Broderson IC-100-3A Operation And Maintenance Manual Download | Manualshive

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PRINTED IN USA

COPYRIGHT



2017

P/N 990-30235

BRODERSON MFG. CORP.

LENEXA, KANSAS 66215

OPERATION AND

MAINTENANCE MANUAL

IC-100-3A
4x2 & 4x4

OWNER: ______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

SOLD AND SERVICED BY: _______________________________________________________

_______________________________________________________

_______________________________________________________

MODEL NO. ___________________________ SERIAL NO._____________________________

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Summary of Contents for IC-100-3A

Page 1: ..._ ______________________________________________________________________ ______________________________________________________________________ SOLD AND SERVICED BY ___________________________________...

Page 2: ...product WITHOUT LIMITING THE GENERALITY OF THE FOREGOING BMC EXPRESSLY DISCLAIMS THAT THE WARRANTY MADE HEREIN EXTENDS TO A PERSON WHO RENTS OR LEASES ANY BMC PRODUCT OR WHO PURCHASES ANY BMC PRODUCT...

Page 3: ...t Line Reeving 2 18 Safety Devices 2 19 Outrigger Check Valve 2 19 Boom Elevation Cylinder Holding Valve 2 19 Telescope Cylinder Holding Valve 2 19 Anti Two Block System 2 19 Optional Equipment Operat...

Page 4: ...justments 3 18 Control Valves 3 18 Boom Elevation Cylinder Holding Valve 3 19 Telescope Cylinder Holding Valve 3 20 Engine Maintenance 3 20 Air Cleaner Service 3 20 Cooling System 3 21 Spare Parts Lis...

Page 5: ...tion required for these conditions The recommendations for periodic inspection test and maintenance are minimum standards for safe and economical performance When ordering parts the unit serial number...

Page 6: ...1 2 IC 100 3A DIMENSIONS...

Page 7: ...1 3 IC 100 A TURNING DIMENSIONS...

Page 8: ...full power steering The boom assembly includes a hydraulic powered continuous rotation turret 3 section boom hydraulic boom elevating cylinder hydraulic boom telescoping cylinders and hydraulic powere...

Page 9: ...ngine 7950 kg Front Axle 8910 pounds 4040 kg Rear Axle 8610 pounds 3910 kg 4 Wheel Drive 18 370 lbs w Cummins 3 3L Engine 8330 kg Front Axle 9010 lbs 4090 kg Rear Axle 9360 lbs 4240 kg Steering Turnin...

Page 10: ...cylinder 199 CID 3 3 L bore 3 74 inches 95 mm stroke 4 53 inches 115mm 74 HP 55kW at governed speed of 2600 RPM Maximum torque 274 pounds foot 371 Nm at 1600 RPM 90 amp alternator included 17 6 gallo...

Page 11: ...Drop center axle beam casting with 1 degree oscillation in either direction Optional 4 Wheel drive Planetary drive steer axle with overall 13 76 1 ratio including the reduction through the front axle...

Page 12: ...ndustrial Tire Non Marking Net weight 193 pounds 88 kg Chassis Standard Cargo Deck Total Deck Area 53 square feet 5 m A maximum of 14 000 pounds 6350 kg may be carried on the deck when centered over o...

Page 13: ...aillight Grilles Consists of welded steel protective grilles for headlights and taillights Easily removable for replacing bulbs Chassis Options and Accessories Auxiliary Winch Optional worm gear winch...

Page 14: ...tructure with laminated glass front and top Top glass is 3 8 inch thick Door is equipped with a keyed lock to protect operator s station Includes defroster fan 24 000 BTU heater with two speed fan and...

Page 15: ...y flasher switch at operator s station 12V horn actuated by button located on shifting control Back Up Alarm Provides pulsating sound from a 102 dB alarm when ignition is on and transmission is in rev...

Page 16: ...ar hoist is hydraulically powered to provide a bare drum line pull of 11 300 lbs 5200 kg at a speed of 100 feet per minute 30 5 m min Hoist drum 11 65 inch 296 mm diameter by 12 89 inches 327 mm long...

Page 17: ...h 254 mm O D sheave for 9 16 inch 14 mm rope Has swivel hook with safety latch A 90 pound 41 kg downhaul weight and swivel hook are also provided for single part line Optional Boom Attachments Boom Ex...

Page 18: ......

Page 19: ...y practice which will divert his attention while actually operating the crane 6 Do not run the engine in an enclosed area or indoors without adequate ventilation 7 Do not use ether for starting Ether...

