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IMT 5525 Manual

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5525/6025/6625:99903289:
Volume 2 - PARTS AND SPECIFICATIONS
20040302
Model 5525 Crane
Model 6025 Crane
Model 6625 Crane
IOWA MOLD TOOLING CO., INC.
BOX 189, GARNER, IA 50438-0189
MANUAL PART NUMBER 99903289
Manual Effective Through July, 2004
Section 1 CRANE SPECIFICATIONS
Section 2 CRANE REFERENCE
Section 3 REPLACEMENT PARTS
Section 4 GENERAL REFERENCE
TEL: 641-923-3711
6625

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Summary of Contents for IMT 5525

  • Page 1 5525/6025/6625:99903289: 20040302 Model 5525 Crane Model 6025 Crane Model 6625 Crane Volume 2 - PARTS AND SPECIFICATIONS Section 1 CRANE SPECIFICATIONS Section 2 CRANE REFERENCE Section 3 REPLACEMENT PARTS Section 4 GENERAL REFERENCE 6625 IOWA MOLD TOOLING CO., INC. BOX 189, GARNER, IA 50438-0189...
  • Page 2 35-38 MODELS AND STANDARD CONTROL & HYD KIT FOR 5525 20020416 3-1, 43-50 ECN 8909 - ADDED 5525 RCLC DECAL TO KIT, RENUMBERED PAGES 20020422 2-6, 3-23 CORRECTED SPARE PARTS LIST, ECN 8910 - NEW HOSE LENGTHS IN HYD KIT...
  • Page 3 Treat this equipment with respect and service it regularly. These two things can add up to a safer working environment. Read and familiarize yourself with the IMT OPERATOR'S CRANE SAFETY MANUAL before operating or performing any maintenance on your crane.
  • Page 4 5525/6025/6625:99903289:20010915 NOTES...

  • Page 5: Table Of Contents

    ROTATION SYSTEM ....................3 HYDRAULIC SYSTEM ....................3 EXCESSIVE LOAD LIMIT SYSTEM (ELLS) .............. 3 WINCH - 6025 & 6625 MODELS ................3 WINCH - 5525 MODEL ....................3 MINIMUM CHASSIS SPECIFICATIONS ..............4 GEOMETRIC CONFIGURATION ................4 5525 CAPACITY CHART .................... 5 6025 CAPACITY CHART ....................

  • Page 6: General Specifications

    5525/6025/6625:99903289: 20020208 MODELS 5525, 6025 AND 6625 CRANE SPECIFICATIONS GENERAL SPECIFICATIONS 5525 6025 6625 CRANE RATING 55,000 ft-lb 60,000 ft-lb 66,000 ft-lb (7.6 ton-meters) (8.3 ton-meters) (9.1 ton-meters) HORIZONTAL REACH 25’-4” (7.7 m) 25’-4” (7.7 m) 25’-4” (7.7 m) from centerline of rotation HYDRAULIC EXTENSIONS (2) 78”...

  • Page 7: Performance Characteristics

    The winch meets ANSI B30.5 standards. WINCH - 5525 MODEL The winch is powered using a hydraulic motor driving a 27:1 worm gear arrangement with a mechanical brake. Maximum single line lifting capacity of the winch, achieved on the second layer of wire rope, is 5500 lb (2495 kg).

  • Page 8: Minimum Chassis Specifications

    In addition to these specifications, heavy duty electrical and cooling systems are required. It is recommended that the vehicle be equipped with an engine tachometer, auxiliary brake lock, and power steering. IMT reserves the right to change specifications or design without notice. 6'-10"...

  • Page 9: 5525 Capacity Chart

    5525/6025/6625:99903289: 20020225 5525 HYDRAULIC CAPACITY CHART Values in the box denote See reduced capacity placard for XXXX lb the use of 2 part line. XXXX kg additional information if applicable. Maximum 1 part line is 5500 lb (2495 kg). 26'-7"...

  • Page 10: 6025 Capacity Chart

    20010920 5525/6025/6625:99903289: 6025 HYDRAULIC CAPACITY CHART Values in the box denote See reduced capacity placard for additional XXXX lb the use of 2 part line. XXXX kg information if applicable. Maximum 1 part line is 5500 lb (2494 kg). 26'-7"...

  • Page 11: 6625 Capacity Chart

    20010920 5525/6025/6625:99903289: 6625 HYDRAULIC CAPACITY CHART Values in the box denote See reduced capacity placard for additional XXXX lb the use of 2 part line. XXXX kg information if applicable. Maximum 1 part line is 5500 lb (2494 kg). 26'-7"...

  • Page 12: Reduced Capacity Lift Charts

    5525/6025/6625:99903289: 20040225 REDUCED CAPACITY LIFT CHARTS If the IMT crane is installed by an IMT distributor, the distributor is responsible for stability confir- The Reduced Capacity Lift Chart System was mation. IMT supplies a generic RCLC decal for conceived to inform the end user of the allow- dealer installation.

