Operator's Crane Safety Manual (99900313)Operator’s Crane Safety Manual IOWA MOLD TOOLING CO.,...

CR SFTY: 99900313: i20090420

Operator’sCrane Safety Manual

IOWA MOLD TOOLING CO., INC.BOX 189, 500 HWY 18 WEST, GARNER, IA 50438

TEL: 641-923-3711FAX: 641-923-2424

MANUAL PART NUMBER 99900313

Iowa Mold Tooling Co., Inc. is an Oshkosh Corporation company.

CR SFTY: 99900313: ii

This Crane Safety Manual is intended as a basic source of information on the safe operation of your crane. Itprovides general information as well as specific information on IMT cranes and their operation as concerns safety.It is not intended as an all encompassing “rule-book” on crane safety. IMT presents this information as areference and guide only. It is your responsibility to identify specific safety hazards and determine properprocedures to prevent those hazards from inflicting injury.

We at IMT believe that safety is paramount in the operation of its equipment. Please furnish a copy of thismanual to all persons involved in the operation and maintenance of your IMT crane. IMT grants you, thepurchaser, the right to reproduce this document for that purpose and to further the education in safe operation andmaintenance.

Copies of this manual are also available from IMT and its distributors at a nominal price. Please contact yourdistributor or IMT for additional copies.

INTRODUCTION

NOTICE TO THE OWNER / USERIf your crane is involved in a property damage accident, contact your IMT distributor immediatelyand provide them with the details of the accident and the serial number of the crane. If anaccident involves personal injury, immediately notify your distributor and IMT’s Safety Directorat:

IOWA MOLD TOOLING CO., INC.500 HWY 18 WEST, GARNER, IA 50438

641 - 923 - 3711

20000705

REVISIONS LISTDATE LOCATION DESCRIPTION OF CHANGE- - -20010907 12-12 CORRECTED MISSPELLING20061020 1-1 UPDATE WITH NEW OWNER STATEMENT.20080508 1-1 UPDATED OSHKOSH STATEMENT.20090420 8-5 ADDED WIRE ROPE LAY INFORMATION

9-5 THRU 8 ADDED STABILITY TEST

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Section 1. GENERAL INFORMATIONGeneral 1-1Crane Safety Manual 1-2

Section 2. CRANE COMPONENTIDENTIFICATION

Component Identification 2-1

Section 3. DECALSDecal Placement - Telescoping Cranes 3-1Decal Placement - Articulating Cranes 3-2"Danger” Decal Descriptions 3-3Instructional Decals 3-10

Section 4. HAND SIGNALSSignals 4-1

Section 5. THE OPERATOROperator Qualifications 5-1Physical Condition 5-1Operator Conduct 5-1Knowledge And Abilities Required 5-2

Section 6. CRANE OPERATIONOperation Responsibilities 6-1Inspections 6-1Crane Transport 6-1Crane Set-Up 6-2Safe Crane Operation 6-3Crane Capacity 6-3Crane Controls 6-3Operating The Crane 6-3Maintenance 6-4Important Precautions 6-4Fire Precautions 6-4Winch Related Precautions 6-5Engaging The PTO 6-5Disengaging The PTO 6-5

Section 7. CRANE OPERATIONNEAR POWERLINES

Precautions 7-1If Electrical Contact Occurs 7-2

Section 8. WIRE ROPE PRECAUTIONSGeneral 8-1Wire Rope Description 8-1Basic Information 8-1Wire Rope Inspection 8-2Wire Rope Precautions 8-2Lubrication Of Wire Rope 8-2When To Replace Wire Rope 8-3Wire Rope Slings 8-4Basic Hitches 8-4Sling Loading 8-5Wire Rope Lay 8-5Wedge Socket Attachment 8-6Cable Thimble Attachment 8-6

Section 8A. HOOK PRECAUTIONSGeneral 8A-1Latches 8A-1Hook Swivels 8A-2Hook Precautions 8A-2Hook Inspection 8A-3New and Repaired Hooks 8A-3Hooks in Regular Use 8A-3Hooks Not in Regular Use 8A-3Methods of Hook Inspection 8A-3Hook Inspection Checklist 8A-4Hook Testing 8A-4Definitions 8A-5

Section 9. CAPACITY PLACARDSCrane Capacity Placards 9-1Capacity Conditions 9-1Using The Capacity Placard

(Articulating Cranes) 9-1Using The Capacity Placard

(Telescoping Cranes) 9-2Crane Stability 9-5

Section 9A. CAPACITY ALERT SYSTEMSCrane Capacity Alert System

(Electrically Operated) 9A-1Capacity Alert System

(Hydraulically Operated) 9A-2Crane Capacity Audible Alert System

(Electrically Operated) 9A-3

Section 10. OPERATIONAL REFERENCEExtension Boom Sequence 10-1Anti Two-Blocking Device 10-2Figure-Four Folding Cranes 10-3Stowing Telescoping Cranes 10-5Stowing Articulating Cranes 10-6Outrigger Operation 10-7Direction Terminology 10-9Crane Lubrication 10-10

Section 11. MAINTENANCE PRECAUTIONSMaintenance Precautions 11-1General Precautions 11-1Chemicals 11-2

Section 12. REFERENCE DATATurntable Bearing FastenerTightening Sequence 12-1Tire Inflation Pressures - Bias Ply 12-2Tire Inflation Pressures - Radial Ply 12-3Tire Inflation Pressures - Wide Base & Low Profile 12-4Tire Inflation Pressures - Imported 12-5Torque Data Chart 12-6Crane Inspection Checklist 12-7

TABLE OF CONTENTS

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A-1. By-Stander Clearance 1-1A-2. Typical Page Description 1-2A-3. Revised Page 1-2B-1. Telescoping Crane - Major Assemblies 2-1B-2. Telescoping Crane - Hydraulic Components 2-1B-3. Articulating Crane - Major Assemblies 2-2B-4. Articulating Crane - Hydraulic Components 2-2B-5. Typical Gear Train Configuration 2-3C-1. Decal Locations On Telescoping Cranes 3-1C-2. Decal Locations On Articulating Cranes 3-2C-3. Decal - Electrocution Hazard 3-3C-4. Decal - Electrocution Hazard 3-3C-5. Decal - Electrocution Hazard 3-4C-6. Decal - Electrocution Hazard 3-4C-7. Decal - Electrocution Hazard-RC Oper 3-5C-8. Decal - Electrocution Hazard-RC Oper 3-5C-9. Decal - Electrocution Hazard-RC Oper 3-5C-10. Decal - Electrocution Hazard-RC Oper 3-5C-11. Decal - Outrigger Foot Crushing Hazard 3-6C-12. Decal - Moving Outrigger Hazard 3-6C-13. Decal - Moving Boom Hazard 3-6C-14. Decal - Moving Driveline Hazard 3-7C-15. Decal - Two Block Hazard 3-7C-16. Decal - Riding on Boom Hazard 3-7C-17. Decal - Hoisting Personnel Hazard 3-8C-18. Decal - Untrained Operator Hazard 3-8C-19. Decal - Multiple Operation Hazard 3-8C-20. Decal - Failure to Obey Hazard 3-9C-21. Decal - Failure to Obey Hazard 3-9C-22. Decal - Free Falling Manual Boom Hazard 3-9C-23. Decal - Warning Manual Outriggers 3-10C-24. Decal - Set Up / Stow Instructions 3-10C-25. Decal - Rotational Alignment 3-10C-26. Decal - Grease Weekly 3-11C-27. Decal - Rotate Crane / Grease 3-11C-28. Decal - Contact IMT 3-11C-29. Decal - Return Line 3-12C-30. Decal- Suction Line 3-12C-31. Decal - Lubricate Worm Gear 3-12C-32. Decal - Caution Do Not Wash / Wax 3-13C-33. Decal - Boom Angle Indicator 3-13C-34. Decal - Caution Oil Level 3-13C-35. Decal - Hyd Oil Fill Recommendations 3-14D-1. Crane Operation Hand Signals 4-2E-1. Operator Qualifications 5-1E-2. Physical Considerations 5-1E-3. Safety Is Your Responsibility 5-2F-1. Crane Set-Up Precautions 6-2F-2. Do Not Ride The Loadline 6-5F-3. PTO Danger Decal 6-5G-1. Electrical Hazard Warning Decal 7-1G-2. Required Clearances Of Cranes

From Electrical Transmission Lines 7-2G-3. Danger Zone For Cranes Operating

Near Electrical Transmission Lines 7-2

H-1. When To Replace Wire Rope 8-3H-2. Basic Hitches 8-4H-3. Load at Various Sling Angles 8-5H-4. Approved Wedge Socket Attachment Methods 8-6H-5. Approved Cable Thimble Attachment Method 8-6H1-1. Common Hooks 8A-1H1-2. Hook Terminology 8A-2I-1. One-Part Line Configuration 9-2I-2. Two-Part Line Configuration 9-2I-3. Three-Part Line Configuration 9-2I-4. Articulating Crane Capacity Placard Description 9-3I-5. Telescoping Crane Capacity Placard Description 9-4I-6. Stability Chart-Crane Mounted Behind Cab 9-7I-7. Stability Chart-Rear Mounted Crane 9-8I1-1. General Capacity Alert System

