Bil-Jax ESP 19 Hydraulic Lift Platform Manual
The Bil-Jax ESP 19 hydraulic lift is designed for use as a warehouse stocking and order picking vehicle. The maximum platform load is limited to 450 lbs and all operations are powered by a 24-Volt DC battery package. A 40-amp battery charger and plug-in receptacle are included for recharging the batteries. The platform lift function is hydraulic, including a hydraulic cylinder, reservoir, and pump. The hydraulic pump motor is driven by a 24-Volt DC electric motor. Elevation is by a 1-3/4 inch linear-displacement hydraulic cylinder and four telescoping mast sections. Other electrically powered functions include a two-wheel drive transaxle for floor travel and pushbutton steering. Floor travel and platform lift functions are controlled from an upper control box located on the lift platform.
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This equipment is designed and manufactured in compliance with the duties, responsibilities and standards set forth in the ANSI, CE, CSA and/or AS standards in effect at the time of manufacture.
This equipment will meet or exceed applicable ANSI,
CE, CSA and/or AS codes and standards when operated in accordance with manufacturer’s recommendations.
It is the responsibility of the user to follow all regional codes and regulations that govern the safe operation of this equipment.
Obtain, read and obey all safety precautions before performing maintenance or repairs or attempting to operate this equipment. This includes all manufacturer recommendations as well as those directives set forth by government and local authorities.
To ensure proper and safe use of this equipment, it is strongly recommended that only trained and authorized personnel attempt to operate and maintain the boom lift.
This manual shall be considered a permanent and necessary component of the machine and shall be kept with the boom lift at all times.
Owners and Lessors should complete a full inspection of all components and perform a test of all functions, including brake functions, before commissioning or reselling the machine. Repair or replace all damaged or malfunctioning components.
Bil-Jax, Inc. is dedicated to the continuous improvement of this and all Bil-Jax products. Therefore, equipment information is subject to change without notice. Direct any questions or concerns regarding errors or discrepancies in this manual to the Bil-Jax Service
Department.
Copyright © Bil-Jax, Inc. 2008. All Rights Reserved.
“Bil-Jax” is a registered trademark and “A Step
Above” and “X-Boom” are trademarks of Bil-Jax,
Inc. Contact Bil-Jax for replacement manuals.
125 Taylor Parkway
Archbold, Ohio 43502
B33-01-0110
2
TABLE OF CONTENTS
TABLE OF CONTENTS
ILLUSTRATIONS AND TABLES
1 SAFETY
LEGEND: SAFETY ADVISORIES
BEFORE OPERATION
DURING OPERATION
MAINTENANCE SAFETY
BATTERY MAINTENANCE
DAMAGED EQUIPMENT POLICY
3
4
5
6
7
7
9
9
10
2 INTRODUCTION 11
SPECIFICATIONS 12
WARRANTY 12
3 OPERATION
OPERATOR CONTROLS
NORMAL OPERATING PROCEDURE
EMERGENCY LOWERING PROCEDURE
LIFT VEHICLE TRANSPORT
13
13
15
16
17
4 MAINTENANCE 19
SCHEDULED SERVICE CHECKS
UNDERGUARD SERVICE CHECK
HYDRAULIC SYSTEM
PRESSURE RELIEF VALVE ADJUSTMENT
19
21
23
24
FLOW RESTRICTOR VALVE REPLACEMENT 24
VALVE OPERATION 25
HYDRAULIC CYLINDER REPAIR
ELECTRICAL SYSTEM
LIFT CHAINS AND SLIDE BLOCKS
26
27
28
TROUBLESHOOTING 30
TROUBLESHOOTING AIDS 33
DECAL REPLACEMENT
APPENDIX A: PART LISTS
APPENDIX B: REFURBISHMENT
47
51
81
3
4
TABLES AND ILLUSTRATIONS
Table 1-1
Table 2-1
Figure 3-1
Figure 3-2
Figure 3-3
Figure 3-4
Figure 3-5
Figure 3-6
Table 4-1
Table 4-2
Figure 4-1
Figure 4-2
Figure 4-3
Figure 4-4
Figure 4-5
Minimum Safe Approach Distances
Specifications
Lower Control Box
Upper Control Box
Battery On/Off Switch
Emergency Lowering Valve
Lifting and Tow Procedures
Travel Brake and Steering Linkage
Daily/Weekly Service Checks
6 Month/Yearly Service Checks
Underguard
Lift Chains Lubrication
Mast Slide Ways Lubrication
Rear Casters Lubrication
Front Caster Pillow Block Lubrication
Figure 4-6
Figure 4-7
Pressure Relief Valve Adjustment
Flow Restrictor Valve
Figure 4-8
Figure 4-9
Valve Operation
Hydraulic Cylinder Disassembly
Figure 4-10 Battery Charger Cord
Figure 4-11 Chain Elongation Inspection
Figure 4-12 Lift Chains Adjustment
Figure 4-13 Slide Blocks Adjustment
Table 4-3 Troubleshooting
Figure 4-14 Main Controller Board
Table 4-4 Main Controller LED Indicators
Figure 4-15 Hydraulic Diagram
Figure 4-16 PC Logic Diagram
Figure 4-17 Electrical Layout
Figure 4-18 Drive Wiring Diagrams
Figure 4-19 Upper Control Wiring Diagram
Table 5-1 Replacement Decals
Figure 5-1
Figure 5-2
Decal Locations, Side View
Decal Locations, Rear View
42
43
45
48
49
50
33
34
40
41
28
28
29
30
22
22
22
22
17
19
20
21
24
24
25
26
27
7
12
13
14
15
16
17
1
SAFETY
Proper training is required for the safe operation of any mechanical device.
Failure to follow all instructions and safety precautions in this manual and attached to the lift will result in death or personal injury.
Prior to Operation:
Read, understand and obey all instructions and safety precautions in this manual and attached to the lift.
Read, understand and obey all applicable government regulations.
Become familiar with the proper use of all controls.
Inexperienced users should receive instruction before attempting to operate or maintain the machine.
The use of intelligence and common sense is the best practice when following any safety policy.
5
LEGEND: SAFETY ADVISORIES
The following safety advisories are used throughout this manual to indicate specific hazards when operating or maintaining the machine. Read, understand and obey all safety advisories to prevent improper service, damage to equipment, personal injury or death.
DANGER
Warns of operation near electrical power sources that could lead to personal injury or death.
WARNING
Describes conditions or practices that could lead to personal injury or death.
CAUTION
Contains information important in the prevention of errors that could damage machine or components.
NOTE: Contains additional information important for performing a procedure.
6
BEFORE OPERATION
Read and observe the following general safety precautions before operating the ESP 19.
ALWAYS survey the usage area for potential hazards such as untampered earth fills, unlevel surfaces, overhead obstructions, and electrically charged conductors or wires. Be aware of any potential hazards and always consider what could happen. Watch for moving vehicles in the operating area.
ALWAYS read, understand, and follow the procedures in this manual before attempting to operate equipment.
ALWAYS inspect the equipment for damaged or worn parts. Check for cracked welds, hydraulic leaks, damaged wiring, loose wire connectors, damaged casters, and damaged pothole guards.
Also check for any improper operation. NEVER operate equipment if damaged in any way.
Improperly operating equipment must be repaired before using.
ALWAYS wear proper clothing for the job. Wear protective equipment as required by federal, state, or local regulations.
ALWAYS locate, read, and follow all directions and warnings displayed on the equipment.
ALWAYS inspect the equipment for “DO NOT USE” tags installed by maintenance personnel. NEVER use tagged equipment until repairs are made and all tags are removed by authorized maintenance personnel.
ALWAYS make sure the platform is free of mud, grease, or other foreign material. This will reduce the possibility of slipping.
NEVER allow improperly trained personnel to operate this equipment. Only trained and authorized personnel shall be allowed to operate this equipment.
NEVER operate this equipment if you are under the influence of alcohol or drugs or if you feel ill, dizzy, or unsteady in any way. Operators must be physically fit, thoroughly trained, and not easily excitable.
NEVER modify, alter, or change the equipment in any way that would affect its original design or operation in any way.
NEVER operate this equipment in ways for which it is not intended.
DURING OPERATION
Ensure the following general safety precautions are followed while operating the ESP 19:
DANGER
This machine is NOT insulated for use near electrical power lines and DOES NOT provide protection from contact with or close proximity to any electrically charged conductor. Operator must maintain safe clearances at all times (3.05 meters minimum) and must always allow for platform movement due to gusty winds. Always contact power company before working near power lines. Assume every power line is live.
Power lines can be blown by the wind. Refer to
Table 1-1 for minimum safe approach distances between the machine and electrical power lines.
Table 1-1. Minimum Safe Approach Distances
Voltage Range
(Phase to Phase)
0 to 300V
Over 300V to 50KV
Over 50KV to 200KV
Over 200KV to 350KV
Over 350KV to 500KV
Over 500KV to 750KV
Over 750KV to 1000KV
Minimum Safe Approach Distance
(Feet) (Meters)
Avoid Contact
10 3.05
15
20
25
35
45
4.60
6.10
7.62
10.67
13.72
ALWAYS position lift far enough away from power sources to ensure that no part of the lift can accidentally reach into an unsafe area.
ALWAYS operate only on a firm and level surface.
NEVER use on surfaces that do not support the weight of the equipment and its rated load capacity.
ALWAYS keep yourself and all personnel away from potential pinch or shear points.
ALWAYS report any misuse of equipment to the proper authorities. Horseplay is prohibited.
ALWAYS maintain good footing on the platform.
NEVER wear slippery soled shoes.
ALWAYS make certain all personnel are clear and there are no obstructions before repositioning platform.
7
ALWAYS cordon off area around the base to keep personnel and other equipment away from it while in use.
ALWAYS stay clear of wires, cables, and other overhead obstructions.
ALWAYS disconnect power at the batteries when not in use to guard against unauthorized use.
NEVER allow electrode contact with any part of the platform if welding is being performed from the platform.
NEVER override or by-pass manufacturer's safety devices.
NEVER release the travel brake or tow the lift vehicle while a person or materials are on board.
NEVER stand or sit on guard rails. Work only within the platform guard rail area and do not lean out over guard rails to perform work.
NEVER attempt to increase working height with boxes, ladders, or other means.
NEVER operate this equipment when exposed to high winds, thunderstorms, ice, or any other weather conditions that would compromise the safety of the operator.
NEVER climb up or down masts.
NEVER allow ropes, electric cords, hoses, etc. to become entangled in the equipment when the platform is being raised or lowered.
NEVER exceed manufacturer's platform load limits and make sure all materials are evenly distributed over the entire platform.
NEVER exceed platform load ratings by transferring loads to platform at elevated heights.
NEVER use guard rails to carry materials and never allow overhang of materials when raising or lowering platform.
8
MAINTENANCE SAFETY
Read and observe the following general safety precautions when performing maintenance on the
ESP 19.
ALWAYS perform maintenance procedures according to manufacturer's requirements. NEVER short change maintenance procedures.
ALWAYS check hydraulic system. Make sure all lines, connectors, and fittings are tight and in good condition.
ALWAYS keep all mechanisms properly adjusted and lubricated according to maintenance schedule and manufacturers specifications.
ALWAYS perform a function check of operating controls before each use and after repairs have been made.
ALWAYS locate and protect against possible pinch points prior to performing maintenance and repairs.
ALWAYS use only factory-approved parts to repair or maintain this equipment. If this equipment is rebuilt, retesting is required in accordance with factory instructions.
NEVER add unauthorized fluids to the hydraulic system or battery. Check manufacturers specifications.
NEVER exceed the manufacturer's recommended relief valve settings.
NEVER attempt repairs you do not understand.
Consult manufacturer if you have any questions regarding proper maintenance, specifications, or repair.
