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TELESCOPIC PERSONNEL LIFT This equipment is designed and manufactured in compliance with the duties, responsibilities, and standards set forth for manufacturers in the ANSI 92.6 standard in effect at the time of manufacture. This equipment will meet or exceed applicable OSHA codes and ANSI A92.6 standards when used in accordance with sections 5, 6, 7, 8, 9, 10, and 11 of ANSI A92.6 and all other manufacturer’s recommendations.
Table of Contents 1 Safety................................................................................................................1-1 1-1 Introduction.............................................................................................1-1 1-2 Before Operation....................................................................................1-3 1-3 During Operation ....................................................................................1-4 1-4 Maintenance Safety.................
List of Illustrations Figure 3-1. Figure 3-2. Figure 3-3. Figure 3-4. Figure 3-5. Figure 3-6. Figure 4-1. Figure 4-2. Figure 4-3. Figure 4-4. Figure 4-5. Figure 4-6. Figure 4-7. Figure 4-8. Figure 4-9. Figure 4-10. Figure 4-11. Figure 4-12. Figure 4-13. Figure 4-14. Figure 4-15. Figure 4-16. Figure 4-17. Figure 4-18. Figure 4-19. Figure 5-1. Figure 5-2. Figure 5-3. Figure 6-1. Figure 6-2. Figure 6-3. Figure 6-4. Figure 6-5. Figure 6-6. Figure 6-7. Figure 6-8. Figure 6-9. Figure 6-10. Figure 6-11.
List of Tables Table 1-1. Table 2-1. Table 4-1. Table 4-2. Table 4-3. Table 4-4. Table 5-1. Table 6-1. Table 6-2. Table 6-3. Table 6-4. Table 6-5. Table 6-6. Table 6-7. Table 6-8. Table 6-9. Table 6-10. Table 6-11. Table 6-12. Table 6-13. Table 6-14. Table 7-1. Minimum Safe Approach Distances .......................................................1-4 Specifications ..........................................................................................2-2 Daily/Weekly Service Checks......................
iv
1 Safety 1-1 INTRODUCTION Familiarity and proper training are required for the safe operation of mechanical equipment. Equipment operated improperly or by untrained personnel can be dangerous. Read the operating instructions in this manual and become familiar with the location and proper use of all controls. Inexperienced operators should receive instruction from persons who are familiar with the equipment before operating the machine.
ESP 19 Safety Notes This manual contains DANGERS, WARNINGS, CAUTIONS, and NOTES that must be followed to prevent the possibility of improper service, damage to the equipment, or personal injury. DANGER Dangers warn of equipment operation near electrical power lines that could lead to personal injury or death. WARNING Warnings describe conditions or practices that could lead to personal injury or death.
1 — SAFETY 1-2 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.
ESP 19 1-3 DURING OPERATION Read and observe the following general safety precautions at all times during operation of 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 (10 feet minimum) and always allow for platform movement such as wind induced sway.
1 — SAFETY • 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.
ESP 19 1-4 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.
1 — SAFETY 1-5 DAMAGED EQUIPMENT POLICY Safety Statement At Bil-Jax, we are dedicated to the safety of all users of our products. Therefore, all BilJax 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.
ESP 19 1-8
2 Introduction 2-1 GENERAL DESCRIPTION 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.
ESP 19 2-2 SPECIFICATIONS ESP 19 Electric Hydraulic Lift Platform Model Number ESP 19 Manufactured by: Serial Number ________________ Bil-Jax, Inc. 125 Taylor Parkway Archbold, Ohio 43502 800-537-0540 Table 2-1. Specifications 2-3 Rated Platform Load 450 lbs (204 kg) total including operator [1 person + materials not to exceed 450 lbs (204 kg)] Extended Platform Height 19 ft 3 in (5.9 m) Retracted Platform Height 20 in. (50.8 cm) Platform Dimensions 30 in. W x 30 in. L x 42 in. H (0.76 m x 0.
3 Operation 3-1 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.
ESP 19 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 floor-travel joystick with thumb-switch steering.
3 — OPERATION 3-2 NORMAL OPERATING PROCEDURE Perform the following procedures to operate the ESP 19 platform lift vehicle. 1. 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. 2. 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. 3. Make sure battery charger cord is disconnected from wall outlet.
