51.
72063186
WASHER .38 FLAT ASTM F436
7
11
13.
60030082
SHEAVE-7.00 NYLON W/BEARING
2
52.
72066145
HAIR PIN .19 ZINC
7
2
15.
60030395
GUIDE-FEED TUBE
2
53.
72532351
ADPTR-M STR/M JIC 4 4
4
4
22.
60030410
WEAR PAD-INNER CYL EZ3000
1
56.
72602046
CAP SCR .38-16 X 1.75 SH ZINC
7
4
36.
70034382
CAP-GREASE PRO20 GC-RED
7
2
58.
72661718
PIN-SNAPLOCK .25 X 1.75
7
2
38.
72053508
ZERK-NPT .12
7
2
REV C 20140825
3.
51722432
CYL-2.50/1.75 56.12S 77.38CC C
1
4.
51722743
KIT-HYD FEEDER TUBE EZ3000
7.
51722947
8.
52704255
9.
ITEM
PART #
DESCRIPTION
Chapter 3 Parts
21
2nd Extension Assembly (99905730-3)
3
49, 56
49
16
41, 49, 51
39
49
45
35
27
17
DETAIL C
17
56
24
18
12
B
60
24
29
59
46
50
1
25 15 2
51
49
41
DETAIL B
NOTES (SEE REFERENCE NUMBER IN BOX):
1
3/8-16 JAM NUT
2
ITEM #13, FEEDER TUBE GUIDE, SHOWN FOR CLARITY, IS MOUNTED INSIDE THE BOOM. NOTE THE
LOCATION OF THE JAM NUT.
2ND EXTENSION ASSEMBLY (99905730-3) PARTS LIST
ITEM
PART #
DESCRIPTION
KIT
QTY
ITEM
PART #
DESCRIPTION
KIT
QTY
CAP SCR .38-16X.75 HH GR5 Z
7
4
72060052
CAP SCR .38-16X2.50 HH GR5 Z
7
2
72063003
WASHER .38 FLAT
7
4
72063005
WASHER .50 FLAT
7
4
72063051
WASHER .38 LOCK
7
18
3.
51722432
CYL-2.50/1.75 56.12S 77.38CC C
1
4.
51722743
KIT-HYD FEEDER TUBE EZ3000
1
7.
51722947
KIT-HRDW BOOM ASM EZ3000
1
41.
12.
52725820
WELDMT-2
1
45.
15.
60030395
GUIDE-FEED TUBE
2
46.
16.
60030396
WEAR PAD-RC 0.81X6.00X4.00
1
49.
17.
60030397
WEAR-PAD-EZ3000 STINGER
2
50.
72063053
WASHER .50 LOCK
7
4
18.
60030398
WEAR PAD-EZ3000
1
51.
72063186
WASHER .38 FLAT ASTM F436
7
11
24.
60030415
WEAR PAD-RND 0.25X2.50X1.00X.25
6
56.
72602046
CAP SCR .38-16X 1.75 SH ZINC
7
4
25.
60030416
WEAR PAD-RND 0.25X2.50X1.25X.88
1
59.
60142811
LOCK PLATE – WEAR PAD
1
27.
60030425
WEAR PAD-RND 0.44X1.25X.50X.50
4
60.
72602101
CAP SCR .50-13X .63 HH GR5 Z
2
29.
60030532
WEAR PAD-RC UHMW .31X7.125X6
1
REV C 20140825
ND
EXT BOOM EZ3000
35.
60140033
LOCK PLATE-WEAR PAD
39.
72060044
2
22
EZ Hauler 3400LP Manual # 99905829
Top Feeder Tube Assembly (99905730-4)
TOP FEEDER TUBE ASSEMBLY
D
1
57 48
53 5
DETAIL D
53
57 48
53
2
53
CONNECT TO “R” PORT
ON EXTENSION CYLINDER
1
DETAIL E
2
CONNECT TO “E” PORT
ON EXTENSION CYLINDER
E
TOP FEEDER TUBES & EXTENSION CYLINDER
TOP FEEDER TUBE (99905730-4) PARTS LIST
ITEM
PART #
DESCRIPTION
KIT #
QTY
1.
51398869
HOSE-FJ .25 X 8.12 (4-4) 100R17
4
1
2.
51398870
HOSE-FJ .25 X 9.50 (4-4) 100R17
4
1
4.
51722743
KIT-HYD FEEDER TUBE EZ3000
1
5.
51722747
FEEDER TUBE-UPPER EZ3000
2
7.
51722947
KIT-HRDW BOOM ASM EZ3000
48.
72063049
WASHER .25 LOCK
7
53.
72532351
ADPTR-M STR/M JIC 4 4
4
4
57.
72602047
CAP SCR .25-20X 1.00 SH ZINC
7
8
REV C 20180825
1
8
Chapter 3 Parts
23
Bottom Feeder Tube Assembly (99905730-5)
6
54
55
55
37
54
54
6
54
37
DETAIL F
37
54
54
6
54
1 43
55
55
21
G
54
37
1 43
6
BOTTOM FEEDER TUBE & EXTENSION
CYLINDER ASSEMBLY
21
F
BOTTOM FEEDER TUBE ASSEMBLY
DETAIL G
NOTES:
1
USE BLUE THREAD LOCKER
BOTTOM FEEDER TUBE (99905730-5) PARTS LIST
ITEM
PART #
DESCRIPTION
4.
51722743
KIT-HYD FEEDER TUBE EZ3000
KIT #
QTY
1
6.
51722909
FEEDER TUBE-LOWER EZ3000
2
7.
51722947
KIT-HRDW BOOM ASM EZ3000
1
21.
60030404
GUIDE-FEED TUBE
2
37.
71413607
TUBE-HYD EZ3000 FEED TUBE
2
43.
72060652
SCR-MACH .25-20X 1.50 RDH
7
2
54.
72533376
ADPTR-M FACE/M STR 4 4
4
4
55.
72533594
ELBOW-M STR/90/M JIC 4 6
4
2
REV C 20140825
24
EZ Hauler 3400LP Manual # 99905829
First Stage Extension Assembly (99905730-6)
26
51
49
40
33
40 49 51
32
31
39
49
45
35
27
24
30
32
33
30
40
31
40
49
51
24
26
DETAIL H
34
46
50
42
H
19
24
20
23
11
1
24
10
19
1st STAGE EXTENSION ASSEMBLY
23
FIRST STAGE EXTENSION ASSEMBLY (99905730-6) PARTS LIST
ITEM
PART #
DESCRIPTION
KIT
QTY
ITEM
PART #
DESCRIPTION
KIT
QTY
7.
51722947
KIT-HRDW BOOM ASM EZ3000
1
32.
60135203
SHIM-1.00X3.00X0.015THK
A/R
10.
52724768
WLDMT-AUGER MOUNT EZ3000
1
33.
60135204
SHIM-1.00X3.00X0.031THK
A/R
11.
52725819
WLDMT-1ST EST BOOM EZ3000
1
34.
60140009
LOCK PLATE-WEAR PAD
14.
60030353
WEAR PAD-RND .25X2.00X1.00X.75
1
35.
60140033
LOCK PLATE-WEAR PAD
19.
60030399
WEAR PAD-RC 0.25X6.00X9.00
2
39.
72060044
CAP SCR .38-16X.75 HH GR5 Z
7
20.
60030402
WEAR PAD-RC 0.31X6.00X8.00
1
40.
72060050
CAP SCR .38-16X2.00 HH GR5ZC
7
8
23.
60030411
WEAR PAD-RC 0.25X6.81X2.50
2
42.
7260091
CAP SCR .50-13X1.00 HH GR5 Z
7
2
24.
60030415
WEAR PAD-RND .25X2.50X1.00X.25
6
45.
72063003
WASHER .38 FLAT
7
4
26.
60030417
WEAR PAD-RC 0.25X7.00X8.00
1
46.
72063005
WASHER .50 FLAT
7
4
27.
60030425
WEAR PAD-RND 0.44X1.25X.50X.50
4
49.
72063051
WASHER .38 LOCK
7
18
28.
60030473
WEAR PAD-RC 0.25X6.00X6.00
1
50.
72063053
WASHER .50 LOCK
7
4
30.
60135201
SHIM-1.00X2.00X0.15THK
A/R
51.
72063186
WASHER .38 FLAT ASTM F436
7
11
31.
60135202
SHIM-1.00X2.00X0.031THK
A/R
REV C 20140825
1
2
4
Chapter 3 Parts
25
99905730 Parts List, Complete
99905730 PARTS LIST, COMPLETE
ITEM
KIT
QTY
1.
51398869
PART #
DESCRIPTION
HOSE-FJ .25 X 8.12 (4-4) 100R17
4
1
ITEM
31.
60135202
PART #
DESCRIPTION
SHIM-1.00X2.00X0.031THK
KIT
QTY
2.
51398870
HOSE-FJ .25 X 9.50 (4-4) 100R17
4
1
32.
60135203
SHIM-1.00X3.00X0.015THK
A/R
3.
51722432
CYL-2.50/1.75 56.12S 77.38 CC C
1
33.
60135204
SHIM-1.00X3.00X0.031THK
A/R
4.
51722743
KIT-HYD FEEDER TUBE EZ3000
1
34.
60140009
LOCK PLATE-WEAR PAD
1
5.
51722747
FEEDER TUBE-UPPER EZ3000
2
35.
60140033
LOCK PLATE-WEAR PAD
2
6.
