6006i Manual

6006i Manual

Manual # 99904597

IMT 6006i - Technical

Specifications & Parts

12v Model (Effective S/N 6006i091002)

Revised 20140925

IOWA MOLD TOOLING CO., INC.

PO Box 189

Garner, IA 50438

Tel: 641-923-3711 FAX: 641-923-2424

Website: http://www.imt.com

Copyright © 2014 Iowa Mold Tooling Co., Inc.

All rights reserved

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

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

Contents

Revisions .................................................................................................................................................... iii

Electric Crane Introduction 5

i

Technical Specifications 7

6006i Technical Data .................................................................................................................................... 7

6006i Capacity Chart .................................................................................................................................... 9

Geometric Configuration ............................................................................................................................ 10

Pump & Motor Performance ....................................................................................................................... 11

Crane Reference 13

Assemblies & Grease Zerk Locations ......................................................................................................... 14

6006i Recommended Spare Parts List ........................................................................................................ 15

Crane Installation (99904394) .................................................................................................................... 17

Electric Crane Battery Circuit (99904884) ................................................................................................. 22

Electric Crane Control ................................................................................................................................ 22

Telescopic Crane Orientation ..................................................................................................................... 23

Parts 25

Parts Information ........................................................................................................................................ 26

Electric Crane Power Safety ....................................................................................................................... 28

Base & Mast Assembly (99904454) (See Parts List for Effectivity) .......................................................... 29

Base & Mast Assembly (99904454) (See Parts List for Effectivity) .......................................................... 32

Valve Bank (73734304) .............................................................................................................................. 35

Cylinder, Lower (51721396) ...................................................................................................................... 36

Boom Assembly (99904335) ...................................................................................................................... 39

Cylinder, Extension (51721386) ................................................................................................................. 42

Crane & Winch Assembly (99904456) (See Parts List for Effectivity) ..................................................... 44

Crane & Winch Assembly (99904456) (See Parts List for Effectivity) ..................................................... 48

Winch (71570923) ...................................................................................................................................... 52

Power Unit (73511282)(Effective 10/11/12) .............................................................................................. 53

Power Unit (73511155) (Through 10/11/12) .............................................................................................. 54

Electrical Installation (99904437) (See Parts List for Effectivity).............................................................. 55

Electrical Installation (99904437) (See Parts List for Effectivity).............................................................. 57

Tethered Control Installation (99904593) ................................................................................................... 59

Radio Control Installation, Standard (99904594) ....................................................................................... 60

Radio Control Installation, Proportional (99904595) ................................................................................. 61

Harness, Radio (77441270) ........................................................................................................................ 62

Harness, Tethered (77441269) .................................................................................................................... 64

Handle Assembly, Tethered (51721502) .................................................................................................... 65

Hydraulic Installation (99904458) .............................................................................................................. 68

6006i Decal Installation (95721549)........................................................................................................... 75

ii Contents

General Reference 77

Inspection Checklist .................................................................................................................................... 77

Deficiency / Recommendation / Corrective Action Report ........................................................................ 82

Thread Torque Chart (English) ................................................................................................................... 84

Thread Torque Chart (Metric) .................................................................................................................... 85

Turntable Bearing Thread Tightening Sequence ........................................................................................ 86

Turntable Bearing Inspection ...................................................................................................................... 87

Turntable Bearing Tilt Test ......................................................................................................................... 87

Contents iii

Revisions

20091023

20100324

20100427

20100615

20100923

20111028

20120326

20121011

20130129

20130413

20130513

20130520

20130601

20130605

20130621

20130901

20131114

20131120

20140925

DATE

20090521

LOCATION

99904454,

99904335,

99904456,

99904593,

99904437,

99904458

99904458

99904458

99904884

DESCRIPTION

ECNs 11032, 11032-1, 11033: MINOR PARTS AND ASSEMBLY

CHANGES AS A RESULT OF PRODUCTION AUDIT.

99904394

71570923

99904458

99904458

51721396,

51721386

99904454

99904437

99904456

99904456

99904454

99904456

99904454

99904456

99904437

99904456

51721502

ECN 11099 - ADDED SPACER

ECN 11182 - ADDED PRESSURE TEST PORT

ADDED 99904884 AND EDITED ELECTRIC CRANE 99904394 STEP

5; ECN 11233 - ADDED WINCH CONTACTOR COVER PART NUM.

ADDED DUAL BATTERY WIRING INFORMATION

UPDATED WINCH SPARE PARTS

ECN 11569 - UPDATE HYD MOTOR PORTS AND BOM

ECN 11686 - CORRECT HOSES.

ECN 11581 - CYLINDER DRAWING UPDATE.

ECN 11829 - POWER UNIT CHANGED

ECN 11829-1 - POWER CABLE CHANGED

ECN 11948 - A2B SWITCH MODIFICATIONS

ECN 11977-3 - CONTACTOR CHANGE

ECN 11977 - BASE WELDMENT CHANGE

ECN 11977-2 - CORD REEL CHANGE

ECN 11977-4 - PIN CHANGE

ECN 12007 - CONTACTOR HARDWARE CHANGE

ECN 11977-1 - A2B WELDMENT CHANGE

REMOVED TETHERED PROPORTIONAL REMOTE

POTENTIOMETER ADJUSTMENT PROCEDURE.

ECN 12063 – UPDATED HARNESS DRAWINGS AND SCHEMATICS 77441269

77441270

GREASING

INSTRUCTIONS

99904454

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

ECN 12286 – 76039295 was REF, now quantity 1

C

H A P T E R

1

Electric Crane Introduction

5

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

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

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

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

Warranty of this unit will be void on any part of the unit subjected to misuse due to overloading, abuse, lack of maintenance and unauthorized modifications. No warranty - verbal, written or implied - other than the official, published IMT new machinery and equipment warranty will be valid with this unit. In addition, it is also the user’s responsibility to be aware of existing Federal,

State and Local codes and regulations governing the safe use and maintenance of this unit. This crane was designed and built to meet the standards of ANSI/ASME B30.5, Mobile & Locomotive

Cranes. Contact the American Society of Mechanical Engineers (www.asme.org) for more information.

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

NOTE

A NOTE is used to either convey additional information or to provide further emphasis for a previous point.

CAUTION

A CAUTION is used when there is the very strong possibility of damage to the equipment or premature equipment failure.

WARNING

A WARNING is used when there is the potential for personal injury or death.

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

C

H A P T E R

2

Technical Specifications

In This Chapter

6006i Technical Data ................................................................ 7

6006i Capacity Chart ................................................................ 9

Geometric Configuration ........................................................... 10

Pump & Motor Performance ..................................................... 11

6006i Technical Data

GENERAL SPECIFICATIONS

CRANE RATING

MAXIMUM HORIZONTAL REACH (from centerline of rotation)

HYDRAULIC EXTENSION (1)

MANUAL EXTENSION (1)

LIFTING HEIGHT (from base of crane to centerline of sheave)

38,000 ft-lb at 11'-0" (5.3 tm at 3.3 m)

22'-0" (6.7 m)

72" (183 cm)

72" (183 cm)

23'-6" (7.2 m)

CRANE WEIGHT (1H1M)

CRANE STORAGE HEIGHT

MOUNTING SPACE REQUIRED (crane base)

HYDRAULIC SYSTEM OPERATING PRESSURE

MAXIMUM HYDRAULIC FLOW

OIL RESERVOIR CAPACITY

OIL TYPE

ELECTRICAL SYSTEM REQUIREMENTS

1450 lb (660 kg)

37" (94 cm)

18" x 18" (45.7 cm x 45.7 cm)

2500 psi (172 bar)

2.6 gpm

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.

33" (84 cm)

CENTER OF GRAVITY

- HORIZONTAL FROM CENTERLINE OF ROTATION

(BOOMS RETRACTED)

- HORIZONTAL FROM CENTERLINE OF ROTATION

(BOOMS EXTENDED)

65.5" (166 cm)

- VERTICAL FROM BOTTOM OF CRANE BASE

TIE-DOWN BOLT PATTERN (on center)

ROTATION TORQUE

18" (45.7 cm)

14.75" x 14.75" (37.5 cm x 37.5 cm)

4000 ft-lb

MINIMUM CHASSIS REQUIREMENT 10,500 lb (4763 kg) GVWR

* The two batteries must be identical in size with maximum cold-crank amp rating of 1000 CCA.

7

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

CYLINDER SPECIFICATIONS

LOWER BOOM CYLINDER

EXTENSION BOOM CYLINDER

WINCH SPECIFICATIONS

FIRST WRAP LINE SPEED

THIRD WRAP LINE SPEED

ROPE DIAMETER

WIRE ROPE LENGTH

CABLE BREAKING STRENGTH

PERFORMANCE CHARACTERISTICS

ROTATION

LOWER BOOM ELEVATION

EXTENSION CYLINDER

4.5" bore, 21.43" stroke (11.4 cm bore, 54.4 cm stroke)

2.5" bore; 72" stroke (6.4 cm bore; 183 cm stroke)

11.5 ft/min (3.5 m/min)

14 ft/min (4.3 m/min)

3/8" (9.6 mm)

80' (24.3 m)

15,100 lb (6,850 kg)

Continuous 360° (6.28 rad)

-5° to +75° (-0.1 to +1.3 rad)

72" (1.8 m)

6006i Capacity Chart

Chapter 2 Technical Specifications 9

24'

7.3 m

21'

6.4 m

6000

2720

3610

1640

18'

5.5 m

15'

4.6 m

12'

3.6 m

9'

2.7 m

6'

1.8 m

3'

0.9 m

6000

2720

2780

1260

4990

2265

6000

2720

75°

3890

1765

60°

6000

2720

45°

6000

2720

30°

5340

2420

15°

4680

2125

3950

1790

3300

1495

2860

1300

2400

1090

2340

1060

2010

910

1660

755

0

(Base)

3'

0.9 m

6'

1.8 m

9'

2.7 m

12'

3.6 m

15'

4.6 m

18'

5.5 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.

21'

6.4 m

IOWA MOLD TOOLING CO., INC.

BOX 189, GARNER, IA 50438-0189

TEL: 641-923-3711 FAX: 641-923-2424

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

Geometric Configuration

5'-10"

(1.77 m)

4'-3"

(1.30 m)

23'-1"

(7.03 m)

17'-3"

(5.30 m)

11'-10"

(3.60 m)

2'-9"

(83.8 cm)

1'-7" (48.2 cm)

10'-0" (3.05 m)

16'-0" (4.88 m)

22'-0" (6.71 m)

Chapter 2 Technical Specifications 11

Pump & Motor Performance

The 12V Powerpack Motor for the 5005i and 6006i crane cannot be run continuously without serious motor damage. The pump has a

maximum

duty cycle of 2.5 minutes which must be followed by cool-down to ambient temperature. It can be run intermittently according to the following charts.

20.0

5

310

I - 2.5 CC

15.0

4

248

180 AMPS

Q - 2.5 CC

3

186

10.0

2500 PSI

2

124

5.0

1

62

0.0

0

0

0 25

500

50

1000

75

1500 2000

PSI

2500 3000 3500

100 125

BAR

150 175 200 225 250 275

0

4000

CAUTION

Avoid motor damage! Operate within performance curves shown.

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

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

C

H A P T E R

3

Crane Reference

In This Chapter

Assemblies & Grease Zerk Locations ....................................... 13

6006i Recommended Spare Parts List ..................................... 14

Crane Installation (99904394) .................................................. 16

Electric Crane Battery Circuit (99904884) ................................ 22

Electric Crane Control .............................................................. 22

Telescopic Crane Orientation ................................................... 23

13

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

Assemblies & Grease Zerk Locations

EXTENSION BOOM

SNATCH

BLOCK

HOOK

LOWER BOOM

WINCH

1

LOWER CYLINDER

3

2

6

MAST

HYDRAULIC

RESERVOIR

4

5

POWER UNIT CRANE BASE

ITEM LOCATION DESCRIPTION LUBRICANT FREQUENCY

1.

2.

3.

Lower Cylinder Rod

Lower Cylinder Base

Gear Rotator Grease Extension

*Rotate crane while greasing.

Power Unit

Power Unit

Shell Alvania 2EP or

Shell Retinax "A"

Weekly

4.

5.

6. Lower Boom Pin

NOTE: All application points must be greased weekly under normal workloads and moderate weather conditions.

Under severe operating conditions, lubricate more frequently. See the IMT Electric Crane Operation & Safety manual for additional lubrication requirements.

