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Zoomlion ZA16JERT 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
ZA16JERT
Operation and Safety Manual
EN-OP

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Summary of Contents for Zoomlion ZA16JERT

  • 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 ZA16JERT Operation and Safety Manual 2022.5 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 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 ........................ 1-1 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 Raise and lowering the upper boom ................ 4-4 4.2.6 Telescoping the upper boom ...................
  • Page 9 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 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 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. This decal will have a red background.
  • 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 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 ZA16JERT 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 2.1 Machine Components Figure 2-1 Components 1 Table 2-1 Component Instruction Name Name Foot Switch Platform Console Manual Storage Container Main Boom (Upper Boom) Sliding Mid-Rail Tower Boom Lanyard Anchorage Points Ground Control Console Swing Gate Steering Tire Non-Steering Tire...
  • Page 30 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 Turntable slew switch Provide 360°...
  • 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 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 2- 6...
  • 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 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 Drive select switch Platform leveling switch Horn switch Power/Emergency stop switch Drive direction confirm switch Drive/Steer controller Main boom telescope switch Jib lift switch Platform rotate switch Work light switch Function speed control Main Lift/Swing Controller Tower boom lift switch 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 Turning the knob all the way counterclockwise until it clicksto put drive, main lift and swing into creep mode. 12) Main Lift/Swing Controller Provides main boom lift and platform swing. 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.
  • Page 40 Table 2-4 Platform Indicator Panel Instruction Name Platform overload indicator Wire rope loosen indicator Tilt Alarm Warning Light Main boom system fault indicator Creep Speed Indicator System fault indicator Soft touch indicator Drive direction confirm indicator Limited position indicator Footswitch indicator 1）...
  • Page 41 If the tilt alarm sounds with the platform downhill, proceed as follows: Retract the main boom; Lower the tower boom; Lower the main boom. 4） Main boom system fault indicator (not equipped) Indicates that the length of main boom cannot measure, need check boom length sensor.
  • Page 42 must be released and depressed again to enable the controls. Releasing the footswitch stops all platform controls. To avoid serious injury, do not remove, modify or disable the foot switch by blocking or any other means. Foot switch must be adjusted if malfunctions occur. 2- 14...
  • Page 45 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 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; Alarm and indicator (if equipped); 10) Nuts, bolts and other fasteners; 11) Platform entry mid-rail or gate; 12) Platform load cell;...
  • Page 47 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 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; 3）...
  • Page 49 Release the drive control handle. Check test result: the machine should turn in the direction that the control handle operates. Release the drive handle, the drive function is disabled. Test the Drive Enable System Select Platform Mode; Press down the foot switch and activate each boom and platform function button;...
  • Page 50 Avoid hazardous situations; Perform a pre-operation inspection at all times; Implement functional test before operating the machine at all times; Inspect job site; Know and understand the workplace inspection before going on to the next section; Only use the machine as it was intended. 3.3.1 Workplace inspection principle The workplace inspection helps the operator determine if the workplace is suitable for safe machine operation.
  • Page 51 3.4 Decal Inspection Figure 3-1 Decal Position...
  • Page 52 Figure 3-1 Decal Position (continuous) 3- 8...
  • Page 53 Figure 3-1 Decal Position (continuous)
  • Page 54 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- 10...
  • Page 55 Table 3-1 Decals Numbers are corresponded to the decal (not all decal are pasted on the machine) Part No. Decal 00773407000201290 Label- Yellow triangle 00773407000201280 Label- Blue arrow 00773407000201300 Label- Blue triangle 00773407000201340 Label- Yellow arrow 00773407000401271 Warn- Prohibit high pressure water-beaktest 02564407000401110 Hazard- Tip-over Hazard I...
