Broderson RT-400-A Operation And Maintenance Manual Download

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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

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-wheel drive

Windshield wiper switch

Steering wheel tilt

Summary of Contents for RT-400-A

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: ...on 2 28 Front Auxiliary Winch 2 30 Pintle Hooks 2 31 Switch and Indicator Symbols 2 32 SECTION 3 MAINTENANCE Safety Rules 3 1 New Unit Inspection and Test 3 3 Operator Inspection and Test 3 4 Maintena...

Page 4: ...ake Bleeding Adjusting 3 21 Purging the Hydraulic System 3 34 Rotation Bearing Lubrication 3 15 Steering System 3 31 Towing 3 22 Transmission Maintenance Transmission Oil 3 17 Filter 3 18 Oil Change 3...

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...

Page 6: ......

Page 7: ...1 3 RT 400 A TURNING DIMENSIONS...

Page 8: ...m elevation cylinder hydraulic boom telescope cylinder and hydraulic powered hoist Rated Capacity Limiter RCL is standard RT 400 A 4 section hydraulically extended boom with capacity of 40 000 pounds...

Page 9: ...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 10: ...tegral to the rear axle Steering 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 steeri...

Page 11: ...ator compartment is equipped with safety glass and sliding door for entry and egress Door is equipped with a keyed lock to protect the operator s station Includes dome light heater AC with 2 speed fan...

Page 12: ...e turret to light ground under boom tip Includes switch at operator s station Net Weight 10 pounds 5kg Hydraulic System Standard Two piston pumps mounted on and driven by the main transmission deliver...

Page 13: ...er 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 it will block the...

Page 14: ......

Page 15: ...ine 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...

Page 16: ...2 2 8 The Rated Capacity Limiter must be checked after each setup for the proper operating configuration on the display...

Page 17: ...swinging load can cause instability or loss of control of the load Be aware that the Anti Two Block System and the Rated Capacity Limiter can cause sudden stopping of boom movement which can cause th...

Page 18: ...e page 2 23 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 19: ...of counterweight 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...

Page 20: ...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 v...

Page 21: ...When raising the boom or moving the unit with boom elevated be sure there is adequate overhead clearance for boom 3 Cranes with front steering require close watch because of tail swing when the chass...

Page 22: ...nk can cause a burst of fuel and vapor when the cap is removed Always refuel with proper fuel and into proper tank 9 Know your visibility limitations Loads being carried hanging on the hook can add fu...

Page 23: ...r Analog and Digital Inputs and outputs to aid with trouble shooting b A fuse and relay diagram that will show the operator when a fuse or relay has an issue and highlight which fuse or relay it is fo...

Page 24: ...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 25: ...em 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 Fo...

Page 26: ...cated at the operator s right will lower the boom pulling back will raise the boom 4 Hoist Pushing the far right joystick will lower the load line pulling back will raise the load line Included in thi...

Page 27: ...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 28: ...h 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 29: ...ill 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 w...

Page 30: ...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 31: ...d 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 a...

Page 32: ...utriggers 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 RT 400 continues to...

Page 33: ...is 40 000 pounds 18100 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 34: ...2 20...

Page 35: ...2 21...

Page 36: ...2 22...

Page 37: ...t shows that 10 000 pounds 4500 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 490 pounds 223 kg The rigger...

Page 38: ...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 39: ...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 use...

Page 40: ...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 41: ...rotary switch designed to disconnect the battery positive terminal from the electrical circuit It is located inside the right side engine compartment cover Locking tabs allow the use of lock out tag...

Page 42: ...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...

Page 43: ...on 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 wei...

Page 44: ...l 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 Ne...

Page 45: ...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 towe...

Page 46: ...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 47: ...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 48: ...in If injured by escaping fluid see a doctor at once Serious reaction or infection can occur 6 Wear safety glasses and safety shoes 7 Do not wear loose fitting or torn clothing 8 Remove rings and othe...

Page 49: ...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...

Page 50: ...elerator pedal 14 Check power steering for operation 15 Check operation of transmission gear selector switches 16 Check lights for operation 17 Test drive unit and check for normal operation 18 Check...

Page 51: ...e section 3 __ 10 Check parking brake operation 11 Check power steering operation 12 Observe chassis for normal driving operation 13 Observe boom operation for normal power speed and sequencing 14 Che...

Page 52: ...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 p...

Page 53: ...ot pounds for nut 13 Check axle mounting bolts 682 foot pounds 14 Torque wheel mounting nuts 475 foot pounds 645Nm torque 15 Check for loose pins or pin retainers 16 Check brake lines and steering lin...

Page 54: ...lter 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 Chan...

Page 55: ...ist 2 5 gallons 9 5L Axle Differential Housing 5 4 gallons 20 5L Hubs 0 5 gallons 1 85L Transmission 5 gallons 19L not including oil cooler and lines Engine oil capacity 10 5 quarts 10L Engine cooling...

Page 56: ...3 9 RT 400 A LUBRICATION CHART...

Page 57: ...3 10 RT 400 A LUBRICATION CHART...

Page 58: ...3 11 RT 400 A LUBRICATION CHART...

Page 59: ...ck 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 C...

Page 60: ...te 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...

Page 61: ...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 62: ...dal 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 Brake Unloadin...

Page 63: ...charging instructions included with commercially available gauge kits 5 Measure accumulator gas pre charge pressure Nominal pressure is 1000 100 PSI 69 6 8 bar W A R N I N G NEVER use shop air or oxy...

Page 64: ...L 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 mate...

Page 65: ...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 66: ...o 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 Remo...

Page 67: ...3 20 TRANSMISSION HYDRAULIC SYSTEM A pump in the transmission provides hydraulic power for operating the range shift solenoid and 4X4 disconnect solenoid...

Page 68: ...e 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...

Page 69: ...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 70: ...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 71: ...LANGE MOUNT INSTALLATION INSPECTION The following steps will assure that the wire rope aka hoist rope hoist cable or load line winds smoothly and evenly on the hoist and will yield greater safety and...

Page 72: ...eet 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 ins...

Page 73: ...s 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 mou...

Page 74: ......

Page 75: ...ing valve monitors the brake system pressure and when necessary demands pressure from hy draulic system to change the brake system 3 Machine Level Sensor located below the slewing bearing monitors the...

Page 76: ...n components including the components for the RCL system Electrical components connects above rotation include 1 Swing Position Sensor located in the slipring itself transmits data to the above rota t...

Page 77: ...ue 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 th...

Page 78: ...tem 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 operati...

Page 79: ...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 80: ...sene 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 damag...

Page 81: ...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 82: ...3 Take care not to over tighten pipe threads 4 Do not use Teflon tape to seal pipe treads Loctite type anaerobic sealant is preferred Leaks in component parts such as pumps valves and motors that can...

Page 83: ...linder 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...

Page 84: ...d 6300kg load on a 4 part line is required for this test Use the hoist to lift this load about 6 inches 15cm above the ground The radius of the test load should be within the rating on the capacity ch...

Page 85: ...orizontal 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 w...

Page 86: ...3 39 BOOM CHAIN ADJUSTMENT...

Page 87: ...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...

Page 88: ...wing function will appear loose if too much gap Retighten 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 re...

Page 89: ...andle 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 sm...

Page 90: ...le 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 loc...

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...

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