operation, safety & maintenance guide - imt · equipment modifications must be performed with...

DSC OPERATION GUIDE: 99903447: SECTION 0: INTRODUCTIONI

Section 1 OPERATION & MAINTENANCESection 2 INSTALLATION

OPERATION, SAFETY &MAINTENANCE GUIDE

IOWA MOLD TOOLING CO., INC.BOX 189, GARNER, IA 50438-0189

TEL: 641-923-3711

MANUAL PART NUMBER: 99903447

20070510

Iowa Mold Tooling Co., Inc. is an Oshkosh Truck Corporation company.

DSC OPERATION GUIDE: 99903447: SECTION 0: INTRODUCTIONII

REVISIONS LISTDATE LOCATION DESCRIPTION OF CHANGE

20020801 ALL NEW RELEASE - VERSION 120021110 OPERATION & RELEASED INFORMATION ON DSS BODIES

INSTALLATION20030130 2-5,23,24 ECN 9125 - WIRING & ELECTRIC CRANE INSTALLATION INFORMATION20030423 2-5 ECN 9132 - CHANGE TO WIRING20030715 2-4,26 ECN 9132 - ADDED WIRING, COMP. INSTALLATION DWG.20030807 2-3,5,23 ECN’s 9224, 9227 - CHANGES TO WIRING, RIVET LENGTHS20030814 1-4,5 EDITS TO REDUCED CAPACITY WORDING, LOAD CHART20030825 2-26 ECN 9231 - DISTANCE CHANGE ON 9990352420040402 1-2,6-8, 10 REPLACED ORIGINAL PHOTOS WITH NEW PHOTOS WITH CURRENT LATCHES20050131 2-3 ADDED 77441093 HARNESS MARKER EXT 11’ RSD TO 99903481 INSTL. KIT20050523 2-4 CORRECTED MISPRINT ON ITEM #17 - SCREW20050921 2-25 ECN 9855 - ADDED 77441158 TO 99901295 DRAWING20060313 2-23,24 ECN 9982 - ADDED FUSES FOR CIRCUIT PROTECTION, UPDATED WIRING DIAGRAMS20070329 COVER UPDATED OWNERSHIP STATEMENT20070510 2-24 ECN 9000 - REVERSED PIN 30 AND 87

20020801

DSC OPERATION GUIDE: 99903447: SECTION 0: INTRODUCTIONIII

INTRODUCTIONThis manual is intended as a basic source of information on safely operating and maintaining your IMT DiamondSeries body. Although safety issues regarding your product are addressed in this manual, it is not intended asan all encompassing “rule book” on safety. It is YOUR RESPONSIBILITY as the product owner/operator toidentify specific safety hazards and determine proper procedures to prevent hose hazards from infilcting injury.

This manual is divided into sections which nclude an operation guide, a maintenance checklist and guide, safetyinformation, and general reference information pertinent to your IMT Diamond Series product.

Familiarity with this manual, government regulations, hazards and the specific operations of your equipment is anecessity. You must use caution and follow all safety procedures and applicable regulations while operating andmaintaining your equipment.

Equipment modifications must be performed with IMT approved accessories, parts and optional equipment. DONOT alter or modify any safety device, whether electrical, hydraulic, or mechanical in nature.

To highlight safety issues, NOTE’s, CAUTION’s and WARNING’s are included throughout the manual. They aredefined as:

NOTEA NOTE IS USED TO EITHER CONVEY ADDITIONAL INFORMATION OR TO

PROVIDE FURTHER EMPHASIS FOR A PREVIOUS POINT.

CAUTIONA CAUTION IS USED WHEN THERE IS A STRONG POSSIBILITY OF

DAMAGE TO THE EQUIPMENT OR PREMATURE EQUIPMENT FAILURE.

WARNINGA WARNING IS USED WHEN THERE IS THE POTENTIAL FOR PERSONAL INJURY OR DEATH.

It is the responsibility of the owner and/or designated employee to inform all operators, maintenance personneland others involved in the equipment operation about safe operation, maintenance, and repair procedures. If anyquestions arise, contact IMT or your IMT distributor for clarification. Please furnish a copy of this manual to allpersons involved in operation or maintenance of your equipment. IMT grants you, the purchaser, the right toreproduce this document for that purpose and to further the education in safe operation and maintenance.

NOTICE TO THE OWNER / USERIf your equipment is involved in a property damage accident, contact your IMT distributorimmediately and provide them with the details of the accident and the serial number of theequipment. If an accident involves personal injury, immediately notify your distributor andIMT’s Safety Director at:

IOWA MOLD TOOLING CO., INC.500 HWY 18 WEST, GARNER, IA 50438

641 - 923 - 3711

20020801

DSC OPERATION GUIDE: 99903447: SECTION 0: INTRODUCTIONIV

NOTES:

20020801

DSC OPERATION GUIDE: 99903447: SECTION 1: OPERATION1-1

SECTION 1. OPERATION & MAINTENANCE

1.0 FEATURES .................................................................................................................... 21.1 BODY CONFIGURATION .............................................................................................. 22.0 MINIMUM CHASSIS REQUIREMENTS ........................................................................ 23.0 VEHICLE POSITION...................................................................................................... 23.1 BODY SET-UP ............................................................................................................... 34.0 UNIT CAPACITY ........................................................................................................... 45.0 BODY FEATURES ......................................................................................................... 65.1 COMPARTMENT DOORS & LATCHES........................................................................ 65.2 MASTER LOCK SYSTEM ............................................................................................. 65.3 COMPARTMENT OPTIONS .......................................................................................... 75.3.1 ADJUSTABLE SHELF................................................................................................ 75.3.2 BOOKSHELF.............................................................................................................. 75.3.3 TANK BRACKET ........................................................................................................ 75.3.4 ROLL-OUT DRAWER ................................................................................................. 75.4 TIE-DOWNS ................................................................................................................... 75.5 TRAILER HITCH ON BUMPER..................................................................................... 75.6 TAILGATE ...................................................................................................................... 76.0 LIGHTING ...................................................................................................................... 86.1 COMPARTMENT LIGHT OR FLOODLIGHT OPTIONS ................................................ 87.0 PTO OPTION ................................................................................................................. 87.1 ENGAGING THE PTO.................................................................................................... 87.2 DISENGAGING THE PTO.............................................................................................. 88.0 COMPRESSOR ............................................................................................................. 99.0 SAFETY EQUIPMENT ................................................................................................... 910.0 GUIDE TO MAINTENANCE......................................................................................... 911.0 GREASE REQUIREMENTS ........................................................................................ 912.0 TROUBLESHOOTING............................................................................................... 10

20021101


1.0 FEATURESYour IMT Diamond Series body offers numer-ous features to improve your mobile worksiteconditions. Whether you will be using the IMTDiamond Series vehicle for utility work, con-struction, municipal applications, or more,your IMT Diamond Series vehicle will improveyour ability to work on the road. Features ofthe IMT Diamond Series body include:

Flush mounted doors with hiddenhinges and durable, tee-style leak-proofplastic latchesDOT lights and reflectorsMaster lock systems42” high compartmentsRecessed cargo tie-downsOutriggersOptional adjustable shelvesOptional compartment lightsOptional hydraulic systemsOptional compressor

1.1 BODY CONFIGURATIONKnow the components of your unit. Doing sowill aid in the communication of problems tomaintenance personnel as well as provideimmediate reference during an emergencysituation. Use Figures 1A and 1B for compo-nent identification for your IMT DiamondSeries body.

