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Manual # 99904380
IMT 3203i Technical
Specifications & Parts
Revision Date 20150707
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.
Contents
i
ii Contents
Revisions
Contents
20091023
20091216
20100311
20100427
20100615
20100923
20101203
20110614
20111121
20120326
20120103
20120512
20121011
20121114
20130121
20130129
20130327
DATE
20080528
20080702
20080908
20081107
20090210
20090305
20090311
20090515
99904394
71570922
99904316
99904316,
99904317
51721267,
51722111
51721267
99904315
99904317
99904315
41721489
99904317
99904316
99904317
99904457
99904389
LOCATION
VARIOUS
77441270
95721267
99904315,
99904317,
99904377,
99904389,
99904394,
73734304
99904315-
99904316,
99904389,
99904578,
51722111
99904593 –
99904595
99904315,
99904317,
99904361,
99904389
99904389,
99904361,
99904316,
99904317,
99904593
99904361,99904
316
99904317,
99904361
99904361
99904884
DESCRIPTION
ECN 10747- PRE-PRODUCTION CHANGES
ECN 10803 - PROP VALVE CHANGE TO HARNESS
ADDED PRESSURE SWITCH, COUNTERBALANCE VALVE
ECN 10865 - MOVED INSTALLATION LOCATION OF POWER AND
GROUND CABLES, CHANGED VALVE BANK COIL ORIENTATION,
ADDED SWITCH MOUNTING BRACKET TO INSTALLATION KIT;
ECN 10868 - HYDRAULIC INSTALLATION KIT CHANGES; ECN
10868-1 - REPLACED COUNTERBALANCE VALVES IN LOWER
CYLINDERS
ECN 10945 - NEW CONTACTOR SWITCH; ECN 10923 - NEW
EXTENSION CYLINDER.
ADDED SHEAVE & HOOK LATCH KIT SPARE PART NUMBERS.
ECN 10987 – ADDED REFERENCE DRAWINGS FOR CONTROL
MODULE INSTALLATION.
ECN 10977, 10991 - CHANGED WINCH PART NUMBER, CHANGED
PROPORTIONAL VALVE PORT ID.
ECN 11033 - PRODUCTION AUDIT COMPONENT CHANGES
ECN 11099, 11116 - HYDRAULIC SYSTEM CHANGES
ECN 11153- ADDED DOWNHAUL WEIGHT; ECN 11146 - HOSE
CORRECTIONS.
ECN 11182 - ADDED PRESSURE PORT TO ELBOW IN HYD KIT.
ADDED 99904884 AND EDITED ELECTRIC CRANE 99904394 STEP
5; CORRECTED 99904317 TYPO.
ADDED DUAL BATTERY WIRING INFORMATION
UPDATED WINCH SPARE PARTS
ECN 10713-3 - MODIFIED WEAR PADS FOR THICKNESS
ECN 11432 - UPDATED LOWER BOOM
ECN 11628 - UPDATED STABILIZER WORDING.
ECN 11581 - CYLINDER UPDATES. ADDED PROP
INSTRUCTIONS FOR REMOTE.
ECN 11872 – MAIN CYLINDER BOM CHANGE
ECN 11835-2 – PIN REPLACEMENT
ECN 11829 – POWER UNIT CHANGED
ECN 11835 – SNATCH BLOCK, CORD REEL, AND WIRE ROPE
CHANGED
ECN 11835-4 – BRIDLE RING REMOVED
ECN 11829-1 – POWER CABLE CHANGE
ECN11829-2 – POWER CABLE LENGTH CHANGED iii
iv Contents
20130328
20130401
20130509
20130522
20130613
20130620
20131113
99904317
99904316
99904361
99904315
99904316
99904317
99904316
99904317
99904389
99904315
99904317
99904327
99904361
99904315
99904315
99904389
70734746
20131120
20140925
99904316-2
99904316-3
99904316-4
99904316
77441270
77441269
99904315
99904361
Greasing
Instructions
99904315
ECN 11835-1 – EXTENSION CYLINDER PIN REMOVED
ECN 11835-3 – GEAR GUARD CHANGE AND SINGLE STINGER
CHANGE
ECN 11835-7 – WINCH CONNECTOR AND BRACKET CHANGE
ENC 11835-8 – 225A CONTACTOR, CABLE REDUCTION, VALVE
BANK BRACKET CHANGE
ENC 11835-6 – BASE WELDMENT CHANGE
ECN 12007 – VALVE BANK HARDWARE CHANGE
REMOVED TETHERED PROPOTIONAL REMOTE
POTENTIOMETER ADJUSTMENT PROCEDURE.
ECN 12045 – 72066143 to 70734805
ECN 12045 – 72066143 to 70734805
ECN 12045 – 72066143 to 70734805
ECN 12045 – 72066143 to 70734805
ECN 12063 – updated schematic and harness
ECN 12063 – updated schematic and harness
ECN 12084 – hydraulic kit
ECN12084 – added second item 5 & 18
ECN 12264 – Molub-Alloy 882 was Molub-Alloy 936.
ECN 12283 – 76039295 was REF, now quantity 1
C H A P T E R 1
Electric Crane Introduction
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:
NOTE
A NOTE is used to either convey additional information or to provide further emphasis for a previous point.
CAUTION
A CAUTION is used when there is the very strong possibility of damage to the equipment or premature equipment failure.
WARNING
A WARNING is used when there is the potential for personal injury or death.
For a safe work environment, treat this equipment with respect and service it regularly.
C H A P T E R 2
Technical Specifications
7
In This Chapter
3203i Technical Data ................................................ 7
3203i Capacity Chart ................................................ 8
3203i Geometric Configuration ................................. 10
Pump & Motor Performance ..................................... 10
3203i Technical Data
GENERAL SPECIFICATIONS
CRANE RATING
MAXIMUM HORIZONTAL REACH (from centerline of rotation)
HYDRAULIC EXTENSION (1)
MANUAL EXTENSION (1)
LIFTING HEIGHT (from base of crane to centerline of sheave)
CRANE WEIGHT (1H1M)
CRANE STORAGE HEIGHT
MOUNTING SPACE REQUIRED (crane base)
HYDRAULIC SYSTEM OPERATING
PRESSURE
MAXIMUM HYDRAULIC FLOW
12,000 ft-lb at 7'-6" (1.6 tm at 2.3 m)
15'-0" (4.6 m)
48" (122 cm)
48" (122 cm)
16'-2" (4.9 m)
635 lb (288 kg)
29" (73.7 cm)
14" x 18" (35.5 cm x 45.7 cm)
2500 psi (172 bar)
1.6 gpm (6 lpm)
OIL RESERVOIR CAPACITY
OIL TYPE
1.5 gallons (5.7 l)
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)
22.88" (58.1 cm)
- HORIZONTAL FROM CENTERLINE OF
ROTATION (BOOMS EXTENDED)
43.00" (109.2 cm)
- VERTICAL FROM BOTTOM OF CRANE
BASE
TIE-DOWN BOLT PATTERN (on center)
12.75" (32.4 cm)
12" x 12" (30.5 cm x 30.5 cm) or 11.5" x 14.75" (29.2 cm x
37.5 cm)
ROTATION TORQUE 2500 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.
8 IMT 3203i Technical Specifications & Parts Manual # 99904380
CYLINDER SPECIFICATIONS
LOWER BOOM CYLINDER
EXTENSION BOOM CYLINDER
WINCH SPECIFICATIONS
WINCH PULL LINE
PULL LINE SPEED WITHOUT LOAD
ROPE DIAMETER
2.75" bore; 16" stroke (7 cm bore; 40.6 cm stroke)
1.5" bore; 48" stroke (3.8 cm bore; 122.0 cm stroke)
2000 lb (907 kg)
23 ft/min (7 m/min)
7/32" (5.56 mm)
WIRE ROPE LENGTH
CABLE NOMINAL STRENGTH
PERFORMANCE CHARACTERISTICS
65' (19.81 m)
5600 lb (2540 kg)
SPECIFICATION
ROTATION Continuous 360° (6.28 rad)
LOWER BOOM ELEVATION -5° to +75° (-0.1 to +1.3 rad)
SPEED
44 seconds
10 seconds
EXTENSION CYLINDER 48" (122.0 cm) 10 seconds total
3203i Capacity Chart
3203i CAPACITY CHART
16'
4.8m
LB
KG
2350
1065
1450
660
Maximum 1-part line capacity is 2000 lb (907 kg).
For greater loads, use
2-part line.
NOTE: Boxes denote
2-part line.
14'
4.2m
12'
3.6m
3135
1420
1140
520
1990
905
10'
3.0m
8'
2.4m
6'
1.8m
4'
1.2m
7
5
°
4000
1815
6
0
°
3050
1385
45
°
2460
1115
30
°
2140
970
1575
715
1350
615
1195
540
15°
1905
865
975
440
850
385
2'
0.6m
0
(Base)
0
2'
0.6m
4'
1.2m
6'
1.8m
1670
755
8'
2.4m
10'
3.0m
1050
475
12'
3.6m
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.
14'
4.2m
730
330
IOWA MOLD TOOLING CO., INC.
BOX 189, GARNER, IA 50438-0189
TEL: 641-923-3711 FAX: 641-923-2424
70397348
Chapter 2 Technical Specifications 9
10 IMT 3203i Technical Specifications & Parts Manual # 99904380
3203i Geometric Configuration
4'-0"
(1.22 m)
3'-0"
(0.91 m)
1'-11"
(0.39 m)
16'-2"
(4.92 m)
12'-3"
(3.75 m)
8'-5"
(2.60 m)
1'-3" (38 cm)
7'-0" (2.13 m)
11'-0" (3.35 m)
15'-0" (4.57 m)
Chapter 2 Technical Specifications 11
Pump & Motor Performance
The Powerpack Motor for the 3203i and 4004i crane cannot be run continuously without serious motor damage. The 3203i and 4004i pump has a maximum duty cycle of 4.5 minutes which must be followed by cool-down to ambient temperature. It can be run intermittently according to the following charts.
25.0
6 300
20.0
15.0
10.0
5.0
0.0
5
4
I - 1.6 CC 250
200
180 AMPS
1
0
3
2
Q - 1.6 CC
150
100
2500 PSI
50
0
0
500 1000 1500 2000 2500 3000 3500 4000 4500
PSI
0 25 50 75 100 125 150 175 200 225 250 275 300
BAR
CAUTION
Avoid motor damage! Operate within performance curves shown.
12 IMT 3203i Technical Specifications & Parts Manual # 99904380
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 4.5 minutes, which MUST be followed by a complete cool-down to ambient.
C H A P T E R 3
Crane Reference
In This Chapter
Assemblies & Grease Zerk Locations ....................... 14
3203i Recommended Spare Parts List ..................... 15
Crane Installation (99904394) .................................. 16
Electric Crane Battery Circuit (99904884) ................ 21
Telescopic Crane Orientation ................................... 22
Electric Crane Control .............................................. 24
13
14 IMT 3203i Technical Specifications & Parts Manual # 99904380
Assemblies & Grease Zerk Locations
EXTENSION
BOOM
LOWER
BOOM
SNATCH
BLOCK
WINCH
HOOK
1
LOWER
CYLINDER
2
6
MAST
3
HYDRAULIC
RESERVOIR
POWER
UNIT
4
5
CRANE
BASE
ITEM LOCATION DESCRIPTION LUBRICANT FREQUENCY
1.
2.
3.
Lower Cylinder Rod
Lower Cylinder Base
Gear Rotator Grease Extension
*Rotate crane while greasing.
Power Unit
Shell Alvania 2EP or
Shell Retinax "A"
Weekly
4.
5.
6.
Power Unit
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.
NOTE: Image may be different depending on production date. Grease points should be identical.
Chapter 3 Crane Reference
3203i Recommended Spare Parts List
(See Parts List for Effectivity Dates)
Part Number Description Quantity Effective Through
51721267 Lower Cylinder
51744137 SEAL KIT-IMT 2.75B 1.75R 1.50 S 1
60127432 PISTON-2.75 BORE X 1.75 ROD 1.63 STGR
60127434 HEAD-2.75 BORE X 1.75 ROD
73054999 VALVE-COUNTERBALANCE
77041786 SWITCH-PRESS 2750 PSI 1
51722111 Extension Cylinder
94397290 SEAL KIT-IMT 1.50 BORE 1.00 ROD .75
60135105 HEAD-1.50 BORE X 1.00 ROD
60135106 PISTON-1.50 BORE X .75 STGR 1
73054999 VALVE-COUNTERBALANCE SUN01 CBBC-LHN 1
99904315 Base & Mast Assembly
1
1
1
1
1
60118032 CABLE CONNECTOR MODIFICATION 1
72601931 CAP SCREW .44-14X 3.00 HH 156 KSI PROOF L 16
73511156 MOTOR-HYDRAULIC 101 1035 009
76039295 GASKET-GEAR
77441534 SWITCH- 225A CONTACTOR (12 or 24V)
1
1
1
77441281 CABLE CONNECTOR-FEMALE
77441285 TERMINAL RING, INSULATED 3/8 STUD
73734304 Valve Bank (12V)
73540327
73540326
COIL (VALVE BANK) (12V)
VALVE ASSEMBLY (VALVE & COIL) (12V)
73734375 Valve Bank (24V)
77040527 COIL (VALVE BANK) (24V)
73540336 VALVE ASSEMBLY (VALVE & COIL) (24V)
73511283 Power Unit (12V)
1
3
6
70733826
73511171
FILL CAP ELECTRIC CRANES
PUMP-GEAR ELECTRIC CRANE
73540323 VALVE-RELIEF ELECTRIC CRANE
73734332 KIT-TUBE POWER UNIT ELECTRIC CRANE
74397392 RESERVOIR TANK ELECTRIC CRANE
3
6
1
1
1
1
1
77043060 MOTOR-POWER UNIT ELECTRIC CRANE
73511305 Power Unit (24V)
77043066 MOTOR (24V)
73511306 PUMP
73540517 RELIEF VALVE ASSEMBLY
74399495 RESERVOIR
70734788 BREATHER CAP
73734791 TUBE-SUCTION
70734792 STRAINER
1
1
1
1
1
1
1
1
10/12/2012
02/23/2010
02/23/2010
04/25/2013
15
16 IMT 3203i Technical Specifications & Parts Manual # 99904380
Part Number Description Quantity Effective Through
99904316 Boom Assembly
60030373 WEAR PAD- EXT CYLINDER
60030374
60030375
WEAR PAD-ROUND 1.00 DIA X .50 DIA X .75L
WEAR PAD-ROUND 3.00 DIA X 1.00 DIA X .55L
60030376
60132302
71734311
71734314
72661543
WEAR PAD-ROUND 3.50 X 1.00 DIA X .615 LG
STOP SCREW 3/8-24 X .50
PIN-QUICK RELEASE.62D/4.5 CRIT
PIN-QUICK RELEASE.62D/6.5 CRIT
PIN-QUICK 316-10QP
60030372
60133938
60030369
72661711
60030483
51721494
70580059
71413185
72601798
SHEAVE- 5.5 NYLATRON
WEAR PAD-ROUND 0.25 X 1.00 X 0.50 X 0.50
WEAR PAD-ROUND 0.19 X 2.00 X 1.00 X 0.50
CLEVIS PIN 0.5 x 3.00
SHEAVE-8.0 NYLATRON
99904317 Crane & Winch Assembly
CORD REEL ASSEMBLY- 5ft PACKARD CONNECTOR 1
WIRE ROPE ASM-.22(7X19)X65FT PGA 1
SPRING-.105WIRE 0.75OD 2.875 LG
WASHER-LOCK 12MM
1
4
1
2
2
1
1
72601935
72601938
77041459
CAP SCREW M12-1.75X 40 SH PLAIN
BOLT-EYE # 8-32X .75
SWITCH-LIMIT ZE-N-2S
77441096
77566638
77744175
CONNECTOR- .50 STR RLF .25-.38
71570922 WINCH (12V)
77041801 CONTACTOR (12 OR 24V)
BRAKE ASSEMBLY
BRUSH KIT
71570922 WINCH (24V)
77041928 CONTACTOR (12 OR 24V)
77566638
77744175
BRAKE ASSEMBLY
BRUSH KIT
99904394 Electrical Installation
77441116
77441219
FUSEHOLDER, HIGH AMP
FUSE-225 AMP
1
1
4
1
1
1
1
1
1
1
1
1
2
4
1
1
2
1
6
1
11/14/2012
10/11/2012
Chapter 3 Crane Reference 17
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.
7.
8.
9.
CRANE INSTALLATION PARTS LIST
ITEM
1.
2.
3.
5.
6.
PART #
51721572
91721647
91721751
51725572
60251272
DESCRIPTION KIT #
ELECTRIC CRANE BODY INSTALLATION
HARDWARE KIT- 3203i/4004i ELEC CRANE
BODY INSTALLATION
HARDWARE KIT- 5005i ELEC CRANE BODY
INSTALLATION
DRAWING-CRANE & WINCH ASSEMBLY 3203I
BRACKET-SWITCH 300 AMP ELEC CRANE #1 & #4
10.
11.
12.
13.
14.
70734331
72042097
77040209
77040529
77441116
77441219
89044276
89392333
SWITCH-300A KEYED BATTERY DISCONNECT #1 & #4
LEVEL INDICATOR LEVEL
TERMINAL-RING NI .38 STUD 1 WIRE
TERMINAL-RING NI .31 STUD 1-2 WIRE
FUSEHOLDER-HIGH AMP2 BOLT WITH
COVER
FUSE-225 AMP
CABLE-#1 WELDING
#1 & #4
#1 & #4
#4
#4
#4
#1 & #4
15.
16.
17.
72060208
72601862
72063116
TUBE-HEAT SHRINK AMP
CAP SCREW .75-10X 2.50 HH GR8 Z
NUT .75-10 HEX NYLOC GR8Z
WASHER .75 N FLAT H ASTMF436Z
#1 & #4
#2
#2
#2
18.
19.
20.
72060002
72060634
72062000
21.
22.
72062106
72063001
REV. E 20120918
CAP SCREW .25-20X .75 HH GR5 Z
SCREW-MACHINERY #10-24X .50 RDH
NUT .25-20 HEX
NUT 10-24 HEX NYLOCK
WASHER .25 FLAT
#2 & #3
#2 & #3
#2 & #3
#2 & #3
#2 & #3
QUANTITY
1
1
1
1
1
9
2
REF
1
1
4
8
4
4
4
4
4
8
2
35 FT
0.50 FT
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 3/4-10x2.5" mounting cap screws (item # 15) and 3/4" washers (item #16) to secure the crane base to the truck body (see figure). Torque the cap screws to 280 ft-lb.
18 IMT 3203i Technical Specifications & Parts Manual # 99904380
NOTE:
The 3/4-10 x 2.5" grade 8 zinc coated capscrews are designed for a crane box thickness of
1/2" only. A different crane box may require different capscrews. All mounting capscrews must be grade 8 zinc coated with a minimum thread engagement of 1.25" (3.175 cm).