ESP 19 10. 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. 11. 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. 12. If any equipment motion continues after the pushbutton, joystick, or selector switch is released, press the EMERGENCY STOP pushbutton, Figure 3-2.
3 — OPERATION 3-3 EMERGENCY LOWERING PROCEDURES In an emergency, a person at floor level can lower the platform by holding the UPPER key switch in the LOWER CONTROL position and turning the DOWN position. (If the upper control box emergency stop pushbutton is depressed, the platform will not lower.) CONTROL/OFF/LOWER CONTROL the UP/DOWN selector switch to An emergency lowering valve is shown in Figure 3-4.
ESP 19 3-4 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 Pockets 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.
4 Maintenance 4-1 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 Service Check Daily before use Weekly 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.
ESP 19 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.
4 — MAINTENANCE 4-2 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. 1. Turn power to lift ON and raise cage/platform using the lower control box a minimum of 3 feet above the underguard. 2. Place a weight of at least 15 lbs. on the underguard. Refer to Figure 4-1. 15 LB.
ESP 19 4-3 LUBRICATION Lubrication makes operation of the ESP 19 more efficient and extends the life of the lift vehicle. Perform the following lubrication procedures. 1. Lubricate lift chains with clean 40-weight oil. Refer to Figure 4-2. LIFT CHAINS LIFT CHAINS Figure 4-2. Lift Chains Lubrication 2. NOTE: Clean the mast slide ways, Figure 4-3, and lightly spray the slide ways with a dry silicone lubricant. The slide blocks have a high level of lubricity and need only be kept clean.
4 — MAINTENANCE Figure 4-4. Rear Casters Lubrication 3. 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. 4. Remove, clean, and lubricate steering linkage with wheel bearing grease. 5. 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. Figure 4-5.
ESP 19 4-4 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.
4 — MAINTENANCE Pressure Relief Valve Adjustment Perform the following procedure to adjust the pressure relief valve. Refer to Figure 4-6. 1. Move the ESP 19 lift platform to the fully DOWN position. 2. Center 450 pounds of weight on the lift platform. 3. Loosen the jam nut. The pressure relief valve is on the back side of the pump. 4. Turn the pressure relief valve adjust screw 1/8th turn counterclockwise. This will adjust the relief valve bypass pressure setting for less than 450 pounds of lift.
ESP 19 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. 1.
4 — MAINTENANCE 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.
ESP 19 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. 4-10 1. 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. 2.
4 — MAINTENANCE Hydraulic Cylinder Repair Procedure Perform the following procedure to repair the hydraulic lift cylinder. Refer to Figure 49. 1. 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. 2. Remove piston rod (6) and wear ring (7). 3. Inspect piston rod (6) and wear ring (7) for gouges, scratches, and wear. Replace worn or damaged components. 4.
ESP 19 Figure 4-9. Hydraulic Cylinder Disassembly 4-5 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.
4 — MAINTENANCE 3. Once the battery voltage reaches a predetermined level programmed in the electronic control, the yellow “80% CHARGE” LED will illuminate. 4. 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.
ESP 19 Lift Chain Adjustment 1. 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. 2. Remove the plexiglass cover from the base. 3. 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. 4.
4 — MAINTENANCE 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.
ESP 19 4-7 TROUBLESHOOTING Table 4-3. Troubleshooting Chart Problem 1. 2. 3. 4-16 Lift vehicle controls do not work at upper or lower control box. Lift vehicle controls do not work at upper control box, but do work at lower control box. When UP function is selected, pump motor runs but will not raise the platform. Cause Correction a. Master power switch turned off. a. Turn on master power switch. b. Low battery power or faulty battery circuit. b. Recharge batteries per paragraph 4-4.
4 — MAINTENANCE Table 4-3. Troubleshooting Chart (Continued) Problem 4. 5. ENABLE pushbutton blinks when pressed. When DOWN function is selected, lift platform will not descend. Cause Correction a. ENABLE pushbutton has been pressed down for longer than 5 seconds without a function being selected. a. Release ENABLE pushbutton and press again. b. Joystick potentiometer out of adjustment (will not return to center). b.
