Dominator I Parts & Specifications

Transcription

1 Manual Part # Dominator I Parts & Specifications Manual Effective January 1, 2006 Revised IOWA MOLD TOOLING CO., INC. PO Box 189 Garner, IA Tel: FAX: Website: Copyright 2011 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. Printed on 21 January, 2011

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3 i Contents Revisions...v Specifications 9 Dominator Chassis Specifications...11 Assemblies & Installation 13 Body Assembly ( )...14 Body Components...16 Dominator I/DSC12 Door Assembly ( )...18 Dominator I Crane Installation Hole Pattern ( )...20 Hydraulic Installation ( ) (Eff )...21 Hydraulic Reservoir ( ) (Eff )...25 Hydraulic Installation ( ) (Thru )...26 Hydraulic Reservoir ( ) (Thru )...32 Reference, Hyd. Reservoir Plumbing ( ) (Thru 2006)...33 Installation Kit, Compartment Pressure Fan Option ( )...35 Compressor Mounting Locations ( )...36 Weather-Strip Installation ( )...38 Battery Cover Installation ( )...39 Installation, 2008 Chassis ( )...40 Electric Crane Installation (2003i, 3203i, 4004i, 5005i, 6006i) ( )...43 Electrical Installation (1015E & 2020E) ( )...48 Chassis Installation 49 Installation Kit- 9' Body - Ford ( )...50 Installation Kit - 11' Body- Ford 15,000 & 17,500 GVW ( )...51 Installation Kit- 11' Body - Ford 19,000 GVW ( )...52 Installation Kit - Selector Valve - Ford Automatic Transmissions ( )...53 Installation Kit, Hydraulic, Ford 4x2 MY2011 ( )...55 Installation, DEF Tank Hoses on 2011 Ford F550 ( )...56 PTO Wiring Installation-2006 & 2007 ( )...57 PTO Wiring Installation Through 2005 ( )...62 PTO/Pump Rotation Guide ( )...67 Compartment Options 69 Compartment Layout ( )...70 Parts List, Shelves ( )...71 Installation Drawing, Shelves ( )...73 Installation Drawing, Door Trays ( )...74 Parts List, Drawer Units and Kits...75 Dominator I & II Drawer Set Reference Drawing...77 Drawer Components...79 Compartment Options...80 Tool Box Tray ( )...81

4 ii Contents Tank Bracket, 2-Bottle ( )...82 Tank Bracket, 3-Bottle ( )...83 Slide Out Tray ( )...84 Pull-Out Bin Sets...85 Tailgate & Bumper Options 87 Tailgate Assembly ( )...88 Tailgate - Workbench ( )...90 Bumper Hitch & Workbench Options...92 Air System Options 93 Air Tank Options...93 Air Tank Kit, 22.5 Gallon ( )...94 Air Tank Kit, 35 Gallon ( )...95 Air Tank Kit, 58 Gallon ( )...97 Air Tank Drain Assembly ( )...99 Air Tank Kit, 28 Gallon ( ) Air Tank Drain Assembly ( ) Air Tank Kit, 22 Gallon ( ) Air Tank Kit, Dual 10 Gallon ( ) Stepless Ear Clamp Installation ( ) Moisture Separator / Regulator / Oiler Assembly ( ) Moisture Separator / Regulator / Oiler Parts ( ) Moisture Separator / Regulator / Oiler Installation Hose Reel ( ) Telescoping Tops 111 Telescopic Top Installation ( ) Boom Supports 115 Boom Support ( ) Boom Support, Adjustable, 1015 & 2020 ( ) Boom Support, Adjustable, ( ) Outriggers 121 Front Outriggers ( / ) Front Outrigger, RH Pullout ( ) Rear Outriggers, Manual Out / Manual Down ( / ) Rear Outriggers, Manual Out/Power Down ( / ) Rear Outriggers, Power Out/Power Down (Kit / Dwg ) Outrigger Hydraulic Installation ( ) Cylinder, Power Out (3B142860) (Effective 2-07, prior to 8-05) Cylinder, Power Out ( ) (Used 9-05 to 1-07) Outrigger Assembly ( ) Outrigger Assembly, Stationary Mount ( ) Cylinder ( ) (Thru. 9-05, Eff. 2/07) Cylinder ( ) (Eff through 1/07) Valvebank, Power Out/Power Down ( ) (Eff )...140

5 Contents iii Valvebank, Power Out/Power Down ( ) (Through ) Valvebank, Manual Out/Power Down ( ) (Eff ) Valvebank, Manual Out/Power Down ( ) (Through ) Outrigger Override Installation & Operation ( ) Electrical Options & Installation 151 Electrical Panel ( ) Electrical Installation ( ) (Eff ) Chassis Electrical Installation ( ) (Eff )...157

6 iv Contents Power Panel (Dom 1-2) ( ) Electrical Installation ( ) (Eff thru ) Fuse Block, EFM, & Relay Bracket Installation ( ) (Thru ) Crane Installation Comparison Light Installation ( ) By-Pass Procedure for Reverse Activated Floodlights Electrical Outlet ( ) Light Reel Kits Miscellaneous Options 171 Salvage / Plumbing Installation Kit ( ) Salvage Tank Installation, Welder in Load Bed ( ) Salvage Pump Assembly ( ) (Eff. 6-08) Antifreeze/Salvage/Water Pump ( ) (Eff ) Salvage Pump Assembly ( /Dwg ) (Thru 5-08) Headache Rack Parts & Installation ( ) Master Lock System Drawing ( ) Dominator I Master Lock Kits Fuel Fill, Chevy/GMC ( ) Welder Platforms 187 Installation Kit, Dominator I & DSC20 (Kit /Dwg ) Welder Deck, 24" Long with 2 Underbody Toolboxes ( ) Welder Deck, 35" Long with 2 Underbody Toolboxes ( ) Welder Deck, 36" Long with Flat Deck ( ) Welder Deck, 24" Long with Tall Compartment ( ) Welder Deck, 35" Long with Curbside Tall Compartment ( ) Welder Deck, 35" Long with Streetside Tall Compartment ( ) Dominator Decal Examples & Placement 197 Decal List Dominator and Crane Logo Placement Body Safety Decal Placement Dominator Control Decal Placement Crane Safety Decal Placement on Dominator Door Hydraulic Oil Decal Placement Fuel Tank Decal Placement Air Tank Decal Placement Outrigger Decal Placement Reflector & Hitch Decal Placement Compressor Decal Placement Thread Torque Chart (English) 211 Thread Torque Chart (Metric) 212

7 Contents v Revisions DATE LOCATION DESCRIPTION New release INSTALLATION KITS ECN DRAWING IMPROVEMENT TO , , , ECN CHANGE TO VIEW OF FRONT PULLOUT O/R KIT ( ) ECN CHANGE TO SHELF INSTALLATION PARTS, ECN , ECN EASE OF ASSEMBLY ECN REMOVED SHIMS; (ECN 9000) - ADDED HOLE LOCATION FOR FLOOR WITHOUT WELDER CUTOUT ECN ADDED HINGES TO TELE TOP DRAWING ECN LENGTHENED THREADED ROD ON RESERVOIR , ECN HARDWARE CHANGE ON , NEW CAP SCREW ON KEY CYLINDER ECN 9899 ADDED KEY CYLINDER REPLACEMENT INFORMATION TO BODY ASSEMBLY INFORMATION ECN WASHER CHANGE ADDED GROMMET TO ELECTRICAL KIT , ECN ADDED DOM 4 COMPONENTS TO DRAWINGS , , , , , ADDED PORT TUBE OPTION TO OUTRIGGER ASSEMBLIES ECN CHANGED HARDWARE KIT IN , CYLINDER CHANGE ECN ADDED NEW ELEC INSTALLATION DWG ECN CHANGED DIVIDER IN , ECN STANDARDIZED MOUNTING HOLE LOCATIONS ADDED HORIZONTAL TRAY ASSEMBLY DRAWING - TO COMPARTMENT SECTION ECN UPDATE TELE TOP HARDWARE , , , , , Compartment Options ECN CHANGED HARDWARE ON OUTRIGGER & BOOM SUPPORT KITS ECN CHANGED HARDWARE ON MUD FLAP KITS ON INSTALL DWGS. ECN ADDED TERMINAL & SEAL TO PARTS LIST; ECN NEW ELEC INSTALLATION Added drawer set and individual drawer drawings. ( , , , , sets; 13", 26", 39" wide drawer components.) ECN Added information to reservoir drawing. (Not exported)

8 vi Contents ECN Changed light from to ECN Changed bolts in from to Update BOM ECN Added 2006& 2007 chassis wiring Corrected incorrect part number Added notes to drawing ECN Updated hose length WELDER DECKS NEW DRAWINGS , , , , , , CYLINDERS ECN New cylinders in , , ROLLOUT ECN New drawings for many rollout drawer sets. DRAWERS ECN New weatherstrip installation drawing. Notes on changed to reflect new weatherstrip ECN 10397, New outrigger valves. New drawings , ECN NEW O/R OVERRIDE , 26, 39 Updated drawings with purchased part numbers only. Drawer components ECN Added mud flap installation instructions. Pull-Out Bin Corrected part number errors. Sets ECN Changed crane box compartment light from to ECN Added item #17, locking pin note to cylinder drawing ECN Clamp was Master lock kits ECN Standardized master lock hardware kits for 9', 11', and 13-14' bodies Added note to vise mounting bracket ECN Changed master lock installation. Also updated bracket information on Corrected part numbers for 56" tall divider panel Added FLR installation drawing. Specifications Added chassis specifications , Add part descriptions on door parts list, changed drawing to rev. A on , ECN Added stepless ear clamp install instructions, added hydraulic installation drawing , ECN New hardware in , new salvage pump assembly ECN Battery relocation instructions ECN Updates to telescoping top ECN Changed to single inlet hydraulic pumps ECN Changed hoses, adapter in kit ECN New hydraulic installation drawing, new reservoir assembly Added version of hydraulic reservoir installation Added replacement lock set information. Added pump parts , Added electric crane installation drawings ECN Compressor spacing requirements. Added summary drawings to replace individual drawer and drawer set drawings , , Corrected outrigger kit part numbers. ECN tray assembly updated.

9 Contents vii ,9990 ECN Changed outrigger manual override decal to , Decal list Updated to show 2 batteries Added DEF tank hoses on 2011 F550 installation information. Decals ECN Updated drawings ECN Electrical update to light install ECN Added note to for Ford 4x4, added new drawing for MY2011 Ford 4x Added power panel harness drawing.

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11 9 C HAPTER 1 Specifications SPECIFICATIONS 9-foot 11-foot Body Rating 38,000 ft-lb 38,000 ft-lb Body Weight 2,921 to 2,971 lb (Based on configuration) 3,297 lb to 3,447 lb (Based on configuration) Body Width (including rain eaves) 96 in 96 in Sidepack Height 44 in 44 in Sidepack Depth 22 in 22 in Cargo Deck Width 50 in 50 in Workbench Depth 21 in 21 in Tailgate Height 10 in 10 in Storage Capacity (including workbench) 97.2 ft³ to ft³ (Based on configuration) ft³ to ft³ (Based on configuration) Angle of Departure LH 1st Vertical 29.5 W x 38.5 H 29.5 W x 38.5 H LH 2nd Vertical N/A 16.5 W x 38.5 H LH Horizontal 43.0 W x 21.0 H 44.5 W x 21.0 H LH Rear 18.0 W x 38.5 H 18.0 W x 38.5 H RH 1st Vertical 29.5 W x 38.5 H 29.5 W x 38.5 H RH 2nd Vertical N/A 16.5 W x 38.5 H RH Horizontal 43.0 W x 21.0 H 44.5 W x 21.0 H RH Rear 18.0 W x 38.5 H 18.0 W x 38.5 H

12 10 Dominator I Parts & Specifications Manual Part # Standard Configurations 9-foot body 44" standard left-hand and right-hand sidepacks Right front raised* to foot body 44" standard left-hand and right-hand sidepacks Right front raised* to 60" Left front raised* to 60" Right and left front raised* to 60". * Includes 1st and 2nd vertical compartments. Body Materials The sidepacks are constructed of 10-gauge and 12-gauge galvannealed steel. The floor structure is constructed of 12-gauge galvannealed and 1/8 deckplate steel. The workbench is constructed of galvannealed and cold rolled steel. Body Weights 9 ft RH & LH standard 2,921 lb 9 ft RF raised 2,971 lb 11 ft RH & LH standard 3,297 lb 11 ft RF raised 3,372 lb 11 ft LF raised 3,372 lb 11 ft RF & LF raised 3,447 lb Body Sub-Structure Patent pending inverted A-frame design constructed of 12-gauge galvannealed material with integral crane box, front outrigger receptacles and rear outrigger housing. Electrical System The electrical system consists of a central power distribution point in the crane box using automotive-style harnesses. The circuits use white wire with the circuit function printed every 3. The harness is protected by an overbraid that is heat and cut resistant. Doors The doors are constructed of 14-gauge galvannealed steel with internal formed eaves and hemmed edges. The latches are a 3-point, locking rotary T-handle style. They are constructed of cast steel with a powder-coat finish. The hinges are stainless steel with composite washers. Storage Capacity 9 ft RH & LH standard 97.2 ft3 9 ft RF raised ft3 11 ft RH & LH standard ft3 11 ft RF raised ft3 11 ft LF raised ft3 11 ft RF & LF raised ft3 Options 1. Drawers and drawer sets 6. Individual incandescent compartment lights 2. Standard adjustable shelves 7. Work lights 3. 3" high divided adjustable shelves 8. Compartment pressurization system 4. Manual and hydraulic outriggers 9. Air systems 5. Workbench vises and vise plates 10. Telescopic cranes up to 38,000 ft-lb

13 Chapter 1 Specifications 11 Dominator Chassis Specifications CHASSIS SPECIFICATIONS Minimum Cab-to-Axle Dimensions (Cab-to-Trunnion for tandem axle) Dominator I & II without Welder Single Axle (CA) Tandem Axle (CT) Deck 9' Body 60" 11' Body 84" 13' Body 108" 14' Body 120" Dominator I & II with Welder Single Axle (CA) (based on width Tandem Axle (CT) Deck of welder deck selected) 9' Body 84" - 96" 11' Body 108" - 120" 13' Body 132" - 144" 14' Body 144" - 156" Dominator IV without Welder Single Axle (CA) Deck 14' Body 120" 19' Body 150" Dominator IV with Welder Deck Single Axle (CA) (based on width of welder deck selected) 14' Body 144" - 156" Tandem Axle (CT) 19' Body 174" - 186" Tandem Axle (CT) (based on width of welder deck selected)

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15 13 C HAPTER 2 Assemblies & Installation In This Chapter Body Assembly ( )...14 Body Components...16 Dominator I/DSC12 Door Assembly ( )...18 Dominator I Crane Installation Hole Pattern ( )...19 Hydraulic Installation ( ) (Eff )...21 Hydraulic Reservoir ( ) (Eff )...25 Hydraulic Installation ( ) (Thru )...26 Hydraulic Reservoir ( ) (Thru )...32 Reference, Hyd. Reservoir Plumbing ( ) (Thru 2006)...33 Installation Kit, Compartment Pressure Fan Option ( )...35 Compressor Mounting Locations ( )...36 Weather-Strip Installation ( )...38 Battery Cover Installation ( )...39 Installation, 2008 Chassis ( )...40 Electric Crane Installation (2003i, 3203i, 4004i, 5005i, 6006i) ( )...42 Electrical Installation (1015E & 2020E) ( )...48

16 14 Dominator I Parts & Specifications Manual Part # Body Assembly ( ) 15 APPLY WEATHERSTRIP TO DOOR WITHOUT LATCH CRANE SIDE ONLY 16 7 (2 PLCS) /8" HOLE APPLY TREAD DECAL FLUSH TO BOTTOM & OUTSIDE EDGE OF SIDEPACK DETAIL A SCALE 1/4 RH SIDEPACK SHOWN. LH ASSEMBLY IS SIMILAR. DOOR JAM WEATHERSHIP APPLIED TO BODY (SEE NOTE): (DOM I 9' BODY) (DOM I 11' BODY) (DOM II 11' BODY) (DOM II 13' BODY) (DOM II 14' BODY) (DOM IV 14' BODY) (DOM IV 19' BODY) 2 ROD ATTACHMENT HARDWARE INCLUDED WITH LATCH NOTE: WEATHERSTRIP WAS CHANGED EFFECTIVE THE OLD WEATHERSTRIP IS AVAILABLE FOR SERVICE. CHECK THE DOOR BRACE FOR A 1/8" HOLE TO DETERMINE WHICH WEATHERSTRIP PART NUMBER YOUR BODY REQUIRES. MODEL WEATHERSTRIP PART # FOR DOORS WITHOUT 1/8" HOLE IN BRACE (PRIOR TO ) DOMINATOR I 9' DOMINATOR I 11' DOMINATOR II 11' DOMINATOR II 13' DOMINATOR II 14' DOMINATOR IV 14' DOMINATOR IV 19' WEATHERSTRIP PART # FOR DOORS WITH 1/8" HOLE IN BRACE (AS SHOWN IN DRAWING) (POST )

17 Chapter 2 Assemblies & Installation (10 PLCS) BODY ASSEMBLY PARTS LIST ( ) ITEM PART # DESCRIPTION QUANTITY LATCH ASM-3PT COMPRESSION A/R 2. VARIOUS ROD-DOOR A/R HANDLE-BODY BOLT ON 7.0X2.5BLK STEP GRIP STRUT LH CAP SCR-SS.31-18X1.00 TRH PHH STEP GRIP STRUT RH CAP SCR-THD CUT.31-18X.75 HWH1 (WAS ) WASHER-SS.31 R FLAT WRT TYPE 304 (WAS 6) NUT-SS HEX NYLOC FENDER RUBBER (DOM 2,3) FENDER RUBBER (DOM 1) FENDER RUBBER (DOM 4-14') FENDER RUBBER (DOM 4-19') RIVET-AL LG HD.25X.50 GRIP A/R PLUG-PLSTC BUTTON BP-1-1/8 A/R TREAD-SHUR STEP 12"X 21 in WEATHERSTRIP-.75X.38 TRIM-LOC X119 BT A/R EDGING-PLASTIC BLK A/R DRIP TRAY (DOM 1 & 2) DRIP TRAY (DOM 4) 1 REV. F NOTE: FEATURES SHOWN ARE NOT AVAILABLE ON ALL MODELS. CHECK SPECIFICATIONS OR WITH YOUR IMT DISTRIBUTOR FOR MORE INFORMATION.

18 16 Dominator I Parts & Specifications Manual Part # Body Components Body Description Body Assembly Part # DOMINATOR I BODY-11' RIGHT RAISED COMPARTMENTS 1-2/ LEFT STANDARD DOMINATOR I BODY-11' RIGHT STANDARD / LEFT STANDARD DOMINATOR I BODY-11' RIGHT RAISED COMPARTMENTS 1-2/ LEFT RAISED COMP DOMINATOR I BODY-11' RIGHT STANDARD / LEFT RAISED COMP DOMINATOR I BODY-9' RIGHT RAISED COMPARTMENTS 1-2/ LEFT STANDARD DOMINATOR I BODY-9' RIGHT STANDARD/ LEFT STANDARD Body Assembly Part # Component Part # Component Description DRAWING- DOMINATOR BASE BODY ASM DRAWING- DOOR ASSY ROD-DOOR LG W/.75" OFFSET ROD-DOOR LG W/.75" OFFSET ROD-DOOR LG W/.75" OFFSET ROD-DOOR LG W/.75" OFFSET PLUG-PLSTC BUTTON BP-1-1/ LATCH ASM-3PT COMPRESSION WEATHERSTRIP-108ft ROLL.62X WEATHERSTRIP- 88ft ROLL.62X WEATHERSTRIP-.75X.38 TRIM-LOC X119 BT EDGING-PLASTIC BLK FENDER RUBBER SCR-THRD.CUT.31-18X.75 HWH-1 (for step) KIT-HRDW DOM CRANE DRIP TRAY STEP GRIP STRUT RH (BLACK) STEP GRIP STRUT LH (BLACK) DECAL KIT-OUTSIDE HANDLE-BODY BOLT ON 7.0X2.5BLK MANUAL-DOM 1(II) W/BIND DRIP TRAY-CRANE COMPT DOM TREAD-SHUR STEP 12"X 21 in KIT-HRDW DOM RIVET/GRAB HANDLE ELEC KIT-DOM2 (II) BASE KIT (CHASSIS) ELEC KIT-DOM2 (II) BASE KIT (BODY) HARNESS-DOM (II) 9' FRT JUMPER HARNESS-DOM (II) 11' FRT JUMPER REV

19 Chapter 2 Assemblies & Installation 17 KEY CYLINDER REPLACEMENT: The Dominator service vehicle uses door latch assembly on all compartment doors. Upon installation, the latch assemblies have a common key cylinder, part number However, the key cylinders can be changed so compartments use different keys. This feature allows different Dominator compartments to have different keys, thus increasing security. Part # , Cylinder / Key Tool for Compression Latch, is required to change the key cylinders on the Dominators. Alternate key cylinders include: Cylinder/Key Compression Latch J Cylinder/Key Compression Latch J Cylinder/Key Compression Latch J Cylinder/Key Compression Latch J Cylinder/Key Compression Latch J Cylinder/Key Compression Latch J Cylinder/Key Compression Latch J Cylinder/Key Compression Latch J Cylinder/Key Compression Latch J Cylinder/Key Compression Latch J210

20 18 Dominator I Parts & Specifications Manual Part # Dominator I/DSC12 Door Assembly ( ) (3 PER HINGE) A (1 PER HINGE) 17 BEFORE ASSEMBLY, APPLY LOCTITE 515 AROUND EACH HOLE. DETAIL A ITEM LOCATION BODY 44" DOM 1 /DSC20 14 (4 PER HINGE) 52" DSC /DOMCS 60" DSC /DOMCS 60" DOM 1 /DSC20 1 LEFT VERT 1 ALL N/A LEFT VERT 2 11' N/A LEFT VERT 2 13' N/A N/A N/A N/A 2 LEFT VERT 2 14' N/A N/A N/A N/A 3 LEFT VERT 3 13' & 14' N/A N/A N/A N/A 4 LEFT HORIZ W/LATCH 11', 13', 14' N/A N/A 4 LEFT HORIZ W/LATCH 9' N/A N/A N/A 5 LEFT HORIZ W/O LATCH 11', 13', 14' N/A N/A 5 LEFT HORIZ W/O LATCH 9' N/A N/A N/A 6 LEFT REAR ALL N/A RIGHT VERT 1 ALL RIGHT VERT 2 11' RIGHT VERT 2 13' N/A N/A N/A N/A

21 Chapter 2 Assemblies & Installation 19 ITEM LOCATION BODY 44" DOM 1 /DSC20 52" DSC /DOMCS 60" DSC /DOMCS 8 RIGHT VERT 2 14' N/A N/A N/A N/A 9 RIGHT VERT 3 13' & 14' N/A N/A N/A N/A 10 RIGHT HORIZ W/LATCH 11', 13', 14' N/A N/A 10 RIGHT HORIZ W/LATCH 9' N/A N/A N/A 11 RIGHT HORIZ W/O LATCH 11', 13', 14' N/A N/A 11 RIGHT HORIZ W/O LATCH 9' N/A N/A N/A 12 RIGHT REAR ALL N/A N/A 60" DOM 1 /DSC20 13 WORKBENCH ALL SCREW-MACH.25-20X.75 ALL TRHTORXSS (4 PER HINGE) 15 NUT-SS NYLOC (3 PER ALL HINGE) 16 WELD NUT (1 PER ALL HINGE) 17 HINGE-SS 10GA BUTT ALL REV B NOTE: Not all body sizes are available in all models. Check the model specifications for appropriate sizes.

