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Zoomlion ZA10RJE Operation And Safety Manual

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ZOOMLION INTELLIGENT ACCESS MACHINERY CO.,LTD.
Add:Tengfei Road 997, Wangcheng District, Changsha, Hunan,PRC
E-mail:awm@zoomlion.com
Open up the WeChat, Scan the QR code above; All rights reserved 2015 © Zoomlion,reserves all rights,Without the written permission of Zoomlion, the contents of any part of this sample may not be copied for any purpose.
Zip Code:410200
Tel:400-800-0157
ZA10RJE
Operation and Safety Manual

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  • Page 1 Add:Tengfei Road 997, Wangcheng District, Changsha, Hunan,PRC E-mail:awm@zoomlion.com Tel:400-800-0157 Open up the WeChat, Scan the QR code above; All rights reserved 2015 © Zoomlion,reserves all rights,Without the written permission of Zoomlion, the contents of any part of this sample may not be copied for any purpose.
  • Page 3 Operation and Safety Manual ZA10RJE Operation and Safety Manual 2021.03 A...
  • Page 5 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 6 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. Failure to comply with the safety precautions listed in this manual could result in potential mild personal injury.

  • Page 7: Table Of Contents

    Foreword ............................I Safety Precaution Icons ........................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 8 SECTION 4 OPERATION INSTRUCTION ................4-1 4.1 General ............................4-1 4.2 Machine Operation ........................4-1 4.2.1 Drive operation ......................4-1 4.2.2 Platform leveling ..................... 4-3 4.2.3 Platform rotating ..................... 4-3 4.2.4 Turntable slewing ....................4-3 4.2.5 Upper boom lift ....................... 4-4 4.2.6 Telescoping the upper boom ..................
  • Page 9 SECTION 6 STORAGE AND EX-FACTORY TEST ..............6-1 6.1 Storage Conditions ........................6-1 6.2 Ex-factory Test Items ........................ 6-1 SECTION 7 TECHNICAL PARAMETER ................. 7-1...
  • Page 11 履带起重机操作手册 第一章 安全操作说明...

  • Page 13: 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 14: 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 15 Read operational Read service Fire hazard No smoking Explosion hazard manual manual Maintain required Electrocution hazard Burn hazard Prohibit Step on Avoid contact clearance Electrocution hazard Tip-over hazard Tip-over hazard Tip-over hazard Tip-over hazard Lanyard anchorage Wheel load Wind speed Maximum capacity Tie-down point points...
  • Page 16 No smoking. Runaway hazard Fall Hazards Tire disassembly Explosion hazard No flame. Stop engine. Trained and authorized Stop engine. Prohibit Lifting Lifting point Avoid contact personnel operate the machine only Recovery procedure if tilt alarm sounds while elevated Platform uphill: Platform downhill: 1.