  • Page 13: Stability Confirmation Process

    2) Position the crane at full, horizontal reach. Once the booms are retracted, re-check stabil- For a 5525 crane, use a 2,172 ± 10 lb test ity by again rotating the crane around the sides weight suspended over the rear of the truck.
  • Page 14 5525/6025/6625:99903289: 1-10...
  • Page 15 5525/6025/6625:99903289: 20010915 SECTION 2: CRANE REFERENCE MAJOR CRANE ASSEMBLIES ..................3 GREASE ZERK LOCATIONS & LUBRICANT REQUIREMENTS ......... 4 RECOMMENDED SPARE PARTS LIST ................ 5 CONTROL VALVE TROUBLESHOOTING ..............9 ELEC SCHEMATIC (99903187) ................... 11 WINCH BRAKE HARNESS & DUAL PRESSURE SYSTEM ........12 ANTI TWO-BLOCKING DEVICE ..................
  • Page 16 5525/6025/6625:99903289: 20010915 NOTES...

  • Page 17: Major Crane Assemblies

    5525/6025/6625:99903289: 20010915 2ND STAGE EXTENSION BOOM 1ST STAGE EXTENSION BOOM LOWER BOOM 6625 WINCH MAST BASE EXTENSION LOWER CYLINDERS CYLINDER (INTERNAL) MAJOR CRANE ASSEMBLIES...

  • Page 18: Grease Zerk Locations & Lubricant Requirements

    5525/6025/6625:99903289: 20011210 GREASE ZERK LOCATIONS & LUBRICANT REQUIREMENTS 6625 ITEM LOCATION DESCRIPTION LUBRICANT FREQUENCY WEEKLY...

  • Page 19: Recommended Spare Parts List

    RECOMMENDED SPARE PARTS LIST 1 YEAR SUPPLY MODEL 5525/ 6025 / 6625 TELESCOPING CRANE FOR MANUAL: 99903289 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.
  • Page 20 Cord Reel 77041459 Limit Switch 60030313 Sheave-Snatch Block 71073035 Hook 70732882 Hook 70074004 Safety Latch 60122358 Downhaul Weight 72661367 73733171 5525 Worm Gear Winch 70570198 73051513 Motor 70055117 Pillow Block 76393419 Oil Seal 70143948 Bushing 70143949 Bushing 76393420 O-ring 76394300...
  • Page 21 5525/6025/6625:99903289: 20011210 INSTALLATION GENERAL CRANE INSTALLATION CAUTION The 3.0” bolts supplied are for use on bodies with a crane box top plate thickness of 7/8-1” only. Determine the crane box top plate thickness prior to mounting. If different length bolts are required, they must be 1-8, grade 8 (minimum) of the proper length.
  • Page 22 5525/6025/6625:99903289: 20010915 HYDRAULIC INSTALLATION HYDRAULIC INSTALLATION...

  • Page 23: Control Valve Troubleshooting

    5525/6025/6625:99903289: 20010915 CONTROL VALVE TROUBLESHOOTING HYDRAULICS-VALVEBANK GENERAL RELIEF VALVE ELECTRICAL-AMP DRIVER POWER LED PROPORTIONAL VALVE PMW% LED DIRECTIONAL VALVES MIN POTENTIOMETER...
  • Page 24 5525/6025/6625:99903289: 20010915 2-10 If the valve shifts using manual overrides, the problem is of an electrical nature. Valve coils are interchangeable and may be changed by removing the coil nut. This allows mainte- nance personnel to isolate individual coil failures. If the valve cannot be actuated manually or electrically, it is necessary to replace the section.

  • Page 25: Elec Schematic (99903187)

    5525/6025/6625:99903289: 20030707 2-11 ELEC SCHEMATIC (99903187) NOTE: This electrical schematic illustrates how an IMT- manufactured crane would typically be mounted on an IMT-manufactured body.

  • Page 26: Winch Brake Harness & Dual Pressure System

    5525/6025/6625:99903289: 2-12 WINCH BRAKE HARNESS & DUAL PRESSURE SYSTEM WINCH BRAKE HARNESS Winch Down 5R-P201 5R-J203 TO WINCH BRAKE SOLENOID 5R-J202 CONNECTORS PLACED IN BETWEEN WINCH DOWN SEALED RELAY AND BASE DUAL PRESSURE SYSTEM Boom Down 5R-CJ202 5R-CP201 CONNECTS INLINE WITH...

  • Page 27: Anti Two-Blocking Device

    5525/6025/6625:99903289: 20010915 2-13 ANTI TWO-BLOCKING DEVICE IMT telescoping cranes using a winch are equipped with an Anti Two-Blocking Device which is designed to provide a method of sensing an approaching Two-Blocking situation and prevent the crane from entering that situation. It is the operator's responsibility to avoid Two-Blocking and not to rely on this device alone.

  • Page 28: Excessive Load Limit System (Ells) Test Procedure

    5525/6025/6625:99903289: 20010915 2-14 Excessive Load Limit System (ELLS) TEST PROCEDURE...
  • Page 29 5525/6025/6625:99903289: 20010915 2-15 ADAPTER 5000 PSI LIQUID FILLED PRESSURE GAUGE TEST PROCEDURE A. Position Crane Boom...
  • Page 30 5525/6025/6625:99903289: 20010915 2-16 B. Attach Pressure Gage Valve Block Base End of Main Cylinder Fitting connecting Port Tube to Valve Block Fitting connecting Port Tube to Base End of Cylinder Remove Remove Fitting on Remove Port Tube Valve Block Fitting...
  • Page 31 5525/6025/6625:99903289: 20010915 2-17 C. Test System TABLE 1 FUNCTIONS SHUT DOWN BY ELLS MAX. TEST WINCH EXTENSION LOWER GAGE CRANE DOWN PRESSURE MODEL ALLOWED 1014 2600 1014A 3000 2015 3000 2020 3000 3016 3000 3020 3300 3816 3500 5016 3500...

