IMT 4004i Parts & Specifications
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IMT 4004i Parts & Specifications

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IOWA MOLD TOOLING CO., INC.
P.O. Box 189
Garner, IA 50438
Tel: 641.923.3711
Fax: 641.923.2424
www.imt.com
Manual # 99904386
4004i
Parts &
Specifications
Revised 06-18-2020
Copyright © 2020 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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  • Page 1 P.O. Box 189 Garner, IA 50438 Tel: 641.923.3711 Fax: 641.923.2424 www.imt.com Manual # 99904386 4004i Parts & Specifications Revised 06-18-2020 Copyright © 2020 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.
  • Page 2 70490167 3.27” 2.70” ORANGE , BLACK AND WHITE 5-29-18 PROP 65 70490167 4004i - Manual # 99904386...

  • Page 3: Table Of Contents

    Load Capacity Chart (70397414) ........................6 Geometric Configuration ..........................7 Pump & Motor Performance ..........................8 Assemblies & Grease Zerk Locations ......................10 4004i Recommended Spare Parts List ......................11 Crane Installation (99904394) ........................13 Electric Crane Battery Circuit (99904884) ....................18 Telescopic Crane Orientation ........................19 Electric Crane Control ..........................20...
  • Page 4 This page left intentionally blank 4004i - Manual # 99904386...

  • Page 5: Introduction

    Introduction Section - 1 Section - 1 Introduction 4004i - Manual # 99904386...

  • Page 6: Introduction

    No warranty - verbal, written or implied - other than the official, published IMT new machinery and equipment warranty will be valid with this unit. In addition, it is also the user’s responsibility to be aware of existing Federal, State and Local codes and regulations governing the safe use and maintenance of this unit.

  • Page 7: Specifications

    Specifications Section - 2 Section - 2 Specifications 4004i - Manual # 99904386...

  • Page 8: 4004I Technical Data

    75’ (22.9 m) Cable Nominal Strength 7000 lb (3175 kg) PERFORMANCE CHARACTERISTICS SPECIFICATIONS SPEED Rotation 360º (Continuous) 44 seconds Lower Boom Elevation -5º to +75º 10 seconds Extension Cylinder 48” (122.0 cm) 10 seconds total CHASSIS REQUIREMENTS 4004i - Manual # 99904386...
  • Page 9 Elevated RPM required if additional high amperage draw systems will be in use Engine while crane is being operated. Duty cycle and absolute continuous on-time according to the crane user manual. Duty Cycle Winch is not operated simultaneously with any other function. 4004i - Manual # 99904386...

  • Page 10: Load Capacity Chart (70397414)

    .OO5“ VELVET FINISH LEXAN REVISIONS ECN/CN DESCRIPTION DATE ADHESIVE: 3M 468 HI-PERFORMANCE APPLIED AFTER SCREENING 4004i - Manual # 99904386 ADDED WIRE ROPE INFORMATION 12-15-15 SIZE: 6”W x 8.5"H PER ASME B30 5-1.1.3 COLORS: BLACK ON WHITE BACKGROUND, AS SHOWN VENDOR: CREATIVE SCREEN PRINT (CRE10) OR EQUIV.

  • Page 11: Geometric Configuration

    Section - 2 Geometric Configuration 4'-2" (1.28 m) 3'-2" (96 cm) 2'-3" (67.4 cm) 16'-10" (5.14 m) 13'-0" (3.96 m) 9'-5" (2.87 m) 4004i 1'-4" (40 cm) 8'-0" (2.43 m) 12'-0" (3.65 m) 16'-0" (4.87 m) 4004i - Manual # 99904386...

  • Page 12: Pump & Motor Performance

    The five minute duty cycle must be adhered to. Operators have a choice of running the crane intermittently all day, using the duty cycles per the S2 and S3 curves, or at full power for 4.5 minutes, which MUST be followed by a complete cool-down to ambient. 4004i - Manual # 99904386...
  • Page 13 Specifications Section - 3 Section - 3 Crane Reference 4004i - Manual # 99904386...

  • Page 14: Assemblies & Grease Zerk Locations

    NOTE: All application points must be greased weekly under normal workloads and moderate weather condi- tions. Under severe operating conditions, lubricate more frequently. See the IMT Electric Crane Opera- tion & Safety manual P/N: 99905190, for additional lubrication requirements. NOTE: Image may be different depending on production date.

