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Broderson IC-35-2G Operation And Maintenance Manual

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PRINTED IN USA
P/N 990-30229
MAINTENANCE MANUAL
OWNER: _________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
SOLD AND SERVICED BY: _________________________________________________________
MODEL NO. ___________________________ SERIAL NO. ______________________________
OPERATION AND
IC-35-2G
_________________________________________________________
_________________________________________________________
COPYRIGHT 2016
BRODERSON MFG. CORP.

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Summary of Contents for Broderson IC-35-2G

  • Page 1 PRINTED IN USA COPYRIGHT 2016 P/N 990-30229 BRODERSON MFG. CORP. OPERATION AND MAINTENANCE MANUAL IC-35-2G 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………..………………………………………… 1-1 Dimensions and Orientation IC-35-2G………..………… 1-2 Turning Dimensions………..……………………………… 1-3 Description and Specifications………..…………………… 1-4 SECTION 2 OPERATION Safety Rules………...……………………………………… 2-1 Instruments and Controls………..………………………… 2-5 Control Functions…………………………………… 2-6 Sequence of Operation………..…………………………… 2-7 Driving the Vehicle……….…………………………...
  • Page 4 SECTION 3 MAINTENANCE (cont'd) Hydraulic System Maintenance………...………………… 3-19 Purging the Hydraulic System……….……………… 3-23 Bleeding the Brakes……..…………...………………3-25 Hydraulic Seals………..……………………………… 3-26 Hydraulic System Adjustments………….…………………3-27 Control Valves………..……………………………… 3-27 Boom Cylinder Holding Valve………..……………… 3-28 Extension Cylinder Holding Valve………..…………3-28 Engine Maintenance………..…………………………… 3-29 Air Cleaner Service……...…………………………… 3-29 Cooling System………..………………………………...

  • Page 5: Introduction

    BRODERSON MANUFACTURING CORP. IC-35 INDUSTRIAL CRANE INTRODUCTION The Broderson IC-35 was designed and built to provide safe, dependable and efficient crane service. This we assure by our testing and quality control procedures. properly utilize the full potential of the equipment, the following customer controlled conditions must exist: 1.

  • Page 6: Dimensions And Orientation Ic-35-2G

    DIMENSIONS AND ORIENTATION IC-35-2G...

  • Page 7: Turning Dimensions

    TURNING DIMENSIONS...

  • Page 8: Description And Specifications

    SECTION 1 DESCRIPTION AND SPECIFICATIONS BMC’s IC-35-2G is a self-propelled industrial crane designed for in-plant lifting and material handling applications. It has the special features of low height, narrow width, short length, cargo deck, rear wheel steer, and front wheel drive. The basic unit consists of a chassis and hydraulic boom assembly.
  • Page 9 Weight Distribution: Front Axle 3780 pounds (1715 kg) Rear Axle 4080 pounds (1850 kg) Total 7860 pounds (3565 kg) Tire Footprint Area: 46 square inches (297 cm ), each Outrigger Footprint Area: 48 square inches (310 cm ), each Drawbar Pull: 2120 pounds (960 kg) Gradeability: 30% (1)
  • Page 10 Engine: Standard Gasoline: Kubota 1.6 L, EFI Dual Fuel, EPA Tier 4 Final 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, 43.7 HP (32.6 kW) at governed speed of 2600 rpm.
  • Page 11 Brakes: Standard: Primary braking from hydrostatic transmission. Foot-actuated disc brake attached to each torque hub for additional braking in some conditions. Parking brake switch locks brakes to hold crane when not being driven. Tires: Standard: 7.50 x 10 pneumatic tires, 16-ply. Pressurized to 150 PSI (1000 kPa) for crane rated loads.
  • Page 12 Headlight and Taillight Grilles: Consists of welded steel protective grilles for headlights and taillights. Easily removes or swings out of way for replacing bulbs. Optional Chassis Accessories: Auxiliary Winch: Optional worm gear winch mounted behind front bumper, with a single lever control at the operator’s console.
  • Page 13 Operator Guard: Tubular steel weldment with heavy expanded steel mesh top bolts over operator’s compartment. Net Weight: 60 pounds (27 kg) Operator Guard Cover: Vinyl cover with windows to go over operator guard for inclement weather operations. Net Weight: 12 pounds (6 kg) Floormat: Ribbed vinyl mat with foam backing for operator comfort.
  • Page 14 Hydraulic System: Standard: Tandem pump mounted to rear end of hydrostatic piston pump, which is driven by the engine crankshaft. Delivers 6 gpm (23 L/min) at 2,600 PSI (179 bar) for boom circuits and 17 gpm (64 L/min) at 2,250 PSI (155 bar) for hoist circuit.
  • Page 15 Downhaul and Sheave Block: Includes downhaul weight and hook for single part line. Downhaul and hook assembly weight is 40 pounds (18 kg). Downhaul is designed to clamp dead end of rope. Also includes sheave block for two-parting line for lifts over 4000 pounds (1800 kg).

