IMT 4004i User manual

IOWA MOLD TOOLING CO., INC.
P.O. Box 189
Garner, IA 50438
Tel: [phone]
Fax: [phone]
www.imt.com
Revised 06-18-2020
Copyright © 2020 Iowa Mold Tooling Co., Inc.
All rights reserved
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any
means, electronic, mechanical, photocopying, recording or otherwise without the prior written permission of Iowa
Mold Tooling Co., Inc.
Iowa Mold Tooling Co., Inc. is an Oshkosh Corporation Company
4004i
Parts &
Specifications
Manual # 99904386

ii
4004i - Manual # 99904386
Operating, servicing and maintaining this vehicle
or equipment can expose you to chemicals
including engine exhaust, carbon monoxide,
phthalates, and lead, which are known to the
State of California to cause cancer and birth
defects or other reproductive harm. To minimize
exposure, avoid breathing exhaust, do not idle the
engine except as necessary, service your vehicle
or equipment in a well-ventilated area and wear
gloves or wash your hands frequently when
servicing. For more information go to
www.P65Warnings.ca.gov.
70490167
70490167
PROP 65
BKS 5-29-18
ORANGE , BLACK AND WHITE
3.27” 2.70”
CN

iii
4004i - Manual # 99904386
Table of Contents
Introduction 1
Introduction ....................................................................................................................................................2
Specications 3
4004i Technical Data......................................................................................................................................4
Load Capacity Chart (70397414)...................................................................................................................6
Geometric Conguration ................................................................................................................................7
Pump & Motor Performance ..........................................................................................................................8
Assemblies & Grease Zerk Locations..........................................................................................................10
4004i Recommended Spare Parts List ........................................................................................................ 11
Crane Installation (99904394)......................................................................................................................13
Electric Crane Battery Circuit (99904884) ...................................................................................................18
Telescopic Crane Orientation.......................................................................................................................19
Electric Crane Control..................................................................................................................................20
Parts 21
Parts Information..........................................................................................................................................22
Electric Crane Power Safety ........................................................................................................................24
Base & Mast Assembly (99904325).............................................................................................................26
Valve Bank (73734304)................................................................................................................................30
Cylinder, Lower (51721268).........................................................................................................................32
Crane & Winch Assembly (99904327) .........................................................................................................34
Boom Assembly (99904326)........................................................................................................................40
Snatch Block (51724950).............................................................................................................................52
Cylinder, Extension (51725007)...................................................................................................................54
Cylinder, Extension (51722111) ...................................................................................................................56
Winch (71570922)........................................................................................................................................58
Snatch Block (51724950).............................................................................................................................59
Power Unit 73511283 (12V) & 73511305 (24V) ...........................................................................................60
Power Unit (73511169).................................................................................................................................62
Hydraulic Installation (99904388) ................................................................................................................63
Tethered Control Installation (99904593).....................................................................................................70
Radio Control Installation, Standard (99904594).........................................................................................72
Radio Control Installation, Proportional (99904595) ....................................................................................73
Electrical & Lighting 75
Electrical Installation (99904392).................................................................................................................76
Light Kit (99906234).....................................................................................................................................78
275 & 225-Amp Contactor Replacement (99904578 ...................................................................................84
Harness, Radio (77441270).........................................................................................................................87
Harness, Tethered (77441269) ....................................................................................................................89
Harness, LED Boom Tip Jumper (77441689) ..............................................................................................95
Harness, Light SW A2B CRD Reel (77441674) ..........................................................................................97
Harness, Limit Switch Jumper (77441678) ..................................................................................................99
Protective Sleeve Installation (70034573) .................................................................................................100
General Information 102
Decal Installation (99904410) ....................................................................................................................103
Turntable Bearing Thread Tightening.........................................................................................................106
Torque Charts ............................................................................................................................................107
Torque Charts (Metric) ...............................................................................................................................108

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iv
4004i - Manual # 99904386

