Volume 2 - PARTS AND SPECIFICATIONS IOWA MOLD TOOLING CO., INC. BOX 189, GARNER, IA TEL: MANUAL PART NUMBER

Transcription

1 : : Model Crane Volume 2 - PARTS AND SPECIFICATIONS Section 1 CRANE SPECIFICATIONS Section 2 CRANE REFERENCE Section 3 REPLACEMENT PARTS Section 4 GENERAL REFERENCE IOWA MOLD TOOLING CO., INC. BOX 189, GARNER, IA TEL: MANUAL PART NUMBER Iowa Mold Tooling Co., Inc. is an Oshkosh Corporation company.

2 : : REVISIONS LIST DATE LOCATION DESCRIPTION OF CHANGE ECN ADD ELEMENT & GASKET ECN ADD O-RING KIT REF 3-33 ADD CTRL BOX ASM CORRECTED SPARE PARTS LIST ECN CHANGED FLOODLIGHT KIT , 3-3 NEW OWNERSHIP STATEMENT; UPDATED SERIAL TAG LOCATION INFO THROUGHOUT ECN UPDATED STABILIZER WORDING, ADDED CRANE LEVEL, STABILIZER DEPLOY DECALS

3 : : 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. 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. 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 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. Treat this equipment with respect and service it regularly. These two things can add up to a safer working environment. Read and familiarize yourself with the IMT OPERATOR S CRANE SAFETY MANUAL before operating or performing any maintenance on your crane.

4 : : NOTES

5 : : SECTION 1. SPECIFICATIONS SECTION 1. MODEL CRANE SPECIFICATIONS GENERAL SPECIFICATIONS... 3 PERFORMANCE CHARACTERISTICS... 4 POWER SOURCE... 4 CYLINDER HOLDING VALVES... 4 ROTATION SYSTEM... 4 HYDRAULIC SYSTEM... 4 SELECTED WEIGHTS OF ANCILLARY EQUIPMENT... 4 CAPACITY CHART... 5 GEOMETRIC CONFIGURATION... 6 CRANE MOUNTED ON CHASSIS... 7 MINIMUM CHASSIS SPECIFICATIONS... 8

6 : : SECTION 1. SPECIFICATIONS NOTES

7 : : SECTION 1. SPECIFICATIONS SPECIFICATIONS-MODEL CRANE GENERAL SPECIFICATIONS *CRANE RATING (ANSI B30.22) ,000 ft-lbs (44.25 ton-m) *MAXIMUM CRANE RATING ,000 ft-lbs (44.25 ton-m) HORIZONTAL REACH from centerline of rotation (8.38m) HYDRAULIC EXTENSION (1.98m) VERTICAL REACH from mounting surface (10.18m) VERTICAL REACH from ground / 43 frame ht (11.28m) CRANE WEIGHT... 16,500 lbs (7485 kgs) STABILIZER SPAN - BASE MOUNTED (5.49m) STABILIZER SPAN - AUXILIARY (required) (4.27m) STABILIZER PADS x 16 (40.64 x 40.64cm) STABILIZER PADS - AUXILIARY x 14 (35.56 x 35.56cm) CRANE STORAGE HEIGHT from mounting surface (2.87m) CRANE STORAGE HEIGHT from ground / 43 frame ht (3.96m) **MOUNTING SPACE REQUIRED (1.78m) ROTATIONAL TORQUE... 38,320 ft-lbs (5.30 ton-m) OPTIMUM PUMP CAPACITY gpm (132.5 lpm) SYSTEM OPERATING PRESSURE psi (207 bar) OIL RESERVOIR CAPACITY U.S. gallons (227 liters) HOOK APPROACH - HORIZONTAL from centerline of rotation (2.16 m) HOOK APPROACH - VERTICAL from mounting surface (2.39m) ***HORIZONTAL CENTER OF GRAVITY (1.27m) from centerline of rotation away from stabilizers ***VERTICAL CENTER OF GRAVITY from mounting surface (1.83m) * Maximum Crane Rating (ft-lbs) is defined as that rated load (lbs) which when multiplied by its respective distance (ft) from centerline of rotation gives the greatest ft-lb value. ANSI B30.22 Crane Rating (ft-lbs) = With all extensions retracted and inner plus outer boom in a horizontal position, rated load (lbs) X respective distance (ft) from centerline of rotation = nominal ft-lb value. ** Mast swing within the confines of the crane base requiring no additional space behind the cab. *** Crane in stowed position.

8 : : SECTION 1. SPECIFICATIONS PERFORMANCE CHARACTERISTICS ROTATION: sec INNER BOOM ELEVATION: -30 to sec (ext), 22 sec (retract) OUTER BOOM ARTICULATION: sec (ext), 23 sec (retract) TELESCOPIC EXTENSION: 78 (1.98m) 20 sec (ext), 20 sec (retract) POWER-OUT STABILIZER: 60 (1.52m) 8 sec POWER-DOWN STABILIZER: 26 (66cm) 13 sec POWER SOURCE Load sensing piston pump and PTO application. Minimum horsepower required is 68 HP. CYLINDER HOLDING VALVES The holding sides of all standard cylinders are equipped with integral-mounted holding or counterbalance valves to prevent sudden cylinder collapse in case of hose or other hydraulic failure. The power-out and power-down stabilizer cylinders have positive, pilot operated holding valves that open only upon command. The counterbalance 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. ROTATION SYSTEM Rotation of the crane is accomplished through a turntable bearing, powered by two high-torque hydraulic disc-valve motors through two planetary gear boxes. A fail-safe, spring-loaded brake is an integral part of each planetary gear box which provides rotational and parking brake action. Total gear reduction is 99:1. HYDRAULIC SYSTEM The hydraulic system is a closed center, load sensing, standby pressure system providing 35 GPM (132.5 LPM) optimum oil flow at 3000 PSI (207 bar). Stack type control valve with radio remote plus single operational control handles located on driver s side of the crane for all lift, telescope and swing functions is standard. Single control lever for each stabilizer function, located on the same side as the stabilizer, is standard. System includes hydraulic oil reservoir, return line filters, closed center, load sensing control valve and a variable displacement radial piston pump. SELECTED WEIGHTS OF ANCILLARY EQUIPMENT AUXILIARY STABILIZERS 1770 lbs (803 kgs) 18 SUB-FRAME 1800 lbs (816 kgs) PUMP & PTO 140 lbs (64 kgs) MOUNTING HARDWARE 520 lbs (235 kgs) OIL RESERVOIR 190 lbs (86 kgs) OIL (60 gallons / 227 liters) 420 lbs (190 kgs) IMT reserves the right to change specifications and design without notice.

