00001007:99900142: Model 1007 Crane Section 1 SPECIFICATIONS Section 2 CRANE REFERENCE Section 3 REPLACEMENT PARTS Section 4 GENERAL REFERENCE IOWA MOLD TOOLING CO., INC. BOX 189, GARNER, IA 50438-0189 TEL: 641-923-3711 MANUAL PART NUMBER 99900142 Volume 2 - PARTS AND SPECIFICATIONS 20110209 Iowa Mold Tooling Co., Inc. is an Oshkosh Corporation company.
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1007 Crane (99900142) - IMT99900142: Model 1007 Crane Section 1 SPECIFICATIONS Section 2 CRANE REFERENCE Section 3 REPLACEMENT PARTS Section 4 GENERAL REFERENCE IOWA MOLD TOOLING CO.,
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20001212 3-22 ECN8635-90713620-ADD AUX CHASSIS GRD INFO20010208 2-05 CORRECT SPARE PARTS LIST20030129 1-6 ECN 9120 - UPDATED CAPACITY PLACARD IN MANUAL20040129 3-5,20,24 ECN 9361 - ADDED RUBBER BUMPER TO PREVENT PULLEY/BEARING INTERFERENCE.20040608 3-15,16,22,26 ECN 9493 - MOVED SOLENOID FROM CONTROL KIT TO INSTL KIT20070212 COVER, 1-3, 3-3 UPDATED COVER, SPECS WITH LOGO, OWNERSHIP STATEMENT, UPDATED S/N TAG.20070607 3-5,20 ECN 10379 - MOVED SPACER, RUBBER BUMPER, FROM WINCH KIT TO MAST ASM.20091210 3-18,20 UPDATED REMOTE HANDLE IN WINCH KITS20110209 3-12 ADDED 94014962 TUBE ASSEMBLY TO VALVEBANK (73073039)
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00001007:99900142:
INTRODUCTION
Read and familiarize yourself with theIMT OPERATOR’S CRANE SAFETY MANUAL
before operating or performing any maintenanceon your crane.
19971010
This volume deals with information applicable to yourparticular crane. For operating, maintenance andrepair instructions, refer to Volume 1, OPERATION,MAINTENANCE AND REPAIR.
We recommend that this volume be kept in a safeplace in the office.
This manual is provided to assist you with orderingparts for your IMT truck-mounted articulating crane.It also contains additional instructions regarding yourparticular installation.
It is the user’s responsibility to maintain and operatethis unit in a manner that will result in the safestworking conditions possible.
Warranty of this unit will be void on any part of theunit subjected to misuse due to overloading, abuse,lack of maintenance and unauthorized modifications.No warranty - verbal, written or implied - other thanthe official, published IMT new machinery andequipment warranty will be valid with this unit.
In addition, it is also the user’s responsibility to beaware of existing Federal, State and Local codes andregulations governing the safe use and maintenanceof this unit. Listed below is a publication that the usershould thoroughly read and understand.
ANSI/ASME B30.22ARTICULATING BOOM CRANES
The American Society of Mechanical EngineersUnited Engineering Center
345 East 47th StreetNew York, NY 10017
Three means are used throughout this manual to gainthe attention of personnel. They are NOTE’s,CAUTION’s and WARNING’s and are defined asfollows:
NOTEA NOTE is used to either convey additionalinformation or to provide further emphasis for aprevious point.
CAUTIONA CAUTION is used when there is the very strongpossibility of damage to the equipment or prematureequipment failure.
WARNINGA WARNING is used when there is the potential forpersonal injury or death.
Treat this equipment with respect and service itregularly. These two things can add up to a saferworking environment.
00001007:99900142: 20000728NOTES
00001007:99900142: 1-119941010
SECTION 1. 1007 CRANE SPECIFICATIONS
GENERAL SPECIFICATIONS .......................................................................................3
POWER SOURCEPower is supplied to the electric motor by a solenoid connected to the 12-VDC truck battery. The chassis must beequipped with a 4000 watt Delco Freedom battery (or equivalent) connected in parallel to the chassis’ standardheavy-duty battery. The chassis must also be equipped with a heavy-duty alternator (63 amp for GM vehicles and60 amp for Ford vehicles).
ROTATION SYSTEMTurntable bearing with external worm gear powered with a high-torque hydraulic motor through a self-locking worm.Total gear reduction is 63 to 1.
00001007:99900142: 1-419941010CYLINDER HOLDING VALVESThe base ends (extend side) of the lower boom cylinder is equipped with an integral-mounted counter-balance valve to prevent sudden cylinder collapse in case of hose or other hydraulic failure.
The counter balance valve serves several functions. First, it is a holding valve. Secondly, it is designedto control the speed at which the lowering function operates, and allows that motion to be metered underload. Finally, it prevents the loss of an excess amount of oil in the event of a hose failure. Only the oil inthe hose, at the time of the failure, will be lost.
HYDRAULIC SYSTEMOpen-centered, full-pressure system that requires 1-1/2 GPM (5.7 liters/min) optimum oil flow at 2350PSI (162 bar). The control valvebank is a 3 spool, stack-type, 12 VDC valvebank. The hydraulicsystem includes a 3-gallon (11.4 liter) hydraulic oil reservoir, a 60-mesh suction-line strainer, a hydraulicpump driven by a heavy-duty electric motor and all necessary hoses and fittings.
