IMT 6006i - Technical Specifications & Parts...20111028 99904458 ECN 11569 - UPDATE HYD MOTOR PORTS AND BOM 20120326 99904458 ECN 11686 - CORRECT HOSES. 51721396, 51721386 ECN 11581

Manual # 99904597

IMT 6006i - Technical Specifications & Parts

12v Model (Effective S/N 6006i091002)

Revised 20140925

IOWA MOLD TOOLING CO., INC.

PO Box 189 Garner, IA 50438

Tel: 641-923-3711 FAX: 641-923-2424 Website: http://www.imt.com

Copyright © 2014 Iowa Mold Tooling Co., Inc. All rights reserved

No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise without the prior written permission of Iowa Mold Tooling Co., Inc.

Iowa Mold Tooling Co., Inc. is an Oshkosh Corporation Company.

i

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

Electric Crane Introduction 5

Technical Specifications 7

6006i Technical Data .................................................................................................................................... 7 6006i Capacity Chart .................................................................................................................................... 9 Geometric Configuration ............................................................................................................................ 10 Pump & Motor Performance ....................................................................................................................... 11

Crane Reference 13

Assemblies & Grease Zerk Locations ......................................................................................................... 14 6006i Recommended Spare Parts List ........................................................................................................ 15 Crane Installation (99904394) .................................................................................................................... 17 Electric Crane Battery Circuit (99904884) ................................................................................................. 22 Electric Crane Control ................................................................................................................................ 22 Telescopic Crane Orientation ..................................................................................................................... 23

Parts 25

Parts Information ........................................................................................................................................ 26 Electric Crane Power Safety ....................................................................................................................... 28 Base & Mast Assembly (99904454) (See Parts List for Effectivity) .......................................................... 29 Base & Mast Assembly (99904454) (See Parts List for Effectivity) .......................................................... 32 Valve Bank (73734304) .............................................................................................................................. 35 Cylinder, Lower (51721396) ...................................................................................................................... 36 Boom Assembly (99904335) ...................................................................................................................... 39 Cylinder, Extension (51721386) ................................................................................................................. 42 Crane & Winch Assembly (99904456) (See Parts List for Effectivity) ..................................................... 44 Crane & Winch Assembly (99904456) (See Parts List for Effectivity) ..................................................... 48 Winch (71570923) ...................................................................................................................................... 52 Power Unit (73511282)(Effective 10/11/12) .............................................................................................. 53 Power Unit (73511155) (Through 10/11/12) .............................................................................................. 54 Electrical Installation (99904437) (See Parts List for Effectivity).............................................................. 55 Electrical Installation (99904437) (See Parts List for Effectivity).............................................................. 57 Tethered Control Installation (99904593) ................................................................................................... 59 Radio Control Installation, Standard (99904594) ....................................................................................... 60 Radio Control Installation, Proportional (99904595) ................................................................................. 61 Harness, Radio (77441270) ........................................................................................................................ 62 Harness, Tethered (77441269) .................................................................................................................... 64 Handle Assembly, Tethered (51721502) .................................................................................................... 65 Hydraulic Installation (99904458) .............................................................................................................. 68 6006i Decal Installation (95721549)........................................................................................................... 75

ii Contents

General Reference 77

Inspection Checklist .................................................................................................................................... 77 Deficiency / Recommendation / Corrective Action Report ........................................................................ 82 Thread Torque Chart (English) ................................................................................................................... 84 Thread Torque Chart (Metric) .................................................................................................................... 85 Turntable Bearing Thread Tightening Sequence ........................................................................................ 86 Turntable Bearing Inspection ...................................................................................................................... 87 Turntable Bearing Tilt Test ......................................................................................................................... 87

Contents iii

Revisions DATE LOCATION DESCRIPTION 20090521 99904454,

99904335, 99904456, 99904593, 99904437, 99904458

ECNs 11032, 11032-1, 11033: MINOR PARTS AND ASSEMBLY CHANGES AS A RESULT OF PRODUCTION AUDIT.

20091023 99904458 ECN 11099 - ADDED SPACER 20100324 99904458 ECN 11182 - ADDED PRESSURE TEST PORT 20100427 99904884 ADDED 99904884 AND EDITED ELECTRIC CRANE 99904394 STEP

5; ECN 11233 - ADDED WINCH CONTACTOR COVER PART NUM. 20100615 99904394 ADDED DUAL BATTERY WIRING INFORMATION 20100923 71570923 UPDATED WINCH SPARE PARTS 20111028 99904458 ECN 11569 - UPDATE HYD MOTOR PORTS AND BOM 20120326 99904458 ECN 11686 - CORRECT HOSES. 51721396,

51721386 ECN 11581 - CYLINDER DRAWING UPDATE.

20121011 99904454 ECN 11829 - POWER UNIT CHANGED 20130129 99904437 ECN 11829-1 - POWER CABLE CHANGED 20130413 99904456 ECN 11948 - A2B SWITCH MODIFICATIONS 20130513 99904456 ECN 11977-3 - CONTACTOR CHANGE 20130520 99904454 ECN 11977 - BASE WELDMENT CHANGE 20130601 99904456 ECN 11977-2 - CORD REEL CHANGE 20130605 99904454

99904456 ECN 11977-4 - PIN CHANGE

20130621 99904437 ECN 12007 - CONTACTOR HARDWARE CHANGE 20130901 99904456 ECN 11977-1 - A2B WELDMENT CHANGE 20131114 51721502 REMOVED TETHERED PROPORTIONAL REMOTE

POTENTIOMETER ADJUSTMENT PROCEDURE. 20131120 77441269

77441270 ECN 12063 – UPDATED HARNESS DRAWINGS AND SCHEMATICS

20140925 GREASING INSTRUCTIONS

ECN 12264 – MOLUB-ALLOY 882 WAS MOLUB-ALLOY 936.

99904454 ECN 12286 – 76039295 was REF, now quantity 1

5

This volume deals with information applicable to your particular crane. For operating, maintenance and repair instructions, refer to IMT Electric Cranes Operation & Safety (IMT part number 99904381.)

We recommend that this volume be kept in a safe place in the office.

This manual is provided to assist you with ordering parts for your IMT crane. It also contains additional instructions regarding your particular installation.

It is the user’s responsibility to maintain and operate this unit in a manner that will result in the safest working conditions possible.

Warranty of this unit will be void on any part of the unit subjected to misuse due to overloading, abuse, lack of maintenance and unauthorized modifications. No warranty - verbal, written or implied - other than the official, published IMT new machinery and equipment warranty will be valid with this unit. In addition, it is also the user’s responsibility to be aware of existing Federal, State and Local codes and regulations governing the safe use and maintenance of this unit. This crane was designed and built to meet the standards of ANSI/ASME B30.5, Mobile & Locomotive Cranes. Contact the American Society of Mechanical Engineers (www.asme.org) for more information.

Throughout the manual, NOTEs, CAUTIONs and WARNINGs are used to draw the attention of personnel. They are defined as follows:

For a safe work environment, treat this equipment with respect and service it regularly.

C H A P T E R 1

Electric Crane Introduction

CAUTIONA CAUTION is used when there is the

very strong possibility of damage to theequipment or premature equipment

failure.

WARNINGA WARNING is used when there is thepotential for personal injury or death.

NOTEA NOTE is used to either convey

additional information or to providefurther emphasis for a previous point.

7

In This Chapter 6006i Technical Data ................................................................ 7 6006i Capacity Chart ................................................................ 9 Geometric Configuration ........................................................... 10 Pump & Motor Performance ..................................................... 11

6006i Technical Data GENERAL SPECIFICATIONS CRANE RATING 38,000 ft-lb at 11'-0" (5.3 tm at 3.3 m) MAXIMUM HORIZONTAL REACH (from centerline of rotation)

22'-0" (6.7 m)

HYDRAULIC EXTENSION (1) 72" (183 cm) MANUAL EXTENSION (1) 72" (183 cm) LIFTING HEIGHT (from base of crane to centerline of sheave)

23'-6" (7.2 m)

CRANE WEIGHT (1H1M) 1450 lb (660 kg) CRANE STORAGE HEIGHT 37" (94 cm) MOUNTING SPACE REQUIRED (crane base) 18" x 18" (45.7 cm x 45.7 cm) HYDRAULIC SYSTEM OPERATING PRESSURE 2500 psi (172 bar) MAXIMUM HYDRAULIC FLOW 2.6 gpm OIL RESERVOIR CAPACITY 1.5 gallons (5.7 l) OIL TYPE ISO VG32, low pour, anti-wear hydraulic oil ELECTRICAL SYSTEM REQUIREMENTS 12VDC with two 1000 amp batteries* and 100 amp

alternator min. CENTER OF GRAVITY - HORIZONTAL FROM CENTERLINE OF ROTATION (BOOMS RETRACTED)

33" (84 cm)

- HORIZONTAL FROM CENTERLINE OF ROTATION (BOOMS EXTENDED)

65.5" (166 cm)

- VERTICAL FROM BOTTOM OF CRANE BASE 18" (45.7 cm) TIE-DOWN BOLT PATTERN (on center) 14.75" x 14.75" (37.5 cm x 37.5 cm) ROTATION TORQUE 4000 ft-lb MINIMUM CHASSIS REQUIREMENT 10,500 lb (4763 kg) GVWR * The two batteries must be identical in size with maximum cold-crank amp rating of 1000 CCA.

C H A P T E R 2

Technical Specifications

8 IMT 6006i - Technical Specifications & Parts 12v Model (Effective S/N 6006i091002)

CYLINDER SPECIFICATIONS LOWER BOOM CYLINDER 4.5" bore, 21.43" stroke (11.4 cm bore, 54.4 cm stroke) EXTENSION BOOM CYLINDER 2.5" bore; 72" stroke (6.4 cm bore; 183 cm stroke) WINCH SPECIFICATIONS FIRST WRAP LINE SPEED 11.5 ft/min (3.5 m/min) THIRD WRAP LINE SPEED 14 ft/min (4.3 m/min) ROPE DIAMETER 3/8" (9.6 mm) WIRE ROPE LENGTH 80' (24.3 m) CABLE BREAKING STRENGTH 15,100 lb (6,850 kg) PERFORMANCE CHARACTERISTICS ROTATION Continuous 360° (6.28 rad) LOWER BOOM ELEVATION -5° to +75° (-0.1 to +1.3 rad) EXTENSION CYLINDER 72" (1.8 m)

Chapter 2 Technical Specifications 9

6006i Capacity Chart

IOWA MOLD TOOLING CO., INC.BOX 189, GARNER, IA 50438-0189TEL: 641-923-3711 FAX: 641-923-2424

DISTANCE IN FEET/METERS / LOAD IN POUNDS/KG.Weight of load handling devices are part of the load lifted

and must be deducted from the capacity.

15°

30°

45°

60°

75°

18'5.5 m

15'4.6 m

12'3.6 m

9'2.7 m

6'1.8 m

3'0.9 m

0(Base)

24'7.3 m

21'6.4 m

18'5.5 m

15'4.6 m

12'3.6 m

9'2.7 m

6'1.8 m

3'0.9 m

21'6.4 m

60002720

60002720

60002720

60002720

49902265

36101640

60002720

38901765

27801260

53402420

33001495

23401060

46802125

28601300

2010910

39501790

24001090

1660755


Geometric Configuration 5'-10"

(1.77 m)

4'-3"(1.30 m)

2'-9"(83.8 cm)

1'-7" (48.2 cm)

10'-0" (3.05 m)16'-0" (4.88 m)

22'-0" (6.71 m)

23'-1"(7.03 m)

17'-3"(5.30 m)

11'-10"(3.60 m)

Chapter 2 Technical Specifications 11

Pump & Motor Performance The 12V Powerpack Motor for the 5005i and 6006i crane cannot be run continuously without serious motor damage. The pump has a maximum duty cycle of 2.5 minutes which must be followed by cool-down to ambient temperature. It can be run intermittently according to the following charts.

0

1

2

3

4

5

0.0

5.0

10.0

15.0

20.0

0

62

124

186

248

310

0 500 1000 1500 2000 2500 3000 3500 4000PSI

BAR0 25 50 75 100 125 150 175 200 225 250 275

Q - 2.5 CC

I - 2.5 CC

180 AMPS

2500 PSI

CAUTIONAvoid motor damage! Operate within

performance curves shown.


The five minute duty cycle must be adhered to. Operators have a choice of running the crane intermittently all day, using the duty cycles per the S2 and S3 curves, or at full power for 2.5 minutes, which MUST be followed by a complete cool-down to ambient.

13

In This Chapter Assemblies & Grease Zerk Locations ....................................... 13 6006i Recommended Spare Parts List ..................................... 14 Crane Installation (99904394) .................................................. 16 Electric Crane Battery Circuit (99904884) ................................ 22 Electric Crane Control .............................................................. 22 Telescopic Crane Orientation ................................................... 23

C H A P T E R 3

Crane Reference


Assemblies & Grease Zerk Locations

54

6

CRANE BASE

WINCH

SNATCHBLOCK

MAST

POWER UNIT

LOWER BOOM

EXTENSION BOOM

HOOK

HYDRAULICRESERVOIR

LOWER CYLINDER

32

1

ITEM LOCATION DESCRIPTION LUBRICANT FREQUENCY 1. Lower Cylinder Rod Shell Alvania 2EP

or Shell Retinax "A"

Weekly

2. Lower Cylinder Base 3. Gear Rotator Grease Extension

*Rotate crane while greasing. 4. Power Unit 5. Power Unit 6. Lower Boom Pin NOTE: All application points must be greased weekly under normal workloads and moderate weather conditions. Under severe operating conditions, lubricate more frequently. See the IMT Electric Crane Operation & Safety manual for additional lubrication requirements.

