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Broderson IC-600-A, Operation And Maintenance Manual

The Broderson IC-600-A is a powerful industrial crane designed for heavy lifting operations. Ensure optimal performance and safety with our comprehensive Operation And Maintenance Manual. Download this essential manual for free from our website, manualshive.com, and have it readily available for all your operational needs.

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SECTION 3  MAINTENANCE

Safety Rules……………...………………………………………………………………..3-1
New Unit Inspection and Test……………..…………………………………………….3-3
Operator Inspection and Test……..……….…………………………………………….3-4
Maintenance Checklist………………...…………………………………………………….

3-6

Fluid Volume…………………...…………..…………………………………………………….

3-8

Lubrication……………………...………………………………………………………………….

3-8

Lubrication Chart………………………………..………………………………………………

3-8

Lubrication Schedule……………………………..…………………………………………..

3-12

Boom Chain Lubrication…………………………….……………………………………….

3-13

Rub Pad Adjustment…………………………….…...……………………………………….

3-14

Rotation System Lubrication………………………….…………………………………..

3-15

Brake System Maintenance……………...……………………………………………….

3-15

Transmission Maintenance………..……………………………………………………….

3-17

Transmission Fluids……………………………...……………………………………………

3-17

Transmission Filter Change……...…………..……………………………………………

3-18

Transmission Fluid Change……...…………..……………………………………………

3-19

Transmission Hydraulic System……...………………………………………………….3-20

Transmission Shifter……..………...…………..……………………………………………

3-20

Adjusting and Bleeding the Parking Brake...………………………………

3-21

Transmission Troubleshooting……………......………………………………

3-21

Towing…………………………………….……………......………………………………

3-22

Wheel Alignment……..…………………...………………………………………………….

3-23

Drive Axles, Hubs and  Differentials……....…………………………………………. 3-23
Hoist Cable Installation & Inspection & Lubrication………..……..…………………..3-24
Control and Hydraulic System ……….…….…………………………………………….

3-26

JIC Schematic…………………………………..………………………………………………….

3-27

Electrical System & Controls…………….………………………………………………….

3-28

Control System Faults……...…….………………………………………………….

3-30

Hydraulic System Maintenance……………..…………………………………………..3-31

Steering System……………………………….………………………………………………..

3-31

Care of Hydraulic Oil……………………………...…………………………………………..

3-32

Hydraulic Oil Specification…………………………...…………………………………….

3-33

Removal of Air from Hydraulic Circuits……………………..…….….…………….

3-34

Hydraulic Seals………………………………...…………………………………………………

3-35

Pressure Settings……………………..…………………………………………………………

3-36

Hoist & Boom Circuit…………….…………………………………………………….

3-36

Swing and Outrigger Circuit……………………………..………………………..

3-36

Brake System Circuit……………...………………………..………………………..

3-36

Boom Lift Cylinder Holding Valve……………..………………………………

3-36

Telescope Cylinder Holding Valves…………………...…………………….

3-37

Boom Sequence……………..………………………………………………………… 3-38

Valve Settings………………………………...…………………...…………………….

3-38

Boom Troubleshooting………………...…………………...…………………….

3-38

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

3-39

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

3-40

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

3-40

Cooling System………………………………...…………………………………………………

3-40

Spare Parts Lists………………………………...……………………………………………….

3-40

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

3-40

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

3-41

Fasteners…………………………………...……………………………………………………….

3-41

Rotation Gearbox……………………………...……………………………………………….

3-41

Relieving Hydraulic Pressure….………...……………………………………………….

3-41

Manual Override of Hydraulic Functions…………………………………..…………………………………………………….

3-42

Torque Data…………………………………..…………………………………………………….

3-45

Wiring Diagram…….…………………………………………………….
JIC Schematic…………………………………..………………………..

Summary of Contents for IC-600-A

Page 1: ...________________________________________________________________ _________________________________________________________________________ SOLD AND SERVICED BY ________________________________________________________ ___________________________________________________________ ___________________________________________________________ MODEL NO ___________________________SERIAL NO _________________...

Page 2: ...w 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 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 sign...

Page 3: ...y Chart Metric 2 21 Capacity Example 2 22 Sheave Block and Downhaul Weight 2 23 Multi Part Line Reaving 2 24 Safety Devices 2 25 Outrigger Check Valve 2 25 Boom Cylinder Holding Valve 2 25 Telescope Cylinder Holding Valve 2 25 Hoist Brake and Holding Valve 2 25 Anti Two Block System 2 25 Emergency Stop Switch 2 26 Operator Present Seat Switch 2 26 Operator Present Trigger Switch 2 26 Battery Disco...