2.0 MINIMUM CHASSIS REQUIRE-MENTSThe minimum chassis requirements for anIMT Diamond Series body are:

10,500 lb gross vehicle weightDual rear wheels6,000 lb rear axle4,500 lb front axle9’ body - 60” cab to axle distance (CA)

3.0 VEHICLE POSITIONBefore beginning work with your unit, park thecarrier vehicle over a firm and level surface foradequate outrigger support. If outriggersappear to bury themselves in a less than firmsurface, then DO NOT perform a lift until asuitable location is found. DO NOT positionthe outriggers near sharp drop-offs or areas ofuncertain firmness.

20040402

Figure 1A: Component Identificationfrom Side of Body

Figure 1B: Component Identificationfrom Rear of Body

DOT Light Kit

Bumper

Master Lock Handle Master Lock HandleBody Compartments Outrigger

Crane


3.1 BODY SET-UPRear outriggers are included on all IMT Dia-mond Series crane bodies to stabilize the unitwhen using the crane. The Diamond Seriescrane units include a manual out/manualdown outrigger on the crane mount side of thebody, and a manual down outrigger on theother side of the body.

WARNINGOUTRIGGERS CAN PINCH, STRIKE, OR

CRUSH PEOPLE OR OBJECTS!MAKE SURE THERE ARE NO OB-

STRUCTIONS BEFORE OPERATINGOUTRIGGERS.

Although the outriggers are critical to safe andstable operation, they can be hazardous dueto their close proximity to the operator andother personnel. They are the only compo-nent of the body which normally contact theground.

To set up the outriggers:1) Release the pin which locks the manualout/manual down outrigger in the retracted,locked position.

2) Extend the outrigger. Be careful not tooverextend - there is no positive stop on thisoutrigger and it could fall and hurt you ordamage equipment. Once extended, replace

the pin to lock the outrigger.

3) Remove the outrigger leg pin, and lowerthe outrigger leg until full ground contact andsolid stability is achieved. Replace the pin.

4) Repeat step three for the manual downoutrigger.

Figure 2: Outrigger Set-UpOutrigger in Retracted Position

Outrigger Extended

Outrigger extended with Leg Lowered

20021101


4.0 UNIT CAPACITYThe capacity of the crane on your DiamondSeries body is dependent upon the cranerating and the chassis upon which the body isinstalled.

Your IMT DSC crane body is rated for an IMT20,000 ft-lb crane (IMT Model 2020), and yourIMT DSS body is rated for up to a 1/2-toncrane. However, to determine the cranecapacity for a particular lifting situation, youmust know both your load and the direction ofyour lift to determine the capacity for yourparticular situation.

On a DSC body, you should find a capacityplacard, similar to the sample in Figure 3,mounted on your crane or body. Exceedingthe limits presented on the capacity placardwill create severe safety hazards and willshorten the life of the crane. You and otherconcerned personnel must know the loadcapacity of the crane and the weight of theload being lifted!

In some cases, due to chassis front axlelimitations, the capacity of your unit may bereduced when lifting beyond 90° from the backof the truck using a 9-foot body. Figure 4illustrates a sample capacity placard for thereduced lifting capacity of the IMT DiamondSeries body using an IMT 2020 crane. Thecrane capacity may be reduced up to 66% forlifts made further than 90° behind the back ofthe truck.

WARNINGNEVER EXCEED THE RATED LOAD CAPACITIES.OF THE UNIT. DOING SO WILL CAUSESTRUCTURAL DAMAGE AND DAMAGE TOCRANE WINCHES AND CABLES AND TO THEBODY, WHICH CAN LEAD TO SERIOUSINJURIES OR DEATH.

Prior to lifting a load:1. Determine the weight of the load.

2. Determine the weight of any load handlingdevices.

3. Add the weight of the load and the weight ofthe load handling devices. The sum will bethe total weight of the load being lifted.

4. Determine the distance from the centerlineof crane rotation to the centerline of the loadbeing lifted.

5. Determine the distance from the centerlineof crane rotation to the centerline of where theload is to be moved to.

6. The actual distance used should be figuredas the larger of items 4 and 5 above.

7. Determine at what angle the crane will beoperated (for example 30°, 45°, etc.) byreferencing the angle indicator on the lowerboom.

8. Make certain that 2-part line is used for anylift which requires 2-part line. (Note: The two-part line weight is noted in a box on the capac-ity chart.)

Figure 3: Sample Capacity Placard

20030814

FULL CRANE CAPACITY CHART2nd Extension Out

1st Extension Out

2nd Extensionin 2’-0"

1st Extensionin 3’-0"

Extensions In

15’

18’

20’-11"

12’

9’

6’

1’-5"

00

( )3’ 6’ 10’ 12’ 15’ 18’ 20’

0�1660 1320 1000 8002000

20601700

13602300

1900

2360

1860

1600

2000

2440

820

3040

40002680

5000

50004000

3340

2860 1520

1020

900

1400

1140

1120

cL Weights in pounds (lb); distances in feet (’) and inches (").

SAMPLE


FULL CRANE CAPACITY CHART2nd Extension Out

1st Extension Out



Extensions In

15’

18’

20’-11"

12’

9’

6’

1’-5"

00

( )3’ 6’ 10’ 12’ 15’ 18’ 20’

0�1660 1320 1000 8002000

20601700

13602300

1900

2360

1860

1600

2000

2440

820

3040

40002680

5000

50004000

3340

2860 1520

1020

900

1400

1140

1120

cL

LIMITED WORK AREA CAPACITY CHART2nd Extension Out

1st Extension Out



Extensions In

15’

18’

20’-11"

12’

9’

6’

1’-5"

00

( )3’ 6’ 10’ 12’ 15’ 18’ 20’

0�830 665 555 5001000

1035860

6101155

960

1175

940

1000

1110

1615

515

1795

21551330

2695

32352000

1665

1410 770

575

575

785

640

705

cL

Full Crane Capacity

Work Area

(IMT 2020 Crane)Work AreaLimited by

Front Axle andTire Ratings

DSC20 REDUCED CAPACITY LOAD CHART

TRUCK

Weights in pounds (lb); distances in feet (’) and inches ("). Weights in pounds (lb); distances in feet (’) and inches (").

