IMT 1015 Operation?And Safety
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IMT 1015 Operation?And Safety

Telescopic crane. volume 1
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99903514:TELESCOPIC CRANE:
20140915
i
SECTION 0: INTRODUCTION
VOLUME 1
TELESCOPIC CRANE
OPERATION AND SAFETY
IOWA MOLD TOOLING CO., INC.
BOX 189, GARNER, IA 50438-0189
TEL: 641-923-3711
TECHNICAL SUPPORT FAX: 641-923-2424
MANUAL PART NUMBER 99903514
Iowa Mold Tooling Co., Inc. is an Oshkosh Corporation Company.

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  • Page 1 99903514:TELESCOPIC CRANE: 20140915 SECTION 0: INTRODUCTION VOLUME 1 TELESCOPIC CRANE OPERATION AND SAFETY IOWA MOLD TOOLING CO., INC. BOX 189, GARNER, IA 50438-0189 TEL: 641-923-3711 TECHNICAL SUPPORT FAX: 641-923-2424 MANUAL PART NUMBER 99903514 Iowa Mold Tooling Co., Inc. is an Oshkosh Corporation Company.
  • Page 2 Much of the material contained in this manual is Modifications to your crane must be performed specific to IMT telescopic cranes. Much of the general crane safety information is directly taken with IMT approved accessories, parts and from The American Society of Mechanical optional equipment.
  • Page 3 20030115 SECTION 0: INTRODUCTION This volume includes information that is common to all IMT telescopic cranes. For specific information, refer to Volume 2, PARTS AND SPECIFICATIONS. Volume 2 contains information on Specifications, Crane Description, and Parts specific to your crane model. IMT recommends that Volume 1, OPERA- TION and SAFETY, and Volume 2, PARTS and SERVICE, be kept with the crane at all times.
  • Page 4 99903514:TELESCOPIC CRANE: SECTION 0: INTRODUCTION REVISIONS LIST DATE LOCATION DESCRIPTION OF CHANGE 20050301 SECTION 1 - OPERATION UPDATED INFORMATION FOR NEW RADIO SECTION 5 - DECALS UPDATED PER DECAL DESIGN CHANGES 20070215 COVER UPDATED LOGOS WITH OSHKOSH INFO 20080110 1-13, 5-8 ECN 10653 - ADDED INSTRUCTIONS FOR SINGLE LINE DOWNHAUL WEIGHT, 20090418 2-12...

  • Page 5: Table Of Contents

    99903514: TELESCOPIC CRANE: 20030115 SECTION 1: OPERATION SECTION 1: OPERATION 1-1: GENERAL ......................... 2 1-2: DAILY SAFETY INSPECTIONS ..................2 1-3: WORK SITE PREPARATION ..................... 2 1-3-1: ELECTRICAL HAZARDS ....................2 1-3-2: WORK STATION POSITIONING ..................4 1-3-3: OUTRIGGERS ........................ 4 1-4: STARTING CRANE OPERATION ..................

  • Page 6: 1-1: General

    “DANGER ZONE”,or 1-2: DAILY SAFETY INSPECTIONS the minimum clearance distance for a Using the Crane Log, IMT Manual No. 99900686, powerline. or the inspection checklist in the reference section of this manual, inspect the crane on a NOTE: daily, weekly, and monthly basis.
  • Page 7 99903514: TELESCOPIC CRANE: 20030115 SECTION 1: OPERATION NORMAL VOLTAGE MINIMUM REQUIRED kV (Phase to Phase) CLEARANCE Feet (meters) OPERATION NEAR From 0 to 10 ( 3.05) HIGH VOLTAGE From 50 to 200 15 ( 4.60) POWERLINES From 200 to 350 20 ( 6.10) From 350 to 500 25 ( 7.62)

  • Page 8: 1-3-2: Work Station Positioning

    99903514: TELESCOPIC CRANE: 20030115 SECTION 1: OPERATION 1-3-2: WORK STATION POSITIONING Before setting up the outriggers,park the carrier vehicle over a firm and level surface for ad- Park the working unit on firm, level and dry equate outrigger support. If outriggers appear to pavement or ground close to the job.

  • Page 9: 1-4: Starting Crane Operation

    PTO, move the valve to the “ON” position. 7) Release the clutch gradually. IMT recommends running the system 10-15 8) Warm the engine to operating temperature. cycles with a light load, then 10-15 cycles with a 9) Begin crane operation.

  • Page 10: 1-6: Crane Controls

    SECTION 1: OPERATION 1-6: CRANE CONTROLS To operate the radio remote, IMT telescopic cranes may be equipped with 1) Make sure the large red “Emergency Stop” either a radio or tethered remote control. All button is not pressed in. This button must be controls have decals which indicate operating pulled out for the remote to operate.

  • Page 11: 1-6-2: Changing The Battery In The Radio Remote Control

    99903514: TELESCOPIC CRANE: 20030115 SECTION 1: OPERATION 1-6-2: CHANGING THE BATTERY IN THE RADIO REMOTE CONTROL A button on the bottom of the radio remote handset closes the battery compartment. Slide the button toward the back of the handset, and the battery compartment will open.

  • Page 12: 1-6-5: Electric Cranes

    99903514: TELESCOPIC CRANE: 20030115 SECTION 1: OPERATION 1-6-5: ELECTRIC CRANES 4) When done with the function, continue to hold the trigger assembly in until all immediate Electric cranes have no PTO or pumps, but movements of the crane have been completed. they do have tethered remote controls which are similar in operation to the hydraulically controlled 5) If no further work with the crane is needed,...

  • Page 13: 1-7: Crane Capacity And Load Limits

    1-7: CRANE CAPACITY AND LOAD LIM- as the larger of items 4 and 5 above. The IMT crane is designed to lift specific loads. 7. Determine at what angle the crane will be These loads are defined on the capacity placard operated (for example 30°, 45°, etc.) by refer-...

