4004i Manual

4004i Manual
Manual # 99904386
IMT 4004i Technical
Specifications & Parts
Revised 20140909
IOWA MOLD TOOLING CO., INC.
PO Box 189
Garner, IA 50438
Tel: 641-923-3711 FAX: 641-923-2424
Website: http://www.imt.com
Copyright © 2014 Iowa Mold Tooling Co., Inc.
All rights reserved
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any
form or by any means, electronic, mechanical, photocopying, recording or otherwise without the
prior written permission of Iowa Mold Tooling Co., Inc.
Iowa Mold Tooling Co., Inc. is an Oshkosh Corporation Company.
i
Contents
Revisions .................................................................................................................................................... iii
Electric Crane Introduction
5
Technical Specifications
7
4004i Technical Data .................................................................................................................................... 7
4004i Capacity Chart .................................................................................................................................... 9
4004i Geometric Configuration .................................................................................................................. 10
Pump & Motor Performance ....................................................................................................................... 11
Crane Reference
13
Assemblies & Grease Zerk Locations ......................................................................................................... 14
4004i Recommended Spare Parts List (See Parts List for Effectivity Dates) ............................................. 15
4004i Recommended Spare Parts List (See Parts List for Effectivity Dates) ............................................. 17
Crane Installation (99904394) .................................................................................................................... 19
Electric Crane Battery Circuit (99904884) ................................................................................................. 24
Telescopic Crane Orientation ..................................................................................................................... 25
Electric Crane Control ................................................................................................................................ 25
Parts
27
Parts Information ........................................................................................................................................ 28
Electric Crane Power Safety ....................................................................................................................... 30
Base & Mast Assembly (99904325) (See Parts List for Effectivity Dates) ............................................... 31
Base & Mast Assembly (99904325) (See Parts List for Effectivity Dates) ............................................... 34
Valve Bank (73734304) .............................................................................................................................. 37
Cylinder, Lower (51721268) ...................................................................................................................... 38
Crane & Winch Assembly (99904327) (See Parts List for Effectivity Dates) ............................................ 40
99904327 Parts List, Complete (See Parts List for Effectivity Dates) ............................................ 48
99904327 Parts List, Complete (See Parts List for Effectivity Dates) ............................................ 50
Boom Assembly (99904326) (See Parts List for Effectivity Dates) ........................................................... 52
99904326 Parts List, Complete (Effective from 01/09/13).............................................................. 70
99904326 Parts List, Complete (See Parts List for Effectivity Dates) ............................................ 71
ii
Contents
Cylinder, Extension (51725007) (Effective 01-09-13) .............................................................................. 72
Cylinder, Extension (51722111) (Through 01-09-13) ................................................................................ 74
Cylinder, Extension (51721291) (Through 12-29-08) ................................................................................ 76
Winch (71570922) ...................................................................................................................................... 78
Power Unit (7351128312V & 7351130524v) (Effective 10/11/12) .......................................................... 79
Power Unit (73511169) (Through 10/11/12) .............................................................................................. 80
Hydraulic Installation (99904388) .............................................................................................................. 81
Tethered Control Installation (99904593) (Effective 04/25/13) ................................................................ 90
Tethered Control Installation (99904593) (Through 04/25/13) ................................................................. 91
Radio Control Installation, Standard (99904594) ....................................................................................... 92
Radio Control Installation, Proportional (99904595) ................................................................................. 93
Electrical Installation (99904392) (See Parts List for Effectivity Dates) ................................................... 94
Electrical Installation (99904392) (See Parts List for Effectivity Dates) ................................................... 96
225-Amp Contactor Replacement (99904578) (Effective 04/25/13) .......................................................... 98
275-Amp Contactor Replacement (99904578) (Through 04/25/13)........................................................... 99
Harness, Radio (77441270) ...................................................................................................................... 100
Harness, Tethered (77441269) .................................................................................................................. 102
Handle Assembly, Tethered (70734746) (Effective 04/25/13) ................................................................. 103
Handle Assembly, Tethered (51721502) (Effective Through 04/25/13) .................................................. 104
4004i Decal Installation (99904410)......................................................................................................... 107
General Reference
109
Inspection Checklist .................................................................................................................................. 109
Deficiency / Recommendation / Corrective Action Report ...................................................................... 114
Thread Torque Chart (English) ................................................................................................................. 116
Thread Torque Chart (Metric) .................................................................................................................. 117
Turntable Bearing Thread Tightening Sequence ...................................................................................... 118
Turntable Bearing Inspection.................................................................................................................... 119
Turntable Bearing Tilt Test....................................................................................................................... 119
Contents
Revisions
DATE
LOCATION
DESCRIPTION
20080908
20081107
ECN 10747 - CYLINDER PARTS LIST CHANGE
ECN 10877, 10868, 10868-1 - RELOCATED ELECTRICAL
COMPONENTS FOR EASIER ASSEMBLY, CHANGED HYDRAULIC
KITS, CHANGED LOWER CYLINDER COUNTERBALANCE VALVES
20100324
51721268
99904325,
99904327,
99904392,
99904388,
51721268
99904325,
99904326,
99904392,
99904578,
51722111
99904593 99904595
99904327,
99904388,
99904392
99904392,
99904593,
99904326
99904325,
99904327,
99904388
99904388
99904388,
99904327
99904388
20100427
99904884
20100615
20100923
20101220
20110614
99904394
71570922
99904326
99904326,
99904327
99904388
51721268,
51722111
51721267
99904325
99904327
99904325
41721489
99904326
99904327
99904327
99904392
99904388
99904327
99904326
99904327
20090210
20090305
20090311
20090518
20091023
20091216
20111031
20120326
20120103
20120512
20121011
20121114
20130121
20130327
20130328
20130401
ECNs 10923, 10945, 10972 - REPLACED 275 AMP CONTACTOR
SWITCH, ADDED NEW EXT CYLINDER
ECN 10987 - ADDED UPDATED CONTROLS INSTALLATION
DRAWINGS, ADDED SHEAVE & LATCH KIT PART NUMBERS.
ECN 10977, 10991 - CHANGED WINCH PART NUMBER, CHANGED
PROPORTIONAL VALVE PORT ID.
ECN 11033 - ADDED TERMINALS TO ELECTRICAL SCHEMATIC,
REPLACED PIN 72661543 WITH HAIR PIN.
ECN 11031 - MINOR PARTS CHANGES & DRAWING UPDATES TO
MATCH.
ECN 11116 - 99904388 UPDATE.
ECN 11146 - HYDRAULIC HOSE IDENTIFICATION, ECN 11153ADDED LOCKING COLLAR.
ECN 11182 - UPDATED 99904388 HYD KIT TO ADD PRESSURE
TEST PORT.
ADDED 99904884 AND EDITED ELECTRIC CRANE 99904394 STEP
5.
ADDED DUAL BATTERY WIRING INFORMATION.
UPDATED WINCH SPARE PARTS
ECN 10713-3- WEAR PAD CHANGES
ECN 11432 - UPDATED LOWER BOOM
ECN 11609 - UPDATE HYD MOTOR PORTS
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 11829-2 – POWER CABLE LENGTH CHANGED
ECN 11835-1 – EXTENSION CYLINDER PIN REMOVED
ECN 11835-3 – GEAR GUARD CHANGE AND SINGLE STINGER
CHANGE
iii
iv
Contents
20130509
20130522
20130613
20130620
20131113
20131120
20140909
99904326
99904327
99904392
99904325
99904388
99904392
99904325
99904325
99904392
70734746
77441269
77111270
GREASING
INSTRUCTIONS
ECN 11835-7 – WINCH CONTACTOR AND BRACKET CHANGE
ECN 11835-8 – 225A CONTACTOR, CABLE REDUCTION, VALVE
BANK BRACKET CHANGE
ECN 11835-6 – BASE WELDMENT CHANGE
ECN 12009 – VALVE BANK HARDWARE CHANGE
REMOVED TETHERED PROPORTIONAL REMOTE
POTENTIOMETER ADJUSTMENT PROCEDURE.
ECN 12063 – UPDATED HARNESS DRAWINGS AND SCHEMATICS
ECN 12264 – MOLUB-ALLOY 882 WAS MOLUB-ALLOY 936.
5
CHAPTER 1
Electric Crane Introduction
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.
7
CHAPTER 2
Technical Specifications
In This Chapter
4004i Technical Data ................................................................ 7
4004i Capacity Chart ................................................................ 9
4004i Geometric Configuration ................................................. 10
Pump & Motor Performance ..................................................... 11
4004i Technical Data
GENERAL SPECIFICATIONSCRANE RATING
18,000 ft-lb at 8'-0" (2.5 tm at 2.4 m)
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
16'-0" (4.9 m)
OIL RESERVOIR CAPACITY
OIL TYPE
ELECTRICAL SYSTEM REQUIREMENTS
1.5 gallons (5.7 l)
ISO VG32, low pour, anti-wear hydraulic oil
12VDC with two 1000 amp batteries* and 100 amp alternator
min.
CENTER OF GRAVITY
- HORIZONTAL FROM CENTERLINE OF
ROTATION (BOOMS RETRACTED)
- HORIZONTAL FROM CENTERLINE OF
ROTATION (BOOMS EXTENDED)
- VERTICAL FROM BOTTOM OF CRANE
BASE
TIE-DOWN BOLT PATTERN (on center)
48" (122 cm)
48" (122 cm)
17'-2" (5.2 m)
758 lb (344 kg)
32" (81.3 cm)
14" x 18" (35.5 cm x 45.7 cm)
2500 psi (172 bar)
1.6 gpm (6 lpm)
32" (81.3 cm)
46" (116.8 cm)
16" (40.6 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
3500 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 4004i Technical Specifications & Parts Manual #99904386
CYLINDER SPECIFICATIONS
LOWER BOOM CYLINDER
EXTENSION BOOM CYLINDER
3.5" bore; 16" stroke (8.9 cm bore; 40.6 cm stroke)
1.5" bore; 48" stroke (3.8 cm bore; 122.0 cm stroke)
WINCH SPECIFICATIONS
WINCH PULL LINE
PULL LINE SPEED WITHOUT LOAD
ROPE DIAMETER
2000 lb (907 kg)
23 ft/min (7 m/min)
1/4" (6.35 mm)
WIRE ROPE LENGTH
CABLE BREAKING STRENGTH
75' (22.9 m)
7000 lb (3175 kg)
PERFORMANCE CHARACTERISTICS
SPECIFICATION
SPEED
ROTATION
LOWER BOOM ELEVATION
Continuous 360° (6.28 rad)
-5° to +75° (-0.1 to +1.3 rad)
44 seconds
13.5 seconds
EXTENSION CYLINDER
48" (122.0 cm)
10 seconds total
Chapter 2 Technical Specifications
4004i Capacity Chart
3560
1615
16'
4.8 m
14'
4.2 m
4000
1815
4000
1815
1450
660
4000
1815
1980
900
3490
1585
45
°
6'
1.8 m
1710
775
2320
1050
60
°
8'
2.4 m
2190
995
2940
1335
12'
3.6 m
10'
3.0 m
Maximum 1-part line
capacity is 2000 lb (907 kg).
For greater loads, use
2-part line.
NOTE: Boxes denote
2-part line.
°
30
4'
1.2 m
3020
1370
1270
575
1750
795
2680
1215
°
15
2'
0.6 m
0
(Base) 0
( CL )
2'
0.6 m
4'
1.2 m
6'
1.8 m
2330
1055
8'
2.4 m
10'
3.0 m
1500
680
12'
3.6 m
14'
4.2 m
1080
490
16'
4.8 m
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.
IOWA MOLD TOOLING CO., INC.
BOX 189, GARNER, IA 50438-0189
TEL: 641-923-3711 FAX: 641-923-2424
9
10
IMT 4004i Technical Specifications & Parts Manual #99904386
4004i Geometric Configuration
4'-2"
(1.28 m)
3'-2"
(96 cm)
2'-3"
(67.4 cm)
16'-10"
(5.14 m)
13'-0"
(3.96 m)
9'-5"
(2.87 m)
4004i
1'-4" (40 cm)
8'-0" (2.43 m)
12'-0" (3.65 m)
16'-0" (4.87 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
I - 1.6 CC
5
15.0
10.0
4
200
180 AMPS
3
2
250
150
Q - 1.6 CC
100
2500 PSI
5.0
1
0.0
0
50
0
0
500
25
1000
50
75
1500
2000 2500
PSI
3000
3500
4000
0
4500
100 125 150 175 200 225 250 275 300
BAR
CAUTION
Avoid motor damage! Operate within
performance curves shown.
12
IMT 4004i Technical Specifications & Parts Manual #99904386
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.
13
CHAPTER 3
Crane Reference
In This Chapter
Assemblies & Grease Zerk Locations ....................................... 14
4004i Recommended Spare Parts List ..................................... 15
Crane Installation (99904394) .................................................. 18
Electric Crane Battery Circuit (99904884) ................................ 24
Telescopic Crane Orientation ................................................... 25
Electric Crane Control .............................................................. 25
14
IMT 4004i Technical Specifications & Parts Manual #99904386
Assemblies & Grease Zerk Locations
EXTENSION
BOOM
LOWER
BOOM
SNATCH
BLOCK
WINCH
HOOK
1
6
LOWER
CYLINDER
MAST
2
3
HYDRAULIC
RESERVOIR
4
POWER
UNIT
ITEM
1.
2.
3.
5
CRANE
BASE
LOCATION DESCRIPTION
LUBRICANT
FREQUENCY
Lower Cylinder Rod
Shell Alvania 2EP
Lower Cylinder Base
or
Weekly
Gear Rotator Grease Extension
*Rotate crane while greasing.
Shell Retinax "A"
4.
Power Unit
5.
Power Unit
6.
Lower Boom Pin
NOTE: All application points must be greased weekly under normal workloads and moderate weather conditions.
Under severe operating conditions, lubricate more frequently. See the IMT Electric Crane Operation & Safety
manual for additional lubrication requirements.
NOTE: Image may be different depending on production date. Grease points should be similar.
Chapter 3 Crane Reference
4004i Recommended Spare Parts List
(See Parts List for Effectivity Dates)
Part Number
Description
51721268 Lower Cylinder
51744172
SEAL KIT-IMT 3.5B 1.75R 1.50 S
60132397
PISTON-2.75 BORE X 1.75 ROD 1.63 STGR
6HD35017
HEAD-3.5 BORE X 1.75 ROD
73054999
VALVE-CBAL
77041786
SWITCH-PRESS 2750
51721291 Extension Cylinder (effective through 01/09/13)
94397290
SEAL KIT-IMT 1.50 BORE 1.00 ROD .75
60131651
HEAD-1.50 BORE X 1.00 ROD
60132177
PISTON-1.50 BORE X .75 STGR
(effective through 02/23/10)
73054999
VALVE-CBAL SUN01 CBBC-LHN
(effective through 02/23/10)
99904325 Base & Mast Assembly
60118032
CABLE CONNECTOR MODIFICATION
72060178
CAP SCR .62-11X 4.00 HH
73511157
MOTOR-HYD 101 1702 009
76039295
GASKET-GEAR
77441336
SWITCH- 275A CONTACTOR
(effective through 04/26/13)
77441281
CABLE CONNECTOR-FEMALE
77441285
TERM RING INSUL 3/8 STUD
Quantity
1
1
1
1
1
1
1
1
31
1
1
1
1
73734304 Valve Bank
73540327
COIL (VALVE BANK) (12V)
73540326
VALVE ASSEMBLY (VALVE & COIL) (12V)
3
6
73511169 Power Unit (12V) (effective through 10/11/12)
70733826
FILL CAP ELECTRIC CRANES
73511171
PUMP-GEAR 3203/4004I ELECTRIC CRANE
73540323
VALVE-RELIEF ELECTRIC CRANE
73734332
KIT-TUBE POWER UNIT ELECTRIC CRANE
74397392
RESERVOIR TANK ELECTRIC CRANE
77043060
MOTOR-POWER UNIT ELECTRIC CRANE
1
1
1
1
1
1
73511283 Power Unit (12V) 73511305 (24V)
77043065
MOTOR 12VDC
77043066
MOTOR 24VDC
73511306
PUMP
73540517
RELIEF VALVE ASSEMBLY
74399495
RESERVOIR
70734788
BREATHER CAP
73734791
TUBE-SUCTION
70734792
STRAINER
A/R
A/R
1
1
1
1
1
1
15
16
IMT 4004i Technical Specifications & Parts Manual #99904386
Part Number
Description
99904326 Boom Assembly
60030373
WEAR PAD- EXT CYLINDER
60030374
WEAR PAD-RND 1.00 DIA X .50 DIA X .75L
60030375
WEAR PAD-RND 3.00 DIA X 1.00 DIA X .55L
60030376
WEAR PAD-RND 3.50 X 1.00 DIA X .615
60132302
STOP SCREW 3/8-24 X .50
71734311
PIN-QUICK RLSE .62D/4.5 CRIT
71734314
PIN-QUICK RLSE .62D/6.5 CRIT
72661543
PIN-QUICK 316-10QP
60030372
SHEAVE- 5.5 NYLATRON
99904327 Crane & Winch Assembly
51721494
CORD REEL ASM- 5ft PACKARD CONNECTOR
(effective through 11/14/12)
70580197
WIRE ROPE ASM-.25(7X19 GAC) X 75' RRL
(effective through 11/14/12)
71413185
SPRING-.105WIRE 0.75OD 2.875 LG
72601798
WASHER-LOCK 12MM
72601935
CAP SCR M12-1.75X 40 SH PLAIN
72601938
BOLT-EYE # 8-32X .75
77041459
SWITCH-LIMIT ZE-N-2S
77441096
CONNECTOR- .50 STR RLF .25-.38
77041801
CONTACTOR, WINCH (12V or 24V)
(effective through 10/11/12)
Quantity
1
8
2
2
4
1
1
2
2
1
1
1
4
4
1
1
1
1
Chapter 3 Crane Reference
4004i Recommended Spare Parts List
(See Parts List for Effectivity Dates)
Part Number
Description
51721268 Lower Cylinder
51744172
SEAL KIT-IMT 3.5B 1.75R 1.50 S
60132397
PISTON-2.75 BORE X 1.75 ROD 1.63 STGR
6HD35017
HEAD-3.5 BORE X 1.75 ROD
73054999
VALVE-CBAL
77041786
SWITCH-PRESS 2750
51725007 Extension Cylinder (effective from 01/09/13)
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
(effective from 02/23/10)
73054999
VALVE-CBAL SUN01 CBBC-LHN
(effective from 02/23/10)
99904325 Base & Mast Assembly
60118032
CABLE CONNECTOR MODIFICATION
72060178
CAP SCR .62-11X 4.00 HH
73511157
MOTOR-HYD 101 1702 009
76039295
GASKET-GEAR
77441336
SWITCH- 275A CONTACTOR
(effective from 04/26/13)
77441281
CABLE CONNECTOR-FEMALE
77441285
TERM RING INSUL 3/8 STUD
Quantity
1
1
1
1
1
1
1
1
31
1
1
1
1
73734304 Valve Bank (12V)
73540327
COIL (VALVE BANK) (12V)
73540326
VALVE ASSEMBLY (VALVE & COIL) (12V)
3
6
73734375 Valve Bank (24V)
77040527
COIL (24V)
73540336
VALVE ASSEMBLY (24V)
3
6
73511169 Power Unit (12V) (effective through 10/11/12)
70733826
FILL CAP ELECTRIC CRANES
73511171
PUMP-GEAR 3203/4004I ELECTRIC CRANE
73540323
VALVE-RELIEF ELECTRIC CRANE
73734332
KIT-TUBE POWER UNIT ELECTRIC CRANE
74397392
RESERVOIR TANK ELECTRIC CRANE
77043060
MOTOR-POWER UNIT ELECTRIC CRANE
1
1
1
1
1
1
73511305 Power Unit (24V)
99904326 Boom Assembly
60030373
WEAR PAD- EXT CYLINDER
60030374
WEAR PAD-RND
60030375
WEAR PAD-RND
1
8
2
17
18
IMT 4004i Technical Specifications & Parts Manual #99904386
Part Number
Description
60030376
WEAR PAD-RND
60132302
STOP SCREW 3/8-24 X .50
71734311
PIN-QUICK RLSE .62D/4.5 CRIT
71734314
PIN-QUICK RLSE .62D/6.5 CRIT
72661543
PIN-QUICK 316-10QP
60030372
SHEAVE- 5.5 NYLATRON
60133938
WEAR PAD – RND 0.25 X 1.00 X 0.50 X 0.50
60030369
WEAR PAD – RND 0.19 X 2.00 X 1.00 X 0.50
72661711
CLEVIS PIN 0.5 x 3.00
60030483
SHEAVE - 8.0 NYLATRON
99904327 Crane & Winch Assembly
51713168
CORD REEL ASM- 5ft PACKARD CONNECTOR
(effective from 11/14/12)
70580197
WIRE ROPE ASM-.25(7X19 GAC) X 75' RRL
(effective through 11/14/12)
71413185
SPRING-.105WIRE 0.75OD 2.875 LG
72601798
WASHER-LOCK 12MM
72601935
CAP SCR M12-1.75X 40 SH PLAIN
72601938
BOLT-EYE # 8-32X .75
77041459
SWITCH-LIMIT ZE-N-2S
77441096
CONNECTOR- .50 STR RLF .25-.38
77041801
CONTACTOR, WINCH (12V or 24V)
(effective through 10/11/12)
Quantity
2
4
1
1
2
2
2
1
1
1
1
1
1
4
4
1
1
1
1
Chapter 3 Crane Reference
19
Crane Installation (99904394)
In addition to meeting the minimum chassis specifications noted in the Technical Data section of
this manual, make sure there is sufficient room for mounting the crane and the platform is strong
enough to support the crane and rated load. Install the crane only on an IMT designed and
approved truck body. The body must be designed to sustain the forces imposed by the crane
when lifting the full rated load. Install the body on the chassis before installing the crane. Refer
to the following table for parts referenced in the following crane installation drawings.