22 20 Dominator I Parts & Specifications Manual Part # Dominator I Crane Installation Hole Pattern ( ) 21.50" 17.82" C B C B 4.93" 14.57" A A 16.19" 10.44" 10.76" 3.07" 0 C B A C B A " 10.63" 17" 2.25" 19.13" HOLE INDEX PER CRANE MODEL: A 1015 WS i 4004i (Models with serial number beginning with 4004i08...) B 2002i (Adapter plate required at installation.) i (Models with 6-digit serial number - Adapter plate required at installation.) C i 6006i REV. H

23 Chapter 2 Assemblies & Installation 21 Hydraulic Installation ( ) (Eff ) HYD COOLER (CAS3560 ONLY) HOSE "B" OUT TO TANK (CAS3560 ONLY) HOSE "N" FROM COMPRESSOR TO COOLER (CAS3560 ONLY) HOSE "B" RETURN TO TANK (CAS435HA ONLY) CAS3560 SHOWN - SEE NOTES FOR CAS435H DIFFERENCES HOSE "C" CAS3560 ONLY 12 HOSE "A" TO "PRESSURE" INLET OF COMPRESSOR 11 (SUCTION HOSE) HOSE "M" TO "T" ON VALVEBANK ( FROM OUTRIGGER KIT) 14 HOSE "J" HOSE "H" TO "P" ON VALVEBANK HOSE "L" TO CRANE RETURN SWIVEL HOSE "K" TO "PB" ON VALVEBANK TO CRANE PRESSURE SWIVEL FRONT OF BODY 1 SUCTION SECTION STREET SIDE RETURN SECTION CURB SIDE

24 22 Dominator I Parts & Specifications Manual Part # HOSE IDENTIFICATION CHART A COMPRESSOR PRESSURE HOSE B COMPRESSOR TO TANK C COMPRESSOR CASE DRAIN H CRANE PRESSURE J CRANE RETURN TO TANK K CRANE PRESSURE EXT L CRANE TANK EXT M OUTRIGGER VALVEBANK RETURN (FROM OUTRIGGER KIT) N COOLER INLET PARTS LIST ITEM PART # DESCRIPTION QUANTITY RESERVOIR ASSEMBLY NIPPLE-PIPE BLK 1.50X CLOSE VALVE-BALL VALVE-BALL FILTER-HYD RET 10MIC 1.25 NPTF ADPTR-MPT/HEX/MPT REDUCER BUSH-STL A/R ADPTR-MPT/M JIC A/R TEE-MALE RUN 1 MPT X 1 JIC A/R 9. SEE CHART HOSEBARB-STRAIGHT SEE CHART CLAMP-HOSE T-BOLT HOSE-HYD R4 A/R HOSE-HYD 1.50 SUCTION A/R ELBOW-MPT/90/M JIC.75 6 A/R VALVE BANK 2 SEC (MAN OUT/HYD DOWN) VALVE BANK 3 SEC (HYD OUT/HYD DOWN) ADPTR-M JIC/M JIC 8 8 (MANUAL OUTRIGGERS) ADPTR-M STR/M JIC 8 8 (HYD OUTRIGGERS) ADPTR-M JIC/M JIC (MAN OUTRIGGERS) TEE-MALE JIC TUBE (HYD OUTRIGGERS) WASHER.50 FLAT NUT HEX NYLOCK ROD-THREADED X NEW

25 Chapter 2 Assemblies & Installation 23 HYDRAULIC INSTALLATION COMPONENTS - UNITS WITH WELDER DECKS ( ) (EFF ) INSTALLATION KIT HOSE KIT APPLICATION CRANE WITH WELDER DECK CAS435HA COMP. WITH WELDER DECK CAS3560 WITH WELDER DECK CRANE, CAS435HA WITH WELDER DECK CRANE, CAS3560 WITH WELDER DECK A COMP PRESSURE HOSE ASSEMBLY B COMP TANK HOSE ASSEMBLY C COMP CASE DRAIN HOSE ASSEMBLY H CRANE PRESSURE See chart B See chart B See chart B HOSE ASSEMBLY J CRANE RETURN TO TANK HOSE ASSEMBLY See chart B See chart B See chart B K CRANE PRESSURE HOSE ASSEMBLY L CRANE TANK HOSE ASSEMBLY N COOLER INLET HOSE ASSEMBLY 7 REDUCER BUSHING FITTING HOSEBARB STRAIGHT 10 CLAMP-HOSE (2) (2) (2) (2) (2) 12 ELBOW-CASE DRAIN CA COMP AIR FITTING CA COMP AIR FITTING CA COMP AIR FITTING CH COMP HYD FITTING CH COMP HYD FITTING

26 24 Dominator I Parts & Specifications Manual Part # HYDRAULIC INSTALLATION COMPONENTS - UNITS WITHOUT WELDER DECKS ( ) (EFF ) INSTALLATION KIT HOSE KIT A APPLICATION COMP PRESSURE HOSE ASSEMBLY CRANE W/O WELDER DECK CAS435HA W/O WELDER DECK CAS3560 W/O WELDER DECK CRANE, CAS435HA W/O WELDER DECK CRANE, CAS3560 W/O WELDER DECK B COMP TANK HOSE ASSEMBLY C COMP CASE DRAIN HOSE ASSEMBLY H CRANE PRESSURE See chart B See chart B See chart B HOSE ASSEMBLY J CRANE RETURN TO TANK HOSE ASSEMBLY See chart B See chart B See chart B K CRANE PRESSURE HOSE ASSEMBLY L CRANE TANK HOSE ASSEMBLY N COOLER INLET HOSE ASSEMBLY 7 REDUCER BUSHING FITTING HOSEBARB STRAIGHT 10 CLAMP-HOSE (2) (2) (2) (2) (2) 12 ELBOW-CASE DRAIN CA COMP AIR FITTING CA COMP AIR FITTING CA COMP AIR FITTING CH COMP HYD FITTING CH COMP HYD FITTING CHART B - PRESSURE & RETURN HOSES, BY BODY LENGTH 9' BODY 9' BODY WITH WELDER DECK 11' BODY 11' BODY WITH WELDER DECK H -- CRANE PRESSURE HOSE J -- CRANE RETURN TO TANK HOSE NOTE: QUANTITY SHOWN IN PARENTHESES (). NOT ALL BODY SIZES ARE AVAILABLE FOR ALL MODELS. CHECK THE MODEL SPECIFICATIONS FOR THE APPROPRIATE SIZES.

27 Chapter 2 Assemblies & Installation 25 Hydraulic Reservoir ( ) (Eff ) PARTS LIST 15 ITEM PART # DESCRIPTION QUANTITY SIGHT GAUGE PLUG W/ REFLECTOR PLUG-PIPE MAGNETIC.75NPT SQHD WELDMENT, HYD RESERVOIR ELBOW-STREET STL 1.00 X 90 DEG FILL-BREATHER BAYONET DIFFUSER-INTERNAL 55 GPM 3.00NPT NPT STRAINER-INTERNAL 50 GPM 3.00NPT NPT REDUCER BUSH-BLK NIPPLE-PIPE BLK 1.25X CLOSE REDUCER BUSH-STL ELBOW-STREET STL 1.25 X 90 DEG PLUG-PIPE SQ HD STL.75 1 REV. B NOTE: IF RESERVOIR IS NOT REQUIRED, USE COVER KIT TO COVER OPENINGS IN FLOOR.

28 26 Dominator I Parts & Specifications Manual Part # Hydraulic Installation ( ) (Thru ) HYD. COOLER (CAS3560 ONLY) OUT TO TANK (HOSE "B") HOSE "N" FROM COMPRESSOR TO COOLER (CAS3560 ONLY) IN FROM "T" PORT ON COMPRESSOR (HOSE "N") COMPRESSOR (VIEWED FROM TOP) PORT P (HYD OIL IN) (CAS3560) PORT P (HYD OIL OUT) (CAS3560) PORT IDENTIFICATION HOSE "C" (CAS3560 ONLY) SUCTION HOSE HOSE A CAS435HA: TO "P" CAS3560: TO "HYD OIL IN" HOSE "M" TO "T" ON VALVEBANK ( FROM OUTRIGGER KIT) HOSE "J" HOSE "H" TO "P" ON VALVE BANK HOSE "B" 9 6 HOSE "L" TO CRANE RETURN SWIVEL HOSE "K" TO "PB" ON VALVEBANK TO CRANE PRESSURE SWIVEL

29 Chapter 2 Assemblies & Installation 27 FRONT OF BODY SUCTION SECTION (STREET SIDE) , RETURN SECTION (CURB SIDE) 16 NOTES: 1 ITEMS 23, 24 ARE REQUIRED FOR 1-1/4" SUCTION LINE. HOSE IDENTIFICATION CHART A COMPRESSOR PRESSURE B COMPRESSOR TANK C COMPRESSOR CASE DRAIN F STRAINER TO PUMP G STRAINER TO PUMP H CRANE PRESSURE J CRANE RETURN TO TANK K CRANE PRESSURE EXT L CRANE TANK EXT M OUTRIGGER VALVEBANK RETURN (FROM OUTRIGGER KIT) N COOLER INLET CHART B: CRANE PRESSURE & RETURN TO TANK HOSES 9' BODY 9' WITH WELDER DECK 11' BODY 11' WITH WELDER DECK 13' & 14' BODY 13' & 14' WITH WELDER DECK H J

30 28 Dominator I Parts & Specifications Manual Part # PARTS LIST (THRU ) ITEM PART # DESCRIPTION QUANTITY FILTER-HYD RET 10MIC 1.25 NPTF REDUCER BUSH-STL TEE-MALE RUN 1 MPT X 1 JIC VALVE-BALL ADPTR-M STR/M JIC VALVE BANK, 3-SECTION (HYD OUT/HYD DOWN) (WAS ) VALVE BANK, 2-SECTION (MAN OUT/HYD DOWN) (WAS ) TEE-MALE JIC TUBE ELBOW-MPT/90/M JIC ADPTR-MPT/HEX/MPT D(II)- RESERVOIR ASM D1 30 GAL ADPTR-M STR/F JIC SWL ELBOW-M JIC/90/F JIC SW NIPPLE-BARB STL 1.50MPT ADPTR-M STR/M JIC ELBOW-M JIC/90/F SW TUBE ADPTR-M NPT/F JIC SW VALVE-BALL ADPTR-M STR/M JIC CAP SCR.25-20X.62 HH GR5 Z WASHER.25 W FLAT ANSI B27.2Z GUARD-HYD RESERVOIR (WAS ) REDUCER BUSH-STL A/R NIPPLE-BARB STL 1.25MPT 1.50 A/R REV. E

31 Chapter 2 Assemblies & Installation 29 HYDRAULIC INSTALLATION COMPONENTS-UNITS WITH WELDER DECKS ( ) (THRU ) INSTALLATION KIT HOSE KIT A B C F G H J K L N APPLICATION COMP PRESSURE HOSE ASSEMBLY COMP TANK HOSE ASSEMBLY COMP CASE DRAIN HOSE ASSEMBLY STRAINER TO PUMP HOSE STRAINER TO PUMP HOSE CRANE PRESSURE HOSE ASSEMBLY CRANE RETURN TO TANK HOSE ASSEMBLY CRANE PRESSURE HOSE ASSEMBLY CRANE TANK HOSE ASSEMBLY COOLER INLET HOSE ASSEMBLY CRANE WITH WELDER DECK NOT USED (WAS ) See chart B See chart B CAS435HA WITH WELDER DECK (WAS ) NOT USED (WAS CAS3560 WITH WELDER DECK (WAS ) NOT USED (WAS ) CR/CAS435 WITH WELDER DECK D1 FORD AUTO CRANE CAS435HA WITH WELDER DECK (WAS ) NOT USED (WAS See chart B See chart B (WAS ) NOT USED (WAS ) See chart B See chart B REDUCER BUSH REDUCER BUSH FITTING SUCTION TEE 24 ELBOW-RETURN 25 HOSEBARB-STRAIGHT (WAS (WAS ) ) 26 CLAMP (2) (2) (WAS ) CR/CAS WITH WELDER DECK FORD MANUAL (WAS ) NOT USED (WAS ) See chart B See chart B (2) (WAS ) CRANE CAS3560 WITH WELDER DECK (WAS ) NOT USED (WAS NOT USED (WAS ) See chart B See chart B (WAS ) (2) (WAS ) 27 HOSEBARB-ELBOW NOT USED (WAS ) 28 CLAMP (2) (2) (2) NOT USED (WAS ) NOT USED (WAS )

32 30 Dominator I Parts & Specifications Manual Part # HYDRAULIC INSTALLATION COMPONENTS-UNITS WITH WELDER DECKS ( ) (THRU ) INSTALLATION KIT HOSE KIT ELBOW-CASE DRAIN CA COMP AIR FITTING (WAS ) CA COMP AIR FITTING ( 1) CA COMP AIR FITTING CH COMP HYD FITTING CH COMP HYD FITTING (WAS ) CH COMP HYD FITTING CH COMP HYD FITTING CH COMP HYD FITTING (WAS ) (WAS ) (WAS (WAS ) ) NOTE: QUANTITY SHOWN IN PARENTHESES (). NOT ALL BODY SIZES ARE AVAILABLE FOR ALL MODELS. CHECK THE MODEL SPECIFICATIONS FOR THE APPROPRIATE SIZES HYDRAULIC INSTALLATION COMPONENTS-UNITS WITHOUT WELDER DECKS ( ) (THRU ) INSTALLATION KIT HOSE KIT A B C F G H APPLICATION COMP PRESSURE HOSE ASSEMBLY COMP TANK HOSE ASSEMBLY COMP CASE DRAIN HOSE ASSEMBLY STRAINER TO PUMP HOSE STRAINER TO PUMP HOSE CRANE PRESSURE HOSE ASSEMBLY CRANE WITHOUT WELDER DECK NOT USED (WAS ) See chart B CAS435HA WITHOUT WELDER DECK (WAS ) NOT USED (WAS ) CAS3560 WITHOUT WELDER DECK (WAS ) NOT USED (WAS ) CR/CAS435 WITHOUT WELDER DECK D1 FORD AUTO CRANE CAS435HA WITHOUT WELDER DECK (WAS ) NOT USED (WAS ) See chart B (WAS ) NOT USED ( ) See chart B CR/CAS WITHOUT WELDER DECK FORD MANUAL (WAS ) NOT USED ) See chart B CRANE CAS3560 WITHOUT WELDER DECK (WAS ) NOT USED (WAS ) NOT USED ( ) See chart B

33 Chapter 2 Assemblies & Installation 31 HYDRAULIC INSTALLATION COMPONENTS-UNITS WITHOUT WELDER DECKS ( ) (THRU ) INSTALLATION KIT HOSE KIT J K L N CRANE RETURN TO TANK HOSE ASSEMBLY CRANE PRESSURE HOSE ASSEMBLY CRANE TANK HOSE ASSEMBLY COOLER INLET HOSE ASSEMBLY See chart B See chart B See chart B REDUCER BUSH REDUCER BUSH FITTING SUCTION TEE 24 ELBOW-RETURN HOSEBARB-STRAIGHT (WAS (WAS ) ) 26 CLAMP (2) (WAS ) 27 HOSEBARB-ELBOW 28 CLAMP (2) (2) (2) 29 ELBOW-CASE DRAIN CA COMP AIR FITTING (WAS ) CA COMP AIR FITTING ( 1) CA COMP AIR FITTING ( 1) CH COMP HYD FITTING CH COMP HYD FITTING CH COMP HYD FITTING CH COMP HYD FITTING CH COMP HYD FITTING (WAS ) (2) (WAS ) (WAS ) See chart B (2) (WAS ) NOTE: QUANTITY SHOWN IN PARENTHESES (). NOT ALL BODY SIZES ARE AVAILABLE FOR ALL MODELS. CHECK THE MODEL SPECIFICATIONS FOR APPROPRIATE SIZES. (REV. E ) See chart B (WAS ) (2) (WAS )

34 32 Dominator I Parts & Specifications Manual Part # Hydraulic Reservoir ( ) (Thru ) FRONT OF BODY PARTS LIST ITEM PART # DESCRIPTION QUANTITY WELDMENT, HYD RESERVOIR ELBOW-STREET STL 1.00 X 90 DEG SIGHT GAUGE PLUG W/REFLCT PLUG-PIPE MAGNETIC.75NPT SQHD FILL-BREATHER BAYONET WASHER.50 FLAT NUT HEX NYLOCK ROD-THREADED X (WAS ) DECAL-MOBILOIL RESERVOIR (NOT SHOWN) 1 REV. E NOTE: IF RESERVOIR IS NOT REQUIRED, USE COVER KIT TO COVER OPENINGS IN FLOOR.

35 Chapter 2 Assemblies & Installation 33 Reference, Hyd. Reservoir Plumbing ( ) (Thru 2006) SUCTION SECTION (STREET SIDE) USE (BLUE) 9 12 LOCKTITE FRONT OF BODY , USE 242 (BLUE) 11 LOCKTITE RETURN SECTION (CURB SIDE) SUCTION ASSEMBLY NOTES: 1 SUB-ASSEMBLE FITTINGS (GROUP 1) AND FITTINGS (GROUP 2). 2 INSTALL GROUP 1 INTO RESERVOIR. 3 ASSEMBLY GROUP 2 ONTO GROUP 1. RETURN ASSEMBLY NOTES:

36 34 Dominator I Parts & Specifications Manual Part # SUB-ASSEMBLE GROUPS, DIVIDED AS SHOWN. 2 ASSEMBLE GROUPS TOGETHER. 3 INSTALL ASSEMBLY ONTO RESERVOIR. NOTES: 1 ITEMS #23, 27 NOT USED ON SINGLE INLET PUMPS. REFERENCE, HYD. RESERVOIR PLUMBING ( ) (Thru 2006) ITEM PART # DESCRIPTION QUANTITY RESERVOIR ASSEMBLY GUARD-HYD RESERVOIR NUT-TINNERMAN 1/4-20UNC WASHER.25 FLAT CAP SCR.25-20X.62 HH GR5 Z BLOCK - HYD RESERVOIR NPT ALUMINUM Q O RING 3.62X 3.88X CAP SCR.62-11X 1.50 SH PLAIN STRAINER-INTERNAL 50 GPM 3.00NPT 2.00NPT DIFFUSER-INTERNAL 55 GPM 3.00NPT 2.00NPT REDUCER BUSH-BLK ELBOW-STREET STL 1.50 X 90 DEG ADPTR-MPT/HEX/MPT VALVE-BALL REDUCER BUSH-STL (AS REQUIRED) ADPTR-MPT/HEX/MPT FILTER-HYD RET 10MIC 1.25 NPTF REDUCER BUSH-STL (AS REQUIRED) ADPTR-MPT/M JIC (AS REQUIRED) TEE-MALE RUN 1 MPT X 1 JIC (AS REQUIRED) TEE-STREET STL 1.25 (AS REQUIRED) SEE CHART HOSEBARB-STRAIGHT (AS REQUIRED) CLAMP-HOSE BOLT (AS REQUIRED) SEE CHART HOSEBARB-ELBOW (AS REQUIRED) 1 NOTE: ITEM #20 (FILTER) CAN BE PURCHASED SEPARATELY FROM IMT. ITEMS #18 AND ARE INCLUDED WITH OPTIONAL INSTALLATION KITS. REV B

37 Chapter 2 Assemblies & Installation 35 Installation Kit, Compartment Pressure Fan Option ( ) NOTE - AIR FLOW DIRECTION IS OUT OF CRANE COMPARTMENT 9,10 AS REQ'D 6 WIRE HARNESS CONNECTS TO HARNESS ON BACK OF ELEC. PANEL TERMINATE FAN WIRING WITH ITEMS 7,8 & 11. BLACK WIRE - CAVITY A RED WIRE - CAVITY B 3 (4 PLCS) (4 PLCS) 1 2 NOTE AIR FLOW DIRECTION OUT OF CRANE COMPT 1 4 (4 PLCS) PARTS LIST ITEM PART # DESCRIPTION QUANTITY GUARD-FILTER 12V FAN FAN-12V AXIAL NUT 8-32 HEX NYLOCK SCR-MACH # 8-32X 2.50 RDH GUARD-CHROME WIRE 12V FAN HARNESS-COMPARTMENT FAN TERM-PKRD WPK 18-20GA MALE CONN-PKRD WP 2 CAV MALE/SHROUD RETAINER-ZIP TIE ELEC HARNESS TIES-PLASTIC.18W 8.00L BLACK SEAL-PKRD WP/MP 16 GA GREEN 4 NEW

38 36 Dominator I Parts & Specifications Manual Part # Compressor Mounting Locations ( ) CAS435HA Compressor Mounting Locations CAS435HA INSTALLATION ON SERIES 1 AND SERIES 2 DOMINATOR 4.40" 13.38" ø0.44" TYP (4) 12.75" 12.00" CAS435HA INSTALLATION ON SERIES 2 DOMINATOR WITH HEADACHE RACK AND STANDARD HEIGHT SIDEPACK ON COMPRESSOR SIDE 4.40" 13.38" ø0.44" TYP (4) 18.75" 12.00" NOTE: When installing a compressor, maintain a minimum clearance of 8" on each end of the compressor. If installing a compressor with a hydraulic aftercooler, maintain a minimum space of 10" between the compressor and aftercooler, while still maintaining the 8" of clearance on each end of the compressor-cooler combination.

39 Chapter 2 Assemblies & Installation 37 CAS2545 & CAS3560 Compressor Mounting Locations CAS3560 & CAS2545 INSTALLATION ON SERIES 1 AND SERIES 2 DOMINATORS CAS3560 & CAS2545 INSTALLATION ON SERIES 2 DOM WITH HEADACHE RACK, STANDARD HEIGHT SIDEPACK ON COMPRESSOR SIDE, AND TELESCOPIC ROOF. 4.38" 12.25" 10.50" 12.00" 12.00" ø0.44" TYP (10) 6.00" 18.00" MIN. 4.38" 12.25" 16.5" 6" 12" 18" MIN. ø0.44" TYP (10) CAS3560 & CAS2545 INSTALLATION ON SERIES 2 DOM WITH HEADACHE RACK ANDSTANDARDHEIGHT SIDEPACK ON COMPRESSOR SIDE 4.38" 12.25" 16.50" 12.00" 12.00" ø0.44" TYP (10) 6.00" 18.00" MIN. NOTE: When installing a compressor, maintain a minimum clearance of 8" on each end of the compressor. If installing a compressor with a hydraulic aftercooler, maintain a minimum space of 10" between the compressor and aftercooler, while still maintaining the 8" of clearance on each end of the compressor-cooler combination.

40 38 Dominator I Parts & Specifications Manual Part # Weather-Strip Installation ( ) WEATHER-STRIP: TOP WILL CAP THE SIDE. GAP BETWEEN WEATHER-STRIP AND DOOR JAM IS ACCEPTABLE. A VIEW A-A WEATHER-STRIP FLUSH WITH DOOR OPENING. B B WEATHER-STRIP BOTTOM IS UNDER THE SIDE.

