Broderson IC-400-3B Operation And Maintenance Manual
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Broderson IC-400-3B Operation And Maintenance Manual

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PRINTED IN USA
P/N 990-30259
MAINTENANCE MANUAL
OWNER:_______________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
SOLD AND SERVICED BY:________________________________________________________
MODEL
NO.
______________________________
OPERATION AND
IC-400-3B
___________________________________________________________
___________________________________________________________
___________________________SERIAL
COPYRIGHT 2019
BRODERSON MFG. CORP.
LENEXA, KANSAS 66215
NO.

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Questions and answers

Eugene
February 26, 2025

The steering mode switch is blinking and round steer mode won't work, screen says round mode request

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2 comments:
Mr. Anderson
February 26, 2025

When the steering mode switch is blinking and round steer mode won't work on a Broderson IC-400-3B, it likely means the wheels are not centered. The system uses electronic sensors to detect when the wheels are centered before switching modes. If the wheels are not properly aligned, the new mode will not engage, and the indicator may blink. Ensure the wheels are centered before selecting round steer mode.

This answer is automatically generated

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Eugene
February 27, 2025

@Mr. Anderson well hard to center when that mode can't be selected or any mode. Front rear crab none! Won't give you the option or the alignment on the other screen

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Summary of Contents for Broderson IC-400-3B

  • Page 1 PRINTED IN USA COPYRIGHT 2019 P/N 990-30259 BRODERSON MFG. CORP. LENEXA, KANSAS 66215 OPERATION AND MAINTENANCE MANUAL IC-400-3B OWNER:_______________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ SOLD AND SERVICED BY:________________________________________________________ ___________________________________________________________ ___________________________________________________________ MODEL ___________________________SERIAL ______________________________...
  • Page 2 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 its standard form of Warranty...
  • Page 3 Broderson Manufacturing Corp. 14741 W. 106 Street Lenexa, Kansas, 66215 U.S.A. 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 Service Manager. Also, please notify your Broderson dealer.
  • Page 4 IC-400-B DIMENSIONS...
  • Page 5 IC-600-A TURNING DIMENSIONS...

  • Page 6: Description And Specifications

    SECTION 1 DESCRIPTION AND SPECIFICATIONS The IC-400-B is a self-propelled Industrial Crane designed for lifting and material handling, with special features of self-loading cargo decks, 4-wheel steer, and 4-wheel drive. The basic unit consists of a chassis and hydraulic boom assembly. The chassis includes a frame, four hydraulic independently controlled outriggers, engine, 6-speed transmission, front steering-driving axle &...
  • Page 7 General: (continued) Extension: W/O Boom Extension With Boom Extension Sheave Height (Nominal): 80 feet (24.37 m) 99 feet (30.18 m) Horizontal Reach: 69 feet (21.03 m) 90 feet (27.43 m) Weight: Total 55,200 pounds (25,038 kg) Front Axle 31,154 pounds (14,131 kg) Rear Axle 24,046 pounds (10,907 kg) Turning Radius: (4-Wheel Steering)

