Download Parts and Specifications Manual for 30 Foot IMT Telescopic Crane

Manual Part # 99905181
Model 8600 30-foot Parts &
Specifications
Effective S/N 86301101001
Revised 20120815
IOWA MOLD TOOLING CO., INC.
PO Box 189
Garner, IA 50438
Tel: 641-923-3711 FAX: 641-923-2424
Website: http://www.imt.com
Copyright © 2012 Iowa Mold Tooling Co., Inc.
All rights reserved
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any
form or by any means, electronic, mechanical, photocopying, recording or otherwise without the
prior written permission of Iowa Mold Tooling Co., Inc.
Iowa Mold Tooling Co., Inc. is an Oshkosh Corporation Company.
Printed on 20 August, 2012
i
Contents
Revisions .............................................................................................................................................. iii
Introduction
5
Specifications
7
Model 8600 30' Specifications ................................................................................................................ 7
8600-30' Minimum Chassis Specifications ............................................................................................ 10
Dimensional Drawing .......................................................................................................................... 11
30' 8600 Capacity Chart ....................................................................................................................... 13
Crane Reference
15
Greasing Instructions ........................................................................................................................... 16
8600 30' Recommended Spare Parts ..................................................................................................... 18
Installation Introduction ....................................................................................................................... 19
Dominator II - 8600 - 10000 Crane Installation Kit (99905067) .................................................. 20
Additional Installation Components, Non-IMT Body (93713748) .................................... 22
Telescopic Crane Orientation ............................................................................................................... 23
Crane Controls ..................................................................................................................................... 23
Parts
25
Parts Information ................................................................................................................................. 26
Base & Mast Assembly, Test Stand (99904923).................................................................................... 28
Base & Mast Assembly, Truck Mount (99904923)................................................................................ 30
Boom Assembly (99904923) ................................................................................................................ 32
Valvebank Assembly (99904923) ......................................................................................................... 34
Winch & Anti-Two-Block Assembly (99904923) ................................................................................. 35
Crane & Winch Assembly (99904923) ................................................................................................. 36
Flip Sheave Assembly (99904923) ....................................................................................................... 38
30' Model 8600 Crane Parts List, Complete (99904923) ............................................................. 40
Gear Rotator (71056577) ...................................................................................................................... 44
Lower Cylinder (51723694) ................................................................................................................. 46
Extension Cylinder Assembly (51723604) ............................................................................................ 48
Cylinder (51723931) ................................................................................................................. 50
Cylinder (51723927) ................................................................................................................. 52
Winch, Planetary (71570968) ............................................................................................................... 54
Valvebank (73734727) ......................................................................................................................... 57
Seal Kit for 73734727 (94399214) ............................................................................................. 58
Connection Block Seal Kit for 73734727 (94399213) ................................................................ 60
ii
Contents
Hydraulic Schematic (99905018).......................................................................................................... 62
Radio Remote Harness (77441481) ...................................................................................................... 65
Decal Placement, 8600 30' Crane.......................................................................................................... 67
Option-Winch Roller (99905054) ......................................................................................................... 69
Option - Boom Tip Light Kit (99905289) ............................................................................................. 71
General Reference
75
Inspection Checklist ............................................................................................................................. 75
Deficiency / Recommendation / Corrective Action Report .................................................................... 80
Thread Torque Charts........................................................................................................................... 82
Contents
Revisions
DATE
LOCATION
DESCRIPTION
20111031
20120313
77441481
DECALS
ECN 11624 - Harness change
ECN 11712 - 70399345 replaced 70396787.
20120815
99904923
73734727
ECN 11774 - Added cable guide.
ECN 11783 - 73734727 was 73734635
iii
5
CHAPT
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1
Introduction
This volume includes specifications, installation information, and spare parts drawings applicable
to your particular crane. For operating, maintenance and repair instructions, see the Telescopic
Crane Operation, Maintenance and Repair Manual (IMT part number 99905190).
It is your responsibility to operate and maintain this unit in a manner that will result in the safest
working conditions possible. You must be aware of existing Federal, State and Local codes and
regulations governing the safe use and maintenance of this IMT crane. The crane was designed
and built to meet the standards of ANSI/ASME B30.5, Mobile & Locomotive Cranes. Contact the
American Society of Mechanical Engineers (www.asme.org) for more information on
ANSI/ASME B30.5.
Misuse of the crane through overloading, abuse, lack of maintenance and unauthorized
modifications will void the warranty on any part of the unit subjected to this misuse. No warranty
- verbal, written or implied - other than the official, published IMT new machinery and equipment
warranty will be valid with this unit.
Throughout the manual, NOTEs, CAUTIONs and WARNINGs are used to draw the attention of
personnel. They are defined as follows:
NOTE
A NOTE is used to either convey additional information or to provide further emphasis for a
previous point.
CAUTION
A CAUTION is used when there is the very strong possibility of damage to the equipment or
premature equipment failure.
WARNING
A WARNING is used when there is the potential for personal injury or death.
For a safe work environment, treat this equipment with respect and service it regularly.
7
CHAPT
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2
Specifications
In This Chapter
Model 8600 30' Specifications .................................................. 7
8600-30' Minimum Chassis Specifications ................................ 9
Dimensional Drawing................................................................ 11
30' 8600 Capacity Chart ........................................................... 13
Model 8600 30' Specifications
GENERAL SPECIFICATIONS
CRANE RATING (Crane rating (ft-lb) is the
rated load (lb) multiplied by the respective
distance (ft) from centerline of rotation with all
extensions retracted and lower boom in
horizontal position.)
HORIZONTAL REACH - FLIP SHEAVE UP
(From centerline of rotation)
HORIZONTAL REACH - FLIP SHEAVE DOWN
(From centerline of rotation)
FULLY RETRACTED LENGTH
HYDRAULIC EXTENSIONS (2)
LIFTING HEIGHT (From base of crane)
CRANE WEIGHT
CRANE STORAGE HEIGHT
MOUNTING SPACE REQUIRED (Crane base)
OPTIMUM PUMP CAPACITY
SYSTEM OPERATING PRESSURE
CENTER OF GRAVITY
 Horizontal from Centerline of Rotation
 Vertical from Bottom of Crane Base
TIE-DOWN BOLT PATTERN (8 bolts)
ROTATIONAL TORQUE
60,000 ft-lb (8.3 tm)
30'-10" (9.4 m)
30'-0" (9.1 m)
12'-11" (3.9 m)
102" & 102" (259 cm & 259 cm)
32'-1" (9.8 m)
2,410 lb (1,093 kg)
40.6" (103 cm)
20" x 21" (50.8 cm x 53.3 cm)
10 -12 U.S gpm (37.9 - 45.4 l/min)
3,000 psi (206.8 bar)
49.9" (126.8 cm)
22.2" (56.4 cm)
14.75" x 14.75" (37.5 cm x 37.5 cm)
9,000 ft-lb (1.2 tm)
8
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
PERFORMANCE CHARACTERISTICS
SPECIFICATIONS
SPEED
ROTATION
400° (7.0 rad.)
30 seconds
LOWER BOOM ELEVATION -10° to +80° (-0.17 to +1.4 rad) 12 seconds to raise or lower
EXTENSION CYLINDERS
(2)
WINCH SPEED (single line)
102" & 102" (259 cm & 259
cm)
33 seconds to extend or retract
60 feet per minute
Chapter 2 Specifications
9
POWER SOURCE
Hydraulic power is provided by an integral mounted hydraulic pump and PTO application. Other
standard power sources may be used. Minimum power required is 23.5 horsepower based on
10-12 GPM (37.9 - 45.4 liters/min) at 3,000 PSI (207 bar).
CYLINDER HOLDING VALVES
The holding sides of all cylinders are equipped with integral-mounted counterbalance valves or
load-holding check valves to prevent sudden cylinder collapse in case of hose failure.
ROTATION SYSTEM
Rotation of the crane is accomplished through a turntable gear bearing powered by a hightorque hydraulic motor through worm gear reduction. Standard rotation is 400º (6.98 rad).
HYDRAULIC SYSTEM (PTO DRIVEN)
The hydraulic system is an open-centered, full-pressure system that requires 10-12 GPM (37.9 45.4 liters/min.) optimum oil flow at 3000 psi (207 bar). It is equipped with a four-section, stacktype, electric, remote control valve with an RF remote-control system with a 40' (9.1 m) radio
elimination cable. The system includes a separate hydraulic oil reservoir, suction line filter,
return-line filter and control valve.
OVERLOAD PROTECTION SYSTEM
Overloading of the crane is prevented by the overload protection system. A pressure transducer
mounted on the lower cylinder senses overload conditions. When in an overload situation, the
winch-up, extension-out, and boom-down functions are stopped. To relieve the situation, raise
the boom, retract the extensions, or lower the winch.
WINCH
The 4,300 lb (1,950 kg) planetary winch is powered using a high-torque hydraulic motor. The
lifting capacity of the winch is 4,300 lb (1,950 kg) one-part line. Maximum two-part line capacity
is based on the maximum crane capacity. The winch is equipped with 120 ft (36.5 m) of 3/8"
(9.5 mm), 6X25 FW PRF RRL IWRC XIPS wire rope. A compact, anti-two block device is
included to prevent the lower block or hook assembly from coming in contact with the boom
sheave assembly. The winch meets ANSI B30.5 standards.
10
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
8600-30' Minimum Chassis Specifications
CRANE MODEL
8600 - 30'
CHASSIS STYLE
BODY STYLE
Conventional Cab
Dominator™ II minimum
CAB-TO-AXLE (1)
84 - 120" (213 - 305 cm)
RESISTANCE TO BENDING
MOMENT
FRAME SECTION MODULUS
1,200,000 in-lb (138,255 kg-m)
RATED MOMENT
60,000 ft-lb (8295 kg-m)
14.2 cubic inches (232.7 cc)
GROSS VEHICLE WEIGHT RATING 26,000 lb (11,793 kg) minimum
(2)
NOTES:
1
The Cab to Axle (CA) dimension varies based on the configuration of the body, crane, and
auxiliary equipment including welder decks. Make sure the CA is free and clear from
obstructions everywhere except between the frame rails.
2
The Gross Vehicle Weight Rating (GVW) is a minimum guideline. Contact IMT if you have
questions regarding your particular installation.
3
In addition to these specifications, heavy duty electrical and cooling systems are required. It
is recommended that the vehicle be equipped with an engine tachometer, auxiliary brake
lock, and power steering.
4
Weight distribution calculations are required to determine final axle loading.
5
All chassis, crane and body combinations must be stability-tested to ensure stability per
ANSI B30.5
Iowa Mold Tooling Co., Inc. reserves the right to change specifications and design without notice.
Chapter 2 Specifications
Dimensional Drawing
Dimensions for 30' 7500 and 8600 Crane
5'-8"
(1.7 m)
32'-1"
(9.8 m)
(Fully
extended)
2'-8"
(0.8 m)
15'-4"
(4.7 m)
(Fully
retracted)
13'-0"
(4.0 m)
(Fully retracted)
30'-0"
(9.1 m)
(Fully extended)
11
12
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
MOUNTING HOLE PATTERN
(FROM BASE OF CRANE)
6.6" (16.8 cm)
14.75"
(37.5 cm)
RADIUS 20" (51 cm)
SWING CLEARANCE
8" (20.3 cm)
18.1"
22.9"
(46 cm)
(58.2 cm)
23.4"
(59.3 cm)
13.75"
(34.9 cm)
14.75"
(37.5 cm)
15.9"
(40.4 cm)
TOP VIEW
20.8" (52.8 cm)
175" (444 cm)
47.8" (121 cm)
29.6"
(75.2 cm)
CENTER
OF GRAVITY
40.6"
(103.1 cm)
21.4"
(54.4 cm)
8.7"
(22.0 cm)
17.75"
(45.0 cm)
47.3" (120.1 cm)
6.5"
(16.5 cm)
50.4" (128.0 cm)
Chapter 2 Specifications
30' 8600 Capacity Chart
80°
7125
3230
• Values in the box indicate thexxxx lb
use of 2-part line is required. xxxx kg
75°
5240
2375
60 °
2860
1300
• Maximum 1-part line w eight is 4300 lb
(1950 kg).
• The w eight of load-handling devices is
part of the load lif ted and must be
deducted from the rated capacity.
45 °
8600
3900
8600
3900
7070
3205
8600
3900
2385
1080
4665
2115
3820
1735
7375
3345
2065
935
30 °
3335
1515
6310
2860
5660
2570
5135
2330
4625
2100
13'-0"
(4.0 m)
3010
1365
1830
830
2650
1200
1575
715
21'-6"
(6.6 m)
30'-0"
(9.1 m)
15°
0°
IOWA MOLD TOOLING CO., INC.
BOX 189, GARNER, IA 50438-0189
TEL: 641-923-3711 FAX: 641-923-2424
70399105
13
15
CHAPT
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3
Crane Reference
In This Chapter
Greasing Instructions................................................................ 15
8600 30' Recommended Spare Parts ....................................... 18
Installation Introduction............................................................. 19
Telescopic Crane Orientation ................................................... 23
Crane Controls ......................................................................... 23
16
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
Greasing Instructions
Different lubricants are required for different sections of your crane. Contact your lubricant
supplier for specific product information. Follow the grease and lubricant specifications and
intervals listed in this manual for best results.
Crane grease zerks must be greased on a weekly basis during normal operating conditions.
Under severe operating conditions the zerks must be greased more frequently. Each grease
zerk is marked with a decal, “Grease Weekly”, as shown. Rotate the worm gear bearing when
greasing the worm gear bearing grease zerks.
Crane worm gear bearing teeth must be lubricated weekly with Molub-Alloy 936 or equivalent,
applied with a grease gun or brush. Cover all teeth with grease and leave no exposed metal
surfaces showing.
Weekly, remove cover and lubricate
with MOLUB-ALLOY 936SF open-gear
compound while rotating crane.