  • Page 15: 4004I Recommended Spare Parts List

    Specifications Crane Reference 4004i Recommended Spare Parts List 51721268 LOWER CYLINDER QTY. 51744172 SEAL KIT-IMT 3.50 X 1.75R X 1.50 STGR 60132397 PISTON-2.75 BORE X 1.75 ROD 1.63 STGR 6HD35017 HEAD-3.5 BORE X 1.75 ROD 73054999 VALVE-CBAL 77041786 SWITCH-PRESS 2750...
  • Page 16 SPRING-.105WIRE 0.75OD 2.875 LG 70735101 HOOK-SWVL POS LOCK BBRG 2TON (EFFECTIVE 1/1/2018) 72601798 WASHER-LOCK 12MM 72601935 CAP SCREW M12-1.75X 40 SH PLAIN 72601938 BOLT-EYE # 8-32X 1.125 77041459 SWITCH-LIMIT ZE-N-2S 77441096 CONNECTOR- .50 STR RLF .25-.38 4004i - Manual # 99904386...

  • Page 17: Crane Installation (99904394)

    Install the crane only on an IMT designed and approved truck body. The body must be designed to sustain the forces imposed by the crane when lifting the full rated load.
  • Page 18 The 3/4-10 x 2.5” grade 8 zinc coated capscrews are designed for a crane box thickness of 1/2” only. A different crane box may require different capscrews. All mounting capscrews must be grade 8 zinc coated with a minimum thread engagement of 1.25” (3.175 cm). 4004i - Manual # 99904386...
  • Page 19 Use the parts list above to identify parts. Your crane installation kit, 51721572, includes a 10.7 m (35’) long cable, IMT # 89044276 (item #13 in the parts list). Approximately 7.6 m (25’) of this cable is required to connect the crane power switch to the vehicle battery, and the rest of the cable is used for ground connec- tions between the crane, vehicle battery, auxiliary battery, and chassis ground.
  • Page 20 The vehicle factory ground is NOT sufficient to carry the current required by the crane. Without this extra ground cable, your crane may not operate at rated capacity, and motor, contactor, or electrical damage may occur. 4004i - Manual # 99904386...
  • Page 21 TO CRANE TO CHASSIS GROUND BATTERY (+) (225-AMP 10 (5/16" RING FUSE) (FUSEHOLDER) TERMINAL) NOTES: 1. Use bulkhead pass-through connectors when power or ground passes through a compartment wall 2. Reference drawing 99904884 for wiring diagram. 4004i - Manual # 99904386...

  • Page 22: Electric Crane Battery Circuit (99904884)

    Specifications Crane Reference Electric Crane Battery Circuit (99904884) NOTE: 1. Electric bulkhead pass-thru connector. Use whenever power or ground passes through a compartment wall. 4004i - Manual # 99904386...

  • Page 23: Telescopic Crane Orientation

    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°...

  • Page 24: Electric Crane Control

    Crane Reference Electric Crane Control IMT’s Electric Cranes are controlled by radio or tethered remote controls. This telescopic crane includes a tethered remote control with a radio remote control option. For complete details on operating your telescopic crane, refer to the IMT Electric Cranes Operation & Safety manual, part number 99904381.

  • Page 25: Parts

    Parts Section - 4 Section - 4 Parts 4004i - Manual # 99904386...

  • Page 26: Parts Information

    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.
  • Page 27 3. Give the serial number of the unit.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. 4004i - Manual # 99904386...

  • Page 28: Electric Crane Power Safety

    70392865 WARNING AVOID SERIOUS INJURY! 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. 4004i - Manual # 99904386...
  • Page 29 This page left intentionally blank 4004i - Manual # 99904386...

  • Page 30: Base & Mast Assembly (99904325)

    APPLY RUST PREVENTATIVE TORQUE TO 160 FT-LBS 23 30 25 30 22 29 28 TORQUE TO 160 FT-LBS 45 33 BASE & MAST ASSEMBLY POWER UNIT & GEAR GUARD INSTALLAION HYDRAULIC MOTOR & VALVE BANK ASSEMBLY 4004i - Manual # 99904386...
  • Page 31 WLDMT-BASE 4004I 52725114 MAST WELDMENT-4004I 60140618 PIN-TYPE NN 1.00 X 8.25 52721315 WLDMT-GEAR SHROUD 4004I 60141143 PLATE- ELEC ROTATOR BRKT TOP 4004I 60141128 PLATE-ELEC ROTATOR BRKT BOTTOM 60132385 SPACER- POWER UNIT 60132856 BRKT-GREASE HOSE MNTG 4004I 71056633 GEAR-TRNTBL BRG 12.63” DIA 70580194 CLAMP-I”...
  • Page 32 1. Apply black “molub-alloy 936 sf heavy” gear grease to turntable gear. WARNING DO NOT CONNECT ELECTRICAL POWER TO CRANE UNTIL ALL CONNECTIONS HAVE BEEN TESTED. SEVER INJURY COULD RESULT. ATTACH ELECTRICAL WIRES AND GROUNDS TO COMPO- NENTS BEFORE CONNECTING TO MAST. 4004i - Manual # 99904386...
  • Page 33 Section - 4 99904325-1 ITEM NO. PART NO. DESCRIPTION KIT NO. QTY. 51721375 KIT-HRDW BASE & MAST 4004I 51721268 CYL-3.5/1.7 16.06S 30.44CC C 60140618 PIN-TYPE NN 1.00 X 8.25 70034382 CAP-GREASE PRO20 GC-RED 72060046 CAP SCR .38-16X 1.00 HH GR5 Z 72063051 WASHER .38 LOCK...

