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Copyright © 2014 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.
Oshkosh Corporation Classification: Unrestricted
IMT Electric Cranes
Operation & Safety
Manual # 99904381
IOWA MOLD TOOLING CO., INC.
Tel: 641-923-3711
Website: http://www.imt.com
Revised 20180530
PO Box 189
Garner, IA 50438
FAX: 641-923-2424
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Table of Contents
Troubleshooting
Related Manuals for IMT 2003i
Summary of Contents for IMT 2003i
- Page 1 Oshkosh Corporation Classification: Unrestricted Manual # 99904381 IMT Electric Cranes Operation & Safety Revised 20180530 IOWA MOLD TOOLING CO., INC. PO Box 189 Garner, IA 50438 Tel: 641-923-3711 FAX: 641-923-2424 Website: http://www.imt.com Copyright © 2014 Iowa Mold Tooling Co., Inc.
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Page 3: Table Of Contents
Holding Valves ............................24 Double & Single Line ..........................25 Operation Electric Crane Start-up and Task Performance ................... 27 IMT Electric Crane Controls ........................29 Tethered Remote Handle Operating Instructions ................29 Radio Remote Controls ........................30 Proportional Remote Controls ......................31... - Page 4 Oshkosh Corporation Classification: Unrestricted Contents Crane Shut Down ............................33 Operation in Poor Conditions ........................33 Hand Signals ............................... 34 Maintenance & Repair Maintenance Introduction ........................... 38 Electric Crane Power Safety ........................38 Maintenance Schedule ..........................39 Electric Crane Lubrication .......................... 39 Grease Zerks ...............................
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Page 5: Revisions
Oshkosh Corporation Classification: Unrestricted Contents Revisions DATE LOCATION DESCRIPTION 20090417 Maintenance Added Wire Rope Lay description. Stability Test Added instructions for completing stability test. 20090521 Crane Decals Revised decal placement drawing to general decals for all models. 20111121 ECN 11628 - Revised wording to stabilizers. Updated safety decals. 20120914 Updated stability test ECN 12264 –... - Page 6 Oshkosh Corporation Classification: Unrestricted Contents...
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Page 7: Introduction
Introduction GENERAL This manual will help you operate your IMT crane correctly and safely. The manual does not replace any government regulations, safety codes or insurance carrier requirements. Read and understand the manual and all safety procedures for this crane prior to operation. - Page 8 NOTICE TO THE OWNER / USER If the crane 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 Technical Support IOWA MOLD TOOLING CO., INC.
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Page 9: Crane Models & Features
Oshkosh Corporation Classification: Unrestricted Chapter 1 Introduction Crane Models & Features VERSIONS & OPTIONS This manual includes information regarding the following IMT crane models: ▪ 2003i with Short Mast or Tall Mast ▪ 3203i with 1 Hydraulic & 1 Manual Extension; 2 Manual Extensions; 1 Hydraulic Extension;... -
Page 10: Crane Identification
Oshkosh Corporation Classification: Unrestricted IMT Electric Cranes Operation & Safety Manual # 99904381 Crane Identification Every IMT crane has an identification placard (see figure). SERIAL NUMBER PLACARD PLACARD DESCRIPTION CONTENTS Model Number Crane model number. IOW A MOLD TOOLING CO., INC. -
Page 11: Safety
Oshkosh Corporation Classification: Unrestricted H A P T E R Safety In This Chapter Safety Instructions ..............10 Daily Safety Inspection ............. 12 Electrical Hazards ..............13 Crane Capacity ................ 16 Electric Crane Danger Decal Placement ........17 Work Site Planning ..............19 Stabilizer Operation .............. -
Page 12: Safety Instructions
Oshkosh Corporation Classification: Unrestricted IMT Electric Cranes Operation & Safety Manual # 99904381 Safety Instructions WARNING Keep children, by-standers, and persons not required in the operation of equipment at least 10’-0” (3.05 m) from the outermost range of the crane. - Page 13 Do NOT permit the lower load block or hook assembly to contact the upper load block or boom point sheave assembly. This is two blocking. IMT telescoping cranes with a winch are equipped with an anti-two blocking device, but the crane operator must avoid two-blocking and must not rely on the device alone.
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Page 14: Daily Safety Inspection
Daily Safety Inspection Use the Crane Log, IMT Manual No. 99900686, the inspection checklist in the reference section of this manual, or the following list when inspecting your unit at start-up and during operation: 1 Vehicle - Check oil level, battery, lights, brakes, and tires for inflation, pressure, cuts, and loose or missing wheel lugs. -
Page 15: Electrical Hazards
Oshkosh Corporation Classification: Unrestricted Chapter 2 Safety Electrical Hazards DANGER ELECTROCUTION HAZARD ▪ Vehicle is not insulated. ▪ Do NOT raise boom into power lines. ▪ Look up and use light to search for power lines in the dark. ▪ Keep boom and vehicle a minimum of 20 ft. - Page 16 Oshkosh Corporation Classification: Unrestricted IMT Electric Cranes Operation & Safety Manual # 99904381 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.
