5200/780:99900922: 20120531

5200 Series Crane

& Model 780 (Metric Version)
Volume 2 - PARTS AND SPECIFICATIONS
Section
Section
Section
Section
Section

1
1A.
2
3
4

SPECIFICATIONS-5200 SERIES
SPECIFICATIONS-780 CRANE
CRANE REFERENCE
REPLACEMENT PARTS
GENERAL REFERENCE

IOWA MOLD TOOLING CO., INC.

BOX 189, GARNER, IA 50438-0189
TEL: 641-923-3711
MANUAL PART NUMBER 99900922
Iowa Mold Tooling Co., Inc. is an Oshkosh Corporation company.

5200/780:99900922: --------

REVISIONS LIST
DATE
20001102

20120419

LOCATION
2-5
3-10
3-11
3-25
3-25
2-05-06
3-43
2-6
2-6
3-31
3-32
3-1
3-25
3-47 THROUGH 52
3-5,20
3-38,39
3-44
3-39
3-26
3-37
3-40
3-45
3-1,2,27 ON
3-40
3-13
3-4,6,7,14,15
3-27
3-4,12,19
1-1
3-4
3-4,19
3-51
3-51
3-37
SECTIONS 1-4
3-27
3-41
3-6,13,18, 35

20120531

3-38

20010109
20010215
20010417
20010419
20010419

20010907
20011023
20011204

20020318
20020724

20030715
20040527
20051104
20060616
20061020
20070816
20081104
20100322
20110928
20111219

DESCRIPTION OF CHANGE
REV SPL
ECN8615-41710920-CHG INNER CYL PN
3B270000-REPLACE INNER CYL ASM
91710962-CHG BOM & DWG (NEW CBAL VALVE)
ECN9000-91710962-ADD HOSE 29.51395954, DELETE 1 4.51393922 HOSE, CHG DWG
UPDATE SPARE PARTS LIST
ITEM #5 77041345 WAS 77041014
CHG ASM DESIGNATION 90713554 TO 91716707
CHG ASM DESIGNATION 90713554 TO 90716707
REMOVED DRAWING 90713554 AND ADDED 90716707
ADDED SECOND DRAWING OF 90716707 ON NEW PAGE
REVISED INDEX
ECN 8758 ADDED ITEM 30 TO HYDRAULIC KIT 91710962
ECN 8783 ADDED RADIO RMT KIT
ADDED MOBILTAC LUBRICATION NOTE
ECN 8794 - NEW OVERLOAD VALVE BLOCK
ECN 8834 - NEW LIGHT KIT
ECN 9996 - ADDED 31717516 CAP ALERT KIT
ECN 8972 - ADDED HYD SCHEMATIC FOR SELECTOR VALVE
ECN 8972 - WINCH KIT 31717776 REPLACES 31705009
ECN 8973 - CHANGES TO CAP ALERT/SHUTDOWN KITS
ECN 8972 - BOM CHANGES TO 31717218 FLOOD LIGHT KIT
ECN 8972 - UPDATED TOC FOR NEW PAGE
ECN 9201 - CHANGES TO CAP SHUTDOWN KIT
ECN 9468 - CHANGE TO ROD ASM ON 3C180920
ECN 9832 - CYL CHANGE 71411814 REPL. 3B221850; 71411815 REPL. 3C180920
ECN 9843 - VALVE ADDED TO 91710962 HYD KIT
ECN 9832-2 - REVERSED CYLINDER CHANGE
UPDATED OWNERSHIP STATEMENT. ECN 10300-1, CHANGED HOOK ON 41710943, 41710939
ECN 10539 - UPDATED BOLT LENGTHS #36,68 IN 41712219
ECN 10767 - HARDENED TEETH ON TURNTABLE GEAR
ECN 10903 - 51717059 UPDATE.
ECN 11213 - ADDED RELAY TO 51717059 JIC BOX ASSEMBLY
ECN 11299 - REVISED WINCH FITTINGS
ECN 11628 - UPDATE STABILIZER WORDING.
ECN 11621 - ADDED HYD OVERLOAD KIT
ECN 11606 - ADDED TWO-BLOCK DAMAGE PREVENTION KIT
ECN 11615 - REPLACED WAFER LOCK WITH STOP TUBE IN CYLINDERS, ADDED REMOTE CALI
BRATION PROCEDURE
ECN 11736 - UPDATED WINCH KIT

5200/780:99900922: 19980519

INTRODUCTION
This volume deals with information applicable to your
particular crane. For operating, maintenance and
repair instructions, refer to Volume 1, OPERATION,
MAINTENANCE AND REPAIR.
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. Listed below is a publication that the user
should thoroughly read and understand.
ANSI/ASME B30.22
ARTICULATING BOOM CRANES
The American Society of Mechanical Engineers
United Engineering Center
345 East 47th Street
New York, NY 10017
Three means are used throughout this manual to gain
the attention of personnel. They are NOTEs,
CAUTIONs and WARNINGs and 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.
Treat this equipment with respect and service it
regularly. These two things can add up to a safer
working environment.

Read and familiarize yourself with the

IMT OPERATORS CRANE SAFETY MANUAL
before operating or performing any maintenance
on your crane.

5200/780:99900922: 20000728

NOTES

5200/780:99900922: 19961125

1-1

SECTION 1. SPECIFICATIONS-5200 SERIES

SECTION 1. 5200 SERIES CRANE SPECIFICATIONS

GENERAL .................................................................................................................................................. 3
PERFORMANCE CHARACTERISTICS ..................................................................................................... 4
POWER SOURCE ...................................................................................................................................... 4
CYLINDER HOLDING VALVES ................................................................................................................. 4
ROTATION SYSTEM .................................................................................................................................. 4
HYDRAULIC SYSTEM ............................................................................................................................... 4
STOWED POSITION & STABILIZER DIMENSIONS-1H EXT-5200 SERIES ............................................ 5
HOOK APPROACH DIMENSIONS-1H EXT-5200 SERIES ....................................................................... 5
GEOMETRIC CONFIGURATION-1H EXT-5200 SERIES ........................................................................... 6
GEOMETRIC CONFIGURATION-2H & 2H/1M EXT-5200 SERIES ............................................................ 7
HOOK APPROACH DIMENSIONS-2H/1M EXT-5200 SERIES .................................................................. 8
STOWED POSITION & STABILIZER DIMENSIONS-2H/1M EXT-5200 SERIES .......................................... 8
CAPACITY CHART-5200 SERIES CRANE ................................................................................................ 9
MINIMUM CHASSIS SPECIFICATIONS - .................................................................................................. 10

5200/780:99900922: 19961125

1-2

NOTES

SECTION 1. SPECIFICATIONS-5200 SERIES

5200/780:99900922: 2111219

1-3

SECTION 1. SPECIFICATIONS-5200 SERIES

5200 SERIES CRANE SPECIFICATIONS

GENERAL

5200 SERIES CRANE

2H
52000 ft-lbs

*CRANE RATING (ANSI B30.22)

1H
52000 ft-lbs

2H1M
51330 ft-lbs

*MAXIMUM CRANE RATING

52560 ft-lbs

52060 ft-lbs

52000 ft-lbs

HORIZONTAL REACH
from centerline of rotation

20'-1'

26'-4'

32'-2'

HYDRAULIC EXTENSION

70'

70' X 2

70' X 2

MANUAL EXTENSION

None

None

70'

VERTICAL REACH
from mounting surface

26'-6'

32'-4'

37'-10'

VERTICAL REACH
from ground / 40' frame ht.

29'-10'

35'-8'

41'-2'

CRANE WEIGHT

2820 lbs

3060 lbs

3140 lbs

STABILIZER SPAN

12'-4'

12'-4'

12'-4'

STABILIZER PADS

12' x 12'

12' x 12'

12' x 12'

CRANE STORAGE HEIGHT

from mounting surface

7'-0'

7'-0'

7'-0'

CRANE STORAGE HEIGHT

from ground / 40' frame ht.

10'-4'

10'-4'

10'-4'

**MOUNTING SPACE REQUIRED

28'

28'

28'

ROTATIONAL TORQUE

7800 ft-lbs

7800 ft-lbs

7800 ft-lbs

OPTIMUM PUMP CAPACITY

9 U.S. GPM

9 U.S. GPM

9 U.S. GPM

SYSTEM OPERATING PRESSURE

2500 PSI

2500 PSI

2500 PSI

OIL RESERVOIR CAPACITY

17 U.S. Gallons

17 U.S. Gallons

17 U.S. Gallons

HOOK APPROACH - HORIZONTAL

from centerline of rotation

2'-11'

3'-1'

3'-1'

HOOK APPROACH - VERTICAL

from mounting surface

6'-9'

6'-4'

6'-4'

* Maximum Crane Rating (ft-lbs) is defined as that rated load (lbs) which when multiplied by its respective
distance (ft) from centerline of rotation gives the greatest ft-lb value.
ANSI B30.22 Crane Rating (ft-lbs) = With all extensions retracted and inner plus outer boom in a horizontal
position, rated load (lbs) X respective distance (ft) from centerline of rotation = nominal ft-lb value.
** Allow an additional 5' between the cab and crane base for swing clearance.
IOWA MOLD TOOLING CO., INC.
BOX 189, GARNER, IA 50438-0189
TEL: 641-923-3711 FAX: 641-923-2424

5200/780:99900922: 20111219

1-4

PERFORMANCE CHARACTERISTICS
ROTATION:
INNER BOOM ELEVATION:
OUTER BOOM ARTICULATION:
TELESCOPIC EXTENSIONS:
SINGLE STAGE EXTENSION:
VERTICAL STABILIZER STROKE:

450
-49 to +77
139
70'/70'
70'
24'

SECTION 1. SPECIFICATIONS-5200 SERIES

30 seconds
24 seconds
21 seconds
26 / 15 seconds
15 seconds
6 seconds

POWER SOURCE

Integral-mounted hydraulic pump and PTO application. Other standard power sources may be utilized minimum power required is 17 horsepower.

CYLINDER HOLDING VALVES

The holding sides of all standard cylinders are equipped with integral-mounted holding or counter-balance
valves to prevent sudden cylinder collapse in case of hose or other hydraulic failure. The stabilizer cylinders
have positive, pilot-operated holding valves that open only on command.
The inner cylinders have single pilot-operated counter balance valves while the outer and extension boom
cylinders have double counter-balance valves. The counter-balance valve serves several functions. First,
it is a holding valve. Secondly, it is so constructed that it will control the lowering function and allow that
motion to be feathered while under load. Finally, if a hose breaks, the only oil loss will be that in the hose.

ROTATION SYSTEM

Rotation of the crane is accomplished through a turntable bearing, powered by a high torque hydraulic
motor through a ring and pinion type spur gear train. Total gear reduction is 39.61 : 1.

HYDRAULIC SYSTEM

The hydraulic system is an open centered, full pressure system, requiring 9 GPM optimum oil flow, at 2500
PSI. Eight-spool, stack-type control valve, six of which are used for the standard crane and the remaining
two are plugged, but easily adapted for additional optional features. Dual operational handles for six
functions are located at both sides of crane for convenient operation. System includes hydraulic oil
reservoir, suction-line strainer, pump, 8-section control valve, return-line filter and all hoses and fittings.
IMT reserves the right to change specifications and design without notice.

5200/780:99900922:

20111219

1-5

SECTION 1. SPECIFICATIONS-5200 SERIES

HOOK APPROACH DIMENSIONS-1H EXT-5200 SERIES

STOWED POSITION & STABILIZER DIMENSIONS-1H EXT-5200 SERIES

5200/780:99900922:

19961125

1-6

SECTION 1. SPECIFICATIONS-5200 SERIES

GEOMETRIC CONFIGURATION-1H EXT-5200 SERIES

5200/780:99900922:

19961125

1-7

SECTION 1. SPECIFICATIONS-5200 SERIES

GEOMETRIC CONFIGURATION-2H & 2H/1M EXT-5200 SERIES

5200/780:99900922:

20111219

1-8

SECTION 1. SPECIFICATIONS-5200 SERIES

HOOK APPROACH DIMENSIONS-2H/1M EXT-5200 SERIES

STOWED POSITION & STABILIZER DIMENSIONS-2H/1M EXT-5200 SERIES

5200/780:99900922: 20000710

1-9

SECTION 1. SPECIFICATIONS-5200 SERIES

641-923-3711

CAPACITY CHART-5200 SERIES CRANE

5200/780:99900922: 20111219

1-10

SECTION 1. SPECIFICATIONS-5200 SERIES

MINIMUM CHASSIS SPECIFICATIONS FOR STANDARD 5200 SERIES CRANE

Crane Mount

Behind Cab

Crane Working Area

360

Chassis Style

Conventional Cab

Front Axle Rating (GAWR)

7000 lbs

Rear Axle Rating (GAWR)

Single Axle
14,000 lbs

Wheelbase

171"

Cab-to-axle

102"

Stabilizer Width Required

12'-4"

RBM
Frame Section Modulus
Frame Yield Strength

720,000 in-lbs
14.4 cubic inches
50,000 psi

Minimum Finished Unit Weight

To Maintain Vehicle Stability
Front Axle
* 5300 lbs
Rear Axle
* 6100 lbs
Total Finished Unit Wt.
11400 lbs

* Allows lifting full capacity load in a 360 arc when crane is installed immediately behind the cab. Great
care should be taken when swinging the load from rear of vehicle to front of vehicle since the front axle
springs will compress, thus affecting the levelness of the vehicle.

NOTES:
1. GAWR means Gross Axle Weight Rating and is dependent on all components of the vehicle such as
axles, tires, wheels, springs, brakes, steering and frame strength meeting the manufacturers
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 further information.
3. Weight distribution calculations are required to determine final axle loading.
4. All chassis and crane combinations must be stability tested to ensure stability per ANSI B30.22

5200/780:99900922: 19961125

1A-1

SECTION 1A. SPECIFICATIONS-780 CRANE

SECTION 1A. MODEL 780 CRANE SPECIFICATIONS

GENERAL ..................................................................................................................................................... 3
PERFORMANCE CHARACTERISTICS ......................................................................................................... 3
POWER SOURCE ......................................................................................................................................... 3
CYLINDER HOLDING VALVES ..................................................................................................................... 4
ROTATION SYSTEM ..................................................................................................................................... 4
HYDRAULIC SYSTEM .................................................................................................................................. 4
SELECTED WEIGHTS OF ANCILLARY EQUIPMENT ................................................................................. 4
HOOK APPROACH DIMENSIONS (1 HYD EXTENSION) ............................................................................. 5
GEOMETRIC CONFIGURATION -1 HYD EXTENSION -MODEL 780 CRANE ............................................. 5
STOWED POSITION AND STABILIZER DIMENSIONS (1 HYD EXTENSION) .............................................. 5
HOOK APPROACH DIMENSIONS-2H/1M ..................................................................................................... 6
GEOMETRIC CONFIGURATION-2HYD & 2HYD/1MNL EXTENSIONS-MODEL 780 CRANE ....................... 6
STOWED POSITION AND STABILIZER DIMENSIONS - 2H/1M................................................................... 6
CAPACITY CHART-MODEL 780 CRANE....................................................................................................... 7

5200/780:99900922: 19961125

1A-2

NOTES

SECTION 1A. SPECIFICATIONS-780 CRANE

5200/780:99900922: 20111219

1A-3

SECTION 1A. SPECIFICATIONS-780 CRANE

MODEL 780 CRANE SPECIFICATIONS

GENERAL

780-1H
7 ton-meters

780-2H
7 ton-meters

780-2H1M
7 ton-meters

HORIZONTAL REACH
from centerline of rotation

6.12m

8.03m

9.80m

HYDRAULIC EXTENSION

178cm

178cm x 2

178cm x 2

MANUAL EXTENSION

None

None

178cm

VERTICAL REACH
from mounting surface

8.08m

9.86m

11.53m

VERTICAL REACH
from ground / 102cm frame ht.

9.09m

10.87m

12.55m

**BASE CRANE WEIGHT

1090kg

1200kg

1235kg

STABILIZER SPAN

3.76m

3.76m

3.76m

STABILIZER PADS

30 x 30cm

30 x 30cm

30 x 30cm

CRANE STORAGE HEIGHT

from mounting surface

2.13m

2.13m

2.13m

CRANE STORAGE HEIGHT

from ground / 102cm frame ht.

3.15m

3.15m

3.15m

*MOUNTING SPACE REQUIRED

71cm

71cm

71cm

ROTATIONAL TORQUE

1120 kg-m

1120 kg-m

1120 kg-m

OPTIMUM PUMP CAPACITY

34 liters/minute

34 liters/minute

34 liters/minute

SYSTEM OPERATING PRESSURE

172 bar

172 bar

172 bar

OIL RESERVOIR CAPACITY

64 liters

64 liters

64 liters

HOOK APPROACH - HORIZONTAL

from centerline of rotation

89cm

94cm

94cm

HOOK APPROACH - VERTICAL

from mounting surface

2.06m

1.93m

1.93m

CRANE RATING (ANSI B30.22)

* Allow an additional 8cm between the cab and crane base for swing clearance.
** Without stabilizers, hydraulic oil reservoir and mounting accessories.