  • Page 17: Safety Operation

    1.6 Safety Operation 1.6.1 Operator safety Personal Fall Protection Personal fall protection equipment (PFPE) is required when operating this machine. If PFPE is required in job site or in operator's manual, the following rule 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 18 Keep away from the machine if it contacts energized power lines. Personnel on the ground or in the platform must not touch or operate the machine until energized power lines are shut off. Do not operate the machine during lightning or storms. Do not use the machine as a ground for welding.
  • Page 19 machine is on a severe slope. If the tilt alarm sounds when the platform is raised, use extreme caution. Identify the condition of the boom on the slope as shown below. Follow the steps to lower the boom before moving to a firm, level surface.
  • Page 20 Use extreme care and slow speeds while driving the machine in the stowed position across uneven terrain, debris, unstable or slippery surfaces and near holes and drop-offs; Do not drive the machine on or near uneven terrain, unstable surfaces or other hazardous conditions with the boom raised or extended;...
  • Page 21 Table 1-4 Maximum allowable manual force Model Manual force Maximum occupants ZA10RJE 400 N Do not place or attach fixed or overhanging loads to any part of this machine; Do not place ladders or scaffolds in the platform or against any part of this machine;...
  • Page 22 Fall Hazards Occupants must wear a safety belt or harness in accordance with governmental regulations. Attach the lanyard to the anchor provided in the platform; Do not sit, stand or climb on the platform guard rails. Maintain a firm footing on the platform floor at all times;...
  • Page 23 Collision Hazard Be aware of limited sight distance and blind spots when driving and operating; Check the work area for overhead obstructions or other possible hazards; Be aware of crushing hazards when grasping the platform guard rail; Be aware of the boom position and tail swing when rotating the turntable; Operators must comply with employer, job site, and governmental rules regarding use of personal protective equipment.
  • Page 24 Do not lower the boom unless the area below is clear of personnel and obstructions. Limit travel speed according to the condition of the ground surface, congestion, slope, location of personnel, and any other factors which may cause collision. Observe and use the color-coded direction arrows on the platform controls and drive chassis for drive and steer functions.
  • Page 25 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; Be sure operator's safety, and responsibilities manuals are complete, legible, and in the storage container located on the machine.
  • Page 26 Battery Safety Burn hazard Batteries contain acid. Always wear protective clothing and eye wear when working with batteries; Avoid spilling or contacting battery acid, Neutralize battery acid spills with baking soda and water; Do not expose the battery or charger in water or rain while charging. Explosion Hazard Keep sparks, flames, and lighted tobacco away from batteries.

  • Page 29: Section 2 Machine Components And Controls

    SECTION 2 MACHINE COMPONENTS AND CONTROLS 2.1 Machine Components Figure 2-1 Components 1 Table 2-1 Component Instruction Name Name Foot Switch Main Boom (Upper Boom) Manual Storage Container Tower Boom Sliding Mid-Rail Ground Control Console Lanyard Anchorage Points Steering Tire Non-Steering Tire Work Platform Battery Box...

  • Page 30: Machine Controls And Indicators

    2.2 Machine Controls and Indicators The manufacturer had no direct control over machine application and operation. The user and operator are responsible for conforming with good safety practices. 2.2.1 Ground Control Console Boom lift, Boom extend/retract, Tower boom lift, Turntable swing, Jib lift, platform leveling, platform rotating device and auxiliary control device both equip with spring so that they will back to neutral when releasing;...
  • Page 31 Table 2-2 Ground Control Panel Instruction Name Turntable slew switch Main boom lift switch Tower boom lift switch Main boom telescope switch Jib lift switch Platform rotate switch Platform leveling switch Power/Emergency stop switch Platform/Ground Select Switch Function Enable Switch Display Jib rotate switch Turntable slew switch...
  • Page 32 Jib lift switch (if equipped) Provide raising and lowering of the jib. Platform rotate switch Provides platform rotate controls. Only use the platform leveling override function for slight leveling of the platform when platform is lowered. incorrect use could cause the load/occupants to shift or fall. failure to do so could result in death or serious injury.

  • Page 33: Ground Control Indicator Panel

    To use auxiliary power, operate a single action only. (Compound operation is beyond the capacity of auxiliary pump motor) 10) Function Enable Switch When the engine is running, the switch must be held "DOWN" to enable all boom controls. 11) Display Display shows fault conditions, function parameters, parameter modification and machine information.
  • Page 34 The function classification is as shown below: Figure 2-4 No.1 indicates title; No.2 indicates fault code; No.3 indicates dynamic parameter monitor;No.4 indicates status indicator, stowed position and work station. When the articulating boom lift is in stowed position with no fault code, the interface is as shown below: Figure 2-5...
  • Page 35 When the articulating boom lift is in working position with no fault code, the interface is as shown below: Figure 2-6 When the system alarm occurs, the fault codes are displayed in a scrolling manner as shown below: among them, the fault code display column 22051 is the fault code, you can refer to the fault code table to find the corresponding troubleshooting.

