IMT 5005i Technical Specifications & Parts

Transcription

1 Manual # IMT 5005i Technical Specifications & Parts Revised IOWA MOLD TOOLING CO., INC. PO Box 189 Garner, IA Tel: FAX: Website: Copyright 2014 Iowa Mold Tooling Co., Inc. All rights reserved No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise without the prior written permission of Iowa Mold Tooling Co., Inc. Iowa Mold Tooling Co., Inc. is an Oshkosh Corporation Company.

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3 i Contents Revisions... iii Electric Crane Introduction 5 Technical Specifications i Technical Data i Capacity Chart... 9 Geometric Configuration Pump & Motor Performance Crane Reference 13 Assemblies & Grease Zerk Locations i Recommended Spare Parts List Crane Installation ( ) Electric Crane Battery Circuit ( ) Telescopic Crane Orientation Electric Crane Control Parts 25 Parts Information Electric Crane Power Safety Base & Mast Assembly ( ) (See Parts List for Effectivity) Base & Mast Assembly ( ) (See Parts List for Effectivity) Valve Bank ( ) Cylinder, Lower ( ) Boom Assembly ( ) Cylinder, Extension ( ) Crane & Winch Assembly ( ) (See Parts List for Effectivity) Crane & Winch Assembly ( ) (See Parts List for Effectivity) Winch ( ) Power Unit ( V & V) (Effective 10/11/12) Power Unit ( )(Through 10/11/12) Electrical Installation ( )(See Parts List for Effectivity) Electrical Installation ( )(See Parts List for Effectivity) Amp Contactor Replacement ( ) Tethered Control Installation ( ) Radio Control Installation, Standard ( ) Radio Control Installation, Proportional ( ) Harness, Radio ( ) Harness, Tethered ( ) Handle Assembly, Tethered ( ) Hydraulic Installation ( ) Decal Installation ( )... 76

4 ii Contents General Reference 79 Inspection Checklist Deficiency / Recommendation / Corrective Action Report Thread Torque Chart (English) Thread Torque Chart (Metric) Turntable Bearing Thread Tightening Sequence Turntable Bearing Inspection Turntable Bearing Tilt Test... 89

5 Contents iii Revisions DATE LOCATION DESCRIPTION ECN CHANGED COUNTERBALANCE VALVE , ECN UPDATED CONTROLS, ELECTRICAL INSTALLATION , , , ECN CONTACTOR SWITCH CHANGE , ECN REPLACED WELDED VB MOUNTING WITH BOLT-ON VB MOUNTING ECN ADDED NEW MOUNTING LOCATION DRAWINGS. ADDED REPLACEMENT PART NUMBERS FOR SHEAVE AND , , , , LATCH KIT. ECN 10977, CHANGED PROP. VALVE LOCATION, CHANGED WINCH PART NUMBER. ECNs , PRODUCTION AUDIT PARTS CHANGES ECN ADDED SPACER ECN UPDATED HYDRAULIC KIT TO ADD PRESSURE TEST PORT ADDED AND EDITED ELECTRIC CRANE STEP 5; ECN ADDED WINCH CONTACTOR COVER PART NUM ADDED DUAL BATTERY WIRING INFORMATION UPDATED WINCH SPARE PARTS , ECN CYLINDER UPDATES. ADDED PROP INSTRUCTIONS FOR REMOTE ECN POWER UNIT CHANGED ECN POWER CABLE CHANGED ECN A2B SWITCH MODIFICATIONS ECN CONTACTOR CHANGED ECN BASE WELDMENT CHANGE ECN CORD REEL CHANGE ECN PIN CHANGE ECN CONTACTOR HARDWARE CHANGE ECN A2B WELDMENT CHANGE REMOVED TETHERED PROPORTIONAL REMOTE POTENTIOMETER ADJUSTMENT PROCEDURE ECN UPDATED HARNESS DRAWINGS AND SCHEMATICS GREASING INSTRUCTIONS ECN MOLUB-ALLOY 882 WAS MOLUB-ALLOY 936.

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7 5 C HAPTER 1 Electric Crane Introduction This volume deals with information applicable to your particular crane. For operating, maintenance and repair instructions, refer to IMT Electric Cranes Operation & Safety (IMT part number ) We recommend that this volume be kept in a safe place in the office. This manual is provided to assist you with ordering parts for your IMT crane. It also contains additional instructions regarding your particular installation. It is the user s responsibility to maintain and operate this unit in a manner that will result in the safest working conditions possible. Warranty of this unit will be void on any part of the unit subjected to misuse due to overloading, abuse, lack of maintenance and unauthorized modifications. No warranty - verbal, written or implied - other than the official, published IMT new machinery and equipment warranty will be valid with this unit. In addition, it is also the user s responsibility to be aware of existing Federal, State and Local codes and regulations governing the safe use and maintenance of this unit. This crane was designed and built to meet the standards of ANSI/ASME B30.5, Mobile & Locomotive Cranes. Contact the American Society of Mechanical Engineers ( for more information. Throughout the manual, NOTEs, CAUTIONs and WARNINGs are used to draw the attention of personnel. They are defined as follows: NOTE A NOTE is used to either convey additional information or to provide further emphasis for a previous point. CAUTION A CAUTION is used when there is the very strong possibility of damage to the equipment or premature equipment failure. WARNING A WARNING is used when there is the potential for personal injury or death. For a safe work environment, treat this equipment with respect and service it regularly.

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9 7 C HAPTER 2 Technical Specifications In This Chapter 5005i Technical Data i Capacity Chart... 9 Geometric Configuration Pump & Motor Performance i Technical Data GENERAL SPECIFICATIONS CRANE RATING 30,000 ft-lb at 10'-0" (4.1 tm at 3.0 m) MAXIMUM HORIZONTAL REACH (from centerline of 22'-0" (6.7 m) rotation) HYDRAULIC EXTENSION (1) MANUAL EXTENSION (1) LIFTING HEIGHT (from base of crane to centerline of sheave) CRANE WEIGHT (1H1M) CRANE STORAGE HEIGHT MOUNTING SPACE REQUIRED (crane base) HYDRAULIC SYSTEM OPERATING PRESSURE 72" (183 cm) 72" (183 cm) 23'-6" (7.2 m) 1440 lb (653 kg) 37" (94 cm) 18" x 18" (45.7 cm x 45.7 cm) 2500 psi (172 bar) MAXIMUM HYDRAULIC FLOW 2.6 gpm OIL RESERVOIR CAPACITY 1.5 gallons (5.7 l) OIL TYPE ISO VG32, low pour, anti-wear hydraulic oil ELECTRICAL SYSTEM REQUIREMENTS 12VDC with two 1000 amp batteries* and 100 amp alternator min. CENTER OF GRAVITY - HORIZONTAL FROM CENTERLINE OF ROTATION 33" (84 cm) (BOOMS RETRACTED) - HORIZONTAL FROM CENTERLINE OF ROTATION (BOOMS EXTENDED) 65.5" (166 cm) - VERTICAL FROM BOTTOM OF CRANE BASE 18" (45.7 cm) TIE-DOWN BOLT PATTERN (on center) 14.75" x 14.75" (37.5 cm x 37.5 cm) ROTATION TORQUE 4000 ft-lb MINIMUM CHASSIS REQUIREMENT 10,500 lb (4763 kg) GVWR * The two batteries must be identical in size with maximum cold-crank amp rating of 1000 CCA.

