Zoomlion RT60 Manual

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

FEBRUARY 2013
MAINTENANCE AND
SERVICE MANUAL
Edition 2

FEBRUARY 2013

Edition 2 Page i
Feb/2013
(Thank you letter)
Owners, Users and Operators:
Zoomlion Cranes appreciates your selection of the ZOOMLION Rough Terrain Crane for your
application.
No one should do the maintenance/service tasks to the crane unless they read and know the
data in this manual and the other technical documents supplied with the crane.
The Maintenance and Service Manual provides periodic inspections, maintenance and service
procedures that are necessary to make sure the performance, safety and reliability are at the
highest level. They can also increase the service life of the crane.
When you follow the instructions in this manual, your crane can operate at MAXIMUM
EFFICIENCY.
To look after your rights & interests and safety, you must obey all safety data in the
Maintenance and Service Manual. Only approved personnel can disassemble and adjust
hydraulic system components during maintenance. When a hydraulic component malfunctions
or is damaged, tell the local repair facility.
You do not have to keep the Maintenance & Service Manual in the cab of the crane. The
Maintenance & Service Manual must be with the crane if it is sold.
If there is something in the manual that you do not understand, speak with us. We (Zoomlion
Cranes) are NOT responsible for damages from an operator or service technician who does not
obey the instructions in the Maintenance and Service Manual.
THANK YOU!
Mobile Crane Branch Company of ZOOMLION Heavy Industry Science and Technology Co.,
Ltd
Copyright
Under the copyright laws, this manual cannot 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. Printed in the United States

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Contents
(Thank you letter)...........................................................................................................................i
Contents....................................................................................................................................... iii
About This Manual........................................................................................................................v
Safety.......................................................................................................................................... vii
Introduction................................................................................................................................1
1.1 INTRODUCTION.........................................................................................................1
1.2 OPERATOR OBSERVATION .....................................................................................1
1.3 WIRE-ROPE INSPECTION RECORD........................................................................3
1.4 ENGINE MAINTENANCE ...........................................................................................4
1.5 ENGINE RADIATOR MAINTENANANCE...................................................................7
1.6 TRANSMISSION MAINTENANCE..............................................................................8
1.7 AXLE MAINTENANCE..............................................................................................10
1.8 TIRE MAINTENANCE...............................................................................................11
1.9 BRAKE SYSTEM MAINTENANCE ...........................................................................14
1.10 AIR SYSTEM MAINTENANCE .................................................................................15
1.11 BATTERY MAINTENANCE.......................................................................................15
1.12 FUEL, COOLANT AND TORQUE CONVERTER HYDRAULIC TRANSMISSION
OIL.............................................................................................................................16
1.13 LUBRICATION..........................................................................................................17
1.14 HYDRAULIC OIL.......................................................................................................24
1.15 GEAR OIL .................................................................................................................28
1.16 LUBRICATING GREASE..........................................................................................30
1.17 LUBRICATING POINTS............................................................................................31
1.18 ADJUST, CLEAN AND REPLACE THE PARTS.......................................................33
1.19 BATTERY MAINTENANCE AND SERVICE .............................................................50
1.20 BATTERY MAINTENANCE – WINTER ....................................................................51
1.21 OPERATION IN WINTER .........................................................................................52
1.22 OPERATION IN SUMMER........................................................................................53
Troubleshooting............................................................................................................................1

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2.1 ELECTRICAL SYSTEM ..............................................................................................1
2.2 HYDRAULIC SYSTEM................................................................................................3
2.3 EXTEND / RETRACT SYSTEM..................................................................................4
2.4 DERRICKING MECHANISM.......................................................................................5
2.5 SWING MECHANISM .................................................................................................6
2.6 HOIST MECHANISM ..................................................................................................7
2.7 OUTRIGGERS............................................................................................................8
2.8 TRANSMISSION.........................................................................................................9
2.9 BRAKE SYSTEM ......................................................................................................12
2.10 STEERING SYSTEM................................................................................................13
2.11 FRONT / REAR AXLES ............................................................................................16
2.12 DRIVE SHAFT...........................................................................................................18
2.13 TIRES........................................................................................................................19
Inspection....................................................................................................................................23
3.1 PRE-START INSPECTION.......................................................................................23
3.2 NEW CRANE SPECIAL BREAK-IN REQUIREMENTS ............................................27
3.3 PERIODIC INSPECTIONS AND SERVICE..............................................................27
3.4 PERIODIC CRANE INSPECTIONS..........................................................................35
3.5 INSPECTIONS AND MAINTENANCES DURING BREAK-IN PERIOD....................42

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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 is for maintaining and servicing the RT 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 end of this section.
Again, we at ZOOMLION appreciate your selection of our crane. User safety is most important. To
complete on-site tasks safely, operators and service technicians must be responsible. Obey the
instructions that follow:
•Comply - with Occupational Safety and Health Administration (OSHA), Federal,
State and Local Regulations.
•Read, Understand and Follow - the instructions in this and other manuals and
documents that come with the crane.
•Use Good, Safe Work Practices - in a common sense way.
•Only have trained operators and service technicians - 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.