41 Chapter 2 Assemblies & Installation 39 Battery Cover Installation ( ) 1 2 NOTE: BATTERY COVER NOT SHOWN FOR CLARITY CHASSIS BATTERIES RELOCATED TO COMPARTMENT PARTS LIST ITEM PART # DESCRIPTION KIT # QUANTITY STUD-ELEC PASS THROUGH.38 RED REF STUD-ELEC PASS THROUGH.38 BLK REF HARDWARE KIT-BATTERY COVER BRACKET-BATTERY COVER MOUNT COVER-BATTERY DOM COMPARTMENT LATCH-RUBBER T-HANDLE # CAP SCR.10-24X.50 BTNHD ZC # NUT HEX NYLOCK # WASHER.31 FLAT # NUT HEX NYLOCK # CAP SCR.31-18X.75 HH GR5 Z #3 2 REV. A

42 40 Dominator I Parts & Specifications Manual Part # Installation, 2008 Chassis ( ) 12 13, 14(2),15 (4 PLCS) 11 13, 14(2),15 (4 PLCS) 13, 14(2),15 (4 PLCS) (BOTH SIDES) 2 4 ALL PARTS QTY PER SIDE 5,7(4),8,16 (3 PLCS) 5,7(2),8,16 (3 PLCS) 1 3 5,7(2),8,16 (3 PLCS) 5,6,7,8 (4 PLCS)

43 Chapter 2 Assemblies & Installation 41 NOTES: 1 INSTALL EXHAUST CONNECTOR ONTO EACH EXHAUST TIP. DO NOT COVER AIR HOLES IN ORIGINAL TIPS. WELD ALL AROUND. CONNECT WELDER GROUND TO ONLY TO AVOID DAMAGE TO TRUCK COMPUTER PARTS LIST ITEM PART # DESCRIPTION QUANTITY BRACKET-MUD FLAP DOM1 FORD 6.4L BRACKET-MUD FLAP DOM1 SIDE 2 PROTECTOR MUD FLAP W/IMT LOGO 16H X 24W MTG BRKT-WIRE HARNESS CAP SCR.31-18X 1.25 HH GR5 Z WASHER.31X1.50 OD ZINC WASHER.31 FLAT NUT HEX NYLOCK 26

44 42 Dominator I Parts & Specifications Manual Part # PARTS LIST ITEM PART # DESCRIPTION QUANTITY BRACKET-BODY FRT DOM1 9' BODY BRACKET-BODY FRT DOM1 11' BODY SNGL 2 WALL FRAME BRACKET-BODY FRT DOM1 11' BODY DBL 2 WALL FRAME SHIM-BODY MTG REAR DOM1 DBL WALL 2 FRAME ONLY CAP SCR.62-11X 2.00 HH GR8 Z WASHER.62 FLAT ASTM F NUT HEX ZINC NYLOK GR WASHER-BONDED PLTD EXH CONNECTOR-4.00ID ELBOW (6.4) 2 NEW

45 Chapter 2 Assemblies & Installation 43 Electric Crane Installation (2003i, 3203i, 4004i, 5005i, 6006i) ( ) Install the IMT 2003i, 3203i, 4004i, 5005i, and 6006i model cranes using the instructions in In addition to meeting the minimum chassis specifications noted in the Technical Data section of this manual, make sure there is sufficient room for mounting the crane and the platform is strong enough to support the crane and rated load. Install the crane only on an IMT designed and approved truck body. The body must be designed to sustain the forces imposed by the crane when lifting the full rated load. Install the body on the chassis before installing the crane. Refer to the following table for parts referenced in the following crane installation drawings. CRANE INSTALLATION PARTS LIST ITEM PART # DESCRIPTION KIT # QUANTITY ELECTRIC CRANE BODY INSTALLATION HARDWARE KIT- 3203i/4004i ELEC CRANE 1 BODY INSTALLATION HARDWARE KIT- 5005i ELEC CRANE BODY 1 INSTALLATION DRAWING-CRANE & WINCH ASSEMBLY 3203I REF 5. Body IMT BODY ASSEMBLY REF BRACKET-SWITCH 300 AMP ELEC CRANE SWITCH-300A KEYED BATTERY DISCONNECT # LEVEL INDICATOR LEVEL # TERMINAL-RING NI.38 STUD 1 WIRE # TERMINAL-RING NI.31 STUD 1-2 WIRE # FUSEHOLDER-HIGH AMP2 BOLT WITH #1 1 COVER FUSE-225 AMP # CABLE-#1 WELDING #1 35 FT TUBE-HEAT SHRINK AMP #1.50 FT CAP SCREW.75-10X 2.50 HH GR8 Z # CAP SCREW X 3.00 HHGR8Z # NUT HEX CENTER LOCKING # NUT HEX CENTER LOCK # WASHER.75 N FLAT H ASTMF436Z # WASHER 1.0 FLAT HI STR # CAP SCREW.25-20X.75 HH GR5 Z #2 & # SCREW-MACHINERY #10-24X.50 RDH #2 & # NUT HEX #2 & # NUT HEX NYLOCK #2 & # WASHER.25 FLAT #2 & #3 8 REV

46 44 Dominator I Parts & Specifications Manual Part # To install the crane: 1 Use a lifting device capable of lifting the weight of the crane as indicated in the Technical Data section of this manual. Attach fabric slings to the crane lower boom, centered approximately 18 inches (46 cm) from the mast hinge. Make certain the crane is well balanced on the slings by slowly lifting approximately 6" (15 cm) off the ground. Lift the crane and apply a bead of waterproof compound, such as silicon based caulk, to the bottom of the base. Move the chassis under the crane and lower the crane into the desired position. Install the mounting cap screws (item # 15) and washers (item #16) to secure the crane base to the truck body (see figure). Torque the 3/4" cap screws (used on models 3203i and 4004i) to 280 ft-lb and torque to 1" cap screws (used on models 5005i and 6006i) to 680 ft-lb. NOTE: The 3/4-10 x 2.5" grade 8 zinc coated capscrews (models 3203i and 4004i) are designed for a crane box thickness of 1/2" only. The 1-8 x 3" grade 8 zinc coated capscrews (model 5005i and 6006i) are designed for a crane box top thickness of 7/8" to 1" only. A different crane box may require different capscrews. If different length bolts are required, they must be the same size and of sufficient length. Failure to use proper length bolts may cause the bolts to bottom out before torquing. 15, ,17

47 Chapter 2 Assemblies & Installation 45 MOUNTING PATTERNS ø0.81" 2003i MOUNTING PATTERN 12" 10" 5" 5" 3203i & 4004i MOUNTING PATTERN ø0.81" ø9.5" 6" 5.75" 5005i & 6006i MOUNTING PATTERN 18" 14.75" 7.38" ø1.13" ø6" 6" 6" 4.63" 4.63" 9.25" 12" 18" 14.75" 12" 7.38" 6" 9" 7.38" 14.75" 18" 4.75" 4.75" 9.5" ALLOW 12" RADIUS FOR SWING CLEARANCE ALLOW 16" RADIUS FOR SWING CLEARANCE 11.5" 12" 14" 9" ø13" ALLOW 16" RADIUS FOR SWING CLEARANCE 2 The electrical power switch (item #7) provides power for the crane. Install the switch onto the power unit cover KEY SUPPLIED 6 WITH SWITCH. SPARE 2.75" KEY " 13.5" 3.5" 4 HOLES, 0.266" DIA. LOCATION OF SWITCH BRACKET IN CRANE BOX INSIDE VIEW OF CRANE BOX 3 Install the vehicle level indicator (item #8) parallel to the door reinforcements.

48 46 Dominator I Parts & Specifications Manual Part # After mounting your crane, wire the crane to the vehicle's 12VDC electrical system using the following steps. Use the parts list above to identify parts. Your crane installation kit, , includes a 10.7 m (35') long cable, IMT # (item #13 in the parts list). Use this cable to ground the auxiliary battery, the underhood battery, and to connect the batteries to the fuses and the fuses to the the crane on-off switch. Cut the cable to length after determining the lengths required. 5 Ground the crane by connecting the crane ground cable to bare metal inside the crane box. POWER CABLE BRACKET A GROUND CABLE (GROUND TO BARE METAL INSIDE CRANE BOX) 7 MALE POWER CABLE CONNECTOR (#13) ON-OFF SWITCH TO FUSE (CUT TO LENGTH) 6 Connect the crane power cable from the male power cable connector to the on-off power switch. Connect cable (item # ), cut to length, from the crane power switch (item #7) to an electrical bulkhead connector, which will be connected to the fuses in step #8. Use 3/8" (0.95 cm) ring terminals (item # ) for each connection. Heat shrink the connections (item # ). WARNING Protect the power cable from damage by fastening it inside the frame channel and covering it with protective covering including loom, conduit, etc. Be sure to use rubber grommets or other protection when running the power cable through steel bulkheads. 7 Use approximately 4' (1.2 m) of the cable (item #13) to ground both the vehicle battery and auxiliary battery. Connect one end of the ground cable to the negative terminal on the battery, and the other end to bare metal on the truck body. Use a 5/16" (0.79 cm) ring terminal (item # ) to connect to the truck body.

49 Chapter 2 Assemblies & Installation 47 WARNING Install the ground cable to the negative terminal of the batteries! The crane electrical ground completes the electrical circuit through the structure of the crane to the vehicle frame. The vehicle factory ground is NOT sufficient to carry the current required by the crane. Without this extra ground cable, your crane may not operate at rated capacity, and motor, contactor, or electrical damage may occur. 8 Mount one 225-amp fuse holder (item #11) close to the vehicle battery in a location which can be easily accessed if the fuse needs to be replaced. Repeat with the auxiliary battery. Use approximately one foot (30.5 cm) of cable (item #13) to connect the positive terminals on the vehicle batteries to the fuse holders. Connect the other end of each fuse holder to the bulkhead pass-through connector from step #6, which is then connected to the crane power switch. Cables connect to the fuse holders using 5/16" (0.79 cm) ring terminals (item # ). Heat shrink connections. 10 (-) (+) 1 AUXILIARY BATTERY 13-CABLE # (CUT TO LENGTH) (BATTERY (-) TO CHASSIS GROUND) TO CHASSIS GROUND 13-CABLE # (CUT TO APPROX. 1' (30.5 cm)) (FUSE TO BATTERY (+)) FUSE DETAIL 13-CABLE # (CUT TO LENGTH) BULKHEAD 2 PASS-THROUGH CONNECTOR 13-CABLE # (CUT TO LENGTH) (CRANE ON-OFF SWITCH TO FUSE) FUSE DETAIL (+) 13-CABLE # (CUT TO APPROX. 1' (30.5 cm)) (FUSE TO BATTERY (+)) (-) UNDERHOOD 1 BATTERY FROM ON-OFF SWITCH IN CRANE BOX 10 (5/16" RING TERMINA)L 13-C (CUT TO CRANE TO 12 BATTERY (+) (225-AMP 10 (5/16" RING FUSE) 11 TERMINAL) (FUSEHOLDER) NOTES: 1. Use the highest rating cold-cranking amp battery available up to 1,000 CCA. Underhood and auxiliary batteries must be identical. 2. Use bulkhead pass-through connectors when power or ground passes through a compartment wall. 3. Reference drawing for wiring diagram. 10 TO CHASSIS GROUND

50 48 Dominator I Parts & Specifications Manual Part # Electrical Installation (1015E & 2020E) ( ) 6 BLACK 2,3,4,5 BROWN NOTE: INSTALL DECAL #1 NEXT TO PARKING BRAKE ACTUATOR ON DASH PANEL. BATTERY PLUG CONNECTION P2 ON VALVEBANK J2 ON CABLE ASSEMBLY 87 IGN V 30 PARKING BRAKE NOTE: SEE APPROPRIATE SPEED CONTROL KIT FOR PARKING BRAKE WIRING. 1 WIRES IN HARNESS ARE 14GA, 19/27 STRANDS, AND MUST MEET FORD SPECIFICATION MIL-85B OR CHRYSLER SPECIFICATION MS PARTS LIST ITEM PART # DESCRIPTION QUANTITY DECAL-CAUTION BRAKE/COMP CAP SCR 1/4-20X1.25 HHGR NUT 1/4-20 HEX NYLOC ZINC WASHER 1/4-FLAT RELAY HARNESS 1 REV. B

51 49 C HAPTER 3 Chassis Installation In This Chapter Installation Kit- 9' Body - Ford ( )...50 Installation Kit - 11' Body- Ford 15,000 & 17,500 GVW ( )...51 Installation Kit- 11' Body - Ford 19,000 GVW ( )...52 Installation Kit - Selector Valve - Ford Automatic Transmissions ( )...53 Installation Kit, Hydraulic, Ford 4x2 MY2011 ( )...54 Installation, DEF Tank Hoses on 2011 Ford F550 ( )...56 PTO Wiring Installation-2006 & 2007 ( )...57 PTO Wiring Installation Through 2005 ( )...62 PTO/Pump Rotation Guide ( )...67

52 50 Dominator I Parts & Specifications Manual Part # Installation Kit- 9' Body - Ford ( ) BODY MOUNTING BRACKET (2) STREET SIDE VIEW SHOWN " /8-11X2 CAP SCR, HHGR8Z (4-2/SIDE) /8 TOP LOCK NUT, GR8 (4-2/SIDE) /8 FLAT WASHER (8-4/SIDE) DRILL 5/8" DIA. HOLES THROUGH CHASSIS FRAME FOR 5/8" GRADE 8 FASTENERS (BOTH SIDES) 4.50" APPROX. FROM CAB /8-11X2 CAP SCR, HHGR8Z (8-4/SIDE) /8-11 HEX ZINC NYLOC NUT, GR8 (8-4/SIDE) /8 FLAT WASHER (16-8/SIDE) /16X1 CAP SCREW (6-3/SIDE) /16 NYLOC NUT (6-3/SIDE) /16 FLAT WASHER (6-3/SIDE) /16 X 1.5 FENDER WASHER (6-3/SIDE) MUD FLAP (2) MUD FLAT /16X1 CAP SCR (6) MOUNTING BRACKET (2) /16 NUT NYLOC GR8 (6) /16 FLAT WASHER (6) /16 THREAD SEAL WASHER (6) REV E NOTE: 1 FOR REAR END, USE GRADE #8 FASTENERS. 2 5/8-11 CAP SCREW & NYLOC NUT TORQUE VALUE = 220 FT-LB PLAIN, 160 FT-LB PLATED 3 WHEN USING A TORQUE WRENCH, ALWAYS HOLD THE BOLT AND APPLY TORQUE TO THE NUT. BOLTS MAY PASS THROUGH FRAME IN EITHER DIRECTION. 4 ALL CHASSIS FRAME HOLES MUST BE DRILLED THE SAME SIZE AS THE BOLTS USED. 5 KIT , FOR A CHEVY 4500/550 CHASSIS, IS THE SAME AS EXCEPT SHIMS ARE REQUIRED BETWEEN THE OUTSIDE OF THE CHASSIS AND THE INSIDE OF THE FLOOR GUSSETS DUE TO A SMALLER SIZE CHASSIS.

53 Chapter 3 Chassis Installation 51 Installation Kit - 11' Body- Ford 15,000 & 17,500 GVW ( ) BODY MOUNTING BRACKET (2) 31.25" STREET SIDE VIEW SHOWN " /8-11X2 CAP SCR, HHGR8Z (4-2/SIDE) /8-11 TOP LOCK NUT, GR8 (4-2/SIDE) /8 FLAT WASHER (8-4/SIDE) DRILL 2 5/8" DIA. HOLES THROUGH CHASSIS FRAME FOR 5/8" GRADE 8 FASTENERS (BOTH SIDES) 8.00" APPROX /8X2 CAP SCR, HHGR8Z (8-4/SIDE) /8-11 ZINC NYLOC NUT, GR8 (8-4/SIDE) /8 FLAT WASHER (16-8/SIDE) /16X1 CAP SCR (6) /16 NUT NYLOC GR8 (6) /16 FLAT WASHER (9) /16 THREAD SEAL WASHER (3) /16X1 CAP SCREW (6-3/SIDE) /16 NYLOC NUT (6-3/SIDE) /16 FLAT WASHER (6-3/SIDE) /16 X 1.5 FENDER WASHER (6-3/SIDE) MUD FLAP (2) MUD FLAT MOUNTING BRACKET (2) REV. F NOTE: 1 FOR REAR END, USE GRADE 8 FASTENERS. 2 5/8-11 CAP SCREW & NUT TORQUE VALUE = 220 FT-LB PLAIN, 160 FT-LB PLATED 3 WHEN USING A TORQUE WRENCH, ALWAYS HOLD THE BOLT AND APPLY TORQUE TO THE NUT. BOLTS MAY PASS THROUGH FRAME IN EITHER DIRECTION. 4 ALL CHASSIS FRAME HOLES MUST BE DRILLED THE SAME SIZE AS THE BOLTS USED. 5 KIT , FOR A CHEVY 4500/550 CHASSIS, IS THE SAME AS EXCEPT SHIMS ARE REQUIRED BETWEEN THE OUTSIDE OF THE CHASSIS AND THE INSIDE OF THE FLOOR GUSSETS DUE TO A SMALLER SIZE CHASSIS.

54 52 Dominator I Parts & Specifications Manual Part # Installation Kit- 11' Body - Ford 19,000 GVW ( ) 31.25" STREET SIDE VIEW SHOWN " /8-11X2 CAP SCR, HHGR8Z (4-2/SIDE) /8 TOP LOCK NUT, GR8 (4-2/SIDE) BODY /8 FLAT WASHER (8-4/SIDE) MOUNTING BRACKET (2) DRILL THREE 5/8" DIA. HOLES THROUGH CHASSIS FRAME FOR 5/8" GRADE 8 FASTENERS (BOTH SIDES) (2) REAR SHIM. WELD SHIM TO REAR OF CHASSIS. DO NOT WELD AHEAD OF REAR OF SHIM. 8.00" APPROX /8-11X2 CAP SCR, HHGR8Z (8-4/SIDE) /8-11 HEX ZINC NYLOC NUT, GR8 (8-4/SIDE) /8 FLAT WASHER (16-8/SIDE) /16X1 CAP SCREW (6-3/SIDE) /16 NYLOC NUT (6-3/SIDE) /16 FLAT WASHER (6-3/SIDE) /16 X 1.5 FENDER WASHER (6-3/SIDE) MUD FLAP (2) MUD FLAT MOUNTING BRACKET (2) /16X1 CAP SCR (6) /16 NUT NYLOC GR8 (6) /16 FLAT WASHER (9) /16 THREAD SEAL WASHER (3) REV. E NOTE: 1 FOR REAR END, USE GRADE 8 FASTENERS. 2 5/8-11 CAP SCREW & NUT TORQUE VALUE = 220 FT-LB PLAIN, 160 FT-LB PLATED 3 WHEN USING A TORQUE WRENCH, ALWAYS HOLD THE BOLT AND APPLY TORQUE TO THE NUT. BOLTS MAY PASS THROUGH FRAME IN EITHER DIRECTION. 4 ALL CHASSIS FRAME HOLES MUST BE DRILLED THE SAME SIZE AS THE BOLTS USED.

55 Chapter 3 Chassis Installation 53 Installation Kit - Selector Valve - Ford Automatic Transmissions ( ) Used on Ford/Dodge 4x4 chassis with crane/compressor. Use for MY2011 Ford 4x2 chassis. FROM CRANE &CPRSR RETURN LINES TO RETURN FILTER #17, FORD F350, F450, F550 STREETSIDE (DRIVER'S SIDE) FRAME RAIL 11(2) PTO P1 1 T 2 P2CRANE PRESSURE 3200 COMPRESSOR PRES. P3 PSIG 3 HYDRAULIC SCHEMATIC 1 (LOCATED APPROX. 5.5" BEHIND THE TRANSMISSION SUPPORT CROSSMEMBER. THE EXISTING HOLES IN THE FRAMEWILLHAVETOBEENLARGED TO ACCOMODATE A 3/8" CAP SCREW.) 5(2) 6(2) 12(2) SEE ELECTRICAL DETAILS 1 BLUE (GROUND) BROWN (12 V SIGNAL) 13(2) 14(2) REF TO PRESSURE PORT ON HYDRAULIC PUMP 3 15 REF DOM ELECTRICAL DETAILS TO CPRSR PRESSURE TO CRANE PRESSURE SEE NOTE 1 8(2) 2 DIN CONN. ON SOLENOID BROWN BLUE "TO SELECTOR" CIRCUIT FROM IMT CHASSIS HARNESS WIRE STAMPED WITH CIRCUIT DESIGNATION

56 54 Dominator I Parts & Specifications Manual Part # PARTS LIST ITEM PART # DESCRIPTION QUANTITY BRACKET, SELECTOR VALVE MTG VALVE-SELECTOR WITH RELIEF 12V 15GPM HOSE-FF 1/2X32.5 OAL (8-8) (WAS ) HOSE-FJ 1/2X46 OAL (8-8) (WAS ) CAP SCR 3/8-16X1.75 HHGR5Z NUT 3/8-16 HEX NYLOC ELBOW #8MSTR #8MJIC ADAPTER #8MSTR #8MJIC (WAS ) ADPTR #8MSTR #8MJIC TEE-SWIVEL NUT RUN JIC.75 A/R TEE-SWIVEL NUT RUN JIC 16 CTR 8 A/R CAP SCR 5/16-18 X 2.5 SH PLAIN WASHER 3/8 FLAT WASHER 5/16 FLAT NUT 5/16-18 HEX NYLOC COIL REF SOLENOID VALVE REF NIPPLE-PIPE BLK 1 X COUPLING-BLK 1 1 REV. C

57 Chapter 3 Chassis Installation 55 Installation Kit, Hydraulic, Ford 4x2 MY2011 ( ) FROM TANK EX: TO CMPRSR T: TO TANK P: FROM PUMP PR: PRIORITY TO CRANE 55 6 DRIVER'S SIDE FRAME RAIL PARTS LIST ITEM PART # DESCRIPTION QUANTITY VALVE ASSEMBLY, PROP FLOW CONTROL, 1 10 PSI PTO (INCLUDES PUMP) NIPPLE-BARB STL 24 STR ADPTR-M STR/M JIC ADPTR-M STR/M JIC ELBOW-M STR/90/M JIC BRACKET-PRIORITY FLOW CONTROL 1 NEW

58 56 Dominator I Parts & Specifications Manual Part # Installation, DEF Tank Hoses on 2011 Ford F550 ( ) ELBOW-FPT/90/BARB POLY TO FILL NECK INSIDE OF BODY ELBOW-MPT/90/BARB POLY TO FUEL TANK OF CHASSIS ELBOW-BARB/90/BARB.75.75

59 Chapter 3 Chassis Installation 57 PTO Wiring Installation-2006 & 2007 ( ) Allison T1000/T2000 TCM with Single PTO (4th Generation) (2006-7) ( ) IGNITION 12V TO PTO GROUND SPLICE ( ) CHASSIS ELEC. INSTALL. INSTR. 1,2 3 3 PTO 5 E-BRAKE 80-PIN CONNECTOR ON T.C.M. WIRE 43 (143) GM (143) WIRE 50 (150) GM (104) NOTE: 1 Different chassis may have different codes for the TCM wire numbers. 2 TCM for Freightliner is behind the dash on the passenger side of the cab. Splice into appropriate wires at that location. 3 TCM for Sterling Actera is located under the cab. Use customer access Metripack connector located on the driver's side wheel well. Use cavity "F" for pin 43 and cavity "G" for pin 50. Use item #5 terminal to connect. 4 TCM for International 4300 and 4400 models is located under the cab. Use customer access Metripack connector located in the driver's side, upper wheel well. Use cavity "B" for wire 43 and cavity "C" for wire 50. Use item #5 terminal to connect and newer GM Transmission Connector (Located near upfitter connector in the engine compartment on the right side) Wire 143 = Pin C; Wire 104 = Pin K. ALLISON T1000/T2000 4th GEN SINGLE PTO WIRING PARTS LIST ITEM PART # DESCRIPTION QUANTITY FUSE HOLDER W/O FUSE FUSE-ATC 7.5 AMP RELAY TERMINAL, MP GA MALE DIODE SWITCH-ROCKER 1 NEW

60 58 Dominator I Parts & Specifications Manual Part # Allison T1000/T2000 TCM with Dual PTO (4th Generation) (2006-7) ( ) COMPRESSOR SWITCH TO PTO GROUND SPLICE (REF CHASSIS ELEC. INSTL. INSTRUCTIONS) 4 PTO SOLENOID IGNITION 12 V 6 CRANE SWITCH COMP RELAY PTO CMPRSR PTO 1, E-BRAKE 80-PIN CONNECTOR ON T.C.M. WIRE 43 (143) GM (143) WIRE 50 (150) GM (104) 3 4 CRANE RELAY PTO CRANE PTO NOTE: 1 Different chassis may have different codes for the TCM wire numbers. 2 TCM for Freightliner is behind the dash on the passenger side of the cab. Splice into appropriate wires at that location. 3 TCM for Sterling Actera is located under the cab. Use customer access Metripack connector located on the driver's side wheel well. Use cavity "F" for pin 43 and cavity "G" for pin 50. Use item #5 terminal to connect. 4 TCM for International 4300 and 4400 models is located under the cab. Use customer access Metripack connector located in the driver's side, upper wheel well. Use cavity "B" for wire 43 and cavity "C" for 50. Use item #5 terminal to connect and newer GM Transmission Connector (Located near upfitter connector in the engine compartment on the right side) Wire 143 = Pin C; Wire 104 = Pin K. ALLISON T1000/T2000 4th GEN DUAL PTO WIRING PARTS LIST ITEM PART # DESCRIPTION QUANTITY FUSE HOLDER W/O FUSE FUSE-ATC 7.5 AMP DIODE AMP/ 274 V RELAY TERMINAL, MP GA MALE SWITCH-ROCKER 2 NEW

61 Chapter 3 Chassis Installation 59 Allison T3000/T4000 TCM with Single PTO (4th Generation) (2006-7) ( ) IGNITION 12 V 1, TO PTO GROUND SPLICE (REF CHASSIS ELEC. INSTALL. INSTRUCTIONS) PTO E-BRAKE PIN 45 (145) 3 80 PIN CONNECTOR ON T.C.M. PIN 17 (117) PIN 3 (103) 3 NOTE: 1 Different chassis may have different codes for the TCM wire numbers. 2 TCM for Freightliner is behind the dash on the passenger side of the cab. Splice into appropriate wires at that location and newer GM Transmission Connector (Located near upfitter connector in the engine compartment on the right side) Pin 45 = Pin A; Pin 17 = Pin B; Pin 3 = Pin J ALLISON T3000/T4000 4th GEN SINGLE PTO WIRING PARTS LIST ITEM PART # DESCRIPTION QUANTITY FUSE HOLDER W/O FUSE FUSE-ATC 7.5 AMP RELAY TERMINAL MP GA DIODE AMP/ 274 V SWITCH-ROCKER 1 NEW

