Page 1 For reference only. Operators manual should be consulted and adhered to. OPERATOR'S MANUAL FOR RT55 ROUGH TERRAIN CRANE Address:Quantang Indust=rial Park, 2nd Yuanda Road, Changsha Economic and Technological Development Zone, Hunan Province, China Postcode: 410131 Website: www.zoomlion.com...
Page 2 For reference only. Operators manual should be consulted and adhered to. RT55 ROUGH TERRAIN CRANE OPERATOR’S MANUAL Edition 1 Dec. 2013...
Page 3 For reference only. Operators manual should be consulted and adhered to.
Page 4 The operator must keep this manual in the cab of the crane. If there is anything in the manual that you do not understand, speak with us. We (Zoomlion Cranes) are NOT responsible for damages from an operator who does not obey the instructions in the OPERATOR’S MANUAL.
Page 5 For reference only. Operators manual should be consulted and adhered to. 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.
Page 6: Table Of Contents
For reference only. Operators manual should be consulted and adhered to. Contents To owners, users and operators ....................I Safety ............................II 1 Foreword ........................01-1 2 Nomenclature ........................ 02-1 3 Introduction ........................03-1 4 Safety ..........................04-1 5 Operating conditions and points for attention ............05-1 5.1 Operating conditions ....................
Page 7 For reference only. Operators manual should be consulted and adhered to. 8 Transportation and storage ..................08-1 8.1 Transportation ......................08-1 8.2 Storage ........................08-3 9 Specifications ........................ 09-1 9.1 Conversion tables ...................... 09-1 9.2 Average weight of materials ..................09-3 9.3 Torque values ......................
Page 8 For reference only. Operators manual should be consulted and adhered to.
Page 9 For reference only. Operators manual should be consulted and adhered to.
Page 10 Read and understand the data that comes with this crane. Help is available from the distributors of your ZOOMLION crane and from the ZOOMLION Mobile Crane Branch Company. This manual contains the instructions and data on the operation, maintenance, lubrication, and adjustments of the Rough Terrain Crane.
Page 11 For reference only. Operators manual should be consulted and adhered to.
Page 12 For reference only. Operators manual should be consulted and adhered to.
Page 13 For reference only. Operators manual should be consulted and adhered to.
Page 14 For reference only. Operators manual should be consulted and adhered to. To aid in understanding the contents of this manual, refer to the figure below. Each numbered term can represent several components of the same main part. RT55 Rough Terrain Crane 02 - 1...
Page 15 For reference only. Operators manual should be consulted and adhered to.
Page 16 For reference only. Operators manual should be consulted and adhered to.
Page 17 For reference only. Operators manual should be consulted and adhered to.
Page 18 For reference only. Operators manual should be consulted and adhered to. CRANE PERIODIC INSPECTION CHECKLIST This inspection checklist provides supplementary data to facilitate the correct operation and maintenance of the crane. RT55 Rough Terrain Crane 03 - 1...
Page 19 For reference only. Operators manual should be consulted and adhered to. MAINTENANCE LOG Item Adjusting Condition Date 03 - 2 RT55 Rough Terrain Crane...
Page 20 For reference only. Operators manual should be consulted and adhered to. 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.
Page 21 If there is anything in this manual that is not clear or which you think is necessary, write to the address that follows: Rough Terrain Crane R & D Institute Zoomlion Mobile Crane Branch Company Quantang Industrial Park, 2 Yuanda Road,...
Page 22 For reference only. Operators manual should be consulted and adhered to.
Page 23 For reference only. Operators manual should be consulted and adhered to.
Page 24 For reference only. Operators manual should be consulted and adhered to. 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.
Page 25: Safety
For reference only. Operators manual should be consulted and adhered to. 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.
Page 26 For reference only. Operators manual should be consulted and adhered to.  Make sure that all the mechanical functions of the crane can operate.  Make sure that the system operating gauges and indicators, and warning signals function.  Keep all the glazed surfaces, instruments, windows, and lights clean. ...
Page 27 For reference only. Operators manual should be consulted and adhered to. 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. ...
Page 28 For reference only. Operators manual should be consulted and adhered to.  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. ...
Page 29 For reference only. Operators manual should be consulted and adhered to.  Decrease radius at the start of the lift to let the load radius increase during lift.  Know the weight of the hook and rigging.  Know the boom length, jib length, and the area where you have to move the load. ...
Page 30: Safety
For reference only. Operators manual should be consulted and adhered to.  Do not use the controls and the steering-wheel as hand holds.  Keep the equipment clean and dry.  Replace all broken ladders.  Keep the non-slip surfaces in good condition. ...