ESP 19 Table 4-3. Troubleshooting Chart (Continued) Problem 7. 8. 9. 4-18 Cause When joystick is moved, lift f. vehicle will not travel. (cont) When steering thumb switch is pressed, steering wheels do not swivel. When BATTERY ON/OFF switch is turned ON, hydraulic pump starts up. Correction Motor controller, motor controller output wiring, or transaxle drive motor faulty. f. Check for output voltage to drive motor when joystick is engaged.
4 — MAINTENANCE 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.
ESP 19 Table 4-4.
4 — MAINTENANCE 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.
ESP 19 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.
4 — MAINTENANCE 4. • 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. 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.
ESP 19 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.
4 — MAINTENANCE 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 CONDITION Beeeep____Beeeep____Beeeep____ (long beep, long pause, long beep, long pause…) Normal Motion Indicator – Machine operating properly.
ESP 19 B02-03-0038 Steering Cylinder B02-03-0040 Lift Cylinder C1 C2 FB FA B02-05-0034 Pump Unit D C3 C A M Figure 4-15.
4 — MAINTENANCE Raise Gate Switch Lower E-Stop Enable Upper Control Box Drive FWD Drive REV Steer Right Main Control Board Steer Left Beacon Lamp 2 Amp 15’ Switch Platform Raise 1.
4-28 Lift Cylinder 86 87 85 87a 30 W B B B W 2 AMP 4 1 Y/ Gr EASI TXD EASI RXD W R B G G NO 15' Cut Out Switch W R W B B G W R B 1.5 NO NO Upper Lower Cntls Cntls W B W R B 1.0 W DOUT 1 PWR LEFT PWR Right PWR PUMP Figure 4-17.
4 — MAINTENANCE _ BATTERY 18-5 COM WIRE + MOTOR CONTROLLER Motor (-) (+) CAN P5V CAN GND CAN-HI CAN-L0 Power (+) 1 2 3 4 Brake 1 +24V 2 Motor FW SWITCH 3 (+) +24V 4 1 Y/Gr 3 4 2 FREEWHEEL SWITCH 1 C NO 2 NC TRANSAXLE BRAKE 2 1 _ BATTERY + R B 24 VOLT BATTERY CHARGER MASTER POWER SWITCH 110 VOLT CHARGING CORD PUMP UNIT START SOLENOID Figure 4-18.
ESP 19 Right Turn Left Turn Steering Display R w W Enable W Enable Up Down E-Stop R B 3 4 1 1 1 2 Y 3 2 4 3 2 4 Figure 4-19.
5 Replacement Decals 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 Qty Decal No. Description of Decal Qty B06-00-0009 Warning...Moving telescopic masts will create... 2 B06-00-0383 Danger...Failure To Comply With The Following... 1 B06-00-0034 Danger...During charging, explosive oxyhydrogen gas...
ESP 19 OPERATION INSTRUCTIONS FOR ESP 19 E.S.P. 19 1. Read and follow safety precautions and all responsibilities sections set forth in the operators manual 2. Make sure the lift is on a firm and level surface and that there are no potential hazards such as overhead obstructions or electrically charged conductors, DO NOT use the lift where such hazards exist. 3. Check the lift for damaged or worn parts and repair or replace as necessary. 4. Check to be sure that the cage is properly attached to the lift.
5 — REPLACEMENT DECALS WARNING BATTERY CHARGER CORD BOX STAY CLEAR WHILE WORK PLATFORM IS RAISED To charge batteries, plug cord into 3-prong 115V outlet only. • DO NOT work, stand, sit or place any part of your body under the work platform while platform is raised. Cord must be placed into box and lid closed and latched or lift will not operate. • DO NOT allow children to stand, sit or play on this lift. • DO NOT place any objects on the base of the lift while the platform is raised.
ESP 19 0469 0500 SH EL F 046 9 -00- PL AT FO R M A 0461 0009 A 0146 0173 0500 CTA TH • D IS O IS D NO O N D N T st O to O OT an T ol N s, O us d or T W A W O R K R B06 FA eq us e M IL AS UR ui e this sit pm th m on T E CO TO en is as th is VE CO t, m t R M m as cove m as TO PL er t co r ch t FA Y W an ve as co IL IT di r as a ver. w AN H se or D TH or a sh k RE ES an el plat SU E y f or fo LT IN rm ST ot IN RU he wor . SE CT r ob kb RI IO je en OU NS ct ch s S by IN M on it.
