S.D.P. EZ Hauler 4100 User manual

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: [phone] FAX: [phone]
Website: http://www.sdpmfg.com
Crane manufactured exclusively for S.D.P. MANUFACTURING, INC. by Iowa Mold Tooling Co.,
Inc.
Copyright © 2006 Iowa Mold Tooling Co., Inc.
All rights reserved
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any
form or by any means, electronic, mechanical, photocopying, recording or otherwise without the
prior written permission of Iowa Mold Tooling Co., Inc
Iowa Mold Tooling Co., Inc. is an Oshkosh Truck Corporation Company.

i
Contents
Revisions .................................................................................................................................................... iii
Introduction 5
Safety............................................................................................................................................................6
Daily Safety Inspection.................................................................................................................................7
Specifications 9
EZ Hauler 4100 Specifications .....................................................................................................................9
Geometric Configuration ............................................................................................................................11
Capacity Chart ............................................................................................................................................12
Recommended Spare Parts List ..................................................................................................................13
EZ Hauler 4100 Crane Assemblies, Grease Zerk Locations.......................................................................14
Parts 15
Parts Information ........................................................................................................................................16
Base and Mast Assemblies .........................................................................................................................18
Base & Mast Assembly (99903705)................................................................................................18
Gear Rotator (71056608) (Alternate configuration) ........................................................................20
Cylinder, Lower (51719040A) ........................................................................................................22
Valvebank Assembly (51719584, Drawing 99903708)...................................................................24
Valvebank (70733995) ....................................................................................................................25
Valve Bank Components (99904107) ..............................................................................................26
Valve, Counterbalance (73540163) .................................................................................................27
Boom Assemblies & Cylinders...................................................................................................................28
Boom Assembly (99903706)...........................................................................................................28
Mast - Boom Assembly (99903707)................................................................................................35
Boom Tip Asembly (51719583)......................................................................................................37
Cylinder Assembly, Extension (41718922).....................................................................................39
Winch, Planetary (71570781)..........................................................................................................40
Hydraulics...................................................................................................................................................42
Hydraulic Layout (99903715) .........................................................................................................42
Hydraulic Schematic (99903702) ....................................................................................................45
Control Valve Cross Section & Torques .........................................................................................47
EZ Hauler 4100 Control Valve Troubleshooting Guide..................................................................49
Electrical.....................................................................................................................................................52
Wiring Layout (77441178)..............................................................................................................52
Wiring Diagram (77441178) ...........................................................................................................53
Wiring Schematic (77441178).........................................................................................................54
Proportional Actuator System Specifications (77441178)...............................................................55
Light Switch Harness (77441179) ...................................................................................................57
Wiring Harness, Radio Remote (99903721-1) ................................................................................58
Wiring Schematic, Radio Remote (99903721-2) ............................................................................59
Miscellaneous .............................................................................................................................................60
Decal Placement (99903714)...........................................................................................................60
Retainer Frame, Auger (51719581).................................................................................................61

ii Contents
Swivel Assembly, Auger (51719582)..............................................................................................63
Crane Reference 65
Wire Rope Inspection & Replacement........................................................................................................65
Hook Inspection..........................................................................................................................................66
Holding Valve Inspection ...........................................................................................................................67
Inspection Checklist....................................................................................................................................68
Deficiency / Recommendation / Corrective Action Report ........................................................................72
Thread Torques...........................................................................................................................................74
Turntable Bearing Thread Tightening Sequence ........................................................................................76

