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

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PRINTED IN USA
P/N 990-30209
MAINTENANCE MANUAL
OWNER:_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
SOLD AND SERVICED BY:________________________________________________________
MODEL NO._________________________ SERIAL NO.
OPERATION AND
RT-300-2G
________________________________________________________
________________________________________________________
COPYRIGHT 2013
BRODERSON MFG. CORP.
LENEXA, KANSAS 66215
_____________________________
Courtesy of Crane.Market

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  • Page 1 PRINTED IN USA COPYRIGHT 2013 P/N 990-30209 BRODERSON MFG. CORP. LENEXA, KANSAS 66215 OPERATION AND MAINTENANCE MANUAL RT-300-2G OWNER:_______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ SOLD AND SERVICED BY:________________________________________________________ ________________________________________________________ ________________________________________________________ MODEL NO._________________________ SERIAL NO. _____________________________ Courtesy of Crane.Market...
  • 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 it’s standard form of Warranty...

  • Page 3: Table Of Contents

    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 of Operation…..……………………………... 2-12 Driving the Vehicle........... 2-12 Normal Gauge Readings.........
  • Page 4 SECTION 3 MAINTENANCE (cont'd) Hydraulic System Adjustments........3-23 Control Valves..........3-23 Boom Sequence Valves........3-24 Boom Cylinder Holding Valves......3-25 Crowd Cylinder Holding Valves......3-26 Hydraulic Seals..........3-27 Mechanical Adjustments..........3-28 General............3-28 Chain Adjustments........... 3-28 Crowd Cylinder Assembly........ 3-31 Boom Assembly..........

  • Page 5: Introduction

    RT-300 ROUGH TERRAIN CRANE INTRODUCTION The Broderson RT-300 was designed and built to provide safe, dependable and efficient crane service. This we warrant by our testing and quality control procedures. To properly utilize the full potential of the equipment, the following customer controlled conditions must exist: The operator must understand the equipment.
  • Page 6 DIMENSIONAL DATA Courtesy of Crane.Market...

  • Page 7: Turning Dimensions

    RT-300-2G TURNING DIMENSIONS Courtesy of Crane.Market...

  • Page 8: Description And Specifications

    A Rated Capacity Limiter (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 Weight For Basic Machine: Total 44,800 pounds (20,320 kg) Front Axle 23,730 pounds (10,310 kg) Rear Axle 22,070 pounds (10010 kg) Drawbar Pull: 30,000 pounds (13,600 kg) Hoist Pull (Bare Drum) 13,100 pounds (5940 kg) Boom Functions Boom Movement Boom Speeds Rotation Continuous 3.5 rpm...
  • Page 10 Transmission: Standard: Funk Manufacturing Co. Model 2000 powershift transmission with 6 forward speeds and 3 reverse. Provides full powershifts at maximum engine speed in all gears. All shifting is done with a single-lever electrical control in the operator compartment. The transmission includes an automatic rear axle disconnect for two-wheel drive in speeds 4, 5 and 6 in forward and speed 3 in reverse.
  • Page 11 Chassis: Standard: Engine Covers: Flip-up side covers. Steps: Grip-strut steps and grab bars provide easy two-step access to operator’s compartment. Outriggers: Four independently controlled outriggers of swing-down design. Hydraulic cylinders are equipped with direct connected holding valves. Foot pad dimensions: 20 inches (51 cm) by 16 inches (41 cm). Sheave Block and Downhaul Weight Storage: Tray on left-hand side behind hydraulic tank for storing sheave block and downhaul weight for single-part line.
  • Page 12 Pintle Hook Rear: T-60-AOL Holland pintle hook mounted on rear frame member, rated for 30,000 pounds (13,600 kg) trailer weight. Net Weight: 15 pounds (6.8 kg) Operator Compartment: Standard: Operator control station provides one-position access to all chassis and crane controls.
  • Page 13 Electrical System: Standard Battery: 12 Volt, Group 31, 950 CCA battery. Instrument Group: Located at operator’s station, and includes fuel gauge, transmission oil temperature gauge, and hydraulic oil temperature gauge. Units with EPA Tier 3 engine include voltmeter, oil pressure gauge, and water temperature gauge. Units with EPA Tier 4i engine include an electronic display for engine data.
  • Page 14 Boom: Standard: High strength steel construction, equipped with bearing pads for efficient support and extension. Double-acting hydraulic cylinders extend and retract the second and third boom sections. Double runs of high strength leaf chain extend and retract the fourth section. The second stage extends first and retracts last, controlled by sequencing valves in the boom.
  • Page 15 Sheave Block: Double sheave block for four-part-line requirements. 12-inch (30.5 cm) O.D. sheaves for 9/16 inch (14 mm) diameter wire rope. Swivel hook with safety latch. Includes bar on top to actuate trip arm of anti-two-block device. 440- pound (200 kg) weight provides positive overhaul. Optional Boom Attachments: Boom Extension - 20 Ft.
  • Page 16 Courtesy of Crane.Market...

