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operation and maintenance manual ic-80-1j, 2j & 3j

Contents

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2. ARY TELESC CYLINDER d STAGE SE HOLDI ALVE 1 RATIC AR RELIEF OLDIN Y TELESCOPE ER Gi ALVE LEI CYLINDER i e A RAA 5 HOLDIN ALVE ATS 1 ae n BREATHER H REA 22 5 OO an a gt HUTOFF JUTRICGER TELE L H REA LH FRONT FRONT REAR FRONT WINCH HOIST 5 RESERVOIR d e ma die e n x nis apy 95 LITER L4 Rd hd Mg 2 LH ETE i 1 LE i rH T I T f L D E pe Ea E BAM Un EH AR TI ds bes TROL VALVE 1 60 d PE mene s a ALVES E NOTE PILOT OPERATE A FLO FRONT x l FRONT EA TA CENTERPOST CHART FRONT Galt 6 2 er STEERINC a INT WINCH LH RH D C JNAL LENOID VALVE 4 2 WHEEL
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6. 3 18 Boom Elevation Cylinder Holding Valve 3 19 Telescope Cylinder Holding Valve 3 20 Engine 3 20 Air Cleaner 3 20 Cooling 3 21 Spare Parts 3 21 Major Engine 3 21 Mechanical 5 3 21 Fasteriers 3 21 Swing 3 21 Rear Wheel 3 21 Wheel Toe In 3 21 Transmission Troubleshooting amp Overhaul 3 21 Park Brake Test and Adjustment 3 22 Torque 3 23 Wiring BRODERSON MANUFACTURING CORPORATION IC 80 INDUSTRIAL CRANE INTRODUCTION The Broderson 80 was designed and built to provide safe dependable and efficient crane service This we warrant by our testing and quality control procedures To 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
7. ez ij N c 3130 43991810 F BR TURN SIG HEADLIGHT WASHER N TRANSMISSION SHIFTER HORN ff 7 A 0 2 9 6626 CE WE Of Le 82 62 9 s seze eere LINN H3SN3 NOO INVHO9VIG 08 21
8. IC 80 J JIC SCHEMATIC RAKE MARY TELESCOPE CYLINDER 2nd STAGE ELEASE 1 HO ALVE I 251 RELIEF HOLDIN ALVE SECONDARY TELESCOPE STAGE H ALVE a In 251 RELIEF ING MOT TRIGGER CYLINDERS FEATHER d 10 MICRON H FRONT REA 1 i VESH FT TRIGGERS ON LH REAR FRONT FRONT REAR FRONT WINCH HOIST i L4 bd bd bd bd bd a n hi H 1 5 i E 121 417 1 T Tee TL L TL L TA LG Te TROL VALVE 1 STEERI ER TES 3 pcr 4 CHECK P ETE ALVES M PX NUTS STEERING PRIORITY i PILOT OPERATED L AL E FLC HOWN AT FRONT2 E 1 REA 12 1 Li FRONT 7 7 REA HART 1 i as v FRONT jm 4 TEE 4 gt YLIN 4 LH H i i LENOID VALVE 2 WHEEL REA 4 WHEEL STEE CI ed UE 500 00334 TRIGGER CYLINDER 3 13 IC 80 J METRIC JIC SCHEMATIC 3 14
9. 4 09 02 VPL sualan 97800799 SVSNVM VX3N31 4 ONIANLIVANNVIN Airirgvavo 9rnvsidAH WYNLONYLS Ag 6 2 4 2 N3H1O 9NIddlL 33V 0108 SAVOT JO 6 NO S3lLI VdV2 SQVO 40 9698 SMIODIMLNO NO 4 NOISN31X3 NO SQVO 3914 LON OG AllI2VdV2 WOOS Q332X3 LON LSNW NOISN31X3 WOOS 08 21 SIHL NO O1 G3NIVLNIVIN 38 16 SNOLLIQNO2 Sg 1 14 009 01 SLNN 133HM 30301 40 31va ON ONINIW SVIA 9L 51 1 X 9 HOS ISd 021 SVIS Y7 911 000 HO 154 OLL Y7 SLMOL ISd SEL S8100S L JO HLON3H1S INNINININ V 3403 IAIM DYMI THM dI3 9 X 9 VIC 94 6 38 LSNW LINN SIHL NO LSIOH SHL 7 E pz N d nous a a 1 aagana NO T m N3AO ET 1331 sao SLUVLS 54015 ATHLOONS ATMOS S 1OHLNOO SITNVYGAH TIY 31v43d0 9 ENVY T3A31 9NILOOd 1
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12. AlI2VdVO 51 09 SVSNVM VX3N31 d3O2 YO TVUNLINULS 33v N3HLO AS INIT 0108 lt A 9560601 96 ASN 1uVd 319 16 ISN 2 09 SGIOA SI ASNSIN SI NOISN31X3 WOOS iD vay OL NOILVLO WO3J 1334 NI Sniavy 3 1 OL 40 NOLLVLOS 40 5 SI VE ZE 06 80 90 02 81 9 0 8 9 P 40 ON 1943 ON 1300IN NOISN31X3 WOO 135440 304 81 0 WOOS 9 90 GN Si 0088 0008 002 0922 05 01 Q3NIV LNIVIN 38 LSNW SNOILIGNOD 3S3H1 581 14 009 OL SLNN 133HM 0057 0088 042 00 gt HULL SVIA Ud 91 91
13. DO NOT PICK AND CARRY WITH BOOM EXTENSION INSTALLED MACHINE DAMAGE MAY OCCUR DURING TRANSIT WHILE BOOM EXTENSION LOADED A 651 00160 2 24 FRONT AUXILIARY WINCH The front auxiliary winch is mounted behind the front bumper and is controlled from the operator compartment The winch with 75 feet 23 m of 3 8 inch 9 5 mm diameter 6X36 IWRC EIP wire rope 15100 pound 67 kN breaking strength and 3 ton 2700 kg hook has a single part line capacity of 5000 pounds 2270 kg on the first wrap The front auxiliary winch is designed for the following uses 1 2 As a tag line for restraining loads on the boom load line during pick and carry operation To drag loads on the ground to a position where they may be safely lifted with the boom To pull the crane out of mud or other obstacles 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 Never lift or carry personnel with the winch and wire rope Do not allow anyone to stand near or under the load being moved Be 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 Stand clear of a loaded winch cable If it breaks it can be very dangerous Keep hands clear of the winch and any sheaves that the cable passes over when the winch is being operated
14. NOLLV LOM 40 H31N32 NOUS 1510 TVLNOZIMOH SI SNIOVY 0707 oor 06 08 OL 09 OS Ov OF 072 UAI 30 ON IVINS ON NOISNALX3 WOOS 135440 4 0 SH ISNI NOISNaLXa LHOIVYLS 0 3SN oO pz SUNG saver 0674 0961 081 020 05 m OL GANIVLNIVIN 38 LSM SNOLLIQNOO 5 UIN 829 OL SLNN 133HM 0061 0851 0221 0601 TUE oS Vi 3 0t SVIS Hd 91 S1 LL X 9 ed 228 pare 11142 099 020 01 SVIS H Y7 91 S1 00 0L 892 02 09 Sv 08 0 FTONV TVI VA 645 056 319NYV WOO ov OL 30 HLONSMIS V 1 135440 15 NOISNA LXI NOOSA YILIN woos 9 X 9 VIG 38 LSNW LINN SIH L NO ANIT LSIOH QVO 088 01 089 061 vor m 05 7 026 057 072 022 00 x 0901 059 068 062 06 5 OZ 059 00 085 08 1 09 og diosa TN 007 094 05 057 el snows sano 17 0991 088 009 055 549 02 PEE E 0891 0001 0991 059 09 pa 0581 1 3117 0844 022 ss 0 2 0002 0621 0002 058 09 0 SLUVIS 64016 ATHLOOWS ATMOTS 51054409 31743409 0555 0251
15. 3NIT 1 OL 40 NOLLV LOH 40 H31N32 TWLNOZINOH 1 SI SNIAYY 0401 NOISN31X3 WOOS 145440 0 HO St 0 ISN NOISN31X3 WOO 1HOIVHIS 304 0 ISN 0066 0006 0092 0522 06 oozy 0096 0022 1123 0007 0005 0026 0092 osez 1 015 04 09 SP 06 0 mow 319NV NoIsnaixa 195330 LHOIVYLS NOISNSLX3 IWOO8 1004 01 woos O 00 005 05 005 009 00EL 002 ac 059 007 092 0081 008 0091 096 ve 056 006 051 osp ze 0812 0001 086 099 06 osez 00 0022 094 82 ossz 0021 0592 058 92 0082 ose 05 2 0001 ve 0906 ossi 0506 OSLL 005 0081 OOS ose oz gt 006 0022 006 0891 2 1122 0046 00 0502 9 0029 0056 0029 0992 lo 0019 122 0019 0026 0022 0019 0044 00st oL 00001 0018 00001 0095 8 00071 00001 00071 0654 9 00081 00 000 1 0006 6 NO uzganu NO SH399IJ41n0 NO NO 1334 1NOUA NOILVIOM 2096 sniava SaNnod NI 6 4 gt NOISNSLX3 INOOS NIYIN 29V4UNS 1 NO NOILV343dO OL AlddV SAILISVdV9 vZL 1 E 591 0008 OLSGVOT p 5 303 3NI1 QVO 1 1uVd OML ASN 681 06 IM 697 0006 01 SQVO1 1uVd 319NIS IS
16. 75800759 svs NVM N 3 1 Airiravavo 1 Q31INI1 33V SNHRIn LOVInNVIN 5 JO 9694 AMV NO 40 98 99 NO NOISN31X3 WOO amp NO SQVO LON ALI2VdVO WOOS 033233 LON 15 SQVO 1 NOISN31X3 WOO8 NOILNYO 40 Alva ON 1914385 ON SIHL NO savo SGIOA ShOGHVZVH SI ASNSIN SI NOISN31X3 WOOS WOO 01 301S 9NIATddV HO SONILVY ALI2VdV2 OVO GALVY OL GANIVLNIV 38 LSNW SNOLLIQNOO 3S3H1 881714 005 O1 SLNN 133HM 300301 QVO13V2LLH3A OL 3NVH2 40 NOLLV LOH 40 3831N32 161 TV INOZIHOH AHL SI avo1 NOISN31X3 WOOS 136340 0 HO SL ISN NOISN31X3 WOOS 1H9IVH1S 804 0 ISN 697 21 LM 5 97 0008 OL SAYOT Lp 50 OML ISN sa7 06 1 e 0006O0LSQVO1 9 2 1uVd 319 16 ISN lo OL NOILVLOY 3 WO 1334 NI 0 8 90 ZZ 00 8 Ob HL ZL 0 8 9 V 9
17. 652 00603 A WARNING TURRES ASSEMBLY KEEP ALL PARTS OF THE BODY INSIDE OPERATOR COMPARTMENT KEEP CLEAR DEATH OR SERIOUS INJURY CAN RESULT DEATH OR SERIOUS INJURY CAN FROM MOVING MACHINERY 652 00602 RESULT FROM BEING TRAPPED 652 00605 2 4 CAUTION Keep hands out of Anti Two Block mechanism Serious injury can result from moving parts 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 away from electric power lines See chart on side of turntable for boom clearance ADANGE ELECTROCUTION HAZARD DEATH OR SERIOUS INJURY WILL RESULT FROM BOOM LOAD LINE OR LOAD CONTACTING ELECTRIC LINES DO NOT USE CRANE WITHIN 10 FEET OF ELECTRIC LINES CARRYING UP TO 50 000 VOLTS ONE ADDITIONAL CLEARANCE IS REQUIRED FOR EVERY ADDITIONAL 3
18. EXTENSION 1 The boom extension must installed on the main boom tip and the load line downhaul weight and wedge socket installed on the boom extension and secured with all of the retainer pins Draw the load line taut with the hoist by pulling the downhaul weight against the bottom of the tip sheave plates while holding the Anti Two Block override switch under the control panel WARNING Be careful not to operate the TELESCOPE lever while overriding the Anti Two Block system This may break the load line and allow the boom extension and downhaul weight to fall causing death or serious injury to personnel Remove the offset index pin from the boom extension knuckle To loosen the pin it may be necessary to rock the boom extension tip up and down manually while maintaining the proper tension in the load line Lower or raise the load line with the hoist until the 0 15 or 30 degree offset holes align in the knuckle Insert the index pin in the knuckle and retain it with the hairpin cotter STOWING THE OFFSETTABLE BOOM EXTENSION 1 2 If the boom extension is offset to 15 or 30 degrees return it to the zero offset position as described above Reverse the procedure described in steps 7 through 14 in the Boom Extension installation procedure on previous page 2 23 CAPACITY EXAMPLES FOR BOOM EXTENSION The MAIN BOOM and BOOM EXTENSION capacity charts must both be considered when using the boom extension The s
19. 3 operator must observe the safety rules 4 equipment must be given proper maintenance This manual was written to provide information required for these conditions 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 80 Operation and Maintenance Manual Part Number 990 30179 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 1 1 IC 80 1J DIMENSIONS 9900 299 0 0
20. 50 hour maintenance 50 and 250 hour lubrication Clean engine and battery Change engine oil and filter Clean crankcase breather Clean and inspect distributor and ignition wires Clean the air filter Clean element every 100 hours if used in dusty conditions Check engine mounts and radiator mounts Inspect all bolts on the machine for tightness Visually inspect all welds for cracks Check hydraulic fittings and centerpost for leaks Check park brake cable adjustment Clean the two steering alignment proximity sensors tips with a rag 3 5 500 HOUR OR 6 MONTH INTERVAL I OY gi de Corm 50 and 250 hour maintenance 50 250 and 500 hour lubrication Change fuel filter element Change air filter element Check antifreeze for protection level and cleanliness Inspect engine fan and belt Check water pump and connections for leaks Check fuel pump and connections for leaks Change hydraulic filter element if not changed in the last 250 hours and inspect oil from element Change transmission filter element and inspect oil from element Check condition of all operational and warning placards Torque mounting bolts on swing bearing and gearbox winch and axles See page 3 23 Inspect boom sections for signs of overload excessive wear or other damage Check axle toe in 1000 HOUR OR 12 MONTH INTERVAL 500 50 250 500 1000 h