5 — REPLACEMENT DECALS 0009 R WA NIN G 0138 ING RN WA 0492 ION UT CA 0382 0390 E TIC NO h itc r sw we e. r po us r off ste t in we ma no po e s. n rn en for Tu wh tur rie be 1. off to tte r re ba x off ilu in bo we 0492 Fa dra ol r po -00ll B06 wi contr ste rn g ma . Tu 2005 2. turninh onax, Inc. itc sw © Bil-J 0462 UTA X BO RD CO cord GER plugonly. AR ries,outlet box CH tte5V intod or ERYarge ba g 11 acedtche ch on pl la BATT To 3-pr t be and 0383 2 046 -00B06 0461 to d e.
ESP 19 5-6
6 Parts List 6-1
ESP 19 6-1 FIRST MOVING MAST PARTS LIST Refer to Table 6-1 for the parts list for the first moving mast. 4 5 2 4 6 7 12 3 13 14 8 15 9 11 10 1 16 11 17 9 10 17 19 19 22 21 18 24 3 18 4 23 20 17 4 18 Figure 6-1.
6 — PARTS LIST Table 6-1. First Moving Mast Parts List Item No. Part No. Description Qty 1 B16-01-0044 First Moving Mast Weldment 1 2 0090-0770 Pin, Cotter 3/16 x 1-1/2 in. 2 3 B36-01-0002 Axle, Sheave 3 4 0090-0425 Washer, Flat, 5/8 in. 6 5 B26-00-0009 Sheave Assembly, Chain 2 6 0090-0188 Nut, Nylon Lock, 3/8-16 1 7 0090-0422 Washer, Flat, 3/8 in. 1 8 B40-00-0003 Cable, Steel, 3/16 in. 1 9 0090-0389 Screw, Set, 1/2-20 x 1/2 in.
ESP 19 6-2 SECOND MOVING MAST PARTS LIST Refer to Table 6-2 for the parts list for the second moving mast. 25 24 2 3 4 10 1 4 5 17 11 9 22 8 6 7 23 9 10 Chain from Base Mast 8 18 13 17 6 19 3 16 13 7 15 11 12 20 14 15 4 16 13 Figure 6-2.
6 — PARTS LIST Table 6-2. Second Moving Mast Parts List Item No. Part No. Description Qty 1 B16-01-0040 Second Moving Mast Weldment 1 2 0090-0770 Pin, Cotter, 3/16 x 1-1/2 in. 2 3 B36-01-0002 Axle, Sheave 3 4 0090-0425 Washer, Flat, 5/8 in. 6 5 B26-00-0009 Sheave Assembly, Chain 2 6 0090-0389 Screw, Set, 1/2-20 x 1/2 in. 8 7 0090-0403 Screw, Sheet Metal, #10 x 1 in. 4 8 B31-00-0001 Slide Block, Plastic 4 9 B40-00-0003 Cable, Steel, 3/16 in.
ESP 19 6-3 THIRD MOVING MAST PARTS LIST Refer to Table 6-3 for the parts list for the third moving mast. 2 3 4 4 1 5 6 8 7 9 10 Chain from 1st Mast 8 18 13 6 16 17 19 3 7 11 12 15 20 4 21 4 13 14 15 Figure 6-3.
6 — PARTS LIST Table 6-3. Third Moving Mast Parts List Item No. Part No. Description Qty 1 B16-01-0041 Third Moving Mast Weldment 1 2 0090-0770 Pin, Cotter, 3/16 x 1-1/2 in. 2 3 B36-01-0002 Axle, Sheave 3 4 0090-0425 Washer, Flat, 5/8 in. 6 5 B26-00-0009 Sheave Assembly, Chain 2 6 0090-0389 Screw, Set, 1/2-20 x 1/2 in. 8 7 0090-0403 Screw, Sheet Metal, #10 x 1 in. 4 8 B31-00-0001 Slide Block, Plastic 4 9 B40-00-0003 Cable, Steel, 3/16 in.
ESP 19 6-4 FOURTH MOVING (PLATFORM) MAST PARTS LIST Refer to Table 6-4 for the parts list for the forth moving (platform) mast. 19 18 2 3 1 4 5 6 20 19 21 17 12 7 16 nd Chain from 2 Mast 8 9 15 14 10 13 11 Figure 6-4.