  • Page 32: Ells Troubleshooting Procedure

    5525/6025/6625:99903289: 20010915 2-18 ELLS TROUBLESHOOTING PROCEDURE A. Find which solenoid actuates which function "PINS" ON HARNESS "RECEPTACLES" ON HARNESS FOR CONTINUITY TO FOR CONTINUITY TO CRANE FUNCTIONS PRESSURE SWITCH...
  • Page 33 CYLINDER (70146297) ..............................22 HYDRAULIC KIT - 5525 (91717399-1) ..........................23 HYDRAULIC KIT - 5525 (91717399-2) ..........................24 HYDRAULIC KIT - 5525 RADIO REMOTE (91717400-1) ....................25 HYDRAULIC KIT - 5525 RADIO REMOTE (91717400-2) ....................26 HYDRAULIC KIT (91716519-1) ............................27 HYDRAULIC KIT (91716519-2) ............................
  • Page 34 5525/6025/6625: 99903289: 20010915 NOTES...

  • Page 35: Parts Information

    Volume 1. For optional equipment, refer to the cylinder case (See figure below) against the appropriate manual, or consult your IMT sales information included in the service manual. You reprsentative. must include the part number stamped on the cylinder case when ordering parts.

  • Page 36: Winch / Cable / Hook Kit (31716518)

    5525 MODEL ONLY 5525/6025/6625: 99903289: 20021114 WINCH / CABLE / HOOK KIT (31716518) 24. 77044468 CONNECTOR 1/2 STR RLF 25. 60122311 SPACER 52712162 WINCH DRUM 26. 52715833 GUARD, WLDMT BOOM TIP 70570198 WINCH 27. 72060104 CAP SCR 1/2-13 X 6.5 72060921 CAP SCR 1/2-13 X 3.75 HH GR5 4...

  • Page 37: Winch / Cable / Hook Kit-Planetary (31716521)

    6025 & 6625 MODELS 5525/6025/6625: 99903289: 20021114 WINCH / CABLE / HOOK KIT-PLANETARY (31716521) 19. 72062103 NUT 3/8-16 HEX NYLOC 20. 60122358 PLATE-SINGLE SHEAVE 70146319 WINCH-PLANETARY 21. 72661514 PIN-LOCK W/ HANDLE 70580168 WIRE ROPE ASM, LH (EFF. 11/02) 22. 72661543...

  • Page 38: Winch (70570198)

    5525 MODEL ONLY 5525/6025/6625: 99903289: 20020208 WINCH (70570198)

  • Page 39: Winch Planetary (70146319)

    6025 & 6625 MODELS 5525/6025/6625: 99903289: 20010915 WINCH PLANETARY (70146319) NOTE: Do not use EP type gear lubes in the brake section of this winch. EP lubes may prevent the clutch from locking up, causing a load to fall, resulting in property...

  • Page 40: Cord Reel Assembly (51713168)

    ALL MODELS 5525/6025/6625: 99903289: 20010915 CORD REEL ASSEMBLY (51713168) BLACK 1,2,3 WHITE CUT CORD TO 36" LENGTH BEFORE ATTACHING PACKARD CONNECTOR...

  • Page 41: Base Asm (41716514)

    ALL MODELS 5525/6025/6625: 99903289: 20020219 BASE ASM (41716514) NOTE: GEAR ROTATOR 71056577 USED ON CRANE SERIAL NO. 6625021001 AND BEYOND. 8 (2) 12,13,14,15 11 (2) 3 (2) NOTES: 1. APPLY "MOLLUB-ALLOY 935F" TO TURNTABLE BEARING AND WORM TEETH AT ASSEMBLY.

  • Page 42: Gear Rotator (71056574)

    5525/6025/6625: 99903289: 20011210 3-10 GEAR ROTATOR (71056574) NOTE: Because of the difficulty in correctly setting the worm to bearing backlash, IMT recommends no repair to the rotator assembly. Contact IMT for information. GUIDE MUST BE FLUSH WITH BOTTOM OF HOUSING. BEARING...

  • Page 43: Mast Asm (41716515)

    ALL MODELS 5525/6025/6625: 99903289: 20011210 3-11 MAST ASM (41716515) NOTES: 1. TORQUE ITEM #4 AND ITEM #8 TO 280 FT-LB. 2. DO NOT USE PERMANENT THREAD LOCK ON ITEM #4 OR ITEM #8. THESE 8 HOLES REQUIRE LONG CAP SCREWS (#8) AND...
  • Page 44 5525 MODEL ONLY 5525/6025/6625: 99903289: 20020821 3-12 LOWER BOOM ASM - 5525 (41717301) 13. 72063003 WASHER 3/8 W FLAT ANSI B27.2Z 52716469 BOOM – LOWER WLDMT 14. 72062103 NUT 3/8-16 HEX NYLOC ZINC (INCLUDES 25) 15. 72063001 WASHER 1/4 LOCK ZINC 52716486 PIN –...
  • Page 45 6025 MODEL ONLY 5525/6025/6625: 99903289: 20020821 3-13 LOWER BOOM ASM - 6025 (41717027) 13. 72063003 WASHER 3/8 W FLAT ANSI B27.2Z 52716469 BOOM – LOWER WLDMT 14. 72062103 NUT 3/8-16 HEX NYLOC ZINC (INCLUDES 25) 15. 72063001 WASHER 1/4 LOCK ZINC 52716486 PIN –...
  • Page 46 6625 MODEL ONLY 5525/6025/6625: 99903289: 20020821 3-14 LOWER BOOM ASM - 6625 (41716516) 13. 72063003 WASHER 3/8 FLAT 14. 72062103 NUT 3/8-16 HEX NYLOC ZINC 52716469 BOOM – LOWER WLDMT 15. 72063001 WASHER 1/4 LOCK ZINC (INCLUDES 25) 16. 72062104...