51722909
FEEDER TUBE-LOWER EZ3000
2
36.
70034382
CAP-GREASE PRO20 GC-RED
7.
51722947
KIT-HRDW BOOM ASM EZ3000
1
37.
71413607
TUBE-HYD EZ3000 FEED TUBE
8.
52704255
PIN-TYPE T .75 X 1.88
2
38.
72053508
ZERK-NPT .12
7
2
9.
52722328
BOOM ASM – STINGER EZ3000
1
39.
72060044
CAP SCR .38-16X.75 HH GR5 Z
7
4
10.
52724768
WLDMT-AUGER MOUNT EZ3000
1
11.
52725819
WLDMT-1
12.
52725820
WLDMT-2
13.
60030082
14.
A/R
7
2
2
40.
72060050
CAP SCR .38-16X2.00 HH GR5ZC
7
8
ST
EXT BOOM EZ3000
1
41.
72060052
CAP SCR .38-16X2.50 HH GR5 Z
7
2
ND
EXT BOOM EZ3000
1
42.
72060091
CAP SCR .50-13X1.00 HH GR5 Z
7
2
SHEAVE-7.00 NYLON W/BEARING
2
43.
72060652
SCR-MACH .25-20X1.50 RDH
7
2
60030353
WEAR PAD-RND .25X2.00X1.00X.75
1
44.
72062103
NUT .38-16 HEX NYLOCK
7
1
15.
60030395
GUIDE-FEED TUBE
2
45.
72063003
WASHER .38 FLAT
7
4
16.
60030396
WEAR PAD-RC 0.81X6.00X4.00
1
46.
72063005
WASHER .50 FLAT
7
4
17.
60030397
WEAR PAD-EZ3000 STINGER
2
47.
72063030
MACHY BUSHING .75X10 GA NR
7
2
18.
60030398
WEAR PAD-EZ3000
1
48.
72063049
WASHER .25 LOCK
7
8
19.
60030399
WEAR PAD-RC 0.25X6.00X9.00
2
49.
72063051
WASHER .38 LOCK
7
18
20.
60030402
WEAR PAD-RC 0.31X6.00X8.00
1
50.
72063053
WASHER .50 LOCK
7
4
21.
60030404
GUIDE-FEED TUBE
2
51.
72063186
WASHER .38 FLAT ASTM F436
7
11
22.
60030410
WEAR PAD-INNER CYL EZ3000
1
52.
72066145
HAIR PIN .19 ZINC
7
2
23.
60030411
WEAR PAD-RC 0.25X6381X2.50
2
53.
72532351
ADPTR-M STR/M JIC 4 4
4
4
24.
60030415
WEAR PAD-RND .25X2.50X1.00X.25
6
54.
72533376
ADPTR-M FACE/M STR 4 4
4
4
25.
60030416
WEAR PAD-RND .12X2.00X1.25X.88
1
55.
72533594
ELBOW-M STR/90/M JIC 4 6
4
2
26.
60030417
WEAR PAD-RC .25X7.00X8.00
1
56.
72602046
CAP SCR .38-16X 1.75 SH ZINC
7
4
27.
60030425
WEAR PAD-RND .44X1.25X.50X.50
4
57.
72602047
CAP SCR .25-20X 1.00 SH ZINC
7
8
28.
60030473
WEAR PAD-RC 0.25X6.00X6.00
1
58.
72661718
PIN-SNAPLOCK .25 X 1.75
7
2
29.
60030532
WEAR PAD-RC UHMW
1
59.
60142811
LOCK PLATE – WEAR PAD
1
30.
60135201
SHIM-1.00X2.00X0.015THK
A/R
60.
72602101
CAP SCR .50-13X.63 HH GR5 Z
2
REV C 20140825
26
EZ Hauler 3400LP Manual # 99905829
Cylinder, Third Extension (51722432)
DRILL #15 HOLE 1/16" DEEP.
PRESS IN PIN # 60125699.
A
14
19
4
16
18
11
12
17 3
9 17 15
13.36"
A
16
13
2
SECTION A-A
7
8
8
5
10
6
77.38" CLOSED - 133.5" OPEN - 56.12" STROKE
NOTES:
1
REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS DISASSEMBLED. THIS
WILL REDUCE FUTURE DOWNTIME. NOTE: YOUR SEAL KIT INCLUDES A WAFER LOCK. IF YOUR
CYLINDER IS STAMPED WITH A NOTE: "IMT P/N 51722423 AND JI REV. _ MONTH/DAY/YEAR" ON THE
CASE, DO NOT INSTALL THE WAFER LOCK WITH THE OTHER SEALS.
2
APPLY REGULAR GRADE ANTI-SEIZE AND LUBRICATING COMPOUND TO THREADS ON CYLINDER
HEAD ONLY. KEEP AWAY FROM ALL SEALS.
3
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.
4
PISTON TORQUE (ITEM #5) - 500-530 FT-LB; HEAD GLAND TORQUE (ITEM #9) - 250 FT-LB.
51722432 PARTS LIST
ITEM
PART #
DESCRIPTION
1.
91744176
SEAL KIT - IMT 2.50B X 1.75R 1.50 STGR
KIT #
QTY
2.
52722434
ROD ASM-1.75 DIA X 76.88 LG 1.50 S
1
3.
52722433
CASE ASM-2.50 BORE X 71.57LG
1
1
4.
60125699
PIN - LOCK TUBE 0.19 OD X 0.065 WALL
5.
60134013
PISTON-2.50 BORE X 1.50 STGR
#1
1
1
6.
60133610
STOP TUBE-1.75 ROD X 3.57LG 4 HOLE
1
8.
60136599
STOP TUBE-1.75 ROD X 3.13 LONG
2
9.
6HD25017
HEAD-2.50 BORE X 1.75 ROD (DUCTILE IRON)
1
10.
72062305
COLLAR-LOCK 1.50-12 THREADED 1-PC
11.
7Q072222
O RING 1.50X 1.75X .12 70
#1
1
1
12.
7Q072228
O RING 2.25X 2.50X .12 70
#1
1
13.
7Q10P228
BACKUP RING-2.25 ID X 2.50 OD
#1
1
14.
7R14P017
ROD WIPER - TYPE D 1.75 ROD
#1
1
15.
7R546017
U-CUP SEAL (LSU) 1.50 ID X 2.00D
#1
1
16.
7T2N4025
WEAR RING-PISTON 2.50 ODX .50W
#1
2
17.
7T2NX420
WEAR RING-ROD 1.75 ID X 0.50 W
#1
2
18.
7T66P250
PISTON SEAL-DYNAMIC 2.50in CP
#1
1
19.
73054218
VALVE-CHECK PILOT/OPEN NONVENT 100 PSI (WAS 73054999)
REV B 20110125
1
Chapter 3 Parts
Top Feeder Tube Assembly (51722747)
2
A
5
6
3
4
SECTION A-A
A
NOTES:
1
REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE TUBE IS DISASSEMBLED.
51722747 PARTS LIST
ITEM
PART #
DESCRIPTION
1.
51744195
SEAL KIT-IMT 1.14B 1.00R
1
2.
52722326
ROD WLDMT- UPPER FEED TUBE
1
3.
52722665
CASE WLDMT- UPPER FEED TUBE
4.
76398867
WEAR RING-ROD 1.00 ID X .50W
#1
1
5.
76534650
U-CUP LOADED 1.00X1.25X.250 B
#1
1
6.
76398868
ROD WIPER-TYPE D 1.00 ROD
#1
1
NEW 20100215
KIT #
QTY
1
27
28
EZ Hauler 3400LP Manual # 99905829
Bottom Feeder Tube Assembly (51722909)
C
C
2
5
6
4
3
NOTES:
1
REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE TUBE IS DISASSEMBLED.
51722909 PARTS LIST
ITEM
PART #
DESCRIPTION
1.
51744195
SEAL KIT-IMT 1.14B 1.00R
1
2.
52722325
ROD WLDMT-LOWER FEED TUBE
1
3.
52722664
CASE WLDMT- LOWER FEED TUBE EZ3400LP
4.
76398867
WEAR RING-ROD 1.00 ID X .50W
#1
1
5.
76398868
ROD WIPER-TYPE D 1.00 ROD
#1
1
6.
76534650
U-CUP LOADED 1.00X1.25X.250 B
#1
1
NEW 20100215
KIT #
QUANTITY
1
Chapter 3 Parts
29
Crane & Winch Assembly (99905831)
EXTENSION CYLINDER ASSEMBLY (99905831-2)
17
29
85
71
65
72
48
86
28 85
86
72
9
9
94
29 17
85
97
6
5
62
95
94
65 85
82
30
95
97 85
30
77
87
79
49
71
85
32
34
79
19
87
18
107
87
79
18
20
33
78
83
64
12 85
83
64
EXTENSION CYLINDER ASSEMBLY (99905831-2) PARTS LIST
ITEM
PART #
DESCRIPTION
KIT
QTY
ITEM
PART #
DESCRIPTION
KIT
QTY
5.
51722423
CYL-2.50/1.75 56.12S 75.31CC C
1
64.
72060091
CAP SCR .50-13X1.00 HH GR5Z
105
5
6.
51722424
CYL-2.50/1.75 56.12S 77.88CC C
1
65.
72060118
CAP SCR .50-13X2.00 HH GR8 Z
105
4
7.
51722744
KIT-HYD ASM EZ3000
1
71.