  • Page 34: Valve Bank (73734304)

    Parts Section - 4 Valve Bank (73734304) 6.284 SAE #4 ORB PORT (4 PLACES) 2.438 SAE #4 ORB PORT SAE #4 ORB PORT SAE #4 ORB PORT (2 PLACES) EXTENSION MAIN ROTATE HYDRAULIC SCHEMATIC 4004i - Manual # 99904386...
  • Page 35 CONNECT A PUMP CABLE OF 3 GPM AND 3000PSI TO “P” CONNECT “T” TO TANK CAP ALL SETUP: OTHER PORTS. APPLY FLOW TO “P” AND VERIFY FLOW BACK TO TANK AT LOW PRESSURE. TEST: ELECTRICALLY SHIFT EACH COIL AND VERIFY THAT THE SYSTEM GOES TO THE BENCH RELIEF SETTING.END OF TEST 4004i - Manual # 99904386...

  • Page 36: Cylinder, Lower (51721268)

    Parts Section - 4 Cylinder, Lower (51721268) PRESS IN P/N 60125699 SECTION B-B 4004i - Manual # 99904386...
  • Page 37 ROD: Ø1.75 X 28.81LG OPER. PSI: 2500 PSI PISTON TORQUE: 710-740 PSI STINGER: Ø1.50 X 3.92LG HEAD TORQUE: 350 FT-LB CYL. STROKE: 16.06” CARTRIDGE TORQUE: 30-35 FT-LB LOCKNUT TORQUE: 12 FT-LB CAP SCR TORQUE: 16 FT-LB 4004i - Manual # 99904386...

  • Page 38: Crane & Winch Assembly (99904327)

    Parts Section - 4 Crane & Winch Assembly (99904327) APPLY SERVICEABLE LOCTITE TO CAP SCREW CONNECT THE WIRE TERMINALS (77040051 ) TO COMMON AND NORMALLY OPEN ON ATB SWITCH 29 28 DETAIL B DETAIL A 4004i - Manual # 99904386...
  • Page 39 Parts Section - 4 99904327 COMPLETE PARTS LIST ITEM NO. PART NO. DESCRIPTION KIT NO. QTY. 99904325 DWG-BASE AND MAST ASM 4004I 99904326 DWG-BOOM ASM 4004I 51721321 KIT-HRDW 3203I CRANE & WINCH 51724950 SNATCH BLOCK- 3203I-4004I 52725018 WLDMT-ATB TRIP MECHANISM 70580197 WIRE ROPE ASM-.25(7X19 GAC) X 75’...
  • Page 40 72601805 CAP SCR M12-1.75X 25 HHZ 72602011 SCR-MACH # 8-32X .62 BTNHD ZC 60140653 COVER- VALVE BANK 3203I 72060000 CAP SCR .25-20X .50 HH GR5 Z 70735101 HOOK-SWVL POS LOCK BBRG 2TON REV. X CN885 4004i - Manual # 99904386...
  • Page 41 REV. X CN885 NOTES: 1. Use anti-seez on pins. 2. All electrical grounds must be free of paint, grease, and oil. 3. If required use (72063033) machny bushings between mast and boom when installing pin, 60140618. 4004i - Manual # 99904386...
  • Page 42 Section - 4 99904327-2 DOUBLE APPLICATION SINGLE APPLICATION ITEM NO. PART NO. DESCRIPTION KIT NO. QTY. 51724950 SNATCH BLOCK- 3203I-4004I 70580197 WIRE ROPE ASM-.25(7X19 GAC) X 75’ RRL 70735101 HOOK-SWVL POS LOCK BBRG 2TON REV. X CN885 4004i - Manual # 99904386...
  • Page 43 This page left intentionally blank 4004i - Manual # 99904386...