  • Page 47: Cylinder - 5525 (70146462)

    5525 MODEL ONLY 5525/6025/6625: 99903289: 3-15 20020208 CYLINDER - 5525 (70146462) 35.75 RETRACTED 56.25 EXTENDED 20.50 STROKE...

  • Page 48: Cylinder - 6025 (70146427)

    6025 MODEL ONLY 5525/6025/6625: 99903289: 20010915 3-16 CYLINDER - 6025 (70146427) 35.75 RETRACTED 56.25 EXTENDED 20.50 STROKE...

  • Page 49: Cylinder - 6625 (70146304)

    6625 MODEL ONLY 5525/6025/6625: 99903289: 20010915 3-17 CYLINDER - 6625 (70146304) 35.75 RETRACTED 56.25 EXTENDED 20.50 STROKE...

  • Page 50: Valve (73540094)

    ALL MODELS 5525/6025/6625: 99903289: 20030325 3-18 VALVE (73540094) 73540051 VALVE-CBAL FAUV BLOCK FV-5481 1 73540052 VALVE-CBAL 1.75: 1 3300 PSI ADJ 70145750 ORIFICE FV-1147-H(.030)-M 77041626 PRESSURE SWITCH (8533-3500-R-9109SP) 77041625 PRESSURE SWITCH (8533-3100-R-9517SP) 72533477 PLUG-STR HOL HEX STL 44 THD THRU HOLE FOR 5/16 BOLT...

  • Page 51: Extension Boom Assembly (41716517)

    ALL MODELS 5525/6025/6625: 99903289: 20020821 3-19 EXTENSION BOOM ASSEMBLY (41716517) 51716461 EXTENSION CYLINDER ASM 12. 60122986 PIN – TYPE A 1.25 X 7.00 (6.31) 52716467 BOOM – EXT WLDMT 1 STAGE 13. 72063035 MACH BUSHING 1.25 X 7.00 (6.31)2 52716473 BOOM –...

  • Page 52: Cyl Asm - Extension (51716461)

    ALL MODELS 5525/6025/6625: 99903289: 20020821 3-20 CYL ASM – EXTENSION (51716461) 001EE0006 HYDRAULIC LINE - 6625 EXT CYL 2 70146296 CYL – 2.7/1.7 78.00S 118.88CC C 70146297 CYL – 2.5/1.7 78.00S 121.50CC C 103MG0006 CLEVIS PIN – EXT CYL 106EA0006 FLARELESS TUBE NUT – 6 106EB0007 FLARELESS TUBE FERRELE –...

  • Page 53: Cylinder (70146296)

    ALL MODELS 5525/6025/6625: 99903289: 20010915 3-21 CYLINDER (70146296) 10 13 15 8 7 19 3 18 11 14 16 20 21 17 6 5 118.88 RETRACT 198.88 EXTEND 78.00 STROKE...

  • Page 54: Cylinder (70146297)

    ALL MODELS 5525/6025/6625: 99903289: 20010915 3-22 CYLINDER (70146297) 3 14 9 10 12 16 17 8 13 6 6 1115 2 7 4...

  • Page 55: Hydraulic Kit - 5525 (91717399-1)

    5525 MODEL ONLY 5525/6025/6625: 99903289: 20020508 3-23 HYDRAULIC KIT - 5525 (91717399-1) IN-LINE (PART OF 5) 2REF 27. 72533162 ELBOW #8MSTR #8MFACE 90° 2REF 73733395 VALVE BANK 5020/3820 PROPN 28. 72533166 ADPTR #8MSTR #8MFACE 90° 2REF (INCLUDES 24, 27, 28) 29.

  • Page 56: Hydraulic Kit - 5525 (91717399-2)

    5525 MODEL ONLY 20020225 5525/6025/6625: 99903289: 3-24 HYDRAULIC KIT - 5525 (91717399-2) PARTS LIST ON PREVIOUS PAGE CONTINUED ON NEXT PAGE...
  • Page 57 5525 MODEL ONLY 5525/6025/6625: 99903289: 20020225 3-25 HYDRAULIC KIT - 5525 RADIO REMOTE (91717400-1) CONTINUED ON NEXT PAGE PORT C WINCH PORT 18 WINCH LOWER PORT B (UP) ROTATION PORT A (DN) REMOVE #27 AT ASSEMBLY AND INSTALL ITEM #28 IN VALVE BANK...

  • Page 58: Hydraulic Kit - 5525 Radio Remote (91717400-1)

    5525 MODEL ONLY 20020225 5525/6025/6625: 99903289: 3-26 HYDRAULIC KIT - 5525 RADIO REMOTE (91717400-2) PARTS LIST ON PREVIOUS PAGE...