  • Page 14: 1-7-1: Reduced Capacity (Rclc)

    99903514: TELESCOPIC CRANE: 20030115 1-10 SECTION 1: OPERATION 1-7-1: REDUCED CAPACITY (RCLC) In some cases, the capacity of a crane is REDUCED CAPACITY PLACARD reduced when lifts are performed on the sides of the truck. If your vehicle cannot lift full capaci- BASED UPON THE FINAL INSTALLED PACKAGE, THIS CRANE CANNOT LIFT FULL HYDRAULIC CAPACITY THROUGHOUT THE ENTIRE CRANE ROTATION.

  • Page 15: 1-8: Crane Capacity Alert System (Electrically Operated)

    The pressure switch is available If an operator attempts to lift a load which through IMT and its distributors and easily exceeds the rated capacity of the crane, the replaced.

  • Page 16: 1-9: Anti Two Blocking System

    Once again the function should be non-existent with no tightening of the winch IMT telescopic cranes have two types of anti cable. If operation other than described occurs, two-blocking systems; a rod and weight system stop immediately and reverse the function.
  • Page 17 99903514: TELESCOPIC CRANE: 20030115 1-13 SECTION 1: OPERATION Figure A-15: Approaching Two-Blocking Figure A-14: Normal Work Position Situation NOTE: ”TWO-BLOCKING” IS THE CONDITION IN WHICH THE SNATCH BLOCK OR HOOK ASSEMBLY COMES IN CONTACT WITH THE UPPER LOAD BLOCK OR BOOM POINT SHEAVE ASSEMBLY.

  • Page 18: 1-10: Changing From Double To Single-Part Line

    99903514: TELESCOPIC CRANE: 20030115 1-14 SECTION 1: OPERATION 1-10: CHANGING FROM DOUBLE TO SINGLE-PART LINE Initially, your crane is set up with two-part line. Single-part line gives you a closer load distance and faster line speed. If you require a closer load distance or a faster Downhaul line speed, first check that you have the capac- weight - installed...

  • Page 19: 1-11: Task Performance

    99903514: TELESCOPIC CRANE: 20030115 1-15 SECTION 1: OPERATION 1-11: TASK PERFORMANCE WARNING To operate the crane: DO NOT ATTEMPT TO HANDLE A LOAD IF OUTRIGGERS ARE UNABLE TO MAKE 1) Position the crane as close to the job as SOLID CONTACT WITH THE GROUND. possible on a firm, dry and level surface.

  • Page 20: 1-12: Crane Shutdown

    99903514: TELESCOPIC CRANE: 20030115 1-16 SECTION 1: OPERATION CAUTION boom does not move out of the boom rest DO NOT ATTEMPT TO ROTATE THE during transit. See Figure A-18. CRANE BEFORE PLACING IT IN THE DEPLOYED POSITION. DAMAGE TO 4. Stow the outriggers. EQUIPMENT AND INJURY TO PERSON- NEL MAY RESULT.

  • Page 21: 1-14-1: Dusty And Sandy Areas

    99903514: TELESCOPIC CRANE: 20030115 1-17 SECTION 1: OPERATION 1-14: OPERATION IN ADVERSE Wash off salt water and dry all parts thoroughly. CONDITIONS Paint the exposed surfaces immediately. Place a film of lubricant or grease on all polished or 1-14-1: DUSTY AND SANDY AREAS machined surfaces and other surfaces which Operating in dusty or sandy areas presents cannot be painted.

  • Page 22: 1-15: Hand Signals

    99903514: TELESCOPIC CRANE: 20030115 1-18 SECTION 1: OPERATION leading to the suction port on the pump is not 1-15: HAND SIGNALS clogged, or that the hydraulic oil itself does not Hand signals can be used to communicate have a jelling condition. between crane operators and assistants when the job site noise level is to high to communi- CAUTION...
  • Page 23 99903514: TELESCOPIC CRANE: 20030115 1-19 SECTION 1: OPERATION Figure A-21: Hand Signals...

  • Page 24: Important! Notes For Safe Operation

    IMPORTANT! NOTES FOR SAFE OPERATION ANTI-TWO BLOCK: IMT telescoping cranes using a winch are equipped with an anti-two blocking device, but me- chanical devices cannot be substituted for good operator judgement. It is the operator’s respon- sibility to avoid two-blocking and not to rely on the device alone.
  • Page 25 99903514: TELESCOPIC CRANE: 20030115 1-21 SECTION 1: OPERATION FIRE PRECAUTIONS FIRE PRECAUTIONS To avoid fires, 1. Use safety-type portable gasoline containers equipped with an automatic closing cap and flame arrester. 2. DO NOT refuel while the vehicle engine is running. 3.
  • Page 26 99903514: TELESCOPIC CRANE: 1-22 SECTION 1: OPERATION...
  • Page 27 2-3: LUBRICATION ........................3 2-4: LUBRICATION POINTS ..................... 3 MODELS 3020, 3820, & 5020 ....................4 MODELS 1015 & 2020 ......................4 MODELS 5525, 6025, & 6625 ....................5 MODELS 7020 & 7025 ......................5 2-5: HYDRAULIC SYSTEM ....................... 6 2-5-1: HYDRAULIC OIL SPECIFICATIONS ................

  • Page 28: 2-1: General

    SECTION 2: MAINTENANCE 2-2: MAINTENANCE SCHEDULE 2-1: GENERAL Detailed steps on numerous maintenance To obtain reliable and satisfactory service, IMT procedures are described in the following telescopic cranes require a consistent preventa- pages. Use the following chart to help you tive maintenance schedule.

