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Bil-Jax ESP 19 Personal Lift User Manual

1. batteries plug cord body under the work platform while platform is into 3 prong 115V outlet only raised DO NOT allow children to stand sit or play on Cord must be placed into box this lift DO place any objects on the base of the lift and lid closed and latched or L INSTRUCTIONS MAY lift will not operate IN SERIOUS CRUSHING INJURY OR oem m d Bil Jax Inc 2004 B06 00 0462 06 00 0457 06 00 0462 MAXIMUM CAPACITY 150185 Bil Jcx Inc 2004 B06 00 0458 A B06 00 0458 X 800 225 3765 FOR SERVICE FOR BICYCLES ONLY mile 06 00 0456 06 00 0459 06 00 0460 THE HYDRAULIC SYSTEM OF THIS MACHINE 15 DESIGNED TO USE INS PITE PURE SAE 10W LOW FOAMING HYDRAULIC OIL Bil Jax Inc 2004 06 00 0068 B06 00 0068 B06 00 0066 FOR TRANSPORT ONLY BIl Jax Inc 2004 06 00 0066 This machine must not be operated on any slope greater Rated Number of Occupants One 1 A Forkliff Pockets than 5 degrees iri serious injury or death Tip Over Hazard TA DO NOT exceed rated capacity Maximum Capacity 450 165 204 kg DO NOT exert horizontal side force to the platform while elevated Failure to comply with the preceding instructions may result in the machine tipping over causing serious injury or death to the operator Rated Horiz
2. xog Jodeeg UOJIMS UOIMS leeuw 5 9 eal NC eyoig SS Q4 ON QW WO OW HOLIMS Md IN lt ON N ASd NYO YOLOW AMALIE 809 04 uoo 1edan 9 4 17 Electrical Layout Figure 4 28 4 MAINTENANCE BATTERY 20 MOTOR CONTROLLER FREEWHEEL SWITCH c HQ TRANSAXLE NO Bo NC BRAKE BATTERY 24 VOLT BATTERY CHARGER MASTER er SWITCH CHARGING CORD Lt PUMP UNIT START SOLENOID Figure 4 18 Drive Wiring Diagram 4 29 ESP 19 Steering Display E bs R W Enable 4 30 _J Down
3. 10 O DOWN ON HORN ON TES Horn 979 wn Cura ON HOUR METER O Of pwr BUZZER RS232 RXD O of RS232 TXD O RS232 GND 9 CANH1O Of aasa MAST SWITCH MAST pwr O of UPPER CONTROLS O Of UP CTRL srece PWRO Of LOWER DOWN1O Of Lowerinc Jewe O LOWER UP O Of rasne TILT 5 5 8107 Of MACHINE 2 UNDERCAGE Of UNDERCAGE LONAC Of DIN1 ONC pwr OO DINZ O of DIN2 ON Q of SPARE 5 10 Of AGND O Of AIN1 O Of STEERING 5 107 Of STEERING GND O Of STEERING INTO Figure 4 14 Main Controller Board ESP 19 4 20 Table 4 4 Main Controller LED Indicators Indicator Function Color Main Error Codes Red Controller Flashes 1 Main Controller OK Flashes 2 Short or open at hydraulic pump output Diagnostics 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 System Error Codes Green Diagnostics 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 EASLTXD Upper Control Transmi
4. M2 Connect input cord only to properly grounded three wire outlet with specified voltage and frequency Always wear safety goggles and face shield when working on or near battery Check battery acid level at the start of each day If acid does not cover the plates add only enough distilled or demineral ized water to completely cover the plates Keep terminals and terminal connections clean Consult Operation and Maintenance Manual for additional information on battery maintenance right or left 000 0038 mora The joystick and steering thumb switch may be operated simultaneously for smooth maneuvering DO NOT attempt to operate the drive function and the raise lower function at the same time B06 00 0034 This lift is equipped with a level sensor that will prevent the lift from raising or driving with platform elevated CHECK LEVEL while on an unlevel surface If the lift fails to raise or drive while elevated lower platform immediately LUDUM Bil Jax Inc 2004 06 00 0461 B06 00 0461 FAILURE TO COMPLY WITH THE FOLLOWING SAFETY INSTRUCTIONS OR ANY OTHER IMPROPER USE OF THIS EQUIPMENT WILL RESULT IN SERIOUS INJURY OR DEATH BEFORE USE Work oniy wihin the platform guard rea and do not attempt to increase working This equipment to be used by competent fully rained and authorized personnel only height with boxes ladders scaffolding or any o
5. Figure 4 19 Upper Control Wiring Diagram 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 Description of Decal Description of Decal Qty B06 00 0009 Warning Moving telescopic 2 06 00 0383 Danger Failure To Comply With 1 masts will create The Following B06 00 0034 Danger During charging explo 1 sive oxyhydrogen gas B06 00 0037 Lubricate Semi Annually 06 00 0066 Insert Forks Minimum 32 B06 00 0455 Bil Jax Vertical transfer type B06 00 0068 SAE 10W Hydraulic Oil decal B06 00 0138 Warning Maintenance decal B06 00 0456 800 225 3765 For Service 1 B06 00 0146 Danger High voltage line warn 1 B06 00 0457 Warning Stay clear while work 1 ing platform is raised B06 00 0173 Safety harness lanyard attachment B06 00 0458 Maximum Capacity 150 165 pomt B06 00 0459 For Bicycles Only B06 00 0192 Operation and service manual B06 00 0460 Caution Black on Yellow inside B06 00 0461 Instructions for ESP 19 B06 00 0225 Warning Stay clear when raising 2 or lowering B06 00 0462 Battery Charger Cord Box B06 00 0289 Check level with cage fully down 06 00 0463 Do Not Pick Machine Up From This End 06 00 0297 Forklift Pockets SERE 2 06 00 0464 Emergency Lowering B06 00 0339 Warning Full Body Harness and Lanyard Not used
6. 12 B01 10 0281 Joystick Switch Plate Assembly Includes Circuit Board 0090 0224 Screw Machine 18 32 x 3 8 Cap Manual Tube 5 5 5 gt 62 6 23 ESP 19 6 12 UPPER CONTROL BOX PARTS LIST Refer to Table 6 12 for the parts list for the upper control box Figure 6 12 Upper Control Box 6 24 6 PARTS LIST Table 6 12 Upper Control Box Parts List gsi ey i i i i 5 Push Buton s 009 swich 5 Pat Top Conrad i i i i z i i i i i z i z i z z i i z z 6 25 ESP 19 6 13 HYDRAULIC UNIT PARTS LIST 6 E TA 5 Figure 6 13 Hydraulic Unit Assembly 6 26 6 PARTS LIST Table 6 13 Hydraulic Unit Parts List Qe mesas rap cge 5 Boriso Cap B02150441 Valve Fow Consol 779 02156 2 Valve Cartridge Way Postion Plug Nylon Motor Spring Retaining Port Filter Re Re Re _ 6 27 ESP 19 6 14 HYDRAULIC CYLINDER FITTINGS AND HOSES PARTS LIST Figure 6 14 Hydraulic Cylinder Fittings and Hoses 6 28 6 PARTS LIST
7. Operation and I2 L JAX Maintenance Manual A STEP ABOVE 9 AERIAL WORK PLATFORMS ESP 19 Electric Stock Picker ESO MI SSS SSN SN B33 01 0086 02 TELESCOPIC PERSONNEL LIFT This equipment is designed and manufactured in compliance with the duties re sponsibilities 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 stan dards when used in accordance with sections 5 6 7 8 9 10 and 11 of ANSI A92 6 and all other manufacturer s recommendations It is the responsibility of the user of this equipment to follow all applicable ANSI OSHA Federal State and local codes and regulations that govern the safe opera tion of this equipment Table of Contents ida CDS 1 1 151 dntroduction ober Hee REID RH D ERE tet 1 1 1 2 Before Operation nose mede det 1 3 1 3 DunngOperation z menge ebrei Denton 1 4 1 4 Maintenance Safety 1 6 1 5 Damaged Equipment Policy sese 1 7 2 1 2 1 General Description pore neta 2 1 2 2 lt 2 2 2 3 Warranty 2 2 M 3 1 3 1 Operator Controls iscsi steve
8. Start Solenoid fSteering 83 J Right Solenoid Sensor Ci 3 Start Solenoid Cage j Lent Tur j f E Left Solenoid Switch LoL s T Forward Lf isi Hms H ssi He L Reverss HHD HEY 110v Box l Switch Parking Brake 110v Switch Transaxle Box Relay Motor Master Start Power Solenoid Hydraulic Pump Motor Figure 4 16 PC Logic Diagram 4 27 ESP 19 AYZ 10 OO Buzzer STEERING GND STEERING 5V UNDER CAGE TILT SENSOR PWR L CNTLS UP PWR L CNTLS DN UPPER CNTLS SPARE 5V PWR DIN 2 PWR DIN 1 PWR PWR PWR ISv3 ISv3 MAST SW CAN GND PWR POS PWR GND lt e PWR E UOJIMS G o L ON iS 9 UOYOSJOlg M EASI GND EASI 24V SONDA umoq JOPUIAD ur
9. 12 13 14 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 AII 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 For more information on battery charging operations refer to the bat tery 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 unau thorized equipment operation 3 3 3 OPERATION EMERGENCY LOWERING PROCEDURES 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
10. 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 3 Written records of repairs accomplished on the aerial platform The records shall include corrective action accomplished and identification of the person s performing the repairs 4 Predelivery preparation performed prior to each delivery 5 Name of the person s trained 6 Name of the person s providing training 7 Name of the person s provided with familiarization upon delivery unless this individual has been provided with familiarization on the same model or one having characteristics consistent with the one being delivered within the prior 90 days 8 Name of person s providing familiarization upon delivery 6 15 2 Proof of training Owners providing training should provide successful trainees a means to evidence their training and shall provide such proof if requested by the trainee The document evidencing the training shall include the following information 1 Name of entity providing training or retraining 2 Name of trainer s 3 Clear id
