3020 Parts & Specifications
Contents
1. 53 Handle Assembly Tethered Remote w Engine Start 51719470 54 Tethered Remote Calibration Mode nn eene 56 Electrical Harness Tethered Remote 77441164 sse 56 Electrical Schematic Tethered 77441164 57 Controls Installation Radio Remote Kit 90719400 Dwg 99903697 59 MiscellafieollS 60 3020 51 D cal Kat 95721952 1 cte atr loan RO ERU OE AU arde 60 ii Contents Installation Kit 03719609 i m ete etie irt ei h te REDE alas ya 62 Cord Reel Assembly 51720302 n ener enne enne 63 Boom Support Assembly 51714181 sse eene enne 64 Chassis Wiring Harness 99903340 isses ener nennen nnne 65 General Reference 67 Inspection Checklist ohio e tuse d t v b prt tete se 68 Deficiency Recommendation Corrective Action 72 Wire Rope Inspection amp Replacement nn enne ennemi nennen nnns 74 Hook Inspection Jie etit e een eene PE Meu ie UR D ES 75 Holding Valve Inspection n 76 Anti Two Block Device Inspection2. ze a Outrigger cylinder s N 82 Inner boom cylinder s Co 83 Outer boom cylinder s Rotation cylinder s Jib lift cylinder s Valves for failure to maintain correct settings Rotation Sys Rotation drive system for proper backlash clearance amp abnormal wear deformation and cracks cO i 86 i other irregularities 90 95 Extension cylinder s i Hyd Filters Hydraulic filters for replacement per maintenance schedule Jib extension cylinder s Other per customer requirements oo Lubrcaton Check tightness of all fasteners and bolts using torque specifications on component drawings or torque chart TO Wear Pads Wear pads for excessive wean 102 Loadline Loadline for proper attachment to drum i DENEN E Im QQ 78 79 81 4 5 7 8 1 2 3 4 7 100 101 102 72 3020 Parts amp Specifications Manual Part 99904521 Deficiency Recommendation Corrective Action Report UNIT 1 0 NUMBER GUIDELINES 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
3. a 38 3020 Parts amp Specifications Manual Part 99904521 Cylinder Extension 51720936 Eff 5 07 C 18 Des i k Z E PENES EL qm LL 5 IN N 128 86 CLOSED 236 88 OPEN 108 Doom SECTION A A 13 FET 4 va z Z E LK 55 2212 27 8 166 4911 1194516 DETAIL NOTES 1 ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS DISASSEMBLED THIS WILL REDUCE FUTURE DOWNTIME 2 APPLY 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 1720936 PARTS LIST TEM PART DESCRIPTION 5 2720934 5 2 50 X 119 21 LONG ASM 1 50 DIA X 56 38 LG 1 25 S 6HD25015 EAD 2 50 BORE X 1 50 ROD DUCTILE IRON ISTON 2 50 BORE X 1 25 STGR DUCT IRON 075015 TUBE 1 50 ROD X 75 LONG C022020 TUBE W HOLES 1 50 ROD X 0 75 LONG 52720935 OD ASM 1 50 DIA X 72 00 LG 1 25 S 7T61N125 OCK RING NYLON 1 25 7T66P025 ISTON SEAL DYNAMIC 2 50 7T2NX417 EAR RING ROD 1 50 IDX0 50W 717234025 EAR RING PISTON 2 50 50W 6 6 42 x r e Be od S Chapter4 Parts 39 TEM PAR
4. nn 76 Thread TOrques 14 a ett E T Turntable Bearing Thread Tightening Sequence 80 Turntable Bearing Inspection 81 Turntable Bearing Tilt eene 81 Contents iii Revisions DATE LOCATION DESCRIPTION 20081110 20081110 THROUGHOUT 3020 MANUAL RE RELEASE 20100617 73734473 ECN 11134 VALVEBANK 73734473 REPLACED 73734194 20110210 REPL VALVE ADDED INFORMATION REPLACING VALVE COILS COILS iv Contents 3020 Manual Effectivity Manual 99904521 is effective for model 3020 cranes produced from 2008 forward with crane serial numbers beginning with the sequence 3020SII08 However some 3020 cranes which have serial numbers which indicate they were produced prior to the design change but they include the new design Cranes with the following serial numbers were built with the new design and include the parts in manual 99904521 3020071001 3020071002 3020071006 3020071007 3020071008 3020081002 3020081004 3020081006 3020081007 3020081008 3020081009 3020081010 3020081011 3020081012 3020081013 3020081014 3020081016 CHAPTER 1 Introduction This volume deals with information applicable to your particular crane For operating maintenance and repair instructions refer to Telescopic Crane Volum
5. E Ed eo ce da 19 Parts 21 rne e GR HUE RE ERG UR Re de tute ED e ea RETE EE Ri ayq 22 Base and Mast Assemblie eene e eed ie e Petre e eee 24 Base amp Mast Assembly 99903947 Primary Configuration 24 Gear Rotator 71056543 Primary sss ener 26 Crane amp Worm Winch Assembly 99903948 Primary Configuration 28 Winch Worm 71057936 a te cese este an aaa 31 Cylinder Lower 3820 51720921 5 17 07 33 Boom Assemblies ho Cylinders 35 Boom amp Winch Assembly 99904008 Eff 8 1 06 2 0 1 0 600 0000000000000000 04 35 Cylinder Extension 51720936 Eff 5 07 sse enne nennen 38 Hydraulic Mg 40 Hydraulic Installation Worm Winch 99903944 nennen 40 Valve Bank Worm Winch 73734473 Eff 1 10 sse eene 43 Valve Bank Worm Winch 73734194 From 5 4 07 to 12 09 44 Telescopic Valve Bank Replacement 99904783 46 Replacement Valve u Q u u T did te 48 Harness Valvebank 77441204 Eff 8 1 06 n renes 51 Controls esto tte tcc Perd ce REL 53 Controls Installation Tethered Kit 90719399 Dwg 99903697
6. 001 49 Controls Installation Radio Remote Kit 90719400 Dwg 99903697 USE OPTIONAL CABLE 70733889 FOR TETHERED OPERATION OF RADIO TRANSMITTER CONNECT TO HARNESS FROM VALVE BANK 0719400 TETHERED CONTROLS PARTS LIST TEM PART amp DESCRIPTION MAST WELDMENT 10733956 063166 062194 N N 0733883 TRANSMITTER RADIO REMOTE TELE 51719413 HARDWARE KIT TELE CRANE RADIO CONTROLS z o e o N 3020 Parts amp Specifications Manual Part 99904521 60 Miscellaneous 3020 SII Decal Kit 95721952 PLACARD DECAL PLACEMENT IF NOT SHOWN ON CRANE PLACEMENT TEM 2 o lt a Q z lt LLI gt na lt z lt ON I EN O NN 15 OUTRIGGERS OR BUMPER GUSSET Parts 61 6 2 ON REAR OUTRIGGERS 2 ON SIDEPACK FRONT WALLS AT OR NEAR DRIVELINE ON ALL FOUR SIDES OF CARRIER VEHICLE 9 ON OIL RESERVOIR 8 10 BASE OVER WORM DRIVE 9903752 PARTS LIST TEM ART DESCRIPTION 719347 DECAL KIT TELESCOPIC INCL 4 14 28 719348 DECAL KIT BODY INCL 15 22 29 5721952 DECAL KIT 3020 391612 DECAL GREASE WEEKLY LEFT 0391613 DECAL GREASE WEEKLY RIGHT 392399 DECAL LUBRICATION 392524 DECAL ROTATE WHILE GREASING 0395090 DECAL GREASE WORM DRIVE BRNGS 395324 DECAL ASME ANSI B30 5 0395670 DECAL CAUTION DOWNHAUL WT 1391522 DECAL
7. Manual Part 99904521 3020 Parts amp Specifications Effective August 15 2008 Revision Date 20110210 4M gt 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 2011 lowa 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 lowa Mold Tooling Co Inc lowa Mold Tooling Co Inc is an Oshkosh Corporation Company Printed on 10 February 2011 Contents REVISIONS ooh GOES a ao deci e a sua su au Re ur Hi 3020 MAa ual e ERROR ee e eon ee at e A EN tete iv Introduction 5 Specifications 7 Specifications mic eo ee eo 7 Geometric Won Surat ti teer net ose sees 10 Capacity Placard 3020 uu u ttt eee ae e e EE NECARE INE c er Uu een legs 11 Crane Reference 13 Assemblies and Grease Zerk Locations eere 14 3020 Recommended Spare Parts List nn ener enne nnne 15 3020 Crane 1 17 Telescopic Crane Orientation rte i e aree ERR 19 Crane Controls oio eee ene op TR eti iecit Pd re coe dp ale aa