21. Front Axle Rear Axle 80 1 Continuous 0510 70 12 feet Hyd 3 66 m 2 RPM 12 seconds 17 seconds 28 2 feet 8 6 m 37 4 feet 11 4 m 20 2 feet 6 1 m 30 1 feet 9 2 m 16 200 pounds 7350 kg 7325 pounds 8325 kg 8875 pounds 4025 kg With GM 3 0L gasoline engine Steering Turning Radius Aisle Width for 90 Turn Steering Modes Road Speed Drawbar Pull Gradeability 80 2 Continuous 0510 70 14 5 feet Hyd 4 42 m 2 RPM 12 seconds 21 seconds 31 7 feet 9 7 m 41 0 feet 12 5 m 24 0 feet 7 3 m 34 0 feet 10 3 m 16 400 pounds 7440 kg 7650 pounds 8470 kg 8750 pounds 8970 kg 80 3 Continuous 0510 70 18 5 feet Hyd 5 64 m 2 RPM 12 seconds 27 seconds 37 4 feet 11 4 m 46 6 feet 14 2 m 30 0 feet 9 1 m 40 0 feet 12 1 m 16 750 pounds 7600 kg 8325 pounds 3775 kg 8425 pounds 3825 kg 12 75 feet 3 89 m 4 Wheel Steer 9 6 feet 2 92 m Rear Steer Round Steer Crab Steer STANDARD 22 MPH 35 4 km h 15 500 pounds 703 kg 1 63 percent 32 degrees 1 Calculated values based on GM 3 0L Gasoline Engine Wheels may spin before these values are reached Grade Limit 1596 8 5 degrees 1 7 Standard Gasoline GM 3 0L EPA Tier w Dual Fuel GM Model 3 0L industrial gasoline engine with multi port electronic fuel injection dual fuel catalytic converter and engine ma
22. Parking brake is set D 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 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 L Engine air filter restriction indicator Transmission oil temperature Engine start Brake fluid fill location Engine idle set Hydraulic oil low level mark Check engine do Hydraulic oil filter restriction indicator Stop engine Hydraulic temperature gauge Wait to start engine preheat grid heater glow plug switch SE St Hydraulic oil temperature high Gas fuel only Hydraulic oil pressure gauge OR hydraulic oil pressure low Diesel fuel only Et Positive polarity Fuel level gauge Negative polarity Drain 10 11 12 13 14 SAFETY RULES Lower load and boom shut down engine remove key and put it in a safe place Place warnings on th
23. 1 NOISN31X3 WOOS 00571 00201 0097 0082 9 e 184 0092 00081 009 000 1 0056 5 9 TIVHS ONITNVH qvo 1 NO YAGENYNO SH3OOnIDO NO yagana NO 1333 NOLLVINSNI 121312373 ON ONILVY 39 V L10A ANIT ON 3AVH 13318 LINN SIHL NO SWOOS LNOYS NOILV IOM 095 sniav 486 Sv MOT Hil HUM ANONA NOOB WOUDVUd 193108 Asavo SONNOd SALLIOWdW9 NOISN31X3 WOOS avo1 08 09 HLOOWS NO S310NIN OF L4 002 TAAVL n awy 13 31 Wald NO NOILVYIAO OL Alddv 6 4 01 07 1NO34 QNIH38 LSM 1NOH4 931995133 WOOS ALdW3 597 00071 ALIOVdV2 3230 2 ALI 3VdV 04 2 16 79800759 SVSNVM VXINIT duo 08 21 HO WHNLONYLS S3Lovdv9 N3HLO GALINIT INIT JO 9654 JUV NO 40 58
24. N i i m 22 ema N p L H IHSI NOS ALLY TO LEFT HAND DASH d ANEL NOISSIINSNVH L ANV 3NION3 OL LINN
25. O O O O O O O O O O O O O O O O HIGH IDLE CONTROL ROCKER SWITCH Three mode steering is standard Rear steer 4 wheel round steer and crab steer can be selected with a switch on the dashboard The steering wheel is directly mounted to the steering control unit of the all hydraulic power steering system The steering system will provide limited steering even if the engine should stop 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 2 9 CONTROL VALVE FUNCTIONS The controls for operating the outriggers boom rotation boom elevation boom extension and hoist are located along the forward dashboard area The control handles are directly connected to the 3 position hydraulic valves The placard located next to these handles identifies the function and direction resulting from each handle movement RIGHT EXTEND LOWER DOWN DOWN DOWN DOWN OUT f LOWER ey lg T T T A R R R LEFT LEFT RIGHT RIGHT FRONT 9 SWING TELESCOPE BOOM REAR FRONT FRONT REAR WINCH 4 5 v v 9 9 V v v E E E E MADE LEFT RETRACT RAISE UP R UP R UP R UP IN IN THE RAISE 1 2 3 4 5 6 1 Swing Pulling back on the lever will rotate the boom to the operator s left pushing forwa
26. in pinch point areas 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 3 1 20 21 22 23 24 25 26 If it is necessary to work the boom or outriggers an un stowed condition block them to prevent them from dropping unexpectedly Use a hoist when lifting components that weigh 50 pounds 22 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 misuse of a rope clip on the hoist rope Replace any instruction or warning placards that are lost or damaged or are not readable Always replace all guards and covers after 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
27. the boom Proper lifting and securing practices are the responsibility of the rigger in charge A 652 00639 23 When transporting the crane be sure it is properly secured to the vehicle Utilize the tie down anchors as indicated on the crane to stabilize the load and prevent shifting during transport Use caution to not over tighten the chains and binders when securing the crane to the transport vehicle Proper securement and prudent shipping practices are the responsibility of the carrier ub A 652 00626 A 652 00627 2 6 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 determine 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
28. 0250 Change 912 Mo Spray Brush or Soak See Procedures in Manual Multi Purpose Gun Grease Multi Purpose Gear Lube SAE 80W 90 Open Gear Grease Such as Mobilkote S Silicone Lube Aerosol with Concentrating Tube Wheel Bearing Grease Worm Gear Exxon Cylesstic TK 460 WIRE 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 X 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 WARNING Always wear heavy leather gloves when handling wire rope HOIST CABLE INSTALLATION AND INSPECTION The following steps will assure that the wire rope winds smoothly and evenly on the hoist and will yield greater safety and longer 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 b
29. 086 2 uo TT TIOINSA 138 3 0242 081 02 2 op P ana A E 08 0922 st O 3NVH2 ONILVH3dO 340438 NOLLVH3dO 0755 0282 075 098 08 NOISN31X3 WOOS ONIMOLS 43149 TWNOLLONN SI HOLIMS 19078 OML ILNY 0057 0795 0877 0872 EKA SP 001 NO N3HM Sp 1 NOISN21x3 WoOS 0665 0857 0665 0555 0c 081 2n vel dGAH WRWIXVIN 0918 0929 0 1 oler m 40 TIVHS S3130 539038 SLHOAMTNVHNMOG sHoOH qvo SYZOORUNONO MJHHDHNO SHJOORIInONO sJHHDHNO 9 191419373 ON ONLLWY 39V L10A ON 1331S LINN SIHL NO SWOOS 1 NH3JAO NOILV IOM 09 sniava Sv NOOR HAM INNO NONO O3USLNZO 1831909 xuyo NI SSLLIOVdV9 NOISN3IX3 WOOS NIVW avon 08 9 INaWaAVd HLOOWS NO 31nNIN 09 WAWY SS31 1 ay 5 13 31 Wala OL A1ddV S3ILIOVAVD 1NON4 Q3H31N32 38 5 9907 1NO34 WOOS ALdW3 BY 0989 ALIOVdVO MOS
30. CAUTION FLYING OBJECTS DO NOT EXCEED THE WORKING STRENGTH OF THE ROPE SERIOUS INJURY OR MACHINE DAMAGE CAN RESULT FROM OVERLOADING A 651 00175 2 25 PINTLE HOOKS Available Pintle Hooks allow the crane to tow other disabled vehicles and trailers and drag loads 1 Observe the capacity ratings marked near the hook when towing 2 Exceeding the capacities can damage the drivetrain 3 Use slow and smooth motions to avoid shock loads or overrunning loads Make sure other vehicle is occupied and controlling the vehicle being towed Pintle Hooks also allow the crane to be towed 1 Use appropriately sized straps or chains 2 Place transmission in Neutral Utilize an Operator to activate brakes as needed and steer the crane while being towed 3 not exceed a towing speed of 5 MPH 8 km h NOTICE 2 000 LBS 8 9 kN M 10 000 LBS 44 kN A 650 00368 2 26 SWITCH AND INDICATOR SYMBOLS ON BMC CRANES The following list shows the 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 IT 14 Windshield washer switch Off Stop Windshield defroster switch E3 Battery not charging Heater switch Hour meter Air conditioner switch Read operator s manual Ventilation fan switch Sound level notification
31. 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 stability C Remove load hook from load before traveling Cranes with rear steering require close watch because of tail swing when the chassis is A WARNING PINCH POINTS turned in tight quarters KEEP ALL PARTS OF THE BODY INSIDE OPERATOR COMPARTMENT DEATH OR SERIOUS INJURY CAN RESULT FROM MOVING MACHINERY A 652 00602 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 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 2 7 8 Shut off engine before refueling and remove fuel cap slowly Vapor pressure tank can cause a burst of fuel and vapor when the cap is removed Aways refuel with proper fuel and into proper tank 9 Know your visibility limitations Loads being carried on the deck or han
32. OF DEFECTIVE 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 WARRAN
33. Standard 12 Volt Battery Gas Units Group 27 with 540 CCA rating Diesel Units Group 31 with 950 rating Instrument Group Located at operator s station and includes fuel gauge hourmeter and bubble level Hourmeter records hours only during actual engine operation Also included are warning lights for low oil and transmission pressure turn signal high beams hazard lights parking brake hydraulic oil temperature battery check engine stop engine coolant temperature engine oil pressure transmission temperature and outriggers Lighting Group Consists of two 12V lamps with high and low beams for driving integral tail brake and turn signal lights and backup lights in rear front turn signals and emergency flasher switch at operator s station 12V horn actuated by button located on shifting control Back Up Alarm Provides pulsating sound from a 97 dB alarm when ignition is on and transmission is in reverse Conforms to SAE J994b Outrigger Alarm System 112 dB alarm with alternating two tone sound is actuated by a switch when the OUTRIGGER DOWN controls are operated Optional Electrical Accessories Strobe Lights Two yellow strobe lights one on each side of turret weight box for high visibility all around crane Flash 60 120 times per minute Each strobe draws only one half amp Includes operator controlled switch Boom Work Lights Two work lights one on left side of boom to light boom tip and one on right s
34. firm level surface Use timber or steel plate cribbing under outrigger shoes as needed on soft or uneven surfaces Outriggers should be set during all crane operations except for pick and carry 8 Meter the controls when beginning or ending movement This prevents suddenly starting or stopping which causes unsafe load swinging and shock loads on the equipment The control should be slightly actuated to begin movement and then slowly increased to desired speed Metering can be improved by coordinating with the accelerator pedal 9 Release accelerator during idle time ABH E IM NORMAL GAUGE READINGS Level Indicator Do not operate crane if it is not level Fuel Do not allow tank to become empty The engine will be difficult to restart and may require bleeding of diesel injectors Keep fuel tank full when idle to prevent condensation 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 spray 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 movem
