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Zoomlion ZS1623RT Operation And Safety Manual

Self-propelled rough-terrain scissor lifts
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Zoomlion Heavy Industry Science&Technology Co.Ltd.
Add:ZOOMLION Wangcheng Industrial Park,Tengfei Road 997,
Wangcheng District,Changsha,Hunan,PRC.
Email:awm@zoomlion.com
Use Wechat to scan the above QR code for Zoomlion product information.
Copyright 2015 Zoomlion Heavy Industry Co., Ltd. All rights reserved. Without the written permission of Zoomlion Heavy Industry Science & Technology Co., Ltd.. This sample may be copied for any purpose.
Zip Code:410013
Mobile:400-800-0157
Self-Propelled Rough-Terrain Scissor Lifts
Operation and Safety Manual
ZOOMLION

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  • Page 1 Use Wechat to scan the above QR code for Zoomlion product information. Copyright 2015 Zoomlion Heavy Industry Co., Ltd. All rights reserved. Without the written permission of Zoomlion Heavy Industry Science & Technology Co., Ltd.. This sample may be copied for any purpose.
  • Page 2 Operation and Safety Manual ZOOMLION ZS1623RT Operation and Safety Manual April 2020 Version A...

  • Page 4: Foreword

    Foreword Zoomlion appreciates your choice of our machine for your application. The Operation and Safety Manual must be read and understood in its entirety before operating the machine. This manual introduces you safety information, significant technical specs, safety operation in detail for working efficiency improving.

  • Page 5: Safety Precaution Icon

    Safety Precaution Icons This manual has the following safety precaution icons: Failure to comply with the safety precautions listed in this manual could result in personal injury or death. Failure to comply with the safety precautions listed in this manual could result in potential personal injury or death.

  • Page 6: Table Of Contents

    Contents Foreword ............................. I Safety Precaution Icon ......................II Contents ............................ III SECTION 1 Safety Precautions ..................... 1-1 1.1 General..........................1-1 1.2 Pre-operation ........................1-1 1.3 Hazard Classification ......................1-2 1.4 Intended Use ........................1-2 1.5 Safety Alert Symbols and Maintenance ................1-2 1.6 Safety Operation ........................

  • Page 7: Contents

    Contents 3.2 Function Test ........................3-3 3.2.1 Function test fundamentals ................3-3 3.2.2 Turn on the Power Switch................. 3-3 3.2.3 Ground function test ..................3-3 3.2.4 At the platform controls ..................3-5 3.2.5 Turn off the main power switch ................. 3-8 3.3 Workplace Inspection ......................
  • Page 8 Contents 4.9.2 How to fold guard ..................... 4-7 4.9.3 How to raise guard ................... 4-8 4.9.4 Operation after usage ..................4-9 4.10 Transport and Lift ......................4-9 4.10.1 Observe and obey ..................4-9 4.10.2 Transport......................4-9 4.10.3 Lift ......................... 4-11 SECTION 5 Maintenance .......................
  • Page 9 Contents 5.6.4 Hydraulic Oil Viscosity and Temperature Limit ..........5-13 5.6.5 Hydraulic oil replacement ................5-13 5.7 Starting Steps ........................5-14 5.7.1 Drive pump oiling .................... 5-14 5.7.2 Exhaust air from the pump's inlet oil line ............5-14 SECTION 6 Storage And Ex-Factory Test ................6-1 6.1 Storage Conditions ......................
  • Page 10 履带起重机操作手册 第一章 安全操作说明...

  • Page 12: Section 1 Safety Precautions

    1.1 General To Owners/Users/Operators: Zoomlion appreciates your choice of our machine for your application. Our number one priority is user safety, which is best achieved by our joint efforts. The following requirements need to be adhere to for the purpose of safety operating: Obey all user rules, job site regulations and governmental regulations.