CONTROLSRemote control with a 10-foot (3.05m) control cable.
* Based on 36,000 PSI yield frame material (A-36).
In addition to these specifications, a heavy-duty battery and alternator are required. It is recommendedthat the vehicle have power steering and dual rear wheels. IMT recommends adherence to the upperlimit of these specifications for best total system performance.
IMT reserves the right to change design and specifications without notice.
00001007:99900142: 1-519941010
GEOMETRIC CONFIGURATION
00001007:99900142: 1-3
IOWA MOLD TOOLING CO., INC.BOX 189, GARNER, IA 50438-0189
TEL: 641-923-3711 FAX: 641-923-2424
1007 CRANE SPECIFICATIONS
20000629
GENERAL SPECIFICATIONSCRANE RATING 10,500 ft-lbs (1.46 ton-meters)
REACH - from centerline of rotation 7'-0" (2.13m)
HYDRAULIC EXTENSION 31-1/2" (80cm)
LIFTING HEIGHT - from base of crane 11'-8" (3.56m)
WEIGHT OF CRANE 580 lbs (263.1 kg)
MOUNTING SPACE REQUIRED (crane base) 14-1/2" X 17"
TIE-DOWN BOLT PATTERN 11-1/2" X 14-3/4" (29.2cm X 37.5cm) on center
HORIZONTAL CENTER OF GRAVITYfrom centerline of rotation-stored position 3" (7.6cm)
VERTICAL CENTER OF GRAVITYfrom bottom of crane base - stored position 30" (76.2cm)
OPTIMUM PUMP CAPACITYelectric, single stage 1-1/2 U.S. Gallons/minute (5.7 liters/minute)
OIL RESERVOIR CAPACITY 3 U.S. Gallons (11.4 liters)
DESIGN FACTORS - pins and hydraulics 4/1
PERFORMANCE CHARACTERISTICSROTATION: 400° (6.98 Rad.) *90 secondsLOWER BOOM ELEVATION: -90° to +60° (-1.57 Rad. to +1.05 Rad.) *35 secondsEXTENSION BOOM: 31-1/2" (80cm) *18 seconds* Times are based on 1-1/2 GPM (5.7 liters/minute) optimum oil flow.
POWER SOURCEPower is supplied to the electric motor by a solenoid connected to the 12-VDC truck battery. The chassis must beequipped with a 4000 watt Delco Freedom battery (or equivalent) connected in parallel to the chassis’ standardheavy-duty battery. The chassis must also be equipped with a heavy-duty alternator (63 amp for GM vehicles and60 amp for Ford vehicles).
ROTATION SYSTEMTurntable bearing with external worm gear powered with a high-torque hydraulic motor through a self-locking worm.Total gear reduction is 63 to 1.
00001007:99900142: 1-620030129
71392336
00001007:99900142: 2-119941010
SECTION 2. 1007 CRANE REFERENCE
MAJOR CRANE ASSEMBLIES ..................................................................................3
WELDMENT PART NUMBER LOCATIONS ...............................................................3
NOTE: All application points must be greased weekly under normal work loads and moderate weather conditions.Under severe operating conditions, lubrication should be performed more frequently. See Volume 1; Operation,Maintenance and Repair for additional lubrication requirements.
ITEM LOCATION DESCRIPTION LUBRICANT FREQUENCY
1. TURNTABLE/BEARING GREASE EXTENSION*ROTATE CRANE WHILE GREASING
2. WORM GEAR COVER 3. WORM GEAR END 4. LOWER CYLINDER BASE 5. LOWER CYLINDER ROD 6. MAST/LOWER BOOM HINGE PIN
SHELL ALVANIA 2EP
OR
SHELL RETINAX “A”
WEEKLY
19910823
00001007:99900142: 2-520010208
RECOMMENDED SPARE PARTS LIST1 YEAR SUPPLY
1007 CRANEFOR MANUAL: 99900142
This spare parts list does not necessarily indicate that the items can be expected to fail in the course of a year. It is intended to provide theuser with a stock of parts sufficient to keep the unit operating with the minimal down-time waiting for parts. There may be parts failures notcovered by this list. Parts not listed are considered as not being Critical or Normal Wear items during the first year of operations and you needto contact the distributor or manufacturer for availability. SHELF
LIFE(MO)
ORDERQTYCODEQTYDESCRIPTIONPART NO.ITEM NO.