35. high side of the bearing gear teeth Adjust the gearbox inward until there is light contact between pinion and bull gear teeth Retighten the four mounting bolts and the four side bolts REAR WHEEL BEARINGS Rear wheel bearings are adjusted with a light snug fit Assure that hubs are free to rotate by hand after adjustment WHEEL TOE IN SETTING Wheels are set for zero toe in TRANSMISSION TROUBLESHOOTING AND OVERHAUL Procedures for transmission troubleshooting and overhaul are beyond the scope of the BMC Maintenance and Parts Manuals The transmission factory service manual is available Order BMC Part NO 99000021 3 21 PARK BRAKE TEST AND ADJUSTMENT Check tightness of parking brake lever daily while operating it Perform the following test weekly and at the 50 hour maintenance interval 1 2 3 4 ON O O 11 12 13 14 Park the crane on level pavement While holding the foot brake pedal down release the park brake lever and adjust the knob on the end of the lever until the park brake feels tight when applied Fully apply the parking brake Start the engine retract the boom to the appropriate traveling position and raise the outriggers Select fourth gear Push down hard on the foot brake pedal Select forward gear Move the park brake lever fractionally downward just over center slightly releasing it Hold park brake lever switch in the off position located in the lever bracket Slowly rel
36. 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 See Boom Extension Capacity Example Page 2 24 Refer to the IC 80 3J capacity chart on the preceding page A load weighing 9500 pounds 4309 kg is to be lifted onto the deck of the crane for transport to a new location We see on the chart that 9000 pounds 4080 kg is the maximum load on one part line so the sheave block is required The charts show the weight of the standard sheave block to be 124 pounds 56 kg The rigger says that two slings are required weighing a total of 40 pounds 18 kg The total load is 9500 124 40 9664 pounds 4309 56 18 4383 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 10 000 pounds 5170 kg at a 6 foot 1 5 m load radius However this radius is less than the distance from the center of rotation to the front bumper so the load cannot be lifted this way This leaves the ON OUTRIGGERS columns outriggers should always be used whenever possible anyway We see that we can lift up to 10 000 pounds 4400 kg at an 8 foot 2 5 m load radius either over the front or over the side If the load is compact enough to allow the crane within the 8 foot 2 5 m radius ove
37. lift must be made without a properly functioning load indicator or 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 to perform safely Daily 1 Check levels of engine oil coolant and transmission fluid 2 Drain water from diesel fuel filter 3 Check air cleaner intake system for cracks or looseness 4 Check general condition of tires 5 Visually inspect for loose pins bolts physical damage and leaks 6 Check hydraulic hoses particularly those that flex during crane operation 7 Check hydraulic oil level 8 Check fuel level 9 Check hydraulic filter indicator gauge after running at least twenty minutes Check hydraulic service brake operation Check parking brake operation Check power steering operation Observe chassis for normal driving operation Observe boom operation for normal power and speed Check load line and hooks for damage Check condition of sheaves and load line retainers Check anti two block system for proper operation Check horn back up alarm and outrigger alarm for proper operation Check operation of all transmission gears forward and reverse Clean all glass if equipped and check for cracks Check oper
38. or the hydraulic cylinder Refer to the maintenance instructions ANTI TWO BLOCK SYSTEM This system prevents damage to the hoist rope and machine components from accidentally pulling the load hook against the boom tip A pivot arm actuated electric switch is connected through a cable reel mounted on the boom to a solenoid dump valve in the hydraulic circuit This valve will dump the HOIST RAISE TELESCOPE EXTEND and 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 or TELESCOPE RETRACT 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 left side of the instrument panel 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 this key in an emergency should use good judg ment 2 21 OPTIONAL EQUIPMENT INSTALLING BOOM EXTENSION ON TIP OF BOOM 1 2 Set the outriggers Raise and extend boom 30 feet 9 m above the ground paying out load line until hook is just above ground Position boom over front lower and retract boom leaving the load line on the ground If the sheave block is installed remove it Remove load line from tip sheaves and lay over opposite side of stored boom
39. transmission fluid with the dipstick and add fluid through the dipstick tube as required Use Mobil ATF Type F or equivalent Transmission factory service manuals are available from Broderson Order BMC Part Number 990 00021 USE ATF TYPE F FLUID ONLY TRANSMISSION FLUID SHOULD BE CHECKED WHEN COLD AND ENGINE OFF 650 00359 DRIVE AXLES HUBS AND DIFFERENTIALS Maintain lubricant to levels shown here with Mobil 424 or equivalent OIL FILL LEVEL PLUG OIL DRAIN PLUG FLUID VOLUME CHART HYDRAULIC RESERVOIR 25 Gallons 95 L FUEL TANK 20 Gallons 76 L PLANETARY HOIST 2 5 Quarts 2 4 L FRONT AUXILIARY WINCH 2 Pints 1 L PLANETARY DRIVE AXLE 11 Quarts 10 L Center Section amp 0 75 Quart 7 L each end TRANSMISSION POWERSHIFT 17 5 Quarts 16 6 L ENGINE COOLING SYSTEM 15 14 L to 17 16 L Quarts depending on engine and heater 3 7 80 LUBRICATION CHART 02 62 S Le L 9 72 97 92 9c 3 8 80 LUBRICATION SCHEDULE LUBRICATION INTERVALS ITEM DESCRIPTION LUBE 50 250 500 1000 MONTHS HOUR H
40. 0 000 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 POWER COMPANY AND ASK THEM TO DE ENERGIZE THE 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 ft m Operation Near High Voltage Power Lines to 50 10 3 05 Over 50 to Over 200 to Over 350 to Over 500 to 25 Over 750 to 1000 Operation in Transit With No to 0 75 Over 0 75 50 50 345 Over 345 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 21 Do not operate outside during thunderstorms Avoid all lightning strike opportunities 2 5 22 Crane has four lifting rings at each corner of load deck for lifting the crane Use proper slings and rigging methods to keep the load balanced during the lift Do not lift by
41. 0458 001 BOOM CYLINDER HOLDING VALVE A holding valve is directly connected to the base of the boom lift cylinder barrel and to the base of the primary telescope cylinder rod These valves are 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 in the horizontal position over the front of the crane and raise rated load about 6 inches 15 cm above the ground using the boom lift cylinder not the hoist An example of rated load for the IC 80 3J is 4400 pounds 1950 kg at a 16 foot 5 0 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 lift cylinders always relieve trapped pressure by lowering the boom fully turning off the engine and cycling the BOOM lever To adjust the holding valve loosen the jam nuts on the adjusting screw and tighten the screw 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 3 19 TELESCOPE CYLINDER HOLDING VALVE A holding valve is directly connected to the base of the primary telescope cylinder rod The valve is to hold the boom in position should loss of power or pressure li
42. 105 01 SY399IYLNO QN31X3 KT38023S NUVA 319IH3A 135 S1UVd 35001 6123430 318ISIA HOS TIO 3NI9N3 TIO OFINVAGAH 13 31 AIAH 9NILVN3dO 30438 QV3 l NOLLVH3dO NOISN31X3 008 ONIMOLS 43149 TYNOLLONNA SI HOLIMS 52018 OMLILNY WOOS 3SV8 NO Q3MOLS N3HM S871 001 1 NOISN31X3 ISd 0092 n vaAH WNINIXVIN 30 1 0 9 38 TIVHS S321A30 YIHLO 542018 400H S1H9I3M SMOOH QVO INTIVA NOLLVINSNI 1213123713 ONILVY 39 V L10A INIT ON 1331S LINN SIHL SWOOS 13 37 1 304 SALLIOVdVO GNNOYD O1 36012 1415504 SV SV 008 1NO34 H3AO Q3N31N32 NOOS LSILYOHS IHL MIld IN3W3AVd HLOOWS S3LNNIN 06 NI 14 002 13AVAL INNINIXVIN Z SS31 39 1SNW 9334 3 1XV 1NO34 Q3831N32 38 15 SQVO 1230 1 03194134 WOOS ALdW3 S97 00071 ALIOVdvo XIIA ALNYYYYM SGIOA ShOGNVZVH SI ISNSIN SI NOISN31X3 WOOS YO WOO OL 301S 9NIATddY SONILVY 9NIQ339XI
43. 11 X 98 154 021 0005 002 009 m SVIS 91 81 00705 404 ISd OLL 02 209 20 0 FIONV TVI VA f SHOL 154 SEL FHIL 319NV WOO8 NIVIA 881 00S L 40 HLONIYLS 198350 LHDIVULS NOISN31X3 WOOd 1003 01 wooa ONMITH3E dI3 9 X 9 VIA 91 6 38 LSNW LINN SIHL NO INIT LSIOH 3HL 0861 006 0091 67 ve SL 1 4 00 2 0001 Sez 929 44 m 0052 Sei 006 529 06 E 0052 522 9212 924 80 1NON4 TN 05 0 0571 0570 058 92 SAONO ANOS 1 2 0018 099 0992 0001 0058 0581 0562 05 ids Lis 0898 05 2 0555 088 02 gt 0507 0052 0566 009 8L SLAVS 54016 GIOAV ATHLOONS ATMOTS 51051409 9 1532 0962 0657 0061 9 gt ez NVE TRAST ONV ON SNAS AVE LAS Y 0999 0996 0999 052 w o E MDC TATEM RT 0595 0559 2 o 330438 0022 0029 0022 000 0L e N ze SZ NOISN31X3 WOOS ONIMOLS 83147 TWNOLLONNA SI HOLIMS 0520 0528 0520 0595 8 Gp gt Woog NO 18 N3HM 00
44. 3A31 1003 GMOS 01 5439911 0 1 5 AT38n23S HAVd 319IH3A 136 95007 6123430 3 18ISIA 404 LINN MOSH 110 3NION3 110 40 13 31 Z ONILVH3dO 438 NOISN31X3 WOOS ONIMOLS HO 9NIAO 130 TVNOILONN SI HOLIMS 42018 OML ILNY Noosa 3SV8 NO N3HM Sp 1 NOISN31X3 WOO 081 1 30 38 TIVHS S391A30 H3HLO S1H9I3M INVHNMOG S400H 1991440378 ON ONILVY ON 13315 TIY LINN SIHL NO HLOONS 4 3914 ANNOYS OL 35012 0407 31815504 SV SV WOOS 31VH3dO 1NO3 H3AO Q3H31N32 NOO8 1V2ILOVHd LSILYOHS IHL ANY 3214 LN3W3AVd HLOOWS NO 06 NI 09 13AVHL WNNIXVN SS3138 LSNW 5 3 1Xv 1NOM4 Q3H31N32 38 5 5 1NO34 WOOS ALdW3 BY 0989 ALIOVdvO
45. 79 mm long This winch includes 75 feet 23 m of 3 8 inch 9 5 mm wire rope hook and four way roller guide Net Weight 100 pounds 45 kg Pintle Hook Rear T 60 A Holland pintle hook mounted on rear frame member provides capacity for 2000 Ibs 900 kg tongue weight and 10 000 Ibs 4530 kg trailer weight Net Weight 10 pounds 5 kg Pintle Hook Front T 60 A Holland pintle hook mounted on front frame member Provides same capacity as rear pintle hook Net Weight 25 pounds 11 kg Rearview Mirrors One right hand and one left hand mirror 6 inchs 152 mm wide x 16 inches 406 mm high mounted on deck stakes Pivot out of way when contacted by obstacle at side of deck Net Weight 12 pounds 5 kg Operator s Compartment Standard Operators control station provides one position access to all operating functions Includes adjustable operator s seat and retracting seat belt 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 Operator s Compartment Options and Accessories Operator s Guard Not Available with Cab Tubular steel weldment with heavy expanded steel mesh top section bolts over the operator s compartment Net Weight 55 pounds 25 kg Operator s Guard Cover Clear vinyl cover goes over guard for inclement weather Has zipper and velcro roll up door Net Weight 15 Pounds 7 kg O
46. 8 9 49601 sl F pg i NE ud prat M A 56 I 119081 2 um 022 6 5 01 9 I e d 22 Bs zh 2 1 _ 9 1 1 2 56 J 107792 ue 7 Lb HOV3M Fol NOILV LOM avol lt 02 OL _ HLON31 WOOS 28 52 OL ZZ Ll 6 46 46 22 6 1 W9 681 i z ES X 15062 L 3 L x E xL LI 7 web ZS xZ N 1 _ 6 04 4569 L 8 6 45 21 2 0821 1 3 IC 80 3J DIMENSIONS 98900 99 WOL6E 01 21 812 98 6 15061 SLL wGL CY ees i 1
47. ANVW opse 0 62 055 0261 0 06 oL vado 08vv 012 08vv 0292 92 Ku 0865 0 Sv 0918 0089 0122 oser GL 0 0 YVA 611 SUNSSAYd WnWIXVW NO NO NO 3313 30 1 38 32IA30 QVO 10 549018 S1H9I3M 10 VHNMOG SHOOH QVO1 INTIVA 2 12373 ON 39 V L10A ANIT ON 13315 LINN SIHL NO INO 33AO NOLLVIOM 096 sniave aaAvd HLOOWS MOld ANNOYS O1 36012 31615504 SINV9O1IM NI S3lLIOVdVO9 NOISN3LX3 NIVIN avol L 0 8 21 SV SY 1008 1 40 1NONJ OOS 1 212 4 LS3140HS 3014 02 IN3W3AVd HLOOWS NO 06 NI SHi313W 09 1 WNWNIXVW SS3138 13 31 OL LYWHD ALIOVdVO 9 1NO34 38 LSNW 1NO3 15 4134 WOOS ALdW3 BY 0969 ALI9Vdvo