  • Page 29: 2-3: Lubrication

    99903514:TELESCOPIC CRANE: 20030115 SECTION 2: MAINTENANCE 2-3: LUBRICATION 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.

  • Page 30: Models 3020, 3820, & 5020

    20030115 SECTION 2: MAINTENANCE NOTE Figure B-4: Components & Grease COMPONENTS ON CRANE DIAGRAMS ARE Zerk Locations - Models 1015 & 2020 IDENTIFIED BY NAME; GREASE ZERKS ARE 1. Worm Gear IDENTIFIED BY NUMBER. 2. Turntable Bearing - Grease Extension 3.

  • Page 31: Models 5525, 6025, & 6625

    99903514:TELESCOPIC CRANE: 20030115 SECTION 2: MAINTENANCE Figure B-6: Component & Grease Zerk NOTE COMPONENTS ON CRANE DIAGRAMS Locations - Models 5525, 6025, 6625 ARE IDENTIFIED BY NAME; GREASE 1. Turntable Bearing Grease Extension (Rotate ZERKS ARE IDENTIFIED BY NUMBER. crane while greasing) 2.

  • Page 32: 2-5: Hydraulic System

    99903514:TELESCOPIC CRANE: 20030115 SECTION 2: MAINTENANCE 2-5: HYDRAULIC SYSTEM 2-5-2: LOW TEMPERATURE HYDRAULIC 2-5-1: HYDRAULIC OIL SPECIFICATIONS OIL SPECIFICATIONS The hydraulic oil is the power transmission In conditions below -25°F, use gear oil which medium, system lubricant, and coolant. Under meets MIL-L-2105C Grade 75W (GO-75).

  • Page 33: 2-5-4: Hydraulic Fluid Deterioration

    99903514:TELESCOPIC CRANE: 20030115 SECTION 2: MAINTENANCE 2-5-4: HYDRAULIC FLUID DETERIORA- NOTE DISPOSE OF WASTE OIL IN A RESPON- TION SIBLE MANNER, FOLLOWING ANY FED- ERAL, STATE OR LOCAL REGULATIONS. NOTE: DO NOT USE ENGINE OIL AS AN ALTER- 4. Remove the reservoir return line. Direct the NATIVE FOR HYDRAULIC FLUID.

  • Page 34: 2-5-7: Hydraulic Pressure Relief

    If you suspect the components, the filter must be changed after 50 system relief pressure of malfunctioning, see hours of new-unit operation and every 200 hours your IMT dealer for testing and replacement. thereafter. WARNING Check the vacuum gauge reading on the suc- SETTING THE PRESSURE RELIEF tion line filter for a reading greater than 8”...

  • Page 35: 2-6: Wire Rope & Hook Maintenance

    1. INSPECTOR - The wire rope inspector 2-6-2: WIRE ROPE LUBRICATION must keep written reports of the rope condition Wire rope used on IMT cranes does not have on file at the work site and must have the continuous lubrication replenishment. Use open...

  • Page 36: 2-6-3: Wire Rope Maintenance

    If the daily wire rope inspection shows a problem with the wire rope, the rope must be repaired or replaced. Use only original wire rope from IMT. Failure to do so may cause problems with the anti-two block system and the downhaul weights.

  • Page 37: 2-6-5: Wire Rope Slings

    99903514:TELESCOPIC CRANE: 20030115 2-11 SECTION 2: MAINTENANCE A sling eye should never be used over a hook or 2-6-5: WIRE ROPE SLINGS pin with a body diameter larger than the natural Rated load (rated capacity) of a wire rope sling width of the eye.

  • Page 38: 2.6-6: Wire Rope Lay

    99903514:TELESCOPIC CRANE: 20090416 2-12 SECTION 2: MAINTENANCE SLING LOADING 2.6-6: WIRE ROPE LAY Sling angle (angle of loading) is the angle Wire rope “lay” indicates the directions strands measured between a horizontal line and the lay in the rope - right or left. When you look sling leg or body.

  • Page 39: 2-7: Periodic Vehicle Inspection

    NOTE BASE ASSEMBLY A CRANE LOG BOOK,PART NO. 1. Check base casting housing for cracks. 99900686, IS AVAILABLE FROM IMT. THE CRANE LOG PROVIDES A CONVENIENT 2. Check for proper rotation function by making AND PRECISE INSPECTION RECORDING several start-stop operations. Maximum allow- METHOD.

  • Page 40: 2-10: Tethered Remote Control Inspection

    2. HYDRAULIC PUMP 2-11: CORROSION CONTROL A. Check for leaks at shaft seal. IMT treats metal to metal surfaces and hard- B. Check for drop in operating speed. ware on new cranes with Cortex VCI-389, a C. Check hydraulic oil for excessive chemical for rust prevention.

  • Page 41: 2-13: Chemical Safety

    99903514:TELESCOPIC CRANE: 20030115 2-15 SECTION 2: MAINTENANCE 2-13: CHEMICAL SAFETY Many chemicals are available for cleaning and lubricating your equipment. Prior to opening or using any chemical for cleaning, lubrication, or other procedure, READ THE LABEL. Labels on chemical containers list important information on health, safety, and the product itself.

