2820 20K Crane

Manual Part Number 99904817
2820 20K Parts &

Specifications
Manual for 2820 Crane on DSC20 Body

Revision Date 20140627
IOWA MOLD TOOLING CO., INC.

PO Box 189
Garner, IA 50438
Tel: 641-923-3711 FAX: 641-923-2424
Website: http://www.imt.com
Copyright 2014 Iowa Mold Tooling Co., Inc.

All rights reserved
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any
form or by any means, electronic, mechanical, photocopying, recording or otherwise without the
prior written permission of Iowa Mold Tooling Co., Inc.
Iowa Mold Tooling Co., Inc. is an Oshkosh Corporation Company.
Contents
Revisions .................................................................................................................................................... iii
Introduction
Specifications
2820 General Specifications ......................................................................................................................... 7

2820 Performance Characteristics ................................................................................................................ 8
2820 System Specifications .......................................................................................................................... 8
2820 Geometric Configuration ................................................................................................................... 10
2820 20K Capacity Chart ........................................................................................................................... 11
Crane Reference
13
Major Assemblies, Part Number Locations ................................................................................................ 13

Grease Zerk Locations ................................................................................................................................ 14
Recommended Spare Parts List .................................................................................................................. 15
Crane Installation ........................................................................................................................................ 16
Telescopic Crane Orientation ..................................................................................................................... 18
Crane Control.............................................................................................................................................. 18
Parts
19
Parts Information ........................................................................................................................................ 20
Base and Mast Assemblies ......................................................................................................................... 22
Crane Assembly (41718361) ........................................................................................................... 22
Mast Assembly (41718359)............................................................................................................. 24
Gear Rotator (71056543) (Primary) ................................................................................................ 26
Valve, Counterbalance (73540035) ................................................................................................. 28
Boom Assemblies & Cylinders ................................................................................................................... 29
Boom Assembly (41718360) ........................................................................................................... 29
Lower Boom Cylinder (51717905) ................................................................................................. 32
Extension Cylinder (51717895)....................................................................................................... 34
Winch, Worm, 2820 & 5020 (70570501) ........................................................................................ 36
Hydraulics ................................................................................................................................................... 38
Hydraulic Kit - Tethered (91718323) .............................................................................................. 38
Hydraulic Kit - Radio (91718330)................................................................................................... 41
Valvebank, Tethered Remote (70733399) ....................................................................................... 44
Valvebank, Radio Remote (73733931) ........................................................................................... 46
Controls ...................................................................................................................................................... 47
Control Kit - Tethered Remote (91714443) .................................................................................... 47
Cable Assembly, Tethered Remote (70733394) .............................................................................. 48
Handle Assembly, Tethered Remote (51713182)............................................................................ 49
Tethered Proportional Remote Potentiometer Adjustment................................................... 52
2820 Control Kit (90718831) (Ref. 99903629) ............................................................................... 53
Cable Assembly, Radio Remote (77441101) .................................................................................. 54
Electrical Schematic, Radio Remote (77441101) ............................................................................ 55
ii
Contents
Miscellaneous ............................................................................................................................................. 57
Decal Placement, 2820 20K Crane (Ref 99903727) ........................................................................ 57
Installation Kit (93715267) ............................................................................................................. 59
Chassis Wiring Harness (99903340) ............................................................................................... 60
General Reference
61
Inspection Checklist .................................................................................................................................... 61

Deficiency / Recommendation / Corrective Action Report ........................................................................ 66
Wire Rope Inspection & Replacement........................................................................................................ 68
Hook Inspection .......................................................................................................................................... 69
Holding Valve Inspection ........................................................................................................................... 70
Anti-Two-Block Device Inspection ............................................................................................................ 70
Thread Torque Chart (English) ................................................................................................................... 71
Thread Torque Chart (Metric) .................................................................................................................... 72
Turntable Bearing Thread Tightening Sequence ........................................................................................ 73
Turntable Bearing Inspection...................................................................................................................... 74
Turntable Bearing Tilt Test......................................................................................................................... 74
Contents
Revisions
DATE
LOCATION
DESCRIPTION
20100816
20111011
20120404
41718359
91718323
51717905,
51717895
99903629
91714443
41718359
41718361
ECN 11291 - #40 hydraulic motor should be 73511041.

ECN 11568 - Tethered hydraulic kit update.
ECN 11581, 11615 - Cylinder drawing updates. Prop. remote
potentiometer settings.
ECN 12237 Updated drawing, items 6 & 7 rotated
ECN 12237 Added base and mast note
20140627
iii
CHAPTER 1
Introduction
This volume deals with information applicable to your particular crane. For operating,
maintenance and repair instructions, refer to Telescopic Crane Volume 1: OPERATION,
MAINTENANCE AND REPAIR. (IMT part number 99903514.)
We recommend that this volume be kept in a safe place in the office.
This manual is provided to assist you with ordering parts for your IMT crane. It also contains
additional instructions regarding your particular installation.
It is the users responsibility to maintain and operate this unit in a manner that will result in the
safest working conditions possible.
Warranty of 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 will be
valid with this unit. In addition, it is also the users responsibility to be aware of existing Federal,
State and Local codes and regulations governing the safe use and maintenance of this unit. This
crane was designed and built to meet the standards of ANSI/ASME B30.5, Mobile & Locomotive
Cranes. Contact the American Society of Mechanical Engineers (www.asme.org) for more
information.
Throughout the manual, NOTEs, CAUTIONs and WARNINGs are used to draw the attention of
personnel. They are defined as follows:
NOTE
A NOTE is used to either convey
additional information or to provide
further emphasis for a previous point.
CAUTION
A CAUTION is used when there is the
very strong possibility of damage to the
equipment or premature equipment
failure.
WARNING
A WARNING is used when there is the
potential for personal injury or death.
For a safe work environment, treat this equipment with respect and service it regularly.
CHAPTER 2
Specifications
In This Chapter
2820 General Specifications ..................................................... 7
2820 Performance Characteristics ........................................... 8
2820 System Specifications ..................................................... 8
2820 Geometric Configuration .................................................. 10
2820 20K Capacity Chart ......................................................... 11
2820 General Specifications

CRANE RATING *
28,000 ft-lb (3.9 ton-meters)
REACH (from centerline of rotation)

HYDRAULIC EXTENSIONS (2)
20'-6" (6.2 m)
60" (152 cm)
48" (122 cm)
none
22'-2" (6.8 m)
1400 lb (635 kg)
31" (79.0 cm)
20" x 21" (50.8 cm x 53.3 cm)
MANUAL EXTENSION
LIFTING HEIGHT (from base of crane)
CRANE WEIGHT
STORAGE HEIGHT (crane only)
MOUNTING SPACE REQUIRED (crane
base)
OPTIMUM PUMP CAPACITY (PTO Driven)
SYSTEM OPERATING PRESSURE
LOWER BOOM CYLINDER
EXTENSION CYLINDER
HORIZONTAL CENTER OF GRAVITY (from
centerline of rotation)
VERTICAL CENTER OF GRAVITY (from
bottom of crane base)
TIE-DOWN BOLT PATTERN (on center)
ROTATIONAL TORQUE
DESIGN FACTORS - pins and hydraulics
6 U.S. GPM (22.7 l/min)

2475 psi (170 bar)
3.5" bore; 21-5/8" stroke (8.9 cm bore; 54.9 cm stroke)
2.5" bore; 108" stroke (6.35 cm bore; 274.3 cm stroke)
37" (94.0 cm)
18" (45.7 cm)
14-3/4" x 14-3/4" (37.5 cm x 37.5 cm)
9000 ft-lb (1.2 ton-m)
4/1
* Crane rating (ft-lb) is the rated load (lb) multiplied by the respective distance (ft) from centerline
of rotation with all extensions retracted and lower boom in horizontal position.
2820 20K Parts & Specifications Manual #99904817
2820 Performance Characteristics

SPECIFICATION
ROTATION
400 (7.0 rad)
LOWER BOOM ELEVATION -0 to +72 (0 to +1.3 rad)
PTO
EXTENSION CYLINDER (2) 60" / 48" (152.4 cm / 121.9

cm)
WINCH
single part line
58 seconds
12 seconds up
15 seconds down
18 seconds out
17 seconds in
27 ft/min (8.2 m/min)
WINCH
13.5 ft/min (4.1 m/min)
two part line
2820 System Specifications

POWER SOURCE
PTO DRIVEN - Integral mounted hydraulic pump and PTO application. Other standard power
sources may be used. Minimum power required is 15 horsepower based on 6 GPM (22.7
liters/min) at 2475 PSI (170 bar).
CYLINDER HOLDING VALVES
The base ends (extend sides) of the lower boom and extension cylinders are equipped with
integral-mounted counter-balance valves to prevent sudden cylinder collapse in case of hose or
other hydraulic failure. The extend side of the lower boom cylinder is equipped with a 10 gpm
counterbalance valve.
The counter balance valve serves several functions. First, it is a holding valve. Secondly, it is
designed to control the speed at which the lowering function operates, and allows that motion to
be metered under load. Finally, it prevents the loss of an excess amount of oil in the event of a
hose failure. Only the oil in the hose, at the time of the failure, will be lost.
ROTATION SYSTEM
Turntable bearing with external worm gear powered with a high-torque hydraulic motor through a
self-locking worm. Total gear reduction is 85 to 1.
HYDRAULIC SYSTEM (PTO DRIVEN)
Open-centered, full-pressure system that requires 6 gpm optimum oil flow at 2475 psi. Fourspool, stack-type, electric, remote control valve with 30-foot control cable. System includes
control valve and return-line filter.
Chapter 2 Specifications
EXCESSIVE LOAD LIMIT SYSTEM (ELLS)