48. DIFYING THE WARRANTY 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 Document Number WI SM 002 Rev A Effective August 1 2009 TABLE OF CONTENTS SECTION 1 DESCRIPTION and SPECIFICATIONS ATFOGUGTION 1 1 IC 80 1J 1 2 IC 80 2J 2 2 1 3 IC 80 3J 1 4 Turning 1 5 Description and 1 6 SECTION2 OPERATION Safety Rules oris 2 1 Instruments and 5 2 8 Control 2 22 2 10 Four Whe
49. LIN 38V 25800959 9 98 LM ta ONINN LOVANNVIN SAVOT ONiddll 40 4 54 NO S3lLIDVdVO 40 98 SYFDORILNO NO 64 op 1A NOISN31X3 WOOS NO 3214 LON OG 4 2 WOOS NIV Q332X3 LON 1SNW NOISN31X3 WOOS gt 0918 OL SQVO1 KEA 0807 01 ANG RIVAA eA IN QvO1 SI SI NOISN31X3 WOOS WOOS O1 50 01 301S ONIATdd SONILVY ALIOVdVO ONIO330X3 1874 OML asn Iuvd 319NIS ISN 1 01 40 NOLLV LO 40 5 SI 007 UAI 30 Alva ON 191435 ON NOISN31X3 136440 0 SH 0 ISN NOISN31X3 WOOS 1HOIVHIS 0 ISN OL NOILVLOY 4 NI Sniavy 3NY32 SIHL NO Savo a T 2 n OL Q3NIV LNIVI LSN
50. Mr A 222 7 j m m 08 022 6 I 46 4 UN 2 4 Rr _ 4619 LL S292 WL 6 0 Ll HOV3MH NOLLV LOH b avo1 99 6 OL 810 v HLON31 WNOOS Z 8 1 OL Z Z 1 22 6 7 E 4D i 7 LE m wel 681 W9062 861 6 9 9 71 J 2 4 0821 1 4 IC 80 J TURNING DIMENSIONS 12 9 3 89 m RADIUS 25 6 7 77 m DIA CHASSIS CLEARANCE CIRCLE 17 43 cm 7 2 92 AISLE WIDTH 40 104 cm gt 53 137 cm RADIUS CORNER CLEARANCE 11 2 3 40 m TURNING RADIUS 7 2 9 7 2 92m AISLE WIDTH FOUR WHEEL STEER IC 80 J 4x2 65200687 DESCRIPTION AND SPECIFICATIONS The IC 80 J is a self propelled Industrial Crane designed for in plant lifting and material handling applications with special features of low height narrow width short length cargo deck and standard four wheel steer and front wheel drive The chassis includes a frame four independently controlled hydraulic outriggers engine torque converter 4 speed powershift tra
51. N NOILVLOY 3 1334 NI 107 86 96 76 TE OF 82 92 6 02 81 OL FL ZVL OL 8 9 V ol oS 402 122 ve 92 0 80 06 ve 9 486 08 21 07 ev 09 PV ALIOVdVO 3NV3D gt 9p ub 90 2 17 CAUTION A capacity load may be carried on the boom or a capacity load may be carried on the deck but not at the same time The total of the percent of deck load and the percent of boom load must not exceed 100 For example if the boom load is 10076 of its capacity at its current load radius the deck load capacity is 0 If the boom load is 6096 of the load rating for its load radius the deck load capacity is 40 of maximum 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
52. OUR HOUR HOUR X Accelerator Pedal Anti Two Block Arm Axle Differential Axle Kingpins Axle Pivot Pin Axle Planetary Hubs Boom Oylinder Pins Boom Ext Pins Boom Hinge Pin Boom Rub Pads Brake Lever Parking Brake Linkages Brake Reservoir Cab Hinges amp Latches Control Valve Links Drive Shaft Joints Engine Oil Gas Engine Hook Swivel amp Pin Hydraulic Oil Outrigger Legs Pump Shaft Rotation Bearing Rotation Gearbox Rotation Gear Teeth Sheave Block Sheave Pins Steering Rod Ends Transmission Wheel Bearings Rear Winch es Wire Rope Wire Rope Retainers LUBE SYMBOLS 2 5 2 424 Mobil Fluid 424 or Equivalent DTE Mobil DTE 10 Excel 15 or Equivalent Do not use brake fluid EO Engine Oil See Specs in Engine Manual HO Hydraulic Fluid See Specs in Hyd Sec MPG MPL OGG SIL WBG WGO 3 9 NOTES 1 Zerk Diesel 2 Pans Oilcan Check 950 Change 912 8 Zerks 1 Zerk Std 2 Zerks 4x4 Check 950 Change 912 2 Zerks Wipe on 1 Zerk Spray or Wipe Check 850 Change When Brakes are Serviced 3 Zerks Std 6 Zerks 4x4 Check Daily Change 850 then 2250 Hrs or 3 Mo Max Check Daily Change 21000 Hours or 12 Mo Max Wipe on Legs 2 Zerks 1 Zerk Check 9250 Change 224 Brush On 2 Zerks 1 Zerk Std 2 Boom Extension 6 Zerks Std 4 Zerks 4x4 Check 850 Change 912 Mo Clean amp Repack Check
53. PRINTED USA COPYRIGHTO 2011 P N 990 30179 BRODERSON MFG CORP OPERATION AND MAINTENANCE MANUAL IC 80 1J 2J amp 3J 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
54. REAR 4 WHEEL STEE E 500 00335 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 80 is equipped with a 100 mesh suction strainer breather filter 10 micron return line filter and a 25 gallon 95 L tank The filter must be changed whenever the filter indicator gauge under the control panel points to the red sector at full engine speed or at 500 hours or six months maximum Note The oil should be warmed by at least 15 minutes of normal operation to get a good reading The indicator should be checked daily The filter is located under the crane to the rear of the hydraulic tank Clean the filter and the surrounding parts with pressure washer before changing to prevent dirt from getting into the clean oil tube To minimize oil loss close the shutoff valves under the ta
55. RESSURE ADJUST SCREW AND 1 Winch Circuit 2500 PSI 172 bar at full flow did 2 Boom and Outrigger Circuit 2600 PSI 180 bar at full flow 3 Boom swing work ports 1500 PSI 103 bar at full flow A good quality pressure gauge with at least a 3000 PSI 207 bar scale is required to make adjustments properly A 3000 PSI 207 bar working pressure hose with adapters to fit the 3 8 tube pressure ports is required to install the gauge where it can be read easily The following procedures are suggested when taking pressure readings WINCH CIRCUIT Remove the 3 8 JIC cap from the fitting on the front of the control valve near the winch control section and install a 3000 PSI 207 bar pressure gauge To obtain full flow reading run pump full speed pull winch control to RAISE position and hold until maximum reading is made anti two block override switch must be actuated If a pressure of 2500 PSI 172 bar is not possible check the following Broken mechanical connection to the pump shaft Low oil level in the reservoir Clogged suction filter or shutoff valve not fully opened Valve spool linkage not allowing control valve to fully open Valve spool should move 3 8 10mm each way from neutral position Anti two block system malfunction Adjust relief valve by loosening nut on top of relief cartridge above winch gauge port and turning socket head screw clockwise to increase pressure or counter clockwise to lower pres
56. SED WIRE ROPE FAILURE MAY CAUSE SERIOUS INJURY OR DEATH SEE ANSI B30 5 SEC 5 2 4 FOR PROPER INSPECTION AND MAINTENANCE B 652 00614 2 1 3 Keep operator s compartment and decks free of mud and grease 4 If 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 FLYING OBJECTS FALLING OBJECTS DO NOT USE CRANE WITHOUT DO NOT USE ROPE CLIP ON LIVE SIDE CABLE RETAINER PIN S IN PLACE OF THE LOAD HOIST ROPE OVER CABLE SHEAVE DEATH OR SERIOUS INJURY CAN RESULT PRON A SE UBS WEAKENED ROPES WHEN DOWNHAUL WEIGHT AND HOOK ARE PULLED OVER END OF BOOM CAUSED BY A ROPE CLIP A 652 00615 9 The Rated Capacity Limiter must be checked before each shift and after each setup for the proper operating configuration on the display 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 2 LIFTING 1 Always refer to Crane Capacity Chart in operator s 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 surrou
57. SH399h4100 6 NOISN31X3 WOOS NO SAVOT 3914 LON AlI2VdV2 WOOS NIVIN 1332X3 LON LSNW 5 NOISN31X3 WOO8 NOILNVD ShOQNVZVH SI SSNSIN SI NOISN31X3 WOOS 3H1 3015 NO SONILVY ALIOVdV2 9 OL 3NYH2 40 NOIL V LOM 40 YILNI NON 5 1 1 2 SI 001 NOISN31X3 WOOF 138340 0 SH 0 3S NOISN31X3 WOOS 1HOIVHIS 0 ISN 40 31va 1VINAS ON 3 ANVH9 SIHL NO Savo OL 1 38 15 SNOLLIQNO2 3S3H I WN 829 OL SLNN 133HM FULL SVIS 91 S1 L1 X 9 HO 228 Y7 Ud 91 S1 00701 ed 892 Y7 Hd8L 9110 056 2UNSS2Md 071 JO HLONSNIS DNIMVIUS WNWINIW V LN31VAIno3 DUMI THM dI2 9 X 9 WIC 38 LSNW LINN 6 NO ANIT LSIOH 301S ED 1NOM4 SAONO 1 4 1 1 7 IN 1NOM4 YAO 1421 x NMOG i 15 54015 ATHLOONS A1M07S S 1OH1NO2 9 T
58. T PLATFORMS TO BOONTIS OR FROM AN UNTRAINED OPERATOR LOAD LINE THIS PRODUCT IS NOT INTENDED TO LIFT TRAINING INCLUDES COMPLETE KNOWLEDGE OF YOUR EMPLOYER S PERSONNEL DEATH OR SERIOUS INJURY WORK RULES ALL GOVERNMENTAL REGULATIONS AND CAN RESULT MANUFACTURE S OPERATION AND SAFETY MANUALS FOR THIS 652 00612 A 652 00604 4 The operator shall be responsible for those operations under his direct control Whenever there is any doubt as to safety the operator shall have the authority to stop and refuse to handle loads until safety has been assured 5 The operator shall not engage in any practice which will divert his attention while actually operating the crane 6 Do not run the engine an enclosed area or indoors without adequate ventilation 7 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 8 This list of rules is only a supplement to all federal state and local safety rules that may apply CRANE CONDITION 1 Before beginning operation each day thoroughly inspect the entire crane to be sure it is in good operating condition 2 Inspect load hoist rope and wedge socket daily We recommend rope inspection replacement and maintenance in accordance with ANSI B30 5 Sec 5 2 4 NWARNING FALLING OBJECTS WIRE ROPE WILL FAIL IF WORN OUT OVERLOADED MISUSED DAMAGED IMPROPERLY MAINTAINED OR ABU
59. TY MADE HEREIN 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 MO
60. W SNOLLIGNOD 849 OL SLNN 133HM 06 08 07 09 OS Ov OF 02 rz HULL SVIA Ud 9L 91 11 X 9 ed 228 06 USE ozo 0 Hd 91 1 00 01 641851 0061 0851 0221 0601 FULL ASL SHOL 4 056 AUNSSAYd 0218 0922 OStL 08 401 3 o e NX 071 40 HLONSYLS WNWININ Y LN3TVAIND3 04 009 0 W 96 X 9 VIG pL 38 LSNW LINN SIHL NO INIT 1SIOH WOOS 0 1 gt 13 330 HO 1H9IVMIS NOISN31X3 INOO8 YILIN woos 1 020 024 006 002 v6 m SL o s 09 099 OLLL oiv 08 x s 1 TN 018 ove OLeL oes 04 a i L J 0651 056 0651 009 59 9 aagana NO N0 NAO 092 0901 079 029 09 1437 0281 0611 0981 097 ss p oz 0502 0951 0502 0 8 05 gt SLUVLS 64016 GIOAV 1 1 018 61081 31743409 osez 0851 osez 0101 sv gt 2 91004 GMOS 01 IN31X3 0122 088 0122 orci ov 0 8 siuva 35007 5193430 LINN 0606 0922 0606 0051 se m 3NION3 TIO 13 31 Z ONLLVH3dO 330438 TW
61. acity 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 The Rated Capacity Limiter RCL 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 Please read the RCL Operation Manual The Rated Capacity Limiter displays a load load radius and boom angle that are obtained from electronic calculations using readings from pressure length and angle sensors These readings cannot be exact and should be treated as estimates In general the smaller the load and the higher the boom angle the larger the percent of error Be aware that the electronic and mechanical components cannot be 100 fail safe Do not consider the system as a substitute for good jud
62. andling a load near capacity limits or near a two blocking condition SUDDEN STOPS POSSIBLE DO NOT EXCEED CAPACITIES OR RANGE LIMITS LISTED ON LOAD CHART ALWAYS OPERATE SLOWLY WHEN NEAR CAPACITY LOADS RCL SYSTEM WILL STOP OPERATION WHEN SENSING OVERLOAD CONDITIONS DEATH SERIOUS INJURY OR PROPERTY DAMAGE CAN RESULT FROM SWINGING LOAD A 652 00613 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 being handled Boom extension capacities de
