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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Summarization of Contents
SECTION 0: INTRODUCTION
GENERAL
Information for safe and proper crane operation. Not intended to replace regulations.
OWNER RESPONSIBILITIES
Owner's role in informing personnel about safe operation and maintenance.
NOTICE TO THE OWNER / USER
Procedure for reporting property damage or personal injury accidents.
REVISIONS LIST
List of changes made to the manual over time.
SECTION 1: OPERATION
1-1: GENERAL
General information on operating a crane according to standards.
1-2: DAILY SAFETY INSPECTIONS
Procedures for daily checks to ensure safe operation and equipment integrity.
1-3: WORK SITE PREPARATION
Importance of preparing the environment for safe crane operation.
1-3-1: ELECTRICAL HAZARDS
Details on identifying and avoiding hazards associated with electrical powerlines.
1-3-2: WORK STATION POSITIONING
Guidelines for parking the crane unit on firm, level ground and avoiding obstructions.
1-3-3: OUTRIGGERS
Safety precautions and procedures for deploying outriggers for stable operation.
1-4: STARTING CRANE OPERATION
Steps for safely starting the crane by engaging the PTO and warming up the engine.
1-4-1: ENGAGING THE POWER TAKE OFF (PTO)
Detailed instructions for engaging the PTO for both automatic and manual transmissions.
1-4-2: DISENGAGING THE PTO
Procedure for safely disengaging the PTO before moving the vehicle.
1-5: ROTATOR WORM GEAR BREAK-IN
Procedure for breaking in the rotator worm gear to ensure proper performance and longevity.
1-6: CRANE CONTROLS
General information on crane controls, including radio and tethered remote operation.
1-6-1: RADIO REMOTE CONTROLS
Operation of radio remote controls for boom extension, rotation, winch, and engine speed.
1-6-2: CHANGING THE BATTERY IN THE RADIO REMOTE CONTROL
Steps for accessing and replacing the battery in the radio remote handset.
1-6-3: RADIO REMOTE BACKUP HAND SET
Information on using the tethered backup handset when the radio remote fails.
1-6-4: TETHERED REMOTE CONTROLS
Instructions for operating tethered remote controls, similar to radio controls.
1-6-5: ELECTRIC CRANES
Operation of electric cranes, which use tethered remotes similar to hydraulic cranes.
1-7: CRANE CAPACITY AND LOAD LIMITS
Importance of understanding and adhering to crane capacity placards to prevent hazards.
1-7-1: REDUCED CAPACITY (RCLC)
Explanation of reduced capacity lift charts and their color-coding system.
1-8: CRANE CAPACITY ALERT SYSTEM (ELECTRICALLY OPERATED)
Description of the capacity alert system designed to prevent overloading.
1-9: ANTI TWO BLOCKING SYSTEM
Explanation of the anti two-blocking system and daily checks for its operation.
1-10: CHANGING FROM DOUBLE TO SINGLE-PART LINE
Steps for converting the crane from double-part line to single-part line configuration.
1-11: TASK PERFORMANCE
Step-by-step procedure for operating the crane for various tasks.
1-11-1: TROUBLESHOOTING
Common crane problems, their causes, and suggested resolutions.
1-12: CRANE SHUTDOWN
Procedure for safely shutting down the crane and securing it for transport.
1-13: OPERATORS
Qualifications and requirements for crane operators as defined by OSHA and other regulations.
1-14: OPERATION IN ADVERSE CONDITIONS
Procedures for operating the crane in various challenging environmental conditions.
1-14-1: DUSTY AND SANDY AREAS
Specific maintenance and operational advice for dusty or sandy environments.
1-14-2: HIGH HUMIDITY OR SALT AIR CONDITIONS
Recommendations for protecting the crane in high humidity or salt air conditions.
1-14-3: HIGH ALTITUDE
Considerations for operating the crane at high altitudes.
1-14-4: COLD WEATHER
Procedures for operating and warming up the crane in cold weather conditions.
1-15: HAND SIGNALS
Standard hand signals for crane operation communication between operator and signal person.
IMPORTANT! NOTES FOR SAFE OPERATION
Key safety reminders covering anti-two-blocking, extension sequence, crane operation, and overload systems.
FIRE PRECAUTIONS
Safety measures to prevent fires, including refueling and fire extinguisher requirements.
SECTION 2: MAINTENANCE
2-1: GENERAL
General advice for obtaining reliable service and performing maintenance safely.
2-2: MAINTENANCE SCHEDULE
A chart outlining lubrication and inspection schedules based on time intervals.
