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Broderson IC-20-1K Operation And Maintenance Manual

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PRINTED IN USA
P/N 990-30221
MAINTENANCE MANUAL
OWNER: _________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
SOLD AND SERVICED BY:__________________________________________________________
MODEL NO. ___________________________ SERIAL NO. ______________________________
OPERATION AND
IC-20-1K
__________________________________________________________
__________________________________________________________
COPYRIGHT 2018
BRODERSON MFG. CORP.
LENEXA, KANSAS 66215

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Summary of Contents for Broderson IC-20-1K

  • Page 1 PRINTED IN USA COPYRIGHT 2018 P/N 990-30221 BRODERSON MFG. CORP. LENEXA, KANSAS 66215 OPERATION AND MAINTENANCE MANUAL IC-20-1K OWNER: _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ SOLD AND SERVICED BY:__________________________________________________________ __________________________________________________________ __________________________________________________________ MODEL NO. ___________________________ SERIAL NO. ______________________________...
  • Page 2 STATEMENT OF WARRANTY FOR MOBILE CRANES Broderson Manufacturing Corp. ("BMC") warrants its products to be free from defects in material or workmanship at the date of shipment from BMC. This warranty shall be effective only when validated by the return to BMC of its standard form of Warranty...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 DESCRIPTION AND SPECIFICATIONS Introduction………………………………………………………………… Dimension and Orientation………………………………………………. Turning Dimensions………………………………………………………. Description and Specification……………………………………………. SECTION 2 OPERATION Safety Rules………………………………………………………………. General……………………………………………………….. Crane Conditions……………………………………………… Lifting…………………………………………………………… Travel…………………………………………………………… Instruments and Controls………………………………………………… Sequence of Operation…………………………………………………… Driving the Vehicle……………………………………………. Operating the Crane………………………………………….. Crane Capacity Chart…………………………………………………….. 2-10 Capacity Example……………………………………………..
  • Page 4 TABLE OF CONTENTS (CONTINUED) JIC Schematic…………………………………………………………….. 3-13 Hydraulic System…………………………………………………………. 3-14 Steering System………………………………………………………….. 3-14 Propulsion System……………………………………………………….. 3-16 Start-Up Procedure………………………………………………………. 3-18 Piston Pump Troubleshooting…………………………………………… 3-19 Care of Hydraulic Oil……………………………………………………… 3-20 Approved Hydraulic Fluids……………………………………………….. 3-21 Control Valve Adjustment………………………………………………… 3-22 Boom Circuits…….…….…….………………………………… 3-22 Hoist and Outrigger Circuits…………………………………. 3-22 Boom Cylinder Holding Valve………………………………..
  • Page 5 IC-20 INDUSTRIAL CRANE INTRODUCTION The Broderson IC-20 was designed and built to provide safe, dependable and efficient crane service. This, we assure, by our testing and quality control procedures. To properly utilize the full potential of the equipment, the following customer controlled conditions must exist: 1.
  • Page 6 DIMENSIONS AND ORIENTATION IC-20-1K...
  • Page 7 TURNING DIMENSIONS...

  • Page 8: Section 1 Description And Specifications

    SECTION I DESCRIPTION AND SPECIFICATIONS The IC-20-1K is a self-propelled industrial crane designed for in-plant lifting and material handling applications. It is powered by either a dual fuel (gasoline/LPG) or diesel engine. The IC-20 has special features of low height, narrow width, short length, cargo deck, rear wheel steer and front wheel drive.