9 : : SECTION 1. SPECIFICATIONS IOWA MOLD TOOLING CO., INC. BOX 189 GARNER IA Capacities through geometric range are limited to those shown in horizontal position. Loads shown are based on crane structural or hydraulic capability. Before lift is made, stability must be checked per SAE J765A. Model Working loads will be limited to those shown. Deduct the weight of load handling devices. EXTENSION BOOM DEPLOYED 37-0 (11.28m) EXTENSION BOOM RETRACTED 31-5 (9.58m) (3.94m) 43 (1.09m) FRAME HT. 0 CENTERLINE OF ROTATION 15-0 (4.57m) 21-0 (6.40m) -5-0 (-1.52m) 27-6 (8.38m) LBS KGS CENTERLINE OF ROTATION 15-0 (4.57m) 21-0 (6.40m) 27-6 (8.38m)

10 : : SECTION 1. SPECIFICATIONS GEOMETRIC CONFIGURATION

11 : : SECTION 1. SPECIFICATIONS CRANE MOUNTED ON CHASSIS

12 : : SECTION 1. SPECIFICATIONS MINIMUM CHASSIS SPECIFICATIONS For Standard Crane CRANE MOUNT... Behind Cab CRANE WORKING AREA CHASSIS STYLE... Conventional Cab FRONT AXLE RATING (GAWR) lbs (9072 kg) REAR AXLE RATING (GAWR) lbs (23587 kg) Tandem Axle WHEELBASE ' (5385mm) CAB-TO-AXLE ' (3810mm) FRAME HEIGHT FROM GROUND... 43' (1092mm) maximum RBM... 4,740,000 in-lbs (587,760 kgs/m) FRAME SECTION MODULUS cubic inches (663cc) FRAME YIELD STRENGTH ,000 PSI (77,341,000 kgs/m 2 ) MIN AFTER FRAME (3556mm) CHASSIS FRAME RAIL WIDTHS OUTSIDE DIMENSION (864mm) minimum to 40 (1016mm) maximum INSIDE DIMENSION (610mm) minimum to 30 (762mm) maximum To maintain vehicle stability, it will be necessary to provide auxiliary stabilizers which have, at a minimum, 14'-0' (4.26m) span. A subframe/torsion box must be used to tie the auxiliary stabilizers to the crane. For each application contact IMT for a weight distribution and stability analysis. NOTES: 1. GAWR means Gross Axle Weight Rating and is dependent on all components of the vehicle such as 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 further information. 3. Weight distribution calculations are required to determine final axle loading. 4. All chassis and crane combinations must be stability tested to ensure stability per ANSI B30.22 IOWA MOLD TOOLING CO., INC. BOX 189, GARNER, IA TEL: FAX:

13 : : SECTION 2. CRANE REFERENCE SECTION 2. MODEL CRANE REFERENCE MAJOR CRANE ASSEMBLIES... 3 WELDMENT PART NUMBER LOCATIONS... 3 GREASE ZERK LOCATIONS & LUBRICANT REQUIREMENTS... 4 RECOMMENDED SPARE PARTS LIST... 5 INSTALLATION... 7 GENERAL... 7 CRANE MOUNTING... 7 HYDRAULIC INSTALLATION... 8

14 : : SECTION 2. CRANE REFERENCE NOTES

15 : : SECTION 2. CRANE REFERENCE MAJOR CRANE ASSEMBLIES STABILIZER WELDMENT PART NUMBER LOCATIONS STABILIZER

16 : : SECTION 2. CRANE REFERENCE GREASE ZERK LOCATIONS & LUBRICANT REQUIREMENTS ITEM LOCATION DESCRIPTION LUBRICANT FREQUENCY 1. TURNTABLE/BEARING GREASE EXTENSION *ROTATE CRANE WHILE GREASING 2. DRIVE GEAR GREASE EXTENSION 3. LATCH PIN 4. OUTER BOOM TRUNNION 5. SHEAVE PIN (OPTIONAL CABLE & HOOK KIT) SHELL ALVANIA 2EP OR SHELL RETINAX A WEEKLY 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.

17 : : SECTION 2. CRANE REFERENCE RECOMMENDED SPARE PARTS LIST 1 YEAR SUPPLY MODEL TELESCOPING CRANE FOR MANUAL: 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. ASSEMBLY DESIGNATION BASE ASM 43 7BF81225 BUSHING 2 W 48 7Q O-RING 4 W C BALANCE VALVE CARTRIDGE 4 C 3B PWR OUT STABILIZER CYLINDER VALVE 2 C 3C B SEAL KIT 2 W PWR DN STABILIZER CYLINDER 1 9C SEAL KIT 2 W VALVE 10GPM 4 C 20 7BF81520 BUSHING 4 W AUX STABILIZER ASSEMBLY WEAR PAD 2 W WEAR PAD 2 W 3B B AUX STABILIZER PWR DN CYLINDER CBAL VALVE 10GPM 4 C 7 9C SEAL KIT 2 W 18 7BF81215 BUSHING 4 W AUX STABILIZER PWR OUT CYLINDER VALVE 2 C 8 9B SEAL KIT 2 W MAST ASM BEARING 2 W INNER BOOM ASM BEARING 4 W BEARING 12 W 3D INNER BOOM CYLINDER 1 9X SEAL KIT 2 W 7 6IX80243 PISTON 2 W 17 6HXB0040 HEAD 2 W C BALANCE VALVE 2 W BEARING 8 W OUTER BOOM ASM WEAR PAD 8 W WEAR PAD 4 W BEARING 4 W 3C OUTER BOOM CYLINDER 1 9C SEAL KIT 1 W 16 6HX70040 HEAD 1 W C BAL VALVE 2 C BEARING 4 W EXTENSION BOOM ASM WEAR PAD 4 W WEAR PAD 2 W 3C ITEM NO. PART NO. DESCRIPTION EXTENSION BOOM CYLINDER 3 6I PISTON 1 W 4 6H HEAD 1 W C BAL VALVE 2 C 6 9C SEAL KIT 1 W WEAR PAD 4 W CAPACITY ALERT KIT PRESSURE SWITCH 1 C 2 7Q O-RING 1 W OIL RESERVOIR ASM-60 GAL RETURN TANK FILTER 3 P QTY CODE SHELF LIFE (MO) ORDER QTY