  • Page 17: Safety Rules

    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 user and his operating personnel. 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 18 3. Keep operator's compartment and steps free of mud and grease. 4. Keep all window glass clean. Keep gauges clean. 5. Tools, lubricants, or rags on the crane should be kept in a secured toolbox. 8. The Rated Capacity Limiter must be checked before each shift and after each setup for the proper operating configuration on the display.
  • Page 19 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 20 9. Crane may tip at less than rated loads if the surface is uncompacted or wet dirt, or soft soil with frozen crust, thin or cracked pavement, or surface near a hole or ledge. Always use adequate outrigger floats and/or cribbing. See page 2-19. 10.
  • Page 21 C A U T I O N Keep hands out of Anti-Two-Block mechanism. Serious injury can result from moving parts. 17. 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.
  • Page 22 22. 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.
  • Page 23 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 24 Courtesy of Crane.Market...

  • Page 25: Instruments And Controls

    OPERATION INSTRUMENTS AND CONTROLS The Broderson RT-300 dashboard is equipped with a standard instrument package showing, fuel level, transmission oil temperature, hydraulic oil temperature and engine hours. Also included are indicator lights for two-wheel drive, four-wheel drive, and parking brake. Units with EPA Tier 3 engine include gauges for electrical system volts, oil pressure and water temperature.

  • Page 26: Control Functions

    Lights on the dashboard indicate two-wheel or four-wheel drive operation. Four-wheel drive is automatically disengaged in forward gears 4, 5 and 6 and in reverse gear 3. Avoid four-wheel drive operation on pavement except for short distances. The steering wheel is directly mounted to the steering control unit of the all-hydraulic power steering system.
  • Page 27 Crowd or Telescope: There is a SLOW CROWD lever and an INTERMEDIATE CROWD lever. Pulling back on either lever will retract the boom; pushing forward will extend the boom. Pushing simultaneously on both levers produces fast extension speed. Maximum retraction speed is produced with the INTERMEDIATE CROWD lever alone. Attempting to retract with both levers will stall the engine or produce excess heat in the hydraulic system.

  • Page 28: Sequence Of Operation

    SEQUENCE OF OPERATION DRIVING THE VEHICLE The following procedure is recommended for driving the vehicle to the job site: 1. Perform the daily inspection and test. (See Page 3-4) 2. Switch park brake on. 3. Place powershift transmission lever in neutral. 4.

  • Page 29: Operating The Crane

    OPERATING THE CRANE The following procedure is recommended for placing the crane in operation: Perform daily inspection and test. (See Page 3-4) Switch park brake to "on." Place transmission shift lever in neutral. Start engine and allow a warming period. While warming the engine set up the Rated Capacity Limiter configuration.