Chapter 3 Crane Reference 15

6006i Recommended Spare Parts List

This parts list is intended to provide the user with a stock of parts sufficient to keep the unit operating with the minimal down-time waiting for parts, but it does not indicate these items will fail within a year. In addition, there may be parts failures not covered by this list. Parts not listed are considered as not being Critical or Normal Wear items during the first year of operations and you need to contact the distributor or manufacturer for availability.

Part Number Description

51721396 Lower Cylinder

9D181823 SEAL KIT

6ID45143

6HD45022

73054999

77041786

PISTON

HEAD

VALVE-COUNTERBALANCE

SWITCH-PRESS 2750 psi

51721386 Extension Cylinder

51744143 SEAL KIT

6HD25015

60127830

73054999

HEAD

PISTON

VALVE

99904454 Base & Mast Assembly

60118032

72060173

73051513

76039295

CABLE CONNECTOR MODIFICATION

CAP SCREW .62-11X 3.75 HH

MOTOR-HYDRAULIC

GASKET-GEAR

77441336

77441281

77441285

SWITCH- 275A CONTACTOR

CABLE CONNECTOR-FEMALE

TERM RING INSULATED 3/8 STUD

72060178 CAP SCREW .62-11X 4.00 HEX HEAD GRADE 8

ZINC

73734304 Valve Bank (12V)

77040327

73540326

COIL (VALVE BANK)

VALVE ASSEMBLY (VALVE & COIL)

73734735 Valve Bank (24V)

77040527

73540326

COIL (24V)

SOLENOID VALVE (24V)

73511155 Power Unit (through 10/11/12)

70733826

73511170

BREATHER CAP

PUMP-GEAR 5005/6006I ELECTRIC CRANE

73540323

73734332

74397392

77043060

VALVE-RELIEF ELECTRIC CRANE

KIT-TUBE POWER UNIT ELECTRIC CRANE

RESERVOIR TANK ELECTRIC CRANE

MOTOR-POWER UNIT ELECTRIC CRANE, 12V

Quantity

1

18

1

1

1

1

1

15

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

6

3

6

3

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

Part Number Description

73511282 12V Power Unit (effective 10/11/12)

77043065

73511307

MOTOR (12V)

PUMP

73540517

74399495

70734788

RELIEF VALVE ASSEMBLY

RESERVOIR

BREATHER - CAP

73734791

70734792

TUBE - SUCTION

STRAINER

73511308 24V Power Unit

77043066

73511307

73540517

74399495

70734788

73734791

MOTOR (24V)

PUMP

RELIEF VALVE ASSEMBLY

RESERVOIR

BREATHER - CAP

TUBE - SUCTION

70734792 STRAINER

99904335 Boom Assembly

60030380 WEAR PAD- EXTENSION CYLINDER

60030339

60030340

60030341

WEAR PAD-BLOCK 4.50 X 4.50 X .44

WEAR PAD-BLOCK 4.50 X 3.50 X .44

Quantity

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

WEAR PAD-ROUND 2.00 DIA X .60 DIA X 1.00 LG 6

2

2

60133062

60132302

72661514

WEAR PAD-ROUND 1.00 DIA X .62 DIA X .81L

STOP SCREW 3/8-24 X .50

PIN-LOCK W/HANDLE .875 X 4.25

70144211 PIN- .75X 6.50 LONG

60030134 SHEAVE- 8.00 NYLATRON GSM

99904456 Crane & Winch Assembly

51720302

51725225

70580198

71413196

72601798

72601935

CORD REEL ASSEMBLY (through 06/01/13)

CORD REEL ASSEMBLY (effective 06/01/13)

WIRE ROPE ASSEMBLY

SPRING-.105WIRE 0.75OD 2.875 LG

72601938

77041459

77441096

77041802

77041936

WASHER-LOCK 12MM

CAP SCREW M12-1.75X 40 SOCKET-HEAD

PLAIN

BOLT-EYE # 8-32X .75

SWITCH-LIMIT

CONNECTOR- .50 STRAIN RELIEF .25-.38

CONTACTOR, WINCH (through 05/13/13)

CONTACTOR, WINCH (effective 05/13/13)

71570923 Winch (12V)

77041802

77041936

CONTACTOR (through 05/13/13)

CONTACTOR (effective 05/13/13)

77566637

77744174

BRAKE ASSEMBLY

BRUSH KIT

2

2

1

1

2

1

1

1

1

4

4

1

1

1

1

1

1

1

1

1

Crane Installation (99904394)

Chapter 3 Crane Reference 17

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.

9.

10.

10.

11.

11.

12.

12.

13.

6.

7.

8.

CRANE INSTALLATION PARTS LIST

ITEM

1.

2.

PART #

51721572

91721647

DESCRIPTION

ELECTRIC CRANE BODY INSTALLATION

3.

4.

5.

91721751

51725572

99904317

HARDWARE KIT- 3203i/4004i ELEC CRANE BODY

INSTALLATION

HARDWARE KIT- 5005i ELEC CRANE BODY

INSTALLATION

KIT-ELECTRIC CRANE BODY INSTALLATION

DRAWING-CRANE & WINCH ASSEMBLY

60251272

70734331

72042097

BRACKET-SWITCH 300 AMP ELEC CRANE

SWITCH-300A KEYED BATTERY DISCONNECT

LEVEL INDICATOR LEVEL

77040209

77040529

77040529

77441116

77441116

77441219

77441219

89044276

TERMINAL-RING NI .38 STUD 1 WIRE

TERMINAL-RING NI .31 STUD 1-2 WIRE

TERMINAL-RING NI .31 STUD 1-2 WIRE

FUSEHOLDER-HIGH AMP2 BOLT WITH COVER

FUSEHOLDER-HIGH AMP2 BOLT WITH COVER

FUSE-225 AMP

FUSE-225 AMP

CABLE-#1 WELDING

14.

15.

16.

17.

18.

19.

89392333

72601621

72062375

72063066

72060002

72060634

20.

21.

72062000

72062106

22. 72063001

REV. 20120918

TUBE-HEAT SHRINK AMP

CAP SCR 1.00- 8X 3.00 HH GR8 Z

NUT 1.00- 8 HEX NYLOC GR8Z

WASHER 1.00 HI STR ZINC YELLOW

CAP SCREW .25-20X .75 HH GR5 Z

SCREW-MACHINERY #10-24X .50 RDH

NUT .25-20 HEX

NUT 10-24 HEX NYLOCK

WASHER .25 FLAT

KIT #

#1 & #4

#1 & #4

#1 & #4

#1 & #4

#1

#4

#1

#4

#1

#4

#1 & #4

#1 & #4

#3

#3

#3

#2 & #3

#2 & #3

#2 & #3

#2 & #3

#2 & #3

QUANTITY

1

1

1

1

REF

1

1

1

1

3

9

1

2

1

2

35 FT

4

4

8

.50 FT

4

4

8

4

4

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

To install the crane:

1

Use a lifting device capable of lifting the weight of the crane as indicated in the Technical

Data section of this manual. Attach fabric slings to the crane lower boom, centered approximately 18 inches (46 cm) from the mast hinge. Make certain the crane is well balanced on the slings by slowly lifting approximately 6" (15 cm) off the ground. Lift the crane and apply a bead of waterproof compound, such as silicon based caulk, to the bottom of the base. Move the chassis under the crane and lower the crane into the desired position.

Install the 1-8x3" mounting cap screws (item # 15), 1" nuts (item #16) and 1" washers (item

#17) to secure the crane base to the truck body (see figure). Torque the cap screws to 680 ft-lb (94 kg-m).

NOTE:

The 1-8 x 3" grade 8 zinc coated capscrews are designed for a crane box thickness of 7/8" to

1" only. A different crane box may require different capscrews. All mounting capscrews must be grade 8 zinc coated of proper length. Failure to use proper length capscrews could cause the bolts to bottom out before torqued.

5005i - 6006i MOUNTING PATTERN

18"

14.75"

7.38"

1.13"

15.17

(SEE

NOTE)

7.38"

14.75"

18"

9"

9" 13"

ALLOW 16" (40.6 cm) RADIUS

FOR SWING CLEARANCE

16,17

Chapter 3 Crane Reference 19

2

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

18

22

KEY SUPPLIED

WITH 70734331

SWITCH. SPARE

KEY - 70734357.

19

7

6

21

6

2.75"

5.03"

13.5"

3.5"

4 HOLES,

0.266" DIA.

8

22

20

LOCATION OF

SWITCH BRACKET

IN CRANE BOX

INSIDE VIEW

OF CRANE BOX

3

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

4

After mounting your crane, wire the crane to the vehicle's 12VDC electrical system using the following steps. Use the parts list above to identify parts. Your crane installation kit,

51721572, includes a 10.7 m (35') long cable, IMT # 89044276 (item #13 in the parts list).

Approximately 7.6 m (25') of this cable is required to connect the crane power switch to the vehicle battery, and the rest of the cable is used for ground connections between the crane, vehicle battery, auxiliary battery, and chassis ground. Cut the cable to length after determining the lengths required.

5

Ground the crane by connecting the crane ground cable to bare metal inside the crane box.

6

Connect the crane power cable from the male power cable connector to the power switch.

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

WARNING

Protect the power cable from damage by fastening it inside the frame channel and covering it with protective covering including loom, conduit, etc. Be sure to use rubber grommets or other protection when running the power cable through steel bulkheads.

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

POWER

CABLE

BRACKET

A

13

14

9

GROUND CABLE (GROUND

TO BARE METAL INSIDE

CRANE BOX)

7

7

MALE POWER

CABLE CONNECTOR

89044276 (#13)

ON-OFF SWITCH TO FUSE

(CUT TO LENGTH)

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

77040529) to connect to the truck body.

WARNING

Install the ground cable to the negative terminal of the batteries! The crane electrical ground completes the electrical circuit through the structure of the crane to the vehicle frame. The vehicle factory ground is

NOT sufficient to carry the current required by the crane. Without this extra ground cable, your crane may not operate at rated capacity, and motor, contactor, or electrical damage may occur.

Chapter 3 Crane Reference 21

8

Mount the 225-amp fuse holder (item #11) close to the vehicle battery in a location which can be easily accessed if the fuse needs to be replaced. Repeat with the auxiliary battery.

Use approximately one foot (30.5 cm) of cable (item #13) to connect the positive terminal on the vehicle batteries to the fuse holders. Connect the other end of each fuse holder to the bulkhead pass-through connector from step #6, which is then connected to the crane power switch. Cables connect to the fuse holders using 5/16" (0.79 cm) ring terminals (item #10 -

77040529). Heat shrink connections.

1000 CC A

AUXILIA RY

BATTE RY (IN CRANE BOX)

11

13

11

89044276 or 77040009

FUSE TO B ATTE RY (+)

(APPROXIM ATE LY 1FT)

HE AT SHRINK

12

29

11

89044276 or 77040009

BATTE RY (-) TO CHASSIS GROUND

(CUT T O LENGTH)

HE AT SHRINK

11 TO CHASSIS GROUND

FROM ON-OFF SWITCH

IN CRANE BOX

13-CABLE #89044276 or

27-CABLE #77040009

(CUT T O LENGTH)

(CRANE ON-OFF

SWITCH TO FUSE)

ITEMS WITHIN BOXARE ONLY NEEDED

WHENAUXILIARY BATTERY IS

INSTALLED IN CRANE BOX.

* MATCHED BATTERIESARE REQUIRED*

13-CABLE #89044276 or

27-CABLE #77040009

(CUT T O LENGTH)

(CRANE ON-OFF

SWITCH TO FUSE)

12

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

11

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. (IMT # 77041774)

3. Reference drawing 99904884 for wiring diagram.

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

Electric Crane Battery Circuit (99904884)

CRANE

SW

225A

1

GROUND AT

CHASSIS FRAME

18" (457 mm)

MAXIMUM

225A

UNDERHOOD

BATTERY

GROUND AT

CHASSIS FRAME 18" (457 mm)

MAXIMUM

2ND AUX

BATTERY

GROUND AT

CHASSIS FRAME

NOTES (SEE REFERENCE NUMBER IN BOX):

1

ELECTRIC BULKHEAD PASS-THRU CONNECTOR. USE WHENEVER POWER OR GROUND PASSES

THROUGH A COMPARTMENT WALL.

