Broderson IC-200-2J Operation And Maintenance Manual
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Broderson IC-200-2J Operation And Maintenance Manual

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PRINTED IN USA
P/N 990-30215
MAINTENANCE MANUAL
OWNER:_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
SOLD AND SERVICED BY:________________________________________________________
MODEL
NO._________________________________
OPERATION AND
IC-200-2J & 3J
________________________________________________________
________________________________________________________
NO.________________________
COPYRIGHT 2017
BRODERSON MFG. CORP.
LENEXA, KANSAS 66215
SERIAL

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  • Page 1 PRINTED IN USA COPYRIGHT 2017 P/N 990-30215 BRODERSON MFG. CORP. LENEXA, KANSAS 66215 OPERATION AND MAINTENANCE MANUAL IC-200-2J & 3J 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 SECTION 1 DESCRIPTION AND SPECIFICATIONS Introduction………………………………………………………………… IC-200-2J Dimensions……………………………………………………. IC-200-3J Dimensions……………………………………………………. Turning Dimensions………………………………………………………. Description and Specifications……………………………………………. SECTION 2 OPERATION Safety Rules……………………………………………………………….. Crane Conditions……………………………………………… Lifting…………………………………………………………… Travel…………………………………………………………… Instruments and Controls………………………………………………… Three Mode Steering..…….…………………………………. Control Functions……………………………………………… Sequence of Operation…………………………………………………… 2-10 Driving the Vehicle……………………………………………..

  • Page 4: Table Of Contents

    TABLE OF CONTENTS (CONTINUED) SECTION 3 MAINTENANCE Safety Rules……………………………………………………………….. New Unit Inspection and Test……………………………………………. Operator Inspection and Test……………………………………………. Maintenance Checklist……………………………………………………. Fluid Volume………………………………………………………………. Lubrication…………………………………………………………………. Lubrication Chart……………………………………………… Lubrication Schedule………………………………………….. 3-10 Boom Chain Lubrication………………………………………. 3-11 Rotation System Lubrication………………………………….. 3-12 Transmission Fluids…………………………………………… 3-12 Axle Lubrication………………………………………………… 3-12 Wire Rope Lubrication…………………………………………...
  • Page 5 IC-200-J INDUSTRIAL CRANE INTRODUCTION The Broderson IC-200-J was designed and built to provide safe, dependable and efficient crane service. This we warrant by our testing and quality control procedures. To properly utilize the full potential of the equipment, the following customer controlled conditions must exist: The operator must understand the equipment.
  • Page 6 IC-200-2J DIMENSIONS...
  • Page 7 IC-200-3J DIMENSIONS...
  • Page 8 IC-200-J TURNING DIMENSIONS...
  • Page 9 A Rated Capacity Limiter is standard. IC-200-2J: 3-section hydraulically extended boom with capacity of 30,000 pounds (13600 kg) at a 6-foot (1.8 m) load radius. Horizontal reach of 36 feet (11.0 m) and vertical reach of 45 feet (13.7 m).
  • Page 10 Gradeability (Calculated): 54 percent (28 degrees) Grade Limit: 15 percent (9 degrees) 1) Calculated values based on GM 4.3L Gasoline Engine. (Wheels may spin before these values are reached.) Boom Movement: IC-200-2J IC-200-3J Rotation Continuous Continuous Elevation 0 to 73 degrees...