  • Page 9: Description And Specification

    DESCRIPTION AND SPECIFICATIONS (CONTINUED) Drawbar Pull: 3000 pounds (1360 kg) Gradeability: 53% (28 degrees) Wheels may spin before these calculated values are reached. Grade Limit: Forward and backward Sideways with no load Boom Movement: Rotation 90 degrees Elevation 75 degrees Telescope 9 feet (2.74 m) Tailswing...
  • Page 10 ENGINE: Standard: Kubota 1.6L, EFI Dual Fuel, EPA Tier 2 Certified: Kubota WG1605-GL-E3 gasoline engine complete with multi-port electronic fuel injection, dual fuel, and engine management system. Water-cooled, 4-cylinder, 94 CID (1.6 L), 3.11-inch (79 mm) bore, 3.09-inch (78.4 mm) stroke, 57.0 HP (32.6 kW) at governed speed of 2600 rpm.
  • Page 11 Tires: Standard: 7.50 x 10 pneumatic tires, 16-ply. Pressurized to 145 psi (1000 kPa) for crane rated loads. Optional Tires: Solid Rubber Tires: For applications where hazardous ground conditions exist. These tires do not change the overall height or ground clearance. Net Weight: 240 pounds (109 kg) Solid Rubber Tires Non-Marking: Same as solid rubber tires except non-marking.
  • Page 12 includes 80 feet (24.3 m) of -inch (7.94 mm) wire rope, hook and 4-way roller 5/16 guide. (Also, see page 2-17.) Net Weight: 130 pounds (59 kg) Pintle Hook: T-60-A Holland 5-ton pintle hook mounted on rear frame member. Net Weight: 7 pounds (3 kg) Lifting Sling : Three-leg hitch consisting of heavy-duty pear link and 3 wire ropes with swaged- on clevis ends for attaching to lift points on crane chassis and turntable.
  • Page 13 Optional Electrical Accessories: Strobe Light: One yellow strobe light mounted on operator guard for high visibility. Flashes 60- 120 times per minute. Draws 1/2 amp. Includes operator-controlled switch. When the operator guard is not ordered, the strobe light is mounted outside the operator's compartment on the left side.
  • Page 14 Main Hoist Rope: Main hoist rope is -inch (8 mm) diameter, Warrington-Seale 5/16 construction, 6x36 classification, IPS grade, IWRC core, RRL lay, minimum breaking strength 9160 lbs (4155 kg), 80’ (24 m) long. Weight per foot is 0.2 lbs (.3 kg per m). Note that rope weight is not included in load calculations.

  • Page 15: Section 2 Operation

    OPERATION SAFETY RULES GENERAL: 1. Since the manufacturer has no direct control over machine application and operation, conformance with good safety practice is the responsibility of the user and his operating personnel. 4. The operator shall be responsible for those operations under his direct control. Whenever there is any doubt regarding safety, the operator shall have the authority to stop and refuse to handle loads until safety has been assured.
  • Page 16 5. Tools, lubricants, or rags on the crane should be kept in a secured toolbox. 8. If the crane is equipped with a Rated Capacity Limiter, it must be checked before each shift and after each setup for the proper operating configuration on the display. It must be inspected before each shift and tested with a known load at least once a month as described in the RCL Operation Manual.
  • Page 17 LIFTING: 1. Always refer to Crane Capacity Chart in operator's compartment before handling load. Do not exceed load ratings. Under some conditions the standard capacity ratings cannot be recommended and must be adjusted downward to compensate for special hazards, such as weak supporting ground, wind, hazardous surroundings, operator inexperience, etc.
  • Page 18 9. Crane may tip at less than rated loads if the surface is uncompacted, or if there is wet dirt, soft soil with frozen crust, thin or cracked pavement, or surface near a hole or ledge. Always use adequate outrigger floats and/or cribbing. See page 2-13. 10.
  • Page 19 18. Always keep crane boom at least 10 feet (3 m) away from electric power lines. See chart on side of turntable for boom clearance. 19. If boom should accidentally contact a power line, keep ground personnel away from crane. Stay in the crane until the power source is de-energized. Move the crane away from electrical hazard if this does not cause new hazards.
  • Page 20 TRAVEL: 1. For Pick and Carry operation: Traveling with suspended loads involves so many variables, such as ground conditions, boom length, and vehicle acceleration, that it is impossible to devise a single standard rating procedure with any assurance of safety. For such operations, the user must evaluate prevailing conditions and determine safe practices using precautions, such as the following: A.

