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TABLE OF CONTENTS (CONTINUED)

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

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

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

3-22

Hoist Circuit…………………………………………………….

3-22

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

3-23

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

3-23

Telescopic Cylinder Holding Valves………………………….

3-24

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

3-24

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

3-26

Air Cleaner Service……………………………….….……….

3-26

Cooling System…………………………………………………

3-27

Spare Parts Lists……………………………………………….

3-27

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

3-27

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

3-27

Fasteners……………………………………………………….

3-27

Rotation Gearbox……………………………………………….

3-27

Axle Wheel Nuts………………………………………………..

3-27

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

3-27

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

3-27

Torque Data…………………………………………………….

3-29

Courtesy of Crane.Market

Содержание IC-200-2H

Страница 1: ..._______________________________________________________ _______________________________________________________________________ SOLD AND SERVICED BY ___________________________________________________...

Страница 2: ...location selected by it for inspection and testing to determine w hether they were defective at t he date of shipment prior to replacement thereof The warranty herein made is extended only to the orig...

Страница 3: ...Rated Capacity Limiter 2 11 Crane Capacity 2 12 Crane Capacity Chart IC 200 2H 2 14 Crane Capacity Chart IC 200 3H 2 15 Capacity Example 2 16 Sheave Block and Downhaul Weight 2 17 Two Part Line Reavin...

Страница 4: ...6 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 Pressure Sett...

Страница 5: ...for these conditions T he recommendations for periodic inspection test and maintenance are minimum standards for safe and economical performance When ordering parts the unit serial number unit model...

Страница 6: ...1 2 IC 200 2H DIMENSIONS Courtesy of Crane Market...

Страница 7: ...1 3 IC 200 3H DIMENSIONS Courtesy of Crane Market...

Страница 8: ...1 4 IC 200 H TURNING DIMENSIONS Courtesy of Crane Market...

Страница 9: ...pe cylinders and hydraulic powered hoist A Rated Capacity Limiter is standard IC 200 2H 3 section hydraulically extended boom with capacity of 30 000 pounds 13600 kg at a 6 foot 1 8 m load radius Hori...

Страница 10: ...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 feet 15 2 m With...

Страница 11: ...Fuel Engine Only Heater for engine Engine coolant heater installed with hoses in coolant system to circulate warm water through engine Plug s into 120V AC ex tension cord 1500 watts Transmission Stan...

Страница 12: ...0 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 steer An ele...

Страница 13: ...nt of hook block so main winch line can be used f or pulling loads at or near floor level Also for anchoring tag lines from load on hook Tie Downs Two holes in t he rear bumper in conjunction with the...

Страница 14: ...e 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 Protection Sys...

Страница 15: ...ting control Instrument Group Located at operator s station includes fuel gauge and hourmeter which records hours only during actual engine operation Also included are warning lights for low oil and t...

Страница 16: ...by hydraulic motor and w orm gear drive Sw ing gearbox may be adjusted as w ear occurs to minimize backlash Boom is at tached by high strength steel weldment Boom Hoist Standard Turret mounted planeta...

Страница 17: ...tension may be st owed alongside base boom section when not in use Tip sheave attaching brackets and pins included Deduct 400 pounds 180 kg from Capacity Chart when boom extension is in the stowed pos...

Страница 18: ...Courtesy of Crane Market...

Страница 19: ...ch will divert his at tention 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 hig hly fl...

Страница 20: ...ants 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 disp...

Страница 21: ...er 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 a shor t d...

Страница 22: ...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 sure...

Страница 23: ...e chang ed Unauthorized addition of counterweight in the field to increase lifting ability constitutes a safety hazard 19 Always keep crane boom at least 10 f eet 3 m away from electric power lines Se...

Страница 24: ...onsibility 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 pr even...

Страница 25: ...ate 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 3km h to prop...

Страница 26: ...operated as t hey are in ot her vehicles already familiar to the operator A lever on t he steering column controls the powershift transmission M oving the lever upward engages the transmission clutch...

Страница 27: ...ext 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 pushing forward...

Страница 28: ...ission 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 to medium to fu...

Страница 29: ...ure 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 attachment the loa...

Страница 30: ...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 t he crane is int ended to assist the op...

