Broderson RT-300-2G Operation And Maintenance Manual Download

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TABLE OF CONTENTS

SECTION 1

DESCRIPTION AND SPECIFICATIONS

Introduction.................................................................... 1-1

Dimensions

and

Orientation........................................... 1-2

Turning

Dimensions...………………………………...…...

1-3

Description

and

Specifications....................................... 1-4

SECTION 2

OPERATION

Safety

Rules..................................................................

2-1

Instruments and Controls.............................................. 2-9

Control

Functions........................................................

2-10

Sequence

Operation…..……………………………...

2-12

Driving

the

Vehicle...........................................

2-12

Normal

Gauge Readings................................. 2-12

Operating

the

Crane........................................

2-13

Rated

Capacity Limiter................................................ 2-13

Crane

Capacity............……......................................... 2-14

Capacity Chart......……………………............... 2-17

Capacity

Chart Metric...……………….............. 2-18

Sheave

Block and Downhaul....................................... 2-21

Boom

Tip

Reeving

Pattern...............................

2-22

Safety

Devices............................................................

2-23

Optional

Equipment..................................................... 2-25

Boom

Extension...............................................

2-25

Front

Auxiliary Winch....................................... 2-27

Pintle

Hooks.....................................................

2-28

Switch

and

Indicator Symbols...................................... 2-29

SECTION 3

MAINTENANCE

Safety

Rules..................................................................

3-1

New

Unit

Inspection and Test........................................ 3-3

Operator

Inspection and Test........................................ 3-4

Maintenance Checklist.................................................. 3-6

Chain

Lubrication.......................................................... 3-8

Lubrication Chart........................................................... 3-9

Wire

Rope

Lubrication................................................. 3-11

Rotation

Bearing Lubrication........................................ 3-11

Brake

System Maintenance......................................... 3-11

Engine

Maintenance.................................................... 3-14

Air

Cleaner Service.......................................... 3-14

Cooling

System................................................

3-14

Spare

Parts

List...............................................

3-14

Major

Engine

Servicing....................................

3-14

Care

Hydraulic

Oil...................................................

3-15

Hydraulic

Oil

Specification...........................................

3-16

Purging

the

Hydraulic

System.....................................

3-17

Hydraulic

System.........................................................

3-19

JIC Hydraulic System Schematic................................. 3-20

JIC Hydraulic System Schematic Metric...................... 3-21

Steering

System..........................................................

3-22

Courtesy of Crane.Market

Summary of Contents for RT-300-2G

Page 1: ..._______________________________________________________ _______________________________________________________________________ SOLD AND SERVICED BY ___________________________________________________...

Page 2: ...her 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 or...

Page 3: ...l Equipment 2 25 Boom Extension 2 25 Front Auxiliary Winch 2 27 Pintle Hooks 2 28 Switch and Indicator Symbols 2 29 SECTION 3 MAINTENANCE Safety Rules 3 1 New Unit Inspection and Test 3 3 Operator Ins...

Page 4: ...3 28 General 3 28 Chain Adjustments 3 28 Crowd Cylinder Assembly 3 31 Boom Assembly 3 31 Rotation Gearbox Adjustment 3 32 Wheel Alignment 3 33 Transmission Maintenance 3 34 Transmission Oil 3 34 Filt...

Page 5: ...or 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 num...

Page 6: ...1 2 DIMENSIONAL DATA Courtesy of Crane Market...

Page 7: ...1 3 RT 300 2G TURNING DIMENSIONS Courtesy of Crane Market...

Page 8: ...miter RCL is standard RT 300 2G 4 section hydraulically extended boom with capacity of 30 000 pounds 13 600 kg at 10 feet 3 05 m Horizontal reach of 60 feet 18 3 m and maximum height of 70 feet 21 3 m...

Page 9: ...or setting engine speed at 1200 or 1800 rpm Diesel oxidation catalyst muffler air intake pre cleaner charge air cooler 1500 watt 120 VAC block heater and grid heater included Tier 4 Interim engines mu...