Chapter 3 Crane Reference 15

6006i Recommended Spare Parts List This parts list is intended to provide the user with a stock of parts sufficient to keep the unit operating with the minimal down-time waiting for parts, but it does not indicate these items will fail within a year. In addition, there may be parts failures not covered by this list. Parts not listed are considered as not being Critical or Normal Wear items during the first year of operations and you need to contact the distributor or manufacturer for availability. Part Number Description Quantity 51721396 Lower Cylinder 9D181823 SEAL KIT 1 6ID45143 PISTON 1 6HD45022 HEAD 1 73054999 VALVE-COUNTERBALANCE 1 77041786 SWITCH-PRESS 2750 psi 1 51721386 Extension Cylinder 51744143 SEAL KIT 1 6HD25015 HEAD 1 60127830 PISTON 1 73054999 VALVE 1 99904454 Base & Mast Assembly 60118032 CABLE CONNECTOR MODIFICATION 1 72060173 CAP SCREW .62-11X 3.75 HH 18 73051513 MOTOR-HYDRAULIC 1 76039295 GASKET-GEAR 1 77441336 SWITCH- 275A CONTACTOR 1 77441281 CABLE CONNECTOR-FEMALE 1 77441285 TERM RING INSULATED 3/8 STUD 1 72060178 CAP SCREW .62-11X 4.00 HEX HEAD GRADE 8

ZINC 15

73734304 Valve Bank (12V) 77040327 COIL (VALVE BANK) 6 73540326 VALVE ASSEMBLY (VALVE & COIL) 3 73734735 Valve Bank (24V) 77040527 COIL (24V) 6 73540326 SOLENOID VALVE (24V) 3 73511155 Power Unit (through 10/11/12) 70733826 BREATHER CAP 1 73511170 PUMP-GEAR 5005/6006I ELECTRIC CRANE 1 73540323 VALVE-RELIEF ELECTRIC CRANE 1 73734332 KIT-TUBE POWER UNIT ELECTRIC CRANE 1 74397392 RESERVOIR TANK ELECTRIC CRANE 1 77043060 MOTOR-POWER UNIT ELECTRIC CRANE, 12V 1


Part Number Description Quantity 73511282 12V Power Unit (effective 10/11/12) 77043065 MOTOR (12V) 1 73511307 PUMP 1 73540517 RELIEF VALVE ASSEMBLY 1 74399495 RESERVOIR 1 70734788 BREATHER - CAP 1 73734791 TUBE - SUCTION 1 70734792 STRAINER 1 73511308 24V Power Unit 77043066 MOTOR (24V) 1 73511307 PUMP 1 73540517 RELIEF VALVE ASSEMBLY 1 74399495 RESERVOIR 1 70734788 BREATHER - CAP 1 73734791 TUBE - SUCTION 1 70734792 STRAINER 1 99904335 Boom Assembly 60030380 WEAR PAD- EXTENSION CYLINDER 1 60030339 WEAR PAD-ROUND 2.00 DIA X .60 DIA X 1.00 LG 6 60030340 WEAR PAD-BLOCK 4.50 X 4.50 X .44 2 60030341 WEAR PAD-BLOCK 4.50 X 3.50 X .44 2 60133062 WEAR PAD-ROUND 1.00 DIA X .62 DIA X .81L 2 60132302 STOP SCREW 3/8-24 X .50 2 72661514 PIN-LOCK W/HANDLE .875 X 4.25 1 70144211 PIN- .75X 6.50 LONG 1 60030134 SHEAVE- 8.00 NYLATRON GSM 2 99904456 Crane & Winch Assembly 51720302 CORD REEL ASSEMBLY (through 06/01/13) 1 51725225 CORD REEL ASSEMBLY (effective 06/01/13) 1 70580198 WIRE ROPE ASSEMBLY 1 71413196 SPRING-.105WIRE 0.75OD 2.875 LG 1 72601798 WASHER-LOCK 12MM 4 72601935 CAP SCREW M12-1.75X 40 SOCKET-HEAD

PLAIN 4

72601938 BOLT-EYE # 8-32X .75 1 77041459 SWITCH-LIMIT 1 77441096 CONNECTOR- .50 STRAIN RELIEF .25-.38 1 77041802 CONTACTOR, WINCH (through 05/13/13) 1 77041936 CONTACTOR, WINCH (effective 05/13/13) 1 71570923 Winch (12V) 77041802 CONTACTOR (through 05/13/13) 1 77041936 CONTACTOR (effective 05/13/13) 1 77566637 BRAKE ASSEMBLY 1 77744174 BRUSH KIT 1


Crane Installation (99904394) 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 1. 51721572 ELECTRIC CRANE BODY INSTALLATION 1 2. 91721647 HARDWARE KIT- 3203i/4004i ELEC CRANE BODY

INSTALLATION 1

3. 91721751 HARDWARE KIT- 5005i ELEC CRANE BODY INSTALLATION

1

4. 51725572 KIT-ELECTRIC CRANE BODY INSTALLATION 1 5. 99904317 DRAWING-CRANE & WINCH ASSEMBLY REF 6. 60251272 BRACKET-SWITCH 300 AMP ELEC CRANE #1 & #4 1 7. 70734331 SWITCH-300A KEYED BATTERY DISCONNECT #1 & #4 1 8. 72042097 LEVEL INDICATOR LEVEL #1 & #4 1 9. 77040209 TERMINAL-RING NI .38 STUD 1 WIRE #1 & #4 1 10. 77040529 TERMINAL-RING NI .31 STUD 1-2 WIRE #1 3 10. 77040529 TERMINAL-RING NI .31 STUD 1-2 WIRE #4 9 11. 77441116 FUSEHOLDER-HIGH AMP2 BOLT WITH COVER #1 1 11. 77441116 FUSEHOLDER-HIGH AMP2 BOLT WITH COVER #4 2 12. 77441219 FUSE-225 AMP #1 1 12. 77441219 FUSE-225 AMP #4 2 13. 89044276 CABLE-#1 WELDING #1 & #4 35 FT 14. 89392333 TUBE-HEAT SHRINK AMP #1 & #4 .50 FT 15. 72601621 CAP SCR 1.00- 8X 3.00 HH GR8 Z #3 4 16. 72062375 NUT 1.00- 8 HEX NYLOC GR8Z #3 4 17. 72063066 WASHER 1.00 HI STR ZINC YELLOW #3 8 18. 72060002 CAP SCREW .25-20X .75 HH GR5 Z #2 & #3 4 19. 72060634 SCREW-MACHINERY #10-24X .50 RDH #2 & #3 4 20. 72062000 NUT .25-20 HEX #2 & #3 4 21. 72062106 NUT 10-24 HEX NYLOCK #2 & #3 4 22. 72063001 WASHER .25 FLAT #2 & #3 8 REV. 20120918


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 1-8x3" mounting cap screws (item # 15), 1" nuts (item #16) and 1" washers (item #17) to secure the crane base to the truck body (see figure). Torque the cap screws to 680 ft-lb (94 kg-m).

NOTE:

The 1-8 x 3" grade 8 zinc coated capscrews are designed for a crane box thickness of 7/8" to 1" only. A different crane box may require different capscrews. All mounting capscrews must be grade 8 zinc coated of proper length. Failure to use proper length capscrews could cause the bolts to bottom out before torqued.

18"

1.13"

18"9"

9" 13"

15.17(SEE

NOTE)

5005i - 6006i MOUNTING PATTERN

ALLOW 16" (40.6 cm) RADIUSFOR SWING CLEARANCE

16,17

14.75"

7.38"

14.75"7.38"


2 The electrical power switch (item #7) provides power for the crane. Install the switch onto the power unit cover.

7

8

21

6

18

19 6

2022

22

LOCATION OFSWITCH BRACKET

IN CRANE BOX

4 HOLES,0.266" DIA.

3.5"

5.03"

2.75"

13.5"

INSIDE VIEWOF CRANE BOX

KEY SUPPLIEDWITH 70734331

SWITCH. SPAREKEY - 70734357.

3 Install the vehicle level indicator (item #8) parallel to the door reinforcements.

4 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, 51721572, includes a 10.7 m (35') long cable, IMT # 89044276 (item #13 in the parts list). Approximately 7.6 m (25') of this cable is required to connect the crane power switch to the vehicle battery, and the rest of the cable is used for ground connections between the crane, vehicle battery, auxiliary battery, and chassis ground. 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.

6 Connect the crane power cable from the male power cable connector to the power switch. Connect cable (item #13 - 89044276), cut to length, from the crane power switch (item #7) to the fuse. Use 3/8" (0.95 cm) ring terminals (item #9 - 77040209) for each connection. Heat shrink the connections (item #14 - 89392333).

WARNINGProtect the power cable from damage byfastening it inside the frame channel and

covering it with protective covering includingloom, conduit, etc. Be sure to use rubber

grommets or other protection when runningthe power cable through steel bulkheads.


A 13

7

14

9POWERCABLEBRACKET

GROUND CABLE (GROUNDTO BARE METAL INSIDECRANE BOX)

MALE POWERCABLE CONNECTOR 89044276 (#13)

ON-OFF SWITCH TO FUSE(CUT TO LENGTH)

7 Use approximately 4' (1.2 m) of the cable (item #13) to ground the vehicle battery. Connect one end of the ground cable to the negative terminal on the vehicle battery, and the other end to bare metal on the truck body. Use a 5/16" (0.79 cm) ring terminal (item #10 - 77040529) to connect to the truck body.

WARNINGInstall the ground cable to the negative

terminal of the batteries! The crane electricalground completes the electrical circuit

through the structure of the crane to thevehicle frame. The vehicle factory ground is

NOT sufficient to carry the current required bythe crane. Without this extra ground cable,

your crane may not operate at rated capacity,and motor, contactor, or electrical damage

may occur.


8 Mount the 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 terminal 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 #10 - 77040529). Heat shrink connections.

FROM ON-OFF SWITCHIN CRANE BOX

1000 CC AAUXILIA RYBATTE RY (IN CRANE BOX)

11

12

1311

11

TO CHASSIS GROUND

89044276 or 77040009BATTE RY (-) TO CHASSIS GROUND(CUT T O LENGTH)

89044276 or 77040009FUSE TO B ATTE RY (+)(APPROXIM ATE LY 1FT)

13-CABLE #89044276 or27-CABLE #77040009(CUT T O LENGTH)(CRANE ON-OFFSWITCH TO FUSE)

HE AT SHRINK

HE AT SHRINK

TO CHASSIS GROUND

UNDERHOODBATTE RY

13-CABLE #89044276 or27-CABLE #77040009(CU T TO LENGTH)

13-CABLE #89044276 or27-CABLE #77040009(CU T TO APPROX. 1' (30.5 CM))(FUSE TO B ATTE RY (+))

12

1113

11

ITEMS WITHIN BOXARE ONLY NEEDEDWHENAUXILIARY BATTERY ISINSTALLED IN CRANE BOX.* MATCHED BATTERIESARE REQUIRED*

13-CABLE #89044276 or27-CABLE #77040009(CUT T O LENGTH)(CRANE ON-OFFSWITCH TO FUSE)

2911

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. (IMT # 77041774)

3. Reference drawing 99904884 for wiring diagram.


Electric Crane Battery Circuit (99904884)

GROUND ATCHASSIS FRAME

225A


UNDERHOODBATTERY

2ND AUXBATTERY

225A18" (457 mm)MAXIMUM

18" (457 mm)MAXIMUM


SW

CRANE

1

NOTES (SEE REFERENCE NUMBER IN BOX): 1 ELECTRIC BULKHEAD PASS-THRU CONNECTOR. USE WHENEVER POWER OR GROUND PASSES

THROUGH A COMPARTMENT WALL.

Electric Crane Control IMT's electric cranes are controlled by radio or tethered remote controls. This telescopic crane includes a tethered remote control with a radio remote control option. For complete details on operating your telescopic crane, refer to the IMT Electric Cranes Operation & Safety (part number 99904381).


Telescopic Crane Orientation When an IMT telescopic crane is not factory-installed on a body, the crane is packed with the boom oriented as it is built on a test stand to facilitate handling. Install the crane on the body with boom pointing backward. Once the crane is bolted down, it can be rotated 180° (3.14 radians) to the boom rest.

400°ROTATION

OUTLINE OFTRUCK BODY

REAR OFTRUCK

BOOMREST

25

In This Chapter Parts Information ...................................................................... 26 Electric Crane Power Safety ..................................................... 28 Base & Mast Assembly (99904454).......................................... 29 Valve Bank (73734304) ............................................................ 35 Cylinder, Lower (51721396) ..................................................... 36 Boom Assembly (99904335) .................................................... 39 Cylinder, Extension (51721386) ............................................... 42 Crane & Winch Assembly (99904456) ...................................... 44 Winch (71570923) .................................................................... 52 Power Unit (73511282) ............................................................ 53 Power Unit (73511155)............................................................. 54 Electrical Installation (99904437) .............................................. 55 Tethered Control Installation (99904593) ................................. 59 Radio Control Installation, Standard (99904594) ...................... 60 Radio Control Installation, Proportional (99904595) ................. 61 Harness, Radio (77441270) ..................................................... 62 Harness, Tethered (77441269) ................................................. 64 Handle Assembly, Tethered (51721502) .................................. 65 Hydraulic Installation (99904458) ............................................. 68 6006i Decal Installation (95721549) ......................................... 75

C H A P T E R 4

Parts


Parts Information GENERAL

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

WARNINGDo not attempt to repair any component

without reading the information contained inthe repair section. Pay particular attention to

statements marked Warning, Caution orNote in that section. Failure to comply withthese instructions may result in damage tothe equipment, personal injury or death.

