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IMT 3203i 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 # 99904380
3203i
Parts &
Specifications
Revised 08-18-2020
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 # 99904380 3203i Parts & Specifications Revised 08-18-2020 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 3203i - Manual # 99904380...

  • Page 3: Table Of Contents

    Load Capacity Chart ............................6 Geometric Configuration ..........................7 Pump & Motor Performance ..........................8 Assemblies & Grease Zerk Locations ......................10 3203i Recommended Spare Parts List ......................11 Crane Installation (99904394) ........................13 Electric Crane Battery Circuit (99904884) ....................20 Telescopic Crane Orientation ........................21 Electric Crane Control ..........................22 Parts Parts Information ............................24...
  • Page 4 General Information Decal Installation (99904375) ........................110 Turntable Bearing Thread Tightening Sequence ..................113 Thread Torque Chart ..........................114 3203i - Manual # 99904380...
  • Page 5 3203i - Manual # 99904380...
  • Page 6 3203i - Manual # 99904380...

  • Page 7: Introduction

    Introduction Section - 1 Section - 1 Introduction 3203i - Manual # 99904380...

  • Page 8: 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 9: Specifications

    Specifications Section - 2 Section - 2 Specifications 3203i - Manual # 99904380...

  • Page 10: 3203I Technical Data

    65’ (19.81 m) Cable Nominal Strength 5600 lb (2540 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 3203i - Manual # 99904380...
  • Page 11 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. 3203i - Manual # 99904380...

  • Page 12: Load Capacity Chart

    DISTANCE IN FEET/METERS / LOAD IN POUNDS/KG. Weight of load handling devices are part of the load lifted and must be deducted from the capacity. IOWA MOLD TOOLING CO., INC. BOX 189, GARNER, IA 50438-0189 TEL: 641-923-3711 FAX: 641-923-2424 70397348 3203i - Manual # 99904380...

  • Page 13: Geometric Configuration

    Specifications Section - 2 Geometric Configuration 4'-0" (1.22 m) 3'-0" (0.91 m) 1'-11" (0.39 m) 16'-2" (4.92 m) 12'-3" (3.75 m) 8'-5" (2.60 m) 1'-3" (38 cm) 7'-0" (2.13 m) 11'-0" (3.35 m) 15'-0" (4.57 m) 3203i - Manual # 99904380...

  • Page 14: Pump & Motor Performance

    S2 and S3 curves, or at full power for 4.5 minutes, which MUST be followed by a complete cool-down to ambient. CAUTION Avoid motor damage! Operate within performance curves shown. 3203i - Manual # 99904380...
  • Page 15 Specifications Section - 3 Section - 3 Crane Reference 3203i - Manual # 99904380...

  • Page 16: Assemblies & Grease Zerk Locations

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

  • Page 17: 3203I Recommended Spare Parts List

    HEAD-2.75 BORE X 1.75 ROD 73054999 VALVE-COUNTERBALANCE 77041786 SWITCH-PRESS 2750 PSI 51722111 EXTENSION CYLINDER 94397290 SEAL KIT-IMT 1.50 BORE 1.00 ROD .75 60135105 HEAD-1.50 BORE X 1.00 ROD 60135106 PISTON-1.50 BORE X .75 STGR 73054999 VALVE-COUNTERBALANCE SUN01 CBBC-LHN 99904315 BASE & MAST ASSEMBLY...
  • Page 18 77041801 CONTACTOR (12 OR 24V) 77566638 BRAKE ASSEMBLY 77744175 BRUSH KIT 71570922 WINCH (24V) 77041928 CONTACTOR (12 OR 24V) 77566638 BRAKE ASSEMBLY 77744175 BRUSH KIT 99904394 ELECTRICAL INSTALLATION 77441116 FUSEHOLDER, HIGH AMP 77441219 FUSE-225 AMP 3203i - Manual # 99904380...