2-3: LUBRICATION
Information on different lubricants required for crane sections and product specifications.
2-4: LUBRICATION POINTS
Guidance on weekly greasing of zerks and worm gear lubrication.
2-5: HYDRAULIC SYSTEM
Information on hydraulic oil specifications, fluid level, and deterioration.
2-5-1: HYDRAULIC OIL SPECIFICATIONS
Details on required hydraulic oil quality, antiwear properties, and viscosity specifications.
2-5-2: LOW TEMPERATURE HYDRAULIC OIL SPECIFICATIONS
Specifications for hydraulic oil suitable for use in temperatures below -25°F.
2-5-3: HYDRAULIC FLUID LEVEL
Procedure for checking and maintaining the hydraulic oil reservoir level.
2-5-4: HYDRAULIC FLUID DETERIORATION
Methods for identifying hydraulic oil deterioration and recommended replacement intervals.
2-5-5: CHANGING HYDRAULIC OIL
Step-by-step procedure for changing hydraulic oil and purging the system.
2-5-6: PURGING AIR FROM THE HYDRAULIC SYSTEM
Procedure to expel trapped air from the hydraulic cylinder for smooth operation.
2-5-7: HYDRAULIC PRESSURE RELIEF
Explanation of the hydraulic system relief valve and safety precautions.
2-5-8: HYDRAULIC CYLINDER HOLDING CAPABILITIES
Information on holding valves that prevent sudden cylinder movement during component failure.
2-5-9: HYDRAULIC FILTER REPLACEMENT
Schedule and procedure for replacing hydraulic oil filters to maintain system cleanliness.
2-5-10: HYDRAULIC SYSTEM TROUBLESHOOTING
Common hydraulic system issues related to oil viscosity and their effects.
2-6: WIRE ROPE & HOOK MAINTENANCE
Guidelines for maintaining wire rope and hooks to ensure safe lifting operations.
2-6-1: WIRE ROPE INSPECTION
Requirements and methods for inspecting wire rope for safety and serviceability.
2-6-2: WIRE ROPE LUBRICATION
Instructions for lubricating wire rope to protect it from wear and corrosion.
2-6-3: WIRE ROPE MAINTENANCE
General maintenance requirements for wire rope, including repair or replacement.
2-6-4: WIRE ROPE REPLACEMENT
Conditions under which wire rope must be replaced, with visual examples.
2-6-5: WIRE ROPE SLINGS
Information on wire rope sling rated loads, proper usage, and inspection criteria.
2-6-6: WIRE ROPE LAY
Explanation of wire rope lay direction and its importance for winch spooling.
2-6-7: HOOK & LATCH MAINTENANCE
Maintenance requirements for swivel hooks, including lubrication and latch inspection.
2-7: PERIODIC VEHICLE INSPECTION
Importance of maintaining the carrier vehicle's safe operating condition.
2-8: PERIODIC CRANE INSPECTION
Guidance on using the inspection checklist for maintaining safe crane operation.
2-9: ADDITIONAL INSPECTIONS
Specific inspections required every three months or more frequently under heavy use.
2-10: TETHERED REMOTE CONTROL INSPECTION
Procedures for checking tethered remote controls for corrosion and functionality.
2-11: CORROSION CONTROL
Methods for preventing and addressing corrosion on crane metal surfaces and components.
2-12: LONG TERM STORAGE
Recommendations for storing the crane to prolong component life and prevent deterioration.
2-13: CHEMICAL SAFETY
Safety precautions and information for handling cleaning and lubricating chemicals.
2-14: EXCESSIVE LOAD LIMIT SYSTEM (ELLS) TEST PROCEDURE
Procedure for testing the ELLS to ensure it prohibits excessive overloading.
2-15: ELLS TROUBLESHOOTING PROCEDURE
Step-by-step guide for troubleshooting the ELLS by identifying component issues.
2-16: WINCH TROUBLESHOOTING
Common winch problems, their possible causes, and recommended cures.
SECTION 3: REPAIR
3-1: GENERAL
General information to help service and repair IMT telescopic cranes safely.
3-2: REPAIR PRECAUTIONS
Safety precautions to be taken before starting repairs to ensure safe operation.
3-3: SYSTEMATIC REPAIR PROCEDURE
A logical approach to diagnosing and correcting problems, including consulting support.
3-4: CLEANLINESS
Importance of keeping working parts clean to preserve crane life and prevent damage.
3-5: HYDRAULIC SYSTEM
Precautions for working on the hydraulic system to prevent contamination and component damage.