  • Page 17: 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. 3. The operator shall be responsible for those operations under direct...
  • Page 18 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 19 14. Be sure at least five wraps of rope are left on the hoist drum to ensure against rope pulling out of its anchor. 15. Never wrap the hoist rope around a load. Always use approved rigging. 16. Avoid pinch points such as between a rotating turret and the cab or operator guard, or in access holes of a telescop- ing boom.
  • 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

    OPERATION INSTRUMENTS AND CONTROLS The Broderson IC-35 instrument panel is equipped with a display screen showing electrical system amperage, fuel level, oil pressure, water temperature, hydraulic oil temperature, and engine hours. Also included is a bubble level, to level the machine.
  • Page 22 The hydrostatic transmission control switch is located on the right instrument panel. It has FORWARD, NEUTRAL, and REVERSE positions. The speed of the transmission is controlled by the engine speed, which is controlled with the accelerator pedal. A pedal-activated brake is provided to hold the machine on slopes. Normal braking is provided by the hydrostatic transmission when the accelerator pedal is released.

  • Page 23: Sequence Of Operation

    SEQUENCE OF OPERATION DRIVING THE VEHICLE The following procedure is recommended for driving the vehicle to the job site: Perform the daily inspection and test. (See Page 3-4) Apply park brake. Leave hydrostatic transmission switch in neutral. Start engine and allow a warming period. (If equipped with Safety Shutdown System, depress reset button while starting and for a few seconds after.) While warming the engine, set up the Rated Capacity Limiter configuration.

  • Page 24: Operating The Crane

    OPERATING THE CRANE The following procedure is recommended for placing the crane in operation: 1. Perform daily inspection and test. (See Page 3-4) 2. Apply park brake. 3. Leave transmission control switch in neutral. 4. Start engine and allow a warming period at low rpm engine speed. 5.

  • Page 25: Rated Capacity Limiter

    RATED CAPACITY LIMITER (RCL) A Rated Capacity Limiter is installed on the crane to assist the operator in estimating loads and measuring load radii. Please read the RCL Operation Manual for complete instructions on operation of the system. Following are some additional operating tips. Always be aware that the RCL can stop boom movement at capacity load conditions and in two-blocking conditions.

  • Page 26: Crane Capacity

    CRANE CAPACITY Before lifting loads, the operator must read the Crane Capacity Chart and adhere to the load capacities and radii of handling given. The information provided on this chart is based on stability, structural strength and hydraulic capacity. To operate the crane safely, the operator must know the weight of the load and handling devices and the radius of the lifting operation.
  • Page 27 CRANE CAPACITY CHART DEFINITIONS AND RULES: The load radius is the horizontal distance from the centerline of boom rotation (the center of the turntable when it is level), to the vertical load line with the load suspended. Because of deflections of the boom and carrier, the load radius increases when a load is hoisted from its resting place.
  • Page 28 CAPACITY EXAMPLE Refer to the IC-35-2G Capacity Chart on the following page. A load weighing 4500 pounds (2040 kg) is to be lifted onto the deck of the crane for transport to a new location.

  • Page 29: Crane Capacity Chart Ic-35-2G

    CRANE CAPACITY CHART FOR IC-35-2G 2-13...

  • Page 30: Crane Capacity Chart Ic-35-2G Metric

    CRANE CAPACITY CHART FOR IC-35-2G METRIC 2-14...

  • Page 31: Sheave Block And Downhaul

    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 32: Two-Part-Line Reeving

    TWO-PART LINE REEVING When resting the downhaul or sheave block on the ground for changing it, use the following procedure to prevent fouling the load line on the hoist. Raise the boom about 5 feet (1.52 m) and lower the hoist until the hook nearly touches the ground. Then lay the hook on the ground by lowering the boom, not the hoist.

  • Page 33: Safety Devices

    SAFETY DEVICES There are safety devices on the IC-35 to maintain control of a load in case of power or hydraulic line failure or human error. The operator should understand the function and operation of these devices, so that a continual check on their performance can be made. OUTRIGGER CYLINDER CHECK VALVE: A double-acting check valve is flange-mounted on each of the outrigger cylinders.

  • Page 34: Optional Equipment Operation

    HOIST BRAKE AND HOLDING VALVE: The hoist has an automatic brake in the gearbox and a holding valve mounted directly on the hoist motor to hold the load. A clutch in the gearbox allows the winch to turn freely in the RAISE direction. The brake is pilot-released in the LOWER direction and should allow smooth stops of a load on the hoist.

  • Page 35: Front Auxiliary Winch

    STOWING THE BOOM EXTENSION: Reverse the procedure described in steps 7 through 14 in the installation procedure above. Lay the load line back in the tip sheaves and insert both retainer pins and cotters. Replace all of the pins in their lugs for storage and insert their cotters. FRONT AUXILIARY WINCH: The front auxiliary winch is mounted behind the front bumper and is controlled from the operator compartment.