  • Page 36: Platform Control Console

    When certain states occur, the status indicator lights up and flashes; When the specific state is released, the turntable indicator light returns to gray, as shown in the following figure: Figure 2-8 2.2.3 Platform Control Console Avoid serious injury, do not operate machine if any control levers or toggle switches controlling platform movement do not return to the off or neutral position when released.
  • Page 37 Table 2-3 Platform control panel instruction Item Work light switch Drive direction confirm switch Drive select switch Horn switch Power/Emergency stop switch Platform leveling switch Drive/Steer joystick Upper boom telescope switch Tower boom lifting switch Jib rotate switch Jib lift switch Platform rotate switch Upper boom lift/Swing Controller Avoid serious injury, do not operate machine if any control levers or toggle switches controlling...
  • Page 38 Power/Emergency stop switch Push in the platform red Emergency Stop button to the off position; Power is shut off to the platform functions. when pull out (on), power turns on to the platform functions. Drive direction confirm switch When the boom is swung over the rear tires or further in either direction, the Drive Orientation indicator will illuminate when the drive function is selected.

  • Page 39: Platform Control Indicator Panel

    Push forward to lift up, pull backward to lower. Move left to swing clockwise, move right to swing counterclockwise. 13) Tower boom lift switch Provides for raising and lowering of tower boom when positioned up or down. 2.2.4 Platform Control Indicator Panel Note: The indicator lights will illuminate for approximately 1 second when the key is positioned to the on position to act as a self test.
  • Page 40 1） Platform overload indicator Indicates the platform has been overloaded. 2） Wire rope loosen indicator (not equipped) Indicates loosen or damage of main boom wire rope, service or adjust it immediately. 3） Tilt Alarm Warning Light This illuminator indicates that the chassis is on a slope. As long as the X-axis tilt angle of the chassis exceeds 2 °...
  • Page 41 reminder that all functions are set to slowest speed. The light will be on continuously if the operator selects creep speed. 6） System fault indicator Indicates system faults. 7） Soft touch indicator If light goes on, soft touch function activates. 8）...

  • Page 45: 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 principles of safe machine operation contained in this operational manual. Only use the machine as it was intended; Know and understand the pre-operation inspection before going on to the next section; Implement functional test before operating the machine at all times;...
  • Page 46 Check the following components or areas for damage, improperly installed, or missing parts and unauthorized modifications: Electrical components, wiring, and electrical cables; Hydraulic hoses, fittings, cylinders, and manifolds; Hydraulic tank; Drive motor, reducer; Motor driver; Wear pads; Tires and wheels; Limited switch and horn;...

  • Page 47: Ground Function Check

    3.2 Function Test 3.2.1 Function test principle 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 48: Platform Function Check

    Attempt to activate each boom and platform function button. Check test result: All boom and platform functions should operate through a full cycle. Manual descent system 1） Push the emergency switch on the main valve all the way in; 2） Insert the manual pump operating lever on the turntable into the manual pump and push the manual pump up and down to lower the main boom and the tower boom;...
  • Page 49 c） Test the Horn Press the horn button at the platform controls. Check test result: The horn should sound. Test the Steering Select Platform Mode; Press down the foot switch and activate each boom and platform function button; Move the steering handle; Release the steering handle.

  • Page 50: Workplace Inspection

    Check test result: the drive speed should switch to low speed with the upper boom extended. Lower the upper boom to stowed position; Attempt to operate drive handle. Check test result: the drive speed should switch to high speed with the upper boom retracted to stowed position.

  • Page 51: Workplace Inspection

    3.3.2 Workplace inspection Be aware of and avoid the following hazardous situations: Drop-offs or holes; bumps, floor obstructions, or debris; Sloped surfaces; Unstable or slippery surfaces; Overhead obstructions and high voltage conductors; Hazardous locations; Inadequate surface support to withstand all load forces imposed by the machine; Wind and weather conditions;...