Battery Maintenance
Read and observe the following general safety precautions when performing battery maintenance on the ESP 19.
Check battery charge indicator for proper state of charge on maintenance free batteries before using lift.
ALWAYS wear safety glasses when working near battery.
ALWAYS avoid contact with battery acid. Battery acid causes serious burns. Avoid contact with skin or eyes. If accidental contact occurs, flush with water and consult a physician immediately.
ALWAYS disconnect ground cable first when removing battery.
ALWAYS connect ground cable last when installing battery.
ALWAYS charge batteries in open, well-ventilated areas.
NEVER smoke when servicing battery.
NEVER allow batteries to overcharge and boil.
NEVER short across battery posts to check for current. NEVER break a live circuit at battery.
NEVER jump start other vehicles using lift battery.
9
10
DAMAGED EQUIPMENT POLICY
Safety Statement
At Bil-Jax, we are dedicated to the safety of all users of our products. Therefore, all Bil-Jax lifts are designed, manufactured, and tested to comply with current applicable Federal OSHA and ANSI codes and regulations.
Damage Policy
There may be occasions when a Bil-Jax lift is involved in an incident that results in structural damage to the lift. This can seriously compromise the ability of the lift to perform in a safe manner. Therefore, whenever a Bil-Jax lift is damaged structurally or when there is the possibility of structural damage (this damage may be internal and is not always visible to the naked eye), Bil-Jax requires that the lift be returned to our facility at 125 Taylor Parkway, Archbold, Ohio, for reconditioning. If you have any questions concerning what constitutes structural damage, please call the Bil-Jax Service Department at 800-537-0540.
Damage Repair Notice
There may be occasions when a Bil-Jax lift is involved in an incident resulting in nonstructural damage. When this occurs and repairs are made by the owner or area distributor, please notify Bil-Jax of these non-maintenance repairs and request a repair form to be filled out and returned to Bil-Jax.
2
INTRODUCTION
The ESP 19 hydraulic lift is designed and manufactured for use as a warehouse stocking and order picking vehicle. Its guard rail design permits the operator to ride on the platform with the load, while transferring parts to and from multiple overhead storage locations. The maximum platform load is limited to 450 lbs.
All ESP 19 operations are powered by a 24-Volt DC battery package. A 40-amp battery charger and plug-in receptacle are included in the system for recharging the batteries at the end of each work period. A charge level indicator displays the battery charge status.
The platform lift function is hydraulic, including a hydraulic cylinder, reservoir, and pump. The hydraulic pump motor is driven by a 24-Volt DC electric motor.
Elevation is by a 1-3/4 inch linear-displacement hydraulic cylinder and four telescoping mast sections. The lower mast section is raised by hydraulic cylinder.
The upper mast sections are raised mechanically by connecting sets of chains and sheaves (pulleys). The lift platform rises four inches for each inch of hydraulic cylinder extension.
Other electrically powered functions include a two-wheel drive transaxle for floor travel and pushbutton steering. The maximum travel speed is enabled only when the lift platform is down. When the platform is raised, the travel speed is limited.
The transaxle includes an electric brake that locks the drive wheels whenever forward or reverse travel is halted. The electric brake is normally applied; the brake disengages when forward or reverse travel is enabled with the joystick. In case of a loss of battery power, a manual free wheel lever can be used to disengage the electric brake, allowing the lift vehicle to be towed.
Floor travel and platform lift functions are controlled from an upper control box located on the lift platform. Floor travel is by joystick control with pushbutton steering. Lift functions are by pushbutton control. Platform lift can also be controlled from a lower control box mounted on the vehicle base. An electronic level sensor disables all lift and travel functions except platform lowering if the lift vehicle base is more than one degree out of level. While out of level, travel can be resumed after the lift platform is fully lowered.
With equipment power on or off, turning an emergency lowering valve knob lowers the lift platform at a controlled, safe speed. The lowering valve knob is visible and readily accessible from floor level.
Proper lift vehicle operation and safety are assured by performing the scheduled inspection and maintenance procedures set forth in this manual. The risk of platform free-fall is eliminated by proper maintenance of the chains, sheaves and sheave pins, a properly installed flow restrictor valve, and a clean mast. The restrictor valve (non-adjustable) fixes the maximum rate of platform descent to approximately 0.6 feet per second, whether the platform is empty or fully loaded.
With the restrictor valve properly installed, a hydraulic hose failure will result in the same maximum rate of descent.
Carefully read and understand all of the safety instructions in Section 1 and all operating instructions in Section 3 of this manual before operating the lift vehicle
11
12
SPECIFICATIONS
ESP 19 Electric Hydraulic Lift Platform
Model Number ESP 19 Serial Number ________________
Manufactured by: Bil-Jax, Inc.
125 Taylor Parkway
Archbold, Ohio 43502
800-537-0540
Table 2-1. Specifications
Rated Platform Load
Extended Platform Height 19 ft 3 in (5.9 m)
Retracted Platform Height 20 in. (50.8 cm)
Platform Dimensions
450 lbs (204 kg) total including operator
[1 person + materials not to exceed 450 lbs (204 kg)]
Base Dimensions
30 in. W x 30 in. L x 42 in. H
(0.76 m x 0.76 m x 1.07 m)
30-1/2 in. W x 63 in. L x 80 in. H
(0.77 m x 1.60 m x 2.03 m)
Gross Shipping Weight
Platform Lift Time
2150 lbs (975 kg)
20 seconds empty, 32 seconds loaded
Platform Retraction Time 22 seconds empty, 22 seconds loaded
Platform Lift Rate Lift platform empty: 0.66 ft (0.3 m)/sec.
Lift platform loaded: 0.42 ft (0.19 m)/sec.
Hydraulic System Pressure 1200 psi empty, 2100 psi loaded
Travel Speeds (Maximum) Lift platform lowered: 2.5 mph
Lift platform raised: 0.5 mph
Power Source DC – two in-series 12 volt maintenance-free batteries
WARRANTY
Bil-Jax warrants its telescopic lifts for one year from the date of delivery against all defects of material and workmanship, provided the unit is operated and maintained in compliance with Bil-Jax’s operating and maintenance instructions; structural components are warranted for three years. Bil-Jax will, at its option, repair or replace any unit or component part which fails to function properly in normal use.
This warranty does not apply if the lift and/or its component parts have been altered, changed, or repaired without the consent of Bil-Jax or by anyone other than Bil-Jax or its factory trained personnel, nor if the lift and/or its components have been subjected to misuse, negligence, accident or any conditions deemed other than those considered as occurring during normal use.
Components not manufactured by Bil-Jax are covered by their respective manufacturer’s warranties. A list of those components and their warranties is available upon written request to Bil-Jax.
Bil-Jax shall not in any event be liable for the cost of any special, indirect, or consequential damages to anyone, product, or thing. This warranty is in lieu of all other warranties expressed or implied. We neither assume nor authorize any representative, or other person, to assume for us any other liability in connection with the sale, rental, or use of this product.
3
OPERATION
OPERATOR CONTROLS
Most of the operator controls for the ESP 19 are located on the upper and lower control boxes. Other operator controls include the BATTERY ON/OFF switch and the emergency lowering valve. The BATTERY ON/OFF switch, located on the left side of the lift base, is the main power disconnect switch for the lift vehicle. The location and operation of the emergency lowering valve is described in paragraph
3-3.
Lower Control Box
The lower control box, Figure 3-1, is located on the lift base and contains three controls: UP/DOWN,
EMERGENCY STOP
, and UPPER CONTROL/OFF/LOWER
CONTROL. The lower control box enables lift operations from floor level.
The UPPER CONTROL/OFF/LOWER CONTROL key switch selects the active
(upper or lower) control location. To enable an UP or DOWN lift motion from the floor, turn and hold the key switch in the LOWER CONTROL position. To enable lift vehicle travel or platform elevation from the upper control box, turn the key switch to the UPPER CONTROL position. To disable lift vehicle operations, turn the key switch to the OFF position and remove the key.
Turn the UP/DOWN selector switch to the UP position to raise the lift platform or to the DOWN position to lower the platform. (The key switch must be held in the
LOWER CONTROL position to enable the UP/DOWN selector switch).
Press the EMERGENCY STOP button to stop all equipment motion. If the lift vehicle is moving forward or back, pressing the EMERGENCY STOP button engages the travel brake causing travel to stop quickly. To resume lift vehicle operation, turn the EMERGENCY STOP button clockwise.
Figure 3-1. Lower Control Box
13
14
Upper Control Box
The upper control box, Figure 3-2, is in the lift cage. The upper control box enables lift and travel operations whenever the BATTERY ON/OFF switch is in the ON position and the lower control box key switch is in the UPPER CONTROL position.
Upper control box controls include four pushbuttons and a forward/reverse floortravel joystick with thumb-switch steering.
ENABLE
PUSHBUTTONS
STEERING
THUMB
SWITCH
UP
PUSHBUTTON
DOWN
PUSHBUTTON
EMERGENCY
STOP
PUSHBUTTON
TRAVEL
JOYSTICK
Figure 3-2. Upper Control Box
Press and hold either one of the ENABLE pushbuttons to enable a control function. An ENABLE pushbutton must be pressed to enable the lift, steering, and travel functions. The ENABLE pushbutton must be held down to continue the equipment function.
With one of the ENABLE pushbuttons depressed, press the UP [ ] pushbutton to raise the platform or press the DOWN [ ] pushbutton to lower the platform.
With one of the ENABLE pushbuttons depressed, move the travel joystick forward or back to move the lift vehicle in the forward or reverse direction. For slow speeds, move the joystick forward or back just a little. For faster speeds, move the joystick more.
With one of the ENABLE pushbuttons depressed, press the left or right side of the thumb switch to steer the rear wheels to the left or right. The steering can be adjusted before or during floor travel.
Press the EMERGENCY STOP button to stop all equipment motion. If the lift vehicle is moving forward or back, a travel brake is applied causing travel to stop.
To resume lift vehicle operations, turn EMERGENCY STOP button clockwise.
NORMAL OPERATING PROCEDURE
Perform the following procedures to operate the
ESP 19 platform lift vehicle.
Read and follow all safety precautions contained in
Section 1 and all responsibilities outlined in the ANSI
A92.3 reprint in Section 7 of this manual.
Check the lift vehicle for damage or worn parts. If damage or part wear is found, do not operate the vehicle until the problem is corrected.
Make sure battery charger cord is disconnected from wall outlet. Place cord back into its box and close and latch lid. LIFT WILL NOT OPERATE IF LID IS
NOT CLOSED SECURELY.
Turn the BATTERY ON/OFF switch, Figure 3-3, to the ON position.
Observe the battery charge level indicator. Verify that the battery charge level is 3/4 or more.
sounds an alarm beeper. Once the platform is lowered, floor travel is again enabled to allow travel to a level area.
During floor travel and lift operations, the alarm beeper should sound. If the alarm beeper does not work properly, do not operate the lift vehicle.
During lift platform descent, the amber caution light should blink on and off. If the caution light does not blink on and off, do not use the lift vehicle.
If any equipment motion continues after the pushbutton, joystick, or selector switch is released, press the
EMERGENCY STOP
pushbutton, Figure 3-2.
All equipment motion should stop immediately.
At the end of each workday and whenever a low battery alarm sounds, transport the lift vehicle to the recharge site and plug in the charge cord. Verify that the ON-CHARGING indicator lights up on the battery charger.
NOTE: For more information on battery charging operations, refer to the battery charging procedure in paragraph 4-4.
To shut down the equipment, turn the UPPER
CONTROL/OFF/LOWER CONTROL key switch and the BATTERY ON/OFF switch to OFF. Remove the key to prevent unauthorized equipment operation.
Figure 3-3. Battery On/Off Switch
Turn the UPPER CONTROL/OFF/LOWER
CONTROL key switch, Figure 3-1, to the UPPER
CONTROL position.