CRANE INSTALLATION PARTS LIST
ITEM
PART #
DESCRIPTION
1.
51721572
ELECTRIC CRANE BODY INSTALLATION
2.
91721647
HARDWARE KIT- 3203i/4004i ELEC CRANE BODY
INSTALLATION
3.
91721751
HARDWARE KIT- 5005i ELEC CRANE BODY
INSTALLATION
4.
51725572
5.
99904317
DRAWING-CRANE & WINCH ASSEMBLY 3203I
6.
60251272
BRACKET-SWITCH 300 AMP ELEC CRANE
7.
70734331
SWITCH-300A KEYED BATTERY DISCONNECT
8.
72042097
LEVEL INDICATOR LEVEL
9.
77040209
TERMINAL-RING NI .38 STUD 1 WIRE
10.
77040529
TERMINAL-RING NI .31 STUD 1-2 WIRE
10.
77040529
TERMINAL-RING NI .31 STUD 1-2 WIRE
11.
77441116
FUSEHOLDER-HIGH AMP2 BOLT WITH COVER
11.
77441116
FUSEHOLDER-HIGH AMP2 BOLT WITH COVER
12.
77441219
FUSE-225 AMP
12.
77441219
FUSE-225 AMP
13.
89044276
CABLE-#1 WELDING
14.
89392333
TUBE-HEAT SHRINK AMP
15.
72060208
CAP SCREW .75-10X 2.50 HH GR8 Z
16.
72601862
NUT .75-10 HEX NYLOC GR8Z
17.
72063116
WASHER .75 N FLAT H ASTMF436Z
18.
72060002
CAP SCREW .25-20X .75 HH GR5 Z
19.
72060634
SCREW-MACHINERY #10-24X .50 RDH
20.
72062000
NUT .25-20 HEX
21.
72062106
NUT 10-24 HEX NYLOCK
22.
72063001
WASHER .25 FLAT
REV. 20120918
KIT #
QUANTITY
1
1
1
#1, #4
#1, #4
#1, #4
#1, #4
#1
#4
#1
#4
#1
#4
#1, #4
#1, #4
#2
#2
#2
#2 & #3
#2 & #3
#2 & #3
#2 & #3
#2 & #3
REF
1
1
1
1
3
9
1
2
1
2
35 FT
.50 FT
4
4
8
4
4
4
4
8
20
IMT 4004i Technical Specifications & Parts Manual #99904386
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.
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).
6"
15,17
(SEE
NOTE)
9.5" DIA.
0.81" DIA.
5.75"
6" 7.38"
12"
14.75"
18"
11.5"
12"
14"
ALLOW 16"
RADIUS FOR
SWING CLEARANCE
MOUNTING HOLE PATTERN
16,17
Chapter 3 Crane Reference
21
2 The electrical power switch (item #7) provides power for the crane. Install the switch onto
the power unit cover.
22
18
7
21
19
KEY SUPPLIED
WITH 70734331
SWITCH. SPARE
KEY - 70734357.
6
13.5"
6
2.75"
3.5"
5.03"
8
4 HOLES,
0.266" DIA.
20
22
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.
22
IMT 4004i Technical Specifications & Parts Manual #99904386
A
13
POWER
CABLE
BRACKET
GROUND CABLE (GROUND
TO BARE METAL INSIDE
CRANE BOX)
MALE POWER
CABLE CONNECTOR
14
9
7
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
8
23
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 CC A
AUXILIA RY
BATTE RY (IN CRANE BOX)
89044276 or 77040009
FUSE TO B ATTE RY (+)
(APPROXIM ATE LY 1FT)
HE AT SHRINK
12
13-CABLE #89044276 or
27-CABLE #77040009
(CUT T O LENGTH)
(CRANE ON-OFF
SWITCH TO FUSE)
29
11
13
11
11
89044276 or 77040009
BATTE RY (-) TO CHASSIS GROUND
(CUT T O LENGTH)
12
HE AT SHRINK
11
TO CHASSIS GROUND
13-CABLE #89044276 or
27-CABLE #77040009
(CU T TO APPROX. 1' (30.5 CM))
(FUSE TO B ATTE RY (+))
UNDERHOOD
BATTE RY
11
13
FROM ON-OFF SWITCH
IN CRANE BOX
13-CABLE #89044276 or
27-CABLE #77040009
(CUT T O LENGTH)
(CRANE ON-OFF
SWITCH TO FUSE)
11
ITEMS WITHIN BOXARE ONLY NEEDED
WHENAUXILIARY BATTERY IS
INSTALLED IN CRANE BOX.
* MATCHED BATTERIESARE REQUIRED*
13-CABLE #89044276 or
27-CABLE #77040009
(CU T TO LENGTH)
TO CHASSIS GROUND
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.
24
IMT 4004i Technical Specifications & Parts Manual #99904386
Electric Crane Battery Circuit (99904884)
CRANE
GROUND AT
CHASSIS FRAME
18" (457 mm)
MAXIMUM
SW
1
225A
UNDERHOOD
BATTERY
225A
18" (457 mm)
MAXIMUM
GROUND AT
CHASSIS FRAME
2ND AUX
BATTERY
GROUND AT
CHASSIS FRAME
NOTES (SEE REFERENCE NUMBER IN BOX):
1
ELECTRIC BULKHEAD PASS-THRU CONNECTOR.
THROUGH A COMPARTMENT WALL.
USE WHENEVER POWER OR GROUND PASSES
Chapter 3 Crane Reference
25
Telescopic Crane Orientation
When an IMT telescopic crane is not factory-installed on a body, the crane is packed with the
boom oriented as it is built on a test stand to facilitate handling. Install the crane on the body
with boom pointing backward. Once the crane is bolted down, it can be rotated 180° (3.14
radians) to the boom rest.
BOOM
REST
400°
ROTATION
OUTLINE OF
TRUCK BODY
REAR OF
TRUCK
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).
27
CHAPTER 4
Parts
In This Chapter
Parts Information ...................................................................... 28
Electric Crane Power Safety ..................................................... 30
Base & Mast Assembly (99904325).......................................... 31
Valve Bank (73734304) ............................................................ 36
Cylinder, Lower (51721268) ..................................................... 38
Crane & Winch Assembly (99904327) ...................................... 40
Boom Assembly (99904326) .................................................... 52
Cylinder, Extension (51725007) (Effective 01/09/13) ................ 72
Cylinder, Extension (51722111) (Through 01/09/13) ................ 74
Cylinder, Extension (51721291) (Through 12/29/08) ................ 76
Winch (71570922) .................................................................... 77
Power Unit (73511283 & 73511305) (Effective 10/11/13) ........ 79
Power Unit (73511169) (Through 10/11/12) ............................. 80
Hydraulic Installation (99904388) ............................................. 81
Tethered Control Installation (99904593) ................................. 90
Radio Control Installation, Standard (99904594) ...................... 92
Radio Control Installation, Proportional (99904595) ................. 93
Electrical Installation (99904392) .............................................. 94
275-Amp Contactor Replacement (99904578) ......................... 98
Harness, Radio (77441270) ..................................................... 100
Harness, Tethered (77441269)................................................. 102
Handle Assembly, Tethered (70734746) (Effective 04/25/13) .. 103
Handle Assembly, Tethered (51721502) (Through 04/25/13) ... 104
4004i Decal Installation (99904410) ......................................... 107
28
IMT 4004i Technical Specifications & Parts Manual #99904386
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
Chapter 4 Parts
29
CYLINDER IDENTIFICATION
To insure proper replacement parts are received, it is necessary to specify the complete
number/letter sequence for any part requested. Part numbers may be cross checked by
comparing the stamped identification on the cylinder case (See figure below) against the
information contained in the service manual. You must include the part number stamped on the
cylinder case when ordering parts.
CYLINDER
PART NUMBER
LOCATION
WELDMENT IDENTIFICATION
Each of the major weldments - base, mast, inner boom, outer boom, extension boom and
stabilizer weldments bear a stamped part number. Any time a major weldment is replaced, you
must specify the complete part number as stamped on the weldment. The locations of the part
numbers are shown in the Crane Reference Section.
ORDERING REPAIR PARTS
When ordering replacement parts:
1 Give the model number of the unit.
2 Give the serial number of the unit.
3 Specify the complete part number. When ordering cylinder parts, or one of the main
weldments, always give the stamped part number.
4 Give a complete description of the part.
5 Specify the quantity required.
30
IMT 4004i Technical Specifications & Parts Manual #99904386
Electric Crane Power Safety
Your electric crane runs using power from the vehicle battery.
maintenance or repairs, disconnect the power to the crane.
DANGER
Before beginning major
POWER SWITCH
TURNED TO OFF
POSITION.
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
31
Base & Mast Assembly (99904325)
(See Parts List for Effectivity Dates)
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.
27 32
12
41
6
42
20, 35, 34
36
36
3
D
DETAIL D
44
20
43
13 1
18
23, 30
2
15, 33
22
25, 30
16
11
48
50
28
15, 33
26
14
39
2
21
29
28
3
19
5
47
17
31
40
22
37
28
29
14
28
26
38
49
22, 29, 28
48
2
45, 33
37
31
22
48
29
50
21
HYDRAULIC MOTOR &
VALVEBANK ASSEMBLY
4
2
20
BASE & MAST ASSEMBLY
CYLINDER INSTALLATION
51
7
30
24
8
POWER UNIT & GEAR
GUARD INSTALLATION
32
IMT 4004i Technical Specifications & Parts Manual #99904386
NOTES (SEE REFERENCE NUMBER IN BOX):
1
APPLY BLACK "MOLUB-ALLOY 882 HEAVY" GEAR GREASE TO TURNTABLE GEAR.
2
TORQUE TO 160 FT-LB.
3
APPLY RUST PREVENTATIVE.
4
USE NEVER-SEEZ ON PIN.
99904325 PARTS LIST
ITEM PART #
DESCRIPTION
1.
51721375
HARDWARE KIT-BASE & MAST
2.
91722220
ELECTRICAL INSTALLATION KIT (WAS 91721554 THROUGH 12-29-08)
3.
51721540
HYDRAULIC KIT-4004I
4.
51721268
CYL-3.5/1.7 16.06S 30.44CC C
5.
52721309
WELDED ASSEMBLY-BASE
6.
52725114
WELDED ASSEMBLY - MAST (WAS 52721310 THROUGH 12-29-08)
(effective from 04/25/13)
7.
60140618
PIN (effective from 12/05/12)
8.
52721315
WELDED ASSEMBLY-GEAR SHROUD 4004I
9.
60141143
WELDED ASSEMBLY- ELEC ROTATOR BRACKET TOP 4004I
(effective from 05/10/13)
10.
60141128
WELDED ASSEMBLY- ELEC ROTATOR BRACKET BOTTOM (effective
from 05/10/13)
11.
60132385
SPACER- POWER UNIT
12.
60132856
BRACKET-GREASE HOSE MNTG 4004I
13.
71056633
GEAR-TURNTABLE BEARING 12.63" DIA
14.
70580194
CLAMP-I" CONDUIT HANGER W/BOLT
15.
72060178
CAP SCREW .62-11X 4.00 HH GR8 Z
16.
73511283
POWER UNIT- 1.19CC 12VDC GC (effective from 10/11/12)
17.
73511157
MOTOR-HYD 101 1702 009
18.
73734304
VALVE BANK- SEC SERIES 3GPM @ 500PSI
19.
76039295
GASKET
20.
70034382
CAP-GREASE PRO20 GC-RED
21.
72060000
CAP SCREW .25-20X .50 HH GR5 Z
22.
72060002
CAP SCREW .25-20X .75 HH GR5 Z (effective through 04/25/13)
23.
72060044
CAP SCREW .38-16X .75 HH GR5 Z (effective through 04/25/13)
24.
72060046
CAP SCREW .38-16X 1.00 HH GR5 Z
25.
72060050
CAP SCREW .38-16X 2.00 HH GR5ZC
26.
72062104
NUT .25-20 HEX NYLOCK (effective from 04/25/13)
27.
72062207
NUT 8-32 HEX NYLOCK (effective from 04/25/13)
28.
72063001
WASHER .25 FLAT (effective from 064/21/13)
29.
72063049
WASHER .25 LOCK
30.
72063051
WASHER .38 LOCK
31.
72063053
WASHER .50 LOCK
32.
72063271
WASHER # 8 W FLAT ANSI B27.2Z (effective from 04/25/13)
33.
72063119
WASHER .62 FLAT ASTM F436
34.
72053508
ZERK-NPT .12
35.
72053301
COUPLING-BLK .12
36.
72602009
SCREW-MACH # 8-32X 1.25 BTNHD SS (effective from 04/25/13)
37.
72601949
CAP SCREW .50-13X 1.25 SH ZC
38.
51721664
CABLE ASSEMBLY- 1GA-5/16RNGX 1/4RNGX 48.00LG
KIT #
QTY
REF
REF
REF
1
1
1
1
1
1
1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#2
1
1
1
2
15
1
1
1
1
5
3
8
2
1
2
3
5
10
8
4
2
5
31
1
1
5
2
1
Chapter 4 Parts
99904325 PARTS LIST
ITEM PART #
DESCRIPTION
39.
51721943
CABLE ASSEMBLY- 1GA-3/8RNGX SWVL FX 11.00LG
40.
51721944
CABLE ASSEMBLY- 1GA-3/8RNGX SWVL MX 60.00LG
41.
77441534
SWITCH- 225A CONTACTOR (effective from 04/25/13)
42.
77441312
CABLE ASSEMBLY-10GA-#10RNGX 1/4RNGX 6.00LG
43.
72534547
ELBOW-STREET STL .12 X 45 DEG
44.
53000700
GREASE EXTENSION- 8.00 OAL 6.00HOSE
45.
72060173
CAP SCREW .62-11X 3.75 HH GR8 Z
46.
60140642
BRKT-3203-4004 VLV MNT (effective from 04/25/13)
47.
72060004
CAP SCR 0.25-20 X 1.00 HH GR5 Z (effective from 04/25/13)
48.
72063003
WASHER 0.38 FLAT (effective from 04/25/13)
49.
72062103
NUT 0.38-16 HEX NYLOCK (effective from 04/25/13)
50.
72060048
CAP SCR 0.38-16 X 1.5 HH GR5 Z (effective from 04/25/13)
51.
71415014
KEEPER PIN 0.38 (effective from 12/05/12)
REV L 20140214
KIT #
#2
#2
#2
#3
#3
#1
#1
#1
#1
#1
#1
33
QTY
1
1
1
1
1
1
16
1
1
4
2
2
1
34
IMT 4004i Technical Specifications & Parts Manual #99904386
Base & Mast Assembly (99904325)
(See Parts List for Effectivity Dates)
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.
47
48
12
24
27
6
29 36
21,39,40
DETAIL A
3
21 50
18
A
41
49
15 1
24,33
19
2
16,37
23
30
16,37
28 3
5
45
26,33 22
32
30
11
9
14
2
13
23
20
17
34
46
44
28
23
43
14
10
23,30,32
2
37,51
BASE & MAST
ASSEMBLY
43
32
23
34
8
30
32
22
POWER UNIT
& GEAR GUARD
INSTALLATION
HYDRAULIC MOTOR
& VALVEBANK
ASSEMBLY
4
38
31
21
21
7
33
CYLINDER INSTALLATION
4
25
Chapter 4 Parts
35
NOTES (SEE REFERENCE NUMBER IN BOX):
1
APPLY BLACK "MOLUB-ALLOY 882 HEAVY" GEAR GREASE TO TURNTABLE GEAR.
2
TORQUE TO 160 FT-LB.
3
APPLY RUST PREVENTATIVE.
4
USE NEVER-SEEZ ON PIN.
99904325 PARTS LIST
ITEM PART #
DESCRIPTION
1.
51721375
HARDWARE KIT-BASE & MAST
2.
91722220
ELECTRICAL INSTALLATION KIT (WAS 91721554 THROUGH 12-29-08)
3.
51721540
HYDRAULIC KIT-4004I
4.
51721268
CYL-3.5/1.7 16.06S 30.44CC C
5.
52721309
WELDED ASSEMBLY-BASE
6.
52722161
WELDED ASSEMBLY - MAST (WAS 52721310 THROUGH 12-29-08)
(effective through 04/25/13)
7.
52721265
PIN (effective through 12/05/12)
8.
52721315
WELDED ASSEMBLY-GEAR SHROUD 4004I
9.
