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Zoomlion RT100 Operator's Manual

Rough terrain crane
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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

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  • Page 1 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...
  • Page 2 RT100 ROUGH TERRAIN CRANE OPERATOR’S MANUAL Edition 1 D e c 2013...
  • Page 4 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.
  • Page 5 Refers to a tip or hint in the operation instructions. Important Emphasizes the importance of the data in this manual. This symbol shows a step or procedure that is not approved and can cause a dangerous situation. RT100 Rough Terrain Crane...

  • Page 6: Table Of Contents

    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 RT100 Rough Terrain Crane...
  • Page 7 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...
  • Page 10 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.
  • Page 14 = 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. 02 - 1 RT100 Rough Terrain Crane...
  • Page 18 CRANE PERIODIC INSPECTION CHECKLIST This inspection checklist provides supplementary data to facilitate the correct operation and maintenance of the crane. 03 - 1 RT75 Rough Terrain Crane...
  • Page 19 MAINTENANCE LOG Item Adjusting Condition Date 03 - 2 RT75 Rough Terrain Crane...
  • Page 20 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. 03 - 3 RT100 Rough Terrain Crane...
  • Page 21 If there is anything in this manual that is not clear or which you think is necessary, write to the address that follows: Rough Terrain Crane R & D Institute Zoomlion Mobile Crane Branch Company Quantang Industrial Park, 2 Yuanda Road,...
  • Page 24 Refers to a tip or hint in the operation instructions. Important Emphasizes the importance of the data in this manual. This symbol shows a step or procedure that is not approved and can cause a dangerous situation. 04 - 1 RT100 Rough Terrain Crane...

  • Page 25: Safety

    Comply with the requirements, that apply, as follows:  Occupational Safety and Health Administration (OSHA) standards  American National Standards Institute (ANSI)  China National Standards GB/T3811.  Make sure that all the mechanical functions of the crane can operate. 04 - 2 RT100 Rough Terrain Crane...
  • Page 26 Use the shortest boom possible.  If a load is off the ground or the crane is on, you must stay in the cab.  Always use outriggers as the Load Ratings and Operator’s Manual tells. 04 - 3 RT100 Rough Terrain Crane...

  • Page 27: Safety

    Know the weight of the load that you must lift.   Find the lift-radius, boom angle, and the rated lift limits of the crane. Tell the signal person how to communicate with the operator.  04 - 4 RT100 Rough Terrain Crane...
  • Page 28 Rated capacity indicator (RCI)  wrap indicator. Operation overload prevention  Know the weight of the load.  Decrease radius at the start of the lift to let the load radius increase during lift. 04 - 5 RT100 Rough Terrain Crane...
  • Page 29 Slip and fall prevention  Make sure that you stop the crane before you move on and off the equipment. Do not jump.  Do not use the controls and the steering-wheel as hand holds. 04 - 6 RT100 Rough Terrain Crane...
  • Page 30 Use a weak soap and water to clean the safety signs. Do not use solvent-based cleaners. Solvents can cause damage to the safety sign material. The graphics, on the pages that follow, give an example of each safety decal and its location. 04 - 7 RT100 Rough Terrain Crane...
  • Page 31 Left-hand side Right-hand side Figure 04 – 1 Overview of the Safety Signs on the Machine 04 - 8 RT100 Rough Terrain Crane...
  • Page 32 Figure 04 – 2 Danger – Crush Hazard Figure 04 – 3 Danger – Electrocution Hazard 04 - 9 RT100 Rough Terrain Crane...
  • Page 33 Figure 04 – 4 Hand Signals for Crane Operation 04 - 10 RT100 Rough Terrain Crane...
  • Page 34 Figure 04 – 5 Danger – Explosion / Burn Hazard Figure 04 – 6 Danger – Crush Hazard 04 - 11 RT100 Rough Terrain Crane...
  • Page 35 Figure 04 – 7 Danger – Burn Hazard Figure 04 – 8 Prohibited – No Thoroughfare Figure 04 – 9 Prohibited - No Access / Only Authorized Personnel Figure 04 – 10 CAUTION - Risk of Falling 04 - 12 RT100 Rough Terrain Crane...
  • Page 36 Figure 04 – 12 No Swing over the Rear with -3° Figure 04 – 13 Entanglement Hazard Keep all open flames and sparks away. Figure 04 – 14 Keep All Open Flames and Sparks Away – RH Only 04 - 13 RT100 Rough Terrain Crane...
  • Page 37 Figure 04 – 15 Be Careful in the Working Radius – RH Only Figure 04 – 16 No Walk – RH Only 04 - 14 RT100 Rough Terrain Crane...