72062107
NUT .50-13 HEX CENTER LOCK Z
105
4
9.
52722016
WLDMT-TRUNNION 6022
2
72.
72062335
CAP SCR .44-14X3.00 SH GR8 Z
105
4
12.
52722361
PINY TYPE-MM 1.50X11.88 (11.19)
1
77.
72063003
WASHER .38 FLAT
105
15
17.
52725629
WLDMT-BRACKET OUTER CYL CVR
4
78.
72063005
WASHER .50 FLAT
105
6
18.
60030415
WEAR PAD-RND .25X2.50X1.00X.25
2
79.
72063037
MACHY BUSHING 1.50X10 GA NR
105
5
19.
60030425
WEAR PAD-RND .44X1.25X.50X.50
2
82.
72063051
WASHER .38 LOCK
105
2
20.
60030474
WEAR PAD-RC .31X6.00X6.00
1
83.
72063053
WASHER .50 LOCK
105
5
28.
60133733
CLAMP PLATE 1.00X1.00X3.00
2
85.
72063132
WASHER .50 FLAT ASTM F436
105
19
29.
60133759
CLAMP-PLATE TOP DUAL CYL
2
86.
72063269
WASHER .44 N FLAT H ASTM F436
105
4
30.
60133760
CLAMP-PLATE BOTTOM DUAL CYL
2
87.
72066132
RETAINING RING-EXT 1.50 HD
105
5
32.
60134504
PIN-TYPE A 1.50X9.88 (9.31)
1
94.
72533163
ELBOW-M STR/90/M FACE 6 6
7
2
33.
60140009
LOCK PLATE-WEAR PAD
1
95.
72533186
ADPTR-M FACE/M STR 6 6
7
2
34.
60140033
LOCK PLATE-WEAR PAD
1
97.
72601369
CAP SC .50-13X3.00 HH GR8 Z
105
8
48.
71413280
TUBE ASM-HYD .38X71.19 LG
1
105.
91726172
KIT-HRDW CRANE & WNCH ASM
49.
71413281
TUBE ASM-HYD .38X57.11LG
1
107.
99905830
DWG-BASE & MAST ASM
62.
72060044
CAP SCR .38-16X .75 HH GR5 Z
2
NEW 20140623
105
1
1
30
EZ Hauler 3400LP Manual # 99905829
ENERGY CHAIN ASSEMBLY (99905831-3)
TORQUE TO REQUIRED SPECIFICATIONS
AND BACK OFF ONE HALF TURN, UPPER
BOLTS ONLY.
100
1
68
77
26
25
100
47
63
77
47
63
77
15
74
70
74
70
77
68
77
68
ENERGY CHAIN ASSEMBLY (99905831-3) PARTS LIST
ITEM
PART #
DESCRIPTION
1.
51395728
HOSE-JJ .50X17.50 (8-8) 100R17
7.
51722744
KIT-HYD ASM EZ3000
1
15.
52722832
ENERGY CHAIN TRAY WLDMT EZ3000
1
25.
60126637
TUBING CLAMP 0.63 X 2.27
3
26.
60126691
ENERGY CHAIN ASM EZHAULER III
1
47.
71411213
TUBE ASM
63.
72060047
CAP SCR .38-16X1.25 HH GR5 Z
105
4
68.
72062103
NUT .38-16 HEX NYLOCK
105
13
70.
72062106
NUT 10-24 HEX NYLOCK
105
6
74.
72063000
WASHER .19 W FLAT ANSI B27.2Z
105
6
77.
72063003
WASHER .38 FLAT
105
15
100.
72601744
CAP SCR #10-24X1.00 SH
105
6
105.
91726172
KIT-HRDW CRANE & WINCH ASM EZ3000
NEW 20140623
KIT #
7
QTY
1
2
1
Chapter 3 Parts
HYDRAULIC TUBE ASSEMBLY (99905831-4)
51
50
38
38
38
43
38
43
68
25
77
68
25
77
68
42
52
76
81
39 39
53
68
39
39
39
39
42
68
42
68
HYDRAULIC TUBE ASSEMBLY (99905831-4) PARTS LIST
ITEM
PART #
DESCRIPTION
8.
51722754
AUGER RELEASER SUPPORT PARTS
KIT #
QTY
1
25.
60126637
TUBING CLAMP 0.63X2.27
3
38.
70034402
CLAMP-TWIN TUBE .62 OD
4
39.
70034432
CLAMP-TWIN TUBE .50 OD
6
42.
70143829
COVER PLT-PAR29 CPT2
3
43.
70144819
COVER-PLT-PAR29 CPT3
2
50.
71413634
TUBE ASM- 0.63 OD X 0.063 W X 119.10
1
51.
71413635
TUBE ASM- 0.63 OD X 0.063 W X 118.85
1
52.
71413636
TUBE ASM- 0.50 OD X 0.063 W X 51.16
1
53.
71413637
TUBE ASM- 0.50 OD X 0.063 W X 63.81
61.
72060027
CAP SCR .31-18 X 1.50 HH GR5 Z
105
1
68.
72062103
NUT .38-16 HEX NYLOCK
105
13
76.
72063002
WASHER .31 FLAT
105, 8
3
77.
72063003
WASHER .38 FLAT
105
15
81.
72063050
WASHER .31 LOCK
105
105.
91726172
KIT-HRDW CRANE & WINCH ASM EZ3000
NEW 20140623
1
1
1
61
31
32
EZ Hauler 3400LP Manual # 99905829
WINCH & VALVEBANK COVER ASSEMBLY (99905831-5)
WINCH & VALVEBANK COVER ASSEMBLY (99905831-5) PARTS LIST
ITEM
PART #
DESCRIPTION
KIT
QTY
DESCRIPTION
KIT
QTY
75.
72063001
WASHER .25 FLAT
105
13
1
77.
72063003
WASHER .38 FLAT
105
15
1
78.
72063005
WASHER .50 FLAT
105
6
ROPE GUIDE-ROUND 2.50X9.75
1
80.
72063049
WASHER .25 LOCK
105
8
60105544
PLATE-ANGLE PLASTIC
2
84.
72063116
WASHER .75 N FLAT H ASTMF
105
2
27.
60128886
COVER VALVE BANK
1
85.
72063132
WASHER .50 FLAT ASTM F436
105
19
35.
60141623
COVER-OUTER CYLINDER
1
91.
72532359
ADPTR-M STR/M JIC 10 8
7
2
36.
60142640
PIN-TYPE A 0.75X11.69 (11.32)
1
96.
72533490
ADPTR-M BSPP/M JIC 4 4
7
1
55.
71570981
WINCH-A55 EZ3
1
97.
72601369
CAP SCR .50-13X 3.00 HH GR8 Z
105
8
57.
72060000
CAP SCR .25-20X .50 HH GR5 Z
105
4
98.
72601725
SCR-MACH #6-32 .50 RDH
105
2
58.
72060001
CAP SCR .25-20X .62 HH GR5 Z
105
4
99.
72601726
NUT 6-32 HEX NYLOCK
105
2
59.
72060002
CAP SCR .25-20X .75 HH GR5 Z
105
2
101.
72661710
RETAINING RING-EXT .75 HD
105
2
66.
72060753
CAP SCR .38-16X1.00 SH PLAIN
105
2
102.
77040581
FLOODLIGHT-LED 12-36VDC
104
3
68.
72062013
NUT .38-16 HEX NYLOCK
105
13
103.
77441179
HARNESS-EZ HAULER III
104
1
69.
72062104
NUT .25-20 HEX NYLOCK
105
2
104.
90726162
LIGHT-KIT EZ3000 LED
1
73.
72062356
NUT .50-13 HEX GR8 YZ NYLOCK
105
4
105.
91726172
KIT-HRDW CRANE & WINCH
1
2.
51719813
CABLE ASM-E STOP SWITCH EZH3
1
3.
51719826
CABLE ASM-HOP ALARM EZH3
7.
51722744
KIT-HYD ASM EZ3000
22.
60030529
24.
NEW 20140623
ITEM
PART #
Chapter 3 Parts
33
AUGER ASSEMBLY (99905831-6)
88
4
64
83
85
14
16
46
90
87 79
56
67
37
88
13 85
83 64
1
79
87
54
67
90
10
46
DETAIL C
89
31
21
76
60
31
C
89
11
45
DETAIL D
D
NOTES (SEE REFERENCE NUMBER IN BOX):
1
SECURE AUGER SWING WITH ZIP TIES.
AUGER ASSEMBLY (99905831-6) PARTS LIST
ITEM
PART #
DESCRIPTION
KIT
QTY
DESCRIPTION
KIT
QTY
8
1
56.
72053507
ZERK-STR THD .25-28
105
1
AUGER RELEASE SUPPORT PARTS
1
60.
72060025
CAP SCR .31-18X1.00 HH GR5 Z
8
2
52722321
WLDMT-AUGER LATCH PIVOT
1
64.
72060091
CAP SCR .50-13X1.00 HH GR5 Z
105
5
11.
52722322
WLDMT-AUGER RELEASE HANDLE
1
67.
72062056
NUT .31-24 HEX JAM ZINC
13.
52722363
PIN-TYPE MM 1.50X6.56 (5.94)
8
1
76.
72063002
WASHER .31 FLAT
14.
52722364
PIN-TYPE MM 1.25X5.69 (4.94)
8
1
79.
72063037
16.
52724771
WLDMT-AUGER SWING
8
1
83.
72063053
21.