9.5" DIA.
0.81" DIA.
6"
5.75"
15,17
(SEE
NOTE)
6" 7.38"
14.75"
12"
18"
11.5"
12"
14"
ALLOW 16"
RADIUS FOR
SWING CLEARANCE
MOUNTING HOLE PATTERN
16,17
Chapter 3 Crane Reference 19
2 The electrical power switch (item #7) provides power for the crane. Install the switch onto the power unit cover.
18
22
KEY SUPPLIED
WITH 70734331
SWITCH. SPARE
KEY - 70734357.
19
7
6
21
6
2.75"
5.03"
13.5"
3.5"
4 HOLES,
0.266" DIA.
8
22
20
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.
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).
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.
20 IMT 3203i Technical Specifications & Parts Manual # 99904380
POWER
CABLE
BRACKET
A
13
14
9
GROUND CABLE (GROUND
TO BARE METAL INSIDE
CRANE BOX)
7
MALE POWER
CABLE 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 both the vehicle battery and auxiliary 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.
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.
Chapter 3 Crane Reference 21
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.
1000 CCA
AUXILIA RY
BATTERY (IN CRANE BOX)
89044276 or 77040009
FUSE TO BATTERY (+)
(APPROXIMATELY 1FT)
11
13
11
HEAT SHRINK
12
29
11
89044276 or 77040009
BATTERY (-) TO CHASSIS GROUND
(CUT TO LENGTH)
HEAT SHRINK
11 TO CHASSIS GROUND
FROM ON-OFF SWITCH
IN CRANE BOX
13-CABLE #89044276 or
27-CABLE #77040009
(CUT TO LENGTH)
(CRANE ON-OFF
SWITCH TO FUSE)
13-CABLE #89044276 or
27-CABLE #77040009
(CUT TO LENGTH)
(CRANE ON-OFF
SWITCH TO FUSE)
11
13
11
12
13-CABLE #89044276 or
27-CABLE #77040009
(CUT TO APPROX. 1' (30.5 CM))
(FUSE TO BATTERY (+))
UNDERHOOD
BATTERY
ITEMS WITHIN BOXARE ONLY NEEDED
WHENAUXILIARY BATTERY IS
INSTALLED IN CRANE BOX.
* MATCHED BATTERIESARE REQUIRED*
13-CABLE #89044276 or
27-CABLE #77040009
(CUT TO LENGTH)
(5/16" RING
TERMINA L
10
TO CRANE
TO CHASSIS GROUND
(5/16" RING
TERMINAL)
10
12
(225-AMP
FUSE)
TO
BATTERY (+)
11
(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 99904884 for wiring diagram.
22 IMT 3203i Technical Specifications & Parts Manual # 99904380
Electric Crane Battery Circuit (99904884)
CRANE
SW
225A
1
GROUND AT
CHASSIS FRAME
18" (457 mm)
MAXIMUM
225A
UNDERHOOD
BATTERY
GROUND AT
CHASSIS FRAME 18" (457 mm)
MAXIMUM
2ND AUX
BATTERY
GROUND AT
CHASSIS FRAME
NOTE:
1 ELECTRIC BULKHEAD PASS-THRU CONNECTOR. USE WHENEVER POWER OR GROUND PASSES
THROUGH A COMPARTMENT WALL.
Telescopic Crane Orientation
Chapter 3 Crane Reference 23
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.
BOOM
REST
OUTLINE OF
TRUCK BODY
REAR OF
TRUCK
400°
ROTATION
24 IMT 3203i Technical Specifications & Parts Manual # 99904380
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).
C H A P T E R 4
Parts
In This Chapter
Parts Information ................................................................. 26
Electric Crane Power Safety ................................................ 28
Base & Mast Assembly (99904315)..................................... 29
Valve Bank (73734304) ....................................................... 35
Cylinder, Lower (51721267) ................................................ 36
Boom Assembly (99904316) ............................................... 38
Crane & Winch Assembly (99904317) ................................. 56
Cylinder, Extension (51725007) (Effective 01/09/13 ) .......... 68
Cylinder, Extension (51722111) (Through 01/09/13) ........... 70
Cylinder, Extension (51721291) (Through 12/29/08 ) .......... 72
Winch (71570922) ............................................................... 73
Power Unit (73511283 & 73511305).................................... 74
Power Unit (73511169)........................................................ 75
Hydraulic Installation (99904361) ........................................ 76
Tethered Control Installation (99904593) ............................ 85
Radio Control Installation, Standard (99904594) ................. 87
Radio Control Installation, Proportional (99904595) ............ 88
Electrical Installation (99904389) ......................................... 89
275-Amp Contactor Replacement (99904578) .................... 93
225-Amp Contactor Replacement (99904578) .................... 94
Harness, Radio (77441270) ................................................ 95
Harness, Tethered (77441269) ............................................ 97
Handle Assembly, Tethered (70734746) ............................. 98
Handle Assembly, Tethered (51721502) ............................. 98
Decal Installation (99904375) .............................................. 102
25
26 IMT 3203i Technical Specifications & Parts Manual # 99904380
Parts Information
GENERAL
This section contains the exploded parts drawings and accompanying parts lists for the assemblies used on this crane. These drawings are intended to be used in conjunction with the instructions found in the maintenance and repair manuals for this crane family. For optional equipment such as winches and remote controls, refer to the appropriate service manual.
WARNING
Do not attempt to repair any component without reading the information contained in the repair section. Pay particular attention to statements marked Warning, Caution or
Note in that section. Failure to comply with these instructions may result in damage to the equipment, personal injury or death.
CRANE IDENTIFICATION
Every 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
IOWA MOLD TOOLING CO., INC.
BOX 189, GARNER, IA 50438-0189
MODEL
NUMBER
SERIAL
NUMBER
MFG
DATE
CYLINDER IDENTIFICATION
Chapter 4 Parts 27
To insure proper replacement parts are received, it is necessary to specify the complete number/letter sequence for any part requested. Part numbers may be cross checked by comparing the stamped identification on the cylinder case (See figure below) against the information contained in the service manual. You must include the part number stamped on the cylinder case when ordering parts.
CYLINDER
PART NUMBER
LOCATION
WELDMENT IDENTIFICATION
Each of the major weldments - base, mast, inner boom, outer boom, extension boom and stabilizer weldments bear a stamped part number. Any time a major weldment is replaced, you must specify the complete part number as stamped on the weldment. The locations of the part numbers are shown in the Crane Reference Section.
ORDERING REPAIR PARTS
When ordering replacement parts:
1 Give the model number of the unit.
2 Give the serial number of the unit.
3 Specify the complete part number. When ordering cylinder parts, or one of the main weldments, always give the stamped part number.
4 Give a complete description of the part.
5 Specify the quantity required.
28 IMT 3203i Technical Specifications & Parts Manual # 99904380
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
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
Effectivity Dates)
Base & Mast Assembly (99904315)
(See Parts List for
WARNING
Avoid injury! Do NOT connect electrical power to crane until all connections have been tested. Attach electrical wires and grounds to components before connecting to mast.
20
4
20
1 35 35 2
12
31 31 41
50
29
24
6 34 2
CONTACTOR
20
20
3
20
33
42
17
18
25
27
36
7
39
26
25
9
26
13
22
3
5
19
16
38
22
40
37
30
10
13
25
37
30
27
28
22
HYDRAULIC MO TOR &
VALVE BANK ASSEMBLY
27
28
45
15, 31
BASE & ROTATOR ASSEMBLY
NOTES (SEE REFERENCE NUMBER IN BOX):
1 BOLTS CONNECT WITH PART NUMBER 52721306.
11
45
27
POWER UNIT
GEAR GUARD
INSTALLATION
21
28
27
27
28
21
2 TORQUE TO 142 N-m (105 FT-LB).
3 APPLY RUST PREVENTATIVE
4 APPLY BLACK "MOLUB-ALLOY 882 HEAVY" GEAR GREASE TO TURNTABLE GEAR.
29
44
29
29
44
23
27
28
21
8
27
28
21
30 IMT 3203i Technical Specifications & Parts Manual # 99904380
99904315 PARTS LIST
27.
28.
29.
30.
31.
32.
21.
22.
23.
24.
25.
26.
33.
34.
35.
36.
37.
38.
39.
40.
41.
14.
15.
16.
17.
18.
18.
19.
20.
8.
9.
10.
11.
12.
13.
5.
6.
7.
ITEM PART #
1. 51721319
DESCRIPTION
HARDWARE KIT-BASE & MAST ASSEMBLY
2.
3.
4.
91722219
51725663
51721267
ELEC. INSTALLATION KIT- 3203I
HYDRAULIC KIT (effective from 09/06/13)
CYLINDER- 2.75B X 1.75R X 16.06S 46.50 CC C
52725036
52725030
60140618
BASE WELDMENT- 3203I (effective from 06/12/13)
MAST WELDMENT-3203I (effective from 04/25/13)
PIN TYPE NN 1.00 X 8.25 (effective from 12/05/12)
60140637
60141129
60141128
SHROUD-TURN TABLE GEAR 3203i (effective from 12/26/12)
ELECTRIC ROTATOR BRACKET TOP (effective from 05/13/13)
ELECTRIC ROTATOR BRACKET BOTTOM (effective from 05/10/13)
60132385 SPACER- POWER UNIT
77441534 SWITCH- 225A CONTACTOR 12 OR 24V (effective from 04/25/13)
70580194 CLAMP-I" CONDUIT HANGER W/BOLT
71056678 GEAR-TURNTABLE BEARING (effective from 06/12/13)
72602081 CAP SCREW (effective from 06/12/13)
73511156 MOTOR-HYDRAULIC 101 1035 009
73511283 POWER UNIT- 1.19CC 12VDC (effective from 10/11/12)
73734304 VALVE BANK-3 SEC SERIES 3GPM @ 500PSI
73734375 VALVE BANK-3 SEC SERIES 3GPM @ 500PSI (24V) (effective from 04/25/13)
76039295 GASKET
70034382 CAP-GREASE #1
KIT # QTY
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
5
1
16
1
1
1
72060000
72060002
72060044
72060046 CAP SCREW .38-16X 1.00 HH GR5 Z
72062104 NUT .25-20 HEX NYLOCK (effective from 04/25/13)
72062107
72063001 WASHER .25 FLAT (effective from 06/21/13)
72063049 WASHER .25 LOCK
72063051
72063053 WASHER .50 LOCK
72063132 WASHER .50 FLAT ASTM F436 (effective from 06/12/13)
72063271
72534418
72601932
72601939
72602009 SCR-MACH # 8-32X 1.25 BTNHD SS
72601949 CAP SCREW .50-13X 1.25 SH ZC
51721664 CABLE ASM- 1GA-5/16RNGX 1/4RNGX 48.00LG
51721943 CABLE ASM- 1GA-3/8RNGX SWVL FX 11.00LG
51721944
77441312
CAP SCREW .25-20X .50 HH GR5 Z
CAP SCREW .25-20X .75 HH GR5 Z
CAP SCREW .38-16X .75 HH GR5 Z (effective from 11/17/08)
NUT .50-13 HEX CENTER LOCK Z
WASHER .38 LOCK
WASHER # 8 W FLAT ANSI B27.2Z
ZERK-NPT .12 X 1.75 LG
CAP SCREW .50-13X 4.00 SH ZC
CAP SCREW .50-13X 4.50 SH ZC
CABLE ASM- 1GA-3/8RNGX SWVL MX 60.00LG
CABLE ASM-10GA-#10RNGX 1/4RNGX 6.00LG
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#2
#2
#2
#2
4
2
1
1
1
13
2
1
1
11
9
4
2
20
4
1
3
2
4
5
1
42.
42.
43.
72534875 ELBOW-STREET STL M6 x 90 DEG (effective to 9/6/13)
72531130 ELBOW-STREET STL .12 X 90 DEG (effective from 2/10/15)
72062207 NUT 8-32 HEX NYLOCK #1
1
1
4
99904315 PARTS LIST
ITEM PART #
44. 72060051
DESCRIPTION
CAP SCR .38-16X 2.25 HH GR5 Z
45. 72060004 CAP SCR .25-20X 1.00 HH GR5 Z (effective from 04/25/13)
48.
49.
50.
72060048
72063003
71415014
CAP SCR .38-16X 1.50 HH GR5 Z
WASHER .38 FLAT
KEEPER PIN 0.38 (effective from 12/05/12)
51.
52.
53.
60140642 BRKT 3203-4004 VALVE MNT (effective from 04/25/13)
72062103 NUT 0.38-16 HEX NYLOCK (effective from 04/25/13)
72060021 CAP SCR 0.31-18 X 0.5 HH GR5 Z (effective from 10/11/12)
54. 72063050 WASHER-LOCK 0.31 ZINC (effective from 10/11/12)
REV. R 20140916
Chapter 4 Parts 31
#1
#1
#1
KIT # QTY
2
2
#1
#1
2
4
1
1
2
1
1
32 IMT 3203i Technical Specifications & Parts Manual # 99904380
Base & Mast Assembly (99904315)
Effectivity Dates)
(See Parts List for
WARNING
Avoid injury! Do NOT connect electrical power to crane until all connections have been tested. Attach electrical wires and grounds to components before connecting to mast.
37
30
21
4
21
CYLINDER
INSTALLATION
7 7
32
25
1 40
40 2 12
34
34
47 24
13
26
18
39 2
DETAIL A
21
21
3
21
38
48
19
42
29
44
5
28
9
27
45
46
27
6
BASE &
ROTATOR
ASSEMBLY
14
23
28 3
5
15 4
17
20
43
33
14
23
29
31
51
16,36
43
33
NOTES (SEE REFERENCE NUMBER IN BOX):
1 BOLTS CONNECT WITH PART NUMBER 52721306.
2 TORQUE TO 142 N-m (105 FT-LB).
31
23
HYDRAULIC MOTOR
& VALVEBANK
ASSEMBLY
11
3 APPLY RUST PREVENTATIVE
4 APPLY BLACK "MOLUB-ALLOY 882 HEAVY" GEAR GREASE TO TURNTABLE GEAR.
5 ALIGN WITH 72601939 CAP SCREWEWS.
6 TORQUE TO 133 N-m (98 FT-LB).
7 USE NEVER-SEEZ ON PIN.
49
35
A
41
41
41
32
32
50
24
32
50 29
31 22
22
31
29
29
31
22
POWER UNIT
& GEAR GUARD
INSTALLATION
8
29
31
22
Chapter 4 Parts
35.
36.
37.
38.
39.
40.
27.
28.
29.
30.
31.
32.
33.
34.
41.
42.
43.
44.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
6.
7.
8.
9.
3.
4.
5.
99904315 PARTS LIST
ITEM PART # DESCRIPTION
1. 51721319 HARDWARE KIT-BASE & MAST ASSEMBLY
2. 91722219 ELEC. INSTALLATION KIT- 3203I
51721322 HYDRAULIC KIT (effective through 09/06/13)
51721267 CYLINDER- 2.75B X 1.75R X 16.06S 46.50 CC C
52721258 BASE WELDMENT- 3203I (effective through 06/12/13)
10.
11.
12.
13.
14.
15.
16.
52722160 MAST WELDMENT-3203I (effective through 04/25/13)
52721265 PIN (effective through 12/05/12)
52721301 WELDMENT-GEAR SHROUD (effective through 12/26/12)
52721306 WELDMENT-ELECTRIC ROTATOR BRACKET TOP (effective through
05/10/13)
52721307 WELDMENT- ELECTRIC ROTATOR BRACKET BOTTOM (effective through
05/10/13)
60132385 SPACER- POWER UNIT
77441336 SWITCH- 275A CONTACTOR
(effective through 046/25/13)
60133635 CONTACT JUNCTION (effective through 04/25/13)
70580194 CLAMP-I" CONDUIT HANGER W/BOLT
71056634 GEAR-TURNTABLE BEARING (effective through 06/12/13)
72601931 CAP SCREW .44-14X 3.00 HH 156 KSI PROOF LOAD
(effective through 06/12/13)
73511156 MOTOR-HYDRAULIC 101 1035 009
73511169 POWER UNIT- 1.59CC 12VDC GC (effective through 10/11/12)
73734304 VALVE BANK-3 SEC SERIES 3GPM @ 500PSI
76039295 GASKET
70034382 CAP-GREASE
72060000 CAP SCREW .25-20X .50 HH GR5 Z
72060002 CAP SCREW .25-20X .75 HH GR5 Z
72060044 CAP SCREW .38-16X .75 HH GR5 Z (effective through 11/17/08)
72060046 CAP SCREW .38-16X 1.00 HH GR5 Z
72062002 NUT .38-16 HEX
72062104 NUT .25-20 HEX NYLOCK (effective through 04/25/13)
72062107 NUT .50-13 HEX CENTER LOCK Z
72063001 WASHER .25 FLAT (effective through 06/21/13)
72063034 MACHINERY BUSHING 1.00X10 GA NR (effective through 12/05/12)
72063049 WASHER .25 LOCK
72063051 WASHER .38 LOCK
72063053 WASHER .50 LOCK
72063132 WASHER .50 FLAT ASTM F436 (effective through 06/12/13)
72063271 WASHER # 8 W FLAT ANSI B27.2Z
72063269 WASHER .44 N FLAT H ASTM F436 (effective through 06/12/13)
72066125 RETAINING RING-EXT 1.00 HD (effective through 12/05/12)
72534418 ZERK-NPT .12 X 1.75 LG
72601932 CAP SCREW .50-13X 4.00 SH ZC
72601939 CAP SCREW .50-13X 4.50 SH ZC
72602009 SCR-MACH # 8-32X 1.25 BTNHD SS
72601941 SCR-MACH .25-20X .38 BTNHD ZC (effective through 04/25/13)
72601949 CAP SCREW .50-13X 1.25 SH ZC
51721664 CABLE ASM- 1GA-5/16RNGX 1/4RNGX 48.00LG
#1
#1
#1
#1
#1
#1
#1
#1
#1
#2
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
KIT # QTY
1
1
1
1
1
1
1
1
1
1
1
1
33
1
2
1
16
4
16
1
1
13
2
4
1
2
1
4
2
4
2
2
7
1
9
5
4
5
2
1
1
1
REF
1
1
34 IMT 3203i Technical Specifications & Parts Manual # 99904380
99904315 PARTS LIST
ITEM PART # DESCRIPTION
45. 51721943 CABLE ASM- 1GA-3/8RNGX SWVL FX 11.00LG
46. 51721944 CABLE ASM- 1GA-3/8RNGX SWVL MX 60.00LG
47.
48.
49.
77441312 CABLE ASM-10GA-#10RNGX 1/4RNGX 6.00LG
72531130 ELBOW-STREET STL .12 X 90 DEG (effective through 09/06/13)
72062207 NUT 8-32 HEX NYLOCK
50.
51.