10 8 IMT 5005i Technical Specifications & Parts Manual # CYLINDER SPECIFICATIONS LOWER BOOM CYLINDER EXTENSION BOOM CYLINDER 4.0" bore; 21.43" stroke (10 cm bore; 54.4 cm stroke) 2.5" bore; 72" stroke (6.4 cm bore; 183 cm stroke) WINCH SPECIFICATIONS WINCH PULL LINE 3000 lb (1361 kg) PULL LINE SPEED WITHOUT LOAD 37 ft/min (11.2 m/min) ROPE DIAMETER 5/16" (8 mm) WIRE ROPE LENGTH 80' (24.3 m) CABLE BREAKING STRENGTH 10,540 lb (4,780 kg) PERFORMANCE CHARACTERISTICS SPECIFICATION SPEED ROTATION Continuous 360 (6.28 rad) 48 seconds LOWER BOOM ELEVATION -5 to +75 (-0.1 to +1.3 rad) 30 seconds (raise); 38 (lower) EXTENSION CYLINDER 72" (1.8 m) 30 seconds (out); 35 (in)

11 Chapter 2 Technical Specifications i Capacity Chart 24' 7.3 m 21' 6.4 m Maximum 1-part line capacity is 3000 lb (1360 kg). For greater loads, use 2-part line. NOTE: Boxes denote 2-part line. 18' 5.5 m 15' 4.6 m 12' 3.6 m 9' 2.7 m 6' 1.8 m ' 0.9 m (Base) 3' 0.9 m 6' 1.8 m 9' 2.7 m 12' 3.6 m 15' 4.6 m 18' 5.5 m DISTANCE IN FEET/ METERS / LOAD IN POUNDS/KG. Weight of load handling devices are part of the load lifted and must be deducted from the capacity. 21' 6.4 m IOWA MOLD TOOLING CO., INC. BOX 189, GARNER, IA TEL: FAX:

12 10 IMT 5005i Technical Specifications & Parts Manual # Geometric Configuration 5'-10" (1.77 m) 4'-3" (1.30 m) 23'-1" (7.03 m) 2'-9" (83.8 cm) 17'-3" (5.30 m) 11'-10" (3.60 m) 1'-7" (48.2 cm) 10'-0" (3.05 m) 16'-0" (4.88 m) 22'-0" (6.71 m)

13 Chapter 2 Technical Specifications 11 Pump & Motor Performance The 12V Powerpack Motor for the 5005i and 6006i crane cannot be run continuously without serious motor damage. The pump has a maximum duty cycle of 2.5 minutes which must be followed by cool-down to ambient temperature. It can be run intermittently according to the following charts I CC AMPS Q CC PSI PSI BAR CAUTION Avoid motor damage! Operate within performance curves shown.

14 12 IMT 5005i Technical Specifications & Parts Manual # The five minute duty cycle must be adhered to. Operators have a choice of running the crane intermittently all day, using the duty cycles per the S2 and S3 curves, or at full power for 2.5 minutes, which MUST be followed by a complete cool-down to ambient.

15 13 C HAPTER 3 Crane Reference In This Chapter Assemblies & Grease Zerk Locations i Recommended Spare Parts List Crane Installation ( ) Electric Crane Battery Circuit ( ) Telescopic Crane Orientation Electric Crane Control... 23

16 14 IMT 5005i Technical Specifications & Parts Manual # Assemblies & Grease Zerk Locations EXTENSION BOOM SNATCH BLOCK LOWER BOOM HOOK WINCH 1 LOWER CYLINDER MAST HYDRAULIC RESERVOIR 4 POWER UNIT 5 CRANE BASE ITEM LOCATION DESCRIPTION LUBRICANT FREQUENCY 1. Lower Cylinder Rod Shell Alvania 2EP 2. Lower Cylinder Base 3. Gear Rotator Grease Extension *Rotate crane while greasing. or Weekly 4. Power Unit Shell Retinax "A" 5. Power Unit 6. Lower Boom Pin NOTE: All application points must be greased weekly under normal workloads and moderate weather conditions. Under severe operating conditions, lubricate more frequently. See the IMT Electric Crane Operation & Safety manual for additional lubrication requirements.

17 Chapter 3 Crane Reference i Recommended Spare Parts List This parts list is intended to provide the user with a stock of parts sufficient to keep the unit operating with the minimal down-time waiting for parts, but it does not indicate these items will fail within a year. In addition, there may be parts failures not covered by this list. Parts not listed are considered as not being Critical or Normal Wear items during the first year of operations and you need to contact the distributor or manufacturer for availability. Part Number Description Quantity Lower Cylinder 9D SEAL KIT 1 6ID40143 PISTON 1 6HD40022 HEAD VALVE-CBAL SWITCH-PRESS 2750 psi Extension Cylinder SEAL KIT 1 6HD25015 HEAD PISTON VALVE Base & Mast Assembly CABLE CONNECTOR MODIFICATION CAP SCR.62-11X 3.75 HH MOTOR-HYD GASKET-GEAR SWITCH- 275A CONTACTOR CABLE CONNECTOR-FEMALE TERM RING INSUL 3/8 STUD Valve Bank (12V) COIL (VALVE BANK) VALVE ASSEMBLY (VALVE & COIL) Valve Bank (24V) COIL (24V) SOLENOID VALVE (24V) Power Unit (through 10/11/12) BREATHER CAP PUMP-GEAR 5005/6006I ELECTRIC CRANE VALVE-RELIEF ELECTRIC CRANE KIT-TUBE POWER UNIT ELECTRIC CRANE RESERVOIR TANK ELECTRIC CRANE MOTOR-POWER UNIT ELECTRIC CRANE Power Unit (12V) (effective 10/11/12) MOTOR (12V) PUMP 1