18 : : SECTION 2. CRANE REFERENCE NOTES

19 : : SECTION 2. CRANE REFERENCE 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, Installation). INSTALLATION 2. Install the truck frame support so that the tie-down studs pass through the supports (See figure below). Cut the support to the inside dimensions of the truck frame. Allow about 1/16" (1.6mm) extra. Grind the end of the support to fit inside the frame channel. Use a hammer to drive it into position if necessary. Components used in each installation may vary. It is important to use hoses of proper length, pumps of correct size, and PTO s of adequate speed ratio and power rating. CRANE MOUNTING 1. 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. See SPECIFICATIONS in Section 1 for crane weight. Using an overhead hoist and fabric slings of adequate capacity, lift the crane about a foot to see if the crane is adequately balanced. If not, lower hoist and adjust slings. Re-check balance and reposition crane until mounting surface is level. 3. Allow sufficient clearance between the cab, or other obstructions, and crane base. Position the crane on the chassis per the applicable installation drawing, centering the mounting slots over the truck frame rails. While holding crane with hoist, start mounting hardware per figure below. Note position of support weldments on truck frame. Hand tighten nuts. Observe underside of crane base. No clearance between base and frame is allowed. 4. Torque the 2"-4 1/2 mounting hardware to 1125 ftlbs (510 kg-m). When torquing the mounting hardware the following precautions must be followed: A. Never use lock washers. B. Hardened washers must be used, and under the turning element, whether the turning element is the nut or the head of the bolt. C. Torque values specified are with residual oils or without special lubricants applied to the threads. If special lubricants are used, such as Never-Seize compound graphite and oil, molybdenum disulphite collodial copper or white lead, reduce torque values 10%. Torque values for threaded fasteners are not affected with the use of Loctite. D. Do not use rusty fasteners, the rust will alter torque values significantly. E. Touch-up paint around mounting anchor plates. CAUTION DO NOT ATTEMPT TO APPLY THE SAME TORQUE TO THE TIE ROD AND SELF-LOCKING NUTS AS SHOWN IN THE TORQUE DATA CHART. DO NOT EXCEED 1125 FT. LBS. (156 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. CRANE INSTALLATION

20 : : SECTION 2. CRANE REFERENCE HYDRAULIC INSTALLATION 1. Install a 2-1/2" nipple and gate valve to the reservoir.. 2. Install the 2-1/2" diameter suction hose between the pump and the reservoir, using barbed nipples, hose clamps, and adapter fittings as needed (See figure below). 3. Install the 3/4" diameter pressure hose between the pump and the valve bank inlet section. 4. Install the 1-1/4" diameter return hose between the valve bank outlet section and the return line filter. 5. Install the 3/8" pressure hose from the load sense port on the control valves to the load sense port on the pump through series of shuttle valves (see figure). 6. Install kidney loop valve using 3/8 hoses. The pressure line of pump to port s on the valve. The load sense line on the pump goes to port x on the valve. Port t on the valve returns to the reservoir. 7. Fill the hydraulic reservoir (refer to Volume 1 for hydraulic oil specifications). 9. Start the vehicle engine and test each crane function individually. Conduct a visual inspection to make certain that there are no leaks and that everything is operating properly. 10. Lightly turn the flow compensator (load sense) adjustment in until it stops. 11. Turn the pressure compensator adjustment until desired system pressure is reached (see specifications). Lock the adjustment lock nut. 12. Turn the flow compensator adjustment out until standby pressure of approximately 250 PSI (17.24 bar) is reached. Lock the flow compensator adjustment lock nut. 13. Operate all hydraulic functions to ensure proper pressure settings. NOTE PUMP PRESSURE ADJUSTMENTS MAY VARY SLIGHTLY FROM ONE MANUFACTURER TO ANOTHER. 14. Check the oil level in the reservoir. Add oil if needed. 8. Check all connections for leaks. HYDRAULIC INSTALLATION

21 : : SECTION 3. PARTS SECTION 3. MODEL REPLACEMENT PARTS PARTS INFORMATION... 3 CRANE IDENTIFICATION... 3 CYLINDER IDENTIFICATION... 3 WELDMENT IDENTIFICATION... 3 ORDERING REPAIR PARTS... 3 BASE & STABILIZER ASM ( )... 4 BASE & STABILIZER ASM ( )... 5 PWR OUT STABILIZER CYLINDER (3B144860)... 6 PWR DN STABILIZER CYLINDER (3C145860)... 7 AUX STABILIZER ASM ( )... 8 AUX STABILIZER PWR DN CYLINDER (3B020860)... 9 AUX STABILIZER PWR OUT CYLINDER (3B148860) MAST ASM ( ) INNER BOOM ASM ( ) INNER BOOM CYLINDER (3D203970) OUTER BOOM ASM ( ) OUTER BOOM CYLINDER (3C204970) EXTENSION BOOM ASM ( ) EXTENSION BOOM CYLINDER (3C209970) INSTALLATION KIT ( ) INSTALLATION KIT ( ) DECAL KIT ( ) HYDRAULIC KIT ( ) HYDRAULIC KIT ( ) HYDRAULIC KIT ( ) HYDRAULIC KIT ( ) HYDRAULIC KIT ( ) REMOTE CONTROL KIT ( ) CABLE ASM-JIC BOX ( ) CAPACITY ALERT KIT-3000 PSI ( ) FLOODLIGHT KIT ( ) ROTATION SPEED REDUCER ( ) OIL RESERVOIR ASM-60 GAL ( ) KIT-CONTROL ( ) CTRL BOX-RADIO ( )... 33

22 : : SECTION 3. PARTS NOTES

23 : SECTION 3. PARTS 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. For optional equipment, refer to the appropriate manual, or consult your IMT sales reprsentative. WARNING DO NOT ATTEMPT TO REPAIR ANY COMPONENT WITHOUT READING THE INFORMATION 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 attached to the mast or to one of the booms in a prominent location. When ordering parts, communicating warranty information, or referring to the unit in correspondence, always include the serial number and model number. All inquiries should be directed to: Iowa Mold Tooling Co., Inc. Box 189, Garner, IA Telephone: Product Support Fax: PARTS INFORMATION CYLINDER IDENTIFICATION To insure that the proper cylinder replacement parts are recieved, it is necessary to specify the complete number/letter sequence for any part requested. Part numbers must be verified by checking the number stamped on the cylinder case (See figure below) against the information included 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 stabilizers, have a part number stamped on them. Any time one of the weldments is to be replaced, it is necessary to specify the complete part number as stamped on that weldment. The location of the part numbers are shown in Section 2. ORDERING REPAIR PARTS When ordering replacement parts it is important to follow the steps as outlined below. 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 MOLD TOOLING CO., INC. BOX 189, GARNER, IA MODEL NUMBER SERIAL NUMBER MFG DATE SERIAL NUMBER PLACARD CYLINDER PART NUMBER LOCATION