PERFORMANCE CHARACTERISTICS
ROTATION:
INNER BOOM ELEVATION:
OUTER BOOM ARTICULATION:
TELESCOPIC EXTENSIONS:
SINGLE STAGE EXTENSION:
VERTICAL STABILIZER STROKE:

POWER SOURCE

450/7.85 Rad.
-49 to +77/-.86 to 1.34 Rad.
139/2.43 Rad.
178/178cm
178cm
61cm

30 seconds
24 seconds
21 seconds
26 / 15 seconds
15 seconds
7 seconds

Integral-mounted hydraulic pump and PTO application. Other standard power sources may be utilized - minimum power
required is 17 horsepower.

5200/780:99900922: 20111219

1A-4

SECTION 1A. SPECIFICATIONS-780 CRANE

CYLINDER HOLDING VALVES

The holding sides of all standard cylinders are equipped with integral-mounted holding or counter-balance
valves to prevent sudden cylinder collapse in case of hose or other hydraulic failure. The stabilizer cylinders
have positive, pilot-operated holding valves that open only on command.
The inner cylinders have single pilot-operated counter balance valves while the outer and extension boom
cylinders have double counter-balance valves. The counter-balance valve serves several functions. First,
it is a holding valve. Secondly, it is so constructed that it will control the lowering function and allow that
motion to be feathered while under load. Finally, if a hose breaks, the only oil loss will be that in the hose.

ROTATION SYSTEM

Rotation of the crane is accomplished through a turntable bearing, powered by a high torque hydraulic
motor through a ring and pinion type spur gear train. Total gear reduction is 39.61 : 1.

HYDRAULIC SYSTEM

The hydraulic system is an open centered, full pressure system, requiring 34 liters/minute optimum oil flow,
at 172 bar. Eight-spool, stack-type control valve, six of which are used for the standard crane and the
remaining two are plugged, but easily adapted for additional optional features. Dual operational handles for
six functions are located at both sides of crane for convenient operation. System includes hydraulic oil
reservoir, suction-line strainer, pump, 8-section control valve, return-line filter and all hoses and fittings.

SELECTED WEIGHTS OF ANCILLARY EQUIPMENT

STABILIZERS
HYDRAULIC OIL RESERVOIR

167 kg
23 kg

IMT reserves the right to change specifications and design without notice.

IOWA MOLD TOOLING CO., INC.

BOX 189, GARNER, IA 50438-0189
TEL: 641-923-3711
FAX: 641-923-2424

5200/780:99900922:19961125

HOOK APPROACH DIMENSIONS

(1 HYD EXTENSION)

1A-5

SECTION 1A. SPECIFICATIONS-780 CRANE

STOWED POSITION AND STABILIZER

DIMENSIONS (1 HYD EXTENSION)

GEOMETRIC CONFIGURATION -1 HYD EXTENSION - MODEL 780 CRANE

5200/780:99900922: 19961125

HOOK APPROACH DIMENSIONS-2H/1M

1A-6

SECTION 1A. SPECIFICATIONS-780 CRANE

STOWED POSITION AND STABILIZER

DIMENSIONS - 2H/1M

GEOMETRIC CONFIGURATION-2HYD & 2HYD/1MNL EXTENSIONS-MODEL 780 CRANE

5200/780:99900922: 20000710

1A-7

SECTION 1A. SPECIFICATIONS-780 CRANE

CAPACITY CHART-MODEL 780 CRANE

5200/780:99900922: 19961125

1A-8

SECTION 1A. SPECIFICATIONS-780 CRANE

5200/780:99900922: 19961125

2-1

SECTION 2. CRANE REFERENCE

SECTION 2. 5200/780 CRANE REFERENCE

MAJOR CRANE ASSEMBLIES ....................................................................................... 3
WELDMENT PART NUMBER LOCATIONS .................................................................... 3
GREASE ZERK LOCATIONS & LUBRICANT REQUIREMENTS ................................... 4
RECOMMENDED SPARE PARTS LIST .......................................................................... 5
RECOMMENDED SPARE PARTS LIST (CONT.) ............................................................ 6
INSTALLATION ................................................................................................................ 7
CRANE MOUNTING ......................................................................................................... 7
HYDRAULIC INSTALLATION .......................................................................................... 8
WINCH TROUBLESHOOTING ........................................................................................ 9

5200/780:99900922: 19961125

2-2

NOTES

SECTION 2. CRANE REFERENCE

5200/780:99900922: 20111219

2-3

SECTION 2. CRANE REFERENCE

STABILIZER
SLEEVE
STABILIZER
ARM

STABILIZER
LEG

MAJOR CRANE ASSEMBLIES

STABILIZER
ARM

WELDMENT PART NUMBER LOCATIONS

STABILIZER
LEG

5200/780:99900922: 19961125

2-4

SECTION 2. CRANE REFERENCE

GREASE ZERK LOCATIONS & LUBRICANT REQUIREMENTS

ITEM
1.
2.
3.
4.
5.
6.
7.
8.
9.

LOCATION DESCRIPTION
DRIVE GEAR GREASE EXTENSION
TURNTABLE/BEARING GREASE EXTENSION
*ROTATE CRANE WHILE GREASING
PINION GEAR
MAST/INNER BOOM HINGE PIN
OUTER CYLINDER BASE
INNER CYLINDER ROD
OUTER CYLINDER ROD
INNER/OUTER BOOM HINGE PIN
EXTENSION CYLINDER ROD (2H ONLY)

LUBRICANT

FREQUENCY

SHELL ALVANIA 2EP

OR

WEEKLY

SHELL RETINAX A

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 Volume 1; Operation,
Maintenance and Repair for additional lubrication requirements.

5200/780:99900922:

20111219

2-5

SECTION 2. CRANE REFERENCE

RECOMMENDED SPARE PARTS LIST

1 YEAR SUPPLY
5200/780 CRANE
FOR MANUAL: 99900922

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. Part s not listed are considered as not being Critical or Normal Wear items during the first year of operations a nd you need to
contact the distributor or manufacturer for availability.
SHELF
ASSEMBLY
LIFE
ORDER
DESIGNATION
ITEM NO.
PART NO.
DESCRIPTION
QTY
CODE
(MO)
QTY
41712219.01.20010308

3B221850.01.19961125

41710870.01.19961125
41710920.01.19961125
3B270000.01.20001102

41710914.01.19961125

3C180920.01.19961125

41710943.01.19961125
3B200920.01.19961125

41710939.01.19961125

41710940.01.19961125

3K185920.01.19970721

(CONTINUED)

BASE AND POWER DOWN/MANUAL OUT STABILIZER ASM

9
60020115
BUSHING
10
60020116
BUSHING
11
60020187
BUSHING
12
60020188
BUSHING
22
60030053
ROLLER
30
71056265
PINION GEAR
POWER DOWN STABILIZER CYLINDER
3
6I025087
PISTON
4
6H025015
HEAD
5
73054004
WEAR PAD
9
9B101214
SEAL KIT
MAST ASM
2
7BF81520
BUSHING
INNER BOOM ASM
4
7BF81220
BUSHING
INNER BOOM CYLINDER
3
6I035125
PISTON
4
6H035025
HEAD
5
9C142020
SEAL KIT
16
73054887
CBAL VALVE
20
7BF81020
BUSHING
OUTER BOOM ASM
5
7BF81220
BUSHING
9
60030175
WEAR PAD
10
60030060
WEAR PAD
OUTER BOOM CYLINDER
3
6I045143
PISTON
4
6H045030
HEAD
5
9C182423
SEAL KIT
15
73054242
VALVE 25GPM
19
7BF81220
BUSHING
20
7BF81520
BUSHING
EXTENSION BOOM ASM - 1 HYDRAULIC
3
60030238
WEAR PAD-BEVELED
EXTENSION BOOM CYLINDER - 1H
3
6I302125
PISTON
4
6H030020
HEAD
5
73054242
COUNTERBALANCE VALVE
7
9C156920
SEAL KIT
EXTENSION BOOM ASM - 2 HYDRAULIC
16
60030173
WEAR PAD
17
60030172
WEAR PAD
18
60030174
WEAR PAD
22
60030060
WEAR PAD
EXTENSION BOOM ASM - 2 HYD/1 MNL
16
60030173
WEAR PAD
17
60030172
WEAR PAD
18
60030174
WEAR PAD
22
60030060
WEAR PAD
EXTENSION BOOM CYLINDER - 2H
5
6I095850
PISTON
6
6I025087
PISTON
7
6H271511
HEAD
8
6H112820
HEAD
11
73054242
VALVE
12
9X095850
SEAL KIT

1
1
1
1
2
1

W
W
W
W
W
C

1
1
2
2

W
W
C
W

12

1
1
2
2
8

W
W
W
C
W

4
1
2

W
W
W

1
1
1
2
2
2

W
W
W
C
W
W

1
1
2
1

W
W
C
W

1
1
1
2

W
W
W
W

1
1
1
2

W
W
W
W

1
1
1
1
2
1

W
W
W
W
C
W

5200/780:99900922: 20010419

2-6

SECTION 2. CRANE REFERENCE

RECOMMENDED SPARE PARTS LIST (CONT.)

ASSEMBLY
DESIGNATION
70732573.01.19980721

93704355.01.19980721
90716707.01.19961125

51713429.01.19961125

51713568.01.19961125

ITEM NO.

PART NO.

DESCRIPTION

RESERVOIR ASM
10
70144326 STRAINER
18
70034410
DIFFUSER
19
70732793
SCREEN
INSTALLATION KIT
73052006
ELEMENT 10MIC
70048149
ELEMENT 100 MESH
PROPORTIONAL REMOTE CONTROL KIT
5
73054876
FLOW VALVE
10
77041251
RELAY
11
77041237
SOLENOID 12V
PROPORTIONAL REMOTE HANDLE ASM
16
77040371
TOGGLE SWITCH SPST
17
77040372
TOGGLE SWITCH SPDT
18
77040373
TOGGLE SWITCH SPST
CABLE ASM-JIC BOX 94"
3
77041345
TOGGLE SWITCH ST
4
77041354
TOGGLE SWITCH DT
17
77041056
FUSE 20A IN-LINE

QTY

CODE

1
1
1

P
P
P

6
6

P
P

1
2
1

W
W
W

1
6
2

W
W
W

2
1
1

W
W
W

SHELF
LIFE
(MO)

ORDER
QTY

5200/780:99900922:

19961125

2-7

SECTION 2. CRANE REFERENCE

INSTALLATION
GENERAL
This section contains specific instructions for the
installation of your crane. Prior to installing the crane
and hydraulic components, make sure the chassis is
ready to receive the crane (refer to VOLUME 1,
Installation).

CRANE MOUNTING
1. See SPECIFICATIONS in Section 1 for crane
weight. Using an overhead hoist and fabric slings of
adequate capacity, lift the crane about a foot to see if
the crane is adequately balanced. If not, lower hoist
and adjust slings. Re-check balance and re-position
crane until mounting surface is level.
2. Install the truck frame support so that the tie- down
studs pass through the supports (See figure below).
Cut the support to the inside dimensions of the truck
frame. Allow about 1/6' (1.6mm) extra. Grind the end
of the support to fit inside the frame channel. Use a
hammer to drive it into position if necessary.

3. Allow sufficient clearance between the cab and

crane base, at least 5' (12.7cm). Position the crane on
the chassis per the applicable installation drawing,
centering the mounting slots over the truck frame rails.
While holding crane with hoist, start mounting
hardware per figure below. Note position of support
weldments on truck frame. Hand tighten nuts. Observe
underside of crane base. No clearance between base
and frame bars is allowed.
4. Torque the 1"-8 UNC Grade 5 mounting hardware
to 442 ft-lbs (62 kg-m). When torquing the mounting
hardware the following precautions must be followed:
A. Never use lock washers.
B. Hardened washers must be used, and under
the turning element, whether the turning element is the
nut or the head of the bolt.
C. Torque values specified are with residual oils
or without special lubricants applied to the threads. If
special lubricants are used, such as Never-Seize
compound graphite and oil, molybdenum disulphite
collodial copper or white lead, reduce torque values
10%. Torque values for threaded fasteners are not
affected with the use of Loctite.
D. Do not use rusty fasteners, the rust will alter
torque values significantly.
E. Touch-up paint around mounting anchor
plates.
CAUTION
DO NOT ATTEMPT TO APPLY THE SAME TORQUE
TO THE TIE ROD AND SELF-LOCKING NUTS AS
SHOWN IN THE TORQUE DATA CHART. DO NOT
EXCEED 442 FT-LBS (62 KG-M). EXCEEDING THIS
TORQUE VALUE COULD DAMAGE EITHER THE
CHASSIS OR CRANE BASE.
POWER WRENCHING IS NOT RECOMMENDED
UNTIL THE LEAD THREAD OF THE NUT INSERT IS
ENGAGED BY HAND TURNING.

CRANE INSTALLATION

5200/780:99900922: 19961125

2-8

SECTION 2. CRANE REFERENCE

7. Open the gate valve at the suction-line filter.

HYDRAULIC INSTALLATION
To install the hydraulic hoses, fittings, etc:
1. Install the hydraulic reservoir on the crane
base.
2. Plumb the suction-line filter as shown in figure
below.
3. Install the 1-1/4" suction hose between the
suction-line filter and the pump inlet. Tighten the
hose clamps.
4. Install the 1/2" pressure hoses between the
pump outlet and the inlet port on the valvebank.
5. Install the return filter and gate valve on the
reservoir. Install the hose between the valvebank
and return filter.

CAUTION
FAILURE TO OPEN THE GATE VALVE WILL RESULT
IN A DRY RUNNING PUMP WHICH MAY DAMAGE
THE PUMP.

8. Open the return gate valve.

9. Start the vehicles engine and engage the
PTO. Allow the system to run for about five
minutes and then check the vacuum gauge on the
suction-line filter (it should read 8" mercury or
less). If the vacuum reading is too high, check to
make certain that the gate valve is opened
completely. If the valve is fully opened, check for
a collapsed or restricted suction line.
10. Cycle all hydraulic functions. Check for leaks,
and refill the reservoir if necessary.

6. Fill the hydraulic reservoir to the FULL mark.

HYDRAULIC INSTALLATION

5200/780:99900922: 19961125

2-9

SECTION 2. CRANE REFERENCE

5200/780:99900922:

19961125

2-10

(BLANK)

SECTION 2. CRANE REFERENCE

5200/780: 99900922:20020724

3-1

SECTION 3. PARTS

SECTION 3. REPLACEMENT PARTS 5200/780 CRANE

PARTS INFORMATION ................................................................................................................................. 3
STD BASE & MNL OUT STABILIZER ASM (41712219-1) ............................................................................. 4
STD BASE & MNL OUT STABILIZER ASM (41712219-2) ............................................................................. 5
PWR DN STABILIZER CYL-STD (3B221850) ................................................................................................ 6
OPTION-PWR OUT STABILIZER KIT (31712253) ......................................................................................... 7
OPTION-PWR OUT STABILIZER CYL (3B220850) ....................................................................................... 8
MAST ASM (41710870) ................................................................................................................................. 9
INNER BOOM ASM (41710920) .................................................................................................................... 10
INNER BOOM CYL (3B270000) ..................................................................................................................... 11
OUTER BOOM ASM (41710914) ................................................................................................................... 12
OUTER BOOM CYLINDER (3C180920) ......................................................................................................... 13
EXT BOOM ASM-1H (41710943) ................................................................................................................... 14
EXT BOOM CYLINDER-1H (3B200920) ......................................................................................................... 15
EXT BOOM ASM-2H (41710939) ................................................................................................................... 16
EXT BOOM ASM-2H1M (41710940) .............................................................................................................. 17
EXT BOOM CYLINDER-2H (3K185920) ......................................................................................................... 18
BASE & PWR OUT STABILIZER ASM (41712220-1) .................................................................................... 19
BASE & PWR OUT STABILIZER ASM (41712220-2) .................................................................................... 20
RESERVOIR ASM (70732573) ....................................................................................................................... 21
INSTALLATION KIT (93704355) .................................................................................................................... 22
DECAL KIT-5200 SERIES CRANE (95712260-1) ............................................................................................ 23
DECAL KIT-5200 SERIES CRANE (95712260-2) ............................................................................................ 24
HYDRAULIC KIT (91710962) ......................................................................................................................... 25
SELECTOR VALVE-HYDRAULIC SCHEMATIC (31717782) ........................................................................... 26
HYDRAULIC OVERLOAD KIT (51717127) ..................................................................................................... 27
VB ASM-8 SECT/MNL (51710944) ................................................................................................................ 28
VALVEBANK (70731499) ............................................................................................................................... 28
VB ASM 4R/4M (51711707) ........................................................................................................................... 29
VALVEBANK (70732848) ............................................................................................................................... 29
VB ASM 5R/3M (51711706) ........................................................................................................................... 30
VALVEBANK (70732847) ............................................................................................................................... 30
VB ASM 6R/2M (51711708) ........................................................................................................................... 31
VALVEBANK (70732849) ............................................................................................................................... 31
CONTROL KIT 6F MNL (90704417) .............................................................................................................. 32
PROPL RMT CONTROL KIT (90716707) ..................................................................................................... 33
PROPL RMT HANDLE ASM (51713429) ...................................................................................................... 35
TETHERED PROPORTIONAL REMOTE POTENTIOMETER ADJUSTMENT ................................................ 35
CABLE ASM-JIC BOX 94" (51713568) .......................................................................................................... 36
OPTION-DBL HOSE REEL KIT (31712113) ................................................................................................... 37
OPTION-WINCH KIT (31717776) ................................................................................................................... 38
OPTION-WINCH KIT (31717776) ................................................................................................................... 39
OPTION-CABLE & HOOK KIT (31705637) .................................................................................................... 40
TWO-BLOCK DAMAGE PREVENTION KIT (51724350 / DWG 99905344) .................................................... 41