Enter the platform cage and close the entry gate.
LIFT WILL NOT OPERATE IF THE GATE IS NOT
CLOSED COMPLETELY.
Use the upper control box controls to operate the lift vehicle.
Position the lift vehicle at the work area. Make sure the vehicle is on a firm and level surface and that there are no potential hazards such as speed bumps, open floor drains, potholes, overhead obstructions or electrically charged conductors. Do not operate the lift vehicle if such hazards exist in the immediate area.
NOTE: The lift vehicle is equipped with a level sensor. When the vehicle is on a slope greater than 1 degree, the level sensor disables all functions other than platform lowering and
15
EMERGENCY LOWERING PROCEDURE
In an emergency, a person at floor level can lower the platform by holding the UPPER
CONTROL/OFF/LOWER CONTROL key switch in the LOWER CONTROL position and turning the
UP/DOWN selector switch to the DOWN position. (If the upper control box emergency stop pushbutton is depressed, the platform will not lower.)
An emergency lowering valve is shown in Figure 3-4.
In case of a total loss of battery power, a person at floor level can safely lower the platform by opening the emergency lowering valve.
WARNING
Do not climb out of the lift cage while the lift platform is elevated. The lift mast cannot be climbed safely. An elevated lift platform has a high center of gravity and can be tipped easily.
Standing on or leaning out from the outside of a cage rail may cause the lift vehicle to tip over.
Tipping the lift vehicle over can cause severe injury or death and equipment damage.
If you lose power while elevated in the cage, instruct someone on ground level to open the emergency lowering valve. Do not leave the cage to climb down the lift mast or storage shelves.
To lower the platform, pull and hold the red valve knob until the platform starts to descend. When the platform is fully lowered, release the knob to close the valve.
16
Figure 3-4. Emergency Lowering Valve
LIFT VEHICLE TRANSPORT
The platform vehicle is equipped with lifting and tow features, Figure 3-5. Read the following instructions before using these features to lift or tow the vehicle.
Figure 3-5. Lifting and Tow Features.
CAUTION
Do not attempt to push the lift vehicle or use the lift vehicle to pull another vehicle or object.
Pushing the lift vehicle or using the vehicle for towing may cause serious equipment damage.
The forks of a lift truck (2-ton minimum capacity) can be used to raise the ESP 19 for loading onto a trailer or for blocking up the lift vehicle for maintenance.
Forks must be inserted a minimum of 32 inches before raising the ESP 19.
Before towing the ESP 19 lift vehicle, you must manually disengage the travel brake and disconnect the steering cylinder from the steering linkage. Refer to the illustrations in Figure 3-6.
Figure 3-6. Travel Brake and Steering Linkage
17
18
4
MAINTENANCE
SCHEDULED SERVICE CHECKS
Daily/Weekly Service Checks
Perform the daily and weekly service checks listed in Table 4-1.
Table 4-1. Daily/Weekly Service Checks
Daily before use Weekly Service Check
Check that all upper and lower control box controls work properly.
Check for hydraulic oil leaks.
Check for loose or missing parts.
Check for and retighten loose nuts and bolts.
Check that cage gate is secure.
Ensure Operation Manual is in manual tube.
Verify that underguard shuts down operation when weight is applied.
19
20
6 Month/Yearly Service Checks
Perform the service checks in Table 4-2 every 6 months or every 12 months, as indicated.
Table 4-2. 6 Month/Yearly Service Checks
Service Check
Check chain assemblies for split leaves, loose pins, excessive wear, or elongation.
Verify that cage is securely bolted to lift mast.
Check that slide blocks and their paths are clean and lightly lubricated with a dry silicone lubricant.
Verify that all safety decals are present and legible.
Check for wear on chain sheaves, sheave axles, and bearings.
Check caster axle and swivel bolts for wear.
Check casters for cracks or excessive wear.
Lubricate lift chains with 40weight oil.
Check hydraulic
UP
and
DOWN valves operation.
Clean battery terminals.
Check operation of emergency lowering valve.
Grease rear caster swivel bolts, axles and wheels.
Grease steering linkage pivot bolts.
Grease front caster pillow blocks.
Check battery cables and wiring for loose connections and damaged wires.
Replace hydraulic oil.
Check slide blocks for wear.
Check for mast sway.
Load test with 450 pounds.
Every
6 months
Every
12 months
UNDERGUARD SERVICE CHECK
The underguard is a safety device located under the cage/platform that shuts down operation of the lift when weight is applied. Perform the following procedure weekly to verify the underguard is working properly.
Turn power to lift ON and raise cage/platform using the lower control box a minimum of 3 feet above the underguard.
Place a weight of at least 15 lbs. on the underguard. Refer to Figure 4-1.
15 LB. WEIGHT
UNDERGUARD
UNDERGUARD
CLAMP
Figure 4-1. Underguard
BEFORE ATTEMPTING TO LOWER THE LIFT,
MAKE SURE AREA UNDERNEATH AND
AROUND THE CAGE/PLATFORM IS CLEAR
OF PERSONNEL OR OTHER OBJECTS. Using the lower control box with power ON, attempt to lower lift. A warning beeper should sound and the lift should not lower. The lift should still be able to raise. With someone in the cage, switch to upper controls and attempt to drive. A warning beeper should sound and the lift should not drive.
If the lift lowers or drives, the switches below the underguard may need to be adjusted or replaced. To adjust or replace underguard switches, shut power OFF to lift, then remove two of the underguard clamps from one side of the lift. The switches below the underguard can be adjusted by loosening the screws or removed for replacement.
Retest whenever underguard is removed and switches are adjusted or replaced.
21
Lubrication makes operation of the ESP 19 more efficient and extends the life of the lift vehicle.
Perform the following lubrication procedures.
Lubricate lift chains with clean 40-weight oil.
Refer to Figure 4-2.
LIFT
CHAINS
LIFT
CHAINS
Figure 4-2. Lift Chains Lubrication
Clean the mast slide ways, Figure 4-3, and lightly spray the slide ways with a dry silicone lubricant.
NOTE: The slide blocks have a high level of lubricity and need only be kept clean. To reduce wear and extend service life, the slide ways should be cleaned and lightly lubricated with a dry type silicon lubricant.
Figure 4-4. Rear Casters Lubrication
See Figure 4-4. Grease rear caster axles and swivel bolts at the grease fittings provided. Add about 1/2 ounce of clean #2 NGLI grease to each fitting.
Remove, clean, and lubricate steering linkage with wheel bearing grease.
Apply about 1/2 ounce of clean #2 NGLI grease to the fitting on each front wheel pillow block,
Figure 4-5. Do not over-grease the pillow block bearings.
22
Figure 4-3. Mast Slide Ways Lubrication
Figure 4-5. Front Caster Pillow Blocks
Lubrication.
HYDRAULIC SYSTEM
Hydraulic system maintenance varies by the amount of use and the environment in which the lift vehicle is used. Keeping the hydraulic oil clean and the reservoir properly filled will help prevent possible damage to the system.
Hydraulic System Inspection
Check all hydraulic hoses and fittings for leaks and damage daily. Tighten or replace as necessary to prevent hydraulic oil loss.
Fluid Check and Replacement
With the platform in its lowest position, the hydraulic oil level should be at the MAXIMUM level mark (1-
1/2 in. from top of reservoir).
The reservoir is initially filled with Energol HLP-HD46
(BP Oil); a high grade, non-foaming hydraulic oil.
This oil is recommended for use in climatic temperatures as low as -20
°F/-29°C. Dextron
Automatic Transmission Fluid Type A is recommended for use in temperatures as low as -
40
°F/-40°C.
If either of these oils is not available, a good grade
SAE 10W hydraulic oil may be used where the minimum climatic temperature is above 32
°F/0°C.
An SAE 5W hydraulic oil may be used where temperatures are as low as 0
°F/-18°C.
Do not mix different hydraulic oils. Clean the reservoir and sump strainer and replace the hydraulic oil at least once a year. Clean the reservoir and sump strainer and replace the oil whenever contamination is suspected.
Hydraulic System Air Bleeding Procedure
Delayed response or uneven movement of the hydraulic cylinder may indicate trapped air in the hydraulic oil.
NOTE: Whenever the upper control box emergency stop pushbutton is engaged, lift operation remains enabled at the lower control box. However, the UP or DOWN lift motion will be intermittent. Intermittent lift motion should not be mistaken as trapped air in the hydraulic system.
Perform the following procedure to bleed trapped air from the hydraulic system.
Fill the reservoir to the MAXIMUM level with the proper hydraulic fluid.
Fully raise the lift platform.
Lower the lift platform to allow oil with entrapped air to return to the reservoir. Be careful not to overflow the hydraulic reservoir.
Leave the lift platform down and the lift vehicle at rest for 10 to 15 minutes while air escapes the hydraulic oil.
Repeat steps 2 through 4 as needed. Each time the platform is lowered, refill the reservoir to prevent pumping more air into the hydraulic cylinder.
23
Pressure Relief Valve Adjustment
Perform the following procedure to adjust the pressure relief valve. Refer to Figure 4-6.
Move the ESP 19 lift platform to the fully DOWN position.
Center 450 pounds of weight on the lift platform.
Loosen the jam nut. The pressure relief valve is on the back side of the pump.
Turn the pressure relief valve adjust screw 1/8 th turn counterclockwise. This will adjust the relief valve bypass pressure setting for less than 450 pounds of lift.
Place the key switch in the LOWER CONTROL position and press the UP pushbutton. The pump should run, bypassing oil to the hydraulic reservoir.
CAUTION
Do not adjust the pressure relief valve for a bypass pressure higher than needed to raise the 450 pound load. Hydraulic system overload may occur at a higher bypass pressure, causing hydraulic failures or damage to the equipment.
With the platform lift function enabled (pump running), turn the pressure relief valve adjust screw clockwise just enough to smoothly raise the platform without bypassing oil to the hydraulic reservoir.
Retighten the jam nut.
Figure 4-6. Pressure Relief Valve Adjustment
Flow Restrictor Valve Replacement
WARNING
Closely read and adhere to the following instructions whenever you remove and install the flow restrictor valve. Failure to properly install the flow restrictor valve can result in serious injury or death to personnel or damage to the equipment.
The flow restrictor valve, Figure 4-7, is located inside the base of the hydraulic lift cylinder. If the flow restrictor valve needs to be removed or replaced, it is important that it be properly reinstalled.
Raise the platform and masts high enough to access the fitting. Support the raised platform using a forklift or hoist to prevent it from lowering.
WARNING
Never work under the lift while it is raised unless the platform is fully supported to prevent it from lowering. Failure to properly support a raised platform can result in serious crushing injury or death.
Remove the hydraulic line from the fitting. Then, remove the fitting.
Remove the flow restrictor valve using a 3/16” allen wrench.
When reinstalling the flow restrictor valve, make sure it is tightened in all the way against the bottom.
When reinstalling the fitting, do not tighten it against the flow restrictor. If the fitting is turned in too far, it can reduce or stop the oil flow to the cylinder.
Finally, reconnect the hydraulic line to the fitting.
Make sure the o-ring seal on the face of the fitting is not cut or torn.
Figure 4-7. Flow Restrictor Valve
24
Valve Operation
Refer to Figure 4-8 for valve locations and the hydraulic diagram in Figure 4-15. The valves are labeled on the valve manifold as A, B, C, FA and FB.
The platform down valve is located at the base of the lift cylinder.
Steering Valve Right (A): Pressing the
ENABLE
and the thumb steering switch to the right energizes the steering valve, causing the steering cylinder to extend and execute a right turn.
Steering Valve Left (B): Pressing the
ENABLE
and the thumb steering switch to the left energizes the steering valve, causing the steering cylinder to retract and execute a right turn.