ASSEMBLYDESIGNATION
41704562.01.19980831 BASE ASM 5 60030116 THRUST BEARING 2 W 8 70055147 BEARING 1 W 9 70055148 BEARING 1 W10 70056307 WORM GEAR 1 C11 71056308 TURNTABLE BEARING 1 W19 72062162 NUT 15 W22 72063117 WASHER 15 W25 72601313 CAP SCR 15 W26 73051482 MOTOR 1 C
41705155.01.19950717 MAST ASM10 72063117 WASHER 12 W12 72601144 CAP SCR 12 W13 70142779 SUCTION STRAINER 1 W
41705145.01.19980806 LOWER BOOM ASM 3 60030109 WEAR PAD 1 W
41705143.01.19980806 EXTENSION BOOM ASM 4 60030109 WEAR PAD 1 W
3B031840.01.19971010 LOWER BOOM CYLINDER 6 9C121217 SEAL KIT 1 W17 73054304 VALVE 10 GPM 1 C
3B030840.01.19940912 EXTENSION CYLINDER 7 9B081012 SEAL KIT 1 W
91705142.01.19941109 HYDRAULIC KIT-3 SECTION/POWER UNIT 8 73073039 VALVEBANK 1 W27 70073616 POWER UNIT 1 W
90705141.01.19950721 CONTROL KIT-3 FUNCTION/POWER UNIT10 77041091 SOLENOID 3-POLE 12V 1 W11 77041237 SOLENOID 12V 150A 1 W
51705139.01.19910830 REMOTE HANDLE ASSEMBLY-3 FUNCTION/SINGLE PUMP11 77041345 TOGGLE SWITCH ST 1 W12 77041346 TOGGLE SWITCH DT 3 W
00001007:99900142: 2-619971010
(BLANK)
00001007:99900142: 2-719910823
INSTALLATION
CRANE INSTALLATION
INSTALLATION
NOTEThese instructions apply only to IMT bodies.
1. Inspect the carrier vehicle for compliance with theMinimum Chassis Specifications as shown in Section1. Specifications.
2. Locate the center point of the crane support 15-3/4" from the side wall of the body and 18" from therear edge of the body. For right side mount, centerpoint is to be 16-1/2" from side wall and 18-7/8" fromrear edge of body.
3. Cut a 6-1/2" x 4-1/2" rectangular hole centered onthe point located in Step 2. The 4-1/2" dimensionmust be parallel with the side wall of the body.
CAUTIONBefore cutting the hole, make certain it will not interferewith the body frame members. Do not cut any framemembers when cutting the hole.
The fiberglass body deck consists of fiberglassimpregnated expanded metal. Use a metal-cuttingblade in the saw.
4. Insert the crane support in the hole and weld thecrane support to the deck. Drill the four mountingholes.
CAUTIONThe “diamond plate” deck on the fiberglass bodyappears to be metal. Is is, in fact, fiberglass and willbe damaged by attempting to weld the crane supportto the deck. Use the crane support as a templateand drill the four holes.
5. Position the support plate in the hole and installthe crane on top of the plate. Use a lifting devicecapable of supporting the crane (580 lbs). Installthree bolts through the top of the crane base, throughthe deck and into the crane support bottom plate.Install the fourth bolt with washer and nut from thebottom side.
6. Weld the 4" x 2" x 1/4" wall support tube to thetruck frame and rear side of the crane support tube.Weld outrigger tube to chassis and front of cranesupport tube. Weld angle from bottom support plateto outrigger tube.
NOTEIf optional outrigger support tube is not ordered, usea 4" x 2" x 1/4" wall tube (customer supplied). Allwelding must be done by an AWS qualified welder.
7. Spray paint all unpainted surfaces.
8. Feed the battery cable through the support tubeand base and connect it to the power unit solenoid.Connect the other end to the underhood solenoidwhich is connected to the positive (+) side of thebattery.
Refer to the parts drawings of the installation kits inSection 4 for specific part numbers.
00001007:99900142: 2-819910823
HYDRAULIC INSTALLATION
POWER UNIT INSTALLATION GROUND WIRE INSTALLATION
00001007: 3-199900142:19990715
SECTION 3. REPLACEMENT PARTS 1007 CRANE
PARTS INFORMATION ..................................................................................................3
BASE ASM (41704562) ..................................................................................................4
GENERALThis section contains the exploded partsdrawings and accompanying parts lists for theassemblies used on this crane. These drawingsare intended to be used in conjunction with theinstructions found in the REPAIR section inVolume 1.
WARNINGDO NOT ATTEMPT TO REPAIR ANY COMPONENTWITHOUT READING THE INFORMATIONCONTAINED IN THE REPAIR SECTION IN VOLUME1. PAY PARTICULAR ATTENTION TO STATEMENTSMARKED WARNING, CAUTION, OR NOTE IN THATSECTION. FAILURE TO COMPLY WITH THESEINSTRUCTIONS MAY RESULT IN DAMAGE TO THEEQUIPMENT, PERSONAL INJURY, OR DEATH.
CRANE IDENTIFICATIONEvery IMT crane has an identification placard(see figure) attached to the crane base, mast,or inner boom. When ordering parts,communicating warranty information, orreferring to the unit in correspondence, alwaysinclude the serial number and model numbers.All inquiries should be addressed to:
Iowa Mold Tooling Co., Inc.Box 189, Garner, IA 50438-0189Telephone: 641-923-3711Technical Support Fax: 641-923-2424
PARTS INFORMATIONCYLINDER IDENTIFICATIONTo insure proper replacement parts arereceived, it is necessary to specify thecomplete number/letter sequence for any partrequested. Part numbers may be crosschecked by comparing the stampedidentification on the cylinder case (See figurebelow) against the information contained in theservice manual. You must include the partnumber stamped on the cylinder case whenordering parts.