24 : SECTION 3. PARTS BASE & STABILIZER ASM ( ) ITEM PART NO. DESCRIPTION QTY 1. 3B CYLINDER-PWR OUT C CYLINDER-PWR DN ROTATION LATCH (INCL:43) OUTIGGER ARM STABILIZER LEG/PAD COVER-STABILIZER TUBE HOUSING-STABILIZER PIN BASE PIN LATCH FOLLOWER DETENT HOUSING PIN PIN PIN COVER-PINION GEAR COVER-CTRL HANDLE-SS COVER-VB Y SPRING TURNTABLE GEAR BEARING ROT N GEAR BOX (PART OF 29) REF ZERK 1/8NPT CAP SCR 1/4-20X3/4 HHGR CAP SCR 1/2-13X1 HHGR CAP SCR 1/2-13X2 HHGR CAP SCR 5/8-11X1-1/2 SH SCR 5/16-18X3/4 SLFTPG HH CAP SCR 1/2-13X3-1/4 HHGR GEAR BOX ASM (INCL:21&44) WASHER 1/4 WRT WASHER 5/16 WRT MACH BUSHING 1X10GA NR WASHER 1/4 LOCK WASHER 1/2 LOCK WASHER 5/8 LOCK MACH BUSHING 2X10GA NR WASHER 3/4 FLAT HARD RETAINING RING 1 HD RETAINING RING 2 HD BALL 9/16DIA CAP SCR 3/4-10X4-1/2 HHGR COVER BF81225 BUSHING (PART OF 3) 2REF HYD MOTOR (PART OF 29) REF NUT 1/2-13 HEX CTR LK VALVE BLOCK (INCL:48-53) CAP SCR 3/8-16X2-1/2 SH Q O-RING (PART OF 46) 4REF CARTRIDGE VALVE(PART OF 46) 4REF SHUTTLE BALL (PART OF 46) 2REF SHUTTLE SEAL (PART OF 46) 2REF PLUG (PART OF 46) 2REF BODY (PART OF 46) 2REF HOSE CLAMP NUT 3/8-16 LOCK GREASE EXT MTG BAR COUPLING 1/8NPT CAP SCR 3/8-16X1-1/2 HHGR HOSE CLAMP CABLE GUIDE WASHER 3/8 WRT NUT 1/2-13 LOCK STUD 4 WARNING Any time the gear-bearing bolts have been removed, they must be replaced with new bolts of identical grade and size. Failure to replace gear-bearing bolts may result in bolt failure due to metal fatigue causing serious injury or death. NOTES Motor (44) and gearbox (21) come assembled-check oil level. Use WT oil if needed. CONTINUED ON FOLLOWING PAGE NOTE INSTALL DECAL-FULLY DEPLOYED - ON TOP OF STABILIZER BEAMS WHEN BEAMS ARE FULLY EXTENDED. DECAL MUST BE VISIBLE.

25 : SECTION 3. PARTS BASE & STABILIZER ASM ( )

26 : 3B SECTION 3. PARTS PWR OUT STABILIZER CYLINDER (3B144860) 1. 4B CASE ASM (INCL:18) G ROD ASM I PISTON H HEAD VALVE CAP SCR 1/4-20X1-1/4 SH C STOP TUBE B SEAL KIT (INCL:9-17) T66P025 PISTON SEAL (PART OF 8) 1REF 10. 7T61N087 LOCK RING SEAL (PART OF 8) 1REF 11. 7Q O-RING (PART OF 8) 1REF 12. 6A WAFER LOCK (PART OF 8) 1REF 13. 7T2N8015 WEAR RING (PART OF 8) 1REF 14. 7Q O-RING (PART OF 8) 1REF 15. 7Q10P228 BACK-UP RING (PART OF 8) 1REF 16. 7R14P015 ROD WIPER (PART OF 8) 1REF 17. 7R ROD SEAL (PART OF 8) 1REF 18. 7PNPXT02 PLUG 1/8NPT (PART OF 1) 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, 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.

27 : 3C SECTION 3. PARTS PWR DN STABILIZER CYLINDER (3C145860) 1. 9C SEAL KIT(INCL:3-6,8,12,13,15,16,19) PNPXT02 PLUG 1/8NPT (PART OF 11) 2REF 3. 7Q O-RING (PART OF 1) 1REF 4. 7T66P050 PISTON SEAL (PART OF 1) 1REF 5. 7T65I050 PISTON RING (PART OF 1) 2REF 6. 7T61N181 LOCK RING SEAL (PART OF 1) 1REF 7. 6I PISTON A WAFER LOCK (PART OF 1) 1REF 9. 6C STOP TUBE G ROD ASM (INCL:20) C CASE ASM (INCL:2) Q O-RING (PART OF 1) 1REF 13. 7Q10P350 BACK-UP RING (PART OF 1) 1REF 14. 6C STOP TUBE R ROD SEAL (PART OF 1) 1REF 16. 7R14P025 ROD WIPER (PART OF 1) 1REF VALVE 10GPM H HEAD T2N8027 WEAR RING (PART OF 1) 1REF 20. 7BF81520 BUSHING (PART OF 10) 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, 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.

28 : SECTION 3. PARTS AUX STABILIZER ASM ( ) 1. 3B CYLINDER-PWR DN B CYLINDER-PWR OUT OUTIGGER ARM ARM HOUSING LEG HOUSING-STABILIZER WEAR PAD WEAR PAD PIN HOSE CLAMP PIN PIN PIN COVER-STABILIZER HOUSING COVER-ARM HOUSING REAR MTG ANGLE FRONT MTG ANGLE CAP SCR 1/4-20X3/4 HHGR DECAL-DANGER STAND CLEAR CAP SCR 3/4-10X2-1/2 HHGR CAP SCR 5/8-11X2-1/2 SH NUT 5/8-11 LOCK NU 3/8-16 LOCK NUT 3/4-10 LOCK WASHER 1/4 WRT MACH BUSHING 1X10GA NR MACH BUSHING 1-1/2X10GA NR WASHER 1/4 LOCK RETAINING RING 1 EXT HD RETAINING RING 1-1/2 EXT HD DECAL-FULLY DEPLOYED 2 NOTE INSTALL DECAL-FULLY DEPLOYED - ON TOP OF STABILIZER BEAMS WHEN BEAMS ARE FULLY EXTENDED. DECAL MUST BE VISIBLE.