18 16 IMT 5005i Technical Specifications & Parts Manual # RELIEF VALVE ASSEMBLY RESERVOIR BREATHER - CAP TUBE - SUCTION STRAINER Power Unit (24V) MOTOR (24V) PUMP RELIEF VALVE ASSEMBLY RESERVOIR BREATHER - CAP TUBE - SUCTION STRAINER Boom Assembly WEAR PAD- EXT CYLINDER 6006I WEAR PAD-RND 2.00 DIA X.60 DIA X 1.00 LG WEAR PAD-BLOCK 4.50 X 4.50 X WEAR PAD-BLOCK 4.50 X 3.50 X WEAR PAD-RND 1.00 DIA X.62 DIA X.81L STOP SCREW 3/8-24 X PIN-LOCK W/HANDLE.875 X PIN-.75X 6.50LG WORKSAVER SHEAVE NYLATRON GSM Crane & Winch Assembly CORD REEL ASM- 10 ft (through 06/01/13) CORD REEL ASM- 10 ft (effective 06/01/13) WIRE ROPE ASM-.31 x 80' SPRING-.105WIRE 0.75OD LG WASHER-LOCK 12MM CAP SCR M X 40 SH PLAIN BOLT-EYE # 8-32X SWITCH-LIMIT ZE-N-2S CONNECTOR-.50 STR RLF CONTACTOR-WINCH 12V (through 05/13/13) CONTACTOR-WINCH 12V (effective 05/13/13) 1

19 Chapter 3 Crane Reference 17 Crane Installation ( ) In addition to meeting the minimum chassis specifications noted in the Technical Data section of this manual, make sure there is sufficient room for mounting the crane and the platform is strong enough to support the crane and rated load. Install the crane only on an IMT designed and approved truck body. The body must be designed to sustain the forces imposed by the crane when lifting the full rated load. Install the body on the chassis before installing the crane. Refer to the following table for parts referenced in the following crane installation drawings. CRANE INSTALLATION PARTS LIST ITEM PART # DESCRIPTION KIT # QUANTITY ELECTRIC CRANE BODY INSTALLATION HARDWARE KIT- 3203i/4004i ELEC CRANE BODY 1 INSTALLATION HARDWARE KIT- 5005i ELEC CRANE BODY 1 INSTALLATION KIT ELECTRIC CRANE BODY INSTALLATION DRAWING-CRANE & WINCH ASSEMBLY REF BRACKET-SWITCH 300 AMP ELEC CRANE #1 & # SWITCH-300A KEYED BATTERY DISCONNECT #1 & # LEVEL INDICATOR LEVEL #1 & # TERMINAL-RING NI.38 STUD 1 WIRE #1 & # TERMINAL-RING NI.31 STUD 1-2 WIRE # TERMINAL-RING NI.31 STUD 1-2 WIRE # FUSEHOLDER-HIGH AMP2 BOLT WITH COVER # FUSEHOLDER-HIGH AMP2 BOLT WITH COVER # FUSE-225 AMP # FUSE-225 AMP # CABLE-#1 WELDING #1 & #4 35 FT TUBE-HEAT SHRINK AMP #1 & #4.50 FT CAP SCR X 3.00 HH GR8 Z # NUT HEX NYLOC GR8Z # WASHER 1.00 HI STR ZINC YELLOW # CAP SCREW.25-20X.75 HH GR5 Z #2 & # SCREW-MACHINERY #10-24X.50 RDH #2 & # NUT HEX #2 & # NUT HEX NYLOCK #2 & # WASHER.25 FLAT #2 & #3 8 REV

20 18 IMT 5005i Technical Specifications & Parts Manual # To install the crane: 1 Use a lifting device capable of lifting the weight of the crane as indicated in the Technical Data section of this manual. Attach fabric slings to the crane lower boom, centered approximately 18 inches (46 cm) from the mast hinge. Make certain the crane is well balanced on the slings by slowly lifting approximately 6" (15 cm) off the ground. Lift the crane and apply a bead of waterproof compound, such as silicon based caulk, to the bottom of the base. Move the chassis under the crane and lower the crane into the desired position. Install the 1-8x3" mounting cap screws (item # 15), 1" nuts (item #16) and 1" washers (item #17) to secure the crane base to the truck body (see figure). Torque the cap screws to 680 ft-lb (94 kg-m). NOTE: The 1-8 x 3" grade 8 zinc coated capscrews are designed for a crane box thickness of 7/8" to 1" only. A different crane box may require different capscrews. All mounting capscrews must be grade 8 zinc coated of proper length. Failure to use proper length capscrews could cause the bolts to bottom out before torqued. 5005i i MOUNTING PATTERN 18" 14.75" 7.38" 1.13" (SEE NOTE) 9" 7.38" 14.75" 18" 9" 13" ALLOW 16" (40.6 cm) RADIUS FOR SWING CLEARANCE 16,17

21 Chapter 3 Crane Reference 19 2 The electrical power switch (item #7) provides power for the crane. Install the switch onto the power unit cover KEY SUPPLIED 6 WITH SWITCH. SPARE 2.75" KEY " 13.5" 3.5" 4 HOLES, 0.266" DIA. LOCATION OF SWITCH BRACKET IN CRANE BOX INSIDE VIEW OF CRANE BOX 3 Install the vehicle level indicator (item #8) parallel to the door reinforcements. 4 After mounting your crane, wire the crane to the vehicle's 12VDC electrical system using the following steps. Use the parts list above to identify parts. Your crane installation kit, , includes a 10.7 m (35') long cable, IMT # (item #13 in the parts list). Approximately 7.6 m (25') of this cable is required to connect the crane power switch to the vehicle battery, and the rest of the cable is used for ground connections between the crane, vehicle battery, auxiliary battery, and chassis ground. Cut the cable to length after determining the lengths required. 5 Ground the crane by connecting the crane ground cable to bare metal inside the crane box. 6 Connect the crane power cable from the male power cable connector to the power switch. Connect cable (item # ), cut to length, from the crane power switch (item #7) to the fuse. Use 3/8" (0.95 cm) ring terminals (item # ) for each connection. Heat shrink the connections (item # ). WARNING Protect the power cable from damage by fastening it inside the frame channel and covering it with protective covering including loom, conduit, etc. Be sure to use rubber grommets or other protection when running the power cable through steel bulkheads.

22 20 IMT 5005i Technical Specifications & Parts Manual # POWER CABLE BRACKET A GROUND CABLE (GROUND TO BARE METAL INSIDE CRANE BOX) 7 MALE POWER CABLE CONNECTOR (#13) ON-OFF SWITCH TO FUSE (CUT TO LENGTH) 7 Use approximately 4' (1.2 m) of the cable (item #13) to ground the vehicle battery. Connect one end of the ground cable to the negative terminal on the vehicle battery, and the other end to bare metal on the truck body. Use a 5/16" (0.79 cm) ring terminal (item # ) to connect to the truck body. WARNING Install the ground cable to the negative terminal of the batteries! The crane electrical ground completes the electrical circuit through the structure of the crane to the vehicle frame. The vehicle factory ground is NOT sufficient to carry the current required by the crane. Without this extra ground cable, your crane may not operate at rated capacity, and motor, contactor, or electrical damage may occur. 8 Mount the 225-amp fuse holder (item #11) close to the vehicle battery in a location which can be easily accessed if the fuse needs to be replaced. Repeat with the auxiliary battery. Use approximately one foot (30.5 cm) of cable (item #13) to connect the positive terminal on the vehicle batteries to the fuse holders. Connect the other end of each fuse holder to the bulkhead pass-through connector from step #6, which is then connected to the crane power switch. Cables connect to the fuse holders using 5/16" (0.79 cm) ring terminals (item # ). Heat shrink connections.

