IOWA MOLD TOOLING 14K160TH User manual

Printed on 23 May, 2011
Manual # 99903184
14K160TH OTR Body & Air
Compressor
Commander IV OTR Body & Compressor Parts - Specifications - Instructions
Revised 20110519
IOWA MOLD TOOLING CO., INC.
PO Box 189
Garner, IA 50438
Tel: [phone] FAX: [phone]
Website: http://www.imt.com
Copyright © 2011 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.

i
Contents
Introduction 3
Revisions ......................................................................................................................................................5
Parts - OTR Body 7
OTR Body Recommended Spare Parts.........................................................................................................8
Installation Kit - Body (93715891)...............................................................................................................9
OTR Package Assembly (51715800-1) ......................................................................................................11
OTR Package Assembly (51715800-2) ......................................................................................................12
OTR Package Assembly (51715800-3) ......................................................................................................13
OTR Package Assembly (51715800-4) ......................................................................................................14
OTR Package Assembly (51715800-5) ......................................................................................................15
Body Assembly (51715799-1)....................................................................................................................16
Body Assembly (51715799-2)....................................................................................................................18
Body Assembly (51715799-3)....................................................................................................................19
Body Assembly (51715799-4)....................................................................................................................21
Body Assembly (51715799-5)....................................................................................................................22
Body Assembly (51715799-6)....................................................................................................................23
DAR130 Compressor Specifications 25
Compressor Safety 29
Compressor Precautions .............................................................................................................................30
Compressor Safety......................................................................................................................................31
Compressor Warning Decals ......................................................................................................................33
Compressor Instruction Decals...................................................................................................................35
Compressor Terminology...........................................................................................................................35
Description of Components ........................................................................................................................36
Compressor Lubrication & Maintenance 41
Lubrication and Maintenance Chart............................................................................................................42
Lubricant Recommendations ......................................................................................................................43
Commander IV Compressor Preventative Maintenance Kit.......................................................................44
Compressor Maintenance Procedure ..........................................................................................................45
Compressor Troubleshooting......................................................................................................................49
Compressor Recommended Spare Parts.....................................................................................................52
Compressor Operation 55
Compressor Start Up/Shutdown .................................................................................................................55
Compressor Controls ..................................................................................................................................56
Compressor Operating Conditions..............................................................................................................57

ii Contents
Sub-Zero Temperature Operating Instructions ...........................................................................................58
Compressor Parts 59
Compressor Integral Components...............................................................................................................60
Compressor Air-Oil Schematic...................................................................................................................61
Hydraulic Schematic...................................................................................................................................62
Oil Cooler ...................................................................................................................................................63
Hose Ports...................................................................................................................................................65
Compressor Air Inlet System......................................................................................................................66
Compressor Discharge System...................................................................................................................67
Compressor Electrical System....................................................................................................................70
Wiring Diagram..........................................................................................................................................71
Compressor & Mounting System................................................................................................................72
Air Tank......................................................................................................................................................74
Murphy Latching Relay - Retrofit Kit (99903400).....................................................................................75
Wiring Instructions - Murphy Latching Relay Kit (99903401)..................................................................77