29 : 3B SECTION 3. PARTS AUX STABILIZER PWR DN CYLINDER (3B020860) ITEM PART NO. DESCRIPTION QTY 1. 4B CASE ASM (INCL:3) G ROD ASM (INCL:17) PNPXT02 PIPE PLUG 1/8NPT (PART OF 1) 2REF COUNTERBALANCE VALVE 10GPM H HEAD I PISTON C SEAL KIT (INCL:8-17) Q O-RING (PART OF 7) 1REF 9. 7T66P040 PISTON SEAL (PART OF 7) 1REF 10. 7T65I040 PISTON RING (PART OF 7) 2REF 11. 6A WAFER LOCK (PART OF 7) 1REF 12. 7Q O-RING (PART OF 7) 1REF 13. 7Q10P342 BACK-UP RING (PART OF 7) 1REF 14. 7R14P020 ROD WIPER (PART OF 7) 1REF 15. 7R U-CUP SEAL (PART OF 7) 1REF 16. 7T61N143 LOCK RING (PART OF 7) 1REF 17. 7T2N8022 ROD WEAR RING (PART OF 7) 1REF 18. 7BF81215 BUSHING (PART OF 2) 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, 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.

30 : 3B SECTION 3. PARTS AUX STABILIZER PWR OUT CYLINDER (3B148860) 1. 4B CASE ASM G ROD ASM I PISTON H HEAD VALVE CAP SCR 1/4-20X1-1/4 SH C STOP TUBE B SEAL KIT (INCL:9-17) T66P025 PISTON SEAL (PART OF 8) 1REF 10. 7T61N087 LOCK RING (PART OF 8) 1REF 11. 7Q O-RING (PART OF 8) 1REF 12. 6A WAFER LOCK (PART OF 8) 1REF 13. 7T2N8015 WEAR RING (PART OF 8) 1REF 14. 7Q O-RING (PART OF 8) 1REF 15. 7Q10P228 BACK-UP RING (PART OF 8) 1REF 16. 7R14P015 ROD WIPER (PART OF 8) 1REF 17. 7R U-CUP LOADED (PART OF 8) 1REF 18. 7PNPXT02 PIPE PLUG 1/8NPT (PART OF 1) 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, 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.

31 : SECTION 3. PARTS MAST ASM ( ) MAST (INCL:2) BEARING (PART OF 1) 2REF WASHER 3/4 FLAT HARD CAP SCR 3/4-10X5 HHGR HOSE CLAMP CAP SCR 3/8-16X2-1/4 HHGR NUT 3/8-16 LOCK SERIAL NUMBER PLACARD POP RIVET 1/8X3/8GRIP HOSE HOLDER 2 WARNING Anytime the gear bearing bolts have been removed, they must be replaced with bolts of identical grade and size. Failure to replace the gear bearing bolts may result in serious injury or death. NOTES 1. Apply Never-Seez to collar ID. 2. It is imperative that Never-Seez be applied in such a manner that it does not come in contact with any Gar- Max bearing. 3. Apply permanent thread lock to bolts. 4. Torque bolts to 280 ft-lbs (38.7 kg-m)

32 : SECTION 3. PARTS INNER BOOM ASM ( ) MAST ASM REF INNER BOOM (INCL:12) PIN PIN PIN RETAINER PLATE PIN PIN RETAINER PLATE CAP SCR 5/8-11X1 HHGR CAP SCR 3/4-10X1-1/2 HHGR NUT 1 3/4-5 LOCK D CYLINDER (INCL:17) BEARING (PART OF 2) 4REF KIT-CAPACITY ALERT 3000PSI TUBE ASM HOSE CLAMP COVER PLATE BEARING (PART OF 11) 12REF NUT CAP SCR 5/16-18X1-1/4 HHGR5 2 NOTES 1. Apply Never-Seez to collar ID. 2. Apply Never-Seez to pin at pin cap, not to exceed the width of the collar. 3. It is imperative that Never-Seez be applied in such a manner that it does not come in contact with any Gar- Max bearing. 4. If required, shim pin retainer plates flush (-0/+0.06 ) with outside of collar using 3/4 flat washers, as required. 5. Clean/primer all pin retaining plate cap screws and apply a serviceable thread locker to a minimum of three threads. Torque pin retainer plate cap screws as follows: 3/4-10 cap screw (gr5 plated) ft-lbs (27.7 kg-m) 5/8-11 cap screw (gr5 plated) ft-lbs (15.9 kg-m)

33 : 3D SECTION 3. PARTS INNER BOOM CYLINDER (3D203970) 1. 9X SEAL KIT (INCL:3-6,8,12,13,15,16,20) PNPXT02 PIPE PLUG 1/8NPT (PART OF 11) 3REF 3. 7Q BACK-UP RING (PART OF 1) 1REF 4. 7T66P080 PISTON SEAL (PART OF 1) 1REF 5. 7T2N4080 WEAR RING (PART OF 1) 2REF 6. 7T61N243 LOCK RING (PART OF 1) 1REF 7. 6IX80243 PISTON A WAFER LOCK (PART OF 1) 1REF 9. 6C STOP TUBE G ROD ASM (INCL:19) D CASE ASM (INCL:2&19) Q O-RING (PART OF 1) 1REF 13. 7Q10P443 BACK-UP RING (PART OF 1) 1REF 14. 6C STOP TUBE R U-CUP LOADED (PART OF 1) 1REF 16. 7R14P040 ROD WIPER (PART OF 1) 1REF 17. 6HXB0040 HEAD COUNTERBALANCE VALVE 25GPM BEARING (PART OF 10&11) 4REF 20. 7T2N2X42 WEAR RING (PART OF 1) 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.

