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OPERATION AND MAINTENANCE MANUAL IC-35-2F

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5. 3 5 L brication i o is cet che deb sae tte 3 7 Rotation 3 7 Torque Hub 3 7 Wire 3 7 Lubrication Chart and Schedule 3 8 Hoist Cable Installation and Inspection 3 10 Hydraulic System 3 13 JIC 2 3 12 JIC Schematic 3 12M Steering 222 2 3 13 Propulsion 3 15 Hydraulic System 3 17 Transmission Start Up Procedure 3 17 Transmission Troubleshooting 3 19 Care of Hydraulic 3 20 Hydraulic Oil Specifications 3 21 SECTION3 MAINTENANCE cont d Hydraulic System 3 17 Purging the Hydraulic System 3 21 Bleeding the 5 3 23 Hydraulic 3 24 Hydraulic System 3 25
6. 2122 1 3 Description and 5 1 4 SECTION2 OPERATION Safety 2 1 Instruments 8 2 5 Control 2 2 2022 2 5 Sequence 2 6 Driving the 2 2 2 6 Operating the 2 7 Normal Gauge 5 2 7 Rated Capacity 2 8 Crane 2 9 Crane Capacity 2 11 Crane Capacity Chart IC 35 2F 2 12 Crane Capacity Chart IC 35 2F Metric 2 12M Sheave Block and 2 13 Two Part Line 020 02002 2 14 Safety 5 2 15 Optional Equipment 2 16 Boom Extension sse 2 16 Front Auxiliary 2 17 Switch and Indicator Symbols on BMC Cranes 2 18 SECTION3 MAINTENANCE Safety RUES cro eit rH re 3 1 Inspection and Testing 3 3 Maintenance
7. TAN NTH c l v 30915 340253181 LE TI b YIH H 1NOH 1 1 Eae 390953131 SILVWAHOS 46 66 21 3 12M HYDRAULIC SYSTEM The IC 35 hydraulic system consists of three subsystems driven by a triple pump The 34 gpm 129 L min piston pump powers the propulsion system The 6 gpm 23 L min gear pump supplies the hydrostatic steering function and the boom and outrigger functions The hoist and optional front winch are powered by the 17 gpm 64 L min pump The boom outrigger and hoist functions are controlled by a single valve assembly with two inlet ports The 6 gpm 23 L min pump flow enters the left hand port and supplies the swing boom telescope and outrigger sections The 17 gpm 64 L min pump flow enters the mid inlet port to supply the hoist Adjustment procedures for the crane hydraulic functions are given on page 3 25 The schematic of the hydraulic system is shown on the page 3 12 The steering system and propulsion systems are also shown in diagrams on the following pages STEERING SYSTEM The 35 steering system is a load sensing demand type system that takes only as much flow as is needed when steering and directs the excess flow to the control valve for boom and outrigger functions The priority flow
8. O POSITRACTION FLOW DIVIDER m DRAIN kid 2 GEAR PUMP CHARGE PUMP wU PISTON FILTER J w PUMP vcr aee OIL TANK CASE DRAIN TEMPERATURE SENSOR FILTER y CRANE WINCH VALVE VALVE VALVE COOLER TESS START UP PROCEDURE PISTON PUMP When initially starting a new or rebuilt transmission pump it is extremely important that the start up procedure be followed It prevents damaging the unit that might occur if the system is not properly purged and charged with oil before start up ij After the propulsion components have been properly installed fill pump housing at least half full with new hydraulic fluid as specified on page 3 21 Connect all hydraulic lines and check to be sure they are tight Check the wiring connections to the pump control Fill the reservoir with approved hydraulic fluid that is new and clean Install a O to 300 psi 0 to 20 bar gauge in the charge pressure port The port is the highest port on top of the pump and has a 6 elbow with a 14 hose that connects with the brake release valve This may be disconnected or a tee may be inserted See figure below Gasoline or L P Engines Remove the coil wire and turn the engine over for 15 seconds Diesel Engines Shut off the fuel flow to the injectors and turn the engine over for 15 seconds This procedure enables the charge pump to pick up the oil
9. DE 2 Pumpis noisy 3 Sluggish response to acceleration or deceleration System will not operate in either direction Brake switch tripped Oil supply low filter clogged Oil too heavy Bypass valve open Bad electrical connection Circuit breaker open Defective switch Defective RPM sensor Defective controller circuit Defective pump solenoid Defective brake release solenoid Low charge pressure below 200 PSI 14 Bar Charge pump relief valve damaged Damaged internal charge check valve Charge pump key sheared Charge pump worn or scored or damaged Drive coupling broken Forward or reverse relief valve stuck open Air in system Clogged filter Internal pump or motor wear or damage Air in system Low charge pressure Loose bypass valve Defective brake release solenoid Internal pump or motor wear or damage Reliefe valve dirty and damged Release brake switch Check oil level fill Replace filter element Use proper viscosity oil Close bypass valve Check all related connections Fix short overload or breaker Replace switch Fix or replace sensor Replace controller circuit Replace pump solenoid Fix or replace solenoid or wiring See below N O P Q Remove relief valve parts Examine parts and seat Replace damaged parts Disassemble and determine if check valve is faulty Inspect charge pump for damage amp replace key Remove parts and examine Re
10. IN RAISE Swing Pulling back on the lever will rotate the boom to the operator s left pushing forward will rotate it to the operator s right Boom Pulling back will raise the boom pushing forward will lower it 2 5 Telescope Pulling back on the lever will retract the boom pushing forward will extend the boom Hoist Pulling back on the lever will raise the hook pushing forward will lower the hook Outriggers The four outriggers may be operated simultaneously or individually Special attention must be given to avoid hitting personnel or obstacles All controls may be used for simultaneous operation to achieve combinations of movements Some controls must be used together For instance the boom telescope and the hoist controls must be used together to maintain clearance between boom and load line hook Avoid holding a control lever in the open position after the function has reached the end of its travel This will impose unnecessary stresses on the components and heat in the hydraulic system SEQUENCE OF OPERATION DRIVING THE VEHICLE The following procedure is recommended for driving the vehicle to the job site Perform the daily inspection and test See Page 3 4 Apply park brake Leave hydrostatic transmission switch in neutral Start engine and allow a warming period If equipped with Safety Shutdown System depress reset button while starting and for a few seconds after 5 While warming the engine set up
11. monec 6 MONTH INTERVAL For usage less than 250 hours in 6 months 1 Perform 250 hour maintenance and lubrication 2 Change hydraulic filter elements and inspect oil 12 MONTH INTERVAL For usage less than 500 hours per year 1 Perform 6 month maintenance 2 Perform 500 hour maintenance 3 Change hydraulic fluid and filters and clean breather and reservoir 24 MONTH INTERVAL 12 month maintenance Pressure test engine cooling system Flush cooling system Change engine thermostat Fill with new coolant and distilled water Perform engine maintenance specified in engine manual for 24 month interval S N HOURS DATE BY COMMENTS amp PARTS REQUIRED 3 6 ROTATION BEARING LUBRICATION There is one grease zerk in a hole on the right hand side of the turntable base plate This should be used to lubricate the bearing every 50 hours Rotate the turntable about 45 degrees and pump some grease into the zerk Repeat until the turntable has rotated two revolutions Use about 4 ounces of grease each time the bearing is lubricated Also lubricate the gear teeth of the rotation bearing at the 50 hour interval Remove the pinion cover Brush open gear grease such as Mobilkote 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 TORQU
12. variable speed hydrostatic transmission front driving and rear power steering axles The boom assembly includes a hydraulic powered continuous rotation turret 3 section telescopic boom hydraulic boom elevating cylinder hydraulic boom extension cylinders and hydraulic powered hoist A Rated Capacity Limiter is also standard IC 35 2F 3 section hydraulically extended boom with capacity of 8 000 pounds 3629 kg at a 4 foot 1 2 m load radius Horizontal reach of 19 feet 2 inches 5 84 m and vertical reach of 26 feet 7 92 m Hoist is located on back of turret GENERAL Length Chassis 9 feet 11 inches 3 02 m Overall 11 feet 11 inches 3 63 m Width 5 feet 0 inches 1 52 m Height Deck 28 inches 71 12 cm Overall 6 feet 6 inches 1 98 m Wheelbase 6 feet 0 inches 1 83 m Ground Clearance Chassis 7 inches 17 78 cm Minimum Rear Axle Angle of Approach Angle of Departure Turning Radius Min Aisle Width 90 degree Turn Min Travel Speed Max 5 inches 12 7 cm 26 degrees 21 degrees 11 feet 2 inches 3 40 m 8 feet 3 inches 2 52 m 10 mph 16 km h Weight Distribution Front Axle Rear Axle Total Tire Footprint Area Outrigger Footprint Area Drawbar Pull Gradeability Grade Limit Boom Movement Rotation Elevation Extension Tail swing Boom Speeds Rotation Elevation Extension Sheave Height Without Jib With Jib Horizontal Reach Without Jib With Jib 3780
13. 9 E z0 1 46 aub 06 able Lah Mg 4 ovg _ 66 wo _ EU site Su B E i Sla 1 w b J 042 4 2 4 1 Hp Omm u 96 1 HVO 9 9 Y 79 s 1 _ w 19 2 6 __ 0G v 40 2 GALOVYLSY Z Z NOILV LOH 3 204 ZXY oj 32 56 01 NOILV LOH 26 2 0792 f 49 A QNVH 1331 i NN 92 uo02 V 6 g L t iT z a 10 9 39 29 Sle IDEE 0 c t C Qu401 9 We 622 6 e LH9IM 1 2 TURNING DIMENSIONS E 1 3 SECTION 1 DESCRIPTION AND SPECIFICATIONS BMC s IC 35 2F is a self propelled industrial crane designed for in plant lifting and material handling applications It has the special features of low height narrow width short length cargo deck rear wheel steer and front wheel drive The basic unit consists of a chassis and hydraulic boom assembly The chassis includes a frame four hydraulic outriggers engine
14. ADJUSTMENTS Wheel bearing adjustment must be maintained at all times Adjustment is made each time the bearings are repacked annually Wheel bearings are adjusted by the ad justing nut This nut should be tightened until only a slight drag is felt when rotating the wheel WHEEL ALIGNMENT Toe in which is the setting of the steering wheels so they are closer together at the front than at the rear is adjusted by lengthening or shortening the tie rods Proper toe in for the rear wheels is zero 3 28 TORQUE DATA BOLT SAE GRADE SAE GRADE SAE GRADE GRADE 1OR2 5 8 MEDIUM CARBON MEDIUM CARBON MATERIAL LOW CARBON ALLOY STEEL MINIMUM TENSILE 64 000 PSI 120 000 PSI 150 000 PSI STRENGTH 441 MPa 827 MPa 1034 MPa BOLT SIZE RECOMMENDED TORQUE VALUES FT LBS N m 10 5 14 22 30 37 50 60 81 92 125 132 179 179 180 244 120 163 401 190 258 473 641 282 382 714 968 THE FOLLOWING RULES APPLY TO THE CHART Consult manufacturers specific recommendations when available The chart may be used with coarse and fine thread fasteners lightly lubricated Increase torque by 2096 when multiple tooth shakeproof lockwashers are used The torque values are given in foot pounds N m Inch pounds equivalent may be obtained by multiplying by 12 3 29 8 4 2 BATTERY 35 2EF M 5 DIA
15. Control 3 25 Boom Cylinder Holding Valve 3 26 Extension Cylinder Holding Valve 3 26 Engine 3 27 Air Cleaner 3 27 Cooling teeta eeeeeeaeees 3 27 Spare Parts 3 27 Major Engine 3 27 Mechanical 3 28 eeeeeereererrserrerrrerrrererrrrr ren 3 28 Rotation 3 28 Wheel 685 2 2 2 212 1 3 28 Wheel 2 07272 3 28 Torque 3 29 BRODERSON MANUFACTURING CORP IC 35 INDUSTRIAL CRANE INTRODUCTION The Broderson 35 was designed and built to provide safe dependable and efficient crane service This we assure by our testing and quality control procedures properly utilize the full potential of the equipment the following customer controlled conditions must exist 1 The operator must understand the equipment 2 The operator must know the operating characteristics 3 The operator must observe the safety rules 4 The equipment must be given proper maintenance This manual was written to pro
16. before start up Replace the coil wire or return the fuel flow to the injectors Keep the transmission control switch in the neutral position start the engine and run it at a low idle The charge pump should immediately pick up oil and fill the system If there is indication of fill in 30 seconds gauge in charge pressure port of the pump should register about 220 psi 15 bar stop engine and determine the cause TRANSMISSIOM PUMP EDC EDC TANK PB EDC NOT SHOWN BYPASS THIS VIEW VALVE RH SIDE TOP VIEW LH SIDE PA FORWARD PRESSURE PB REVERSE PRESSURE EDC ELECTRIC DISPLACEMENT CONTROL CHARGE 3 17 6 After the system shows signs of filling run it in neutral and low idle for 5 minutes Then extend the outriggers so that drive wheels can spin freely Reconnect the brake release 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 increase to full throttle for one minute in each direction 7 Check fluid level in the reservoir and fill to the proper level Check all line connections for leaks and tighten if necessary 3 18 IC 35 PISTON PUMP TROUBLESHOOTING