Page 20: ...Do not use ether for starting Ether is highly flammable and can be ignited by the intake manifold heater grid causing engine damage or operator injury 7 8 9 The Rated Capacity Limiter must be checked...

Page 21: ...an cause the load to swing Swing the boom slowly whenever these systems might stop the boom 3 Do not allow anyone to put any part of his body under a load The load may lower or fall if there are damag...

Page 22: ...quate parts of load hoist line for lifting heavy loads 12 Always be sure the rope is properly seated and wound evenly on hoist drum 13 Keep hands away from load hoist rope when hoist is being operated...

Page 23: ...terweight supplied with this crane should never be changed Unauthorized addition of counterweight in the field to increase lifting ability constitutes a safety hazard 19 Always keep crane boom at leas...

Page 24: ...are the responsibility of the rigger in charge 23 When transporting the crane be sure it is properly secured to the vehicle Utilize the tie down anchors as indicated on the crane to stabilize the loa...

Page 25: ...time J Do not pick and carry with boom extension installed K Do not exceed the OVER FRONT ON RUBBER capacity 2 When raising the boom or moving the unit with boom elevated be sure there is adequate ove...

Page 26: ...cated on the left side of the steering column Move the lever down for a left turn up for a right turn The emergency flasher lights are actuated by a switch on the instrument panel The hand brake lever...

Page 27: ...ot accelerator either temporarily release the parking brake fully or turn the engine off Three mode steering is standard Rear steer 4 wheel round steer and crab steer can be selected with a switch on...

Page 28: ...ng forward will lower load line All controls may be used for simultaneous operation to achieve combinations of movements Some controls must be used together For instance the boom telescope and the hoi...

Page 29: ...eutral 4 Start engine and allow a warming period at low RPM 5 While warming the engine set up the Rated Capacity Limiter configuration 6 Move accelerator pedal from medium to full speed 7 Set all outr...

Page 30: ...able load radius the boom can be raised or retracted to a safe radius or the load may be lowered to a safe place using the hoist control If the boom extension is at its angle limit the boom must be ra...

Page 31: ...il safe Do not consider the system as a substitute for good judgment training experience or accepted safe operating practices The operator is solely responsible for operation of the crane Setting the...

Page 32: ...cities are given in direct relation to the radius at which the load is being handled Boom extension capacities depend on the boom angle as well as the load radius The capacities shown on the capacity...

Page 33: ...2 15...

Page 34: ...to the deck of the crane for transport to a new location We see on the chart that 10 000 pounds 4500 kg is the maximum load on one part line so the sheave block is required The charts show the weight...

Page 35: ...ins that pass through the sheave plates must be locked in place with cotters to hold the line on the sheaves The load line must pass through the center of the downhaul through the wedge socket and the...

Page 36: ...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 This will seriously weaken the rope by meta...

Page 37: ...NDER HOLDING VALVE A single acting holding valve is flange mounted to the cylinder rod end This valve holds the cylinder in the extended position should power or hydraulic pressure line failure occur...

Page 38: ...ion around to the front until the outer lugs mesh 10 Insert the attach pins in their outer lugs and retain them with hairpin cotters To insert pin it may be necessary to rock boom extension 11 Replace...

Page 39: ...e and allow the boom extension and downhaul weight to fall causing death or serious injury to personnel 3 Remove the offset index pin from the boom extension knuckle To loosen the pin it may be necess...

Page 40: ...ON STRAIGHT OR OFFSET MAIN BOOM ANGLE 30 shows the capacity at the 15 boom extension angle to be 2400 pounds 1090 kg Since 2400 pounds 1090 kg is less than 3700 pounds 1700 kg the load including the d...

Page 41: ...o a position where they may be safely lifted with the boom 3 To pull the crane out of mud or other obstacles 4 To pull a smaller vehicle that is stuck W A R N I N G The front winch is not designed for...

Page 42: ...ooks also allow the crane to be towed 1 Use appropriately sized straps or chains 2 Place transmission in Neutral Utilize an Operator to activate brakes as needed and steer the crane while being towed...

Page 43: ...art Windshield washer switch Off Stop Windshield defroster switch Battery not charging Heater switch Hour meter Air conditioner switch Read operator s manual Ventilation fan switch Sound level notific...

Page 44: ...ator Transmission oil temperature Engine start Brake fluid fill location Engine idle set Hydraulic oil low level mark Check engine Hydraulic oil filter restriction indicator Stop engine Hydraulic temp...

