Zoomlion RT100 User manual

OPERATOR'S MANUAL FOR
RT100 ROUGH TERRAIN CRANE
Address:Quantang Indust=rial Park, 2nd Yuanda Road,
Changsha Economic and Technological Development
Zone, Hunan Province, China
Postcode: 410131
Website: www.zoomlion.com

RT100 ROUGH TERRAIN CRANE
OPERATOR’S
MANUAL
Edition 1
Dec 2013

RT100 Rough Terrain Crane I
Zoomlion Cranes appreciates your selection of the ZOOMLION Rough Terrain Crane
for your application.
No one should operate the crane unless they read and understand the information in
this manual.
When you follow the instructions in this manual, your crane can operate at MAXIMUM
EFFICIENCY.
The operator must keep this manual in the cab of the crane.
If there is anything in the manual that you do not understand, speak with us. We
(Zoomlion Cranes) are NOT responsible for damages from an operator who does not
obey the instructions in the OPERATOR’S MANUAL.
The OPERATOR’S MANUAL is an important part of the crane. If the crane becomes the
property of a different person, make sure that the manual stays in the cab of the crane.
THANK YOU!
Mobile Crane Branch Company of ZOOMLION Heavy Industry Science and Technology
Co., Ltd.
Copyright
Under the copyright laws, this manual may not be copied, photocopied, reproduced,
translated, or reduced to any electronic medium or machine readable form, in whole or
part, without the prior written consent of Zoomlion Heavy Industry Science and
Technology Co., Ltd.
Copyright © 20XX, Zoomlion Heavy Industry Science and Technology Co., Ltd.
All rights reserved.

II RT100RoughTerrainCrane
HazardIndicators
DANGER,WARNING,CAUTION,ATTENTION,NOTE,andIMPORTANTlabelsareon
signsanddecals,andasyoureadthismanualtoshowimportantinstructions.Inthis
manual,DANGER,WARNING,andCAUTIONlabelsarebeforetheparagraphoritemto
whichtheyapply.ATTENTION,NOTE,andIMPORTANTfollowtheparagraphoritem
theyapplyto.Themarkersareasfollows:
Danger
Referstoadangeroussituationwhich,ifyoudonotprevent,willcausedeathor
injury.
Warning
Referstoapossibledangeroussituationwhich,ifyoudonotprevent,couldcause
deathorinjury.
Caution
Referstoapossibledangeroussituationwhich,ifyoudonotprevent,maycause
lightormoderateinjury.
Attention
Referstoasituationwhich,ifyoudonotprevent,maycausepropertyorequipment
damage.
Note
Referstoatiporhintintheoperationinstructions.
Important
Emphasizestheimportanceofthedatainthismanual.
Thissymbolshowsasteporprocedurethatisnotapprovedandcancauseadangerous
situation.

RT100 Rough Terrain Crane III
To owners, users and operators............................................................................................I
Safety....................................................................................................................................... II
1 Foreword.........................................................................................................................1-1
2 Nomenclature.................................................................................................................2-1
3 Introduction.................................................................................................................... 3-1
4 Safety ...............................................................................................................................4-1
5 Operating conditions and points for attention........................................................... 5-1
5.1 Operating conditions................................................................................................. 5-1
5.2 Pre-departure checks (to job-site).............................................................................5-3
6 Controls and instruments..............................................................................................6-1
7 Operating instructions...................................................................................................7-1
7.1 Safety equipment.......................................................................................................7-1
7.2 Starting the engine ....................................................................................................7-2
7.3 After the engine starts ............................................................................................... 7-2
7.4 Cold weather starting.................................................................................................7-3
7.5 Move and park the crane........................................................................................... 7-3
7.6 Economical driving .....................................................................................................7-4
7.7 Steering operation......................................................................................................7-5
7.8 Braking operation .......................................................................................................7-6
7.9 Transmission operation..............................................................................................7-6
7.10 Towing......................................................................................................................7-8
7.11 PTO operation ...........................................................................................................7-8
7.12 Outrigger operation................................................................................................. 7-10
7.13 Hoist operation ....................................................................................................... 7-13
7.14 Main boom extend / retract function operation....................................................... 7-23
7.15 Boom derrick operation.......................................................................................... 7-27
7.16 Swing operation.......................................................................................................7-29
7.17 Multifunctions...........................................................................................................7-32
7.18 Jib operation............................................................................................................7-37
7.19 Rooster sheave .......................................................................................................7-44
7.20 Vehicular operation..................................................................................................7-46
7.21 On tires lifts............................................................................................................. 7-49
7.22 Unusual operating conditions................................................................................. 7-50
7.23 Counterweight operation........................................................................................ 7-52