17. control the vehicle speed to be compatible with conditions of rough roads or uneven terrain When this crane is to be parked on a grade set parking brake and block wheels or extend outriggers fully WARNING THIS VEHICLE IS EQUIPPED WITH A BACK UP ALARM ALARM MUST SOUND WHEN BACKING OPERATOR MUST MAKE CERTAIN ALARM IS WORKING BEFORE OPERATING THIS VEHICLE 651 0014 Shut off engine before refueling and remove fuel cap slowly Vapor pressure in tank can cause a burst of fuel and vapor when the cap is removed 2 4 OPERATION INSTRUMENTS AND CONTROLS The Broderson 35 instrument panel is equipped with a standard instrument package showing electrical system amperage fuel level oil pressure water temperature hydraulic oil temperature and engine hours Also included is a bubble level to level the machine When unit is equipped with optional diesel engine a glow plug light and glow plug button are included The 35 is equipped with a lighting package including an on off switch two headlights and two taillights A 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 vehicle is left unattended The hydrostatic transmission control switch is also located on the instrument panel has FORWARD NEUTRAL and REVERSE positions The speed of the transmiss
18. control valve is in the line between the 6 gpm 23 L min pump section and control valve Oil from the 6 gpm 23 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 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 priority valve to divert the required amount of oil to the steering control unit to meet the steering system requirements The excess oil not required for steering flows to the crane control valve as usual Since the amount of oil required for steering is usually a small portion of the pump output the crane control valve is always operational while the unit is being steered Crane operation speed is reduced such a slight amount it is usually not noticed The steering control unit is non load reactive This means that bumps curbs and obstacles cannot change the steering angle and are not felt in the steering wheel It also means that the wheels do not recenter when the steering wheel is released The steering wheel must be turned back to center at the end of a turn There is a check valve in the pressure line between the priority valve and the steering control unit This prevents pressure in the steering cylinders from venting back into the pressure line when the
19. drag loads sideways 5 DANGER RIDING ON CRANE LOADLINE CAN RESULT IN A WARNING DEATH OR SERIOUS INJURY NEVER RIDE ON HOOK LOAD OR ANY OUTRIGGERS CAN CAUSE DEVICE ATTACHED TO LOADLINE SERIOUS CRUSHING INJURY B 651 00113 STAND CLEAR Level the crane before lifting small incline will significantly reduce the capacity Use appropriate cribbing under the outriggers for leveling All outriggers must be fully extended and tires must clear the ground to use the OUTRIGGERS ratings Always use outriggers if possible If you must lift on rubber keep the load as close to the ground as possible to prevent tipover Move the load very slowly and use tag lines to prevent load swinging Crane may tip at less than rated loads if the surface is uncompacted or wet dirt or soft soil with frozen crust thin or cracked pavement or surface near a hole or ledge Always use adequate outrigger floats and or cribbing See page 2 11 The operator shall not leave the controls while the load is suspended Always use adequate parts of load hoist line for lifting heavy loads Always be sure the rope is properly seated and wound level on hoist drum Keep hands away from load hoist rope when hoist is being operated 2 2 14 Be sure at least five wraps of rope are left on the hoist drum to insure against rope pulling out of its anchor 15 Never wrap the hoist rope around a load Always use approved rigging A D
20. engine Spark Arrestor Muffler Spark arrestor muffler used in addition to standard muffler Net Weight 10 pounds 5 kg Engine Shutdown Kit Consists of Murphy switches that shut engine down if water temperature is excessive or oil pressure is too low For diesel engine only Hydrostatic Transmission Pump Standard Sauer Danfoss piston type 2 8 CID 45mL per revolution direct driven from engine crankshaft Maximum flow 34 gpm 129 L min maximum pressure 4 000 PSI 275 bar Electrohydraulic servo and electronic automotive type controller Axles Standard Front Axle Channel shaped structure houses torque hubs brakes and hydraulic drive motors Front axle oscillates a total of 1 5 inches 38 mm to minimize wheel spin on uneven surfaces Rear Axle Fixed rigid to frame Box beam crossmember and thrust bearing supported wheel hubs Steering Standard Full hydraulic steering unit controls 2 5 inch 63 mm steering cylinder attached to rear axle Limited steering if engine dies 1 6 Brakes Standard Primary braking from hydrostatic transmission Foot actuated disc brake attached to each torque hub for additional braking in some conditions Parking brake switch locks brakes to hold crane when not being driven Tires Standard 7 50 x 10 pneumatic tires 16 ply Pressurized to 150 psi 1000 kPa for crane rated loads Optional Tires Solid Rubber Tires For applications where hazardous ground conditions exist Th
21. in that system has been disconnected To bleed the pressure released section run the engine to pressurize it and slowly loosen the lower bleed screw until oil flows from the bleed screw Be careful to avoid oil spraying into your face or other parts of your body After air has escaped close the bleed screw and repeat on the other side of the axle Test brake for proper release To bleed the pedal operated section depress pedal and open the upper bleed screw Close the screw and allow pedal to return Repeat on each brake until pedal is firm Apply brakes firmly four times and repeat the process once more Keep reservoir full of hydraulic oil during bleeding Once a year bleed the pedal operated brakes to force new oil into the brake lines and cavities 3 23 HYDRAULIC SEALS WARNING Do not check for hydraulic leaks with hands If a mist of hydraulic oil is noticed around a line or component use cardboard or other material to check for location of leak High pressure fluid leaking from a small hole can be almost 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 All hydraulic fittings and hose connections should be kept tight to prevent loss of fluid from the system and unnecessary dripping from the machine Most hydraulic fittings on the 35 crane use o ring seals and if tightening the fitting fails to stop the leak the o ring shoul
22. of the test load should be within the rating on the capacity chart Use great care to prevent the load from hitting the crane Turn the engine off and pull the TELESCOPE lever to the RETRACT position If the boom retracts the valve should be adjusted To adjust the holding valve loosen the lock nut on the adjusting screw and turn the screw clockwise until unpowered movement stops Retighten the lock nut to hold the proper adjustment 3 26 ENGINE MAINTENANCE AIR CLEANER SERVICE Clean out the dust cup every 50 hours Loosen the clamps around the cup and housing and remove the cup Dump dust out of cup Clean gasket and sealing surfaces with a damp cloth Replace cup gasket if it shows signs of damage Replace cup with arrows pointing up and tighten clamp Clean the intake 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 element every 500 hours or 6 months Remove and clean the dust cup and gasket and the intake cap Remove the wing nut on the element and gently remove the element Bumping the element during removal may cause dirt to fall into the clean air tube Clean the inside of the housing carefully with a damp cloth To clean the element use a compressed air blower nozzle with less than 100 psi 7 bar and blow air from the inside of the element Shake dust off of the outside of t
23. pounds 1715 kg 4080 pounds 1850 kg 7860 pounds 3565 kg 46 square inches 297 cm each 48 square inches 310 cm each 2120 pounds 960 kg 30 1 2096 Continuous 70 degrees 12 feet 3 66 m 3 feet 6 inches 1 07 m 360 deg in 39 sec 1 5 rpm 17 seconds 32 seconds 26 feet 0 inches 7 92 m 33 feet 4 inches 10 16 m 19 feet 2 inches 5 84 m 27 feet 2 inches 8 28 m 1 Calculated value based on GM 2 4L engine Engine Standard Gasoline GM 2 4L Woodward EFI Dual Fuel EPA Tier Certified Industrial gasoline engine complete with multi port electronic fuel injection dual fuel and engine management system Water cooled 4 cylinder 147 CID 2 4 L 3 44 inch 87 4 mm bore 3 94 inch 100 mm stroke 65 HP 48 kW at governed speed of 2500 rom Maximum torque 137 foot pounds 185 Nm at 2300 rpm 70 amp alternator 13 5 gallon 51 L gas tank and 33 Ib 15 kg LPG tank Includes high temperature low oil pressure shutdown engine management system and a catalytic converter muffler Optional Engines and Accessories Kubota 2 4L EPA Interim Tier 4 Certified Kubota V2403 M E3B diesel engine Water cooled 4 cylinder naturally aspirated 148 CID 2 4 L 3 43 inch 87 mm bore 4 03 inch 102 mm stroke 48 9 HP 36 5 kW at governed speed of 2700 rpm Maximum torque 118 ft lbs 160 Nm of torque at 1800 rpm 12V 40 amp alternator Dry Weight 406 pounds 184 kg No weight change from gasoline
24. reason for the excessive temperature located and corrected The fins on the oil cooler and engine radiator may be dirty and need cleaning The transmission speed is controlled by an electronic circuit that senses engine speed and signals the transmission pump to deliver a proportional flow of oil to the wheel drive motors There is a manual operator lever on the control coil of the pump for testing A manual bypass valve is built into the piston pump It appears like a shaft with a cross hole in it on the side of the pump If the machine cannot run under its own power it can be towed for very short distances at 5 mph 8 km h or less by turning the bypass valve counterclockwise 4 turns It must be turned back again as far as possible to run normally CAUTION The crane will roll freely down inclines with the bypass valve open Keep the valve closed except when towing and the crane is secured to the tow vehicle An operator must be in the crane to operate the brakes 3 15 IC 35 PROPULSION SYSTEM 3 16 DRIVE WHEEL TORQUE HUB AED PARK BRAKE DRIVE MOTOR
25. winch is mounted behind the front bumper and is controlled from the operator compartment The winch with the 5 16 7 9 mm wire rope 10 500 pound 4762 kg breaking strength and 2 ton hook has a single part line capacity of 3 000 pounds 1360 kg A pulling eye is provided below the winch for two parting the line with a sheave block allowing 6 000 pound 2720 kg pulls An additional sheave block is not provided with this option The front auxiliary winch is designed for the following uses 1 Asa tag line for restraining loads on the boom load line during pick and carry operation 2 To drag loads 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 WARNING The front winch is not designed for lifting personnel or loads Observe the following safety rules 1 Never lift or carry personnel with the winch and wire 2 Do not allow anyone to stand near or under the load being moved 3 sure the cable is securely anchored in the drum and that at least 5 wraps of rope remain on the drum to insure against the rope pulling out of its anchor 4 Stand clear of a loaded winch cable If it breaks it can be very dangerous 5 Keep hands clear of the winch and any sheaves that the cable passes over when the winch is being operated 2 17 SWITCH AND INDICATOR SYMBOLS ON BMC CRANES The following list shows th
26. 0 250 500 1000 MONTHS NOTES SYMBOL HOUR HOUR HOUR HOUR Accelerator Linkage 2 Points Not Anti Two Block Arm 2 Points Axle Kingpins 4 Zerks Axle Pivot Pin 1 Zerk Axle Planetary Hubs Check 950 Change 912 Boom Extension Pins 6 Pins Wipe Boom Rub Pads Spray or Wipe Brakes Check 250 Change 912 Control Valve Links 12 Points Driveshaft Joints 2 Zerks Engine Check Daily Change 9250 Hrs or 6 Mo Max Hook Swivel amp Pin Wipe Hydraulic Oil Check Daily Change 91000 Hours or 12 Mo Max Outrigger Legs Wipe Upper amp Lower Sides Pedal Hinges 2 Points Rotation Bearing 1 Zerk Rotation Gearbox Check 2250 Change 912 Rotation Gear Teeth Brush On Sheave Block 2 Zerks Sheave Pins 1 Zerk Std 1 On Boom Ext Steering Cylinder Ends 2 Zerks Steering Sector 1 Zerk Steering Tie Rod End 4 Zerks Wheel Bearings Rear Clean amp Repack Winch es Check 9250 Change 912 Wire Rope Spray Brush or Soak Wire Rope Retainers See Procedures in the Manual LUBE SYMBOLS FLUID VOLUMES HO Approved Hydraulic Fluids See Page 3 21 Brake Reservoir 1 Pt 0 5 L EO Engine Oil See Specs in Engine Manual Engine Coolant Gal 11 L Multi Purpose Gun Grease Engine Oil Kubota 10 Qt 9 5 L MPL Multi Purpose Gear Lube SAE 80W 90 Engine Oil GM 4 5 Qt 4 25 L OGG Open Gear Grease Such as Mobilkote S Fuel Tank 13 5 Gal 511 SIL Sili
27. 40 foot 42 6 m long load line instead of standard 85 foot 26 m Net Weight 14 pounds 7 kg Boom Swing Standard Heavy duty ball bearing rotation gear with external teeth supports boom Rotation is powered by hydraulic motor and worm gear drive 360 degree continuous rotation Boom Attachments Standard Anti Two Block Device Has electric solenoid dump valve which prevents damage to hoist rope and machine components from accidentally pulling load hook against boom tip This valve will dump the HOIST RAISE TELESCOPE EXTEND BOOM LOWER and SWING LEFT RIGHT circuits No other circuits are affected These circuits are returned to normal operations by operating the HOIST LOWER or TELESCOPE RETRACT control This system uses a trip arm to activate switch Rated Capacity Limiter Operator s aid that warns operator of impending overload with audible and visual signals Has read outs for load boom angle boom length and load radius In the event of an overload dumps the following boom functions HOIST RAISE TELESCOPE EXTEND BOOM LOWER SWING LEFT and SWING RIGHT These circuits are returned to normal 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 Attachments Boom Extension 8 Foot 2 4 m Provides 8 feet 2 4 m of additional length for lifting loads with load line Boom extension may be stowe
