IMT Volume 1 Operation, Maintenance and Repair 99900037

Table of Content:

1 ELECTRONIC MANUALS
2 FRONT COVER
3 INTRODUCTION
4 REVISIONS LIST
5 MAINTENANCE AND REPAIR MANUAL
6 REFERENCE TO SAFETY MANUAL
7 OTHER IMT PUBLICATIONS
8 TABLE OF CONTENTS
9 LIST OF ILLUSTRATIONS
10 OPERATION
10.1 1-1. GENERAL
10.2 1-2. VEHICLE CONTROLS
10.3 1-3. CRANE CONTROLS
10.4 Figure A-1. TYPICAL CRANE CONTROL DECALS
10.5 Figure A-2. TYPICAL REMOTE CONTROL DECALS
10.6 Figure A-3. TYPICAL WALLBOARD CRANE CONTROL DECAL
10.7 Figure A-4. TYPICAL LOADER CONTROL DECAL (TOE/HEEL)
10.8 Figure A-5. TYPICAL LOADER CONTROL DECAL (TOE/TOE)
10.9 1-3-1. REMOTE CONTROLS
10.10 1-3-2. GENERAL THEORY OF OPERATION
10.11 1-4. SAFETY FACTORS
10.12 1-4-1. LOAD LIMITS
10.13 1-4-2. EQUIPMENT INSPECTION
10.14 1-4-3. WORK STATION POSITIONING
10.15 1-4-4. OPERATING RESTRICTIONS
10.16 1-5. ENGINE SPEED REGULATION
10.17 Figure A-7. FORMULA – ENGINE RPM
10.18 1-6. LOAD LIFTING
10.19 1-7. STABILTY RATINGS
10.20 1-8. ANTI TWO BLOCKING SYSTEM
10.21 1-9. TASK PERFORMANCE
10.22 1-10. CRANE SHUTDOWN
10.23 1-11. OPERATORS
10.24 1-12. OPERATION IN ADVERSE CONDITIONS
10.25 1-12-1. DUSTY AND SANDY AREAS
10.26 1-12-2. HIGH HUMIDITY OR SALT AIR CONDITIONS
10.27 1-12-3. HIGH ALTITUDE
10.28 1-12-4. COLD WEATHER
10.29 1-13. HAND SIGNALS
10.30 Figure A-8. HAND SIGNALS
10.31 1-14. CRANE CAPACITY ALERT SYSTEM (ELECTRICALLY OPERATED)
10.32 Figure A-9. GENERAL CAPACITY ALERT SYSTEM WIRING DIAGRAM (ELECTRICAL)
10.33 1-15. CAPACITY ALERT SYSTEM (HYDRAULICALLY OPERATED)
10.34 Figure A-10.GENERAL CAPACITY ALERT SYSTEM DIAGRAM (HYDRAULIC)
10.35 1-16. CRANE CAPACITY AUDIBLE ALERT SYSTEM (ELECTRICALLY OPERATED)
10.36 Figure A-11. GENERAL CAPACITY AUDIBLE ALERT SYSTEM WIRING DIAGRAM
11 DECALS
11.1 Figure A1-1. DECAL LOCATIONS ON TELESCOPING CRANES
11.2 1A-1. DECAL PLACEMENT-TELESCOPING CRANES
11.3 Figure A1-2. DECAL LOCATIONS ON ARTICULATING CRANES
11.4 1A-2. DECAL PLACEMENT -ARTICULATING CRANES
11.5 1A-3. “DANGER” DECAL DESCRIPTIONS
11.6 1A-4. INSTRUCTIONAL DECALS
12 MAINTENANCE
12.1 2-1. GENERAL
12.2 2-2. LUBRICANTS
12.3 2-3. LUBRICATION
12.4 2-4. HYDRAULIC FLUID SPECIFICATION
12.5 Figure B-2. LUBRICATION PRODUCT & SCHEDULE
12.6 Figure B-3. HYDRAULIC FLUID SPECIFICATIONS
12.7 Figure B-1. GREASE WEEKLY DECAL
12.8 Figure B-4. TYPICAL GREASE ZERK LOCATIONS-TELESCOPING CRANES
12.9 Figure B-5. TYPICAL GREASE ZERK LOCATIONS-ARTICULATING CRANES
12.10 Figure B-6. TYPICAL GREASE ZERK LOCATIONS-WALLBOARD CRANES
12.11 Figure B-7. TYPICAL GREASE ZERK LOCATIONS-SPIDER LEG OUTRIGGERS
12.12 Figure B-8. TYPICAL GREASE ZERK LOCATIONS-LOG LOADERS
12.13 Figure B-9. HYDRAULIC FLUID PRECAUTIONS
12.14 2-5. HYDRAULIC OIL DETERIORATION
12.15 2-6. HYDRAULIC SYSTEM PURGING
12.16 2-7. PURGING AIR FROM THE SYSTEM
12.17 2-8. SYSTEM RELIEF PRESSURE
12.18 2-9. CYLINDER HOLDING CAPABILITIES
12.19 2-10. FILTER ELEMENT REPLACEMENT
12.20 2-11. WIRE ROPE MAINTENANCE
12.21 Figure B-10. SWIVEL HOOK GREASE ZERK
12.22 2-12. HOOK MAINTENANCE
12.23 Figure B-11. ROPE ATTACHMENTS
12.24 2-13. PERIODIC VEHICLE INSPECTION
12.25 2-14. PERIODIC CRANE INSPECTION
12.26 2-15. ADDITIONAL INSPECTIONS
12.27 2-16. REMOTE CONTROL INSPECTION
12.28 2-17. CORROSION CONTROL
12.29 2-18. LONG TERM STORAGE