  • Page 13: Hazard Classification

    1.3 Hazard Classification Decals on this machine use symbols, color coding, and signal words to identify the following: Safety alert symbol—used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
  • Page 14 Read operational Read service manual Crushing hazard Crushing hazard Collision hazard manual Electrocution Tip-over hazard Tip-over hazard Tip-over hazard Tip-over hazard hazard Electrocution Explosion hazard Fire hazard Burn hazard Dermohemia hazard hazard Keep clear of Keep away from Move machine to Engage safety arm outriggers and Close chassis tray...
  • Page 15 Batteries used as 3-wire grounded AC Replace damaged Chock the wheels Release brakes counterweights power supply only wire and cable Transporting Lanyard anchorage Wheel load Tie-down points No smoking diagram points Voltage rating for Pressure rating for Manual force Wind speed power to platform air line to platform Maximum capacity...

  • Page 16: Safety Operation

    1.6 Safety Operation 1.6.1 Operator safety Personal fall protection equipment (PFPE) is required when operating this machine. If PFPE is required in job site or in operator's manual, following rules should be complied with: all PFPE must comply with applicable governmental regulations, and must be inspected and used in accordance with the PFPE manufacturer’s instructions.

  • Page 17: Tip-Over Hazard

    Do not operate the machine during lightning or storms. Do not use the machine as a ground for welding. 1.6.2.2 Tip-over hazard Occupants, equipment and materials shall not exceed the maximum platform capacity. Table 1-2 Rated Load Capacity on Platform Model Maximum Capacity Extended ZS1623RT 680kg/1500lbs 230kg/510 lbs...
  • Page 18 12.5 m/s (28 mph ). Indoor use: do not exceed the rated values of allowable manual force and maximum occupants listed in Table 1-3. Table 1-3 Maximum allowable manual force Model Manual force Maximum occupants ZS1623RT 400N/90 lbs force...
  • Page 19 Do not operate the machine in strong or gusty winds. Do not increase the surface area of the platform or the load. Increasing the area exposed to the wind will decrease machine stability. Use extreme care and slow speeds while driving the machine in the stowed position across uneven terrain, debris, unstable or slippery surfaces and nearholes and drop-offs.

  • Page 20: Crush Hazard

    Do not modify or alter an aerial work platform without prior written permission from the manufacture. Do not alter or disable the limit switches. Do not alter or disable machine components that in any way affect safety and stability. Do not replace items critical to machine stability with items of different weight or specification. Mounting attachments for holding tools or other materials onto the platform, toeboards, or guard rail system can increase the weight in the platform and the surface area of the platform or the load.
  • Page 21 Table 1-4 Rated slope in stowed position Maximum Slope Rating in Maximum Side Slope Rating Model Stowed Position in Stowed Position ZS1623RT 40% (22° ) 40% (22° ) 1-10...

  • Page 22: Fall Off Hazard

    1.6.2.5 Fall off hazard The guard rails system provides fall protection. If occupant(s) of the platform are required to wear personal fall protection equipment (PFPE) due to job site or employer rules, PFPE and its use shall be in accordance with the PFPE manufacturer's instructions and applicable governmental requirements. Use approved lanyard attachment point provided.

  • Page 23: Collision Hazard

    1.6.2.6 Collision hazard No stunt driving or horseplay while operating a machine. Be aware of limited sight distance and blind spots when driving and operating. Be aware of extended platform position when moving the machine. Be sure the machine is on a level surface or secured before releasing the brake. Operators must comply with employer, job site, and governmental rules regarding use of personal protective equipment.

  • Page 24: Burn Hazard

    Limit travel speed according to the condition of the ground surface, congestion, slope, location of personnel, and any other factors which may cause collision. Do not operate a machine in the path of any crane or moving overhead machinery unless the controls of the crane have been locked out and/or precautions have been taken to prevent any potential collision.

  • Page 25: Explosion And Fire Hazard

    Electric shock or burn hazard. Conduct daily check with wires and cables. Change damaged items prior to operation. Avoid contact with battery terminals. Remove all rings, watches and jewelry. Connect the battery charger to a grounded, AC 3-wire electrical outlet only. 1.6.2.8 Explosion and fire hazard Do not operate the machine or charge the battery in hazardous locations or locations where potentially flammable or explosive gases or particles may be present.