28. ACITIES IN POUNDS 360 ROTATION OVER FRONT 30 ON ON ON ON E FEET RUBBER OUTRIGGERS RUBBER OUTRIGGERS 4 5000 8000 6700 8000 26 40 5 4000 6800 5800 6800 2 P poa 6 2850 5850 5100 5850 Sy gt o 8 1800 4150 3500 4150 22 3 30 10 1250 3200 2350 3400 20 5 2 12 900 2350 1750 2850 n 27 14 700 1850 1350 2450 2 16 600 1500 1100 2150 1e 20 18 500 1250 950 1950 14 LZ 19 450 1150 900 1850 20 400 1100 850 1600 10 z 22 300 900 700 1450 2 24 250 800 600 1300 2 26 200 700 500 1150 EA E 27 150 650 450 1100 UU i i6 de 20 r 26270 8 FOOT BOOM EXTENSION STRAIGHT OR OFFSET RADIUS IN FEET FROM ROTATION TO LOAD EXTENSION MAIN BOOM ANGLE 3RD STAGE TIP BOOM EXT TIP S anere 09 10 209 30 40 50 609 70 uw lt 5 0 1100 1200 1300 1450 1600 1850 2300 3500 2 cmd 15 1100 1250 1350 1500 1700 2050 29 4 E 27 23 30 EA 1100 1200 1300 1450 1600 21 TWO PART LOAD LINE FOR LOADS UP TO 8000 LBS WT 60 LBS L SINGLE PART LOAD TO 4000 LBS WT 40 LBS EXCEEDING CAPACITY RATINGS OR APPLYING SIDE LOADS TO THE OR BOOM EXTENSION 15 MISUSE IS HAZARDOUS AND VOIDS WARRANTY CAUTION BOOM EXTENSION LOADS MUST NOT EXCEED MAIN BOOM CAPACITY BOOM EXTENSION DEDUCT 100 LBS WHEN STOWED ON BASE BOOM DO NOT PICK amp CARRY WITH LOADS
29. ANGER KEEP CLEAR OF SWINGING TURRET TO PREVENT SERIOUS BODILY INJURY 4651 00150 16 Avoid pinch points such as between a rotating turret and the cab or operator guard or in access holes of a telescop ing boom 17 Avoid two blocking a Stop raising hoist line before downhaul or hook block strikes boom tip plates b Pay out hoist line while extending boom c Maintain clearance between downhaul weight or hook block and boom tip while booming down DANGER Two blocking will abruptly stop boom lowering and boom swing as well as hoist and 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 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 3m away from electric power lines See chart on side of turntable for boom clearance A DANGER ELECTROCUTION HAZARD DEATH OR SERIOUS INJURY WILL RESULT FROM BOOM LOAD LINE OR LOAD CONTACTING ELECTRIC LINES DO NOT USE CRANE WITHIN 10 FEET 3m OF ELECTRIC LINES CARRYING UP TO 50 000 VOLTS ONE FOOT ADDITIONAL CLEARANCE IS REQUIRED FOR EVERY ADDITIONAL 30 000 VOLTS OR LESS IF IT IS NECESSARY TO PLACE ANY PART OF THE CRANE OR LOAD CLOSER THAN 10 FEET FROM A POWER LINE CONTACT THE ELECTRIC P
30. ARK BRAKE L T HHH reu SOLENOID VALVE PRESSURE RELEASE M FWD REV SWITCH HC JETER LE pressure SOLENOID VALVE he E 22 HEA m EVENT DRIVING THRU UsES PUMP CHARGE PRESSURE 1 L 2 B 7 bs 15 A L ae 4 E o 7 n 2 lt o M A gt 16 d E x T V a d 1 09 E 5 BRAKE SWITCH HUNE HOUR T ZR 20 49 26 _ _ lt auos X i 39 40 54 59 Noe g 2 5 C 600 31958 ___ BREAKER PANEL TAN amp 22 SIDE DASH PANEL 44 2 15 eS ee vu tc ie RE u OUTRIGGER ALARM onc FAKE 2 E AD 4 SWITCHS ON En 22 od m 4 CONTROL VALVE 5 ESSuRE A 3LK o P 4 EC 2 N RED ENGINE wu E WATER TEME EV g NOT ON OUTRIGGERS ETE ae 116 5 PUSH AND HOLD TO START ENGINE
31. BLE ANCHOR FOR 3 8 9 5 mm DIA ROPE 3 10 10 11 12 13 14 15 16 17 Slowly rotate the hoist while applying tension on the cable in front of the boom Wear heavy leather gloves and wrap rags around the cable to wipe off any dirt from the cable Keep hands away from the sheaves and hoist drum while the cable is moving After two turns of the hoist drum stop the hoist and push the cable tightly against the flange of the drum with a wooden or rubber mallet Slowly rotate the drum until the first layer of cable is on the drum If any gaps between the rope appear stop the hoist and tap the cable toward the flange There must be no gaps After the first layer is on the drum the hoist may be turned a little faster until the remainder of the cable is installed Leave about 15 feet b m of cable on the ground to install the sheave block See the Operation Section for instructions on reeving and wedge socket attachment Install the cable retainer pins and cotters in the tip sheave plates For the cable break in lower the outriggers and attach a load of about 1 000 pounds 500 kg Extend the boom fully Position the load at a 6 foot 2 m load radius over the right hand side of the crane Hoist and lower the load three times and check winding of the rope on the hoist Attach about 3 000 pounds 1400 kg and repeat Be sure that the cable winds evenly on the hoist If the cable appears to twist too much remov
32. E HUBS Use Mobilube HD 80W 90 gear lube or equivalent SAE 80W 90 OIL FILL On new cranes drain oil after first 50 hours of use and refill Check oil level every 50 OIL LEVEL Sd Drain and refill after 1 000 hours of operation or after one year of ser OIL DRAIN vice whichever comes first WIRE ROPE LUBRICATION The wire rope should be cleaned and lubricated every 50 hours of normal operation and more frequently when used in dirty or corrosive environments Whenever the rope is dirty or dry it should be serviced The rope should be cleaned with solvent and compressed air or solvent and rags A wire brush may be used for difficult areas The recommended lubricant is AMOVIS 2 It should be sprayed or dripped onto the rope where it is bent as it passes over the tip sheave Wrap rags around the wire rope behind the sheave and swab the excess oil that is carried along on the rope Always wear heavy leather gloves when handling wire rope 3 7 IC 35 LUBRICATION CHART 1227202 7 6 26 6 25 17 18 13 8 X 19 3 8 IC 35 LUBRICATION SCHEDULE LUBRICATION INTERVALS ITEM DESCRIPTION LUBE 5
33. EXTENDS TO A PERSON WHO RENTS OR LEASES ANY BMC PRODUCT OR WHO PURCHASES ANY BMC PRODUCT AS A USED PRODUCT For purposes hereof a BMC product shall conclusively be deemed used after the expiration of twelve 12 months from its placement in service as evidenced by a duly completed and signed warranty validation certificate actually received by Broderson or after such earlier time as it has been operated for more than one hundred 100 hours BMC shall have no liability hereunder with respect to products which have been subjected to misuse negligence accident or other external forces which may have caused or accentuated any apparent failure of such products to conform to the warranty herein made BMC does not warrant any of its products to meet any state local or municipal law ordinance code rule or regulation The purchaser must assume the responsibility for maintaining and operating the products which are the subject of this warranty in compliance with such of the foregoing as may be applicable and BMC shall not be liable for the purchaser s failure to meet such responsibility THE WARRANTY HEREIN MADE IS IN LIEU OF ANY OTHER WARRANTY EXPRESS OR IMPLIED BMC MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER EXPRESS OR IMPLIED WARRANTY OF ANY KIND TO ANY PURCHASER LESSEE OR RENTER OF NEW OR USED BMC PRODUCTS OR ANY OTHER PERSON WHATSOEVER NO PERSON IS AUTHORIZED TO ACT ON BEHALF OF BMC IN MODIFYING THE WA
34. IS HAZARDOUS AND VOIDS WARRANTY CAUTION BOOM EXTENSION LOADS MUST NOT EXCEED MAIN BOOM CAPACITY BOOM EXTENSION DEDUCT 45 kg WHEN STOWED ON BASE BOOM DO NOT PICK amp CARRY WITH LOADS ON BOOM EXTENSION ENSURE ANTI TWO BLOCK SWITCH IS FUNCTIONAL AFTER DEPLOYING OR STOWING BOOM EXTENSION CAPACITIES ON OUTRIGGERS ARE 85 OF TIPPING LOADS CAPACITIES ON RUBBER ARE 75 OF TIPPING LOADS CAPACITIES BELOW BOLD LINE ARE LIMITED BY TIPPING OTHER CAPACITIES ARE LIMITED BY STRUCTURAL OR HYDRAULIC CAPABILITIES BOOMS ON THIS UNIT ARE ALL STEEL AND HAVE NO LINE VOLTAGE RATING THE LOAD LINE ON THIS UNIT MUST BE 10 mm DIA 6X36 EIP RRL IWRC WIRE ROPE OR EQUIVALENT WITH A MINIMUM BREAKING STRENGTH OF 67 kN OPERATION 1 READ AND UNDERSTAND OWNERS MANUAL BEFORE OPERATING THIS CRANE 2 CHECK LEVEL OF ENGINE OIL AND HYDRAULIC OIL DAILY 3 CHECK UNIT FOR VISIBLE DEFECTS DAILY 4 EXTEND OUTRIGGERS FULLY IF POSSIBLE IF NOT USE ON RUBBER CHART 5 AVOID QUICK STARTS AND STOPS WHEN OPERATING OR DRIVING CRANE TIRE PRESSURE 1000 kPa FOR 7 50 X 10 16PL MODEL NO MAXIMUM HYDRAULIC PRESSURE 180 bar SERIAL NO DATE OF MFR BRODERSON MANUFACTURING CORP LENEXA KANSAS 65400803 2 12M SHEAVE BLOCK AND DOWNHAUL WEIGHT The capacity chart shows the approved hoist rope arrangements The downhaul weight and sheave blocks supplied by Broderson are specially designed to operate the anti two block system Other blocks or downhaul
35. M AS LOW AS POSSIBLE WITH THE LOAD CLOSE TO THE GROUND PICK AND CARRY CAPACITIES ARE FOR SMOOTH LEVEL PAVED SURFACE MODEL NO SERIAL NO DATE OF MFR DECK LOAD 6000 LBS MAX CENTERED BETWEEN WHEELS WITH NO BOOM LOAD DECK LOADS MUST BE CENTERED BEHIND THE FRONT AXLE SPEED MUST BE LESS THAN 2 MPH MAXIMUM TRAVEL 200 FT IN 30 MINUTES BRODERSON MANUFACTURING CORP LENEXA KANSAS 65400797 2 12 CRANE CAPACITY CHART FOR IC 35 2F METRIC METERS 70 Ss oe IC 35 2F METRIC 9 0 a 50 8 0 7 0 6 0 5 0 2 20 4 0 10 3 0 1 9 lt 0 2 0 3 0 4 0 5 0 6 0 7 0 8 2 RADIUS IN METERS FROM G ROTATION TO LOAD 3RD STAGE BOOM EXT TIP 58 8 1 L TWO PART LOAD LINE FOR LOADS UP TO SINGLE PART LOAD TO 1815 kg WT 18 kg 1815 kg WT 27 kg 1 Y O R S DOWN LEFT SIDE c OVER FRONT a ON RUBBER OVER FRONT REAR 1 7 FRONT IY ONOS ri g 15 RIGHT SIDE r LOAD RADIUS IS THE HORIZONTAL DISTANCE FROM THE CENTER OF ROTATION OF THE UNLOADED CRANE TO THE VERTICAL LOAD LINE WITH THE LOAD APPLIED LOAD HOOKS DOWNHAUL WEIGHTS HOOK BLOCKS AND OTHER LOAD HANDLING DEVICES EXCEPT HOIST ROPE SHALL BE CONSIDERED PART OF THE LOAD PICK AND CARRY WITH THE SHORTEST PRACTICAL BOOM CENTERED OVER THE FRONT OPERATE WITH THE BOOM AS LOW AS
36. ON BOOM EXTENSION ENSURE ANTI TWO BLOCK SWITCH IS FUNCTIONAL AFTER DEPLOYING OR STOWING O R S DOWN P BOOM EXTENSION LEFT SIDE CAPACITIES ON OUTRIGGERS ARE 85 OF TIPPING LOADS CAPACITIES ON RUBBER ARE 75 OF E pnr OVER FRONT 15 TIPPING LOADS CAPACITIES BELOW BOLD LINE ARE LIMITED BY TIPPING OTHER CAPACITIES ARE 15 Ex ON RUBBER LIMITED BY STRUCTURAL OR HYDRAULIC CAPABILITIES x 1 REAR T FRONT BOOMS ON THIS UNIT ARE ALL STEEL AND HAVE NO LINE VOLTAGE RATING FRONT T SNORS 291 ap THE LOAD LINE ON THIS UNIT MUST 3 8 DIA 6X36 EIP RRL IWRC WIRE OR EQUIVALENT pe ze 15 WITH A MINIMUM BREAKING STRENGTH OF 15 100 LBS OPERATION RIGHT SIDE 1 READ AND UNDERSTAND OWNERS MANUAL BEFORE OPERATING THIS CRANE 2 CHECK LEVEL OF ENGINE OIL AND HYDRAULIC OIL DAILY LOAD RADIUS IS THE HORIZONTAL DISTANCE FROM THE CENTER OF ROTATION OF THE UNLOADED CRANE TO THE VERTICAL LOAD LINE WITH THE LOAD APPLIED 3 CHECK UNIT FOR VISIBLE DEFECTS DAILY 4 EXTEND OUTRIGGERS FULLY IF POSSIBLE IF NOT USE ON RUBBER CHART 5 AVOID QUICK STARTS AND STOPS WHEN OPERATING OR DRIVING CRANE TIRE PRESSURE 145 PSI FOR 7 50 X 10 16PL MAXIMUM HYDRAULIC PRESSURE 2600 PSI LOAD HOOKS DOWNHAUL WEIGHTS HOOK BLOCKS AND OTHER LOAD HANDLING DEVICES EXCEPT HOIST ROPE SHALL BE CONSIDERED PART OF THE LOAD PICK AND CARRY WITH THE SHORTEST PRACTICAL BOOM CENTERED OVER THE FRONT OPERATE WITH THE BOO
37. OWER COMPANY AND ASK THEM TO DE ENERGIZE THE THIS CRANE IS NOT INSULATED POWER LINES AND VISIBLY GROUND THEM BEFORE YOU GO TO WORK REQUIRED CLEARANCE FOR NORMAL VOLTAGE IN OPERATION NEAR HIGH VOLTAGE POWER LINES AND OPERATION IN TRANSIT WITH NO LOAD AND BOOM OR MAST LOWERED Normal Voltage kV Minimum Required Clearance Phase to Phase Operation Near High Voltage Power Lines to 50 Over 50 to 200 Over 200 to 350 Over350 to 500 25 7 62 Over 500 to 750 35 10 67 Over 750 to 1000 w 45 13 72 Operation Transit With Load and Boom or Mast Lowered to 0 75 Over0 75to 50 Over 50 to 345 Over345 to 750 Over 750 to 1000 REF ASME ANSI B30 5 1989 B 651 00097 20 If boom should accidentally contact a power line keep ground personnel away from crane Stay in the crane until the power source is de energized Move the crane away from electrical hazard if this does not cause new hazards If it is absolutely necessary to leave the crane jump clear of the crane with both feet together Hop away from the crane with feet together The ground surface may be energized 2 3 TRAVEL 1 For Pick and Carry operation 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 assurance of safety For such operations the user must evaluate prevailing conditions and dete
38. PARTS IS IMPOSSIBLE OR IS DEEMED BY BMC TO BE IMPRACTICAL REPLACEMENT OF THE ENTIRE PRODUCT OR AT BMC S OPTION REFUND OF THE PURCHASE PRICE The replacement remedies include labor in connection with the removal of defective parts and the installation of their replacements as well as the cost of delivery and transportation of defective products or parts and the replacements thereof The sole purpose of these remedies is to provide the purchaser with free replacement of defective parts or in the limited circumstances specified replacement of the entire product or a refund of the purchase price These exclusive remedies shall not be deemed to have failed of their essential purpose so long as BMC is willing and able to replace defective parts or the entire product or to refund the purchase price The remedies herein provided shall be available only if BMC is given reasonable access to the product including all allegedly defective parts promptly after the defect is discovered BMC shall have the right to return any allegedly defective parts to its plant 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 only to the original purchaser from BMC and any subsequent purchaser who buys a BMC product as a new product WITHOUT LIMITING THE GENERALITY OF THE FOREGOING BMC EXPRESSLY DISCLAIMS THAT THE WARRANTY MADE HEREIN