  • Page 40: Operating Conditions

    If wind speed is greater than the permissible value of 45 ft/s (13.8 m/s), while the crane is in operation, do the tasks that follow: Stop the work (safely lower the load). Retract the boom. Correctly stow the boom. 05 - 1 RT100 Rough Terrain Crane...
  • Page 41 To make an estimate of the wind speed, use the table that follows: Wind force Wind speed Effect of the wind on the land Beaufort Description ft-in/s scale Calm 0 - 8″ 0 - 0.2 No wind, smoke rises vertically Wind direction shown by smoke Light air 1′-4″...

  • Page 42: Pre-Departure Checks (To Job-Site)

    (12) Examine the air filter assembly. Clean the contamination from the bottom of the air filter. (13) Turn the ignition switch to stage “I” and examine the functions of the items that follow: 05 - 3 RT100 Rough Terrain Crane...
  • Page 43 (2) Make sure that each indicator operates. (3) Make sure that the generator operates. (4) Make sure that the park brake is not ON. (5) Move the transmission selection lever to the “F1” position and slowly increase the speed. 05 - 4 RT100 Rough Terrain Crane...
  • Page 44 10 PSI (0.069 MPa). If this occurs, stop the engine. Measure the oil level in the engine and check for leaks. If the oil level is at the correct level and there are no leaks, examine the lubricating system. Send it 05 - 5 RT100 Rough Terrain Crane...
  • Page 45 Do not add a large quantity of cold water to the engine if the engine coolant temperature is above the maximum limit. This can kill or blind you and cause damage to the engine. 05 - 6 RT100 Rough Terrain Crane...
  • Page 46  The steering wheel has a mechanical limit. Do not continue to turn the wheel when at the limit. Do not keep the wheel at the limit for long periods of time. 05 - 7 RT100 Rough Terrain Crane...
  • Page 47 Put the chocks on the wheels.  Examine the vehicle to find the part that caused the malfunction. Be careful of the road conditions while you move around the vehicle. 05 - 8 RT100 Rough Terrain Crane...
  • Page 48 ) Do not move a load above personnel. ) Do not move personnel on the load or other equipment used to lift. ) Do not use the crane for the tasks that follow: 05 - 9 RT100 Rough Terrain Crane...
  • Page 49 Lift a load that is not in balance. ) Do not try to lift a load that is buried or frozen on the ground. ) Do not extend / retract the boom with a suspended load. 05 - 10 RT100 Rough Terrain Crane...
  • Page 50 ) A noise sounds when the load is at 90% of the capacity of the crane. When this occurs, be careful as you continue to lift. ) If the crane was changed, do not operate the crane until approved personnel examine the changed part. 05 - 11 RT100 Rough Terrain Crane...
  • Page 51 The protective material between the edges of load and wire rope is missing.  The light level at the job-site goes below a safe work condition.  Equipment malfunction or damage to the crane that decreases the safe operation of the crane. 05 - 12 RT100 Rough Terrain Crane...
  • Page 52 Use proper coolant.  When the coolant temperature is extremely high, hot water will spray. Therefore, tighten or loosen the radiator cover using a piece of cloth. Otherwise, there is a risk of burn hazard. 05 - 13 RT100 Rough Terrain Crane...
  • Page 56 This part of the chapter is to show you the controls and instruments on the RT100 rough terrain crane. This is only a small part of the data that you must know before you can safely operate the crane. Do not operate the crane until you are trained in all the other sections of this manual.
  • Page 57 25. Hand / Foot Throttle Select Switch 26. Counterweight Cylinders Extend / Retract Switch 27. Left Counterweight Cylinder Extend / Retract Switch 28. Right Counterweight Cylinder Extend / Retract Switch 29. Hand Throttle 06 - 2 RT100 Rough Terrain Crane...
  • Page 58 SWITCH (21) (See Figure 06 – 1). RIGHT FRONT OUTRIGGER SWITCH – Used to select outrigger cylinder (jack or beam) to be extended / retracted with OUTRIGGER EXTEND / RETRACT MASTER SWITCH (21) (See Figure 06 – 1). RT100 Rough Terrain Crane 06 - 3...
  • Page 59 12. CAB HEATER POWER SWITCH – Used to turn on the cab heater. The controls to adjust heat are on the AIR CONDITIONER CONTROL PANEL (5) (See Figure 06 – 06 - 4 RT100 Rough Terrain Crane...
  • Page 60 Left Counterweight Cylinder Extend / Retract Switch – Push up to retract the left counterweight cylinder, down to extend. Right Counterweight Cylinder Extend / Retract Switch – Push up to retract the right counterweight cylinder, down to extend. 06 - 5 RT100 Rough Terrain Crane...
  • Page 61 Examine and clean. according to the working conditions Electromagnetic Make sure that it operates smoothly Every quarter clutch and is clean. Make sure that the connector is set in Connector Every month place. 06 - 6 RT100 Rough Terrain Crane...
  • Page 62 – Push down the CAB HEATER POWER SWITCH on the dash. RESULT: - The heater is ON. – Turn the A/C FAN SPEED / MASTER SWITCH (1) counter-clockwise between 3 fan speed (HI, MID, LOW) to get the correct temperature. 06 - 7 RT100 Rough Terrain Crane...
  • Page 63 Keep the surface of the condenser clean. When you clean the condenser, do not use steam. Before you disassemble the A/C system, correctly remove the refrigerant. Do not disassemble the A/C system in an area with high humidity. 06 - 8 RT100 Rough Terrain Crane...
  • Page 64 Prefabricated key 5 (radio) / Repeat Play (Playback) Button Prefabricated key 6 (Broadcasting) / next folder selection (Playback) Set the ignition switch to "I", when you use the CD player with the engine in the OFF position. 06 - 9 RT100 Rough Terrain Crane...