5200/780: 99900922:20020724

3-2

SECTION 3. PARTS

CAPACITY ALERT KIT - 3100 (31713333) ..................................................................................................... 43

OPTION-AUGER MTG KIT (51707059) ......................................................................................................... 44
OPTION -AUGER HOSE REEL KIT-V20 (51707805) ...................................................................................... 45
OPTION-AUX RESERVOIR-30GAL (31701760) ............................................................................................. 46
OPTION-SGL HOSE REEL KIT (31712487) .................................................................................................. 47
OPTION - LIGHT KIT (31717218) .................................................................................................................. 48
DECAL KIT-MODEL 780 CRANE (95711801-1) .............................................................................................. 49
DECAL KIT-MODEL 780 CRANE (95711801-2) .............................................................................................. 50
RADIO REMOTE RETROFIT KIT (99903330-1) ............................................................................................ 51
ELEC. SCHEMATIC - RADIO REMOTE RETROFIT (99903330-2) .................................................................. 52
CABLE ASM-18GA/24 WIREX115 (51714624) .............................................................................................. 53
JIC BOX ASM-RADIO REMOTE (51717059) ................................................................................................. 54
RADIO REMOTE KIT (73733600-1) ............................................................................................................... 55
RADIO REMOTE KIT (73733600-2) ............................................................................................................... 56

5200/780: 99900922.01.20111219

3-3

SECTION 3. PARTS

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
REPAIR section in Volume 1. 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 IN VOLUME
1. PAY PARTICULAR ATTENTION TO STATEMENTS
MARKED WARNING, CAUTION, OR NOTE IN THAT
SECTION. F AILURE 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) attached to the mast. When ordering p arts,
communicating warranty information, or referring to
the unit in correspondence, always include the serial
number and model numbers. All inquiries should be
addressed to:
Iowa Mold Tooling Co., Inc.
Box 189, Garner, IA 50438-0189
Telephone: 641-923-3711
Product Support Fax: 641-923-2424

SERIAL NUMBER PLACARD

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 p arts.

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 figure
below.

ORDERING REPAIR PARTS

When ordering replacement p arts:

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 p art.
5. Specify the quantity required.

CYLINDER PART NUMBER LOCATION

5200/780: 41712219.01.REV. M 20111219

3-4

SECTION 3. PARTS

STD BASE & MNL OUT STABILIZER ASM

(41712219-1)
ITEM PART NO.

1.
2.
3.
5.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
33.
34.
35.

3B221850
99903611
70732573
71145016
52070138
52712217
60020115
60020116
60020187
60020188
71056011
52712252
52705871
53000714
53000717
60107648
60010235
60010351
60010844
60030053
60102767
60106032
60106314
60106886
60106968
60102769
71056264
71056265
71056627
72053301
72053508
72060002

DESCRIPTION

POWER DOWN CYLINDER

INSTRUCTIONS, HYD SHUTDN
RESERVOIR ASM
STOP BLOCK
T PIN
BASE (INCL. 9-13)
BUSHING (PART OF 8)
BUSHING (PART OF 8)
BUSHING (PART OF 8)
BUSHING (PART OF 8)
DRIVE GEAR (PART OF 8)
ARM
LEG
GREASE EXTENSION
GREASE EXTENSION
HOSE CLAMP
PINION COVER
SPRING
GREASE PLATE
ROLLER
ACCESS COVER
STUD 1/2-13 X 2
PIN
PINION SPACER
PIN
GEAR GUARD-INTERMEDIATE
INTERMEDIATE GEAR
PINION GEAR
TURNTABLE GEAR-BEARING
COUPLING 1/8NPT
ZERK, GREASE, 1/8 NPT
CAP SCR 1/4-20 X 3/4 HH GR5

NOTE

QTY

2
1REF
1
1
2
1
1REF
1REF
1REF
1REF
1REF
2
2
1
1
2
1
2
1
4
1
2
4
1
2
1
1
1
1
2
3
2

INSTALL 70399271 - DECAL-FULLY DEPLOYED - ON TOP

OF STABILIZER BEAMS WHEN BEAMS ARE FULLY
EXTENDED. DECAL MUST BE VISIBLE.

CONTINUED ON FOLLOWING PAGE

36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.

55.
56.
58.
59.
60.
61.
62.
64.
65.
66.
67.
68.
69.
70.

72060054
72060092
72060102
72060833
72062080
72062103
72062107
72063002
72053281
72063027
72063039
72063049
72063053
72063116
72066095
72066178
72060207
73540004
73051004
73054538
72060738
5V151830
7Q072112
72066125
72066185
72060046
72063003
60108883
70058060
89393036
72531826
72060023
72063050
60119748
72060006
72063001
72062104

CAP SCR 3/8-16 X 3 HH GR5 2

CAP SCR 1/2-13 X 1-1/4 HH GR5 2
CAP SCR 1/2-13 X 5-1/2 HH GR5 4
CAP SCR 5/16 X 3/4 HH SLFTPG 2
NUT 1/2-13 LOCK
2
NUT 3/8-16 LOCK
8
NUT 1/2-13 CTR LOCK
4
WASHER 5/16 WRT
2
STRT ELBOW 1/8 NPT 90o
1
MACH BUSHING 5/8 X 14GA
2
MACH BUSHING 2 X 10GA
1
WASHER 1/4 LOCK
2
WASHER 1/2 LOCK
2
WASHER 3/4 FLAT HARD
20
RETAINING RING 2" EXT
1
COTTER PIN 1/8 X 1
8
CAP SCR 3/4-10 X 3 HH GR8
20
HYD MOTOR (FROM 5-15-98)
1
HYD MOTOR (TO 5-15-98)
1
CBALANCE VALVE (TO 5-15-98) 2
CAP SCR (TO 5-15-98)
4
MOTOR BLOCK (TO 5-15-98)
1
O-RING (TO 5-15-98)
2
RETAINING RING 1" EXT HD
4
COTTER PIN
2
CAP SCR 3/8-16 X 1 HH GR5
4
WASHER 3/8 WRT
10
CHAIN
2
LINK, COLD SHUT
2
SLEEVE
5
RED. BUSHING 1/4 X 1/8 NPT
1
CAP SCR 5/16-18 X 3/4 HH GR5 2
WASHER 5/16 LOCK
2
GUARD-CTRL HANDLE
2
CAP SCR 1/4-20X1-1/2 HHGR5 8
WASHER 1/4 WRT
16
NUT 1/4-20 LOCK
8

5200/780: 41712219.01.20111219

3-5

SECTION 3. PARTS

STD BASE & MNL OUT STABILIZER ASM

(41712219-2)
WARNING
ANYTIME A GEAR-BEARING BOLT IS REMOVED, IT
MUST BE REPLACED WITH A NEW BOLT OF THE
IDENTICAL GRADE AND SIZE. F AILURE TO
REPLACE GEAR-BEARING BOLTS MAY RESULT IN
BOLT FAILURE DUE TO METAL FATIGUE, CAUSING
SERIOUS INJURY OR DEATH.

CAUTION
BEFORE TIGHTENING TURNTABLE BEARING
BOLTS, REFER TO THE TURNTABLE BEARING
FASTENER TIGHTENING SEQUENCE AND TORQUE
DATA CHART IN THE REFERENCE SECTION.

5200/780: 3B221850.01.REV C 20120410

3-6

PWR DN STABILIZER CYL-STD

(3B221850)
ITEM PART NO

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.

DESCRIPTION

4B221850 CASE (INCL:6)

2G221850 ROD
6I025087
PISTON
6H025015 HEAD
73054004
LOCKING/ HOLDING VALVE
7PNPXT02 PLUG 1/8NPT (PART OF 1)
6C150015 STOP TUBE
72060708
CAP SCR 1/4-20 X 1 1/4 SH
9B101214 SEAL KIT (INCL:10-18)
7Q072137 O-RING (PART OF 9)
7T66P025 SEAL, PISTON (PART OF 9)
7T61N087 LOCK RING SEAL (PART OF 9)
7T2N8015 WEAR RING (PART OF 9)
60138272 STOP TUBE (PART OF 9)
(WAS 6A025015)
7Q072228 O-RING (PART OF 9)
7Q10P228 BACK-UP RING (PART OF 9)
7R546015 ROD SEAL (PART OF 9)
7R14P015 ROD WIPER (PART OF 9)
60125699 PIN-LOCK TUBE (PART OF 9)

QTY

1
1
1
1
1
3REF
1
6
1
1REF
1REF
1REF
1REF
1REF
1REF
1REF
1REF
1REF
1REF

SECTION 3. PARTS

NOTE
IT IS RECOMMENDED THAT ALL COMPONENTS OF
THE SEAL KIT BE REPLACED WHENEVER THE
CYLINDER IS DISASSEMBLED. THIS WILL REDUCE
FUTURE DOWNTIME.
APPLY
LUBRIPLATE
#630-2
MEDIUM
HEAVY,MULTI-PURPOSE LUBRICANT OR
EQUIVALENT TO ALL PISTON, HEAD GLAND, AND
HOLDING VALVE SEALS, NYLON LOCK RING, CAST
IRON PISTON RINGS, AND ROD STINGER
THREADS.
APPLY NEVER-SEEZ REGULAR GRADE ANTISEIZE AND LUBRICATING COMPOUND TO
CYLINDER HEAD AND CASE THREADS.

5200/780: 31712253.01.20111219

OPTION-PWR OUT STABILIZER KIT

(31712253)
ITEM PART

1.
2.
3.
4.
6.
7.
8.
9.

3B220850
51703590
51704280
70029451
72053758
71039096
72060928
72062080

DESCRIPTION

POWER OUT CYLINDER

HOSE ASSEMBLY 1/4X23
HOSE ASSEMBLY 1/4X40
CONTROL HANDLE
ELBOW 7/16MSTR 7/16MJIC 90
KNOB
CAP SCR 1/2-13X2-1/4 HHGR5
NUT1/2-13 LOCK

3-7

QTY

2
2
4
2
4
2
4
4

SECTION 3. PARTS
10.
11.
12.
13.
15.
16.
17.
18.
21.
22.
23.

72532707
72532768
72066168
72066338
52704745
72066336
72066337
52704744
71382277
70392864
70399271

ADAPTER #4MJIC #6FJIC

TEE 7/16MJIC
COTTER PIN
CLEVIS PIN
CONTROL ROD - MALE
COTTER PIN
PIN
CONTROL ROD - FEMALE
DECAL- PWR OUT STAB
DECAL - WARN STAB STD CLR
DECAL-FULLY DEPLOYED

STABILIZER

NOTE: INSTALL # 23, DECAL,AT FULL STAB EXTENSION

2
2
2
2
2
1
1
1
2
2
2

5200/780: 3B220850.01.20111219

OPTION-PWR OUT STABILIZER CYL

(3B220850)

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

4B220850
4G220850
6C125007
6H012007
6I012050
9B050608
7Q072021
7Q072214
7Q10P214
7R100750
7R13P007
7T66P012
72066029

CASE ASM
ROD ASM
STOP TUBE 1-1/4
HEAD
PISTON
SEAL KIT (INCL:7-12)
O-RING (PART OF 6)
O-RING (PART OF 6)
BACK-UP RING (PART OF 6)
U-CUP SEAL (PART OF 6)
ROD WIPER (PART OF 6)
PISTON SEAL (PART OF 6)
RETAINING RING

3-8

1
1
1
1
1
1
1REF
1REF
1REF
1REF
1REF
1REF
1

SECTION 3. PARTS

NOTE
IT IS RECOMMENDED THAT ALL COMPONENTS OF
THE SEAL KIT BE REPLACED WHENEVER THE
CYLINDER IS DISASSEMBLED. THIS WILL REDUCE
FUTURE DOWNTIME.
APPLY
LUBRIPLATE
#630-2 MEDIUM
HEAVY,MULTI-PURPOSE LUBRICANT OR
EQUIVALENT TO ALL PISTON, HEAD GLAND, AND
HOLDING VALVE SEALS, NYLON LOCK RING, CAST
IRON PISTON RINGS, AND ROD STINGER
THREADS.
APPLY NEVER-SEEZ REGULAR GRADE ANTISEIZE AND LUBRICATING COMPOUND TO
CYLINDER HEAD AND CASE THREADS.

5200/780: 41710870.01.19961125

MAST ASM (41710870)

ITEM PART NO.

1.
2.
3.
4.
5.
6.
7.
8.
9.

52710871
7BF81520
60010118
60104539
70029119
72060931
72062103
72063119
72066340

DESCRIPTION

3-9
QTY

MAST (INCL:2)
1
BUSHING (PART OF 1)
2REF
HOSE CLAMP
2
PINION GEAR COVER
1
SERIAL NO. PLACARD
1
CAP SCR 5/8-11X2-3/4 HH GR8 18
NUT 3/8-16 LOCK
2
WASHER 5/8 FLAT HARD
18
POP RIVET 1/8
2

SECTION 3. PARTS

WARNING
ANYTIME A GEAR-BEARING BOLT IS REMOVED,
IT MUST BE REPLACED WITHA NEW BOLT OF THE
IDENTICAL GRADE AND SIZE. F AILURE TO
REPLACE GEAR-BEARING BOLTS MAY RESULT IN
BOLT FAILURE DUE TO METAL FATIGUE, CAUSING
SERIOUS INJURY OR DEATH.
CAUTION
BEFORE TIGHTENING TURNTABLE BEARING
BOLTS, REFER TO THE TURNTABLE BEARING
FASTENER TIGHTENING SEQUENCE AND
TORQUE DATA CHART IN THE REFERENCE
SECTION.

5200/780: 41710920.01.20001102

INNER BOOM ASM (41710920)

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

3B270000
52704342
52710909
7BF81220
60106331
60107303
60107305
60010118
72053508
72060049
72060147
72062103
60109337

INNER CYLINDER
2
PIN
1
INNER BOOM (INCL:4)
1
BUSHING (PART OF 3)
12REF
PIN RETAINER PLATE
4
PIN
1
PIN
2
HOSE CLAMP
1
ZERK 1/8NPT
1
CAP SCR 3/8-16X1-3/4 HH GR5 1
CAP SCR 5/8-11X1 HH GR5
7
NUT 3/8-16 LOCK
1
PIN RETAINER PLATE
3

3-10

SECTION 3. PARTS

NOTE
ANYTIME THE PIN RETAINER PLATE BOLTS HAVE
BEEN REMOVED, APPLY LOCTITE 262 TO THE
THREADS BEFORE RE-ASSEMBLY.

5200/780: 3B270000.01.20001102

INNER BOOM CYL (3B270000)

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.

4B142920
4H142920
6I035125
6H035025
9C142020
7Q072338
7Q10P338
7T2N8027
7R546025
7R14P025
7Q072151
7T66P035
7T65I035
7T61N125
6A025025
73054887
6C150025
6C300025
72053507
7BF81020
7PNPXT02

CASE ASM (INCL: 20 & 21)

ROD ASM (INCL: 19 & 20)
PISTON
HEAD
SEAL KIT (INCL:6-15)
O-RING (PART OF 5)
BACK-UP RING (PART OF 5)
WEAR RING (PART OF 5)
ROD SEAL (PART OF 5)
ROD WIPER (PART OF 5)
O-RING (PART OF 5)
PISTON SEAL (PART OF 5)
PISTON RING (PART OF 5)
LOCK RING (PART OF 5)
WAFER LOCK (PART OF 5)
CBAL VALVE
STOP TUBE
STOP TUBE
ZERK 1/4-28(PART OF 2)
BUSHING (PART OF 1 & 2)
PLUG 1/8NPT (PART OF 1)

3-11
1
1
1
1
1
1REF
1REF
1REF
1REF
1REF
1REF
1REF
2REF
1REF
1REF
1
1
1
1REF
4REF
3REF

SECTION 3. PARTS

NOTE
IT IS RECOMMENDED THAT ALL COMPONENTS OF
THE SEAL KIT BE REPLACED WHENEVER THE
CYLINDER IS DISASSEMBLED. THIS WILL REDUCE
FUTURE DOWNTIME.
APPLY
LUBRIPLATE
#630-2 MEDIUM
HEAVY,MULTI-PURPOSE LUBRICANT OR
EQUIVALENT TO ALL PISTON, HEAD GLAND, AND
HOLDING VALVE SEALS, NYLON LOCK RING, CAST
IRON PISTON RINGS, AND ROD STINGER
THREADS.
APPLY NEVER-SEEZ REGULAR GRADE ANTISEIZE AND LUBRICATING COMPOUND TO
CYLINDER HEAD AND CASE THREADS.