11. 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 e ALWAYS wear safety glasses when working near battery e 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 e ALWAYS disconnect ground cable first when removing battery e ALWAYS connect ground cable last when installing battery e ALWAYS charge batteries in open well ventilated areas e NEVER smoke when servicing battery e NEVER allow batteries to overcharge and boil e NEVER short across battery posts to check for current NEVER break a live cir cuit at battery e NEVER jump start other vehicles using lift battery 1 6 1 5 1 SAFETY 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 Fed eral 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 struc tural damage to the lift This can seriously compromise the ability of the lift to perform in a safe manner Therefore whenever a Bil Ja
12. 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 0 76 m x 0 76 m x 1 07 m Base Dimensions 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 2150 lbs 975 kg Platform Lift Time 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 de fects of material and workmanship provided the unit is operated and maintained in com pliance 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 compo nent 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
13. 779 m B03 00 0009 Chain Assy includes items 12 13 14 15 16 and Lower Clevis shown on next page NOTE It is recommended that chain parts be purchased as an assembly 6 3 ESP 19 6 4 6 2 SECOND MOVING MAST PARTS LIST Refer to Table 6 2 for the parts list for the second moving mast 4 59 2 Pd eI E PR 9 10 Chain from Base Mast Figure 6 2 Second Moving Mast 6 PARTS LIST Table 6 2 Second Moving Mast Parts List 5 wm serow 1 s 831 00 0001 Side Blok 779 20 00 0003 cable 03 00 0009 Chain Assy includes items 10 11 12 17 22 and 23 NOTE It is recommended that chain parts be purchased as an assembly 6 5 ESP 19 6 6 6 3 THIRD MOVING MAST PARTS LIST Refer to Table 6 3 for the parts list for the third moving mast 3 AM cm 6 s id 10 Chain from 1 Mast Figure 6 3 Third Moving Mast 6 PARTS LIST Table 6 3 Third Moving Mast Parts List 5 wm serow 1 s 831 00 0001 Side Blok 779 E B03 00 0009 Chain Assy includes items 10 11 12 17 and Upper Clevis amp Lock Nut shown on page 6 4 NOTE It is recommended that chain parts be purchased as an assembly 6 7 ESP 19 6 4 FOURTH MOVING PLATFORM MAST PARTS LIST Refer to Table 6 4 for the parts list for th
14. To operate lift from the ground tum and hold lower control switch to lower control setting then select either up or down function To operate lift from the platform tum lower control switch to upper control setting Make sure battery charger cord is disconnected from outlet placed back into its box and lid is closed and latched LIFT WILL NOT OPERATE IF LID IS NOT CLOSED SECURELY 10 Enter platform and be certain that the entry gate is closed completely LIFT WILL NOT OPERATE IF ENTRY GATE IS NOT CLOSED COMPLETELY TO RAISE OR LOWER Depress and hold one of the enable buttons one enable button is on the front of the joystick handle the other is located to the left of the joystick Press either the raise or lower button TO DRIVE Depress and hold one of the enable buttons one enable button is on the front of the joystick handle the other is located to the left of the joystick Push joystick in the direction forward or backward that you wish to travel Press the steering thumb switch on the top of the joystick in the direction you wish the lift to tum either EQUIPMENT WILL RESULT IN INJURY OR DEATH 4 Risk of Electric Shock DO NOT expose charger to rain power wash detergents or spray DO NOT use frayed or damaged electric cords when charging During charging explosive oxyhydrogen gas is generated DO NOT smoke or allow open fire sparks or embers near battery when charging
15. and HRMTR turn ON If not the main controller may be faulty 4 For faulty LEFT RIGHT command a Hold ENABLE amp LEFT switch on the joystick check LED s PUMP ON amp LEFT ON turn ON If not the LEFT switch on the joystick or the main controller may be faulty Hold ENABLE amp RIGHT switch on the joystick check LED s PUMP ON amp 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 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 Faulty wiring between the LED board and the joystick board or a loose connection The wiring between the steering angle sensor to the main controller Steering IN may be faulty 4 23 ESP 19 Motor Controller Troubleshooting 1 Make sure there is Power present 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
16. 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 sec tions 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 plat form is down When the platform is raised the travel speed is limited The transaxle in cludes 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 re verse 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 lif
17. 2 lift mast Check that slide blocks and their paths are clean and lightly lubricated Y 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 EA lift chains with 40 weight NOR Check hydraulic UP and DOWN valves operation Check operation of emergency d lowering valve Grease rear caster swivel bolts axles and wheels Grease steering linkage pivot bolts Grease front caster pillow blocks pow Check battery cables and wiring for loose connections and damaged wires Check slide blocks for wear Check for mast sway Load test with 450 pounds 4 2 4 MAINTENANCE UNDERGUARD SERVICE CHECK The underguard is a safety device located under the cage platform that shuts down op eration 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 Ibs on the underguard Refer to Figure 4 1 15 LB WEIGHT UNDERGUARD Figure 4 1 Underguard 3 BEFORE ATTEMPTING TO LOWER THE LIFT MAKE SURE AREA UNDERNEATH AND AROUND THE CAGE PLATFORM IS CLEAR OF PERSONNEL OR OTHER OBJECTS Using the l
18. 3 2 Upper Control Box EMERGENCY PUSHBUTTON 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 4 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 3 OPERATION 3 2 NORMAL OPERATING PROCEDURE Perform the following procedures to operate the ESP 19 platform lift vehicle 1 NOTE Read and follow all safety precautions contained in Section and all responsi bilities outlined in the ANSI A92 3 reprint in Section 7 of this manual Check
19. 4 5 Pressure Relief Valve 4 7 Fl w Restrictor 4 8 Valve Operation sacs i 4 0 Hydraulic Cylinder Disassembly eene 4 12 Battery Charger eee ret to ppt 4 12 Chain Elongation Inspection esee 4 13 Lift Chains Adjustment 4 14 Slide Blocks Adjustment eese eren 4 15 Main Controller Board eese 4 19 Hydrauh Diagrames etre tee RIOT 4 26 PC Dogic ecd oti ot ees 4 27 Hlectrical Eay out ppt a D UR ERR tines 4 28 Drive Wiring 4 29 Upper Control Wiring Diagram 4 30 Replacement ree re ter 5 2 Decal Locations Side View sese 5 4 Decal Locations Rear View esee eene 5 5 First Moving Mast rede eger ree 6 2 Second Moving 6 4 Third Moving Mast derunt prd ERE RARE 6 6 Fourth Moving Platform 6 8 Battery Compartment eerte tete tete 6 10 Hydraulic Pump Compartment eese 6 12 accetta deben tede tei 6 14 B se Mast enne ertt UI err ERU 6 16 Drive Axles uana ame Pa ten HERR 6 18 bend 6 20 Platforms eg A alee deu RR eiie 6 22 Upper
20. 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 2 Knows the operating and maintenance manuals supplied by the manufacturer are stored in the weather resistant compartment and is familiar with the operating and safety manuals 3 Understands all control functions placards and warnings 4 Is aware of and understands all safety devices specific to the model aerial platform being used 7 8 Workplace Inspection Before the aerial platform is used and during use the user shall check the area in which the aerial platform is to be used for possible hazards such as but not limited to 1 Drop offs or holes 2 Slope s 3 Bumps and floor obstructions 4 Debris 5 Overhead obstructions and high voltage conductors 6 Hazardous locations and atmospheres reference ANSI NFPA 505 1996 7 Inadequate surface and support to withstand all load forces imposed by the aerial platform in all operating configurations 8 Wind and weather conditions 9 Presence of unauthorized persons 10 Other possible unsafe conditions 7 9 Determination Of Hazardous Locations It shall be the responsibility of the user to determine the hazard classification potential presence of flamma