Electric Crane Control

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

Chapter 3 Crane Reference 23

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

OUTLINE OF

TRUCK BODY

REAR OF

TRUCK

400°

ROTATION

C

H A P T E R

Parts

4

In This Chapter

Parts Information ...................................................................... 26

Electric Crane Power Safety ..................................................... 28

Base & Mast Assembly (99904454).......................................... 29

Valve Bank (73734304) ............................................................ 35

Cylinder, Lower (51721396) ..................................................... 36

Boom Assembly (99904335) .................................................... 39

Cylinder, Extension (51721386) ............................................... 42

Crane & Winch Assembly (99904456) ...................................... 44

Winch (71570923) .................................................................... 52

Power Unit (73511282) ............................................................ 53

Power Unit (73511155)............................................................. 54

Electrical Installation (99904437) .............................................. 55

Tethered Control Installation (99904593) ................................. 59

Radio Control Installation, Standard (99904594) ...................... 60

Radio Control Installation, Proportional (99904595) ................. 61

Harness, Radio (77441270) ..................................................... 62

Harness, Tethered (77441269) ................................................. 64

Handle Assembly, Tethered (51721502) .................................. 65

Hydraulic Installation (99904458) ............................................. 68

6006i Decal Installation (95721549) ......................................... 75

25

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

Parts Information

GENERAL

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

WARNING

Do not attempt to repair any component without reading the information contained in the repair section. Pay particular attention to statements marked Warning, Caution or

Note in that section. Failure to comply with these instructions may result in damage to the equipment, personal injury or death.

CRANE IDENTIFICATION

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

Address all inquiries to your authorized IMT distributor or to:

Iowa Mold Tooling Co., Inc.

Box 189, Garner, IA 50438-0189

Telephone: 641-923-3711

Technical Support Fax: 641-923-2424

IOWA MOLD TOOLING CO., INC.

BOX 189, GARNER, IA 50438-0189

MODEL

NUMBER

SERIAL

NUMBER

MFG

DATE

CYLINDER IDENTIFICATION

Chapter 4 Parts 27

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

CYLINDER

PART NUMBER

LOCATION

WELDMENT IDENTIFICATION

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

ORDERING REPAIR PARTS

When ordering replacement parts:

1

Give the model number of the unit.

2

Give the serial number of the unit.

3

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

4

Give a complete description of the part.

5

Specify the quantity required.

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

Electric Crane Power Safety

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

POWER SWITCH

TURNED TO

OFF

POSITION.

DANGER

AVOID DEATH OR SERIOUS

INJURY!

Before beginning any work on crane,

1

Turn OFF crane power supply in crane cabinet.

Remove crane power disconnect cable from vehicle battery.

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.

Base & Mast Assembly (99904454)

(See Parts List for Effectivity)

Chapter 4 Parts 29

5

11

28, 38

3

28, 37

36, 26

29, 22, 10

23, 33, 31

47

54

29, 22, 10

31, 42

45

BASE & ROTATOR

ASSEMBLY

3

55

26, 36

31, 33, 23

50

49

2

53

27, 37

30

39

5

A

30

12

5

14

6

ELECTRIC ROTATOR

BRACKET LOCATION

35

44

24, 34

9

17

13

52

18, 20, 19

1

ROTATOR & MAST

ASSEMBLY

48

46

41

43

51, 34

7

DETAIL A

VALVE BANK & POWER

UNIT ASSEMBLY

33

22

51

15

16

18

18

4

7

56

35

25

LOWER CYLINDER &

GEAR SHROUD ASSEMBLY

8

23, 33, 31

CONTACTOR ASSEMBLY

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.

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

3

4

5

NOTES (SEE REFERENCE NUMBER IN BOX):

1

APPLY BLACK "MOLUB-ALLOY 882 HEAVY" GEAR GREASE TO TURNTABLE GEAR.

2

APPLY RUST PREVENTATIVE.

TORQUE TO 160 FT-LB

SEE ELECTRIC ROTATOR BRACKET LOCATION (VIEW A).

USE THESE TAPPED HOLES FOR ELECTRICAL BRACKET.

6

USE ANTI-SEIZE.

7

ATTACH GROUND CABLE HERE.

28.

29.

30.

31.

33.

34.

35.

36.

37.

38.

39.

22.

23.

24.

25.

26.

27.

13.

14.

15.

16.

17.

18.

19.

20.

4.

5.

6.

7.

8.

9.

10.

11.

12.

99904454 PARTS LIST

ITEM PART # DESCRIPTION

1.

2.

3.

51721422

91722221

51721707

KIT-HRDW BASE & MAST 5005I

KIT- 5005I ELECTRICAL INSTALLATION

KIT-HYD 5005I

51721396

52725224

52722162

60141134

60132610

60132385

70580194

71056632

60132856

CYL- 4.50B X 2.25R X 21.43S 33.45 CC C

WLDMT- BASE 5005I (effective from 05/20/13)

MAST WELDMENT-5005I/6006I

PIN-TYPE MM 1.50X 8.25 (7.69) (effective from 06/05/13)

SHROUD- TURNTABLE GEAR 5005I

SPACER- POWER UNIT

CLAMP-I" CONDUIT HANGER W/BOLT

GEAR-TRNTBL BRG 17.60" DIA

MNT BRK GREASE HOSE 4004I

73051513

73734304

60133635

72062002

76039295

70034382

72053301

72053508

72060002

72060001

72060051

72060091

72060147

72060173

MOTOR-HYD 158-1083-001

VALVE BANK-3 SEC SERIES 3GPM @ 500PSI 12VDC

CONTACT JUNCTION

NUT .38-16 HEX

GASKET-GEA19 008-10056-1

CAP-GREASE PRO20 GC-RED

COUPLING-BLK .12

ZERK-NPT .12

CAP SCR .25-20X .75 HH GR5 Z (WAS 9)

CAP SCR 0.25-20 X 0.62 HH GR5 (effective from 05/20/13)

CAP SCR .38-16X 2.25 HH GR5 Z

CAP SCR .50-13X 1.00 HH GR5 Z

CAP SCR .62-11X 1.00 HH GR5 Z

CAP SCR .62-11X 3.75 HH GR8 Z

72060178

72062104

72062207

72063001

72063049

72063051

72063053

72063055

72063119

72063216

72063271

CAP SCR .62-11X 4.00 HH GR8 Z

NUT .25-20 HEX NYLOCK

NUT 8-32 HEX NYLOCK

WASHER .25 FLAT

WASHER .25 LOCK

WASHER .38 LOCK

WASHER .50 LOCK

WASHER .62 LOCK

WASHER .62 FLAT ASTM F436

WASHER .62 N FLAT-CUT 3816

WASHER # 8 W FLAT ANSI B27.2Z

7

5

2

1

2

18

3

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

QTY

1

1

1

3

3

2

15

2

4

8

10

31

2

4

#1

#1

#1

#1

#1

#1

KIT #

#1

#1

#1

#1

#1

#1

#1

#1

#1

#1

#1

#1

#1

#1

Chapter 4 Parts

44.

45.

46.

47.

48.

49.

99904454 PARTS LIST

ITEM PART # DESCRIPTION

41.

42.

43.

72602009

72601941

72602010

SCR-MACH # 8-32X 1.25 BTNHD SS

SCR-MACH .25-20X .38 BTNHD ZC

SCR-MACH # 8-32X 1.50 BTNHD ZC

72601949

51721944

77441336

51722218

77441312

77441332

CAP SCR .50-13X 1.25 SH ZC

CABLE ASM- 1GA-3/8RNGX SWVL MX 60.00LG

SWITCH- 275A CONTACTOR (SSC42-275)

CABLE ASM- 1GA-3/8RNGX SWVL FX 13.50LG

CABLE ASM-10GA-#10RNGX 1/4RNGX 6.00LG

CABLE ASM- 1GA-1/4RNGX 3/8RNGX 46.50LG BLK

50.

51.

52.

53.

54.

51395121

72060044

60132301

73511282

60141131

55.

56.

60141130

71415015

REV L 20140916

HOSE-AA .13 X 13.50 (2-2) 100R17

CAP SCR .38-16X .75 HH GR5 Z

BRACKET-VALVE MOUNT

POWER UNIT- 2.65CC 12VDC GC (effective from 10/11/12)

WLDMT- ELEC ROTATOR BRKT BOTTOM 5005I (effective from 05/20/13)

WLDMT- ELEC ROTATOR BRKT TOP 5005I (effective from 05/20/13)

KEEPER-PIN 0.50 (effective from 06/05/13)

#2

#2

#2

#3

#1

KIT #

#1

#1

#1

#1

#2

#2

31

1

2

1

1

1

1

1

1

1

1

2

1

1

QTY

3

1

1

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

Base & Mast Assembly (99904454)

(See Parts List for Effectivity)

13

9 4

32,42

32,41

3

5

ELECTRIC

ROTATOR

BRACKET

LOCATION

34

30,40

12,25,33

51

26,35,37

12,25,33

10

49

30,40

26,35,37

53

54

14

6

48

39

2

20

16

56

31,41

3

BASE & ROTATOR

ASSEMBLY

21,22,23

1

5

ROTATOR & MAST

ASSEMBLY

99904454 DRAWINGS

50

52

55

18

19

44

21

37

25

DETAIL A

34

43

A

45

47

15

11

6

7

17

9

10

4

29,36,39

28,38

VALVEBANK & POWER

UNIT ASSEMBLY

21

5

38,55

7

8

24,35,37

35,46

LOWER CLYINDER

& GEAR SHROUD ASSEMBLY

CONTACTOR ASSEMBLY

Chapter 4 Parts

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.

NOTES (SEE REFERENCE NUMBER IN BOX):

1

APPLY BLACK "MOLUB-ALLOY 882 HEAVY" GEAR GREASE TO TURNTABLE GEAR.

2

3

4

5

APPLY RUST PREVENTATIVE.

TORQUE TO 160 FT-LB

SEE ELECTRIC ROTATOR BRACKET LOCATION (VIEW A).

USE THESE TAPPED HOLES FOR ELECTRICAL BRACKET.

6

USE ANTI-SEIZE.

7

ATTACH GROUND CABLE HERE.

17.

18.

19.

20.

21.

22.

23.

24.

11.

12.

13.

14.

15.

16.

99904454 PARTS LIST

ITEM PART # DESCRIPTION

1.

2.

3.

4.

5.

6.

51721422

91722221

51721707

51721396

52721356

52722162

KIT-HRDW BASE & MAST 5005I

KIT- 5005I ELECTRICAL INSTALLATION

KIT-HYD 5005I

CYL- 4.50B X 2.25R X 21.43S 33.45 CC C

WLDMT- BASE 5005I (effective through 05/20/13)

MAST WELDMENT-5005I/6006I

7.

8.

9.

10.

52721425

60132610

52721420

52721421

PIN-TYPE MM 1.50X 8.25 (7.69) (effective through 06/05/13)

SHROUD- TURNTABLE GEAR 5005I

WLDMT- ELEC ROTATOR BRKT TOP 5005I (effective through 05/20/13)

WLDMT- ELEC ROTATOR BRKT BOTTOM 5005I

(effective through 05/20/13)

SPACER- POWER UNIT

CLAMP-I" CONDUIT HANGER W/BOLT

25.

26.

28.

60132385

70580194

71056632

60132856

73511155

73051513

73734304

60133635

72062002

76039295

70034382

72053301

72053508

72060000

72060002

72060004

72060051

GEAR-TRNTBL BRG 17.60" DIA

MNT BRK GREASE HOSE 4004I

POWER UNIT- 2.65CC 12VDC GC (effective through 10/11/12)

MOTOR-HYD 158-1083-001

VALVE BANK-3 SEC SERIES 3GPM @ 500PSI 12VDC

CONTACT JUNCTION

NUT .38-16 HEX

GASKET-GEA19 008-10056-1

CAP-GREASE PRO20 GC-RED

COUPLING-BLK .12

ZERK-NPT .12

CAP SCR .25-20X .50 HH GR5 Z (WAS 72060001)

(effective through 05/20/13)

CAP SCR .25-20X .75 HH GR5 Z (WAS 9)

CAP SCR .25-20X 1.0 HH GR5 Z (WAS 72060043)

(effective through 05/20/13)

CAP SCR .38-16X 2.25 HH GR5 Z

33

#1

#1

#1

#1

#1

#1

#1

#1

KIT #

1

1

1

1

1

1

1

1

QTY

1

1

1

3

1

1

3

1

1

1

1

1

1

1

2

1

7

2

2

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

34.

35.

36.

37.

38.

39.

99904454 PARTS LIST

ITEM PART # DESCRIPTION

29.

30.

31.

32.

33.