52721314
WELDED ASSEMBLY- ELEC ROTATOR BRACKET TOP 4004I
(effective through 05/10/13)
10.
52721307
WELDED ASSEMBLY- ELEC ROTATOR BRACKET BOTTOM (effective
through 05/10/13)
11.
60132385
SPACER- POWER UNIT
12.
60132856
BRACKET-GREASE HOSE MNTG 4004I
13.
60133635
CONTACT JUNCTION (effective through 04/25/13)
14.
70580194
CLAMP-I" CONDUIT HANGER W/BOLT
15.
71056633
GEAR-TURNTABLE BEARING 12.63" DIA
16.
72060178
CAP SCREW .62-11X 4.00 HH GR8 Z
17.
73511157
MOTOR-HYD 101 1702 009
18.
73511169
POWER UNIT- 1.59CC 12VDC GC (effective through 10/11/12)
19.
73734304
VALVE BANK-3 SEC SERIES 3GPM @ 500PSI
20.
76039295
GASKET
21.
70034382
CAP-GREASE PRO20 GC-RED
22.
72060000
CAP SCREW .25-20X .50 HH GR5 Z
23.
72060002
CAP SCREW .25-20X .75 HH GR5 Z (effective through 04/25/13)
24.
72060044
CAP SCREW .38-16X .75 HH GR5 Z (effective through 04/25/13)
25.
72060046
CAP SCREW .38-16X 1.00 HH GR5 Z
26.
72060050
CAP SCREW .38-16X 2.00 HH GR5ZC
27.
72062002
NUT .38-16 HEX (effective through 04/25/13)
28.
72062104
NUT .25-20 HEX NYLOCK (effective through 04/25/13)
29.
72062207
NUT 8-32 HEX NYLOCK (effective through 04/25/13)
30.
72063001
WASHER .25 FLAT (effective through 064/21/13)
31.
72063034
MACHY BUSHING 1.00X10 GA NR (effective through 12/05/12)
32.
72063049
WASHER .25 LOCK
33.
72063051
WASHER .38 LOCK
34.
72063053
WASHER .50 LOCK
36.
72063271
WASHER # 8 W FLAT ANSI B27.2Z (effective through 04/25/13)
37.
72063119
WASHER .62 FLAT ASTM F436
38.
72066125
RETAINING RING-EXTERNAL 1.00 HD (effective through 12/05/12)
39.
72053508
ZERK-NPT .12
KIT #
QTY
REF
REF
REF
1
1
1
1
1
1
1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
1
1
1
2
1
15
1
1
1
1
5
3
8
2
1
2
1
2
4
6
1
8
4
2
4
31
1
1
36
IMT 4004i Technical Specifications & Parts Manual #99904386
99904325 PARTS LIST
ITEM PART #
DESCRIPTION
40.
72053301
COUPLING-BLK .12
41.
72602009
SCREW-MACH # 8-32X 1.25 BTNHD SS (effective through 04/25/13)
43.
72601949
CAP SCREW .50-13X 1.25 SH ZC
44.
51721664
CABLE ASSEMBLY- 1GA-5/16RNGX 1/4RNGX 48.00LG
45.
51721943
CABLE ASSEMBLY- 1GA-3/8RNGX SWVL FX 11.00LG
46.
51721944
CABLE ASSEMBLY- 1GA-3/8RNGX SWVL MX 60.00LG
47.
77441336
SWITCH- 275A CONTACTOR (SSC42-275) (effective through 04/25/13)
48.
77441312
CABLE ASSEMBLY-10GA-#10RNGX 1/4RNGX 6.00LG
49.
72534547
ELBOW-STREET STL .12 X 45 DEG
50.
53000700
GREASE EXTENSION- 8.00 OAL 6.00HOSE
51.
72060173
CAP SCREW .62-11X 3.75 HH GR8 Z
REV. D 20090518
KIT #
#1
#1
#1
#2
#2
#2
#2
#3
#3
#1
QTY
1
4
2
1
1
1
1
1
1
1
16
Chapter 4 Parts
Valve Bank (73734304)
2,3(2)
4
2,3(2)
2,3(2)
SAE #4
ORB PORT
(4 PLACES)
4
1
4
4
4
SAE #4
ORB PORT
SAE #4
ORB PORT
4
4
EXTENSION
SAE #4
ORB PORT
(2 PLACES)
MAIN
ROTATE
A1
B1 A2
B2 A3
S1
S2
S3
B3
P
T
HYDRAULIC SCHEMATIC
73734304 PARTS LIST (12V)
ITEM
PART #
DESCRIPTION
1.
MANIFOLD VALVE BODY
2.
73540326
SOLENOID VALVE (INCLUDES COIL)
3.
73540327
COIL, 12V.
4.
PLUG, EXPANDER, 7MM
REV A 20081028
73734375 PARTS LIST (24V)
ITEM
PART #
DESCRIPTION
1.
MANIFOLD VALVE BODY
2.
73540326
SOLENOID VALVE (24V)
3.
73540327
COIL, 24V.
4.
PLUG, EXPANDER, 7MM
REV
QUANTITY
1
3
6
7
QUANTITY
1
3
6
7
37
38
IMT 4004i Technical Specifications & Parts Manual #99904386
Cylinder, Lower (51721268)
30.44" CLOSED - 46.5" OPEN - 16.06" STROKE
8 1
13
5
3
7 4 17 17 10 6 9
16
2
15 11 1214 15
NOTES:
1 DRILL #15 HOLE 3/16" DEEP. PRESS IN PIN # 60125699.
2
TO REDUCE DOWNTIME, REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS
DISASSEMBLED.
3
APPLY "NEVER-SEEZ" REGULAR GRADE ANTI-SEIZE AND LUBRICATING COMPOUND TO THREADS ON
CYLINDER HEAD ONLY. KEEP AWAY FROM ALL SEALS.
4
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.
5
ITEM #9, STOP TUBE, REPLACES 6A025017 WAFER LOCK. USE STOP TUBE INSTEAD OF WAFER LOCK
WHEN RESEALING CYLINDER.
51721268 CYLINDER DATA
CASE
ROD
STROKE
DRY WEIGHT
TEST PRESSURE
OPERATING PRESSURE
TORQUES
51721268 PARTS LIST
ITEM
PART #
1.
51744172
2.
52721304
3.
52721308
4.
60132397
5.
6HD35017
6.
6C175017
7.
72062305
8.
60125699
ø4" O.D. X ø3.5" BORE X 24.98" LENGTH
ø1.75" X 28.81 LONG
16.06"
65.73 LB
3000 PSI
2500 PSI
PISTON TO ROD: 710 - 740 FT-LB
HEAD GLAND TO CYLINDER: 350 FT-LB
CARTRIDGE: 30-35 FT-LB
CAP SCREW: 16 FT-LB
DESCRIPTION
SEAL KIT-3.50B 1.75R 1.50S
ROD ASM-1.75 DIA X 28.81 LG 1.50 S
CASE ASM- 3.50 BORE X 25.89 LG
PISTON- 2.75 BORE X 1.75 ROD 1.63 STGR
HEAD - 3.50 BORE X 1.75 ROD
STOP TUBE-1.75 ROD X 1.75 LONG
COLLAR-LOCK 1-1/2-12 X 2.375 X .563
PIN - LOCK TUBE 0.19 OD X 0.065 WALL
KIT #
#20
#20
#20
#20
#20
#20
#20
#1
QUANTITY
1
1
1
1
1
1
1
1
Chapter 4 Parts
51721268 PARTS LIST
ITEM
PART #
9.
60138273
10.
7Q072222
11.
7Q072338
12.
7Q10P338
13.
7R14P017
14.
7R546017
15.
7T2NX420
16.
7T66P350
17.
7T2N4035
19.
77041786
20.
51721268A
21.
73054999
REV. D 20120326
DESCRIPTION
STOP TUBE (WAS 6A025017)
O RING 1.50X 1.75X .12 70
O RING 3.12X 3.50X .19 70
BACKUP RING-3.12 ID X 3.50 OD
ROD WIPER - TYPE D 1.75 ROD
U-CUP SEAL (LSU) 1.50 ID X 2.00D
WEAR RING-ROD 1.75 ID X 0.50 W
PISTON SEAL-DYNAMIC 3.50" CP
WEAR RING-PISTON 3.50X3.25X.5
PRESSURE SWITCH, 2750 PSI
CYLINDER
VALVE-COUNTERBALANCE
KIT #
#1
#1
#1
#1
#1
#1
#1
#1
#1
#3
39
QUANTITY
1
1
1
1
1
1
2
1
2
1
1
1
40
IMT 4004i Technical Specifications & Parts Manual #99904386
Crane & Winch Assembly (99904327)
(See Parts List for Effectivity Dates)
CRANE & WINCH ASSEMBLY (99904327-2) (See Parts List for Effectivity Dates)
A
B
7
47
8
50 27
28
APPLY SERVICEABLE
LOCTITE TO CA P SCREW
50
27
49
52
21
48
20
9
33
45
25 46
34 35
36 23
36
22
24
5
24
42
18
22
9
16
22
41
13
18
22
50
18
20
44
23
19
11
43
40
43
41
13
1
10
30
DE TAIL B
27, 21
29, 28
27, 17
52
22
DE TAIL A
NOTE:
1
CONNECT WIRE TERMINALS (77040051) TO COMMON AND NORMALLY OPEN ON ANTI-TWO-BLOCK
SWITCH.
99904327-2 PARTS LIST
ITEM PART #
DESCRIPTION
1.
99904325
DRAWING-BASE AND MAST ASSEMBLY
2.
99904326
DWG-BOOM ASM 4004i
3.
51721321
KIT-HDRW 3203i CRANE & WINCH
5.
52725018
WELDED ASSEMBLY-ATB TRIP MECHANISM (effective from 01/09/13)
7.
71570922
WINCH-DC2000 2.1 HP 12V
8.
77041932
CONTACTOR-WINCH DC2000 (effective from 05/09/13)
9.
72034485
CLAMP-PLASTIC 1/4" CABLE
10.
77041459
SWITCH-LIMIT
11.
77441096
CONNECTOR- .50 STRAIN RELIEF .25-.38
KIT #
QTY
REF
REF
1
1
1
1
2
1
1
Chapter 4 Parts
99904327-2 PARTS LIST
ITEM PART #
DESCRIPTION
13.
71413185
SPRING-.105WIRE 0.75OD
16.
72060073
CAP SCR .44-14X 4.50 HEX HEAD GRADE 5 ZINC
17.
72062093
NUT # 8-32 HEX ZINC
18.
72062104
NUT .25-20 HEX NYLOCK (effective from 11/14/12)
19.
72062105
NUT .44-14 HEX NYLOCK
20.
72062106
NUT 10-24 HEX NYLOCK
21.
72062207
NUT 8-32 HEX NYLOCK (effective from 04/22/13)
22.
72063001
WASHER .25 FLAT (effective from 04/25/13)
23.
72063002
WASHER .31 FLAT
24.
72063004
WASHER .44 FLAT
25.
72063049
WASHER .25 LOCK (effective from 04/25/13)
27.
72063271
WASHER # 8 W FLAT ANSI B27.2Z (effective from 04/22/13)
28.
72601798
WASHER-LOCK 12MM (effective from 04/22/13)
29.
72601935
CAP SCREW M12-1.75X40 SOCKET HEAD, PLAIN
30.
72601938
BOLT-EYE #8-32 X 1.125
31.
72601941
CAP SCREW .25-20X .38 BUTTONHEAD ZINC COATED (effective from
04/22/13)
33.
72066535
CLAMP-HOSE VINYL COVERED .38
34.
51713168
CORD REEL ASM (effective from 11/14/12)
35.
60140565
BRACKET- CORD REEL MNT (effective from 11/14/12)
36.
72060003
CAP SCR .25-20 X .88 (effective from 11/14/12)
40.
72062114
NUT 0.75-10 HEX NYLOCK (effective from 01/09/13)
41.
72060209
CAP SCR 0.75-10 X 2.75 HH GR8 (effective from 01/09/13)
42.
72063008
WASHER 0.75 FLAT (effective from 01/09/13)
43.
72601942
SCR MACH #6-32 X 1.5 (effective from 01/09/13)
44.
60030484
SHEAVE 9.0 NYLATRON GSM (effective from 01/09/13)
45.
72060007
CAP SCR .25-20X 1.75 HEX HEAD GRADE 5 ZINC
46.
70034381
SUPPORT
47.
70034503
COVER-ELECTRIC CONTACTOR (effective from 05/09/13)
48.
52725097
WLDMT-WINCH CONTACTOR BRACKET (effective from 05/09/13)
49.
72601805
CAP SCR M12-1.75 X 2.5 HH2 (effective from 04/22/13)
50.
72602011
SCR-MACH #8-32 X 0.62 BTNHD (effective from 04/22/13)
52.
72060000
CAP SCR 0.25-20 X 0.50 HH GR5 (effective from 06/20/13)
REV S 20130614
KIT #
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
41
QTY
1
1
1
4
1
2
3
9
3
2
6
6
6
4
1
1
1
1
1
2
1
1
1
2
1
2
2
1
1
2
6
1
42
IMT 4004i Technical Specifications & Parts Manual #99904386
CRANE & WINCH ASSEMBLY (99904327-2)
A
B
16
31
35 48
4
27
39
13
10
27
39
21
13
8
37 32
36
33
19
29 37
23
33
19
11
1
36
22
DETAIL B
35,46
17
43,44
25
34,41
30,41
DETAIL A
NOTE:
1
CONNECT WIRE TERMINALS (77040051) TO COMMON AND NORMALLY OPEN ON ANTI-TWO-BLOCK
SWITCH.
99904327-2 PARTS LIST
ITEM PART #
DESCRIPTION
1.
99904325
DRAWING-BASE AND MAST ASSEMBLY
4.
51721494
CORD REEL ASM- 4' (effective through 11/14/12)
8.
52721275
WELDED ASSEMBLY-ATB TRIP MECHANISM (effective through
01/09/13)
10.
60132111
BRACKET- CORD REEL MNT (effective through 11/14/12)
11.
60132216
DOWNHAUL WEIGHT (effective through 11/14/12)
13.
70034381
SUPPORT
16.
71570922
WINCH-DC2000 2.1 HP 12V
17.
77041801
CONTACTOR-WINCH DC2000 (effective through 05/09/13)
19.
72034485
CLAMP-PLASTIC 1/4" CABLE
21.
72661543
PIN-QUICK 316-10QP (effective through 11/14/12)
22.
77041459
SWITCH-LIMIT
23.
77441096
CONNECTOR- .50 STRAIN RELIEF .25-.38
25.
71413185
SPRING-.105WIRE 0.75OD
27.
72060007
CAP SCR .25-20X 1.75 HEX HEAD GRADE 5 ZINC
29.
72060073
CAP SCR .44-14X 4.50 HEX HEAD GRADE 5 ZINC
30.
72062093
NUT # 8-32 HEX ZINC
31.
72062104
NUT .25-20 HEX NYLOCK (effective through 11/14/12)
32.
72062105
NUT .44-14 HEX NYLOCK
KIT #
#3
#3
#3
#3
#3
#3
QTY
REF
1
1
1
1
2
1
1
2
1
1
1
1
2
1
1
2
1
Chapter 4 Parts
99904327-2 PARTS LIST
ITEM PART #
DESCRIPTION
33.
72062106
NUT 10-24 HEX NYLOCK
34.
72062207
NUT 8-32 HEX NYLOCK (effective through 04/22/13)
35.
72063001
WASHER .25 FLAT (effective through 04/25/13)
36.
72063002
WASHER .31 FLAT
37.
72063004
WASHER .44 FLAT
39.
72063049
WASHER .25 LOCK (effective through 04/25/13)
41.
72063271
WASHER # 8 W FLAT ANSI B27.2Z (effective through 04/22/13)
43.
72601798
WASHER-LOCK 12MM (effective through 04/22/13)
44.
72601935
CAP SCREW M12-1.75X40 SOCKET HEAD, PLAIN
46.
72601941
CAP SCREW .25-20X .38 BUTTONHEAD ZINC COATED (effective
through 04/22/13)
48.
72066535
CLAMP-HOSE VINYL COVERED .38
REV. H 20110614
KIT #
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
43
QTY
2
1
11
3
2
9
2
4
4
3
1
44
IMT 4004i Technical Specifications & Parts Manual #99904386
CRANE & WINCH ASSEMBLY (99904327-3) (See Parts List for Effectivity Dates)
26
15
12
39
38
23
31
14, 25, 22
37
38
26
15
22, 25, 14
NOTES:
1
USE ANTI-SEEZ 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.
99904327-3 PARTS LIST
ITEM
PART #
DESCRIPTION
3.
51721321
KIT-HRDW 3203 CRANE & WINCH
12.
77441278
GROUND STRAP- 8IN
14.
72060002
CAP SCR .25-20X .75 HEX HEAD GRADE 5 ZINC (effective from 04/25/13)
15.
72060046
CAP SCR .38-16X 1.00 HEX HEAD GRADE 5 ZINC
22.
72063001
WASHER .25 FLAT (effective through 04/25/13)
23.
72063002
WASHER .31 FLAT
25.
72063049
WASHER .25 LOCK (effective through 04/25/13)
26.
72063051
WASHER .38 LOCK
31.
72601941
CAP SCREW .25-20X .38 BUTTONHEAD ZINC COATED (effective from
04/22/13)
37.
60140618
PIN (effective from 12/05/12)
38.
71415014
KEEPER PIN 0.38 (effective from 12/05/12)
39.
60140617
PIN (effective from 12/05/12)
51.
60140653
WELDED ASSEMBLY- COVER VALVE BANK (effective from 12/05/12)
REV S 20130614
KIT #
#3
#3
#3
#3
#3
#3
#3
QTY
1
1
4
2
9
3
6
2
1
1
2
1
1
Chapter 4 Parts
45
CRANE & WINCH ASSEMBLY (99904327-3) (See Parts List for Effectivity Dates)
42
38
42
40
28
38
7
24
46
6
26,35,39
40
28
12
26,35,39
9
26,35,39
26,35,39
NOTES:
1
USE ANTI-SEEZ 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.
99904327-3 PARTS LIST
ITEM
PART #
DESCRIPTION
6.
52721265
PIN (effective through 12/05/12)
7.
52724112
PIN (WAS 52721266) (effective through 12/05/12)
9.
52721982
WELDED ASSEMBLY- COVER VALVE BANK (effective through
12/05/12)
12.
60133631
COVER-CONTACTOR (effective through 04/25/13)
24.
77441278
GROUND STRAP- 8IN
26.
72060002
CAP SCR .25-20X .75 HEX HEAD GRADE 5 ZINC (effective through
04/25/13)
28.
72060046
CAP SCR .38-16X 1.00 HEX HEAD GRADE 5 ZINC
35.
72063001
WASHER .25 FLAT (effective through 04/25/13)
36.
72063002
WASHER .31 FLAT
38.
72063034
MACHINERY BUSHING (effective through 12/05/12)
39.
72063049
WASHER .25 LOCK (effective through 04/25/13)
40.
72063051
WASHER .38 LOCK
42.
72066125
RETAINING RING-EXT (effective through 12/05/12)
46.
