Broderson IC-280-A Accompaniment To The Installation, Operation And Maintenance Manual Download

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PRINTED IN USA



202

P/N 990-30249

BRODERSON MFG. CORP.

LENEXA, KANSAS 66215

OPERATION AND

MAINTENANCE MANUAL

IC-280-A

OWNER:_______________________________________________________________________

_________________________________________________________________________

SOLD AND SERVICED BY:________________________________________________________

___________________________________________________________

MODEL NO. ___________________________

SERIAL NO. ______________________________

Summary of Contents for IC-280-A

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: ...Rated Capacity Limiter 2 11 Crane Capacity 2 12 Crane Capacity Chart IC 280 A 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 S...

Page 4: ...aintenance 3 17 Care of Hydraulic Oil 3 17 Hydraulic Oil Specification 3 18 Removal of Air from Hydraulic Circuits 3 19 Hydraulic Seals 3 20 Pressure Settings 3 21 Hoist Circuit 3 21 Boom and Outrigge...

Page 5: ...mation 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 numb...

Page 6: ...1 2 IC 280 A DIMENSIONS...

Page 7: ...1 3 IC 280 A TURNING DIMENSIONS...

Page 8: ...m hydraulic boom elevating cylinder hydraulic boom telescope cylinder and hydraulic powered hoist Rated Capacity Limiter RCL is standard IC 280 A Capacity of 40 000 pounds 18 144 kg at a 6 foot 1 8 m...

Page 9: ...fler Air intake pre cleaner Charge air cooler 550 watt 120V AC block heater and grid heater included Net Weight 766 pounds 348 kg Cummins Tier 4 Final Aftertreatment To adhere with Tier 4 Final requir...

Page 10: ...ing 2 aluminum LP tanks Spark Arrester Muffler Dual Fuel Only Spark arrester muffler used in addition to standard muffler Net Weight 10 pounds 5kg Engine Heater Heater for LPG engine Standard with die...

Page 11: ...Tire Options Foam Filling of Tires Foam filling of four IC 250 tires Net Weight 2000 pounds 907kg Non Marking Pnuematic 385 65 22 5 16 ply Net Weight 20 pounds 9kg Spare Tire and Wheel Mounted Extra w...

Page 12: ...wire rope hook and 4 way roller guide This rope can pull 5800 pounds 2360 kg with a safety factor of 3 5 1 Net Weight 250 pounds 113 kg Pintle Hook Rear T 60 AOL Holland pintle hook mounted on rear f...

Page 13: ...partment Net Weight 5 pounds 2 kg Noise Reduction Kit Cab Includes vinyl floor mats and control valve cover and side panels of foam backed perforated vinyl for noise reduction Net Weight 15 pounds 7 k...

Page 14: ...line strainer and 10 micron return line filter 54 gallon 204 L reservoir equipped with breather and filler cap Boom Assembly Standard Four section high strength steel construction equipped with bearin...

Page 15: ...hook with safety latch 300 lb 136 kg weight provides positive overhaul Includes bar on top to actuate trip arm of Anti Two Block Device Optional Boom Attachments Boom Extension 20 foot 6 1 m Offsettab...

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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: ...ys use adequate 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 bein...

Page 21: ...d never be changed Unauthorized addition of counterweight in the field to increase lifting ability constitutes a safety hazard 19 If voltage is known use chart on side of turntable to determine requir...

Page 22: ...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 23: ...the operator must take care to control the vehicle speed to be compatible with conditions of rough roads or uneven terrain 6 When this crane is to be parked on a grade set parking brake and block whee...

Page 24: ...or that gear To put the transmission in reverse the machine should be brought to a stop The lever then is pulled downward through the NEUTRAL position into REVERSE The transmission and drive train com...

Page 25: ...d controls Beams In Out Pulling switches back controls Jacks Up 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 leve...

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 t...

Page 27: ...AISE CONTROL as this may increase the overload If the load is at the maximum allowable load radius the boom can be raised or retracted to a safe radius or the load may be lowered to a safe place using...