39. POSSIBLE WITH THE LOAD CLOSE TO THE GROUND PICK AND CARRY CAPACITIES ARE FOR SMOOTH LEVEL PAVED SURFACE DECK LOAD 2720 kg MAX CENTERED BETWEEN WHEELS WITH NO BOOM LOAD DECK LOADS MUST BE CENTERED BEHIND THE FRONT AXLE SPEED MUST BE LESS THAN 3 km h MAXIMUM TRAVEL 60 m IN 30 MINUTES CRANE CAPACITY CHART CAPACITIES APPLY TO OPERATION ON FIRM LEVEL SURFACE Loap MAIN BOOM OR EXTENSION CAPACITIES IN KILOGRAMS 360 ROTATION OVER FRONT ON ON ON ON METERS RUBBER OUTRIGGERS RUBBER OUTRIGGERS 1 2 2260 3620 3040 3630 1 5 1850 3120 2650 3120 2 0 1090 2420 2120 2420 o 2 5 780 1830 1520 1830 8 3 0 580 1480 1090 1560 2 3 5 440 1160 850 1350 5 4 0 350 920 680 1180 4 5 300 770 560 1050 5 0 260 650 480 950 5 8 200 520 410 840 gt 6 0 190 500 390 750 6 5 150 430 340 680 2 7 0 120 380 290 620 7 5 100 350 250 570 t 82 70 290 200 500 gt Boom 2 44 m BOOM EXTENSION STRAIGHT OR OFFSET 8 ExTENSION MAIN BOOM ANGLE P ANGLE 0 10 20 30 40 50 60 70 0 500 540 590 660 720 840 1040 1590 3 15 500 560 610 680 770 930 30 500 540 590 660 720 USE 0 FOR STRAIGHT BOOM EXTENSION USE 0 15 OR 30 FOR OFFSET BOOM EXTENSION EXCEEDING CAPACITY RATINGS OR APPLYING SIDE LOADS TO THE BOOM OR BOOM EXTENSION IS MISUSE
40. PRINTED IN USA COPYRIGHTO 2011 P N 990 30168 BRODERSON MFG CORP OPERATION AND MAINTENANCE MANUAL IC 35 2F OWNER SOLD AND SERVICED BY MODEL NO SERIAL NO BRODERSON MANUFACTURING CORP STATEMENT OF WARRANTY FOR MOBILE CRANES Broderson Manufacturing Corp BMC warrants its products to be free from defects in material or workmanship at the date of shipment from BMC This warranty shall be effective only when validated by the return to BMC of it s standard form of Warranty Validation Certificate duly completed and signed by the original purchaser from BMC and any subsequent purchaser who buys a BMC product as a new product and then only as to defects reported to BMC in writing within 1 year or 2000 hours whichever occurs first from the date a product is placed in service as evidenced by such warranty validation certificate THIS WARRANTY APPLIES TO ALL PARTS OF BMC S PRODUCTS EXCEPT ENGINES DRIVE TRAINS HYDRAULIC SYSTEM COMPONENTS OR ACCESSORY EQUIPMENT WITH RESPECT TO WHICH BMC MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND NO OTHER WARRANTY OF ANY KIND EXPRESS OR IMPLIED the sole warranties if any with respect thereto being those made by the respective manufacturers thereof THE SOLE REMEDY FOR BREACH BY BMC OF THIS WARRANTY SHALL BE THE REPLACEMENT OF ANY PARTS OF ITS PRODUCTS WHICH WERE DEFECTIVE AT THE DATE OF SHIPMENT OR IF AND ONLY IF REPLACEMENT OF DEFECTIVE
41. RRANTY HEREIN MADE OR IN MAKING ANY ADDITIONAL OR OTHER WARRANTY IN NO EVENT SHALL BMC BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND WHATSOEVER THIS EXCLUSION OF INCIDENTAL AND CONSEQUENTIAL DAMAGES IS INTENDED TO BE INDEPENDENT OF ALL OTHER PROVISIONS OF THIS STATEMENT OF WARRANTY AND SHALL BE GIVEN FULL EFFECT NOTWITHSTANDING THE UNENFORCEABILITY OR FAILURE OF THE ESSENTIAL PURPOSE OF ANY OTHER PROVISION OF THIS STATEMENT OF WARRANTY THE FOREGOING DISCLAIMERS OF WARRANTIES AND DISCLAIMER OF LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES SHALL BE EFFECTIVE REGARDLESS OF WHETHER THE EXPRESS WARRANTY CONTAINED HEREIN BECOMES EFFECTIVE AS PROVIDED IN THE FIRST PARAGRAPH HEREOF Document Number WI SM 002 Rev A Effective August 1 2009 IC 35 2F Operation and Maintenance Manual Addendum for Drum Rotation Indicator Drum Rotation Indication DRI is a new feature added to Broderson Manufacturing Corp cranes shipped after November 1 2011 The following information in bold is supplemental to the Operation and Maintenance Manual Section 1 Description and Specifications Operator s Compartment Standard features Drum Rotation Indicator Provides tactile feedback to operator when hoist drum is rotating Feedback device attached to hoist control handle Feedback is proportional to hoist speed Section 3 Maintenance OPERATOR INSPECTION AND TEST An operator in the course of normal operation should make certain observ
42. TURER S OPERATOR eactualy opetating AND SAFETY MANUALS RELATIVE TO THIS hes MACHINE S SAFE USE 5 This list of rules is only a supplement to AN UNTRAINED OPERATOR SUBJECTS HIMSELF AND OTHERS TO all federal state and local safety rules DEATH OR SERIOUS INJURY that may apply 651 00058 CRANE CONDITION 1 Before beginning operation each day thoroughly inspect the entire crane to be sure itis in good operating condition 2 Inspect load hoist and wedge socket daily We recommend rope inspection replacement and maintenance in accordance with ANSI B30 5 1994 Sec 5 2 4 3 Keep operator s compartment and decks free of mud and grease 4 crane is equipped with a cab keep all window glass clean Keep gauges clean 5 Tools lubricants or rags on the crane should be kept in a secured toolbox 6 Do not use ether for starting Ether is highly flammable and can be ignited by the intake manifold heater grid causing engine damage or operator injury 7 8 WARNING WARNING DO NOT USE CRANE UNLESS CABLE RETENTION PINS NEVER USE ROPE CLIP ON LIVE SIDE OF ARE IN PLACE OVER CABLE SHEAVE DOWN HAUL THE LOAD HOIST ROPE THIS WILL WEIGHT AND HOOK CAN BE PULLED OVER END OF SERIOUSLY WEAKEN THE ROPE DEATH BOOM IF CABLE RETENTION PINS ARE NOT IN PLACE OR SERIOUS INJURY CAN RESULT PERSONS NEAR CRANE CAN BE STRUCK AND SERIOUS FROM THE USE OF A ROPE CLIP ON THE INJURY OR DEATH CAN RESULT 651 0014 HOIST 9 The Rat
43. UR INTERVAL 0 09 o i 50 hour maintenance 50 and 250 hour lubrication Change engine oil and filter Check tension of fan and alternator belts Clean battery Inspect all bolts for tightness Visually inspect all welds for cracks Clean or change air filter every 100 hours if used in dusty conditions Check hydraulic fittings for leaks Inspect air intake system for cracks and leaks 500 HOUR INTERVAL SE qup eel 10 Inspect boom sections for signs of overload excessive wear or other damage 12 13 50 and 250 hour maintenance 50 250 and 500 hour lubrication Change fuel filter element Check antifreeze for protection level and cleanliness Inspect engine fan and belt Clean crankcase vent Adjust engine valve clearance per engine manual after first 500 hrs and at 1000 hrs thereafter Change hydraulic filter elements and inspect oil from elements for water or excessive contamination Check condition of all operational and warning placards Torque mounting bolts on rotation bearing and gearbox winch and axles Replace air filter element Bleed brakes per pg 3 23 3 5 1000 HOUR INTERVAL 50 250 and 500 hour maintenance 50 250 500 and 1000 hour lubrication Adjust engine valve clearance per engine manual Check and adjust engine speed Perform engine maintenance specified in engine manual Change hydraulic fluid and filters and clean breather and reservoir
44. WARM CLIMATE COOL CLIMATE MOBIL ATF D M MOBIL MULTI VEHICLE ATF MOBIL MULTI VEHICLE ATF DEXRON VI DEXRON VI Mobil ATF D M was used at the factory to fill the hydraulic system of your 35 CAUTION Never add kerosene or other thinners to hydraulic oil These fluids have low aniline points and consequently will cause rapid deterioration of certain packings and seals in the hydraulic system CAUTION Serious damage to the pumps will result if they are run with the shutoff valves closed or with insufficient oil level in the reservoir Observe the operation of the machine If the oil is too cold the machine will be sluggish and should be warmed up further before sustained hard work is attempted If the oil is too hot leakage will increase pump efficiency will go down and moving parts will not be properly lubricated If operating temperature is excessive rapid deterioration 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 THE HYDRAULIC SYSTEM If excessive water or other contamination is found in the hydraulic oil the source should be found and fixed and the oil should be changed However there will still be contami nated oil in the hydraulic cylinders This oil should be purged by the following procedure 1 Drain the reservoir open the three gate valves under the reservoir an
45. WEDGE SOCKET When resting the downhaul or sheave block 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 Then lay the hook on the ground by lowering the boom not the hoist 2 14 SAFETY DEVICES There are safety devices on the 35 to maintain control of a load in case of power hydraulic line failure or human error The operator should understand the function and operation of these devices so that a continual check on their performance can be made OUTRIGGER CYLINDER CHECK VALVE A double acting check valve is flange mounted on each of the outrigger cylinders This valve holds the outrigger in the extended position should power or hydraulic line failure occur This valve has no adjustment If an outrigger creeps up while supporting a load there is an internal leak in the valve or in the outrigger piston seal In either case maintenance is required BOOM ELEVATION CYLINDER HOLDING VALVE A single acting holding valve is built into the cylinder barrel This valve holds the boom in the elevated position should power or hydraulic pressure line failure occur This valve is adjustable to hold the desired load If the boom creeps down with loads to maximum capacity this valve should be adjusted If adjustment fails to cor
46. ations inspections and tests to assure that the unit is ready and able to perform safely Daily 1 Check radiator coolant level 2 Check engine oil level 3 Check general condition of tires 4 Visually inspect for loose pins and physical damage 5 Check fuel level 6 Check engine oil pressure 7 Check engine coolant temperature 8 Check battery charging amperage 9 Check hydrostatic transmission temperature 10 Check hydrostatic transmission control switch and accelerator operation 11 Check parking brake operation 12 Check power steering operation 13 Observe chassis for normal driving operation 14 Observe boom operation for normal power and speed 15 Check load line and hooks for damage 16 Check condition of sheaves and load line retainers 17 Check hydraulic oil level 18 Check anti two block system for proper operation 19 Check back up alarm 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 warning light for proper operation as described on page 2 9 23 Check that the Drum Rotation Indicator is functioning Ref Addendum part number 990 30197 TABLE OF CONTENTS SECTION 1 DESCRIPTION and SPECIFICATIONS EE 1 1 Dimensions and Orientation 35 2 1 2 Turning
47. 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 maximum allowable at the indicated radius The greatest load that may be handled by the BMC 35 is 8 000 pounds 3630 kg but only at a 4 foot 1 2 m radius and on outriggers All variances of loads and radii of handling are shown on the crane capacity chart A metal chart is attached near the operators seat and a laminated chart is included in the literature compartment for the express purpose of informing the operator when a load can or cannot be safely handled The capacities shown in the 360 ROTATION columns of the capacity chart apply to the entire 360 degree rotation of the boom and are maximum allowable at the indicated radius The capacities OVER FRONT are limited as follows On Outriggers rotation is limited to an arc of 15 either side of the crane centerline On Rubber Boom rotation is limited to the boom centered over front Pick and carry operations are limited to the boom centered over front Note that the 360 DEGREE ROTATION capacities at some load radii are much less than the OVER FRONT capacities The least stable position of the boom is over the side of the crane Use great care when swinging a load from the front or rear of the crane toward the side of the crane The load must be known in order to assure that the crane will not tip 2 10 CAUTION A capacity load
48. cone Lube Aerosol with Concentrating Tube Hoist 2 Pts 11 WBG Wheel Bearing Grease Hyd Tank 14 Gal 531 2 AMOVIS 2 Hyd Sys Total 18 Gal 681 Torque Hubs Total 2 Pts 1 L Winch Aux Front 8 Oz 250 mL 3 9 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 possible the cable should be rolled off a storage spool and straightened out on the ground in line with the boom If the ground is not clean or the space is too limited the cable can be wound directly 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 Install the cable over the boom tip sheave and route it through the cable retainer loops to the hoist drum 4 Position the hoist drum with the cable anchor on top 5 Insert the cable through the anchor slot and wrap it around the anchor wedge The end of the cable should extend past the wedge by about one inch 6 Slide the cable and wedge into the drum socket and pull firmly on the free end of the cable to set the wedge Seat the wedge securely with a brass or rawhide mallet ANCHOR WEDGE ce 032 81 mm DIA ANNEALED a NE STEEL WIRE JL WIRE SEIZING HOIST CA
49. ct for loose pins and physical damage 5 Check fuel level 6 Check engine oil pressure 7 Check engine coolant temperature 8 Check battery charging amperage 9 Check hydrostatic transmission temperature 10 Check hydrostatic transmission control switch and accelerator operation 11 Check parking brake operation 12 Check power steering operation 13 Observe chassis for normal driving operation 14 Observe boom operation for normal power and speed 15 Check load line and hooks for damage 16 Check condition of sheaves and load line retainers 17 Check hydraulic oil level 18 Check anti two block system for proper operation 19 Check back up alarm 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 warning light for proper operation as described on page 2 9 Weekly Checktire pressure 145 psi 1000 kPa Visually inspect wheel nuts Check lights Check power steering lines for damage Check operation of horn Check operation of hoist brake for smoothness Check outrigger holding valves for operation Check boom cylinder holding valve for operation Check boom telescope cylinder holding valve for operation 10 Check swing gears for looseness or backlash 11 Check operation of windshield wipers if equipped 12 Boom extension if equipped prop