  • Page 44: Boom Assembly (99904326)

    Parts Section - 4 Boom Assembly (99904326) BOOM ASSEMBLY: 1 HYDRAULIC EXTENSION, 1 MANUAL EXTENSION 4004i - Manual # 99904386...
  • Page 45 KIT-HRDW 3203 BOOM ASY 51725007 CYL-1.50/1.0 48.00S 7.38CC C 52724109 WLDMT-LOWER BOOM 4004I 52721312 WLDMT- 1ST EXT 4004I 52725023 WLDMT- 2ND ST EXT 4004I 52725024 WLDMT-2ND STAGE MANUAL EXT 4004I 60030373 WEAR PAD- EXT CYLINDER 60030374 WEAR PAD-RND 0.25X 1.00X .50X .31 60030376 WEAR PAD-RND 0.30X 3.50X 1.00X 0.615...
  • Page 46 Parts Section - 4 BOOM ASSEMBLY, 2 MANUAL EXTENSIONS 4004i - Manual # 99904386...
  • Page 47 KIT-HRDW 3203 BOOM ASY 51725007 CYL-1.50/1.0 48.00S 7.38CC C 52724109 WLDMT-LOWER BOOM 4004I 52721312 WLDMT- 1ST EXT 4004I 52725023 WLDMT- 2ND ST EXT 4004I 60132302 STOP SCREW 3/8-24 X .50 52725024 WLDMT-2ND STAGE MANUAL EXT 4004I 60030373 WEAR PAD- EXT CYLINDER 60030374 WEAR PAD-RND 0.25X 1.00X .50X .31...
  • Page 48 Parts Section - 4 BOOM ASSEMBLY: 1 HYDRAULIC EXTENSION BOOM ASSEMBLY 1 HYDRAULIC EXTENSION 4004i - Manual # 99904386...
  • Page 49 51725007 CYL-1.50/1.0 48.00S 7.38CC C 52724109 WLDMT-LOWER BOOM 4004I 52721312 WLDMT- 1ST EXT 4004I 52725023 WLDMT- 2ND ST EXT 4004I 60030374 WEAR PAD-RND 0.25X 1.00X .50X .31 60030376 WEAR PAD-RND 0.30X 3.50X 1.00X 0.615 60132302 STOP SCREW 3/8-24 X .50 71734311 PIN-QUICK RLSE .62D/4.5 CRIT...
  • Page 50 Parts Section - 4 BOOM ASSEMBLY: 1 MANUAL EXTENSION BOOM ASSEMBLY 1 MANUAL EXTENSION 4004i - Manual # 99904386...
  • Page 51 DESCRIPTION KIT NO. QTY. 51721320 KIT-HRDW 3203 BOOM ASY 52724109 WLDMT-LOWER BOOM 4004I 52725024 WLDMT-2ND STAGE MANUAL EXT 4004I 60030374 WEAR PAD-RND 0.25X 1.00X .50X .31 60030376 WEAR PAD-RND 0.30X 3.50X 1.00X 0.615 60132302 STOP SCREW 3/8-24 X .50 71734314 PIN-QUICK RLSE .62D/5.75 CRIT...
  • Page 52 Parts Section - 4 BOOM ASSEMBLY: 1 HYDRAULIC EXTENSION, 1 MANUAL EXTENSION BOOM ASSEMBLY 1 HYDRAULIC EXTENSION 1 MANUAL EXTENSION 4004i - Manual # 99904386...
  • Page 53 72062104 NUT .25-20 HEX NYLOCK 72063001 WASHER .25 FLAT 72063051 WASHER .38 LOCK 72661711 CLEVIS PIN .50 X 3.00 70034490 PLATE-ANGLE PLASTIC 3.50” 72661766 LOCKING PIN RUE RING .50 72661543 PIN-QUICK 316-10QP REV. O CN682 4004i - Manual # 99904386...
  • Page 54 Parts Section - 4 BOOM ASSEMBLY: MANUAL EXTENSIONS BOOM ASSEMBLY MANUAL EXTENSIONS 4004i - Manual # 99904386...
  • Page 55 PIN-QUICK RLSE .62D/4.5 CRIT 71734314 PIN-QUICK RLSE .62D/5.75 CRIT 72063051 WASHER .38 LOCK 72661711 CLEVIS PIN .50 X 3.00 70034490 PLATE-ANGLE PLASTIC 3.50” 72661766 LOCKING PIN RUE RING .50 72661543 PIN-QUICK 316-10QP REV. O CN682 4004i - Manual # 99904386...