72060051 CAP SCR .38-16X 2.25 HH GR5 Z
72060004 CAP SCR .25-20X 1.00 HH GR5 Z (effective through 04/25/13)
REV. G 20090518
KIT # QTY
#2 1
#2 1
#2
#3
#1
1
1
4
2
2
Valve Bank (73734304)
2,3(2)
4
2,3(2) 2,3(2)
Chapter 4 Parts 35
4
4
4
1
SAE #4
ORB PORT
4 4
EXTENSION MAIN
SAE #4
ORB PORT
(4 PLACES)
4
ROTATE
SAE #4
ORB PORT
A1
S1
B1 A2
S2
B2 A3
S3
B3
P T
HYDRAULIC SCHEMATIC
73734304 PARTS LIST (12V)
ITEM PART # DESCRIPTION
1.
2. 73540326
MANIFOLD VALVE BODY
SOLENOID VALVE 12V (INCLUDES COIL)
3.
4.
73540327 COIL, 12V
PLUG, EXPANDER, 7MM
REV A 20081028
73734375 PARTS LIST (24V)
ITEM PART # DESCRIPTION
1. MANIFOLD VALVE BODY
2.
3.
73540336
73540527
4.
REV A 20081028
SOLENOID VALVE 24V (INCLUDES COIL)
COIL, 24V
PLUG, EXPANDER, 7MM
SAE #4
ORB PORT
(2 PLACES)
QUANTITY
1
3
6
7
QUANTITY
1
3
6
7
36 IMT 3203i Technical Specifications & Parts Manual # 99904380
Cylinder, Lower (51721267)
2
19
30.44" CLOSED - 46.5" OPEN -
16.06" STROKE
14.5"
6 8
3.08"
DRILL #15 HOLE, 3/16" DEEP.
PRESS IN PIN 60125699
3
5
16
7 4 10 12 10
13
14
2 9 11 9
NOTES:
1 TO REDUCE DOWNTIME, REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS
DISASSEMBLED.
2 APPLY 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 6A025017 WAFER LOCK. USE STOP TUBE INSTEAD OF WAFER LOCK
WHEN RESEALING CYLINDER.
51721267 CYLINDER DATA
CASE
ROD
STROKE
DRY WEIGHT
TEST PRESSURE
OPERATING PRESSURE
TORQUES
ø8.3 cm (3.25") OUTSIDE DIAMETER X ø7.0 cm (2.75")
BORE X 69.0 cm (27.19") LENGTH
ø4.4 cm (1.75") X 73.2 cm (28.81") LONG
40.8 cm (16.06")
26.3 kg (57.94 LB)
207 N-m (3000 PSI)
172 bar (2500 PSI)
PISTON 82-85 KG-M (710-740 PSI)
HEAD 38 KG-M (275 FT-LB)
CARTRIDGE 4-4.8 KG-M (30-35 FT-LB)
CAP SCREW 2.2 KG-M (16 FT-LB)
3.
4.
5.
51721267 PARTS LIST
ITEM
1.
2.
PART #
51744137
52721303
52721304
60127432
60127434
DESCRIPTION
SEAL KIT
CASE ASSEMBLY
ROD ASSEMBLY
PISTON
HEAD
KIT #
#20
#20
#20
#20
#20
1
1
1
QUANTITY
1
1
51721267 PARTS LIST
ITEM PART #
6.
7.
6C175017
72062305
8.
9.
10.
11.
12.
13.
60138273
7T2NX420
76396596
76396597
76396598
7Q072222
14.
15.
16.
17.
19.
7Q072332
7Q10P332
7R14P017
60125699
77041786
20.
21.
51721267A
73054999
REV. D 20120326
DESCRIPTION
STOP TUBE
COLLAR-LOCK
STOP TUBE (WAS 6A025017)
WEAR RING-ROD
WEAR RING-PISTON
SEAL- ROD
PISTON SEAL-DYNAMIC
O RING
O RING
BACKUP RING
ROD WIPER -
PIN - LOCK TUBE
PRESSURE SWITCH, 2750 PSI
CYLINDER
VALVE, COUNTERBALANCE
Chapter 4 Parts 37
#1
#1
#1
#1
#1
#1
#1
KIT #
#20
#20
#20
#1
#1
#2
1
1
1
1
1
1
1
1
1
1
1
2
2
QUANTITY
1
1
38 IMT 3203i Technical Specifications & Parts Manual # 99904380
Boom Assembly (99904316)
(See Parts List for Effectivity Dates)
Boom Assembly - 1 Hydraulic & 1 Manual Extension
1
NOTES (SEE REFERENCE NUMBER IN BOX):
5 INSTALL WEAR PADS AFTER INSTALLING CYLINDER.
99904316-2 PARTS LIST
ITEM PART #
1. 51721320
DESCRIPTION
KIT-HRDW 3203 HYD BOOM ASY
2.
3.
4.
51725007 CYLINDER (WAS 51721291 THRU 12-29-08) (effective from 01/09/13)
52724108
LOWER BOOM WELDED COMPONENT – 3203i (WAS 52721260 THRU
12-29-08, 52722118 THRU 5-1-11)
52721261 WELDED COMPONENT- EXTENSION 1ST STAGE 3203i
KIT # QTY
1
1
1
1
Chapter 4 Parts
99904316-2 PARTS LIST
ITEM PART #
5.
6.
DESCRIPTION
52725021
WELDED COMPONENT- 2ND STAGE EXTENSION 3203i (effective from
01/09/13)
60030373 WEAR PAD- EXT CYLINDER
7.
8.
9.
60030374 WEAR PAD-RND 0.25X 1.00X .50X .31
60030375 WEAR PAD-RND 0.30X 3.00X 1.00X .25
60030376 WEAR PAD-RND 0.30X 3.50X 1.00X 0.615
10. 60132302 STOP SCREW 3/8-24 X .50
11. 71734311 PIN-QUICK RLSE .62D/4.5 CRIT
12. 72060928 CAP SCR .50-13X 2.25 HH GR5 Z
13. 72063005 WASHER .50 FLAT
14. 72063051 WASHER .38 LOCK
15. 72063053 WASHER .50 LOCK
16. 70734912 COTTER PIN BOWTIE .63
17. 60133938 WEAR PAD-RND 0.25X 1.00X .50X .50 STL
18. 60030369 WEAR PAD-RND 0.19X 2.00X 0.60X .50
19. 72661711 CLEVIS PIN .50 X 3.00
20. 70734805 COTTER PIN BOWTIE .50
REV. P 20150313
KIT #
#1
#1
#1
#1
39
QTY
1
1
4
1
REF
2
1
REF
REF
4
1
1
1
6
1
2
40 IMT 3203i Technical Specifications & Parts Manual # 99904380
Boom Assembly - 1 Hydraulic & 1 Manual Extension
1 32
11
9
2
9
3
30
27
7
2
18
19
32
11
30
27
2
4
13
26
21
8
29
28
9
9
16
23,25
10
A
28
13
4
9
5
SECTION A-A
B
32
B
32
SECTION B-B
31
20,25
32
15
9
5
A
9
33
NOTES (SEE REFERENCE NUMBER IN BOX):
1 INSTALL WEAR PADS AFTER INSTALLING CYLINDER.
3.
10.
11.
13.
15.
16.
18.
4.
5.
7.
8.
9.
2 APPLY ANTI-SEEZ.
99904316-2 PARTS LIST
ITEM
1.
2.
PART #
51721320
51722111
52724108
52721261
52721262
60010469
60030373
60030374
60030375
60030376
60132302
71734310
71734311
70034382
DESCRIPTION
HARDWARE KIT-BOOM ASSEMBLY
CYLINDER (WAS 51721291 THRU 12-29-08)
(effective through 01/09/13)
LOWER BOOM WELDED COMPONENT - 3203I (WAS
52721260 THRU 12-29-08, 52722118 THRU 5-1-11)
WELDED ASSEMBLY- EXTENSION 1ST STAGE 3203I
WELDED ASSEMBLY- 2ND STAGE EXTENSION 3203I
PIN (effective through 01/09/13)
WEAR PAD- EXTENSION CYLINDER
WEAR PAD-ROUND
WEAR PAD-ROUND
WEAR PAD-ROUND
STOP SCREW 3/8-24 X .50
PIN-QUICK RELEASE (effective through 11/14/12)
PIN-QUICK RELEASE
CAP-GREASE (effective through 01/09/13) #1
KIT # QUANTITY
1
1
1
1
2
4
1
1
1
1
1
1
1
6
21.
23.
25.
26.
27.
99904316-2 PARTS LIST
ITEM PART #
19.
20.
72053507
72060029
72060928
72062109
72063002
72063005
72063034
28.
29.
30.
31.
72063051
72063053
72066125
72066144
32.
33.
60133938
60030369
REV. H 20110610
Chapter 4 Parts 41
DESCRIPTION
ZERK-STR THD .25-28 (effective through 01/09/13)
CAP SCREW .31-18X 2.00 HH GR5 Z
(effective through 01/09/13)
CAP SCREW .50-13X 2.25 HH GR5 Z
NUT .31-18 HEX NYLOCK (effective through 01/09/13)
WASHER .31 FLAT (effective through 016/09/13)
WASHER .50 FLAT
MACHINERY BUSHING 1.00X10 GA NR
(effective through 01/09/13)
WASHER .38 LOCK
KIT # QUANTITY
#1
#1
#1
#1
#1
#1
#1
#1
WASHER .50 LOCK #1
RETAINING RING-EXT 1.00 HD (effective through 01/09/13) #1
1
2
1
2
4
1
2
4
1
2
HAIR PIN .16 ZINC
WEAR PAD-ROUND
WEAR PAD-ROUND 2" DIA X .60 DIA X 1 LONG
REF
2
1
42 IMT 3203i Technical Specifications & Parts Manual # 99904380
Boom Assembly - 2 Manual Extensions ( See Parts List for Effectivity Dates)
99904316-3 PARTS LIST
ITEM PART #
1. 51721320
DESCRIPTION
HARDWARE KIT-3203i HYDRAULIC BOOM ASSEMBLY
3.
4.
52724108 WELDED ASSEMBLY-LOWER BOOM 3203I (WAS 52722118)
5.
7.
52721261 WELDED ASSEMBLY- EXTENSION 1ST STAGE 3203I
52725021
WELDED ASSEMBLY- 2ND STAGE EXTENSION 3203I (effective from 01/09/13)
60030374 WEAR PAD-ROUND
8. 60030375 WEAR PAD-ROUND
9. 60030376 WEAR PAD-ROUND
10. 60132302 STOP SCREW 3/8-24 X .50
KIT # QTY
1
1
1
1
6
1
2
4
99904316-3 PARTS LIST
ITEM PART #
11. 71734311
DESCRIPTION
PIN-QUICK RELEASE
14. 72063051 WASHER .38 LOCK
16. 70734912 COTTER PIN BOWTIE .63
17. 60133938 WEAR PAD-ROUND
18. 60030369 WEAR PAD-ROUND
19. 72661711 CLEVIS PIN 0.5 X 3.00
20. 70734805 BOWTIE COTTER PIN
21. 71734314 PIN-QUICK RELEASE
REV. P 20150313
Chapter 4 Parts 43
KIT #
#1
QTY
1
4
REF
2
1
REF
REF
1
44 IMT 3203i Technical Specifications & Parts Manual # 99904380
Boom Assembly - 2 Manual Extensions ( See Parts List for Effectivity Dates)
11
9
13
28
31
9
3
28
13
17
13
28
9
18
19
9
23,25
16
11
31
4
31
32
10
28
13
15
32
9
5
9
20,25
33
99904316-3 PARTS LIST
ITEM PART #
1. 51721320
DESCRIPTION
HARDWARE KIT-3203i HYDRAULIC BOOM ASSEMBLY
3.
4.
5.
9.
10.
52724108
52721261
52721262
60030374
60030375
WELDED ASSEMBLY-LOWER BOOM 3203I (WAS 52722118)
WELDED ASSEMBLY- EXTENSION 1ST STAGE 3203I
WELDED ASSEMBLY- 2ND STAGE EXTENSION 3203I
(effective through 01/09/13)
WEAR PAD-ROUND
11.
13.
15.
60030376
60132302
71734310
WEAR PAD-ROUND
WEAR PAD-ROUND
STOP SCREW 3/8-24 X .50
PIN-QUICK RELEASE (effective through 11/14/12)
16.
17.
18.
19.
20.
71734311
71734314
70034382
72053507
72060029
REV. H 20110610
PIN-QUICK RELEASE
PIN-QUICK RELEASE
CAP-GREASE (effective through 01/09/13)
ZERK-STR THD .25-28 (effective through 01/09/13)
CAP SCREW .31-18X 2.00 HH GR5 Z (effective to 01/09/13)
#1
#1
#1
KIT # QUANTITY
1
1
1
1
6
1
2
4
1
1
1
1
1
2
Boom Assembly - 1 Hydraulic Extension (See Parts List for Effectivity Dates)
7
Chapter 4 Parts
9
45
7
3
6
15
13
12
20
2
19
9
22
17
17
99904316-4 PARTS LIST
ITEM PART # DESCRIPTION
1.
2.
3.
51721320 HARDWARE KIT
51725007
52724108
CYLINDER (WAS 51721291 THRU 12-29-08)
(effective from 01/09/13)
LOWER BOOM WELDED COMPONENT - 3203I
(WAS 52721260 THRU 12-29-08, 52722118 THRU 5-1-11)
60030373 WEAR PAD- EXTENSION CYLINDER
60030374 WEAR PAD-ROUND
6.
7.
9.
13.
15.
17.
19.
60030376 WEAR PAD-ROUND
72063005 WASHER .50 FLAT
72063053 WASHER .50 LOCK
60133938 WEAR PAD-ROUND
72661711 CLEVIS PIN 0.50 X 3.00
20.
22.
70734912 COTTER PIN BOWTIE .63
52725022
WELDED COMPONENT- 2ND STAGE MANUAL EXTENSION 3203I
(effective from 01/09/13)
REV. P 20150313
KIT #
#1
#1
QTY
1
1
1
1
2
2
1
1
2
REF
REF
1
46 IMT 3203i Technical Specifications & Parts Manual # 99904380
Boom Assembly - 1 Hydraulic Extension (See Parts List for Effectivity Dates)
11
9
9
3
30
27
7
8
29
26
21
27
30
23,25
31
20
2
15
11
6
32
32
99904316-4 PARTS LIST
ITEM PART # DESCRIPTION
1.
2.
3.
6.
51721320 HARDWARE KIT
51722111 CYLINDER (WAS 51721291 THRU 12-29-08)
(effective through 01/09/13)
52724108 LOWER BOOM WELDED COMPONENT - 3203I (WAS 52721260
THRU 12-29-08, 52722118 THRU 5-1-11)
52721263 WELDED COMPONENT- 2ND STAGE MANUAL EXTENSION
3203I (effective through 01/09/13)
60010469 PIN (effective through 01/09/13) 7.
8.
9.
11.
60030373
60030374
60030376
WEAR PAD- EXTENSION CYLINDER
WEAR PAD-ROUND
WEAR PAD-ROUND
15.
18.
19.
20.
21.
23.
25.
26.
71734310 PIN-QUICK RELEASE (effective through 11/14/12)
70034382 CAP-GREASE (effective through 01/09/13)
72053507 GREASE POINT-STR THD .25-28
(effective through 01/09/13)
72060029 CAP SCREW .31-18X 2.00 HEX HEAD GRADE 5 ZINC
(effective through 01/09/13)
72060928 CAP SCREW .50-13X 2.25 HEX HEAD GRADE 5 ZINC
72062109 NUT .31-18 HEX NYLOC (effective through 01/09/13)
72063002 WASHER .31 FLAT (effective through 01/09/13)
72063005 WASHER .50 FLAT
KIT # QUANTITY
1
1
#1
#1
#1
#1
#1
#1
#1
1
1
1
1
2
2
1
1
1
2
1
2
4
1
99904316-4 PARTS LIST
ITEM PART # DESCRIPTION
27.
29.
30.
31.
72063034 MACHINERY BUSHING 1.00X10 GA NR
(effective through 01/09/13)
72063053 WASHER .50 LOCK
72066125 RETAINING RING-EXT 1.00 HD (effective through 01/09/13)
72066144 HAIR PIN .16 ZINC
32. 60133938 WEAR PAD-ROUND
REV. H 20110610
Chapter 4 Parts
#1
#1
1
2
1
2
47
KIT # QUANTITY
#1 2
48 IMT 3203i Technical Specifications & Parts Manual # 99904380
Boom Assembly - 1 Hydraulic Extension & 1 Manual Extension (See Parts List for Effectivity Dates)
99904316-5 PARTS LIST
ITEM
1.
10.
11.
14.
16.
23.
24.
25.
PART # DESCRIPTION
51721320 KIT-HRDW 3203 HYD BOOM ASY
60132302 STOP SCREW 3/8-24 X .50
71734311 PIN-QUICK RLSE .62D/4.5 CRIT
72063051 WASHER .38 LOCK
70734912 COTTER PIN BOWTIE .63
70034490 PLATE-ANGLE PLASTIC 3.50"
72062104 NUT .25-20 HEX NYLOCK
72063001
REV. P 20150313
WASHER .25 FLAT
KIT #
#1
#1
#1
QTY
1
4
1
4
REF
2
2
4
Chapter 4 Parts
Boom Assembly - 1 Hydraulic Extension & 1 Manual Extension (See Parts List for Effectivity Dates)
31
13
28
31
15
28
49
13
16
22
24
14
24
24
14
24
22
99904316-5 PARTS LIST
ITEM
1.
13.
14.
15.
16.
18.
PART #
51721320
60132302
70034490
71734310
71734311
70034382
22.
24.
28.
31.
72062104
72063001
72063051
72066144
REV. H 20110610
DESCRIPTION
HARDWARE KIT-BOOM ASSEMBLY
STOP SCREW 3/8-24 X .50
PLATE-ANGLE PLASTIC 3.50"
KIT #
PIN-QUICK RELEASE (effective through 11/24/12)
PIN-QUICK RELEASE
CAP-GREASE (effective through 01/09/13) #1
NUT .25-20 HEX NYLOCK
WASHER .25 FLAT
WASHER .38 LOCK
HAIR PIN .16 ZINC
#1
#1
#1
1
1
1
QUANTITY
1
2
2
2
4
4
REF
50 IMT 3203i Technical Specifications & Parts Manual # 99904380
Boom Assembly - 1 Manual Extension (See Parts List for Effectivity Dates)
99904316-6 PARTS LIST
ITEM
1.
PART # DESCRIPTION
51721320 KIT-HRDW 3203 HYD BOOM ASY
10.
14.
16.
60132302
72063051
70734912
STOP SCREW 3/8-24 X .50
WASHER .38 LOCK
COTTER PIN BOWTIE .63
19.
20.
21.
23.
72661711 CLEVIS PIN .50 X 3.00
70734805 COTTER PIN BOWTIE .50
71734314 PIN-QUICK RLSE .62D/5.75 CRIT
70034490 PLATE-ANGLE PLASTIC 3.50"
24.
