Broderson IC-200-2J Operation And Maintenance Manual Download Page 34 | Manualshive

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Broderson IC-200-2J Operation And Maintenance Manual Download Page 34

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Summary of Contents for IC-200-2J

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: ...2 10 Rated Capacity Limiter 2 11 Crane Capacity 2 12 Crane Capacity Chart IC 200 2H 3H 2 14 Crane Capacity Chart IC 200 2H 3H Metric 2 15 Capacity Example 2 16 Sheave Block and Downhaul Weight 2 17 T...

Page 4: ...chematic 3 16 JIC Schematic Metric 3 17 Hydraulic System Maintenance 3 18 Care of Hydraulic Oil 3 18 Hydraulic Oil Specification 3 19 Removal of Air from Hydraulic Circuits 3 20 Hydraulic Seals 3 21 P...

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 200 2J DIMENSIONS...

Page 7: ...1 3 IC 200 3J DIMENSIONS...

Page 8: ...1 4 IC 200 J TURNING DIMENSIONS...

Page 9: ...oom telescope cylinders and hydraulic powered hoist 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...

Page 10: ...ominal W O Boom Extension 45 feet 4 inches 13 8 m 58 feet 8 inches 17 90 m With Boom Extension 59 feet 6 inches 18 10 m 73 feet 8 inches 22 40 m Horizontal Reach W O Boom Extension 36 feet 11 0 m 50 f...

Page 11: ...L fuel tank capacity High temperature and low oil pressure shutdown included in engine management system Throttle control switch for setting engine speed at 1600 RPM Air intake pre cleaner Charge air...

Page 12: ...arm water through engine Plugs into 120V AC extension cord 550 watts Transmission Standard 2 Wheel Drive Powershift transmission with four speeds in forward and reverse Provides powershifts at any eng...

Page 13: ...Net Weight 160 pounds 73 kg Steering Standard Hydraulic steering unit with two 3 inch 7 6 cm cylinders attached to each axle Allows limited steering when engine is not running Rear axle is the primary...

Page 14: ...ide for attachment of hook block so main winch line can be used for pulling loads at or near floor level Also for anchoring tag lines from load on hook Tie Downs Two holes in the rear bumper in conjun...

Page 15: ...Not Available with Cab Tubular steel weldment with heavy expanded steel mesh top section bolts over the operator s compartment Operator Guard is not designed rated or certified as a Falling Objects Pr...

Page 16: ...s station and includes fuel gauge voltmeter oil pressure water temperature hour meter and def tank level Hour meter records hours only during actual engine operation Displays warnings for check engin...

Page 17: ...hree or four section high strength steel construction equipped with bearing pads for efficient support and extension Double acting hydraulic cylinder telescopes booms The telescope cylinder and the do...

Page 18: ...mm diameter wire rope Swivel hook with safety latch 200 pound 95 kg weight provides positive overhaul Includes bar on top to actuate trip arm of Anti Two Block device Optional Boom Attachments Boom Ex...

Page 19: ...ook with safety latch Includes bar on top to actuate trip arm of Anti Two Block device Net Weight 124 pounds 56 kg for 2H and 200 pounds 91 kg for 3H Searcher Hook Nose Mount 5000 pound capacity hook...

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Page 21: ...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 22: ...Tools lubricants or rags on the crane should be kept in a secured toolbox 6 7 8 The Rated Capacity Limiter must be checked before each shift and after each setup for the proper operating configuratio...

Page 23: ...om 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 damaged parts in the crane Also the load may...

Page 24: ...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 25: ...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 least 10 feet 3 m away from electric po...

Page 26: ...n 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 a...

Page 27: ...he operator must take care to control the vehicle speed to be compatible with conditions of rough roads or uneven terrain 7 When this crane is to be parked on a grade set parking brake and block wheel...

Page 28: ...ngages the transmission clutch for forward travel Rotating the handle of the lever selects the gear that is desired first through fourth and engages the clutch for that gear To put the transmission in...

Page 29: ...ard located next to these handles identifies the function and direction resulting from each handle movement 1 Swing or Slewing Pulling back on the lever will rotate the boom to the operator s left pus...

Page 30: ...3 Place transmission control lever in neutral 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...

Page 31: ...ad If you are sure this will not cause an overload you can press and hold the CANCEL button on the RCL control and swing the boom to a safer position If the load is the maximum for the loadline or att...

Page 32: ...g the entire lifting operation The weights of the hooks blocks downhaul weights slings and other handling devices must be added with the load The Rated Capacity Limiter on the crane is intended to ass...

Page 33: ...al condition such as soft sloping or uneven terrain high wind or hazardous surroundings constitutes a deviation The main boom capacities are given in direct relation to the radius at which the load is...

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Page 36: ...X 5 X 5 1 5 m x 1 5 m x 1 5 m and weighing 14 000 pounds 6350 kg is to be lifted onto the deck of the crane for transport to a new location We see on the chart that 7500 pounds 3400 kg is the maximum...

Page 37: ...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 38: ...loads up to 15 000 pounds The wedge socket should be pinned to the wedge socket anchor as shown in the figure The dead end of the rope in the wedge socket should be clamped as shown in the figures Th...

Page 39: ...n and should allow smooth stops of a load on the hoist BOOM TELESCOPE CYLINDER HOLDING VALVE A single acting holding valve is flange mounted to the cylinder rod end This valve holds the cylinder in th...