23 Chapter 3 Crane Reference CC A AUXILIA RY BATTE RY (IN CRANE BOX) or FUSE TO B ATTE RY (+) (APPROXIM ATE LY 1FT) HE AT SHRINK CABLE # or 27-CABLE # (CUT T O LENGTH) (CRANE ON-OFF SWITCH TO FUSE) or BATTE RY (-) TO CHASSIS GROUND (CUT T O LENGTH) HE AT SHRINK CABLE # or 27-CABLE # (CU T TO APPROX. 1' (30.5 CM)) (FUSE TO B ATTE RY (+)) 11 TO CHASSIS GROUND UNDERHOOD BATTE RY FROM ON-OFF SWITCH IN CRANE BOX 13-CABLE # or 27-CABLE # (CUT T O LENGTH) (CRANE ON-OFF SWITCH TO FUSE) ITEMS WITHIN BOXARE ONLY NEEDED WHENAUXILIARY BATTERY IS INSTALLED IN CRANE BOX. * MATCHED BATTERIESARE REQUIRED* 13-CABLE # or 27-CABLE # (CU T TO LENGTH) NOTES: TO CHASSIS GROUND 1. Use the highest rating cold-cranking amp battery available up to 1,000 CCA. Underhood and auxiliary batteries must be identical. 2. Use bulkhead pass-through connectors when power or ground passes through a compartment wall. (IMT # ) 3. Reference drawing for wiring diagram.

24 22 IMT 5005i Technical Specifications & Parts Manual # Electric Crane Battery Circuit ( ) CRANE SW 1 GROUND AT CHASSIS FRAME 225A 18" (457 mm) MAXIMUM 225A 18" (457 mm) MAXIMUM UNDERHOOD BATTERY GROUND AT CHASSIS FRAME 2ND AUX BATTERY GROUND AT CHASSIS FRAME NOTES (SEE REFERENCE NUMBER IN BOX): 1 ELECTRIC BULKHEAD PASS-THRU CONNECTOR. USE WHENEVER POWER OR GROUND PASSES THROUGH A COMPARTMENT WALL.

25 Chapter 3 Crane Reference 23 Telescopic Crane Orientation When an IMT telescopic crane is not factory-installed on a body, the crane is packed with the boom oriented as it is built on a test stand to facilitate handling. Install the crane on the body with boom pointing backward. Once the crane is bolted down, it can be rotated 180 (3.14 radians) to the boom rest. BOOM REST OUTLINE OF TRUCK BODY 400 ROTATION REAR OF TRUCK Electric Crane Control IMT's electric cranes are controlled by radio or tethered remote controls. This telescopic crane includes a tethered remote control with a radio remote control option. For complete details on operating your telescopic crane, refer to the IMT Electric Cranes Operation & Safety (part number ).

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27 25 C HAPTER 4 Parts In This Chapter Parts Information Electric Crane Power Safety Base & Mast Assembly ( ) Valve Bank ( ) Cylinder, Lower ( ) Boom Assembly ( ) Cylinder, Extension ( ) Crane & Winch Assembly ( ) Winch ( ) Power Unit ( & ) Power Unit ( ) Electrical Installation ( ) Amp Contactor Replacement ( ) Tethered Control Installation ( ) Radio Control Installation, Standard ( ) Radio Control Installation, Proportional ( ) Harness, Radio ( ) Harness, Tethered ( ) Handle Assembly, Tethered ( ) Hydraulic Installation ( ) Decal Installation ( )... 76

28 26 IMT 5005i Technical Specifications & Parts Manual # Parts Information GENERAL This section contains the exploded parts drawings and accompanying parts lists for the assemblies used on this crane. These drawings are intended to be used in conjunction with the instructions found in the maintenance and repair manuals for this crane family. For optional equipment such as winches and remote controls, refer to the appropriate service manual. WARNING Do not attempt to repair any component without reading the information contained in the repair section. Pay particular attention to statements marked Warning, Caution or Note in that section. Failure to comply with these instructions may result in damage to the equipment, personal injury or death. CRANE IDENTIFICATION Every IMT crane has an identification placard (see figure). This placard is attached to the inner boom, mast, or crane base. When ordering parts, communicating warranty information, or referring to the unit in correspondence, always include the serial number and model numbers. Address all inquiries to your authorized IMT distributor or to: Iowa Mold Tooling Co., Inc. Box 189, Garner, IA Telephone: Technical Support Fax: IOWA MOLD TOOLING CO., INC. BOX 189, GARNER, IA MODEL NUMBER SERIAL NUMBER MFG DATE

29 Chapter 4 Parts 27 CYLINDER IDENTIFICATION To insure proper replacement parts are received, it is necessary to specify the complete number/letter sequence for any part requested. Part numbers may be cross checked by comparing the stamped identification on the cylinder case (See figure below) against the information contained in the service manual. You must include the part number stamped on the cylinder case when ordering parts. CYLINDER PART NUMBER LOCATION WELDMENT IDENTIFICATION Each of the major weldments - base, mast, inner boom, outer boom, extension boom and stabilizer weldments bear a stamped part number. Any time a major weldment is replaced, you must specify the complete part number as stamped on the weldment. The locations of the part numbers are shown in the Crane Reference Section. ORDERING REPAIR PARTS When ordering replacement parts: 1 Give the model number of the unit. 2 Give the serial number of the unit. 3 Specify the complete part number. When ordering cylinder parts, or one of the main weldments, always give the stamped part number. 4 Give a complete description of the part. 5 Specify the quantity required.

30 28 IMT 5005i Technical Specifications & Parts Manual # Electric Crane Power Safety Your electric crane runs using power from the vehicle battery. Before beginning major maintenance or repairs, disconnect the power to the crane. DANGER POWER SWITCH TURNED TO OFF POSITION. AVOID DEATH OR SERIOUS INJURY! Before beginning any work on crane, Turn OFF crane power supply in crane cabinet. Remove crane power disconnect cable from vehicle battery. 1 Make sure the power switch located inside the crane cabinet is turned to the OFF position. 2 Make sure the crane power disconnect cable is disconnected from the vehicle battery.