3
This volume provides information on the installation, operation, spare parts, and repair of your
Commander IV body and compressor.
WARNING
READ YOUR MANUAL!! FAILURE TO READ, UNDERSTAND AND FOLLOW ANY SAFETY
PROCEDURES APPLICABLE TO YOUR EQUIPMENT MAY RESULT IN EQUIPMENT DAMAGE,
SERIOUS INJURY, OR DEATH.
MANUAL STRUCTURE
Throughout this manual, three means are used to draw the attention of personnel. They are
NOTEs, CAUTIONs and WARNINGs and are defined as follows:
NOTE
A NOTE is used to either convey additional information or to provide further emphasis for a
previous point.
CAUTION
A CAUTION is used when there is the very strong possibility of damage to the equipment or
premature equipment failure.
WARNING
A WARNING is used when there is the potential for personal injury or death.
Use caution and common sense while operating and maintaining the crane, and follow all safety
procedures and regulations. Treat this equipment with respect and service it regularly. In
addition to reading the manual, become familiar with government regulations, hazards, and the
specific operation of your crane. Refer to ANSI/ASME B30.22, the standard for Articulating
Boom Cranes, for more information on crane design and test criteria. (You may obtain this
publication from ASME at www.asme.org.) Crane operators must also be familiar with OSHA
29CFR, Subpart N, Article 1926.550 and CAL-OSHA Title 8, Article 93 (California).
MODIFICATIONS
Modifications to your crane must be performed with IMT approved accessories, parts and
optional equipment. If in doubt about the safety, compatibility, or appropriateness of any
modifications, contact IMT prior to making those modifications. DO NOT alter or modify any
safety device! All safety devices must be inspected, tested and maintained in proper working
condition.
C
HAPTER
1
Introduction

4 14K160TH OTR Body & Air Compressor Manual # 99903184
Note that decals regarding crane safety and operation are considered safety equipment. They
must be maintained just as any other safety device. Decals must be kept clean and legible to
the operator, operational personnel, and bystanders as specified in the decal section of this
manual. DO NOT remove, disable, or disregard any safety device attached to your crane.
The crane owner and/or designated employee is responsible for informing all operators,
maintenance personnel, and others involved in equipment operation about the safe operation
and maintenance of the crane. If questions arise, contact IMT or your IMT distributor for
clarification.
WARRANTY
Warranty of this unit will be void on any part of the unit subjected to misuse due to overloading,
abuse, lack of maintenance and unauthorized modifications. No warranty - verbal, written or
implied - other than the official, published IMT new machinery and equipment warranty will be
valid with this unit.
NOTICE TO THE OWNER / USER
If your equipment is involved in a property damage accident, contact your IMT distributor
immediately and provide them with the details of the accident and the serial number of the
equipment. If an accident involves personal injury, immediately notify your distributor and IMT’s
Technical Support at:
IOWA MOLD TOOLING CO., INC.
500 HWY 18 WEST
GARNER, IA 50438
641 - 923 - 3711

Chapter 1 Introduction 5
Revisions
DATE LOCATION DESCRIPTION
20070424
Manual release in new format.
20070807
51715799-2
Hardware changes.
20080904
SPARE PARTS
Fan sensor # 302899
20090105
51715799
ECN 10854 - New body weldment drawings.
20090305
51715799-3
ECN 10854 – New drawing for page 3.
20090423 51715799-1 ECN 10938 - Update body lights to LED.
20090526 COMPRESSOR
PARTS
Added additional spare parts drawings.
20110519
51716427
ECN 11459 - Removed chassis ground cable due to superior ground
connections in chassis.

7
In This Chapter
OTR Body Recommended Spare Parts .................................... 7
Installation Kit - Body (93715891) ............................................. 9
OTR Package Assembly (51715800-1) .................................... 11
OTR Package Assembly (51715800-2) .................................... 12
OTR Package Assembly (51715800-3) .................................... 13
OTR Package Assembly (51715800-4) .................................... 14
OTR Package Assembly (51715800-5) .................................... 15
Body Assembly (51715799-1) .................................................. 16
Body Assembly (51715799-2) .................................................. 17
Body Assembly (51715799-3) .................................................. 19
Body Assembly (51715799-4) .................................................. 21
Body Assembly (51715799-5) .................................................. 22
Body Assembly (51715799-6) .................................................. 23
C
HAPTER
2
Parts - OTR Body