72601941
CAP SCREW .25-20X .38 BUTTONHEAD ZINC COATED (effective
through 04/22/13)
REV. H 20110614
KIT #
QTY
1
1
1
#3
1
1
7
#3
#3
#3
#3
#3
#3
#3
#3
2
11
3
2
9
2
2
3
46
IMT 4004i Technical Specifications & Parts Manual #99904386
SINGLE & DOUBLE PART LINE (99904327-4) (Effective From 11/14/12)
6
4
6
DOUBLE LINE APPLICATION
4
SINGLE LINE APPLIC ATION
99904327-4 PARTS LIST
ITEM
PART #
4.
51724950
6.
70580197
REV S 20130614
DESCRIPTION
QUANTITY
SNATCH BLOCK
1
WIRE ROPE ASSEMBLY-.25(7X19GAC) X 75' RRL 1
Chapter 4 Parts
SINGLE & DOUBLE PART LINE (99904327-4) (Effective Through 11/14/12)
11
21
14
5
DOUBLE LINE
18,20
15
21
14
49
11
18,20
50
SINGLE LINE
99904327-4 PARTS LIST
ITEM
PART #
5.
52721264
11.
60132216
14.
70580197
15.
71073921
15.
51715352
18.
71734310
20.
72066144
21.
72661543
49.
71413869
REV. H 20110614
DESCRIPTION
WELDMENT-SNATCH BLOCK
DOWNHAUL WEIGHT
WIRE ROPE ASSEMBLY-.25(7X19GAC) X 75' RRL
HOOK- 2 TON SWIVEL
LATCH KIT-1.5 - 2 TON (PART OF 15)
PIN-QUICK RELEASE
HAIR PIN .16 ZINC
PIN-QUICK 316-10QP
COLLAR-SHAFT 2 PIECE 1/2"
QUANTITY
1
1
1
1
REF
1
1
1
1
47
48
IMT 4004i Technical Specifications & Parts Manual #99904386
99904327 Parts List, Complete (See Parts List for Effectivity Dates)
99904327 PARTS LIST
ITEM
PART #
1.
99904325
2.
99904326
3.
51721321
4.
51724950
5.
52725018
6.
7.
8.
70580197
71570922
77041932
9.
10.
11.
12.
13.
14.
72034485
77041459
77441096
77441278
71413185
72060002
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
72060046
72060073
72062093
72062104
72062105
72062106
72062207
72063001
72063002
72063004
72063049
72063051
72063271
72601798
72601935
72601938
72601941
32.
77040051
DESCRIPTION
DRAWING-BASE AND MAST ASSEMBLY
DRAWING-BOOM ASSEMBLY
HARDWARE KIT-CRANE & WINCH
SNATCH BLOCK (effective from 11/14/12)
WELDED ASSEMBLY-ATB TRIP MECHANISM (effective from
01/09/13)
WIRE ROPE ASM-.25(7X19GAC) X 75' RRL
WINCH-DC2000 2.1 HP 12V
CONTACTOR-WINCH DC2000
(effective from 05/09/13)
CLAMP-PLASTIC 1/4" CABLE
SWITCH-LIMIT
CONNECTOR- .50 STRAIN RELIEF .25-.38
GROUND STRAP- 8IN
SPRING-.105WIRE 0.75OD
CAP SCR .25-20X .75 HEX HEAD GRADE 5 ZINC
(effective through 04/25/13)
CAP SCR .38-16X 1.00 HEX HEAD GRADE 5 ZINC
CAP SCR .44-14X 4.50 HEX HEAD GRADE 5 ZINC
NUT # 8-32 HEX ZINC
NUT .25-20 HEX NYLOCK (effective through 11/14/12)
NUT .44-14 HEX NYLOCK
NUT 10-24 HEX NYLOCK
NUT 8-32 HEX NYLOCK (effective through 04/22/13)
WASHER .25 FLAT (effective from 04/25/13)
WASHER .31 FLAT
WASHER .44 FLAT
WASHER .25 LOCK (effective from 04/25/13)
WASHER .38 LOCK
WASHER # 8 W FLAT ANSI B27.2Z (effective through 04/22/13)
WASHER-LOCK 12MM (effective from 04/22/13)
CAP SCREW M12-1.75X40 SOCKET HEAD, PLAIN
BOLT-EYE # 8-32X .75
CAP SCREW .25-20X .38 BUTTONHEAD ZINC COATED (effective
from 04/22/13)
TERMINAL
KIT #
QTY
REF
REF
1
1
1
33.
72066535
CLAMP-HOSE VINYL COVERED .38
1
34.
35.
36.
51713168
60140565
72060003
CORD REEL ASM (effective from 11/14/12)
BRKT-CORD REEL MNT 3203I
CAP SCR 0.25-20 X 0.88 (effective from 11/14/12)
1
1
2
37.
38.
60140618
71415014
PIN (effective from 12/05/12)
KEEPER PIN 0.38 (effective from 12/05/12)
39.
40.
60140617
72062114
PIN (effective from 12/05/12)
NUT 0.75-10 HEX NYLOCK (effective from 01/09/13)
1
1
1
#3
#3
2
1
1
1
1
4
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
2
1
1
4
1
2
3
9
3
2
6
2
2
6
4
1
1
#3
2
#3
1
2
#3
1
1
Chapter 4 Parts
49
99904327 PARTS LIST
ITEM
PART #
DESCRIPTION
41.
72060209
CAP SCR 0.75-10 X 2.75 HH GR8
KIT #
#3
QTY
1
42.
72063008
WASHER 0.75 FLAT (effective from 01/09/13)
#3
1
43.
72601942
SCR-MACH #6-32 X 1.5 (effective from 01/09/13)
#3
2
44.
60030484
SHEAVE-9.0 NYLATRON GSM (effective from 01/09/13)
45.
46.
47.
72060007
70034381
70034503
CAP SCR .25-20X 1.75 HEX HEAD GRADE 5 ZINC
SUPPORT
COVER – ELEC CONTACTOR (effective from 05/09/13)
48.
52725097
WLDMT – WINCH CONTACTOR BRKT (effective from 05/09/13)
49.
72601805
CAP SCR M12-1.75 X 25 HH2 (effective from 04/22/13)
#3
2
50.
72602011
SCR-MACH #8-32 X 0.62 (effective from 04/22/11)
#3
6
51.
52.
60140653
72060000
WELDED ASSEMBLY- COVER VALVE BANK (effective from 12/05/12)
CAP SCR 0.25-20 X 0.50 HH GR5 (effective from 06/20/13)
REV H 20110614
1
#3
2
2
1
1
1
1
50
IMT 4004i Technical Specifications & Parts Manual #99904386
99904327 Parts List, Complete (See Parts List for Effectivity Dates)
99904327 PARTS LIST
ITEM
PART #
1.
99904325
2.
99904326
3.
51721321
4.
51721494
5.
52721264
6.
52721265
7.
52724112
8.
52721275
9.
52721982
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
60132111
60132216
60133631
70034381
70580197
71073921
51715352
71570922
77041801
71734310
72034485
72066144
72661543
77041459
77441096
77441278
71413185
72060002
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
72060007
72060046
72060073
72062093
72062104
72062105
72062106
72062207
72063001
72063002
72063004
72063034
72063049
72063051
72063271
DESCRIPTION
DRAWING-BASE AND MAST ASSEMBLY
DRAWING-BOOM ASSEMBLY
HARDWARE KIT-CRANE & WINCH
CORD REEL ASM- 4' (effective through 11/14/12)
WLDMT-SNATCH BLOCK (effective through 11/14/12)
PIN (effective through 12/05/12)
PIN (WAS 52721266) (effective through 12/05/12)
WELDED ASSEMBLY-ATB TRIP MECHANISM (effective through
01/09/13)
WELDED ASSEMBLY- COVER VALVE BANK (effective through
12/05/12)
BRACKET- CORD REEL MNT (effective through 11/14/12)
DOWNHAUL WEIGHT (effective through 11/14/12)
COVER-CONTACTOR (effective through 04/25/13)
SUPPORT
WIRE ROPE ASM-.25(7X19GAC) X 75' RRL
HOOK- 2 TON SWVL (effective through 11/14/12)
LATCH KIT-1.5 - 2 TON (PART OF 15) (effective through 11/14/12)
WINCH-DC2000 2.1 HP 12V
CONTACTOR-WINCH DC2000 (effective through 05/09/13)
PIN-QUICK RELEASE (effective through 11/14/12)
CLAMP-PLASTIC 1/4" CABLE
HAIR PIN .16 ZINC (effective through 11/14/12)
PIN-QUICK 316-10QP (effective through 11/14/12)
SWITCH-LIMIT
CONNECTOR- .50 STRAIN RELIEF .25-.38
GROUND STRAP- 8IN
SPRING-.105WIRE 0.75OD
CAP SCR .25-20X .75 HEX HEAD GRADE 5 ZINC
(effective through 04/25/13)
CAP SCR .25-20X 1.75 HEX HEAD GRADE 5 ZINC
CAP SCR .38-16X 1.00 HEX HEAD GRADE 5 ZINC
CAP SCR .44-14X 4.50 HEX HEAD GRADE 5 ZINC
NUT # 8-32 HEX ZINC
NUT .25-20 HEX NYLOCK (effective through 11/14/12)
NUT .44-14 HEX NYLOCK
NUT 10-24 HEX NYLOCK
NUT 8-32 HEX NYLOCK (effective through 04/22/13)
WASHER .25 FLAT (effective through 04/25/13)
WASHER .31 FLAT
WASHER .44 FLAT
MACHINERY BUSHING (effective through 12/05/12)
WASHER .25 LOCK (effective through 04/25/13)
WASHER .38 LOCK
WASHER # 8 W FLAT ANSI B27.2Z (effective through 04/22/13)
KIT #
QTY
REF
REF
1
1
1
1
1
1
1
#3
#3
1
1
1
2
1
1
REF
1
1
1
2
1
1
1
1
1
1
7
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
#3
2
2
1
1
2
1
2
1
11
3
2
2
9
2
2
Chapter 4 Parts
99904327 PARTS LIST
ITEM
PART #
42.
72066125
43.
72601798
44.
72601935
45.
72601938
46.
72601941
51
47.
77040051
DESCRIPTION
RETAINING RING-EXT (effective through 12/05/12)
WASHER-LOCK 12MM (effective through 04/22/13)
CAP SCREW M12-1.75X40 SOCKET HEAD, PLAIN
BOLT-EYE # 8-32X .75
CAP SCREW .25-20X .38 BUTTONHEAD ZINC COATED (effective
through 04/22/13)
TERMINAL
48.
72066535
CLAMP-HOSE VINYL COVERED .38
1
49.
71413869
COLLAR-SHAFT 2 PIECE 1/2" (effective through 11/14/12)
1
50.
71073921
HOOK-SWIVEL WITH LATCH (effective through 11/14/12)
1
REV H 20110614
KIT #
#3
#3
#3
#3
#3
QTY
2
4
4
1
3
#3
2
52
IMT 4004i Technical Specifications & Parts Manual #99904386
Boom Assembly (99904326) (See Parts List for Effectivity Dates)
Boom Assembly - 1 Hydraulic & 1 Manual Extension
9
8
8
3
17
19
14
7
22
10 18
2
18
10
23
23
20
4
28
9
21
5
12
24
21
BOOMASSEMBLY
1 HYDRAULIC EXTENSION
1 MANUAL EXTENSION
22
23
23
NOTE:
1
APPLY NEVER-SEEZ.
2
INSTALL WEAR PADS AFTER INSTALLING CYLINDER.
99904326-2 PARTS LIST
ITEM PART #
DESCRIPTION
KIT #
1.
51721320
HARDWARE KIT-BOOM ASSEMBLY
2.
51725007
CYL-1.50/1.0 48.00S (effective from 01/09/13)
3.
52724109
LOWER BOOM - 4004I (WAS 52721311 THROUGH 12-29-08, 52722119
THROUGH 5-1-11)
QTY
1
1
1
4.
5.
6.
52721312
52725023
52725024
WELDMENT- 1ST EXTENSION 4004I
WELDMENT- 2ND ST EXTENSION 4004I (effective from 01/09/13)
WELDMENT-2nd STAGE MANUAL EXTENSION 4004I (effective from
01/09/13)
1
1
1
7.
8.
9.
11.
60030373
60030374
60030376
60132302
WEAR PAD- EXTENSION CYLINDER
WEAR PAD-ROUND (WAS 8, 6)
WEAR PAD-ROUND
STOP SCREW 3/8-24 X .50
1
2
2
4
Chapter 4 Parts
99904326-2 PARTS LIST
ITEM PART #
DESCRIPTION
12.
71734311
PIN-QUICK RELEASE 0.62D/4.5 CRIT
14.
72060928
CAP SCREW .50-13X 2.25 HH GR5 Z
17.
72063005
WASHER .50 FLAT
19.
72063053
WASHER .50 LOCK
20.
72066144
HAIR PIN .16 ZINC
21.
60133938
WEAR PAD-ROUND 1 X .5 X .75 L
22.
60030434
WEAR PAD-ROUND 3 X 1 X .49L
23.
60030379
WEAR PAD-ROUND 1 X .5 X .5L
24.
72661711
CLEVIS PIN 0.50 X 3.00
26.
72063051
WASHER .38 LOCK (effective from 01/09/13)
28.
70734805
COTTER PIN BOWTIE .50
REV L 20130816
53
KIT #
QTY
#1
#1
#1
1
1
1
REF
2
2
4
REF
2
REF
#1
54
IMT 4004i Technical Specifications & Parts Manual #99904386
Boom Assembly - 1 Hydraulic & 1 Manual Extension
10
9
9
3
28
24
25
27
19
8
7
31
2
11 26
2
26
16
11
32
17
25
28
32
18
18
23
23
23
21
29
4
23
10
30
5
21
14
13
30
31
32
32
NOTE:
1
APPLY NEVER-SEEZ.
2
INSTALL WEAR PADS AFTER INSTALLING CYLINDER.
99904326-2 PARTS LIST
ITEM
PART #
DESCRIPTION
1.
51721320 HARDWARE KIT-BOOM ASSEMBLY
2.
51722111 CYL-1.50/1.0 48.00S 63.88CC C (WAS 51721291 THROUGH 12-29-08)
(effective through 01/09/13)
KIT #
QTY
1
1
3.
52724109
LOWER BOOM - 4004I (WAS 52721311 THROUGH 12-29-08, 52722119
THROUGH 5-1-11)
1
4.
5.
52721312
52721313
1
1
6.
52721470
WELDMENT- 1ST EXTENSION 4004I
WELDMENT- 2ND ST EXTENSION 4004I
(effective through 01/09/13)
WELDMENT-2nd STAGE MANUAL EXTENSION 4004I (effective through
01/09/13)
1
Chapter 4 Parts
99904326-2 PARTS LIST
ITEM
PART #
DESCRIPTION
60030372 SHEAVE - 5.5 NYLATRON (PART OF 5 & 6)
7.
60010469 PIN-TYPE A 1.00X 6.25 ( 5.81)
8.
60030373 WEAR PAD- EXTENSION CYLINDER
9.
60030374 WEAR PAD-ROUND (WAS 8, 6)
10.
60030376 WEAR PAD-ROUND
11.
60132302 STOP SCREW 3/8-24 X .50
13.
71734310 PIN-QUICK RLSE .50D/3.5 CRIT (effective through 11/14/12)
16.
70034382 CAP-GREASE (effective through 01/09/13)
17.
72053507 ZERK-STR THD .25-28 (effective through 01/09/13)
18.
72060029 CAP SCREW .31-18X 2.00 HH GR5 Z
(effective through 01/09/13)
19.
72060928 CAP SCREW .50-13X 2.25 HH GR5 Z
21.
72062109 NUT .31-18 HEX NYLOCK (effective through 01/09/13)
23.
72063002 WASHER .31 FLAT (effective through 01/09/13)
24.
72063005 WASHER .50 FLAT
25.
72063034 MACHY BUSHING 1.00X10 GA NR (effective through 01/09/13)
26.
72063051 WASHER .38 LOCK (effective through 01/09/13)
27.
72063053 WASHER .50 LOCK
29.
72066144 HAIR PIN .16 ZINC
30.
60133938 WEAR PAD-ROUND 1 X .5 X .75 L
31.
60030434 WEAR PAD-ROUND 3 X 1 X .49L
32.
60030379 WEAR PAD-ROUND 1 X .5 X .5L
REV G 20110613
KIT #
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
55
QTY
2REF
1
1
2
2
4
1
1
1
2
1
2
4
1
2
4
1
REF
2
2
4
56
IMT 4004i Technical Specifications & Parts Manual #99904386
Boom Assembly - 2 Manual Extensions (See Parts List for Effectivity Dates)
8
9
10
20
18
8
3
13
18
10
18
22
20
10
18
23
10
12
4
23
9
21
5
28
24
21
22
BOOMASSEMBLY
2 MANUAL EXTENSIONS
23
23
99904326-3 PARTS LIST
ITEM
PART #
DESCRIPTION
KIT #
1.
51721320
HARDWARE KIT-BOOM ASSEMBLY
2.
51725007
CYL-1.50/1.0 48.00S 63.88CC C (WAS 51721291 THROUGH 12-2908) (effective from 01/09/13)
QTY
1
1
3.
52724109
LOWER BOOM - 4004I (WAS 52721311 THROUGH 12-29-08,
52722119 THROUGH 5-1-11)
1
4.
5.
8.
9.
52721312
52725023
60030374
60030376
WELDMENT- 1ST EXTENSION 4004I
WELDMENT- 2ND ST EXTENSION 4004I (effective from 01/09/13)
WEAR PAD-ROUND (WAS 8, 6)
WEAR PAD-ROUND
1
1
2
2
10.
12.
13.
18.
20.
60132302
71734311
71734314
72063051
72066144
STOP SCREW 3/8-24 X .50
HITCH PIN W/CLIP .62
HITCH PIN W/CLIP .62
WASHER .38 LOCK
HAIR PIN .16 ZINC
4
1
1
4
REF
#1
Chapter 4 Parts
99904326-3 PARTS LIST
ITEM
PART #
DESCRIPTION
21.
60133938
WEAR PAD-ROUND 1 X .5 X .75 L
22.
60030434
WEAR PAD-ROUND 3 X 1 X .49L
23.
60030379
WEAR PAD-ROUND 1 X .5 X .5L
24.
72661711
CLEVIS PIN 0.50 X 3.00
28..
70734805
COTTER PIN BOWTIE .50
REV L 20130816
KIT #
57
QTY
2
2
4
REF
REF
58
IMT 4004i Technical Specifications & Parts Manual #99904386
Boom Assembly - 2 Manual Extensions (See Parts List for Effectivity Dates)
9
10
11
29
9
26
3
15
26
11
26
29
31
11
26
32
14
4
16
11
23
32
17
30
23
18
10
18
21
23
29
5
23
30
21
31
32
32
99904326-3 PARTS LIST
ITEM PART #
DESCRIPTION
1.
51721320
HARDWARE KIT-BOOM ASSEMBLY
2.
51722111
CYL-1.50/1.0 48.00S 63.88CC C (WAS 51721291 THROUGH 12-29-08)
(effective through 01/09/13)
KIT #
QTY
1
1
3.