  • Page 8: Gear Ratio

    Forward gear ratios and speeds: Reverse gear ratios and speeds: GEAR RATIO SPEED GEAR RATIO SPEED 8.93 2.1 mph (3.4 km/h) 8.93 2.7 mph (4.3 km/h) 4.63 4.0 mph (6.4 km/h) 4.63 6.3 mph (10.1 km/h) 1.70 10.5 mph (16.9 km/h) 1.70 mph (25.4 km/h) 3.75...
  • Page 9 Outriggers: Four hydraulic out-and-down outriggers of box-beam construction. Independent controls for each outrigger. Hydraulic cylinders are equipped with direct-connected holding valves. Pad dimensions: 11.5 inches (29cm) x 11.5 inches (29cm). Pulling Eyes: Two heavy duty lugs on front bumper provide for attachment of hook block so main winch line can be used for pulling loads at or near floor level;...
  • Page 10 Operator Compartment: Standard: Operator control station provides one-position access to all chassis and crane functions. Includes adjustable operator's seat and seat belt, arm rests, and tilt steering column. Also includes access point to J1939 CAN Bus System. All Weather Cab: Consists of rigid-mounted canopy section with safety glass and removable hinged door.
  • Page 11 Back-Up Alarm: Provides pulsating sound from a 102 dB alarm when ignition is on and transmission is in reverse. Conforms to SAE J994B. Outrigger Alarm System: 102 dB alarm with alternating 2-tone sound is actuated when the OUTRIGGER DOWN, OUTRIGGER BEAMS OUT or OUTRIGGER BEAMS IN controls are operated. Emergency Stop Switch: A two-position push button switch located on the LH side of the dash panel.
  • Page 12 Downhaul Weight and Hook: Downhaul weight and 14,000-pound (6350 kg) rated swivel hook to use with wedge socket on 5/8-inch (16 mm) load line. Specially designed to work with the anti-two-block system and to clamp the dead end of the rope. Weighs 180 pounds (82 kg) Anti-Two-Block Device: Prevents damage to hoist rope and/or machine components from accidentally pulling sheave block or downhaul weight against boom tip.
  • Page 13 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 owner and operator. 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.
  • Page 14 3. Keep operator's compartment and decks free of mud and grease. 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. 8. The Rated Capacity Limiter must be checked after each setup for the proper operating configuration on the display.
  • Page 15 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 surroundings, operator inexperience, etc.
  • Page 16 9. 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. 10. Crane may tip at less than rated loads if the surface is uncompacted, has wet dirt or soft soil with frozen crust, thin or cracked pavement, or surface near a hole or ledge.
  • Page 17 CAUTION Keep hands out of Anti-Two-Block mechanism. Serious injury can result from moving parts. 18. 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.
  • Page 18 23. Crane has four lifting rings, one 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 the boom. Proper lifting and securing practices are the responsibility of the rigger in charge.
  • Page 19 TRAVEL: 1. For Pick and Carry operation: Traveling with suspended loads involves so many variables, such as ground conditions, boom length, and vehicle acceleration, that it is impossible to devise a single standard rating procedure with any assurance of safety. For such operations, the user must evaluate prevailing conditions and determine safe practices using precautions, such as the following: A.
  • Page 20 CAUTION Do not allow fuel 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. 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.

  • Page 21: Instruments And Controls

    INSTRUMENTS AND CONTROLS The IC-400 instrument panel is equipped with a monitor display that includes warning lights and push buttons to change display screens. The display includes: Engine Hour Meter Engine RPM Incremental Adjust Engine RPM Tachometer Machine Fuel Level Engine Coolant Machine Hydraulic Temperature...
  • Page 22 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. The BMC IC-400 is equipped with a standard lighting package. The controls for the lights are located in the 15-button panel located below the main display screen.
  • Page 23 The powershift transmission is controlled through the series of buttons on the 12-button panel to the right of the operator. There are two ranges for this transmission and 3 gears in each range for FORWARD and REVERSE. The shifting is electronically-controlled. The transmission and drivetrain 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.
  • Page 24 CONTROL VALVE FUNCTIONS The control valves for the IC-400-B utilize an electronic/ hydraulic system, whereas the valves are not mounted in the cab. Boom Function: Controls for operating boom rotation, boom elevation, boom extension and hoist are actuated by two, single-axis joysticks with one mounted to each arm rest of the operator compartment.

  • Page 25: Operating The Crane

    SEQUENCE OF OPERATION DRIVING THE VEHICLE The following procedure is recommended for driving the vehicle: Perform the daily inspection and test. (See Page 3-4) Start engine and allow a warming period. While warming the engine, set up the Rated Capacity Limiter (RCL) configuration. Stow boom over front.
  • Page 26 NORMAL GAUGE READINGS The IC-400 is equipped with two, full color touch screen displays. The main display is on the right side of the cab. This display is programmed to be the primary controller for the machine. It will monitor engine information directly off the SAE J1939 CAN bus network provided by the engine manufacturer.
  • Page 27 Any time there is a control system fault detected, there will be a pop-up window identifying what the fault is. The various diagnostics screens will help identify the issue that needs to be resolved. If there is an engine warning or engine stop signal, either the amber (warning) or red (stop) icons on the main display will be lit until resolved.
  • Page 28 RATED CAPACITY LIMITER (RCL) A rated capacity limiter (RCL) is installed on the crane to assist the operator in estimating loads and measuring load radii. Following are some operating tips. Always be aware that the RCL can stop boom movement at capacity load conditions and in two-blocking conditions.