Contents iii
Revisions
DATE LOCATION DESCRIPTION
20050809 ECN 9882 – UPDATES TO 99903705, 3706, 3707, 3715 BASED ON
PRE-PRODUCTION CHANGES.
20050909 99903706 ECN 9895 - ADDED CABLE GUIDES TO BOOM EXTENSIONS
20050919 51719583,
99903708
ECN 9891 - CHANGES PER PRODUCTION
41718922 ECN 9925 - CHANGE TO 41718922
99903705,
99903707
ECN 9897 - ADDED DRAWING REFERENCES
20051011 99903705, 707 ECN 9933 - ADDED OVERLOAD PROTECTION SYSTEM,
THREADED MOUNTING HOLES IN MAST
20060221 51719583 ECN 10029 - CHANGE HOOK FROM 70732870 TO 70732871.
77441178 ECN 10036 - INCREASE FUSE SIZE, REMOVE DIODE FROM ELEC
SYSTEM
20060302 71056608 ADDED GEAR ROTATOR COMPONENT PART NUMBERS
20060329 51719583,
99903706
ECN 10077 - ADDED AUGER SWIVEL STOP AND HARDWARE
20060502 99903706,
41718922
ECN 10116, 10077 - CLAMP PLATE ON EXT CYL,
20060721 51719040A,
99903706
ECN 10143 - ADD NOTE TO PAINT CYLINDER WHITE. ECN 10137 -
UPDATE 99903706 DRAWING TO REV J.
20060831 MODEL
CHANGE
ECN 10241 - CHANGED MODEL FROM 3500 TO 3800, UPDATED
MANUAL AND CAPACITY CHART.
99903706,
99903715
ECN 10240 - DESIGN CHANGES
20061002 99904017 ECN 10269 - ADDED 99904017
20061024 99903715 ECN 10286 – UPDATE 99903715 TO REV . D.
20061120 99903706 UPDATE TO REV. K.

5
This manual includes parts, specifications, and installation information for your particular crane.
It is your responsibility to maintain and operate this unit in a manner that will result in the safest
working conditions possible.
Warranty of this unit will be void on any part of the unit subjected to misuse due to overloading,
abuse, lack of maintenance and unauthorized modifications. No warranty - verbal, written or
implied - other than the official, published IMT new machinery and equipment warranty will be
valid with this unit. In addition, it is also the user’s responsibility to be aware of existing Federal,
State and Local codes and regulations governing the safe use and maintenance of this unit. This
crane was designed and built to meet the standards of ANSI/ASSE A10.31-1995, Safety
Requirements, Definitions, and Specifications for Digger Derricks. Contact the American
National Standards Institute (www.ansi.org) for more information.
Throughout this manual, three means are used to draw the attention of personnel. They are
NOTEs, CAUTIONs and WARNINGs and are defined as follows:
NOTE
A NOTE is used to either convey additional information or to provide further emphasis for a
previous point.
CAUTION
A CAUTION is used when there is the very strong possibility of damage to the equipment or
premature equipment failure.
WARNING
A WARNING is used when there is the potential for personal injury or death.
For optimum safety, treat this equipment with respect and service it regularly.
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.

9
In This Chapter
EZ Hauler 4100 Specifications..................................9
Geometric Configuration ........................................... 11
Capacity Chart........................................................... 12
Recommended Spare Parts List ............................... 12
EZ Hauler 4100 Crane Assemblies, Grease Zerk Locations 14
EZ Hauler 4100 Specifications
CRANE RATING * 30,000 ft-lb (4.1 ton-meters)
REACH (from centerline of rotation) 34'-4" (10.5 m)
HYDRAULIC EXTENSIONS (3) 69.56" each (177 cm)
208.68" total (530 cm)
MANUAL EXTENSION 66" (168 cm)
LIFTING HEIGHT (from base of crane) 41' (12.5 m)
CRANE WEIGHT 2,470 lb (1120 kg)
MOUNTING SPACE REQUIRED (crane
base)
21" x 21" (53.3 cm x 53.3 cm)
* Crane rating (ft-lb) is the rated load (lb) multiplied by the respective distance (ft) from centerline
of rotation with all extensions retracted and lower boom in horizontal position.
PERFORMANCE CHARACTERISTICS
ROTATION 400 degrees 76 seconds
LOWER BOOM ELEVATION 0 - 72 degrees 33 seconds extension
26 seconds retraction
EXTENSION BOOMS
(total time)
53.0" + 51.75"
(135 cm + 131 cm)
61 seconds extension
40 seconds retraction
CYLINDERS
BORE STROKE
LOWER BOOM CYLINDER 5" (13 cm) 30.15" (77 cm)
FIRST, SECOND, AND
THIRD EXTENSION
CYLINDER
2.5" (6 cm) 69.56" (177 cm)
CHAPTER 2
Specifications

