Model 8000L Material Handling Crane

Transcription

1 L: : Model 8000L Material Handling 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: TECHNICAL SUPPORT FAX: MANUAL PART NUMBER Iowa Mold Tooling Co., Inc. is an Oshkosh Corporation company.

2 L: : REVISIONS LIST DATE LOCATION DESCRIPTION OF CHANGE ,8 LOOM ID INCREASED FROM 1/2 TO 5/ ,8 # WAS ECN HOSE ROUTING CHANGE TO , 3-3 NEW OWNERSHIP STATEMENT; UPDATED SERIAL TAG LOCATION INFO. 3-6 ECN UPDATE TO THROUGHOUT ECN UPDATED STABILIZER WORDING, ADDED LEVEL, STAB DECAL

3 L: : 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. 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 L: : NOTES

5 L: : SECTION 1. SPECIFICATIONS 8000L MATERIAL HANDLING CRANE PERFORMANCE CHARACTERISTICS... 3 POWER SOURCE... 3 SPECIFICATIONS... 3 CYLINDER HOLDING VALVES... 4 ROTATION SYSTEM... 4 HYDRAULIC SYSTEM... 4 OPERATOR S STATION... 4 MINIMUM CHASSIS SPECIFICATIONS... 4 RECOMMENDED CHASSIS SPECIFICATIONS... 4 GEOMETRIC CONFIGURATION L / 25 BOOM... 5 GEOMETRIC CONFIGURATION L / 21 BOOM... 6 STABILIZER DIMENSIONS... 7 CAPACITY CHART-8000L CRANE... 8

6 L: : NOTES

7 L: : SPECIFICATIONS 8000L MATERIAL HANDLING CRANE GENERAL 25' BOOM 21' BOOM CRANE RATING 80,000 ft-lbs (11.06 ton-m) 80,000 ft-lbs (11.06 ton-m) HORIZONTAL REACH 25'-0' (7.62m) 21'-0" (6.40m) (from centerline of rotation) * LIFTING HEIGHT 33'-8' (10.26m) 29'-10" (9.09m) (from mounting surface) CRANE WEIGHT 6350 lbs (2880 kg) 6030 lbs (2735 kg) (less grapple) ** STABILIZER SPAN AT GROUND LEVEL 9'-4' (2.84m) 9'-4" (2.84m) MAXIMUM 10'-6' (3.20m) 10'-6" (3.20m) STABILIZER PADS 12' X 21' (30.5x53.3cm) 12" X 21" (30.5x53.3cm) ** CRANE STORAGE HEIGHT 13'-3' (4.04m) 13'-3" (4.04m) MOUNTING SPACE REQUIRED 28" (71.1cm) 28" (71.1cm) OPTIMUM PUMP CAPACITY (tandem) 15/25 gpm (56.8/94.6 lpm) 15/25 gpm (56.8/94.6 lpm) SYSTEM OPERATING PRESSURE 3000 psi (207 bar) 3000 psi (207 bar) OIL RESERVOIR CAPACITY 49 Gallons (185 liters) 49 Gallons (185 liters) ROTATIONAL TORQUE 16,000 ft-lbs (2.21 ton-m) 16,000 ft-lbs (2.21 ton-m) HORIZ. HOOK APPROACH 4'-0' (1.22m) 3'-9" (1.14m) (from centerline of rotation) * VERT. HOOK APPROACH 11'-2' (3.40m) 12'-2" (3.71m) (from mounting surface) * Add frame height of 40' (1.02m) for dimension from ground level. ** Using 40" (1.02m) frame height. PERFORMANCE CHARACTERISTICS The hydraulic system is designed to allow simultaneous, full speed operation of the inner and outer cylinders and crane rotation. Simultaneous operation of other functions alone or with these three functions depends on the operator s ability to feather the controls. Optimum pump flows are 15 GPM (56.8 lpm) to the inner valve bank and 25 GPM (94.6 lpm) to the outer/swing valve bank. At these flows, the inner and outer cylinders will both extend in 15 seconds and crane rotation will be 3 RPM. POWER SOURCE Integral-mounted tandem hydraulic pump and PTO application. Other standard power sources may be utilized for non-truck mounted applications. IOWA MOLD TOOLING CO., INC. BOX 189, GARNER, IA TEL: FAX:

8 L: : CYLINDER HOLDING VALVES The holding sides of all cylinders are equipped with integral-mounted holding or counter-balance valves to prevent sudden cylinder collapse in the case of hose or other hydraulic system failure. The stabilizer cylinders have positive, pilot-operated holding valves that open only on command. The inner, outer and extension boom cylinders have pilot operated counter-balance valves. The counter-balance valve serves several functions. First, it is a holding valve. Secondly, it is so constructed that it will control the lowering function and allow that motion to be feathered while under load. Finally, if a hose breaks, the only oil loss will be that in the hose. ROTATION SYSTEM Rotation of the crane is accomplished through a turntable bearing, powered by a high torque hydraulic motor through a heavy-duty gear box equipped with a heat treated pinion. The pinion runs on the external gear teeth of the turntable bearing to accomplish the rotation function. Limited 650 rotation is standard. Consult factory for 360 continuous rotation. A spring applied, hydraulic release rotation brake provides positive stopping and starting of the rotation process. HYDRAULIC SYSTEM The hydraulic system is a combination of open center and pressure compensated systems. There are two, 4-section control valves. One is open center and the other is a closed center, pressure compensated valve featuring an unloader system to allow the use of a tandem, fixed displacement pump. System pressure is 3000 PSI (207 bar) and requires a tandem pump rated at 3000 PSI (207 bar) and developing 15/25 GPM (56.8/94.6 lpm) flows. The two control valves are located at the top (mastmounted) control station and feature integral, manual joystick handles. The system includes a hydraulic oil reservoir with suction line strainer and air breather, return line filters, two 4-section control valves and all hoses and plumbing. OPERATOR S STATION Crane controls are located on a rotating platform attached to the side of the mast of the standard unit. This platform is accessible from both sides of the crane by the standard dual ladders. MINIMUM CHASSIS SPECIFICATIONS BODY STYLE Conventional Cab Conventional Cab WHEELBASE 213" 541cm CAB-TO-AXLE 144" 366cm FRAME SECTION MODULUS 22 cubic inches 360cc RBM 1,100,000 in-lbs 12,674 kg-m FRONT AXLE RATING 9000 lbs 4083 kg REAR AXLE RATING lbs 8165 kg TRANSMISSION 5-speed manual 5-speed manual RECOMMENDED CHASSIS SPECIFICATIONS BODY STYLE Conventional Cab Conventional Cab WHEELBASE 234" 595cm CAB-TO-AXLE 156" 396cm FRAME SECTION MODULUS 22 cubic inches 360cc RBM 1,100,000 in-lbs 12,674 kg-m FRONT AXLE RATING lbs 5443 kg REAR AXLE RATING lbs 9072 kg TRANSMISSION 5-speed manual 5-speed manual NOTE: The addition of counter-weight/sub-frame/auxiliary stabilizers to the chassis may be required to achieve and maintain full 360 stability for certain applications. In addition to these specifications, heavy-duty electrical and cooling systems and dual rear wheels are required. It is recommended that the vehicle be equipped with an electric engine tachometer, auxiliary brake lock, and power steering. IMT reserves the right to change specifications and design without notice.

