Broderson IC-100-B Operation And Maintenance Manual
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Broderson IC-100-B Operation And Maintenance Manual

4x2 & 4x4
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PRINTED IN USA
P/N 990-30257
MAINTENANCE MANUAL
OWNER: ______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
SOLD AND SERVICED BY: _______________________________________________________
MODEL NO. ___________________________ SERIAL NO._____________________________
OPERATION AND
IC-100-B
4x2 & 4x4
_______________________________________________________
_______________________________________________________
COPYRIGHT 2019
BRODERSON MFG. CORP.
LENEXA, KANSAS 66215

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  • Page 1 PRINTED IN USA COPYRIGHT 2019 P/N 990-30257 BRODERSON MFG. CORP. LENEXA, KANSAS 66215 OPERATION AND MAINTENANCE MANUAL IC-100-B 4x2 & 4x4 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 IC-100-3B Dimensions…………..………………………… 1-2 Turning Dimensions……………..…………………………… 1-3 Description and Specifications……..……………………… 1-4 SECTION 2 OPERATION Safety Rules………………………………………………. Instruments and Controls……………………………….. Control Functions…………….………...…………… 2-10 Three-Mode Steer Operation………..……………… 2-10 Sequence of Operation………………………………….. 2-10 Driving the Vehicle…………………...……………… 2-10 Operating the Crane……………….…………………...
  • Page 4 SECTION 3 MAINTENANCE (continued) Hoist Cable Installation and Inspection………..………… 3-10 Hydraulic System Description…………………...………… 3-12 Steering System……………………………………... 3-12 JIC Schematic………………………………..……… 3-13 JIC Schematic, Metric………………………………. 3-14 Hydraulic System Maintenance…………………...………. 3-15 Care of Hydraulic Oil……………………………….… 3-15 Hydraulic Oil Specifications………………………… 3-16 Hydraulic Seals……………………………………… 3-17 Hydraulic System Adjustments……………...……………..

  • Page 5: Introduction

    This unit must not be altered or modified without written factory approval. To reorder this manual, ask for IC-100-B Operation and Maintenance Manual, Part Number- 990-30257. Contact your Broderson Service Representative at: Broderson Manufacturing Corp.

  • Page 6: Ic-100-3B Dimensions

    IC-100-3B DIMENSIONS...

  • Page 7: Turning Dimensions

    IC-100-B TURNING DIMENSIONS...

  • Page 8: Description And Specifications

    DESCRIPTION AND SPECIFICATIONS The IC-100-B is a self-propelled Industrial Crane designed for in-plant lifting and material handling applications, with special features of low height, narrow width, short length, cargo deck, and standard four-wheel steer and front-wheel drive. The chassis includes a frame,...
  • Page 9 General Continued: Boom Movement: Rotation Continuous Elevation 0° to 70° Telescope 20 feet Hydrualic (6.10 m) Boom Speeds: Rotation 2 RPM Elevation 12 seconds Telescope 30 seconds Sheave Height: (Nominal) W/O Boom Extension 39.7 feet (12.1 m) With Boom Extension 49.3 feet (15.0 m) Horizontal Reach: W/O Boom Extension...
  • Page 10 Engine: Standard Gasoline: GM 3.0L EPA Tier II w/ Dual Fuel: GM Model 3.0L industrial gasoline engine with multi-port electronic fuel injection, dual fuel, catalytic converter, and engine management system. Water cooled, 4-cylinder, 181 CID (3.0 L), bore 4.00 inches (102 mm), stroke 3.60 inches (91 mm), 59 HP (44 kW) at governed speed of 2500 RPM.
  • Page 11 4X2 GAS 4X2 DIESEL 4X4 DIESEL Travel Drawbar Travel Drawbar Travel Drawbar Speed Pull Speed Pull Speed Pull Gear Ratios (km/h) (kg) (km/h) (kg) (km/h) (kg) 5.72/1 9500 10,500 13,500 (4300) (4800) (6100) 3.23/1 5500 6000 9000 (11) (2500) (11) (2700) (10) (4100)
  • Page 12 Tires: Standard: 10:00 x 15, 16-ply, highway type tread. Mining and Industrial Tires: 36 x11-15, 16-ply rating pneumatic tires. Net Weight: 120 pounds (57 kg) Mining and Industrial Tires, Non-Marking for 4x2: 10.00 x 15, 16-ply rating pneumatic tires. Net Weight: 120 pounds (57 kg) Tire Options: Solid Rubber Tires: 8:25 x 15.
  • Page 13 Steps: A step is located on each front corner providing access to deck area. Battery: Located behind door on left-hand, rear corner of chassis. Compartment available on right-hand, rear corner of chassis for second battery, if necessary. Outriggers: Four hydraulic outriggers of box-beam construction. Independent controls for each outrigger.
  • Page 14 Operator's Compartment: Standard: Operator’s control station provides one-position access to all operating functions. Includes adjustable operator's seat and retracting seat belt, fire extinguisher, and bubble level. Drum Rotation Indicator: Provides visible feedback to operator when hoist drum is rotating. Light on dash flashes when drum is turning.
  • Page 15 Electrical System: Standard: 12-Volt Battery: Gas Units: Group 27 with 540 CCA rating. Diesel Units: Group 31 with 950 CCA rating. Instrument Group: Located at operator's station and includes fuel gauge, hourmeter, and bubble level. Hourmeter records hours only during actual engine operation. Also included are: warning lights for low oil and transmission pressure, turn signal, high beams, hazard lights, parking brake, hydraulic oil temperature, battery, check engine, stop engine, coolant temperature, engine oil...
  • Page 16 Hydraulic System: Standard: Tandem pump, direct-driven by engine crankshaft, delivers 16 GPM (61 L/min) at 3000 PSI (207 bar) and 32 GPM (121 L/min) at 3000 PSI (207 bar) at 2500 RPM governed engine speed. System protected by relief valves, suction line strainer and 10-micron full-flow return line filter.
  • Page 17 Rated Capacity Limiter: Operator's aid that warns operator of impending overload with audible and visual signals. Has read-outs for load, boom angle, boom length and load radius. In the event of an overload, dumps the following boom functions: HOIST RAISE, TELESCOPE EXTEND, BOOM LOWER, SWING LEFT and SWING RIGHT.