50. d along side base boom section when not in use sheave attaching brackets and pins included Deduct 100 pounds 45 kg from Capacity Chart when boom extension is in stowed position Includes switch and trip arm for Anti Two Block system Net Weight 130 pounds 59 kg Boom Extension 8 Foot 2 4 m Offset Same as standard boom extension except has three settings 0 degrees in line 15 degrees offset and 30 degrees offset Net Weight 150 pounds 68 kg Searcher Hook 2000 pounds 907 kg capacity Swivel hook with spring latch hangs from support structure projecting outward from boom tip Net Weight 30 pounds 14 kg Specifications subject to change without notice OPERATION SAFETY RULES GENERAL 1 Since the manufacturer has no direct control over machine application and operation conformance with good safety practice is the responsibility of the user and his operating personnel 2 3 The operator shall be responsible for those operations under his direct A DANG control Whenever there is any doubt as to safety the operator shall have the authority to stop and refuse to handle YOU MUST NOT OPERATE THIS MACHINE loads until safety has been assured UNLESS YOU ARE QUALIFIED BY TRAINING AND EXPERIENCE TRAINING INCLUDES COMPLETE KNOWLEDGE OF practice which will divert his attention YOUR EMPLOYER S WORK RULES ALL GOVERNMENTAL whil REGULATIONS AND MANUFAC
51. d be replaced Notes 1 When installing an o ring fitting with an adjustable nut and washer be sure to back off the nut washer and o ring as far as possible before threading the fitting into the port Then turn the fitting into the port as far as possible with fingers and turn it backward until it is oriented properly Torque the nut with a wrench while holding the fitting with a wrench 2 Lubricate all seals before assembling 3 Take care not 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 by tightening bolts can usually be stopped by replacing the seals in the component Seal and packing replacement is the only maintenance which owners should attempt on component parts unless they have a well equipped shop with mechanics trained in hydraulic component overhaul Leakage in the pump suction line may not cause oil to appear externally but may allow air to enter the line during operation The air entrained in the oil will cause pumps to be noisy and if allowed to continue can damage the pump If a pump becomes noisy immediately check the fluid level in the reservoir and be sure all suction fittings are tight If noise continues squirt hydraulic fluid on the suction connections Listen for a change in the noise and watch for oil being sucked into a small opening in the connect
52. d remove the two filter elements and the strainer 2 Disconnect the following hoses The four hoses at the reservoir the return hose at the inlet of the smaller filter the case drain hose at the hydrostatic transmission piston pump the two pressure hoses at the double gear pump the two pressure hoses at the right hand wheel motor 3 Allow the oil to drain from the hoses and be careful to prevent dirt from getting in the hoses 4 Blow out the oil cooler with compressed air through the hoses attached to it 3 21 10 11 12 13 14 15 16 17 18 19 Clean the reservoir and strainer and replace the filter elements and hoses except the return hose at the inlet of the smaller filter and the case drain hose at the hydrostatic pump Attach 3 4 return hose at the hydrostatic pump case drain port and run it into a waste oil sump or barrel Also run the return hose disconnected from the smaller filter into the waste oil sump or barrel Do not plug these hoses Close the small gate valve under the reservoir and plug the case drain hose that is disconnected from the hydrostatic transmission pump Leave the two large gate valves open Fill the reservoir with clean oil Do not start the engine or move any controls until the proper point in this procedure If the piston pump has been removed replaced or repaired follow the start up procedure on page 3 17 Monitor the oil level and do not allo
53. damage to the crane and endanger people and property The operator who uses this key in an emergency should use good judgment WARNING Even though the crane is equipped with anti two block device we strongly recommend that the operator always watch the downhaul and stop lifting before two blocking occurs Two blocking can break the load hoist rope and let the load fall This could cause death or serious injury 2 15 HOIST BRAKE AND HOLDING VALVE The hoist has an automatic brake in the gearbox and a holding valve mounted directly on the hoist motor to hold the load A clutch in the gearbox allows the winch to turn freely in the RAISE direction The brake is pilot released in the LOWER direction and should allow smooth stops of a load on the hoist OPTIONAL EQUIPMENT BOOM EXTENSION CAPACITY CHART The boom extension will increase the main boom length by 8 feet 2 4 m The main boom and boom extension capacity charts must both be considered when using the boom extension The smaller capacity specified by the two charts must be used Do not pick and carry with the boom extension installed INSTALLING BOOM EXTENSION ON TIP OF BOOM 1 2 10 11 12 13 14 Set the outriggers If the sheave block is installed remove it Pay out 20 feet 6 m of load line Lower and retract boom and position over front Remove load line from tip sheaves and lay over left hand side of boom Make sure the front stow pin is in p
54. e sudden stopping by the system can cause dangerous load swinging which can cause death or injury to personnel or property damage by impact with the load or by the crane tipping 2 9 WARNING The Rated Capacity Limiter can suddenly stop the BOOM LOWER and SWING functions causing the load to bounce or swing Use great care when handing a load near capacity limits or near a two blocking condition CRANE CAPACITY CHART DEFINITIONS AND RULES The load radius is the horizontal distance from the centerline of boom rotation the center of the turntable when it is level to the vertical load line with the load suspended Because of deflections of the boom and carrier the load radius increases when a load is hoisted from its resting place The load radius may be measured with a measuring tape If the desired load radius falls between two load radii on the chart it is recommended to use the load radius with the lower capacity and not try to interpolate between the numbers Load capacity ratings on this equipment are 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 conditions Any unfavorable environmental condition such as soft sloping or uneven terrain high wind or hazardous surroundings constitutes a deviation The main boom capacities are given in direct relation to the radius at which the load is
55. e symbols used to label switches and indicators on BMC cranes Most symbols are derived from the ISO 3767 1 1998 E standard Not all symbols will be included on your BMC crane On Start af t Windshield washer switch Off Stop Windshield defroster switch O E3 Battery not charging Heater switch Hour meter Air conditioner switch Bik Read operator s manual Ventilation fan switch 0 Sound level notification Parking brake is set Headlights main high beam 4 wheel round steer Work light Rear wheel steer Hazard lights Crab steer Rotating beacon or strobe lights 2 wheel drive Turn signals left right 4 wheel drive Windshield wiper switch 4 6 Steering wheel tilt 2 18 Tire pressure Engine oil pressure low Lift point Engine coolant fill location Tie down point Engine coolant temperature high Transmission oil fill location Engine coolant low level mark Transmission oil pressure C T Engine air filter restriction indicator Transmission oil temperature Engine start Brake fluid fill location eG d Engine idle set Hydraulic oil low level mark Check engine OO de 4 Hydraulic oil filter restriction indicator Stop engine Hyd
56. e the sheave block and rewind the cable on the drum as in Steps 7 11 Never lift more than the rated load on the Capacity Chart for the parts of line and type of wire rope being used Lubricate the cable as recommended in the Wire Rope Lubrication section Inspect maintain and replace the cable in accordance with ANSI B30 5 1982 Section 5 2 4 JIC SCHEMATIC 3 TWA away QION
57. ed weighing a total of 40 pounds 18 kg The total load is 4500 60 40 4600 pounds 2086 kg Looking at the 360 ROTATION ON RUBBER column we see that the load is too heavy for this condition The OVER THE FRONT ON RUBBER column shows that we can lift 5100 pounds 22120 kg at a 6 foot 2 m load radius However we cannot get that close to the load so the load cannot be lifted this way This leaves the ON OUTRIGGERS columns The outriggers should always be used whenever possible anyway We see that we can lift up to 5850 pounds 2420 kg at a 6 foot 2 m load radius either over the front or over the side Checking the chart again we see that the load is within the deck load limit of 6000 pounds 2720 kg Note The travel speed with the load must be limited to 3 mph 4 km h or less if conditions dictate REMEMBER THAT AS THE BOOM IS LOADED DEFLECTION OF THE BOOM TIRES ETC WILL INCREASE THE LOAD RADIUS SO BE CONSERVATIVE IN YOUR CAPACITY ESTIMATE CRANE CAPACITY CHART FOR IC 35 2F USE 0 FOR STRAIGHT BOOM EXTENSION USE 0 15 OR 30 FOR OFFSET BOOM EXTENSION 70 CRANE CAPACITY CHART CAPACITIES APPLY TO OPERATION ON FIRM LEVEL SURFACE 60 IC 35 2F LOAD MAIN BOOM OR EXTENSION CAP
58. ed Capacity Limiter must be checked before each shift and after each setup for the proper operating configuration on the display It must be inspected before each shift and tested with a known load at least once a month as described in the RCL operation manual 2 1 LIFTING 1 10 11 12 13 Always refer to Crane Capacity Chart in operators compartment before handling load Do not exceed load ratings Under some conditions the standard capacity ratings cannot be recommended and must be adjusted downward to compensate for special hazards such as weak supporting ground wind hazardous surroundings operator inexperience etc The weight of the load should always be known Be careful to prevent load swinging A swinging load can cause instability or loss of control of the load aware that the Anti Two Block System and the Rated Capacity Limiter can cause sudden stopping of boom movement which can cause the load to swing Swing the boom slowly whenever these systems might stop the boom Do not allow anyone to put any part of his body under a load The load may WARNING lower or fall if there are damaged parts in the crane Also the load drop BE PREPARED FOR SUDDEN MOVEMENTS short distance due to thermal contraction DEATH SERIOUS INJURY OR PROPERTY DAMAGE CAN RESULT FROM UNEXPECTED CHANGES IN LOAD of the hydraulic oil in the cylinders 651 00161 Do not use crane to
59. erated relief Broken mechanical connection to the pump shaft Worn or defective hydraulic pump ATTACH PRESSURE GAUGE HERE NO RIGHT REAR OUTRIGGER HOIST INLET OUTLET RIGHT FRONT RELIEF SECTION OUTRIGGER LEFT FRONT OUTRIGGER INLET OUTLET LEFT REAR RELIEF SECTION TELESCOPE OUTRIGGER OPTIONAL FRONT WINCH 22 SWING BOOM i I 1 LS 1 11 oeque ATTACH H AN AN AN AN PRESSURE M Ww d LY 1 GAUGE HERE T RELIEF PRESSURE RELIEF PRESSURE 2600 PSI ADJUST SCREW AND 2250 PSI 179 Bar 155 Bar The relief pressure for the hoist valve can be adjusted similarly to the boom circuit Connect a 3 000 psi 200 bar gauge to the test fitting on the mid inlet section of the valve Disconnect both hoses at hoist motor and install plugs Do not connect hoses together Operate hoist control in either direction Run engine at full throttle Adjust relief valve to 2250 psi 155 bar at full flow 3 25 BOOM CYLINDER HOLDING VALVE A holding valve is built into the base of the boom lift cylinder barrel This valve is designed to hold the boom in position should loss of power or pressure line failure occur To check the boom lift cylinder holding valve set the outriggers place the boom i
60. erly pinned with retainers in place 13 Clean all glass if equipped and check for cracks C uS WARNING Vapor can form inside a fuel tank and cause a buildup of pressure This can result in a sudden expulsion of gasoline and vapor from the filler neck when the gas cap is removed from a hot tank Remove cap slowly Fuel spray may cause injury 3 4 IC 35 MAINTENANCE CHECKLIST Refer to the component maintenance section of this manual and to the engine operator s manual for complete instructions 50 HOUR INTERVAL 50 hour lubrication as shown on lube schedule Inspect wire rope thoroughly Inspect for physical damage and leaks Check tire pressure and condition 145 psi 1000 kPa Clean radiator fins Change engine oil and filter after first 50 hours and at 250 hours thereafter Change the hydraulic filters after the first 100 hrs and at 500 hrs thereafter Check rotation gear and pinion fit and gear train backlash Check rotation bearing and gearbox bolt tightness Check axle mounting bolts and pins Torque wheel mounting nuts 60 ft 105 80 N m front 200 ft Ibs 270 N m rear Check for loose pins or pin retainers Check steering lines for damage Inspect sheaves and hooks for damage or excessive wear Perform a load test according to the Rated Capacity Limiter User Manual Check operation of outrigger warning light as described on page 2 9 250 HO