9 L: : GEOMETRIC CONFIGURATION L / 25 BOOM

10 L: : GEOMETRIC CONFIGURATION L / 21 BOOM

11 L: : STABILIZER DIMENSIONS RAILROAD TIE 98

12 L: : CAPACITY CHART-8000L CRANE Loads shown are based on crane structural or hydraulic capability. Before lift is made, stability must be checked per SAE J765A. Working loads will be limited to those shown. Deduct the weight of load handling devices. 25-FOOT BOOM 21-FOOT BOOM OPERATION ABOVE THIS LEVEL IS NOT RECOMMENDED LIFTING HEIGHT (FEET) FRAME HT DISTANCE FROM CENTERLINE OF ROTATION (FEET)

13 L: : SECTION 2. REFERENCE 8000L MATERIAL HANDLING CRANE MAJOR CRANE ASSEMBLIES... 3 GREASE ZERK LOCATIONS & LUBRICANT REQUIREMENTS... 4 RECOMMENDED SPARE PARTS LIST... 5 JOYSTICK CONTROLS... 7 PRECAUTIONS... 8

14 L: : NOTES

15 L: : MAJOR CRANE ASSEMBLIES

16 L: : GREASE ZERK LOCATIONS & LUBRICANT REQUIREMENTS ITEM LOCATION DESCRIPTION LUBRICANT FREQUENCY 1. FOOT PEDAL 1A. LINKAGE 2. BELLCRANK 3. TURNTABLE/BEARING GREASE EXTENSION *ROTATE CRANE WHILE GREASING 4. INNER CYLINDER BASE 5. MAST/INNER BOOM HINGE PIN 6. INNER CYLINDER ROD 7. OUTER CYLINDER BASE 8. OUTER CYLINDER ROD 9. INNER BOOM/OUTER BOOM HINGE PIN 10. GRAPPLE SWIVEL 11. GRAPPLE CYLINDER ROD & BASE 12. GRAPPLE HEAD 13. GRAPPLE JAW HINGES 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 L: : RECOMMENDED SPARE PARTS LIST 1 YEAR SUPPLY 8000L 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 3B ITEM NO. PART NO. DESCRIPTION QTY STABILIZER CYLINDER 5 9B SEAL KIT 2 W MAST ASM-650 ROTATION GEAR BEARING 1 W MAST ASM-650 ROTATION MOTOR 1 W C BAL VALVE 1 C PINION GEAR 1 W MAST ASM-CONTINUOUS ROTATION GEAR BEARING 1 W MAST ASM-CONTINUOUS ROTATION MOTOR 1 W C BAL VALVE 1 C PINION GEAR 1 W 3C INNER BOOM CYLINDER BALL BUSHING 2 W 7 9C SEAL KIT 2 W C BAL VALVE 1 C OUTER & EXTENSION BOOM ASSEMBLY SLIDE BUSHING 1 W SLIDE BUSHING 1 W 3C B CODE OUTER BOOM CYLINDER BALL BUSHING 2 W 7 9C SEAL KIT 2 W C BAL VALVE 1 C EXTENSION BOOM CYLINDER 6 9C SEAL KIT 1 W C BAL VALVE 25GPM 2 C HYDRAULIC KIT-7 FUNCTION ROTATION VELOCITY FUSE 2 W CHECK VALVE 2 W HYDRAULIC KIT-8 FUNCTION ROTATION VELOCITY FUSE 2 W CHECK VALVE 2 W HYDRAULIC KIT-7 FUNCTION-21 -CONTINUOUS ROTATION VELOCITY FUSE 2 W CHECK VALVE 2 W HYDRAULIC KIT-8 FUNCTION-25 -CONTINUOUS ROTATION VELOCITY FUSE 2 W CHECK VALVE 2 W INSTALLATION KIT - FRONT MOUNT SCREEN 100 MESH 1 W RETURN FILTER ELEMENT 4 P SHELF LIFE (MO) ORDER QTY

18 L: : NOTES

19 L: : JOYSTICK CONTROLS CAUTION BEFORE OPERATING THE CRANE, THE OPERATOR MUST FAMILIARIZE HIMSELF WITH ALL CONTROLS. 1. LEFT JOY-STICK PULL BACK TO RAISE INNER BOOM PUSH FORWARD TO LOWER INNER BOOM PUSH LEFT TO OPEN GRAPPLE PUSH RIGHT TO CLOSE GRAPPLE 2. RIGHT JOY-STICK PULL BACK TO RAISE OUTER BOOM PUSH FORWARD TO LOWER OUTER BOOM PUSH LEFT TO ROTATE GRAPPLE COUNTERCLOCKWISE PUSH RIGHT TO ROTATE GRAPPLE CLOCKWISE 3. LEFT LEVER PUSH DOWN TO LOWER LEFT R PULL UP TO RAISE LEFT R 4. RIGHT LEVER PUSH DOWN TO LOWER RIGHT R PULL UP TO RAISE RIGHT R 5. FOOT PEDAL PUSH DOWN WITH LEFT FOOT TO SWING LEFT PUSH DOWN WITH RIGHT FOOT TO SWING RIGHT 6. RIGHT FWD LEVER PUSH FORWARD TO EXTEND EXTENSION BOOM (OPTIONAL) PULL BACK TO RETRACT EXTENSION BOOM (OPTIONAL)