  • Page 56 Table 3-1 Decals (continuous) Numbers are corresponded to the decal (not all decal are pasted on the machine) Part No. Decal 00773407000201411 Label- Lanyard Anchorage Point 00773407000401321 Warn- Crushing hazard Ⅱ 00773407000401201 Caution- Prohibit Lanyard 00773407000401231 Warn- Foot Switch Malfunction 00773407000401141 Label- Platform Console Instruction...
  • Page 57 Numbers are corresponded to the decal (not all decal are pasted on the machine) Part No. Decal 00773407010401021 Caution-Risk of Pinching Hand 02564407000401330 Label- Work Platform 00773407000401221 Platform Indicator Panel Instruction 00773407000401081 Label- Platform Indicator Panel Instruction 00773407000201020 Label-Zoomlion LOGO II 00773407000401391 Caution-Preserve the manual 00773407000401461 Label-Platform AC power 3-13...
  • Page 58 Numbers are corresponded to the decal (not all decal are pasted on the machine) Part No. Decal 00773407000201181 Label- Prohibit Step on 02564407000401020 Model LOGO 00773407000401381 Danger- Explosion Hazard II 00773407000401151 Caution- Cut off Battery 00773407000201010 Label-Zoomlion LOGO I 00773407000201421 Label- Tie down point 00773407000201241 Label- Prohibit Lifting 3- 14...
  • Page 59 Numbers are corresponded to the decal (not all decal are pasted on the machine) Part No. Decal 02564407000401010 Model LOGO 00773409910401041 Plate 00773407000401191 Danger- Crushing Hazard 00773407000401311 Danger- Tip-over Hazard II 00773407000201431 Label- Lift 00771407000201120 Label- ZOOMLION-120 LOGO 00773407000401211 Danger- Crushing Hazard 3-15...
  • Page 60 Table 3-1 Decals (continuous) Numbers are corresponded to the decal (not all decal are pasted on the machine) Part No. Decal 1040400096 GB/T12618-1990 3×9 Blind Rivets 00773407010401441 Caution- Main Power Operating Instruction 02564407000401100 Label- Wheel Load 00773407000401361 Danger- Tip-over Hazard III 00773407010401501 Hazard- Electrocution 02564407000401120...
  • Page 61 Table 3-1 Decals (continuous) Numbers are corresponded to the decal (not all decal are pasted on the machine) Part No. Decal 00775607000401321 Warn-Non-insulated 00771407000401191 QR code 3-17...
  • Page 65 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 5 degrees with platform elevated, do not drive on side slopes which exceed 24 degrees in stowed position.
  • Page 67 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 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 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 70 Note: traction machine is not recommended.If the machine must be towed; the speed must not exceed 3.2 km/h (1.99mph). Securing to Truck or Trailer for Transit Always use the turntable rotation lock pin each time the machine is transported. Panel Cradle Installation. Insert the hook piece through the slots in the panel cradle base.
  • Page 71 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; Use nylon tape to secure the platform.Do not use excessive downward force when securing the boom section.
  • Page 75 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 76 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 77 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 78 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 79 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 80 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 81 Lube -Changcheng 7408B-1 Gear Grease. Interval –Every 4 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 –25-30 L (6.6-7.9 us gal ).
  • Page 82 Hydraulic Tank Breather Maintenance Point(s) –Tank Breather. Interval –Change after first 50 hrs. and every 6 months or 1,000 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 83 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 84 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 300 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 87 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 89 履带起重机操作手册 第一章 安全操作说明...
  • Page 91 SECTION 7 TECHNICAL PARAMETER Table 7-1 Technical Parameters Model ZA16JERT Parameters Max Platform Height 15.8m 51ft 11in Max Work Height 17.8m 58ft 5in Max Work Outreach 9.72m 31ft 11in Up and Over Height 26ft 3in Overall Length 25ft 4in 7.7m...
  • Page 92 Figure 7-1 ZA16JERT Range of Motion 7- 2...
  • Page 93 Figure 7-2 ZA16JERT Dimension in Traveling Mode...