Wiring Diagram (Electrical) 9A-1I1-2. General Capacity Alert System

Diagram (Hydraulic) 9A-2I1-3. General Capacity Audible Alert System

Wiring Diagram 9A-3J-1. Proper Extension Boom Deployment 10-1J-2. Improper Extension Boom Deployment 10-1J-3. Two-Blocking Decal 10-2J-4. Anti Two-Blocking Device Components 10-2J-5. Normal Work Position 10-2J-6. Approaching Two-Blocking Situation 10-2J-7. Stow / Unfold Decal 10-3J-8. Unfolding Sequence 10-3J-9. Folding Sequence 10-4J-10. Telescoping Crane Stowage Configuration 10-5J-11. Articulating Crane Stowage

Configuration - Boom Support 10-6J-12. Articulating Crane Stowage

Configuration - Retracted Outer Boom 10-6J-13. Outrigger Deployment Sequence 10-7J-14. Moving Outrigger Decal 10-8J-15. Stand Clear Decal 10-8J-16. Outrigger Storage Sequence 10-8J-17. Crane Operation Directional Terminology 10-9J-18. Grease Weekly Decal 10-10J-19. Lubrication Product and Schedule 10-10J-20. Typical Grease Zerk Locations -

Telescoping Cranes 10-11J-21. Typical Grease Zerk Locations -

Articulating Cranes 10-12K-1. Chemical Container Label 11-2L-1a. Turntable Bearing Fastener Tightening Sequence 12-1L-1. Tire Load And Inflation Pressures - Bias Ply 12-2L-1A. Tire Load And Inflation Pressures - Radial Ply 12-3L-1B. Tire Load And Inflation Pressures -

Wide Base & Low Profile Radial Ply 12-4L-1C. Tire Load And Inflation Pressures -

Imported Radial Ply 12-5L-2. Recommended Bolt Torques 12-6

LIST OF ILLUSTRATIONS

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GENERAL��

WARNINGFAILURE TO READ, UNDERSTAND AND FOLLOWANY SAFETY PROCEDURES APPLICABLE TO YOUREQUIPMENT MAY RESULT IN EQUIPMENT DAMAGE,SERIOUS INJURY OR DEATH.

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WARNINGCHILDREN, BY-STANDERS AND PERSONS NOTREQUIRED IN THE OPERATION OF EQUIPMENTMUST BE KEPT AT A SAFE DISTANCE FROM THATEQUIPMENT. A DISTANCE OF 10'-0” (3.05m) FROMTHE OUTERMOST RANGE OF THE CRANE AND ITSLOAD IS AN ABSOLUTE MINIMUM.

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Figure A-1. By-Stander Clearance

CR SFTY: 99900313: 1-219981012

Figure A-2. Typical Page Description Figure A-3. Revised Page

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NOTEA NOTE IS USED TO EITHER CONVEY ADDITIONALINFORMATION OR TO PROVIDE FURTHEREMPHASIS FOR A PREVIOUS POINT.

CAUTIONA CAUTION IS USED WHEN THERE IS THE STRONGPOSSIBILITY OF DAMAGE TO THE EQUIPMENT ORPREMATURE EQUIPMENT FAILURE.

WARNINGA WARNING IS USED WHEN THERE IS THEPOTENTIAL FOR PERSONAL INJURY OR DEATH.

CR SFTY: 99900313: 2-119981012

Section 2. CRANE COMPONENT IDENTIFICATION

Figure B-1. Telescoping Crane - Major Assemblies

COMPONENT IDENTIFICATION��

��

Figure B-2. Telescoping Crane - Hydraulic Components

NOTE 1.ROTATION SYSTEMS WILL VARY DEPENDING ONTHE CRANE MODEL. WORM GEAR SYSTEM ISSHOWN.

NOTE 2.EXTENSION BOOM CYLINDERS MAY BEINTERNALLY MOUNTED OR EXTERNALLYMOUNTED, DEPENDING ON THE CRANE MODEL.

NOTE 1.THERE MAY BE MORE THAN ONE EXTENSIONBOOM AND THEY WILL BE IN NUMERICAL ORDERSUCH AS 2ND STAGE OR 3RD STAGE EXTENSIONBOOMS.

CR SFTY: 99900313: 2-219981012

Figure B-3. Articulating Crane - Major Assemblies

Figure B-4. Articulating Crane - Hydraulic Components

NOTE 1.CYLINDER MAY BE INTERNALLY OR EXTERNALLYMOUNTED DEPENDING ON THE CRANE MODEL.

NOTE 2.“FIGURE-4 FOLDING” ARTICULATING CRANESUTILIZE TWO INNER BOOM CYLINDERS WHILEMOST ARTICULATING CRANES USE ONE INNERBOOM CYLINDER.

NOTE 3.HYDRAULIC CONTROLS ARE NORMALLY PRESENTON BOTH SIDES OF CRANE BASE. REMOTECONTROLS MAY ALSO BE USED.

NOTE 1.OUTRIGGER DESIGN MAY VARY DEPENDING ONTHE CRANE MODEL.

NOTE 2.EXTENSION BOOMS MAY NUMBER MORE THAN 3AND WILL BE IN NUMERICAL ORDER SUCH AS 4TH,5TH AND 6TH STAGE EXTENSION BOOMS.

CR SFTY: 99900313: 2-319981012

ITEM DESCRIPTION

1. ROTATION MOTOR 2. HYDRAULIC BRAKE 3. DRIVE GEAR 3A. UPPER DRIVE GEAR BUSHING 3B. LOWER DRIVE GEAR BUSHING 3C. DRIVE GEAR GREASE PLATE 4. INTERMEDIATE GEAR 5. PINION GEAR 5A. UPPER PINION GEAR BUSHING 5B. LOWER PINION GEAR BUSHING 5C. INTERMEDIATE GEAR THRUST BEARING 6. TURNTABLE GEAR BEARING

Figure B-5. Typical Gear Train Configuration

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CR SFTY: 99900313: 3-120000705

Section 3. DECALSDECAL PLACEMENT - TELESCOPINGCRANESThe positioning of decals on a telescopingcrane is usually similar between varyingmodels. Figure C-1 illustrates commonpositioning of decals used on telescopingcranes.

ITEM DECAL DESCRIPTION QTY SEE FIG.

1. WARNING-MANUAL OUTRIGGER 2 C-23 2. GREASE WEEKLY-LEFT ARROW AR C-26 3. GREASE WEEKLY-RIGHT ARROW AR C-26 4. SUCTION LINE 1 C-30 5. RETURN LINE 1 C-29 6. CAUTION-DO NOT WASH/WAX 1 C-32 7. ROTATE CRANE/GREASE 1 C-27 8. CRANE MODEL NUMBER 2 9. DANGER-ELECTROCUTION 1 C-410. DANGER-UNTRAINED OPERATOR 2 C-1811. DANGER-OPERATION 2 C-1912. DANGER-TWO BLOCKING 2 C-1513. DANGER-HOISTING PERSONNEL 2 C-1714. DANGER-OUTRIGGER STAND CLEAR 2 C-1115. DANGER-ELECTROCUTION 4 C-616. DANGER-OPERATION CONDITIONS 2 C-2017. DANGER-OUTRIGGER MOVING 2 C-1218. DANGER-CRANE LOADLINE (TRUCK) 4 C-1619. IMT DIAMOND 220. DANGER-OPERATION RESTRICTIONS 2 C-2121. DANGER-RC ELECTROCUTION-LG 1 C-822. DANGER-ROTATING DRIVELINE 1 C-1423. CONTACT IMT 1 C-2824. CAUTION-OIL LEVEL 1 C-3425. ANGLE CHART- RIGHT SIDE 1 C-3326. ANGLE CHART-LEFT SIDE 1 C-3327. CAPACITY CHART 228. LUBRICATE WORM GEAR 1 C-3129. DANGER-RC ELECTRO-HANDLE 1 C-1030. DANGER-FREEFALLING MNL BOOM 1 C-2231. HYDRAULIC OIL RECOMMENDATION 1 C-35

Figure C-1. DECAL LOCATIONS ON TELESCOPING CRANES

NOTEPLACEMENT OF A HAZARD WARNING DECAL MUSTBE IN A POSITION WHICH IS EASILY VISIBLE TOTHE PERSON RESPONSIBLE FOR TAKING THEAPPROPRIATE ACTION WHICH THAT DECALADDESSES.

CR SFTY: 99900313: 3-2

ITEM DECAL DESCRIPTION QTY SEE FIG.

1. IMT DIAMOND 2 2. SET UP/STOW INSTRUCTIONS 1 C-24 3. GREASE WEEKLY-LEFT ARROW AR C-26 4. GREASE WEEKLY-RIGHT ARROW AR C-26 5. SUCTION LINE 1 C-30 6. RETURN LINE 1 C-29 7. CRANE MODEL NUMBER 2 8. CAUTION-DO NOT WASH/WAX 1 C-32 9. ROTATE CRANE/GREASE 1 C-2710. DANGER-ELECTROCUTION 2 C-311. DANGER-UNTRAINED OPERATOR 2 C-1812. DANGER OPERATION 2 C-1913. DANGER-OUTRIGGER STAND CLEAR 2 C-1114. DANGER-ELECTROCUTION 4 C-515. DANGER-OPERATION CONDITIONS 2 C-2016. DANGER-OUTRIGGER MOVING 2 C-1217. DANGER OPERATION RESTRICTIONS 2 C-2118. DANGER-STOWING/UNFOLDING 2 C-1319. DANGER-ROTATING DRIVELINE 1 C-1420. CONTACT IMT 1 C-2821. CAUTION-OIL LEVEL 2 C-3422. CAPACITY CHART 223. STREET SIDE CONTROLS 124. CURB SIDE CONTROLS 125. OUTRIGGER CONTROLS SS 126. OUTRIGGER CONTROLS CS 127. CRANE ROTATION ALIGNMENT 1 C-2528. DANGER-RC ELECTROCUTION-LG 2 C-729. DANGER-RC ELECTROCUTION-HANDLE 1 C-930. DANGER-TWO BLOCKING 2 C-1531. DANGER-CRANE LOADLINE (TRUCK) 4 C-1632. DANGER-HOISTING PERSONNEL 2 C-1733. DANGER-FREEFALLING MNL BOOM 1 C-2234. HYDRAULIC OIL RECOMMENDATION 1 C-35

Figure C-2. DECAL LOCATIONS ON ARTICULATING CRANES

NOTEPLACEMENT OF A HAZARD WARNING DECAL MUSTBE IN A POSITION WHICH IS EASILY VISIBLE TOTHE PERSON RESPONSIBLE FOR TAKING THEAPPROPRIATE ACTION WHICH THAT DECALADDESSES.

