Model 425AT Crane - Iowa Mold Tooling Co., Inc.

Transcription

000425AT:99900653: 20061020
Model 425AT Crane
Volume 2 - PARTS AND SPECIFICATIONS
Section
Section
Section
Section
1
2
3
4
SPECIFICATIONS
CRANE REFERENCE
REPLACEMENT PARTS
GENERAL REFERENCE
Manufactured Exclusively for
AUTO TRUCK, INC.
by
IOWA MOLD TOOLING CO., INC.
MANUAL PART NUMBER 99900653
Iowa Mold Tooling Co., Inc. is an Oshkosh Truck Corporation company.
000425AT:99900653: --------
REVISIONS LIST
DATE
20000914
LOCATION
2-5, 2-6
SECT 3-PARTS
20010118
20010720
20011204
3-20
3-16
3-4
3-31
3-4
3-16
1-1
20030512
20060321
20061020
DESCRIPTION OF CHANGE
ECN 8609-REVISED SPARE PARTS LIST
ECN 8609-REORGANIZED ALL OF SECT 3 WITH ADDITION OF FAUVER 18D VB ASM:
41710765, 41716193, 3C166000, 73540080, 91716194, 73733479, 73733411, 99903200 ADDED
EFF WITH SN 425AT2K1024 ON.
ECN9000-51715568-ADD RED/BLU & YEL/BLU - CHG DWG
ECN 8723 - #5 73540044 WAS 73054936
MOBILTAC 375NC LUBRICANT NOTE ADDED
ECN 8834 - LIGHT KIT REPLACED
BASE ASM (41707659) - ITEM 33 WAS 34, CHANGED NUMBERING
VB-5 SECTION (73733479) ITEM #3 CHANGED TO 73054934
UPDATED WITH NEW OWNERSHIP STATEMENT.
000425AT:99900653: 19980504
INTRODUCTION
This volume deals with information applicable to your
particular crane. For operating, maintenance and
repair instructions, refer to Volume 1, OPERATION,
MAINTENANCE AND REPAIR.
Before operation of performance of any maintenance
on your crane, familiarize yourself with the
OPERATOR’S CRANE SAFETY MANUAL, part
number 99900313. It provides information critical to
the safe operation and maintenance of your crane. It
is the user’s responsibility to maintain and operate
this unit in a manner that will result in the safest
working conditions possible.
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 crane. It also contains specifications,
description and installation information.
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 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. Listed below is a publication that the user
should thoroughly read and understand.
ANSI/ASME B30.22
ARTICULATING BOOM CRANES
The American Society of Mechanical Engineers
United Engineering Center
345 East 47th Street
New York, NY 10017
Three means are used throughout this manual to gain
the attention of personnel. They are NOTE’s,
CAUTION’s and WARNING’s and 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.
Read and familiarize yourself with the
IMT OPERATOR’S CRANE SAFETY MANUAL
before operating or performing any maintenance
on your crane.
000425AT:99900653: 20000801
NOTES
000425AT:99900653: 19920203
1-1
SECTION 1. 425AT CRANE SPECIFICATIONS
GENERAL SPECIFICATIONS ....................................................................................... 3
LIFTING CAPACITY (from centerline of rotation) ......................................................... 3
PERFORMANCE CHARACTERISTICS: ....................................................................... 3
POWER SOURCE........................................................................................................... 3
CYLINDER HOLDING VALVES ..................................................................................... 3
ROTATION SYSTEM ...................................................................................................... 4
HYDRAULIC SYSTEM ................................................................................................... 4
CYLINDERS ................................................................................................................... 4
MINIMUM CHASSIS SPECIFICATIONS ........................................................................ 4
CAPACITY CHART ........................................................................................................ 5
GEOMETRIC CONFIGURATION .................................................................................... 6
000425AT:99900653: 19920203
1-2
NOTES
000425AT:99900653: 20000705
1-3
425AT CRANE SPECIFICATIONS
GENERAL SPECIFICATIONS
CRANE RATING
39,000 ft-lbs (5.39 ton-m)
REACH - FROM CENTERLINE OF ROTATION
25'-2" (7.67m)
HYDRAULIC EXTENSIONS
45"/51" (114.3cm/129.5cm)
MANUAL EXTENSION
45" (114.3cm)
LIFTING HEIGHT - FROM BASE OF CRANE
31'-2" (9.50m)
CRANE WEIGHT
2100 lbs (953 kg)
STORAGE HEIGHT-FROM BASE OF CRANE
7'-0" (2.13m)
MOUNTING SPACE REQUIRED
27-1/2" x 14-3/4" (69.8 x 48.26cm)
MOUNTING HOLE PATTERN
14-3/4" x 14-3/4" (37.46 x 37.46cm)
OPTIMUM PUMP CAPACITY
7 U.S. GPM (26.5 liters/min)
OIL RESERVOIR CAPACITY
17 U.S. GAL. (64.3 liters)
DESIGN FACTORS (PINS & HYDRAULICS)
4/1
LIFTING CAPACITY (FROM CENTERLINE OF ROTATION)
9'-3" (2.82m)
13'-5" (4.09m)
17'-2" (5.23m)
21'-5" (6.53m)
25'-2" (7.67m)
4200 lbs (1905 kg)
2900 lbs (1315 kg)
2250 lbs (1020 kg)
1800 lbs (816 kg)
1350 lbs (612 kg)
Deduct the weight of load handling devices from the capacities listed above.
PERFORMANCE CHARACTERISTICS:
ROTATION:
INNER BOOM ELEVATION:
OUTER BOOM ARTICULATION:
TWO-STAGE EXTENSION
1ST STAGE: 45" (114.3cm)
2ND STAGE: 51" (129.5cm)
450o (7.85 Rad.)
-20° to +72° (-0.35 Rad. to +1.26 Rad.)
125° (2.18 Rad.)
30 seconds
15 seconds
17 seconds
21 seconds
10 seconds
POWER SOURCE
Integral-mounted hydraulic pump and PTO application. Other standard power sources may be utilized minimum power required is 12 horsepower.
CYLINDER HOLDING VALVES
The holding sides of all cylinders are equipped with integral-mounted holding and/or counter-balance
valves to prevent sudden cylinder collapse in case of hose or other hydraulic failure. The outrigger
cylinders have positive, pilot-operated holding valves that open only upon command.
The inner, outer and extension cylinders have counter-balance valves. The counter-balance valve
serves several functions. First, it is a holding valve. Secondly, it is so constructed that it will control the
lowering function and allow that motion to be feathered while under load. Finally, if a hose breaks, the
only oil loss will be that in the hose.
BOX 189, GARNER, IA 50438-0189
TEL: 641-923-3711 FAX: 641-923-2424
000425AT:99900653: 20000905
1-4
ROTATION SYSTEM
Turntable bearing powered with a high-torque hydraulic motor through a ring-and-pinion type spur gear
train (total gear reduction is 43.1 to 1).
HYDRAULIC SYSTEM
Open-centered, full-pressure system that requires 7 GPM (26.5 liters/min.) optimum oil flow at 2,350
PSI (162 bar). Six-spool, stack-type control valve operated remotely. System includes hydraulic oil
reservoir, suction-line filter, pump, 6-section valvebank, return-line filter and all hoses and fittings.
CYLINDERS
INNER CYLINDER
BORE
5" (12.7cm)
STROKE
19-1/4" (48.9cm)
OUTER CYLINDER
5" (12.7cm)
21-1/2" 54.6cm)
TWO-STAGE EXTENSION CYLINDER
1ST STAGE
2ND STAGE
4" (10.2cm)
2-1/2" (6.4cm)
45" (114.3cm)
51" (129.5cm)
MINIMUM CHASSIS SPECIFICATIONS
BODY STYLE
Conventional Cab
WHEEL BASE
175" (444.5cm)
CAB TO AXLE
102" (259.1cm)
* FRAME SECTION MODULUS
14 cubic inches (229.5cc)
RBM
680,000 in-lbs (7837 kg-m)
FRONT AXLE RATING
7000 lbs (3175 kg)
REAR AXLE RATING
15,000 lbs (6804 kg)
TRANSMISSION
4-SPEED
* Frame material is 50,000 PSI minimum.
In addition to these specifications, heavy-duty electrical and cooling systems and dual rear wheels are
required. It is recommended that the vehicle be equipped with an electric tachometer, auxiliary brake
lock, power steering and 5-speed transmission in lieu of a 4-speed transmission.
000425AT:99900653: 19920203
1-5
CAPACITY CHART
000425AT:99900653: 19920203
1-6
GEOMETRIC CONFIGURATION
000425AT:99900653: 20000914
2-1
SECTION 2. 425AT CRANE REFERENCE
MAJOR CRANE ASSEMBLIES ................................................................................ 3
WELDMENT PART NUMBER LOCATIONS ............................................................. 3
GREASE ZERK LOCATIONS & LUBRICANT REQUIREMENTS ........................... 4
RECOMMENDED SPARE PARTS LIST.................................................................... 5
INSTALLATION .......................................................................................................... 7
CRANE INSTALLATION............................................................................................ 7
HYDRAULIC INSTALLATION ................................................................................... 8
PROPORTIONAL REMOTE CONTROLS ................................................................. 9
000425AT:99900653: 19920203
2-2
NOTES
000425AT:99900653: 19920203
2-3
MAJOR CRANE ASSEMBLIES
WELDMENT PART NUMBER LOCATIONS
000425AT:99900653: 19920203
2-4
GREASE ZERK LOCATIONS & LUBRICANT REQUIREMENTS
ITEM
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
LOCATION DESCRIPTION
DRIVE GEAR GREASE EXTENSION
TURNTABLE/BEARING GREASE EXTENSION
*ROTATE CRANE WHILE GREASING
PINION GEAR
MAST/INNER CYLINDER HINGE PIN
MAST/INNER BOOM HINGE PIN
INNER CYLINDER ROD/INNER BOOM HINGE PIN
INNER BOOM/OUTER BOOM HINGE PIN
OUTER CYLINDER ROD
OUTER BOOM TRUNNION PIN
EXTENSION CYLINDER ROD
LUBRICANT
FREQUENCY
SHELL ALVANIA 2EP
OR
WEEKLY
SHELL RETINAX “A”
NOTE: All application points must be greased weekly under normal work loads and moderate weather conditions.
Under severe operating conditions, lubrication should be performed more frequently. See Volume 1; Operation,
Maintenance and Repair for additional lubrication requirements.
000425AT:99900653: 20000914
2-5
RECOMMENDED SPARE PARTS LIST
1 YEAR SUPPLY
425AT CRANE
FOR MANUAL: 99900653
This spare parts list does not necessarily indicate that the items can be expected to fail in the course of a year. It 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. 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.
SHELF
ASSEMBLY
LIFE
ORDER
DESIGNATION
ITEM NO.
PART NO.