72060091

72060147

72060173

72060178

72062104

CAP SCR .50-13X 1.00 HH GR5 Z

CAP SCR .62-11X 1.00 HH GR5 Z

CAP SCR .62-11X 3.75 HH GR8 Z

CAP SCR .62-11X 4.00 HH GR8 Z

NUT .25-20 HEX NYLOCK

72062207

72063001

72063132

72063049

72063051

72063053

NUT 8-32 HEX NYLOCK

WASHER .25 FLAT

WASHER .50 FLAT ASTM F436 (effective through 06/05/13)

WASHER .25 LOCK

WASHER .38 LOCK

WASHER .50 LOCK

48.

49.

50.

51.

52.

53.

40.

41.

42.

43.

44.

45.

46.

47.

72063055

72063119

72063216

72063271

72066132

72602009

72601941

72602010

72601949

51721944

77441336

51722218

77441312

77441332

54.

55.

51395121

72060044

56. 60132301

REV. E 20090520

WASHER .62 LOCK

WASHER .62 FLAT ASTM F436

WASHER .62 N FLAT-CUT 3816

WASHER # 8 W FLAT ANSI B27.2Z

RETAINING RING-EXT 1.50 HD (effective through 06/05/13)

SCR-MACH # 8-32X 1.25 BTNHD SS

SCR-MACH .25-20X .38 BTNHD ZC

SCR-MACH # 8-32X 1.50 BTNHD ZC

CAP SCR .50-13X 1.25 SH ZC

CABLE ASM- 1GA-3/8RNGX SWVL MX 60.00LG

SWITCH- 275A CONTACTOR (SSC42-275)

CABLE ASM- 1GA-3/8RNGX SWVL FX 13.50LG

CABLE ASM-10GA-#10RNGX 1/4RNGX 6.00LG

CABLE ASM- 1GA-1/4RNGX 3/8RNGX 46.50LG BLK

HOSE-AA .13 X 13.50 (2-2) 100R17

CAP SCR .38-16X .75 HH GR5 Z

BRACKET-VALVE MOUNT

1

1

1

2

1

1

1

2

1

4

1

3

1

1

2

31

2

4

8

1

10

3

3

QTY

1

2

18

15

2

#1

#2

#2

#2

#2

#2

#3

#1

#1

#1

#1

#1

#1

#1

#1

#1

#1

#1

#1

#1

#1

#1

KIT #

#1

#1

#1

#1

#1

Valve Bank (73734304)

2,3(2)

4

2,3(2)

2,3(2)

Chapter 4 Parts 35

4

4

4

1

SAE #4

ORB PORT

(4 PLACES)

4

SAE #4

ORB PORT

4

4

EXTENSION MAIN

ROTATE

SAE #4

ORB PORT

A1

S1

B1 A2

S2

B2 A3

S3

B3

P

HYDRAULIC SCHEMATIC

73734304 PARTS LIST

ITEM

1.

PART #

2.

3.

73540326

73540327

4.

REV A 20081028

DESCRIPTION

MANIFOLD VALVE BODY

SOLENOID VALVE (INCLUDES COIL)

COIL, 12V.

PLUG, EXPANDER, 7MM

T

QUANTITY

1

3

6

7

SAE #4

ORB PORT

(2 PLACES)

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

Cylinder, Lower (51721396)

2

16

5

14

9

17

14

6

8

7

15

10

11

21

4

13

15

12

19

3

Chapter 4 Parts 37

6 8

33.52" CLOSED

54.88" OPEN

21.43" STROKE

DRILL #15

HOLE 3/16"

DEEP, PRESS

IN PIN 60125699 7

A

3

A

16

5 14 17

9

14

SECTION A-A

4

10

11

15

13

4

15

12

NOTES:

1

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

DISASSEMBLED.

2

APPLY "NEVER-SEEZ" REGULAR GRADE ANTI-SEIZE AND LUBRICATING COMPOUND TO THREADS ON

CYLINDER HEAD ONLY. KEEP AWAY FROM ALL SEALS.

3

APPLY "LUBRIPLATE" NO. 630-2 MEDIUM HEAVY, MULTI-PURPOSE LUBRICANT, TO ALL PISTON, HEAD

GLAND, AND HOLDING VALVE SEALS, NYLON LOCK RING, CAST IRON PISTON RINGS, AND ROD

STINGER THREADS.

6.

7.

8.

9.

10.

11.

12.

4

ITEM #8, STOP TUBE, REPLACES 6A025022 WAFER LOCK. USE STOP TUBE INSTEAD OF WAFER LOCK

WHEN RESEALING CYLINDER.

51721396 CYLINDER DATA

CASE

ROD

STROKE

DRY WEIGHT

TEST PRESSURE

OPERATING PRESSURE

TORQUE VALUES

ø5.13" O.D. X ø4.5" BORE X 30.89" LENGTH

ø2.25" X 29.83" LONG

21.43"

112.87 LB

3000 PSI

2500 PSI

PISTON TO ROD: 710 - 740 FT-LB

HEAD GLAND TO CYLINDER: 450 FT-LB

CARTRIDGE TORQUE - 30-35 FT-LB

51721396 PARTS LIST

ITEM PART #

1.

2.

9D181823

52721397

DESCRIPTION

SEAL KIT

ROD ASSEMBLY

KIT #

#20

#20

QUANTITY

1

1

3.

4.

5.

52721399

6HD45022

6ID45143

CASE ASSEMBLY

HEAD

PISTON

#20

#20

#20

1

1

1

60125920

60125699

60138275

7Q072155

7Q072346

7Q10P346

7R14P022

STOP TUBE

PIN - LOCK TUBE

STOP TUBE (WAS 6A025022)

O RING 4.00X 4.19X .09 70

O RING 4.12X 4.50X .19 70

BACKUP RING-4.12 ID X 4.50 OD

ROD WIPER-TYPE D 2.25 ROD

#20

#20

#1

#1

#1

#1

#1

1

1

1

1

1

1

1

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

51721396 PARTS LIST

ITEM PART #

13.

14.

15.

16.

17.

7R546022

7T2N4045

7T2NX625

7T61N143

7T66P045

19.

20.

77041786

51721396A

21. 73054999

REV D 20120326

DESCRIPTION

U-CUP LOADED 2.25X2.75X.38 "B

WEAR RING - PISTON 4.50 O.D. X .50 W

WEAR RING-ROD 2.25 IDX0.75

LOCK RING-NYLON 1.43

PISTON SEAL-DYNAMIC 4.50in

SWITCH-PRESS 2750 PSI NC 42in LEAD

CYL-4.5/2.2 21.43S 33.45CC C

VALVE-CBAL SUN01 CBBC-LHN

KIT #

#1

#1

#1

#1

#1

#3

1

1

1

2

1

1

QUANTITY

1

2

Boom Assembly (99904335)

BOOM ASSEMBLY, 1H 1M (99904335)

Chapter 4 Parts 39

BOOM EXTENSIONS (1H 1M)

(COMPLETE)

23

30

15

7

20

21

15

30

23

25

28

29

14

29

3

29

14

2

9

10

9

8

29

28

25

13

31

9

17

22

22

27

27

29

30

24

19

9

31

13

11

18

27

26

27

26

12

10

4

16

12

9

11

6

9

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

BOOM ASSEMBLY, 1H (99904335)

BOOM EXTENSIONS (1H)

(COMPLETE)

9

10

9

25

28

29

14

29

23

30

15

7

20

15

30

23

3

29

14

2

29

28

25

8

29

30

24

22

27

17

22

27

27

26

27

26

16

12

10

5

12

3.

4.

5.

6.

99904335 PARTS LIST

ITEM PART # DESCRIPTION

1.

2.

3.

51721423

51721386

52721358

HARDWARE KIT-BOOM 5005I

CYLINDER

LOWER BOOM WELDMENT - 5005I (through 05/13/13)

52725221

52721359

52721474

52721360

LOWER BOOM WELDMENT - 5005I-6006I (effective 05/13/13)

WELDMENT- EXTENSION 1ST STAGE 5005I

WELDMENT- EXTENSION 1ST STAGE 5005I

WELDMENT- 2ND STAGE EXTENSION 5005I

KIT #

1

1

1

1

QTY

1

1

1

20.

21.

22.

23.

24.

25.

12.

13.

14.

15.

16.

17.

18.

19.

99904335 PARTS LIST

ITEM PART #

7.

60030134

60133939

DESCRIPTION

SHEAVE- 8.00 NYLATRON (PART OF 6)

PIN-TYPE M 1.50X 6.00

8.

9.

10.

11.

60030380

60030339

60030340

60030341

WEAR PAD- EXT CYLINDER 6006I

WEAR PAD-RND 2.00 DIA X .60 DIA X 1.00 LG

WEAR PAD-BLOCK 4.50 X 4.50 X .44

WEAR PAD-BLOCK 4.50 X 3.50 X .44

60133062

60132302

60105544

72063273

72661514

72066144

70144211

72066145

WEAR PAD-RND 1.00 DIA X .62 DIA X .81L

STOP SCREW 3/8-24 X .50

PLATE-ANGLE PLASTIC

WASHER .52ID X 2.00OD X 10GA

PIN-LOCK W/HANDLE .875 X 4.25

HAIR PIN .16 DIA .63-1.00 SHAFT (PART OF 72661514)

PIN- .75X 6.50LG

HAIR PIN .19 DIA .63-1.00 SHAFT (PART OF 70144211)

26.

27.

28.

29.

30.

31.

70034382

72053507

72060013

72060092

72060928

72062103

72062104

72063001

72063003

72063005

72063053

72063051

REV. B 20090521

CAP-GREASE

ZERK-STR THD .25-28

CAP SCREW .25-20X 3.25 HH GR5 Z

CAP SCREW .50-13X 1.25 HH GR5 Z

CAP SCREW .50-13X 2.25 HH GR5 Z

NUT .38-16 HEX NYLOCK

NUT .25-20 HEX NYLOCK

WASHER .25 FLAT

WASHER .38 FLAT

WASHER .50 FLAT

WASHER .50 LOCK

WASHER-LOCK .38 ZINC

Chapter 4 Parts 41

5

3

2

2

4

2

2

1

2

1

1

2

2

1

1

1

1

2

2

2

6

2

2

QTY

2REF

1

1

#1

#1

#1

#1

#1

#1

#1

#1

#1

REF

REF

#1

#1

#1

KIT #

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

Cylinder, Extension (51721386)

2

8

14

17

4

15

17

13

12

9

10

5

11

16

6

18

16

7

3

DRILL #15 HOLE, 3/16" DEEP.

PRESS IN PIN 60125699

8

4

9

7.23 - 7.51" CLOSED

79.13-79.63" OPEN

71.90 - 72.12" STROKE

2

14 17 15 13 12 17 10 5 11

16

18

16

6

7

3

Chapter 4 Parts 43

NOTES:

1

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

DISASSEMBLED.

2

3

APPLY "NEVER-SEEZ" REGULAR GRADE ANTI-SEIZE AND LUBRICATING COMPOUND TO THREADS ON

CYLINDER HEAD ONLY. KEEP AWAY FROM ALL SEALS.

APPLY "LUBRIPLATE" NO. 630-2 MEDIUM HEAVY, MULTI-PURPOSE LUBRICANT, TO ALL PISTON, HEAD

GLAND, AND HOLDING VALVE SEALS, NYLON LOCK RING, CAST IRON PISTON RINGS, AND ROD

STINGER THREADS.

4

ITEM #10, STOP TUBE, REPLACES 6A025015 WAFER LOCK. USE STOP TUBE INSTEAD OF WAFER LOCK

WHEN RESEALING CYLINDER.

51721386 CYLINDER DATA

CASE

ROD

STROKE

DRY WEIGHT

TORQUES

TEST PRESSURE

OPERATING PRESSURE

ø3" O.D. X ø2.5" BORE X 81.26" LENGTH

ø1.5" X 82.69" LONG

72"

84.65 LB

PISTON: 250 FT-LB

HEAD: 500-530 FT-LB

CARTRIDGE: 30-35 FT-LB

CAP SCREW: 16 FT-LB

3000 PSI

2500 PSI

51721386 PARTS LIST

5.

6.

7.

8.

9.

10.

ITEM

1.

2.

3.

4.

PART #

51744143

52721387

52721388

6HD25015

60127864

60127830

72062323

73054999

60125699

60138272

11.

12.

13.

14.

15.

7Q072218

7Q072228

7Q10P228

7R14P015

7R546015

16.

17.