61. ese tires do not change the overall height or ground clearance Net Weight 240 pounds 109 kg Solid Rubber Tires Non Marking Same as solid rubber tires except non marking Net Weight 240 pounds 109 kg Foam Filling of Tires Standard tires foam filled to prevent flats Net Weight 312 pounds 142 kg Spare Tire amp 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 area A maximum of 6 000 pounds 2720 kg may be carried on the deck when centered over or to the rear of the front axle Nine stake pockets are provided in deck and nine 1 3 inch 34 mm outside diameter pipe stakes Outriggers Four hydraulic outriggers with box beam construction Independent controls for each Hydraulic cylinders are equipped with direct connected holding valves Pad dimensions are 6 inches 152 mm by 8 inches 203 mm Lifting Rings Includes four lift rings one at each corner of the chassis for attaching lifting sling cables Front Pulling Eye Heavy eye in front bumper provides for attachment of hook block so main winch line can be used for pulling loads at or near floor level 1 7 Headlight and Taillight Grilles Consists of welded steel protective grilles for headlights and taillights Easily removes or swings out of way for replacing bulbs Optional Chassis Accessories Auxiliary Winch Optional worm gear winch m
62. fter working on the crane After working on the hydraulic system remove air from the lines and cylinders involved by cycling them full stroke with the engine running until the functions operate smoothly 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 and computer and the engine electronic control module When welding on the boom or turntable assembly remove the cable reel and any other electronic components bolted to these assemblies When using pressure spray to clean the crane cover all electronic components with sheets of plastic to protect them from spray 3 2 MAINTENANCE The Broderson 1C 35 Industrial Crane will perform better and longer if a program of inspection lubrication adjustment and general preventive maintenance is followed We recommend the following schedule NEW UNIT INSPECTION AND TEST The following inspection and test should be made before placing the unit on the job This will insure that no damage or loss of operating capability occurred during shipment Check for physical damage Check for leaks at fittings and drips under chassis Check radiator coolant level Check engine oil level Check hydraulic oil reservoir level Check fuel tank level Check tire pressure Check for loose pins bolts and retainers Operate foot brake Check for operation 10 Operate park brake Check for o
63. g or stopping imposing undue shock loads on the equipment especially when handling heavy loads The control should be slightly actuated to begin movement and then slowly increased to desired speed The throttle may be moved to high position for maximum operating speed 9 Release accelerator during idle time mc NORMAL GAUGE READINGS Engine Coolant Temperature Allow engine to warm up before operating crane Stop engine if temperature exceeds 220 F 104 C Engine Oil Pressure Stop engine if oil pressure does not exceed 10 psi 0 7 bar at low idle Pressure varies with engine rpm Voltmeter The voltmeter should read about 13 to 14 volts when the engine is running Transmission Temperature Normal operating temperature is in the range of 75 F to 200 F 24 C to 93 If the reading on the gauge which starts at 100 F 38 exceeds 200 F 93 C shut down the unit and determine the cause of excessive heating Level Indicator Do not operate crane if it is not level 2 7 Fuel Do not allow fuel tank to become empty The engine will be difficult to restart and may require bleeding of diesel injectors Keep tank full when idle to prevent conden sation in tank WARNING Vapors can be formed inside a fuel tank and cause a buildup of pressure that can result in a sudden expulsion of gasoline and gasoline vapors from the filler neck when the fuel cap is removed from a hot tank Remove cap slowly Fuel s
64. genuine OEM parts as required by EPA regulations MAJOR ENGINE SERVICING OR OVERHAUL Major servicing or overhaul is beyond the scope of this manual Consult authorized engine service manual or rely on an authorized engine service center 3 27 MECHANICAL ADJUSTMENTS FASTENERS All fasteners in the IC 35 should be checked and retightened if required as a part of the preventive maintenance program Particular attention should be given to the axle wheel and hub mounting bolts pump mounting bolts rotation bearing bolts rotation gearbox bolts and hoist bolts All bolts used in assembly are heat treated Grade 5 except the bolts attaching the rotation bearing to the mainframe and turret which are Grade 8 socket heads The torque chart on the next page can be used on all bolts ROTATION GEARBOX The rotation gearbox assembly is attached to the chassis top plate by four capscrews It is held in proper engagement with the external teeth on the bull gear by two jackscrews in front of the 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 teeth If adjustment is required loosen the gearbox mounting bolts and the side bolts Tighten the two front jackscrews until proper adjustment is obtained Tighten the mounting bolts and the side bolts Lock jackscrews and bolts into position WHEEL BEARING
65. he element Make sure the gaskets and element fit properly and reassemble being careful not to allow any dust into the intake pipe Do not remove an element just for inspection This may do more harm than good You cannot judge the element condition 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 will make more frequent service necessary If there is a significant amount of dust in the dust cup when it is cleaned every 50 hours clean the element every 100 hours and replace every 200 hours or more frequently in extremely dusty conditions Excessive exhaust smoke or loss of power may indicate a plugged filter COOLING SYSTEM Check the level of coolant in the radiator overflow tank daily Add a mixture of antifreeze and distilled water 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 the antifreeze protection level every 500 hours Every two years flush the cooling system and replace the thermostat and coolant Pressure test the system as specified by the engine manufacturer SPARE PARTS LIST A spare parts list including oil filter fuel filter etc may be found in the Parts Manual under Engine Installation Replace engine parts only with
66. in the operator compartment is in FORWARD and the accelerator pedal is depressed the pump starts delivering oil to the wheel drive motors for forward travel When the accelerator is released the pump blocks the flow and the wheel drive motors stop If this is done on level ground the crane will stop and stand still If this is done on an incline the crane will stop but then creep down the incline due to oil leaking through the wheel drive motors ALWAYS apply the parking brake when the crane is stopped When parking on a slope also set the outriggers or place wheel chocks on the downhill side of the wheels A positraction flow divider is located in the line between the pump and drive motors When a wheel is lifted off the ground is on ice or for any reason starts to spin 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 the wheel with traction If the unit stops moving the engine speed will have to be increased to resume travel The crane is equipped with an oil cooler that will allow it to operate properly when the ambient temperature is slightly over 100 38 An oil temperature gauge is provided just ahead of the steering wheel The sensor for this gauge is located in the return line to the oil tank If this gauge reads above 200 F 93 C the unit should be shut down and the
67. ion When the reservoir is full the shutoff valve is open and all suction connections are tight most pump noises will disappear If they do not a worn or faulty pump is indicated On a routine basis all hoses should be checked for wear deterioration and physical damage Defective hoses should be replaced for maximum economy for the user 3 24 CONTROL VALVE ADJUSTMENTS The crane control valve has two relief valves to protect the hydraulic components The relief valves are adjustable and should be checked and set as follows 1 Boom and outrigger circuits 2 600 psi 179 bar at full flow 2 Hoist circuit 2 250 psi 155 bar at full flow BOOM AND OUTRIGGER CIRCUITS Remove the 3 8 tube cap from the test fitting on the left hand side of the control valve and install a 3 000 psi 200 bar test gauge To obtain full flow reading run pump at full speed and actuate BOOM control lever to LOWER position and hold until maximum reading is made pressure of 2 600 psi 179 bar is not possible check the following 1 Low oil level in the 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 8 mm each way from neutral 4 Adjust relief valve by removing cap on of relief cartridge and turning socket head screw clockwise to increase pressure or counter clockwise to lower pressure Foreign particle in pilot op
68. ion is controlled by the engine speed which is controlled with the accelerator pedal A pedal activated brake is provided to hold the machine on slopes Normal braking is provided by the hydrostatic transmission when the accelerator pedal is released The brake pedal actuates disc brakes attached to each torque hub The parking brake is applied by a lever on the dash The steering wheel is directly mounted to the steering control unit of the all hydraulic power steering system The system will provide limited steering if the engine stops running The Rated Capacity Limiter display and input panel are mounted on the dashboard Instructions are in the RCL Operation Manual and additional information is in the Operating the Crane section the Crane Capacity section and Maintenance Section of this manual CONTROL FUNCTIONS The controls for operating the outriggers boom swing boom elevation 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 controlled and the movement resulting from each handle actuation RIGHT EXTEND LOWER DOWN DOWN DOWN DOWN A CAUTION OUT LOWER 4 T T A A REAR 8 FRONT R FRONT REAR oR FRONT SWING TELESCOPE BOOM 1 RIGHT 4 RIGHT 0 6290305 wincH HOIST v pue ww LEFT RETRACT RAISE UP R UP R UP R UP
69. lace and the attach pins are removed from the lugs on the boom tip and the mating lugs on the boom extension Remove the rear locking pin and swing the boom extension away from the rear end of the boom until the attaching lugs mesh on the right hand side of the boom Insert the attach pins in the right hand lugs and retain them with the hairpin cotters Remove the front stow pin and swing the boom extension around to the front until the left hand lugs mesh Insert the left hand attach pins in their lugs and retain them with hairpin cotters To insert the fourth pin it may be necessary to rock boom extension side to side or up amp down Replace the lock pin and stow pin in their brackets for storage and insert their hairpin cotters Lay the load line over the main boom and extension tip sheaves and insert the cable retainer pins and cotters Install the downhaul weight wedge socket and swivel hook on the load line if they are not already installed Disconnect the anti two block wiring cable from the switch on the main boom tip and connect it to the cable connector on the boom extension base 2 16 STOWING THE BOOM EXTENSION 1 Reverse the procedure described in steps 7 through 14 in the installation procedure above 2 Lay the load line back in the tip sheaves and insert both retainer pins and cotters 3 Replace all of the pins in their lugs for storage and insert their cotters FRONT AUXILIARY WINCH The front auxiliary
70. may be carried on the boom or a capacity load may be carried on the deck DO NOT carry capacity deck loads and capacity boom loads at the same time CAUTION The capacities of this crane are based on all outriggers being FULLY EXTENDED to a FIRM LEVEL surface The crane may tip at less than capacity loads if operated in the following manner A Outriggers only partially extended and resting on curbing shoring etc If the outriggers are not all the way DOWN they are not all the way OUT B Outriggers extended to a surface that appears to be firm but is unable to support the outrigger pad at full rated loads Examples of this type surface are 1 Thin or cracked blacktop or concrete 2 Dirt that appears dry and firm on top but is moist or unpacked beneath the surface 3 Dirt with a frozen but thin crust C Crane operated on a hill or sloping surface Crane will tip at less than rated capacity when load is lifted on downhill side CAPACITY EXAMPLE Refer to the IC 35 2F Capacity Chart on the following page load weighing 4500 pounds 2040 kg is to be lifted onto the 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 on one part line so the sheave block is required The charts show the weight of the standard sheave block to be 60 pounds 27 kg The rigger says that two slings are requir