  • Page 21: Instruments And Controls

    INSTRUMENTS AND CONTROLS The IC-20-1K has a lower and upper instrument panel. The lower panel consists of the standard engine display screen and controls. The display shows the electrical system voltage, water temperature, oil pressure, hydraulic oil temperature, and fuel level. There are controls for the gas/LPG functions, throttle, headlight switch, key switch horn button, and transmission.
  • Page 22 A neutral safety switch in starter circuit prevents starting engine with the transmission engaged. The control lever must be in NEUTRAL to start engine. The steering wheel is directly mounted on the steering control unit of the power steering system. The steering system will provide limited steering even if the engine should stop running.

  • Page 23: Sequence Of Operation

    SEQUENCE OF OPERATION DRIVING THE VEHICLE The following procedure is recommended for driving the vehicle: CAUTION Be sure the backrest bar is lowered behind you before operating the crane. Apply parking brake. Ensure that the hydrostatic transmission control lever is in NEUTRAL. Start engine and allow a warming period.

  • Page 24: Crane Capacity Chart

    The capacities shown on the capacity chart are the maximum allowable at the indicated radius. The greatest load that may be handled by the BMC IC-20-1K is 5000 pounds (2268 kg), but only at a 4-foot (1.2 m) radius, and on outriggers. All variances of loads and radii of handling are shown on the crane capacity chart.
  • Page 25 2-11...
  • Page 26 2-12...
  • Page 27 CAPACITY EXAMPLE (See 7-foot (2.1 m) Jib Capacity Example Page 2-17) Refer to the IC-20-1K capacity chart on the preceding page. A load that is 4 feet (1.2m) wide and weighs 2800 pounds (1270 kg) is to be lifted from the side and loaded onto the deck of the crane for transport to a new location.

  • Page 28: Sheave Block And Downhaul Weight

    SHEAVE BLOCK AND DOWNHAUL WEIGHT The capacity chart shows the approved hoist rope arrangements. The downhaul weight and sheave blocks supplied by Broderson are specially designed to operate the Anti- Two-Block system. Other blocks or downhauls may bypass this system and create a dangerous condition.

  • Page 29: Two-Part Line Reaving

    TWO-PART LINE REEVING For loads above 2500 pounds (1135 kg) the sheave block must be used. The wedge socket should be pinned to the 2-part line lug, as shown in the figure. The dead end of the rope in the wedge socket should be clamped, as shown in the figure. The clamp must not be used on the live part of the rope.

  • Page 30: Safety Devices

    SAFETY DEVICES There are certain safety devices on the IC-20 that are designed to maintain control of a load in case of power or hydraulic line failure. The operator should understand the function and operation of these devices so that a continual check on their performance can be made.

  • Page 31: Optional Equipment

    OPTIONAL EQUIPMENT 7-FOOT (2.1 m) JIB: CAPACITY EXAMPLES FOR 7-FOOT (2.1 m) JIB (SEE CAPACITY CHART PAGE 2-11) The 7-foot (2.1 m) jib has bail bars that allow positioning in-line with the main boom or 30 degrees offset from the main boom. The jib rating, either offset or in-line, is by load radius only.

