Table of Contents
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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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Table of Contents
Troubleshooting
Related Manuals for IMT 3820
Summarization of Contents
Section 0: Introduction
General Crane Operation Information
Information for safe and proper operation of the crane.
Owner Responsibilities
Owner's responsibility for informing personnel about safe operation.
Accident Reporting Procedure
Procedure for reporting property damage or personal injury accidents.
Revisions List
List of changes and updates made to the manual.
Section 1: Operation
General Operation and Safety
Crane operation requires compliance with qualifications and understanding of safety.
Daily Safety Inspections
Daily, weekly, and monthly inspections of crane components.
Work Site Preparation
Importance of preparing work site for safe crane operation.
Electrical Hazards
Avoiding the "DANGER ZONE" around power lines.
Section 1: Operation - Controls and Capacity
Crane Controls Overview
General guidance on operating crane controls and remote systems.
Radio Remote Controls Operation
Operation of radio remote controls, including emergency stop.
Tethered Remote Controls Operation
Operating procedures for tethered remote controls.
Electric Cranes Operation
Operation of electric cranes using tethered remote controls.
Section 1: Operation - Load Limits and Safety
Crane Capacity and Load Limits
Importance of knowing load capacities and weight of lifted items.
Reduced Capacity (RCLC) System
Explanation of the Reduced Capacity Lift Chart system for side operation.
Capacity Alert System
How the capacity alert system prevents lifting over rated capacity.
Section 1: Operation - Systems and Procedures
Anti Two-Blocking System
Function and daily checks of the anti two-blocking system.
Task Performance
Step-by-step procedure for operating the crane.
Troubleshooting Crane Operation Problems
Common crane problems and their probable solutions.
Crane Operator Qualifications
Qualifications and requirements for crane operators.
Section 1: Operation - Shutdown and Conditions
Crane Shutdown Procedure
Procedures for safely shutting down and stowing the crane.
Operation in Adverse Conditions
Precautions for operating in challenging environmental conditions.
Cold Weather Operation
Procedures for cold weather operation, including warm-up.
Hand Signals for Crane Operation
Standard hand signals for crane operation communication.
Section 1: Operation - Safety Notes
Important Notes for Safe Operation
Crucial safety reminders for operating the crane.
Fire Precautions
Precautions to prevent fires and fire extinguisher requirements.
Section 2: Maintenance - General and Schedule
General Maintenance Guidelines
Importance of preventive maintenance and safety precautions.
Maintenance Schedule Overview
Schedule for weekly, monthly, quarterly, and annual maintenance tasks.
Lubrication Procedures
Lubricant specifications and intervals for various crane components.
Lubrication Points Identification
Weekly lubrication requirements for grease zerks and worm gears.
Section 2: Maintenance - Hydraulic System
Hydraulic Oil Specifications
Specifications for high-quality antiwear hydraulic oil.
Hydraulic Fluid Level Check
Procedure for checking and maintaining the hydraulic fluid level.
Changing Hydraulic Oil
Procedure for changing hydraulic oil and purging the system.
Hydraulic Filter Replacement
Schedule and procedure for replacing hydraulic filters.
Section 2: Maintenance - Wire Rope and Hooks
Wire Rope Inspection Requirements
OSHA requirements for wire rope inspection and record-keeping.
Wire Rope Lubrication
Lubrication method for wire rope using open gear lubricant.
Wire Rope Sling Inspection
Rated load factors and inspection of wire rope slings.
Hook and Latch Maintenance
Weekly lubrication and inspection of hooks and latches.
Section 2: Maintenance - Vehicle and Systems
Periodic Vehicle Inspection
Importance of inspecting the carrier vehicle per manufacturer recommendations.
Periodic Crane Inspection
Using the inspection checklist for safe crane operation.
Corrosion Control Procedures
Using Cortex VCI-389 and washing procedures for corrosion prevention.
Long Term Storage Maintenance
Maintaining the crane during long-term storage.
Section 2: Maintenance - Specialized Systems
Excessive Load Limit System (ELLS) Test Procedure
Procedure to test the Excessive Load Limit System (ELLS).
ELLS Troubleshooting Procedure
Step-by-step troubleshooting for the ELLS system.
Winch Troubleshooting Guide
Common winch problems and their probable cures.
Section 3: Repair - General and Hydraulic
General Repair Information
General information and precautions for crane repair.
Repair Precautions
General precautions to take before starting crane repairs.
Systematic Repair Procedure
A systematic approach to diagnosing and repairing crane issues.
Hydraulic System Cleanliness
Precautions for maintaining a clean hydraulic system.
Section 3: Repair - Rotation and Pins
Pinion, Drive Gear Bushing Removal/Replacement
Procedures for removing and replacing pinion and drive gear bushings.
Critical Structural Pins Inspection
Inspection and removal of critical structural pins.
Bearings and Bushings Types
Types of bearings and bushings used on crane models.
Bearing Inspection and Replacement
Inspecting and replacing crane bearings and bushings.
Section 3: Repair - Valvebank
Valvebank Components Description
Description of valvebank components and their functions.
Hydraulic Relief Valve Function
Function and replacement of the hydraulic relief valve.
Proportional Valve Operation
How proportional valves control crane function speed.
Directional Valves Operation
How directional valves control crane function direction.
Section 3: Repair - Cylinders and Boom
Lower Cylinder Removal and Replacement
Procedure for replacing the lower hydraulic cylinder.
External Extension Cylinder Replacement
Replacing external extension cylinders on specific models.
Internal Cylinder Removal and Replacement
Procedure for removing and replacing internal cylinders.
Lower Boom Removal and Replacement
Procedure for removing and replacing the lower boom.
