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IMT 5020 User Manual
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99903514:TELESCOPIC
CRANE:
i
SECTION 0: INTRODUCTION
VOLUME 1
IOW
A
MOLD T
OOLING CO., INC.
BOX 189, GARNER, IA
50438-0189
TEL: 641-923-3711
TECHNICAL
SUPPOR
T F
AX: 641-923-2424
MANUAL
P
AR
T NUMBER 99903514
TELESCOPIC CRANE
OPERA
TION AND
SAFETY
20140915
Iowa Mold T
ooling Co., Inc. is an Oshkosh Corporation Compa
ny
.
2
Table of Contents
Section 1: Operation
5
Table of Contents
5
1-1: General
6
1-2: Daily Safety Inspections
6
1-3: Work Site Preparation
6
1-3-1: Electrical Hazards
6
1-3-2: Work Station Positioning
8
1-3-3: Outriggers
8
1-4: Starting Crane Operation
9
1-4-2: Disengaging the Pto
9
1-5: Rotator Worm Gear Break-In
9
1-6: Crane Controls
10
1-6-1: Radio Remote Controls
10
1-6-2: Changing the Battery in the Radio Remote Control
11
1-6-3: Radio Remote Backup Handset
11
1-6-4: Tethered Remote Controls
11
1-6-5: Electric Cranes
12
1-7: Crane Capacity and Load Limits
13
1-7-1: Reduced Capacity (Rclc)
14
1-8: Crane Capacity Alert System (Electrically Operated)
15
1-9: Anti Two Blocking System
16
1-10: Changing from Double to Single-Part Line
18
1-11: Task Performance
19
1-11-1: Troubleshooting
19
1-12: Crane Shutdown
20
1-13: Operators
20
Operation in Adverse Conditions
21
1-14-1: Dusty and Sandy Areas
21
1-14-2: High Humidity or Salt Air Conditions
21
1-14-3: High Altitude
21
1-14-4: Cold Weather
21
1-15: Hand Signals
22
Important! Notes for Safe Operation
24
Section 2: Maintenance
27
2-1: General
28
2-2: Maintenance Schedule
28
2-3: Lubrication
29
2-4: Lubrication Points
29
Models 3020, 3820, & 5020
30
Models 1015 & 2020
30
Models 5525, 6025, & 6625
31
Models 7020 & 7025
31
2-5-1: Hydraulic Oil Specifications
32
2-5-2: Low Temperature Hydraulic Oil Specifications
32
2-5-3: Hydraulic Fluid Level
32
2-5: Hydraulic System
32
2-5-4: Hydraulic Fluid Deterioration
33
2-5-5: Changing Hydraulic Oil
33
2-5-10: Hydraulic System Troubleshooting
34
2-5-7: Hydraulic Pressure Relief
34
2-5-8: Hydraulic Cylinder Holding Capabilities
34
2-5-9: Hydraulic Filter Replacement
34
2-6-1: Wire Rope Inspection
35
2-6-2: Wire Rope Lubrication
35
2-6: Wire Rope & Hook Maintenance
35
2-6-3: Wire Rope Maintenance
36
2-6-4: Wire Rope Replacement
36
2-6-5: Wire Rope Slings
37
2-6-7: Hook & Latch Maintenance
38
2.6-6: Wire Rope Lay
38
2-7: Periodic Vehicle Inspection
39
2-8: Periodic Crane Inspection
39
2-9: Additional Inspections
39
2-10: Tethered Remote Control Inspection
40
2-11: Corrosion Control
40
2-12: Long Term Storage
40
2-13: Chemical Safety
41
2-14: Excessive Load Limit System (Ells) Test Procedure
42
2-15: Ells Troubleshooting Procedure
47
2-16: Winch Troubleshooting
48
Section 3: Repair
49
3-1: General
50
3-2: Repair Precautions
50
3-3: Systematic Repair Procedure
50
3-4: Cleanliness
51
3-5: Hydraulic System
51
3-6: Fasteners & Torque Values
51
3-7: Crane Base Removal and Replacement
52
3-8-1: Removing the Worm Drive Winch
52
3-8-2: Planetary Winch (Models 6025 and 6625)
52
3-8: Worm Drive Winch
52
3-9: Crane Rotation System
52
3-9-1: Removing the Crane Rotation System
53
3-9-3: Worm End Play & Backlash - Integral Base & Worm Drive
53
3-10: Wear Pads
57
3-9-6: Rotation Motor and C'bal Valve Removal and Replacement
57
3-11: Pins
58
3-12-1: Bearing Types
58
3-12-2: Bearing Inspection & Replacement
58
3-12: Bearings & Bushings
58
3-13-1: Valvebank Components
59
3-13: Valvebank
59
3-13-2: Valvebank Troubleshooting
61
3-13-3: Single Valve Replacement
61
3-13-4: Valvebank Removal and Replacement
61
3-14: Lower Cylinder Removal & Replacement
62
3-15: External Extension Cylinder-Removal and Replacement
62
3-16: Internal Cylinder Removal and Replacement
63
3-17: Lower Boom Removal and Replacement
63
3-18: Wire Rope Removal/Replacement
63
Section 4: Installation
73
4-1: General
74
4-2-1: Frame Strength
74
4-2: Chassis Preparation
74
4-3-1: Pto Installation
74
4-3: Pto and Pump
74
4-3-2: Pump Installation
75
4-3-3: Driveline Application
76
4-4: Engine Speed Regulation
78
4.5.1 General
78
4.5.2 Chassis Information
78
Model Specific Crane & Hydraulic Installation Guides
78
Model 1015 Crane Installation
79
Model 2020 Crane Installation
80
Model 3020 Crane Installation
81
Model 3820 Crane Installation
82
Model 5020 Crane Installation
83
Model 6020 Crane Installation
84
Models 5525, 6025, and 6625 Crane Installation
85
Hydraulic Installation - Models 3020, 3820, 5020, 5525, 6020, 6025, 6625
87
Model 7020 Crane Installation
88
4.15 Model 7025 Crane Installation
89
Hydraulic & Electrical Installation - Models 7020 & 7025
90
Section 6: Reference
103
Inspection Checklist
104
Section 6: Reference
104
Crane Capacity & Stability
108
Understanding the Capacity Placard
108
Stability Test
109
Torque Data Chart - Domestic
113
Torque Data Chart - Metric
114
Turntable Bearing Fastener Tightening Sequence
115
Turntable Bearing Inspection for Replacement
116
Direction Terminology
117
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IMT 5020 Specifications
General
Brand
IMT
Model
5020
Category
Construction Equipment
Language
English
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