DESCRIPTION
QTY
CODE
(MO)
QTY
41707659.01.19961011
41716193.01.20000914
3C166000.01.20000914
41711600.01.19970123
3C081712.01.19990127
41705246.01.19920203
3K095850.01.19970718
91716194.01.20000914
73733479.01.20000914
73731911.01.19920203
51715568.01.20000914
BASE ASM
3
60020114
BUSHING
4
60020115
BUSHING
5
60020116
BUSHING
6
60020154
BUSHING
14
7Q072112
O-RING
15
71056010
PINION GEAR
33
73054538
COUNTERBALANCE VALVE
INNER BOOM ASM
3
60020131
BUSHING
INNER BOOM CYLINDER
3
6H500025
HEAD
4
6I500181
PISTON
5
7BF81220
BUSHING
6
7BF81020
BUSHING
7
9C166000
SEAL KIT
21
73540052
CBAL VALVE
26
77041605
PR SWITCH
OUTER BOOM ASM
3
60020131
BUSHING
4
60030015
WEAR PAD
9
60020126
BUSHING
OUTER BOOM CYLINDER
3
6H050025
HEAD
4
6I050181
PISTON
6
73054242
VALVE
7
9A202029
SEAL KIT
18
7BF81220
BUSHING
19
7BF81520
BUSHING
EXTENSION BOOM ASM
8
60030007
WEAR PAD
9
60030064
WEAR PAD
10
60030145
WEAR PAD
25
60030127
WEAR PAD
EXTENSION CYLINDER
4
6H271511
HEAD
5
6H112820
HEAD
6
6I025087
PISTON
7
6I095850
PISTON
11
73054242
VALVE
13
9X095850
SEAL KIT
HYDRAULIC KIT 5F
6
72532740
ELBOW
VALVEBANK ASM 5-SECTION
5
7Q072205
O-RING
6
76392808
O-RING
7
70143337
O-RING
10
73054624
PROPORTIONAL SOLENOID
14
77041361
COIL
VALVEBANK ASM 4-SECTION
3
73054034
VALVE
4
73054935
VALVE
6
7Q072013
O-RING
REMOTE HANDLE ASM
11
70394183
TRIGGER ASM
16
77040371
TOGGLE SWITCH SPST
17
77040372
TOGGLE SWITCH SPDT
18
77040373
TOGGLE SWITCH SPST
1
1
1
1
2
1
2
W
W
W
W
W
W
C
2
W
1
1
4
2
1
1
1
W
W
W
W
W
C
C
2
2
4
W
W
W
1
1
1
1
2
2
W
W
C
W
W
W
2
1
1
1
W
W
W
W
1
1
1
1
2
1
W
W
W
W
C
W
2
W
2
10
5
1
6
W
W
W
C
W
1
1
12
C
C
W
1
1
6
2
W
W
W
W
000425AT:99900653: 20000914
2-6
(BLANK)
000425AT:99900653: 19920203
2-7
INSTALLATION
GENERAL
This section contains specific instructions for the
installation of your crane. Prior to installing the crane
and hydraulic components, make sure the chassis is
ready to receive the crane (refer to Volume 1,
MAINTENANCE AND REPAIR for chassis
preparation. Each installation may vary in
components used. It is important to use hoses of
proper length, pumps of correct size, and PTO’s of
adequate speed. Reinforce the chassis frame as
necessary and install the PTO and pump.
CRANE INSTALLATION
In addition to meeting Minimum Chassis
Specifications in Section 1, there must be sufficient
room for mounting the crane and the platform must be
strong enough to support the crane and rated load.
2. Install the mounting tie-rods, washers, and locknuts to secure the crane base to the mounting
surface (see figure below). Tighten and torque the
mounting hardware to 200 ft-lbs (28 kg-m).
CAUTION
Do not attempt to apply the same torque to the tie rod
and self-locking nuts as shown in the Torque Data
Chart in the APPENDIX in Volume 1. Do not exceed
200 ft. lbs. (28 kg-m). Exceeding this torque value
could damage either the chassis or crane base.
Power wrenching is not recommended until the lead
thread of the nut insert is engaged by hand turning.
3. Touch up paint on crane and chassis as
necessary.
To install the crane on the chassis:
1. Use a lifting device capable of lifting the weight of
the crane - 2100 lbs. (953 kg). Attach the lifting
device to the lift bracket welded to the top of the inner
boom. Secure the lifting device to prevent slippage
and lift the crane. Apply a bead of waterproof
compound, such as silicon based caulk, to the
bottom of the base. Move the carrier vehicle into
position under the crane and lower the crane into
position on the chassis. Allow sufficient room
between the crane and cab for mast rotation.
CRANE INSTALLATION
000425AT:99900653: 19920203
2-8
HYDRAULIC INSTALLATION
Installations vary and it will be necessary for the
installer to determine the best configuration for his
individual installation. Following is a general guide to
installation (see figure below).
5. Fill the hydraulic reservoir (refer to Volume 1 for
hydraulic oil specifications).
6. Check all connections for leaks.
7. Open the gate valves.
1. Install the suction filter to the suction port, and a
return filter to the return port of the standard reservoir
with 1-1/4" nipples and gate valves.
2. Install a 1-1/4" diameter hose between the pump
and the suction filter, using barbed nipples and hose
clamps.
3. Install a 1/2" diameter hose between the pump
and the valvebank inlet section.
4. Install a 3/4" diameter hose between the
valvebank outlet section and the reservoir.
CAUTION
Failure to open the gate valve will result in a dry
running pump which may damage the pump.
8. Start the vehicle engine and tes each crane
function individually. Conduct a visual inspection to
make certain there are no leaks and that everything
is operating properly.
9. Check the oil level in the reservoir and add oil if
necessary.
GENERAL HYDRAULIC INSTALLATION
000425AT:99900653: 19920203
GENERAL
2-9
PROPORTIONAL REMOTE CONTROLS
This section is provided to help the operator and the
installer become familiar with proportional remote
controls. It discusses the theory of operation,
installation, and troubleshooting.
OPERATION
The speed at which a crane operates is directly
related to the amount of oil supplied to its main
control valve. The proportional remote control feature
regulates the amount of oil that is made available to
the main control valve, thereby controlling the speed
of operation. This is accomplished by means of an
electrically controlled hydraulic system consisting of
a remote control, an amp driver, and a flow control.
An increase in signal voltage to the amp driver
causes it to provide higher signal voltage to the flow
control solenoid. Higher signal voltage at the flow
control solenoid causes it to limit the flow of oil
allowed to bypass to the reservoir. Limiting the
amount of oil that is bypassed forces more oil
downstream, thus increasing the speed of operation.
REMOTE CONTROL
The remote control allows the operator to control the
crane remotely. It provides the housing for the
switches that control which crane function, or
functions, are to be activated. It also houses the
potentiometer and trigger assembly that actually
provide the signal voltage to the amp driver. It is
connected to the main control valve and the amp
driver through a 30 foot cable. The function switches
in the remote control are simple on/off switches and
have no effect on the speed of the function. The
speed of the function selected is controlled only by
the trigger, therefore, if two functions are selected at
the same time, when the trigger is pulled, the speed
of both functions will increase.
AMP DRIVER
The amp driver is an electronic device used to take
the signal that it receives from the trigger in the
remote control, and subsequently provide a signal
voltage to the flow control solenoid. It is often
mounted to the mast of the crane, but may be
mounted in an alternate location.
FLOW CONTROL
The flow control may either be an integral part of the
inlet on the main control valve, or a separate valve
body, depending on the crane model. Its purpose is
to regulate the amount of oil flow to the main control
valve. In the normal state, the flow control will direct
the flow of oil to the reservoir. Its operation is
completely dependent on a variation in signal voltage
from the amp driver. As the signal voltage from the
amp driver increases, the flow control begins to limit
the flow of oil being bypassed, which causes a
greater flow directed upstream to the main control
valve. Inversely, when the signal voltage from the
amp driver begins to drop, the flow control will let
more oil bypass to the reservoir, resulting in lesser
flow upstream to the main control valve.
GENERAL INSTALLATION
Refer to the parts drawings in Section 3 for your
particular proportional remote control system. The
installer must be familiar with the information relating
to the crane that is to be installed, before attempting
to make that installation. Electrical contacts must be
clean and free of oil or other contaminants. Proper
ground must be established. This will be
accomplished by connecting a 12-gauge (minimum)
wire from the ground point of the electrical system to
a 5/16 inch self tapping screw installed in the truck
frame.
AMP DRIVER REPLACEMENT
The purpose of this paragraph is to familiarize repair
and maintenance personnel with amp driver
replacement on cranes produced prior to 1-1-90. Prior
to 1-1-90, the amp driver used on proportional remote
control cranes was part number 77041329. After that
date, the amp driver was changed to part number
77041390.
NOTE
THE DRAWINGS IN THIS MANUAL ARE SHOWN
WITH THE CURRENT PRODUCTION AMP DRIVER,
PART NUMBER 77041390. FOR DRAWINGS WITH
THE 77041329 AMP DRIVER, REFER TO MANUAL
PART NUMBER 99900256.
AMP DRIVER IDENTIFICATION
Identifying the amp driver used on your crane can be
accomplished either by the serial number of the
crane, or by determining the material that the
enclosure is constructed of. The 77041329 amp
driver is housed in a steel enclosure which mounts
directly to the crane. The 77041390 amp driver is
housed in a cast aluminum or plastic enclosure,
which is mounted on an aluminum mounting plate.
The aluminum mounting plate, in turn, attaches to the
crane.
000425AT:99900653: 19920203
2-10
AMP DRIVER INSTALLATION
To replace an old style amp driver with a current
model:
1. Clearly mark each electrical wire in a manner that
can be identified later, and disconnect the 12VDC
power source.
2. Disconnect the marked electrical wiring, and
remove the amp driver.
4. Drill a 1/4” diameter hole in either bottom corner of
the enclosure to allow moisture condensation to
escape.
5. Using the electrical schematic for your crane,
connect the wiring as indicated.
6. Check all connections to make certain that they
are correct. Reconnect the 12VDC power source.
3. Install the new amp driver using the same
mounting holes.
TROUBLESHOOTING CHART
000425AT: 99900635:20000914
3-1
SECTION 3. REPLACEMENT PARTS 425AT CRANE
PARTS INFORMATION ............................................................................................................................. 3
MAST ASM (41710765) ............................................................................................................................. 5
INNER BOOM ASM (41716193) ................................................................................................................ 6
INNER CYL (3C166000) ............................................................................................................................ 7
C’BAL VALVE (73540080) ......................................................................................................................... 8
INNER BOOM ASM (41701135) ................................................................................................................ 9
INNER CYL (3C078712) .......................................................................................................................... 10
OUTER BOOM ASM (41711600) ............................................................................................................. 11
OUTER CYL (3C081712) ......................................................................................................................... 12
EXT BOOM ASM (41705246) .................................................................................................................. 13
EXT CYL (3K095850) .............................................................................................................................. 14
HYD KIT-5F (91716194) ........................................................................................................................... 15
VB-5 SECT (73733479) ........................................................................................................................... 16
WIRE HARNESS-VB (73733411-1) .......................................................................................................... 17
WIRE HARNESS-VB (73733411-2) .......................................................................................................... 18
ELEC SCHEMATIC (99903200) ............................................................................................................... 19
RMT HANDLE ASM (51715568) .............................................................................................................. 20
CABLE ASM 14GA 6WIRE X 35' (51713199) .......................................................................................... 21
HYD KIT 6F-OPTION (91710763) ............................................................................................................ 22
HYD KIT-4F (91710764) ........................................................................................................................... 23
VB ASM 6-SECT-OPTION (73732632) ..................................................................................................... 24
VB ASM 4-SECT (73731911) ................................................................................................................... 25
CTRL KIT-OPTION (90710762) ................................................................................................................ 26
RMT HANDLE ASM 6F-PROPL W/SPD-OPTION (51710014) ................................................................. 27
INSTALLATION KIT (93710761) .............................................................................................................. 28
DECAL KIT (95710760) .......................................................................................................................... 29
HYD KIT-5F (91711604) ........................................................................................................................... 30
LIGHT KIT-OPTION (31717128) .............................................................................................................. 31
CAPACITY ALERT KIT-AUDIBLE (31711428) .......................................................................................... 32
CABLE ASM 90" JIC BOX (51710725) .................................................................................................... 33
HOSE REEL KIT-DBL-OPTION (31711966) ............................................................................................. 34
HYD KIT-6R/3M-OPTION (91712122-1) .................................................................................................... 35
HYD KIT-6R/3M-OPTION (91712122-2) .................................................................................................... 36
VB ASM-6R/3M (51712112) ..................................................................................................................... 37
VB (51712110) ......................................................................................................................................... 38
RMT CTRL KIT (90713578) ..................................................................................................................... 39
RMT CTRL KIT-V20R 6R/3M (90713579) ................................................................................................. 40
CABLE ASM-JIC BOX 90" (51713573) .................................................................................................... 41
RMT HANDLE ASM-PROPL (51713429) ................................................................................................. 42
CABLE ASM-JIC BOX 50" (51713570) .................................................................................................... 43
000425AT: 99900653:19980826
3-2
000425AT: 99900653.01.20061020
3-3
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 REPAIR section in Volume 1.