63. ation of all warning and safety devices Check operation of Rated Capacity Limiter according to the RCL User Manual Check the outrigger warning light for proper operation as described on page 2 9 Check Drum Rotation Indicator for proper operation Weekly Check tire pressure 110 PSI 758 kPa bias belted 135 PSI 930 kPa radial or 120 PSI 827 kPa for mining tire Check for loose wheel nuts Check lights and turn signals Check power steering lines for damage Check brake lines for damage Check operation of horn Check operation of hoist brake for smoothness Check outrigger holding valves for operation Check boom topping holding valve for operation Check swing gears for looseness or backlash Check boom extension cylinder holding valve for operation Check operation of windshield wipers if equipped Boom extension if equipped properly pinned with retainers in place Check all steering modes Clean all glass and check for cracks 3 4 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 IC 80 MAINTENANCE CHECKLIST Refer to the component maintenance section of this manual and to the engine operator s manual for complete instructions 50 HOUR INTERVAL Qvo X O dl 50 hour lubrica
64. derstand 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 built into 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 an outrigger creeps up while supporting a load there is an internal leak in the valve or in the outrigger cylinder piston seal 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 adjust able to hold the desired load If the boom creeps down with loads up through maximum capacity 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 BOOM TELESCOPE CYLINDER HOLDING VALVE A single acting holding valve is flange mounted to the cylinder rod end This valve holds the cylinder in the extended 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
65. e tie down location for transporting crane by truck or cargo container Steps A step is located on each front corner providing access to deck area Battery Located behind door on left hand rear corner of chassis Compartment available on right hand rear corner of chassis for second battery if necessary Outriggers Four hydraulic outriggers of box beam construction Independent controls for each outrigger Hydraulic cylinders are equipped with direct connected holding valves Pad dimensions 9 inches 23 cm x 12 inches 30 cm Pulling Eyes Heavy eyes on front bumper provided for attachment of hook block so main hoist line can be used for pulling loads at or near floor level Vandalism Protection Lockable hood for protection of engine compartment Accessory Storage Box Consists of box under front deck plate for carrying sheave block and other items Flush fitting cover is lockable Storage box is 14 inches deep 35 cm x 1072 inches wide 26 cm x 27 inches 68 cm long Headlight and Taillight Grilles Consists of welded steel protective grilles for headlights and taillights Easily removable for replacing bulbs Chassis Options and Accessories Auxiliary Winch Optional worm gear winch mounted behind front bumper with a lever control at the operator s console Hydraulic powered to provide bare drum line pull of 5 000 pounds 2260 kg at 46 feet per minute 14 m min Winch drum is 3 inches 90 mm diameter by 11 inches 2
66. e ground for changing it use the following procedure to prevent fouling the load line on the hoist Raise the boom about 5 feet 1 5 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 19 TWO PART LINE REEVING For loads above 9000 pounds 4080 kg the sheave block must be used The wedge socket should be pinned to the two part line lug 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 KT RETAINER PIN WEDGE SOCKET W COTTER PIN W COTTER WEDGE SOCKET FALLING OBJECTS DO NOT USE ROPE CLIP ON LIVE SIDE OF THE LOAD HOIST ROPE DEATH OR SERIOUS INJURY CAN RESULT FROM A SERIOUSLY WEAKENED ROPE CAUSED BY A ROPE CLIP 2 20 SAFETY DEVICES There are certain safety devices on the 80 that are designed to maintain control of a load even though power or hydraulic line failure should occur The operator should un
67. e ignition switch and crane controls to prevent unauthorized starting or movement during maintenance Disconnect battery when disabling crane Disconnect battery RCL and engine electronic module gas engine only 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 fingers clothing and hair away from moving parts A WARNING PINCH POINTS KEEP HANDS OUT DEATH OR SERIOUS INJURY CAN RESULT FROM MOVING PARTS 652 00603 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
68. ease the foot brake pedal If the machine has not moved use maximum engine speed The machine should not move Do not do this test for longer than 30 seconds Reduce engine speed to an idle Return the park brake lever to the fully on position from its partially applied position Place transmission in neutral If the machine moved during the test set the crane on outriggers and adjust the clearance between the park brake pad and brake disc and repeat the test Maximum clearance is 010 25 mm with park brake lever in the OFF position 3 22 TORQUE DATA BOLT SAE GRADE SAE GRADE SAE GRADE GRADE 1 82 5 8 MEDIUM CARBON MEDIUM CARBON MATERIAL LOW CARBON ALLOY STEEL Q amp T 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 92 125 132 120 163 190 258 282 382 THE FOLLOWING RULES APPLY 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 23
69. ecommended oils are not available These motor oils are not suitable substitutes when changing hydraulic oil because they lack certain additives that are needed for hydraulic system use 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 pump will result if it is run with the shutoff valve 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 to prevent damage 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 A possible indication of excessive oil temperature is a control valve lever that becomes hard to operate or sticks instead of returning to neutral 3 16 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
70. el Steer 2 10 Sequence of 2 10 Driving the 2 10 Operating the 2 11 Normal Gauge 2 11 Rated Capacity 2 12 Grane Capacity i ooi i debet 2 13 Crane Capacity Chart 80 14 2 15 Crane Capacity Chart 80 2 2 16 Crane Capacity Chart 80 34 2 17 Capacity 2 18 Sheave Block and Downhaul Weight 2 19 Two Part Line 2 20 Safety DeviC8s deb 2 21 Outrigger Check 2 21 Boom Elevation Cylinder Holding Valve 2 21 Telescope Cylinder Holding Valve 2 21 Anti Two Block 2 21 Optional Equipment 2 22 Installing and Stowing Boom Extension 2 23 Capacity Examples for Boom Extension 2 24 Front Auxiliary 2 25 Pintle HOOKS egets 2 26 Switch and Indicator Symb
71. ent 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 If 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 retracted to a safe radius or the load may be lowered to a safe place using the hoist control If the boom extension is at its angle limit the boom must be raised or the load 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 c
72. ent 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 690 kPa and blow air from the inside of the element Shake dust off of the outside of the element Make sure the gaskets and element fit properly and 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 it every 200 hours or more frequently in extremely dusty conditions Excessive exhaust smoke or loss of power may indicate a plugged filter 3 20 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 flus
73. erating 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 re center 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 pressure is low This eliminates steering wheel kickback when the steering wheel is released The steering system pressure was set at 1900 PSI 131 bar at the factory and this should not need adjustment For the four wheel drive option the pressure is set at 2500 PSI 173 bar The three steering modes are selected b
74. extension Make sure the front stow pin is in place and both sets of attach pins are removed from the lugs Remove the rear stow pin and swing the boom extension away from the rear end of the boom until the attaching inner lugs mesh on the near side of the boom Insert the attach pins in these inner lugs and retain them with the hairpin cotters Remove the front stow pin and swing the boom extension around to the front until the outer lugs mesh Insert the attach pins in their outer lugs and retain them with hairpin cotters To insert pin it may be necessary to rock boom extension Replace the rear stow pin and front 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 Check the Anti Two Block System for proper operation Store the Boom Extension in reverse order Lay the load line back in the boom tip sheaves and insert both retainer pins amp cotters Replace all of the pins in their lugs for storage and insert their hairpin cotters Install the sheave block on the load line if desired 2 22 SETTING THE OFFSET ANGLE ON THE OFFSETTABLE
75. g 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 ON 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 2 3 9 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 14 15 500 LBS 1 7029 10 operator shall not leave the controls while the load is suspended 11 Always use adequate parts of load hoist line for lifting heavy loads 12 Always be sure the rope is properly seated and wound evenly on hoist drum 13 Keep hands away from load hoist rope when hoist is being operated 14 Be sure at least three wraps of rope are left on the hoist drum to ensure against rope pulling out of its anchor 15 Never wrap the hoist rope around a load Always use approved rigging 16 Avoid pinch points such as between a rotating turret and the cab or in access holes of a telescoping boom or between the two block mechanism A WARNING PINCH POINTS KEEP HANDS OUT DEATH OR SERIOUS INJURY CAN RESULT FROM MOVING PARTS
76. ging on the hook can add further limitations to visibility during travel Always use a signal person when in doubt INSTRUMENTS AND CONTROLS The IC 80 instrument panel is equipped with a fuel gauge an hourmeter and a bubble level Also included are warning lights for low oil and transmission pressure check engine high coolant and transmission temperature turn signal high beam hazard lights and parking brake The ignition switch is key operated and has OFF RUN and START positions The ignition switch should always be turned off and the key removed when the vehicle is left unattended A horn button is on the shifting control The 80 is equipped with a standard lighting package An on off switch and a high beam indicator are on the instrument panel The dimmer switch is located on the left hand steering column control Stop lights are controlled by operating the foot brakes The turn signal control is located on the left side of the steering column Move the lever down for a left turn up for a right turn The emergency flasher lights are actuated by a switch on the instrument panel The hand brake lever is located on the right side of the operator s seat To apply lift the lever until the over center position is reached When adjustment is required turn the knurled knob on the end of the lever clockwise to tighten The brake must be released before adjustment can be made A warning light shows when the hand brake is applied The bra