20 L: : OPERATION PRECAUTIONS PRECAUTIONS MAINTENANCE PRECAUTIONS 1. Read and Understand the IMT Crane Safety Manual. 2. Beware of overhead electrical lines. 3. Apply truck brakes and block the wheels when operating. 4. Extend both stabilizers. Use wood blocking on slippery surfaces. Soft or unstable footing can pose hazards. The crane should be operated on as level a plane as possible. 5. Operate the crane slowly at first, especially when swinging the booms. Plan each movement in advance, allowing time to slow down the swing before reversing direction. Use a feathering or inching technique to give a smooth working cycle. This is accomplished by moving the controls slowly into a partial open position. As the operator becomes more experienced he can move the controls into the full open position. Avoid quick, jerking movements. 6. Always lift your load so you have maximum stability by knuckling in simultaneously while lifting up. 7. During operations, periodically check stabilizers for adequate crane stability. 8. Do not pick up more material than the grapple attachment rating recommends. 9. Never allow riders on the crane. 10. Never allow people to be under or near the load or raised boom. 11. Never move the truck while the operator is on the crane. 12. Never leave a live load unattended. Always disengage the PTO. 13. Always lower the grapple to the ground or truck bed before leaving the operator s platform during and after loading. WARNING Be alert to unusual sounds and vibrations. The cyclic nature of the loading on the mounting bolts of the rotation bearing gives rise to the possibility of their working loose or to inelastic deformation of the threads and other stressed surfaces. Bolts should be checked periodically. Retighten to ft-lbs (maximum) torque on the 3/4-10 grade 8 socket head cap screws. 1. HYDRAULIC SYSTEM - The most important factor in the operation and maintenance of the hydraulic system is cleanliness. This begins with flushing of the hydraulic system whenever a considerable amount of maintenance work has been performed that might introduce dirt, metal chips or any other foreign material into the system. When maintenance is performed on any hydraulic component, the parts should be cleaned thoroughly and lubricated with clean hydraulic oil before assembly. This is done to clean off any dirt which might be sticking to the part and also to provide a layer of lubricant to avoid metal to metal contact when the equipment is placed into operation. 2. WELDING - When performing electric welding on the crane, attach the ground to the assembly being welded. If the welding arc is grounded through any of the bearings which connect the assemblies, the bearings are likely to become damaged as a result of arcing. 3. GEAR REDUCTION BOX - Oil should be changed after the first 50 hours of use and at 500 hour intervals thereafter. Unit requires 4.5 pints of EP 80/90 gear oil. Output shaft bearings have grease fittings which should be greased sparingly every 50 hours of operation. 4. GENERAL - It is recommended that all mechanical parts and hydraulic components be checked regularly to avoid the possibility of injury or downtime as a result of loose bolts and pins, damaged hydraulic lines, or partial failure of any part. 14. Always fully retract the stabilizers before moving.

21 L: : SECTION 3. REPLACEMENT PARTS 8000L MATERIAL HANDLING CRANE PARTS INFORMATION... 3 STEM ASM ( )... 4 STABILIZER CYLINDER (3B025920)... 5 MAST ASM-650 ROT N ( )... 6 MAST ASM-650 ROT N ( )... 7 MAST ASM-CONT ROT N ( )... 8 MAST ASM-CONT ROT N ( )... 9 ROTATION BRAKE ( ) INNER BOOM ASM-21 ( ) INNER BOOM ASM-25 ( ) INNER BOOM CYLINDER (3C152980) OUTER BOOM ASM-21 ( ) OUTER BOOM ASM-20 ( ) OUTER & EXT BOOM ASM-25 ( ) OUTER BOOM CYLINDER (3C092950) EXTENSION BOOM CYLINDER (3B275960) CONTROL KIT-8F 25 ( ) VALVEBANK ASM 5-SECT RH ( ) VALVEBANK ASM 4-SECT LH 21 ( ) VALVEBANK ASM 4-SECT LH 25 ( ) HYDRAULIC KIT-7F ROT N ( ) HYDRAULIC KIT-8F ROT N ( ) HYDRAULIC KIT-7F-21 CONT ROT N ( ) HYDRAULIC KIT-8F-25 CONT ROT N ( ) INSTALLATION KIT-FRONT MNT ( ) DECAL KIT-21 ( ) DECAL KIT-25 ( ) GRAPPLE MTG KIT-NON DAMPENED-S&L ( ) GRAPPLE MTG KIT-DAMPENED-S&L ( ) GRAPPLE MTG KIT- NON DAMPENED-S&L ( )... 31

22 L: : NOTES

23 L: : 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 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 IN VOLUME 1. PAY PARTICULAR ATTENTION TO STATEMENTS MARKED WARNING, CAUTION, OR NOTE IN THAT SECTION. FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN DAMAGE TO THE EQUIPMENT, PERSONAL INJURY, OR DEATH. CRANE IDENTIFICATION Every IMT crane has an identification placard (see figure) 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. All inquiries should be addressed to: Iowa Mold Tooling Co., Inc. Box 189, Garner, IA Telephone: Technical Support Fax: PARTS INFORMATION CYLINDER IDENTIFICATION To insure proper replacement parts are received, it is necessary to specify the complete number/letter sequence for any part requested. Part numbers may be cross checked by comparing the stamped identification on the cylinder case (See figure below) against the information contained in the service manual. You must include the part number stamped on the cylinder case when ordering parts. WELDMENT IDENTIFICATION Each of the major weldments - base, mast, inner boom, outer boom, extension boom and 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. ORDERING REPAIR PARTS When ordering replacement parts: 1. Give the model number of the unit. 2. Give the serial number of the unit. 3. Specify the complete part number. When ordering cylinder parts, or one of the main weldments, always give the stamped part number. 4. Give a complete description of the part. 5. Specify the quantity required. IOWA MOLD TOOLING CO., INC. BOX 189, GARNER, IA MODEL NUMBER SERIAL NUMBER MFG DATE SERIAL NUMBER PLACARD CYLINDER PART NUMBER LOCATION CYLINDER PART NUMBER LOCATION