WARNING
DO NOT ATTEMPT TO REPAIR ANY COMPONENT
WITHOUT READING THE INFORMA TION
CONTAINED IN THE REPAIR SECTION IN VOLUME
1. 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.
CYLINDER IDENTIFICATION
To insure proper replacement parts are received, it is
necessary to specify the complete number/letter
sequence for any part requested. Part numbers may
be cross checked by comparing the stamped
identification on the cylinder case (See figure below)
against the information contained in the service
manual. You must include the part number stamped
on the cylinder case when ordering parts.
WELDMENT IDENTIFICATION
Each of the major weldments - base, mast, inner
boom, outer boom, extension boom and outrigger
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
Section 2.
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.
IOWA M OLD TOOLING CO., INC.
BOX 189, GARNER, IA 50438-0189
MODEL
NUMBER
SERIAL
NUMBER
MFG
DATE
SERIAL NUMBER PLACARD
CYLINDER
PART NUMBER
LOCATION
CYLINDER PART NUMBER LOCATION
000425AT: 41707659.01.20030512
3-4
BASE ASM (41707659)
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
15.
16.
17.
18.
19.
20.
21.
23.
24.
52707658
60020114
60020115
60020116
60020154
71056011
53000704
53000715
60010235
60121351
60104694
60106032
71056010
71056012
71056389
72053301
72053508
72053589
72060092
72060833
72060931
BASE (INCL:3-7)
BUSHING (PART OF 2)
BUSHING (PART OF 2)
BUSHING (PART OF 2)
BUSHING (PART OF 2)
DRIVE GEAR (PART OF 2)
GREASE EXTENSION 34"
GREASE EXTENSION 18"
PINION COVER
GREASE PLATE
PINION SPACER
STUD 1/2-13X2
PINION GEAR
INTERMEDIATE GEAR
TURNTABLE BEARING
COUPLING 1/8NPT
ZERK 1/8NPT
STREET ELBOW 1/8NPT 90°
CAP SCR 1/2-13X1-1/4 HH GR5
SCR 5/16-18X3/4 HH SLFTPG
1
1REF
1REF
1REF
1REF
1REF
1
1
1
1
1
2
1
1
1
2
3
1
2
2
24
25.
26.
27.
28.
29.
30.
31.
32.
72062080
72063002
72063003
72063035
72063053
72063119
72066084
73540004
73051004
73054538
5V151830
7Q072112
72060738
34. 71143519
NUT 1/2-13 LOCK
2
WASHER 5/16 WRT
2
WASHER 3/8 WRT
2
MACH BUSHING 1-1/4X10GA NR 1
WASHER 1/2 LOCK
2
WASHER 5/8 FLAT HARD GR8 24
RETAINING RING 1-1/4 EXT STD 1
HYD MOTOR (FROM 5-15-98)
1
HYD MOTOR (TO 5-15-98)
1
C’BALANCE VALVE (TO 5-15-98) 2
MOTOR BLOCK (TO 5-15-98)
1
O-RING (TO 5-15-98)
2
CAP SCR (TO 5-15-98)
4
SLIDE-CAST 450° ROTATION
1
WARNING
Anytime a gear-bearing bolt is removed, it must be
replaced with a new bolt of the identical grade and
size. Failure to replace gear-bearing bolts may result
in bolt failure due to metal fatigue causing serious
injury or death.
NOTE:
APPLY MOBILTAC 375NC LUBRICANT OR
EQUIVALENT TO THE EXTERNAL TEETH OF THE
TURNTABLE BEARING AND PINOIN GEAR.
000425AT: 41710765.01.20000914
MAST ASM (41710765)
1.
2.
3.
4.
5.
6.
7.
52710729
60104540
70029119
72060931
72063119
72066340
60122749
60115956
8. 72060002
9. 72063001
10. 72062104
MAST
1
PINION COVER
1
SERIAL NO. PLACARD
1
CAP SCR 5/8-11X2-3/4 HHGR8 18
WASHER 5/8 FLAT HARD GR8 18
POP RIVET 1/8
2
COVER (eff:425AT2K1024 +)
1
COVER (pre:425AT2K1024)
1
(NOT SHOWN)
CAP SCR 1/4-20X3/4 HH GR5
4
WASHER 1/4 WRT
4
NUT 1/4-20 LOCK
4
3-5
WARNING
Anytime a gear-bearing bolt is removed, it must be
replaced with a new bolt of the identical grade and
size. Failure to replace gear-bearing bolts may result
in bolt failure due to metal fatigue causing serious
injury or death.
000425AT: 41716193.01.20000914
3-6
INNER BOOM ASM (41716193)
(EFF: SN 425AT2K1024 ON)
1. 3C166000 INNER CYLINDER
2. 52701155 INNER BOOM
3. 60020131 BUSHING (PART OF 2)
4. 52703711 PIN
5. 52703758 PIN
6. 52715936 PIN
7. 72053508 ZERK 1/8NPT
8. 60109337 RETAINER PLATE 3”
9. 72060147 CAP SCR 5/8-11X1 HHGR5
1
1
2REF
1
1
1
3
3
3
000425AT: 3C166000.01.20000914
3-7
INNER CYL (3C166000)
1. 4C166000 CASE (INCL:5)
2. 4G078710 ROD (INCL:6)
3. 6H500025 HEAD
4. 6I500181 PISTON
5. 7BF81220 BUSHING (PART OF 1)
7. 9C166000 SEAL KIT (INCL:8-17)
8. 6A025025 WAFER LOCK (PART OF 7)
9. 7Q072157 O-RING (PART OF 7)
10. 7Q072350 O-RING (PART OF 7)
11. 7Q10P350 BACK-UP RING (PART OF 7)
12. 7R14P025 ROD WIPER (PART OF 7)
13. 7R546025 ROD SEAL (PART OF 7)
14. 7T2NX427 WEAR RING (PART OF 7)
15. 7T61N181 LOCK RING SEAL (PART OF 7)
16. 7T65I050 PISTON RING (PART OF 7)
17. 7T66P050 PISTON SEAL (PART OF 7)
18. 72533186 ADAPTER #6MFACE #6MSTR
19. 3C166000A CYLINDER
20. 73540080 CBAL VALVE (INCL:21,26)
21. 73540052 CBAL VALVE (PART OF 20)
22. 72060037 CAP SCR 5/16-18X4 HHGR5
23. 72063002 WASHER 5/16 WRT
24. 72062109 NUT 5/16-18 LOCK
25. 70146237 TUBE ASM
26. 77041605 PR SWITCH (PART OF 20)
1
1
1
1
4REF
2REF
1
1REF
1REF
1REF
1REF
1REF
1REF
2REF
1REF
2REF
1REF
4
1
1
1REF
2
4
2
2
1REF
NOTE
IT IS RECOMMENDED THAT ALL COMPONENTS
OF THE SEAL KIT BE REPLACED WHENEVER THE
CYLINDER IS DISASSEMBLED. THIS WILL
REDUCE FUTURE DOWNTIME.
APPLY “LUBRIPLATE #630-2” MEDIUM HEAVY,
MULTI-PURPOSE LUBRICANT OR EQUIVALENT TO
ALL PISTON AND HEAD GLANDS, LOCK RING AND
ROD THREADS BEFORE ASSEMBLY.
USE “NEVER-SEEZ” OR EQUIVALENT BETWEEN
THE HEAD AND THE CASE WHEN ASSEMBLING
THE CYLINDER. KEEP AWAY FROM ALL SEALS.
000425AT: 73540080.01.20000914
3-8
C’BAL VALVE (73540080)
1. 73540051 CBAL VALVE
2. 73540052 CBAL VALVE
4. 70145750 ORIFICE
6. 77041605 PR SWITCH
7. 72533477 PLUG 7/16STR HOLHX
1
1
1
1
2
000425AT: 41701135.01.20000914
3-9
INNER BOOM ASM (41701135)
(BEFORE SN: 425AT2K1024)
1. 3C078712 INNER CYLINDER
2. 52701155 INNER BOOM (INCL:3)
3. 60020131 BUSHING (PART OF 2)
4. 52703711 PIN
5. 52703758 PIN
6. 52715936 PIN
7. 72053508 ZERK 1/8NPT
8. 60109337 PIN RETAINER PLT 3”
9. 72060147 CAP SCR 5/8-11X1 HHGR5
1
1
2REF
1
1
1
3
3
3
000425AT: 3C078712.01.20000914
3-10
INNER CYL (3C078712)
1. 4C078711 CASE (INCL:5&18)
2. 4G078710 ROD (INCL:19)
3. 6H050025 HEAD
4. 6I050181
PISTON
5. 7PNPXT02 PIPE PLUG 1/8 (PART OF 1)
6. 73054242 VALVE - 25GPM
7. 9C202029 SEAL KIT (INCL:8-173)
8. 6A025025 WAFER LOCK (PART OF 7)
9. 7Q072157 O-RING (PART OF 7)
10. 7Q072350 O-RING (PART OF 7)
11. 7Q10P350 BACK-UP RING (PART OF 7)
12. 7R14P025 ROD WIPER (PART OF 7)
13. 7R546025 ROD SEAL (PART OF 7)
14. 7T2N8027 WEAR RING (PART OF 7)
15. 7T61N181 LOCK RING SEAL (PART OF 7)
16. 7T65I050
PISTON RING (PART OF 7)
17. 7T66P050 PISTON SEAL (PART OF 7)
1
1
1
1
3REF
1
1
1REF
1REF
1REF
1REF
1REF
1REF
1REF
1REF
2REF
1REF
4REF
2REF
NOTE
THE CYLINDER. KEEP AWAY FROM ALL SEALS.
000425AT: 41711600.01.20000612
3-11
OUTER BOOM ASM (41711600)
1.
2.
3.
4.
5.
6.
7.
8.
9.
3C081712
52711599
60020131
60030015
52703767
52703710
60102558
60102559
60020126
OUTER CYLINDER
OUTER BOOM (INCL:3)
BUSHING (PART OF 2)
WEAR PAD
PIN
PIN
PIN
ROLLER (INCL:9)
BUSHING (PART OF 8)
1
1
2REF
2
2
1
1
1
4REF
10.
11.
12.
13.
14.
15.
16.