Lift Valve (C): Pressing the
ENABLE
and
UP pushbuttons energizes the platform lift valve, causing the lift cylinder to extend.
Down Valve (D): Pressing the
ENABLE
and
DOWN pushbuttons energizes the platform down valve. Oil flows back into the reservoir, causing the lift cylinder to retract.
Steering Speed Adjust Valve (FA): Adjust to control left turn – steering cylinder retraction rate.
Steering Speed Adjust Valve (FB): Adjust to control right turn – steering cylinder extension rate.
Figure 4-8. Valve Operation
25
Hydraulic Cylinder Repair
CAUTION
Hydraulic cylinder removal requires extensive disassembly of the ESP 19 lift vehicle. Contact
Bil-Jax for assistance before removing the hydraulic cylinder.
Hydraulic Cylinder Removal
It is recommended that Bil-Jax be contacted for assistance before removing the hydraulic cylinder.
Make sure hydraulic cylinder is completely retracted and pressure is released from the system. Place a pan underneath the cylinder to catch the hydraulic oil.
Disconnect the hydraulic hose from the flow restrictor valve and drain the hydraulic oil from the cylinder. Remove the two bolts, washers, and nuts securing the hydraulic cylinder to the base.
Remove the plexiglass cover from the base.
Remove the mounting bolt, washer, and nut securing hydraulic cylinder to the lower mast.
Disconnect the two lift chains from the base mast.
Using a crane with at least one ton of lifting capacity, lift the lower mast section high enough to remove the clamp securing the cylinder to the base. Remove the clamp and cylinder from the unit.
After hydraulic cylinder maintenance is completed, reinstall the cylinder in the reverse order of removal.
Hydraulic Cylinder Repair Procedure
Perform the following procedure to repair the hydraulic lift cylinder. Refer to Figure 4-9.
Remove gland nut (1) from cylinder jacket (2). If worn, replace gland nut (1), o-ring (3), packing ring (4), and rod wiper (5) with a new gland nut assembly.
Remove piston rod (6) and wear ring (7).
Inspect piston rod (6) and wear ring (7) for gouges, scratches, and wear. Replace worn or damaged components.
Thoroughly clean the inside surface of cylinder jacket (2).
1
4
5
Lubricate wear ring (7) with clean hydraulic oil or petrolatum. Slide piston rod (6) with wear ring
(7) into cylinder jacket (2).
Lubricate o-ring (3), packing ring (4), and rod wiper (5) with clean hydraulic oil or petrolatum.
Slide gland nut (1) onto piston rod (6). Fully thread the gland nut into cylinder jacket (2).
Reinstall the hydraulic cylinder in the lift vehicle and reconnect the hydraulic hose.
Refill the hydraulic reservoir.
Stroke the cylinder to seat and align packing ring
(4) and wear ring (7).
Bleed all trapped air from the hydraulic system.
1. Gland Nut
2. Cylinder Jacket
3. O-ring
4. Packing Ring
5. Rod Wiper
6. Piston Rod
7.
Wear Ring
3
2
6
7
Figure 4-9. Hydraulic Cylinder Disassembly
26
ELECTRICAL SYSTEM
Regular maintenance is necessary to keep the electrical system in proper working order. Check daily all electrical wires for cuts, broken wires, potential short circuits, and any other damage.
Battery Care and Charging
The electric system is designed to provide power for a normal work shift. However, the charge life of the battery pack depends on machine usage. Plan your work to prevent unnecessary use of electrical power.
Since the power source for the machine is a battery pack, proper battery care is important. Recharge the batteries after each work shift. When the machine is not being used, the batteries should be charged at least once a week. Normal battery charging time should be 10 to 12 hours. If the battery is extremely low, charging time may be as long as 24 hours.
Clean the battery terminals every 6 months. Remove the cables from the battery posts, clean the battery posts and cable ends to shiny metal, and replace the cables. Always connect the insulated cable from the starter solenoid to the most positive post. Lubricate the outside of the battery post connections with petroleum jelly or grease.
Battery Charging Procedure
Remove the battery charger cord from its box and plug into a 3-prong 115V outlet, Figure 4-10.
When there is power to the battery charger, a red “ON-CHARGING” LED on the charger will be lit and the ammeter will display the rate of charge.
Once the battery voltage reaches a predetermined level programmed in the electronic control, the yellow “80% CHARGE”
LED will illuminate.
The charge will be completed 3-1/2 hours after the yellow “80% CHARGE” LED is lit. The charger and all LED’s will automatically shut off.
The battery charge level indicator should indicate at least 3/4 charge.
NOTE: If the battery voltage does not reach the
80% level within 14 hours, the charger will shut off and the “CHECK BATTERY” LED will light up.
CAUTION
Before making or breaking connections between charger and battery, always remove the power cord from the 115 volt outlet. For more information, refer to the instructions supplied with the battery charger.
After the charge cycle is completed, disconnect the battery charger cord from the wall outlet, place it back into its box, and close and latch the lid.
LIFT
WILL NOT OPERATE IF THE LID IS NOT CLOSED
SECURELY.
Figure 4-10. Battery Charger Cord
27
LIFT CHAINS AND SLIDE BLOCKS
WARNING
Do not operate a unit on which any chain assembly is damaged or in need of replacement.
Operating a unit with a damaged chain can cause severe injury or death to personnel and damage to equipment.
Inspect all lift chains every 6 months. Inspect for signs of wear, split leaves, loose pins, clevis damage, and elongation. Replace any chain that is damaged in any way. Chain assemblies may be ordered from your dealer or direct from the factory.
Do not operate a unit on which any chain assembly is damaged and in need of replacement.
Chain Elongation Inspection
Refer to Figure 4-11. Measure 20 pitches of chain.
Twenty pitches of new chain should measure 12.5 in. (31.75 cm). Replace the chain if a 20-pitch length measures over 12.75 in. (32.385 cm).
After making a lift chain adjustment, verify that at least 1/8 in. (3 mm) of the threaded clevis rod extends beyond the lock nut. Also recheck the slack of all lift chains at mid-span; verify that all lift chains are equally snug.
If a single lift chain requires frequent adjustment, the clevis lock nut is probably worn. Replace any clevis lock nut that does not hold position during use.
Replace the plexiglass cover.
LIFT
CHAINS
CLEVIS
LIFT
CHAINS
CLEVIS
Figure 4-11. Chain Elongation Inspection
Lift Chain Adjustment
Raise the platform to the maximum height.
Then, lower the platform while someone verifies that all sheaves (pulleys) are turning and that the chains are not visibly damaged or worn.
Remove the plexiglass cover from the base.
When the platform is fully lowered, the lift chains should be equally tight. Check each lift chain at mid-span. The lift chains should flex about 1/2 to
3/4 inch (12 to 19 mm), but there should be no loose play.
If a lift chain is loose, tighten the related clevis,
Figure 4-12. Tighten the clevis lock nut until the lift chain just becomes snug. Do not over-tighten any lift chain. (An over-tightened lift chain will raise the platform from its rest position at the bottom of the base slide ways).
LOCK
NUT
LOCK
NUT
Figure 4-12. Lift Chains Adjustment.
28
Slide Block Adjustment
Annually check for wear on the slide blocks and replace or retighten as necessary. If the lift exhibits excessive mast sway, it is probable that the slide blocks need adjustment. The slide blocks should be adjusted so that there is no air gap between the slide block and the mast the slide block is moving against. There are 16 slide blocks, - 8 upper and 8 lower. Three upper slide blocks are shown in Figure
4-13.
Start with the slide blocks on one side of the inner mast. Adjust the upper and lower slide blocks on one side, followed by the upper and lower slide blocks on the opposite side. Repeat the adjustments for the center mast slide blocks, followed by the outer mast slide blocks. The adjustment procedure is the same for all slide blocks:
Loosen, but do not remove the slotted hex screw securing the slide block.
Use an Allen wrench to turn the set screws clockwise. This will push the block in against the next mast. Do not overtighten. Tighten the slotted hex head screw to secure the slide block in position.
After all adjustments are made, fully extend the lift. If the platform can be raised and lowered without hesitation or stopping, the blocks are properly adjusted.
Figure 4-13. Slide Blocks Adjustment
NOTE: The plastic slide blocks in the mast are made of a bearing material which has a high degree of lubricity and need only be kept clean.
However, precautions should be taken to ensure that the paths along which the blocks move are kept clean and lightly lubricated with a dry type silicon lubricant.
29
TROUBLESHOOTING
Table 4-3. Troubleshooting Chart
Problem Cause Correction
1. Lift vehicle controls do not work at upper or lower control box. a. Master power switch turned off. b. Low battery power or faulty battery circuit. c. Emergency stop button engaged
(pushed in). d. Battery ground or in-series battery cable loose. e. Circuit breaker tripped. f. Battery cable or equipment ground lead loose or corroded. a. Turn on master power switch. b. Recharge batteries per paragraph
4-4. Check for faulty battery or cables if red battery charger LED is lit. c. Rotate emergency stop buttons clockwise to disengage. d. Check for and repair loose battery connections or ground fault. e. Reset breaker. If breaker trips again, locate and correct short to ground in power circuit wiring. f. Clean and reconnect loose or corroded battery cable or ground lead.
2. Lift vehicle controls do not work at upper control box, but do work at lower control box.
UP function is selected, pump motor runs but will not raise the platform. a. Emergency stop button engaged
(pushed in) on upper control box. b. Upper control box cable connectors unplugged. c. Upper control box cable connectors plugged into wrong receptacles. d. Enable pushbutton switch or wiring faulty. a. Rotate emergency stop buttons clockwise to disengage. b. Plug in cable connectors at front of upper control box. c. Plug in cable connectors in opposite receptacles at upper control box. d. Repair wire break or replace faulty switch. a. Hydraulic oil level low in reservoir. b. More than 450 lbs. on lift platform. c. Emergency lowering valve open. d. Up valve solenoid or solenoid wiring faulty. e. Down valve sticking open or leaking. f. UP switch or UP switch wiring faulty.
g. Mast sections dirty; slide blocks binding. h. Internal leakage in hydraulic cylinder. a. Check reservoir level. If low, check for oil system leakage. Refill reservoir and bleed air from hydraulic system per instructions in paragraph 4-3. b. Ensure load is 450 lbs. or less. c. Close emergency lowering valve. d. Check voltage at up valve solenoid. If no voltage, check wiring. If voltage, exchange solenoids and recheck function; replace solenoid if faulty. e. Repair or replace down valve. f. Check for lighted UP LED when up switch is engaged. If LED does not light, signal is not reaching main controller; repair wire break or replace faulty switch. g. Clean and lubricate masts with dry silicone. If needed, adjust slide bocks per paragraph 4-5. h. Check cylinder housing for heat buildup due to leakage. If leakage is indicated, repair or replace hydraulic cylinder.
30
Table 4-3. Troubleshooting Chart (Continued)
Problem Cause Correction
blinks when pressed. a. ENABLE pushbutton has been pressed down for longer than 5 seconds without a function being selected. b. Joystick potentiometer out of adjustment (will not return to center). a. Release ENABLE pushbutton and press again. c. Did not press ENABLE pushbutton first before moving joystick to forward or reverse drive. d. Tried to drive forward or reverse and raise or lower the platform at the same time. b. Adjust joystick forward/reverse travel potentiometer for null drive signal with joystick at center. c. Release ENABLE pushbutton and press again before moving joystick. d. Release ENABLE pushbutton and run only one function (drive or lift) at a time.
DOWN function is selected, lift platform will not descend. a. Down valve solenoid or solenoid wiring faulty. b. Down valve sticking; does not open. c. DOWN switch or DOWN switch wiring faulty. d. Underguard switches activated a. Check voltage at down valve solenoid. If no voltage, check wiring. If voltage, exchange solenoids and recheck function; replace solenoid if faulty. b. Repair or replace down valve. c. Check for lighted DOWN LED when down switch is engaged. If
LED does not light, signal is not reaching main controller; repair wire break or replace faulty switch.
d. Remove object from underguard or readjust/replace switches. a. Lift vehicle more than 1 degree out of level. a. Lower lift platform and drive lift vehicle to level area.