6 — PARTS LIST Table 6-4. Fourth Moving (Platform) Mast Parts List Item No. Part No. Description Qty 1 B16-01-0042 Fourth Moving (Platform) Mast Weldment 1 2 0090-0014 Screw, Cap, 1/4-20 x 2-1/4 in. 2 3 B01-09-0026 Grommet, Plastic 2 4 B29-00-0160 Bracket, Outreach 1 5 0090-0206 Washer, Lock, Split, 1/4 in. 2 6 0090-0159 Nut, Hex, 1/4-20 2 7 B31-00-0001 Slide Block, Plastic 2 8 0090-0389 Screw, Set, 1/2-20 x 1/2 in. 4 9 0090-0403 Screw, Sheet Metal, #10 x 1 in.
ESP 19 6-5 BATTERY COMPARTMENT PARTS LIST Refer to Table 6-5 for the parts list for the battery compartment. 3 4 1 2 5 6 7 8 9 11 10 16 12 12 15 14 13 14 17 1 18 15 20 1 19 21 23 22 25 26 27 25 28 31 32 Figure 6-5.
6 — PARTS LIST Table 6-5. Battery Compartment Parts List Item No. Part No. Description Qty 1 0090-0183 Nut, Nylon Lock, 1/4-20 7 2 B04-07-0036 Clamp, Cable/Hose, DG 16 1 3 B01-01-0144 Cable, Battery, 2 Ga. x 104 in. 1 4 B01-01-0027 Cable, Battery, 2 Ga. x 19 in. 1 5 B01-01-0130 Cable, Battery, 4 Ga. x 68 in. 1 6 0090-0188 Nut, Nylon Lock, 3/8-16 1 7 B01-10-0282 Controller, Motor 1 8 0090-0028 Screw, Cap, 5/16-18 x 3/4 in. 2 9 0090-0208 Washer, Lock, 5/16 in.
ESP 19 6-6 HYDRAULIC PUMP COMPARTMENT PARTS LIST Refer to Table 6-6 for the parts list for the hydraulic pump compartment. 1 2 3 4 8 9 5 6 7 11 12 14 2 10 4 13 2 15 18 5 2 16 2 20 4 19 3 17 21 2 2 22 26 25 5 23 18 24 Figure 6-6.
6 — PARTS LIST Table 6-6. Hydraulic Pump Compartment Parts List Item No. Part No. Description Qty 1 B01-10-0291 Converter, 24 Volt DC-DC 1 2 0090-0183 Nut, Nylon Lock, 1/4-20 22 3 0090-0419 Washer, Flat, 1/4 in. 6 4 0090-0005 Screw, Cap, 1/4-20 x 3/4 in. 16 5 0090-0210 Washer, Lock, Split, 3/8 in. 5 6 0090-0162 Nut, Hex, 3/8-16 1 7 B04-07-0036 Clamp, Cable/Hose, DG 16 4 8 0090-0232 Screw, Machine, #10-24 x 5/8 in. 1 9 0090-0001 Screw, Cap, 1/4-20 x 1/2 in.
ESP 19 6-7 BASE PARTS LIST Refer to Table 6-7 for the parts list for the base. 25 24 2 1 26 3 32 2 7 26 4 7 24 9 5 27 8 28 30 6 31 29 7 10 11 23 7 12 18 19 22 20 Y NC GE ER OP EM ST R PE UP NTR CO WER LO NTR F OF CO WN DO 15 UP 21 13,14 17 16 Figure 6-7.
6 — PARTS LIST Table 6-7. Base Parts List Item No. Part No. Description Qty 1 B07-01-2003 Edge, Top Cover 1 2 0090-0344 Screw, Threadcutting, #10-24 x 1/2 in. 8 3 B05-00-0005 Tape, Foam Adhesive 4 B18-00-0177 Plexiglass, 1/8 in. 1 5 B24-01-0013 Frame, Aluminum, 18-1/4 in. 2 6 B24-01-0009 Frame, Aluminum, 20 in.