Page 31 For reference only. Operators manual should be consulted and adhered to. Figure 04 – 1 Overview of the Safety Signs on the Machine 04 - 8 RT55 Rough Terrain Crane...
Page 32 For reference only. Operators manual should be consulted and adhered to. Figure 04 – 2 Danger – Crush Hazard Figure 04 – 3 Danger – Electrocution Hazard RT55 Rough Terrain Crane 04 - 9...
Page 33 For reference only. Operators manual should be consulted and adhered to. Figure 04 – 4 Hand Signals for Crane Operation 04 - 10 RT55 Rough Terrain Crane...
Page 34 For reference only. Operators manual should be consulted and adhered to. Figure 04 – 5 Danger – Explosion / Burn Hazard Figure 04 – 6 Danger – Crush Hazard RT55 Rough Terrain Crane 04 - 11...
Page 35 For reference only. Operators manual should be consulted and adhered to. Figure 04 – 7 Danger – Burn Hazard Figure 04 – 8 Prohibited – No Thoroughfare Figure 04 – 9 Prohibited - No Access / Only Authorized Personnel 04 - 12 RT55 Rough Terrain Crane...
Page 36 For reference only. Operators manual should be consulted and adhered to. Figure 04 – 10 CAUTION - Risk of Falling Figure 04 – 11 CAUTION - Swinging Load Figure 04 – 12 No Swing over the Rear with -3° RT55 Rough Terrain Crane 04 - 13...
Page 37 For reference only. Operators manual should be consulted and adhered to. Figure 04 – 13 Entanglement Hazard Figure 04 – 14 Keep All Open Flames and Sparks Away – RH Only Figure 04 – 15 Be Careful in the Working Radius – RH Only 04 - 14 RT55 Rough Terrain Crane...
Page 38 For reference only. Operators manual should be consulted and adhered to. Figure 04 – 16 No Walk – RH Only RT55 Rough Terrain Crane 04 - 15...
Page 39 For reference only. Operators manual should be consulted and adhered to.
Page 40 For reference only. Operators manual should be consulted and adhered to.
Page 41 For reference only. Operators manual should be consulted and adhered to.
Page 42: Operating Conditions
For reference only. Operators manual should be consulted and adhered to. 5.1 OPERATING CONDITIONS Always use the correct light diesel fuel 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.
Page 43 For reference only. Operators manual should be consulted and adhered to. Retract the boom.   Correctly stow the boom.   To make an estimate of the wind speed, use the table that follows: Wind Force Wind Speed Effect of the wind on the land Beaufort Description ft-in/s...
Page 44: Pre-Departure Checks (To Job-Site)
For reference only. Operators manual should be consulted and adhered to. 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.
Page 45 For reference only. Operators manual should be consulted and adhered to. Instrument panel   Switches   All lights   Turn signals   Wipers   Miscellaneous displays.   (14) Adjust the mirrors for clear vision to the rear. B.
Page 46 For reference only. Operators manual should be consulted and adhered to. C. MOVE THE CRANE TO THE JOB-SITE Danger Do not let the vehicle move forward when transmission is in neutral. Warning Do not operate a vehicle if a warning indicator illuminates. Stop the vehicle and have it repaired.
Page 47 For reference only. Operators manual should be consulted and adhered to. 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.
Page 48 For reference only. Operators manual should be consulted and adhered to. temperature is above the maximum limit. This can kill or blind you and cause damage to the engine. ) Low engine coolant: Caution Use soft water, e. g. tap water, for coolant. Do not use hard water (river water).
Page 49 For reference only. Operators manual should be consulted and adhered to. 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. ) If the engine stops because the fuel tank is empty, air can go into the fuel system.
Page 50 For reference only. Operators manual should be consulted and adhered to. Examine the vehicle to find the part that caused the malfunction. Be careful of the  road conditions while you move around the vehicle. If you cannot repair the vehicle, tell the servicing and repair facility. ...
Page 51 For reference only. Operators manual should be consulted and adhered to. ) Do not move personnel on the load or other equipment used to lift. ) Do not use the crane for the tasks that follow: Lift a load that is above the capacity of the crane. ...
Page 52 For reference only. Operators manual should be consulted and adhered to. ) Keep no less than 3 wraps of wire rope on the drum. ) When the load is off the ground, do not adjust the hoist mechanism brake. ) When the load is off the ground, the operator must stay in the cab. ) When the job-site is near live power lines, you must keep a safe distance.
Page 53 For reference only. Operators manual should be consulted and adhered to. ) Stop the operation or do not start to lift a load, if one of the items that follows occurs: An overload or if the weight of the load is unknown. ...
Page 54 For reference only. Operators manual should be consulted and adhered to.
Page 55 For reference only. Operators manual should be consulted and adhered to.
Page 56 For reference only. Operators manual should be consulted and adhered to. 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.
