Broderson IC-80 Series Maintenance Manual
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Broderson IC-80 Series Maintenance Manual

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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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Summary of Contents for Broderson IC-80 Series

  • Page 1 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._____________________________...

  • Page 2: Safety Rules

    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.
  • Page 3 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.

  • Page 4: Maintenance

    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.

  • Page 5: Operator Inspection And Test

    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.

  • Page 6: Maintenance Checklist

    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.
  • Page 7 500 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.
  • Page 8 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.

  • Page 9: Lubrication Chart

    IC-80 LUBRICATION CHART...

  • Page 10: Lubrication Schedule

    IC-80 LUBRICATION SCHEDULE LUBRICATION INTERVALS ITEM DESCRIPTION LUBE 1000 MONTHS NOTES HOUR HOUR HOUR HOUR Accelerator Pedal 1 Zerk (Diesel) Anti-Two-Block Arm 2 Points - Oilcan Axle Differential Check @50, Change @12 Mo. Axle Kingpins 8 Zerks Axle Pivot Pin 1 Zerk Std., 2 Zerks 4x4 Axle Planetary Hubs Check @50, Change @12 Mo.

  • Page 11: Wire Rope Lubrication

    WIRE ROPE LUBRICATION The wire rope should be cleaned and lubricated every 50 hours of normal operation and more frequently when used in dirty or corrosive environments. Whenever the rope is dirty or dry, it should be serviced. The rope should be cleaned with solvent and compressed air or solvent and rags.
  • Page 12 4. Position the hoist drum with the cable anchor on top. 5. Insert the cable through the anchor slot and wrap it around the anchor wedge. The end of the cable should extend past the wedge by about 1 inch (24 mm). 6.

  • Page 13: Hydraulic System

    HYDRAULIC SYSTEM The IC-80 hydraulic system consists of two subsystems, driven by a double pump with a single inlet port. The 16 GPM (61 L/min) vane pump supplies the hydrostatic steering function and the boom and outrigger functions. The hoist and brake booster are powered by the 32 GPM (121 L/min) vane pump.

  • Page 16: Care Of Hydraulic Oil

    CARE OF HYDRAULIC OIL The hydraulic system contains many highly pressurized, precision components. protect these, it is very important to keep the hydraulic oil clean, at proper temperature, within the oil specification and to the proper fill level. The IC-80 is equipped with a 100-mesh suction strainer, a breather filter, a 10-micron return-line filter and a 25 gallon (95 L) tank.
  • Page 17 HYDRAULIC OILS FOR IC-80 AMBIENT TEMP RANGE: -40° to 75°F -15° to 110°F 50° to 130°F (-40° to 24°C) (-26° to 43°C) (10° to 54°C) POUR POINT: -40°F MAX -15°F MAX 0°F MAX (-40°C MAX) (-26°C MAX) (-18°C MAX) VISCOSITY INDEX: 140 MIN 95 to 100 95 to 100...

  • Page 18: Hydraulic Seals

    HYDRAULIC SEALS W A R N I N G 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 leak. High pressure fluid leaking from a small hole, can be almost invisible, yet have enough force to penetrate the skin.

  • Page 19: Pressure Settings

    PRESSURE SETTINGS The hydraulic system is divided into two pressure circuits, each having its own protective adjustable relief valve in the inlet sections of the control valve. The functions operated by the control valve sections require different pressures for different functions. These are shown below: 1.

  • Page 20: Boom And Outrigger Circuit

    BOOM AND OUTRIGGER CIRCUIT: The relief valve pressure setting at the inlet for boom control sections is 2600 PSI (179 bar). This pressure is required for all but the swing control section. Two work port relief valves are installed in the swing section. These relief valves are set at 1500 PSI (103 bar).

  • Page 21: Telescope Cylinder Holding Valve

    TELESCOPE CYLINDER HOLDING VALVE: A holding valve is directly connected to the base of the primary telescope cylinder rod. The valve is to hold the boom in position should loss of power or pressure line failure occur. The holding valve should be checked with the boom elevated to the maximum angle and the boom extended to a 5 foot (1.5 m) load radius.
  • Page 22 COOLING SYSTEM: Check the level of coolant in the radiator overflow tank daily. Add a mixture of antifreeze and distilled water to the overflow tank as required to maintain the coolant level. Check the radiator fins for dirt or debris daily and wash the fins with a pressure or steam cleaner every 50 hours or as required.

  • Page 23: Park Brake Test And Adjustment

    PARK BRAKE TEST AND ADJUSTMENT: Check tightness of parking brake lever daily while operating it. Perform the following test weekly and at the 50 hour maintenance interval: Park the crane on level pavement. While holding the foot brake pedal down, release the park brake lever and adjust the knob on the end of the lever until the park brake feels tight when applied.

  • Page 24: Torque Data

    TORQUE DATA BOLT SAE GRADE SAE GRADE SAE GRADE GRADE 1 OR 2 MARKING MEDIUM CARBON MEDIUM CARBON MATERIAL STEEL ALLOY STEEL LOW CARBON Q & T Q & T MINIMUM TENSILE 64,000 PSI 120,000 PSI 150,000 PSI STRENGTH (441 MPa) (827 MPa) (1034 MPa) BOLT SIZE...

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Ic-80-1jIc-80-2jIc-80-3j

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