  • Page 26: Machine Damage Hazard

    Immediately tag and remove from service a damaged or malfunctioning machine. Be sure all maintenance has been performed as specified in this manual and the appropriate Zoomlion service manual. Be sure all decals are in place and legible.

  • Page 30: Section 2 Machine Components And Controls

    SECTION 2 MACHINE COMPONENTS AND CONTROLS 2.1 Machine Components ZS1623RT Figure 2-1 Components 1 Table 2-1 Component Instruction 1 Item Item Item Platform Console Fixed platform Non-steering tire Manual Storage Scissor arm Steering tire Container Fuel tank (behind the Platform extension...

  • Page 31: Machine Controller

    2.2 Machine Controller The manufacturer has no direct control over machine application and operation. The user and operator are responsible for conforming with good safety practices. 2.2.1 Ground controller Figure 2-2 Ground Control Panel Table 2-2 Ground Control Panel Instruction Item Item Key select switch...
  • Page 32 Overload indicator When the platform is overloaded, indicator lights up. Engine start button Press this button to start engine. Engine preheat button Press this button to active engine glow plug to help start the engine in cold conditions. Key switch. Turn the switch to the platform position and the platform controls will operate.

  • Page 33: Platform Control Unit (Pcu)

    2.2.2 Platform control unit (PCU) Figure 2-5 Platform Control Panel Table 2-5 Platform control panel instruction Item Item Outrigger enable button with indicator Drive function switch Outrigger automatic leveling button Function enable switch Thumb rocker type switch for Light steering Horn button Proportional control handle Engine idle speed select button with...
  • Page 34 Horn button. Press the horn button and the horn will sound. Release the horn button and the horn will not sound. Outrigger enable button with indicator Press the button to activate outrigger up/down function. Outrigger automatic leveling button Press the button to start engine. Engine start button Press the button to start engine.
  • Page 35 panel and the machine will move in the direction that the blue arrow points. Move the control handle in the direction indicated by the yellow arrow on the control panel and the machine will move in the direction that the yellow arrow points. Function enable switch Lift function: press and hold the function enable switch to enable the lift function on the platform control handle.

  • Page 38: Section 3 Machine Inspection

    SECTION 3 MACHINE INSPECTION 3.1 General An operator must not operate the machine, only if: He has learned and practiced the principled of safe machine operation contained in this operational manual. Avoid hazardous situation. Perform a pre-operation inspection at all times. Know and understand the pre-operation inspection before going on to the next section.
  • Page 39 Check for engine coolant leak and proper liquid level. Add coolant if needed. See Maintenance section. Check the following components or areas for damage, improperly installed, or missing parts and unauthorized modification: Electrical components, wiring, and electrical cables. Hydraulic hoses, fittings, cylinders, manifolds. Drive motors.

  • Page 40: Function Test

    3.2 Function Test 3.2.1 Function test fundamentals The function tests are designed to discover any malfunctions before the machine is put into service. The operator must follow the step-by-step instructions to test all machine functions. A malfunctioning machine must never be used. If malfunctions are discovered, the machine must be tagged and removed from service.
  • Page 41 Start engine. See Operation Instruction section. Test emergency stop Push in the ground red Emergency Stop Button to off position. Result: engine turns off. No function should operate. Pull out the red Emergency Stop Button to the on position, and restart engine.. Test the Up/Down functions.

  • Page 42: At The Platform Controls

    3.2.4 At the platform controls Test emergency stop. Push in the platform red Emergency Stop Button to the off position. Result: no function should operate. Result: no function should operate. Pull out the Red Emergency Stop button to on position. Test the horn.
  • Page 43 Slowly move the control handle in the direction indicated by the blue arrow, then in the direction indicated by the yellow arrow. Result: no function should operate. Test the steering. Caution: When performing the steer and drive function tests, stand in the platform facing the steer end of the machine.
  • Page 44 Test the tilt sensor operation. Note: Perform this test with the platform controller on the ground. Don't stand inside the platform. Fully lower the platform. Move the machine to an inclined surface that exceeds the maximum tilt angle allowed by the level sensor (see the nameplate), but the inclined angle does not exceed 5 °...