CRANE IDENTIFICATION

Every IMT crane has an identification placard (see figure). This placard is attached to the inner boom, mast, or crane base. When ordering parts, communicating warranty information, or referring to the unit in correspondence, always include the serial number and model numbers. Address all inquiries to your authorized IMT distributor or to:

Iowa Mold Tooling Co., Inc. Box 189, Garner, IA 50438-0189 Telephone: 641-923-3711 Technical Support Fax: 641-923-2424

MODELNUMBER

SERIALNUMBER

MFGDATE

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

Chapter 4 Parts 27

CYLINDER IDENTIFICATION

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

CYLINDERPART NUMBER

LOCATION

WELDMENT IDENTIFICATION

Each of the major weldments - base, mast, inner boom, outer boom, extension boom and stabilizer weldments bear a stamped part number. Any time a major weldment is replaced, you must specify the complete part number as stamped on the weldment. The locations of the part numbers are shown in the Crane Reference Section.

ORDERING REPAIR PARTS

When ordering replacement parts:

1 Give the model number of the unit.

2 Give the serial number of the unit.

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

4 Give a complete description of the part.

5 Specify the quantity required.


Electric Crane Power Safety Your electric crane runs using power from the vehicle battery. Before beginning major maintenance or repairs, disconnect the power to the crane.

DANGER

POWER SWITCHTURNED TO OFFPOSITION.

AVOID DEATH OR SERIOUS INJURY!

Before beginning any work on crane,

Turn OFF crane power supply in crane cabinet.

Remove crane power disconnect cable from vehicle battery.

1 Make sure the power switch located inside the crane cabinet is turned to the OFF position.

2 Make sure the crane power disconnect cable is disconnected from the vehicle battery.

Chapter 4 Parts 29

Base & Mast Assembly (99904454) (See Parts List for Effectivity)

11

26, 36

29, 22, 1031, 33, 23

23, 33, 31

27, 37

28, 38

28, 37

1250

6

1317

18, 20, 19

24, 34

5

9

36, 26

49

45

29, 22, 10

47

30

3544

14

52

3322

53

54

55

DETAIL A

A

31, 42

18

418

8

46

4851

16153039

4143

7

23, 33, 31

51, 34

563525

CONTACTOR ASSEMBLY

LOWER CYLINDER &GEAR SHROUD ASSEMBLY

BASE & ROTATORASSEMBLY

ELECTRIC ROTATORBRACKET LOCATION

VALVE BANK & POWERUNIT ASSEMBLY

1

2

3

5

7

3

5

ROTATOR & MASTASSEMBLY

WARNINGAvoid injury! Do NOT connect electrical power

to crane until all connections have beentested. Attach electrical wires and grounds to

components before connecting to mast.


NOTES (SEE REFERENCE NUMBER IN BOX): 1 APPLY BLACK "MOLUB-ALLOY 882 HEAVY" GEAR GREASE TO TURNTABLE GEAR.

2 APPLY RUST PREVENTATIVE.

3 TORQUE TO 160 FT-LB

4 SEE ELECTRIC ROTATOR BRACKET LOCATION (VIEW A).

5 USE THESE TAPPED HOLES FOR ELECTRICAL BRACKET.

6 USE ANTI-SEIZE.

7 ATTACH GROUND CABLE HERE. 99904454 PARTS LIST ITEM PART # DESCRIPTION KIT # QTY 1. 51721422 KIT-HRDW BASE & MAST 5005I 1 2. 91722221 KIT- 5005I ELECTRICAL INSTALLATION 1 3. 51721707 KIT-HYD 5005I 1 4. 51721396 CYL- 4.50B X 2.25R X 21.43S 33.45 CC C 1 5. 52725224 WLDMT- BASE 5005I (effective from 05/20/13) 1 6. 52722162 MAST WELDMENT-5005I/6006I 1 7. 60141134 PIN-TYPE MM 1.50X 8.25 (7.69) (effective from 06/05/13) 1 8. 60132610 SHROUD- TURNTABLE GEAR 5005I 1 9. 60132385 SPACER- POWER UNIT 1 10. 70580194 CLAMP-I" CONDUIT HANGER W/BOLT 2 11. 71056632 GEAR-TRNTBL BRG 17.60" DIA 1 12. 60132856 MNT BRK GREASE HOSE 4004I 1 13. 73051513 MOTOR-HYD 158-1083-001 1 14. 73734304 VALVE BANK-3 SEC SERIES 3GPM @ 500PSI 12VDC 1 15. 60133635 CONTACT JUNCTION 1 16. 72062002 NUT .38-16 HEX #1 1 17. 76039295 GASKET-GEA19 008-10056-1 1 18. 70034382 CAP-GREASE PRO20 GC-RED #1 3 19. 72053301 COUPLING-BLK .12 #1 1 20. 72053508 ZERK-NPT .12 #1 1 22. 72060002 CAP SCR .25-20X .75 HH GR5 Z (WAS 9) #1 7 23. 72060001 CAP SCR 0.25-20 X 0.62 HH GR5 (effective from 05/20/13) 5 24. 72060051 CAP SCR .38-16X 2.25 HH GR5 Z #1 2 25. 72060091 CAP SCR .50-13X 1.00 HH GR5 Z #1 1 26. 72060147 CAP SCR .62-11X 1.00 HH GR5 Z #1 2 27. 72060173 CAP SCR .62-11X 3.75 HH GR8 Z #1 18 28. 72060178 CAP SCR .62-11X 4.00 HH GR8 Z #1 15 29. 72062104 NUT .25-20 HEX NYLOCK #1 2 30. 72062207 NUT 8-32 HEX NYLOCK #1 4 31. 72063001 WASHER .25 FLAT #1 8 33. 72063049 WASHER .25 LOCK #1 10 34. 72063051 WASHER .38 LOCK #1 3 35. 72063053 WASHER .50 LOCK #1 3 36. 72063055 WASHER .62 LOCK #1 2 37. 72063119 WASHER .62 FLAT ASTM F436 #1 31 38. 72063216 WASHER .62 N FLAT-CUT 3816 #1 2 39. 72063271 WASHER # 8 W FLAT ANSI B27.2Z #1 4

Chapter 4 Parts 31

99904454 PARTS LIST ITEM PART # DESCRIPTION KIT # QTY 41. 72602009 SCR-MACH # 8-32X 1.25 BTNHD SS #1 3 42. 72601941 SCR-MACH .25-20X .38 BTNHD ZC #1 1 43. 72602010 SCR-MACH # 8-32X 1.50 BTNHD ZC #1 1 44. 72601949 CAP SCR .50-13X 1.25 SH ZC #1 2 45. 51721944 CABLE ASM- 1GA-3/8RNGX SWVL MX 60.00LG #2 1 46. 77441336 SWITCH- 275A CONTACTOR (SSC42-275) #2 1 47. 51722218 CABLE ASM- 1GA-3/8RNGX SWVL FX 13.50LG #2 1 48. 77441312 CABLE ASM-10GA-#10RNGX 1/4RNGX 6.00LG #2 1 49. 77441332 CABLE ASM- 1GA-1/4RNGX 3/8RNGX 46.50LG BLK #2 1 50. 51395121 HOSE-AA .13 X 13.50 (2-2) 100R17 #3 1 51. 72060044 CAP SCR .38-16X .75 HH GR5 Z #1 2 52. 60132301 BRACKET-VALVE MOUNT 1 53. 73511282 POWER UNIT- 2.65CC 12VDC GC (effective from 10/11/12) 1 54. 60141131 WLDMT- ELEC ROTATOR BRKT BOTTOM 5005I (effective from 05/20/13) 1 55. 60141130 WLDMT- ELEC ROTATOR BRKT TOP 5005I (effective from 05/20/13) 1 56. 71415015 KEEPER-PIN 0.50 (effective from 06/05/13) 1 REV L 20140916


Base & Mast Assembly (99904454) (See Parts List for Effectivity)

13

9

1454

6

1620

910

15

5

11

53

4910

51

34

3948

17

56

3725

30,40 30,40

31,41

2

3

4

26,35,37

26,35,3712,25,33

12,25,33

BASE & ROTATORASSEMBLY ROTATOR & MAST

ASSEMBLY

21,22,231 VALVEBANK & POWER

UNIT ASSEMBLY

5

528,38

ELECTRICROTATORBRACKETLOCATION

332,41

32,42

99904454 DRAWINGS

A

21

4

2144

7

8

50

5255

1918

34 43

4547

6

7

LOWER CLYINDER& GEAR SHROUD ASSEMBLY

29,36,39

24,35,37

CONTACTOR ASSEMBLY

38,55

35,46

DETAIL A

Chapter 4 Parts 33

WARNINGAvoid injury! Do NOT connect electrical power

to crane until all connections have beentested. Attach electrical wires and grounds to

components before connecting to mast. NOTES (SEE REFERENCE NUMBER IN BOX): 1 APPLY BLACK "MOLUB-ALLOY 882 HEAVY" GEAR GREASE TO TURNTABLE GEAR.

2 APPLY RUST PREVENTATIVE.

3 TORQUE TO 160 FT-LB

4 SEE ELECTRIC ROTATOR BRACKET LOCATION (VIEW A).

5 USE THESE TAPPED HOLES FOR ELECTRICAL BRACKET.

6 USE ANTI-SEIZE.

7 ATTACH GROUND CABLE HERE. 99904454 PARTS LIST ITEM PART # DESCRIPTION KIT # QTY 1. 51721422 KIT-HRDW BASE & MAST 5005I 1 2. 91722221 KIT- 5005I ELECTRICAL INSTALLATION 1 3. 51721707 KIT-HYD 5005I 1 4. 51721396 CYL- 4.50B X 2.25R X 21.43S 33.45 CC C 1 5. 52721356 WLDMT- BASE 5005I (effective through 05/20/13) 1 6. 52722162 MAST WELDMENT-5005I/6006I 1 7. 52721425 PIN-TYPE MM 1.50X 8.25 (7.69) (effective through 06/05/13) 1 8. 60132610 SHROUD- TURNTABLE GEAR 5005I 1 9. 52721420 WLDMT- ELEC ROTATOR BRKT TOP 5005I (effective through 05/20/13) 1 10. 52721421 WLDMT- ELEC ROTATOR BRKT BOTTOM 5005I

(effective through 05/20/13) 1

11. 60132385 SPACER- POWER UNIT 1 12. 70580194 CLAMP-I" CONDUIT HANGER W/BOLT 2 13. 71056632 GEAR-TRNTBL BRG 17.60" DIA 1 14. 60132856 MNT BRK GREASE HOSE 4004I 1 15. 73511155 POWER UNIT- 2.65CC 12VDC GC (effective through 10/11/12) 1 16. 73051513 MOTOR-HYD 158-1083-001 1 17. 73734304 VALVE BANK-3 SEC SERIES 3GPM @ 500PSI 12VDC 1 18. 60133635 CONTACT JUNCTION 1 19. 72062002 NUT .38-16 HEX #1 1 20. 76039295 GASKET-GEA19 008-10056-1 1 21. 70034382 CAP-GREASE PRO20 GC-RED #1 3 22. 72053301 COUPLING-BLK .12 #1 1 23. 72053508 ZERK-NPT .12 #1 1 24. 72060000 CAP SCR .25-20X .50 HH GR5 Z (WAS 72060001)

(effective through 05/20/13) #1 3

25. 72060002 CAP SCR .25-20X .75 HH GR5 Z (WAS 9) #1 7 26. 72060004 CAP SCR .25-20X 1.0 HH GR5 Z (WAS 72060043)

(effective through 05/20/13) #1 2

28. 72060051 CAP SCR .38-16X 2.25 HH GR5 Z #1 2


99904454 PARTS LIST ITEM PART # DESCRIPTION KIT # QTY 29. 72060091 CAP SCR .50-13X 1.00 HH GR5 Z #1 1 30. 72060147 CAP SCR .62-11X 1.00 HH GR5 Z #1 2 31. 72060173 CAP SCR .62-11X 3.75 HH GR8 Z #1 18 32. 72060178 CAP SCR .62-11X 4.00 HH GR8 Z #1 15 33. 72062104 NUT .25-20 HEX NYLOCK #1 2 34. 72062207 NUT 8-32 HEX NYLOCK #1 4 35. 72063001 WASHER .25 FLAT #1 8 36. 72063132 WASHER .50 FLAT ASTM F436 (effective through 06/05/13) #1 1 37. 72063049 WASHER .25 LOCK #1 10 38. 72063051 WASHER .38 LOCK #1 3 39. 72063053 WASHER .50 LOCK #1 3 40. 72063055 WASHER .62 LOCK #1 2 41. 72063119 WASHER .62 FLAT ASTM F436 #1 31 42. 72063216 WASHER .62 N FLAT-CUT 3816 #1 2 43. 72063271 WASHER # 8 W FLAT ANSI B27.2Z #1 4 44. 72066132 RETAINING RING-EXT 1.50 HD (effective through 06/05/13) #1 1 45. 72602009 SCR-MACH # 8-32X 1.25 BTNHD SS #1 3 46. 72601941 SCR-MACH .25-20X .38 BTNHD ZC #1 1 47. 72602010 SCR-MACH # 8-32X 1.50 BTNHD ZC #1 1 48. 72601949 CAP SCR .50-13X 1.25 SH ZC #1 2 49. 51721944 CABLE ASM- 1GA-3/8RNGX SWVL MX 60.00LG #2 1 50. 77441336 SWITCH- 275A CONTACTOR (SSC42-275) #2 1 51. 51722218 CABLE ASM- 1GA-3/8RNGX SWVL FX 13.50LG #2 1 52. 77441312 CABLE ASM-10GA-#10RNGX 1/4RNGX 6.00LG #2 1 53. 77441332 CABLE ASM- 1GA-1/4RNGX 3/8RNGX 46.50LG BLK #2 1 54. 51395121 HOSE-AA .13 X 13.50 (2-2) 100R17 #3 1 55. 72060044 CAP SCR .38-16X .75 HH GR5 Z #1 2 56. 60132301 BRACKET-VALVE MOUNT 1 REV. E 20090520

Chapter 4 Parts 35

Valve Bank (73734304)

1

4 4

4444

4

SAE #4ORB PORT(2 PLACES)

SAE #4ORB PORT

SAE #4ORB PORT(4 PLACES)

SAE #4ORB PORT

2,3(2) 2,3(2)

2,3(2)

B2A2 B3A3B1A1

S2 S3S1

P T

EXTENSION MAINROTATE

HYDRAULIC SCHEMATIC 73734304 PARTS LIST ITEM PART # DESCRIPTION QUANTITY 1. MANIFOLD VALVE BODY 1 2. 73540326 SOLENOID VALVE (INCLUDES COIL) 3 3. 73540327 COIL, 12V. 6 4. PLUG, EXPANDER, 7MM 7 REV A 20081028


Cylinder, Lower (51721396)

2

7

3

16

5

149

146

8

15

11

1315

12

19

4

1017 21

Chapter 4 Parts 37

A

A

3

16 5 14 9 14

6 8

1115 1315

12

7

410417

DRILL #15HOLE 3/16"DEEP, PRESSIN PIN 60125699

33.52" CLOSED54.88" OPEN

21.43" STROKE

SECTION A-A

NOTES: 1 TO REDUCE DOWNTIME, REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS

DISASSEMBLED.