DECAL PLACEMENT - ARTICULATINGCRANESThe positioning of decals on an articulatingcrane is usually similar between varyingmodels. Figure C-2 illustrates commonpositioning of decals used on articulating cranesusing remote controls. Decals specific toremote controls will not be used on manuallycontrolled cranes.

20000705

CR SFTY: 99900313: 3-3

“DANGER” DECAL DESCRIPTIONSAll operators must familiarize themselves with the“DANGER” DECAL DESCRIPTIONS heading in thissection. Your equipment may have additional safetydecals that are not described here. Any safetydecals affixed to your equipment must be identified,read and understood.

The materials and adhesives used in the productionof these decals were designed for maximumdurability, adhesion and legibility. Nevertheless, if adecal (including capacity chart) becomes damagedor illegible, replace it at your earliest opportunity. If acrane is repaired or repainted, replace all decalsbefore the crane is put back into service. Individualdecals as well as complete decal kits are availablefrom IMT.

Shown in the following figures are the safety decalsused on IMT cranes. They are shown here as an aidin their identification with an explanation of theirpurpose, where they are placed on the crane and thenormal quantity used on each crane. All decals areshown half-size.

Figure C-3

DECAL: Electrocution Hazard

PART NUMBER: 70392813

FUNCTION: To inform the operator of thehazard associated with contact or proximityto electrical lines, the possibleconsequences should the hazard occur, andhow to avoid the hazard.

WHERE USED: Articulating cranes

PLACEMENT: At or near the operator’scontrol station(s).

QUANTITY: 2

Figure C-4



FUNCTION: To inform the operator of thehazard associated with contact or proximityto electrical lines, the possibleconsequences should the hazard occur, andhow to avoid the hazard.

WHERE USED: Service body mountedTelescoping Cranes - remote controls.

PLACEMENT: At or near the remote controlhandle storage point.

QUANTITY: 1

20000705

DANGER

Maintain safe clearance from electrical lines.Allow for boom, electrical line, and loadline swaying. This crane does not provide protection from contactwith or proximity to an electrically charged conductor. Maintain a clearance of at least 10 feet betweenany part of the crane, loadline or load and any electrical line carrying up to 50,000 volts (50 kV). If electricalline voltage is unknown, assume maximum voltageand maintain a clearance of at least 45 feet.

70392813

NOMINAL VOLTAGE, kV MINIMUM REQUIRED (Phase to Phase) DISTANCE to 50_____________10 feetOver 50 to 200_____________15 feetOver 200 to 350_____________20 feetOver 350 to 500_____________25 feetOver 500 to 750_____________35 feetOver 750 to 1000_____________45 feet

ELECTROCUTION HAZARDTHIS CRANE IS NOT INSULATED

WILL RESULT FROM CONTACTOR INADEQUATE CLEARANCE

DEATH OR SERIOUS INJURY

DANGER

Maintain safe clearance from electrical lines.Allow for boom, electrical line, and loadline swaying. This crane does not provide protection from contactwith or proximity to an electrically charged conductor. Maintain a clearance of at least 10 feet betweenany part of the crane, loadline or load and any electrical line carrying up to 50,000 volts (50 kV). If electricalline voltage is unknown, assume maximum voltageand maintain a clearance of at least 45 feet.

70394444

NOMINAL VOLTAGE, kV MINIMUM REQUIRED (Phase to Phase) DISTANCE to 50_____________10 feetOver 50 to 200_____________15 feetOver 200 to 350_____________20 feetOver 350 to 500_____________25 feetOver 500 to 750_____________35 feetOver 750 to 1000_____________45 feet

ELECTROCUTION HAZARDTHIS CRANE IS NOT INSULATED

WILL RESULT FROM CONTACTOR INADEQUATE CLEARANCE


CR SFTY: 99900313: 3-4

Figure C-6



FUNCTION: To inform the operator and other personnelin the work area of the hazard associated with contact orproximity to electrical lines, the possible consequencesshould the hazard occur, and how to avoid the hazard.

WHERE USED: Service body mounted TelescopingCranes - remote controls

PLACEMENT: On all four sides of the carrier vehicle.

QUANTITY: 4

Figure C-5



FUNCTION: To inform the operator and other personnelin the work area of the hazard associated with contact orproximity to electrical lines, the possible consequencesshould the hazard occur, and how to avoid the hazard.

WHERE USED: Articulating cranes

PLACEMENT: On all four sides of the carrier vehicle.

QUANTITY: 4

20000705

ELECTROCUTION HAZARDDEATH OR SERIOUS INJURY

KEEP CLEAR OF TRUCK AND LOAD

ELECTROCUTION HAZARDDEATH OR SERIOUS INJURY

KEEP CLEAR OF TRUCK AND LOAD

CR SFTY: 99900313: 3-5

Figure C-9

DECAL: Electrocution Hazard-Remote Control Operation


FUNCTION: To inform the operator of the lack ofprotection from electrocution afforded by the remotecontrol handle, the possible consequences of the cranebecoming electrically charged, and how to avoid thehazard.

WHERE USED: Articulating cranes - remote controls

PLACEMENT: On the hand held controller.

QUANTITY: 1

Figure C-10

DECAL: Electrocution Hazard-Remote Control Operation


FUNCTION: To inform the operator of the lack ofprotection from electrocution afforded by the remotecontrol handle, the possible consequences of the cranebecoming electrically charged, and how to avoid thehazard.

WHERE USED: Service body mounted TelescopingCranes - remote controls

PLACEMENT: On the hand held controller.

QUANTITY: 1

Figure C-8

DECAL: Electrocution Hazard-RemoteControl Operation


FUNCTION: To inform the operator andother personnel in the work area of the lackof protection from electrocution afforded bythe remote control handle, the possibleconsequences of the crane becomingelectrically charged, and how to avoid thehazard.

WHERE USED: Service body mountedTelescoping Cranes - remote controls

PLACEMENT: At or near the remote controlhandle storage point.

QUANTITY: 1

Figure C-7

DECAL: Electrocution Hazard-RemoteControl Operation


FUNCTION: To inform the operator andother personnel in the work area of the lackof protection from electrocution afforded bythe remote control handle, the possibleconsequences of the crane becomingelectrically charged, and how to avoid thehazard.

WHERE USED: Articulating cranes - remotecontrols

PLACEMENT: If crane is equipped withmanual control(s) in addition to remotecontrols, placed at or near the operator’smanual control station(s). If crane isequipped with remote controls only, placedat remote control handle storage point.

QUANTITY: 2 or 1 if only with remotecontrols.

20000705

DANGERThis remote control does not provide any

protection against��

MAINTAIN SAFE CLEARANCESFROM ELECTRICAL LINES 70392889

DANGERThis remote control does not provide any

protection against��

MAINTAIN SAFE CLEARANCESFROM ELECTRICAL LINES 70394446

CR SFTY: 99900313: 3-6

Figure C-13

DECAL: Moving Boom Hazard


FUNCTION: To inform the operator and other personnelin the work area of the hazard associated with a movingboom especially while stowing and unfolding the crane,the possible consequences should the hazard occur, andhow to avoid the hazard.

USED ON: Articulating Cranes

PLACEMENT: At or near the operator’s control station(s)and/or the boom stow area(s).

QUANTITY: 2

Figure C-11

DECAL: Outrigger Foot Crushing Hazard


FUNCTION: To inform the operator and other personnelin the work area of the hazard associated with theoperation of the outriggers, the possible consequencesshould the hazard occur, and how to avoid the hazard.

USED ON: Articulating and Service body mountedTelescoping Cranes

PLACEMENT: On each outrigger.

QUANTITY: 2

Figure C-12

DECAL: Moving Outrigger Hazard


FUNCTION: To inform the operator of the hazardassociated with outrigger operation, the possibleconsequences should the hazard occur, and how to avoidthe hazard.

USED ON: Articulating and Service body mountedTelescoping Cranes.

PLACEMENT: At or near the operator’s outrigger controlstation(s).

QUANTITY: 2

20000705

DANGER

70392864

DANGER

70392867

A MOVING OUTRIGGERWILL CAUSE

SERIOUS CRUSHING INJURYDo not operate any outrigger unless youor a signal person can see that allpersonnel are clear of the outrigger andits ground contact point.

DANGER

70392890

● Stand on the side opposite the boomwhen folding or stowing the crane.Stay clear of the boom when operating orservicing the crane.

●

A MOVING BOOMWILL CAUSE


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Figure C-15

DECAL: Two Block Hazard


FUNCTION: To inform the operator of the hazardassociated with bringing the sheave(s) into contact withthe hook, snatch block or load, the possibleconsequences should the hazard occur, and how to avoidthe hazard.


