Volume 1 - Operation, Maintenance & Repair

VOLUME1:99900037:20140915iVOLUME 1OPERATION, MAINTENANCE AND REPAIRIOWA MOLD TOOLING CO., INC.BOX 189, GARNER, IA 50438-0189TEL: 641-923-3711TECHNICAL SUPPORT FAX: 641-923-2424MANUAL PART NUMBER 99900037Iowa Mold Tooling Co., Inc. is an Oshkosh Corporation company.

VOLUME1:99900037:19960517iiINTRODUCTIONThis volume includes information that is common to allcranes and loaders manufactured by IMT. For specificinformation, refer to Volume 2, PARTS ANDSPECIFICATIONS. Volume 2 contains information onSpecifications, Crane Description, Installation and Partswhich is specific to your model of crane. It isrecommended that Volume 1, OPERATION,MAINTENANCE AND REPAIR be kept with the crane atall times.This manual is provided to aquaint you with the operationof your IMT truck-mounted, hydraulic operated crane andto supply you with information necessary for properequipment maintenance.NOTEA NOTE IS USED TO EITHER CONVEYADDITIONAL INFORMATION OR TO PROVIDEFURTHER EMPHASIS FOR A PREVIOUS POINT.CAUTIONA CAUTION IS USED WHEN THERE IS THESTRONG POSSIBILITY OF DAMAGE TO THEEQUIPMENT OR PREMATURE EQUIPMENTFAILURE.WARNINGA WARNING IS USED WHEN THERE IS THEPOTENTIAL FOR PERSONAL INJURY OR DEATH.Before operation or the performance of any maintenanceon your IMT crane, familiarize yourself with theOPERATOR’S CRANE SAFETY MANUAL, part number99900313. It provides information critical to the safeoperation and maintenance of your crane. Reference tothe Safety Manual will be found throughout this manualas an aid in safe operation and maintenance.It is the user’s responsibility to maintain and operate thisunit in a manner that will result in the safest workingconditions possible.Three means are used throughout this manual to gain theattention of operating and service personnel. They areNOTEs, CAUTIONs and WARNINGs and are defined asfollows:Warranty of this unit will be void on any part of the unitsubjected to misuse due to overloading, abuse, lack ofmaintenance or unauthorized modifications. No warranty verbal, written or implied - other than the official publishedIMT new machinery and equipment warranty will be validwith this unit.In addition, it is the user’s responsibility to be aware ofexisting Federal, State and Local codes and regulationsgoverning the safe use and maintenance of this unit.Read and familiarize yourself with theIMT OPERATOR’S CRANE SAFETY MANUALbefore operating or performing any maintenanceon your crane.REVISIONS LISTDATE200303152006102020111230LOCATION3A-1 THRU 3A-101-11ATHROUGHOUTSECTION 1201205213A20140915FIGURE A1-31FIGURE A1-35DESCRIPTION OF CHANGEREPLACED WITH UPDATED CYLINDER REPAIR INSTRUCTIONSNEW OWNERSHIP STATEMENTUPDATED DECAL DRAWINGSECN 11628 - UPDATED DECAL DRAWINGS, STABILIZER WORDING, ADDED STABILIZER DECALECN 11606 - UPDATED DESCRIPTION OF OVERLOAD PREVENTION SYSTEM, TWO-BLOCKPREVENTION SYSTEMUPDATE CYLINDER REPAIR SECTION TO INCLUDE STOP TUBE RING REPLACEMENT FOR WAFERLOCK.ECN 12264 - MOLUB-ALLOY 882 WAS MOLUB-ALLOY 936.ECN 12279 - REMOVED MOBIL OIL INFO FROM 70394189