25.
72062104
72063001
REV. P 20150313
NUT .25-20 HEX NYLOCK
WASHER .25 FLAT
KIT #
#1
#1
#1
QTY
1
4
4
REF
REF
REF
1
2
2
4
Boom Assembly - 1 Manual Extension (See Parts List for Effectivity Dates)
31
31
13
28
22
24
14
24
28
13
17
Chapter 4 Parts
15
51
24
14
24
22
99904316-6 PARTS LIST
ITEM PART #
1.
13.
51721320
60132302
14.
15.
70034490
71734310
17.
18.
22.
24.
28.
31.
71734314
70034382
72062104
72063001
72063051
72066144
REV. H 20110610
DESCRIPTION
HARDWARE KIT-BOOM ASSEMBLY
STOP SCREW 3/8-24 X .50
PLATE-ANGLE PLASTIC 3.50"
PIN-QUICK RELEASE
(effective through 11/24/12)
PIN-QUICK RELEASE
CAP-GREASE (effective through 01/09/13)
NUT .25-20 HEX NYLOCK
WASHER .25 FLAT
WASHER .38 LOCK
HAIR PIN .16 ZINC
#1
#1
#1
#1
KIT # QUANTITY
1
4
2
1
1
1
2
4
2
REF
52 IMT 3203i Technical Specifications & Parts Manual # 99904380
Boom Assembly - 1 Hydraulic & 1 Manual Extension
1
NOTES (SEE REFERENCE NUMBER IN BOX):
1 INSTALL WEAR PADS AFTER INSTALLING CYLINDER.
99904316-2 PARTS LIST
ITEM PART # DESCRIPTION
1.
2.
3.
4.
5.
6.
7.
8.
51721320 KIT-HRDW 3203 HYD BOOM ASY
51725007 CYLINDER (WAS 51721291 THRU 12-29-08) (effective from 01/09/13)
52724108
LOWER BOOM WELDED COMPONENT – 3203i (WAS 52721260 THRU
12-29-08, 52722118 THRU 5-1-11)
52721261 WELDED COMPONENT- EXTENSION 1ST STAGE 3203i
52725021
WELDED COMPONENT- 2ND STAGE EXTENSION 3203i (effective from
01/09/13)
60030373 WEAR PAD- EXT CYLINDER
60030374 WEAR PAD-RND 0.25X 1.00X .50X .31
60030375 WEAR PAD-RND 0.30X 3.00X 1.00X .25
KIT # QTY
1
1
1
1
1
1
6
1
99904316-2 PARTS LIST
ITEM PART # DESCRIPTION
9.
10.
11.
12.
60030376 WEAR PAD-RND 0.30X 3.50X 1.00X 0.615
60132302 STOP SCREW 3/8-24 X .50
71734311 PIN-QUICK RLSE .62D/4.5 CRIT
72060928 CAP SCR .50-13X 2.25 HH GR5 Z
13.
14.
15.
16.
72063005 WASHER .50 FLAT
72063051 WASHER .38 LOCK
72063053 WASHER .50 LOCK
70734912 COTTER PIN BOWTIE .63
17.
18.
19.
20.
60133938 WEAR PAD-RND 0.25X 1.00X .50X .50 STL
60030369 WEAR PAD-RND 0.19X 2.00X 0.60X .50
72661711 CLEVIS PIN .50 X 3.00
70734805 COTTER PIN BOWTIE .50
REV. P 20150313
Chapter 4 Parts 53
KIT #
#1
#1
#1
#1
QTY
2
4
1
1
1
4
1
REF
2
1
REF
REF
54 IMT 3203i Technical Specifications & Parts Manual # 99904380
99904316 Parts List, Complete
(See Parts List for Effectivity Dates)
6.
7.
8.
9.
99904316 PARTS LIST
ITEM PART # DESCRIPTION
1.
2.
3.
4.
5.
51721320 KIT-HRDW 3203 HYD BOOM ASY
51725007 CYLINDER (WAS 51721291 THRU 12-29-08) (effective from 01/09/13)
52724108
LOWER BOOM WELDED COMPONENT – 3203i (WAS 52721260 THRU
12-29-08, 52722118 THRU 5-1-11)
52721261 WELDED COMPONENT- EXTENSION 1ST STAGE 3203i
52725021
WELDED COMPONENT- 2ND STAGE EXTENSION 3203i (effective from
01/09/13)
60030373 WEAR PAD- EXT CYLINDER
60030374 WEAR PAD-RND 0.25X 1.00X .50X .31
60030375 WEAR PAD-RND 0.30X 3.00X 1.00X .25
60030376 WEAR PAD-RND 0.30X 3.50X 1.00X 0.615
10. 60132302 STOP SCREW 3/8-24 X .50
11. 71734311 PIN-QUICK RLSE .62D/4.5 CRIT
12. 72060928 CAP SCR .50-13X 2.25 HH GR5 Z
13. 72063005 WASHER .50 FLAT
14. 72063051 WASHER .38 LOCK
15. 72063053 WASHER .50 LOCK
16. 70734912 COTTER PIN BOWTIE .63
17. 60133938 WEAR PAD-RND 0.25X 1.00X .50X .50 STL
18. 60030369 WEAR PAD-RND 0.19X 2.00X 0.60X .50
19. 72661711 CLEVIS PIN .50 X 3.00
20. 70734805 COTTER PIN BOWTIE .50
21. 71734314 PIN-QUICK RLSE .62D/5.75 CRIT
22. 52725022 WLDMT- 2ND STAGE MANUAL EXT 3203I
23. 70034490 PLATE-ANGLE PLASTIC 3.50"
24. 72062104 NUT .25-20 HEX NYLOCK
25. 72063001 WASHER .25 FLAT
REV. P 20150313
KIT # QTY
1
1
1
1
1
2
1
REF
REF
1
1
2
2
4
4
1
1
1
6
1
2
1
4
1
REF
#1
#1
#1
#1
#1
#1
99904316 Parts List, Complete
(See Parts List for Effectivity Dates)
99904316 PARTS LIST
ITEM
1.
2.
PART #
51721320
51722211
3.
4.
5.
6.
7.
8.
9.
10.
11.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
52724108
52721261
52721262
52721263
60030372
60010469
60030373
60030374
60030375
60030376
60132302
70034490
71734310
71734311
71734314
70034382
72053507
72060029
72060928
72062104
72062109
72063001
72063002
72063005
72063034
72063051
72063053
72066125
31.
32.
72066144
60133938
33. 60030369
REV H 20110610
DESCRIPTION
HARDWARE KIT
CYLINDER (WAS 51721291 THRU 12-29-08)
(effective through 01/09/13)
LOWER BOOM WELDED COMPONENT - 3203I
(WAS 52721260 THRU 12-29-08, 52722118
THRU 5-1-11)
WELDED COMPONENT- EXTENSION 1ST
STAGE 3203I
WELDED COMPONENT- 2ND STAGE
EXTENSION 3203i (effective through 01/09/13)
WELDED COMPONENT-2ND STAGE MANUAL
EXTENSION 3203i (effective through 01/09/13)
SHEAVE- 5.5 NYLATRON (PART OF 5 & 6)
KIT #
PIN (effective through 01/09/13)
WEAR PAD- EXTENSION CYLINDER
WEAR PAD-ROUND (WAS 6)
WEAR PAD-ROUND
WEAR PAD-ROUND
STOP SCREW 3/8-24 X .50
PLATE-ANGLE PLASTIC
HITCH PIN WITH CLIP
(effective through 01/09/13)
HITCH PIN WITH CLIP
HITCH PIN WITH CLIP
CAP (effective through 01/09/13)
GREASE POINT (effective through 01/09/13)
CAP SCREW .31-18X 2.00 HEX HEAD GRADE 5 #1
ZINC (effective through 01/09/13)
CAP SCREW .50-13X 2.25 HEX HEAD GRADE 5 #1
ZINC
NUT .25-20 HEX NYLOC #1
NUT .31-18 HEX NYLOC
(effective through 01/09/13)
WASHER .25 FLAT
#1
#1
WASHER .31 FLAT (effective through 01/09/13) #1
WASHER .50 FLAT
MACHINERY BUSHING 1.00X10 GA NR
(effective through 01/09/13)
WASHER .38 LOCK
WASHER .50 LOCK
#1
#1
#1
#1
#1
#1
RETAINING RING-EXT 1.00 HD
(effective through 01/09/13)
HAIR PIN .16 ZINC
WEAR PAD-ROUND 1" DIA. X 1/2" DIA. X 3/4L
WEAR PAD-ROUND 2" DIA X .60 DIA X 1L
#1
Chapter 4 Parts
QUANTITY
1
1
1
4
4
1
2
4
1
2
REF
2
1
1
1
1
2
2
1
1
1
1
1
2
2
4
2
1
2REF
1
1
6
1
55
56 IMT 3203i Technical Specifications & Parts Manual # 99904380
Crane & Winch Assembly (99904317)
(See Parts List for Effectivity Dates)
BOOM ASSEMBLY (99904317-2)
A
49
7
20
8
50
28
48
9
27
50
20
9
21
27
46
50
18, 22 18, 22
34
35
36
25
23
18
22
33
52
45
22
B
43
19
24
27
27
21
5
13 30
42
40
41
24
16
44
44
10
11
1
DETAIL B
30
27, 21
27, 17
28
29
13
52 22
DETAIL A
NOTES (SEE REFERENCE NUMBER IN BOX):
1 CONNECT THE WIRE TERMINALS (77040051) TO COMMON AND NORMALLY OPEN ON ANTI-TWO-BLOCK
SWITCH.
11.
13.
16.
17.
18.
99904317-2 PARTS LIST
ITEM PART # DESCRIPTION
1.
3.
5.
7.
8.
99904315 DRAWING-BASE AND MAST ASSEMBLY 3203
51721321 KIT-HRDW 3203 CRANE AND WINCH ASSY.
52725018 ANTI-TWO-BLOCK TRIP MECHANISM WELDED COMPONENT
(effective from 01/09/13)
71570922 WINCH- DC2000
9.
10.
77041932 WINCH- DC2000 SWITCH (PART OF WINCH)
(effective from 05/09/13)
72034485 CLAMP-PLASTIC 1/4" CABLE
77041459 SWITCH-LIMIT
77441096
71413185
72060073
72062093
72062104
CONNECTOR- .50 STRAIN RELIEF
SPRING
CAP SCREW .44-14X 4.50 HEX HEAD GRADE 5 ZINC
NUT #8-32 HEX ZINC
NUT .25-20 HEX NYLOCK
KIT # QUANTITY
#3
#3
#3
#3
1
1
1
1
1
3
1
1
1
1
1
4
Chapter 4 Parts 57
24.
25.
27.
28.
29.
30.
99904317-2 PARTS LIST
ITEM PART # DESCRIPTION
19.
20.
21.
22.
23.
72062105
72062106
72062207
72063001
72063002
NUT .44-14 HEX NYLOCK
NUT 10-24 HEX NYLOCK
NUT 8-32 HEX NYLOCK
WASHER .25 FLAT
WASHER .31 FLAT
72063004
72063049
72063271
WASHER .44 FLAT
WASHER .25 LOCK
WASHER #8 FLAT
72601798 WASHER-LOCK 12MM
72601935 CAP SCREW M12-1.75 X 40 SOCKET HEAD CAP SCREW
72601938 BOLT-EYE # 8/32X .75
31.
33.
34.
35.
36.
40.
41.
42.
43.
44.
72601941 CAP SCREW .25-20 X .38 BUTTON-HEAD, ZINC
72060003 CAP SCREW 0.25-20 X 0.88 HH GR5 Z
72066535 CLAMP-LOOP .38 VINYL COVERED
51713168 CORD REEL ASSEMBLY
(effective from 01/14/12)
60140565 BRACKET- CORD REEL MOUNT
(effective from 01/14/12)
72060209 CAP SCREW 0.75-10 X 2.75 HH GR8 Z
(effective from 01/09/13)
72062114 NUT 0.75-10 HEX NYLOCK
(effective from 01/09/13)
72063008 WASHER 0.75 FLAT (effective from 01/09/13)
60030483 SHEAVE-8.0 NYLATRON GSM
(effective from 01/09/13)
72061942 SCREW MACHINE #6-32 X 1.5
(effective from 01/09/13)
70034381 SUPPORT
72060007 CAP SCREW .25-20X 1.75 HEX HEAD GRADE 5 ZINC
#3
#3
#3
#3
#3
45.
46. #3
47.
48.
52725097 WLDMT WINCH CONTACTOR BRACKET (effective from 05/09/13)
72601805 CAP SCREW M12-1.75 X 2.5 HH Z #3
49.
50.
70034503 COVER – ELEC CONTACTOR
(effective from 0/09/13)
72602011 SCREW-MACHINE #8-32 X 0.62
(effective from 04/22/13)
52. 72060000 CAP SCREW 0.25-20 X 0.5 HH GR5 Z
(effective from 06/20/13)
REV. S 20130614
#3
#3
#3
#3
#3
#3
#3
KIT # QUANTITY
#3
#3
1
2
#3
#3
#3
3
13
4
2
6
6
6
4
1
1
1
1
1
1
2
1
1
2
2
2
1
2
1
6
1
58 IMT 3203i Technical Specifications & Parts Manual # 99904380
Crane & Winch Assembly (99904317)
Effectivity Dates)
(See Parts List for
BOOM ASSEMBLY (99904317-2)
A
4
33
19
33
19
16
31,35
48
10
27
36
39
13
21
32
37
11
8
37 29
23
22
DETAIL B
1
17
35,46
43
44
34,41
30,41
45
DETAIL A
25
1.
3.
4.
NOTES (SEE REFERENCE NUMBER IN BOX):
1 CONNECT THE WIRE TERMINALS (77040051) TO COMMON AND NORMALLY OPEN ON ANTI-TWO-BLOCK
SWITCH.
99904317-2 PARTS LIST
ITEM PART #
8.
10.
11.
13.
16.
17.
19.
21.
22.
99904315
51721321
51721494
52721275
60132111
60132216
70034381
71570922
77041801
72034485
72661543
77041459
DESCRIPTION
DRAWING-BASE AND MAST ASSEMBLY 3203
KIT-HDRW 3203 CRANE AND WINCH ASSY
CORD REEL ASSEMBLY
(effective through 11/14/12)
ANTI-TWO-BLOCK TRIP MECHANISM WELDED
COMPONENT (effective through 01/09/13)
BRACKET- CORD REEL MOUNT
(effective through 11/14/12)
DOWNHAUL WEIGHT
(effective through 11/14/12)
SUPPORT
WINCH- DC2000
WINCH- DC2000 SWITCH (PART OF WINCH)
(effective through 05/09/13)
CLAMP-PLASTIC 1/4" CABLE
PIN-QUICK (effective through 11/14/12)
SWITCH-LIMIT
KIT # QUANTITY
1
1
1
1
1
1
2
1
1
2
1
1
29.
30.
31.
32.
33.
34.
35.
36.
37.
39.
41.
43.
99904317-2 PARTS LIST
ITEM PART #
23.
25.
27.
77441096
71413185
72060007
44.
45.
46.
72060073
72062093
72062104
72062105
72062106
72062207
72063001
72063002
72063004
72063049
72063271
72601798
72601935
72601938
72601941
48. 72066535
REV. J 20110614
DESCRIPTION KIT #
CONNECTOR- .50 STRAIN RELIEF
SPRING #3
CAP SCREW .25-20X 1.75 HEX HEAD GRADE 5 #3
ZINC
CAP SCREW .44-14X 4.50 HEX HEAD GRADE 5 #3
ZINC
NUT #8-32 HEX ZINC #3
#3 NUT .25-20 HEX NYLOCK
(effective through 11/14/12)
NUT .44-14 HEX NYLOCK
NUT 10-24 HEX NYLOCK
#3
#3
NUT 8-32 HEX NYLOCK
(effective through 04/22/13)
#3
WASHER .25 FLAT (effective through 04/25/13) #3
WASHER .31 FLAT (effective through 01/09/13) #3
WASHER .44 FLAT #3
WASHER .25 LOCK (effective through 04/25/13) #3
WASHER #8 FLAT (effective through 04/22/13) #3
WASHER-LOCK 12MM
(effective through 04/22/13)
CAP SCREW M12-1.75 X 40 SOCKET HEAD
CAP SCREW
BOLT-EYE # 8/32X .75
#3
#3
#3
CAP SCREW .25-20 X .38 BUTTON-HEAD, ZINC #3
(effective through 04/22/13)
CLAMP-LOOP .38 VINYL COVERED
Chapter 4 Parts
1
2
1
12
4
2
9
2
4
QUANTITY
1
1
2
1
1
2
4
1
3
1
59
60 IMT 3203i Technical Specifications & Parts Manual # 99904380
MAST & BOOM ASSEMBLY (99904317-3) (See Parts List for Effectivity Dates)
31
12
39
37
26
15
22, 25, 14
26
15
38
37
51
22, 25, 14
NOTES:
1 USE LUBRICATION COMPOUND ON PINS.
2 KEEP ELECTRICAL GROUNDS FREE OF PAINT, GREASE AND OIL.
3 IF REQUIRED, USE MACHINERY BUSHINGS (# 70603033) BETWEEN MAST AND BOOM WHEN
INSTALLING PIN # 52721265.
99904317-3 PARTS LIST
ITEM PART #
3.
38.
39.
51.
12.
14.
15.
22.
51721321
DESCRIPTION
KIT-HRDW 3203 CRANE AND WINCH ASSY.
60140618 PIN (effective from 12/05/12)
60140617 PIN (WAS 52721266) (effective from 12/05/12)
60140653 WELDED COMPONENT, VALVE BANK COVER (effective from 12/05/12)
77441278 GROUND STRAP
#3 72060002 CAP SCREW .25-20X .75 HEX HEAD GRADE 5 ZINC (effective from
04/25/13)
72060046 CAP SCREW .38-16X 1.00 HEX HEAD GRADE 5 ZINC
72063001 WASHER .25 FLAT (effective from 04/25/13)
#3
#3
KIT # QTY
1
1
1
1
1
7
2
12
25.
26.
31.
72063049
72063051
WASHER .25 LOCK (effective from 04/25/13)
WASHER .38 LOCK
#3
#3
72601941 CAP SCREW .25-20 X .38 BUTTON-HEAD, ZINC (effective from 04/22/13) #3
37. 71415014 KEEPER PIN 0.38
REV. J 20110614
9
2
3
2
MAST & BOOM ASSEMBLY (99904317-3) (See Parts List for Effectivity Dates)
Chapter 4 Parts 61
42
38
42
38
46
24
7
40
28
26,35,39
12
26,35,39
6
40
28
9
26,35,39
26,35,39
NOTES:
1 USE LUBRICATION COMPOUND ON PINS.
2 KEEP ELECTRICAL GROUNDS FREE OF PAINT, GREASE AND OIL.
3 IF REQUIRED, USE MACHINERY BUSHINGS (# 70603033) BETWEEN MAST AND BOOM WHEN
INSTALLING PIN # 52721265.
