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Zoomlion ZS1930E Series Operation And Safety Manual

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Operation and Safety Manual
ZOOMLION
ZS1930E Series
ZS1530E Series
Operation and Safety Manual
Oct 2023 Version A

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  • Page 1 Operation and Safety Manual ZOOMLION ZS1930E Series ZS1530E Series Operation and Safety Manual Oct 2023 Version A...
  • Page 3 Operation and safety manual 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 4: Safety Precaution Icons

    Operation and safety manual 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 5: Table Of Contents

    Operation and safety manual 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 6: Contents

    Operation and safety manual 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 At the electronic controls ....................3-3 3.2.4 At the platform controls ....................3-5 3.2.5 Turn off the main power switch ..................3-9 3.3 Check the Liner Actuator ..........................
  • Page 7 Operation and safety manual Contents 4.5.1 Driving on a slope ......................4-8 4.5.2 Operating on a slope ...................... 4-9 4.6 Traction ..............................4-9 4.7 Operation Code ............................4-11 4.7.1 Operation indicator code ....................4-11 4.7.2 Platform overload ......................4-12 4.7.3 Battery level indicator....................4-12 4.8 Safety Arm and Guard Operation ......................
  • Page 8 Operation and safety manual Contents 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 SECTION 8 DISPOSAL ..........................8-1 8.1 Service life ..............................8-1 8.2 Disposal ..............................

  • Page 11: 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 12: Hazard Classification

    Operation and safety manual Read, understand and obey all applicable governmental regulations. The operator is properly trained to safely operate the machine. 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.
  • Page 13 Operation and safety manual 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...
  • Page 14 Operation and safety manual 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...

  • Page 15: Safety Operation

    Operation and safety manual 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 16: Tip-Over Hazard

    Capacity on Platform Extended ZS1530E Series 240Kg/530 lbs 100kg/220 lbs ZS1930E Series 230kg/510 lbs 113kg/250 lbs Do not elevate the platform unless the machine is on firm level ground. Do not depend on the tilt alarm as a level indicator. The tilt alarm sounds on the chassis only when the machine is on a severe slope.
  • Page 17 2 (Indoor)/ 1 (Outdoor) 90 lbs force /45 lbs force 400N/200N ZS1930E Series 2 (Indoor)/ 1 (Outdoor) 90 lbs force /45 lbs force Do not operate the machine in strong or gusty winds. Do not increase the surface area of the platform or the load.
  • Page 18 Operation and safety manual Push the machine or other objects with the platform. Contact adjacent structures with the platform. Tie the platform to adjacent structures. Place loads outside the platform perimeter. Operate the machine with the chassis trays open. Push off or pull toward any object outside of the platform. Do not modify or alter an aerial work platform without prior written permission from the manufacture.

  • Page 19: Crush Hazard

    Stowed Position for the Stowed Position ZS1530E Series 30% (17°) 30% (17°) ZS1930E Series 25% (14°) 25% (14°) 1.6.2.5 Fall off hazard The guard rails system provides fall protection. If occupant(s) of the platform are required to wear...

  • Page 20: Collision Hazard

    Operation and safety manual requirements. Use approved lanyard attachment point provided. Do not sit, stand or climb on the platform guard rails. Maintain a firm footing on the platform floor at all times. Do not climb down from the platform when raised. Keep the platform floor clear of debris.
  • Page 21 Operation and safety manual Be aware of crushing hazards when grasping the platform guard rail. Observe and use the color-coded direction arrows on the platform controls and the platform decal plate for drive and steer functions. Do not lower the platform 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.

  • Page 22: Burn Hazard

    Operation and safety manual collision. 1.6.2.7 Burn hazard Liquid or gas burn hazard. Do not operate a machine with a hydraulic oil or air leak. An air leak or hydraulic leak can penetrate and/or burn skin. Batteries contain acid. Always wear protective clothing and eye wear when working with batteries.

  • Page 23: 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 27: Section 2 Machine Components And Controls

    Operation and safety manual SECTION 2 MACHINE COMPONENTS AND CONTROLS 2.1 Machine Components ZS1930E Series. Figure 2-1 Components 1 Table 2-1 Component instruction 1 Item Item Item Manual pump Platform Console Fixed platform (HD series only) Manual Storage Container Scissor arm...
  • Page 28 Operation and safety manual ZS1530E Series. Figure 2-2 Components 2 Table 2-2 Component instruction 2 Item Item Item Platform Console Foot switch Pothole guard Platform extension Scissor arm Charger Manual Storage Container Lifting linear actuator Steering wheel Platform guard rails Entry ladder Safety arm Platform entry gate...