  • Page 36: Switch And Indicator Symbols On Bmc Cranes

    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 37 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 39: Maintenance

    MAINTENANCE SAFETY RULES Lower load and boom, shutdown 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 40 Use a hoist when lifting components that weigh 50 pounds (23 kg) or more. Follow all hoist and rigging safety rules. Do not use lower grade fasteners if replacements are necessary. 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.
  • Page 41 MAINTENANCE The Broderson IC-35 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 42 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: 1. Check radiator coolant level. 2. Check engine oil level. 3.

  • Page 43: Ic-35 Maintenance Checklist

    IC-35 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.
  • Page 44 1000 HOUR INTERVAL: 1. 50, 250 and 500 hour maintenance. 2. 50, 250, 500 and 1000 hour lubrication. 3. Adjust engine valve clearance per engine manual. 4. Check and adjust engine speed. 5. Perform engine maintenance specified in engine manual. 6.
  • Page 45 _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________...

  • Page 46: Lubrication

    ROTATION BEARING LUBRICATION There is one grease zerk in a hole on the right-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.
  • Page 47 IC-35 LUBRICATION CHART...
  • Page 48 IC-35 LUBRICATION SCHEDULE LUBRICATION INTERVALS LUBE ITEM DESCRIPTION 1000 MONTHS NOTES SYMBOL HOUR HOUR HOUR HOUR Accelerator Linkage 2 Points (Not on E.F.I.) 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...

  • Page 49: Hoist Cable Installation And Inspection

    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 50 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 51: Jic Schematic

    JIC SCHEMATIC 3-13...

  • Page 52: Jic Schematic Metric

    JIC SCHEMATIC METRIC 3-14...

  • Page 53: Steering System

    HYDRAULIC SYSTEM The IC-35 hydraulic system consists of three subsystems, driven by a triple pump. The 34 gpm (129 L/min) piston pump powers the propulsion system. The 6 gpm (23 L/min) gear pump supplies the hydrostatic steering function, and the boom and outrigger functions.
  • Page 54 STEERING SYSTEM 3-16...
  • Page 55 PROPULSION SYSTEM The propulsion system is a closed-loop hydrostatic transmission. The variable volume piston pump is driveline driven from the engine crankshaft. The pump can deliver up to 34 gpm (129 L/min) or 4,000 PSI (276 bar) to the wheel drive motors. The flow from the wheel drive motors returns directly to the pump inlet, not the reservoir.

  • Page 56: Ic-35 Propulsion System

    IC-35 PROPULSION SYSTEM 3-18...
  • Page 57 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 damaging the unit that might occur if the system is not properly purged and charged with oil before start-up. 1.
  • Page 58 6. After the system shows signs of filling, run it in neutral and low idle for 5 minutes. Then extend the outriggers so that drive wheels can spin freely. Reconnect the brake release valve if disconnected in step 3. Place the control switch in the FORWARD position and slowly push the accelerator until the wheels turn slowly.
  • Page 59 IC-35 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 60: 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-35 is equipped with a 100-mesh suction strainer, a 10-micron suction filter, a breather filter, a 10-micron, return-line filter and a 14-gallon (53 L) tank.

  • Page 61: Purging The Hydraulic System

    APPROVED HYDRAULIC FLUIDS WARM CLIMATE: COOL CLIMATE: MOBIL AW-68 MOBIL DTE-13/UNIV. ATF MOBIL DTE-26 TEXAMATIC TYPE F CONOCO SUPER 68 PARADENE AW22 TEXACO HD68 PRESSURFLO 22 C A U T I O N Never add kerosene or other "thinners" to hydraulic oil. These fluids have low aniline points and consequently will cause rapid deterioration of certain packings and seals in the hydraulic system.
  • Page 62 Clean the reservoir and strainer, and replace the filter elements and hoses, except the return hose at the inlet of the smaller filter, and the case drain hose at the hydrostatic pump. Attach a ¾-inch I.D. return hose at the hydrostatic pump case drain port and run it into a waste oil sump or barrel.

  • Page 63: Bleeding The Brakes

    Position the crane so that the boom may later be fully topped up, rotated and extended. Do not operate these functions until the proper step. Close the small gate valve in the return line and disconnect the return hose from the return filter inlet again.

  • Page 64: 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 65 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 and outrigger circuits 2,600 PSI (179 bar) at full flow. 2.

  • Page 66: Boom Cylinder Holding Valve

    (not the hoist). An example of rated load for the IC-35-2G is 4,150 pounds (1830 kg) at an 8- foot (2.5 m) load radius, with outriggers extended and the boom over the front. Turn the engine off and move the BOOM lever to the LOWER position.

  • Page 67: Engine Maintenance

    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 68: Mechanical Adjustments

    MECHANICAL ADJUSTMENTS FASTENERS: All fasteners in the IC-35 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, rotation gearbox bolts and hoist bolts.

  • Page 69: Torque Data

    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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