60030475
WEAR PAD-RC 0.50X1.75X6.00
8
1
85.
31.
60134453
PIPE-AUGER RELEASE
1
87.
37.
70034382
CAP-GREASE PRO20 GC-RED
1
45.
71039096
KNOB-CONTROL 1.50 BLK
46.
71058002
CLEVIS W/.31-24 THD
54.
81414119
THREADED ROD .31-24X14.75 LG
4.
51722366
DWG-AUGER RETAINER FRAME
8.
51722754
10.
NEW 20140623
ITEM
PART #
105
2
105, 8
3
MACHY BUSHING 1.50X10 GA NR
105
5
WASHER .50 LOCK
105
5
72063132
WASHER .50 FLAT ASTM F436
105
19
72066132
RETAINING RING-EXT 1.50 HD
105
5
88.
72066168
COTTER PIN .09X.75 ZINC
1
89.
72066192
COTTER PIN .19X1.00
8
2
90.
72066338
PIN-CLIVES .31X1.00 ZINC
8
1
105.
91726172
KIT-HRDW CRANE & WINCH
105
8
2
105
2
8
2
1
34
EZ Hauler 3400LP Manual # 99905829
VALVE BANK CAPS (99905831-7)
93
92
SOME PARTS REMOVED FOR CLARITY
92
VALVE BANK CAPS (99905831-7) PARTS LIST
ITEM
PART #
DESCRIPTION
7.
51722744
KIT-HYD ASM EZ3000
92.
72532674
CAP-JIC STL 4 ( .44 THD)
7
9
93.
72532675
CAP-JIC STL 8 ( .75 THD)
7
2
NEW 20140623
KIT #
QTY
1
Chapter 3 Parts
35
99905831 Parts List, Complete
99905831 PARTS LIST, COMPLETE
ITEM
PART #
DESCRIPTION
KIT
QTY
7
1
55.
71570981
WINCH-A55 EZ3
CABLE ASM-E STOP SWITCH EZH3
1
56.
72053507
ZERK-STR THD .25-28
105
1
51719826
CABLE ASM-HOP ALARM EZH3
1
57.
72060000
CAP SCR .25-20X.50 HH GR5 Z
105
4
4.
51722366
DWG-AUGER RETAINER FRAME
1
58.
72060001
CAP SCR .25-20X.62 HH GR5 Z
105
4
5.
51722423
CYL-2.50/1.75 56.12S 75.31CC C
1
59.
72060002
CAP SCR .25-20X.75 HH GR5 Z
105
2
6.
51722424
CYL-2.50/1.75 56.12S 77.88CC C
1
60.
72060025
CAP SCR .31-18X1.00 HH GR5 Z
8
2
7.
51722744
KIT-HYD ASM EZ3000
1
61.
72060027
CAP SCR .31-18X1.50 HH GR5 Z
105
1
8.
51722754
AUGER RELEASE SUPPORT PARTS
1
62.
72060044
CAP SCR .38-16X.75 HH GR5 Z
105
2
9.
52722016
WLDMT-TRUNNION 6022
2
63.
72060047
CAP SCR .38-16X 1.25 HH GR5 Z
105
4
10.
52722321
WLDMT-AUGER LATCH PIVOT
1
64.
72060091
CAP SCR .50-13X 1.00 HH GR5 Z
105
5
11.
52722322
WLDMT-AUGER RELEASE HANDLE
1
65.
72060118
CAP SCR .50-13X 2.00 HH GR8 Z
105
4
12.
52722361
PIN TYPE-MM 1.50X11.88 (11.19)
1
66.
72060753
CAP SCR .38-16X 1.00 SH PLAIN
105
2
13.
52722363
PIN-TYPE MM 1.50X6.56 (5.94)
8
1
67.
72062056
NUT .31-24 HEX JAM ZINC
105
2
14.
52722364
PIN-TYPE MM 1.25X5.69 (4.94)
8
1
68.
72062103
NUT .38-16 HEX NYLOCK
105
13
15.
52722832
ENERGY CHAIN TRAY WLDMT
1
69.
72062104
NUT .25-20 HEX NYLOCK
105
2
16.
52724771
WLDMT-AUGER SWING
1
70.
72062106
NUT 10-24 HEX NYLOCK
105
6
17.
52725629
WLDMT-BRACKET OUTER CYL CVR
4
71.
72062107
NUT .50-13 HEX CENTER LOCK Z
105
4
18.
60030415
WEAR PAD-RND .25X2.50X1.00X.25
2
72.
72062335
CAP SCR .44-14X 3.00 SH GR8 Z
105
4
19.
60030425
WEAR PAD-RND .44X1.25X.50X.50
2
73.
72062356
NUT .50-13 HEX GR8 YZ NYLOCK
105
4
20.
60030474
WEAR PAD-RC .31X6.00X6.00
1
74.
72063000
WASHER .19 W FLAT ANSI B27.2Z
105
6
21.
60030475
WEAR PAD-RC .50X1.75X6.00
1
75.
72063001
WASHER .25 FLAT
105
13
22.
60030529
ROPE GUIDE-ROUND 2.50X9.75
1
76.
72063002
WASHER .31 FLAT
105, 8
3
23.
60030530
ROPE GUIDE-1.50X.50X9.25
1
77.
72063003
WASHER .38 FLAT
105
15
1.
51395728
HOSE-JJ .50X17.50 (8-8) 100R17
2.
51719813
3.
8
8
8
ITEM
PART #
DESCRIPTION
KIT
QTY
1
24.
60105544
PLATE-ANGLE PLASTIC
2
78.
72063005
WASHER .50 FLAT
105
6
25.
60126637
TUBING CLAMP .63X2.27
3
79.
72063037
MACHY BUSHING 1.50X10 GA NR
105
5
26.
60126691
ENERGY CHAIN ASM EZHAULER3
1
80.
72063049
WASHER .25 LOCK
105
8
27.
60128886
COVER VALVE BANK
1
81.
72063050
WASHER .31 LOCK
105
1
28.
60133733
CLAMP PLATE-1.00X1.00X3.00
2
82.
72063051
WASHER .38 LOCK
105
2
29.
60133759
CLAMP-PLATE TOP DUAL CYL
2
83.
72063053
WASHER .50 LOCK
105
5
30.
60133760
CLAMP-PLATE BOTTOM DUAL CYL
2
84.
72063116
WASHER .75 N FLAT H ASTMF
105
2
31.
60134453
PIPE-AUGER RELEASE
1
85.
72063132
WASHER .50 FLAT ASTM F436
105
19
32.
60134504
PIN-TYPE A 1.50X9.88 (9.31)
1
86.
72063269
WASHER .44 N FLAT H ASTM
105
4
33.
60140009
LOCK PLATE-WEAR PAD
1
87.
72066132
RETAINING RING-EXT 1.50 HD
105
5
34.
60140033
LOCK PLATE-WEAR PAD
1
88.
72066168
COTTER PIN .09X.75 ZINC
35.
60141623
COVER-OUTER CYLINDER
1
89.
72066192
COTTER PIN .19X1.00
36.
60142640
PIN-TYPE A 0.75X11.69 (11.32)
1
90.
72066338
37.
70034382
CAP-GREASE PRO20 GC-RED
1
91.
72532359
38.
70034402
CLAMP-TWIN TUBE .62 OD
4
92.
39.
70034432
CLAMP-TWIN TUBE .50 OD
6
40.
70034447
TIES-PLASTIC .25W 11.38L BLACK
41.
70034459
42.
70143829
43.
8
2
105
2
PIN-CLEVIS .31X1.00 ZINC
8
2
ADPTR-M STR/M JIC 10 8
7
2
72532674
CAP-JIC STL 4 (.44 THD)
7
9
93.
72532675
CAP-JIC STL 8 (.75 THD)
7
2
A/R
94.
72533163
ELBOW-M STR/90/M FACE 6 6
7
2
TIES-PLASTIC .50W 34.25 L BLK
2
95.
72533186
ADPTR-M FACE/M STR 6 6
7
2
COVER PLT-PAR29 CPT2
3
96.
72533490
ADPTR-M BSPP/M JIC 4 4
7
1
70144819
COVER-PLT-PAR29 CPT3
2
97.
72601369
CAP SCR .50-13X3.00HH GR8 Z
105
8
44.
70732871
HOOK-SWVL L-322A-3T W/LATCH
1
98.
72601725
SCR-MACH #6-32 .50 RDH PHLPS
105
2
45.
71039096
KNOB-CONTROL 1.50 BLK
1
99.
72601726
NUT 6-32 HEX NYLOCK
105
2
46.
71058002
CLEVIS W/ .31-24 THD
2
100.
72601744
CAP SCR #10-24X1.00 SH
105
6
47.
71411213
TUBE ASM-.063ODX.063WX14.12
2
101.
72661710
RETAINING RING-EXT .75 HD
105
2
48.
71413280
TUBE ASM-HYD .38X71.19 LG
1
102.
77040581
FLOODLIGHT-LED 12-36VDC
104
3
49.
71413281
TUBE ASM-HYD .38X57.11 LG
1
103.
77441179
HARNESS-EZ HAULER III LS
104
50.
71413634
TUBE ASM-.63ODX.063WX119.10
1
104.
90726162
LIGHT KIT-EZ3000 LED
1
51.
71413635
TUBE ASM-.63ODX.063WX118.85
1
105.
91726172
KIT-HRDW CRANE & WINCH ASM
1
52.