  • Page 65: Controls And Instruments

    Free swing – Push to operate the FREE SWING. Push again to release this function. (Located on left side of joystick) Note Only when the operator’s seat is occupied and the icon on the display lights up, the joysticks can initiate various movements. 06 - 10 RT100 Rough Terrain Crane...
  • Page 66 You can adjust the steering wheel height and angle when you push the pedal at the bottom of the steering wheel. DO NOT adjust the steering wheel while you move the crane. This can kill you. Lock the steering wheel after adjustment. RT100 Rough Terrain Crane 06 - 11...
  • Page 67 Pull in the direction of the operator for high beam. Push in the direction of the dash for low beam. 06 - 12 RT100 Rough Terrain Crane...
  • Page 68 Move the joystick rearward to spool-up main winch rope. Move the joystick left to lift the boom. Move the joystick right to lower the boom. Horn – Push and hold-in to make a sound. (Located on left side of joystick). 06 - 13 RT100 Rough Terrain Crane...
  • Page 69 Figure 06 – 10 Right Joystick (Boom Hoist / Main Winch Control) Note Only when the operator’s seat is occupied and the icon on the display lights up, the joysticks can initiate various movements. 06 - 14 RT100 Rough Terrain Crane...
  • Page 70 The Work Mode Screen (when the parking brake is ON) or Travel Mode Screen (when the parking brake is OFF) appears on the monitor. See Figures 06 – 13 and 06 – 14 respectively. 06 - 15 RT100 Rough Terrain Crane...
  • Page 71 Under Travel Mode Screen, the virtual gauges such as odometer, tachometer, fuel gauge and engine coolant temperature gauge will be displayed on the screen. See Table 06 – 2. Under any screen, the function keys at the bottom are available for switching between various screens. 06 - 16 RT100 Rough Terrain Crane...
  • Page 72 Do not move the crane when the indicator for the service or parking brake system illuminate. Do not move the crane when the engine oil pressure low indicator illuminates. Stop the engine to prevent damage to the engine. 06 - 17 RT100 Rough Terrain Crane...
  • Page 73 Battery charging system fault. INDICATOR Illuminates: CORNER MARKER LIGHTS INDICATOR The corner marker lights are ON. Illuminates: LOW BEAM INDICATOR Low beam lights are ON. Illuminates: HIGH BEAM INDICATOR High beam lights are ON. 06 - 18 RT100 Rough Terrain Crane...
  • Page 74 DO NOT move the crane. Illuminates: CLUTCH The clutch is disengaged and the DISENGAGING service brake indicator illuminates when INDICATOR the service brake is applied. Illuminates: PTO INDICATOR Shows that the PTO is engaged. RT100 Rough Terrain Crane 06 - 19...
  • Page 75 Shows that the swing lock is NOT INDICATOR engaged. Illuminates: NEUTRAL 0 Shows that the transmission is in the POSITION INDICATOR "N0" position. Illuminates: NEUTRAL 1 Shows that the transmission is in the "N POSITION INDICATOR 1" position. 06 - 20 RT100 Rough Terrain Crane...
  • Page 76 INDICATOR properly to start the engine. Shows that the glow plugs are hot enough, the light goes out. Illuminates: WATER IN FUEL INDICATOR Shows that the fuel contains water. RT100 Rough Terrain Crane 06 - 21...
  • Page 77 Only when the indicator lights up, can the superstructure movements be INDICATOR initiated. When driving the crane, the joysticks and boom extend/retract pedal remain active. Crane operations can occur if either joysticks or pedal are used unintentionally. 06 - 22 RT100 Rough Terrain Crane...
  • Page 78 Press the key “BACK” to return the Travel Mode Screen or Work Mode Screen. Press the key “MENU" to enter the Main Menu Screen. Press the key “HOME” to return to the Travel Mode Screen. Figure 06 – 15 Vehicle Status RT100 Rough Terrain Crane 06 - 23...
  • Page 79 Main Menu Screen. Press the relevant function keys to move the cursor left and right to select the items as follows: Monitoring, Real-time warning, Parameter settings, Maintenance, 简体中文(Chinese), Information and Password etc. And then press the key “ENTER” to enter the required screen. 06 - 24 RT100 Rough Terrain Crane...