70396270

XXXX lb

Figure 4: Sample Reduced Capacity Chart

20030814

SAMPLE


5.0 BODY FEATURES5.1 COMPARTMENT DOORS &LATCHESYour IMT Diamond Series body features 42”high compartments on each side of the body.The vertical compartments have springs onthe doors. To close these compartments,push gently on the spring to release it prior toclosure.

Compartments which open horizontally do nothave springs, and the doors use gravity toopen fully.

All compartment doors have a leak-proof “T”style latching system. After compartmentdoors are closed, the latch turns to lock intoplace. After the latch is rotated into latchingposition, the striker draws the door into theweather-strip when the “T” is pushed into thelocking position.

5.2 MASTER LOCK SYSTEMCompartments on both sides of the body canbe locked using the “Master Lock” system.See Figure 6 for the Master Lock handle.

To operate the Master Lock system,

1) Close all cabinet doors on the side youwish to lock.

2) Push the Master Lock handle completelyin, and secure the locking system with apadlock. The hole in the system is largeenough for a 1/4” padlock.

3) Repeat for the other side of the body, ifdesired.

To release the Master Lock system,

1) Remove the padlock from the Master Lockhandle.

2) Pull the handle open.

NOTETHE MASTER LOCK HANDLE IS SPRING

LOADED WHEN YOU RELEASE THELOCKS.

Figure 7: Master Lock HandleFigure 5: Door Latches

Latches on the IMT Diamond Series bodyhave a two-step closure feature. They mustbe turned to completely lock the door. SeeFigure 6 for latch in open position.

MasterLockHandle

20040402

Figure 6: Latch in Open Position


5.3 COMPARTMENT OPTIONS5.3.1 ADJUSTABLE SHELFAdjustable shelves are an option for both thehorizontal and vertical compartments on thesides of your IMT Diamond Series body.These shelves can be raised and lowered tothe position you require using the brackets onthe cabinet interior.

5.3.2 BOOKSHELFA bookshelf is available for the horizontalcompartment on the left side of your body.This shelf can be used to hold parts manualsor other technical books required in your work.

5.3.3 TANK BRACKETThe right front compartment on your body isvented for oxygen or acetylene. You canpurchase a tank bracket to support two tanksof oxygen or acetylene for this cabinet only.

WARNINGONLY THE RIGHT FRONT COMPART-MENT IS VENTED ON THE IMT DIA-

MOND SERES BODY. DO NOT USEOTHER COMPARTMENTS FOR OXY-

GEN, ACETYLENE, OR OTHER GASES.

5.3.4 ROLL-OUT DRAWERA roll-out drawer option is also available for thefront right and front left compartments. Thesedrawers can be accessed by pulling on them.

The drawers roll out from the body on steeltracks.

CAUTIONBE SURE TO ROLL THE DRAWER INCOMPLETELY PRIOR TO SHUTTING

THE COMPARTMENT DOOR.

5.4 TIE-DOWNSThe bed of the IMT Diamond Series bodyfeatures four tie-downs which can be used tosecure items to the body or to remove thebody from the chassis. These tie-downs lieflush in the bed when not in use.

5.5 TRAILER HITCH ON BUMPERThe rear bumper of the body has a mountingplate which can be used for a trailer hitch.Figure 8 shows the decal located on thebumper.

Figure 9: Maximum Bumper Load Decal

Note that the chassis trailer rating may belower than the figures indicated. Be sure notto exceed the maximum rated load for the rearbumper or chassis.

5.6 TAILGATEYour IMT Diamond Series body has a stan-dard poly tailgate which drops in and out of therear of the bed.

A hinged tailgate is available for your body, andthe 8” high tailgate attaches to the sides of thebed. This tailgate gives you slightly moreroom at the rear of the bed because bracketsto support the poly tailgate are not required.

Maximum Towable Load: 16,000 lbMaximum Tongue Weight: 2,000 lbTow vehicle trailer rating may be less.

DO NOT exceed the chassis manufacturer’s trailer towing ratings. 70

3962

66

Horizontalcompartmentwith shelf

Right frontcompartmentwith tank bracketassembly

Figure 8: Compartment Options

20040402


6.0 LIGHTINGStandard IMT Diamond Series bodies areequipped with DOT lights and reflectors.Lighting options include a compartment lightkit and a flood light kit with two flood lights forthe rear of the body.

6.1 COMPARTMENT LIGHT OR FLOOD-LIGHT OPTIONSIf your body has a compartment light orfloodlight kit, these lights are operated using acontrol panel inside the compartment. SeeFigure 9. Using the control panel, you canoperate the air compressor, the right and leftcompartment lights, and the flood lights.

Figure 10: Compartment Light ControlPanel

7.1 ENGAGING THE PTOA. Automatic Transmission1) Set the vehicle parking brake.2) Turn on the vehicle engine.3) Put the vehicle in “Park” or “Neutral”.4) Engage the PTO according to themanufacturer’s instructions. With an electri-cal “Hot Shift” PTO, press the switch to the“ON” position. NOTE: A light will come on toshow the PTO is engaged.5) Warm the engine to operating tempera-ture.6) Begin crane operation.

B. Manual Transmission1) Set the vehicle parking brake.2) Place the transmission in “Neutral”.3) Make certain the PTO lever is in the “OFF”position.4) Start the vehicle engine.5) Fully depress the clutch.6) Engage the PTO. With a cable-shiftPTO, move the lever to the “ON” position.With an air shift PTO, move the valve to the“ON” position.7) Release the clutch gradually.8) Warm the engine to operating tempera-ture.9) Begin crane operation.

7.2 DISENGAGING THE PTO1) Fully depress the vehicle’s clutch pedal (ifmanual).2) Disengage the PTO (OFF).3) Release the clutch pedal gradually.

DANGER:DO NOT COME IN CONTACT WITH THEPTO. DEATH OR SERIOUS INJURY MAY

OCCUR.

WARNING:DISENGAGE THE PTO PRIOR TO

MOVING THE VEHICLE. FAILURE TODO SO MAY CAUSE PUMP AND PTO

DAMAGE, AND INADVERTENT OPERA-TION OF THE CRANE DRIVE TRAIN,

WHICH COULD CAUSE AN ACCIDENT.

7.0 PTO OPTIONIf you have a crane mounted on your IMTDiamond Series body, this crane may beelectric, or may be powered by a pump andpower take-off (PTO).

