Broderson IC-250-3D Operation And Maintenance Manual Download

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SECTION 3 MAINTENANCE

Safety Rules………………………………………………………………..

3-1

New Unit Inspection and Test…………………………………………….

3-3

Operator Inspection and Test…………………………………………….

3-4

Maintenance Checklist…………………………………………………….

3-6

Fluid Volume…………..…………………………………………………….

3-8

Lubrication………………………………………………………………….

3-9

Lubrication Chart………………………………………………

3-9

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…………………………………………

3-13

Hoist Cable Installation and Inspection…………………………………..

3-13

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

3-15

Steering System………………………………………………..

3-15

JIC Schematic………………………………………………….

3-16

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

Pressure Settings…………………………………………………………

3-22

Hoist Circuit…………………………………………………….

3-22

Boom and Outrigger Circuit…………………………………..

3-23

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

3-23

Telescope Cylinder Holding Valves………………………….

3-24

Boom Chain Adjustment…………………………………………………..

3-25

Engine Maintenance……………………………………………………….

3-27

Air Cleaner Service…………………………………………….

3-27

Cooling System…………………………………………………

3-27

Spare Parts Lists……………………………………………….

3-27

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

3-27

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

3-28

Fasteners……………………………………………………….

3-28

Rotation Gearbox……………………………………………….

3-28

Transmission and Axle Overhaul……………………………..

3-28

Park Brake Test and Adjustment……………………………..

3-28

Torque Data…………………………………………………….

3-30

Wiring Diagram…………………………………………………….

Summary of Contents for IC-250-3D

Page 1: ...________________________________________________________________ _________________________________________________________________________ SOLD AND SERVICED BY ________________________________________...

Page 2: ...ant or any other location selected by it for inspection and testing to determine whether they were defective at the date of shipment prior to replacement thereof The warranty herein made is extended o...

Page 3: ...Rated Capacity Limiter 2 11 Crane Capacity 2 12 Crane Capacity Chart IC 250 3D 2 14 Capacity Example 2 15 Sheave Block and Downhaul Weight 2 16 Two Part Line Reaving 2 17 Four Part Line Reaving 2 17...

Page 4: ...C Schematic 3 16 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 Pressure Settings 3 22 H...

Page 5: ...rmation 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 num...

Page 6: ...1 2 IC 250 3D DIMENSIONS...

Page 7: ...1 3 IC 250 3D TURNING DIMENSIONS...

Page 8: ...rret proportional 4 section telescopic boom hydraulic boom elevating cylinder hydraulic boom telescope cylinder and hydraulic powered hoist Rated Capacity Limiter RCL is standard IC 250 3D 4 section h...

Page 9: ...rol switch for setting engine speed at 1200 or 1800 RPM Diesel oxidation catalyst muffler Air intake pre cleaner Charge air cooler 1500 watt 120 VAC block heater and grid heater included Net Weight 20...

Page 10: ...ll torque ratio of 2 2 1 attached to engine flywheel Front Axle Standard Planetary drive steer front axle with 15 78 to 1 0 ratio Differential equipped with limited slip feature Driving effort is appl...

Page 11: ...eck when centered over or between axles Seven stake pockets are provided along edges of deck for 1 inch 25mm pipe stakes Stakes furnished Cargo decks have skid resistant coating Headlight and Tailligh...

Page 12: ...wide x 16 406mm high mounted on deck stakes Pivot out of way when contacted by obstacle at side of deck Net Weight 12 pounds 5kg Operator Compartment Standard Operator control station provides one po...

Page 13: ...r fuel tank and belt driven compressor with magnetic clutch driven by engine Net Weight 125 lbs 57kg Electrical System Standard 12 Volt DC Battery Diesel Units Group 31 with 950 CCA rating LP Units Gr...

Page 14: ...om elevation cylinders are equipped with cylinder mounted holding valves Boom angle indicators are on each side of boom Boom Rotation Standard Heavy duty bearing rotation gear with external teeth supp...

Page 15: ...0 Ft 6 1m Offset Provides 20 feet 6 1m of additional length for lifting loads with load line Boom extension may be stowed alongside base boom section when not in use Tip sheave attaching brackets and...

Page 16: ......

Page 17: ...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 18: ...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 19: ...wly 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 drop...

Page 20: ...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 21: ...erweight in the field to increase lifting ability constitutes a safety hazard 19 Always keep crane boom at least 20 feet 6 m away from any electric power lines of unknown voltage If voltage is known u...

Page 22: ...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 23: ...ere 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 3...

Page 24: ...pplied The brake and accelerator pedals are located and operated as they are in other vehicles already familiar to the operator A lever on the steering column controls the powershift transmission Movi...

Page 25: ...ntrols Beams In and Out Pulling switches back controls Jacks Up and Down 5 Front Winch Optional Pulling back will pay winch line in pushing forward will pay winch line out 6 Hoist Pulling back on the...