PLACEMENT: At or near the operator’s control station(s).

QUANTITY: 2

Figure C-14

DECAL: Rotating Driveline Hazard


FUNCTION: To inform personnel of the hazardassociated with servicing an operating driveline or PTO,the possible consequences should the hazard occur, andhow to avoid the hazard.

USED ON: Articulating and Service body mountedTelescoping Cranes that are driven by a PTO/pumpsystem.

PLACEMENT: At or near the drive line.

QUANTITY: 2

Figure C-16

DECAL: Riding on Boom, Hook, or Loadline Hazard


FUNCTION: To inform personnel in the work area ofthe possible consequences of riding on the boom,boom hook, the load or winch loadline, and how toavoid the hazard.


PLACEMENT: On all four sides of the vehicle.

QUANTITY: 4

20000705

DANGER

70392891

Keep clear of rotating drive shaft.●

● Never work on or near an installedpower take-off or driveline with theengine running.

WIN

CH PULL

BOOM EXTENDIN

G

BOOMDOWN

DANGER

70392861

70392868

DANGER

Never ride on boom, hook, load or any deviceattached to crane boom or loadline.

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Figure C-19

DECAL: Operation Hazards


FUNCTION: To inform the operator of precautionsnecessary in the safe operation of the crane, and thepossible consequences of operation without taking thoseprecautions.



QUANTITY: 2

Figure C-17

DECAL: Hoisting Personnel on Boom, Hook, or LoadlineHazard


FUNCTION: To inform the operator of the hazardassociated with lifting personnel with the boom, boomhook, the load or winch loadline, the possibleconsequences of lifting personnel, and how to avoid thehazard.



QUANTITY: 2

Figure C-18

DECAL: Untrained Operator Hazard


FUNCTION: To inform the operator of the need for propertraining, familiarity with safe operating procedures, andthe possible consequences of operation without training.



QUANTITY: 2

20000705

DANGER

70392863

HOISTING PERSONNEL ONBOOM, HOOK, LOAD OR LOADLINE

WILL RESULT IN


Never hoist personnel on boom, hook, loador any device attached to crane boom

DANGER

70392814

AN UNTRAINED OPERATORSUBJECTS HIMSELF AND

OTHERS TO

DEATH OR SERIOUS INJURYYOU MUST NOT OPERATE

THIS CRANE UNLESS●

●

●

You have been trained in the safeoperation of this crane.

You have read, understand and follow the safety and operating recommendations contained in the crane manufacturer’s manuals, your employer’s work rules, applicable government regulations and industry standards.

You read, understand and follow all safety signs and are sure that all guards, safety signs and other safety features are in place and in proper condition.

DANGER

70392815

FAILURE TO OBEY THE FOLLOWINGWILL RESULT IN

DEATH OR SERIOUS INJURY●●

●●●

●

●●

●

Inspect crane and its operation daily.For crane stability use only on solid, level

surface with outriggers properly extended.Crane must be level.Operate all controls slowly and smoothly.Never operate the crane with personnel under

boom or load.Keep load under boom tip. Do not side load

boom or drag loads. Avoid free swinging loads.Keep at least 3 wraps of loadline on winch drum.For travel, boom and outriggers must be in

stowed position.The operator must reduce loads to allow for

factors such as wind, ground conditions, operating speeds and the effect of freely suspended loads.

CR SFTY: 99900313: 3-9

Figure C-22

DECAL: Free Falling Manual Boom Extension(s) Hazard


FUNCTION: To inform the operator of precautionsnecessary in the safe deployment of manually operatedextension booms, and the possible consequences of nottaking those precautions.


PLACEMENT: At or near the manual boom extension(s)retention mechanism(s).

QUANTITY: 1

Figure C-21

DECAL: Failure to Obey Hazards-Load Charts, CraneRatings, Winch Ratings, Accessories, and Manual BoomExtensions.


FUNCTION: To inform the operator of the hazardassociated with overloading the crane, the possibleconsequences should the hazard occur, and how to avoidthe hazard.



QUANTITY: 2

Figure C-20

DECAL: Failure to Obey Hazards-Inspections,Modifications, and Chassis Selection.


FUNCTION: To inform personnel of the hazardassociated with improper maintenance and unauthorizedmodifications, the possible consequences should thehazard occur, and how to avoid the hazard.



QUANTITY: 2

20000705

DANGER

70392866


DEATH OR SERIOUS INJURY●

●

●

Follow all recommended inspections andmaintenance practices listed in the cranemanufacturer’s manuals. If manuals aremissing from this crane, contactmanufacturer for replacement.

Do not modify or alter this crane without written manufacturer’s approval. Use onlymanufacturer approved attachments orparts on this crane.

Crane must be mounted on factoryrecommended chassis. If remounted orrebuilt, the crane must be recertified.

DANGER

70392888


DEATH OR SERIOUS INJURYINSTABILITY OR

STRUCTURAL DAMAGE●

●

●

●

Read, understand and follow the crane load and work area charts.

Do not exceed winch or crane ratings.

Weights of accessories attached to theboom or loadline must be deducted fromthe load chart ratings or be added to the

load weight.

Do not exceed manual boom extension or jib load ratings at reduced boom lengths.

DANGER

70394443

FREE FALLINGMANUAL BOOM EXTENSION(S)

WILL CAUSEDEATH OR SERIOUS INJURY

●

●●

Do not stand in front of extension(s) when removing retention pin(s).Do not let extension(s) free fall.Properly install retention pin(s) prior to

operation.

CR SFTY: 99900313: 3-10

Figure C-25

DECAL: Rotational Alignment


FUNCTION: To provide the operator with a method ofknowing when the crane mast and base are in alignmentfor placing the crane into the stored position.

USED ON: All cranes requiring alignment of mast andbase before storing.

PLACEMENT: Upper half on the mast base plate edge.Lower half on the base gear-bearing guard. To be appliedwhen the crane is in its approved stored position.

QUANTITY: 1

Figure C-24

DECAL: Set Up/Stow Instructions


FUNCTION: To provide the operator with sequencialsteps to be taken in the set up and storing of a Figure-4folding crane.

USED ON: All Figure-4 folding cranes.

PLACEMENT: At or near the operator’s station.

QUANTITY: 1

Figure C-23

DECAL: Warning - Manual Outriggers


FUNCTION: To warn the operator of precautionsnecessary in the deployment of manual outriggers and toinstruct in their use.

USED ON: All cranes equipped with manual outriggers.

PLACEMENT: On each outrigger.

QUANTITY: 1 per outrigger leg.

INSTRUCTIONAL DECALSShown in this section are instructional decals whichmay be affixed to your crane. Some are relevant tomaintenance while others focus on operation. Theyare provided here as reference in the understandingof their purpose and placement.

20000705

70391598

INSTRUCTIONSSET UP FOR OPERATION1. Position outriggers.2. Retract extension.3. Retract outer boom cylinder.4. Raise inner boom.

STOWING FOR TRAVEL1. Retract extension.2. Retract outer boom cylinder.3. Lower inner boom.4. Stow outriggers.

7039

1583

1

1

44

2

3

1

2

4

3

CR SFTY: 99900313: 3-11

Figure C-26

DECAL: Grease Weekly - Left Arrow


DECAL: Grease Weekly - Right Arrow


FUNCTION: To inform maintenance personnel of thelocation and necessity to apply grease to zerks on aweekly basis.

USED ON: All cranes.

PLACEMENT: At grease zerks with arrow pointing towardthe zerk.

QUANTITY: 1 per grease zerk

Figure C-27

DECAL: Rotate Crane/Grease


FUNCTION: To inform maintenance personnel that it isnecessary to rotate the crane while greasing the turntablegear-bearing. Rotation is required for proper and evendistribution of grease to the gear-bearing.

USED ON: All cranes with turntable gear-bearings.

PLACEMENT: At or near the gear-bearing’s grease zerklocation.

QUANTITY: 1

Figure C-28

DECAL: Contact IMT


FUNCTION: To provide the owners/operators andmaintenance personnel with the address and telephonenumber of IMT for service and repair purposes, safetyquestions, etc.


PLACEMENT: Visible from the operator’s station.

QUANTITY: 1

ROTATE CRANEWHILE GREASING

TURNTABLEGEAR-BEARING

20000705

CONTACT

500 HWY 18 WEST, GARNER, IA 50438

7039

2982

CR SFTY: 99900313: 3-12

Figure C-31

DECAL: Lubricate Worm Gear


FUNCTION: To inform maintenance personnel of theneed to lubricate the worm gear on a weekly basis.

USED ON: All cranes which use a worm gear drive forcrane swing.

PLACEMENT: On the worm gear cover.

QUANTITY: 1

Figure C-30

DECAL: Suction Line


FUNCTION: To aid in the identification of the hydraulicsystem suction line to minimize errors during hydraulicmaintenance.

USED ON: All cranes with hydraulic fluid reservoirs.

PLACEMENT: On the hydraulic fluid reservoir at thesuction line.

QUANTITY: 1

Figure C-29

DECAL: Return Line


FUNCTION: To aid in the identification of the hydraulicsystem return line to minimize errors during hydraulicmaintenance.


PLACEMENT: On the hydraulic fluid reservoir at thereturn line.

QUANTITY: 1

20000705

RETURNLINE

7039

2109

SUCTIONLINE

7039

2108

Weekly, remove cover and lubricateworm with MOLUB-ALLOY 936SFopen-gear compound while rotating crane.