Page 10: ...slip differential Rear Axle Standard AxleTech planetary driving steering axle with 16 42 to 1 ratio Rear axle is mounted with rubber elements to allow oscillation Axle is not available with no spin or...

Page 11: ...Winch Optional planetary gear winch mounted on front outrigger frame with a single lever control on the operator console Hydraulic powered to provide bare drum line pull of 15 000 lbs 6800 kg and 29 f...

Page 12: ...dle Feedback is proportional to hoist speed Operator Compartment Options Window Wiper Top Window 12 volt electric wiper on top window operated with its own switch Operator Guard Tubular steel weldment...

Page 13: ...es pulsating sound from 102 dB alarm when ignition is on and transmission is in reverse Conforms to SAE J994B Outrigger Alarm System 102 dB alarm with alternating two tone sound is actuated by a switc...

Page 14: ...e rope Weighs 180 pounds 82 kg Boom Rotation Heavy duty ball bearing with external teeth supports boom Rotation is by hydraulic motor and compound planetary gear drive A spring applied hydraulically r...

Page 15: ...20 Ft 6 1 m Offset Provides 20 feet 6 1 m of additional length for lifting loads with load line May be set at 0 in line 15 or 30 degrees offset Swing away boom extension may be stowed alongside base b...

Page 16: ...Courtesy of Crane Market...

Page 17: ...ich 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 fla...

Page 18: ...the crane should be kept in a secured toolbox 6 7 8 The Rated Capacity Limiter must be checked before each shift and after each setup for the proper operating configuration on the display It must be...

Page 19: ...the boom slowly whenever these systems might stop the boom 3 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 lo...

Page 20: ...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...

Page 21: ...o increase lifting ability constitutes a safety hazard 19 Always keep crane boom at least 20 feet 6 0 m away from any electric power lines of unknown voltage If voltage is known use chart on side of t...

Page 22: ...ors 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...

Page 23: ...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 Cranes with booms that extend ahead of the chas...

Page 24: ...2 8 Courtesy of Crane Market...

Page 25: ...re in other vehicles already familiar to the operator For units with Tier 3 engine a switch operated 3 speed engine control is provided for use when operating the crane controls only Low speed is the...

Page 26: ...ering on the rear axle is centered D A N G E R Like other mobile cranes the RT 300 will tip over more readily than other types of vehicles The operator should always control the vehicle speed to be co...

Page 27: ...g both levers simultaneously Outriggers The four outriggers may be operated independently or simultaneously Special attention must be given to avoid hitting personnel or obstacles Assure that the outr...

Page 28: ...ide a poisonus 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 NORMAL GAUGE RE...

Page 29: ...that the RCL can stop boom movement at capacity load conditions and in two blocking conditions Use good judgment in controlling the speed of boom movements to prevent shock loads and swinging loads I...

Page 30: ...e weights of the hooks blocks downhaul weights slings and other handling devices must be added with the load The Rated Capacity Limiter on the crane is intended to assist the operator in estimating lo...

Page 31: ...oad 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 in...

Page 32: ...e front outrigger housing On Rubber Operations including pick and carry are limited to the boom centered over front in line with the chassis Note that the 360 DEGREE ROTATION capacities at some load r...

Page 33: ...2 17 CAPACITY CHART FOR RT 300 2G Courtesy of Crane Market...

Page 34: ...2 18 CAPACITY CHART FOR RT 300 2G METRIC Courtesy of Crane Market...

Page 35: ...t retract completely before the second stage begins to retract Adjust the sequencing per the maintenance section of this manual if the boom does not sequence properly Do not operate the crane at a loa...

Page 36: ...lbs at a 20 ft load radius 7850 kg at a 6 0 m load radius If possible the crane should be positioned to lift the load over the front This is the best position for stability However in this example th...

Page 37: ...wer tip sheave that is directly below it 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 ce...