Introduction 1 Section - 1
4004i - Manual # 99904386
IntroductionSection - 1

Introduction 2 Section - 1
4004i - Manual # 99904386
Introduction
This manual includes parts, specications, and installation information for your particular crane. It is your
responsibility to maintain and operate this unit in a manner that will result in the safest working conditions possible.
Warranty of this unit will be void on any part of the unit subjected to misuse due to overloading, abuse, lack of
maintenance and unauthorized modications. No warranty - verbal, written or implied - other than the o󰀩cial,
published IMT new machinery and equipment warranty will be valid with this unit. In addition, it is also the user’s
responsibility to be aware of existing Federal, State and Local codes and regulations governing the safe use
and maintenance of this unit. This crane was designed and built to meet the standards of ANSI / ASSE A10.31-
1995, Safety Requirements, Denitions, and Specications for Digger Derricks. Contact the American National
Standards Institute (www.ansi.org) for more information.
Throughout this manual, four means are used to draw the attention of personnel. They are NOTE, CAUTION and
WARNING and DANGER are dened 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.
DANGER
Danger indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury. Danger is used in the
extreme situations.
For a safe work environment, treat this equipment with respect and service it regularly

Specications 3 Section - 2
4004i - Manual # 99904386
SpecificationsSection - 2

Specications 4 Section - 2
4004i - Manual # 99904386
4004i Technical Data
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.)
18,000 ft-lb at 8’-0” (2.5 tm at 2.4 m)
Horizontal Reach (From Centerline Of Rotation) 16’-0” (4.9 m)
Hydraulic Extension (1) 48” (122 cm)
Manual Extension (1) 48” (122 cm)
Lifting Height (From Base of Crane to Centerline of Sheave) 17’-2” (5.2 m)
Crane Weight (1H1m) 758 lb (344 kg)
Crane Storage Height 32” (81.3 cm)
Mounting Space Required (Crane Base) 14” x 18” (35.5 cm x 45.7 cm)
Hydraulic System Operating Pressure 2500 psi (172 Bar)
Maximum Hydraulic Flow 1.6 gpm (6 Lpm)
Oil Reservoir Capacity 1.5 gallons (5.7 L)
Oil Type ISO VG32, Low Pour, Anti-Wear Hydraulic Oil
CENTER OF GRAVITY
Horizontal from Centerline of Rotation (Booms Retracted) 32” (81.3 cm)
Horizontal from Centerline of Rotation (Booms Extended) 46” (116.8 cm)
Vertical from Bottom of Crane Base 16” (40.6 cm)
Tie-Down Bolt Pattern (On Center) 12” x 12” or 11.5” x 14.75”
(30.5 cm x 30.5 cm) or (29.2 cm x 37.5 cm)
Rotation Torque 3500 ft-lb
CYLINDER SPECIFICATIONS
Lower Boom Cylinder 3.5” bore; 16” stroke
(8.9 cm bore; 40.6 cm stroke)
Extension Boom Cylinder 1.5” bore; 48” stroke
(3.8 cm bore; 122.0 cm stroke)
WINCH SPECIFICATIONS
Winch Pull Line 2000 lb (907 kg)
Pull Line Speed Without Load 23 ft/min (7 m/min)
Rope Diameter 1/4” (6.35 mm)
Wire Rope Length 75’ (22.9 m)
Cable Nominal Strength 7000 lb (3175 kg)
PERFORMANCE CHARACTERISTICS
SPECIFICATIONS SPEED
Rotation 360º (Continuous) 44 seconds
Lower Boom Elevation -5º to +75º 10 seconds
Extension Cylinder 48” (122.0 cm) 10 seconds total
CHASSIS REQUIREMENTS

Specications 5 Section - 2
4004i - Manual # 99904386
GVWR 15,000 lb (6803 kg) (Minimum)
ELECTRICAL REQUIREMENTS
System Voltage 12 Volts
Battery
Minimum of 2 identical batteries in parallel
750 CCA MIN per battery.
Must meet chassis manufacturer’s specications.
Batteries must be fully charged prior to use.
Alternator 200 Amperes MINIMUM
Engine Elevated RPM required if additional high amperage draw systems will be in use
while crane is being operated.
Duty Cycle
Duty cycle and absolute continuous on-time according to the crane user
manual.
Winch is not operated simultaneously with any other function.