  • Page 59: Hydraulic Kit (91716519-1)

    6025-6625 MODELS 5525/6025/6625: 99903289: 20020225 3-27 HYDRAULIC KIT (91716519-1) 18. 72533156 ELBOW #12MSTR #8MFACE 90° 2REF 19. 72533186 ADPTR #6MFACE #6MSTR 3REF 73733395 VALVE BANK 5020/3820 PROPN 20. 72533423 ADPTR #8MFACE #6MSTR 1REF (INCLUDES 24, 27, 28) 21. 72533540 SWIVEL #4MFACE #4MFACE 90°...

  • Page 60: Hydraulic Kit (91716519-2)

    6025-6625 MODELS 5525/6025/6625: 99903289: 20020225 3-28 HYDRAULIC KIT (91716519-2) PARTS LIST ON PREVIOUS PAGE...
  • Page 61 6025-6625 MODELS 5525/6025/6625: 99903289: 20020225 3-29 HYD KIT -6025/ 6625 RADIO REMOTE (91717393-1) CONTINUED ON NEXT PAGE SEE SOLENOID DETAIL PORT C PORT 18 WINCH WINCH EXT LOWER ROT PORT B (UP) PORT A (DN) 29,39 RETURN 29,39 PRESSURE LOWER CYL...

  • Page 62: Hyd Kit -6025/ 6625 Radio Remote (91717393-1)

    6025-6625 MODELS 5525/6025/6625: 99903289: 20020225 3-30 HYD KIT -6025/ 6625 RADIO REMOTE (91717393-2) PARTS LIST ON PREVIOUS PAGE...

  • Page 63: Control Kit, Tethered - 5525 (90717396-1)

    5525 MODEL ONLY 5525/6025/6625: 99903289: 20030410 3-31 CONTROL KIT, TETHERED - 5525 (90717396-1) CONTINUED ON NEXT PAGE 51716562 HANDLE ASM 77441006 HARNESS-DUAL PRESS SWITCH 70034439 LOCK WIRE 60119299 BRACKET 77044645 NUT-DEUTSCH 24 77044646 WASHER-LOCK DEUTSCH 70733394 CABLE ASM - TETHERED...

  • Page 64: Control Kit, Tethered - 5525 (90717396-2)

    5525 MODEL ONLY 5525/6025/6625: 99903289: 20020508 3-32 CONTROL KIT, TETHERED - 5525 (90717396-2) PARTS LIST ON PREVIOUS PAGE...
  • Page 65 6025 & 6625 MODELS 5525/6025/6625: 99903289: 20030410 3-33 CONTROL KIT, TETHERED (90716520-1) 51716562 HANDLE ASM W/ENG START 40’ 77045870 WINCH BRAKE HARNESS 77441006 DUAL-PRESS SWITCH HARNESS 70034439 LOCK WIRE LEAD SEAL 8” 60119299 BRACKET-DEUTSCH CONN. 77044645 NUT-DEUTSCH 24 77044646 WASHER-LOCK DEUTSCH...

  • Page 66: Control Kit, Tethered (90716520-1)

    6025 & 6625 MODELS 5525/6025/6625: 99903289: REV B 20030611 3-34 CONTROL KIT, TETHERED (90716520-2) PARTS LIST ON PREVIOUS PAGE...
  • Page 67 5525 MODEL ONLY 5525/6025/6625: 99903289: 20030410 3-35 CONTROL KIT-5525 RADIO REMOTE (90717398-1) CONTINUED ON NEXT PAGE 70733354 RADIO RMT-TELESCOPIC 77441006 HARNESS-DUAL PRESS SWITCH 70034439 LOCK WIRE - LEAD SEAL 8” 72601778 CAP SCR METRIC 6-1.00 X 12 HHZ 4 72601762...

  • Page 68: Control Kit-5525 Radio Remote (90717398-1)

    5525 MODEL ONLY 5525/6025/6625: 99903289: 20020508 3-36 CONTROL KIT-5525 RADIO REMOTE (90717398-2) PARTS LIST ON PREVIOUS PAGE...

  • Page 69: Control Kit-6025 & 6625 Radio Remote (90717156-1)

    MODELS 6025 & 6625 5525/6025/6625: 99903289: 20030410 3-37 CONTINUED ON NEXT PAGE CONTROL KIT-6025 & 6625 RADIO REMOTE (90717156-1) 70733354 RADIO RMT-TELESCOPIC 77045870 HARNESS-WINCH BK PIGTAIL 77441006 HARNESS-DUAL PRESS SWITCH 70034439 LOCK WIRE - LEAD SEAL 8” 72601778 CAP SCR METRIC 6-1.00 X 12 HHZ 4...
  • Page 70 6625 MODEL ONLY 5525/6025/6625: 99903289: 20020508 3-38 CONTROL KIT-6625 RADIO REMOTE (90717156-2) PARTS LIST ON PREVIOUS PAGE...

  • Page 71: Valve Bank (73733395)

    ALL MODELS 5525/6025/6625: 99903289: 20030325 3-39 VALVE BANK (73733395) 13. 77044574 CONN-CKRD F 2-WAY WEARTPK 9REF 14. 77044550 TERMINAL-FEM 18-20GA WTPK 9REF 73540028 BLOCK-INLET VB FV-5128-M1 1REF 15. 70394069 SEAL-CABLE CONN WEARPK 2REF 73540027 END CAP-VB FV-5128-M2 1REF 16. 70145830...

