Professional Documents
Culture Documents
Imt 2003i Parts Service
Imt 2003i Parts Service
Contents
Revisions .................................................................................................................................................... iii
Introduction
Safety
Operation
21
27
Technical Specifications
37
ii
Contents
Crane Reference
41
Parts
45
Parts Information ........................................................................................................................................ 46
Crane Assembly & Complete Parts List (99904352-1) .............................................................................. 48
Base & Mast Assembly (99904352-2) (See Parts List for Effectivity Dates) ............................................. 50
Base & Mast Assembly (99904352-2) (See Parts List for Effectivity Dates) ............................................. 52
Boom Assembly (99904352-3) ................................................................................................................... 54
Electrical Box & Gear Guard (99904352-4) ............................................................................................... 55
Boom, Winch, & Crane Assembly (99904352-5)....................................................................................... 56
Electrical Installation (99904398)............................................................................................................... 58
Electric Crane Battery Circuit (99904884) ................................................................................................. 59
Winch (71570921) (Eff 2-09) ..................................................................................................................... 60
Winch (71570875) (Through 2-09) ............................................................................................................ 61
Handle Assembly, Tethered Remote (51721683) ....................................................................................... 63
Turntable Gear (71056635)......................................................................................................................... 65
Decal Kit (95721546) ................................................................................................................................. 67
General Reference
69
Contents
Revisions
DATE
LOCATION
DESCRIPTION
20090312
THROUGHOUT
20100427
20100615
20100812
20111117
20131120
20140909
99904884
SPECS.
71570921
99904352-2
GREASING
INSTRUCTIONS
iii
CHAPTER 1
Introduction
GENERAL
This manual will help you operate your IMT crane correctly and safely. The manual does not
replace any government regulations, safety codes or insurance carrier requirements. Read and
understand the manual and all safety procedures for this crane prior to operation.
WARNING
Failure to read, understand and follow any
safety procedures for this equipment may
result in death, serious injury or equipment
damage.
Use caution and common sense. Refer to ANSI/ASME B30.5, the standard for Telescoping and
Mobile Boom Cranes, for more information on crane design and test criteria. (Contact the
American Society of Mechanical Engineers at www.asme.org for information on ANSI/ASME
B30.5.) Crane operators must also be familiar with OSHA 29CFR, Subpart N, Article 1926.550
and CAL-OSHA Title 8, Article 93 (California).
CRANE AND SAFETY EQUIPMENT MODIFICATIONS
Do not modify your crane with anything other than IMT approved equipment. If in doubt, contact
IMT prior to making modifications. DO NOT alter or modify any safety device! All safety devices
must be inspected, tested and maintained in proper working condition.
Decals regarding crane safety and operation are safety equipment and must be maintained.
Decals must be kept clean and legible.
OWNER RESPONSIBILITIES
You must maintain and operate this unit for the safest working conditions possible. You must
follow existing Federal, State, and Local codes and regulations governing the safe use and
maintenance, and must make sure anyone involved in equipment operation understands how to
operate and maintain the crane safely. Contact IMT or your IMT distributor for clarification.
WARRANTY
The equipment warranty on 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 is valid with this unit.
MANUAL STRUCTURE
Throughout the manual, NOTEs, CAUTIONs, WARNINGs and DANGERs 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.
WARNING
A WARNING is used when there is the
potential for personal injury or death.
CAUTION
A CAUTION is used when there is the
very strong possibility of damage to the
equipment or premature equipment
failure.
DANGER
Danger indicates an imminently hazardous
situation which, if not avoided, will result
in death or serious injury. Danger is used
in the most extreme situations.
CHAPTER 2
Safety
In This Chapter
Safety Instructions .................................................................... 8
Daily Safety Inspection ............................................................. 9
Electrical Hazards .................................................................... 11
Crane Capacity ........................................................................ 14
Electric Crane Danger Decal Placement .................................. 16
Work Site Planning ................................................................... 18
Stabilizer Operation .................................................................. 19
Ground Support ........................................................................ 20
Winch Safety ............................................................................ 20
Safety Instructions
WARNING
Keep children, by-standers, and persons not
required in the operation of equipment at
least 10-0 (3.05 m) from the outermost
range of the crane.
Do NOT operate crane unless you have been trained in safe operation.
Read, understand, and follow manual, labels, safety instructions, and your employers work
rules.
Make sure guards, safety signs, and safety features are in place and in good condition.
Read, understand and follow the crane load and work area charts. Do not exceed crane or
winch ratings.
Keep three wraps of loadline on winch.
Know the position of the booms at all times while operating the crane. Eliminate swing by
positioning the boom tip directly over the center of the load before lifting.
ELECTRICAL SYSTEM
This crane operates using electrical power from the vehicle battery.
DANGER
Avoid electrocution! Do NOT work on the
crane before turning off the crane power
supply in the crane cabinet and removing
the crane power disconnect cable from
the vehicle battery.
Chapter 2 Safety
STABILITY
Use crane on solid, level surface with stabilizers properly extended, and keep vehicle level.
Reduce loads when operating on uneven ground. Keep personnel clear of moving stabilizers.
When you rotate the crane, the load may change from being supported by the stabilizers to the
vehicle suspension. Be cautious as you rotate the crane, because the springs on the carrier
vehicle will respond differently to the load than the tires will.
WINCH
Never use the winch to drag a load into position before lifting. This may sideload the crane or
stress the wire rope beyond safe limits. Equipment damage may result.
When using a winch, always keep the tip of the extension boom as close to the load as practical.
This will prevent the load from swinging out of control when using the rotation (swing) function.
DANGER
DO NOT permit personnel to ride the
boom, loadline, hook or load, as this
action may cause DEATH or serious injury.
Use only specified wire rope for lifting. Retain at least three full wraps of wire rope on the winch
drum at all times.
WIRE ROPE
Before extending the boom, always pay out the wire rope. Failure to do so may overstress the
wire rope and cause a two block condition.
10
Chapter 2 Safety
11
Electrical Hazards
DANGER
ELECTROCUTION HAZARD
Look up and use light to search for power lines in the dark.
Keep boom and vehicle a minimum of 20 ft. (6.1 m) away from power lines.
If you touch a charged vehicle while standing on the ground, you will die.
Overhead power lines are not insulated. While some lines have a weather covering and appear
to be insulated, they are not. The vehicle or parts of the vehicle do not need to touch the power
line for the vehicle to become energized. Electricity will arc across gaps, and all overhead wires
or cables should be considered hazardous and dangerous. Always operate the crane so that no
part of the crane or load enters the "Danger Zone", the minimum clearance distance for a
powerline.
DANGER
VOLTAGE HAZARD
The danger zone of a particular powerline is based on its voltage. High voltage levels increase
the danger zone. See figure.
DANGER ZONE
AVOID THIS AREA.
12
DANGER
Electrocution Hazard
Never approach this vehicle or the
load if it is near power lines.
Death or serious injury will result from
touching or being near this vehicle if it
becomes charged.