7T2N4025

7T2NX417

18. 7T66P250

REV B 20120326

DESCRIPTION

IMT SEAL KIT-2.50 B X 1.50 R 1.25 STGR

ROD ASM-1.50 DIA X 86.63 LG 1.25 S

CASE ASM-2.50 BORE X 82.51 LG

HEAD-2.50 BORE X 1.50 ROD (DUCTILE IRON)

STOP TUBE-1.50 ROD X 3.56LG 4 HOLE

PISTON-2.50 BORE X 1.25 STGR

COLLAR-LOCK 1-1/4-12 X 2.063 X 1/2

VALVE-CBAL

PIN - LOCK TUBE 0.19 OD X 0.065 WALL

STOP TUBE (WAS 6A025015)

O RING 1.25X 1.50X .12 70

O RING 2.25X 2.50X .12 70

BACKUP RING-2.25 ID X 2.50 OD

ROD WIPER TYPE D 1.50 ROD

U-CUP 1.50 ID X 2.00 OD

WEAR RING-PISTON 2.50 ODX .50W

WEAR RING-ROD 1.50 IDX0.50W

PISTON SEAL-DYNAMIC

#1

#1

#1

#1

#1

#1

#1

#1

#1

#1

KIT #

2

2

1

1

1

1

1

1

1

1

1

1

1

1

QUANTITY

1

1

1

1

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

Crane & Winch Assembly (99904456)

(See Parts List for Effectivity)

WINCH & BOOM ASSEMBLY

A

30

37

4

28

46

38

36

36

52

B

29

38

12

25

27

21

18

28

38

36

34

20

46

36

34

20

47

8

37

33

27

25

49

40

48

51

48 48

34

20

48

49

40

53

34

20

CONNEC T THE WIRE TERMINALS (77040051)

TO COMMON AND NORMAL LY OPEN

ON ATB SWITCH

10

23

15

22

DETAI L B

19

48

48

40, 35

41

42

40, 32

26

28 36

DETAI L A

8

NOTES (SEE REFERENCE NUMBER IN BOX):

1

CONNECT THE WIRE TERMINALS (77040051) TO "COMMON" AND "NORMALLY OPEN" ON ANTI-TWO-

BLOCK SWITCH.

CRANE ASSEMBLY

Chapter 4 Parts 45

6

54

39

31

24

36

44

36, 38, 28

7

54

9

39

31

11

36, 38, 28

28, 38, 36

NOTES (SEE REFERENCE NUMBER IN BOX):

1

2

3

USE ANTI-SEIZE ON PINS.

KEEP ELECTRICAL GROUNDS FREE OF PAINT, GREASE, AND OIL

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

52721425.

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

SINGLE AND DOUBLE LINE

10

21

14

50

50

17

27

25

13

21

15

10

14

13

17

7.

8.

9.

99904456 PARTS LIST

ITEM PART #

1.

2.

3.

4.

5.

6.

10.

11.

DESCRIPTION

99904454 DRAWING-BASE & MAST ASSEMBLY 6006I

99904335 BOOM ASSEMBLY 5005I-6006i

51721424 HARDWARE KIT-CRANE & WINCH 6006I

51725225 CORD REEL ASSEMBLY- 10' W/PACKARD CONNECTOR (effective from

06/01/13)

52717885 WELDMENT- SNATCH BLOCK

60141135 PIN (effective from 06/05/13)

60141134 PIN (effective from 06/05/13)

52725226 WELDMENT-ATB TRIP MECHANISM 5005i/6006i (effective from 09/01/13)

52722163 COVER-VALVE BANK 5005i/6006i

60122263 PLATE-SINGLE SHEAVE 3820

60134104 COVER-CONTACTOR (5005I-6006I)

KIT #

12.

13.

14.

70034381 SUPPORT

70144209 PIN- .75X 4.50 LG WS80-WS100

72066144 HAIR PIN .16 DIA .63-1.00 SHAFT (PART OF 70144209) #13

15.

16.

17.

70149793 COLLAR-SHAFT 2 PIECE 11/16 IN

70580198 WIRE ROPE ASSEMBLY

71073920 HOOK-SWIVEL W/LATCH

QTY

REF

REF

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

29.

30.

31.

32.

33.

24.

25.

26.

27.

28.

99904456 PARTS LIST

ITEM PART # DESCRIPTION

72661665 LATCH KIT (PART OF 17)

18. 71570923 WINCH-12VDC

19.

20.

21.

22.

23.

77041936 CONTACTOR-WINCH 12V DC3000

(effective from 05/13/13)

72034485 CLAMP-PLASTIC 1/4" CABLE

72661543 PIN-QUICK 316-10QP

77041459 SWITCH-LIMIT

77441096 CONNECTOR- .50 STR RLF .25-.38

77441282 GROUND STRAP- 12IN

70034382 CAP-GREASE PRO20 GC-RED

71413196 SPRING-.105WIRE 0.75OD 2.875 LG

72053508 ZERK-NPT .12

72060000 CAP SCREW .25-20X .50 HH GR5 Z

(effective from 04/03/13)

72060007 CAP SCREW .25-20X 1.75 HH GR5 Z

34.

35.

36.

72060075 CAP SCREW .44-14X 5.50 HH GR5 Z

72060091 CAP SCREW .50-13X 1.00 HH GR5 Z

72062093 NUT # 8-32 HEX ZINC

72062105 NUT .44-14 HEX NYLOCK

72062106 NUT 10-24 HEX NYLOCK

72062207 NUT 8-32 HEX NYLOCK

72063001 WASHER .25 FLAT (effective from 04/03/13)

37.

38.

39.

40.

41.

42.

43.

44.

72063004 WASHER .44 FLAT

72063049 WASHER .25 LOCK

72063053 WASHER .50 LOCK

72063271 WASHER # 8 W FLAT ANSI B27.2Z

(effective from 05/13/13)

72601798 WASHER-LOCK 12MM

72601935 CAP SCREW M12-1.75X 40 SH ZC

72601938 BOLT-EYE # 8-32X 1.125

72601941 SCREW-MACH .25-20X .38 BTNHD ZC

(effective from 05/13/13)

77040051 TERMINAL-SPRSPADE I #8 STUD 16-14 45.

46.

47.

48.

49.

50.

51.

52.

53.

72062104 NUT 0.25-20 HEX NYLOCK

72060003 CAP SCR 0.25-20 X 0.88 GR5

72602011 SCR MACH #8-32 X 0.62 BTNHD

72063239 WASHER LOCK

60030327 SPACER- SNATCH BLOCK

71413880 COVER WITHOUT SOCKET

60140565 BRKT-CORD REEL MNT 3203I

52725217 WLDMT-WINCH CONTACTOR BRKT

54. 71415015 KEEPER PIN 0.50

REV N 20140130

Chapter 4 Parts 47

#3

#3

#3

#3

#3

#3

#3

#3

#3

#3

#3

#3

#3

#3

#3

#3

#3

#3

#3

#3

#3

#3

#3

#3

#3

KIT # QTY

REF

1

1

2

2

1

1

1

2

2

2

6

2

4

4

1

1

4

1

16

2

11

2

4

2

1

2

1

1

1

3

1

4

1

1

1

3

10

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

Crane & Winch Assembly (99904456)

(See Parts List for Effectivity)

WINCH & BOOM ASSEMBLY

A

46

37

18

50

19

35

20

35

20

28

39

37

28

39

35

20

4

37

35

20

B

30

39

12

25

27

21

31

38

38

8

34

27

25

10

15

23

1

43

44

36,41

22

DETAIL B

33,41

26

DETAIL A

NOTES (SEE REFERENCE NUMBER IN BOX):

1

CONNECT THE WIRE TERMINALS (77040051) TO "COMMON" AND "NORMALLY OPEN" ON ANTI-TWO-

BLOCK SWITCH.

CRANE ASSEMBLY

Chapter 4 Parts 49

42

42

24

37

46

6

48

40

32

28,37,39

9

7

48

40

32

29,37,39

11

28,37,39

NOTES (SEE REFERENCE NUMBER IN BOX):

1

USE ANTI-SEIZE ON PINS.

2

KEEP ELECTRICAL GROUNDS FREE OF PAINT, GREASE, AND OIL

3

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

52721425.

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

SINGLE AND DOUBLE LINE

10

21

DOUBLE LINE

14

49

14

49

17

27

25

13

21

15

10

13

SINGLE LINE

17

99904456 PARTS LIST

ITEM PART # DESCRIPTION

1.

2.

3.

4.

99904454

99904335

51721424

51720302

DRAWING-BASE & MAST ASSEMBLY 6006I

BOOM ASSEMBLY 5005I-6006i

HARDWARE KIT-CRANE & WINCH 6006I

5.

6.

7.

8.

9.

10.

52717885

52719630

52721425

52722112

52722163

60122263

CORD REEL ASSEMBLY- 10' W/PACKARD CONNECTOR (effective through 06/01/13)

WELDMENT- SNATCH BLOCK

PIN (effective through 06/05/13)

PIN (effective through 06/05/13)

WELDMENT-ATB TRIP MECHANISM 5005i/6006i (effective through

09/01/13)

COVER-VALVE BANK 5005i/6006i

PLATE-SINGLE SHEAVE 3820

KIT #

11.

12.

60134104

70034381

COVER-CONTACTOR (5005I-6006I)

SUPPORT

1

1

1

2

1

1

1

1

QTY

REF

REF

1

1

Chapter 4 Parts

29.

30.

31.

32.

33.

34.

21.

22.

23.

24.

25.

26.

27.

28.

16.

17.

18.

19.

20.

99904456 PARTS LIST

ITEM PART # DESCRIPTION

13.

14.

15.

70144209

72066144

70149793

PIN- .75X 4.50 LG WS80-WS100

HAIR PIN .16 DIA .63-1.00 SHAFT (PART OF 70144209)

COLLAR-SHAFT 2 PIECE 11/16 IN

70580198

71073920

72661665

71570923

77041802

72034485

WIRE ROPE ASSEMBLY

HOOK-SWIVEL W/LATCH

LATCH KIT (PART OF 17)

WINCH-12VDC

CONTACTOR-WINCH 12V DC3000 (effective through 05/13/13)

CLAMP-PLASTIC 1/4" CABLE

72661543

77041459

77441096

77441282

70034382

71413196

72053508

72060000

72060004

72060007

72060075

72060091

72062093

72062105

PIN-QUICK 316-10QP

SWITCH-LIMIT

CONNECTOR- .50 STR RLF .25-.38

GROUND STRAP- 12IN

CAP-GREASE PRO20 GC-RED

SPRING-.105WIRE 0.75OD 2.875 LG

ZERK-NPT .12

CAP SCREW .25-20X .50 HH GR5 Z (effective through 04/03/13)

CAP SCREW .25-20X 1.00 HH GR5 Z (effective through 05/20/13)

CAP SCREW .25-20X 1.75 HH GR5 Z

CAP SCREW .44-14X 5.50 HH GR5 Z

CAP SCREW .50-13X 1.00 HH GR5 Z

NUT # 8-32 HEX ZINC

NUT .44-14 HEX NYLOCK

35.

36.

37.

38.

39.

40.

41.

42.

43.

72062106

72062207

72063001

72063004

72063049

72063053

72063271

72066132

72601798

44.

45.

46.

47.

48.

72601935

72601938

72601941

77040051

72063132

49.

50.

60030327

71413880

REV. G 20100427

NUT 10-24 HEX NYLOCK

NUT 8-32 HEX NYLOCK

WASHER .25 FLAT (effective through 04/03/13)

WASHER .44 FLAT

WASHER .25 LOCK

WASHER .50 LOCK

WASHER # 8 W FLAT ANSI B27.2Z (effective through 05/13/13)

RETAINING RING-EXT 1.50 HD (effective through 06/05/13)

WASHER-LOCK 12MM

CAP SCREW M12-1.75X 40 SH ZC

BOLT-EYE # 8-32X 1.125

SCREW-MACH .25-20X .38 BTNHD ZC (effective through 05/13/13)

TERMINAL-SPRSPADE I #8 STUD 16-14

WASHER .50 FLAT ASTM F436 (effective through 06/05/13)

SPACER- SNATCH BLOCK

COVER WITHOUT SOCKET

#3

#3

#3

#3

#3

#3

#3

#3

#3

#3

KIT #

#13

#3

#3

#3

#3

#3

#3

#3

#3

#3

#3

#3

#3

#3

#3

2

1

1

4

1

12

2

2

1

1

3

7

1

1

1

1

3

1

1

4

QTY

1

1

1

1

1

REF

2

1

4

1

3

2

2

2

11

2

2

2

4

51

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

Winch (71570923)

CABLE

BUSHING

32000212

DRUM

DUST

MASK

73540402

ELECTRIC

MOTOR, 12VDC

NYL WASHER

32000480

OIL SEAL

32000388

ELECTRIC

THERMAL SWITCH

SPACER

BEARING

PLATE,

SPACER

CAPSCREW

NYL WASHER

32000480

SEAL- 32000388

BUSHING

32000212

BRAKE DRIVER

SCREW

32000385

BRAKE

DRIVER

BRAKE

ASM

77056667

HOSE

CLAMP

BEARING

TOL RING

MOTOR SHAFT

SPACER SHAFT

CARRIER ASM

HEX

CARRIER

ASM

RING

GEAR

RET. RING

PLUG

DRUM ASM

SEAL

DRUM SUPPORT

CLUTCH

RETAINER

CLUTCH RING GEAR

CARRIER ASM

THRUST PLATE

LABEL

GEAR

HOUSING

ASM

GASKET

32000231

REPLACEMENT PARTS:

CONTACTOR - IMT # 77041802

BRAKE ASM - IMT # 77056667

MOTOR - IMT # 73540402

SCREW

PLATE, SPACER

CAPSCREW

DRUM

SUPPORT

PLATE, SPACER

CAPSCREW

1

Power Unit (73511282)

(Effective 10/11/12)

3

Chapter 4 Parts 53

6

2

7

5

4

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

73511282 PARTS LIST

ITEM PART #

1.