77. gment 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 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 a 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 the 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 13 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 h
78. h 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 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 MECHANICAL ADJUSTMENTS FASTENERS All fasteners on the IC 80 should be checked and retightened if required as a part of the preventive maintenance program Particular attention should be given to the drive axle mounting bolts pump mounting bolts pump drive shaft bolts swing bearing bolts swing gearbox bolts winch bolts and wheel nuts All bolts used in assembly are heat treated Grade 5 or 8 Torque the swing bearing mounting bolts 3 4 diameter Grade 8 to 280 Ib ft 380 Nm or the nuts to 280 Ib ft 380 Nm The torque chart page 3 23 be used on all other bolts SWING GEARBOX The swing gearbox assembly is attached to the chassis top plate by four cap screws It is held in proper engagement with the external teeth on the bull gear by two setscrews It is further restrained from torsional movement by four bolts two on each side of the gearbox mounting flange The gearbox should be adjusted with the boom centered over front of the chassis This centers the gearbox pinion on the
79. 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 80 crane use o ring seals and if tightening the fitting fails to stop the leak the o ring should 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 li
80. heels are steered past the centered position SEQUENCE OF OPERATION DRIVING THE VEHICLE The following procedure is recommended for driving the vehicle 1 Perform the daily inspection and test See Page 3 4 2 Apply park brake 3 Place transmission control lever in neutral 4 Start engine and allow a warming period 2 10 5 While warming the engine set up the Rated Capacity Limiter configuration 6 Stow boom over front 7 Pull hoist line snug 8 Retract outriggers fully 9 Step on the brake pedal 10 Release park brake lever 11 Shift transmission to desired gear 12 Place forward reverse lever in desired position 13 Release brake and press on accelerator pedal 14 Slow down when making turns 15 Set park brake and lower outriggers or chock wheels to park WARNING Engine exhaust contains carbon monoxide a poisonous gas that is invisible and odorless Breathing engine exhaust fumes can cause death or serious illness Do not run the engine in enclosed areas without adequate ventilation 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 Place transmission control lever in neutral Start engine and allow a warming period at low RPM While warming the engine set up the Rated Capacity Limiter configuration Move accelerator pedal from medium to full speed Set all outriggers fully down on
81. ide of the turret to light ground under boom tip Includes switch at operator s station Net Weight 10 pounds 5 kg Work Lights Rear Two work lights recessed into rear bumper Provides lighted work area to rear of machine Hydraulic System Standard Tandem pump direct driven by engine crankshaft delivers 16 GPM 61 L min at 2 600 PSI 179 bar and 32 GPM 121 L min at 2 500 PSI 172 bar at 2 500 RPM governed engine speed System protected by relief valves suction line strainer and 10 micron full flow return line filter 25 gallon 95 L reservoir equipped with filler cap and breather element 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 Telescope cylinder and the boom elevation cylinder are equipped with direct connected holding valves Boom angle indicator on side of boom Boom Rotation Standard Heavy duty bearing rotation gear with external teeth supports boom Rotation is powered by hydraulic motor and worm gear drive Rotation gearbox may be adjusted as wear occurs to minimize backlash Boom is attached by high strength steel weldment Boom Hoist Standard Turret mounted planetary gear hoist is hydraulically powered to provide a bare drum line pull of 10 000 Ibs 4536 kg at a speed of 110 feet per minute 34 m min Hoist drum 934 inch 248 mm diameter by 13 inches 330
82. ill 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 transmission oil level Check fuel tank level Check tire pressure Check for loose pins bolts and retainers 10 Check for operation of foot brake 11 Check for operation and adjustment of parking brake See page 3 22 12 Check for operation of accelerator pedal 13 Start engine 14 Check power steering for operation Check all steering modes 15 Check operation of transmission gear selector lever 16 Check lights and turn signals for operation 17 Test drive unit and check for normal operation 18 Check operation of hydraulic outriggers 19 Check boom swing 20 Check boom elevation 21 Check boom extension pay out hoist cable during power extension 22 Perform cable break in procedure See page 3 10 23 Check anti two block system for proper operation and cutout of boom functions 24 Perform a load test according to the Rated Capacity Limiter Operation Manual 25 Check the outrigger warning light for proper operation as described on page 2 9 26 Check operation of Drum Rotation Indicator o co X Oo ede WARNING When the Rated Capacity Limiter is inoperative or malfunctioning it must be repaired as soon as reasonably possible When a
83. inches 546 mm from top to saddle of load hook 10 inch 254 mm O D sheave for 9 16 inch 14 mm rope Has swivel hook with safety latch 90 pound 41 kg downhaul weight and swivel hook are also provided for single part line Optional Boom Attachments Boom Extension 10 Ft 3 m Provides 10 feet 3 m of additional length for lifting loads with load line Boom extension may be stowed alongside base boom section when not in use Tip sheave attaching brackets and pins included Deduct 100 pounds 45 kg from Capacity Chart when boom extension is in the stowed position Includes switch for Anti Two Block Net Weight 300 pounds 136 kg Boom Extension 10 Ft 3m Offset Has three settings 0 degrees in line 15 degrees offset and 30 degrees offset Net Weight 350 pounds 159 kg Searcher Hook Nose Mount 5 000 pound 2268 kg capacity Swivel hook with spring latch hangs from support structure projecting outward from boom tip Net Weight 41 pounds 19 kg Specifications subject to change without notice OPERATION SECTION 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 AWARNING UNSAFE OPERATION DO NOT OPERATE THIS MACHINE FALLING HAZARD UNLESS YOU ARE QUALIFIED BY DO NOT INSTALL PERSONNEL TRAINING AND EXPERIENCE DEATH OR SERIOUS INJURY CAN RESUL
84. k with new hydraulic oil that meets the specifications in the table below Open the shutoff valves Start the engine and run it at low idle for 10 minutes then at high idle for 3 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 full mark if necessary with cylinders retracted 3 15 HYDRAULIC OILS FOR 80 AMBIENT TEMP RANGE 40 to 75 F 40 to 24 15 to 110 26 to 43 C 50510 130 10 to 54 POUR POINT 40 F MAX 15 F MAX 0 F MAX 40 C MAX 26 C MAX 18 C MAX VISCOSITY INDEX 140 MIN 95 to 100 95 to 100 VISC SSU 100 200 MAX 230 MAX 340 MAX 38 210 44 47 53 99 EXAMPLES MOBIL DTE 13 MOBIL AW 46 MOBIL AW 68 MOBIL UNIV ATF MOBIL DTE 25 MOBIL DTE 26 TEXAMATIC TYPE F CONOCO SUPER 46 CONOCO SUPER 68 TEXACO HD 46 TEXACO HD 68 OTHER REQUIREMENTS Must contain rust and oxidation inhibitor and antifoam and anti wear agents Must pass Vickers Vane Pump Test The 80 is factory filled with hydraulic oil for the 9 269 to 110 F 43 C range If significant portions of time are spent operating below 20 F 7 C or above 100 F 43 the oil should be replaced with an extreme temperature oil The oils shown are compatible with and may be combined with SAE 10W or SAE 20W 20 motor oil if it is necessary to add oil between changes and the r
85. ke and accelerator pedals are located and operated as they are in other vehicles already familiar to the operator A lever on the steering column controls the powershift transmission Moving the lever upward engages the transmission clutch for forward travel Rotating the handle of the lever selects the gear that is desired first through fourth and engages the clutch for that gear To put the transmission in reverse the machine should be brought to a stop The lever then is pulled downward through the neutral position into reverse The transmission and drive train components can be damaged by shifting from forward to reverse or vice versa while the unit is in motion or while the engine speed is above 1000 RPM neutral safety switch prevents starting the engine with the transmission engaged The shift lever must be in neutral to start the engine 2 8 Normal engine speed control uses the foot accelerator pedal On gas engines only a three position switch on the right dash panel provides preset engine speeds Parking brake must be set to activate system Press the high idle control switch temporarily to the right the engine will lock into the preset levels The center position of the switch enables the engine to dwell at 1 800 RPM The left switch position will lower the engine speed to 1 200 RPM To restore the foot accelerator either temporarily release the parking brake fully or turn the engine off 1200 RPM 1800 RPM MOMENTARY
86. maller capacity specified by the two charts must be used Refer to the IC 80 3J Capacity Chart on page 2 17 for the following examples In this first example the boom is elevated to 30 over the side of the crane The boom extension is offset to 15 and the load radius is 20 feet 6 m The outriggers are fully extended on concrete pavement and the crane is level The column for 360 ROTATION ON OUTRIGGERS shows the capacity at the 20 feet 6 m load radius to be 3400 pounds 1570 kg The column for 10 FOOT 8 METER BOOM EXTENSION STRAIGHT OR OFFSET MAIN BOOM ANGLE 30 shows the capacity at the 15 boom extension angle to be 2400 pounds 1090 kg Since 2400 pounds 1090 kg is less than 3400 pounds 1570 kg the load including the downhaul weight and slings must be limited to 2400 pounds 1090 kg In the second example the boom is elevated to 45 over the side of the crane The boom extension is offset to 30 and the load radius is 26 feet 8 m The outriggers are fully extended on concrete pavement and the crane is level The column for 360 ROTATION ON OUTRIGGERS shows the capacity at the 26 feet 8 m load radius to be 2450 pounds 1090 kg The column for 10 FOOT 3 METER BOOM EXTENSION STRAIGHT OR OFFSET MAIN BOOM ANGLE 45 shows the capacity at the 30 boom extension angle to be 2500 pounds 1130 kg Since 2450 pounds 1090 kg is less than 2500 pounds 1130 kg the load must be limited to 2450 pounds 1090 kg CAUTION