ESP 19 6-8 BASE MAST PARTS LIST Refer to Table 6-8 for the parts list for the base mast. 9 1 6 2 10 11 12 3 19 7 4 34 13 5 15 14 16 17 18 21 20 22 31 35 23 24 27 25 32 31 30 20 26 33 21 28 29 8 Figure 6-8.
6 — PARTS LIST Table 6-8. Base Mast Parts List Item No. Part No. Description Qty 1 0090-0188 Nut, Nylon Lock, 3/8-16 1 2 0090-0422 Washer, Flat, 3/8 in. 1 3 B40-00-0003 Cable, Steel, 3/16 in. 1 4 0090-0389 Screw, Set, 1/2-20 x 1/2 in. 4 5 0090-0403 Screw, Sheet Metal, #10-24 x 1 in. 2 6 B31-00-0001 Slide Block, Plastic 2 7 B01-01-0142 Cord, Coiled, 16-2 1 8 0090-0684 Rivet, Pop, 3/16 x 1/2 in. 2 9 B40-01-0008 Chain, Lift 2 10 0090-0860 Pin, Cotter, 1.
ESP 19 6-9 DRIVE AXLE PARTS LIST Refer to Table 6-9 for the parts list for the drive axle components. 4 1 2 5 3 6 6C 6B 8 9 7 13 14 17 10 11 12 16 15 Figure 6-9.
6 — PARTS LIST Table 6-9. Drive Axle Item No. 1 2 3 4 5 6 6A 6B 6C 7 8 9 10 11 12 13 14 15 16 17 Part No. 0090-0049 B30-00-0050 0090-0188 0090-0065 B07-06-5995 B01-07-0015 B01-07-0012 B01-07-0011 B01-07-0013 B07-07-5022 B30-00-0049 B07-06-5946 B25-00-0073 0090-0422 0090-1096 0090-0367 0090-1071 B08-02-0015 0090-0776 0090-0617 Description Screw, Cap, 3/8-16 x 2-1/4 in. Pad Assembly, Torsion Nut, Nylon Lock, 3/8-16 Screw, Cap, 1/2-13 x 1 in.
ESP 19 6-10 STEERING PARTS LIST Refer to Table 6-10 for the parts list for the steering components. 1 3 15 19 6 4 7 5 8 8 9 16 18 17 19 2 11 12 9 14 20 10 8 8 22 21 8 13 23 9 8 10 9 10 24 12 10 10 12 20 7 8 25 9 24 27 7 9 24 18 28 29, 29A 30 31 32 31 17 17 33 Figure 6-10.
6 — PARTS LIST Table 6-10. Steering Parts List Item No. Part No. Description Qty 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 0090-0239 B01-02-0105 0090-0182 B24-01-0015 0090-0824 0090-0035 0090-0188 0090-0422 0090-0420 0090-0185 0090-0192 0090-0574 B00-00-0009 B11-01-0149 0090-0881 0090-1072 0090-0429 B25-00-0096 0090-0046 B07-08-0037 B11-01-0138 B07-06-5826 0090-0045 0090-1061 B11-01-0100 0090-0080 B02-03-0038 Screw, Machine, #10-24 x 1-1/2 in.
ESP 19 6-11 PLATFORM PARTS LIST Refer to Table 6-11 for the parts list for the platform. 30 5 32 3 11 10 6 4 9 7 29 19, 19A 10 31 13 12 14 15 16 1 8 18 27 8 8 24 28 23 26 2 B I L J A X 25 3 4 33 34 Figure 6-11.
6 — PARTS LIST Table 6-11. Platform Parts List Item No. Part No. Description Qty 1 B17-00-0137 Weldment, Platform 1 2 0090-0053 Screw, Cap, 3/8-16 x 3 in. 2 3 0090-0422 Washer, Flat, 3/8 in. 4 4 0090-0188 Nut, Nylon Lock, 3/8-16 4 5 B17-00-0138 Gate 1 6 B39-00-0048 Gas Shock, Gate 1 7 0090-0076 Screw, Cap, 1/2-13 x 3-1/2 in. 1 8 0090-0574 Washer, Flat, 1/2 in. 5 9 0090-0033 Screw, Cap, 5/16-18 x 1-3/4 in.
ESP 19 6-12 UPPER CONTROL BOX PARTS LIST Refer to Table 6-12 for the parts list for the upper control box. 13 14 12 16 17 15 14 18 3 21 6,7 5,7 20 19 23 4,7 24 24 22 25 8 26 8 9 2 27 29 10 28 30 31 11 32 Figure 6-12.