21. Control ete et i te reet ege ri 6 24 Hydraulic Unit 6 26 Hydraulic Cylinder Fittings and Hoses eese 6 28 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 esee 4 1 Monthly Service 4 2 Troubleshooting Chart 4 16 Main Controller LED Indicators eene 4 20 Replacement 5 5 1 First Moving Mast Parts List 6 3 Second Moving Mast Parts 45 6 5 Third Moving Mast Parts 1151 6 7 Fourth Moving Platform Mast Parts List sss 6 9 Battery Compartment Parts List eese 6 11 Hydraulic Pump Compartment Parts 1186 2 22221 6 13 Base Parts Mast sista tiie ities Rin ith oa 6 15 Base Mast Parts Listy 6 17 Axle Parts s die 6 19 Steering Parts Tastin naa ehe nee etes 6 21 Platform List eoo nube RR On etel 6 23 Upper Control Box Parts 118 6 25 Hydraulic Unit Parts List 6 27 Hydr
22. If the battery does not reach the 80 level in 14 WORKFORCE CR ORLA GUSTING This machine is designed and manufactured in hours the charger will shut off and the check battery AERIAL WORK PLATFORMS compliance with the ANSI A92 6 standard in force on pu ue b ied at wold pre enged 06 00 0383 the date of manufacture Dealers owners users n e y operators lessors lessees are responsible for OFF inspection maintenance training and operation as B06 00 0383 required by A92 6 and the owners manual B06 00 0349 Alterations modifications or changes to this machine without the written authorization of bil jax inc as well as any unauthorized adjustment of valves disabling or by passing of safety devices or the OPERATION AND SERVICE Improper use i shall exempt inc rom any liability for any resulting injuries or damage MANUAL INSIDE B06 00 0192 06 00 0382 SAFETY FAILURE TO COMPLY 06 00 0192 B06 00 0382 WITH THE FOLLOWING MAINTENANCE REQUIREMENTS COULD RESULT IN SERIOUS INJURY OR DEATH Follow complete maintenance schedule outlined in Owner s Manual loe m and Section 6 of the ANSI standard reprinted in the Owner s Manual Inspect all chain assemblies fasteners pins and related parts daily forwear damage popertightness and function Replace according B06 00 0173 to Owner s Man
23. Modifications Modification or alteration of an aerial platform or the fabrication and attaching of frameworks or the mounting of attachments for holding tools or materials onto the platform or the guardrail system shall only be accomplished with the prior written permission of the manufacturer 30 Assistance to the operator If an operator encounters any suspected malfunction of the aerial platform or any hazard or potentially unsafe condition relating to capacity intended use or safe operation of the aerial platform the operator shall cease operation of the aerial platform and request further information from the employer 31 Problems or malfunctions Any problem s or malfunction s that affect the safety of operations shall be repaired prior to use of the aerial platform 32 Carrying materials larger than the platform The user shall ensure 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 35 Adequate support requirements The user shall insure the support surface is adequate for the aerial platform and the load car
24. and parts manuals within 60 days of acquisition 3 Shall within 60 days of acquisition of the aerial platform provide the manufacturer with the full name and address of the buyer along with the model and serial number of the aerial platform acquired 4 Shall if the aerial platform is used perform either a frequent inspection or an annual inspection prior to placing the unit in service 5 Shall become familiar with and conform with the responsibilities of owners as set forth in the ANSI SIA A92 6 1999 Manual of Responsibilities for Dealers Owners Users Operators Lessors Lessees and Brokers of Self Propelled Elevating Work Platforms 6 3 Manuals 6 3 1 Machine manual s Owners shall provide 5 of the operating and maintenance manual s with each rental lease or sales delivery by ensuring they are properly stored in the weatherproof compartment that is a part of the aerial platform The manual s is considered an integral part of the aerial platform and is vital to communicate necessary safety information to owners users and operators In addition repair and parts manuals should be provided with each sale delivery 6 3 2 Manual of responsibilities The ANSI SIA A92 6 1999 Manual of Responsibilities for Dealers Owners Users Operators Lessors Lessees and Brokers of Self Propelled Elevating Work Platforms shall be provided and stored in the weather resistant storage compartment 6 4 Maintenance Inspection And Repair
25. 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 35 Adequate support requirements The operator shall insure the support surface is adequate for the aerial platform and the load carried 36 Leveling the aerial platform Outriggers and leveling devices supplied by the manufacturer shall be utilized to level the aerial platform when provided 37 Protecting against unauthorized use The operator shall not use rent lease or provide the aerial platform for any form of beneficial use to another entity without the authorization of the user 8 11 Record Of Training When provided or when obtained upon the operator s request proof of training provided by the training entity should be retained by the operator Records shall contain the following information 1 Name of entity providing training or retraining 2 Name of trainer s 3 Clear identification that training covered Self Propelled Elevating Work Platforms 4 Date of training 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
26. hazards such as but not limited to 1 Drop offs or holes 2 Slope s 3 Bumps and floor obstructions 4 Debris 5 Overhead obstructions and electrical conductors 6 Hazardous locations 7 Inadequate surface and support to withstand all load forces imposed by the aerial platform in all operating configurations 8 Wind and weather conditions 9 Other possible unsafe conditions 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 4 All personnel on the aerial platform have appropriate safety gear for the work and environment envisioned 8 9 Understanding Of Hazardous Locations It shall be the responsibility of the operator to understand the hazard classification potential presence of flammable or explosive gases or particles of the intended location of operation according to ANSI NFPA 1996 8 10 Operator Warnings And Instructions The operator shall ensure the operation of the aerial platform is in compliance with the following 1 Fall protection The guardrail system of the a
27. including but not limited to the following 1 Operating and emergency controls 2 Safety devices 3 Personal protective devices 4 Air hydraulic and fuel system leaks 5 Cables and wiring harness 6 Loose or missing parts 7 Tires and wheels 8 Placards warnings control markings and operating manuals 9 Outriggers stabilizers and other structures 10 Guardrail system 11 Items specified by the manufacturer 8 4 Problems Or Malfunctions Any problems or malfunctions that affect the safety of operations shall be repaired prior to the use of the aerial platform 8 5 Training Retraining And Familiarization 8 5 1 General training Only personnel who have received general instructions regarding the inspection application and operation of aerial platforms including recognition and avoidance of hazards associated with their operation shall operate an aerial platform Such items covered shall include but not necessarily limited to the following issues and requirements 1 The purpose and use of manuals 2 That operating manuals are an integral part of the aerial platform and must be stored properly in the weather resistant compartment when not in use 3 A pre start inspection 4 Responsibilities associated with problems or malfunctions affecting the operation of the aerial platform 5 Factors affecting stability 6 The purpose of placards and decals 7 Workplace inspection 8 Safety rules and regulations 9
28. on lifts with 06 00 0469 Warning This is not a work fully enclosed platform platform or a shelf B06 00 0349 Operation Instructions for Battery 1 B06 00 0470 Low battery alarm Charger B06 00 0492 Turn Master Power Switch Off B06 00 0359 Serial Number Tag Not available 1 B06 00 0500 Maximum Capacity 450 Ib as replacement part B06 00 0501 Tip Over Hazard B06 00 0382 tion Thi hine designed E B06 00 0509 Wheel Loading and manufactured B06 00 0532 Slope Warning B06 00 0390 Trans Axle Instruction B06 00 0453 ESP 19 Horizontal Logo 2 1 B06 00 0454 ESP 19 Vertical Logo 2 2 5 1 ESP 19 OPERATION INSTRUCTIONS FOR ESP 19 5 Read follow safety precautions and all responsibilities sections set forth the operators manual ESP 19 Make sure the lift is on a firm and level surface and that there are no potential hazards such as overhead SERIAL ESP 4 FAILURE TO COMPLY WITH THE FOLLOWING INSTRUCTIONS obstructions or electrically charged conductors DO NOT use the lift where such hazards exist PLATFORM 196 OR ANY OTHER IMPROPER USE OR MAINTENANCE OF THIS Check the lift for damaged or wom parts and repair or replace as necessary Check to be sure that the cage is properly attached to the lift Tum master power switch to on Check to be sure all safety devices are functioning properly