  • Page 56: Snatch Block (51724950)

    Parts Section - 4 Snatch Block (51724950) 4004i - Manual # 99904386...
  • Page 57 CLEVIS PIN .50 X 3.00 52704828 PIN-TYPE T .75X 3.00 72053508 ZERK-NPT .12 72066145 HAIR PIN .19 ZINC 60030243 SPACER-POL .52X 1.50X .50 70734805 COTTER PIN BOWTIE .50 72063030 MACHY BUSHING .75X10 GA NR REV. D 4004i - Manual # 99904386...

  • Page 58: Cylinder, Extension (51725007)

    Parts Section - 4 Cylinder, Extension (51725007) SECTION A-A 4004i - Manual # 99904386...
  • Page 59 ITEM NO. PART NO. DESCRIPTION KIT NO. QTY. 94397290 IMT SEAL KIT-1.50 BORE 1.00 ROD .75 STGR 52722110 ROD ASM-1.00 DIA X 61.38 LG .75 S 52725008 CASE ASM-1.50 BORE X 58.25 LG 60135105 HEAD-1.50 BORE X 1.00 ROD (DUCTILE IRON) 60132170 STINGER LOCK .75-16 X 1.75 LG...

  • Page 60: Cylinder, Extension (51722111)

    Ø1.00 OD X 61.38LG OPER. PSI: 2500 PSI STINGER: Ø0.75 X 2.750LG PISTON TORQUE: 100-130 FT-LB HEAD TORQUE: 200 FT-LB CYL. STROKE: 48.00" CARTRIDGE TORQUE: 30-35 FT-LB LOCKNUT TORQUE: CAP SCR TORQUE: 100-130 FT-LB SECTION A-A 4004i - Manual # 99904386...
  • Page 61 ITEM NO. PART NO. DESCRIPTION KIT NO. QTY. 94397290 IMT SEAL KIT-1.50 BORE 1.00 ROD .75 STGR 52722110 ROD ASM-1.00 DIA X 61.38 LG .75 S 52721293 CASE ASM-1.50 BORE X 58.25 LG 60135105 HEAD-1.50 BORE X 1.00 ROD (DUCTILE IRON) 60132170 STINGER LOCK .75-16 X 1.75 LG...

  • Page 62: Winch (71570922)

    RING GEAR THRUST WASHER 32000480 THRUST WASHER DRUM PLUG NOTE: For 24V system, use 71571008 WINCH REPLACEMENT PART NUMBERS: B rake - IMT P/N: 77056662 Motor - IMT P/N: 73511210 Contactor - IMT P/N: 77041862 4004i - Manual # 99904386...

  • Page 63: Snatch Block (51724950)

    CLEVIS PIN .50 X 3.00 52704828 PIN-TYPE T .75X 3.00 72053508 ZERK-NPT .12 72066145 HAIR PIN .19 ZINC 60030243 SPACER-POL .52X 1.50X .50 70734805 COTTER PIN BOWTIE .50 72063030 MACHY BUSHING .75X10 GA NR REV. D CN616-1 4004i - Manual # 99904386...

  • Page 64: Power Unit 73511283 (12V) & 73511305 (24V)

    Parts Section - 4 Power Unit 73511283 (12V) & 73511305 (24V) 4004i - Manual # 99904386...
  • Page 65 RELIEF VALVE ASSEMBLY 74399495 RESERVOIR 70734788 BREATHER CAP 73734791 TUBE-SUCTION 70734792 STRAINER REV. INITIAL RELEASE. NOTES: For parts not listed, contact: Iowa Mold Tooling Co., Inc. Box 189, Garner, IA 50438-0189 Telephone: 641-923-3711 Technical Support Fax: 641-923-2424 4004i - Manual # 99904386...

  • Page 66: Power Unit (73511169)

    Car t r i dge V a lv e Chec k V a lv e Retur n Line Suction Line Pipe Pipe ADAPTER / RESERVOIR SECTION Tube Kit (Suction Line & Return Line Pipes) (73734332) 4004i - Manual # 99904386...

  • Page 67: Hydraulic Installation (99904388)