Specications 6 Section - 2
4004i - Manual # 99904386
Load Capacity Chart (70397414)
BY
CAPACITY CHART -
IMT 4004i CRANE
4-14-08
IOWA MOLD TOOLING CO., INC
BOX 189, GARNER, IA 50438
TEL: [phone] FAX: [phone]
TECH PUBS GENERATED DRAWING
DR AWN B Y
AP P R OVE D B Y DAT E
DAT E S CALE
T ITL E
S IZ E DW G NO
PAT
A
FU L L
S H T OF
1 1
NOTES:
MATL: .OO5“ VELVET FINISH LEXAN
ADHESIVE: 3M 468 HI-PERFORMANCE APPLIED AFTER SCREENING
SIZE: 6”W x 8.5"H
COLORS: BLACK ON WHITE BACKGROUND, AS SHOWN
VENDOR: CREATIVE SCREEN PRINT (CRE10) OR EQUIV.
70397414
IOWA MOLD TOOLING CO., INC.
BOX 189, GARNER, IA 50438-0189
TEL: [phone] FAX: [phone]
70397414
4004i CAPACITY CHART
75°
60°
45°
30°
15°
16'
4.8 m
4000
1815
4000
1815
3560
1615
2190
995
2940
1335
4000
1815
1710
775
2320
1050
3490
1585
3020
1370
1980
900
1450
660
1270
575
2680
1215
1080
490
1500
680
2330
1055
Maximum 1-part line
capacity is 2000 lb (907 kg).
For greater loads, use
2-part line.
NOTE: LBS/KG denote
2-part line.
14'
4.2 m
12'
3.6 m
10'
3.0 m
8'
2.4 m
6'
1.8 m
4'
1.2 m
2'
0.6 m
0
(Base) 16'
4.8 m
14'
4.2 m
12'
3.6 m
10'
3.0 m
8'
2.4 m
6'
1.8 m
4'
1.2 m
2'
0.6 m
0
ADDED WIRE ROPE INFORMATION
PER ASME B30 5-1.1.3
WIRE ROPE DATA:
DIAMETER; 0.25, NON-ROTATION RESISTANT, MINIMUM BREAKING LOAD; 7000,
MAXIMUM SINGLE LINE LOAD; 2000 lb (907 kg).
DISTANCE IN FEET/METERS / LOAD IN POUNDS/KG. WEIGHT OF LOAD HANDLING
DEVICES ARE PART OF THE LOAD LIFTED AND MUST BE DEDUCTED FROM THE CAPACITY.
REVISIONS
DESCRIPTIONECN/CNREV DATE
A 277 12-15-15 BKS

Specications 7 Section - 2
4004i - Manual # 99904386
GeometricConguration
16'-10"
(5.14 m)
13'-0"
(3.96 m)
9'-5"
(2.87 m)
8'-0" (2.43 m)
12'-0" (3.65 m)
16'-0" (4.87 m)
4'-2"
(1.28 m)
3'-2"
(96 cm)
2'-3"
(67.4 cm)
4004i
1'-4" (40 cm)

Specications 8 Section - 2
4004i - Manual # 99904386
Pump & Motor Performance
The ve minute duty cycle must be adhered to. Operators have a choice of running the crane intermittently all
day, using the duty cycles per the S2 and S3 curves, or at full power for 4.5 minutes, which MUST be followed by
a complete cool-down to ambient.
180 AMPS
0
1
2
3
4
5
6
0.0
5.0
10.0
15.0
20.0
25.0
Q - 1.6 CC
I - 1.6 CC
0
50
100
150
200
300
250
0 500 1000 1500 2000 2500 3000 3500 4000 4500
PSI
BAR
0 25 50 75 100 125 150 175 200 225 250 275 300
2500 PSI