17.
18.
20.
60103463
72053508
72060023
72063035
72060147
72063050
72066129
60109337
72661157
RETAINING PLATE
ZERK 1/8NPT
CAP SCR 5/16-18X3/4 HHGR5
MACH BUSHING 1-1/4X10GA
CAP SCR 5/8-11X1 HHGR5
WASHER 5/16 LOCK
RETAINING RING 1-1/4 HD
RETAINER PLATE 3”
GROOVE PIN 1/2 X 2-1/2
EXTENSION CYLINDER
2
2
8
1
2
8
1
2
1
REF
000425AT: 3C081712.01.19990127
3-12
OUTER CYL (3C081712)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
16.
17.
15.
18.
19.
4C081711
4G081710
6H050025
6I050181
7PNPXT02
73054242
9A202029
72053507
7Q072157
7Q072350
7Q10P350
7R14P025
7R546025
7T2N8027
7T65I050
7T66P050
7T61N181
7BF81220
7BF81520
CASE (INCL:5&18)
ROD (INCL:8&19)
HEAD
PISTON
PIPE PLUG 1/8 (PART OF 1)
VALVE 25GPM
SEAL KIT (INCL:9-17)
ZERK 1/4-28 (PART OF 2)
O-RING (PART OF 7)
O-RING (PART OF 7)
BACK-UP RING (PART OF 7)
ROD WIPER (PART OF 7)
ROD SEAL (PART OF 7)
WEAR RING (PART OF 7)
PISTON SEAL (PART OF 7)
LOCK RING SEAL (PART OF 7)
BUSHING (PART OF 1)
BUSHING (PART OF 2)
1
1
1
1
3REF
1
1
1REF
1REF
1REF
1REF
1REF
1REF
1REF
2REF
1REF
1REF
2REF
2REF
NOTE
IT IS RECOMMENDED THAT ALL COMPONENTS OF
THE SEAL KIT BE REPLACED WHENEVER THE
CYLINDER IS DISASSEMBLED. THIS WILL REDUCE
FUTURE DOWNTIME.
APPLY “LUBRIPLATE #630-2” MEDIUM HEAVY, MULTIPURPOSE LUBRICANT OR EQUIVALENT TO ALL
PISTON AND HEAD GLANDS, LOCK RING AND ROD
THREADS BEFORE ASSEMBLY.
USE “NEVER-SEEZ” OR EQUIVALENT BETWEEN THE
HEAD AND THE CASE WHEN ASSEMBLING THE
CYLINDER. KEEP AWAY FROM ALL SEALS.
000425AT: 41705246.01.19920203
3-13
EXT BOOM ASM (41705246)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
3K095850
52070151
52701716
52705249
52705250
52705251
60020197
60030007
60030064
60030145
60102341
60102649
60104028
EXTENSION CYLINDER
PIN
HOOK - 5-TON SWVL
EXT BOOM - 1ST STAGE
EXT BOOM - 2ND STAGE
EXT BOOM - 3RD STAGE
ROLLER
WEAR PAD
WEAR PAD
WEAR PAD
LOCK PLATE
RETAINING PLATE
PIN
1
1
1
1
1
1
2
2
1
1
4
2
1
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
60107294
72053507
72060046
72060092
72060238
72062073
72063010
72063051
72063053
72066125
72066145
60030127
72060915
STROKE STOP
1
ZERK 1/4-28 (PART OF 1)
REF
CAP SCR 3/8-16X1 HH GR5
12
CAP SCR 1/2-13X1-1/4 HH GR5 2
CAP SCR 1 1/4-7X6 HH GR5
1
NUT 1 1/4-7 LOCK
1
WASHER 1" WRT
2
WASHER 3/8 LOCK
12
WASHER 1/2 LOCK
2
RETAINING RING 1" EXT HD
2
HAIR PIN 3/16
1
WEAR PAD
1
CAP SCR 3/8-16X1 FLTHD SOC 2
000425AT: 3K095850.01.19970718
3-14
EXT CYL (3K095850)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
4K095850
4H095850
4G095850
6H271511
6H112820
6I025087
6I095850
4FG12085
6C300015
6C075015
73054242
7PNPXT02
9X095850
7Q072228
7Q10P228
7Q072342
7Q10P342
7T2N4037
7R546015
7R546035
7R14P015
7R14P035
7T65I040
7Q072137
7T66P025
7Q072153
7T66P040
7Q072147
7T61N087
7T2N8015
6A025015
72053507
CASE (INCL: 12)
INNER CASE
ROD
HEAD
HEAD
PISTON
PISTON
MOUNTING RING
STOP TUBE
STOP TUBE
VALVE
PIPE PLUG 1/8NPT (PART OF 1)
SEAL KIT
O-RING (PART OF 13)
O-RING (PAQRT OF 30)
WEAR RING (PART OF 13)
O-RING (PART OF 13)
O-RING (PART OF 13)
O-RING (PART OF 13)
LOCK-RING SEAL
ROD WEAR RING (PART OF 13)
WAFER LOCK (PART OF 13)
ZERK 1/4-28
1
1
1
1
1
1
1
1
1
1
2
8
1
1REF
1REF
1REF
1REF
1REF
1
1REF
1REF
1REF
2REF
1REF
1REF
1REF
1REF
1REF
1REF
1
1REF
1
NOTE
THE CYLINDER.
000425AT: 91716194.01.20000914
HYD KIT-5F (91716194)
1. 73733479 VB 5-SECT
1
2. 72060002 CAP SCR 1/4-20X3/4 HHGR5
4
3. 72062104 NUT 1/4-20 LOCK
4
4. 72532351 ADAPTER #4MSTR #4MJIC
2
5. 72532358 ADAPTER #8MSTR #8MJIC
4
6. 72532740 ELBOW #8MSTR #8MJIC SW90° 2
7. 51716271 HOSE KIT (INCL:8-11)
1
8. 51395853 HOSE-FF .25X71 #4#6
2REF
9. 51395855 HOSE-FF .38X182 #6#8
2REF
10. 51395742 HOSE-FF .38X126 #6#8
2REF
11. 51395854 HOSE-FF .38X78 #6#6
2REF
12. 72532738 CAP 9/16JIC
2
3-15
000425AT: 73733479.01.20060321
3-16
VB-5 SECT (73733479)
1. 73540028 INLET BLOCK
2. 73540027 END CAP
3. 73054934 VALVE-PROP FLOW CTRL
4. 73054935 VALVE-RELIEF
5. 73540044 VALVE SECT
6. 7Q072013 O-RING
7. 72533477 PLUG #4STR HOLHX
8. 70145829 EXPANDER PLUG
9.
ROD 1/4-20X14
10.
ROD 1/4-20X12-3/4
11. 72062000 NUT 1/4-20 HEX
12. 72063047 WASHER #10 LOCK
13. 77044574 CONNECTOR
1
1
1
1
5
12
1
4
2
1
5
5
11
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
77044550
70394069
70145830
77044595
72601704
72061705
77044594
72533052
72053760
72532358
72533567
72533603
72532738
73733411
72532666
TERMINAL-F
SEAL-CABLE
BRACKET
VALVE DRIVER
MACH SCR #6-32X3/4 RDHD
WASHER #6 WRT
CABLE SEAL
ADAPTER #6MSTR #6FSTR
ELBOW #6MSTR #6FSTR
ADAPTER #8MSTR #8MJIC
ELBOW #6MSTR #6MJIC XLG
PLUG 9/16 HOLHX
CAP 9/16JIC
WIRE HARNESS
ELBOW #8MSTR #8MJIC XLG
22
2
2
1
3
3
22
10
5\
1
5
1
2
1
1
000425AT: 73733411.01.20000914
3-17
WIRE HARNESS-VB (73733411-1)
ALL ITEMS ARE REFERENCE ONLY
1. 77044573 SHROUD CONN 2-CONT
2. 77044574 TOWER CONN 2-CONT
3. 77044576 TERMINAL-M
4. 77044577 TERMINAL-F
5. 77044578 CABLE SEAL
6. 77044620 CONN RCPT
7. 77044550 SOCKET
10. 77044624 SHROUD CONN 4-CONT
11. 77044676 PLUG
11
1
26
10
36
1
23
1
1
1
2
000425AT: 73733411.02.20000914
WIRE HARNESS-VB (73733411-2)
3-18
000425AT: 99903200.01.20000914
3-19
ELEC SCHEMATIC (99903200)
1. 51713199 CABLE ASM 14GA/6WIRE X 35’
2. 51715568 HANDLE ASM
3. 60119299 MTG BRACKET
4. 77044645 NUT
5. 77044646 WASHER
6. 70034439 LOCK WIRE LEAD SEAL 8”
1
1
1
1
1
1
000425AT: 51715568.01.20010118
RMT HANDLE ASM (51715568)
1. 89044214 WIRE 18GA GRN (7-2.25”/1-3.5”) 1.61FT
2. 60119335 CONTROL HANDLE
1
3. 60111141 TRIGGER (PART OF 11)
1REF
4. 60119277 COVER
1
5. 70034306 BACK COVER
1
7. 77044196 STRAIN RELIEF 3/4
1
8. 77044621 PIN
23
9. 77044862 DECAL-DGR RC ELECTRO SM
1
10. 70394282 DECAL-RC HANDLE
1
3-20
11.
14.
15.
16.
17.
18.
20.
21.
22.
23.
24.
25.
70394183
72061009
77040051
77040371
77040372
77040373
77044579
89044100
77040147
77040047
72060602
70145495
TRIGGER ASM (INCL:3)
SHT MTL SCR #6X3/4 PH
TERMINAL #8 SPRSPD 16-14GA
TOGGLE SWITCH SPST
TOGGLE SWITCH SPDT
TOGGLE SWITCH SPST
CONNECTOR
CABLE 18GA 24WIRE
TERMINAL 1/4 FSLPON 22-18GA
TERMINAL 1/4 MSLPON 16-14GA
MACH SCR #6-32X3/8 RDHD
HEAT SHRINK 3/4 W/ADHESIVE
1
8
31
1
6
2
1
30FT
3
3
4
.50FT
000425AT: 51713199.01.20000914
3-21
CABLE ASM 14GA 6WIRE X 35' (51713199)
1. 77044575 SHROUD CONNECTOR
2. 77044576 TERMINAL
3. 77044578 CABLE SEAL
4. 89044354 CABLE
5. 77040051 TERMINAL-SPRSPADE
1
6
6
1
6
000425AT: 91710763.01.19930203
3-22
HYD KIT 6F-OPTION (91710763)
1.
2.
3.
4.
5.
6.
7.
8.
73732632
72053763
72060002
72062104
72532351
72532358
72532699
72532700
VALVEBANK 6-SECT PROP RC
ELBOW 3/4MSTR 3/4MJIC 90°
NUT 1/4-20 LOCK
ADAPTER 7/16MSTR 7/16MJIC
ELBOW 9/16MSTR9/16MJIC XLG
1
2
4
4
2
5
3
6
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
72532707
72053760
72532364
5V151830
51710753
51706916
51710727
51710726
51710724
72532740
ADAPTER 7/16MJIC 9/16FJIC
3
ELBOW 9/16MSTR 9/16MJIC 90° 3
ADAPTER 3/4MSTR 1-1/16MJIC 1
MOTOR BLOCK
1REF
HOSE ASM 1/2X24
1
HOSE ASM 1/4X72
2
HOSE ASM 3/8X182
2
HOSE ASM 3/8X126
2
HOSE ASM 3/8X78
2
ELBOW #8MSTR#8MJIC90°SW 2
000425AT: 91710764.01.19930203
3-23
HYD KIT-4F (91710764)
1.