A pressure switch which is mounted on the extend side of the lower boom cylinder and
connected electrically to the lift side of the winch, the extend side of the extension boom, and the
down side of the lower boom provides the capacity alert system. If the operator attempts to lift a
load exceeding the rated capacity of the crane, the winch lift, extension out and lower boom
down functions will not operate. To relieve the situation, the the operator may set the load down
(winch down) or retract the extension boom (extension in).
WINCH
The winch is powered by a hydraulic motor through a 31:1 ratio worm-gear drive with a
mechanical brake. Line speed is 27 ft/min (8.2m/min) at optimum oil flow for 1-part line and 13.5
ft/min (4.1 m/min) for 2-part line. The maximum single-line capacity of the winch is 2,500 lb.
The winch is equipped with 85 ft (26 m) of 5/16 (0.8 cm) 6 X 25 FW PRF RRL IWRC IPS wire
rope. A nylon sheave is located at the tip of the extension boom. The ratio of winch drum and
sheave pitch diameter to wire rope diameter is 18:1 or larger. An anti-two block device is
included to prevent the lower block or hook assembly from coming in contact with the boom
sheave assembly.
MINIMUM CHASSIS SPECIFICATIONS
CHASSIS STYLE
WHEELBASE
CAB-TO-AXLE
RESISTANCE TO BENDING
MOMENT
FRAME SECTION MODULUS
FRAME YIELD STRENGTH
FRONT AXLE RATING (GAWR)
REAR AXLE RATING (GAWR)
Conventional Cab
137" - 161" (348 cm - 409 cm)
60" - 84" (152 cm - 213 cm)
420,000 in-lb (47,454 N-m)
8.4 in (138 cm)
50,000 psi (3,447 bar)
5,600 lb (2,540 kg)
11,000 lb (5,000 kg)
Chassis specifications revised 20050920.
NOTES:
1 GAWR means Gross Axle Weight Rating. GAWR is dependent on all vehicle components
including axles, tires, wheels, springs, brakes, steering and frame strength meeting the
manufacturer's recommendations. Always specify GAWR when purchasing a truck.
2 Minimum axle requirements may increase with use of diesel engines, longer wheelbase or
service bodies. Contact the factory for more information.
3 Weight distribution calculations are required to determine final axle loading.
All chassis, crane and body combinations must be stability-tested to ensure stability per ANSI
B30.5
Iowa Mold Tooling Co., Inc. reserves the right to change specifications and design without notice.
10
2820 Geometric Configuration

3'-9"
(1.14 m)
3'-1"
(0.94 m)
2'-3"
(0.69 m)
22'-2"
(6.76 m)
18'-3"
(5.56 m)
13'-4"
(4.06 m)
1'-6"
(0.46 m)
2'-7"
(0.79 m)
11'-6"
(3.51 m)
16'-6"
(5.03 m)
20'-6"
(6.25 m)
Chapter 2 Specifications
2820 20K Capacity Chart
2820 CAPACITY CHART

2440
22'-2"
1107
6.76 m
1600
726
4000
18'-3"
1814
5.56 m
2680
1120
1216
508
80
1860
5000
13'-4"
844
4000
2268
900
1814
60
408
1520
2860
45
4.06 m
689
1297
820
2300
30
1043
2060
15
372
1360
934
934
2000
907
800
1320
362
599
1'-6"
0.46 m
2'-3" 3'-9" 6'-5" 8'-5"

0.69 m 1.14 m 1.98 m
11'-6"
16'-6"
2.57 m
3.51 m
5.03 m
REACH IN FEET / METERS
CAPACITY IN POUNDS / KILOGRAMS
Maximum 1-part line capacity is

2500 pounds (1134 kg). For
greater loads, use 2-part line.
20'-6"
6.25 m
Weight of load handling devices are part of the load

lifted and must be deducted from the capacity.

BOX 189, GARNER, IA 50438-0189
TEL: 641-923-3711 FAX: 641-923-2424
70398885
11
13
CHAPTER 3
Crane Reference
In This Chapter
Major Assemblies, Part Number Locations ............................... 13
Grease Zerk Locations ............................................................. 14
Recommended Spare Parts List ............................................... 15
Crane Installation ..................................................................... 16
Telescopic Crane Orientation ................................................... 18
Crane Control ........................................................................... 18
Major Assemblies, Part Number Locations

EXTENSION BOOM
W/ INTERNAL HYDRAULIC
EXTENSION CYLINDER
EXT. BOOM PART NO.
WINCH
MAST
MAST PART NUMBER
ROTATION
MOTOR
LOWER BOOM
LOWER
CYLINDER
BASE
BASE WELDMENT
PART NUMBER
LOWER BOOM
PART NUMBER
14
Grease Zerk Locations

4
(OTHER
SIDE)
5
OTHER
SIDE
6 OTHER
SIDE
ITEM
1.
2.
3.
4.
5.
6.
7.
8.
LOCATION DESCRIPTION
Gear Rotator Grease Extension
*Rotate Crane While Greasing.
Lower Cylinder Base
Lower Cylinder Rod
Pillow Block
Upper Sheave Pin
Lower Sheave Pin
Snatch Block Sheave Pin
Worm Drive Bearings
*3 Pumps / Then Rotate Fully
LUBRICANT
FREQUENCY
Shell Alvania 2EP

or
Weekly
Shell Retinax "A"
Extreme Pressure EP2 Grease
Every 3 Months
NOTE: All application points must be greased weekly under normal work loads and moderate
weather conditions. Under severe operating conditions, lubrication should be performed more
frequently. See the Volume 1: Telescopic Crane Operation & Safety (99903514) for additional
lubrication requirements.
Chapter 3 Crane Reference
15
Recommended Spare Parts List

Recommended Spare Parts for one-year for the 2820 Crane:
NOTE: This spare parts list does not necessarily indicate that the items can be expected to fail in
the course of a year. It is intended to provide the user with a stock of parts sufficient to keep the
unit operating with the minimal down-time waiting for parts. There may be parts failures not
covered by this list. Parts not listed are considered as not being Critical or Normal Wear items
during the first year of operations and you need to contact the distributor or manufacturer for
availability.
Base Assembly
73051919
Hydraulic Motor
70034473
Bushing
Lower Boom
60030331
Wear Pad
60122985
Side Wear Pads
Lower Cylinder
51744127
Seal Kit
77041561
Pressure Switch
73540035
C'Bal Valve
Extension Boom Assembly
60030330
Wear Pad
60030328
Wear Pad
60122985
Side Wear Pad
60030136
Sheave
70146464
Tube Assembly, Cylinder
Extension Cylinder
73054999
C'Bal Valve
51744128
Seal Kit
Winch/Cable/Hook Kit
73511041
Hydraulic Motor
70580170
Cable Assembly
51713168
Cord Reel
77041459
Limit Switch
60030136
Sheave
71073920
Hook
60030327
Spacer-Hook
Installation Kit
73052092
Filter Element
Winch
76393174
O-Ring
76393173
Oil Seal
70055202
Ball Bearing
70733294
Brake Kit
1
2
1
2
1
1
1
2
2
2
1
2
1
1
1
1
1
1
1
1
2
2
1
1
2
1
16
76393171
Gasket
Valve Bank Parts
70145626
Coil
70145625
Relief Valve
70145624
Solenoid Valve
Valve Bank Handle Assembly
51713182
Tethered Control Handle
2
1
1
1
1
Crane Installation
GENERAL
This section contains instructions for the installation of your crane. Prior to installing the crane
and hydraulic components, make sure that the chassis is ready to receive the crane (see the
Installation Section of the IMT Telescopic Crane Operation & Safety Manual, 99903514).
Reinforce the chassis frame, as necessary, and install the PTO and pump.
Each installation may vary in components used. It is important to use hoses of proper length,
pumps of correct size, and PTOs of adequate speed. Study the applicable installation kit in the
parts section before attempting any installation.
CRANE INSTALLATION
In addition to meeting Minimum Chassis Specifications, there must be sufficient room for
mounting the crane and the platform must be strong enough to support the crane and rated load.
Install the 2820 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. In addition,
an IMT designed body is designed to take full advantage of the standard reservoir placement.
This reservoir is installed in the cargo area of the body. Before attempting to install the crane,
the body must be installed.
To install the crane:
1 Use a lifting device capable of lifting the weight of the crane, 1,400 lbs (635 kg). Attach fabric
slings to the crane lower boom, centered approximately 18 inches from the mast hinge.
Make certain the crane is well balanced on the slings by slowly lifting approximately 6" off the
ground. Lift the crane, apply a bead of waterproof compound, such as silicon based caulk, to
the bottom of the base. Move the chassis under the crane and lower the crane into the
desired position.
Chapter 3 Crane Reference
17
2 Install the 1-8x3" mounting cap screws and 1" washers to secure the crane base to the truck
body (see figure). Torque the cap screws to 680 ft-lbs (94 kg-m).
Mounting holes
as viewed from
top of crane box.
6.0"
14.75"
Apply boom level indicator

on top of crane mounting box
using double-stick tape or
equivalent.
8.38"
4X
1.13
THRU
7.38"
Back of
truck body
1-8x3 Cap Screw

and 2 1" Washers
(4 Places).
Torque cap screw
to 680 ft-lb.
14.75"
18
Telescopic Crane Orientation

When an IMT telescopic crane is not factory-installed on a body, the crane is packed with the
boom oriented as it is built on a test stand to facilitate handling. Install the crane on the body
with boom pointing backward. Once the crane is bolted down, it can be rotated 180 (3.14
radians) to the boom rest.
BOOM
REST
400
ROTATION
OUTLINE OF
TRUCK BODY
REAR OF
TRUCK
Crane Control
IMT's telescopic cranes are controlled by radio or tethered remote controls. The 2820 crane
includes a tethered remote control with a radio remote control option. For complete details on
operating your 2820 telescopic crane, refer to the IMT Telescopic Crane Operation & Safety
Manual (part number 99903514).
19
CHAPTER 4
Parts
In This Chapter
Parts Information ...................................................................... 20
Base and Mast Assemblies ...................................................... 22
Boom Assemblies & Cylinders.................................................. 29
Hydraulics ................................................................................ 38
Controls .................................................................................... 47
Miscellaneous .......................................................................... 56
20
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
BOX 189, GARNER, IA 50438-0189
MODEL
NUMBER
SERIAL
NUMBER
MFG
DATE
Chapter 4 Parts
21
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.
22
Base and Mast Assemblies

Crane Assembly (41718361)
15
14
14
10
8
7
11
12
13
4
USE BLUE THREAD LOCKER
ON SOCKET HEAD CAP SCREW
USE BLUE THREAD LOCKER

ON SOCKET HEAD CAP SCREW
NOTES:
1
BASE AND MAST ASSEMBLY AS MOUNTED ON TRUCK.
13
12
8
11
Chapter 4 Parts
41718361 PARTS LIST

ITEM
PART #
1.
41718359
2.
41718360
3.
52717885
4.
52714976
5.
52715266
6.
70580170
7.
71073920
8.
70144209
9.
72053508
10.
70034382
11.
60030327
12.
72063053
13.
72060091
14.
72066145
15.
70149793
REV. B 20050608
DESCRIPTION
MAST ASSEMBLY DRAWING
BOOM ASSEMBLY DRAWING
SNATCH BLOCK WELDMENT
PIN
PIN
WIRE ROPE ASM
SWIVEL HOOK W/LATCH
PIN
GREASE ZERK NPT 1/8
CAP, GREASE ZERK
SPACER
WASHER 1/2 LOCK
CAP SCREW 1/2-13X1 HHGR5Z
HAIR PIN .19 ZINC
COLLAR- SHAFT, 11/16" (WAS 70145201)
QUANTITY
1
1
1
1
1
1
1
2
1
1
2
2
2
2
1
23
24
Mast Assembly (41718359)