2 APPLY "NEVER-SEEZ" REGULAR GRADE ANTI-SEIZE AND LUBRICATING COMPOUND TO THREADS ON CYLINDER HEAD ONLY. KEEP AWAY FROM ALL SEALS.

3 APPLY "LUBRIPLATE" NO. 630-2 MEDIUM HEAVY, MULTI-PURPOSE LUBRICANT, TO ALL PISTON, HEAD GLAND, AND HOLDING VALVE SEALS, NYLON LOCK RING, CAST IRON PISTON RINGS, AND ROD STINGER THREADS.

4 ITEM #8, STOP TUBE, REPLACES 6A025022 WAFER LOCK. USE STOP TUBE INSTEAD OF WAFER LOCK WHEN RESEALING CYLINDER.

51721396 CYLINDER DATA CASE ø5.13" O.D. X ø4.5" BORE X 30.89" LENGTH ROD ø2.25" X 29.83" LONG STROKE 21.43" DRY WEIGHT 112.87 LB TEST PRESSURE 3000 PSI OPERATING PRESSURE 2500 PSI TORQUE VALUES PISTON TO ROD: 710 - 740 FT-LB

HEAD GLAND TO CYLINDER: 450 FT-LB CARTRIDGE TORQUE - 30-35 FT-LB

51721396 PARTS LIST ITEM PART # DESCRIPTION KIT # QUANTITY 1. 9D181823 SEAL KIT #20 1 2. 52721397 ROD ASSEMBLY #20 1 3. 52721399 CASE ASSEMBLY #20 1 4. 6HD45022 HEAD #20 1 5. 6ID45143 PISTON #20 1 6. 60125920 STOP TUBE #20 1 7. 60125699 PIN - LOCK TUBE #20 1 8. 60138275 STOP TUBE (WAS 6A025022) #1 1 9. 7Q072155 O RING 4.00X 4.19X .09 70 #1 1 10. 7Q072346 O RING 4.12X 4.50X .19 70 #1 1 11. 7Q10P346 BACKUP RING-4.12 ID X 4.50 OD #1 1 12. 7R14P022 ROD WIPER-TYPE D 2.25 ROD #1 1


51721396 PARTS LIST ITEM PART # DESCRIPTION KIT # QUANTITY 13. 7R546022 U-CUP LOADED 2.25X2.75X.38 "B #1 1 14. 7T2N4045 WEAR RING - PISTON 4.50 O.D. X .50 W #1 2 15. 7T2NX625 WEAR RING-ROD 2.25 IDX0.75 #1 2 16. 7T61N143 LOCK RING-NYLON 1.43 #1 1 17. 7T66P045 PISTON SEAL-DYNAMIC 4.50in #1 1 19. 77041786 SWITCH-PRESS 2750 PSI NC 42in LEAD 1 20. 51721396A CYL-4.5/2.2 21.43S 33.45CC C 1 21. 73054999 VALVE-CBAL SUN01 CBBC-LHN #3 1 REV D 20120326

Chapter 4 Parts 39

Boom Assembly (99904335) BOOM ASSEMBLY, 1H 1M (99904335)

2021

2

2914292825

2528

29

1429

2430

29

8

13

9

1911

13

189

17

2726

16

2627

4

6

1012

12119

9

3

10

2227

2227

7153023

1530

23

9

9

3131

BOOM EXTENSIONS (1H 1M)(COMPLETE)


BOOM ASSEMBLY, 1H (99904335)

20

2

109

9

1429

292825

2528

29

1429

2430

298

17

2227

2227

2726

27

26

16

12

10

125

3

715

3023

1530

23

BOOM EXTENSIONS (1H)(COMPLETE)

99904335 PARTS LIST ITEM PART # DESCRIPTION KIT # QTY 1. 51721423 HARDWARE KIT-BOOM 5005I 1 2. 51721386 CYLINDER 1 3. 52721358 LOWER BOOM WELDMENT - 5005I (through 05/13/13) 1 3. 52725221 LOWER BOOM WELDMENT - 5005I-6006I (effective 05/13/13) 1 4. 52721359 WELDMENT- EXTENSION 1ST STAGE 5005I 1 5. 52721474 WELDMENT- EXTENSION 1ST STAGE 5005I 1 6. 52721360 WELDMENT- 2ND STAGE EXTENSION 5005I 1

Chapter 4 Parts 41

99904335 PARTS LIST ITEM PART # DESCRIPTION KIT # QTY 60030134 SHEAVE- 8.00 NYLATRON (PART OF 6) 2REF 7. 60133939 PIN-TYPE M 1.50X 6.00 1 8. 60030380 WEAR PAD- EXT CYLINDER 6006I 1 9. 60030339 WEAR PAD-RND 2.00 DIA X .60 DIA X 1.00 LG 6 10. 60030340 WEAR PAD-BLOCK 4.50 X 4.50 X .44 2 11. 60030341 WEAR PAD-BLOCK 4.50 X 3.50 X .44 2 12. 60133062 WEAR PAD-RND 1.00 DIA X .62 DIA X .81L 2 13. 60132302 STOP SCREW 3/8-24 X .50 2 14. 60105544 PLATE-ANGLE PLASTIC 2 15. 72063273 WASHER .52ID X 2.00OD X 10GA 2 16. 72661514 PIN-LOCK W/HANDLE .875 X 4.25 1 17. 72066144 HAIR PIN .16 DIA .63-1.00 SHAFT (PART OF 72661514) REF 1 18. 70144211 PIN- .75X 6.50LG 1 19. 72066145 HAIR PIN .19 DIA .63-1.00 SHAFT (PART OF 70144211) REF 1 20. 70034382 CAP-GREASE #1 1 21. 72053507 ZERK-STR THD .25-28 #1 1 22. 72060013 CAP SCREW .25-20X 3.25 HH GR5 Z #1 2 23. 72060092 CAP SCREW .50-13X 1.25 HH GR5 Z #1 2 24. 72060928 CAP SCREW .50-13X 2.25 HH GR5 Z #1 1 25. 72062103 NUT .38-16 HEX NYLOCK #1 2 26. 72062104 NUT .25-20 HEX NYLOCK #1 2 27. 72063001 WASHER .25 FLAT #1 4 28. 72063003 WASHER .38 FLAT #1 2 29. 72063005 WASHER .50 FLAT #1 5 30. 72063053 WASHER .50 LOCK #1 3 31. 72063051 WASHER-LOCK .38 ZINC #1 2 REV. B 20090521


Cylinder, Extension (51721386)

2

8

9

1417

415

1713

12

10

511

166

1816

7

3

14 17 15 171213

4 9

2 37616181611510

8

DRILL #15 HOLE, 3/16" DEEP.PRESS IN PIN 60125699 7.23 - 7.51" CLOSED

79.13-79.63" OPEN71.90 - 72.12" STROKE

Chapter 4 Parts 43

NOTES: 1 TO REDUCE DOWNTIME, REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS

DISASSEMBLED.

2 APPLY "NEVER-SEEZ" REGULAR GRADE ANTI-SEIZE AND LUBRICATING COMPOUND TO THREADS ON CYLINDER HEAD ONLY. KEEP AWAY FROM ALL SEALS.

3 APPLY "LUBRIPLATE" NO. 630-2 MEDIUM HEAVY, MULTI-PURPOSE LUBRICANT, TO ALL PISTON, HEAD GLAND, AND HOLDING VALVE SEALS, NYLON LOCK RING, CAST IRON PISTON RINGS, AND ROD STINGER THREADS.

4 ITEM #10, STOP TUBE, REPLACES 6A025015 WAFER LOCK. USE STOP TUBE INSTEAD OF WAFER LOCK WHEN RESEALING CYLINDER.

51721386 CYLINDER DATA CASE ø3" O.D. X ø2.5" BORE X 81.26" LENGTH ROD ø1.5" X 82.69" LONG STROKE 72" DRY WEIGHT 84.65 LB TORQUES PISTON: 250 FT-LB

HEAD: 500-530 FT-LB CARTRIDGE: 30-35 FT-LB CAP SCREW: 16 FT-LB

TEST PRESSURE 3000 PSI OPERATING PRESSURE 2500 PSI 51721386 PARTS LIST ITEM PART # DESCRIPTION KIT # QUANTITY 1. 51744143 IMT SEAL KIT-2.50 B X 1.50 R 1.25 STGR 1 2. 52721387 ROD ASM-1.50 DIA X 86.63 LG 1.25 S 1 3. 52721388 CASE ASM-2.50 BORE X 82.51 LG 1 4. 6HD25015 HEAD-2.50 BORE X 1.50 ROD (DUCTILE IRON) 1 5. 60127864 STOP TUBE-1.50 ROD X 3.56LG 4 HOLE 1 6. 60127830 PISTON-2.50 BORE X 1.25 STGR 1 7. 72062323 COLLAR-LOCK 1-1/4-12 X 2.063 X 1/2 1 8. 73054999 VALVE-CBAL 1 9. 60125699 PIN - LOCK TUBE 0.19 OD X 0.065 WALL #1 1 10. 60138272 STOP TUBE (WAS 6A025015) #1 1 11. 7Q072218 O RING 1.25X 1.50X .12 70 #1 1 12. 7Q072228 O RING 2.25X 2.50X .12 70 #1 1 13. 7Q10P228 BACKUP RING-2.25 ID X 2.50 OD #1 1 14. 7R14P015 ROD WIPER TYPE D 1.50 ROD #1 1 15. 7R546015 U-CUP 1.50 ID X 2.00 OD #1 1 16. 7T2N4025 WEAR RING-PISTON 2.50 ODX .50W #1 2 17. 7T2NX417 WEAR RING-ROD 1.50 IDX0.50W #1 2 18. 7T66P250 PISTON SEAL-DYNAMIC #1 1 REV B 20120326


Crane & Winch Assembly (99904456) (See Parts List for Effectivity) WINCH & BOOM ASSEMBLY

A

DETAIL A

B

DETAIL B

40, 35

40, 32

26

22

23

3420

3420

3420

3420

4

2838

2825

21

1025

3037

3733

CONNEC T THE WIRE TERMINALS (77040051)TO COMMON AND NORMAL LY OPENON ATB SWITCH

15

27

2718

4142

1238

2936

36

38

51

19

3628

8

8

52

473646

4636

4848

4849

40

48 4940

53

4848

NOTES (SEE REFERENCE NUMBER IN BOX): 1 CONNECT THE WIRE TERMINALS (77040051) TO "COMMON" AND "NORMALLY OPEN" ON ANTI-TWO-

BLOCK SWITCH.