62 60 Dominator I Parts & Specifications Manual Part # Allison T3000/T4000 TCM with Dual PTO (4th Generation) (2006-7) ( ) COMPRESSOR SWITCH 7 IGNITION 12 V 1,2 4 3 E-BRAKE CRANE SWITCH COMP RELAY TO PTO GROUND SPLICE (REF CHASSIS ELEC. INSTL. INSTRUCTIONS) PTO SOLENOID 4 CMPRSR PTO 3 CRANE RELAY 4 CRANE PTO PIN 45 (145) 80 PIN CONNECTOR ON T.C.M. PIN 17 (117) 4 PIN 3 (103) NOTE: 1 Different chassis may have different codes for the TCM wire numbers. 2 TCM for Freightliner is behind the dash on the passenger side of the cab. Splice into appropriate wires at that location and newer GM Transmission Connector (Located near upfitter connector in the engine compartment on the right side) Pin 45 = Pin A; Pin 17 = Pin B; Pin 3 = Pin J ALLISON T3000/T4000 4th GEN DUAL PTO WIRING PARTS LIST ITEM PART # DESCRIPTION QUANTITY FUSE HOLDER W/O FUSE FUSE-ATC 7.5 AMP DIODE AMP/ 274 V RELAY TERMINAL, MP GA MALE REF SWITCH-ROCKER 2 NEW

63 Chapter 3 Chassis Installation 61 Allison T1000/T2000 TCM Freightliner - Single PTO (4th Generation) (2006-7) ( ) TO FREIGHTLINER HARNESS (BACK OF CAB) CONNECTION TO PTO SOLENOID CONNECTOR 200D 151T (PURPLE) GROUND (BLACK) 2 PIN CONNECTOR 1 80-PIN CONNECTOR ON T.C.M. E-BRAKE WIRE 43 (143) WIRE 50 (150) 1 PTO PTO PRESSURE SWITCH PTO ENGAGE (IMT HARNESS) (PURPLE) TO FREIGHTLINER HARNESS (BACK OF CAB) CONNECTION TO PTO PRESSURE SWITCH GROUND (BLACK) 2 PIN CONNECTOR ALLISON T1000/T2000 4th GEN FREIGHTLINER PTO WIRING PARTS LIST ITEM PART # DESCRIPTION QUANTITY RELAY DIODE AMP/ 274 V 2 NEW

64 62 Dominator I Parts & Specifications Manual Part # PTO Wiring Installation Through 2005 ( ) Allison T1000/T2000 TCM with Single PTO Through 2005 ( ) IGNITION 12V 1,2 SUPPLIED WITH PTO PTO LAMP PTO PRESS SWITCH 3 SWITCH 3 PTO 5 E-BRAKE GREY CONNECTOR ON TCM WIRE J1-06 WIRE J1-19 NOTE: 1 Different chassis may have different codes for the TCM wire numbers. 2 TCM for Freightliner is behind the dash on the passenger side of the cab. Splice into appropriate wires at that location. 3 TCM for Sterling Actera is located under the cab. Use customer access Metripack connector located on the driver's side wheel well. Use cavity "F" for wire J1-06 and cavity "G" for wire J1-19. Use item #4 terminal to connect. 4 TCM for International 4300 and 4400 models is located under the cab. Use customer access Metripack connector located in the driver's side, upper wheel well. Use cavity "B" for wire J1-06 and cavity "C" for J1-19. Use item #4 terminal to connect. 5 GM Transmission Connector (Located near upfitter connector in the engine compartment on the right side) Wire 106 = Pin B; Wire 119 = Pin J ALLISON T1000/T2000 SINGLE PTO WIRING PARTS LIST ITEM PART # DESCRIPTION QUANTITY FUSE HOLDER W/O FUSE FUSE-ATC 7.5 AMP RELAY TERMINAL, MP GA MALE DIODE, 2.2 AMP 1 REV. B

65 Chapter 3 Chassis Installation 63 Allison T1000/T2000 TCM with Dual PTO Through 2005 ( ) IGNITION 12V 1,2 4 3 E-BRAKE GREY CONNECTOR ON TCM SUPPLIED WITH PTO WIRE J1-06 WIRE J1-19 COMP. PTO LAMP COMPRESS SWITCH CRANE PTO LAMP CRANE SWITCH COMP RELAY 3 4 CRANE RELAY 4 PTO SOLENOID PTO COMPRESSOR PTO PTO CRANE PTO PTO PRESS SWITCH PTO PRESS SWITCH NOTE: 1 Different chassis may have different codes for the TCM wire numbers. 2 TCM for Freightliner is behind the dash on the passenger side of the cab. Splice into appropriate wires at that location. 3 TCM for Sterling Actera is located under the cab. Use customer access Metripack connector located on the driver's side wheel well. Use cavity "F" for wire J1-06 and cavity "G" for wire J1-19. Use item #5 terminal to connect. 4 TCM for International 4300 and 4400 models is located under the cab. Use customer access Metripack connector located in the driver's side, upper wheel well. Use cavity "B" for wire J1-06 and cavity "C" for J1-19. Use item #4 terminal to connect. 5 GM Transmission Connector (Located near upfitter connector in the engine compartment on the right side) Wire 106 = Pin B; Wire 119 = Pin J ALLISON T1000/T2000 DUAL PTO WIRING PARTS LIST ITEM PART # DESCRIPTION QUANTITY FUSE HOLDER W/O FUSE FUSE-ATC 7.5 AMP DIODE AMP RELAY TERMINAL, MP GA MALE 2 REV. B

66 64 Dominator I Parts & Specifications Manual Part # Allison T3000/T4000 TCM with Single PTO Through 2005 ( ) IGNITION 12V SUPPLIED WITH PTO 1,2 3 PTO LAMP PTO PRESSURE SWITCH 5 E-BRAKE SWITCH PTO PTO 3 PIN 2 GRAY CONNECTOR ON TCM PIN 30 PIN 31 3 NOTE: 1 Different chassis may have different codes for the TCM wire numbers. 2 TCM for Freightliner is behind the dash on the passenger side of the cab. Splice into appropriate wires at that location. 3 GM transmission connector (located near the GM upfitter connector in the engine compartment on the right side); Pin 2 = Pin A, Pin 30 = Pin B, Pin 31 = Pin J ALLISON T3000/T4000 SINGLE PTO WIRING PARTS LIST ITEM PART # DESCRIPTION QUANTITY FUSE HOLDER W/O FUSE FUSE-ATC 7.5 AMP RELAY TERMINAL, MP GA MALE 3 REV. B

67 Chapter 3 Chassis Installation 65 Allison T3000/T4000 TCM with Dual PTO Through 2005 ( ) IGNITION 12V 1,2 4 3 E-BRAKE SUPPLIED WITH PTO COMP. PTO LAMP COMPRESS SWITCH CRANE PTO LAMP CRANE SWITCH COMP RELAY CRANE RELAY 4 PTO SOLENOID 4 PTO PRESS SWITCH PTO COMPRESSOR PTO PTO CRANE PTO PTO PRESS SWITCH 3 PIN 2 GREY CONNECTOR ON TCM PIN 30 4 PIN 31 NOTE: 1 Different chassis may have different codes for the TCM wire numbers. 2 TCM for Freightliner is behind the dash on the passenger side of the cab. Splice into appropriate wires at that location. 3 GM transmission connector (located near the GM upfitter connector in the engine compartment on the right side); Pin 2 = Pin A, Pin 30 = Pin B, Pin 31 = Pin J 4 Use item #5 to connect. ALLISON T3000/T4000 DUAL PTO WIRING PARTS LIST ITEM PART # DESCRIPTION QUANTITY FUSE HOLDER W/O FUSE FUSE-ATC 7.5 AMP DIODE 2.2 AMP RELAY TERMINAL, MP GA MALE REF REV. B

68 66 Dominator I Parts & Specifications Manual Part # Allison T1000/T2000 TCM with Single PTO on Freightliner with PTO Dash Switch Through 2005 ( ) TO FREIGHTLINER HARNESS (BACK OF CAB) CONNECTION TO PTO SOLENOID CONNECTOR 200D 151T (PURPLE) GROUND (BLACK) 2 PIN CONNECTOR 1 E-BRAKE WIRE J1-06 WIRE J PTO PTO ENGAGE (IMT HARNESS) 2 PTO PRESSURE SWITCH (PURPLE) TO FREIGHTLINER HARNESS (BACK OF CAB) CONNECTION TO PTO PRESSURE SWITCH GROUND (BLACK) 2 PIN CONNECTOR GREY CONNECTOR ON TCM ALLISON T1000/T2000 TCM SINGLE PTO ON FREIGHTLINER WITH PTO DASH SWITCH ITEM PART # DESCRIPTION QUANTITY RELAY DIODE, 2.2 AMP 2 REV. B

69 Chapter 3 Chassis Installation 67 PTO/Pump Rotation Guide ( ) PTO ROTATION IS OPPOSITE OF ENGINE ROTATION (OPP) LOOKING AT PUMP SHAFT LOOKING AT REAR OF PUMP FRONT OF TRUCK P S S P CCW CW CW LOOKING FROM REAR OF TRUCK, PTO ROTATES CW LOOKING FROM FRONT OF TRUCK, PUMP / DRIVE EQUIPMENT ROTATES CCW LOOKING AT PUMP SHAFT LOOKING AT REAR OF PUMP S P P S FRONT OF TRUCK CW CCW CCW LOOKING FROM REAR OF TRUCK, PTO ROTATES CCW LOOKING FROM FRONT OF TRUCK, PUMP / DRIVE EQUIPMENT ROTATES CW PTO ROTATION IS THE SAME AS ENGINE ROTATION (ENG) NOTES: 1 The pump / driven equipment should always rotate in the opposite direction of the PTO. 2 A geared adapter will always change the rotation of the PTO.

70

71 69 C HAPTER 4 Compartment Options In This Chapter Compartment Layout ( )...69 Parts List, Shelves ( )...70 Installation Drawing, Shelves ( )...72 Installation Drawing, Door Trays ( )...74 Parts List, Drawer Units and Kits...75 Dominator I & II Drawer Set Reference Drawing...77 Drawer Components...78 Compartment Options...80 Tool Box Tray ( )...80 Tank Bracket, 2-Bottle ( )...82 Tank Bracket, 3-Bottle ( )...83 Slide Out Tray ( )...84 Pull-Out Bin Sets...85

72 70 Dominator I Parts & Specifications Manual Part # Compartment Layout ( ) LR LH LV3 LV2 LV1 SEE PARTS LIST CHART RH RV3 RV2 RV Compartment Key LR Left Rear LH Left Horizontal LV1 Left Vertical 1 LV2 Left Vertical 2 LV3 Left Vertical 3 RH Right Horizontal RV1 Right Vertical 1 RV2 Right Vertical 2 RV3 Right Vertical 3 NOTE: The Left and Right Vertical 3 compartments are only used on Dominator II 13' and 14' bodies COMPARTMENT LAYOUT PARTS LIST ITEM PART # DESCRIPTION QUANTITY 1. SEE CHART SHELF 1 2. SEE CHART SHELF END 1 3. SEE CHART SHELF END NUT HEX NYLOC (WAS ) CAP SCR.31-18X.75 HH (WAS ) WASHER.31 FLAT 18-8 (WAS ) 4 REV H

73 Chapter 4 Compartment Options 71 Parts List, Shelves ( ) COMPARTMENT LOCATION ITEM #3 - SHELF END ITEM #1 - SHELF ITEM #2 - SHELF END SHELF WIDTH (INCHES) SHELF DIVIDER ( ) SHELF KIT NUMBER LEFT VERT INCLUDED LEFT VERT 2-11' INCLUDED LEFT VERT 2-13' INCLUDED LEFT VERT 2-14' INCLUDED LEFT VERT 3-13' INCLUDED LEFT VERT 3-14' INCLUDED LEFT HORIZONTAL 11',13',14' INCLUDED LEFT HORIZONTAL 9' INCLUDED LEFT REAR INCLUDED RIGHT VERT INCLUDED RIGHT VERT INCLUDED RIGHT VERT 2-13' INCLUDED RIGHT VERT 2-14' INCLUDED RIGHT VERT 3-13' INCLUDED RIGHT VERT 3-14' INCLUDED RIGHT HORIZONTAL ',13',14' INCLUDED RIGHT HORIZONTAL 9' INCLUDED

74 72 Dominator I Parts & Specifications Manual Part # DIVIDER PANELS ITEM #3 - SHELF END 20" DIVIDER PANEL ( ) 40" TALL DIVIDER PANEL ( ) ITEM #1 - SHELF ITEM #2 - SHELF END SHELF WIDTH (INCHES) SHELF DIVIDER SHELF KIT NUMBER SHELVES INCLUDED (3) (4) " TALL DIVIDER PANEL ( ) REV. M

75 Chapter 4 Compartment Options 73 Installation Drawing, Shelves ( ) 1OR POSITION AND DRILL AT ASSEMBLY PARTS LIST ITEM PART # DESCRIPTION QUANTITY PANEL DIVIDER DOM ADJ SHELF 60"H (WAS ) PANEL DIVIDER DOM ADJ SHELF 44", 52" H 1 (WAS ) PANEL DIVIDER DOM ADJ SHELF 22"H 1 4. SEE CHART SHELF KIT DOM 1.50"H X SEE CHART SHELF KIT DOM 1.50"H X CAP SCR-SS.31-18X 1.00 HH AS REQ'D NUT-SS HEX NYLOC AS REQ'D WASHER-SS-BONDED PLTD.31 AS REQ'D REV. H

76 74 Dominator I Parts & Specifications Manual Part # Installation Drawing, Door Trays ( ) " TYP " TYP 5 6 3" 7 3" 1 3" 3" 3 3" 38.89" 31.88" 27.63" 26.5" 23.5" " 8.25" TYP 3" 3" A DETAIL A HARDWARE PER TRAY: (4 TYP) (4 TYP) DRILL AT ASSEMBLY. 20.5" 19" 19" NOTE: 1 Position all tray applications 3.0" above latch hole opening. Space all double tray applications 8.25" apart PARTS LIST ITEM PART # KIT # DESCRIPTION QUANTITY TRAY-TORCH DOM W-LATCH REF TRAY-SPRAY CAN DOM W DOOR REF TRAY-TORCH DOM W-LATCH REF TRAY-SPRAY CAN DOM W DOOR REF TRAY-SPRAY CAN DOM W DOOR REF TRAY-SPRAY CAN DOM W DOOR REF TRAY-SPRAY CAN DOM 23.5 W DOOR REF TRAY-SPRAY CAN DOM W DOOR REF TRAY-SPRAY CAN DOM W DOOR REF TRAY-WELDMENT TORCH DOM 19" W/LATCH REF NOTE: Not all trays are available on all models. Check the door widths on your model to determine appropriate options. REV. D

77 Chapter 4 Compartment Options 75 Parts List, Drawer Units and Kits LR LH LV3 LV2 LV1 CHASSIS CAB RH RV3 RV2 RV1 Compartment Key LR Left Rear RH Right Horizontal LH Left Horizontal RV3 Right Vertical 3 LV3 Left Vertical 3 RV2 Right Vertical 2 LV2 Left Vertical 2 RV1 Right Vertical 1 LV1 Left Vertical 1 NOTE: The Left and Right Vertical 3 compartments are only used on Dominator II 13' and 14' bodies. The body configuration determines the rollout drawer sets which can be used in each body. COMPARTMENT BODY LENGTH DRAWER SET WIDTH LEFT & RIGHT VERTICAL 1 9', 11', 13', 14' 26" Wide LEFT & RIGHT VERTICAL 2 11' & 13' 13" Wide 14' 26" Wide LEFT & RIGHT VERTICAL 3 13' & 14' 13" Wide LEFT & RIGHT 39" Wide HORIZONTAL LEFT REAR 13" Wide DRAWER SET WIDTH COMPARTMENT APPLICATION 13" WIDE LEFT & RIGHT VERTICAL 2-11' & 13' BODIES; LEFT & RIGHT VERTICAL 3-13' & 14' BODIES PART # 3" HIGH DRAWERS 5" HIGH DRAWERS 7" HIGH DRAWERS " " " " " " " " " " " " " " 26" WIDE LEFT & RIGHT VERTICAL 1; LEFT & RIGHT VERTICAL " DRAWER SET OVERALL HEIGHT

78 76 Dominator I Parts & Specifications Manual Part # DRAWER SET WIDTH COMPARTMENT APPLICATION - 13' & 14' BODIES 39" WIDE LEFT & RIGHT HORIZONTAL COMPARTMENTS PART # 3" HIGH DRAWERS 5" HIGH DRAWERS 7" HIGH DRAWERS " " " " " " " " " " " " " " " DRAWER SET OVERALL HEIGHT

79 Chapter 4 Compartment Options 77 Dominator I & II Drawer Set Reference Drawing SAMPLE DRAWER SET DRAWING WITH 3", 5", AND 7" HIGH DRAWERS SAMPLE DRAWING WITH 3" DRAWERS ONLY HEIGHT WIDTH RISER HEIGHT 3.0" DEPTH NOTE: 1 Complete drawer set part numbers are included in Parts List, Drawer Units and Kits. 2 The quantity of items 1-5, panels, risers, and shelves, is 1 per drawer set. 3 The quantities of items 6-11, slides and drawers, are based on the number of drawers in the complete kits. drawer slides.

80 78 Dominator I Parts & Specifications Manual Part # ITEM DESCRIPTION 13" SET 26" SET 39" SET 1. PANEL-SIDE, LH REF REF REF 2. PANEL-SIDE, RH REF REF REF 3. RISER SHELF PANEL-DRAWER BACK REF REF REF 6. DRAWER SLIDE W-TABS LH DRAWER SLIDE W-TABS RH SHELF-ADJUSTABLE END " DRAWER " DRAWER " DRAWER

81 Chapter 4 Compartment Options 79 Drawer Components SAMPLE DRAWING - DRAWER WITH 4 DIVIDERS 1 (DIVIDER) 4 (LOCK) SAMPLE DRAWING - DRAWER WITH CENTER AND SIDE DIVIDERS 3 (DIVIDER-HEMMED) 1 (DIVIDER) 2 (DIVIDER-CENTER) 4 (LOCK) NOTE: 1 All drawers are painted. 2 Each IMT drawer comes with the standard lock Optional replacement drawer lock sets are available for IMT drawers. Replacement lock sets and can be ordered from IMT customer service. DRAWER PART # DRAWER WITH DIVIDER DIMENSIONS DRAWER COMPONENT PART NUMBERS (QUANTITY IN PARENTHESES) ITEM 1-DIVIDER ITEM 2- DIVIDER, CENTER ITEM 3- DIVIDER, HEMMED " H X 13" W (4) " H X 13" W (4) " H X 13" W (4) " H X 26" W (6) (2) " H X 26" W (6) (2) " H X 26" W (6) (2) " H X 39" W (9) (2) (2) " H X 39" W (9) (2) (2) " H X 39" W (9) (2) (2)

82 80 Dominator I Parts & Specifications Manual Part # Compartment Options Part # Dimensions / Description Compartments Available Roll-out Tool Box Tray Tray dimensions 32"W x 18.5"D LV1, LV2, RV1, RV2 Oxygen / Acetylene Tank Bracket Tank bracket Oxy/Acet 3 tanks with hook LV1, RV Tank bracket Oxy/Acet 2 tanks with hook (Mounted on front wall in vented compartment) LV1, RV1 Pull-out Drawer Sets drawer set with base 18"D x 8.12"W x 19"H LV1, LV2, LV3, RV1, RV2, RV3, LH, RH, LR drawer set with base 18"D x 8.12"W x 23"H LV1, LV2, LV3, RV1, RV2, RV3, LR bolt drawer set w/base 18"D x 16.25"W x LV1, LV2, LV3, RV1, RV2, RV3, LR 35.5"H bolt drawer set w/base 18"D x 16.25"W x LV1, LV2, LV3, RV1, RV2, RV3, LR 39.5"H drawer set with base 18"D x 8.12"W x 11"H LV1, LV2, LV3, RV1, RV2, RV3, LH, RH, LR Slide-out Parts Book Tray Slide out parts / book tray LH, RH Bookshelf Bookshelf dimensions 8"H x 45"L x 12"D RH, LH Bookshelf dimensions 8"H x 26"L x 12"D RH, LH Note: Left Vertical Compartment 3 (LV3) and Right Vertical Compartment 3 (RV3) are only available on Dominator I and II 13' and 14' models, and may not be available on your model. Check your product specifications.

83 Chapter 4 Compartment Options 81 Tool Box Tray ( ) 2,5,6,8 1 3,5,6,7 4,5,6,8 9,10, PARTS LIST ITEM PART # DESCRIPTION QUANTITY TRAY 16-3/4 X MTG BRACKET 32" MTG BRACKET DRAWER SLIDE NUT #10-24 LOCK WASHER #10 WRT MACH SCR #10-24 X 5/8 FLHD MACH SCR #10-24 X 5/8 RDHD CAP SCR 5/16-18X3/4 BTNHD WASHER 5/16 WRT NUT 5/16-18 LOCK 4 REV. A

84 82 Dominator I Parts & Specifications Manual Part # Tank Bracket, 2-Bottle ( ) 6,7,10 (4 PLCS) 4,5,6 (6 PLCS) PARTS LIST ITEM PART # DESCRIPTION QUANTITY HOOK-WLDMT (J) (BOLT IN) BRACKET ACET BOTTLE BRACKET OXY BOTTLE WASHER.25 FLAT CAP SCR.31-18X 1.00 HH GR5 Z NUT HEX NYLOCK WASHER.31 FLAT STRAP-36" BOTTLE HOLDER W/ SNAP HOOK CHAIN CONNECTOR-THREADED CAP SCR.31-18X.75 HH GR5 Z 4 REV A

85 Chapter 4 Compartment Options 83 Tank Bracket, 3-Bottle ( ) Reference the drawing for the Tank Bracket, 2-Bottle. The Tank Bracket, 3-Bottle, has an additional bracket for the oxygen bottle PARTS LIST ITEM PART # DESCRIPTION QUANTITY HOOK-WLDMT (J) (BOLT IN) BRACKET ACET BOTTLE BRACKET OXY BOTTLE WASHER.25 FLAT CAP SCR.31-18X 1.00 HH GR5 Z NUT HEX NYLOCK WASHER.31 FLAT STRAP-36" BOTTLE HOLDER W/ SNAP HOOK CHAIN CONNECTOR-THREADED CAP SCR.31-18X.75 HH GR5 Z 4 REV

86 84 Dominator I Parts & Specifications Manual Part # Slide Out Tray ( ) 10 9 SEE VIEW A-A 1 B-B B-B (RIGHT SIDE ONLY) 4,5,6,7 8 VIEW B-B 5,6,8,11 VIEW A-A PARTS LIST ITEM PART # DESCRIPTION QUANTITY SHELF MOUNTING BRACKET, HORIZONTAL (RIGHT 1 HAND) SPACER-HORIZ BOOK TRAY LATCH-COMPRESSOR GATE CAP SCR X1 HHGR5Z NUT X HEX NYLOC ZINC WASHER 0.31 LOCK ZINC WASHER 0.31 W FLAT SHELF - ADJ BRACKET-MOUNTING (LEFT HAND) 1 REV. A

87 Chapter 4 Compartment Options 85 Pull-Out Bin Sets Pull-out bins are available for IMT Dominators in sets of 2, 4, 5, 16, and 18 units. BIN SET PARTS LISTS # BINS / QUANTITY ITEM PART # DESCRIPTION 2-BINS ( ) 4-BINS ( ) CABINET (2-BIN SET) CABINET (4-BIN SET) 1 5-BINS ( ) 16-BINS ( ) CABINET (5-BIN SET) CABINET (16-BIN SET) CABINET (18-BIN SET) BIN DIVIDER 3.38X CAP SCR 1/4-20X3/4 HHGR NUT 1/4-20 LOCK WASHER 1/4 WRT Bin Set with Base ( ) 3 18-BINS ( ) 1 2 ITEMS 4,5,6 NOT SHOWN

88 86 Dominator I Parts & Specifications Manual Part # Bin Set with Base ( ) 3 5-Bin Set with Base ( ) 3 2 ITEMS 4-7 NOT SHOWN ITEMS 4,5,6 NOT SHOWN Bin Set with Base ( ) 18-Bin Set with Base ( ) ITEMS 4,5,6 NOT SHOWN 1 ITEMS 4,5,6 NOT SHOWN 1

89 87 C HAPTER 5 Tailgate & Bumper Options In This Chapter Tailgate Assembly ( )...87 Tailgate - Workbench ( )...90 Bumper Hitch & Workbench Options...91

90 88 Dominator I Parts & Specifications Manual Part # Tailgate Assembly ( ) 1 9, , ,13,14 TO EXISTING HOLES IN BODY TAILGATE ASSEMBLY 3 BOTTOM SPRING CONNECTION TAILGATE INSTALLATION 12,13,14 TO EXISTING HOLES IN BODY 15 INSTALLATION NOTES: 1 INSTALL ROD WELDMENT #2 INTO PANEL #3 SLOTS. 2 CONNECT SPRING #7 BETWEEN PANEL #3 BRACKET AND ROD #2 BRACKET. 3 JOIN PANEL #1 OVER PANEL #3. 4 CONNECT PANEL #1 TO PANEL #3 WITH RIVET #6. 5 INSERT LOWER MOUNTING PIN OF MOUNTING BRACKETS #17 AND #18 INTO LOWER HOLE OF ASSEMBLED TAILGATE. 6 BOLT ASSEMBLY TO REAR OF BODY. 7 CABLE #15 WILL SHARE THE TOP MOUNTING HOLE IN BRACKETS #17 AND #18. ATTACH THE OTHER END OF CABLE TO THE TOP END OF THE TAILGATE TO HOLD THE TAILGATE PARALLEL TO THE CARGO FLOOR PARTS LIST ITEM PART # DESCRIPTION QUANTITY TAILGATE WELDMENT REAR COVER TAILGATE WELDMENT LATCH ROD TAILGATE WELDMENT FRONT COVER RIVET-ALUMINUM.257 DIA X.38 GRIP SPRING-COMPRESSION.50 X 3.50 X 14GA BRACKET, TAILGATE REAR COVER WASHER.25 FLAT (WAS ) CAP SCREW X.75 HH GR5Z (WAS ) NUT HEX NYLOC (WAS ) WASHER.38 FLAT (WAS SS) CAP SCREW.38-16X 1.25 HHGR5Z (WAS ) 4

91 Chapter 5 Tailgate & Bumper Options PARTS LIST NUT HEX NYLOC (WAS ) CABLE, PLASTIC COATED TAILGATE POST WELDMENT, RH TAILGATE POST WELDMENT, LH 1 REV. F 2007

92 90 Dominator I Parts & Specifications Manual Part # Tailgate - Workbench ( ) DETAIL A " 58.75" A 7.06" 2" 4.88" 53.32" NOTES: 1 PLUG STANDARD UPPER HOLE FOR GRAB HANDLE WITH PLUG # (QTY 2). 2 GRAB HANDLE WILL BE ROTATED TO BE STRAIGHT UP AND DOWN. DRILL NEW UPPER HOLE FOR GRAB HANDLE. 3 PLUG HOLES FOR STANDARD SLAM TAILGATE WITH PLUG # (QTY 4).

