Broderson IC-20-1K Operation And Maintenance Manual Download

Page: 4 / 65

TABLE OF CONTENTS (CONTINUED)

JIC Schematic……………………………………………………………..

3-13

Hydraulic System………………………………………………………….

3-14

Steering System…………………………………………………………..

3-14

Propulsion System………………………………………………………..

3-16

Start-Up Procedure……………………………………………………….

3-18

Piston Pump Troubleshooting……………………………………………

3-19

Care of Hydraulic Oil………………………………………………………

3-20

Approved Hydraulic Fluids………………………………………………..

3-21

Control Valve Adjustment…………………………………………………

3-22

Boom Circuits…….…….…….…………………………………

3-22

Hoist and Outrigger Circuits………………………………….

3-22

Boom Cylinder Holding Valve………………………………..

3-23

Extension Cylinder Holding Valve……………………………

3-23

Engine Maintenance………………………………………………………

3-24

Air Cleaner Service……………………………………………

3-24

Cooling System………………………………………………..

3-24

Spare Parts Lists………………………………………………

3-24

Major Engine Servicing or Overhaul…………………………

3-24

Mechanical Adjustments………………………………………………….

3-25

Fasteners………………………………………………………

3-25

Wheel Bearing Adjustments………………………………….

3-25

Wheel Alignment………………………………………………

3-25

Torque Data………………………………………………………………..

3-26

Summary of Contents for IC-20-1K

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: ...Reaving 2 15 Safety Devices 2 16 Outrigger Cylinder Check Valve 2 16 Boom Elevation Cylinder Holding Valve 2 16 Boom Extension Cylinder Holding Valve 2 16 Boom Extension Cylinder Holding Valve 2 16 An...

Page 4: ...ic Fluids 3 21 Control Valve Adjustment 3 22 Boom Circuits 3 22 Hoist and Outrigger Circuits 3 22 Boom Cylinder Holding Valve 3 23 Extension Cylinder Holding Valve 3 23 Engine Maintenance 3 24 Air Cle...

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

Page 6: ...1 2 DIMENSIONS AND ORIENTATION IC 20 1K...

Page 7: ...1 3 TURNING DIMENSIONS...

Page 8: ...oom elevating cylinder and hydraulic powered hoist General Length Chassis 9 feet 1 inch 2 77 m Overall 9 feet 1 inch 2 77 m Width 4 feet 1 22 m Height Deck 28 inches 711 mm Overall 5 feet 6 inches 1 6...

Page 9: ...m Movement Rotation 90 degrees Elevation 75 degrees Telescope 9 feet 2 74 m Tailswing 2 feet 5 5 8 inches 753 mm Boom Speed Rotation 10 seconds Elevation 9 seconds Telescope 25 seconds Sheave Height W...

Page 10: ...150 5 N m at 1600 rpm 12V 60 amp alternator Net weight 432 pounds 196 kg Hydrostatic Transmission Pump Standard Sauer Danfoss piston type 2 8 CID 45 mL per revolution direct driven from engine cranksh...

Page 11: ...ockets are provided in deck and six 1 3 inch 34 mm diameter pipe stakes Optional Deck Mats Deck Mats Rubber mats inch 6 mm thick covering the 3 deck sections Protects delicate loads from scratching an...

Page 12: ...rovides 1 position access to all chassis crane functions Operator s Compartment Accessories Operator Guard Tubular steel weldment with heavy expanded steel mesh top section bolts over operator s compa...

Page 13: ...ee section high strength steel construction equipped with bearing pads for efficient support and extension Double acting hydraulic cylinders extend boom sections The primary extension cylinder and the...

Page 14: ...e requirements Six inch O D sheave for 5 16 inch 8 mm diameter wire rope Swivel hook with safety latch Fifty pounds of weight provides positive overhaul Includes bar on top to actuate anti two block s...

Page 15: ...or shall not engage in any practice which will divert his attention while actually operating the crane 6 This list of rules is only a supplement to all federal state and local safety rules that may ap...

Page 16: ...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...

Page 17: ...movement which can cause the load to swing Move 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...

Page 18: ...the hoist drum to insure 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 the cab o...

Page 19: ...r The ground surface may be energized 20 The amount of counterweight supplied with this crane should never be changed Unauthorized addition of counterweight in the field to increase lifting ability co...

Page 20: ...ONT ON RUBBER capacity 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 center...

Page 21: ...d on the display After the engine is started and the throttle is set release the parking brake and move the control lever smoothly until the desired speed is reached Always operate this transmission c...

Page 22: ...d will rotate it to the operator s right Boom Pulling back will raise the boom pushing forward will lower it Telescope Pulling back on the lever will retract the boom pushing forward will extend the b...

Page 23: ...lness Do not run the crane in enclosed areas withough adequate ventilation The following procedure is recommended for placing the crane in operation 1 Apply parking brake 2 Start engine and allow warm...

Page 24: ...given in direct relation to the radius at which the load is being handled The capacities shown on the capacity chart are the maximum allowable at the indicated radius The greatest load that may be ha...

Page 25: ...2 11...

Page 26: ...2 12...

Page 27: ...ifted on downhill side CAPACITY EXAMPLE See 7 foot 2 1 m Jib Capacity Example Page 2 17 Refer to the IC 20 1K capacity chart on the preceding page A load that is 4 feet 1 2m wide and weighs 2800 pound...