5200/780: 41710914.01.REV. E 20060616

OUTER BOOM ASM (41710914)

ITEM PART NO.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

3C180920
52704432
52704341
52710916
7BF81220
60109337
72053508
72060147
60030175
60030060
60107550
72063051
72060044
52703767
70392190
72060002

DESCRIPTION

OUTER CYLINDER
PIN
PIN
OUTER BOOM (INCL:5)
BUSHING (PART OF 4)
PIN RETAINER PLATE 3"
ZERK 1/8NPT
CAP SCR 5/8-11X1 HH GR5
WEAR PAD
WEAR PAD
LOCK PLATE
WASHER 3/8 LOCK
CAP SCR 3/8-16X3/4 HH GR5
PIN
BUMPER
CAP SCR 1/4-20X3/4 HHGR5

3-12
QTY

1
1
1
1
4REF
3
2
3
1
2
2
4
4
1
1
1

SECTION 3. PARTS

NOTE
ANYTIME THE PIN RETAINER PLATE BOLTS HAVE
BEEN REMOVED, APPLY LOCTITE 262 TO THE
THREADS BEFORE RE-ASSEMBLY.

5200/780: 3C180920.01.REV. D 20120417

3-13

OUTER BOOM CYLINDER (3C180920)

ITEM PART NO.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.

DESCRIPTION

QTY

4C258870 CASE ASM (INCL:20-22)

1
52718647 ROD (INCL:19,21) (WAS 4H180920) 1
6I045143
PISTON
1
6H045030 HEAD
1
9C182423 SEAL KIT (INCL:6-14,18)
1
7Q072345 O-RING (PART OF 5)
1REF
7Q10P346 BACK-UP RING (PART OF 5)
1REF
7T2N8032 ROD WEAR RING (PART OF 5) 1REF
7R546030 U-CUP SEAL (PART OF 5)
1REF
7R14P030 ROD WIPER (PART OF 5)
1REF
7Q072155 O-RING (PART OF 5)
1REF
7T66P045 PISTON SEAL (PART OF 5)
1REF
7T65I045
PISTON RING (PART OF 5)
2REF
7T61N143 LOCK RING (PART OF 5)
1REF
73054242
VALVE 25GPM
2REF
6C150030 STOP TUBE 1-1/2
1
6C300030 STOP TUBE 3
1
60138277 STOP TUBE (PART OF 5)
1REF
(WAS 6A025030)
7BF81220 BUSHING (PART OF 2)
2REF
7BF81520 BUSHING (PART OF 1)
2REF
72053507
ZERK 1/4-28 (PART OF 1 & 2)
2REF
7PNPXT02 PLUG 1/8NPT (PART OF 1)
2REF
60125699 PIN-LOCK TUBE
1

SECTION 3. PARTS

NOTE
IT IS RECOMMENDED THAT ALL COMPONENTS OF
THE SEAL KIT BE REPLACED WHENEVER THE
CYLINDER IS DISASSEMBLED. THIS WILL REDUCE
FUTURE DOWNTIME.
APPLY
LUBRIPLATE
#630-2
MEDIUM
HEAVY,MULTI-PURPOSE LUBRICANT OR
EQUIVALENT TO ALL PISTON, HEAD GLAND, AND
HOLDING VALVE SEALS, NYLON LOCK RING, CAST
IRON PISTON RINGS, AND ROD STINGER
THREADS.
APPLY NEVER-SEEZ REGULAR GRADE ANTI-SEIZE
AND LUBRICATING COMPOUND TO CYLINDER HEAD
AND CASE THREADS.
ITEM #18, STOP TUBE, REPLACES 6A025030 WAFER
LOCK. USE STOP TUBE INSTEAD OF WAFER LOCK
WHEN RESEALING CYLINDER.
PRESS LOCKING PIN (ITEM #23) INTO #15 HOLE
DRILLED 0.188" DEEP.

5200/780: 41710943.01.REV. A 20061031

EXT BOOM ASM-1H (41710943)

ITEM PART NO.

1.
2.
3.
4.
5.
6.
7.

3B200920
52710942
60030238
52705801
60108902
60107324
60107324

DESCRIPTION

EXTENSION CYLINDER-1H
1ST STG EXTENSION BOOM
WEAR PAD-BVLD
PIN (PART OF 11)
PIPE (PART OF 11)
HOOK LINK (PART OF 11)
SWIVEL HOOK 8-TON
(PART OF 11) (WAS 60103575)

3-14

SECTION 3. PARTS
8. 72601666

QTY

1
1
1
1REF
1REF
2REF
1REF

9.
10.
11.
12.
13.
14.

72062073
72066145
51706200
60107292
72060091
72063053

CAP SCR 1 1/4-7X4 HH GR5

(PART OF 11)
1REF
NUT 1 1/4-7 LOCK (PART OF 11) 1REF
HAIR PIN 3/16 (PART OF 11)
1REF
HOOK ASM (INCL:4-10)
1
LOCK PLATE
4
CAP SCR 1/2-13X1 HH GR5
8
WASHER 1/2 LOCK
8

5200/780: 3B200920.01.19961125

3-15

EXT BOOM CYLINDER-1H (3B200920)

ITEM PART NO.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.

4B200920
4G200920
6I302125
6H030020
73054242
6C150020
9C156920
6A025020
7T66P300
7T61N125
7T2N4030
7Q072124
7Q072334
7Q10P334
7T2N4022
7R546020
7R14P020
7PNPXT02

DESCRIPTION

CASE ASM (INCL: 18)

ROD ASM
PISTON
HEAD
COUNTERBALANCE VALVE
STOP TUBE
SEAL KIT (INCL:8-17)
WAFER LOCK (PART OF 7)
PISTON SEAL (PART OF 7)
LOCK RING (PART OF 7)
WEAR RING (PART OF 7)
O-RING (PART OF 7)
O-RING (PART OF 7)
BACKUP RING (PART OF 7)
ROD WEAR RING (PART OF 7)
U-CUP SEAL (PART OF 7)
ROD WIPER (PART OF 7)
PLUG 1/8NPT (PART OF 1)

QTY

1
1
1
1
2
2
1
1REF
1REF
1REF
2REF
1REF
1REF
1REF
1REF
1REF
1REF
8REF

NOTE
IT IS RECOMMENDED THAT ALL COMPONENTS OF
THE SEAL KIT BE REPLACED WHENEVER THE
CYLINDER IS DISASSEMBLED. THIS WILL REDUCE
FUTURE DOWNTIME.
APPLY
LUBRIPLATE
#630-2 MEDIUM
HEAVY,MULTI-PURPOSE LUBRICANT OR
EQUIVALENT TO ALL PISTON, HEAD GLAND, AND
HOLDING VALVE SEALS, NYLON LOCK RING, CAST
IRON PISTON RINGS, AND ROD STINGER
THREADS.
APPLY NEVER-SEEZ REGULAR GRADE ANTISEIZE AND LUBRICATING COMPOUND TO
CYLINDER HEAD AND CASE THREADS.

SECTION 3. PARTS

5200/780: 41710939.01.REV. D 20061031

EXT BOOM ASM-2H (41710939)

ITEM PART NO.

1.
2.
3.
4.
5.
6.
7.

3K185920
51706200
52705801
60108902
60107324
72062073
70734177

8. 72601666
9. 72066145
10. 52710941

DESCRIPTION

TELESCOPIC CYLINDER
HOOK ASM (INCL:3-9)
PIN (PART OF 2)
SPACER (PART OF 2)
HOOK LINK (PART OF 2)
NUT 1 1/4-7 LOCK (PART OF 2)
SWVL HOOK 8TON (PART OF 2)
(WAS 60103575)
CAP SCR 1 1/4-7X4 HHGR5
(PART OF 2)
HAIR PIN 3/16 (PART OF 2)
1ST STG EXT BOOM

3-16
QTY

1
1
1REF
1REF
2REF
1REF
1REF
1REF
1REF
1

SECTION 3. PARTS
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.

52706708
60101906
60107292
72060091
72063053
60030173
60030172
60030174
60020197
72066125
72063010
60030060
60107550
72063051
72060044

2ND STG EXT BOOM

PIN
LOCK PLATE
CAP SCR 1/2-13X1 HH GR5
WASHER 1/2 LOCK
WEAR PAD
WEAR PAD
WEAR PAD
ROLLER
RETAINING RING 1"
WASHER 1 WRT
WEAR PAD
LOCK PLATE
WASHER 3/8 LOCK
CAP SCR 3/8-16X3/4 HH GR5

1
1
4
8
8
1
1
1
2
2
2
2
2
4
4

5200/780: 41710940.01.REV. E 20061030

EXT BOOM ASM-2H1M (41710940)

ITEM PART NO.

1.
2.
3.
4.
5.
6.
7.

3K185920
51706200
52705801
60108902
60107324
72062073
70734177

8. 72601666
9.
10.
11.
12.
13.

72066145
52710941
52706708
60101906
60107292

DESCRIPTION

TELESCOPIC CYLINDER
HOOK ASM (INCL:3-9)
PIN (PART OF 2)
SPACER (PART OF 2)
HOOK LINK (PART OF 2)
NUT 1 1/4-7 LOCK (PART OF 2)
SWVL HOOK 7TON (PART OF 2)
(WAS 60103575)
CAP SCR 1 1/4-7X4 HHGR5
(PART OF 2)
HAIR PIN 3/16 (PART OF 2)
1ST STG EXT BOOM
2ND STG EXT BOOM
PIN
LOCK PLATE

3-17
QTY

1
1
1REF
1REF
2REF
1REF
1REF
1REF
1REF
1
1
1
4

SECTION 3. PARTS
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.

72060091
72063053
60030173
60030172
60030174
60020197
72066125
72063010
60030060
60107550
72063051
72060044
52710938
52704383
72066145
60107294
72060094

CAP SCR 1/2-13X1 HHGR5

8
WASHER 1/2 LOCK
10
WEAR PAD
1
WEAR PAD
1
WEAR PAD
1
ROLLER
2
RETAINING RING 1"
2
WASHER 1 WRT
2
WEAR PAD
2
LOCK PLATE
2
WASHER 3/8 LOCK
4
CAP SCR 3/8-16X3/4 HHGR5
4
3RD STG EXT BOOM
1
PIN
1
HAIR PIN 3/16
1
STOP
1
CAP SCR 1/2-13X1-3/4 HHGR5
2

5200/780: 3K185920.01.REV D 20120419

3-18

EXT BOOM CYLINDER-2H (3K185920)

ITEM PART NO.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.

DESCRIPTION

4K185920 CASE ASM (INCL:29)

4H185920 CASE/ROD ASM
4G185920 ROD ASM (INCL:30)
4FG12085 MOUNTING RING
6I095850
PISTON
6I025087
PISTON
6H271511 HEAD
6H112820 HEAD
6C300015 STOP TUBE 3"
6C050015 STOP TUBE 1/2"
73054242
VALVE
9X095850 SEAL KIT (INCL:13-28,31)
7R546035 U-CUP SEAL (PART OF 12)
7R14P035 ROD WIPER (PART OF 12)
7Q072342 O-RING (PART OF 12)
7Q10P342 BACK-UP RING (PART OF 12)
7Q072153 O-RING (PART OF 12)
7T66P040 PISTON SEAL (PART OF 12)
7Q072147 O-RING (PART OF 12)
7T65I040
PISTON RING (PART OF 12)
7R546015 U-CUP SEAL (PART OF 12)
7R14P015 ROD WIPER (PART OF 12)
7Q072228 O-RING (PART OF 12)
7Q10P228 BACK-UP RING (PART OF 12)
7Q072137 O-RING (PART OF 12)
7T66P025 PISTON SEAL (PART OF 12)
7T61N087 LOCK RING (PART OF 12)
60138272 STOP TUBE (PART OF 12)
(WAS 6A025015)
7PNPXT02 PLUG 1/8NPT (PART OF 1)
72053507
ZERK 1/4-28 (PART OF 3)
7T2N4037 WEAR RING (PART OF 12)
7T2N8015 WEAR RING (PART OF 12)

QTY

1
1
1
1
1
1
1
1
1
1
2
1
1REF
1REF
1REF
1REF
1REF
1REF
1REF
2REF
1REF
1REF
1REF
1REF
1REF
1REF
1REF
1REF
8REF
1REF
1REF
1REF

NOTE
IT IS RECOMMENDED THAT ALL COMPONENTS OF
THE SEAL KIT BE REPLACED WHENEVER THE
CYLINDER IS DISASSEMBLED. THIS WILL REDUCE
FUTURE DOWNTIME.
APPLY
LUBRIPLATE
#630-2
MEDIUM
HEAVY,MULTI-PURPOSE LUBRICANT OR
EQUIVALENT TO ALL PISTON, HEAD GLAND, AND
HOLDING VALVE SEALS, NYLON LOCK RING, CAST
IRON PISTON RINGS, AND ROD STINGER
THREADS.
APPLY NEVER-SEEZ REGULAR GRADE ANTI-SEIZE
AND LUBRICATING COMPOUND TO CYLINDER HEAD
AND CASE THREADS.
ITEM #28, STOP TUBE, REPLACES 6A025015 WAFER
LOCK. USE STOP TUBE INSTEAD OF WAFER LOCK
WHEN RESEALING CYLINDER.
1ST STAGE CYLINDER TORQUES: PISTON: 100-130
FT-LB, HEAD: 350 FT-LB, CARTRIDGE - 30-35 FT-LB.
2ND STAGE CYLINDER TORQUES: PISTON: 100-130
FT-LB, HEAD: 250 FT-LB, CARTRIDGE - 30-35 FT-LB.

SECTION 3. PARTS

5200/780: 41712220.01.REV. K 20111219

BASE & PWR OUT STABILIZER ASM

(41712220-1)

1.
3.
5.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
46.
47.
48.
49.
50.
51.
52.
53.
55.
56.
58.
59.
60.
61.
62.
63.
64.
65.
66.

3B221850
70732573
71145016
52712214
60020115
60020116
60020187
60020188
71056011
52712252
52705871
53000714
53000717
60107648
60010235
60010844
60030053
60102767
60106032
60106314
60106886
60106968
60102769
71056264
71056265
71056627
72053301
72053508
72060002
72060053
72060092
72060102
72060833
72062080
72062103
72062107
72063002
72063003
72063039
72063049
72063053
72063116
72066095
72066178
72060207
73540004
72066125
72053281
72060046
72063003
72531826
72060023
72063050
60119748
72060005
72063001
72062104

CYLINDER
2
RESERVOIR ASM 3625/4825
1
SLIDING STOP BLOCK
1
BASE (INCL 9-13)
1
BUSHING
1REF
BUSHING
1REF
BUSHING
1REF
BUSHING
1REF
DRIVE GEAR
1REF
ARM, OR
2
LEG, OR
2
EXT, GREASE
1
EXT, GREASE
1
CLAMP, HOSE
2
CLOVER, PINION GEAR
2
PLATE, GREASE
1
ROLLER
4
ACCESS HOLE COVER
1
STUD, MOTOR BRK
2
PIN, TYPE O
4
SPACER, PINION GEAR
1
PIN-TYPE A
2
GUARD, INT. GEAR
1
GEAR, INTERMEDIATE
1
GEAR, PINION
1
GEAR, TURNTABLE BEARING
1
COUPLING, BLK 1/8
2
ZERK, GREASE 1/8
3
CAP SCR 1/4-20 X 3/4 HH GR5Z 2
CAP SCR 3/8-16 X 2.75 HH GR5Z 2
CAP SCR 1/2-13 X 1.25 HH GR5Z 2
CAP SCR 1/2-13 X 5.5 HH GR5Z 4
SCR, SELF-TAP 5/16-18 X 3/4 HH 2
NUT, LOCK 1/2-13 HEX
2
NUT, LOCK 3/8-16 HEX
8
NUT, CTR LOCK 1/2-13 HEX
4
WASHER, WRT 5/16
2
WASHER, WRT 3/8
2
MACH BUSHING 2.00 X 10 GA NR 1
LOCKWASHER 1/4
2
LOCKWASHER 1/2
2
WASHER, FLAT 3/4
20
RING, RETAINER, EXT 2 STD
1
COTTER PIN, 1/8
8
CAP SWCR 3/4-10 X 3.0 HH GR8 20
MOTOR ASM
1
RING, RETAINING EXT 1 HD
4
ELBOW, STR 1/8
1
CAP SCR 3/8-16 X 1 HH GR5Z
4
WASHER, WRT 3/8
8
RED BUSHING, STL 1/4-1/8
1
CAP SCR 5/16-18 X 3/4 HH GR5Z 2
LOCKWASHER 5/16
2
CONTROL HANDLE GUARD
2
CAP SCR 1/4-20 HH GR5
8
WASHER 1/4 FLAT
16
NUT 1/4-20 HEX SELF-LOCK
8

3-19

SECTION 3. PARTS
DRAWING VIEW ON NEXTPAGE

5200/780: 41712220.02.20111219

BASE & PWR OUT STABILIZER ASM

(41712220-2)

3-20

SECTION 3. PARTS
PARTS LIST ON PREVIOUS PAGE

5200/780: 70732573.01.19980721

RESERVOIR ASM (70732573)

ITEM PART NO.