70394445
From 0 to 0.75
From 0.75 to 50
From 50 to 345
From 345 to 750
From 750 to 1000
4 (0.22)
6 (0.83)
10 (3.05)
16 (4.87)
20 (8.10)
Make sure the work area is clear of major obstacles and overhead obstructions
Do not work within 20 feet (6.10 m) of high-voltage lines energized up to 35,000 volts, and
50 feet (15.24 m) of high-voltage lines energized up to 50,000 volts or of unknown voltage. It
is the law. The operator can be liable if activities in violation of this law cause injury or
property damage.
Only operate in conditions where the vehicle and equipment can be stabilized. Do not set up
or operate on soft soil, mud, snow or other unstable ground conditions that could allow the
vehicle or equipment to shift and move within 20 feet (6.10 m) of a power line.
Look up and live. Always check the operating vicinity for power lines before you drive into it.
Tree branches can hide power lines or cables from view. If operating at night, use powerful
lights to search for power lines or poles.
Do not rely on cage-type boom guards, insulating links, or proximity warning devices for
safety. Adhere to the required distances listed in table titled REQUIRED CLEARANCE OF
CRANES FROM ELECTRICAL TRANSMISSION LINES.
Chapter 2 Safety
13
When using rope to steady a load or restrain spinning of the load, be aware that rope will
also conduct electricity, especially if wet or damp.
Reduce operating speed when in close proximity to powerlines in order to allow the operator
more reaction time.
Replace any wire rope which has had high voltage contact.
14
Crane Capacity
The IMT crane is designed to lift specific loads. These loads are defined on the capacity placard
mounted near the operators station and on the crane. Exceeding the limits presented on the
capacity placard will create severe safety hazards and will shorten the life of the crane. The
operator and other concerned personnel must know the load capacity of the crane and the
weight of the load being lifted!
The capacity chart for each model is located in the specific crane technical specifications manual
and on placards on the crane and body.
WARNING
Never exceed the cranes rated load
capacities. Doing so will cause structural
damage to winches and cables which can
lead to death or serious injury.
NOTE
Capacity Placards are intentionally located
near the operator to assure ready reference
in determining when a load can or cannot be
handled.
Load limit information on the capacity
placards is formulated on 85% of tipping.
Tipping refers to the crane actually tipping
with its opposite stabilizer and tires having
broken contact with the surface.
Chapter 2 Safety
6'
(1.8 m)
5'
(1.5 m)
4'
(1.2 m)
45
30
3'
(.91 m)
15
2'
(.61 m)
1'
(.31 m)
(Short Base)
0
(CL)
1'
(.31 m)
2'
(.61 m)
3'
(.91 m)
4'
(1.2 m)
5'
(1.5 m)
6'
(1.8 m)
7'
(2.1 m)
15
16
Chapter 2 Safety
17
Additional danger decals are applied inside the truck body door. These decals include the
following.
Electrocution Hazard
Crane and remote control are not insulated.
Death or serious injury will result from approaching or contacting a power line.
WARNING
Falling Load Hazard
Fall Hazard
DIST ANCE IN FEE T / METERS / LOAD IN POUNDS / KG
Weight of load handling devices are part of the load lifted
and must be deducted from the capacity.
Overload Hazard
70396613
There are two warning decals applied to the front, sides and rear of the carrier vehicle.
18
PARKING BRAKE
"ON."
TRANSMISSION
IN NEUTRAL.
LOAD DOES
NOT EXCEED
CRANE
CAPACITY.
STABILIZERS ARE FULLY OUT AND DOWN
ON A FIRM AND LEVEL SURFACE.
Lift safety depends on work site preparation. Plan your lifts carefully. Consider:
Powerlines
Bystanders
Overhead obstructions
Determine the weight of the load to be lifted. Use the crane capacity chart to make sure all lifts
are performed within the rated capacity of the crane. Position the carrier vehicle with these
capacities in mind and avoid any overhead obstructions which can impair the lift.
DANGER
AVOID POWER LINES! Read and
understand the Electrical Hazard section
of this manual before attempting any
crane operations near powerlines.
Position the carrier vehicle so that when the crane is fully extended it can't contact electrically
charged lines or apparatus. Twenty feet (6.10 meters) is the minimum distance that any portion
of the crane, loadline or load can be to electrical lines carrying up to 35,000 volts. Allow 50 feet
(15.24 m) minimum for powerlines with unknown voltages, or with voltages above 35,000 volts.
In windy conditions, allow extra space for powerline and loadline sway and deflection. Provide
additional clearance between the crane and electrical lines. If the powerline or apparatus
voltage is not known, contact the electrical utility prior to the lift.
If a lift is impossible to perform within the minimum distance between electrical source and
crane, ask the power company to de-energize the powerlines or apparatus before any lift is
attempted.
Use a qualified signal person or spotter when working near electrical sources, even if the
powerline has been de-energized.
Chapter 2 Safety
19
Stabilizer Operation
Stabilizers help stabilize the crane and carrier vehicle during a lift, but they can be hazardous
due to their close proximity to the operator and other personnel. They are the only component of
the crane which normally contact the ground.
WARNING
Stabilizers can cause serious injury!
There are various stabilizer designs available, but all require extreme caution in their use. See
figures for proper stabilizer operation sequence and warnings.
BACK OF TRUCK
WARNING!
STABILIZERS C AN PINCH, STRIKE,
OR CRUSH OBJECTS OR PEOPLE.
MAKE SURE THERE ARE NO
OBSTRUCTIONS IN OR NEAR THE
STABILIZER P ATH.
WARNING
BACK OF TRUCK
1. EXTEND STABILIZER ARMS TO
THEIR FULL HORIZONTAL
OPERATING LIMIT.
BACK OF TRUCK
Crush Hazard
Before extending stabilizers:
Look around vehicle.
Clear area of all people.
Extending stabilizers on people
may injure or kill.
70392864
20
Ground Support
Position the carrier vehicle on a firm, level surface for adequate stabilizer support. If stabilizers
appear to bury themselves in a less than firm surface, then DO NOT perform a lift until a suitable
location is found. DO NOT position the stabilizers near sharp drop-offs or areas of uncertain
firmness.
Before a lift is made, be certain that the parking brake is set and the drive axle is disengaged.
Extend stabilizers fully out and then down. Park the carrier vehicle so that it is level from the
front to the rear. Use the power down stabilizer function to level the vehicle from side-to-side.
Utilize a signal person if the stabilizers are not in view from the operators station when
extending or lowering the stabilizers.
Winch Safety
1 DO NOT pull the load block or sheave back so that it makes contact with the boom tip. This
is two blocking and should be avoided.
2 Pay out loadline before the boom is extended to avoid two blocking.
3 DO NOT permit personnel to ride the boom, loadline, hook or load. This action may cause
DEATH or serious injury.