  • Page 32: Rated Capacity Limiter

    OPTIONAL EQUIPMENT RATED CAPACITY LIMITER: A Rated Capacity Limiter (RCL) may be installed on the crane to assist the operator in estimating loads and measuring load radii. Please read the RCL Operation Manual and the following information for complete instructions on operation of the system. After starting the engine, always set up the correct Rated Capacity Limiter config- uration.
  • Page 33 WARNING We recommend the emergency override switch be used with discretion. Improper or careless use of this switch can cause damage to the crane and endanger people and property. The operator who uses the switch in an emergency should use good judgment. The Rated Capacity Limiter on the crane is intended to assist the operator in estimating loads and measuring load radii and to alert the operator to impending overload conditions.
  • Page 34 SWITCH AND INDICATOR SYMBOLS ON BMC CRANES The following list shows the symbols used to label switches and indicators on BMC cranes. Most symbols are derived from the ISO 3767-1:1998(E) standard. Not all symbols will be included on your BMC crane. On/Start Windshield washer switch Off/Stop...
  • Page 35 Tire pressure Engine oil pressure low Lift point Engine coolant fill location Engine coolant Tie-down point temperature high Engine coolant low level Transmission oil fill location mark Engine air filter restriction Transmission oil pressure indicator Transmission oil Engine start temperature Brake fluid fill location Engine idle set Hydraulic oil low-level mark...
  • Page 37 MAINTENANCE SAFETY RULES 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 or when welding on crane. Relieve hydraulic pressure when working on hydraulic parts by cycling the controls with the engine shut down.
  • Page 38 15. Do not work on any machine that is supported only by jacks or a hoist. Always use adequate blocks or jack stands. 16. If it is necessary to work on the boom or outriggers in an unstowed condition, block them to prevent them from dropping unexpectedly.
  • Page 39 MAINTENANCE The Broderson IC-20-1K 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 ensure that no damage or loss of operating capability occurred during shipment.
  • Page 40 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 and able to perform safely. Daily: Check radiator coolant level. Check engine oil level. Check general condition of tires.
  • Page 41 IC-20 MAINTENANCE CHECKLIST Refer to the component maintenance section of this manual and to the engine operator's manual for complete instructions. 50-HOUR INTERVALS: 50-hour lubrication, as shown on lube schedule. Inspect wire rope thoroughly. Inspect for physical damage and leaks. Check tire pressure and condition (145 psi (1000 kPa)).
  • Page 42 1000-HOUR INTERVALS: 1. 50, 250 and 500-hour maintenance. 2. 50, 250, 500 and 1000-hour lubrication. 3. Adjust engine valve clearance per engine manual. 4. Change hydraulic fluid and filters and clean breather and reservoir. 1500-HOUR INTERVALS: 1. 50, 250, and 500-hour maintenance. 2.
  • Page 43 COMMENTS & PARTS REQUIRED:__________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________...
  • Page 44 ROTATION SYSTEM LUBRICATION There is one grease fitting on the right-hand side of the rotation bearing. This should be used to lubricate the bearing every 50 hours. Rotate the turntable 90 degrees while pumping grease into the fitting. Use about 3 ounces (89 mL) of grease each time the bearing is lubricated.
  • Page 45 IC-20 LUBRICATION CHART...
  • Page 46 IC-20 LUBRICATION SCEDULE LUBRICATION INTERVALS ITEM DESCRIPTION LUBE 500 1000 MONTHS NOTES SYMBOL HOUR HOUR HOUR HOUR Anti-Two-Block Arm 2 Points Axle Kingpins 4 Zerks Axle Pivot Pin 1 Zerk Axle Planetary Hubs Check @50, Change @12 Mo.* Boom Extension Pins 6 Pins - Wipe Boom Rub Pads Spray or Wipe...
  • Page 47 HOIST CABLE INSTALLATION AND INSPECTION The following steps will assure that the wire rope winds smoothly and evenly on the hoist and will yield greater safety and longer cable life: Refer to Section 1 of this manual for complete replacement rope specifications. 1.