6. Alarm is sounding; lift
UP and travel functions stopped working.
7. When joystick is moved, lift vehicle will not travel. b. Free wheel lever in free wheel (tow) position. c. Joystick or joystick wiring faulty. d. Main controller or main controller signal wiring faulty. e. Motor controller 24-volt power cable disconnected. a. Check wheels for blocking; remove travel obstacle. b. Move free wheel lever back to drive position. c. Check for lighted travel LED when joystick is engaged. If travel LED does not light, travel signal is not reaching main controller; repair wire break or replace faulty joystick. d. Check for output voltage to motor controller when joystick is engaged. If travel signal is not present at main controller, contact
Bil-Jax for assistance. If travel signal is not present at motor controller, repair wire break. e. Check connection of 24-volt power cable to motor controller; repair faulty power cable connection.
31
Table 4-3. Troubleshooting Chart (Continued)
Problem Cause Correction
7. When joystick is moved, lift vehicle will not travel.
(cont) f. Motor controller, motor controller output wiring, or transaxle drive motor faulty. g. Transaxle drive train damaged. f. Check for output voltage to drive motor when joystick is engaged. If drive voltage is not present at motor controller, replace motor controller. If drive voltage does not reach drive motor, repair wire break. If drive voltage is present at drive motor, replace drive motor. g. If transaxle drive motor runs, inspect drive train components for damage. Repair or replace transaxle gearhouse, if damaged.
8. When steering thumb switch is pressed, steering wheels do not swivel. a. Wheels turned to steering limit. b. 10 Amp Motors fuse burned out on main controller board. c. Internal steering actuator fuse. d. Thumb switch or thumb switch wiring faulty. e. Actuator or actuator wiring faulty. f. Steering linkage failed. g. Main controller faulty. a. Turn wheels in opposite direction. b. Replace 10 Amp Motors fuse. c. Replace steering actuator fuse. d. Check for lighted steering LED when thumb switch is engaged. If
LED does not light, signal is not reaching main controller; repair wire break or replace faulty joystick. e. Check actuator wiring for operating voltage. If voltage is present, replace faulty actuator. If voltage is not present, check actuator wiring for continuity; repair wire breaks. f. Check steering linkage for damage; replace damaged parts. g. Contact Bil-Jax for assistance.
9. When BATTERY ON/OFF switch is turned ON, hydraulic pump starts up.
a. Motor start relay failure; relay contacts fused shut. a. Replace motor start relay.
32
Troubleshooting Aids
See Table 4-4 for interpreting LED indicators located on the main controller board shown in Figure 4-14. Hydraulic and PC logic diagrams are shown in
Figures 4-15 and 4-16. An electrical wiring diagram is shown in Figure 4-17.
PWR GND
PWR POS
EASI-24V
EASI-GND
PUMP ON
PUMP
PWR
RIGHT
PWR
LEFT
PWR
DOUT1
RIGHT ON
LEFT ON
DOUT1 ON
DOUT2 ON
PWR
DOUT2
PWR
DOWN
PWR
UP
DOWN ON
UP ON
HORN ON
PWR
HORN
PWR
HRMTR ON
HOUR METER
PWR
BUZZER
RS232-RXD
RS232-TXD
RS232-GND
CANH
CANL
CAN P5V
CAN GND
MAST SWITCH
MAST DOWN PWR
UPPER CONTROLS
UP CTRL SELECTED PWR
LOWER DOWN
LOWERING
PWR
RAISING
LOWER UP
PWR
TILT SENSOR
MACHINE LEVEL
PWR
UNDERCAGE SAFETY
UNDERCAGE OK PWR
DIN1 ON
DIN2 ON
DIN1
PWR
DIN2
PWR
JTAG DB-9
DIAG
LEDS
SPARE +5V
AGND
AIN1
STEERING +5V
STEERING GND
STEERING IN
Figure 4-14. Main Controller Board
33
34
Table 4-4. Main Controller LED Indicators
Main
Controller
Diagnostics
System
Diagnostics
Error Codes
Flashes 1: Main Controller OK
Flashes 2: Short or open at hydraulic pump output
Flashes 3: Short circuit on the Up, Down, Horn, Buzzer, or Hour Meter outputs
Flashes 4: Short circuit on one of the Steering outputs
Flashes 5: Error reading/writing NVM-using default values
Error Codes
Flashes 1: System OK
Flashes 2: Tilt limit exceeded
Flashes 3: Transaxle brake error
Flashes 4: Unable to Communicate with Motor Controller
Flashes 5: Unable to Communicate with Joystick
Red
Green
EASI-RXD
Mast Down
Upper Control Receiving
Mast Down Switch Output
Lower Down Lower Mast Down Output
Lower Raise Lower Mast Up Output
Upper
Controls
Upper Controls Activated
Steer Left
Steer Right
Down Valve
Up Valve
Steer Left Output
Steer Right Output
Platform Down Output
Platform Up Output
Green
Green
Green
Green
Green
Green
Green
Green
Green
Horn ON
Hour Meter
Horn Output
Hour Meter On Output
Green
Green
Pump ON Pump Motor Running Output Green
IN-4, IN-5, IN-6, IN-7 (Spare Inputs) Green
NOTE: If a short is detected on either Up, Down, Horn, or Buzzer, none of the outputs will function. If any of the error codes listed above are detected, see the following pages to further troubleshoot the problem.
Main Controller Troubleshooting
Lower Control Mode
• Up Command Does Not Work
1. Check if the LED “UP CTRL SEL” on the main controller is OFF.
If it’s ON, check the Upper/Lower selector switch and make sure it’s set to Lower Control.
2. While holding “UP” command switch ON, a. Check LED labeled “RISING” on the main controller. It should be ON, indicating the UP command switch is OK.
If the LED is OFF, the UP/DOWN command switch on the machine or the wiring may be faulty. b. LED’s labeled “PUMP ON” and “UP ON” should be ON.
If LED “RISING” is ON, but LED’s “PUMP ON” or “UP
ON” are OFF, the main controller may be faulty.
• Down Command Does Not Work
1. Check if the LED “UP CTRL SEL” on the main controller is OFF.
If it’s ON, check the Upper/Lower selector switch and make sure it’s set to Lower Control.
2. While holding “DOWN” command switch ON, a. Check LED labeled “LOWERING” on the main controller.
It should be ON, indicating the DOWN command switch is OK. If the LED is OFF, the UP/DOWN command switch on the machine or the wiring may be faulty. b. LED labeled “DOWN ON” should be ON. If LED
“LOWERING” is ON, but LED “DOWN ON” is OFF, the main controller may be faulty.
35
36
Upper Control Mode
• No Power To The Joystick: No Communication
-There is power on the main controller, but not on the joystick.
1. When in Upper Control Mode, LED “UP CTRL SEL” should be
ON. If it’s OFF, check the Upper/Lower selector switch and make sure it’s set to Upper Control.
2. Make sure the joystick is connected to EASI POS and EASI NEG terminals of the main controller.
3. Make sure E-STOP switch on the joystick is OFF.
4. Make sure LED’s EASI-TXD and RXD on the main controller are blinking at high frequency. If not, Check Fuse F1 located on the main controller. If all of the above are O.K, the joystick may be faulty.
•
Joystick Does Not Drive The Motor
-Moving the joystick forward or reverse does not drive the machine.
1. Check if there is communication between the main controller and the joystick. If L1 and L2 LED’s on the joystick are not blinking rapidly, there is no communication. Refer to the previous step to troubleshoot "No Communication".
2. L1 and L2 on the joystick are blinking rapidly, but unit still does not drive, then: a. Press "ENABLE" on the joystick, move the joystick forward, Check if LED "HRMTR ON" turns on. If not on, the main controller may be faulty. Check fuse F2 on the main controller. b. If the LED turns on, but unit still doesn't drive, the motor controller may be faulty. Refer to the Motor Controller
Troubleshooting section.
•
UP/DOWN, LEFT/RIGHT Commands Do Not Work
-When pressing UP, DOWN, LEFT, or RIGHT switches on the joystick, the machine does not respond.
1. Check if there is communication between the main controller and the joystick. If L1 and L2 LED’s on the joystick are not blinking rapidly, there is no communication. Refer to the previous step to troubleshoot "No Communication".
2. For faulty UP command: a. Hold "UP" switch on the joystick, make sure it lights up.
If it doesn't, the internal bulb may be blown or the switch may be faulty. b. Press "UP" and "ENABLE" on the joystick. Make sure that LED's "PUMP ON", "UP ON" and "HRMTR ON" turn
ON. If not, the main controller may be faulty.
3. For faulty DOWN command: a. Hold "DOWN" switch on the joystick, make sure it lights up. If it doesn't, the internal bulb may be blown or the switch may be faulty.
b. Press "DOWN" and "ENABLE" on the Joystick. Make sure LED's "DOWN ON" and "HRMTR ON" turn ON. If not, the main controller may be faulty.
4. For faulty LEFT/RIGHT command: a. Hold "ENABLE" & "LEFT" switch on the joystick, check
LED’s "PUMP ON" & "LEFT ON" turn ON. If not, the
"LEFT" switch on the joystick or the main controller may be faulty. b. Hold "ENABLE" & "RIGHT" switch on the joystick, check
LED’s "PUMP ON" & "RIGHT ON" turn ON. If not, the
"RIGHT" switch on the joystick or the main controller may be faulty.
•
Joystick Switches Work But Do Not Light Up
-"ENABLE", "UP", "DOWN", steering LED’s do not light up, but the functionality is fine.
1. "ENABLE", "UP", "DOWN" switches work but the bulbs inside the switches won't turn ON possibly because of internal bulbs being blown or the wiring to the bulb may be loose.
2. Steering angle LED display won't turn ON due to possible following reasons: a. Blown LED's (very unlikely that all LED's are blown), if none turn ON, the joystick may not be providing proper signal. b. Faulty wiring between the LED board and the joystick board or a loose connection. c. The wiring between the steering angle sensor to the main controller (Steering IN) may be faulty.
37
Motor Controller Troubleshooting
1. Make sure there is Power present on the Motor Controller unit.
L2 should be ON, if not ON, check to see if the power cable is properly connected to the unit. If still no power to the unit, please check resistances between the following terminals. If any resistance fails, the motor controller is faulty. a. GND and POWER
Very High ~ M ohms b. GND and MOTOR +
Very High c. GND and MOTOR -
Very High d. POWER and MOTOR +
Very High e. POWER and MOTOR -
2. Make sure the unit is communicating with the main controller
(refer to the Blink Codes). L7 and LED1 on the motor controller should be blinking at high frequency. If not, check wiring between J12 of the motor controller to the main controller.
Check fuse on the motor controller.
3. Make sure the brake is ok. a. L5 on the Motor Controller is ON and L6 is OFF. If L5 is
OFF, it means that the brake's manual override system is activated. In such case, the motor controller will not drive the motor. Manual override lever situated on the brake should be disengaged in order for the motor controller to drive the motor.
4. L6 should only turn ON when the joystick is moved either forward or reverse. If L6 remains ON or OFF regardless of the position of the joystick, the motor controller may be faulty.
38
Beeper Codes
The audible alarm beeper can be used to troubleshoot conditional problems with the ESP as opposed to the electrical errors listed on the previous pages. The following beeper codes are listed by the length of time the audible alarm sounds.
BEEPER CODES
Beeeep____Beeeep____Beeeep____
(long beep, long pause, long beep, long pause…)
Be__Be__Be__Be__
(short beep, pause, short beep, pause…)
B_B_Be_B_B_Be_
(very short beep, short pause, very short beep, short pause, short beep, short pause…)
CONDITION
Normal Motion Indicator – Machine operating properly.