WELDMENT IDENTIFICATIONEach of the major weldments - base, mast,inner boom, outer boom, extension boom andoutrigger weldments bear a stamped partnumber. Any time a major weldment isreplaced, you must specify the complete partnumber as stamped on the weldment. Thelocations of the part numbers are shown infigure below.
27. 72601486 CAP SCR 1/2-13X1-3/4 SH 228. 60121433 SHIM 2.25X1.81X16GA REF
WARNINGANY TIME THE GEAR-BEARING BOLTS HAVEBEEN REMOVED, THEY MUST BE REPLACEDWITH NEW BOLTS OF IDENTICAL GRADE ANDSIZE. FAILURE TO REPLACE GEAR-BEARINGBOLTS MAY RESULT IN BOLT FAILURE DUE TOMETAL FATIGUE CAUSING SERIOUS INJURY ORDEATH.
NOTES:1. BEARINGS MUST BE PACKED WITH GREASE ATASSEMBLY.
2. APPLY “MOLUB-ALLOY 936” TO TURNTABLEBEARING AND WORM GEAR TEETH AT ASSEMBLY.
3. INITIAL LUBRICATION OF BOTH SIDES OF THRUSTBEARING IS REQUIRED AT TIME OF INSTALLATION.SEE NOTE 4 FOR APPROVED LUBRICANTS.
4. APPROVED LUBRICANTS ARE “SLIP PLATE”,“LUBRI-PLATE” OR OTHER LUBRICANTS CONTAININGGRAPHITE OR MSO2.
5. SHIM AS REQUIRED IF NEEDED.
00001007: 3-541705155.01.REV. F: 20070607WARNING
ANY TIME THE GEAR-BEARING BOLTS HAVEBEEN REMOVED, THEY MUST BE REPLACEDWITH NEW BOLTS OF IDENTICAL GRADE ANDSIZE. FAILURE TO REPLACE GEAR-BEARINGBOLTS MAY RESULT IN BOLT FAILURE DUE TOMETAL FATIGUE CAUSING SERIOUS INJURY ORDEATH.
11
8514
7
3
8
6
10
9
2
15 13 1614
17
1. TORQUE TO 115 FT-LB2. DO NOT USE THREAD LOCKER.
MAST ASM (41705155)ITEM PART NO. DESCRIPTION QTY 1. 52705153 RESERVOIR (PART OF 14) 1REF 2. 52705154 MAST 1 3. 60108164 POWER UNIT COVER 1 4. 70392298 BREATHER (PART OF 14) 1REF 5. 72060021 CAP SCR 5/16-18X1/2 HH GR5 4 6. 72060833 SCR 5/16-18X3/4 HH SLFTPG 4 7. 72532261 SIGHT GAUGE 3/4 (PART OF 14) 1REF 8. 72063050 WASHER 5/16 LOCK 8 9. 72063117 WASHER 9/16 HARD GR8 1210. 72601144 CAP SCR 9/16-12 X 2 HHGR8 1211. 70142779 SUCTION STRAINER S5-100-RV 1
(PART OF 12)12. 51705236 RESERVOIR ASM (1,4,7,11,17) 113. 60126047 SPACER 1.38 OD X 1.5 1
LONG .26 BORE14. 72060010 CAP SCR .25-20 X 2.50 HHGR5Z 115. 72062104 NUT .25-20 HEX NYLOC 116. 70392190 BUMPER-RUBBER 117. 72053246 PLUG-PIPE SQ HD BLK .38 1
(PART OF #12)
00001007: 3-641705145.01.19980806
LOWER BOOM ASM (41705145)ITEM PART NO. DESCRIPTION QTY
LOWER BOOM CYLINDER (3B031840)ITEM PART NO. DESCRIPTION QTY
1. 4B031840 CASE (INCL:3&18) 1 2. 4G031840 ROD (INCL:3) 1 3. 72053507 ZERK 1/4-28 (PART OF 1&2) 2REF 4. 6I030106 PISTON 1 5. 6H030015 HEAD 1 6. 9C121217 SEAL KIT (INCL:7-16) 1 7. 7Q072334 O-RING (PART OF 6) 1REF 8. 7Q10P334 BACK-UP RING (PART OF 6) 1REF 9. 7T2N8015 WEAR RING (PART OF 6) 1REF10. 7R546015 ROD SEAL (PART OF 6) 1REF11. 7R14P015 ROD WIPER (PART OF 6) 1REF12. 7T61N106 LOCK RING SEAL (PART OF 6) 1REF13. 7T65I030 PISTON RING (PART OF 6) 2REF14. 7T66P030 PISTON SEAL (PART OF 6) 1REF15. 7Q072145 O-RING (PART OF 6) 1REF16. 6A025015 WAFER LOCK (PART OF 6) 1REF17. 73054304 VALVE 10 GPM 118. 7PNPXT02 PLUG 1/8NPT (PART OF 1) 3REF
NOTEIT IS RECOMMENDED THAT ALL COMPONENTSOF THE SEAL KIT BE REPLACED WHENEVER THECYLINDER IS DISASSEMBLED. THIS WILLREDUCE FUTURE DOWNTIME.
