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RT60 Operation Manual 21031217

1. B d pue RT60 Rough Terrain Crane 06 3 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI Set the steering switch to crab or 4 wheel steer only when the axles are in the center position If you do not this the range of steering decreases and it can lock If the wheels lock set the steering switch to 2 wheel steer and turn front wheels Move the switch to crab or 4 wheel steer and then put the wheels to the center position Be careful when the superstructure is not in the travel position The steering is opposite when the boom is in the rear position 6 STEERING SWITCH The 4 modes are as follows OD 0 0 D OW 040 0 2 wheel steer front wheel 2 wheel steer rear wheel Crab steer 4 wheel steer 7 HIGH LOW SPEED SELECT SWITCH FOR AUX WINCH Sets the auxiliary winch speed to OFF LOW or HIGH 8 EMERGENCY STOP BUTTON In an emergency push this button to immediately STOP all crane functions Turn the button clockwise to release the button 9 WORK LIGHTS SWITCH Push down to turn on the headlights and boom work lights up to turn off 10 HAZARD LIGHTS SWITCH Push down to turn on the rotating beacon and flash the turn signals and boom head light 11 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
2. E suonipuoo Funesado Points for attention when adding coolant 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 RT60 Rough Terrain Crane 05 13 OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE Chapter 6 Controls and instruments y d 2 ZOOMLION F OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI This part of the chapter is to show you the controls and instruments on the 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 12 3 4 5 6 7 8 9 10 11 os _ e os pue s o1juo 1213 14 15 16 17 18 19 20 21 22 23 24 25 26 Figure06 1 Upper Controls and Instruments RT60 Rough Terrain Crane 06 1 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI LEGEND 1 High Low Speed Select Switch for 13 Left Rear Outrigger Switch Main Winch 14 Emergency Stop Button 2 Steering Switch 15 Right Front Outrigger Switch Camera Display 16 Right Rear Outrigger Switch 4 High Low Speed Select Switch for 17 Work Light Switch Aux Winch 18 Hazard Lights Switch 5 Air Conditioner Control Panel 19 Cigarette Lighter 6 A C Fan Speed Mmaster Switc
3. MENU HOME eee se see M Figure 06 24 Transmission Warning RT60 Rough Terrain Crane 06 30 Un r e 72 pu 01002 rM E d mt un pug s o quo 2 ZOO M LI ON OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE 6 3 3 4 PARAMETER SETTINGS The Parameter Settings Screen is shown as following See Figure 06 25 In the Parameter Settings Screen you can adjust the brightness of the system Press the keys BACK or MENU to return to the Main Menu Screen Press the key HOME to enter the Travel Mode Screen Parameter Settings Brightness Setting BACK ENTER MENU HOME X nm l M Figure 06 25 Parameter Settings 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 Brightness Setting HMI Brightness BACK e MENU HOME Figure 06 26 Brightness Setting 06 31 RT60 Rough Terrain Crane 2 ZOQ M LI ON y OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE 6 3 3 5 Maintenance The Maintenance Screen is shown as following See Figure 6 27 In the Maintenance Screen move the cursor left right and press the key ENTER to select the items such as Engine Di
4. c m C 77 When you use the A C function where it is cool and has a high level of humidity examine the evaporator at a regular interval In these conditions the evaporator freezes and causes a blockage for the air that goes through it If you operate the crane in a cold area or in the winter season set the A C system to ON for 10 minutes each month Make sure that the A C is in the OFF mode when the engine is OFF or at idle speed for long time The battery drains in these conditions When you move the crane a long distance at low speed with the A C in the ON mode put the transmission in a low gear This increases the engine RPM and decreases the load on the transmission RT60 Rough Terrain Crane 06 8 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI Set the A C to the OFF position when you do one of the items that follow e Movethe crane quickly e Move up along hill slope Make sure that the refrigerant in the A C system is at the correct level at regular intervals If there are unusual vibrations noises or smells during operation stop and examine the crane immediately Do not operate the crane that has a malfunction 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 e un
5. o5 T ms e gt 07 36 RT60 Rough Terrain Crane 2 ZOQ M LION y 4 OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE 7 18 JIB OPERATION This crane is equipped with a 2 section jib Jib section is in lattice structure and jib section 11 is in box shaped structure The jibs can be carried on the main boom when the crane is in the travel position or while the jib is not required The jibs is then folded alongside the main boom locked in the right side position Before lifting load with jib set up the outriggers ASSEMBLY The jib can be assembled below an angle of 0 20 or 40 to the telescopic boom according to working requirements Take out the auxiliary hook from the hook holder before assembling the jib See the following figure 5 Co Ei z 79 i s rmt um c oO RT60 Rough Terrain Crane 07 37 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE Assembly of the jib below an angle of 0 a Extend the outriggers and level the crane Fig 07 36 b Completely retract the boom and luff it down to the front in 3 position Ensure there is 40 m swing space from the swing center c Remove the pin at point A jel al un d co p DO m marty m o US 07 38 RT60 Rough Terrain Crane 2 ZOOMLION f OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI d Rotate the jib around
6. xc o EE The rated lifting capacity If the boom length is L2 m the rated lifting capacity is W2 If the boom length is L3 m the rated lifting capacity is Wa kg Fig 07 6 Find out the corresponding rated lifting capacity according to actual working conditions RT60 Rough Terrain Crane 2 ZOOMLION f OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI b LIFTING HEIGHT CHART Supposed lifting height About H m Supposed working radius About R m Boom length L m Boom angle About Fig 07 7 The data shown in the lifting height chart do not consider about the deflection of boom Lene di es AS p ra un fm Q un RT60 Rough Terrain Crane 07 15 2 ZOOM LION f OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE c WORKING RADIUS Working a without load The rated lifting capacity changes in relation to the working radius Working radius with a load Figure07 8 Working Radius The balance valve fitted in hoist gear can not only ensure stable hoist movements but also make the load stop at any required position The hoist rope may be not long enough at longer booms and higher lifting heights Change line parts to get longer rope Before changing the line parts install the anti two block counterweight gune1od un um C m
7. D 5 Swing the jib to the front working area and luff it down in the 3 position before assembly All assembly and disassembly work from a high position must generally be carried out by using suitable aids ladders stairs etc to ensure safety RT60 Rough Terrain Crane 07 43 2 ZOOMLION f OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE Fig 07 48 6 Jib removal should be carried slowly 7 Remove and store the auxiliary hook according to the conductor s hand signals Fig 07 49 8 Fully retract the boom before jib assembly and dismantling 7S am d na C As d T Re um m am 07 44 RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 7 19 ROOSTER SHEAVE The rooster sheave is composed of the bracket sheave spindle sheave 1 and pins It is possible to fold the rooster sheave on the side in transport position and not used position Sheave 3 Top section Sheave 1 Sheave Bracket Connecting pin spindle Fig 07 50 Use of this rooster sheave saves the time of hoist when lifting small load lt 5 5 Ton with auxiliary hook thus to improve the working efficiency ASSEMBLY a Swing the boom to the side or rear working area and luff the boom down to 3 position b Remove the securing pin and swing the bracket forwards until the connecting pin can
8. Fig 07 27 Move the right joystick and tilt the boom extend retract pedal at a time to initiate required crane movements MAIN WINCH AUXILIARY WINCH Move forward to pay out aux winch rope Move forward to pay out main winch rope Left joystick joystick Fig 07 28 Move left and right joysticks at a time to initiate required crane movements 07 32 RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI LUFF TELESCOPE Tilt forward to extend boom Move left to luff f am Move right to luff As down Boom extend retract pedal i Right ein os Tilt backward to retract boom Move the right joystick and tilt the boom extend retract pedal at a time to initiate required crane movements LUFF AUXILIARY WINCH Viove forward to pay out aux winch rope Viove right to lufi boom down Ket Move left to luff 7 M g Left joystick Right joystick suneiodg un m O 9 un Move left and right joysticks at a time to initiate required crane movements RT60 Rough Terrain Crane 07 33 un um C m HERE t a Tail C a a 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE SWING LUFF Move right to swing right Viove right to luff boom down a Am n n Move right to ir Move lef
9. m c O Li 2 un RT60 Rough Terrain Crane 07 13 un um m HERE t un am S d ual C a 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE LOAD RATING CHART INTERPRETATION In the following pages are examples of a load chart these example charts may differ from the chart supplied with your crane Always use the load rating chart supplied with the crane to interpret the conditions and limitations that exist when making a lift with the crane The determining factors are lifted load radius boom angle working position hoist line reeving tire pressure travel data use of jib and any other special conditions that exits such as wind velocity soil conditions etc a 07 14 LOAD RATING TABLE How to look up rated lifting capacity Find out the suitable boom length according to the lifting height and working radius in lifting height chart and then find out the rated lifting capacity from the load rating chart according to the boom length NOTE If lift a load with the jib assembled find out the rated lifting capacity according to the boom angle listed in the load rating chart For example If the outrigger beams are fully extended and the boom is over side or over rear determine the rated lifting capacity according to the following figure Whats the rated lifting capacity with L2 mor L3 m boom at R m orking radius
10. 56 5 67 7 172 206 Breaks twigs off trees impedes progress Slight structural damage roof Strong Gale 68 3 80 5 20 8 24 5 tiles and chimney covers etc blown off 81 0 92 10 247 283 Trees uprooted considerable damage occurs G Do not operate the crane until the conditions are safe Large branches in motion difficult to use umbrellas whistling heard telegraph wires 05 2 RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 5 2 PRE DEPARTURE CHECKS TO JOB SITE A VEHICLE CHECKS PRIOR TO ENGINE START 1 Do a check of the level of coolant and add more if below the cold engine level 2 Do a check of the fuel level and make sure that you have more than is necessary to complete the task 3 Make sure that the parts in the steering and brake systems are flexible safe and reliable 4 Make sure that the parts that follow are tight e Bolts in universal joints for steering axles e Front and rear axles mounting bolts e Wheel bolts e Drive shaft mounting bolts e Engine and transmission mounting bolts b Examine all tires for the correct pressure 6 Examine the items that follow for damage e Condition of tires e Door locks suonipuoo e Doors te x 4 T 2 e Windows e Crane control mechanisms Examine the fittings of oil pipes air pipes and water pipes
11. 7 8 BRAKING OPERATION SERVICE BRAKE Apply the service brake as follows under normal condition a Depress the brake pedal half when there is about 82 115 ft 25 35 m away from the specified stopping location b Release the brake pedal gradually about 1 3 1 2 of the applied pedal stroke when there is 16 20 ft b 6 m away from the specified stopping location As approaching the stopping location depress the brake pedal completely to stop the vehicle at the specified location EMERGENCY BRAKE In an emergency depress the brake pedal quickly and completely to stop the vehicle immediately At this time the crane may lurch forward so you must be careful If emergency brake is applied frequently the abrasion of tire and friction lining will be increased and the service life of each part will be shortened Applying emergency brake should only be permitted in a clear emergency Operate with extreme caution in rainy days or on frozen road POINTS FOR ATTENTION DURING BRAKING a Apply brake smoothly to avoid uncontrolled lurching Use emergency braking only in emergency situations b If the service brake indicator does not light up when the brake pedal is depressed stop the vehicle right away It may be caused by decreased braking performance because of hydraulic oil leakage Please contact Zoomlion service station in your area c The vehicle adopts dual circuit brake system If one line of the brake system fails
12. 1 pu s o1juo Ld un Land 0 c m 7 06 4 RT60 Rough Terrain Crane SJUSLUTLOSUI 4 7 oe wees B As me _ 2 ZOOMLION f OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 06 5 Figure 06 3 Right Dash OUTRIGGER EXTEND RETRACT MASTER SWITCH Used with switches 12 13 15 16 in Figure 06 1 to extend and retract the outrigger beams and jacks Push down to retract up to extend You must set the swing lock switch to LOCK when the boom is in the travel position SWING LOCK SWITCH Push down to disengage swing lock up to engage Do not use this switch until you stop the crane 2 WHEEL 4 WHEEL DRIVE SWITCH Push up to engage 2 wheel drive down to engage 4 wheel drive HAND FOOT THROTTLE SELECT SWITCH Push up to select foot throttle down to select hand throttle BYPASS SWITCH Push down to bypass the switch off when the RCI sounds the alarm and switches off the movements BYPASS SWITCH not used with Greer LMI system RT60 Rough Terrain Crane 2 ZOOMLION f OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 6 1 1 AIR CONDITIONER CONTROL PANEL 1 2 3 4 Figure 06 4 Air Conditioner Control Panel FUNCTIONS 1 A C FAN SPEED MASTER SWITCH Used to control the fan blower modes OFF HI MID LOW 2 FAN POWER INDICATOR 3 COOL MODE INDICATOR 4 CAB COOLER POWER SWI
13. HERE t m 07 16 RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI OPERATION MAIN HOIST GEAR Make sure the seat occupied and move the right joystick forwards backwards to make main winch up and down If the load is not straightly below the boom press the free swing button to make the load automatically align with the boom And then release the free swing button Right joystick Neutral position stop rj S Move Move em T backward forward ne take in main pay out winch rope main Td A P rope mme 1 amp t a P Los Q un 09 RT60 Rough Terrain Crane 07 17 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE OPERATION AUXILIARY HOIST GEAR Make sure the seat occupied and move the left joystick forwards backwards to make auxiliary winch up and down If the load is not straightly below the boom press the free swing button to make the load automatically align with the boom And then release the free swing button Left joystick Neutral position stop Move backward in aux mM winch rope m Move forward pay out aux 1 X winch rope iN jel al un d p O m marty m o US 07 18 RT60 Rough Terrain Crane 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE After the hoist mov
14. Lund em P C o gt pue s o1 uo 06 9 RT60 Rough Terrain Crane Z ZOOMLION 6 1 2 MEDIA PLAYER 10 11 12 13 14 15 RT60 Rough Terrain Crane OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE DS POWER Power Button SD CARD Port USB Port LCD Display Band Selector Setting Button Mute Button Dsp Button Volume Function knob Mode Button A Button Button 1 Button 2scan Button 3p Button 4 Button Sret Button 6pv Button 1 gt il 2 scan 3 4 rom Sret 6 v f 9 12 2 16 17 3 18 Figure 06 5 Media Player LEGEND Press power button turn on off the Media Player AM FM function selection Sound menu function selection Telephone mute function Time display Short press display time long press A V button for seconds to adjust the time Clockwise feature adds counterclockwise rotation reduced functionality Press mode button to select radio and SD or USB Low Scan radio on a playback High end scanning radio Next playback Prefabricated key 1 radio pause playback playback Prefabricated key 2 radio 10seconds browsing playback Prefabricated key 3 radio previous folder selection Playback Prefabricated key 4 radio Shuffle Playback Prefabricated key 5 radio Repeat Play Playback Prefabricated key 6 Broadcasting next folder selection Playback Set the ignition switch to I when you u
15. e un z 22 9 uoneuodsue p ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 2 Trailer b c 08 2 You can move the crane on a trailer for long distances Before you operate the crane read the manuals that come with the crane Read and follow all general safety rules Prepare Trailer Make sure that ramps are in position and the path of travel is clear while you load Pre Start Inspection Refer to the Maintenance and Service Manual for a Pre Start Inspection procedure Pre Move Checklist Refer to the Maintenance and Service Manual for a Pre Move Inspection procedure Load the Crane I Use the reverse gear if you back the equipment onto the trailer Use the forward gear if you move forward onto the trailer INO If the crane has a 4 wheel drive mode use the low range to engage it Co To move the crane onto the trailer apply the service brake and then turn the park brake switch to OFF Move the transmission shift lever to the F1 position Slowly release the service brake Use the throttle pedal to increase speed When you move up the ramp keep the speed of the crane slow Use the steering wheel to control the direction of the front tires Push the service brake to stop When the crane is in position move the front tires to the middle position Move the transmission shift lever to the neutral position Apply the park brake and rele