Specications 9 Section - 3
4004i - Manual # 99904386
Crane ReferenceSection - 3

Specications 10 Crane Reference
4004i - Manual # 99904386
Assemblies & Grease Zerk Locations
ITEM NO. LOCATION DESCRIPTION LUBRICANT FREQUENCY
1LOWER CYLINDER ROD
SHELL
ALVANIA 2 EP
OR
SHELL
RETINAX “A:
WEEKLY
2LOWER CYLINDER BASE
3GEAR ROTATOR GREASE EXTENSION
*ROTATE CRANE WHILE GREASING.
4POWER UNIT
5POWER UNIT
6LOWER BOOM PIN
7. SNATCH BLOCK
NOTE:
All application points must be greased weekly under normal workloads and moderate weather condi-
tions. Under severe operating conditions, lubricate more frequently. See the IMT Electric Crane Opera-
tion & Safety manual P/N: 99905190, for additional lubrication requirements.
NOTE:
Image may be di󰀨erent depending on production date. Grease points should be identical.
4
5
LOWER
CYLINDER
3
6
CRANE
BASE
WINCH
SNATCH
BLOCK
MAST
POWER
UNIT
LOWER
BOOM
EXTENSION
BOOM
HOOK
2
1
HYDRAULIC
RESERVOIR

Specications 11 Crane Reference
4004i - Manual # 99904386
4004i Recommended Spare Parts List
51721268 LOWER CYLINDER QTY.
51744172 SEAL KIT-IMT 3.50 X 1.75R X 1.50 STGR 1
60132397 PISTON-2.75 BORE X 1.75 ROD 1.63 STGR 1
6HD35017 HEAD-3.5 BORE X 1.75 ROD 1
73054999 VALVE-CBAL
77041786 SWITCH-PRESS 2750
51725007 EXTENSION CYLINDER (EFFECTIVE 01/2013 TO PRESENT)
94397290 SEAL KIT-IMT 1.50 BORE 1.00 ROD .75 1
60135105 HEAD-1.50 BORE X 1.00 ROD (DUCTILE IRON 1
60135106 PISTON-1.50 BORE X .75 STGR (DUCT IRON) 1
73054999 VALVE-CBAL SUN01 CBBC-LHN
99904325 BASE & MAST ASSEMBLY
72060178 CAP SCR .62-11X 4.00 HH 31
73511157 MOTOR-HYD 101 1702 009 1
76039295 GASKET-GEAR 1
77441534 SWITCH-225A CONTACTOR 12V OR 24V 1
73734304 VALVE BANK (12V)
73540327 COIL (VALVE BANK) (12V) 3
73540326 VALVE ASSEMBLY (VALVE & COIL) (12V) 6
73511169 POWER UNIT (12V) (THROUGH 10/2012)
70733826 FILL CAP ELECTRIC CRANES 1
73511171 PUMP-GEAR ELECTRIC CRANE 1
73540323 VALVE-RELIEF ELECTRIC CRANE 1
73734332 KIT-TUBE POWER UNIT ELECTRIC CRANE 1
74397392 RESERVOIR TANK ELECTRIC CRANE 1
77043060 MOTOR-POWER UNIT ELECTRIC CRANE 1
73511283 POWER UNIT (24V)
77043065 MOTOR-POWER UNIT 12V ELECTRIC CRANE AR
77043066 MOTOR-POWER UNIT 24V ELECTRIC CRANE AR
73511306 PUMP 1
73540517 RELIEF VALVE ASSEMBLY 1
74399495 RESERVOIR 1
70734788 BREATHER CAP 1
73734791 TUBE-SUCTION 1
70734792 STRAINER 1