  • Page 19: 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 20 THICKNESS PRIOR TO MOUNTING. IF DIFFERENT LENGTH BOLTS ARE REQUIRED, THEY MUST BE 1.00-8, GRADE 8, ZINC COATED, OF PROPER LENGTH. FAILURE TO USE PROPER LENGTH BOLTS MAY CAUSE THE BOLTS TO BOTTOM OUT BEFORE TORQUING. 3203i - Manual # 99904380...
  • Page 21 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 connections between the crane, vehicle battery, auxiliary battery, and chassis ground.
  • Page 22 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. 3203i - Manual # 99904380...
  • Page 23 (CUT TO LENGTH) (CRANE ON-OFF SWITCH TO FUSE) ITEMS WITHIN BOX ARE ONLY NEEDED WHEN AUXILIARY BATTERY IS 13-CABLE #8 INSTALLED IN CRANE BOX. 27-CABLE #7 * MATCHED BATTERIES ARE REQUIRED* (CUT TO LEN TO CHASSIS GROUND 3203i - Manual # 99904380...
  • Page 24 DESCRIPTION KIT NO. QTY. KIT-ELECTRICAL CRANE BODY INSTALLATION 51721572 (FOR DUAL UNDERHOOD BATTERY) 91721647 KIT-HRDW 3203I/4004I ELEC CRANE BODY INSTL 91721751 KIT-HRDW 5005I ELEC CRANE BODY INSTL 51725112 KIT-ELECTRIC CRANE BODY INSTALLATION KIT-ELECTRIC CRANE BODY INSTALLATION 51725572 (FOR SINGLE UNDERHOOD BATTERY) 99904317 DWG-CRANE &...
  • Page 25 This page left intentionally blank 3203i - Manual # 99904380...

  • Page 26: 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. 3203i - Manual # 99904380...

  • Page 27: 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 28: 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 &...

  • Page 29: Parts

    Parts Section 4 Section 4 Parts 3203i - Manual # 99904380...

  • Page 30: 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 31 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. 3203i - Manual # 99904380...

  • Page 32: Electric Crane Power Safety

    70392865 1. Make sure the power switch located inside the crane cabinet is turned to the OFF position. 2. Make sure the crane power disconnect cable is disconnected from the vehicle battery. 3203i - Manual # 99904380...
  • Page 33 This page left intentionally blank 3203i - Manual # 99904380...

  • Page 34: Base & Mast Assembly (99904315)

    TORQUE TO 105 FT-LB P/N 52721306 TORQUE TO 105 FT-LB CONTACTOR APPLY RUST PREVENTATIVE APPLY RUST PREVENTATIVE POWER UNIT & GEAR GUARD INSTALLATION BASE & ROTATOR ASSEMBLY 45 37 HYDRAULIC MOTOR & VALVE BANK ASSEMBLY 3203i - Manual # 99904380...
  • Page 35 72601932 CAP SCR .50-13X 4.00 SH ZC 72601939 CAP SCR .50-13X 4.50 SH ZC 72601949 CAP SCR .50-13X 1.25 SH ZC 72602009 SCR-MACH # 8-32X 1.25 BTNHD SS 72602081 CAP SCR .50-13X 3.00 SH ZINC 3203i - Manual # 99904380...
  • Page 36 KIT- 3203I ELECTRICAL INSTALLATION REV. U CN885 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. 3203i - Manual # 99904380...
  • Page 37 CYL- 2.75B X 1.75R X 16.06S 46.50 CC C 60140618 PIN-TYPE NN 1.00 X 8.25 70034382 CAP-GREASE PRO20 GC-RED 71415014 KEEPER-PIN .38 72060046 CAP SCR .38-16X 1.00 HH GR5 Z 72063051 WASHER .38 LOCK REV U CN885 3203i - Manual # 99904380...

  • Page 38: 99904315 With Mte Power Unit

    Parts Section 4 99904315 With Mte Power Unit NOTE: SEPARATE VIEW AND BILL OF MATERIALS SHOWING MTE POWER UNIT NOTE: SEPARATE VIEW SHOWING MTE POWER UNIT HYDRAULIC MOTOR & VALVE BANK ASSEMBLY 3203i - Manual # 99904380...
  • Page 39 72601932 CAP SCR .50-13X 4.00 SH ZC 72601939 CAP SCR .50-13X 4.50 SH ZC 72601949 CAP SCR .50-13X 1.25 SH ZC 72602009 SCR-MACH # 8-32X 1.25 BTNHD SS 72602081 CAP SCR .50-13X 3.00 SH ZINC 3203i - Manual # 99904380...
  • Page 40 POWER UNIT- 0.61 GPM 201 MTE REV. U CN885 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. 3203i - Manual # 99904380...