99904317-3 PARTS LIST
ITEM PART # DESCRIPTION KIT # QUANTITY
1 6. 52721265 PIN (effective through 12/05/12)
7. 52724112 PIN (WAS 52721266) (effective through 12/05/12)
9. 52721982 WELDED COMPONENT, VALVE BANK COVER
(effective through 04/25/13)
12. 60133631 COVER – CONTACTOR (effective through 04/25/13)
1
1
1
1 24. 77441278 GROUND STRAP
26. 72060002 CAP SCREW .25-20X .75 HEX HEAD GRADE 5 ZINC
(effective through 04/25/13)
28. 72060046 CAP SCREW .38-16X 1.00 HEX HEAD GRADE 5 ZINC
#3
#3
7
35. 72063001 WASHER .25 FLAT (effective through 04/25/13)
37. 72063004 WASHER .44 FLAT
#3
#3
38. 72063034 MACHINERY BUSHING 1 X 10 GA NR (effective through 12/05/12) #3
2
12
2
2
39.
40.
42.
72063049
72063051
72066125
WASHER .25 LOCK (effective through 04/25/13)
WASHER .38 LOCK
RETAINING RING-EXT 1.00 HD (effective through 12/05/12)
46. 72601941 CAP SCREW .25-20 X .38 BUTTON-HEAD, ZINC
(effective through 04/22/13)
REV. J 20110614
#3
#3
#3
#3
9
2
2
3
62 IMT 3203i Technical Specifications & Parts Manual # 99904380
SINGLE & DOUBLE PART LINE (99904317-4) (Effective from 11/14/12)
4
6
DOUBLE LINE
SINGLE LINE
6
4
99904317-4 PARTS LIST
ITEM PART #
4. 51724950
6. 70580059
REV. S 20130614
DESCRIPTION
SNATCH BLOCK
WIRE ROPE ASSEMBLY
QUANTITY
1
1
SINGLE & DOUBLE PART LINE (99904317-4) (Effective Through 11/14/12)
11
21
DOUBLE LINE
18
15
14
5
Chapter 4 Parts 63
21
14
49
11
18
50
SINGLE LINE
99904317-4 PARTS LIST
ITEM
5.
11.
PART #
52721264
60132216
14.
15.
70580197
71073921
51715352
18.
21.
71734310
72661543
49. 71413869
REV. J 20110614
DESCRIPTION
SNATCH BLOCK WELDED COMPONENT
DOWNHAUL WEIGHT
WIRE ROPE ASSEMBLY
HOOK- 2 TON SWIVEL
LATCH KIT-1.5 - 2 TON (PART OF 71073921)
1
1
QUANTITY
1
1
PIN-QUICK RELEASE
PIN-QUICK
COLLAR-SHAFT 2 PIECE 1/2"
1
1
1
64 IMT 3203i Technical Specifications & Parts Manual # 99904380
99904317 Parts List, Complete
(See Parts List for Effectivity Dates)
5.
6.
7.
8.
15.
16.
23.
25.
26.
27.
28.
29.
9.
10.
11.
12.
13.
14.
17.
18.
19.
20.
21.
22.
32.
33.
34.
35.
36.
99904317 PARTS LIST
ITEM
1.
2.
PART #
99904315
99904316
3.
4.
51721321
51724950
30.
31.
37.
38.
52725018
70580059
71570922
77041932
72034485
77041459
77441096
77441278
71413185
72060002
72060046
72060073
72062093
72062104
72062105
72062106
72062207
72063001
72063002
72063049
72063051
72063271
72601798
72601935
72601938
72601941
77040051
72060003
72066535
51713168
60140565
71415014
60140618
DESCRIPTION
DRAWING-BASE AND MAST ASSEMBLY 3203
DRAWING-BOOM ASSEMBLY 3203I
HARDWARE KIT-CRANE & WINCH
SNATCH BLOCK WELDED COMPONENT (effective from 11/14/12)
ANTI-TWO-BLOCK TRIP MECHANISM WELDED
COMPONENT (effective from 01/08/13)
WIRE ROPE ASSEMBLY (effective from 11/14/12)
WINCH- DC2000
CONTACTOR, WINCH 12V DC2000 (effective from
05/09/13)
CLAMP-PLASTIC 1/4" CABLE
SWITCH-LIMIT
CONNECTOR- .50 STRAIN RELIEF
KIT #
GROUND STRAP
SPRING
CAP SCREW .25-20X .75 HEX HEAD GRADE 5
ZINC (effective from 04/25/13)
CAP SCREW .38-16X 1.00 HEX HEAD GRADE 5
ZINC
CAP SCREW .44-14X 4.50 HEX HEAD GRADE 5
ZINC
NUT #8-32 HEX ZINC
NUT .25-20 HEX NYLOCK
NUT .44-14 HEX NYLOCK
#3
#3
#3
#3
#3
#3
#3
NUT 10-24 HEX NYLOCK #3
NUT 8-32 HEX NYLOCK (effective from 04/22/13) #3
#3 WASHER .25 FLAT (WAS 13)
(effective from 04/25/13)
WASHER .31 FLAT (effective from 01/09/13)
WASHER .25 LOCK (effective from 04/25/13)
#3
#3
WASHER .38 LOCK
WASHER #8 FLAT (effective from 04/22/13)
WASHER-LOCK 12MM
#3
#3
CAP SCREW M12-1.75 X 40 SOCKET HEAD CAP
SCREW
BOLT-EYE # 8/32X .75
CAP SCREW .25-20 X .38 BUTTON-HEAD, ZINC
(WAS 4) (effective from 04/22/13)
TERMINAL
CAP SCREW .25-20 X 0.88 HH GR5 Z
CLAMP-LOOP 0.38 VINYL COVERED
CORD REEL ASSEMBLY (effective from 11/14/12)
BRACKET- CORD REEL MOUNT
(effective from 11/14/12)
KEEPER PIN 0.38 (effective from 12/05/12)
PIN (effective from 12/5/12)
#3
#3
#3
#3
#3
#3
2
1
1
1
4
2
1
1
1
1
1
1
4
6
2
6
6
4
1
4
1
2
3
13
1
1
2
2
1
1
1
2
1
QUANTITY
REF
REF
1
1
41.
42.
43.
44.
46.
99904317 PARTS LIST
ITEM PART #
39.
40.
60140617
72060209
72062114
72063008
60030483
72061942
72060007
47.
48.
49.
50.
52.
45.
51.
REV J 20110610
52725097
72601805
70034503
72602011
72060000
70034381
60140653
Chapter 4 Parts
DESCRIPTION
PIN (WAS 52721266) (effective from 12/5/12)
CAP SCREW 0.75-10 X 2.75 HH GR8 Z
(effective from 01/09/13)
NUT 0.75-10 HEX NYLOCK
(effective from 01/09/13)
WASHER 0.75 FLAT (effective from 01/09/13)
SHEAVE 8.0 NYLATRON GSM
(effective from 01/09/13)
SCREW MACHINE #6-32 X 1.5
(effective from 01/09/13)
CAP SCREW .25-20X 1.75 HEX HEAD GRADE 5
ZINC
WLDMT WINCH CONTACTOR BRKT
(effective from 05/09/13)
CAP SCREW M12-1.75 X 25 HHZ
(effective from 04/22/13)
COVER ELECTRIC CONTACTOR
(effective from 05/09/13)
SCREW-MACH #8-32 X 0.62
(effective from 04/22/13)
CAP SCREW 0.25-20 X 0.5 HH GR5 Z
(effective from 06/30/13)
SUPPORT
WELDED COMPONENT, VALVE BANK COVER
(effective from 12/05/12)
#3
#3
KIT #
#3
#3
#3
#3
1
6
1
2
1
2
1
1
1
2
2
QUANTITY
1
1
65
66 IMT 3203i Technical Specifications & Parts Manual # 99904380
99904317 Parts List, Complete
(See Parts List for Effectivity Dates)
99904317 PARTS LIST
ITEM
1.
2.
PART #
99904315
99904316
3.
4.
51721321
51721494
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
52721264
52721265
52724112
52721275
52721982
60132111
60132216
60133631
70034381
70580197
71073921
51715352
71570922
77041801
71734310
72034485
72066144
72661543
77041459
77441096
77441278
71413185
72060002
72060007
72060046
72060073
72062093
72062104
72062105
72062106
72062207
DESCRIPTION
DRAWING-BASE AND MAST ASSEMBLY 3203
DRAWING-BOOM ASSEMBLY 3203I
HARDWARE KIT-CRANE & WINCH
CORD REEL ASSEMBLY (effective through
11/14/12)
SNATCH BLOCK WELDED COMPONENT (effective through 11/14/12)
PIN (effective through 12/5/12)
PIN (WAS 52721266) (effective through 12/5/12)
ANTI-TWO-BLOCK TRIP MECHANISM WELDED
COMPONENT (effective through 11/14/12)
WELDED COMPONENT, VALVE BANK COVER
(effective through 04/25/13)
BRACKET- CORD REEL MOUNT (effective through
11/14/12)
DOWNHAUL WEIGHT (effective through 11/14/12)
COVER - CONTACTOR (effective through 04/25/13)
SUPPORT
WIRE ROPE ASSEMBLY (effective through
11/14/12)
HOOK- 2 TON SWIVEL (effective through 11/14/12)
LATCH KIT-1.5 - 2 TON (PART OF 15) (effective through 11/14/12)
WINCH- DC2000
CONTACTOR, WINCH 12V DC2000 (effective through 05/09/13)
PIN-QUICK RELEASE (effective through 11/14/12)
CLAMP-PLASTIC 1/4" CABLE
HAIR PIN (effective through 11/14/12)
PIN-QUICK (effective through 11/14/12)
KIT #
SWITCH-LIMIT
CONNECTOR- .50 STRAIN RELIEF
GROUND STRAP
SPRING
CAP SCREW .25-20X .75 HEX HEAD GRADE 5
ZINC (effective through 04/25/13)
CAP SCREW .25-20X 1.75 HEX HEAD GRADE 5
ZINC
CAP SCREW .38-16X 1.00 HEX HEAD GRADE 5
ZINC
CAP SCREW .44-14X 4.50 HEX HEAD GRADE 5
ZINC
NUT #8-32 HEX ZINC
NUT .25-20 HEX NYLOCK
#3
#3
#3
#3
#3
NUT .44-14 HEX NYLOCK
NUT 10-24 HEX NYLOCK
#3
#3
NUT 8-32 HEX NYLOCK (effective through 04/22/13) #3
#3
#3
2
2
1
2
1
1
1
1
1
1
7
1
1
2
1
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
QUANTITY
REF
REF
1
1
99904317 PARTS LIST
ITEM PART #
35. 72063001
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
77040051
72066535
71413869
50. 71073921
REV J 20110610
72063002
72063004
72063034
72063049
72063051
72063271
72066125
72601798
72601935
72601938
72601941
Chapter 4 Parts
DESCRIPTION
WASHER .25 FLAT (WAS 13)
(effective through 04/25/13)
WASHER .31 FLAT (effective through 01/09/13)
WASHER .44 FLAT
MACHINERY BUSHING 1 X 10 GA NR (effective through 12/05/12)
WASHER .25 LOCK (effective through 04/25/13)
WASHER .38 LOCK
WASHER #8 FLAT (effective through 04/22/13)
KIT #
#3
#3
#3
#3
#3
#3
#3
RETAINING RING-EXT 1.00 HD
(effective through 12/5/12)
#3
WASHER-LOCK 12MM (effective through 04/22/13) #3
#3 CAP SCREW M12-1.75 X 40 SOCKET HEAD CAP
SCREW
BOLT-EYE # 8/32X .75 #3
#3 CAP SCREW .25-20 X .38 BUTTON-HEAD, ZINC
(WAS 4)
TERMINAL #3
CLAMP-LOOP .38 VINYL COVERED
COLLAR-SHAFT 2 PIECE 1/2" (effective through
11/14/12)
HOOK-SWIVEL WITH LATCH
(effective through 11/14/12)
4
4
1
3
9
2
2
2
1
2
1
1
QUANTITY
12
4
2
2
67
68 IMT 3203i Technical Specifications & Parts Manual # 99904380
Cylinder, Extension (51725007)
(Effective 01/09/13)
3
6
14
13
7
9
13
5
11
4
15
12
10
2
8
8
11.13 ±0.100 CLOSED - 48.00 ±0.100 STROKE - 59.13 ±0.200 OPEN
11
4 15 12 10 6 7 13 14
9
13 5 3
Chapter 4 Parts 69
NOTES:
1 TO REDUCE DOWNTIME, REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS
DISASSEMBLED.
2 APPLY 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.
51725007 CYLINDER DATA
CASE
ROD
STROKE
DRY WEIGHT
TEST PRESSURE
OPERATING PRESSURE
TORQUES
ø5 cm (1.88") O.D. X ø3.8 cm (1.5") BORE X 147 cm (58.25")
LONG
ø2.54 cm (1") X 156 cm (61.38") LONG
122 cm (48")
16.5 kg (36.45 LB)
207 bar (3000 PSI)
172 bar (2500 PSI)
PISTON 13.8-18 KG- M (100-130 FT-LB)
HEAD 27.7 KG-M (200 FT-LB)
CARTRIDGE 4.1-4.8 KG-M (30-35 FT-LB)
51725007 PARTS LIST
3.
4.
5.
6.
ITEM
1.
2.
7.
8.
PART #
94397290
52722110
52725008
60135105
60132170
60132173
60135106
73054999
9.
10.
11.
12.
13.
76397127
76397128
76397129
76534502
76534503
14.
15.
7Q072018
7Q072129
REV A 20130604
DESCRIPTION
IMT SEAL KIT-1.50 BORE 1.00 ROD .75 STGR
ROD ASM-1.00 DIA X 61.38 LG .75 S
CASE ASM-1.50 BORE X 58.25 LG
HEAD-1.50 BORE X 1.00 ROD (60131651)
STINGER LOCK .75-16 X 1.75 LG
STOP TUBE-1.00 ROD X 4.00 LONG
PISTON-1.50 BORE X .75 STGR (60132177)
VALVE-CBAL SUN01 CBBC-LHN
WEAR RING-PISTON 1.50OD X .75W
WEAR RING-ROD 1.12 ID X .38W
ROD WIPER-TYPE AN 1.00 ROD
U-CUP LOADED 1.00X1.25X.250 B
U-CUP LOADED 1.25X1.50X.250 B
O RING .75X .88X .06 70
O RING 1.56X 1.75X .09 70
1
1
1
1
1
1
2
1
1
1
1
QUANTITY
1
1
1
1
70 IMT 3203i Technical Specifications & Parts Manual # 99904380
Cylinder, Extension (51722111)
(Through 01/09/13)
3
6
13
7
9
13
5
11
4
15
12
10
8
8
7.16 - 7.60" CLOSED
55.24 - 55.52" OPEN
47.92 - 48.08" STROKE
4 15
11
1210 6
14 13 9 13 7 5 3
Chapter 4 Parts 71
NOTES:
1 TO REDUCE DOWNTIME, REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS
DISASSEMBLED.
2 APPLY 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.
51722111 CYLINDER DATA
CASE
ROD
STROKE
DRY WEIGHT
TEST PRESSURE
OPERATING PRESSURE
TORQUES
ø5 cm (2") O.D. X ø3.8 cm (1.5") BORE X 147 cm (58") LONG
ø2.54 cm (1") X 147 cm (58") LONG
122 cm (48")
18.1 kg (39.86 LB)
207 bar (3000 PSI)
172 bar (2500 PSI)
PISTON 13.8-18 KG- M (100-130 FT-LB)
HEAD 27.7 KG-M (200 FT-LB)
CARTRIDGE 4.1-4.8 KG-M (30-35 FT-LB)
51722111 PARTS LIST
7.
8.
9.
10.
11.
12.
4.
5.
6.
ITEM
1.
2.
3.
PART #
94397290
52722110
52721293
60135105
60132170
60132173
60135106
73054999
76397127
76397128
76397129
76534502
13.
14.
76534503
7Q072018
15. 7Q072129
REV B 20120326
DESCRIPTION
IMT SEAL KIT-1.50 BORE 1.00 ROD .75 STGR
ROD ASM-1.00 DIA X 61.38 LG .75 S
CASE ASM-1.50 BORE X 58.25 LG
HEAD-1.50 BORE X 1.00 ROD (60131651)
STINGER LOCK .75-16 X 1.75 LG
STOP TUBE-1.00 ROD X 4.00 LONG
PISTON-1.50 BORE X .75 STGR (60132177)
VALVE-CBAL SUN01 CBBC-LHN
WEAR RING-PISTON 1.50OD X .75W
WEAR RING-ROD 1.12 ID X .38W
ROD WIPER-TYPE AN 1.00 ROD
U-CUP LOADED 1.00X1.25X.250 B
U-CUP LOADED 1.25X1.50X.250 B
O RING .75X .88X .06 70
O RING 1.56X 1.75X .09 70
1
1
1
1
1
1
2
1
1
1
1
1
QUANTITY
1
1
1
72 IMT 3203i Technical Specifications & Parts Manual # 99904380
Cylinder, Extension (51721291)
(Through 12/29/08)
8
63.88" CLOSED - 111.88" OPEN
4 15
48"
STROKE
11
12 10
6
14 13 9 13 7 5 3
NOTES:
1 TO REDUCE DOWNTIME, REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS
DISASSEMBLED.
2 APPLY 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.
51721291 CYLINDER DATA
CASE
ROD
STROKE
DRY WEIGHT
TEST PRESSURE
OPERATING PRESSURE
TORQUES
ø5 cm (2") O.D. X ø3.8 cm (1.5") BORE X 147 cm (58")
LENGTH
ø2.54 cm (1") X 147 cm (58") LONG
122 cm (48")
18.1 kg (39.86 LB)
207 bar (3000 PSI)
172 bar (2500 PSI)
ITEM #5, LOCK NUT: 407 N-m (300 FT-LB)
5.
6.
7.
8.
9.
10.
51721291 PARTS LIST
ITEM PART #
1.
2.
3.
4.
94397290
52721292
52721293
60131651
60132170
60132173
60132177
73054999
76397127
76397128
DESCRIPTION
IMT SEAL KIT
ROD ASSEMBLY
CASE ASSEMBLY
HEAD
STINGER LOCK
STOP TUBE
PISTON
VALVE-COUNTERBALANCE
WEAR RING-PISTON
WEAR RING-ROD
#1
#1
KIT #
1
1
1
1
1
1
QUANTITY
1
1
1
1
51721291 PARTS LIST
ITEM PART #
11.
12.
13.
14.
76397129
76534502
76534503
7Q072018
15. 7Q072129
NEW 20080314
DESCRIPTION
ROD WIPER
U-CUP LOADED
U-CUP LOADED
O RING
O RING
Winch (71570922)
Chapter 4 Parts 73
KIT #
#1
#1
#1
#1
#1
2
1
1
QUANTITY
1
1
WINCH REPLACEMENT PARTS
BRAKE - IMT # 77056662
MOTOR - IMT # 73511210
CONTACTOR - IMT # 77041862
NOTE: For 24V systems use 71571008.