NOTE:FOLLOW MANUFACTURER INSTRUC-TIONS TO ENGAGE THE PTO IN YOURVEHICLE. THE INSTRUCTIONS IN THISMANUAL MAY NOT BE ACCURATE FOR

ALL PTO’S.

20040402


8.0 COMPRESSORYour IMT Diamond Series body may have anair compressor. See the compressor manualfor complete details on operating the com-pressor.

9.0 SAFETY EQUIPMENTSafety equipment options that may be pur-chased with the IMT Diamond Series bodyinclude a fire extinguisher or complete safetykit which includes a mounted fire extinguisherand a triangular traffic warning bracket.

10.0 GUIDE TO MAINTENANCETo obtain reliable and satisfactory service, theIMT Diamond Series body requires a consis-tent preventive maintenance schedule. Takenecessary and reasonable precautions duringDiamond Series maintenance to avoid equip-ment and personal injury.

WARNINGBEFORE PERFORMING ANY MAINTE-

NANCE FUNCTION, BE SURE ALLSYSTEMS ARE “OFF”. TURN OFF ALLSYSTEMS USING THE ELECTRICAL

PANEL IN THE REAR OF THE VEHICLE.

Prior to beginning vehicle maintenance,1. Park the vehicle is an area where otherequipment is not operating and where there isno through traffic.

2. Set the vehicle parking brake.

3. Place all controls in the “OFF” position anddisable all systems.

4. Disconnect the PTO, if applicable.

5. Relieve the hydraulic pressure from allcircuits before disconnecting any hydraulicfittings or components.

6. Replace parts with only factory-approvedreplacements.

After maintenance, before putting the truckback into service,

1. Replace all shrouds, guards, and safetydevices which were removed.

2. If applicable, purge all trapped air in thehydraulic system to prevent erratic operation.

3. Remove grease and oil from all controls.

11.0 GREASE REQUIREMENTSHinges and latches on the compartment doorsof the Diamond Series body should begreased once or twice per year. Grease usinga multi-purpose spray grease. (IMT usesMystic JT-6 grease but an equivalent grease isacceptable.)

20020801


12.0 TROUBLESHOOTINGUse the following table to help you diagnose andresolve problems with your IMT Diamond Seriesvehicle. For issues not listed on this chart,contact IMT Technical Support at 641-923-3711.

PROBLEM CAUSE SOLUTIONLights do not operate. Faulty wiring. Check fuses in wiring. Replace if

needed.

Doors do not latch. Latch is not completely turned Make sure latch is turned so door isin closed position. sealed.

Master lock system does not work. Doors aren’t completely closed. Fully latch all doors.

Misalignment of components. Adjust finger positioning on master lock.rod.

20040402

DSC OPERATION GUIDE: 99903447: SECTION 2: INSTALLATION2-1

SECTION 2. INSTALLATION

20030130

1.0 INSTALLATION INTRODUCTION ................................................................................. 22.0 CHASSIS SPECIFICATIONS ........................................................................................ 23.0 COMPONENT INSTALLATION ..................................................................................... 3

ELECTRICAL INSTALLATION (99903481) ................................................................... 3DOOR ASSEMBLY (99903548) ..................................................................................... 4FRONT END WIRING (99903444) ................................................................................. 5

4.0 CHASSIS INSTALLATION............................................................................................. 6INSTALLATION FOR FORD GVW UP TO 17,500 LBS ................................................. 6

5.0 OPTIONS INSTALLATION............................................................................................. 7PTO & PUMP ................................................................................................................. 7DRIVELINE & PUMP INSTALLATION ........................................................................... 8COMPRESSOR INSTALLATION ................................................................................... 8DRIVELINE INSTALLATION TECHNIQUES ................................................................. 8INSTALLATION - HYDRAULIC CRANE KIT (1) .......................................................... 12INSTALLATION - HYDRAULIC CRANE KIT (2) .......................................................... 13INSTALLATION - HYDRAULIC CRANE KIT (3) .......................................................... 14HYDRAULIC SCHEMATIC (4) ..................................................................................... 15INSTALLATION - COMPRESSOR HYD KIT (1) ........................................................... 16INSTALLATION - COMPRESSOR HYDRAULIC KIT (2) ............................................. 17COMPRESSOR HYD KIT (3) ....................................................................................... 18INSTALLATION - CRANE & COMPRESSOR HYD KIT (1) ......................................... 19INSTALLATION - CRANE & COMPRESSOR HYD KIT (2) ......................................... 20INSTALLATION - CRANE & COMPRESSOR HYD KIT (3) ......................................... 21INSTALLATION - CRANE & COMPRESSOR HYD KIT (4) ......................................... 22HYDRAULIC TELESCOPING CRANE-ELECTRICAL INSTALLATION (99901294) .. 23ELECTRIC TELESCOPING CRANE-ELECTRICAL INSTALLATION (99903519) ..... 24DA435HA COMPRESSOR-ELECTRICAL (99901295) ............................................... 2520013 COMPRESSOR - INSTALLATION DRAWING (99903524) ............................... 26


1.0 INSTALLATION INTRODUCTIONYou may have purchased your IMT DiamondSeries body as a ship-out unit or as an installedunit on a chassis. If you purchased a ship-outunit, you received a primed body and uninstalledcomponents including the master lock system,lights, wiring, weatherstripping and any optionsyou may have ordered.

IMT recommends that you finish the body,including painting, wiring, and weatherstripping,prior to installing it on a chassis.

The installation instructions in this manual arearranged in the appropriate order:! Component installation including doors andlights! Chassis installation on specific chassissizes! Options installation

2.0 CHASSIS SPECIFICATIONSYour IMT Diamond Series body is designed forinstallation on a dual rear wheel chassis only.Installations differ based on the gross vehicleweight (GVW).

20020801


ELECTRICAL INSTALLATION (99903481)1. 70145799 RETAINER-ELEC HARNESS 34

(NOT SHOWN)2. 77044237 TERMINAL-BULLET PLUG 13. 70034366 PLUG-PLASTIC BUTTON 1-1/8” 84. 76393636 GROMMET - RUBBE R2.00 45. 77040358 LIGHT-CLEAR AMBER 26. 77040357 LIGHT-CLEAR RED 2

7. 72062106 NUT #10-24 HEX NYLOC ZINC 38. 72060636 SCREW-MACH #10-24 X 3/4 RDH 29. 77441004 LIGHT-LICENSE PLATE PLASTIC 110. 51715985 KIT-LICENSE PLATE HARDWARE 111. 77040419 LIGHT-MODULE TRUCKLIGHT RH 112. 77040418 LIGHT-MODULE TRUCKLIGHT LH 113. 77441022 HARNESS-TRUCK TAIL LIGHT 214. 77441021 HARNESS-FRONT MARK LIGHTS 215. 77441020 HARNESS-REAR DOT LIGHTS 116. 77441090 HARNESS, EXT COMPT RR A/R

77441091 HARNESS MARKER EXT 9’ A/R77441092 HARNESS MARKER EXT 11’ A/R77441093 HARNESS, MARKER EXT 11’ RSD A/R

3.0 COMPONENT INSTALLATION

REV B 20050131

ASSEMBLY NOTES1. The electrical harness fitsthrough a channel above thedoors. This keeps it from beingable to move around, fall into thedoor openings, or get tangledwith other equipment.