  • Page 41: Mte Replacement Power Unit Instuctions (52725032-Service)

    For replacing current power unit with alternate MTE model, Use updated spacer (60132385), and drill Ø.44 mounting hole above existing one shown in view above. Replace hydraulic fitting (72532699) with (72534567).See drawing (99904361) for detailed view. 3203i - Manual # 99904380...

  • Page 42: Valve Bank (73734304)

    CONNECT "T" TO TANK CAP ALL OTHER PORTS TEST: APPLY FLOW TO "P" AND VERIFY FLOW BACK TO TANK AT LOW PRESSURE ELECTRICALLY SHIFT EACH COIL AND VERIFY THAT THE SYSTEM GOES TO THE BENCH RELIEF SETTING 3203i - Manual # 99904380...
  • Page 43 SOLENOID VALVE 24V (INCLUDES COIL) 73540527 COIL, 24V PLUG, EXPANDER, 7MM REV. A NOTE: For parts not listed, please contact IMT Technical Support:: Iowa Mold Tooling Co., Inc. Box 189, Garner, IA 50438-0189 Telephone: 641-923-3711 Technical Support Fax: 641-923-2424 3203i - Manual # 99904380...

  • Page 44: Cylinder, Lower (51721267)

    Parts Section 4 Cylinder, Lower (51721267) 3203i - Manual # 99904380...
  • Page 45 1.75 X 28.81LG OPER. PSI: 2500 PSI PISTON TORQUE: 710-740 PSI STINGER: 1.50 X 3.92LG HEAD TORQUE: 275 FT-LB CYL. STROKE: 16.06” CARTRIDGE TORQUE: 30-35 FT-LB LOCKNUT TORQUE: 12 FT-LB CAP SCR TORQUE: 16 FT-LB 3203i - Manual # 99904380...

  • Page 46: Boom Assembly (99904316)

    Parts Section 4 Boom Assembly (99904316) SEE NOTE#1 SECTION A-A SECTION B-B SCALE 3 / 8 BOOM ASSEMBLY 1 HYDRAULIC EXTENSION 1 MANUAL EXTENSION NOTE: Install wear pads after installing cylinders 3203i - Manual # 99904380...
  • Page 47 DESCRIPTION KIT NO. QTY. 51721320 KIT-HRDW 3203 HYD BOOM ASY 51725007 CYL-1.50/1.0 48.00S 7.38CC C 52721261 WLDMT- EXTENSION 1ST STAGE 3203I 52724108 WLDMT-LOWER BOOM 3203I 52725021 WLDMT- 2ND STAGE EXTENSION 3203I 60030369 WEAR PAD-RND 0.19X 2.00X 0.60X .50 60030373 WEAR PAD- EXT CYLINDER 60030374 WEAR PAD-RND 0.25X 1.00X .50X .31...
  • Page 48 Parts Section 4 99904316-1 BOOM ASSEMBLY 2 MANUAL EXTENSIONS 3203i - Manual # 99904380...
  • Page 49 ITEM PART DESCRIPTION KIT NO. QTY. 51721320 KIT-HRDW 3203 HYD BOOM ASY 52721261 WLDMT- EXTENSION 1ST STAGE 3203I 52724108 WLDMT-LOWER BOOM 3203I 52725021 WLDMT- 2ND STAGE EXTENSION 3203I 60030369 WEAR PAD-RND 0.19X 2.00X 0.60X .50 60030374 WEAR PAD-RND 0.25X 1.00X .50X .31 60030375 WEAR PAD-RND 0.30X 3.00X 1.00X .25...
  • Page 50 Parts Section 4 99904316-2 BOOM ASSEMBLY 1 HYDRAULIC EXTENSION 3203i - Manual # 99904380...
  • Page 51 KIT-HRDW 3203 HYD BOOM ASY 51725007 CYL-1.50/1.0 48.00S 7.38CC C 52724108 WLDMT-LOWER BOOM 3203I 52725022 WLDMT- 2ND STAGE MANUAL EXT 3203I 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 60133938 WEAR PAD-RND 0.25X 1.00X .50X .50 STL...
  • Page 52 Parts Section 4 99904316-3 BOOM ASSEMBLY 1 MANUAL EXTENSION 3203i - Manual # 99904380...
  • Page 53 71734311 PIN-QUICK RLSE .62D/4.5 CRIT 72062104 NUT .25-20 HEX NYLOCK 72063001 WASHER .25 FLAT 72063051 WASHER .38 LOCK 72661543 PIN-QUICK 316-10QP 72661711 CLEVIS PIN .50 X 3.00 72661766 LOCKING PIN RUE RING .50 REV. S. 3203i - Manual # 99904380...
  • Page 54 Parts Section 4 99904316-4 BOOM ASSEMBLY 1 HYDRAULIC EXTENSION 1 MANUAL EXTENSION 3203i - Manual # 99904380...
  • Page 55 71734314 PIN-QUICK RLSE .62D/5.75 CRIT 72062104 NUT .25-20 HEX NYLOCK 72063001 WASHER .25 FLAT 72063051 WASHER .38 LOCK 72661543 PIN-QUICK 316-10QP 72661711 CLEVIS PIN .50 X 3.00 72661766 LOCKING PIN RUE RING .50 REV. S 3203i - Manual # 99904380...