24 L: STEM ASM ( ) ITEM PART NO. DESCRIPTION QTY 1. 3B CYLINDER-STABILIZER HANDLE LADDER-CURBSIDE LADDER-STREETSIDE STEM PLATFORM WASHER 3/8 LOCK STABILIZER LEG PIN RETAINER 3" PIN PIN CAP SCR 1/4-20X2-1/4 HHGR CAP SCR 5/16-18X1 HHGR CAP SCR 3/8-16X1 HHGR CAP SCR 3/8-16X1-1/4 HHGR NUT 3/8-16 LOCK NUT 1/4-20 LOCK WASHER 1/4 WRT WASHER 3/8 WRT WASHER 5/16 LOCK 8

25 L: 3B STABILIZER CYLINDER (3B025920) ITEM PART NO. DESCRIPTION QTY 1. 4B CASE ASM G ROD ASM I PISTON H HEAD B SEAL KIT (INCL:6-14) Q O-RING (PART OF 5) 1REF 7. 7Q10P338 BACKUP RING (PART OF 5) 1REF 8. 7T2N8022 WEAR RING (PART OF 5) 1REF 9. 7R U-CUP SEAL (PART OF 5) 1REF 10. 7R14P020 ROD WIPER (PART OF 5) 1REF 11. 7T61N143 LOCK RING (PART OF 5) 1REF 12. 7T2N4035 WEAR RING-PISTON(PART OF 5)2REF 13. 7T66P350 PISTON SEAL (PART OF 5) 1REF 14. 6A WAFER LOCK (PART OF 5) 1REF 15. 6C STOP TUBE 1-1/2" C STOP TUBE 3" 1 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, HOLDING VALVE SEALS, NYLON LOCK RING, CAST IRON PISTON RINGS AND ROD THREADS. APPLY NEVER-SEEZ REGULAR GRADE ANTI- SEIZE AND LUBRICATING COMPOUND TO CYLINDER HEAD THREADS. DO NOT APPLY NEVER-SEEZ TO ANY SEALS.

26 L: REV. D MAST ASM-650 ROT N ( ) ITEM PART NO. DESCRIPTION QTY GEAR BEARING CAP SCR 3/4-10X3-1/2 SH CAP SCR 1/2-13x1 HHGR GEAR GUARD PIPE RING CAP SCR 1/2-13X2-1/2 HHGR ROLLER MAST ZERK 1/8NPT STREET ELBOW 1/8NPT GREASE EXT 29" COUPLING 1/8NPT LOOM 2FT ADHESIVE AR HOSE CLAMP CAP SCR 3/8-16X2 HHGR WASHER 3/8 WRT WASHER 3/8 LOCK SPACER CAP SCR 1/2-13X1-3/4 HHGR WASHER 1/2 WRT HOSE CLAMP BRACKET HOSE CLAMP WASHER 1/2 LOCK 1 WARNING ANYTIME A GEAR-BEARING BOLT IS REMOVED, IT MUST BE REPLACED WITH A NEW BOLT OF THE IDENTICAL GRADE AND SIZE. FAILURE TO REPLACE GEAR-BEARING BOLTS MAY RESULT IN BOLT FAILURE DUE TO METAL FATIQUE, CAUSING SERIOUS INJURY OR DEATH. CAUTION REFER TO THE TURNTABLE BEARING FASTENER TIGHTENING SEQUENCE INSTRUCTIONS IN THE REFERENCE SECTION PRIOR TO TIGHTENING TURNTABLE GEAR FASTENERS. NOTE INSTALL GEAR BEARING WITH A MINIMUM GEAR BACKLASH OF " ( mm). MEASURED BETWEEN SWING PINION AND GEAR BEARING TEETH WITH YELLOW PAINT. NOTE APPLY MOBILTAC 375NC LUBRICANT (OR EQUIVALENT) TO THE EXTERNAL TEETH OF THE TURNTABLE BEARING AND PINION GEAR.

27 L: MAST ASM-650 ROT N ( ) ITEM PART NO. DESCRIPTION QTY CAP SCR 3/4-10X2-1/2 HHGR GEAR BOX HYD MOTOR CAP SCR 1/2-13X1-1/4 HHGR VALVEPACK PINION GEAR PINION GEAR CAP CAP SCR 1/2-20X1-1/4 HHGR WASHER 1/2 LOCK NUT 1/2-13 LOCK HYD BRAKE GASKET-BRAKE/CRANE BASE GASKET-BRAKE STUD 1/2-13X Q O-RING 2REF C BAL VALVE 2REF CAP SCR 3/8-16X2-1/2 SH 4 NOTE 1 FILL WITH 4.25 PINTS (2 LITERS) OF 80/90 EP GREASE. SHOULD BE FILLED TO WITHIN 1-3/8 (35mm) FROM TOP FILL PLUG. NOTE 2 USE A CLEANER/PRIMER ON THREADS. APPLY A SERVICEABLE THREAD LOCKER. TORQUE CAP SCREWS TO 75 FT-LBS (10.37 KG-M). NOTE 3 APPLY MOBILTAC 375NC LUBRICANT (OR EQUIVALENT) TO THE EXTERNAL TEETH OF THE TURNTABLE BEARING AND PINION GEAR.

28 L: MAST ASM-CONT ROT N ( ) ITEM PART NO. DESCRIPTION QTY GEAR BEARING CAP SCR 3/4-10X3-1/2 SH CAP SCR 1/2-13x1 HHGR GEAR GUARD WASHER 1/2 LOCK SLEEVE ROTATION BRAKE CAP SCR 1/2-13X1-1/2 HHGR CAP SCR 5/16-18X2-1/2 HHGR MAST ZERK 1/8NPT STREET ELBOW 1/8NPT GREASE EXT 29" WASHER 5/16 LOCK COUPLING 1/8NPT WASHER 5/16 WRT LOOM 2FT ADHESIVE AR HOSE CLAMP CAP SCR 3/8-16X2 HHGR WASHER 3/8 WRT WASHER 3/8 LOCK SPACER CAP SCR 1/2-13X1-3/4 HHGR WASHER 1/2 WRT HOSE CLAMP BRACKET HOSE CLAMP 1 WARNING ANYTIME A GEAR-BEARING BOLT IS REMOVED, IT MUST BE REPLACED WITH A NEW BOLT OF THE IDENTICAL GRADE AND SIZE. FAILURE TO REPLACE GEAR-BEARING BOLTS MAY RESULT IN BOLT FAILURE DUE TO METAL FATIQUE, CAUSING SERIOUS INJURY OR DEATH. CAUTION REFER TO THE TURNTABLE BEARING FASTENER TIGHTENING SEQUENCE INSTRUCTIONS IN THE REFERENCE SECTION PRIOR TO TIGHTENING TURNTABLE GEAR FASTENERS. NOTE INSTALL GEAR BEARING WITH A MINIMUM GEAR BACKLASH OF " ( mm). MEASURED BETWEEN SWING PINION AND GEAR BEARING TEETH WITH YELLOW PAINT. NOTE APPLY MOBILTAC 375NC LUBRICANT (OR EQUIVALENT) TO THE EXTERNAL TEETH OF THE TURNTABLE BEARING AND PINION GEAR.