  • Page 11 Optional Engines and Engine Accessories: Diesel Engine: Cummins QSB3.3L Turbo, EPA Tier 3: Cummins Model QSB3.3 turbocharged diesel engine. Water cooled, 4-cylinder, 199 CID, 3.74-inch bore, 4.53-inch stroke, 99 HP at governed speed of 2500 RPM. Maximum torque is 304 ft-lbs at 1400 RPM. 120-amp alternator included. 30-gallon fuel tank capacity.
  • Page 12 Hood for Diesel Engine Compartment The Tier 4 Final Cummins Engine package utilizes a sliding hood to access the engine bay. To open, lift and pull the hood towards the rear of the machine. When closing, push forward and when almost fully closed, lift the hood and push to fully close the hood, lifting the hood gets it over a hump and into a recess that acts as a latching mechanism to keep the hood from opening during operation.
  • Page 13 Front Axle: Standard: Planetary drive/steer front axle with 15.78 to 1.0 ratio. Differential equipped with "limited slip" feature. Driving effort is applied to wheel that has traction. Front axle mounted rigidly to frame. Calculated Performance: Gear Drawbar Pull (pounds) Travel Speeds (MPH) 17,000* 8,900* 5,100*...
  • Page 14 Spare Tire and Wheel Mounted, Non-Marking Pnuematic: Extra wheel with Non-Marking tire (385/65D22.5,16 ply) mounted, ready for service. Net Weight: 350 pounds (159 kg) Chassis: Standard: Cargo Deck: ²) Total Deck Area: 66 Square Feet (6 m . A maximum of 17,000 pounds (7700 kg) may be carried on the deck at creep speed when centered over or between axles.
  • Page 15 Pintle Hook - Rear: T-60-AOL Holland pintle hook mounted on rear frame member, provides capacity for 6000-pound (2700 kg) tongue weight and 30,000-pound (13600 kg) trailer weight. Net Weight: 15 pounds (7 kg) Pintle Hook - Front: T-60-AOL Holland pintle hook mounted on front frame member, provides same capacity as rear pintle hook.
  • Page 16 Suspension Seat: Vinyl seat with a small suspension built in. Net Weight: 15 pounds (7 kg) Deluxe Seat: Deluxe seat with upholstery springs provides additional operator comfort. Net Weight: 15 pounds (7 kg) Noise Reduction Kit - Cab: Includes vinyl floor mats and control valve cover and side panels of foam-backed, perforated vinyl for noise reduction.
  • Page 17 Optional Electrical Accessories: Strobe Lights: Two yellow strobe lights, one on each side of turret weight box, for high visibility all around crane. Flashes 60-120 times per minute. Each strobe draws only one- half amp. Includes operator controlled switch. Net Weight: 5 pounds (2 kg) Rear Work Lights: Two halogen flood lights mounted between the grille bars in the rear bumper.
  • Page 18 Boom Attachments: Standard: Anti-Two-Block Device: Prevents damage to hoist rope and/or machine components from accidentally pulling sheave block or downhaul weight against boom tip. Consists of trip arm at boom tip, which is moved upward by sheave block or downhaul weight as hook approaches boom tip.
  • Page 19 Two-Part-Line Sheave Block: Single sheave block for 2-part-line requirements. Block is specially designed to reduce height, 23 inches (58 cm) from top to saddle of load hook. 10-inch (254 mm) O.D. sheave for 1/2-inch (13 mm) rope. Swivel hook with safety latch. Includes bar on top to actuate trip arm of Anti-Two-Block device.