IV RT100 Rough Terrain Crane
8 Transportation and storage......................................................................................... 8-1
8.1 Transportation ...........................................................................................................8-1
8.2 Storage......................................................................................................................8-2
9 Specifications..................................................................................................................9-1
9.1 Conversion tables......................................................................................................9-1
9.2 Average weight of materials......................................................................................9-3
9.3 Torque values............................................................................................................9-5
9.4 Technical specifications ............................................................................................9-6

RT100 Rough Terrain Crane 01 - 1
The owner of this crane must know federal, state and local rules. When your
equipment is in operation, the area must be safe for employees and non-employees.
Do not cause damage to other equipment or local structures while you operate this
crane. The rules change by location and this manual does not give that data.
ZOOMLION makes manuals for different construction and industrial equipment. It is
policy to include applicable national consensus, industry standards and safety data
with the manuals. Use these data to give applicable training to personnel who are to
operate, do the maintenance and supervise the equipment correctly and safely.
We make equipment for heavy-duty labor. Do the periodic inspections regularly
because the equipment wears. This prevents accidents, decreases downtime and
helps equipment work satisfactorily. The goal of these inspections is to find worn,
cracked, damaged parts and loose or missing fasteners before they cause a problem.
Correct training and inspection procedures are necessary to prevent injury to persons,
property damage and high maintenance costs.
Read and understand the data that comes with this crane. Help is available from the
distributors of your ZOOMLION crane and from the ZOOMLION Mobile Crane Branch
Company.
This manual contains the instructions and data on the operation, maintenance,
lubrication, and adjustments of the Rough Terrain Crane. Do not operate the crane
before you understand the data in this manual.

RT100 Rough Terrain Crane 02 - 1
To help you understand the contents of this manual, refer to the figure below. Each
numbered term can represent several components of the same main part.
LEGEND
1. BOOM SYSTEM = Main boom assy., jib assy., telescoping mechanism, hook block,
auxiliary hook, hoist rope.
2. SWING SYSTEM = Superstructure, counterweight, main and auxiliary winches,
swing bearing, swing reducer, derricking cylinder, cab, air
conditioner and cab heater.
3. CHASSIS = Power system, drive system, steering system, air intake system,
exhaust system, cooling system, fuel supply system, chassis
frame assy. and vehicle body system.
4. OUTRIGGERS = Outrigger beams, outrigger jacks, cylinders and outrigger floats.

RT75 Rough Terrain Crane 03 - 1
CRANE PERIODIC INSPECTION CHECKLIST
This inspection checklist provides supplementary data to facilitate the correct operation
and maintenance of the crane.
Component Inspected Interval Function Adjusting Condition Maintenance condition Component Inspected Inspection Code Function Adjusting Condition Maintenance Condition

03 - 2 RT75 Rough Terrain Crane
MAINTENANCE LOG
Item
Adjusting Condition
Date

RT100 Rough Terrain Crane 03 - 3
About This Manual
General
The data (data, specifications, illustrations) in this manual is for cranes in production at the
time of this manuals publication. We reserve the right to make changes to this manual at
any time, without obligation.
This manual contains the instructions to move and operate the RT75 Crane in the field.
Follow the operation and maintenance procedures to make sure that your machine
operates at MAXIMUM EFFICIENCY. Use the CRANE PERIODIC INSPECTION
CHECKLIST. Keep a maintenance log to monitor all maintenance work on the machine.
An example of a Maintenance Log and Crane Periodic Inspection Checklist is at the
beginning of this section.
Again, we appreciate your selection of our crane. User safety is most important. To
complete on-site tasks safely, operators must be responsible. Obey the instructions that
follow:
Comply –with Occupational Safety and Health Administration (OSHA), Federal, State,
and Local Regulations.
Read, Understand, and Follow –the instructions in this and other manuals and
documents that come with the crane.
Use Good, Safe Work Practices –in a common sense way.
Only have trained operators –directed by informed and knowledgeable job-site
supervisors.
Do not use this crane –before the portable fire extinguisher, installed in the cab,
agrees with local fire protection rules.
Note
OSHA prohibits the alteration or modification of this crane without written
manufacturer’s approval. Use only factory approved parts to service or repair
the crane.
If you make modifications/additions "which affect the safe operation of the
equipment" to the crane before you use it, the crane owner must make sure
that the modifications/additions agree with OSHA 1926:1412.