  • Page 29: Crane Capacity

    CRANE CAPACITY Before lifting loads, the operator must read the Crane Capacity Chart and adhere to the load capacities and radii of handling stated in the chart. The information provided on this chart is based on stability, structural strength and hydraulic capacity. To operate the crane safely, the operator must know the weight of the load and handling devices, and the radius of the lifting operation.
  • Page 30 W A R N I N G The Rated Capacity Limiter can suddenly stop the BOOM LOWER, TELESCOPE EXTEND, and HOIST RAISE functions, causing the load to bounce or swing. Use great care when handling a load near capacity limits or near a two-blocking condition. NOTICE The outriggers should always be set before configuring the Rated Capacity Limiter.
  • Page 31 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.

  • Page 32: Capacity Chart

    CAPACITY CHART...
  • Page 33 CAPACITY CHART, METRIC...
  • Page 34 CAUTION The ON OUTRIGGERS capacities of this crane are based on all outriggers being FULLY DEPLOYED to a FIRM surface with no load on the tires. The crane may tip at less than capacity loads if operated in the following manner: A.

  • Page 35: Sheave Block And Downhaul Weight

    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 BMC Anti-Two-Block system. Other blocks or downhauls may bypass this system and create a dangerous condition.
  • Page 36 MULTI-PART LINE REEVING For loads above 12,500 pounds (5670 kg) the sheave block must be used. The 4-part-line sheave block can be used for loads up to 50,000 pounds (22,680 kg). The wedge socket 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.
  • Page 37 SAFETY DEVICES There are certain safety devices on the IC-400 that are designed to maintain control of a load even if power or hydraulic line failure occurs. The operator should understand the function and operation of these devices so that a continual check on their performance can be made.
  • Page 38 EMERGENCY STOP SWITCH: A two-position push button switch located on the top left-hand side of the dash panel is designed to stop the engine and shutdown the control system. Push switch in to disconnect power to the engine run circuit and control system circuit. Twist and pull to restore power. ARM FUNCTION BUTTON: On the 15-button panel there is an ARM button that must be engaged before the pilot joysticks will function.

  • Page 39: Optional Equipment

    OPTIONAL EQUIPMENT NOTICE Use appropriate ladders/steps to gain access to the boom tip and deck to perform this installation. INSTALLING AND STOWING BOOM EXTENSION: Set the outriggers. Raise and extend the boom about 30 feet (9 m) above the ground, paying out load line until hook is just above ground.
  • Page 40 18. Replace all of the pins in their lugs for storage and insert their hairpin cotters. 19. Install the sheave block on the load line, if desired. 20. Check the Anti-Two-Block system for proper operation, and set Rated Capacity Limiter configuration.
  • Page 41 CAPACITY EXAMPLES FOR BOOM EXTENSION The boom extension may lift loads in any swing position when the outriggers are OUT & DOWN. The boom extension may lift loads over the front on IN & DOWN outriggers. The LOAD RADIUS and BOOM EXTENSION ANGLE capacity charts must both be considered when using the boom extension.

  • Page 42: Front Auxiliary Winch

    FRONT AUXILIARY WINCH: The front auxiliary winch is mounted to the front bumper and is controlled from the operator compartment. The winch has 125’ (38 m) of 9/16” (14 mm)-6x36 EIP-RRL-IWRC wire rope with a 33,600-pound (150 kN) minimum breaking force and a 5-ton (4.5-metric ton) rated hook.

  • Page 43: Pintle Hooks

    PINTLE HOOKS: Available Pintle Hooks allow the crane to tow other disabled vehicles and trailors, 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 vehicle being towed is occupied to steer and brake.
  • Page 44 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 Windshield washer switch Off/Stop...
  • Page 45 Tire pressure Engine oil pressure low Lift point Engine coolant fill location Engine coolant Tie-down point temperature high Engine coolant low level Transmission oil fill location mark Engine air filter restriction Transmission oil pressure indicator Transmission oil Engine start temperature Brake fluid fill location Engine idle set Hydraulic oil low-level mark...
  • Page 47 MAINTENANCE SAFETY RULES 1. Before doing maintenance, lower load, lower boom and retract boom, move to a safe place, shutdown engine, and remove key. Place warnings on the ignition switch and crane controls to prevent unauthorized starting or movement during maintenance. Disconnect battery using Battery Disconnect Switch mounted on front hood cover, and lockout if need- 2.
  • Page 48 15. If it is necessary to work on the boom in an unstowed condition, block it to prevent it from dropping unexpectedly. 16. Use a hoist when lifting components that weigh 50 pounds (22 kg) or more. Follow all hoist and rigging safety rules.