2.

3.

77043065

73511307

73540517

4.

5.

6.

74399495

70734788

73734791

7. 70734792

NEW 20130809

DESCRIPTION

MOTOR 12VDC

PUMP

RELIEF VALVE ASSEMBLY

RESERVOIR

BREATHER CAP

TUBE-SUCTION

STRAINER

KIT #

1

1

1

QUANTITY

A/R

1

1

1

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

Power Unit (73511155)

(Through 10/11/12)

FAN SHROUD

BREATHER CAP

(70733826)

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

(73511170)

RETURN LINE PIPE

SUCTION

LINE PIPE

ADAPTER / RESERVOIR

SECTION

TUBE KIT (73734332)

(SUCTION & RETURN LINE PIPES)

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

Electrical Installation (99904437)

(See Parts List for Effectivity)

1

9

Chapter 4 Parts 55

9

22

8

24

23

20

7

21

4

3

10

A

9

5

7

17

16

15

12

6

2

2

14

ELECTRIC RO TATOR BRACKET

(BOTTOM)

11

CRANE BASE

TO BOOM GROUND

AS VIEWED FROM REAR

GROUND CABLES ROUTED TO OUTSIDE OF MAST

13

WIRE HARNESS

(WINCH DOWN)

TO CRANE BOX

19

WIRE HARNESS

(WINCH UP)

18

2

TO 300 AMP KEYED SWITCH

IN CRANE BOX

TORQUE TO 8-15 FT-LBS

10

DE TAI L A

WIRE HARNESS

(RADIO CONTROL)

WIRE HARNESS

(TETHERED CONTROL)

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

NOTES (SEE REFERENCE NUMBER IN BOX):

1

WRAP CABLES AND MOTOR TERMINALS WITH RUBBER BOOTS. KEEP 3/8" OF RED WIRE VISIBLE.

2

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

14.

15.

16.

17.

18.

19.

8.

9.

10.

11.

12.

13.

5.

6.

7.

2.

3.

4.

99904437 PARTS LIST

ITEM

1.

PART #

91722221

51721944

71570923

73511282

77041936

77441282

51721718

DESCRIPTION

5005I ELECTRICAL INSTALLATION KIT (WAS 91721555)

CABLE ASSEMBLY- 1GA-3/8RNGX SWVL MX 60.00LG

WINCH-12V

POWER UNIT (effective from 10/11/12)

KIT #

#1

CONTACTOR-WINCH 12V (effective from 05/13/13)

GROUND STRAP- 12IN

CABLE ASSEMBLY- 2GA-5/16RNG X 3/8RNG X 25.00LG (WAS 51721500) #1

51721720

51721721

77441336

51722218

77441312

77441332

CABLE ASSEMBLY- 2GA-5/16RNGX 3/8RNGX 10.00LG

CABLE ASSEMBLY- 2GA-5/16RNGX 5/16RNGX 18.00LG

SWITCH- 275A CONTACTOR (WAS 77441277)

CABLE ASM - 1GA - 3/8RNG X SWVL 13.5 LG

CABLE ASSEMBLY-10GA-#10RNGX 1/4RNGX 6.00LG

CABLE ASSEMBLY- 1GA-1/4RNGX 3/8RNGX 46.50LG

#1

#1

#1

#1

#1

20.

21.

22.

23.

24.

51721717

60133635

72060044

72062179

72601278

77040186

51722412

77441302

77441303

72063050

72060021

REV. F 20090521

CABLE ASSEMBLY- 2GA-5/16RNGX 3/8RNGX 35.50LG

CONTACT JUNCTION

CAP SCREW 3/8-16 X 3/4 HHGR5Z

NUT 0.38-16 HEX CENTER LOCKING (effective from 06/21/13)

CAP SCREW M8-1.25 X 20 HHZ

TERM-FSLPON I .25 TAB 16-14GA

CABLE ASM- 2GA-.31RNG X .31RNG X 18.00LG

TERM INSUL RED #8-2 GA WIRE

TERM INSUL BLK #8-2 GA WIRE

WASHER 0.31 LOCK (effective from 06/21/13)

CAP SCR 0.31-18 X 0.50 GR5 (effective from 06/21/13)

#1

#1

1

1

1

1

1

REF

REF

REF

1

1

1

1

REF

REF

QTY

1

1

REF

REF

1

3

1

REF

1

1

Electrical Installation (99904437)

(See Parts List for Effectivity)

1

10

Chapter 4 Parts 57

10 21

22

9

8

23

4

3

A

10

5

7

18

17

16

13

11

6

ELECTRIC

ROTATOR

BRACKET

(BOTTOM)

CRANE BASE

TORQUE TO

8-15 FT-LB

12

2

2

2

15

TO BOOM

GROUND

AS VIEWED

FROM REAR

WIRE HARNESS

(WINCH DOWN)

GROUND CABLES ROUTED

TO OUTSIDE OF MAST

WIRE HARNESS

(WINCH UP)

14

TO

CRANE

BOX

20

20

19

TO 300 AMP

KEYED SWITCH

IN CRANE BOX

11

DETAIL A

WIRE HARNESS

(RADIO CONTROL)

WIRE HARNESS

(TETHERED

CONTROL)

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

NOTES (SEE REFERENCE NUMBER IN BOX):

1

WRAP CABLES AND MOTOR TERMINALS WITH RUBBER BOOTS. KEEP 3/8" OF RED WIRE VISIBLE.

2

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

15.

16.

17.

18.

19.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

2.

3.

4.

99904337 PARTS LIST

ITEM

1.

PART #

91722221

DESCRIPTION

5005I ELECTRICAL INSTALLATION KIT (WAS 91721555)

51721944

71570923

73511155

CABLE ASSEMBLY- 1GA-3/8RNGX SWVL MX 60.00LG

WINCH-12V

POWER UNIT (effective through 10/11/12)

77041802

77441282

51721718

51721719

51721720

51721721

77441336

51722218

77441312

77441332

CONTACTOR-WINCH 12V (effective through 05/13/13)

GROUND STRAP- 12IN

CABLE ASSEMBLY- 2GA-5/16RNG X 3/8RNG X 25.00LG (WAS

51721500)

CABLE ASSEMBLY- 2GA-5/16RNGX 3/8RNGX 15.00LG

(effective through 03/27/13)

CABLE ASSEMBLY- 2GA-5/16RNGX 3/8RNGX 10.00LG

CABLE ASSEMBLY- 2GA-5/16RNGX 5/16RNGX 18.00LG

SWITCH- 275A CONTACTOR (WAS 77441277)

CABLE ASM - 1GA - 3/8RNG X SWVL 13.5 LG

20.

21.

22.

51721717

60133635

72060044

72062002

72601278

72601278

51722412

77441302

23. 77441303

REV. F 20090521

CABLE ASSEMBLY-10GA-#10RNGX 1/4RNGX 6.00LG

CABLE ASSEMBLY- 1GA-1/4RNGX 3/8RNGX 46.50LG

CABLE ASSEMBLY- 2GA-5/16RNGX 3/8RNGX 35.50LG

CONTACT JUNCTION

CAP SCREW 3/8-16 X 3/4 HHGR5Z

NUT 3/8-16 HEX (effective through 06/25/13)

CAP SCREW M8-1.25 X 20 HHZ

TERM-FSLPON I .25 TAB 16-14GA

CABLE ASM- 2GA-.31RNG X .31RNG X 18.00LG

TERM INSUL RED #8-2 GA WIRE

TERM INSUL BLK #8-2 GA WIRE

#1

KIT #

#1

#1

#1

#1

#1

#1

#1

#1

#1

QUANTITY

1

1

REF

REF

REF

1

1

1

1

REF

REF

REF

REF

REF

1

1

1

1

3

1

1

1

1

7

Tethered Control Installation (99904593)

Chapter 4 Parts 59

4

9

11

2

12

99904593 PARTS LIST

ITEM

1.

2.

PART #

91721524

51721502

4.

7.

9.

71413190

72062106

72063268

11.

12.

72602013

77044667

REV. A 20090521

DESCRIPTION QUANTITY

CONTROL KIT- TETHERED ELECTRIC CRANE 1

HANDLE ASM-TETHERED ELECTRIC CRANES 1

RELAY-2 RELAY MODULE

NUT 10-24 HEX NYLOCK

WASHER #10 W FLAT ANSI B27.2Z

1

2

2

SCR-MACH #10-24X 1.25 BTNHD ZC

PLUG CAP-DEUTSCH HDC36-24

2

1

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

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

Radio Control Installation, Standard

(99904594)

3

8

9

5

4

5005i / 6006i

STANDARD

RADIO CONTROL

INSTALLATION

99904594 PARTS LIST

ITEM

1.

PART #

91721523

DESCRIPTION

CONTROL KIT- RADIO ELECTRIC CRANE

QUANTITY

1

2.

3.

4.

5.

8.

9.

60133634

70734329

70734330

72060005

72063001

72063049

SLEEVE-TYPE C .63X .81X .31

RECEIVER - RADIO REMOTE TELE VORC

TRANSMITTER-RADIO REMOTE ELECTRIC

CRANE

CAP SCR .25-20X 1.25 HH GR5 Z

WASHER .25 FLAT

WASHER .25 LOCK

2

1

1

2

4

2

NEW 20090305

NOTE: See 99904522 for installation drawing prior to 2-15-09. Component parts are the same.

Radio Control Installation, Proportional

(99904595)

Chapter 4 Parts 61

3

8

9

4

5005i / 6006i

PROPORTIONAL

RADIO CONTROL

INSTALLATION

99904595 PARTS LIST

ITEM

1.

3.

4.

PART #

91721644

70734347

70734348

DESCRIPTION

CONTROL KIT- PROP ELECTRIC CRANE-12V

RECEIVER-PROP RADIO ELECTRIC CRANE CRANE

TRANSMITTER-RADIO ELECTRIC CRANE PROP

QUANTITY

1

1

1

5.

8.

72060005

72063001

CAP SCR .25-20X 1.25 HH GR5 Z

WASHER .25 FLAT

2

4

9. 72063049 WASHER .25 LOCK 2

NEW 20090305

NOTE: See 99904523 for installation drawing prior to 2-15-09. Component parts are the same.