16. the other could still work normally which greatly enhance working safety If you suspect brakes are not working properly contact Zoomlion service station in your area If the tire blows out suddenly during driving don t depress the brake pedal immediately Hold the steering wheel carefully to control the driving direction and release the throttle pedal immediately to decelerate the vehicle until it stops in a safe place fame bd 2S A Z B O ms US un 07 6 RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 7 9 TRANSMISSION OPERATION The transmission is hydraulically driven and power shifted Shifting method is as follows a transmission is divided into high gear and low gear ranges The low gear range is in manual shifting mode and the vehicle is started in the 1 gear position The high gear range is in automatic shifting mode and the vehicle can be started at any gear position b When shifting the transmission shift lever must be shifted in position c When there is abnormal noise in the transmission or it is difficult to operate the steering wheel bring the vehicle to a standstill and rectify it at once according to the Transmission Maintenance and Service Manual d The transmission shift lever should be moved to N position when parking the vehicle e Checkthe transmission oil level when the vehicle is stopped and the engi
17. 12 operation of the crane RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI TROUBLESHOOTING ENGINE If failures occur during crane operation stop working immediately and remove the safety hazards At the same time disengage the PTO for transmission and make the engine run at idle speed After that check control instruments e g transmission oil pressure gauge and engine coolant temperature gauge etc for functional work It is a normal phenomenon that the engine oil pressure low indicator lights up when starting the engine with the PTO engaged The warning indicator will go off after the oil pressure increases to the specified value 1 The illumination of the engine oil pressure low indicator indicates that the engine oil pressure decreases abnormally Bring the vehicle to a standstill immediately and contact the manufacturer or specialized repair factory Do not turn off the engine immediately when it is overheated Otherwise the engine will be sintered caused by sudden raising coolant temperature Check for leaks when the engine is running for cooling Stop the engine after the coolant temperature decreases At this time reinspect engine coolant level and check fan belt for damages and loosening 2 When the engine coolant temperature gauge points to the red area cool down the engine at the RPM a little higher than the idle RPM gt a E P
18. 148 95 ft 45 4 m Max traveling speed 24 23 mph 39 km h Three steering modes 2 wheel steer front wheel 4 wheel steer and Crab steer Overall dimensions 44 8 ft x 10 8 ft x 12 3 13662 x 3300 x 3750 mm Refer to Figure 09 1 Deadweight 48 8 tn 44 26 t Ability to pick and carry loads Rough terrain travel performance proads Li O 2 Lond 72 09 6 RT60 Rough Terrain Crane e a Z lt ae ml 2 4 oA n P 74 lt Z 2 oZ lt e ZOOMLION 6991 ug oe e Em 3 S 1 u ae c Oe Toes gt A 6 ilius im Ee 7 EDT r7 OOF 29961 1 OVERALL VIEW RT60 ROUGH TERRAIN CRANE Fig 09 Specifications 09 7 RT60 Rough Terrain Crane 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE Table 09 6 MAIN TECHNICAL DATA Max rated lifting capacity x working Ibxft 13228x9 2 radius kgxm 60000x2 8 2 ft 1468761 Max load moment of basic boom 1991 Working E Max load moment of max length main 860158 performance boom KN m 1166 Max lifting height of max length main 148 95 m 45 4 ft 204 1 Max lifting height of jib 62 2 in 538x130x148 EN Overall dimensions L x W
19. 30 minutes CHARGE THE BATTERY BEFORE STOPPING THE ENGINE The idle speed must be high enough to charge the battery but not higher than half of the maximum one STOPPING THE ENGINE Always idle the engine for at least 5 minutes before stopping it This gives the engine a chance to cool down and prevents overheating which can be caused by localized hot spots in the engine This cool down period is extremely critical on machines equipped with a turbocharged engine After several minutes at idle the engine may be shut off by pushing the engine stop button Turn the ignition switch to the stage OFF after the engine has stopped TRAVELING AROUND THE JOB SITE When traveling around a job site it is very important that the crane operator is very aware of what is happening with the crane as well as with other vehicles and personnel on the job site The crane operator should observe the following rules as well as good common sense while moving a crane around a job site a Carry the boom over the front only b Lockthe swing brake and swing lock C Secure the hook block to the bumper loop or raise the hook block close to the boom head sheaves before moving d Make sure all outriggers are completely retracted before moving the crane e Do not travel with boom above horizontal unless the surface is firm level and free of bumps and potholes f Watch for overhead obstructions such as trees power lines or bridges g If the
20. Average weight of materials 09 3 TONCQUE WINS 09 5 9 4 Technical specification nennen nnne nennen nns 09 6 IV RT60 Rough Terrain Crane ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE Chapter 1 Foreword 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 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 4 um C gt 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
21. English mode 7 In Chinese mode under Travel Mode Screen or Work Mode Screen press E3 MENU to enter Main Menu Screen Under Main Menu Screen press or to move the cursor left or right to select the English item see Figure 06 18 and press fi ENTER After this operating monitor displays all information in English mode see Figure 06 19 Switch to Chinese mode In English mode under Travel Mode Screen or Work Mode Screen press MENU to enter Main Menu Screen Under Main Menu Screen press or to move the cursor left or right to select the 5 Chinese item see Figure 06 19 and press ENTER After this operating monitor displays all information in Chinese mode see Figure 06 18 RT60 Rough Terrain Crane 06 26 s orjuo 4 un p m p CD un 2 ZOO M LI ON OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE 22 ZOOMLION 9 sz 05 18 2 d 22 ZOOMLION Real time Parameter Maintenance Warning Settings Dorn Information Password Monitoring m I d Lnd un pue s o3juo Eee omo s HOME Figure 06 19 Main Menu English mode 6 3 3 2 MONITORING In the Monitoring Screen move the cursor left right and press the key ENTER to select the items such as Travel mode Work mode Vehicle status and Bus status See Figure 06 20 Press th
22. MANUAL FOR ROUGH TERRAIN CRANI Use equipment which does the work safely Make a decision on how to safely move equipment to the job site Find gas lines power lines and structures Make sure that the work surface can hold the crane and load Find out how to rig the load If necessary make the special safety precautions Know the weather conditions Keep equipment that is not necessary away from the job site Set the crane to use the shortest possible boom and radius G Operator safety check Safety related items must be in position Look at the crane logbook for maintenance and inspection records Make sure to complete necessary repairs Examine the wire rope for damage kinks broken wires etc Make sure that all field modifications are approved Do an inspection for air and hydraulic oil leaks Examine the control positions before you start the engine After you start the engine examine all the instruments and indicators for the correct values Do a test on the controls Check brakes Lift and hold a load 2 inch 50 mm off of the work surface to examine the load brakes H Operator aids check Anti Two Block devices Boom angle indicator Backup alarms Swing lockout device Rated capacity indicator RCI 3 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 RT60 Rough Terrain Crane 0
23. TIME WARNING In the Real time Warning Screen move the cursor left right and press the key ENTER to select the items such as System warning Engine warning or Transmission warning See Figure 06 22 Press the keys BACK or MENU to return to the Main Menu Screen Press the key to enter the Travel Mode Screen Heal time Warning System Warning Engine Warning Transmission Warning ENTER MENU HOME Figure 06 22 Real time Warning 1 System warning move the cursor to select the icon System warning and press the key ENTER to enter the System Warning Screen See Figure 06 16 2 Engine warning move the cursor to select the icon Engine warning and press the key ENTER to enter the Engine Warning Screen See Figure 06 23 pue sjonuop i Gr oo un 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 24 06 29 RT60 Rough Terrain Crane 2 ZOO M LI ON y OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE Engine Warning ENGINE SPN DESCRIPTION BACK Pgup Paon wee MENU HOME n n a n Figure 06 23 Engine Warning Transmission Warning TRANSISSION SPN DESCRIPTION BACK PgUp Poon
24. ZOOMLION f OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE AIR BRAKES At least once a day drain the water accumulation from the air tanks Special attention must be given to the hydraulic oil during very cold weather NEVER ENGAGE THE HYDRAULIC PUMP AND ACTUATE THE HYDRAULIC SYSTEM BEFORE THE HYDRAULIC OIL IS WARM Cold sluggish oil can cause pump cavitation If the crane is not equipped with a reservoir immersion heater and running the oil over relief will not warm it sufficiently to prevent pump cavitation with the engine running very slowly cease attempts to engage the main pump until an external heat source can be obtained Once the reservoir is warm to the touch actuate the hydraulic system by engaging the hydraulic pump Continue warming the oil and slowly cycle all crane functions actuating all cylinders in turn swing the upperstructure and operating the winches in both directions The hydraulic oil may be run over relief to aid in the warm up process To do this actuate a function allow the cylinders involved to reach the limits of their travel and hold the control in the engaged position for a few seconds When running hydraulic oil over relief to warm it be sure to restrict the flow to as slow a speed as possible by moderating pressure on the controls being engaged and running the engine at low speed At the end of the work period or whenever the crane is to be left idle for extended periods prevent it from bei
25. and engine oil Make your selection on the lowest ambient temperature where you are to do the work Refer to the table below for more data on diesel and engine oil Obey the Engine Manual if the data in this table is incorrect Engine Emission Oil Brand Specification According to guidelines Sulfur content lt 15 PPM per US EPA Tier 3 according to US EPA2007 CH 4 stage API classification Emission Standards regulations According to guidelines Sulfur content lt 50 PPM per EURO Stage III A according to EN 590 CH 4 stage API classification Emission Standards regulations e The fuel sulfur content in the fuel must be less than 15 PPM to obey US EPA Tier 3 Emission Standards e The fuel sulfur content must be less than 50 PPM to obey EURO Stage III A Emission Standards e Do not use fuel that is mixed with a lubricant or accredited additives All mechanical components are in a break in state during initial crane operation less than 100 operating hours You must follow the below instructions during this time period e The working load and working speed must not be too high e The maximum lift capacity should not be larger than 80 of the rate e not operate the crane at a speed that is more than the maximum limits Make sure that you do all of the work on level ground that is hard The ground must hold more than the load bearing capacity permissible ground pressure 507 6 psi 3 5 MPa Use material su
26. cause a dangerous situation RT60 Rough Terrain Crane 22 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE Contents To owners users and operators ssssssssssssesesseee nennen nnne nennn nnn nnne ni sn sensa anri saa anna nns III EE EONO O 01 1 02 1 eR Emm 03 1 E 04 1 5 Operating conditions and points for attention 05 1 Del o E S 05 1 5 2 Pre departure checks to 05 3 6 Controls and instruments nna annes nnn 06 1 6 1 Upper controls and instruments 06 1 6 1 1 Air conditioner control 06 6 6 1 2 Media 06 9 62 Grotio 06 10 scere Tom 06 15 Dd Boom Mode seleeHoliasesenequmimesu ead uix es 06 36 7 EE EEEren Rna 07 1 ME Ee eR m m 07 1 T2 TIS engine TE E UT 07 2 7 93 ODETAUNG ihe CNGING NEUE 07 2 7 4 Cold weather starting 07 2 7 5 Starting off and
27. e Examine the function of the thermostat Check the coolant level Check the fan belt for damage e sure that the fan belt is not too loose Do not add a large quantity of cold water to the engine if the engine coolant 05 6 RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI temperature is above the maximum limit This can kill or blind you and cause damage to the engine c Low engine coolant Use soft water g tap water for coolant Do not use hard water river water 1 Do not add a large quantity of cold water too quickly When it is necessary to add cold water put the water in slowly Follow the below instructions to add coolant e Put together water antifreeze and or anti rust fluid in the correct ratio e Loosen the cap to the coolant tank with a wet rag to release the pressure in the tank After you release the pressure continue to remove the cap The fluid released is hot and pressurized and can cause burns or blindness Always keep your face away from the cap on the coolant tank e Add the water mix to the applicable coolant tank fill line and then install the cap Do not operate the engine continuously at high speeds without a load gt a E P E suonipuoo Funesado 7 Put the crane in a lower gear before you move up a slope to decrease the load on the engine and drive line Note
28. function you must move the anti two block weight with the hook block Rated Capacity Indicator When the actual load is near the rated one it sends out acoustic sound You can only do safe crane movements that are on the screen at this time Move the load into a permitted condition to stop alarms and continue correct crane operation For details please refer to Rated Capacity Indicator Manual Emergency Stop 1 You can find the emergency stop button on the lower left side of the dash 2 When you push the button all crane operations immediately STOP includes the engine Turn the button clockwise to release it and continue usual crane operation 3 Only use the EMERGENCY STOP BUTTON in a clear emergency 3 Wrap When there are only 3 wraps of wire rope remaining on the winch the winch main or auxiliary does not turn When this occurs you can only do Boom Retract and Winch up operations Seat Occupied Indicator 1 This indicator illuminates when the seat switch is activated by sitting in the operator seat m re zo 42 c m oO 09 Un 2 The seat switch controls the functions of the left and right joystick as well as the boom telescoping extend retract foot pedal 3 Only when the operator s seat is occupied and the icon on the display is lit will the crane functions be active via joystick and telescoping pedal When driving the crane the joysticks and boom extend retr
29. parking operation 07 3 rro ECONOMIC OVIN 07 4 Tl SIC daeee rco gm UU m 07 5 P AO Emm 07 6 7 9 Transmission operato 07 7 e NEMO 07 8 ARE 07 8 7 12 Outrigger operation ssseeessssssssesseeeeeeeenen nennen nennen nnns 07 10 SML Eee 07 13 7 14 Operation of main boom and its telescoping 07 23 rc MEER eee ilo p DRM 07 26 LENG SWIG ODS AU ON ES ERREUR 07 28 7 17 Simultaneous crane movements cccccseeccceescceceeececeeeeeeseeceseeeceeseeceesueeesseeetsaes 07 31 PAW GINO ORCL AOI NR TT eum 07 37 MESI ENSIS m 07 45 wVeniculars9Berallolluesstcsasetonbuminunias gem iced meu nde ue causan MANUS 07 47 RT60 Rough Terrain Crane ZOOMLION f OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI TAN FONES E E a 07 50 7 22 Unusual operating conditions 07 51 9 Transportation and storage ustannnencedsnnaadeuctaeds passe 08 1 Uic eem E 08 1 P ioo RR 08 3 MOS CIN ONS m 09 1 91 lt CONVELSIOMTADICS 09 1 9 2
30. 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 RT60 Rough Terrain Crane 01 1 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE Chapter 2 Nomenclature 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 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 m 4 Land m m _ AS e _ 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 RT60 Rough Terrain Crane 02 1 ZOOMLION OPERATOR S MA
31. s seat is occupied and the icon display lights up the joysticks can initiate various movements La un pue sjonuop 06 15 RT60 Rough Terrain Crane 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 6 3 Monitor Figure 06 11 Overview Z ZOOMLION 92 Bo ie 86 11 MUER 7 ey 5 gt LJ I i Hx II E ZOOMLION HEAVY INDUSTRY SCIENCE amp TECHNOLOGY CO LTD Figure 06 12 System Start up After being switched on a The monitor system runs up See Figure 06 12 b 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 RT60 Rough Terrain Crane 06 16 4 ae a un DUB d mt un pue s o3juo 2 ZOO M Li ON OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE 22 ZOOMLION 2013 11 08 08 00 2 9 Air Pressure PercentLoad 096 PercentTorque 0 Swing Angle 0 MainPressure Obar d SwingPressure _ Qbar exe Figure 06 13 Work Mode Under Work Mode Screen the virtual tachometer will be displayed on the screen See Table 06 2 Z ZOOMLION 2013 11 08 08 00 Total Distance Trip Distance TN Engine Hours 0 e 15 20 Sy 10 h io 25 5 x1
32. safety checks have been made When properly adjusted the parking brake will hold this machine on a 20 grade if the tires have adequate traction It is recommended that when parked on a grade that the wheels be chocked a Engage the swing lock b Secure hook block to the bumper loop If this is impractical pull the anti two block weight up to within approximately 30 mm 1 to the boom head or until hook block lightly contacts boom head When carrying out these operations the bypass key switch should be switched on Failure to pull the hook block up to the head when traveling or to secure it to the bumper loop will result in excessive swaying of the hook block and possible damage to crane Continuing to pull the hook block up after contact has been made may result in damage to the boom head sheaves and anti two block switch Check whether the outrigger beams are secured with retaining pins d Disconnect the main pump and disengage the PTO if the crane is to be driven more than 2 miles 3 22 km e Shift into high range two wheel drive f Check the tires for proper inflation pressure as indicated on the Standard Tire Pressure Table un ie 0 Ls un g Adjust the seat and mirrors for clear vision to the rear h Check that the transmission oil pressure is within the normal operating range of 17 2 to 20 7 bar or 250 to 300 psi with 82 2 93 3 C oil temperature and
33. the cause of the out of tolerance indication Do the steps to decrease the coolant temperature FUEL RESERVE LOW INDICATOR Illuminates Shows that the fuel reserve is lower than the permitted value 1 4 of the total LEFT TURN SIGNAL Flashes Crane moves to the left RIGHT TURN SIGNAL Flashes Crane moves to the right HIGH PRESSURE Illuminates FILTER DIRTY Shows that the high pressure filter is INDICATOR dirty CHARGE Illuminates MONITORING Battery charging system fault INDICATOR CORNER MARKER LIGHTS INDICATOR Illuminates The corner marker lights are ON LOW BEAM Illuminates INDICATOR Low beam lights are ON HIGH BEAM Illuminates INDICATOR High beam lights are ON 06 19 RT60 Rough Terrain Crane Z ZOOMLION INDICATOR SYMBOL DESCRIPTION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE FUNCTION AIR CONDITIONER Illuminates INDICATOR Air conditioner is ON FAULTY OUTRIGGER OPERATION Shows that the outrigger system has a INDICATOR malfunction TRANSMISSION OIL PRESSURE LOW INDICATOR Illuminates Shows that the transmission oil pressure is too low SERVICE BRAKE INDICATOR Illuminates The service brake is ON PARKING BRAKE INDICATOR Illuminates The parking brake is ON SWING LOCKOUT DEVICE PRESSURE LOW INDICATOR Illuminates Shows th