  • Page 19: Safety Rules

    OPERATION SECTION 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 20 3. Keep operator's compartment and decks free of mud and grease. 4. If crane is equipped with a cab, keep all window glass clean. Keep gauges clean. 5. Tools, lubricants, or rags on the crane should be kept in a secured toolbox. 6.
  • Page 21 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 22 9. Crane may tip at less than rated loads if the surface is uncompacted or if wet dirt, or soft soil with frozen crust, thin or cracked pavement, or [the surface] is near a hole or ledge. Always use adequate outrigger floats and/or cribbing. See page 2-14. 10.The operator shall not leave the controls while the load is suspended.
  • Page 23 CAUTION Keep hands out of Anti-Two-Block mechanism. Serious injury can result from moving parts. 17. Avoid two-blocking. A. Stop raising hoist line before downhaul or hook block strikes boom tip plates. B. Pay out hoist line while extending boom. C. Maintain clearance between downhaul weight or hook block and boom tip while booming down.
  • Page 24 22. Crane has four lifting rings, one at each corner of load deck, for lifting the crane. Use proper slings and rigging methods to keep the load balanced during the lift. Do not lift by the boom. Proper lifting and securing practices are the responsibility of the rigger in charge.
  • Page 25 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 26: Instruments And Controls

    8. Shut off engine before refueling and remove fuel cap slowly. Vapor pressure in tank can cause a burst of fuel and vapor when the cap is removed. Aways refuel with proper fuel and into proper tank. 9. Know your visibility limitations. Loads being carried on the deck or hanging on the hook can add further limitations to visibility during travel.
  • Page 27 Normal engine speed-control uses the foot accelerator pedal. On gas engines, only a 3- position switch on the right dash panel provides pre-set engine speeds. Parking brake must be set to activate system. Press the high idle control switch temporarily to the right; the engine will lock into the preset levels.

  • Page 28: Control Functions

    CONTROL VALVE FUNCTIONS The controls for operating the outriggers, boom rotation, boom elevation, boom extension, and hoist are located along the forward dashboard area. The control handles are directly connected to the 3-position hydraulic valves. The placard located next to these handles identifies the function and direction resulting from each handle movement.

  • Page 29: Operating The Crane

    5. While warming the engine, set up the Rated Capacity Limiter configuration. 6. Stow boom over front. 7. Pull hoist line snug. 8. Retract outriggers fully. 9. Step on the brake pedal. 10. Release park brake lever. 11. Shift transmission to desired gear. 12.