87. mm long Provides even pull and long cable life The hoist includes 125 feet 38 m of 9 16 inch 14 mm wire rope Boom Attachments Standard Anti Two Block Device Prevents damage to hoist rope and or machine components from accidentally pulling sheave block or downhaul weight against boom tip Consists of trip arm at boom tip which is moved upward by sheave block or downhaul weight as hook approaches boom tip Trip arm actuates electric switch which is connected through cable reel mounted on boom to solenoid dump valve in the hydraulic circuit This valve will dump 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 or TELESCOPE RETRACT control 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 There is also an override switch under the dashboard Sheave Block Downhaul Weight A 124 pound 56 kg sheave block is provided for two part line requirements Block is shorter than normal 2172
88. nagement system Water cooled 4 cylinder 181 CID 3 0 L bore 4 00 inches 102 mm stroke 3 60 inches 91 mm 59 HP 44 kW at governed speed of 2 500 RPM Maximum torque 138 pounds foot 187 Nm at 1 600 RPM Also includes special exhaust valves seats and valve rotators for use with LPG 70 amp alternator 17 6 gallon 66 6 L fuel tank and 33 pounds 15 kg LPG tank High temperature and low oil pressure shutdown is included in engine management system Throttle control switch for setting engine speed at 1200 or 1800 RPM Optional Engines and Engine Accessories Diesel Engine Cummins B 3 3L Turbo EPA Tier IV Interim Cummins B 3 3 turbo charged diesel industrial engine Water cooled 4 cylinder 199 CID 3 3 L bore 3 74 inches 95 mm stroke 4 53 inches 115mm 74 55kW at governed speed of 2 600 RPM Maximum torque 274 pounds foot 371 Nm at 1600 RPM 90 amp alternator included 17 6 gallon 66 6 L fuel tank Net Weight 180 pounds 82 kg Spark Arrester Muffler Spark arrester muffler used in addition to standard muffler Net Weight 10 pounds 5 kg Catalytic Converter Catalytic converter for diesel engine Reduces emissions Net weight 10 pounds 5 kg Engine Heater Engine coolant heater installed with hoses in coolant system to circulate warm water through engine Plugs into 120 volt AC extension cord 1 500 watts Transmission Powershift transmission with four speeds in forward and reverse Provides
89. ndings operator inexperience etc The weight of the load should always be known A WARNING CRUSH HAZARD KEEP MACHINE STABLE AT ALL TIMES OPERATOR COMPARTMENT WILL NOT PREVENT CRUSHING DEATH OR SERIOUS INJURY CAN RESULT FROM MACHINE TIP OVER A 652 00648 Be careful to prevent load swinging A swinging load can cause instability or loss of control of the load Be 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 A WARNING load The load may lower or LOAD POSITION DRIFT fall if there are damaged STAY CLEAR OF SUSPENDED LOAD parts in the crane Also the BE PREPARED FOR SUDDEN MOVEMENTS load may drop a short DEATH SERIOUS INJURY OR PROPERTY DAMAGE CAN RESULT FROM UNEXPECTED CHANGES IN LOAD distance due to thermal POSITION DUE TO CHANGES IN HYDRAULICS FRICTION contraction of the hydraulic OR DRUM WRAP A 651 00161 oil in the cylinders Do not use crane to drag loads sideways WARNING 6 A WARNING FALLING HAZARD NEVER RIDE ON HOOK LOAD OR ANY DEVICE ATTACHED TO LOADLINE n STAND CLEAR OUTRIGGERS CAN CAUSE SERIOUS CRUSHING INJURY 8 651 00036 RIDING ON CRANE LOADLINE CAN RESULT IN DEATH OR SERIOUS INJURY A 652 00606 Level the crane before liftin
90. ne during operation The air entrained in the oil will cause pumps to be noisy and if allowed to continue can damage the pump 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 connection 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 PRESSURE SETTINGS The hydraulic system is divided into two pressure circuits each having its own protective adjustable relief valve in the inlet sections of the control valve The functions operated by the control valve sections require different pressures for different functions These are shown below OPTIONAL FRONT WINCH RIGHT REAR O R RIGHT FRONT O R LEFT FRONT O R LEFT REAR O R ATTACH PRESSURE GAUGE HERE HOIST INLET OUTLET RELIEF SECTION INLET OUTLET RELIEF SECTION WL N N BB ATTACH PRESSURE GAUGE HERE 2600 PSI 180 BAR RELIEF PRESSURE ADJUST SCREW AND LOCK NUT 1500 PSI 180 BAR 103 BAR RELIEF P
91. ne failure The holding valve should checked with the boom elevated to the maximum angle and the boom extended to a 5 foot 1 5 m load radius A 18 000 pound 8160 kg load on a two part line is required for this test Use the hoist to lift this load about 6 inches 15 cm above the ground The radius 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 tighten screw until unpowered movement stops Retighten the lock nut to hold the proper adjustment 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 elem
92. nk BE SURE SHUTOFF VALVES ARE FULLY OPENED BEFORE STARTING ENGINE Remove the filter element and catch the hydraulic oil in a clean container Pour the remaining oil out of the old element into the clean container and inspect the oil for water and excessive contaminants water is found the oil should be changed in the reservoir and purged out of the cylinders If excessive particles are found the source should be located and fixed and the oil should be purged Lubricate the new element seal and install the new element Open the shutoff valves Run the engine and check for any leaking around the seal 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 and outrigger cylinders Leave the shutoff valves open and remove the drain plug Catch the oil and dispose of it properly Remove the breather from the top of the tank and clean the element with solvent and compressed air Clean out the tank with solvent and compressed air The suction strainer is threaded into the hydraulic tank suction port To service drain the oil from the tank Remove the suction hose from the strainer fitting Remove the suction strainer by turning the hex bushing counterclockwise Wash the element in clean solvent and allow to dry Apply oil to the o ring on the strainer and reassemble Replace the filter as described previously and refill the tan
93. nsmission front planetary drive steer and rear steer axles fuel tank hydraulic tank control station and full power steering The boom assembly includes a hydraulic powered continuous rotation turret 3 section boom hydraulic boom elevating cylinder hydraulic boom telescoping cylinders and hydraulic powered hoist Rated Capacity Limiter is standard IC 80 1J 3 section hydraulically extended boom with capacity of 18 000 pounds 8160 kg at a 5 foot 1 5 m load radius IC 80 2J 3 section hydraulically extended boom with capacity of 18 000 pounds 8160 kg at a 5 foot load 1 5 m radius IC 80 3J 3 section hydraulically extended boom with capacity of 18 000 pounds 8160 kg at a 5 foot load 1 5 m radius General Length IC 80 1J 14 5 feet 4 45 m IC 80 2J 15 8 feet 4 82 m IC 80 3J 17 8 feet 5 44 m Width 78 inches 1 98 Height Overall 7 3 feet 2 21 m Deck 41 inches 1 04 m Wheelbase 86 inches 2 18 m Ground Clearance Chassis Minimum muffler Angle of Approach Angle of Departure Outriggers Spread Penetration 1 6 11 5 inches 292 mm 5 75 inches 146 mm 22 degrees 21 degrees 9 6 feet 2 92 m 3 2 inches 82 mm General Continued Boom Movement Rotation Elevation Telescope Boom Speeds Rotation Elevation Telescope Sheave Height Nominal W O Boom Extension With Boom Extension Horizontal Reach W O Boom Extension With Boom Extension Weight Nominal 2 Wheel Drive
94. ols 2 27 SECTION3 MAINTENANCE Salety Rules E RES 3 1 New Unit Inspection and Testing Checklist 3 3 Operator Inspection and Testing Checklist 3 4 Maintenance 3 5 Lu briGatiOn ette sita ba koc kde c bero 3 7 Swing Bearing esse 3 7 Transmission 5 3 7 Axle L bricatiori n 3 7 SECTION 3 MAINTENANCE cont d Fluid Volume 3 7 Lubrication 3 8 Lubrication 24 3 9 Hoist Cable tee D eie 3 10 Hoist Cable Installation and Inspection 3 10 Hydraulic System 3 12 Steering 3 12 JIC 5 3 13 JIC Schematic 3 14 Hydraulic System 3 15 Care of Hydraulic 3 15 Hydraulic Oil Specifications 3 16 Hydraulic 3 17 Hydraulic System 5 3 18 Control
95. ondition To remedy this raise the boom slightly Or 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 key switch 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 There is a light on the dashboard to warn that one or more outriggers is not fully extended when using the ON OUTRIGGERS setup on the RCL Check the light daily when the outriggers are down and check to see that there is no load on the hook by raising and lowering each outrigger about three inches The light should come on when an outrigger is up 2 12 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 cap
96. our 12 month lubrication Adjust engine valve clearance per engine manual Perform engine maintenance specified in engine manual Change hydraulic fluid and filter and clean breather and reservoir Change transmission fluid and filter and clean strainer Replace vapor block inside slip ring See turret sub assembly in parts manual 24 MONTH INTERVAL om S N 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 HOURS DATE BY COMMENTS amp PARTS REQUIRED 3 6 LUBRICATION SWING BEARING LUBRICATION There is one grease zerk in a hole on the left 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 6 ounces 180 cc of grease each time the bearing is lubricated Also lubricate the gear teeth of the swing 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 check the coverage of the grease on all of the teeth Replace the pinion cover TRANSMISSION Check the
97. p 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 4 6 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 extend the outriggers and attach a load of about 1 000 pounds 450 kg Extend the boom fully Position the load at a 6 foot 1 8 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 1350 kg and repeat Be sure that the cable winds evenly on the hoist If the cable appears to twist too much remove 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 Section 5 2 4 If the wire rope needs to be replaced use 125 feet 38 m of 9 16 14 3 mm diameter 6X36 EIP RRL IWRC breaking strength 31 500 Ibs 140 kN HYDRAULIC SYSTEM The IC 80 hydraulic system consists of two subsystems driven by a double pump with a single inlet por
98. pend 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 1C 80 is 18 000 pounds 8160 kg but only at a 5 foot 1 5 m radius and on outriggers All variances of loads and radii of handling are shown on the crane capacity chart 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 rotation of the boom and are maximum allowable at the indicated radius The capacities OVER FRONT are limited as follows On Outriggers Boom 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 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 14 SVSNVM VX3N31 gt HO TVUNLONULS QILINI 33v ONIddIL CI
