Zoomlion ZS1623RT Use and care manual

Self-Propelled Rough-Terrain Scissor Lifts
Operation and Safety Manual
ZOOMLION
Add:ZOOMLION Wangcheng Industrial Park,Tengfei Road 997,
Wangcheng District,Changsha,Hunan,PRC.
Zip Code:410013
Email:[email protected] Mobile:[phone]
Zoomlion Heavy Industry Science&Technology Co.Ltd.
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.

ZOOMLION
Operation and Safety Manual
April 2020 Version A
ZS1623RT
Operation and Safety Manual

Foreword
I
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. Keep this manual properly at all times for looking up.
Do not operate the machine if there is any doubt in operation, please consult local service team for
troubleshooting. Zoomlion AWP Machinery Company does not take the consequence of wrong operation.
This manual should be considered a permanent part of your machine and should remain with the machine
at all times.
The content is underintellectual propertyprotection, permission is required for a copyor other application.
There might be some tiny differences in details between your machine and the upgraded one due to the
continuous improving. For clarification, questions, or additional information regarding any portions of
this manual, Contact ZoomlionAWP Machinery.
Our company reserves the right to modify this manual as technical improvement without notice.
Thank you for your trust and support for Zoomlion products!
Zoomlion Aerial Work Platform Machinery Company

Safety Precaution Icons
II
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.
Indicates risks unrelated with personal injury (such as property damage).

III
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 ................................................................................................................1-5
1.6.1 Operator safety.................................................................................................1-5
1.6.2 Workplace safety..............................................................................................1-5
1.6.2.1 Electric shock hazard......................................................................1-5
1.6.2.2 Tip-over hazard ...............................................................................1-6
1.6.2.3 Crush hazard...................................................................................1-9
1.6.2.4 Danger of operation on the slope....................................................1-9
1.6.2.5 Fall off hazard ............................................................................... 1-11
1.6.2.6 Collision hazard.............................................................................1-12
1.6.2.7 Burn hazard...................................................................................1-13
1.6.2.8 Explosion and fire hazard..............................................................1-14
1.6.2.9 Machine damage hazard...............................................................1-15
1.6.2.10 Component damage hazard .......................................................1-15
SECTION 2 Machine Components And Controls................................................................2-1
2.1 Machine Components........................................................................................................2-1
2.2 Machine Controller.............................................................................................................2-2
2.2.1 Ground controller..............................................................................................2-2
2.2.2 Platform control unit (PCU)...............................................................................2-3
SECTION 3 Machine Inspection............................................................................................3-1
3.1 General...............................................................................................................................3-1
3.1.1 Pre-operation inspection fundamentals............................................................3-1
3.1.2 Pre-operation inspection...................................................................................3-1

Contents
IV
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.........................................................................................................3-9
3.3.1 Workplace inspection fundamentals.................................................................3-9
3.3.2 Workplace inspection........................................................................................3-9
3.4 Decals Inspection.............................................................................................................3-10
SECTION 4 Operation Instruction ........................................................................................4-1
4.1 General...............................................................................................................................4-1
4.2 Machine Operation.............................................................................................................4-1
4.2.1 Turn on/off main power switch..........................................................................4-1
4.2.2 Emergency stop................................................................................................4-1
4.2.3 Start engine ......................................................................................................4-2
4.2.4 Operation from Ground.....................................................................................4-2
4.2.5 Operation from Platform ...................................................................................4-2
4.3 Operation on Slope............................................................................................................4-4
4.3.1 Driving on a slope.............................................................................................4-4
4.3.2 Operating on a slope ........................................................................................4-6
4.4 Extending and retracting platform......................................................................................4-5
4.5 Emergency lowering...........................................................................................................4-4
4.5.1 On ground controller.........................................................................................4-4
4.5.2 On platform controller.......................................................................................4-5
4.6 Operation from ground controller.......................................................................................4-6
4.7 Outrigger operation............................................................................................................4-6
4.7.1 Control a single outrigger .................................................................................4-6
4.7.2 After each use...................................................................................................4-6
4.8 Operation Code..................................................................................................................4-9
4.8.1 Operation Indicator code ..................................................................................4-6
4.8.2 Platform overload .............................................................................................4-7
4.9 Safety Arm and Guard Operation.......................................................................................4-7
4.9.1 How to use the safety arm................................................................................4-7

V
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 .......................................................................................................5-1
5.1 General...............................................................................................................................5-1
5.1.1 Maintenance symbols legend...........................................................................5-1
5.1.2 Pre-Start Inspection..........................................................................................5-1
5.1.3 Maintenance Hazard ........................................................................................5-2
5.1.4 Body Injury Hazard...........................................................................................5-2
5.2 Power System Maintenance ..............................................................................................5-3
5.2.1 Engine oil level..................................................................................................5-3
5.2.2 Diesel requirements..........................................................................................5-3
5.2.3 Engine coolant level inspection ........................................................................5-4
5.3 Battery Maintenance ..........................................................................................................5-5
5.4 Regular Maintenance.........................................................................................................5-5
5.4.1 Hydraulic reservoir............................................................................................5-5
5.4.2 Travel reducer...................................................................................................5-5
5.4.3 Replace engine oil............................................................................................5-6
5.4.4 Fuel filter...........................................................................................................5-6
5.4.5 High pressure filter ...........................................................................................5-7
5.4.6 Air filter..............................................................................................................5-8
5.4.7 Engine coolant..................................................................................................5-8
5.5 Tire and Wheel...................................................................................................................5-9
5.5.1 Tire replacement...............................................................................................5-9
5.5.2 Wheel and tire requirements ............................................................................5-9
5.5.3 Wheel installation ...........................................................................................5-10
5.6 Hydraulic System Maintenance ....................................................................................... 5-11
5.6.1 Hydraulic oil level............................................................................................ 5-11
5.6.2 Hydraulic oil capacity...................................................................................... 5-11
5.6.3 Hydraulic oil specification ............................................................................... 5-11

Contents
VI
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.............................................................................................................6-1
6.2 Ex-factory Test Items..........................................................................................................6-1
SECTION 7 Technical Parameter ..........................................................................................7-1

履带起重机操作手册
第一章 安全操作说明

SAFETY PRECAUTIONS
1-1
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:
a) Obey all user rules, job site regulations and governmental regulations.
b) Read, understand and obey all operating instructions on the machine and in this manual.
c) Keep good safety operating convention.
d) Allow only those authorized and qualified personnel to operate the machine under the supervision
of an experienced and qualified operator.
e) An operator must not operate the machine if he has any doubts.
Zoomlion appreciates your choice of our machine for your application.
1.2 Pre-operation
FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL COULD
RESULT IN PERSONAL INJURY OR DEATH.
An operator must not operate the machine, only if:
a) He has learned and practiced the principles of safe machine operation contained in this operational
manual.
1) Avoid hazardous situations.
2) Be aware of safety rules before further operation.
3) Perform a pre-operation inspection at all times.
4) Implement functional test before operating the machine at all times.
5) Inspect job site. The unit must work on a solid and level ground.
6) Only use the machine as it was intended.
b) Read, understand and obey the manufacturer’s instructions and safety rules—safety and operator’s
manuals and machine decals.
c) Read, understand and obey employer’s safety rules and worksite regulations.
d) Read, understand and obey all applicable governmental regulations.
e) The operator is properly trained to safely operate the machine.

SAFETY PRECAUTIONS
1-2
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. This decal will
have a red background.
Indicates a hazardous situation which, if not avoided, could result in death or serious injury. This decal
will have an orange background.
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. This decal
will have a yellow background.
Indicates a property damage message. This decal will have a blue background.
1.4 Intended Use
This machine is intended to be used onlyto lift personnel, along with their tools, and materials to an aerial
work site.
1.5 Safety Alert Symbols and Maintenance
Replace any missing or damaged safety signs. Keep operator safety in mind at all times. Use mild soap
and water to clean safety signs. Do not use solvent-based cleaners because they may damage the safety
sign material.

SAFETY PRECAUTIONS
1-3
Read operational
manual
Read service manual
Crushing hazard
Crushing hazard
Collision hazard
Tip-over hazard
Tip-over hazard
Tip-over hazard
Tip-over hazard
Electrocution
hazard
Electrocution
hazard
Explosion hazard
Fire hazard
Burn hazard
Dermohemia hazard
Engage safety arm
Keep away from
moving parts
Keep clear of
outriggers and
tires
Move machine to
level ground
Close chassis tray
Lower the platform
Do not set up where
it cannot be leveled
with outtriggers
Maintain required
clearance
Compartment
maintenance
implement by trained
and authorized
personnel only
Use a piece of
cardboard or paper
to search for leaks
Figure 1-1 Symbol and Hazard Pictorials Definitions

SAFETY PRECAUTIONS
1-4
Batteries used as
counterweights
Chock the wheels
Release brakes
3-wire groundedAC
power supply only
Replace damaged
wire and cable
Wheel load
Transporting
diagram
Tie-down points
Lanyard anchorage
points
No smoking
Voltage rating for
power to platform
Pressure rating for
air line to platform
Manual force
Wind speed
Maximum capacity
Outdoor
Indoor
砸压的危险
降低时握住栏杆
支腿负载
Figure 1-1 Symbol and Hazard Pictorials Definitions

SAFETY PRECAUTIONS
1-5
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.
1.6.2 Workplace safety
1.6.2.1 Electric shock hazard
This machine is not electrically insulated and will not provide protection from contact with or proximity
to electrical current.
a) Obey all local and governmental regulations regarding required clearance from electrical power lines.
Keep required clearance listed in Table 1-1.
Table 1-1 Required Clearance
No.
Voltage
Required clearance
1
0 to 50KV
3.05 m/10ft
2
50 to 200KV
4.60 m/15ft
3
200 to 350KV
6.10 m/20ft
4
350 to 500KV
7.62 m/25ft
5
500 to 750KV
10.67m/35ft
6
750 to 1000KV
13.72m/45ft

SAFETY PRECAUTIONS
1-6
b) Allow for platform movement, electrical line sway or sag, and beware of strong or gusty winds.
c) 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.
1.6.2.2 Tip-over hazard
a) Occupants, equipment and materials shall not exceed the maximum platform capacity.
Table 1-2 Rated Load
Model
Maximum Capacity
Capacity on Platform
Extended
ZS1623RT
680kg/1500lbs
230kg/510 lbs

SAFETY PRECAUTIONS
1-7
b) Do not elevate the platform unless the machine is on firm level ground.
c) 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.
If the tilt alarm sounds: use extreme caution to lower the platform with the emergency lowering pull
rod. Move the machine to a firm, level surface before lifting.
d) Do not drive over 1.1km/h with the platform raised.
Outdoor use: do not raise the platform when wind speeds may exceed 12.5 m/s(28 mph ).Lower the
platform and stop operating the machine if the wind speed exceeds 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
4

SAFETY PRECAUTIONS
1-8
e) 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.
f) 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.
g) Do not drive the machine on or near uneven terrain, unstable surfaces or other hazardous conditions
with the platform raised or extended.
h) The following operations are prohibited at any circumstances:
1) Push the machine or other objects with the platform.
2) Contact adjacent structures with the platform.
3) Tie the platform to adjacent structures.
4) Place loads outside the platform perimeter.
5) Operate the machine with the engine trays open.
6) Push off or pull toward any object outside of the platform.

SAFETY PRECAUTIONS
1-9
i) Do not modify or alter an aerial work platform without prior written permission from the
manufacture.
1) Do not alter or disable the limit switches.
2) Do not alter or disable machine components that in any way affect safety and stability.
3) Do not replace items critical to machine stability with items of different weight or specification.
4) 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.
j) Do not use lead acid or lithium-ion batteries that weigh less than the original equipment. Batteries
are used as counterweight and are critical to machine stability.
k) Do not place or attach fixed or overhanging loads to any part of this machine.
l) Do not place ladders or scaffolds in the platform or against any part of this machine.
m) Do not transport tools and materials unless they are evenly distributed and can be safely handled by
person(s) in the platform.
n) Do not use the machine on a moving or mobile surface or vehicle. Be sure the tires are in good
condition and the lug nuts tightened, besides the opening pin installed in the right position.
1.6.2.3 Crush hazard
a) Keep hands and limbs out of scissors.
b) Do not work under the platform or in the scissor links without the safety arm in place.
c) Use common sense and planning when operating the machine with the controller from the ground.
Maintain safe distances between the operator, the machine and fixed objects.
1.6.2.4 Danger of operation on the slope
Do not drive the machine on a slope that exceeds the slope and side slope rating of the machine. Slope
rating applies to machines in the stowed position.