  • Page 52: Decal Inspection

    3.4 Decal Inspection Figure 3-1 Decal Position...
  • Page 53 Figure 3-1 Decal Position (continuous)
  • Page 54 Figure 3-1 Decal Position (continuous) 3-10...
  • Page 55 Figure 3-1 Decal Position (continuous) Use the pictures on next page to verify that all decals are legible and in place. Below is a numerical list with quantities and descriptions. 3-11...
  • Page 56 Table 3-1 Decals Code/ Content Decal 00773407000201290 Label- Yellow triangle 00773407000201340 Label- Yellow arrow 00773407000201300 Label- Blue triangle 00773407000201280 Label- Blue arrow 00773407000401271 Warn- Prohibit high pressure water-beaktest 00773207000401111 Hazard- Tip-over Hazard I 00773407000201411 Label- Lanyard Anchorage Point 3-12...
  • Page 57 Table 3-1 Decals (cont.) Code/ Content Decal 00773407000401321 Warn- Crushing hazard Ⅱ 00773407000401201 Caution- Prohibit Lanyard 00773407000401231 Warn- Foot Switch Malfunction 00773407000401141 Label- Platform Console Instruction 00773207000401531 Label-Hood 00773207000401331 Label- Work Platform 00773407000401221 Platform Indicator Panel Instruction 3-13...
  • Page 58 Table 3-1 Decals (cont.) Code/ Content Decal 00773207000401061 Label- Wheel Load 00773407000401561 Danger- Tip-over Hazard III 00773407010401501 Hazard- Electrocution 00773207000401121 Label- Transport and Lift Instruction 00773407000401391 Caution-Preserve the manual 00773407000201181 Label- Prohibit Step on 00773207000201010 LOGO-ZA10RJE 3-14...
  • Page 59 Table 3-1 Decals (cont.) Code/ Content Decal 00773407000201020 Label -Zoomlion LOGO II 00773407000401381 Danger- Explosion Hazard II 00773407000401151 Caution- Cut off Battery 00773407000201010 Label -Zoomlion LOGO I 00773407000201421 Label- Tie down point 00773407000201241 Label- Prohibit Lifting 00773407000401081 Platform Indicator Panel...
  • Page 60 Table 3-1 Decals (cont.) Code/ Content Decal 00773409910401041 Plate 00773407000401191 Danger- Crushing Hazard 00773407000401311 Danger- Tip-over Hazard II 00773407000201431 Label- Lift point 00773207000401010 Label- ZOOMLION 00773407000401211 Danger- Crushing Hazard 1040400096 GB/T12618-1990 3×9 Rivet 3-16...
  • Page 61 Table 3-1 Decals (cont.) Code/ Content Decal 00773407010401441 Caution- Main Power Operating Instruction 00773407010401021 Danger- Ground control instruction 00771407000401191 QR code 3-17...

  • Page 65: 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 66 Do not drive with upper boom out of transport mode except on a smooth, firm level surface. To avoid loss of travel control or upset on grades and side slopes exceeding those specified on machine nameplate. Do not drive on side slopes which exceed 3 degrees with platform elevated, do not drive on side slopes which exceed 19 degrees in stowed position.

  • Page 67: Platform Leveling

    4.2.2 Platform leveling Only use the platform leveling function for slight leveling of the platform when the platform is in low position. Incorrect use could cause the load/occupants to shift or fall.failure to do so could result in death or serious injury.

  • Page 68: Upper Boom Lift

    4.2.5 Upper boom lift To raise or lower the upper boom, move the lifting handle on the platform or position the Upper Boom Lift on ground to UP or DOWN until the desired height is reached. 4.2.6 Telescoping the Upper Boom Move the telescoping switch to Extend or Retract position, the upper boom could extend or retract.

  • Page 69: Electric Emergency Lowering System

    operating the override switch in the platform or ground mode will activate the override system. At this time, the functions of upper boom lifting, upper boom telescoping, turntable rotation, jib lifting, platform leveling, and platform rotation can be operated. Enable the platform override system: Turn the Main Power Switch to ON position;...

  • Page 70: Manual Swing Override

    CHINA Department of Transportation regulations, other localized regulations, and their company policy. ZOOMLION customers needing to containerize any lift or ZOOMLION product should source a...

  • Page 71: Release The Brake While Towing

    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 72: Securing The Chassis

    4.3.3 Securing the Chassis Use chains of ample load capacity; Use a minimum of 4 chains; Adjust the rigging to prevent damage to the chains. Figure 4-5 Lifting and Securing Instructions 4.3.4 Securing the Platform Be sure the boom and the platform are in stowed position; Use the straps between the platform rotator (see Figure below) and platform base to secure the platform;...
  • Page 73 Use a cable tie or rope to secure the slider to the upper square tube of the work platform to prevent the slider from bumping during transportation. Figure 4-7 Securing the Platform...