74 IMT 3203i Technical Specifications & Parts Manual # 99904380
1
Power Unit (73511283
(Effective 10/11/12)
12V
& 73511305
24V
)
3
6
2
7
NOTE: Pump pressure relief valve setting = 2500 psi (172 bar)
73511283 (12V) & 73511305 (24V) PARTS LIST
2.
3.
4.
5.
ITEM
1.
1.
PART #
77043065
77043066
73511306
73540517
74399495
70734788
6.
7.
73734791
70734792
NEW 20130809
DESCRIPTION
MOTOR 12VDC
MOTOR 24VDC
PUMP
RELIEF VALVE ASSEMBLY
RESERVOIR
BREATHER CAP
TUBE-SUCTION
STRAINER
5
4
KIT #
1
1
1
1
1
1
QUANTITY
A/R
A/R
Power Unit (73511169)
(Through 10/11/12)
Chapter 4 Parts 75
NOTE: Pump pressure relief valve setting = 2500 psi (172 bar)
76 IMT 3203i Technical Specifications & Parts Manual # 99904380
Hydraulic Installation (99904361)
VALVE BANK (99904361-2)
TANK
(RETURN)
ROTATION CW
EXTENSION OUT
HYD
MOTOR
(PORT A)
HYD
MOTOR
(PORT B)
ROTATION CCW
EXTENSION IN
BOOM UP
EXT CYL
RETRACT
PORT
PRESSURE
EXT CYL
EXTEND
PORT
BOOM DOWN
LOWER CYL
RETRACT
PORT
LOWER CYL
EXTEND
PORT
Chapter 4 Parts
1H1M ON/OFF RADIO CONTROL / TETHERED CONTROL (99904361-3) (Effective 04-25-13)
77
13
7
14
9
15
8
11
15
12
20 2
34
35
12
11
6
VALVE BANK
(PO RT B1)
12
12
EXTENSION CYLINDER (PO RT R)
EXTENSION CYLINDER (PO RT E)
17
16
12
VALVE BANK
(PO RT A1)
TO LOWER CYLINDER (PO RT R)
19
TO VALVE BANK (PO RT B2)
12
TO LOWER CYLINDER (PO RT E)
1H1M
TETHERED CONTROL
TO VALVE BANK (PO RT A2)
10
13
POWER UNI T &
HYDRAULIC RESEVIOR
6
7
15
HYDRAULIC
MO TOR
15
12
8 9
REAR OF MAS T
WITHOU T PROPO RTIONA L VALVE
VALVE BANK
14
11
11
18
12
EXTENSION CYLINDER
12
20, 2
12
17
16
19
12
VAVLE BANK
12
10
FRON T OF MAS T
WITH EXTENSION CYLINDER
12
LOWER CYLINDER
12
78 IMT 3203i Technical Specifications & Parts Manual # 99904380
1H1M PROPORTIONAL CONTROL (99904361-4) (Effective 04-25-13)
TO VALVE BLOCK
PORT P (PRESSURE)
TO VALVE BLOCK
PORT T (TANK)
25
13
27
34
35
12
TO POWER UNIT
PROPORTIONAL VALVE
7
12
9
28
14
11
11
22
32
31
25
15
29 4
15
8
36
32
VALVE BANK
(PORT B1)
12
12
16
17
VALVE BANK
(PORT A1)
12
27
TO LOWER CYLINDER (PORT R)
23
24
12
TO LOWER CYLINDER (PORT E)
TO VALVE BANK (PO RT B2)
TO VALVE BANK (PORT A2)
10
1H1M
PROPORTIONAL CONTROL
18
POWER UNI T &
HYDRAULIC RESEVIOR
29 PROPO RTIONA L
VALVE
22
27
24
26
4
13
7
25
8 9
14
11
VALVE BANK
11
EXTENSION CYLINDER
HYDRAULIC
MOTOR
REAR OF MAS T
WITH PROPO RTIONA L VALVE
(SEE NOTE)
28, 12
12
16
12
12
VALVE BANK
12
23
12
12
17 12
12 10
LOWER CYLINDER
Chapter 4 Parts
1H/2M ON-OFF RADIO CONTROL & TETHERED CONTROL (99904361-5) (Effective 04-25-13)
79
POWER UNI T &
HYDRAULIC RESEVIOR
VALVE BANK
13
7
12
20
2
14
34
35
3
SEE NOTE
12
6
13
6
7
15
HYDRAULIC
MO TOR
15
8 9
12
14
11
11
REAR OF MAS T
WITHOU T PROPO RTIONA L VALVE
9
8
11
1M/2M
TETHERED CONTROL
15
18
SEE NOTE #1
3
VALVE BANK
20, 2 12
19
SEE NOTE #1
3 12
10
LOWER CYLINDER
FRON T OF MAS T
WITHOU T EXTENSION CYLINDER
12
12
TO LOWER CYLINDER (PO RT R)
19
TO VALVE BANK (PO RT B2)
12
TO LOWER CYLINDER (PO RT E)
TO VALVE BANK (PO RT A2)
10
NOTE:
1 CRANES WITHOUT EXTENSION CYLINDER USE PLUGS (72532522) TO BLOCK HYDRAULIC PORTS B1 &
A1 ON THE VALVE BLOCK.
10.
11.
12.
13.
14.
15.
16.
7.
8.
9.
3.
4.
5.
5.
6.
99904361 PARTS LIST
ITEM PART #
1.
2.
99904317
70145928
72532522
73540325
51721322
51725633
51397335
51397336
51397337
51397338
51397339
72053758
72532351
72532699
72533567
72533589
51395219
DESCRIPTION
DRAWING-CRANE & WINCH ASSEMBLY
FLOW LIMITER
PLUG-STR HEX HD STL .44
VALVE-PROPORTIONAL FLOW CONTROL
HYDRAULIC KIT (effective through 09/16/13)
HYDRAULIC KIT (effective from 09/16/13)
HOSE-FZ .25 X 13.50 (4-4) 100R17
HOSE-FI .25 X 12.50 (4-4) 100R17
HOSE-FJ .25 X 7.00 (4-4) 100R17
HOSE-FJ .25 X 9.25 (4-4) 100R17
HOSE-FF .25 X 23.50 (4-4) 100R17
ELBOW-M STR/90/M JIC 4 4
ADAPTER-M STR/M JIC 4 4
ELBOW-M STR/90/M JIC 6 4 (WAS 2)
ELBOW-M STR/90/M JIC XLG 4 4
ADAPTER-M STR/M JIC 10 4
HOSE-FF .25 X 18.00 (4-4) 100R17
KIT # QUANTITY
REF
#5
#5
#5
#5
#5
#5
#5
#5
#5
#5
#5
1
2
1
REF
REF
1
1
1
1
1
3
2
1
1
2
6
80 IMT 3203i Technical Specifications & Parts Manual # 99904380
24.
25.
26.
27.
28.
29.
30.
99904361 PARTS LIST
ITEM PART #
17.
18.
18.
51395872
72534875
72531130
51395380 19.
20.
21.
22.
23.
72532992
91721626
51395663
51397339
51397434
51397452
72053758
72532351
72532981
72534477
51721645
31.
32.
34.
72060009
72063001
72534714
35. 72532674
REV. M 20130925
DESCRIPTION
HOSE-FF .25 X 21.00 (4-4) 100R17
ELBOW-STREET STL M6 x 90 DEG (effective to 9/6/13)
ELBOW-STREET STL .12 X 90 DEG (effective from 2/10/15)
HOSE-FF .25 X 22.00 (4-6) 100R17
ADAPTER-M STR/F STR 4 6
HYDRAULIC KIT-3203i PROPORTIONAL
HOSE-FJ .25 X 14.00 (4-4) 100R17
HOSE-FF .25 X 23.50 (4-4) 100R17
HOSE-FZ .25 X 16.00 (4-4) 100R17
HOSE-FI .25 X 11.50 (4-4) 100R17
ELBOW-M STR/90/M JIC 4 4
ADAPTER-M STR/M JIC 4 4
TEE-SWVL NUT RUN JIC 4
ADAPTER-M STR/M JIC 4 4 XLG
HARDWARE-PROPORTIONAL CONTROL VALVE
CAP SCREW .25-20X 2.25 HH GR5 Z
WASHER .25 FLAT
TEE-STL JIC/STR/JIC 4 6 4 BRANCH
CAP-JIC STL 4 (0.44 THD)
NOTE: DESIGN INCLUDING ITEM #2, 70145928, EFFECTIVE S/N 3203i091012.
#21
#21
#21
#21
#30
#30
#5
#5
KIT # QUANTITY
#5 1
#5
#5
#5
1
1
1
#5
#21
#21
#21
#21
1
REF
1
1
1
1
2
2
1
1
1
2
1
1
REF
Chapter 4 Parts
1H1M ON/OFF RADIO CONTROL / TETHERED CONTROL (99904361-3) (Through 04-25-13)
81
13
7
14
12
20 2
34
11
35
6
12
13
POWER UNIT &
HYDRAULIC
RESERVOIR
7
HYD
MOTOR
15 15
12
VALVE
BANK
14
11
11
6
13
8
9
9
15
8
11
15
TO LOWER
CYLINDER (PORT R)
19
VB (PORT B1)
16
14
EXTENSION
CYLINDER (PORT R)
14
EXTENSION
CYLINDER (PORT E)
17
12
VALVEBANK
(PORT A1)
12
REAR OF MAST
WITHOUT PROPORTIONAL VALVE
EXT CYLINDER
RETRACT
PORT
14
EXTEND PORT
14
2,20
12
18
12
19
17
16
12
VALVE
BANK
12
10
LOWER
CYLINDER
FRONT OF MAST
WITH EXTENSION CYLINDER
12
TO VALVE
BANK
(PORT B2)
10
TO LOWER
CYLINDER (PORT E)
TO VALVE BANK
(PORT A2)
82 IMT 3203i Technical Specifications & Parts Manual # 99904380
1H1M PROPORTIONAL CONTROL (99904361-4) (Through 04-25-13)
PROPORTIONAL
VALVE
22
25
9
28
29 4
14
15
15
27
13
8
7
12
11
27
34
31,32,33
25
24
TO VALVE
BANK
(PORT B2)
TO LOWER
CYLINDER
(PORT R)
23
TO VALVE
BLOCK
PORT P
(PRESSURE)
11
35
12
TO VALVE
BLOCK
PORT T
(TANK)
TO POWER
UNIT
POWER UNIT &
HYDRAULIC 29
RESERVOIR
PROPORT.
VALVE
22
27
24
4
11
13
13
7
25
8 9
26
VALVE
BANK
14
11
HYD
MOTOR
12,28
REAR OF MAST
WITH PROPORTIONAL VALVE (NOTE)
VB
(PORT B1)
12
VB
(PORT A1)
10
12
16
14
EXTENSION
CYLINDER (PORT R)
14
17
EXTENSION
CYLINDER (PORT E)
TO LOWER
CYLINDER
(PORT E)
EXT CYLINDER
(RETRACT
PORT) 14
18
12
14 (EXTEND PORT)
VALVE
BANK
26
12
23
16
17
12
12
10
FRONT OF MAST
WITH EXTENSION CYLINDER
12
LOWER
CYLINDER
TO VALVE BANK
(PORT A2)
Chapter 4 Parts
1H/2M ON-OFF RADIO CONTROL & TETHERED CONTROL (99904361-5) (Through 04-25-13)
83
9
8
13
7
14
12
20 2
11
34
35
12
3 (NOTE)
6
11
15
15
13
POWER UNIT &
HYDRAULIC
RESERVOIR
6
7
HYD
MOTOR
15 15
13
8
9
12
REAR OF MAST
VALVE
BANK
14
11
11
WITHOUT PROPORTIONAL VALVE
18
VALVE
BANK
2,20
12
12
(NOTE) 3
19
(NOTE) 3
12
10
LOWER
CYLINDER
FRONT OF MAST
WITHOUT EXTENSION CYLINDER
TO LOWER
CYLINDER (PORT R)
19
TO VALVE
BANK (PORT B2)
12
10
12
TO LOWER
CYLINDER (PORT E)
TO VALVE BANK
(PORT A2)
NOTE:
1 CRANES WITHOUT EXTENSION CYLINDER USE PLUGS (72532522) TO BLOCK HYDRAULIC PORTS B1 &
A1 ON THE VALVE BLOCK.
12.
13.
14.
15.
16.
4.
5.
6.
7.
8.
9.
10.
11.
99904361 PARTS LIST
ITEM PART #
1.
2.
3.
99904317
70145928
72532522
73540325
51721322
51397335
51397336
51397337
51397338
51397339
72053758
72532351
72532699
72533567
72533589
51395219
DESCRIPTION
DRAWING-CRANE & WINCH ASSEMBLY
FLOW LIMITER
PLUG-STR HEX HD STL .44
VALVE-PROPORTIONAL FLOW CONTROL
HYDRAULIC KIT
HOSE-FZ .25 X 13.50 (4-4) 100R17
HOSE-FI .25 X 12.50 (4-4) 100R17
HOSE-FJ .25 X 7.00 (4-4) 100R17
HOSE-FJ .25 X 9.25 (4-4) 100R17
HOSE-FF .25 X 23.50 (4-4) 100R17
ELBOW-M STR/90/M JIC 4 4
ADAPTER-M STR/M JIC 4 4
ELBOW-M STR/90/M JIC 6 4 (WAS 2)
ELBOW-M STR/90/M JIC XLG 4 4
ADAPTER-M STR/M JIC 10 4
HOSE-FF .25 X 18.00 (4-4) 100R17
KIT #
#5
#5
#5
#5
#5
#5
#5
#5
#5
#5
#5
6
1
3
1
1
2
2
1
QUANTITY
REF
1
2
1
REF
1
1
1
84 IMT 3203i Technical Specifications & Parts Manual # 99904380
22.
23.
24.
25.
26.
27.
99904361 PARTS LIST
ITEM PART #
17.
18.
19.
20.
21.
51395872
72531130
51395380
72532992
91721626
51395663
51397339
51397434
51397452
72053758
72532351
28.
29.
30.
31.
32.
33.
34.
72532981
72534477
51721645
72060007
72063001
72063049
72534714
35. 72532674
REV. J 20100311
DESCRIPTION
HOSE-FF .25 X 21.00 (4-4) 100R17
ELBOW-STREET STL .12 X 90 DEG
HOSE-FF .25 X 22.00 (4-6) 100R17
ADAPTER-M STR/F STR 4 6
HYDRAULIC KIT-3203i PROPORTIONAL
HOSE-FJ .25 X 14.00 (4-4) 100R17
HOSE-FF .25 X 23.50 (4-4) 100R17
HOSE-FZ .25 X 16.00 (4-4) 100R17
HOSE-FI .25 X 11.50 (4-4) 100R17
ELBOW-M STR/90/M JIC 4 4
ADAPTER-M STR/M JIC 4 4
TEE-SWVL NUT RUN JIC 4
ADAPTER-M STR/M JIC 4 4 XLG
HARDWARE-PROPORTIONAL CONTROL VALVE
CAP SCREW .25-20X 1.75 HH GR5 Z
WASHER .25 FLAT
WASHER .25 LOCK
TEE-STL JIC/STR/JIC 4 6 4 BRANCH
CAP-JIC STL 4 (0.44 THD)
NOTE: DESIGN INCLUDING ITEM #2, 70145928, EFFECTIVE S/N 3203i091012.
#21
#21
#21
#21
#21
#21
KIT #
#5
#5
#5
#5
#21
#21
#30
#30
#30
#5
#5
2
2
2
1
1
1
REF
1
1
1
2
1
1
1
QUANTITY
1
1
1
1
REF
Tethered Control Installation (99904593)
(Effective 04-25-13)
Chapter 4 Parts 85
8
10
5
10
7
3203i/4004i
CRANE
14
4
99904593 PARTS LIST
ITEM PART #
2.
4.
5.
7.
8.
91725111
70734746
60133633
72060002
72062104
10.
14.
72063001
77441536
REV B 20130306
DESCRIPTION
CONTROL KIT- TETHERED ELECTRIC CRANE 1
HANDLE ASM-TETHERED ELECTRIC CRANES 1
COVER- WINDOW
CAP SCR .25-20X .75 HH GR5 Z
NUT .25-20 HEX NYLOCK
WASHER .25 FLAT
PLUG CAP-DEUTSCH HDC36-24
QUANTITY
1
2
2
4
1
NOTE: See 99904377 for installation drawing prior to 2-15-09. Component parts are the same.
86 IMT 3203i Technical Specifications & Parts Manual # 99904380
Tethered Control Installation (99904593)
04-25-13)
(Through
6
8
7
4
3
8
5
9
10
2
3203i / 4004i
TETHERED
REMOTE
INSTALLATION
12
3.
4.
5.
99904593 PARTS LIST
ITEM
1.
2.
PART #
91721524
51721502
60133633
71413190
72060002
DESCRIPTION QUANTITY
CONTROL KIT- TETHERED ELECTRIC CRANE 1
HANDLE ASM-TETHERED ELECTRIC CRANES 1
COVER- WINDOW
RELAY-2 RELAY MODULE
CAP SCR .25-20X .75 HH GR5 Z
1
1
2
6.
7.
8.
72062104
72062106
72063001
NUT .25-20 HEX NYLOCK
NUT 10-24 HEX NYLOCK
WASHER .25 FLAT
2
2
4
9.
10.
72063268
72601994
WASHER #10 W FLAT ANSI B27.2Z
SCREW-MACHINE #10-24X .75 BTNHD ZC
2
2
12. 77044667 PLUG CAP-DEUTSCH HDC36-24 1
REV A 20090515
NOTE: See 99904377 for installation drawing prior to 2-15-09. Component parts are the same.
Radio Control Installation, Standard
(99904594)
7
8
3
2
Chapter 4 Parts 87
8
6
4
3203i / 4004i
STANDARD
RADIO CONTROL
INSTALLATION
99904594 PARTS LIST
4.
6.
7.
ITEM
1.
2.
3.
PART #
91721523
60133634
70734329
70734330
72060008
72062104
DESCRIPTION
CONTROL KIT- RADIO ELECTRIC CRANE
SLEEVE-TYPE C .63X .81X .31
RECEIVER - RADIO REMOTE TELE VORC
QUANTITY
1
2
1
TRANSMITTER-RADIO REMOTE ELECTRIC CRANE 1
CAP SCR .25-20X 2.00 HH GR5 Z
NUT .25-20 HEX NYLOCK
2
2
8. 72063001
NEW 20090305
WASHER .25 FLAT 4
NOTE: See 99904522 for installation drawing prior to 2-15-09. Component parts are the same.
NOTE: Image may be different depending on assembly date but control installation is identical.