Page 40: ...Insert the attach pins in the right hand lugs and retain them with the hairpin cotters 9 Remove the front stow pin and swing the boom extension around to the front until the left hand lugs mesh 10 Ins...

Page 41: ...under the control panel WARNING Be careful not to operate the TELESCOPE lever while overriding the anti two block system This may break the load line and allow the boom extension and downhaul weight t...

Page 42: ...r BOOM EXTENSION MAIN BOOM ANGLE 30 shows the capacity at the 15 boom extension angle to be 3000 pounds 1369 kg Since 3000 pounds 1360 kg is less than 4550 pounds 2010 kg the load including the downha...

Page 43: ...ads on the ground to 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...

Page 44: ...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 Pintle Hooks also allow the crane to...

Page 45: ...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 46: ...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 47: ...on or infection can occur 6 Wear safety glasses and shoes 7 Do not wear loose fitting or torn clothing 8 Remove rings and other jewelry 9 Wear heavy leather gloves when working on wire rope 10 Keep fi...

Page 48: ...ngine running until the functions operate smoothly 23 When welding on the crane or on anything connected to the crane by wire rope or other conducting link disconnect the battery the Rated Capacity Li...

Page 49: ...or pedal 13 Start engine 14 Check power steering for operation 15 Check operation of transmission gear selector lever 16 Check lights for operation 17 Test drive unit and check for normal operation 18...

Page 50: ...proper operation 17 Check back up alarm for proper operation 18 Check operation of all transmission gears forward and reverse 19 Clean all glass if equipped and check for cracks 20 Check operation of...

Page 51: ...6 Check operation of horn 7 Check operation of hoist brake for smoothness 8 Check outrigger holding valves for operation 9 Check boom lift holding valve for operation 10 Check rotation gears for loose...

Page 52: ...h 13 Check rotation bearing and gearbox bolt tightness 14 Check axle mounting bolts and pins 15 Torque wheel mounting nuts 500 foot pounds 680 N m torque 16 Check for loose pins or pin retainers 17 Ch...

Page 53: ...place vapor block inside slip ring See turret installation in parts manual 6 Perform all maintenance required by engine manual 7 Place vapor block inside slilp ring See turret installation in parts ma...

Page 54: ...gallons 1 5 L each hub 4x4 Rear axle 4 68 gallons housing 17 7 L 44 gallons 1 7 L each hub 4x2 Rear axle 0 gallons housing 44 gallons 1 7 L each hub Transmission 17 5 quarts 16 6 L Engine cooling syst...

Page 55: ...3 9 IC 200 LUBRICATION CHART...

Page 56: ...0 or 3 Mo Max 20 Hook Swivel Pin SIL X 21 Hydraulic Oil HO X X 12 Max Check Daily Change 1000 Hours or 12 Mo Max 22 Outrigger Legs MPG X Wipe on Legs 23 Pump Shaft MPG X 2 Zerks 24 Rotation Bearing MP...

Page 57: ...ontally 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 fittin...

Page 58: ...side of the pinion at four places around the bearing Rotate the boom several times and check the coverage of the grease on all of the teeth Also lubricate the pinion bearings at the zerk below the pin...

Page 59: ...ing wire rope 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 Re...

Page 60: ...e hoist may be turned a little faster until the remainder of the cable is installed 12 Leave about 30 feet 9 m of cable on the ground to install the sheave block See the Op eration Section for instruc...

Page 61: ...pump goes into the priority valve at port P When no 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...

Page 62: ...3 16...

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Page 64: ...hould 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 should be purged Lubricate the new element seal an...

Page 65: ...ed oils are not availa ble 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 Never ad...

Page 66: ...der and between turret side plates Ensure that the boom is free of obstructions Ensure that the hook will not hit the ground and foul the hoist line d Find the small hose that connects to the piston s...

Page 67: ...not 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 stoppe...

Page 68: ...taking pressure readings HOIST CIRCUIT Remove the 3 8 JIC cap from the fitting on the front of the control valve near the hoist control section and install a 3000 PSI 207 bar pressure gauge To obtain...

Page 69: ...1 9 340 00031 Shim 020 Gresen 0459 001 9 340 00030 Shim 040 Gresen 0458 001 Pressure is changed approximately 100 to 125 PSI 7 to 9 bar for each 010 shim BOOM CYLINDER HOLDING VALVE A holding valve is...

Page 70: ...relative to the 3rd stage As shown in Illustration 1 13 mm clearance must be held between the 4th stage tip and 3rd stage tip To increase this distance loosen the retraction adjustment and tighten the...

Page 71: ...3 25 IC 200 3 BOOM CHAIN ADJUSTMENT...

Page 72: ...nozzle with less than 100 PSI and blow air from the inside of the element Shake dust off of the outside of the element Make sure the gaskets and element fit properly and reas semble being careful not...

Page 73: ...ts or nuts to 270 300 foot pounds 370 410 Nm Note the inspection torque is less than the installation torques If any nuts or bolts rotate at less than the inspection torque re torque all swing bearing...

Page 74: ...ot moved use maximum engine speed The machine should not move 9 Do not do this test for longer than 30 seconds 10 Reduce engine speed to an idle 11 Return the park brake lever to the fully ON position...

Page 75: ...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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