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Feb/2013
OSHA prohibits the alteration or modification of this crane without written
manufacturer’s approval. Use only the 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.
Speak with us if special data is necessary for the maintenance or operation of your RT Crane. Send your
machine model and a serial number to make sure that you receive the correct data.
If there is anything in this manual that is not clear or which you think is necessary, write to the address
that follows:
Rough Terrain Crane R & D Institute
Zoomlion Mobile Crane Branch Company
Quantang Industrial Park, 2nd Yuanda Road,
Economic and Technological Development Zone,
Changsha, Hunan Province, China, 410131
You can also speak to us by telephone at 0086-84671997 (international), 0731-84671997 (in China).
Thank You!

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Feb/2013
Safety
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.
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.
HAZARD INDICATORS
DANGER, WARNING, CAUTION and NOTE 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. NOTEs follow the paragraph or item they apply to. The labels 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.
Refers to a possible dangerous situation which, if you do not prevent, may cause light or moderate injury.
Refers to a tip or hint in the instructions.

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INTENDED USE
Scope
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. Rules change by location and this manual does not give that data.
ZOOMLION makes manuals for different construction and industrial equipment. It is policy to include
applicable national consensus, industry standards and safety data with the manuals. Use this 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 periodic inspections regularly because the equipment wears
during operation. This prevents accidents, decreases downtime and helps equipment work satisfactorily. The
goal of these inspections is to find worn, cracked, damaged parts and loose or missing fasteners before they
cause a problem.
Correct training and inspection procedures are necessary to prevent injury to persons, property damage and
high maintenance costs.
Read and understand the data that comes with this crane. Help is available from the distributors of your
ZOOMLION crane and from the ZOOMLION manufacturing facility.
This manual contains the instructions and data on the operation, maintenance, lubrication and adjustments of
the Rough Terrain Crane. Do not operate or service the crane before you understand the data in this manual.

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Nomenclature
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.

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CRANE PERIODIC INSPECTION CHECKLIST
This inspection checklist provides supplementary data to facilitate the correct operation and maintenance
of the crane.
Component Inspected Interval Function Adjusting Condition Maintenance Condition Component Inspected Inspection Code Function Adjusting Condition Maintenance Condition

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MAINTENANCE LOG
Item
Adjusting Condition
Date

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MAINTENANCE AND SERVICE MANUAL FOR ROUGH TERRAIN CRANE
Chapter 1 Maintenance and Service

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Feb/2013 Maintenance and Service
Introduction
1.1 INTRODUCTION
A set of preventive maintenance tasks is necessary to extend the serviceable life of
the crane. The tasks can help to maximize efficient service and decrease the time
the crane is at the repair facility. This section has checks and procedures which you
are to do on daily, weekly, monthly and semi-annual intervals. These intervals are
specified in conditions of calendar and hours of operation.
The checks for long intervals include all the checks that you do in the shorter
intervals. Thus, the weekly check includes all items in the daily check. The monthly
check includes the weekly and the daily checks. The semi-annual check includes the
quarterly, monthly, weekly and daily checks.
The chart makes it possible for you to record the preventive maintenance tasks that
you complete. It also supplies you with a tool to find the problem areas and to
examine the value of the maintenance tasks. The items in each check interval on the
chart are assembled by their applicable headings and explained in this chapter.
This maintenance schedule is a procedure to make sure that basic preventive
maintenance tasks are completed in the usual conditions that you operate. The
conditions which increase wear, loads or strain on the crane, usually make it
necessary to decrease the interval time. Before you change the maintenance
schedule, examine your operation and the maintenance records of the crane. Think
about all the factors involved and make a new schedule that is sufficient to align the
usual maintenance tasks.
As a part of each preventive maintenance check, refer to the Engine Manufacturer’s
Manual for engine maintenance tasks. When you do the servicing of the engine, use
the data in the engine manual if this chapter has data that is different.
1.2 OPERATOR OBSERVATION
A. Do a visual inspection for:
(1) Unusual conditions
(2) Hydraulic system leaks or damage.
B. Examine the area around the engine for:
(1) Belts (tension and wear)
(2) Coolant level
(3) Engine oil level
(4) Hydraulic transmission oil level

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(5) Air cleaner vacuum actuated indicator
(6) Air inlet
(7) Silencer and exhaust device.
C. Examine the condition of each battery.
D. Examine the boom for:
(1) Sheave (wear or damage)
(2) The function of the anti-two block system
(3) Wire-rope on the winches (wear and breaks)
(4) Wear of the cylinder pin.
E. Tires, axles and drivelines (wear or damage).
F. Examine the cab for:
(1) Gauge and indicator functions
(2) Function of the switches and joysticks
(3) Clear windows
(4) Safety device in position
(5) Each light operates
(6) Cleanliness: free from dirt, mud and waste material.

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1.3 WIRE-ROPE INSPECTION RECORD
WIRE-ROPE INSPECTION RECORD
(See pages 1-37 and 1-38)
Place of inspection_________________________ Date _______________
DESCRIPTION OF CRANE
Make _____________________________ Model_________ Serial No.___________
Type and Arrangement of Attachments ___________________________________________
Date of Last Rope Inspection___________________________________________________
Hours and Time of Service Since Last Inspection ___________________________________
RESULT OF INSPECTION
Rope Inspected Type and Size Conditions noted Recommendations
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
___________________ Inspector: