Order Picker MANUAL
Order Picker MANUAL
ZDYT-300kg/3.0-3.5m
OPERATION INSTRUCTION
TABLE OF CONTENTS
SUBJECT‐SECTION,PARAGRAPH PAGE NO.
PREFACE..........................................................................3
APPLICATION.....................................................
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SAFETY PREAUTIONS
General.
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Trip and Fall Hazard. ..
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Electrocution Hazard..
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Tipping Hazard..
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Crushing And Collision Hazard..
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PRE-OPERATION
Pre-Service Check.
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Personnel Training.
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Operator Training. ..
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Training Supervision.
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Operator Responsibility.
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Workplace Inspection..
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Machine Inspection.
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TECHNICAL SPECIFICATIONS.........................................................8
OPERATING GUIDE
Maximum Speed / Profile Indicator.......
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Maximum Speed Indicator..
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Profile Indicator..
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Horn Button..
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Speed / Profile Decrease Button..
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Speed / Profile Increase Button..
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Actuator Buttons and LEDs..
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Control Panel ..............................................................10
MATTERS NEEDING ATTENTION
Oil Change In The Hydraulic System ............................................12
Battery Charger............................................................13
Battery ..................................................................13
OPERATOR MAINTENANCE
Hydraulic Oil (HO) .....
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1
Lubrication Specifications .....................................................14
ELECTRICAL DIAGARAM.....................................................18
SPARE PARTS.................................................。...........20
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PREFACE
Read this instruction carefully before the machine is taken into use to avoid
errors. Correct operations and regular inspections are factors of vital importance
for the operating economy and lifetime of the machine.
These important parts are described in the following related sections.
All the information contained in this booklet is based on the data available at
the time of printing, the manufacturer reserves the right to modify its products
at any time, without notice and without liability. It is therefore advisable to
regularly check for any changes.
Ⅰ APPLICATION
Electric Aerial Order Picker is the best equipment for materials picking and
handling. It’s intended for use on plane and level floors. Easy driving and
operating. Lift or fall steadily. Safe and reliable. Suitable for order picking
application in distribution warehouses.
Ⅱ SAFETY PRECAUTIONS
GENERAL
This section outlines the necessary precautions for proper and safe machine usage and maintenance. For proper
machine use, it is mandatory that a daily routine be established based on the content of this manual. A maintenance
program, using the information provided in this manual and the Service and Maintenance Manual, must also be
established by a qualified person and must be followed to ensure that the machine is safe to operate.
The owner/user/operator/lessor/lessee of the machine should not accept operating responsibility until this manual has
been read, training is accomplished, and operation of the machine has been completed under the supervision of an
experienced and qualified operator.
If there are any questions with regard to safety, training, inspection, maintenance, application, and operation, please
contact the manufacturer.
y Before operating the machine, make sure all railing and gates are fastened in their proper position.
y
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y
y
y Keep both feet firmly positioned on the platform floor at all times. Never use ladders, boxes, steps, planks, or
similar items on platform to provide additional reach.
y Never use the mast assembly to enter or leave the platform.
y Use extreme caution when entering or leaving platform. Ensure that the mast assembly is fully lowered. Face the
machine when entering or leaving the platform. Always maintain “three point contact” with the machine, using
two hands and one foot or two feet and one hand at all times during entry and exit.
y Platform-to-structure transfers at elevated positions are discouraged. Where transfer is necessary, enter/exit
through the gate only with the platform within 1 foot (0.3m) of a safe and secure structure. 100% tie-off is also
required in this situation utilizing two lanyards. One lanyard must be attached to the platform with the second
lanyard attached to the structure. The lanyard connected to the platform must not be disconnected until such
time the transfer to the structure is safe and complete.
Electrocution Hazard
Maintain a clearance of at least 10 ft (3m) between any part of the machine and its occupants, their tools, and their
equipment from any electrical line or apparatus carrying up to 50,000 volts. One foot (0.3m) additional clearance is
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required for every additional 30,000 volts or less.