  • Page 56: Crane & Winch Assembly (99904317)

    Parts Section 4 Crane & Winch Assembly (99904317) 18 22 18 22 CONNECT THE WIRE TERMINALS (77040051) TO COMMON AND NORMALLY OPEN ON ATB SWITCH. DETAIL B DETAIL A 3203i - Manual # 99904380...
  • Page 57 72060007 CAP SCR .25-20X 1.75 HH GR5 Z 72601805 CAP SCR M12-1.75X 25 HHZ 70034503 COVER-ELEC CONTACTOR 72602011 SCR-MACH # 8-32X .62 BTNHD ZC 72060000 CAP SCR .25-20X .50 HH GR5 Z REV. X CN885 3203i - Manual # 99904380...
  • Page 58 Parts Section 4 99904317-1 3203i - Manual # 99904380...
  • Page 59 WASHER .25 LOCK 72063051 WASHER .38 LOCK 72601941 SCR-MACH .25-20X .38 BTNHD ZC 71415014 KEEPER-PIN .38 60140618 PIN-TYPE NN 1.00 X 8.25 60140617 PIN-TYPE NN 1.00 X 6.50 60140653 COVER- VALVE BANK 3203I REV. X CN885 3203i - Manual # 99904380...
  • Page 60 Parts Section 4 99904317-2 DOUBLE LINE SINGLE LINE 3203i - Manual # 99904380...
  • Page 61 Section 4 99904317-2 PARTS LIST PART ITEM NO. DESCRIPTION KIT NO. QTY. 51724950 SNATCH BLOCK- 3203I-4004I 70580059 WIRE ROPE ASM-.22 X 7 X 19 X 65FT PGA 70735101 HOOK-SWVL POS LOCK BBRG 2TON REV. X CN885 3203i - Manual # 99904380...
  • Page 62 60140617 PIN-TYPE NN 1.00 X 6.50 72060209 CAP SCR .75-10X 2.75 HH GR8 Z 72062114 NUT .75-10 HEX NYLOCK 72063008 WASHER .75 FLAT 60030483 SHEAVE- 8.0 NYLATRON GSM 72601942 SCR-MACH # 6-32X 1.50 RND PHLPS 3203i - Manual # 99904380...
  • Page 63 CAP SCR M12-1.75X 25 HHZ 70034503 COVER-ELEC CONTACTOR 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 3203i - Manual # 99904380...

  • Page 64: Cord Reel - 6.7M, Electric 2 - Wire (70735052)

    Parts Section 4 Cord Reel – 6.7m, Electric 2 – Wire (70735052) 5.25 6.00 126.00" 7.75 50.0" (1.27 m) 276" (7 m) EXTENSION 3203i - Manual # 99904380...