34. to give directions If a signal person is necessary the operator must obey only the signals from the approved signal person You must obey the STOP signal from all personnel in the area Keep a fully charged fire extinguisher and first aid kit in the cab at all times The operator must know how to use the fire extinguisher and how to apply the items in the first aid kit Look for the movement of other equipment trucks and personnel at the job site Personnel must stay off the crane platform while the crane is in operation All personnel must be in a safe area before you move the hook boom load or outriggers otop and start the movement of the load smoothly and move at a speed that keeps the load in your control Keep a minimum of three full wraps of wire rope on the drum Use the tag lines to keep the load in control Keep the load near the ground 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 Hatings and Operator s Manual tells RT60 Rough Terrain Crane 04 3 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI C Signal personnel responsibilities Use and understand all standard hand signals Help the operator to operate safely and satisfactorily Keep safe all personnel and property Understand the work you must do Stay where you can see the full operation and where personnel can see you D Responsibiliti
35. x H 13662 x 3300 x 3750 7 Distance between outriggers in 272 272 Longitudinal x transversal mm 6900 x 6900 EN Main boom length Completely retracted 449 1693 Dienste completely extended 11400 43000 Jib length section 1 section 1 394 669 len 2 10000 17000 10 Boom Boom ange 3 78 ft min 492 Max hoist rope speed Main winch 150 18 Min boom extending time boom Min boom extending ime time 140 ES Min boom retracting time 120 Working speeds Min boom luffing up time 56 Min boom luffing down time os 63 owing speed 0 2 5 psi 3916 Rated working pressure 27 Hydraulic gal min 106 system Rated working oil flow 400 gal 185 Hydraulic oil tank capacity IE 700 lbs 97577 a Complete vehicle kerb mass EG 44260 Ibs 60600 Mass Front axle load 25220 lbs 41976 Rear axle load 19040 09 8 RT60 Rough Terrain Crane 77 s Co Q r jew 5 un 2 ZOOM LION p OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 24 Max traveling speed Forwards mph 24 23 backwards km h 39 95 Wheelbase tm 3950 Traveling 103 Lr Treads Front rear Lm 2605 ES Max gradeability 75 9 5 2 C O AS p un RT60 Rough Terrain Crane 09 9 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI STANDARD SUPERSTRUCTURE EQUIPMENT 1 BOOM U shaped boom welded from high strength steel 1 basic boom and 4 telescopic sections The tel
36. 00rpm 5 km h 0 j C c Figure 06 14 Travel Mode Trip Distance is the crane travel distance from the departure place to the destination Press the function key TRIP DIS to begin to record the travel distance At this time the key turns to grey Press the key again to finish the travel distance recording and the key turns to green 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 17 RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI For the icons displayed on the screen please refer to Table 06 3 Table 06 2 Gauges DESCRIPTION FUNCTION Tachometer Displays engine speed RPM and equipment operating time Displays the speed of the crane in kilometers per hour km h Odometer when the crane is moving Displays the engine coolant temperature in degrees Celsius Engine coolant C5 temperature gauge GREEN normal range RED the engine has a large load on it Fuel gauge Displays as a percent full the amount of fuel in the tank Ay cauTION The engine should not operate for a long interval if the coolant temperature indication is in the red area Decrease the speed of the engine or decrease the load on the en
37. 06 33 Engine History Warning 06 35 RT60 Rough Terrain Crane 2 ZOO M LI ON P OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE Transmission History Warning NO TRANS SPN occurrence time disappearance time Figure 06 34 Transmission History Warning Finished Date serve Tel SlaveBox Num MasterBox Num SlaveController Program Edition MasterController Program Edition HMI Program Edition ACK MENU HOME Figure 06 35 About RT60 Rough Terrain Crane 06 36 ez m un pu 01002 Gr oo un pue sjonuop 2 ZOQ M LI ON OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE 6 3 3 7 PASSWORD In the Main Menu Screen move the cursor to select the icon Password and press the key ENTER to enter the Password Screen See Figure 06 36 Enter the correct passwords to consult more information Password Please enter your password OBA HOHE Ee E CANCEL ENTER MENU HOME Figure 06 36 Password Note The password is only available for the service technician 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 E87 Vv 7 Nix C S Figure 6 37 Camera Display 06 37 RT60 Rough Terrain Crane 2 ZOOM LION f OPER
38. 1 2 ZOQ M Li ON OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE The switch moves to the neutral position automatically 3 Do this step until all 2 front or rear outrigger jacks are retracted c Push an outrigger switch 1 of 4 to the BEAM position 1 Push the outrigger extend retract master switch to the RETRACT position at the same time INO After the outrigger retracts fully release the master switch The switch moves to the neutral position automatically 3 Do this step until all 4 outriggers are retracted d Install the outrigger retaining pins INSTALL AND REMOVE THE OUTRIGGER FLOATS a Installation Before you extend the outriggers remove the socket pin from the outrigger floats and pull out the outrigger floats When the hole aligns with the vertical cylinder install the socket pin b Removal After you fully retract the outriggers remove the socket pin and push in the outrigger float until it in the correct position Install the socket pins e Before you move the outriggers make sure that there is clearance to prevent injury to personnel or damage to the crane and other objects e Do not move the outriggers if you have a load off the ground e You can adjust the speed slow or fast of the outriggers movement extend or retract by the engine RPM increase or decrease e Make sure that you install the outrigger floats before you move the outriggers e sure that you remove the retai
39. 2 1 MPa b Examine the compressed air supply c Examine the engine coolant temperature gauge 1 After the engine has the time to warm up the pointer must point to the green range between 158 F 70 C and 203 F 95 C d Make sure that the transmission gears shift correctly e Make sure that the 360 superstructure lock moves correctly 2 Make sure that each indicator operates 3 Make sure that the generator operates 4 Make sure that the park brake is not ON b Move the transmission gear selector to the F1 position and slowly increase the speed RT60 Rough Terrain Crane ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI C MOVE THE CRANE TO THE JOB SITE Do not let the vehicle move forward when transmission is in neutral Do not operate a vehicle if a warning indicator illuminates Stop the vehicle and have it repaired 1 If a warning indicator illuminates decrease your speed immediately and stop at a safe location for maintenance checks 2 Do not skip a gear when you move through the gear cycle 3 During driving if there is any abnormal sound smell vibration or acceleration bring the vehicle to a standstill immediately and check If the cause of problem is unclear or if the problem cannot be rectified send the vehicle to the specialized repair factory 4 Stop the vehicle if there are unusual conditions with the items in the below list oteering Braking Sounds
40. 30 21 827 22 224 22 621 23 018 23 415 23 812 24 209 24 606 29 003 25 400 09 1 v m 1 O m o OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI ZOOMLION Table 09 2 LIQUID WEIGHTS AND MEASURES Table 09 3 METRIC EQUIVALENTS jroodg 2 _ un LIQUID MEASURE 4 gills equals 1 pint 2 pints i 1 quart 4 quarts 1 gallon 7 48 gallons i 1 cu ft 240 gallons of Ton water 340 gallons of 1 Ton gasoline MEASURES OF WEIGHTS 16 ounces equals 1 pound 2000 pounds 1 short ton 2240 pounds 1 long ton 100 cu feet AQ cu feet 1 register ton 1U S shipping CIRCULAR MEASURE 60 seconds equals 1 minute 60 minutes degree 90 degrees quadrant 360 degrees circumference SURVEYOR S MEASURE 7 92 inches equals 1 link 100 links 66 feet or 4 rods or 1 chain 80 chains 1 mile 09 2 LIQUID MEASURE litre equals 0353 cu ft 1 litre i 2642 gallon 1 litre i 61 023 cu in 1 litre 2 202 Ibs of water 62 F 1 cu foot 28 32 litres 1 gallon 1 3 785 litres 1 cu inch 0164 litre MEASURE OF WEIGHTS equals 0353 ounce 2 205 Ibs 28 35 grams 454 kilogram 907 metric ton ELECTRICAL UNITS 1 34 46 watts 1 kilowatt equals 1 horsepower RT60 Rough Terrain Crane ZOOMLION 9 2 AVERAGE WEIGHT OF MATERIALS OPERATOR S MANUAL FOR ROUGH TERRAIN
41. 4 5 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI Know the weight of the hook and rigging e Know the boom length jib length and the area where you have to move the load Use next lower rated capacity when working at the boom length or radius between the figures on the rated lifting capacity chart Do not lift a load until you know if the load is less than the capacity limit of the crane Only operate with the recommended counterweights It is dangerous if you do not use the approved charts to calculate the decrease or increase in counterweight Do not lift the load if winds are dangerous If necessary lower the boom See the Load Ratings for possible restrictions Avoid side loading Do not let the load or other objects hit the boom Release the load slowly be sure the boom does not tighten against back stops Put the boom point directly above the load Be sure that the load hangs freely J Operation setup Be sure the load bearing surface can hold the weight of the crane and load Make crane level check frequently and re level them when necessary Assemble barricades to keep personnel out of the load move radius K Power line safety Find power lines in the area before you start a task Follow national and local regulations and ANSI B30 5 when you operate around power lines Do not remove the material from below power lines if the boom or crane can touch the lines Do not let th
42. 53 91 Stone quarried piled Basalt granite gneiss 1556 544 Limestone marble quartz 1540 33 Sandstone 1329 548 Shale 1491 688 Greenstone hornblende 1734 898 09 3 v 2 1 As 2 ZOOM LION f OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI Wood Miscellaneous Cedar 356 708 Water 4 C 1011 7536 Fir Douglas 518 848 Water 100 C 969 5972 Oak 680 988 875 606 Paper 940 412 Pine Oregon 518 848 Glass common 2626 668 Pine southern 616 132 680 988 Petroleum 729 63 875 606 Spruce 453 992 Coal anthracite 762 058 875 606 Black walnut 599 918 Coal bituminous 648 5 875 606 Coal coke 372 922 518 848 pads 2 _ un 09 4 RT60 Rough Terrain Crane ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 9 3 TORQUE RATINGS Table 09 5 TORQUE RATING FOR DRY UNCOATED FASTENERS TORQUE VALUES TO BE WITHIN 5 ALL FIGURES IN N M This table does not apply to hydraulic connections 1 3 2 The torque value is within 5 The above table is suitable for coarse threaded bolts The friction factor is 70 of the yield point value NORMAL DIAMETER GRADE 5 6 GRADE 8 8 GRADE 10 9 GRADE 12 9 MM 6 3 3 7 9 9 11 8 8 8 5 18 25 4 30 4 10 16 5 35 49 4 99 2 12 28 61 86 103 16 70 149 210 252 20 136 3 290 409 490 24 235 500 705
43. 845 30 472 1004 1416 1697 36 822 1749 2466 2956 42 1319 2806 3957 4742 48 1991 4236 9973 7159 56 3192 6791 9575 11477 64 4769 10147 14307 17148 72 6904 14689 20712 24824 4 The above values are suitable for the fasteners lubricated For the fasteners not lubricated the torque value is 13396 of the corresponding one shown in the above table RT60 Rough Terrain Crane 09 5 v2 2 1 O As m o 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 9 4 TECHNICAL SPECIFICATION INTRODUCTION RT60 rough terrain crane is of wide tread short wheelbase high stability small turning radius and 360 swing function which can carry out On Tires Lifts in narrow areas and has the ability to pick and carry loads It can be widely used in construction building sites oil fields warehouses freight yards and logistics bases etc to carry out lifting work short distance transit and pick and carry operations in narrow working areas RT60 rough terrain crane consists of the superstructure and special purpose chassis including power system drive system Suspension system steering system brake system hoist gear luffing gear swing gear boom system turntable chassis frame outrigger hydraulic system electrical system and cab etc Distinguishing characteristics Max rated lifting capacity 66 1 tn at 9 2 ft 60 t at 3 m radius Max lifting height
44. ATION The outrigger switches and bubble level indicator are in the cab The outrigger switches control the movements for all the outriggers Refer to Figure 07 4 The outrigger switches are shown below Outrigger switches on the left side of the dash Outrigger extend retract master switch on the right side of the dash Extend _ Retract Figure 07 4 Outrigger Switches Make sure that the RCI is set to match the outrigger configuration It is dangerous to set the RCI incorrectly Make sure that you do all of the work on level ground that is hard The ground must hold more than the load bearing capacity permissible ground pressure 507 6 psi 3 5 MPa Use material such as wooden timbers below the outrigger floats if the work area is soft or not flat 2 i unendo d m ur um Fr Lnd Me um m ur 07 10 RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI EXTEND THE OUTRIGGERS a Remove the outrigger beam retaining pin b Push and hold 2 or 4 outrigger switches the BEAM position 1 Push and hold the outrigger extend retract master switch to the EXTEND position INO After the outriggers move to the FULLY or INTERMEDIATELY marks release the master switch The switch moves to the neutral position automatically c After the 4 outrigger beams extend to the correct positions push and ho
45. ATOR S MANUAL FOR ROUGH TERRAIN CRANE Manual Video control After the vehicle power on turn on the power supply switch of the camera display the display will show the vision of the camera after 5 seconds OS button Power control V1 V2 button Switch the vision between video and video two L R button Switch the vision to enantiomorphous status 2 3 4 MENU button Enter the brightness contrast or color adjusting option 5 A button Increase the brightness contrast or adjust the color 6 V button Decrease the brightness contrast or adjust the color m et Z pr w co me on C RT60 Rough Terrain Crane 06 38 OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE Chapter 7 Operating instructions 2 ZOQ M LI ON F 4 OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE 7 1 SAFETY EQUIPMENT Anti Two Block System Examine the anti two block switches on the boom the jib and auxiliary sheave heads for damage Make sure that the switch weights operate correctly and they are on the lift cable in the correct position Examine the electrical equipment and wires that attach to the cable reel Do an inspection of the wires along the length of the cable Look for indications of wear damage or incorrect installation Make sure that the tension on the spring loaded cable reel is correct and that the reel turns freely Note When you do a check of the anti two block switch
46. CRANI Table 09 4 AVERAGE WEIGHT OF MATERIALS KILOGRAM PER CUBIC METER Metals alloys ores Aluminum cast hammered 2675 31 Brass cast rolled 8658 276 Bronze 8252 926 Copper cast rolled 9014 984 Gold cast hammered 19537 87 lron gray cast 7166 588 Iron slag 2788 808 Lead 11511 94 Manganese 7701 65 13733 258 Nickel 8706 918 Steel 7798 934 7928 646 Tin cast hammered 7442 226 Tin cast hammered 7442 226 Tungsten 19456 8 Zinc cast rolled 7134 16 Masonry Ashlar masonry 2318 602 2626 668 Rubble masonry 2221 318 2529 384 Dry rubble masonry 1783 54 2107 82 Granite Syenite Gneiss Limestone Sandstone Bluestone 1670 042 2075 392 Concrete masonry 1621 4 2075 392 Portland cement 3177 944 Portland cement loose 1524 116 Lime gypsum loose 859 342 1037 696 Mortar lime set 1670 042 Brick Masonry RT60 Rough Terrain Crane Earth Clay dry 1021 482 Clay damp plastic 1783 54 Clay amp gravel dry 1621 4 Earth dry loose 1232 264 Earth dry packed 1540 3395 Earth moist loose 1264 692 Earth moist packed 1556 544 Earth mud flowing 1751 112 Earth mud packed 1864 61 Riprap limestone sandstone 1297 12 amp shale 1702 47 Sand gravel dry loose 1459 26 1702 47 Sand gravel dry packed 1621 4 1945 68 Sand gravel wet 2042 964 Excavations in water Sand or gravel 972 84 Sand or gravel amp clay 1053 91 Clay 1297 12 River mud 1459 26 Soil 1134 98 Stone riprap 10
47. HTER Push in the cigarette lighter for 3 to 5 sec Pull it out to use it After you use it put it in its initial position Note To use the cigarette lighter the engine must be ON or the ignition must be in the I position 4 STEERING WHEEL AND COMBINATION SWITCHES The crane has a hydraulic booster system which makes it easy to turn the crane in all conditions 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 RT60 Rough Terrain Crane 06 12 zum un 2 D tl Ce un 5 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI PE amp 2 OS 7 Figure 06 9 Combination Switches A GEAR SELECTOR Use to control the transmission gear selection Pull in the direction of the operator for forward Push in the direction of the dash for reverse Turn the handle to set the speed PARKING BRAKE INDICATOR Not used C TURN SIGNAL INDICATOR Not used PARKING BRAKE SWITCH Set the switch to the P position when the crane is in the correct position to operate Note If you park the crane on a slope you must put the chocks before and behind the wheels lt un Land on P C o gt pue s o1 uo E HAZARD LIGHTS SWITCH Push in t
48. ILIARY WINCH APPROACHING LOWER LIMIT INDICATOR Illuminates Shows that the auxiliary winch is near the minimum wire rope wrap limit 3 turns on the drum 2 WHEEL DRIVE INDICATOR Illuminates Shows that the crane is in the 2 wheel drive mode 4 WHEEL DRIVE INDICATOR Illuminates Shows that the crane is in the 4 wheel drive mode AXLE SUSPENSION LOCKED INDICATOR Illuminates Shows that the axle suspension is locked AXLE SUSPENSION SET TO SPRUNG INDICATOR SWING LOCK INDICATOR Illuminates Shows that the axle suspension is not in the locked position Illuminates Shows that the swing lock is engaged SWING UNLOCK INDICATOR Illuminates Shows that the swing lock is NOT engaged NEUTRAL 0 POSITION INDICATOR Illuminates Shows that the transmission is in the NO position NEUTRAL 1 POSITION INDICATOR Illuminates Shows that the transmission is in the N 1 position 06 21 RT60 Rough Terrain Crane Z ZOOMLION INDICATOR SYMBOL DESCRIPTION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE FUNCTION NEUTRAL 2 POSITION INDICATOR Illuminates Shows that the transmission is in the N 2 position FORWARD SPEEDS INDICATOR Illuminates Shows that the gear selector is in the forward direction REVERSE SPEEDS Illuminates Shows that the gear selector is in the INDICATOR dM reverse direction I