Page 57 For reference only. Operators manual should be consulted and adhered to. LEGEND High / Low Speed Select Switch for 13. Left Rear Outrigger Switch Main Winch 14. Emergency Stop Button Steering Switch 15. Right Front Outrigger Switch Camera Display 16. Right Rear Outrigger Switch High / Low Speed Select Switch for 17.
Page 58 For reference only. Operators manual should be consulted and adhered to. Figure 06 – 2 Left Dash 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 –...
Page 59 For reference only. Operators manual should be consulted and adhered to. 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.
Page 60 For reference only. Operators manual should be consulted and adhered to. 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.
Page 61 For reference only. Operators manual should be consulted and adhered to. 6.1.1 AIR CONDITIONER CONTROL PANEL Figure 06 – 4 Air Conditioner Control Panel FUNCTIONS A/C FAN SPEED / MASTER SWITCH – Used to control the fan blower modes: OFF, HI, MID, LOW.
Page 62 For reference only. Operators manual should be consulted and adhered to. Table 06 – 1 Air Conditioner Maintenance Requirements Item Requirements Maintenance interval Condenser fan Examine and repair. Every quarter motor Evaporator fan Examine and repair. Every quarter motor Every month or increase the maintenance frequency Condenser Examine and clean.
Page 63 For reference only. Operators manual should be consulted and adhered to. 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  Turn on the A/C FAN SPEED / MASTER SWITCH (1) after the engine is started: –...
Page 64 For reference only. Operators manual should be consulted and adhered to. Set the A/C to the OFF position when you do one of the items that follow: • Move the crane quickly. • Move up a long hill slope. Make sure that the refrigerant in the A/C system is at the correct level at regular intervals.
Page 65 For reference only. Operators manual should be consulted and adhered to. 6.1.2 MEDIA PLAYER Figure 06 – 5 Media Player LEGEND Power Button Press power button turn on/off the Media Player SD CARD Port USB Port LCD Display Band Selector AM / FM function selection Setting Button Sound menu function selection...
Page 66: Controls And Instruments
For reference only. Operators manual should be consulted and adhered to. 6.2 CONTROLS AND INSTRUMENTS Figure 06 – 6 Controls and Instruments 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.
Page 67 For reference only. Operators manual should be consulted and adhered to. BOOM EXTEND / RETRACT PEDAL 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 CIGARETTE LIGHTER Push-in the cigarette lighter for 3 to 5 sec.
Page 68 For reference only. Operators manual should be consulted and adhered to. Figure 06 – 9 Combination Switches 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.
Page 69 For reference only. Operators manual should be consulted and adhered to. 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.
Page 70 For reference only. Operators manual should be consulted and adhered to. 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 –...
Page 71 For reference only. Operators manual should be consulted and adhered to. 6.3 Monitor Figure 06 – 11 Overview Figure 06 – 12 System Start-up After being switched on: The monitor system runs up. See Figure 06 – 12. The Work Mode Screen (when the parking brake is ON) or Travel Mode Screen (when the parking brake is OFF) appears on the monitor.
Page 72 For reference only. Operators manual should be consulted and adhered to. Figure 06 – 13 Work Mode Under Work Mode Screen, the virtual tachometer will be displayed on the screen. See Table 06 – 2. Figure 06 – 14 Travel Mode Trip Distance is the crane travel distance from the departure place to the destination.
Page 73 For reference only. Operators manual should be consulted and adhered to. 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.
Page 74 For reference only. Operators manual should be consulted and adhered to. Table 06 – 3 Indicators – Universal Symbol Identification INDICATOR SYMBOL DESCRIPTION FUNCTION Illuminates: ENGINE COOLANT Shows that the engine coolant level is LOW INDICATOR too low. Illuminates: ENGINE OIL Shows that the engine oil pressure is too PRESSURE LOW low or the oil filter screen is dirty.
Page 75 For reference only. Operators manual should be consulted and adhered to. INDICATOR SYMBOL DESCRIPTION FUNCTION Illuminates: AIR CONDITIONER Air conditioner is ON. INDICATOR Illuminates: FAULTY OUTRIGGER OPERATION Shows that the outrigger system has a INDICATOR malfunction. Illuminates: TRANSMISSION OIL PRESSURE LOW Shows that the transmission oil pressure INDICATOR is too low.
Page 76 For reference only. Operators manual should be consulted and adhered to. INDICATOR SYMBOL DESCRIPTION FUNCTION Illuminates: AXLE CENTERED INDICATOR Shows that the rear axle is centered. Illuminates: SUPERSTRUCTURE Shows that the superstructure is in the POSITION INDICATOR initial position. Illuminates: MAIN WINCH APPROACHING Shows that the main winch is near the...