4 Use only specified wire rope for lifting.
5 Retain at least three full wraps of wire rope on the winch drum at all times.
6 See Wire Rope Precautions for additional information.
21
CHAPTER 3
Operation
In This Chapter
Electric Crane Start-up and Task Performance ........................ 21
Tethered Remote Handle Operating Instructions ...................... 23
Crane Shut Down ..................................................................... 24
Operation in Poor Conditions.................................................... 25
Hand Signals ............................................................................ 25
22
Lifting a Load:
1 Position the crane as close to the job as possible on a firm, dry and level surface. Avoid
overhead obstructions on the work side of the unit.
2 Set the auxiliary (parking) brake. Make sure the vehicle engine is on and the transmission is
in park or neutral.
3 Make sure the crane electric power switch, located in the crane remote storage cabinet, is
turned to the "ON" position.
4 See the Electric Crane Controls section for information on how to move a load using your
controls.
5 Before conducting any boom operations, make sure vehicle is stable. Extend both
stabilizers on carrier vehicle. Level the vehicle side to side. Provide blocks if necessary to
level the unit on sloping ground or bearing pads if the stabilizers tend to sink into soft terrain
or hot asphalt. Some concrete or asphalt surfaces are relatively thin and cannot withstand
the stabilizer loading. Concrete can break through and cause instability.
WARNING
Avoid injury or equipment damage! Do NOT
attempt to handle a load if the stabilizers are
unable to make solid contact with the ground.
Stability over the front (without front stabilizers) can be hampered by raising the vehicle
excessively. Use extreme caution when operating in areas around the truck which are not
supported by stabilizers because of cushion of tires and springs. When swinging loads from
areas supported by stabilizers, use extreme caution because of potential sudden shifting of
the support point. Always keep the load as close to the ground as possible.
CAUTION
Avoid injury or equipment damage! Do NOT
attempt to rotate the crane before placing it in
the deployed position.
Chapter 3 Operation
POWER
ON
ROTATE
CW
ROTATE
CCW
OFF
WINCH
UP
WINCH
DOWN
23
24
1 Make sure the vehicle engine is on; the vehicle is in park or neutral; and the parking brake is
on.
2 Make sure the crane electric power switch, located in the crane cabinet, is turned to the "ON"
position.
3 Turn on the crane remote power via the on/off switch of the tethered remote handle.
4 Pull back on the trigger until the power unit begins to run.
5 Select the required function on the crane handle to move the crane as desired, making sure
not to release tension on the trigger assembly.
6 When done with the function, continue to hold the trigger assembly in until all immediate
movements of the crane have been completed.
7 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.
8 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.
POWER SWITCH
TURNED TO OFF
POSITION.
Chapter 3 Operation
25
Hand Signals
Hand signals can be used to communicate between crane operators and assistants when the
job site noise level is too high to communicate in other ways.
Signals to the operator shall follow ASME B30.5 standards, unless voice communication is
utilized. Signals shall be discernible or audible at all times. No response by the operator is to be
made unless the signal is clearly understood.
For operations not covered by the ASME hand signals, additions to or modifications may be
made. These special signals must be agreed upon by the operator and signal person before the
crane is operated.
If verbal instructions are required rather than hand signals, all crane motions must be stopped
before doing so. Figure includes an illustration of the hand signal, the operation associated with
the signal, and a description of the signal. The operator and signal person must review these
signals and agree to their use before implementation. For complete hand signal information,
refer to ASME/ANSI B30.5 - Mobile and Locomotive Cranes, published by the American Society
of Mechanical Engineers.
The hand signals presented by The American Society of Mechanical Engineers have been
accepted by the Occupational Safety and Health Administration (OSHA).
26
27
CHAPTER 4
Maintenance Introduction
Proper, regularly scheduled maintenance is essential in keeping your crane at peak operating
efficiency. This section outlines maintenance information and service intervals which should be
followed by maintenance personnel.
Following the designated lubrication procedures is important in providing maximum crane life.
The procedures and lubrication charts in this section include information on the types of
lubricants used, location of lubrication points and frequency of lubrication. Information
concerning the lubrication requirements of the truck chassis is not included. Refer to the
appropriate truck manufacturers manuals for chassis lubrication requirements.
The service intervals specified are for normal operation where moderate temperatures, humidity
and atmospheric conditions prevail. In areas of extreme conditions, the service periods and
lubrication specifications should be altered to meet those conditions. For information concerning
extreme condition lubrication, contact your local service representative.
CAUTION
All maintenance personnel must be familiar
with equipment operation and safety per the
specific operation manual for their product
prior to beginning maintenance.
28
POWER SWITCH
TURNED TO OFF
POSITION.
DANGER
AVOID DEATH OR SERIOUS
INJURY!
Before beginning any work on
crane,
Make sure the power switch located inside the crane cabinet is turned to the OFF position.
Make sure the crane power disconnect cable is disconnected from the vehicle battery.
Maintenance Schedule
Detailed steps on numerous maintenance procedures are described in the following pages. Use
the following chart to help you determine the time schedule of the maintenance requirements.
TIME FRAME
Weekly
MAINTENANCE ACTIVITY
Lubricate:
Turntable Bearing
Hinge Pins
Monthly
Grease Zerks
Complete all required monthly inspections. (See IMT Inspection Checklist
in the General Reference section of this manual.)
Quarterly
Every year
Every 2 years
Inspect pins.
29
LUBRICATION PRODUCT
Shell Alvania 2EP or
Shell Retinax "A" or
Mobilith AW2 or
equivalent
Lithium or GP bearing
lube
APPLICATION METHOD
Hand Grease Gun or
Pneumatic Pressure
Gun
INTERVAL
Weekly
Grease gun
Every 50 hours
Grease Zerks
Crane grease zerks must be greased on a weekly basis during normal operating conditions.
Under severe operating conditions the zerks must be greased more frequently. Each grease
zerk is marked with a decal, Grease Weekly, as shown.
Crane worm gear teeth and bearing teeth must be lubricated weekly with Molub-Alloy 882 Heavy
or equivalent. See chart for the lubrication product schedule. Apply products with a grease gun
or brush as directed.
30
Pins are frequently used as structural components on IMT cranes. Critical structural pins which
require inspection and repair include pins which secure the lower boom assembly to the mast,
pins which secure the main cylinder base end to the mast, pins which secures the main cylinder
rod end to the lower boom assembly, pins which secure the main cylinder to the extension
cylinder section, and pins which secure the extension boom assembly to the boom tip.
Every two years, disassemble the crane and inspect the critical structural pins (noted above) for
damage. Check pins for signs of wear, using Pin Defect chart. The pin should be shiny with no
galling or pitting in the contact areas. Minor blemishes (see chart) can be dressed and the pins
can be reused. Pins with cracks which extend into the pin cross section must be replaced. To
repair pins, dress the edges of the flaw with a file so no metal protrudes above the circular
surface of the pin. Pins with defects larger than those listed, or with large cracks extending into
the pin cross section, must be replaced.
PIN DEFECT
Nick, gouge or scratch
Circular scratch around the pin
Lengthwise scratch
MAXIMUM TOLERANCE
Up to 1/8" (3.2 mm) diameter
Up to 1/16" (1.6 mm) wide or deep
Up to 1/32" (0.8 mm)
NOTE
Use care when removing pins not to crush
the snap ring groove.