Page 38: ...the striker plate bolted on top of the block should meet the boom sheave plates squarely when pulled up snugly When resting the downhaul or sheave block on the ground for changing it use the following...

Page 39: ...ble to hold the desired load If the boom creeps in under load this valve should be adjusted If adjustment fails to correct the problem there is an internal leak in the holding valve or the hydraulic c...

Page 40: ...ion to extend before and retract after the lighter third and fourth stages This arrangement assures that the boom is as strong as possible The third stage must not extend until the RCL boom length rea...

Page 41: ...o gain access to the boom tip to perform this installation 1 Set the outriggers 2 Raise and extend boom 30 feet 9 m above the ground paying out load line until hook is just above ground 3 Position boo...

Page 42: ...TTING THE OFFSET ANGLE ON THE OFFSETTABLE BOOM EXTENSION 1 The boom extension must be installed on the main boom tip and the load line downhaul weight and wedge socket installed on the boom extension...

Page 43: ...osition 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 A front winch must not be used for lifti...

Page 44: ...in 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 U...

Page 45: ...d 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...

Page 46: ...ssion 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 gaug...

Page 47: ...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 7 Wear safety glasses and shoes 8 Do not...

Page 48: ...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 24 When welding on the crane or on any...

Page 49: ...ation 17 Check steering operation in each steering selector valve position 18 Check rear axle indicator for operation 19 Perform cable break in procedure as described on page 3 39 20 Check transmissio...

Page 50: ...ing voltage 15 Check transmission temperature 16 Check hydraulic filter indicator gauge after running at least twenty minutes 17 Check hydraulic brake operation Check warning light operation as shown...

Page 51: ...heck operation of hoist brake for smoothness 9 Check outrigger holding valves for operation 10 Check boom topping holding valve for operation 11 Check boom crowd holding valve for operation 12 Check t...

Page 52: ...rbox bolt tightness 17 Check axle mounting bolts 18 Torque wheel mounting nuts to 475 foot pounds 645 N m 19 Check for loose pins or pin retainers 20 Check brake lines and steering lines for damage 21...

Page 53: ...form 250 hour maintenance and lubrication 2 Change transmission filter if not changed in last six months and inspect fluid 3 Change hydraulic filter element and inspect oil 12 MONTH INTERVAL For usage...

Page 54: ...extended and horizontal to lubricate the chains The extension chains are exposed under the bottom of the boom A series of access windows exposes the retraction chains Lubricate the chains with 30 weig...

Page 55: ...3 9 Courtesy of Crane Market...

Page 56: ...16 Zerks plus Oilcan 17 Pedal Hinges SIL X 3 Points Oilcan 18 Pump Shaft Spline MPG X 1 Zerk 19 Rotation Bearing MPG X 2 Zerks 20 Rotation Gearbox MPL X 12 Check 250 Change 12 Mo 21 Rotation Gear Teet...

Page 57: ...th of the rotation bearing at the 50 hour intervals 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...

Page 58: ...ssure to the accumulators if low pressure is detected No routine maintenance is needed on the brake unloading valve The operator can hear the accumulators charge If the accumulators charge frequently...

Page 59: ...e charge pressure Nominal pressure is 1000 100 psi 69 6 8 bar W A R N I N G NEVER use shop air or oxygen to pre charge accumulators ONLY use inert dry nitrogen N2 gas Failure to use proper gas can cau...

Page 60: ...t than usual is in the air especially soot will make more frequent changes necessary Excessive exhaust smoke or loss of power may indicate a plugged filter Tier 4i Engine Check the air filter restrict...

Page 61: ...ct the oil for water and excessive contaminants If water is found the oil should be changed in the reservoir and purged out of the cylinders If excessive particles are found the source should be locat...

Page 62: ...lic oil These fluids have low aniline points and consequently will cause rapid deterioration of certain packings and seals in the hydraulic system C A U T I O N Serious damage to the pump will result...