  • Page 65: Cord Reel Assembly, 4.17' W/Packard Connector (51727064)

    COLOR BROWN BLUE WIRE LENGTH: 50" ITEM NO. PART NO. DESCRIPTION QTY. 99904315 DWG-BASE AND MAST ASM 3203 99904316 DWG-BOOM ASM 3203I 51721321 KIT-HRDW 3203 CRANE & WINCH 51724950 SNATCH BLOCK- 3203I-4004I REV. INITIAL RELEASE 3203i - Manual # 99904380...

  • Page 66: Snatch Block (51724950)

    Parts Section 4 Snatch Block (51724950) 1.780 3203i - Manual # 99904380...
  • Page 67 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 3203i - Manual # 99904380...

  • Page 68: Cylinder, Extension (51725007)

    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 CARTRIDGE TORQUE: CYL. STROKE: 48.00" 30-35 FT-LB LOCKNUT TORQUE: 100-130 FT-LB CAP SCR TORQUE: SECTION A-A 3203i - Manual # 99904380...
  • Page 69 51725007 PARTS LIST ITEM NO. PART NO. DESCRIPTION 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 70: 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 3203i - Manual # 99904380...
  • Page 71 51722111 PARTS LIST ITEM PART 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 72: Cylinder, Extension (51721291)

    Parts Section 4 Cylinder, Extension (51721291) 3203i - Manual # 99904380...
  • Page 73 51721291 PARTS LIST ITEM NO. PART NO. DESCRIPTION KIT NO. 94397290 IMT SEAL KIT-1.50 BORE 1.00 ROD .75 STGR 52721292 ROD ASM-1.00 DIA X 61.38 LG .75 S 52721293 CASE ASM-1.50 BORE X 58.25 LG 60131651 HEAD-1.50 BORE X 1.00 ROD 60132170 STINGER LOCK .75-16 X 1.75 LG...

  • Page 74: Winch (71570922)

    (QTY 10) RING GEAR THRUST WASHER 32000480 THRUST WASHER DRUM PLUG NOTE: For 24V system, use 71571008 WINCH REPLACEMENT PART NUMBERS: Brake - IMT P/N: 77056662 Motor - IMT P/N: 73511210 Contactor - IMT P/N: 77041862 3203i - Manual # 99904380...

  • Page 75: Power Unit (73511432)

    Parts Section 4 Power Unit (73511432) 3000 HYDRAULIC SCHEMATIC 3203i - Manual # 99904380...

  • Page 76: Power Unit 73511283 (12V) & 73511305 (24V)

    Parts Section 4 Power Unit 73511283 (12V) & 73511305 (24V) 3203i - Manual # 99904380...
  • Page 77 STRAINER SUCTION TUBE MOUNT FOR ELECTRIC 74399495 RESERVOIR ELECTRIC CRANE PLASTIC 5.3L 70734788 CAP-BREATHER BUCHER PWR UNIT 74399495 77043065 MOTOR-POWER UNIT 12V ELECTRIC CRANE 77043066 MOTOR-POWER UNIT 24V ELECTRIC CRANE 73540517 VALVE-CART RELIEF 1500-3000 PSI FOR ELEC REV. AC 3203i - Manual # 99904380...

  • Page 78: Hydraulic Installation (99904361)