Apply a lubricating compound like
Never-Seez prior to reinstalling pins. Avoid
getting Never-Seez on Gar-Max bushings.
WARNING
Disconnect electrical power to crane prior to
beginning major maintenance or repairs.
See Maintenance Safety (see "Electric Crane Power Safety" on page 28) for details.
31
When pads wear such that boom sections rub on boom sections with the result of metal
scraping and the removal of paint on the boom sections.
With the boom sections extended in the horizontal position, there is noticeable droop. Any
visible droop in the boom sections indicates the need for wear pad replacement.
2ND
EXTENSION
BOOM
WEAR
PAD
WEAR
PADS
WEAR
PAD
1ST
EXTENSION
BOOM
WEAR
PADS
LOWER
BOOM
32
2 Start the crane. Slowly cycle the boom in and out with no load to purge air from system.
3 After the air has been purged from the system, check the reservoir oil level. Top off oil level
if needed.
33
Apply
3 Apply lubricant heavily to portions which encounter bending such as at the sheave and
winch.
Corrosion can be cause for replacement. Any development of corrosion must be noted and
monitored closely.
When there are either three broken wires in one strand or a total of six broken wires in all
strands in any one rope lay.
34
When flat spots on the outer wires appear and those outside wires are less than 2/3 the
thickness of the unworn outer wire.
When there is noticeable heat damage (discoloration) of the rope by any means.
When the diameter is reduced from nominal size by 1/32" (0.8 mm) or more.
NOMINAL
SIZE - 1/32" NOMINAL
SIZE
(0.8 mm)
If a broken wire protrudes or loops out from the core of the rope.
Additional Inspections
Every three months, and more frequently when the equipment is subject to heavy usage,
perform the following inspections in addition to those specified in the Crane Inspection Checklist
in the Reference Section.
LOWER AND EXTENSION BOOMS
1 Check structural defects evidenced in weld cracks, dents or bends.
2 Check slide pads for wear.
3 Check lower and extension cylinder pins for proper installation. Check hinge pin bushings
for excessive wear.
35
Maximum
3 Check for proper gear mesh in turntable gear-bearing. Check motor and gear-mounting
bolts for tightness.
HYDRAULIC SYSTEM
1 CYLINDERS
a) Check rods for damage such as scarring, nicks, dents and rust on out-of-service units.
b) Check for leaks at weld joints and rod seals. Check for drift indicating leakage around
piston rings or defective holding valves.
c) Check extension cylinder head and piston positions.
d) Check cylinder case for dents.
2 HYDRAULIC POWER UNIT
a) Check for leaks at shaft seal.
b) Check for drop in operating speed.
c) Check hydraulic oil for excessive heating.
d) Check bolts and fasteners for tightness.
e) Note any unusual vibration or noise.
37
CHAPTER 5
Technical Specifications
In This Chapter
2003i Technical Data ................................................................ 37
2003i Capacity Chart ................................................................ 39
2003i Geometric Configuration & Mounting Pattern .................. 40
38
65' (19.8 m)
5,600 lb (2540 kg)
PERFORMANCE CHARACTERISTICS
SPECIFICATION
ROTATION
SPEED
64 seconds
6'
(1.8 m)
5'
(1.5 m)
4'
(1.2 m)
45
30
3'
(.91 m)
15
2'
(.61 m)
1'
(.31 m)
(Short Base)
0
(CL)
1'
(.31 m)
2'
(.61 m)
3'
(.91 m)
4'
(1.2 m)
5'
(1.5 m)
6'
(1.8 m)
7'
(2.1 m)
39
40
8'-4"
(2.54 m)
12.6"
(31.9 cm)
2003i
1'-8"
(50.2 cm)
3'-11"
(1.19 m)
SHORT BASE
TALL BASE
4'-0" (1.22 m)
5'-6" (1.67 m)
6'-6" (1.98 m)
2003i MOUNTING HOLE PATTERN
1.25"
(3.18 cm)
6.0" DIA.
(15.2 cm)
9.25"
(23.5 cm)
12.0"
(30.5 cm)
0.81" DIA.
(2.0 cm)
6.0"
(15.2 cm)
41
CHAPTER 6
Crane Reference
In This Chapter
2003i Assemblies & Grease Zerk Locations ............................. 41
2003i Recommended Spare Parts ............................................ 43
Electric Crane Control .............................................................. 44
42
MANUAL
EXTENSION
BOOM
SNATCH
BLOCK
LOWER
BOOM
HOOK
WINCH
ELECTRICAL
BOX
CRANE
MAST
1
TURNTABLE
GEAR BEARING
2
3
CRANE BASE
ITEM
1.
2.
3.
LOCATION DESCRIPTION
Gear Rotator Grease Extension
*Rotate crane while greasing.
Turntable gear
Turntable gear
LUBRICANT
Shell Alvania 2EP
or
Shell Retinax "A"
FREQUENCY
Weekly
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 Electric Crane Operation & Safety manual (IMT # 99904381) for
additional lubrication requirements.
Quantity
16
1
2
4
2
3
3
1
WINCH (71570875)
77566639
BRAKE
1
1
1
43
44
45
CHAPTER 7
Parts
In This Chapter
Parts Information ...................................................................... 46
Crane Assembly & Complete Parts List (99904352-1) .............. 48
Base & Mast Assembly (99904352-2) ...................................... 50
Boom Assembly (99904352-3) ................................................. 54
Electrical Box & Gear Guard (99904352-4) .............................. 55
Boom, Winch, & Crane Assembly (99904352-5)....................... 56
Electrical Installation (99904398) .............................................. 58
Electric Crane Battery Circuit (99904884) ................................ 59
Winch (71570921) (Eff 2-09) .................................................... 60
Winch (71570875) (Through 2-09) ........................................... 61
Handle Assembly, Tethered Remote (51721683) ..................... 63
Turntable Gear (71056635) ...................................................... 64
Decal Kit (95721546) ................................................................ 67
46
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 50438-0189
Telephone: 641-923-3711
Technical Support Fax: 641-923-2424
IOWA MOLD TOOLING CO., INC.
BOX 189, GARNER, IA 50438-0189
MODEL
NUMBER
SERIAL
NUMBER
MFG
DATE
Chapter 7 Parts
47
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.