MOLUB-ALLOY is a registered tradem ark of
Cas trol Industrial PLD Dow ners Grove , IL 1-800-621-6221
Chapter 3 Crane Reference
17
Flip
Sheave
Zerk
Opposite Side of Crane
Snatch
Block
Zerk
Remove guard. Grease
worm gear teeth with
Molub-Alloy 936 or
equivalent. Spray or
brush on.
Turntable
Bearing
Grease
Zerk
LOCATION
Base - Turntable Bearing
Grease Zerk
Flip Sheave Pin
Snatch Block Pin
Worm Gear Bearings Grease
Zerks (*Rotate crane while
greasing)
Rotation Worm Gear Teeth
NOTE:
Rotated view
LUBRICANT
Worm Gear Grease Zerks
APPLICATION
METHOD
Extreme Pressure Lithium
Grease such as
Apply with hand or
Shell Alvania 2EP,
pneumatic pressure
Shell Retinax "A",
grease gun.
Mobilgrease XHP 462,
Cenex ML 365,
Xtreme True-Flo MP EP2
Lithium Grease
or equivalent.
Molub-Alloy 936 or
equivalent
Brush or spray on.
FREQUENCY
Weekly
Weekly
18
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
8600 30' Recommended Spare Parts
This parts list 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, but it does not indicate these items will
fail within a year. In addition, there may be parts failures not covered by this list. Parts not listed
are considered as not being Critical or Normal Wear items during the first year of operations.
BASE & MAST ASSEMBLY
73051919
HYDRAULIC MOTOR
72601949
CAP SCREW 0.50-13 X 1.25 SHZC
72601629
CAP SCREW .75-10 X 4.00 HEX HEAD GR8 Z
72601817
CAP SCREW .75-10 X 3.25 HEX HEAD GR8 Z
BOOM ASSEMBLY
60030336
WEAR PAD-RC
60030337
WEAR PAD-ROUND
60030421
WEAR PAD-RC
60030422
WEAR PAD-ROUND
60030423
WEAR PAD-RC
60030425
WEAR PAD-ROUND
60030428
WEAR PAD-ROUND
ANTI-TWO-BLOCK ASSEMBLY
77041863
LIMIT SWITCH
CRANE & WINCH ASSEMBLY
52718741
PIN
52723036
PIN
71073035
HOOK, SWIVEL 5.0T
70580202
WIRE ROPE ASSEMBLY
60030134
SHEAVE
LOWER CYLINDER (51723694)
94399129
SEAL KIT
51723931 CYLINDER (PART OF 51723604 EXT. CYLINDER ASSEMBLY)
94399160
SEAL KIT
51723927 CYLINDER (PART OF 51723604 EXT. CYLINDER ASSEMBLY)
94399162
SEAL KIT
WINCH (71570968)
IN PROCESS
VALVE BANK (73734727)
94399213
SEAL KIT, CONNECTION BLOCK
94399214
SEAL KIT, VALVE SECTIONS
77041898
SOLENOID, 12V
1
2
4
16
1
2
1
1
4
2
4
1
2
1
1
1
1
1
1
1
1
1
1
Chapter 3 Crane Reference
19
Installation Introduction
GENERAL
This section contains instructions for the installation of your crane. Prior to installing the crane
and hydraulic components, make sure that the chassis is ready to receive the crane (see the
Installation Section of the IMT Telescopic Crane Operation & Safety Manual, 99905190).
Reinforce the chassis frame, as necessary, and install the PTO and pump.
Each installation may vary in components used. It is important to use hoses of proper length,
pumps of correct size, and PTO’s of adequate speed. Study the applicable installation kit in the
parts section before attempting any installation.
CRANE INSTALLATION
In addition to meeting Minimum Chassis Specifications, there must be sufficient room to
mounting the crane and the platform must be strong enough to support the crane and rated load.
Install the crane only on an IMT designed and approved truck body. The body must be designed
to sustain the forces imposed by the crane when lifting the full rated load. In addition, an IMT
designed body is designed to take full advantage of the standard reservoir placement. This
reservoir is installed in the cargo area of the body. Before attempting to install the crane, the
body must be installed.
20
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
Dominator II - 8600 - 10000 Crane Installation Kit (99905067)
2
3
CUT WASHER LOCATIONS
5,7
5,6
41
7(6)
5(8) 2
6(2)
5,7
5,7
DOOR
SIDE
5,7
5,7
5,7
5,6
REAR
OF TRUCK
NOTES (SEE REFERENCE NUMBER IN BOX):
1 INSTALL THE LEVEL INDICATOR (72042097) PARALLEL TO THE DOOR REINFORCEMENTS.
2
TORQUE MOUNTING BOLTS TO 680 FT-LB (94 KG-M). (8 PLACES) USE THE SUPPLIED 3" (7.6 cm) BOLTS
WITH A CRANE BOX TOP PLATE THICKNESS OF 1/2" TO 5/8" (1.3 cm TO 1.6 cm) ONLY. DETERMINE THE
THICKNESS OF THE CRANE BOX TOP PLATE PRIOR TO MOUNTING. IF DIFFERENT LENGTH BOLTS ARE
REQUIRED, THEY MUST BE 1-8, GRADE 8, ZINC COATED, OF PROPER LENGTH. FAILURE TO USE
PROPER LENGTH BOLTS MAY CAUSE THE BOLTS UNDER THE CRANE SWING BEARING TO BOTTOM
OUT BEFORE TORQUING. INSURE A MINIMUM OF 1-1/2" (3.8 cm) THREAD ENGAGEMENT.
Chapter 3 Crane Reference
21
CRANE MOUNTING HOLE LOCATIONS
14.75" (37.5 cm)
7.38"
(18.7 cm)
2.38"
(6 cm)
Ø1.13" (2.9 cm)
THROUGH CRANE
BOX TOP ONLY
(8 PLACES)
7.25"
(18.4 cm)
6.75"
(17.1 cm)
13.75"
(34.9 cm)
14.75"
(37.5 cm)
REAR OF
TRUCK
Ø6" (15.2 cm)
THROUGH CRANE
BOX TOP ONLY
99905067 PARTS
ITEM
PART #
1.
93713669
2.
CRANE
3.
BODY
4.
72042097
5.
72601748
6.
72063066
7.
72063286
REV D 20120523
DESCRIPTION
INSTALLATION KIT
CRANE ASSEMBLY
DOMINATOR BODY
LEVEL INDICATOR LEVEL
CAP SCREW
WASHER
WASHER
DETAILS
7500-10000
KIT #
#1
1.00- 8X 3.00 SH GR8
#1
1.00 FLAT HI STR
#1
FLAT 1.00 H ASTM F436 #1
Z-CUT
QUANTITY
1
1
1
1
8
2
6
22
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
Additional Installation Components, Non-IMT Body (93713748)
Chassis Wiring Harness (77441476 / 99905212)
TO RECOMMENDED
SWITCHED 12V POWER
(NOT TO EXCEED 7 AMPS)
TO RECOMMENDED 12V CRANE
HOURMETER (12V LATCHING SIGNAL
WHEN LINK IS ESTABLISHED
BETWEEN RADIO AND TRANSMITTER)
BOOM
FLOOD
LIGHTS
12V NORMALLY CLOSED
OUTPUT FROM BOOM STOW SENSOR
12V NORMALLY OPEN OUTPUT
FROM BOOM STOW SENSOR
CRANE
HOURMETER
ENGINE
SPEED
TO RECOMMENDED OEM
12V SPEED CONTROL
STOW
SIGNAL POWER
TO 12V SOURCE FOR BOOM
STOW SENSOR POWER
IN-LINE 5A FUSE
GROUND
TO BATTERY GROUND
TO RECOMMENDED
ENGINE KILL OPTION
30
85
87A
87
86
TO RECOMMENDED
SELECTOR SOLENOID
TO RECOMMENDED
COMPRESSOR ON
(12V LATCHING SIGNAL)
COMPRESSOR
ON
ENGINE
STOP
SELECTOR
SOLENOID
POWER
IN-LINE
15A FUSE
IMT HARNESS
77441476
Filter (10 micron) (73052091)
Used on ship-out IMT telescopic cranes.
TO RECOMMENDED OEM
12V ENGINE START
(12V MOMENTARY SIGNAL)
ENGINE
START
87A
87
86
30
85
TO 12V
IGNITION
KEYED POWER
TO 12V BATTERY
SOURCE
RECOMMENDED
USING PTO
GROUND SIGNAL
Chapter 3 Crane Reference
23
Telescopic Crane Orientation
When an IMT telescopic crane is not factory-installed on a body, the crane is packed with the
boom oriented as it is built on a test stand to facilitate handling. Install the crane on the body
with boom pointing backward. Once the crane is bolted down, it can be rotated 180° (3.14
radians) to the boom rest.
BOOM
REST
400°
ROTATION
OUTLINE OF
TRUCK BODY
REAR OF
TRUCK
Crane Controls
IMT's telescopic cranes are controlled by radio remote controls. See the Telescopic Crane Radio
Remote System manual, IMT # 99905114, for complete details on the radio remote system.
25
CHAPT
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4
Parts
In This Chapter
Parts Information ...................................................................... 26
Base & Mast Assembly, Test Stand (99904923)....................... 28
Base & Mast Assembly, Truck Mount (99904923) .................... 30
Boom Assembly (99904923) .................................................... 32
Valvebank Assembly (99904923) ............................................. 34
Winch & Anti-Two-Block Assembly (99904923) ........................ 35
Crane & Winch Assembly (99904923) ...................................... 36
Flip Sheave Assembly (99904923) ........................................... 38
Gear Rotator (71056577) ......................................................... 44
Lower Cylinder (51723694) ...................................................... 46
Extension Cylinder Assembly (51723604) ................................ 48
Winch, Planetary (71570968) ................................................... 54
Valvebank (73734727) ............................................................. 57
Hydraulic Schematic (99905018) .............................................. 62
Radio Remote Harness (77441481) ......................................... 64
Decal Placement, 8600 30' Crane ............................................ 67
Option-Winch Roller (99905054) .............................................. 69
Option - Boom Tip Light Kit (99905289).................................... 70
26
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
Parts Information
GENERAL
This section contains the exploded parts drawings and accompanying parts lists for the
assemblies used on this crane. These drawings are intended to be used in conjunction with the
instructions found in the maintenance and repair manuals for this crane family. For optional
equipment such as winches and remote controls, refer to the appropriate service manual.
WARNING
DO NOT ATTEMPT TO REPAIR ANY COMPONENT WITHOUT READING THE
INFORMATION CONTAINED IN THE REPAIR SECTION. PAY PARTICULAR ATTENTION
TO STATEMENTS MARKED WARNING, CAUTION, OR NOTE IN THAT SECTION.
FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN DAMAGE TO THE
EQUIPMENT, PERSONAL INJURY, OR DEATH.
CRANE IDENTIFICATION
Every IMT crane has an identification placard (see figure). This placard is attached to the inner
boom, mast, or crane base. When ordering parts, communicating warranty information, or
referring to the unit in correspondence, always include the serial number and model numbers.
Address all inquiries to your authorized IMT distributor or to:
Iowa Mold Tooling Co., Inc.
Box 189, Garner, IA 50438-0189
Telephone: 641-923-3711
Technical Support Fax: 641-923-2424
IOWA MOLD TOOLING CO., INC.
BOX 189, GARNER, IA 50438-0189
MODEL
NUMBER
SERIAL
NUMBER
MFG
DATE
Chapter 4 Parts
27
CYLINDER IDENTIFICATION
To insure proper replacement parts are received, it is necessary to specify the complete
number/letter sequence for any part requested. Part numbers may be cross checked by
comparing the stamped identification on the cylinder case (See figure below) against the
information contained in the service manual. You must include the part number stamped on the
cylinder case when ordering parts.
CYLINDER
PART NUMBER
LOCATION
WELDMENT IDENTIFICATION
Each of the major weldments - base, mast, inner boom, outer boom, extension boom and
stabilizer weldments bear a stamped part number. Any time a major weldment is replaced, you
must specify the complete part number as stamped on the weldment. The locations of the part
numbers are shown in the Crane Reference Section.
ORDERING REPAIR PARTS
When ordering replacement parts:
1
Give the model number of the unit.
2
Give the serial number of the unit.
3
Specify the complete part number. When ordering cylinder parts, or one of the main
weldments, always give the stamped part number.
4
Give a complete description of the part.
5
Specify the quantity required.
28
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
Base & Mast Assembly, Test Stand (99904923)
1 64
5
64 1
7
1 67
6
67 1
1 66
65
11 2
33 2
34
77
77
59
41
51
41
3 111
5
50 2 4
126 6
126 7
111 3
115
80
81
77
NOTES (SEE REFERENCE NUMBER IN BOX):
1
TORQUE TO 280 FT-LB (38.7 KG-M)
2
USE RUST PREVENTATIVE ON SLIDE STOP, BEARING RACE, BOTTOM OF MAST AND TOP OF GEAR
BEARING.
3
APPLY BLUE THREAD LOCKER.
4
APPLY GEAR LUBE ON GEAR TEETH.
5
BASE AND MAST ASSEMBLY SHOWN AS MOUNTED ON THE TEST STAND. NOTE ORIENTATION OF
MOTOR. BOTTOM VIEW OF ROTATION ASSEMBLY.
6
PORT A
7
PORT B
BASE & MAST ASSEMBLY, TEST STAND MOUNT (99904923)
ITEM
PART #
DESCRIPTION
DETAILS
1.
91723059 KIT-HARDWARE BASE & MAST
5.
91723584 HARDWARE KIT
6.
91723601 HYDRAULIC KIT
11.
52722950 MAST WELDMENT
KIT #
QTY
1
1
1
1
Chapter 4 Parts
BASE & MAST ASSEMBLY, TEST STAND MOUNT (99904923)
ITEM
PART #
DESCRIPTION
DETAILS
33.
60120138 SLIDE-ROTATION STOP
34.
60128849 GEAR GUARD
41.
70029595 THREADED PLUG
1.00-8
50.
71056577 GEAR ROTATOR
0.75 BOLTS
51.
76039295 GASKET
59.
73051919 MOTOR-HYDRAULIC
64.