    HYDRAULIC MOTOR PORT "A" PRESSURE ROTATION CLOCKWISE (CW) HYDRAULIC MOTOR PORT "B" LOWER CYLINDER TAMK RETURN EXTENSION CYLINDER EXTEND PORT EXTEND PORT EXTENSION CYLINDER OUT EXTENSION CYLINDER IN ROTATION COUNTER CLOCKWISE (CCW) BOOM DOWN BOOM UP 4004i - Manual # 99904386...
  • Page 68 VALVE BANK HYDRAULIC MOTOR (PORT A1) REAR OF MAST WITHOUT PROPORTIONAL VALVE TO LOWER CYLINDER (PORT R) TO LOWER CYLINDER (PORT E) TO VALVE BANK (PORT B2) 1H1M TO VALVE BANK (PORT A2) ON/OFF RADIO TETHERED 4004i - Manual # 99904386...
  • Page 69 Section - 4 99904388 PARTS LIST ITEM NO. PART NO. DESCRIPTION KIT NO. QTY. 99904327 DWG-CRANE & WINCH ASM 4004I 70145928 FLOW LIMITER-28051-806-1.0 6 72532522 PLUG-STR HEX HD STL .44 73540325 VALVE-PROP FLOW CNTRL 12V ELEC CRANE 51721540 KIT-HYD 4004I 51397335 HOSE-FZ .25 X 13.50 (4-4) 100R17...
  • Page 70 TO LOWER CYLINDER (PORT E) TO VALVE BANK (PORT B2) NOTE: 1H1M 1. CRANES WITHOUT EXTENSION CYLINDER USE PLUGS (72532522) TO BLOCK HYDRAULIC PORTS B1 & A1 ON THE VALVE BLOCK. PROPORTIONAL VALVE TO VALVE BANK (PORT A2) 4004i - Manual # 99904386...
  • Page 71 Parts Section - 4 99904388-2 ITEM NO. PART NO. DESCRIPTION KIT NO. QTY. 99904327 DWG-CRANE & WINCH ASM 4004I 70145928 FLOW LIMITER-28051-806-1.0 6 72532522 PLUG-STR HEX HD STL .44 73540325 VALVE-PROP FLOW CNTRL 12V ELEC CRANE 51721540 KIT-HYD 4004I 51397335 HOSE-FZ .25 X 13.50 (4-4) 100R17...
  • Page 72 TO BLOCK HYDRAULIC PORTS B1 & A1 ON THE VALVE BLOCK. TO LOWER CYLINDER (PORT R) TO LOWER CYLINDER (PORT E) 1H1M ON OFF RADIO TO VALVE BANK (PORT B2) TETHERED W/OUT EXTENSION CYLINDER TO VALVE BANK (PORT A2) 4004i - Manual # 99904386...
  • Page 73 Section - 4 99904388-3 PARTS LIST ITEM NO. PART NO. DESCRIPTION KIT NO. QTY. 99904327 DWG-CRANE & WINCH ASM 4004I 70145928 FLOW LIMITER-28051-806-1.0 6 72532522 PLUG-STR HEX HD STL .44 73540325 VALVE-PROP FLOW CNTRL 12V ELEC CRANE 51721540 KIT-HYD 4004I 51397335 HOSE-FZ .25 X 13.50 (4-4) 100R17...

  • Page 74: Tethered Control Installation (99904593)

    Parts Section - 4 Tethered Control Installation (99904593) 3203i/4004i CRANE TETHERED CONTROLS 4004i - Manual # 99904386...
  • Page 75 CONTROL KIT- TETHERED ELECTRIC CRANE 91725111 3203/4004 70734746 HANDLE ASM-TETHERED ELECTRIC CRANES 60133633 COVER- WINDOW 72060002 CAP SCR .25-20X .75 HH GR5 Z 72062104 NUT .25-20 HEX NYLOCK 72063001 WASHER .25 FLAT 77441536 PLUG CAP-DEUTSCH HDC36-24 REV. B 4004i - Manual # 99904386...

  • Page 76: Radio Control Installation, Standard (99904594)

    Parts Section - 4 Radio Control Installation, Standard (99904594) 3203i/4004i CRANE ON-OFF RADIO CONTROLS 4004i - Manual # 99904386...

  • Page 77: Radio Control Installation, Proportional (99904595)

    72060008 CAP SCR .25-20X 2.00 HH GR5 Z 72062104 NUT .25-20 HEX NYLOCK 72063001 WASHER .25 FLAT 73540325 VALVE-PROP FLOW CNTRL 12V ELEC CRANE 77441270 HARNESS-RADIO ELECTRIC CRANE 91721626 KIT-HYD PROP ELEC CRANE REV. A 4004i - Manual # 99904386...
  • Page 78 This page left intentionally blank 4004i - Manual # 99904386...

  • Page 79: Electrical & Lighting

    Electrical & Lighting Section - 5 Section - 5 Electrical & Lighting 4004i - Manual # 99904386...

  • Page 80: Electrical Installation (99904392)

    SEE NOTE 2 WIREHARNESS RADIO & TETHER CONTROL (REAR VIEW) MAST LH SIDE GROUND ELECTRIC ROTATOR BRACKET (TOP) CRANE BOX ELECTRIC ROTATOR BRACKET (BOTTOM) TO CRANE BOX GROUND TO 300 AMP KEYED SWITCH IN CRANE BOX 4004i - Manual # 99904386...
  • Page 81 TERM INSUL RED #8-2 GA WIRE 72060021 CAP SCR .31-18X .50 HH GR5 Z 72063050 WASHER .31 LOCK REV. L NOTES: 1. Wrap winch cables with Black Spiral Wrap. 2. Torque to 8-15 ft-lbs (2 places). 4004i - Manual # 99904386...