  • Page 80 “简体中文” (Chinese) item, see Figure 06 – 19, and press “ENTER”. After this operating, monitor displays all information in Chinese mode, see Figure 06 – 18. RT100 Rough Terrain Crane 06 - 25...
  • Page 81 Travel mode, Work mode, Vehicle status and Bus status. See Figure 06 – 20. Press the key “BACK” or “MENU” to return to the Main Menu Screen. Press the key “HOME" to enter the Travel Mode Screen. 06 - 26 RT100 Rough Terrain Crane...
  • Page 82 “ENTER” to enter the Bus Status Screen. See Figure 06 – 21. If the communication between the controllers fails, it means that the network signal between the controllers is disconnected. Figure 06 – 21 Bus Status RT100 Rough Terrain Crane 06 - 27...
  • Page 83 “ENTER” to enter the Engine Warning Screen. See Figure 06 – 23. (3) Transmission warning: move the cursor to select the icon “Transmission warning” and press the key “ENTER” to enter the Transmission Warning Screen. See Figure 06 – 06 - 28 RT100 Rough Terrain Crane...
  • Page 84 Figure 06 – 23 Engine Warning Figure 06 – 24 Transmission Warning RT100 Rough Terrain Crane 06 - 29...
  • Page 85 Brightness settings: press the key “ENTER” to enter the Brightness Settings Screen. Press the function keys “+” and “-” to adjust the brightness. See Figure 06 – 26. Figure 06 – 26 Brightness Setting 06 - 30 RT100 Rough Terrain Crane...
  • Page 86 Press the function key “DIAG” and press the keys “PgUp” and “PgDn” to increase and decrease the engine idle speed by 50 rpm. The engine idle speed varies within 650 – 1200 rpm. RT100 Rough Terrain Crane 06 - 31...
  • Page 87 “ENTER” to enter the Error Diagnostic Screen. See Figure 06 – 29 and Figure 06 – 30. There are 2 pages of the error diagnostic information. Press the keys “PgUp” and “PgDn” to consult the diagnostic information. Figure 06 – 29 Error Diagnostic 1 06 - 32 RT100 Rough Terrain Crane...
  • Page 88 Figure 06 – 31 Information (1) System history warning: move the cursor to select the icon “System history warning” and press the key “ENTER” to enter the System History Warning Screen to consult the RT100 Rough Terrain Crane 06 - 33...
  • Page 89 (4) About: move the cursor to select the icon “About” and press the key “ENTER” to enter the About Screen to consult the basic information about the crane. See Figure 06 – Figure 06 – 32 System History Warning Figure 06 – 33 Engine History Warning 06 - 34 RT100 Rough Terrain Crane...
  • Page 90 Figure 06 – 34 Transmission History Warning Figure 06 – 35 About RT100 Rough Terrain Crane 06 - 35...
  • Page 91 All screens (except the Travel Mode Screen and Work Mode Screen) have a function key “HOME”. You can press the key “HOME” to return to the Travel Mode Screen. 6.4 Vehicle Camera MENU V1/V2 Figure 6-37 Camera Display 06 - 36 RT100 Rough Terrain Crane...
  • Page 92 4. MENU button Enter the brightness , contrast or color adjusting option 5. △ button Increase the brightness, contrast or adjust the color 6. ▽ button Decrease the brightness, contrast or adjust the color RT100 Rough Terrain Crane 06 - 37...

  • Page 96: Safety Equipment

    (via joystick and telescoping pedal). Caution When driving the crane, the joysticks and boom extend/retract pedal remain active. Crane operations can occur if either joysticks or pedal are used unintentionally. RT100 Rough Terrain Crane 07 - 1...

  • Page 97: Starting The Engine

    This cool down period is very important for a crane with a turbocharged engine. This is because the turbocharged engine makes more heat than an engine that dose not have a turbocharger. If more data about the engine is necessary, look in the Engine Manufacturer’s Manual. 07 - 2 RT100 Rough Terrain Crane...

  • Page 98: Cold Weather Starting

    If you operate the crane in very low temperature areas, the engine can be hard to start. The optional flame starting device is very important for the normal engine start. Please speak with the Zoomlion Service Department if you select a flame starting device for your crane. 7.5 MOVE AND PARK THE CRANE Make sure that the crane has a sufficient quantity of brake pressure before you try to move the crane.

