Broderson IC-400-3B Operation And Maintenance Manual Download | Manualshive

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FLUID VOLUME

Hydraulic Reservoir – 156 gallons (509 L)
Fuel Tank – 80 gallons (303 L)
Planetary Hoist – 6.5 quarts (6.2 L)
Axle – Differential Housing – 5.4 gallons (20.5 L), Hubs – .5 gallons (1.85 L)
Transmission – 5 gallons (19 L)—

Not including oil cooler and lines.

Engine Oil Capacity – 10.5 quarts (10 L)
Engine Cooling System – 14 quarts (13.2 L) fill to bottom of fill neck in surge tank.

IC-400-3B LUBRICATION CHART

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Summary of Contents for IC-400-3B

Page 1: ...________________________________________________________________ _________________________________________________________________________ SOLD AND SERVICED BY ________________________________________...

Page 2: ...product WITHOUT LIMITING THE GENERALITY OF THE FOREGOING BMC EXPRESSLY DISCLAIMS THAT THE WARRANTY MADE HEREIN EXTENDS TO A PERSON WHO RENTS OR LEASES ANY BMC PRODUCT OR WHO PURCHASES ANY BMC PRODUCT...

Page 3: ...ide information required for these conditions The recommendations for periodic inspection test and maintenance are minimum standards for safe and economical performance When ordering parts the unit se...

Page 4: ...1 2 IC 400 B DIMENSIONS...

Page 5: ...1 3 IC 600 A TURNING DIMENSIONS...

Page 6: ...oom telescope cylinder and hydraulic powered planetary gear hoist Rated Capacity Limiter RCL is standard IC 400 B 4 section hydraulically extended boom with capacity of 50 000 pounds 22 680 kg at an 8...

Page 7: ...e when coolant is too hot or oil pressure is too low Charge air cooler grid heater and engine block heater which plugs into 120 volt AC extension cord are included Tier 4 Final engines require the use...

Page 8: ...ndard Hydraulic steering unit with a 4 0 inch 10 1 cm cylinder attached to each axle Allows limited steering when engine is not running Selecting front wheel steering 4 wheel steering or crab steering...

Page 9: ...e side panels allow improved access to engine with boom centered over the front of machine Engine fluid levels can be checked without starting engine and swinging boom Chassis Options and Accessories...

Page 10: ...itch Push button switch on LH panel separates boom function from outrigger functions Operator Compartment Options and Accessories Floor Mat Vinyl mat with foam backing covers floor front wall and unde...

Page 11: ...return line filter Hydraulic Reservoir 156 gallon 509 L capacity equipped with 10 micron breather on top and oil level gauge on side Boom Standard Four section high strength steel construction equippe...

Page 12: ...ength and load radius In the event of an overload it blocks the following boom functions HOIST RAISE TELESCOPE EXTEND BOOM LOWER SWING LEFT and SWING RIGHT These circuits are returned to normal by low...

Page 13: ...ice which will divert his attention while actually operating the crane 6 Do not run the engine in an enclosed area or indoors without adequate ventilation 7 Do not use ether for starting Ether is high...

Page 14: ...rease 4 Keep all window glass clean Keep gauges and displays clean 5 Tools lubricants or rags on the crane should be kept in a secured toolbox 6 7 8 The Rated Capacity Limiter must be checked after ea...

Page 15: ...e 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 t...

Page 16: ...e page 2 22 11 The operator shall not leave the controls while the load is suspended 12 Always use adequate parts of load hoist line for lifting heavy loads 13 Always be sure the rope is properly seat...

Page 17: ...rweight in the field to increase lifting ability constitutes a safety hazard 20 Always keep crane boom at least 20 feet 6 m away from any electric power lines of unknown voltage If voltage is known us...

Page 18: ...s are the responsibility of the rigger in charge 24 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 lo...

Page 19: ...FRONT ON RUBBER capacity 2 When raising the boom or moving the unit with boom elevated be sure there is adequate overhead clearance for boom 3 For carrying loads on decks A Boom must be retracted cen...

Page 20: ...n tank 9 Shut off engine before refueling and remove fuel cap slowly Vapor pressure in tank can cause a burst of fuel and vapor when the cap is removed Always refuel with proper fuel and into proper t...