29. pump motor runs but for oil system leakage Refill reservoir will not raise the platform and bleed air from hydraulic system per instructions in paragraph 4 3 More than 450 Ibs on lift platform b Ensure load is 450 165 or less Emergency lowering valve open c Close emergency lowering valve Up valve solenoid solenoid wiring d Check voltage at up valve solenoid If faulty no voltage check wiring If voltage exchange solenoids and recheck func tion replace solenoid if faulty Down valve sticking open orleaking e Repair or replace down valve UP switch or UP switch wiring faulty f Check for lighted UP LED when up switch is engaged If LED does not light signal is not reaching main con troller repair wire break or replace faulty switch Mast sections dirty slide blocks 6 Clean and lubricate masts with dry binding silicone If needed adjust slide bocks per paragraph 4 5 Internal leakage in hydraulic cylinder h Check cylinder housing for heat buildup due to leakage If leakage is indicated repair or replace hydraulic cylinder 4 16 4 MAINTENANCE Table 4 3 Troubleshooting Chart Continued Problem Cause Correction 4 ENABLE pushbutton blinks ENABLE pushbutton has been a Release ENABLE pushbutton and when pressed pressed down for longer than 5 press again seconds without a function being selected Joystick potentiometer out of adjust b Adjust joys
30. the specific make and model of the aerial platform The inspection shall include all items specified by the manufacturer for a frequent inspection and shall include but not be limited to the following 1 All functions and their controls for speed s smoothness and limits of motion 2 Lower controls including the provisions for overriding of upper controls 3 chain and cable mechanisms for adjustment and worn or damaged parts 4 7 3 ESP 19 7 4 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 The owner shall not place the aerial platform into service until all malfunctions and problems have been corrected 6 7Annual Inspection The owner of an aerial platform shall ensure that an annual inspection is performed on the aerial platform no later than 13 months from the date of the prior annual inspection The inspection shall be performed by a person s qualified as a mechanic on the specific make and model of the aerial platform The inspection shall include all items specified by the manufacturer for an annual inspection 6 8 Maintenance Safety Precautions Before adjustments
31. 2 controls in the Off position and all operating systems secured from inadvertent motion by brakes blocks or other means 3 Elevating assembly and platform lowered to the full down position if possible or otherwise secured by blocking or cribbing to prevent dropping 4 Hydraulic oil pressure relieved from all hydraulic circuits before loosening or removing hydraulic components 5 Safety props or latches installed where applicable as prescribed by the manufacturer 7 4 Replacement Parts When parts or components are replaced they shall be identical or equivalent to original aerial platform parts or components 7 5 Maintenance Training The user shall insure only qualified personnel inspect and maintain the aerial platform in accordance with the manufacturer s recommendations and sections 7 3 and 7 4 of this standard 7 6 Operator Training And Retraining Whenever a user directs or authorizes an individual to operate an aerial platform the user shall ensure the person has been 1 Trained before being assigned to operate the aerial platform 2 Familiarized with the aerial platform to bo operated 3 Made aware of responsibilities of operators as outlined in Section 8 of this standard 4 Retrained if necessary based on the user s observation and evaluation of the operator 7 6 1 Trainee records A record of the trainee s aerial platform instruction shall be maintained by the user for at least 4 years 7 ANSI REPRINT
32. 20 6 11 Platform Parts 6 22 6 12 Upper Control Box Parts List 6 24 6 13 Hydrauh Unit Parts List zu ener egre nhe 6 26 6 14 Hydraulic Cylinder Fittings and Hoses Parts List 6 28 ANSE Reprint teet tecto ea epe teo ts lave 7 1 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 Figure 6 12 Figure 6 13 Figure 6 14 Lower Control BOX i rto eati tete ie 3 1 Upper Control eer 3 2 Battery On Off Switch esee 3 3 Emergency Lowering 3 5 Fifine Pockets 3 6 Travel Brake and Steering 3 6 Underguard 4 trt e tete edd 4 3 Lift Chains Lubrication eese eene 4 4 Mast Slide Ways Lubrication 4 4 Rear Casters L bricati n nitet tere 4 5 Front Caster Pillow Blocks
33. 34 Pump Hydraulic see pages 6 26 amp 6 27 for component parts listing 6 13 ESP 19 6 7 BASE PARTS LIST Refer to Table 6 7 for the parts list for the base Figure 6 7 Base 6 14 6 PARTS LIST Table 6 7 Base Parts List i 5 6 82401 0009 Frame Aluminum 20i 77 9 2 Nur Nylon Lock soa wlw _ TR TUR INU Re 6 15 ESP 19 6 8 BASE MAST PARTS LIST Refer to Table 6 8 for the parts list for the base mast Figure 6 8 Base Mast 6 16 6 PARTS LIST Table 6 8 Base Mast Parts List museo side Blocks 77 s cain B01 03 0066 Switch Limit Level Sensor T B03 00 0009 Chain Assy includes items 9 10 11 12 13 and Lower Clevis shown on page 6 4 NOTE It is recommended that chain parts be purchased as an assembly RINT 52 2 gt ro to 2 6 17 ESP 19 6 9 DRIVE AXLE PARTS LIST Refer to Table 6 9 for the parts list for the drive axle components Figure 6 9 Drive Axle 6 18 6 PARTS LIST Table 6 9 Drive Axle 2 B30000050 PadAss
34. 6 4 1 Maintenance The owner of an aerial platform shall arrange that the maintenance specified in this standard be properly performed on a timely basis The owner shall establish a preventive maintenance program in accordance with the manufacturer s recommendations and based on the environment and severity of use of the aerial platform 6 4 2 Inspection The owner shall arrange for frequent and annual inspections to be performed as specified by the manufacturer All malfunctions and problems identified in the inspection shall be corrected before the aerial platform is returned to service 6 4 3 Repairs When the aerial platform is damaged or in need of repair all malfunctions and problems identified shall be corrected before the aerial platform is returned to service 6 5 Pre delivery Preparation Aerial platforms shall be inspected serviced and adjusted to manufacturer s requirements prior to each delivery by sale lease or rental 6 6 Frequent Inspection The owner of an aerial platform shall ensure that a frequent inspection is performed in accordance with the manufacturer s instructions on an aerial platform 1 That has been in service for 3 months or 150 hours whichever occurs first 2 That has been out of service for a period longer than 3 months 3 That was purchased used This inspection shall be accomplished prior to the aerial platform being placed in service The inspection shall be made by a person qualified as a mechanic on
35. 9 1 4 1 3 DURING OPERATION Read and observe the following general safety precautions at all times during operation of the ESP 19 N 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 Always contact the power company before performing work near power lines As sume every line is hot Remember power lines can be blown by the wind Refer to Table 1 1 for minimum safe approach distances between machine and electrical power lines Table 1 1 Minimum Safe Approach Distances Voltage Range Minimum Safe Approach Distance Phase to Phase Feet Meters 0 to 300V 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 72 e ALWAYS position lift far enough away from power sources to ensure that part of the lift can accidentally reach into an unsafe area e 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 e ALWAYS keep yourself and all personnel away from potential pinch or shear points e ALWAYS report an
36. Authorization to operate 10 Operator warnings and instructions 11 Actual operation of the aerial platform Under the direction of a qualified person the trainee shall operate the aerial platform for a sufficient period of time to demonstrate proficiency in the actual operation of the aerial platform 8 5 2 Retraining The operator shall be retrained when so directed by the user based on the user s observation and evaluation of the operator 8 5 3 Familiarization When an operator is directed to operate an aerial platform he she is not familiar with the operator shall receive instructions regarding the following items 1 The location of the weather resistant compartment for manual storage 2 The purpose and function of all controls 3 Safety devices and operating characteristics specific to the aerial platform 8 6 Before Operation Before operation the operator shall 1 Read and understand the manufacturer s operating instruction s and user s safety rules or have them explained 2 Understand all labels warnings and instructions displayed on the aerial platform or have them explained 3 Ensure all occupants of the aerial platform wear appropriate personal safety equipment for the conditions including the environment in which the aerial platform will be operated 8 7 Workplace Inspection Before the aerial platform is used and during use the operator shall check the area in which the aerial platform is to be used for possible