MOLUB-ALLOY is a registered trademark ofCastrol Industrial PLD Downers Grove, IL 1-800-621-6221

7039

2399

CR SFTY: 99900313: 3-13

Figure C-34

DECAL: Caution - Oil Level


FUNCTION: To caution the operator to check thehydraulic reservoir oil level regularly.


PLACEMENT: At or near the normal operating station.

QUANTITY: 1

Figure C-33

DECAL: Boom Angle Indicator - Left Hand


DECAL: Boom Angle Indicator - Right Hand


FUNCTION: To display to the operator the actual angle ofthe boom of a telescoping crane.

USED ON: All telescoping cranes.

PLACEMENT: On the left or right side of the lower boomin alignment with the angle indicator arrow.

QUANTITY: 1

Figure C-32

DECAL: Caution - Do Not Wash/Wax


FUNCTION: To inform maintenance personnel not to usehigh pressure washers and not to wax the crane for aperiod of 60 days after delivery. The use of high pressurewashers and wax is detrimental to the crane’s paint untilcured.


PLACEMENT: Near the crane operating station.

QUANTITY: 1

20000705

7039

2213

CAUTIONOIL LEVEL MUST BE CHECKEDREGULARLY.

PRECAUCIONEL NIVEL DEL ACEITE SE DEBEVERIFICAR REGULARMENTE.

AVISLE NIVEAU D’HUILE DOIT ÊTREVÉRIFIER RÉGULIÉREMENT.

71039134

CR SFTY: 99900313: 3-14

Figure C-35

DECAL: Hydraulic Oil Reservoir Fill Recommendations


FUNCTION: To inform operator and maintenancepersonnel of the recommended hydraulic oil to be usedunder differing climatic conditions.


PLACEMENT: On or near the hydraulic oil reservoir.

QUANTITY: 1

20000705

CR SFTY: 99900313: 4-119981012

Section 4. HAND SIGNALSSIGNALS��

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CR SFTY: 99900313: 4-219981012

Figure D-1.CRANE OPERATION HAND SIGNALS

CR SFTY: 99900313: 5-119981012

Section 5. THE OPERATOROPERATOR QUALIFICATIONS��

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WARNINGOPERATION OF A CRANE MUST NOT BEPERFORMED BY PERSONS UNDER THEINFLUENCE OF ALCOHOL, DRUGS, MEDICATIONSOR ANY CHEMICALS CAPABLE OF IMPAIRING THEABILITIES OF THAT PERSON.PHYSICAL CONDITION

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FIGURE E-1.OPERATOR QUALIFICATIONS

FIGURE E-2.PHYSICAL CONSIDERATIONS

CR SFTY: 99900313: 5-219981012

Figure E-3. SAFETY IS YOUR RESPONSIBILITY

OPERATOR CONDUCT��

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CR SFTY: 99900313: 6-119981012

Section 6. CRANE OPERATIONOPERATION RESPONSIBILITIES��

INSPECTIONS� ��

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CRANE TRANSPORT&��

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CR SFTY: 99900313: 6-219981012 3� 6*�:*��

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CRANE SET-UP,��0��5��

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WARNINGTHE PRESENCE OF ANY ELECTRICALLY CHARGEDPOWERLINES MUST BE AVOIDED. READ ANDUNDERSTAND SECTION 7, CRANE OPERATIONNEAR POWERLINES, BEFORE ATTEMPTING ANYCRANE OPERATIONS NEAR POWERLINES.

5�� 0�� %�� 3��<'�3+��=�� +3�333�>��%�� "�� <'3�+��=�� '3�333�>��

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FIGURE F-1. CRANE SET-UP PRECAUTIONS

CR SFTY: 99900313: 6-319981012

SAFE CRANE OPERATION� �� 8�� @��

CRANE CAPACITY � A��

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CRANE CONTROLS � ! ��

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OPERATING THE CRANE � � ��

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CR SFTY: 99900313: 6-419981012

MAINTENANCE � *�� 8��

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CR SFTY: 99900313: 6-519981012

WINCH RELATED PRECAUTIONS � 6*�:*�� C��D��

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ENGAGING THE PTO � ��

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DISENGAGING THE PTO � /�� ;��

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FIGURE F-2.DO NOT RIDE LOAD, HOOK OR BOOM

FIGURE F-3.PTO DANGER DECAL

CR SFTY: 99900313: 6-619981012

CR SFTY: 99900313: 7-119981012

Section 7. CRANE OPERATION NEAR POWERLINESPRECAUTIONS�� !

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FIGURE G-1. ELECTRICAL HAZARD WARNING DECAL

CR SFTY: 99900313: 7-219981012

IF ELECTRICAL CONTACT OCCURS

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FIGURE G-3.DANGER ZONE FOR CRANES OPERATING NEAR ELECTRICAL TRANSMISSION LINES

FIGURE G-2.REQUIRED CLEARANCES OF CRANES FROM ELECTRICAL TRANSMISSION LINES

CR SFTY: 99900313: 8-119981012

Section 8. WIRE ROPE PRECAUTIONSGENERAL��

WIRE ROPE DESCRIPTIONBy definition, a wire rope is a machine. A typical wire ropewill contain many individual wires which are formed andfabricated to operate at close bearing tolerances with oneanother. As a wire rope bends, each of its many wiresbend to accommodate the difference in length betweenthe inside and outside of the bend. The sharper the bend,the greater the movement.

Every wire rope has three basic components:

1. The wires which form the strands and collectively providerope strength.

2. The strands which are wound helically around the core.

3. The core which forms a foundation for the strands. The coreof IWRC (independent wire rope core) wire rope is a smallerwire rope which is similar to an outer strand of the rope.Only IWRC or strand core contributes strength to the ropeand an IWRC normally provides only about 7 1/2% of therope’s nominal strength.

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BASIC INFORMATION��

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CR SFTY: 99900313: 8-219981012

WIRE ROPE INSPECTION2�� 3��3��-#.(�� -#.(��(/#��(#0'��1��

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1. Kinking (Sharp bends) 2. Crushing 3. Unstranding 4. Birdcaging 5. Core protrusion 6. Rope diameter loss 7. Rope strand uneveness 8. General corrosion 9. Broken strands10. Cut strands11. Heat damage12. Integrity of end attachments

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1. The entire length of the rope 2. The wire rope eye

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WIRE ROPE PRECAUTIONSNEVER overload a wire rope. This means never use thewire rope where the load applied to it is greater than theworking load determined by dividing the nominal strengthof the rope by the appropriate design factor.

NEVER shock load a wire rope. A sudden application offorce or load can cause both visible external damage andinternal damage. There is no practical way to estimate theforce applied by shock loading a rope. The suddenrelease of a load can also damage a wire rope.

AVOID the formation of kinks. Kinks will cause severeweakness in the rope. No corrections are available forkinked rope.

DO NOT intentionally knot wire rope.

DO NOT drag wire rope over a non-rotating support suchas a non-functioning sheave. Severe abrasion caused toouter wire strands will result from friction.

DO NOT use worn sheaves or flat grooved sheaves. Theydo not provide support to the full radius of the rope.Flattening and distortion will result.

DO NOT use nicked or otherwise broken sheaves. Nicksand cracks in sheaves will cut the wire rope.

EVENLY WRAP wire rope onto the drum. Uneveness willcause crushing and/or crimping of the rope.

SELECT replacement wire rope to match the capacity anduse of the crane. The crane was originally equipped withappropriate wire rope.

DO NOT expose the rope to corrosive chemicals, heat orelectrical contact.

LUBRICATE the rope frequently to reduce friction andhelp prevent corrosion.

LUBRICATION OF WIRE ROPE��

5�� *

1. Clean the rope of dirt, dust and any other foreign matter.

2. Apply a light lubricant which will penetrate the strands of therope. Apply by dropping on, spraying on or brushing on.

3. Apply lubricant heavily to portions which encounter bendingsuch as at the sheave and winch.

CR SFTY: 99900313: 8-319981012

FIGURE H-1. WHEN TO REPLACE WIRE ROPE

WHEN TO REPLACE WIRE ROPE2�� *

CR SFTY: 99900313: 8-419981012WIRE ROPE SLINGS2��$��%�� $�� %��

2��

WARNINGA HAND-TUCKED EYE SPLICE CAN UNLAY(UNRAVEL) AND FAIL IF THE SLING IS ALLOWED TOROTATE DURING USE.

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BASIC HITCHES6'2��(5�� 7�� (�� (�� 4��

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FIGURE H-2. BASIC HITCHES

CR SFTY: 99900313: 8-520090420SLING LOADINGSling angle (angle of loading) is the angle measuredbetween a horizontal line and the sling leg or body.This angle is very important and can have a dramaticeffect on the rated load of the sling. When this angledecreases, the load on each leg increases. Thisprinciple applies wheter one sling is used with legsat an angle in a basket hitch, or for multi-leg bridleslings. Horizontal sling angles of less than 30° shallnot be used. See Figure H-3.

FIGURE H-3. LOAD AT VARIOUS SLING ANGLES

RIGHT LAY

LEFT LAY

WIRE ROPE LAYWire rope “lay” indicates the directions strandslay in the rope - right or left. When you lookdown a rope, strands of a right lay rope goaway from you to the right, like a right handscrew thread. Left lay is the opposite, andcorresponds to a left hand screw thread.

You must choose the correct lay for your winchdrum to avoid winch spooling problems andrope which does not lay correctly. Use thefollowing graphics to help in selecting thecorrect wire rope based on the direction of drumwinding.