    TANK (RETURN) (PORT B) EXTENSION CYLINDER LOWER CYLINDER RETRACT PORT RETRACT PORT PRESSURE EXTENSION CYLINDER LOWER CYLINDER EXTEND PORT EXTEND PORT ROTATION CLOCKWISE (CW) EXTENSION OUT ROTATION COUNTER CLOCKWISE (CCW) EXTENSION IN BOOM DOWN BOOM UP 3203i - Manual # 99904380...
  • Page 79 (PORT A1) LOWER CYLINDER FRONT OF MAST WITH EXTENSION CYLINDER TO LOWER CYLINDER (PORT R) TO LOWER CYLINDER (PORT E) TO VALVE BANK (PORT B2) 1H1M ON/OFF RADIO CONTROL TETHERED CONTROL TO VALVE BANK (PORT A2) 3203i - Manual # 99904380...
  • Page 80 VALVE BANK (PORT B1) VALVE BANK VALVE BANK (PORT A1) LOWER CYLINDER TO LOWER CYLINDER (PORT R) TO LOWER CYLINDER (PORT E) TO VALVE BANK (PORT B2) 1H1M PROPORTIONAL CONTROL TO VALVE BANK (PORT A2) 3203i - Manual # 99904380...
  • Page 81 TO VALVE BANK (PORT B2) TO LOWER CYLINDER (PORT E) NOTE: 1. CRANES WITHOUT EXTENSION CYLINDER USE PLUGS (72532522) TOO BLOCK HYDRAULIC PORTS B1 & A1 ON THE VALVE BLOCK. TO VALVE BANK (PORT A2) 3203i - Manual # 99904380...
  • Page 82 Section 4 99904361 COMPLETE PARTS LIST ITEM NO. PART NO. DESCRIPTION KIT NO. QTY. 99904317 DWG-CRANE & WINCH ASM 3203I 70145928 FLOW LIMITER-28051-806-1.0 6 72532522 PLUG-STR HEX HD STL .44 73540325 VALVE-PROP FLOW CNTRL 12V ELEC CRANE 51725663 KIT-HYD 3203 51397335 HOSE-FZ .25 X 13.50 (4-4) 100R17...

  • Page 83: Tethered Control Installation (99904593)

    CONTROL KIT- TETHERED ELECTRIC CRANE 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 3203i - Manual # 99904380...

  • Page 84: Radio Control Installation, Standard (99904594)

    SLEEVE-TYPE C .63X .81X .31 70734329 RECEIVER - RADIO REMOTE TELE VORC 70734330 TRANSMITTER-RADIO REMOTE ELECTRIC CRANE 72060008 CAP SCR .25-20X 2.00 HH GR5 Z 72062104 NUT .25-20 HEX NYLOCK 72063001 WASHER .25 FLAT REV. INITIAL RELEASE 3203i - Manual # 99904380...

  • Page 85: 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 3203i - Manual # 99904380...
  • Page 86 This page left intentionally blank 3203i - Manual # 99904380...

  • Page 87: Lighting & Electrical

    Lighting & Electrical Section 4 Section 4 Lighting & Electrical 3203i - Manual # 99904380...

  • Page 88: Electrical Installation (99904389)

    (TOP) CRANE BASE ELECTRIC ROTATOR BRACKET (BOTTOM) TO CRANE BOX GROUND NOTE: TO 300 AMP KEYED SWITCH 1. WRAP WINCH CABLES WITH "BLACK SPIRAL WRAP" IN CRANE BOX 2. TORQUE TO 8-15 FT-LBS (2 PLACES) 3203i - Manual # 99904380...
  • Page 89 CABLE ASM-10GA-#10RNGX 1/4RNGX 6.00LG 77441302 TERM INSUL RED #8-2 GA WIRE 77441303 TERM INSUL BLK #8-2 GA WIRE 72060021 CAP SCR .31-18X .50 HH GR5 Z 72063050 WASHER .31 LOCK 51726427 CABLE ASM-2GA-5/16RNGX3/8RNGX 25.00LG B REV. N 3203i - Manual # 99904380...

  • Page 90: Cable Assembly (51726427)

    Lighting & Electrical Section 4 Cable Assembly (51726427) BLACK HEAT BLACK HEAT SHRINK SHRINK #2GA WIRE 5/16 TERMINAL 3/8 TERMINAL RING #2GA WIRE RING #2GA WIRE 3203i - Manual # 99904380...

  • Page 91: Light Kit (99906234)

    Section 4 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 92 Section 4 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 3203i - Manual # 99904380...
  • Page 93 Lighting & Electrical Section 4 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 3203i - Manual # 99904380...
  • Page 94 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. 3203i - Manual # 99904380...
  • Page 95 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 3203i - Manual # 99904380...
  • Page 96 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 3203i - Manual # 99904380...
  • Page 97 This page left intentionally blank 3203i - Manual # 99904380...