49. LOW to get the necessary temperature 2 FAN SPEED MASTER SWITCH Used to change between the 4 fan speeds OFF HI MID LOW When the switch is set to blow air the FAN POWER INDICATOR red illuminates 06 7 RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI Note The switch is the master power to the COOL function and must be ON HI MID LOW for the COOL function to operate 3 HEAT mode e Turn on the A C FAN SPEED MASTER SWITCH 1 after the engine is started Set the FAN SPEED MASTER SWITCH 1 to blow air RESULT The FAN POWER INDICATOR red illuminates 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 Hl MID LOW to get the correct temperature Do not disassemble an A C system that is in the Warranty Period without consent from the A C manufacturer Examine the condition and tension of the compressor belt at a regular interval If necessary adjust the tension on the belt You must clean the condenser at a regular interval You must use the same type of refrigerant and compressor oil to complete the repairs on the A C Set the FAN mode to HI when you first start to cool the cab Do not use the parts to repair the A C system that are not approved by the manufacturer s o1juo n
50. Make sure that the RPM of the engine is around maximum when you move up a slope Do not bypass gears when you move to a lower gear Slow the crane down before you change to a lower gear 8 Do the items that follow before you go down a long hill slope e Make sure that the brake system can stop the crane before you go onto the slope e Putthe transmission in the F1 position before you go down the slope 9 Know the below data while you steer the crane e When you go into a corner put the transmission in a lower gear and apply a small quantity of pressure on the brakes RT60 Rough Terrain Crane 05 7 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 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 10 If the engine stops because the fuel tank is empty air can go into the fuel system When this occurs you remove the air from the fuel lines 11 When you move the crane between locations only one person is approved to be in the cab D CRANE MOVEMENT IN OFF ROAD CONDITIONS When the rear axle is in the mud no traction or on rough terrain follow these steps e Put the transmission in the F1 position This applies more torque to the drive system e Put the vehicle in the 4 wheel drive mode e the vehicle or put rigid materials e g pieces of wood or iron plates below the wheels E
51. NI Allow surfaces to cool Contact with hot surfaces before servicing can couse burns e 6 Figure04 7 Danger Burn Hazard 7 Figure 04 8 Prohibited No Thoroughfare Figure 04 9 Prohibited No Access Only Authorized Personnel Q 9 Figure 04 10 CAUTION Risk of Falling 04 12 RT60 Rough Terrain Crane 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 10 Figure 04 11 CAUTION Swinging Load No swing over the rear with 3 boom angle 11 Figure 04 12 No Swing over the Rear with 3 ENTANGLEMENT HAZARD cloar oi rotating drivelines Death or Serious Injury result eri angine before performing contact with rotating drivelines 12 Figure 04 13 Entanglement Hazard Keep all open flames and sparks away 13 Figure 04 14 Keep All Open Flames and Sparks Away RH Only RT60 Rough Terrain Crane 04 13 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI BE CAREFUL IN THE WORKING RADIUS 14 Figure 04 15 Careful in the Working Radius RH Only NO WALK 15 Figure 04 16 No Walk RH Only 04 14 RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE Chapter 5 Operating conditions and points for attention 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 5 1 OPERATING CONDITIONS A Always use the correct light diesel fuel
52. NUAL FOR ROUGH TERRAIN CRANE Chapter 3 Introduction 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI CRANE PERIODIC INSPECTION CHECKLIST This inspection checklist provides supplementary data to facilitate the correct operation and maintenance of the crane Component Inspected Adjusting Condition Maintenance condition Component Inspected Adjusting Condition Maintenance Condition uornonpoqju C gt E Inspection Code TEEPE LL LELEEEEE LL e RT60 Rough Terrain Crane 03 1 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI MAINTENANCE LOG Item Adjusting Condition Date Land Q A Lnd C eme 03 2 RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 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 thi
53. OPE Torsion resistant hoist rope Max line pull 15737 Ibf 70 kN Max hoist rope speed 492 ft min 150 m min At the 4 layer Rope diameter 0 75 in 019 mm Rope length 656 ft 200 m 4 3 HOOK BLOCK 60 tn 60 t rotatable main hook with 5 sheaves and hook latch can be secured at the front section of turntable 6 1 tn 5 5 t rotatable auxiliary hook with single sheave used for rooster sheave and jib operations can also be secured to the hook latch and stored in the auxiliary hook holder if not required 5 SWING GEAR It consists of hydraulic motor planetary gear reducer pinion gear and swing bearing etc Via the planetary gear reducer the hydraulic motor drives the pinion gear to rotate and makes the swing bearing outer ring rotate around its inner toothed ring fixed on chassis frame providing superstructure with 360 unlimited swing Hydraulically controlled normally closed brake with controllable free swing function and pneumatic swing lockout device owing speed 0 2 5 r min 6 TURNTABLE Has wall type construction v2 2 m Coco m o RT60 Rough Terrain Crane 09 11 proads e un 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 7 09 12 HYDRAULIC SYSTEM 7 1 OIL PUMP One double gear pump for boom telescope luffing and hoist One double gear pump for outriggers swi
54. OUGH TERRAIN CRANE CHANGE OFFSET FROM 0 TO 20 OR 40 SEE FIG 07 45 AND FIG 07 46 a 07 42 Retract the boom and set up the outriggers Luff the boom down to 0 position Reeve the hoist rope to jib sheave over main boom sheave and fix it onto jib head hole Remove the pins and spring loaded pins at point F from the pull bracket Insert the removed pins and spring loadd pins at point G for the 20 position or point H for the 40 position Pay out the hoist rope and luff the boom up slowly till pin at point G or point H touches pin A SU Li al E z dl L e Up LIU phan mun cr arai E E 2 a adl ue a am Fo Point F for 0 position Pull bracket Fig 07 45 RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 20 or 40 Fig 07 46 REMOVAL Proceed analogously in the reverse order Luff the boom up a little to facilitate dismantling 1 Ensure that there are no obstacles persons within the jib swing range 2 Set the outriggers and swing the jib over front before assembling dismantling the jib 3 Do not operate or travel the crane after removing the jib retaining pin on boom side Otherwise the jib may fall off 4 Turn the HIGH LOW SPEED CHANGEOVER SWITCH FOR AUX WINCH to stage High or Low during jib operation unedo un m O Q _ yn
55. PARK THE VEHICLE Make sure that the hazard indicator illuminates when the vehicle is parked on the road at night 1 When you park the vehicle follow the instructions below a 2 P A P e Inbad weather condition rain snow ice or on a slope make sure that there is a lot of clearance in front and to the aft of the vehicle e Putthe park brake switch to the P position and put the chocks against the wheels e Putthe transmission in the neutral position 2 Before you stop the engine do the items that follow e Push the accelerator pedal 2 or 3 times to increase the engine RPM This makes the oil flow into each part of the engine e Letthe engine idle while you monitor the coolant temperature e Stop the engine when the coolant temperature is in the correct range e Putthe battery master switch to the OFF position F EMERGENCY STOP ON THE ROADWAY If the crane malfunctions on the roadway do the items that follow e Setthe hazard lights to ON and put the safety triangles in position e Set the park brake if you stop because of a drive train drive shaft axle failure or you make an emergency stop on a slope Put the chocks on the wheels 05 8 RT60 Rough Terrain Crane 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI e Examine the vehicle to find the part that caused the malfunction Be careful of the road conditions while you move a
56. RRAIN CRANE ethylene glycol and a corrosion inhibitor Water containing more than small concentrations of salt or minerals should not be used in the cooling system Salt facilitates corrosion and minerals deposited on the coolant passage walls Both processes inhibit proper cooling Air circulation around the engine and battery must not be restricted Keep air intake and exhaust openings clear of leaves paper or other foreign matter which may restrict air flow Keep the engine clean of dirt grease and other substances which inhibit heat dissipation Use sound judgment in operating the engine Avoid the two extremes of racing and lugging Advance the throttle only enough to handle the load yet be certain that the engine speed is high enough to maintain adequate fan speed for cooling Run the engine only when engaged in work operations or when traveling the crane Avoid prolonged periods at idle and shut the engine down if operations are interrupted SANDY OR DUSTY WORK SITES The presence of large amounts of sand or dust at the work site can contribute to accelerated component wear Either substance will act as an abrasive when deposited on moving parts of the crane The problem is combated by more frequent lubrication and by the servicing of breathers and filters at shorter intervals Follow the recommendations below when operating in sand or dust on a regular basis a b e Keep sand and dust out of the hydraulic system b
57. TCH Refrigeration ON OFF Starts or stops the function of the compressor e ee DUB 50190 RT60 Rough Terrain Crane 06 6 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI Table 06 1 Air Conditioner Maintenance Requirements motor motor Every month or increase the maintenance frequency Condenser Examine and clean according to the working conditions Every quarter or increase the Evaporator Examine and clean MEN UEMEMNGS Tes ple moy P according to the working conditions Electromagnetic Make sure that it operates clutch smoothly and is clean Every quarter Make sure that the connector 15 Every month Set in place Connector A Component Location e Evaporator Air outlet in the cab e Condenser In front of the engine e Condenser fan On the front of the engine also the radiator fan B Cab Temperature Control Functions 1 Refrigeration e The first time you use the COOL function do the items that follow 5 un _ e C pue s o1juo Start the engine Set the A C FAN SPEED MASTER SWITCH 1 to blow air RESULT FAN POWER INDICATOR 2 red illuminates Set the CAB COOLER POWER SWITCH 4 to position COOL RESULT COOL MODE INDICATOR 3 green illuminates Turn the A C FAN SPEED MASTER SWITCH 1 counter clockwise to 3 fan speed Hl MID
58. Vision creates future 2 ZOOMLION 2 ZOOMLION OPERATOR S MANUAL FOR RT60 ROUGH TERRAIN CRANE ZOOMLION HEAVY INDUSTRY SCIENCE AND TECHNOLOGY CO LTD Address Quantang Indust rial Park 2nd Yuanda Road Changsha Economic and Technological Development Zone Hunan Province China Postcode 410131 Website www zoomlion com ZOOMLION HEAVY INDUSTRY SCIENCE AND TECHNOLOGY CO LTD 2 ZOOMLION RT60 ROUGH TERRAIN CRANE OPERATOR S MANUAL Edition 1 Dec 2013 OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE ZOOM LIO IN To owners users and operators 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 la
59. act pedal remain active Crane operations can occur if either joysticks or pedal are used unintentionally RT60 Rough Terrain Crane 07 1 2 ZOQ M Li ON OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE 7 2 STARTING THE ENGINE Start the engine only after the inspection has been completed At ambient temperature over 0 C 32 F follow the starting procedure below a Move the transmission shift lever to the neutral position b Put the parking brake switch in the ON position d Turn the ignition switch to the ON position Turn the ignition switch to the START position to start the engine Release the ignition switch key as soon as the engine starts If the engine stalls during the start up procedure allow the engine to stop running before restarting the starter Do not engage the starter motor for more than 15 seconds at a time Should the engine fail to start within 15 seconds allow the starter motor to cool for 2 minutes before attempting to start the engine again Once the engine is started check the gauges for proper readings If the gauges do not register normal readings stop the engine and determine the cause Avoid full Throttle operation when the engine is cold Always allow the engine to reach normal operating temperature before commencing operations 7 3 OPERATING THE ENGINE When the engine reaches operating temperature operations may begin While the engine is running check the gauges at freq
60. agnostic Error Diagnostic or GPS Temporary Unlock according to the work requirements Press the keys BACK or MENU to return to the Main Menu Screen Press the key to enter the Travel Mode Screen Engine Diagnostic Error Diagnostic GPS Temp Unlock ENTER MENU HOME Figure 06 27 Maintenance 1 Engine Diagnostic move the cursor to select the icon Engine diagnostic and press the key ENTER to enter the Engine Diagnostic Screen See Figure 06 28 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 Ed 22 m SJUSUITLDSUI RT60 Rough Terrain Crane 06 32 t A E d mt un pue s o3juo ZOOMLION 06 33 OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE Engine Diagnostic 2013 07 01 08 00 BACK DIAG Poup PgDn MENU HOME l ee Figure 06 28 Engine Diagnostic Error Diagnostic move the cursor to select the icon Error diagnostic press the key 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 Error Check 01 MainWinchH
61. ase the service brake Turn the engine to OFF Secure the Crane To prevent the crane from movements make sure that the tires are chocked and attach the chains Unload the Crane To unload the crane do the Load the Crane task in the opposite sequence RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 8 2 STORAGE Do the steps that follow if you do not use the crane for more than 6 months 1 Clean contamination off of the crane 2 Fully retract all the cylinder pistons 3 Fully extend the outriggers to lift the tires away from the ground Inflate the tires to specified pressure and put wooden wedges below the tires The wooden wedges cannot touch the tires 4 Remove the battery and keep it in a dry location with good airflow Charge it once every half month and discharge it every three months in regular intervals Fill the fuel tank with oil 9 Fill the coolant tank 9 7 You must lubricate the surfaces of all the exposed metal components to prevent corrosion 8 Remove all contamination dust and sand from the wire ropes and lubricate them with ZG 3 a calcium based graphite grease 9 Keep the crane in a garage If not put a water proof cloth on it to prevent corrosion In rainy season areas examine the crane frequently to prevent corrosion Protect the crane from very cold weather conditions 10 Operate the engine for 15 to 30 minutes ea
62. at the pressure to the swing lockout device is too low EMERGENCY BRAKE SYSTEM PRESSURE LOW INDICATOR Illuminates Shows that the pressure in the emergency brake system is too low Use the service brake system to bring the crane to a stop SERVICE BRAKE SYSTEM PRESSURE LOW INDICATOR Illuminates Shows that the pressure in the service brake system is too low DO NOT move the crane PARKING BRAKE SYSTEM PRESSURE LOW INDICATOR Illuminates Shows that the pressure in the parking brake system is too low DO NOT move the crane F1 am m CU CLUTCH DISENGAGING INDICATOR Illuminates The clutch is disengaged and the service brake indicator illuminates when the service brake is applied PTO INDICATOR Illuminates Shows that the PTO is engaged RT60 Rough Terrain Crane 06 20 pug s o uo j gr 1 p un pue sjonuop Z ZOOMLION INDICATOR SYMBOL DESCRIPTION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE FUNCTION AXLE CENTERED INDICATOR Illuminates Shows that the rear axle is centered SUPERSTRUCTURE POSITION INDICATOR Illuminates Shows that the superstructure is in the initial position MAIN WINCH APPROACHING LOWER LIMIT INDICATOR Illuminates Shows that the main winch is near the minimum wire rope wrap limit 3 turns on the drum AUX
63. ature is 51 C 977 If the transmission temperature rises above 121 1 C while traveling the crane must be stopped and allowed to cool Shift to neutral and run the engine at 1000 1200 rpm The temperature should drop rapidly to the engine coolant temperature If the temperature does not drop trouble is indicated and should be determined before moving again Overheating generally occurs due to working in too high a gear ratio DO NOT SHUT OFF THE ENGINE WHEN THE TRANSMISSION IS OVERHEATING NEVER SHIFT BETWEEN FORWARD AND REVERSE WHILE THE CRANE IS IN MOTION fame bd 2S A Z B O ms US un Full power shifts under load may be made without endangering the transmission or drive components However downshifts should not be made when the vehicle speed exceeds the maximum speed of the next lower range Downshifting at excessive speeds will overspeed the drive train components with possible resultant damage to the drive shafts Observe the restrictions given in the following chart during on the road operation Maximum permissible running intervals are given in terms of miles and hours of travel time Stop the crane when either limit has been reached whichever comes first and allow the crane to cool for the period indicated 07 48 RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE Table 07 1 Running Interval 4 hours 2 hours Cooling time 1 hour
64. be pinned Top section Rooster sheave RT60 Rough Terrain Crane 07 45 un m O Q _ yn Ln i pe m D OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE c Auxiliary hoist rope from auxiliary winch must be laid over the upper rope guides and fed on the main boom head over sheave 3 see Fig 07 53 and over sheave 1 see Fig 07 53 of the rooster sheave Mount the auxiliary hook and anti two block switch Ensure that the anti two block switch functions correctly and all assembly connections are reliable REMOVAL Proceed analogously in the reverse order 1 Fold the jib before operating with the rooster sheave 2 Remove and store the auxiliary hook according to the conductor s hand signals ur pr m a 07 46 RT60 Rough Terrain Crane 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE 7 20 VEHICULAR OPERATION The Rough Terrain Crane is capable of both off road and limited on road travel The kind of travel undertaken will determine how the carrier is operated Before moving the crane either around the work site or between sites carefully consider the terrain type road conditions and any hazards likely to be encountered en route Think the move through in advance and carry it out safely PRE MOVE CHECK LIST Before driving the crane to and from job site ensure the following