2.
3.
4.
5.
6.
7.
8.
73731911
72053763
72060002
72062104
72532351
72532358
72532699
72532700
VALVEBANK 4-SECT PROP RC
NUT 1/4-20 LOCK
ELBOW 9/16MSTR9/16MJIC XLG
1
2
4
4
2
5
1
4
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
72532707
72053760
72532364
5V151830
51707967
51706916
51710727
51710726
51710724
72532740
1
MOTOR BLOCK
1REF
HOSE ASM 1/2X17
1
HOSE ASM 1/4X72
2
HOSE ASM 3/8X182
2
HOSE ASM 3/8X126
2
HOSE ASM 3/8X78
2
ELBOW #8MSTR#8MJIC90° SW 2
000425AT: 73732632.01.19920203
VB ASM 6-SECT-OPTION (73732632)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
72062000
72063049
7Q072205
76392808
70143337
94731958
60025664
73054624
73054623
60025709
73054636
77041361
70143336
TIE ROD ASM (INCL:2-3)
1
TIE ROD (PART OF 1)
4REF
NUT (PART OF 1)
8REF
LOCKWASHER (PART OF 1)
8REF
O-RING
2
O-RING
10
O-RING PLATE
5
INLET ASM (INCL:9-11)
1
INLET BLOCK (PART OF 8)
1REF
PROPL SOLENOID (PART OF 8) 1REF
RELIEF 2500PSI (PART OF 8)
1REF
OUTLET BLOCK
1
VALVE SECT W/COILS (INCL:14) 6
COIL (PART OF 13)
6REF
MOUNTING FOOT
2REF
3-24
000425AT: 73731911.01.19920203
VB ASM 4-SECT (73731911)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
94731957
70143335
72062000
72063049
7Q072205
76392808
70143337
94731958
60025664
73054624
73054623
60025709
73054636
77041361
70143336
TIE ROD ASM (INCL:2-3)
1
TIE ROD (PART OF 1)
4REF
NUT (PART OF 1)
8REF
LOCKWASHER (PART OF 1)
8REF
O-RING
2
O-RING
6
O-RING PLATE
3
INLET ASM (INCL:9-11)
1
INLET BLOCK (PART OF 8)
1REF
PROPL SOLENOID (PART OF 8) 1REF
RELIEF 2500PSI (PART OF 8)
1REF
OUTLET BLOCK
1
VALVE SECT W/COILS (INCL:14) 4
COIL (PART OF 13)
4REF
MOUNTING FOOT
2REF
3-25
000425AT: 90710762.01.19990827
3-26
CTRL KIT-OPTION (90710762)
1.
2.
3.
4.
77044837
72060703
72063049
51710725
AMP DRIVER
CAP SCR 1/4-20X1/2 SH
WASHER 1/4 LOCK
CABLE ASM 72"
1
2
4
1
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
51710014
77041251
77041237
51704784
77044341
60111832
72061009
60111833
72060006
77040282
77040186
77040051
89044231
89044231
REMOTE HANDLE ASM 6-FCTN
RELAY
SOLENOID 12V 150A
CABLE ASM #1 WIRE X 6
TERMINAL BLOCK
TERM STRIP MTG PLATE
SPACER 3/8TUBE X 1
TERM-PIGBAC 1/4TAB 16-14GA
TERMINAL 1/4 FSLPON
TERMINAL #8 STUD
WIRE 14GA GRN X 3
WIRE 14GA GRN X 10
1
2
1
1
1
1
2
2
2
11
16
4
10
1
000425AT: 51710014.01.19930304
3-27
RMT HANDLE ASM 6F-PROPL W/SPDOPTION (51710014)
ITEM PART
DESCRIPTION
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
HANDLE
1
HANDLE BACK
1
CABLE 18GA/24WIRE
45FT
WIRE 18GA GREEN
2.33FT
DECAL-REMOTE CONTROL
1
DECAL-DANGER RC ELECTRO 1
SERIAL NO. PLACARD
1
4
POP RIVET 1/8
2
TERM 1/4 FSLPON 16-14GA
24
TOGGLE SWITCH-SGL THROW 2
TOGGLE SWITCH-DBL THROW 6
60111140
70034306
89044100
89044214
70392703
70392862
70029119
72061009
72066340
77040186
77041345
77041346
QTY
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
77041347
77044196
77044146
77044147
51708800
60111141
60111142
70143223
72060636
72060669
72061000
72062106
TOGGLE SWITCH-MOM.
STRAIN RELIEF 3/4
CONNECTOR 16 PIN
CABLE CLAMP
POTENTIOMETER
TRIGGER
MTG BRKT-POTENTIOMETER
SPRING
MACH SCR #10-24X3/4
CAP SCR #10-32X5/8
SHT MTL SCR #6X1/2
NUT #10-24 HEX
1
1
1
1
1
1
1
1
2
1
1
2
NOTE:
1. INSTALL ITEM 6 ON REMOTE CONTROL HANDLE.
000425AT: 93710761.01.19940603
3-28
INSTALLATION KIT (93710761)
1.
2.
3.
4.
60106481
72063066
72062141
73052012
70048149
5.
6. 73054130
7. 60103870
TIE-DOWN STUD 1-8X12-1/2
WASHER 1 HI STR
NUT 1-8 LOCK
SUCTION FILTER
FILTER ELEMENT 100MESH
RESERVOIR ASM
GATE VALVE 1-1/4
FILTER BRACKET
4
8
8
1
REF
REF
1
1
1.
2.
3.
4.
5.
6.
7.
8.
RESERVOIR 17 GAL
MTG BRKT
NUT 3/8-16 LOCK
SIGHT GAUGE 3/4NPT
FILL CAP
PLUG-MAGNETIC 3/4NPT
FILL NECK SCREEN
1
1
4
4
1
1
1
1
52705133
60108148
72060044
72062103
72532261
73014671
73052021
73141276
000425AT: 95710760.01.20000516
3-29
DECAL KIT (95710760)
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
70391583
70391612
70391613
70392108
70392109
70392213
70392524
70392813
70392814
70392815
70394189
70392865
DECAL-SETUP/STOW
DECAL-GREASE WKLY LEFT
DECAL-GREASE WKLY RIGHT
DECAL-SUCTION LINE
DECAL-RETURN LINE
DECAL-CAUTION WASH/WAX
DECAL-ROTATE/GREASE
DECAL-DGR ELECTROCUT’N
DECAL-DGR OPER TRAINING
DECAL-DANGER OPERATION
DECAL-RECOMMEND HYD OIL
DECAL-DANGER ELECT HZD
1
3
5
1
1
1
1
2
2
2
1
4
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
70392866
70393497
70392888
70392890
70392891
70392982
71393496
71039134
70392863
70392868
70394443
70392889
70395323
DECAL-DANGER OPER COND
DECAL-IDENTIFICATION
DECAL-DGR OPER RESTRICT
DECAL-DANGER FOLD/STOW
DECAL-DANGER DRIVELINE
DECAL-CONTACT IMT
CAPACITY PLACARD
DECAL-CAUTION OIL LEVEL
DECAL-DGR HOIST PERS
DECAL-DGR CR LOADLINE
DECAL-DGR FREEFALL BOOM
DECAL-DANGER RC ELECTRO
DECAL-ASME/ANSI B30.22
2
2
2
2
2
1
2
2
1
4
1REF
2
1
000425AT: 91711604.01.20000914
3-30
HYD KIT-5F (91711604)
1. 73732831 VALVEBANK 5-SECT PROP RC
2. 72053763 ELBOW 3/4MSTR 3/4MJIC 90°
3. 72060002 CAP SCR 1/4-20X3/4 HH GR5
4. 72062104 NUT 1/4-20 LOCK
5. 72532351 ADAPTER 7/16MSTR 7/16MJIC
6. 72532358 ADAPTER 3/4MSTR 3/4MJIC
7. 72532699 ELBOW 9/16MSTR 7/16MJIC 90°
8. 72532700 ELBOW 9/16MSTR9/16MJIC XLG
1
2
4
4
2
5
1
5
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
72532707
72053760
72532364
5V151830
51710753
51706916
51710727
51710726
51710724
72532740
51704582
1
MOTOR BLOCK
1REF
HOSE ASM 1/2X24
1
HOSE ASM 1/4X72
2
HOSE ASM 3/8X182
2
HOSE ASM 3/8X126
2
HOSE ASM 3/8X78
2
ELBOW #8MSTR#8MJIC90° SW 2
HOSE ASM 3/8X209
2
000425AT: 31717218.01.20011203
3-31
OPTION - LIGHT KIT (31717218)
ITEM PART NO.
DESCRIPTION
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
CABLE ASM- FLOOD LIGHTS
1
GUARD
1
FLOOD-LT-COMP WORK LAMP
2
SWITCH BRACKET - 1 HOLE
1
TOGGLE SWITCH
1
CONNECTOR
2
TERMINAL-F 18-20 GA
2
SEAL CABLE CONNECTOR
4
WASHER 1/4 LOCK
2
WASHER 3/8 LOCK
2
TERMINAL, RING #10 STUD 16-14 1
WIRE-BLACK STRD TYPE
36”
CAP SCR 1/4-20 X 1/2 HH GR5
2
CAP SCR 3/8-16 X 3/4 HH GR5
2
NUT 1/4-20 HEX ZINC
51717219
60107762
77040424
60103535
77041345
77044574
77044550
70394069
72063049
72063051
77040000
89044274
72060000
72060044
72062000
QTY
DRILL .313" HOLE AND TAP
3/8-16 IN TOP OF INNER
BOOM (2). CENTER THE LIGHT
BRACKET ON THE LENGTH
OF THE BOOM.
CRANE INNER BOOM
TO LIGHT
SWITCH
14
10
2
6
7(2)
8(2)
1
6
7(2)
8(2)
1 REF
TO LIGHTS
GROUND
"12 V"
15
9
3
4
11
12
3
5
13
000425AT: 31711428.01.19950811
3-32
CAPACITY ALERT KIT-AUDIBLE
(31711428)
1.
2.
3.
4.
5.
6.
72060731
60025221
72532140
7Q072015
77041222
89044188
7. 99900118
MANIFOLD
PLUG 9/16-18 STR THD HH
O-RING
PRESSURE SWITCH 2400PSI
WIRE-14GA
(Customer Supplied)
INSTALLATION DWG
4
1
1
1
1
REF
1
NOTE
This capacity alert system consists of a pressure
switch mounted on the lift side of the inner boom lift
cylinder which senses hydraulic pressure. It is to be
connected electrically (by the customer) to an audible
warning device such as the truck chassis horn, using
14-gauge wire.