Page 77 For reference only. Operators manual should be consulted and adhered to. INDICATOR SYMBOL DESCRIPTION FUNCTION Illuminates: NEUTRAL 2 Shows that the transmission is in the "N POSITION INDICATOR 2" position. Illuminates: FORWARD SPEEDS Shows that the gear selector is in the INDICATOR forward direction.
Page 78 For reference only. Operators manual should be consulted and adhered to. INDICATOR SYMBOL DESCRIPTION FUNCTION Illuminates: HAZARD LIGHTS Shows that the crane is in operation and INDICATOR the hazard lights are ON. Illuminates: HIGH-SPEED Shows that the transmission high-low INDICATOR speed valve is connected.
Page 79 For reference only. Operators manual should be consulted and adhered to. 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”...
Page 80 For reference only. Operators manual should be consulted and adhered to. 6.3.2 SYSTEM WARNING Under Travel Mode Screen 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.
Page 81 For reference only. Operators manual should be consulted and adhered to. 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, 简体中文(Chinese), Information and Password etc.
Page 82 For reference only. Operators manual should be consulted and adhered to. Figure 06 – 18 Main Menu (Chinese mode) 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.
Page 83 For reference only. Operators manual should be consulted and adhered to. 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”...
Page 84 For reference only. Operators manual should be consulted and adhered to. 6.3.3.3 REAL-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 –...
Page 85 For reference only. Operators manual should be consulted and adhered to. Figure 06 – 23 Engine Warning Figure 06 – 24 Transmission Warning 06 - 30 RT55 Rough Terrain Crane...
Page 86 For reference only. Operators manual should be consulted and adhered to. 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”...
Page 87 For reference only. Operators manual should be consulted and adhered to. 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 Diagnostic, Error Diagnostic or GPS Temporary Unlock according to the work requirements.
Page 88 For reference only. Operators manual should be consulted and adhered to. Figure 06 – 28 Engine Diagnostic (2) Error Diagnostic: move the cursor to select the icon “Error diagnostic” and press the key “ENTER” to enter the Error Diagnostic Screen. See Figure 06 – 29 and Figure 06 –...
Page 89 For reference only. Operators manual should be consulted and adhered to. 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.
Page 90 For reference only. Operators manual should be consulted and adhered to. 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.
Page 91 For reference only. Operators manual should be consulted and adhered to. Figure 06 – 34 Transmission History Warning Figure 06 – 35 About RT55 Rough Terrain Crane 06 - 36...
Page 92 For reference only. Operators manual should be consulted and adhered to. 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.
Page 93 For reference only. Operators manual should be consulted and adhered to. 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. button Power control 2.
Page 94 For reference only. Operators manual should be consulted and adhered to.
Page 95 For reference only. Operators manual should be consulted and adhered to.
Page 96: Safety Equipment
For reference only. Operators manual should be consulted and adhered to. 7.1 SAFETY EQUIPMENT A. 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.
Page 97: Starting The Engine
For reference only. Operators manual should be consulted and adhered to. 7.2 STARTING THE ENGINE After you do an inspection, start the engine. If the temperature is above 32℉(0℃), use the steps that follow to start the engine: Move the gear selector to the neutral position. ...
Page 98: Cold Weather Starting
If you operate the crane in very low temperature areas, the engine can be hard to start. The optional flame starting device is very important for the normal engine start. Please speak with the Zoomlion Service Department if you select a flame starting device for your crane. 7.5 MOVE AND PARK THE CRANE...
Page 99: Economical Driving
For reference only. Operators manual should be consulted and adhered to. (5) Do not turn the ignition switch to “O” at this time. Stop the engine and keep electrical power applied to the engine for 30 seconds to let the engine data transfer to the ECU.
Page 100: Steering Operation
For reference only. Operators manual should be consulted and adhered to. 7.7 STEERING OPERATION 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.
Page 101: Braking Operation
For reference only. Operators manual should be consulted and adhered to. 7.8 BRAKING OPERATION A. Service Brake When it is necessary to stop the crane, follow these items: Start to apply the service brake in a sufficient amount of time to let you bring the ...
Page 102: Transmission Operation
For reference only. Operators manual should be consulted and adhered to. 7.9 TRANSMISSION OPERATION The transmission is hydraulically driven and power shifted. To step through the gears in the transmission, follow these points: The transmission has two gear range levels: low and high. The low gear range is a ...
Page 103: Towing
For reference only. Operators manual should be consulted and adhered to. 7.10 TOWING Caution When the crane is in-tow, do not make sudden changes in speed. This can damage the tow coupling. Warning If the engine cannot operate, do not tow the crane. To prepare the crane to be towed, do the items that follow: Operate the engine at idle (keeps the transmission oils in motion) ...