GREASE ZERK (PART OF
CYLINDER ASSEMBLY)
5
22
32
35
34
13
43 36
28(2) 36
30(2)
13
TORQUE CAP
SCREW TO 160 FT-LB
11
20(2)
2
41
19
23
USE CUT
WASHERS
(72063216)
38(4)
33(4)
35(6)
17
11
36
37
USE CUT
WASHERS
(72063216)
36
DETAIL A
30(2)
27(4)
29(4)
45 (SEE NOTE 2)
31
21
12
19
MASTUSE CUT
USE CUT TOP VIEW
WASHERS 29
WASHERS
(72063216)
(72063216)
10
25
8
16 17
10
1
11
24(2)
7
39
19(2)
29(2)
USE BLUE THREAD LOCK
26
40
14
11
15
APPLY 3 PUMPS OF EXTREME PRESSURE (EPS) GREASE

TO WORM BEARINGS. ROTATE CRANE FULLY AFTER
APPLYING GREASE.
NOTE:
1
DO NOT USE THREAD LOCK ON ROTATOR BEARING BOLTS (ITEM #37).
USE SHIM AS REQUIRED. CUT IN TWO FOR SINGLE THICKNESS, OR BEND FOR DOUBLE THICKNESS.
BASE AND MAST ASSEMBLY SHOWN AS MOUNTED ON TRUCK.
Chapter 4 Parts
41718359 PARTS LIST

ITEM
PART #
DESCRIPTION
1.
51395121
HOSE-AA .13X 13.50 OAL( 2- 2)
2.
51717905
CYL-3.5/2.2 21.62S 34.63CC C
3.
51718387
HARDWARE KIT
4.
52714976
PIN
5.
52714977
MAST WELDMENT
6.
52718340
7.
60119128
8.
60120138
9.
60120192
10.
70029595
11.
70034382
12.
70055185
13.
70145864
14.
70570501
15.
71056543
16.
72053301
17.
72053508
19.
72060004
20.
72060037
21.
72060048
22.
72060091
23.
72060596
24.
72060774
25.
72060794
26.
72062004
27.
72062104
28.
72062109
29.
72063001
30.
72063002
31.
72063051
32.
72063053
33.
72063054
34.
72063119
35.
72063216
36.
72533186
37.
72601482
38.
72601499
39.
73051919
40.
73511041
41.
73733931
42.
91718330
43.
73540035
44.
60120192
45.
60132917
REV. N 20140617
DRUM-WINCH WELDMENT
COVER-VALVEBANK
SLIDE-ROTATION STOP
GEAR GUARD
THREADED PLUG 1.00-8
CAP- GREASE ZERK (PART OF #3)
BEARING-FLANGE BLK
TUBE ASM-LOWER BOOM CYL
WINCH
BASE ASM
COUPLING-BLK .12
ZERK-NPT .12
CAP SCR .25-20X 1.00 HH GR5 Z (PART OF #3)
CAP SCR .31-18X 4.00 HH GR5 Z
CAP SCR .38-16X 1.50 HH GR5 Z (WAS 72060046)
CAP SCR .50-13X 1.00 HH GR5 (PART OF #3)
SET SCR .50-13X .75 SH PLAIN
CAP SCR .44-14X 1.25 SH PLAIN (PART OF #3)
CAP SCR .50-13X 1.25 SH PLAIN (PART OF #3)
NUT .50-13 HEX
NUT .25-20 HEX NYLOCK (PART OF #3)
NUT .31-18 HEX NYLOCK
WASHER .25 FLAT (PART OF #3)
WASHER .31 FLAT (PART OF #3)
WASHER .38 LOCK (PART OF #3)
WASHER .62 FLAT ASTM F436 (PART OF #3)
WASHER .62 N FLAT-CUT 3816
ADPTR-M FACE/M STR 6 6
CAP SCR .62-11X 2.50 HH GR5ZC (PART OF #3)
CAP SCR .56-12X 1.25 HH GR5 Z (PART OF #3)
MOTOR-HYDRAULIC (WAS 73511070)
MOTOR-HYDRAULIC T-SERIES (WAS 73511069)
VALVE BANK-4 SEC
HYDRAULIC KIT
VALVE, COUNTERBALANCE
GEAR GUARD
SHIM-WINCH DRIVE
QUANTITY
1
1
1
1
1
1
1
1
1
2
5
1
2
1
1
1
2
8
2
4
1
1
2
2
1
8
2
12
4
4
1
4
13
6
4
19
4
1
1
1
1
1
1
A/R
25
26
Gear Rotator (71056543) (Primary)

A
15
23
10
18
19
11
14
BEARING
GREASE
ZERK
LOCATION
1/8-27
N.P.T.
3
21
13
5
17
22
4
12
20
LOADING
PLUG
LOCATION
18, 19
*7
8
16
10 *5
15
4
8
3 *1
6
5
20
21
*8
11
12
*1 3 20
21
*8
5
6
7
11
2 *4
16 *1
SECTION A-A
12,13,14
*3
NOTES (*)
4 INSTALL SEALS #3 AND #16 WITH LOCTITE PLASTIC GASKET ON O.D. LUBRICATE SEAL SURFACE
BEFORE ASSEMBLY.
5
PACK CAVITIES WITH EPO GREASE
SHIM TO OBTAIN 0.000 / 0.004 END PLAY ON WORM SHAFT.
LUBRICATE O-RING #2 WITH WORM GEAR OIL BEFORE INSTALLING.
INSTALL BOLTS #10 WITH LOCTITE #242.
SET BACKLASH BETWEEN WORM AND ROTATION BEARING 0.005 - 0.012.
10 TIGHTEN 5/8-11 UNC GRADE 8 MOUNTING BOLTS AS FOLLOWS: TIGHTEN PROGRESSIVELY AND AT
180 INTERVALS. FIRST INTERVAL AT 70 FT-LB. SECOND INTERVAL AT 140 FT-LB. THIRD INTERVAL AT
210 FT-LB. TIGHTEN BOLTS IN ORDER SHOWN IN DIAMONDS (<>). DO NOT USE LOCTITE ON
MOUNTING BOLTS.
11 ITEM #20 SHIPS LOOSE. INSTALL ITEM #21 FOR SHIPPING.
Chapter 4 Parts
WARNING
Anytime the gear-bearing bolts have been
removed,they must be replaced with new
bolts of identical grade and size. Failure to
replace gear-bearing bolts may result in bolt
failure due to metal fatigue, causing death or
serious injury.
71056543 PARTS LIST
ITEM
PART #
1.
70056527
2.
70395074
3.
70395076
4.
70145786
5.
70055271
6.
70055281
7.
70145501
8.
70056550
9.
70145787
10.
72601734
DESCRIPTION
ROTATION BEARING
O-RING
SEAL
SNAP RING
BEARING-CONE
BEARING-CUP
BEARING RETAINER
WORM
HOUSING
CAP SCREW
DETAILS
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
CAP SCREW
SHIM
SHIM
SHIM
GASKET
PLUG
PIN
CAP SCREW
WASHER
ZERK
VENT PLUG
1/2-13X1-1/4 FERRY
.005" THICK
.015" THICK
.030" THICK
REV. B 20031029
72601733
73145506
73145505
73145504
76395075
72533604
72661504
72601751
72063219
72533605
72533439
3/8-16X1-1/4 SH
3/8X1
5/8-11X2-3/4 HHGR8
5/8 FLAT HARD
QUANTITY
1
1
2
1
2
2
1
1
1
4
4
2
2
2
1
1
2
23
23
2
2
27
28
Valve, Counterbalance (73540035)

THRU HOLE
FOR 5/16 BOLT (2 PLS)
4,7
ORIFICE PLUG
UNDER SAE #4 PLUG
PRESSURE SWITCH
3300 PSI
SAE #6 ORBP
SAE #6 ORBP
9/16-18 THD (3 PLS)
CYL E
CYL R
R
73540035 PARTS LIST
ITEM
PART #
1.
73540051
2
73540052
4.
70145750
6.
77041561
7.
72533477
REV. C 20031104
COUNTERBALANCE VALVE
NON-VENTED
TORQUE TO 40 FT-LB
SET TO 3300 PSI @ 1 GPM
E
DESCRIPTION
VALVE, C-BAL
VALVE, C-BAL
ORIFICE
PRESSURE SWITCH
PLUG, STR HOL HEX STL 7/16 THD
QUANTITY
1
1
1
1
2
Chapter 4 Parts
Boom Assemblies & Cylinders

Boom Assembly (41718360)
DO NOT OVERTIGHTEN.
MUST BE FREE TO PIVOT.
19,31(2),50(2),51
(2 PLCS)
36
13 ADJUST
TENSION TO
ALLOW 1" OF TRAVEL
24,28,31(2)
ADD NEVER-SEEZ TO BOLT
SPACER AND PIVOT POINTS.
25,27,32(2)
24,28,31(2),38
17,23,30
(3 PLCS)
39
40
21
18
28,31,32(2)
(2 PLCS)
20
17,29,30
3
12
10
41
14
USE
8 NEVER14
SEEZ ON
PIN
22,30,34
(2 PLCS)
9
26
11
4 15
37
5
29
30
Boom Assembly (41718360) (on page 29)

A
16
2820
EXTENSION
CYLINDER
LOCATING HOLES
ON FRONT OF WEAR
PAD FACE CYLINDER
RODS
DETAIL A
SCALE 1/2
SIDE OF WEAR PAD

WITHOUT LOCATING
HOLES FACE THIS SIDE
AND SLIDE UP AGAINST
WELDED BLOCKS
DETAIL B
SCALE 3/4
41718360 PARTS LIST
ITEM
PART #
1.
51713168
2.
51717874
3.
51717875
4.
51717895
5.
51718383
6.
52717865
7.
52718005
8.
60010470
9.
60030328
10.
60030331
11.
60030333
12.
60030330
13.
60119011
14.
60122985
15.
60126157
16.
70030332
17.
70034381
18.
70034382
19.
70146096
20.
70396121
21.
72053508
22.
72060000
23.
72060007
24.
72060055
25.
72060098
26.
72060972
DESCRIPTION
CORD REEL ASM
WELDMENT-LOWER BOOM
MACHINING-2ND EXT BOOM
CYLINDER
HARDWARE KIT-2820 BOOM ASY (INCL 19-38)
WELDMENT-1ST STAGE EXT
TUBE WELDMENT- ANTI TWO BLOCK
PIN
WEAR PAD-RND 1.94 DIA 0.740 SHNKX0.25
WEAR PAD-RC 0.50 X 5.00 X 5.88
WEAR PAD-RC 0.44 X 4.88 X 5.00
WEAR PAD-RC 0.50 X 4.88 X 5.00
DOWN HAUL WEIGHT
WEAR PAD-RND
WASHER-.50 N FLAT CUT
WEAR PAD-BLOCK 2.00 X 3.50 X 3.50
SUPPORT-GP STAUFF LN-4190-PA
CAP- GREASE ZERK
SPRING 0.62 X 2.50 X 14 GA.
CAP-PLSTC
ZERK-NPT .12
CAP SCR .25-20X .50 HH GR5 Z
CAP SCR .38-16X .75 FLH BRS
QUANTITY
1
1
1
1
1
1
1
1
2
1
1
1
1
4
4
1
4
2
2
2
2
2
3
2
1
4
Chapter 4 Parts
41718360 PARTS LIST