  • Page 21: 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 as to safety, the operator shall have the authority to stop and refuse to handle loads until safety has been assured.
  • Page 22 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. 8.
  • Page 23 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 24 9. Crane may tip at less than rated loads if the surface is uncompacted or wet dirt, or 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.The operator shall not leave the controls while the load is suspended.
  • Page 25 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 26 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 27 2. When raising the boom or moving the unit with boom elevated, be sure there is adequate overhead clearance for boom. 3. For carrying loads on decks: A. Boom must be retracted, centered and lowered as close as possible. B. 2 MPH (3km/h) maximum road speed. Reduce speed below 2 MPH (3km/h) to properly match condition of road surface and deck load stability.
  • Page 28 INSTRUMENTS AND CONTROLS The IC-200 instrument panel is equipped with a fuel gauge, an hourmeter and a bubble level. Also included are warning lights for low oil and transmission pressure, check engine, high coolant and transmission temperature, turn signal, high beam, hazard lights, parking brake and optional four-wheel drive.
  • Page 29 THREE MODE STEERING FUNCTIONS The IC-200-J is equipped with three-mode steering: four-wheel round steering can be used for making tight turns; two-wheel rear steering should be used for traveling long distances; crab steering can be used for maneuvering in tight places. A switch on the dashboard sets the mode.
  • Page 30 SEQUENCE OF OPERATION DRIVING THE VEHICLE The following procedure is recommended for driving the vehicle: Perform the daily inspection and test. (See Page 3-4) Apply park brake. Place transmission control lever in neutral. Start engine and allow a warming period. While warming the engine, set up the Rated Capacity Limiter configuration.
  • Page 31 W A R N I N G Vapors can be formed inside fuel tank and cause buildup of pressure that can result in sudden expulsion of gasoline and gasoline vapors from the filler neck when the fuel cap is removed from a hot tank. Remove cap slowly. Fuel spray may cause injury. RATED CAPACITY LIMITER (RCL) A rated capacity limiter is installed on the crane to assist the operator in estimating loads and measuring load radii.
  • Page 32 If there is a malfunction of the RCL or Anti-Two-Block system that causes loss of boom movement and cannot be remedied by the procedures above, the override keyswitch under the dashboard may be required to move the boom. W A R N I N G We recommend the CANCEL button and emergency override switch be used with discretion.
  • Page 33 The Rated Capacity Limiter is designed to stop crane functions at the limitations of the capacity chart. These are: BOOM LOWER, TELESCOPE EXTEND, HOIST RAISE, SWING LEFT and SWING RIGHT. Great care must be exercised when handling a load near capacity or near a two-blocking condition.
  • Page 34 2-14...
  • Page 35 2-15...
  • Page 36 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 37 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 38 MULTI-PART LINE REEVING For loads above 7500 pounds (3400 kg) the sheave block must be used. The 4-part-line sheave block can be used for loads up to 30,000 pounds. The optional 2-part-line sheave block can be used for loads up to 15,000 pounds. The wedge socket should be pinned to the wedge socket anchor as shown in the figure.
  • Page 39 SAFETY DEVICES There are certain safety devices on the IC-200 that are designed to maintain control of a load even if power or hydraulic line failure should occur. The operator should understand the function and operation of these devices so that a continual check on their performance can be made.
  • Page 40 OPTIONAL EQUIPMENT N O T I C E Use appropriate ladders/steps to gain access to the boom tip and deck to perform this installation. INSTALLING AND STOWING BOOM EXTENSION: Set the outriggers. Raise and extend the boom about 30 feet (9 m) above the ground, paying out load line until hook is just above ground.
  • Page 41 17. Lay the load line back in the boom tip sheaves and insert both retainer pins & cotters. 18. Replace all of the pins in their lugs for storage and insert their haipin cotters. 19. Install the sheave block on the load line, if desired. 20.
  • Page 42 CAPACITY EXAMPLES FOR BOOM EXTENSION The BOOM EXTENSION ANGLE and the LOAD RADIUS capacity charts must both be considered when using the boom extension. The smaller capacity specified by the 2 charts must be used. Refer to the IC-200-3J, Capacity Chart on page 2-14 for the following examples: In this first example the boom is elevated to 30°...
  • Page 43 FRONT AUXILIARY WINCH: The front auxiliary winch is mounted behind the front bumper and is controlled from the operator compartment. The winch has 115’ (35 m) of 7/16” (11 mm) diameter 6x36 EIP- IWRC wire rope (20,200 pound (91 kn) minimum breaking force) and a 5-ton (4.5 metric ton) hook.
  • Page 44 PINTLE HOOKS: Available Pintle Hooks allow the crane to tow other disabled vehicles and trailors, and drag loads. 1. Observe the capacity ratings marked near the hook when towing. 2. Exceeding the capacities can damage the drivetrain. 3. 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 45 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 46 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 47 MAINTENANCE SAFETY RULES 1. 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. Disconnect battery, RCL and engine electronic module when welding on crane.
  • Page 48 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.