  • Page 30: Crane Capacity

    If there is a malfunction of the RCL or Anti-Two-Block system that causes loss of boom movement and cannot be remedied by the procedures above, the override keyswitch under the dashboard may be required to move the boom. W A R N I N G We recommend the CANCEL button and emergency override switch be used with discretion.
  • Page 31 The Rated Capacity Limiter is designed to stop three crane functions at the limitations of the capacity chart. These are: BOOM LOWER, TELESCOPE EXTEND and HOIST RAISE. Great care must be exercised when handling a load near capacity or near a two- blocking condition.
  • Page 32 The capacities shown in the 360° ROTATION columns of the capacity chart apply to the entire 360 degree rotation of the boom and are maximum allowable at the indicated radius. The capacities OVER FRONT are limited to the following: On Outriggers -- Boom rotation is limited to an arc not to exceed the eight- foot wide front outrigger housing.

  • Page 33: Capacity Chart

    CAPACITY CHART FOR RT-300-2G 2-17 Courtesy of Crane.Market...
  • Page 34 CAPACITY CHART FOR RT-300-2G METRIC 2-18 Courtesy of Crane.Market...
  • Page 35 CAPACITY EXAMPLE (Also see Boom Extension Capacity Example) Refer to the RT-300-2G capacity chart on the preceding page. A load 5' X 5' X 5' (1.5m X 1.5m X 1.5m) and weighing 14000 lbs (6350 kg) is to be lifted for transport to a new location.
  • Page 36 Looking at the "360° ROTATION, ON RUBBER" column, we must use the capacity at the 16 ft (4.5 m) radius, which is the next larger radius on the chart from the actual load radius of 14.5 ft (4.4 m). The capacity on rubber is 8300 lbs (4320 kg). This leaves the ON OUTRIGGERS columns.

  • Page 37: Sheave Block And Downhaul

    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 Anti- Two-Block system. Other blocks or downhauls may bypass this system and create a dangerous condition.
  • Page 38 The dead end of the rope in the wedge socket should be clamped as shown in the figure. 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 striker plate bolted on top of the block should meet the boom sheave plates squarely when pulled up snugly.

  • Page 39: Safety Devices

    SAFETY DEVICES There are safety devices on the RT-300 to maintain control of a load in case of power or hydraulic line failure. The operator should understand the function and operation of these devices so that a continual check on their performance can be made. OUTRIGGER CYLINDER CHECK VALVE: A double-acting check valve is integrally mounted on each of the outrigger cylinders.
  • Page 40 HOIST BRAKE AND HOLDING VALVE: The hoist has an automatic brake in the gearbox and a holding valve mounted directly on the hoist motor to hold the load. A clutch in the gearbox allows the hoist to turn freely in the RAISE direction.

  • Page 41: Optional Equipment

    OPTIONAL EQUIPMENT OPERATIONS BOOM EXTENSION CAPACITY CHART: The boom extension will increase the main boom reach by 20 feet (6.1 m). It will also pin in 3 positions relative to the main boom: In Line, 15° Offset, and 30° Offset. The main boom and boom extension capacity charts must both be considered when using the boom extension.
  • Page 42 12. Lay the load line over the main boom and extension tip sheaves and insert the cable retainer pins and cotters. 13. Install the downhaul weight, wedge socket and swivel hook on the load line if they are not already installed. 14.

  • Page 43: Front Auxiliary Winch

    STOWING THE OFFSETTABLE BOOM EXTENSION: 1. If the boom extension is offset to 15 or 30 degrees, return it to the zero offset position as described above. 2. Perform steps 16-20 of the boom extension installation and stowing procedure. 3. Set the Rated Capacity Limiter configuration. FRONT AUXILIARY WINCH: A front auxiliary winch mounted on the front outrigger housing and controlled from the operator compartment.

  • Page 44: 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 other vehicle is occupied and controlling the vehicle being towed.

  • Page 45: Switch And Indicator Symbols

    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 46 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

    MAINTENANCE SAFETY RULES Lower load and boom, raise outriggers, shutdown engine, remove key and put it in a safe place. Place warnings on the ignition switch and crane controls to prevent unauthorized starting or movement during maintenance. Disconnect battery when disabling crane or when welding on crane. Disconnect the transmission shifter, RCL, and battery when welding on crane.
  • Page 48 Do not work on any machine that is supported only by jacks or a hoist. Always use adequate blocks or jack stands. If it is necessary to work on the boom or outriggers in an unstowed condition, block them to prevent them from dropping unexpectedly. Use a hoist when lifting components that weigh 50 (22 kg) pounds or more.