48
2003i
TALL
BASE
2003i
SHORT
BASE
DESCRIPTION
HARDWARE KIT, 2002I
KIT, ELECTRICAL INSTALLATION
WELDMENT-BASE 20002I
WELDMENT-TALL BASE 2003I
WELDMENT-MAST 2002I
LOWER BOOM- 2002I
EXTENSION BOOM-2002I
SNATCH BLOCK- 2002I
TURNTABLE GEAR SHROUD
WELDMENT-ELEC ROTATOR BRKT TOP
WELDMENT- ELEC ROTATOR BRKT BOTTOM
WEAR PAD-RND 2.00 DIA X .60 DIA X 1.00 LG
WEAR PAD-RND 1.00 DIA X .50 DIA X .50L
STOP SCREWEW 3/8-24 X .50
PIN- .75X 6.50LG WORKSAVER
WIRE ROPE ASM-.22 X 7 X 19 X 65ft PGA
CLAMP-I" CONDUIT HANGER W/BOLT
HOOK- 1 TON
GEAR-TRNTBL BRG 2002i
KIT #
QUANTITY
1
1
1
1
1
1
1
1
1
1
1
2
4
2
2
1
2
1
1
Chapter 7 Parts
DESCRIPTION
BRKT-WIRE HARNESS 2003I
TURNTABLE RING
WINCH-DC500-12VDC (WAS 71570875 THROUGH 209)
CONTACTOR-WINCH 12V DC500
PIN-QUICK RLSE .50D/3.5 CRIT
HAIR PIN .16 DIA .63-1.00 SHAFT (PART OF 71734310)
ADPTR-MPT/HEX/MPT .12 .12
ELBOW-STREET STL .12 X 90 DEG
CAP-GREASE PRO20 GC-RED
ZERK-NPT .12 X 1.75 LG
SCREW-MACH # 6-32 .50 RDH PHLPS
CAP SCREW .25-20X .50 HH GR5 Z
CAP SCREW .25-20X .62 HH GR5 Z
CAP SCREW .25-20X .75 HH GR5 Z
CAP SCREW .25-20X 1.00 HH GR5 Z
CAP SCREW .25-20X 2.25 HH GR5 Z
CAP SCREW .38-16X 1.00 HH GR5 Z
CAP SCREW .38-16X 1.25 HH GR5 Z
CAP SCREW .62-11X 2.00 HH GR8 Z
CAP SCREW .62-11X 3.00 HH GR8 Z
CAP SCREW .25-20X .38 BTNHD ZC
NUT .25-20 HEX NYLOCK
NUT 6-32 HEX NYLOCK
WASHER #6 W FLAT ANSI B27.2
WASHER .25 FLAT
WASHER .38 FLAT
WASHER .62 FLAT ASTM F436
WASHER .25 LOCK
WASHER .38 LOCK
CLAMP-UMP20 S464-G12
CABLE ASM-1GA-3/8RNG X SWVL MX 60.00 LG
CABLE ASM-4GA-1/4RNGX SWVL FX 17.50 LG
HANDLE ASM-TETHERED ELECTRIC CRANES
HARNESS-TETHER ELECTRIC CRANE 2003i
KIT #
#24
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#2
#2
#2
#2
49
QUANTITY
1
1
1
1
3
3
1
1
4
1
4
4
2
2
4
1
2
4
16
15
2
7
4
4
12
2
31
6
8
3
1
1
1
1
50
19
37
29
30
28
27
49
46
42
53
22 1
29
17
10
34
3
40,47 3
5
39,47
3
17
34
42
52
11
19
51
45
48
33
MAST ASSEMBLY
BASE ASSEMBLY
DESCRIPTION
KIT-HARDWARE
KIT- 2003I ELECTRICAL INSTALLATION
WELDMENT-BASE
WELDMENT-MAST
KIT #
QUANTITY
1
1
1
1
Chapter 7 Parts
52721307
17.
19.
21.
26.
70580194
71056635
71056636
72053719
27.
72531130
28.
29.
70034382
72534418
32.
72060001
33.
72060002
36.
72060046
38.
72060151
39.
72060177
41.
72062104
44.
72063001
45.
72063003
46.
72063119
47.
72063049
48.
72063051
50.
51721944
51.
51722289
REV. C 20090311
DESCRIPTION
WELDMENT-ELEC ROTATOR BRACKET TOP
(effective through 05/10/13)
WELDMENT- ELEC ROTATOR BRACKET BOTTOM
(effective through 05/10/13)
CLAMP-I" CONDUIT HANGER W/BOLT
GEAR-TRNTBL BRG
TURNTABLE RING
ADPTR-MPT/HEX/MPT .12 .12
(effective through 09/03/13)
ELBOW-STREET STL .12 X 90 DEG
(effective through 09/03/13)
CAP-GREASE PRO20 GC-RED
ZERK-NPT .12 X 1.75 LG
(effective through 09/03/13)
CAP SCREW .25-20X .62 HH GR5 Z
CAP SCREW .25-20X .75 HH GR5 Z
CAP SCREW .38-16X 1.00 HH GR5 Z
CAP SCREW .62-11X 2.00 HH GR8 Z
CAP SCREW .62-11X 3.00 HH GR8 Z
NUT .25-20 HEX NYLOCK
WASHER .25 FLAT
WASHER .38 FLAT (effective through 09/03/13)
WASHER .62 FLAT ASTM F436
WASHER .25 LOCK
WASHER .38 LOCK
CABLE ASSEMBLY- 1GA-3/8RNGX SWVL MX 60.00LG
CABLE ASSEMBLY- 4GA-1/4RNGX SWVL FX 17.50LG
KIT #
51
QUANTITY
1
1
2
1
1
1
1
#1
#1
4
1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#2
#2
2
2
2
16
15
7
12
2
31
6
8
1
1
52
19
37
29
30
28
27
49
46
42
22 1
29
17
2
3
53
10
34
40,47 3
5
39,47
3
17
34
42
52
11
19
51
45
48
33
MAST ASSEMBLY
BASE ASSEMBLY
KIT #
QUANTITY
1
1
1
1
Chapter 7 Parts
KIT #
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#2
#2
QUANTITY
2
1
1
4
2
2
2
16
15
7
12
3
31
6
8
1
1
1
1
1
1
#1
53
54
13
48
24
6
48
14
41
44
44
1 25
35
7
12
24
13
13
NOTES (SEE REFERENCE NUMBER IN BOX):
1
DESCRPITION
KIT-HARDWARE
LOWER BOOM
EXTENSION BOOM
SHEAVE (PART OF #7)
WEAR PAD-RND 2.00 DIA X .60 DIA X 1.00 LG
WEAR PAD-RND 1.00 DIA X .50 DIA X .50L
STOP SCREW 3/8-24 X .50
PIN-QUICK RLSE .50D/3.5 CRIT
HAIR PIN .16 DIA .63-1.00 SHAFT (PART OF 71734310)
CAP SCR .25-20X 2.25 HH GR5 Z
NUT .25-20 HEX NYLOCK
WASHER .25 FLAT
WASHER .38 LOCK
KIT #
#24
#1
#1
#1
#1
QUANTITY
1
1
1
2
4
2
3
3
1
7
12
8
Chapter 7 Parts
55
KIT #
#1
#1
#1
#1
QUANTITY
1
4
12
6
3
56
22
16
25 1
8
2
40
24
44
17
37,48
41,44
18
23
34
44
42
34 44 20
52
30 43
15
53
77041800
DESCRIPTION
KIT-HARDWARE
KIT- 2003I ELECTRICAL INSTALLATION
SNATCH BLOCK- 2002I
SHEAVE (PART OF #8)
PIN- .75X 6.50LG WORKSAVER
WIRE ROPE ASM-.22 X 7 X 19 X 65ft PGA
CLAMP-I" CONDUIT HANGER W/BOLT
HOOK- 1 TON
BRKT-WIRE HARNESS 2003I
WINCH-DC500 12VDC (WAS 71570875
THROUGH 2-09)
CONTACTOR-WINCH 12V DC500
KIT #
QUANTITY
1
1
1
REF
2
1
2
1
1
1
1
Chapter 7 Parts
DESCRIPTION
PIN-QUICK RLSE .50D/3.5 CRIT
HAIR PIN .16 DIA .63-1.00 SHAFT (PART OF
71734310)
SCR-MACH # 6-32 .50 RDH PHLPS
CAP SCR .25-20X 1.00 HH GR5 Z
CAP SCR .38-16X 1.25 HH GR5 Z
SCR-MACH .25-20X .38 BTNHD ZC
NUT .25-20 HEX NYLOCK
NUT 6-32 HEX NYLOCK
WASHER #6 W FLAT ANSI B27.2
WASHER .25 FLAT
WASHER .38 LOCK
HANDLE ASM-TETHERED ELECTRIC CRANES
HARNESS-TETHER ELECTRIC CRANE 2003i
KIT #
#24
QUANTITY
3
3
#1
#1
#1
#1
#1
#1
#1
#1
#1
#2
#2
4
4
4
2
7
4
4
12
8
1
1
57
58
13
3
6
5
12
W2
W1
GROUND
(CONTACTOR
MOUNTING
BRACKET)
WIRE HARNESS
W2 (WINCH DOWN)
WINCH
WIRE HARNESS
W3 (POWER)
WINCH
13
(+)
10
9
TO 300 AMP
KEYED SWITCH
IN CRANE BOX
W2
WIRE HARNESS
W2 (WINCH DOWN)
9.