Страница 31: ...t he basis t hat operations are to be conducted on firm and level terrain and in a saf e environment These capacity ratings are reduced in pr oportion to the deviation from the prescribed conditions A...

Страница 32: ...2 14 Courtesy of Crane Market...

Страница 33: ...2 15 Courtesy of Crane Market...

Страница 34: ...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 t he chart that 7500 pounds 3400 kg is t he maximum load on one part...

Страница 35: ...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 cla...

Страница 36: ...15 000 pounds The wedge socket should be pinned t o the wedge socket anchor as shown in the figure The dead end of the rope in the wedge socket should be clam ped as shown in the figures The clamp mus...

Страница 37: ...ld 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 the extended...

Страница 38: ...h pins in the right hand lugs and retain them with the hairpin cotters 9 Remove the front stow pin and sw ing the boom extension around to the front until the left hand lugs mesh 10 Insert the attach...

Страница 39: ...trol 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 to fall causin...

Страница 40: ...ENSION 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 t han 4550 pounds 2010 kg the load including the downhaul weight...

Страница 41: ...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 is not desi...

Страница 42: ...in 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 U...

Страница 43: ...ield 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 Park...

Страница 44: ...r Brake fluid fill location Engine start Brake malfunction Engine idle set Hydraulic oil low level mark Check engine Hydraulic oil filter restriction indicator Stop engine Hydraulic temperature gauge...

Страница 45: ...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 fingers clothing...

Страница 46: ...ntil 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 Limiter display a...

Страница 47: ...tart 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 Check operat...

Страница 48: ...rs 16 Check anti two block system for 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 c...

Страница 49: ...tion 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 looseness or backl...

Страница 50: ...age or excessive wear 19 Visually inspect welds on boom turret and outriggers 20 Perform a load test according to the Rated Capacity Limiter Operation Manual 21 Check operation of outrigger warning li...

Страница 51: ...ing system 4 Fill with new coolant and distilled water 5 Perform all maintenance required by engine manual S N _______________ HOURS ________ DATE ________ BY _____________________ COMMENTS PARTS REQU...

Страница 52: ...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 system Gas 15 14...

Страница 53: ...3 9 IC 200 LUBRICATION CHART Courtesy of Crane Market...

Страница 54: ...x 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 MPG X 1 Zerk 2...

Страница 55: ...e are grease fittings on chain sheav e 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 fittings Do not a...

Страница 56: ...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 pinion teeth Re...

Страница 57: ...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 cable needs to be repl aced use d...

Страница 58: ...urned 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 instructions on reeving...

Страница 59: ...the priority valve at port P When no st eering is r equired the entire flow goes through the priority valve and leaves through port EF to the crane valve The crane operating speed is not affected sin...

Страница 60: ...3 16 Courtesy of Crane Market...

Страница 61: ...3 17 Courtesy of Crane Market...

Страница 62: ...in the reservoir and purged out of the cylinders If excessive particles are found the source should be locat ed and fixed and the oil should be purged Lubricate the new element seal and inst all the...

Страница 63: ...ot availa ble These motor oils are not suitable substitutes when changing hydraulic oil because t hey lack certain additives that are needed for hydraulic system use C A U T I O N Never add kerosene o...

Страница 64: ...en 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 side of the cy...

Страница 65: ...n pipe threads 4 Do not use Teflon tape to seal pipe treads Loctite type anaerobic sealant is preferred Leaks in com ponent parts such as pum ps valves and m otors that cannot be stopped by tightening...

Страница 66: ...re 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 inst all a 3000 PSI 207 bar pressure gauge To obtain full flow re...

Страница 67: ...031 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 directly...

Страница 68: ...he 3 rd stage As show n in Illustration 1 13 mm clearance must be held between the 4th stage tip and 3rd stage tip To increase this dis tance loosen the retraction adjustment and tighten the extension...

Страница 69: ...3 25 IC 200 3 BOOM CHAIN ADJUSTMENT Courtesy of Crane Market...

Страница 70: ...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 to allow any...

Страница 71: ...e 5 or 8 Torque the rotation bearing mounting bolts 3 4 Gr 8 to 325 foot pounds 440 Nm or the nuts to 325 foot pounds 440 Nm Torque the wheel nuts to 500 foot pounds 678 Nm The torque chart on the nex...

Страница 72: ...m aximum 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 from its pa...

Страница 73: ...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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