RIGHT LAYOVERWIND

RIGHT LAYUNDERWIND

LEFT LAYOVERWIND

LEFT LAYUNDERWIND

FIGURE H-4. WIRE ROPE LAY

CR SFTY: 99900313: 8-619981012

CABLE THIMBLE ATTACHMENTWhen attaching a cable thimble to a winch wirerope, proceed as follows and refer to Figure H-5.

1. Note that the base of the clip is applied to thelive end of the rope and the U-bolt is applied to thedead end.

2. Attach the first clip (item 1) so the U-bolt is noless than the clip base width from the dead end ofthe rope.

3. Attach the second clip (item 2) as near the loopas possible.

WEDGE SOCKET ATTACHMENTWhen attaching a wedge socket, use one of theapproved methods displayed in Figure H-4.

FIGURE H-5. APPROVED WEDGE SOCKET ATTACHMENT METHODS

FIGURE H-6. APPROVED CABLE THIMBLE ATTACHMENT METHOD

CR SFTY: 99900313: 8A-119981012

Section 8A. HOOK PRECAUTIONSGENERAL��

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#�� 99:�)(#;+��)9(��

FIGURE H1-1. COMMON HOOKS

NOTE: All hooks shown with Latch.

CR SFTY: 99900313: 8A-219981012

HOOK SWIVELS �� 2�� 8��

HOOK PRECAUTIONS$9�(9��

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CAUTIONTHE CRIMPING EFFECT OF WEDGE SOCKETS CANREDUCE THE SAFE WORKING LIMIT OF A LINE BYAS MUCH AS 30%.

FIGURE H1-2. HOOK TERMINOLOGY

CR SFTY: 99900313: 8A-319981012

HOOK INSPECTION)�� 1�� 1��>��1�� 1��

NEW AND REPAIRED HOOKS;��)(#;+��)9(�� +�:�)#��

HOOKS IN REGULAR USE)�� "�+?=+(��;+�)9$)��

HOOKS NOT IN REGULAR USE �� #��)(#;+��)9(� +�:�)#��

METHODS OF HOOK INSPECTION

CR SFTY: 99900313: 8A-419981012

HOOK INSPECTION CHECKLIST

HOOK TESTING �� 2�� @3��1��&#��$+")()�)9(#��+#�0�

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CR SFTY: 99900313: 8A-519981012DEFINITIONS&;��'(#)*'#!+�,-.�/.3/DEB0

ABNORMAL OPERATING CONDITIONS+��

ADMINISTRATIVE OR REGULATORY AUTHORITYF�� 4��

APPOINTED'� ��

CRACK'��3��

DESIGNATED#�� 1��

FORGING LAP'��

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SERVICE, SEVERE ��

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CR SFTY: 99900313: 8A-619981012

CR SFTY: 99900313: 9-119981012

Section 9. CAPACITY PLACARDSCRANE CAPACITY PLACARDSYour IMT crane is designed for specific loads.Those loads are described on the capacity placardwhich is mounted near the normal operator’s station.Exceeding the limits presented on the capacityplacard will create severe safety hazards and willshorten the life of the crane. The operator and otherconcerned personnel must know the load capacitiesof the crane and the weight of the load being lifted!

WARNINGNEVER EXCEED THE CRANE’S RATED LOADCAPACITIES. DOING SO WILL CAUSE STRUCTURALDAMAGE AND DAMAGE TO WINCHES AND CABLESWHICH CAN LEAD TO SERIOUS INJURIES ORDEATH.

Capacity placards for telescoping and articulatingcranes vary in their graphic representation of loadlimits while presenting load ranges (See Figures I-4and I-5 for comparison). Any load handlingequipment such as hooks, cables and attachmentsmust be added to the weight of the load being lifted.As these attachments vary widely, it is the operator’sresponsibility to account for their added weight.

Other variables which must be accounted for andconsidered in the amount of weight being lifted areconditions of the surface supporting the outriggerand carrier vehicle, wind speed, out-of-levelpositioning of the vehicle or crane, and variations inoperating speed.

CAPACITY CONDITIONSThe capacity placard information is based on thecrane, winch, cable and outriggers beingstructurally sound and a stability tipping factorof 85%.

Conditions which must be met to provide forstated capacity placard ratings are as follows:1. Outriggers fully extended and outrigger padsfirmly contacted with a solid, stabile and levelsurface.

2. The crane has been installed on a factoryapproved vehicle and in a factory approvedfashion.

3. The carrier vehicle’s tires are properlyinflated.

4. Any load handling devices have been addedto the weight being lifted.

5. Extreme wind velocities are not present.

6. The crane is operated in a smooth andcontrolled manner.

7. Any required counterweights have beenadded.

USING THE CAPACITY PLACARD(ARTICULATING CRANES)

Perform the following steps before a load islifted (Refer to Figure I-4):1. Determine the weight of the load.

2. Determine the weight of any load handlingdevices.

3. Add the weight of the load and the weightof the load handling devices. The sum will bethe total weight of the load being lifted.

4. Determine the distance from the centerlineof crane rotation to the centerline of the loadbeing lifted.

5. Determine the distance from the centerlineof crane rotation to the centerline of where theload is to be moved to.

6. The actual distance used should be figuredas the larger of items 4 and 5 above.

7. Refer to the crane’s capacity placard anddetermine within which range the lift will beaccomplished.

8. Refer to the capacity of that range to becertain the load being lifted does not exceed thecrane’s capacity within that range.

9. If a winch is used for the lift, make certainthe load does not exceed the winch or winch linecapacity. See Figures I-1, I-2 and I-3.

CR SFTY: 99900313: 9-219981012

USING THE CAPACITY PLACARD(TELESCOPING CRANES)Perform the following steps before a load is lifted:

1. Determine the weight of the load.

2. Determine the weight of any load handlingdevices.

3. Add the weight of the load and the weightof the load handling devices. The sum will bethe total weight of the load being lifted.

4. Determine the distance from the centerlineof crane rotation to the centerline of the loadbeing lifted.

5. Determine the distance from the centerlineof crane rotation to the centerline of where theload is to be moved to.

6. The actual distance used should be figuredas the larger of items 4 and 5 above.

7. Determine at what angle the crane will beoperated (for example 30°, 45°, etc.) byreferencing the angle indicator on the lowerboom.

8. Make certain that 2-part line is used for anylift which requires 2-part line. See Figures I-1and I-2.See Figure I-5 for reference.

WARNINGWinchs rigged with single or multi-part lines may havethe ability to exceed crane capacities.Refer to thecrane’s capacity placard noting the angle required forthe lift and the range of the lift at that angle. Makecertain the total load being lifteddoes not exceed thecrane’s capacity at that angle and range.

FIGURE I-2.TWO-PART LINE CONFIGURATION

FIGURE I-3.THREE-PART LINE CONFIGURATION

FIGURE I-1.ONE-PART LINE CONFIGURATION

CR SFTY: 99900313: 9-319981012NOTE

THE CAPACITY PLACARD SHOWN ON THIS PAGE ISAN EXAMPLE ONLY! THE CAPACITIES ARE NOTINTENDED FOR USE ON ANY PARTICULAR CRANE.

1. Crane model number.

2. This note is a reminder that it is necessary to add theweight of load handling devices to the weight of the objectbeing lifted in order to derive the actual total load beinglifted.

3. Crane booms shown at their maximum elevation.

4. Crane booms shown at their maximum reach fromcenterline of rotation.

5. Range designation (1, 2, 3, 4) which are to becompared to the range capacity chart shown as item 6.Range 1 indicates a load attached to the outer boom hookand kept within a distance of 6'-0" (1.83 meters) from thecenterline of rotation. Range 2 indicates a load attachedto the outer boom hook but operated through its maximumrange of 10'-0" (3.05 meters) from centerline of rotation.Range 3 indicates a load attached to the fully retractedextension boom at a maximum distance from centerline ofrotation of 13'-5" (4.09 meters). Range 4 indicates a loadattached to the fully extended extension boom at thecranes maximum range of 17'-5" (5.31 meters).

6. The load/range chart indicates the maximum totalload allowable within specified ranges. For example: anylift within Range 3 will be limited to 3600 pounds (1633kilograms) at 13'-5" from centerline of rotation. See Note1, 2 and 3.

7. Lifting height reference dimensions from ground level.If your crane is mounted on other than a normal carriervehicle, add or subtract variances to or from thesedimensions. See Note 2.

Note 1. Capacities are normally shown in pounds firstwith their converted metric equivalent in kilograms alsolisted.

Note 2. Dimensions are normally shown in feet andinches first with their converted metric equivalent inmeters also listed.

Note 3. Occasionally capacity placards maycontaintranslations of the English language in French, Spanish,etc.

FIGURE I-4. ARTICULATING CRANECAPACITY PLACARD

CR SFTY: 99900313: 9-419981012NOTE

THE CAPACITY PLACARD SHOWN ON THIS PAGE ISAN EXAMPLE ONLY! THE CAPACITIES ARE NOTINTENDED FOR USE ON ANY PARTICULAR CRANE.

1. Crane model number.

2. This note is a reminder that it isnecessary to add theweight of load handling devices to the weight of the objectbeing lifted in order to derive the actual total load beinglifted.

3. Capacities which are “boxed” indicate cranecapacities which exceed 1-part line capabilities. To liftthese maximum loads in these ranges, it is necessary touse 2-part line. See Note 1.

4. Capacities which are not “boxed” are within 1-part linelimits. See Note 1.

5. Distances from centerline of rotation to various liftingpoints. See Note 2.

6. Lifting height reference dimensions frombase ofcrane. The mounting height of the crane must be addedto these dimensions to determine accurate verticalheights. See Note 2.