65. before restarting it d You must always know the weather forecasts of your area before starting work O fas bd 2S A Z B O ms US un 07 54 RT60 Rough Terrain Crane OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE Chapter 8 Transportation and storage 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 8 1 TRANSPORTATION Transport the Crane 1 Train or Ship a You can move the crane by its power for a short distance or by other carriers for a long distance train or ship If you move the crane chock the wheels and make the crane safe with wire ropes Fully close the windows and door to keep rain and moisture out of the cab Lock the door and windows Follow the protection procedures to prevent corrosion and rust if you move the crane by sea b The positions to lift the crane are in the Figure 08 1 Follow applicable rules while you lift eee YW D a E Lo di LL E maar 1 G LA nin LSA X e See Se NIZ SZ YD af A 1 5 0 e ae DELLI Y dur Uc 18108 89 Figure 08 1 Crane Lift Points Before you lift make sure that the slings have sufficient strength to hold the crane e mm p e d Land 2 79 uoneyodsuel p RT60 Rough Terrain Crane 08 1 o 4
66. ch as wooden timbers below the outrigger floats if the work area is soft or not flat Before you operate the crane that is supported on outriggers all wheels must not touch the ground Before On tires lifts make sure that you align the crane wheels to the middle Do not operate the crane if the temperature at the job site is more than 4 F to 104 F 20 C to 40 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 e Stop the work safely lower the load RT60 Rough Terrain Crane 05 1 suonipuoo siurmgrad te pem eno o x 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI e Retract the boom e Correctly stow the boom To make an estimate of the wind speed use the table that follows Wind Force Wind Speed nie Scale escription ft in s n Wind direction shown by smoke dbi 6 drift but not by wind vanes Light Breeze 5 3 9 40 Wind felt on face leaves rustle vanes move by wind Genie Leaves and small twigs in ee 11 2 17 5 3 4 5 3 constant motion wind extends light flag 18 1 25 7 55 78 omall branches move Breeze 26 3 34 9 8 10 6 omall trees in leaf begin to sway Breeze Uo jonuaTe syuiod suonip Sa Whole trees in motion difficult 5 to walk against the wind
67. ch month Examine the mechanisms at idle speed to make sure that they operate correctly 11 Make sure that one person keeps the crane prepared for operation 12 If you do not operate the crane for more than three months Operate the engine at idle speed for one hour in the three month interval 13 If you do not operate the crane for more than 18 months e Keep the crane clean and do the usual maintenance e Replace aged seal components e Do a general inspection of the engine to see if you must replace the coolant diesel oil and air fuel filters co 2 un amad _ c JQ C uoneyodsuel p RT60 Rough Terrain Crane 08 3 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE Chapter 9 Specifications ZOOMLION 9 1 CONVERSION TABLES Table 09 1 CONVERSION TABLE OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI DECIMAL AND METRIC EQUIVALENTS OF FRACTIONS OF AN INCH Decimals Fractions Decimals Millimeters i Millimeters of an inch ofan inch of an inch Fractions of an inch 1 64 1 32 3 64 1 16 0 64 3 32 7164 1 8 9 64 5 32 11 64 3 16 13 64 7132 15 64 1 4 17 64 9 32 19 64 5 16 21 64 11 32 23 64 3 8 25 64 13 32 27 64 7 16 29 64 15 32 31 64 1 2 RT60 Rough Terrain Crane 13 097 13 494 13 891 14 287 14 684 15 081 15 478 15 875 16 272 16 688 17 085 17 462 17 859 18 256 18 653 19 050 19 447 19 843 20 240 20 637 21 034 21 4
68. d is off the ground do not adjust the hoist mechanism brake 12 When the load is off the ground the operator must stay in the cab 13 When the job site is near live power lines you must keep a safe distance Make sure that the dangerous area has a cover or is fenced off 14 When the load is off the ground move the load in a slow and smooth direction 15 Constantly monitor the system gauges and indicators when the crane is in operation If you find a malfunction stop the operation 16 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 17 If the crane was changed do not operate the crane until approved personnel examine the changed part RT60 Rough Terrain Crane 05 11 9 2 E p E suonipuoo surmprad 2 ZOOM LION f OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 18 Stop the operation or do not start to lift a load if one of the items that follows occurs overload or if the weight of the load is unknown The load lift moves out of position the rigging becomes too loose or the load is out of balance e The protective material between the edges of load and wire rope is missing e The light level at the job site goes below a safe work condition e Equipment malfunction or damage to the crane that decreases the safe 5 x gt A z A 05
69. d to chassis frame with planetary reducer and brake 5 2 Rear axle Total oscillation steering and driving axle with planetary reducer and brake STEERING SYSTEM Hydraulic four wheel full power steering for two wheel four wheel coordinated or four wheel crab steer is easily controlled by steering wheel Provides 3 steering modes 2 wheel steer front wheel steer 4 wheel steer all wheel steer 4 wheel steer crab steer RT60 Rough Terrain Crane 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 10 11 SUSPENSION SYSTEM Front axle rigidly mounted to chassis frame Rear axle oscillation axle connecting to chassis frame via hydraulic suspension cylinder BRAKE SYSTEM 8 1 SERVICE BRAKE Hydraulically controlled disc brake on all wheels 8 2 PARKING BRAKE Electrically controlled front axle mounted spring set air released parking brake ELECTRICAL SYSTEM 24 Volt DC 2 batteries each with 120 Ah FUEL TANK Capacity 79 gal 300 L Tire Size 26 5 25 32PR RT60 Rough Terrain Crane 09 15 95 2 C my m CQ p 4 un 2 ZOOM LION f OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI SAFETY DEVICES 1 Rated capacity indicator RCI NO Rotating beacon and horn CO Anti Two Block devices iN 3 wrap C1 Balance valve N O Hydraulic safety valve CO Swing brake 9 1 Hydraulic lock Swing locko
70. e Operator s Manual The operator must always think about the safety of all personnel in the area e Only personnel who show that they can safely control a RT75 crane can operate the crane 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 RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI Make sure that the system operating gauges and indicators and warning signals function Keep all the glazed surfaces instruments windows and lights clean Remove all oil grease mud ice and snow from walkway surfaces Read and understand all Decals and Warnings Keep all tools and other necessary items in the toolbox Do not lift a load without a Load Ratings in the cab Read and understand the Load Ratings Make sure that the load to lift is less than the capacity of the crane Be in good physical condition and free from effects of alcohol drugs and medications Be sure to not decrease vision hearing or reaction time Keep personnel equipment and material that are not necessary for your task at the job site out of the area The operator must know the hand signals When the view of the operator is blocked or if the task is in a dangerous area use signal personnel
71. e brake pedal gradually and start to drive Ensure the brake pressure is sufficient when starting off the vehicle Otherwise accident may occur PARKING OPERATION a Depress brake pedal gently to decelerate the vehicle meanwhile downshift the transmission to F1 position b When the vehicle is driving at low speed depress the brake pedal completely to stop the vehicle at the specified place Turn the parking brake switch to stage P and move the transmission shift lever to N position Never depress brake pedal violently and completely except in a clear emergency during driving When the Crab steer or 4 wheel steer steering program is switched on center the rear axles before stopping the vehicle d Run the engine at idle speed for several minutes to cool down the engine gradually e Keep the engine electrified for about 30 seconds after engine shutdown in order to save the running data of ECU And then turn the ignition switch to stage 0 and pull it Out do SUTE ri jut s un f O Ls un If the battery master switch is activated for a long time after the crane is parked electricity consumption of battery circuit breakdown or accident may occur f When the vehicle is being parked on a slope wheels must be chocked g Hazard lights must be turned on when parking the vehicle at night special situations are excluded to avoid being rear collisi
72. e crane or load touch electrical lines Do not go near the minimum permitted clearance for operation of a crane near electrical lines f you touch the electrical lines stay on the crane until the boom moves off the lines or until the power line current is off Keep all personnel off the crane if it touches power lines If you must move from the crane JUMP DO NOT STEP OFF Jump with feet together Use signal person when you operate around power lines L Slip and fall prevention e 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 RT60 Rough Terrain Crane 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI M Keep the equipment clean and dry Replace all broken ladders Keep the non slip surfaces in good condition Wear a safety harness when you climb the counterweight and attach the harness in the necessary points Do not walk on the boom Travel Be careful when you move cranes on or off the job site Look for personnel power lines low or narrow clearance bridge or road load limits steep hills or rough terrain Correctly stow the boom before you move the crane Inflate the tires to the specified pressure Move slowly and prevent sudden movement Wear seat belt correctly when you move the crane Make sure that the travel surface can hold the weight of the crane and load Always use the
73. e key BACK or MENU to return to the Main Menu Screen Press the key to enter the Travel Mode Screen 06 27 RT60 Rough Terrain Crane 2 ZOO M LI ON i OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE Monitoring Travel Mode Work Mode Vehicle Status BUS Status i BACK gt ENTER MENU HOME mma jess aia naa Figure 06 20 Monitoring 1 Travel mode move the cursor to select the icon Travel mode and press the key ENTER to enter the Travel Mode Screen See Figure 06 13 2 Work mode move the cursor to select the icon Work mode and press the key ENTER to enter the Work Mode Screen See Figure 06 14 3 Vehicle status move the cursor to select the icon Vehicle status and press the key ENTER to enter the Vehicle Status Screen See Figure 06 15 4 Bus status move the cursor to select the icon Bus status and press the key 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 BUS Status bh we Engine we Transmission SlaveController Figure 06 21 Bus Status RT60 Rough Terrain Crane 06 28 wm zinc 3 p d on m cC 2 ZOQ M LI ON OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE 6 3 3 3 REAL
74. e power to the oil pump to carry out various movements via hydraulic system POINTS FOR ATTENTION BEFORE OPEARTION Ensure the follow prerequisites are met before engaging the PTO a b d e m am imi ml 7 Nae dS E PUES 09 77 07 8 Engine must be turned off The joysticks in the cab should be set in neutral position The outrigger switches should be placed in neutral position The transmission shift lever should be moved to neutral position The parking brake of chassis should be activated RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI ENGAGING THE PTO a Turn on the shutoff gate valve of the hydraulic oil tank Hydraulic oil tank Turn the handle of the shutoff gate valve on the hydraulic oil tank in the direction shown in the left figure to connect the hydraulic oil tank and the oil lines The hydraulic system may be damaged seriously if the shutoff gate valve is closed Shutoff gate valve b Engage the PTO The PTO handle is located near the turntable Pull the handle upwards to engage the PTO In winter run the engine without load for 15 20 minutes before lifting operation DISENGAGING THE PTO a Disengage the PTO TEARS O suono n ysul Push down the PTO handle to disengage the PTO RT60 Rough Terrain Crane 07 9 2 ZOOMLION P 4 OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE IINE 7 12 OUTRIGGER OPER
75. een or Work Mode Screen press the function key WARN to enter the System Warning Screen You can consult the current warning information about the vehicle Remedy the malfunctions immediately according the displayed information 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 System Warning NO CODE WAVE Ta allate MY T Lift the alarm BACK PgUp PgDn at MENU HOME Figure 06 16 System Warning i Gr oo un pue sjonuop 06 25 RT60 Rough Terrain Crane Z ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE 6 3 3 MAIN MENU Under Travel Mode Screen or Work Mode Screen press the function key MENU to enter the 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 ij 4p x Chinese Information and Password etc And then press the key ENTER to enter the required screen 22 ZOOMLION 1 Real time Parameter Maintenance Warning Settings Monitoring m D m Information Password aN Figure 06 17 Main Menu 6 3 3 1 LANGUAGE SWITCHING You can make the monitor displaying all information in English or Chinese mode under Main Menu Screen 1 Switch to
76. elescopic section Z Telescopic Telescopic section 3 section ll dl pd _ ee Sl a a a a a CS a aed l d d i SS rr r rT FP ma aea a ea E a ae a a meor r A M ae Telescoping Boom extension Boom retraction oom extension cylinder cyliner Il wire rope wire rapa Il wire rope Fig 07 18 1 Telescoping cylinder Telescoping cylinder II Boom extension wire rope Boom retraction wire rope Boom retraction wire rope Il DP 9 Im Boom extension wire rope 5 z 79 Ld un eS c nd p The balance valve fitted in hydraulic system can not only provide stable telescoping movements but also keep the boom stop at any required position The length detector fitted on the left side of the boom can measure the boom length in real time and transmit the information to the rated capacity indicator The boom information will be displayed on the screen RT60 Rough Terrain Crane 07 23 2 ZOO M L i OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE BOOM EXTENDING a Make sure the seat occupied and activate the pedal to extend the boom Boom extend Tilt the pedal retract pedal forwards to it extend
77. ements finished move the joystick to the neutral position slowly to stop the movements The hoist speed increases as the HIGH LOW SPEED CHANGEOVER SWITCH FOR MAIN AUXILIARY WINCH on the dash is turned to stage High and the joysticks is moved further forward or backward Hoist speed also varies with the engine speed Do not change the speed abruptly to ensure stable movements If the hook block contacts the anti two block weight acoustic visual warning will be sent out and the movements Winch up Boom extend and Luff boom down will be switched off if there are only 3 wraps of rope remained on the winch the movement Winch down will be switched off if the actual load exceeds the rated one acoustic visual warning will be sent out and the movements Winch up Boom extend and Luff boom down will be switched off If necessary this switch off can be bypassed by the bypass key switch in cab Only carry out bypassed movements with maximum care and minimum speed during commissioning and maintenance It is forbidden to use the bypass key switch during normal crane operation 1 Select proper line parts in accordance with the actual boom length and load weights to be picked If the hook rotates due to twisted rope lay down the load on the ground Don t lift the load until the rope is totally untangled 2 Be sure to provide for no less than three full wraps of wire rope remaining on the winch drum under any wor
78. engine at idle Colder oil and higher RPM may create pressures over 20 7 bar Low pressure may indicate a worn charge pump clogged filter or low oil level Never move the carrier if the transmission oil pressure is below 17 2bar 250 psi Low pressure will cause transmission slippage and consequent premature failure of the clutch packs RT60 Rough Terrain Crane 07 47 2 ZOQ M Li ON OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE MOVING THE CRANE TO A JOB SITE The procedure for moving a crane is as follows a Start the engine b Allow air pressure build up c Apply the swing lock d Apply the service brake e Release the parking brake f Select the desired transmission range Good judgment in the selection of gear range and route of travel is essential when operating off the road Though designed primarily for use in off road conditions there may be instances when highway travel is necessary In such instances the crane is subject to the same regulations which govern the operation of other heavy equipment on public roads Adequate lighting flares flags and safety equipment should be on the cranes at all times When operating on hard surfaces use high range F1 thru two wheel drive only Failure to do so may result in severe drive line wind up and component failure In addition to conditions of terrain gear selection while traveling is also determined by transmission temperature Normal operating temper
79. ents Information Transmission System History Warning Engine History Warning History Warning BACK 4 ENTER MENU HOME 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 RT60 Rough Terrain Crane 06 34 v un sjonuon ru E d Lnd un pug sjoOnuo 2 ZOO M LI ON OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE system defects See Figure 06 32 2 Engine history warning move the cursor to select the icon Engine history warning and press the key ENTER to enter the Engine History Warning Screen to consult the engine defects See Figure 06 33 3 Transmission history warning move the cursor to select the icon Transmission history warning and press the key ENTER to enter the Transmission History Warning Screen to consult the transmission defects See Figure 06 34 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 35 System History Warning NO CODE Warning message occurrence time disappearance time Figure 06 32 System History Warning Engine History Warning NO ENGINE SPN occurrence time disappearance time Figure
