1015 Parts & Specifications

Transcription

1 Manual Part # Parts & Specifications 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 Introduction 5 Specifications 7 General Specifications... 7 Performance Characteristics... 8 Geometric Configuration Capacity Chart Crane Reference 13 Crane Assemblies & Grease Zerks Recommended Spare Parts List Crane Installation Telescopic Crane Orientation Electric Remote Handle Operating Instructions Remote Engine Speed Control (From Crane) Parts 23 Parts Information Base & Mast Assemblies Base Assembly ( ) Mast Assembly ( ) Speed Reducer ( ) Winch/Cable/Hook Kit ( ) Cable & Hook Kit ( ) (Effective 05/30/13) Cable & Hook Kit ( ) (Through 05/30/13) Cord Reel Assembly ( ) Boom Assemblies & Cylinders Lower Boom Assembly ( ) Lower Cylinder (3B195010) (Thru. 9-05, Eff. 2-07) Lower Cylinder ( ) (Eff through 1-07) Counterbalance Valve Assembly ( ) Extension Boom Assembly ( ) Installation - Manual Extension Boom Stop ( ) Extension Cylinder (3B180010) (Thru. 9-05, Eff. 2-07) Extension Cylinder ( ) (Eff through 1-07) Controls & Hydraulics, Power Unit Hydraulic Power Unit - DC ( ) Hydraulic Kit-Power Unit ( ) Control Kit-Power Unit ( ) Schematic, Power Unit ( ) Valvebank, Power Unit ( ) Handle Assembly, Remote, Power Unit ( )... 58

4 ii Contents Controls & Hydraulics, PTO Hydraulic Kit, Proportional PTO ( ) Hydraulic Kit, Non-Proportional PTO ( ) Control Kit, Proportional PTO ( ) Control Kit, Non-Proportional PTO ( ) Schematic, Proportional Remote Control ( ) Schematic, Non-Prop Remote Control ( ) Valvebank, Non-Prop Remote Control ( ) Valvebank, Tethered Remote ( ) Handle Assembly, Remote, PTO On/Off ( ) Handle Assembly, Tethered Remote ( ) Cable Assembly, Tethered Remote ( ) Controls & Hydraulics, Radio Remote Hydraulic Kit, Radio Remote ( ) Control Kit, Radio Remote ( ) (REF ) Valvebank, Radio Remote ( ) Cable Assembly, Radio Remote ( ) Electrical Schematic, Radio Remote ( ) Stabilizers (Reference Aux Stabilizer Manual) Miscellaneous Reservoir Assembly ( ) Reservoir ( ) Decal Placement, 1015 PTO ( ) Decal Placement, 1015 Pump ( ) Installation Kit, Power Unit ( ) Chassis Wiring Harness ( ) General Reference 105 Inspection Checklist Deficiency / Recommendation / Corrective Action Report Wire Rope Inspection & Replacement Hook Inspection Holding Valve Inspection Anti-Two-Block Device Inspection Thread Torque Chart (English) Thread Torque Chart (Metric) Turntable Bearing Thread Tightening Sequence Turntable Bearing Inspection Turntable Bearing Tilt Test

5 Contents iii Revisions DATE LOCATION DESCRIPTION RELEASE IN NEW FORMAT DECAL KITS REPLACED ; REPLACED BOOM AND POWER STABILIZER CYLINDERS CHANGED. ECN UPDATED BOOM AND EXTENSION CYLINDERS AND ASSEMBLY DRAWINGS. CYLINDER WAS 3B195010, WAS 3B180010, AND WAS 3B DECAL KITS ADDED TO DECAL PLACEMENT DRAWINGS AND LOWER, EXTENSION, POWER OUT CYLINDERS ECN REPL. BY 3B195010; REPL. BY 3B180010; REPL. BY 3B B180010, 3B ECN ADDED LOCKING PIN TO CYLINDER; ADDED CRANE ORIENTATION DRAWING; ADDED CABLE NOTES TO HANDLE ASSEMBLIES , UPDATED SCHEMATIC TO 11X17 SIZE B ECN ADDED LOCKING PIN TO CYLINDER ECN ADDED SHIM UPDATED DRAWING , ECN Manual boom stop , ECN Revisions to manual extension boom stop kits ECN Update to hyd kit B195010, ECN Updated cylinders and removed wafer lock. 3B ECN Updated ext boom drawing ECN Updated drawing and parts list items 13 & Spare Parts List Per engineering mark-up, 9D to 9D ECN Snatch block changed ECN Updated drawing, items 6 & 7 rotated ECN Added base and mast Note # ECN was ECN Molub-Alloy 882 was Molub-Alloy ECN Add spacers to hook kit assembly.

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7 5 C HAPTER 1 Introduction This volume includes specifications, installation information, and spare parts drawings applicable to your particular crane. For operating, maintenance and repair instructions, see Telescopic Crane Volume 1: OPERATION, MAINTENANCE AND REPAIR. (IMT part number ) It is your responsibility to operate and maintain this unit in a manner that will result in the safest working conditions possible. You must be aware of existing Federal, State and Local codes and regulations governing the safe use and maintenance of this IMT crane. The 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 on ANSI/ASME B30.5. Misuse of the crane through overloading, abuse, lack of maintenance and unauthorized modifications will void the warranty on any part of the unit subjected to this misuse. No warranty - verbal, written or implied - other than the official, published IMT new machinery and equipment warranty will be valid with this unit. 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 Specifications In This Chapter General Specifications... 7 Performance Characteristics... 8 Geometric Configuration Capacity Chart General Specifications CRANE RATING 10,500 ft-lb (1.46 ton-meters) REACH (from centerline of rotation) 15'-0" (4.57 m) HYDRAULIC EXTENSION 36" (91.4 cm) MANUAL EXTENSION 48" (121.9 cm) LIFTING HEIGHT (from base of crane) 16'-1" (4.90 m) CRANE WEIGHT 660 lb (299 kg) STORAGE HEIGHT (crane only) 26" (66.0 cm) MOUNTING SPACE REQUIRED (crane base) 14-1/2" x 17" (36.8 cm x 43.2 cm) TIE-DOWN BOLT PATTERN 11-1/2" x 14-3/4" (29.2 cm x 37.5 cm) on center HORIZONTAL CENTER OF GRAVITY 15" (38.1 cm) (from centerline of rotation) VERTICAL CENTER OF GRAVITY 13" (33.0 cm) (from bottom of crane base) OPTIMUM PUMP CAPACITY (PTO) 5 GPM (18.9 liters/min.) *OPTIMUM PUMP CAPACITY (electric two-stage) 1.5 & 3.5 GPM (5.7 & 13.2 liters/min) OIL RESERVOIR CAPACITY (electric two-stage) 5 gallons (18.9 liters) ROTATIONAL TORQUE 1500 ft-lb (0.2 ton-m) DESIGN FACTORS - pins and hydraulics 4/1 * The two-stage pump delivers 1.5 GPM (5.7 liters/min) at low speed, and 3.5 GPM (11.4 liters/min) at high speed. Normally, when operating under load, the pump will be operated as a single-stage pump. The pump will be operated as a two-stage pump to save time during set up.

10 Parts & Specifications Manual Part # Performance Characteristics SPECIFICATION ** PTO ***POWER UNIT ROTATION seconds 50 seconds LOWER BOOM -0 to seconds 9 seconds ELEVATION EXTENSION BOOM 36" (91.4 cm) 8 seconds 12 seconds WINCH Single part line 25 ft/min (7.6 m/min) 12 ft/min (3.7 m/min) WINCH Two part line 12 ft/min (3.7 m/min) 6 ft/min (1.8 m/min) ** All times are based on 5 GPM (18.9 liters/min) PTO delivery rate. *** All times are based on 3.5 GPM (13.2 liters/min) pump delivery rate CYLINDERS BORE STROKE LOWER BOOM CYLINDER 2-1/2" (6.4 cm) 18' (45.7 cm) EXTENSION BOOM CYLINDER 2' (5.1 cm) 36' (91.4 cm) POWER SOURCE Integral mounted hydraulic pump and PTO application. Other standard power sources may be used. Minimum power required is 8 horsepower based on 5 GPM (18.9 liters/min) at 2,250 PSI (155 bar). ELECTRIC MOTOR Power is supplied to the electric motor by a solenoid connected to the 12-VDC truck battery. The chassis must be equipped with a 4000 watt Delco Freedom battery (or equivalent) connected in parallel to the chassis standard heavy-duty battery. The chassis must also be equipped with a heavy-duty alternator (63 amp for GM vehicles and 60 amp for Ford vehicles). ROTATION SYSTEM Turntable bearing with external worm gear powered with a high-torque hydraulic motor through a selflocking worm. Total gear reduction is 63 to 1. CYLINDER HOLDING VALVES The base ends (extend sides) of the lower boom and extension cylinders are equipped with integralmounted counter-balance valves to prevent sudden cylinder collapse in case of hose or other hydraulic failure. The counter-balance valve serves several functions. First, it is a holding valve. Secondly, it is designed to control the speed at which the lowering function operates, and allows that motion to be metered under load. Finally, it prevents the loss of an excess amount of oil in the event of a hose failure. Only the oil in the hose, at the time of the failure, will be lost. EXCESSIVE LOAD LIMIT SYSTEM (ELLS) Overloading of the crane is limited by the ELLS. This is done by disarming the crane functions which make possible the application of greater than allowable stress to the crane structure and components. Functions controlled by the ELLS are winch up, extension out and lower boom down. To relieve the situation, the operator may set the load down (winch down) or retract the extension boom (extension in).