8. QVOTH3AO 8cN gt HONIM LL gt 1I1dS 0 gt HIMOd HSHdlND 6 gt 98754 8 gt gt O N V S8y SH gt gt OIN vss TIX 3NION3 LHVLS ANIONA IM GNAIXA NI GNALX3 IM HONIM NAAOG HONIM SSANXVH ANVYD WOO8 2 NO 31VLOM IM NMOG 0 31 VLOH 9 WOO Q33dS 0869 d3MOd dO1S 3 QNnOHO O N SSVdA8 WOOd 5 dNISN3 gt d3MOd LL 3 d3MOd 3NVYV3O 0 gt OO ID JHOd INVHOOHd 6 gt gt O N LHOd INVHOOMHd 8 gt gt O N ddM 1404 INVHOOMHd Z gt gt O N IM LNO ess do IM dN HONIM SSVdAd WOO TA NMOG INOOg INdLNO dOHd HONIM 3ATVA 21901 INO SLIOAS L HALAINOLNALOd 0 HONIM HONIAA QvOTH3AO 8cV INOOg 299 45 NMOG INOOg NO ALVLOU ALVLOY aNnOSNHO HdMOd 3NVSHO Y Y Y Y Y Y Y Y Y Y Y Y m a MERE NN CR A i EE EH 4 o Vir 1 26 jeaujoe 3 61215000 9 A3H 9 LYVLS 3NION3 H3MOd HSYdINS IN TID 3NION3 f d3adS ANIONA NMOG HONIM dN HONIM N NMOG WOOd d Wood 3 NI GNALXS LNO ALVLOY V MO ALVLOY H3MOd H3MOd 3NVSHO H HHLSINOLNALOd 3 SLIOA S
9. Values in the box indicate the use of 2 part line is required Maximum 1 part line weight is 3000 Ib 1360 kg The weight of load handling devices is part of the load lifted and must be deducted from the rated capacity 1660 2100 755 16 6 5 0m 6 25 m IOWA MOLD TOOLING CO INC BOX 189 GARNER IA 50438 0189 TEL 641 923 3711 FAX 641 923 2424 CHAPTER 3 Crane Reference In This Chapter Assemblies and Grease Zerk Locations 14 3020 Recommended Spare Parts List 14 3020 Crane Installation 17 Telescopic Crane Orientation 19 Grane Controls 19 14 3020 Parts amp Specifications Manual Part 99904521 Assemblies and Grease Zerk Locations 5 Ext Boom Other Winch 2 Lower Boom Manual side w Internal Hyd Cylinder 3 Extension Cylinder Block B Rotation 47 Motor 7 Note Components are identified by name grease zerks are identified by number Gear Rotator Grease Extension Shell Alvania 2EP Rotate Crane While Greasing or Lower Cylinder Base Sell ROUNAK AS 6 LowerSheavePin NOTE All application points must be greased weekly under normal work loads and moderate weath
10. 16 THROUGH BOOM SIDE PLATE THEN THROUGH WIRE ROPE CLEVIS FOR SINGLE LINE APPLICATION INSTALL PIN 16 THROUGH WIRE ROPE CLEVIS AS SHOWN 2 IF REQUIRED USE 72063037 MACHINERY BUSHINGS BETWEEN MAST amp BOOM WHEN INSTALLING PIN 8 3 FOR SINGLE LINE MOUNT DOWNHAUL WEIGHT OVER CLEVIS 4 USE 70034069 AS NEEDED TO SECURE WIRE HARNESS 5 VIEW SHOWN WITH CRANE AS POSITIONED ON ASSEMBLY STAND Chapter4 Parts 29 99903948 WINCH amp MOTOR ASSEMBLY USE BLUE THREAD LOCKER PORT B PORTA 44 45 4 PLCS 82 HYDRAULIC MOTOR PORT 38 IDENTIFICATION USE BLUE THREAD LOCKER 40 43 4 PLCS 9903948 PARTS LIST PART DESCRIPTION 99903947 DWG BASE amp MAST ASY 52719629 PIN TYPE MM 1 50X 9 75 9 19 52719630 MM 1 50X 8 75 8 19 30 3020 Parts amp Specifications Manual Part 99904521 9903948 PARTS LIST TEM DESCRIPTION 51720916 CYLINDER 5020 WAS 71412008 THRU 4 3 07 51720921 CYLINDER 3820 WAS 71411871 THRU 5 17 07 71057936 WINCH 3820 70570501 WINCH 5020 i PIN LOCK W HANDLE 875 X 4 25 IN QUICK 316 10QP 73733171 PIN LOCK 1X6 W HAIR PIN 70034382 CAP GREASE 72053508 ZERK NPT 12 72060002 CAP SCR 25 20X 75 HH GR5Z 72060091 SCR 50 13 1 00 HH GR5 Z 2062107 50 13 HEX CENTER LOCK Z 2063001 WASHER 25 FLAT 72063049 WASHER 25 LOCK 72063053 WASHER 50 LOCK 72063132 WASHER 50 F
11. indeterminate clamp loads after torquing Failure to replace gear bearing bolts may result in bolt failure due to metal fatigue causing serious injury or DEATH When using the torque data in the torque charts the following rules should be observed 1 Bolt manufacturer s particular specifications should be consulted when provided Flat washers of equal strength must be used 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 the charts by the factor 90 The use of Loctite does not affect the torque values 78 3020 Parts amp Specifications Manual Part 99904521 FINE THREAD TORQUE CHART ENGLISH TIGHTENING TORQUE SAE J429 SAE J429 BOLT DIA GRADE 5 GRADE 8 LB FT LB FT LB FT LB 71620 pass ps h pe fe 220 ps po meis Pos po A o gt NJ Q 5 58 18 o fo 6 prs 2 5 t 95 zs eo s 108 zs 15 15612 ars 65 255 rie s 5 ets pen TIGHTENING TORQUE SAE J429 SAE J429 BOLT DIA GRADE 5 GRADE 8 INCHES 16 14 0 4375 ESE 16 12 0 5625 10 8 11 0
12. Start 51719470 SJP START OJERANE OFF EXT WINCH ROTATION 1 DOWN LOWE R SN OUT UP Cw CRN ONLY IDLE THIS JUMPER 3 5 ALL OTHERS 2 25 1 RED BLU BLK RED RED BL 17 BRN 51719470 HANDLE ASSEMBLY WIRE FUNCTIONS SOLIDISTRIPE YEL BLK ORN BLK BLU BLK RED BLK ORN RED i BRN RED BLUIRED ONERE I BLK RED BRN BLK BLK ORN BRN BLU pce e 4 YEL RED eS BLK BLU RED BLU BLU ORN MEME EE ORN BLU ees YEL BLU dl RED RON UJ 2 r 1719470 PARTS LIST TEM PARTS DESCRIPTION 9044214 WIRE 18GA GRN ONTROL HANDLE RIGGER PART OF 11 VER 70034306 ACK COVER TRAIN RELIEF 3 4 70394447 ECAL DGR RC ELECTRO SM i 70396719 ECAL CTRL RIGGER ASM INCL 3 HT MTL SCR 6X3 4 PH 77040051 ERM SPRSPD 8 16 14GA OGGLE SWITCH SPST OGGLE SWITCH SPDT 77040373 OGGLE SWITCH SPST OGGLE SWITCH SPDT ONNECTOR 1 89044100 CABLE 18GA 24WIRE NOTE MUST ORDER 40 FT REF 51717817 TETHERED CABLE 40 INCL 8 15 24 20 21 11 77040147 TERM FSLPON 1 4 22 18 Q Q A Al N BRI N G po a a a aly a O UJ B ass ayo 9 T z 2 hi e n N N Parts 55 56 3020 Parts amp Specifications Manual Part 99904521 517
13. a designated person who has been selected or assigned by the employer or the employer s 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 8 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
14. amp Specifications Manual Part 99904521 Boom Support Assembly 51714181 6 9 12 4 USE THE 1 75 SCREW AS STOP FOR THE SADDLE WHILE ROTATING SIDE TO SIDE 1714181 PARTS LIST TUBE S 72060048 _ G 7206000 CAP SCR S6 T6XT SIGHHGRS 2 _ CORN 72060101 SCR 1 2 13 5 HHGR5 72601671 SCR 3 4 10 5 1 2 HHGR5 72062103 NUT 3 8 16 LOCK o mens 2 1 206244 NUT 34 10 LOCK 72063003 WASHER 3 8 WRT H3 72063008 WASHER 112 WRT n WASHERGHWRT 2 a WASHER BONDED PLTD 51716384 HARDWARE KIT INCL 5 15 20040206 Chassis Wiring Harness 99903340 TO RECOMMENDED OEM 12V SPEED CONTROL amp ENGINE SPEED ORANGE ENGINE KILL LI OPTION TO BATTERY GROUND lt SROUND TO RECOMMENDED BLACK 87A 30 057 85 TH ENGINE KILL YELLOW FOR FORD AUTO TRANS ONLY lt C SELECTOR BROWN WIRE ON SOLENOID SELECTOR VALVE NOTE BLUNT CUT AND SHRINK WRAP ANY UNUSED WIRES 22 TE PART 51715664 Note Used on all ship out IMT telescopic cranes Parts 65 TO RECOMMENDED COMPRESSOR COMPRESSOR ENGAGE RED y TO RECOMMENDED OEM ENGINE 12 ENGINE START START BL E 87A
15. situation 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 XR CA ITEM EXPLANATION DATE CORRECTED Chapter5 General Reference T3 XR CA ITEM EXPLANATION DATE CORRECTED 74 3020 Parts amp Specifications Manual Part 99904521 Wire Rope Inspection amp Replacement 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 three broken wires in one strand or a total of six broken wires in all c When flat spots on the outer wires appear and those outside wires are less than 2 3 the thickness of the unworn outer wire e When kinking crushing birdcaging or other distortion occurs f When there is noticeable heat damage discoloration of the rope by any means g When the diameter is reduced from nominal size by 1 32 0 8 mm or more NOMINAL SIZE 1 32 0 8 mm NOMINAL h Ifa broken wire protrudes or loops out from the core of the 5555055 Chapter 5 General Reference 75 Hook Inspection Ho