- Page 17 Oshkosh Corporation Classification: Unrestricted Chapter 2 Safety ▪ When using rope to steady a load or restrain spinning of the load, be aware that rope will also conduct electricity, especially if wet or damp. ▪ Reduce operating speed when in close proximity to powerlines in order to allow the operator more reaction time.
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Page 18: Crane Capacity
IMT Electric Cranes Operation & Safety Manual # 99904381 Crane Capacity The IMT crane is designed to lift specific loads. These loads are defined on the capacity placard mounted near the operator’s station and on the crane. Exceeding the limits presented on the capacity placard will create severe safety hazards and will shorten the life of the crane. -
Page 19: Electric Crane Danger Decal Placement
Oshkosh Corporation Classification: Unrestricted Chapter 2 Safety Electric Crane Danger Decal Placement... - Page 20 Oshkosh Corporation Classification: Unrestricted IMT Electric Cranes Operation & Safety Manual # 99904381 Additional danger decals are applied inside the truck body door. These decals include the following. Electrocution Hazard Crane and remote control are not insulated. Death or serious injury will result from approaching or contacting a power line.
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Page 21: Work Site Planning
Oshkosh Corporation Classification: Unrestricted Chapter 2 Safety Work Site Planning NO OVERHEAD OBSTRUCTIONS. NO POWERLINES PARKING BRAKE "ON." TRANSMISSION LOAD DOES IN NEUTRAL. NOT EXCEED CRANE CAPACITY. STABILIZERS A RE FULLY OUT AND DOWN ON A FIRM AND LEVEL SURFACE. Lift safety depends on work site preparation. -
Page 22: Stabilizer Operation
Oshkosh Corporation Classification: Unrestricted IMT Electric Cranes Operation & Safety Manual # 99904381 Use a qualified signal person or spotter when working near electrical sources, even if the powerline has been de-energized. Stabilizer Operation Stabilizers help stabilize the crane and carrier vehicle during a lift, but they can be hazardous due to their close proximity to the operator and other personnel. -
Page 23: Ground Support
Oshkosh Corporation Classification: Unrestricted Chapter 2 Safety There are various stabilizer designs available, but all require extreme caution in their use. See figures for proper stabilizer operation sequence and warnings. BACK OF TRUCK WARNING! STABILIZERS C AN PINCH, STRIKE, OR CRUSH OBJECTS OR PEOPLE. MAKE SURE THERE ARE NO OBSTRUCTIONS IN OR NEAR THE STABILIZER P ATH. -
Page 24: Winch Safety
Oshkosh Corporation Classification: Unrestricted IMT Electric Cranes Operation & Safety Manual # 99904381 Winch Safety 1 DO NOT pull the load block or sheave back so that it makes contact with the boom tip. This is two blocking and should be avoided. -
Page 25: Electric Crane Anti Two Block System
Oshkosh Corporation Classification: Unrestricted Chapter 2 Safety Electric Crane Anti Two Block System WARNING Any Anti Two Blocking System consists of a series of mechanical components and cannot be 100% fail safe. Do NO T use the Anti Two Block System as a substitute for good judgement, experience and accepted safe crane operating practices. -
Page 26: Holding Valves
Oshkosh Corporation Classification: Unrestricted IMT Electric Cranes Operation & Safety Manual # 99904381 If the anti two block function appears to be functioning normally, winch the cable down until the sensing weight swings free. Holding Valves The hydraulic cylinders have holding valves that prevent sudden movement of the cylinder rods in the event of a hydraulic hose or other hydraulic component failure. -
Page 27: Double & Single Line
Oshkosh Corporation Classification: Unrestricted Chapter 2 Safety Double & Single Line Your crane can be operated with two-part or single-part line. Single-part line gives you a longer load distance and faster line speed. If you require a longer load distance or a faster line speed, first check that you have the capacity to lift your load using single part line. -
Page 29: Operation
H A P T E R Operation In This Chapter Electric Crane Start-up and Task Performance ......27 IMT Electric Crane Controls ............. 29 Crane Shut Down ..............33 Operation in Poor Conditions............ 33 Hand Signals ................34 Electric Crane Start-up and Task Performance... - Page 30 3 Make sure the crane electric power switch, located in the crane remote storage cabinet, is turned to the "ON" position. 4 See the Electric Crane Controls (see "IMT Electric Crane Controls" on page 29) section for information on how to move a load using your controls.