80. erature must be between 158 F and 203 F 70 C and 95 C Do not move the crane at high speed when the coolant temperature is less than 158 F 70 C Do not operate the engine at high speeds without a load for extended periods of time Do not move the crane at high speeds with a heavy load until the engine coolant temperature is a minimum 158 F 70 C When the coolant temperature is in the yellow area between 203 F and 212 F 95 C 100 C the engine is too hot Park the crane Operate the engine at a RPM immediately above idle to help cool the engine Or as you move put the transmission in a lower gear range to decrease the load on the engine Do not stop the engine immediately when the engine coolant temperature is above the maximum limit If you stop the engine the coolant temperature increases suddenly and damage to the engine occurs Operate the engine at a RPM immediately above idle to help decrease the coolant temperature 4 lon When the coolant temperature gauge points to the red area between 212 F and 248 F 100 C 120 C continuously it shows that the engine is above limits If you stop the engine the coolant temperature increases suddenly and damage to the engine occurs Operate the engine at a RPM immediately above idle to help decrease the coolant temperature When the coolant temperature goes back to the green or yellow area do the items that follow e Examine the engine area for leaks
81. es in heat cold and humidity high altitude salt water and dusty or sandy work sites When operating under such conditions special precautions must be taken to prevent damage minimize wear and avoid component deterioration EXTREME COLD In periods of extreme cold the problems of freeze damage inadequate lubrication and battery failure may become particularly troublesome With the onset of very cold weather it is advisable to winterize the crane by servicing the cooling system and switching to the lubricants recommended for cold weather usage Follow the recommendations in this manual when the crane must be operated in very cold conditions a To prevent freeze damage to the cooling system and cracking of the engine block or head drain and flush the cooling system Clean the radiator exterior making certain the air passages through the core and the cooling fins are free of foreign matter Refill the cooling system adding an anti freeze solution recommended by the engine manufacturer in an amount and strength appropriate to the anticipated temperatures A corrosion inhibitor is recommended Never use a chromate base corrosion inhibitor when the coolant contains ethylene glycol Use only non chromate base inhibitors Chromate base inhibitors reacting with ethylene glycol can produce chromium hydroxide commonly known as green slime This substance reduces the heat transfer rate and can cause serious engine overheating Ins
82. es of all crew members Correct the conditions and procedures that are not safe Obey WARNING signs Do your work safely and do not make dangerous conditions Know and understand correct procedures for crane erection and rigging Tell the operator and the signal person of dangerous conditions power lines cables work surface that is not stable etc E Management responsibilities The operator must be competent in good physical condition and have applicable licenses The operator signal person and riggers must receive training in correct crane operation The operator and the signal person must know all standard hand signals Have a supervisor at the job site to be responsible for safety Give crew members the safety instructions and tell them to report conditions that are not safe to the supervisors Supply the operator with accurate data on the load that they have to lift Make sure that all personnel know applicable OSHA and ANSI B30 5 requirements and the instructions in manuals F Planning the job 04 4 Understand the work that you must do Think of all possible dangerous conditions risks at the job site Know the type of personnel that is necessary Give the tasks to personnel 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 RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S
83. escoping system consists of two single stage telescoping cylinders with 2 sets of wire ropes used to extend and retract the telescopic sections synchronically The telescoping cylinder is equipped with a plunge jointed balance valve Five sheaves are welded to the telescopic section 4 The crane incorporates a Quick Reeving boom head and block which do not require removal of the wedge socket from the rope in order to change the reeving The rooster sheave is optional Min main boom length 37 4 ft 11400 mm Max main boom length 141 1 ft 48000 mm Max boom extending time About 140 s 2 JIB One side stow swing on lattice type jib and one inserted box type jib The box type jib can be secured into the lattice one Single sheave mounted on jib head It remains stowed on the side of boom not in used Offset 0 20 and 40 Jib length 32 8 ft 60 8 ft 10 m 17 m 3 LUFFING GEAR Rear mounted single luffing cylinder with two way balance valve Luff angle 3 78 Luff speed 3 78 565 proads Li O 2 Lond 72 09 10 RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 4 HOIST GEAR 4 1 MAIN AND AUXILIARY WINCHES The main and auxiliary winches are all equipped with variable axial plunger hydraulic motor and planetary reducer The winches are driven by the hydraulic motor with planetary reducer to lift or lower the load 4 2 WIRE R
84. for leakage zi Examine the air pressure tank for condensation drain the water as necessary Examine the battery terminals for too much corrosion and make sure that the power wires are tight 10 Examine the level of the battery electrolyte adjust as necessary 11 Examine the air filter indicator If the indicator is red clean or replace the filter cartridge The air filter system must be clean prior to starting the engine 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 RT60 Rough Terrain Crane 05 3 e 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 05 4 e Instrument panel e Switches e All lights e Turn signals e Wipers e Miscellaneous displays 14 Adjust the mirrors for clear vision to the rear GENERAL CHECKS AT VEHICLE START UP Before you start the vehicle on a steep slope or a muddy road move the transmission gear selector into F1 position Do not turn the power supply OFF while the engine in ON If you turn the power supply OFF the electrical system does not operate and you remove the data from the ECU 1 Examine the controls and instruments Examine the engine oil pressure gauge 1 The engine oil pressure must be between 240 PSI 1 7 MPa 310 PSI
85. g Outrigger boxes are directly welded onto the chassis frame The outriggers can be completely extended intermediately extended or completely retracted Longitudinal distance between outriggers 22 6 ft 6900 mm Transversal distance between outriggers Completely extended 22 6 ft 6900 mm Intermediately extended 15 8 ft 4830 mm Completely retracted 9 1 ft 2760 mm RT60 Rough Terrain Crane 09 13 v2 2 m Coco m o proads Li O 2 Lond 72 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI STANDARD CHASSIS EQUIPMENT 1 09 14 TYPE Left side mounted cab rear mounted engine Drive mode 4 x 2 and 4 x 4 CHASSIS FRAME Integral box type construction welded by high strength steel ENGINE 3 1 MODEL CUMMINS QSB6 7 3 2 TYPE Four stroke cycles 6 cylinder diesel direct injection water cooled turbocharged 3 3 PERFORMANCE Max output power 160 KW 2500 RPM Max output torque 649 ft lb 880 N m 1500 RPM DRIVE SYSTEM Electrically controlled automatic hydraulic transmission with two driving modes of 2 wheel drive and 4 wheel drive Several speeds forward and reverse with electro hydraulic power shift and automatic locking mechanism The hydraulic oil pump and steering oil pump directly take off power from the transmission AXLE 5 1 FRONT AXLE Steering and driving axle rigidly mounte
86. g effects of salt moisture or both To protect exposed metallic surfaces wiring hoist rope paint and other items keep them dry and well lubricated where salt or high humidity are encountered Follow the recommendations below when operating in these conditions a Make frequent inspections for rust and corrosion and remove them as soon as they are detected Dry and paint exposed surfaces after rust and corrosion have been removed b Where paint may not be applied such as on polished or machined surfaces coat the area with grease or lubricant to repel water c Keep bearings and their surrounding surfaces well lubricated to prevent the entry of water d Hoist rope must be kept well lubricated to prevent moisture and salt from penetrating the cable strands HIGH ALTITUDES Variations in altitude alter the fuel air mixture burned in the engine and affect the engine s performance At high altitudes atmospheric pressures are lower and less oxygen is available for combustion of the fuel Keeping the air cleaner clean and free of obstructions will help alleviate high altitude problems At high altitudes closely monitor the engine temperature for overheating STORMS In case of storms take the following precautions a If possible support the load and completely retract the boom b If caught by a sudden storm switch off the engine and leave the machine c If the machine is struck by lightning check general machine operation
87. g radius will increase during lifting a load with boom lowered down So as to make the crane topple over due to overloading Operate the crane strictly in accordance with the Load Rating Chart unedo un m O Q _ yn D RT60 Rough Terrain Crane 07 27 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE 7 16 SWING OPERATION SWING GEAR The swing gear which can realize 360 full range swing operation consists of hydraulic motor planetary gear reducer swing cushion valve drive gear swing bearing and swing lockout device etc Swing reducer swing bearing Fig 07 23 Operator s rear and side vision field is greatly restricted during swing operation Therefore operate the crane with maximum care and ensure that there are no obstacles persons in the swing radius Send out a short warning signal horn before crane operation The swing radius of crane tail is 3780 mm O fas 2S L Z B O ms US 07 28 RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI SWING OPERATION DURING LIFTING Disengage the swing lock SWING UNLOCK INDICATOR illuminates Fig 07 24 Swing speed increases as the joystick is moved further left or right Swing speed also varies with the engine speed Do not change the swing speed abruptly to ensure stable crane operations Neu
88. gine If the temperature does not go down stop the crane and examine the engine coolant system The engine can be damaged if you cannot find a solution to the problem Always use clean fuel s o1juo n m a e Ld m m C E Ti A WARNING Before you stop the engine operate the engine at idle for a short period of time This helps the engine coolant temperature to be stable Ay Do not move the crane when the indicator for the service or parking brake system illuminate 0 Do not move the crane when the engine oil pressure low indicator illuminates Stop the engine to prevent damage to the engine RT60 Rough Terrain Crane 06 18 p m I un pue sjonuop Z ZOOMLION Table 06 3 INDICATOR SYMBOL DESCRIPTION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE Indicators Universal Symbol Identification FUNCTION ENGINE COOLANT LOW INDICATOR Illuminates Shows that the engine coolant level is too low ENGINE OIL PRESSURE LOW INDICATOR Illuminates Shows that the engine oil pressure is too low or the oil filter screen is dirty Stop the engine immediately to prevent damage ENGINE COOLANT TEMPERATURE HIGH INDICATOR Illuminates Shows that the engine coolant temperature is high Examine the coolant temperature indication and find
89. h 20 Ignition Switch 7 Cab Heater Power Switch 21 Outrigger Extend Retract Master 8 Cab Cooler Power Switch Switch 9 Monitor Display 22 Swing Lock Switch 10 Media Player 23 2 Wheel 4 Wheel Drive Switch 11 Rated Capacity Indicator RCI Display 24 Hand Foot Throttle Select Switch 25 Bypass Switch 12 Left Front Outrigger Switch 26 Hand Throttle pue s o1 uo un P C Lab 06 2 RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN 9 10 11 Figure 06 2 Left Dash 1 LEFT REAR 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 2 LEFT 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 3 HIGH LOW SPEED SELECT SWITCH FOR MAIN WINCH Sets the main winch speed to OFF LOW or HIGH 4 RIGHT REAR 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 5 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
90. he socket Even line parts NOTE Dead end the rope on the hook block for an even number of parts e Change the line parts Pull the wire rope outwards while lowering the hook 1 Install the counterweight of anti two block according to the following illustration Socket on boom Counterweight Counterweight Socket on hook block ounterweight for even number of line parts Counterweight for odd number of line parts Fig 07 16 RT60 Rough Terrain Crane 07 21 un m O 2 9 un aurjeJod 2 ZOOM LION f OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE 2 Spool the rope smoothly and orderly onto the drum 3 Mount the socket and rope clamp as shown in the figure below Socket Rope clamp P k GG d il ET E T Re um m am 07 22 RT60 Rough Terrain Crane 2 ZOQ M LI ON y OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE 7 14 OPERATION OF MAIN BOOM AND ITS TELESCOPING SYSTEM This crane consists of 5 U type profile boom sections two telescoping cylinders and two sets of wire ropes The telescopic section 1 is driven by telescopic cylinder and telescopic sections 2 and 4 are driven by telescoping cylinder Il and two sets of wire ropes The telescoping principle is shown in the following figure Telescopic section Boom retraction Basic boom wire rana T
91. he turntable after swing operation Swing operation should be done strictly as per technical requirements with different working conditions of crane O fas 2S 2 L Z B O ms US 07 30 RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 7 17 SIMULTANEOUS CRANE MOVEMENTS The simultaneous crane movements which can greatly improve the working efficiency refer to that the crane can use more than one function at a time Before initiate crane simultaneous movements you should a Not attempt to move the joysticks to their limit positions b Depress throttle pedal c Take maximum care to avoid accident The crane offers 9 simultaneous crane movements Simultaneous crane movements can only be carried out without load or when the load has been lifted away from the ground DO NOT EXTEND RETRACT THE BOOM WITH LOAD unedo Q un m O Li 2 un RT60 Rough Terrain Crane 07 31 un um C m HERE t a Tail C a a 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE MAIN WINCH TELESCOPE Move forward to pay out main winch rope Tilt forward to extend boom ar ust y Move backward to take in main wire rope Boom exten retract pedal Tees Buc i E 7 i _ Right joystick Tilt backward to retract boom
92. here 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 amp D Institute Zoomlion Mobile Crane Branch Company Quantang Industrial Park 2 Yuanda Road Economic and Technological Development Zone Changsha Hunan Province China 410131 You can also speak to us by telephone at 0086 84671987 international 0731 84671987 domestic Q e Lnd iv ae band 03 4 RT60 Rough Terrain Crane ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE Chapter 4 Safety 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 4 1 HAZARD INDICATORS DANGER WARNING CAUTION ATTENTION NOTE and IMPORTANT labels are on signs and decals and as you read this manual to show important instructions In this manual DANGER WARNING and CAUTION labels are before the paragraph or item to which they apply ATTENTION NOTE and IMPORTANT follow the paragraph or item they apply to The markers are as follows Refers to a dangerous situation which if you do not prevent will cause death or injury Refers to a possible dangerous situation which if you do not prevent could cause death or injury A Caution Refers to a possible dangerous situation which if you do not prevent may cause light or moderate injury Attention Refers to a situation which if you do not prevent may cause property o
93. king conditions 3 Lift the load vertically and it is forbidden to lift the load diagonally Do not laterally drag the load which is still on the ground 4 Lift the load away from the ground a little and stop for a while Continue lifting after ensure that there is no hazard around Do not attempt to use more than one function such as Luff boom up and Boom extend to lift the load away from the ground un ie un 5 Do not change between Winch up and Winch down jerkily If you want to interchange the two movements return the joystick to neutral position and ensure the winding drum has stopped rotating Otherwise the machine will be damaged 6 The slings must be of enough strength The lifting capacity includes the mass of hook block and slings besides that of the load 7 The crane cannot be used to lift person RT60 Rough Terrain Crane 07 19 2 ZOOM LION f OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE HOIST LINE REEVING Before reeving the crane in preparation for any job retract the boom and swing it over front Change the line parts as follows a Luff the boom down to lay down the hook onto the ground Fig 07 11 b Remove the rope securing tubes imi m os pa e gt un 07 20 RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI d Remove t
94. ld the 2 front or rear outrigger switches to the JACK position 1 Push and hold the outrigger extend retract master switch to the EXTEND position INO After the 4 outriggers hold the weight of the crane wheels off the ground release the master switch The switch moves to the neutral position automatically d Make the crane level Look at the bubble level to tell if the crane is at level M If the bubble indicator does not show a level indication you can move each outrigger to make the crane level e Forexample If the crane is low on the right front do the steps that follow I Push the right front outrigger switch to the JACK position 2 Push the outrigger extend retract master switch to the EXTEND position at the same time 3 Monitor the bubble indictor When the bubble is at the correct position release the switches f Install the outrigger retaining pins RETRACT THE OUTRIGGERS jut s un c c ie Li Lad un Retract the boom and attach it to the support before you retract the outriggers a Remove the outrigger beam retaining pins b Push and hold 2 front or rear outrigger switches to the JACK position Push the outrigger extend retract master switch to the RETRACT position at the same time INO After the 2 front or rear outrigger jacks fully retract release the master switch RT60 Rough Terrain Crane 07 1