  • Page 45: Turn Off The Main Power Switch

    Pull out the red Emergency Stop button to on position. Press the function enable switch on control handle. Slowly move the handle in the direction indicated by the yellow arrow. Result: Platform should lower. Test the swinging system Caution: Implement this test on ground with platform controller. Do not stand in the platform. Start the engine with platform controller.

  • Page 46: Workplace Inspection

    3.3 Workplace Inspection An operator must not operate the machine, only if: He has learned and practiced the principles of safe machine operation contained in this operational manual. Avoid hazardous situations. Perform a pre-operation inspection at all times. Implement functional test before operation the machine at all times. Inspect job site.

  • Page 47: Decals Inspection

    Use the lists and pictures below to verify that all decals are legible and in place. Table 3-1 Decal 1（ZS1621RT） Code Item 00775607000401090 Danger- Crushing Hazard 00775807000201120 Label- ZOOMLION Logo Label- Lifting 00773407000201430 00775807000201080 Label- Forward 00775807000201030 Label- Outrigger Load...
  • Page 48 Figure 3-1 Decal Position 1（ZS1623RT） 3-11...
  • Page 49 Table 3-2 Decal 2（ZS1623RT） Code Item 00775607000401090 Danger- Crushing Hazard 00775807000201120 Label- ZOOMLION LOGO 00775607000401080 Label- Safety Arm 00773407000201420 Label- Tie Down 00773407000201430 Label- Lifting 00775807000201030 Label- Outrigger Load 00775807000201040 Label- Away from Outrigger 00775807000401010 Label- Wheel Load 00773407000201010 Label- ZOOMLION_70Logo 00775807000201050 Label- 4×...
  • Page 50 Figure 3-2 Decal Position 2（ZS1623RT） 3-13...

  • Page 54: Section 4 Operation Instruction

    SECTION 4 OPERATION INSTRUCTION 4.1 General An operator must not operate the machine, only if: He has learned and practiced the principles of safe machine operation contained in this operational manual. Avoid hazardous situations. Perform a pre-operation inspection at all times. Implement functional test before operating the machine at all times.

  • Page 55: Emergency Stop

    4.2.2 Emergency stop Push in the red Emergency Stop button to the off position at the electronic controls or the platform controls to stop all functions, and turn off the engine. Repair any function that operates when Power Switch and red Emergency Stop button are pushed in.
  • Page 56 Adjust platform position Press the lift function enable button. On the LCD screen, a circle below the lift function symbol will turn on. If the control handle is not moved within seven seconds of pushing the lift button, the circle below the lift function symbol will turn off and lift function will not operate.

  • Page 57: Operation On Slope

    Press and hold function enable switch on handle. Increase speed: slowly move the control handle off center. Decrease speed: slowly move the control handle toward center. Stop: return the control handle to center or release the function enable switch. Use the color-coded direction arrows on the platform controls and on the platform to identify the direction the machine will travel.
  • Page 58 Table 4-1 Slope rating Maximum side slope rating, stowed position ZS1623RT 22° Table 4-2 Side slope rating Maximum side slope rating, stowed position ZS1623RT 22° Slope rating is limited by ground conditions and traction. Press the drive speed button to the fast drive speed mode.

  • Page 59: Operating On A Slope

    Max slope rated rating Max side slope rated rating 2° ZS1623RT 3° If the slope exceeds the maximum slope or side slope rating, tilt alarm will sound, then the platform must be lowered carefully. Move the machine to a firm, level surface before lifting.

  • Page 60: Control A Single Outrigger

    LL Off-Level. OL Overload. CH Chassis Mode Operation. 18 Pothole Guard Fault. 37 Battery Exhausted. Refer to Zoomlion Maintenance manual for further information. A code and a description of a code can also be viewed at the electronic controls LCD display.

  • Page 61: Platform Overload

    4.8.2 Platform overload If the platform controller LED diagnostic readout displays OL, and the electronic controller LCD diagnostic readout displays OL as well, it indicates platform overloaded, all functions will stop. Alarm will sound. Press the red Emergency Stop button to off position. Remove load from platform.