11 Chapter 2 Specifications 9 WINCH The winch is powered by a hydraulic motor through a 38:1 ratio worm-gear drive which also functions as a brake. Line speed is 25 ft/min (7.6m/min) at optimum oil flow for 1-part line and 12 ft/min (3.8m/min) for 2- part line. The winch is equipped with 65 ft (19.81m) of 7/32 (.56cm) 7 X 19 class aircraft cable having a lifting capacity of 1600 lbs (726 kg) at 2800 PSI (193 bar) for 1-part line and 3200 lbs (1452 kg) for 2-part line. A nylon sheave riding on a lubricated needle bearing is located at the tip of the extension boom. The ratio of winch drum and sheave pitch diameter to wire rope diameter is 20:1. An anti-two block device is included to prevent the lower block or hook assembly from coming in contact with the boom sheave assembly. HYDRAULIC SYSTEM (PTO DRIVEN) Open-centered, full-pressure system that requires 5 GPM (18.9 liters/min) optimum oil flow at 2250 PSI (155 bar). The control valvebank is a 4-spool, stack-type, 12 VDC valvebank. The hydraulic system includes a 100-mesh suction-line strainer, a return line filter and the control valvebank. An optional hydraulic reservoir is available. ELECTRO-HYDRAULIC SYSTEM (2-SPEED / AUTO-SHIFT) Open-centered, full-pressure system that features a 2-stage hydraulic pump, with the first stage delivering 1.5 GPM (5.7 liter/min) and the second stage delivering 3.5 GPM (13.2 liters/min) at 2250 PSI (155 bar). The operation of the circuit automatically shifts from high to low speed when the crane reaches a certain pressure or load level. The control valvebank is a 4-spool, stack type, 12VDC valve system. The system includes a 5 gallon (18.9 liter) hydraulic reservoir, 10-micron spin-on-type return filter, a hydraulic pump driven by a totally enclosed fan cooled 12VDC motor and all necessary hoses and fittings. CONTROLS Remote control with a 30-foot (9.14m) control cable. MINIMUM CHASSIS SPECIFICATIONS BODY STYLE Conventional Cab WHEEL BASE " ( cm) CAB TO AXLE 60-84" ( cm) FRAME SECTION MODULUS 5.91 cubic inches (97 cc) *RBM 212,760 in-lb (2451 kg-meter) FRONT AXLE RATING lb ( kg) REAR AXLE RATING lb ( kg) * Based on 36,000 PSI yield frame material (A-36). In addition to these specifications, a heavy-duty battery and alternator are required. It is recommended that the vehicle have power steering and dual rear wheels.

12 Parts & Specifications Manual Part # Geometric Configuration 4'-9" (1.45 m) 4'-5" (1.35 m) 4'-1" (1.24 m) 3'-10" (1.17 m) 3'-6" (1.07 m) 3'-2" (0.97 m) 2'-11" (0.89 m) 2'-7" (0.79 m) 16'-1" (4.90 m) 15'-1" (4.60 m) 14'-2" (4.32 m) 13'-3" (4.04 m) 12'-3" (3.73 m) 11'-3" (3.43 m) 10'-4" (3.15 m) 9'-4" (2.84 m) 22" (55.9 cm) 18" (45.7 cm) 25" (63.5 cm) 17" (43.2 cm) 14.5" (36.8 cm) 8'-0" (2.44 m) 9'-0" (2.74 m) 10'-0" (3.05 m) 11'-0" (3.35 m) 12'-0" (3.66 m) 13'-0" (3.96 m) 14'-0" (4.27 m) 15'-0" (4.57 m)

13 Chapter 2 Specifications Capacity Chart 1015 CAPACITY CHART 2nd Extension Out 2nd Extension In 2'-0" (61cm) 1st Extension Out 1st Extension In 2'-0" (61cm) Extensions In '-1" (4.9m) 15'-0" (4.6m) 12'-0" (3.7m) 9'-0" (2.7m) 6'-0" (1.8m) 3'-0" (0.9m) 0 CENTERLINE 3' (0.9m) 0 Maximum 1-part line capacity is 1600 lbs (725 kgs). For greater loads, use 2-part line ' 5' 7' 8' 13' 14' 15' (4.6m) 6' 9' 10' 11' 12' (1.8m) (2.7m) (3.7m) REACH IN FEET (METERS) CAPACITY IN POUNDS (KILOGRAMS) 1'-5" (0.4m) Weight of load handling devices are part of the load lifted and must be deducted from the capacity. IOWA MOLD TOOLING CO., INC. BOX 189, GARNER, IA TEL: FAX:

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15 13 C HAPTER 3 Crane Reference In This Chapter Crane Assemblies & Grease Zerks Recommended Spare Parts List Crane Installation Telescopic Crane Orientation Electric Remote Handle Operating Instructions Remote Engine Speed Control (From Crane)... 21

16 Parts & Specifications Manual Part # Crane Assemblies & Grease Zerks MAST 5 FIRST STAGE EXT. BOOM SECOND STAGE EXT. BOOM 6 (OTHER SIDE) WINCH LOWER BOOM BASE 2 7 NOTE: Descriptions indicate major crane assemblies, and numbers indicate grease zerk locations. ITEM LOCATION LUBRICANT REQUIREMENT FREQUENCY 1 Worm Gear 2 Turntable Bearing Grease Extension (Rotate crane while greasing.) Shell Alvania 2EP or Weekly 3 Lower Cylinder Base Shell Retinax "A" 4 Lower Cylinder Rod 5 Mast / Lower Boom Hinge Pin 6 Sheave pin 7 Snatch Block Pin NOTE: All application points must be greased weekly under normal workloads and moderate weather conditions. Under severe operating conditions, lubrication should be performed more frequently. See the IMT Manual, , Volume 1: Telescopic Crane Operation, Safety & Maintenance for additional lubrication requirements.

17 Chapter 3 Crane Reference Recommended Spare Parts List This spare parts list does not necessarily indicate that the items can be expected to fail in the course of a year. It is intended to provide the user with a stock of parts sufficient to keep the unit operating with the minimal down-time waiting for parts. There may be parts failures not covered by this list. Parts not listed are considered as not being Critical (C) or Normal Wear (W) items during the first year of operations and you need to contact the distributor or manufacturer for availability. BASE ASSEMBLY ( ) THRUST BEARING 2 W BEARING 1 W BEARING 1 W WORM GEAR 1 W MOLUB 2 P WINCH / CABLE / HOOK KIT ( ) BEARING 1 W SWITCH 1 W CABLE & HOOK KIT ( ) ROLLER BEARING 1 W WIRE ROPE 7/32"X65' 1 W SWIVEL HOOK 1-1/2 TON 1 W INNER RACE 1 W CORD REEL ASSEMBLY ( ) CORD REEL 1 W LOWER BOOM ASSEMBLY ( ) WEAR PAD 1 W LOWER BOOM CYLINDER (3B195010) 6HD25015 HEAD 1 W 6ID25087 PISTON 1 W 9D SEAL KIT 1 W C'BAL VALVE 1 C EXTENSION BOOM ASSEMBLY, 15' ( ) SHEAVE W/BEARING 1 W EXTENSION BOOM CYLINDER (3B180010) 6HD20012 HEAD 1 W 6ID20075 PISTON 1 W 9D SEAL KIT 1 W C BALANCE VALVE 10GPM 1 C HYDRAULIC POWER UNIT ( ) RELIEF CARTRIDGE 1 W KICK DOWN CARTRIDGE 1 W STARTER COIL 1 W

18 Parts & Specifications Manual Part # VALVEBANK-PROP L REMOTE CONTROL ( ) COIL 1 C RELIEF VALVE 1 C SOLENOID VALVE 4 C VALVEBANK-RADIO REMOTE ( ) COIL 1 C RELIEF VALVE 1 C SOLENOID VALVE 4 C VALVEBANK - POWER UNIT ( ) RELIEF VALVE 1 C SOLENOID VALVE 4 C VALVEBANK - NON PROPORTIONAL ( ) RELIEF VALVE 1 C SOLENOID VALVE 4 C REMOTE HANDLE ASSEMBLY-POWER UNIT ( ) TOGGLE SWITCH SPDT 4 W TOGGLE SWITCH SPST 1 W TOGGLE SWITCH SPDT 4 W DIODE BOARD 1 W REMOTE HANDLE ASSEMBLY - PTO (ON/OFF) ( ) TOGGLE SWITCH SPST 2 W TOGGLE SWITCH SPDT 4 W TOGGLE SWITCH SPST 1 W TOGGLE SWITCH SPDT 1 W REMOTE HANDLE ASM-PTO-PROPL ( ) TOGGLE SWITCH SPST 2 W TOGGLE SWITCH SPDT 4 W TOGGLE SWITCH SPST 2 W TOGGLE SWITCH SPDT 1 W INSTALLATION KIT-POWER UNIT ( ) FUSE 1 C