3-7: CRANE BASE REMOVAL AND REPLACEMENT
Procedure for removing and replacing the crane base assembly.
3-8: WORM DRIVE WINCH
Information on worm drive winches, including oil requirements and removal procedures.
3-8-1: REMOVING THE WORM DRIVE WINCH
Step-by-step instructions for removing and reinstalling the worm drive winch.
3-8-2: PLANETARY WINCH (MODELS 6025 AND 6625)
Details on planetary winches used in specific models, including oil change intervals.
3-9: CRANE ROTATION SYSTEM
Overview of crane rotation systems and how to identify the applicable type for a model.
3-9-1: REMOVING THE CRANE ROTATION SYSTEM
Procedure for safely removing the crane rotation system.
3-9-2: SETTING BACKLASH - IMT BASE & WORM DRIVE (1007, 1015, 2020)
Instructions for setting backlash on specific IMT base and worm drive rotation systems.
3-9-3: WORM END PLAY & BACKLASH - INTEGRAL BASE & WORM DRIVE (3020, 3820, 5020, 5525, 6025, 6625)
Procedure for setting worm end play and backlash on integral base systems.
3-9-4: TURNTABLE GEAR REMOVAL & REPLACEMENT (7020 & 7025)
Procedure for removing and replacing the turntable gear assembly on specific crane models.
3-9-5: PINION, DRIVE GEAR BUSHING REMOVAL & REPLACEMENT (7020, 7025)
Instructions for removing and replacing pinion and drive gear bushings in the crane base.
3-9-6: ROTATION MOTOR AND C’BAL VALVE REMOVAL AND REPLACEMENT (7020, 7025)
Procedure for removing and replacing the rotation motor and counterbalance valve.
3-10: WEAR PADS
Information on wear pads, when to replace them, and their locations on the boom.
3-11: PINS
Importance of pins as structural components, inspection criteria, and removal procedures.
3-12: BEARINGS & BUSHINGS
Information on bearing types, locations, and inspection/replacement procedures.
3-12-1: BEARING TYPES
Description of roller bearings and bushings used in different crane models.
3-12-2: BEARING INSPECTION & REPLACEMENT
Procedures for inspecting bearings and bushings for wear and damage.
3-13: VALVEBANK
Overview of valvebank components and their operating characteristics.
3-13-1: VALVEBANK COMPONENTS
Description of electrical-amp driver, PMW% LED, and MIN potentiometer functions.
RELIEF VALVE
Function of the relief valve in limiting system pressure and preventing damage.
PROPORTIONAL VALVE
How proportional valves control oil flow and function to dictate crane speed.
DIRECTIONAL VALVES
Role of directional valves in controlling crane function direction and manual override.
3-13-2: VALVEBANK TROUBLESHOOTING
Steps for troubleshooting valvebank issues, including coil operation and foreign material.
3-13-3: SINGLE VALVE REPLACEMENT
Procedure for replacing a single valve within the valvebank.
3-13-4: VALVEBANK REMOVAL AND REPLACEMENT
Instructions for removing and reinstalling the entire valvebank assembly.
3-14: LOWER CYLINDER REMOVAL & REPLACEMENT
Procedure for replacing the lower cylinder if it leaks, is bent, or damaged.
3-15: EXTERNAL EXTENSION CYLINDER-REMOVAL AND REPLACEMENT
Steps for removing and installing external extension cylinders on specific models.
3-16: INTERNAL CYLINDER REMOVAL AND REPLACEMENT
Procedure for removing and replacing internal cylinders, including specific model considerations.
3-17: LOWER BOOM REMOVAL AND REPLACEMENT
Procedure for safely removing and replacing the lower boom assembly.
3-18: WIRE ROPE REMOVAL/REPLACEMENT
Steps for removing and replacing wire rope as defined in maintenance guidelines.
SECTION 3A. CYLINDER REPAIR
TOOLS REQUIRED
List of essential tools needed for cylinder disassembly and repair.
3A-1. CYLINDER DISASSEMBLY
Step-by-step instructions for disassembling inner, outer, extension, and stabilizer cylinders.
SEAL INSTALLATION GUIDELINES
Guidelines for proper installation of seals to ensure maximum sealing capability.
3A-2. CYLINDER ASSEMBLY
Step-by-step procedure for assembling cylinder components, including seals and wear rings.
APPENDIX: PISTON & HEAD SPANNER WRENCH ATTACHMENT PART NUMBERS
Part numbers for spanner wrench attachments required for torqueing cylinder heads and pistons.