7. Crane boom angle reference figures. The angle ofthe lower boom as shown by the angle indicator on thelower boom should be compared to these figures.

Note 1. Capacities are normally shown in pounds firstwith their converted metric equivalent in kilograms alsolisted.

Note 2. Dimensions are normally shown in feet andinches first with their converted metric equivalent inmeters also listed.

Note 3. Angles are shown in degrees from horizontal.

Note 4. Occasionally capacity placards maycontaintranslations of the English language in French, Spanish,etc.

FIGURE I-5. TELESCOPIC CRANE CAPACITY PLACARD

CR SFTY: 99900313: 9-520090420

STABILITY TESTEvery IMT factory-installed crane includes acompleted stability chart. Any installer other thanIMT also has the responsibility to complete astability chart. Cranes are tested for stability to85% of “tipping”. “Tipping” refers to the craneactually tipping with its opposite outrigger and tireshaving broken contact with the surface. TheStability Test is per SAE J765a.

Figures entered on the stability chart are for aspecific truck and crane combination. If the craneor vehicle are modified or replaced with another, itis necessary to recalculate stability. By referringto the stability chart for your crane/chassis combi-nation, it is possible to determine the loads per-mitted in the derated load range of your crane.

CAUTION

THE PERCENTAGES GIVEN IN THE GRAY AREAOF THE STABILITY CHART ARE BASED ONACTUAL VEHICLE STABILITY AND DO NOT TAKEFRONT AXLE RATING INTO CONSIDERATION. DUETO THE CAPACITY RATING OF THE FRONT AXLE,THE LOADING 75° TO EITHER SIDE OF THECENTERLINE OVER THE CAB MUST BESEVERELY RESTRICTED.

Determine the stability of your truck and cranecombination per the following procedure:1) Use Figure F-2: Stability Chart - CraneMounted Behind Cab for cranes mounted directlybehind the chassis cab, and use Figure F-3:Stability Chart -Rear Mounted Crane for cranesmounted at the rear of the chassis.

2) On the appropriate figure, fill out items Athrough L.

3) Perform the stability test on a flat hard surface.Ideally this surface will be concrete, but asphalt orhard-packed gravel are acceptable. Only autho-rized testing personnel may be in or near the testarea. Per SAE J765a, the area must be within 1%of level.

4) Position and lower the outriggers until theweight of the crane has been removed from thetruck springs.

5) Extend the crane to full horizontal position,centered over the rear of the truck.

6) From the capacity placard, determine the rated

load at the maximum horizontal reach. Place aweight equal to 118% of that rated load at themaximum horizontal reach (L). Keep the loadclose to the ground to avoid excessive tipping.

L = ft.

7) Slowly start rotating the load counterclockwise.Through every 5° increment, check whether allvehicle tires remain in contact with the test sur-face.

NOTE: To make it easier to visualize degrees,compare the rotation to numbered positions on aclock face. As a point of reference, the rearcenter of the truck is the 0° (12 o’clock) position,and the front center is the 180° (6 o’clock) posi-tion.

8) If at any point through the rotation cycle, anyone of the vehicle tires starts to break contact withthe test surface, stop the rotation and note theposition of the crane (X°). This is the balancepoint which determines 85% of tipping for therated load.

X° =

9) After the balance point has been reached,retract the extension boom until all tires are in fullcontact with the test surface again.

10) Continue rotating the boom after stability hasbeen regained. Again, watch all vehicle tires for apoint of instability. If a point of instability reoccurs(one of the vehicle tires breaks contact with thetest surface), retract the extension boom untilstability is regained.

11) Repeat this cycle through a full 180°.

12) At the end of the 180° arc, physically measurethe existing horizontal distance from the centerlineof rotation to the centerline of the load (K).

K = ft.

1 30 7 1502 60 8 1203 90 9 904 120 10 605 150 11 306 180 12 0

CLOCK POS.

DEGREES (º)

CLOCK POS.

DEGREES (º)

CR SFTY: 99900313: 9-61998101213) To determine the percent of full capacity in thederated zone, divide the remaining horizontaldistance (K) by the original maximum horizontaldistance (L). Multiply this figure by 100.

K / L x 100 = %

14) Enter the derated percent of full capacity (Z%)obtained in step 13 on the appropriate figureFigure F-2: Stability Chart - Crane MountedBehind Cab or Figure F-3: Stability Chart -RearMounted Crane. In the derated zone, eachindividual capacity on the capacity chart must bemultiplied by the derated percent of full capacity(Z%). The reduced capacities must maintain 85%of tipping in the derated zone.

15) If the crane is a side mount, repeat the stabil-ity test by rotating the crane clockwise through180° of arc to find X1°, Y1° and Z1°.

X1° =

Y1° =

Z1° =

16) The figures obtained indicate the stabilityrange of the particular truck and crane combina-tion only. If either the truck or crane is changes ormodified, the stability calculations must be re-peated.

17) Rotate the crane at least 5 times to using thecompleted figure to ensure the rating is accurate.

18) Be sure all information has been recorded onthe appropriate figure., and in the service manual.

19) Record the total length of time to test thecrane (total crane test and inspection time shouldapproximate 4 hours per SAE J765a (1979).

Total hours:

When applicable, this stability test conforms toSAE J765a, ANSI B30.15 and USAS B30.5.

LIFTING IN THE DERATED ZONE

If it is absolutely necessary to perform a lift withinthe derated load capacity zones (Y or Y1), pro-ceed as follows:

1) Determine the distance from centerline ofrotation to the centerline of the load being lifted.

2) Determine the distance from centerline ofrotation to the centerline of where the load is to bemoved to.

3) The actual distance used should be figured asthe larger of items 1 and 2 above.

4) Refer to the crane’s capacity placard anddetermine within which range the lift will be ac-complished.

5) Refer to the capacity of that range and multiplythat figure by the derated capacity percentage (Zor Z1).

6) Make certain that the weight of the load plusany load handling devices does not exceed thatfigure.

EXAMPLE

If Z% = 70% and crane capacity at the desiredrange = 2000 lb, then:

.70 x 2000 lb = 1400 lb

Thus, even though the crane is rated for 2000 lbat that particular range, by making the lift withinthe derated load capacity zone the load must notexceed 1400 lb.

CR SFTY: 99900313: 9-7

FIGURE I-6: STABILITY CHART - CRANE MOUNTED BEHIND CAB

20090420

CR SFTY: 99900313: 9-8

FIGURE I-7: STABILITY CHART - REAR-MOUNTED CRANE

20090420

CR SFTY: 99900313: 9A-119981012

Section 9A. CAPACITY ALERT SYSTEMSCRANE CAPACITY ALERT SYSTEM(ELECTRICALLY OPERATED)��

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FIGURE I1-1. GENERAL CAPACITY ALERT SYSTEM WIRING DIAGRAM (ELECTRICAL)

CR SFTY: 99900313: 9A-219981012

CAPACITY ALERT SYSTEM(HYDRAULICALLY OPERATED)��

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FIGURE I1-2. GENERAL CAPACITY ALERT SYSTEM DIAGRAM (HYDRAULIC)

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CR SFTY: 99900313: 9A-319981012

CRANE CAPACITY AUDIBLE ALERTSYSTEM (ELECTRICALLY OPERATED)��

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FIGURE I1-3. GENERAL CAPACITY AUDIBLE ALERT SYSTEM WIRING DIAGRAM

CR SFTY: 99900313: 9A-419981012

CR SFTY: 99900313: 10-119981012

Section 10. OPERATIONAL REFERENCEEXTENSION BOOM SEQUENCE��

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FIGURE J-2. IMPROPER EXTENSION BOOM DEPLOYMENT

FIGURE J-1. PROPER EXTENSION BOOM DEPLOYMENT

CR SFTY: 99900313: 10-219981012

ANTI TWO-BLOCKING DEVICE�� !�� "#��$��%�&�� &�� "#��$�� &�� '� ��&�� "#��$�� &�� &��$��

NOTE”Two-Blocking” is the condition in which the lower loadblock or hook assembly comes in contact with the upperload block or boom point sheave assembly.

FIGURE J-4.ANTI TWO-BLOCKING DEVICE

COMPONENTS

FIGURE J-6APPROACHING TWO-BLOCKING

SITUATIONFIGURE J-5.

NORMAL WORK POSITION

FIGURE J-3. TWO BOCKING DECAL

CR SFTY: 99900313: 10-319981012

FIGURE J-8. UNFOLDING SEQUENCE

FIGURE J-7. STOW/UNFOLD DECAL

FIGURE-FOUR FOLDING CRANES ��(�� "(�� "�� !�� &��&�� (�� )"*�)"+��)",�� $��

CR SFTY: 99900313: 10-419981012

FIGURE J-9. FOLDING SEQUENCE

CR SFTY: 99900313: 10-5

STOWING TELESCOPING CRANES �� &��(�� )"-.� �� &�� &�� &�� &�� $�� &�� $� �� &��!/0!12�� &��

WARNINGWHEN STORING A CRANE FOR LONG PERIODS ORJUST FOR OVERNIGHT, PUT THE CRANE IN ITSDESIGNED STOWING POSITION. REMOVE THEIGNITION KEYS AND LOCK THE CARRIER VEHICLETO PREVENT UNAUTHORIZED OPERATION OF THECRANE AND ASSOCIATED EQUIPMENT.UNAUTHORIZED USE CAN RESULT IN PROPERTYDAMAGE, PERSONAL INJURY OR DEATH.