71413636
TUBE ASM-.50ODX.063WX51.16
1
106.
99905730
DWG-BOOM ASM EZ3000
1
53.
71413637
TUBE ASM-.50ODX.063WX53.81
1
107.
99905830
DWG-BASE & MAST ASM
1
54.
71414119
THREADED ROD-.31-24X14.75LG
1
NEW 20140623
105
8
8
8
1
36
EZ Hauler 3400LP Manual # 99905829
Auger Retainer Frame (51722366)
9,13
(2 PLCS)
14,16
(2 PLCS)
7
10,12,15
11
(2 PLCS)
3
14
(4 PLCS)
4
5,6,8,14,16
(2 PLCS)
51722366 PARTS LIST
ITEM
PART #
DESCRIPTION
1.
51719555
KIT-HARDWARE AUGER RETAINER FRAME
1
2.
52719019
RETAINER FRAME WELDMENT
1
3.
52722320
LATCH RELEASE- AUGER
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 RELEASE .62D/5.0 CRIT
1
8.
72053508
ZERK-NPT .12
9.
72060188
CAP SCREW .75-10X 3.50 HH GR5 Z
1
10.
72060622
SCREW-MACH #10-32X .50 RDH
1
1
11.
72062114
NUT .75-10 HEX NYLOCK
1
2
12.
72063400LP
WASHER .19 W FLAT ANSI B27.2Z
1
1
13.
72063008
WASHER .75 FLAT
1
4
14.
72063034
MACHY BUSHING 1.00X10 GA NR
1
8
15.
72063047
WASHER #10 LOCK
1
1
16.
72066125
RETAINING RING-EXT 1.00 HD
1
4
NEW 20100224
KIT #
QTY
2
2
Chapter 3 Parts
Light Switch Harness (77441179)
J1
S1
1
2
3
LIGHT SWITCH A
LIGHT SWITCH B
J1
1) N/C
2) LIGHT SWITCH
3) LIGHT SWITCH
S1
J1
S1
LOCATOR CODE: J1
PACKARD:12015792
TERM: 12124580
CAVITY
COLOR
SEAL: 12015323
GA.
PRINT LABEL
TO
CON-SPLC
CAVITY
A
RED
16
LIGHT SWITCH
TO
S1
2
B
RED
16
LIGHT SWITCH
TO
S1
3
PRINT LABEL
TO
CON-SPLC
CAVITY
LOCATOR CODE: S1
EATON SWITCH: 8510K9
CAVITY
COLOR
GA.
2
RED
16
LIGHT SWITCH
TO
J1
A
3
RED
16
LIGHT SWITCH
TO
J1
B
NEW 20050719
37
38
EZ Hauler 3400LP Manual # 99905829
Wiring Harness (77441356)
77441356-1 DRAWING
R1 RELAY
J6
W1 W2
B A
LEFT
FLOOD
LIGHT
F1
RECEIVER
FORWARD
FLOOD
LIGHT
J5
J1
W3
W5 W4 W3
E-STOP
J2
ALARM
J7
REV. B 20100301
FLOOD
LIGHT
SWITCH
J3
RIGHT
FLOOD
LIGHT
J4
HORN POWER (NO)
W4 HOP SWITCH (NC) PRESS. SW
W5
SWITCH PWR (COM)
Chapter 3 Parts
77441356-2 SCHEMATIC
85
RADIO
E-STOP
86
87a
30
87
OVERLOAD
SYSTEM
2
15 AMP
FUSE
1 3
1
1 3
1 3
4
1 3
1
3
1
RADIO
RECEIVER
1
3
15 AMP
FUSE
AUGER
EV9
LIFT
2
2
BOOM WINCH
EXTEND
AUXILIARY ROTATION
+
2
POWER SOURCE
(9 - 30 VOLTS)
2
1
2
DC
DC
2
2
2
TR2
A Stroke
5V EXTERNAL
5V EXTERNAL
TR3
Gain
Adjustment
B Stroke
Gain
Adjustment
supply range
alarm detection
3
input signal
stage
34 kOhms
input range
alarm detection
PID
analog
controller
Dither
Generator
4 5V EXTERNAL
A: 2.5-0.9 V
B: 2.5-4.1 V
VARIABLE
INPUT SIGNAL
DUAL
PWM DRIVER
Hall effect
position transducer
input storage
WIRING CHART
1
+12 VOLTS
2
GROUND
3
CONTROL SIGNAL
4
FLOOD LIGHT CONTROLS
TR1
Neutral
Position
Adjustment
SP
+5V
REMOTE
CONTROL
LEVER
TP
ELECTROHYDRAULIC
ACTUATOR
VPB
Tp
VPA
Pp
PRESS.
REDUCING
VALVE
RPM
39
40
EZ Hauler 3400LP Manual # 99905829
Mod. MLT/FD4 Proportional Actuator System - Electro-hydraulic proportional actuators with
closed-loop position control of the valve spool stroke and integrated electronics.
ELECTRICAL SPECIFICATIONS
Supply voltage
Max. current draw
Max. power absorption
Input impedance
Voltage control range
9-30 VDC
750 mA/section
8 watt
40 KOhm
Neutral position - 2.5 volt ± 0.1 volts at rest (0.5 volts total dead zone)
Netraul 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 pin #1 power source) WHERE CONTROL DOES NOT PROVIDE FOR
PROTECTION
HYDRAULIC SPECIFICATIONS
Max. supply pressure
Min.supply pressure
Max. back pressure
Pilot flow requirement
Oil temperature range
Oil viscosity range
Filtration:
A
DEUTSCH 4 POLE
LED ADJ.
TRIMMERS
Deutsch Model DT04
4-Pin Connection Diagram
2
3
35 bar (508 psi)
12 bar (175 psi)
1.5 bar (22 psi)
0.2 lpm (0.05 gpm)
-20 to +95º C
3 cSt - 650 cSt
18/15 (ISO 4406)
BLUE
YELLOW / GREEN
BROWN
BLACK
1 (+) / Power Source
2 (- ) / Power Source
3 Control Signal
4 +5 volt voltage supply to
the remote control
potentiometer
1
4
Viewed from A
ADJUSTING TRIMMERS
REMOTE CONTROL
GREEN LED: NEUTRAL POS.
POTENTIOMETER
T1: NEUTRAL POS. ADJ. TRIMMERCHARACTERISTIC
Configuration
Ohmic resistance
Electrical power rating
Output voltage
3-pin
1k/ 5K /10 Kohm
0.25 watt
95-98% of Vin
Chapter 3 Parts
41
77441356-3 WIRING
W1 POWER A
W2 GROUND B
SPLICE A
J6
LEFT FLOOD PWR A
LEFT FLOOD GND B
F1
SPLICE B
J4
J5
RIGHT FLOOD PWR A
RIGHT FLOOD GND B
SPLICE B
SPLICE A
SPLICE A
A LIGHT SWITCH
SPLICE C
FRONT FLOOD PWR A
B LIGHT SWITCH
FRONT FLOOD GND B
SPLICE C
A E-STOP
B RADIO POWER
RADIO PWR 1
SPLICE A
J1
RADIO/VALVE GND 2
LIGHT CONTROL 3
SPLICE C
PRESSURE SWITCH INPUT 4
J7
HORN GROUND A
30
R1
87a
87
HORN POWER B
86
W3 HORN POWER
W4
HOP SWITCH
W5
SWITCH PWR
J2
85
42
EZ Hauler 3400LP Manual # 99905829
Cylinder, Extension (51722423)
75.31" CLOSED - 131.43" OPEN
56.12" STROKE
7
A
A
2
5 18 11
10 16 16
6
8
8
19
17
9 12 17
13 15 4
SECTION A-A
14
DRILL #15 HOLE 3/16" DEEP.
PRESS IN PIN # 60125699.
NOTES:
1
REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS DISASSEMBLED. THIS
WILL REDUCE FUTURE DOWNTIME. NOTE: YOUR SEAL KIT INCLUDES A WAFER LOCK. IF YOUR
CYLINDER IS STAMPED WITH A NOTE: "IMT P/N 51722423 AND JI REV. _ MONTH/DAY/YEAR" ON THE
CASE, DO NOT INSTALL THE WAFER LOCK WITH THE OTHER SEALS.
2
APPLY REGULAR GRADE ANTI-SEIZE AND LUBRICATING COMPOUND TO THREADS ON CYLINDER
HEAD ONLY. KEEP AWAY FROM ALL SEALS.
3
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.
4
PISTON TORQUE (ITEM #5) - 500-530 FT-LB; HEAD GLAND TORQUE (ITEM #9) - 250 FT-LB.
51722423 PARTS LIST
ITEM
PART #
DESCRIPTION
1.
91744176
SEAL KIT - IMT 2.50B X 1.75R 1.50 STGR
1
2.
52722427
CASE ASM-2.50 BORE X 69.01LG
1
4.
60125699
PIN - LOCK TUBE 0.19 OD X 0.065 WALL
1
5.
60134013
PISTON-2.50 BORE X 1.50 STGR
1
6.
60133610
STOP TUBE-1.75 ROD X 3.57LG 4 HOLE
1
8.
60136599
STOP TUBE-1.75 ROD X 3.13 LONG
2
9.
6HD25017
HEAD-2.50 BORE X 1.75 ROD (DUCTILE IRON)
1
10.
72062305
COLLAR-LOCK 1.50-12 THREADED 1-PC
11.
7Q072222
O RING 1.50X 1.75X .12 70
#1
1
12.