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Page 31: Imt Electric Crane Controls
Oshkosh Corporation Classification: Unrestricted Chapter 3 Operation IMT Electric Crane Controls IMT's electric cranes are controlled by radio or tethered remote controls. This telescopic crane includes a tethered remote control with a radio remote control option. Tethered Remote Handle Operating Instructions... -
Page 32: Radio Remote Controls
Oshkosh Corporation Classification: Unrestricted IMT Electric Cranes Operation & Safety Manual # 99904381 8 Turn off power to the handset. NOTE Excessive or rapid “On/Off” cycling of the trigger assembly should be avoided, particularly if a function is engaged. This w ill cause premature aging or extensive damage to the power unit components. -
Page 33: Proportional Remote Controls
Oshkosh Corporation Classification: Unrestricted Chapter 3 Operation 6 Turn the crane electric power switch, located in the crane cabinet, to the "OFF" position. Emergency Stop Emergency Stop Button pressed "IN"- Button pulled "OUT"- Crane will not operate. Crane will operate. Proportional Remote Controls The electric crane proportional remote is factory-programmed with the functions shown in the following chart. - Page 34 Oshkosh Corporation Classification: Unrestricted IMT Electric Cranes Operation & Safety Manual # 99904381 WINCH WINCH UP (WINCH LINE WINCH DOWN (WINCH LINE RETRACTS) EXTENDS) LOWER BOOM DOWN (MOVES DOWN) UP (MOVES UP) To operate the crane using the radio remote: 1 Make sure the vehicle engine is on;...
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Page 35: Crane Shut Down
Oshkosh Corporation Classification: Unrestricted Chapter 3 Operation Crane Shut Down 1 Retract the extension boom (and cable if applicable). POWER SWITCH TURNED TO OFF 2 Stow the crane in its travel configuration. POSITION. 3 Secure the hook. 4 Stow the stabilizers. 5 Turn the crane power supply, located in the crane cabinet, to the OFF position. -
Page 36: Hand Signals
Oshkosh Corporation Classification: Unrestricted IMT Electric Cranes Operation & Safety Manual # 99904381 Hand Signals Hand signals can be used to communicate between crane operators and assistants when the job site noise level is too high to communicate in other ways. - Page 37 Oshkosh Corporation Classification: Unrestricted Chapter 3 Operation LOWER BOOM - With arm extended, EMERGENCY STOP- Both arms fingers closed, thumb pointing extended, palms down, move arms downward. back and forth horizontally. TRAVEL- Arm extended forward, HOIST- With forearm vertical, hand open and slightly raised, forefinger pointing up, move make pushing motion in direction hand in small horizontal circles.
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Page 39: Maintenance & Repair
Oshkosh Corporation Classification: Unrestricted H A P T E R Maintenance & Repair In This Chapter Maintenance Introduction ............38 Electric Crane Power Safety ............. 38 Maintenance Schedule ............. 39 Electric Crane Lubrication ............39 Grease Zerks ................40 Crane Hydraulic Oil Specifications ........... 40 Electric Crane Power Unit Components ........ -
Page 40: Maintenance Introduction
Oshkosh Corporation Classification: Unrestricted IMT Electric Cranes Operation & Safety Manual # 99904381 Maintenance Introduction Proper, regularly scheduled maintenance is essential in keeping your crane at peak operating efficiency. This section outlines maintenance information and service intervals which should be followed by maintenance personnel. -
Page 41: Maintenance Schedule
Every 6 months Purge hydraulic system and replace hydraulic oil and filter. or 800 hours Every year Complete all required annual inspections. (See IMT Inspection Checklist in the General Reference section of this manual.) Every 2 years Inspect pins. Electric Crane Lubrication Different lubricants are required for different sections of your crane. -
Page 42: Grease Zerks
Crane Hydraulic Oil Specifications Hydraulic Oil Specifications The hydraulic oil for your electric crane must be ISO VG32, low pour, anti-wear hydraulic oil. IMT recommends SAE oil based on the following temperature ranges: SAE DESIGNATION TEMPERATURE RANGE 5W-20 -10 to 180°... -
Page 43: Electric Crane Power Unit Components
Oshkosh Corporation Classification: Unrestricted Chapter 4 Maintenance & Repair Electric Crane Power Unit Components Your electric crane includes a power unit made up of a DC battery power source, motor, hydraulic pump, and hydraulic reservoir. POWER PACK CONFIGURATION & NOMENCLATURE Start Sw itch Fan Shroud D.C.Motor... - Page 44 Oshkosh Corporation Classification: Unrestricted IMT Electric Cranes Operation & Safety Manual # 99904381 ADAPTER / RESERVOIR CONFIGURATION Breather Cap Reservoir Relief Valve Adaptor Gear Pump Return Line Pipe, Relief Valve Cartridge Valve Check Valve Return Line Suction Line Pipe Pipe...