  • Page 99: Economical Driving

    Keep the operation of the air conditioner system at a minimum.  Always use the correct type of fuel and engine lubricants.  Keep to the preventive maintenance schedule.  07 - 4 RT100 Rough Terrain Crane...

  • Page 100: Steering Operation

    When you complete the turn, lightly and immediately turn the steering-wheel to the neutral position to prevent an unstable condition. Decrease the speed of the vehicle and move down one transmission gear if you  have a sharp turn. 07 - 5 RT100 Rough Terrain Crane...

  • Page 101: Braking Operation

    If the tire blows out suddenly during the move, do not push the brake pedal immediately. Hold the steering-wheel tightly with two hands, decrease the speed, and move the crane to a safe area. 07 - 6 RT100 Rough Terrain Crane...

  • Page 102: Transmission Operation

    DO NOT stop the engine when the transmission oil temperature is too high. DO NOT move the crane when the transmission oil pressure is lower than 240 psi. DO NOT move the crane with the gear selector in the “N” position. 07 - 7 RT100 Rough Terrain Crane...

  • Page 103: Towing

    Open the shutoff gate valve of the hydraulic oil tank. When this valve opens, hydraulic oil from the tank flows through hydraulic lines. Turn the handle of the shutoff gate valve on the hydraulic oil tank in the direction shown. 07 - 8 RT100 Rough Terrain Crane...
  • Page 104 The PTO handle is located near the superstructure. Pull the handle up to engage the PTO. Figure 07 – 2 Engage PTO Handle (3) Disengage the PTO. Push down the PTO handle to disengage the PTO. Figure 07 – 3 Disengage PTO Handle 07 - 9 RT100 Rough Terrain Crane...

  • Page 105: Outrigger Operation

    After the outriggers move to the “FULLY” or “INTERMEDIATELY” marks, release the master switch. The switch moves to the neutral position automatically. After the 4 outrigger beams extend to the correct positions, push and hold 07 - 10 RT100 Rough Terrain Crane...
  • Page 106 After the outrigger retracts fully, release the master switch. The switch moves to the neutral position automatically. Do this step until all 4 outriggers are retracted. Install the outrigger retaining pins. 07 - 11 RT100 Rough Terrain Crane...
  • Page 107 When the crane is on a level area, examine the bubble indicator. The  bubble shows in the middle of the indicator. If not, adjust the nuts below the indicator. 07 - 12 RT100 Rough Terrain Crane...

  • Page 108: Hoist Operation

    Use the below figure to find out the rated load if the outrigger beams are fully extended and the main boom is over side or over rear. Figure 07 – 5 Rated Load Use working conditions to find the rated load. 07 - 13 RT100 Rough Terrain Crane...
  • Page 109 Main Winch (1) The right joystick controls the main winch. Push the joystick forward to reel-off to move the load down. Pull it to the rear to spool-up to move the load up. 07 - 14 RT100 Rough Terrain Crane...
  • Page 110 (c) Push FREE SWING button again to disengage free swing. The FREE SWING indicator goes off. (d) The Main Winch Control is on the dash. Set it for the necessary winch speed (high or low). 07 - 15 RT100 Rough Terrain Crane...
  • Page 111 Neutral position: stop Move the Move the joystick joystick backward: forward: spool up the reel off the main winch main winch Activate the main winch mechanism Figure 07 – 9 Main Winch - Right Joystick 07 - 16 RT100 Rough Terrain Crane...
  • Page 112 Pull it to the rear to spool-up to move the load Note Only when the operator’s seat is occupied and the icon on the display lights up,can the joysticks initiate various movement. Figure 07 – 10 Auxiliary Winch - Left Joystick 07 - 17 RT100 Rough Terrain Crane...
  • Page 113 If necessary, this switch-off can be bypassed by the bypass key switch in cab. When the maintenance personnel repair or check out the functions on the crane, they can turn the bypass key switch. Do bypassed movement with maximum precaution and minimum speed. 07 - 18 RT100 Rough Terrain Crane...
  • Page 114 Do not try to lift a load that weighs more than the lift capacity of the  crane. Do not use the crane to lift personnel.  07 - 19 RT100 Rough Terrain Crane...
  • Page 115 (b) Remove the pins on the hook block and boom head to let the wire rope unreave. Figure 07 – 12 Hook Assembly (c) Remove the anti-two block weight. Figure 07 – 13 Anti-Two Block Weight 07 - 20 RT100 Rough Terrain Crane...
  • Page 116 Figure 07 – 16 Even and Odd Line Parts Put the wire-rope on the winch spool smoothly and in sequence. (g) Install the socket and wire-rope clamp. Refer to Figure 07 – 17. 07 - 21 RT100 Rough Terrain Crane...
  • Page 117 (h) Do not install the wire rope clamp on the live side of the wire rope. Figure 07 – 17 Rope Clamp 07 - 22 RT100 Rough Terrain Crane...