000425AT: 51710725.01.19950811
3-33
CABLE ASM 90" JIC BOX (51710725)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
89044100
60107719
72061000
89044034
77044341
77040186
77044018
77044148
77044151
77044201
77040051
77044196
77044202
77040047
CABLE 10GA/24WIRE 90"
JIC BOX
CABLE 16GA/4WIRE 72"
TERM BLOCK-4 CONTACT
STRAIN RELIEF 1/2
CAP & CHAIN ASM
RECEPTACLE ASM 24-SOCKET
NUT 1/2 LOCK ELECTRICAL
TERM #8 SPRSPD 16-14GA
STRAIN RELIEF 3/4
NUT 3/4 LOCK ELECTRICAL
TERM 1/4 MSLPON 16-14GA
1
1
4
1
1
13
1
1
1
1
14
1
1
2
000425AT: 31711966.01.19931203
3-34
HOSE REEL KIT-DBL-OPTION (31711966)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
70732863
70732864
51393812
60117715
72533380
72533382
72533381
72532353
60107482
72060097
HOSE REEL LH
HOSE REEL RH
HOSE ASM 1/4X300 FF TWIN
MTG BRACKET
COUPLER DISC 1/2
NIPPLE DISC 1/4
CAP 1/4
BULKHEAD PLATE
CAP SCR 1/2-13X3 HHGR5
1
1
2
2
2
2
4
8
1
4
11.
12.
13.
14.
15.
16.
17.
72060093
72062080
72053499
72063003
72060092
72063053
60107294
18. 51704968
CAP SCR 1/2-13X1-1/2 HHGR5 4
NUT 1/2-13 LOCK
8
ADAPTER 1/4MPT #4MJIC
4
WASHER 3/8 WRT
4
CAP SCR (PART OF EXT ASM) 2REF
WASHER (PART OF EXT ASM) 2REF
STROKE STOP
(PART OF EXT ASM)
1REF
HOSE ASM 1/4X186 FF
4
000425AT: 91712122.01.19941201
3-35
HYD KIT-6R/3M-OPTION (91712122-1)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
51712112
51705894
51705088
51712120
51712119
51712121
51705047
51712118
51393812
51706916
51712117
51709389
51706054
72532351
72532358
72532740
72532668
72532669
VALVEBANK ASM
HOSE ASM 1/4X48 FF
HOSE ASM 3/8X85 FF
HOSE ASM 3/8X144 FF
HOSE ASM 3/8X198 FF
HOSE ASM 1/4X168 FF
HOSE ASM 1/2X28 FF
HOSE ASM 3/8X240 FF
HOSE ASM 1/4X300 TWIN
HOSE ASM 1/4X71 FF
HOSE ASM 3/8X71 FF
HOSE ASM 1/2X14 FF
HOSE ASM 1/4X72 FF
ELBOW #8MSTR#8MJIC 90° SW
ELBOW #12MSTR #10FJIC
ADAPTER #8MJIC #10FJIC
1
2
2
2
2
4
1
2
2REF
6
8
2
1
2
4
2
1
1
CONTINUED
19.
20.
21.
22.
23.
24.
25.
26.
27.
29.
30.
31.
32.
33.
35.
72532951
72053763
72532360
72532658
72532665
72533239
72532739
72532360
72532658
73054876
73054420
72060029
72062109
72060032
60117938
ADAPTER #12MSTR #8FSTR
ELBOW #8MSTR #8MJIC 90°
ELBOW #8MJIC #8FJIC SW
ADAPTER #4MJIC #4MJIC
ADAPTER #8MJIC #8MJIC
ELBOW #8MJIC #8FJIC
VALVE-PROPNL PRI FLOW
SELECTOR VALVE
CAP SCR 5/16-18X2
NUT 5/16-18 LOCK
CAP SCR 5/16-18X2-3/4
MTG PLT-VB
1
1
1
1
1
6
8
3
2
REF
1
2
5
3
1
000425AT: 91712122.02.19941201
HYD KIT-6R/3M-OPTION (91712122-2)
3-36
000425AT: 51712112.01.19941201
3-37
VB ASM-6R/3M (51712112)
1.
2.
3.
4.
5.
6.
7.
8.
9.
51712110
60106322
72532669
72053747
72053558
72053555
72053676
72532972
72531427
VALVEBANK 9-SECT 6R/3M
ELBOW-PRESSURE GAUGE
ADAPTER #12MSTR 3/4FPT
ADAPTER 3/4MPT 3/4MPT
TEE 3/4NPT
ADAPTER 3/4MPT #12MJIC
ELBOW 3/4MPT #12MJIC 90°
1
1
1
1
1
1
1
1
1
10.
11.
12.
13.
14.
15.
16.
17.
72532785
72053241
72053777
72532665
72532657
72532658
73014848
94731839
CAP #12JIC
PIPE PLUG 1/4NPT
ELBOW #8MSTR #8MJIC 45°
TEE #8JIC SWVL NUT RUN
ELBOW #8MJIC #8FJIC SWVL
HANDLE
LINK & PIN KIT
1
1
18
7
1
1
9
9
000425AT: 51712110.01.19941201
VB (51712110)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
73054432
73054468
73054502
73054442
73073022
73731424
73054537
73054516
73054007
60108011
72062037
51393494
7Q072117
7Q072119
73054010
VALVE SECT 4-WAY #8
3
VALVE SECT REMOTE 4-WAY #8 6
VALVE SECT REMOTE UTIL
1
END COVER RH
1
CONVERSION PLUG
1
END COVER LH
1
RELIEF VALVE 2500PSI
1
RELIEF-NON ADJ 1300PSI
2
RELIEF-NON ADJ 1800PSI
1
STUD 3/8-24X20-1/2
3
NUT 3/8-24 HEX
6
O-RING KIT
REF
O-RING
22
O-RING
22
LOAD CHECK PLUG
13
3-38
000425AT: 90713578.01.20000719
3-39
RMT CTRL KIT (90713578)
1.
2.
3.
4.
5.
6.
7.
8.
77044852
72060703
72063049
51713573
51713429
77041251
77041237
51704784
AMP DRIVER
WASHER 1/4 LOCK
CABLE ASM-JIC BOX 90"
HANDLE ASM
RELAY
SOLENOID 12V
CABLE ASM #1WIRE X 6
1
2
4
1
1
2
1
1
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
77044341
60111832
72061009
60111833
72060006
77040282
77040186
77040051
89044231
89044231
TERMINAL BLOCK-4
1
MOUNTING PLATE
1
2
SPACER
2
CAP SCR 1/4-20X1-1/2 HHGR5 2
TERM 1/4 PIGGYBACH 16-14
11
TERM 1/4 FSLPON
16
TERM #8 SPRSPD
4
WIRE 14GA GRN X 3
10
WIRE 14GA GRN X 10
1
000425AT: 90713579.01.19990827
3-40
RMT CTRL KIT-V20R 6R/3M (90713579)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
77044837
72060004
72063001
77040186
73054876
72060052
72062103
51713570
51713429
77041251
77041237
51704784
72060002
72062104
AMP DRIVER
CAP SCR 1/4-20X1 SH
WASHER 1/4 WRT
PRIORITY FLOW VALVE
CAP SCR 3/8-16X2-1/2 HHGR5
NUT 3/8-16 LOCK
CABLE ASM
HANDLE ASM
RELAY
SOLENOID 12V
CABLE ASM #1WIRE X 6
CAP SCR 1/4-20X3/4 HHGR5
NUT 1/4-20 LOCK
1
2
4
2
1
2
2
1
1
2
1
1
2
6
000425AT: 51713573.01.19960809
3-41
CABLE ASM-JIC BOX 90" (51713573)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
89044100
90713577
77044667
89044034
77044341
77040186
77044018
77044620
77044580
77044201
77040051
77044196
77044202
77040047
CABLE 18GA/24WIRE X 90
JIC BOX ASM
PLUG-CAP
CABLE 16GA/4WIRE X 72
TERM BLOCK-4
STRAIN RELIEF 1/2
CONNECTOR
SOCKET
NUT 1/2 ELEC LOCK
STRAIN RELIEF 3/4
NUT 3/4 ELEC LOCK
TERM 1/4 MSLPON 16-14GA
1
1
1
1
1
13
1
1
23
1
14
1
1
2
000425AT: 51713429.01.19980225
RMT HANDLE ASM-PROPL (51713429)
1.
2.
3.
4.
5.
6.
8.
9.
10.
11.
12.
14.
15.
60045031
60119335
60111141
60119277
70034306
70029119
77044621
70392862
71394282
51707507
72066340
72061009
77040051
WIRE 18GA X 4 GRN
8
CONTROL HANDLE BACK
1
TRIGGER
1
COVER
1
BACK COVER
1
SERIAL NUMBER PLACARD
1
PIN
23
DECAL-DGR RC ELECTRO
1
DECAL-RC HANDLE
1
POTENTIOMETER ASM(INCL:22) 1
POP RIVET
2
8
25
3-42
16.
17.
18.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
77040371
77040372
77040373
77044579
89044100
77040047
77040186
60111142
72060669
72060636
72062106
70143223
72061000
77044196
TOGGLE SWITCH SPST
TOGGLE SWITCH SPDT
TOGGLE SWITCH SPST
CONNECTOR
CABLE 18GA/24WIRE X 45FT
TERM MSLPON(PART OF 11)
MTG BRACKET
CAP SCR #10-32X5/8 SH
CAP SCR #10-24X3/4 SH
NUT #10-24 LOCK
SPRING
CONNECTOR
1
6
2
1
1
3REF
3
1
1
2
2
1
1
1
000425AT: 51713570.01.19990719
3-43
CABLE ASM-JIC BOX 50" (51713570)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
89044100
90713575
77041345
77041354
77044018
77044201
77044196
77044202
77044468
77040186
77040282
77040051
CABLE 18GA/24WIRE
JIC BOX
TOGGLE SWITCH ST
TOGGLE SWITCH DT
STRAIN RELIEF 1/2
NUT 1/2 ELEC LOCK
STRAIN RELIEF 3/4
NUT 3/4 ELEC LOCK
STRAIN RELIEF 1/8-1/4
TERM 1/4 PIGBAC 16-14GA
50"
1
2
1
2
3
1
1
1
25
3
4
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
77044620
77044580
70393257
77044341
77041056
77040048
89044232
77044668
89044354
77041423
77044667
77044645
77044646
CONNECTOR
SOCKET
DECAL-JIC BOX
TERMINAL BLOCK-4
FUSE 20A IN-LINE
BUTT CONNECTOR 16-14GA
WIRE 14GA RED X 3
PLUG-SEAL
CABLE 14GA/6WIRE
DIODE
PLUG-CAP
NUT
WASHER-LOCK
1
23
1
1
1
4
2
1
84
1
1
1
1
000425AT:
3-44
20000710
4-1
SECTION 4. GENERAL REFERENCE
INSPECTION CHECKLIST .............................................................................................. 3
WIRE ROPE INSPECTION ............................................................................................... 7
HOOK INSPECTION ......................................................................................................... 7
HOLDING VALVE INSPECTION ...................................................................................... 8
ANTI-TWO BLOCKING DEVICE INSPECTION ............................................................... 8
TORQUE DATA CHART - DOMESTIC ............................................................................. 9
TORQUE DATA CHART - METRIC................................................................................. 10
TURNTABLE BEARING FASTENER TIGHTENING SEQUENCE ................................ 11
TURNTABLE BEARING INSPECTION FOR REPLACEMENT ..................................... 12
20000710
4-2
NOTES
4-3
Inspection Checklist
NOTICE
The user of this form is responsible in determining that these
inspections satisfy all applicable regulatory requirements
OWNER/COMPANY
1
CRANES
TYPE OF INSPECTION (check one)
DAILY (if deficiency found)
CONTACT PERSON
MONTHLY
CRANE MAKE & MODEL
DATE INSPECTED
CRANE SERIAL NUMBER
HOUR METER READING (if applicable)
UNIT I.D. NUMBER
INSPECTED BY (print)
LOCATION OF UNIT
SIGNATURE OF INSPECTOR
QUARTERLY
ANNUAL
TYPE OF INSPECTION
NOTES:
Daily and monthly inspections are to be performed by a designated person, who has been selected or assigned by the
employer or the employers representative as being competent to perform specific duties.