  • Page 30: 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 31: 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 32 W A R N I N G The Rated Capacity Limiter can suddenly stop the boom lower and swing functions, causing the load to bounce or swing. Use great care when handling a load near capacity limits or near a two-blocking condition. 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.
  • Page 33 2-15...

  • Page 34: Capacity Example

    C A U T I O N A capacity load may be carried on the boom, or a capacity load may be carried on the deck, but not at the same time. The total of the percent of deck load and the percent of boom load must not exceed 100%.

  • Page 35: 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 36: Two-Part-Line Reeving

    TWO-PART LINE REEVING For loads above 10,000 pounds (4500 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 37: Safety Devices

    SAFETY DEVICES There are certain safety devices on the IC-100 that are designed to maintain control of a load even though power or hydraulic line failure could occur. The operator should understand the function and operation of these devices so that a continual check on their performance can be made.

  • Page 38: Optional Equipment Operation

    OPTIONAL EQUIPMENT INSTALLING BOOM EXTENSION ON TIP OF BOOM: Set the outriggers. Raise and extend boom 30 feet (9 m) above the ground, paying out load line until hook is just above ground. Position boom over front, lower, and retract boom leaving the load line on the ground. If the sheave block is installed, remove it.
  • Page 39 SETTING THE OFFSET ANGLE ON THE OFFSETTABLE BOOM EXTENSION: 1. The boom extension must be installed on the main boom tip & the load line, downhaul weight and wedge socket installed on the boom extension, and secured with all of the retainer pins.

  • Page 40: Capacity Examples For Boom Extension

    CAPACITY EXAMPLES FOR BOOM EXTENSION The MAIN BOOM and BOOM EXTENSION capacity charts must both be considered when using the boom extension. The smaller capacity specified by the two charts must be used. Refer to the IC-100-3B Capacity Chart on page 2-15 for the following examples: In this first example the boom is elevated to 30°...

  • Page 41: Front Auxiliary Winch

    FRONT AUXILIARY WINCH: The front auxiliary winch is mounted behind the front bumper and is controlled from the operator compartment. The winch, with 75 feet (23 m) of 3/8-inch (9.5 mm) diameter 6X36- IWRC-EIP wire rope (15,100 pound (67 kN) breaking strength) and 3-ton (2700 kg) hook, has a single-part-line capacity of 5000 pounds (2270 kg) on the first wrap.

  • Page 42: Pintle Hooks

    PINTLE HOOKS: Available Pintle Hooks allow the crane to tow other disabled vehicles and trailers, and drag loads. Observe the capacity ratings marked near the hook when towing. Exceeding the capacities can damage the drivetrain. Use slow and smooth motions to avoid shock loads or overrunning loads. Make sure other vehicle is occupied and controlling the vehicle being towed.

  • Page 43: Switch And Indicator Symbols

    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 44 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 45: Maintenance

    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 46 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 47 MAINTENANCE The Broderson IC-100 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 48 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 49: Maintenance Checklist

    W A R N I N G Vapor can form inside a fuel tank and cause a build-up 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.
  • Page 50 500 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 51: Lubrication

    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 a Universal Tractor Fluid (UTF), such as Mobil 424 or equivalent.

  • Page 52: Lubrication Chart

    IC-100 LUBRICATION CHART...

  • Page 53: Lubrication Schedule

    IC-100 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 54: Hoist Cable

    HOIST CABLE LUBRICATION The hoist cable is a wire rope and 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 com- pressed air or solvent and rags.
  • Page 55 CAUTION For a correct assembly, it is necessary to have a minimum pre-load of 5% of the cable breaking force. The cable breaking force depends on the diameter and of the cable type, and it must be indicated on the cable certificate. 6.

  • Page 56: Hydraulic System Description

    HYDRAULIC SYSTEM The IC-100 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 & outrigger functions. The hoist and brake booster are powered by the 32-GPM (121 L/min) vane pump.
  • Page 57 3-13...
  • Page 58 3-14...

  • Page 59: 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 the proper temperature, within the oil specification, and to the proper fill level. The IC-100 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 60 HYDRAULIC OILS FOR IC-100 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 61: 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 62 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 63: Boom Elevation Cylinder Holding Valve

    BOOM AND OUTRIGGER CIRCUIT: The relief valve pressure setting at the inlet for boom control sections is 3000 PSI (207 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 64: 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 65: Cooling System

    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 66: 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 67: 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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