72060207 CAP SCREW
.75-10 X 3.00 HEX HEAD GR8 Z
65.
72063116 WASHER
.75 N FLAT H ASTM F436 Z
66.
72601629 CAP SCREW
.75-10 X 4.00 HEX HEAD GR8 Z
67.
72601817 CAP SCREW
.75-10 X 3.25 HEX HEAD GR8 Z
77.
70034382 CAP-GREASE
80.
72053301 COUPLING
BLK .12
81.
72053508 ZERK
NPT 0.12
111.
72601949 CAP SCREW
.50-13 X 1.25 SOCKET HEAD
ZINC-COATED
115.
51395121 HOSE
AA .13 X 13.5 0 OAL (2-2)
128.
72533613 ADAPTER
M STR/M JIC 10 6
REV. G 20120815
KIT #
29
#1
#1
#1
#1
#5
#5
#5
#5
QTY
1
1
2
1
1
1
2
22
4
16
6
1
4
2
#6
#6
1
2
#50
30
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
Base & Mast Assembly, Truck Mount
(99904923)
NOTE: This base and mast assembly is shown as it if it were mounted on a truck.
1 64
1 67
64 1
1 67
67 1
1 66
65
11 2
5
41
34
6
41
33 2 4
111 3
7
51
111 3
59
128 7
128 6
77
115 80 81
50 2
77
77
NOTES (SEE REFERENCE NUMBER IN BOX):
1
TORQUE TO 280 FT-LB (38.7 KG-M)
2
USE RUST PREVENTATIVE ON SLIDE STOP, BEARING RACE, BOTTOM OF MAST AND TOP OF GEAR
BEARING.
3
APPLY BLUE THREAD LOCKER.
4
APPLY GEAR LUBE ON GEAR TEETH.
5
BASE AND MAST ASSEMBLY SHOWN AS MOUNTED ON THE TRUCK. VIEW A FROM BOTTOM OF
ROTATION ASSEMBLY.
6
PORT A
7
PORT B
Chapter 4 Parts
BASE & MAST ASSEMBLY, TRUCK MOUNT (99904923)
ITEM
PART #
DESCRIPTION
1.
91723059 KIT-HARDWARE BASE & MAST
5.
91723584 HARDWARE KIT
6.
91723601 HYDRAULIC KIT
11.
52722950 MAST WELDMENT
33.
60120138 SLIDE-ROTATION STOP
34.
60128849 GEAR GUARD
41.
70029595 THREADED PLUG
50.
71056577 GEAR ROTATOR
51.
76039295 GASKET
59.
73051919 MOTOR-HYDRAULIC
64.
72060207 CAP SCREW
65.
72063116 WASHER
66.
72601629 CAP SCREW
67.
72601817 CAP SCREW
77.
70034382 CAP-GREASE
80.
72053301 COUPLING
81.
72053508 ZERK
111.
72601949 CAP SCREW
115.
51395121
128.
72533613
REV. G 20120815
HOSE
ADAPTER
DETAILS
KIT #
#1
#1
#1
#1
#5
#5
#5
#5
QTY
1
1
1
1
1
1
2
1
1
1
2
22
4
16
6
1
4
2
#6
#6
1
2
1.00-8
0.75 BOLTS
#50
.75-10 X 3.00 HEX HEAD GR8 Z
.75 N FLAT H ASTM F436 Z
.75-10 X 4.00 HEX HEAD GR8 Z
.75-10 X 3.25 HEX HEAD GR8 Z
BLK .12
NPT 0.12
.50-13 X 1.25 SOCKET HEAD
ZINC-COATED
AA .13 X 13.5 0 OAL (2-2)
M STR/M JIC 10 6
31
32
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
Boom Assembly (99904923)
101
108
37 1
101
108
14
44
104(6)
9
26
22
28
87(6)
25
44
28
106(6)
36
29
131133
129
13
130
132 134
87(6)
104(6)
45
45
35 106(6)
26
29
24
23
23
39
12
2
39
105
89
14 0.77"
44
108"
6"
6.5"
6"
3
13 1.46" 45
108"
6"
4
6.5"
6"
NOTES (SEE REFERENCE NUMBER IN BOX):
1 APPLY NEVER SEEZ.
2
INSTALL EXTENSION CYLINDER FIRST, FOLLOWED BY RETAINERS AND WEAR PADS.
3
TORQUE TO 280 FT-LB (38.7 KG-M). USE BLUE THREAD LOCKER.
4
START WITH RED SEGMENT. ALIGN WITH PLATE EDGE.
99904923 BOOM ASSEMBLY
ITEM
PART #
DESCRIPTION
5.
91723584 HARDWARE KIT
9.
51723604 CYLINDER ASSEMBLY
DETAILS
2.50/ 1.50 2.75/1.75 204.0S
144.6
KIT #
QUANTITY
1
1
Chapter 4 Parts
99904923 BOOM ASSEMBLY
ITEM
PART #
DESCRIPTION
12.
52723022 WELDMENT-LOWER BOOM
13.
52723023 WELDMENT-1st STAGE EXT BOOM
14.
52723024 WELDMENT-2nd STAGE EXT BOOM
22.
60030336 WEAR PAD-RC
23.
60030337 WEAR PAD-ROUND
24.
60030421 WEAR PAD-RC
25.
60030422 WEAR PAD-ROUND
26.
60030423 WEAR PAD-RC
28.
60030425 WEAR PAD-ROUND
29.
60030428 WEAR PAD-ROUND
35.
60135667 CAP-LOWER BOOM
36.
60135668 CAP-FIRST STAGE
37.
60135669 PIN
39.
60135833 RETAINER-1st STAGE EXTENSION
CYLINDER
44.
70399044 TAPE -REFLECTIVE RED/ SILVER
45.
70399045 TAPE -REFLECTIVE RED/ SILVER
87.
72060093 CAP SCREW
89.
72060206 CAP SCREW
101.
72063035 MACHINERY BUSHING
104.
72063053 WASHER
105.
72063116 WASHER
106.
72063132 WASHER
108.
72066129 RETAINING RING-EXTERNAL
129.
72062080 NUT
130.
72602073 CAP SCREW
131.
72602075 CAP SCREW
132.
60140029 BRACKET-CABLE GUIDE
133.
60140030 ROLLER-CABLE GUIDE
134.
72063005 WASHER
135.
93724760 CABLE GUIDE KIT
REV G 20120815
DETAILS
KIT #
7500/10000
7500/10000
7500/10000
.19 X 6.00 X 6.00
2.00 DIA X 1.00 DIA X 1.188 LG
.25 X 6.00 X 6 .00
2.00 DIA X .50 DIA X 1.69 L
0.25 X 2.25 X 6.00L
1.25 DIA X 0.50 DIA X 0.94L
2.0 0 DIA X .75 DIA X .72L
1.2 5X 6.89 ( 6.46)
1.25 X108.00
2.00 X108.00
.50-13 X 1.5 HEX HEAD GR5 Z
.75-10 X 2.00 HEX HEAD GR8Z
1.25 X10 GA NR
.50 LOCK
FLAT .75N ASTM F436Z
.50 FLAT ASTM F436
1.25 HD
.50-13 HEX NYLOCK
.50-13 X 11.5 HHGR5Z
.50-13 X 12.5 HHGR5Z
.50 FLAT
#5
#5
#5
#5
#5
#5
#5
#135
#135
#135
#135
#135
#135
33
QUANTITY
1
1
1
1
2
1
1
4
2
4
1
1
1
2
2
2
12
1
2
17
1
17
2
2
1
1
1
2
2
1
34
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
Valvebank Assembly (99904923)
WINCH
(DOWN)
EXT CYL
(RETRACT)
LOWER CYL
(RETRACT)
ROTATION
CW
CASE DRAIN
RETURN
(TANK)
73
20
PRESSURE
72
71
72 71
61
73
117
119
73
125
ROTATION
CCW
71
123
LOWER CYL
(EXTEND)
EXT CYL
(EXTEND)
WINCH
(UP)
72
117
122
117
127
117
119
119
121
119
VALVEBANK ASSEMBLY PARTS LIST (99904923)
ITEM
PART #
DESCRIPTION
3.
91723543 HARDWARE KIT-VALVEBANK MOUNT
6.
91723601 HYDRAULIC KIT
20.
52723563 WELDMENT-MAST VALVEBANK
BRACKET
61.
73734727 VALVE BANK (WAS 73734635)
71.
72601797 WASHER-LOCK
72.
72602065 WASHER-FLAT
73.
72602052 CAP SCREW
117.
72532356 ADAPTER
119.
72532358 ADAPTER
121.
72532361 ADAPTER
122.
72532670 ELBOW
123.
72532690 ELBOW
125.
72532792 ADAPTER
127.
72533583 ELBOW
REV G 20120815
DETAILS
KIT #
10 GPM
8 MM
M8
M8-1.25X 16 HEX HEAD Z
M STR/M JIC 8 6
M STR/M JIC 8 8
M STR/M JIC 8 10
M JIC/45/ F JIC 8 8
M JIC/90 /FJIC SW 4 4
M STR/M JIC 8 4
M STR/45/ M JIC 8 6
#3
#3
#3
#6
#6
#6
#6
#6
#6
#6
QUANTITY
1
1
1
1
3
3
3
4
4
1
1
1
1
1
Chapter 4 Parts
35
Winch & Anti-Two-Block Assembly (99904923)
2 126
54
93
107
55
62
107
93
110
3 120
112
4 120
78
90 1
NOTES (SEE REFERENCE NUMBER IN BOX):
1 USE BLUE LOCTITE
2
CASE DRAIN
3
PORT B
4
PORT A
WINCH ASSEMBLY, ANTI-TWO-BLOCK ASSEMBLY (99904923)
ITEM
PART #
DESCRIPTION
DETAILS
5.
91723584 HARDWARE KIT
6.
91723601 HYDRAULIC KIT
54.
71570968 WINCH-PLANETARY
4400 LINE PULL (A41)
55.
72034485 CLAMP-PLASTIC
1/4 " CABLE
62.
77041863 SWITCH-LIMIT
DT04-4P CONN
78.
71413185 SPRING
.105 WIRE 0.75OD 2 .875 LG
90.
72060640 SCREW-MACHINERY
10-24 X 1.50 ROUND HEAD
93.
72062093 NUT
#8 -32 HEX ZINC
107.
72063271 WASHER
# 8 W FLAT ANSI B 27. 2Z
110.
72601938 BOLT-EYE
# 8-32X 1.125
112.
72602022 BOLT-SHOULDER
.38X 1.25
120.
72532359 ADAPTER
M STR/M JIC 10 8
126.
72533490 ADAPTER
M BSPP/M JIC 4 4
REV G 20120815
KIT #
#5
#5
#5
#5
#5
#5
#6
#6
QUANTITY
1
1
1
9
1
1
2
2
2
1
1
2
1
36
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
Crane & Winch Assembly (99904923)
68,69(4)
109 57 2
56 2
120
120
16 1
106
104
2 56
2 57
109
56 2
K
124
2 57 109
2 56
84,99,103
79
79
57 2
118
124
8
116
83,98,102
40
3 70(4)
86
2 57
2 56
10 1
106 104
86
83,98,102
84,99,103
DETAIL K
106 104
86
1 10
NOTES (SEE REFERENCE NUMBER IN BOX):
1 APPLY ANTI-SEEZ TO BOOM AND CYLINDER MOUNTING PINS ON THE MAST.
2
IF REQUIRED, USE 72063038 OR 72063039 MACHINERY BUSHINGS BETWEEN THE MAST AND LOWER
BOOM.
3
APPLY BLUE LOCKTITE.
CRANE & WINCH ASSEMBLY (99904923)
ITEM
PART #
DESCRIPTION
1.
91723059 KIT-HARDWARE BASE &
MAST
2.
91723579 HARDWARE KIT-WINCH
MOUNT
5.
91723584 HARDWARE KIT
8.
51723694 CYLINDER
10.
52718741 PIN
16.
52723036 PIN
40.
60136475 COVER-VALVE BANK
DETAILS
KIT #
QUANTITY
1
1
4.75/2.50 25.06S 45.52CCC
MM 2.00 X 12.75 (11.94 )
MM 2.00 X 9.00 (8.19 )
1
1
2
1
1
Chapter 4 Parts
CRANE & WINCH ASSEMBLY (99904923)
ITEM
PART #
DESCRIPTION
56.
72063038 MACHINERY BUSHING
57.
72063039 MACHINERY BUSHING
68.
72062108 NUT
69.
72063132 WASHER
70.
72602061 STUD
79.
83.
84.
86.
98.
99.
102.
103.
104.
106.
109.
72034479
72060002
72060044
72060091
72063001
72063003
72063049
72063051
72063053
72063132
72066136
116.
72532355
118.
72532357
120.
72532359
124.
72532700
REV G 20120815
PLUG-PLASTIC
CAP SCREW
CAP SCREW
CAP SCREW
WASHER
WASHER
WASHER
WASHER
WASHER
WASHER
RETAINING RINGEXTERNAL
ADAPTER
ADAPTER
ADAPTER
ELBOW
DETAILS
2.00 X14 GA NR
2.00 X10 GA NR
.50 -20 HEX CENTER LOCK
.50 FLAT ASTM F436
0.50-13(20)X2.5 NC(NF) GR8
STL
.50-13 X .50 UNC-2B
.25-20 X .75 HEX HEAD GR5 Z
.38-16 X .75 HEX HEAD GR5 Z
.50-13 X 1.00 HEX HEAD GR5 Z
.25 FLAT
.38 FLAT
.25 LOCK
.38 LOCK
.50 LOCK
.50 FLAT ASTM F436
2.00 HD
KIT #
M STR/M JIC 6 6
M STR/M JIC 6 8
M STR/M JIC 10 8
M STR/90/ M JIC XL 6 6
37
#2
#2
#2
QUANTITY
AS REQUIRED
AS REQUIRED
4
4
4
#5
#5
#5
#5
#5
#5
#5
#5
#5
#5
#5
2
4
4
5
10
16
6
4
17
17
3
#6
#6
#6
#6
1
1
2
2
38
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
Flip Sheave Assembly (99904923)
46
21
43
81,77
A
92,114
113
88 1
98(2),95
38
85,99,96(4)
60
53
100 58 104
86 106
17
113
19
75
49
99
91
99
91
31,88
7
55,97
18
15 99,94
27
113
98,102,82
74
99,94
30
77,81,27
47
30 106
42
86
77,81
60
52
DETAIL A
95
48
76 76
NOTES (SEE REFERENCE NUMBER IN BOX):
1 USE BLUE LOCKTITE.
FLIP SHEAVE ASSEMBLY PARTS (99904923)
ITEM
PART #
DESCRIPTION
4.