93 Chapter 5 Tailgate & Bumper Options PARTS LIST ITEM PART # DESCRIPTION QUANTITY MTG ANGLE-TAILGATE SUPPORT ROD-WORKBENCH SUPPORT TUBE-WORKBENCH SPACER-POL.52X 1.50X TAILGATE-WORKBENCH-WLDMT 12inH WASHER.50 FLAT NUT HEX NYLOCK CAP SCR.50-13X 2.50 HH GR5 Z CAP SCR.50-13X 1.50 HH GR5 Z CAP SCR.50-13X 2.75 HH GR5 Z LATCH-END GATE LEFT HAND LATCH-END GATE RIGHT HAND BODY WELD DRAWING REF NEW

94 92 Dominator I Parts & Specifications Manual Part # Bumper Hitch & Workbench Options Dominator I/DSC20 Bumper Hitch & Workbench Options PART NUMBER DESCRIPTION NOTES Pintle ball combination with 2" removable ball for hitch receiver mounting Hitch for hitch receiver mounting Vise mounting bracket Can be located on RH side, LH side, or both with quantity of Note: See drawing for installation instructions Combination vise, 5" Can be located on RH side, LH side, or both with quantity of Vise plate, weld-on 12" x 12" Can be located on RH side, LH side, or both with quantity of 2 x 1/2" Pintle hitch mount

95 93 C HAPTER 6 Air System Options In This Chapter Air Tank Options...93 Air Tank Kit, 22.5 Gallon ( )...94 Air Tank Kit, 35 Gallon ( )...95 Air Tank Kit, 58 Gallon ( )...97 Air Tank Drain Assembly ( )...98 Air Tank Kit, 28 Gallon ( ) Air Tank Drain Assembly ( ) Air Tank Kit, 22 Gallon ( ) Air Tank Kit, Dual 10 Gallon ( ) Stepless Ear Clamp Installation ( ) Moisture Separator / Regulator / Oiler Assembly ( ) Moisture Separator / Regulator / Oiler Parts ( ) Moisture Separator / Regulator / Oiler Installation Hose Reel ( ) Air Tank Options PART # DESCRIPTION LOCATION Air Tank Kit, 22.5 Gal Mount between the frame for all units Air Tank Kit, 2-15 Gal (30 Mount between the frame at the rear of the body. Gal Total) Air Tank Kit, 22 Gal Mount on one side parallel to driveshaft Air Tank Kits, 2-15 Gal Mount one on each side of frame. Tanks Air Tank Kit, 35 Gal Mount on top of street side compartments Air Tank Kit, 58 Gal Mount on top of street side compartments.

96 94 Dominator I Parts & Specifications Manual Part # Air Tank Kit, 22.5 Gallon ( ) (4) 11 SEE NOTE 2 5 SEE NOTE (2) 16(4) 2 4 9(12) TO FRONT 8(4) PARTS LIST ITEM PART # DESCRIPTION QUANTITY DRAIN ASM (INCL:1) AIR TANK 22-1/2 GALLON ADAPTER 1/4MPT 1/4MPT HEX STREET ELBOW 3/4NPT TEE 1/ CAP SCR 1/2-13X1-1/2 HHGR5 (WAS ) NUT 1/2-13 LOCK WASHER 1/2 WRT REDUCER BUSHING 1-1/4X3/4NPT HOSE FTG TYPE O 1/4 1/ SAFETY VALVE 1/4 200PSI DECAL-DANGER EXPLODING TANK BRACKET SPRING CAP SCR 1/2-13X3-1/4 HHGR5 4 REV. J

97 Chapter 6 Air System Options 95 Air Tank Kit, 35 Gallon ( ) 4 7-REARWARD 1/4"FITTING 5-FORWARD 1/4"FITTING CURB SIDE 14-DRIVER SIDE FORWARD 1/4"FITTING 18-REARWARD 1/4"FITTING THESE TWO(2) CLAMPS USE THE SAME #

98 96 Dominator I Parts & Specifications Manual Part # NOTES: 1 ITEMS ARE USED TO SECURE TANK (#1) TO BRACKET (#4), AND BRACKET TO BODY. 2 ITEMS ARE USED TO SECURE CLAMP (#12) TO BODY. 3 ITEM 28 AND ONE OF ITEM 9 MAY NOT BE REQUIRED, OR MAY REPLACE ITEMS 14 & PARTS LIST ITEM PART # DESCRIPTION QUANTITY TANK-AIR 35 GAL X DECAL-AIR TANK DRAIN DECAL-DANGER EXPLODING TANK BRACKET-AIR TANK 58 GAL MECH PLUG-PIPE SQ HD BLK PLUG-PIPE SOC HD GLV VALVE-SAFETY PSI REDUCER BUSH-BLK ELBOW-STREET BLK.75 X 90 DEG NIPPLE-BARB BRS.75 MPT CLAMP-.75 STEPLESS EAR (WAS ) CLAMP-UMP20 S464-G HOSE-GP.75 X #300 WP (GRAY) 31' ELBOW-STREET BLK.75 X NIPPLE-PIPE BLK.75 X CLOSE VALVE-BALL HOSE FTG-TYPE O STL GAUGE-PRESSURE AIR 300# ELBOW-STREET BLK.25 X CAP SCR X 1.00 HH GR5 ZINC WASHER.25 W FLAT ANSI B27.2Z NUT HEX NYLOC ZINC CAP SCR X 1.25 HH GR5 ZINC WASHER.38 W FLAT ANSI B27.2Z NUT HEX NYLOC ZINC CAP SCR X 1.00 HH GRD5 ZINC WASHER-BONDED PLTD NIPPLE-PIPE BLK.75 X REV. C REV. B

99 Chapter 6 Air System Options 97 Air Tank Kit, 58 Gallon ( ) ,18,19, 20,21, TO FLR 14,15, ,18,19, 20,21,22 TO COMPRESSOR NOTE: 1 LOCATE DECAL #24 AS CLOSE TO DRAIN VALVE AS POSSIBLE, IN CLEAR VIEW OF OPERATOR PARTS LIST ITEM PART # DESCRIPTION QUANTITY TANK-AIR 58 GAL BRACKET-AIR TANK 58 GAL MECH GAUGE-PRESS AIR 300# BTM MNT REDUCER BUSH-BLK TEE-BLK HOSE HTG-TYPE O STL NIPPLE-PIPE BLK.75 X CLOSE REDUCER BUSH-BLK VALVE-SAFETY PSI CAP SCR X 1.00 HH GR5 Z NUT HEX ZINC WASHER.38 W FLAT AHSI B27.2Z WASHER.38 LOCK ZINC 12

100 98 Dominator I Parts & Specifications Manual Part # PARTS LIST ITEM PART # DESCRIPTION QUANTITY DRAIN ASM-AIR TANK UNDER DECK CLAMP-HOSE VINYL COVERED RIVET-POP AL.12 X.375 GRIP HOSE-GP.75 X 300# WP (GRAY) 31 FT CLAMP-HOSE VINYL COVERED CAP SCR X.75 HH GR5 Z WASHER.25 LOCK ZINC WASHER.25 W FLAT ANSI B27.2Z NUT HEX ZINC CLAMP-.75 STEPLESS EAR (WAS ) DECAL-DANGER EXPLODING TANK 1 REV. C REV. B

101 Chapter 6 Air System Options 99 Air Tank Drain Assembly ( ) TO AIR TANK DRAIN ,9,10 11, PARTS LIST ITEM PART # DESCRIPTION QUANTITY MOUNTING BRACKET, 3/4 AIR TANK DRAIN NIPPLE-PIPE BLK 3/4XCLOSE WASHER-FLAT 1" COUPLING-STL 3/4 HEX ELBOW-STREET STL 3/4 X NIPPLE-BARB BRS 3/4 MPT CAP SCR 5/16-18X1 HHGR NUT 5/16-18 HEX NYLOC WASHER 5/16 FLAT HOSE-GP 3/4X300# WP 10' VALVE-BALL 3/ DECAL-AIR TANK DRAIN CLAMP-.75 STEPLESS EAR (WAS ) RED BUSHING-STL 3/4-1/ MUFFLER-AIR 1/2" NPT 1 REV. J

102 100 Dominator I Parts & Specifications Manual Part # Air Tank Kit, 28 Gallon ( ) ,13,14 CROSS-CHASSIS FRAME AIR OUT 14,10 TO SALVAGE KIT TO DRAIN ASSEMBLY 2 AIR IN 14, , ,11,12 NOTE: LOCATE DECAL AS CLOSE TO DRAIN VALVE AS POSSIBLE-IN CLEAR VIEW OF OPERATOR PARTS LIST ITEM PART # DESCRIPTION QUANTITY DRAIN ASM BRACKET ROD 3/8-16 X AIR TANK, 28 GAL PIPE NIPPLE 1/2 NPT STREET ELBOW 3/8 NPT RED BUSHING PIPE PLUG 3/4 NPT SH BARB NIPPLE 3/4 MPT 3/4 HOSE STREET ELBOW 3/4 NPT NUT 3/8-16 LOCK WASHER 3/8 FLAT STREET ELBOW 1/4 NPT RED BUSHING 1-1/4 3/ CAP SCR 3/8-16 C 3.5 HHGR SAFETY VALVE 1/4 NPT 200 PSI DECAL-DANGER AIR TANK 1 REV. A

103 Chapter 6 Air System Options 101 Air Tank Drain Assembly ( ) 2 TO AIR TANK DRAIN TO AIR TANK DRAIN NOTE: 1 ITEM #13, DECAL, NOT SHOWN. PLACE DECAL AS CLOSE TO DRAIN VALVE AS POSSIBLE, IN CLEAR VIEW OF OPERATOR PARTS LIST ITEM PART # DESCRIPTION QUANTITY MTG. BRKT.-3/4 AIR TANK DRAIN NIPPLE-PIPE BLK.75X CLOSE WASHER-FLAT 1.00 (AS NEEDED) ELBOW-STREET BLK..75 X 90 DEG COUPLING-BLK ELBOW-STREET STL..75 X 90 DEG NIPPLE-BARB BRS..75 MPT CAP SCR X 1.00 HH GR NUT HEX NYLOC ZINC WASHER.31 W FLAT ANSI B27.2Z HOSE-GP.75X300# WP (GRAY) 10 FT VALVE-BALL DECAL-AIR TANK DRAIN CLAMP-.75 STEPLESS EAR (WAS ) TEE-BLK.75 1 REV. A

104 102 Dominator I Parts & Specifications Manual Part # Air Tank Kit, 22 Gallon ( ) 24 FROM COMPRESSOR TO FILTER/ REGULATOR/ LUBRICATOR " FOR 84" CAB TO AXLE 13 TYP (2) 16 TYP (2) 17 TYP (4) (HARDWARE NOT SHOWN) 12 PART OF #1 REAR OF CAB 4 CHASSIS DRIVELINE SUPPORT BRACKET 1999 FORD SUPER DUTY FRAME (F350, F450, F550) 2 15 TYP (3) 22 TYP (3) 18 TYP (6) 13 TYP (4) 16 TYP (4) 17 TYP (8) 3TYP(2) NOTES: 1 INSTALLATION SHOWN ON 84" C.A. CHASSIS. 2 THREE MOUNTING HOLES ARE EXISTING HOLES IN THE CHASSIS FRAME. 3 THE TANK WILL SIT COMPLETELY BEHIND THE REAR OF THE CAB, ONCE MOUNTED. 4 FOR A 60" C.A. CHASSIS, THE TANK WILL HANG UNDER THE CHASSIS APPROX. 2'. HOLES WILL NEED TO BE DRILLED FOR THIS INSTALLATION.

105 Chapter 6 Air System Options THE AIR TANK MOUNTING BRACKET (#4) ATTACHES TO THE CHASSIS DRIVELINE SUPPORT BRACKET. (TWO HOLES ARE PROVIDED IN THE CHASSIS DRIVELINE SUPPORT BRACKET.) PARTS LIST ITEM PART # DESCRIPTION QUANTITY DRAIN ASM (NOT SHOWN) BRACKET BRACKET BRACKET TANK-22 GAL DECAL-DANGER EXPLODING TANK REDUCER BUSHING 3/8-1/4NPT BARB NIPPLE 3/4MPT 3/4HOSE STREET ELBOW 3/4NPT HARDWARE KIT (INCL ) REDUCER BUSHING 1-1/4-3/4NPT CAP SCR 3/8-16X1-1/2 HHGR5 (PART OF 11) CAP SCR 9/16-12X2 HHGR8 (PART OF 11) NUT 3/8-16 LOCK (PART OF 11) WASHER 3/8 WRT (PART OF 11) WASHER 9/16 WRT (PART OF 11) NUT 9/16-12 HEX TOP LOCK GR8Z (PART OF 2 11) CLAMP-.75 STEPLESS EAR (WAS ) SAFETY VALVE 1/4NPT 200PSI HOSE 3/4 300PSI 20FT ELBOW-STREET STL 1/4X90 (NOT SHOWN) 2 REV. F

106 104 Dominator I Parts & Specifications Manual Part # Air Tank Kit, Dual 10 Gallon ( ) TOP HOLES ONLY. CLIP INTO CHASSIS CAB TOP HOLES USED FOR MOUNTING RUNNING BOARDS ,23,24 21,22 23 FASTEN TO RUNNING BOARD MOUNTING POINT UNDER CHASSIS ROCKER PANEL #5 ATTACHES TO THREADED SEAT BELT STUD, USING #13 (TYP 2) 9 TO FRL (REF) TO OTHER TANK DRAIN TO COMPRESSOR 8 10 TO OTHER TANK DRAIN TO TANK DRAIN (REF )

107 Chapter 6 Air System Options PARTS LIST ITEM PART # DESCRIPTION QUANTITY AIR TANK 10 GAL STRAP-AIR TANK 10 GAL BRACKET LH BRACKET RH BRACKET-STRAP NIPPLE-PIPE BLK 3/4 X CLOSE 1REF TEE STL 3/ ELBOW-STREET STL 3/4 X NIPPLE-BARB STL 3/4 MPT 3/ CLAMP-.75 STEPLESS EAR (WAS ) 8REF ADPTR 3/4MPT 3/4MPT HEX NUT METRIC 12MM CENT LOCK 2REF ELBOW-STREET STL 1.00 X NIPPLE-BARB STL 1.00 MPT HOSE-AIR 1.00 X RED ORTAC SAFETY VALVE 1/4 200 PSI CAP SCR 3/8-16 X 1.50 HH GR5 Z 8REF NUT 3/8-16 HEX NYLOC ZINC 24REF WASHER 3/8 FLAT 48REF CAP SCR 3/8-16 X 1.25 HH GR5 Z 16REF CAP SCR 5/16-18 X 1.00 HH GR5 Z 2REF NUT 1/4-20 HEX NYLOC ZINC 2REF WASHER 5/16 FLAT 4REF CLIP-BODY SPEED NUT 3/8-16 8REF REV. A

108 106 Dominator I Parts & Specifications Manual Part # Stepless Ear Clamp Installation ( ) INSTALLING A STEPLESS EAR CLAMP When there is sufficient room, use standard jaw pincers to position a properly-sized ear clamp on a hose fitted with a hose stem. Close ear clamp fully with uniform force until there is only a 1/16" gap remaining. The visible deformation of the clamp ear provides a visible, instant check that the closure is complete. INSTALLING A STEPLESS EAR CLAMP IN RESTRICTED SPACE When space is restricted, use side jaw pincers held parallel to the hose to position and clamp a properly-sized ear clamp on a hose fitted with a hose stem. Close ear clamp fully with uniform force until there is only a 1/16" gap remaining. The visible deformation of the clamp ear provides a visible, instant check that the closure is complete. REMOVING A STEPLESS EAR CLAMP To remove a stepless ear clamp, grasp the strip end with a pincer and pull it away. NOTE: Stepless ear clamps can only be used once. When removed, they must be discarded and replaced with new clamps.

109 Chapter 6 Air System Options 107 Moisture Separator / Regulator / Oiler Assembly ( ) NOTE: 1 When installing fittings, seal threads with Pro Lock pipe sealant with teflon (#51464) or equivalent. This sealant is a low strength anaerobic paste. Thread tape is not acceptable PARTS LIST ITEM PART # DESCRIPTION QUANTITY AIR PRESSURE GAUGE 300PSI MOISTURE SEP/REG/OILER STREET ELBOW 3/8NPT 45 BRASS REDUCER BUSHING 1/2-1/4NPT BRS STREET ELBOW 1/4NPT 90 SHORT TEE 3/8NPT BRS RUN TEE 1/2NPT BRS RUN REDUCER BUSHING 3/8-1/4NPT BRS BARB NIPPLE 1/2MPT 3/4NPT 90 4

110 108 Dominator I Parts & Specifications Manual Part # PARTS LIST QUICK DISCONNECT 3/8MPT 1/4DIS CAP SCR, SS 1/4-20 X 1/2 HH * WASHER, SS 1/4 LOCK * T X5 2MIL ZIPLOC BAG * 4 * NOT SHOWN REV. B Moisture Separator / Regulator / Oiler Parts ( ) KIT-JOINER SET & T-BRACKET (TYP 2) SIGHT DOME ASM FILTER, COMPLETE PLUG, FILL W/O-RING LUBRICATOR, AIR, COMPLETE BOWL O-RING REGULATOR, COMPLETE BOWL O-RING COMPONENT PART ASSEMBLIES: FILTER REPLACEMENT PARTS INCLUDE ELEMENT KIT (5-MICRON ELEMENT, ELEMENT RETAINER, DEFLECTOR, AND BOWL O-RING) AND ELEMENT (5-MICRON ELEMENT ONLY) AIR REGULATOR REPLACEMENT PARTS INCLUDE DIAPHRAGM KIT AND SPRING, AIR REGULATOR LUBRICATOR REPLACEMENT PARTS INCLUDE BY-PASS KIT, WHICH INCLUDES MODULE, CHECK BALLS, ELASTOMER, AND GASKET.

111 Moisture Separator / Regulator / Oiler Installation Chapter 6 Air System Options 109

112 110 Dominator I Parts & Specifications Manual Part # Hose Reel ( ) PARTS LIST ITEM PART # DESCRIPTION QUANTITY HOSE REEL STREET ELBOW, STL 1/2X90 (WAS ) PIPE CAP 1/2NPT CAP SCR 3/8-16X1 SS (WAS ) 4REF NUT SS 3/8-16 LOCK (WAS ) 4REF WASHER 3/8 WRT (WAS ) 8REF HOSE CLAMP (WAS QTY 2) 4REF BARB NIPPLE 1/2MPT 3/4HOSE (WAS QTY 2) HOSE 3/4 300# 36" HOSE GUIDE & ROLLER ASM BOLT, STV SS #10-24X3/4 FLH (WAS 4REF ) NUT SS #10-24 LOCK (WAS ) 4REF HARDWARE KIT, HOSE REEL (INCL. 4-7,11,12) REF REV

113 111 C HAPTER 7 Telescoping Tops Telescopic Top Installation ( ) (6 PLCS) 27, , ,27,28 (8 PLCS) HEIGHT ABOVE SIDEPACK' WHEN ROOF IS RETRACTED: 18.25" FOR 43" ROOF 0.99" FOR 26" ROOF 1 (8 PLCS) 5,6 (2 PLCS) 16 8 (8 PLCS) 24,25 (2 PLCS) 7 (8 PLCS) 8 (2 PLCS) , 27, 28 (QUANTITY VARIES) (TWO SIDES) 26, 27, 28 (4 PLCS) NOTE: FOR ASSEMBLIES WITH SWING UP DOORS, REAR POST IS FLUSH WITH BACK OF SIDEPACK (2) , 24(2), 26 (6 PLCS) NOTE: THE COMPLETE ASSEMBLY DETAIL IS FOR THE 43" HIGH VERSION AND ITS ASSOCIATED "SWING" DOORS. VIEW ABOVE DETAILS THE 26" HIGH VERSION WITH SWING-UP DOOR. NOTE: FOR ASSEMBLIES WITH SWING OUT DOORS, REAR POST IS 0.9" BEHIND BACK OF SIDEPACK. SECURE POST ON CRANE BOX SIDE WITH ITEMS #22, 24, 26.