  • Page 82: Light Kit (99906234)

    Section - 5 Light Kit (99906234) ITEM NO. PART NO. DESCRIPTION KIT NO. QTY. 51727279 ELECT KIT-BOOM FLOOD LIGHTS 3203I-4004I 60145332 SLEEVE-TYPE C .44X .75X .25 60145055 BRACKET-LIGHT 3203I-4004I 72060074 CAP SCR .44-14X 5.00 HH GR5 Z 72063002 WASHER .31 FLAT...
  • Page 83 Section - 5 99906234-1 ITEM NO. PART NO. DESCRIPTION KIT NO. QTY. 51727279 ELECT KIT-BOOM FLOOD LIGHTS 3203I-4004I 77044574 CONN-PKRD WEATHERPACK 2 CAV FEMALE/TOWER 77044927 CABLE SEAL-PKRD WP/MP 14 GA GREY 77045888 TERM-PKRD WEATHERPACK 14-16GA FEMALE REV. C CN989 4004i - Manual # 99904386...
  • Page 84 Electrical & Lighting Section - 5 99906234-2 ITEM NO. PART NO. DESCRIPTION QTY. 51727279 ELECT KIT-BOOM FLOOD LIGHTS 3203I-4004I 51727416 CORD REEL ASM 4.75’ W/PACKARD CONN 3-WIR 60132111 BRKT- CORD REEL MNT REV. C CN989 4004i - Manual # 99904386...
  • Page 85 TO "UP" AS ON, AND "DOWN" AS OFF. NOTE: TOGGLE SWITCH 77041345 IS PART OF HARNESS 77441674. INSTALL TOGGLE SWITCH IN VALVE BANK COVER TO "UP" AS ON, AND "DOWN" AS OFF. NOTE: TOGGLE SWITCH 77041345 IS PART OF HARNESS 77441674. 4004i - Manual # 99904386...
  • Page 86 DISCONNECTS FROM OLD REEL AND CONNECTS TO CJ-401 OR CONNECTS TO NEW LIMIT SWITCH CONNECTOR CP-400 CONNECTS TO NEW REEL EXCESS HARNESS AND WIRES ARE ZIP TIED TO LIGHT BRACKET CJ-200 AND CJ-201 CONNECT TO LIGHT ASSEMBLIES 4004i - Manual # 99904386...
  • Page 87 HARNESS AND SWITCH ARE PLACED THROUGHBACK OF MAST (WAS PLUGGED INTO OLD REEL) AND SWITCH IS BOLTED TO BACK BOTTOM HOLE IN COVER PLUG 3-WAY FEMALE CONNECTOR INTO NEW REEL WITH 3 PRONG MALE CONNECTOR BOOM TIP LIGHT INSTALL/RETROFIT 4004i - Manual # 99904386...

  • Page 88: 225-Amp Contactor Replacement

    Electrical & Lighting Section - 5 275 & 225-Amp Contactor Replacement (99904578 SWITCH MOUNTED INSIDE MAST 275A CONTACTOR SWITCH MOUNTED INSIDE MAST 225A CONTACTOR 4004i - Manual # 99904386...
  • Page 89 The mounting space for the 77441534 is 3.6” horizontally by 2.1” vertically. 2. The 77441336 was mounted inside the mast, as shown. Use the replacement kit when mounting a replacement 77441534 inside the mast where the 77441336 was located. 4004i - Manual # 99904386...
  • Page 90 This page left intentionally blank 4004i - Manual # 99904386...

  • Page 91: Harness, Radio (77441270)

    Electrical & Lighting Section - 5 Harness, Radio (77441270) REV. L CN773 4004i - Manual # 99904386...
  • Page 92 Electrical & Lighting Section - 5 77441270-1 4004i - Manual # 99904386...