  • Page 42: 2-14: Excessive Load Limit System (Ells) Test Procedure

    2-14: EXCESSIVE LOAD LIMIT SYSTEM (ELLS) TEST PROCEDURE Use this procedure to test the Excessive Load Limit System (ELLS) used on the IMT Telescoping Crane models. Following this test procedure will ensure the system is currently operable and will not allow the crane to be excessively overloaded.
  • Page 43 99903514:TELESCOPIC CRANE: 20030115 2-17 SECTION 2: MAINTENANCE MALE MALE STRAIGHT STRAIGHT THREAD THREAD ADAPTER 1/4” FEMALE MALE PIPE THREAD MALE MALE 5000 PSI LIQUID FILLED PRESSURE GAUGE #6 FEMALE HOSE ENDS 3/8” OR 1/4” #6 FEMALE #6 FEMALE SAE 100R16 HOSE END HOSE END HOSE X 4”...
  • Page 44 99903514:TELESCOPIC CRANE: 20030115 2-18 SECTION 2: MAINTENANCE B. Attach Pressure Gage (Procedure used depends on cylinder block used on crane.) -Use Procedure 1 for cranes featuring a large valve block with a smaller block attached and the port tubes welded directly to the valve block and cylinder. -Use Procedure 2 for cranes with only one valve block and the port tubes are removable by use of fittings on the valve block and on the cylinder.
  • Page 45 99903514:TELESCOPIC CRANE: 20030115 2-19 SECTION 2: MAINTENANCE 2. Procedure 2 (Large valve block only – port tubes removable) a. Remove bolts that attach the valve block to the cylinder b. BE AWARE OF TRAPPED PRESSURE BEHIND THE PLUG IN THIS STEP!! PRESSURIZED OIL MAY CAUSE SERIOUS INJURY!! Turn off fitting connecting port tube to base end of cylinder (end closest to crane base).
  • Page 46 ELLS. Figure B-17: Functions Shut Down by ELLS FUNCTIONS SHUT DOWN BY ELLS MAX. TEST WINCH EXTENSION LOWER GAGE CRANE DOWN PRESSURE MODEL ALLOWED 1015 3000 2020 3000 3020 3300 3820 3500 5020 3500 5525 3300 6020...

  • Page 47: 2-15: Ells Troubleshooting Procedure

    99903514:TELESCOPIC CRANE: 20030115 2-21 SECTION 2: MAINTENANCE 2-15: ELLS TROUBLESHOOTING PROCEDURE Each function (winch up, winch down, extension in, etc.) is actuated by a solenoid that shifts the valve spool to perform the particular function. The solenoids are located on the valve bank. Each solenoid has two wires protruding with a connector on the end that is plugged into a connector on the wire harness for the crane.

  • Page 48: 2-16: Winch Troubleshooting

    MOTOR INLET PRESSURE IS LESS THAN TEST HYDRAULIC PUMP. CHECK MAIN RELIEF - SPECIFICATIONS WITH LOAD STALLED. MODEL 1015 - 2250 PSI MODEL 2020 - 2350 PSI MODELS 3020, 3820, 5020, 5525, 6025, 6625 - 3000 PSI MODEL 7020/7025 - 2500 PSI BRAKE SHOULD ENGAGE IN PAYOUT RUN WINCH WITH NO LOAD IN BOTH DIRECTIONS.
  • Page 49 3-9: CRANE ROTATION SYSTEM .................... 4 3-9-1: REMOVING THE CRANE ROTATION SYSTEM ............5 3-9-2: SETTING BACKLASH - IMT BASE & WORM DRIVE (1007, 1015, 2020) ..... 5 3-9-3: WORM END PLAY & BACKLASH - INTEGRAL BASE & WORM DRIVE (3020, 3820, 5020, 5525, 6025, 6625) .......................

  • Page 50: 3-1: General

    The information supplied in this section of the condition. manual is designed to help you service and repair of your IMT telescopic crane. Information on inspection, lubrication and general mainte- 3-3: SYSTEMATIC REPAIR PROCEDURE nance information can be found in the previous 1) Begin repairs by studying the hydraulic sections of this manual.

  • Page 51: 3-4: Cleanliness

    Relieve hydraulic pressure. ALWAYS REPLACE IT WITH A NEW BOLT Inspect all seals during assembly and OF THE SAME GRADE. disassembly. IMT recommends installing new seals after hydraulic system repairs. When the maximum recommended torque value has been exceeded, replace the fastener.

  • Page 52: 3-7: Crane Base Removal And Replacement

    Fill plug mission fluid in the brake section. 3-9: CRANE ROTATION SYSTEM IMT telescopic cranes have two types of rotation systems; an integral base and worm drive system and a turntable system. Use the follow- ing chart and the parts manual to determine which type of rotation system is applicable for your telescopic crane.

  • Page 53: 3-9-1: Removing The Crane Rotation System

    TOPLAND ROOT DIAMETER AND TANGENT TO THE GEAR FILLET TEETH. Telescopic crane models 1007, 1015, and 2020 have a common gear and rotation system. To PITCHLINE set the backlash on these models, BACKLASH 1. Bolt the worm gear in place.
  • Page 54 99903514:TELESCOPIC CRANE: 20030115 SECTION 3: REPAIR To set the worm end play: 6. After setting the backlash, torque the bearing retaining allen head capscrews which 1. Locate the high tooth on the gear. (The high watching the indicator dial so that the cor- spot on the bearing is marked by the manu- rect backlash setting is maintained.
  • Page 55 99903514:TELESCOPIC CRANE: 20030115 SECTION 3: REPAIR 9. Thoroughly clean the top of the crane base and bottom of the new turntable gear bear- ing. The mating surfaces must be clean and dry - no oil or grease. 10. Install the new gear bearing, with ball loading plug located next to pinion gear (See Figure C-6), using new bolts, hardened flat wash- ers and Loctite 262 or an equivalent thread...
  • Page 56 Slide the intermediate gear out of place. the way. 5. Install the grease plate and rotation motor. 5. Install the bushing removal tool (IMT part Lubricate the drive gear. number 92091200) as shown in Figure C-8. 6. Connect the hydraulic hoses to the motor.