19 Chapter 3 Crane Reference 17 Crane Installation This section is intended to serve as a guide in the installation of the IMT 1015 crane. Since each installation is unique, certain components may need to be modified. In the case of the IMT 1015 crane, the power unit's battery cable must be cut to the proper length. The installation instructions are designed for use with an IMT body installed on a vehicle which meets the minimum chassis specifications as defined in the 1015 Performance Characteristics (see "Performance Characteristics" on page 8). If this crane is being installed on a body other than an IMT Mechanics Body, check with IMT to determine the suitability of that body. WARNING Avoid death or serious injury! Do not use this crane on a body which cannot handle the loads imposed on it by the crane. 17" 14-3/4" 8-1/2" 7-3/8" 4" DIA. 13/16" DIA (4 PLCS) /16" FRONT ROTATIONAL STOP RANGE 11-1/2" 5-5/16" 14-1/2" BOLT FLAT WASHER BASE (REF) MTG SURFACE FLAT WASHER LOCK WASHER NUT CRANE INSTALLATION The crane requires a mounting space of at least 14-1/2" wide by 17" long. If necessary, the truck body can be reinforced to give sufficient strength to support the crane in its operating condition. Locate and drill the four 13/16" holes (see figure). Use a pilot drill first and then the 13/16" drill. Cut the 4" diameter hole with a saw after starting with a drill. Deburr all holes. Lift the crane into position on the body. Use a lifting device capable of supporting the crane, which weighs 650 pounds (295 kg). Install the bolts, lockwashers, flat washers and nuts to secure the crane to the chassis (see figure). Torque the bolts to 200 ft-lb. (27.66 kg-m).

20 Parts & Specifications Manual Part # NOTE In addition to these specifications, a heavy-duty batter and alternator are required. IMT recommends that the vehicle have power steering and dual rear wheels. IMT recommends adherence to the upper limit of these specifications for best system performance. BODY REINFORCEMENT If, after talking with the factory, it has been determined that the body will not support the crane with the full, rated load, the body can be reinforced as shown below. Use 1/4" fillet welds and an AWS qualified welder. 1/4" PLATE ALL TUBING MUST BE AT LEAST 2" x 2" x 3/16" WALL THICKNESS EXCEPT AS NOTED. TRUCK FRAME 2 x 4"

21 Chapter 3 Crane Reference 19 Telescopic Crane Orientation When an IMT telescopic crane is not factory-installed on a body, the crane is packed with the boom oriented as it is built on a test stand to facilitate handling. Install the crane on the body with boom pointing backward. Once the crane is bolted down, it can be rotated 180 (3.14 radians) to the boom rest. BOOM REST OUTLINE OF TRUCK BODY 400 ROTATION REAR OF TRUCK

22 Parts & Specifications Manual Part # Electric Remote Handle Operating Instructions ENGINE STOP CPRSR POWER CRANE ENGINE START OPTION OFF EXTENSION ROTATION IN CCW CW OUT WINCH DOWN UP LOWER DOWN UP ENGINE SPD FAST IDLE TRIGGER 1 Turn on the power via the on/off switch of the tethered remote handle. 2 Pull back on the trigger until the power unit begins to run. 3 Select the required function on the crane handle to move the crane as desired, making sure not to release tension on the trigger assembly. 4 When done with the function, continue to hold the trigger assembly in until all immediate movements of the crane have been completed. 5 If no further work with the crane is needed, or if all immediate movements of the crane have been completed, then release the trigger assembly to return the power unit back to a rested state. 6 Turn off power to the handset. NOTE Excessive or rapid On/Off cycling of the trigger assembly should be avoided, particularly if a function is engaged. This will cause premature aging or extensive damage to the power unit components.

23 Chapter 3 Crane Reference 21 Remote Engine Speed Control (From Crane) Engine speed can be controlled from the remote control handle. When the engine speed switch is activated, voltage is applied at terminal 10 of relay E. The coil of relay E is energized and current is allowed to flow to the signal input of the speed control currently installed. The speed of the engine will remain higher as long as the engine speed switch in the remote control handle is allowed to remain in the same position. If this switch is returned to its original position, the engine speed control coil will be de-energized through relay E. Compressor operation will begin when the Compressor-OFF-Crane switch on the handset is toggled to the Compressor position. At that time, the power from the handset will provide power to the pressure switch on the compressor. When the pressure switch signals a need for more air pressure, the switch will trip and provide a signal to terminal 5 of the relay board. Relay C energizes the coil in the relay, connecting terminal 4 to terminal C of the relay which is HOT from relay B. Reference Figure 6 showing circuits energized (in bold) when engine speed is increased by the compressor. This will provide a HOT signal at terminal 4 which then provides a 12-volt signal to input of the speed control currently installed. ENGINE STOP POWER ENGINE START CPRSR CRANE OFF EXTENSION WINCH ROTATION IN CCW DOWN LOWER DOWN OPTION OUT UP ENGINE SPD FAST CW UP IDLE

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25 23 C HAPTER 4 Parts In This Chapter Parts Information Base & Mast Assemblies Boom Assemblies & Cylinders Controls & Hydraulics, Power Unit Controls & Hydraulics, PTO Controls & Hydraulics, Radio Remote Stabilizers Miscellaneous... 96

26 Parts & Specifications Manual Part # 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

27 Chapter 4 Parts 25 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.

28 Parts & Specifications Manual Part # Base & Mast Assemblies Base Assembly ( ) REF (SEE NOTE 4) 20 REF 5 REF 18 REF 15 REF 1 REF 20 REF 5 REF 20 REF 3 11 (SEE NOTE 2) REF REF 24 SEE NOTE REF (SEE NOTE 4) 9 (SEE NOTE 1) 1 4,13,15, (SEE NOTE 2) 8 (SEE NOTE 1)

29 Chapter 4 Parts 27 WARNING Anytime 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 death or serious injury. NOTES: 1 BEARINGS MUST BE PACKED WITH GREASE AT ASSEMBLY AND AFTER REPAIR. 2 APPLY "MOLUB-ALLOY 882 HEAVY" TO TURNTABLE BEARING AND WORM GEAR TEETH AT ASSEMBLY. 3 AT INSTALLATION, INITIALLY LUBRICATE BOTH SIDES OF THRUST BEARING, USING "SLIP PLATE", "LUBRIPLATE" OR OTHER LUBRICANTS CONTAINING GRAPHITE OR MSO2. 4 SHIM AS REQUIRED AS NEEDED. BASE ASSEMBLY PARTS LIST ( ) ITEM PART # DESCRIPTION KIT # QUANTITY BASE TURNTABLE GUARD-RH TURNTABLE GUARD-LH TUBING 1/4 X THRUST BEARING SUPPORT PLATE COVER BEARING BEARING WORM GEAR TURNTABLE BEARING SLIDE COUPLING 1/8NPT WASHER 5/16 LOCK ZERK 1/8NPT # CAP SCR 1/4-20X1/2 HHGR5 # CAP SCR 5/16-18X3/4 HHGR5 # NUT 7/8-9 LOCK 2-PC GR8 # NUT 9/16-12 HEX GR8 # WASHER 1-1/8 FLAT # WASHER 1/4 LOCK # WASHER 9/16 FLAT HARD GR8 # ADAPTER 1/8POLY-FLO 1/ ELBOW 1/8MPT 1/4POLYFLO CAP SCR 9/16-12X3-1/2 HHGR8 # MOTOR CAP SCR 1/2-13X2.00 SH # SHIM 2.25X1.81X16GA REF KIT HDRW 1015 BASE & MAST 1

30 Parts & Specifications Manual Part # Mast Assembly ( ) STOP IS TOWARD REAR NOTE: 1 DO NOT USE THREAD LOCKER ON ITEM #5. WARNING Anytime 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 death or serious injury.