4.
9.
10.
11.
13.
14.
15.
18.
19.
20.

(530047)
(820117)
70144326
73052001
72062000
72063001
76393565
70034410
70732791
72053415

DESCRIPTION

COVER
DIPSTICK ASM
STRAINER 100MESH
PLUG 3/4FPT SQHD MAGNETIC
NUT 1/4-20 HEX
WASHER 1/4 FLAT
O-RING
DIFFUSER 3/4NPT
SCREEN 100MESH
PLUG 3/4 SQHD STEEL

3-21
QTY

1
1
1
1
6
6
1
1
1
2

SECTION 3. PARTS

5200/780: 93704355.01.19980721

INSTALLATION KIT (93704355)

ITEM PART NO.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

70732573
72060004
72060046
72062103
72062104
72063001
72063003
72066516
72531427
72532346
72532670
72532834
72532972
73054129

DESCRIPTION

3-22
QTY

RESERVOIR ASM 17.3GAL

1REF
CAP SCR 1/4-20X1 HHGR5Z
2
CAP SCR 3/8-16X1 HHGR5Z
4
NUT 3/8-16 HEX NYLOC
4
NUT 1/4-20 HEX NYLOC
2
WASHER 1/4W
4
WASHER 3/8W
8
HOSE CLAMP 1-1/4 2BOLT
2
ELBOW 3/4MPT #12MJIC 90o
4
BARB NIPPLE 1-1/4 1-1/4 90o
1
1
ELBOW #8MJIC #8FJIC 45o
BEAD NIPPLE 1.00NPT 1-1/4 90o 1
ADPTR #8MJIC #12FJIC
1
GATE VALVE 3/4 BRASS
1

SECTION 3. PARTS
15.
16.
17.
18.
19.
20.
21.
23.
24.
25.
26.
27.
28.
30.
31.

72053141
73052000
60121443
51393468
51394360
51394916
60350060
60010354
60107478
60107829
52706660
72062141
72063066
72060002
72063049

PIPE NIPPLE BLK 3/4XCLOSE

1
HYD FILTER 10MIC 3/4NPTF
1
OIL FILTER BRACKET
1
HOSE 3/4X60 #12F#12F
1
HOSE 3/4X24 #12F#12F
1
HOSE 1/2X99 #8F#8F
1
HOSE 1-1/4 100R4 X 63
1
CLAMP PLATE
4
WASHER-SQUARE TIE DOWN
8
STUD-TIE DOWN 1X18
8
SUPPORT-TRUCK FRAME 9-1/2 4
NUT 1-8 HEX LOCK
16
WASHER 1.00 HI STR
8
CAP SCR 1/4-20X3/4 HHGR5Z
2
WASHER 1/4 LOCK
2

5200/780: 95712260.01.REV D 20111219

DECAL KIT-5200 SERIES CRANE

(95712260-1)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

70029251
70391583
70391612
70391613
70392108
70392109
71393822
70392213
70392524
70392813
70392814
70392815
70392864
70392865
70392866

17. 70392888

IMT DIAMOND
DECAL-SETUP/STOW
DECAL-GREASE WEEKLY LH
DECAL-GREASE WEEKLY RH
DECAL-SUCTION LINE
DECAL-RETURN LINE
DECAL-5200 SERIES IDENT
DECAL-CAUTION WASH/WAX
DECAL-ROTATE/GREASE
DECAL-DANGER ELECTRO
DECAL-WARNING OPERATOR
DECAL-WARNING OPERATION
DECAL-WARN STAB STD CLR
DECAL-DANGER ELECTRO
DECAL-WARNING OPER COND

3-23

2
2
4
5
1
1
2
1
1
2
2
2
2
4
2

DECAL-WARN OPER RESTRICT 2

STABILIZER (OTHER SIDE)

NOTE: INSTALL #35, LEVEL, ON FRONTAND SIDE OF CRANE

BASE.

SECTION 3. PARTS
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.

70392890
70392891
70392982
71039134
71393864
71392255
71392256
71392257
71392258
71392365
70392889
70394190
70394189
70394443
70392868
70392863
70395323
72042097

DECAL-DGR STOW/UNFOLD
DECAL-DANGER DRIVELINE
DECAL-CONTACT IMT
DECAL-CAUTION OIL LEVEL
CAPACITY PLACARD
DECAL-CTRLS STREETSIDE
DECAL-CTRLS CURBSIDE
DECAL-STAB PWR DN SS
DECAL-STAB PWR DN CS
DECAL-ROTATION ALIGNMENT
DECAL-DGR RC ELECTRO LG
DECAL-CAUTION NOT A STEP
PLACARD-OIL REC
DECAL-DGR FREEFALLING BM
DECAL-DANGER CR LOADLINE
DECAL-DANGER HOIST PERS
DECAL-ASME/ANSI B30.22
LEVEL

CONTINUED ON FOLLOWING PAGE

2
2
1
1
2
1
1
1
1
1
2
2
1
1REF
4
2
1
2

5200/780: 95712260.02.19970530

DECAL KIT-5200 SERIES CRANE

(95712260-2)

3-24

SECTION 3. PARTS

5200/780: 91710962.02.REV. M 20111219

3-25

HYDRAULIC KIT (91710962)

1REF
2REF
2REF
1REF
2REF
2REF
1REF
2REF
4
2
1REF
3
9
2

15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.

72062103
72060048
51716367
72053763
73540061
72060008
72063049
72532657
72532665
72533663
51395859
51394424
51395858
51394588
51395954
72532980
73054426

NUT 3/8-16 LOCK

CAP SCR 3/8-16X1-1/2 HH GR5
HOSE KIT (INCL:2-8,10,26-29)
ELBOW #8MSTR #8MJIC 90
CBAL VALVE
CAP SCR 1/4-20X2 HHGR5
WASHER 1/4 LOCK
TEE #8JIC SWVLNUTRUN
ADAPTER #4MJIC #8FJIC
ELBOW #8MJIC #8MJIC 90
HOSE-FJ .25X14.5 #4#4 (PO 17)
HOSE-FF .38X12 #8#8 (PO 17)
HOSE-FF .38X20 #8#8 (PO 17)
HOSE-FF .38X41 #8#8 (PO 17)
HOSE-FJ .38X22 #8#8 (PO 17)
SWIVEL #8MJIC #8FJIC IN-LINE
VALVE-ADJ RELIEF

3
3
1
2
1
2
2
1
1
1
1REF
2REF
1REF
1REF
1REF
1
1

NOTE: SEE HYDRAULIC OVERLOAD, SEE DRAWING 51717127.

STAB STAB

14. 72531205

VALVEBANK ASM
HOSE ASM 1/4X51 #4F#4F
HOSE ASM 3/8X33 #6F#8F
HOSE ASM 3/8X26 #8F#8F
HOSE ASM 3/8X111 #6F#8F
HOSE ASM 3/8X113 #6F#6F
HOSE ASM 3/8X231 #6F#8F
HOSE ASM 3/8X93 #6F#6F
ELBOW 9/16MSTR 9/16MJICXLG
ELBOW 7/16MJIC 7/16FJIC
HOSE ASM 1/2X231 #8F#8F
ADAPTER 7/16MSTR 7/16MJIC
ADAPTER 3/4MSTR 3/4MJIC
(WAS 8)
TEE 3/4MJIC 1/2TUBE
STAB

51710944
51393928
51393957
51393922
51393923
51393955
51393956
51393954
72532700
72532690
51393958
72532351
72532358

STAB

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

SECTION 3. PARTS

5200/780: 31717782.01.20020724

3-26

SECTION 3. PARTS

SELECTOR VALVE-HYDRAULIC SCHEMATIC (31717782)

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

73054420
72532951
72053763
72532665
51703659
72533239
72532981
72532690
51396095

SELECTOR VALVE
1
ADPTR #12 MSTR #8 FSTR
3
ELBOW #8MSTR #8MJIC 90
3
ADPTR #4MJIC #8FJIC
3
HOSE ASM FF 1/4 X 22.00
2
ADPTR #4MJIC #4MJIC
2
TEE-SWIVEL NUT RUN JIC#4
1
ELBOW #4MJIC #4FJIC SWIVEL 1
HOSE FF 1/4 X 65.00 OAL (4-4)
1
EXISTING HOSE TO BOOM TIP 2REF
EXISTING HOSE TO BOOM TIP 2REF

11

TO BOOM TIP
TO
POWER
OUT

10

TO POWER OUT

TO
BOOM
TIP

PO
STAB STAB
BT

10

11

2
4
4

2
3

3
2

WINCH
(push)

SELECTOR
(pull)
BOOM TIP

BT

5200/780: 51717127 REV B 201 11219

3-27

HYDRAULIC OVERLOAD KIT (51717127)

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.

72532657
72532658
73540463
72532358
73054426
72533374
72532950
72532696
72532972
72532772
72532141
51395154
51394546
51395153
72060034
72062109
72532360
77441025

TEE-SWIVEL NUT RUN JIC#8

ELBOW #8MJIC #8FJIC SWIVEL
VALVE BLOCK ASSEMBLY
ADPTR-M STR/M JIC 8 8
VALVE-ADJ RELIEF
TEE-SWIVEL NUT RUN JIC 6
TEE-SWIVEL NUT RUN JIC 12
ELBOW-MJIC/FJIC SW 12 12
ADAPTER MJIC/FJIC 8 12
ELBOW MJIC/FJIC SW 6 6
PLUG-STR HEX HD STL .75 THD
HOSE-FF .38 X .51 OAL (6-8)
HOSE-FF .38 X 51 OAL (8-8)
HOSE-FF .50 X 8.0 OAL (8-8)
CAP SCR .31-18 X 3.25 HHGR5Z
NUT .31-18 HEX NYLOC ZINC
ADAPTER-MSTR/MJIC 12 8
HARNESS-OVERLOAD

1
1
1
6
1
3
1
1
1
3
3
3
2
1
3
3
1
1

SECTION 3. PARTS
NOTES:
1) The overload system functions such that when the inner
cylinders are overloaded, the pressure switch mounted on
the inner cylinder will activate the solenoid dump valve(s),
thus dumping oil to tank instead of the outer cylinder
extend, extension cylinder extend, or winch up
functions. This will prevent pressure build-up for these
functions, as the system is based on the oil taking the path of
least resistance.
2)

The functions that will shut down, if overloaded, are:

a) Inner Boom Retract
b) Outer Boom Extend
c) Extension Cylinder Extend
d) Winch Up

3)

Install a relief (#73054426 - 700 psi) in the extend line of the

extension cylinder so the cylinder will not extend when the
dump system is activated.

4)

This system is used in conjunction with the electric capacity

alert kit.

STAB STAB

5200/780: 51710944.01.19961125

VB ASM-8 SECT/MNL (51710944)

ITEM PART NO.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

72532722
72532738
72053760
72053763
72053766
72532707
72532700
72532657
72532675
70731499
72053763

DESCRIPTION

3-28

SECTION 3. PARTS

QTY

ADAPTER #10MSTR #6FSTR

16
CAP 9/16JIC STL
4
ELBOW #6MSTR #6MJIC 90
7
ELBOW #8MSTR #8MJIC 90
1
ELBOW #10MSTR #12MJIC 90 1
ADAPTER #4MJIC #6FJIC
2
ELBOW #6MSTR #6MJIC XLG
8
TEE 3/4JIC SWVL NUT
1
CAP 3/4JIC STL
1
VALVEBANK 8-SECTION
1
ELBOW #6MSTR #8MJIC 90
1

VALVEBANK (70731499)
ITEM PART NO.

1.
2.
3.
4.
5.
6.
7.

73054490
73054488
94731681
73731576
7Q072018
7Q072021
7Q072017

DESCRIPTION

TANDEM VALVE SECTION

END CAP LH
TIE ROD KIT
END CAP RH
O-RING
O-RING
O-RING

QTY

8
1
1
1
18
9
9

5200/780: 51711707.01.19980519

VB ASM 4R/4M (51711707)

ITEM PART NO.

1.
2.
3.
4.
5.
6.
7.
8.
11.

70732848
72533052
72532738
72053760
72053763
72053766
72532707
72532700
72053764

DESCRIPTION

3-29

SECTION 3. PARTS

QTY

VALVEBANK 8-SECT
1
ADAPTER #8MSTR #6FSTR
15
CAP 9/16JIC
4
ELBOW #6MSTR #6MJIC 90
7
ELBOW #8MSTR #8MJIC 90
2
ELBOW #10MSTR #12MJIC 90 1
ADAPTER #4MJIC #6FJIC
2
ELBOW #6MSTR #6MJIC XLG
8
ELBOW #10MSTR #8MJIC 90
1

VALVEBANK (70732848)
ITEM PART NO.

1.
2.
3.
4.
5.
6.
7.
8.

73540007
73054845
73054488
73540009
94731681
7Q072018
7Q072021
7Q072017

DESCRIPTION

VALVE SECTION-MNL
VALVE SECTION-RMT
END COVER LH
END COVER RH
TIE ROD KIT
O-RING
O-RING
O-RING

QTY

4
4
1
1
1
18
9
9

5200/780: 51711706.01.19980519

VB ASM 5R/3M (51711706)

ITEM PART NO.

1.
2.
3.
4.
5.
6.
7.
8.
11.

70732847
72533052
72532738
72053760
72053763
72053766
72532707
72532700
72053764

DESCRIPTION

3-30

SECTION 3. PARTS

QTY

VALVEBANK 8-SECT
1
ADAPTER #8MSTR #6FSTR
15
CAP 9/16JIC
4
ELBOW #6MSTR #6MJIC 90
7
ELBOW #8MSTR #8MJIC 90
2
ELBOW #10MSTR #12MJIC 90 1
ADAPTER #4MJIC #6FJIC
2
ELBOW #6MSTR #6MJIC XLG
8
ELBOW #10MSTR #8MJIC 90
1

VALVEBANK (70732847)
ITEM PART NO.

1.
2.
3.
4.
5.
6.
7.
8.

73540007
73054845
73054488
73540009
94731681
7Q072018
7Q072021
7Q072017

DESCRIPTION

VALVE SECTION-MNL
VALVE SECTION-RMT
END COVER LH
END COVER RH
TIE ROD KIT
O-RING
O-RING
O-RING

QTY

3
5
1
1
1
18
9
9

5200/780: 51711708.01.19980519

VB ASM 6R/2M (51711708)

ITEM PART NO.

1.
2.
3.
4.
5.
6.
7.
8.
11.

70732849
72533052
72532738
72053760
72053763
72053766
72532707
72532700
72053764

DESCRIPTION

3-31

SECTION 3. PARTS

QTY

VALVEBANK 8-SECT
1
ADAPTER #8MSTR #6FSTR
15
CAP 9/16JIC
4
ELBOW #6MSTR #6MJIC 90
7
ELBOW #8MSTR #8MJIC 90
2
ELBOW #10MSTR #12MJIC 90 1
ADAPTER #4MJIC #6FJIC
2
ELBOW #6MSTR #6MJIC XLG
8
ELBOW #10MSTR #8MJIC 90
1

VALVEBANK (70732849)
ITEM PART NO.

1.
2.
3.
4.
5.
6.
7.
8.

73540007
73054845
73054488
73540009
94731681
7Q072018
7Q072021
7Q072017

DESCRIPTION

VALVE SECTION-MNL
VALVE SECTION-RMT
END COVER LH
END COVER RH
TIE ROD KIT
O-RING
O-RING
O-RING

QTY

2
6
1
1
1
18
9
9

5200/780: 90704417.01.19961125

CONTROL KIT 6F MNL (90704417)

ITEM PART NO.

1.
2.
3.
4.
5.
6.
7.
9.
10.
11.
12.