Page 28: ...ding paragraph Verified weights and measured radii must take precedence over the Rated Capacity Limiter readings Please read the RCL Operation Manual The Rated Capacity Limiter displays a load load ra...

Page 29: ...wn on the capacity chart are the maximum allowable at the indicated radius The greatest load that may be handled by the BMC IC 280 is 40 000 pounds 18 143 kg but only at a 6 foot 1 8 m radius and on o...

Page 30: ...2 14...

Page 31: ...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 10 000 pounds 4536 kg is the maximum load on one par...

Page 32: ...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 33: ...d for loads up to 20 000 pounds 9072 kg 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 t...

Page 34: ...under 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...

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 W A R N I N G 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 w...

Page 37: ...ION MAIN BOOM ANGLE 30 shows the capacity for the 15 boom extension angle to be 2600 pounds 1180kg Since 2600 pounds 1180 kg is less than 7700 pounds 3492 kg the load including the downhaul weight and...

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...

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Page 43: ...n 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 fin...

Page 44: ...g on the crane or on anything connected to the crane by wire rope or other conducting link disconnect the battery the Rated Capacity Limiter display computer and the engine electronic control module W...

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: ...peration 12 Observe boom operation for normal power and speed 13 Check load line and hooks for damage 14 Check condition of sheaves and load line retainers 15 Check Anti Two Block system for proper op...

Page 47: ...opping 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 1...

Page 48: ...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 torque 16 Check for loose pin...

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

Page 50: ...iary Winch 2 pints 0 9 L 4x4 Front Axle 5 98 gallons 22 6 L housing 39 gallons 1 5 L each hub 4x4 Rear Axle 4 68 gallons 17 7 L housing 44 gallons 1 7 L each hub Transmission 17 5 quarts 16 6 L Engine...

Page 51: ...3 9 IC 280 A LUBRICATION CHART...

Page 52: ...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 Teeth OGG X Brush On 24 Rotation Pinion Brg MPG X 1 Zerk 2...

Page 53: ...tally 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 grease sheave fittings generously Do n...

Page 54: ...obilkote S on the teeth on each 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 TRA...

Page 55: ...es when handling 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 ca...

Page 56: ...the 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 9 m of cable on the ground to install the sheave block See t...

Page 57: ...M 110 L 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 The cr...

Page 58: ...3 16 HYDRAULIC SCHEMATIC...

Page 59: ...ld 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 and i...

Page 60: ...e not available These motor oils are not suitable substitutes when changing hydraulic oil because they lack cer tain additives that are needed for hydraulic system use C A U T I O N Never add kerosene...

Page 61: ...nts especially 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 s...

Page 62: ...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 63: ...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 5000 PSI 345 bar pressure gauge To obtain full flow reading r...

Page 64: ...hange the pressure by approximately 1325 PSI 91 bar Turning clockwise will increase pressure Turning counter clockwise will decrease pressure When done adjusting lock in place with nut NOTE All relief...

Page 65: ...the front and outriggers set record the pressure on the gauge while slowly raising the boom tip about 3 feet 1 m above its horizontal position Then return the boom control lever to NEUTRAL and record...

Page 66: ...d stage and 2nd 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 chains un t...

Page 67: ...3 25 BOOM CHAIN ADJUSTMENT...

Page 68: ...to the overflow tank as required to maintain the coolant level Check the radiator fins for dirt or debris daily and wash the fins with a pressure or steam cleaner every 50 hours or as required Check t...

Page 69: ...ring mounting bolts to 625 foot pounds 850 Nm while holding the nuts stationary or torque the nuts to 625 foot pounds 850 Nm while holding the bolts stationary ROTATION GEARBOX The rotation gearbox as...

Page 70: ...in the OFF position 7 Slowly release the foot brake pedal 8 If the machine has not moved use maximum engine speed The machine should not move 9 Do not do this test for longer than 30 seconds 10 Reduce...

Page 71: ...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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