51719413 HARDWARE KIT-CRANE
RADIO CONTROLS
5.
91723584 HARDWARE KIT
7.
51723610 CORD REEL ASSEMBLY
15.
52723030 PIN
17.
52723058 WELDMENT- ANTI-TWO
BLOCK BRACKET
18.
52723062 WELDMENT-FLIP SHEAVE
19.
52723063 WELDMENT- SNATCH BLOCK
21.
60030134 SHEAVE
27.
60030424 CAP- ANTI-TWO BLOCK PIN
30.
60030429 WEAR PAD- ANTI-TWO
BLOCK BRACKET
31.
60109337 PIN RETAINER PLATE
38.
52723623 HOOK HOLDER-WELDMENT
42.
70034517 SPLIT SHEAVE PROTECTOR
43.
70145121 COLLAR-SHAFT 2 PIECE
46.
70580202 WIRE ROPE ASSEMBLY
47.
72661514 PIN-LOCK WITH HANDLE
48.
70734559 TRANSMITTER-RADIO
REMOTE
DETAILS
30' WITH CONNECTOR
M 1.50X 3.38
KIT #
QUANTITY
1
1
1
1
1
7500/8600
7500/8600
8.00 NYLATRON GSM
1
1
1
2
2
3.00 DIA
1
1
1
1
1
1
1
7/8 in.
0.38 (6X25 )X130 ft LH LAY
Chapter 4 Parts
FLIP SHEAVE ASSEMBLY PARTS (99904923)
ITEM
PART #
DESCRIPTION
49.
70734560 RECEIVER-RADIO REMOTE
52.
71073035 HOOK-SWIVEL
53.
71414204 PLATE-SINGLE SHEAVE
55.
72034485 CLAMP-PLASTIC
58.
72661641 PIN-QUICK
60.
73734565 PIN-LOCK WITH HANDLE
74.
72062194 NUT-STAINLESS STEEL
75.
72063166 WASHER-FLAT
76.
72601846
CAP SCREW
77.
81.
82.
85.
70034382
72053508
72060000
72060064
CAP-GREASE
ZERK
CAP SCREW
CAP SCREW
86.
72060091
CAP SCREW
88.
72060147
CAP SCREW
91.
72060893
CAP SCREW
92.
72062000
94.
72062103
95.
72062104
96.
72062105
97.
72062106
98.
72063001
99.
72063003
100.
72063010
102.
72063049
104.
72063053
106.
72063132
113.
72661543
114.
72661694
REV G 20120815
NUT
NUT
NUT
NUT
NUT
WASHER
WASHER
WASHER
WASHER
WASHER
WASHER
PIN-QUICK
BRIDLE RING
DETAILS
5.0T W/LATCH
(20 #) .38 WIRE ROPE
1/4 " CABLE
5/16-2-1/16 ZINC YELLOW
1.00 X 3.50 WITH HAIRPIN
.25 -20 NYLOC
.25 R WRT 18 -8 .62 OD
STAINLESS STEEL
.25-20 X 1.25 HEX HEAD
STAINLESS STEEL
NPT 0.12
.25-20 X .50 HEX HEAD GR5 Z
.44-14 X 1.50 HEX HEAD GR5
Z
.50-13 X 1.00 HEX HEAD GR5
Z
.62-11 X 1.00 HEX HEAD GR5
Z
.38-16 X 3.25 HEX HEAD GR5
Z
.25-20 HEX
.38-16 HEX NYLOCK
.25-20 HEX NYLOCK
.44-14 HEX NYLOCK
10-24 HEX NYLOCK
.25 FLAT
.38 FLAT
1.00 FLAT
.25 LOCK
.50 LOCK
.50 FLAT ASTM F436
1-1/12 ID X 1/ 4-20
KIT #
39
#4
#4
QUANTITY
1
1
1
9
1
2
2
2
#4
2
#5
#5
#5
#5
6
4
2
4
#5
5
#5
1
#5
2
#5
#5
#5
#5
#5
#5
#5
#5
#5
#5
#5
#5
#5
3
2
2
4
8
10
16
1
6
17
17
3
3
40
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
30' Model 8600 Crane Parts List, Complete (99904923)
99904923 PARTS LIST, COMPLETE
ITEM
PART #
DESCRIPTION
1.
91723059 KIT-HARDWARE BASE &
MAST
2.
91723579 HARDWARE KIT-WINCH
MOUNT
3.
91723543 HARDWARE KIT-VALVEBANK
MOUNT
4.
51719413 HARDWARE KIT-CRANE
RADIO CONTROLS
5.
91723584 HARDWARE KIT
6.
91723601 HYDRAULIC KIT
7.
51723610 CORD REEL ASSEMBLY
8.
51723694 CYLINDER
9.
51723604 CYLINDER ASSEMBLY
10.
11.
12.
13.
52718741
52722950
52723022
52723023
14.
52723024
15.
16.
17.
52723030
52723036
52723058
18.
19.
52723062
52723063
20.
52723563
21.
22.
23.
60030134
60030336
60030337
24.
25.
26.
27.
28.
29.
30.
60030421
60030422
60030423
60030424
60030425
60030428
60030429
31.
32.
33.
34.
35.
36.
60109337
70034490
60120138
60128849
60135667
60135668
PIN
MAST WELDMENT
WELDMENT-LOWER BOOM
WELDMENT-1st STAGE EXT
BOOM
WELDMENT-2nd STAGE EXT
BOOM
PIN
PIN
WELDMENT- ANTI-TWO
BLOCK BRACKET
WELDMENT-FLIP SHEAVE
WELDMENT- SNATCH
BLOCK
WELDMENT-MAST
VALVEBANK BRACKET
SHEAVE
WEAR PAD-RC
WEAR PAD-ROUND
WEAR PAD-RC
WEAR PAD-ROUND
WEAR PAD-RC
CAP- ANTI-TWO BLOCK PIN
WEAR PAD-ROUND
WEAR PAD-ROUND
WEAR PAD- ANTI-TWO
BLOCK BRACKET
PIN RETAINER PLATE
PLATE-ANGLE PLASTIC
SLIDE-ROTATION STOP
GEAR GUARD
CAP-LOWER BOOM
CAP-FIRST STAGE
DETAILS
KIT #
QUANTITY
1
1
1
1
30' WITH CONNECTOR
4.75/2.50 25.06S 45.52CCC
2.50/ 1.50 2.75/1.75 204.0S
144.6
MM 2.00 X 12.75 (11.94 )
1
1
1
1
1
7500/10000
7500/10000
2
1
1
1
7500/10000
1
M 1.50X 3.38
MM 2.00 X 9.00 (8.19 )
1
1
1
7500/8600
7500/8600
1
1
1
8.00 NYLATRON GSM
.19 X 6.00 X 6.00
2.00 DIA X 1.00 DIA X 1.188
LG
.25 X 6.00 X 6 .00
2.00 DIA X .50 DIA X 1.69 L
0.25 X 2.25 X 6.00L
1.25 DIA X 0.50 DIA X 0.94L
2.0 0 DIA X .75 DIA X .72L
3.00 DIA
3.5"
1
1
2
1
1
4
2
2
4
2
1
2
1
1
1
1
Chapter 4 Parts
99904923 PARTS LIST, COMPLETE
ITEM
PART #
DESCRIPTION
37.
60135669 PIN
38.
52723623 HOOK HOLDER-WELDMENT
39.
60135833 RETAINER-1st STAGE
EXTENSION CYLINDER
40.
60136475 COVER-VALVE BANK
41.
70029595 THREADED PLUG
42.
70034517 SPLIT SHEAVE PROTECTOR
43.
70145121 COLLAR-SHAFT 2 PIECE
44.
70399044 TAPE -REFLECTIVE RED/
SILVER
45.
70399045 TAPE -REFLECTIVE RED/
SILVER
46.
70580202 WIRE ROPE ASSEMBLY
47.
72661514 PIN-LOCK WITH HANDLE
48.
70734559 TRANSMITTER-RADIO
REMOTE
49.
70734560 RECEIVER-RADIO REMOTE
50.
71056577 GEAR ROTATOR
51.
76039295 GASKET
52.
71073035 HOOK-SWIVEL
53.
71414204 PLATE-SINGLE SHEAVE
54.
71570968 WINCH-PLANETARY
55.
72034485 CLAMP-PLASTIC
56.
72063038 MACHINERY BUSHING
DETAILS
1.2 5X 6.89 ( 6.46)
KIT #
QUANTITY
1
1
2
7/8 in.
1.25 X108.00
1
2
1
1
2
2.00 X108.00
2
0.38 (6X25 )X130 ft LH LAY
1
1
1
1.00-8
0.75 BOLTS
#50
5.0T W/LATCH
(20 #) .38 WIRE ROPE
4400 LINE PULL (A41)
1/4 " CABLE
2.00 X14 GA NR
57.
72063039
MACHINERY BUSHING
2.00 X10 GA NR
58.
59.
60.
61.
72661641
73051919
73734565
73734727
5/16-2-1/16 ZINC YELLOW
62.
63.
64.
77041863
77441481
72060207
PIN-QUICK
MOTOR-HYDRAULIC
PIN-LOCK WITH HANDLE
VALVE BANK (WAS
73734635)
SWITCH-LIMIT
HARNESS (WAS 77441426)
CAP SCREW
65.
66.
72063116
72601629
WASHER
CAP SCREW
67.
72601817
CAP SCREW
68.
69.
70.
72062108
72063132
72602061
NUT
WASHER
STUD
71.
72.
73.
74.
72601797
72602065
72602052
72062194
WASHER-LOCK
WASHER-FLAT
CAP SCREW
NUT-STAINLESS STEEL
1.00 X 3.50 WITH HAIRPIN
10 GPM
DT04-4P CONN
.75-10 X 3.00 HEX HEAD GR8
Z
.75 N FLAT H ASTM F436 Z
.75-10 X 4.00 HEX HEAD GR8
Z
.75-10 X 3.25 HEX HEAD GR8
Z
.50 -20 HEX CENTER LOCK
.50 FLAT ASTM F436
0.50-13(20)X2.5 NC(NF) GR8
STL
8 MM
M8
M8-1.25X 16 HEX HEAD Z
.25 -20 NYLOC
41
1
1
1
1
1
1
9
AS
REQUIRED
AS
REQUIRED
1
1
2
1
#1
1
1
2
#1
#1
22
4
#1
16
#2
#2
#2
4
4
4
#3
#3
#3
#4
3
3
3
2
42
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
99904923 PARTS LIST, COMPLETE
ITEM
PART #
DESCRIPTION
75.
72063166 WASHER-FLAT
76.
72601846
CAP SCREW
77.
78.
79.
80.
81.
82.
83.
84.
85.
70034382
71413185
72034479
72053301
72053508
72060000
72060002
72060044
72060064
CAP-GREASE
SPRING
PLUG-PLASTIC
COUPLING
ZERK
CAP SCREW
CAP SCREW
CAP SCREW
CAP SCREW
86.
72060091
87.
88.
72060093
72060147
89.
72060206
90.
91.
72060640
72060893
92.
93.
94.
95.
96.
97.
98.
99.
100.
101.
102.
103.
104.
105.
106.
107.
108.
109.
110.
111.
72062000
72062093
72062103
72062104
72062105
72062106
72063001
72063003
72063010
72063035
72063049
72063051
72063053
72063116
72063132
72063271
72066129
72066136
72601938
72601949
112.
113.
114.
115.
72602022
72661543
72661694
51395121
DETAILS
.25 R WRT 18 -8 .62 OD
STAINLESS STEEL
.25-20 X 1.25 HEX HEAD
STAINLESS STEEL
.105 WIRE 0.75OD 2 .875 LG
.50-13 X .50 UNC-2B
BLK .12
NPT 0.12
.25-20 X .50 HEX HEAD GR5 Z
.25-20 X .75 HEX HEAD GR5 Z
.38-16 X .75 HEX HEAD GR5 Z
.44-14 X 1.50 HEX HEAD GR5
Z
CAP SCREW
.50-13 X 1.00 HEX HEAD GR5
Z
CAP SCREW
.50-13 X 1.5 HEX HEAD GR5 Z
CAP SCREW
.62-11 X 1.00 HEX HEAD GR5
Z
CAP SCREW
.75-10 X 2.00 HEX HEAD
GR8Z
SCREW-MACHINERY
10-24 X 1.50 ROUND HEAD
CAP SCREW
.38-16 X 3.25 HEX HEAD GR5
Z
NUT
.25-20 HEX
NUT
#8 -32 HEX ZINC
NUT
.38-16 HEX NYLOCK
NUT
.25-20 HEX NYLOCK
NUT
.44-14 HEX NYLOCK
NUT
10-24 HEX NYLOCK
WASHER
.25 FLAT
WASHER
.38 FLAT
WASHER
1.00 FLAT
MACHINERY BUSHING
1.25 X10 GA NR
WASHER
.25 LOCK
WASHER
.38 LOCK
WASHER
.50 LOCK
WASHER
FLAT .75 N H ASTM F436 Z
WASHER
.50 FLAT ASTM F436
WASHER
# 8 W FLAT ANSI B 27. 2Z
RETAINING RING-EXTERNAL 1.25 HD
RETAINING RING-EXTERNAL 2.00 HD
BOLT-EYE
# 8-32X 1.125
CAP SCREW
.50-13 X 1.25 SOCKET HEAD
ZINC-COATED
BOLT-SHOULDER
.38X 1.25
PIN-QUICK
BRIDLE RING
1-1/12 ID X 1/ 4-20
HOSE
AA .13 X 13.5 0 OAL (2-2)
KIT #
#4
QUANTITY
2
#4
2
#5
#5
#5
#5
#5
#5
#5
#5
#5
6
1
2
1
4
2
4
4
4
#5
5
#5
#5
12
1
#5
1
#5
#5
2
2
#5
#5
#5
#5
#5
#5
#5
#5
#5
#5
#5
#5
#5
#5
#5
#5
#5
#5
#5
#5
3
2
2
2
4
8
10
16
1
2
6
4
17
1
17
2
2
3
1
2
#5
#5
#5
#6
1
3
3
1
Chapter 4 Parts
99904923 PARTS LIST, COMPLETE
ITEM
PART #
DESCRIPTION
116.