52704397
52704744
52704745
70029451
71039096
60030068
60030069
72066338
72661169
72066168
72063119

DESCRIPTION

CTRL HNDL MTG ROD

CONTROL ROD F
CONTROL ROD M
CONTROL HANDLE
KNOB
SPACER 1-3/8
SPACER 1-3/4
CLEVIS PIN 5/16X1
CLEVIS PIN 5/16X3/4
COTTER PIN 3/32X3/4
WASHER 5/8

3-32
QTY

2
6
12
12
12
2
6
12
6
18
8

SECTION 3. PARTS

5200/780: 90713554.01.20010419

3-33

PROPL RMT CONTROL KIT (90716707)

1. 77044837

2. 72060703
3. 72063049
4. 77040186
5. 73054876
6.
7.
8.
9.

72060051
72062103
51713568
51713429

10.
11.
12.
13.
14.

77041251
77041237
51704784
72060004
72062104

VALVE DRIVER-REPL
W/COMMAND ARTCL
CAP SCR .25-20 x .50 SH
WASHER .25 LOCK
TERM - F SLPON I .25
TAB 16-14GA
PROPORTIONAL PRIORITY
FLOW VALVE - 3000
CAP SCR .38-16X2.5 HHGR5
NUT .38-16 SLFLKG
CABLE ASM-JIC BOX 6x6x4
HANDLE ASMREMOTE CONTROL
BOSCH RELAY
SOLENOID 12V
CABLE ASM #1WIRE X 6.00
CAP SCR .25-20X1 HHGR5 Z
NUT .25-20 HEX NYLOC Z

1
2
2
2
1
2
2
1
1
2
1
1
4
4

SECTION 3. PARTS

CONTINUED ON NEXT PAGE

5200/780: 90713554.01.20010419

3-34

SCHEMATIC REMOTE CONTROL KIT

V12R (90716707)
ITEM PART NO.

1.
2.
3.
4.
5.
6.
7.
8.
9.

73054876
51709389
51716706
72532360
72532358
73054426
51708692
72532951
72053763

DESCRIPTION

QTY

VALVE-PROPN PRIORITY FLOW REF

HOSE ASM 1/2X14 #8F#8F
1
HOSE ASM 1/2X9 #8F#8F
1
ADAPTER #12MSTR #8MJIC
1
ADAPTER #8MSTR #8MJIC
2
RELIEF VALVE 750 PSI
1
HOSE ASM 3/8X4 #8F#8F
1
ADAPTER #12MSTR #8FSTR
2
ELBOW #8MSTR #8MJIC 90
3

SECTION 3. PARTS

5200/780: 51713429.01.19980220

3-35

PROPL RMT HANDLE ASM (51713429)

ITEM PART NO.

DESCRIPTION

1.
2.
3.
4.
5.
6.
8.
9.
10.
11.
12.
14.
15.
16.
17.
18.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.

WIRE 18GA X 4 GRN

8
CONTROL HANDLE BACK
1
TRIGGER
1
COVER
1
BACK COVER
1
SERIAL NUMBER PLACARD
1
PIN
23
DECAL-DGR RC ELECTRO
1
DECAL-RC HANDLE
1
POTENTIOMETER ASM(INCL:22) 1
POP RIVET
2
SHT MTL SCR #6X3/4 PH
8
TERM #8 SPRSPD 16-14GA
25
TOGGLE SWITCH SPST
1
TOGGLE SWITCH SPDT
6
TOGGLE SWITCH SPST
2
CONNECTOR
1
CABLE 18GA/24WIRE X 45FT
1
TERM MSLPON(PART OF 11)
3REF
TERM 1/4 FSLPON 16-14GA
3
MTG BRACKET
1
CAP SCR #10-32X5/8 SH
1
CAP SCR #10-24X3/4 SH
2
NUT #10-24 LOCK
2
SPRING
1
SHT MTL SCR #6X1/2 PH
1
CONNECTOR
1

60045031
60119335
60111141
60119277
70034306
70029119
77044621
70392862
71394282
51707507
72066340
72061009
77040051
77040371
77040372
77040373
77044579
89044100
77040047
77040186
60111142
72060669
72060636
72062106
70143223
72061000
77044196

QTY

SECTION 3. PARTS

TETHERED PROPORTIONAL REMOTE

POTENTIOMETER ADJUSTMENT
NOTES: 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.

2.
3.
4.

5.
6.
7.

8.

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.

A
B

5200/780: 51713568.01.19980220

CABLE ASM-JIC BOX 94" (51713568)

ITEM PART NO.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

89044100
90713575
77041345
77041354
77044018
77044201
77044196
77044202
77044468
77040186
77040282

DESCRIPTION

CABLE 18GA/24WIRE X 94
JIC BOX
TOGGLE SWITCH ST
TOGGLE SWITCH DT
STRAIN RELIEF 1/2
NUT 1/2 ELEC LOCK
STRAIN RELIEF 3/4
NUT 3/4 ELEC LOCK
STRAIN RELIEF 1/2
TERM 1/4 FSLPON 16-14GA
TERM 1/4 PIGBAC 16-14GA

3-36
QTY

1
1
2
1
2
3
1
1
1
25
3

SECTION 3. PARTS
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.

77040051
77044620
77044580
70393257
77044341
77041056
77040048
89044232
77044668
89044354
77041423
77044667

TERM #8 SPRSPD 16-14GA

CONNECTOR
SOCKET
DECAL-JIC BOX
TERMINAL BLOCK-4
FUSE 20A IN-LINE
BUTT CONNECTOR 16-14GA
WIRE 14GA RED X 3
PLUG-SEAL
CABLE 14GA/6WIR
DIODE
PLUG-CAP

4
1
23
1
1
1
4
2
1
84"
1
1

5200/780: 31712113.01.19961125

3-37

OPTION-DBL HOSE REEL KIT (31712113)

ITEM PART NO.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

70732863
70732864
51393812
60117715
72533380
72533382
72533381
72532353
60115137
72060097

DESCRIPTION

HOSE REEL-LH
HOSE REEL-RH
HOSE ASM 1/4X300 TWIN FF
BRACKET-HOSE REEL MTG
DISC COUPLER 1/4NPT
DISC NIPPLE 1/4NPT
CAP 1/4
ADAPTER #6MSTR #4MJIC
ANGLE
CAP SCR 1/2-13X3 HHGR5

QTY

1
1
2
2
2
2
4
8
2
4

SECTION 3. PARTS
11.
12.
13.
14.
16.
18.
23.
24.
25.
26.
27.
28.

72060093
72062080
72053499
72063003
72060044
51708885
71039096
70029451
52704745
52704744
72066338
72066168

CAP SCR 1/2-13X1-1/2 HHGR5

NUT 1/2-13 LOCK
ADAPTER 1/4MPT #4MJIC
WASHER 3/8 WRT
CAP SCR 3/8-16X3/4 HHGR5
HOSE ASM 1/4X229 FF
KNOB
CONTROL HANDLE
CONTROL ROD-MALE
CONTROL ROD-FEMALE
CLEVIS PIN 5/16X1
COTTER PIN .09X3/4

4
8
4
8
4
4
4
4
4
2
6
6

5200/780: 31717776.B: 20120531

3-38

OPTION-WINCH KIT (31717776)

EFFECTIVE S/N 5200R101027
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

51707970
52703575
72060199
72062114
60010869
60010868
71057607
72063053
72060797
72062004

11.
12.
13.
14.
15.
16.

71030906
72066168
72661169
72066338
52704745
52704744

HOSE-FF .38 X 22 (8-8) 100R16

BRACKET, MOUNTING
SCREW, CAP .75-10 X 9 HHGR5
NUT, LOCK .75-10
STUD .50-13 X 4.5
SPACER
WINCH (INCL #30)
LOCKWASHER .50
CAP SCREW .50-13 X 2.5 SH
SCREW, CAP .50-13 X 2.5 SH
(WAS 2)
KNOB
COTTER PIN .09 X .75
PIN .31 X .75
PIN CLEVIS .31 X 1.00
CONTROL ROD, MALE
CONTROL ROD, FEMALE

1
1REF
2REF
2REF
4REF
2REF
1REF
6REF
2REF
4REF

SECTION 3. PARTS
17.
18.
19.
20.

70029451
51395383
51706518
73054218

21.
22.
23.
24.
25.

72532358
72534435
70144192
72063030
72060596

26. 31904002
27.
28.
29.
30.
31.
32.

2
3
1
2
2
1

51724374
70034381
72060006
72060000
72063001
72063049

CONTROL HANDLE
2
HOSE-FF .38 X 192 (8-8) 100R17 2
HOSE-FF .38 X 21 (8-8) 100R16 1
VALVE-CHECK PILOT/OPEN NONVENT
(PART OF #26)
1REF
ADPTR-MSTR/MJIC 8 8 (#26)
6REF
ELBOW-MSTR/90/MJIC XLG 10 8 2REF
MANIFOLD-CAVITY BLOCK
1REF
MACHY BUSHING .75 X 10 GA
8REF
SET SCREW .50-13 X .75 SH
1REF
(PART OF #7)
WINCH KIT, 4000 #
1
(INCL 2-10,15,23-29,32,33)
CORD REEL ASM
1
SUPPORT
3
CAP SCREW .25-20X1.5 HHGR5Z 3
CAP SCREW .25-20X.50 HHGR5Z 3
WASHER-FLAT .25
3
WASHER-LOCK .25 ZINC
3

CONTROL HANDLE
MOUNTING ROD (REF)
11
12

OUTER BOOM (REF)

15

17
14

12
(USE AS
SPACERS)
(4 PLACES)

4" REF

24

16
12
13

2
4

15

6
26

14
11

25

CONTROL HANDLE
MOUNTING ROD (REF)

17

21
RAISE

18

21
20 & 23

VB

8
8

21 19 22

LOWER

18

21

MOTOR WINCH

21 1

21

10
V1
C1
20 & 23
V2
C2

22

5200/780: 31717776.01: 20020724

OPTION-WINCH KIT (31717776)

USED THROUGH S/N 5200R101026
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.

52703575
72060199
72062114
60010869
60010868
71057607
72063053
72060797
72062004
71039096
72066168
72661169
72066338
72053497
52704745
52704744
70029451

MTG. BRACKET
SCREW, CAP 3/4-10 X 9 HHGR5
LOCK NUT 3/4-10
STUD 1/2-13 X 4.5
SPACER
WINCH (INCL. #30)
LOCKWASHER 1/2
SCREW, CAP 1/2-13 X 2.5 SH
NUT 1/2-13
KNOB
COTTER PIN .09 X 3/4
PIN 5/16 X 3/4
PIN, CLEVIS 5/16 X 1.00
ADPTR 1/2MPT 3/4MJIC
MALE CONTROL ROD
FEMALE CONTROL ROD
CONTROL HANDLE

3-39

1REF*
2REF*
2REF*
4REF*
2REF*
1REF*
6REF*
2REF*
4REF*
2
3
1
2
2REF*
2
1
2

SECTION 3. PARTS
19.
20.
21.
23.
24.
25.
26.
27.
28.
29.
30.

51396269
72053760
72532700
73054006
72532670
72053744
72053629
60101420
72532138
72063030
72060598

31. 31904002
32. 72533342
33. 72053611

HOSE-FF 3/8 X 264 OAL (6-8)

2
ELBOW 9/16MSTR 9/16MJIC 90 1
ELBOW 9/16 MSTR 9/16MJIC XLG 1
CHECK VALVE
1REF*
ELBOW #8MJIC #8FJIC 45
2REF*
ADPTR #10MSTR 1/2FPT
2REF*
ADPTR 1/2MPT 3/8MPT HEX
1REF*
TUBE
1REF*
BUSHING, RED 3/8MPT-1/4FPT 1REF*
MACH BUSHING 3/4X10 GA
8REF*
SET SCREW 1/2-13 X 3/4 SH
1REF
(PART OF #7)
WINCH KIT
1
(INCL. *S - 2-10,14,23-29,32,33)
FLRLS TUBE 45 MPT #4 1/4
2REF*
TEE 3/8 NPT
1REF*

5200/780: 31705637.01.19961125

3-40

OPTION-CABLE & HOOK KIT (31705637)

ITEM PART NO.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

52070705
52704143
60107592
70034204
70055024
70055025
70058033
70731716
72053508
72066145
52070151

DESCRIPTION

QTY

PIN
1
YOKE
1
CABLE 3/8X65'
1
SHEAVE 10-1/4 NYLON
1
BEARING
1
RACE
1
CABLE CLAMP 3/8
1
SWVL HOOK W/WEDGE SOCKET 1
ZERK 1/8NPT
1
HAIR PIN
2
PIN
1

SECTION 3. PARTS

5200/780: 99905322.01: 20111216

3-41

SECTION 3. PARTS

TWO-BLOCK DAMAGE PREVENTION

KIT (51724350 / DWG 99905344)
ITEM PART NO.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

51724375
72661693
51724374
70034381
72060006
72060000
72063001
72063049
60107237
60138820

DESCRIPTION

QTY

YOKE-TWO-BLK DMG PREV ASM

BLOCK-TPD .25-20X .44X 0.91DIA
CORD REEL ASM
SUPPORT
CAP SCR .25-20X 1.50 HH GR5 Z
CAP SCR .25-20X .50 HH GR5 Z
WASHER .25 FLAT
WASHER .25 LOCK
BLOCK-TPD .25-20 X 1 X 1 X .5
BRACKET

1
5
1
3
3
3
3
3
1
1

6,8
1.25"
2
6,8

10

2.00"

2
2.00"

5,7

1.25"

4
1
TYP

NOTE: USE EXISTING

SHEAVE, BEARING & PIN

.13

8.25"
1.00"

.75"

.13
3"

5200/780: 51717127.01.20011127

3-42

OPTION-HYD OVERLOAD KIT 3F

(51717127)

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.

72532657
72532658
73540085
72532358
73054426
72533374
72532950
72532696
72532972
72532772
72532679
51395154
51394546
51395153
72060034
72062109
72532360
77441025

TEE 3/4JIC SWVL NUT RUN

ELBOW #8MJIC #8FJIC
VALVE BLOCK ASM
ADAPTER #8MSTR #8MJIC
RELIEF VALVE - ADJ
TEE #4JIC SWVL NUT RUN
TEE 1-1/16JIC SWVL NUT RUN
ELBOW #12MJIC #12FJIC SWVL
ADAPTER #8MJIC #12FJIC
ELBOW #6MJIC #6FJIC SWVL
PLUG JIC HEX HD STL 3/4
HOSE ASM 3/8X51 FF
HOSE ASM 3/8X51 FF
HOSE ASM 1/2X8 FF
CAP SCR 5/16-18 X 3.25 HH GR5
NUT 5/16-18 HEX NYLOC
ADPTR #12MSTR #8MJIC
OVERLOAD HARNESS

1
1
1
5
1
2
1
1
1
2
3
2
1
1
3
3
1
1

PRESSURE SWITCH

18

SECTION 3. PARTS

NOTES:
1. Function of system is such that when the inner cylinders
are overloaded, the pressure switch, mounted on the inner
cylinder, will activate the solenoid dump valve(s); thus
dumping oil to tank instead of the outer cylinder extend,
extension cylinder extend, or winch up functions, which
will not allow pressure to build for these functions. This
system is based on the fact that the oil will take the path of
least resistance.
2. The following functions will shut down if overloaded:
a. Outer boom extend
b. Extension cylinder extend
c. Winch up
3. Install a relief (#73054426, 700 psi) in the extend line of
the extension cylinder so cylinder will not extend when the
dump system is activated.
4. Use kit in conjunction with electric capacity alert kit.

INNER
CYLINDER

11

15 (3)
16 (3)

A-12V POWER
B-GROUND

3
17

EXT
CYLINDER

12
13

TO WINCH

EXISTING
HOSE
4
5
4

EXISTING
HOSE

EXISTING
HOSE

14

13

10

OUTER
CYLINDER

12

10

CRANE
VALVE BANK
EXTEND

EXISTING
HOSE
TO
TANK

7
8

R
9

EXTEND

UP

ROT INNER OUTER EXT WINCH OPT

RETRACT RETRACT DOWN

OR

OR

5200/780: 31713333.01.20030715

3-43

SECTION 3. PARTS

CAPACITY ALERT KIT - 3100 (31713333)

1.
2.
3.
4.
5.

77041476
7Q072015
72532140
60025221
72060731

PRESSURE SWITCH
O-RING
PLUG 9/16-18 STR THD HH
MANIFOLD
CAP SCR 5/16-18X 3/4 SH

1
1
1
1
4

5 (4)

TO BE WIRED TO
CHASSIS HORN

4
1
2

TO MAIN (INNER)
BOOM CYLINDER BLOCK

CAPACITY SHUTDOWN KIT - 3100 PSI

(31717516)
1.
2.
3.
4.
5.

77041625
7Q072015
72532140
60025221
72060731

PRESSURE SWITCH
O-RING
PLUG 9/16 STR HH STL
MANIFOLD
CAP SCR 5/16-18 X 3/4 SHZ

1
1
1
1
4

5 (4)

1
3

TO INNER BOOM
CYLINDER BLOCK

5200/780: 51707059.01.19961125

OPTION-AUGER MTG KIT (51707059)

ITEM PART NO.