  • Page 49: New Unit Inspection And Test

    MAINTENANCE The Broderson IC-200 Industrial Crane will perform better and longer if a program of inspec- tion, 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.

  • Page 50: 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 51 OPERATOR INSPECTION AND TEST Weekly: 1. Check tire pressure: 120 PSI (827 kPa). 2. Check for loose wheel nuts. (500 foot-pounds (680 N-m) torque required.) 3. Check lights and turn signals. 4. Check power steering lines for damage. 5. Check brake lines for damage. 6.

  • Page 52: Maintenance Checklist

    IC-200 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 53 500 HOUR OR 6 MONTH INTERVAL: 1. 250 hour maintenance. 2. 50, 250 and 500 hour lubrication. 3. Check antifreeze for protection level and cleanliness. 4. Change hydraulic filter element, if not changed in the last 250 hours and inspect oil from element.

  • Page 54: Fluid Volume

    FLUID VOLUME Hydraulic reservoir – 54 gallons (204 L) Fuel tank – 30 gallons (113 L) Planetary hoist – 2.5 quarts (2.4 L) Front auxiliary winch – 2 pints (0.9 L) 4x2 & 4x4 Front axle – 5.98 gallons (22.6 L) housing, 39 gallons (1.5 L) each hub 4x4 Rear axle –...

  • Page 55: Lubrication Chart

    IC-200 LUBRICATION CHART...

  • Page 56: Ic-200 Lubrication Schedule

    IC-200 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 4 Zerks Axle Pivot Pin 1 Zerk Axle Planetary Hubs Check @50, Change @12 Mo.

  • Page 57: Boom Chain Lubrication

    IC-200-3 BOOM CHAIN LUBRICATION Lubricate inner chains and chain sheaves through windows with boom fully extended and set horizontally. There are grease fittings on chain sheave shafts both inside and outside the boom. Reach in through boom windows with a long tipped oil can and spray chains generous- ly and grease sheave fittings.
  • Page 58 DRIVE AXLES-HUBS AND DIFFERENTIALS: Maintain lubricant to levels shown here with Mobil 424 or equivalent. Axle factory service manuals are available from Broderson. Order BMC Part No. 990-00020. *No lubricant is required in the center section of the 2WD rear axle.

  • Page 59: 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 60 6. 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 one inch (24 mm). 7. Slide the cable and wedge into the drum socket and pull firmly on the free end of the cable to set the wedge.

  • Page 61: Hydraulic System Description

    HYDRAULIC SYSTEM The IC-200 hydraulic system consists of 2 subsystems, driven by a double pump with a single inlet port. The 29 GPM (110 L/min) vane pump supplies the hydrostatic steering function and the boom and outrigger functions. The hoist and brake booster are powered by the 34 GPM (129 L/min) vane pump.
  • Page 62 3-16...
  • Page 63 3-17...

  • Page 64: Care Of Hydraulic Oil

    CARE OF HYDRAULIC OIL The hydraulic system contains many highly pressurized, precision components. To 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-200 is equipped with a 100-mesh suction strainer, a breather filter, a 10-micron return- line filter and a 54-gallon (204 L) tank.
  • Page 65 HYDRAULIC OILS FOR IC-200 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) (-26°C) (-18°C) VISCOSITY INDEX: 140 MIN 95 to 100 95 to 100 VISC.

  • Page 66: Removal Of Air From Hydraulic Circuits

    REMOVAL OF AIR FROM HYDRAULIC CIRCUITS To remove air from hydraulic circuits, perform the following steps: 1. Ensure all main shutoff valves on the reservoir are open. 2. Start the engine. 3. Raise and lower the boom minimum five times. Ensure that the cylinder travels full stroke.

  • Page 67: 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 68: Pressure Settings

    PRESSURE SETTINGS: The hydraulic system is divided into two pressure circuits, each having its own protective ad- justable 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 be- low: 1.

  • Page 69: 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) for IC-200-1 & 2, 3000 PSI (207 bar) for IC-200-3. This pressure is required for all but the swing control section.
  • Page 70 TELESCOPE CYLINDER HOLDING VALVE: A holding valve is directly connected to the base of the primary telescope cylinder rod. The valve is designed to hold the boom in position should loss of power or pressure line failure oc- cur. The holding valve should be checked with the boom elevated to the maximum angle and the boom extended to a 6 foot (1.8 m) load radius.
  • Page 71 IC-200-3 BOOM CHAIN ADJUSTMENT 3-25...

  • Page 72: Engine Maintenance

    ENGINE MAINTENANCE: Refer to the engine manual for engine maintenance. AIR CLEANER SERVICE: Gas or Dual Fuel Engine: 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.

  • Page 73: 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 radia- tor fins for dirt or debris daily and wash the fins with a pressure or steam cleaner every 50 hours or as required.
  • Page 74 4. Push down hard on the foot brake pedal. 5. Select forward gear. 6. Move the park brake lever fractionally downward, just over center, slightly releasing it. Hold park brake lever switch in the off position (located in the lever bracket). 7.

  • Page 75: 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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Ic-200-3j

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