  • Page 72: Valve Bank (73733380)

    ALL MODELS 5525/6025/6625: 99903289: 20030410 3-40 VALVE BANK (73733380) 12. 72063047 WASHER #10 LOCK ZINC 5REF 13. 77044574 CONN-CKRD F 2-WAY WEARTPK 9REF 73540028 BLOCK-INLET VB FV-5128-M1 1REF 14. 77044550 TERMINAL-FEM 18-20GA WTPK 18REF 73540027 END CAP-VB FV-5128-M2 1REF 15. 70394069...

  • Page 73: Installation Kit (93716522)

    6025/ 6625 MODELS 5525/6025/6625: 99903289: 20020225 3-41 VALVE-SOLENOID DUMP 6025/6625 CABLE LENGTH = 5.0" 2,3,4 (51717338) 73540090 VALVE-SOLENOID 77044574 CONNECTOR-PKRD 2CAV F 77044550 TERMINAL-PKRD 18-20GA FEM 70394069 CABLE SEAL-PKRD WP/MP 16GA SAE #4 SAE #4 ALL MODELS 20020821 CRANE INSTALLATION KIT (93716522) 72601748 CAP SCREW 1.0-8X 3.0 SH GR8...

  • Page 74: Decal Kit - 5525 (95717305-1)

    5525 MODEL ONLY 5525/6025/6625: 99903289: 20020508 3-42 DECAL KIT - 5525 (95717305-1) 16. 70392866 DECAL-DANGER OPER CONDITIONS 70391598 DECAL-WARNING 315A OUT 17. 70392867 DECAL-DANGER OUTRG (MV) 70391612 DECAL-GREASE WEEKLY (LEFT) 4 18. 70392868 DECAL-DANGER CR LOADLINE 70391613 DECAL-GREASE WEEKLY (RT) 19.

  • Page 75: Decal Kit - 5525 Tape Application (95717305-2)

    5025 MODEL ONLY 5525/6025/6625: 99903289: 20020416 3-43 DECAL KIT - 5525 TAPE APPLICATION (95717305-2) 60350086 TAPE-GREEN REFLECT 2.0X4.0 60350087 TAPE-YELLOW REFLECT 2.0X12.5 60350088 TAPE-GREEN REFLECT 2.0X16.0 60350089 TAPE-YELLOW REFLECT 2.0X9.5 60350090 TAPE-RED REFLECT 2.0X14.75 60350091 TAPE-YELLOW REFLECT 2.0X2.25 70396193 DECAL-RED CAPACITY 5025 NOTES: 3.

  • Page 76: Decal Kit - 6025 (95717028-1)

    6025 MODEL ONLY 5525/6025/6625: 99903289: 20020508 3-44 DECAL KIT - 6025 (95717028-1) 16. 70392866 DECAL-DANGER OPER CONDITIONS 70391598 DECAL-WARNING 315A OUT 17. 70392867 DECAL-DANGER OUTRG (MV) 70391612 DECAL-GREASE WEEKLY (LEFT) 4 18. 70392868 DECAL-DANGER CR LOADLINE 70391613 DECAL-GREASE WEEKLY (RT) 19.

  • Page 77: Decal Kit - Tape Application (95717028-2)

    6025 MODEL ONLY 5525/6025/6625: 99903289: 20011107 3-45 DECAL KIT - TAPE APPLICATION (95717028-2) 60350086 TAPE-GREEN REFLECT 2.0X4.0 60350087 TAPE-YELLOW REFLECT 2.0X12.5 60350088 TAPE-GREEN REFLECT 2.0X16.0 60350089 TAPE-YELLOW REFLECT 2.0X9.5 60350090 TAPE-RED REFLECT 2.0X14.75 60350091 TAPE-YELLOW REFLECT 2.0X2.25 70396097 DECAL-RED CAPACITY 6025 NOTES: 3.

  • Page 78: Decal Kit - 6625 (95716800)

    6625 MODEL ONLY 5525/6025/6625: 99903289: 20010820 3-46 DECAL KIT - 6625 (95716800) 16. 70392866 DECAL-DANGER OPER CONDITIONS 70391598 DECAL-WARNING 315A OUT 17. 70392867 DECAL-DANGER OUTRG (MV) 70391612 DECAL-GREASE WEEKLY (LEFT) 4 18. 70392868 DECAL-DANGER CR LOADLINE 70391613 DECAL-GREASE WEEKLY (RT) 19.

  • Page 79: Chassis Wiring Harness (99903340)

    20011217 5525/6025/6625: 99903289: 3-47 CHASSIS WIRING HARNESS (99903340) NOTE: TO BE USED ONLY ON SHIP-OUT TELESCOPIC CRANES W/O IMT-INSTALLED BODIES. ORANGE...

  • Page 80: Handle Asm W/Eng Start - Handle & Trigger (51716562)

    ALL MODELS 5525/6025/6625: 99903289: 20020225 3-48 HANDLE ASM W/ENG START - HANDLE & CONTINUED ON NEXT PAGE TRIGGER (51716562) 89044214 WIRE-18GA GRN STRD (7 @ 1.61 FT 2.25”, 1 @ 3.50”) 14. 72061009 SCR-SHT MET #6 X 3/4 PH ZA...