7Q072228
O RING 2.25X 2.50X .12 70
#1
1
13.
7Q10P228
BACKUP RING-2.25 ID X 2.50 OD
#1
1
14.
7R14P017
ROD WIPER - TYPE D 1.75 ROD
#1
1
15.
7R546017
U-CUP SEAL (LSU) 1.50 ID X 2.00D
#1
1
16.
7T2N4025
WEAR RING-PISTON 2.50 ODX .50W
#1
2
17.
7T2NX420
WEAR RING-ROD 1.75 ID X 0.50 W
#1
2
18.
7T66P250
PISTON SEAL-DYNAMIC 2.50in CP
#1
1
19.
52722426
ROD ASM-1.75 DIA X 74.81 LG 1.50 STGR
REV B 20110125
KIT #
QTY
1
1
Chapter 3 Parts
43
Cylinder, Extension (51722424)
19 20
20
A
18
15 5
10 15 17
13
12 11
9
3
8 16
4
A
14 16
SECTION A-A
#15 HOLE DRILLED 0.188” DEEP.
PRESS IN PART # 60125699.
2
7
6
7
77.88” CLOSED - 134.00” OPEN - 56.12” STROKE
NOTES:
1
REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS DISASSEMBLED. THIS
WILL REDUCE FUTURE DOWNTIME. NOTE: YOUR SEAL KIT INCLUDES A WAFER LOCK. IF YOUR
CYLINDER IS STAMPED WITH A NOTE: "IMT P/N 51722423 AND JI REV. _ MONTH/DAY/YEAR" ON THE
CASE, DO NOT INSTALL THE WAFER LOCK WITH THE OTHER SEALS.
2
APPLY REGULAR GRADE ANTI-SEIZE AND LUBRICATING COMPOUND TO THREADS ON CYLINDER
HEAD ONLY. KEEP AWAY FROM ALL SEALS.
3
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.
4
PISTON TORQUE (ITEM #5) - 500-530 FT-LB; HEAD GLAND TORQUE (ITEM #9) - 250 FT-LB.
51722424 PARTS LIST
ITEM
PART #
DESCRIPTION
1.
91744176
SEAL KIT - IMT 2.50B X 1.75R 1.50 STGR
1
2.
52722428
ROD ASM-1.75 DIA X 74.81 LG 1.50 S
1
3.
52722427
CASE ASM-2.50 BORE X 69.01LG
4.
60125699
PIN - LOCK TUBE 0.19 OD X 0.065 WALL
5.
60134013
PISTON-2.50 BORE X 1.50 STGR
1
6.
60133610
STOP TUBE-1.75 ROD X 3.57LG 4 HOLE
1
7.
60136599
STOP TUBE-1.75 ROD X 3.13 LONG
2
8.
6HD25017
HEAD-2.50 BORE X 1.75 ROD (DUCTILE IRON)
1
9.
72062305
COLLAR-LOCK 1.50-12 THREADED 1-PC
1
10.
7Q072222
O RING 1.50X 1.75X .12 70
#1
11.
7Q072228
O RING 2.25X 2.50X .12 70
#1
1
12.
7Q10P228
BACKUP RING-2.25 ID X 2.50 OD
#1
1
13.
7R14P017
ROD WIPER - TYPE D 1.75 ROD
#1
1
14.
7R546017
U-CUP SEAL (LSU) 1.50 ID X 2.00D
#1
1
15.
7T2N4025
WEAR RING-PISTON 2.50 ODX .50W
#1
2
16.
7T2NX420
WEAR RING-ROD 1.75 ID X 0.50 W
#1
2
17.
7T66P250
PISTON SEAL-DYNAMIC 2.50in CP
#1
1
18.
7PNPXT02
PLUG-PIPE SOC HD TAPED .12
1
19.
73054999
VALVE-CBAL
1
20.
72053763
ELBOW-M STR/90/M JIC 8 8
2
REV B 20131216
KIT #
QTY
1
#1
1
1
44
EZ Hauler 3400LP Manual # 99905829
Winch Assembly (71570981)
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
4
24
3
25
2
26
1
27
35
34
33
32
31
30
29
28
71570981 PARTS LIST
ITEM
PART #
DESCRIPTION
QTY
ITEM
PART #
DESCRIPTION
QTY
1.
CONNECTION, 90° CONICAL
1
19.
RETAINING RING
1
2.
CAPSCREW, SOCKET HEAD
2
20.
SEAL
1
3.
73540308
VALVE ASM, DUAL COUNTERBALANCE
1
21.
SOCKET HEAD CAP SCREW
8
4.
73511162
MOTOR, HYDRAULIC
1
22.
OIL RETAINER SEAL
1
5.
73511163
BRAKE UNIT
1
23.
ANTI-ROTATION FLANGE
1
6.
CAPSCREW, SOCKET HEAD
8
24.
SHIM RING
2
7.
MOTOR SIDE SUPPORT
1
25.
BALL BEARING
1
OIL RETAINER SEAL
1
26.
CAPSCREW, SOCKET HEAD
6
9.
WINCH DRUM
1
27.
GEAR SIDE SUPPORT
1
10.
GUIDE BUSHING
1
28.
RETAINING RING
1
11.
PLUG
2
29.
SUN GEAR
1
12.
WASHER, COPPER
2
30.
REDUCTION GEAR UNIT
1
13.
CROSS MEMBER
2
31.
SUN GEAR
1
14.
HEX SCREW
4
32.
FASTENING SURFACE PLATE
2
15.
SIDE FLANGE (GEAR SIDE)
1
33.
CAPSCREW, SOCKET HEAD
8
16.
THIMBLE
1
34.
STRAIGHT PIPE FITTING
1
18.
REDUCTION GEAR UNIT
1
35.
BRAKE PIPE
1
8.
73534535
REV 20100215
73534536
45
Hydraulic Installation (99904827)
HYDRAULIC SCHEMATIC (99904827-2)
71413636
13
14
25
45
71411213
26
27
29
30
42 42 42 42
23
5
P
5
A
5
4
4
4
UP OUT OUT UP
6
6
A
A
8
12
13 13
34
6 7
11
E
B
5
DN
5
5
IN
IN
4
DN
4
4
43
B
13
28
29
31
33
14
CW
6
42 42
26
6
42
22
42
45
12
14
22
42
24
16
18
19
R
20
E
C-BAL VLV
WINCH 17
PORT B (DN)
17
LOWER CYL
71413637
51722424
ER
CYL E
CYL R
BRAKE
51722748
ROTATION PORT A (CW)
18
PORT A (UP)
51722747
PORT B (CCW)
1
21
36
CCW BR
B
6
51722432
R
AUG WIN EXT STG LOW AUX AUX ROT
R
10
51722748
32
43
23
14
1
71411213
51722747
50
20
19
51
35
51722423
46
HYDRAULIC COMPONENTS (99904827-3)
51722419
LOWER CYL.
SAE #4
RETURN PORT
51722745
VALVE BANK
ASSEMBLY
PRESSURE
RETURN
SAE #4
EXTEND
PORT
77041845
PRESSURE
SWITCH
51722432
EXT CYL
RETURN
EXTEND
51722432
EXT CYL
51722747
TOP FEEDER TUBE
51722909
BOTTOM
FEEDER
TUBE
51722424
EXT CYL
RETURN
51722423
EXT CYL
EXTEND
99904827 PARTS LIST
ITEM
PART #
DESCRIPTION
KIT #
QUANTITY
1.
51722745
VALVE BANK ASSEMBLY, 8-SECTION
2.
70734456
VALVE BANK-HAWE
#1
1REF
3.
51722746
HYDRAULIC KIT, VALVE BANK
#1
1REF
4.
72532356
ADAPTER-MSTR/MJIC 8 G
#1
6REF
5.
72532358
ADAPTER-MSTR/MJIC 8 8
#1
6REF
6.
72532792
ADAPTER-MSTR/MJIC 8 4
#1
6REF
7.
72534712
ADAPTER-MJIC/MBSPP 4 2
#1
1REF
8.
72532981
TEE-SWIVEL NUT RUN JIC 4
#1
1REF
9.
51722743
HYDRAULIC KIT-FEEDER TUBE
10.
51398869
HOSE-FJ .25 X 8.12 (4-4) 100R17
#9
1REF
11.
51398870
HOSE-FJ .25 X 9.50 (4-4) 100R17
#9
1REF
12.
72533594
ELBOW-MSTR/90/MJIC 4 8 (WAS 72053758)
#9
2REF
13.
72532351
ADAPTER-MSTR/MJIC 4 4
#9
4REF
14.
72533376
ADAPTER-MFACE/MSTR 4 4
#9
4REF
15.
51722744
KIT-HYDRAULIC ASSEMBLY
16.
72053763
ELBOW-MSTR/90/MJIC 8 8
#15
1REF
17.
72532359
ADAPTER-MSTR/MJIC 10 8
#15
2REF
1
1
1
Chapter 3 Parts
99904827 PARTS LIST
ITEM
PART #
DESCRIPTION
KIT #
QUANTITY
18.
72532775
ADAPTER-MSTR/MJIC 4 6
#15
2REF
19.
72533163
ELBOW-MSTR/90/MFACE 6 6
#15
2REF
20.
72533186
ADAPTER-MFACE/MSTR 6 6
#15
2REF
21.
72533490
ADAPTER-MJIC/MBSPP 4 4
#15
1REF
22.