10 EZ Hauler 4100 Manual Part # 99903718
SYSTEM SPECIFICATIONS
ROTATION SYSTEM
Turntable bearing with an external worm gear driving an intermediate gear, powered by a high-
torque hydraulic motor through a self-locking worm.
MOTOR DISPLACEMENT 5.9 ci/rev
MOUNTING FLANGE 2 bolt std: 3.25" dia. x 0.12 pilot, 0.535" dia. mounting holes on
4.18" dia. b. c.
OUTPUT SHAFT 1" dia. straight with woodruff key and 1/4-2 threaded hole
PORT TYPE 0.875-14 UNF-2B o-ring port, size 10. Accepts fittings for SAE
J1926.
CASE DRAIN No case drain
SPECIAL FEATURES High pressure shaft seal
COLOR Gloss black
CYLINDER HOLDING VALVES
The base ends (extend sides) of the lower boom and extension cylinders are equipped with
integral-mounted counter-balance valves to prevent sudden cylinder collapse in case of hose or
other hydraulic failure.
The counter balance valves serve several functions. These include:
1 Holding valves
2 Speed control for the lowering function via which causes that function to be metered under
load
3 Prevention of excessive oil loss during a hose failure.
WINCH
The winch is powered by a hydraulic motor through a planetary gear with a mechanical brake.
Only single line is permitted. The maximum single line capacity is 3800 lb. The winch is
equipped with 1/2" diameter synthetic fiber rope.
HYDRAULIC SYSTEM
The six-section crane valvebank is operated by a radio remote control with a manual handle as a
back-up system. The handle is stored behind the cover on the mast.

Chapter 2 Specifications 11
Geometric Configuration
28'-10"
5'-11"
41'
4'-4"
3'-4"
5'-8"
35'-7"
34'-4"

12 EZ Hauler 3800 Manual Part # 99903718
Capacity Chart
Crane manufactured exclusively for
S.D.P. MANUFACTURING, INC.
by
IOWA MOLD TOOLING CO., INC.
• Single-part line lifting, ONLY.
• All outriggers must be extended and set firmly
on ground and machine leveled before crane operation.
• Capacities shown in pounds for FULL 360° degree work zone.
REACH FROM CENTERLINE OF ROTATION
4100
lb
2800
lb
1536
lb
1129
lb
900
lb
600
lb
6' 12' 15' 22' 27' 34'
41'
MAX.
REACH
5'-11"
80°
10°

Chapter 2 Specifications 13
Recommended Spare Parts List
This spare parts list does not necessarily indicate that the items can be expected to fail in the
course of a year. It is intended to provide the user with a stock of parts sufficient to keep the unit
operating with minimal down-time waiting for parts. There may be parts failures not covered by
this list. Parts not listed are considered not to be Critical or Normal Wear items during the first
year of operations, and you will need to contact your distributor or manufacturer for availability.
ASSEMBLY NAME (PART #)
COMPONENT PART # DESCRIPTION QUANTITY
BASE & MAST ASSEMBLY (99903705)
73051963 HYDRAULIC MOTOR 1
LOWER CYLINDER (51719040A)
51744139 SEAL KIT 1
BOOM ASSEMBLY (99903706)
41719025 E-CHAIN KIT 1
52719329 RESTRAINING PIN WELDMENT 3
60030342 WEAR PAD 1
60030343 WEAR PAD 1
60030344 WEAR PAD 1
60030345 WEAR PAD 1
60030346 WEAR PAD 1
60030347 WEAR PAD 1
60030348 WEAR PAD 1
60030350 WEAR PAD 1
60123777 WEAR PAD 8
60125458 WEAR PAD 6
60127562 WEAR PAD 1
60127564 WEAR PAD 1
60127565 WEAR PAD 1
60127867 WEAR PAD 1
70142209 PIN 1
EXTENSION CYLINDER ASSEMBLY (41718922)
51744143 SEAL KIT 3 (1 KIT PER
CYLINDER)
WINCH (71570781)
71411150 CABLE WEDGE 1
SEAL KIT 1