Page 104 For reference only. Operators manual should be consulted and adhered to. Figure 07 – 1 Hydraulic Oil Tank Warning You must open the shutoff gate valve before you engage the PTO. You can cause damage the hydraulic system if the valve is closed when you engage the PTO.
Page 105: Outrigger Operation
For reference only. Operators manual should be consulted and adhered to. 7.12 OUTRIGGER OPERATION 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: Figure 07 –...
Page 106 For reference only. Operators manual should be consulted and adhered to. the 2 front (or rear) outrigger switches to the “JACK” position. Push and hold the outrigger extend / retract master switch to the “EXTEND” position. After the 4 outriggers hold the weight of the crane (wheels off the ground), release the master switch.
Page 107 For reference only. Operators manual should be consulted and adhered to. (3) Install and remove the outrigger floats. 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.
Page 108: Hoist Operation
For reference only. Operators manual should be consulted and adhered to. 7.13 HOIST OPERATION The hoist mechanism consists of the hydraulic motor, winch reducer, brake, rope guider, anti-two block system, 3 wrap, hoist rope and main hook and auxiliary hook. The winch mechanism mainly includes two parts - main winch and auxiliary winch.
Page 109 For reference only. Operators manual should be consulted and adhered to. (b) Lift Height Chart. Figure 07 – 6 Lift Height Caution The data in the Lift Height Chart does not include the bend of the main boom. (c) Working Radius. Figure 07 –...
Page 110 For reference only. Operators manual should be consulted and adhered to. Figure 07 – 8 Joystick Locations Note Only when the operator’s seat is occupied and the icon on the display lights up,can the right joystick initiate various movement. (2) If the end of the boom is not directly above the load lift point when you lift a load, do the steps that follow: (a) Push the FREE SWING button.
Page 111 For reference only. Operators manual should be consulted and adhered to. Right joystick Neutral position: stop Move the Move the joystick joystick backward: forward: spool up the reel off the main winch main winch Activate the main winch mechanism Figure 07 – 9 Main Winch - Right Joystick 07 - 16 RT55 Rough Terrain Crane...
Page 112 For reference only. Operators manual should be consulted and adhered to. Auxiliary Winch (1) The left joystick controls the auxiliary winch. Push the joystick forward to reel-off to move the load down. Pull it to the rear to spool-up to move the load up. Note Only when the operator’s seat is occupied and the icon on the display lights...
Page 113 For reference only. Operators manual should be consulted and adhered to. (a) After you complete the movement, move the joystick to the neutral position slowly to stop the movements. (b) The two winches (main and auxiliary) have a speed selector switch. You can set a slow or high speed for the winch movements (reel-off or spool-up).
Page 114 For reference only. Operators manual should be consulted and adhered to. Warning Do not use the bypass key switch when you do usual crane operations. Caution Choose the correct line parts for the boom length and load weights. If  the hook turns because of the rope, put the load on the ground.
Page 115 For reference only. Operators manual should be consulted and adhered to. D. Hoist Line Reeving (1) Before you start to change the wire-rope parts, fully retract the boom and move it to the front of the crane. (2) Change the wire-rope parts as follows: (a) Derrick the boom down to put the hook on the ground.
Page 116 For reference only. Operators manual should be consulted and adhered to. (d) Remove the wedge and socket assembly (beckett). Figure 07 – 14 Even Line Parts Note Dead end the rope on the hook block for an odd number of parts, and on the boom head for an even number of parts.
Page 117 For reference only. Operators manual should be consulted and adhered to. (h) Do not install the wire rope clamp on the live side of the wire rope. Figure 07 – 17 Rope Clamp 07 - 22 RT55 Rough Terrain Crane...
Page 118: Main Boom Extend / Retract Function Operation
For reference only. Operators manual should be consulted and adhered to. 7.14 MAIN BOOM EXTEND / RETRACT FUNCTION OPERATION The boom has four parts to it: a basic boom and three telescopic sections. The basic boom section attaches to the superstructure with a pivot connection. The three telescopic sections move together to increase the length / range of the boom.
Page 119 For reference only. Operators manual should be consulted and adhered to. Operate - extend the boom. (1) Pull the PTO handle up to the engage position. Figure 07 – 19 PTO Handle Engage Position (2) To extend the boom, activate the deadman switch to use this function. Figure 07 –...
Page 120 For reference only. Operators manual should be consulted and adhered to. Derrick boom down.  If you must extend the boom more, use the reel-off function (right joystick forward) to lower the hook block. The crane has a bypass key switch that prevents the warning indications. When the maintenance personnel repair or check out the functions on the crane, they can turn the bypass key switch.