52724109
LOWER BOOM - 4004I (WAS 52721311 THROUGH 12-29-08, 52722119
THROUGH 5-1-11)
1
4.
5.
9.
10.
52721312
52721313
60030374
60030376
WELDMENT- 1ST EXTENSION 4004I
WELDMENT- 2ND ST EXTENSION 4004I (effective through 01/09/13)
WEAR PAD-ROUND
WEAR PAD-ROUND
1
1
2
2
Chapter 4 Parts
99904326-3 PARTS LIST
ITEM PART #
DESCRIPTION
11.
60132302
STOP SCREW 3/8-24 X .50
13.
71734310
PIN-QUICK RLSE .50D/3.5 CRIT
(effective through 11/14/12)
14.
71734311
HITCH PIN W/CLIP .62
15.
71734314
HITCH PIN W/CLIP .62
16.
70034382
CAP-GREASE (effective through 01/09/13)
17.
72053507
ZERK-STR THD .25-28 (effective through 01/09/13)
18.
72060029
CAP SCREW .31-18X 2.00 HH GR5 Z (effective through 01/09/13)
21.
72062109
NUT .31-18 HEX NYLOCK (effective through 01/09/13)
23.
72063002
WASHER .31 FLAT (effective through 01/09/13)
26.
72063051
29.
72066144
30.
60133938
31.
60030434
32.
60030379
REV G 20110613
WASHER .38 LOCK
HAIR PIN .16 ZINC
WEAR PAD-ROUND 1 X .5 X .75 L
WEAR PAD-ROUND 3 X 1 X .49L
WEAR PAD-ROUND 1 X .5 X .5L
KIT #
#1
#1
#1
#1
#1
#1
59
QTY
4
1
1
1
1
1
2
2
4
4
REF
2
2
4
60
IMT 4004i Technical Specifications & Parts Manual #99904386
BOOM ASSEMBLY, 1 HYDRAULIC EXTENSION (See Parts List for Effectivity Dates)
9
8
3
8
7
17
19
14
28
2
24
9
6
21
BOOMASSEMBLY
1 HYDRAULIC EXTENSION
21
99904326-4 PARTS LIST
ITEM PART #
DESCRIPTION
1.
51721320 HARDWARE KIT-BOOM ASSEMBLY
2.
51725007 CYL-1.50/1.0 48.00S 63.88CC C (WAS 51721291 THROUGH 12-29-08)
(effective from 01/09/13)
KIT #
QTY
1
1
3.
52724109
LOWER BOOM - 4004I (WAS 52721311 THROUGH 12-29-08, 52722119
THROUGH 5-1-11)
1
6.
7.
8.
9.
14.
52725024
60030373
60030374
60030376
72060928
WELDMENT-2nd STAGE MANUAL EXTENSION (effective from 01/09/13)
WEAR PAD- EXTENSION CYLINDER
WEAR PAD-ROUND
WEAR PAD-ROUND
CAP SCREW .50-13X 2.25 HH GR5 Z
1
1
2
2
1
17.
19.
20.
72063005
72063053
72066144
WASHER .50 FLAT
WASHER .50 LOCK
HAIR PIN .16 ZINC
21.
60133938 WEAR PAD-ROUND 1.0 X 0.5 X 0.75L
24.
72661711 CLEVIS PIN 0.5 X 3.0
28.
70734805 COTTER PIN BOWTIE .50
REV L 20130816
#1
#1
#1
1
1
REF
2
REF
REF
Chapter 4 Parts
61
BOOM ASSEMBLY, 1 HYDRAULIC EXTENSION (See Parts List for Effectivity Dates)
10
9
3
9
19
28
27
24
25
8
7
23
21
18,23
16
29
17
23
21
2
25
28
13
6
10
30
30
99904326-4 PARTS LIST
ITEM PART #
DESCRIPTION
1.
51721320
HARDWARE KIT-BOOM ASSEMBLY
2.
51722111
CYL-1.50/1.0 48.00S 63.88CC C (WAS 51721291 THROUGH 12-29-08)
(effective through 01/09/13)
KIT #
QTY
1
1
3.
52724109
LOWER BOOM - 4004I (WAS 52721311 THROUGH 12-29-08, 52722119
THROUGH 5-1-11)
1
6.
52721470
1
7.
8.
60030372
60010469
60030373
WELDMENT-2nd STAGE MANUAL EXTENSION 4004I (effective through
01/09/13)
SHEAVE - 5.5 NYLATRON (PART OF 5 & 6)
PIN-TYPE A 1.00X 6.25 ( 5.81) (effective through 01/09/13)
WEAR PAD- EXTENSION CYLINDER
2REF
1
1
62
IMT 4004i Technical Specifications & Parts Manual #99904386
99904326-4 PARTS LIST
ITEM PART #
DESCRIPTION
9.
60030374
WEAR PAD-ROUND
10.
60030376
WEAR PAD-ROUND
13.
71734310
PIN-QUICK RLSE .50D/3.5 CRIT (effective through 11/14/12)
16.
70034382
CAP-GREASE (effective through 01/09/13)
17.
72053507
ZERK-STR THD 0.25-28
18.
72060029
CAP SCREW .31-18X 2.00 HH GR5 Z
19.
72060928
CAP SCREW .50-13X 2.25 HH GR5 Z
21.
23.
72062109
72063002
24.
72063005
25.
72063034
27.
72063053
28.
72066125
29.
72066144
30.
60133938
REV G 20110613
KIT #
QTY
2
2
1
#1
#1
#1
1
2
1
NUT .31-18 HEX NYLOCK
WASHER .31 FLAT
#1
#1
2
4
WASHER .50 FLAT
MACHY BUSHING 1.00X10 GA NR (effective through 01/09/13)
WASHER .50 LOCK
RETAINING RING-EXT 1.00 HD (effective through 01/09/13)
HAIR PIN .16 ZINC
WEAR PAD-ROUND 1.0 X 0.5 X 0.75L
#1
#1
#1
#1
1
2
1
2
REF
2
Chapter 4 Parts
63
BOOM ASSEMBLY, 1 MANUAL EXTENSION (Effective from 01/09/13)
8
9
20
8
10
18
3
18
10
13
28
6
24
9
BOOMASSEMBLY
1 MANUAL EXTENSION
21
21
99904326-5 PARTS LIST
ITEM
PART #
DESCRIPTION
1.
51721320
HARDWARE KIT-BOOM ASSEMBLY
3.
52724109
LOWER BOOM - 4004I (WAS 52721311 THROUGH 12-29-08,
52722119 THROUGH 5-1-11)
6.
52725024
WELDMENT-2nd STAGE MANUAL EXTENSION 4004I
8.
60030374
WEAR PAD-ROUND
9.
60030376
WEAR PAD-ROUND
11.
60132302
STOP SCREW 3/8-24 X .50
13.
71734314
HITCH PIN W/CLIP .62
14.
72060928
CAP SCREW .50-13X 2.25 HH GR5 Z
20.
72066144
21.
60133938
24.
72661711
28.
70734805
REV L 20130816
HAIR PIN .16 ZINC
WEAR PAD-ROUND 1 X .5 X .75 L
CLEVIS PIN 0.5 X 3.0
COTTER PIN BOWTIE .50
KIT #
#1
QTY
1
1
1
2
2
2
1
1
REF
2
REF
REF
64
IMT 4004i Technical Specifications & Parts Manual #99904386
BOOM ASSEMBLY, 1 MANUAL EXTENSION (See Parts List for Effectivity Dates)
9
10
29
9
11
26
26
3
11
15
18,23
23
21
29
23
21
6
13
16 17
10
30
30
99904326-5 PARTS LIST
ITEM PART #
DESCRIPTION
1.
51721320 HARDWARE KIT-BOOM ASSEMBLY
3.
52724109 LOWER BOOM - 4004I (WAS 52721311 THROUGH 12-29-08, 52722119
THROUGH 5-1-11)
6.
52721470 WELDMENT-2nd STAGE MANUAL EXTENSION 4004I (effective through
01/09/13)
60030372 SHEAVE - 5.5 NYLATRON (PART OF 5 & 6)
9.
60030374 WEAR PAD-ROUND
10.
60030376 WEAR PAD-ROUND
11.
60132302 STOP SCREW 3/8-24 X .50
13.
71734310 PIN-QUICK RLSE .50D/3.5 CRIT (effective through 11/14/12)
15.
71734314 HITCH PIN W/CLIP .62
16.
70034382 CAP-GREASE (effective through 01/09/13)
17.
72053507 ZERK-STR THD .25-28 (effective through 01/09/13)
18.
72060029 CAP SCREW .31-18X 2.00 HH GR5 Z (effective through 01/09/13)
KIT #
QTY
1
1
1
#1
#1
#1
2REF
2
2
2
1
1
1
1
2
19.
72060928
CAP SCREW .50-13X 2.25 HH GR5 Z
#1
1
21.
72062109
NUT .31-18 HEX NYLOCK (effective through 01/09/13)
#1
2
Chapter 4 Parts
99904326-5 PARTS LIST
ITEM PART #
DESCRIPTION
23.
72063002 WASHER .31 FLAT (effective through 01/09/13)
26.
72063051 WASHER .38 LOCK
29.
72066144 HAIR PIN .16 ZINC
30.
60133938 WEAR PAD-ROUND 1 X .5 X .75 L
REV G 20110613
KIT #
#1
#1
65
QTY
4
2
REF
2
66
IMT 4004i Technical Specifications & Parts Manual #99904386
BOOM ASSEMBLY, 1 HYDRAULIC, 1 MANUAL EXTENSION (Effective from 01/09/13)
20
10
18 25
18
10
12
24
16
15
16
27
16
15
BOOMASSEMBLY
1 HYDRAULIC EXTENSION
1 MANUAL EXTENSION
16
27
99904326-6 PARTS LIST
ITEM
PART #
DESCRIPTION
1.
51721320
HARDWARE KIT-BOOM ASSEMBLY
11.
60132302
STOP SCREW 3/8-24 X .50
12.
71734311
HITCH PIN W/CLIP .62
16.
72063001
WASHER .25 FLAT
20.
24.
72066144
72661711
27.
70034490
28.
70734805
REV L 20130816
KIT #
#1
QTY
1
2
1
4
HAIR PIN .16 ZINC
CLEVIS PIN 0.5 X 3.0
REF
REF
PLATE-ANGLE PLASTIC 3.50"
COTTER PIN BOWTIE .50
2
REF
Chapter 4 Parts
67
BOOM ASSEMBLY, 1 HYDRAULIC, 1 MANUAL EXTENSION (See Parts List for Effectivity Dates)
29
11
26
29
26
11
14
13
22
20
22
12
16
22
20
17
22
12
99904326-6 PARTS LIST
ITEM
PART #
DESCRIPTION
1.
51721320 HARDWARE KIT-BOOM ASSEMBLY
11.
60132302 STOP SCREW 3/8-24 X .50
12.
70034490 PLATE-ANGLE PLASTIC 3.50"
13.
71734310 PIN-QUICK RLSE .50D/3.5 CRIT (effective through 11/14/12)
14.
71734311 HITCH PIN W/CLIP .62
16.
70034382 CAP-GREASE (effective through 01/09/13)
17.
72053507 ZERK-STR THD .25-28 (effective through 01/09/13)
22.
72063001 WASHER .25 FLAT
26.
72063051
29.
72066144
REV G 20110613
WASHER .38 LOCK
HAIR PIN .16 ZINC
KIT #
#1
#1
#1
QUANTITY
1
2
2
1
1
1
1
4
#1
4
REF
68
IMT 4004i Technical Specifications & Parts Manual #99904386
BOOM ASSEMBLY, MANUAL EXTENSIONS (Effective from 01/09/13)
28
20
10
18
20
18
10
12
10
18
15 16
27
18
10
24
16
13
BOOMASSEMBLY
MANUAL EXTENSIONS
16
27
16 15
99904326-7 PARTS LIST
ITEM
PART #
DESCRIPTION
1.
51721320
HARDWARE KIT-BOOM ASSEMBLY
10.
60132302
STOP SCREW 3/8-24 X .50
12.
71734311
HITCH PIN W/CLIP .62
13.
71734314
HITCH PIN W/CLIP .62
18.
72063051
WASHER .38 LOCK
20.
72066144
HAIR PIN .16 ZINC
24.
72661711
CLEVIS PIN .50 X 3.00
27.
70034490
PLATE-ANGLE PLASTIC 3.50”
28.
70734805
COTTER PIN BOWTIE .50
REV L 20130816
KIT #
#1
QTY
1
4
1
1
4
REF
REF
2
REF
Chapter 4 Parts
69
BOOM ASSEMBLY, MANUAL EXTENSIONS (See Parts List for Effectivity Dates)
29
29
11
29
26
26
11
11
14
26
26
11
20
22
12
13
22
15
17
16
22
12
22 20
99904326-7 PARTS LIST
ITEM
PART #
DESCRIPTION
1.
51721320
HARDWARE KIT-BOOM ASSEMBLY
10.
60132302
STOP SCREW 3/8-24 X .50
13.
71734310
PIN-QUICK RLSE .50D/3.5 CRIT (effective through 11/14/12)
14.
71734311
HITCH PIN W/CLIP .62
15.
71734314
HITCH PIN W/CLIP .62
16.
70034382
CAP-GREASE (effective through 01/09/13)
17.
72053507
ZERK-STR THD .25-28 (effective through 01/09/13)
26.
72063051
WASHER .38 LOCK
27.
70034490
PLATE-ANGLE PLASTIC 3.50"
29.
72066144
HAIR PIN .16 ZINC
REV G 20110613
KIT #
#1
#1
#1
QUANTITY
1
4
1
1
1
1
1
4
2
REF
70
IMT 4004i Technical Specifications & Parts Manual #99904386
99904326 Parts List, Complete (Effective from 01/09/13)
99904326 PARTS LIST
ITEM
PART #
DESCRIPTION
1.
51721320
HARDWARE KIT-BOOM ASSEMBLY
2.
51725007
CYL-1.50/1.0 48.00S 63.88CC C (WAS 51721291 THROUGH 12-29-08)
3.
52724109
LOWER BOOM - 4004I (WAS 52721311 THROUGH 12-29-08, 52722119
THROUGH 5-1-11)
4.
52721312
WELDMENT- 1ST EXTENSION 4004I
5.
52725023
WELDMENT- 2ND ST EXTENSION 4004I
6.
52725024
WELDMENT-2nd STAGE MANUAL EXTENSION 4004I
7.
60030373
WEAR PAD- EXTENSION CYLINDER
8.
60030374
WEAR PAD-ROUND (WAS 8, 6)
9.
60030376
WEAR PAD-ROUND
10.
60132302
STOP SCREW 3/8-24 X .50
12.
71734311
HITCH PIN W/CLIP .62
13.
71734314
HITCH PIN W/CLIP .62
14.
72060928
CAP SCREW .50-13X 2.25 HH GR5 Z
15.
72062104
NUT .25-20 HEX NYLOCK
16.
72063001
WASHER .25 FLAT
17.
72063005
WASHER .50 FLAT
18.
72063051
WASHER .38 LOCK
19.
72063053
WASHER .50 LOCK
20.
72066144
HAIR PIN .16 ZINC
21.
60133938
WEAR PAD-ROUND 1 X .5 X .75 L
22.
60030434
WEAR PAD-ROUND 3 X 1 X .49L
23.
60030379
WEAR PAD-ROUND 1 X .5 X .5L
24.
72661711
CLEVIS PIN 0.5 X 3.0
27.
70034490
PLATE-ANGLE PLASTIC 3.50"
28.
70734805
COTTER PIN BOWTIE .50
REV L 20130816
KIT #
#1
#1
#1
#1
#1
#1
QTY
1
1
1
1
1
1
1
2
2
4
1
1
1
2
4
1
4
1
REF
2
2
4
REF
2
REF
Chapter 4 Parts
71
99904326 Parts List, Complete (See Parts List for Effectivity Dates)
99904326 PARTS LIST
ITEM
PART #
DESCRIPTION
1.
51721320
HARDWARE KIT-BOOM ASSEMBLY
2.
51722111
CYL-1.50/1.0 48.00S 63.88CC C (WAS 51721291 THROUGH 12-29-08)
(effective through 01/09/13)
3.
52724109
LOWER BOOM - 4004I (WAS 52721311 THROUGH 12-29-08, 52722119
THROUGH 5-1-11)
4.
52721312
WELDMENT- 1ST EXTENSION 4004I
5.
52721313
WELDMENT- 2ND ST EXTENSION 4004I
(effective through 01/09/13)
6.
52721470
WELDMENT-2nd STAGE MANUAL EXTENSION 4004I (effective through
01/09/13)
60030372
SHEAVE - 5.5 NYLATRON (PART OF 5 & 6)
7.
60010469
PIN-TYPE A 1.00X 6.25 ( 5.81) (effective through 01/09/13)
8.
60030373
WEAR PAD- EXTENSION CYLINDER
9.
60030374
WEAR PAD-ROUND (WAS 8, 6)
10.
60030376
WEAR PAD-ROUND
11.
60132302
STOP SCREW 3/8-24 X .50
12.
70034490
PLATE-ANGLE PLASTIC 3.50"
13.
71734310
PIN-QUICK RLSE .50D/3.5 CRIT (effective through 11/14/12)
14.
71734311
HITCH PIN W/CLIP .62
15.
71734314
HITCH PIN W/CLIP .62
16.
70034382
CAP-GREASE (effective through 01/09/13)
17.
72053507
ZERK-STR THD .25-28 (effective through 01/09/13)
18.
72060029
CAP SCREW .31-18X 2.00 HH GR5 Z (effective through 01/09/13)
19.
72060928
CAP SCREW .50-13X 2.25 HH GR5 Z
20.
72062104
NUT .25-20 HEX NYLOCK
21.
72062109
NUT .31-18 HEX NYLOCK (effective through 01/09/13)
22.
72063001
WASHER .25 FLAT
23.
72063002
WASHER .31 FLAT (effective through 01/09/13)
24.
72063005
WASHER .50 FLAT
25.
72063034
MACHY BUSHING 1.00X10 GA NR (effective through 01/09/13)
26.
72063051
WASHER .38 LOCK
27.
72063053
WASHER .50 LOCK
28.
72066125
RETAINING RING-EXT 1.00 HD (effective through 01/09/13)
29.
72066144
HAIR PIN .16 ZINC
30.
60133938
WEAR PAD-ROUND 1 X .5 X .75 L
31.
60030434
WEAR PAD-ROUND 3 X 1 X .49L
32.
60030379
WEAR PAD-ROUND 1 X .5 X .5L
REV. G 20110613
KIT #
QTY
1
1
1
1
1
1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
2REF
1
1
2
2
4
2
1
1
1
1
1
2
1
2
2
4
4
1
2
4
1
2
REF
2
2
4
72
IMT 4004i Technical Specifications & Parts Manual #99904386
Cylinder, Extension (51725007)
(Effective 01-09-13)
3
5
9
6
14
13
13
7
10
12
15
4
11
2
8
A
8
11.13 ±0.100 CLOSED
48.00 ±0.100 STROKE
59.13 ±0.200 OPEN
3.50
3.50
11
4 15 12 10
A
SECTION A- A
6
7
13
14
9
13
5
3
Chapter 4 Parts
73
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 148 cm (58.25") LONG
ø2.54 cm (1") X 155 cm (61") 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
ITEM
PART #
1.