Quarterly and annual inspections are to be performed by a qualified person who, by possession of a recognized degree in
an applicable field or certificate of professional standing, or who, by extensive knowledge, training and experience has
successfully demonstrated the ability to solve or resolve problems related to the subject matter and work.
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 outriggers fully
extended.
DAILY (D): Before each day of operation, those items designated with a (D) must be inspected. This inspection need not be
recorded unless a deficiency (✘ ) is found. If the end user chooses to record all daily inspections and those daily inspections
include the monthly inspection requirements, there would be no need for a separate monthly inspection.
MONTHLY (M): Monthly inspections or 100 hours of normal operation (which ever comes first) includes all daily inspections
plus items designated with an (M). This inspection must be recorded.
QUARTERLY (Q): Every three to four months or 300 hours of normal operation (which ever comes first) includes all daily and
monthly inspection items plus items designated with a (Q). This inspection must be recorded.
ANNUAL (A): Each year or 1200 hours of normal operation (which ever 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 recorded.
✔ = SATISFACTORY
✘ = DEFICIENCY
(must be corrected prior to operation)
FREQUENCY ITEM
D
D
D
D
D
D
D
D
D
D
1
2
3
4
5
6
7
8
9
10
D
D
D
D
D
11
12
13
14
15
KEY
Labels
Controls
Station
Hyd System
Hook
Rope
Pins
General
Operation
Remote Ctrls
Electrical
Anti 2-Blocking
INSPECTION DESCRIPTION
R = RECOMMENDATION
(should be considered for corrective action)
NA = NOT APPLICABLE
STATUS
✔ ,
✘
R, NA
All load charts, safety & warning labels, & control labels are present and legible.
Check all safety devices for proper operation.
Control mechanisms for proper operation of all functions, leaks & cracks.
Control and operator’s station for dirt, contamination by lubricants, & foreign materials.
Hydraulic system (hoses, tubes & fittings) for leakage & proper oil level.
Presence & proper operation of hook safety latches.
Proper reeving of wire rope on sheaves & winch drum.
Proper engagement of all connecting pins & pin retaining devices.
Overall observation of crane for damaged or missing parts, cracked welds & presence of safety covers.
During operation, observe crane for abnormal performance, unusual wear
(loose pins, wire rope damage, etc.).
If observed, discontinue use & determine cause & severity of hazard.
Operate remote control devices to check for proper operation.
Operate all lights, alarms, etc. to check for proper operation.
Operate anti 2-blocking device to check for proper operation.
Other
Other
REV: 6-18-99
20000710
20000710
4-4
✔ = SATISFACTORY
✘ = DEFICIENCY
FREQUENCY ITEM
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
Q
Q
Q
Q
Q
Q
Q
Q
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
KEY
Daily
Cylinders
Valves
Valves
Valves
General
Electrical
Structure
Welds
Pins
Hardware
Wear Pads
Pump & Motor
PTO
Hyd Fluid
Hyd Lines
Hook
Rope
Manual
Daily
Monthly
Rotation Sys
Hardware
Structure
Hardware
Hyd Lines
CRANES
R = RECOMMENDATION
NA = NOT APPLICABLE
All daily inspection items.
Visual inspection of cylinders for leakage at rod, fittings & welds. Damage to rod & case.
Holding valves for proper operation.
Control valve for leaks at fittings & between sections.
Control valve linkages for wear, smoothness of operation & tightness of fasteners.
Bent, broken or significantly rusted/corroded parts.
Electrical systems for presence of dirt, moisture & frayed wires.
All structural members for damage.
All welds for breaks & cracks.
All pins for proper installation & condition.
All bolts, fasteners & retaining rings for tightness, wear & corrosion
Presence of wear pads.
Hydraulic pumps & motors for leakage at fittings, seals & between sections.
Transmission/PTO for leakage, abnormal vibration & noise.
Quality of hydraulic fluid and for presence of water.
Hoses & tubes for leakage, abrasion damage, blistering, cracking, deterioration, fitting leakage & secured properly.
Load hook for abnormal throat distance, twist, wear & cracks.
Condition of load line.
Presence of operator’s manuals with unit.
Other
All monthly inspection items.
Condition of wear pads
Rotation bearing for proper torque of all accessible mounting bolts.
Base mounting bolts for proper torque.
All structural members for deformation, cracks & corrosion.
●
Base
●
Outrigger beams & legs
●
Mast
●
Inner boom
●
Outer boom
●
Extension(s)
●
Jib boom
●
Jib extension(s)
●
Other
Pins, bearings, shafts, gears, rollers, & locking devices for wear, cracks, corrosion & distortion.
● Rotation bearing(s)
●
Inner boom pivot pin(s) & retainer(s)
●
Outer boom pivot pin(s) & retainer(s)
●
Inner boom cylinder pin(s) & retainer(s)
●
Outer boom cylinder pin(s) & retainer(s)
●
Extension cylinder pin(s) & retainer(s)
●
Jib boom pin(s) & retainer(s)
●
Jib cylinder pin(s) & retainer(s)
●
Jib extension cylinder pin(s) & retainer(s)
●
Boom tip attachments
●
Other
Hoses, fittings & tubing for proper routing, leakage, blistering, deformation & 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
2
STATUS
✔ ,
✘
R, NA
20000710
4-5
Q
70
Q
71
72
73
74
75
76
77
78
79
80
Q
Q
A
A
A
A
A
A
A
A
A
A
A
A
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
Q
KEY
Pumps, PTO’s
& Motors
Valves
Cylinders
Winch
Hyd Filters
Daily
Monthly
Quarterly
Hyd Sys
Controls
Valves
Valves
Rotation Sys
Lubrication
Hardware
Wear Pads
Loadline
3
CRANES
✔ = SATISFACTORY
✘ = DEFICIENCY
FREQUENCY ITEM
R = RECOMMENDATION
NA = NOT APPLICABLE
STATUS
✔ ,
✘
R, NA
Pumps, PTO’s & motors for loose bolts/fasteners, leaks, noise, vibration, loss of performance,
heating & excess pressure.
● Winch motor(s)
● 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)
● Outrigger or auxiliary control valve(s)
● Other
● Other
Hydraulic cylinders for drifting, rod seal leakage & leakage at welds.
Rods for nicks, scores & dents. Case for damage. Case & rod ends for damage & abnormal wear.
● Outrigger cylinder(s)
● Inner boom cylinder(s)
● Outer boom cylinder(s)
● Extension cylinder(s)
● Rotation cylinder(s)
● Jib lift cylinder(s)
● Jib extension cylinder(s)
● Other
Winch, sheaves & drums for damage, abnormal wear, abrasions & other irregularities.
Hydraulic filters for replacement per maintenance schedule.
All monthly inspection items.
All quarterly inspection items.
Hydraulic fluid change per maintenance schedule.
Control valve calibration for correct pressures & relief valve settings
Safety valve calibration for correct pressures & relief valve settings.
Valves for failure to maintain correct settings.
Rotation drive system for proper backlash clearance & abnormal wear, deformation & cracks.
Gear oil change in rotation drive system per maintenance schedule.
Check tightness of all fasteners and bolts.
Wear pads for excessive wear.
Loadline for proper attachment to drum.
Deficiency / Recommendation / Corrective Action Report
DATE
OWNER
UNIT I.D. NUMBER
GUIDELINES
A. A deficiency (✘) may constitute a hazard. ✘ 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 manufacturers recommendations, specifications and requirements.
NOTE: Deficiencies (✘) listed must be followed by the corresponding corrective action taken (CA).
✘ = DEFICIENCY
R = RECOMMENDATION
✘,
R, CA ITEM # EXPLANATION
CA = CORRECTIVE ACTION TAKEN
DATE
CORRECTED
20000710
4-6
Deficiency / Recommendation / Corrective Action Report (cont)
✘,
R, CA
ITEM #
EXPLANATION
If additional space is required, reproduce this page and attach to this report.
4
DATE
CORRECTED
20000710
WIRE ROPE INSPECTION
Wire rope with any of the deficiencies shown below shall be
removed and replaced immediately.
A.
Corrosion can be cause for replacement. Any
development of corrosion must be noted and
monitored closely.
B.
When there are either 3 broken wires in one strand
or a total of six broken wires in all strands in any one
rope lay.
4-7
HOOK INSPECTION
Hooks having any of the listed deficiencies shall be
removed from service unless a qualified person approves
their continued use and initiates corrective action. Hooks
approved for continued use shall be subjected to periodic
inspection.
A.
DISTORTION
Bending / Twisting
A bend or twist exceeding 10° from the plane of the
unbent hook.
Increased Throat Opening
HOOK WITHOUT LATCH: An increase in throat
opening exceeding 15% (Or as recommended by the
manufacturer)
C.
D.
When there is a decrease of diameter indicating a
core failure.
E.
When kinking, crushing, birdcaging or other
distortion occurs.
F.
HOOK WITH LATCH: An increase of the dimension
between a fully-opened latch and the tip section of the
hook exceeding 8% (Or as recommended by the
manufacturer)
When flat spots on the outer wires appear and those
outside wires are less than 2/3 the thickness of the
unworn outer wire.
When there is noticeable heat damage
(discoloration) of the rope by any means.
B.
WEAR
If wear exceeds 10% of the original sectional
dimension. (Or as recommended by the manufacturer)
C.
CRACKS, NICKS, GOUGES
Repair of cracks, nicks, and gouges shall be carried out
by a designated person by grinding longitudinally,
following the contour of the hook, provided that no
dimension is reduced more than 10% of its original
value. (Or as recommended by the manufacturer) (A
qualified person may authorize continued use if the
reduced area is not critical.)
D. LATCH
Engagement, Damage & Malfunction
If a latch becomes inoperative because of wear or
deformation, and is required for the service involved, it
shall be replaced or repaired before the hook is put
back into service. If the latch fails to fully close the
throat opening, the hook shall be removed from service
or “moused” until repairs are made.
E.
G. When the diameter is reduced from nominal size by
1/32" or more.
H.
If a broken wire protrudes or loops out from the core
of the rope.
HOOK ATTACHMENTS & SECURING MEANS
If any indication of distortion, wear, cracks, nicks or
gouges are present, unless a qualified person
authorizes their use. (Or as recommended by the
manufacturer)
20000710
HOLDING VALVE INSPECTION
The cylinders are equipped with holding valves that prevent
sudden movement of the cylinder rods in the event of a
hydraulic hose or other hydraulic component failure. The
valve is checked in the following manner:
4-8
COARSE THREAD BOLTS
TIGHTENING TORQUE
1. With a full rated load, extend the cylinder in question
and kill the engine.
2. Operate the control valve to retract the cylinder. If the
cylinder “creeps”, replace the holding valve. If the
cylinder does not “creep”, the valve is serviceable.
ANTI-TWO BLOCKING DEVICE INSPECTION
(See Vol. 1, Operation, Maintenance and Repair for a
complete description)
The anti two block system should be checked daily as
follows:
1. Examine flexible rod and weight to insure free
unrestricted mechanical operation
2. Examine cord for damage, cuts or breaks. Grasp cord
and pull to check operation of cord reel. The cord should
retract on reel when released.