Page 26: ...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 27: ...and 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 hoist lower control and the load or attachment c...

Page 28: ...dling devices must be added with the load 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...

Page 29: ...e given on the basis that operations are to be conducted on firm and level terrain and in a safe environment These capacity ratings are reduced in proportion to the deviation from the prescribed condi...

Page 30: ...2 14...

Page 31: ...oad 6 X 6 X 6 1 5m x1 5m x 1 5m and weighing 14 000 pounds 6350kg is to be lifted onto the deck of the crane for transport to a new location We see on the chart that 9000 pounds 4080kg is the maximum...

Page 32: ...pins 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 th...

Page 33: ...for loads up to 18 000 pounds 8160kg 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...

Page 34: ...der load this valve should be adjusted If adjustment fails to correct the problem there is an internal leak in the holding valve or the hydraulic cylinder Refer to the maintenance instructions HOIST B...

Page 35: ...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 36: ...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 37: ...ENSION MAIN BOOM ANGLE 30 shows the capacity for the 15 boom extension angle to be 2600 pounds 1180kg Since 2600 pounds 1180kg is less than 7000 pounds 3300kg the load including the downhaul weight an...

Page 38: ...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 39: ...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 40: ...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 41: ...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 42: ......

Page 43: ...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 44: ...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 45: ...tor 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 1...

Page 46: ...3 Observe boom operation for normal power and speed 14 Check load line and hooks for damage 15 Check condition of sheaves and load line retainers 16 Check anti two block system for proper operation 17...

Page 47: ...pping holding valves for operation 10 Check rotation gears for looseness or backlash 11 Check boom extension cylinder holding valve for operation 12 Check operation of windshield wipers if equipped 13...

Page 48: ...heck rotation gear and pinion fit and gear train backlash 13 Check rotation bearing and gearbox bolt tightness 14 Check axle mounting bolts and pins 15 Torque wheel mounting nuts 500 foot pounds 680Nm...

Page 49: ...anual 4 Change hydraulic fluid and filter and clean breather and reservoir 5 Change transmission fluid and filter and clean strainer 6 Replace vapor block in slip ring See turret installation in parts...

Page 50: ...22 6L housing 39 gallons 1 5L each hub 4x4 Rear axle 4 68 gallons 17 7L housing 44 gallons 1 7L each hub 4x2 Rear axle 0 gallons housing 44 gallons 1 7L each hub Transmission 17 5 quarts 16 6L Engine...

Page 51: ...3 9 IC 250 3D LUBRICATION CHART...

Page 52: ...Oil HO X X 12 Max Check Daily Change 1000 Hours or 12 Mo Max 20 Outrigger Legs Beams MPG X Wipe on legs bottom of beams 21 Pump Shaft MPG X 2 Zerks 22 Rotation Bearing MPG X 1 Zerk 23 Rotation Gear Te...

Page 53: ...lly 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 generously and grease sheave fittings Do...

Page 54: ...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 Replace the pinion cover TRANSMISSION Check the transmission...

Page 55: ...ire 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 If the...

Page 56: ...e first layer is on the drum the hoist may be turned a little faster until the remainder of the cable is installed 12 Leave about 30 feet 9m of cable on the ground to install the sheave block See the...

Page 57: ...e 29 GPM 110L min section of the 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...

Page 58: ...3 16...

Page 59: ...3 17...

Page 60: ...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 61: ...ls 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 Never add kero...

Page 62: ...cially around the topping cylinder 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 hos...

Page 63: ...t 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 64: ...dings 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 207bar pressure gauge To obtain full flow reading ru...

Page 65: ...low 9 340 00070 Work Port Relief Valve Gresen 7460 002 PS 1500 C 9 340 00032 Shim 010 Gresen 0462 001 9 340 00031 Shim 020 Gresen 0459 001 9 340 00030 Shim 040 Gresen 0458 001 Pressure is changed appr...

Page 66: ...lower pressure side is the problem side Try to raise the pressure in the problem side to match the pressure on the other valve by tight ening the adjusting screw on the holding valve after removing th...

Page 67: ...he rear 3rd stage and 2 nd stage windows as shown in Illustration 3 See arrows in the windows for measuring locations Measure the outside chains at midspan Snug the 4TH stage extension and retraction...

Page 68: ...3 26 BOOM CHAIN ADJUSTMENT...

Page 69: ...nd replace or clean it before reassembling air cleaner Conditions where more dirt than usual is in the air especially soot will make more frequent service necessary If there is a significant amount of...

Page 70: ...Nm while holding the bolts stationary ROTATION GEARBOX The rotation gearbox assembly is attached to the chassis top plate by four cap screws It is held in proper engagement with the external teeth on...

Page 71: ...ine 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 from its partially applied position Place...

Page 72: ...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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