29 L: MAST ASM-CONT ROT N ( ) ITEM PART NO. DESCRIPTION QTY CAP SCR 3/4-10X2-1/2 HHGR GEAR BOX HYD MOTOR CAP SCR 1/2-13X1-1/4 HHGR VALVEPACK PINION GEAR PINION GEAR CAP CAP SCR 1/2-20X1-1/4 HHGR WASHER 1/2 LOCK NUT 1/2-13 LOCK HYD BRAKE GASKET-BRAKE/CRANE BASE GASKET-BRAKE STUD 1/2-13X Q O-RING 2REF C BAL VALVE 2REF CAP SCR 3/8-16X2-1/2 SH 4 NOTE 1 FILL WITH 4.25 PINTS (2 LITERS) OF 80/90 EP GREASE. SHOULD BE FILLED TO WITHIN 1-3/8 (35mm) FROM TOP FILL PLUG. NOTE 2 USE A CLEANER/PRIMER ON THREADS. APPLY A SERVICEABLE THREAD LOCKER. TORQUE CAP SCREWS TO 75 FT-LBS (10.37 KG-M). NOTE 3 APPLY MOBILTAC 375NC LUBRICANT (OR EQUIVALENT) TO THE EXTERNAL TEETH OF THE TURNTABLE BEARING AND PINION GEAR.

30 L: ROTATION BRAKE ( ) ITEM PART NO. DESCRIPTION QTY COVER CASE BASE PISTON SHAFT GASKET BASE GASKET BEARING BEARING CAP SCR 12POINT 1/2-13X CAP SCR #10-24X3/4 SH BACKUP RING BACKUP RING O-RING O-RING SEAL HEX PLUG SPRING FRICTION DISC SEPARATOR PLATE O-RING GASKET SPACER-NOT USED 24. M PLUG 4

31 L: INNER BOOM ASM-21 ( ) ITEM PART NO. DESCRIPTION QTY INNER BOOM PIN C INNER CYLINDER CAP SCR 5/16-18X2 HHGR COVER PLATE TUBE CLAMP 2-HOLE NUT 2-12 LOCK ZERK 1/8NPT PIN NUT 1-1/5 LOCK PIN HYD TUBE ASM 1/2X HYD TUBE ASM 1/2X131 4

32 L: INNER BOOM ASM-25 ( ) ITEM PART NO. DESCRIPTION QTY INNER BOOM PIN C INNER CYLINDER CAP SCR 5/16-18X2 HHGR COVER PLATE TUBE CLAMP 2-HOLE NUT 2-12 LOCK ZERK 1/8NPT PIN NUT 1-1/5 LOCK PIN HYD TUBE ASM 1/2X HYD TUBE ASM 1/2X CAP SCR 5/16-18X3-1/4 HHGR5 2

33 L: 3C INNER BOOM CYLINDER (3C152980) ITEM PART NO. DESCRIPTION QTY 1. 4C CASE ASM (INCL:3,4) G ROD ASM (INCL:3,4) BALL BUSHING (PART OF 1&2) 2REF ZERK 1/8NPT90 (PART OF 1&2) 2REF 5. 6HX05530 HEAD IX05520 PISTON C SEAL KIT(INCL:8-16) Q O-RING (PART OF 7) 1REF 9. 7Q10P354 BACKUP RING (PART OF 1) 1REF 10. 7T2N9032 WEAR RING (PART OF 7) 1REF 11. 7R U-CUP SEAL (PART OF 7) 1REF 12. 7R14P030 ROD WIPER (PART OF 7) 1REF 13. 7T66P550 PISTON SEAL (PART OF 7) 1REF 14. 7T2N4055 WEAR RING (PART OF 7) 2REF 15. 7T61N200 LOCK RING (PART OF 7) 1REF 16. 6A WAFER LOCK (PART OF 7) 1REF 17. 6C STOP TUBE C BAL VALVE PLUG C BAL VALVE PLUG 1 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, HOLDING VALVE SEALS, NYLON LOCK RING, CAST IRON PISTON RINGS AND ROD THREADS. APPLY NEVER-SEEZ REGULAR GRADE ANTI- SEIZE AND LUBRICATING COMPOUND TO CYLINDER HEAD THREADS. DO NOT APPLY NEVER-SEEZ TO ANY SEALS.

34 L: OUTER BOOM ASM-21 ( ) ITEM PART NO. DESCRIPTION QTY OUTER BOOM C OUTER CYLINDER PIN PIN NUT 2-12 JAM CAP SCR 5/16-18X2 HHGR COVER PLATE TUBE CLAMP HYD TUBE ASM 1/2X PIN LOAD SLEEVE NUT 1 1/2-12 JAM OUTER BOOM ASM-20 ( ) ITEM PART NO. DESCRIPTION QTY OUTER BOOM C OUTER CYLINDER PIN PIN NUT 2-12 JAM CAP SCR 5/16-18X2 HHGR COVER PLATE TUBE CLAMP HYD TUBE ASM 1/2X PIN LOAD SLEEVE NUT 1 1/2-12 JAM 1