VOLUME1:99900037:20000706MAINTENANCE AND REPAIR MANUALThis manual is divided into specific sections in orderto keep similar subject matter under one heading.There will however be instances when a particularsubject may be presented in more than one section ofthe manual. This redundancy is necessary inproviding comprehensive information.This manual will also be subject to revisions andadditions. As new or revised information is released,new pages will be available which will be identified inthe upper-right-hand corner by a revision number anddate. Any new pages released should be insertedinto your manual in place of “old pages”.New sections may also be provided. When received,they should be inserted into your manual in its propernumerical sequence.iiiAdditional information is available which addressesspecific topics which relate to crane installation,maintenance and repair. These are listed below andinclude their IMT part number and brief description.They may be ordered from IMT by contacting theProduct Support Department at the followingaddress:IOWA MOLD TOOLING CO., INC.BOX 189, GARNER, IA 50438-0189TEL: 641-923-3711TECHNICAL SUPPORT FAX: 641-923-2424MINIMUM CHASSIS SPECIFICATIONSFor mounting of IMT Truck mounted cranesDomestic Version - 99900765Metric Version - 99900764Instructions and calculations for determining suitabletruck frame strength. Also minimum chassisspecifications for most IMT cranes.REFERENCE TO SAFETY MANUALThroughout this manual, reference will be made tothe IMT OPERATOR’S CRANE SAFETYMANUAL. These references will direct you toimportant information applicable to the relevantsubject. Also, additional information may becontained in the reference box. A sample of thisreference is shown below.The term SAFETY MANUAL will be usedthroughout this manual and is to be construed as theIMT OPERATOR’S CRANE SAFETY MANUAL.OTHER IMT PUBLICATIONSHYDRAULIC PUMP SELECTION GUIDE99900698An aid in the selection of hydraulic pumps for usewith cranes and compressors.CRANE LOG99900686Crane and Vehicle log for the recording of inspections,tests, maintenance, repairs and modifications for aone-year period.

VOLUME1:99900037:19970415ivTABLE OF CONTENTSSection 1. OPERATION1-1.GENERAL .1-2.VEHICLE CONTROLS .1-3.CRANE CONTROLS .1-3-1. REMOTE CONTROLS .1-3-2. GENERAL THEORY OF OPERATION .1-4.SAFETY FACTORS .1-4-1. LOAD LIMITS .1-4-2. EQUIPMENT INSPECTION .1-4-3. WORK STATION POSITIONING .1-4-4. OPERATING RESTRICTIONS .1-5.ENGINE SPEED REGULATION .1-6.LOAD LIFTING .1-7.STABILITY RATINGS .1-8.ANTI TWO BLOCKING SYSTEM .1-9.TASK PERFORMANCE .1-10. CRANE SHUTDOWN .1-11. OPERATORS .1-12. OPERATION IN ADVERSE CONDITIONS .1-12-1. DIRTY AND SANDY AREAS .1-12-2. HIGH HUMIDITY OR SALT AIR CONDITIONS .1-12-3. HIGH ALTITUDE .1-12-4. COLD WEATHER .1-13. HAND SIGNALS .1-14. OVERLOAD PREVENTION SYSTEM (ELECTRICALLY OPERATED) .1-15. OVERLOAD PREVENTION SYSTEM (HYDRAULICALLY OPERATED) 1-101-111-111-111-111-111-121-141-14Section 1A. DECALS1A-1. DECAL PLACEMENT-TELESCOPING CRANES .1A-2. DECAL PLACEMENT-ARTICULATING CRANES .1A-3. “DANGER” DECAL DESCRIPTIONS .1A-4. INSTRUCTION DECALS .1A-11A-21A-31A-10Section 2. MAINTENANCE2-1.GENERAL .2-2.LUBRICANTS .2-3.LUBRICATION .2-4.HYDRAULIC FLUID SPECIFICATIONS .2-5.HYDRAULIC OIL DETERIORATION .2-6.HYDRAULIC SYSTEM PURGING .2-7.PURGING AIR FROM THE SYSTEM .2-8.SYSTEM RELIEF PRESSURE .2-9.CYLINDER HOLDING CAPABILITIES .2-10. FILTER ELEMENT REPLACEMENT .2-11. WIRE ROPE MAINTENANCE .2-12. HOOK MAINTENANCE .2-13. PERIODIC VEHICLE INSPECTION .2-14. PERIODIC CRANE INSPECTION .2-15. ADDITIONAL INSPECTIONS .2-16. REMOTE CONTROL INSPECTION .2-17. CORROSION CONTROL .2-18. LONG TERM STORAGE .2-19. PROPORTIONAL REMOTE CONTROL TROUBLESHOOTING 32-142-142-152-15