Page 45: ...ole can be almost invisible yet have enough force to penetrate the skin If injured by escaping fluid see a doctor at once Serious reaction or infection can occur 6 Wear safety glasses and shoes 7 Do n...

Page 46: ...s and cylinders involved by cycling them full stroke with the engine running until the functions operate smoothly 23 When welding on the crane or on anything connected to the crane by wire rope or oth...

Page 47: ...13 Start engine 14 Check power steering for operation Check all steering modes 15 Check operation of transmission gear selector lever 16 Check lights and turn signals for operation 17 Test drive unit...

Page 48: ...r proper operation 18 Check horn back up alarm and outrigger alarm for proper operation 19 Check operation of all transmission gears forward and reverse 20 Clean all glass if equipped and check for cr...

Page 49: ...warm oil change element if indicated 14 Check diesel engine idle and maximum speed and adjust if necessary 15 Check swing gear and pinion fit and gear train backlash 16 Check swing bearing and gearbo...

Page 50: ...erform engine maintenance specified in engine manual 5 Change hydraulic fluid and filter and clean breather and reservoir 6 Change transmission fluid and filter and clean strainer 7 Replace vapor bloc...

Page 51: ...otate the boom several times and check the coverage of the grease on all of the teeth Replace the pinion cover TRANSMISSION Check the transmission fluid with the dipstick and add fluid through the dip...

Page 52: ...3 8 IC 100 LUBRICATION CHART...

Page 53: ...draulic Oil HO X X 12 Max Check Daily Change 1000 Hours or 12 Mo Max 20 Outrigger Legs MPG X Wipe on Legs 21 Pump Shaft MPG X 2 Zerks 22 Rotation Bearing MPG X 1 Zerk 23 Rotation Gearbox WGO X 24 Chec...

Page 54: ...LANGE MOUNT INSTALLATION INSPECTION The following steps will assure that the wire rope aka hoist rope hoist cable or load line winds smoothly and evenly on the hoist and will yield greater safety and...

Page 55: ...eet 12 m of cable on the ground to install the sheave block The sheave block must be used for cable preloading to ensure enough rope can be spooled off the hoist drum See the Operation Section for ins...

Page 56: ...ort EF to the crane valve The crane operating speed is not affected since there is no loss of volume passing through the priority valve When the steering wheel is turned the load sensing line signals...

Page 57: ...3 13...

Page 58: ...3 14...

Page 59: ...voir and purged out of the cylinders If excessive particles are found the source should be located and fixed and the oil should be purged Lubricate the new element seal and install the new element Ope...

Page 60: ...ommended oils are not available These motor oils are not suitable substitutes when changing hydraulic oil because they lack certain additives that are needed for hydraulic system use C A U T I O N Nev...

Page 61: ...ot to over tighten pipe threads 4 Do not use Teflon tape to seal pipe treads Loctite type anaerobic sealant is preferred Leaks in component parts such as pumps valves and motors that cannot be stopped...

Page 62: ...adings WINCH CIRCUIT Remove the 3 8 JIC cap from the fitting on the front of the control valve near the winch control section and install a 4000 PSI 275 bar pressure gauge To obtain full flow reading...

Page 63: ...0 C 9 340 00032 Shim 010 25 mm Gresen 0462 001 9 340 00031 Shim 020 5 mm Gresen 0459 001 9 340 00030 Shim 040 1 mm Gresen 0458 001 BOOM CYLINDER HOLDING VALVE A holding valve is directly connected to...

Page 64: ...amp Clean the intake cap screen every 50 hours and perform a thorough inspection of the air intake pipes and joints Clean the filter element every 250 hours or every 3 months whichever comes sooner an...

Page 65: ...ts as follows Inner race hex head bolts or nuts 230 250 foot pounds 310 340 Nm Outer race socket head cap screws or nuts 250 270 foot pounds 340 370 Nm Note the inspection torques are less than the in...

Page 66: ...aximum engine speed The machine should not move 11 Do not do this test for longer than 30 seconds 12 Reduce engine speed to an idle 13 Return the park brake lever to the fully on position from its par...

Page 67: ...16 24 32 40 54 60 81 1 2 37 50 60 81 92 125 9 16 53 72 88 119 132 179 5 8 74 100 120 163 180 244 3 4 120 163 200 271 296 401 7 8 190 258 302 409 473 641 1 282 382 466 632 714 968 THE FOLLOWING RULES A...

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