  • Page 49: Maintenance

    MAINTENANCE The Broderson IC-400 Industrial Crane will perform better and longer if a program of inspec- tion, lubrication, adjustment and general preventive maintenance is followed. We recommend the following schedule: NEW UNIT INSPECTION AND TEST The following inspection and test should be made before placing the unit on the job. This will insure that no damage or loss of operating capability occurred during shipment.

  • Page 50: Operator Inspection And Test

    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.
  • Page 51 Weekly: 1. Check tire pressure: 100 PSI (690 kPa). 2. Check for loose wheel nuts. 475 foot-pounds (645 Nm) torque required. 3. Check lights and turn signals. 4. Check power steering lines for damage. 5. Check brake lines for damage. 6.
  • Page 52 IC-400-B MAINTENANCE CHECKLIST Refer to the component maintenance section of this manual and to the Engine Operator's Manual for complete instructions. 50-HOUR INTERVAL: 1. 50-hour lubrication, as shown on lube schedule. 2. Inspect wire rope thoroughly. 3. Inspect for physical damage and leaks. 4.
  • Page 53 500-HOUR OR 6-MONTH INTERVAL: 1. 250-hour maintenance. 2. 50, 250, and 500-hour lubrication. 3. Check antifreeze for protection level and cleanliness. 4. Change hydraulic filter element, if not changed in the last 250 hours and inspect oil from element. 5. Change transmission filter element and inspect oil from element. 6.

  • Page 54: Fluid Volume

    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...
  • Page 55 IC-400-3B LUBRICATION CHART...
  • Page 56 IC-400-3B LUBRICATION CHART...
  • Page 57 IC-400-3B LUBRICATION CHART...
  • Page 58 IC-400-3B LUBRICATION SCHEDULE LUBRICATION INTERVALS LUBE SYMBOL ITEM DESCRIPTION 500 1000 MONTHS NOTES HOUR HOUR HOUR HOUR Anti-Two-Block Arm 2 Points Axle Differential Check @50, Change @12 Mo. Axle Kingpins 8 Zerks Axle Hubs Check @50, Change @12 Mo. Boom Extension Pins Wipe on.

  • Page 59: Boom Chain Lubrication

    BOOM CHAIN LUBRICATION Put the crane on outriggers before beginning. The machine may tip in other configurations. Extend the boom fully and lower to horizontal. Turn off the engine. Using appropriate 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.
  • Page 60 RUB PAD ADJUSTMENT The rub pads on the sides of the boom may require adjustments as they wear. Adjustable rub pads are located at the tips of the outer boom, second stage, and third stage. Adjustable rub pads are also located at the bases of the second stage, third stage, and fourth stage. To determine if adjustment is required: 1.

  • Page 61: Brake System Maintenance

    ROTATION BEARING LUBRICATION There is one grease zerk remote mounted in on the right side of the chassis pedestal. It is lo- cated just above the battery compartment. This should be used to lubricate the bearing every 50 hours. Rotate the turntable at least one revolution while pumping grease into the zerk. Use about 8 ounces (230 cc) of grease each time the bearing is lubricated.
  • Page 62 The operator can hear the accumulators charge. If the accumulators charge frequently without depressing the brake pedal, the brake unloading valve, accumulators, or brake hoses may be leaking. If no leaks can be found, check accumulator pre-charge pressure. If pre-charge pressure is adequate, it may be necessary to repair or replace the brake unloading valve.

  • Page 63: Transmission Maintenance

    TRANSMISSION MAINTENANCE The transmission is a 3-speed-forward, three-speed-reverse, 2-range Dana 32000 series powershift transmission. The transmission is bolted directly to the flywheel housing of the en- gine and is connected by drive shafts to the front and rear axles. A torque converter transmits power from the flywheel to the transmission.
  • Page 64 Check the oil level weekly by removing the ADD plug on the transmission. The ADD plug is located near the left-hand side of the transmission, near the engine. Make sure the area around the plug is clean before removing. Check the oil level in NEUTRAL at idle speed, with the oil warm.