6 — PARTS LIST Table 6-12. Upper Control Box Parts List Item No. Part No. B01-10-0273 Description Joystick Assembly Qty 1 1 B01-10-0198 Circuit Board, Joystick (Not Shown) 1 2 B01-10-0201 Stop Switch, Emergency 1 3 B01-10-0205 Protection Skin, Push Button 3 4 B01-10-0202 Push Button, Arrow Up 1 5 B01-10-0203 Push Button, Arrow Down 1 6 B01-10-0204 Push Button, Enable 1 7 B01-10-0207 Mini Lamp, 6.
ESP 19 6-13 HYDRAULIC UNIT PARTS LIST 8 9 9 6 8 7 5 10 11 6 4 3 12 13 2 14 16 17 18 19 20 21 15 22 27 1 23 30 24 23 28 5 31 32 29 Figure 6-13.
6 — PARTS LIST Table 6-13. Hydraulic Unit Parts List Item No. Part No. Description Qty B02-05-0034 Pump Unit Complete 1 1 B02-15-0423 Reservoir, Plastic 1 2 B02-15-0412 Clamp, Reservoir 1 3 B02-15-0418 Breather Cap 1 4 B02-15-0438 Valve Assembly, 24VDC 1 5 0090-1060 Screw, Socket Head Cap, 1/4-20 x 2-3/4 in.
ESP 19 6-14 HYDRAULIC CYLINDER, FITTINGS, AND HOSES PARTS LIST 2 3 4 5 6 8 1 7 16, 17 9 13 14 10 14 11 12 15 Figure 6-14.
6 — PARTS LIST Table 6-14. Hydraulic Cylinder, Fittings, and Hoses Parts List Item No. 1 Part No. B02-03-0040 2 3 Qty Cylinder, Hydraulic Lift, 1.75 in. Bore x 54 in. Stroke Wiper, Rod 1 1 Nut, Gland 1 4 Packing 1 5 O-Ring 1 Piston Rod 1 Ring, Wear 1 Jacket, Cylinder 1 6 B02-13-0096 Description NSS 7 8 NSS 9 B02-02-0230 Fitting, 4MFS-4ORM 90° 2 10 B02-03-0038 1 12 B02-04-0094 Cylinder, Hydraulic Steering, 1.5 in. Bore x 4 in. Stroke Valve, Flow Control, 1.
ESP 19 6-30
7 ANSI Reprint The following sections are reprinted from the ANSI A92.6-1999 code in effect at the time of manufacture. Permission to reprint has been granted by the Scaffold Industry Association. 5. Responsibilities of Dealers 5.1 Basic Principles.
ESP 19 5.8 Familiarization On Delivery. Upon delivery by sale, lease, rental or any form of use, the dealer shall have the responsibility with the person designated by the receiving entity for accepting the aerial platform to: 1) Identify the weather resistant compartment (for manual storage). 2) Confirm the manuals, as specified by the manufacturer, are on the aerial platform. 3) Review control functions. 4) Review safety devices specific to the model aerial platform being delivered. 5.9 Dealer As User.
7 — ANSI REPRINT 6. Responsibilities of Owners 6.1Basic Principles. Sound principles of safety, training, inspection, maintenance, application, and operation consistent with all data available regarding the parameters of intended use and expected environment shall be applied in the performance of the responsibilities of owners with due consideration of knowledge that the aerial platform will be carrying personnel. 6.2 Responsibilities Upon Purchase.
ESP 19 emergency and safety devices; (5) Lubrication of all moving parts, inspection of filter element(s), hydraulic oil, engine oil, and coolant, as specified by the manufacturer; (6) Visual inspection of structural components and other critical components such as fasteners, pins, shafts, and locking devices; (7) Placard, warnings, and control markings; (8) Additional Items specified by the manufacturer.
7 — ANSI REPRINT 6.15 Record Retention And Dissemination. 6.15.1 Record retention. The owner shall retain the following records for at least 4 years: (1) Name and address of the purchaser of each aerial platform by serial number and date of delivery. (2) Written records of the frequent and annual inspections and repairs performed. The record shall include deficiencies found, corrective action accomplished and identification of the person(s) performing the inspection and repairs.