27.
72062080
28.
72062103
29.
72062104
30.
72063001
31.
72063003
32.
72063005
34.
72063049
36.
72066145
37.
72601777
38.
72661312
39.
77041459
40.
77044468
41.
60105544
48.
72063034
49.
72066125
50.
72063117
51.
72062179
REV E 20111010

NUT .38-16 HEX NYLOCK (WAS 6)
WASHER .25 FLAT
WASHER .38 FLAT
WASHER .50 FLAT (WAS 10)
WASHER .25 LOCK
HAIR PIN .19 ZINC
BOLT-SHLDR .50X .63
CLAMP- .50 LOOP CUSHIONED
SWITCH-LIMIT
CONNECTOR
PLATE-ANGLE PLASTIC
MACHY BUSHING 1.00 X 10 GA NR
RETAINING RING-EXT 1.00 HD
WASHER .56 FLAT ASMT F436
NUT .38-16 HEX CENTER LOCKING
1
4
1
6
10
6
2
1
4
1
1
1
2
2
2
4
2
31
32
Lower Boom Cylinder (51717905)

56.25" OPEN - 34.63" CLOSED - 21.62" STROKE
6.75"
12
12
15
2
1
14
11 13 11 4
SECTION A-A
SCALE 1/2
7 8
10
NOTES:
1
REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS DISASSEMBLED. THIS
WILL REDUCE FUTURE DOWNTIME.
APPLY REGULAR GRADE ANTI-SEIZE AND LUBRICATING COMPOUND TO THREADS ON CYLINDER

HEAD ONLY. KEEP AWAY FROM ALL SEALS.
APPLY "LUBRIPLATE" NO. 630-2 MEDIUM HEAVY, MULTI-PURPOSE LUBRICANT, TO ALL PISTON, HEAD
GLAND, AND HOLDING VALVE SEALS, NYLON LOCK RING, CAST IRON PISTON RINGS, AND ROD
STINGER THREADS.
FOR LOCKING PIN (ITEM #15), DRILL #15 HOLE 0.188" DEEP. PRESS IN PIN # 60125699.
ITEM #6, STOP TUBE, REPLACES 6A025022 WAFER LOCK. USE STOP TUBE INSTEAD OF WAFER LOCK
WHEN RESEALING CYLINDER.
TORQUE PISTON TO 710-740 FT-LB; HEAD TO 350 FT-LB; CAP SCREW TO 16 FT-LB.
51717905 PARTS LIST

ITEM
PART #
1.
52717906
2.
4G245980
3.
60124587
4.
6C150022
5.
6HD35022
6.
60138275
7.
7Q072338
8.
7Q10P338
9.
7R14P022
10.
7R746022
11.
7T2N4035
12.
7T2NX625
13.
7T66P350
14.
7T61N143
DESCRIPTION
CASE ASSEMBLY
ROD ASSEMBLY
PISTON
STOP TUBE
HEAD
STOP TUBE (WAS 6A025022)
O RING
BACKUP RING
ROD WIPER
U-CUP
WEAR RING-PISTON
WEAR RING-ROD
PISTON SEAL-DYNAMIC
LOCK RING
QUANTITY
1
1
1
1
1
1
1
1
1
1
2
2
1
1
Chapter 4 Parts
51717905 PARTS LIST

ITEM
PART #
DESCRIPTION
15.
60125699
PIN-LOCKING TUBE
16.
51744127
SEAL KIT (INCL 6-15)
REV C 20120404
QUANTITY
1
1
33
34
Extension Cylinder (51717895)
239.00" OPEN - 131" CLOSED - 108" STROKE

20
19 18
20
5
11
14
8
8 7 17
5
1
6
15 13 4
17 17 12
9
A
10
16 16 11
18 19 10
10
SECTION A-A
5 11
19
16
13 17
12 15
14
18
20
3
8
14
17
15
13
12
17
14
17
15
12
11
9
18
19
10
17
13
16
20
NOTES:
1
REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS DISASSEMBLED. THIS
WILL REDUCE FUTURE DOWNTIME.
APPLY REGULAR GRADE ANTI-SEIZE AND LUBRICATING COMPOUND TO THREADS ON CYLINDER

HEAD ONLY. KEEP AWAY FROM ALL SEALS.
APPLY "LUBRIPLATE" NO. 630-2 MEDIUM HEAVY, MULTI-PURPOSE LUBRICANT, TO ALL PISTON, HEAD
GLAND, AND HOLDING VALVE SEALS, NYLON LOCK RING, CAST IRON PISTON RINGS, AND ROD
STINGER THREADS.
FOR LOCKING PIN (ITEM #20), DRILL #15 HOLE 0.188" DEEP. PRESS IN PIN # 60125699.
TORQUE PISTON TO 500-530 FT-LB; HEAD TO 250 FT-LB; CARTRIDGE TO 30-35 FT-LB.
Chapter 4 Parts
51717895 PARTS LIST

ITEM
PART #
1.
51717893
2.
51744128
3.
52717892
4.
52717894
5.
60124842
6.
60124843
7.
60124847
8.
60124854
9.
73054999
10.
7Q072026
11
7Q072129
12
7Q072228
13
7Q10P228
14.
7R14P015
15.
7R546015
16.
7T2N4020
17.
7T2NX417
18.
7T61N125
19.
7T66P020
20.
60125699
REV F 20120404
DESCRIPTION
ROD
SEAL KIT
ROD ASSEMBLY
CASE WELDMENT
PISTON
HEAD
CASE-INNER
STROKE STOP
C'BAL VALVE
O-RING (PART OF #2)
O-RING (PART OF #2)
O-RING (PART OF #2)
BACK-UP RING (PART OF #2)
ROD WIPER (PART OF #2)
U-CUP (PART OF #2)
WEAR RING-PISTON (PART OF #2)
WEAR RING (PART OF #2)
LOCK RING (PART OF #2)
PISTON SEAL (PART OF #2)
PIN-LOCKING TUBE (PART OF #2)
QUANTITY
1
1
1
1
2
2
1
2
1
2
2
2
2
2
2
2
4
2
2
2
35
36
Winch, Worm, 2820 & 5020 (70570501)

2
3
5
4
6
6
8
19
1
11
7
8
9
15
16
12 REF
18
14
13
17
12
15
12
20
12 REF
HYD END W/O MOTOR
IF SPECIFIED
18
2 REF
1* #17 (REF) OIL BRAKE DETAIL

WINCH SPECIFICATIONS
GEAR RATIO
OUTPUT TORQUE
MAXIMUM INPUT TORQUE
MAXIMUM INPUT SPEED
INSTALLED WEIGHT
LUBRICATION
70570501 PARTS LIST
ITEM
PART #
1.
70143673
2.
70143672
3.
70048142
4.
70145277
5.
76393174
6.
72601568
7.
76393173
8.
70143670
9.
70143669
31:1
19,800 IN-LB
1,161 IN-LB
400 RPM
41 LB
EP140 (1 U.S. PINT)
DESCRIPTION
SHAFT
HOUSING
BREATHER
COVER, WINCH
O-RING
CAP SCR
SEAL
BUSHING
WASHER
QUANTITY
1
1
1
1
1
4
1
2
2
Chapter 4 Parts
70570501 PARTS LIST

10.
70143668
11.
70056542
12.
70056541
13.
72661348
14.
70055202
15.
70143865
16.
72601567
17.
70733294
18.
76393171
19.
70143658
20.
70034440
REV. B 20031104
KEY
GEAR
WORM
RETAINING RING
BEARING
PIPE PLUG
CAP SCR
BRAKE KIT
GASKET
KEY
PLASTIC CAP
2
1
1
2
2
2
2
1
2
1
1
37
38
Hydraulics
Hydraulic Kit - Tethered (91718323)
LOWER CYL
EXT CYL
11
2
8
11
2
8
25
15
10
18,19,20
24
23
1
ROTATION
PRESSURE
(SEE INSTL KIT)
EXTENSION
LOWER
WINCH
R
25
24
12
RETURN
(SEE INSTL KIT)
7
13
13
9
PORT A
PORT B
(DOWN)
(UP)
WINCH
16
14
ROTATION
9
PORT B
(CCW)
9
PORT A
(CW)
14
Chapter 4 Parts
Hydraulic Kit (91718323 & 91718330)

EXTENSION
CYLINDER
LOWER BOOM
MAST
WINCH
HOSES (2)
GEAR ROTATOR
21
PART
OF MAST
WHEN MOUNTING
VALVEBANK, SLIDE
VALVEBANK OVER ALL 1
THE WAY TO THE END
OF THE SLOT IN
DIRECTION INDICATED.
LOWER CYLINDER
23
LOWER CYL. HOSES (2)
EXT. CYL. HOSES (2)
3
2820 VALVE
BANK SYSTEM
PRESSURE
SETTING- LOWER CYLINDER
AND EXTENSION CYLINDER HOSES
3000 psi
ROUNTED THROUGH MAST AND
PLACED IN SLEEVE #22.
SOLENOID
CONNECTIONS
HYDRAULIC
CONNECTIONS
HYDRAULIC
CONNECTIONS
PORT B
PORT A
HYDRAULIC MOTOR
PORT IDENTIFICATIONS
(ROTATION & WINCH)
SOLENOID
CONNECTIONS
VALVEBANK ORIENTATION
91718323 (TETHERED) PARTS LIST

ITEM
PART #
DESCRIPTION
1.
70733399
VALVE BANK (TETHERED - USE IN
91718323)
2.
72532792
ADPTR #8MSTR #4MJIC
3.
51395929
HOSE-FJ .25 X 11.75 (4-4) 100R17
4.
51395538
HOSE-FJ 1/4X36 OAL (4-4)
5.
51394946
6.
51395611
7.
51394948
8.
72532690
ELBOW #4MJIC #4FJIC SW
9.
72532722
ADPTR #10MSTR #6FSTR
10.
72532657
TEE-SWVL NUT RUN JIC 8
11.
72532353
ADTPR #6MSTR #4MJIC
12.
72532671
TEE #8JIC SWVL NUT BRANCH
13.
72532699
ELBOW #6MSTR #4MJIC 90
QUANTITY
1
2
1REF
2REF
2REF
2REF
2REF
2
4
1
2
1
4
39
40
91718323 (TETHERED) PARTS LIST