The minimum safe approach distance may be reduced if insulating barriers are installed to prevent contact, and if the
barriers are rated for the voltage of the line being guarded. These barriers shall not be part of (or attached to) the
machine. The minimum safe approach distance shall be reduced to a distance within the designed working
dimensions of the insulating barrier. This determination shall be made by a qualified person in accordance with
employer, local, or governmental requirements for work practices near energized equipment.
Tipping Hazard
y The user should be familiar with the surface before driving. Do not exceed the allowable side slope and
grade while driving.
y Do not elevate platform or drive with platform elevated while on a slope, or on an uneven or soft surface.
y Before driving on floors, bridges, trucks, and other surfaces, check allowable capacity of the surfaces.
y Never exceed the maximum platform capacity. Distribute loads evenly on platform floor.
y Keep the chassis of the machine a minimum of 2 ft. (0.6m) from holes, bumps, drop-offs, obstructions, debris,
concealed holes, and other potential hazards at the ground level.
y Never attempt to use the machine as a crane. Do not tie-off machine to any adjacent structure.
y Do not increase the platform size with unauthorized deck extensions or attachments, increasing the area
exposed to wind will decrease stability.
y If mast assembly or platform is caught so that one or more wheels are off the ground, the operator must be
removed before attempting to free the machine. Use cranes, forklift trucks, or other appropriate equipment to
stabilize machine and remove personnel.
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y During operation, keep all body parts inside platform railing.
y Always post a lookout when driving in areas where vision is obstructed.
y Keep non-operating personnel at least 6 ft. (1.8m) away from machine during all driving operations.
y Limit travel speed according to conditions of ground surface, congestion, visibility, slope, location of personnel,
and other factors causing hazards of collision or injury to personnel.
y Be aware of stopping distances in restricted or close quarters or when driving in reverse.
y Do not drive at high speeds in restricted or close quarters or when driving in reverse.
y Exercise extreme caution at all times to prevent obstacles from striking or interfering with operating controls and
persons in the platform.
y Ensure that operators of other overhead and floor level machines are aware of the aerial work platform’s
presence. Disconnect power to overhead cranes.
y Warn personnel not to work, stand, or walk under a raised platform. Position barricades on floor as necessary.
WARNING
FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL COULD RESULT IN
MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
PRE-OPERATION
Pre-Service Check
1.If the machine has been damaged during transport, it must not be put into service, and you should immediately
contact your dealer.
2.The machine has been lubricated before delivery, and the hydraulic unit has been filled with hydraulic oil.
3.If a battery has been supplied with the machine, the battery is charged.
Check that the acid level is correct in each cell and that the specific gravity is in order.
Personnel Training
The aerial platform is a personnel-handling device; so it is necessary that it be operated and maintained only by
trained personnel.
Persons under the influence of drugs or alcohol or who are subject to seizures, dizziness or loss of physical control
must not operate this machine.
Operator Training
Operator training must cover:
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1. Use and limitations of the controls in the platform and at the ground, emergency controls and safety systems.
2. Control labels, instructions, and warnings on the machine.
3. Rules of the employer and government regulations.
4. Use of approved fall protection device.
5. Enough knowledge of the mechanical operation of the machine to recognize a malfunction/
6. The safest means to operate the machine where overhead obstructions, other moving equipment, and obstacles,
depressions, holes, drop-offs are present.
7. Means to avoid the hazards of unprotected electrical conductors.
8. Specific job requirements or machine application.
Training Supervision
Training must be done under the supervision of a qualified person in an open area free of obstructions until the trainee
has developed the ability to safely control and operate the machine.
Operator Responsibility
The operator must be instructed that he/she has the responsibility and authority to shut down the machine in case of a
malfunction or other unsafe condition of either the machine or the job site.
NOTE: The Manufacturer or Distributor will provide qualified people for training assistance with the first unit(s)
delivered and from that time forward as requested by the user or his/her personnel.