  • Page 57: 3-9-6: Rotation Motor And C'bal Valve Removal And Replacement

    99903514:TELESCOPIC CRANE: 20030115 SECTION 3: REPAIR 3-9-6: ROTATION MOTOR AND C’BAL boom to gain access to the wear pads. VALVE REMOVAL AND REPLACEMENT 3. To access the wear pads at the bottom of (7020, 7025) the lower boom assembly, completely pull out the extension boom section(s).

  • Page 58: 3-11: Pins

    3-12: BEARINGS & BUSHINGS 3-12-1: BEARING TYPES Roller bearings are used on sheaves in the 1007, 1015 and 2020 cranes. Bushings, which are bearings without moving parts, are used on the cylinders and booms of some crane models. See chart for bushing locations.

  • Page 59: 3-13: Valvebank

    99903514:TELESCOPIC CRANE: 20030115 3-11 SECTION 3: REPAIR 4. Replace the bearing if needed. Otherwise, PMW% LED lightly grease and reassemble. The PMW% LED indicates the condition of the output current flowing to the proportional valve. The LED will change colors from red to yellow To replace bearings: to green.
  • Page 60 99903514:TELESCOPIC CRANE: 20030115 3-12 SECTION 3: REPAIR HYDRAULICS-VALVEBANK DIRECTIONAL VALVES RELIEF VALVE The directional valves (4) control the direction of the crane functions. When one of the solenoids The relief valve limits the maximum system is energized, it shifts the valve spool. This pressure.

  • Page 61: 3-13-2: Valvebank Troubleshooting

    There are different replacement valves for valvebanks Questionable Operation of Coil - Remove with blue or silver end caps. Contact IMT the coil at the top of the valve, then remove technical support for more information.

  • Page 62: 3-14: Lower Cylinder Removal & Replacement

    SUPPORT THE CRANE BASE, MAST, AND DER-REMOVAL AND REPLACEMENT BOOMS PRIOR TO REMOVING ANY CYLIN- Models 1015, and 2020 telescopic cranes have DERS! FAILURE TO SUPPORT THE CRANE external extension cylinders. See Figure C-14 FULLY CAN CAUSE PERSONAL INJURY AND for identification.

  • Page 63: 3-16: Internal Cylinder Removal And Replacement

    If the base. wire rope is damaged, bent, or worn as defined Models including the 1015 and 2020 do not in Section 2-6, replace it using the following have pins securing the cylinders, and you steps: must remove bolts or fasteners.
  • Page 64 99903514:TELESCOPIC CRANE: 3-16 SECTION 3: REPAIR...
  • Page 65 99903514:TELESCOPIC CRANE: 20030315 3A-1 SECTION 3A: CYLINDER REPAIR SECTION 3A. CYLINDER REPAIR TOOLS REQUIRED ........................2 3A-1. CYLINDER DISASSEMBLY .................... 2 FIGURE C1-1. TYPICAL CYLINDER AND SEAL KIT COMPONENTS ........4 FIGURE C1-2. SEAL INSTALLATION GUIDELINES ............... 5 3A-2. CYLINDER ASSEMBLY ....................6 APPENDIX: PISTON &...
  • Page 66 USE SOLVENTS IN A WELL VENTILATED AREA. an up-and-down or side-to-side motion. Set the IGNORING THESE WARNINGS WILL CAUSE cylinder case to one side. SERIOUS INJURY OR DEATH. IMT RECOMMENDS USING AN ALKALINE CLEANER. SPANNER WRENCH WARNING DO NOT USE COMPRESSED AIR TO ASSIST IN WITHDRAWING THE PISTON/ROD ASSEMBLY.
  • Page 67 99903514:TELESCOPIC CRANE: 20120521 3A-3 SECTION 3A: CYLINDER REPAIR 4. Secure the rod pin boss with a pin clamped in NOTE the vise. Unscrew the piston using the spanner FURTHER WORK SHOULD BE PERFORMED IN A wrench. Carefully inspect the piston and rod threads WARM ENVIRONMENT OF 70°F OR MORE.
  • Page 68 99903514:TELESCOPIC CRANE: 20120521 3A-4 SECTION 3A: CYLINDER REPAIR CAUTION 15. Attempt to dress any nicks or gouges that may DAMAGING THE EDGES OF THE GROOVE WILL have occurred during disassembly using fine grade CAUSE PREMATURE SEAL FAILURE. emery cloth. 14. Remove the companion o-ring and nylon insert WARNING using the plastic awl.
  • Page 69 99903514:TELESCOPIC CRANE: 20030315 3A-5 SECTION 3A: CYLINDER REPAIR SEAL INSTALLATION GUIDELINES CAUTION REPLACE ALL SEALS IN THE SEAL KIT. DOING SO WILL REDUCE EXPENSIVE DOWNTIME IN THE NEAR FUTURE. To provide maximum sealing capabilities of cylinder seals, proper installation is required. Improper or careless installation accounts for the failure of seals as much as does wear.
  • Page 70 99903514:TELESCOPIC CRANE: 20030315 3A-6 SECTION 3A: CYLINDER REPAIR 3A-2. CYLINDER ASSEMBLY 6. Position the head with the rod wiper pocket “up”. 7. Using the Rod Seal Installation Tool, install Rod NOTE seal as follows: BEFORE ASSEMBLY OF CYLINDER, FAMILIARIZE YOURSELF WITH FIGURE C1-2,...
  • Page 71 99903514:TELESCOPIC CRANE: 20120521 3A-7 SECTION 3A: CYLINDER REPAIR 10. Lubricate the inside diameter of the head with a PISTON TORQUE CHART nonfibrous grease such as Lubriplate. THREAD DIAMETER TORQUE REQ’MENT 1/2” ID 30- 40 ft-lb 11. Carefully slide the head onto the rod. Make 3/4”...
  • Page 72 99903514:TELESCOPIC CRANE: 20030315 3A-8 SECTION 3A: CYLINDER REPAIR 19. Secure the cylinder and torque the head per the 20. Install the holding valves and their o-rings. The Head Torque Chart. Use a spanner attachment on a o-rings must be in good condition and properly torque wrench to measure the torque.
  • Page 73 4.5 MODEL SPECIFIC CRANE & HYDRAULIC INSTALLATION GUIDES ......6 4.5.1 GENERAL ......................... 6 4.5.2 CHASSIS INFORMATION ....................6 4.6 MODEL 1015 CRANE INSTALLATION ................7 4.7 MODEL 2020 CRANE INSTALLATION ................8 4.8 MODEL 3020 CRANE INSTALLATION ................9 4.9 MODEL 3820 CRANE INSTALLATION ................