Machine Out of Level With
Platform Down – Platform will not raise.
Machine Out of Level With
Platform Raised – Platform will not raise and machine will not drive.
B_Beeeeep_B_Beeeeep_B_Beeeeep_
(very short beep, short pause, very long beep, short pause, very short beep, short pause…)
Beeeeeeeeep
(continuous beep)
Object On Underguard – Platform will not lower and machine will not drive.
Low Battery Warning –
Immediately drive machine to recharging area and plug-in to wall outlet.
39
B02-03-0040
Lift Cylinder
C3
D
C
C1
FB
B02-03-0038
Steering Cylinder
FA
C2
B02-05-0034
Pump Unit
A
B
M
40
Figure 4-15. Hydraulic Diagram.
Main
Control
Board
2 Amp
Gate
Switch
E-Stop
Enable
Raise
Lower
Drive FWD
Drive REV
Steer Right
Steer Left
Upper Control Box
Beacon Lamp
15’
Switch
1.5 Deg
Level
Sensor
1 Deg
Level
Sensor
LSI
Steering
Sensor
SSI
Under
Cage
UCI
Mast
Switch
MSI
110v Box
Switch
10
Amp
110v Switch
Box Relay
-
+
-
+
Master
Power
Platform Raise
Platform Lower
Right Turn
LSI
UCI
FWI
Left Turn
Forward
Reverse
LSI
LSI
MSI
MSI
SSI
SSI
FWI
FWI
Start Solenoid
Up Valve
Down Valve
Start Solenoid
Right Solenoid
Start Solenoid
Left Solenoid
Free
Wheel
Switch
FWI
Motor
Controller
Start
Solenoid
Parking
Brake
M
Transaxle
Motor
M
Hydraulic
Pump Motor
Figure 4-16. PC Logic Diagram.
41
42
Figure 4-17. Electrical Layout.
Figure 4-18. Drive Wiring Diagrams.
43
44
Figure 4-18. Drive Wiring Diagrams (2).
Figure 4-19. Upper Control Wiring Diagram.
45
46
5
DECAL REPLACEMENT
Decals contain information that is required for the safe and proper use of the aerial work platform. Decals should be considered necessary components of the machine and should be checked before each use to verify that they are correctly attached and legible.
Use the following guides to find the correct location of all decals.
47
Refer to Table 5-1, and Figures 5-1, 5-2, and 5-3 for descriptions and locations of decals on the ESP 19.
Table 5-1. Replacement Decals.
Decal No. Description of Decal
B06-00-0009 Warning...Moving telescopic masts will create...
B06-00-0034 Danger...During charging, explosive oxyhydrogen gas...
Qty
2
1
B06-00-0066 Insert Forks Minimum 32”…
B06-00-0068 SAE 10W Hydraulic Oil
B06-00-0138 Warning...(Maintenance decal) 1
B06-00-0146 Danger...(High voltage line warning)
1
2 B06-00-0173 Safety harness lanyard attachment point
B06-00-0192 Operation and service manual inside
B06-00-0225 Warning...Stay clear when raising or lowering
4
2
1
1
2
B06-00-0289 Check level with cage fully down
1
1
1 B06-00-0339 Warning…Full Body Harness and Lanyard…(Not used on lifts with fully enclosed platform)
B06-00-0349 Operation Instructions for
Battery Charger
B06-00-0359 Serial Number Tag (Not available as replacement part)
B06-00-0382 Caution...This machine designed and manufactured...
1
1
1
Decal No. Description of Decal
B06-00-0383 Danger...Failure To Comply
With The Following...
B06-00-0390 Trans Axle Instruction
B06-00-0453 ESP 19 Horizontal Logo
B06-00-0454 ESP 19 Vertical Logo
B06-00-0455 Bil-Jax (Vertical transfer type decal)
B06-00-0456 800-225-3765 For Service
B06-00-0457 Warning...Stay clear while work platform is raised
B06-00-0458 Maximum Capacity 150 lbs.
Qty
1
1
1
B06-00-0460 Caution (Black on Yellow)
B06-00-0461 Operation Instructions for ESP
19
B06-00-0462 Battery Charger Cord Box
B06-00-0463 Do Not Pick Machine Up From
This End
2
1
2
2
2
2
2
4
1
1
1
1 B06-00-0469 Warning...This is not a work platform or a shelf
B06-00-0470 Low battery alarm
B06-00-0492 Turn Master Power Switch
Off…
B06-00-0500 Maximum Capacity...450 lb.
B06-00-0501 Tip Over Hazard
1
1
4
2
2
2
48
Figure 5-1. Decal Locations, Side View.
49
50
0009
WARNING
0138
0492
0390
0461
0470
0455
El ec tr ic
St oc k
Pi ck e r
800-
CTG
225-
3765
CA
UTION
WARNING h
NO
1.
Turn off when to not po in po turn ol bo wer use wer batteries.
2.
Failure will drain contr master
Turn turning switc h on.
©
Bil-J ax,
Inc.
20
05
off off bef ore wer po
B06-00-
049
UT
DANGER
BAT
TER into
ORD
BO
X
Y CH
ARG
ER C plug cord only
.
outlet batteries, into box or be placed and
B0
6-0
0-0 462 lift will not
© B il-J ax,
Inc
. 20
CT G
d
W
ARNING
Ba fo
This wi a to we r l ift lif th ig tw
Over ry we st ta l c ht ab ust t m o ba om of
16
NO
T ili tte bi re pl ht ty.
is cr iti ca be rie ne d
5 lb s.
e wi er th we ig ht
DO ba rie tte s onl y ac le ss of
Bil-Jax
Use au th pa rts or iz ed re
Bil-J ax, Inc.
2005
equipped s ha m in vi ng imu m pl ac em en
B06-00-0501
UT
0382
0462
0383
0501
0453
0456
B0
0-0
45
6
0454
0359
0464
CT
G
GTG
DO NO
T PICK
2004
UP FR
OM THIS
END
B06-00-0463
(
0037
ON STEERING
)
PIVOT BLOCK
(
0289
ON RESERVOIR
)
INSIDE
(
0068
ON FRAME BEHIND
DOOR BY RESERVOIR
)
(
0349
INSIDE
DOOR
)
(
0034
INSIDE
DOOR
)
0463
Figure 5-2. Decal Locations, Rear View.
APPENDIX A:
PART LISTS
51
52
9
10
FIRST MOVING MAST
4
2
4
5
6
7
3
8
11
16
1
15
12
13
14
11
17
17
9
10
21
18
18
19
19
22
24
20
17
18
3
4
19
23
4
Item No.
1
2
Part No. Description
B16-01-0044 First Moving Mast Weldment
0090-0770 Pin, Cotter 3/16 x 1-1/2 in.
8
9
10
11
4
5
6
7
16
17
18
19
0090-0425 Washer, Flat, 5/8 in.
B26-00-0009 Sheave Assembly, Chain
0090-0188
0090-0422
Nut, Nylon Lock, 3/8-16
Washer, Flat, 3/8 in.
B40-00-0003 Cable, Steel, 3/16 in.
0090-0389 Screw, Set, 1/2-20 x 1/2 in.
0090-0403 Screw, Sheet Metal, #10 x 1
B31-00-0001 Slide Block, Plastic
0090-0192
0090-0042
0090-0210
0090-0162
FIRST MOVING MAST PARTS LIST
Nut, Nylon Lock, 1/2-13
Screw, Cap, 3/8-16 x 1 in.
Washer, Lock, Split, 3/8 in.
Nut, Hex, 3/8-16
6
2
1
1
Qty
1
2
3
1
8
4
4
2
2
2
2
2
6
6
6
1
1
1
1
1
1
16 and Lower Clevis (shown on next page)
53
54
SECOND MOVING MAST
4
5
4
3
2
1
25
24
9
8
6
7
23
22
10
17
11
9
10
Chain from Base Mast
17
11
12
8
13
13
6
14
15
16
16
18
19
3
7
15
20
13
15
16
4
21
4
Item No.
1
2
Part No. Description
B16-01-0040 Second Moving Mast Weldment
0090-0770 Pin, Cotter, 3/16 x 1-1/2 in.
23
24
25
4
5
6
7
8
9
13
15
16
19
SECOND MOVING MAST PARTS LIST
0090-0425 Washer, Flat, 5/8 in.
B26-00-0009 Sheave Assembly, Chain
0090-0389
0090-0403
Screw, Set, 1/2-20 x 1/2 in.
Screw, Sheet Metal, #10 x 1 in.
B31-00-0001 Slide Block, Plastic
B40-00-0003 Cable, Steel, 3/16 in.
0090-0042
0090-0210
0090-0162
0090-0147
0090-0192
0090-0422
0090-0188
Screw, Cap, 3/8-16 x 1 in.
Washer, Lock, Split, 3/8 in.
Nut, Hex, 3/8-16
Pin, Cotter, 1/8 x 1-1/4 in.
Nut, Nylon Lock, 1/2-13
Washer, Flat, 3/8 in.
Nut, Nylon Lock, 3/8-16
1
1
1
6
4
1
1
1
1
2
2
6
2
8
4
Qty
1
2
3
4
1
4
4
2
6
1
6
22 and 23
55
56
THIRD MOVING MAST
2
3
4
5
4
1
8
6
7
9
10
17
11
12
8
13
6
20
7
15
16
18
19
3
4
21
4
13
14
15
16
Item No.
1
2
Part No. Description
B16-01-0041 Third Moving Mast Weldment
0090-0770 Pin, Cotter, 3/16 x 1-1/2 in.
4
5
6
7
8
9
13
15
16
19
0090-0425 Washer, Flat, 5/8 in.
B26-00-0009 Sheave Assembly, Chain
0090-0389
0090-0403
Screw, Set, 1/2-20 x 1/2 in.
Screw, Sheet Metal, #10 x 1 in.
B31-00-0001 Slide Block, Plastic
B40-00-0003 Cable, Steel, 3/16 in.
0090-0042
0090-0210
0090-0162
0090-0147
THIRD MOVING MAST PARTS LIST
Screw, Cap, 3/8-16 x 1 in.
Washer, Lock, Split, 3/8 in.
Nut, Hex, 3/8-16
Pin, Cotter, 1/8 x 1-1/4 in.
6
2
8
4
Qty
1
2
3
4
1
2
2
2
6
1
6
6
2
1
1
1
1
1 and Upper Clevis & Lock Nut (shown on
57
58
FOURTH MOVING MAST (PLATFORM)
19
18
3
2
1
4
5
6
20
21
19
17
16
15
14
13
11
10
8
9
12
7
Item No.
1
2
Part No. Description
B16-01-0042 Fourth Moving (Platform) Mast Weldment
0090-0014 Screw, Cap, 1/4-20 x 2-1/4 in.
4
5
6
7
8
9
11
12
17
18
19
20
21
FOURTH MOVING MAST PARTS LIST
B29-00-
Outreach
0090-0206
0090-0159
Washer, Lock, Split, 1/4 in.
Nut, Hex, 1/4-20
B31-00-0001 Slide Block, Plastic
0090-0389 Screw, Set, 1/2-20 x 1/2 in.
0090-0403 Screw, Sheet Metal, #10 x 1 in.
0090-0802
0090-0182
Screw, Machine, #10-24 x 7/8 in.
Nut, Nylon Lock, #10-24
B40-00-0003 Cable, Steel, 3/16 in.
B07-01-2033 Edge, Top Cover
0090-0344 Screw, Threadcutting, #10-24 x 1/2 in.
B18-00-0178 Plexiglass, 1/8 in.