Page 121 For reference only. Operators manual should be consulted and adhered to. Solutions: Make sure that the hydraulic oil temperature does not increase too  high. Extend the boom to the correct length.  Do not extend / retract the boom with a suspended load. ...
Page 122: Boom Derrick Operation
For reference only. Operators manual should be consulted and adhered to. 7.15 BOOM DERRICK OPERATION To move the boom up or down (derricking), hydraulic oil is pumped in or vented out of the derricking cylinder. The boom angle (boom derricking) is adjusted from -3°- 78°, by telescoping derricking cylinder.
Page 123 For reference only. Operators manual should be consulted and adhered to. Warning Do all derricking movements smoothly. You can cause damage to the crane if you move the load up or down with quick stops. You can cause a dangerous condition if you try to lift a heavy load with the boom at a low angle.
Page 124: Swing Operation
For reference only. Operators manual should be consulted and adhered to. 7.16 SWING OPERATION Swing Mechanism The superstructure, which includes the cab, moves around a full 360° range by the swing mechanism. The components that make up the swing mechanism are as follows: Hydraulic Motor ...
Page 125 For reference only. Operators manual should be consulted and adhered to. Caution When you turn the crane, your view to the rear and side can be blocked. Be careful. Make sure that work-site personnel and equipment are clear from the area of travel. Send out a short warning sound (horn) before you move the crane.
Page 126 For reference only. Operators manual should be consulted and adhered to. Make sure that the outriggers are in the correct position and RCI is set  to the proper configuration before you swing the superstructure with a load on the boom. Monitor the area as you move a load.
Page 127: Multifunctions
For reference only. Operators manual should be consulted and adhered to. 7.17 MULTIFUNCTIONS The crane can do two operations or more at the same time. This increases the quantity of work that the crane can do. B. Before you start, make sure that you examine or do the items that follow: The hydraulic system works correctly and gives a sufficient flow for multifunctioning.
Page 128 For reference only. Operators manual should be consulted and adhered to. D. Main Winch + Auxiliary Winch To move the main winch and the auxiliary winch at the same time, move (push and/or pull) the left and right joysticks. The main hook and auxiliary hook move up and/or down. Refer to Figure 07 –...
Page 129 For reference only. Operators manual should be consulted and adhered to. Derrick + Auxiliary Winch You can move the boom up or down and move the auxiliary hook up or down at the same time. To do this, push or pull the left joystick and move the right joystick left or right. Refer to Figure 07 –...
Page 130 For reference only. Operators manual should be consulted and adhered to. H. Swing + Main Winch You can swing the superstructure to the left or right and move the main hook up or down at the same time. To do this, move the left joystick left or right and push or pull the right joystick.
Page 131 For reference only. Operators manual should be consulted and adhered to. Swing + Auxiliary Winch (1) You can swing the superstructure to the left or right and move the auxiliary hook up or down at the same time. For this type of move, it is necessary for the operator to move the joystick two adjacent directions.
Page 132 For reference only. Operators manual should be consulted and adhered to. Note To add a third or fourth multifunction operation, lightly apply the correct controls. If you do another operation, some or all of the crane functions in operation can decrease.
Page 133: Jib Operation
For reference only. Operators manual should be consulted and adhered to. 7.18 JIB OPERATION The crane has a 2-section jib. Section 1 is a lattice structure and section 2 is a box-shaped structure. When the operation does not use the jib, it is installed on the right side of the boom. It connects to boom by pins.
Page 134 For reference only. Operators manual should be consulted and adhered to. (5) Move front of the jib away from the main boom (jib pivots at pin 2). Pin 2 Figure 07 – 39 Pin (2) Location (6) Align the end of the jib with the connection points on the end of the boom. Install the pin (3) and pin (4) and retaining clip.
Page 135 For reference only. Operators manual should be consulted and adhered to. (8) Move the jib (pivots on pin 3 and pin 4) to the front of the main boom. Figure 07 – 42 Move the Jib (9) Align the end of the jib with connection points on the main boom. Install the pin (5) and pin (6) and the retaining clip.
Page 136 For reference only. Operators manual should be consulted and adhered to. (11) Pull out the section 2, and stop when it touches the limit stop. Align the holes and install the pin (7) and the retaining clip. Figure 07 – 45 Pin (7) Installation (12) Reeve the wire-rope from the auxiliary winch through the end of the jib.
Page 137 For reference only. Operators manual should be consulted and adhered to. Change the jib offset from 0° to 20° or 40°. Refer to Figures 07 – 46 and 07 – 47. (1) Fully retract the boom. (2) Make sure that the outriggers are fully extended. (3) Derrick the boom to 0°...