  • Page 74: 4-1: General

    3). Make sure that the pump rotates in the Use the information in this section to prepare proper direction and tighten the pump mount- the truck chassis for installation of an IMT ing bolts. frame-mounted hydraulic crane. It contains 5. Install the suction-line filter below the top of information regarding PTO and pump installa- the truck frame and within 48"...

  • Page 75: 4-3-2: Pump Installation

    SECTION 4: INSTALLATION 99903514:TELESCOPIC CRANE: 20030115 PTO manufacturers provide specific installa- 11. Install the shifter cable to suit conditions. tion instructions with their products. Their Always allow a slight overshift on lever or knob instructions should be followed when installing to make certain PTO is fully engaged.

  • Page 76: 4-3-3: Driveline Application

    20030115 SECTION 4: INSTALLATION 99903514:TELESCOPIC CRANE: 4-3-3: DRIVELINE APPLICATION When you cannot directly mount the pump/ PTO is not feasible, you may use an auxiliary driveshaft. To select the auxiliary driveshaft for your installation, consider the following: 1. The driveshaft must be able to transmit the necessary torque and RPM required.
  • Page 77 SECTION 4: INSTALLATION 99903514:TELESCOPIC CRANE: 20030115 Driveshaft installation guidelines: 4. Check pump rotation and install pump, pumpend yoke and PTO end yoke. WARNING DRIVESHAFTS ARE DANGEROUS! 5. If a setscrew protrudes above end yoke PLACE DRIVESHAFT IN AN UNEX- hub, replace it with a recessed allen-head set POSED OR SHIELDED POSITION TO screw.

  • Page 78: 4-4: Engine Speed Regulation

    Once you’ve obtained this information, 4.5.2 CHASSIS INFORMATION record it below. Your crane is designed for use with an IMT body installed on a vehicle meeting minimum PUMP CAPACITY ENGINE TO PTO RATIO chassis requirements including a specific...

  • Page 79: Model 1015 Crane Installation

    SECTION 4: INSTALLATION 99903514:TELESCOPIC CRANE: 20030115 4.6 MODEL 1015 CRANE INSTALLA- TION MINIMUM CHASSIS SPECIFICATIONS BODY STYLE Conventional WHEELBASE 137” - 161” CAB TO AXLE 60” - 84” FRAME SECTION MODULUS 5.91 in³ 212,760 in-lb (based on 36,000 psi yield frame mat’l)

  • Page 80: Model 2020 Crane Installation

    TIONS, A HEAVY-DUTY BATTERY AND ALTERNATOR ARE REQUIRED. IT IS RECOMMENDED THAT THE VEHICLE HAVE POWER STEERING AND DUAL REAR WHEELS. IMT RECOMMENDS ADHERENCE TO THE UPPER LIMIT OF THESE SPECIFI- CATIONS FOR BEST SYSTEM PER- FORMANCE. BODY REINFORCEMENT If, after talking with the factory, it has been...

  • Page 81: Model 3020 Crane Installation

    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 in- stalled in the cargo area of the body.

  • Page 82: Model 3820 Crane Installation

    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 in- stalled in the cargo area of the body.

  • Page 83: Model 5020 Crane Installation

    14.75“ rated load. Install the crane only on an IMT (37.5cm) designed and approved truck body. The body must be designed to sustain the forces imposed by the crane when lifting the full rated load.

  • Page 84: Model 6020 Crane Installation

    Specifications, there must be sufficient room for 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.

  • Page 85: Models 5525, 6025, And 6625 Crane Installation

    2” THREAD ENGAGEMENT. CRANE INSTALLATION In addition to meeting Minimum Chassis Specifications, there must be sufficient room for mounting the crane and the platform must be strong enough to support the crane and rated load. Install the crane only on an IMT...
  • Page 86 SECTION 4: INSTALLATION 99903514:TELESCOPIC CRANE: 20030115 4-14 MOUNTING HOLE LAYOUT AND CRANE INSTALLATION DRAWINGS - 5525, 6025, AND 6625 MODEL CRANES 14.75" (37.5 cm) 7.38" TYP (18.7 cm) 6.44" 14.75" (16.4 cm) (37.5 cm) 3.31" (8.4 cm) 6.87" TYP (17.4 cm) MOUNTING HOLES AS VIEWED FROM THE TOP OF THE CRANE MOUNTING HOLE LAYOUT...

  • Page 87: Hydraulic Installation - Models 3020, 3820, 5020, 5525, 6020, 6025, 6625

    SECTION 4: INSTALLATION 99903514:TELESCOPIC CRANE: 20030115 4-15 4.13 HYDRAULIC INSTALLATION - 2. Fill the hydraulic reservoir with oil as specifed in the Maintenance Section of the MODELS 3020, 3820, 5020, 5525, 6020, Telescopic Crane Operation,Maintenance & 6025, 6625 Repair Manual. Before installation, familiarize yourself with the installation kit drawing in the parts section for 3.