2. The connectors on theelectrical harnesses can only beplugged into the correct con-nectors at the other end. Theycannot be connected incorrectlyas they will only fit into oneconnector.

RH

SID

EPA

CK

SH

OW

N W

ITH

TO

P/B

AC

K R

EM

OV

ED

FO

R C

LAR

ITY

14

4,5

4,6

10

3

1512

2,7,

8,9

4,6 11

13

14

16


ASSEMBLY NOTES1. Center doors in door jams priorto the final screw tightening.

2. Install weatherstripping wi ththe “bulb side” facing the door, forproper seal when the door isclosed.

3. The door spring is constructedwith a cable inside the spring sothe door cannot be opened too far.

4. Bolt item #11, cable, to the doorand upper door jam on horizontaldoors. This prevents the door fromopening too far and damaging itselfor the body.

20030612

9� LH SIDEPACK SHOWN. RH IS MIRROR IMAGE.QTY LISTED IS FOR BOTH SIDES.

11� BODY IS IDENTICAL, EXCEPT 2ND VERTICAL COMPARTMENTCOMPONENTS ARE SAME AS REAR COMPARTMENT.

2

98

13

24

10,14

3

1319,20,22

1 1223

5,18

VIEW SHOWN WITH TOP/BACKPANEL REMOVED FOR CLARITY.

11

19,20,217,1716

15

FRONT

HARDWARESUPPLIED

WITH DOORS

4

DOOR ASSEMBLY (99903548)(EFFECTIVE 5-15-03. REPL. 99903480)

9’ 11’1. 52718140 DOOR WELDMENT-FRONT 2 22. 52718139 DOOR WELDMENT-REAR 2 43. 52718141 DOOR WELDMENT-HORIZ 2 24. 70393719 RUBBER PLUG 8 125. 72060636 SCR-MACH #10-24 X 3/4 RDH PH 8 12

7. 72062104 NUT 1/4-20 HEX NYLOC ZINC 8 128. 60123528 MANUAL BOX 1 19. 72061004 SCR-SHT MET 14X3/4 SLT HEX 6 610. 72661575 LATCH-3-PT T-STYLE W/STRIKE 6 811. 72661550 CABLE-PLASTIC COATED 2 212. 70396116 DOOR HOLDER-SPRING 4 613. 89396430 WEATHERSTRIPPING 60’ 80’14. 76396419 GASKET-LATCH 6 815. 60123799 SPACER-SPRING DOOR STOP 4 616. 60123800 BRACKET-SPRING DOOR STOP 4 617. 72601652 SCR-MACH 1/4-20 X 3/4 RH 20 2818. 72062106 NUT 10-24 HEX NYLOC ZINC 8 1219. 72601590 CAP SCR SS 5/16-18 X 1.00 TRH 8 820. 72063002 WASHER 5/16 FLAT 8 821. 72062109 NUT 5/16-18 HEX NYLOC ZINC 4 422. 72062001 NUT 5/16-18 HEX ZINC 4 423. 72061100 SCR-SELF TAP 10 X 1/2 HH SLOT 8 824. 72661349 POP RIVET .19 X .25 GRIP 24 32

DSC OPERATION GUIDE: 99903447: SECTION 2: INSTALLATION2-5REV C 20030807

FRONT END WIRING (99903444)1. 77040391 RELAY-12V DC 75 AMP 12. 77045873 ELEC 3POS TERM BLOCK 13. 77045874 ELEC 3POS TERM BLK JUMPER 24. 77045905 MAIN POWER HARNESS 15. 77040186 TERM-FSLPON I 1/4TAB 16-14GA 26. 77040053 TERM-RING I 1/4 STUD 12-10GA 27. 60124592 BRACKET-SWITCH (NOT SH) 18. 70396254 DECAL-SWITCH BRACKET (N/S) 19. 60250624 BRKT-CIRCUIT BRKR MTG 1

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4.0 CHASSIS INSTALLATION

20020801


PTO & PUMPGENERALThis section pertains to the installation of theIMT compressor, PTO and pump. The instruc-tions are intended as a guide to assist you withyour particular installation. These instructionswill provide only general information.

PTO AND PUMP INSTALLATIONThe pump may either be installed directly on thePTO (see below) or, as an optional method, itmay be driven by a driveline (see followingpage).

PTO INSTALLATIONPower take-off manufacturers provide specificinstallation instructions for their products.Those instructions should be followed wheninstalling a PTO. Check with the PTOmanufacturer’s representative for specificinstructions regarding your particular make,model and year of vehicle. The following in-structions are a guide in this application.

PTO INSTALLATION

allowance of .006" to .012". If the backlash isexcessive, remove gaskets and check backlashagain until it is corrected.

3. Remove the PTO and apply Permatex® tothe gaskets. If the holes for the studs aretapped through the transmission housing, applyPermatex to the studs and tighten them down.Make certain that the studs do not interfere withthe transmission gears.

Registered Trademark of Permatex Co., Inc., Kansas City, Kansas

CAUTIONAVOID CONTACT OF PERMATEX WITH

TRANSMISSION FLUID.

4. Install the PTO and gaskets. Torque thenuts to 30 - 35 ft-lbs (4.14 - 4.84 kg-m) for a 6-bolt PTO and 45 - 50 ft-lbs (6.22 - 6.91 kg-m) for8-bolt PTO’s. Recheck the backlash.

5. Install the shifter cable to suit conditions.Always allow for a slight overshift on lever orknob to ensure the PTO is fully disengaged.

CAUTIONIT IS IMPORTANT THAT ADEQUATE

SPACE BE ALLOWED FOR FULL EN-GAGEMENT OF THE PTO. MODIFY THEEXHAUST OR OTHER OBSTRUCTIONS

AS NEEDED.

CAUTIONAVOID SHARP BENDS IN THE SHIFTERCABLE. ALL BENDS SHOULD HAVE ATLEAST A 6" RADIUS. TIGHTER BENDS

WILL CAUSE DIFFICULT OPERATION OFTHE SHIFTER KNOB.

6. Replace the transmission oil. If the PTO islocated below the transmission oil level, anadditional quantity of oil will be required.

7. Start the engine, engage the PTO and checkfor proper PTO rotation. Allow it to run for 5 - 10minutes. Check for leaks, unusual noise andproper operation.