95. le is controlled by the luffing cylinder so as to have the working radius changed The boom angle varies from 3 78 The 3 boom angle provides great convenience for jib assembly line parts changing and boom head parts maintenance The balance valves fitted in hydraulic system can not only ensure the boom raised up and lowered down steadily but also keep the boom stop at any required position The luffing movements are controlled by the right joystick Luff speed increases as the joystick is moved further left or right Luff speed also varies with the engine speed Do not change the luff speed abruptly to ensure stable crane operations Move joystick right luff boom down Move joystick left luff boom up Right joystick Fig 07 21 A boom angle indicator and a boom angle detector are fitted on the boom see the flowing figure The boom angle indicator indicates boom angle relative to upper structure and the electronic angle detector transmits boom angle information to the rated capacity indicator which displays on the screen Boom angle detector Boom angle indicator m 2 5 489 L Z B ms US Luffing cylinder 07 26 RT60 Rough Terrain Crane 2 ZOOMLION J OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 1 Always operate and release the controls slowly to minimize dynamic effects of the load 2 The workin
96. lluminates CRAB STEER INDICATOR Shows that the Crab steer steering program is switched to ON 4 WHEEL STEER INDICATOR Illuminates Shows that the 4 wheel steer steering program is switched to ON 2 WHEEL STEER FRONT WHEEL INDICATOR Illuminates Shows that the 2 wheel steer front wheel steering program is switched to ON 2 WHEEL STEER Illuminates Shows that the 2 wheel steer rear REAR WHEEL INDICATOR wheel steering program is switched to ON Illuminates ENGINE STOP INDICATOR ECU detects a serious failure and you must stop the engine immediately ENGINE WARNING Shows that the ECU detects common INDICATOR failure Illuminates Shows that the engine is cool and the WAIT TO START glow plugs must have time to heat up INDICATOR properly to start the engine Shows that the glow plugs are hot enough the light goes out WATER IN FUEL INDICATOR Shows that the fuel contains water RT60 Rough Terrain Crane 06 22 p F1 am m CU sjonuog La un pue s o1juo 2 ZOQ M LI ON F 9 OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE INDICATOR SYMBOL DESCRIPTION FUNCTION Illuminates Shows that the crane is in operation and the hazard lights are ON HAZARD LIGHTS INDICATOR Illuminates Shows that the tra
97. m contacting electric 50 TO 200KV ower lines 200 TO 350 2OFT 6 10m Always contact the electric power line owner The 350 TO SOOKV 25FT 7 62m electric power shall be disconnected or the power 500 TO 750 lines moved or insulated betore machine m f J TETAN 2 Figure 04 3 Danger Electrocution Hazard RT60 Rough Terrain Crane 04 9 2 ZOOMLION f OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI USE MAIN HOIST USE AUXILIARY RAISE BOOM HOIST ti F j LOWER BOOM Wove sow RAISETHE BOOM LOWER THE BOOM LOWER THE LOAD RAISE THE LOAD SWING TRAVEL EXTEMD BOOM RETRACT BOOM EXTEND RETRACT BOOM ONE TRACK TELESCOPING TELESCOPING TELEBCOPING TELESCOPING BOOMS BOOS BOOMS BDMS 3 Figure 04 4 Signals for Crane Operation 04 10 RT60 Rough Terrain Crane 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI Hazard Will cause death burns or blindness due to ignition of explosive gases or contact with corrosive acid Keep all open flames and sparks away 4 Figure 04 5 Danger Explosion Burn Hazard TROANGER ZZ DANG TLL i Crush Hazard Death or Serious Injury Keep clear of moving machine can result from contact with moving machine 5 Figure 04 6 Danger Crush Hazard RT60 Rough Terrain Crane 04 11 2 ZOOMLION f OPERATOR S MANUAL FOR ROUGH TERRAIN CRA
98. ne is running at idle speed The oil temperature of transmission should be between 180 200 F 82 93 C for normal operation When the oil temperature exceeds 250 F 121 1 C stop the vehicle immediately to cool down move the transmission shift lever to N position and keep the engine RPM within 1000 1200 rpm then the oil temperature will decrease immediately It is forbidden to turn off the engine when the transmission gear oil temperature is excessively high It is forbidden to drive the vehicle when the transmission oil pressure is lower than 240 psi Excessively low oil pressure may result in clutch skid thus shorten the service life of clutch jut s un c c ie Li Lad un During driving do not shift between forward gear and reverse gear It is forbidden to make the vehicle glide forward by its inertia when the transmission is moved to the neutral position RT60 Rough Terrain Crane 07 7 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE 7 10 TOWING The tow coupling may be damaged when towing the vehicle with the tow coupling at high speed suddenly If the vehicle is to be towed it will be necessary to run the engine at idle speed to lubricate the transmission clutches and disconnect the drive shafts for front and rear axles If the engine cannot be run the vehicle is not permitted to be towed 7 11 PTO OPERATION The function of PTO is to transmit engin
99. ng frozen to the ground by parking it on a wood concrete asphalt or mat surface EXTREME HEAT Like extreme cold requires that precautions be taken with respect to the cooling system the battery and lubrication Protect the crane by performing the following recommended procedures a 07 52 High temperatures necessitate the use of lubricants which are both more viscous and which resist deterioration at higher operating temperatures Refer to the Operator s Manual and lubricate the crane using the lubricants recommended for the expected temperatures Crankcase oil is particularly important because it helps dissipate heat Check the oil level frequently and add oil as necessary to maintain required level Too little oil will hinder heat dissipation To ensure proper coolant circulation drain and flush the cooling system clean any foreign matter from the radiator cooling fins and through core air passages replace defective hoses tighten hose clamps tension the water pump drive belt properly eliminate any leaks detected and fill the system with a 50 solution of ethylene glycol A corrosion inhibitor is recommended Engine overheating due to loss of coolant will most often be corrected by SLOWLY adding coolant while the engine is running at FAST IDLE Should this fail to correct the problem drain and flush the system and refill with fresh coolant 50 solution of RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TE
100. ng gear steering system and optional equipment such as air conditioning 7 2 CONTROL VALVE Pilot operated 4 section proportional valve with adjustable relief valve 7 3 PIPELINE The pipelines are equipped with an air cooled oil cooler driven by hydraulic motor and a pressure detecting port System pressure can be read from the gauges on the dash 7 4 HYDRAULIC RESERVOIR Capacity About 185 gal 700 L 7 5 FILTER Return line filter with the filtering accuracy of 10 CRANE CONTROLS The superstructure movements are controlled by two hydraulically controlled joysticks on both sides of operator s seat comply with ISO standard requirements The left joystick controls swing and auxiliary winch movements The right joystick controls luffing and main winch movements The boom extend retract pedal controls boom extension and retraction The joysticks and the boom extend retract pedal can provide the crane with simultaneous movements CAB There is only one cab for RT60 rough terrain crane It can be used as operator s cab as well as driver s cab The left side mounted cab is equipped with an operator s seat The crane adopts EATON Ji ning hydraulic steering gear Yuxin He nan special air conditioning and Jingwei Beijing special cab heater Exhaust emission complies with the requirements of Europe Environment Protection There are two control boxes on both sides of operator s seat The left right control box can be p
101. ning pins before you extend or retract the outrigger beams After the outrigger beams are in position install the retaining pins fame bd 2S A Z B O ms US un e Before you extend or retract the outriggers make sure that the floats are clear from all objects e Make sure that all the tires are off the ground crane weight held up by the outriggers before you start to lift a load e 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 RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 7 13 HOIST OPERATION The hoist gear consists of the hydraulic motor winch reducer brake rope guider anti two block system Cis wrap hoist rope and main auxiliary hooks and so on The hoist gear includes two parts main winch and auxiliary winch The joysticks controlling the main auxiliary winches are installed in the cab The joystick controlling main winch is on the right side of the seat namely right joystick the joystick controlling auxiliary winch is on the left side of the seat namely left joystick See the following figure Please read the Load Rating Chart and the Lifting Height Chart before carrying out hoist movements Right joystick Left joystick m m em pe go 72
102. nsmission high low speed valve is connected HIGH SPEED INDICATOR Illuminates Shows that the transmission high low speed valve is disconnected LOW SPEED INDICATOR Illuminates SEAT OCCUPIED Only when the indicator lights up can INDICATOR the superstructure movements be 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 23 RT60 Rough Terrain Crane 2 ZOQ M LI ON OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE 6 3 1 VEHICLE STATUS Under Travel Mode Screen or Work Mode Screen press the function key STATUS to enter the Vehicle Status Screen You can consult the basic information about the vehicle 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 Vehicle Status Engine Rotate Speed 0 rpm Pedal Position Engine Oil Pressure 0 bar Engine Coolant Temp Gear Box Oil Pressure 0 bar Gear Box Temp Slave Controller Voltage 0 0 V Master Controller Voltage AirPress 0 bar MENU HOME Figure 06 15 Vehicle Status 1 tl gm t j pale C SJUSUITLDSUI RT60 Rough Terrain Crane 06 24 2 ZOQ M LI ON OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE 6 3 2 SYSTEM WARNING Under Travel Mode Scr
103. o set the warning hazard lights to ON The indicator illuminates flashes F CORNER MARKER LIGHTS LOW BEAM SWITCH Push the switch up to turn ON the corner marker lights Push the switch down illuminate the low beam lights SERVICE BRAKE INDICATOR Not used H WIPER CONTROL Windshield wiper operation 4 speed settings J Timed Interval Intermittent Low Speed II High Speed O OFF Push the button on the end of the handle to spray washer fluid onto the window Pull in the direction of the operator for high beam Push in the direction of the dash for low beam 06 13 RT60 Rough Terrain Crane ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI The spray of washer fluid stops after 15 seconds or if the washer fluid tank is empty Do not operate the wipers on hot sunny days unless you use spray the window with wiper fluid When the temperature is below freezing make sure that the wiper blades are not stuck to the window before you set the wipers to ON 5 BRAKE PEDAL Push the brake pedal to decelerate or stop the crane 6 IGNITION SWITCH The 4 positions of the switch are as follows All circuits this does not include the starter are ON Il This position does not have a function IIl A temporary position use it to operate the starter O All circuits are OFF Note Make sure that you release the ignition III position when the engine starts You cannot remove the key from the igniti
104. oistCir MainWinchDescendCir e AuxWinchHoistcir f5 AuxWinchDescendCir f a FreeSlewCir v ww o s Figure 06 29 Error Diagnostic 1 RT60 Rough Terrain Crane 2 ZOO LI ON WE OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE Error Check 02 S gt L m LeftHighBeamcCir v RightHighBeamCir ReverseBuzzerCir E m gt LeftLowBeamcCir RightLlowBeamCir ParkingLampCir e A LeftReverseLampCir P RightReverseLampCir HydraulicFanCir LeftFrontTurnLampCir RightFrontTurnLampCir GearboxFanCir N LetRearTurnLampCir e RightRearTurnLampCir OilPressureSensor1 LeftSideLampCir RightSideLampCirCir e OilPressureSensor2 OilLevelCir e BACK PgUp MENU MENU HOME HOME Figure 06 30 Error Diagnostic 2 3 GPS Temp Unlock move the cursor to select the icon GPS Temp unlock and press the key ENTER to enter the GPS Temp Unlock Screen Enter the temporary password to unlock the GPS temporarily 6 3 3 6 INFORMATION The Information Screen is shown as following See Figure 06 31 In the Information Screen move the cursor left right and press the key ENTER to select the items such as System history warning Engine history warning Transmission history warning and About about the vehicle basic parameters according to the requirem
105. on by other vehicles Hazard lights also can be illuminated when the battery and engine are disconnected RT60 Rough Terrain Crane 07 3 a m m t m p s uml a a GS a a a 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE 7 6 ECONOMICAL DRIVING Economical driving which can save fuel and prolong service lives of tires must follow the items below a Develop good driving habits b Do not unnecessarily run the engine at high speed Shift the transmission into high gear as much as possible during driving Shift the transmission into low gear only when the engine RPM is unstable during driving c Depress and release the throttle pedal gently Avoid sharp turning jackrabbit starting and emergency braking except in a clear emergency Thus it can not only ensure safety but also reduce fuel consumption d Keep driving at medium speed drive at a speed of 3 4 of the max driving speed in normal conditions so that fuel can be burnt fully and the displacement and fuel consumption can be reduced e Advance gearshift is necessary before accelerating f Keep coolant temperature varying from 70 C to 95 C during driving Excessively high or low engine coolant temperature will impair the engine performance g Check tire pressure frequently to ensure the crane drives with normal tire pressure If the tire pressure is excessively low the rolling resistance tire ab
106. on until the switch is in the position OFF 7 THROTTLE PEDAL Push the pedal to increase the engine RPM release the pedal to decrease it The movement of the items that follow can increase or decrease as the speed of the engine changes Boom swing Increase or decrease the angle of the boom Extend or retract the boom Hoist movements raise or lower a load Note You can use the throttle pedal with the joysticks and boom extend retract pedal to increase decrease the speed of the items in 7 8 HAND THROTTLE You can use the hand throttle after the HAND FOOT THROTTLE SELECT SWITCH is activated 9 BUBBLELEVEL You use this to make sure that the crane is level RT60 Rough Terrain Crane 06 14 un gt c m C Lam d Ti pu s o1juo 2 ZOO M LI y 4 OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE 10 BOOM HOIST MAIN WINCH CONTROL Move the joystick forward to reel off main winch rope 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 Free swing Push to operate the FREE SWING Push again to release this function Located on right side of joystick Figure 06 10 Right Joystick Boom Hoist Main Winch Control Note on the Only when the operator
107. or smells Vibrations Sudden speed increase or decrease If you cannot find or correct the problem send the vehicle for repair b Check the following instruments for functions 6 Monitor the indicators gauges that follow Stop the engine if the engine oil pressure low indicator illuminates The engine oil pressure low indicator illuminates if the engine oil filter screen is dirty If this occurs examine the engine oil pressure If it is in the correct pressure range check and clean the engine oil filter screen a Engine oil pressure low indicator 1 Not illuminated 2 When the engine runs at idle the minimum oil pressure is 55 1 psi 0 38 MPa When the engine runs without a load the minimum oil pressure is 10 psi 0 069 MPa If the pressure is less than the minimum value the indicator illuminates If this occurs stop the engine Measure the level of RT60 Rough Terrain Crane 05 5 gt a E P E suonipuoo Funesado 2 P m A jus 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI the oil in the engine and check for leaks If the oil level is at the correct level and there are no leaks it is an unserviceable lubricating system Send the crane to the factory for repair b Engine coolant temperature gauge INO 3 The coolant temp
108. park brake when you park the crane Safety sign maintenance During the daily inspection make sure that the decals show and are in good condition Replace all missing or damaged safety signs The safety of the operator is always important 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 RT60 Rough Terrain Crane 04 7 2 ZOOMLION p OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI a a Un m d eo 5 i iQ INR UNE A A CUN aN T iv i a P M Eb 1 pow 08 TUTE VES TES 7 m uU n Wl Lo rk V D UJ s ul P r AM i as m b rm d Po n LT Ler I Lr Hr P rr D 47 i ex i n eo a ie x T 2 3 12 X13 11 i3 Right hand side Figure 04 1 Overview of the Safety Signs on the Machine 04 8 RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI ae 6 4 by ion Vilar en RAD VU GLEE AE A 220 Maintain required clearance Flectrocution Hazard UNE VOLTAGE CLEARANCE TO 1OFT 3 05m Death or injury can result fro
109. pect the thermostat clamps radiator hoses and radiator core for proper condition Replace the parts if necessary Condensation in the fuel tank contaminates the fuel supply with water which can freeze in the fuel lines and block the fuel flow to the engine To minimize this possibility keep the tank as full as is practical during cold weather This may entail refilling the tank more frequently than usual but the inconvenience is small compared to clearing a blocked fuel line If water should be noticed in the fuel supply drain the tank and refill it with uncontaminated fuel Lubricate the crane with the lubricants recommended for cold weather operation If necessary change the engine oil and other lubricants in order to conform to the recommendations The battery is more likely to sustain freeze damage if not kept fully charged because its electrolyte will freeze at a higher temperature than that in a fully charged battery Be certain the battery is charging when the engine is running and use an external charger to restore full charge when the crane is not being operated During extremely cold weather it is advisable to remove and store the battery in a heated area when the crane is to remain idle overnight or for any extended period RT60 Rough Terrain Crane 07 51 un a Lii Ls un mod un C m pe unl wa pF Nae a Dj pm me 2
110. r equipment damage Note 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 RT60 Rough Terrain Crane 04 1 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 4 2 SAFETY SYMBOL The safety symbol used on the Danger Warning and Caution labels tells personnel of possible death injury or property damage Obey all safety data that follows this symbol to prevent dangerous conditions A Caution 4 3 Hazard classification Hazard classification is a system to show different classes of possible injury levels A safety symbol and a signal word show how dangerous the level of possible injury can be A signal word without a safety symbol refers to property damage protection devices or important data You will find this system used in this manual and on signs on the crane to help find and prevent dangerous situations 4 4 SAFETY This section contains the safety rules that you must follow You must read and understand the Operator s Manual It contains the instructions for the specified machine All personnel must be safe at the work location Attention A Moving personnel Only use a crane to lift personnel when it is the less dangerous mode to move them to areas that are hard to access B Operator s responsibilities e Read and understand th