31 Chapter 4 Parts 29 Base & Mast Assembly ( ) (See Parts List for Effectivity) WARNING Avoid injury! Do NOT connect electrical power to crane until all connections have been tested. Attach electrical wires and grounds to components before connecting to mast , ELECTRIC RO TATOR BRACKE T LOC ATION VALVE BANK & POWER UNI T BASE & RO TATOR ASSEMB LY ROTATOR & MAS T ASSEMB LY A LOWER CYLINDER & GEAR SHROUD ASSEMB LY CONTACTOR ASSEMB LY 15 DETAIL A

32 30 IMT 5005i Technical Specifications & Parts Manual # NOTES (SEE REFERENCE NUMBER IN BOX): 1 APPLY BLACK "MOLUB-ALLOY 882 HEAVY" GEAR GREASE TO TURNTABLE GEAR. 2 APPLY RUST PREVENTATIVE. 3 TORQUE TO 160 FT-LB 4 SEE VIEW A. 5 USE THESE TAPPED HOLES FOR ELECTRICAL BRACKET. 6 USE ANTI-SEIZE PARTS LIST ITEM PART # DESCRIPTION KIT # QTY HARDWARE KIT-5005I BASE & MAST ELEC. INSTALLATION KIT- 5005I (WAS THROUGH ) HYDRAULIC KIT-5005I CYLINDER BASE WELDMENT- 5005I (effective from 05/20/13) MAST WELDMENT I (WAS THROUGH ) PIN (effective from 06/05/13) SHROUD- TURNTABLE GEAR (effective through 06/05/13) SPACER- POWER UNIT CLAMP GEAR-TURNTABLE BEARING MOUNTING BRACKET, GREASE HOSE MOTOR-HYDRAULIC VALVE BANK-3 SEC SERIES 500PSI CONTACT JUNCTION NUT HEX # GASKET CAP-GREASE # COUPLING-BLK.12 # ZERK-NPT.12 # CAP SCREW.25-20X.62 HH GR5 Z (effective from 05/20/13) # CAP SCREW.25-20X.75 HH GR5 Z # CAP SCREW.38-16X.62 HH GR5 Z # CAP SCREW.38-16X 2.25 HH GR5 Z # CAP SCREW.50-13X 2.00 HH GR5 Z # CAP SCREW.62-11X 1.00 HH GR5 Z # CAP SCREW.62-11X 3.75 HH GR8 Z # CAP SCREW.62-11X 4.00 HH GR8 Z # NUT HEX NYLOCK # NUT 8-32 HEX NYLOCK (WAS ) # WASHER.25 FLAT # WASHER.25 LOCK # WASHER.38 LOCK # WASHER.50 LOCK # WASHER.62 LOCK # WASHER.62 FLAT ASTM F436 # WASHER.62 N FLAT-CUT 3816 #1 2

33 Chapter 4 Parts PARTS LIST ITEM PART # DESCRIPTION KIT # QTY WASHER.38 W FLAT ANSI B27.2 D # WASHER #10 W FLAT ANSI B27.2Z # SCREW-MACHINERY #8-32 X 1.25 BTNHD ZC (WAS ) # CAP SCREW.25-20X.38 BTNHD ZC # SCREW-MACH #8-32X 1.50 BTNHD ZC (WAS ) # CAP SCREW.50-13X 1.25 SH ZC # CABLE ASSEMBLY- 1GA-3/8RNGX SWVL MX 60.00LG # SWITCH- 275A CONTACTOR (WAS ) CABLE ASSEMBLY - 1GA X 3/8 RNG X SWIVEL 13.5 LONG # CABLE ASSEMBLY-10GA-#10RNGX 1/4RNGX 6.00LG # CABLE ASSEMBLY- 1GA-1/4RNGX 3/8RNGX 46.50LG BLK # HOSE-AA.13 X (2-2) 100R17 # CAP SCREW 3/8-16 X 3/4 HEX HEAD GRADE 5 ZINC # BRACKET-VALVE MOUNT POWER UNIT (effective from 10/11/12) WELDMENT- ELEC ROTATOR BRKT BOTTOM (effective from 05/20/13) WELDMENT- ELEC ROTATOR BRKT TOP (effective from 05/20/13) KEEPER PIN 0.50 (effective from 06/05/13) 1 REV. F

34 32 IMT 5005i Technical Specifications & Parts Manual # Base & Mast Assembly ( ) (See Parts List for Effectivity) WARNING Avoid injury! Do NOT connect electrical power to crane until all connections have been tested. Attach electrical wires and grounds to components before connecting to mast BASE & ROTATOR ASSEMBLY ROTATOR & MAST ASSEMBLY A ELECTRIC ROTATOR BRACKET LOCATION VALVEBANK & POWER UNIT DETAIL A CONTACTOR ASSEMBLY LOWER CYLINDER & GEAR SHROUD ASSEMBLY

35 Chapter 4 Parts 33 NOTES (SEE REFERENCE NUMBER IN BOX): 1 APPLY BLACK "MOLUB-ALLOY 882 HEAVY" GEAR GREASE TO TURNTABLE GEAR. 2 APPLY RUST PREVENTATIVE. 3 TORQUE TO 160 FT-LB 4 SEE VIEW A. 5 USE THESE TAPPED HOLES FOR ELECTRICAL BRACKET. 6 USE ANTI-SEIZE PARTS LIST ITEM PART # DESCRIPTION KIT # QTY HARDWARE KIT-5005I BASE & MAST ELEC. INSTALLATION KIT- 5005I (WAS THROUGH ) HYDRAULIC KIT-5005I CYLINDER BASE WELDMENT- 5005I (effective through 05/20/13) MAST WELDMENT I (WAS THROUGH ) PIN SHROUD- TURNTABLE GEAR (effective through 06/05/13) WELDMENT- ELEC ROTATOR BRKT TOP (effective through 05/20/13) WELDMENT- ELEC ROTATOR BRKT BOTTOM (effective through 1 05/20/13) SPACER- POWER UNIT CLAMP GEAR-TURNTABLE BEARING MOUNTING BRACKET, GREASE HOSE POWER UNIT (effective through 10/11/12) MOTOR-HYDRAULIC VALVE BANK-3 SEC SERIES 500PSI CONTACT JUNCTION NUT HEX # GASKET CAP-GREASE # COUPLING-BLK.12 # ZERK-NPT.12 # CAP SCREW.25-20X.62 HH GR5 Z (effective through 05/20/13) # CAP SCREW.25-20X.75 HH GR5 Z # CAP SCREW.38-16X.62 HH GR5 Z # CAP SCREW.38-16X 2.25 HH GR5 Z # CAP SCREW.50-13X 2.00 HH GR5 Z # CAP SCREW.62-11X 1.00 HH GR5 Z # CAP SCREW.62-11X 3.75 HH GR8 Z # CAP SCREW.62-11X 4.00 HH GR8 Z # NUT HEX NYLOCK # NUT 8-32 HEX NYLOCK (WAS ) # WASHER.25 FLAT # WASHER.50 FLAT (effective through 06/05/13) # WASHER.25 LOCK #1 8