34 : SECTION 3. PARTS OUTER BOOM ASM ( ) TRUNNION OUTER BOOM (INCL:20) INNER BOOM REF PIN RETAINER PLATE PIN PIN PIN PIN WEAR PAD PIN RETAINER PLATE 3-1/ SIDE RETAINER PLATE PIN RETAINER CAP 3-3/ CAP SCR 1/2-13X1-1/4 HHGR CAP SCR 5/8-11X1 HHGR CAP SCR 3/4-10X1-1/2 HHGR WASHER 1/2 LOCK C OUTER CYLINDER WEAR PAD ZERK 1/8NPT BEARING (PART OF 2) 4REF

35 : 3C SECTION 3. PARTS OUTER BOOM CYLINDER (3C204970) ITEM PART NO. DESCRIPTION QTY 1. 9C SEAL KIT (INCL:3-5,7,11-15,19) PNPXT02 PIPE PLUG 1/8NPT (PART OF 10) 2REF 3. 7Q BACK-UP RING (PART OF 1) 1REF 4. 7T66P070 PISTON SEAL (PART OF 1) 1REF 5. 7T61N218 LOCK RING (PART OF 1) 1REF 6. 6IX70218 PISTON A WAFER LOCK (PART OF 1) 1REF 8. 6C STOP TUBE G ROD ASM (INCL:18) C CASE ASM (INCL:2&18) Q O-RING (PART OF 1) 1REF 12. 7Q10P363 BACK-UP RING (PART OF 1) 1REF 13. 7T2N2X42 WEAR RING (PART OF 1) 1REF 14. 7R U-CUP LOADED (PART OF 1) 1REF 15. 7R14P040 ROD WIPER (PART OF 1) 1REF 16. 6HX70040 HEAD COUNTERBALANCE VALVE 25GPM BEARING (PART OF 10&11) 4REF 19. 7T2N4070 WEAR RING (PART OF 1) 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, 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.

36 : SECTION 3. PARTS EXTENSION BOOM ASM ( ) OUTER BOOM 1REF PIN EXTENSION BOOM PIN WEAR PAD SWIVEL LINK-15 TON PIN HOOK-SWIVEL 15TON W/LATCH WEAR PAD CAP SCR 3/8-16X1-1/2 FLATHD SOC WASHER 1-1/2 WRT RETAINING RING 1-1/2 EXT HD WASHER 1-1/4 WRT NUT 1 1/4-7 HEX STL INSERT GR HAIR PIN 3/ C EXT CYLINDER (INCL:17,18&20`) WEAR PAD (PART OF 16) 4REF CAP SCR 1/4-20 SH(PART OF 16) 12REF NUT 3/8-16 LOCK NUT 1/4-20 LOCK (PART OF 16) 12REF

37 : 3C SECTION 3. PARTS EXTENSION BOOM CYLINDER (3C209970) 1. 4C CASE ASM (INCL:19) G ROD ASM I PISTON H HEAD COUTERBALANCE VALVE 25GPM C SEAL KIT (INCL:7-16) T61N200 LOCK RING (PART OF 6) 1REF 8. 7T66P500 PISTON SEAL (PART OF 6) 1REF 9. 7T2N4050 WEAR RING (PART OF 6) 2REF 10. 7Q O-RING (PART OF 6) 1REF 11. 6A WAFER LOCK (PART OF 6) 1REF 12. 7Q O-RING (PART OF 6) 1REF 13. 7Q10P350 BACK-UP RING (PART OF 6) 1REF 14. 7T2N8032 WEAR RING (PART OF 6) 1REF 15. 7R U-CUP SEAL (PART OF 6) 1REF 16. 7R14P030 ROD WIPER (PART OF 6) 1REF CAP SCR 1/4-20X1-1/4 FLATHDSOC WEAR PAD PNPXT02 PIPE PLUG 1/8NPT (PART OF 1) 2REF 20. 6C STOP TUBE PORT TUBE ELBOW #8MSTR #8MFACE ADAPTER #8MSTR #8MFACE NUT 1/4-20 LOCK 12 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.

38 : SECTION 3. PARTS INSTALLATION KIT ( ) SUPPORT TIE-DOWN STUD 2-4 1/2X CLAMP PLATE WASHER 2 FLAT NUT 2-4 1/2 HEX STL INSERT GR5 16

39 : SECTION 3. PARTS INSTALLATION KIT ( ) PUMP 1REF ELBOW #10MSTR #12MFACE HOSE 3/4X40 #12# TEE #12 UNION FACE TEE #12 RUN FACE HOSE 3/4X48 #12# ADAPTER #12MJIC 3/4MPT HOSE 3/4X36 #12# ELBOW #12MJIC #12FJIC SWVL HOSE 3/4X60 #12# SHUTTLE VALVE HOSE 3/8X72 #12# HOSE 3/8X12 #6# ADAPTER #6MSTR #6MFACE ELBOW #6MSTR #6MFACE REDUCER BUSHING 1-1/4 3/4NPT ADAPTER #8MJIC #12FJIC ELBOW #12MSTR #16MJIC ELBOW #10MSTR #12MJIC HOSE 1X60 #16#16 FF HOSE 3/8X24 #6#8 FF HOSE 3/8X24 #6#16 FF TEE #12JIC RUN NIPPLE 1-1/2NPT X CLOSE HOSE 1-1/ ADAPTER #24MSTR 1-1/2FPT SW ELBOW 1-1/2NPT HOSE 2-1/ TEE 1-1/4NPT STL BALL VALVE 2-1/2NPT NIPPLE 2-1/2NPT X CLOSE BARB NIPPLE 2-1/2NPT BELL COUPLING 2-1/2 1-1/2NPT ELBOW #6MSTR #6MJIC HOSE 3/8X72 #8#8 FF ADAPTER #6MSTR #6MJIC BARB NIPPLE 1-1/4MPT HOSE 3/4X HOSE CLAMP 1-1/ HOSE CLAMP 2-1/ REDUCER BUSHING 1-1/2 1-1/4NPT ADAPTER #6MSTR #8MJIC ELBOW #8MJIC 1/2MPT REDUCER BUSHING 3/4-3/8NPT VALVE 1REF OIL RESERVOIR ASM TEE #6JIC SWVL NUT RUN ELBOW #6JIC SWVL ELBOW #16MSTR #12MJIC ADAPTER 1-1/4MPT #16MJIC ELBOW #8MJIC #8FJIC SWVL ADAPTER #12MSTR #12MFACE BARB NIPPLE ELBOW 1-1/4 1-1/ HOSE 3/8X HOSE 3/8X HOSE 3/8X26 #6# HOSE 3/8X19 #6#6 1