15.
72532665
ADPTR #4MJIC #8FJIC
16.
72053758
ELBOW-M STR/90/M JIC 4 4
18.
72060002
CAP SCR 1/4-20 X 3/4 HHGR5
19.
72063001
WASHER 1/4 FLAT
20.
72062104
NUT 1/4-20 NYLOC
21.
60350073
SLEEVE
22.
51718324
HOSE KIT (INCL. 4-7,23-25)
23.
51394951
HOSE-FJ 1/2 X 10.5 OAL (8-8)
24.
51394503
HOSE-FF 1/2X28 OAL (8-8)
25.
72533648
SWIVEL-#8 MJIC #8MJIC 90
REV E 20111010
1
1
4
4
4
1
1
1REF
2REF
2REF
Chapter 4 Parts
Hydraulic Kit - Radio (91718330)

LOWER
CYL
11
EXT
CYL
11
2
8
2
8
6
25
24
23
10
P
ROTATION
PRESSURE
(SEE INSTL KIT)
15
18,19,20
1
EXTENSION
LOWER
WINCH
R
25
24
12
RETURN
(SEE INSTL KIT)
5
9
PORT A
(DN)
14
PORT B
(UP)
WINCH
ROTATION
9
PORT B
(CCW)
13 13
9
PORT A
(CW)
14
41
42
EXTENSION
CYLINDER
LOWER BOOM
MAST
WINCH
HOSES (2)
GEAR ROTATOR
21
PART
OF MAST
WHEN MOUNTING
VALVEBANK, SLIDE
VALVEBANK OVER ALL 1
THE WAY TO THE END
OF THE SLOT IN
DIRECTION INDICATED.
LOWER CYLINDER
23
LOWER CYL. HOSES (2)
EXT. CYL. HOSES (2)
3
2820 VALVE
BANK SYSTEM
PRESSURE
SETTING- LOWER CYLINDER
AND EXTENSION CYLINDER HOSES
3000 psi
ROUNTED THROUGH MAST AND
PLACED IN SLEEVE #22.
SOLENOID
CONNECTIONS
HYDRAULIC
CONNECTIONS
HYDRAULIC
CONNECTIONS
PORT B
PORT A
HYDRAULIC MOTOR
PORT IDENTIFICATIONS
(ROTATION & WINCH)
SOLENOID
CONNECTIONS
VALVEBANK ORIENTATION
91718330 (RADIO) PARTS LIST

ITEM
PART #
DESCRIPTION
1.
73733931
VALVE BANK (RADIO - USE IN 91718330)
2.
72532792
ADPTR #8MSTR #4MJIC
3.
51395929
HOSE-FJ .25 X 11.75 (4-4) 100R17
4.
51395538
5.
51394946
6.
51395611
7.
51394948
8.
72532690
ELBOW #4MJIC #4FJIC SW
9.
72532722
ADPTR #10MSTR #6FSTR
10.
72532657
TEE-SWVL NUT RUN JIC 8
11.
72532353
ADTPR #6MSTR #4MJIC
12.
72532671
TEE #8JIC SWVL NUT BRANCH
13.
72532699
14.
72532985
15.
72532665
ADPTR #4MJIC #8FJIC
16.
72533376
ADAPTER MFACE/MSTR 4 4
QUANTITY
1
2
1REF
2REF
2REF
2REF
2REF
2
4
1
2
1
2
2
1
1
Chapter 4 Parts
91718330 (RADIO) PARTS LIST

18.
72060002
CAP SCR 1/4-20 X 3/4 HHGR5
19.
72063001
WASHER 1/4 FLAT
20.
72062104
NUT 1/4-20 NYLOC
21.
60350073
SLEEVE
22.
51718324
HOSE KIT (INCL. 4-7,23-25)
23.
51394951
HOSE-FJ 1/2 X 10.5 OAL (8-8)
24.
51394503
HOSE-FF 1/2X28 OAL (8-8)
25.
72533648
SWIVEL-#8 MJIC #8MJIC 90
REV G 20111010
4
4
4
1
1
1REF
2REF
2REF
43
44
Valvebank, Tethered Remote (70733399)

HYDRAULIC SCHEMATIC
b
P5
P15
a
P14
b
P6
a
P13
b
P7
a
P12
b
P8
a
P11
1 3,4
P5
P6
P7
P8
13,14,15
22(8)
METAL
CLAMP
23
19,20
PLASTIC
CLAMP
24 1
23
P14 P13 P12 P11
18
6
7,8
25,26
12 11
10
2
9
16
NOTES (SEE REFERENCE NUMBER IN BOX):

1
PROPORTIONAL PRIORITY FLOW REGULATOR. 12V DC.
PERCENT OF SIGNAL INDICATOR COLOR CHANGING LED:

a) RED = OFF, ZERO % TRIGGER
b) GREEN = FULL ON, 100% TRIGGER.
c)
SHORTED COIL OR OTHER WILL SHOW AS RED WITH 100% TRIGGER.
POWER INDICATOR LED.

a) OFF - BLANK
b) ON - RED LIGHT
RELIEF VALVE. 2300 PSI, 5 GPM.
CONNECT P109 AND J9 TOGETHER.
ADD DUST CAP TO J16.
70733399 PARTS LIST

ITEM
PART #
1.
70145629
2.
70145628
3.
70145627
4.
70145626
5.
70145625
6.
70145624
7.
70143337
8.
70145623
DESCRIPTION
INLET BODY
OUTLET BODY
FLOW REG
COIL
RELIEF VALVE
SOLENOID VALVE
O-RING PLATE
O-RING
QUANTITY
1
1
1
1
1
4
5
10
Chapter 4 Parts
70733399 PARTS LIST

9.
70145622
10.
70145621
11.
72062000
12.
72063047
13.
77044574
14.
77044577
15.
77044578
16.
70145738
17.
70145620
18.
77044826
19.
72601704
20.
72601705
21.
70733394
22.
72532353
23.
72053762
24.
72532357
25.
70145884
26.
70145885
REV. C 20031027
THREADED ROD GR8

THREADED ROD GR8
NUT 1/4-20
WASHER 1/4 LOCK
CONNECTOR TOWER
CONNECTOR TERMINAL
CABLE SEAL
MOUNTING FOOT
NAME TAG
VALVE DRIVER
MACH SCR (USE LOCTITE 242)
WASHER #6 FLAT
WIRING HARNESS (SEE DWG)
ADAPTER #6MSTR #4MJIC
PLUG
ORIFICE PLUG
2
2
6
6
9
18
18
2
1
1
3
3
1
8
2
1
1
1
45
46
Valvebank, Radio Remote (73733931)

HYDRAULIC
SCHEMATIC
WINCH
DOWN(A) UP(B)
b
P5
P15
a
P14
EXTENSION
LOWER
IN(A) OUT(B) DOWN(A) UP(B)
b
P6
a
P13
b
P7
a
P12
ROTATION
CCW(A) CW(B)
b
P8
a
P11
3,4
EXT
ROT
WINCH LOW
P5 P6 P7 P8
13,14,15
22 (8 PLCS)
23
24 1
23
P14 P13 P12 P11
6
25,26
5
7,8
12 11
10
2
9
16
73733931 PARTS LIST

ITEM
PART #
1.
70145629
2.
70145628
3.
70145627
4.
70145626
5.
70145625
6.
70145624
7.
70143337
8.
70145623
9.
70145622
10.
70145621
11.
72062000
12.
72063047
13.
77044574
14.
77044577
15.
77044578
16.
70145738
17.
70145620
21.
77441101
22.
72532353
23.
72053762
24.
72532357
25.
70145884
26.
70145885
DESCRIPTION
INLET BODY
OUTLET BODY
PROPORTIONAL FLOW REGULATOR
COIL 12VDC
RELIEF VALVE SET AT 2300PSI
SOLENOID VALVE
O-RING PLATE
O-RING
ROD 1/4-20X11.5 GR8
ROD 1/4-20X9.5 GR8
NUT 1/4-20
WASHER 1/4 LOCK
CONNECTOR TOWER
CONNECTOR TERMINAL
CABLE SEAL
MOUNTING FOOT
NAME TAG
HARNESS (NOT SHOWN)
PLUG HEX SOCHD
ORIFICE PLUG
QUANTITY
1
1
1
1
1
4
5
10
2
2
6
6
9
18
18
2
1
1
8
2
1
1
1
47
Controls
Control Kit - Tethered Remote (91714443)
PART OF CORD REEL
CORD REEL
PART OF
PRESSURE SWITCH
PRESSURE
SWITCH
J10
P10
ROUTE WIRES
ON INSIDE
OF MAST
1
5
CORD
REEL
J9
P9
5
ANTI-TWOBLOCK SWITCH
ROUTE VALVE BANK

WIRE HARNESS THROUGH
CENTER HOLES OF BASE,
TURNTABLE BEARING, AND
MAST.
2,3,4
(3 AND 4
SHIPPED LOOSE)
NOTES (SEE REFERENCE NUMBER IN BOX):

1
SHIP PARTS 14, 15 LOOSE IN BAG.
SEE DRAWING 99903263 FOR WIRE CONNECTIONS AND ELECTRICAL SCHEMATIC.
BASE AND MAST ASSEMBLY SHOWN AS MOUNTED ON TRUCK.
91714443 PARTS LIST

ITEM
PART #
1.
51713182
2.
60119299
3.
77044645
DESCRIPTION
HANDLE ASM
BRACKET
NUT-DEUTSCH 24 SHELL
QUANTITY
1
1
1
48
91714443 PARTS LIST

4.
77044646
5.
70034439
6.
99903263
7.
99900339
WASHER-LOCK DEUTSCH
LOCK WIRE LEAD SEAL 8"
SCHEM - ELEC PROP RC TELE
MANUAL-PROP RMT CONTROL
1
2
1
1
REV. E 20050608
Cable Assembly, Tethered Remote (70733394)

J15
1(10)
3(20)
5(20)
J5
J6
J7
J8
R1
8(1)
11(4)
12(1)
P10
2
4(2)
5(2)
P1
P16 J17
6
7(23)
J9
CONNECTOR (1)
TERMINAL (7)
WEDGE (1)
CAV. PLUG (1)
J14
9
4(4)
5(4)
J13
J12
J11
10
3(4)
5(4)
P2
P3
J4
70733394 PARTS LIST

ITEM
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
REV. F 20040205
PART #
77044573
77044574
77044576
77044577
77044578
77044620
77044580
77044623
77044624
DESCRIPTION
SHROUD CONN 2-CONTACT
TOWER CONN
TERMINAL-M
TERMINAL-F
CABLE SEAL
CONN RCPT
SOCKET
SOCKET, RELAY
TOWER CONN 4-CONTACT
SHROUD CONN 4-CONTACT
TERMINAL
RELAY
QUANTITY
10REF
2REF
24REF
8REF
32REF
1REF
23REF
1REF
1REF
1REF
4REF
1REF
Parts
Handle Assembly, Tethered Remote (51713182)