88 IMT 3203i Technical Specifications & Parts Manual # 99904380
Radio Control Installation, Proportional
(99904595)
7
8
3
2
8
6
4
3203i / 4004i
PROPORTIONAL
RADIO CONTROL
INSTALLATION
3.
4.
6.
99904595 PARTS LIST
ITEM
1.
2.
PART #
91721644
60133634
70734347
70734348
72060008
DESCRIPTION
CONTROL KIT- PROP ELECTRIC CRANE-12V
SLEEVE-TYPE C .63X .81X .31
QUANTITY
1
2
RECEIVER-PROP RADIO ELECTRIC CRANE CRANE 1
TRANSMITTER-RADIO ELECTRIC CRANE PROP
CAP SCR .25-20X 2.00 HH GR5 Z
1
2
7.
8.
72062104
72063001
NUT .25-20 HEX NYLOCK
WASHER .25 FLAT
2
4
NOTE: See 99904523 for installation drawing prior to 2-15-09. Component parts are the same.
NOTE: Image may be different depending on assembly date but control installation is identical.
Electrical Installation (99904389)
Effectivity Dates)
(See Parts List for
Chapter 4 Parts 89
2
5
10
17
18
6
19
11
12
16
3
15
19
MAS T
REAR PL ATE
GROUND
9
14
11 (REAR VIEW)
ELECTRIC RO TATOR BRACKE T
(TOP)
MAS T
LH SIDE
GROUND
CRANE BASE
TORQUE TO 8-15 F T-LBS 14
12
ELECTRIC RO TATOR BRACKE T
(BOT TOM)
WIRE HARNESS
(RADIO & TETHERED CONTROL)
TO CRANE BOX
GROUND
WIRE HARNESS
(POWER)
TO 300 AMP KEYED SWITCH
IN CRANE BOX
99904389 PARTS LIST
ITEM PART #
1.
DESCRIPTION
91722219 KIT- 3203I ELECTRICAL INSTALLATION (WAS 91721525 THRU 12-29-08)
KIT # QTY
1
5.
6.
7.
2.
3.
4.
8.
9.
10.
11.
71570922
73511283
89034049
77041932 CONTACTOR-WINCH 12V (effective through 05/09/13)
51721718 CABLE ASSEMBLY (effective through 03/27/13)
51721497
51721498
51721499
51721664
51721943
WINCH
POWER UNIT (effective through 10/11/12)
SPIRAL WRAP – BLACK
CABLE ASSEMBLY
CABLE ASSEMBLY
CABLE ASSEMBLY
CABLE ASSEMBLY
CABLE ASSEMBLY
#1
#1
#1
#1
#1
#1
1
1
1
1
REF
REF
1
REF
2
1
90 IMT 3203i Technical Specifications & Parts Manual # 99904380
99904389 PARTS LIST
ITEM PART # DESCRIPTION
12.
13.
14.
51721944
51721719
CABLE ASSEMBLY
CABLE ASSEMBLY (effective through 03/27/13)
77441534 SWITCH-225A CONTACTOR (WAS 77441277 THRU 12-29-08) (effective through 04/25/13)
77441312 CABLE ASSEMBLY 15.
16.
17.
77441302
77441303
TERMINAL-INSULATED RED #8-2 GA WIRE
TERMINAL-INSULATED BLACK #8-2 GA WIRE
18.
19.
72060021
72063050
REV. L 20130619
CAP SCREW 0.31-18 X .5 HH GR5 Z
WASHER 0.31 LOCK
#1
KIT # QTY
#1
#1
#1
1
1
1
1
1
1
1
1
Chapter 4 Parts 91
Electrical Installation (99904389)
Dates)
(See Parts List for Effectivity
WRAP WINCH CABLES
WITH BLACK SPIRAL WRAP
3
8
17
11
12
6
16
4 5
19
2
MAST
REAR
PLATE
GROUND
9
20
10
21
18
14
(REAR VIEW)
ELECTRIC ROTATOR
BRACKET (TOP)
MAST
LH SIDE
GROUND
CRANE BASE
TORQUE TO
8-15 FT-LB
13
15
ELECTRIC ROTATOR
BRACKET (BOTTOM)
WIRE HARNESS
(RADIO CONTROL)
TO CRANE
BOX GROUND
WIRE HARNESS
(TETHERED CONTROL)
TO 300 AMP KEYED
SWITCH IN CRANE BOX
5.
6.
7.
2.
3.
4.
99904389 PARTS LIST
ITEM PART # DESCRIPTION
1. 91722219 KIT- 3203I ELECTRICAL INSTALLATION (WAS 91721525 THRU 12-29-08)
60133635 CONTACT JUNCTION (effective through 04/28/13)
71570922 WINCH
72060044 CAP SCREW .38-16 X .75 HEX HEAD GRADE 5 ZINC
(effective through 04/25/13)
72062002 NUT .38-16 HEX (effective through 04/25/13)
73511169 POWER UNIT (effective through 10/11/12)
89034049 SPIRAL WRAP – BLACK
KIT # QTY
1
REF
REF
REF
REF
REF
1
18
92 IMT 3203i Technical Specifications & Parts Manual # 99904380
99904389 PARTS LIST
ITEM PART # DESCRIPTION
8.
9.
10.
11.
12.
77041801 CONTACTOR-WINCH 12V (effective through 05/09/13)
51721495 CABLE ASSEMBLY (effective through 03/27/13)
51721497 CABLE ASSEMBLY
51721498 CABLE ASSEMBLY
51721499 CABLE ASSEMBLY
13.
14.
15.
51721664 CABLE ASSEMBLY
51721943 CABLE ASSEMBLY
51721944 CABLE ASSEMBLY
16.
17.
18.
51721974 CABLE ASSEMBLY (effective through 04/22/13)
51721976 CABLE ASSEMBLY (effective through 03/27/13)
77441336 SWITCH-275A CONTACTOR (WAS 77441277 THRU 12-29-08) (effective through 04/25/13)
77441312 CABLE ASSEMBLY 19.
20.
21.
77441302 TERMINAL-INSULATED RED #8-2 GA WIRE
77441303 TERMINAL-INSULATED BLACK #8-2 GA WIRE
REV. G 20090515
#1
#1
#1
#1
#1
#1
#1
KIT # QTY
REF
#1 1
#1
#1
#1
1
1
1
1
1
1
1
1
1
1
1
1
Chapter 4 Parts
225-Amp Contactor Replacement (99904578)
(Effective 04/25/13)
2
5
3
7
10
6
4
8
93
NOTES:
1 THE 77441534 CONTACTOR IS SMALLER THAN THE 77441336. THE MOUNTING SPACE FOR THE
77441336 IS 3.4" SQUARE. THE MOUNTING SPACE FOR THE 77441534 IS 3.6" HORIZONTALLY BY 2.1"
VERTICALLY.
2 THE 77441336 WAS MOUNTED INSIDE THE MAST, AS SHOWN. USE THE REPLACEMENT KIT WHEN
MOUNTING A REPLACEMENT 77441534 INSIDE THE MAST WHERE THE 77441336 WAS.
99904578 PARTS LIST
ITEM PART #
1.
2.
3.
91722165
DESCRIPTION
HARDWARE KIT-CONTACTOR REPLACEMENT
60251278 PLATE-CONTACTOR MNT
72063047 WASHER #10 LOCK
4.
5.
6.
72063239 WASHER # 8 LOCK
72063268 WASHER #10 W FLAT ANSI B27.2Z
72063271 WASHER # 8 W FLAT ANSI B27.2Z
7.
8.
72602007 SCREW-MACHINE #10-24X .62 BUTTONHEAD, ZINC-COATED #1
72602011 SCREW-MACHINE # 8-32X .62 BUTTONHEAD, ZINC-COATED #1
9. 77441534 SWITCH- 225A CONTACTOR
REV B 20130702
KIT #
#1
#1
#1
#1
QUANTITY
1
1
4
4
4
4
4
4
1
94 IMT 3203i Technical Specifications & Parts Manual # 99904380
275-Amp Contactor Replacement (99904578)
(Through 04-25-13)
2
5
3
7
9
6
4
8
6
4
8
NOTES:
1 CONTACTOR 77441277 REPLACED BY 77441336 IN JANUARY 2009. CONTACTOR 77441336 EFFECTIVE
ON CRANES WITH SERIAL NUMBERS STARTING WITH THE FOLLOWING SERIAL NUMBERS: 3203i091006
(Model 3203i), 4004i091002 (Model 4004i), 6006i091001 (Model 6006i).
2 THE 77441336 CONTACTOR IS SMALLER THAN THE 77441277. THE MOUNTING SPACE FOR THE
77441277 IS 3.6" HORIZONTALLY BY 4.9" VERTICALLY. THE MOUNTING SPACE FOR THE 77441336 IS
3.4" SQUARE.
3 THE 77441277 WAS MOUNTED INSIDE THE MAST, AS SHOWN. USE THE REPLACEMENT KIT WHEN
MOUNTING A REPLACEMENT 77441336 INSIDE THE MAST WHERE THE 77441277 WAS.
4.
5.
6.
7.
99904578 PARTS LIST
ITEM PART #
1.
2.
3.
91722165
60251278
72063047
72063239
72063268
72063271
72602007
8.
9.
72602011
77441336
NEW 20090210
DESCRIPTION
WASHER #10 LOCK
WASHER # 8 LOCK
WASHER #10 W FLAT ANSI B27.2Z
WASHER # 8 W FLAT ANSI B27.2Z
KIT #
HARDWARE KIT-CONTACTOR REPLACEMENT
PLATE-CONTACTOR MNT
#1
#1
#1
#1
SCREW-MACHINE #10-24X .62 BUTTONHEAD,
ZINC-COATED
SCREW-MACHINE # 8-32X .62 BUTTONHEAD,
ZINC-COATED
SWITCH- 275A CONTACTOR
#1
#1
QUANTITY
1
1
4
4
4
4
4
4
1
Harness, Radio (77441270)
Chapter 4 Parts 95
A B B A
96 IMT 3203i Technical Specifications & Parts Manual # 99904380
SCHEMATIC, HARNESS, RADIO (77441270)
CJ-500
RADIO RECEIVER
TETHER INTER FACE
RS485 B
GROUND
RS485 A
+ B ATT
SHIELD (OPT)
3
4
2
1
5
N/C
N/C 2
1
GROUND 3
PROPO RTIONA L 4
N/C 5
CP-1200
POWER (RADIO)
RADIO RECEIVER
BOOM U P
INTER FACE
(GR AY)
BOOM DOWN
6
7
8
EXTEND OU T 9
WINCH U P 10
EXTEND IN 11
WINCH DOWN 12
1
2
P7
PROPO RTIONA L
SPLICE G SPLICE G
1
2
P1 BOOM U P
1
2
P2 BOOM DOWN
1
2
P3
EXTEND OU T
W4
WINCH U P
1
2
P4 EXTEND IN
W5 WINCH DOWN
SPLICE G SPLICE G
B
A
J10
ANTI-TWO
A
P10
B
2800 PSI
ROTATE CW
1
CP-1201
RADIO RECEIVER
INTER FACE
(BLACK)
ROTATE CCW 2
HYDRAULIC PUM P 3
N/C
N/C
4
5
N/C
6
RS485 A
RS485 B
7
8
N/C 9
N/C 10
N/C 11
A2B/OVERLOAD 12
15A
W1
HYDRAULIC PUM P
W2
POWER
W3
GROUND
2
1
P5 RO TATE CW
2
1
P6 RO TATE CCW
BOOM
DOWN
EXTEND
OUT
EXTEND
IN
ROTATE
CW
ROTATE
CCW
Harness, Tethered (77441269)
CJ-2300
BOOM UP
HYDRAULIC
PUMP W1
FUSED
15A
FUSE
W4 W5
WINCH UP WINCH DOWN
W3
GROUND
A B B A
CJ-2300
TETHER HANDLE
CRANE POWER O
BOOM U P P
BOOM DOWN N
EXTEND OU T B
EXTEND IN F
RO TATE CW A
RO TATE CCW K
POWER L
HYDRAULIC PUM P S
WINCH DOWN C
WINCH U P D
15A
W1 W2 W3
1 2 3 4 5 6
CP-600
REL AY MODULE
1 2 3 4 5 6
CP-601
REL AY MODULE
Chapter 4 Parts 97
CP-600
RELAY
CP-601
B
A
J10
A
P10
B
ANTI-TWO
2800 PSI
W4 WINCH DOWN
W5 WINCH U P
1
2
P1 BOOM U P
1
2
P2 BOOM DOWN
1
2
P3 EXT OU T
2
1
P4 EX T IN
2
1
P5 RO TATE CW
2
1
P6 RO TATE CCW
98 IMT 3203i Technical Specifications & Parts Manual # 99904380
Handle Assembly, Tethered (70734746)
04/25/13)
(Effective
ROT
CCW
WINCH
DOWN
EXT
OUT
BM
UP
ROT
CW
WINCH
UP
EXT
IN
BM
DOWN
Handle Assembly, Tethered (51721502)
04/25/13)
(Through
NOTE: Tethered handle assembly is non-serviceable. If damaged a new assembly is required.
Chapter 4 Parts 99
6,9,12,27
OFF
POWER
ON
ROT
CCW
EXT
IN
WINCH
DOWN
LOWER
DOWN
CW
OUT UP
UP
2
14
4,10
29
28
25
24
TO SWITCH #19
SOLDER WIRE
TO TERMINAL
3 26
BLACK
(S) HYD
PUMP
23
13
7 21
30
8,20
100 IMT 3203i Technical Specifications & Parts Manual # 99904380
Tethered Remote Handle Assembly (51721502)
R E D
RED/BLK
(WIN UP)
18
1 (REF) GRN
(TO ROTARY SWITCH)
BLK/ORN (CRANE PWR)
ORN/BLK (EXT OUT) 5
YEL (BOOM UP)
15(16)
YEL/BLK
(ROT CW)
1 4
1(6)
ORN
17
BLU/BLK
17
BRN/BLK (ROT CCW)
17
BRN (EXT IN)
WIRE FUNCTIONS
P
Q
R
S
T
U
V
K
L
M
N
O
F
G
H
J
C
D
E
SOLID/STRIPE
A YEL/BLK
B ORN/BLK
BLU/BLK
RED/BLK
ORN/RED
BRN
BRN/RED
BLU/RED
BLK/RED
BRN/BLK
RED
BLU
ORN
BLK/ORN
YEL
BRN/BLU
YEL/RED
BLK
BLK/BLU
RED/BLU
BLU/ORN
FUNCTION
ROT CW
EXT OUT
WINCH DN
WINCH UP
-
-
-
EXT IN
-
ROT CCW
POWER
-
LOWER DN
CRANE POWER
-
-
LOWER UP
-
-
HYD PUMP
-
SOLID/STRIPE
W ORN/BLU
X YEL/BLU
- RED/RON
51716404 PARTS LIST
8.
9.
10.
11.
12.
13.
14.
15.
4.
5.
6.
7.
ITEM
1.
2.
3.
17.
18.
20.
21.
23.
24.
25.
26.
27.
PART #
60045031
60119335
60111141
60119277
70034306
70029119
77044196
77044621
70394447
70394142
77044969
72066340
72531833
72061009
77040051
77040372
77040373
77044579
89044100
77044695
70733518
51716499
72601346
70395995
FUNCTION
-
-
-
Chapter 4 Parts
DESCRIPTION
WIRE 18GA X 4 GRN
CONTROL HANDLE
TRIGGER (PART OF 25)
COVER
BACK COVER
PLACARD, SERIAL NUMBER
CORD GRIP, LOCTITE
PIN
DECAL-DGR RC ELECTRO SM
DECAL-TELESCOPIC REMOTE 95
SWITCH, ROTARY ELEC (PART OF 25)
POP RIVET
BUSHING, RED STL 3/4 X 1/2
SHT MTL SCR #6X3/4 PH
TERM-SPRSPD #8 16-14GA
TOGGLE SWITCH SPDT
TOGGLE SWITCH SPST
CONNECTOR
CABLE 18GA 24WIRE
4
1
1
30 FT
TERMINAL, FSLPON
BRACKET, TRIGGER (PART OF 25)
1
1REF
TRIGGER ASSEMBLY (INCL 3,11,24,26,28-29) 1
SCR-MACH #8-32 PAN HEAD (PART OF 25) 4REF
1 DECAL-CAUTION RC HANDLE ELEC PWR
UNIT
SPRING, TENSION (PART OF 25)
SCR-SHT METAL #6X1/2 PH (PART OF 25)
1REF
1REF
HEAT SHRINK 0.33 FT
2
1
8
16
23
1
1
1REF
1
1
1
1
QUANTITY
6
1
1REF
28.
29.
70143223
72061000
30. 70145495
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.
101
102 IMT 3203i Technical Specifications & Parts Manual # 99904380
Decal Installation (99904375)
12
25
27
33
30
26
34
22
33
34
28
9
34
26
29
11
33
28
35
32
6,7,10
DECAL PLACEMENT (IF NOT SHOWN ON CRANE)
ITEM #
15,21,23,
24,28,31,35
16
19
18,20
37,38
36
PLACEMENT
AT OR NEAR REMOTE HANDLE STORAGE POINT
2 ON REAR STABILIZERS
AT OR NEAR DRIVELINE
ON SIDES AND REAR OF CARRIER VEHICLE
ON FRONT OF CARRIER VEHICLE
ON CRANE POWER CABLE CONNECTION AT VEHICLE BATTERY
27
12
25
99904375 PARTS LIST
ITEM PART #
10.
11.
12.
13.
14.
15.
5.
6.
7.
8.
9.
1.
2.
3.
4.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
70397348
71397349
71397350
70397334
70397351
70397411
34.
35.
36.
37.