35 L: OUTER & EXT BOOM ASM-25 ( ) ITEM PART NO. DESCRIPTION QTY 1. 3C OUTER CYLINDER PIN PIN NUT 2-12 LOCK END BOOM CAP SCR 3/8-16X3/4 HH GR WASHER PIN B EXTENSION CYLINDER PIN EXTENSION BOOM SLIDE BUSHING MACH SCR 3/8-16X1-1/ NUT 3/8-16 LOCK SLIDE SPACER SLIDE BUSHING CAP SCR 3/8-16X7/8 HHGR TUBE CLAMP 2-HOLE COVER PLATE CAP SCR 5/16-18X2 HHGR HYD TUBE ASM 1/2X76 4

36 L: 3B OUTER BOOM CYLINDER (3C092950) ITEM PART NO. DESCRIPTION QTY 1. 4C CASE ASM G ROD ASM BALL BUSHING(PART OF 1&2) 2REF ZERK 1/8NPT90 (PART OF 1&2) 2REF 5. 6HX06530 HEAD IX05520 PISTON C SEAL KIT (INCL:8-16) Q O-RING (PART OF 7) 1REF 9. 7Q10P354 BACKUP RING (PART OF 7) 1REF 10. 7T2N8032 WEAR RING (PART OF 7) 1REF 11. 7R U-CUP SEAL (PART OF 7) 1REF 12. 7R14P030 ROD WIPER (PART OF 7) 1REF 13. 7T66P550 PISTON SEAL (PART OF 7) 1REF 14. 7T2N4055 WEAR RING (PART OF 7) 2REF 15. 7T61N200 LOCK RING (PART OF 7) 1REF 16. 6A WAFER LOCK (PART OF 7) 1REF 17. 6C STOP TUBE C BAL VALVE PLUG 2 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, HOLDING VALVE SEALS, NYLON LOCK RING, CAST IRON PISTON RINGS AND ROD THREADS. APPLY NEVER-SEEZ REGULAR GRADE ANTI- SEIZE AND LUBRICATING COMPOUND TO CYLINDER HEAD THREADS. DO NOT APPLY NEVER-SEEZ TO ANY SEALS.

37 L: 3B EXTENSION BOOM CYLINDER (3B275960) ITEM PART NO. DESCRIPTION QTY 1. 4B CASE ASM G ROD ASM I PISTON H HEAD C STOP TUBE 3/ C SEAL KIT (INCL:7-16) A WAFER LOCK (PART OF 6) 1REF 8. 7T66P300 PISTON SEAL (PART OF 6) 1REF 9. 7T61N125 LOCK RING (PART OF 6) 1REF 10. 7T2N4030 WEAR RING-1" (PART OF 6) 2REF 11. 7Q O-RING (PART OF 6) 1REF 12. 7Q O-RING (PART OF 6) 1REF 13. 7Q10P334 BACKUP RING (PART OF 6) 1REF 14. 7T2N4022 WEAR RING (PART OF 6) 1REF 15. 7R U-CUP (PART OF 6) 1REF 16. 7R14P020 ROD WIPER (PART OF 6) 1REF C BAL VALVE 25GPM 2 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, HOLDING VALVE SEALS, NYLON LOCK RING, CAST IRON PISTON RINGS AND ROD THREADS. APPLY NEVER-SEEZ REGULAR GRADE ANTI- SEIZE AND LUBRICATING COMPOUND TO CYLINDER HEAD THREADS. DO NOT APPLY NEVER-SEEZ TO ANY SEALS.

38 L: CONTROL KIT-8F 25 ( ) ITEM PART NO. DESCRIPTION QTY BELL CRANK PEDAL BELL CRANK TOE/TOE/SWG PIN YOKE STUD 3/8-24X4-7/ STUD 3/8-24X8-1/ CONTROL HANDLE KNOB CLEVIS 3/ ZERK 1/8NPT CAP SCR 1/2-13X1-1/4 HHGR NUT 3/8-24 HEX NUT 1/2-13 LOCK WASHER 1/2 LOCK MACH BUSHING 1X10GA NR HAIR PIN 1/ COTTER PIN-SPCL SHORT COTTER PIN 3/32X3/ CLEVIS PIN 1/4X CLEVIS PIN 3/8X1-1/ CHAIR ARM REST SET NUT 5/16-18 LOCK CAP SCR 5/16-18X2-3/4 HHGR TREAD 12 3FT

39 L: VALVEBANK ASM 5-SECT RH ( ) ITEM PART NO. DESCRIPTION QTY VALVEBANK ELBOW #12MSTR #12MJIC STREET ELBOW 1/4NPT ADAPTER #12MSTR #8MJIC DISCONNECT NIPPLE 1/4NPT ELBOW-PR GAUGE MOD 1 NOTE PLASTIC CAPS ON EXPOSED FITTING ENDS ARE TO REMAIN ON THE FITTINGS UNTIL THE VALVEBANK IS INSTALLED.

40 L: VALVEBANK ASM 4-SECT LH 21 ( ) ITEM PART NO. DESCRIPTION QTY VALVEBANK ELBOW #12MSTR #12MJIC STREET ELBOW 1/4NPT ADAPTER #12MSTR #8MJIC DISCONNECT NIPPLE 1/4NPT PLUG #12MSTR PR GAUGE MOD PLUG 1-1/16STR HH 2 NOTE PLASTIC CAPS ON EXPOSED FITTING ENDS ARE TO REMAIN ON THE FITTINGS UNTIL THE VALVEBANK IS INSTALLED.

41 L: VALVEBANK ASM 4-SECT LH 25 ( ) ITEM PART NO. DESCRIPTION QTY VALVEBANK ELBOW #12MSTR #12MJIC STREET ELBOW 1/4NPT ADAPTER #12MSTR #8MJIC DISCONNECT NIPPLE 1/4NPT PLUG #12MSTR PR GAUGE MOD 1 NOTE PLASTIC CAPS ON EXPOSED FITTING ENDS ARE TO REMAIN ON THE FITTINGS UNTIL THE VALVEBANK IS INSTALLED.