  • Page 62: Operation After Usage

    The transport vehicle must be secured to prevent rolling while the machine is being loaded. Be sure the vehicle capacity, loading surfaces and chains or straps are sufficient to withstand the machine weight. ZOOMLION lifts are very heavy relative to their size. See the serial label for the machine weight.
  • Page 63 Pull out the red Emergency Button at both the ground and platform controls to the on position. Press and hold the drive/steer function enable switch on the control handle. Move the control handle off center and immediately release it to reset the brakes. Push the red Emergency Stop button at both ground and platform controls to the off position.

  • Page 64: Lift

    4.10.3 Lift Observe and Obey: Only qualified riggers should rig and lift the machine. Only qualified forklift operators should lift the machine with a forklift. Be sure the crane capacity, loading surfaces and straps or lines are sufficient to withstand the machine weight.
  • Page 65 Table 4-4 Center of gravity Model X Axis Y Axis ZS1623RT 1.5m/4ft 10in 0.95 m/3ft 1in Figure 4-2 Center of gravity 4-12...

  • Page 68: Section 5 Maintenance

    Disposal of materials should be according to the regulations of government and relevant environmental protection administration. Use only ZOOMLION approved replacement parts. ZOOMLION assumes no responsibility for hazards occurred to equipment and personnel caused by the use of unauthorized parts.

  • Page 69: Maintenance Hazard

    Limit switches and horn. Alarm and indicator (if equipped). Nuts, bolts and other fasteners. Brake release unit. 5.1.3 Maintenance Hazard Shut off power to all controls and ensure that all moving parts are secured from inadvertent motion prior to performing any adjustments or repairs. Never work under an elevated platform until it has been fully lowered to stowed position, if possible, or otherwise supported and restrained from movement with appropriate safety props, blocking, or overhead supports.

  • Page 70: Power System Maintenance

    5.2 Power System Maintenance 5.2.1 Engine oil level Maintaining the engine oil at the proper level is essential to machine operation. Improper oil levels can damage engine components. Note: Check engine oil level after engine turns off. Check oil level indicator, and add oil as needed. Do not overfill.

  • Page 71: Engine Coolant Level Inspection

    5.2.3 Engine coolant level inspection Maintain the engine coolant at the proper level is essential to engine lifespan. Improper coolant level can damage the engine cooling ability and engine components. Daily checks allow the inspector to identify changes in oil level that might indicate the presence of cooling system problems. Burn Hazard Mind hot engine components and coolant.

  • Page 72: Battery Maintenance

    5.3 Battery Maintenance Battery inspection Proper battery condition is essential to good machine performance and operational safety. Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions. This inspection is not required for machines with sealed or non-maintainable batteries. Check electrolyte level of the battery every two weeks.

  • Page 73: Hydraulic Reservoir

    5.4.1 Hydraulic reservoir Capacity- 65-80L/17-21 us gal Interval- Check level daily; change every year or 2000 hours of operation. Note：On machines which are new, those recently overhauled , or after changing hydraulic oil, operate all system a minimum of two complete cycles and recheck oil level in reservoir. A.

  • Page 74: Replace Engine Oil

    Omni 5.4.3 Replace engine oil - Deutz 2.9 L4/ Cummins QSF 2.8/ Kohler KDI2504 Kubota Figure 5-7 Engine oil port Maintenance point - Oil adding port/rotary fixed element Capacity - 10L/2.6 us gal Lubricating oil - Engine oil Interval - Every half a year or 500 hrs of operation Note - Check oil level everyday/replace it according to engine manual 5.4.4 Fuel filter - Kubota V2403-M-DI A.

  • Page 75: High Pressure Filter

    Maintenance point - Replaceable filter Interval - Check drain off water everyday, and change it every half a year or 500 hrs of operation B.Second class fuel filter Kubota Figure 5-9 Second class fuel filter Maintenance point - Replaceable filter Interval - Every half a year or 500 hrs of operation Maintenance point - Replaceable filter Interval - Check drain off water everyday, and change it every half a year or 300 hrs of operation...