31 Chapter 4 Parts PARTS LIST ITEM PART # DESCRIPTION KIT # QUANTITY MAST COVER CAP SCR 1/4-20X3/4 HHGR5 # WASHER 1/4 LOCK # CAP SCR 9/16-12X2 HHGR8 # WASHER 9/16 HARD FLAT # PLACARD-SERIAL NUMBER POP RIVET 1/8X3/8GRIP KIT HRDW 1015 BASE & MAST 1

32 Parts & Specifications Manual Part # Speed Reducer ( ) , , NOTES (SEE REFERENCE NUMBER IN BOX): 1 USE GASKETS TO OBTAIN.005/.015 END PLAY ON OUTPUT SHAFT. 2 USE GASKETS TO OBTAIN.000/.004 END PLAY ON WORM SHAFT. 3 INSTALL REDUCER (#30), PIPE PLUG (#32), AND SHIPPING PLUG (#29) WITH PIPE SEALANT WITH TEFLON. SHIP ZERK (#26) LOOSE. 4 INSTALL SEALS (#27 AND #28) WITH LOCTITE 609 ON O.D. LUBRICATE SEAL SURFACE BEFORE ASSEMBLY. 5 INSTALL BOLTS USING LOCTITE 242. TORQUE TO FT-LB. 6 CAUTION - USED FOR OIL LEVEL. DO NOT USE LOCTITE. DO NOT OVERTIGHTEN PARTS LIST ITEM PART # DESCRIPTION QUANTITY HOUSING GEAR, WORM GASKET, COVER (.015") GASKET, BRG. RET. (.015") SHAFT, OUTPUT COVER RETAINER, BEARING (Effective 11/01/94) WASHER, 5/16 SEALING GASKET, BRG. RET. (.031") WORM (Effective 11/01/94) ADAPTER, MOTOR (Effective 11/01/94) BEARING, CONE 2

33 Chapter 4 Parts PARTS LIST ITEM PART # DESCRIPTION QUANTITY BEARING, CUP WASHER,THRUST BUSHING, (1.25 X 1.50 X.75) ZERK,LINCOLN #5013 (Effective 11/01/94) SEAL, NAT'L # (Effective 11/01/94) SEAL, NAT'L # PLUG,SLT HD,1/4-28 TPRD (Effective 11/01/94) BUSHING,RED 3/8X1/ VENT, 1/8 NPT, 1-5PSI PLUG, 3/8 NPT, SKT HD DRIVE SCREW KEY, 5/16 X5/16 X3-3/ KEY, 5/16X5/16X LABEL PLATE, 2 7/8 X CAPSCREW, HXZD 5/16NCX.88GR CAPSCREW, HXZD 5/16NC1.25GR LOCKWASHER, STD 5/16 ZD GASKET, COVER (.031") (Effective 11/01/94) ADAPTER MTR (Through 11/01/94) RETAINER BEARING (Through 11/01/94) WORM (Through 11/01/94) GASKET MOTOR 1 REV

34 Parts & Specifications Manual Part # Winch/Cable/Hook Kit ( ) 3 LOWER BOOM (REF) ROUTE CABLE THRU GUIDES ON CRANE BOOMS EXTENSION BOOM (REF) (SEE 177 NOTE 1) CORD REEL 13 (REF) BLK WHT 5 5 NO COM NC SWITCH 10 (REF) 2 NOTE: 1 USE SHIM AS REQUIRED. CUT IN TWO PIECES FOR SINGLE, OR BEND FOR DOUBLE THICKNESS PARTS LIST ITEM PART # DESCRIPTION QUANTITY MAST 1REF SNATCH BLOCK AND CABLE KIT (SEE DWG) (Effective 05/30/13) CABLE & HOOK KIT (SEE DWG) (Through 05/30/13) WINCH DRUM KEY (PART OF 21) 1REF TERMINAL #8 SPRSPD 16-14GA CABLE WELDMENT WASHER 5/16 FLAT BEARING NUT #8-32 HEX NYLOC SWITCH CAP SCR 1/4-20X3.5 HHGR5 (WAS ) 2

35 Chapter 4 Parts PARTS LIST CAP SCR 5/16-18X1 HHGR CORD REEL ASM STRAIN RELIEF 1/ WASHER 1/4 WRT (WAS 4) WASHER 1/4 LOCK WASHER 5/16 LOCK MOTOR CAP SCR 1/4-20X2 HHGR COVER MTG BLOCK SPEED REDUCER CAP SCR 1/4-28X3/4 SH COVER (WAS ) WASHER.16 FLAT WASHER #10 LOCK HARDWARE KIT, BASE & MAST (INCL. 7,12,17,22) REF HARDWARE KIT, BOOMS (INCL. 9,11,14-16,19,24-25) REF TUBE SHIM-WINCH DRIVE AS REQUIRED REV. F

36 Parts & Specifications Manual Part # Cable & Hook Kit ( ) (Effective 05/30/13) PARTS LIST ITEM PART # DESCRIPTION QUANTITY SHEAVE PLATE SHEAVE 5.5 NYLATRON GSM 0.75 BORE CLEVIS PIN 0.50 X HAIR PIN HOOK-SWVL S-322A2T W/LATCH NUT HEX NYLOCK CAP SCR X 4.00 HH GR8 Z NUT HEX NYLOCK CAP SCR X 3.50 HH GR8 Z WIRE ROPE ASM 0.22 X 7 X 19 X 65 FT. PGA (NOT SHOWN) SPACER-POL.52X 1.50X KIT-HDRW 1015 SNATCH BLOCK REF REV B

37 Chapter 4 Parts 35 Cable & Hook Kit ( ) (Through 05/30/13) 12(2) (2) , PARTS LIST ITEM PART # DESCRIPTION QUANTITY PIN SNATCH BLOCK SHEAVE (INCL:7,16) SIDE PLATE SET SCR 5/16-18X3/8SH (DRUM) HOOK 2-TON ROLLER BEARING (PART OF 3) 1REF WIRE ROPE ASM 7/32" X 65' SWIVEL HOOK 1-1/2 TON ZERK 1/8NPT CAP SCR 1/2-13X3 HHGR NUT 1/2-13 LOCK MACH BUSHING 3/4X10GA HAIR PIN 3/ INNER RACE (PART OF 3) 1REF

38 Parts & Specifications Manual Part # Cord Reel Assembly ( ) 4 5,6 3 P9 1,2,3 1 2 NOTES (SEE REFERENCE NUMBER IN BOX): 1 CUT TO LENGTH. 2 WHITE 3 BLACK PARTS LIST ITEM PART # DESCRIPTION QUANTITY TOWER CONNECTOR PIN 18-20GA (Through 03/22/96) TERMINAL FEM GA 2 (Effective 03/22/96) CABLE SEAL CORD REEL WIRE MARKER WIRE MARKER 1

39 Chapter 4 Parts 37 Boom Assemblies & Cylinders Lower Boom Assembly ( ) PARTS LIST ITEM PART # DESCRIPTION KIT # QUANTITY 1. 3B LOWER CYLINDER (WAS FROM THROUGH 2-07) LOWER BOOM WEAR PAD (WAS ) PIN INDICATOR PIN ZERK 1/8NPT #17 1

40 Parts & Specifications Manual Part # PARTS LIST ITEM PART # DESCRIPTION KIT # QUANTITY NUT 3/8-16 LOCK # WASHER 3/8 WRT # WASHER 1/2 WRT # MACH BUSHING 1X10GA NR RETAING RING 1 EXT HD WASHER 1/4 WRT # SUPPORT HOSE GUARD NUT 1/4-20 LOCK # HARDWARE KIT REF REV G

41 Chapter 4 Parts 39 Lower Cylinder (3B195010) (Thru. 9-05, Eff. 2-07) 18 (4) 19 (2) DRILL #15 HOLE 3/16" DEEP. PRESS IN # (2) 24 (4) 25 (2) NOTES: 1 REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS DISASSEMBLED. THIS WILL REDUCE FUTURE DOWNTIME. 2 APPLY REGULAR GRADE ANTI-SEIZE AND LUBRICATING COMPOUND TO THREADS ON CYLINDER HEAD ONLY. KEEP AWAY FROM ALL SEALS. 3 APPLY "LUBRIPLATE" NO 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 #7, STOP TUBE, REPLACES 6A WAFER LOCK. USE STOP TUBE INSTEAD OF WAFER LOCK WHEN RESEALING CYLINDER. 3B PARTS LIST ITEM PART # DESCRIPTION KIT# QUANTITY 1. 4B CASE ASM 1REF 2. 4G ROD ASM 1REF 3. 6HD25015 HEAD 1REF 4. 6ID25087 PISTON 1REF ZERK STR THD 1/4-28 1REF 6. 9D SEAL KIT 1REF STOP TUBE (WAS 6A025015) #6 1REF 8. 7Q O-RING #6 1REF 9. 7Q O-RING #6 1REF 10. 7Q10P228 BACKUP RING #6 1REF 11. 7R14P015 ROD WIPER #6 1REF 12. 7R U-CUP #6 1REF

42 Parts & Specifications Manual Part # B PARTS LIST ITEM PART # DESCRIPTION KIT# QUANTITY 13. 7T61N087 LOCK RING #6 1REF 14. 7T66P025 PISTON SEAL 1REF 15. 7T2NX417 WEAR RING-ROD #6 2REF 16. 7T2N4025 WEAR RING-PISTON #6 1REF 17. 6C STOP TUBE 1REF ADPTR #6M FACE #6 M STR TUBE ASM PRESS SWITCH #20 1REF VALVE C BALANCE VALVE #21 1REF CAP SCR 5/16-18X WASHER 5/16 FLAT NUT 5/16 HEX NYLOC ZINC B195010A CYLINDER PIN-LOCKING TUBE 1 REV. D