37. 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 stor age shelves To lower the platform pull and hold the red valve knob until the platform starts to de scend When the platform is fully lowered release the knob to close the valve Figure 3 4 Emergency Lowering Valve 3 5 ESP 19 3 4 LIFT VEHICLE TRANSPORT The platform vehicle is equipped with lifting and tow features Figure 3 5 Read the fol lowing instructions before using these features to lift or tow the vehicle LIFTING POCKETS Figure 3 5 Lifting Pockets AY 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 r
38. Table 6 14 Hydraulic Cylinder Fittings and Hoses Parts List Item No B02 03 0040 Cylinder Hydraulic Lift 1 75 in Bore x 54 in Stroke B02 13 0096 Nut Gland 7 Ring Wear Jacket Cylinder B02 02 0230 Fitting 4AMFS A4ORM 90 10 B02 03 0038 Cylinder Hydraulic Steering 1 5 in Borex 4 in Stroke 12 B02 04 0094 Valve Flow Control 1 25 gpm 1 1 w 2 4FMFS fittings 14 15 Pump Hydraulic i 7 NSS Not Sold Separately 6 29 ESP 19 6 30 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 Sound principles of safety training inspection maintenance application and operation consistent with all data available regarding the parameters intended use and expected environment shall be applied in the training of operators in maintenance application safety provisions and operation of the aerial platform with due consideration of the knowledge that the aerial platform will be carrying personnel 52 Manuals 5 2 1 Machine manual s Dealers shall keep and maintain copy s of the 1 Operating manual 2 Maintenance manual 3 Parts manual 4 Repair manual The operating manual and maintenance manual shall be provided with each rental lease or sale delivery and shall be stored in the weath
39. ain a firm footing on the platform floor while working thereon Climbing by occupants on the midrail or toprail of the aerial platform is prohibited The use of planks ladders or any other device on the aerial platform for achieving additional height or 7 7 ESP 19 7 8 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 The user shall direct the operator to immediately report to a supervisor any problem s or malfunction s that become evident during operation The user shall ensure all problems and malfunctions that affect the safety of operations are repaired prior to continued use 12 Reporting potentially hazardous locations The user shall direct the operator to immediately report to a supervisor any potentially hazardous location s one having potentially flammable or explosive gases or particles that become evident during operation 13 Hazardous location operation Operation of aerial platforms not approved and marked for operation in a hazardous location one having potentially flammable or explosive gases or particles shall be prohibited 14 Entanglement Care shall be taken to prevent r
40. aise 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 LINKA STEERING CYLINDER STEERING jm GE E k TRANSAXLE LEVER Figure 3 6 Travel Brake and Steering Linkage 3 6 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 Daily Service Check 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 Verify that underguard shuts down operation when weight is applied 4 1 ESP 19 4 2 6 Month Yearly Service Checks Perform the service checks in Table 4 2 every 6 months or every 12 months as indi cated Table 4 2 6 Month Yearly Service Checks Every Every Service Check 6 months 12 months Check chain assemblies for split leaves loose pins excessive wear or Y elongation Verify that cage is securely bolted to
41. and repairs are started on an aerial platform the following precautions shall be taken as applicable 1 Powerplant stopped and starting means rendered inoperative 2 AII controls in the off position and all operating systems secured from inadvertent motion by brakes blocks or other means 3 Elevating assembly and platform lowered to the full down position if possible or otherwise secured by blocking or cribbing to prevent dropping 4 Hydraulic oil pressure relieved from all hydraulic circuits before loosening or removing hydraulic components 5 Safety props or latches installed where applicable as prescribed by the manufacturer 6 9 Replacement Parts When parts or components are replaced they shall be identical or equivalent to original aerial platform parts or components 6 10 Maintenance And Inspection Training The owners shall train their maintenance personnel in inspection and maintenance of the aerial platform in accordance with the manufacturer s recommendations and sections 6 2 6 11 of this standard 6 11 Training 6 11 1 Operator training Whenever an owner directs or authorizes an employee to operate an aerial platform loading unloading inspecting or any form of use the owner shall assume the responsibilities of the user as specified in Section 7 of this standard and shall ensure that the person has been 1 Trained 2 Familiarized with the aerial platform to be operated 3 Made aware of the responsibilities of
42. aulic Cylinder Fittings and Hoses Parts 1184 6 29 Minimum Safe Approach Distance M S A D to energized exposed or insulated power lines and 7 15 Safety INTRODUCTION Familiarity and proper training are required for the safe operation of mechanical equip ment 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 per sons who are familiar with the equipment before operating the machine The use of intel ligence and common sense in the operation of mechanical equipment is the best practice in any safety policy Be professional and always observe the safety procedures set forth in this manual ANSI state and local codes and regulations pertaining to this equipment should be obtained read and thoroughly understood before attempting to operate this equipment Persons under the influence of drugs alcohol or prescription medication should not be on or near this equipment Common sense should be implemented at all times during the use of this equipment Do not operate this equipment in areas where equipment or user may come in contact with live power source The information contained herein is not to be considered as legal advice and is intended for informational p
43. ble or explosive gases or particles of the intended location of operation Aerial platforms operated in hazardous locations shall be approved in accordance with and of the type required by ANSI NFPA 505 1996 7 10 Operator Warnings And Instructions The user shall direct personnel operating the aerial platform to be in compliance with the provisions set forth in this standard The user shall monitor their performance and supervise their work to ensure the use application and operation of the aerial platform is in conformance with the provisions set forth in this standard warn personnel of potential hazards provide means to protect against identified hazards and explain the potential consequences of not following proper operating guidelines Instructions and guidelines regarding proper operation shall include but not necessarily be limited to the following issues and subjects 1 Fall protection The guardrail system of the aerial platform provides fall protection If worksite rules require an occupant s of the platform to wear restraint or body positioning devices occupants shall comply with instructions provided by the aerial platform manufacturer regarding anchorage s 2 Slope and grade The aerial platform shall not be operated in any manner on grades side slopes or ramps exceeding those for which the aerial platform is rated by the manufacturer 3 Deployment of stability enhancing means Outriggers stabilizers extendible axles osci
44. ct 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 LIFT CHAINS AND SLIDE BLOCKS WARNING Do not operate a unit on which any chain assembly is damaged or in need of re placement 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 as semblies 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 lt gt 5 8 IN 1 5875 CM PITCH ra ra gt gt 4 7 gt lt 20 PITCHES 12 5 31 75 REPLACE CHAIN IF 20 PITCHES MEASURES OVER 12 75 32 385 Figure 4 11 Chain Elongation Inspection 4 13 ESP 19 Lift Chain Adjustment 4 14 Ra