36 34 IMT 5005i Technical Specifications & Parts Manual # PARTS LIST ITEM PART # DESCRIPTION KIT # QTY WASHER.38 LOCK # WASHER.50 LOCK # WASHER.62 LOCK # WASHER.62 FLAT ASTM F436 # WASHER.62 N FLAT-CUT 3816 # WASHER.38 W FLAT ANSI B27.2 D # WASHER #10 W FLAT ANSI B27.2Z # RETAINING RING-EXT 1.50 HD (effective through 06/05/13) # SCREW-MACHINERY #8-32 X 1.25 BTNHD ZC (WAS ) # CAP SCREW.25-20X.38 BTNHD ZC # SCREW-MACH #8-32X 1.50 BTNHD ZC (WAS ) # CAP SCREW.50-13X 1.25 SH ZC # CABLE ASSEMBLY- 1GA-3/8RNGX SWVL MX 60.00LG # SWITCH- 275A CONTACTOR (WAS ) CABLE ASSEMBLY - 1GA X 3/8 RNG X SWIVEL 13.5 LONG # CABLE ASSEMBLY-10GA-#10RNGX 1/4RNGX 6.00LG # CABLE ASSEMBLY- 1GA-1/4RNGX 3/8RNGX 46.50LG BLK # HOSE-AA.13 X (2-2) 100R17 # CAP SCREW 3/8-16 X 3/4 HEX HEAD GRADE 5 ZINC # BRACKET-VALVE MOUNT 1 REV. C

37 Chapter 4 Parts 35 Valve Bank ( ) 2,3(2) 4 2,3(2) 2,3(2) SAE #4 ORB PORT SAE #4 ORB PORT (4 PLACES) 4 SAE #4 ORB PORT 4 4 EXTENSION MAIN ROTATE SAE #4 ORB PORT (2 PLACES) A1 B1 A2 B2 A3 B3 S1 S2 S3 P HYDRAULIC SCHEMATIC T PARTS LIST (12V) ITEM PART # DESCRIPTION QUANTITY 1. MANIFOLD VALVE BODY SOLENOID VALVE (INCLUDES COIL) COIL, 12V PLUG, EXPANDER, 7MM 7 REV A PARTS LIST (24V) ITEM PART # DESCRIPTION QUANTITY 1. MANIFOLD VALVE BODY SOLENOID VALVE (24V) COIL (24V) 6 4. PLUG, EXPANDER, 7MM 7 REV A

38 36 IMT 5005i Technical Specifications & Parts Manual # Cylinder, Lower ( ) A " CLOSED " OPEN " STROKE DRILL #15 HOLE 3/16" DEEP. PRESS IN PIN A SECTION A-A NOTES: 1 TO REDUCE DOWNTIME, REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS DISASSEMBLED. 2 APPLY "NEVER-SEEZ" REGULAR GRADE ANTI-SEIZE AND LUBRICATING COMPOUND TO THREADS ON CYLINDER HEAD ONLY. KEEP AWAY FROM ALL SEALS. 3 APPLY "LUBRIPLATE" NO MEDIUM HEAVY, MULTI-PURPOSE LUBRICANT, TO ALL PISTON, HEAD GLAND, AND HOLDING VALVE SEALS, NYLON LOCK RING, CAST IRON PISTON RINGS, AND ROD STINGER THREADS. 4 ITEM #8, STOP TUBE, REPLACES 6A WAFER LOCK. USE STOP TUBE INSTEAD OF WAFER LOCK WHEN RESEALING CYLINDER CYLINDER DATA CASE ø4.5" O.D. X ø4.0" BORE X 28.53" LENGTH ROD ø2.25" X 31.2" LONG STROKE 21.43" DRY WEIGHT 93.6 LB TEST PRESSURE 3000 PSI OPERATING PRESSURE TORQUES 2500 PSI PISTON TO ROD: FT-LB HEAD GLAND TO CYLINDER: 400 FT-LB\ CARTRIDGE: FT-LB PARTS LIST ITEM PART # DESCRIPTION KIT # QUANTITY 1. 9D SEAL KIT-IMT 4.00B 2.25R 1.44S # ROD ASM-2.25 DIA X LG 1.44 S 1.50 # CASE ASM-4.00 BORE X LG # HD40022 HEAD-4.00 BORE X 2.25 ROD (DUCTILE IRON) # ID40143 PISTON-4.00 BORE X 1.44 STGR (DUCT IRON) # STOP TUBE ROD X.78 LONG # PIN - LOCK TUBE 0.19 OD X WALL # STOP TUBE (WAS 6A025022) # Q O-RING X # Q O-RING X # Q10P342 BACK-UP RING 3.62 BORE 4 O.D THK # R14P022 ROD WIPER-TYPE D 2.25 ROD #1 1

39 Chapter 4 Parts PARTS LIST ITEM PART # DESCRIPTION KIT # QUANTITY 13. 7R U-CUP LOADED 2.25X2.75X.38 "B # T2N4040 WEAR RING - PISTON 4.00 O.D. X.50 W # T2NX625 WEAR RING-ROD 2.25 IDX0.75 # T61N143 LOCK RING-NYLON 1.43 # T66P040 PISTON SEAL DYNAMIC 4.00" # PRESSURE SWTICH 2750 PSI A CYL-4.0/ S 33.45CC C VALVE-COUNTERBALANCE #3 1 REV. D

40 38 IMT 5005i Technical Specifications & Parts Manual # Boom Assembly ( ) BOOM ASSEMBLY, 1H 1M ( ) BOOM EXTENSIONS (1H 1M) (COMPLETE)

41 Chapter 4 Parts 39 BOOM ASSEMBLY, 1H ( ) BOOM EXTENSIONS (1H) (COMPLETE) PARTS LIST 12 ITEM PART # DESCRIPTION KIT # QUANTITY HARDWARE KIT-BOOM 5005I CYLINDER LOWER BOOM WELDMENT I 1 (through 05/13/ LOWER BOOM WELDMENT I 1 (effective 05/13/13) WELDMENT- EXTENSION 1ST STAGE 5005I 1

42 40 IMT 5005i Technical Specifications & Parts Manual # PARTS LIST ITEM PART # DESCRIPTION KIT # QUANTITY WELDMENT- EXTENSION 1ST STAGE 5005I WELDMENT- 2ND STAGE EXTENSION 5005I SHEAVE NYLATRON (PART OF 6) 2REF PIN-TYPE M 1.50X WEAR PAD- EXT CYLINDER 6006I WEAR PAD-RND 2.00 DIA X.60 DIA X 1.00 LG WEAR PAD-BLOCK 4.50 X 4.50 X WEAR PAD-BLOCK 4.50 X 3.50 X WEAR PAD-RND 1.00 DIA X.62 DIA X.81L STOP SCREW 3/8-24 X PLATE-ANGLE PLASTIC WASHER.52ID X 2.00OD X 10GA PIN-LOCK W/HANDLE.875 X HAIR PIN.16 DIA SHAFT (PART OF REF ) PIN-.75X 6.50LG HAIR PIN.19 DIA SHAFT (PART OF REF ) CAP-GREASE # ZERK-STR THD # CAP SCREW.25-20X 3.25 HH GR5 Z # CAP SCREW.50-13X 1.25 HH GR5 Z # CAP SCREW.50-13X 2.25 HH GR5 Z # NUT HEX NYLOCK # NUT HEX NYLOCK # WASHER.25 FLAT # WASHER.38 FLAT # WASHER.50 FLAT # WASHER.50 LOCK # WASHER-LOCK.38 ZINC #1 2 REV. B

