Manual Part # 99905190 IMT Telescopic Crane Operation & Safety Manual Revision Date 20140915 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. 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. i Contents Revisions ..................................................................................................................................................... iv Introduction 5 Crane Component Identification ................................................................................................................... 7 Crane Safety.................................................................................................................................................. 8 Operation 11 Initial Operation Requirements ................................................................................................................... 12 Daily Safety Inspections ............................................................................................................................. 12 Preparing the Job Site ................................................................................................................................. 13 Electrical Hazards ....................................................................................................................................... 14 Stabilizers ................................................................................................................................................... 16 Telescopic Crane Controls .......................................................................................................................... 18 Crane Operation Using the Proportional Remote ....................................................................................... 18 Overload Protection System ....................................................................................................................... 21 Receiver Display ......................................................................................................................................... 22 Radio Elimination Cable ............................................................................................................................. 23 Crane Capacity ............................................................................................................................................ 24 Task Performance ....................................................................................................................................... 27 Anti-Two Block System ............................................................................................................................. 28 Auto-Release Hook Storage ........................................................................................................................ 29 Winch .......................................................................................................................................................... 30 Flip Sheave Feature .................................................................................................................................... 31 Double & Single Line ................................................................................................................................. 32 Load Level Indicator ................................................................................................................................... 32 Options ........................................................................................................................................................ 33 Emergency Manual Operation .................................................................................................................... 33 Crane Shut Down ........................................................................................................................................ 34 Troubleshooting .......................................................................................................................................... 35 Operation in Adverse Conditions ................................................................................................................ 36 Cold Weather ................................................................................................................................... 36 Signals ........................................................................................................................................................ 38 Maintenance 41 Maintenance Introduction ........................................................................................................................... 41 Maintenance Schedule ................................................................................................................................ 42 Greasing Instructions .................................................................................................................................. 43 New Crane Rotator Worm Gear Break-In Period ............................................................................ 45 ii Contents Hydraulic Fluid Level ................................................................................................................................. 45 Crane Hydraulic Oil Specifications ............................................................................................................ 46 Changing Hydraulic Oil & Filter ................................................................................................................ 46 Purging Air from Hydraulic System ........................................................................................................... 47 Hydraulic Pressure Relief ........................................................................................................................... 47 Hydraulic Cylinder Holding Capability ...................................................................................................... 48 Winch Oil Specifications ............................................................................................................................ 48 Wire Rope & Hook Maintenance ............................................................................................................... 49 Wire Rope Inspection ...................................................................................................................... 49 Wire Rope Lubrication .................................................................................................................... 50 Wire Rope Maintenance .................................................................................................................. 50 Wire Rope Inspection & Replacement ............................................................................................ 50 Wire Rope Slings ............................................................................................................................. 51 Wire Rope Lay ................................................................................................................................ 52 Hook Maintenance ........................................................................................................................... 52 Contents iii Periodic Inspection ..................................................................................................................................... 53 Additional Inspection .................................................................................................................................. 53 Corrosion Control ....................................................................................................................................... 54 Long-Term Storage ..................................................................................................................................... 55 Repair 57 Repair Precautions ...................................................................................................................................... 58 Systematic Repair Procedure ...................................................................................................................... 58 Associating Radio Remote Receiver and Transmitter ................................................................................ 59 Wear Pads ................................................................................................................................................... 60 Cylinder Repair ........................................................................................................................................... 61 Pin Removal & Inspection .......................................................................................................................... 62 Bushings ..................................................................................................................................................... 63 Wire Rope Removal & Replacement .........................................................................................................