16. 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 Chapter 5 General Reference 69 INSPECTION CHECKLIST STATUS KEY S Satisfactory R Recommendation should be considered for corrective action X 7 Deficient must be corrected prior to operation NA Not Applicable FREQUENCY ITEM perecnon DESCRIPTION STATUS S R X Labels All load charts safety amp warning labels and control labels are present and legible Crane Crane Check all safety devices for proper operation cracks foreign material Hydraulic Hydraulic system hoses tubes fittings for leakage and proper oil System level Presence and proper operation of hook safety latches Proper reeving of wire rope on sheaves and winch drum Proper engagement of all connecting pins and pin retaining devices General Overall observation of crane for damaged or missing parts cracked welds and presence of safety covers 0 Operation During operation observe crane for abnormal performance unusual wear loose pins wire rope damage etc If observed discontinue 4 1 5 1 use
17. 041561 RESSURE SWITCH BF81215 BUSHING 7 16 3020 Parts amp Specifications Manual Part 99904521 OOM amp WINCH ASSEMBLY 99903683 1713168 CORD REEL ASSEMBLY 0030330 WEAR PAD 0030331 WEAR PAD 0030339 WEAR PAD 0030340 WEAR PAD 0030341 WEAR PAD 0122985 WEAR PAD 7041459 LIMIT SWITCH D101220 3054999 lt E I x 2 o o T N o SEAL KIT COUNTERBALANCE VALVE lt gt lt UJ gt z gt z Q zn Ei N Q A A N 2 3540252 VALVE PROP FLOW 3540254 VALVE RELIEF 3540375 SOLENOID VALVE SECTION NSTALLATION KIT 93719692 3052092 HYDRAULIC FILTER ELEMENT Chapter3 Crane Reference 17 3020 Crane Installation GENERAL This section contains instructions for the installation of your crane Prior to installing the crane and hydraulic components make sure that the chassis is ready to receive the crane see the Installation Section of the IMT Telescopic Crane Operation amp Safety Manual 99903514 Reinforce the chassis frame as necessary and install the PTO and pump 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 Study the applicable installation kit in the parts section before attempting any installation CRANE INSTALLATION In addition to meeting the minimum chassis specifications there must
18. 0609 N x o N N e cO 7 7 m Col Col AJ a AJ AJ AJ AJ ay a N NINI NINI Q BJ O N AJ o LE o o OTN gt S N 26 3020 Parts amp Specifications Manual Part 99904521 Gear Rotator 71056543 Primary 18 19 7 5 Me Z M SS Z Z la 9 ic Noel TA Z a V 4 e dm s II P Us 7 GY Z 68 b 72 19 16 4 SECTION 4 8 11 7 21 8 6 2 4 20 8 12 13 14 3 NOTES 1 INSTALL SEALS 3 AND 16 WITH LOCTITE PLASTIC GASKET O D LUBRICATE SEAL SURFACE BEFORE ASSEMBLY 2 PACK CAVITIES WITH EPO GREASE 3 SHIM TO OBTAIN 0 000 0 004 END PLAY ON WORM SHAFT 4 LUBRICATE O RING Z2 WITH WORM GEAR OIL BEFORE INSTALLING 5 INSTALL BOLTS 10 WITH LOCTITE 242 6 SET BACKLASH BETWEEN WORM AND ROTATION BEARING 0 005 0 012 7 TIGHTEN 5 8 11 UNC GRADE 8 MOUNTING BOLTS AS FOLLOWS TIGHTEN PROGRESSIVELY AND AT 180 INTERVALS FIRST INTERVAL AT 70 FT LB SECOND INTERVAL 140 FT LB THIRD INTERVAL 210 FT LB TIGHTEN BOLTS IN ORDER SHOWN IN DIAMONDS lt gt DO NOT USE LOCTITE ON MOUNTING BOLTS 8 ITEM 20 SHIPS LOOSE INSTALL ITEM 21 FOR SHIPPING Chapter4 Parts 27 WARNING ANY TIME THE GEAR BEARING BOLTS HAVE BEEN REMOVED THEY MUST BE REPLACED WITH NEW BOLTS OF IDEN
19. 1 DEGNEETONDTPNBEGGIERATINGE i DECACMANUAFOVERRIDEINST PEPACSERVIGESREPAIR Pi 27 NT SIN S ISI SI SISI SISI N S G1 A 9 N gt 9 N 62 3020 Parts amp Specifications Manual Part 99904521 Installation Kit 93719692 MOUNTING HOLES AS VIEWED FROM TOP OF CRANE BOX BACK OF TRUCK BODY CAUTION THE 3 BOLTS SUPPLIED ARE FOR USE ON BODIES WITH A CRANE BOX TOP PLATE THICKNESS OF 7 8 TO 1 ONLY DETERMINE THE CRANE BOX TOP PLATE THICKNESS PRIOR TO MOUNTING IF DIFFERENT LENGTH BOLTS ARE REQUIRED THEY MUST BE 1 8 GRADE 8 ZINC COATED OF THE PROPER LENGTH FAILURE TO USE PROPER LENGTH BOLTS MAY CAUSE THE BOLTS UNDER THE WORM HOUSING OUT BEFORE TORQUEING INSURE MINIMUM OF 1 1 2 THREAD ENGAGEMENT NOTE 1 LEVEL INDICATOR MUST BE INSTALLED PARALLEL TO THE DOOR REINFORCEMENTS 2 TORQUE TO 680 FT LB ART DESCRIPTION 50125848 72065066 3052091 FILTER HYD 10MIC 1 25 NPTF 2042097 LEVEL INDICATOR 72601748 Parts 63 Cord Reel Assembly 51720302 126 OVERALL BROWN LENGTH TO WIRE HARNESS 12 ROTATION TO ANTI 2 LOCK 51720302 PARTS LIST TEM DESCRIPTION QUANTITY CORD REEL CONNECTION WP 2CAV FEMALE TOWER TERMINAL WP 18 20GA FEMALE SEAL WIRE MARKER WIRE MARKER BRACKET CORD REEL REV A20060815 64 3020 Parts
20. 19470 PARTS LIST 77040047 TERM MSLPON 1 4 16 14 72060602 MACH SCR 6 32X3 8 RDHD 25 70145495 TUBING HEAT SHRINK 5FT REV 20071016 jet He I NOTE KIT 51717817 TETHERED CABLE 40 FEET INCLUDES ITEMS 8 15 QTY 24 20 21 AND 25 ORDER 51717817 TO REPLACE THE CABLE ASSEMBLY Tethered Remote Calibration Mode To enter the calibration mode on the tethered remote control 1 Turn on the CRANE switch 2 With the trigger released hold the momentary EXTENSION OUT and WINCH UP switches while activating the momentary LOWER DOWN switch four 4 times in succession 3 The CRANE AND COMPRESSOR ON output and LED will begin to flash indicating successful entry to the calibration mode Release momentary switches at this time 4 Use the CCW CW momentary switches to adjust the minimum output to the valve CCW will increase the minimum output and CW will decrease the minimum output 5 To adjust the maximum output to the valve squeeze the trigger all the way and use the CCW CW switches in a similar manner CCW will increase the maximum output and CW will decrease the maximum output 6 When finished move the CRANE switch to the OFF position to save the new values to flash memory and exit the calibration mode Electrical Harness Tethered Remote 77441164 LOGIC amp VALVE TETHER CONNECTION DRIVER MODULE 71411554 CP 700 CP 552 CP 553 CJ 550 CJ 551 Wa CRANE HARNESS CONNECTION RECEIVER CONNECTION
21. 30341 EAR PAD BLOCK 4 50 X 3 50 X 44 0 LATE ANGLE PLASTIC 1 LATE SINGLE SHEAVE EAR PAD RND IN TYPE A 1 25X 4 91 4 32 6 60127979 LATE EXT CYL C CLIP 70034381 UPPORT 70396734 ECAL BOOM LENGTH INDICATOR AP GREASE PRING 0 62 X 2 50 X 14 GA 70396121 AP PLSTC 1 00 TUBE OD X 0 68 HGT BLACK LUG PLSTC 50 13 50UNC 2B AP SCR 25 20X 50 HH GR5 Z 72060006 25 20 1 50 GR5 Z 7 72060055 CAP SCR 38 16X 3 50 HH GR5Z 72060098 5 50 13 3 50 GR5 Z 4 72062080 50 13 NYLOCK 72062103 38 16 NYLOCK 72062179 NUT 38 16 HEX CENTER LOCKING 7 2063001 WASHER 25 FLAT 72063003 WASHER 38 FLAT 72063005 50 FLAT 2063035 BUSHING 1 25X10 GA NR 72063049 WASHER 25 LOCK 72063117 56 FLAT ASTM F436 72066129 RETAINING RING EXT 1 25 HD 72601757 TUD 30 13X 2 00 NC GR5 STL AIR PIN 19 ZINC 72661312 LAMP 50 LOOP CUSHIONED 77041459 WITCH LIMIT YLINDER WAS 71411883 THRU 4 07 77441096 ONNECTOR 50 STR RLF 25 38 OOM LOWER WLDMT ASM 51720302 ORD REEL ASM 10 72034485 LAMP PLASTIC 1 4 CABLE 72062106 UT 10 24 HEX NYLOCK 2053508 12 7 60030369 EAR PAD RND 2 00 DIA X 60 DIA X 0 75 L 559 lt A z A o o N x 7 42 Q Q N o m lt