Page 4: ...ication 3 24 Control and Hydraulic System 3 26 JIC Schematic 3 27 Electrical System Controls 3 28 Control System Faults 3 30 Hydraulic System Maintenance 3 31 Steering System 3 31 Care of Hydraulic Oil 3 32 Hydraulic Oil Specification 3 33 Removal of Air from Hydraulic Circuits 3 34 Hydraulic Seals 3 35 Pressure Settings 3 36 Hoist Boom Circuit 3 36 Swing and Outrigger Circuit 3 36 Brake System Ci...

Page 5: ...tion required for these conditions The recommendations for periodic inspection test and maintenance are minimum standards for safe and economical performance When ordering parts the unit serial number unit model number part number part description and quantity must be provided This unit must not be altered or modified without written factory approval To reorder this manual ask for IC 600 A Operati...

Page 6: ...1 2 IC 600 A DIMENSIONS ...

Page 7: ...1 3 IC 600 A TURNING DIMENSIONS ...

Page 8: ...oom telescope cylinder and hydraulic powered planetary gear hoist Rated Capacity Limiter RCL is standard IC 600 A 4 section hydraulically extended boom with capacity of 60 000 pounds 27 216 kg at an 8 foot 2 4 m load radius Horizontal reach of 70 feet 21 34 m and vertical reach of 81 1 feet 24 71 m General Length Overall 32 feet 10 inches 10 01 m Chassis 17 feet 9 inches 5 41 m Width 8 feet 6 inch...

Page 9: ... engine 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 of Ultra Low Sulfur Diesel ULSD that meets the EPA defined sulfur content of 15 parts per million ppm Tier 4 Final engines also use Diesel Exhaust Fluid DEF and DEF must be added as needed to m...

Page 10: ... Standard 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 is done through electronic push button operator interface in the operator compartment Electronic sensors and control module automatically sense when the steering is centered upon the selection of...

Page 11: ...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 Auxiliary Winch Optional planetary gear winch mounted on front outrigger bumper with a single lever control in the operator compartment Hydraulic powered to provide bare drum line pull of 15 000 lbs 6...

Page 12: ...d man switch 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 under seat compartment of operator s compartment Net Weight 5 pounds 2kg Noise Reduction Kit Cab Includes vinyl floor mats and side panels of foam backed perforated vinyl for noise reduction Net W...

Page 13: ... flow of 103 GPM 390 L min at 4000 PSI 275 8 bar and 2600 RPM engine speed System protected by relief valves suction line strainers and a 150 GPM 10 micron 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 equipped with lubricant filled bearing pads for eff...

Page 14: ...d Capacity Limiter Operational 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 blocks 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 re...

Page 15: ......

Page 16: ...tice 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 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 ...

Page 17: ...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 each setup for the proper operating configuration on the display ...

Page 18: ...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 the boom slowly whenever these systems might stop the boom 4 Do not allow anyone to put any part of his body under a load The load may lower or fall if there are damaged parts in the crane Also the loa...

Page 19: ...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 seated and wound evenly on hoist drum 14 Keep hands away from load hoist rope when hoist is being operated 15 Be sure at least three wraps of rope are left on the hoist drum to ensure against rope pulling...

Page 20: ...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 use chart on side of turntable to determine required clearance distance When in doubt contact local power authority 21 If boom should accidentally contact a power line keep ground personnel away from cr...

Page 21: ...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 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 th...

Page 22: ...nstalled K Do not exceed the OVER FRONT ON RUBBER capacity 2 When raising the boom or moving the unit with boom elevated be sure there is adequate overhead clearance for boom 3 For carrying loads on decks A Boom must be retracted centered and lowered as close as possible B 2 MPH 3km h maximum road speed Reduce speed below 2 MPH 3km h to C Remove load hook from load before traveling 4 Cranes with r...

Page 23: ...in 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 tank 10 Know your visibility limitations Loads being carried on the deck or hanging on the hook can add further limitations to visibility during travel Always use a signal person when in doubt ...

Page 24: ...iagram that will show the operator when a fuse or relay has an issue and highlight which fuse or relay it is for easy locating This page can be accessed through pressing the icon or the physical button below the icon on the 15 button panel Climate Page Provides controls for the heating and cooling in the operator compartment This page can be accessed through pressing the icon or the physical butto...

Page 25: ...ring column provides tilting and telescope features and each have a hold lever on the side of the column to hold the column in the preferred position for the operator The park brake switch is located on the 12 button panel located to the right of the operator To apply ensure that the machine is stopped and push the N P NEUTRAL PARK side of the rocker switch and the switch itself will light up Once...