  • Page 29: Machine Controller

    Operation and safety manual 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 Electronic control unit (ECU) Figure 2-3 Electronic control Panel Table 2-3 Electronic control panel instruction Item Item...

  • Page 30: Platform Control Unit (Pcu)

    Operation and safety manual Emergency stop switch. Push in the Red Emergency Button to the off position to stop all functions. Pull out the Red Emergency Button to the on position to operate the machine. 2.2.2 Platform control unit (PCU) Figure 2-4 Platform control panel Table 2-4 Platform control panel instruction Item...
  • Page 31 Operation and safety manual Lift function button. Push this button to activate the lift function. If the control handle is not moved within seven seconds, press the lift function button again. Proportional control handle and function enable switch for drive, steer and lift functions. Lift function: press and hold the function enable switch to enable the lift function on the platform control handle.

  • Page 35: Section 3 Machine Inspection

    Operation and safety manual 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 36 Operation and safety manual unauthorized modification: Electrical components, wiring, and electrical cables. Lifting linear actuator, steering linear actuator. Drive motors. Wearing pads. Tires and wheels. Alarm and indicator (if equipped). Nuts, bolts and other fasteners. Brake release components. Safety arm. 10) Platform extension.

  • Page 37: Function Test

    Operation and safety manual 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 38 Operation and safety manual Observe the diagnostic LCD readout on the electronic controls. The LCD should display the model and hour meter: Push in the ground red Emergency Stop Button to off position. Result: No function should operate. Pull out the red Emergency Stop Button to the on position. Test the Up/Down functions.

  • Page 39: At The Platform Controls

    Operation and safety manual illuminate and alarm will sound. Be sure there is no personnel or obstructions under the platform when lowering. Release and move the control handle to continue the lowering operation. Test emergency lowering. Activate the platform up function by pressing both the enable button and the platform up button, raise the platform to limit height.
  • Page 40 Operation and safety manual Press the lift function enable button, the indicator lights up. Press and hold the function enable switch on the control handle when indicator lighting, and slowly move the control handle in the direction indicated by the blue arrow. 10) Result: the platform should raise.
  • Page 41 Operation and safety manual yellow triangle on control panel. Result: the steer wheels move towards the direction indicated by the yellow triangle. Test driving and braking. The brake must be able to hold the machine on any slope it is able to climb. This test is performed on the ground with a platform controller.
  • Page 42 Operation and safety manual Move the control handle in the direction indicated by the blue arrow, then move the control handle in the direction indicated by the yellow arrow. Result: the drive function should not work in either direction. Lower the platform and remove both pieces of wood. Test elevated drive speed.

  • Page 43: Turn Off The Main Power Switch

    Operation and safety manual illuminate, and an alarm should sound. The platform controls LED readout should display 18 and the electronic controls LCD should display 18: Pothole Guard Fault. 10) Press the drive function button. 11) Press and hold the functional enable switch on the control handle. 12) Slow move the control handle in the direction indicated by the blue arrow, then in the direction indicated by the yellow arrow.

  • Page 44: Workplace Inspection

    Operation and safety manual Check test results: motor brake works normally, and the machine stop lifting and hold in the current position. Check if there is any abnormal shaking or sounds of liner actuator when lifting, if so, stop using the machine immediately and mark it.