114 112 Dominator I Parts & Specifications Manual Part # PARTS LIST ITEM PART # DESCRIPTION QUANTITY ROLLER HINGE-SS 10GA BUTT LATCH ASM-3PT COMPRESSION BUMPER-RUBBER 1.25 DIA X NUT HEX KIT CAP SCR.38-16X 2.00 HH GR5ZC KIT SCR-MACH.25-20X.75TRHTORXSS KIT NUT-SS NYLOC KIT PIN-QUICK RLSE.50D/1.5 W/ 12inL SCR-THRD.CUT.31-18X.75 HWH-1 KIT 11. #11 (SEE CHART) ANGLE-T TOP FRONT FILLER #12 (SEE CHART) SPACER REAR POST 43 H #13 (SEE CHART) BRACKET-SIDE T TOP WLDMT #14 (SEE CHART) BRACKET-SIDE T TOP WLDMT #15 (SEE CHART) TRACK-T TOP LOWER RFLR #16 (SEE CHART) TOP-TELESCOPE REAR SECT #17 (SEE CHART) TOP-TELESCOPE CTR SECT #18 (SEE CHART) TOP-TELESCOPE FRT SECT #19 (SEE CHART) TRACK-T TOP LOWER LFRR #20 (SEE CHART) TRACK-T TOP UPPER LID-ASSEMBLY RIVET-POP AL.12 X.375 GRIP KIT SCR-MACH 10-24X 1.50 RDH KIT NUT HEX NYLOCK KIT WASHER.19 W FLAT ANSI B27.2Z KIT NUT HEX NYLOCK KIT WASHER.31 FLAT KIT CAP SCR.31-18X 1.00 HH GR5 Z KIT CAP SCR.31-18X 1.25 HH GR5 Z KIT 30. #30 (SEE CHART) DOOR-TEL TOP WLDMT FLIP UP DOOR #31 (SEE CHART) PANEL T-TOP REAR POST LR #33 (SEE CHART) DOOR-TEL TOP WLDMT W-SWING WO-LTCH #34 (SEE CHART) DOOR-TEL TOP WLDMT W-SWING W-LTCH #35 (SEE CHART) ROD-DOOR W/.75" OFFSET TOP #36 (SEE CHART) ROD-DOOR W/ 2.75" OFFSET BOTTOM DOOR CATCH-ASM ZINC 4" 2 PC #38 (SEE CHART) PANEL T-TOP REAR POST RR 1 REV. E

115 Chapter 7 Telescoping Tops 113 TELESCOPING TOP COMPONENT KIT INFORMATION MODEL 9' L 26" H 9' L 43" H 11' L 26" H 11' L 43" H 13' L 26" H 14' L 26" H 14' L 43" H ITEM DESCRIPTION PART # ANGLE #11 N/A N/A N/A N/A SPACER #12 N/A N/A N/A N/A MTG BRACKET-SIDE # MTG BRACKET-SIDE #14 N/A N/A N/A N/A N/A TRACK-LOWER #15 N/A N/A N/A N/A TOP-REAR # TOP-CENTER # TOP-FRONT # TRACK-LOWER # TRACK-UPPER # DOOR-HINGE UP # POST-LEFT REAR # DOOR-SWING W/O #33 N/A N/A N/A N/A LATCH DOOR-SWING #34 N/A N/A N/A N/A W/LATCH DOOR ROD-TOP # DOOR ROD-BOTTOM # POST-RIGHT REAR # HARDWARE KIT

116

117 115 C HAPTER 8 Boom Supports In This Chapter Boom Support ( ) Boom Support, Adjustable, 1015 & 2020 ( ) Boom Support, Adjustable, ( ).118

118 116 Dominator I Parts & Specifications Manual Part # Boom Support ( ) " DOMINATOR WITH 1015 CRANE " DOMINATOR WITH 2020 CRANE 65.50" DOMINATOR WITH CRANE

119 Chapter 8 Boom Supports 117 Boom Support, Adjustable, 1015 & 2020 ( ) " re NOTE: 1 Hardware included in kit # POSITION BOOM SUPPORT 58" FROM REAR OF DOMINATOR SIDEPACK ASSEMBLY AS SHOWN. 2 Rotate and arrange pedestal #2 and saddle #5 or #6 based on chassis exhaust PARTS LIST ITEM PART # DESCRIPTION QUANTITY BOLT-U ADJ BOOM SUPPORT PEDESTAL-WLDMT ADJ 3.5X3.5X WEAR PAD-RC UHMW.75X4.00X TUBE-PEDESTAL TEL 4.0X4.0X SADDLE-BOOM SUPT 1015/ SADDLE-BOOM SUPPORT DOM 3820 & UP CAP SCR.38-16X 1.50 HH GR5 Z CAP SCR.75-10X 6.00 HH GR5 Z NUT HEX NYLOCK 2

120 118 Dominator I Parts & Specifications Manual Part # PARTS LIST NUT HEX NYLOCK NUT HEX NYLOCK WASHER.38 FLAT WASHER.50 FLAT WASHER.75 FLAT WASHER-BONDED PLTD.38 4 REV. B Boom Support, Adjustable, ( ) (4X) 6 (4X) 11 (4X) 15 (4X) 11 (4X) 9 NOTE: 1

121 Chapter 8 Boom Supports Hardware included in kit # Rotate and arrange pedestal #1 and saddle #10 based on chassis exhaust PARTS LIST ITEM PART # DESCRIPTION QUANTITY PEDESTAL-WLDMT ADJ WEAR PAD TUBE-PEDESTAL SADDLE-BOOM SUPPORT DOM 3820 & UP CAP SCR.38-16X 1.50 HH GR5 Z CAP SCR.50-13X 5.00 HH GR5 Z NUT HEX NYLOCK NUT HEX NYLOCK NUT HEX NYLOCK WASHER.38 FLAT (WAS 8) WASHER.50 FLAT WASHER.75 FLAT CAP SCR.75-10X 6.00 HH GR5 Z (WAS ) WASHER-BONDED PLTD.38 4 REV D

122

123 121 C HAPTER 9 Outriggers In This Chapter Front Outriggers ( / ) Front Outrigger, RH Pullout ( ) Rear Outriggers, Manual Out / Manual Down ( / ) Rear Outriggers, Manual Out/Power Down ( / ) Rear Outriggers, Power Out/Power Down (Kit / Dwg ) Outrigger Hydraulic Installation ( ) Cylinder, Power Out (3B142860) (Effective 2-07, prior to 8-05) Cylinder, Power Out ( ) (Used 9-05 to 1-07) Outrigger Assembly ( ) Outrigger Assembly, Stationary Mount ( ) Cylinder ( ) (Thru. 9-05, Eff. 2/07) Cylinder ( ) (Eff through 1/07) Valvebank, Power Out/Power Down ( ) (Eff ) Valvebank, Power Out/Power Down ( ) (Through ) Valvebank, Manual Out/Power Down ( ) (Eff ) Valvebank, Manual Out/Power Down ( ) (Through ) Outrigger Override Installation & Operation ( )...148

124 122 Dominator I Parts & Specifications Manual Part # Front Outriggers ( / ) A PARTS ARE UNIVERSAL FOR RIGHT OR LEFT SIDE INSTALLATION DETAIL A SCALE 1/ / PARTS LIST ITEM PART # DESCRIPTION QUANTITY OUTRG FRT TUBE EXT OUTRG FRT BTM PAD PIN-QUICK RLSE.50/2.5CRIT RNG CAP SCR.50-13X 3.50 HH ( ) NUT NYLOC ( ) 1 REV. A

125 Chapter 9 Outriggers 123 Front Outrigger, RH Pullout ( ) 5 SIDE PACK - REF 3.66" FROM OUTSIDE OF SIDEPACK ,14 ATTACH CHAIN TO ITEM #7 9,10,12 (5 PLCS) AT ASSEMBLY, DRIL 5ø0.41"HOLESIN PANEL USING ITEM #2 AS A GUIDE PARTS LIST ITEM PART # DESCRIPTION QUANTITY KIT-HDWR DOM I FRNT OR (INCL. 7-14) OUTRG KIT-RH FRONT PULLOUT OUTRIGGER ARM RH PULLOUT CHAIN-.12 X 9.00in LONG OUTRG FRT TUBE EXT OUTRG FRT BTM PAD PIN-QUICK RLSE PIN-QUICK RLSE.50/2.5CRIT RNG CAP SCR.38-16X 1.25 HH GR5 Z (WAS ) NUT HEX NYLOCK NUT HEX NYLOCK WASHER.38 FLAT CAP SCR.50-13X 3.50 HH GR8 Z (WAS ) NUT HEX TOP LOCK GR8Z(WAS ) 1 REV. C

126 124 Dominator I Parts & Specifications Manual Part # Rear Outriggers, Manual Out / Manual Down ( / ) THIS PANEL USED TO BLOCK THE VALVEBANK OPENING ON THE BACK OF THE CRANE BOX. 11,14 (2X) LOCK PIN LOCATED AND 3 INSTALLED IN CRANE BOX , PARTS LIST ITEM PART # DESCRIPTION QUANTITY CRANK ASM-BINKLEY OUTRG 315A CRANK HANDLE-BINKLEY WLDMT ARM-OUTRG ADJ MAN CRANK (DOM 1) ARM-OUTRG ADJ MAN CRANK (DOM 2) ARM-OUTRG STAT MAN CRANK (DOM 1) ARM-OUTRG STAT MAN CRANK 7X5 (DOM 2) PIN-WLDMT (DOM 1) PIN-WLDMT (DOM 2) SPRING 1

127 Chapter 9 Outriggers PARTS LIST ROLLER-UHMW.50 X 2.00 X 1.38 LG PIN PANEL-CRANE BOX VALVE BLOCK COVER KNOB-CONTROL 1.50 BLK CAP SCR.38-16X 1.00 HH GR5 Z CAP SCR.50-13X 5.75 HH GR5 Z (DOM 2) CAP SCR.50-13X 5.00 HH GR5 Z (DOM I) NUT HEX NYLOCK WASHER.38 LOCK MACHY BUSHING.75X14 GA NR (WAS ) COTTER PIN.12X1.00 PLAIN COTTER PIN.16X1.00 PLAIN 1 REV. K

128 126 Dominator I Parts & Specifications Manual Part # Rear Outriggers, Manual Out/Power Down ( / ) DECAL PLACED ABOVE 26VALVE BANK INSIDE CRANE BOX. 22, VALVE IS INSTALLED ON BACK WALL OF CRANE BOX. 21, (2) (4) 16(3) LOCK PIN IS LOCATED IN CRANE BOX. 20, (2) 1 33(2) 15(4) CJ-200 CJ CJ-205 CONNECTS TO ELECTRICAL PANEL (INSIDE CRANE BOX) CJ CP-206 CP PARTS LIST CJ-201 CJ-203 CJ-204 ITEM PART # DESCRIPTION QUANTITY OUTRIGGER ASM EXTENSION (DOM 1) OUTRIGGER ASM STATIONARY MOUNT (DOM 1 1) PIN-WLDMT - T (DOM 1) WEAR PAD-RC 2.00 X 2.00 X

129 Chapter 9 Outriggers PARTS LIST ITEM PART # DESCRIPTION QUANTITY WEAR PAD-RC 2.00 X 2.00 X VALVE BANK 2 SEC W/SOLENOIDS (WAS THROUGH ) HARNESS-DOM(II) OUTRIGGER REF KIT HOSE MANUAL OUT HYD OUTRIGGERS REF HOSE-FJ.25 X OAL (4-6) 100R HOSE-FZ.25 X OAL (4-6) 100R HOSE-FJ.25 X OAL (4-6) 100R HOSE-FZ.25 X OAL (4-6) 100R HOSE-FF.25 X (4-4) 100R ELBOW-M STR/90/M JIC ELBOW-M STR/M JIC XLG ELBOW-M STR/90/M JIC 8 8 REF ADPTR-M STR/M JIC ELBOW-M JIC/90/M JIC 4 4 BLKHD ADPTR-M STR/M JIC CAP SCR.31-18X 2.50 HH GR5 Z CAP SCR.31-18X 1.25 HH GR5 Z CAP SCR.50-13X 1.50 HH GR8 Z CAP SCR.38-16X 4.00 HH GR5 Z NUT HEX NYLOCK NUT HEX TOP LOCK GR8 Z WASHER.38 LOCK DECAL-OUTRIGGER MANUAL OVERRIDE 1 (WAS THROUGH DEC. 2009) COTTER PIN.12X1.00 PLAIN COTTER PIN.16X1.00 PLAIN PIN-TYPE O.50X 2.88 ( 2.63) SPRING-COMPRESSION.062 X 1.50 X.845OD ROLLER-UHMW.50 X 2.00 X 1.38 LG CAM CLAMP 1.00 DIA. X CLAMP-.62 LOOP CUSHIONED MACHY BUSHING.75X14 GA NR WLDMT CHANNEL HOSE CARRIER 1 REV B

130 128 Dominator I Parts & Specifications Manual Part # Rear Outriggers, Power Out/Power Down (Kit / Dwg ) DECAL PLACED ABOVE 24 VALVE BANK INSIDE CRANE BOX. 29,33 27,31 17,21 28, (2) 18(2) VALVE IS INSTALLED ON BACK WALL OF CRANE BOX. LOCK PIN IS LOCATED IN CRANE BOX , VIEW AS SEEN FROM REAR OF CRANE BOX. 20(6) (3) 5 CP (2) CJ-200 CJ-202 CJ CJ-201 CJ-203 CJ (2) 19(4) HARNESS CONNECTS TO ELECTRICAL PANEL INSIDE CRANE BOX. CJ-400 CP-401 PARTS LIST ITEM PART # DESCRIPTION QUANTITY OUTRIGGER ASM EXTENSION OUTRIGGER ASM STATIONARY MOUNT PIN WEAR PAD-RC 2.00 X 2.00 X WEAR PAD-RC 2.00 X 2.00 X

131 Chapter 9 Outriggers 129 PARTS LIST ITEM PART # DESCRIPTION QUANTITY VALVE BANK 3 SEC W/SOLENOIDS HARNESS-OUTRIGGER REF HOSE KIT-POWER OUT HYD OUTRIGGERS REF HOSE-FZ.25 X OAL (4-6) 100R HOSE-FJ.25 X OAL (4-6) 100R HOSE-FJ.25 X OAL (4-6) 100R HOSE-FZ.25 X OAL (4-6) 100R HOSE-FJ.25 X OAL (4-6) 100R HOSE-FZ.25 X OAL (4-6) 100R HOSE-FF.25 X (4-4) 100R ELBOW-M STR/90/M JIC ELBOW-M STR/M JIC XLG ELBOW-M JIC/F JIC SW ELBOW-M JIC/90/M JIC 4 4 BLKHD ELBOW-M STR/90/M JIC ADPTR-M STR/M JIC ADPTR-M STR/M JIC ADPTR-M STR/M JIC B CYLINDER DECAL-OUTRIGGER MANUAL OVERRIDE 1 (WAS THROUGH ) CAP SCR.31-18X 2.50 HH GR5 Z CAP SCR.31-18X 1.25 HH GR5 Z CAP SCR.50-13X 1.50 HH GR8 Z CAP SCR.50-13X 5.75 HH GR5 Z CAP SCR.38-16X 4.00 HH GR5 Z NUT HEX NYLOCK NUT HEX TOP LOCK GR8 Z NUT HEX NYLOCK WASHER.38 LOCK COTTER PIN.12X1.00 PLAIN COTTER PIN.16X1.00 PLAIN WLDMT CHANNEL HOSE CARRIER CAM CLAMP 1.00 DIA. X CLAMP-.62 LOOP CUSHIONED MACHY BUSHING.75X14 GA NR ROLLER-UHMW.50 X 2.00 X 1.38 LG SPRING-COMPRESSION.062 X 1.50 X.845OD ROLL PIN.50X PIN-TYPE O.50X 2.88 ( 2.63) 2 REV C

132 130 Dominator I Parts & Specifications Manual Part # Outrigger Hydraulic Installation ( ) Drawing 4 3 POWER OUT CYLINDER CURBSIDE OUTRIGGER 12 BULKHEAD USE FITTINGS STREETSIDE OUTRIGGER PARTS LIST ITEM PART # DESCRIPTION QUANTITY KIT HOSE MANUAL OUT HYD OUTRIGGERS REF KIT HOSE POWER OUT HYD OUTRIGGERS REF ELBOW-M STR/90/M JIC ELBOW-M STR/M JIC XLG ELBOW-M JIC/90/F JIC SW ELBOW-M JIC/90/M JIC 4 4 BLKHD VALVE BANK 3 SEC W/SOLENOIDS DOM OUTRIG VALVE BANK 2 SEC W-SOLENOIDS DOM OUTRIG HOSE-FZ.25 X (4-6) 100R HOSE-FJ.25 X (4-6) 100R HOSE-FZ.25 X (4-6) 100R HOSE-FJ.25 X (4-6) 100R HOSE-FF.25 X (4-4) 100R HOSE-FZ.25 X (4-6) 100R HOSE-FJ.25 X (4-6) 100R17 1 NEW

133 Chapter 9 Outriggers Drawing 8 B3 B2 B1 PB P A3 A2 A1 T ITEM DESCRIPTION PORT SIZE B3 POWER OUT CYLINDER RETURN -6 A3 POWER OUT CYLINDER PRESSURE -6 B2 CURB SIDE POWER DOWN RETURN -6 A2 CURB SIDE POWER DOWN PRESSURE -6 B1 STREET SIDE POWER DOWN RETURN -6 A1 STREET SIDE POWER DOWN PRESSURE -6 T TANK PORT -8 PB POWER BEYOND PORT -8 P PRESSURE PORT -8

134 132 Dominator I Parts & Specifications Manual Part # Cylinder, Power Out (3B142860) (Effective 2-07, prior to 8-05) SAE #4 O-RING PORTS (2) 7, Ø CLOSED OPEN STROKE NOTES: 1 REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS DISASSEMBLED. THIS WILL REDUCE FUTURE DOWNTIME. 2 APPLY REGULAR GRADE ANTI-SEIZE AND LUBRICATING COMPOUND TO THE THREADS ON THE CYLINDER HEAD ONLY. KEEP AWAY FROM ALL SEALS. 3 APPLY "LUBRIPLATE" NO 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. 3B PARTS LIST ITEM PART # DESCRIPTION QUANTITY 1. 4B CASE ASM G ROD ASM C STOP TUBE H HEAD I PISTON B SEAL KIT REF 7. 7Q O-RING Q O-RING Q10P214 BACKUP RING R U-CUP SEAL R13P007 ROD WIPER T66P012 PISTON SEAL RETAINING RING 1 REV. B

135 Chapter 9 Outriggers 133 Cylinder, Power Out ( ) (Used 9-05 to 1-07) 50.0 ± 0.12" RETRACT EXTEND 42.0 ± 0.06" STROKE DETAIL B DETAIL A DETAIL A SCALE 4:1 DETAIL B SCALE 3:1

136 134 Dominator I Parts & Specifications Manual Part # NOTES: 1 TO REDUCE DOWNTIME, REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS DISASSEMBLED CYLINDER DATA EXTENDED 1.23 IN², 0.22 GAL RETRACTED 0.79 IN², 0.14 GAL CASE 1.25 BORE X ø1.63 ROD ø DRY WEIGHT 19.7 LB TEST PRESSURE 3000 PSI OPERATING PRESSURE 2500 PSI PORTS SAE #4 O-RING BOSS (7/16-20 UNF-2B) CYLINDER TUBE BURST PRESSURE 20,000 PSI TORQUE TORQUE LOCKNUT (#6) WITH THREADLOCK COMPOUND TO FT-LB PARTS LIST ITEM PART # DESCRIPTION QUANTITY CASE WELDMENT ROD WELDMENT HEAD GLAND PISTON REF- LOCKNUT 1-14 UNS SEAL KIT 1 NEW

137 Chapter 9 Outriggers 135 Outrigger Assembly ( ) 7 A B 4 A SECTION A-A DETAIL B PARTS LIST ITEM PART # DESCRIPTION QUANTITY WLDMT-OUTRIGGER SLIDEOUT ASM P PORT TUBE OD X 20.8 LG ELBOW-M STR/90/M JIC RING-LOCK DOMINATOR OUTRIGGER RETAINING RING-4.50 DIA X SET SCR-SS.38-16X.50 SOC HEAD CYLINDER-3.50 BORE X 18.00S 28.38CC O.R. 1 (WAS ) REV. A

138 136 Dominator I Parts & Specifications Manual Part # Outrigger Assembly, Stationary Mount ( ) SECTION A-A AA PARTS LIST ITEM PART # DESCRIPTION QUANTITY WELDMENT-OUTRIGGER STATIONARY P PORT TUBE OD X 20.8 LG RING-LOCK DOMINATOR OUTRIGGER RETAINING RING-4.50 DIA X ELBOW-M STR/90/M JIC SET SCR-SS.38-16X.50 SOC HEAD CYLINDER-3.50 BORE X 18.00S CC O.R. (WAS ) 1 REV. A

139 Chapter 9 Outriggers 137 Cylinder ( ) (Thru. 9-05, Eff. 2/07) B B DRILL #15 HOLE 3/16" DEEP. PRESS IN PIN # 17. NOTES: 1 REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS DISASSEMBLED. THIS WILL REDUCE FUTURE DOWNTIME. 2 APPLY REGULAR GRADE ANTI-SEIZE AND LUBRICATING COMPOUND TO THREADS ON CYLINDER HEAD ONLY. KEEP AWAY FROM ALL SEALS. 3 APPLY "LUBRIPLATE" NO 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 PARTS LIST ITEM PART # DESCRIPTION QUANTITY 1. 4G ROD ASSEMBLY CASE ASSEMBLY ID35125 PISTON HD35025 HEAD c STOP TUBE A WAFER LOCK Q O RING 3.12X 3.50X Q10P338 BACKUP RING-3.12 ID X 3.50 OD 1

140 138 Dominator I Parts & Specifications Manual Part # PARTS LIST 9. 7t61n125 LOCK RING-NYLON T66P035 PISTON SEAL Q O RING 3.00X 3.19X R14P025 ROD WIPER-TYPE D 2.25 ROD T2N4035 WEAR RING-PISTON 3.50X3.25X T2NX427 WEAR RING-ROD 2.50 ID X 0.50W HAL R U-CUP LOADED 2.50X3.00X.38 "B VALVE-CHECK PILOT/OPEN NONVENT LOCKING PIN 1 9C SEAL KIT REF REV. A

141 Chapter 9 Outriggers 139 Cylinder ( ) (Eff through 1/07) SAE #8 O-RING BOSS SAE #4 O-RING BOSS(3/4-16 UNF-2B) (7/16-20 UNF) SAE #8 O-RING BOSS (3/4-16 UNF-2B) ± 0.06" STROKE ± 0.12 RETRACT EXTEND NOTES: 1 TO REDUCE DOWNTIME, REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS DISASSEMBLED CYLINDER DATA EXTENDED 9.62 IN², 0.75 GAL RETRACTED 4.71 IN², 0.37 GAL CASE 3.50 BORE X ø4.50 ROD ø2.50 DRY WEIGHT 90.7 LB TEST PRESSURE 3500 PSI OPERATING PRESSURE 3000 PSI PORTS SAE #8 O-RING BOSS (3/4-16 UNF-2B) (QTY 2) AND SAE #4 O-RING BOSS (7/16-20 UNF-2B) (QTY 2) CYLINDER TUBE BURST PRESSURE 19,380 PSI TORQUES TORQUE LOCKNUT (#5) WITH THREADLOCK COMPOUND TO FT-LB USING LOCTITE GRADE 271 OR EQUIVALENT. TORQUE O-RING BOSS PLUG (#6) WITH THREADLOCK COMPOUND TO FT-LB USING LOCTITE GRADE 243 OR EQUIVALENT. TORQUE HEAD GLAND (#3) TO FT-LB. TORQUE CHECK VALVE TO FT-LB CYLINDER DATA ITEM PART # DESCRIPTION QUANTITY CASE WELDMENT ROD WELDMENT HEAD GLAND PISTON 1 5. REF LOCKNUT, UNF 1 6. REF PLUG, #4 STEEL HEX HOL SEAL KIT CHECK VALVE PO 1 NEW

142 140 Dominator I Parts & Specifications Manual Part # Valvebank, Power Out/Power Down ( ) (Eff ) NOTE: EFFECTIVE S/N DOMS2S P SCHEMATIC A1 B1 A2 B2 A3 1 4 PB NOTES (SEE REFERENCE NUMBER IN BOX): 1 TORQUE TO 25 FT-LB. 2 TORQUE TO 3 FT-LB A 2B 2C 8 B3 V2 T

143 Chapter 9 Outriggers TORQUE TO 90 FT-LB PARTS LIST ITEM PART # DESCRIPTION QUANTITY VALVE BANK 3 SEC W/SOLENOIDS DOM 1 OUTRIG VALVE-SOLENOID (INCLUDES 2 OF ITEM ) COIL-12VDC LEAD WIRE VALVE-RELIEF 3200 PSI VALVE-SOLENOID SOFT SHIFT (INCLUDES 1 ITEM ) COIL-12VDC 36W LEADWIRE MANIFOLD SAE -2 PLUG SAE -4 PLUG SAE -6 PLUG SAE -8 PLUG 2 NEW

144 142 Dominator I Parts & Specifications Manual Part # Valvebank, Power Out/Power Down ( ) (Through ) NOTE: EFFECTIVE THROUGH S/N DOMS2S , 4 3, 3, 3, , ,8 9 DATE CODE 1 6 A B PUSH BUTTON OVERRIDES THE 4W3P VALVE TO THIS POSITION. P T P A1 B1 A2 B2 A3 B3 3A 3B 3C 4 90 PSI PSI PB HYDRAULIC SCHEMATIC T

145 Chapter 9 Outriggers PARTS LIST ITEM PART # DESCRIPTION QUANTITY VALVE, RELIEF 3000 PSI VALVE, POPPET VALVE, SPOOL COIL, 12V PLUG, ORIFICE 1 6. MANIFOLD 1 7. PLUG, EXPANDER 3 8. PLUG, SAE # PLUG, SAE # NAME PLATE CHECK VALVE COIL, 12VDC ORIFICE DISK, DIA WIRE MARKERS 1REF PLASTIC PLUG, SAE #8 3

146 144 Dominator I Parts & Specifications Manual Part # Valvebank, Manual Out/Power Down ( ) (Eff ) NOTE: EFFECTIVE S/N DOMS2S SCHEMATIC A1 B1 A2 B2 A3 B3 P A B 8 20 V2 9 1 PB T NOTES (IF TIED TO DRAWING, SEE REFERENCE NUMBER IN ): 1 TORQUE TO 25 FT-LB. 2 TORQUE TO 3 FT-LB. 3 TORQUE TO 90 FT-LB.

