Broderson IC-80 Series User manual

PRINTED IN USA COPYRIGHT2011
P/N 990-30179 BRODERSON MFG. CORP.
MAINTENANCE MANUAL
IC-80-1J, 2J & 3J
OWNER: ______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
SOLD AND SERVICED BY: _______________________________________________________
_______________________________________________________
_______________________________________________________
MODEL NO. ___________________________ SERIAL NO._____________________________
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3-1
MAINTENANCE
SAFETY RULES
1. Lower load and boom, shut down engine, remove key and put it in a safe place.
Place warnings on the ignition switch and crane controls to prevent unauthorized
starting or movement during maintenance. Disconnect battery when disabling crane.
Disconnect battery, RCL and engine electronic module (gas engine only) when
welding on crane.
2. Relieve hydraulic pressure when working on hydraulic parts by cycling the controls
with the engine shut down.
3. Allow fluids and parts to cool before working on them.
4. Read maintenance instructions before beginning work.
5. Do not check for hydraulic leaks with hands. If a mist of hydraulic oil is noticed
around a line or component, use cardboard or other material to check for location of
leaks. High pressure fluid leaking from a small hole, can be almost invisible, yet
have enough force to penetrate the skin. If injured by escaping fluid, see a doctor at
once. Serious reaction or infection can occur.
6. Wear safety glasses and shoes.
7. Do not wear loose-fitting or torn clothing.
8. Remove rings and other jewelry.
9. Wear heavy leather gloves when working on wire rope.
10. Keep fingers, clothing and hair away from moving parts.
11. To prevent falls, clean areas of crane that are stepped on for access to crane parts.
Wear slip resistant footwear.
12. Avoid placing body parts in pinch points. Use tools that extend through the pinch
points when possible. Block the moving parts securely when it is necessary to work
in pinch point areas.
13. When inflating or adding air to a tire, place a tire cage over the tire and use a clip-on
inflater chuck with an extension hose that will permit standing behind the tire tread
when inflating.
14. Do not work on any machine that is supported only by jacks or a hoist. Always use
adequate blocks or jack stands.
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3-2
15. If it is necessary to work on the boom or outriggers in an un-stowed condition, block
them to prevent them from dropping unexpectedly.
16. Use a hoist when lifting components that weigh 50 pounds (22 kg) or more. Follow
all hoist and rigging safety rules.
17. Do not use lower grade fasteners if replacements are necessary.
18. When reinstalling wiring or plumbing after repairs, be sure that it will not be damaged
by rubbing against sharp, rough or hot surfaces or edges.
19. Never use a rope clip on live side of the load hoist rope. This will seriously weaken
the rope. Death or serious injury can result from the misuse of a rope clip on the
hoist rope.
20. Replace any instruction or warning placards that are lost or damaged or are not
readable.
21. Always replace all guards and covers after working on the crane.
22. After working on the hydraulic system, remove air from the lines and cylinders
involved by cycling them full stroke with the engine running until the functions
operate smoothly.
23. When welding on the crane or on anything connected to the crane by wire rope or
other conducting link, disconnect the battery, the Rated Capacity Limiter display and
computer and the engine electronic control module (gas engine only). When welding
on the boom or turntable assembly, remove the cable reel and any other electronic
components bolted to these assemblies.
24. When using pressure spray to clean the crane, cover all electronic components with
sheets of plastic to protect them from spray.
25. Do not allow antifreeze to contact skin. Rinse off spills immediately with plenty of
water. Antifreeze is highly toxic if ingested.
26. Always disconnect negative cable first and refasten last to prevent accidental short
through chassis components.
C A U T I O N
Even with low voltage electrical systems, severe arcing can occur. Electrical
shock or component damage can result from contact with energized conductors.
Use caution when working with any electrical device.
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3-3
MAINTENANCE
The Broderson IC-80 Industrial Crane will perform better and longer if a program of
inspection, lubrication, adjustment and general preventive maintenance is followed. We
recommend the following schedule:
NEW UNIT INSPECTION AND TEST
The following inspection and test should be made before placing the unit on the job.
This will insure that no damage or loss of operating capability occurred during shipment.