9
ENGINE
STOP
14
22
ENGINE
POWER
START
CMP
CRANE
OFF
EXT. WINCH
ROTATION IN DOWN LOWER

DOWN
CCW
ENG SPD
FAST
OPTION
CW
OUT
UP
RED
ORN/RED
GRN
YEL/RED
BLK
BLU/RED
11
UP
IDLE
3
4,10
2
24
8,20
7
21
25
23
49
50
Handle Assembly, Tethered Remote Kit (51713182)
16
15(31)
RED
BLK/BLU
RED/
BLK
19 BLK
BLK/ORN
ORN/BLK
16 14
BLU
YEL/
BLK
BRN/RED
YEL
(THIS JUMPER 3.5";
ALL OTHERS 2.25".)
1 18
BLK/RED
ORN
17
BLU/BLK
18
RED/BLU
BRN/BLK
17
17
BRN
Handle Assembly, Tethered Remote Kit (51713182)

WIRE FUNCTIONS
SOLID/STRIPE
A
YEL/BLK
B
ORN/BLK
C
BLU/BLK
D
RED/BLK
E
ORN/RED
F
BRN
G
BRN/RED
H
BLU/RED
J
BLK/RED
K
BRN/BLK
L
RED
M
BLU
N
ORN
O
BLK/ORN
P
YEL
Q
BRN/BLU
R
YEL/RED
S
BLK
T
BLK/BLU
U
RED/BLU
V
BLU/ORN
W
ORN/BLU
X
YEL/BLU
RED/RON
FUNCTION
ROT CW
EXT OUT
WINCH DN
WINCH UP
EXT IN
ENG START
ENG SPEED
ROT CCW
POWER
ENG STOP
LOWER DN
SOL POWER
LOWER UP
CRANE
CPRSR
OPTION
-
51713182 PARTS LIST

ITEM
1.
2.
PART #
89044214
60119335
DESCRIPTION
WIRE 18GA GRN
CONTROL HANDLE
QUANTITY
1.61 FT
1
Parts
51713182 PARTS LIST
ITEM
3.
4.
5.
7.
8.
9.
10.
11.
14.
15.
16.
17.
18.
19.
20.
21.
PART #
60111141
60119277
70034306
77044196
77044621
70394447
70394142
70394183
72061009
77040051
77040371
77040372
77040373
77040374
77044579
89044100
DESCRIPTION
TRIGGER (PART OF 11)
COVER
BACK COVER
STRAIN RELIEF 3/4
PIN
DECAL-DGR RC ELECTRO SM
DECAL-CTRL
TRIGGER ASM (INCL 3)
SHT MTL SCR #6X3/4 PH
TERM-SPRSPD #8 16-14GA
TOGGLE SWITCH SPST
TOGGLE SWITCH SPDT
TOGGLE SWITCH SPST
TOGGLE SWITCH SPDT
CONNECTOR
CABLE 18GA 24WIRE (NOTE: MUST ORDER
30-FEET.)
TERM-FSLPON 1/4TAB 22-18
TERM-MSLPON 1/4TAB 16-14
MACH SCR #6-32X3/8 RDHD
TUBING-HEAT SHRINK
QUANTITY
1REF
1
1
1
23
1
1
1
8
31
2
4
2
1
1
30 FT
22.
77040147
3
23.
77040047
3
24.
72060602
4
25.
70145495
.5 FT
REV. H 20071016
NOTE: KIT # 51717816, TETHERED CABLE - 30 FEET, INCLUDES ITEMS 8, 15 (QTY 24), 20, 21, AND 25.
ORDER 51717816 TO REPLACE THE CABLE ASSEMBLY.
51
52
Tethered Proportional Remote Potentiometer Adjustment
A
B
NOTE
ONLY use this procedure to set the low-end
output on the remote handle assembly if
crane functions operate without pulling the
proportional trigger.
You may need a second operator to help
with steps 4 and 5.
1
Following proper crane and stabilizer set-up, with the PTO engaged and the truck running, move the crane from
the stowed position to a position off to the side of the truck. Unstow the winch cable hook and lower the winch
approx (6) six feet.
Remove the back cover of the remote control handle.
Loosen screw A slightly. (Note: Screw style may vary).
While holding WINCH DOWN function, very slowly, rotate screw B clockwise until all movement has stopped.
Release WINCH DOWN function.
Tighten screw A
Test by operating WINCH DOWN, WINCH UP, ROTATE CCW, and ROTATE CW without pulling the
trigger. If any of these functions move, repeat steps 2 through 6.
Replace control back cover and properly stow the crane and stabilizers.
Parts
2820 Control Kit (90718831) (Ref. 99903629)

6,7
2
16
3,4,5
17,18,19
(4 EACH)
BLACK
J10 P10
PRESSURE
A A
SWITCH
B B
(NC)
RED
1
BLACK B B
WHITE A A
P9 J9
CORD REEL
8 (2)
9 (2)
ANTI-2-BLOCK
SWITCH (NO)
ANTI-TWO-BLOCK DETAIL
6, 7
RECEIVER ASSEMBLY DETAIL
90718830 PARTS LIST
ITEM
PART #
1.
70034439
2.
70733921
4.
70733883
6.
60125959
7.
72066340
8.
72601846
9.
72062194
10.
99903628
13.
99903629
REV. C 20050608
DESCRIPTION
LOCKWIRE LEAD SEAL, 8"
RECEIVER, RADIO REMOTE
TRANSMITTER, RADIO REMOTE
BRACKET, TETHER CONNECTOR
RIVET, POP, 1/8 X 3/8 GRIP
CAP SCR-22 1/4-20X1-1/4 HH
NUT-SS 1/4-20 NYLOC
INSTRUCTIONS, RADIO REMOTE
INSTALLATION DRAWING, RADIO REMOTE
QUANTITY
2
1
1
1
1
2
2
1
1
53
54
Cable Assembly, Radio Remote (77441101)

PROP
VALVE
J15
CJ-500
A B
EXT
BOOM
IN LOW
WINCH
BOOM ROT
DOWN
DN CCW
J5
J6
J7
J8
A B
A B
A B
A B
ANTI-TWO
J9
A
CJ-1200
CJ-1201
4175554
P10
OVERPRESSURE
4175552
J14 J13 J12
J11
WINCH
LOW
UP EXT BOOM ROT
BOOM UP CCW
OUT
CJ-800
Parts
Electrical Schematic, Radio Remote (77441101)
55
56
CJ-500
RADIO RECEIVER
TETHER INTERFACE
RS485 B
GROUND
RS485 A
+ BATTERY
SHIELD (OPT)
1
2
3
4
5
SPLICE D
BODY SELECT INPUT
GROUND
PROPORTIONAL INPUT
POWER (RADIO)
SPEED OUTPUT
ROTATE CCW
CJ-1200
RADIO RECEIVER
INTERFACE
SPLICE G
SPLICE B
SPLICE P
SPLICE G
A
B J15 PROPORTIONAL
SPLICE P
A J8 ROTATE CCW
B
A J7 BOOM DOWN
B
A J11 ROTATE CW
B
A J12 BOOM UP
B
LOWER BOOM DOWN 10

ROTATE CW 11
LOWER BOOM DOWN 12
SPLICE G
SPLICE G
SPLICE G SPLICE G SPLICE G

OVERPRESSURE
A P10
B
B J9
A
SPLICE G
WINCH DOWN
WINCH UP
2
3
EXT BOOM OUT
ENGINE START
ENGINE KILL
CJ-1201
RS485 A
RADIO RECEIVER
INTERFACE
RS485 B
COMPRESSOR
SPLICE G SPLICE G SPLICE G
B J5 WINCH DOWN
A
B J14 WINCH UP
A
EXT BOOM IN
ANTI-TWO BLOCK
B J6 EXTENSION IN
A
B
A J13 EXTENSION OUT
SPLICE C
A2B/OVERLOAD 12
1 2 3 45 67 8
CJ-800
VEC INTERFACE
Parts
57
Miscellaneous
Decal Placement, 2820 20K Crane (Ref 99903727)
25 (THIS SIDE)
26 (OTHER SIDE)
19 (EACH
3 (OTHER SIDE) SIDE)
2(OTHER SIDE)
11(EACH SIDE)
8 (EACH SIDE)
2(OTHER
SIDE)
20 (INSIDE
COVER)
16
23
2(OTHER
SIDE)
3
2
12
DECAL PLACEMENT
ITEM NO.
6,10,23,24,27
1
14
15,18
17
22
99903727 PARTS LIST
ITEM
PART #
1.
70391598
2.
70391612
3.
70391613
4.
95719347
5.
95719348
6.
70392213
7.
70392524
8.
70396454
9.
95722799
10.
70396613
11.
70395670
12.
70395090
13.
70392399
14.
70392864
15.
70394445
16.
70395324
17.
70394189
18.
70392868
21 (EACH
SIDE)
7,13
LOCATION
AT OR NEAR REMOTE CONTROL STORAGE POINT.
ONE ON EACH OUTRIGGER
2 ON FRONT SIDEPACKS, 2 ON REAR STABILIZERS
ONE ON EACH SIDE OF CARRIER VEHICLE
AT OR NEAR HYDRAULIC RESERVOIR
AT OR NEAR DRIVELINE
DESCRIPTION
DECAL-WARNING, STABILIZER
DECAL-GREASE WKLY LH
DECAL-GREASE WKLY RH
DECAL KIT (TELE-COMMON)
DECAL KIT (BODY-COMMON)
DECAL-CAUTION DON'T WASH/WAX
DECAL-ROTATE CRANE WHILE GREASING
DECAL - 2820 ID
DECAL KIT - 2820 20K MODEL SPECIFIC
DECAL-CRANE SAFETY/OPERATION
DECAL-CAUTION DOWNHAUL WT
DECAL-GREASE WORM DRIVE BRNGS
DECAL-LUBRICATE WORM
DECAL-WARNING STAND CLEAR
DECAL-DANGER ELEC HZD LG
DECAL-ASME/ANSI B30.5
PLACARD-MOBILOIL RESERVOIR
DECAL-WARNING CR LOADLINE
QUANTITY
2
4
3
1
1
1
1
2
1
1
2
1
1
4
4
1
1
4
PART OF #5
PART OF # 4
PART OF # 4
PART OF #4
PART OF #4
PART OF #9
PART OF #5
PART OF #4
PART OF #4
PART OF #4
PART OF # 5
PART OF # 5
PART OF #4
PART OF #5
PART OF #5
58
99903727 PARTS LIST

19.
70392887
20.
70394166
21.
71394081
22.
70392891
23.
70398885
24.
71039134
25.
71393664
26.
71393665
27.
70392982
REV 20091222
DECAL-DIAMOND IMT 5X10