94397290
2.
52722110
3.
52725008
4.
60135105
5.
60132170
6.
60132173
7.
60135106
8.
73054999
9.
76397127
10.
76397128
11.
76397129
12.
76534502
13.
76534503
14.
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
QUANTITY
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
74
IMT 4004i Technical Specifications & Parts Manual #99904386
Cylinder, Extension (51722111) (Through 01-09-13)
3
5
9
7
13
6
10
12
15
4
11
8
7.16 - 7.60" CLOSED
55.24 - 55.52" OPEN
47.92 - 48.08" STROKE
8
4 15
111210
NOTES:
6
14 13 9 13 7 5 3
13
Chapter 4 Parts
75
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
ITEM
PART #
1.
94397290
2.
52722110
3.
52721293
4.
60135105
5.
60132170
6.
60132173
7.
60135106
8.
73054999
9.
76397127
10.
76397128
11.
76397129
12.
76534502
13.
76534503
14.
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
QUANTITY
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
76
IMT 4004i Technical Specifications & Parts Manual #99904386
Cylinder, Extension (51721291) (Through 12-29-08)
63.88" CLOSED - 111.88" OPEN
8
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
51721291 PARTS LIST
ITEM
PART #
1.
94397290
2.
52721292
3.
52721293
4.
60131651
5.
60132170
6.
60132173
7.
60132177
8.
73054999
9.
76397127
10.
76397128
11.
76397129
12.
76534502
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)
DESCRIPTION
IMT SEAL KIT
ROD ASSEMBLY
CASE ASSEMBLY
HEAD
STINGER LOCK
STOP TUBE
PISTON
VALVE-COUNTERBALANCE
WEAR RING-PISTON
WEAR RING-ROD
ROD WIPER
U-CUP LOADED
KIT #
#1
#1
#1
#1
QUANTITY
1
1
1
1
1
1
1
1
1
1
1
1
Chapter 4 Parts
51721291 PARTS LIST
ITEM
PART #
13.
76534503
14.
7Q072018
15.
7Q072129
NEW 20080314
DESCRIPTION
U-CUP LOADED
O RING
O RING
KIT #
#1
#1
#1
77
QUANTITY
2
1
1
78
IMT 4004i Technical Specifications & Parts Manual #99904386
Winch (71570922)
SPACER (QTY 3)
32000212
BUSHING
BOLT (QTY 3)
ROD
SCREW (X5)
TAG
32000388
SEAL
RING GEAR
BOLT (QTY 3)
DRUM
SUPPORT
76394906
GASKET
76394906 GASKET
GEAR
INPUT
76394906 GASKET
BRAKE ASM
77056662
GEAR HOUSING
CARRIER ASM
CLUTCH
RING GEAR 32000480
THRUST
WASHER
CAPSCREW
(QTY 10)
MOTOR
73511210
PLUG
WINCH REPLACEMENT PARTS
BRAKE - IMT # 77056662
MOTOR - IMT # 73511210
CONTACTOR - IMT # 77041862
NOTE: For 24V systems use 71571008
DRUM
SUPPORT
32000480
THRUST WASHER
DRUM
Chapter 4 Parts
79
Power Unit (7351128312V & 7351130524v)
(Effective 10/11/12)
NOTE: Pump pressure relief valve setting = 2500 psi (172 bar)
73511283 (12V) & 73511305 (24V) PARTS LIST
ITEM
PART #
DESCRIPTION
1.
77043065
MOTOR 12VDC
1.
77043066
MOTOR 24VDC
2.
73511306
PUMP
3.
73540517
RELIEF VALVE ASSEMBLY
4.
74399495
RESERVOIR
5.
70734788
BREATHER CAP
6.
73734791
TUBE-SUCTION
7.
70734792
STRAINER
NEW 20130809
KIT #
QUANTITY
A/R
A/R
1
1
1
1
1
1
80
IMT 4004i Technical Specifications & Parts Manual #99904386
Power Unit (73511169) (Through 10/11/12)
BREATHER CAP
(70733826)
FAN SHROUD
RESERVOIR
(74397392)
D.C. MOTOR
(77043060)
(12 VDC)
RELIEF
VALVE
(73540323)
ADAPTOR
RETURN
LINE PIPE,
RELIEF VALVE
D.C. MOTOR
(77043060)
(12 VDC)
MOTOR SECTION
GEAR PUMP
(73511171)
RETURN LINE PIPE
ADAPTER / RESERVOIR
SECTION
NOTE: Pump pressure relief valve setting = 2500 psi (172 bar)
SUCTION
LINE PIPE
TUBE KIT (73734458)
(SUCTION & RETURN LINE PIPES)
Chapter 4 Parts
81
Hydraulic Installation (99904388)
VALVE BANK (99904388-2)
HYD
MOTOR
(PORT A)
EXT CYL
RETRACT
PORT
LOWER CYL
RETRACT
PORT
PRESSURE
TANK
(RETURN)
HYD
MOTOR
(PORT B)
EXTENSION OUT
EXTENSION IN
BOOM UP
ROTATION
CW
EXT CYL
EXTEND
PORT
ROTATION CCW
BOOM DOWN
LOWER CYL
EXTEND
PORT
82
IMT 4004i Technical Specifications & Parts Manual #99904386
1H1M ON/OFF RADIO CONTROL / TETHERED CONTROL (99904388-3) (Effective 04/25/13)
EXTENSION CYLINDER
16
13
34
35
7
12
EXTEND PO RT
12
12
RETRAC T PO RT
2
12
12
20
14
17
6
9
19
12
10
12
11
11
WITH EXTENSION CYLINDER
FRON T OF MAS T
8
VALVE BANK
14
VALVE BANK
(PO RT B1)
12
EXTENSION CYLINDER (PO
RT R)
12 EXTENSION CYLINDER (PO
16
17
15
15
7
RT E)
13
18
POWER UNI T &
HYDRAULIC RESEVIOR
VALVE BANK
(PO RT A1)
15
12
9
8
35
6
HYDRAULIC MO TOR
REAR OF MAS T
WITHOU T PROPO RTIONA L VALVE
12
TO LOWER CYLINDER (PO
RT R)
19
12
TO LOWER CYLINDER (PO
RT E)
TO VALVE BANK (PO RT B2)
10
TO VALVE BANK (PO RT A2)
12
20, 2
12
1H1M
ON/OFF RADIO
TETHERED
11
11
Chapter 4 Parts
83
1H1M ON/OFF RADIO CONTROL / TETHERED CONTROL (99904388-3) (Through 04/25/13)
POWER UNIT &
HYDRAULIC
RESERVOIR
34
13
35
VALVE
BANK
20 2
7
12
12
9
15
11
14
13
15
13
6
14
15
6
11
8
15
12
HYD
MOTOR
7
8
11
11
9
REAR OF MAST
WITHOUT PROPORTIONAL VALVE
VB (PORT B1)
14 EXTENSION
CYLINDER (PORT R)
16
14 EXTENSION
CYLINDER (PORT E)
17
EXT CYLINDER
EXTEND PORT
14
RETRACT 14
2,20
12
PORT
19
18
17
TO LOWER
CYLINDER (PORT R)
19
TO VALVE
BANK
(PORT B2)
TO VALVE BANK
(PORT A2)
12
VALVEBANK
(PORT A1)
16
12 VALVE 1210
BANK
12
10 TO LOWER
CYLINDER (PORT E)
12
LOWER
CYLINDER
FRONT OF MAST
WITH EXTENSION CYLINDER
12
84
IMT 4004i Technical Specifications & Parts Manual #99904386
1H1M PROPORTIONAL CONTROL (99904388-4) (Effective 04/25/13)
WITH EXTENSION CYLINDER
FRON T OF MAS T
EXTENSION CYLINDER
TO VALVE BLOCK
PORT P (PRESSURE)
8
TO VALVE BLOCK
PO RT T ( TANK)
25
7 27
12
12
TO POWER UNI T
2, 31
PROPO RTIONA L VAVLE
11
14
9
12
RETRAC T PO RT
12
12
12
12
23
10
9
11
8
POWER UNI T &
HYDRAULIC RESEVIOR
22
PROPO RTIONA L VALVE
29
VALVE BANK
(PO RT B1)
12
22
15
EXTENSION CYLINDER (PO
12
33
32
29 4
RT R)
EXTENSION CYLINDER (PO
RT E)
15
16
13
17
VALVE BANK
(PO RT A1)
18
27
32
31
EXTEND PO RT
35
12
28
12
34
13
12
26
TO LOWER CYLINDER (PO
24
RT R)
23
12
TO LOWER CYLINDER (PO
TO VALVE BANK (PO RT B2)
TO VALVE BANK (PO RT A2)
10
1H1M
PROPORTIONAL VALVE
RT E)
35
25
7
4
VALVE BANK
27
24
12, 28
11 15
14
11
9
8
HYDRAULIC MO TOR
11
REAR OF MAS T
WITH PROPO RTIONA L VALVE
(SEE NOTE)
Chapter 4 Parts
85
1H1M PROPORTIONAL CONTROL (99904388-4) (Through 04/25/13)
PROPORTIONAL
VALVE
TO VALVE
BLOCK
PORT P
(PRESSURE)
34
13
25
7
12
28
35
27
FRONT OF MAST
WITH EXTENSION CYLINDER
TO POWER
UNIT
12
(RETRACT EXT CYLINDER
8
PORT) 14
14 (EXTEND PORT)
14
11
9
11
12
14
8
22
TO VALVE
BLOCK
PORT T
(TANK)
27
25
24
31,32,33
TO VALVE
BANK
(PORT B2)
TO VALVE BANK
(PORT A2)
VB
12(PORT A1)
TO LOWER
CYLINDER
(PORT R)
23
10
9
16
14 EXTENSION
CYLINDER (PORT E)
17
VB
(PORT B1)
15
15
29 4
EXTENSION
CYLINDER (PORT R)
12
TO LOWER
CYLINDER
(PORT E)
12
12
2,31
23
12
12
10
POWER UNIT &
HYDRAULIC
RESERVOIR
18
PROPORT.
VALVE
22
VALVE
BANK
29
4
27
15
12,28
11 15
14
24
35
13
25
9
7
11
11
8
HYD
MOTOR
REAR OF MAST
WITH PROPORTIONAL VALVE (NOTE)
86
IMT 4004i Technical Specifications & Parts Manual #99904386
1H/2M ON-OFF RADIO CONTROL & TETHERED CONTROL (99904388-5) (Effective 04/25/13)
VALVE BANK
20, 2
13
7
35
20
12
34
3
3
SEE NOTE #1
19
12
2
3
12
14
9
10
6
11
8
12
12
LOWER CYLINDER
WITHOU T EXTENSION CYLINDER
FRON T OF MAS T
11
POWER UNI T &
HYDRAULIC RESEVIOR
VALVE BANK
14
15
13
15
15
12
9
8
35
6
18
15
11
7
11
HYDRAULIC MO TOR
REAR OF MAS T
WITHOU T PROPO RTIONA L VALVE
12
TO LOWER CYLINDER (PO
NOTE:
1. CRANES WITHOU T EXTENSION CYLINDER USE PLUGS (72532522)
TO BLOCK HYDRAULIC PO RTS B1 & A1 ON THE VALVE BLOCK.
RT R)
12
19
TO LOWER CYLINDER (PO
TO VALVE BANK (PO RT B2)
10
RT E)
1H1M
ON OFF RADIO
TETHERED
W/OUT EXTENSION CYLINDER
TO VALVE BANK (PO RT A2)
NOTE:
1
CRANES WITHOUT EXTENSION CYLINDER USE PLUGS (72532522) TO BLOCK HYDRAULIC PORTS B1 &
A1 ON THE VALVE BLOCK.
99904388 PARTS LIST
ITEM
PART #
1.
99904327
2.
70145928
3.
72532522
4.
73540325
5.
51721540
6.
51397335
DESCRIPTION
DRAWING-CRANE & WINCH ASSEMBLY
FLOW LIMITER
PLUG-STR HEX HD STL .44
VALVE-PROP FLOW CONTROL 12V
HYDRAULIC KIT-HYD 4004I
HOSE-FZ .25 X 13.50 (4-4) 100R17
KIT #
#5
QUANTITY
REF
1
2
1
REF
1
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
HOSE-FI .25 X 12.50 (4-4) 100R17
HOSE-FJ .25 X 8.5 (4-4) 100R17
HOSE-FJ .25 X 10.75 (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
#5
#5
#5
#5
#5
#5
#5
#5
#5
#5
1
1
1
1
2
6
1
3
2
1
51397336
51397399
51397403
51397339
72053758
72532351
72532699
72533567
72533589
51395219
Chapter 4 Parts
99904388 PARTS LIST
ITEM
PART #
17.
51395872
18.
72534547
19.
51395380
20.
72532992
21.
91721626
22.
51395663
23.
51397339
24.
51397434
25.
51397452
26.
72053758
27.
72532351
28.
72532981
29.
72534477
30.
51721645
31.
7206009
32.
72063001
34.
72532674
35.
72534714
REV. K 20111031
DESCRIPTION
HOSE-FF .25 X 21.00 (4-4) 100R17
ELBOW-STREET STL .12 X 45 DEG
HOSE-FF .25 X 22.00 (4-6) 100R17
ADAPTER-M STR/F STR 4 6
KIT-HYD PROP ELEC CRANE
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 10 4
TEE-SWIVEL NUT RUN JIC 4
ADAPTER-M STR/M JIC 4 4 XLG
HARDWARE KIT-PROPORTIONAL CONTROL
VALVE ELEC CRANE
CAP SCREW .25-20X 1.75 HH GR5 Z
WASHER .25 FLAT
CAP-JIC STL 4 (.44 THD)
TEE-STL JIC/STR/JIC 4 6 4 BRANCH
KIT #
#5
#5
#5
#5
#21
#21
#21
#21
#21
#21
#21
#21
#30
#30
#5
#5
QUANTITY
1
1
1
1
REF
1
1
1
1
1
1
1
1
REF
2
2
1
1
87
88
IMT 4004i Technical Specifications & Parts Manual #99904386
1H/2M ON-OFF RADIO CONTROL & TETHERED CONTROL (99904388-5) (Through 04/25/13)
POWER UNIT &
HYDRAULIC
RESERVOIR
34
13
20 2
7
35
7
3 (NOTE)
12
12
14
6
11
13
11
9
6
VALVE
BANK
HYD
MOTOR
15
15
35
14
12
11
8 9
11
REAR OF MAST
WITHOUT PROPORTIONAL VALVE
8
15
VALVE
BANK
2,20
12
15
(NOTE) 3
18
(NOTE) 3
12
10
TO LOWER
CYLINDER (PORT R)
12
LOWER
CYLINDER
FRONT OF MAST
WITHOUT EXTENSION CYLINDER
19
12
TO VALVE
BANK (PORT B2)
10
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.
99904388 PARTS LIST
ITEM
PART #
1.
99904327
2.
70145928
3.
72532522
4.
73540325
5.
51721540
6.
51397335
DESCRIPTION
DRAWING-CRANE & WINCH ASSEMBLY
FLOW LIMITER
PLUG-STR HEX HD STL .44
VALVE-PROP FLOW CONTROL 12V
HYDRAULIC KIT-HYD 4004I
HOSE-FZ .25 X 13.50 (4-4) 100R17
KIT #
#5
QUANTITY
REF
1
2
1
REF
1
7.
8.
9.
10.
11.
12.
13.
14.
HOSE-FI .25 X 12.50 (4-4) 100R17
HOSE-FJ .25 X 8.5 (4-4) 100R17
HOSE-FJ .25 X 10.75 (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
#5
#5
#5
#5
#5
#5
#5
#5
1
1
1
1
2
6
1
3
51397336
51397399
51397403
51397339
72053758
72532351
72532699
72533567
12
19
Chapter 4 Parts
99904388 PARTS LIST
ITEM
PART #
15.
72533589
16.
51395219
17.
51395872
18.
72534547
19.
51395380
20.
72532992
21.
91721626
22.
51395663
23.
51397339
24.
51397434
25.
51397452
26.
72053758
27.
72532351
28.
72532981
29.
72534477
30.
51721645
31.
72060007
32.
72063001
33.
72063049
34.
72532674
35.
72534714
REV. K 20111031
DESCRIPTION
ADAPTER-M STR/M JIC 10 4
HOSE-FF .25 X 18.00 (4-4) 100R17
HOSE-FF .25 X 21.00 (4-4) 100R17
ELBOW-STREET STL .12 X 45 DEG
HOSE-FF .25 X 22.00 (4-6) 100R17
ADAPTER-M STR/F STR 4 6
KIT-HYD PROP ELEC CRANE
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 10 4
TEE-SWIVEL NUT RUN JIC 4
ADAPTER-M STR/M JIC 4 4 XLG
HARDWARE KIT-PROPORTIONAL CONTROL
VALVE ELEC CRANE
CAP SCREW .25-20X 1.75 HH GR5 Z
WASHER .25 FLAT
WASHER .25 LOCK
CAP-JIC STL 4 (.44 THD)
TEE-STL JIC/STR/JIC 4 6 4 BRANCH
KIT #
#5
#5
#5
#5
#5
#5
#21
#21
#21
#21
#21
#21
#21
#21
#30
#30
#30
#5
#5
QUANTITY
2
1
1
1
1
1
REF
1
1
1
1
1
1
1
1
REF
2
2
2
1
1
89
90
IMT 4004i Technical Specifications & Parts Manual #99904386
Tethered Control Installation (99904593)
(Effective 04/25/13)
8
10
5
10
7
3203i/4004i
CRANE
4
14
99904593 PARTS LIST
ITEM
PART #
DESCRIPTION
QUANTITY
2.
91725111
CONTROL KIT- TETHERED ELECTRIC CRANE 1
4.
70734746
HANDLE ASM-TETHERED ELECTRIC CRANES 1
5.
60133633
COVER- WINDOW
1
7.
72060002
CAP SCR .25-20X .75 HH GR5 Z
2
8.
72062104
NUT .25-20 HEX NYLOCK
2
10.
72063001
WASHER .25 FLAT
4
14.
7741536
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.
Chapter 4 Parts
Tethered Control Installation (99904593)
(Through 04/25/13)
6
8
3
7
8
5
4
9
10
2
3203i / 4004i
TETHERED
REMOTE
INSTALLATION
12
99904593 PARTS LIST
ITEM
PART #
DESCRIPTION
QUANTITY
1.
91721524
CONTROL KIT- TETHERED ELECTRIC CRANE 1
2.
51721502
HANDLE ASM-TETHERED ELECTRIC CRANES 1
3.
60133633
COVER- WINDOW
1
4.
71413190
RELAY-2 RELAY MODULE
1
5.
72060002
CAP SCR .25-20X .75 HH GR5 Z
2
6.
72062104
NUT .25-20 HEX NYLOCK
2
7.
72062106
NUT 10-24 HEX NYLOCK
2
8.
72063001
WASHER .25 FLAT
4
9.
72063268
WASHER #10 W FLAT ANSI B27.2Z
2
10.