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

Harness, Radio (77441270)

A B B A

SCHEMATIC, HARNESS, RADIO (77441270)

CJ-500

RADIO RECEIVER

TETHER INTER FACE

RS485 B

GROUND

RS485 A

+ B ATT

SHIELD (OPT)

1

2

3

4

5

CP-1200

RADIO RECEIVER

INTER FACE

(GR AY)

N/C

1

N/C

2

GROUND

3

PROPO RTIONA L

4

N/C

5

POWER (RADIO)

6

BOOM U P

7

BOOM DOWN

8

EXTEND OU T

9

WINCH U P

10

EXTEND IN

11

WINCH DOWN

12

1

2

P7 PROPO RTIONA L

Chapter 4 Parts

SPLICE G SPLICE G

1

2

P1 BOOM U P

1

2

P2 BOOM DOWN

1

2

P3

EXTEND OU T

W4

WINCH U P

1

2

P4 EXTEND IN

W5 WINCH DOWN

SPLICE G SPLICE G

63

B

A

J10

ANTI-TWO

A

B

P10 2800 PSI

CP-1201

RADIO RECEIVER

INTER FACE

(BLACK)

ROTATE CW

1

ROTATE CCW 2

HYDRAULIC PUM P

3

N/C

N/C

4

5

N/C

6

RS485 A

RS485 B

7

8

N/C 9

N/C 10

N/C

11

A2B/OVERLOAD 12

15A

W1

HYDRAULIC PUM P

W2

POWER

W3

GROUND

2

1

P5 RO TATE CW

2

1

P6 RO TATE CCW

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

Harness, Tethered (77441269)

CJ-2300

BOOM UP

BOOM

DOWN

EXTEND

OUT

EXTEND

IN

ROTATE

CW

ROTATE

CCW

HYDRAULIC

PUMP

W1

FUSED

15A

FUSE

W4 W5

WINCH UP

WINCH DOWN

W3

GROUND

A B B

A

CP-600

RELAY

CP-601

CJ-2300

TETHER HANDLE

CRANE POWER O

BOOM U P P

BOOM DOWN

N

EXTEND OU T

B

EXTEND IN F

RO TATE CW

A

RO TATE CCW K

POWER

L

HYDRAULIC PUM P S

WINCH DOWN C

WINCH U P

D

B

A

A

B

J10

P10

ANTI-TWO

2800 PSI

W4

WINCH DOWN

W5 WINCH U P

1

2

P1 BOOM U P

1

2

P2 BOOM DOWN

1

2

P3 EXT OU T

2

1

P4 EX T IN

2

1

P5 RO TATE CW

2

1

P6 RO TATE CCW

15A

W1

W2 W3

1 2 3 4 5 6

CP-600

REL AY MODULE

1 2 3 4 5 6

CP-601

REL AY MODULE

Chapter 4 Parts 65

Handle Assembly, Tethered (51721502)

6,9,12,27

14

29

28

OFF

POWER

ON

ROT

CCW

EXT

IN

WINCH

DOWN

LOWER

DOWN

CW

OUT UP

UP

4,10

25

24

TO SWITCH #19

SOLDER WIRE

TO TERMINAL

BLACK

(S) HYD

PUMP

23

2

3 26

13

7

21

30

8,20

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

Tethered Remote Handle Assembly (51721502)

R E D

RED/BLK

(WIN UP)

18

1 (REF) GRN

(TO ROTARY SWITCH)

BLK/ORN (CRANE PWR)

ORN/BLK (EXT OUT)

5

YEL (BOOM UP)

15(16)

YEL/BLK

(ROT CW)

1 4

1(6)

ORN

17

BLU/BLK

17

BRN/BLK (ROT CCW)

17

BRN (EXT IN)

WIRE FUNCTIONS

M

N

O

P

Q

R

H

J

K

L

S

T

U

V

W

X

-

D

E

F

G

SOLID/STRIPE

A YEL/BLK

B

C

ORN/BLK

BLU/BLK

RED/BLK

ORN/RED

BRN

BRN/RED

BLU/RED

BLK/RED

BRN/BLK

RED

BLU

ORN

BLK/ORN

YEL

BRN/BLU

YEL/RED

BLK

BLK/BLU

RED/BLU

BLU/ORN

ORN/BLU

YEL/BLU

RED/RON

FUNCTION

ROT CW

EXT OUT

WINCH DN

WINCH UP

-

EXT IN

-

-

-

ROT CCW

POWER

-

LOWER DN

CRANE POWER

LOWER UP

-

-

-

-

-

-

HYD PUMP

-

-

14.

15.

17.

18.

20.

21.

23.

24.

6.

7.

8.

9.

10.

11.

12.

13.

25.

26.

27.

3.

4.

5.

51716404 PARTS LIST

ITEM PART #

1.

2.

60045031

60119335

60111141

60119277

70034306

70029119

77044196

77044621

70394447

70392809

77044969

72066340

72531833

72061009

77040051

77040372

77040373

77044579

89044100

77044695

70733518

51716499

72601346

70395995

Chapter 4 Parts

28.

29.

70143223

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) 1

SCR-MACH #8-32 PAN HEAD (PART OF 25) 4REF

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

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.

67

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

Hydraulic Installation (99904458)

VALVE BANK

TANK

(RETURN)

ROT CW

ROT CCW

HYDRAULIC

MOTOR

(PORT B)

EXTENSION

OUT

EXTENSION

IN

HYDRAULIC

MOTOR

(PORT A)

EXT. CYL.

RETRACT

PORT

PRESSURE

BOOM UP

BOOM DOWN

EXT. CYL.

EXTEND

PORT

LOWER

CYL.

RETRACT

PORT

LOWER

CYL.

EXTEND

PORT

PLUMBING INSTALLATION - BEHIND MAST (99904458-3)

Chapter 4 Parts 69

3

9

11

8

10

POWER UNIT &

HYD RESERVOIR

31

4

13

A B 13

4

19

31

10

3

21

POWER UNIT &

HYD RESERVOIR

HYDRAULIC

MOTOR

REAR OF MAST

WITHOUT PROP VALVE

PROPORTIONAL

VALVE

24

23

19

9,23

20

22

13

A B

13

5

HYDRAULIC

MOTOR

REAR OF MAST

WITH PROP VALVE

(SEE NOTE)

5

VALVE

BANK

8

8

VALVEBANK

11

8

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

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

EXT CYL

14

RETRACT

PORT

12 12

14

EXTEND

PORT

VALVEBANK

9

9

7

6

9 9

WITH EXT CYLINDER

FRONT OF MAST

VALVEBANK

9

15

9

5

5

5

9

9

9

LOWER CYL

15

9

LOWER CYL

5

WITHOUT EXT CYLINDER

FRONT OF MAST

NOTE:

1

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

EXCEPT 51397335 (ITEM #3)

2

CRANES WITHOUT EXTENSION CYLINDER USE PLUGS 72532522 TO BLOCK HYDRAULIC PORTS B1 AND

A1 ON THE VALVE BLOCK.

ELECTRIC CRANE WITH HYDRAULIC INSTALLATION (99904458-4)

30

31

10

9

3

9

4

Chapter 4 Parts 71

20

11

8

8

4

13

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

PROPORTIONAL VALVE ASSEMBLY INSTALLATION (99904458-5)

31

30

10

3

1

9

20

23

8

11

4

9

4

8

TO VALVE

BLOCK PORT (P)

(PRESSURE)

TO VALVE

BLOCK T (TANK)

TO POWER UNIT

PROPORTIONAL VALVE

13

INSTALLATION WITHOUT HYDRAULIC EXTENSION (99904458-6)

29

16

24

23

18

22

31

30

10

3

9

4

15

20

11

8

4

8

19

26,28

13

13

INSTALLATION WITH HYDRAULIC EXTENSION (99904458-7)

Chapter 4 Parts 73

TO VB PORT B1

(RETRACT PORT)

6

12

14

14

TO EXT CYL PORT "R"

TO EXT CYL PORT "E"

12

7

9

TO VB PORT B2

(RETRACT PORT)

5

9

TO VB PORT A1

(EXTEND PORT)

5

TO VB PORT A2

(EXTEND PORT)

99904458 PARTS LIST

9.

10.

11.

12.

13.

14.

15.

16.

6.

7.

8.

ITEM

1.

2.

3.

4.

5.

PART #

99904456

51721707

51397336

51395874

51397480

51396413

51395422

72053758

72532351

72532699

72533567

72534567

72533589

72533052

72532522

73540325

DESCRIPTION

DRAWING-CRANE & WINCH 6006I

HYDRAULIC KIT

HOSE-FI .25 X 12.50 (4-4) 100R17

HOSE-FJ .25 X 26.00 (4-4) 100R17

HOSE-FF .25 X 27.50 (4-4) 100R17

HOSE-FF .25 X 22.00 (4-4) 100R17

HOSE-FF .25 X 24.00 (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 4 4

#2

#2

#2

ELBOW-M STR/90/M JIC XLG 6 4

ADAPTER-M STR/M JIC 10 4

ADAPTER-M STR/F STR 8 6

PLUG-STRAIGHT HEX HD STL .44

VALVE-PROPORTIONAL FLOW CONTROL, 12V

ELEC CRANE

#2

#2

#2

KIT #

#2

#2

#2

#2

#2

#2

2

2

2

2

1

7

1

1

1

1

2

QUANTITY

1

1

1

2

2

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

99904458 PARTS LIST

ITEM

17.

18.

PART #

91721626

51395663

19.

20.

21.

22.

23.

24.

25.

51397434

51397452

72053758

72532351

72532981

72534477

51722635

26.

27.

28.

72063001

72063049

72060009

29.

30.

60134907

72532674

31. 72534714

REV. J 20120326

DESCRIPTION

HYDRAULIC KIT-PROPORTIONAL

HOSE-FJ .25 X 14.00 (4-4) 100R17

HOSE-FZ .25 X 16.00 (4-4) 100R17

HOSE-FI .25 X 11.50 (4-4) 100R17

ELBOW-M STR/90/M JIC 4 4

ADAPTER-M STR/M JIC 4 4

TEE-SWVL NUT RUN JIC 4

ADAPTER-M STR/M JIC 4 4 XLG

HARDWARE KIT-PROPORTIONAL CONTROL

VALVE, ELEC CRANE

WASHER .25 FLAT

WASHER .25 LOCK

CAP SCREW .25-20X 2.25 HH GR5 Z

PLATE-SPACER PROP VALVE

CAP-JIC STL 4 (.44 THD)

TEE-STL JIC/STR/JIC 4 6 4 BRANCH

KIT #

#17

#17

#17

#17

#17

#17

#17

#25

#25

#25

#2

#2

1

1

1

2

2

2

2

1

1

1

1

1

1

QUANTITY

1

1

6006i Decal Installation (95721549)

Chapter 4 Parts 75

12

25

27

14

26

22

12

9

4

5

27

25

26

13

5

5

4

11

4

28

31

30

6,7,10

DECAL PLACEMENT (IF NOT SHOWN ON CRANE)

ITEM #

15,21,23,

24,28,29

16

19

PLACEMENT

AT OR NEAR REMOTE HANDLE STORAGE POINT

2 ON REAR STABILIZERS

AT OR NEAR DRIVELINE

18,20 ON ALL FOUR SIDES OF CARRIER VEHICLE

32 ON CRANE POWER CABLE CONNECTION AT VEHICLE BATTERY

99904375 PARTS LIST

ITEM PART # DESCRIPTION KIT #

1.

2.

95719347

95719348

DECAL KIT - TELE COMMON

DECAL KIT - BODY COMMON

QTY IN KIT QTY ON

CRANE

1

1

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

99904375 PARTS LIST

ITEM PART # DESCRIPTION KIT #

12.

13.

14.

15.

16.

17.

3.

4.

5.

6.

7.

8.

9.

10.

11.

24.

25.

26.

27.

28.

29.

18.

19.

20.

21.

22.

23.

70392868

70392891

70394445

70396613

70394189

71039134

70392982

71394453

70392887

70396781

70397493

70397334

30.

31.

