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Broderson IC-20-1J Operation And Maintenance Manual

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PRINTED IN USA
P/N 990-30172
MAINTENANCE MANUAL
OWNER: _________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
SOLD AND SERVICED BY:__________________________________________________________
MODEL NO. ___________________________ SERIAL NO. ______________________________
OPERATION AND
IC-20-1J
__________________________________________________________
__________________________________________________________
COPYRIGHT 2011
BRODERSON MFG. CORP.
LENEXA, KANSAS 66215
Courtesy of Crane.Market

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  • Page 1 PRINTED IN USA COPYRIGHT 2011 P/N 990-30172 BRODERSON MFG. CORP. LENEXA, KANSAS 66215 OPERATION AND MAINTENANCE MANUAL IC-20-1J OWNER: _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ SOLD AND SERVICED BY:__________________________________________________________ __________________________________________________________ __________________________________________________________ MODEL NO. ___________________________ SERIAL NO. ______________________________ Courtesy of Crane.Market...
  • 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 it’s 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…………………………………………………………….. 3-12 Hydraulic System…………………………………………………………. 3-13 Steering System………………………………………………………….. 3-13 Propulsion System……………………………………………………….. 3-15 Start-Up Procedure………………………………………………………. 3-17 Piston Pump Troubleshooting…………………………………………… 3-18 Care of Hydraulic Oil……………………………………………………… 3-19 Approved Hydraulic Fluids……………………………………………….. 3-20 Control Valve Adjustment………………………………………………… 3-21 Boom Circuits…….…….…….………………………………… 3-21 Hoist and Outrigger Circuits…………………………………. 3-21 Boom Cylinder Holding Valve………………………………..

  • Page 5: Introduction

    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-20-1J Courtesy of Crane.Market...

  • Page 7: Turning Dimensions

    TURNING DIMENSIONS Courtesy of Crane.Market...

  • Page 8: Description And Specification

    SECTION I DESCRIPTION AND SPECIFICATIONS The IC-20-1J 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 SPECIFICATIONS (CONTINUED) Drawbar Pull: 3000 pounds (1360 kg) Gradeability: 53% (28 degrees) Calculated values based on GM 2.4L Gasoline engine. Wheels may spin before these values are reached. Grade Limit: Forward and backward Sideways with no load Boom Movement: Rotation 90 degrees Elevation...
  • Page 10 ENGINE: Standard: GM 2.4L, Woodward EFI Dual Fuel, EPA Tier II Certified: Industrial gasoline engine complete with multi-port electronic fuel injection, dual fuel, and engine management system. Water-cooled, 4-cylinder, 147 CID (2.4 L), 3.44-inch (87.4 mm) bore, 3.94-inch (100 mm) stroke, 65 HP (48 kW) at governed speed of 2500 rpm.
  • Page 11 Brakes: Standard: Primary braking from hydrostatic transmission. Foot-actuated hydraulic disc brake for additional braking. Spring-applied, hydraulic-released park brake, actuated from a toggle switch on control panel. All braking is on front wheels. Tires: Standard: 7.50 x 10 pneumatic tires, 16 ply. Pressurized to 145 psi (1000 kPa) for crane rated loads.
  • Page 12 Lifting Sling Brackets: Two lift rings in front deck and lug on turntable for attaching lifting sling. Optional Chassis Accessories: Auxiliary Winch: Optional worm gear winch mounted behind front bumper, with a selector valve and single lever control at the operator's console. Hydraulic powered to provide bare-drum line pull of 3000 pounds (1360 kg) at 20 ft/min (6m/min).
  • Page 13 Battery: Group 24 with 550 CCA rating. Lighting Group: Consists of two headlights and taillight and 12 volt horn activated by button on instrument panel. Instrument Group: Located at operator's station and includes lighted fuel gauge, volt meter, oil pressure, water temperature and hydraulic oil temperature gauges. Hourmeter records hours only during actual engine operation.
  • Page 14 Boom Hoist: Standard: Turret-mounted, worm gear hoist is hydraulically powered to provide bare- drum line pull of 3,100 pounds (1400 kg). The IC-20 has a line speed of 63 ft/min (19 m/min). Hoist drum is 5 5/8 inch (143 mm) diameter by 4 7/8 inches (124 mm) long and provides even pull and long cable life.

  • 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 as to 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

    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 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.
  • 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

    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-20-1J has a lower and upper instrument panel. The lower panel consists of the standard engine instruments and controls. These instruments show the electrical system voltage, water temperature, oil pressure, and fuel level. There are also controls for the gas/LPG functions and throttle.
  • 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-20-1J is 5,000 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 Courtesy of Crane.Market...
  • Page 26 2-12 Courtesy of Crane.Market...

  • Page 27: Capacity Example

    CAPACITY EXAMPLE (See 7 foot (2.1 m) Jib Capacity Example Page 2-17) Refer to the IC-20-1J 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 2,500 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- 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 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

    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 36 Courtesy of Crane.Market...

  • Page 37: Section 3 Maintenance

    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: New Unit Inspection And Test

    MAINTENANCE The Broderson IC-20-1J 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 insure that no damage or loss of operating capability occurred during shipment.

  • Page 40: 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 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

    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 INTERVAL: 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 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 43: Rotation System Lubrication

    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 44: Ic-20 Lubrication Chart

    IC-20 LUBRICATION CHART Courtesy of Crane.Market...
  • Page 45 IC-20 LUBRICATION SCEDULE LUBRICATION INTERVALS ITEM DESCRIPTION LUBE 500 1000 MONTHS NOTES SYMBOL HOUR HOUR HOUR HOUR Accelerator Linkage 2 Points 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 46: 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: 1. If possible, the cable should be rolled off a storage spool and straightened out on the ground in line with the boom.
  • Page 47 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 48: Jic Schematic

    JIC SCHEMATIC 3-12 Courtesy of Crane.Market...

  • Page 49: Hydraulic System

    HYDRAULIC SYSTEM The IC-20 hydraulic system consists of three subsystems, 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 50 STEERING SYSTEM 3-14 Courtesy of Crane.Market...

  • Page 51: Propulsion System

    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 3,000 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 52 IC-20 PROPULSION SYSTEM 3-16 Courtesy of Crane.Market...

  • Page 53: Start-Up Procedure

    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 54: Ic-20 Piston Pump Troubleshooting

    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 55: 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 tem-perature, 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 56: Approved Hydraulic Fluids

    APPROVED HYDRAULIC FLUIDS WARM CLIMATE: COOL CLIMATE: MOBIL ATF D/M* MOBIL MULTI-VEHICLE ATF MOBIL MULTI-VEHICLE ATF DEXRON VI DEXRON VI *MOBIL ATF D/M was used at the factory to fill the hydraulic system of your IC-20. CAUTION 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 57: Control Valve Adjustment

    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 -- 2,500 psi (172 bar) at full flow. 2.

  • Page 58: Boom Cylinder Holding Valve

    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 59: 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 60: Mechanical Adjustments

    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 61: 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...
  • Page 62 Courtesy of Crane.Market...
  • Page 63 Courtesy of Crane.Market...

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