22. 4 TIM 3NISN3 LYVLS 3NISN3 1 1X3 NI INOO8 1X3 df HONIM L NMOG HONIM AOVAYALNI H3AI3O93H LOcL dO QN Fr 391195 dN WOOd H3MOT1 MO 104692 gt AdOVAYALNI H3AISO3H OIQV LL MO 31V LOH Na 0 Na NOO8 H3MOT1 0021 49 LOS t ISa 0096 61 9 lt 6 MOO ALVLOY P dOlS c L 00 332145 WNOILYOdOUd z 002 dO 9 39 IN 3911959 j 8 NMOG WOO8 2 INdLNO d33dS 9 OldV S ANIT H3MOd LNdLNO 4015 3 r LNd1N0 ANNOYS el OIN 4 S 140 a1aiHs v 11 84 X3onds lt S9rS3 OILVINAHOS 7199119313 7061771 CS o lt lt GNNOYO L 998754 A9VAYALNI YSHLAL 33 3934 OIQVH 009 39I dS Controls Controls Installation Tethered Kit 90719399 Dwg 99903697 12 ROUTE HARNESS THROUGH CRANE BASE MOUNT WITH PARTS 4 12 15 16 6 7 8 2PLCS 4 CONNECT TO HARNESS FROM VALVEBANK 3 4 5 2 PLCS 0719399 TETHERED CONTROLS PARTS LIST TEM DESCRIPTION MAST WLDMNT HARDWARE KIT TELE CRANE TETH CONTROLS INCL 3 11 72601827 SCR SS 25 20X 75 HH GR5 REV B 20050513 Harc S S 53 54 3020 Parts amp Specifications Manual Part 99904521 Handle Assembly Tethered Remote w Engine
23. 625 15 NIN aj aj O co mar ha pa 880 270 950 N co Chapter5 General Reference FINE THREAD TORQUE CHART METRIC TIGHTENING TORQUE SAE J429 SAE J429 BOLT DIA GRADE 5 GRADE 8 INCHES 265 74620 044 8 6 4 bP 1220 ps k p mw kR 9716 18 5446 075 W 58 mn 0875 e Qe e Ma f 6 167 fa 1 1 8 12 1 125 9 200 150 ha 19 29 20 138 12 1 375 232 174 375 281 112 12 15 304 228 492 369 COARSE THREAD TORQUE CHART METRIC TIGHTENING TORQUE SAE J429 SAE J429 SIZE BOLT DIA GRADE 5 GRADE 8 DIA TPI INCHES fie PLATED KG M KG M _ 13 8 16 0 375 NJ oO C1 E 9 16 12 10 5625 N gt gt NJ Q N N Oj Co e o Co N gt NJ N NJ Q BJ N gt gt O1 GI N AJ gt gt AJ fl N gt gt Co NI QJ BJ NJ O Alo o j 78 1 1 8 7 0 82 133 1 1 4 7 1 25 155 116 251 188 13886 fos Bos fe goo 2 1 1 2 6 45000 270 210 438 328 79 80 3020 Parts amp Specifications Manual Part 99904521 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 varie
24. A 30 TO 12V POWER Bre I BATTERY i 86 ls SOURCE BROWN 85 IN LINE 10 F SE L TO 12V 7 IGNITION KEYED POWER CHAPTER 5 General Reference In This Chapter Inspection 7700 0 68 Deficiency Recommendation Corrective Action Report 72 Wire Rope Inspection amp Replacement 74 Hook 75 Holding Valve Inspection dt tes NE 76 Anti Two Block Device Inspection 76 Thread Tergq uesS a Gal aes 77 Turntable Bearing Thread Tightening Sequence 80 Turntable Bearing Inspection 81 Turntable Bearing Tilt Test 81 68 3020 Parts amp Specifications Manual Part 99904521 Inspection Checklist NOTICE The user of this form is responsible for determining that these inspections satisfy all applicable regulatory requirements OWNER COMPANY TYPE OF INSPECTION circle one CONTACT PERSON DAILY MONTHLY QUARTERLY ANNUAL CRANE amp MODEL DATE INSPECTED CRANE SERIAL NUMBER HOURMETER READING if applicable UNIT 1 0 NUMBER INSPECTED BY print LOCATION OF UNIT SIGNATURE OF INSPECTOR TYPE OF INSPECTION NOTES Daily and monthly inspections are to be performed by
25. ANGLE INDICATOR RH 1391523 DECAL ANGLE INDICATOR LH 0391598 DECAL WARNING MANUAL O R 392864 DECAL OUTRIGGER STAND CLEAR 0392868 DECAL DANGER LOADLINE TRUCK 0392891 DECAL DANGER DRIVELINE 394189 DECAL OIL RESERVOIR 0394445 DECAL DANGER ELECTROCUTION 396613 DECAL CRANE OPERATION 1039134 DECAL CAUTION OIL LEVEL 0392887 DECAL DIAMOND IMT 5 00 X 10 00 397659 DECAL 3020 ID 0397658 DECAL CP 3020 394453 DECAL 4 TON LD BLOCK RATING 0396631 DECAL MANUAL OP 0394166 DECAL MANUAL OVERRIDE INST 0392982 DECAL SERVICE amp REPAIR 7 20 0 A o UANTITY col cO cO oy e N olo N e S Aj aj Oo N N o TESTES N Ee DECAL KIT TELESCOPIC COMMON DECAL KIT BODY ACOMMON INCE 15122289 Ce ECAP AREAS WEEKLY _ se _ DECALGREASE WEEK i DECALLUBRICATION T j DEGNEROTATEWHIEEGRERSING DECALGREASEWORMDRIVEBRNGS PF APA A BO DECAL Ap C DEGACANGEEINDIERTOR RH tf DECALANGLEINDIGATOR GR DEGALAMARNINGUMANUAEORC U j ME 100382864 DECAL OUTRIGGER STAND CLEAR B 0 1 DEGALDANGERIOADLNECRUCK s A PE CAE DANGER DRIVEEINE C gt ss xj DECAL DANGER PLECIROCUNON a esa DEGACORANEOPEBATON _ Pe j DECAL DIAMOND IMT 500X I0 j sees Ree
26. CAP SCREW 1 8X3 GR8 4 PLACES Chapter3 Crane Reference 19 Telescopic Crane Orientation When an IMT telescopic crane is not factory installed on a body the crane is packed with the boom oriented as it is built on a test stand to facilitate handling Install the crane on the body with boom pointing backward Once the crane is bolted down it can be rotated 180 3 14 radians to the boom rest BOOM REST 400 ROTATION OUTLINE OF TRUCK BODY REAR OF TRUCK Crane Control IMT s telescopic 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 Telescopic Crane Operation amp Safety Manual part number 99903514 CHAPTER 4 Parts In This Chapter Parts 2 22 Base and Mast Assemblies 24 Boom Assemblies amp Cylinders 35 PAV CUNO 40 amp sedet 53 Miscellaneous tote eoe eee ze 60 22 3020 Parts amp Specifications Manual Part 99904521 Parts Information GENERAL This section contains the exploded parts drawings and accompanying parts lists for the as
27. LAT ASTM 436 72066132 IRETAINING RING EXT 1 50 HD 72532355 ADPTR M STR M JIC 6 6 72532356 ADPTR M STR M JIC 8 6 72532357 ADPTR M STR M JIC 6 8 i LBOW M STR 90 M JIC 10 8 4 72534435 ELBOW M STR 90 M XLG 10 8 1 WIVEL M JIC 90 M 10 10 72533648 SWIVEL M JIC 90 M JIC 8 8 EARING FLANGE BLK FC4 35 1 5 INCH DRUM MACHINED 3816 52719749 WINCH MNT WLDMNT IES PLASTIC 72060047 CAP SCR 38 16X 1 25 HH GR5 Z 4 SCR 50 13X 75 SH PLAIN i AP SCR 44 14X 1 25 SH PLAIN 3 72063051 WASHER 38 LOCR 72063054 WASHER 56 LOCK 72601499 CAP SCR 56 12X 1 25 HH GR5 Z 73051940 5020 73511069 MOTOR 3820 REV C 20090114 QUANTITY REF CO NI oy cO 7 7 gt N NJ OO BJ ol BJ AJ BJ AI NJ Z Z Z rm m m mi mj m O m Winch Worm 71057936 1057936 PARTS LIST TEM IPART DESCRIPTION 170143673 SHAFT OUTPUT 1 OUSING 1 USHING amp BRTHER 3 8 OVER 76393174 O RING 72601568 CAP SCREW IL SEAL USHING 70143669 WASHER 70143668 EY 70056428 EAR SR 7 70056427 WORM SR RING ALL BEARING I PE PLUG AP SCREW RAKE KIT INCL 27 38 E a oal A oln 0 NI Sm oj CO aj N G A
28. LE 3 16 DEEP PRESS IN PIN 60125699 34 3020 Parts amp Specifications Manual Part 99904521 1720921 PARTS LIST TEM ART DESCRIPTION 2720923 CASE ASSEMBLY INCL 11 20 1720921A YLINDER INCL 1 3 4 6 7 9 14 1744131 EAL KIT INCL 6 8 21 23 28 2720922 OD ASM INCL 11 20 0125699 IN LOCK TUBE 0125918 ISTON 0125920 TOP TUBE A025022 AFER LOCK HD40022 EAD 1412660 UBE ASM 053507 ERK STR THD 25 28 2060037 AP SCR 31 18X 4 00 HH GR5 Z 062109 NUT 31 18 HEX NYLOCK 2062305 COLLAR LOCK 1 1 2 12 X 2 375 X 563 063002 WASHER 31 FLAT 533186 ADPTR M STR 66 3540035 VALVE CBAL 1 75 1 NV INCL 18 19 540052 VALVE CBAL 7041561 RESSURE SWITCH F81215 USHING STL 1 50 PIN X 1 25 LG 072128 RING 1 487X 1 693X 0 103 70 1412665 UBE ASM Q10P342 ACK UP RING 3 62 BORE 4 O D 0 07 THK R14P022 OD WIPER TYPE D 2 25 ROD 546022 U CUP LOADED 2 25X2 75X 38 B 2N4040 WEAR RING PISTON 4 00 O D X 50 W T2NX625 EAR RING ROD 2 25 IDX0 75 T66P040 ISTON SEAL DYNAMIC 4 00 Q072342 RING 3 62 X 4 0 19 70 NEW 20070410 UANTITY O i 70 o 42 o I i O Q 1 1 1 1 1 1 1 1 1 1 2 2 2 JI N N C S pm WAKRLOCK 71 12 N A i 1 or x x N UJ J AN CO N S N gt 2 Chapter4 Parts 35 Boom Assembli