  • Page 45: Workplace Inspection

    Operation and safety manual 3.4.2 Workplace inspection Be aware of and avoid the following hazards: Drop-offs or holes. Bumps, floor obstructions or debris. Sloped surfaces. Unstable or smooth surfaces. Overhead obstructions and electric lines. Hazardous locations Inadequate surface support to withstand all load forces imposed by the machine. Wind and weather conditions.
  • Page 46 Operation and safety manual 3.5 Decals Inspection Use the lists and pictures below to verify that all decals are legible and in place. Table 3-1 Decal 1（ZS1930E Series） Code Item 00775207050401080 Label- Electrocution Hazard 00775207050401050 Label- Lifting and Tying 007753070A1601030...
  • Page 47 Operation and safety manual Figure 3-1 Decal position1（ZS1930E Series） 3-13...
  • Page 48 Operation and safety manual Figure 3-2 Decal position2（ZS1930E Series） 3-14...
  • Page 49 Operation and safety manual Figure 3-3 Decal position3（ZS1930E Series） 3-15...
  • Page 50 Operation and safety manual ZS1930E Series Figure 3-4 Decal 1 3-16...
  • Page 51 Operation and safety manual Table 3-2 Decal 2（ZS1530E Series） Code Item 00775207050401080 Label- Electrocution Hazard 00775207031601070 Label- Wheel Load, 390kg/860 lbs 00775207050401010 Label- Anti-pinch 00775207050402020 Label- 4m Left 00775207050402010 Label- Crushing and Safety Arm 00775207050403080 Label- Platform Power Rated Voltage 00775207050403020 Danger- Tip-over Hazard 00775207050403050...
  • Page 52 Operation and safety manual Figure 3-5 Decal position1（ZS1530E Series） 3-18...
  • Page 53 Operation and safety manual Figure 3-6 Decal position2（ZS1530E Series） 3-19...
  • Page 54 Operation and safety manual Figure 3-7 Decal position3（ZS1530E Series） 3-20...
  • Page 55 Operation and safety manual ZS1530E Series Figure 3-8 Decal 2 3-21...

  • Page 59: Section 4 Operation Instruction

    Operation and safety manual 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 60: Emergency Stop

    Operation and safety manual 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. Repair any function that operates when Power Switch and red Emergency Stop button are pushed in. 4.2.3 Emergency lowering Cut off power supply, the press the emergency lowering knob to lower the platform.

  • Page 61: Adjust Platform Position

    Operation and safety manual 4.4.2 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 62: Drive Speed Selection

    Operation and safety manual 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 63: Indoor And Outdoor Working Mode Selection

    Operation and safety manual 4.4.8 Indoor and outdoor working mode selection Figure 4-1 Electronic control Panel Table 4-1 Electronic control panel instruction Item Item Lifting enable button 10A breaker Menu escape button Menu down button Menu up button Menu enter button LCD diagnostic readout Platform up button Key switch...
  • Page 64 Operation and safety manual Figure 4-2 Platform control panel Table 4-2 Platform control panel instruction Item Item Emergency stop switch Steering thumb button Horn button LED Readout Lift function button Drive function button Control handle Drive speed button...
  • Page 65 Operation and safety manual Push the emergency stop switch to OFF position, and turn the key switch to Ground position. Press the Input button on menu and pull out emergency stop button to ON position to enter the Menu interface. Press Down button, then press Enter button when the display shows as below.

  • Page 66: Operation On Slope

    Determine the longitudinal and lateral ratings and slope of the slope under machine retract condition. Table 4-3 Longitudinal rating Maximum longitudinal rating in the stowed state ZS1530E Series 17° ZS1930E Series 14° Table 4-4 Lateral rating Maximum lateral rating in the stowed state ZS1530E Series 17°...

  • Page 67: Operating On A Slope

    Move the machine to a firm, level surface before lifting. 4.6 Traction Notice (ZS1530E/ZS1930E Series): It is not recommended that this machine be towed, except in the event of an emergency such as a machine malfunction or a total machine power failure.
  • Page 68 Operation and safety manual ③ Turn the key switch to electronic control. ④ Until the following interface appears on the LCD reading device: ⑤ Scroll to the following screen by pressing the Menu Down Button: ⑥ Press Menu Entry Button to display following interface: ⑦...

  • Page 69: Operation Code

    Operation and safety manual Figure 4-3 Brake diagram ⑤ Tighten the bolt to release the brake. ⑥ Repeat this process for the other wheel drive. Mechanical brake release（ZS1530E）: ① Press device main power switch, platform emergency stop button and ground emergency stop button.

  • Page 70: Platform 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. 4.7.2 Platform overload...

  • Page 71: Safety Arm And Guard Operation

    Operation and safety manual Use the LED diagnostic readout to determine the lead acid or lithium-ion battery level.When Low Charge appears on the platform controls LED display, the machine must be taken out of service and charged, otherwise all machine functions will be disabled. Battery Battery Level:90-100%...

  • Page 72: How To Raise Guard

    Charge the battery in a well-ventilated area. Use proper AC input voltage for charging as indicated on the charger. Use only a ZOOMLION authorized battery and charger. 4.9.2 Charging the battery Be sure the batteries are connected before charging the batteries.