  • Page 98: 225-Amp Contactor Replacement

    Lighting & Electrical Section 4 275 & 225-Amp Contactor Replacement (99904578 SWITCH MOUNTED INSIDE MAST 275A CONTACTOR SWITCH MOUNTED INSIDE MAST 225A CONTACTOR 3203i - Manual # 99904380...
  • Page 99 NOTES: 1. Contactor 77441277 replaced by 77441336 in January 2009. Contactor 77441336 effective on cranes with serial numbers starting with the following serial numbers: 3203i091006 (Model 3203i), 4004i091002 (Model 4004i), 6006i091001 (Model 6006i). 2. The 77441336 contactor is smaller than the 77441277. The mounting space for the 77441277 is 3.6” horizontally by 4.9”...

  • Page 100: Harness, Radio (77441270)

    Lighting & Electrical Section 4 Harness, Radio (77441270) REV. L CN773 3203i - Manual # 99904380...
  • Page 101 Lighting & Electrical Section 4 77441270-1 3203i - Manual # 99904380...

  • Page 102: Harness, Tethered (77441269)

    Lighting & Electrical Section 4 Harness, Tethered (77441269) RELAY REV. H 3203i - Manual # 99904380...
  • Page 103 Lighting & Electrical Section 4 77441269-1 3203i - Manual # 99904380...
  • Page 104 Lighting & Electrical Section 4 Handle Assembly, Tethered (70734746) 3203i - Manual # 99904380...
  • Page 105 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. 3203i - Manual # 99904380...
  • Page 106 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 3203i - Manual # 99904380...
  • Page 107 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. 3203i - Manual # 99904380...

  • Page 108: Harness, Led Boom Tip Jumper (77441689)

    Lighting & Electrical Section 4 Harness, LED Boom Tip Jumper (77441689) 3203i - Manual # 99904380...
  • Page 109 Lighting & Electrical Section 4 77441689-1 3203i - Manual # 99904380...

  • Page 110: Harness, Light Sw A2B Crd Reel (77441674)

    Lighting & Electrical Section 4 Harness, Light SW A2B CRD Reel (77441674) REV. B 3203i - Manual # 99904380...
  • Page 111 Lighting & Electrical Section 4 77441674-1 NOTE: Seal contact 87A of R100. All wire White GXL. Include washer and nut for S100 switch. 3203i - Manual # 99904380...

  • Page 112: Harness, Limit Switch Jumper (77441678)

    Lighting & Electrical Section 4 Harness, Limit Switch Jumper (77441678) 3203i - Manual # 99904380...

  • Page 113: 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. 3203i - Manual # 99904380...
  • Page 114 This page left intentionally blank 3203i - Manual # 99904380...
  • Page 115 General Information Section 5 Section 5 General Information 3203i - Manual # 99904380...
  • Page 116 General Information Section 5 Decal Installation (99904375) 6,7,10 3203i - Manual # 99904380...
  • Page 117 ITEM NO. PART NO. DESCRIPTION KIT NO. CR ANE 95719347 DECAL KIT - TELE COMMON 95719348 DECAL KIT - BODY COMMON 95721446 DECAL KIT - 3203I SPECIFIC 70391612 DECAL-GREASE WEEKLY (LEFT) 70391613 DECAL-GREASE WEEKLY (RIGHT) 70392399 DECAL-LUBRICATE WORM 70392524 DECAL-ROTATE CRANE WHILE GREAS...
  • Page 118 Section 5 QTY IN ITEM NO. PART NO. DESCRIPTION KIT NO. CR ANE 70397404 DECAL-DANGER, UNPLUG CRANE 70397405 DECAL-CRANE POWER DISCONNECT 70397389 DECAL-DANGER ELEC HZD MED TELE DECAL-DANGER CR LOADLINE (MED 70397390 TRK) REV. C 3203i - Manual # 99904380...
  • Page 119 • .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. 3203i - Manual # 99904380...
  • Page 120 Failure to replace gear-bearing bolts may result in bolt failure due to metal fatigue causing death or serious injury. 3203i - Manual # 99904380...
  • Page 121 Failure to replace gear-bearing bolts may result in bolt failure due to metal fatigue causing death or serious injury. 3203i - Manual # 99904380...
  • Page 122 Revisions DATE LOCATION DESCRIPTION 5-29-2020 99906234 CN989...
  • Page 123 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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