Page 21: ...for Analog and Digital Inputs and outputs to aid with trouble shooting b A fuse relay diagram that will show the operator when a fuse or relay has an issue and highlight which fuse or relay it is for...

Page 22: ...tons simultaneously Repeating this will disengage the emergency flasher lights The steering column provides tilting and telescope features and each have a hold lever on the side of the column to hold...

Page 23: ...stem Press the preset button once to engage the low idle state of the engine a second time to engage the mid range set point of 1200 RPM and a third time to engage the high idle set point of 1800 RPM...

Page 24: ...3 vhabh 3 anww3 wvaLh3etL3wvb 3wngLf3 dwwngr3mbkl3anww3 hbncL3 etL3 wvb 3 wngLP3 3 Dgkwd L 3 ng3 etnc3 yvscenkl3 nc3 b3 hdp3 hvebenvg3 ng nkbevh3 etbe3 anww3 inmhbeL3 bc3 etL3 jvnce3 0hdp3 hvebeLcP33...

Page 25: ...n the lifting radius for the load being lifted 3 Start engine and allow a warming period at low RPM if not already running 4 Apply park brake which also places the transmission in NEUTRAL 5 Set all ou...

Page 26: ...ch parameter Engine and system fault codes will display on the home screen as a pop up window when those events occur It also has warning and shutdown icons that will turn on when a critical threshold...

Page 27: ...will also sound A pop up window identifying what the engine fault s is will also appear on the screen alerting the operator of the issue There may be several to scroll through W A R N I N G The crane...

Page 28: ...nged TELESCOPE RETRACT SWING LEFT or SWING RIGHT may also be used if safe DO NOT USE THE BOOM RAISE CONTROL as this may increase the overload If the load is at the maximum allowable load radius the bo...

Page 29: ...and measured radii must take precedence over the Rated Capacity Limiter readings The Rated Capacity Limiter displays a load load radius and boom angle that are obtained from electronic calculations us...

Page 30: ...default the configuration to an ON RUBBER chart The IC 400 is equipped with transducers that detect when all the outriggers are completely deployed These transducer inputs are fed to the RCL which all...

Page 31: ...is 50 000 pounds 22 680 kg but only at an 8 foot 2 4 m radius on outriggers All load ratings operating radii work areas boom extension offsets and outrigger conditions are shown on the capacity chart...

Page 32: ...2 2M3 CAPACITY CHART...

Page 33: ...2 213 CAPACITY CHART METRIC...

Page 34: ...art shows that 12 500 pounds 5670 kg is the maximum load on one part line so the sheave block is required The chart also shows the weight of the standard sheave block to be 470 pounds 213 kg The rigge...

Page 35: ...Notice the load limit for each hoist rope arrangement For single part reeving the load line must pass through the center of the downhaul through the wedge socket and the dead end clamped in the block...

Page 36: ...should be pinned to the wedge socket anchor at the boom tip as shown in the figure The dead end of the rope in the wedge socket should be clamped as shown in the figure below The clamp must not be us...

Page 37: ...ing holding valve is mounted to the telescoping cylinder This valve holds the cylinder in the extended position if power or hydraulic pressure line failure occurs This valve is adjustable to hold the...

Page 38: ...he use of lock out tag out if needed for maintenance or repair BRAKE PRESSURE WARNING ICON An indicator icon is included in the main display to alert the operator when the hydraulic pressure is low in...

Page 39: ...and lugs and retain them with the hairpin cotters 9 Remove the front stow pin and swing the boom extension around to the front until the left hand lugs mesh 10 Insert the attach pins in their outer lu...

Page 40: ...not to operate the TELESCOPE EXTEND 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...

Page 41: ...ROTATION or OVER FRONT shows the capacity is at the 44 foot 13 m load radius to be 8050 pounds 3650 kg The column for BOOM EXTENSION MAIN BOOM ANGLE 50 shows the capacity for the 15 boom extension of...

Page 42: ...loads on the boom load line during pick and carry operation 2 To drag loads on the ground to a position where they may be safely lifted with the boom 3 To pull the crane out of mud or other obstacles...

Page 43: ...n damage the drivetrain 3 Use slow and smooth motions to avoid shock loads or overrunning loads Make sure vehicle being towed is occupied to steer and brake Pintle Hooks also allow the crane to be tow...