Section 3A: Cylinder Repair - Disassembly
Cylinder Disassembly Instructions
Instructions for disassembling inner, outer, extension, and stabilizer cylinders.
Cylinder Assembly Steps
Steps for assembling cylinder components.
Typical Cylinder and Seal Kit Components
Diagram identifying typical cylinder and seal kit parts.
Seal Installation Guidelines
Guidelines for proper installation of cylinder seals.
Section 3A: Cylinder Repair - Assembly and Torque
Cylinder Assembly Procedure
Steps for assembling cylinder components.
Piston Torque Chart
Torque specifications for tightening the piston onto the rod.
Head Torque Chart
Torque specifications for tightening the cylinder head.
Spanner Wrench Attachment Part Numbers
Part numbers for spanner wrench attachments used for torquing.
Section 4: Installation - General and PTO
General Installation Guidance
Guidance for preparing truck chassis for hydraulic crane installation.
Chassis Preparation Steps
Steps for preparing the truck chassis before crane installation.
PTO Installation Procedure
Procedures for installing the Power Take Off (PTO).
Pump Installation Procedure
Steps for installing the hydraulic pump and adapters.
Section 4: Installation - Driveline and Engine
Driveline Application Considerations
Factors to consider when selecting and installing auxiliary driveshafts.
Driveshaft Installation Guidelines
Safety guidelines for installing driveshafts.
Engine Speed Regulation
Determining required engine RPM for proper pump speed and crane performance.
Chassis Information for Crane Installation
Chassis requirements for IMT cranes, including RBM.
Section 4: Installation - Model Specific (1015-3820)
Model 1015 Crane Installation
Chassis specifications and installation steps for the Model 1015 crane.
Model 2020 Crane Installation
Chassis specifications and installation steps for the Model 2020 crane.
Model 3020 Crane Installation
Chassis specifications and installation steps for the Model 3020 crane.
Model 3820 Crane Installation
Chassis specifications and installation steps for the Model 3820 crane.
Section 4: Installation - Model Specific (5020-7025)
Model 5020 Crane Installation
Chassis specifications and installation steps for the Model 5020 crane.
Model 6020 Crane Installation
Chassis specifications and installation steps for the Model 6020 crane.
Models 5525, 6025, and 6625 Installation
Chassis specifications and installation steps for Models 5525, 6025, 6625.
Mounting Layout and Installation Drawings (5525-6625)
Diagrams for mounting hole layout and crane installation for specific models.
Section 4: Installation - Hydraulic and Electrical
Hydraulic Installation for Multiple Models
Hydraulic component installation for various crane models.
Model 7020 Crane Installation
Chassis specifications and installation steps for the Model 7020 crane.
Model 7025 Crane Installation
Chassis specifications and installation steps for the Model 7025 crane.
Hydraulic & Electrical Installation (7020 & 7025)
Hydraulic and electrical installation for Models 7020 & 7025.
Section 5: Decals - Placement and Danger
Decal Placement on Telescoping Cranes
Common placement of decals on telescoping cranes.
Danger Decal Descriptions
Descriptions of danger decals and their functions.
Instructional Decal Descriptions
Descriptions of instructional decals for maintenance and operation.
Crane Operation Hazard Decals
Hazard warnings for operation, including electrocution and falling loads.
Section 5: Decals - Specific Hazards and Lubrication
Electrocution Hazard Decals
Hazard warnings for proximity to electrical lines and remote control safety.
Riding Hazard Decals
Warnings against riding on crane components, which can cause injury or death.
Stabilizer Foot Crushing Hazard Decals
Hazard warnings for stabilizer operation, including crushing risks.
Worm Drive Bearing Lubrication Decal
Reminder for periodic lubrication of worm drive bearings.
Section 5: Decals - Contact and Fluid Information
Contact IMT Decal
Contact information for IMT for service, repair, and safety questions.
Hydraulic Return Line Decal
Identifies the hydraulic system return line for maintenance.
Hydraulic Suction Line Decal
Identifies the hydraulic system suction line for maintenance.
Rotate While Greasing Decal
Informs about the need to lubricate the rotation gear weekly.
Section 6: Reference - Inspection and Capacity
Inspection Checklist
A checklist for performing regular crane inspections.
Crane Capacity and Stability
Information on crane capacity and stability factors.
Understanding the Capacity Placard
How to read and interpret crane capacity placards.
Stability Test Procedure
Procedure for conducting a crane stability test.
Section 6: Reference - Documentation and Charts
Crane Inspection Checklist Details
Checklist for daily, monthly, quarterly, and annual crane inspections.
Inspection Checklist Key
Key for understanding inspection checklist frequency and status codes.
Deficiency/Recommendation/Corrective Action Report
Form for documenting deficiencies, recommendations, and corrective actions.
Torque Data Chart - Domestic
Torque values for fine and coarse thread bolts (domestic).
Section 6: Reference - Stability and Conversions
Crane Capacity and Stability Factors
Factors affecting crane capacity and stability.
Understanding the Capacity Placard
How to read and interpret crane capacity placards.
Lifting in Derated Load Capacity Zones
Procedures for lifting loads within derated capacity zones.
Torque Data Chart - Metric
Torque values for fine and coarse thread bolts (metric).
Section 6: Reference - Bearing and Terminology
Turntable Bearing Fastener Tightening Sequence
Sequence for tightening turntable bearing fasteners.
Turntable Bearing Inspection
How to inspect turntable bearings for wear or damage.
Direction Terminology for Crane Operation
Terms used to describe crane operation directions.
Conversion Factors Table
Table of common conversion factors for measurements.
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