72532355 ADAPTER
117.
72532356 ADAPTER
118.
72532357 ADAPTER
119.
72532358 ADAPTER
120.
72532359 ADAPTER
121.
72532361 ADAPTER
122.
72532670 ELBOW
123.
72532690
124.
72532700
125.
72532792
126.
72533490
127.
72533583
128.
72533613
129.
72062080
130.
72602073
131.
72602075
132.
60140029
133.
60140030
134.
72063005
135.
93724760
REV G 20120815
ELBOW
ELBOW
ADAPTER
ADAPTER
ELBOW
ADAPTER
NUT
CAP SCREW
CAP SCREW
BRACKET-CABLE GUIDE
ROLLER-CABLE GUIDE
WASHER
CABLE GUIDE KIT
43
DETAILS
M STR/M JIC 6 6
M STR/M JIC 8 6
M STR/M JIC 6 8
M STR/M JIC 8 8
M STR/M JIC 10 8
M STR/M JIC 8 10
M JIC/45/ F JIC 8 8
KIT #
#6
#6
#6
#6
#6
#6
#6
QUANTITY
1
4
1
4
2
1
1
M JIC/90 /FJIC SW 4 4
M STR/90/ M JIC XL 6 6
M STR/M JIC 8 4
M BSPP/M JIC 4 4
M STR/45/ M JIC 8 6
M STR/M JIC 10 6
.50-13 HEX NYLOCK
.50-13 X 11.5 HHGR5Z
.50-13 X 12.5 HHGR5Z
#6
#6
#6
#6
#6
#6
#135
#135
#135
#135
#135
#135
1
2
1
1
1
2
2
1
1
1
2
2
1
.50 FLAT
44
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
Gear Rotator (71056577)
A
23
15
17
GUIDE MUST BE
FLUSH WITH
BOTTOM OF
HOUSING.
10
1
7
11
6
4
11
14
20
10
22
BEARING
GREASE
ZERK LOC.
1/8-27 N.P.T.
21
13
5
2
19
12
18,19
(NOTE 6)
3
LOADING
PLUG LOC.
8
16
9
18
13,14,15
(NOTE 3)
1
9
16 4
6
5
3 (NOTE 1)
A
20
21
(NOTE 1)
3
20
8
21
17 (NOTE 1)
7
12
2 (NOTE 4)
6
SECTION A-A
5
NOTES
1
Install seals #3 and #17 with Loctite plastic gasket on O.D. Lubricate seal surface before
assembly.
2
Pack cavities with EPO grease.
3
Shim to obtain 0.000/0.004" end play on worm shaft.
4
Lubricate o-ring #2 with worm gear oil before installing.
5
Set backlash between worm and rotation bearing 0.005 - 0.012". Tighten bolts numbered 1,
2, 3, 4.
6
Tighten 3/4-10UNC Grade 8 mounting bolts as follows:
a) Tightening must be progressive and at 180 degree intervals. First interval at 130 ft-lb.
Second interval at 280 ft-lb. Third interval at 380 ft-lb.
b) Tighten bolts in order shown in diamonds.
7. Do not use Loctite on mounting bolts.
Chapter 4 Parts
71056577 PARTS LIST
ITEM
PART #
1.
71056607
2.
70395074
3.
70395076
4.
70145786
5.
70055271
6.
70055281
7.
70145501
8.
70056550
9.
70146322
10.
70145848
11.
72601754
12.
72601733
13.
73145506
14.
73145505
15.
73145504
16.
76039295
17.
72533604
18.
72601817
19.
72063116
20.
72533605
21.
72533439
REV B 20050314
DESCRIPTION
GEAR BEARING
O-RING
SEAL
SNAP RING
CONE BEARING
CUP BEARING
RETAINER, BEARING
WORM
MAIN HOUSING
HOSE GUIDE
SCREW
CAP SCREW
SHIM, METAL (0.005)
SHIM, METAL (0.015)
SHIM, METAL (0.030)
GASKET
PLUG
CAP SCREW
WASHER
ZERK
VENT PLUG
DETAILS
SLT FH1.25-20 NC X 1/2
FERRY 1/2NCX1-1/4
3/4-10X3-1/4 HHGR8
3/4 FLAT
QUANTITY
1
1
2
1
2
2
1
1
1
1
2
4
2
1
1
1
1
23
23
2
2
45
46
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
Lower Cylinder (51723694)
R
E
TE
5
1
17 11
12 12
11
8
6 8
2
9.5"
RETRACT
PORT
45°
TEST
PORT
5.25"
13
EXTEND
PORT
13
POLYGON BEARING
70055368
(2 PCS EACH END)
10 15
8 7 1110 11
8
STAMP PART NUMBER
AND REVISION.
16
45°
9
14
R1.63" TYP
Ø2" TYP
3
COUNTERBORED
FOR BEARINGS
Ø2.5" ROD
Ø4.75" BORE
Ø5.5" BARREL
25.06" STROKE
4
SPACER
BETWEEN
BEARINGS
45.52" RETRACTED
70.58" EXTENDED
±0.063"
3
2
3
A
6 54
3
4
A
2
1
1
A
SECTION A-A
SECTION A-A
A
PISTON SEALS
ITEM NO.
1
2
3
4
DESCRIPTION
PISTON
PISTON SEAL
WEAR RING
O-RING
QTY.
1
1
2
1
SEAL KIT # 94399129. INCLUDES ALL SEALS.
SEALS CANNOT BE PURCHASED INDIVIDUALLY.
ROD SEALS
ITEM NO. DESCRIPTION
1
ROD BEARING
2
WIPER
3
ROD SEAL
4
WEAR RING
5
BACK-UP RING
6
O-RING
QTY.
1
1
1
1
1
1
Chapter 4 Parts
47
NOTES:
1
SEE PART NUMBER AND REVISION STAMPED ON CYLINDER.
2
REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS DISASSEMBLED TO
REDUCE DOWNTIME.
3
APPLY "LUBRIPLATE" NO. 630-2 MEDIUM-HEAVY, MULTI-PURPOSE LUBRICANT TO ALL PISTON, ROD
BEARING AND HOLDING VALVE SEALS.
4
TORQUE ROD BEARING TO 500-600 FT-LB (69-83 KG-M); PISTON SET SCREW TO 12-18 FT-LB (1.7-2.5
KG-M) AND PISTON TO 200-300 FT-LB (27.6 - 41.5 KG-M).
5
USE BLUE LOCTITE ON PISTON.
6
TO LOCK THE ROD BEARING ON THE CYLINDER, DRILL A #26 HOLE 0.25-0.30" DEEP IN A SEAM
BETWEEN THE ROD BEARING AND THE CASE. INSTALL THE LOCKING SCREW (ITEM #9, SELF-TAPPING
#8-32 X 0.25" SET SCREW) IN THE HOLE UNTIL SEATED.
51723694 PARTS LIST
ITEM
PART #
1.
52723918
2.
52723919
3.
71414683
4.
71414684
5.
71414693
6.
71414694
7.
73540444
8.
9.
10.
11.
12.
13.
14.
15.
73540490
16.
17.
77041866
REF
94399129
REV B 20120712
DESCRIPTION
CASE
ROD ASSEMBLY
PISTON ASSEMBLY
ROD BEARING ASSEMBLY
TRANSFER TUBE
TRANSFER TUBE
VALVE BLOCK ASSEMBLY
FITTING ADAPTER
LOCKING SCREW
HEX BOLT
WASHER
NYLOC NUT
PLASTIC PLUG SAE O-RING
NYLON TIP SET SCREW
COUNTERBALANCE VALVE
STEEL SAE O-RING PLUG
PRESSURE TRANSDUCER
SEAL KIT
DETAILS
5/16"-18 X 4.00 GR5
.31 FLAT
.31-18
#6
.250-20 UNC
#4
QUANTITY
1
1
1
1
1
1
1
4
1
2
4
2
3
1
1
1
1
48
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
Extension Cylinder Assembly (51723604)
1
2
SECTION B-B
STAMP PART # AND REVISION DATE
3
5
13
12
12
5
12
7
4.88"
5
5
13
4
7
140.06" RETRACTED (REF)
102" STROKE
Ø1.5" ROD
Ø2.5" BORE
3
Ø3" BARREL 1
Ø2"
Ø1.27"
B
9
7
8
10
3/4-10 UNC
0.75" DEEP
Ø1.75" ROD
Ø2.75" BORE
Ø3.25" BARREL
102" STROKE
136.94" RETRACTED (REF)
4
6
2
144.69 CLOSED - 348.69 OPEN - 204.00 STROKE
SECTION A-A
NOTES:
1
TEST CYLINDER AT 3500 PSI.
2
TORQUE NUT #3 (1.25-12 UNF) TO 810.7 FT-LB (112 KG-M).
3
PAINT BLACK SEMI-GLOSS.
4
INSTALL HOSE CLAMPS AFTER PAINTING.
51723604 PARTS LIST
ITEM
PART #
1.
51723931
2.
51723927
3.
4.
5.
6.
DESCRIPTION
CYLINDER ASSEMBLY
CYLINDER ASSEMBLY
SELF-LOCKING NUT
PIN
FITTING ADAPTER
WASHER
DETAILS
1.25-12
QUANTITY
1
1
1
1
4
2
B
Chapter 4 Parts
51723604 PARTS LIST
ITEM
PART #
7.
8.
9.
73054807
10.
11.
12.
13.
71414720
REV. B 20110407
DESCRIPTION
HAIRPIN, COTTER
PLASTIC PLUG SAE O-RING
VALVE, COUNTERBALANCE
SAE O-RING PLUG
SAE O-RING PLUG, STEEL
HOSE CLAMP
TUBE LINE
DETAILS
#6
#2
#4
#56
QUANTITY
2
2
1
1
3
3
2
49
50
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
Cylinder (51723931)
STAMP WITH PART
NUMBER AND REVISION.
4.88"
SECTION B-B
143.62" CLOSED - 245.62" OPEN - 102" STROKE
7
1
Ø3" BARREL
Ø2.5" BORE
Ø2"
Ø1.5" ROD 6
3
1.25-12 UNC 2A
4
B
A
30.44"
STROKE
LIMITER
SECTION A-A
SEALS FOR 51723931 PISTON
4
A
171°
5
2
B
Ø1.27"
SEALS FOR 51723931 ROD BEARING
A
2
5
A
6
2
3
4
3
1
SECTION A-A
1
SECTION A-A
ITEM NO.
1
2
3
4
A
PISTON SEALS
DESCRIPTION
PISTON
PISTON SEAL
O-RING
WEAR RING (PISTON)
A
ROD SEALS
QTY.
1
1
1
1
ITEM NO.
1
2
3
4
5
6
DESCRIPTION
ROD BEARING
ROD SEAL
WIPER
WEAR RING
O-RING
BACK-UP RING
QTY.
1
1
1
1
1
1
SEAL KIT # 94399160, INCLUDES ALL ROD AND PISTON SEALS FOR 51723931. SEALS CANNOT BE PURCHASED INDIVIDUALLY.
NOTES:
1
SEE PART NUMBER AND REVISION STAMPED ON CYLINDER.
2
REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS DISASSEMBLED TO
REDUCE DOWNTIME.
3
APPLY "LUBRIPLATE" NO. 630-2 MEDIUM-HEAVY, MULTI-PURPOSE LUBRICANT TO ALL PISTON, ROD
BEARING AND HOLDING VALVE SEALS.
4
TORQUE ROD BEARING TO 200-300 FT-LB (27.6 - 41.5 KG-M).
5
TORQUE PISTON NUT (#4) TO 412.3 FT-LB (57 KG-M).
Chapter 4 Parts
51
6
TO LOCK THE ROD BEARING ON THE CYLINDER, DRILL A #26 HOLE 0.25-0.30" DEEP IN A SEAM
BETWEEN THE ROD BEARING AND THE CASE. INSTALL THE LOCKING SCREW (ITEM #9, SELF-TAPPING
#8-32 X 0.25" SET SCREW) IN THE HOLE UNTIL SEATED.
7
SEAL KIT 94399160 INCLUDES ALL SEALS FOR CYLINDER 51723931.
51723931 PARTS LIST
ITEM
PART #
1.
52724028
2.
71414724
3.
52724029
4.
5.
71414723
6.
7.
73050199
REF
94399160
NEW 20110407
DESCRIPTION
CASE
PISTON ASSEMBLY
ROD ASSEMBLY
SELF-LOCKING NUT
ROD BEARING ASSEMBLY
LOCKING SCREW
STROKE LIMITER
SEAL KIT
DETAILS
1.00-14 UNF
QUANTITY
1
1
1
1
1
1
1
1
52
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
Cylinder (51723927)
SECTION B-B
3"
STAMP WITH PART
NUMBER AND REVISION.
.
A
R1.25"
7
5
SECTION A-A
R1.16"
B
Ø1.27"
2
3.63"
Ø1.03"
4
Ø1.75" ROD
Ø2.75" BORE
A
6
Ø3.25" BARREL
139.94" CLOSED - 241.94" OPEN - 102" STROKE
SEALS FOR 51723927 PISTON
1
4 4
2
4
SEALS FOR 51723927 ROD BEARING
4
4
5 1
A
2
A
3
6
3
SECTION A-A
A
A
SECTION A-A
ROD SEALS
PISTON SEALS
ITEM NO.