Page 44: ...art Windshield washer switch Off Stop Windshield defroster switch Battery not charging Heater switch Hour meter Air conditioner switch Read operator s manual Ventilation fan switch Sound level notific...

Page 45: ...ator Transmission oil temperature Engine start Brake fluid fill location Engine idle set Hydraulic oil low level mark Check engine Hydraulic oil filter restriction indicator Stop engine Hydraulic temp...

Page 46: ......

Page 47: ...f injured by escaping fluid see a doctor at once Serious reaction or infection can occur 6 Wear safety glasses and shoes 7 Do not wear loose fitting or torn clothing 8 Remove rings and other jewelry 9...

Page 48: ...ly 23 When welding on the crane or on anything connected to the crane by wire rope or other conducting link disconnect the battery the Rated Capacity Limiter components controls system and its compute...

Page 49: ...ck operation of transmission gear selector lever 16 Check lights for operation 17 Test drive unit and check for normal operation 18 Check operation of hydraulic outriggers 19 Check boom rotation 20 Ch...

Page 50: ...steering operation 12 Observe chassis for normal driving operation 13 Observe boom operation for normal power speed and sequencing 14 Check load line and hooks for damage 15 Check condition of sheave...

Page 51: ...ake for smoothness 8 Check outrigger holding valves for operation 9 Check boom topping holding valves for operation 10 Check rotation gears for looseness or backlash 11 Check boom extension cylinder f...

Page 52: ...ds for nut 13 Check axle mounting bolts 682 foot pounds 925 Nm 14 Torque wheel mounting nuts 475 foot pounds 645 Nm torque 15 Check for loose pins or pin retainers 16 Check brake lines and steering li...

Page 53: ...er and clean breather and reservoir 5 Change transmission fluid filter and clean strainer 24 MONTH INTERVAL 1 12 month maintenance 2 Pressure test engine cooling system 3 Flush cooling system 4 Change...

Page 54: ...st 6 5 quarts 6 2 L Axle Differential Housing 5 4 gallons 20 5 L Hubs 5 gallons 1 85 L Transmission 5 gallons 19 L Not including oil cooler and lines Engine Oil Capacity 10 5 quarts 10 L Engine Coolin...

Page 55: ...3 02 IC 400 3B LUBRICATION CHART...

Page 56: ...3 1 2 IC 400 3B LUBRICATION CHART...

Page 57: ...3 112 IC 400 3B LUBRICATION CHART...

Page 58: ...000 hours then 250 or 12 mo Max 14 Rotation Bearing MPG X 1 Zerk 15 Rotation Gear Teeth OGG X Brush On 16 Rotation Pinion Bearing MPG X 1 Zerk 17 Rotation Gearbox WGO X 24 Check 250 Change 24 Mo 18 Sh...

Page 59: ...iate ladders or steps lubricate inner chains and chain sheaves through windows There are grease fittings on chain sheave shafts both inside and outside the boom Reach in through boom windows with a lo...

Page 60: ...the hoist 4 Check to make sure the wire rope does not contact the mounts for the wire rope retain ers 5 LOWER the boom and check to make sure the rope does not slip off the sides of the rub pads moun...

Page 61: ...but do not start the engine Pump the brake pedal several times to discharge the ac cumulators If the icon does not turn on there is a malfunction in the sensor or wiring The problem must be found and...

Page 62: ...umulators store hydraulic oil under pressure for use at the brake calipers They are bladder type accumulators and require a pre charge pressure in the gas bladder The brake accumulator pre charge pres...

Page 63: ...The oil used in this transmission is Mobil ATF D M automatic transmission fluid with the Allison C 3 rating See the recommendations below Other oils can cause shortened transmission life due to materi...

Page 64: ...ler that is part of the radiator package The filter is located on the side of the chassis behind the right rear wheel Change the filter on a new machine after the first 20 hours Thereafter the filter...

Page 65: ...warm the oil above 100 F 40 C 2 Remove the transmission drain plug and drain the oil Check for water foam or exces sive particles in the oil 3 Change the filter element as described previously 4 Remo...

Page 66: ...3 4 2 TRANSMISSION HYDRAULIC SYSTEM A pump in the transmission provides hydraulic power for operating the range shift solenoid and 4X4 disconnect solenoid...