APPLY “LUBRIPLATE #630-2” MEDIUM HEAVY,MULTI-PURPOSE LUBRICANT OR EQUIVALENT TOALL PISTON AND HEAD GLANDS, LOCK RING ANDROD THREADS BEFORE ASSEMBLY.
USE “NEVER-SEEZ” OR EQUIVALENT BETWEENTHE HEAD AND THE CASE WHEN ASSEMBLINGTHE CYLINDER.
00001007: 3-93B030840.01.19940912
EXTENSION CYLINDER (3B030840)ITEM PART NO. DESCRIPTION QTY
1. 4B030840 CASE 1 2. 4G030840 ROD ASM 1 3. 6C150012 STOP TUBE 1.5" 1 4. 6C300012 STOP TUBE 3" 1 5. 6H020012 HEAD 1 6. 6I020075 PISTON 1 7. 9B081012 SEAL KIT (INCL:8-16) 1 8. 7Q072129 O-RING (PART OF 7) 1REF 9. 7T66P020 PISTON SEAL (PART OF 7) 1REF10. 7T61N075 LOCK RING (PART OF 7) 1REF11. 6A025012 WAFER LOCK (PART OF 7) 1REF12. 7Q072224 O-RING (PART OF 7) 1REF13. 7Q10P224 BACKUP RING (PART OF 7) 1REF14. 7R546012 U-CUP (PART OF 7) 1REF15. 7R14P012 ROD WIPER (PART OF 7) 1REF16. 7T2N8012 WEAR RING-ROD (PART OF 7) 1REF
NOTEIT IS RECOMMENDED THAT ALL COMPONENTSOF THE SEAL KIT BE REPLACED WHENEVER THECYLINDER IS DISASSEMBLED. THIS WILLREDUCE FUTURE DOWNTIME.
APPLY “LUBRIPLATE #630-2” MEDIUM HEAVY,MULTI-PURPOSE LUBRICANT OR EQUIVALENT TOALL PISTON AND HEAD GLANDS, LOCK RING ANDROD THREADS BEFORE ASSEMBLY.
USE “NEVER-SEEZ” OR EQUIVALENT BETWEENTHE HEAD AND THE CASE WHEN ASSEMBLINGTHE CYLINDER.
00001007: 3-1091705142.01.19941109
HYDRAULIC KIT-3 SECT/PWR UNIT(91705142)ITEM PART NO. DESCRIPTION QTY
(PART OF INSTL. KIT)11. 77041237 SOLENOID 12V 80% 150A 112. 51704784 CABLE ASM #1WIRE X 6” 113. 77040051 TERM #8 SPRSPD 16-14GA 1014. 70034060 TIE 8" 415. 51705388 CABLE ASM #1WIRE X 72” 1
INSTALLATION OF AUXILIARY CHASSIS GROUND CABLEKIT (51716427)Due to the increased use of electrical components installed onIMT products, we have instituted the practice of installing anauxiliary ground cable between the chassis frame and batteryground terminal, to assist the electrical system of both IMTproduct and chassis. If your equipment does not include thecable, consider adding the ground cable for added assistance.Install the auxiliary ground cable as follows:
1. Connect one end of cable to chassis frame using 3/8” x 1-1/2” bolt, 5/16” flat washer, 3/8” lock washer, and 3/8” hex nut.See Note.
2. Connect the remaining end of the cable to the groundterminal of the chassis battery or to the engine block. SeeNote.
NOTEGround connections made to metal surfaces shall maintaincontact integrity when subjected to the normal effects of aging,temperature cycling, moisture, splash, spray washing, fatigue,and other environmental conditions. Metal surfaces shall be freeof primer, paint, rust, and corrosion, and have a bright, polishedappearance immediately before the ground terminal is connected.A steel flat washer, with an outside diameter approximately equalto the ring terminal diameter, shall be placed between bolt headand terminal. Grounding studs and joints shall be dedicated tothe ground and not be used as a structural joint.
00001007: 3-2351713619.01.19970428
REMOTE HANDLE ASM (51713619)ITEM PART NO. DESCRIPTION QTY
1. 60045031 WIRE 18GA GRN X 4 3 2. 60119335 CONTROL HANDLE 1 4. 60119277 FRONT COVER 1 5. 70034306 BACK COVER 1 6. 70029119 SER NO PLACARD 1 7. 77044096 CORD GRIP 1 9. 70394447 DECAL-DGR RC ELECTRO SM 110. 70394142 DECAL-REMOTE 1
D 1 Labels All load charts, safety & warning labels, & control labels are present and legible.
D 2 Check all safety devices for proper operation.
D 3 Controls Control mechanisms for proper operation of all functions, leaks & cracks.
D 4 Station Control and operator’s station for dirt, contamination by lubricants, & foreign materials.
D 5 Hyd System Hydraulic system (hoses, tubes & fittings) for leakage & proper oil level.
D 6 Hook Presence & proper operation of hook safety latches.
D 7 Rope Proper reeving of wire rope on sheaves & winch drum.
D 8 Pins Proper engagement of all connecting pins & pin retaining devices.
D 9 General Overall observation of crane for damaged or missing parts, cracked welds & presence of safety covers.
D 10 Operation During operation, observe crane for abnormal performance, unusual wear
(loose pins, wire rope damage, etc.).
If observed, discontinue use & determine cause & severity of hazard.
D 11 Remote Ctrls Operate remote control devices to check for proper operation.
D 12 Electrical Operate all lights, alarms, etc. to check for proper operation.
D 13 Anti 2-Blocking Operate anti 2-blocking device to check for proper operation.
D 14 Other
D 15 Other
STATUS
FREQUENCY
✔ ,✘
R, NAINSPECTION DESCRIPTIONKEYITEM
✔ = SATISFACTORY✘ = DEFICIENCY
(must be corrected prior to operation)
R = RECOMMENDATION(should be considered for corrective action)
NA = NOT APPLICABLE
RE
V: 6
-18-
99NOTICE
The user of this form is responsible in determining that these
inspections satisfy all applicable regulatory requirements
20000710
4-4 SECTION 4. GENERAL REFERENCE
M 16 Daily All daily inspection items.
M 17 Cylinders Visual inspection of cylinders for leakage at rod, fittings & welds. Damage to rod & case.M 18 Valves Holding valves for proper operation.
M 19 Valves Control valve for leaks at fittings & between sections.
M 20 Valves Control valve linkages for wear, smoothness of operation & tightness of fasteners.M 21 General Bent, broken or significantly rusted/corroded parts.
M 22 Electrical Electrical systems for presence of dirt, moisture & frayed wires.
M 23 Structure All structural members for damage.M 24 Welds All welds for breaks & cracks.
M 25 Pins All pins for proper installation & condition.
M 26 Hardware All bolts, fasteners & retaining rings for tightness, wear & corrosionM 27 Wear Pads Presence of wear pads.
M 28 Pump & Motor Hydraulic pumps & motors for leakage at fittings, seals & between sections.
M 29 PTO Transmission/PTO for leakage, abnormal vibration & noise.M 30 Hyd Fluid Quality of hydraulic fluid and for presence of water.
M 31 Hyd Lines Hoses & tubes for leakage, abrasion damage, blistering, cracking, deterioration, fitting leakage & secured properly.
M 32 Hook Load hook for abnormal throat distance, twist, wear & cracks.
M 33 Rope Condition of load line.M 34 Manual Presence of operator’s manuals with unit.
M 35 Other
Q 36 Daily All daily inspection items.Q 37 Monthly All monthly inspection items.
Q 38 Condition of wear pads
Q 39 Rotation Sys Rotation bearing for proper torque of all accessible mounting bolts.Q 40 Hardware Base mounting bolts for proper torque.
Q 41 Structure All structural members for deformation, cracks & corrosion.42 ● Base
Q 89 Winch Winch, sheaves & drums for damage, abnormal wear, abrasions & other irregularities.
Q 90 Hyd Filters Hydraulic filters for replacement per maintenance schedule.A 91 Daily All daily inspection items.
A 92 Monthly All monthly inspection items.A 93 Quarterly All quarterly inspection items.
A 94 Hyd Sys Hydraulic fluid change per maintenance schedule.
A 95 Controls Control valve calibration for correct pressures & relief valve settingsA 96 Valves Safety valve calibration for correct pressures & relief valve settings.
A 97 Valves Valves for failure to maintain correct settings.
A 98 Rotation Sys Rotation drive system for proper backlash clearance & abnormal wear, deformation & cracks.A 99 Lubrication Gear oil change in rotation drive system per maintenance schedule.
A 100 Hardware Check tightness of all fasteners and bolts.
A 101 Wear Pads Wear pads for excessive wear.A 102 Loadline Loadline for proper attachment to drum.
WIRE ROPE INSPECTIONWire rope with any of the deficiencies shown below shall beremoved and replaced immediately.
A. Corrosion can be cause for replacement. Anydevelopment of corrosion must be noted andmonitored closely.
B. When there are either 3 broken wires in one strandor a total of six broken wires in all strands in any onerope lay.
C. When flat spots on the outer wires appear and thoseoutside wires are less than 2/3 the thickness of theunworn outer wire.
D. When there is a decrease of diameter indicating acore failure.
E. When kinking, crushing, birdcaging or otherdistortion occurs.
F. When there is noticeable heat damage(discoloration) of the rope by any means.
G. When the diameter is reduced from nominal size by1/32" or more.
H. If a broken wire protrudes or loops out from the coreof the rope.
HOOK INSPECTIONHooks having any of the listed deficiencies shall beremoved from service unless a qualified person approvestheir continued use and initiates corrective action. Hooksapproved for continued use shall be subjected to periodicinspection.
A. DISTORTIONBending / TwistingA bend or twist exceeding 10° from the plane of theunbent hook.
Increased Throat OpeningHOOK WITHOUT LATCH: An increase in throatopening exceeding 15% (Or as recommended by themanufacturer)
HOOK WITH LATCH: An increase of the dimensionbetween a fully-opened latch and the tip section of thehook exceeding 8% (Or as recommended by themanufacturer)
B. WEARIf wear exceeds 10% of the original sectionaldimension. (Or as recommended by the manufacturer)
C. CRACKS, NICKS, GOUGESRepair of cracks, nicks, and gouges shall be carried outby a designated person by grinding longitudinally,following the contour of the hook, provided that nodimension is reduced more than 10% of its originalvalue. (Or as recommended by the manufacturer) (Aqualified person may authorize continued use if thereduced area is not critical.)