ESP 19 Brokers of Self-Propelled Elevating Work Platforms shall be provided and stored in the weather resistant storage compartment. 7.3 Inspection And Maintenance. Users shall inspect and maintain the aerial platform as required to ensure proper operation. The frequency of inspection and maintenance shall be determined by the manufacturer's recommendations and be compatible with operating conditions and the severity of the operating environment.
7 — ANSI REPRINT 7.7 Familiarization Before Use. The user shall permit only properly trained personnel to operate an aerial platform. The user shall ensure that before use the operator is familiar with the model of the aerial platform to be operated, and specifically: (1) Knows where the weather resistant compartment for manual storage is located.
ESP 19 reach is prohibited. (10) Precaution for other moving equipment. When other moving equipment and vehicles are present, special precautions shall be taken to comply with local ordinances or safety standards established for the workplace. Warnings such as, but not limited to, flags, roped-off areas, flashing lights, and barricades shall be used as appropriate. (11) Reporting problems or malfunctions.
7 — ANSI REPRINT that only tools and materials, which are evenly distributed and can be safely handled by a person(s) working from the platform, are transported. (33) Rated horizontal force. The user shall direct the operator not to exceed the manufacturer’s rated horizontal force. (34) Bridge cranes. When an aerial platform is to operate within the area of travel of a bridge crane or similar equipment, steps shall be taken to prevent a collision with the aerial platform.
ESP 19 8.2 Manuals. 8.2.1 Machine manuals. The operator shall ensure the operating and maintenance manuals are stored in the weather resistant storage compartment on the aerial platform. The manual(s) is considered an integral part of the aerial platform and is vital to communicate necessary safety information to the operator. The operator shall be familiar with the manuals and reference them as required. 8.2.2 Manual of responsibilities. The ANSI/SIA A92.
7 — ANSI REPRINT 8.8 Prior To Each Elevation. Before each elevation of the platform, the operator shall ensure: (1) Outriggers, stabilizers, extendable axles, or other stability enhancing means are used as required by the manufacturer. (2) Guardrails are installed and access gates or openings are closed per manufacturer's instructions. (3) The load and its distribution on the platform and any platform extension(s) are in accordance with the manufacturer's rated capacity for that specific configuration.
ESP 19 free of flame, sparks, or other hazards that may cause fire or explosion. (18) Battery charging. Batteries shall only be charged in a well-ventilated area free of flame, sparks, or other hazards that may cause fire or explosion. (19) Improper platform stabilization. The aerial platform shall not be positioned against another object to steady the platform. (20) Misuse as a crane. The aerial platform shall not be used as a crane. (21) Unusual operating support conditions.
7 — ANSI REPRINT 9. Responsibilities Of Lessors 9.1 Basic Principles. Sound principles of safety, training, inspections, maintenance, application, and operation consistent with all data available regarding the parameters of intended use and expected environment shall be applied in the performance of responsibilities of lessors with due consideration of the knowledge that the aerial platform will be carrying personnel. 9.2 Lessor As A Dealer.
ESP 19 M.S.A.D. = Minimum Safe Approach Distance (See Table 7-1). DENOTES PROHIBITED ZONE • Do not allow machine, personnel, or conductive materials inside prohibited zone. • Maintain M.S.A.D. from all energized lines and parts as well as those shown. • Assume all electrical parts and wires are energized unless known otherwise. Diagrams shown are only for purposes of illustrating M.S.A.D. work positions, not all work positions.
7 — ANSI REPRINT Table 7-1. Minimum Safe Approach Distance (M.S.A.D.) to energized (exposed or insulated) power lines and parts Voltage Range (Phase to Phase) Minimum Safe Approach Distance (Feet) 0 to 300V (Meters) Avoid Contact Over 300V to 50KV 10 3.05 Over 50KV to 200KV 15 4.60 Over 200KV to 350KV 20 6.10 Over 350KV to 500KV 25 7.62 Over 500KV to 750KV 35 10.67 Over 750KV to 1000KV 45 13.
ESP 19 7-16
125 Taylor Parkway Archbold, OH 43502 Phone (419) 445-8915 (800) 537-0540 Fax (419) 445-0367