  • Page 49: New Unit Inspection And Test

    MAINTENANCE The Broderson RT-300 Rough Terrain Crane will perform better and longer if a program of inspection, 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 and able to perform safely. Daily: Check levels of engine oil, coolant and transmission fluid. Drain fuel-water separator.
  • Page 51 OPERATOR INSPECTION AND TEST (continued) Weekly: 1. Check tire pressure -- 100 psi (690 kPa). 2. Visually inspect axle mounting bolts. 3. Check for loose wheel nuts (475 ft.-lbs. (645Nm) torque required. 4. Check lights and turn signals. 5. Check brake lines and power steering lines for damage. 6.

  • Page 52: Maintenance Checklist

    RT-300 MAINTENANCE CHECKLIST Refer to the component maintenance section of this manual and to the engine operator's manual for complete instructions. 50 HOUR INTERVAL: 50 hour lubrication as shown on lube schedule. Check fluid levels in engine, transmission, hydraulic tank and parking brakes. Check tension and condition of engine belts.
  • Page 53 500 HOUR INTERVAL: 50 and 250 hour maintenance. 50, 250 and 500 hour lubrication. Check antifreeze for protection level and cleanliness. Change hydraulic filter element and inspect oil from element. Check condition of all operational and warning placards. Torque mounting bolts on rotation bearing and gearbox, winch, axles and front outrigger.
  • Page 54 CHAIN AND CHAIN SHEAVE LUBRICATION The chains and chain sheaves should be lubricated every 250 hours. Chain sheaves have lubricated bearings and can be reached with the boom retracted or fully extended as shown below. Use all-purpose grease in a grease gun. The boom must be fully extended and horizontal to lubricate the chains.
  • Page 55 Courtesy of Crane.Market...
  • Page 56 RT-300 LUBRICATION SCHEDULE LUBRICATION INTERVALS LUBE SYMBOL ITEM DESCRIPTION 500 1000 MONTHS NOTES HOUR HOUR HOUR HOUR Accelerator Linkage 7 Points - Oilcan Anti-Two-Block Arm 2 Points - Oilcan Axle Differential Check @50, Change @12 Mo. Axle Kingpins 8 Zerks Axle U-Joints 8 Zerks Axle Planetary Hubs...

  • Page 57: Wire Rope Lubrication

    WIRE ROPE LUBRICATION The wire rope should be cleaned and 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 compressed air or solvent and rags. A wire brush may be used for difficult areas.
  • Page 58 C A U T I O N Brake dust may be hazardous. Observe precautions to prevent breathing large amounts of brake dust. Brake Pads and Rotors: Recall that the steering system on the RT-300 is non-load reactive. The operator will not be able to “feel” pad or rotor problems in the steering wheel. On a weekly basis, check to see if the rotors appear worn, grooved, warped, or otherwise damaged.
  • Page 59 Brake Accumulators: Mounted under covers behind the operator’s seat. The brake accumulators 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.

  • Page 60: Engine Maintenance

    ENGINE MAINTENANCE Refer to the engine manual for engine maintenance. AIR CLEANER SERVICE Tier 3 Engine: Clean out the dust cup every 50 hours. Loosen the clamps around the cup and housing and remove the cup. Dump dust out of cup. Clean gasket and sealing surfaces with a damp cloth.

  • Page 61: Care Of Hydraulic Oil

    CARE OF HYDRAULIC OIL The hydraulic system contains many precision, highly pressurized components. To protect these, it is very important to keep the hydraulic oil clean, at proper temperature, within the oil specification and to the proper fill level. The RT-300 is equipped with a 100-mesh suction strainer, a breather filter and a 10- micron, return-line filter on a 70-gallon (265 L) tank.
  • Page 62 HYDRAULIC OILS FOR RT-300 AMBIENT TEMP: -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 (-40°C MAX) (-26° C) (-18°C) VISCOSITY INDEX: 140 MIN 5 to 100 5 to 100 VISC.