Specications 12 Crane Reference
4004i - Manual # 99904386
99904326 BOOM ASSEMBLY QTY.
60030373 WEAR PAD- EXT CYLINDER 1
60030374 WEAR PAD-ROUND 1.00 DIA X .50 DIA X .75L 6
60030376 WEAR PAD-ROUND 3.50 X 1.00 DIA X .615 LG 2
60132302 STOP SCREW 3/8-24 X .50 4
71734311 PIN-QUICK RELEASE.62D/4.5 CRIT 1
71734314 PIN-QUICK RELEASE.62D/6.5 CRIT 1
72661543 PIN-QUICK 316-10QP 2
60133938 WEAR PAD-ROUND 0.25 X 1.00 X 0.50 X 0.50 2
72661711 CLEVIS PIN 0.5 X 3.00 1
99904327 CRANE & WINCH ASSEMBLY
51721494 CORD REEL ASSEMBLY- 5FT PACKARD CONNECTOR 1
70580197 WIRE ROPE ASM-.22(7X19)X65FT PGA 1
71413185 SPRING-.105WIRE 0.75OD 2.875 LG 1
70735101 HOOK-SWVL POS LOCK BBRG 2TON (EFFECTIVE 1/1/2018) 1
72601798 WASHER-LOCK 12MM 4
72601935 CAP SCREW M12-1.75X 40 SH PLAIN 4
72601938 BOLT-EYE # 8-32X 1.125 1
77041459 SWITCH-LIMIT ZE-N-2S 1
77441096 CONNECTOR- .50 STR RLF .25-.38 1

Specications 13 Crane Reference
4004i - Manual # 99904386
Crane Installation (99904394)
In addition to meeting the chassis requirements noted in the Technical Data section of this manual, make sure
there is su󰀩cient room for mounting the crane, and the platform is 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. Install the body on the chassis before installing the
crane. Refer to the following table for parts referenced in the following crane installation drawings.
ITEM NO. PART NO. DESCRIPTION KIT NO. QTY
1. 51721572 ELECTRIC CRANE BODY INSTALLATION 1
2. 91721647 HARDWARE KIT- 3203I/4004I ELEC CRANE BODY
INSTALLATION 1
3. 91721751 HARDWARE KIT- 5005I ELEC CRANE BODY
INSTALLATION 1
5. 51725572 DRAWING-CRANE & WINCH ASSEMBLY 3203I REF
6. 60251272 BRACKET-SWITCH 300 AMP ELEC CRANE 1 & 4 1
7. 70734331 SWITCH-300A KEYED BATTERY DISCONNECT 1 & 4 1
8. 72042097 LEVEL INDICATOR LEVEL 1 & 4 1
9. 77040209 TERMINAL-RING NI .38 STUD 1 WIRE 1 & 4 1
10. 77040529 TERMINAL-RING NI .31 STUD 1-2 WIRE 4 9
11. 77441116 FUSEHOLDER-HIGH AMP2 BOLT WITH COVER 4 2
12. 77441219 FUSE-225 AMP 4 2
13. 89044276 CABLE-#1 WELDING 1 & 4 35 FT
14. 89392333 TUBE-HEAT SHRINK AMP 1 & 4 0.50 FT
15. 72060208 CAP SCREW .75-10X 2.50 HH GR8 Z 2 4
16. 72601862 NUT .75-10 HEX NYLOC GR8Z 2 4
17. 72063116 WASHER .75 N FLAT H ASTMF436Z 2 8
18 72060002 CAP SCREW .25-20X .75 HH GR5 Z 2 & 3 4
19. 72060634 SCREW-MACHINERY #10-24X .50 RDH 2 & 3 4
20. 72062000 NUT .25-20 HEX 2 & 3 4
21. 72062106 NUT 10-24 HEX NYLOCK 2 & 3 4
22. 72063001 WASHER .25 FLAT 2 & 3 8
REV. E 20120918
TO INSTALL THE CRANE:
1. To install the crane: Use a lifting device capable of lifting the weight of the crane as indicated in the Technical
Data section of this manual. Attach fabric slings to the crane lower boom, centered approximately 18
inches (46 cm) from the mast hinge. Make certain the crane is well balanced on the slings by slowly lifting
approximately 6” (15 cm) o󰀨 the ground. Lift the crane and apply a bead of waterproof compound, such as
silicon based caulk, to the bottom of the base. Move the chassis under the crane and lower the crane into the
desired position.
NOTE:
Install the 3/4-10x2.5” mounting cap screws (item # 15) and 3/4” washers (item #16) to secure the crane base to the
truck body (see gure on next page). Torque the cap screws to 280 ft-lb.
2. The electrical power switch (item #7) provides power for the crane. Install the switch onto the power unit cover.