71. n the horizontal position over the front of the crane and raise rated load about one foot above the ground using the boom lift cylinder not the hoist An example of rated load for the 35 2 is 4 150 pounds 1830 kg at 8 foot 2 5 m load radius with outriggers extended and the boom over the front Turn the engine off and move the BOOM lever to the LOWER position If the boom moves down adjust the holding valve WARNING Before working on the holding valves or plumbing to the boom cylinders always relieve trapped pressure by lowering the boom fully turning off the engine and cycling the BOOM and TELESCOPE lever To adjust the holding valve loosen the jam nut on the adjusting screw 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 leakage or the valve may be malfunctioning EXTENSION CYLINDER HOLDING VALVE A holding valve is directly connected to the base of the primary extension cylinder rod The valve is designed to hold the boom in position should loss of power or pressure line failure occur The holding valve should be checked with the boom elevated to the maximum angle and the boom extended to a 4 foot 1 2 m load radius An 8 000 pound 3630 kg load on a two part line is required for this test Use the hoist to lift this load about six inches above the ground The radius
72. nd lowering each outrigger about three inches The light should come on when an outrigger is up CRANE CAPACITY Before lifting loads the operator must read the Crane Capacity Chart and adhere to the load capacities and radii of handling given The information provided on this chart is based on stability structural strength and hydraulic capacity To operate the crane safely the operator must know the weight of the load and handling devices and the radius of the lifting operation The crane must not be loaded beyond the specifications of the capacity chart except for test purposes as provided in ASME B30 5 Section 5 2 2 The person responsible for the lift must be sure that the load does not exceed the crane ratings at any radius at which the load may be during the entire lifting operation The weights of the hooks blocks downhaul weights slings and other handling devices must be added with the load Please read the RCL Operation Manual 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 overload conditions The use of the Rated Capacity Limiter does not replace the requirements of the preceding paragraph Verified weights and measured radii must take precedence over the Rated Capacity Limiter readings The Rated Capacity Limiter displays a load load radius and boom angle that are obtained from electronic calculations using readings f
73. nder the tank Be sure shutoff valves are fully opened before starting engine Remove the filter elements and catch the hydraulic oil in a clean container Pour the remaining oil out of the old 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 excessive particles are found the source should be located and fixed and the oil should be purged Lubricate each new element seal and install the new elements Open the shutoff valves Run the engine and check for any leaking around the seals The hydraulic oil should be changed every 1000 hours or once a year whichever is sooner Wash the oil tank and filters before changing the oil Retract the telescope boom lift and outrigger cylinders Leave the shutoff valves open and remove the drain plug Catch the oil and dispose of it properly Clean the breather element in the fill cap with solvent and compressed air Clean out the tank with solvent and compressed air Replace the filters as described previously and refill the tank with new hydraulic oil that meets the specifications in the table below Start the engine and run it at low idle for 15 minutes to filter the new oil Then cycle all of the hydraulic cylinders at low idle and low pressure Add hydraulic oil to the dipstick level mark if necessary with cylinders retracted 3 20 APPROVED HYDRAULIC FLUIDS
74. ng and hair away from moving parts To prevent falls clean areas of crane that are stepped on for access to crane parts Wear slip resistant footwear Avoid placing body parts in pinch points Use tools that extend through the pinch points when possible Block the moving parts securely when it is necessary to work in pinch points When inflating or adding air to a tire place a tire cage over the tire and use a clip on inflater chuck with an extension hose that will permit standing behind the tire tread when inflating Do not work on any machine that is supported only by jacks or a hoist Always use adequate blocks or jack stands If it is necessary to work on the boom or outriggers in an unstowed condition block them to prevent them from dropping unexpectedly 3 1 16 17 18 19 20 21 22 23 24 Use a hoist when lifting components that weigh 50 pounds 23 kg or more Follow all hoist and rigging safety rules Do not use lower grade fasteners if replacements are necessary When reinstalling wiring or plumbing after repairs be sure that it will not be damaged by rubbing against sharp rough or hot surfaces or edges Never use a rope clip on live side of the load hoist rope This will seriously weaken the rope Death or serious injury can result from the use of a rope clip on the hoist rope Replace any instruction or warning placards that are lost or damaged Always replace all guards and covers a
75. one fold out window in rear to provide flow through ventilation Defroster fan and dome light included Net Weight 180 pounds 82 kg Cab Heater Heater with two speed fan for units without All Weather Cab Net Weight 15 pounds 7 kg 1 8 Operator Guard Tubular steel weldment with heavy expanded steel mesh top bolts over operator s compartment Net Weight 60 pounds 27 kg Operator Guard Cover Vinyl cover with windows to go over operator guard for inclement weather operations Net Weight 12 pounds 6 kg Floormat Ribbed vinyl mat with foam backing for operator comfort Electrical System Standard Electrical Group 12 Volt DC Battery Group 24 with 550 CCA rating Lighting Group Consists of two headlights taillights and 12V horn activated by button on instrument panel Instrument Group Located at operators station and includes fuel gauge ammeter oil pressure water temperature and hydraulic oil temperature gauges Hourmeter records hours only during actual engine operation Outrigger Alarm System 112 dB alarm with alternating two tone sound is actuated by a switch when the outrigger down controls are operated Back up Alarm Provides pulsating 97 dB sound from solid state alarm when ignition is on and transmission is in reverse Optional Electrical Accessories Strobe Lights Two yellow strobe lights mounted on turret for high visibility Flash 60 120 times per minute Draw 1 2 amps each Incl
76. ounted behind front bumper with a single lever control at the operator s console Hydraulic powered to provide bare drum line pull of 3 000 pounds 1360kg at 20 ft min 6 m min Winch drum is 3 5 inch 89 mm dia by 6 2 inches 159 mm long The winch includes 80 feet 24 3 m of 5 16 inch 7 94 mm wire rope hook and four way roller guide Net Weight 120 pounds 55 kg Pintle Hook T 60 A Holland pintle hook mounted on rear frame member Rated for 10 000 pounds 44 kN pull and 2000 pounds 8 9 kN vertical load Net Weight 7 pounds 3 kg Lifting Sling Sling to attach to lifting rings Net Weight 20 pounds 9 kg Rear View Mirrors One right hand and one left hand mirror 6 152 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 Compartment Standard Operator control station provides one position access to all chassis and crane functions Includes adjustable operator s seat and retracting seat belt Operator s Compartment Accessories All Weather Cab Consists of rigid mounted canopy section and removable hinged door with safety glass Rugged canopy structure with laminated glass front and top Door is equipped with a keyed lock to protect operator s station Cab door adds 4 inches 102 mm to crane width on operator s side Includes heater with two speed fan and 12V electric windshield wiper Includes sliding window in the door and
77. peration and warning light 11 Operate throttle Check for 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 operation 18 Test drive unit and check for normal operation 19 Check operation of hydraulic outriggers 20 Check boom swing 21 Check boom elevation 22 Check boom extension pay out hoist cable during power extension 23 Perform cable break in procedure 24 Check anti two block system for proper operation and cutout of boom functions 25 Perform a load test according to the Rated Capacity Limiter Operation Manual 26 Check the outrigger warning light for proper operation as described on page 2 9 c0 00 WARNING When the Rated Capacity Limiter is inoperative or malfunctioning it must be repaired as soon as reasonably possible When a lift must be made without a properly functioning RCL the designated lift supervisor must establish procedures for determining load weights and load radii and conducting the lift safely 3 3 OPERATOR INSPECTION AND TEST An operator in the course of normal operation should make certain observations inspections and tests to assure that the unit is ready and able to perform safely Daily 1 Check radiator coolant level 2 Check engine oil level 3 Check general condition of tires 4 Visually inspe
78. place defective parts If severe scoring is indicated remove complete pump unit disassemble and inspect for damage Inspect coupling for sheared spline Remove relief valve Clean or replace Fill oil reservoir Check and fix suction line leaks Replace filter element Disassemble inspect and repair See Steps 1 B 1 D 2 A See Step 1 L Close bypass valve Fix or replace solenoid wiring Disassemble inspect and repair Remove clean and replace Pump should be disassembled only by experienced hydraulic pump repair personnel preferably at a Sauer Danfoss Service Center 3 19 CARE OF HYDRAULIC OIL The hydraulic system contains many highly pressurized precision components To protect these it is very important to keep the hydraulic oil clean at proper temperature within the oil specification and to the proper fill level The 35 is equipped with 100 mesh suction strainer 10 micron suction filter a breather filter a 10 micron return line filter and a 14 gallon 53 L tank The filters must be changed after the first 100 engine hours to eliminate the contaminants generated during run in Thereafter they are to be changed at every 500 hour maintenance interval The filters are located under the deck cover Clean the filter and the surrounding parts with steam or pressure washer before changing to prevent dirt from falling into the clean oil tube To minimize oil loss close the shutoff valves u
79. pray may cause injury RATED CAPACITY LIMITER RCL A rated capacity limiter is installed on the crane to assist the operator in estimating loads and measuring load radii Please read the RCL Operation Manual for complete instructions on operation of the system Following are some additional operating tips Always be aware that the RCL can stop boom movement at capacity load conditions and in two blocking conditions Use good judgment in controlling the speed of boom movements to prevent shock loads and swinging loads If the RCL system stops the crane movement there are various remedies that may be used to restart operation the hook is two blocked it should be lowered using the HOIST control if safe The BOOM RAISE and TELESCOPE RETRACT may also be used if this is safer In some unusual circumstances it may be necessary to swing the boom before lowering the load If you are sure this will not cause an overload you can turn the override key that is under the left instrument panel 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 changed TELESCOPE RETRACT may also be used and swing may be used if safe as described in the preceding paragraph DO NOT use the BOOM RAISE control as this may increase the overload If the load is at the maximum allowable load radius the boom can be raised or ret
80. pressure is low This eliminates steering wheel kickback when the steering wheel is released The steering system pressure relief valve inside the priority valve is set at 1250 psi 86 bar at the factory and should not need adjustment 3 13 STEERING SYSTEM STEERING VALVE PR STEERING ees Oc CYLINDER H t VALVE 7 7 LOAD SENSING LINE gt LS T r ze a CF P PRIORITY VALVE VALVE WINCH 4 VALVE n Y O OIL TANK O O PUMP NA 4 3 14 PROPULSION SYSTEM The propulsion system is a closed loop hydrostatic transmission The variable volume piston pump is driveline driven from the engine crankshaft The pump can deliver up to 34 gpm 129 L min or 4 000 psi 276 bar to the wheel drive motors The flow from the wheel drive motors returns directly to the pump inlet not the reservoir The built in charge pump maintains approximately 220 psi 15 bar of pressure to the intake side of the piston pump whenever the engine is running Excess flow from the 9 gpm 34 L min charge pump combines with case drain flow and goes through the cooler and returns to tank When the transmission control switch
81. racted 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 hoisted down If the boom is fully lowered until it stops about 0 the RCL will show an overload condition because the boom lift pressure sensors cannot read a useful pressure in this condition To remedy this raise the boom slightly On the other hand if the boom is fully raised about 70 the RCL may show an overload condition because the pressure in the boom lift cylinder is sensed to be an overload To correct this condition the override key may be turned and held and the boom lowered just slightly Then check for other conditions before lowering further If there is a malfunction of the RCL or Anti Two Block system that causes loss of boom movement and cannot be remedied by the procedures above the override keyswitch under the dashboard may be required to move the boom WARNING We recommend the emergency override switch be used with discretion Improper or careless use of this switch can cause damage to the crane and endanger people and property The operator who uses the switch in an emergency should use good judgment 2 8 There is a light on the dashboard to warn that one or more outriggers is not fullyextended when using the On Outriggers setup on the RCL Check the light daily when the outriggers are down and there is no load on the hook by raising a