14 EZ Hauler 4100 Manual Part # 99903718
EZ Hauler 4100 Crane Assemblies, Grease
Zerk Locations
12
3
4
56
LOWER
CYLINDER
WORM
GEAR
BASE
MAST
LOWER
BOOM
EXTENSION
BOOMS
(INTERNAL CYLINDERS)
ITEM LOCATION DESCRIPTION LUBRICANT FREQUENCY
1. INTERMEDIATE GEAR
2. WORM GEAR
3. TURNTABLE (ROTATE CRANE WHILE
GREASING)
4. LOWER CYLINDER (LOWER END)
5. LOWER CYLINDER (UPPER END)
6. SHEAVE
SHELL ALVANIA 2EP
OR
SHELL RETINAX "A"
WEEKLY

15
In This Chapter
Parts Information ....................................................... 16
Base and Mast Assemblies ....................................... 18
Boom Assemblies & Cylinders .................................. 28
Hydraulics.................................................................. 42
Electrical.................................................................... 52
Miscellaneous............................................................ 60
CHAPTER 3
Parts

16 EZ Hauler 4100 Manual Part # 99903718
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: [phone]
Technical Support Fax: [phone]
MODEL
NUMBER
SERIAL
NUMBER
MFG
DATE
IOWA MOLD TOOLING CO., INC.
BOX 189, GARNER, IA 50438-0189

Chapter 3 Parts 17
CYLINDER IDENTIFICATION
To insure proper replacement parts are received, it is necessary to specify the complete
number/letter sequence for any part requested. Part numbers may be cross checked by
comparing the stamped identification on the cylinder case (See figure below) against the
information contained in the service manual. You must include the part number stamped on the
cylinder case when ordering parts.
CYLINDER
PART NUMBER
LOCATION
WELDMENT IDENTIFICATION
Each of the major weldments - base, mast, inner boom, outer boom, extension boom and
outrigger weldments bear a stamped part number. Any time a major weldment is replaced, you
must specify the complete part number as stamped on the weldment. The locations of the part
numbers are shown in the Crane Reference Section.
ORDERING REPAIR PARTS
When ordering replacement parts:
1 Give the model number of the unit.
2 Give the serial number of the unit.
3 Specify the complete part number. When ordering cylinder parts, or one of the main
weldments, always give the stamped part number.
4 Give a complete description of the part.
5 Specify the quantity required.

18 EZ Hauler 4100 Manual Part # 99903718
Base and Mast Assemblies
Base & Mast Assembly (99903705)
5
33
9
10
6
8
9
32
38
36
17
1
21
15
12
11
4
23
16
19
26
9
9
28 29 31
30
30
30
27
30
40
3
7
37
25
44
14,20,22 (4 plcs)
13,22 (4 PLCS)
GREASE ZERK
PART OF ROTATOR
(2 PLCS)
35
(3 PLCS)
42
(2 PLCS)
41 (2 PLCS)
(USED TO FASTEN
SHIPPING BLOCKING)
USE
ANTI-SEEZ
USE BLUE
THREAD LOCK
18,20
(3 PLCS)
(VB)
10mm NUT FROM
VB HANDLE
REMOVE HANDLE
AND 10mm NUT
TORQUE TO
160 FT-LB
SECURE
VB HANDLE
HERE
JAM NUT
(PART OF
#39)
24,34 (16 PLCS)
99903705 PARTS LIST
ITEM PART # DESCRIPTION QUANTITY
1. 51719040A CYLINDER 1
2. 51719567 HARDWARE KIT, BASE & MAST ASM (INCL.
9,13-26,41-42)
1