Page 28: ...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 29: ...n 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 metal...

Page 30: ...ed position should power or hydraulic pressure line failure occur This valve is adjustable to hold the desired load If the boom creeps in under load this valve should be adjusted If adjustment fails t...

Page 31: ...9 mm diameter 6X36 IWRC IPS wire rope 9160 pound 4155 kg breaking strength and 2 ton hook has a single part line capacity of 2500 pounds 1100 kg on the first wrap The front auxiliary winch is designe...

Page 32: ...you are sure this will not cause an overload you can swing the boom to a safer position If the load is the maximum for the loadline or attachment the load should be set down in a safe place using the...

Page 33: ...rator is solely responsible for operation of the crane Setting the Rated Capacity Limiter for the configuration of the crane is necessary before starting a lift If incorrectly set the system will not...

Page 34: ...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 35: ...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 36: ......

Page 37: ...ure fluid leaking from a small hole 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 7 Wear...

Page 38: ...king on the hydraulic system remove air from the lines and cylinders involved by cycling them full stroke with the engine running until the functions operate smoothly 24 When welding on the crane or o...

Page 39: ...e pressure 9 Check for loose pins bolts and retainers 10 Check brake fluid reservoir for appropriate fluid level 11 Operate foot brake Check for operation 12 Operate park brake Check for operation and...

Page 40: ...load line and hooks for damage 14 Check condition of sheaves and load line retainers 15 Check hydraulic oil level 16 Check anti two block system for proper operation 17 Check back up alarm for proper...

Page 41: ...INTERVALS 1 50 hour maintenance 50 and 250 hour lubrication 2 Adjust fan belt tension 3 Check tension of fan and alternator belts 4 Clean battery 5 Inspect all bolts for tightness 6 Visually inspect...

Page 42: ...n 250 hours in 6 months 1 Perform 250 hour maintenance and lubrication 2 Change hydraulic filter elements and inspect oil 12 MONTH INTERVAL For usage less than 500 hours per year 1 Perform 6 month mai...

Page 43: ...___________________________ _______________________________________________________________________ _______________________________________________________________________ ____________________________...

Page 44: ...Drain and refill after 1 000 hours of operation or after one year of ser vice whichever comes first WIRE ROPE LUBRICATION The wire rope should be cleaned and lubricated every 50 hours of normal opera...

Page 45: ...3 9 IC 20 LUBRICATION CHART...

Page 46: ...Points 16 Rotation Bearing MPG X 1 Zerk 17 Rotation Cylinders MPG X 4 Zerks 18 Sheave Block MPG X 2 Zerks 19 Sheave Pins MPG X 1 Zerk Std 1 On Boom Ext 20 Steering Cylinder Ends MPG X 2 Zerks 21 Stee...

Page 47: ...clean or the space is too limited the cable can be wound directly from the storage spool onto the hoist but the spool must rotate in the same direction as the hoist 2 Check the seizings on the ends o...

Page 48: ...nd to install the sheave block See the Operation Section for instructions on reeving and wedge socket attachment 12 Install the cable retainer pins and cotters in the tip sheave plates 13 For the cabl...

Page 49: ...3 13 JIC SCHEMATIC...

Page 50: ...o steering is required the entire flow goes through the priority valve and leaves through port EF to the crane valve The crane operating speed is not affected since there is no loss of volume passing...

Page 51: ...3 15 STEERING SYSTEM...

Page 52: ...off the ground is on ice or for any reason starts to spin it will momentarily take more oil than the wheel that has traction When this happens a spool inside the positraction valve will shift and res...

Page 53: ...3 17 IC 20 PROPULSION SYSTEM...

Page 54: ...figure below 4 Start the engine at the lowest speed and shut it off again after running 5 seconds Repeat this twice This procedure enables the charge pump to draw in the oil before running the pump c...

Page 55: ...cored or damaged Remove parts and examine Replace defective parts If severe scoring is indicated remove complete pump unit disassemble and inspect for damage M Drive coupling broken Inspect coupling f...

Page 56: ...sive contaminants If water is found the oil should be changed in the reservoir and purged out of the cylinders If excessive particles are found the source should be located and fixed and the oil shoul...

Page 57: ...and seals in the hydraulic system CAUTION Serious damage to the pumps will result if they are run with the shutoff valve closed or with insufficient oil level in the reservoir Observe the operation of...

Page 58: ...pump shaft 2 Low oil level in the reservoir 3 Clogged suction filter or shut off valve not fully opened 4 Valve spool linkage not allowing control valve to fully open Valve spool should move 5 16 inc...

Page 59: ...ng valve loosen the jam nuts on the adjusting screw and tighten the screw until unpowered boom movement stops Retighten the jam nuts If adjusting the valve does not help the cylinder may have internal...

Page 60: ...ndition by its appearance If you think the filter may need service remove it and replace or clean it before reassembling air cleaner Conditions where more dirt than usual is in the air especially soot...

Page 61: ...mainframe and turret which are Grade 8 The torque chart on the next page can be used on all bolts WHEEL BEARING ADJUSTMENTS Wheel bearing adjustment must be maintained at all times Adjustment is made...

Page 62: ...7 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...

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