Chapter 4 Parts 45

CRANE ASSEMBLY

39 31

39 31

443624

9

1128, 38, 36

36, 38, 28

546

754

36, 38, 28

NOTES (SEE REFERENCE NUMBER IN BOX):

1 USE ANTI-SEIZE ON PINS.

2 KEEP ELECTRICAL GROUNDS FREE OF PAINT, GREASE, AND OIL

3 IF REQUIRED, USE 72063036 MACHINERY BUSHINGS BETWEEN MAST AND BOOM WHEN INSTALLING 52721425.


SINGLE AND DOUBLE LINE

17

10

15

17

10

21

25

14

14

21

27

13

13

5050

99904456 PARTS LIST ITEM PART # DESCRIPTION KIT # QTY 1. 99904454 DRAWING-BASE & MAST ASSEMBLY 6006I REF 2. 99904335 BOOM ASSEMBLY 5005I-6006i REF 3. 51721424 HARDWARE KIT-CRANE & WINCH 6006I 1 4. 51725225 CORD REEL ASSEMBLY- 10' W/PACKARD CONNECTOR (effective from

06/01/13) 1

5. 52717885 WELDMENT- SNATCH BLOCK 1 6. 60141135 PIN (effective from 06/05/13) 1 7. 60141134 PIN (effective from 06/05/13) 1 8. 52725226 WELDMENT-ATB TRIP MECHANISM 5005i/6006i (effective from 09/01/13) 1 9. 52722163 COVER-VALVE BANK 5005i/6006i 1 10. 60122263 PLATE-SINGLE SHEAVE 3820 1 11. 60134104 COVER-CONTACTOR (5005I-6006I) 1 12. 70034381 SUPPORT 2 13. 70144209 PIN- .75X 4.50 LG WS80-WS100 1 14. 72066144 HAIR PIN .16 DIA .63-1.00 SHAFT (PART OF 70144209) #13 1 15. 70149793 COLLAR-SHAFT 2 PIECE 11/16 IN 1 16. 70580198 WIRE ROPE ASSEMBLY 1 17. 71073920 HOOK-SWIVEL W/LATCH 1

Chapter 4 Parts 47

99904456 PARTS LIST ITEM PART # DESCRIPTION KIT # QTY 72661665 LATCH KIT (PART OF 17) REF 18. 71570923 WINCH-12VDC 1 19. 77041936 CONTACTOR-WINCH 12V DC3000

(effective from 05/13/13) 1

20. 72034485 CLAMP-PLASTIC 1/4" CABLE 4 21. 72661543 PIN-QUICK 316-10QP 1 22. 77041459 SWITCH-LIMIT 1 23. 77441096 CONNECTOR- .50 STR RLF .25-.38 1 24. 77441282 GROUND STRAP- 12IN 1 25. 70034382 CAP-GREASE PRO20 GC-RED #3 3 26. 71413196 SPRING-.105WIRE 0.75OD 2.875 LG #3 1 27. 72053508 ZERK-NPT .12 #3 3 28. 72060000 CAP SCREW .25-20X .50 HH GR5 Z

(effective from 04/03/13) #3 10

29. 72060007 CAP SCREW .25-20X 1.75 HH GR5 Z #3 2 30. 72060075 CAP SCREW .44-14X 5.50 HH GR5 Z #3 1 31. 72060091 CAP SCREW .50-13X 1.00 HH GR5 Z #3 2 32. 72062093 NUT # 8-32 HEX ZINC #3 1 33. 72062105 NUT .44-14 HEX NYLOCK #3 1 34. 72062106 NUT 10-24 HEX NYLOCK #3 4 35. 72062207 NUT 8-32 HEX NYLOCK #3 1 36. 72063001 WASHER .25 FLAT (effective from 04/03/13) #3 16 37. 72063004 WASHER .44 FLAT #3 2 38. 72063049 WASHER .25 LOCK #3 11 39. 72063053 WASHER .50 LOCK #3 2 40. 72063271 WASHER # 8 W FLAT ANSI B27.2Z


41. 72601798 WASHER-LOCK 12MM #3 4 42. 72601935 CAP SCREW M12-1.75X 40 SH ZC #3 4 43. 72601938 BOLT-EYE # 8-32X 1.125 #3 1 44. 72601941 SCREW-MACH .25-20X .38 BTNHD ZC


45. 77040051 TERMINAL-SPRSPADE I #8 STUD 16-14 #3 2 46. 72062104 NUT 0.25-20 HEX NYLOCK #3 2 47. 72060003 CAP SCR 0.25-20 X 0.88 GR5 #3 2 48. 72602011 SCR MACH #8-32 X 0.62 BTNHD #3 6 49. 72063239 WASHER LOCK #3 2 50. 60030327 SPACER- SNATCH BLOCK 2 51. 71413880 COVER WITHOUT SOCKET 1 52. 60140565 BRKT-CORD REEL MNT 3203I 1 53. 52725217 WLDMT-WINCH CONTACTOR BRKT 1 54. 71415015 KEEPER PIN 0.50 2 REV N 20140130


Crane & Winch Assembly (99904456) (See Parts List for Effectivity) WINCH & BOOM ASSEMBLY

A

B

26

22

234637

3520

3520

3520 3520

4

28 39

28 25

21

1025

3138

3834

15

8

27

27

18

19

4344

1239

3037

37

39

1

DETAIL B

DETAIL A

36,41

33,41

50

NOTES (SEE REFERENCE NUMBER IN BOX): 1 CONNECT THE WIRE TERMINALS (77040051) TO "COMMON" AND "NORMALLY OPEN" ON ANTI-TWO-

BLOCK SWITCH.

Chapter 4 Parts 49

CRANE ASSEMBLY

42

42

740

32

6

4032

463724

9

11

48

48

28,37,39

28,37,39

29,37,39

NOTES (SEE REFERENCE NUMBER IN BOX): 1 USE ANTI-SEIZE ON PINS.

2 KEEP ELECTRICAL GROUNDS FREE OF PAINT, GREASE, AND OIL

3 IF REQUIRED, USE 72063036 MACHINERY BUSHINGS BETWEEN MAST AND BOOM WHEN INSTALLING 52721425.


SINGLE AND DOUBLE LINE

17

10

15

17

10

21

25

14

14

21

27

13

13

4949

DOUBLE LINE

SINGLE LINE

99904456 PARTS LIST ITEM PART # DESCRIPTION KIT # QTY 1. 99904454 DRAWING-BASE & MAST ASSEMBLY 6006I REF 2. 99904335 BOOM ASSEMBLY 5005I-6006i REF 3. 51721424 HARDWARE KIT-CRANE & WINCH 6006I 1 4. 51720302 CORD REEL ASSEMBLY- 10' W/PACKARD CONNECTOR (effective

through 06/01/13) 1

5. 52717885 WELDMENT- SNATCH BLOCK 1 6. 52719630 PIN (effective through 06/05/13) 1 7. 52721425 PIN (effective through 06/05/13) 1 8. 52722112 WELDMENT-ATB TRIP MECHANISM 5005i/6006i (effective through

09/01/13) 1

9. 52722163 COVER-VALVE BANK 5005i/6006i 1 10. 60122263 PLATE-SINGLE SHEAVE 3820 1 11. 60134104 COVER-CONTACTOR (5005I-6006I) 1 12. 70034381 SUPPORT 2

Chapter 4 Parts 51

99904456 PARTS LIST ITEM PART # DESCRIPTION KIT # QTY 13. 70144209 PIN- .75X 4.50 LG WS80-WS100 1 14. 72066144 HAIR PIN .16 DIA .63-1.00 SHAFT (PART OF 70144209) #13 1 15. 70149793 COLLAR-SHAFT 2 PIECE 11/16 IN 1 16. 70580198 WIRE ROPE ASSEMBLY 1 17. 71073920 HOOK-SWIVEL W/LATCH 1 72661665 LATCH KIT (PART OF 17) REF 18. 71570923 WINCH-12VDC 1 19. 77041802 CONTACTOR-WINCH 12V DC3000 (effective through 05/13/13) 1 20. 72034485 CLAMP-PLASTIC 1/4" CABLE 4 21. 72661543 PIN-QUICK 316-10QP 1 22. 77041459 SWITCH-LIMIT 1 23. 77441096 CONNECTOR- .50 STR RLF .25-.38 1 24. 77441282 GROUND STRAP- 12IN 1 25. 70034382 CAP-GREASE PRO20 GC-RED #3 3 26. 71413196 SPRING-.105WIRE 0.75OD 2.875 LG #3 1 27. 72053508 ZERK-NPT .12 #3 3 28. 72060000 CAP SCREW .25-20X .50 HH GR5 Z (effective through 04/03/13) #3 7 29. 72060004 CAP SCREW .25-20X 1.00 HH GR5 Z (effective through 05/20/13) #3 2 30. 72060007 CAP SCREW .25-20X 1.75 HH GR5 Z #3 2 31. 72060075 CAP SCREW .44-14X 5.50 HH GR5 Z #3 1 32. 72060091 CAP SCREW .50-13X 1.00 HH GR5 Z #3 2 33. 72062093 NUT # 8-32 HEX ZINC #3 1 34. 72062105 NUT .44-14 HEX NYLOCK #3 1 35. 72062106 NUT 10-24 HEX NYLOCK #3 4 36. 72062207 NUT 8-32 HEX NYLOCK #3 1 37. 72063001 WASHER .25 FLAT (effective through 04/03/13) #3 12 38. 72063004 WASHER .44 FLAT #3 2 39. 72063049 WASHER .25 LOCK #3 11 40. 72063053 WASHER .50 LOCK #3 2 41. 72063271 WASHER # 8 W FLAT ANSI B27.2Z (effective through 05/13/13) #3 2 42. 72066132 RETAINING RING-EXT 1.50 HD (effective through 06/05/13) #3 2 43. 72601798 WASHER-LOCK 12MM #3 4 44. 72601935 CAP SCREW M12-1.75X 40 SH ZC #3 4 45. 72601938 BOLT-EYE # 8-32X 1.125 #3 1 46. 72601941 SCREW-MACH .25-20X .38 BTNHD ZC (effective through 05/13/13) #3 3 47. 77040051 TERMINAL-SPRSPADE I #8 STUD 16-14 #3 2 48. 72063132 WASHER .50 FLAT ASTM F436 (effective through 06/05/13) #3 2 49. 60030327 SPACER- SNATCH BLOCK 2 50. 71413880 COVER WITHOUT SOCKET 1 REV. G 20100427


Winch (71570923)

ELECTRICMOTOR, 12VDC

ELECTRICTHERMAL SWITCH

BEARINGSPACER

HOSECLAMP

DRUMSUPPORT

PLATE, SPACER

CAPSCREW

GEAR

BUSHINGCABLE

OIL SEAL32000388

DUSTMASK

DRUM

32000212

NYL WASHER32000480

BRAKE DRIVER

BRAKESCREW32000385

ASM

NYL WASHER32000480

SEAL- 32000388BUSHING32000212

SPACERCAPSCREW

PLATE,

GASKET32000231

PLATE, SPACERCAPSCREW

SCREW

HOUSINGASM

LABEL

PLUG

SEALDRUM ASM

CLUTCHRETAINER

THRUST PLATECARRIER ASM

CLUTCH RING GEAR

RET. RINGBEARING

BRAKE

MOTOR SHAFTSPACER

TOL RING

ASMCARRIER

CARRIER ASMRINGGEAR

HEXSHAFT

DRUM SUPPORT

DRIVER

73540402

77056667

REPLACEMENT PARTS: CONTACTOR - IMT # 77041802 BRAKE ASM - IMT # 77056667 MOTOR - IMT # 73540402

Chapter 4 Parts 53

Power Unit (73511282)(Effective 10/11/12) 1

2

3

6

7

5

4

NOTE: Pump pressure relief valve setting = 2500 psi (172 bar) 73511282 PARTS LIST ITEM PART # DESCRIPTION KIT # QUANTITY 1. 77043065 MOTOR 12VDC A/R 2. 73511307 PUMP 1 3. 73540517 RELIEF VALVE ASSEMBLY 1 4. 74399495 RESERVOIR 1 5. 70734788 BREATHER CAP 1 6. 73734791 TUBE-SUCTION 1 7. 70734792 STRAINER 1 NEW 20130809


Power Unit (73511155) (Through 10/11/12)

FAN SHROUD

D.C. MOTOR(77043060)(12 VDC)

D.C. MOTOR(77043060)(12 VDC)

MOTOR SECTION

ADAPTER / RESERVOIRSECTION TUBE KIT (73734332)

(SUCTION & RETURN LINE PIPES)

RETURN LINE PIPE SUCTIONLINE PIPE

RETURNLINE PIPE,RELIEF VALVE

GEAR PUMP(73511170)

ADAPTOR

RELIEF

(73540323)VALVE

(74397392)RESERVOIR

BREATHER CAP(70733826)

NOTE: Pump pressure relief valve setting = 2500 psi (172 bar)

Chapter 4 Parts 55

Electrical Installation (99904437) (See Parts List for Effectivity)

7

14

9

20

78 12

9

9

6

13

TO 300 AMP KEYED SWITCHIN CRANE BOX

4

WIRE HARNESS(RADIO CONTROL)

WIRE HARNESS(TETHERED CONTROL)

A

DETAIL A

3 5

WIRE HARNESS(WINCH UP)

WIRE HARNESS(WINCH DOWN)

GROUND CABLES ROUTED TO OUTSIDE OF MASTTO BOOM GROUND

2

CRANE BASE

ELECTRIC ROTATOR BRACKET(BOTTOM)

TO CRANE BOX

TORQUE TO 8-15 FT-LBS 10

11

10

15

1716

AS VIEWED FROM REAR

2122

18

2423

19

1

2

2


NOTES (SEE REFERENCE NUMBER IN BOX): 1 WRAP CABLES AND MOTOR TERMINALS WITH RUBBER BOOTS. KEEP 3/8" OF RED WIRE VISIBLE.

2 REMOVE PAINT & DEBRIS FROM SURFACE AND THREADS AT THESE LOCATIONS.

99904437 PARTS LIST ITEM PART # DESCRIPTION KIT # QTY 1. 91722221 5005I ELECTRICAL INSTALLATION KIT (WAS 91721555) 1 2. 51721944 CABLE ASSEMBLY- 1GA-3/8RNGX SWVL MX 60.00LG #1 1 3. 71570923 WINCH-12V REF 4. 73511282 POWER UNIT (effective from 10/11/12) REF 5. 77041936 CONTACTOR-WINCH 12V (effective from 05/13/13) REF 6. 77441282 GROUND STRAP- 12IN 1 7. 51721718 CABLE ASSEMBLY- 2GA-5/16RNG X 3/8RNG X 25.00LG (WAS 51721500) #1 1 8. 51721720 CABLE ASSEMBLY- 2GA-5/16RNGX 3/8RNGX 10.00LG #1 1 9. 51721721 CABLE ASSEMBLY- 2GA-5/16RNGX 5/16RNGX 18.00LG #1 3 10. 77441336 SWITCH- 275A CONTACTOR (WAS 77441277) 1 11. 51722218 CABLE ASM - 1GA - 3/8RNG X SWVL 13.5 LG #1 1 12. 77441312 CABLE ASSEMBLY-10GA-#10RNGX 1/4RNGX 6.00LG #1 1 13. 77441332 CABLE ASSEMBLY- 1GA-1/4RNGX 3/8RNGX 46.50LG #1 1 14. 51721717 CABLE ASSEMBLY- 2GA-5/16RNGX 3/8RNGX 35.50LG #1 1 15. 60133635 CONTACT JUNCTION REF 16. 72060044 CAP SCREW 3/8-16 X 3/4 HHGR5Z REF 17. 72062179 NUT 0.38-16 HEX CENTER LOCKING (effective from 06/21/13) REF 18. 72601278 CAP SCREW M8-1.25 X 20 HHZ REF 19. 77040186 TERM-FSLPON I .25 TAB 16-14GA REF 20. 51722412 CABLE ASM- 2GA-.31RNG X .31RNG X 18.00LG #1 1 21. 77441302 TERM INSUL RED #8-2 GA WIRE 1 22. 77441303 TERM INSUL BLK #8-2 GA WIRE 1 23. 72063050 WASHER 0.31 LOCK (effective from 06/21/13) 1 24. 72060021 CAP SCR 0.31-18 X 0.50 GR5 (effective from 06/21/13) 1 REV. F 20090521

Chapter 4 Parts 57

Electrical Installation (99904437) (See Parts List for Effectivity)

7

15

10

21

8

9

13

10

10

6

14

A

4

3 5

2

11

12

11

16

1817

2020

22 23

19

22

1

WIRE HARNESS(WINCH UP)

WIRE HARNESS(WINCH DOWN)

TOCRANE

BOX

DETAIL A

GROUND CABLES ROUTEDTO OUTSIDE OF MAST

AS VIEWEDFROM REARTO BOOM

GROUND

TO 300 AMPKEYED SWITCHIN CRANE BOX

CRANE BASE

TORQUE TO8-15 FT-LB

ELECTRICROTATORBRACKET(BOTTOM)

WIRE HARNESS(TETHERED

WIRE HARNESS(RADIO CONTROL)

CONTROL)


NOTES (SEE REFERENCE NUMBER IN BOX): 1 WRAP CABLES AND MOTOR TERMINALS WITH RUBBER BOOTS. KEEP 3/8" OF RED WIRE VISIBLE.