  • Page 118: Main Boom Extend / Retract Function Operation

    The length detector (in the main boom, on the left side) measures the boom length and transmits the data to the rated capacity indicator. The boom length data is calculated then the boom configuration shows on the screen. 07 - 23 RT100 Rough Terrain Crane...
  • Page 119 When the warning occurs, the function of the items below, stop: Winch spool-up Boom extension Derrick boom down. If you must extend the boom more, use the reel-off function (right joystick forward) to lower the hook block. 07 - 24 RT100 Rough Terrain Crane...
  • Page 120  The speed of the extend and retract movements change by:  The extend / retract pedal - how far you tilt it  Throttle pedal - increase or decrease the engine RPMs. 07 - 25 RT100 Rough Terrain Crane...
  • Page 121 Make sure that the hydraulic oil temperature does not increase too  high. Extend the boom to the correct length.  Do not extend / retract the boom with a suspended load.  07 - 26 RT100 Rough Terrain Crane...

  • Page 122: Boom Derrick Operation

    Refer to Figure 07 – 24. The operator can see the angle indicator from the cab of the crane. The angle detector is an electronic device that sends the boom angle data to the RCI (Rated Capacity Indicator). The boom angle shows on the display screen. 07 - 27 RT100 Rough Terrain Crane...
  • Page 123 You can cause a dangerous condition if you try to lift a heavy load with the boom at a low angle. Make sure that you follow the Lift Chart. 07 - 28 RT100 Rough Terrain Crane...

  • Page 124: Swing Operation

    360° range. You use the swing lock switch (on the cab dash panel) to engage or disengage the swing lockout device. When the swing lock switch is in the LOCK position, the superstructure cannot move left or right. Figure 07 – 26 Swing Lock Switch 07 - 29 RT100 Rough Terrain Crane...
  • Page 125 The torque on the bolts must be 700 ft·lbs (950 N·m).  The crane can turn with a load above the ground. Do not try to lift the load diagonally. Do not pull a load across the ground. RT100 Rough Terrain Crane 07 - 30...
  • Page 126 UNLOCK position. When crane movements stop, lock the superstructure and ensure the swing lock indicator illuminates. Before you lift and move a load, make sure that the wind and weather conditions are safe to operate. 07 - 31 RT100 Rough Terrain Crane...

  • Page 127: Multifunctions

    You can move the main hook up or down and extend or retract the boom, at the same time. To do this, push or pull the right joystick and push the left pedal. Refer to Figure 07 - Figure 07 – 29 Main Winch + Boom Extend or Retract 07 - 32 RT100 Rough Terrain Crane...
  • Page 128 The boom moves up or down and the boom extends or retracts. Refer to Figure 07 – 31. Figure 07 – 31 Derrick + Boom Extend or Retract 07 - 33 RT100 Rough Terrain Crane...
  • Page 129 Refer to Figure 07 – 33. Figure 07 – 33 Swing + Derrick When you lift the load, it moves. Be careful not to touch the outriggers with the load. 07 - 34 RT100 Rough Terrain Crane...
  • Page 130 (3) Pull aft and to the right (4:30 clock position) - the boom moves down and the main hook moves up. (4) Pull aft and to the left (7:30 clock position) - the boom moves up and the main hook moves down. Figure 07 – 35 Derrick + Main Winch 07 - 35 RT100 Rough Terrain Crane...
  • Page 131 To do this, push the left pedal and move the left joystick left or right. Refer to Figure 07 – 37. Figure 07 – 37 Swing + Boom Extend or Retract 07 - 36 RT100 Rough Terrain Crane...

  • Page 132: Jib Operation

    Figure 07 – 39 Bubble Level Indicator (3) Retract the boom fully. (4) Move the boom to the front of the crane and position it to -3°. (5) Ensure there is 40 m swing space from the swing center. 07 - 37 RT100 Rough Terrain Crane...
  • Page 133 Pin 1 Figure 07 – 40 Pin (1) Removal (7) Move front of the jib away from the main boom (jib pivots at pin 2). Pin 2 Figure 07 – 41 Pin (2) Location 07 - 38 RT100 Rough Terrain Crane...
  • Page 134 (9) Remove the pin 2. Figure 07 – 43 Pin (2) Removal (10) Move the jib (pivots on pin 3 and pin 4) to the front of the main boom. Figure 07 – 44 Move the Jib 07 - 39 RT100 Rough Terrain Crane...
  • Page 135 (7) and the retaining clip. Figure 07 – 47 Pin (7) Installation (14) Reeve the wire-rope from the auxiliary winch through the end of the jib. Install the auxiliary hook and the anti-two block switch. 07 - 40 RT100 Rough Terrain Crane...
  • Page 136 (6) Pay out the hoist rope and derrick the boom up slowly until the pin at point B or point C touches pin A. Figure 07 – 48 Figure 07 – 48 Offset Positions 07 - 41 RT100 Rough Terrain Crane...
  • Page 137 Fully retract the boom. Move the jib to the front of the crane and set the  boom to the -3° position. You must use the correct work stands (ladders, stairs, etc.) when you assemble or disassemble the jib. 07 - 42 RT100 Rough Terrain Crane...
  • Page 138 When you remove the jib, carefully attach it to the side of the boom.  When you remove the auxiliary hook and put it in the stow position,  obey the hand signals from the signal personnel. Figure 07 – 52 Signal Personnel 07 - 43 RT100 Rough Terrain Crane...