43 Chapter 4 Parts 41 Lower Cylinder ( ) (Eff through 1-07) DETAIL C ± 0.06" STROKE DETAIL D 27.0 ± 0.12" RETRACT EXTEND DETAIL C SCALE 3:1 DETAIL D SCALE 2:1 NOTES: 1 TO REDUCE DOWNTIME, REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS DISASSEMBLED CYLINDER DATA EXTENDED 4.91 IN², 0.38 GAL RETRACTED 3.14 IN², 0.24 GAL CASE 2.50 BORE X ø2.50 ROD ø1.50 DRY WEIGHT 34.1 LB TEST PRESSURE 3500 PSI OPERATING PRESSURE 3000 PSI PORTS SAE #6 O-RING BOSS (9/16-18 UNF-2B) CYLINDER TUBE BURST PRESSURE 14,995 PSI TORQUE TORQUE LOCKNUT, #8, TO FT-LB. USE LOCKTITE GRADE 271 OR EQUIVALENT. TORQUE HEAD GLAND, #3, TO FT-LB. TORQUE COUNTERBALANCE VALVE, #5, TO FT-LB. TORQUE PRESSURE SWITCH, #6, TO FT-LB PARTS LIST ITEM PART # DESCRIPTION QUANTITY CASE WELDMENT 1 2, PISTON HEAD GLAND ROD WELDMENT 1

44 Parts & Specifications Manual Part # PARTS LIST ITEM PART # DESCRIPTION QUANTITY VALVE-COUNTERBALANCE PRESSURE SWITCH SEAL KIT 1 8. REF LOCKNUT, 1-14 UNS 1 NEW Counterbalance Valve Assembly ( ) CYL R CYL E 4,7 ORIFICE PLUG UNDER SAE #4 PLUG ORIFICE SIZE (0.030") THRU HOLE FOR 5/16 BOLT (2 PLACES) PRESSURE SWITCH 2800 PSI SAE #6 ORBP SAE #6 ORBP ( THD 3 PLCS) R ORIFICE E 2 6 COUNTERBALANCE VALVE TORQUE TO 40 FT-LB SET TO GPM 1.75:1 NONVENTED PARTS LIST ITEM PART # DESCRIPTION QUANTITY COUNTERBALANCE VALVE 1 (Through 11/12/08) COUNTERBALANCE VALVE 1 (Effective 11/12/08) ORIFICE PRESSURE SWITCH PLUG 7/16STR HOLHEX 2

45 Chapter 4 Parts 43 Extension Boom Assembly ( )

46 Parts & Specifications Manual Part # PARTS LIST ITEM PART # DESCRIPTION DETAILS KIT # QTY HARDWARE KIT-1015 BOOMS EXTENSION BOOM WELDMENT ST STAGE EXT. BOOM - WELDMENT B CYLINDER 2.0/ S 32.00CC C SHEAVE 5.50 NYLON W/BEARING PIN TYPE T.75X ZERK NPT.12 # MACHY BUSHING.75X10 GA NR # HAIR PIN.19 ZINC # PIN-QUICK RELEASE.50D/1.5 CRIT # CAP SCREW.75-10X 2.50 HH GR5 Z # NUT HEX NYLOCK # CLEVIS PIN.50 X HAIR PIN SUPPORT CAP SCREW.25-20X 1.50 HH GR5 Z # WASHER.25 LOCK # PIN-T QUICK RELEASE.50D/4.0 CRIT # LOCK PLATE WASHER.38 LOCK # CAP SCREW.38-16X.75 HH GR5 Z # ROD.25 DIA X LG 1/4-20 X THREAD BOTH ENDS NUT 0.25X.38 CUSTOM NUT HEX # WEAR PAD-ROUND UHMW BOOM STOP NUT HEX NYLOCK # WASHER \.25 FLAT #1 2 REV M Rev K with boom stop effective S/N

47 Chapter 4 Parts 45 Installation - Manual Extension Boom Stop ( ) STOP IS FLUSH WITH END TYP.25 DETAIL A A PARTS LIST ITEM PART # DESCRIPTION DETAILS QUANTITY WASHER.25 LOCK ROD.25 DIA X LG 1/4-20 X NUT 0.25X.38 CUSTOM NUT HEX WEAR PAD-RND UHMW BOOM STOP NUT HEX NYLOCK WASHER.25 FLAT STOP PLATE 1.25 X 1.25 X STOP PLATE 1.00 X 1.00 X.38 1 REV A

48 Parts & Specifications Manual Part # Extension Cylinder (3B180010) (Thru. 9-05, Eff. 2-07) DRILL #15 HOLE 3/16" DEEP. PRESS IN #20. NOTES: SAE #4 O-RING PORTS 1 REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS DISASSEMBLED. THIS WILL REDUCE FUTURE DOWNTIME. 2 APPLY REGULAR GRADE ANTI-SEIZE AND LUBRICATING COMPOUND TO THREADS ON CYLINDER HEAD ONLY. KEEP AWAY FROM ALL SEALS. 3 APPLY "LUBRIPLATE" NO 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. 3B PARTS LIST ITEM PART # DESCRIPTION KIT# QUANTITY 1. 4B CASE ASM G ROD HD20012 HEAD ID20075 PISTON C STOP TUBE C STOP TUBE PNPXT02 PLUG #1 3REF C BALANCE VALVE 10GPM D SEAL KIT (INCL:10-19) STOP TUBE (PART OF 9) (WAS 6A025012) #9 1REF 11. 7Q O-RING (PART OF 9) #9 1REF 12. 7Q O-RING (PART OF 9) #9 1REF 13. 7Q10P224 BACK RING (PART OF 9) #9 1REF 14. 7R14P012 ROD WIPER (PART OF 9) #9 1REF 15. 7R U-CUP (PART OF 9) #9 1REF 16. 7T61N075 LOCK RING SEAL (PART OF 9) #9 1REF 17. 7T66P020 PISTON SEAL (PART OF 9) #9 1REF

49 Chapter 4 Parts 47 3B PARTS LIST ITEM PART # DESCRIPTION KIT# QUANTITY 18. 7T2NX415 WEAR RING (PART OF 9) #9 2REF 19. 7T2N4020 WEAR RING (PART OF 9) #9 1REF PIN-LOCKING TUBE 1 REV. E

50 Parts & Specifications Manual Part # Extension Cylinder ( ) (Eff through 1-07) 6 8 A VIEW A-A 38 A DETAIL C DETAIL D (STROKE) 2X - #10-24 UNC-2B 1/2 FULL THREAD 32.0 ± 0.12" RETRACT 68.0 ± 0.18" EXTEND DETAIL C SCALE 3:1 DETAIL D SCALE 3:1

51 Chapter 4 Parts 49 NOTES: 1 TO REDUCE DOWNTIME, REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS DISASSEMBLED CYLINDER DATA EXTENDED 3.17 IN², 0.49 GAL RETRACTED 1.95 IN², 0.30 GAL CASE 2.00 BORE X ø2.38 ROD ø1.25 DRY WEIGHT 35.4 LB TEST PRESSURE 3500 PSI OPERATING PRESSURE 3000 PSI PORTS SAE #4 O-RING BOSS (7/16-20 UNF-2B) CYLINDER TUBE BURST PRESSURE 14,270 PSI TORQUES TORQUE LOCKNUT, #5, TO FT-LB. USE THREADLOCK COMPOUND LOCTITE 271 OR EQUIVALENT. TORQUE COUNTERBALANCE VALVE, #8, TO FT-LB. TORQUE O-RING BOSS PLUG, #6, TO FT-LB. USE THREADLOCK COMPOUND LOCTITE GRADE 243 OR EQUIVALENT PARTS LIST ITEM PART # DESCRIPTION QUANTITY CASE WELDMENT ROD WELDMENT HEAD GLAND PISTON 1 5. REF LOCKNUT, 3/4-16 UNF 1 6. REF PLUG, #4 SAE STEEL HOL HEX SEAL KIT VALVE, COUNTERBALANCE 1 NEW

52 Parts & Specifications Manual Part # Controls & Hydraulics, Power Unit Hydraulic Power Unit - DC ( ) RESERVOIR O-RING ( ) 6 A 9/16-18 PRESSURE PORT (SAE #6 O-RING, STAMPED "P") RED POWER CABLE BOOTS SHOWN IN THIS VIEW ONLY A 3 SEAL SEAM AFTER ASSEMBLY WITH SILICON RTV 0.75 NPT DRAIN PORT 5

53 Chapter 4 Parts DRAWING 1000 PSI 2350 PSI ADJUSTABLE RELIEF VALVE 2500 PSI TORQUE CARTRIDGE TO IN-LB TANK PORT SAE (PLASTIC PLUG) KICK DOWN VALVE SET TO 1000 PSI TORQUE CARTRIDGE TO IN-LB SOLENOID OPERATED RELEASE VALVE 2-POSITION, NORMALLY CLOSED 12 V DC TORQUE IN-LB HYDRAULIC SCHEMATIC 1/4" FEMALE SPADE (4 PLCS) BLACK (2" WIRE EXPOSED) STD LOOM BLACK (2" WIRE WHITE EXPOSED) (2" WIRE EXPOSED) SECTION A-A SCALE 1:1 4-PIN CONNECTOR 16 AWG GREEN (2" WIRE EXPOSED) BLK FRN WHT PLUG TORQUE IN-LB CHECK VALVE TORQUE IN-LB ITEM #10 - CABLE ASSEMBLY ( ) PARTS LIST ITEM PART # DESCRIPTION QUANTITY DUMP VALVE RELIEF CARTRIDGE MOTOR/VALVE/PUMP KICK DOWN CARTRIDGE RESERVOIR TUBE-TANK LINE TUBE-SUCTION STARTER COIL BREATHER CABLE ASM (SEE DWG) CABLE-STARTER COIL 1

54 Parts & Specifications Manual Part # Hydraulic Kit-Power Unit ( ) 8 8 EXT CYL 6 6 LOWER CYL F FLOW DIRECTION POWER UNIT ,14,15 ROTATION 1 LOWER EXTENSION WINCH PORT "A" (DOWN) PORT "B" (UP) WINCH 5 12 ROTATION 9 PORT "B" (CCW) 12 9 PORT "A" (CW) NOTE: 1 REMOVE EXISTING FITTING FROM VALVE AND ADD ITEM #16 ( ).