1.
2.
3.
4.
5.

51705062
60108961
72533101
72533102
72053670

DESCRIPTION

HOSE ASM 1/2X48 FF

SWIVEL LINK-AUGER
DISCONNECT COUPLER 3/8FPT
DISCONNECT NIPPLE 3/8FPT
ADAPTER 3/8MPT 3/4MJIC

3-44
QTY

2
1
1
1
4

SECTION 3. PARTS

5200/780: 51707805.01.19961125

3-45

OPTION -AUGER HOSE REEL KIT-V20

(51707805)
ITEM PART NO.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

51704918
51703664
60025240
70029451
52702016
52702018
60118684
72060157
72062091
70731877
71039096
72053497
72533101
72533102
60111589
72053670

DESCRIPTION

HOSE ASM 1/2X282 FF

HOSE ASM 1/2X228 FF
CONTROL HANDLE
CONTROL HANDLE
CONTROL ROD F
CONTROL ROD M
BULKHEAD PLATE
CAP SCR 5/8-11X4-1/2 HH GR8
NUT 5/8-11 LOCK
HOSE REEL
KNOB
ADAPTER 1/2MPY 3/4MJIC
DISCONNECT COUPLER 3/8FPT
DISCONNECT NIPPLE 3/8FPT
VB MTG PLATE
ADAPTER 3/8MPT 3/4MJIC

QTY

2
1
1
1
1
1
1
1
1
2
1
4
1
1
1
2

SECTION 3. PARTS
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
30.
32.
34.
35.
36.
37.

60111573
72060047
72060093
72062103
72063001
72063003
72063053
72066168
72066338
72532666
60030069
94731839
60111412
51707856
99900183
72060033
72063002
72062109

GUSSET
CAP SCR 3/8-16X1-1/4 HH GR5
CAP SCR 1/2-13X1-1/2 HH GR5
NUT 3/8-16 LOCK
WASHER 1/4 WRT
WASHER 3/8 WRT
WASHER 1/2 LOCK
COTTER PIN 3/32X3/4
CLEVIS PIN 5/16X1
ELBOW 3/4MSTR 3/4MJIC XLG
SPACER 5/8X1X1-3/4
LINK & PIN KIT
HOSE REEL MTG BRACKET
VALVEBANK V20 1-SECTION
VB MTG MODIFICATION DWG
CAP SCR 5/16-18X3 HH GR5
WASHER 5/16 WRT
NUT 5/16-18 LOCK

2
8
4
8
4
8
4
2
2
2
1
1
1
1
1
3
3
3

5200/780: 31701760.01.19961125

OPTION-AUX RESERVOIR-30GAL
(31701760)
ITEM PART NO.

1.
2.
3.
4.
5.
6.

52701550
73141276
73014671
72060093
72063053
72062004

DESCRIPTION

RESERVOIR
STRAINER
FILL CAP
CAP SCR 1/2-13X1-1/2 HHGR5
WASHER 1/2 LOCK
NUT 1/2-13 HEX

3-46

QTY

1
1
1
4
4
4

SECTION 3. PARTS

5200/780: 31712487.01.19961125

3-47

OPTION-SGL HOSE REEL KIT (31712487)

ITEM PART NO.

2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

70732864
51393812
60117715
72533380
72533382
72533381
72532353
60115137
72060097
72060093

DESCRIPTION

QTY

HOSE REEL-RH
1
HOSE ASM 1/4X300 TWIN FF
1
HOSE REEL MTG BRACKET
1
DISCONNECT COUPLER 1/4NPT 1
DISCONNECT NIPPLE 1/4NPT
1
CAP
2
ADAPTER #6MSTR #4MJIC
4
ANGLE
1
CAP SCR 1/2-13X3 HHGR5
2
CAP SCR 1/2-13X1-1/2 HHGR5
2

SECTION 3. PARTS
12.
13.
14.
16.
18.
23.
24.
25.
26.
27.
28.

72062080
72053499
72063003
72060044
51708885
71039096
70029451
52704745
52704744
72066338
72066168

NUT 1/2-13 LOCK

ADAPTER 1/4MPT #4MJIC
WASHER 3/8 WRT
CAP SCR 3/8-16X3/4 HHGR5
HOSE ASM 1/4X229 FF
KNOB
CONTROL HANDLE
CONTROL ROD-M
CONTROL ROD-F
CLEVIS PIN 5/16X1
COTTER PIN .09X.75

4
2
4
2
2
2
2
2
1
3
3

5200/780: 31717218.01.20011127

3-48

OPTION - LIGHT KIT (31717218)

ITEM PART NO.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

51717219
60107762
77040424
60103535
77041345
77044574
77044550
70394069
72063049
72063051
77040000
89044274
72060000
72060044
72062000

DESCRIPTION

SECTION 3. PARTS

QTY

CABLE ASM- FLOOD LIGHTS

1
GUARD
1
FLOOD-LT-COMP WORK LAMP
2
SWITCH BRACKET - 1 HOLE
1
TOGGLE SWITCH
1
CONNECTOR
2
TERMINAL-F 18-20 GA
2
SEAL CABLE CONNECTOR
4
WASHER 1/4 LOCK
2
WASHER 3/8 LOCK
2
TERMINAL, RING #10 STUD 16-14 1
WIRE-BLACK STRD TYPE
36
CAP SCR 1/4-20 X 1/2 HH GR5
2
CAP SCR 3/8-16 X 3/4 HH GR5
2
NUT 1/4-20 HEX ZINC

DRILL .313" HOLE AND TAP

3/8-16 IN TOP OF INNER
BOOM (2). CENTER THE LIGHT
BRACKET ON THE LENGTH
OF THE BOOM.

CRANE INNER BOOM

TO LIGHT
SWITCH

14
10

6
7(2)
8(2)

1
6
7(2)
8(2)

1 REF
TO LIGHTS
GROUND

"12 V"

3
4

11
12

15
9

5
13

5200/780: 95711801.01.20111219

3-49

DECAL KIT-MODEL 780 CRANE (957118011)

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

70029251
70391583
70391612
70391613
70392108
70392109
70393761
70392213
70392524
70392813
70392814
70392815
70392864
70392865
70392866

17. 70392888

IMT DIAMOND
DECAL-SETUP/STOW
DECAL-GREASE WEEKLY LH
DECAL-GREASE WEEKLY RH
DECAL-SUCTION LINE
DECAL-RETURN LINE
DECAL-780 IDENT
DECAL-CAUTION WASH/WAX
DECAL-ROTATE/GREASE
DECAL-DANGER ELECTRO
DECAL-WARNING OPERATOR
DECAL-WARNING OPERATION
DECAL-WARN STAB STD CLR
DECAL-DANGER ELECTRO
DECAL-WARN OPER COND

2
2
4
5
1
1
2
1
1
2
2
2
2
4
2

DECAL-WARN OPER RESTRICT 2

STABILIZER
(OTHER SIDE)

NOTE: PLACE ITEM #35, LEVEL, ON FRONTAND SIDE OF

CRANE BASE.

SECTION 3. PARTS
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.

70392890
70392891
70392982
71039134
71392731
71392255
71392256
71392257
71392258
71392365
70392889
70394190
70394189
70394443
70392868
70392863
70395323
72042097

DECAL-DGR STOW/UNFOLD
DECAL-DANGER DRIVELINE
DECAL-CONTACT IMT
DECAL-CAUTION OIL LEVEL
CAPACITY PLACARD
DECAL-CTRLS STREETSIDE
DECAL-CTRLS CURBSIDE
DECAL-STAB PWR DN SS
DECAL-STAB PWR DN CS
DECAL-ROTATION ALIGNMENT
DECAL-DGR RC ELECTRO LG
DECAL-CAUTION NOT A STEP
PLACARD-OIL REC
DECAL-DGR FREEFALLING BM
DECAL-DANGER CR LOADLINE
DECAL-DANGER HOIST PERS
DECAL-ASME/ANSI B30.22
LEVEL

CONTINUED ON FOLLOWING PAGE

2
2
1
1
2
1
1
1
1
1
2
2
1
1REF
4
2
1
2

5200/780: 95711801.02.19970530

DECAL KIT-MODEL 780 CRANE

(95711801-2)

3-50

SECTION 3. PARTS

5200/780: 999003330.01.20011023

3-51

RADIO REMOTE RETROFIT KIT

(99903330-1)
1. 73733600
2. 77045894
3. 60123676
4. 51717059
5. 72060005
6. 72062104
7. 72601761
8. 72601762
10. 73054876
1REF
11. 72060051
12. 72062103
13. 77041251
14. 77041237
15. 51704784

RADIO REMOTE KIT

HARNESS
MOUNTING PLATE
JIC BOX ASM
CAP SCR 1/4-20X1.25
NUT 1/4-20HEX NYLOC ZINC
CAP SCR 6MMX12MMX1.00
WASHER LOCK 6MM
VALVE-PROPN PRIORITY FLOW

1
1
1
1
6
6
4
4

CAP SCR 3/8-16X2.25

NUT 3/8-16 HEX NYLOC ZINC
RELAY
SOLENOID
CABLE ASM

2
2
3
1
1

BASE REF

5
4

7
8

5
2

SECTION 3. PARTS

CONTINUED ON NEXT PAGE

EFFECTIVE 09-21-01

5200/780: 99903330.02: 20011023

4 REF

ELEC. SCHEMATIC - RADIO REMOTE

RETROFIT (99903330-2)

3-52

SECTION 3. PARTS

PARTS LIST ON PREVIOUS PAGE

EFFECTIVE 09-21-01

5200/780: 51714624.01.19980810

CABLE ASM-18GA/24 WIREX115

(51714624)
ITEM PART NO.

1. 77044621
2. 77044579
3. 89044100

DESCRIPTION

PIN
CONNECTOR
CABLE 18GA/24 WIREX115

3-53

QTY

24
1
1

SECTION 3. PARTS

5200/780: 51717059.01.REV. B 20100322

JIC BOX ASM-RADIO REMOTE (51717059)

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

89044100
90714496
77041345
77041354
77044018
77044201
77044196
77044202
77044620
77040186

CABLE 18GA/24
7.83 FT
JIC BOX ASM 6X6X6
1
TOGGLE SWITCH (WAS 77041237)2
TOGGLE SWITCH
1
CONNECTOR 1/2 STR RLF
3
NUT ELEC 1/2 LOCK
3
CONNECTOR 3/4 STR RLF
1
NUT ELEC 3/4 LOCK
1
CONNECTOR
1
TERMINAL FSLPON 1 .25TAB
14

3-54

SECTION 3. PARTS
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.

77040282
77044668
77040051
77044667
70393257
77044341
77041056
89044232
77044646
89044354
77044468
77044645
77041251

TERMINAL PIGBAC
6
SEAL PLUG
2
TERMINAL SPRSPADE
6
CAP PLUG
1
DECAL 6X6X4 JIC BOX
1
TERMINAL BLOCK 4 CONTACT
1
IN-LINE 20 AMP FUSE
1
WIRE 14GA RED
.5 FT
WASHER LOCK
1
CABLE 14GA/6
7 FT
CONNECTOR 1/2 STR RLF
1
NUT DEUTSCH
1
RELAY-12V 30 AMP NOM/
1
40 AMP MAX

3-55

P3: Trimming Potentiometer to Adjust Dither Amplitude

Adjust clockwise or counterclockwise for smoothness of
operation.

J2: CONTROL RANGE OF OUTPUT CURRENT

(ONLY CURRENT - CONTROL)
- PIN 2/3 CONNECTED: D-2A

RADIO RMT RECEIVER

RADIO RMT TRANSMITTER
BATTERY-VERSA PAK 3.6V
BATTERY HOUSING
BATTERY CHARGER
MAGNET- RADIO RMT TRANSM.

P2: Trimming Potentiometer for Initial Value Adjustment

On transmitter, engage Rotation CW or CCW function switch.
Without pulling trigger, adjust P2 counterclockwise until
crane begins to move. At this time, adjust P2 clockwise
until no movement is detected. Slightly engage
trigger and adjust P2 to fine tune.

73733588
73733589
70146100
70146101
70146102
70146103

J1: PULSE/DITHER FREQUENCY

- NO JUMPER

1.
2.
3.
4.
5.
6.

JUMPER CONNECTIONS INSIDE RECEIVER

RADIO REMOTE KIT (73733600-1)

P1: Trimming Potentiometer for Maximum Values

On transmitter handle, engage Rotation CW or CCW
function switch and pull trigger fully on. Crane MAY
or MAY NOT begin to move at this time due to
initial P1 setting. Turn P1 potentiometer counterclockwise until desired maximum speed is obtained
or until speed no longer continues to increase.

5200/780: 73733600.01: 20011023

SECTION 3. PARTS

1
1
2
1
1
1
CONTINUED ON NEXT PAGE

5200/780: 73733600.02: 20011023

3-56

RADIO REMOTE KIT (73733600-2)

SECTION 3. PARTS

PARTS LIST ON PREVIOUS PAGE

2
1

20000710

4-1

SECTION 4. GENERAL REFERENCE

SECTION 4. GENERAL REFERENCE

INSPECTION CHECKLIST .............................................................................................. 3
WIRE ROPE INSPECTION ............................................................................................... 7
HOOK INSPECTION ......................................................................................................... 7
HOLDING VALVE INSPECTION ....................................................................................... 8
ANTI-TWO BLOCKING DEVICE INSPECTION ............................................................... 8
TORQUE DATA CHART - DOMESTIC ............................................................................. 9
TORQUE DATA CHART - METRIC ................................................................................ 10
TURNTABLE BEARING FASTENER TIGHTENING SEQUENCE ................................ 11
TURNTABLE BEARING INSPECTION FOR REPLACEMENT ..................................... 12

20000710

4-2

NOTES

SECTION 4. GENERAL REFERENCE

4-3
NOTICE

The user of this form is responsible in determining that these

SECTION 4. GENERAL REFERENCE

Inspection Checklist

OWNER/COMPANY

TYPE OF INSPECTION (check one)

DAILY (if deficiency found)

CONTACT PERSON

CRANES

inspections satisfy all applicable regulatory requirements

MONTHLY

CRANE MAKE & MODEL

DATE INSPECTED

CRANE SERIAL NUMBER

HOUR METER READING (if applicable)

UNIT I.D. NUMBER

INSPECTED BY (print)

LOCATION OF UNIT

SIGNATURE OF INSPECTOR

QUARTERLY
ANNUAL

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 deployed according to the
crane manufacturers directions.
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 (which ever 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 months or 300 hours of normal operation (which ever 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 (which ever 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.

= SATISFACTORY

R = RECOMMENDATION (Should be
considered for corrective action)
NA = Not Applicable

FREQUENCY ITEM

D
D
D
D
D
D
D
D
D

1
2
3
4
5
6
7
8
9

10

D
D
D

11
12
13

KEY

Labels
Crane
Controls
Station
Hyd System
Hook
Wire Rope
Pins
General
covers.
Operation
Remote Ctrls
Electrical
Anti Two-Block or
Two-Block Damage
Prevention

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.)

INSPECTION DESCRIPTION

All load charts, safety & warning labels, & control labels are present and legible.
Check all safety devices for proper operation.
Control mechanisms for proper operation of all functions, leaks & cracks.
Control and operators station for dirt, contamination by lubricants, & foreign materials.
Hydraulic system (hoses, tubes & fittings) for leakage & proper oil level.
Presence & proper operation of hook safety latches.
Inspect for apparent deficiencies per applicable requirements and manufacturers specifications.
Proper engagement of all connecting pins & pin retaining devices.
Overall observation of crane for damaged or missing parts, cracked welds & presence of safety
During operation, observe crane for abnormal performance, unusual wear (loose pins, wire rope
damage, etc.). If observed, discontinue use & determine cause & severity of hazard.
Operate remote control devices to check for proper operation.
Operate all lights, alarms, etc. to check for proper operation.
Operate anti-two-blocking or two-block prevention devices to check for proper operation.

STATUS

R,
X, NA

REV: 11-22-11

20111122

20111122

4-4

Inspection Checklist
= SATISFACTORY

R = RECOMMENDATION (Should be
considered for corrective action)
NA = Not Applicable
FREQUENCY ITEM

D
D

14
15

or similar.
D
16

KEY

SECTION 4. GENERAL REFERENCE

CRANES
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.)

INSPECTION DESCRIPTION

Tires
Check tires (when in use) for proper inflation and condition.
Ground
Ground conditions around the equipment for proper support, including ground settling under and
conditions around and around stabilizers and supporting foundations, ground water accumulation,

Level Position The equipment for level position within tolerances specified by the equipment manufacturers
recommendations, both before each shift and after each move and setup.
17 Operator Cab Significant cracks, breaks, or other deficiencies that would hamper the operator s view.
Windows
18 Rails, rail stops,
Rails, rail stops, rail clamps and supporting surfaces when the equipment has rail traveling.