Page 26: ...ystem 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 Four wheel or 2 wheel drive is selected from the 12 button powertrain panel located to the right of the operator The transmission and drivetrain components can be damaged if attempting to shift from ...

Page 27: ...oad line pulling back will raise the load line Included in this joystick is a drum rotation indicator that will vibrate as the Hoist Drum rotates Holding a finger over the top of the lever will give the operator the strongest feel for the vibration NOTE Joysticks may be used together for simultaneous operation to achieve combinations of movements Some controls must be used together For instance th...

Page 28: ...in 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 outriggers fully down on firm level surface Use appropriate cribbing under outrigger shoes as needed on soft ground Outriggers should remain set during all crane operations except for pick and carry 6 ...

Page 29: ...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 has been exceeded These icons include the following Battery Charging System Error Engine Warning Light Engine Shutdown Light Engine Grid Heater Wait to Start Light Engine Coolant Level Indicator Ligh...

Page 30: ... 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 will not operate if it is not level Level Guide Screen Within the outrigger display screen there is a bubble level that provides feedback to the operator on the current status of the cranes level Thi...

Page 31: ...anged 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 boom can be raised or retracted to a safe radius or the load may be lowered to a safe place using HOIST LOWER If the boom extension is at its lower angle limit the boom must be raised or the load hoist...

Page 32: ...ad 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 Be aware that the electronic and mechanical components cannot be 100 fail safe Do not consider the system as a substitute for good judgment training experience or accepted safe operating practices The op...

Page 33: ...rs are completely deployed These transducer inputs are fed to the RCL which allows it to decide which chart to work with Outriggers or Rubber Once the RCL is in run mode the IC 600 continues to detect when outrigger positions change An allowance is made for one outrigger to lift due to chassis flex When two are detected to be lifted the audio alarm will sound and the machine will be placed into an...

Page 34: ... is 60 000 pounds 27 200 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 A laminated chart is attached near the operator s seat as well as in the literature compartment An electronic version of the chart may also be accessed through the Dash Display These charts are for t...

Page 35: ...2 20 CAPACITY CHART CRANE CAPACITY VALUES ENLARGED ...

Page 36: ...2 21 CAPACITY CHART METRIC CRANE CAPACITY VALUES ENLARGED ...

Page 37: ... shows that 15 000 pounds 6800 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 584 pounds 265 kg The rigger indicates that two slings are required weighing a total of 50 pounds 23kg The total load is 16 000 584 50 16 634 lbs 7257 265 23 7545 kg The 360 ROTATION ON RUBBER column of the chart allows lifting up...

Page 38: ...s 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 as shown in the figure below When resting the downhaul or sheave block on the ground for changing it use the following procedure to prevent fouling the load line on the hoist Raise the boom about 5 ...

Page 39: ...t 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 used on the live part of the rope This will seriously weaken the rope The sheave block should hang straight and the top of the block should meet the boom sheave plates squarely when pulled up snug ...

Page 40: ...ting 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 desired load If the boom creeps in under load the 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...

Page 41: ...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 the accumulators This system should be checked daily See Driving the Vehicle section on page 2 13 If the warning icon shows on the display during normal operations stop work and repair the system imm...

Page 42: ...he boom 8 Insert the attach pins in the right hand 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 lugs and retain them with hairpin cotters To insert the fourth pin it may be necessary to rock boom extension side to side or up and down 11 Replace the fr...

Page 43: ...ton on the RCL Display W A R N I N G Be careful 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 personnel 3 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...

Page 44: ...0 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 offset to be 2900 pounds 1300 kg Since 2900 pounds 1300 kg is less than 8050 pounds 3650 kg the load including the downhaul weight and slings must be limited to 2900 pounds 1300 kg EXAMPLE 2 The boom i...

Page 45: ... loads on the boom load line during pick and carry operation 2 To drag loads on the ground to a position where they may be safely lifted with the boom 3 To pull the crane out of mud or other obstacles 4 To pull a smaller vehicle that is stuck W A R N I N G The front winch is not designed for lifting personnel or loads Observe the following safety rules 1 Never lift or carry personnel with the winc...

Page 46: ...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 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 Do not exceed a towing speed of 5...

Page 47: ...tart 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 notification Parking brake is set Headlights main high beam 4 wheel round steer Work light Rear wheel steer Hazard lights Crab steer Rotating beacon or strobe lights 2 wheel drive Turn signals left right 4 ...