72533589
ADAPTER-MSTR/MJIC 10 4 (WAS 72533613)
#15
2REF
23.
51396739
HOSE-FF .50X126 (8-8) 100R17
#15
2REF
24.
72532666
ELBOW-MSTR/90/MJIC XLG 8 8
#15
1REF
25.
51395728
HOSE-JJ .50X17.5 (8-8) 100R17
#15
1REF
26.
51398907
HOSE-FF .50X32 (8-8) 100R17
#15
2REF
27.
51397506
HOSE-FJ .50 X 37.5 (8-8) 100R17
#15
1REF
28.
51396490
HOSE-FZ .50 X 38 (8-8) 100R17
#15
1REF
29.
51398908
HOSE-FF .38 X 31 (6-8) 100R17
#15
2REF
30.
51398909
HOSE-FF .38 X 24.5 (6-6) 100R17
#15
1REF
31.
51398910
HOSE-FF .38 X 25.5 (6-6) 100R17
#15
1REF
32.
51398913
HOSE-FJ .38 X 36 (6-6) 100R17
#15
1REF
33.
51398915
HOSE-FZ .38 X 37.5 (6-6) 100R17
#15
1REF
34.
51398912
HOSE-FJ .25X34.5 (4-4) 100R17
#15
1REF
35.
51395201
HOSE-FF .38X15 (8-8) 100R17
#15
1REF
36.
51395238
HOSE-FF .38 X 16 (8-8) 100R17
#15
1REF
37.
60350066
SLEEVE-HOSE 1.63" D X 19"
#15
1REF
38.
60350071
SLEEVE-HOSE 1.63" D X 20"
#15
1REF
39.
60350075
SLEEVE-HOSE 1.63" D X 24"
#15
1REF
40.
60350084
SLEEVE-HOSE 1.63" D X 27"
#15
1REF
41.
60350162
SLEEVE-HOSE 1.63" D X 30"
#15
1REF
42.
72532674
CAP-JIC STL 4 (.44 THD)
#15
9REF
43.
72532675
CAP-JIC STL 8 (.75 THD)
#15
2REF
44.
71411213
TUBE-HYD EZ3400LP FEED TUBE
2
45.
71413607
TUBE ASSEMBLY-14.12 LONG
2
46.
71413634
TUBE ASSEMBLY-120.3 LONG
1
47.
71413635
TUBE ASSEMBLY-121.3 LONG
1
48.
71413636
TUBE ASSEMBLY-51.16 LONG
1
49.
71413637
TUBE ASSEMBLY-53.81 LONG
1
50.
71413280
TUBE ASSEMBLY-HYD 71.19 LONG ORFS/ORF
1
51.
71413281
TUBE ASSEMBLY-HYD 57.11 LONG ORFS/ORF
1
REV A 20100520
47
48
EZ Hauler 3400LP Manual # 99905829
Valve Bank Assembly (51722745)
1
5
3
4
6
7
51722745 PARTS LIST
ITEM
PART #
DESCRIPTION
1.
70734456
VALVE BANK
1
2.
51722746
HYDRAULIC KIT-HYD VALVEBANK
1
3.
72532356
ADPTR-M STR/M JIC 8 6
6
4.
72532358
ADPTR-M STR/M JIC 8 8
6
5.
72532792
ADPTR-M STR/M JIC 8 4
6
6.
72534712
ADPTR-M JIC/M BSPP 4 2
1
7.
72532981
TEE-SWVL NUT RUN JIC 4
1
REV. B 20110715
QTY
Chapter 3 Parts
Valve Bank (70734456)
VALVEBANK ASSEMBLY
STINGER EXTEND
EXT CYLINDER EXTEND
WINCH UP
AUGER A
PRESSURE
RETURN
AUGER B
WINCH DOWN
EXT CYLINDER
RETRACT
LOWER CYLINDER EXTEND
AUX A
AUX A
ROTATION CCW
WINCH BRAKE
ROTATION CW
AUX B
AUX B
LOWER CYLINDER RETRACT
STINGER RETRACT
49
50
EZ Hauler 3400LP Manual # 99905829
EZ Hauler 3400LP Decal Placement
(95722759)
10
13
10
14
15 (OTHER SIDE)
9
6 (QTY 1)
9
8
11,12
DECAL KIT - EZ HAULER 3400LP (95722759)
ITEM
PART #
DESCRIPTION
1.
95722760
DECAL KIT-EZ HAULER 3400LP/5500
2.
95719347
DECAL KIT-TELE COMMON
3.
70392863
DECAL-DANGER HOISTING PERSONNEL
1
4
4.
70392864
DECAL-DANGER STAB STAND CLEAR
1
4
5.
70396614
DECAL-DANGER, CRANE SAFETY
1
1
6.
70398809
DECAL-CONTROLS
1
1
7.
70396748
DECAL-DANGER, ELECTROCUTION
1
4
8.
70398808
DECAL-CAPACITY CHART EZ3400LP
9.
70391612
DECAL-GREASE WEEKLY (LEFT)
2
AS NEEDED
10.
70391613
DECAL-GREASE WEEKLY (RIGHT)
2
AS NEEDED
11.
70392399
DECAL-LUBRICATE WORM
2
1
12.
70392524
DECAL-ROTATE CRANE WHILE GREAS
2
1
13.
70394443
DECAL-DANGER FREEFALLING BOOMS
2
1
14.
71391522
DECAL-ANGLE INDICATOR RH
2
1
15.
71391523
DECAL-ANGLE INDICATOR LH
2
1
16.
70392213
DECAL-CAUTION DONT WASH/WAX
2
1
REV 20110125
KIT #
QUANTITY
1
1
2
51
CHAPTER 4
Crane Reference
In This Chapter
Wire Rope Inspection & Replacement ....................................... 52
Hook Inspection ........................................................................53
Holding Valve Inspection...........................................................54
Inspection Checklist ..................................................................54
Deficiency / Recommendation / Corrective Action Report ......... 59
Thread Torques ........................................................................61
Turntable Bearing Thread Tightening Sequence ....................... 61
52
EZ Hauler 3400LP Manual # 99905829
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.
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" (0.8 mm) or more.
NOMINAL
SIZE - 1/32" NOMINAL
SIZE
(0.8 mm)
h If a broken wire protrudes or loops out from the core of the rope.
Chapter 4 Crane Reference
53
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
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
wired closed (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).
54
EZ Hauler 3400LP Manual # 99905829
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
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:
MONTHLY
QUARTERLY
ANNUAL
Chapter 4 Crane Reference
55
TYPE OF INSPECTION
NOTES:
Daily and monthly inspections are to be performed by a “competent person”, who is capable of identifying existing
and predictable hazards in the surroundings or working conditions which are unsanitary, hazardous, or dangerous
to employees, and who has authorization to take prompt corrective measures to eliminate them.
Quarterly and annual inspections are to be performed by a “qualified person” who, by possession of a recognized
degree, certificate, or professional standing, or who by extensive knowledge, training and experience, successfully
demonstrated the ability to solve/resolve problems relating to the subject matter, the work, or the project.
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 stabilizers fully
extended.
DAILY (D): Before each shift of operation, those items designated with a (D) must be inspected.
MONTHLY (M): Monthly inspections or 100 hours of normal operation (whichever comes first) includes all daily
inspections plus items designated with an (M). This inspection must be recorded and retained for a minimum of 3
months.
QUARTERLY (Q): Every three to four months or 300 hours of normal operation (whichever comes first) includes all
daily and monthly inspection items plus items designated with a (Q). This inspection must be documented,
maintained, and retained for a minimum of 12 months, by the employer that conducts the inspection.
ANNUAL (A): Each year or 1200 hours of normal operation (whichever 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 documented, maintained, and retained for a minimum of 12 months, by the employer that conducts the
inspection.
INSPECTION CHECKLIST STATUS KEY:
S = Satisfactory
R = Recommendation
(Should be considered for corrective action)
NA = Not Applicable
X = Deficient
(NOTE: If a deficiency is found, an immediate determination must
be made as to whether the deficiency constitutes a safety hazard
and must be corrected prior to operation.)
FREQUENCY
ITEM
KEY
INSPECTION DESCRIPTION
D
1
Labels
D
D
2
3
Crane
Controls
D
4
Station
D
5
D
D
6
7
Hydraulic
System
Hook
Wire Rope
All load charts, safety & warning labels, and control labels are
present and legible.
Check all safety devices for proper operation.
Control mechanisms for proper operation of all functions,
leaks and cracks.
Control and operator's station for dirt, contamination by
lubricants, and foreign material.
Hydraulic system (hoses, tubes, fittings) for leakage and
proper oil level.
Presence and proper operation of hook safety latches.
Inspect for apparent deficiencies per applicable requirements
and manufacturer’s specifications.
STATUS
(S,R,X,NA)
56
EZ Hauler 3400LP Manual # 99905829
FREQUENCY
ITEM
KEY
INSPECTION DESCRIPTION
D
8
Pins
D
9
General
D
10
Operation
D
D
D
11
12
13
D
D
14
15
Remote Ctrl
Electrical
Anti-TwoBlock or
Two-Block
Damage
Prevention
Tires
Ground
Conditions
Proper engagement of all connecting pins and pin retaining
devices.
Overall observation of crane for damaged or missing parts,
cracked welds, and presence of safety covers.
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.
Operate remote control devices to check for proper operation.
Operate all lights, alarms, etc. to check for proper operation.