77045883
10.
77044659
11.
71056635
12.
71570921
13.
77041800
REV. B 20090311
(-)
10
8
9
WIRE
HARNESS
CJ-200
WIRE
HARNESS
W1 (WINCH
UP)
W3
5
GROUND
(CONTACTOR
MOUNTING
BRACKET)
SUPPLIED
WITH
CONTACTOR
1 11
2
W1
WIRE HARNESS
W1 (WINCH UP)
DESCRIPTION
KIT- 2003I ELECTRICAL INSTALLATION
CABLE ASM- 1GA-3/8RNGX SWVL MX 60.00LG
CABLE ASM- 4GA-1/4RNGX SWVL FX 17.50LG
HARNESS-TETHER ELECTRIC CRANE 2003i
CABLE ASM- 4GA-1/4RNGX 1/4RNGX 5.50LG
CABLE ASM- 4GA-1/4RNGX 1/4RNGX 15.75LG
CABLE ASM- 4GA-1/4RNGX 1/4RNGX 17.00LG
CONN-PKRD WEATHERPACK 2 CAV
FEMALE/TOWER
TERM-PKRD WEATHERPACK 12GA FEMALE
CABLE SEAL-PKRD WP/MP 10-12 GA BLUE
GEAR-TRNTBL BRG 2002i
WINCH-DC500 12VDC
CONTACTOR-WINCH 12V DC500
KIT #
#1
#1
#1
#1
#1
#1
#1
#1
#1
QUANTITY
1
1
1
1
1
1
1
1
2
2
REF
REF
REF
Chapter 7 Parts
59
GROUND AT
CHASSIS FRAME
18" (457 mm)
MAXIMUM
SW
1
225A
UNDERHOOD
BATTERY
225A
18" (457 mm)
MAXIMUM
GROUND AT
CHASSIS FRAME
2ND AUX
BATTERY
GROUND AT
CHASSIS FRAME
NOTES (SEE REFERENCE NUMBER IN BOX):
1
60
Drum bushing
Capscrew
Gasket
Cable
Drum
support
Ring gear
73511211
Winch Motor
Stage 3
Carrier asm
Capscrew
Clutch
retainer
Stage 2
Carrier asm
Gasket
Sun
gear
Capscrew
(Qty 10)
Gear
arm
Stage 1
Carrier asm
Hex
shaft
Drum
support
Drum bushing
77056663
Brake Assembly
Remote
control
WINCH SPECIFICATIONS
MOTOR TYPE:
12V
MOTOR HP:
1:1
GEAR RATIO:
261:1
WEIGHT:
25 LB
MAX RATED LOAD:
1100 LB (500 KG)
MAX WIRE ROPE RECOMMENDED:
3/16" 4200 LB (1909 KG) MIN. BREAKING STRENGTH
LAYER
LOAD (LB)
SPEED (FPM)
1
1100
16.9
2
965
19.3
3
859
21.6
4
775
24.0
1st Layer
LINE LOAD (LB)
LINE SPEED (FPM)
AMP DRAW
0
21.3
38
500
19.5
65
750
18.4
78
1100
16.9
99
Chapter 7 Parts
61
6
8
9
23
10
2
20
11
22
8
13
15
12
19
17
18
14
16
DESCRIPTION
CONTACTOR
COVER
SCREW
CABLE (QUANTITY 2)
DRUM BUSHING, NYLATRON
CAPSCREW (QUANTITY 2)
DRUM SUPPORT
GASKET
RING GEAR
CARRIER ASSEMBLY (STAGE 3)
CARRIER ASSEMBLY (STAGE 2)
CARRIER ASSEMBLY (STAGE 1)
SUN GEAR
GEAR ARM
CAPSCREW (QUANTITY 10)
REMOTE CONTROL
HEX SHAFT
21
62
DESCRIPTION
DRUM
BRAKE ASSEMBLY
CLUTCH RETAINER
DRUM SUPPORT
MOTOR COUPLER
MOTOR
WINCH SPECIFICATIONS
MOTOR TYPE: 12V
MOTOR HP:
1:1
GEAR RATIO:
261:1
WEIGHT:
25 LB
MULTI-LAYER PERFORMANCE
LAYER
LOAD (LB)
1
1100
2
965
3
859
4
775
FIRST LAYER PERFORMANCE
LOAD (LB)
SPEED (FPM)
0
6.5
500
5.9
750
5.6
1100
5.2
SPEED (FPM)
16.9
19.3
21.6
24.0
AMP DRAW
38
65
78
99
Chapter 7 Parts
4
3
5,7
6,7
1
2
WIRING CHART
PIN#
COLOR
A
RED
B
GREEN/BLACK
C
GREEN
D
WHITE
E
WHITE/BLACK
FUNCTION
HOT TO SWITCHES
WINCH DOWN
WINCH UP
ROTATE CW
ROTATE CCW
6,7
63
64
DESCRIPTION
CABLE END-CRANE
CABLE
HOUSING
REMOTE OVERLAY
TOGGLE SWITCH, SPST
TOGGLE SWITCH, DPDT
RUBBER BOOT
TERMINAL, A, FEM .250 FI 14-16 BL
TERMINAL, B, FEM .250 FI 10-12 YW
QUANTITY
1
1
1
1
1
2
3
2
1
Chapter 7 Parts
7/8" HEX
6 X 0.375"
10,416 FT-LB
16,000 IN-LB
1/4 HP CONTINUOUS DUTY @ 2400 RPM.