8. Retorque the mounting bolts.

1. If the vehicle is new, drain the transmissionoil into a clean container for reuse. If the vehicleis used, drain and dispose of the transmissionoil properly.

2. Temporarily install the PTO with the propergaskets and only two studs. Snug the PTOdown and check the backlash for maximum

5.0 OPTIONS INSTALLATION

20020801


DRIVELINE & PUMP INSTALLATIONThe pump may be driven as shown in figure“Driveline & Pump Installation” as an optionalmethod to the one shown in “PTO Installation”.The following steps are a guide in this applica-tion.

1. Install the PTO (refer to “PTO Installation”).

2. Loosely bolt the pump mounting bracket tothe adjustable bracket in figure below.

3. Bolt the adjustable bracket to the frame at apoint that will not exceed 48" (122cm) from thePTO and will not cause a joint angle greaterthan 3°.

4. Check the pump rotation and install pump,pump end yoke and PTO end yoke.

5. Size, cut and weld the driveline to thenecessary length. Ensure driveline balance andrun out meet specification. Allow 1" (2.54cm)extra for PTO end yoke.

6. Install driveline in phase with proper operat-ing angle calculations, lock set screws andgrease U-joints and mating spline.

7. Ensure all mounting bolts are tight.

COMPRESSOR INSTALLATIONSee Installation Kit Drawing in the Parts Sectionof your compressor manual for specific installa-tion and parts information.

DRIVELINE INSTALLATION TECH-NIQUESU-JOINT OPERATING ANGLESEvery U-joint that operates at an angle createsvibration.

U-joint operating angles are probably the mostcommon cause for driveline vibration in vehiclesthat have been reworked or that have hadauxiliary equipment installed.

WARNING! Inspect the final position of the drivelineto see if operators or other personnel areprotected from rotating driveline hazards.

! If the protection is insufficient, install aguard. Contact IMT for instructions onguarding a rotating driveline.

FAILURE TO HEED THIS WARNING MAYRESULT IN SERIOUS INJURY ORDEATH.

DRIVELINE & PUMP INSTALLATION

20020801


When reworking a chassis or installing a newdriveshaft in a vehicle, make sure that you followthe basic rules that apply to u-joint operatingangles, as follows:

1. U-joint operating angles at each end of ashaft should always be at least 1°.

2. U-joint operating angles on each end of adriveshaft should always be equal within 1° ofeach other.

3. U-joint operating angles should not be largerthan 3°. If more than 3°, make sure they do notexceed the maximum recommended angles forthe RPM at which they will be operating.

A u-joint operating angle is the angle that occursat each end of a driveshaft when the outputshaft of the transmission and the input shaft ofthe pump are not in line. See figure.

The connecting driveshaft operates with anangle at each u-joint. It is that angle that createsa vibration.

REDUCING AND CANCELING VIBRATIONA key point to remember about u-joint operatingangles: To reduce the amount of vibration, theangles on each end of a driveshaft shouldalways be SMALL.

To cancel an angle vibration, the u-joint operat-ing angles need to be EQUAL within 1° at eachend of a shaft. See figure.

SGL PLANE & COMPOUND U-JOINT OPERATINGANGLESThere are two types of u-joint operating angles,single plane and compound.

SINGLE PLANESingle plane angles occur when the transmis-sion and pump components are in line whenviewed from either the top or side, but not both.

Determine the u-joint operating angle in anapplication where the components are in linewhen viewed from the top, but not in line whenviewed from the side, is as simple as measur-ing the slope of the components in the sideview, and adding or subtracting those slopes todetermine the angle. See figure.

These angles should be SMALL and equal within1°.

Determine the u-joint operating angles on ashaft that is straight when viewed from the sideand offset when viewed from the top requiresthe use of a special chart (See accompanyingchart). In this type of application, the centerlinesof the connected components must be parallelwhen viewed from the top, as shown. Theseangles should also be SMALL and equal within1°. See figure.

Look at the angle chart and note that the smallerthe offset, the smaller the resultant angle.

To reduce the possibility of vibration, keep anyoffset between connected points to a minimum.

20020801


There are two things which can be done tomake certain single plane angles are SMALLand EQUAL:

! Make sure that the transmission and pumpare mounted so that their centerlines are parallelwhen viewed from both the side and the top.

! Make sure the offset between them is mall inboth views.

COMPOUND ANGLESCompound u-joint operating angles occur whenthe transmission and pump are not in line whenviewed from both, the top and side. Theircenterlines, however, are parallel in both views.See figure.

TRUE U-JOINT OPERATING ANGLEThe true u-joint operating angle, which must becalculated for each end of the shaft with com-pound angles, is a combination of the u-jointoperating angle in the top view, as determinedfrom the chart, and the measured u-joint operat-ing angle in the side view.

To determine the true u-joint operating angle forone end of a shaft, (compound angle C° in theformula shown in figure below) insert the u-jointoperating angle measurement obtained in theside view and the u-joint operating angle ob-tained from the chart into the formula.

Do the same for the other end of the shaft.Compare the resultant calculated u-joint operat-ing angle for each end. They should be EQUALwithin 1°. If they are not, the driveshaft willvibrate.

ELIMINATING COMPOUND ANGLE INDUCEDVIBRATIONSCompound u-joint operating angles are one ofthe most common causes for driveline vibration.To avoid thease problems, remember theseimportant considerations:

When setting up an application that requirescompound u-joint operating angles, always keepthe centerlines of the transmission and pumpparallel in both views.

Always keep the offset between their horizontaland vertical centerlines small.

NOTECenterlines of transmission and axle mustbe parallel in both top and side views to usethis method of determining true u-jointoperating angle.

Contact IMT Technical Support if you havean application which cannot be installed withparallel centerlines.

20020801


ANGLE SIZEThe magnitude of a vibration created by a u-jointoperating angle is proportional to the size of theu-joint operating angle. IMT recommends true u-joint operating angles of 3° or less.

Obtain the true u-joint operating angle, asexplained above, and if it is greater than 3°,compare it to the Driveshaft RPM/MaximumOperating Angle chart.

The angles shown on the chart are the MAXI-MUM u-joint operating angles recommended byIMT and are directly related to the speed of thedriveshaft. Any u-joint operating angle greaterthan 3° will lower u-joint life and may causevibration. Remember to check maximum safedriveshaft RPM as recommended by thedriveshaft manufacturer.