  • Page 88: Model 7020 Crane Installation

    TRANSMISSION 5-speed GAGED BY HAND TURNING. CRANE INSTALLATION Install the 7020 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. Before attempting to install the crane, first install the truck body.

  • Page 89: 4.15 Model 7025 Crane Installation

    THREAD OF THE NUT INSERT IS EN- GAGED BY HAND TURNING. CRANE INSTALLATION Install the 7025 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. Before attempting to install the crane, first install the truck body.

  • Page 90: Hydraulic & Electrical Installation - Models 7020 & 7025

    SECTION 4: INSTALLATION 99903514:TELESCOPIC CRANE: 20030115 4-18 4.16 HYDRAULIC & ELECTRICAL ELECTRICAL INSTALLATION INSTALLATION - MODELS 7020 & 7025 Familiarize yourself with the information on Proportional Remote Controls contained in this manual. Install the electrical components HYDRAULIC INSTALLATION per the diagrams shown in the Parts Section. Before beginning hydraulic installation, refer to the Installation Kit in the Parts Section for TEST...
  • Page 91 SECTION 5: DECALS 99903514:TELESCOPIC CRANE: 20050120 SECTION 5: DECALS 5-1. DECAL PLACEMENT-TELESCOPING CRANES ............... 2 5-2. “DANGER” DECAL DESCRIPTIONS .................. 3 5-3. INSTRUCTIONAL DECAL DESCRIPTIONS ................ 6...
  • Page 92 1, 11, 16, 17 AT OR NEAR REMOTE CONTROL GREASE WEEKLY E-10 HANDLE STORAGE POINT 10. GREASE WORM DRIVE BEARING E-11 ON ALL FOUR SIDES OF CARRIER 11. CONTACT IMT E-12 VEHICLE 12. RETURN LINE E-13 ON REMOTE CONTROL 13. SUCTION LINE E-14...
  • Page 93 IMT. The following figures show the safety decals used on IMT cranes. They are illustrated here as an aid in their identification with an explanation of their purpose, where they are placed on the crane and the normal quantity used on each crane.
  • Page 94 SECTION 5: DECALS 20120104 99903514:TELESCOPIC CRANE: DANGER Electrocution Hazard Never approach this vehicle or the load if it is near power lines. Death or serious injury will result from touching or being near this vehicle if it becomes charged. 70394445 Figure E-3 DECAL: Electrocution Hazard PART NUMBER: 70394445...
  • Page 95 SECTION 5: DECALS 99903514:TELESCOPIC CRANE: 20120104 Figure E-5 Figure E-6 DECAL: Electrocution Hazard via Remote Control DECAL: Rotating Driveline Hazard PART NUMBER: 70394447 PART NUMBER: 70392891 FUNCTION: To inform the operator of the lack of FUNCTION: To inform personnel of the hazard protection from electrocution afforded by the remote associated with servicing an operating driveline or control handle, the possible consequences of the crane...
  • Page 96 SECTION 5: DECALS 99903514:TELESCOPIC CRANE: 20120104 5-3. INSTRUCTIONAL DECAL DESCRIPTIONS Shown in this section are instructional decals which may be affixed to your crane. Some are relevant to maintenance while others focus on operation. They are provided here as reference in the understanding of their purpose and placement.
  • Page 97 FUNCTION: To provide the owners/operators and YOUR AUTHORIZED maintenance personnel with the address and DEALER telephone number of IMT for service and repair purposes, safety questions, etc. Visit our dealer locator: USED ON: All cranes. www.imt.com PLACEMENT: Visible from the operator’s station.
  • Page 98 SECTION 5: DECALS 99903514:TELESCOPIC CRANE: 20080110 Figure E-16 DECAL: Rotate While Greasing ROTATE CRANE PART NUMBER: 70392524 WHILE GREASING FUNCTION: To inform and remind operators to rotate TURNTABLE the crane while greasing the turntable rotation system. GEAR-BEARING USED ON: All cranes. PLACEMENT: On the gear cover.
  • Page 99 SECTION 5: DECALS 99903514:TELESCOPIC CRANE: 20050125 Figure E-20 DECAL: ASME B30.5 This crane has been manufactured NOTICE in accordance with ASME B30.5, PART NUMBER: 70395324 Mobile and Locomotive Cranes. 70395324 FUNCTION: To inform operator and maintenance personnel of the specification to which the crane was manufactured.
  • Page 100 PART NUMBER: Varies based on valvebank. desired function. 70396631 on 5525, 6025, 6625. TO OPERATE INDIVIDUAL CRANE FUNCTIONS: 70394166 on all telescopic cranes except 1015 Manually depress plunger located on the end of each and 2020, and 5525, 6025, and 6625 after solenoid spool.
  • Page 101 SECTION 5: DECALS 99903514:TELESCOPIC CRANE: 20120105 5-11 Figure E-36 DECAL: Stabilizer - Fully Deployed PART NUMBER: 70399271 FUNCTION: To inform operator when the stabilizer arm is fully deployed (extended). When the stabilizer 70399271 arm is fully extended, this decal will be completely visible.
  • Page 102 SECTION 5: DECALS 99903514:TELESCOPIC CRANE: 5-12...
  • Page 103 99903514:TELESCOPIC CRANE: SECTION 6. GENERAL REFERENCE 20030115 SECTION 6: REFERENCE INSPECTION CHECKLIST ......................2 CRANE CAPACITY & STABILITY ....................6 UNDERSTANDING THE CAPACITY PLACARD ................6 STABILITY TEST ..........................7 TORQUE DATA CHART - DOMESTIC ..................11 TORQUE DATA CHART - METRIC ....................12 TURNTABLE BEARING FASTENER TIGHTENING SEQUENCE ..........