55 Chapter 4 Parts PARTS LIST ITEM PART # DESCRIPTION QUANTITY VALVEBANK 4-SECT HOSE KIT (INCL:3-7,17,27,28) HOSE-FJ.50X11.5 #8#8 1REF HOSE-FJ.25X34 #4#4 1REF HOSE-FJ.25X39 #4#4 2REF HOSE-FJ.25X67 #4#4 2REF HOSE-FJ.25X24 #4#4 2REF ADAPTER #4MSTR #4MJIC ADAPTER #10MSTR #6FSTR ADAPTER #6MSTR #4MJIC TEE #8JIC SWVLNUTRUN ELBOW #6MSTR #4MJIC CAP SCR 1/4-20X3/4 HHGR WASHER 1/4 WRT NUT 1/4-20 LOCK FLOW LIMITER HOSE-FJ 25X34 #4#6 1REF ADAPTER #6MSTR #8MJIC ELBOW #8MJIC #8FJIC SWVL WASHER 5/16 LOCK WASHER 5/16 WRT CAP SCR 5/16-18X1 HHGR ADAPTER 3/8MPT #8FJIC FILTER-RETURN 10MIC 3/4FPT ELBOW 3/8MPT #8MJIC POWER UNIT 12V HOSE-FJ 50X23.5 #8 #8 1REF HOSE-FJ 38 X 28 #8#8 1REF ELBOW-#6MSTR/90/#8MJIC XLG 1 REV A

56 Parts & Specifications Manual Part # Control Kit-Power Unit ( ) PART OF CORD REEL CORD REEL PART OF PRESSURE SWITCH ROUTE WIRES ON INSIDE OF MAST 2 ROUTE VALVEBANK WIRE HARNESS THROUGH CENTER HOLES OF BASE, TURNTABLE BEARING, AND MAST 4,14,15 NOTES: 1 SHIP PARTS 14, 15 LOOSE IN BAG. 2 SEE FOR WIRE CONNECTIONS AND ELECTRICAL SCHEMATIC.

57 Chapter 4 Parts 55 Schematic, Power Unit ( ) 5 (ATTACH TO TOP LEFT POWER UNIT MOUNTING CAPSREW) 4,14,15 2 POWER UNIT THESE ITEMS ARE LOCATED TOGETHER (VALVE BANK) CIRCULAR 24 PIN REMOTE CONTROL HANDLE BLACK WHITE GREEN BLACK P4 J4 A A B B C C D D BLACK P1 J1 ORANGE/RED E E YELLOW/RED R R LT.BLU/RED H H BRN S S BLK YELLOW/RED A POWER UNIT SOLENOID M 13 A RED B C BLACK D BLACK P3 SPLICE A RED L BLK/BLUE T YELLOW/BLK A TAN/BLK K ORANGE/BLK B TAN F YELLOW P L T A K B F P CRANE POWER COMPRESSOR "CW" ROT "CCW" "OUT" EXT "IN" PART OF INSTALLATION INCLUDES IGN SOLENOIDS ORANGE PINK/BLK N D N D "UP" LOWER "DWN" BLACK C PRESSURE SWITCH NC RED J10 A B P10 A B LT.BLU/BLK C GRY/RED J C J "UP" WINCH "DWN" LT.BLUE M M ENGINE SPEED 17 BLACK CORD REEL WHITE B B A A P9 J9 J15 B A J5 P5 A B B DWN WINCH WINCH A J6 P6 A B B DWN LOWER LOWER A J7 P7 A IN EXT EXT B A B J8 P8 B A B CCW ROT ROT RED/BLUEU UP UP OUT CW COM NC NO 17 B P14 J14 B B P13 J13 B A A B P12 J12 B A A B P11 J11 B A A BRN/RED G ANTI-2-BLOCK SWITCH SPLICE B SPLICE C BLACK B A J16 P2 J2 A B C D E F A B C D E F CONNECTS TO "J1" OF CONTROL BOX ON A IMT MANUFACTURED MECHANICS BODY FOR P2..15 AND J2..15: "P" IS A WEATHERPACK PLUG, FEMALE PINS "J" IS A WEATHERPACK CAP, MALE PINS PARTS LIST ITEM PART # DESCRIPTION QUANTITY HANDLE ASSEMBLY, RC ELECTRIC BRACKET, MOUNTING CLAMP CABLE ASSEMBLY 1REF NUT-DEUTSCH 24 SHELL WASHER-LOCK DEUTSCH LOCK WIRE LEAD SEAL 8" 2 REV. E

58 Parts & Specifications Manual Part # Valvebank, Power Unit ( ) P5 WIN P6 LOW P7 EXT P8 ROT ,16,17 METAL CLAMP 1 P14 P13 P12 P11 2 METAL CLAMP SOLENOID VALVE, CONNECTOR (4 PLCS) WIRE LEAD LENGTH 2-3/4 5 - RELIEF VALVE TORQUE TO 30 FT-LB 2300 PSI, 5 GPM 7, TORQUE TO 80 IN-LB WINCH DOWN (A) UP (B) b P5 a P14 EXT IN (A) OUT (B) b P6 a P13 LOWER DN (A) UP (B) b P7 ROT CCW (A) CW (B) a P12 b P8 a P11 P T T HYDRAULIC SCHEMATIC PARTS LIST ITEM PART # DESCRIPTION QUANTITY INLET BODY OUTLET BODY RELIEF VALVE (2250 PSI) SOLENOID VALVE O-RING PLATE O-RING THREADED ROD GR THREADED ROD GR NUT 1/ WASHER 1/4 LOCK MOUNTING FOOT NAME TAG CONNECTOR TOWER 9

59 Chapter 4 Parts PARTS LIST ITEM PART # DESCRIPTION QUANTITY CONNECTOR TERMINAL CABLE SEAL CONN SHROUD CABLE PLUG WIRING HARNESS (SEE DWG) ADAPTER #6MSTR #4MJIC ELBOW #6MSTR #8MJIC ADAPTER #6MSTR #8MJIC 1 REV. A

60 Parts & Specifications Manual Part # Handle Assembly, Remote, Power Unit ( ) ENGINE STOP POWER CPRSR OPTION ROT CCW CW 6,9,12,27 ENGINE START CRANE OFF WINCH DOWN LOWER DOWNENG SPD FAST EXT IN OUT UP UP IDLE 14 4, TO SWITCH #19 BLACK SOLDER WIRE TO TERMINAL ,20 Remote Handle Assembly, Power Unit ( ) RED BLK/BLU RED/BLK 19 1 (REF) GRN (TO ROTARY SWITCH) BLK/ORN ORN/BLK 5 YEL YEL/RED 15(19) YEL/BLK 1(6) ORN 17 BLU/BLK 17 BRN/BLK 17 BRN

61 Chapter 4 Parts 59 WIRE FUNCTIONS SOLID/STRIPE FUNCTION A YEL/BLK ROT CW B ORN/BLK EXT OUT C BLU/BLK WINCH DN D RED/BLK WINCH UP E ORN/RED - F BRN EXT IN G BRN/RED - H BLU/RED - J BLK/RED - K BRN/BLK ROT CCW L RED POWER M BLU - N ORN LOWER DN O BLK/ORN SOL POWER P YEL LOWER UP Q BRN/BLU - R YEL/RED PUMP SPD S BLK CRANE T BLK/BLU CPRSR U RED/BLU - V BLU/ORN - W ORN/BLU - X YEL/BLU - - RED/RON PARTS LIST ITEM PART # DESCRIPTION QUANTITY WIRE 18GA X 4 GRN CONTROL HANDLE TRIGGER (PART OF 25) 1REF COVER BACK COVER PLACARD, SERIAL NUMBER CORD GRIP, LOCTITE PIN DECAL-DGR RC ELECTRO SM DECAL-CTRL SWITCH, ROTARY ELEC (PART OF 25) 1REF POP RIVET BUSHING, RED STL 3/4 X 1/ SHT MTL SCR #6X3/4 PH TERM-SPRSPD # GA TOGGLE SWITCH SPDT TOGGLE SWITCH SPST TOGGLE SWITCH SPDT CONNECTOR CABLE 18GA 24WIRE 30 FT PLUG, 1/2 1

62 Parts & Specifications Manual Part # PARTS LIST TERMINAL, FSLPON BRACKET, TRIGGER (PART OF 25) 1REF TRIGGER ASSEMBLY (INCL 3,11,24,26,28-29) SCR-MACH #8-32 PAN HEAD (PART OF 25) 4REF DECAL-CAUTION RC HANDLE ELEC PWR 1 UNIT SPRING, TENSION (PART OF 25) 1REF SCR-SHT METAL #6X1/2 PH (PART OF 25) 1REF HEAT SHRINK 0.33 FT REV. A NOTE: KIT # , TETHERED CABLE - 30 FEET, INCLUDES ITEMS 8, 15 (QTY 24), 20, 21, AND 30. ORDER TO REPLACE THE CABLE ASSEMBLY.