  • Page 81: Handle Asm W/Eng Start - Switches & Face Plate (51716562)

    5525/6025/6625: 99903289: 20020225 3-49 HANDLE ASM W/ENG START - SWITCHES PARTS LIST ON PREVIOUS PAGE CONTINUED ON NEXT PAGE & FACE PLATE (51716562) BLK / BLU BLK/ORN RED/BLK ORN/BLK 15 (31) BRN/RED YEL/BLK THIS JUMPER 3.50". ALL OTHERS 2.25". RED/BLU...

  • Page 82: Handle Asm - Radio Remote Backup (51716912)

    ALL MODELS 5525/6025/6625: 99903289: 20020821 3-50 HANDLE ASM - RADIO REMOTE BACKUP (51716912) 73733374 CABLE ASM 77041404 TOGGLE SWITCH, ON-OFF-ON 77041346 TOGGLE SWITCH, (ON)-OFF-(ON) 60121724 JIC BOX 77040186 TERMINAL-FSLPON 1/4TAB 60045031 WIRE-GREEN 4” LONG 77044018 CONNECTOR 1/2 STR RLF 3/8-1/2 1...

  • Page 83: Boom Support - Dominator 1 (51714181)

    5525/6025/6625: 99903289: 20020508 3-51 BOOM SUPPORT - DOMINATOR 1 (51714181) 52708159 PEDESTAL 60121853 TUBE-PEDESTAL 60120516 BOOM SUPPORT 60030306 WEAR PAD 72060048 CAP SCR 3/8-16 X 1.50 HHGR5 4REF 72060049 CAP SCR 3/8-16 X 1.75 HHGR5 2REF 72060101 CAPSCR 1/2-13 X 5.00 HHGR5...
  • Page 84 5525/6025/6625: 99903289: 3-52...
  • Page 85 20000710 SECTION 4. GENERAL REFERENCE SECTION 4. GENERAL REFERENCE INSPECTION CHECKLIST ....................3 WIRE ROPE INSPECTION ....................7 HOOK INSPECTION ......................7 HOLDING VALVE INSPECTION..................8 ANTI-TWO BLOCKING DEVICE INSPECTION ............... 8 TORQUE DATA CHART - DOMESTIC ................9 TORQUE DATA CHART - METRIC ................10 TURNTABLE BEARING FASTENER TIGHTENING SEQUENCE ........
  • Page 86 20000710 SECTION 4. GENERAL REFERENCE NOTES...
  • Page 87 20000710 SECTION 4. GENERAL REFERENCE Inspection Checklist NOTICE The user of this form is responsible in determining that these CRANES inspections satisfy all applicable regulatory requirements OWNER/COMPANY TYPE OF INSPECTION (check one) DAILY (if deficiency found) QUARTERLY CONTACT PERSON MONTHLY ANNUAL CRANE MAKE &...

  • Page 88: Inspection Checklist

    20000710 SECTION 4. GENERAL REFERENCE Inspection Checklist CRANES = SATISFACTORY R = RECOMMENDATION STATUS = DEFICIENCY (should be considered for corrective action) (must be corrected prior to operation) NA = NOT APPLICABLE INSPECTION DESCRIPTION FREQUENCY ITEM R, NA Daily All daily inspection items. Cylinders Visual inspection of cylinders for leakage at rod, fittings &...
  • Page 89 20000710 SECTION 4. GENERAL REFERENCE Inspection Checklist CRANES = SATISFACTORY R = RECOMMENDATION STATUS = DEFICIENCY (should be considered for corrective action) (must be corrected prior to operation) NA = NOT APPLICABLE FREQUENCY ITEM INSPECTION DESCRIPTION R, NA Pumps, PTO’s Pumps, PTO’s &...
  • Page 90 20000710 SECTION 4. GENERAL REFERENCE Deficiency / Recommendation / Corrective Action Report (cont) DATE R, CA ITEM # EXPLANATION CORRECTED If additional space is required, reproduce this page and attach to this report.

  • Page 91: Wire Rope Inspection

    20000710 SECTION 4. GENERAL REFERENCE HOOK INSPECTION WIRE ROPE INSPECTION Hooks having any of the listed deficiencies shall be Wire rope with any of the deficiencies shown below shall be removed from service unless a qualified person approves removed and replaced immediately. their continued use and initiates corrective action.

  • Page 92: Holding Valve Inspection

    20000710 SECTION 4. GENERAL REFERENCE HOLDING VALVE INSPECTION COARSE THREAD BOLTS The cylinders are equipped with holding valves that prevent TIGHTENING TORQUE sudden movement of the cylinder rods in the event of a hydraulic hose or other hydraulic component failure. The valve is checked in the following manner: 1.

  • Page 93: Torque Data Chart - Domestic

    20000710 SECTION 4. GENERAL REFERENCE TORQUE DATA CHART - DOMESTIC FINE THREAD BOLTS COARSE THREAD BOLTS TIGHTENING TORQUE TIGHTENING TORQUE SAE J429 SAE J429 SAE J429 SAE J429 GRADE 5 GRADE 8 GRADE 5 GRADE 8 SIZE BOLT DIA PLAIN PLATED PLAIN PLATED...