  • Page 63: Purging The Hydraulic System

    PURGING THE HYDRAULIC SYSTEM If excessive water or other contamination is found in the hydraulic oil, the source should be found and fixed, and the oil should be changed. However, there will still be a large quantity of contaminated oil in the hydraulic cylinders. This oil should be purged by the following procedure: After the reservoir is cleaned and the filter replaced, fill the reservoir with clean oil.
  • Page 64 Push all four outrigger levers fully forward and run engine until the outriggers all touch the ground. Stop the engine. Release the outrigger levers and pull the SWING lever fully. Run the engine for 3 seconds and stop engine. Release SWING lever and pull SLOW HOIST lever to full raise position and run engine for 7 seconds, then stop engine.

  • Page 65: Hydraulic System

    c. The boom will lower during this procedure. Ensure no personnel are in potential pinch points, especially around the topping cylinder and between turret side plates. Ensure that the boom is free of obstructions. Ensure that the hook will not hit the ground and foul the hoist line. d.
  • Page 66 Courtesy of Crane.Market...
  • Page 67 Courtesy of Crane.Market...

  • Page 68: Steering System

    STEERING SYSTEM The RT-300 steering system is a load-sensing, demand-type system that takes only as much flow as is needed when steering and directs the excess flow to the control valve for boom and outrigger functions. The priority flow-control valve is in the line between the 28- gpm (106 L/min.) pump section and control valve.

  • Page 69: Hydraulic System Adjustments

    HYDRAULIC SYSTEM ADJUSTMENTS CONTROL VALVES The hydraulic system is divided into three main circuits, each having its own protective relief valve. The relief valves are adjustable on the boom control valves, but not on the brake system. Intermediate speed boom and hoist -- 3000 psi (207 bar) at full flow. Slow boom, hoist and outriggers -- 3000 psi (207 bar) at full flow.

  • Page 70: Boom Sequence Valves

    Swing and slow hoist have spools that bleed pressure from work ports to return galley of valve. Slow crowd and topping have spools that bleed pressure from the retract side work port only, to return galley. All other spools are blocked-port spools. The relief valve pressure setting at the inlet end of the valve is 3000 psi (207 bar).

  • Page 71: Boom Cylinder Holding Valves

    VALVE SETTINGS: Approximate factory settings are 300 psi (21 bar) on extension (upper valve) and 800 psi (55 bar) on retraction (lower valve). Valves are fine tuned, however, to control boom stage sequencing at all boom angles and normal hydraulic oil temperatures. Setting the valves higher than required will generate additional heat in the hydraulic system and also waste fuel.

  • Page 72: Crowd Cylinder Holding Valves

    With rated load on the hook, the boom over the front and outriggers extended, record the pressure on the gauge while slowly raising the boom tip about three feet above its horizontal position. Then return the boom control lever to neutral and record the pressure. Then turn the engine off, push the BOOM lever to the LOWER position and record the pressure on the gauge.

  • Page 73: 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.

  • Page 74: Mechanical Adjustments

    MECHANICAL ADJUSTMENTS GENERAL All fasteners in the RT-300 should be checked, and retightened if required, as a part of the preventive maintenance program. Particular attention should be given to the axle mounting bolts, outrigger bolts, pump mounting bolts, rotation bearing bolts, rotation gearbox bolts and winch bolts.
  • Page 75 Set the space between fourth stage boom tip and third stage tip at 9-3/4" (24.8 cm) (Illustration A). Use a 9¾" (24.8 cm) long wood block to hold this distance while making initial adjustment on the extension and retraction chain adjusters. Snug tighten the retraction chain adjusters first.
  • Page 76 FINAL CHAIN ADJUSTMENT AND FIELD ADJUSTMENT Cycle boom extension from full extension to retraction five times while varying the boom angle. Then set the boom horizontal and fully extended for the final adjustment. (Illustration C) Check both extension and retraction chain "drape" at the center of the 8" (20 cm) third stage inspection windows.

