Broderson IC-35-2G Operation And Maintenance Manual Download

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PRINTED IN USA



2016

P/N 990-30229

BRODERSON MFG. CORP.

OPERATION AND

MAINTENANCE MANUAL

IC-35-2G

OWNER: _________________________________________________________________________

_________________________________________________________________________

SOLD AND SERVICED BY: _________________________________________________________

_________________________________________________________

MODEL NO. ___________________________ SERIAL NO. ______________________________

Summary of Contents for IC-35-2G

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: ...haul 2 15 Two Part Line Reeving 2 16 Safety Devices 2 17 Optional Equipment Operation 2 18 Boom Extension 2 18 Front Auxiliary Winch 2 19 Switch and Indicator Symbols on BMC Cranes 2 20 SECTION 3 MAIN...

Page 4: ...stem Adjustments 3 27 Control Valves 3 27 Boom Cylinder Holding Valve 3 28 Extension Cylinder Holding Valve 3 28 Engine Maintenance 3 29 Air Cleaner Service 3 29 Cooling System 3 29 Spare Parts List 3...

Page 5: ...quired 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 unit m...

Page 6: ...1 2 DIMENSIONS AND ORIENTATION IC 35 2G...

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

Page 8: ...cylinder hydraulic boom extension cylinders and hydraulic powered hoist A Rated Capacity Limiter is also standard IC 35 2G 3 section hydraulically extended boom with capacity of 8 000 pounds 3629 kg...

Page 9: ...ability 30 1 Grade Limit 20 Boom Movement Rotation Continuous Elevation 70 degrees Extension 12 feet 3 66 m Tail swing 3 feet 6 inches 1 07 m Boom Speeds Rotation 360 degrees in 39 sec 1 5 rpm Elevati...

Page 10: ...7 mm bore 4 04 inch 102 mm stroke 49 6 HP 37 0 kW at governed speed of 2700 rpm Maximum torque 111 0 ft lbs 150 5 N m at 1600 rpm 12V 60 amp alternator Hydrostatic Transmission Pump Standard Sauer Dan...

Page 11: ...Net Weight 312 pounds 142 kg Spare Tire Wheel 7 50 x 10 pneumatic tires 16 ply Front or rear axle must be specified Net Weight 80 pounds 37 kg Chassis Standard Cargo Deck 29 square foot 2 7 m2 area A...

Page 12: ...Rear View Mirrors One right hand and one left hand mirror 6 inch 152 mm diameter mounted on deck stakes Pivot out of way when contacted by obstacle at side of deck Net Weight 12 pounds 6 kg Operator s...

Page 13: ...uge voltmeter oil pressure water temperature and hydraulic oil temperature gauges Hour meter records hours only during actual engine operation Outrigger Alarm System 112 dB alarm with alternating two...

Page 14: ...hook and sheave block for 2 part line Required for lifts over 4 000 pounds 1814 kg Sheave block weight is 60 pounds 27 kg Downhaul weight is 40 pounds 18 kg Main hoist rope is 3 8 10 mm diameter Warr...

Page 15: ...rmal by lowering load to a safe resting place with hoist or by retracting or raising boom to a shorter load radius Key operated momentary override switch located under dashboard Optional Boom Attachme...

Page 16: ......

Page 17: ...ning operation each day thoroughly inspect the entire crane to be sure it is in good operating condition 2 Inspect load hoist rope and wedge socket daily We recommend rope inspection replacement and m...

Page 18: ...e to thermal contraction of the hydraulic oil in the cylinders 4 Do not use crane to drag loads sideways 5 6 7 Level the crane before lifting A small incline will significantly reduce the capacity Use...

Page 19: ...extend If the boom is moving fast this will cause the load to bounce or swing which could cause loss of control of load or tipping 18 The amount of counterweight supplied with this crane should never...

Page 20: ...exceed the OVER FRONT 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 b...

Page 21: ...horn button is located on the instrument panel The ignition switch is key operated and has ACC IGN and OFF positions The ignition switch should always be turned off and the key removed when the vehicl...

Page 22: ...tion boom telescope and hoist are located on the control panel The handles are directly connected to the 4 way hydraulic control valves The placards adjacent to these handles identify the function con...

Page 23: ...ut 1050 rpm and maximum speed is about 2500 rpm for gas and 2700 rpm for diesel The hydrostatic transmission will normally stop the crane on a grade but some oil will slip through the wheel drive moto...

Page 24: ...m operating speed 9 Release accelerator during idle time NORMAL GAUGE READINGS Engine Coolant Temperature Allow engine to warm up before operating crane Stop engine if temperature exceeds 220 F 104 C...

Page 25: ...owable 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...

Page 26: ...the higher the boom angle the larger the percent of error and the electronic and mechanical components cannot be 100 fail safe Do not consider the system as a substitute for good judgment training exp...

Page 27: ...triggers All variances of loads and radii of handling are shown on the crane capacity chart A metal chart is attached near the operator s seat and a laminated chart is included in the literature compa...

Page 28: ...deck of the crane for transport to a new location The closest we can get to the load is at a 6 foot 1 83 m load radius over the side We see on the chart that 4000 pounds 1815 kg is the maximum load o...

Page 29: ...2 13 CRANE CAPACITY CHART FOR IC 35 2G...

Page 30: ...2 14 CRANE CAPACITY CHART FOR IC 35 2G METRIC...