DECAL-INSTR FOR MANUAL OPERATION
DECAL-LOAD BLOCK RATING 3.0 TONS
DECAL-DANGER DRIVELINE
DECAL-CAPACITY PLACARD 2820
DECAL-CAUTION OIL LEVEL
DECAL-ANGLE INDICATOR RH
DECAL-ANGLE INDICATOR LH
DECAL-SERVICE & REPAIR
2
1
2
1
2
1
1
1
1
PART OF #9
PART OF #4
PART OF # 9
PART OF # 5
PART OF # 9
PART OF #5
PART OF #9
PART OF #9
PART OF #5
Parts
59
Installation Kit (93715267)
4
2
1
TORQUE TO 680 FT-LB
NOTES:
1
THE 3" BOLTS SUPPLIED ARE FOR USE ON BODIES WITH A CRANE BOX TOP PLATE THICKNESS OF 7/81" ONLY! ON SHIP-OUT CRANES, DETERMINE CRANE BOX TOP PLATE THICKNESS PRIOR TO
MOUNTING THE CRANE. IF BOLTS OTHER THAN THE 3" SUPPLIED BOLTS ARE REQUIRED, THEY MUST
BE 1"-8 GRADE 8 AND THE APPROPRIATE LENGTH.
FAILURE TO USE PROPER LENGTH BOLTS MAY CAUSE THE CAP SCREWS UNDER THE WORM
HOUSING TO BOTTOM OUT BEFORE BEING TORQUED. DURING TORQUEING, CHECK TO SEE THAT
BOLTS ARE TORQUED AND THAT THEY DO NOT BOTTOM OUT ON THE WORM HOUSING. SIZE
CAPSCREWS TO INSURE MINIMUM 1.5" THREAD ENGAGEMENT.
60
93715267 PARTS LIST

ITEM
PART #
1.
72601748
2.
72063066
3.
73052091
73052092
4.
60123848
DESCRIPTION
CAP SCR 1-8X3 SHGR8
WASHER 1 FLAT
RETURN FILTER 10MIC (NOT SHOWN)
FILTER ELEMENT 10MIC
WASHER, SPECIAL 1X2X
QUANTITY
4
4
1
REF
4
REV. E 20031027
Chassis Wiring Harness (99903340)

TO RECOMMENDED
OEM 12V SPEED CONTROL
ENGINE SPEED
TO BATTERY GROUND
GROUND
ORANGE
TO RECOMMENDED
ENGINE KILL
OPTION
30
85
87A
87
86
BLACK
RED
ENGINE KILL
ENGINE
START
YELLOW
FOR FORD AUTO TRANS. ONLY

TO BROWN WIRE ON
SELECTOR VALVE
COMPRESSOR
ON
SELECTOR
SOLENOID
BROWN
NOTE:
BLUNT CUT AND SHRINK WRAP
ANY UNUSED WIRES.
CABLE ASSEMBLY
PART # 51715664
Note: Used on all ship-out IMT telescopic cranes.
TO RECOMMENDED OEM
12V ENGINE START
BLUE
POWER
GREEN
TO RECOMMENDED
COMPRESSOR ENGAGE
IN-LINE 10A FUSE
87A
87
86
30
85
TO 12V
IGNITION
KEYED POWER
TO 12V
BATTERY
SOURCE
61
CHAPTER 5
General Reference
In This Chapter
Inspection Checklist ................................................................. 61
Deficiency / Recommendation / Corrective Action Report......... 66
Wire Rope Inspection & Replacement ...................................... 68
Hook Inspection........................................................................ 69
Holding Valve Inspection .......................................................... 70
Anti-Two-Block Device Inspection ............................................ 70
Thread Torque Chart English ................................................... 71
Thread Torque Chart Metric ..................................................... 72
Turntable Bearing Thread Tightening Sequence ...................... 73
Turntable Bearing Inspection .................................................... 74
Turntable Bearing Tilt Test ....................................................... 74
Inspection Checklist
NOTICE:
The user of this form is responsible for determining that these inspections satisfy all applicable
regulatory requirements.
OWNER/COMPANY:
TYPE OF INSPECTION (circle one):
CONTACT PERSON:
DAILY
CRANE MAKE & MODEL:
DATE INSPECTED:
CRANE SERIAL NUMBER:
HOURMETER READING (if applicable):
UNIT I.D. NUMBER:
INSPECTED BY (print):
LOCATION OF UNIT:
SIGNATURE OF INSPECTOR:
MONTHLY
QUARTERLY ANNUAL
62
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.
INSPECTION CHECKLIST STATUS KEY:

S = Satisfactory
R = Recommendation
(Should be considered for corrective action)
NA = Not Applicable
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)
Chapter 5 General Reference
FREQUENCY
ITEM KEY
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
Inspect for apparent deficiencies per applicable requirements

and manufacturers specifications.
Proper engagement of all connecting pins and pin retaining
devices.
Overall observation of crane for damaged or missing parts,
cracked welds, and presence of safety covers.
During operation, observe crane for abnormal performance,
unusual wear (loose pins, wire rope damage, etc.). If observed,
discontinue use and determine cause and severity of hazard.
Operate remote control devices to check for proper operation.
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
63
STATUS
(S,R,X,NA)
Operate all lights, alarms, etc. to check for proper operation.

Operate anti two-block or two-block damage prevention device to
check for proper operation.
Check tires (when in use) for proper inflation and condition.

Check ground conditions around the equipment for proper
support, watching for ground settling under and around
stabilizers and supporting foundations, ground water
accumulation, or similar conditions.
Check the equipment for level position within the tolerances
specified by the equipment manufacturers recommendations,
both before each shift and after each move and setup.
Check windows for cracks, breaks, or other deficiencies which
would hamper the operator's view.
Check rails, rail stops, rail clamps and supporting surfaces when
the equipment has rail traveling.
Check safety devices and operational aids for proper operation.

Check electrical apparatus for malfunctioning, signs of apparent
excessive deterioration, dirt or moisture accumulation.
Other
Other
All daily inspection items.
Visual inspection of cylinders for leakage at rod, fittings, and
welds. Damage to rod and case.
Holding valves for proper operation.
Control valves for leaks at fittings and between stations.
Control valve linkages for wear, smoothness of operation, and
tightness of fasteners. Relief valve for proper pressure settings.
Bent, broken, or significantly rusted/corroded parts.
Electrical apparatus for malfunctioning, signs of apparent
excessive deterioration, dirt or moisture accumulation. Electrical
systems for presence of dirt, moisture, and frayed wires.
All structural members for damage.
All welds for breaks and cracks.
All pins for proper installation and condition.
64
FREQUENCY
ITEM KEY
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 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
Base mounting bolts for proper torque.

All structural members for deformation, cracks and corrosion.
Base
Stabilizer beams and legs
Mast
Inner Boom
Outer Boom
Extension(s)
Jib boom
Jib extension(s)
Other
Pins, bearing, shafts, gears, rollers, and locking devices for
wear, cracks, corrosion and distortion.
Rotation bearing(s)
Inner boom pivot pin(s) and retainer(s)
Outer boom pivot pin(s) and retainer(s)
Inner boom cylinder pin(s) and retainer(s)
Outer boom cylinder pin(s) and retainer(s)
Extension cylinder pin(s) and retainer(s)
Jib boom pin(s) and retainer(s)
Jib cylinder pin(s) and retainer(s)
Jib extension cylinder pin(s) and retainer(s)
Boom tip attachment
Other
Hoses, fittings and tubing for proper routing, leakage, blistering,
deformation and excessive abrasion.
Pressure line(s) from pump to control valve
Return line(s) from control valve to reservoir
Suction line(s) from reservoir to pump
Pressure line(s) from control valve to each function
Load holding valve pipe(s) and hose(s)
Other
FREQUENCY
ITEM KEY
77
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
103
Valves
A
A
104
105
106
Valves
Rotation
Sys
Lubrication
107
Hardware
A
A
108
109
Wear Pads
Loadline
Pumps and Motors for loose bolts/fasteners, leaks, noise,

vibration, loss of performance, heating & excess pressure.
Winch motor(s)
Rotation motor(s)
Other
Hydraulic valves for cracks, spool return to neutral, sticking
spools, proper relief valve setting, relief valve failure.
Main control valve
Load holding valve(s)
Stabilizer or auxiliary control valve(s)
Other
Other
Hydraulic cylinders for drifting, rod seal leakage and leakage at
welds. Rods for nicks, scores and dents. Case for damage.
Case and rod ends for damage and abnormal wear.
Stabilizer cylinder(s)
Inner boom cylinder(s)
Outer boom cylinder(s)
Extension cylinder(s)
Rotation cylinder(s)
Jib lift cylinder(s)
Jib extension cylinder(s)
Other
Winch, sheaves and drums for damage, abnormal wear,
abrasions and other irregularities.
Hydraulic filters for replacement per maintenance schedule.
All monthly inspection items.
All quarterly inspection items.
Hydraulic fluid change per maintenance schedule.
Control valve calibration for correct pressure & relief valve
settings.
Safety valve calibration for correct pressure & relief valve
settings.
Valves for failure to maintain correct settings.
Rotation drive system for proper backlash clearance & abnormal
wear, deformation and cracks.
Gear oil change in rotation drive system per maintenance
schedule.
Check tightness of all fasteners and bolts, using torque
specifications on component drawings or torque chart.
Wear pads for excessive wear.
Loadline for proper attachment to drum.
65
STATUS
(S,R,X,NA)
Pumps &
Motors
66
Deficiency / Recommendation / Corrective

Action Report
DATE:
OWNER:
UNIT I.D. NUMBER:
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
CA = CORRECTIVE ACTION TAKEN
DATE CORRECTED
X,R,CA
ITEM #
EXPLANATION
67
DATE CORRECTED
68
Wire Rope Inspection & Replacement

Wire rope with any of the deficiencies shown below shall be removed and replaced immediately.
a
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.
When flat spots on the outer wires appear and those outside wires are less than 2/3 the
thickness of the unworn outer wire.
d When there is a decrease of diameter indicating a core failure.
e When kinking, crushing, birdcaging or other distortion occurs.
When there is noticeable heat damage (discoloration) of the rope by any means.
g 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)
h If a broken wire protrudes or loops out from the core of the rope.
69
Hook Inspection
Hooks having any of the listed deficiencies shall be removed from service unless a qualified
person approves their continued use and initiates corrective action. Hooks approved for
continued use shall be subjected to periodic inspection.
a DISTORTION
Bending / Twisting
A bend or twist exceeding 10 from the plane of the unbent hook.
Increased Throat Opening
HOOK WITHOUT LATCH:
An increase in throat opening exceeding 15% (Or as
recommended by the manufacturer).
HOOK WITH LATCH: An increase of the dimension between a fully-opened latch and the tip
section of the hook exceeding 8% (Or as recommended by the manufacturer).
b WEAR
If wear exceeds 10% of the original sectional dimension. (Or as recommended by the
manufacturer).
c CRACKS, NICKS, GOUGES
Repair of cracks, nicks, and gouges shall be carried out by a designated person by grinding
longitudinally, following the contour of the hook, provided that no dimension is reduced more
than 10% of its original value. (Or as recommended by the manufacturer). (A qualified
person may authorize continued use if the reduced area is not critical).
d LATCH
Engagement, Damage & Malfunction
If a latch becomes inoperative because of wear or deformation, and is required for the
service involved, it shall be replaced or repaired before the hook is put back into service. If
the latch fails to fully close the throat opening, the hook shall be removed from service or
wired closed (moused) until repairs are made.
e HOOK ATTACHMENTS & SECURING MEANS
If any indication of distortion, wear, cracks, nicks or
gouges are present, unless a qualified person
authorizes their use. (Or as recommended by the
manufacturer).
70
Holding Valve Inspection