1. Check for physical damage.
2. Check for leaks at fittings and drips under chassis.
3. Check radiator coolant level.
4. Check engine oil level.
5. Check hydraulic oil reservoir level.
6. Check transmission oil level.
7. Check fuel tank level.
8. Check tire pressure.
9. Check for loose pins, bolts, and retainers.
10. Check for operation of foot brake.
11. Check for operation and adjustment of parking brake. (See page 3-22.)
12. Check for operation of accelerator pedal.
13. Start engine.
14. Check power steering for operation. Check all steering modes.
15. Check operation of transmission gear selector lever.
16. Check lights and turn signals for operation.
17. Test-drive unit and check for normal operation.
18. Check operation of hydraulic outriggers.
19. Check boom swing.
20. Check boom elevation.
21. Check boom extension (pay out hoist cable during power extension).
22. Perform cable break in procedure. (See page 3-10.)
23. Check anti-two-block system for proper operation and cutout of boom functions.
24. Perform a load test according to the Rated Capacity Limiter Operation Manual.
25. Check the outrigger warning light for proper operation as described on page 2-9.
26. Check operation of Drum Rotation Indicator.
W A R N I N G
When the Rated Capacity Limiter is inoperative or malfunctioning, it must be
repaired as soon as reasonably possible. When a lift must be made without a
properly functioning load indicator or RCL, the designated lift supervisor must
establish procedures for determining load weights and load radii and conducting
the lift safely.
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3-4
OPERATOR INSPECTION AND TEST
An operator, in the course of normal operation, should make certain observations,
inspections and tests to assure that the unit is ready to perform safely.
Daily:
1. Check levels of engine oil, coolant and transmission fluid.
2. Drain water from diesel fuel filter.
3. Check air cleaner intake system for cracks or looseness.
4. Check general condition of tires.
5. Visually inspect for loose pins, bolts, physical damage and leaks.
6. Check hydraulic hoses, particularly those that flex during crane operation.
7. Check hydraulic oil level.
8. Check fuel level.
9. Check hydraulic filter indicator gauge after running at least twenty minutes.
10. Check hydraulic service brake operation.
11. Check parking brake operation.
12. Check power steering operation.
13. Observe chassis for normal driving operation.
14. Observe boom operation for normal power and speed.
15. Check load line and hooks for damage.
16. Check condition of sheaves and load line retainers.
17. Check anti-two-block system for proper operation.
18. Check horn, back-up alarm and outrigger alarm for proper operation.
19. Check operation of all transmission gears, forward and reverse.
20. Clean all glass (if equipped) and check for cracks.
21. Check operation of all warning and safety devices.
22. Check operation of Rated Capacity Limiter according to the RCL User Manual.
23. Check the outrigger warning light for proper operation as described on page 2-9.
24. Check Drum Rotation Indicator for proper operation.
Weekly:
1. Check tire pressure: 110 PSI (758 kPa) bias belted, 135 PSI (930 kPa) radial, or 120
PSI (827 kPa) for mining tire.
2. Check for loose wheel nuts
3. Check lights and turn signals.
4. Check power steering lines for damage.
5. Check brake lines for damage.
6. Check operation of horn.
7. Check operation of hoist brake for smoothness.
8. Check outrigger holding valves for operation.
9. Check boom topping holding valve for operation.
10. Check swing gears for looseness or backlash.
11. Check boom extension cylinder holding valve for operation.
12. Check operation of windshield wipers (if equipped).
13. Boom extension (if equipped) properly pinned with retainers in place.
14. Check all steering modes.
15. Clean all glass and check for cracks.
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3-5
W A R N I N G
Vapor can form inside a fuel tank and cause a buildup of pressure. This can result
in a sudden expulsion of gasoline and vapor from the filler neck when the gas cap
is removed from a hot tank. Remove cap slowly. Fuel spray may cause injury.
IC-80 MAINTENANCE CHECKLIST
Refer to the component maintenance section of this manual and to the engine operator's
manual for complete instructions.
50 HOUR INTERVAL:
1. 50 hour lubrication as shown on lube schedule.