B24-00-0011 Frame, Aluminum, 11-1/2 in
Qty
1
2
2
1
2
2
2
4
2
1
2
2
2
2
2
1
1
1
2
1
1
4 and Upper Clevis & Lock Nut (shown on
6 4)
59
3
1
2
11
5
6
8
7
10
9
12
BATTERY COMPARTMENT
4
12
13
14
1
15
14
17
1
18
15
20
19
16
21
22
23
24
27
26
25
31
30
29
28
25
32
60
BATTERY COMPARTMENT PARTS LIST
12
13
14
15
8
9
10
11
Item No.
1
2
3
4
5
6
Part No.
0090-0183
Description
Nut, Nylon Lock, 1/4-20
B04-07-0036 Clamp, Cable/Hose, DG 16
B01-01-0144 Cable, Battery, 2 Ga. x 104 in.
B01-01-0027 Cable, Battery, 2 Ga. x 19 in.
B01-01-0130 Cable, Battery, 4 Ga. x 68 in.
0090-0188 Nut, Nylon Lock, 3/8-16
17
18
19
20
21
23
25
26
0090-0028
0090-0208
Screw, Cap, 5/16-18 x 3/4 in.
Washer, Lock, 5/16 in.
B01-01-0131 Cable, Battery, 8 Ga. x 16 in
B01-01-0014 Cable, Battery, 2 Ga. x 8 in.
B01-04-0015 Battery, Maintenance-Free, 12 Volt
B07-01-1144 Bracket, Battery Clamp
0090-0419
0090-0005
Washer, Flat, 1/4 in.
Screw, Cap, 1/4-20 x 3/4 in.
B01-06-0053 Relay, 24 Volt DC, 20 Amp
B01-10-0135 Sensor, Level, 1.5 Degree
B01-01-0113 Plug, Level Sensor
B01-03-0061 Switch, Limit, Underguard
B01-01-0122 Cable Assembly, Underguard Switch
0090-0001
0090-0415
0090-0182
Screw, Cap, 1/4-20 x 1/2 in.
Washer, Flat, #10
Nut, Nylon Lock, #10-24
28 0090-0232 Screw, Machine, #10-24 x 5/8 in.
SEE APPENDIX B FOR MACHINE CHANGES DUE TO
REFURBISHMENT
1
1
1
1
2
2
4
8
4
8
4
1
4
2
2
8
6
2
2
1
1
Qty
7
1
1
1
1
1
1
30
31
32
0090-0048
0090-0210
0090-0422
Screw, Cap, 3/8-16 x 2 in.
Washer, Lock, Split, 3/8 in.
Washer, Flat, 3/8 in.
1
2
2
2
61
14
10
11
12
13
2
8
9
HYDRAULIC PUMP COMPARTMENT
1
2
3
4
5
6
7
2
4
2
15
2
16
17
18
5
19
2
2
20
3
4
21
25
5
22
23
26
18
24
62
HYDRAULIC PUMP COMPARTMENT ASSEMBLY
Item No.
1
2
3
4
5
6
7
24
25
Part No. Description
B01-10-0291 Converter, 24 Volt DC-DC
0090-0183
0090-0419
Nut, Nylon Lock, 1/4-20
Washer, Flat, 1/4 in.
0090-0005
0090-0210
Screw, Cap, 1/4-20 x 3/4 in.
Washer, Lock, Split, 3/8 in.
0090-0162 Nut, Hex, 3/8-16
B04-07-0036 Clamp, Cable/Hose, DG 16
0090-0344
0090-0048
Screw, Threadcutting, #10-24 x 1/2 in.
Screw, Cap, 3/8-16 x 2 in.
16
5
1
4
Qty
1
22
6
18
19
20
21
8
9
10
11
0090-0232
0090-0001
Screw, Machine, #10-24 x 5/8 in.
Screw, Cap, 1/4-20 x 1/2 in.
0090-0415 Washer, Flat, #10
B01-06-0053 Relay, 24 Volt DC, 20 Amp
12
13
0090-0182
B02-15-0425
Nut, Nylon Lock, #10-24
Solenoid, Start, 24VDC
1
1
14 B01-05-0056 1
15
16
B04-07-0015 Clamp, Tie Wrap
B01-10-0280 Control Board, Main
1
2
1
1
3
1
1
4 0090-0422
0090-0040
Washer, Flat, 3/8 in.
Screw, Cap, 3/8-16 x 3/4 in.
B01-10-0247 Sensor, Level, 1.0 Degree
B29-00-0021 Bracket, Level Sensor Mount
2
1
1
1
2
8
2
1 for component parts listing)
SEE APPENDIX B FOR MACHINE CHANGES DUE TO
REFURBISHMENT
63
10
26
24
9
8
32
11
13,14
22
12
20
19
18
UPPER
CONTR
OFF
LO
WER
CONTR
WN
UP DO
15
23
21
17
16
BASE ASSEMBLY
25
24
1
26
3
2
7
4
7
27
28
30
29
31
6
5
2
7
7
64
19
20
26
27
28
29
22
23
24
25
30
31
32
BASE ASSEMBLY PARTS LIST
Item No.
1
2
3
4
5
6
Part No. Description
B07-01-2003 Edge, Top Cover
0090-0344 Screw, Threadcutting, #10-24 x 1/2 in.
B05-00-0005 Tape, Foam Adhesive
B18-00-0177 Plexiglass, 1/8 in.
B24-01-0013 Frame, Aluminum, 18-1/4 in.
B24-01-0009 Frame, Aluminum, 20 in.
9
10
11
12
0090-0182 Nut, Nylon Lock, #10-24
B01-09-0003 Strain Relief, Cable
B01-02-0076 Control Box Assembly, Lower
B19-00-0040 Box, Switch, 3 Position
13
14
B01-02-0078
B01-02-0079
Contacts, Switch, Normally Open
Contacts, Switch, Normally Closed
15 B01-02-0082 Switch, Selector, Keyed
16 B01-02-0081 Switch, Pushbutton, Emergency
17 B01-02-0080 Switch, Selector, Up/Down
B00-00-0130
B00-00-0129
Legend Plate, Emergency Stop
Legend Plate, Up/Down
0090-0232 Screw, Machine, #10-24 x 5/8 in.
B11-01-0146 Weldment, Base and Mast
B01-02-0060 Switch, Master Power
B00-00-0112 Faceplate, Master Power Switch
B01-10-0294 Battery Gauge/Hour Meter
B01-03-0065 Switch, Battery Charger Cord Box
B19-00-0045 Box, Battery Charger Cord
B01-01-0143 Cord, Retractable, 16-3
B04-07-0032 Clamp, Cord, DG-6
0090-0005 Screw, Cap, 1/4-20 x 3/4 in.
0090-0183 Nut, Nylon Lock, 1/4-20
1
1
1
3
3
1
1
1
1
1
1
1
1
1
1
2
1
Qty
1
8
32 in.
1
2
1
2
1
4
2
1
1
2
1
1
SEE APPENDIX B FOR MACHINE CHANGES DUE TO
REFURBISHMENT
65
1
2
3
31
35
4
5
32
33
30
31
BASE MAST ASSEMBLY
6
9
10
19
13
34
11
12
14
7
15
16
17
18
21
20
22
24
23
27
26
25
28
21
29
20
8
66
BASE MAST PARTS LIST
Item No.
1
2
3
4
5
6
7
8
10
13
14
15
16
18
19
20
23
24
25
26
27
29
30
31
32
34
35
Part No.
0090-0188
0090-0422
B40-00-0003
0090-0389
0090-0403
B31-00-0001
B01-01-0193
0090-0684
0090-0860
0090-0192
0090-0071
0090-0212
0090-0166
0090-0654
0090-0185
0090-0344
Description
Nut, Nylon Lock, 3/8-16
Washer, Flat, 3/8 in.
Cable, Steel, 3/16 in.
Screw, Set, 1/2-20 x 1/2 in.
Screw, Sheet Metal, #10-24 x 1 in.
Slide Block, Plastic
Cord, Coiled, 16-2
Rivet, Pop, 3/16 x 1/2 in.
B46-00-0031 Knob, Manual Lowering Valve
B07-06-1060 Extension Rod, Manual Lowering Valve
0090-0042
0090-0210
0090-0422
0090-0498
B01-03-0040
0090-0182
B01-01-0129
0090-0231
B01-03-0066
Pin, Cotter, 1.6 mm
Nut, Nylon Lock, 1/2-13
Screw, Cap, 1/2-13 x 2-1/2 in.
Washer, Lock, Split, 1/2 in.
Nut, Hex, 1/2-13
Clamp, U-bolt, 5/16-18 x 2-1/2 x 2-5/8 in.
Nut, Nylon Lock, 5/16-18
Screw, Thread Cutting, #10-24 x 1/2 in.
Screw, Cap, 3/8-16 x 1 in.
Washer, Lock, Split, 3/8 in.
Washer, Flat, 3/8 in.
Washer, Flat, 3/16 in.
Switch, Limit, Mast
Nut, Nylon Lock, #10-24
Cable Assembly, Mast Limit Switch
Screw, Machine, #10-24 x 1/2
Switch, Limit, Level Sensor
13, and Lower Clevis (shown on page 6-4)
1
2
2
2
1
2
1
4
1
1
1
2
2
2
1
1
1
2
2
1
4
2
2
1
Qty
1
1
1
2
2
2
2
2
2
1
1
1
67
DRIVE AXLE
17
16
14
13
8
9
15
7
10
11
12
1
5
4
2
3
6C
6
6B
6A
68
DRIVE AXLE PARTS LIST
Item No.
1
2
3
4
Part No. Description
0090-0049 Screw, Cap, 3/8-16 x 2-1/4 in.
B30-00-0050 Pad Assembly, Torsion
0090-0188 Nut, Nylon Lock, 3/8-16
0090-0065 Screw, Cap, 1/2-13 x 1 in.
6C
7
9
11
12
13
14
15
16
17
B01-07-0013 Brake Subassembly, Electric
B07-07-5022 Key, Square, 1/4 x 2-1/4 in.
B07-06-5946 Plate, Transaxle Clamp
0090-0422
0090-1096
0090-0367
0090-1071
Washer, Flat, 3/8 in.
Screw, Cap, 3/8-16 x 2 in. – Grade 8
Screw, Set, 1/4-28 x 1/4 in.
Screw, Set, 5/16-18 x 5/8 in.
B08-02-0015 Caster, 10 in. Drive
0090-0776 Washer, Flat, 7/16 in.
0090-0617 Screw, Cap, 7/16-14 x 1 in.
SEE APPENDIX B FOR MACHINE CHANGES DUE TO
REFURBISHMENT
Qty
4
4
2
2
2
1
1
2
1
1
1
1
1
1
2
2
2
2
4
4
69
70
STEERING ASSEMBLY
19
19
20
15
16
17
8
8
21
8
22
9
10
23
3
6
5
9
18
8
14
8
24
10
9
1
2
4
7
8
10
9
13
11
12
12
10
9
26
12
20
7
8
7
10
25
9
24
27
9
24
18
28
29, 29A
31
30
31
32
17
17
33
STEERING ASSEMBLY PARTS LIST
Item No.
4
5
6
7
1
2
3
8
9
10
11
12
Part No. Description
0090-0239 Screw, Machine, #10-24 x 1-1/2 in.
B01-02-0105 Switch, Rotary, Steering Indicator
0090-0182 Nut, Nylon Lock, #10-24
B24-01-0015 Adapter Shaft, Rotary Switch
0090-0824 Screw, Set, #10-32 x 3/16 in.
0090-0035
0090-0188
Screw, Cap, 5/16-18 x 3 in.
Nut, Nylon Lock, 3/8-16
0090-0422
0090-0420
0090-0185
0090-0192
0090-0574
Washer, Flat, 3/8 in.
Washer, Flat, 5/16 in.