Page 138 For reference only. Operators manual should be consulted and adhered to. Figure 07 – 47 Offset Disassemble the Jib After you complete the jib operation, disassemble the jib in reverse order of the assemble steps. Caution Make sure that the area is clear of personnel and equipment before ...
Page 139 For reference only. Operators manual should be consulted and adhered to. Figure 07 – 49 Use a Stand When you remove the jib, carefully attach it to the side of the boom.  When you remove the auxiliary hook and put it in the stow position, ...
Page 140: Rooster Sheave
For reference only. Operators manual should be consulted and adhered to. 7.19 ROOSTER SHEAVE The components of the rooster sheave are as follows: Bracket   Sheave Spindle   Sheave   Pins.   When it is not necessary to use the rooster sheave, make sure that it is attached to the side of the boom.
Page 141 For reference only. Operators manual should be consulted and adhered to. (d) Reeve the auxiliary wire-rope through the rooster sheave. Install the auxiliary hook and the anti-two block switch. Make sure that all connections are tight. (2) Disassembly When it is not necessary to use the rooster sheave, make sure that it is attached to the side of the boom.
Page 142: Vehicular Operation
For reference only. Operators manual should be consulted and adhered to. 7.20 VEHICULAR OPERATION The Rough Terrain Crane can move off-road and a short distance of on-road travel. Before you move the crane, think about the distance and type of terrain that you must move on.
Page 143 For reference only. Operators manual should be consulted and adhered to. D. Move the Crane to a Job-Site (1) Do the items that follow before you move the crane: (a) Start the engine. (b) Idle the engine for a short interval to let the air pressure increase to the correct level.
Page 144 For reference only. Operators manual should be consulted and adhered to. move the gear selector to a lower gear. This can cause the transmission to go too fast and can cause damage to the drive train. (4) Obey the items in the table. Stop the crane when you are at one of the limits in the table.
Page 145: On Tires" Lifts
For reference only. Operators manual should be consulted and adhered to. Caution You can side move the crane on hard surfaces with a slope less than 15°. When on rough terrain surfaces, the slope angle must not be more than 5°. The boom must in the front, at 0°...
Page 146: Unusual Operating Conditions
For reference only. Operators manual should be consulted and adhered to. 7.22 UNUSUAL OPERATING CONDITIONS You must use caution when you operate in the conditions that follow: Extreme Cold   Extreme Heat   Sandy or Dusty Job-Sites  ...
Page 147 For reference only. Operators manual should be consulted and adhered to. (4) Make sure that the air flow around the engine and battery is not blocked. (5) Keep the engine clean. Dirt, grease and other materials can prevent the heat dissipation.
Page 148 For reference only. Operators manual should be consulted and adhered to.
Page 149 For reference only. Operators manual should be consulted and adhered to.
Page 150: Transportation
For reference only. Operators manual should be consulted and adhered to. 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).
Page 151 For reference only. Operators manual should be consulted and adhered to. (b) Prepare Trailer. Make sure that ramps are in position and the path of travel is clear while you load. (c) Pre-Start Inspection Refer to the Operator’s Manual for a Pre-Start Inspection procedure. (d) Pre-Move Checklist Refer to the Operator’s Manual for a Pre-Move Inspection procedure.
Page 152: Storage
For reference only. Operators manual should be consulted and adhered to. 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.
Page 153 For reference only. Operators manual should be consulted and adhered to.
Page 154 For reference only. Operators manual should be consulted and adhered to.
Page 155 For reference only. Operators manual should be consulted and adhered to.
Page 156: Conversion Tables
For reference only. Operators manual should be consulted and adhered to. 9.1 CONVERSION TABLES Table 09 – 1 Decimal and Metric Equivalents of Fractions of an Inch Fractions of Decimals of Fractions of Decimals of Millimeters Millimeters an inch an inch an inch an inch 1/64...
Page 157 For reference only. Operators manual should be consulted and adhered to. Table 09 – 2 Liquid Weights and Measures Table 09 – 3 Metric Equivalents 09 - 2 RT55 Rough Terrain Crane...
Page 158: Average Weight Of Materials
For reference only. Operators manual should be consulted and adhered to. 9.2 AVERAGE WEIGHT OF MATERIALS Average Weight Of Materials (Kilogram Per Cubic Meter) METALS, ALLOYS, ORES EARTH Aluminum, cast-hammered 2675.31 Clay, dry 1021.482 Brass, cast-rolled 8658.276 Clay, damp, plastic 1783.54 Bronze 8252.926...
Page 159 For reference only. Operators manual should be consulted and adhered to. WOOD MISCELLANEOUS Cedar 356.708 Water, 4°C 1011.7536 Fir, Douglas 518.848 Water, 100°C 969.5972 680.988 - 875.556 Paper 940.412 Pine, Oregon 518.848 Glass, common 2626.668 Pine, southern 616.132 - 680.988 Petroleum 729.63 -875.556 Spruce...