29. SKET ROTECTOR DISCARD N 79 Chapter 4 Parts 31 32 3020 Parts amp Specifications Manual Part 99904521 1057936 PARTS LIST 70143658 KEY 0143664 FRICTION DISC 143665 BRAKE HUB 0143662 CAM CLUTCH 0143661 SPRING 0143660 THRUST WASHER 70143666 HOUSING 601565 CAP SCREW SOC HD I 6393172 WASHER SEAL 2601722 LOCKNUT SEAL 2601723 SET SCREW 170143659 JBRAKE SPACER 38 70143663 l STATOR PLATE 170034440 CAP PLASTIC 94396834 SEAL KIT MOTOR PART OF ITEM 20 N N JI N N N N Co cO N REV D 20031201 Chapter4 Parts Cylinder Lower 3820 51720921 Eff 5 17 07 26 28 21 27 5 27 16 26 78 6 SECTION 4 12 57 IN 1 18 GAL 8 59 IN 0 80 GAL 04 5 X 4 08 X 30 31 LONG 92 25 X 32 94 LONG 1 50 S 99 LB 3600 PSI OPERATING PRESSURE 2350 PSI NOTES IF TIED TO DRAWING SEE REFERENCE NUMBER IN 33 1 REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS DISASSEMBLED THIS WILL REDUCE FUTURE DOWNTIME 2 APPLY NEVER SEEZ REGULAR GRADE ANTI SEIZE AND LUBRICATING COMPOUND TO THREADS ON THE CYLINDER HEAD ONLY KEEP AWAY FROM SEALS 3 APPLY LUBRIPLATE NO 630 2 MEDIUM HEAVY MULTI PURPOSE LUBRICANT TO ALL PISTON HEAD GLANDS AND HOLDING VALVE SEALS NYLON LOCK RING CAST IRON PISTON RINGS AND ROD STINGER THREADS 4 DRILL 15 HO
30. SS JUMPER AND CONNECTORS PER WIRING HARNESS DRAWING REMOVE PLUGS AND INSTALL GREASE ZERKS WITH GEAR ROTATOR 9 USE BLUE THREAD LOCKER TORQUE TO 160 FT LB on O N Chapter4 Parts 25 9903947 PARTS LIST TEM PART DESCRIPTION 51720119 HARDWARE KIT BASE amp MAST INCL 13 23 HOSE KIT PLANETARY WINCH INCL 24 25 28 33 HOSE KIT WORM WINCH INCL 25 28 52719628 AST WELDMENT 60120138 SLIDE ROTATION STOP 60120192 GUARD 70029595 THREADED PLUG 1 00 8 o UANTITY REF REF x 71056543 0 73051919 JMOTOR HYD WAS 73511070 THRU 9 15 08 1 76039295 GASKET 77441204 HARNESS TELESCOPIC RADIO REMOTE WAS 77441184 THROUGH 8 1 06 70034382 CAP GREASE 4 IES PLASTIC 72053301 COUPLING BLK 12 72053508 ZERK NPT 12 72060004 CAP SCR 25 20 1 00 HH GR5 Z 72060177 CAP SCR 62 11X 3 00 HH GR8 Z 72060794 SCR 50 13X 1 25 SH PLAIN 2062104 NUT 25 20 HEX NYLOCK WAS 6 2063001 WASHER 25 FLAT WAS 12 72063119 WASHER 62 FLAT ASTM F436 1 ASHER 62 FLAT CUT 3816 72053758 ELBOW M STR 90 M JIC 4 4 1 72533613 ADPTR M STRIM 10 6 7 27 3734473 VALVE BANK MODIFIED INLET WAS 73734194 THROUGH S N 382082091216 502082091012 HOSE AA 13 X 13 50 OAL 2 2 7045945 CONNECTOR DEUTSCH DT 2 PIN RECEPT i 7044668 IPLUG SEAL DEUTSCH 114017 5 ARNESS PRESSURE SWITCH JUMPER 72532351 JADPTR M STRIM JIC 4 4 REV D 2010
31. T UANTITY 78546015 70109228 70072226 N A NI 73054999 0146464 ASM HYD EXT CYL 3820 2H I _ 3 i 2 2 2 2 2 1 2 1 2 7 9 N 22420 6A025015 WAFER LOCK IMT 1 50 2 N lt gt a a 40 3020 Parts amp Specifications Manual Part 99904521 Hydraulics Hydraulic Installation Worm Winch 99903944 1 PRESSURE 3 SEE INSTL Y P 8 1 9 2V ccw u IN UP PORT A UP PORT B DN ROT LOW EXT OUT DOWN A oh 10 A RETURN SEE INSTL KIT ROTATION NOTES 1 INSTALL 60350141 ON HOSES 17 AND 18 AND 19 AND 20 2 INSTALL 60350142 ON HOSES 24 AND 25 AND HOSES 413 14 16 AND 21 3 ITEM 1 73734194 VALVEBANK USED ON CRANES WITH SERIAL NUMBERS 3820S2071163 AND BEYOND Chapter4 Parts 41 9903944 PARTS LIST TEM PART DESCRIPTION KIT QUANTITY IE BANK WORM WINCH WAS 73734194 FROM FROM S N 382052071163 THROUGH 382052091216 WAS 51720111 THRU 5 4 07 2582356 51397080 HOSE FJ 0 62 X 30 OAL 10 10 WAS 51396806 HOSE FJ 0 38 X 20 OAL 8 6 WAS 2 HOSE FJ 0 50 X 30 OAL 8 8 WAS 51396816 REV C 20100609 42 3020 Parts amp Specifications Manual Part 99904521 HYDRAULIC INSTALLATION WORM
32. TICAL GRADE AND SIZE FAILURE TO REPLACE GEAR BEARING BOLTS MAY RESULT IN BOLT FAILURE DUE TO METAL FATIGUE CAUSING DEATH OR SERIOUS INJURY 1056543 PARTS LIST TEM DESCRIPTION 70056527 ROTATION BEARING 70395074 RING AL 70145786 NAP RING 70055271 EARING CONE 70055281 EARING CUP 70145501 EARING RETAINER 70056550 ORM 70145787 HOUSING 0 72601734 CAP SCR 3 8 16X1 1 4 SH 1 72601733 AP SCR 1 2 13X1 1 4 FERRY i 73145506 HIM 005THR HIM 015 73145504 HIM 030THK 76395075 ASKET 72533604 UG 72661504 IN 3 8X1 AP SCR 5 8 11X2 3 4 HHGR8 063219 ASHER 5 8 FLAT HARD 2533605 ERK 1 72533439 VENT PLUG REV B 20031029 o UANTITY OI DJ o m UJ UJ B i NENNT sss N 2 i x gt Q N N N N S N N 28 3020 Parts amp Specifications Manual Part 99904521 Crane amp Worm Winch Assembly 99903948 Primary Configuration Ad DOUBLE LINE PAC APPLICATION DETAIL 13 24 9 22 26 2 GREASE BEARINGS USE BLUE THREAD BEFORE INSTALLING LOCK ON CAP SCREWS BOOMS TO MAST 8 SEE NOTE 2 lt us ANTI SEEZ A USE BLUE THREAD LOCK SCREWS USE ANTI SEEZ 21 24 25 SS 4 PLCS YS 4 22 26 27 ide 2 PLCS ANTI SEEZ DOWNHAUL WEIGHT 16 SINGLE LINE APPLICATION DETAIL NOTES 1 FOR DOUBLE LINE APPLICATION INSTALL PIN
33. UNTING FOOT 532356 ADAPTER MSTR MJIC 8 6 2532358 ADAPTER MSTR MJIC 8 8 533507 LBOW MSTR 90 MJIC 8 10 N N 3540097 Ec C s m N 2534560 2534561 2534562 U LUG STR SOCKET HEAD STL 4 ZERO LEAK LUG STR SOCKET HEAD STL 6 ZERO LEAK U Co q a oy ET co p 3 Slp als 3 t N 7 LUG STR SOCKET HEAD STL 8 ZERO LEAK z o 44 3020 Parts amp Specifications Manual Part 99904521 Valve Bank Worm Winch 73734194 From 5 4 07 to 12 09 NOTE 73734473 replaced 73734194 effective 1 2010 73734473 used on cranes starting with these serial numbers 3820S2091216 5020S2091012 BR WU WD El EO LD LU RL RR Ol ler bh bh o L D LIP A a 73734194 PARTS LIST 73734194 PARTS LIST 256004224420 T 73540251 4 72533507 ELBOW M STR 90 M 8 10 3734194 PARTS LIST TEM PART 73540252 73540253 73540254 77041715 3540027 73540375 91722709 REV 20100615 Chapter4 Parts 45 DESCRIPTION QUANTITY VALVE P FLOW CONTROL INCLUDES COIL 73540253 VALVE COIL VALVE RELIEF OIL SOLENOID VALVE SECT ND CAP VB VALVE SECTION W SOLENOID WAS 73054214 COIL KIT PART OF 10 46 3020 Parts amp Specifications Manual Part 99904521 Telescopic Valve Bank Replacement 99904783 From November 2009 through April 2010 IMT telescopic cranes may have been built with a hybrid valve sectio
34. WINCH 99903944 LOWER CYL amp EXT HOSES ARE ROUTED THROUGH MAST amp PLACED IN SLEEVES EXT CYLINDER PORT IDENTIFICATION PRESSURE amp RETURN LINES 2 HYD MOTOR WINCH D gt WORM DRIVE WINCH PORT IDENTIFICATION 51395121 HOSE FOR GREASING GEARS USED WITH PORTB PORTA 71056543 ROTATOR CONNECT HARNESS WIRES AS SHOWN PER SCHEMATIC HYDRAULIC MOTOR PORT IDENTIFICATION ROTATION amp WINCH HYDRAULIC MOTOR ROTATION PORT amp SOLENOID PORT IDENTIFICATION LOWER CYLINDER PORT IDENTIFICATION Chapter4 Parts 43 Valve Bank Worm Winch 73734473 Eff 1 10 NOTE 73734473 replaced 73734194 effective 1 2010 73734473 used on cranes starting with these serial numbers 3020101005 3820S2091216 5020S2091012 3 4 13 a H c 11 x E 5 I I Er e 9 wo TEM PART 3540394 3540375 VAESECHON R 0744198 REPLACEMENT COIL KIT FOR 73540375 REF 540252 FLOW CONTROL VALVE 3540253 COIL FOR 73540252 540396 RELIEF VALVE N e N N 0145830 MO