Workplace Inspection
y The operator is to take safety measures to avoid all hazards in the work area prior to machine operation.
y Do not operate or raise the platform while on trucks, trailers, railway cars, floating vessels, scaffolds or other
equipment unless approved in writing by the manufacturer.
y This machine can be operated in temperatures of –20℃ to 40℃. Consult the manufacturer for operation
outside this range.
Machine Inspection
y Before machine operation, perform inspections and functional checks.
y Do not operate this machine until it has been serviced and maintained according to requirements specified in the
Service and Maintenance Manual.
y Ensure all safety devices are operating properly. Modification of these devices is a safety violation.
WARNING
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY WITH PRIOR
WRITTEN PERMISSION FROM THE MANUFACTURER
y Do not operate any machine on which the safety or instruction placards or decals are missing or illegible.
y Avoid any build up of debris on platform floor. Keep mud, oil, grease, and other slippery substances from
footwear and platform floor.
Ⅲ TECHNICAL SPECIFICATIONS
Technical specifications and major dimensions are shown in TABLE 1 and
FIGURE 1, respectively.
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FIGURE 1
TABLE 1
TYPE ZDYT3/30 ZDYT3 /35
Maximum Platform Height(H) 3000 3500
Maximum Machine mm
4450 5200
Height(H1)
Rated Capacity kg 300 300
Platform Size(ln) mm 600X640
Maximum Drive Speed
kph 4
(Platform Lowered)
Maximum Drive Speed
kph 1.6
(Platform Raised)
Minimum Turning Radius mm 1500
Maximum Travel Grade
% 15~20
(Grade ability)
Driving Motor v/w 24/2X400~500
Lifting Motor v/kw 24/2
Battery v/Ah 2X12/100
Charger v/A 24/20
Overall Length(A) 1550
Overall Width(B) mm 700
Overall Height(C) 1950 2200
Net Weight kg 574 588
Machine Noise dB 62 62
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Ⅳ OPERATING GUIDE
Joystick
The primary function of the joystick is to control the speed and direction of the
machine. The further you push the joystick from the center position the faster the
machine will move. When you release the joystick the brakes are automatically
applied.
If the machine is fitted with actuators, the joystick can also be used to select and
move actuators.
Maximum Speed / Profile Indicator
This is a gauge which shows the maximum speed setting for the machine or, if the
control system is programmed for drive profile operation, the selected drive profile.
For more information on drive profiles.
This gauge also indicates if the speed of the machine is being limited or if the
control system is locked.
Maximum Speed Indicator
This is a gauge that shows the maximum speed setting of the machine. There are
five speed settings – step 1 is the lowest speed and step 5 is the highest speed. For
details of how to change the maximum speed setting.
Profile Indicator
This is an indicator that shows the selected drive profile. There may be up to 5 drive
profiles available, this depends on the programming of the control system. For details
of how to select drive profiles.
Horn Button
The horn will sound while this button is depressed.
Speed / Profile Decrease Button
This button decreases the maximum speed setting or, if the control system is
programmed for drive profile operation, selects a lower drive profile.
It is possible to program the control system so this button has no effect while the
machine is being driven.
Speed / Profile Increase Button
This button increases the maximum speed setting or, if the control system is
programmed for drive profile operation, selects a higher drive profile.
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It is possible to program the control system so this button has no effect while the
machine is being driven.
Control Panel
There are five buttons and two indicator lights on the control panel. As
it shows:
Button 1 is the on-off button. When you press it, the indicator lamp will
show you the battery capacity.
Button 2 is a horn switch.
Button 3 is used for accelerating. Button 4 is used for decelerating. Press
the button 3 and button 4 can adjust drive speed. Indicator light 7 is used to
display the drive speed.
Button 5 are used for changing mode of the operation (elevating and
traction).