42 L: HYDRAULIC KIT-7F ROT N ( ) ITEM PART NO. DESCRIPTION QTY ADAPTER-PR SW INLINE 1-1/ BULKHD UNION 1-1/16JIC ADAPTER #8MSTR #8MJIC VELOCITY FUSE #12MSTR #12MJIC ELBOW #8MSTR #8MJIC CHECK VALVE 25GPM ADAPTER #10MSTR #8MJIC ADAPTER #8MJIC #12FJIC ADAPTER #4MSTR #4MJIC ELBOW #4MSTR #4MJIC ELBOW #4MJIC #4FJIC SWVL CAP SCR 5/16-18X2-1/2 HHGR NUT 5/16-18 LOCK WASHER 5/16 WRT DISCONNECT COUPLER 3/8F DISCONNECT NIPPLE 3/8M DISCONNECT COUPLER 3/8FPT DISCONNECT NIPPLE 1/2FPT ADAPTER 3/4MPT #16MJIC ADAPTER 1/2MPT #8MJIC HOSE KIT (INCL:24-36) HOSE 1/2X97 #8F#8F 2REF HOSE 1/2X108 #8F #8F 2REF HOSE 1/2X44 #8F #8F 2REF HOSE 1/2X91 #8F #8F 4REF HOSE 1/2X77 #8F #8F 2REF HOSE 1/2X40 #8F #8F 2REF HOSE 3/4X100 #12F #12F 8REF HOSE 1/4X11-1/2 #4F #4F 1REF HOSE 1/2X45 #8F #8F 4REF HOSE 1/2X22 #8F #8J 4REF HOSE 1/2X13 #8F #8F 4REF HOSE 1/2X73 #8F #8F 2REF

43 L: HYDRAULIC KIT-8F ROT N ( ) ITEM PART NO. DESCRIPTION QTY ADAPTER-PR SW INLINE 1-1/ BULKHD UNION 1-1/16JIC ADAPTER #8MSTR #8MJIC VELOCITY FUSE #12MSTR #12MJIC ELBOW #8MSTR #8MJIC CHECK VALVE 25GPM ADAPTER #10MSTR #8MJIC ADAPTER #8MJIC #12FJIC ADAPTER #4MSTR #4MJIC ELBOW #4MSTR #4MJIC ELBOW #4MJIC #4FJIC SWVL CAP SCR 5/16-18X2-1/2 HHGR NUT 5/16-18 LOCK WASHER 5/16 WRT DISCONNECT COUPLER 3/8F DISCONNECT NIPPLE 3/8M DISCONNECT COUPLER 3/8FPT DISCONNECT NIPPLE 1/2FPT ADAPTER 3/4MPT #16MJIC ADAPTER 1/2MPT #8MJIC HOSE KIT (INCL:23-39) HOSE 1/2X97 #8F#8F 2REF HOSE 1/2X108 #8F #8F 2REF HOSE 1/2X44 #8F #8F 2REF HOSE 1/2X91 #8F #8F 4REF HOSE 1/2X77 #8F #8F 2REF HOSE 1/2X40 #8F #8F 2REF HOSE 3/4X100 #12F #12F 8REF HOSE 1/4X11-1/2 #4F #4F 1REF HOSE 1/2X45 #8F #8F 4REF HOSE 1/2X22 #8F #8J 4REF HOSE 1/2X51 #8F #8F 6REF HOSE 1/2X73 #8F #8F 2REF HOSE 1/2X85 #8F #8F 1REF HOSE 1/2X83 #8F #8F 1REF

44 L: REV. B HYDRAULIC KIT-7F-21 CONT ROT N ( ) ITEM PART NO. DESCRIPTION QTY ADAPTER-PR SW INLINE 1-1/ BULKHD UNION 1-1/16JIC ADAPTER #8MSTR #8MJIC VELOCITY FUSE #12MSTR #12MJIC ELBOW #8MSTR #8MJIC CHECK VALVE 25GPM ADAPTER #10MSTR #8MJIC ADAPTER #8MJIC #12FJIC ADAPTER #4MSTR #4MJIC ELBOW #4MSTR #4MJIC ELBOW #4MJIC #4FJIC SWVL ELBOW #16MSTR #16MJIC CAP SCR 5/16-18X2-1/2 HHGR NUT 5/16-18 LOCK WASHER 5/16 WRT DISCONNECT COUPLER 3/8F DISCONNECT NIPPLE 3/8M DISCONNECT COUPLER 3/8FPT DISCONNECT NIPPLE 1/2FPT ADAPTER 3/4MPT #16MJIC ADAPTER 1/2MPT #8MJIC HOSE KIT (INCL:23-41) HOSE 1/2X97 #8F#8F 2REF HOSE 1/2X83 #8F #8F 2REF HOSE 1/2X44 #8F #8F 2REF HOSE 1/2X91 #8F #8F 4REF HOSE 1/2X77 #8F #8F 2REF HOSE 1/2X40 #8F #8F 2REF HOSE 3/4X100 #12F #12F 8REF HOSE 1/2X21 #8F#8F 2REF HOSE 1/4X11-1/2 #4F #4F 1REF HOSE 1/2X45 #8F #8F 4REF HOSE 1/2X22 #8F #8J 4REF HOSE 1/2X13 #8F #8F 4REF HOSE 1/2X73 #8F #8F 2REF HOSE 1/2X19 #8F #8F 2REF HOSE 3/4X65 #12F #12F 4REF ADAPTER #12MSTR #12MJIC CAP SCR 1/2-13X1-3/4 HHGR NUT 1/2-13 LOCK WASHER 1/2 WRT MANIFOLD 1