35. and determine cause and severity of hazard Remote Ctrl Operate remote control devices to check for proper operation Electrical Operate all lights alarms etc to check for proper operation Anti 2 Block Operate anti 2 block device to check for proper operation Other Per customer requirements L Other Per customer requirements All daily inspection items T Holding valves for proper operation Cylinders Visual inspection of cylinders for leakage at rod fittings and welds Damage to rod and case Control valves for leaks at fittings and between stations All structural members for damage All welds for breaks and cracks Hardware All bolts fasteners and retaining rings for tightness wear and corrosion Presence of wear pads Pump amp Hydraulic pumps and motors for leakage at fittings seals and Motor between sections Transmission PTO for leakage abnormal vibration and noise Hyd Fluid Quality of hydraulic fluid and presence of water Valves Control valve linkages for wear smoothness of operation and tightness of fasteners Bent broken or significantly rusted corroded parts fitti Electrical Electrical systems for presence of dirt moisture and frayed wires All pins for proper installation and condition N N e a a e ejej Ojcolco NI gt GG IN I 2 2 2 2 2 2 2 2 2 3 4 5 6 7 8 9 0 3 D p iD iD iD D j p iD 70 3020 Parts amp Specificati
36. and jumper harnesses This kit which comes with 2 coils stem kits and jumpers must be used to replace the coil on the top and bottom of a valve section If the wires are molded in you must replace with 91722709 3 Coils with molded bet no longer If your coil looks like available this same coil from 91722708 you can replace a single coil Order 90744198 Disassemble the valve as follows 1 Remove retainer by rotating counterclockwise with pliers Slide o ring and coil over tube to remove Remove tube using an 11 16 open end wrench Turn counterclockwise NOTE Do not remove valve spool A3 or misplace washer A2 or spring A1 Do not contaminate valve Chapter4 Parts 49 4 Remove pushrod NOTE ORIGINAL PUSHROD IS HEXAGONAL AND 1 138 LONG DO NOT REMOVE FROM BODY DO NOT MISPLACE ITEMS TO BE RE USED O RING RETAINER Valve Disassembly Install the components of repair kit 91722709 as follows Position washer A2 on valve spool A3 Insert pushrod and spring A1 onto tube Install tube clockwise with 19 mm crows foot wrench Torque to 180 Slide o ring coil and second o ring over tube Install retainer clockwise onto tube with 1 1 16 socket Torque to 27 Stretch boot over retainer a WO N a You may need jumper harness IMT 77441393 to electrically connect the valve section to the crane Two of these jumper harnesses we
37. be sufficient room for mounting the crane and the platform must be strong enough to support the crane and rated load Install the 3020 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 In addition an IMT designed body is designed to take full advantage of the standard reservoir placement This reservoir is installed in the cargo area of the body Before attempting to install the crane the body must be installed To install the crane 1 Usea lifting device capable of lifting the weight of the crane up to 1460 Ib 635 kg Attach fabric slings to the crane lower boom centered approximately 18 inches from the mast hinge Make certain the crane is well balanced on the slings by slowly lifting approximately 6 off the ground Lift the crane 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 18 3020 Parts amp Specifications Manual Part 99904521 2 Installthe 1 8x3 mounting cap screws and 1 washers to secure the crane base to the truck body see figure Torque the cap screws to 680 ft Ib 94 kg m 14 3 4 37 5 cm 6 7 16 16 4 cm 02 E ES PL lt Z 2 I f 2 I I I 7 3 8 18 7 lt ra L t gt MOUNTING HOLE DIMENSIONS WASHER 1 4 PLACES NESS
38. conds All times based on 10 GPM 37 9 Ipm PTO delivery rate CYLINDERS LOWER BOOM CYLINDER 4 bore 22 5 stroke 10 2 cm bore 57 29 cm stroke EXTENSION BOOM 2 5 bore 60 48 stroke 6 4 cm bore 152 4 cm 121 0 cm CYLINDER stroke POWER SOURCE PTO DRIVEN Integral mounted hydraulic pump and application Other standard power sources may be used Minimum power required is 23 5 horsepower based on 10 GPM 37 9 liters min at 3 000 PSI 207 bar ROTATION SYSTEM Turntable bearing with external worm gear powered with a high torque hydraulic motor through a self locking worm Total gear reduction is 85 to 1 CYLINDER HOLDING VALVES The base ends extend sides of the lower boom and extension cylinders are equipped with integral mounted counter balance valves to prevent sudden cylinder collapse in case of hose or other hydraulic failure The extend side of the lower boom cylinder is equipped with a 10 gpm counterbalance valve The counter balance valve serves several functions First it is a holding valve Secondly it is designed to control the speed at which the lowering function operates and allows that motion to be metered under load Finally it prevents the loss of an excess amount of oil in the event of a hose failure Only the oil in the hose at the time of the failure will be lost EXCESSIVE LOAD LIMIT SYSTEM ELLS A pressure switch which is mounted on the extend side of the lower boom cylinder and con
39. d 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 4 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 5 If the anti two block function appears to be functioning normally winch the cable down until the sensing weight swings free Chapter5 General Reference 77 Thread Torques 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
40. e 1 OPERATION MAINTENANCE AND REPAIR IMT part number 99903514 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 amp Locomotive Cranes Contact the American Society of Mechanical Engineers www asme org for more information Throughout this manual three means are used to draw the attention of personnel They are NOTES CAUTIONs and WARNINGs 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 equ
41. e made HOOK ATTACHMENTS amp SECURING MEANS EVE If any indication of distortion wear cracks nicks or gouges are present unless a qualified person authorizes their use Or as recommended by the LATCH manufacturer SWIVEL GREASE ZERK e POINT BASE BOWL SADDLE 76 3020 Parts amp Specifications Manual Part 99904521 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 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 Block Device Inspection See the operation maintenance and repair manual for this crane 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 marke
