Zoomlion ZRT850 User manual

Zoomlion Heavy Industry Science & Technology Co.,Ltd.
Address: Quantang Industrial Park, No. 1636, 2nd Yuanda Road, Changsha, Hunan Province, China Postcode: 410131
Website: http://www.zoomlion.com Email: [email protected]
Copyright © 2015 Zoomlion Heavy Industry Science&Technology Co., Ltd. All rights reserved

ZRT850 Rough Terrain Crane
Operator’s Manual
Edition 1 April 2018

To Users
Operator’s Manual for Rough Terrain Crane
Zoomlion 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.
This manual contains the instructions and data on the safety and operation of the rough terrain
crane. 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 is not clear or you do not understand, please contact our
service technician. We (Zoomlion) 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.
The data (data, specifications, illustrations) in this manual is for cranes in production at the time of
this manual’s publication. We reserve the right to make changes to this manual at any time, without
obligation.
The manual has been translated to be best of our knowledge. Zoomlion assumes no liability for
translation errors. The Chinese version of the OPERATOR’S MANUAL is solely applicable for
factual accuracy.
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 © 2017, Zoomlion Heavy Industry Science and Technology Co., Ltd.
All rights reserved.
I

Safety Instructions
Operator’s Manual for Rough Terrain Crane
DANGER, WARNING, CAUTION and NOTICE labels are on signs and decals, and as you read this
manual to show important instructions. In this manual, the labels follow the paragraph or item they
apply to. The markers are as follows:
DANGER
Refers to a dangerous situation which, if you do not prevent, will cause
death or injury.
WARNING
Refers to a possible dangerous situation which, if you do not prevent,
could cause death or injury.
CAUTION
Refers to a possible dangerous situation which, if you do not prevent, may
cause light or moderate injury.
NOTICE
Refers to a situation which, if you do not prevent, may cause property or
equipment damage.
II

Operator’s Manual for Rough Terrain Crane
To Users ........................................................................................................................................I
Safety Instructions.......................................................................................................................II
Chapter 1 Foreword................................................................................................................1-1
Chapter 2Nomenclature ........................................................................................................2-1
Chapter 3 Introduction
3.1 Crane periodic inspection checklist ..............................................................................3-1
3.2 Maintenance log..........................................................................................................3-2
3.3 About this manual........................................................................................................3-3
Chapter 4 safety
4.1 Safety symbol..............................................................................................................4-1
4.2 Hazard classification....................................................................................................4-1
4.3 Safety..........................................................................................................................4-1
4.3.1 Moving personnel.............................................................................................4-1
4.3.2 Operator’s responsibilities................................................................................4-1
4.3.3 Signal personnel responsibilities.......................................................................4-3
4.3.4 Responsibilities of all crew members................................................................4-3
4.3.5 Management responsibilities............................................................................4-3
4.3.6 Planning the job...............................................................................................4-3
4.3.7 Operator safety check......................................................................................4-4
4.3.8 Operator aids check.........................................................................................4-4
4.3.9 Operation overload prevention .........................................................................4-4
4.3.10 Operation setup..............................................................................................4-5
4.3.11 Power line safety............................................................................................4-5
4.3.12 Slip and fall prevention...................................................................................4-5
4.3.13 Travel.............................................................................................................4-5
4.3.14 Safety sign maintenance................................................................................4-6
Contents
ZRT850 Rough Terrain Crane III

Operator’s Manual for Rough Terrain Crane
Chapter 5 Operating conditions and points for attention
5.1 Operating conditions....................................................................................................5-1
5.2 Pre-departure checks (to job-site) ................................................................................5-4
5.2.1 Vehicle checks (prior to engine start)................................................................5-4
5.2.2 General checks at vehicle start up....................................................................5-5
5.2.3 Move the crane to the job-site ..........................................................................5-5
5.2.4 Crane movement in off-road conditions ............................................................5-8
5.2.5 Park the vehicle ...............................................................................................5-8
5.2.6 Emergency stop on the roadway ......................................................................5-9
5.2.7 Prepare the crane for operation........................................................................5-9
5.2.8 When the crane is in operation.........................................................................5-9
Chapter 6 Controls and instruments
6.1 Upper controls and instruments....................................................................................6-1
6.1.1 Air conditioner control panel.............................................................................6-5
6.1.2 Media player....................................................................................................6-8
6.2 Controls and instruments........................................................................................... 6-10
6.2.1 Left joystick.....................................................................................................6-11
6.2.2 Boom extend / retract pedal ........................................................................... 6-12
6.2.3 Cigarette lighter..............................................................................................6-12
6.2.4 Steering wheel and combination switches....................................................... 6-13
6.2.5 Brake pedal....................................................................................................6-14
6.2.6 Ignition switch ................................................................................................ 6-15
6.2.7 Throttle pedal................................................................................................. 6-15
6.2.8 Hand throttle.................................................................................................. 6-15
6.2.9 Bubble level................................................................................................... 6-15
6.2.10 Right joystick................................................................................................6-15
6.3 Monitor...................................................................................................................... 6-17
6.3.1 Vehicle status................................................................................................. 6-24
6.3.2 System warning ............................................................................................. 6-25
6.3.3 Main menu..................................................................................................... 6-26
6.4 Vehicle camera..........................................................................................................6-38
IV ZRT850 Rough Terrain Crane