Page 48: ...cator 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 temperature gauge Wait to start engine preheat grid heater glow plug switch Hydraulic oil temperature high Gas fuel only Hydraulic oil pressure gauge OR hydraulic oil pressure low Diesel fuel only Positi...

Page 49: ...2 32 ...

Page 50: ...If injured by escaping fluid see a doctor at once Serious reaction or infection can occur 6 Wear safety glasses and shoes 7 Do not wear loose fitting or torn clothing 8 Remove rings and other jewelry 9 Wear heavy leather gloves when working on wire rope 10 Keep fingers clothing and hair away from moving parts 11 To prevent falls clean areas of crane that are stepped on for access to crane parts We...

Page 51: ...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 computer transmission shifter main VEC optional camera monitor lower control valve and the engine electronic control module When welding on the boom or turn table assembly disconnect the cable reel cylinder ...

Page 52: ...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 Check boom elevation 21 Check boom extension and sequencing pay out hoist cable during power extension 22 Check boom chains and chain sheaves 23 Perform hoist cable break in procedure as described on pa...

Page 53: ...ering 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 sheaves and load line retainers 16 Check anti two block system for proper operation 17 Check back up alarm for proper operation 18 Check operation of all transmission gears forward and reverse 19 Clean all glas...

Page 54: ...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 for proper sequencing and holding valve performance 12 Check operation of windshield wipers 13 Boom extension if equipped properly pinned with retainers in place 14 Check boom chains and chain sheaves ...

Page 55: ...s 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 lines for damage 17 Inspect sheaves and hooks for damage or excessive wear 18 Visually inspect welds on boom turret and outriggers 19 Perform a load test as described on page 3 3 20 Check operation of ou...

Page 56: ...ter 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 engine thermostat 5 Fill with new coolant and distilled water 6 Perform all maintenance required by Engine Manual S N _______________HOURS ________DATE ________BY _________________________ COMMENTS ...

Page 57: ...st 6 5 quarts 6 2 L Axle Differential Housing 5 4 gallons 20 5 L Hubs 0 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 600 A LUBRICATION CHART ...

Page 58: ...3 9 IC 600 A LUBRICATION CHART ...

Page 59: ...3 10 IC 600 A LUBRICATION CHART ...

Page 60: ...3 11 IC 600 A LUBRICATION CHART ...

Page 61: ...eck Daily Change 1000 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 Sheave Pins MPG X 2 Zerks Std 2 On Boom Ext 19 Transmission ATF X 12 Max Check Weekly Change 600 hours Change Filter 200 hours 20 Hoist MPL X 12 1 Zerk 21 Wire Rope 2 X X Spray Brush o...

Page 62: ...riate 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 long tipped oil can spray chains generously and grease sheave fittings Do not attempt to grease chain shafts or oil chains inside boom with engine running as boom may move while your hands are inside ...

Page 63: ... 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 mounted on the top of the boom 6 Repeat steps 2 5 with the wire rope at the extreme right side of the hoist 7 EXTEND and RAISE the boom fully 8 Lift a 5000 10 000 pound 2250 4500 kg load in this position ...

Page 64: ...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 fixed before driving the crane CAUTION Brake dust may be hazardous Observe precautions to prevent breathing large amounts of brake dust Brake Pads and Rotors Remember that the steering system on the I...

Page 65: ...ccumulators 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 pressure must be maintained on a monthly basis as follows 1 Set park brake or put machine on outriggers Turn off engine 2 Pump the brake pedal several times to discharge stored oil pressure 3 Remove pro...

Page 66: ...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 material incompatibility and inadequate frictional properties for clutch discs The refill capacity is about 4 to 5 gallons 15 L to 19 L AMBIENT TEMPERATURE TRANSMISSION FLUID SPECIFICATIONS Between 10 F and...

Page 67: ...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 should be changed every 200 hours or 6 months which ever is sooner Use the following procedure 1 Clean the filter housing element and nearby hoses 2 Remove the used filter element and catch the oil in...

Page 68: ...to warm the oil above 100 F 40 C 2 Remove the transmission drain plug and drain the oil Check for water foam or excessive particles in the oil 3 Change the filter element as described previously 4 Remove the transmission breather wash it in clean solvent blow it dry and re install 6 Clean and install the transmission drain plug 7 Fill the transmission through the dipstick tube or ADD plug with 4 g...

Page 69: ...3 20 TRANSMISSION HYDRAULIC SYSTEM A pump in the transmission provides hydraulic power for operating the range shift solenoid and 4X4 disconnect solenoid ...