42. er conditions Under severe operating conditions lubrication should be performed more frequently See the Volume 1 Telescopic Crane Operation amp Safety 99903514 for additional lubrication requirements Chapter3 Crane Reference 15 3020 Recommended Spare Parts List 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 not considered as normal wear items during the first year of operations and you need to contact the distributor or manufacturer for availability ASSEMBLY DESCRIPTION PART SPARE PART DESCRIPTION QUANTITY 3051919 HYDRAULIC MOTOR 2060794 CAP SCREW 1 2 13X1 25 SH PLAIN 5055295 GEAR ROTATOR 71056543 0395074 0395076 EAL 0145786 NAP RING 0055271 0055281 0145801 0056550 3145506 3145505 3145804 6395075 0580143 1073035 2 2 O e 2 z m go z z gt m lt es E lt WIRE ROPE ASSEMBLY WORM WINCH HOOK W LATCH OWNHAUL WEIGHT 52719629 52719630 II z Z E e A 2 4396854 6393174 6383173 0055202 0732542 7639317 O lt gt A 1 N gt 1744131 EAL KIT 3540052 OUNTERBALANCE VALVE 7
43. er s Jib extension cylinder pin s and retainer s Boom tip attachment 62 Other 6 Hyd Lines Hoses fittings and tubing for proper routing leakage blistering deformation and excessive abrasion 164 Pressure line s from pump to control valve 6 65 e Return line s from control valve to reservoir 6 Suction line s from reservoir to pump 5 5 5 O NI Pressure line s from control valve to each function Load holding valve pipe s and hose s 7 Pumps Pumps PTO s amp motors for loose bolts fasteners leaks noise PTO s amp vibration loss of performance heating amp excess pressure Motors N 72 J Rotation motor s ser 74 Hydraulic valves for cracks spool return to neutral sticking spools proper relief valve setting relief valve failure 5 control valve N N Q Q rr Q sd fos Chapter5 General Reference 71 FREQUENCY KEY INSPECTION DESCRIPTION STATUS S R X NA 7 la Cid Oumggerorawxiaconmolvawe S Other valves customer requirement __ Other per customer requirements 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 722 CT
44. es amp Cylinders Boom amp Winch Assembly 99904008 Eff 8 1 06 Boom amp Winch Assembly 99904008 uses Cord Reel Assembly 51720302 USE BLUE THREAD LOCKER NOTES 1 INSTALL STUDS IN APPROPRIATE HOLES OUTSIDE HOLES FOR 71057781 WINCH INSIDE HOLES FOR 52719749 WINCH MOUNT WELDMENT 36 3020 Parts amp Specifications Manual Part 99904521 99904008 DRAWING SQ 17 45 ee EM NOTE 1 MMC UNE HT n po Z fao C C 250 SA 711 SEE NOTE 2 Z op 26 29 2 2 ADJUST TENSION TO ALLOW SWITCH FUNCTION CONNECT CORD REEL WIRES TO ANTI 2 LOCK SWITCH WIRES CONNECT TO NORMALLY OPEN amp COMMON 0 50 REF NOTES 1 MOUNTING HARDWARE IS INCLUDED WITH THE SWITCH USE O RINGS SCREWS AND 6 NYLOCR HEX NUTS DO NOT OVER TIGHTEN NUT ANTI TUBE LOCK MUST BE FREE TO PIVOT APPLY BOOM LENGTH INDICATOR TAPE ON BOTH SIDES OF BOOM AND EXTENSION 99904008 PARTS LIST PART DESCRIPTION QUANTITY 51719591 HARDWARE KIT BOOM ASSEMBLY INCL 15 17 37 44 46 52718005 TUBE WELDMENT ANTI TWO BLOCK N 52719119 BOOM 1st STAGE EXT WLDMT 52719120 2 STAGE EXT WLDMT 60030330 VVEAR PAD RC 0 50 X 4 88 X 5 00 60030331 VVEAR PAD RC 0 50 X 4 938 X 5 88 Chapter4 Parts 37 9904008 PARTS LIST TEM PART DESCRIPTION QUANTITY 7 60030339 WEAR PAD RND 2 00 DIA X 60 DIA X 1 0 L WAS 2 60030340 WEAR PAD BLOCK 4 50 X 4 50 X 44 600
45. g 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 16000 1 II III 23516 1221R Loader or 1014 1014A 32018 14K160TH 1225R Tirehand 1015 32027 COMMANDER IV 80001 Model 2015 2020 32030 9800 2109 T30 12916 2820 40 13031 3000 13034 3016 3020 14000 3203i 15000 3816 3820 18000 4004i 20017 421 425 8000L 4300 H1200 5005i H1200RR 5016 5020 T50 6006i 6016 6020 6022 5525 6025 6625 EZ Hauler II EZ Hauler 3000 5500 Ball Dia 875 22 mm 1 00 25 mm 1 18 1 25 30 32 1 5 38 mm 1 75 44 mm Ref mm Rev 20100331
46. h 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 vvhich 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 81 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 Place crane in vertical position Set a dial indicator at 0 on the pinion cover plate at back side of mast Lower crane to the horizontal position OO N Check and record the dial indicator change It should not exceed the tilt measurement noted in the chart below 82 3020 Parts amp Specifications Manual Part 99904521 5 Return the crane to the vertical position The dial indicator should return to 0 Setup 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 bearin
47. he 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 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 the Crane Reference Section ORDERING REPAIR PARTS When ordering replacement parts 1 Give the model number of the unit Give the serial number of the unit Specify the complete part number When ordering cylinder parts or one of the main weldments always give the stamped part number Give a complete description of the part Specify the quantity required 24 3020 Parts amp Specifications Manual Part 99904521 Base and Mast Assemblies Base amp Mast Assembly 99903947 Primary Configuration apt OF 09 Sw SI 4 MUT Re UTY m 2511 NOTES IF TIED TO DRAWING SEE REFERENCE IN BOX D 1 HYDRAULIC FITTINGS ARE PART OF 91720110 PLANETARY WINCH OR 91720113 WORM DRIVE WINCH HOSE KITS USE 70034060 AS NEEDED TO SECURE WIRE HARNESS USE ITEMS 32 33 AND 34 FOR PLANETARY WINCH APPLICATIONS USE RUST PREVENTATIVE ON SLIDE STOP BEARING RACE AND BOTTOM OF MAST INSTALL HARNE
48. ipment 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 CHAPTER 2 Specifications In This Chapter Speolfications 1 a dea ia 7 Geometric Configuration 000001 10 Capacity Placard 3020 11 Specifications GENERAL SPECIFICATIONS CRANE RATING 30 000 ft Ib 4 15 ton meters REACH from centerline of rotation 20 6 6 2 m HYDRAULIC EXTENSIONS 2 60 152 4 cm MANUAL EXTENSION 48 121 9 cm LIFTING HEIGHT from base of 22 5 6 8 OUTRIGGER SPAN required 89 226 cm option Crane Side from Centerline of Chassis STORAGE HEIGHT crane only 39 99 cm MOUNTING SPACE REQUIRED 20 x 21 50 8 cm x 53 3 cm crane base HORIZONTAL CENTER OF 39 99 1 cm GRAVITY from centerline of rotation from bottom of crane base Driven SYSTEM OPERATING PRESSURE 2500 psi 172 bar ROTATIONAL TORQUE 7500 ft Ib 1 04 ton meters Crane rating ft Ib is the rated load Ib multiplied by the respective distance ft from centerline of rotation with all extensions retracted and lower boom in horizontal position 8 3020 Parts amp Specifications Manual Part 99904521 SPEEDS 400 7 0 rad 10 to 80 0 2 to 1 4 rad 60 152 4 cm 9 5 se
49. n due to a supplier model change When ordering replacement parts note the serial number on the valve section and the appearance of the complete valvebank to determine which parts are required Valve for 73734193 and 73734194 Valvebanks Valve Model BV18 with 5 8 threads IP65 Serial tag has no dash at the end of the number Serial tag number Coils are gold ends with no dash Gold colored valve coils Hybrid Valve Section Added to 73734193 to make 73734495 and added to 73734194 to make 73734496 Valve Model BV18 with 5 8 threads IP69 Hybrid Serial tag ends with 9 Serial tag number Coils are silver ends with 9 Silver colored valve coils Chapter4 Parts 47 New Valve Section Valve for 73734472 and 73734473 Valvebanks Valve Model BV18 with M19 threads Serial tag ends with 10 Coils are silver Serial tag number ends with 10 Silver colored valve coils Hybrid Valve Bank 73734495 or 73734496 Valve Model BV18 with 5 8 threads IP69 Hybrid Serial tag ends with 9 Coils are silver A blue tag has been attached to the end of the valvebank to indicate it includes all hybrid valves Valve section serial tag ends with 9 Valve coils OY are silver a 4 9 Blue round tag to indicate hybrid valve bank 48 3020 Parts amp Specifications Manual Part 99904521 Replacement Valve Coils If you have this valve 2 91722708 Valve coil kit which includes connectors
