Broderson IC-80-3L 4X2 Installation And Operating Manual Download | Manualshive

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SECTION 3 MAINTENANCE (continued)

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

3-10

Hydraulic System Description…………………...………… 3-12

Steering System……………………………………... 3-12
JIC Schematic………………………………..……… 3-13
JIC Schematic Metric……………………………….. 3-14

Hydraulic System Maintenance…………………...………. 3-15

Care of Hydraulic Oil……………………………….… 3-15
Hydraulic Oil Specifications………………………… 3-16
Hydraulic Seals……………………………………… 3-17

Hydraulic System Adjustments……………...…………….. 3-18

Control Valves………………………………………… 3-18
Boom Elevation Cylinder Holding Valve…………… 3-19
Telescope Cylinder Holding Valve………………… 3-20

Engine Maintenance……………………………..…………

3-20

Air Cleaner Service………………………………...… 3-20
Cooling System…………………………………..…… 3-21
Spare Parts List……………………………………… 3-21
Major Engine Servicing…………………………….… 3-21

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

3-21

Fasteners…………………………………………...… 3-21
Swing Gearbox…………………………….………… 3-21
Rear Wheel Bearings…………………..…………… 3-21
Wheel Toe-In Setting………………………..……… 3-21

Transmission Troubleshooting & Overhaul………… 3-21
Park Brake Test and Adjustment…………………… 3-22
Torque Data……………..…………………………… 3-23
Wiring Diagram………………….………. (LAST PAGE)

Courtesy of CraneMarket.com

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Summary of Contents for IC-80-3L 4X2

Page 1: ..._______________________________________________________ _________________________________________ _____________________________ SOLD AND SERVICED BY ___________________________ _______________________...

Page 2: ...UT 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 AS A USED PRO...

Page 3: ...o Part Line Reeving 2 21 Safety Devices 2 22 Outrigger Check Valve 2 22 Boom Elevation Cylinder Holding Valve 2 22 Telescope Cylinder Holding Valve 2 22 Anti Two Block System 2 22 Optional Equipment O...

Page 4: ...ystem Adjustments 3 18 Control Valves 3 18 Boom Elevation Cylinder Holding Valve 3 19 Telescope Cylinder Holding Valve 3 20 Engine Maintenance 3 20 Air Cleaner Service 3 20 Cooling System 3 21 Spare P...

Page 5: ...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 unit...

Page 6: ...1 2 IC 80 1L DIMENSIONS Courtesy of CraneMarket com...

Page 7: ...1 3 IC 80 2L DIMENSIONS Courtesy of CraneMarket com...

Page 8: ...1 4 IC 80 3L DIMENSIONS Courtesy of CraneMarket com...

Page 9: ...1 5 IC 80 L TURNING DIMENSIONS Courtesy of CraneMarket com...

Page 10: ...m telescoping cylinders and hydraulic powered hoist Rated Capacity Limiter is standard IC 80 1L 3 section hydraulically extended boom with capacity of 18 000 pounds 8160 kg at a 5 foot 1 5 m load radi...

Page 11: ...t 30 0 feet 6 1 m 7 3 m 9 1 m With Boom Extension 30 1 feet 34 0 feet 40 0 feet 9 2 m 10 3 m 12 1 m Weight Nominal 2 Wheel Drive 15 970 pounds 16 160 pounds 16 540 pounds W GM 3 0L Engine 7244 kg 7330...

Page 12: ...3307 T4F Diesel Kubota V3307 diesel industrial engine Water cooled 4 cylinder 203 27 CID 3 33 L bore 3 7 inches 94 mm stroke 4 72 inch 120 mm 74 3 HP 55 4 kW at governed speed of 2600 RPM Maximum torq...

Page 13: ...ng unit with one double rod cylinder on rear axle and one double rod cylinder on front axle Allows limited steering when engine is not running Rear axle is the primary steer An electric switch in the...

Page 14: ...of deck for 1 3 inch 34 mm pipe stakes Stakes furnished Cargo decks have skid resistant coating Heavy deck loads allowed at creep speed below 2 MPH 3 2 km h and less than 200 feet 61 m in 30 minutes F...