2 REMOVE PAINT & DEBRIS FROM SURFACE AND THREADS AT THESE LOCATIONS.

99904337 PARTS LIST ITEM PART # DESCRIPTION KIT # QUANTITY 1. 91722221 5005I ELECTRICAL INSTALLATION KIT (WAS 91721555) 1 2. 51721944 CABLE ASSEMBLY- 1GA-3/8RNGX SWVL MX 60.00LG #1 1 3. 71570923 WINCH-12V REF 4. 73511155 POWER UNIT (effective through 10/11/12) REF 5. 77041802 CONTACTOR-WINCH 12V (effective through 05/13/13) REF 6. 77441282 GROUND STRAP- 12IN 1 7. 51721718 CABLE ASSEMBLY- 2GA-5/16RNG X 3/8RNG X 25.00LG (WAS

51721500) #1 1

8. 51721719 CABLE ASSEMBLY- 2GA-5/16RNGX 3/8RNGX 15.00LG (effective through 03/27/13)

#1 1

9. 51721720 CABLE ASSEMBLY- 2GA-5/16RNGX 3/8RNGX 10.00LG #1 1 10. 51721721 CABLE ASSEMBLY- 2GA-5/16RNGX 5/16RNGX 18.00LG #1 3 11. 77441336 SWITCH- 275A CONTACTOR (WAS 77441277) 1 12. 51722218 CABLE ASM - 1GA - 3/8RNG X SWVL 13.5 LG #1 1 13. 77441312 CABLE ASSEMBLY-10GA-#10RNGX 1/4RNGX 6.00LG #1 1 14. 77441332 CABLE ASSEMBLY- 1GA-1/4RNGX 3/8RNGX 46.50LG #1 1 15. 51721717 CABLE ASSEMBLY- 2GA-5/16RNGX 3/8RNGX 35.50LG #1 1 16. 60133635 CONTACT JUNCTION REF 17. 72060044 CAP SCREW 3/8-16 X 3/4 HHGR5Z REF 18. 72062002 NUT 3/8-16 HEX (effective through 06/25/13) REF 19. 72601278 CAP SCREW M8-1.25 X 20 HHZ REF 20. 72601278 TERM-FSLPON I .25 TAB 16-14GA REF 21. 51722412 CABLE ASM- 2GA-.31RNG X .31RNG X 18.00LG #1 1 22. 77441302 TERM INSUL RED #8-2 GA WIRE 1 23. 77441303 TERM INSUL BLK #8-2 GA WIRE 1 REV. F 20090521

Chapter 4 Parts 59

Tethered Control Installation (99904593)

7

4

911

12

2

99904593 PARTS LIST ITEM PART # DESCRIPTION QUANTITY 1. 91721524 CONTROL KIT- TETHERED ELECTRIC CRANE 1 2. 51721502 HANDLE ASM-TETHERED ELECTRIC CRANES 1 4. 71413190 RELAY-2 RELAY MODULE 1 7. 72062106 NUT 10-24 HEX NYLOCK 2 9. 72063268 WASHER #10 W FLAT ANSI B27.2Z 2 11. 72602013 SCR-MACH #10-24X 1.25 BTNHD ZC 2 12. 77044667 PLUG CAP-DEUTSCH HDC36-24 1 REV. A 20090521

NOTE: See 99904377 for installation drawing prior to 2-15-09. Component parts are the same.


Radio Control Installation, Standard (99904594)

3

4

89

5

5005i / 6006iSTANDARD

RADIO CONTROLINSTALLATION

99904594 PARTS LIST ITEM PART # DESCRIPTION QUANTITY 1. 91721523 CONTROL KIT- RADIO ELECTRIC CRANE 1 2. 60133634 SLEEVE-TYPE C .63X .81X .31 2 3. 70734329 RECEIVER - RADIO REMOTE TELE VORC 1 4. 70734330 TRANSMITTER-RADIO REMOTE ELECTRIC

CRANE 1

5. 72060005 CAP SCR .25-20X 1.25 HH GR5 Z 2 8. 72063001 WASHER .25 FLAT 4 9. 72063049 WASHER .25 LOCK 2 NEW 20090305 NOTE: See 99904522 for installation drawing prior to 2-15-09. Component parts are the same.

Chapter 4 Parts 61

Radio Control Installation, Proportional (99904595)

38

9

4

5005i / 6006iPROPORTIONALRADIO CONTROL

INSTALLATION

99904595 PARTS LIST ITEM PART # DESCRIPTION QUANTITY 1. 91721644 CONTROL KIT- PROP ELECTRIC CRANE-12V 1 3. 70734347 RECEIVER-PROP RADIO ELECTRIC CRANE CRANE 1 4. 70734348 TRANSMITTER-RADIO ELECTRIC CRANE PROP 1 5. 72060005 CAP SCR .25-20X 1.25 HH GR5 Z 2 8. 72063001 WASHER .25 FLAT 4 9. 72063049 WASHER .25 LOCK 2 NEW 20090305 NOTE: See 99904523 for installation drawing prior to 2-15-09. Component parts are the same.


Harness, Radio (77441270)

A B AB

12

12

12

12

12

12

12

Chapter 4 Parts 63

SCHEMATIC, HARNESS, RADIO (77441270)

12

9

8

2

6

7

5

4

3

1

10

11

12

9

7

6

3

4

SPLICE G

2

5

8

11

10

SPLICE GSPLICE G

1

SPLICE G

12345

A2B/OVERLOAD

RS485 B

ROTATE CCW

CP-1201RADIO RECEIVER

INTER FACE

RS485 A

N/C

HYDRAULIC PUM P

ROTATE CW

INTER FACE

WINCH DOWN

EXTEND IN

EXTEND OU T

WINCH U P

PROPO RTIONA L

CP-1200 POWER (RADIO)

GROUND

RADIO RECEIVER

ROTATE CCW21

ROTATE CW21

BA

P10

EXTEND IN

2 EXTEND OU T

21

WINCH U P

1

WINCH DOWN

2800 PSI

ANTI-TWO

N/C

N/C

N/C

AB

N/C

BOOM DOWN

BOOM U P

N/C

N/C

N/C

2BOOM U P

21

BOOM DOWN

1

GROUND

HYDRAULIC PUM P

POWER

N/C

(GR AY)

(BLACK)

2PROPO RTIONA L1

+ B ATT

RS485 BGROUNDRS485 A

SHIELD (OPT)

CJ-500TETHER INTER FACE

RADIO RECEIVER

15A

P6

P5

J10

W4

P4

P3

W5

P2

P1

P7

W1

W2

W3


Harness, Tethered (77441269)

RELAYCP-601

CJ-2300

W1

W2

W3

HYDRAULICPUMP

POWER

GROUNDW4 W5

A B AB

12

12

12

12

12

12

WINCH UP WINCH DOWN

BOOM UP

BOOMDOWN

EXTENDOUT

EXTENDIN

ROTATECW

ROTATECCW

CP-600

FUSED

FUSE15A

EXT OU T

WINCH U PW5

WINCH DOWN

RO TATE CW

BA

P10

BOOM DOWN

EX T IN

21

BOOM U P

2800 PSI

ANTI-TWO

AB

CJ-2300TETHER HANDLE

W4

W1 W2 W3

RO TATE CCW

EXTEND IN

BOOM U P

RO TATE CW

RO TATE CCW

BOOM DOWN

EXTEND OU T

POWER

HYDRAULIC PUM P

CRANE POWER

WINCH DOWN

WINCH U P

CP-600REL AY MODULE

CP-601REL AY MODULE

21

21

21

21

21

15A

F

P

A

K

N

B

L

S

O

C

D

1 2 3 4 5 6 1 2 3 4 5 6

P3

P5

J10

P2

P4

P1

P6

Chapter 4 Parts 65

Handle Assembly, Tethered (51721502)

2

13

7 21 308,20

3 26

23

BLACK(S) HYDPUMP

TO SWITCH #19

SOLDER WIRETO TERMINAL

4,102524

282914

6,9,12,27

POWER

OFF ON

ROTCCW

CW

EXTIN

OUT

WINCHDOWN

UP

LOWERDOWN

UP


Tethered Remote Handle Assembly (51721502)

5

14

181 (REF) GRN(TO ROTARY SWITCH)

BLK/ORN (CRANE PWR)ORN/BLK (EXT OUT)

YEL/BLK(ROT CW)

1(6)

ORN17

BLU/BLK17

BRN/BLK (ROT CCW)17

BRN (EXT IN)

RE D

RED/BLK(WIN UP)

15(16)YEL (BOOM UP)

WIRE FUNCTIONS SOLID/STRIPE FUNCTION A YEL/BLK ROT CW B ORN/BLK EXT OUT C BLU/BLK WINCH DN D RED/BLK WINCH UP E ORN/RED - F BRN EXT IN G BRN/RED - H BLU/RED - J BLK/RED - K BRN/BLK ROT CCW L RED POWER M BLU - N ORN LOWER DN O BLK/ORN CRANE POWER P YEL LOWER UP Q BRN/BLU - R YEL/RED - S BLK HYD PUMP T BLK/BLU - U RED/BLU - V BLU/ORN - W ORN/BLU - X YEL/BLU - - RED/RON -

Chapter 4 Parts 67

51716404 PARTS LIST ITEM PART # DESCRIPTION QUANTITY 1. 60045031 WIRE 18GA X 4 GRN 6 2. 60119335 CONTROL HANDLE 1 3. 60111141 TRIGGER (PART OF 25) 1REF 4. 60119277 COVER 1 5. 70034306 BACK COVER 1 6. 70029119 PLACARD, SERIAL NUMBER 1 7. 77044196 CORD GRIP, LOCTITE 1 8. 77044621 PIN 23 9. 70394447 DECAL-DGR RC ELECTRO SM 1 10. 70392809 DECAL-ELEC CRANE CONTROL 1 11. 77044969 SWITCH, ROTARY ELEC (PART OF 25) 1REF 12. 72066340 POP RIVET 2 13. 72531833 BUSHING, RED STL 3/4 X 1/2 1 14. 72061009 SHT MTL SCR #6X3/4 PH 8 15. 77040051 TERM-SPRSPD #8 16-14GA 16 17. 77040372 TOGGLE SWITCH SPDT 4 18. 77040373 TOGGLE SWITCH SPST 1 20. 77044579 CONNECTOR 1 21. 89044100 CABLE 18GA 24WIRE 30 FT 23. 77044695 TERMINAL, FSLPON 1 24. 70733518 BRACKET, TRIGGER (PART OF 25) 1REF 25. 51716499 TRIGGER ASSEMBLY (INCL 3,11,24,26,28-29) 1 26. 72601346 SCR-MACH #8-32 PAN HEAD (PART OF 25) 4REF 27. 70395995 DECAL-CAUTION RC HANDLE ELEC PWR

UNIT 1

28. 70143223 SPRING, TENSION (PART OF 25) 1REF 29. 72061000 SCR-SHT METAL #6X1/2 PH (PART OF 25) 1REF 30. 70145495 HEAT SHRINK 0.33 FT NEW 20080407

NOTE: KIT # 51717816, TETHERED CABLE - 30 FEET, INCLUDES ITEMS 8, 15 (QTY 24), 20, 21, AND 30. ORDER 51717816 TO REPLACE THE CABLE ASSEMBLY.