Nut, Nylon Lock, 5/16-18
Nut, Nylon Lock, 1/2-13
Washer, Flat, 1/2 in.
14
15
16
17
19
22
23
24
26
B11-01-0149 Support Arm, Tie Rod
0090-0881 Pin, Cotter, 5/32 x 2 in.
0090-1072
0090-0429
Nut, Castle, 1-8
Washer, Flat, 1 in.
0090-0046
B07-06-5826 Support Linkage, Tie Rod
0090-0045 Screw, Cap, 3/8-16 x 1-1/2 in.
0090-1061 Screw, Cap, 5/16-18 x 2 in. – Grade 8
0090-0080
Screw, Cap, 3/8-16 x 1-3/4 in.
Screw, Cap, 1/2-13 x 4-1/2 in.
Qty
2
8
4
4
4
1
1
1
3
1
1
1
1
1
1
6
2
1
2
15
7
4
1
6
2
1
2
4 in. Stroke
28 0063-0492 Bushing
29 B11-01-0137 Bracket, Wheel, Right
29A B11-01-0105 Bracket, Wheel, Left
30 0090-0112 Bolt, Steering Axle, 3/4-10 x 5 in.
31
32
0090-0428
0090-0195
Washer, Flat, 3/4 in.
Nut, Nylon Lock, 3/4-10
2
1
1
2
4
2
2
SEE APPENDIX B FOR MACHINE CHANGES DUE TO
REFURBISHMENT
71
E
S
P
19
E
S
P
19
-
J
-
J
I
L
I
L
4
30
PLATFORM
3
6
31
10
11
16
10
7
9
8
12
15
5
29
1
18
17
8
28
13
14
20
21
18
22
24
23
27
8
26
19, 19A
32
2
25
3
72
4
34
33
PLATFORM PARTS LIST
6
7
8
9
10
11
2
3
4
Item No. Part No. Description
0090-0053
0090-0422
0090-0188
Screw, Cap, 3/8-16 x 3 in.
Washer, Flat, 3/8 in.
Nut, Nylon Lock, 3/8-16
B39-00-0048 Gas Shock, Gate
0090-0076 Screw, Cap, 1/2-13 x 3-1/2 in.
0090-0574
0090-0033
Washer, Flat, 1/2 in.
Screw, Cap, 5/16-18 x 1-3/4 in.
0090-0420
0090-0185
Washer, Flat, 5/16 in
Nut, Nylon Lock, 5/16-18
13 0090-0224 Screw, Machine, #8-32 x 3/8 in.
14
15
16
0090-0007 Screw, Cap, 1/4-20 x1-1/4 in.
B07-06-5549 Plate, Clamp, Upper Control Box
B18-00-0144 Control Box, Upper Enclosure
17
18
B07-06-5552 Plate, Threaded, Control Box
0090-0183 Nut, Nylon Lock, 1/4-20
19 B11-00-0052Bike Rack Arm, Left
19A B11-00-0052Bike Rack Arm, Right
20
21
22
0090-0001
0090-0419
Screw, Cap, 1/4-20 x 1/2 in.
Washer, Flat, 1/4 in.
B39-00-0034 Gas Shock, Shelf
24 B36-00-0038 Pin, Spring Plunger, Shelf
27
28
31
32
34
0090-0074
0090-0191
Screw, Cap, 1/2-13 x 3 in.
Nut, Jam, Nylon Lock, 1/2-13
0090-0042 Screw, Cap, 3/8-16 x 1 in.
B00-00-0154 Sleeve, Heat Shrink, 1/2 x 5 in.
0090-1052 Screw, Machine, #10-24 x 3/4 in.
Qty
1
2
4
4
1
1
1
5
2
4
2
1
6
4
1
1
2
2
2
2
2
1
1
2
1
6
1
1
2
4
1
1
2
2
4
73
5,7
4,7
8
9
2
3
6,7
UPPER CONTROL BOX
13
21
19
14
17
14
16
12
15
18
20
8
23
24
24
25
26
22
10
11
29
30
31
27
28
32
74
UPPER CONTROL BOX PARTS LIST
Item No. Part No. Description
5
6
7
8
1
2
3
4
B01-10-0198
B01-10-0201
B01-10-0205
B01-10-0202
B01-10-0203
B01-10-0204
B01-10-0207
B01-10-0206
Circuit Board, Joystick (Not Shown)
Stop Switch, Emergency
Protection Skin, Push Button
Push Button, Arrow Up
Push Button, Arrow Down
Push Button, Enable
Mini Lamp, 6.3 volt
Switch, Cherry, Water/Dust Proof
9 B01-10-0317 Plate, Top Control
10 B01-10-0264 Joystick
15
16
17
18
11
12
B01-10-0318 Plate, Drive Direction
B01-10-0311 Rubber Cup, Thumb Switch
13 B01-10-0312Handle, Joystick, Left Half
14 B01-10-0313
B01-10-0312-
B01-10-0315
B01-10-0314
B01-10-0305
Handle, Joystick, Right Half
Switch, Thumb Actuator
Lever, Enable Switch
Pin, Dowel, 1/8 x 3/4 in.
19
20
B01-10-0316
0090-0500
Pushbutton, Enable Switch
Screw, Machine, #4-40 x 3/4 in.
21 B01-10-0218 Clamp
22 B01-10-0217 Screw, Machine, Torx, #6-32 x 3/8 in.
23 B01-10-0210
24 0090-0243 Screw, Machine, #10-32 x 1/2 in.
25 B01-10-0209
26 B01-10-0208
27 B01-10-0306 Pin, Dowel, 3/16 x 3/4 in.
28 B01-10-0308
29 B01-10-0307 Gear, 24 Tooth, Switch Activation
30 B01-10-0310
31 B01-10-0309
32 0090-1087 Screw, Machine, Panhead, #6-32 x
1
1
1
1
3
1
1
1
Qty
1
1
1
3
3
1
1
1
1
1
2
2
1
2
1
2
2
1
1
1
1
1
2
2
75
76
HYDRAULIC UNIT
5
6
7
8
9
9
8
10
6
11
3
2
5
1
30
4
13
16
14
27
17
18
19
20
21
22
15
23
23
24
25
26
28
31
32
29
12
Item No. Part No. Description
B02-05-0034 Pump Unit Complete
4
16
17
18
19
20
21
11
12
13
14
6
7
8
9
24
HYDRAULIC UNIT PARTS LIST
B02-15-0438 Valve Assembly, 24VDC
B02-15-0444 Cap, Cartridge Valve
B02-15-0440 Valve, Pilot Operated Check
Spring for Pilot Operated Check Valve
B02-15-0441 Valve, Flow Control
B02-15-0442 Valve, Cartridge, 3 Way-2 Position
B02-15-0443 Valve, Cartridge Relief
B02-15-0425 Solenoid, Start, 24VDC
B02-15-0490 Plug, Nylon, Motor
B02-15-0424 Motor, Electric, 12VDC
B02-15-0420 Base Assembly, Pump
B02-15-0433 Screw, Spring Retainer, 9/16-18
B02-15-0432 Spring, Check Valve
B02-15-0431 Poppet, Ball Retainer
B02-15-0430 Ball, 5/16 in. Diameter
B02-15-0426 Base, End Head
B02-15-0434 Spring, Retaining, Port Filter
26
27
B02-15-0436
B02-15-0437
Valve, Cartridge Relief
Seal, O-Ring, 3-7/8 x 1/8 in.
28 B02-15-0428 Seal, O-Ring, 5/8 x 1/16 in.
29 B02-15-0401
°
31 B02-15-0403
°
32 B02-15-0404 Filter, Screen (Suction)
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
Qty
1
1
1
1
1
7
2
1
1
2
3
1
1
1
2
77
HYDRAULIC CYLINDER, FITTINGS AND HOSES
2
3
4
5
6
8
16, 17
14
7
1
9
14
13
10
11
12
15
78
Item No.
CYLINDER, FITTINGS AND HOSES PARTS LIST
Part No. Description Qty
1 in. Stroke
2
4
5
7
Packing
O-Ring
9 B02-02-0230
°
1
1
1
1
1
1
1
2
1
12
11
4 in. Stroke
B02-04-0094 Valve, Flow Control, 1.25 gpm
B02-02-0237 Fitting, Straight, 4ORFS-6ORB
1
1
3 w/2 - #4FMFS fittings
14 B02-02-0229
°
*
Handle and knob assembly
B02-13-0097 Seal Kit (Includes items 2, 4, 5, and 7
3
1
1
1
79
80
APPENDIX B:
REFURBISHED UNITS
Visually inspect machine to determine what changes have been made due to refurbishment. Direct all questions to the Bil-Jax Service Department at
800.537.0540.
81
EUCLID MOTOR FACE MOUNT
82
EUCLID MOTOR FACE MOUNT PARTS LIST
Item No.
1
Part No. Description
B07-06-6082 Motor Mount Plate
6
7
8
9
3
4
5
0090-0042
0090-0188
Cap Screw, 3/8-16 x 1
Lock Nut, Nylon, 3/8-16
B01-07-0016 Euclid Drive Motor, 1” Shaft
B07-06-6107 Euclid Motor Spacer
B07-06-6108 Flanged Bearing Holder
0090-1137 Socket Head Cap Screw, 3/8-16 x 3
B25-00-0110 Bearing Flange Mount, 1”
10 0090-1138
11
12
Cap Screw, 7/16-14 x 1 1/4
B07-07-5022 Bar, Square, 1/4 x 2 1/4
14 0090-0776 Washer, Flat, 7/16
Qty
4
2
2
2
2
1
4
12
2
6
4
2
2
2
83
84
EUCLID MOTOR FLANGE MOUNT
Item No.
1
Part No. Description
B11-01-0162 Euclid Motor Mount
8
9
10
4
5
6
EUCLID MOTOR FLANGE MOUNT PARTS LIST
0090-0506
0090-0068
0090-0192
Cap Screw, 1/2-13 x 2 1/2
Cap Screw, 1/2-13 x 1 3/4
Hex Nut, 1/2-13
B07-07-5022 Bar, Square, 1/4 x 2 1/4
0090-0776 Washer, Flat, 1/2
0090-1138 Cap Screw, 7/16-13 x 1 1/2
Qty
2
2
2
1
2
2
4
8
8
2
85
ASI MOTOR MOUNT
86
Item No.
1
2
Part No. Description
B01-07-0016 ASI Drive Motor
B07-06-6082 Motor Mount Plate
4
5
6
7
8
10
11
0090-0042
0090-0188
0090-0081
0090-0192
Cap Screw, 3/8-16 x 1
Lock Nut, Nylon, 3/8-16
Cap Screw, 1/2-13 x 5
Hex Nut, 1/2-13
B07-07-5047 Bar, Square, 5/16 x 1 3/4
0090-0776
0090-1138
ASI MOTOR MOUNT PARTS LIST
Washer, Flat, 7/16
Cap Screw, 7/16-14 x 1 1/4
Qty
4
4
8
8
2
2
1
2
2
2
2
87
STEERING ASSEMBLY (I)
88
STEERING ASSEMBLY (I) PARTS LIST
Item No.
1
2
3
4
Part No. Description
B11-01-0157 Steering Linkage Weldment
B07-06-6091 Bar – Tie Rod
B11-01-0159 Support Linkage Weldment
B11-01-0158 Bar – Support Strap Weldment
Qty
1
1
1
1
1
1
1
89
STEERING ASSEMBLY (II)
90
STEERING ASSEMBLY (II) PARTS LIST
Item No.
1
Part No. Description
B07-08-0037 Knuckle – Tie Rod
Qty
4
91
92
93
94
95
96

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Key features
- 24-Volt DC battery package
- 40-amp battery charger
- 1-3/4 inch linear-displacement hydraulic cylinder
- Two-wheel drive transaxle
- Pushbutton steering
- Upper control box
- Emergency lowering valve