99. perator s Guard Door Hinged door covers operator compartment side opening Has latch handle outside and knob inside Rubber gasket contacts chassis Net Weight 40 pounds 18 kg 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 Top glass is 3 8 inch thick Door is equipped with a keyed lock to protect operators station Includes defroster fan 24 000 BTU heater with two speed fan and 12V electric windshield wiper There are sliding windows in the door and right hand side Dome light is included for operator s convenience Net Weight 215 pounds 98 kg Cab Heater Only Provides 24 000 BTU heater with two speed fan for units without All Weather Cab Net Weight 12 pounds 5 kg Windshield Washer Provides reservoir pump and nozzle for windshield washer Floor Mat Vinyl mat with toam backing covers floor front wall and lower portion of right hand wall of operator s compartment Deluxe Seat Deluxe Seat with upholstery springs provides additional operator comfort Net Weight 15 pounds 7 kg Noise Reduction Kit Cab Includes rubber floor mats and control valve cover and side panels of foam backed perforated vinyl for noise reduction Net Weight 13 pounds 6 kg Air Conditioning Complete system using 134a coolant Has combination cooling and heating unit in cab Net Weight 125 pounds 57 kg Electrical System
100. powershifts at any engine speed in any gear All shifting is done with a single lever electrical control mounted on the steering column Multiple disc clutch packs operated by solenoid valves provide forward neutral reverse and speed selection Equipped with oil cooler and filter Torque Converter Stall torque ratio of 2 2 1 Attached to engine flywheel 1 8 Transmission Gear 1st 2nd ard 4th 1 Drawbar pull is calculated based on GM 3 0L gasoline engine Front Axle Standard Planetary drive axle with 11 625 1 ratio Differential is Spin Front axle STANDARD Forward or Reverse 5 7271 3 23 1 1 711 1 00 1 is mounted rigidly to frame Rear Axle Standard Drop center axle beam casting with 112 degree oscillation in either direction Steering Standard Hydraulic steering unit with one double rod cylinder on rear axle and one double rod cylinder on front axle Allows limited steering when engine is not An electric switch in the operator s Speed MPH km h running Rear axle is the primary steer compartment is used to select rear wheel steering four wheel round steering or crab steering Electronic sensors and control box automatically align the steering when a new mode is selected Brakes Standard Four wheel hydraulic Wet disc brakes are on the front and rear axles Parking brake is disc type Tires Standard 10 00 x 15 16 ply highway type tread Mining and Ind
101. r the front this is the best position for stability Checking the chart again we see that the load is within the deck load limit of 14 000 pounds 6350 kg and that the travel speed with the load must be limited to creep speed Creep speed is less than 2 MPH 3 km h and defined as not to exceed a distance of 200 ft 60 m in a 30 minute period This is an approved relationship between load tire pressure and speed CAUTION AS THE BOOM IS LOADED DEFLECTION OF THE BOOM TIRES ETC WILL INCREASE THE LOAD RADIUS BE CONSERVATIVE IN YOUR CAPACITY ESTIMATE 2 18 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 downhauls may bypass this system and create a 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 RIGHT WIRE ROPE END SHOULD EXTEND APPROXIMATELY 2 1 2 6 cm UP INTO HOLE IN DOWN HAUL WEIGHT ANCHOR BY TIGHTENING BOLT WRONG When resting the downhaul or sheave block on th
102. rd will rotate it to the operator s right 2 Telescope Pulling back on the lever will retract the boom pushing forward will extend the boom 3 Boom Pulling back will raise the boom pushing forward will lower it 4 Outriggers The four outriggers may be operated simultaneously or in pairs left hand or right hand Special attention must be given to avoid hitting personnel or obstacles 5 Front Winch Optional Pulling back will pay winch line in pushing forward will pay winch line out 6 Hoist Pulling back on the lever will raise load line pushing forward will lower load line All controls may be used for simultaneous 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 the hydraulic system THREE MODE STEERING FUNCTIONS The 80 is equipped with three mode steering four wheel round steering can be used for making tight turns two wheel rear steering should be used for traveling long distances and crab steering can be used for maneuvering in tight places A switch on the dashboard sets the mode Electronic sensors and controls automatically align the wheels when a new mode is selected as the w
103. rope or other conducting link disconnect the battery the Rated Capacity Limiter display and computer and the engine electronic control module gas engine only 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 Do not allow antifreeze to contact skin Rinse off spills immediately with plenty of water Antifreeze is highly toxic if ingested Always disconnect negative cable first and refasten last to prevent accidental short through chassis components CAUTION Even with low voltage electrical systems severe arcing can occur Electrical shock or component damage can result from contact with energized conductors Use caution when working with any electrical device A WARNING CHEMICAL EXPLOSION KEEP SPARKS AND OPEN FLAMES AWAY BATTERIES GIVE OFF HYDROGEN GAS WHICH CAN BE EXPLOSIVE DEATH OR SERIOUS INJURY CAN RESULT ALWAYS WEAR EYE PROTECTION 4652 00601 3 2 Broderson 80 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 w
104. sure 7 Foreign particle in pilot operated relief 8 Worn or defective hydraulic pump gen 3 18 BOOM AND OUTRIGGER CIRCUIT The relief valve pressure setting at the inlet for boom control sections is 2600 PSI 179 bar This pressure is required for all but the swing control section Two work port relief valves are installed in the swing section These relief valves are set at 1500 PSI 103 bar The relief pressure at the inlet end of the valve can be adjusted with a wrench and an allen wrench Loosen the nut and tighten the threaded stem with an allen wrench to increase pressure and loosen the stem to decrease pressure Lock in place with the nut Actuate the BOOM LOWER or TELESCOPE RETRACT function with the cylinder fully retracted when making this adjustment While the pressure gauge is attached the swing function may be checked by capping the two work ports of the swing section and actuating the swing control lever in each direction If these pressures are improper the work port relief valve can be removed and shims added or removed as needed Pressure is changed approximately 100 PSI 7 bar to 125 PSI 9 bar for each 010 25 mm shim Part numbers for the work port relief valves and shims 9 340 00070 Work Port Relief Valve Gresen 7460 002 PS 1500 C 9 340 00032 Shim 010 25 mm Gresen 0462 001 9 340 00031 Shim 020 5 mm Gresen 0459 001 9 340 00030 Shim 040 1 mm Gresen
105. t The 16 GPM 61 L min vane pump supplies the hydrostatic steering function and the boom and outrigger functions The hoist and brake booster are powered by the 32 GPM 121 L min vane pump The boom outriggers hoist and optional front winch are controlled by one valve assembly The 16 GPM 61 L min pump flow enters the steering flow control valve first and then flows into the left hand section of the control valve assembly supplying the swing telescope boom and outrigger sections The flow from the 32 GPM 121 L min pump enters the brake booster flow control valve first and all but 4 GPM 15 L min is directed to the inlet section to the left of the hoist valve Adjustment procedures for the crane hydraulic functions are given on page 3 18 through 3 20 The schematic of the hydraulic system is shown on the next page STEERING SYSTEM The three mode steering system is shown in the schematic on the next page The 80 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 control valve is in the line between the 16 GPM 61 L min pump section and control valve Oil from the 16 GPM 61 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 op
106. tion as shown on lube schedule Inspect wire rope thoroughly Inspect for physical damage and leaks Clean radiator fins and check coolant level Check tire pressure and condition Check fluid levels in engine transmission hydraulic tank and brakes Clean air filter inlet Screen and empty the pre cleaner dust cup Inspect air intake and exhaust systems for cracks leaks and loose bolts Change engine oil and filter after first 50 hours and at 250 hours thereafter Torque cylinder head bolts See engine manual Adjust engine valve clearance See engine manual Check tension and condition of fan and alternator belts Check the hydraulic filter indicator with warm oil change element if indicated Check diesel engine idle and maximum speed and adjust if necessary Check swing gear and pinion fit and gear train backlash Check swing bearing and gearbox bolt tightness See page 3 21 Check axle mounting bolts and pins Torque wheel mounting nuts to 500 pounds foot 678 Nm Check for loose pins or pin retainers Check brake lines and steering lines for damage Inspect sheaves and hooks for damage or excessive wear Visually inspect welds on boom turret and outriggers Perform a load test according to the Rated Capacity Limiter User Manual Check operation of outrigger warning light as described on page 2 9 Check tension and condition of engine belts 250 HOUR OR 3 MONTH INTERVAL ED CD SE
107. ustrial Tires Non Marking 10 00 x 15 16 ply rating pneumatic tires Net Weight 120 pounds 57 kg 1 9 Pull Pounds kg 15 500 7031 8700 3946 4600 2087 2500 1134 Tire Options Solid Rubber Tires 8 25 x 15 These tires will reduce overall height and ground clearance by 1 2inches Net Weight 400 pounds 181 kg Foam Filling of Tires 10 00 x 15 All four tires foam filled Net Weight 900 pounds 408 kg Spare Tire and Wheel Mounted Highway Tread 10 00 x 15 16 ply Radial Net weight 163 pounds 74 kg Mining and Industrial Tire Net weight 193 pounds 88 kg Mining and Industrial Tire Non Marking Net weight 193 pounds 88 kg Chassis Standard Cargo Deck Total Deck Area 53 square feet b m A maximum of 14 000 pounds 6350 kg may be carried on the deck when centered over or between axles Seven stake pockets are provided along edges of deck for 1 3 inch 34 mm pipe stakes Stakes furnished Cargo decks have skid resistant coating Heavy deck loads allowed at creep speed below 2 MPH 3 2 km h and less than 200 feet 61 m in 30 minutes Fire Extinguisher 1 A 10 BC 212 pound 1 1kg dry chemical Mounted in operator s compartment Lifting Rings Consists of four rings one at each corner of the load deck so sling can be attached for lifting crane Rings hang below deck surface when not in use Tie Downs Two holes in the rear bumper in conjunction with the pulling eyes provid
108. ut 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 ANCHOR WEDGE 1 24 mm STEEL WIRE 1 4 9 16 14 mm WIRE ROPE SEIZING HOIST CABLE ANCHOR FOR 9 16 DIA 14 mm ROPE 3 10 032 DIA 0 80 mm ANNEALED 10 11 12 13 14 15 16 17 18 Position the hoist drum with the cable anchor on top 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 1 inch 24 mm 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 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 ta
109. y a switch on the dashboard which activates the automatic alignment system Electronic proximity sensors and logic controls delay the switching of the steering mode until the wheels are centered The proximity sensors should be cleaned periodically with a rag to prevent dirt buildup from blocking their operation 3 12

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