43 Chapter 4 Parts 41 Cylinder, Extension ( ) DRILL #15 HOLE, 3/16" DEEP. PRESS IN PIN " CLOSED " OPEN " STROKE

44 42 IMT 5005i Technical Specifications & Parts Manual # NOTES: 1 TO REDUCE DOWNTIME, REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS DISASSEMBLED. 2 APPLY "NEVER-SEEZ" REGULAR GRADE ANTI-SEIZE AND LUBRICATING COMPOUND TO THREADS ON CYLINDER HEAD ONLY. KEEP AWAY FROM ALL SEALS. 3 APPLY "LUBRIPLATE" NO MEDIUM HEAVY, MULTI-PURPOSE LUBRICANT, TO ALL PISTON, HEAD GLAND, AND HOLDING VALVE SEALS, NYLON LOCK RING, CAST IRON PISTON RINGS, AND ROD STINGER THREADS. 4 ITEM #10, STOP TUBE, REPLACES 6A WAFER LOCK. USE STOP TUBE INSTEAD OF WAFER LOCK WHEN RESEALING CYLINDER CYLINDER DATA CASE ø3" O.D. X ø2.5" BORE X 81.26" LENGTH ROD ø1.5" X 82.69" LONG STROKE 72" DRY WEIGHT LB TORQUES PISTON: 250 FT-LB HEAD: FT-LB CARTRIDGE: FT-LB CAP SCREW: 16 FT-LB TEST PRESSURE 3000 PSI OPERATING PRESSURE 2500 PSI PARTS LIST ITEM PART # DESCRIPTION KIT # QUANTITY IMT SEAL KIT-2.50 B X 1.50 R 1.25 STGR ROD ASM-1.50 DIA X LG 1.25 S CASE ASM-2.50 BORE X LG HD25015 HEAD-2.50 BORE X 1.50 ROD (DUCTILE IRON) STOP TUBE-1.50 ROD X 3.56LG 4 HOLE PISTON-2.50 BORE X 1.25 STGR COLLAR-LOCK 1-1/4-12 X X 1/ VALVE-CBAL PIN - LOCK TUBE 0.19 OD X WALL # STOP TUBE (WAS 6A025015) # Q O RING 1.25X 1.50X # Q O RING 2.25X 2.50X # Q10P228 BACKUP RING-2.25 ID X 2.50 OD # R14P015 ROD WIPER TYPE D 1.50 ROD # R U-CUP 1.50 ID X 2.00 OD # T2N4025 WEAR RING-PISTON 2.50 ODX.50W # T2NX417 WEAR RING-ROD 1.50 IDX0.50W # T66P250 PISTON SEAL-DYNAMIC #1 1 REV B

45 Chapter 4 Parts 43 Crane & Winch Assembly ( ) (See Parts List for Effectivity) WINCH & BOOM ASSEMBLY ( ) A B DETAIL B , , DE TAI L A NOTES (SEE REFERENCE NUMBER IN BOX): 1 CONNECT THE WIRE TERMINALS ( ) TO COMMON AND NORMALLY OPEN ON ATB SWITCH.

46 44 IMT 5005i Technical Specifications & Parts Manual # CRANE ASSEMBLY ( ) , 39, 28 36, 39, , 39, 36 28, 39, 36 NOTES (SEE REFERENCE NUMBER IN BOX): 1 USE ANTI-SEEZ ON PINS. 2 KEEP ALL ELECTRICAL GROUNDS FREE OF PAINT, GREASE, AND OIL. 3 IF REQUIRED, USE MACHINERY BUSHINGS BETWEEN MAST AND BOOM WHEN INSTALLING PIN

47 Chapter 4 Parts 45 SINGLE & DOUBLE LINE VIEWS ( ) PARTS LIST ITEM PART # DESCRIPTION KIT # QTY MAST ASSEMBLY-5005I REF BOOM ASSEMBLY 5005I-6006i REF KIT-HARDWARE CRANE & WINCH 6006I CORD REEL ASSEMBLY- 10' W/PACKARD CONNECTOR 1 (effective from 06/01/13) WELDMENT- SNATCH BLOCK PIN (effective from 06/05/13) PIN (effective from 06/05/13) WELDMENT-ATB TRIP MECHANISM 5005i/6006i 1 (effective from 09/01/13) COVER-VALVE BANK PLATE-SINGLE SHEAVE COVER-CONTACTOR (5005i-6006i) SUPPORT PIN HAIR PIN (PART OF ) #13 1

48 46 IMT 5005i Technical Specifications & Parts Manual # PARTS LIST ITEM PART # DESCRIPTION KIT # QTY COLLAR-SHAFT 2 PIECE 11/16 IN WIRE ROPE ASSEMBLY-.31(6X19 IWRC)X 80' RRL HOOK-SWIVEL W/LATCH LATCH, REPLACEMENT (PART OF 14) WINCH-DC V CONTACTOR-WINCH 12V (effective from 05/13/13) CLAMP-PLASTIC 1/4" CABLE PIN-QUICK SWITCH-LIMIT CONNECTOR-.50 STR RLF GROUND STRAP- 12IN CAP-GREASE # SPRING-.105WIRE 0.75OD LG # ZERK-NPT.12 # CAP SCREW.25-20X.50 HH GR5 Z (effective through 04/03/13) # CAP SCREW.25-20X 1.75 HH GR5 Z # CAP SCREW.44-14X 5.50 HH GR5 Z # CAP SCREW.50-13X 1.00 HH GR5 Z # NUT # 8-32 HEX ZINC # NUT HEX NYLOCK # NUT HEX NYLOCK # NUT 8-32 HEX NYLOCK # WASHER.25 FLAT (WAS 8) (effective from 04/03/13) # WASHER.44 FLAT # WASHER.25 LOCK (WAS 8) # WASHER.50 LOCK # WASHER # 8 W FLAT ANSI B27.2Z (effective from 05/13/13) # WASHER-LOCK 12MM # CAP SCREW M X40 SH PLAIN # BOLT-EYE # 8-32X.75 # CAP SCREW.25-20X.38 BTNHD ZC (effective from 05/13/13) # TERM-SPRSPADE I #8 STUD # CAP SCR X 0.88 HH GR5 (effective from 06/01/13) # NUT HEX NYLOCK (effective from 06/01/13) # SCR-MACH #8-32 X 0.62 BTNHD (effective from 05/13/13) # WASHER #8 LOCK (effective from 05/13/13) # COVER WITHOUT SOCKET BRKT-CORD REEL MNT 3203I (effective from 05/13/13) WLDMNT-WINCH CONTACTOR BRKT (effective from 05/13/13) KEEPER-PIN 0.50 (effective from 05/05/13) 2 REV N

49 Chapter 4 Parts 47 Crane & Winch Assembly ( ) (See Parts List for Effectivity) WINCH & BOOM ASSEMBLY ( ) A B DETAIL B ,43 34,43 26 DETAIL A NOTES (SEE REFERENCE NUMBER IN BOX): 1 CONNECT THE WIRE TERMINALS ( ) TO COMMON AND NORMALLY OPEN ON ATB SWITCH.