70397351

70397404

32. 70397405

NEW 20081015

95721549

70391612

70391613

70392399

70392524

70394166

70394443

70395090

70395324

70395670

71391522

71391523

70392213

70392864

70391598

DECAL KIT - 6006i SPECIFIC

DECAL-GREASE WEEKLY (LEFT)

DECAL-GREASE WEEKLY (RIGHT)

DECAL-LUBRICATE WORM

DECAL-ROTATE CRANE WHILE GREAS

DECAL-INSTR FOR MNL OPERATION

DECAL-WARNING FREEFALLING BOOMS

DECAL-GREASE WORM DR BRNGS

DECAL-ASME/ANSI B30.5-TELESCOP

DECAL-CAUTION DOWN HAUL WT

DECAL-ANGLE INDICATOR RH

DECAL-ANGLE INDICATOR LH

DECAL-CAUTION DONT WASH/WAX

DECAL-WARNING STAB STAND CLEAR

DECAL-WARNING, MAN STAB

DECAL-WARNING CR LOADLINE (TRK)

DECAL-DANGER DRIVELINE

DECAL-DANGER ELEC HZD LG TELES

DECAL-CRANE SAFETY & OPER

DECAL-MOBILOIL RESERVOIR

DECAL-CAUTION OIL LEVEL

DECAL-SERVICE & REPAIR

DECAL-LOAD BLOCK RATING 4.0TON

DECAL-DIAMOND IMT 5X10

DECAL-6006i ID

DECAL-CAPACITY CHART 6006i

DECAL-WARNING, ELEC CR OL

DECAL-REMOTE PENDANT STORAGE

DECAL-DANGER, UNPLUG CRANE

DECAL-CRANE POWER DISCONNECT

3

3

3

2

3

3

3

3

3

2

2

2

2

2

2

1

2

2

1

1

1

1

1

1

1

1

1

1

1

2

2

1

1

2

2

1

2

1

1

1

1

4

1

4

1

4

2

2

1

1

1

1

1

1

1

QTY IN KIT QTY ON

CRANE

1

9

6

1

3

3

1

1

0

1

1

1

2

1

1

1

2

0

2

2

1

1

2

2

1

2

1

1

1

1

4

1

4

C

H A P T E R

5

General Reference

77

In This Chapter

Inspection Checklist ................................................................. 77

Deficiency / Recommendation / Corrective Action Report ......... 82

Thread Torques ........................................................................ 84

Turntable Bearing Thread Tightening Sequence ...................... 84

Turntable Bearing Inspection .................................................... 86

Turntable Bearing Tilt Test ....................................................... 87

Inspection Checklist

NOTICE:

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

OWNER/COMPANY:

CONTACT PERSON:

TYPE OF INSPECTION (circle one):

CRANE MAKE & MODEL:

CRANE SERIAL NUMBER:

DAILY MONTHLY QUARTERLY ANNUAL

DATE INSPECTED:

HOURMETER READING (if applicable):

INSPECTED BY (print): UNIT I.D. NUMBER:

LOCATION OF UNIT: SIGNATURE OF INSPECTOR:

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

TYPE OF INSPECTION

NOTES:

Daily and monthly inspections are to be performed by a “competent person”, who is capable of identifying existing and predictable hazards in the surroundings or working conditions which are unsanitary, hazardous, or dangerous to employees, and who has authorization to take prompt corrective measures to eliminate them.

Quarterly and annual inspections are to be performed by a “qualified person” who, by possession of a recognized degree, certificate, or professional standing, or who by extensive knowledge, training and experience, successfully demonstrated the ability to solve/resolve problems relating to the subject matter, the work, or the project.

One hour of normal crane operation assumes 20 complete cycles per hour. If operation exceeds 20 cycles per hour, inspection frequency should be increased accordingly.

Consult Operator / Service Manual for additional inspection items, service bulletins and other information.

Before inspecting and operating crane, crane must be set up away from power lines and leveled with stabilizers fully extended.

DAILY (D): Before each shift of operation, those items designated with a (D) must be inspected.

MONTHLY (M): Monthly inspections or 100 hours of normal operation (whichever comes first) includes all daily inspections plus items designated with an (M). This inspection must be recorded and retained for a minimum of 3 months.

QUARTERLY (Q): Every three to four months or 300 hours of normal operation (whichever comes first) includes all daily and monthly inspection items plus items designated with a (Q). This inspection must be documented, maintained, and retained for a minimum of 12 months, by the employer that conducts the inspection.

ANNUAL (A): Each year or 1200 hours of normal operation (whichever comes first) includes all items on this form which encompasses daily, monthly and quarterly inspections plus those items designated by (A). This inspection must be documented, maintained, and retained for a minimum of 12 months, by the employer that conducts the inspection.

INSPECTION CHECKLIST STATUS KEY:

S = Satisfactory

R = Recommendation

(Should be considered for corrective action)

NA = Not Applicable

X = Deficient

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

FREQUENCY ITEM KEY

D

D

D

D

D

D

D

1

2

3

4

5

6

7

Labels

Crane

Controls

Station

Hydraulic

System

Hook

Wire Rope

INSPECTION DESCRIPTION STATUS

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.

(S,R,X,NA)

Presence and proper operation of hook safety latches.

Inspect for apparent deficiencies per applicable requirements and manufacturer’s specifications.

Chapter 5 General Reference 79

FREQUENCY ITEM KEY

D

D

D

D

D

D

D

D

D

D

D

D

D

D

D

M

M

M

M

M

M

M

M

M

M

M

M

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

Pins

General

Operation

INSPECTION DESCRIPTION

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.

STATUS

(S,R,X,NA)

Remote

Ctrl

Electrical

Anti Two-

Block or

Two-Block

Damage

Prevention

Tires

Ground

Conditions

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.

Level

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.

Operator cab windows

Rails, rail stops, rail clamps and supporting surfaces

Safety devices

Electrical

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

Daily

Other

All daily inspection items.

Cylinders

Valves

Valves

Valves

General

Electrical

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.

Structure

Welds

Pins

All structural members for damage.

All welds for breaks and cracks.

All pins for proper installation and condition.

Hardware All bolts, fasteners and retaining rings for tightness, wear and corrosion.

Wear Pads Presence of wear pads.

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

FREQUENCY ITEM KEY

M

M

M

M

M

M

M

M

M

Q

Q

Q

Q

Q

Q

Q

Q

35

36

37

38

39

40

41

42

43

44

45

46

59

60

61

62

63

64

65

66

67

68

69

70

71

72

73

74

75

76

77

52

53

54

55

56

57

58

47

48

49

50

51

78

INSPECTION DESCRIPTION

Hyd Lines

Pump &

Motor

PTO

Hyd Fluid

Hyd Lines

Hook

Wire Rope

Manual

Daily

Monthly

Rotation

Sys

Hardware

Structure

Hardware

Pumps &

Motors

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.

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)

STATUS

(S,R,X,NA)

Chapter 5 General Reference 81

FREQUENCY ITEM KEY

Q

Q

A

A

A

A

A

A

A

A

Q

Q

A

A

A

A

79

80

81

97

98

99

100

101

102

103

104

105

88

89

90

91

92

93

94

95

96

82

83

84

85

86

87

106

107

108

109

INSPECTION DESCRIPTION

Valves

Cylinders

• 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)

Winch

• Inner boom cylinder(s)

• Outer boom cylinder(s)

• Extension cylinder(s)

• Rotation cylinder(s)

• Jib lift cylinder(s)

Hyd Filters

Daily

Monthly

Quarterly

Hyd Sys

Controls

• 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.

Valves

Valves

Safety valve calibration for correct pressure & relief valve settings.

Valves for failure to maintain correct settings.

Rotation

Sys

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

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

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

Wear Pads Wear pads for excessive wear.

Loadline Loadline for proper attachment to drum.

STATUS

(S,R,X,NA)

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

Deficiency / Recommendation / Corrective

Action Report

DATE: OWNER: UNIT I.D. NUMBER:

GUIDELINES a

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

b

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

c

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

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

X = DEFICIENCY R = RECOMMENDATION CA = CORRECTIVE ACTION TAKEN

X,R,CA ITEM # EXPLANATION DATE CORRECTED

X,R,CA ITEM # EXPLANATION

Chapter 5 General Reference 83

DATE CORRECTED

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

Thread Torque Chart (English)

FINE THREAD BOLTS (ENGLISH)

SIZE BOLT

DIA.

GRADE 5 GRADE 8

COARSE THREAD BOLTS (ENGLISH)

SIZE

BOLT

DIA.

GRADE 5 GRADE 8

3

4

5

SAE J429

GRADE 5

(DIA-TPI) (INCHES) PLAIN

SAE J429

GRADE 8

SAE J429

GRADE 5

SAE J429

GRADE 8

PLATED PLAIN PLATED (DIA-TPI) (INCHES) PLAIN PLATED PLAIN PLATED

(FT-LB) (FT-LB) (FT-LB) (FT-LB) (FT-LB) (FT-LB) (FT-LB) (FT-LB)

5/16-24

3/8-24

7/16-20

1/2-20

9/16-18

5/8-18

3/4-16

7/8-11

1-12

1 1/8-12

1 1/4-12

1 3/8-12

0.3125

0.375

0.4375

0.5

0.5625

0.625

0.75

0.875

1

1.125

1.25

1.375

19

35

55

90

120

170

300

445

645

890

1240

1675

14

26

41

64

90

130

225

325

485

670

930

1255

27

49

78

120

170

240

420

670

995

1445

2010

2710

1 1/2-12

NOTES

1

1.5 2195 1645 3560

Tightening torques provided are midrange.

20

35

58

90

130

180

315

500

745

1085

1510

2035

2670

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

17

31

49

75

110

150

265

395

590

795

1120

1470

1950

13

23

37

57

82

115

200

295

445

595

840

1100

1460

25

44

70

105

155

220

375

605

910

1290

1815

2380

3160

18

33

52

80

115

160

280

455

680

965

1360

1780

2370

2

Consult bolt manufacturer’s particular specifications, when provided.

Use flat washers of equal strength.

All torque measurements are given in foot-pounds.

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 85

Thread Torque Chart (Metric)

FINE THREAD TORQUE CHART (METRIC) COARSE THREAD TORQUE CHART (METRIC)

TIGHTENING TORQUE

SIZE

(DIA-

TPI)

BOLT

DIA.

(INCHES)

TIGHTENING TORQUE

SIZE

(DIA-

TPI)

BOLT DIA

(INCHES)

2

3

4

5

SAE J429

GRADE 5

PLAIN PLATED

(KG-M) (KG-M)

SAE J429

GRADE 8

PLAIN PLATED

(KG-M) (KG-M)

5/16-24 0.3125

3/8-24 0.375

7/16-20 0.4375

1/2-20 0.5

9/16-18 0.5625

5/8-18 0.625

3

5

8

12

17

24

2

4

6

9

12

18

4

7

11

17

24

33

3/4-16

7/8-11

1-12

0.75

0.875

1

41

62

89

31

45

67

58

93

138

1 1/8-12 1.125

1 1/4-12 1.25

123

171

93

129

200

278

1 3/8-12 1.375 232 174 375

1 1/2-12 1.5

NOTES

1

304 228 492

Tightening torques provided are midrange.

44

69

103

150

209

281

369

3

5

8

12

18

25

Consult bolt manufacturer’s particular specifications, when provided.

Use flat washers of equal strength.

All torque measurements are given in kilogram-meters.

5/16-18 0.3125

3/8-16 0.375

7/16-14 0.4375

1/2-13 0.5

9/16-12 0.5625

5/8-11 0.625

3/4-10

7/8-9

1-8

1 1/8-7

1 1/4-7

1 3/8-6

1 1/2-6

0.75

0.875

1

1.125

1.25

1.375

1.5

SAE J429

GRADE 5

PLAIN PLATED

(KG-M) (KG-M)

37

55

82

110

155

203

270

2

4

7

10

15

21

2

3

5

8

11

16

28

41

62

82

116

152

210

SAE J429

GRADE 8

PLAIN PLATED

(KG-M) (KG-M)

3

6

10

15

21

30

52

84

126

178

251

329

438

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.

39

63

94

133

188

246

328

2

5

7

11

16

22

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.

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

Turntable Bearing Thread Tightening

Sequence

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

WARNING

Number 1 can be assigned to any capscrew if the sequence remains the same in reference to number 1.

TIGHTENING PROCEDURE

1

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

2

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

3

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

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

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

4

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

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

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

5

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

Chapter 5 General Reference 87

Turntable Bearing Inspection

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

1

Metal particles present in the bearing lubricant.

2

Increased drive power required to rotate the crane.

3

Noise emitting from the bearing during rotation.

4

Rough rotation.

5

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

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

Turntable Bearing Tilt Test.

(see "Turntable Bearing Tilt Test" on page 87)

Periodic readings indicating a steady increase in TILT may be an indicator of bearing wear.

Note that a bearing found to have no raceway cracks or other structural irregularities should be reassembled and returned to service.

Turntable Bearing Tilt Test

1

Place crane in vertical position.

2

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

3

Lower crane to the horizontal position.

4

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

5

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

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

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

Loader or

Tirehand

Model

1014/1014A

1015

2015/2020

2109

5200R

5217

5800

7020

16000-I, II, III

32018

32027

32030

T30

T40

23516

14K160TH

COMMANDER IV

1221R

1225R

8000L

2820

3000

3016/3020

7025

7200

7415

9800

12916

13031

13034

14000

3203i

3816/3820

4004i

421/425

4300

5005i

8025

9000

15000

18000

20017

8000L

H1200

H1200RR

T50 5016/5020

6006i

6016/6020

6022

5525 / 6025 / 6625

EZ Hauler I, II

EZ Hauler 3000 /

5500

.875" (22 mm) 1.00" (25 mm) 1.5” (38 mm) 1.75" (44 mm) Ball Dia.

(Ref)

Tilt Dim. .060" (1.524 mm) .070" (1.778 mm)

1.18 - 1.25" (30-32 mm)

.075" (1.905 mm) .085” (2.159 mm) .090" (2.286 mm)

Rev 20100331

Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement

Table of contents