Page 160: Torque Values
For reference only. Operators manual should be consulted and adhered to. 9.3 TORQUE VALUES Table 09 – 4 Torque Values for Dry – Uncoated Fasteners Torque Values to be within ± 5% All Figures in N·m Note This table does not apply to hydraulic connections. Normal Grade 5.6 Grade 8.8...
Page 161: Technical Specifications
For reference only. Operators manual should be consulted and adhered to. 9.4 TECHNICAL SPECIFICATIONS RT55 rough terrain crane has the qualities below: Wide Tread  Short Wheelbase  Very Stable  Small Turn Radius  360° Swing Movement.  It can do “On Tires” lifts in areas where there is a small area of space for movement and can lift and move loads.
Page 162 For reference only. Operators manual should be consulted and adhered to. Characteristics: (1) Four steering modes: 2-wheel steer (front wheel), 2-wheel steer (rear wheel), 4-wheel steer and Crab steer (2) Max. rated lift capacity: 60.6 tn at 9.8 ft. (55 t at 3 m) radius (3) Max.
Page 163 For reference only. Operators manual should be consulted and adhered to. Figure 09 – 1 Overall View – RT55 Rough Terrain Crane 09 - 8 RT55 Rough Terrain Crane...
Page 164 For reference only. Operators manual should be consulted and adhered to. Table 09 – 5 Main Technical Data Ser. Type Item Unit Value lb×ft 121254×9.8 Max. rated lift capacity× work radius kg×m 55000×3.0 lbf.ft 1451056 Max. load moment of basic boom kN·m 1967 Work...
Page 165 For reference only. Operators manual should be consulted and adhered to. Ser. Type Item Unit Value Max. travel speed 24.23 Travel km/h (Forwards/backwards) Wheelbase 3950 Treads (Front/ rear) 2605 Max. gradeability 09 - 10 RT55 Rough Terrain Crane...
Page 166 For reference only. Operators manual should be consulted and adhered to. SPECIFICATIONS, UPPERSTRUCTURE Main boom and extend / retract mechanism (1) The main boom 4 box-shape and hexagon boom sections made of high strength steel. (2) The main boom head has 5 sheaves. You do not have to remove wedges when you change line parts.
Page 167 For reference only. Operators manual should be consulted and adhered to. (2) Wire-rope Torsion resistant hoist rope Max. hoist rope strength: 15737 lbf (70 kN) Max. hoist rope speed: 492 ft/min (150 m/min) (At the 4 layer) Rope diameter: Φ 0.75 in (Φ19 mm) Rope length: 607 ft (185 m) (3) Hook block...
Page 168 For reference only. Operators manual should be consulted and adhered to. The other supplies oil for the below uses: Outriggers 　  Swing Mechanism 　  Steering System 　  Optional Equipment (such as air conditioning)  (2) Control valve Quadruple pilot-operated proportional valve, with adjustable relief valve.
Page 169 For reference only. Operators manual should be consulted and adhered to. (4) There are two joystick control boxes on either side of operator seat. The left side control box pivots up to allow for easy entry / egress from the cab. The controls of the superstructure are set to agree with ASME B30.5-2007 standard and with ISO (International Organization for Standardization) standards.
Page 170 For reference only. Operators manual should be consulted and adhered to. outriggers attach safely while you do the work and move. (3) Outrigger boxes are directly welded onto the crane chassis. (4) You can fully and intermediately extend and fully retract the outriggers for crane operation.
Page 171 For reference only. Operators manual should be consulted and adhered to. SPECIFICATIONS - SPECIAL PURPOSE CHASSIS FOR ROUGH TERRAIN CRANE Type (1) Rear-mounted engine, left-hand drive type (2) Drive mode: 4 x 2 and 4 x 4 B. Chassis Frame High-tensile steel, welded integral box-type construction C.
Page 172 For reference only. Operators manual should be consulted and adhered to. 4-wheel steer – all-wheel steer (all wheels turn at the same angle) 4-wheel steer – crab steer (front and back wheels turn in opposite directions). G. Suspension system (1) Front axle: rigidly mounted to the crane chassis (2) Rear axle: Oscillation automatically locks if superstructure is swung more than 3 degrees past boom over the front.
Page 173 For reference only. Operators manual should be consulted and adhered to. SAFETY DEVICES Rated Capacity Indicator (RCI)  Rotating Beacon and Horn  Anti-Two Block Devices  Wrap  Balance Valve  Hydraulic Lock  Hydraulic Safety Valve  Swing Brake ...

Zoomlion RT65 Operator's Manual

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