D. LATCHEngagement, Damage & MalfunctionIf a latch becomes inoperative because of wear ordeformation, and is required for the service involved, itshall be replaced or repaired before the hook is putback into service. If the latch fails to fully close thethroat opening, the hook shall be removed from serviceor “moused” until repairs are made.
E. HOOK ATTACHMENTS & SECURING MEANSIf any indication of distortion, wear, cracks, nicks orgouges are present, unless a qualified personauthorizes their use. (Or as recommended by themanufacturer)
20000710
4-8 SECTION 4. GENERAL REFERENCE
HOLDING VALVE INSPECTIONThe cylinders are equipped with holding valves that preventsudden movement of the cylinder rods in the event of ahydraulic hose or other hydraulic component failure. Thevalve is checked in the following manner:
1. With a full rated load, extend the cylinder in questionand kill the engine.
2. Operate the control valve to retract the cylinder. If thecylinder “creeps”, replace the holding valve. If thecylinder does not “creep”, the valve is serviceable.
ANTI-TWO BLOCKING DEVICE INSPECTION(See Vol. 1, Operation, Maintenance and Repair for acomplete description)The anti two block system should be checked daily asfollows:
1. Examine flexible rod and weight to insure freeunrestricted mechanical operation
2. Examine cord for damage, cuts or breaks. Grasp cordand pull to check operation of cord reel. The cord shouldretract on reel when released.
3. Start vehicle, engage PTO and slowly winch loadlineup until anti-two block weight comes in contact with thehook end of the loadline cable. At the moment the weightis fully supported, a marked difference in winch operationshould be noted. At this point, the winch up functionshould become very sluggish or non-functioning andhave very little pull capability. Slowly increase truckengine speed while simultaneously actuating the winchup function. The winch characteristics should remainsluggish with little or no tensioning of the cable. Ifoperation other than as described occurs, stopimmediately and investigate. Failure to do so will riskdamage to the cable or the crane.If all is well at this point,actuate the boom extend function slowly, and graduallyincrease to full actuation. Once again the function shouldbe sluggish or non-existent with no tightening of thewinch cable. If operation other than described occurs,stop immediately and reverse the function.
The final check involves actuating both the winch up andextend functions together and checking for properoperation of the anti two blocking circuit. Once again,start slowly and stop if it appears the cable is beingtensioned.
If the anti two block function appears to be functioningnormally, winch the cable down until the sensing weightswings free.
When using the torque data in the charts above, the following rulesshould be observed.
1. Bolt manufacturer’s particular specifications should beconsulted when provided.2. Flat washers of equal strength must be used.3. All torque measurements are given in foot-pounds. Toconvert to inch-pounds, multiply by 12.4. Torque values specified are for bolts with residual oils or nospecial lubricants applied. If special lubricants of high stressability, such as Never-Seez compound graphite and oil,molybdenum disulphite, collodial copper or white lead areapplied, multiply the torque values in the charts by the factor .90.The use of Loctite does not affect the torque values listedabove.5. Torque values for socket-head capscrews are the same asfor Grade 8 capscrews.
WARNINGAnytime a gear-bearing bolt is removed, it must be replaced with anew bolt of the identical grade and size. Once a bolt has beentorqued to 75% of its proof load and then removed, the torquecoefficient may no longer be the same as when the bolt was newthus giving indeterminate clamp loads after torquing. Failure toreplace gear-bearing bolts may result in bolt failure due to metalfatique causing serious injury or DEATH.
When using the torque data in the charts above, the following rules should be observed.
1. Bolt manufacturer’s particular specifications should be consulted when provided.
2. Flat washers of equal strength must be used.
3. All torque measurements are given in foot-pounds. To convert to inch-pounds, multiply by 12.
4. Torque values specified are for bolts with residual oils or no special lubricants applied.If special lubricants of high stress ability, such as Never-Seez compound graphite and oil, molybdenumdisulphite, collodial copper or white lead are applied, multiply the torque values in the charts by thefactor .90. The use of Loctite does not affect the torque values listed above.
5. Torque values for socket-head capscrews are the same as for Grade 8 capscrews.
WARNINGAnytime a gear-bearing bolt is removed, it must be replaced with a new bolt of the identical grade and size. Once a bolthas been torqued to 75% of its proof load and then removed, the torque coefficient may no longer be the same as whenthe bolt was new thus giving indeterminate clamp loads after torquing. Failure to replace gear-bearing bolts may result inbolt failure due to metal fatique causing serious injury or DEATH.
When using the torque data in the charts above, the following rules should be observed.
1. Bolt manufacturer’s particular specifications should be consulted when provided.
2. Flat washers of equal strength must be used.
3. All torque measurements are given in kilogram-meters.
4. Torque values specified are for bolts with residual oils or no special lubricants applied.If special lubricants of high stress ability, such as Never-Seez compound graphite and oil, molybdenumdisulphite, collodial copper or white lead are applied, multiply the torque values in the charts by thefactor .90. The use of Loctite does not affect the torque values listed above.