2. Inspect wire rope thoroughly.
3. Inspect for physical damage and leaks.
4. Clean radiator fins and check coolant level.
5. Check tire pressure and condition.
6. Check fluid levels in engine, transmission, hydraulic tank, and brakes.
7. Clean air filter inlet screen and empty the pre-cleaner dust cup.
8. Inspect air intake and exhaust systems for cracks, leaks and loose bolts.
9. Change engine oil and filter after first 50 hours and at 250 hours thereafter
10. Torque cylinder head bolts. (See engine manual)
11. Adjust engine valve clearance. (See engine manual)
12. Check tension and condition of fan and alternator belts.
13. Check the hydraulic filter indicator with warm oil; change element if indicated.
14. Check diesel engine idle and maximum speed and adjust if necessary.
15. Check swing gear and pinion fit and gear train backlash.
16. Check swing bearing and gearbox bolt tightness. (See page 3-21)
17. Check axle mounting bolts and pins.
18. Torque wheel mounting nuts to 500 pounds-foot (678 Nm).
19. Check for loose pins or pin retainers.
20. Check brake lines and steering lines for damage.
21. Inspect sheaves and hooks for damage or excessive wear.
22. Visually inspect welds on boom, turret and outriggers.
23. Perform a load test according to the Rated Capacity Limiter User Manual.
24. Check operation of outrigger warning light as described on page 2-9.
25. Check tension and condition of engine belts.
250 HOUR OR 3 MONTH INTERVAL:
1. 50 hour maintenance.
2. 50 and 250 hour lubrication.
3. Clean engine and battery.
4. Change engine oil and filter.
5. Clean crankcase breather.
6. Clean and inspect distributor and ignition wires.
7. Clean the air filter. (Clean element every 100 hours if used in dusty conditions.)
8. Check engine mounts and radiator mounts.
9. Inspect all bolts on the machine for tightness.
10. Visually inspect all welds for cracks.
11. Check hydraulic fittings and centerpost for leaks.
12. Check park brake cable adjustment.
13. Clean the two steering alignment proximity sensors’ tips with a rag.
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3-6
500 HOUR OR 6 MONTH INTERVAL:
1. 50 and 250 hour maintenance.
2. 50, 250 and 500 hour lubrication.
3. Change fuel filter element.
4. Change air filter element.
5. Check antifreeze for protection level and cleanliness.
6. Inspect engine fan and belt.
7. Check water pump and connections for leaks.
8. Check fuel pump and connections for leaks.
9. Change hydraulic filter element, if not changed in the last 250 hours and inspect oil
from element.
10. Change transmission filter element and inspect oil from element.
11. Check condition of all operational and warning placards.
12. Torque mounting bolts on swing bearing and gearbox, winch and axles. (See page 3-23)
13. Inspect boom sections for signs of overload, excessive wear, or other damage.
14. Check axle toe-in.
1000 HOUR OR 12 MONTH INTERVAL:
1. 500 hour maintenance.
2. 50, 250, 500,1000 hour and 12 month lubrication.
3. Adjust engine valve clearance per engine manual.
4. Perform engine maintenance specified in engine manual.
5. Change hydraulic fluid and filter and clean breather and reservoir.
6. Change transmission fluid and filter and clean strainer.
7. Replace vapor block inside slip ring. See turret sub-assembly in parts manual.
24 MONTH INTERVAL:
1. 12 month maintenance.
2. Pressure test engine cooling system.
3. Flush cooling system.
4. Change engine thermostat.
5. Fill with new coolant and distilled water.
6. Perform engine maintenance specified in engine manual for 24 month interval.
S/N:_______________ HOURS:________ DATE:___________ BY:______________
COMMENTS & PARTS REQUIRED:____________________________________________
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_________________________________________________________________________
_________________________________________________________________________
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_________________________________________________________________________
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3-7
LUBRICATION
SWING BEARING LUBRICATION:
There is one grease zerk in a hole on the left-hand side of the turntable base plate. This
should be used to lubricate the bearing every 50 hours. Rotate the turntable about 45
degrees and pump some grease into the zerk. Repeat until the turntable has rotated two
revolutions. Use about 6 ounces (180 cc) of grease each time the bearing is lubricated.
Also, lubricate the gear teeth of the swing bearing at the 50 hour interval. Remove the
pinion cover. Brush open gear grease, such as Mobilkote-S, on the teeth on each side
of the pinion at four places around the bearing. Rotate the boom several times and
check the coverage of the grease on all of the teeth. Replace the pinion cover.