Hydraulic Installation (99904458)

VALVE BANK

HYDRAULICMOTOR(PORT A)

HYDRAULICMOTOR(PORT B)

PRESSURE

EXT. CYL.RETRACTPORT

EXT. CYL.EXTENDPORT

LOWERCYL.RETRACTPORT

LOWERCYL.EXTENDPORT

BOOM UP

BOOM DOWN

TANK(RETURN)ROT CW

ROT CCWEXTENSIONOUTEXTENSIONIN

Chapter 4 Parts 69

PLUMBING INSTALLATION - BEHIND MAST (99904458-3)

3

19

4 4

20

19

21

3 5

5

1013 13

9

118

8

10 13 138

8

11

24 23

22

A B

31

31

A B

WITH PROP VALVEREAR OF MAST

VALVEBANK

HYDRAULICMOTOR

(SEE NOTE)

HYD RESERVOIRPOWER UNIT &

WITHOUT PROP VALVEREAR OF MAST

VALVE

HYDRAULICMOTOR

HYD RESERVOIRPOWER UNIT &

BANK

PROPORTIONALVALVE

9,23


PLUMBING INSTALLATION - IN FRONT OF MAST (99904458-3)

67

5

5

5

5

14 14

12 12

9

9

99 9

9

15

15

9

9

99

EXT CYL

LOWER CYL

LOWER CYL

WITH EXT CYLINDERFRONT OF MAST

WITHOUT EXT CYLINDERFRONT OF MAST

VALVEBANK

VALVEBANK

RETRACTPORT

EXTENDPORT

NOTE: 1 WHEN CONVERTING TO PROPORTIONAL HYDRAULIC SYSTEM, ALL EXISTING HOSES ARE USED

EXCEPT 51397335 (ITEM #3)

2 CRANES WITHOUT EXTENSION CYLINDER USE PLUGS 72532522 TO BLOCK HYDRAULIC PORTS B1 AND A1 ON THE VALVE BLOCK.

Chapter 4 Parts 71

ELECTRIC CRANE WITH HYDRAULIC INSTALLATION (99904458-4)

3031

10

9

93

4

4

11

8

13

820


PROPORTIONAL VALVE ASSEMBLY INSTALLATION (99904458-5)

30

31

10

9

9

3

44

11

8

13

8

23

1

20

29 231624 19

221826,28

TO VALVEBLOCK PORT (P)

(PRESSURE)

TO VALVEBLOCK T (TANK)

TO POWER UNIT

PROPORTIONAL VALVE

INSTALLATION WITHOUT HYDRAULIC EXTENSION (99904458-6)

13 13

30

31

10

93

4

4

11

8

8

15

20

Chapter 4 Parts 73

INSTALLATION WITH HYDRAULIC EXTENSION (99904458-7)

TO EXT CYL PORT "R"TO EXT CYL PORT "E"

TO VB PORT A1(EXTEND PORT)

TO VB PORT B2(RETRACT PORT)

TO VB PORT B1(RETRACT PORT)

TO VB PORT A2(EXTEND PORT)

5

5 9

9

7

126

1214

14

99904458 PARTS LIST ITEM PART # DESCRIPTION KIT # QUANTITY 1. 99904456 DRAWING-CRANE & WINCH 6006I 1 2. 51721707 HYDRAULIC KIT 1 3. 51397336 HOSE-FI .25 X 12.50 (4-4) 100R17 #2 1 4. 51395874 HOSE-FJ .25 X 26.00 (4-4) 100R17 #2 2 5. 51397480 HOSE-FF .25 X 27.50 (4-4) 100R17 #2 2 6. 51396413 HOSE-FF .25 X 22.00 (4-4) 100R17 #2 1 7. 51395422 HOSE-FF .25 X 24.00 (4-4) 100R17 #2 1 8. 72053758 ELBOW-M STR/90/M JIC 4 4 #2 2 9. 72532351 ADAPTER-M STR/M JIC 4 4 #2 7 10. 72532699 ELBOW-M STR/90/M JIC 6 4 (WAS 2) #2 1 11. 72533567 ELBOW-M STR/90/M JIC 4 4 #2 1 12. 72534567 ELBOW-M STR/90/M JIC XLG 6 4 #2 2 13. 72533589 ADAPTER-M STR/M JIC 10 4 #2 2 14. 72533052 ADAPTER-M STR/F STR 8 6 #2 2 15. 72532522 PLUG-STRAIGHT HEX HD STL .44 2 16. 73540325 VALVE-PROPORTIONAL FLOW CONTROL, 12V

ELEC CRANE 1


99904458 PARTS LIST ITEM PART # DESCRIPTION KIT # QUANTITY 17. 91721626 HYDRAULIC KIT-PROPORTIONAL 1 18. 51395663 HOSE-FJ .25 X 14.00 (4-4) 100R17 #17 1 19. 51397434 HOSE-FZ .25 X 16.00 (4-4) 100R17 #17 2 20. 51397452 HOSE-FI .25 X 11.50 (4-4) 100R17 #17 1 21. 72053758 ELBOW-M STR/90/M JIC 4 4 #17 1 22. 72532351 ADAPTER-M STR/M JIC 4 4 #17 1 23. 72532981 TEE-SWVL NUT RUN JIC 4 #17 1 24. 72534477 ADAPTER-M STR/M JIC 4 4 XLG #17 1 25. 51722635 HARDWARE KIT-PROPORTIONAL CONTROL

VALVE, ELEC CRANE 1

26. 72063001 WASHER .25 FLAT #25 2 27. 72063049 WASHER .25 LOCK #25 2 28. 72060009 CAP SCREW .25-20X 2.25 HH GR5 Z #25 2 29. 60134907 PLATE-SPACER PROP VALVE 1 30. 72532674 CAP-JIC STL 4 (.44 THD) #2 1 31. 72534714 TEE-STL JIC/STR/JIC 4 6 4 BRANCH #2 1 REV. J 20120326

Chapter 4 Parts 75

6006i Decal Installation (95721549)

12

25

9

5

4

4

5

6,7,1028

3130

11

26 1327

54

22

12

25

2614

27

DECAL PLACEMENT (IF NOT SHOWN ON CRANE) ITEM # PLACEMENT 15,21,23, 24,28,29

AT OR NEAR REMOTE HANDLE STORAGE POINT

16 2 ON REAR STABILIZERS 19 AT OR NEAR DRIVELINE 18,20 ON ALL FOUR SIDES OF CARRIER VEHICLE 32 ON CRANE POWER CABLE CONNECTION AT VEHICLE BATTERY 99904375 PARTS LIST ITEM PART # DESCRIPTION KIT # QTY IN KIT QTY ON

CRANE 1. 95719347 DECAL KIT - TELE COMMON 1 2. 95719348 DECAL KIT - BODY COMMON 1


99904375 PARTS LIST ITEM PART # DESCRIPTION KIT # QTY IN KIT QTY ON

CRANE 3. 95721549 DECAL KIT - 6006i SPECIFIC 1 4. 70391612 DECAL-GREASE WEEKLY (LEFT) 1 9 3 5. 70391613 DECAL-GREASE WEEKLY (RIGHT) 1 6 3 6. 70392399 DECAL-LUBRICATE WORM 1 1 1 7. 70392524 DECAL-ROTATE CRANE WHILE GREAS 1 1 1 8. 70394166 DECAL-INSTR FOR MNL OPERATION 1 1 0 9. 70394443 DECAL-WARNING FREEFALLING BOOMS 1 1 1 10. 70395090 DECAL-GREASE WORM DR BRNGS 1 1 1 11. 70395324 DECAL-ASME/ANSI B30.5-TELESCOP 1 1 1 12. 70395670 DECAL-CAUTION DOWN HAUL WT 1 2 2 13. 71391522 DECAL-ANGLE INDICATOR RH 1 1 1 14. 71391523 DECAL-ANGLE INDICATOR LH 1 1 1 15. 70392213 DECAL-CAUTION DONT WASH/WAX 1 1 1 16. 70392864 DECAL-WARNING STAB STAND CLEAR 2 4 2 17. 70391598 DECAL-WARNING, MAN STAB 2 2 0 18. 70392868 DECAL-WARNING CR LOADLINE (TRK) 2 4 4 19. 70392891 DECAL-DANGER DRIVELINE 2 1 1 20. 70394445 DECAL-DANGER ELEC HZD LG TELES 2 4 4 21. 70396613 DECAL-CRANE SAFETY & OPER 2 1 1 22. 70394189 DECAL-MOBILOIL RESERVOIR 2 1 1 23. 71039134 DECAL-CAUTION OIL LEVEL 2 1 1 24. 70392982 DECAL-SERVICE & REPAIR 2 1 1 25. 71394453 DECAL-LOAD BLOCK RATING 4.0TON 3 2 2 26. 70392887 DECAL-DIAMOND IMT 5X10 3 2 2 27. 70396781 DECAL-6006i ID 3 2 2 28. 70397493 DECAL-CAPACITY CHART 6006i 3 2 2 29. 70397334 DECAL-WARNING, ELEC CR OL 3 1 1 30. 70397351 DECAL-REMOTE PENDANT STORAGE 3 1 1 31. 70397404 DECAL-DANGER, UNPLUG CRANE 3 2 2 32. 70397405 DECAL-CRANE POWER DISCONNECT 3 1 1 NEW 20081015

77

In This Chapter Inspection Checklist ................................................................. 77 Deficiency / Recommendation / Corrective Action Report ......... 82 Thread Torques ........................................................................ 84 Turntable Bearing Thread Tightening Sequence ...................... 84 Turntable Bearing Inspection .................................................... 86 Turntable Bearing Tilt Test ....................................................... 87

Inspection Checklist NOTICE:

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

OWNER/COMPANY:

TYPE OF INSPECTION (circle one):

CONTACT PERSON: DAILY MONTHLY QUARTERLY ANNUAL

CRANE MAKE & MODEL: DATE INSPECTED:

CRANE SERIAL NUMBER: HOURMETER READING (if applicable):

UNIT I.D. NUMBER:

INSPECTED BY (print):

LOCATION OF UNIT: SIGNATURE OF INSPECTOR:

C H A P T E R 5

General Reference


TYPE OF INSPECTION NOTES: Daily and monthly inspections are to be performed by a “competent person”, who is capable of identifying existing and predictable hazards in the surroundings or working conditions which are unsanitary, hazardous, or dangerous to employees, and who has authorization to take prompt corrective measures to eliminate them. Quarterly and annual inspections are to be performed by a “qualified person” who, by possession of a recognized degree, certificate, or professional standing, or who by extensive knowledge, training and experience, successfully demonstrated the ability to solve/resolve problems relating to the subject matter, the work, or the project. One hour of normal crane operation assumes 20 complete cycles per hour. If operation exceeds 20 cycles per hour, inspection frequency should be increased accordingly. Consult Operator / Service Manual for additional inspection items, service bulletins and other information. Before inspecting and operating crane, crane must be set up away from power lines and leveled with stabilizers fully extended. DAILY (D): Before each shift of operation, those items designated with a (D) must be inspected. MONTHLY (M): Monthly inspections or 100 hours of normal operation (whichever comes first) includes all daily inspections plus items designated with an (M). This inspection must be recorded and retained for a minimum of 3 months. QUARTERLY (Q): Every three to four months or 300 hours of normal operation (whichever comes first) includes all daily and monthly inspection items plus items designated with a (Q). This inspection must be documented, maintained, and retained for a minimum of 12 months, by the employer that conducts the inspection. ANNUAL (A): Each year or 1200 hours of normal operation (whichever comes first) includes all items on this form which encompasses daily, monthly and quarterly inspections plus those items designated by (A). This inspection must be documented, maintained, and retained for a minimum of 12 months, by the employer that conducts the inspection.

INSPECTION CHECKLIST STATUS KEY: S = Satisfactory X = Deficient

(NOTE: If a deficiency is found, an immediate determination must be made as to whether the deficiency constitutes a safety hazard and must be corrected prior to operation.)

R = Recommendation (Should be considered for corrective action) NA = Not Applicable

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

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

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

cracks.

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

D 5 Hydraulic System

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

D 6 Hook Presence and proper operation of hook safety latches. D 7 Wire Rope Inspect for apparent deficiencies per applicable requirements and

manufacturer’s specifications.

Chapter 5 General Reference 79


D 8 Pins Proper engagement of all connecting pins and pin retaining devices.

D 9 General Overall observation of crane for damaged or missing parts, cracked welds, and presence of safety covers.

D 10 Operation During operation, observe crane for abnormal performance, unusual wear (loose pins, wire rope damage, etc.). If observed, discontinue use and determine cause and severity of hazard.

D 11 Remote Ctrl

Operate remote control devices to check for proper operation.

D 12 Electrical Operate all lights, alarms, etc. to check for proper operation. D 13 Anti Two-

Block or Two-Block Damage Prevention

Operate anti two-block or two-block damage prevention device to check for proper operation.

D 14 Tires Check tires (when in use) for proper inflation and condition. D 15 Ground

Conditions Check ground conditions around the equipment for proper support, watching for ground settling under and around stabilizers and supporting foundations, ground water accumulation, or similar conditions.

D 16 Level Check the equipment for level position within the tolerances specified by the equipment manufacturer’s recommendations, both before each shift and after each move and setup.

D 17 Operator cab windows

Check windows for cracks, breaks, or other deficiencies which would hamper the operator's view.

D 18 Rails, rail stops, rail clamps and supporting surfaces

Check rails, rail stops, rail clamps and supporting surfaces when the equipment has rail traveling.

D 19 Safety devices

Check safety devices and operational aids for proper operation.

D 20 Electrical Check electrical apparatus for malfunctioning, signs of apparent excessive deterioration, dirt or moisture accumulation.

D 21 Other D 22 Other M 23 Daily All daily inspection items. M 24 Cylinders Visual inspection of cylinders for leakage at rod, fittings, and welds.

Damage to rod and case.

M 25 Valves Holding valves for proper operation. M 26 Valves Control valves for leaks at fittings and between stations. M 27 Valves Control valve linkages for wear, smoothness of operation, and

tightness of fasteners. Relief valve for proper pressure settings.

M 28 General Bent, broken, or significantly rusted/corroded parts. M 29 Electrical Electrical apparatus for malfunctioning, signs of apparent

excessive deterioration, dirt or moisture accumulation. Electrical systems for presence of dirt, moisture, and frayed wires.

M 30 Structure All structural members for damage. M 31 Welds All welds for breaks and cracks. M 32 Pins All pins for proper installation and condition. M 33 Hardware All bolts, fasteners and retaining rings for tightness, wear and

corrosion.

M 34 Wear Pads Presence of wear pads.