Page 70: ... 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 that may reveal the cause Try these checks first before making a service call NOTICE For transmission service or overhaul which is beyond the scope of this manual please call your Broderson dealer or t...

Page 71: ...steps 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 parking brake and lubricate the transmission Do not exceed 10 mph 16 km hr If the engine cannot be run release the parking brake by following the manual parking brake release procedure on page 3 21 ...

Page 72: ...3 23 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 73: ...ANGE 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 longer rope life If the cable is not sufficiently compact during the initial assembly phase when it is loaded it may become caught up in the turns below and damaged 1 Position rope spool such that rope...

Page 74: ...a 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 enough rope can be spooled off the hoist drum See the Operation Section for instructions on reeving and wedge socket attachment 11 Install the cable retainer pins and cotters in the tip sheave plate...

Page 75: ...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 mounted inside the chassis on the road side of the machine The braking and steering circuits are sourced through the priority manifold which is mounted inside the chassis on the curb side of the machine...

Page 76: ...3 27 JIC HYDRAULIC SCHEMATIC ...

Page 77: ...ic 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 axles used to indicate when the wheels are straight to allow for steer mode change of state 5 Outrigger Enable Valve located in the outrigger control valve diverts the load sense signal to the pump ...

Page 78: ... 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 on the side of the boom transmits data for boom angle and reel rotations which is used for computing boom length load radius 3 Anti Two Block Switch located on the boom tip provides feedback when the ...

Page 79: ... 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 themselves if they are related to a start up issue If the fault persists troubleshooting steps should be taken based off of the direction provided by the fault s that are being displayed The level sen...

Page 80: ...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 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 no...

Page 81: ...cate 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 Retract the telescope boom and outrigger cylinders Remove the oil and dispose of it properly Remove the breather from the top of the tank Clean the element with solvent and compressed air Open clean ou...

Page 82: ...rosene or other thinners to hydraulic oil These fluids have low aniline points and consequently will cause rapid deterioration of certain packings and seals in the hydraulic system CAUTION Serious damage to the pumps will result if it is run with insufficient oil level in the reser voir or if the pumps are allowed to cavitate Observe the operation of the machine If the oil is too cold below 40 F 5...

Page 83: ...t 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 right three times in each steering mode 8 Check the level of oil in the hydraulic reservoir and add more if necessary 9 Set the crane on outriggers With the boom about halfway extended and about 45 ele...

Page 84: ...g 3 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 cannot be stopped by tight ening 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...

Page 85: ...der barrel This valve is designed to hold the boom in position should loss of power or pressure line failure occur To check the boom lift cylinder holding valve set the outriggers place the boom in the horizon tal 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 The best load for this test is the rated load a...

Page 86: ... 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 chart Use great care to prevent the load from hitting the crane Turn the engine OFF put the key ON and pull the TELESCOPE RETRACT valve spool on the upper control valve If the boom retracts the valve s...

Page 87: ...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 windows for measuring locations Measure the outside chains at midspan Snug the 4th stage extension and retraction chains un til the chain tightness allows the dimensions of approximately 1 25 mm and 5 1...

Page 88: ...3 39 BOOM CHAIN ADJUSTMENT ...

Page 89: ...icator is in 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 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...

Page 90: ...wing function will appear loose if too much gap Re tighten the four mounting bolts and the six side bolts RELIEVING HYDRAULIC PRESSURE W A R N I N G Failure to relieve trapped hydraulic pressure may result in high pressure fluid penetra tion of the skin If injured by escaping fluid see a doctor at once Serious reaction or infection can occur Relieve all trapped hydraulic pressure before disconnect...

Page 91: ...handle is missing an 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 shaft from a valve section indicated in the figure below Upper Control Valve e From left to right the sections control the HOIST TELESCOPE and TOPPING LUFFING functions Each function m...

Page 92: ...ile 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 located within the chassis on the inside of the left frame rail The enable solenoid valve is indicated in the figure below b Disconnect the 2 pin electrical connector on the enable solenoid valve Apply ...

Page 93: ...esponds 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 apply power and ground to the sole noid corresponding to the Diverter Valve The outrigger beam should now retract Use extreme caution The outrigger alarm will not sound l Turn off the crane m Repeat...

Page 94: ... 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 APPLY TO THE CHART 1 Consult manufacturers specific recommendations when available 2 The chart may be used with coarse and fine thread fasteners lightly lubricated 3 Increase torque by 20 when multipl...

Page 95: ...1 W I R I N G IC 600 A WIRING DIAGRAM ...

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Page 98: ...4 W I R I N G ...

Page 99: ...5 W I R I N G ...

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