40 : REV E SECTION 3. PARTS DECAL KIT ( ) DECAL-GREASE WEEKLY-LEFT DECAL-WARNING LOADLINE DECAL-WARNING HOIST PERSON PLACARD-IMT DIAMOND DECAL-SET UP/STOW INSTR DECAL-GREASE WEEKLY-RIGHT DECAL-RETURN LINE DECAL-SUCTION LINE DECAL-CAUTION WASH WAX DECAL-ROTATE CRANE/GREASE DECAL IDENTIFICATION DECAL-DANGER ELECTROCUTION DECAL-WARNING OPER TRAINING DECAL-WARNING OPERATION DECAL-DANGER ELEC HZD-LG DECAL-WARNING OPER CONDITION DECAL-WARNING OPER RESTRICT DECAL-DANGER STOW/UNFOLD DECAL-DANGER DRIVELINE DECAL-CONTACT IMT DECAL-WARNING STAB STD CLR DECAL-CAUTION OIL LEVEL DECAL-CONTROL SS DECAL-SPD CTRL/ENG KILL CAPACITY DECAL-HANDLE DECAL-ALIGN CRANE PLACARD-CAPACITY DECAL-CONTROL STAB SS DECAL-CONTROL STAB CS DECAL-OIL RECOMMENDATIONS DECAL-CTRL AUX STAB CS DECAL-ASME/ANSI B LEVEL 2 STABILIZERS NOTE: PLACE ITEM #38, LEVEL, ON FRONT AND SIDE OF CRANE BASE.

41 : SECTION 3. PARTS HYDRAULIC KIT ( ) ADAPTER #8MSTR #8MFACE HOSE-BBX 3/4X24 #12# HOSE-BBY 3/4X24 #12# PRESSURE SWVL #12FACE HOSE-BBBB 3/4X12 #12# TEE #12MFACE HOSE-BBBB 1/2X135 #12# HOSE-BBBB 1/2X45 #12# HOSE-BBX 1/2X31 #8# HOSE-BBY 1/2X31 #8# PRESSURE SWVL #8FACE HOSE-BBCC 1/2X135 #8# ADAPTER #10MSTR #8MFACE ADAPTER #10MSTR #10MFACE HOSE-BBF 1/2X135 #12# NIPPLE-DIAG W/CAP 9/ CONTINUED ON FOLLOWING PAGE

42 : SECTION 3. PARTS HYDRAULIC KIT ( ) ADAPTER #8MSTR #8MFACE ADAPTER #8MSTR #8MJIC HOSE-BBBB.50X135 #12# HOSE-BBF.50X135 #12# HOSE-BBCC.50X135 #12# SPIRAL WRAP 20FT CONTINUED ON FOLLOWING PAGE

43 : SECTION 3. PARTS HYDRAULIC KIT ( ) HOSE-BBCC.50X46 #8# ELBOW #8MSTR #8MFACE SPIRAL WRAP 6FT CONTINUED ON FOLLOWING PAGE

44 : SECTION 3. PARTS HYDRAULIC KIT ( ) HOSE-XX 1/2X84 #8# HOSE-XX 1/2X96 #8# TEE #8MFACE HOSE-BBBB 1/2X18 #8# HOSE-BBBB 1/4X8 #4# ADAPTER #4MSTR #4MFACE ELBOW #8MSTR #8MFACE ADAPTER #10MSTR #8MFACE ELBOW #4MSTR #4MFACE ELBOW #4MFACE #4FFACE 90 SW ELBOW #8MFACE #8FFACE 90 SW 2 CONTINUED ON FOLLOWING PAGE

45 : SECTION 3. PARTS HYDRAULIC KIT ( ) ADAPTER #8MSTR #8MFACE HOSE-BBX 1/2X60 #8# HOSE-BBY 1/2X60 #8# HOSE-BBX 1/2X160 #8# HOSE-BBY 1/2X160 #8# HOSE-BBY 1/2X300 #8# HOSE-BBX 1/2X300 #8# HOSE-BBY 1/2X264 #8# HOSE-BBX 1/2X264 #8# ELBOW #8MSTR #8MFACE HOSE-BBX 1/2X130 #8# HOSE-BBY 1/2X130 #8#8 1

46 : SECTION 3. PARTS REMOTE CONTROL KIT ( ) CONTROL BOX-OVERLOAD SYS CABLE ASM-PR SW/BOX MTG BRKT-SWITCHES CAP SCR 1/4-20X3/4 HHGR SWITCH BRKT MACH SCR #8-32X3/4 RDHD NUT #8-32 LOCK 2

47 : SECTION 3. PARTS CABLE ASM-JIC BOX ( ) JIC BOX STRAIN RELIEF STRAIN RELIEF TERMINAL BLOCK-14 CONTACT BUTT CONNECTOR 16-14GA CAP SCR #10-32X1/2 SH DIODE 2.2AMO/274V CONNECTOR 3-WAY SEAL-CONNECTOR TERMINAL PIN-FEMALE JUMPER BAR CABLE 14GA/6WIRE 33FT CONNECTOR 4-WAY CABLE 18GA/2WIRE 3FT CABLE 18GA/2WIRE 8FT CABLE 14GA/3WIRE 9FT CABLE 16GA/3WIRE 4FT TERMINAL #8SPRSPD 16-14GA WIRE 16GA GRN X WIRE 16GA RED X WIRE 16GA WHT X HEAT SINK MTG PLATE SHT MTL SCR #6X3/ WIRE 16GA RED X WIRE 16GA WHT X CABLE 18GA/2WIRE X CABLE 16GA/4WIRE 30FT STRAIN RELIEF SWITCH 1

48 : SECTION 3. PARTS CAPACITY ALERT KIT-3000 PSI ( ) PRESSURE SWITCH 3000PSI Q O-RING PLUG 9/16-18 HH MANIFOLD CAP SCR 5/16-18X3/4 SH 4

49 : SECTION 3. PARTS FLOODLIGHT KIT ( ) (EFFECTIVE ) CABLE ASM BRACKET FLOODLIGHT, TOP MOUNT CAP SCR 3/8-16X1.5 HHGR5Z CLAMP-UMP 20 REF CONNECTOR TERMINAL GA FEM SEAL CABLE CONNECTOR WASHER 3/8 FLAT WASHER 3/8 LOCK NUT 3/8-16 HEX 2 (PARTS LIST THROUGH ) FLOODLIGHT 12V CHROME MOUNTING KIT 2REF LIGHT BRACKET LOOM 16FT WIRE 14GA BLK X 18FT WIRE 14GA BLK X SWITCH BRACKET CAP SCR 1/4-20X1/2 HHGR NUT 1/4-20 HEX WASHER 1/4 LOCK TERMINAL #10STUD 16-14GA BUTT CONNECTOR 16-14GA SWITCH PUSH/PULL W/FUSE CAP SCR 3/8-16X1-1/2 HHGR NUT 3/8-16 LOCK WASHER 3/8 FLAT WASHER 3/8 LOCK SPIRAL WRAP X 10 2