5. Torque values for socket-head capscrews are the same as for Grade 8 capscrews.
WARNINGAnytime a gear-bearing bolt is removed, it must be replaced with a new bolt of the identical grade and size. Once a bolthas been torqued to 75% of its proof load and then removed, the torque coefficient may no longer be the same as whenthe bolt was new thus giving indeterminate clamp loads after torquing. Failure to replace gear-bearing bolts may result inbolt failure due to metal fatique causing serious injury or DEATH.
TIGHTENING PROCEDURE:1. Refer to the Torque Data Chart to determine the proper torque value to apply to the size of capscrew
used.
2. Follow the tightening sequence shown in the diagram. Note that the quantity of capscrews may differfrom the diagram, but the sequence must follow the criss-cross pattern as shown in the diagram.
3. Torque all capscrews to approximately 40% of the specified torque value, by following the sequence.(EXAMPLE: .40 x 265 FT-LBS = 106 FT-LBS)(EXAMPLE-METRIC: .40 x 36 KG-M = 14.4 KG-M)
4. Repeat Step 3, but torqueing all capscrews to 75% of the specified torque value. Continue to follow thetightening sequence.
(EXAMPLE: .75 x 265 FT-LBS = 199 FT-LBS)(EXAMPLE-METRIC: .75 x 36 KG-M = 27 KG-M)
5. Using the proper sequence, torque all capscrews to the listed torque value as determined from theTorque Data Chart.
TURNTABLE BEARING FASTENER TIGHTENING SEQUENCERefer to the diagram below for proper tightening/torqueing sequence of the turntable bearing to the cranebase and crane mast. The total quantity of cap screws varies dependent on crane model.
WARNINGNumber 1 can be assigned toany capscrew if the sequenceremains the same in referenceto number 1.
3 711
15
19
23
1
5
9
13
172148
12
16
20
24
2
6
10
14
1822
20000710
4-12 SECTION 4. GENERAL REFERENCE
Before a bearing is removed from a crane forinspection, one of the following conditions should beevident:
1. Metal particles present in the bearinglubricant.2. Increased drive power required to rotate the crane.3. Noise emitting from the bearing during crane
rotation.4. Rough crane rotation.5. Uneven or excessive wear between the pinion
gear and turntable gear.
TURNTABLE BEARING INSPECTION FOR REPLACEMENT
If none of the above conditions exists, the bearing isfunctioning properly and need not be replaced. But, ifone or more of the above conditions exists, inspectionmay be required. Limits are measured in “TILT” which isdependent on the internal clearances of the bearing.TILT is the most practical determination of a bearingsinternal clearance once mounted on a crane.
Periodic readings indicating a steady increase in TILTmay be an indicator of bearing wear. Note that abearing found to have no raceway cracks or otherstructural irregularities should be reassembled andreturned to service.
TEST PROCEDURE
STEP 1.With the crane horizontal and fully extended, measurebetween the top and bottom mounting surfaces of theturntable bearing (A1), using a dial indicator foraccuracy.
STEP 2.Reverse the load by applying minimal downwardpressure on the boom while the boom is in the boomsupport or on a solid surface. Again measure A2.
STEP 3.Subtract A1 from A2 to determine tilt and compare theresult with the accompanying chart.
NOTETHE FIGURES LISTED INTHIS CHART ARESERVICE GUIDELINESAND DO NOT, INTHEMSELVES, REQUIRETHAT THE BEARING BEINSPECTED.
IF THERE IS REASONTO SUSPECT ANEXCESS OF BEARINGWEAR AND THEMEASURED TILTDIMENSION EXCEEDSTHE DIMENSIONLISTED, REMOVE THEBEARING FORINSPECTION.
IMTCRANE,LOADER
ORTIREHAND
MODEL
BALL DIA.(REF)
TILT DIM.(A1-A2)
.060”(1.524mm)
.070”(1.778mm)
.075”(1.905mm)
.090”(2.286mm)
.875”(22mm)
1.00”(25mm)
1.18”-1.25”(30-32mm)
1.75”(44mm)
100710141014A10152015/2020210930003816/38203016/3020421/42543005016/50206016/6020TH7 BODY ROT’NTH1449 BODY ROT’NTH15B CLAMPTH2551B CLAMPTH2557A CLAMP
52005200R5217580070207025720074159000TH10 BODY ROT’NTH14 BODY ROT’N
160003201832030T30T40
980012916130311303414000150001800020017H1200H1200RRT50TH2551B BODY ROT’NTH2557B BODY ROT’NTH2557A BODY ROT’N
COMPARISON CHART - MODEL TO MEASURED TILT DIMENSION
20000710
4-13 SECTION 4. GENERAL REFERENCE
The information within this manual has been compiled and checked but errors do occur. To provide our customers with amethod of communicating those errors we have provided the Manual Change Request form below. In addition to errorreporting, you are encouraged to suggest changes or additions to the manual which would be of benefit to you. Wecannot guarantee that these additions will be made but we do promise to consider them. When completing the form,please write or print clearly. Submit a copy of the completed form to the address listed below.