72601994
SCREW-MACHINE #10-24X .75 BTNHD ZC
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.
91
92
IMT 4004i Technical Specifications & Parts Manual #99904386
Radio Control Installation, Standard
(99904594)
7
8
3
2
8
3203i / 4004i
STANDARD
RADIO CONTROL
INSTALLATION
99904594 PARTS LIST
ITEM
PART #
1.
91721523
2.
60133634
3.
70734329
4.
70734330
6
4
DESCRIPTION
CONTROL KIT- RADIO ELECTRIC CRANE
SLEEVE-TYPE C .63X .81X .31
RECEIVER - RADIO REMOTE TELE VORC
TRANSMITTER-RADIO REMOTE ELECTRIC
CRANE
CAP SCR .25-20X 2.00 HH GR5 Z
NUT .25-20 HEX NYLOCK
WASHER .25 FLAT
QUANTITY
1
2
1
1
6.
72060008
2
7.
72062104
2
8.
72063001
4
NEW 20090305
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.
Chapter 4 Parts
Radio Control Installation, Proportional
(99904595)
7
8
3
2
8
3203i / 4004i
PROPORTIONAL
RADIO CONTROL
INSTALLATION
6
4
99904595 PARTS LIST
ITEM
PART #
DESCRIPTION
QUANTITY
1.
91721644
CONTROL KIT- PROP ELECTRIC CRANE-12V
1
2.
60133634
SLEEVE-TYPE C .63X .81X .31
2
3.
70734347
RECEIVER-PROP RADIO ELECTRIC CRANE CRANE
1
4.
70734348
TRANSMITTER-RADIO ELECTRIC CRANE PROP
1
6.
72060008
CAP SCR .25-20X 2.00 HH GR5 Z
2
7.
72062104
NUT .25-20 HEX NYLOCK
2
8.
72063001
WASHER .25 FLAT
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.
93
94
IMT 4004i Technical Specifications & Parts Manual #99904386
Electrical Installation (99904392)
(See Parts List for Effectivity Dates)
5
SEE NOTE
11
12
18
19
20
16
14
10
9
19
4
MAS T
REAR PL ATE
GROUND
17
15
11
(REAR VIEW)
ELECTRIC RO TATOR BRACKE T
(TOP)
CRANE BOX
13
MAST
LH SIDE
GROUND
TORQUE TO 8-15 F T-LBS
ELECTRIC RO TATOR BRACKE T
(BOT TOM)
12
WIRE HARNESS
(RADIO & TETHERED CONTROL)
TO CRANE BOX
GROUND
WIRE HARNESS
(POWER)
TO 300 AMP KEYED SWITCH
IN CRANE BOX
15
Chapter 4 Parts
99904392 PARTS LIST
ITEM
PART #
1.
91722220
2.
71570922
3.
89034049
4.
73511283
5.
77041932
6.
51721717
7.
51721497
8.
51721498
9.
51721499
10.
51721664
11.
51721943
12.
51721944
13.
51721495
14.
51721718
15.
77441534
16.
77441312
17.
77441302
18.
77441303
19.
72060021
20.
72063050
REV H 20130619
DESCRIPTION
KIT- 4004I ELECTRICAL INSTALLATION (WAS 91721554)
WINCH-DC2000 12V
SPIRAL WRAP-BLACK
POWER UNIT- 2.65CC 12VDC GC (effective from 10/11/12)
CONTACTOR-WINCH DC2000 (effective from 05/09/13)
CABLE ASM- 2GA-5/16RNG X 3/8RNG X 26.5LG
CABLE ASM- 2GA-5/16RNG X 3/8RNG X 8.25LG
CABLE ASM- 2GA-5/16RNG X 1/4RNG X 19.00LG
CABLE ASM- 2GA-5/16RNG X 1/4RNG X 26.50LG
CABLE ASM- 1GA-5/16RNGX 1/4RNGX 48.00LG
CABLE ASM- 1GA-3/8RNGX SWVL FX 11.00LG
CABLE ASM- 1GA-3/8RNGX SWVL MX 60.00LG
CABLE ASM- 26A-5/16RNG X 3/8RNG X 22.0LG
CABLE ASM- 26A-5/16RNG X 3/8 RNG X 25.0LG
SWITCH- 275A CONTACTOR (effective from 04/25/13)
CABLE ASM-10GA #10 RING X 1/4 RING X 6 LONG
TERMINAL-INSULATED RED #8-2 GA WIRE
TERMINAL-INSULATED BLACK #8-2 GA WIRE
CAP SCR 0.31-18 X .5 HH GR5
WASHER 0.31 LOCK
95
KIT #
QITY
1
REF
1.25 FT
REF
REF
#1
#1
#1
#1
#1
#1
1
1
1
1
1
1
#1
#1
1
1
1
1
1
1
96
IMT 4004i Technical Specifications & Parts Manual #99904386
Electrical Installation (99904392)
(See Parts List for Effectivity Dates)
WRAP WINCH CABLES
WITH BLACK SPIRAL WRAP
3
8
11
12
16
17
19
4
6
20
5
MAST
REAR
2 PLATE
GROUND
9
18
21
10
14
(REAR VIEW)
ELECTRIC ROTATOR
BRACKET (TOP)
CRANE BASE
13
ELECTRIC ROTATOR
BRACKET (BOTTOM)
MAST
LH SIDE
GROUND
TORQUE TO
8-15 FT-LB
WIRE HARNESS
(RADIO CONTROL)
15
TO CRANE
BOX GROUND
WIRE HARNESS
(TETHERED CONTROL)
TO 300 AMP KEYED
SWITCH IN CRANE BOX
18
Chapter 4 Parts
99904392 PARTS LIST
ITEM
PART #
1.
91722220
2.
60133635
3.
71570922
4.
72060044
5.
72062002
6.
73511169
7.
89034049
8.
77041801
9.
51721556
10.
11.
12.
13.
14.
15.
16.
51721497
51721498
51721499
51721664
51721943
51721944
51721975
17.
51721976
18.
77441336
19.
77441312
20.
77441302
21.
77441303
REV. F 20090518
DESCRIPTION
KIT- 4004I ELECTRICAL INSTALLATION (WAS 91721554)
CONTACT JUNCTION (effective through 04/25/13)
WINCH-DC2000 12V
CAP SCR .38-16X .75 HH GR5 Z (effective through 04/25/13)
NUT .38-16 HEX (effective through 04/25/13)
POWER UNIT- 2.65CC 12VDC GC (effective through 03/27/13)
SPIRAL WRAP-BLACK
CONTACTOR-WINCH DC2000 (effective through 05/09/13)
CABLE ASM- 2GA-5/16RNG X 3/8RNG X 23.00LG
(effective through 03/27/13)
CABLE ASM- 2GA-5/16RNG X 3/8RNG X 8.25LG
CABLE ASM- 2GA-5/16RNG X 1/4RNG X 19.00LG
CABLE ASM- 2GA-5/16RNG X 1/4RNG X 26.50LG
CABLE ASM- 1GA-5/16RNGX 1/4RNGX 48.00LG
CABLE ASM- 1GA-3/8RNGX SWVL FX 11.00LG
CABLE ASM- 1GA-3/8RNGX SWVL MX 60.00LG
CABLE ASM- 2GA-5/16RNGX 3/8RNGX 19.00LG
(effective through 03/27/13)
CABLE ASM- 2GA-5/16RNGX 3/8RNGX 21.00LG
(effective through 03/27/13)
SWITCH- 275A CONTACTOR (effective through 04/25/13)
CABLE ASM-10GA #10 RING X 1/4 RING X 6 LONG
TERMINAL-INSULATED RED #8-2 GA WIRE
TERMINAL-INSULATED BLACK #8-2 GA WIRE
KIT #
97
#1
QITY
1
REF
REF
REF
REF
REF
1.25 FT
REF
1
#1
#1
#1
#1
#1
#1
#1
1
1
1
1
1
1
1
#1
1
#1
#1
1
1
1
1
98
IMT 4004i Technical Specifications & Parts Manual #99904386
225-Amp Contactor Replacement (99904578)
(Effective 04/25/13)
2
5
3
7
10
6
4
8
SWITCH MOUNTED INSIDE MAS
T
225 A CON TACTOR
NOTES:
1
THE 77441534 CONTACTOR IS SMALLER THAN THE 77441336. THE MOUNTING SPACE FOR THE
77441336 IS 3.6" HORIZONTALLY BY 2.1" VERTICALLY. THE MOUNTING SPACE FOR THE 77441534 IS
3.4" SQUARE.
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 #
DESCRIPTION
1.
91722165
HARDWARE KIT-CONTACTOR REPLACEMENT
2.
60251278
PLATE-CONTACTOR MNT
3.
72063047
WASHER #10 LOCK
4.
72063239
WASHER # 8 LOCK
5.
72063268
WASHER #10 W FLAT ANSI B27.2Z
6.
72063271
WASHER # 8 W FLAT ANSI B27.2Z
7.
72602007
SCREW-MACHINE #10-24X .62 BUTTONHEAD, ZINC-COATED
8.
72602011
SCREW-MACHINE # 8-32X .62 BUTTONHEAD, ZINC-COATED
9.
77441534
SWITCH- 225A CONTACTOR
NEW 20090210
KIT #
#1
#1
#1
#1
#1
#1
QUANTITY
1
1
4
4
4
4
4
4
1
Chapter 4 Parts
99
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.
99904578 PARTS LIST
ITEM PART #
DESCRIPTION
1.
91722165
HARDWARE KIT-CONTACTOR REPLACEMENT
2.
60251278
PLATE-CONTACTOR MNT
3.
72063047
WASHER #10 LOCK
4.
72063239
WASHER # 8 LOCK
5.
72063268
WASHER #10 W FLAT ANSI B27.2Z
6.
72063271
WASHER # 8 W FLAT ANSI B27.2Z
7.
72602007
SCREW-MACHINE #10-24X .62 BUTTONHEAD, ZINC-COATED
8.
72602011
SCREW-MACHINE # 8-32X .62 BUTTONHEAD, ZINC-COATED
9.
77441336
SWITCH- 275A CONTACTOR
NEW 20090210
KIT #
#1
#1
#1
#1
#1
#1
QUANTITY
1
1
4
4
4
4
4
4
1
100
IMT 4004i Technical Specifications & Parts Manual #99904386
B A
1
A B
2 1
2 1
2
1
2
1
2
1
2 1
2
Harness, Radio (77441270)
Chapter 4 Parts
101
SCHEMATIC, HARNESS, RADIO (77441270)
CJ-500
RADIO RECEIVER
TETHER INTER FACE
RS485 B
GROUND
RS485 A
+ B ATT
SHIELD (OPT)
N/C
N/C
1
2
GROUND
3
PROPO RTIONA L
4
N/C
CP-1200
1
2
3
4
5
POWER (RADIO)
1
2
P7
PROPO RTIONA L
5
6
1
2
RADIO RECEIVER
INTER FACE
BOOM U P
7
P1 BOOM U P
(GR AY)
BOOM DOWN
8
EXTEND OU T
9
WINCH U P
10
EXTEND IN
WINCH DOWN
1
P2
2
1
2
ROTATE CW
HYDRAULIC PUM P
CP-1201
1
P4
2
SPLICE G
2
P5 RO TATE CW
1
2
1
3
N/C
5
N/C
6
RS485 A
7
RS485 B
8
(BLACK)
N/C
9
N/C
10
W1 HYDRAULIC PUM
15A
A2B/OVERLOAD
SPLICE G
1
4
EXTEND IN
W5 WINCH DOWN
SPLICE G
2
N/C
N/C
EXTEND OU T
12
RADIO RECEIVER
INTER FACE
P3
W4 WINCH U P
11
SPLICE G
ROTATE CCW
BOOM DOWN
11
W2
POWER
12
W3
GROUND
P
P6
RO TATE CCW
B
J10
A
ANTI-TWO
A
P10
B
2800 PSI
102
IMT 4004i Technical Specifications & Parts Manual #99904386
Harness, Tethered (77441269)
2
CJ-2300
2 1
BOOM UP
1
BOOM
DOWN
2
CP-600
1
EXTEND
OUT
2
RELAY
1
HYDRAULIC
PUMP W1
2
2 1
15A
FUSE
1
ROTATE
CCW
W3
GROUND
BA
ROTATE
CW
CP-601
FUSED
POWERW2
A B
EXTEND
IN
W4 W5
WINCH UP WINCH DOWN
CRANE POWER
BOOM U P
O
1
P1 BOOM U P
2
P
BOOM DOWN
N
EXTEND OU T
B
1
P2
2
BOOM DOWN
1
P3
2
EXT OU T
2
P4
1
EX T IN
CJ-2300
TETHER HANDLE
EXTEND IN
F
RO TATE CW
A
RO TATE CCW
K
POWER
HYDRAULIC PUM
P
WINCH DOWN
WINCH U P
2
1
2
1
P6
L
B
J10
A
ANTI-TWO
S
A
P10
B
2800 PSI
C
W4 WINCH DOWN
D
W5 WINCH U P
1 2 3 4 5 6
15A
W1
W2
W3
1 2 3 4 5 6
CP-600
CP-601
REL AY MODULE
REL AY MODULE
P5 RO TATE CW
RO TATE CCW
Chapter 4 Parts
Handle Assembly, Tethered (70734746)
(Effective 04/25/13)
ROT
CCW
ROT
CW
WINCH
DOWN
WINCH
UP
EXT
OUT
BM
UP
EXT
IN
BM
DOWN
NOTE: Tethered handle assembly is non-serviceable. If damaged a new assembly is required.
103
104
IMT 4004i Technical Specifications & Parts Manual #99904386
Handle Assembly, Tethered (51721502)
(Effective Through 04/25/13)
6,9,12,27
14
29
28
POWER
OFF
ROT
CCW
CW
ON
EXT WINCH
IN DOWN LOWER
DOWN
OUT
UP
BLACK
(S) HYD
PUMP
23
4,10
25
24
UP
TO SWITCH #19
SOLDER WIRE
TO TERMINAL
2
3
13
7
8,20
21
30
26
Chapter 4 Parts
Tethered Remote Handle Assembly (51721502) (Effective Through 04/25/13)
RE D
18
RED/BLK
(WIN UP)
1 (REF) GRN
(TO ROTARY SWITCH)
BLK/ORN (CRANE PWR)
ORN/BLK (EXT OUT)
5
14
YEL (BOOM UP)
15(16)
YEL/BLK
(ROT CW)
1(6)
ORN
17
BLU/BLK
17
BRN/BLK (ROT CCW)
17
BRN (EXT IN)
WIRE FUNCTIONS
SOLID/STRIPE
A
YEL/BLK
B
ORN/BLK
C
BLU/BLK
D
RED/BLK
E
ORN/RED
F
BRN
G
BRN/RED
H
BLU/RED
J
BLK/RED
K
BRN/BLK
L
RED
M
BLU
N
ORN
O
BLK/ORN
P
YEL
Q
BRN/BLU
R
YEL/RED
S
BLK
T
BLK/BLU
U
RED/BLU
FUNCTION
ROT CW
EXT OUT
WINCH DN
WINCH UP
EXT IN
ROT CCW
POWER
LOWER DN
CRANE POWER
LOWER UP
HYD PUMP
-
105
106
IMT 4004i Technical Specifications & Parts Manual #99904386
SOLID/STRIPE
V
BLU/ORN
W
ORN/BLU
X
YEL/BLU
RED/RON
FUNCTION
-
51716404 PARTS LIST
ITEM
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
17.
18.
20.
21.
23.
24.
25.
26.
27.
PART #
60045031
60119335
60111141
60119277
70034306
70029119
77044196
77044621
70394447
70392809
77044969
72066340
72531833
72061009
77040051
77040372
77040373
77044579
89044100
77044695
70733518
51716499
72601346
70395995
28.
70143223
29.
72061000
30.
70145495
NEW 20080407
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-ELEC CRANE CONTROL
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
TERMINAL, FSLPON
BRACKET, TRIGGER (PART OF 25)
TRIGGER ASSEMBLY (INCL 3,11,24,26,28-29)
SCR-MACH #8-32 PAN HEAD (PART OF 25)
DECAL-CAUTION RC HANDLE ELEC PWR
UNIT
SPRING, TENSION (PART OF 25)
SCR-SHT METAL #6X1/2 PH (PART OF 25)
HEAT SHRINK
QUANTITY
6
1
1REF
1
1
1
1
23
1
1
1REF
2
1
8
16
4
1
1
30 FT
1
1REF
1
4REF
1
1REF
1REF
0.33 FT
NOTE: KIT # 51717816, TETHERED CABLE - 30 FEET, INCLUDES ITEMS 8, 15 (QTY 24), 20, 21, AND 30.
ORDER 51717816 TO REPLACE THE CABLE ASSEMBLY.
Chapter 4 Parts
107
4004i Decal Installation (99904410)
12
27
25
33
30
26 34
22
33
28
9
12
34
27
25
11
34
29
26
33
28
35
32
6,7,10
DECAL PLACEMENT (IF NOT SHOWN ON CRANE)
ITEM #
PLACEMENT
15,21,23,
AT OR NEAR REMOTE HANDLE STORAGE POINT
24,28,31,35
16
2 ON REAR STABILIZERS
19
AT OR NEAR DRIVELINE
18,20
ON FRONT, SIDES AND REAR OF CARRIER VEHICLE
37
ON FRONT OF CARRIER VEHICLE
36
ON CRANE POWER CABLE CONNECTION AT VEHICLE BATTERY
99904375 PARTS LIST
ITEM PART #
DESCRIPTION
1.
95719347
DECAL KIT - TELE COMMON
2.
95719348
DECAL KIT - BODY COMMON
3.
95721547
DECAL KIT - 4004i SPECIFIC
KIT #
QTY IN KIT QTY ON CRANE
1
1
1
108
IMT 4004i Technical Specifications & Parts Manual #99904386
99904375 PARTS LIST
ITEM PART #
DESCRIPTION
4.
70391612
DECAL-GREASE WEEKLY (LEFT)
5.
70391613
DECAL-GREASE WEEKLY (RIGHT)
6.
70392399
DECAL-LUBRICATE WORM
7.
70392524
DECAL-ROTATE CRANE WHILE GREAS
8.
70394166
DECAL-INSTR FOR MNL OPERATION
9.
70394443
DECAL-DANGER FREEFALLING BOOMS
10.
70395090
DECAL-GREASE WORM DR BRNGS
11.
70395324
DECAL-ASME/ANSI B30.5-TELESCOP
12.
70395670
DECAL-CAUTION DOWN HAUL WT
13.
71391522
DECAL-ANGLE INDICATOR RH
14.
71391523
DECAL-ANGLE INDICATOR LH
15.
70392213
DECAL-CAUTION DONT WASH/WAX
16.
70392864
DECAL-WARNING STAB STAND CLEAR
17.
70391598
DECAL-WARNING, MAN STAB
18.
70392868
DECAL-DANGER CR LOADLINE (TRK)
19.
70392891
DECAL-DANGER DRIVELINE
20.
70394445
DECAL-DANGER ELEC HZD LG TELES
21.
70396613
DECAL-CRANE SAFETY & OPER
22.
70394189
DECAL-MOBILOIL RESERVOIR
23.