12" LEADS MARKED WITH + AND - FOR CLOCKWISE
ROTATION OF MOTOR WEN VIEWED FROM MOTOR
SHAFT END.
40:1 REDUCTION IN PRIMARY
61:1 REDUCTION IN SECONDARY
2440: 1 REDUCTION TOTAL
SLEWING RING NOT INCLUDED.
DESCRIPTION
BEARING, ROLL CUP & CONE
OIL SEAL
CAP, WORM
SCREW, CBB 1/2-13 X 1 1/5 2
CAPSCREW, HEX HEAD 1/4-20 NC X 3/4
CAPSCREW, HEX HEAD 1/4-20 NC X 1 1/8"
O-RING
MOTOR 1/4 HP 12VDC 2400 RPM
HOUSING
CAPSCREW, 1/2-13 X 1 1/2" HH GRD 8
KEY
SEAL, OIL
HEX PLUG, 1/8-27 NPTF
CAP, BLIND GEAR
QUANTITY
2
2
1
2
12
4
1
1
1
2
1
1
5
1
65
66
DESCRIPTION
SHIM, GEAR .0075 NATURAL
SHIM, GEAR .005 BLUE
SHIM, GEAR .003 GREEN
GEAR, WORM 40:1
VENT, PRESSURE 1-5 PSIG
SEAL, OIL
OIL SEAL
GREASE FITTING
CAPSCREW, 5/16-18 X 1 1/4" SH
ADAPTER
WORM, GROUND
HOUSING
O-RING
BEARING, BALL OPEN
GASKET .010 BROWN
GASKET .0075 CLEAR
GASKET .005 BLUE
GASKET .003 GREEN
GASKET .020 YELLOW
CAP, WORM
SHIM, WORM .005 BLUE
SNAP RING-EXT
BEARING, DOUBLE BALL, SPECIAL
SNAP RING-INT
MOTOR ADAPTER
WORM, GROUND
O-RING
QUANTITY
AS REQ.
AS REQ.
AS REQ.
1
1
1
1
3
4
1
1
1
1
1
AS REQ.
AS REQ.
AS REQ.
AS REQ.
1
1
2
1
1
1
1
1
2
Chapter 7 Parts
1
(BOTH
SIDES)
5
(BOTH
SIDES)
2
4
16,17,18
6
7
DECAL PLACEMENT (IF NOT SHOWN ON CRANE)
ITEM #
PLACEMENT
8,12,14,15,19
AT OR NEAR REMOTE HANDLE STORAGE POINT
13
AT FRONT AND REAR STABILIZERS
10,11
ON ALL FOUR SIDES OF CARRIER VEHICLE
9
ON CRANE POWER CABLE CONNECTION AT VEHICLE BATTERY
95721546
ITEM
1.
2.
3.
4.
5.
6.
PARTS LIST
PART #
70396778
70397481
71394083
70397351
70397413
70397411
DESCRIPTION
DECAL-2003i IDENTIFICATION
DECAL-2003i CAPACITY PLACARD
DECAL-LOAD BLOCK RATING, 2.0 TON
DECAL-REMOTE PENDANT STORAGE
DECAL-IMT DIAMOND 4.5 X 9
DECAL-GREASE WEEKLY, LEFT, SMALL
QUANTITY
2
2
2
1
2
3
3
(BOTH
SIDES)
67
68
DESCRIPTION
DECAL-GREASE WEEKLY, RIGHT, SMALL
DECAL-DANGER, UNPLUG ELEC CRANE
DECAL-ELEC CRANE DISCONNECT
DECAL-DANGER ELEC HZD
DECAL-DANGER CR LOADLINE
DECAL-DANGER ELECTRO TELES
DECAL-WARNING STAB STAND CLEAR
DECAL-SERVICE & REPAIR
DECAL-CAUTION, DON'T WASH/WAX
DECAL-GREASE WORM DRIVE BEARINGS
DECAL-ROTATE CRANE WHILE GREASING
DECAL-LUBRICATE WORM
DECAL-DANGER, CRANE SAFETY
QUANTITY
3
2
1
4
4
1
4
1
1
1
1
1
1
69
CHAPTER 8
General Reference
In This Chapter
Inspection Checklist ................................................................. 69
Deficiency / Recommendation / Corrective Action Report......... 74
Thread Torques ........................................................................ 76
Turntable Bearing Thread Tightening Sequence ...................... 78
Turntable Bearing Inspection .................................................... 79
Turntable Bearing Tilt Test ....................................................... 80
Inspection Checklist
NOTICE:
The user of this form is responsible for determining that these inspections satisfy all applicable
regulatory requirements.
OWNER/COMPANY:
CONTACT PERSON:
DAILY
DATE INSPECTED:
INSPECTED BY (print):
LOCATION OF UNIT:
SIGNATURE OF INSPECTOR:
MONTHLY
QUARTERLY ANNUAL
70
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 fully
extended.
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 (whichever 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 to four months or 300 hours of normal operation (whichever 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 (whichever 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.
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.)
FREQUENCY ITEM
KEY
INSPECTION DESCRIPTION
Labels
D
D
2
3
Crane
Controls
Station
Hydraulic
System
Hook
All load charts, safety & warning labels, and control labels are
present and legible.
Check all safety devices for proper operation.
Control mechanisms for proper operation of all functions, leaks
and cracks.
Control and operator's station for dirt, contamination by lubricants,
and foreign material.
Hydraulic system (hoses, tubes, fittings) for leakage and proper oil
level.
Presence and proper operation of hook safety latches.
STATUS
(S,R,X,NA)
FREQUENCY ITEM
KEY
INSPECTION DESCRIPTION
Wire Rope
Pins
General
10
Operation
11
D
D
12
13
D
D
14
15
Remote
Ctrl
Electrical
Anti TwoBlock or
Two-Block
Damage
Prevention
Tires
Ground
Conditions
16
Level
17
18
19
20
Operator
cab
windows
Rails, rail
stops, rail
clamps and
supporting
surfaces
Safety
devices
Electrical
D
D
M
M
21
22
23
24
Daily
Cylinders
M
M
M
25
26
27
Valves
Valves
Valves
M
M
28
29
General
Electrical
M
M
M
30
31
32
Structure
Welds
Pins
71
STATUS
(S,R,X,NA)
72
FREQUENCY ITEM
KEY
INSPECTION DESCRIPTION
33
Hardware
M
M
34
35
36
Wear Pads
Pump &
Motor
PTO
M
M
37
38
Hyd Fluid
Hyd Lines
M
M
M
M
M
Q
Q
Q
39
40
41
42
43
44
45
46
Hook
Wire Rope
Manual
All bolts, fasteners and retaining rings for tightness, wear and
corrosion.