  • Page 77: 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 78: Maintenance Hazards

    Wear pads; Tires and wheels; Limit switches and horn; Alarm and indicator (if equipped); Nuts, bolts and other fasteners; Brake release unit. 5.1.3 Maintenance hazards Shut off power to all controls and ensure that all moving parts are secured from inadvertent motion prior to performing any adjustments or repairs;...

  • Page 79: Check Hydraulic Oil

    Note: 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 80 Table 5-2 Technical Parameters of Hydraulic Oil Mobil Great Wall Kunlun 10 4632 grease Mobil Mobil Mobil Great Great Technical Aware Caltex Caltex aviation non-flammab DTE 10 DTE 10 DTE 10 Wall Wall Parameter H 32 Rando Rando hydraulic le hydraulic Ultra Ultra Ultra...

  • Page 81: Battery Maintenance

    will shorten the oil's service life, so the hydraulic oil should be changed sooner than the recommended.For small load work, the oil change time can be extended. Cleanliness of the hydraulic oil upon delivery is NAS9 (ISO4406 18/15), and for normal operation, the cleanliness should not be lower than NAS10 (ISO4406 19/16).We suggest that the hydraulic oil should be checked every 6 months, and the oil should be sampled at least once upon the time for oil changing.The oil sample can be sent to the hydraulic oil manufacturer or qualified third-party testing...

  • Page 82: Regular Maintenance

    soda and water. Note: the battery should be fully charged before this inspection. Only qualified riggers should rig the machine; Only certified crane operators should lift the machine and only in accordance with the applicable crane regulations; Be sure that the battery hold-down brackets are in place and secure. Note: adding terminal protectors and a corrosion preventative sealant will help eliminate the corrosion on the battery terminals and cables.
  • Page 83 Lube -Changcheng 7408B-1 Gear Grease. Interval –Every 3 months or 150 hours. Comment –Apply grease and rotate in 90 degree intervals until bearing is completely lubricated. Do not over-lubricate the bearings, otherwise it will cause damage to outside seal of casing. Hydraulic tank Liquid Level –7-12 L (1.8-3.17 us gal ).
  • Page 84 Hydraulic Tank Breather Maintenance Point(s) –Tank Breather. Interval –Change after first 50 hrs. and every 6 months or 300 hrs thereafter. Comment –Remove wing nut and cover to replace.Under certain conditions, it may be necessary to replace on a more frequent basis. Travelling Reduction Gears Lube Point(s) –Level/Fill Plug.

  • Page 85: Tire And Wheel

    ZOOMLION recommends a replacement tire be the same size, ply 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 86 The tightening of the nuts should be done in stages.Following the recommended sequence, tighten nuts per wheel torque; Table 5-3 Wheel Torque Table Torque Sequence 1st Stage 2nd Stage 3rd Stage 75 Nm 150Nm 310 Nm Wheel nuts should be torqued after first 50 hours of operation and after each wheel removal. Check and torque every 3 months or 150 hours of operation.
  • Page 89 SECTION 6 STORAGE AND EX-FACTORY TEST 6.1 Storage Conditions Ambient temperature for machine storage and transportation should be between -20 ℃ and 40 ℃, 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 Testing Items Before Delivery Tests Items...
  • Page 91 履带起重机操作手册 第一章 安全操作说明...
  • Page 93 SECTION 7 TECHNICAL PARAMETER Table 7-1 Technical Parameters Model ZA10RJE Parameters Max platform height 9.55m 31ft 4in Max work height 11.55m 22ft 5in Max horizontal outreach 6.85m 22ft 5in Max up and over height 4.6m 15ft 1in Length (stowed) 5.5m...
  • Page 94 Figure 7-1 ZA10RJE Range of Motion...
  • Page 95 Figure 7-2 ZA10RJE Dimension in Traveling Mode...

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