8 14K160TH OTR Body & Air Compressor Manual # 99903184
OTR Body Recommended Spare Parts
Recommended Spare Parts for one-year for Commander OTR Body:
NOTE: This spare parts list does not necessarily indicate that the items can be expected to fail in
the course of a year. It is intended to provide the user with a stock of parts sufficient to keep the
unit operating with the minimal down-time waiting for parts. There may be parts failures not
covered by this list. Parts not listed are considered as not being Critical or Normal Wear items
during the first year of operations and you need to contact the distributor or manufacturer for
availability.
ASSEMBLY
PART #
PART NO.
DESCRIPTION
QTY
CODE
51715799-1 BODY ASSEMBLY
77040384
LIGHT-COMPARTMENT
2
C
77040404 LIGHT-FLOOD BLACK 2 C
77040543 LIGHT-MARKER-RED 2 C
77040478 LIGHT-MARKER-AMBER 2 C
51715799-2 BODY ASSEMBLY
77040180
LIGHT-BACKUP
2
C
77040493
LIGHT-STOP/TURN/TAIL
2
C
77040006
LIGHT-LICENSE
1
C
ELECTRICAL KIT
77041251
RELAY-P&B
1
C
77041014
SWITCH-PUSH/PULL
1
C
77044672 CIRCUIT BREAKER-40A 1 C
77041104 FUSE-AGC 5 1 C
77042001 LIGHT-RED INDICATOR 1 C
PTO
77041008
SWITCH-PRESSURE PTO
2
C
77041178
SOLENOID VALVE 12V
3WAY
1
C

Chapter 2 Parts - OTR Body 9
Installation Kit - Body (93715891)
16
2.75"
13"
6.5"
5.5"
.81" TYP
6
15 16
5
4
2
3
1
9,10,11
12
13
12
11 7
8
.25
1
2
3
4
5
3
BODY LONG
SILL (REF)
TRUCK
FRAME
(REF)
85.33"
AFTER FRAME
192.0"
CAB TO AXLE
52"
2"
STERLING

10 14K160TH OTR Body & Air Compressor Manual # 99903184
NOTES:
1 WHEN TIGHTENING CLAMP, SPRING WILL BE COMPRESSED FROM A RELAXED 5.50" LENGTH TO A
COMPRESSED LENGTH OF 4.0".
2 USE DOUBLE NUTS ON THE BOTTOM TO AID INSTALLATION.
3 DRILL ALL CHASSIS FRAME HOLES THE SAME SIZE AS THE BOLTS USED.
4 LOCATE SHEAR PLATE 4" BEHIND FRONT UNDERBODY TOOLBOX.
5 WELD LONGSILL ON 3 SIDES ONLY.
6 FOR REAR END, USE GRADE #8 FASTENERS. TORQUE TO 375 FT-LB PLAIN; OR 280 FT-LB PLATED.
WHEN USING TORQUE WRENCH, ALWAYS HOLD THE BOLT AND APPLY TORQUE TO THE NUT. BOLTS
MAY PASS THROUGH FRAME IN EITHER DIRECTION.
93715891 PARTS LIST
ITEM PART # DESCRIPTION QUANTITY
1. 76393799 MUD FLAP 2
2.
72063001
WASHER 1/4 WRT
8
3.
72060025
CAP SCR 5/16-18X1 HHGR5
8
4.
72063078
WASHER 5/16X1-1/2 OD
8
5.
72062109
NUT 5/16-18 LOCK
8
6.
60105107
SHEAR PLATE
2
7.
60108859
CLAMP PLATE (WAS 60105958)
6
8. 60125817 ROD 5/8-11 X 29 (WAS 60109298 - 22.5” ROD) 4
9. 72060151 CAP SCR 5/8-11X2 HHGR8 4
10. 72062233 NUT 5/8-11 HEX TOP LOCK GR8 4
11.
72063119
WASHER 5/8 FLAT HARD
16
12.
72062091
NUT 5/8-11 LOCK (WAS 8)
12
13.
70141935
SPRING
4
14.
72060207
CAP SCR 3/4-10X3 HHGR8
4
15.
72601862
NUT 3/4-10 HEX ZINC NYLOC GR8 (WAS
72062272)
4
16. 72063116 WASHER 3/4 FLAT HARD 8
REV. C 20070424