70397412
70397404
70397405
70397389
38. 70397390
REV. C 20111206
70392864
70391598
70392868
70392891
70394445
70396613
70394189
71039134
70392982
71394083
70399142
70396779
95719347
95719348
95721446
70391612
70391613
70392399
70392524
70394166
70394443
70395090
70395324
70395670
71391522
71391523
70392213
DESCRIPTION KIT #
DECAL KIT - TELE COMMON
DECAL KIT - BODY COMMON
DECAL KIT - 3203i SPECIFIC
DECAL-GREASE WEEKLY (LEFT)
DECAL-GREASE WEEKLY (RIGHT)
DECAL-LUBRICATE WORM
DECAL-ROTATE CRANE WHILE GREAS
DECAL-INSTR FOR MNL OPERATION
DECAL-DANGER FREEFALLING BOOMS
DECAL-GREASE WORM DR BRNGS
DECAL-ASME/ANSI B30.5-TELESCOP
DECAL-CAUTION DOWN HAUL WT
DECAL-ANGLE INDICATOR RH
DECAL-ANGLE INDICATOR LH
DECAL-CAUTION DONT WASH/WAX
DECAL-WARNING STAB STAND CLEAR
DECAL-WARNING, MAN STAB
DECAL-DANGER CR LOADLINE (TRK)
DECAL-DANGER DRIVELINE
DECAL-DANGER ELEC HZD LG TELES
DECAL-CRANE SAFETY & OPER
DECAL-MOBILOIL RESERVOIR
DECAL-CAUTION OIL LEVEL
DECAL-SERVICE & REPAIR
DECAL-LOAD BLOCK RATING 2.0TON
DECAL-DIAMOND IMT 4X8
DECAL-3203i ID
DECAL-CAPACITY CHART 3203i
DECAL-ANGLE INDICATOR RH, SM
DECAL-ANGLE INDICATOR LH, SM
DECAL-WARNING, ELEC CR OL
DECAL-REMOTE PENDANT STORE
DECAL-GREASE WEEKLY (LH) SMALL
DECAL-GREASE WEEKLY (RH) SMALL
DECAL-DANGER, UNPLUG CRANE
DECAL-CRANE POWER DISCONNECT
DECAL-DANGER ELEC HZD MED TELE
DECAL-DANGER CR LOADLINE (MED TRK) 3
3
3
3
3
3
3
3
3
3
3
3
3
3
2
2
2
2
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
Chapter 4 Parts 103
3
2
1
1
1
1
1
3
2
1
1
2
2
2
4
1
1
1
1
4
2
4
1
1
1
2
1
1
1
1
1
1
9
6
1
QTY IN KIT QTY ON
CRANE
1
1
1
0
0
1
1
0
1
1
1
2
0
0
1
3
2
1
1
1
1
1
3
2
1
1
2
2
2
3
1
1
1
1
2
0
3
1
C H A P T E R 5
General Reference
105
In This Chapter
Inspection Checklist ................................................................ 105
Deficiency / Recommendation / Corrective Action Report ........ 110
Thread Torques ....................................................................... 112
Turntable Bearing Thread Tightening Sequence ..................... 114
Turntable Bearing Inspection ................................................... 114
Turntable Bearing Tilt Test ...................................................... 115
Inspection Checklist
NOTICE:
The user of this form is responsible for determining that these inspections satisfy all applicable regulatory requirements.
OWNER/COMPANY:
CONTACT PERSON:
TYPE OF INSPECTION (circle one):
CRANE MAKE & MODEL:
CRANE SERIAL NUMBER:
DAILY MONTHLY QUARTERLY ANNUAL
DATE INSPECTED:
HOURMETER READING (if applicable):
INSPECTED BY (print): UNIT I.D. NUMBER:
LOCATION OF UNIT: SIGNATURE OF INSPECTOR:
106 IMT 3203i Technical Specifications & Parts Manual # 99904380
TYPE OF INSPECTION
NOTES:
Daily and monthly inspections are to be performed by a “competent person”, who is capable of identifying existing and predictable hazards in the surroundings or working conditions which are unsanitary, hazardous, or dangerous to employees, and who has authorization to take prompt corrective measures to eliminate them.
Quarterly and annual inspections are to be performed by a “qualified person” who, by possession of a recognized degree, certificate, or professional standing, or who by extensive knowledge, training and experience, successfully demonstrated the ability to solve/resolve problems relating to the subject matter, the work, or the project.
One hour of normal crane operation assumes 20 complete cycles per hour. If operation exceeds 20 cycles per hour, inspection frequency should be increased accordingly.
Consult Operator / Service Manual for additional inspection items, service bulletins and other information.
Before inspecting and operating crane, crane must be set up away from power lines and leveled with stabilizers fully extended.
DAILY (D): Before each shift of operation, those items designated with a (D) must be inspected.
MONTHLY (M): Monthly inspections or 100 hours of normal operation (whichever comes first) includes all daily inspections plus items designated with an (M). This inspection must be recorded and retained for a minimum of 3 months.
QUARTERLY (Q): Every three to four months or 300 hours of normal operation (whichever comes first) includes all daily and monthly inspection items plus items designated with a (Q). This inspection must be documented, maintained, and retained for a minimum of 12 months, by the employer that conducts the inspection.
ANNUAL (A): Each year or 1200 hours of normal operation (whichever comes first) includes all items on this form which encompasses daily, monthly and quarterly inspections plus those items designated by (A). This inspection must be documented, maintained, and retained for a minimum of 12 months, by the employer that conducts the inspection.
INSPECTION CHECKLIST STATUS KEY:
S = Satisfactory
R = Recommendation
(Should be considered for corrective action)
NA = Not Applicable
X = Deficient
(NOTE: If a deficiency is found, an immediate determination must be made as to whether the deficiency constitutes a safety hazard and must be corrected prior to operation.)
FREQUENCY ITEM KEY
D
D
D
D
D
D
D
1
2
3
4
5
6
7
INSPECTION DESCRIPTION
Labels
Crane
Controls
Station
Hydraulic
System
Hook
All load charts, safety & warning labels, and control labels are present and legible.
Check all safety devices for proper operation.
Control mechanisms for proper operation of all functions, leaks and cracks.
Control and operator's station for dirt, contamination by lubricants, and foreign material.
Hydraulic system (hoses, tubes, fittings) for leakage and proper oil level.
Presence and proper operation of hook safety latches.
Wire Rope Inspect for apparent deficiencies per applicable requirements and manufacturer’s specifications.
STATUS
(S,R,X,NA)
Chapter 5 General Reference 107
M
M
M
M
D
D
D
FREQUENCY ITEM KEY
D
D
D
D
D
D
D
D
D
D
D
INSPECTION DESCRIPTION
8
9
Pins
General
Proper engagement of all connecting pins and pin retaining devices.
Overall observation of crane for damaged or missing parts, cracked welds, and presence of safety covers.
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.
11 Remote Ctrl Operate remote control devices to check for proper operation.
12 Electrical Operate all lights, alarms, etc. to check for proper operation.
Operate anti two-block or two-block damage prevention device to check for proper operation.
13 Anti-Two-
Block or
Two-Block
Damage
Prevention
14 Tires Check tires (when in use) for proper inflation and condition.
15 Ground
Conditions
16 Level
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.
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.
17 Operator cab windows
18 Rails, rail stops, rail clamps and supporting surfaces
Check windows for cracks, breaks, or other deficiencies which would hamper the operator's view.
Check rails, rail stops, rail clamps and supporting surfaces when the equipment has rail traveling.
19 Safety devices
20 Electrical
Check safety devices and operational aids for proper operation.
21
Check electrical apparatus for malfunctioning, signs of apparent excessive deterioration, dirt or moisture accumulation.
Other
STATUS
(S,R,X,NA)
D
M
22
23 Daily
Other
All daily inspection items.
M
M
M
M
M
M
M
M
24 Cylinders
25 Valves
26 Valves
27 Valves
Visual inspection of cylinders for leakage at rod, fittings, and welds.
Damage to rod and case.
Holding valves for proper operation.
Control valves for leaks at fittings and between stations.
Control valve linkages for wear, smoothness of operation, and tightness of fasteners. Relief valve for proper pressure settings.
Bent, broken, or significantly rusted/corroded parts. 28 General
29 Electrical
30 Structure
31 Welds
32
33
Pins
Hardware
Electrical apparatus for malfunctioning, signs of apparent excessive deterioration, dirt or moisture accumulation. Electrical systems for presence of dirt, moisture, and frayed wires.
All structural members for damage.
All welds for breaks and cracks.
All pins for proper installation and condition.
All bolts, fasteners and retaining rings for tightness, wear and corrosion.
34 Wear Pads Presence of wear pads.
35 Pump & Hydraulic pumps and motors for leakage at fittings, seals, and
Motor between sections. Check tightness of mounting bolts.
108 IMT 3203i Technical Specifications & Parts Manual # 99904380
Q
Q
M
M
M
Q
Q
Q
Q
Q
M
M
Q
FREQUENCY ITEM KEY
M
M
M
INSPECTION DESCRIPTION
36 PTO Transmission/PTO for leakage, abnormal vibration & noise, alignment, and mounting bolt torque.
Quality of hydraulic fluid and presence of water. 37 Hyd Fluid
38 Hyd Lines Hoses & tubes for leakage, abrasion damage, blistering, cracking, deterioration, fitting leakage, and secured properly.
39 Hook Load hook for abnormal throat distance, twist, wear, and cracks.
40 Wire Rope Condition of load line.
41 Manual Presence of operator's manual with unit.
42
43
44 Daily
Other
Other
All daily inspection items.
45 Monthly All monthly inspection items.
46 Rotation Sys Rotation bearing for proper torque of all mounting bolts.
47 Hardware Base mounting bolts for proper torque.
All structural members for deformation, cracks and corrosion. 48 Structure
49
50
51
• Base
• Stabilizer beams and legs
• Mast
52
53
54
55
56
57
58 Hardware
• Inner Boom
• Outer Boom
• Extension(s)
• Jib boom
• Jib extension(s)
• Other
Pins, bearing, shafts, gears, rollers, and locking devices for wear, cracks, corrosion and distortion.
• Rotation bearing(s)
• Inner boom pivot pin(s) and retainer(s)
59
60
61
62
63
64
65
66
• Outer boom pivot pin(s) and retainer(s)
• Inner boom cylinder pin(s) and retainer(s)
• Outer boom cylinder pin(s) and retainer(s)
• Extension cylinder pin(s) and retainer(s)
• Jib boom pin(s) and retainer(s)
• Jib cylinder pin(s) and retainer(s)
67
68
• Jib extension cylinder pin(s) and retainer(s)
• Boom tip attachment
69 • Other
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
73
74
75
76
77 Pumps &
Motors
78
79
80
• Return line(s) from control valve to reservoir
• Suction line(s) from reservoir to pump
• Pressure line(s) from control valve to each function
• Load holding valve pipe(s) and hose(s)
• Other
Pumps and Motors for loose bolts/fasteners, leaks, noise, vibration, loss of performance, heating & excess pressure.
• Winch motor(s)
• Rotation motor(s)
• Other
STATUS
(S,R,X,NA)
Chapter 5 General Reference 109
Q
A
A
A
A
Q
A
A
A
A
Q
FREQUENCY ITEM KEY
Q
A
A
A
A
INSPECTION DESCRIPTION
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
Valves
Cylinders
96 Winch Winch, sheaves and drums for damage, abnormal wear, abrasions and other irregularities.
97 Hyd Filters Hydraulic filters for replacement per maintenance schedule.
98 Daily
99 Monthly
100 Quarterly
101 Hyd Sys
Hydraulic valves for cracks, spool return to neutral, sticking spools, proper relief valve setting, relief valve failure.
• Main control valve
• Load holding valve(s)
• Stabilizer or auxiliary control valve(s)
• Other
• Other
Hydraulic cylinders for drifting, rod seal leakage and leakage at welds. Rods for nicks, scores and dents. Case for damage. Case and rod ends for damage and abnormal wear.
• Stabilizer cylinder(s)
• Inner boom cylinder(s)
• Outer boom cylinder(s)
• Extension cylinder(s)
• Rotation cylinder(s)
• Jib lift cylinder(s)
• Jib extension cylinder(s)
• Other
All daily inspection items.
All monthly inspection items.
All quarterly inspection items.
Hydraulic fluid change per maintenance schedule.
102 Controls
103 Valves
104 Valves
Control valve calibration for correct pressure & relief valve settings.
Safety valve calibration for correct pressure & relief valve settings.
Valves for failure to maintain correct settings.
105 Rotation Sys Rotation drive system for proper backlash clearance & abnormal wear, deformation and cracks.
106 Lubrication Gear oil change in rotation drive system per maintenance schedule.
107 Hardware Check tightness of all fasteners and bolts, using torque specifications on component drawings or torque chart.
108 Wear Pads Wear pads for excessive wear.
109 Loadline Loadline for proper attachment to drum.
STATUS
(S,R,X,NA)
110 IMT 3203i Technical Specifications & Parts Manual # 99904380
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
Chapter 5 General Reference 111
DATE CORRECTED
112 IMT 3203i Technical Specifications & Parts Manual # 99904380
Thread Torque Chart (English)
FINE THREAD BOLTS (ENGLISH)
SIZE BOLT
DIA.
GRADE 5 GRADE 8
COARSE THREAD BOLTS (ENGLISH)
SIZE BOLT
DIA.
GRADE 5 GRADE 8
SAE J429
GRADE 5
SAE J429
GRADE 8
SAE J429
GRADE 5
SAE J429
GRADE 8
(DIA-TPI) (INCHES) PLAIN PLATED PLAIN PLATED (DIA-TPI) (INCHES) PLAIN PLATED PLAIN PLATED
(FT-LB) (FT-LB) (FT-LB) (FT-LB)
5/16-24 0.3125 19 14 27 20 5/16-18 0.3125
(FT-LB) (FT-LB) (FT-LB) (FT-LB)
17 13 25 18
3/8-24 0.375 35
7/16-20 0.4375 55
26
41
49
78
35
58
44
70
33
52
1/2-20
9/16-18
5/8-18
3/4-16
7/8-11
1-12
1 1/8-12
1 1/4-12
1 3/8-12
0.5
0.5625
0.625
0.75
0.875
1
1.125
1.25
1.375
90
120
170
300
445
645
890
1240
1675
64
90
130
225
325
485
670
930
1255
120
170
240
420
670
995
1445
2010
2710
90
130
180
315
500
745
1085
1510
2035
1 1/2-12 1.5
NOTES
2195 1645 3560
1 Tightening torques provided are midrange.
2670
3/8-16 0.375 31
7/16-14 0.4375 49
1/2-13 0.5 75
9/16-12 0.5625 110
5/8-11 0.625 150
265 3/4-10
7/8-9
1-8
0.75
0.875
1
1 1/8-7 1.125
395
590
795
1 1/4-7
1 3/8-6
1.25
1.375
1 1/2-6 1.5
1120 840
1470 1100
1950
23
37
57
82
115
200
295
445
595
1460
105
155
220
375
605
910
1290
1815
2380
3160
80
115
160
280
455
680
965
1360
1780
2370
2 Consult bolt manufacturer’s particular specifications, when provided.
3 Use flat washers of equal strength.
4 All torque measurements are given in foot-pounds.
5 Torque values specified are for bolts with residual oils or no special lubricants applied. If special lubricants of high stress ability, such as Never-Seez compound graphite and oil, molybdenum disulphide, colloidal copper or white lead are applied, multiply the torque values in the charts by the factor .90. The use of Loctite does not affect the torque values listed above.
WARNING
Anytime a gear-bearing bolt is removed, it must be replaced with a new bolt of the identical grade and size. Once a bolt has been torqued to 75% of its proof load and then removed, the torque coe fficient may no longer be the same as when the bolt was new thus giving indeterminate clamp loads after torqueing. Failure to replace gear-bearing bolts may result in bolt failure due to metal fatigue causing death or serious injury.
Thread Torque Chart (Metric)
Chapter 5 General Reference 113
FINE THREAD TORQUE CHART (METRIC) COARSE THREAD TORQUE CHART (METRIC)
TIGHTENING TORQUE
SIZE
(DIA-
TPI)
BOLT
DIA.
(INCHES)
TIGHTENING TORQUE
SIZE
(DIA-
TPI)
BOLT DIA
(INCHES)
SAE J429
GRADE 5
PLAIN PLATED
(KG-M) (KG-M)
SAE J429
GRADE 8
PLAIN PLATED
(KG-M) (KG-M)
5/16-24 0.3125 3
3/8-24 0.375 5
7/16-20 0.4375 8
1/2-20 0.5 12
9/16-18 0.5625 17
5/8-18 0.625 24
3/4-16 0.75
7/8-11 0.875
41
62
1-12 1
1 1/8-12 1.125
1 1/4-12 1.25
1 3/8-12 1.375
89
123
171
232
2
4
6
9
12
18
31
45
67
93
129
174
4
7
11
17
24
33
58
93
138
200
278
375
1 1/2-12 1.5
NOTES
304 228 492
1 Tightening torques provided are midrange.
3
5
8
12
18
25
44
69
103
150
209
281
369
5/16-18 0.3125
3/8-16 0.375
7/16-14 0.4375
1/2-13 0.5
9/16-12 0.5625
5/8-11 0.625
3/4-10 0.75
7/8-9
1-8
0.875
1
1 1/8-7 1.125
1 1/4-7 1.25
1 3/8-6 1.375
1 1/2-6 1.5
2 Consult bolt manufacturer’s particular specifications, when provided.
SAE J429
GRADE 5
PLAIN PLATED
(KG-M) (KG-M)
2
4
7
10
15
21
37
55
82
110
155
203
270
2
3
5
8
11
16
28
41
62
82
116
152
210
SAE J429
GRADE 8
PLAIN PLATED
(KG-M) (KG-M)
3
6
10
15
21
30
52
84
126
178
251
329
438
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.
2
5
7
11
16
22
39
63
94
133
188
246
328
WARNING
Anytime a gear-bearing bolt is removed, it must be replaced with a new bolt of the identical grade and size. Once a bolt has been torqued to 75% of its proof load and then removed, the torque coefficient may no longer be the same as when the bolt was new thus giving indeterminate clamp loads after torqueing. Failure to replace gear-bearing bolts may result in bolt failure due to metal fatigue causing death or serious injury.
114 IMT 3203i Technical Specifications & Parts Manual # 99904380
Turntable Bearing Thread Tightening
Sequence
Refer to the turntable bearing thread tightening diagram below for proper tightening/torqueing sequence of the turntable bearing to the crane base and crane mast. The total quantity of cap screws varies dependent on crane model.
WARNING
Number 1 can be assigned to any capscrew if the sequence remains the same in reference to number 1.
TIGHTENING PROCEDURE
1 Refer to the Torque Data Chart to determine the proper torque value to apply to the size of capscrew used.
2 Follow the tightening sequence shown in the diagram. Note that the quantity of capscrews may differ from the diagram, but the sequence must follow the criss-cross pattern as shown in the diagram.
3 Torque all capscrews to approximately 40% of the specified torque value, by following the sequence.
(EXAMPLE: .40 x 265 FT-LB = 106 FT-LB)
(EXAMPLE-METRIC: .40 x 36 KG-M = 14.4 KG-M)
4 Repeat Step 3, but torquing all capscrews to 75% of the specified torque value. Continue to follow the tightening sequence.
(EXAMPLE: .75 x 265 FT-LB = 199 FT-LB)
(EXAMPLE-METRIC: .75 x 36 KG-M = 27 KG-M)
5 Using the proper sequence, torque all capscrews to the listed torque value as determined from the Torque Data Chart.
Chapter 5 General Reference 115
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
Turntable Bearing Tilt Test
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.
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.
116 IMT 3203i Technical Specifications & Parts Manual # 99904380
Set up dial indicator to 0" on pinion cover at back side of mast.
Lower crane to horizontal 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)
Tilt Dim.
.875" (22 mm) 1.00" (25 mm) 1.18 - 1.25" (30-32 mm)
1.5” (38 mm) 1.75" (44 mm)
.060" (1.524 mm) .070" (1.778 mm) .075" (1.905 mm) .085” (2.159 mm) .090" (2.286 mm)
Rev 20100331
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