Specications 14 Crane Reference
4004i - Manual # 99904386
16,17
15,17
(SEE
NOTE)
MOUNTING HOLE PATTERN
ALLOW 16"
RADIUS FOR
SWING CLEARANCE
18"
14.75"
12"
0.81" DIA.
9.5" DIA.
6"
5.75"
6" 7.38"
11.5"
12" 14"
CRANE INSTALLATION - CONTINUED
NOTE:
The 3/4-10 x 2.5” grade 8 zinc coated capscrews are designed for a crane box thickness of 1/2” only. A di󰀨erent
crane box may require di󰀨erent capscrews. All mounting capscrews must be grade 8 zinc coated with a minimum
thread engagement of 1.25” (3.175 cm).

Specications 15 Crane Reference
4004i - Manual # 99904386
CRANE INSTALLATION - CONTINUED
3. Install the vehicle level indicator (item #8) parallel to the door reinforcements.
4. After mounting your crane, wire the crane to the vehicle’s 12VDC electrical system using the following steps.
Use the parts list above to identify parts. Your crane installation kit, 51721572, includes a 10.7 m (35’) long
cable, IMT # 89044276 (item #13 in the parts list). Approximately 7.6 m (25’) of this cable is required to
connect the crane power switch to the vehicle battery, and the rest of the cable is used for ground connec-
tions between the crane, vehicle battery, auxiliary battery, and chassis ground. Cut the cable to length after
determining the lengths required.
5. Ground the crane by connecting the crane ground cable to bare metal inside the crane box.
6. Connect the crane power cable from the male power cable connector to the power switch. Connect cable
(item #13 - 89044276), cut to length, from the crane power switch (item #7) to the fuse. Use 3/8” (0.95 cm)
ring terminal (item #9 - 77040209) for each connection. Heat shrink the connections (item #4 - 89392333).
7
8
21
6
18
19 6
20
22
22
LOCATION OF
SWITCH BRACKET
IN CRANE BOX
4 HOLES,
0.266" DIA.
3.5"
5.03"
2.75"
13.5"
INSIDE VIEW
OF CRANE BOX
KEY SUPPLIED
WITH 70734331
SWITCH. SPARE
KEY - 70734357.
WARNING
Protect the power cable from damage by
fastening it inside the frame channel and
covering it with protective covering including
loom, conduit, etc. Be sure to use rubber
grommets or other protection when running
the power cable through steel bulkheads.

Specications 16 Crane Reference
4004i - Manual # 99904386
7. Use approximately 4’ (1.2 m) of the cable (item #13) to ground both the vehicle battery and auxiliary battery.
Connect one end of the ground cable to the negative terminal on the vehicle battery, and the other end to
bare metal on the truck body. Use a 5/16” (0.79 cm) ring terminal (item #10 - 77040529) to connect to the
truck body.
A13
7
14
9
POWER
CABLE
BRACKET
GROUND CABLE (GROUND
TO BARE METAL INSIDE
CRANE BOX)
MALE POWER
CABLE CONNECTOR 89044276 (#13)
ON-OFF SWITCH TO FUSE
(CUT TO LENGTH)
WARNING
Install the ground cable to the negative
terminal of the batteries! The crane electrical
ground completes the electrical circuit
through the structure of the crane to the
vehicle frame. The vehicle factory ground is
NOT sufficient to carry the current required by
the crane. Without this extra ground cable,
your crane may not operate at rated capacity,
and motor, contactor, or electrical damage
may occur.