147 Chapter 9 Outriggers PARTS LIST ITEM PART # DESCRIPTION QUANTITY VALVE BANK 2 SEC W/SOLENOIDS OUTRIG VALVE-SOLENOID (INCLUDES 2 OF ITEM ) COIL-12VDC LEAD WIRE VALVE-RELIEF 3200 PSI VALVE-SOLENOID SOFT SHIFT (INCLUDES 1 ITEM ) COIL-12VDC 36W LEADWIRE MANIFOLD SAE -2 PLUG SAE -4 PLUG SAE -6 PLUG SAE -8 PLUG PLUG-CAVITY 1 NEW

148 146 Dominator I Parts & Specifications Manual Part # Valvebank, Manual Out/Power Down ( ) (Through ) NOTE: EFFECTIVE THROUGH S/N DOMS2S , 4 3, 12 3, CONNECTOR CONNECTOR ,8 9 DATE CODE NOTE: PUSH BUTTON OVERRIDES THE 4W3P VALVE TO THIS POSITION. A B P T A1 B1 A2 B2 A3 B3 P 2 3A PSI 3B 3C 4 T PB HYDRAULIC SCHEMATIC PARTS LIST ITEM PART # DESCRIPTION QUANTITY VALVE, RELIEF 3000 PSI VALVE, POPPET VALVE, SPOOL COIL, 12V PLUG, ORIFICE 1

149 Chapter 9 Outriggers PARTS LIST 6. MANIFOLD 1 7. PLUG, EXPANDER 3 8. PLUG, SAE # PLUG, SAE # NAME PLATE PLUG, CAVITY COIL, 12VDC PLUG, SAE # PLUG, SAE # I.D. TAGS 1REF PLUG, PLASTIC, SAE #6 4 PLUG, PLASTIC SAE #8 3

150 148 Dominator I Parts & Specifications Manual Part # Outrigger Override Installation & Operation ( ) LEFT O/R LEG RIGHT O/R LEG RIGHT O/R ARM (IF APPLICABLE) PLUNGER LOCKING COLLAR 1 OR USE 9/64" ALLEN WRENCH PLASTIC CAP INSTALLING MANUAL OVERRIDE 1 REMOVE PLASTIC CAP AND DISCARD. 2 REPLACE PLASTIC CAP WITH ITEMS 3, 4, AND 5 AS SHOWN. 3 TURN ADJUSTMENT SCREW (ITEM 4) CLOCKWISE UNTIL YOU FEEL RESISTANCE. TURN COUNTERCLOCKWISE 2 FULL TURNS. 4 TIGHTEN JAM NUT (ITEM 3). MANUAL OVERRIDE PROCEDURE 1 LOOSEN JAM NUT (ITEM 3). 2 TURN ADJUSTMENT SCREW (ITEM 4) CLOCKWISE UNTIL IT BOTTOMS OUT (APPROXIMATELY 6 FULL TURNS).

151 Chapter 9 Outriggers RAISE LOCKING COLLAR AND PUSH PLUNGER DOWN TO RETRACT DESIRED FUNCTION, OR LIFT TO EXTEND DESIRED FUNCTION. 4 RELEASE PLUNGER. 5 RELEASE LOCKING COLLAR ON ANY VALVE ACTIVATED. 6 PUSH AND RELEASE PLUNGER TO RETURN LOCKING COLLAR TO NEUTRAL POSITION. 7 RETURN ADJUSTMENT SCREW (ITEM 4) TO ORIGINAL POSITIONS. 8 TIGHTEN JAM NUT (ITEM 3) PARTS LIST ITEM PART # DESCRIPTION QUANTITY VALVE BANK 3 SEC W/SOLENOIDS REF VALVE BANK 2 SEC W/SOLENOIDS REF NUT # 8-32 HEX ZINC CAP SCR # 8-32X.75 SH PLAIN CAP-OUTRIGGER VALVE MANUAL OVERRIDE KIT-DOM OUTRIGGER VALVE OVERRIDE (INCL. ITEMS 3-5) REF NEW

152

153 151 C HAPTER 10 Electrical Options & Installation In This Chapter Electrical Panel ( ) Electrical Installation ( ) (Eff ) Chassis Electrical Installation ( ) (Eff ) Power Panel (Dom 1-2) ( ) Electrical Installation ( ) (Eff thru ) Fuse Block, EFM, & Relay Bracket Installation ( ) (Thru ) Crane Installation Comparison Light Installation ( ) By-Pass Procedure for Reverse Activated Floodlights Electrical Outlet ( ) Light Reel Kits...170

154 152 Dominator I Parts & Specifications Manual Part # Electrical Panel ( ) , , NOT POLARITY SENSITIVE CONNECTIONS FROM HARNESS (#10) CONNECTIONS FROM HARNESS (#10) CJ-905 CJ-906 CJ-907 CJ-908 CJ-910 CJ-911 TETHER CONNECTION FOR RADIO REMOTE CJ-901 CJ-902 CJ-903 CJ M1 W1 W2 W3 W4 W5 W6 CJ-909

155 Chapter 10 Electrical Options & Installation PARTS LIST ITEM PART # DESCRIPTION QUANTITY ELECTRICAL PANEL DECAL-ELECTRICAL CONTROL PANEL DOM METER-HOUR DATCON PUSH LOCK 3 MOUNTING SWITCH-ROCKER MTG PANEL END SWITCH-ROCKER MTG PANEL MIDDLE SWITCH-ROCKER BODY SWITCH-ROCKER GREEN ACTUATOR SWITCH-ROCKER SINGLE MOUNTING 3 PANEL SWITCH-ROCKER ACTUATOR - FROM A/R OUTRIGGER KIT HARNESS DOM POWER PANEL GROMMET-2 X 6 OVAL CMPT LIGHT LIGHT-COMPARTMENT LED (WAS ) SWITCH-ROCKER BODY MOMENTARY - A/R FROM O/R KIT SWITCH-ROCKER PLUG WASHER-SS 10 WRT TYPE SCR-MACH # 8-32X.75 RDH TIES-PLASTIC.18W 12.00L BLACK 10 REV. A

156 154 Dominator I Parts & Specifications Manual Part # Electrical Installation ( ) (Eff ) ,8, ,17, ,8,27 12,13, ,3,4,5 NOTES (SEE REFERENCE NUMBER IN BOX): 1 LICENSE PLATE KIT TERMINATE WITH , AND GROUND EYELET FROM HARNESS ATTACHES TO ONE OF THE SCREWS. 2 CHASSIS GROUND AND BODY GROUND EYELETS FROM LIGHTING HARNESS SHOULD BE ATTACHED TO CHASSIS AND BODY, RESPECTIVELY. USE HARDWARE ITEMS #23, 24, 25, AND 26. DRILL AS NEEDED. 3 USE HEATSHRINK TO PROTECT UNUSED COMPARTMENT LIGHT CONNECTOR.

157 Chapter 10 Electrical Options & Installation 155 VIEW OF BODY SHOWN WITHOUT DOORS OR SIDEPACK TOPS HARNESS REAR OF BODY TAILLIGHTS, MARKER LIGHTS, ETC. HARNESS AS PART OF CONTROL PANEL CHASSIS, CRANE, OUTRIGGER, LIGHT CONTROLS NOTES (SEE REFERENCE NUMBER IN BOX): HARNESS (ONE PER SIDEPACK) FLOOD LIGHTS, COMPARTMENT LIGHTS 4 EXTENSION HARNESS TO FRONT MARKER LIGHT AND FLOODLIGHTS. ONE PER SIDE 5 9' HARNESS ' HARNESS ', 14' HARNESS ' HARNESS PARTS LIST ITEM PART # DESCRIPTION QUANTITY ELECTRICAL PANEL (DOM4) ELECTRICAL PANEL (DOM1 & DOM2) WASHER.31 LOCK CAP SCR.31-18X.50 HH GR5 Z EDGING-PLASTIC BLK A/R GROMMET-2IN DIA LED MARKER LIGHT-3-BAR LED WASHER.19 W FLAT ANSI B27.2Z NUT HEX NYLOCK LIGHT-LICENSE PLATE MTG BRACKET-WIRE HARNESS (DOM IV) MTG BRKT-WIRE HARNESS (DOM I AND II) CAP SCR.31-18X 1.00 HH GR5 Z 6

158 156 Dominator I Parts & Specifications Manual Part # PARTS LIST ITEM PART # DESCRIPTION QUANTITY WASHER.31 FLAT NUT HEX NYLOCK ALARM-BACK UP HORN CAP SCR.25-20X 1.25 HH GR5 Z (WAS ) WASHER.25 FLAT NUT HEX NYLOCK CAP SCR.38-16X 1.25 HH GR5 Z WASHER.38 W FLAT ANSI B27.2Z WASHER.38 LOCK ZINC NUT HEX NYLOC ZINC GROMMET-FOR LED S/T/T D(I) LIGHT-STOP/TURN/TAIL LED 4in DIA (WAS ) LIGHT-BACKUP GROMMET-TAIL LIGHT SCR-MACH #10-24X.75 RDH PH ZINC LIGHT-CLEARANCE RED LED OVAL 2 W/GROMMET LIGHT-CLEARANCE AMBER LED OVAL W/GROMMET 2 REV. E

159 157 Chassis Electrical Installation ( ) (Eff ) IFTHEWIREBETWEENTHE POWER MODULE (#5) AND THE BATTERYISLONGERTHAN24" INSTALL PARTS #19 AND #20 IN-LINE, AS CLOSE TO THE BATTERY AS POSSIBLE. 19 EXTRA HARDWARE AND BRACKET (#51) ARE SUPPLIED FOR MOUNTING AS NECESSARY. THE RECOMMENDED ORIENTATION OF COMPONENTS IS SHOWN. 1 2,3,4 20 5,6,7,8,9 4,11 LEFT POST: PASS THROUGH (FUSED) 12,13, ,13,15 RIGHT POST: SWITCHED THROUGH RELAY (FUSED) 16 USE HEAT SHRINK (#45) OVER THESE CONNECTIONS PARTS LIST ITEM PART # DESCRIPTION QUANTITY BRACKET-EFM CAP SCR.25-20X.88 HH GR5 Z WASHER.25 FLAT NUT HEX NYLOCK RELAY-12 VOLT POWER RELAY MODULE FUSE-FMX 30 AMP PINK FUSE-FMX 40 AMP GREEN FUSE-FMX 20 AMP BLUE FUSE-FMX 60 AMP YELLOW CONNECTOR - 2 CAV FEMALE SCR-MACH.25-20X 2.00 RDH ZINC 2

160 158 Dominator I Parts & Specifications Manual Part # PARTS LIST ITEM PART # DESCRIPTION QUANTITY NUT 8-32 HEX NYLOCK WASHER-SS 10 WRT TYPE KIT-EFM (ENGINE FUNCTION MODULE) SCR-MACH # 8-32X.75 RDH RELAY-12V 30 AMP NOM/40 AMP MAX TERM-RING I.25 STUD GA TERM-RING NI.25 STUD 8 WIRE FUSEHOLDER-HIGH AMP2 BOLT WITH 1 COVER FUSE-AMG-125 AMP TERM-RING NI.31 STUD 6 WIRE TERM-RING NI.25 STUD 6 WIRE TERM-FEM MP AWG SEAL-MP RED CABLE SEAL TERM-FEM SLIP ON12-10/.25 TAB TERM-FSLPON I.25TAB GA KIT-DIODE DEUTSCH DT SERIES KIT-SPLICE METRIPACK 6 PIN WIRE-6 GA GXL RED A/R HARNESS DOM CHASSIS DOM HARNESS DOM CHASSIS DOM1 & DOM WIRE-14GA RED STRD TYPE GPT A/R WIRE-14GA BLACK STRD TYPE GPT A/R TUBE-HEAT SHRINK.38X 2IN DOUBLE WALL TUBE-HEAT SHRINK-1.5 INCH DUAL WALL 4FT TUBE-HEAT SHRNK.25X 6"LG (OBS) TERM-RING NI.38 STUD 6 WIRE TERM-RING.38 STUD GA WIRE-12GA WHITE STRD TYPE GPT ANGLE-AL.12X1.00X1.00X TIES-PLASTIC.18W 12.00L BLACK CABLE POWER RED #6 X 36 1 REV A

161 21 BATTERY AUTOMATIC SINGLE PTO (MUNCIE/CHELSEA) ALLISON MD (6000/4000) SERIES TRANSMISSION TO PTO GROUND SPLICE A TO PTO ACTIVATION CIRCUIT 12V IGNITION HOT 1 2 NOT USED IN THIS APPLICATION NOTE: WILL ENGAGE THE PTO AND PROVIDE A GROUND SIGNAL TO THE IMT CHASSIS ELECTRICAL WIRING WHEN THE SWITCH IS ACTIVE. THIS ALLOWS ENGINE START TO FUNCTION IF THE PRESSURE SWITCH ON THE PTO OPENS (AFTER ENGINE KILL OCCURS, FOR EXAMPLE.) 28 CONNECTIONS TO HARNESS #30 INTERLOCK POWER IGNITION POWER BATTERY POWER IGNITION & E-BRAKE POWER ENGINE SPEED ENGINE STOP ENGINE START SEE EFM MANUAL DRAWING A POWER/RELAY MODULE - #5 40A 20A POWER/RELAY MODULE - #5 30A 60A A 70A CHASSIS IGNITION SWITCH AND LIGHT SUPPLIED WITH PTO 4 RELAY #1 RELAY #2 RELAY #3 RELAY #4 E-BRAKE IGNITION POWER GROUND a a E-BRAKE (SWITCH SUPPLIED AS PART OF CHASSIS)

162 160 Dominator I Parts & Specifications Manual Part # Power Panel (Dom 1-2) ( ) CP-700 CHASSIS/BODY CONNECTOR CP-650 COMPRESSOR CONNECTOR CP-250 DEUTSCH DIODE IGN+E-BRAKE POWER INTERLOCK POWER IGN POWER CMPRSR POWER ENGINE START ENGINE STOP ENGINE SPEED DUMP SELECTOR CMPRSR ON CMPRSR POWER GROUND FROM PRESSURE SW FAN GROUND FROM PRESSURE SW ENGINE SPEED R S T U V W X Y Z A B C D E F 2 1 S1 S2 S16 A IGN + EBRAKE POWER B INTERLOCK POWER 1 LF FLOOD 2 LR FLOOD 3 L COMPT 4 L AUX 5 RF FLOOD 6 RR FLOOD 7 R COMPT 8 R AUX 9 CRANE CMPT LIGHT 10 N/C 11 N/C 12 N/C 13 N/C 14 N/C 15 N/C 16 N/C 17 CRANE POWER 18 LEFT OUTRG U/D 19 RIGHT OUTRG U/D 20 RIGHT OUTRG I/O CJ-900 FUSE PANEL CP-100 BACKUP SIGNAL BACKUP A CP-850 CRANE CP-450 CRANE 2 CP-251 DEUTSCH DIODE SOL POWER ENGINE STOP GROUND SPEED CMPRSR ON ENGINE START POWER CRANE HOUR METER E-STOP SPEED ENGINE SPEED S4 S6 S8 S6 S9 S10 S11 S12 S13 S14 S15 S6 S6 S6 S6 S17 S18 S A B S20 S20 S20 S20 S S6 W7 CHASSIS GROUND A B ABCD ABCD CJ-200 BODY E-STOP W8 CHASSIS GROUND CP-400 LEFT SIDE LIGHTING NOTE SEQUENCE CJ-400 RIGHT SIDE LIGHTING M1 CP-401 CJ-401

163 161 Electrical Installation ( ) (Eff thru ) TERMINATE WITH , , AND LICENSE PLATE GROUND EYELET KIT FROM HARNESS TO BEATTACHED TO ONEOFTHE SCREWS. 8,9,10, ,18, ,9,10 CHASSIS GROUND AND BODY GROUND EYELETS FROM LIGHTING HARNESS TO BE ATTACHED TO CHASSIS & BODY, RESPECTIVELY. USE HARDWARE #23 - #26 AND DRILL AS NEEDED. 13,14, ,10,22 1,2,3,4 USE HEATSHRINK TO PROTECT UNUSED COMPARTMENT LIGHT CONNECTOR.

164 162 Dominator I Parts & Specifications Manual Part # HARNESS INSTALLATION HARNESS REAR OF BODY: TAIL LIGHTS, MARKER LIGHTS, ETC. VIEW OF BODY SHOWN WITHOUT DOORS OR SIDEPACK TOPS. HARNESS ONE PER SIDEPACK: FLOODLIGHTS, COMPT. LIGHTS HARNESS AS PART OF CONTROL PANEL: CHASSIS, CRANE, OUTRIGGER, LIGHT CONTROLS. EXTENSION HARNESS TO FRONT MARKER LIGHT, FLOODLIGHTS; ONE PER SIDE. 9' ' ' ' PARTS LIST ITEM PART # DESCRIPTION QUANTITY ELECTRICAL PANEL (DOM 1,2) ELECTRICAL PANEL (DOM 4) WASHER.31 LOCK CAP SCR.31-18X.50 HH GR5 Z EDGING-PLASTIC BLK GROMMET-2IN DIA LED MARKER LIGHT-CLEAR AMBER LED 2in DIA LIGHT-3 BAR LED SCR-MACH #10-24X.75 RDH PH ZINC WASHER.19 W FLAT ANSI B27.2Z NUT HEX NYLOCK LIGHT-LICENSE PLATE PLASTIC MTG BRKT-WIRE HARNESS CAP SCR.31-18X 1.00 HH GR5 Z WASHER.31 FLAT NUT HEX NYLOCK ALARM-BACK UP HORN CAP SCR.25-20X.75 HH GR5 Z WASHER.25 FLAT NUT HEX NYLOCK 2

165 Electrical Options & Installation PARTS LIST ITEM PART # DESCRIPTION QUANTITY LIGHT-STOP/TURN/TAIL LED ELEMENT LIGHT-CLEAR BACK UP LIGHT-MARKER CLEAR RED LED THIN LINE CAP SCR.38-16X 1.25 HH GR5 Z WASHER.38 W FLAT ANSI B27.2Z WASHER.38 LOCK ZINC NUT HEX NYLOC ZINC GROMMET 6 REV. A

166 164 Dominator I Parts & Specifications Manual Part # Fuse Block, EFM, & Relay Bracket Installation ( ) (Thru ) EXTRA QUANTITY OF HARDWARE AND BRACKET SUPPLIED FOR MOUNTING AS NECESSARY. ELECTRICAL COMPONENTS ON THIS DRAWING (#5,10,16) MUST BE ORIENTED AS SHOWN FOR THEIR PROTECTION. IF WIRE BETWEEN FUSE BLOCK (#5) AND BATTERY IS OVER 24", INSTALL PARTS #19 AND #20 IN-LINE, AS CLOSE TO THE BATTERY AS POSSIBLE ,12, ,3, , 13, 15 12, 13, 15 USE HEAT SHRINK OVER THESE CONNECTIONS

167 Electrical Options & Installation DRAWING FUSE BLOCK 21 BATTERY A 40A 20A 30A 70A CHASSIS IGNITION A A E-BRAKE (SWITCH SUPPLIED AS PART OF CHASSIS) SEE INSERT DIAGRAM FOR AUTOMATIC APPLICATION REGARDING THIS AREA SWITCH & LIGHT SUPPLIED W/PTO CONNECTIONS TO HARNESS (#30) 4 28 INTERLOCK POWER IGNITION POWER BATTERY POWER IGNITION & E-BRAKE POWER ENGINE SPEED ENGINE STOP ENGINE START RELAY #1 RELAY #2 RELAY #3 RELAY #4 E-BRAKE IGNITION POWER GROUND a a SEE EFM MANUAL INSERT DIAGRAM: AUTOMATIC APPLICATION SINGLE PTO (MUNCIE/CHELSEA) ALLISON MD (3000/4000) SERIES TRANSMISSION DOMINATOR II (POST APRIL 2005) ONLY TO PTO GROUND SPLICE ( DOM CHASSIS ELEC INSTALLATION INSTRUCTIONS) TO PTO ACTIVATION CIRCUIT 12V IGNITION HOT A NOT USED IN THIS APPLICATION NOTE: will engage the PTO and provide a ground signal to the IMT chassis electrical wiring when the switch is active. This allows engine start to function if the pressure switch on the PTO opens (after engine kill occurs, for example).

168 166 Dominator I Parts & Specifications Manual Part # PARTS LIST ITEM PART # DESCRIPTION QUANTITY BRACKET-EFM CAP SCR.25-20X.88 HH GR5 Z (WAS 2) WASHER.25 FLAT NUT HEX NYLOCK (WAS 2) FUSE BLOCK-4 POS MAXI-FUSE FUSE-MAXI 70 AMP FUSE-MAXI 20 AMP FUSE-MAXI 40 AMP FUSE-MAXI 30 AMP RELAY-12V DC 75AMP SCR-MACH # 8-32X 1.00 FH PHLPS SS NUT 8-32 HEX NYLOCK WASHER-SS 10 WRT TYPE KIT-EFM (ENGINE FUNCTION MODULE) SCR-MACH # 8-32X.75 RDH RELAY-40 AMP TERMINAL - RING 6GA NUMBER 10 NON INS TERMINAL - RING 8GA NUMBER 10 NON INS FUSEHOLDER-HIGH AMP2 BOLT WITH 1 COVER FUSE-AMG-125 AMP TERMINAL - RING 6GA NUMBER 10 NON INS FERRULE - FUSE BLOCK 6 GA X 12MM FERRULE - FUSE BLOCK 12 GA X 12MM FERRULE - FUSE BLOCK 8 GA X 12MM TERM-FEM SLIP ON12-10/.25 TAB TERM-FSLPON I.25TAB GA KIT-DIODE DEUTSCH DT SERIES (WAS 2) KIT-SPLICE METRIPACK 6 PIN WIRE-6 GA GXL RED A/R HARNESS, CHASSIS (DOM 1 & 2) HARNESS, CHASSIS (DOM 4) WIRE-14GA RED STRD TYPE GPT A/R WIRE-14GA BLACK STRD TYPE GPT A/R TUBE-HEAT SHRINK 3/8X2 DOUBLE WALL TUBE-HEAT SHRINK 1.5" DUAL WALL 4' TUBE-HEAT SHRINK 1/4X TERMINAL, RING TERMINAL, RING TERMINAL, RING WIRE ANGLE TIES, PLASTIC CABLE, POWER, RED 1 REV. D

169 Electrical Options & Installation 167 Crane Installation Comparison CRANE BASE - PRIMARY CONFIGURATION CRANE BASE - ALTERNATE CONFIGURATION If your body includes a crane, check the crane base configuration (primary or alternate) to determine floodlight installation ( ).