  • Page 94: Torque Data Chart - Metric

    20000710 4-10 SECTION 4. GENERAL REFERENCE TORQUE DATA CHART - METRIC FINE THREAD BOLTS COARSE THREAD BOLTS TIGHTENING TORQUE TIGHTENING TORQUE SAE J429 SAE J429 SAE J429 SAE J429 GRADE 5 GRADE 8 GRADE 5 GRADE 8 SIZE BOLT DIA PLAIN PLATED PLAIN...

  • Page 95: Turntable Bearing Fastener Tightening Sequence

    20000710 4-11 SECTION 4. GENERAL REFERENCE TURNTABLE BEARING FASTENER TIGHTENING SEQUENCE Refer to the diagram below for proper tightening/torqueing sequence of the turntable bearing to the crane base and crane mast. The total quantity of cap screws varies dependent on crane model. WARNING Number 1 can be assigned to any capscrew if the sequence...

  • Page 96: Turntable Bearing Inspection For Replacement

    20000710 4-12 SECTION 4. GENERAL REFERENCE TURNTABLE BEARING INSPECTION FOR REPLACEMENT Before a bearing is removed from a crane for If none of the above conditions exists, the bearing is inspection, one of the following conditions should be functioning properly and need not be replaced. But, if evident: one or more of the above conditions exists, inspection may be required.
  • Page 97 20000710 4-13 SECTION 4. GENERAL REFERENCE The information within this manual has been compiled and checked but errors do occur. To provide our customers with a method of communicating those errors we have provided the Manual Change Request form below. In addition to error reporting, you are encouraged to suggest changes or additions to the manual which would be of benefit to you.
  • Page 98 Iowa Mold Tooling Co., Inc. One manual is provided with each piece of new equipment and additional manuals may be obtained at a nominal price. Your distributor may have access to this manual through the IMT web site at www.IMT.com. IOWA MOLD TOOLING CO., INC.
  • Page 99 6026/6625 WINCH: 99903289: 20020228 APPENDIX A: WINCH APPENDIX A 6025/6625 PLANETARY WINCH 506W WINCH (70146319) ....................3 1.0 Introduction and Theory of Operation ................ 4 2.0 Winch Maintenance ...................... 4 2.1 Daily Maintenance ......................4 2.2 Maintenance at 500 and 1000 Hours ................4 2.3 Complete Teardowns ....................
  • Page 100 6026/6625 WINCH: 99903289: 20011015 APPENDIX A: WINCH WARNING AVOID DEATH OR SERIOUS INJURY! READ THE FOLLOWING WARNINGS! 1. Winches must not be used to lift, hoist, or move people. If your task involves lifting or moving people, you MUST use the proper equipment, not this winch. 2.

  • Page 101: Winch (70146319)

    6026/6625 WINCH: 99903289: 20011015 APPENDIX A: WINCH FIGURE 2: WINCH PARTS BREAKDOWN MOTOR THIS SIDE 38 39 3 4 52 5 19 11 2 28 10 40 20 5 SECTION A-A 37 44 30 13 12 9 5 10 4 16 34 45 31 NOTES:...

  • Page 102: Introduction And Theory Of Operation

    The winch is shipped from the factory with SAE 90 EP gear lubricant in the gearbox and automatic transmission fluid in the brake section. This oil is usable in temperatures from -10° F to +110 ° F, ± 20 ° F. If using the winch in conditions beyond this temperature range, contact IMT for a lubrication recommendation.

  • Page 103: Gearbox Oil Change Procedure

    6026/6625 WINCH: 99903289: 20011015 APPENDIX A: WINCH 2.5 Gearbox Oil Change Procedure 1) Drain the gearbox oil by removing the level plug, item 35, in the center of the output shaft, item 6. 2) Remove the drain plug by rotating the drum so that the plug is visible through the hole in the side of the mounting bracket.
  • Page 104 6026/6625 WINCH: 99903289: 20011015 APPENDIX A: WINCH...

  • Page 105: Disassembly And Assembly

    Replace if necessary. 5) Pilot pressure to operate the brake valve is obtained from inside the manifold block. Motors and cartridge valves are not serviceable in the field. Contact IMT for service on valves. 3.2 Servicing the Brake Section - Disassembly 1) Remove the five nuts, Item 40, and one capscrew holding the brake cover in place.

  • Page 106: Servicing The Drum Section

    6026/6625 WINCH: 99903289: 20011015 APPENDIX A: WINCH 3.3 Reassembly of the Brake Section, continued 3) Install stators and friction discs into the housing, starting with stator and alternating friction discs and stator plates. There is one more stator than friction disc, so the stator will be the last item installed. 4) After installation, check the brake “stack-up”...

  • Page 107: Drum Section Assembly

    6026/6625 WINCH: 99903289: 20011015 APPENDIX A: WINCH 9) Slide the drum, Item 3, off the output shaft, Item 6. 10) Remove the bearing, Item 5, and seal, Item 4, from the drum and inspect the bearing for signs of pitting or spalling.

  • Page 108: Troubleshooting

    6026/6625 WINCH: 99903289: 20011015 APPENDIX A: WINCH 4.0 Troubleshooting PROBLEM SOLUTIONS 1) Winch will not hold load. a) There is excessive back pressure in the system. Check the system for restrictions and reduce the back pressure. b) Brake discs are worn out. Replace brake discs. c) Winch clutch is slipping.

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60256625

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