63 Chapter 4 Parts 61 Controls & Hydraulics, PTO Hydraulic Kit, Proportional PTO ( ) EXT CYL LOWER CYL ,14,15 1 ROTATION 17 LOWER EXTENSION PRESSURE (SEE INSTL KIT) RETURN (SEE INSTL KIT) PORT "A" (DOWN) WINCH WINCH PORT "B" (UP) ROTATION 9 PORT "B" (CCW) 12 9 PORT "A" (CW)

64 Parts & Specifications Manual Part # PARTS LIST ITEM PART # DESCRIPTION QUANTITY VALVEBANK 4-SECT HOSE KIT (INCL:3-7) HOSE-FI 50X11.5 #8 #8 1REF HOSE-FJ 25X34 #4 #4 2REF HOSE-FJ 25X39 #4 #4 2REF HOSE-FJ 25X67 #4 #4 2REF HOSE-FJ 25X24 #4 #4 2REF ADAPTER #4MSTR #4MJIC ADAPTER #10MSTR #6FSTR ADAPTER #6MSTR #4MJIC TEE #8JIC SWVL NUT BRANCH ELBOW #6MSTR #4MJIC CAP SCR 1/4-20X3/4 HHGR WASHER 1/4 WRT NUT 1/4-20 LOCK HOSE-FF 1/2X28 OAL (PART OF 2) 2REF SWIVEL #8MJIC #8MJIC 90 (PART OF 2) 2REF REV. A

65 Chapter 4 Parts 63 Hydraulic Kit, Non-Proportional PTO ( ) EXT CYL LOWER CYL ,14,15 1 ROTATION LOWER EXTENSION PRESSURE (SEE INSTL KIT) RETURN (SEE INSTL KIT) PORT "A" (DOWN) WINCH WINCH PORT "B" (UP) ROTATION 9 PORT "B" (CCW) 12 9 PORT "A" (CW) NOTE: 1 REMOVE EXISTING FITTING FROM VALVE AND ADD ITEM #16 ( ).

66 Parts & Specifications Manual Part # PARTS LIST ITEM PART # DESCRIPTION QUANTITY VALVEBANK 4-SECT HOSE KIT (INCL:3-7, 17) HOSE-FI 50X11 5 #8#8 1REF HOSE-FJ 25X34 #4#4 1REF HOSE-FJ 25X39 #4#4 2REF HOSE-FJ 25X67 #4#4 2REF HOSE-FJ 25X24 #4#4 2REF ADAPTER #4MSTR #4MJIC ADAPTER #10MSTR #6FSTR ADAPTER #6MSTR #4MJIC TEE #8JIC SWVL NUT BRANCH ELBOW #6MSTR #4MJIC CAP SCR 1/4-20X3/4 HHGR WASHER 1/4 WRT NUT 1/4-20 LOCK FLOW LIMITER HOSE-FJ 25X34 #4#6 1REF HOSE-FF 1/2X28 OAL (PART OF 2) 2REF SWIVEL #8MJIC #8MJIC 90 (PART OF 2) 2REF REV.A

67 Chapter 4 Parts 65 Control Kit, Proportional PTO ( ) PART OF CORD REEL CORD REEL PART OF PRESSURE SWITCH ROUTE WIRE ON INSIDE OF MAST 1 ROUTE VALVE BANK WIRE HARNESS THROUGH CENTER HOLES OF BASE, TURNTABLE BEARING, AND MAST PRESSURE SWITCH J10 P10 2,3,4 (SEE NOTE 1) 5 CORD REEL P9 J9 ANTI-2- BLOCK SWITCH 5

68 Parts & Specifications Manual Part # NOTES: 1 ITEMS 3 AND 4 ARE SHIPPED LOOSE IN BAG. 2 SEE FOR WIRE CONNECTIONS AND ELECTRICAL SCHEMATIC. 3 BASE AND MAST ASSEMBLY SHOWN AS MOUNTED ON TRUCK PARTS LIST ITEM PART # DESCRIPTION QUANTITY HANDLE ASSEMBLY W/ENGINE START BRACKET NUT-DEUTSCH 24 SHELL WASHER-LOCK DEUTSCH LOCK WIRE LEAD SEAL ELECTRICAL SCHEMATIC MANUAL, PROP RMT CONTROL 1 REV. F

69 Chapter 4 Parts 67 Control Kit, Non-Proportional PTO ( ) PART OF CORD REEL CORD REEL PART OF PRESS SWITCH ROUTE WIRES ON INSIDE OF MAST 2 ROUTE VALVE BANK WIRE HARNESS THROUGH CENTER HOLDS OF BASE, TURNTABLE BEARING, AND MAST 4,14,15 NOTES: 1 SHIP PARTS 14, 15 LOOSE IN BAG. 2 SEE DRAWING FOR WIRE CONNECTIONS AND ELECTRICAL SCHEMATIC. 3 BASE AND MAST ASSEMBLY SHOWN AS MOUNTED ON TRUCK. REV. E

70 Parts & Specifications Manual Part # Schematic, Proportional Remote Control ( ) Parts List ITEM PART # DESCRIPTION QUANTITY HANDLE ASM (ON-OFF PTO) HANDLE ASM (PROP L PTO) MTG BRACKET NUT WASHER-LOCK LOCK WIRE LEAD SEAL 2

71 Chapter 4 Parts 69 Schematic, Non-Prop Remote Control ( ) THESE ITEMS ARE LOCATED TOGETHER (VALVE BANK) CIRCULAR 4,14, PIN REMOTE CONTROL HANDLE J4 A B C D BLACK A B C D P3 RED BLACK BLACK SPLICE A P1 J1 ORANGE/REDE YELLOW/REDR LT.BLU/RED H BRN S S RED L L BLK/BLUE T T YELLOW/BLKA A TAN/BLK K ORANGE/BLKB TAN YELLOW F P K B F P CRANE POWER COMPRESSOR "CW" ROT "CCW" "OUT" EXT "IN" BLACK C PRESSURE SWITCH NC RED J10 A B P10 A B ORANGE PINK/BLK N D LT.BLU/BLKC GRY/RED J N D C J "UP" LOWER "DWN" "UP" WINCH "DWN" ENGINE SPEED 16 LT.BLUE M M BLACK CORD REEL WHITE COM NC 16 NO ANTI-2-BLOCK SWITCH B A P9 B A J9 J15 B A B J5 P5 A B DWN WINCH WINCH UP B P14 J14 B A B J6 P6 A B DWN LOWER LOWER UP B A P13 J13 B A A B J7 A B J8 P7 A B P8 A B IN EXT EXT OUT B A P12 J12 B A CCW ROT ROT CW B A P11 J11 B A RED/BLUEU BRN/REDG U G ENGINE KILL WINCH SPEED ENG START SPLICE B SPLICE C B RED BLACK BLACK A J16P16 WINCH SPEED P2 J2 A B C D E F A B C D E F CONNECTS TO "J1" OF CONTROL BOX ON A IMT MANUFACTURED MECHANICS BODY FOR P2..15 AND J2..15: "P" IS A WEATHERPACK PLUG, FEMALE PINS "J" IS A WEATHERPACK CAP, MALE PINS PARTS LIST ITEM PART # DESCRIPTION QUANTITY HANDLE ASSEMBLY, RC ON-OFF PTO BRACKET, MOUNTING NUT-DEUTSCH 24 SHELL WASHER-LOCK DEUTSCH LOCK WIRE LEAD SEAL 8" 2 NEW