1
2
3
4
DESCRIPTION
PISTON
PISTON SEAL
O-RING
WEAR RING (PISTON)
QTY.
1
1
1
4
ITEM NO.
1
2
3
4
5
6
DESCRIPTION
ROD BEARING
ROD SEAL
WIPER
O-RING
BACKUP RING
WEAR RING
SEAL KIT # 94399162, WHICH INCLUDES ALL ROD AND PISTON SEALS FOR 51723927.
SEALS CANNOT BE PURCHASED INDIVIDUALLY.
QTY.
1
1
1
1
1
1
B
Chapter 4 Parts
53
NOTES:
1
SEE PART NUMBER AND REVISION STAMPED ON CYLINDER.
2
REPLACE ALL COMPONENTS OF THE SEAL KIT WHENEVER THE CYLINDER IS DISASSEMBLED TO
REDUCE DOWNTIME.
3
APPLY "LUBRIPLATE" NO. 630-2 MEDIUM-HEAVY, MULTI-PURPOSE LUBRICANT TO ALL PISTON, ROD
BEARING AND HOLDING VALVE SEALS.
4
TORQUE ROD BEARING TO 200-300 FT-LB (27.6 - 41.5 KG-M).
5
TORQUE PISTON 200-300 FT-LB (27.6 - 41.5 KG-M).
6
TO LOCK THE ROD BEARING ON THE CYLINDER, DRILL A #26 HOLE 0.25-0.30" DEEP IN A SEAM
BETWEEN THE ROD BEARING AND THE CASE. INSTALL THE LOCKING SCREW (ITEM #6, SELF-TAPPING
#8-32 X 0.25" SET SCREW) IN THE HOLE UNTIL SEATED.
7
SEAL KIT 94399162 INCLUDES ALL SEALS FOR CYLINDER 51723927.
51723927 PARTS LIST
ITEM
PART #
1.
52724034
2.
52724035
3.
73050203
4.
71414725
5.
71414726
6.
7.
REF
94399162
NEW 20110407
DESCRIPTION
CASE
ROD ASSEMBLY
STROKE LIMITER
PISTON ASSEMBLY
ROD BEARING ASSEMBLY
LOCKING SCREW
NYLON TIP SET SCREW
SEAL KIT
DETAILS
.25-20
QUANTITY
1
1
1
1
1
1
1
1
54
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
Winch, Planetary (71570968)
1
2
3
4
5
6
7
8
9
10
11
12 13
14
15
16
34
17
18
32
19
31
33
30
29
20
28 27
26
25 24
23
22
21
20
71570968 PARTS LIST
ITEM
PART #
1.
73540453
Part of 94399223
2.
3.
Part of 94399223
4.
5.
6.
7.
8.
72661702
9.
10.
11.
Part of 94399223
12.
13.
70580214
13.
14.
DESCRIPTION
Hydraulic motor
Seal for motor
Motor mounting flange
Seal
Hex socked head cap screw
Seeger
Engine support
Ball bearing
Retaining ring
Sleeve
Plug
Copper washer
Winch drum
Wedge, winch cable
Thimble
Bearing support
DETAILS
1
2REF
1
1
4
1
1
1
1
1
2
2
1
1
1
1
Chapter 4 Parts
71570968 PARTS LIST
ITEM
PART #
15.
16.
17.
18.
19.
20.
20.
21.
22.
23.
71056673
24.
25.
26.
Part of 94399223
27.
Part of 94399223
28.
Part of 94399223
29.
30.
31.
32.
73540308
Part of 94399223
33.
34.
94399223
DESCRIPTION
Hex socked head cap screw
Seeger
Ball bearing
Seeger
Hub side support
1 Hex socked head cap screw
1 Hex socked head cap screw
Cross member
Fastening surface plate
Brake unit (Reduction gear unit).
Insert
Guide
O-ring joint
Oil retainer seal
V-Ring
Straight pipe fitting (Conical)
90° Connection (Conical)
Hex socked head cap screw
Valve
Seal for valve
Hex socked head cap screw
Plug
SEAL KIT
DETAILS
6
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
2
1
1REF
8
1
REF
55
56
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
71570968 Winch Brake
1
2
3
4
5
6
7
8
9
10 11
26
25
12
24
13
23
14
22
21
20 19
18 17 16
15
71570968 WINCH BRAKE PARTS LIST
ITEM
PART #
DESCRIPTION
1.
Part of 94399223
O-ring joint
2.
Part of 94399223
Antiextrusion ring
3.
Part of 94399223
O-ring joint
4.
Part of 94399223
Antiextrusion ring
5.
Brake Disk
6.
Brake Disk
7.
Gear
8.
Hex socket countersunk head
9.
Flange
10.
Sun gear
11.
Hex socket head cap screw
12.
Hex socket head cap screw
13.
Keep plate
14.
Insert
15.
72661703
Retaining ring
16.
Slewing ring
17.
Planetary gear
18.
Pin
19.
Flange
20.
Flange
21.
Piston
22.
Part of 94399223
O-ring joint
23.
Retaining ring
24.
Support
25.
Belleville washer
26.
Seeger
94399223
SEAL KIT
QUANTITY
1
1
1
1
9
10
1
3
1
1
6
3
1
1
3
6
3
3
1
1
1
1
1
1
2
2
REF
Chapter 4 Parts
Valvebank (73734727)
VALVE SECTIONS
WINCH
EXT CYL
MAIN CYL
ROTATION
WINCH
DRAIN
RELIEF
VALVE
RETURN
(TANK)
PRESSURE
SOLENOID
CONNECTION
BLOCK
Circuitry for coding - DT12
- DT24
4-pin
Coil A Coil B
4
3
4 3 21
73734727 PARTS LIST
PART #
DESCRIPTION
94399213
SEAL KIT, CONNECTION BLOCK
94399214
SEAL KIT, SEALS BETWEEN SECTIONS
77041898
SOLENOID, 12V
77040598
12V COIL FOR 77041898 SOLENOID
WAS 73734635 THROUGH S/N 8600121025.
QUANTITY
1
1
4
1
2
57
58
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
Seal Kit for 73734727 (94399214)
121
6 Nm
103
101
100
100
100
102
100
102
100
100
102
6 Nm
118 108
106
105
108
106
104
104
112
112
109
108
109
108
200
119
6 Nm
105
105
106
106
106
106
110
111
121
111
6 Nm
117
116
116
114
115
113
113
114
117
94399214 SEAL KIT PARTS
ITEM
DESCRIPTION
100.
O-RING
101.
O-RING
102.
O-RING
103.
USIT-RING
116
116
DETAILS
1.78 x 1.02 mm
6.75 x 1.75 mm P5001
25.07 x 2.62 mm Z24
ST 37 STANDARD
115
QUANTITY
2
2
1
1
120
Chapter 4 Parts
94399214 SEAL KIT PARTS
ITEM
DESCRIPTION
104.
O-RING
105.
O-RING
106.
O-RING
108.
O-RING
109.
O-RING
110.
O-RING
111.
O-RING
112.
SEAL NUT
113.
USIT-RING
114.
COPPER RING
115.
SOFT IRON SEAL RING
116.
O-RING
117.
SEAL-LOCK COLLAR NUT
118.
O-RING
119.
O-RING
120.
COPPER RING
121.
SEAL NUT
DETAILS
26.7 x 1.78 mm Z24
12.42 x 1.78 mm P5001
2.90 x 1.78 mm Z24
10.82 x 1.78mm P5001
6.07 x 1.78 mm P5001
3 x 1.5 mm
6.75 x 1.78 mm P5001
ST 37 STANDARD
4 x 8 x 1 mm
17.17 x 1.78 mm P5001
M6 12 x 1
10.00 x 1.00 mm P5001
5.00 x 1.00 mm P5001
5 x 7.5 x 1 mm
QUANTITY
1
3
8
6
4
2
2
2
2
2
2
2
2
1
2
1
2
NOTE: These seals are all part of 94399214, and cannot be purchased individually.
59
60
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
Connection Block Seal Kit for 73734727 (94399213)
104
116
118
117
115
101
100
102
101
100
109
110
112
113
108a
111
108
CONNECTION BLOCK SEAL KIT FOR 73734727 (94399213)
ITEM
DESCRIPTION
DETAILS
100.
O-RING
2.90x1.78 Z24
101.
O-RING
10.82x1.78 P5001
102.
O-RING
12.42x1.78 P5001
104.
O-RING
17.17 x 1.78 P 5001
108.
COPPER RING
SHAPE A DIN 7603 10X14X1.5-Cu
108a.
FITTING SEAL
109.
SEAL RING
8.3X11X1.15 PTFE 7625 109/1
110.
SEAL
1/4" DRV
111.
O-RING
9X1.5 NBR 90 SH
QUANTITY
4
3
1
1
1
1
1
1
1
Chapter 4 Parts
CONNECTION BLOCK SEAL KIT FOR 73734727 (94399213)
ITEM
DESCRIPTION
DETAILS
112.
O-RING
12.42x1.78 P5001
113.
O-RING
14.03x2.61 P5001 94 Sh A
115.
SEAL
G 1/4" DRV 100116-NB 650 NBR
116.
O-RING
15X2 HNBR 90 SH RED SPOT
117.
O-RING
23.52X1.78 HNBR 90 SH RED SPOT
118.
SEAL RING
27X32X2 ST
QUANTITY
1
1
2
1
1
1
NOTE: These seals are all part of 94399213, and cannot be purchased individually.
61
62
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
Hydraulic Schematic (99905018)
28
26
24
22
CASE DRAIN
31
20
16
10
12
CASE
DRAIN
VALVE
BANK
9
4
6
4
6
WINCH
RETURN
(SEE INSTL KIT)
8
17
CW
DN
IN
ROT LOW EXT
CCW
4
UP
13
OUT
4
R
DN
PRESSURE
(SEE INSTL KIT)
WIN
P
UP
6
MTR
15
6
7 (PORT A) (UP)
19
7 (PORT B) (DN)
27
21
EXT
CYL
15
11 (PORT E)
15
11 (PORT R)
23
5 (PORT R) DN
LOWER CYL
30
3 (PORT E) UP
25
29
14 (PORT B) (CCW)
ROTATION
14 (PORT A) (CW)
18
Chapter 4 Parts
63
17
7
7
PORT A
PORT B
PLANETARY WINCH
PORT
IDENTIFICATION
COUNTERBALANCE
VALVE
18
(GREASE HOSE)
WINCH
(BOTTOM
VIEW)
EXT CYL
(RETRACT)
WINCH (DN)
ROT CW
14
RETURN
CASE
DRAIN
PORT B
5
TRANSDUCER
LOWER CYL
(RETRACT)
14
PRESSURE &
RETURN HOSES
PRESSURE
3
LOWER
CYLINDER
LOWER CYLINDER
PORT IDENTIFICATION
PORT A
HYD MOTOR
PORT
IDENTIFICATION
(ROTATION)
ROT CCW
LOWER CYL
(EXTEND)
WINCH (UP)
VALVE BANK
PORT
IDENTIFICATION
EXT CYL
(EXTEND)
RETRACT
PORT (R)
11
11
EXTEND
PORT(E)
EXT CYLINDER
PORT IDENTIFICATION
NOTES:
1 INSTALL SLEEVE #32, 60350141, ON EXTENSION CYLINDER, LOWER CYLINDER AND ROTATION HOSES.
2
INSTALL SLEEVE #33, 60350142, ON WINCH HOSES AND PRESSURE & RETURN VALVE BANK HOSES.
3
INSTALL SLEEVE #34, 60350105, ON PRESSURE & RETURN HOSES AND ROTATION HOSES THROUGH
THE MAST.
99905018 PARTS LIST
ITEM
PART #
DESCRIPTION
1.
2.
91723601 HYDRAULIC KIT-A40-60
73734727 VALVE BANK (WAS 73734635)
3.
4.
5.
6.
7.
8.
72532355
72532356
72532357
72532358
72532359
72532361
ADAPTER
ADAPTER
ADAPTER
ADAPTER
ADAPTER
ADAPTER
DETAILS
4SECTION 10 GPM
PROPORTIONAL
M STR/M JIC 6 6
M STR/M JIC 8 6
M STR/M JIC 6 8
M STR/M JIC 8 8
M STR/M JIC 10 8
M STR/M JIC 8 10
KIT #
QUANTITY
1
1 REF
#1
#1
#1
#1
#1
#1
1
4
1
4
2
1
64
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
99905018 PARTS LIST
ITEM
PART #
9.
72532670
10.
72532690
11.
72532700
12.
72532792
13.
72533583
14.
72533613
15.
72533648
16.
72534412
17.
72533490
18.
51395121
19.
51396017
20.
51397080
21.
51397081
22.
51397082
23.
51396886
24.
51396887
25.
51399077
26.
51399078
27.
51399072
28.
51399073
29.
51399228
30.
51399229
31.
51399074
32.
60350141
33.
60350142
34.
60350105
REV F 20120815
DESCRIPTION
ELBO W
ELBOW
ELBOW
ADAPTER
ELBO W
ADAPTER
SWIVEL
SWIVEL
ADAPTER
HOSE-AA
HOSE-FJ
HOSE-FJ
HOSE-FZ
HOSE-FJ
HOSE-FZ
HOSE-FJ
HOSE-FJ
HOSE-FZ
HOSE-FJ
HOSE-FZ
HOSE-FJ
HOSE-FJ
HOSE-FJ
SLEEVE-HOSE
SLEEVE-HOSE
SLEEVE-HOSE
DETAILS
M JIC/45/F JIC 8 8
M JIC/90/F JIC SW 4 4
M STR/90/M JIC XLG 6 6
M STR/M JIC 8 4
M STR/45/M JIC 8 6
M STR/M JIC 10 6
M JIC/90/M JIC 8 8
M JIC/90/M JIC 10 10
M BSPP/M JIC 4 4
.13 X 13.50 (2-2) 100R17
.50 X 30.00 (8-8) 100R16
.62 X 30.00 (10-10) 100R17
.50 X 31.50 (8-8) 100R17
.50 X 31.00 (8-8) 100R17
.38 X 25.00 (6-6) 100R17
.38 X 24.50 (6-6) R10017
.38 X 29.00 (6-6) 100R17
.50 X 30.00 (8-8) 100R17
.38 X 22.50 (8-6) 100R17
.38 X 25.00 (8-6) 100R17
.38 X 18.00 (8-6) 100R17
.38 X 22.00 (8-6) 100R17
.25 X 32.00 (4-4) 100R2
159 X 12 CUT & SEALED
254 X 15 CUT & SEALED
WRAP AROUND, 4 IN DIA.