Page 31: ...n the sheaves The load line must pass through the center of the downhaul through the wedge socket and the dead end clamped in the block as shown in the figure below For loads above 4 000 pounds 1815 k...

Page 32: ...on the ground for changing it use the following procedure to prevent fouling the load line on the hoist Raise the boom about 5 feet 1 52 m and lower the hoist until the hook nearly touches the ground...

Page 33: ...aulic 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 to correct the problem there is a...

Page 34: ...Make sure the front stow pin is in place and the attach pins are removed from the lugs on the boom tip and the mating lugs on the boom extension 7 Remove the rear locking pin and swing the boom exten...

Page 35: ...ed with this option The front auxiliary winch is designed for the following uses 1 As a tag line for restraining loads on the boom load line during pick and carry operation 2 To drag loads on the grou...

Page 36: ...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 37: ...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 38: ......

Page 39: ...fluid see a doctor at once Serious reaction 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 g...

Page 40: ...cards that are lost or damaged 21 Always replace all guards and covers after working on the crane 22 After working on the hydraulic system remove air from the lines and cylinders involved by cycling t...

Page 41: ...r operation 12 Start engine 13 Check oil pressure 14 Check ammeter 15 Check power steering for operation 16 Check transmission control switch and accelerator pedal for operation 17 Check lights for op...

Page 42: ...for proper operation 20 Check operation of Rated Capacity Limiter according to the RCL User Manual 21 Check hydraulic hoses particularly those that flex during crane operation 22 Check the outrigger...

Page 43: ...f outrigger warning light as described on page 2 9 17 Clean air cleaner inlet dustcap and dust cup 250 HOUR INTERVAL 1 50 hour maintenance 2 50 and 250 hour lubrication 3 Change engine oil and filter...

Page 44: ...500 hours per year 1 Perform 6 month maintenance 2 Perform 500 hour maintenance 3 Change hydraulic fluid filters and clean breather reservoir 4 Check EGR piping per engine manual D1803 only 5 Check i...

Page 45: ..._______________________________ _____________________________________________________________________ _____________________________________________________________________ ____________________________...

Page 46: ...E HUBS Use Mobilube HD 80W 90 gear lube or equivalent SAE 80W 90 On new cranes drain oil after first 50 hours of use and refill Check oil level every 50 hours Drain and refill after 1 000 hours of ope...

Page 47: ...3 9 IC 35 LUBRICATION CHART...

Page 48: ...on Bearing MPG X 1 Zerk 17 Rotation Gearbox MPL X 12 Check 250 Change 12 Mo 18 Rotation Gear Teeth OGG X Brush On 19 Sheave Block MPG X 2 Zerks 20 Sheave Pins MPG X 1 Zerk Std 1 On Boom Ext 21 Steerin...

Page 49: ...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 of the cable and replace them if they are missing or damaged 3 Inst...

Page 50: ...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 cable...

Page 51: ...3 13 JIC SCHEMATIC...

Page 52: ...3 14 JIC SCHEMATIC METRIC...

Page 53: ...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 t...

Page 54: ...3 16 STEERING SYSTEM...

Page 55: ...it will momentarily take more oil than the wheel that has traction When this happens a spool inside the positraction valve will shift and restrict the high flow to the spinning wheel forcing flow to...

Page 56: ...3 18 IC 35 PROPULSION SYSTEM...

Page 57: ...charge pressure port The port is the highest port on top of the pump and has a 6 elbow with a inch hose that connects with the brake release valve This may be disconnected or a tee may be inserted Se...

Page 58: ...valve if disconnected in step 3 Place the control switch in the FORWARD position and slowly push the accelerator until the wheels turn slowly Run for 5 minutes and repeat in REVERSE direction Then inc...

Page 59: ...mine if check valve is faulty P Charge pump key sheared Inspect charge pump for damage replace key Q Charge pump worn or scored or damaged Remove parts and examine Replace defective parts If severe sc...

Page 60: ...elements into the clean container and inspect the oil for water and excessive contaminants If water is found the oil should be changed in the reservoir and purged out of the cylinders If excessive pa...

Page 61: ...oration of the oil will result and moving parts and seals will wear more quickly The cause of the excess heat should be determined and corrected Oil temperature should never exceed 200 F 93 C PURGING...

Page 62: ...of pump damage from cavitation due to low oil level 11 Start the engine and run at low idle for about 10 seconds after flow starts from both return lines into waste oil sump This should purge the pres...

Page 63: ...e boom and fill the reservoir 30 Run engine and cycle all of the cylinders in and out several times BLEEDING THE BRAKES The brake module on the end of each torque hub has a pedal operated function and...

Page 64: ...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 65: ...he reservoir 2 Clogged suction filter or shut off valve not fully opened 3 Valve spool linkage not allowing control valve to fully open Valve spool should move 5 16 inch 8 mm each way from neutral 4 A...

Page 66: ...rew and turn the screw counterclockwise one half turn and retest Repeat until unpowered boom movement stops Retighten the jam nuts If adjusting the valve does not help the cylinder may have internal l...

Page 67: ...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 68: ...e gearbox It is further restrained from torsional movement by four bolts at the sides of the gearbox Proper adjustment exists when there is 010 inch 0 254 mm backlash between the pinion and bull gear...

Page 69: ...16 24 32 5 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 RULE...

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