72 Parts & Specifications Manual Part # Valvebank, Non-Prop Remote Control ( ) P5 WIN P6 LOW P7 EXT P8 ROT 22 METAL CLAMP ,16,17 METAL CLAMP P14 P13 P12 P SOLENOID VALVE,12 VDC CONNECTOR (4 PLCS) WIRE LEAD LENGTH 2-3/4 5 - RELIEF VALVE TORQUE TO 30 FT-LB 2300 PSI, 5 GPM 7, TORQUE TO 80 IN-LB WINCH DOWN (A) UP (B) b P5 a P14 EXT IN (A) OUT (B) b P6 a P13 LOWER DN (A) UP (B) b P7 a P12 ROT CCW (A) CW (B) b P8 a P11 P T T HYDRAULIC SCHEMATIC NOTE: 1 CONNECT J9 AND P10 TOGETHER. 2 ADD DUST CAP TO J PARTS LIST ITEM PART # DESCRIPTION QUANTITY INLET BODY OUTLET BODY RELIEF VALVE (2250 PSI) SOLENOID VALVE O-RING PLATE O-RING THREADED ROD GR THREADED ROD GR8 2

73 Chapter 4 Parts PARTS LIST NUT 1/ WASHER 1/4 LOCK MOUNTING FOOT NAME TAG CONNECTOR TOWER CONNECTOR TERMINAL CABLE SEAL CABLE PLUG WIRING HARNESS (SEE DWG) ADAPTER #6MSTR #4MJIC ELBOW #6MSTR #8MJIC ADAPTER #6MSTR #8MJIC 1 REV. B

74 Parts & Specifications Manual Part # Valvebank, Tethered Remote ( ) P P15 HYDRAULIC SCHEMATIC b P5 a P14 b P6 a P13 b P7 a P12 b P8 a P11 T T 2 1 3,4 23 P5 P6 P7 P8 13,14,15 22(8) METAL CLAMP 3 25, ,20 PLASTIC CLAMP P14 P13 P12 P11 6 7, NOTES (SEE REFERENCE NUMBER IN BOX): 1 PROPORTIONAL PRIORITY FLOW REGULATOR. 12V DC. 2 PERCENT OF SIGNAL INDICATOR COLOR CHANGING LED: a) RED = OFF, ZERO % TRIGGER b) GREEN = FULL ON, 100% TRIGGER. c) SHORTED COIL OR OTHER WILL SHOW AS RED WITH 100% TRIGGER. 3 POWER INDICATOR LED. a) OFF - BLANK b) ON - RED LIGHT 4 RELIEF VALVE PSI, 5 GPM. 5 CONNECT P109 AND J9 TOGETHER. 6 ADD DUST CAP TO J PARTS LIST ITEM PART # DESCRIPTION QUANTITY INLET BODY OUTLET BODY FLOW REG COIL RELIEF VALVE SOLENOID VALVE O-RING PLATE O-RING 10

75 Chapter 4 Parts PARTS LIST THREADED ROD GR THREADED ROD GR NUT 1/ WASHER 1/4 LOCK CONNECTOR TOWER CONNECTOR TERMINAL CABLE SEAL MOUNTING FOOT NAME TAG VALVE DRIVER MACH SCR (USE LOCTITE 242) WASHER #6 FLAT WIRING HARNESS (SEE DWG) ADAPTER #6MSTR #4MJIC ELBOW #6MSTR #8MJIC ADAPTER #6MSTR #8MJIC PLUG ORIFICE PLUG 1 REV. C

76 Parts & Specifications Manual Part # Handle Assembly, Remote, PTO On/Off ( ) 22 ENGINE STOP POWER 6,9,12 ENGINE START CPRSR CRANE OFF EXT WIN ROT IN DN LOWER CCW DOWN ENG SPD OPTION FAST OUT UP CW UP IDLE , , (24) BRN/RED YEL 1 (THIS JUMPER 3.5". ALL OTHERS 2.25".) WIRE FUNCTIONS RED BLK/BLU RED/BLK 19 BLK/ORN & BLK ORN/BLK BLK/RED ORN BRN/BLK BLK/BLU RED SOLID/STRIPE FUNCTION A YEL/BLK ROT CW B ORN/BLK EXT OUT C BLU/BLK WINCH DN D RED/BLK WINCH UP E ORN/RED - F BRN EXT IN G BRN/RED ENG START H BLU/RED - BLU YEL/BLK

77 Chapter 4 Parts 75 J BLK/RED ENG SPD K BRN/BLK ROT CCW L RED POWER M BLU ENG STOP N ORN LOWER DN O BLK/ORN SOL POWER P YEL LOWER UP Q BRN/BLU - R YEL/RED - S BLK RELAY 1 T BLK/BLU CPRSR U RED/BLU - V BLU/ORN - W ORN/BLU - X YEL/BLU - - RED/RON PARTS LIST ITEM PART # DESCRIPTION QUANTITY WIRE 18GA 2.25", 3.5") 1.42' CONTROL HANDLE COVER BACK COVER PIN DECAL-DGR RC ELECTRO SM DECAL-CTRL SHT MTL SCR #6X3/4 PH TERM-SPRSPD # GA TOGGLE SWITCH SPST TOGGLE SWITCH SPDT TOGGLE SWITCH SPST TOGGLE SWITCH SPDT CONNECTOR CABLE 18GA 24WIRE (NOTE: MUST ORDER 30 FT 30-FEET) PLUG, 1/ CONNECTOR 3/4 STRAIN RELIEF HEAT SHRINK 0.50 FT REV. G NOTE: , 30-FOOT TETHERED CABLE ASSEMBLY, INCLUDES #8, 15, 20, 21, AND 24. ORDER FOR SERVICE.

78 Parts & Specifications Manual Part # Handle Assembly, Tethered Remote ( ) ENGINE STOP ROTATION CCW 9 ENGINE POWER START CMP CRANE OFF EXT. IN WINCH DOWN LOWER DOWN ENG SPD RED GRN BLK 23 ORN/RED YEL/RED BLU/RED OPTION CW OUT UP UP FAST IDLE , ,20

79 Chapter 4 Parts 77 Handle Assembly, Tethered Remote Kit ( ) 16 15(31) RED BLK/BLU RED/ BLK 19 BLK BLK/ORN ORN/BLK BRN/RED YEL BLU YEL/ BLK (THIS JUMPER 3.5"; ALL OTHERS 2.25".) 1 18 BLK/RED ORN 17 BLU/BLK RED/BLU BRN/BLK 17 BRN Handle Assembly, Tethered Remote Kit ( ) WIRE FUNCTIONS SOLID/STRIPE FUNCTION A YEL/BLK ROT CW B ORN/BLK EXT OUT C BLU/BLK WINCH DN D RED/BLK WINCH UP E ORN/RED - F BRN EXT IN G BRN/RED ENG START H BLU/RED - J BLK/RED ENG SPEED K BRN/BLK ROT CCW L RED POWER M BLU ENG STOP N ORN LOWER DN O BLK/ORN SOL POWER P YEL LOWER UP Q BRN/BLU - R YEL/RED - S BLK CRANE T BLK/BLU CPRSR U RED/BLU OPTION V BLU/ORN - W ORN/BLU - X YEL/BLU - - RED/RON -

80 Parts & Specifications Manual Part # PARTS LIST ITEM PART # DESCRIPTION QUANTITY WIRE 18GA GRN 1.61 FT CONTROL HANDLE TRIGGER (PART OF 11) 1REF COVER BACK COVER STRAIN RELIEF 3/ PIN DECAL-DGR RC ELECTRO SM DECAL-CTRL TRIGGER ASM (INCL 3) SHT MTL SCR #6X3/4 PH TERM-SPRSPD # GA TOGGLE SWITCH SPST TOGGLE SWITCH SPDT TOGGLE SWITCH SPST TOGGLE SWITCH SPDT CONNECTOR CABLE 18GA 24WIRE (NOTE: MUST ORDER 30-FEET.) 30 FT TERM-FSLPON 1/4TAB TERM-MSLPON 1/4TAB MACH SCR #6-32X3/8 RDHD TUBING-HEAT SHRINK.5 FT REV. H NOTE: KIT # , TETHERED CABLE - 30 FEET, INCLUDES ITEMS 8, 15 (QTY 24), 20, 21, AND 25. ORDER TO REPLACE THE CABLE ASSEMBLY.

81 Chapter 4 Parts 79 Setting Remote Handle Assembly Low-End Output A B NOTE ONLY use this procedure to set the low-end output on the remote handle assembly if crane functions operate without pulling the proportional trigger. You may need a second operator to help with steps 4 and 5. 1 Following proper crane and stabilizer set-up, with the PTO engaged and the truck running, move the crane from the stowed position to a position off to the side of the truck. Unstow the winch cable hook and lower the winch approx (6) six feet. 2 Remove the back cover of the remote control handle. 3 Loosen screw A slightly. (Note: Screw style may vary). 4 While holding WINCH DOWN function, very slowly, rotate screw B clockwise until all movement has stopped. 5 Release WINCH DOWN function. 6 Tighten screw A 7 Test by operating WINCH DOWN, WINCH UP, ROTATE CCW, and ROTATE CW without pulling the trigger. If any of these functions move, repeat steps 2 through 6. 8 Replace control back cover and properly stow the crane and stabilizers.