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Page 45: Power Unit Troubleshooting
Oshkosh Corporation Classification: Unrestricted Chapter 4 Maintenance & Repair Power Unit Troubleshooting CAUTION: AVOID MOTOR DAMAGE! The DC electric motor can overheat. Run for short periods to avoid overheating. The maximum pump working period depends on the pressure required, but working periods should never exceed 5 minutes followed by cool down to ambient temperature. -
Page 46: Purging Air From Hydraulic System
Oshkosh Corporation Classification: Unrestricted IMT Electric Cranes Operation & Safety Manual # 99904381 Purging Air from Hydraulic System Air trapped in the hydraulic cylinder will cause an erratic “bumpy” motion. To expel the air: 1 Hold the control open for a few seconds after the function has “bottomed out”. -
Page 47: Pin Removal & Inspection
Removing crane pins can cause crane sections to suddenly come apart. Pins are frequently used as structural components on IMT cranes. Critical structural pins which require inspection and repair include pins which secure the lower boom assembly to the mast,... -
Page 48: Electric Crane Wear Pads
Electric Crane Wear Pads IMT crane booms extend and retract on synthetic wear pads. The pads drop in place at the top or bottom of the inside of the booms, or snap in place into the sides of the booms. See figure for wear pad locations. -
Page 49: Wire Rope Inspection
Oshkosh Corporation Classification: Unrestricted Chapter 4 Maintenance & Repair 3 After the air has been purged from the system, check the reservoir oil level. Top off oil level if needed. Wire Rope Inspection OSHA requires regular inspections and permanent, signed record-keeping on wire rope inspections. -
Page 50: Wire Rope Lubrication
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 51 Oshkosh Corporation Classification: Unrestricted Chapter 4 Maintenance & Repair When flat spots on the outer wires appear and those outside wires are less than 2/3 the thickness of the unworn outer wire. d When there is a decrease of diameter indicating a core failure. When kinking, crushing, birdcaging or other distortion occurs.
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Page 52: Wire Rope Lay
Oshkosh Corporation Classification: Unrestricted IMT Electric Cranes Operation & Safety Manual # 99904381 Wire Rope Lay Wire rope “lay” indicates the directions strands lay in the rope - right or left. When you look down a rope, strands of a right lay rope go away from you to the right, like a right hand screw thread. - Page 53 Oshkosh Corporation Classification: Unrestricted Chapter 4 Maintenance & Repair BOOM & MAST ASSEMBLY 1 Check control valvebank and all other fittings for oil leaks and tightness. 2 Check all bolts and retainer plates on pin assemblies for proper installation. 3 Check torque on all unit mounting bolts. See the installation drawing in the crane parts manual for mounting bolt torque.
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Page 54: Excessive Load Limitation System
Excessive Load Limitation System Excessive Load Limitation System (ELLS) Testing Excessive Load Limit System (ELLS) used on the IMT Telescoping Crane models ensures the system is currently operable and will not allow the crane to be excessively overloaded. The purpose of the ELLS is to prohibit the excessive overloading of the crane. It does this by disarming the functions that make it possible for the operator to apply greater than allowable stress to the crane structure and components. -
Page 55: Ells Troubleshooting Procedure
Oshkosh Corporation Classification: Unrestricted Chapter 4 Maintenance & Repair 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 57: Stability Test
Oshkosh Corporation Classification: Unrestricted H A P T E R Stability Test In This Chapter Crane Stability ................55 Stability Chart ................58... -
Page 58: Crane Stability
Every IMT factory-installed crane includes a completed stability chart. Any installer other than IMT also has the responsibility to complete a stability chart. Cranes are tested for stability to 85% of “tipping” based on the balance point for a specific truck and crane combination. The Stability Test is per SAE J765a. - Page 59 If either the truck or crane is changed or modified, the stability calculations must be repeated. 2 Contact IMT if you need a modified stability chart for your vehicle. 3 Rotate the crane at least 5 times using the completed figures to ensure the rating is accurate.
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Page 60: Stability Chart
Oshkosh Corporation Classification: Unrestricted IMT Electric Cranes Operation & Safety Manual # 99904381 Stability Chart TRUCK AREA 10 AREA 5 AREA 9 AREA 4 AREA 8 AREA 3 AREA 7 AREA 2 AREA 6 AREA 1 Figure 1: Crane Stability Chart...