Operate anti two-block or two-block damage prevention
device to check for proper operation.
D
16
D
17
D
18
D
19
D
20
D
D
M
M
21
22
23
24
M
M
M
25
26
27
M
M
28
29
M
M
M
M
30
31
32
33
M
34
STATUS
(S,R,X,NA)
Check tires (when in use) for proper inflation and condition.
Check ground conditions around the equipment for proper
support, watching for ground settling under and around
stabilizers and supporting foundations, ground water
accumulation, or similar conditions.
Level
Check the equipment for level position within the tolerances
specified by the equipment manufacturer’s recommendations,
both before each shift and after each move and setup.
Operator
Check windows for cracks, breaks, or other deficiencies
cab windows which would hamper the operator's view.
Rails, rail
Check rails, rail stops, rail clamps and supporting surfaces
stops, rail
when the equipment has rail traveling.
clamps and
supporting
surfaces
Safety
Check safety devices and operational aids for proper
devices
operation.
Electrical
Check electrical apparatus for malfunctioning, signs of
apparent excessive deterioration, dirt or moisture
accumulation.
Other
Other
Daily
All daily inspection items.
Cylinders
Visual inspection of cylinders for leakage at rod, fittings, and
welds. Damage to rod and case.
Valves
Holding valves for proper operation.
Valves
Control valves for leaks at fittings and between stations.
Valves
Control valve linkages for wear, smoothness of operation,
and tightness of fasteners. Relief valve for proper pressure
settings.
General
Bent, broken, or significantly rusted/corroded parts.
Electrical
Electrical apparatus for malfunctioning, signs of apparent
excessive deterioration, dirt or moisture accumulation.
Electrical systems for presence of dirt, moisture, and frayed
wires.
Structure
All structural members for damage.
Welds
All welds for breaks and cracks.
Pins
All pins for proper installation and condition.
Hardware
All bolts, fasteners and retaining rings for tightness, wear and
corrosion.
Wear Pads
Presence of wear pads.
Chapter 4 Crane Reference
FREQUENCY
ITEM
KEY
M
35
M
36
Pump &
Motor
PTO
M
M
37
38
M
39
M
M
M
M
Q
Q
Q
Q
Q
Q
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
Q
59
60
61
62
63
64
65
66
67
68
69
70
Q
71
72
73
74
75
76
77
INSPECTION DESCRIPTION
STATUS
(S,R,X,NA)
78
Hydraulic pumps and motors for leakage at fittings, seals,
and between sections. Check tightness of mounting bolts.
Transmission/PTO for leakage, abnormal vibration & noise,
alignment, and mounting bolt torque.
Hyd Fluid
Quality of hydraulic fluid and presence of water.
Hyd Lines
Hoses & tubes for leakage, abrasion damage, blistering,
cracking, deterioration, fitting leakage, and secured properly.
Hook
Load hook for abnormal throat distance, twist, wear, and
cracks.
Wire Rope
Condition of load line.
Manual
Presence of operator's manual with unit.
Other
Other
Daily
All daily inspection items.
Monthly
All monthly inspection items.
Rotation Sys Rotation bearing for proper torque of all mounting bolts.
Hardware
Base mounting bolts for proper torque.
Structure
All structural members for deformation, cracks and corrosion.
• Base
• Stabilizer beams and legs
• Mast
• Inner Boom
• Outer Boom
• Extension(s)
• Jib boom
• Jib extension(s)
• Other
Hardware
Pins, bearing, shafts, gears, rollers, and locking devices for
wear, cracks, corrosion and distortion.
• Rotation bearing(s)
• Inner boom pivot pin(s) and retainer(s)
• Outer boom pivot pin(s) and retainer(s)
• Inner boom cylinder pin(s) and retainer(s)
• Outer boom cylinder pin(s) and retainer(s)
• Extension cylinder pin(s) and retainer(s)
• Jib boom pin(s) and retainer(s)
• Jib cylinder pin(s) and retainer(s)
• Jib extension cylinder pin(s) and retainer(s)
• Boom tip attachment
• Other
Hyd Lines
Hoses, fittings and tubing for proper routing, leakage,
blistering, deformation and excessive abrasion.
• Pressure line(s) from pump to control valve
• Return line(s) from control valve to reservoir
• Suction line(s) from reservoir to pump
• Pressure line(s) from control valve to each function
• Load holding valve pipe(s) and hose(s)
• Other
Pumps &
Pumps and Motors for loose bolts/fasteners, leaks, noise,
Motors
vibration, loss of performance, heating & excess pressure.
• Winch motor(s)
57
58
EZ Hauler 3400LP Manual # 99905829
FREQUENCY
ITEM
KEY
INSPECTION DESCRIPTION
Q
79
80
81
Q
82
83
84
85
86
87
Q
88
89
90
91
92
93
94
95
96
Q
Q
97
98
A
A
A
A
A
99
100
101
102
103
A
104
A
A
105
106
A
107
A
108
A
A
109
110
• Rotation motor(s)
• Other
Valves
Hydraulic valves for cracks, spool return to neutral, sticking
spools, proper relief valve setting, relief valve failure.
• Main control valve
• Load holding valve(s)
• Stabilizer or auxiliary control valve(s)
• Other
• Other
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.
• Stabilizer cylinder(s)
• Inner boom cylinder(s)
• Outer boom cylinder(s)
• Extension cylinder(s)
• Rotation cylinder(s)
• Jib lift cylinder(s)
• Jib extension cylinder(s)
• Other
Winch
Winch, sheaves and drums for damage, abnormal wear,
abrasions and other irregularities.
Hyd Filters
Hydraulic filters for replacement per maintenance schedule.
Fiberglass
Inspect fiberglass boom for cracking around set screws.
Booms
Boom may have to be extended to inspect the rearmost set
screws through the one inch inspection hole.
Daily
All daily inspection items.
Monthly
All monthly inspection items.
Quarterly
All quarterly inspection items.
Hyd Sys
Hydraulic fluid change per maintenance schedule.
Controls
Control valve calibration for correct pressure & relief valve
settings.
Valves
Safety valve calibration for correct pressure & relief valve
settings.
Valves
Valves for failure to maintain correct settings.
Rotation Sys Rotation drive system for proper backlash clearance &
abnormal wear, deformation and cracks.
Lubrication
Gear oil change in rotation drive system per maintenance
schedule.
Hardware
Check tightness of all fasteners and bolts, using torque
specifications on component drawings or torque chart.
Wear Pads
Wear pads for excessive wear.
Loadline
Loadline for proper attachment to drum.
STATUS
(S,R,X,NA)
Chapter 4 Crane Reference
59
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
X,R,CA
ITEM #
R = RECOMMENDATION
EXPLANATION
CA = CORRECTIVE ACTION TAKEN
DATE CORRECTED
60
X,R,CA
EZ Hauler 3400LP Manual # 99905829
ITEM #
EXPLANATION
DATE CORRECTED
Chapter 4 Crane Reference
61
Thread Torques
FINE THREAD BOLTS (ENGLISH)
SIZE
BOLT
GRADE 5
DIA.
SAE J429
GRADE 5
(DIA-TPI) (INCHES) PLAIN
(FT-LB)
5/16-24
0.3125
19
3/8-24
0.375
35
7/16-20
0.4375
55
1/2-20
0.5
90
9/16-18
0.5625
120
5/8-18
0.625
170
3/4-16
0.75
300
7/8-11
0.875
445
1-12
1
645
1 1/8-12 1.125
890
1 1/4-12 1.25
1240
1 3/8-12 1.375
1675
1 1/2-12 1.5
2195
GRADE 8
COARSE THREAD BOLTS (ENGLISH)
SIZE
BOLT
GRADE 5
DIA.
SAE J429
GRADE 5
SAE J429
GRADE 8
PLATED
(FT-LB)
14
26
41
64
90
130
225
325
485
670
930
1255
1645
PLAIN
(FT-LB)
27
49
78
120
170
240
420
670
995
1445
2010
2710
3560
PLATED
(FT-LB)
20
35
58
90
130
180
315
500
745
1085
1510
2035
2670
(DIA-TPI) (INCHES) PLAIN
(FT-LB)
5/16-18
0.3125
17
3/8-16
0.375
31
7/16-14
0.4375
49
1/2-13
0.5
75
9/16-12
0.5625
110
5/8-11
0.625
150
3/4-10
0.75
265
7/8-9
0.875
395
1-8
1
590
1 1/8-7
1.125
795
1 1/4-7
1.25
1120
1 3/8-6
1.375
1470
1 1/2-6
1.5
1950
GRADE 8
SAE J429
GRADE 8
PLATED
(FT-LB)
13
23
37
57
82
115
200
295
445
595
840
1100
1460
PLAIN
(FT-LB)
25
44
70
105
155
220
375
605
910
1290
1815
2380
3160
PLATED
(FT-LB)
18
33
52
80
115
160
280
455
680
965
1360
1780
2370
NOTES
1 Tightening torques provided are midrange.
2
Consult bolt manufacturer’s particular specifications, when provided.
3
Use flat washers of equal strength.
4
All torque measurements are given in foot-pounds.
5
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 disulphide, colloidal 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 listed above.
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
torqueing. Failure to replace gear-bearing
bolts may result in bolt failure due to metal
fatigue causing death or serious injury.
62
EZ Hauler 3400LP Manual # 99905829
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.
WARNING
Number 1 can be assigned to
any capscrew if the sequence
remains the same in reference
to number 1.
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 torquing 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.