  • Page 104: Section 6: Reference

    99903514:TELESCOPIC CRANE: 20111122 SECTION 6. GENERAL REFERENCE NOTICE Inspection Checklist The user of this form is responsible in determining that these CRANES inspections satisfy all applicable regulatory requirements OWNER/COMPANY TYPE OF INSPECTION (check one) DAILY (if deficiency found) QUARTERLY CONTACT PERSON MONTHLY ANNUAL CRANE MAKE &...
  • Page 105 99903514:TELESCOPIC CRANE: 20111122 SECTION 6. GENERAL REFERENCE Inspection Checklist CRANES  X = Deficient (Note: If a deficiency is found, an immediate = SATISFACTORY STATUS determination must be made as to whether the deficiency R = RECOMMENDATION (Should be constitutes a safety hazard and must be corrected prior to considered for corrective action) ...
  • Page 106 99903514:TELESCOPIC CRANE: 20111122 SECTION 6. GENERAL REFERENCE Inspection Checklist CRANES  X = Deficient (Note: If a deficiency is found, an immediate = SATISFACTORY STATUS determination must be made as to whether the deficiency R = RECOMMENDATION (Should be      , R, constitutes a safety hazard and must be corrected prior to considered for corrective action)
  • Page 107 99903514:TELESCOPIC CRANE: 20111122 SECTION 6. GENERAL REFERENCE Deficiency / Recommendation / Corrective Action Report DATE OWNER UNIT I.D. NUMBER GUIDELINES A deficiency (X) may constitute a hazard. X must be corrected and/or faulty parts replaced before resuming operation. Recommendations (R) should be considered for corrective actions. Corrective action for a particular recommendation depends on the facts in each situation.

  • Page 108: Crane Capacity & Stability

    99903514:TELESCOPIC CRANE: 20120104 SECTION 6. GENERAL REFERENCE CRANE CAPACITY & STABILITY UNDERSTANDING THE CAPACITY The crane capacity is defined on the capacity PLACARD placard, a decal which is mounted near the The following information is defined on Figure F-1, operator’s station on the crane. The capacity a sample capacity placard.

  • Page 109: Stability Test

    Any installer other than IMT also has the responsibility to complete a stability chart. Cranes are tested for stability to 85% of “tipping”, where the crane load is balanced 7) Slowly start rotating the load counterclockwise.
  • Page 110 99903514:TELESCOPIC CRANE: SECTION 6. GENERAL REFERENCE 13) To determine the percent of full capacity in the LIFTING IN THE DERATED ZONE derated zone, divide the remaining horizontal distance (K) by the original maximum horizontal If it is absolutely necessary to perform a lift within distance (L).
  • Page 111 99903514:TELESCOPIC CRANE: 20090420 SECTION 6. GENERAL REFERENCE FIGURE F-2: STABILITY CHART - CRANE MOUNTED BEHIND CAB...
  • Page 112 99903514:TELESCOPIC CRANE: 20090420 6-10 SECTION 6. GENERAL REFERENCE FIGURE F-3: STABILITY CHART - REAR-MOUNTED CRANE...

  • Page 113: Torque Data Chart - Domestic

    99903514:TELESCOPIC CRANE: 20030115 6-11 SECTION 6. GENERAL REFERENCE TORQUE DATA CHART - DOMESTIC FINE THREAD BOLTS COARSE THREAD BOLTS TIGHTENING TORQUE TIGHTENING TORQUE SAE J429 SAE J429 SAE J429 SAE J429 GRADE 5 GRADE 8 GRADE 5 GRADE 8 SIZE BOLT DIA PLAIN PLATED...

  • Page 114: Torque Data Chart - Metric

    99903514:TELESCOPIC CRANE: 20030115 6-12 SECTION 6. GENERAL REFERENCE TORQUE DATA CHART - METRIC FINE THREAD BOLTS COARSE THREAD BOLTS TIGHTENING TORQUE TIGHTENING TORQUE SAE J429 SAE J429 SAE J429 SAE J429 GRADE 5 GRADE 8 GRADE 5 GRADE 8 SIZE BOLT DIA PLAIN PLATED...

  • Page 115: Turntable Bearing Fastener Tightening Sequence

    99903514:TELESCOPIC CRANE: 20030115 6-13 SECTION 6. GENERAL REFERENCE TURNTABLE BEARING FASTENER TIGHTENING SEQUENCE Refer to the diagram below for proper tightening/torquing sequence of the turntable bearing to the crane base and crane mast. The total quantity of cap screws varies dependent on crane model. WARNING Number 1 can be assigned to any capscrew if the sequence...

  • Page 116: Turntable Bearing Inspection For Replacement

    5200 16000 9800 NOTE 1014 5200R 32018 12916 THE FIGURES LISTED IN 1014A 5217 32027 13031 THIS CHART ARE CRANE, 1015 5800 32030 13034 SERVICE GUIDELINES 2015/2020 7020 14000 LOADER 2109 7025 15000 AND DO NOT, IN 3000 7200 18000...

  • Page 117: Direction Terminology

    99903514:TELESCOPIC CRANE: 20030115 6-15 SECTION 6. GENERAL REFERENCE DIRECTION TERMINOLOGY Various terms may be used to describe direc- tions associated with crane operation. Illus- trated here are some of those terms and their variations. CRANE OPERATION DIRECTIONAL TERMINOLOGY...
  • Page 118 99903514:TELESCOPIC CRANE: 20000706 6-16 SECTION 6. GENERAL REFERENCE CONVERSION FACTORS TO CONVERT INTO MULTIPLY BY bars Pounds/sq in (PSI) 14.5 centimeters inches 0.3937 cubic centimeters cubic inches 0.06102 cubic feet cubic centimeters 28,320.0 cubic feet cubic inches 1,728.0 cubic feet cubic meters 0.02832 cubic inches...

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