Page 67: ...to normal operation be sure to fully back the release bolts out to their orginal location TRANSMISSION TROUBLESHOOTING If the transmission does not function properly there are several simple checks t...

Page 68: ...eps please call your Broderson dealer or the Broderson Service Department to have a Dana service representative contact you TOWING If the crane must be towed run the engine at low idle to release the...

Page 69: ...3 432 WHEEL ALIGNMENT DRIVE AXLES HUBS AND DIFFERENTIALS Maintain fluid levels as shown in the figures below If necessary add 80W 90 gear lube Check every 50 hours and change every 12 months...

Page 70: ...NGE MOUNT INSTALLATION INSPECTION The following steps will assure that the wire rope i e hoist rope hoist cable or load line winds smoothly and evenly on the hoist and will yield greater safety and lo...

Page 71: ...little faster until the remainder of the cable is installed 10 Leave about 40 feet 12 m of cable on the ground to install the sheave block The sheave block must be used for cable preloading to ensure...

Page 72: ...es the outrigger control valve lower con trol valve braking and steering circuits The lower control valve is located below the operator station mounted to the chassis The outrigger control valve is mo...

Page 73: ...3 27 JIC HYDRAULIC SCHEMATIC...

Page 74: ...system to change the brake system 3 Machine Level Sensor located below the slewing bearing monitors the machine s level status 4 Steer Position Sensors located in each steer cylinder integral to the...

Page 75: ...n include 1 Swing Position Sensor located in the slipring itself transmits data to the above rota tion control module on the CANOPEN network for swing angular position of the boom 2 Cable Reel mounted...

Page 76: ...sue calibration issue or fault related to the engine operation Prior to attempting to trace or troubleshoot the system machine should be shut off and re started several times as the faults may clear t...

Page 77: ...stem requirements Since the amount of oil required for steering is usually a small portion of the pump output the lower control valve is always operational while the unit is being steered Crane operat...

Page 78: ...ate the new element seal and install the new element 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 Re...

Page 79: ...osene 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 dama...

Page 80: ...left one full revolution Swing the turret right one full revolution 6 Extend and retract each outrigger a minimum of five times 7 With the crane on outriggers steer the crane wheels fully left and ri...

Page 81: ...Take care not to over tighten pipe threads 4 Do not use Teflon tape to seal pipe threads Loctite type anaerobic sealant is preferred Leaks in component parts such as pumps valves and motors that canno...

Page 82: ...der barrel This valve is de signed 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 t...

Page 83: ...6300 kg load on a 4 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 c...

Page 84: ...rizontal then slightly retract the boom to let the chains relax Measure the inside chain drape at the center of the rear 3rd stage and 2nd stage windows as shown in Illustration 3 See arrows in the wi...

Page 85: ...3 39 BOOM CHAIN ADJUSTMENT...

Page 86: ...the Replace Zone replace the primary and secondary filter If the filter has not been changed for over 1000 hours replace the filter regardless of the restriction indicator reading or dash icon COOLIN...

Page 87: ...ng function will appear loose if too much gap Retighten the four mounting bolts and the six side bolts ELVGLHGYARUCSEFTVGWRhELeeTELR R W A R N I N G Failure to relieve trapped hydraulic pressure may r...

Page 88: ...n adjustable wrench may be used Override Handle b Start the engine c Using a ladder or steps access the Upper Control Valve on the right side of the turret d Put the handle on the small protruding sha...

Page 89: ...hile on rubber This may overload the crane g Turn off the crane 4 To override the outrigger functions a Locate the enable solenoid valve on the outrigger control valve The outrigger control valve is l...

Page 90: ...sponds to the Diverter Valve From top to bottom the valve sections control the right rear right front left front and left rear outriggers j Start the crane k On the cab side of the Lower Control Valve...

Page 91: ...16 24 32 40 54 60 81 1 2 37 50 60 81 92 125 9 16 53 72 88 119 132 179 5 8 74 100 120 163 180 244 3 4 120 163 200 271 296 401 7 8 190 258 302 409 473 641 1 282 382 466 632 714 968 THE FOLLOWING RULES A...

Page 92: ...1 W I R I N G IC 400 B WIRING DIAGRAM...

Page 93: ...2 W I R I N G...

Page 94: ...3 W I R I N G...

Page 95: ...4 W I R I N G...

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