  • Page 65: Transmission Fluid Change

    TRANSMISSION FLUID CHANGE: Change the transmission fluid on a new machine after the first 20 hours. If the filter is changed every 200 hours, change the fluid every 600 hours. If the filter has been changed more frequently, change the fluid every other filter change. Use the following procedure: Operate the transmission long enough to warm the oil above 100°F (40°C).
  • Page 66 TRANSMISSION HYDRAULIC SYSTEM: A pump in the transmission provides hydraulic power for operating the range shift solenoid and 4X4 disconnect solenoid.

  • Page 67: Transmission Troubleshooting

    NOTICE For transmission service or overhaul, which is beyond the scope of this manual, please call your Broderson dealer or the Broderson Service Department to have a Dana service representative contact you. If transmission feels like it is slipping, check the transmission oil level. High or low level can cause problems.
  • Page 68 If abnormal contamination is found or a problem cannot be diagnosed and fixed by the above steps, please call your Broderson dealer or the Broderson Service Department to have a Dana service representative contact you.
  • Page 69 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 HOIST CABLE LUBRICATION The hoist cable is a wire rope and should be cleaned & 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 com- pressed air, or solvent and rags.
  • Page 71 CAUTION For a correct assembly, it is necessary to have a minimum pre-load of 5% of the cable breaking force. The cable breaking force depends on the diameter and of the cable type, and it must be indicated on the cable certificate. 6.
  • Page 72 CONTROL AND HYDRAULIC SYSTEM The IC-400 control system is a pilot-actuated hydraulic system that is supplied with flow by two variable displacement pumps. The pumps are mounted on and driven by the transmission and supply flow on demand. The control joysticks are single axis levers mounted on each side of the operator seat.
  • Page 73 JIC HYDRAULIC SCHEMATIC 3-27...

  • Page 74: Electrical And Control System

    ELECTRICAL AND CONTROL SYSTEM The electrical and machine control system of the IC-400 is built utilizing J1939 CAN technology and consists of three major wiring harnesses that connect the machine’s sensors, modules, and devices together. Located in the operator’s compartment are two display units; the main machine display and the RCL display.
  • Page 75 Finally, the below rotation harness connects to the engine for communication to and from the engine through the use of J1939 CAN communication protocol. The harness that connects to the electrical slipring above rotation connects the sensors, mod- ules, and lighting above rotation to the CAN network of the machine. At the top of the turnta- ble is a third control module for the machine.
  • Page 76 CONTROL SYSTEM AND ENGINE FAULTS The control system of the IC-400 routinely checks itself and the rest of the system for potential problems at start-up and during operation. When a fault is detected within the control system or within the engine operation, an error code message will be displayed on the main display, as well as the RCL display in the operator’s compartment.

  • Page 77: Steering System

    STEERING SYSTEM The steering system is also shown in the hydraulic schematic. The IC-400 steering system is a load-sensing, demand-type system that takes only as much flow as needed when steering, and directs the excess flow to the control valve for boom and outrigger functions. Oil from pump P2 goes into the priority valve at port P.

  • Page 78: Care Of Hydraulic Oil

    CARE OF HYDRAULIC OIL The hydraulic system contains many highly pressurized, precision components. To protect the system, it is very important to keep the hydraulic oil clean, within proper temperature range for the oil specification, and to the proper fill level. The IC-400 is equipped with a suction strainer, a breather filter, a single 10-micron return-line filter and a 156-gallon tank (590 L).
  • Page 79 HYDRAULIC OILS FOR IC-400 AMBIENT TEMP RANGE: -40° to 75°F -15° to 110°F 50° to 130°F (40° to 24°C) (26° to 43°C) (10° to 54°C) POUR POINT: -40°F MAX -15°F MAX 0°F MAX (-40°C) (-26°C) (-18°C) VISCOSITY INDEX: 140 MIN 95 to 100 95 to 100 VISC.