Chapter 2 Parts - OTR Body 11
OTR Package Assembly (51715800-1)
HOSE GUIDE
BRACKET (REF)
1
2
3
VIEW A
4
5
7
6
A
51715800 PARTS LIST
ITEM
PART #
DESCRIPTION
QUANTITY
1. 70731371 HOSE GUIDE & ROLLER ASM 2
2. 72060004 CAP SCR 1/4-20X1 HHGR5 4
3. 72062104 NUT 1/4-20 LOCK 4
4. 51715799 BODY ASM (SEE DWG) 1
5.
10001-CMMDR
HYD COMPRESSOR
1
6.
70396127
DECAL
1
7.
301475
DECAL
1

12 14K160TH OTR Body & Air Compressor Manual # 99903184
OTR Package Assembly (51715800-2)
124
VIEW B
3
B
51715800-2 PARTS LIST
ITEM
PART #
DESCRIPTION
QUANTITY
1.
70733434
HOSE REEL 1/2X50'
2
2.
72060047
CAP SCR 3/8-16 X 1-1/4 HHGR5
8
3.
72062103
NUT 3/8-16 LOCK
8
4.
76392821
WASHER 3/8 BONDED
8

Chapter 2 Parts - OTR Body 13
OTR Package Assembly (51715800-3)
DETAIL VIEW
COMPARTMENT LAYOUT
8
8
97
65
7
RIGHT HAND
COMPARTMENT
(REF)
3
14
2
51715800-3 PARTS LIST
ITEM
PART #
DESCRIPTION
QUANTITY
1.
51715850
FRL
1
2.
72060004
CAP SCR 1/4-20X1
4
3.
72062104
NUT 1/4-20 LOCK
4
4.
76392820
WASHER 1/4 BONDED
4
5.
72533140
COUPLING 1/2X1-1/2 BULKHD
1
6. 72053591 STREET ELBOW 1/2NPT 90° 1

14 14K160TH OTR Body & Air Compressor Manual # 99903184
51715800-3 PARTS LIST
ITEM
PART #
DESCRIPTION
QUANTITY
7.
72531547
BARB NIPPLE 1/2MPT 3/4HOSE BRS
2
8.
72066000
HOSE CLAMP SAE12
2
9.
89393634
HOSE 100R4 3/4X25
1
OTR Package Assembly (51715800-4)
FRL (REF)
1
2
1HOSE
REEL
(REF)
3
11
51715800-4 PARTS LIST
ITEM
PART #
DESCRIPTION
QUANTITY
1.
72066000
HOSE CLAMP SAE12
4
2.
89393634
HOSE 100R4 3/4X39
1
3.
89393634
HOSE 100R4 3/4X55
1

Chapter 2 Parts - OTR Body 15
OTR Package Assembly (51715800-5)
RIGHT HAND
COMPARTMENT
(REF)
COMPRESSOR
(REF)
8,9 8,9
5
6
311
10
1
2
1
VIEW A
1,4,5
51715800-5 PARTS LIST
ITEM
PART #
DESCRIPTION
QUANTITY
1.
72053556
STREET ELBOW 3/4NPT 90°
3
2.
72053558
ADAPTER 3/4MPT 3/4MPT HEX
1
3.
73054230
BALL VALVE 3/4NPT
1
4.
72053458
BARB NIPPLE 3/4MPT 3/4HOSE BRS
1
5.
72066000
HOSE CLAMP SAE12
2
6. 89393634 HOSE 100R4 3/4X120 1
8. 72066533 HOSE CLAMP-VINYL CVR 1/2 2
9. 72060833 SCR 5/16-18X3/4 HWH THRD CTG 2
10.
70396133
MUFFLER-AIR 3/4 NPT
1
11.
72053375
REDUCER BUSH-BLK 3/4-1/2
1