ANGLE CHARTFOR DRIVESHAFTS WITH A TOP VIEW ANGLE

DRIVESHAFTRPM

MAXIMUMOPERATING ANGLE

5000 3.2°4500 3.7°4000 4.2°3500 5.0°3000 5.8°2500 7.0°2000 8.7°1500 11.5°

20020801


INSTALLATION - HYDRAULIC CRANEKIT (1)1. 51715358 HOSE/ADAPTER KIT 1

(INCL:13-26)2. 72053145 PIPE NIPPLE 3/4NPT X 4 13. 72060047 CAP SCR 3/8-16X1-1/4 HHGR5 24. 72060049 CAP SCR 3/8-16X1-3/4 HHGR5 15. 72060118 CAP SCR 1/2-13X2 HHGR8 26. 72062103 NUT 3/8-16 LOCK 37. 72063003 WASHER 3/8 WRT 58. 72063053 WASHER 1/2 LOCK 29. 72063132 WASHER 1/2 FLAT HARD 210. 72532710 BEAD NIPPLE #20STR 1-1/4 90° 111. 72661202 CLAMP 3” CUSH LOOP 212. 72661350 CLAMP 3/4 CUSH LOOP 4TUBE 1

13. 51395022 HOSE-FJ 1/2X246 #8#8 1REF14. 51395170 HOSE-FJ 1/2X180 #8#8 1REF15. 72053558 ADAPTER 3/4MPT 3/4MPT 1REF16. 72053729 ADAPTER 1-1/4MPT 1-1/4MPT 1REF17. 72053763 ELBOW #8MSTR #8MJIC 90° 1REF18. 72066516 HOSE CLAMP 1-1/4 2-BOLT 2REF19. 72531422 ELBOW 3/4MPT #8MJIC 90° 1REF20. 72531550 BARB NIPPLE 1-1/4MPT 1-1/4 1REF21. 72531836 RED. BUSHING 1-1/4 - 3/4NPT 2REF22. 72532949 ADAPTER #20MSTR #12FSTR 1REF23. 72532951 ADAPTER #12MSTR #8FSTR 1REF24. 73054230 BALL VALVE 3/4NPT 1REF25. 73054232 BALL VALVE 1-1/4NPT 1REF26. 89393401 HOSE 1-1/4 100R4 70”REF

NOTES:1. The bulkhead reservoir should be mountedto the bulkhead of the body prior to the installation of the hydraulic fittings. If the fittingsare installed on the tank, it will be impossible toinstall the tank on the bulkhead.

2. The filter is purchased separately as a requiredline item from IMT.

3. If this kit is used for a non-IMT installation, the suction strainer is the responsibility of the installer.

CONTINUED ON FOLLOWING PAGE20020801


INSTALLATION - HYDRAULIC CRANE KIT (2)CONTINUED ON FOLLOWING PAGE

20020801


INSTALLATION - HYDRAULIC CRANE KIT (3)CONTINUED ON FOLLOWING PAGE

20020801


HYDRAULIC SCHEMATIC (4)

20020801


NOTES:1. The bulkhead reservoir should be mounted to the bulkheadof the body prior to installation of the hydraulic fittings. If fittings are installed on the tank, it will be impossible to installthe tank on the bulkhead.

2. The filter is purchased as a required line item separately from IMT.

3. If this kit is being used for a non-IMT installation, the suctionstrainer is the responsibility of the installer.

NOTE: ITEMS #25 AND #26 ARE SHOWNIN THE OPEN POSITION IN THIS VIEW.

INSTALLATION - COMPRESSOR HYD KIT (1)1. 51715357 HOSE/ADAPTER KIT (INCL:13-27) 12. 72053145 PIPE NIPPLE 3/4NPT X 4 13. 72060047 CAP SCR 3/8-16X1-1/4 HHGR5 24. 72060049 CAP SCR 3/8-16X1-3/4 HHGR5 15. 72060118 CAP SCR 1/2-13X2 HHGR8 26. 72062103 NUT 3/8-16 LOCK 37. 72063003 WASHER 3/8 WRT 58. 72063053 WASHER 1/2 LOCK 29. 72063132 WASHER 1/2 FLAT HARD 210. 72532710 BEAD NIPPLE #20STR 1-1/4 90° 111. 72661202 CLAMP 3” CUSH LOOP 212. 72661350 CLAMP 3/4 CUSH LOOP 4TUBE 113. 51395171 HOSE-FJ 1/2X105 #8#8 1REF14. 51395172 HOSE-FJ 3/4X61 #12#12 1REF15. 72053558 ADAPTER 3/4MPT 3/4MPT 1REF16. 72053729 ADAPTER 1-1/4MPT 1-1/4MPT 1REF17. 72053763 ELBOW #8MSTR #8MJIC 90° 1REF18. 72066516 HOSE CLAMP 1-1/4 2-BOLT 2REF19. 72531427 ELBOW 3/4MPT #12MJIC 90° 2REF20. 72531550 BARB NIPPLE 1-1/4MPT 1-1/4 1REF21. 72531836 RED. BUSHING 1-1/4 - 3/4NPT 2REF22. 72532360 ADAPTER #12MSTR #8MJIC 1REF23. 72532949 ADAPTER #20MSTR #12FSTR 1REF24. 72532951 ADAPTER #12MSTR #8FSTR 1REF25. 73054230 BALL VALVE 3/4NPT 1REF26. 73054232 BALL VALVE 1-1/4NPT 1REF27. 89393401 HOSE 1-1/4 100R4 70”REF



INSTALLATION - COMPRESSOR HYDRAULIC KIT (2)CONTINUED ON FOLLOWING PAGE

20020801


COMPRESSOR HYD KIT (3)

20020801


INSTALLATION - CRANE & COMPRESSOR HYD KIT (1) 1. 51715356 HOSE/ADAPTER KIT (INCL:13-30) 1 2. 72053145 PIPE NIPPLE 3/4NPT X 4 1 3. 72060047 CAP SCR 3/8-16X1-1/4 HHGR5 2 4. 72060049 CAP SCR 3/8-16X1-3/4 HHGR5 1 5. 72060118 CAP SCR 1/2-13X2 HHGR8 2 6. 72062103 NUT 3/8-16 LOCK 3 7. 72063003 WASHER 3/8 WRT 5 8. 72063053 WASHER 1/2 LOCK 2 9. 72063132 WASHER 1/2 FLAT HARD 210. 72532710 BEAD NIPPLE #20STR 1-1/4 90° 111. 72661202 CLAMP 3” CUSH LOOP 212. 72661350 CLAMP 3/4 CUSH LOOP 4TUBE 113. 51395022 HOSE-FJ 1/2X246 #8#8 1REF14. 51395170 HOSE-FJ 1/2X180 #8#8 1REF15. 51395171 HOSE-FJ 1/2X105 #8#8 1REF16. 51395172 HOSE-FI 3/4X61 #12#12 1REF17. 72053558 ADAPTER 3/4MPT 3/4MPT 1REF18. 72053729 ADAPTER 1-1/4MPT 1-1/4MPT 1REF19. 72053763 ELBOW #8MSTR #8MJIC 90° 1REF20. 72066516 HOSE CLAMP 1-1/4 2-BOLT 2REF21. 72531427 ELBOW 3/4MPT #12MJIC 90° 2REF22. 72531550 BARB NIPPLE 1-1/4MPT 1-1/4 1REF23. 72531836 RED. BUSHING 1-1/4 - 3/4NPT 2REF24. 72532360 ADAPTER #12MSTR #8MJIC 1REF25. 72532950 TEE 1-1/16JIC SWVL-NUT-RUN 1REF26. 72532951 ADAPTER #12MSTR #8FSTR 1REF27. 72532972 ADAPTER #8MJIC #12FJIC 1REF28. 73054230 BALL VALVE 3/4NPT 1REF29. 73054232 BALL VALVE 1-1/4NPT 1REF30. 51395545 HOSE 1-1/4 100R4 X 70 1REF