  • Page 80: Removal Of Air From Hydraulic Circuits

    REMOVAL OF AIR FROM HYDRAULIC CIRCUITS To remove air from hydraulic circuits, perform the following steps: 1. Start the engine. 2. Raise and lower the boom, minimum five times. Ensure that the cylinder travels full stroke. 3. With the boom retracted and elevated to at least 65°, raise and lower the hook at least once with the hoist.

  • Page 81: Hydraulic Seals

    HYDRAULIC SEALS W A R N I N G Do not check for hydraulic leaks with hands. If a mist of hydraulic oil is noticed around a line or component, use cardboard or other material to check for location of leak. High pressure fluid leaking from a small hole, can be almost invisible, yet have enough force to penetrate the skin.

  • Page 82: Pressure Settings

    PRESSURE SETTINGS: The hydraulic system is divided into three pressure circuits, each having its own protective re- lief valve. The functions operated by the control valve sections require different pressures for different functions. These are covered in sections below: 1. Hoist, Boom, & Swing Circuit -- 4000 PSI (276 bar) at full flow 2.

  • Page 83: Telescope Cylinder Holding Valve

    TELESCOPE CYLINDER HOLDING VALVE: There is a single telescoping cylinder on the IC-400 and it has its own holding valve. This valve is designed to hold the boom in position, should loss of power or pressure line failure oc- cur. The holding valve should be checked with the boom elevated to the maximum angle and the boom extended to a 10-foot (3 m) load radius.

  • Page 84: Boom Chain Adjustment

    BOOM SEQUENCE The IC-400 uses a single extension cylinder to extend all three moving stages. The cylinder is a multi-stage design, and uses a chain system to proportionally extend and retract the second, third, & fourth stages together. BOOM CHAIN ADJUSTMENT Study Illustrations 1,2, and 3 on the following page, to understand the chain adjustment proce- dure.
  • Page 85 BOOM CHAIN ADJUSTMENT 3-39...
  • Page 86 ENGINE MAINTENANCE Refer to the Engine Manual for additional engine maintenance. The air filter can be accessed outside of the engine compartment on the left-hand side of the machine. The oil dip stick can be accessed inside the engine compartment on the right-hand side of the machine. Access to the engine oil filter can be found inside the engine compartment on the right-side of the ma- chine.

  • Page 87: Mechanical Adjustments

    MECHANICAL ADJUSTMENTS FASTENERS: All fasteners on the IC-400 should be checked and retightened if required, as a part of the pre- ventive maintenance program. Particular attention should be given to the drive axle mounting bolts, pump mounting bolts, rotation bearing bolts, rotation gearbox bolts, winch bolts, bolts holding extension cylinder to 2 stage and 3 stage.
  • Page 88 1. Turn off the ignition key. 2. To override the HOIST, TELESCOPE, and TOPPING/LUFFING functions: a. Locate the override handle under the operator’s seat. It looks like the figure be- low. If the handle is missing, an adjustable wrench may be used. Override Handle b.
  • Page 89 3. To override the boom swing/slewing: a. The Chassis Control Valve is located within the chassis under the operator com- partment. If your unit has a front winch option, the other section on the lower con- trol valve operates the front winch. Chassis Control Valve b.
  • Page 90 Diverter Valve h. Disconnect the 2-pin electrical connector on a Diverter Valve. Apply 12V to the pin with the white wire. Ground the pin with the black wire. On the Lower Control Valve, locate the outrigger valve section that corresponds to the Diverter Valve.

  • Page 91: Torque Data

    TORQUE DATA BOLT SAE GRADE SAE GRADE SAE GRADE GRADE 1 OR 2 MARKING MEDIUM CARBON MEDIUM CARBON MATERIAL LOW CARBON STEEL ALLOY STEEL Q & T Q & T MINIMUM TENSILE 64,000 PSI 120,000 PSI 150,000 PSI STRENGTH (441 MPa) (827 MPa) (1034 MPa) BOLT SIZE...
  • Page 92 IC-400-B WIRING DIAGRAM W I R I N G...
  • Page 93 W I R I N G...
  • Page 94 W I R I N G...
  • Page 95 W I R I N G...
  • Page 96 W I R I N G...
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  • Page 98 W I R I N G...
  • Page 99 W I R I N G...
  • Page 100 W I R I N G...
  • Page 101 10 | W I R I N G...

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