  • Page 73: Dry Battery Filling And Charging Instructions

    Operation and safety manual Remove the battery vent caps and check the battery acid level. If necessary, add only enough distilled water to cover the plates. Do not add excessive distilled water before the charging process. Replace the battery vent caps. Connect the battery charger to a grounded AC circuit.

  • Page 74: Charging Lithium-Ion Batttery

    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 qualified freight forwarder with expertise in preparing, loading and securing construction and lifting equipment for international shipment.

  • Page 75: Transport

    Operation and safety manual machine weight. ZOOMLION lifts are very heavy relative to their size. See the serial label for the machine weight. Be sure the machine is on a level surface or secured before releasing the brake. Do not allow the rails to fall when the snap pins are removed. Maintain a firm grasp on the rails when the rails are lowered.

  • Page 76: Lift

    Operation and safety manual Figure 4-4 Tie down points 4.11.3 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 77 Adjust the rigging to prevent damage to the machine and to keep the machine level. Table 4-6 Center of gravity Model X Axis Y Axis ZS1530E Series 49.8 cm/1ft 8in 42.1 cm/1ft 5in ZS1930E Series 54 cm/1ft 9in 69.5 cm/2ft 3in 4-19...
  • Page 78 Operation and safety manual Chassis Chassis Lifting Lifting Points (1) Points (2) Figure 4-6 Center of gravity 4-20...

  • Page 81: 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 82: Maintenance Hazard

    Operation and safety manual Electrical components, wiring, and electrical cables. Lifting and steering liner actuator. Drive motor/motor. 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 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.

  • Page 83: Battery Maintenance

    Operation and safety manual 5.2 Battery Maintenance 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 87: Section 6 Storage And Ex-Factory Test

    40℃/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 testing items (ZS1930E Series) Tests Items Load Testing Testing Movement...

  • Page 91: Section 7 Technical Parameter

    Operation and safety manual SECTION 7 TECHNICAL PARAMETER Table 7-1 ZS1930E Series Technical parameter Model ZS1930 Series Parameters Work Height (Indoor) 7.8 m 25ft 7in Work Height (Outdoor) 6.4 m 20ft 12in Platform Height (Indoor) 5.8 m 19ft Platform Height (Outdoor) 4.4 m...
  • Page 92 Operation and safety manual Table 7-1 ZS1930E Series Technical parameter Model ZS1930 Series Parameters Maximum chassis working Angle 3°/1.5° (longitudinal/lateral) Turning Radius (Outside) 1.6 m 5ft 3in Turning Radius (Inside) 0.1 m Gross Vibration Value of Scissor Arm ≤2.5 m/s ≤5.6 mph...
  • Page 93 Operation and safety manual Table 7-2 ZS1530E Series Technical parameter Model ZS1530 Series Parameters Work Height (Indoor) 6.25 m 20ft 6in Work Height (Outdoor) 4.25 m 13ft 11in Platform Height (Indoor) 4.25 m 13ft 11in Platform Height (Outdoor) 3.6 m 11ft 10in Max Height (stowed position) 2.05 m...
  • Page 94 Operation and safety manual Table 7-2 ZS1530E Series Technical parameter Model ZS1530 Series Parameters Turning Radius (Outside) 1.6 m 5ft 3in Turning Radius (Inside) 0.4 m 1ft 4in Gross Vibration Value of Scissor Arm ≤2.5 m/s ≤5.6 mph Highest square root of weighing ≤0.5 m/s ≤1ft 8in /s acceleration bearing by the machine body...
  • Page 95 Operation and Safety Manual Section 8 Disposal...

  • Page 97: Section 8 Disposal

    Operation and safety manual SECTION 8 DISPOSAL 8.1 Service life For 10 years. Please doing complete inspection for every 5years. 8.2 Disposal If the MEWP cannot be repaired, please follow your national regulation to dispose the MEWP.

  • Page 99: Appendix:inspection And Maintenance Record

    Operation and safety manual Appendix:Inspection and Maintenance Records Date record...
  • Page 100 Operation and safety manual Appendix:Inspection and Maintenance Records Date record...
  • Page 101 Add:701 Xulong Nan Lu, Xiangjiang New District, Changsha, Hunan, China 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.

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