  • Page 48 Slowly rotate the hoist while applying tension on the cable in front of the boom. Wear heavy leather gloves and wrap rags around the cable to wipe off any dirt from the cable. Keep hands away from the sheaves and hoist drum while the cable is moving.
  • Page 49 JIC SCHEMATIC 3-13...
  • Page 50 HYDRAULIC SYSTEM The IC-20 hydraulic system consists of three sub-systems, driven by a triple pump. The 30-gpm (114 L/min) piston pump powers the propulsion system. The 6-gpm (23 L/min) gear pump supplies the hydrostatic steering function and the boom functions. The hoist, outriggers, and optional front winch are powered by the 16-gpm (61 L/min) pump.
  • Page 51 STEERING SYSTEM 3-15...
  • Page 52 PROPULSION SYSTEM The propulsion system is a closed-loop hydrostatic transmission. The variable volume piston pump is driveline driven from the engine crank shaft. The pump can deliver up to 30-gpm (114 L/min) or 3000 psi (207 bar) to the wheel drive motors. The flow from the wheel drive motors returns directly to the pump inlet, not the reservoir.
  • Page 53 IC-20 PROPULSION SYSTEM 3-17...
  • Page 54 START-UP PROCEDURE -- PISTON PUMP When initially starting a new or rebuilt transmission pump, it is extremely important that the start-up procedure be followed. It prevents damage to the unit that might occur if the system is not properly purged and charged with oil before start-up. 1.
  • Page 55 IC-20 PISTON PUMP TROUBLESHOOTING TROUBLE CAUSES REMEDIES 1. System will A. Brake switch tripped Release brake switch. not operate B. Oil supply low Check oil level, fill. in either C. Oil filter clogged Replace filter element. direction. D. Oil too heavy Use proper viscosity oil.
  • Page 56 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 the proper temperature, within the oil specification, and to the proper fill level. The IC-20 is equipped with a 100-mesh fill strainer, two, 10-micron suction filters, a breather filter, and a 9.5-gallon (36 L) tank.
  • Page 57 APPROVED HYDRAULIC FLUIDS WARM CLIMATE: COOL CLIMATE: MOBIL ATF D/M* MOBIL MULTI-VEHICLE ATF CASTROL HEAVY DUTY MULTI-PURPOSE ATF DEXRON VI D-A LUBE AUTOTRANS SUPER PLUS TOTAL FLUIDMATIC AV *Total Fluidmatic MV was used at the factory to fill the hydraulic system of your IC-20. Please see BMC drawing 210-00004 for approved alternatives.
  • Page 58 CONTROL VALVE ADJUSTMENTS The crane control valve has two relief valves to protect the hydraulic components. The relief valves are adjustable and should be checked and set as follows: 1. Boom circuits -- 2500 psi (172 bar) at full flow. 2.
  • Page 59 BOOM CYLINDER HOLDING VALVE A holding valve is directly connected to the base of the boom lift cylinder barrel and to the base of the primary extension cylinder rod. These valves are designed to hold the boom in position should loss of power or pressure line failure occur. To check the boom lift cylinder holding valve, set the outriggers, place the boom in the horizontal position over the front of the crane and raise rated load about one foot above the ground, using the boom lift cylinder (not the hoist).
  • Page 60 ENGINE MAINTENANCE AIR CLEANER SERVICE: Clean out the dust cup every 50 hours. Loosen the clamps around the cup and housing and remove the cup. Dump dust out of cup. Clean gasket and sealing surfaces with a damp cloth. Replace cup gasket if it shows signs of damage. Replace cup with arrows pointing up and tighten clamp.
  • Page 61 MECHANICAL ADJUSTMENTS FASTENERS: All fasteners in the IC-20 should be checked, and retightened if required, as a part of the preventive maintenance program. Particular attention should be given to the axle, wheel and hub mounting bolts, pump mounting bolts, rotation bearing bolts, and hoist bolts. All bolts used in assembly are heat-treated Grade 5, except the bolts attaching the rotation bearing to the mainframe and turret, which are Grade 8.
  • Page 62 TORQUE DATA BOLT SAE GRADE SAE GRADE SAE GRADE GRADE 1 OR 2 MARKING MEDIUM CARBON MEDIUM CARBON MATERIAL LOW CARBON STEEL ALLOY STEEL 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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