KIT #
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
#1
QUANTITY
1
1
2
1
1
2
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
2
1
65
Radio Remote Harness (77441481)
POWER (RADIO) 1
N/C 2
ENGINE SPEED 3
ENGINE START
4
ENGINE STOP 5
BLACK
BROWN
WHITE
BLUE
CP-1200
COMPRESSOR ON 6
RADIO
CRANE
HOURMETER 7
RECEIVER
INTERFACE
A2B SIGNAL 8
(GRAY)
A
B
C
D
G
N/C 9
N/C 10
P
GROUND 12
G
G
G
G
G
B
W
2
1
3
4
BOOM UP 1
BOOM DOWN 2
CP-1201
RADIO
RECEIVER
INTERFACE
(BLACK)
3
WINCH OUT
4
CAN HIGH
5
1
2
3
4
TETHER POWER 6
P
POWER (RADIO) 7
CAN LOW 8
BOOM EXTEND
E
2
4
3
1
9
BOOM RETRACT 10
ROTATE CCW 11
R
ROTATE CW 12
C
CJ-1202
1
2
3
4
5
6
7
STOW SENSOR POWER
STOW SENSOR GROUND CJ-401
STOW SENSOR
STOW SENSOR N/C
STOW SENSOR N/O
A TRANSDUCER POWER
B TRANSDUCER SIGNAL
C N/C
TRANSDUCER SIGNAL 11
WINCH IN
GROUND
CAN LOW 1
CJ-400
TETHER POWER (6V) RADIO RECEIVER
TETHER INTERFACE
CAN HIGH 1
8
9
1
2
4
3
10 11 12
BODY INTERFACE
NOTES:
1 USE SHIELDED, TWISTED PAIR FOR CAN LOW, CAN HIGH BETWEEN CP-1201 AND CJ-400.
CP-300
PRESSURE
TRANSDUCER
A GROUND
CJ-300
B A2B SIGNAL
A2B/FLOOD LIGHT
C BOOM FLOOD LIGHT
GROUND
BOOM UP
J2 BOOM UP/DOWN
GROUND
BOOM DOWN
2
4
3
1
GROUND
WINCH IN
GROUND
WINCH OUT
J4 WINCH IN/OUT
WINCH OUT
CP-402
N/C
WINCH OUT
N/C
WINCH OUT LIMIT SWITCH
1
2
3
4
CJ-402
WINCH OUT
LIMIT SWITCH JUMPER
GROUND
BOOM EXTEND
J3 BOOM EXT/RETRACT
GROUND
BOOM RETRACT
ROTATE CCW
GROUND
ROTATE CW
GROUND
A
B CP-401
C CAP
D
J1 ROTATE CW/CCW
66
CP-300
PRESSURE
TRANSDUCER
CJ-300
CP-1201
CJ-401
CP-401
ANTI-TWO/
BOOM FLOOD LIGHT
J4 WINCH UP/DOWN
STOW SENSOR
J3 BOOM EXT/RET
J2 BOOM UP/DOWN
CP-1200
CP-402
J1 ROTATE CW/CCW
WINCH OUT
LIMIT SWITCH
CJ-402
WINCH OUT
LIMIT SWITCH
JUMPER
CJ-1202
CJ-400
REV B 20111028
REPLACED 77441426.
MAKE JUMPER AS
SMALL AS POSSIBLE
Chapter 4 Parts
67
Decal Placement, 8600 30' Crane
9
3 4
23
3
24
22 2
10
4
9
1
83
21
25
6
3
5
4
23
24
11
22
25
NOTES (SEE REFERENCE NUMBER IN BOX):
1
SERIAL NUMBER PLACARD. MOUNT STREETSIDE.
2
PLACE BOTTOM POINT OF DIAMOND ABOVE END OF CYLINDER PIN.
3
CENTER ABOVE HOOK WELDMENT.
4 EITHER SIDE.
DECAL PLACEMENT (IF NOT SHOWN ON CRANE)
ITEM #
PLACEMENT
12,17,19,20, 25
AT OR NEAR REMOTE HANDLE STORAGE POINT
13
2 ON REAR STABILIZERS, 2 ON SIDEPACK FRONT WALLS
15
AT OR NEAR DRIVELINE
14,16
ON ALL FOUR SIDES OF CARRIER VEHICLE
18
ON TOP OF HYDRAULIC RESERVOIR
21
68
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
DECAL PLACEMENT, 8600 30' CRANES (REF 99905087)
ITEM PART #
DESCRIPTION
KIT #
1.
95724111
DECAL KIT - TELE COMMON SIII (7500-14000)
2.
95719348
DECAL KIT - BODY COMMON
3.
4.
5.
6.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
70391612
70391613
70392524
70392399
70395324
70395670
71399136
71399137
70392213
70392864
70392868
70392891
70394445
70396613
70394189
71039134
70392982
70399195
70399140
70399048
70396787
25.
70399105
REV B 20110811
DECAL-GREASE WEEKLY (LEFT)
DECAL-GREASE WEEKLY (RIGHT)
DECAL-ROTATE CRANE WHILE GREAS
DECAL-LUBRICATE WORM
DECAL-ASME/ANSI B30.5-TELESCOP
DECAL-CAUTION DOWN HAUL WT
DECAL-ANGLE INDICATOR RH
DECAL-ANGLE INDICATOR LH
DECAL-CAUTION DONT WASH/WAX
DECAL-WARNING STAB STAND CLEAR
DECAL-WARNING CR LOADLINE (TRK)
DECAL-DANGER DRIVELINE
DECAL-DANGER ELEC HZD LG TELES
DECAL-CRANE SAFETY OPER
DECAL-MOBILOIL RESERVOIR
DECAL-CAUTION OIL LEVEL
DECAL-SERVICE REPAIR
DECAL-DIAMOND IMT 4 X 8 (REFL)
DECAL-DIAMOND IMT 6.75X13.50 (REFL)
DECAL-ID 8600
DECAL-LOAD BLOCK RATING 4.3TONS
(MODELS 7500 / 8600 ONLY)
DECAL-CAP CHART 8600-30'
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
1
1
QTY IN KIT
QTY ON CRANE
1
1
3
2
1
1
1
2
1
1
1
4
4
1
4
1
1
1
1
1
2
3
2
1
1
1
2
1
1
1
4
4
1
4
1
1
1
1
1
2
2REF
2REF
3REF
Chapter 4 Parts
69
Option-Winch Roller (99905054)
Kit 51723636
10
16
10
16
3
5
11
5
16
10
17
1 6
1 6
16
13
10
17 14
8
9
15
9
13
14
12
1
7
15
12
8
18
18
4
NOTES (SEE REFERENCE NUMBER IN BOX):
1
APPLY BLUE LOCKTITE WHEN INSTALLING STUDS INTO WINCH MOUNT CASTING.
99905054 PARTS LIST
ITEM
PART #
1.
71570968
2.
91723544
3.
52723095
4.
5.
6.
52723641
60030439
72602058
DESCRIPTION
WINCH-PLANETARY 4400
LB LINE PULL
HARDWARE KIT-WINCH
ROLLER
ROLLER ASSEMBLYWINCH SWITCH
WELDMENT-BRACKET
SLEEVE-TYPE C
STUD
7.
77041863
SWITCH-LIMIT
DETAILS
KIT #
QUANTITY
REF
1
1
0.38X 0.62X.25
0.50-13(20)X3.00 NC
GR8STL
1
2
2
1
70
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
99905054 PARTS LIST
ITEM
PART #
8.
72060047
9.
72060641
DESCRIPTION
CAP SCREW
MACHINE SCREW
10.
11.
12.
13.
72062093
72062103
72062106
72062108
NUT
NUT
NUT
NUT
14.
15.
72063132
72063268
WASHER
WASHER
16.
72063271
WASHER
17.
18.
72601938
71413185
BOLT-EYE
SPRING
REV A 20110513
DETAILS
.38-16X 1.25 HH G R5 Z
#10-24X 1.75 ROUND
HEAD
#8-32 HEX ZINC
.38-16 HEX NYLOCK
#10-24 HEX NYLOCK
.50-20 HEX CENTER
LOCKING
.50 FLAT ASTM F436
#10 W FLAT ANSI
B27.2Z
# 8 W FLAT ANSI
B27.2Z
# 8-32X 1.125
0.105WIRE 0.75 OD
2.875 LG
KIT #
#2
#2
QUANTITY
2
2
#2
#2
#2
#2
4
2
2
2
#2
#2
2
2
#2
4
#2
#2
2
2
Chapter 4 Parts
71
Option - Boom Tip Light Kit (99905289)
5
4
2
NOTES:
1 LIGHT CAN BE PLACED ON EITHER SIDE.
2
HARNESS CONNECTS TO CORD REEL AND ANTI-TWO-BLOCK SWITCH.
SINGLE INCANDESCENT LIGHT KIT (12V & 24V) (DWG 99905289)
ITEM
1.
PART #
51723830
1A.
51724606
2.
77040424
2A.
77441279
3.
77441470
4.
72063005
5.
72062080
REV B 20120413
DESCRIPTION
ELECTRICAL KIT-BOOM
SINGLE FLOOD LIGHT (12V)
ELECTRICAL KIT-BOOM
SINGLE FLOOD LIGHT (24V)
FLOODLIGHT-COMPOSITE
WORK LAMP TOP MTG (12V)
FLOODLIGHT-COMPOSITE
WORK LAMP TOP MTG (24V)
HARNESS-BOOM TIP FLOOD
LIGHT JUMPER
WASHER
NUT
DETAILS
12V KIT (51723830) 24V KIT (51724606)
KIT #
QUANTITY KIT #
QUANTITY
1
1
#1
.50 FLAT
.50-13 HEX NYLOCK
1
1
#1A
1
#1
1
#1A
1
#2
#2
1
1
#2A
#2A
1
1
72
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
2
2
4
2
4
4
4
NOTES (SEE REFERENCE NUMBER IN BOX:
1 LIGHT CAN BE PLACED ON EITHER SIDE.
2
HARNESS CONNECTS TO CORD REEL AND ANTI-TWO-BLOCK SWITCH.
DUAL LED LIGHT KIT (KIT 51724116 / DWG 99905289)
ITEM PART #
DESCRIPTION
DETAILS
1.
51724116
ELECTRICAL KIT-BOOM DUAL
LED FLOOD LIGHT
2.
77040581
FLOODLIGHT-LED
12-36 VDC
3.
77441473
HARNESS-BOOM TIP LED FLOOD
LIGHT JUMPER
4.
72063002
WASHER
.31 FLAT
REV B 20120413
KIT #
QUANTITY
1
#1
#1
2
1
#1
4
Chapter 4 Parts
5
4
3
ELECTRICAL INSTALLATION, LIGHT KITS (99905289)
ITEM PART #
DESCRIPTION
DETAILS
1.
51723830
ELECTRICAL KIT-BOOM
SINGLE FLOOD LIGHT
1.
51724116
ELECTRICAL KIT-BOOM
DUAL LED FLOOD LIGHT
1.
51724606
ELECTRICAL KIT-BOOM
SINGLE FLOOD LIGHT 24V
3.
77045888
TERMINAL
PKRD WP 14-16GA
FEM
4.
77044927
CABLE SEAL
14GA GRAY
5.
77044574
CONNECTOR
PKRD WP 2CAV FEM
TOWER
REV B 20120416
QUANTITY
1
1
1
2
2
1
73
75
CHAPT
ER
5
General Reference
In This Chapter
Inspection Checklist ................................................................. 75
Deficiency / Recommendation / Corrective Action Report ......... 80
Thread Torque Charts .............................................................. 82
Inspection Checklist
NOTICE:
The user of this form is responsible for determining that these inspections satisfy all applicable
regulatory requirements.
OWNER/COMPANY:
TYPE OF INSPECTION (circle one):
CONTACT PERSON:
DAILY
CRANE MAKE & MODEL:
DATE INSPECTED:
CRANE SERIAL NUMBER:
HOURMETER READING (if applicable):
UNIT I.D. NUMBER:
INSPECTED BY (print):
LOCATION OF UNIT:
SIGNATURE OF INSPECTOR:
MONTHLY
QUARTERLY ANNUAL
76
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
TYPE OF INSPECTION
NOTES:
Daily and monthly inspections are to be performed by a “competent person”, who is capable of identifying existing and predictable
hazards in the surroundings or working conditions which are unsanitary, hazardous, or dangerous to employees, and who has
authorization to take prompt corrective measures to eliminate them.
Quarterly and annual inspections are to be performed by a “qualified person” who, by possession of a recognized degree,
certificate, or professional standing, or who by extensive knowledge, training and experience, successfully demonstrated the
ability to solve/resolve problems relating to the subject matter, the work, or the project.
One hour of normal crane operation assumes 20 complete cycles per hour. If operation exceeds 20 cycles per hour, inspection
frequency should be increased accordingly.
Consult Operator / Service Manual for additional inspection items, service bulletins and other information.
Before inspecting and operating crane, crane must be set up away from power lines and leveled with stabilizers fully extended.
DAILY (D): Before each shift of operation, those items designated with a (D) must be inspected.
MONTHLY (M): Monthly inspections or 100 hours of normal operation (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 to four 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.
INSPECTION CHECKLIST STATUS KEY:
S = Satisfactory
R = Recommendation
(Should be considered for corrective action)
NA = Not Applicable
X = Deficient
(NOTE: If a deficiency is found, an immediate determination must
be made as to whether the deficiency constitutes a safety hazard
and must be corrected prior to operation.)