Page 63: ...sure and return lines which is about what they contain Stop the engine 7 Reconnect the return lines open the shutoff valves and fill the reservoir 8 Run the engine at low idle for thirty minutes to fi...

Page 64: ...uits as follows To remove air from hydraulic circuits perform the following steps 1 Ensure all main shutoff valves on the reservoir are open 2 Start the engine 3 Raise and lower the boom minimum five...

Page 65: ...end the boom Check for spongy operation 13 If necessary cycle functions again to remove remaining air HYDRAULIC SYSTEM The RT 300 hydraulic system consists of three open center circuits driven by a tr...

Page 66: ...Courtesy of Crane Market...

Page 67: ...Courtesy of Crane Market...

Page 68: ...ump 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 no...

Page 69: ...hen taking pressure readings on either of the control valves for the boom winch and outrigger circuits Remove the 3 8 tube cap from the test fitting on the side of the control valve and install 3000 p...

Page 70: ...ers for the work port relief valve and shims are listed in the PARTS section Pressure is changed approximately 100 to 125 psi 6 9 to 8 6 bar for each 010 25 mm shim BOOM SEQUENCE The RT 300 boom crowd...

Page 71: ...ad radius with outriggers extended and the boom over the front The 7500 pounds 3390 kg includes a 7060 pound 3190 kg load and the 440 pound 200 kg sheave block Turn the engine off and move the BOOM le...

Page 72: ...ght hand and vice versa Repeat the pressure tests If the problem side changes the holding valve is at fault if the problem side is the same then the piston seal is leaking After the problem has been s...

Page 73: ...ot to over tighten pipe threads on which Teflon sealer is used particularly in aluminum or castings Leaks in component parts such as pumps valves and motors that cannot be stopped by tightening bolts...

Page 74: ...hile holding the nuts stationary or torque the nuts to 150 foot pounds 200Nm while holding the bolts stationary Grade 9 hex nuts can be identified by the flat top surface Torque the rotation bearing m...

Page 75: ...nsion chain adjusters until they are even with each other While this adjustment is being done the 9 3 4 24 8 cm tip spacing must be held as it is critical for alignment of the boom extension Inspectio...

Page 76: ...heads Do not exceed a torque of 20 foot pounds 27 N m Chain drape should be 2 5 8 1 8 6 7 0 3 cm for retraction chains and 5 5 8 1 8 14 3 0 3 cm for extension chains as shown Illustration C Chain dra...

Page 77: ...an as possible 2 Install the fourth stage into the third stage Guide the chains on through the third stage 3 Install chain sheaves on each end of third stage Install cylinder assembly into rear of thi...

Page 78: ...length of the tooth try a 0 003 0 07 mm gauge If the 0 003 0 07 mm gauge will go completely down the length of the tooth try a 0 004 0 1 mm gauge maximum acceptable The 0 004 0 1 mm gauge may start bu...

Page 79: ...ims should have been installed at that time Check the bearing and pinion tooth surface match to assure that contact is even along the full length of the teeth If contact is not even add additional shi...

Page 80: ...weekly The dipstick is located near the front end and right hand side of the transmission below the small fluid reservoir for the parking brake Make sure the area around the dipstick is clean before r...

Page 81: ...nge Use the following procedure 1 Operate the transmission long enough 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 particl...

Page 82: ...pressure is available through a solenoid valve to release the brake If the engine stops or there is an electric or hydraulic malfunction that stops the pressure a spring will apply the parking brake A...

Page 83: ...smission oil High or low level can cause problems If air bubbles are in the oil and the oil level is not too high there may be a leak in the suction line of the transmission pump 2 Check the parking b...

Page 84: ...the contaminants for further examination 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 Dep...

Page 85: ...he wedge securely with a brass or rawhide mallet 8 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...

Page 86: ...the sheave block and rewind the cable on the drum as in steps 7 11 17 Lubricate the cable as recommended in the Wire Rope Lubrication section Inspect maintain and replace the cable in accordance with...

Page 87: ...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...

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