VOLUME1:99900037:19960517vSection 3. REPAIR3-1.GENERAL .3-2.MAINTENANCE PRECAUTIONS .3-3.GENERAL PRECAUTIONS .3-4.REPAIR PROCEDURES .3-5.CLEANLINESS .3-6.HYDRAULIC SYSTEMS .3-7.FASTENERS AND TORQUE VALUES .3-8.LABEL PARTS WHEN DISASSEMBLING .3-9.BOOM WEAR PADS .3-10. PIN AND BEARING INSPECTION AND INSTALLATION .3-10-1. PIN INSPECTION .3-10-2. PIN BEARING INSPECTION .3-10-3. INSTALLATION .3-11. TURNTABLE GEAR-REMOVAL AND REPLACEMENT .3-12. PINION AND DRIVE GEAR BUSHINGS-REMOVAL AND REPLACEMENT .3-13. REMOVAL AND REPLACEMENT OF STABILIZER ARMS .3-14. VERTICAL STABILIZER CYLINDERS-REMOVAL AND REPLACEMENT .3-15. EXTERNAL HORIZONTAL STABILIZER CYLINDER-REMOVAL AND REPLACEMENT .3-16. FOLD DOWN STABILIZER CYLINDER-REMOVAL AND REPLACEMENT .3-17. EXTENSION CYLINDER-REMOVAL AND REPLACEMENT .3-17-1. EXTERNAL CYLINDER .3-17-2. INTERNAL CYLINDER .3-17-3. BOLT-ON EXTENSION CYLINDER .3-18. REMOVAL AND REPLACEMENT OF OPERATOR CONTROL VALVE .3-19. OUTER BOOM-REMOVAL AND REPLACEMENT .3-20. OUTER CYLINDER-REMOVAL AND REPLACEMENT .3-21. INNER CYLINDER-REMOVAL AND REPLACEMENT .3-22. INNER BOOM-REMOVAL AND REPLACEMENT .3-23. ROTATION MOTOR, COUNTERBALANCE VALVE AND BRAKE-REMOVALAND REPLACEMENT .3-24. ‘KICKOUT’ A-FRAME STABILIZER CYLINDER-REMOVAL AND REPLACEMENT .3-143-14Section 3A. CYLINDER REPAIR3A-1. CYLINDER DISASSEMBLY .3A-2. CYLINDER ASSEMBLY .3A-3. TELESCOPING CYLINDER DISASSEMBLY .3A-4. TELESCOPING CYLINDER ASSEMBLY .3A-13A-53A-73A-8Section 4. CHASSIS PREPARATION FOR INSTALLATION4-1.GENERAL .4-2.CHASSIS PREPARATION .4-2-1. FRAME STRENGTH .4-2-2. FRONT MOUNTED CRANE APPLICATION .4-2-3. REAR MOUNTED CRANE APPLICATION .4-2-4. FRAME REINFORCEMENT .4-3.PTO AND PUMP .4-3-1. PTO INSTALLATION .4-3-2. PUMP INSTALLATION .4-3-3. DRIVELINE APPLICATION .4-14-14-14-14-14-24-34-34-44-4Section 5. 53-73-73-83-83-83-93-93-93-103-123-123-123-133-13

VOLUME1:99900037:19990519viLIST OF -3.D-1.D-2.D-3.D-4.TYPICAL CRANE CONTROL DECALS .TYPICAL REMOTE CONTROL DECALS .TYPICAL WALLBOARD CRANE CONTROL DECALS .TYPICAL LOADER CONTROL DECAL (TOE/HEEL) .TYPICAL LOADER CONTROL DECAL (TOE/TOE) .FORMULA-REQUIRED PUMP SPEED .FORMULA-ENGINE RPM .HAND SIGNALS .DECAL LOCATIONS ON TELESCOPING CRANES .DECAL LOCATIONS ON ARTICULATING CRANES .DECAL-ELECTROCUTION HAZARD .DECAL-ELECTROCUTION HAZARD .DECAL-ELECTROCUTION HAZARD .DECAL-ELECTROCUTION HAZARD .DECAL-ELECTROCUTION HAZARD-REMOTE CONTROL OPERATION .DECAL-ELECTROCUTION HAZARD-REMOTE CONTROL OPERATION .DECAL-ELECTROCUTION HAZARD-REMOTE CONTROL OPERATION .DECAL-ELECTROCUTION HAZARD-REMOTE CONTROL OPERATION .DECAL-STABILIZER FOOT CRUSHING HAZARD .DECAL-MOVING BOOM HAZARD .DECAL-ROTATING DRIVELINE HAZARD .DECAL-TWO BLOCK HAZARD .DECAL-RIDING ON BOOM, HO

operation and maintenance of your crane. Reference to the Safety Manual will be found throughout this manual as an aid in safe operation and maintenance. Three means are used throughout this manual to gain the attention of operating and service personnel. They are NOTEs, CAUTIONs and WARNINGs and are defined as follows: NOTE A NOTE IS USED TO .