  • Page 76: Engine Coolant

    ZOOMLION recommends a replacement tire be the same size, play and brand as originally installed on the machine. Please refer to the ZOOMLION Parts Manual for the part number of the approved tires for a particular machine model. If not using a ZOOMLION approved replacement tire, we recommend that replacement tires have the following characteristics: Equal or greater ply/load rating and size of original;...

  • Page 77: Wheel Installation

    regarding stability. 5.5.3 Wheel installation It is extremely important to apply and maintain proper wheel mounting torque. Wheel nuts must be installed and maintained at the proper torque to prevent loose wheels, broken studs, and possible dangerous separation of wheel from the axle. Be sure to use only the nuts matched to the cone angle of the wheel.

  • Page 78: Hydraulic System Maintenance

    DO NOT mix oils of different brands or types, as they contain different additives which may cause negative effects. If mixing of hydraulic oils is unavoidable, permission must be obtained from the hydraulic oil manufacturer. After-sales service of ZOOMLION does not cover machine malfunction caused by hydraulic oil mixing.
  • Page 79 Table 5-4 Technical Parameters of Hydraulic Oil kinematic Technical Pour Flash viscosity Viscosity Parameters Viscosity Point Point cSt(40℃ index ℃/℉ ℃/℉ Type Grade /104℉) Great Wall 4632 grease non- flammable hydraulic oil N32 28.8-35.2 (Eco-Friendly) Great Wall Ground NO.10 10.53(50℃ —...

  • Page 80: Hydraulic Oil Viscosity And Temperature Limit

    Mobil SHC Aware H 32 30/-22 185/365 （Eco-Friendly) Clarity Synthetic EA 44/-47 221/430 Hydraulic Oil 54/-65 224/435 Mobil DTE 10 Ultra 22 22.4 54/-65 250/482 Mobil DTE 10 Ultra 32 32.7 45/-49 232/450 Mobil DTE 10 Ultra 46 45.6 Chevron/CaltexRando 60/-76 150/302 15.7...

  • Page 81: Hydraulic Oil Replacement

    5.6.5 Hydraulic oil replacement We suggest that changing time of the hydraulic oil is as follows: First changing: operating for 500 hrs after commissioning. Second and subsequent changing: every 2,000 hrs of operation or once a year. The above recommended intervals are suitable for most applications. Higher temperatures and pressures will shorten the oil's service life, so the hydraulic oil should be changed sooner than the recommended.
  • Page 82 If installation of new function pump is required, step a and b should be conducted. If the oil does not drain off from the pipeline, the installation of new function pump which is connected to the inlet pipeline will generate a large amount of vacuum, as such, there is no need to implement step b.

  • Page 86: Section 6 Storage And Ex-Factory Test

    /104℉, with relative humidity not greater than 85% and 100% only for short-term. 6.2 Ex-factory Test Items Machine must complete testing items in the following table before delivery: Table 6-1 Ex-factory test item (ZS1623RT) Tests Items Load Testing Testing Movement...

  • Page 90: Section 7 Technical Parameter

    SECTION 7 TECHNICAL PARAMETER Table 7-1 ZS1623RT Technical Parameter Model ZS1623RT Parameters Work Height 16 m 52ft 6in Platform Length 3.98 m 13ft 1in Platform Width 1.83 m Extension deck Front/rear 1.3m Front/rear 4ft 3in Max Height (Stowed position) 3.15m...
  • Page 91 Table 7-1 ZS1623RT Technical Parameter Model ZS1623RT Parameters Max wind speed 12.5m/s (grade 6) 28 mph Lowest Operating Temperature -25° C -13℉ Working Environment Highest Ambient Temperature 40° C 104℉ Guaranteed Sound Power Level 100dBA Gross 8650 kg 19070lbs Power...
  • Page 92 Appendix:Inspection and Maintenance Records Date record...
  • Page 93 Appendix:Inspection and Maintenance Records Date record...

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