FIGURE J-10. TELESCOPING CRANE STOWAGE CONFIGURATION

19981012

CR SFTY: 99900313: 10-619981012

STOWING ARTICULATING CRANES! �� (�� "3(�� 4(�� )"--5� ��(�� )"-6�� $�� &�� 0��&� �� &��!/0!12�� &��

WARNINGWHEN STORING A CRANE FOR LONG PERIODS ORJUST FOR OVERNIGHT, PUT THE CRANE IN ITSDESIGNED STOWING POSITION. REMOVE THEIGNITION KEYS AND LOCK THE CARRIER VEHICLETO PREVENT UNAUTHORIZED OPERATION OF THECRANE AND ASSOCIATED EQUIPMENT.UNAUTHORIZED USE CAN RESULT IN PROPERTYDAMAGE, PERSONAL INJURY OR DEATH.

FIGURE J-11. ARTICULATING CRANE STOWAGE CONFIGURATION-BOOM SUPPORT

FIGURE J-12.ARTICULATING CRANE STOWAGE CONFIGURATION-RETRACTED OUTER BOOM

CR SFTY: 99900313: 10-719981012

FIGURE J-13. OUTRIGGER DEPLOYMENT SEQUENCE

OUTRIGGER OPERATION7�� 8� �� 8� �� 9�� &�� :��

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CR SFTY: 99900313: 10-819981012

FIGURE J-14.MOVING OUTRIGGER DECAL

FIGURE J-15.STAND CLEAR DECAL

FIGURE J-16. OUTRIGGER STORAGE SEQUENCE

CR SFTY: 99900313: 10-919981012

DIRECTION TERMINOLOGY�� &� ��

FIGURE J-17. CRANE OPERATION DIRECTIONAL TERMINOLOGY

CR SFTY: 99900313: 10-1019981012

CRANE LUBRICATION!�� #� ��

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FIGURE J-18. GREASE WEEKLY DECAL

FIGURE J-19. LUBRICATION PRODUCT AND SCHEDULE

CR SFTY: 99900313: 10-1119981012

WITH SPUR GEAR TRAIN ROTATION

1. DRIVE GEAR2. TURNTABLE-BEARING GREASE EXTENSION

(ROTATE CRANE WHILE GREASING)3. PINION GEAR4. LOWER CYLINDER-BASE END5. MAST/LOWER BOOM HINGE PIN6. LOWER CYLINDER-ROD END7. SHEAVE PIN8. SNATCH BLOCK PIN

WITH WORM GEAR ROTATION

1. WORM GEAR2. TURNTABLE-BEARING GREASE EXTENSION

(ROTATE CRANE WHILE GREASING)3. LOWER CYLINDER-BASE END4. LOWER CYLINDER-ROD END5. MAST/LOWER BOOM HINGE PIN6. SHEAVE PIN7. SNATCH BLOCK PIN

FIGURE J-20. TYPICAL GREASE ZERK LOCATIONS - TELESCOPING CRANES

CR SFTY: 99900313: 10-1219981012

WITH POWER OUT AND DOWN OUTRIGGERS

1. DRIVE GEAR GREASE EXTENSION2. TURNTABLE-BEARING GREASE EXTENSION

(ROTATE CRANE WHILE GREASING)3. PINION GEAR4. MAST/INNER CYLINDER HINGE PIN5. MAST/INNER BOOM HINGE PIN6. OUTER CYLINDER-BASE END7. INNER CYLINDER-ROD END8. INNER BOOM/OUTER BOOM HINGE PIN9. OUTER CYLINDER-ROD END

A-FRAME OUTRIGGERS

5. BASE/OUTRIGGER LEG HINGE PIN6. OUTRIGGER CYLINDER-BASE END7. OUTRIGGER CYLINDER-ROD END

SPIDER LEG OUTRIGGERS

4. OUTRIGGER CYLINDER-BASE END5. UPPER OUTRIGGER ARM/BASE HINGE PIN6. OUTRIGGER CYLINDER-ROD END7. LOWER OUTRIGGER ARM/LEG HINGE PIN8. OUTRIGGER PAD/LEG HINGE PIN

FIGURE J-21. TYPICAL GREASE ZERK LOCATIONS - ARTICULATING CRANES

CR SFTY: 99900313: 11-119981012

Section 11. CRANE MAINTENANCE PRECAUTIONSMAINTENANCE PRECAUTIONS��

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CR SFTY: 99900313: 11-219981012

CHEMICALS#�� ;�� 39�-�.<9��9��

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CR SFTY: 99900313: 12-119981012

Section 12. REFERENCE DATA��

TIGHTENING PROCEDURE:��

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CR SFTY: 99900313: 12-219981012

FIGURE L-1.TIRE LOAD AND INFLATION PRESSURES - BIAS PLY

CR SFTY: 99900313: 12-319981012

FIGURE L-1A.TIRE LOAD AND INFLATION PRESSURES - RADIAL PLY

CR SFTY: 99900313: 12-419981012

FIGURE L-1B.TIRE LOAD AND INFLATION PRESSURES - WIDE BASE & LOW PROFILE RADIAL PLY

CR SFTY: 99900313: 12-519981012

FIGURE L-1C.TIRE LOAD AND INFLATION PRESSURES - IMPORTED RADIAL PLY

CR SFTY: 99900313: 12-6

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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 when thebolt was new thus giving indeterminate clamp loads after torquing. Failure to replace gear-bearing bolts may result in boltfailure due to metal fatique causing serious injury or DEATH.

19981012

CR SFTY: 99900313: 12-719990618

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OWNER/COMPANY

CONTACT PERSON

CRANE MAKE & MODEL

CRANE SERIAL NUMBER

UNIT I.D. NUMBER

LOCATION OF UNIT

CRANES

TYPE OF INSPECTION (check one)

HOUR METER READING (if applicable)

DATE INSPECTED

INSPECTED BY (print)

SIGNATURE OF INSPECTOR

DAILY (if deficiencyfound)

MONTHLY

QUARTERLY

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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, NA

INSPECTION 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

CR SFTY: 99900313: 12-819990618

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

43 ● Outrigger beams & legs

44 ● Mast45 ● Inner boom

46 ● Outer boom

47 ● Extension(s)48 ● Jib boom

49 ● Jib extension(s)

50 ● OtherQ 51 Hardware Pins, bearings, shafts, gears, rollers, & locking devices for wear, cracks, corrosion & distortion.

52 ● Rotation bearing(s)

53 ● Inner boom pivot pin(s) & retainer(s)54 ● Outer boom pivot pin(s) & retainer(s)

55 ● Inner boom cylinder pin(s) & retainer(s)

56 ● Outer boom cylinder pin(s) & retainer(s)57 ● Extension cylinder pin(s) & retainer(s)

58 ● Jib boom pin(s) & retainer(s)

59 ● Jib cylinder pin(s) & retainer(s)60 ● Jib extension cylinder pin(s) & retainer(s)

61 ● Boom tip attachments

62 ● OtherQ 63 Hyd Lines Hoses, fittings & tubing for proper routing, leakage, blistering, deformation & excessive abrasion.

64 ● Pressure line(s) from pump to control valve

65 ● Return line(s) from control valve to reservoir66 ● Suction line(s) from reservoir to pump

67 ● Pressure line(s) from control valve to each function

68 ● Load holding valve pipe(s) and hose(s)69 ● Other

�� CRANES �STATUS

FREQUENCY

✔ , ✘R, NA



(must be corrected prior to operation)

R = RECOMMENDATION(should be considered for corrective action)

NA = NOT APPLICABLE

CR SFTY: 99900313: 12-919990618

STATUS

FREQUENCY

✔ , ✘R, NA



(must be corrected prior to operation)R = RECOMMENDATION

(should be considered for corrective action)NA = NOT APPLICABLEQ 70 Pumps, PTO’s Pumps, PTO’s & motors for loose bolts/fasteners, leaks, noise, vibration, loss of performance,

& Motors heating & excess pressure.71 ● Winch motor(s)

72 ● Rotation motor(s)

73 ● OtherQ 74 Valves Hydraulic valves for cracks, spool return to neutral, sticking spools, proper relief valve setting, relief valve failure.

75 ● Main control valve

76 ● Load holding valve(s)77 ● Outrigger or auxiliary control valve(s)

78 ● Other

79 ● OtherQ 80 Cylinders Hydraulic cylinders for drifting, rod seal leakage & leakage at welds.

Rods for nicks, scores & dents. Case for damage. Case & rod ends for damage & abnormal wear.

81 ● Outrigger cylinder(s)82 ● Inner boom cylinder(s)

83 ● Outer boom cylinder(s)

84 ● Extension cylinder(s)85 ● Rotation cylinder(s)

86 ● Jib lift cylinder(s)

87 ● Jib extension cylinder(s)88 ● Other

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.

�� CRANES �

GUIDELINES�� ✘ �� ✘ �� R��

�� CA��

�� !�� "�� ✘ �� CA�✘ = DEFICIENCY R = RECOMMENDATION CA = CORRECTIVE ACTION TAKEN

��DATE OWNER UNIT I.D. NUMBER

✘ ,R, CA ITEM # EXPLANATION

DATECORRECTED

CR SFTY: 99900313: 12-1019990618

�� ✘ ,

R, CA ITEM # EXPLANATIONDATE

CORRECTED

��

CR SFTY: 99900313: 12-1119981012

CR SFTY: 99900313:20010907 12-12

IOWA MOLD TOOLING CO., INC.BOX 189, 500 HIGHWAY 18 WEST, GARNER, IA 50438

TEL: 641-923-3711FAX: 641-923-2424

Date post:	13-May-2020
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