SECTION 4: INSTALLATION
4-1: GENERAL
General information on preparing the truck chassis for mounting an IMT crane.
4-2: CHASSIS PREPARATION
Steps for preparing the truck chassis, including clearing obstructions and installing PTO/pump.
4-2-1: FRAME STRENGTH
Importance of selecting and potentially reinforcing the truck frame for crane loads.
4-3: PTO AND PUMP
Information on PTO and pump installation, including selection criteria.
4-3-1: PTO INSTALLATION
Introduction to PTO installation, requiring knowledge of vehicle transmission and crane requirements.
4-3-2: PUMP INSTALLATION
Procedure for installing the hydraulic pump, including checking rotation and fittings.
4-3-3: DRIVELINE APPLICATION
Guidelines for selecting and installing auxiliary driveshafts when direct pump/PTO mounting is not feasible.
4-4: ENGINE SPEED REGULATION
How engine speed affects pump delivery rate and crane operating speed.
4.5 MODEL SPECIFIC CRANE & HYDRAULIC INSTALLATION GUIDES
General guide for installing specific IMT crane models and their hydraulic components.
4.5.1 GENERAL
General guidance for model-specific installations, noting component customization.
4.5.2 CHASSIS INFORMATION
Requirements for truck chassis compatibility, including body style and frame strength.
4.6 MODEL 1015 CRANE INSTALLATION
Specific installation details for the Model 1015 crane, including chassis specs and mounting.
4.7 MODEL 2020 CRANE INSTALLATION
Specific installation details for the Model 2020 crane, including chassis specs and mounting.
4.8 MODEL 3020 CRANE INSTALLATION
Specific installation details for the Model 3020 crane, including chassis specs and mounting.
4.9 MODEL 3820 CRANE INSTALLATION
Specific installation details for the Model 3820 crane, including chassis specs and mounting.
4.10 MODEL 5020 CRANE INSTALLATION
Specific installation details for the Model 5020 crane, including chassis specs and mounting.
4.11 MODEL 6020 CRANE INSTALLATION
Specific installation details for the Model 6020 crane, including chassis specs and mounting.
4.12 MODELS 5525, 6025, AND 6625 CRANE INSTALLATION
Specific installation details for Models 5525, 6025, and 6625 cranes.
4.13 HYDRAULIC INSTALLATION - MODELS 3020, 3820, 5020, 5525, 6020, 6025, 6625
General guidance for hydraulic installation for specific crane models.
4.14 MODEL 7020 CRANE INSTALLATION
Specific installation details for the Model 7020 crane, including chassis specs and mounting.
4.15 MODEL 7025 CRANE INSTALLATION
Specific installation details for the Model 7025 crane, including chassis specs and mounting.
4.16 HYDRAULIC & ELECTRICAL INSTALLATION - MODELS 7020 & 7025
Procedures for hydraulic and electrical installation for Models 7020 and 7025.
SECTION 5: DECALS
5-1. DECAL PLACEMENT-TELESCOPING CRANES
Illustration of common decal placement on telescoping cranes.
5-2. “DANGER” DECAL DESCRIPTIONS
Descriptions and functions of critical "DANGER" decals for hazard awareness.
5-3. INSTRUCTIONAL DECAL DESCRIPTIONS
Explanations of instructional decals related to maintenance and operation.
SECTION 6: REFERENCE
INSPECTION CHECKLIST
Forms and procedures for conducting daily, monthly, quarterly, and annual crane inspections.
CRANE CAPACITY & STABILITY
How crane capacity is defined and factors affecting stability.
UNDERSTANDING THE CAPACITY PLACARD
Explanation of information provided on a sample crane capacity placard.
STABILITY TEST
Procedure for performing a stability test to determine safe load limits at various positions.
TORQUE DATA CHART - DOMESTIC
Torque values for various fine and coarse thread bolts in foot-pounds.
TORQUE DATA CHART - METRIC
Torque values for various fine and coarse thread bolts in kilogram-meters.
TURNTABLE BEARING FASTENER TIGHTENING SEQUENCE
Diagram and procedure for torquing turntable bearing fasteners in the correct sequence.
TURNTABLE BEARING INSPECTION FOR REPLACEMENT
Conditions indicating bearing wear and a comparison chart for tilt dimension measurements.
DIRECTION TERMINOLOGY
Various terms used to describe directions associated with crane operation.
CONVERSION FACTORS
Table of common units and their conversion factors for calculations.
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