M 35 Pump & Motor

Hydraulic pumps and motors for leakage at fittings, seals, and between sections. Check tightness of mounting bolts.

M 36 PTO Transmission/PTO for leakage, abnormal vibration & noise, alignment, and mounting bolt torque.

M 37 Hyd Fluid Quality of hydraulic fluid and presence of water. M 38 Hyd Lines Hoses & tubes for leakage, abrasion damage, blistering, cracking,

deterioration, fitting leakage, and secured properly.

M 39 Hook Load hook for abnormal throat distance, twist, wear, and cracks. M 40 Wire Rope Condition of load line. M 41 Manual Presence of operator's manual with unit. M 42 Other M 43 Other Q 44 Daily All daily inspection items. Q 45 Monthly All monthly inspection items. Q 46 Rotation

Sys Rotation bearing for proper torque of all mounting bolts.

Q 47 Hardware Base mounting bolts for proper torque. Q 48 Structure All structural members for deformation, cracks and corrosion. 49 • Base 50 • Stabilizer beams and legs 51 • Mast 52 • Inner Boom 53 • Outer Boom 54 • Extension(s) 55 • Jib boom 56 • Jib extension(s) 57 • Other Q 58 Hardware Pins, bearing, shafts, gears, rollers, and locking devices for wear,

cracks, corrosion and distortion.

59 • Rotation bearing(s) 60 • Inner boom pivot pin(s) and retainer(s) 61 • Outer boom pivot pin(s) and retainer(s) 62 • Inner boom cylinder pin(s) and retainer(s) 63 • Outer boom cylinder pin(s) and retainer(s) 64 • Extension cylinder pin(s) and retainer(s) 65 • Jib boom pin(s) and retainer(s) 66 • Jib cylinder pin(s) and retainer(s) 67 • Jib extension cylinder pin(s) and retainer(s) 68 • Boom tip attachment 69 • Other Q 70 Hyd Lines Hoses, fittings and tubing for proper routing, leakage, blistering,

deformation and excessive abrasion.

71 • Pressure line(s) from pump to control valve 72 • Return line(s) from control valve to reservoir 73 • Suction line(s) from reservoir to pump 74 • Pressure line(s) from control valve to each function 75 • Load holding valve pipe(s) and hose(s) 76 • Other Q 77 Pumps &

Motors Pumps and Motors for loose bolts/fasteners, leaks, noise, vibration, loss of performance, heating & excess pressure.

78 • Winch motor(s)



79 • Rotation motor(s) 80 • Other Q 81 Valves Hydraulic valves for cracks, spool return to neutral, sticking spools,

proper relief valve setting, relief valve failure.

82 • Main control valve 83 • Load holding valve(s) 84 • Stabilizer or auxiliary control valve(s) 85 • Other 86 • Other Q 87 Cylinders Hydraulic cylinders for drifting, rod seal leakage and leakage at

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

88 • Stabilizer cylinder(s) 89 • Inner boom cylinder(s) 90 • Outer boom cylinder(s) 91 • Extension cylinder(s) 92 • Rotation cylinder(s) 93 • Jib lift cylinder(s) 94 • Jib extension cylinder(s) 95 • Other Q 96 Winch Winch, sheaves and drums for damage, abnormal wear, abrasions

and other irregularities.

Q 97 Hyd Filters Hydraulic filters for replacement per maintenance schedule. A 98 Daily All daily inspection items. A 99 Monthly All monthly inspection items. A 100 Quarterly All quarterly inspection items. A 101 Hyd Sys Hydraulic fluid change per maintenance schedule. A 102 Controls Control valve calibration for correct pressure & relief valve settings. A 103 Valves Safety valve calibration for correct pressure & relief valve settings. A 104 Valves Valves for failure to maintain correct settings. A 105 Rotation

Sys Rotation drive system for proper backlash clearance & abnormal wear, deformation and cracks.

A 106 Lubrication Gear oil change in rotation drive system per maintenance schedule.

A 107 Hardware Check tightness of all fasteners and bolts, using torque specifications on component drawings or torque chart.

A 108 Wear Pads Wear pads for excessive wear. A 109 Loadline Loadline for proper attachment to drum.


Deficiency / Recommendation / Corrective Action Report DATE: OWNER: UNIT I.D. NUMBER:

GUIDELINES

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

b Recommendations (R) should be considered for corrective actions. Corrective action for a particular recommendation depends on the facts in each situation.

c Corrective actions (CA), repairs, adjustments, parts replacement, etc. are to be performed by a qualified person in accordance with all manufacturer’s recommendations, specifications and requirements.

NOTE: Deficiencies (X) listed must be followed by the corresponding corrective action taken (CA).

X = DEFICIENCY R = RECOMMENDATION CA = CORRECTIVE ACTION TAKEN

X,R,CA ITEM # EXPLANATION DATE CORRECTED


X,R,CA ITEM # EXPLANATION DATE CORRECTED


Thread Torque Chart (English) FINE THREAD BOLTS (ENGLISH) COARSE THREAD BOLTS (ENGLISH) SIZE BOLT

DIA. GRADE 5

SAE J429GRADE 5

GRADE 8

SAE J429GRADE 8

SIZE BOLT DIA.

GRADE 5

SAE J429GRADE 5

GRADE 8

SAE J429GRADE 8

(DIA-TPI) (INCHES) PLAIN PLATED PLAIN PLATED (DIA-TPI) (INCHES) PLAIN PLATED PLAIN PLATED (FT-LB) (FT-LB) (FT-LB) (FT-LB) (FT-LB) (FT-LB) (FT-LB) (FT-LB) 5/16-24 0.3125 19 14 27 20 5/16-18 0.3125 17 13 25 18 3/8-24 0.375 35 26 49 35 3/8-16 0.375 31 23 44 33 7/16-20 0.4375 55 41 78 58 7/16-14 0.4375 49 37 70 52 1/2-20 0.5 90 64 120 90 1/2-13 0.5 75 57 105 80 9/16-18 0.5625 120 90 170 130 9/16-12 0.5625 110 82 155 115 5/8-18 0.625 170 130 240 180 5/8-11 0.625 150 115 220 160 3/4-16 0.75 300 225 420 315 3/4-10 0.75 265 200 375 280 7/8-11 0.875 445 325 670 500 7/8-9 0.875 395 295 605 455 1-12 1 645 485 995 745 1-8 1 590 445 910 680 1 1/8-12 1.125 890 670 1445 1085 1 1/8-7 1.125 795 595 1290 965 1 1/4-12 1.25 1240 930 2010 1510 1 1/4-7 1.25 1120 840 1815 1360 1 3/8-12 1.375 1675 1255 2710 2035 1 3/8-6 1.375 1470 1100 2380 1780 1 1/2-12 1.5 2195 1645 3560 2670 1 1/2-6 1.5 1950 1460 3160 2370 NOTES 1 Tightening torques provided are midrange.

2 Consult bolt manufacturer’s particular specifications, when provided.

3 Use flat washers of equal strength.

4 All torque measurements are given in foot-pounds.

5 Torque values specified are for bolts with residual oils or no special lubricants applied. If special lubricants of high stress ability, such as Never-Seez compound graphite and oil, molybdenum disulphide, colloidal copper or white lead are applied, multiply the torque values in the charts by the factor .90. The use of Loctite does not affect the torque values listed above.

WARNINGAnytime a gear-bearing bolt is removed, it

must be replaced with a new bolt of theidentical grade and size. Once a bolt hasbeen torqued to 75% of its proof load and

then removed, the torque coe fficient may nolonger be the same as when the bolt was new

thus giving indeterminate clamp loads aftertorqueing. Failure to replace gear-bearingbolts may result in bolt failure due to metal

fatigue causing death or serious injury.


Thread Torque Chart (Metric) FINE THREAD TORQUE CHART (METRIC) COARSE THREAD TORQUE CHART (METRIC)

TIGHTENING TORQUE TIGHTENING TORQUE SIZE (DIA-TPI)

BOLT DIA. (INCHES)

SAE J429GRADE 5

SAE J429GRADE 8

SIZE (DIA-TPI)

BOLT DIA (INCHES)

SAE J429GRADE 5

SAE J429GRADE 8

PLAIN (KG-M)

PLATED (KG-M)

PLAIN (KG-M)

PLATED (KG-M)

PLAIN (KG-M)

PLATED (KG-M)

PLAIN (KG-M)

PLATED (KG-M)

5/16-24 0.3125 3 2 4 3 5/16-18 0.3125 2 2 3 2 3/8-24 0.375 5 4 7 5 3/8-16 0.375 4 3 6 5 7/16-20 0.4375 8 6 11 8 7/16-14 0.4375 7 5 10 7 1/2-20 0.5 12 9 17 12 1/2-13 0.5 10 8 15 11 9/16-18 0.5625 17 12 24 18 9/16-12 0.5625 15 11 21 16 5/8-18 0.625 24 18 33 25 5/8-11 0.625 21 16 30 22 3/4-16 0.75 41 31 58 44 3/4-10 0.75 37 28 52 39 7/8-11 0.875 62 45 93 69 7/8-9 0.875 55 41 84 63 1-12 1 89 67 138 103 1-8 1 82 62 126 94 1 1/8-12 1.125 123 93 200 150 1 1/8-7 1.125 110 82 178 133 1 1/4-12 1.25 171 129 278 209 1 1/4-7 1.25 155 116 251 188 1 3/8-12 1.375 232 174 375 281 1 3/8-6 1.375 203 152 329 246 1 1/2-12 1.5 304 228 492 369 1 1/2-6 1.5 270 210 438 328 NOTES 1 Tightening torques provided are midrange.

2 Consult bolt manufacturer’s particular specifications, when provided.

3 Use flat washers of equal strength.

4 All torque measurements are given in kilogram-meters.

5 Torque values specified are for bolts with residual oils or no special lubricants applied. If special lubricants of high stress ability, such as Never-Seez compound graphite and oil, molybdenum disulphite, collodial copper or white lead are applied, multiply the torque values in the charts by the factor .90. The use of Loctite does not affect the torque values listed above.

WARNINGAnytime a gear-bearing bolt is removed, it

must be replaced with a new bolt of theidentical grade and size. Once a bolt hasbeen torqued to 75% of its proof load and

then removed, the torque coefficient may nolonger be the same as when the bolt was new

thus giving indeterminate clamp loads aftertorqueing. Failure to replace gear-bearingbolts may result in bolt failure due to metal

fatigue causing death or serious injury.


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

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

WARNING

TIGHTENING PROCEDURE

1 Refer to the Torque Data Chart to determine the proper torque value to apply to the size of capscrew used.

2 Follow the tightening sequence shown in the diagram. Note that the quantity of capscrews may differ from the diagram, but the sequence must follow the criss-cross pattern as shown in the diagram.

3 Torque all capscrews to approximately 40% of the specified torque value, by following the sequence.

(EXAMPLE: .40 x 265 FT-LB = 106 FT-LB)

(EXAMPLE-METRIC: .40 x 36 KG-M = 14.4 KG-M)

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

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

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

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


Turntable Bearing Inspection Turntable bearings may experience wear. One of the following conditions may indicate turntable bearing wear:

1 Metal particles present in the bearing lubricant.

2 Increased drive power required to rotate the crane.

3 Noise emitting from the bearing during rotation.

4 Rough rotation.

5 Uneven or excessive wear between the pinion gear and turntable gear.

If one or more of the above conditions exists, further inspection may be required. Limits are measured in “TILT” which is dependent on the internal clearances of the bearing. TILT is the most practical determination of a bearings' internal clearance once mounted on a crane. You can measure the tilt using the Turntable Bearing Tilt Test. (see "Turntable Bearing Tilt Test" on page 87)

Periodic readings indicating a steady increase in TILT may be an indicator of bearing wear. Note that a bearing found to have no raceway cracks or other structural irregularities should be reassembled and returned to service.

Turntable Bearing Tilt Test 1 Place crane in vertical position.

2 Set a dial indicator at 0 on the pinion cover plate at back side of mast.

3 Lower crane to the horizontal position.

4 Check and record the dial indicator change. It should not exceed the tilt measurement noted in the chart below.

5 Return the crane to the vertical position. The dial indicator should return to 0.


Set up dial indicatorto 0" on pinion coverat back side of mast.

Lower crane tohorizontal position.Read dial indicator.

COMPARISON CHART – MEASURED TILT DIMENSION PER CRANE MODEL NOTE: The tilt dimensions listed in this chart are service guidelines and do not, in themselves, require that the bearing be inspected. If there is reason to suspect an excess of bearing wear AND the measured tilt dimension exceeds the dimension listed, remove the bearing for inspection. IMT Crane, Loader or Tirehand Model

1007 1014/1014A 1015 2015/2020 2109 2820 3000 3016/3020 3203i 3816/3820 4004i 421/425 4300 5005i 5016/5020 6006i 6016/6020 6022 5525 / 6025 / 6625 EZ Hauler I, II EZ Hauler 3000 / 5500

5200 5200R 5217 5800 7020 7025 7200 7415 8025 9000

16000-I, II, III 32018 32027 32030 T30 T40

23516 14K160TH COMMANDER IV

1221R 1225R 8000L 9800 12916 13031 13034 14000 15000 18000 20017 8000L H1200 H1200RR T50

Ball Dia. (Ref)

.875" (22 mm) 1.00" (25 mm) 1.18 - 1.25" (30-32 mm)

1.5” (38 mm) 1.75" (44 mm)

Tilt Dim. .060" (1.524 mm) .070" (1.778 mm) .075" (1.905 mm) .085” (2.159 mm) .090" (2.286 mm)

Rev 20100331

Documents

IMT 6006i - Technical Specifications & Parts...20111028 99904458 ECN 11569 - UPDATE HYD MOTOR PORTS AND BOM 20120326 99904458 ECN 11686 - CORRECT HOSES. 51721396, 51721386 ECN 11581