Operator’s Manual for Rough Terrain Crane
Chapter 7 Operating Instructions
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
7.5.1 Move the crane................................................................................................7-3
7.5.2 Park the crane..................................................................................................7-3
7.6 Economical driving.......................................................................................................7-4
7.7 Steering operation........................................................................................................7-5
7.8 Braking operation.........................................................................................................7-5
7.9 Transmission operation................................................................................................7-6
7.10 Towing.......................................................................................................................7-7
7.11 Outrigger operation....................................................................................................7-8
7.11.1 Extend the outrigger......................................................................................7-8
7.11.2 Retract the outrigger.....................................................................................7-9
7.11.3 Install and remove the outrigger floats......................................................... 7-10
7.12 Hoist operation..........................................................................................................7-11
7.12.1 Lift chart and lift height chart.......................................................................7-12
7.12.2 Main winch .................................................................................................7-15
7.12.3 Auxiliary winch............................................................................................7-16
7.12.4 Hoist line reeving........................................................................................7-18
7.13 Main boom extend / retract function operation..........................................................7-20
7.13.1 Operate – extend the boom ........................................................................7-21
7.13.2 Operate – retract the boom.........................................................................7-23
7.14 Derricking operation (operate – boom derrick)..........................................................7-24
7.15 Swing operation.......................................................................................................7-26
7.15.1 Swing mechanism ......................................................................................7-26
7.15.2 Swing lockout device.................................................................................. 7-26
7.15.3 Operate – swing during a lift.......................................................................7-27
7.16 Multifunctions...........................................................................................................7-29
7.17 Jib operation............................................................................................................7-35
7.17.1 Assemble the jib.........................................................................................7-35
7.17.2 Change the jib offset from 0° to 30°.............................................................7-45
7.17.3 Dismantling ................................................................................................7-45
7.18 Rooster sheave........................................................................................................7-47
7.18.1Assembly....................................................................................................7-48
ZRT850 Rough Terrain Crane V

Operator’s Manual for Rough Terrain Crane
7.18.2 Disassembly...............................................................................................7-48
7.19 Vehicular operation.................................................................................................. 7-50
7.19.1 Move the crane to a job-site........................................................................ 7-51
7.19.2 Charge the battery before you stop the engine............................................ 7-52
7.19.3 Stopping the engine.................................................................................... 7-52
7.19.4 Move the crane at the job-site..................................................................... 7-53
7.20 On tires lifts (creeping a load)................................................................................... 7-53
7.21 Unusual operating conditions................................................................................... 7-54
7.21.1Extreme cold .............................................................................................. 7-54
7.21.2 Extreme heat.............................................................................................. 7-55
7.21.3 Sandy or dusty job-sites ............................................................................. 7-55
7.21.4High humidity or saltwater........................................................................... 7-55
7.21.5 High altitudes ............................................................................................. 7-56
7.21.6 Storms........................................................................................................ 7-56
Chapter 8 Transportation and storage
8.1 Transportation..............................................................................................................8-1
8.2 Storage........................................................................................................................8-3
Chapter 9 Specifications
9.1 Conversion tables........................................................................................................9-1
9.2 Average weight of materials.........................................................................................9-4
9.3 Torque values..............................................................................................................9-6
9.4 Technical specifications ...............................................................................................9-7
9.4.1 Crane description.............................................................................................9-7
9.4.2 Specifications – upperstructure........................................................................9-11
9.4.3 Specifications – special purpose chassis for rough terrain crane..................... 9-15
9.4.4 Safety devices................................................................................................9-17
VI ZRT850 Rough Terrain Crane

Rough Terrain Crane Operator’S Manual
Chapter 1 Foreword

Operator’s Manual forRough Terrain Crane
Foreword
CHAPTER 1 FOREWORD
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 makesmanuals for different construction and industrial equipment. It is policy to include
applicable national consensus, industry standards and safety data with themanuals. 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.
ZRT850 Rough Terrain Crane 1-1

Rough Terrain Crane Operator’S Manual
Chapter 2 Nomenclature

起
重
机
说
明
Operator’s Manual for Rough Terrain Crane
Nomenclature
Chapter 2 NOMENCLATURE
To aid in understanding the contents of this manual, refer to the figure below. Each numbered term
can represent several components of the same main part.
1
2
3
4
Figure 2-1 Main components of crane
Pos. Description Illustration
1 Boom system Main boom assy., jib assy., telescoping mechanism, main
and auxiliary hooks, 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
ZRT850 Rough Terrain Crane 2-1

Rough Terrain Crane Operator’S Manual
Chapter 3 Introduction