111. rasion as well as fuel consumption will be increased h Correctly use air conditioning system i Choose proper fuel and lubricating oil j Maintain the vehicle regularly 07 4 RT60 Rough Terrain Crane ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 7 7 STEERING OPERATION The vehicle adopts the hydraulic booster steering system which ensures the safe and reliable steering movement Pay attention to the following items during steering Look around before steering and then operate the steering wheel after ensuring everything is OK If necessary shift the transmission to lower gear to decelerate during steering If steering is not enough decelerate the vehicle gradually and simultaneously operate the steering wheel in the same direction If steering is too much decelerate the vehicle and simultaneously operate the steering wheel in the reverse direction as soon as possible Do not turn the steering wheel in one direction too quickly except in an emergency Turn smoothly to keep crane laterally stable Once the steering is complete turn the steering wheel to the neutral position gently and immediately to avoid making the crane unstable In sharp turning decelerate the vehicle and shift the transmission into low gear RT60 Rough Terrain Crane 07 5 un f C 2 un gt 22 ga 2 ZOQ M Li ON OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE
112. round the vehicle e lf you cannot repair the vehicle tell the servicing and repair facility G PREPARE THE CRANE FOR OPERATION 1 Examine the items that follow e Engine oil for correct level and make sure that it is clean e Coolant for correct level e Fuel tank for correct level e Hydraulic oil tank for correct level 2 Start the engine and check for noises and vibrations that are not usual If necessary engage the PTO H WHEN THE CRANE IS IN OPERATION 1 Personnel must stay away from the area below the boom 2 Do not let personnel on the superstructure while you operate the crane 3 Personnel must stay away from the reach of the boom 4 The crane with extended outriggers must be on the ground with a slope of less than 1 pem E ri 2 suonipuoo Lt RT60 Rough Terrain Crane 05 9 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 6 Do not move personnel on the load or other equipment used to lift 7 Do not use the crane for the tasks that follow Lift a load that is above the capacity of the crane Pulla load at an angle e Lifta load that is not in balance e E 05 10 RT60 Rough Terrain Crane 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 10 Keep no less than 3 wraps of wire rope on the drum s MONS 11 When the loa
113. s 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 m em LL O me 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 a common sense way e 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 RT60 Rough Terrain Crane 03 3 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI Speak with us if special data is necessary for the maintenance or operation of your RT75 Crane Send your machine model and a serial number to make sure that you receive the correct data If t
114. se the CD player with the engine in the OFF position 06 10 F1 m CU of 01007 OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE 1 2 3 Figure 06 6 Controls and Instruments 1 SWING AUX WINCH CONTROL Move the joystick forward to reel off the aux winch rope Move the joystick backward to spool up the aux winch rope Move the joystick to the left to move the boom to the left side Move the joystick to the right to move the boom to the right side pue sjonuop gd un 1 m C LE ur Figure 06 7 Left Joystick Swing Aux Winch Control Horn Push and hold in to make a sound Located on right side of joystick 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 11 RT60 Rough Terrain Crane 2 ZOQ M LI ON di iy d OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE 2 BOOM EXTEND RETRACT PEDAL Tilt pedal forward to extend boom Tilt pedal backward to retract boom Figure 06 8 Boom Extend Retract Pedal Note Only when the operator s seat is occupied and the icon on the display lights up can the boom extend retract function be operated 3 CIGARETTE LIG
115. t and right joysticks at a time to initiate required crane movements Pay attention to avoid the load colliding with outriggers SWING MAIN WINCH Left joystick Right joystick Fig 07 31 Move left and right joysticks at a time to initiate required crane movements 07 34 RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI LUFF MAIN WINCH Luff boom down Pay out main winch rope Luff boom up Pay out main winch rope Luff boom down Take in main winch Luff boom up rope Take in main winch rope Fig 07 32 Move the right joystick between any two adjacent arrows to initiate required crane movements SWING AUXILIARY WINCH Pay out aux winch rope Swit Pay out aux winch rope Swing to left Take in aux winch E m Take in aux winch rope Swing to left P rope Swing to right Fig 07 33 Move the left joystick between any two adjacent arrows to initiate required crane movements RT60 Rough Terrain Crane 07 35 un m O Q _ un aurjeJod 2 ZOOMLION f OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE TELESCOPE SWING Tilt forward to extend boom Swing to right Boom extend retract pedal P Tilt backward to retract boom Fig 07 34 Move the left joystick and tilt the left pedal at the same time to initiate corresponding movements See the illustration el ras imi m
116. terrain is rough or uneven it may be necessary to travel at a reduced speed to prevent topple over un a Lii Ls un h Operating on steep grades requires caution because the oil in the engine or transmission will move to one side of the engine or transmission As a result the engine or transmission may not be fully lubricated which could damage the engine or transmission i operator must be very careful on steep side slopes to avoid tipping the crane This machine can travel on 15 side slopes which have afirm level prepared surface RT60 Rough Terrain Crane 07 49 2 ZOQ M Li ON OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE Due to variations in surface tire pressure bumps potholes etc we recommend that travel on side slopes be limited to 5 and that the boom be horizontal or below See the ON TIRE LIFTS instructions found later in this section for instructions on moving the crane with a load 7 21 ON TIRES LIFTS Listed below are special precautions for On Tires lifts a The boom shall be carried straight over the front of the crane b Travel speed reduced to suit working conditions c Maintain specified tire pressures d Avoid sudden starts and stops e Provide tag or restraint lines to snub swinging of the load f Keep the load as close to ground as possible g Lockthe swing brake and swing lock h Travel must be on a smooth level s
117. the boom Figure 07 19 Extend Retract Pedal Forward Only when the operator s seat is occupied and the icon on the display lights up can the joysticks initiate various movement b Tilt the pedal forward to extend the boom If telescoping cylinder is activated telescopic section 1 extends When cylinder is fully extended LMI will alarm Push button on LMI to change to cylinder Il The telescopic sections 2 and 4 move out at the same C After the boom extends to required position slowly tilt the pedal backward to neutral position If the hook block contacts the anti two block weight during boom telescoping acoustic visual warning will be sent out and the movement Boom extending is switched off Pay out the hoist rope a little if the boom is still needed to be extended c oU t E 5 09 N During commissioning or maintenance the switch off can be bypassed by the bypass key switch However the operation should be carried out with maximum care to prevent accidents 07 24 2 ZOO M L i OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE BOOM RETRACTING a Make sure the seat occupied and activate the pedal to retract the boom b Tilt the pedal backward to retract the boom If telescoping cylinder II is activated telescopic sections 2 3 and 4 retract When cylinder II is fully retracted LMI will alarm Push button on LMI to change to cylinder I The telescopic section 1 will then re
118. the lateral center of pin II Fez S ie pd D AA A ze G4 HL AP ANGERS Fig 07 38 e Connect the jib to the boom head axles at fixing points B and C by inserting pin 1 and guarding with spring loaded pin AM Point C f AN Lene di m AS m p ra un C e 4 un Fig 07 40 RT60 Rough Terrain Crane 07 39 2 ZOOMLION f OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE g Swing the jib forwards h Point D Pin IV Point E Ja am i C ey f EM d il ur um Lnd Re um m am un d pin Fig 07 43 07 40 RT60 Rough Terrain Crane 2 ZOOMLION J OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI j Pull out jib section 1 till it touches retainer align pin holes and insert pin V and spring loaded pin to make jib sections and 11 be secured tightly Fig 07 44 Reeve the auxiliary hoist rope Install the auxiliary hook and the anti two block switch Check the jib for proper assembling Ln i pe m D un m O Q _ yn RT60 Rough Terrain Crane 07 41 a pete um t m p s un m D wm a a 2 ZOOMLION OPERATOR S MANUAL FOR R
119. tract c After the boom retracts to required position slowly tilt the pedal forward to neutral position Fig 07 21 1 The hook will be raised or lowered during the process of boom extending and retracting Therefore move the relevant joystick to pay out or take in the hoist rope to regulate the hook height The operation must be slowly and stably 2 The speed of crane movement Boom extending retracting can be controlled by THROTTLE PEDAL Tilt the pedal all the way forward for high speed extend or retract Do not change the speed jerkily to ensure stable movements 3 Wait for 2 seconds to extend the boom after boom fully retracted 4 Lift the load vertically and it is forbidden to lift the load diagonally Do not laterally drag the load which is still on the ground 5 It is forbidden to use the bypass key switch except under commissioning and maintenance 6 The boom will be retracted a little automatically after the boom is extended for a period of time Surje1od Cause zy Un mad Variation of hydraulic oil temperature extension retraction status boom angle Lubricating status Solutions Keep the hydraulic oil temperature not to rise too high Extend the boom to the desired length 7 Do not extend retract the boom with load 07 25 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE 7 15 LUFFING OPERATION The boom ang
120. tral position stop Move the joystick Bru swing to the right left swing to the left Left joystick unedo un m O 2 9 un Q D RT60 Rough Terrain Crane 07 29 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE SWING LOCKOUT DEVICE The swing lockout device is mounted on the right side of the turntable which is used to lock the turntable at any position Before attempting to swing the superstructure make sure the swing brake is not set and the swing lock is not engaged After finishing work set the swing brake and engage the swing lock p N Fig 07 26 SWING LOCKOUT SWITCH 1 ALWAYS START AND STOP SWINGS GRADUALLY Stopping the swing too abruptly will cause the load to oscillate and impose side loads on the boom 2 In order to ensure safe operation of a new crane check bolts of swing bearing and tighten the bolts with 700 Ibf ft 950 N m tightening torque after initiating for 100 hours Then check and tighten the bolts after 500 operating hours After that check the bolts every 1000 hours 3 crane can swing with load However do not diagonally lift the load which is still on the ground Otherwise it is very dangerous 4 Check whether the outriggers are set up as per load rating chart before swing operation 5 Ensure there is enough space for the crane swing operation 6 Ensure that the turntable is unlocked before swing operation Lock t
121. uent intervals and be alert for any abnormal engine sounds or faulty engine performance When idling for extended periods maintain an idle speed sufficient to prevent the battery from being discharged Keeping the battery in a fully charged state is important for starting the engine Throttle down to half speed or slower with no load for at least 5 minutes before stopping This gives the engine a chance to cool off gradually before it is stopped This cool down period is extremely critical on machines equipped with turbocharged engines due to the excessive build up of heat during normal load operations Nae a Dj pm me mod un C m pe ua wa Consult the engine manufacturer s manual for further operating instructions 7 4 COLD WEATHER STARTING At very low temperatures when the engine is difficult to start an optional flame starting device is very important to help the normal engine start Please contact Zoomlion Service Department if you want to select a flame starting device for your crane 07 2 RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 7 5 STARTING OFF AND PARKING OPERATION STARTING OFF OPERATION After finishing the preparation for driving start the vehicle in the following steps a Depress the brake pedal b Deactivate parking brake 15 c Move the transmission shift lever to the 1 gear position d Release th
122. ulled up The controls of superstructure are arranged according to the requirements of ASME B30 5 2007 standard and comply with ISO International Organization for Standardization standard CAB DIMENSIONS Length 90 6 in 0 2 2300 mm 5 mm Width 41 7 in 0 2 1060 mm 5 mm Height 65 6 in 0 2 1665 mm 5 mm RT60 Rough Terrain Crane ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANI 10 RATED CAPACITY INDICATOR RCI 11 Rated Capacity Indicator with visual and audible warning system and automatic function disconnects If the actual load approaches the rated one the buzzer sends out visual and audible warning If the actual load reaches the rated one all dangerous movements are switched off automatically The rated capacity indicator also can limit the working range including working radius boom angle lifting height and swing range etc Pictographic display includes boom angle moment ratio boom length defaulted hook weight actual working radius swing angle actual load allowable load jib offset line parts boom status outrigger information On Tires indication and percentage of allowable load and hydraulic system pressure registered by bar graph OUTRIGGERS H type hydraulic outriggers can be operated in the cab simultaneously or independently Each vertical jack is equipped with a two way hydraulic lock to ensure that the outriggers can be secured reliably during working or travelin
123. urface that is capable of supporting the weight of the loaded crane The travel surface must also be free of holes or debris that can cause crane instability These precautions are necessary to prevent a pendulum effect of a swinging load The results of this happening can cause a machine tip over 1 Any variation from the above conditions will require the operator to consider the prevailing conditions and reduce the lift capacities accordingly Insufficient tire pressure reduces the ON TIRES capacity Attempts to pick rated capacity without properly inflated tires may cause crane to tip and or result in damage to tires and rims EA a D GS a a a 2 Excessive high hydraulic oil temperatures cause rapid deterioration of rubber components hose O rings etc If hydraulic reservoir temperature reaches 80 C 176 F reduce the duty cycle Stop operations as required to prevent further increase in the hydraulic oil temperature a m m m p s uml a 3 Creep means the crane can be moved at a maximum speed of 1 6 KM h for a distance of 18 M 60 ft and then stop for 30 minutes to cool the tires Overheating will greatly reduce the life of the tires 07 50 RT60 Rough Terrain Crane 2 ZOOMLION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE 7 22 UNUSUAL OPERATING CONDITIONS Special problems in maintenance and operation are caused by unusual conditions such as extrem
124. ut device 0 Boom angle indicator 11 Outrigger beam retaining pin 12 Emergency stop button 2 13 Winch speed sensor pads O 2 oo un 09 16 RT60 Rough Terrain Crane
125. ws 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 RT60 Rough Terrain Crane 2 ZOOM LION OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE Safety Hazard Indicators DANGER WARNING CAUTION ATTENTION NOTE and IMPORTANT labels are on signs and decals and as you read this manual to show important instructions In this manual DANGER WARNING and CAUTION labels are before the paragraph or item to which they apply ATTENTION NOTE and IMPORTANT follow the paragraph or item they apply to The markers are as follows A Danger Refers to a dangerous situation which if you do not prevent will cause death or injury A Warning Refers to a possible dangerous situation which if you do not prevent could cause death or injury A Caution Refers to a possible dangerous situation which if you do not prevent may cause light or moderate injury Refers to a situation which if you do not prevent may cause property or equipment damage Refers to a tip or hint in the operation instructions A Important Emphasizes the importance of the data in this manual This symbol shows a step or procedure that is not approved and can
126. y keeping the reservoir filler cap tight and servicing the hydraulic system filters frequently The fuel system should be kept free of sand and dust by keeping the tank filler cap tight and servicing the fuel filters frequently The engine breathers and air cleaner should also be serviced frequently to prevent sand and dust from entering the engine The engine oil and oil filter should be changed at shorter than normal intervals to ensure a clean oil supply to the engine s moving parts When lubricating the crane thoroughly clean each grease fitting before attaching the grease gun Pump generous amounts of grease into all lubrication points using the fresh grease to pump out the old Adequate ground bearing support must be provided for the outrigger floats when operating in sand Be alert for signs of carrier movement during operations The increased frequency of lubrication and service discussed above should be determined by observations made at the work site Inspection will determine how long it takes for lubricants breathers and filters to accumulate unacceptable amounts of sand or dust The frequency of lubrication and service should be adjusted accordingly HIGH HUMIDITY OR SALTWATER RT60 Rough Terrain Crane 07 53 un a Lii Ls un 2 ZOQ M Li ON OPERATOR S MANUAL FOR ROUGH TERRAIN CRANE In some locations such as coastal areas the crane may be exposed to the deterioratin

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