The cylinders are equipped with holding valves that prevent 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 With a full rated load, extend the cylinder in question and kill the engine.
2 Operate the control valve to retract the cylinder. If the cylinder creeps, replace the holding
valve. If the cylinder does not creep, the valve is serviceable.
Anti-Two-Block Device Inspection

(See the operation, maintenance, and repair manual for this crane for a complete description.)
The anti-two-block system should be checked daily as follows:
1 Examine flexible rod and weight to insure free unrestricted mechanical operation.
2 Examine cord for damage, cuts or breaks. Grasp cord and pull to check operation of cord
reel. The cord should retract on reel when released.
3 Start vehicle, engage PTO and slowly winch loadline up until anti-two-block weight comes in
contact with the hook end of the loadline cable. At the moment the weight is fully supported,
a marked difference in winch operation should be noted. At this point, the winch up function
should become very sluggish or non-functioning and have very little pull capability. Slowly
increase truck engine speed while simultaneously actuating the winch up function. The winch
characteristics should remain sluggish with little or no tensioning of the cable. If operation
other than as described occurs, stop immediately and investigate. Failure to do so will risk
damage to the cable or the crane. If all is well at this point, actuate the boom extend function
slowly, and gradually increase to full actuation. Once again the function should be sluggish
or non-existent with no tightening of the winch cable. If operation other than described
occurs, stop immediately and reverse the function.
4 The final check involves actuating both the winch up and extend functions together and
checking for proper operation of the anti-two-blocking circuit. Once again, start slowly and
stop if it appears the cable is being tensioned.
5 If the anti-two-block function appears to be functioning normally, winch the cable down until
the sensing weight swings free.
71
Thread Torque Chart (English)

FINE THREAD BOLTS (ENGLISH)
SIZE
BOLT
GRADE 5
DIA.
GRADE 8
SAE J429
GRADE 5
(DIA-TPI) (INCHES) PLAIN

(FT-LB)
5/16-24
0.3125
19
3/8-24
0.375
35
7/16-20
0.4375
55
1/2-20
0.5
90
9/16-18
0.5625
120
5/8-18
0.625
170
3/4-16
0.75
300
7/8-11
0.875
445
1-12
1
645
1 1/8-12 1.125
890
1 1/4-12 1.25
1240
1 3/8-12 1.375
1675
1 1/2-12 1.5
2195
COARSE THREAD BOLTS (ENGLISH)

SIZE
BOLT
GRADE 5
DIA.
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
(DIA-TPI) (INCHES) PLAIN

(FT-LB)
5/16-18
0.3125
17
3/8-16
0.375
31
7/16-14
0.4375
49
1/2-13
0.5
75
9/16-12
0.5625
110
5/8-11
0.625
150
3/4-10
0.75
265
7/8-9
0.875
395
1-8
1
590
1 1/8-7
1.125
795
1 1/4-7
1.25
1120
1 3/8-6
1.375
1470
1 1/2-6
1.5
1950
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
Consult bolt manufacturers particular specifications, when provided.
Use flat washers of equal strength.
All torque measurements are given in foot-pounds.
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.
72
Thread Torque Chart (Metric)

FINE THREAD TORQUE CHART (METRIC)
COARSE THREAD TORQUE CHART (METRIC)
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
PLAIN PLATED PLAIN PLATED

(KG-M) (KG-M) (KG-M) (KG-M)
5/16-24 0.3125
3
2
4
3/8-24
0.375
5
4
7
7/16-20 0.4375
8
6
11
1/2-20
0.5
12
9
17
9/16-18 0.5625
17
12
24
5/8-18
0.625
24
18
33
3/4-16
0.75
41
31
58
7/8-11
0.875
62
45
93
1-12
1
89
67
138
1 1/8-12 1.125
123
93
200
1 1/4-12 1.25
171
129
278
1 3/8-12 1.375
232
174
375
1 1/2-12 1.5
304
228
492
NOTES
1 Tightening torques provided are midrange.
3
5
8
12
18
25
44
69
103
150
209
281
369
SAE J429
GRADE 8
PLAIN PLATED PLAIN PLATED

(KG-M) (KG-M) (KG-M) (KG-M)
5/16-18
3/8-16
7/16-14
1/2-13
9/16-12
5/8-11
3/4-10
7/8-9
1-8
1 1/8-7
1 1/4-7
1 3/8-6
1 1/2-6
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
Consult bolt manufacturers particular specifications, when provided.
Use flat washers of equal strength.
All torque measurements are given in kilogram-meters.
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.
73
Turntable Bearing Thread Tightening

Sequence
Refer to the turntable bearing thread tightening diagram below for proper tightening/torquing
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
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.
74
Turntable Bearing Inspection

Turntable bearings may experience wear. One of the following conditions may indicate turntable
bearing wear:
1
Metal particles present in the bearing lubricant.
Increased drive power required to rotate the crane.
Noise emitting from the bearing during rotation.
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 74)
Periodic readings indicating a steady increase in TILT may be an indicator of bearing wear. Note
that a bearing found to have no raceway cracks or other structural irregularities should be reassembled and
returned to service.
Turntable Bearing Tilt Test

1 Place crane in vertical position.
2 Set a dial indicator at 0 on the pinion cover plate at back side of mast.
3 Lower crane to the horizontal position.
4 Check and record the dial indicator change. It should not exceed the tilt measurement noted
in the chart below.
5 Return the crane to the vertical position. The dial indicator should return to 0.
75
Set up dial indicator

to 0" on pinion cover
at back side of mast.
Lower crane to
horizontal position.
Read dial indicator.
COMPARISON CHART MEASURED TILT DIMENSION PER CRANE MODEL
NOTE: The tilt dimensions listed in this chart are service guidelines and do not, in themselves, require that the
bearing be inspected.
If there is reason to suspect an excess of bearing wear AND the measured tilt dimension exceeds the dimension
listed, remove the bearing for inspection.
IMT Crane, 1007
5200
16000-I, II, III
23516
1221R
Loader or
1014/1014A
5200R
32018
14K160TH
1225R
Tirehand
1015
5217
32027
COMMANDER IV 8000L
Model
2015/2020
5800
32030
9800
2109
7020
T30
12916
2820
7025
T40
13031
3000
7200
13034
3016/3020
7415
14000
3203i
8025
15000
3816/3820
9000
18000
4004i
20017
421/425
8000L
4300
H1200
5005i
H1200RR
5016/5020
T50
6006i
6016/6020
6022
5525 / 6025 / 6625
EZ Hauler I, II
EZ Hauler 3000 /
5500
Ball Dia.
.875" (22 mm)
1.00" (25 mm)
1.18 - 1.25" (30-32 1.5 (38 mm)
1.75" (44 mm)
(Ref)
mm)
Tilt Dim.
.060" (1.524 mm)
.070" (1.778 mm)
.075" (1.905 mm)
.085 (2.159 mm) .090" (2.286 mm)
Rev 20100331

2820 20K Crane

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2820 20K Crane

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Manual Part Number 99904817

2820 20K Parts &

Manual for 2820 Crane on DSC20 Body

IOWA MOLD TOOLING CO., INC.

Copyright 2014 Iowa Mold Tooling Co., Inc.

2820 General Specifications ......................................................................................................................... 7

Major Assemblies, Part Number Locations ................................................................................................ 13

Inspection Checklist .................................................................................................................................... 61

ECN 11291 - #40 hydraulic motor should be 73511041.

2820 General Specifications

28,000 ft-lb (3.9 ton-meters)

REACH (from centerline of rotation)

6 U.S. GPM (22.7 l/min)

2820 20K Parts & Specifications Manual #99904817

2820 Performance Characteristics

EXTENSION CYLINDER (2) 60" / 48" (152.4 cm / 121.9

13.5 ft/min (4.1 m/min)

two part line

2820 System Specifications

EXCESSIVE LOAD LIMIT SYSTEM (ELLS)

Chassis specifications revised 20050920.

2820 20K Parts & Specifications Manual #99904817

2820 Geometric Configuration

2820 20K Capacity Chart

2820 CAPACITY CHART

2'-3" 3'-9" 6'-5" 8'-5"

Maximum 1-part line capacity is

Weight of load handling devices are part of the load

IOWA MOLD TOOLING CO., INC.

Major Assemblies, Part Number Locations

2820 20K Parts & Specifications Manual #99904817

Grease Zerk Locations

Shell Alvania 2EP

Shell Retinax "A"

Extreme Pressure EP2 Grease

Chapter 3 Crane Reference

Recommended Spare Parts List

2820 20K Parts & Specifications Manual #99904817

Chapter 3 Crane Reference

Apply boom level indicator

1-8x3 Cap Screw

2820 20K Parts & Specifications Manual #99904817

Telescopic Crane Orientation

2820 20K Parts & Specifications Manual #99904817

2820 20K Parts & Specifications Manual #99904817

Base and Mast Assemblies

USE BLUE THREAD LOCKER

BASE AND MAST ASSEMBLY AS MOUNTED ON TRUCK.

41718361 PARTS LIST

2820 20K Parts & Specifications Manual #99904817

Mast Assembly (41718359)

USE BLUE THREAD LOCK

APPLY 3 PUMPS OF EXTREME PRESSURE (EPS) GREASE

DO NOT USE THREAD LOCK ON ROTATOR BEARING BOLTS (ITEM #37).

BASE AND MAST ASSEMBLY SHOWN AS MOUNTED ON TRUCK.

41718359 PARTS LIST

2820 20K Parts & Specifications Manual #99904817

Gear Rotator (71056543) (Primary)

PACK CAVITIES WITH EPO GREASE

SHIM TO OBTAIN 0.000 / 0.004 END PLAY ON WORM SHAFT.

LUBRICATE O-RING #2 WITH WORM GEAR OIL BEFORE INSTALLING.

INSTALL BOLTS #10 WITH LOCTITE #242.

SET BACKLASH BETWEEN WORM AND ROTATION BEARING 0.005 - 0.012.