50 48 IMT 5005i Technical Specifications & Parts Manual # CRANE ASSEMBLY ( ) 44 30, 38, , 38, ,38,41 29,38,41 NOTES (SEE REFERENCE NUMBER IN BOX): 1 USE ANTI-SEEZ ON PINS. 2 KEEP ALL ELECTRICAL GROUNDS FREE OF PAINT, GREASE, AND OIL. 3 IF REQUIRED, USE MACHINERY BUSHINGS BETWEEN MAST AND BOOM WHEN INSTALLING PIN

51 Chapter 4 Parts 49 SINGLE & DOUBLE LINE VIEWS ( ) DOUBLE LINE SINGLE LINE PARTS LIST ITEM PART # DESCRIPTION KIT # QTY MAST ASSEMBLY-5005I REF BOOM ASSEMBLY 5005I-6006i REF KIT-HARDWARE CRANE & WINCH 6006I CORD REEL ASSEMBLY- 10' W/PACKARD CONNECTOR (effective 1 through 06/01/13) WELDMENT- SNATCH BLOCK PIN (effective through 06/05/13) PIN (effective through 06/05/13) WELDMENT-ATB TRIP MECHANISM 5005i/6006i (effective through 1 09/01/13) COVER-VALVE BANK PLATE-SINGLE SHEAVE COVER-CONTACTOR (5005i-6006i) SUPPORT 2

52 50 IMT 5005i Technical Specifications & Parts Manual # PARTS LIST ITEM PART # DESCRIPTION KIT # QTY PIN HAIR PIN (PART OF ) # COLLAR-SHAFT 2 PIECE 11/16 IN WIRE ROPE ASSEMBLY-.31(6X19 IWRC)X 80' RRL HOOK-SWIVEL W/LATCH LATCH, REPLACEMENT (PART OF 14) WINCH-DC V CONTACTOR-WINCH 12V (effective through 05/13/13) CLAMP-PLASTIC 1/4" CABLE PIN-QUICK SWITCH-LIMIT CONNECTOR-.50 STR RLF GROUND STRAP- 12IN CAP-GREASE # SPRING-.105WIRE 0.75OD LG # ZERK-NPT.12 # CAP SCREW.25-20X.50 HH GR5 Z (effective through 04/03/13) # CAP SCREW X.75 HHGR5Z (effective through 06/20/13) # CAP SCREW.25-20X 1.00 HH GR5 Z (effective through 05/20/13) # CAP SCREW.25-20X 1.75 HH GR5 Z # CAP SCREW.44-14X 5.50 HH GR5 Z # CAP SCREW.50-13X 1.00 HH GR5 Z # NUT # 8-32 HEX ZINC # NUT HEX NYLOCK # NUT HEX NYLOCK # NUT 8-32 HEX NYLOCK # WASHER.25 FLAT (WAS 8) (effective through 04/03/13) # WASHER.44 FLAT # WASHER.50 FLAT (effective through 06/05/13) # WASHER.25 LOCK (WAS 8) # WASHER.50 LOCK # WASHER # 8 W FLAT ANSI B27.2Z (effective through 05/13/13) # RETAINING RING-EXT 1.50 HD (effective through 06/05/13) # WASHER-LOCK 12MM # CAP SCREW M X40 SH PLAIN # BOLT-EYE # 8-32X.75 # CAP SCREW.25-20X.38 BTNHD ZC (effective through 05/13/13) # TERM-SPRSPADE I #8 STUD # COVER WITHOUT SOCKET 1 REV G

53 Chapter 4 Parts 51 Winch ( ) ELECTRIC THERMAL SWITCH SPACER BEARING PLATE, SPACER CAPSCREW ELECTRIC MOTOR, 12VDC NYL WASHER SEAL BUSHING BRAKE DRIVER SCREW HOSE CLAMP CABLE BRAKE ASM PLUG DRUM ASM SEAL DRUM SUPPORT NYL WASHER BRAKE DRIVER BEARING TOL RING CLUTCH RETAINER BUSHING OIL SEAL RET. RING DRUM DUST MASK MOTOR SHAFT HEX SPACER SHAFT CARRIER ASM RING CARRIER GEAR ASM DRUM SUPPORT PLATE, SPACER CAPSCREW GASKET REPLACEMENT PARTS: CONTACTOR - IMT # BRAKE ASM - IMT # MOTOR - IMT # SCREW PLATE, SPACER CAPSCREW CLUTCH RING GEAR CARRIER ASM THRUST PLATE LABEL GEAR HOUSING ASM NOTE: For 24V systems use

54 52 IMT 5005i Technical Specifications & Parts Manual # Power Unit ( V & V) (Effective 10/11/12) NOTE: Pump pressure relief valve setting = 2500 psi (172 bar) (12V) & (24V) PARTS LIST ITEM PART # DESCRIPTION KIT # QUANTITY MOTOR 12VDC A/R MOTOR 24VDC A/R PUMP RELIEF VALVE ASSEMBLY RESERVOIR BREATHER CAP TUBE-SUCTION STRAINER 1 NEW

55 Chapter 4 Parts 53 Power Unit ( )(Through 10/11/12) FAN SHROUD BREATHER CAP ( ) RESERVOIR ( ) D.C. MOTOR ( ) (12 VDC) RELIEF VALVE ( ) ADAPTOR RETURN LINE PIPE, RELIEF VALVE D.C. MOTOR ( ) (12 VDC) MOTOR SECTION GEAR PUMP ( ) RETURN LINE PIPE SUCTION LINE PIPE ADAPTER / RESERVOIR SECTION TUBE KIT ( ) (SUCTION & RETURN LINE PIPES) NOTE: Pump pressure relief valve setting = 2500 psi (172 bar)

56 54 IMT 5005i Technical Specifications & Parts Manual # Electrical Installation ( )(See Parts List for Effectivity) A ELECTRIC ROTATOR BRACKET (BOTTOM) 11 TO BOOM GROUND AS VIEWED FROM REAR WIRE HARNESS (WINCH DOWN) GROUND CABLES ROUTED TO OUTSIDE OF MAST WIRE HARNESS (WINCH UP) 13 TO CRANE BOX CRANE BASE 2 18 TO 300 AMP KEYED SWITCH IN CRANE BOX DETAIL A TORQUE TO 8-15 FT-LBS 10 WIRE HARNESS (RADIO CONTROL) WIRE HARNESS (TETHERED CONTROL)