  • Page 139: Rooster Sheave

    (b) Move the jib over front or over side and set the boom to the -3° position. (c) Remove the securing pin and move the bracket to the front of the boom. Align the connection points. Install the connecting pin. 07 - 44 RT100 Rough Terrain Crane...
  • Page 140 Figure 07 – 55 Attach the Jib to the Side of the Boom When you remove the auxiliary hook and put it in the stow position, obey the hand signals from the signal personnel. Figure 07 – 56 Hand Signal – Stow Position 07 - 45 RT100 Rough Terrain Crane...

  • Page 141: Vehicular Operation

    (250 psi). You can cause damage to the transmission. (h) Make sure that the transmission oil pressure (250 to 300 psi (17.2 to 20.7 bar)) and oil temperature (82.2℃ to 93.3℃) are in the correct range. 07 - 46 RT100 Rough Terrain Crane...
  • Page 142 When you move the crane at a high speed, do not move the gear selector to a lower gear. This can cause the transmission to go too 07 - 47 RT100 Rough Terrain Crane...
  • Page 143 (9) Can be done within permissible angles with caution. The engine and transmission lubricant in the tanks moves to one side. You can  cause damage to the engine or transmission. You can tip over.  07 - 48 RT100 Rough Terrain Crane...

  • Page 144: On Tires Lifts

    When you move a load in the “Creep” mode, the maximum speed is 1.6  km/h. Stop and wait for 30 minutes after you move 60 ft. (18 m) to prevent overheating the tires. 07 - 49 RT100 Rough Terrain Crane...

  • Page 145: Unusual Operating Conditions

    Do not add salt water to the coolant system. (3) If the engine becomes too hot because of coolant loss, slowly add coolant while the engine operates at fast idle. 07 - 50 RT100 Rough Terrain Crane...
  • Page 146 (2) Stop the crane and go into a shelter if conditions are dangerous because of lightning. (3) If lightning hits the crane, make sure that it is safe to operate before you try to start (4) Always be aware for a quick change in the weather. 07 - 51 RT100 Rough Terrain Crane...

  • Page 147: Counterweight Operation

    (6) Push up switch 3 (Refer to Figure 07 – 58) to retract the counterweight cylinders. Make sure that the counterweight lift arms (Refer to Figure 07 – 57 align with the lift pin slots in the superstructure. 07 - 52 RT100 Rough Terrain Crane...
  • Page 148 C. Disassembly Disassemble the counterweight in reverse order of the assemble steps. Assemble and disassemble the counterweight by TWO person.  Do not start the hydraulic motor for A/C if operate the counterweight.  07 - 53 RT100 Rough Terrain Crane...

  • Page 152: Transportation

    (b) The positions to lift the crane are in the Figure 08 – 1. Follow applicable rules while you lift. Figure 08 – 1 Crane Lift Points Warning Before you lift, make sure that the slings have sufficient strength to hold the crane. 08 - 1 RT100 Rough Terrain Crane...
  • Page 153 To prevent the crane from movements, make sure that the tires are “chocked” and attach the chains. (g) Unload the Crane. To unload the crane, do the “Load the Crane” task in the opposite sequence. 08 - 2 RT100 Rough Terrain Crane...

  • Page 154: Storage

    Keep the crane clean and do the usual maintenance.  Replace aged seal components.  Do a general inspection of the engine to see if you must replace the coolant, diesel oil, and air / fuel filters. 08 - 3 RT100 Rough Terrain Crane...

  • Page 158: Conversion Tables

    .4219 10.716 59/64 .9219 23.415 7/16 .4375 11.12 15/16 .9375 23.812 29/64 .4531 11.509 61/64 .9531 24.209 15/32 .4688 11.906 31/32 .9688 24.606 31/64 .4844 12.303 63/64 .9844 25.003 .5000 12.700 1.0000 25.400 9 - 1 RT100 Rough Terrain Crane...
  • Page 159 Table 09 – 2 Liquid Weights and Measures Table 09 – 3 Metric Equivalents 9 - 2 RT100 Rough Terrain Crane...