  • Page 93: Harness, Tethered (77441269)

    Electrical & Lighting Section - 5 Harness, Tethered (77441269) REV. H 4004i - Manual # 99904386...
  • Page 94 Electrical & Lighting Section - 5 77441269-1 4004i - Manual # 99904386...
  • Page 95 Electrical & Lighting Section - 5 Handle Assembly, Tethered (70734746) 4004i - Manual # 99904386...
  • Page 96 Handle Assembly, Tethered (51721502) 6,9,12,27 POWER BLACK 4,10 (S) HYD PUMP WINCH LOWER DOWN DOWN TO SWITCH #19 SOLDER WIRE TO TERMINAL 8,20 NOTES: Tethered handle assembly is non-serviceable. If damaged, a new assembly is required. 4004i - Manual # 99904386...
  • Page 97 EXT OUT BLU/BLK WINCH DN RED/BLK WINCH UP ORN/RED EXT IN BRN/RED BLU/RED BLK/RED BRN/BLK ROT CCW POWER LOWER DN BLK/ORN CRANE POWER LOWER UP BRN/BLU YEL/RED HYD PUMP BLK/BLU RED/BLU BLU/ORN ORN/BLU YEL/BLU RED/RON 4004i - Manual # 99904386...
  • Page 98 SCR-SHT METAL #6X1/2 PH (PART OF 25) 1REF 70145495 HEAT SHRINK 0.33 FT NEW 20080407 NOTE: Kit # 51717816, Tethered Cable - 30 Feet, includes items 8, 15 (qty 24), 20, 21, and 30. Order 51717816 to replace the Cable Assembly. 4004i - Manual # 99904386...

  • Page 99: Harness, Led Boom Tip Jumper (77441689)

    Electrical & Lighting Section - 5 Harness, LED Boom Tip Jumper (77441689) 4004i - Manual # 99904386...
  • Page 100 Electrical & Lighting Section - 5 77441689-1 4004i - Manual # 99904386...

  • Page 101: Harness, Light Sw A2B Crd Reel (77441674)

    Electrical & Lighting Section - 5 Harness, Light SW A2B CRD Reel (77441674) REV. B 4004i - Manual # 99904386...
  • Page 102 Electrical & Lighting Section - 5 77441674-1 NOTE: Seal contact 87A of R100. All wire White GXL. Include washer and nut for S100 switch. 4004i - Manual # 99904386...

  • Page 103: Harness, Limit Switch Jumper (77441678)

    Electrical & Lighting Section - 5 Harness, Limit Switch Jumper (77441678) 4004i - Manual # 99904386...

  • Page 104: Protective Sleeve Installation (70034573)

    Failure to inspect and verify document prior to starting work your company does not have a the fuse holder posts could result on the chassis. Lock-Out/Tag-Out procedure, in a fire. follow OSHA 1910.147, Lock- Out/Tag-Out. 4004i - Manual # 99904386...
  • Page 105 This page left intentionally blank 4004i - Manual # 99904386...

  • Page 106: General Information

    General Information Section - 6 Section - 6 General Information 4004i - Manual # 99904386...

  • Page 107: Decal Installation (99904410)

    General Information Section - 6 Decal Installation (99904410) 4004i - Manual # 99904386...
  • Page 108 70399142 DECAL-DIAMOND IMT 4X8 70396780 DECAL-IDENT 4004I 70397414 DECAL-CP 4004I IMT 71397349 DECAL-ANGLE INDICATOR RH, SM 71397350 DECAL-ANGLE INDICATOR LH, SM 70397334 DECAL-WARNING, ELEC CR OL 70397351 DECAL-REMOTE PENDANT STORE 70397411 DECAL-GREASE WEEKLY (LH) SMALL 4004i - Manual # 99904386...
  • Page 109 QTY ON ITEM NO. PART NO. DESCRIPTION CR ANE 70397412 DECAL-GREASE WEEKLY (RH) SMALL 70397404 DECAL-DANGER, UNPLUG CRANE 70397405 DECAL-CRANE POWER DISCONNECT 70397389 DECAL-DANGER ELEC HZD MED TELE 70397390 DECAL-DANGER CR LOADLINE (MED TRK) REV. C 4004i - Manual # 99904386...

  • Page 110: Turntable Bearing Thread Tightening

    • .75 X 265 ft-lb = 199 ft-lb. • .75 X 36 kg-m = 27 kg-m. 5. Using the proper sequence, torgue all cap screws to the listed torque value as determined from the Torque Data Chart. 4004i - Manual # 99904386...

  • Page 111: Torque Charts

    Failure to replace gear-bearing bolts may result in bolt failure due to metal fatigue causing death or serious injury. 4004i - Manual # 99904386...

  • Page 112: Torque Charts (Metric)

    Failure to replace gear-bearing bolts may result in bolt failure due to metal fatigue causing death or serious injury. 4004i - Manual # 99904386...
  • Page 113 Fax: 641.923.2424 www.imt.com IMT reserves the right to make changes in engineering, design, specifications, add improvements or discontinue manufacturing at any time without notice or obligation. IMT and IMT LOGO are registered trademarks of Iowa Mold Tooling Co., Inc., Garner, IA, USA.

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