3. Start vehicle, engage PTO and slowly winch loadline
up until anti-two block weight comes in contact with the
hook end of the loadline cable. At the moment the weight
is fully supported, a marked difference in winch operation
should be noted. At this point, the winch up function
should become very sluggish or non-functioning and
have very little pull capability. Slowly increase truck
engine speed while simultaneously actuating the winch
up function. The winch characteristics should remain
sluggish with little or no tensioning of the cable. If
operation other than as described occurs, stop
immediately and investigate. Failure to do so will risk
damage to the cable or the crane.If all is well at this point,
actuate the boom extend function slowly, and gradually
increase to full actuation. Once again the function should
be sluggish or non-existent with no tightening of the
winch cable. If operation other than described occurs,
stop immediately and reverse the function.
The final check involves actuating both the winch up and
extend functions together and checking for proper
operation of the anti two blocking circuit. Once again,
start slowly and stop if it appears the cable is being
tensioned.
If the anti two block function appears to be functioning
normally, winch the cable down until the sensing weight
swings free.
SIZE
(DIA-TPI)
SAE J429
SAE J429
GRADE 5
GRADE 8
BOLT DIA
PLAIN PLATED PLAIN PLATED
(INCHES) (FT-LBS) (FT-LBS) (FT-LBS) (FT-LBS)
5/16-18
0.3125
17
13
25
18
3/8-16
0.3750
31
23
44
33
7/16-14
0.4375
49
37
70
52
1/2-13
0.5000
75
57
105
80
9/16-12
0.5625
110
82
155
115
5/8-11
0.6250
150
115
220
160
3/4-10
0.7500
265
200
375
280
7/8-9
0.8750
395
295
605
455
1-8
1.0000
590
445
910
680
1 1/8-7
1.1250
795
595
1290
965
1 1/4-7
1.2500
1120
840
1815
1360
1 3/8-6
1.3750
1470
1100
2380
1780
1 1/2-6
1.5000
1950
1460
3160
2370
When using the torque data in the charts above, the following rules
should be observed.
1. Bolt manufacturer’s particular specifications should be
consulted when provided.
2. Flat washers of equal strength must be used.
3. All torque measurements are given in foot-pounds. To
convert to inch-pounds, multiply by 12.
4. 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.
5. Torque values for socket-head capscrews are the same as
for Grade 8 capscrews.
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 torquing. Failure to
replace gear-bearing bolts may result in bolt failure due to metal
fatique causing serious injury or DEATH.
20000710
4-9
TORQUE DATA CHART - DOMESTIC
FINE THREAD BOLTS
COARSE THREAD BOLTS
TIGHTENING TORQUE
SIZE
(DIA-TPI)
TIGHTENING TORQUE
SAE J429
SAE J429
GRADE 5
GRADE 8
BOLT DIA
SIZE
(DIA-TPI)
SAE J429
SAE J429
GRADE 5
GRADE 8
BOLT DIA
5/16-24
0.3125
19
14
27
20
5/16-18
0.3125
17
13
25
18
3/8-24
0.3750
35
26
49
35
3/8-16
0.3750
31
23
44
33
7/16-20
0.4375
55
41
78
58
7/16-14
0.4375
49
37
70
52
1/2-20
0.5000
90
64
120
90
1/2-13
0.5000
75
57
105
80
9/16-18
0.5625
120
90
170
130
9/16-12
0.5625
110
82
155
115
5/8-18
0.6250
170
130
240
180
5/8-11
0.6250
150
115
220
160
3/4-16
0.7500
300
225
420
315
3/4-10
0.7500
265
200
375
280
7/8-11
0.8750
445
325
670
500
7/8-9
0.8750
395
295
605
455
1-12
1.0000
645
485
995
745
1-8
1.0000
590
445
910
680
1 1/8-12
1.1250
890
670
1445
1085
1 1/8-7
1.1250
795
595
1290
965
1 1/4-12
1.2500
1240
930
2010
1510
1 1/4-7
1.2500
1120
840
1815
1360
1 3/8-12
1.3750
1675
1255
2710
2035
1 3/8-6
1.3750
1470
1100
2380
1780
1 1/2-12
1.5000
2195
1645
3560
2670
1 1/2-6
1.5000
1950
1460
3160
2370
When using the torque data in the charts above, the following rules should be observed.
1. Bolt manufacturer’s particular specifications should be consulted when provided.
3. All torque measurements are given in foot-pounds. To convert to inch-pounds, multiply by 12.
4. 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.
5. Torque values for socket-head capscrews are the same as for Grade 8 capscrews.
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 torquing. Failure to replace gear-bearing bolts may result in
bolt failure due to metal fatique causing serious injury or DEATH.
20000710
4-10
TORQUE DATA CHART - METRIC
FINE THREAD BOLTS
COARSE THREAD BOLTS
TIGHTENING TORQUE
SAE J429
GRADE 5
PLAIN PLATED
(KG-M) (KG-M)
TIGHTENING TORQUE
SAE J429
GRADE 8
PLAIN PLATED
(KG-M) (KG-M)
SIZE
(DIA-TPI)
BOLT DIA
(INCHES)
5/16-24
0.3125
3
2
4
3/8-24
0.3750
5
4
7/16-20
0.4375
8
1/2-20
0.5000
9/16-18
SAE J429
SAE J429
GRADE 5
GRADE 8
(KG-M) (KG-M) (KG-M) (KG-M)
SIZE
(DIA-TPI)
BOLT DIA
(INCHES)
3
5/16-18
0.3125
2
2
3
2
7
5
3/8-16
0.3750
4
3
6
5
6
11
8
7/16-14
0.4375
7
5
10
7
12
9
17
12
1/2-13
0.5000
10
8
15
11
0.5625
17
12
24
18
9/16-12
0.5625
15
11
21
16
5/8-18
0.6250
24
18
33
25
5/8-11
0.6250
21
16
30
22
3/4-16
0.7500
41
31
58
44
3/4-10
0.7500
37
28
52
39
7/8-11
0.8750
62
45
93
69
7/8-9
0.8750
55
41
84
63
1-12
1.0000
89
67
138
103
1-8
1.0000
82
62
126
94
1 1/8-12
1.1250
123
93
200
150
1 1/8-7
1.1250
110
82
178
133
1 1/4-12
1.2500
171
129
278
209
1 1/4-7
1.2500
155
116
251
188
1 3/8-12
1.3750
232
174
375
281
1 3/8-6
1.3750
203
152
329
246
1 1/2-12
1.5000
304
228
492
369
1 1/2-6
1.5000
270
210
438
328
When using the torque data in the charts above, the following rules should be observed.
1. Bolt manufacturer’s particular specifications should be consulted when provided.
3. All torque measurements are given in kilogram-meters.
4. 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.
5. Torque values for socket-head capscrews are the same as for Grade 8 capscrews.
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 torquing. Failure to replace gear-bearing bolts may result in
bolt failure due to metal fatique causing serious injury or DEATH.
20000710
4-11
TURNTABLE BEARING FASTENER TIGHTENING SEQUENCE
Refer to the diagram below for proper tightening/torqueing sequence of the turntable bearing to the crane
base and crane mast. The total quantity of cap screws varies dependent on crane model.
22
3
7
11
18
15
14
19
10
6
23
WARNING
Number 1 can be assigned to
any capscrew if the sequence
remains the same in reference
to number 1.
2
1
24
5
9
20
13
16
17
12
8
4
21
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-LBS = 106 FT-LBS)
(EXAMPLE-METRIC: .40 x 36 KG-M = 14.4 KG-M)
4. Repeat Step 3, but torqueing all capscrews to 75% of the specified torque value. Continue to follow the
tightening sequence.
(EXAMPLE: .75 x 265 FT-LBS = 199 FT-LBS)
(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.
20000710
4-12
TURNTABLE BEARING INSPECTION FOR REPLACEMENT
Before a bearing is removed from a crane for
inspection, one of the following conditions should be
evident:
1. Metal particles present in the bearinglubricant.
2. Increased drive power required to rotate the crane.
3. Noise emitting from the bearing during crane
rotation.
4. Rough crane rotation.
5. Uneven or excessive wear between the pinion
gear and turntable gear.
If none of the above conditions exists, the bearing is
functioning properly and need not be replaced. But, if
one or more of the above conditions exists, 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.
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.
TEST PROCEDURE
STEP 1.
With the crane horizontal and fully extended, measure
between the top and bottom mounting surfaces of the
turntable bearing (A1), using a dial indicator for
accuracy.
STEP 2.
Reverse the load by applying minimal downward
pressure on the boom while the boom is in the boom
support or on a solid surface. Again measure A2.
STEP 3.
Subtract A1 from A2 to determine tilt and compare the
result with the accompanying chart.
COMPARISON CHART - MODEL TO MEASURED TILT DIMENSION
NOTE
THE FIGURES LISTED IN
THIS CHART ARE
SERVICE GUIDELINES
AND DO NOT, IN
THEMSELVES, REQUIRE
THAT THE BEARING BE
INSPECTED.
IF THERE IS REASON
TO SUSPECT AN
EXCESS OF BEARING
WEAR AND THE
MEASURED TILT
DIMENSION EXCEEDS
THE DIMENSION
LISTED, REMOVE THE
BEARING FOR
INSPECTION.
IMT
CRANE,
LOADER
OR
TIREHAND
MODEL
1007
1014
1014A
1015
2015/2020
2109
3000
3816/3820
3016/3020
421/425
4300
5016/5020
6016/6020
TH7 BODY ROT’N
TH1449 BODY ROT’N
TH15B CLAMP
TH2551B CLAMP
TH2557A CLAMP
5200
5200R
5217
5800
7020
7025
7200
7415
9000
TH10 BODY ROT’N
TH14 BODY ROT’N
16000
32018
32027
32030
T30
T40
9800
12916
13031
13034
14000
15000
18000
20017
8000L
H1200
H1200RR
T50
TH2551B BODY ROT’N
TH2557B BODY ROT’N
TH2557A BODY ROT’N
BALL DIA.
(REF)
.875”
(22mm)
1.00”
(25mm)
1.18”-1.25”
(30-32mm)
1.75”
(44mm)
TILT DIM.
(A1-A2)
.060”
(1.524mm)
.070”
(1.778mm)
.075”
(1.905mm)
.090”
(2.286mm)
20000710
4-13
The information within this manual has been compiled and checked but errors do occur. To provide our customers with a
method of communicating those errors we have provided the Manual Change Request form below. In addition to error
reporting, you are encouraged to suggest changes or additions to the manual which would be of benefit to you. We
cannot guarantee that these additions will be made but we do promise to consider them. When completing the form,
please write or print clearly. Submit a copy of the completed form to the address listed below.
MANUAL CHANGE REQUEST
PRODUCT
MANUAL
DATE
MANUAL
PART NO.
SUBMITTED BY
COMPANY
ADDRESS
CITY, STATE, ZIP
TELEPHONE
ERROR FOUND
LOCATION OF ERROR (page no.):
DESCRIPTION OF ERROR:
ERROR FOUND
DESCRIPTION OF ADDITION:
REASON FOR ADDITION:
MAIL TO:
BOX 189
GARNER, IA 50438-0189
ATTN: Technical Publications
BOX 189, 500 HIGHWAY 18 WEST, GARNER, IA 50438
TELEPHONE: 641-923-3711
TECHNICAL SUPPORT FAX: 641-923-2424
www.imt.com

Model 425AT Crane - Iowa Mold Tooling Co., Inc.

Transcription

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