71039134
DECAL-CAUTION OIL LEVEL
24.
70392982
DECAL-SERVICE & REPAIR
25.
71394083
DECAL-LOAD BLOCK RATING 2.0TON
26.
70397413
DECAL-DIAMOND IMT 4.5X9.0
27.
70396780
DECAL-4004i ID
28.
70397414
DECAL-CAPACITY CHART 4004i
29.
71397349
DECAL-ANGLE INDICATOR RH, SM
30.
71397350
DECAL-ANGLE INDICATOR LH, SM
31.
70397334
DECAL-WARNING, ELEC CR OL
32.
70397351
DECAL-REMOTE PENDANT STORE
33.
70397411
DECAL-GREASE WEEKLY (LH) SMALL
34.
70397412
DECAL-GREASE WEEKLY (RH) SMALL
35.
70397404
DECAL-DANGER, UNPLUG CRANE
36.
70397405
DECAL-CRANE POWER DISCONNECT
37.
70397389
DECAL-DANGER ELEC HZD MED TELE
REV A 20111211
KIT #
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
3
3
3
3
3
3
3
3
3
3
3
3
3
QTY IN KIT
9
6
1
1
1
1
1
1
2
1
1
1
4
2
4
1
4
1
1
1
1
2
2
2
2
1
1
1
1
3
3
2
1
1
QTY ON CRANE
0
0
1
1
0
1
1
1
2
0
0
1
2
0
3
1
3
1
1
1
1
2
2
2
2
1
1
1
1
3
3
2
1
1
109
CHAPTER 5
General Reference
In This Chapter
Inspection Checklist ................................................................. 109
Deficiency / Recommendation / Corrective Action Report......... 114
Thread Torques ........................................................................ 116
Turntable Bearing Thread Tightening Sequence ...................... 118
Turntable Bearing Inspection .................................................... 119
Turntable Bearing Tilt Test ....................................................... 119
Inspection Checklist
NOTICE:
The user of this form is responsible for determining that these inspections satisfy all applicable
regulatory requirements.
OWNER/COMPANY:
TYPE OF INSPECTION (circle one):
CONTACT PERSON:
DAILY
CRANE MAKE & MODEL:
DATE INSPECTED:
CRANE SERIAL NUMBER:
HOURMETER READING (if applicable):
UNIT I.D. NUMBER:
INSPECTED BY (print):
LOCATION OF UNIT:
SIGNATURE OF INSPECTOR:
MONTHLY
QUARTERLY ANNUAL
110
IMT 4004i Technical Specifications & Parts Manual #99904386
TYPE OF INSPECTION
NOTES:
Daily and monthly inspections are to be performed by a “competent person”, who is capable of identifying existing and
predictable hazards in the surroundings or working conditions which are unsanitary, hazardous, or dangerous to
employees, and who has authorization to take prompt corrective measures to eliminate them.
Quarterly and annual inspections are to be performed by a “qualified person” who, by possession of a recognized
degree, certificate, or professional standing, or who by extensive knowledge, training and experience, successfully
demonstrated the ability to solve/resolve problems relating to the subject matter, the work, or the project.
One hour of normal crane operation assumes 20 complete cycles per hour. If operation exceeds 20 cycles per hour,
inspection frequency should be increased accordingly.
Consult Operator / Service Manual for additional inspection items, service bulletins and other information.
Before inspecting and operating crane, crane must be set up away from power lines and leveled with stabilizers fully
extended.
DAILY (D): Before each shift of operation, those items designated with a (D) must be inspected.
MONTHLY (M): Monthly inspections or 100 hours of normal operation (whichever comes first) includes all daily
inspections plus items designated with an (M). This inspection must be recorded and retained for a minimum of 3
months.
QUARTERLY (Q): Every three to four months or 300 hours of normal operation (whichever comes first) includes all
daily and monthly inspection items plus items designated with a (Q). This inspection must be documented,
maintained, and retained for a minimum of 12 months, by the employer that conducts the inspection.
ANNUAL (A): Each year or 1200 hours of normal operation (whichever comes first) includes all items on this form
which encompasses daily, monthly and quarterly inspections plus those items designated by (A). This inspection must
be documented, maintained, and retained for a minimum of 12 months, by the employer that conducts the inspection.
INSPECTION CHECKLIST STATUS KEY:
S = Satisfactory
R = Recommendation
(Should be considered for corrective action)
NA = Not Applicable
X = Deficient
(NOTE: If a deficiency is found, an immediate determination must be
made as to whether the deficiency constitutes a safety hazard and
must be corrected prior to operation.)
FREQUENCY ITEM
KEY
INSPECTION DESCRIPTION
D
1
Labels
D
D
2
3
Crane
Controls
D
4
Station
D
5
D
D
6
7
Hydraulic
System
Hook
Wire Rope
All load charts, safety & warning labels, and control labels are
present and legible.
Check all safety devices for proper operation.
Control mechanisms for proper operation of all functions, leaks and
cracks.
Control and operator's station for dirt, contamination by lubricants,
and foreign material.
Hydraulic system (hoses, tubes, fittings) for leakage and proper oil
level.
Presence and proper operation of hook safety latches.
Inspect for apparent deficiencies per applicable requirements and
manufacturer’s specifications.
STATUS
(S,R,X,NA)
Chapter 5 General Reference
FREQUENCY ITEM
KEY
INSPECTION DESCRIPTION
D
8
Pins
D
9
General
D
10
Operation
D
11
D
D
12
13
D
D
14
15
Remote
Ctrl
Electrical
Anti-TwoBlock or
Two-Block
Damage
Prevention
Tires
Ground
Conditions
Proper engagement of all connecting pins and pin retaining
devices.
Overall observation of crane for damaged or missing parts, cracked
welds, and presence of safety covers.
During operation, observe crane for abnormal performance,
unusual wear (loose pins, wire rope damage, etc.). If observed,
discontinue use and determine cause and severity of hazard.
Operate remote control devices to check for proper operation.
D
16
Level
D
17
D
18
D
19
D
20
Operator
cab
windows
Rails, rail
stops, rail
clamps and
supporting
surfaces
Safety
devices
Electrical
D
D
M
M
21
22
23
24
Daily
Cylinders
M
M
M
25
26
27
Valves
Valves
Valves
M
M
28
29
General
Electrical
M
M
M
M
30
31
32
33
Structure
Welds
Pins
Hardware
M
34
Wear Pads
111
STATUS
(S,R,X,NA)
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.
Check tires (when in use) for proper inflation and condition.
Check ground conditions around the equipment for proper support,
watching for ground settling under and around stabilizers and
supporting foundations, ground water accumulation, or similar
conditions.
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.
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.
Check safety devices and operational aids for proper operation.
Check electrical apparatus for malfunctioning, signs of apparent
excessive deterioration, dirt or moisture accumulation.
Other
Other
All daily inspection items.
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.
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.
Presence of wear pads.
112
IMT 4004i Technical Specifications & Parts Manual #99904386
FREQUENCY ITEM
KEY
INSPECTION DESCRIPTION
M
35
M
36
Pump &
Motor
PTO
M
M
37
38
Hyd Fluid
Hyd Lines
M
M
M
M
M
Q
Q
Q
39
40
41
42
43
44
45
46
Hook
Wire Rope
Manual
Hydraulic pumps and motors for leakage at fittings, seals, and
between sections. Check tightness of mounting bolts.
Transmission/PTO for leakage, abnormal vibration & noise,
alignment, and mounting bolt torque.
Quality of hydraulic fluid and presence of water.
Hoses & tubes for leakage, abrasion damage, blistering, cracking,
deterioration, fitting leakage, and secured properly.
Load hook for abnormal throat distance, twist, wear, and cracks.
Condition of load line.
Presence of operator's manual with unit.
Other
Other
All daily inspection items.
All monthly inspection items.
Rotation bearing for proper torque of all mounting bolts.
Q
Q
Q
47
48
49
50
51
52
53
54
55
56
57
58
Q
59
60
61
62
63
64
65
66
67
68
69
70
Q
71
72
73
74
75
76
77
STATUS
(S,R,X,NA)
78
Daily
Monthly
Rotation
Sys
Hardware
Structure
Hardware
Hyd Lines
Pumps &
Motors
Base mounting bolts for proper torque.
All structural members for deformation, cracks and corrosion.
• Base
• Stabilizer beams and legs
• Mast
• Inner Boom
• Outer Boom
• Extension(s)
• Jib boom
• Jib extension(s)
• Other
Pins, bearing, shafts, gears, rollers, and locking devices for wear,
cracks, corrosion and distortion.
• Rotation bearing(s)
• Inner boom pivot pin(s) and retainer(s)
• Outer boom pivot pin(s) and retainer(s)
• Inner boom cylinder pin(s) and retainer(s)
• Outer boom cylinder pin(s) and retainer(s)
• Extension cylinder pin(s) and retainer(s)
• Jib boom pin(s) and retainer(s)
• Jib cylinder pin(s) and retainer(s)
• Jib extension cylinder pin(s) and retainer(s)
• Boom tip attachment
• Other
Hoses, fittings and tubing for proper routing, leakage, blistering,
deformation and excessive abrasion.
• Pressure line(s) from pump to control valve
• Return line(s) from control valve to reservoir
• Suction line(s) from reservoir to pump
• Pressure line(s) from control valve to each function
• Load holding valve pipe(s) and hose(s)
• Other
Pumps and Motors for loose bolts/fasteners, leaks, noise, vibration,
loss of performance, heating & excess pressure.
• Winch motor(s)
Chapter 5 General Reference
FREQUENCY ITEM
KEY
INSPECTION DESCRIPTION
113
STATUS
(S,R,X,NA)
Q
79
80
81
Valves
Q
82
83
84
85
86
87
Cylinders
Q
88
89
90
91
92
93
94
95
96
Winch
Q
A
A
A
A
A
A
A
A
97
98
99
100
101
102
103
104
105
A
106
Hyd Filters
Daily
Monthly
Quarterly
Hyd Sys
Controls
Valves
Valves
Rotation
Sys
Lubrication
A
107
Hardware
A
A
108
109
Wear Pads
Loadline
• Rotation motor(s)
• Other
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
Winch, sheaves and drums for damage, abnormal wear, abrasions
and other irregularities.
Hydraulic filters for replacement per maintenance schedule.
All daily inspection items.
All monthly inspection items.
All quarterly inspection items.
Hydraulic fluid change per maintenance schedule.
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.
Rotation drive system for proper backlash clearance & abnormal
wear, deformation and cracks.
Gear oil change in rotation drive system per maintenance
schedule.
Check tightness of all fasteners and bolts, using torque
specifications on component drawings or torque chart.
Wear pads for excessive wear.
Loadline for proper attachment to drum.
114
IMT 4004i Technical Specifications & Parts Manual #99904386
Deficiency / Recommendation / Corrective
Action Report
DATE:
OWNER:
UNIT I.D. NUMBER:
GUIDELINES
a A deficiency (X) may constitute a hazard. Deficiency must be corrected and/or faulty parts
replaced before resuming operation.
b Recommendations (R) should be considered for corrective actions. Corrective action for a
particular recommendation depends on the facts in each situation.
c Corrective actions (CA), repairs, adjustments, parts replacement, etc. are to be performed by
a qualified person in accordance with all manufacturer’s recommendations, specifications
and requirements.
NOTE: Deficiencies (X) listed must be followed by the corresponding corrective action taken (CA).
X = DEFICIENCY
X,R,CA
ITEM #
R = RECOMMENDATION
EXPLANATION
CA = CORRECTIVE ACTION TAKEN
DATE CORRECTED
Chapter 5 General Reference
X,R,CA
ITEM #
EXPLANATION
115
DATE CORRECTED
116
IMT 4004i Technical Specifications & Parts Manual #99904386
Thread Torque Chart (English)
FINE THREAD BOLTS (ENGLISH)
SIZE
BOLT
GRADE 5
DIA.
GRADE 8
SAE J429
GRADE 5
(DIA-TPI) (INCHES) PLAIN
(FT-LB)
5/16-24
0.3125
19
3/8-24
0.375
35
7/16-20
0.4375
55
1/2-20
0.5
90
9/16-18
0.5625
120
5/8-18
0.625
170
3/4-16
0.75
300
7/8-11
0.875
445
1-12
1
645
1 1/8-12 1.125
890
1 1/4-12 1.25
1240
1 3/8-12 1.375
1675
1 1/2-12 1.5
2195
COARSE THREAD BOLTS (ENGLISH)
SIZE
BOLT
GRADE 5
DIA.
SAE J429
GRADE 5
SAE J429
GRADE 8
PLATED
(FT-LB)
14
26
41
64
90
130
225
325
485
670
930
1255
1645
PLAIN
(FT-LB)
27
49
78
120
170
240
420
670
995
1445
2010
2710
3560
PLATED
(FT-LB)
20
35
58
90
130
180
315
500
745
1085
1510
2035
2670
(DIA-TPI) (INCHES) PLAIN
(FT-LB)
5/16-18
0.3125
17
3/8-16
0.375
31
7/16-14
0.4375
49
1/2-13
0.5
75
9/16-12
0.5625
110
5/8-11
0.625
150
3/4-10
0.75
265
7/8-9
0.875
395
1-8
1
590
1 1/8-7
1.125
795
1 1/4-7
1.25
1120
1 3/8-6
1.375
1470
1 1/2-6
1.5
1950
GRADE 8
SAE J429
GRADE 8
PLATED
(FT-LB)
13
23
37
57
82
115
200
295
445
595
840
1100
1460
PLAIN
(FT-LB)
25
44
70
105
155
220
375
605
910
1290
1815
2380
3160
PLATED
(FT-LB)
18
33
52
80
115
160
280
455
680
965
1360
1780
2370
NOTES
1 Tightening torques provided are midrange.
2
Consult bolt manufacturer’s particular specifications, when provided.
3
Use flat washers of equal strength.
4
All torque measurements are given in foot-pounds.
5
Torque values specified are for bolts with residual oils or no special lubricants applied. If special lubricants of
high stress ability, such as Never-Seez compound graphite and oil, molybdenum disulphide, colloidal copper or
white lead are applied, multiply the torque values in the charts by the factor .90. The use of Loctite does not affect
the torque values listed above.
WARNING
Anytime a gear-bearing bolt is removed, it
must be replaced with a new bolt of the
identical grade and size. Once a bolt has
been torqued to 75% of its proof load and
then removed, the torque 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.
Chapter 5 General Reference
117
Thread Torque Chart (Metric)
FINE THREAD TORQUE CHART (METRIC)
COARSE THREAD TORQUE CHART (METRIC)
TIGHTENING TORQUE
SIZE
BOLT
(DIADIA.
TPI)
(INCHES)
TIGHTENING TORQUE
SIZE
BOLT DIA
(DIA(INCHES)
TPI)
SAE J429
GRADE 5
SAE J429
GRADE 5
SAE J429
GRADE 8
PLAIN PLATED PLAIN PLATED
(KG-M) (KG-M) (KG-M) (KG-M)
5/16-24 0.3125
3
2
4
3/8-24
0.375
5
4
7
7/16-20 0.4375
8
6
11
1/2-20
0.5
12
9
17
9/16-18 0.5625
17
12
24
5/8-18
0.625
24
18
33
3/4-16
0.75
41
31
58
7/8-11
0.875
62
45
93
1-12
1
89
67
138
1 1/8-12 1.125
123
93
200
1 1/4-12 1.25
171
129
278
1 3/8-12 1.375
232
174
375
1 1/2-12 1.5
304
228
492
NOTES
1 Tightening torques provided are midrange.
3
5
8
12
18
25
44
69
103
150
209
281
369
SAE J429
GRADE 8
PLAIN PLATED PLAIN PLATED
(KG-M) (KG-M) (KG-M) (KG-M)
5/16-18
3/8-16
7/16-14
1/2-13
9/16-12
5/8-11
3/4-10
7/8-9
1-8
1 1/8-7
1 1/4-7
1 3/8-6
1 1/2-6
0.3125
0.375
0.4375
0.5
0.5625
0.625
0.75
0.875
1
1.125
1.25
1.375
1.5
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
3
6
10
15
21
30
52
84
126
178
251
329
438
2
5
7
11
16
22
39
63
94
133
188
246
328
2
Consult bolt manufacturer’s particular specifications, when provided.
3
Use flat washers of equal strength.
4
All torque measurements are given in kilogram-meters.
5
Torque values specified are for bolts with residual oils or no special lubricants applied. If special lubricants of
high stress ability, such as Never-Seez compound graphite and oil, molybdenum disulphite, collodial copper or
white lead are applied, multiply the torque values in the charts by the factor .90. The use of Loctite does not affect
the torque values listed above.
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.
118
IMT 4004i Technical Specifications & Parts Manual #99904386
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
3 Refer to the Torque Data Chart to determine the proper torque value to apply to the size of
capscrew used.
4 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.
5 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)
6 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)
7 Using the proper sequence, torque all capscrews to the listed torque value as determined
from the Torque Data Chart.
Chapter 5 General Reference
119
Turntable Bearing Inspection
Turntable bearings may experience wear. One of the following conditions may indicate turntable
bearing wear:
1
Metal particles present in the bearing lubricant.
2
Increased drive power required to rotate the crane.
3
Noise emitting from the bearing during rotation.
4
Rough rotation.
5
Uneven or excessive wear between the pinion gear and turntable gear.
If one or more of the above conditions exists, further inspection may be required. Limits are
measured in “TILT” which is dependent on the internal clearances of the bearing. TILT is the
most practical determination of a bearings' internal clearance once mounted on a crane. You
can measure the tilt using the Turntable Bearing Tilt Test. (see "Turntable Bearing Tilt Test" on
page 119)
Periodic readings indicating a steady increase in TILT may be an indicator of bearing wear. Note
that a bearing found to have no raceway cracks or other structural irregularities should be reassembled and
returned to service.
Turntable Bearing Tilt Test
1 Place crane in vertical position.
2 Set a dial indicator at 0 on the pinion cover plate at back side of mast.
3 Lower crane to the horizontal position.
4 Check and record the dial indicator change. It should not exceed the tilt measurement noted
in the chart below.
5
Return the crane to the vertical position. The dial indicator should return to 0.
120
IMT 4004i Technical Specifications & Parts Manual #99904386
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, 1007
5200
16000-I, II, III
23516
1221R
Loader or
1014/1014A
5200R
32018
14K160TH
1225R
Tirehand
1015
5217
32027
COMMANDER IV 8000L
Model
2015/2020
5800
32030
9800
2109
7020
T30
12916
2820
7025
T40
13031
3000
7200
13034
3016/3020
7415
14000
3203i
8025
15000
3816/3820
9000
18000
4004i
20017
421/425
8000L
4300
H1200
5005i
H1200RR
5016/5020
T50
6006i
6016/6020
6022
5525 / 6025 / 6625
EZ Hauler I, II
EZ Hauler 3000 /
5500
Ball Dia.
.875" (22 mm)
1.00" (25 mm)
1.18 - 1.25" (30-32 1.5” (38 mm)
1.75" (44 mm)
(Ref)
mm)
Tilt Dim.
.060" (1.524 mm)
.070" (1.778 mm)
.075" (1.905 mm)
.085” (2.159 mm) .090" (2.286 mm)
Rev 20100331
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