Page 15: ...hassis Options and Accessories Auxiliary Winch Optional worm gear winch mounted behind front bumper with a lever control at the operator s console Hydraulically powered to provide bare drum line pull...

Page 16: ...e with laminated glass front and top Top glass is 3 8 inch thick Door is equipped with a keyed lock to protect operator s station Includes defroster fan 24 000 BTU heater with 2 speed fan and 12V elec...

Page 17: ...ch at operator s station 12V horn actuated by button located on shifting control Back Up Alarm Provides pulsating sound from a 102 dB alarm when ignition is on and transmission is in reverse Conforms...

Page 18: ...raulically powered to provide a bare drum line pull of 10 000 lbs 4536 kg at a speed of 110 feet per minute 34 m min Hoist drum 9 inch 248 mm diameter by 13 inches 330 mm long Provides even pull and l...

Page 19: ...16 inch 14 mm rope Has swivel hook with safety latch A 90 pound 41 kg downhaul weight and swivel hook are also provided for single part line Optional Boom Attachments Boom Extension 10 Ft 3 m Provide...

Page 20: ...Courtesy of CraneMarket com...

Page 21: ...h 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 is highly flamm...

Page 22: ...nts 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 configuration on the displ...

Page 23: ...load to swing Swing 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 there are damaged parts in t...

Page 24: ...ts 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 14 Be su...

Page 25: ...lied with this crane 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 away...

Page 26: ...nsibility 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 load and prevent...

Page 27: ...ick and carry with boom extension installed K Do not 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...

Page 28: ...ft side of the steering column Move the lever down for a left turn up for a right turn The emergency flasher lights are actuated by a switch on the instrument panel The hand brake lever is located on...

Page 29: ...et engine speeds will appear on the instrument panel Three mode steering is standard Rear steer 4 wheel round steer and crab steer can be selected with a switch on the dashboard The steering wheel is...

Page 30: ...pay winch line in pushing forward will pay winch line out 6 Hoist Pulling back on the lever will raise load line pushing forward will lower load line All controls may be used for simultaneous operatio...

Page 31: ...ne snug 8 Retract outriggers fully 9 Step on the brake pedal 10 Release park brake lever 11 Shift transmission to desired gear 12 Place FORWARD REVERSE lever in desired position 13 Release brake and p...

Page 32: ...events suddenly starting or stopping which causes unsafe load swinging and shock loads on the equipment The control should be slightly actuated to begin movement and then slowly increased to desired s...

Page 33: ...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 raised or the load...

Page 34: ...onsider the system as a substitute for good judgment training experience or accepted safe operating practices The operator is solely responsible for operation of the crane Setting the Rated Capacity L...

Page 35: ...ven in direct relation to the radius at which the load is being handled Boom extension capacities depend on the boom angle as well as the load radius The capacities shown on the capacity chart are the...

Page 36: ...2 16 Courtesy of CraneMarket com...

Page 37: ...2 17 Courtesy of CraneMarket com...

Page 38: ...2 18 Courtesy of CraneMarket com...

Page 39: ...of the crane for transport to a new location We see on the chart that 9000 pounds 4080 kg is the maximum load on one part line so the sheave block is required The charts show the weight of the standar...

Page 40: ...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 dead end clam...

Page 41: ...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 fatigue over...

Page 42: ...A single acting holding valve is flange mounted to the cylinder rod end This valve holds the cylinder in the extended position should power or hydraulic pressure line failure occur This valve is adjus...

Page 43: ...the front until the outer lugs mesh 10 Insert the attach pins in their outer lugs and retain them with hairpin cotters To insert pin it may be necessary to rock boom extension 11 Replace the rear stow...

Page 44: ...the boom extension and downhaul weight to fall causing death or serious injury to personnel 3 Remove the offset index pin from the boom extension knuckle To loosen the pin it may be necessary to rock...