  • Page 160: Average Weight Of Materials

    1621.4 - 2075.392 Basalt, granite, gneiss 1556.544 Portland cement 3177.944 Limestone, marble, quartz 1540.33 Portland cement, loose 1524.116 Sandstone 1329.548 Lime, gypsum, loose 859.342 - 1037.696 Shale 1491.688 Mortar, lime, set 1670.042 Greenstone, hornblende 1734.898 9 - 3 RT100 Rough Terrain Crane...
  • Page 161 680.988 - 875.556 Paper 940.412 Pine, Oregon 518.848 Glass, common 2626.668 Pine, southern 616.132 - 680.988 Petroleum 729.63 -875.556 Spruce 453.992 Coal, anthracite 762.058 -875.556 Black walnut 599.918 Coal, bituminous 648.5-875.556 Coal, coke 372.922-518.848 9 - 4 RT100 Rough Terrain Crane...

  • Page 162: Torque Values

    The friction factor is 0.7 times the yield point value. The above values are suitable for the bolts lubricated. For the bolts without lubrication, the tightening torque is 133% of the corresponding one shown in the above table. 9 - 5 RT100 Rough Terrain Crane...

  • Page 163: Technical Specifications

    C. You can use the crane at the below locations to lift heavy items short distances. Construction Sites  Oil Fields  Warehouses  Freight Yards  Logistics Bases.  D. RT100 rough terrain crane has the components below: Upperstructure  Power System  Drive System  Suspension System  Steering System ...
  • Page 164 (5) Overall dimensions: 46.7ft × 11.9ft × 13ft(14247 mm × 3620 mm × 3960 mm )(Refer to Figure 09 – 1) (6) Deadweight: 71.7ton(65 T) (7) Ability to pick-and-carry loads (8) Rough terrain travel performance. 9 - 7 RT100 Rough Terrain Crane...
  • Page 165 Figure 09 – 1 Overall View – RT100 Rough Terrain Crane 9 - 8 RT100 Rough Terrain Crane...
  • Page 166 67000 75398 Mass Front axle load 34200 72312 Rear axle load 32800 Max. travel speed 15/9.3 (Forwards / backwards) km/h 24/15 181.1 Wheelbase 4600 Travel 112.6 Treads (Front / rear) 2860 Max. gradeability 9 - 9 RT100 Rough Terrain Crane...
  • Page 167 (b) The hydraulic motor drives the winch with a planetary reducer. When the winch turns (rotates), the wire-rope reels off or spools on to the winch. (2) Wire-rope Torsion resistant hoist rope Max. hoist rope strength: 22031 lbf (98 kN) 9 - 10 RT100 Rough Terrain Crane...
  • Page 168 G. Hydraulic system (1) Oil pump Two dual gear pumps One supplies oil for the below uses: Boom Extend / Retract Derrick Hoist The other supplies oil for the below uses: Outriggers Swing Mechanism 9 - 11 RT100 Rough Terrain Crane...
  • Page 169 (3) The switches found on the dash control the outriggers movements. (1) There is one cab on the RT100 rough terrain crane. You can use it as the cab for the operator and for the driver. The cab attaches on the left side of the crane and has a seat for the operator.
  • Page 170 (1) You can operate the H-type outriggers (hydraulic control) in the cab at the same time or independently. (2) Each vertical jack cylinder has a two-way hydraulic lock to make sure that outriggers attach safely while you do the work and move. 9 - 13 RT100 Rough Terrain Crane...
  • Page 171 (4) You can fully and intermediately extend and fully retract the outriggers for crane operation. Outrigger spread (L): 26.2ft (8000 mm) Outrigger spread (W) : Fully extend: 25.9ft(7900 mm ) Intermediately extend: 18.2ft(5540 mm) Fully retract: 10.4ft(3180 mm) 9 - 14 RT100 Rough Terrain Crane...
  • Page 172 Steering system (1) Full hydraulic power steering gear (2) The steering-wheel controls the cylinder to turn the wheels. (3) Four steering modes: 2-wheel steer – front wheel steer 2-wheel steer – rear wheel steer 9 - 15 RT100 Rough Terrain Crane...
  • Page 173 SAFETY DEVICES Rated Capacity Indicator (RCI) Rotating Beacon and Horn Anti-Two Block Devices Wrap Balance Valve Hydraulic Lock Hydraulic Safety Valve Swing Brake Swing Lockout Device Boom Angle Indicator Outrigger Beam Retaining Pin 9 - 16 RT100 Rough Terrain Crane...
  • Page 174 Emergency Stop Button Winch Speed Sensor 9 - 17 RT100 Rough Terrain Crane...

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