45 L: HYDRAULIC KIT-8F-25 CONT ROT N ( ) ITEM PART NO. DESCRIPTION QTY ADAPTER-PR SW INLINE 1-1/ BULKHD UNION 1-1/16JIC ADAPTER #8MSTR #8MJIC VELOCITY FUSE #12MSTR #12MJIC ELBOW #8MSTR #8MJIC CHECK VALVE 25GPM ADAPTER #10MSTR #8MJIC ADAPTER #8MJIC #12FJIC ADAPTER #4MSTR #4MJIC ELBOW #4MSTR #4MJIC ELBOW #4MJIC #4FJIC SWVL ELBOW #16MSTR #16MJIC CAP SCR 5/16-18X2-1/2 HHGR NUT 5/16-18 LOCK WASHER 5/16 WRT DISCONNECT COUPLER 3/8F DISCONNECT NIPPLE 3/8M DISCONNECT COUPLER 3/8FPT DISCONNECT NIPPLE 1/2FPT ADAPTER 3/4MPT #16MJIC ADAPTER 1/2MPT #8MJIC HOSE KIT (INCL:23-41) HOSE 1/2X97 #8F#8F 2REF HOSE 1/2X83 #8F #8F 2REF HOSE 1/2X44 #8F #8F 2REF HOSE 1/2X91 #8F #8F 4REF HOSE 1/2X77 #8F #8F 2REF HOSE 1/2X40 #8F #8F 2REF HOSE 3/4X100 #12F #12F 8REF HOSE 1/2X21 #8F#8F 2REF HOSE 1/4X11-1/2 #4F #4F 1REF HOSE 1/2X45 #8F #8F 4REF HOSE 1/2X22 #8F #8J 4REF HOSE 1/2X51 #8F #8F 6REF HOSE 1/2X73 #8F #8F 2REF HOSE 1/2X85 #8F #8F 1REF HOSE 1/2X83 #8F #8F 1REF HOSE 1/2X19 #8F #8F 2REF HOSE 3/4X65 #12F #12F 4REF ADAPTER #12MSTR #12MJIC CAP SCR 1/2-13X1-3/4 HHGR NUT 1/2-13 LOCK WASHER 1/2 WRT MANIFOLD 1

46 L: INSTALLATION KIT-FRONT MNT ( ) ITEM PART NO. DESCRIPTION QTY CAP SCR 1/2-13X2 HHGR NUT 1/2-13 LOCK FRAME SUPPORT PIPE NIPPLE 1-1/4NPT X RESERVOIR ASM SCREEN 100 MESH REF REDUCER BUSHING 1-1/4X FILTER ELEMENT 25MIC REF DECAL-SUCTION LINE DECAL-RETURN LINE HOSE ASM 1X98 FF HOSE ASM 1X59 FF CLAMP PLATE ADAPTER 1MPT #16MJIC NUT 1 1/4-7 LOCK STL INS GR HOSE CLAMP 1-1/4 2-BOLT BARB NIPPLE #20 STL WASHER 1-1/4 HI-STRENGTH TIE-DOWN STUD 1-1/4X HOSE 1-1/4 100R4 X24" GATE VALVE ADAPTER #20MSTR #16MJIC PLUG 3/4NPT BARB NIPPLE 1-1/4 X 1-1/4NPT NUT 3/8-16 LOCK WASHER 3/8 WRT STRAP TANK BRACKET-LH TANK BRACKET-RH 1

47 L: REV D DECAL KIT-21 ( ) PLACARD-SERIAL NUMBER DECAL-IMT DIAMOND DECAL-GREASE WEEKLY L DECAL-GREASE WEEKLY R DECAL-CAUTION WASH/WAX DECAL-ROTATE/GREASE DECAL-DANGER HOIST PERS DECAL-DANGER OR STD CLR DECAL-DANGER ELEC HZD DECAL-DANGER OR MOVING DECAL-DANGER LOADLINE DECAL-DANGER DRIVELINE DECAL-CONTACT IMT DECAL-JOYSTICK CONTROL DECAL-RECOMMEND HYD OIL DECAL-DANGER 5-COMBINED CAPACITY CHART DECAL-8000L IDENTIFICATION DECAL-CAUTION OIL LEVEL RIVET DECAL-ASME/ANSI B NOTE: PLACE ITEM #22, LEVEL, ON FRONT AND SIDE OF CRANE BASE.

48 L: REV D DECAL KIT-25 ( ) PLACARD-SERIAL NUMBER DECAL-IMT DIAMOND DECAL-GREASE WEEKLY L DECAL-GREASE WEEKLY R DECAL-CAUTION WASH/WAX DECAL-ROTATE/GREASE DECAL-WARNING HOIST PERS DECAL-WARNING STAB STD CLR DECAL-DANGER ELEC HZD DECAL-WARNING LOADLINE DECAL-DANGER DRIVELINE DECAL-CONTACT IMT DECAL-JOYSTICK CONTROL DECAL-RECOMMEND HYD OIL DECAL-DANGER 5-COMBINED CAPACITY CHART DECAL-8000L IDENTIFICATION DECAL-CAUTION OIL LEVEL RIVET DECAL-ASME/ANSI B NOTE: PLACE ITEM #22, LEVEL, ON FRONT AND SIDE OF CRANE BASE.

49 L: GRAPPLE MTG KIT-NON DAMPENED- S&L ( ) ITEM PART NO. DESCRIPTION QTY PIN SWIVEL LINK ZERK 1/8NPT NUT 1 1/4-12 LOCK DISCONNECT COUPLER 1/2FPT DISCONNECT NIPPLE 1/2FPT DISCONNECT COUPLER 3/8FPT DISCONNECT NIPPLE 3/8FPT ADAPTER 1/2MPT #8MJIC ADAPTER 3/8MPT #8MJIC HOSE ASM 3/8X48 FJ ELBOW 3/8MPT #8MJIC 90 4

50 L: GRAPPLE MTG KIT-DAMPENED-S&L ( ) ITEM PART NO. DESCRIPTION QTY SPRING WASHER PIN FRICTION DISC PRESSURE PLATE SWIVEL LINK SLEEVE NUT 1 1/4-12 LOCK DISCONNECT COUPLER 1/2FPT DISCONNECT NIPPLE 1/2FPT DISCONNECT COUPLER 3/8FPT DISCONNECT NIPPLE 3/8FPT ADAPTER 1/2MPT #8MJIC ADAPTER 3/8MPT #8MJIC HOSE ASM 3/8X48 FJ ELBOW 3/8MPT #8MJIC 90 4

51 L: GRAPPLE MTG KIT- NON DAMPENED- S&L ( ) ITEM PART NO. DESCRIPTION QTY BOLT 1 1/4-7X8-1/2 W/HOLE HAIR PIN 3/ SWIVEL LINK ZERK 1/8NPT NUT 1 1/4-7 HEX DISCONNECT COUPLER 1/2FPT DISCONNECT NIPPLE 1/2FPT DISCONNECT COUPLER 3/8FPT DISCONNECT NIPPLE 3/8FPT ADAPTER 1/2MPT #8MJIC ADAPTER 3/8MPT #8MJIC HOSE ASM 3/8X48 FJ ELBOW 3/8MPT #8MJIC 90 8

52 L:

53 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

54 SECTION 4. GENERAL REFERENCE NOTES

55 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