D
D

19
20

Electrical

D
D

21
22

Other
Other

M
M
M
M
M

23
24
25
26
27

M
M

28
29

M
M
M
M
M
M

30
31
32
33
34
35

M
M
M
M
M
M
M
M
Q
Q
Q
Q
Q

36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58

Daily
All daily inspection items.
Cylinders
Visual inspection of cylinders for leakage at rod, fittings & welds. Damage to rod & case.
Valves
Holding valves for proper operation.
Valves
Control valve for leaks at fittings & between sections.
Valves
Control valve linkages for wear , smoothness of operation & tightness of fasteners. Relief valve for
proper pressure settings.
General
Bent, broken or significantly rusted/corroded parts.
Electrical
Electrical apparatus for malfunctioning, signs of apparent excess deterioration, dirt or moisture
accumulation. Electrical systems for presence of dirt, moisture and frayed wires.
Structure
All structural members for damage.
Welds
All welds for breaks & cracks.
Pins
All pins for proper installation & condition.
Hardware
All bolts, fasteners & retaining rings for tightness, wear & corrosion
Wear Pads
Condition of wear pads.
Pump & Motor Hydraulic pumps & motors for leakage at fittings, seals & between sections. Check tightness of
mounting bolts.
PTO
Transmission/PTO for leakage, abnormal vibration & noise, alignment & mounting bolt torque.
Hyd Fluid
Quality of hydraulic fluid and for presence of water .
Hyd Lines
Hoses & tubes for leakage, abrasion damage, blistering, cracking, deterioration, fitting leakage & secured properly .
Hook
Load hook for abnormal throat distance, twist, wear & cracks.
Wire Rope
Condition of load line.
Manual
Presence of operators manuals with unit.
Other
Other
Daily
All daily inspection items.
Monthly
All monthly inspection items.
Rotation Sys Rotation bearing for proper torque of all mounting bolts.
Hardware
Base mounting bolts for proper torque.
Structure
All structural members for deformation, cracks & corrosion.

Base

Stabilizer beams & legs

Mast

Inner boom

Outer boom

Extension(s)

Jib boom

Jib extension(s)

Other
Hardware
Pins, bearings, shaf ts, gears, rollers, & locking devices for wear , cracks, corrosion & distortion.

clamps, supporting
surfaces.
Safety Devices

Safety devices and operational aids for proper operation.

Electrical apparatus for malfunctioning, signs of apparent excessive deterioration, dirt or moisture
accumulation.

2
STATUS

R,
X, NA

20111122

4-5

Inspection Checklist
= SATISFACTORY

R = RECOMMENDATION (Should be
considered for corrective action)
NA = Not Applicable

FREQUENCY ITEM

59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77

KEY

Hyd Lines

Pumps
& Motors

78
79
80
81
82
83
84
85
86
87

Cylinders

Q
Q
A
A
A
A
A
A
A
A
A
A
A
A

88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109

Winch
Hyd Filters
Daily
Monthly
Quarterly
Hyd Sys
Controls
Valves
Valves
Rotation Sys
Lubrication
Hardware
Wear Pads
Loadline

Valves

SECTION 4. GENERAL REFERENCE

CRANES
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.)

INSPECTION DESCRIPTION

Rotation bearing(s)

Inner boom pivot pin(s) & retainer(s)

Outer boom pivot pin(s) & retainer(s)

Inner boom cylinder pin(s) & retainer(s)

Outer boom cylinder pin(s) & retainer(s)

Extension cylinder pin(s) & retainer(s)

Jib boom pin(s) & retainer(s)

Jib cylinder pin(s) & retainer(s)

Jib extension cylinder pin(s) & retainer(s)

Boom tip attachments

Other
Hoses, fittings & tubing for proper routing, leakage, blistering, deformation & 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
Pumps & 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 & leakage at welds.
Rods for nicks, scores & dent s. Case for damage. Case & rod ends for damage & abnormal wear .

Stabiliizer 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 & drums for damage, abnormal wear , abrasions & other irregularities.
Hydraulic filters for replacement per maintenance schedule.
All daily inspection items.
All monthly inspection items.
All quarterly inspection items.
Hydraulic fluid change per maintenance schedule.
Control valve calibration for correct pressures & relief valve settings
Safety valve calibration for correct pressures & relief valve settings.
Valves for failure to maintain correct settings.
Rotation drive system for proper backlash clearance & abnormal wear , deformation & cracks.
Gear oil change in rotation drive system per maintenance schedule.
Check tightness of all fasteners and bolts.
Wear pads for excessive wear .
Loadline for proper attachment to drum.

3
STATUS

R,
X, NA

20111122

4-6

SECTION 4. GENERAL REFERENCE

Deficiency / Recommendation / Corrective Action Report

DATE

OWNER

UNIT I.D. NUMBER

GUIDELINES
A. A deficiency (X) may constitute a hazard. X 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
R = RECOMMENDATION
CA = CORRECTIVE ACTION TAKEN
X, R,
CA

ITEM #

EXPLANATION

If additional space is required, reproduce this page and attach to this report.

DATE
CORRECTED

20000710
WIRE ROPE INSPECTION
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.

B.

When there are either 3 broken wires in one strand

or a total of six broken wires in all strands in any one
rope lay.

4-7

SECTION 4. GENERAL REFERENCE

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)

C. 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.

F.

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" or more.

H. If a broken wire protrudes or loops out from the core

of the rope.

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 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)

20000710
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:

4-8

SECTION 4. GENERAL REFERENCE

COARSE THREAD BOLTS

TIGHTENING TORQUE

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.
TWO BLOCK PREVENTION DEVICE INSPECTION
(See Vol. 1, Operation, Maintenance and Repair for a
complete description)
The two block prevention system halts the winch-up and
extension-out crane functions before the block contacts
the sheave. The two block prevention 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 by the hook end, the winch up function
should become non-functioning, because the two-block
damage prevention switch will stop further movement.
If operation other than as described occurs, stop
immediately and investigate. Failure to do so will risk
damage to the cable or the crane.
Then, extend the winch cable to relieve the two-block
condition, and actuate the boom extend function slowly .
Again, once the weight is fully supported by the hook end,
the boom extend function should become nonfunctioning, because the two-block damage prevention
switch will stop further movement. If operation other than
described occurs, stop immediately , reverse the function,
and check the system.
If the anti two block function appears to be functioning
normally, winch the cable down until the sensing weight
swings free.

SIZE
(DIA-TPI)

SAE J429
SAE J429
GRADE 5
GRADE 8
BOLT DIA
PLAIN PLATED PLAIN PLATED
(INCHES) (FT-LBS) (FT-LBS) (FT-LBS) (FT-LBS)

5/16-18

0.3125

17

13

25

18

3/8-16

0.3750

31

23

44

33

7/16-14

0.4375

49

37

70

52

1/2-13

0.5000

75

57

105

80

9/16-12

0.5625

110

82

155

115

5/8-11

0.6250

150

115

220

160

3/4-10

0.7500

265

200

375

280

7/8-9

0.8750

395

295

605

455

1-8

1.0000

590

445

910

680

1 1/8-7

1.1250

795

595

1290

965

1 1/4-7

1.2500

1120

840

1815

1360

1 3/8-6

1.3750

1470

1100

2380

1780

1 1/2-6

1.5000

1950

1460

3160

2370

When using the torque data in the charts above, the following rules
should be observed.
1. Bolt manufacturer s particular specifications should be
consulted when provided.
2. Flat washers of equal strength must be used.
3. All torque measurements are given in foot-pounds. To
convert to inch-pounds, multiply by 12.
4. Torque values specified are for bolt s 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.
5. Torque values for socket-head cap screws are the same as
for Grade 8 capscrews.
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 af ter torquing. Failure to
replace gear-bearing bolts may result in bolt failure due to metal
fatique causing serious injury or DEA TH.

20000710

4-9

SECTION 4. GENERAL REFERENCE

TORQUE DATA CHART - DOMESTIC

FINE THREAD BOLTS

COARSE THREAD BOLTS

TIGHTENING TORQUE

SIZE
(DIA-TPI)

TIGHTENING TORQUE

SAE J429
SAE J429
GRADE 5
GRADE 8
BOLT DIA
PLAIN PLATED PLAIN PLATED
(INCHES) (FT-LBS) (FT-LBS) (FT-LBS) (FT-LBS)

SIZE
(DIA-TPI)

SAE J429
SAE J429
GRADE 5
GRADE 8
BOLT DIA
PLAIN PLATED PLAIN PLATED
(INCHES) (FT-LBS) (FT-LBS) (FT-LBS) (FT-LBS)

5/16-24

0.3125

19

14

27

20

5/16-18

0.3125

17

13

25

18

3/8-24

0.3750

35

26

49

35

3/8-16

0.3750

31

23

44

33

7/16-20

0.4375

55

41

78

58

7/16-14

0.4375

49

37

70

52

1/2-20

0.5000

90

64

120

90

1/2-13

0.5000

75

57

105

80

9/16-18

0.5625

120

90

170

130

9/16-12

0.5625

110

82

155

115

5/8-18

0.6250

170

130

240

180

5/8-11

0.6250

150

115

220

160

3/4-16

0.7500

300

225

420

315

3/4-10

0.7500

265

200

375

280

7/8-11

0.8750

445

325

670

500

7/8-9

0.8750

395

295

605

455

1-12

1.0000

645

485

995

745

1-8

1.0000

590

445

910

680

1 1/8-12

1.1250

890

670

1445

1085

1 1/8-7

1.1250

795

595

1290

965

1 1/4-12

1.2500

1240

930

2010

1510

1 1/4-7

1.2500

1120

840

1815

1360

1 3/8-12

1.3750

1675

1255

2710

2035

1 3/8-6

1.3750

1470

1100

2380

1780

1 1/2-12

1.5000

2195

1645

3560

2670

1 1/2-6

1.5000

1950

1460

3160

2370

When using the torque data in the charts above, the following rules should be observed.
1. Bolt manufacturers particular specifications should be consulted when provided.
2. Flat washers of equal strength must be used.
3. All torque measurements are given in foot-pounds. To convert to inch-pounds, multiply by 12.
4. 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.
5. Torque values for socket-head cap screws are the same as for Grade 8 cap screws.
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 af
ter torquing. Failure to replace gear-bearing bolts may result in
bolt failure due to metal fatique causing serious injury or DEATH.

20000710

4-10

SECTION 4. GENERAL REFERENCE

TORQUE DATA CHART - METRIC

FINE THREAD BOLTS

COARSE THREAD BOLTS

TIGHTENING TORQUE

SAE J429
GRADE 5
PLAIN PLATED
(KG-M) (KG-M)

TIGHTENING TORQUE

SAE J429
GRADE 8
PLAIN PLATED
(KG-M) (KG-M)

SIZE
(DIA-TPI)

BOLT DIA
(INCHES)

5/16-24

0.3125

3/8-24

0.3750

7/16-20

0.4375

1/2-20

0.5000

9/16-18

SAE J429
SAE J429
GRADE 5
GRADE 8
PLAIN PLATED PLAIN PLATED
(KG-M) (KG-M) (KG-M) (KG-M)

SIZE
(DIA-TPI)

BOLT DIA
(INCHES)

5/16-18

0.3125

3/8-16

0.3750

11

7/16-14

0.4375

10

12

17

12

1/2-13

0.5000

10

15

11

0.5625

17

12

24

18

9/16-12

0.5625

15

11

21

16

5/8-18

0.6250

24

18

33

25

5/8-11

0.6250

21

16

30

22

3/4-16

0.7500

41

31

58

44

3/4-10

0.7500

37

28

52

39

7/8-11

0.8750

62

45

93

69

7/8-9

0.8750

55

41

84

63

1-12

1.0000

89

67

138

103

1-8

1.0000

82

62

126

94

1 1/8-12

1.1250

123

93

200

150

1 1/8-7

1.1250

110

82

178

133

1 1/4-12

1.2500

171

129

278

209

1 1/4-7

1.2500

155

116

251

188

1 3/8-12

1.3750

232

174

375

281

1 3/8-6

1.3750

203

152

329

246

1 1/2-12

1.5000

304

228

492

369

1 1/2-6

1.5000

270

210

438

328

When using the torque data in the charts above, the following rules should be observed.
1. Bolt manufacturers particular specifications should be consulted when provided.
2. Flat washers of equal strength must be used.
3. All torque measurements are given in kilogram-meters.
4. 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.
5. Torque values for socket-head cap screws are the same as for Grade 8 cap screws.
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 af
ter torquing. Failure to replace gear-bearing bolts may result in
bolt failure due to metal fatique causing serious injury or DEATH.

20000710

4-11

SECTION 4. GENERAL REFERENCE

TURNTABLE BEARING FASTENER TIGHTENING SEQUENCE

Refer to the diagram below for proper tightening/torqueing sequence of the turntable bearing to the crane
base and crane mast. The total quantity of cap screws varies dependent on crane model.

18

22

11
15

14

19

10
6

23

WARNING
Number 1 can be assigned to
any capscrew if the sequence
remains the same in reference
to number 1.

2
24

1
5
9

20
13

16
12

21

17

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-LBS = 106 FT-LBS)
(EXAMPLE-METRIC: .40 x 36 KG-M = 14.4 KG-M)
4. Repeat Step 3, but torqueing all capscrews to 75% of the specified torque value. Continue to follow the
tightening sequence.
(EXAMPLE: .75 x 265 FT-LBS = 199 FT-LBS)
(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.

20000710

4-12

SECTION 4. GENERAL REFERENCE

TURNTABLE BEARING INSPECTION FOR REPLACEMENT

Before a bearing is removed from a crane for
inspection, one of the following conditions should be
evident:
1. Metal particles present in the bearinglubricant.
2. Increased drive power required to rotate the crane.
3. Noise emitting from the bearing during crane
rotation.
4. Rough crane rotation.
5. Uneven or excessive wear between the pinion
gear and turntable gear.

If none of the above conditions exists, the bearing is

functioning properly and need not be replaced. But, if
one or more of the above conditions exists, 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.
Periodic readings indicating a steady increase inTILT
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.

TEST PROCEDURE
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.

Set up dial indicator

to 0" on pinion cover
at back side of mast.
Lower crane to
horizontal position.
Read dial indicator.

COMPARISON CHART - MODEL TO MEASURED TILT DIMENSION

NOTE
THE FIGURES 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,
LOADER
OR
TIREHAND
MODEL

1007
1014
1014A
1015
2015/2020
2109
3000
3816/3820
3016/3020
421/425
4300
5016/5020
6016/6020
TH7 BODY ROTN
TH1449 BODY ROTN
TH15B CLAMP
TH2551B CLAMP
TH2557A CLAMP

5200
5200R
5217
5800
7020
7025
7200
7415
9000
TH10 BODY ROTN
TH14 BODY ROTN

16000
32018
32027
32030
T30
T40

9800
12916
13031
13034
14000
15000
18000
20017
8000L
H1200
H1200RR
T50
TH2551B BODY ROTN
TH2557B BODY ROTN
TH2557A BODY ROTN

BALL DIA.
(REF)

.875
(22mm)

1.00
(25mm)

1.18-1.25
(30-32mm)

1.75
(44mm)

TILT DIM.
(A1-A2)

.060
(1.524mm)

.070
(1.778mm)

.075
(1.905mm)

.090
(2.286mm)

20000710

4-13

SECTION 4. GENERAL REFERENCE

The information within this manual has been compiled and checked but errors do occur
. To provide our customers with a
method of communicating those errors we have provided the Manual Change Request form below
. In addition to error
reporting, you are encouraged to suggest changes or additions to the manual which would be of benefit to you. eW
cannot guarantee that these additions will be made but we do promise to consider them. When completing the form,
please write or print clearly. Submit a copy of the completed form to the address listed below
.

MANUAL CHANGE REQUEST

PRODUCT
MANUAL

DATE

MANUAL
PART NO.

SUBMITTED BY
COMPANY
ADDRESS
CITY, STATE, ZIP
TELEPHONE

ERROR FOUND
LOCATION OF ERROR (page no.):
DESCRIPTION OF ERROR:

ERROR FOUND
DESCRIPTION OF ADDITION:

REASON FOR ADDITION:

MAIL TO:

IOWA MOLD TOOLING CO., INC.

BOX 189
GARNER, IA 50438-0189
ATTN: Technical Publications

20000710

4-14

SECTION 4. GENERAL REFERENCE

This parts manual is provided to the user to assist in servicing the equipment. It is the property of Iowa Mold T ooling Co., Inc. and,
as such, may not be reproduced either whole or in part, whether by chemical, electrostatic, mechanical or photographic means
without the expressed written permission of an of ficer of Iowa Mold Tooling Co., Inc. One manual is provided with each piece o f
new equipment and additional manuals may be obt ained at a nominal price. Your distributor may have access to this manual
through the IMT web site at www.IMT.com.

IOWA MOLD TOOLING CO., INC.

BOX 189, GARNER, IA50438-0189
TEL: 641-923-3711
TECHNICAL SUPPORT FAX: 641-923-2424
www.imt.com