45. d 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 1 Remove the battery charger cord from its box and plug into 3 prong 115V outlet Figure 4 10 BATTERY COND 99 mem mem iom en iem sofas DANGER Figure 4 10 Battery Charger Cord 2 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 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 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 A 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 5 After the charge cycle is completed disconne
46. d to steering limit Turn wheels in opposite direction B pressed steering wheels b 10 Amp Motors fuse burned out on b Replace 10 Amp Motors fuse do not swivel main controller board c Internal steering actuator fuse c Replace steering actuator fuse d Thumb switch or thumb switch wiring 4 Check for lighted steering LED when faulty thumb switch is engaged If LED does not light signal is not reaching main controller repair wire break or re place faulty joystick e Actuator or actuator wiring faulty e Check actuator wiring for operating voltage If voltage is present replace faulty actuator If voltage is not pre sent check actuator wiring for conti nuity repair wire breaks f Steering linkage failed f Check steering linkage for damage replace damaged parts 2 Maincontroller faulty 6 Contact Bil Jax for assistance 9 When BATTERY ON OFF Motor start relay failure relay con a Replace motor start relay switch is turned ON hydrau lic pump starts up tacts fused shut 4 18 Troubleshooting Aids 4 MAINTENANCE 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 10 Ofpwr 10 Ofpwr pos ISNA OT PUMP ON 1 O RIGHT ON Taw OJRIGHT eof
47. e Correction 1 Lift vehicle controls do not work at upper or lower con Master power switch turned off Turn on master power switch Low battery power or faulty battery b Recharge batteries per paragraph 4 4 trol box circuit Check for faulty battery or cables if red battery charger LED is lit Emergency stop button engaged c Rotate emergency stop buttons clock pushed in wise to disengage Battery ground or in series battery d Check for and repair loose battery cable loose connections or ground fault Circuit breaker tripped e Reset breaker If breaker trips again locate and correct short to ground in power circuit wiring Battery cable or equipment ground f Clean and reconnect loose or cor lead loose or corroded roded battery cable or ground lead 2 Lift vehicle controls do not Emergency stop button engaged a Rotate emergency stop buttons clock work at upper control box pushed in on upper control box wise to disengage but do work at lower control Upper control box cable connectors b Plug in cable connectors at front of box unplugged upper control box Upper control box cable connectors c Plugin cable connectors in opposite plugged into wrong receptacles receptacles at upper control box Enable pushbutton switch or wiring d Repair wire break or replace faulty faulty switch 3 When function is se Hydraulic oil level low in reservoir a Check reservoir level If low check lected
48. e long beep long pause Normal Motion Indicator Machine operating properly Be Be Be Be short beep pause short beep pause Machine Out of Level With Platform Down Platform will not raise B B Be B B Be very short beep short pause very short beep short pause short beep short pause Machine Out of Level With Platform Raised Platform will not raise and machine will not drive Beeeeep Beeeeep Beeeeep very short beep short pause very long beep short pause very short beep short pause Object On Underguard Platform will not lower and machine will not drive Beeeeeeeeep continuous beep Low Battery Warning Immediately drive machine to recharging area and plug in to wall outlet 4 25 ESP 19 802 03 0038 Steering Cylinder 802 03 0040 Lift Cylinder 802 05 0034 Purmp Unit Figure 4 15 Hydraulic Diagram 4 26 Switch Enable 4 MAINTENANCE E Stop r o Drive FWD L Steer Right Control Board 07 Steer Left Beacon Lamp EN L O 15 r gan Start Solenoid Raise LSI Sensor J Up Valve y Platform Lowerj UCI j Level Down Valve ene ED Right
49. e aerial platform is sold the dealer 1 Shall upon delivery ensure the operating and maintenance manuals are conveyed to the owner 2 Shall upon delivery provide a copy of the ANSI SIA A92 6 1999 Manual of Responsibilities for Dealers Owners Users Operators Lessors Lessees and Brokers of Self Propelled Elevating Work Platforms 3 Should within 60 days of sale provide repair and parts manuals 4 Shall within 60 days of the sale notify the manufacturer or its successor if existing of the sale providing the full name and address of the purchaser 5 Should if the aerial platform is used accomplish an annual machine inspection prior to delivery and provide a copy to the purchaser within 60 days of the sale 6 Shall upon delivery familiarize the person designated by the receiving entity with the aerial platform being acquired 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 Upon purchase of the aerial platform the buyer 1 Shall ensure the operating and maintenance manuals have been received 2 Should acquire repair
50. e 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 PLATFORM STEERING LIFT DE C Figure 4 8 Valve Operation ESP 19 4 10 Hydraulic Cylinder Repair CAUTION Hydraulic cylinder removal requires extensive disassembly of the ESP 19 lift ve hicle 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 hydrau lic cylinder 1 Make sure hydraulic cylinder is completely retracted and pressure is released from the system Place a pan underneath the cylinder to catch th
51. e forth moving platform mast A 5 13 6 8 Figure 6 4 Fourth Moving Platform Mast 6 PARTS LIST Table 6 4 Fourth Moving Platform Mast Parts List s eos 77 779 Screw Sree Maa B03 00 0009 Chain Assy includes items 13 14 15 16 and Upper Clevis amp Lock Nut shown on page 6 4 NOTE It is recommended that chain parts be purchased as an assembly 6 9 ESP 19 6 10 6 5 BATTERY COMPARTMENT PARTS LIST Refer to Table 6 5 for the parts list for the battery compartment Figure 6 5 Battery Compartment 6 PARTS LIST Table 6 5 Battery Compartment Parts List Nut Nylon Lock 38 16 s sse Cap 56134 5 ESP 19 6 6 HYDRAULIC PUMP COMPARTMENT PARTS LIST Refer to Table 6 6 for the parts list for the hydraulic pump compartment Figure 6 6 Hydraulic Pump Compartment 6 PARTS LIST Table 6 6 Hydraulic Pump Compartment Parts List eene S L5 ose 0001 Charger Battery 40 Amp 110 Volt AC 60 26 B02 05 00
52. e hydraulic oil Disconnect the hydraulic hose from the flow restrictor valve and drain the hy draulic 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 sec tion high enough to remove the clamp securing the cylinder to the base Re move the clamp and cylinder from the unit After hydraulic cylinder maintenance is completed reinstall the cylinder in the reverse order of removal 4 MAINTENANCE 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 Re place worn or damaged components Thoroughly clean the inside surface of cylinder jacket 2 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 petro
53. ed bulletins as received from the manufacturer dealer or owner 8 Responsibilities Of Operators 8 1 Basic Principles The information in this standard shall be supplemented by good judgment safety control and caution in evaluating each situation Since the operator is in direct control of the aerial platform conformance with good safety practices in this area is the responsibility of the operator The operator shall make decisions on the use and operation of the aerial platform with due consideration for the fact that his or her own safety as well as the safety of others is dependent on those decisions 7 9 ESP 19 7 10 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 6 1999 Manual of Responsibilities for Dealers Owners Users Operators Lessors Lessees and Brokers of Self Propelled Elevating Work Platforms shall be provided and stored in the weather resistant storage compartment 8 3 Pre start Inspection Before use each day or at the beginning of each shift the aerial platform shall be given a visual inspection and functional test
54. embly Torsion 3 0090 0188 Nut Nylon Lock 3 8 16 4 0090 0065 ___ Screw Cap 1 2 13x1in 6 BOLOT0015 Transaxle Assembly 6B __ 1 07 0011 Motor Subassembly 7 07 07 5022 j Key Squre 1 4 x 2 1 4in 77 B30 00 0049 779 Fa 09 12 Joos 4 Mount Rubber l 1 Screw Cap 3 8 16 x 2 in Grade 8 1 in 0090 0617 Screw Cap 7 16 14 x 1 in 2 3 7 1 2 6 6 19 ESP 19 6 20 6 10 STEERING PARTS LIST Refer to Table 6 10 for the parts list for the steering components Figure 6 10 Steering 6 PARTS LIST Table 6 10 Steering Parts List Qty 0090 0239 Screw Machine 410 24 x 1 1 2 in 2 2 6 0090 0035 5416 18x3in i 6 8 0090 0422 Washer Flat 3 8 in 15 9 00904420 WasherFlatyl6in 7 4 6 2 2 2 8 4 1 4 3 Cylinder Hydraulic Steering 1 5 4 1 in Stroke 2 Bracket Wheel Left 1 2 4 2 2 6 21 ESP 19 6 11 PLATFORM PARTS LIST Refer to Table 6 11 for the parts list for the platform Figure 6 11 Platform 6 22 6 PARTS LIST Table 6 11 Platform Parts List s 39 00 0018 Gas Shock 1 77 Washer Fat Bin Joose 0033 serew Cup