  • Page 77: Crowd Cylinder Assembly

    CROWD CYLINDER ASSEMBLY AND INSTALLATION PROCEDURE (REFER TO CYLINDER ASSEMBLY IN PARTS MANUAL) It is very important to follow this procedure prior to assembling the boom for the RT-300. The primary and secondary cylinder dimensional relationship must be held to assure that the hoses clamp and terminate properly.
  • Page 78 ROTATION GEARBOX INSTALLATION AT TIME OF ROTATION BEARING INSTALLATION The spacing between the rotation bearing and rotation gearbox is preset and non adjustable. However, a set procedure is necessary at the time of assembly. The following sequence should be followed when replacing the rotation bearing: Set the turntable upside down on the floor and loosely mount the rotation bearing and gearbox on the turntable with the "high point"...

  • Page 79: Wheel Alignment

    FIELD REMOVAL AND REPLACEMENT OF THE ROTATION GEARBOX WITHOUT REPLACING ROTATION BEARING Be sure that the boom is well supported from rotation before removing the rotation gearbox. IF NOT SUPPORTED, THE BOOM WILL SWING UNCONTROLLABLY WITHOUT THE GEARBOX IN PLACE. Always replace the same number of shims under the gearbox flange that came from the factory.

  • Page 80: Transmission Maintenance

    TRANSMISSION MAINTENANCE The transmission is a six-speed-forward, three-speed-reverse, Funk Model 2000, powershift transmission. The transmission is bolted directly to the flywheel housing of the engine and is connected by drive shafts to the front and rear axles. A torque converter transmits power from the flywheel to the transmission.
  • Page 81 1. Clean the filter housing, element and nearby hoses. Remove the used filter element and catch the oil in a clean bucket. Empty the element into the bucket and examine the oil for foam, water and excessive particles. By checking the oil at every filter change, trends may be observed which could help in troubleshooting if problems develop.

  • Page 82: Transmission Hydraulic System

    TRANSMISSION HYDRAULIC SYSTEM: A pump in the transmission provides hydraulic power for operating the clutches and the parking brake and provides flow for the torque converter and for lubrication. The hydraulic schematic is shown below. There is a pressure intensifier on the right-hand frame rail near the transmission. This device multiplies the transmission pump pressure by five times and supplies the higher pressure to the parking brake release cylinder.

  • Page 83: Transmission Troubleshooting

    Try these first, and an unnecessary service call may be avoided. NOTE: 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 FUNK MANUFACTURING COMPANY SERVICE REPRESENTATIVE CONTACT YOU.

  • Page 84: Towing

    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 Funk Manufacturing 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 and do not exceed 10 mph (16 km/hr).

  • Page 85: Hoist Cable

    HOIST CABLE INSTALLATION AND INSPECTION The following steps will assure that the wire rope winds smoothly and evenly on the hoist and will yield greater safety and longer cable life: If the cable needs to be replaced, use 350 feet (107m) of 9/16” (14mm) dia. 6 x 36- EIP-RRL-IWRC wire rope (26,250 pounds (117kn) minimum breaking force).
  • Page 86 If the cable appears to twist too much, remove the sheave block and rewind the cable on the drum as in steps 7-11. Lubricate the cable as recommended in the "Wire Rope Lubrication" section. Inspect, maintain and replace the cable in accordance with ANSI B30.5-2007, Section 5-2.4. 3-40 Courtesy of Crane.Market...

  • Page 87: Torque Data

    TORQUE DATA BOLT SAE GRADE SAE GRADE SAE GRADE GRADE 1 OR 2 MARKING MEDIUM CARBON MEDIUM CARBON MATERIAL STEEL ALLOY STEEL LOW CARBON 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 88 Courtesy of Crane.Market...
  • Page 89 Courtesy of Crane.Market...

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