12.30 2-19. PROPORTIONAL REMOTE CONTROL TROUBLESHOOTING
12.31 Figure B-14. VALVEBANK-PROPORTIONAL REMOTE CONTROL
13 REPAIR
13.1 3-1. GENERAL
13.2 3-2. MAINTENANCE PRECAUTIONS
13.3 3-3. GENERAL PRECAUTIONS
13.4 3-4. REPAIR PROCEDURE
13.5 3-5. CLEANLINESS
13.6 3-6. HYDRAULIC SYSTEMS
13.7 3-7. FASTENERS AND TORQUE VALUES
13.8 3-8. LABEL PARTS WHEN DISASSEMBLING
13.9 3-9. BOOM WEAR PADS
13.10 3-10. PIN AND BEARING INSPECTION AND INSTALLATION
13.11 3-10-1. PIN INSPECTION
13.12 3-10-2. PIN BEARING INSPECTION
13.13 3-10-3. INSTALLATION
13.14 3-11. TURNTABLE GEAR – REMOVAL AND REPLACEMENT
13.15 Figure C-1. TURNTABLE GEAR BEARING INSTALLATION
13.16 Figure C-2. BUSHING REMOVAL
13.17 Figure C-3. BUSHING INSTALLATION
13.18 3-12. PINION AND DRIVE GEAR BUSHINGS – REMOVAL AND REPLACEMENT
13.19 3-13. REMOVAL AND REPLACEMENT OF OUTRIGGER ARMS
13.20 3-14. VERTICAL OUTRIGGER CYLINDERS – REMOVAL AND REPLACEMENT
13.21 Figure C-4. POWER DOWN OUTRIGGER
13.22 3-15. EXTERNAL HORIZONTAL OUTRIGGER CYLINDERS – REMOVAL AND REPLACEMENT
13.23 3-16. FOLD-DOWN OUTRIGGER CYLINDER-REMOVAL AND REPLACEMENT
13.24 3-17. EXTENSION CYLINDER-REMOVAL AND REPLACEMENT
13.25 3-17-1. EXTERNAL CYLINDER
13.26 Figure C-5. FOLD-DOWN OUTRIGGER
13.27 3-17-2. INTERNAL CYLINDER
13.28 3-17-3. BOLT-ON EXTENSION CYLINDER
13.29 Figure C-6. EXTERNAL EXTENSION CYLINDER
13.30 Figure C-8. BOLT-ON EXTENSION CYLINDER
13.31 Figure C-7. INTERNAL EXTENSION CYLINDER
13.32 3-18. REMOVAL AND REPLACEMENT OF OPERATOR CONTROL VALVE
13.33 3-19. OUTER BOOM -REMOVAL AND REPLACEMENT
13.34 3-20. OUTER CYLINDER -REMOVAL AND REPLACEMENT
13.35 3-21. INNER CYLINDER -REMOVAL AND REPLACEMENT
13.36 3-22. INNER BOOM -REMOVAL AND REPLACEMENT
13.37 3-23. ROTATION MOTOR, COUNTERBALANCE VALVE AND BRAKE – REMOVAL AND REPLACEMENT
13.38 3-24. ‘KICKOUT’ A-FRAME OUTRIGGER CYLINDER- REMOVAL AND REPLACEMENT
13.39 Figure C-9. ‘KICKOUT’ A-FRAME OUTRIGGER REFERENCE
14 CYLINDER REPAIR
14.1 3A-1. CYLINDER DISASSEMBLY
14.2 Figure C1-1. TYPICAL CYLINDER AND SEAL KIT COMPONENTS
14.3 Figure C1-2. SEAL INSTALLATION GUIDELINES
14.4 3A-2. CYLINDER ASSEMBLY
14.5 3A-3. TELESCOPING CYLINDER DISASSEMBLY
14.6 3A-4. TELECOPING CYLINDER ASSEMBLY
14.7 Figure C1-3. TELESCOPING EXTENSION CYLINDER COMPONENTS
14.8 APPENDIX: PISTON & HEAD SPANNER WRENCH ATTACHMENT PART NUMBERS
15 CHASSIS PREP FOR INSTALLATION
15.1 4-1. GENERAL
15.2 4-2. CHASSIS PREPARATION
15.3 4-2-1. FRAME STRENGTH
15.4 4-2-2. FRONT MOUNTED CRANE APPLICATION
15.5 4-2-3. REAR MOUNTED CRANE APPLICATION
15.6 4-2-4. FRAME REINFORCEMENT
15.7 Figure D-1. TYPICAL TORSIONAL SUB-FRAME
15.8 Figure D-2. FRAME REINFORCEMENT
15.9 4-3. PTO AND PUMP
15.10 4-3-1. PTO INSTALLATION
15.11 4-3-2. PUMP INSTALLATION
15.12 Figure D-3. PTO/PUMP INSTALLATION
15.13 4-3-3. DRIVELINE APPLICATION
15.14 Figure D-4. DRIVELINE APPLICATION
16 GENERAL REFERENCE
16.1 INSPECTION CHECKLIST
16.2 WIRE ROPE INSPECTION
16.3 HOOK INSPECTION
16.4 ANTI-TWO BLOCKING DEVICE INSPECTION
16.5 HOLDING VALVE INSPECTION
16.6 ANTI-TWO BLOCKING DEVICE INSPECTION
16.7 TORQUE DATA CHART – DOMESTIC
16.8 TORQUE DATA CHART – METRIC
16.9 TURNTABLE BEARING FASTENER TIGHTENING SEQUENCE
16.10 TURNTABLE BEARING INSPECTION FOR REPLACEMENT
16.11 CONVERSION FACTORS
16.12 LIMITED WARRANTY