TRANSMISSION:
Check the transmission fluid with the dipstick and add fluid through the dipstick tube as
required. Use Mobil ATF Type F or equivalent. Transmission factory service manuals
are available from Broderson. Order BMC Part Number 990-00021.
DRIVE AXLES--HUBS AND DIFFERENTIALS:
Maintain lubricant to levels shown here with Mobil 424 or equivalent.
FLUID VOLUME CHART:
HYDRAULIC RESERVOIR - 25 Gallons (95 L)
FUEL TANK - 20 Gallons (76 L)
PLANETARY HOIST - 2.5 Quarts (2.4 L)
FRONT AUXILIARY WINCH - 2 Pints (1 L)
PLANETARY DRIVE AXLE – 11 Quarts (10 L) Center Section & 0.75 Quart (.7 L) each
end.
TRANSMISSION, POWERSHIFT - 17.5 Quarts (16.6 L)
ENGINE COOLING SYSTEM - 15 (14 L) to 17 (16 L) Quarts depending on engine and
heater.
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3-8
IC-80 LUBRICATION CHART
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3-9
IC-80 LUBRICATION SCHEDULE
LUBRICATION INTERVALS
ITEM DESCRIPTION LUBE 50 250 500 1000 MONTHS NOTES
HOUR HOUR HOUR HOUR
1 Accelerator Pedal MPG X 1 Zerk (Diesel)
2 Anti-Two-Block Arm SIL X 2 Points - Oilcan
3 Axle Differential 424 X 12 Check @50, Change @12 Mo.
4 Axle Kingpins MPG X 8 Zerks
5 Axle Pivot Pin MPG X 1 Zerk Std., 2 Zerks 4x4
6 Axle Planetary Hubs 424 X 12 Check @50, Change @12 Mo.
7 Boom Cylinder Pins MPG X 2 Zerks
8 Boom Ext. Pins MPG X Wipe on
9 Boom Hinge Pin MPG X 1 Zerk
10 Boom Rub Pads SIL X Spray or Wipe
11 Brake Lever, Parking SIL X
12 Brake Linkages SIL X
13 Brake Reservoir DTE X Check @50, Change When
Brakes are Serviced
14 Cab Hinges & Latches SIL X
15 Control Valve Links SIL X
16 Drive Shaft Joints MPG X 3 Zerks Std., 6 Zerks 4x4
17 Engine Oil (Gas Engine) EO X X 3 Max. Check Daily, Change @50 then
@250 Hrs. or 3 Mo. Max.
18 Hook Swivel & Pin SIL X
19 Hydraulic Oil HO X X 12 Max. Check Daily, Change @1000
Hours or 12 Mo. Max.
20 Outrigger Legs MPG X Wipe on Legs
21 Pump Shaft MPG X 2 Zerks
22 Rotation Bearing MPG X 1 Zerk*
23 Rotation Gearbox WGO X 24 Check @250, Change @24 Mo.
24 Rotation Gear Teeth OGG X Brush On*
25 Sheave Block MPG X 2 Zerks
26 Sheave Pins MPG X 1 Zerk Std, 2 Boom Extension
27 Steering Rod Ends MPG X 6 Zerks Std, 4 Zerks 4x4
28 Transmission TPF X 12 Max. Check @50, Change @12 Mo.
29 Wheel Bearings, Rear WBG 12 Clean & Repack
30 Winch(es) MPL X 12 Check @250, Change @12 Mo.
31 Wire Rope 2-X X Spray, Brush or Soak*
32 Wire Rope Retainers SIL X
*See Procedures in Manual
LUBE SYMBOLS
TPF - ATF Type F MPG - Multi-Purpose Gun Grease
2-X - AMOVIS #2-
X
MPL - Multi-Purpose Gear Lube, SAE 80W-90
424 OGG - Open Gear Grease, Such as Mobilkote S
DTE SIL - Silicone Lube, Aerosol with Concentrating Tub
e
(Do not use brake fluid) WBG - Wheel Bearing Grease
EO - Engine Oil - See Specs in Engine Manual WGO - Worm Gear Oil, Exxon Cylesstic TK 460
HO - Hydraulic Fluid - See Specs in Hyd. Sec.
- Mobil Fluid 424 or Equivalen
t
- Mobil DTE 10 Excel 15 or Equivalen
t
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