55. entification that training covered Self Propelled Elevating Work Platforms 4 Date of training 6 15 3 Record dissemination Upon request an owner accomplishing training and or familiarization shall provide the following 1 To a user proof of training for an operator including name of trainer and date of training 2 To a user the name of the person s receiving familiarization upon delivery of the aerial platform 6 16 Modifications Modification alteration or remanufacture of an aerial platform shall be made only with prior written permission of the manufacturer 6 17 Manufacturer s Safety Bulletins The owner shall comply with safety related bulletins as received from the manufacturer or the dealer 6 18 Responsibilities Upon Sale When the aerial platform is sold the seller 1 Shall upon delivery ensure the operating and maintenance manuals are conveyed to the new owner 2 Shall upon delivery provide a copy of the ANSI SIA A92 6 1999 Manual of Responsibilities for Dealers Owners Users Operators Lessors Lessees and Brokers of Self Propelled Elevating Work Platforms 3 Should provide repair and parts manuals to the new owner 4 Shall upon the request of the new owner offer to do training or advise where training may reasonably be obtained 7 Responsibilities of Users 7 1 Basic Principles The information in this standard must be supplemented by good job management safety control and the application of sound pr
56. er resistant storage compartment on the aerial platform Manual s are considered an integral part of the aerial platform and are vital to communicate necessary safety information to owners users and operators In addition repair and parts manuals should be provided with each sale delivery 5 2 2 Manual of responsibilities The ANSI SIA A92 6 1999 Manual of Responsibilities for Dealers Owners Users Operators Lessors Lessees and Brokers of Self Propelled Elevating Work Platforms shall be provided and stored in the weather resistant storage compartment 5 3 Pre delivery Preparation Aerial platforms shall be inspected serviced and adjusted to manufacturer s requirements prior to each delivery by sale lease or rental 5 4Maintenance Inspection And Repair 5 4 1 Maintenance When a dealer accomplishes preventative maintenance on the aerial platform it shall be in accordance with the manufacturer s recommendations and based on the environment and severity of use 5 42 Inspection When the dealer accomplishes frequent and annual inspections they shall be accomplished in accordance with the manufacturer s manuals 5 4 3 Repairs Repairs accomplished to correct malfunctions and problems shall be in accordance with the manufacturer s manuals and instructions 5 5Maintenance Safety Precautions Before adjustments and repairs are started on an aerial platform the following precautions shall be taken as applicable 1 Powerplant stopped and sta
57. erial platform provides fall protection If worksite rules require an occupant s of the platform to wear restraint or body positioning devices occupants shall comply with instructions provided by the aerial platform manufacturer regarding anchorage s 2 Slope and grade The aerial platform shall not be operated in any manner on grades side slopes or ramps exceeding those for which the aerial platform is rated by the manufacturer 3 Deployment of stability enhancing means Outriggers stabilizers extendible axles oscillating axles or other stability enhancing means shall be deployed and locked into place as required by the manufacturer 4 Guardrail system Guardrails shall be installed and positioned and access gates or openings shall be closed per the manufacturer s instructions 5 Distribution of load The load and its distribution on the platform and any platform extension s shall be in accordance with manufacturer s rated capacity for that specific configuration 6 Maintaining overhead clearance The operator shall ensure adequate clearance is maintained from overhead obstructions and energized electrical conductors and parts 7 Electrocution hazard The operator shall maintain the minimum safe approach distance MSAD from energized power lines and parts as listed in Table 7 1on pages 7 14 amp 7 15 Electrical equipment and lines shall be considered energized until determined to be de energized by tests or other appropriate methods
58. es dur MAXIMUM WHEEL ing operation Failure to wear Full Body Harness and Lanyard may allow operator to fall from platform resulting in serious injury or death B06 00 0339 LOADING Front 950 Ibs 431 kg per wheel Rear 900 Ibs 408 kg per wheel FR NT Gu Bil Jax Inc 2005 806 00 0509 Figure 5 1 Replacement Decals 5 3 ESP 19 0469 0500 We 0009 0146 0173 0500 0459 of Bike Rack Arms Z s 0192 Manual Tube 0460 Both Sides lt S SN SQ SSs 2 5 Ss gt y EE e 0066 P 0501 ef Between Fork ird Below Underguard K 0297 Both Sides 0457 On Underguard 0037 On Pillow Blocks Figure 5 2 Decal Locations Side View 5 4 0359 Tti 0464 5 REPLACEMENT DECALS 0037 ON Sera i a PIVOT BLOCK p 0289 0068 ON FRAME BEHIND DOOR BY RESERVOIR Figure 5 3 Decal Locations Rear View 5 5 ESP 19 5 6 6 Parts List ESP 19 6 1 FIRST MOVING MAST PARTS LIST Refer to Table 6 1 for the parts list for the first moving mast M Ye 5 A Figure 6 1 First Moving Mast 6 2 6 PARTS LIST Table 6 1 First Moving Mast Parts List 776 wenns Nat Nyon Lock 38 16 77 meos cable 36i
59. essure 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 8 turn counterclockwise This will adjust the relief valve bypass pressure setting for less than 450 pounds of lift 5 Place the key switch in the LOWER CONTROL position and press the UP pushbut ton The pump should run bypassing oil to the hydraulic reservoir zt 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 6 With the platform lift function enabled pump running turn the pressure relief valve adjust screw clockwise just enough to smoothly raise the platform with out bypassing oil to the hydraulic reservoir 7 Retighten the jam nut PRESSURE RELIEF VALVE LOCATED ON BACK OF PUMP Figure 4 6 Pressure Relief Valve Adjustment ESP 19 4 8 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
60. evices for DO NOT use near cranes or other moving veces 020 UU ammeter will show the rate of charge DONOT dtivenearloading docks holes itis the operator s responsiblity to comply with all wamings and instructions dues uper NEVER TAKE CHANCES DO NOT operate this f you are under the infuence of depans da drugs or alcohol or if you fell dizzy ill or unsteady in any way E ALWAYS survey job site and identify all potential hazards N structions proper function prior to each use DO NOT leave keys in machine while unattended i DO NOT use without entry gate in NOT allow flames sparks or embers near batteries and do not smoke near C Once the battery voltage reaches a predetermined the closed postion uniess operator is wearing ful body hamess and lanyard and wih batteries Batteries produce highly fammable gases which can explode level programmed in the electronic control the 80 the lanyard attached to factory provided attachment pont Charge yellow LED will tum on DURING USE AEE a D 3 1 2 hours after the yellow light goes on the charge DO NOT raise platform while on uneven soft or sloped surfaces TRAINING AND OPERATION AS REQUIRED BY THE OWNERS MANUAL AND THE will be completed and the charger will automatically P A E opal alase atie AA SNA E OS shut off At this time all the LED s will turn off elevated Im NOTE
61. 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 Very High MOTOR BATTERY MOTOR GND pto qe E Sipad 2 Make sure the unit is communicating with the main controller refer to the Blink Codes L7 and LEDI 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 15 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 4 24 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 paus
62. heck 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 LED labeled DOWN ON should be ON If LED LOWERING is ON but LED DOWN ON is OFF the main controller may be faulty 4 21 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 Make sure the joystick is connected to EASI POS and EASI NEG terminals of the main controller Make sure E STOP switch on the joystick is OFF 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 e 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 joystick If L1 and L2 LED s the joystick are not blinking rapidly