170 168 Dominator I Parts & Specifications Manual Part # Light Installation ( ) TERMINATE WIRES WITH #8, 9, 10. NOT POLARITY 2SENSITIVE. HARDWARE INCLUDED 4,5 1 OPTIONAL LOCATIONS ALL COMPARTMENTS EXCEPT CRANE BOX 6 DETAIL C 7 ADD 1/4" FOR DOM4 CRANE BOX 6.0" 0.5" 0.28" 0.5" (QTY 3) 1.38" 1.50" A 3 B DETAIL B C OPTIONAL LOCATIONS DETAIL A: DIMENSIONS TYPICAL BOTH SIDES -STANDARD (CRANE ROTATOR TO SIDE/FRONT) 0.5" 9.25" 0.5" A 4.63" 4.75" 0.28" (3) SEE DETAILS A & D DETAIL D: ALT. LOCATION CRANE SIDE ONLY (CRANE ROTATOR TO REAR) PARTS LIST ITEM PART # DESCRIPTION FOOT COMPT. LIGHTS 11-FOOT COMPT. LIGHTS 13 & 14- FOOT COMPT. LIGHTS 19-FOOT COMPT. LIGHTS BRACKET-FLOODLIGHT 12V REAR SP FLOODLIGHT-COMPOSITE WORK LAMP CAP SCR-SS.25-20X 1.25 HH WASHER-SS.25 W MS811 FLAT NUT-SS NYLOC LIGHT-COMPARTMENT 12V AMP SCR-SELF TAP-SS #10X.50 HH SLOT CONN-2 CAV TOWER TERM-14-16GA FEMALE CABLE SEAL-14 GA GREY REV. D FLOODLIGHT KIT (2 LIGHTS)

171 Electrical Options & Installation 169 By-Pass Procedure for Reverse Activated Floodlights A floodlight installed on the rear driver's side of the body will illuminate when the chassis transmission is in reverse. NOTE: Some state and local laws prohibit reverse-activated rear-facing floodlights. Consult your local and state regulations regarding reverse-activated, rear-facing floodlights. Disable if necessary. To disable, remove the relay located behind the crane box switch panel as shown. Electrical Outlet ( ) PARTS LIST ITEM PART # DESCRIPTION QUANTITY GROMMET TERMINAL-INSULATED SPADE GA CONNECTOR-1/2 STRAIN RELIEF 3/8-1/ GROUND PLUG ELECTRICAL BOX 2X44 DEEP WELL WEATHERPROOF COVER OUTLET 110V GFI 20A CABLE 14GA/3WIRE 20FT

172 170 Dominator I Parts & Specifications Manual Part # Light Reel Kits LIGHT REEL KIT - 12 VOLT ( ) LIGHT REEL KIT VOLT - LIGHT DUTY ( ) LIGHT REEL KIT VOLT W/50' CORD ( ) ITEM PART # DESCRIPTION 12 VOLT QUANTITY 110 VOLT QUANTITY REEL - 50' REEL - 50' BULB - 12V BULB - 120V 75W ROUGH SERVICE BUTT CONNECTOR TERMINAL CAP SCR 1/4-20X3 HH GR CAP SCR 5/16-18X1 HH GR NUT 1/4-20 LOCK NUT 5/16-18 HEX NYLOC CAP SCR 1/4-20X3/4 HH GR WIRE 14GA YELLOW X 96" WIRE 14GA WHITE X 12" WIRE 12GA/3 WIRE X 216" WASHER 5/16 FLAT VOLT QUANTITY W/CORD

173 171 C HAPTER 11 Miscellaneous Options In This Chapter Salvage / Plumbing Installation Kit ( ) Salvage Tank Installation, Welder in Load Bed ( ) Salvage Pump Assembly ( ) (Eff. 6-08) Antifreeze/Salvage/Water Pump ( ) (Eff ) Salvage Pump Assembly ( /Dwg ) (Thru 5-08) Headache Rack Parts & Installation ( ) Master Lock System Drawing ( ) Dominator I Master Lock Kits Fuel Fill, Chevy/GMC ( )

174 172 Dominator I Parts & Specifications Manual Part # Salvage / Plumbing Installation Kit ( ) 3 2 7,8,9 SELECT FITTING AS NEEDED NOTE: PLUMB INTO LUBRICATED AIR ,8,9 SELECT FITTING AS NEEDED HOLE DETAIL - INSTALLATION OF SALVAGE TANK ON UNITS WITHOUT A WELDER CUTOUT 14.0" 3.50" DETAIL OF HOLE TO BE CUT IN THE FLOOR FOR THE SALVAGE TANK. USE THIS LOCATION ONLY IF THERE IS NOT A WELDER CUTOUT. 5.50" FRONT

175 Chapter 11 Miscellaneous Options PARTS LIST (DRAWING ) ITEM PART # DESCRIPTION QUANTITY 1. REF TANK-WLDMT GALLON SALVAGE TANK WELDMENT GALLON SALVAGE TANK WELDMENT TANK-WLDMT, 34 GAL SALVAGE (LOADBED) TANK-WLDMT, 60 GAL SALVAGE (LOADBED) GALLON SALVAGE KIT (W/O WELDER) GALLON SALVAGE KIT (W/O WELDER) 2. REF PUMP ASM SALVAGE SIGHT GAUGE-.75 PLUG W/REFLCT FAST FILL-VENT (ZV10) REDUCER BUSH-STL ELBOW-MPT/45/M JIC HOSE FTG-TYPE F PARK A/R HOSE FTG-TYPE J PARK A/R HOSE FTG-TYPE Z PARK A/R 10. REF FILTER-REGULATOR-LUBRICATOR TEE-STREET STL NIPPLE-BARB BRS.50MPT/90/.75 (PART OF 1 FRL) REDUCER BUSH-STL NIPPLE-BARB BRS.25MPT HOSE-HYD R PAR A/R HOSE-GP.25 X 250 WP GRAY A/R CLAMP-HOSE SAE 4 SS HYD RESERVOIR WELDMENT FLOOR, 11' RR CRANE 1 REV. A

176 174 Dominator I Parts & Specifications Manual Part # Salvage Tank Installation, Welder in Load Bed ( ) 4 HOLES ø 0.41" 10.0" 10.0" 2.92" SLOT RADIUS 2.50" 15.53" (34 GAL) 24.79" (60 GAL) 4.28" 5.00" 37.75" MOUNTING HOLES AND CUTOUTS FOR INSTALLATION OF SALVAGE TANK WITH WELDER IN LOADBED. NOTE: See for plumbing information.

177 Chapter 11 Miscellaneous Options 175 Salvage Pump Assembly ( ) (Eff. 6-08) PARTS LIST ITEM PART # DESCRIPTION QUANTITY GAUGE-PRESS AIR 300 CNTR MNT REGULATOR-AIR FIXED VALVE-4WAY PUMP-DIAPHRAGM 1.00in METALLIC NIPPLE-PIPE BLK.12X CLOSE REDUCER BUSH-BLK COUPLING-RED BLK NIPPLE-BARB BRS.75MPT NIPPLE-BARB BRS.25MPT ADAPTER-MPT/HEX/MPT ELBOW-STREET STL.25 X 45 DEG ADAPTER-MPT/M JIC ADAPTER-MPT/HEX/MPT ADAPTER-MPT/HEX/MPT CLAMP-HOSE SAE FAST FILL-SOCKET VALVE-BALL HOSE-HYDRAULIC R4 1 REV. A

178 176 Dominator I Parts & Specifications Manual Part # Antifreeze/Salvage/Water Pump ( ) (Eff )

179 Chapter 11 Miscellaneous Options PARTS LIST ITEM PART # DESCRIPTION QUANTITY AIR VALVE ASSEMBLY (PART OF 30) CHECK BALL (PART OF 29) BEARING, SLEEVE 2 4. VALVE, PILOT (PART OF 30) 1 5. INTERMEDIATE 1 6. BUMPER (PART OF 30) 2 7. BUSHING (PART OF 30) 2 8. CAP, AIR INLET ASSEMBLY 1 9. CAPSCREW, 3/8-16 X CAPSCREW, HEX 5/16-18 X CAPSCREW, HEX HD, 5/16-18 X 1 1/ CAPSCREW, HEX HD 5/16-18 X 1 3/ CHAMBER, OUTER DIAPHRAGM (PART OF 29) GASKET, AIR VALVE (PART OF 30) GASKET, PILOT VALVE (PART OF 30) GASKET, AIR INLET CAP (PART OF 30) MANIFOLD, SUCTION MANIFOLD, DISCHARGE O-RING (PART OF 30) PLATE, INNER DIAPHRAGM PLATE, OUTER ACTUATOR PIN (PART OF 30) RING, RETAINER (PART OF 30) DIAPHRAGM ROD SEAL, U-CUP (PART OF 30) SEAT, CHECK BALL (PART OF 29) LOCK WASHER, 5/ FLUID REPAIR KIT (INCL. 2,14,27) REF AIR END KIT (INCL. 1,4,6,7,15-17,20,23,24,26) REF

180 178 Dominator I Parts & Specifications Manual Part # Salvage Pump Assembly ( /Dwg ) (Thru 5-08) ,4, PARTS LIST ITEM PART # DESCRIPTION QUANTITY VALVE-4WAY PUMP CAP SCR.31-18X 1.25 HH GR5 Z NUT HEX NYLOCK WASHER.31 FLAT ADPTR-MPT/HEX/MPT NIPPLE-BARB BRS.75MPT CLAMP-HOSE SAE ADPTR-MPT/M JIC FAST FILL-SOCKET (OS-2) ADPTR-MPT/HEX/MPT REGULATOR-AIR NIPPLE-PIPE BLK.12X CLOSE COUPLING-RED BLK GAUGE-PRESS AIR 300 CNTR MNT ELBOW-STREET STL.25 X 45 DEG HOSE-HYD R4 18" 19 18

181 Chapter 11 Miscellaneous Options PARTS LIST ITEM PART # DESCRIPTION QUANTITY VALVE-BALL NIPPLE-BARB BRS.25MPT REDUCER BUSH-BLK NEW

182 180 Dominator I Parts & Specifications Manual Part # Headache Rack Parts & Installation ( ) 3 2 6, 7 (SEE NOTE #3) 4, 5 4, 5 4, 5, 7 4, 5 4, 5 6, 7 (SEE NOTE #3) 5, 7 1 DETAIL A SCALE 3/16:1 NOTES: 1 Drill 3/8" diameter holes to fasten headache rack.

183 Chapter 11 Miscellaneous Options Item #3, headache rack end, required only with standard compartment. Used on either side. 3 Use bonded washers when attaching to sidepack PARTS LIST ITEM PART # DESCRIPTION QUANTITY 1. N/A BODY-W D2-11' R 1 L STD REF HEADACHE RACK BODY-BOLT ON A/R HEADACHE RACK END GUSSET-BOLT ON A/R CAP SCR.31-18X 1.0 HHGR5Z (WAS A/R , ) WASHER.31 FLAT (WAS ) A/R WASHER-BONDED PLTD.31 A/R NUT HEX NYLOC (WAS ) A/R REF HEADACHE RACK, DOMINATOR STANDARD RIGHT AND STANDARD LEFT REF HEADACHE RACK, DOMINATOR STANDARD LEFT AND RAISED RIGHT REF HEADACHE RACK, DOMINATOR RAISED RIGHT AND LEFT REV B REV. A

184 182 Dominator I Parts & Specifications Manual Part # Master Lock System Drawing ( ) 5 C B C 6 A D D

185 Chapter 11 Miscellaneous Options 183 MASTER LOCK SYSTEM DETAILS AT EACH DOOR ROD LOCATION DETAIL A SCALE 3/ " 1.19" 2.13" " AT END OF EACH ROD 4 10 DETAIL B SCALE 3/8 LOCATE & DRILL THROUGH HEADER AT ASSEMBLY. (HEADER NOT SHOWN) USE BRACKET AT END OF EACH ROD AND AT CENTER OF UNSUPPORTED SPAN OF 40" OR GREATER " 2.31" 1.0" DETAIL D SCALE 1/2 DRILL HOLES IN SIDEPACK 9 THROUGH ONE WALL ONLY. 8 MIRROR AS NEEDED FOR FRONT END OR LEFT SIDEPACK DETAIL C SCALE 3/8" SEE DETAIL "D" FOR DRILLING INSTRUCTIONS

186 184 Dominator I Parts & Specifications Manual Part # MASTER LOCK SYSTEM INSTALLATION C D PARTS LIST ITEM PART # DESCRIPTION QUANTITY BRACKET-PADLOCK MASTER LOCK A/R BRACKET-ROD STOP 2.00 M LOCK A/R COLLAR-SHAFT 2 PIECE 1/2 in. A/R WASHER-SS.50 FLAT TYPE 304 A/R 5. FRONT ROD-MASTER LOCK A/R 6. REAR ROD-MASTER LOCK A/R CAP SCREW-STAINLESS STEEL.31-18X1.00 A/R TRH PHH WASHER.25 FLAT (WAS , A/R ) NUT HEX NYLOC (WAS ) A/R BRACKET-ROD HANGER A/R CARRIAGE BOLT X 1.25 SQNK GR2 A/R (WAS ) GROMMET A/R REV. E

187 Chapter 11 Miscellaneous Options 185 Dominator I Master Lock Kits MASTER LOCK KIT BODY DESCRIPTION # FOOT DOMINATOR WITH RIGHT AND LEFT STANDARD FOOT DOMINATOR WITH RIGHT-FRONT RAISED, LEFT STANDARD FOOT DOMINATOR WITH RIGHT-FRONT RAISED, LEFT STANDARD FOOT DOMINATOR WITH RIGHT AND LEFT STANDARD FOOT DOMINATOR WITH RIGHT FRONT AND LEFT FRONT RAISED QUANTITY KIT # PART # DESCRIPTION DRAWING, INSTALLATION ROD- 106X COLLAR-SHAFT PIECE BRACKET PADLOCK BRACKET-ROD STOP BRACKET-ROD HANGER ROD- 37 X ROD- 43 X ROD- 60 X ROD- 95 X ' HARDWARE KIT ' HARDWARE KIT 1 1

188 186 Dominator I Parts & Specifications Manual Part # Fuel Fill, Chevy/GMC ( ) EXISTING CLAMP EXISTING ELBOW EXISTING TUBE EXISTING CLAMP FRONT OF CHASSIS PARTS LIST ITEM PART # DESCRIPTION QUANTITY ELBOW, 90 DEG FUEL HOSE 2 (RUBBER) HOSE CLAMP TUBE 1 NEW

189 187 C HAPTER 12 Welder Platforms In This Chapter Installation Kit, Dominator I & DSC20 (Kit /Dwg ) Welder Deck, 24" Long with 2 Underbody Toolboxes ( ) Welder Deck, 35" Long with 2 Underbody Toolboxes ( ) Welder Deck, 36" Long with Flat Deck ( ) Welder Deck, 24" Long with Tall Compartment ( ) Welder Deck, 35" Long with Curbside Tall Compartment ( ) Welder Deck, 35" Long with Streetside Tall Compartment ( )...195

190 188 Dominator I Parts & Specifications Manual Part # Installation Kit, Dominator I & DSC20 (Kit /Dwg ) D DETAIL D SECTION C-C

191 Chapter 12 Welder Platforms 189 NOTE: 1 24" DECK SHOWN; 36" INSTALLATION IS SIMILAR. 2 HARDWARE USED TO FASTEN UPPER PART OF BRACKET IS PART OF KIT ITEMS SHOWN ARE INCLUDED WITH A STANDARD BASE WELDER DECK ASSEMBLY PARTS LIST ITEM PART # DESCRIPTION QUANTITY BRACKET-MTG WELDER DECK D1 (II) WASHER.50 FLAT CAP SCR.50-13X 1.25 HH GR5 Z NUT HEX NYLOCK CAP SCR.62-11X 1.75 HH GR5 Z NUT HEX NYLOCK WASHER.62 FLAT TIE DOWN-BODY 4.00 FRAME ROD-THREADED X

192 190 Dominator I Parts & Specifications Manual Part # Welder Deck, 24" Long with 2 Underbody Toolboxes ( ) 1 2 A A SECTION A-A SCALE 0.16: PARTS LIST ITEM PART # DESCRIPTION QUANTITY WELDER DECK-WLDMT 35in L UBT-R UBT LATCH ASM-3PT DOM (II) COMPRESSION TIE DOWN-BODY 4.00 FRAME ROD-THREADED X WASHER.62 FLAT NUT HEX NYLOCK ROD-DOOR 8.12 LG W/.75" OFFSET 4 NEW

193 Chapter 12 Welder Platforms 191 Welder Deck, 35" Long with 2 Underbody Toolboxes ( ) 1 2 B C A B C A SECTION A-A SCALE 0.16:1 7 7 VIEW: INSIDE UBTB VIEW C-C SCALE 0.16: PART LIST ITEM PART # DESCRIPTION QUANTITY WELDER DECK-WLDMT 35in L UBT-R UBT LATCH ASM-3PT DOM (II) COMPRESSION TIE DOWN-BODY 4.00 FRAME ROD-THREADED X WASHER.62 FLAT NUT HEX NYLOCK ROD-DOOR 8.12 LG W/.75" OFFSET 4 NEW

194 192 Dominator I Parts & Specifications Manual Part # Welder Deck, 36" Long with Flat Deck ( ) PARTS LIST ITEM PART # DESCRIPTION QUANTITY HARNESS-LUBE FRONT MARKER LIGHTS HARDWARE KIT WELDER DECK, 36" FLAT TIE DOWN THREADED ROD, X 14 4

195 Chapter 12 Welder Platforms 193 Welder Deck, 24" Long with Tall Compartment ( ) 17 A A SECTION A-A SCALE 0.12:1 13 FOR CLARITY, COMPARTMENT TOP, FLOOR, DOORS NOT SHOWN PARTS LIST ITEM PART # DESCRIPTION QUANTITY REF D(II)-WELDER DECK-W D2 24in L RSD-R UBT INCL PANEL WELDER DECK UBTB RF # PANEL WELDER DECK UBTB RF # CHANNEL-FORM 1.24X 4.00X PANEL-WELDERDECK LF 60H # PANEL-WELDERDECK LF 60H # DOOR STOP-SELF CLOSING SPRING GUSSET-FRONT PANEL RH BTTM D GUSSET-FRONT PANEL LH BTTM D HINGE-SS 10GA BUTT W/IMT LOGO OFFSET BACK-BTM WELDER DECK RF D2 24in SDPK HEADER WELDER DECK CHANNEL-FORM 1.00X 2.00X MTG BAR-WLDR DECK 24in W D(II) BACK-BTM WELDER DECK LF D2 24in TOP WELDER DECK CARGO FLOOR UBTB- 1 VERT COMPT 24in TOP-WELDER DECK RSD COMPT D2 24in DOOR-WLDMT HEM D(II) 18.88H X 20.50W ( DOOR-WLDMT HEM D(II) 56.88H X 20.50W (40 1 NEW

196 194 Dominator I Parts & Specifications Manual Part # Welder Deck, 35" Long with Curbside Tall Compartment ( ) B C SECTION C-C SCALE 0.12:1 C B SECTION B-B SCALE 0.12: PARTS LIST ITEM PART # DESCRIPTION QUANTITY WELDER DECK-WLDMT 35in L UBTB-R RSD LATCH ASM-3PT DOM (II) COMPRESSION ROD-THREADED X TIE DOWN-BODY 4.00 FRAME NUT HEX NYLOCK WASHER.62 FLAT ROD-DOOR 8.12 LG W/.75" OFFSET ROD-DOOR LG W/.75" OFFSET 2 REV. A

197 Chapter 12 Welder Platforms 195 Welder Deck, 35" Long with Streetside Tall Compartment ( ) RIGHT SIDE LEFT SIDE ITEM PART # DESCRIPTION QUANTITY WELDER DECK-WLDMT 35in L RSD-R UBT LATCH ASM-3PT DOM (II) COMPRESSION TIE DOWN-BODY 4.00 FRAME ROD-THREADED X NUT HEX NYLOCK WASHER.62 FLAT ROD-DOOR 8.12 LG W/.75" OFFSET ROD-DOOR LG W/.75" OFFSET 2

198

199 197 C HAPTER 13 Dominator Decal Examples & Placement In This Chapter Decal List Dominator and Crane Logo Placement Body Safety Decal Placement Dominator Control Decal Placement Crane Safety Decal Placement on Dominator Door Hydraulic Oil Decal Placement Fuel Tank Decal Placement Air Tank Decal Placement Outrigger Decal Placement Reflector & Hitch Decal Placement Compressor Decal Placement...210

200 198 Dominator I Parts & Specifications Manual Part # Decal List Dominator I, II, IV, and DSC20 have many common and some unique decals. See the chart below and the decal application photos on subsequent pages for application details. ITE M DECAL PART NUMBER DESCRIPTION QUANTITY PER BODY MODEL NOTES DOMINATOR DECAL KIT 1 ALL INCLUDES ITEMS DECAL-DOMINATOR 2 ALL IDENTIFICATION DECAL-CAUTION, DON'T 1 ALL WASH/WAX DECAL-DIESEL FUEL ONLY 2 ALL FOR DIESEL ENGINES ONLY DECAL-UNLEADED GASOLINE ONLY 2 ALL FOR GASOLINE ENGINES ONLY DECAL-DANGER EXPLODING TANK 1 ALL DECAL-AIR TANK DRAIN 1 ALL DECAL-SERVICE & REPAIR 1 ALL DECAL-FUSE PANEL LAYOUT 1 DOM I & II DECAL-ELECTRICAL PANEL 1 DOM I & II DECAL-SWITCH BRACKET 1 DSC DECAL-ELECTRICAL PANEL 1 DOM IV DECAL-SWITCH PANEL 1 DOM IV MANUAL OPERATION, OUTRIGGER VALVEBANK (WAS PRIOR TO , FROM THRU ) MANUAL OPERATION, DOM IV OUTRIGGER VALVEBANK (WAS THRU ) DECAL-HITCH, RECEIVER 2000V P DECAL-HITCH, PINTLE 6000V P DECAL-CAUTION, WELDING DAMAGE 1 DOM I & II 1 DOM IV 1 DOM I & DSC 1 DOM II & IV 1 ALL BY LIGHT BOX ON REAR OF VEHICLE

201 Chapter 13 Dominator Decal Examples & Placement 199 Dominator and Crane Logo Placement Place the crane model number, item #1; IMT diamond, item #2; and Dominator ID Decal ( ), item #3; on each side of the unit as shown

202 200 Dominator I Parts & Specifications Manual Part # Body Safety Decal Placement Both Sides Both item # , and item # , are applied on all four sides of the carrier vehicle, so the operator can see the dangers regarding electrocution and the crane loadline from any point of crane operation.

203 Chapter 13 Dominator Decal Examples & Placement 201 Dominator Control Decal Placement Decal - Danger, Breathing Hazard Decal - Dominator Fuse Panel Decal - Dominator Electrical Panel (Dominator I and II) (Dominator IV uses Electrical Panel Decal) Decal - Manual Operation, Outrigger (Dominator I and II) (Dominator IV uses )

204 202 Dominator I Parts & Specifications Manual Part # Crane Safety Decal Placement on Dominator Door

205 Chapter 13 Dominator Decal Examples & Placement 203 Hydraulic Oil Decal Placement 1 Place , Decal-Mobil Oil Recommendations, on top of the hydraulic tank and on the right side of the fill cap. Decal must be legible from inside the load bed.

206 204 Dominator I Parts & Specifications Manual Part # Fuel Tank Decal Placement Note: If unleaded gas fuel tank, use decal part number

207 Air Tank Decal Placement Chapter 13 Dominator Decal Examples & Placement 205

208 206 Dominator I Parts & Specifications Manual Part # Outrigger Decal Placement

209 Reflector & Hitch Decal Placement Chapter 13 Dominator Decal Examples & Placement 207

210 208 Dominator I Parts & Specifications Manual Part #

211 Chapter 13 Dominator Decal Examples & Placement 209 Place four red reflector decals, , item #1, at the sides and outer edges of the tailgate as shown. Place two amber reflector decals, , item #2, at the front of the sidepacks as shown. Place the welding caution decal, , item #3, on the side of the light box at the left rear of the body. Place a hitch decal, item #4, above the hitch on the rear of the body. Typically, Dominator I and DSC use Receiver Hitch, 2000 lb tongue and 16,000 lb gross trailer weight. Typically, Dominator II and IV us Pintle Hitch, 6000 lb tongue and 30,000 lb gross trailer weight.

212 210 Dominator I Parts & Specifications Manual Part # Compressor Decal Placement The Dominator 2 may be purchased with a CAS435HA or CAS3560 compressor. Decal placement on a CAS435HA compressor: Decal placement on a CAS3560 compressor: Note: All decals for the CAS3560 air compressor are included on decal sheet See the CAS3560 manual for complete decal placement information.