Indicator light 6 is Battery Gauge. It is used to display electric quantity
or malfunction. The battery Gauge has ten bars. They are not flash when the
machine is good. If the picker has malfunction, they will flash. The detailed
trouble is as follows:
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Behind the joystick there is a big mushroom-shaped button,which is
provided for emergency stop. This should be used only when other means to
stop the platform moving fails. Reset the button by turning the knob in the
direction shown by the arrow. Do not pull the knob.
DAILY CHECK
1. Check that the battery is fully charged (see also the section of the battery).
2. Lift the platform to its top position to check that there is enough hydraulic oil in
the system. Refill if necessary with YA-N32 or a similar oil.
WEEKLY CHECK
The user of the picker should spend a few minutes every week on cleaning.
Special attention should be paid to the wheels and axles, see if there is thread,
rags and the like blocked on.
HALF-YEAR CHECK
1.Lubricate the lifting chain. Check the chain for wear.
2.Check and tighten possible loose screws and nuts and the cable joints of the
battery.
3.Check brush wear in the pump motor, and take away possible irregular
so that a good contact is maintained.
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not been obtained it is necessary to refill.
Forbid to dump the dirty hydraulic oil anywhere at random after the hydraulic
oil is changed. The dirty hydraulic oil must be subject to special prescription
and comply with the current legal provisions in the area and country where the
machine is used.
BATTERY CHARGER
Fan Charger Indicator ON/OFF Switch
AC Input
100%
85%
70%
50%
30%
AC Input Voltage
Battery Indicator Selector
FIGURE 3
When AC input, the fan will running, charge indicator will flash and
battery indicator which displays the battery capacity is on. When
taking out AC, the fan will stop, battery and charge indicator will
still on in a short time, a few minutes later, charge indicator will
put out, battery indicator is still on.
NOTICE
When battery indicator display 30%, please charge in time, and
choose the fit voltage. The machine’s platform drive and elevate
functions are disabled when the battery charge. If the machine will
stop using for a long time, please charge in the fixed time.
BATTERY
To ensure the battery’s better performance and prolong its usage life, examine
the liquid level regularly. If the liquid level is below the lower line, please add
distilled water or purified water till the level reaches the upper line. Refilling
must not take place until charging has been finished, as the acid expands during
charging. The battery surface must be kept clean and dry, as dirt and wet will
cause leakage of current and consequently reduced battery capacity.
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WARNING
For saving the battery, when operate is finished, please turn off the battery
button, pull out the key.
Ⅵ OPERATOR MAINTENANCE
Lubrication
Hydraulic Oil (HO)
Hydraulic oils must have anti-wear qualities, and sufficient chemical stability for mobile hydraulic system service. The
manufacturer recommends Mobil fluid 424 hydraulic oil, which has an SAE viscosity of 10W-30 and a viscosity index
of 152.
For cold weather applications, i.e. When temperatures remain consistently below +20°F (-7℃) The manufacturer
recommends using Mobil DTE 13 hydraulic oil.
Aside from The manufacturer’s recommendations, it is not advisable to mix oils of different brands or types, as they
may not contain the same required additives or be of comparable viscosities. If use of hydraulic oil other than Mobil
fluid 424 is desired, contact the manufacturer for proper recommendations.
KEY SPECIFICATIONS
Multipurpose Grease having a minimum dripping point of 350°F. Excellent water resistance and adhesive
MPG-
qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.)
EPGL- Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 or MIL -Spec MIL –L-2105.
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Table 3-2. Lubrication Intervals for Various Components
COMPO NO/TYPE(a) LUBE/MET INTERVAL (b)
ITEM
LUBE COMMENTS
NENT POINTS HOD 3
MONTHS
6
MONTHS
1
YEAR
2
YEARS
1 Hydraulic oil Fill HO-Check Hyd. Check fluid level every
the Oil Level day. (c)
Reservoir
HO-Change Hyd. √ Change hydraulic oil
Oil every 1 year.