NOTES:1. The bulkhead reservoir should be mounted to the bulkheadof the body prior to installation of the hydraulic fittings. If fittings are installed on the tank, it will be impossible to installthe tank on the bulkhead.

2. The filter is purchased as a required line item separately from IMT.

3. If this kit is being used for a non-IMT installation, the suctionstrainer is the responsibility of the installer.



INSTALLATION - CRANE & COMPRESSOR HYD KIT (2)CONTINUED ON FOLLOWING PAGE

20020801


INSTALLATION - CRANE & COMPRESSOR HYD KIT (3)CONTINUED ON FOLLOWING PAGE

20020801


INSTALLATION - CRANE & COMPRESSOR HYD KIT (4)

20020801

DSC OPERATION GUIDE: 99903447: SECTION 2: INSTALLATION2-23REV C 20060313

NOTE: BODY SHOWN NOT TYPICAL.

HYDRAULIC TELESCOPING CRANE-ELECTRICAL INSTALLATION (99901294) 1. 70394092 DECAL-CAUTION BRK/CMPRSR 1 2. 72050005 CAP SCR 1/4-20X1-1/4 HHGR5 3 3. 72062104 NUT 1/4-20 LOCK 3 4. 72063001 WASHER 1/4 WRT 3 5. 77041251 RELAY 3 6. 51715664 CABLE ASM 14GA X 35’ 1 7. 77041707 FUSE HOLDER-CONNECTOR 1 8. 77041708 FUSE HOLDER-COVER 1 9. 77041709 FUSE HOLDER-TERMINALS 2

6

PLUG CONNECTIONP2 ON VALVEBANKJ2 ON CABLE ASM

BATT

7,8,9

BLACK

BROWN

ORANGE

RED

BLUE

YELLOW10 AMP

IGN12V

8786 85

30 87

86 8530

87

86 8530

2,3,4,52,3,4,5

TO 12VSPEED CTRLSIGNAL INPUT

PARKINGBRAKE

SEE APPROPRIATESPEED CONTROL KITFOR PARKING BRAKEWIRING

TO OEM CHASSISRECOMMENDEDENGINE SHUTDOWNCIRCUIT

TO OEM CHASSISRECOMMENDEDENGINE STARTSOLENOID

GROUNDCONTROLLEDPARKINGBRAKE

TO 12VSPEED CTRLSIGNAL INPUT

IGN 12V

NOTE: ATTACH RED COMP. SIGNALWIRE PER OEM COMPRESSOR MFG.INSTALLATION RECOMMENDATIONS

INSTALL DECAL NEXT TO PARKINGBRAKE ACTUATOR ON DASH PANEL.

NOTES:* = RECOMMENDED WIREWIRE SPECIFICATION:

GAUGE: 14 GA.# STRANDS: 19/27INSULATION THICKNESS: 0.023 MILS-NOM.HEAT RESISTANCE IN ACCORDANCE WITH SAE J-1128TEMPERATURE RANGE: -51 DEG TO +125 DEG CMEET FORD SPEC (MIL-85B) AND CHRYSLER SPEC (MS-900)

DSC OPERATION GUIDE: 99903447: SECTION 2: INSTALLATION2-24REV. B 20070510

NOTE: BODY SHOWN NOT TYPICAL.

ELECTRIC TELESCOPING CRANE-ELECTRICAL INSTALLATION (99903519)1. 70394092 DECAL-CAUTION BRAKE/COMP 12. 72050005 CAP SCR 1/4-20X1.25 HHGR5 13. 72062104 NUT 1/4-20 HEX NYLOC ZINC 14. 72063001 WASHER 1/4-FLAT 15. 77041251 RELAY 16. 77441074 HARNESS 1

DSC OPERATION GUIDE: 99903447: SECTION 2: INSTALLATION2-25REV. A 20050921

DRAWING EFFECTIVE 9/1/05

HARNESS # 77441158

ELECTRICAL SCHEMATIC

9 5 TYP (2)

1,8

7

2,3,4,10

IGNITION12V

TO RECOMMENDEDOEM 12V SPEEDCONTROL SIGNAL INPUT

DEUTSCHCONNECTORSARE PART OFCOMPRESSOR

YELLOWORANGEBLACKREDGREEN

DRAWING THROUGH 9/1/05

DA435HA COMPRESSOR-ELECTRICAL(99901295) 1. 60103535 SWITCH BRACKET 1 2. 72060005 CAP SCR 1/4-20X1-1/4 HHGR5 1 3. 72062104 NUT 1/4-20 LOCK 1 4. 72063001 WASHER 1/4 WRT 1 5. 77040000 TERM-RING #10STUD 16-14GA 2 6. 77040048 BUTT CONNECTOR 16-14GA 2 7. 77040052 TERM-RING 3/8STUD 12-10GA 1 8. 77041004 TOGGLE SWITCH SGL THROW 1 9. 77041056 FUSE 20A IN-LINE 110. 77041251 RELAY 111. 77044237 BULLET PLUG 18-14GA 312. 77044238 BULLET RECPT 18-14GA 3


20013 COMPRESSOR - INSTALLATIONDRAWING (99903524)1. 60125134 BRACE, COMPRESSOR 22. 72060046 CAP SCR 3/8-16X1 HHGR5Z 43. 72062103 NUT 3/8-16 HEX NYLOC ZINC 4

REV. A 20030825

3.39

1

2,3

13.38

9.20 12.00

1. Align braces (Item #1) with holes in inner wall. Keep braces tight againsttop panel, and hole 13.38" dimension.2. Drill holes in front wall of sidepack, using braces as reference.3. Mount braces using 3/8" hardware.4. Drill ł0.44" holes in roof, using braces as template.5. Mount compressor using hardware supplied.

operation, safety & maintenance guide - imt · equipment modifications must be performed with...

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