16 14K160TH OTR Body & Air Compressor Manual # 99903184
Body Assembly (51715799-1)
A
B
14
13
14
13
14
13
12
14
14
12
11
23
13
14
9
9
8
7
5
8
7
6
7
7
7
6
1
2
43,28,
29,30
25,26,
27,35
10,24
DETAIL B
DETAIL A
14(3) 12(3)
51715799-1 PARTS LIST
ITEM
PART #
DESCRIPTION
QUANTITY
1.
52718265
BODY
1
2.
60122496
DOOR-WLDMT 24.00H X 27.75W
2
3. 72661357 HINGE-BUTT 4-NB ZC .50 PIN 4
4. 60122663 BRACKET-HINGE COMMANDER IV STEP 2
5. 52716189 WLDMT-COMMANDER IV STEP 1
6. 72060093 CAP SCREW .50-13X 1.50 HH GR5 Z 4
7.
72063005
WASHER .50 FLAT
10
8.
72062080
NUT .50-13 HEX NYLOCK
4
9.
77040404
FLOODLIGHT-COMPOSITE WORK LAMP SIDE MTG
2
10.
72661470
LATCH ASSEMBLY-1PT W/HDW
2

Chapter 2 Parts - OTR Body 17
51715799-1 PARTS LIST
ITEM
PART #
DESCRIPTION
QUANTITY
11. 89393137 FENDER RUBBER 2
12. 77040543 LIGHT-CLEAR RED LED (77040357 THRU 4-09) 5
13. 77040478 LIGHT-CLEAR AMBER LED (77040358 THRU 4-09) 4
14.
76393636
GROMMET-RUBBER 2.00
9
23.
72661384
RIVET-AL LG HD .25X .50 GRIP
96
24.
76393253
GASKET-LATCH W/STUDS
2
25.
60030324
SPACER-1.38 X 1.50 X .62 COMMANDER DOOR
2
26.
72063166
WASHER-SS .25 R WRT 18-8 .62OD
2
27.
72062194
NUT-SS .25-20 NYLOC
2
28.
72601590
CAP SCR-SS .31-18X1.00 TRH PHH
16
29. 72063002 WASHER .31 FLAT 16
30. 72062167 NUT-SS .31-18 HEX NYLOC 16
35. 72601593 SCR-MACH .25-20X 1.50 FLH SS 2
REV. L 20090423

18 14K160TH OTR Body & Air Compressor Manual # 99903184
Body Assembly (51715799-2)
36 36
40
38
20 21
37
41
39
22
42
96"
85.63"
33.88"
51.75"
82.86"
43 (BOTH SIDES)
(BOTH
SIDES)
40
(BOTH
SIDES)
38
56.81" 58.69" 35.65"
15,17
15,17
15,17
15,17
15,16
15,16
36
(BOTH
SIDES)
233.25"
242"
51715799-2 PARTS LIST
ITEM
PART #
DESCRIPTION
QUANTITY
15.
76392275
GROMMET-TAIL LIGHT
6
16.
77040180
LIGHT-BACKUP
2
17. 77040493 LIGHT-STOP/TURN/TAIL LED 4" 4
20. 77040006 LIGHT-LICENSE PLATE 2
21. 51715985 KIT-LICENSE PLATE HARDWARE 1
22. 60350058 TREAD-SHUR STEP 12in X 26in 2
36.
70039057
REFLECTOR-RED RD
4
37.
70039058
REFLECTOR-AMBER RD
2
38.
70392865
DECAL-DANGER ELEC HAZARD(LARGE
3
39.
71393886
DECAL-DANGER EXPLODING TANK
1
40.
70392868
DECAL-DANGER CR LOADLINE (TRK)
3
41.
70395701
PLACARD-MAX LIFT 14K160TH
1
42.
70392891
DECAL-DANGER DRIVELINE
1
43. 70395823 DECAL-IDENT COMMANDER IV 3
REV. K 20090102