Presence of wear pads.
Hydraulic pumps and motors for leakage at fittings, seals, and
between sections. Check tightness of mounting bolts.
Transmission/PTO for leakage, abnormal vibration & noise,
alignment, and mounting bolt torque.
Quality of hydraulic fluid and presence of water.
Hoses & tubes for leakage, abrasion damage, blistering, cracking,
deterioration, fitting leakage, and secured properly.
Load hook for abnormal throat distance, twist, wear, and cracks.
Condition of load line.
Presence of operator's manual with unit.
Other
Other
All daily inspection items.
All monthly inspection items.
Rotation bearing for proper torque of all mounting bolts.
Q
Q
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
STATUS
(S,R,X,NA)
71
72
73
74
75
76
Daily
Monthly
Rotation
Sys
Hardware
Structure
Hardware
Hyd Lines
FREQUENCY ITEM
KEY
INSPECTION DESCRIPTION
77
Pumps &
Motors
78
79
80
81
Valves
82
83
84
85
86
87
Cylinders
88
89
90
91
92
93
94
95
96
Winch
Q
A
A
A
A
A
97
98
99
100
101
102
Hyd Filters
Daily
Monthly
Quarterly
Hyd Sys
Controls
A
A
A
103
104
105
106
Valves
Valves
Rotation
Sys
Lubrication
107
Hardware
A
A
108
109
Wear Pads
Loadline
73
STATUS
(S,R,X,NA)
74
OWNER:
GUIDELINES
a A deficiency (X) may constitute a hazard. Deficiency must be corrected and/or faulty parts
replaced before resuming operation.
b Recommendations (R) should be considered for corrective actions. Corrective action for a
particular recommendation depends on the facts in each situation.
c Corrective actions (CA), repairs, adjustments, parts replacement, etc. are to be performed
by a qualified person in accordance with all manufacturers recommendations,
specifications and requirements.
NOTE: Deficiencies (X) listed must be followed by the corresponding corrective action taken (CA).
X = DEFICIENCY
X,R,CA
ITEM #
R = RECOMMENDATION
EXPLANATION
DATE CORRECTED
X,R,CA
ITEM #
EXPLANATION
75
DATE CORRECTED
76
GRADE 8
SAE J429
GRADE 5
SAE J429
GRADE 5
SAE J429
GRADE 8
PLATED
(FT-LB)
14
26
41
64
90
130
225
325
485
670
930
1255
1645
PLAIN
(FT-LB)
27
49
78
120
170
240
420
670
995
1445
2010
2710
3560
PLATED
(FT-LB)
20
35
58
90
130
180
315
500
745
1085
1510
2035
2670
GRADE 8
SAE J429
GRADE 8
PLATED
(FT-LB)
13
23
37
57
82
115
200
295
445
595
840
1100
1460
PLAIN
(FT-LB)
25
44
70
105
155
220
375
605
910
1290
1815
2380
3160
PLATED
(FT-LB)
18
33
52
80
115
160
280
455
680
965
1360
1780
2370
NOTES
1 Tightening torques provided are midrange.
2
Torque values specified are for bolts with residual oils or no special lubricants applied. If special lubricants of
high stress ability, such as Never-Seez compound graphite and oil, molybdenum disulphide, colloidal copper or
white lead are applied, multiply the torque values in the charts by the factor .90. The use of Loctite does not affect
the torque values listed above.
WARNING
Anytime a gear-bearing bolt is removed, it
must be replaced with a new bolt of the
identical grade and size. Once a bolt has
been torqued to 75% of its proof load and
then removed, the torque coe fficient may no
longer be the same as when the bolt was new
thus giving indeterminate clamp loads after
torqueing. Failure to replace gear-bearing
bolts may result in bolt failure due to metal
fatigue causing death or serious injury.
77
TIGHTENING TORQUE
SIZE
BOLT
(DIADIA.
TPI)
(INCHES)
TIGHTENING TORQUE
SIZE
BOLT DIA
(DIA(INCHES)
TPI)
SAE J429
GRADE 5
SAE J429
GRADE 5
SAE J429
GRADE 8
3
5
8
12
18
25
44
69
103
150
209
281
369
SAE J429
GRADE 8
0.3125
0.375
0.4375
0.5
0.5625
0.625
0.75
0.875
1
1.125
1.25
1.375
1.5
2
4
7
10
15
21
37
55
82
110
155
203
270
2
3
5
8
11
16
28
41
62
82
116
152
210
3
6
10
15
21
30
52
84
126
178
251
329
438
2
5
7
11
16
22
39
63
94
133
188
246
328
Torque values specified are for bolts with residual oils or no special lubricants applied. If special lubricants of
high stress ability, such as Never-Seez compound graphite and oil, molybdenum disulphite, collodial copper or
white lead are applied, multiply the torque values in the charts by the factor .90. The use of Loctite does not affect
the torque values listed above.
WARNING
Anytime a gear-bearing bolt is removed, it
must be replaced with a new bolt of the
identical grade and size. Once a bolt has
been torqued to 75% of its proof load and
then removed, the torque coefficient may no
longer be the same as when the bolt was new
thus giving indeterminate clamp loads after
torqueing. Failure to replace gear-bearing
bolts may result in bolt failure due to metal
fatigue causing death or serious injury.
78
WARNING
Number 1 can be assigned to
any capscrew if the sequence
remains the same in reference
to number 1.
TIGHTENING PROCEDURE
1 Refer to the Torque Data Chart to determine the proper torque value to apply to the size of
capscrew used.
2 Follow the tightening sequence shown in the diagram. Note that the quantity of capscrews
may differ from the diagram, but the sequence must follow the criss-cross pattern as shown
in the diagram.
3 Torque all capscrews to approximately 40% of the specified torque value, by following the
sequence.
(EXAMPLE: .40 x 265 FT-LB = 106 FT-LB)
(EXAMPLE-METRIC: .40 x 36 KG-M = 14.4 KG-M)
4 Repeat Step 3, but torquing all capscrews to 75% of the specified torque value. Continue to
follow the tightening sequence.
(EXAMPLE: .75 x 265 FT-LB = 199 FT-LB)
(EXAMPLE-METRIC: .75 x 36 KG-M = 27 KG-M)
5 Using the proper sequence, torque all capscrews to the listed torque value as determined
from the Torque Data Chart.
79
Rough rotation.
Uneven or excessive wear between the pinion gear and turntable gear.
If one or more of the above conditions exists, further inspection may be required. Limits are
measured in TILT which is dependent on the internal clearances of the bearing. TILT is the
most practical determination of a bearings' internal clearance once mounted on a crane. You
can measure the tilt using the Turntable Bearing Tilt Test. (see "Turntable Bearing Tilt Test" on
page 80)
Periodic readings indicating a steady increase in TILT may be an indicator of bearing wear.
Note: A bearing found to have no raceway cracks or other structural irregularities should be reassembled
and returned to service.
80
81
Rev 20100331