50 : SECTION 3. PARTS ROTATION SPEED REDUCER ( ) BASE CYLINDER BRAKE CARRIER-PLANET PISTON-BRAKE PLATE-BACKUP GEAR-RING GEAR-PLANET SHAFT-PLANET GEAR-INPUT SHAFT-OUTPUT SPRING COVER-SHIPPING GASKET-HYD MOTOR DISC-FRICTION DISC-BRAKE PLATE-BACKUP NUT CONE-BEARING CUP-BEARING CONE-BEARING CUP-BEARING SEAL SEAL SNAP RING O-RING PIPE PLUG O-RING ROLL PIN BOLT-SHIPPING BOLT CAP SCR WASHER 8

51 : SECTION 3. PARTS OIL RESERVOIR ASM-60 GAL ( )

52 : SECTION 3. PARTS KIT-CONTROL ( )

53 : SECTION 3. PARTS CTRL BOX-RADIO ( ) JIC BOX STRAIN RELIEF STRAIN RELIEF TERMINAL BLOCK-14 CONTACT SWITCH-MAIN BUTT CONNECTOR 16-14GA CAP SCR #10-32X1/2 SH DIODE 2.2A 274V CONNECTOR 3WAY F SEAL TERMINAL PIN JUMPER BAR CABLE 14GA 6WIRE 33FT CONNECTOR 4WAY F WIRE 16GA BLK TERMINAL-FSLPON 1/ GA CABLE 14GA 3WIRE RED/BLU/BLK 8FT CABLE 16GA 3WIRE RED/BLK/GRN 3FT TERMINAL-SPRSPD # GA WIRE 14GA GRN DECAL-EMERGENCY OVERLD REL WIRE 16GA WHT HEAT SHRINK STRAIN RELIEF MTG PLATE-TERM STRIP SWITCH WIRE 16GA RED WIRE 16GA WHT CABLE 16GA 4WIRE 25FT CABLE 18GA 2WIRE SWITCH BOX DECAL-SWITCH BOX 1

54 : 3-34 SECTION 3. PARTS

55 SECTION 4. GENERAL REFERENCE SECTION 4. GENERAL REFERENCE INSPECTION CHECKLIST... 3 WIRE ROPE INSPECTION... 7 HOOK INSPECTION... 7 HOLDING VALVE INSPECTION... 8 TWO BLOCK PREVENTION DEVICE INSPECTION... 8 TORQUE DATA CHART - DOMESTIC... 9 TORQUE DATA CHART - METRIC TURNTABLE BEARING FASTENER TIGHTENING SEQUENCE TURNTABLE BEARING INSPECTION FOR REPLACEMENT... 12

56 SECTION 4. GENERAL REFERENCE NOTES

57 NOTICE The user of this form is responsible in determining that these inspections satisfy all applicable regulatory requirements 4-3 SECTION 4. GENERAL REFERENCE Inspection Checklist CRANES 1 REV: OWNER/COMPANY CONTACT PERSON CRANE MAKE & MODEL TYPE OF INSPECTION (check one) DAILY (if deficiency found) MONTHLY DATE INSPECTED QUARTERLY ANNUAL CRANE SERIAL NUMBER HOUR METER READING (if applicable) UNIT I.D. NUMBER INSPECTED BY (print) LOCATION OF UNIT SIGNATURE OF INSPECTOR TYPE OF INSPECTION NOTES: Daily and monthly inspections are to be performed by a competent person, who is capable of identifying existing and predictable hazards in the surroundings or working conditions which are unsanitary, hazardous, or dangerous to employees, and who has authorization to take prompt corrective measures to eliminate them. Quarterly and annual inspections are to be performed by a qualified person who, by possession of a recognized degree, certificate, or professional standing, or who by extensive knowledge, training and experience, successfully demonstrated the ability to solve/resolve problems relating to the subject matter, the work, or the project. One hour of normal crane operation assumes 20 complete cycles per hour. If operation exceeds 20 cycles per hour, inspection frequency should be increased accordingly. Consult Operator / Service Manual for additional inspection items, service bulletins and other information. Before inspecting and operating crane, crane must be set up away from power lines and leveled with stabilizers deployed according to the crane manufacturer s directions. DAILY (D): Before each shift of operation, those items designated with a ( D) must be inspected. MONTHLY (M): Monthly inspections or 100 hours of normal operation (which ever comes first) includes all daily inspections plus items designated with an ( M). This inspection must be recorded and retained for a minimum of 3 months. QUARTERLY (Q): Every three 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 documented, maintained, and retained for a minimum of 12 months, by the employer that conducts the inspection. ANNUAL (A): Each year or 1200 hours of normal operation (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 documented, maintained, and retained for a minimum of 12 months, by the employer that conducts the inspection. = SATISFACTORY R = RECOMMENDATION (Should be considered for corrective action) NA = Not Applicable X = Deficient (Note: If a deficiency is found, an immediate determination must be made as to whether the deficiency constitutes a safety hazard and must be corrected prior to operation.) STATUS, R, X, NA FREQUENCY ITEM KEY INSPECTION DESCRIPTION D 1 Labels All load charts, safety & warning labels, & control labels are present and legible. D 2 Crane Check all safety devices for proper operation. D 3 Controls Control mechanisms for proper operation of all functions, leaks & cracks. D 4 Station Control and operator s station for dirt, contamination by lubricants, & foreign materials. D 5 Hyd System Hydraulic system (hoses, tubes & fittings) for leakage & proper oil level. D 6 Hook Presence & proper operation of hook safety latches. D 7 Wire Rope Inspect for apparent deficiencies per applicable requirements and manufacturer s specifications. D 8 Pins Proper engagement of all connecting pins & pin retaining devices. D 9 General Overall observation of crane for damaged or missing parts, cracked welds & presence of safety covers. D 10 Operation During operation, observe crane for abnormal performance, unusual wear (loose pins, wire rope damage, etc.). If observed, discontinue use & determine cause & severity of hazard. D 11 Remote Ctrls Operate remote control devices to check for proper operation. D 12 Electrical Operate all lights, alarms, etc. to check for proper operation. D 13 Anti Two-Block or Operate anti-two-blocking or two-block prevention devices to check for proper operation. Two-Block Damage Prevention