2 Caster Axles 2-Grease MPG-Pressure
√
Fittings Gun
3 Swivel 2-Front MPG-Pressure
√
Raceways Casters Gun
Key to Lubricants: MPG- Multipurpose Grease
HO- Hydraulic Oil – ISO-Vg grade 32, 46.
CL- Chain Lube. Use a good quality chain lubricant
Notes: (a) Be certain to lubricate like items on each side of the machine.
(b) Recommended lubricating intervals are based on normal use. If machine is subjected to severe operating
conditions, such as a high number of cycles, location, corrosive/dirty environment, etc., user must adjust
lubricating requirements accordingly.
(c) Prior to checking hydraulic oil level, operate machine through one complete cycle of lift function (full up
and down). Failure to do so will result in incorrect oil level reading on the hydraulic reservoir.
The machine may be winched onto a tilted roll-back truck bed (see important note following), which has been rolled
back to ground level. Disengage the brakes and always winch (pull) from the mast (rear) end of the machine.
IMPORTANT
DO NOT ATTEMPT TO DRIVE MACHINE ONTO, OFF OF, OR PUSH MACHINE ONTO A TILTED ROLL-BACK
TRUCK BED.
THE ZDYT MACHINES POWER MODULE COULD SUSTAIN SERIOUS DAMAGE WHEN THE UNIT IS PUSHED,
OR TOWED AT SPEEDS GREATER THAN 2 MPH.
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IMPORTANT
USE OF EXCESSIVE FORCE WHEN SECURING MACHINE (DRIVE WHEEL LOAD), CAN CAUSE DAMAGE TO
THE MACHINES DRIVE WHEEL COMPONENTS.
The chain should be securely tightened with a force of approximately 100 lb. applied two feet from the pivot handle.
NOTE: Fork-lift trucks must be capable of handling the gross weight of the machine.
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Date Comments
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ES KS
FU2
FU1
KM2
JSM
Brake +ve SSR1 SSR2
Brake -ve
JSK
Motor +ve
ML Motor -ve
VD1 VD2 VD3 VD4 YV KM1 KM2
KM1
V A1
B+ 1 VD5 VD6
GG R 2
1
B-
2
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2
IN SQ1
MR Motor -ve
Motor +ve
Brake -ve
Brake +ve
L
M1 1 PE
KA
3 N
OBC
+ -
Ⅷ Electrical diagram
QQE
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Ⅸ SPARE PARTS
ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY
1 Nut M12 1 32 Piston rod 1
2 Battery 2 33 Spacer sleeve 1
3 Charger 1 34 O-ring 1
4 Safety mantle 1 35 Piston 1
5 Caster 2 36 Gasket ring 1
6 Motor baffle 37 Nut 1
7 Tightening cap 2 38 Retainer pin 1
8 Transition joint 2 39 Explosion relief valve 1
9 Joint 1 40 Cylinder 1
10 Conduit pipe 1 41 Anchor loop 1
11 Pin 1 42 Rubber pad 1
12 Circlip 2 43 Nut 4
13 Pump motor 1 44 O-ring 1
14 Oil tank 1 45 O-ring 1
15 Drive wheel 1 46 Cylinder cap 1
16 Drive motor 1 47 Dust seal 1
17 Circlip 9 48 Plastic clamp 2
18 Nylon pulley 1 49 Protective screen 1
19 Sprocket shaft 1 50 Lateral roller 4
20 Spacer 1 51 Bush 4
21 Inner mast assembly 1 52 Lateral roller retainer 2
22 Bolt 1 53 Pin 4
23 Sprocket shaft 1 54 Work platform 1
24 Circlip 1 55 Baffle 1
25 Bearing 2 56 Gate 2
26 Sprocket 2 57 Joystick 1
27 Chain 2 58 Guardrail 2
28 Chain tightener 2 59 Guardrail Lock 2
29 Roller 8 60 Lock Board 2
30 Bearing 8 61 Wheel Board 2
31 Circlip 8 62 Wheel Base 2
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