50. nected electrically to the lift side of the winch the extend side of the extension boom and the down side of the lower boom provides the capacity alert system If the operator attempts to lift a load exceeding the rated capacity of the crane the winch lift extension out and lower boom down functions will not operate To relieve the situation the operator may set the load down winch down or retract the extension boom extension in WINCH The winch is powered using a hydraulic motor driving a 38 1 worm gear The line speed of 27 0 ft minute 8 1 m min under no load is achieved at an optimum oil flow of 10 GPM 37 9 liters min and one part line Maximum single line winch lifting capacity is 3000 Ib 1360 kg and Chapter2 Specifications 9 maximum two part line lifting capacity is 6000 Ib 2720 kg The winch is equipped with 85 feet 25 9 m 3 8 9 5 mm 6X25 FW PRF RRL IWRC XIPS wire rope Nylon sheaves are located at the tip of the extension boom The ratio of winch drum and sheave pitch diameter is 18 6 1 for the drum and 18 1 for the snatch block and boom tip sheave A compact anti two block device is included to prevent the lower block or hook assembly from coming in contact with the boom sheave assembly HYDRAULIC SYSTEM The hydraulic system is an open centered full pressure system that requires 10 GPM 37 85 liters min optimum oil flow at 2500 psi 172 bar It is equipped with a four section stack type electric remote c
51. oks 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 HOOK WITH LATCH An increase of the dimension between a fully opened latch and the tip section of the hook exceeding 896 Or as recommended by the manufacturer WEAR If wear exceeds 1096 of the original sectional dimension Or as recommended by the manufacturer 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 LATCH Engagement Damage amp 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 wired closed moused until repairs ar
52. ons Manual Part 99904521 FREQUENCY INSPECTION DESCRIPTION STATUS S R X NA Hoses amp tubes for leakage abrasion damage blistering cracking deterioration fitting leakage and secured properly 3 322 Hook hook for abnormal throat distance twist wear and cracks 3 Condition of load line 34 Manual Presence of operator s manual with unit 3 2 36 All daily inspection items 3 Monthly All monthly inspection items 3 3 Rotation Sys Rotation bearing for proper torque of all accessible mounting bolts Base mounting bolts for proper torque All structural members for deformation cracks and corrosion 5 N 35 Der i 37 38 Extensions JCondition of wear pads IU U f 39 40 LN 42 Base 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 in s 1 2 5 7 8 9 40 41 33 46 9 1 7 8 9 3 5 0 3 I 48 5 m Hardware 52 o N Outer boom pivot pin s andretainers 77 777 immerboomcyinderpims andretaimers r Outer boom cylinder pin s and retainers F Extension cyinderpins and retainers EI a alo Jib boom pin s and retainer s Jib cylinder pin s and retain
53. ontrol valve with 30 foot control cable The system includes separate hydraulic oil reservoir suction line filter and return line filter MINIMUM CHASSIS SPECIFICATIONS WHEELBASE 154 391 cm CAB TO AXLE 84 213 cm MOMENT m B cubic inches 163 9 MODULUS FRONT AXLE RATING Sum Ib 2268 kg GAWR REAR AXLE RATING 9500 Ib 4309 kg GAWR 4 speed In addition to these specifications heavy duty electrical and cooling systems are required It is recommended that the vehicle be equipped with an engine tachometer auxiliary brake lock and power steering NOTES 1 GAWR means Gross Axle Weight Rating GAWR is dependent on all vehicle components including axles tires wheels springs brakes steering and frame strength meeting the manufacturer s recommendations Always specify GAWR when purchasing a truck 2 Minimum axle requirements may increase with use of diesel engines longer wheelbase or service bodies Contact the factory for more information 3 Weight distribution calculations are required to determine final axle loading All chassis crane and body combinations must be stability tested to ensure stability per ANSI B30 5 lowa Mold Tooling Co Inc reserves the right to change specifications and design without notice 10 3020 Parts amp Specifications Manual Part 99904521 Geometric Configuration Wy Oy 2 9 j E Chapter2 Specifications 11 Capacity Placard 3020 3020 HYDRAULIC CAPACITY
54. re included with kit 91722709 Plug the jumper harnesses into the plugs on the coils as shown in Figure 3 and connect them to the crane wiring 50 3020 Parts amp Specifications Manual Part 99904521 8 Kit 91722709 has components to repair both sides of the valve section Repair each side individually but be sure to repair both sides before re installing the valve on the crane NOTE REPLACEMENT PUSHROD IS CYLINDRICAL WITH FLAT SIDE AND 1 382 LONG 180 IN LB TU O RING COIL DO NOT REMOVE FROM BODY er DO NOT MISPLACE f ITEMS TO BE RE USED 1232 TIGHTENING TORQUE 10 HEAD Valve Assemblv Harness Valvebank 77441204 Eff 8 1 06 In 77441191 1 THIS JUMPER HARNESS DRAWING FOR REF ONLY Ka ao a a Sh tS 3500 PSI 3100 PSi J13 P10 CP 1201 d SPLICE G SPLICE B D M SPLICE C SPLICE J K L N P CJ 500 77045945 1 1 THIS CONNECTOR PLUG DRAWING IS FOR REFERENCE 4 ONLY TO BE USED WITH WORM WINCH I 51 N c CO HONIM BY L 008 QvOTH3AO 8cV m NF LO LL HONIM COL 420146 1no 1 NaO ECL NE SNC EES ISa 0046 638 321148 LD lo d 53onds e3onas e3onads 93onas 8 42 145 6 HOSSHHdlNOO 98754 V 9875
55. s dependent on crane model 20 3 7 18 e e 5 10e e19 WARNING 23 Number 1 be assigned to 20 capscrew if the sequence e remains the same in reference 1 240 to number es 209 es 160 913 1 e 7 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 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 Torque all capscrews to approximately 4096 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 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 Using the proper sequence torque all capscrews to the listed torque value as determined from the Torque Data Chart Chapter 5 General Reference 81 Turntable Bearing Inspection Turntable bearings may experience vvear One of the follovving conditions may indicate turntable bearing wear Metal particles present in the bearing lubricant Increased drive povver required to rotate the crane Noise emitting from the bearing during rotation OQ N Roug
56. semblies 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 lowa 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 70029119 Chapter4 Parts 23 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 t
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