FREQUENCY
ITEM
KEY
INSPECTION DESCRIPTION
D
1
Labels
D
D
2
3
Crane
Controls
D
4
Station
D
5
D
D
6
7
Hydraulic
System
Hook
Wire Rope
D
8
Pins
All load charts, safety & warning labels, and control labels are present
and legible.
Check all safety devices for proper operation.
Control mechanisms for proper operation of all functions, leaks and
cracks.
Control and operator's station for dirt, contamination by lubricants, and
foreign material.
Hydraulic system (hoses, tubes, fittings) for leakage and proper oil
level.
Presence and proper operation of hook safety latches.
Inspect for apparent deficiencies per applicable requirements and
manufacturer’s specifications.
Proper engagement of all connecting pins and pin retaining devices.
STATUS
(S,R,X,NA)
Chapter 5 General Reference
FREQUENCY
ITEM
KEY
INSPECTION DESCRIPTION
D
9
General
D
10
Operation
D
D
D
11
12
13
D
D
14
15
Remote Ctrl
Electrical
Anti TwoBlock or
Two-Block
Damage
Prevention
Tires
Ground
Conditions
Overall observation of crane for damaged or missing parts, cracked
welds, and presence of safety covers.
During operation, observe crane for abnormal performance, unusual
wear (loose pins, wire rope damage, etc.). If observed, discontinue
use and determine cause and severity of hazard.
Operate remote control devices to check for proper operation.
Operate all lights, alarms, etc. to check for proper operation.
Operate anti two-block or two-block damage prevention device to
check for proper operation.
D
16
D
17
D
18
D
19
D
20
D
D
M
M
21
22
23
24
M
M
M
25
26
27
M
M
28
29
M
M
M
M
30
31
32
33
M
M
34
35
M
36
77
STATUS
(S,R,X,NA)
Check tires (when in use) for proper inflation and condition.
Check ground conditions around the equipment for proper support,
watching for ground settling under and around stabilizers and
supporting foundations, ground water accumulation, or similar
conditions.
Level
Check the equipment for level position within the tolerances specified
by the equipment manufacturer’s recommendations, both before each
shift and after each move and setup.
Operator
Check windows for cracks, breaks, or other deficiencies which would
cab windows hamper the operator's view.
Rails, rail
Check rails, rail stops, rail clamps and supporting surfaces when the
stops, rail
equipment has rail traveling.
clamps and
supporting
surfaces
Safety
Check safety devices and operational aids for proper operation.
devices
Electrical
Check electrical apparatus for malfunctioning, signs of apparent
excessive deterioration, dirt or moisture accumulation.
Other
Other
Daily
All daily inspection items.
Cylinders
Visual inspection of cylinders for leakage at rod, fittings, and welds.
Damage to rod and case.
Valves
Holding valves for proper operation.
Valves
Control valves for leaks at fittings and between stations.
Valves
Control valve linkages for wear, smoothness of operation, and
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 excessive
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 and cracks.
Pins
All pins for proper installation and condition.
Hardware
All bolts, fasteners and retaining rings for tightness, wear and
corrosion.
Wear Pads
Presence of wear pads.
Pump &
Hydraulic pumps and motors for leakage at fittings, seals, and
Motor
between sections. Check tightness of mounting bolts.
PTO
Transmission/PTO for leakage, abnormal vibration & noise, alignment,
and mounting bolt torque.
78
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
FREQUENCY
ITEM
KEY
M
M
37
38
Hyd Fluid
Hyd Lines
M
M
M
M
M
Q
Q
Q
Q
Q
Q
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
Q
59
60
61
62
63
64
65
66
67
68
69
70
Q
71
72
73
74
75
76
77
Q
78
79
80
81
INSPECTION DESCRIPTION
STATUS
(S,R,X,NA)
Quality of hydraulic fluid and presence of water.
Hoses & tubes for leakage, abrasion damage, blistering, cracking,
deterioration, fitting leakage, and secured properly.
Hook
Load hook for abnormal throat distance, twist, wear, and cracks.
Wire Rope
Condition of load line.
Manual
Presence of operator's manual 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 and corrosion.
• Base
• Stabilizer beams and legs
• Mast
• Inner Boom
• Outer Boom
• Extension(s)
• Jib boom
• Jib extension(s)
• Other
Hardware
Pins, bearing, shafts, gears, rollers, and locking devices for wear,
cracks, corrosion and distortion.
• Rotation bearing(s)
• Inner boom pivot pin(s) and retainer(s)
• Outer boom pivot pin(s) and retainer(s)
• Inner boom cylinder pin(s) and retainer(s)
• Outer boom cylinder pin(s) and retainer(s)
• Extension cylinder pin(s) and retainer(s)
• Jib boom pin(s) and retainer(s)
• Jib cylinder pin(s) and retainer(s)
• Jib extension cylinder pin(s) and retainer(s)
• Boom tip attachment
• Other
Hyd Lines
Hoses, fittings and tubing for proper routing, leakage, blistering,
deformation and excessive abrasion.
• Pressure line(s) from pump to control valve
• Return line(s) from control valve to reservoir
• Suction line(s) from reservoir to pump
• Pressure line(s) from control valve to each function
• Load holding valve pipe(s) and hose(s)
• Other
Pumps &
Pumps and Motors for loose bolts/fasteners, leaks, noise, vibration,
Motors
loss of performance, heating & excess pressure.
• Winch motor(s)
• Rotation motor(s)
• Other
Valves
Hydraulic valves for cracks, spool return to neutral, sticking spools,
proper relief valve setting, relief valve failure.
Chapter 5 General Reference
79
FREQUENCY
ITEM
KEY
INSPECTION DESCRIPTION
Q
82
83
84
85
86
87
Q
88
89
90
91
92
93
94
95
96
Q
A
A
A
A
A
A
A
A
97
98
99
100
101
102
103
104
105
A
A
106
107
A
A
108
109
• Main control valve
• Load holding valve(s)
• Stabilizer or auxiliary control valve(s)
• Other
• Other
Cylinders
Hydraulic cylinders for drifting, rod seal leakage and leakage at welds.
Rods for nicks, scores and dents. Case for damage. Case and rod
ends for damage and abnormal wear.
• Stabilizer cylinder(s)
• Inner boom cylinder(s)
• Outer boom cylinder(s)
• Extension cylinder(s)
• Rotation cylinder(s)
• Jib lift cylinder(s)
• Jib extension cylinder(s)
• Other
Winch
Winch, sheaves and drums for damage, abnormal wear, abrasions
and other irregularities.
Hyd Filters
Hydraulic filters for replacement per maintenance schedule.
Daily
All daily inspection items.
Monthly
All monthly inspection items.
Quarterly
All quarterly inspection items.
Hyd Sys
Hydraulic fluid change per maintenance schedule.
Controls
Control valve calibration for correct pressure & relief valve settings.
Valves
Safety valve calibration for correct pressure & relief valve settings.
Valves
Valves for failure to maintain correct settings.
Rotation Sys Rotation drive system for proper backlash clearance & abnormal wear,
deformation and cracks.
Lubrication
Gear oil change in rotation drive system per maintenance schedule.
Hardware
Check tightness of all fasteners and bolts, using torque specifications
on component drawings or torque chart.
Wear Pads
Wear pads for excessive wear.
Loadline
Loadline for proper attachment to drum.
STATUS
(S,R,X,NA)
80
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
Deficiency / Recommendation / Corrective
Action Report
DATE:
OWNER:
UNIT I.D. NUMBER:
GUIDELINES
a A deficiency (X) may constitute a hazard. Deficiency must be corrected and/or faulty parts
replaced before resuming operation.
b Recommendations (R) should be considered for corrective actions. Corrective action for a
particular recommendation depends on the facts in each situation.
c Corrective actions (CA), repairs, adjustments, parts replacement, etc. are to be performed by a
qualified person in accordance with all manufacturer’s recommendations, specifications and
requirements.
NOTE: Deficiencies (X) listed must be followed by the corresponding corrective action taken (CA).
X = DEFICIENCY
X,R,CA
ITEM #
R = RECOMMENDATION
EXPLANATION
CA = CORRECTIVE ACTION TAKEN
DATE CORRECTED
Chapter 5 General Reference
X,R,CA
ITEM #
EXPLANATION
81
DATE CORRECTED
82
Model 8600 30-foot Parts & Specifications Manual Part # 99905181
Thread Torque Charts
FINE THREAD BOLTS (ENGLISH)
SIZE
BOLT
GRADE 5
DIA.
SAE J429
GRADE 5
(DIA-TPI) (INCHES) PLAIN
5/16-24
3/8-24
7/16-20
1/2-20
9/16-18
5/8-18
3/4-16
7/8-11
1-12
1 1/8-12
1 1/4-12
1 3/8-12
1 1/2-12
0.3125
0.375
0.4375
0.5
0.5625
0.625
0.75
0.875
1
1.125
1.25
1.375
1.5
(FT-LB)
19
35
55
90
120
170
300
445
645
890
1240
1675
2195
COARSE THREAD BOLTS (ENGLISH)
SIZE
BOLT
GRADE 5
DIA.
GRADE 8
SAE J429
GRADE 5
SAE J429
GRADE 8
PLATED PLAIN
PLATED
(FT-LB)
14
26
41
64
90
130
225
325
485
670
930
1255
1645
(FT-LB)
20
35
58
90
130
180
315
500
745
1085
1510
2035
2670
(FT-LB)
27
49
78
120
170
240
420
670
995
1445
2010
2710
3560
(DIATPI)
5/16-18
3/8-16
7/16-14
1/2-13
9/16-12
5/8-11
3/4-10
7/8-9
1-8
1 1/8-7
1 1/4-7
1 3/8-6
1 1/2-6
(INCHES) PLAIN
0.3125
0.375
0.4375
0.5
0.5625
0.625
0.75
0.875
1
1.125
1.25
1.375
1.5
(FT-LB)
17
31
49
75
110
150
265
395
590
795
1120
1470
1950
GRADE 8
SAE J429
GRADE 8
PLATED
PLAIN
PLATED
(FT-LB)
13
23
37
57
82
115
200
295
445
595
840
1100
1460
(FT-LB)
25
44
70
105
155
220
375
605
910
1290
1815
2380
3160
(FT-LB)
18
33
52
80
115
160
280
455
680
965
1360
1780
2370
NOTES
1 Tightening torques provided are midrange.
2
Consult bolt manufacturer’s particular specifications, when provided.
3
Use flat washers of equal strength.
4
All torque measurements are given in foot-pounds.
5
Torque values specified are for bolts with residual oils or no special lubricants applied. If special lubricants of
high stress ability, such as Never-Seez compound graphite and oil, molybdenum disulphide, colloidal copper or
white lead are applied, multiply the torque values in the charts by the factor .90. The use of Loctite does not affect
the torque values listed above.
WARNING
Anytime a gear-bearing bolt is removed, it must be replaced with a new bolt of the identical
grade and size. Once a bolt has been torqued to 75% of its proof load and then removed, the
torque coefficient may no longer be the same as when the bolt was new thus giving
indeterminate clamp loads after torquing. Failure to replace gear-bearing bolts may result in bolt
failure due to metal fatigue causing death or serious injury.
Chapter 5 General Reference
FINE THREAD TORQUE CHART (METRIC)
COARSE THREAD TORQUE CHART (METRIC)
TIGHTENING TORQUE
TIGHTENING TORQUE
SIZE
(DIATPI)
SIZE
(DIATPI)
BOLT
DIA.
(INCHES)
SAE J429
GRADE 5
5/16-24
3/8-24
7/16-20
1/2-20
9/16-18
5/8-18
3/4-16
7/8-11
1-12
1 1/8-12
1 1/4-12
1 3/8-12
1 1/2-12
0.3125
0.375
0.4375
0.5
0.5625
0.625
0.75
0.875
1
1.125
1.25
1.375
1.5
BOLT DIA
(INCHES)
SAE J429
GRADE 5
SAE J429
GRADE 8
PLAIN PLATED PLAIN
(KG-M) (KG-M) (KGM)
3
2
4
5
4
7
8
6
11
12
9
17
17
12
24
24
18
33
41
31
58
62
45
93
89
67
138
123
93
200
171
129
278
232
174
375
304
228
492
PLATED
(KG-M)
3
5
8
12
18
25
44
69
103
150
209
281
369
83
SAE J429
GRADE 8
PLAIN PLATED PLAIN PLATED
(KG-M) (KG-M) (KG-M) (KG-M)
5/16-18
3/8-16
7/16-14
1/2-13
9/16-12
5/8-11
3/4-10
7/8-9
1-8
1 1/8-7
1 1/4-7
1 3/8-6
1 1/2-6
0.3125
0.375
0.4375
0.5
0.5625
0.625
0.75
0.875
1
1.125
1.25
1.375
1.5
2
4
7
10
15
21
37
55
82
110
155
203
270
2
3
5
8
11
16
28
41
62
82
116
152
210
3
6
10
15
21
30
52
84
126
178
251
329
438
2
5
7
11
16
22
39
63
94
133
188
246
328
NOTES
1 Tightening torques provided are midrange.
2
Consult bolt manufacturer’s particular specifications, when provided.
3
Use flat washers of equal strength.
4
All torque measurements are given in kilogram-meters.
5
Torque values specified are for bolts with residual oils or no special lubricants applied. If special lubricants of
high stress ability, such as Never-Seez compound graphite and oil, molybdenum disulphide, colloidal copper or
white lead are applied, multiply the torque values in the charts by the factor .90. The use of Loctite does not affect
the torque values listed above.
WARNING
Anytime a gear-bearing bolt is removed, it must be replaced with a new bolt of the identical
grade and size. Once a bolt has been torqued to 75% of its proof load and then removed, the
torque coefficient may no longer be the same as when the bolt was new thus giving
indeterminate clamp loads after torquing. Failure to replace gear-bearing bolts may result in bolt
failure due to metal fatigue causing death or serious injury.