82. raulic temperature gauge Wait to start engine preheat grid heater glow plug switch Cr cr Hydraulic oil temperature high Gas fuel only Hydraulic oil pressure gauge OR hydraulic oil pressure low Diesel fuel only Ier Positive polarity Fuel level gauge Negative polarity Drain 2 19 10 11 12 13 14 15 MAINTENANCE SAFETY RULES Lower load and boom shutdown engine remove key and put it in a safe place Place warnings on the ignition switch and crane controls to prevent unauthorized starting or movement during maintenance Disconnect battery when disabling crane or when welding on crane Relieve hydraulic pressure when working on hydraulic parts by cycling the controls with the engine shut down Allow fluids and parts to cool before working on them Read maintenance instructions before beginning work Do not check for hydraulic leaks with hands If a mist of hydraulic oil is noticed around a line or component use cardboard or other material to check for location of leaks High pressure fluid leaking from a small hole can be almost 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 Wear safety glasses and shoes Do not wear loose fitting or torn clothing Remove rings and other jewelry Wear heavy leather gloves when working on wire rope Keep clothi
83. rect the problem there is an internal leak in a holding valve or a hydraulic cylinder Refer to the maintenance instructions BOOM EXTENSION CYLINDER HOLDING VALVE 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 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 an internal leak in the holding valve or the hydraulic cylinder Refer to the maintenance instructions ANTI TWO BLOCK DEVICE The anti two block device prevents damage to hoist rope or machine components from accidentally pulling load hook against boom tip There is a pivot arm at the boom tip that is moved upward by the load hook as it approaches the boom tip An electric switch connected to a hydraulic solenoid valve dumps the HOIST RAISE TELESCOPE EXTEND BOOM LOWER SWING LEFT and SWING RIGHT circuits No other circuits are affected These circuits are returned to normal operation by operating the HOIST LOWER TELESCOPE RETRACT or BOOM RAISE control An emergency override switch is provided so the boom can be operated in case of system failure This key operated switch is located under the instrument panel WARNING We recommend the emergency override switch be used with discretion Improper or careless use of this switch can cause
84. rmine safe practices using precautions such as the following The boom shall be centered over front axle Use shortest boom practical Carry load as close to ground as practical Reduce travel speed to suit conditions 2 mph 3 km h maximum Maintain specified tire pressures Avoid sudden starts and stops Provide tag or restraint lines to snub swinging of the load Hand held tag lines should be nonconductive Do not carry heavy boom loads and deck loads at the same time Do not pick and carry with boom extension installed Do not exceed the OVER FRONT ON RUBBER capacity gt When raising the boom or moving the unit with boom elevated be sure there is adequate overhead clearance for boom 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 properly match condition of road surface and deck load C Remove load hook from load before traveling Cranes with rear steering require close watch because of tail swing when the chassis is turned in tight quarters WARNING OPERATOR MUST KEEP ALL PARTS OF HIS BODY INSIDE OPERATORS COMPARTMENT WHILE OPERATING THIS UNIT A 651 00045 Every effort has been made to make the BMC Industrial Crane a stable vehicle However with the rigid front axle and the unsprung oscillating rear axle suspension the operator must take care to
85. rom pressure length and angle sensors These readings cannot be exact and should be treated as estimates general the smaller the load and 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 experience or accepted safe operating practices The operator is solely responsible for operation of the crane Setting the Rated Capacity Limiter for the configuration of the crane is necessary before starting a lift If incorrectly set the system will not alert the operator to an impending overload possibly resulting in the loss of life or destruction of property If the Rated Capacity Limiter is inoperative or malfunctioning repair or recalibration of the unit must be done as soon as reasonably possible and the person responsible for lifts must establish procedures for determining load weights and radii and conduct the lifts according to the second paragraph above The Rated Capacity Limiter is designed to stop crane functions that could cause an overload or two blocking These are BOOM LOWER TELESCOPE EXTEND HOIST RAISE SWING LEFT and SWING RIGHT Great care must be exercised when handling a load near capacity or near two blocking condition If the boom is being lowered or swung the load will tend to swing if the Rated Capacity Limiter stops the boom movement If the load is moving too fast th
86. s may bypass this system and create dangerous condition Notice the load limit for each hoist rope arrangement The keeper 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 the dead end clamped in the block as shown in the figure below WIRE ROPE INSTALLATION ROPE STUB amp CLIP FURNISHED BY BMC RIGHT WRONG KINK 21 2 63 5 mm N WIRE ROPE END SHOULD EXTEND APPROXIMATELY 2 1 2 63 5 mm UP LEAN INTO HOLE IN DOWN HAUL WEIGHT BY TIGHTENING BOLT WRONG For loads above 4 000 pounds 1815 kg the sheave block must be used The wedge socket should be pinned to the boom sheave plates as shown in the figure 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 a number of cycles The sheave block should hang straight and the top of the block should meet the boom sheave plates squarely when pulled up snugly 2 13 TWO PART LINE REEVING UB B a Se RETAINER PIN W COTTER e WEDGE SOCKET PIN W COTTER
87. tepping on the brake pedal This combines hydrostatic braking with the action of the disc brakes Operating both accelerator and brake pedal with the right foot is preferred Using the left foot on the brake pedal while simultaneously using the right foot on the accelerator will allow the engine to overspeed WARNING Abrupt braking from stepping on the foot brake at travel speeds may cause loss of control of a load on the hook or on the deck The operator should anticipate stops and slowly let up on the accelerator pedal to make smooth stops DANGER Like other mobile cranes the 35 will tip over more readily than some types of vehicles The operator should always control the vehicle speed to be compatible with terrain or road conditions OPERATING THE CRANE The following procedure is recommended for placing the crane in operation Perform daily inspection and test See Page 3 4 Apply park brake Leave transmission control switch in neutral Start engine and allow a warming period at low rpm engine speed While warming the engine set up the Rated Capacity Limiter configuration Move accelerator pedal to medium to full speed Set all outriggers fully down on firm level surface Use timber or steel plate cribbing under outrigger shoes as needed on soft ground Outriggers should remain set during all crane operations except for pick and carry 8 Meter the controls when beginning or terminating movement to prevent sudden startin
88. that the boom may later be fully topped up rotated and extended Do not operate these functions until the proper step 21 Close the small gate valve in the return line and disconnect the return hose from the return filter inlet again Run the hose into the waste oil sump Shutoff valves in the suction lines must be open 22 Pull the Boom Raise lever fully back in the raise position and start the engine Run at low idle until the boom is fully topped up then stop engine quickly 23 Pull the Swing lever fully Run the engine for 3 seconds and stop engine 24 Release Swing lever push Hoist lever to full Lower position and run engine for 7 seconds then stop engine 25 Fill hydraulic reservoir 26 Remove the hook from the load line and pull load line out of the boom tip 27 Push Telescope lever fully forward in the Extend position Run the engine until the boom extends fully then stop engine 28 Reconnect the return hose Be sure all shutoff valves are open 29 Retract the 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 a spring applied pressure released parking brake Each portion has a bleed screw on the module The upper bleed screw is for the pedal operated system and the lower one is for the pressure released system system should be bled whenever a line
89. the Rated Capacity Limiter configuration 6 Stow boom over front 7 Pull hoist line snug 8 Retract outriggers 9 Step on the brake pedal 10 Turn parking brake off 11 Place transmission switch in forward or reverse 12 Release brake and press on accelerator pedal 13 Slow down when making turns 14 Release accelerator pedal gradually to slow down and stop 15 Step on brake pedal for abrupt stop 16 Set park brake and outriggers or wheel chocks to park AI To start the engine the transmission switch must be in NEUTRAL The switch should always be kept in neutral except for travel Step on the brake before switching to FORWARD or REVERSE Then release the brake and push the accelerator pedal to begin travel Motion begins at engine speed of about 1500 rpm Idle speed is about 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 motors and allow the crane to creep ALWAYS apply parking brake when operating the crane or leaving the crane unattended Also extend the outriggers if possible Remember the hydrostatic transmission is NOT a parking brake 2 6 On level surfaces the brake pedal is not required for normal stopping On slopes the operator may have to coordinate the brake and the accelerator to make smooth starts and stops Emergency stops can be made more quickly by s
90. udes operator controlled switch Boom Work Lights Two work lights one on side of boom to light boom tip and one on side of turret to light ground under boom tip Includes switch at operator s station Net Weight 10 pounds 5 kg 1 9 Hydraulic System Standard Tandem pump mounted to rear end of hydrostatic piston pump which is driven by the engine crankshaft Delivers 6 gpm 23 L min at 2 600 psi 179 bar for boom circuits and 17 gpm 64 L min at 2 250 psi 155 bar for hoist circuit System protected by relief valves and two 10 micron filters Hydraulic reservoir with 14 gallons 53 L capacity Boom Assembly Standard Three section high strength steel construction equipped with bearing pads for efficient support and extension Double acting hydraulic cylinders extend boom sections The primary extension cylinder and the double acting boom elevation cylinder are equipped with direct connected holding valves Boom angle indicator provided on both sides of boom Boom Hoist Standard Turret mounted planetary gear hoist is hydraulically powered to provide bare drum line pull of 5 000 pounds 2268 kg and a line speed of 86 ft min 26 m min Hoist includes 85 feet 26 m of 3 8 inch 9 5 mm wire rope downhaul weight swivel 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 Optional Extra long Wire Rope 1
91. vide information 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 model number part number part description and quantity must be provided This unit must not be altered or modified without written factory approval To reorder this manual ask for IC 35 2F Operation and Maintenance Manual Part Number 0 990 30168 Contact your Broderson service representative at Broderson Manufacturing Corp P O Box 14770 Lenexa Kansas 66285 USA 913 888 0606 NOTICE If this crane becomes involved in an accident please call Broderson Manufacturing Corp at 913 888 0606 and ask for the Legal Department or the Service Manager Also please notify your Broderson dealer 14 DIMENSIONS AND ORIENTATION IC 35 2F TWO 9 64900
92. w it to fall below 5 127 mm from the top of the fill neck during this procedure Run the engine at low idle during this procedure to minimize oil loss and the possibility of pump damage from cavitation due to low oil level 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 pressure and return lines Stop the engine Remove the extra hose from the piston pump case drain reconnect the regular case drain line and fill the reservoir Leave the return hose disconnected from the small filter and leave it in the waste oil sump Run the engine at low idle and turn the steering wheel fully to the right then fully to the left and then back to straight Stop engine Be sure the outriggers are all clear Push both outrigger levers fully forward and run engine until the outriggers are fully extended Stop the engine Release the levers Reconnect the return hose Fill the reservoir and be sure all shutoff valves are open Run the engine at low idle for 15 minutes to filter the oil With the front wheels off the ground set the transmission control switch to FORWARD and push the accelerator slowly until both wheels are turning slowly Run both wheels slowly for 5 minutes Then switch to REVERSE and run both wheels slowly in reverse for 5 minutes Run the wheels at full speed in both direc tions for 1 minute 3 22 20 Position the crane so

OPERATION AND MAINTENANCE MANUAL IC-35-2F

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