Page 45: ...FFSET MAIN BOOM ANGLE 30 shows the capacity at the 15 boom extension angle to be 2400 pounds 1090 kg Since 2400 pounds 1090 kg is less than 3400 pounds 1570 kg the load including the downhaul weight a...

Page 46: ...here 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 is not designed for lifting perso...

Page 47: ...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 be towed 1 Use...

Page 48: ...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 notification Parking...

Page 49: ...ion 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 temperature gauge...

Page 50: ...ost 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 6 Wear safety glasses and shoes 7 Do not wear loose...

Page 51: ...s involved by cycling them full stroke with the engine 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...

Page 52: ...e 14 Check power steering for operation Check all steering modes 15 Check operation of transmission gear selector lever 16 Check lights and turn signals for operation 17 Test drive unit and check for...

Page 53: ...tion 18 Check horn back up alarm and outrigger alarm for proper operation 19 Check operation of all transmission gears FORWARD and REVERSE 20 Clean all glass if equipped and check for cracks 21 Check...

Page 54: ...nge element if indicated 14 Check diesel engine idle and maximum speed and adjust if necessary 15 Check swing gear and pinion fit and gear train backlash 16 Check swing bearing and gearbox bolt tightn...

Page 55: ...aintenance specified in Engine Manual 5 Change hydraulic fluid and filter and clean breather and reservoir 6 Change transmission fluid and filter and clean strainer 7 Replace vapor block inside slip r...

Page 56: ...e the boom several times and check the coverage of the grease on all of the teeth Replace the pinion cover TRANSMISSION Check the transmission fluid with the dipstick and add fluid through the dipstic...

Page 57: ...3 8 IC 80 LUBRICATION CHART Courtesy of CraneMarket com...

Page 58: ...el Pin SIL X 19 Hydraulic Oil HO X X 12 Max Check Daily Change 1000 Hours or 12 Mo Max 20 Outrigger Legs MPG X Wipe on Legs 21 Pump Shaft MPG X 2 Zerks 22 Rotation Bearing MPG X 1 Zerk 23 Rotation Gea...

Page 59: ...N I N G Always wear heavy leather gloves when handling wire rope HOIST CABLE INSTALLATION AND INSPECTION Refer to Section 1 of this manual for complete replacement rope specifications The following st...

Page 60: ...After the first layer is on the drum the hoist may be turned a little faster until the remainder of the cable is installed 11 Leave about 15 feet 4 6 m of cable on the ground to install the sheave bl...

Page 61: ...he crane valve The crane operating speed is not affected since there is no loss of volume passing through the priority valve When the steering wheel is turned the load sensing line signals the priorit...

Page 62: ...3 13 Courtesy of CraneMarket com...

Page 63: ...3 14 Courtesy of CraneMarket com...

Page 64: ...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 install the new element Open the shutoff v...

Page 65: ...re 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 kerosene...

Page 66: ...ten 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 by tightening...

Page 67: ...IRCUIT Remove the 3 8 JIC cap from the fitting on the front of the control valve near the winch control section and install a 3000 PSI 207 bar pressure gauge To obtain full flow reading run pump full...

Page 68: ...32 Shim 010 25 mm Gresen 0462 001 9 340 00031 Shim 020 5 mm Gresen 0459 001 9 340 00030 Shim 040 1 mm Gresen 0458 001 BOOM CYLINDER HOLDING VALVE A holding valve is directly connected to the base of t...

Page 69: ...ntake cap screen every 50 hours and perform a thorough inspection of the air intake pipes and joints Clean the filter element every 250 hours or every 3 months whichever comes sooner and replace the e...

Page 70: ...ner race hex head bolts or nuts 230 250 foot pounds 310 340 Nm Outer race socket head cap screws or nuts 250 270 foot pounds 340 370 Nm Note the inspection torques are less than the installation torqu...

Page 71: ...ect FORWARD gear 8 Move the park brake lever fractionally downward just over center slightly releasing it Hold park brake lever switch in the OFF position located in the lever bracket 9 Slowly release...

Page 72: ...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 APPLY TO THE...

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Page 75: ...Powered by TCPDF www tcpdf org Courtesy of CraneMarket com...

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