63. ies found the corrective action recommended and identification of the person s performing the inspection 4 When employees of the user accomplish repairs on the aerial platform the user shall maintain written records The record shall include the date of repair a description of the work accomplished and identification of the person s performing the repair 7 13 2 Record dissemination 1 When the user directs personnel to accomplish frequent or annual inspections not later than 60 days after the inspections the appropriate records shall be provided to the owner of the aerial platform 2 When the user directs personnel to accomplish repairs on the aerial platform not later than 60 days after the repairs are accomplished the appropriate records shall be provided to the owner 7 13 3 Proof of training Users providing training should provide successful trainees a means to evidence their training and shall provide such proof if requested by the trainee The document evidencing the training shall include the following information 1 Name of entity providing training or retraining 2 Name of trainer s 3 Clear identification that training covered Self Propelled Elevating Work Platforms 4 Date of training 7 14 Modifications Modification alteration or remanufacture of an aerial platform shall be made only with prior written permission of the manufacturer 7 15 Manufacturer s Safety Bulletins The user shall comply with safety relat
64. in Section 6 of this standard 10 4 Lessee As A User When a lessee uses the aerial platform as a user the lessee shall have the responsibilities of users as specified in Section 7 of this standard 10 5 Lessee As An Operator When a lessee uses the aerial platform as an operator the lessee shall have the responsibilities of operators as specified in Section 8 of this standard 11 Responsibilities Of Brokers 11 1 Responsibilities Upon Sale The broker shall 1 Upon delivery ensure the operating and maintenance manuals are provided to the new owner 2 Upon delivery provide a copy of the ANSI SIA A92 6 1999 Manual of Responsibilities for Dealers Owners Users Operators Lessors Lessees and Brokers of Self Propelled Elevating Work Platforms 3 Maintain records of the sale for a minimum of 4 years 11 2 Responsibilities With Re rents Leases Or Any Other Form Of Beneficial Use When compensation is received as a result of a re rent lease or any form of beneficial use of an aerial platform the broker shall 1 Upon delivery ensure the operating and maintenance manuals are provided to the user 2 Upon delivery provide a copy of the ANSI SIA A92 6 1999 Manual of Responsibilities for Dealers Owners Users Operators Lessors Lessees and Brokers of Self Propelled Elevating Work Platforms 3 Ensure operating personnel are familiarized with the aerial platform prior to use 4 Retain records of the transaction for a minimum of 4
65. inciples of safety training inspection maintenance application and operation consistent with all data available regarding the parameters of intended use and expected environment Since the user has direct control over the application and operation of aerial platforms conformance with good safety practices in this area is the responsibility of the user and the operating personnel including the operator Decisions on the use and operation of the aerial platform must always be made with due consideration for the fact that the aerial platform will be carrying personnel whose safety is dependent on those decisions 7 2 Manuals 7 2 1 Machine manuals Users shall keep and maintain copy s of the operating and maintenance manual s in the weather resistant storage compartment provided by the manufacturer The manual s is considered an integral part of the aerial platform and is vital to communicate necessary safety information to users and operators 7 2 2 Manual of responsibilities The ANSI SIA A92 6 1999 Manual of Responsibilities for Dealers Owners Users Operators Lessors Lessees and 7 5 ESP 19 7 6 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 manufacture
66. injury s to personnel 23 Elevated driving requirements Before and during driving while the platform is elevated the operator shall a Maintain a clear view of the support surface and route of travel b Ensure personnel in the worksite area that may be affected are aware of the movement communicating and maneuvering the aerial platform as required to protect against personal injury c Maintain a safe distance from obstacles debris drop offs holes depressions ramps and other hazards to ensure safe travel d Maintain a safe distance from overhead obstacles 24 Stunt driving Stunt driving and horseplay are prohibited 25 Securing the aerial platform The user shall direct the operator to implement means provided to protect against use by unauthorized person s 26 Altering safety devices Interlocks or other safety devices shall not be altered or disabled 27 Snagged platform If the platform basket or supporting assembly becomes caught snagged or otherwise prevented from normal motion by adjacent structures or other obstacles such that control reversal does not free the platform all personnel shall be removed from the platform basket before attempts are made to free the platform using lower controls 28 Vacating or entering an elevated aerial platform If permitted by the manufacturer personnel shall only vacate or enter a raised aerial platform by following the guidelines and instructions provided by the manufacturer 29
67. ise 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 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 proba bly worn Replace any clevis lock nut that does not hold position during use Replace the plexiglass cover ue Figure 4 12 Lift Chains Adjustment 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 ad
68. itch 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 ele vation 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 ESP 19 3 2 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 ENABLE PUSHBUTTONS STEERING THUMB SWITCH UP M PUSHBUTTON DOWN PUSHBUTTON TRAVEL JOYSTICK Figure
69. justed 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 1 2 NOTE 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 ad justed SLIDE BLOCKS Figure 4 13 Slide Blocks Adjustment 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 4 15 ESP 19 4 7 TROUBLESHOOTING Table 4 3 Troubleshooting Chart Problem Caus
70. knowledge that the aerial platform will be carrying personnel 9 2 Lessor As A Dealer When a lessor uses the aerial platform as a dealer the lessor shall have the responsibilities of dealers as specified in Section 5 of this standard 9 3 Lessor As An Owner When a lessor uses the aerial platform as an owner the lessor shall have responsibilities of owners as specified in Section 6 of this standard 9 4 Lessor As A User When a lessor uses the aerial platform as a user the lessor shall have the responsibilities of users as specified in Section 7 of this standard 9 5 Lessor As An Operator When a lessor uses the aerial platform as an operator he shall have the responsibilities of operators as specified in Section 8 of this standard 10 Responsibilities Of Lessees 10 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 lessees with due consideration of the knowledge that the aerial platform will be carrying personnel 10 2 Lessee As A Dealer When a lessee uses the aerial platform as a dealer he shall have the responsibilities of dealers as specified in Section 5 of this standard 10 3 Lessee As An Owner When a lessee uses the aerial platform as an owner the lessee shall have the responsibilities of owners as specified
71. latum 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 Gland Nut Cylinder Jacket O ring Packing Ring Rod Wiper Piston Rod Wear Ring 4 11 ESP 19 4 12 Figure 4 9 Hydraulic Cylinder Disassembly 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 impor tant 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 an
72. ll be removed from the platform basket before attempts are made to free the platform using lower controls 28 Vacating or entering an elevated aerial platform If permitted by the manufacturer personnel shall only vacate or enter a raised aerial platform by following the guidelines and instructions provided by the manufacturer 29 Modifications Modification or alteration of an aerial platform or the fabrication and attaching of frameworks or the mounting of attachments for holding tools or materials onto the platform or the guardrail system shall only be accomplished with the prior written permission of the manufacturer 30 Assistance to the operator If an operator encounters any suspected malfunction of the aerial platform or any hazard or potentially unsafe condition relating to capacity intended use or safe operation of the aerial platform the operator shall cease operation of the aerial platform and request further information from the employer 31 Problem s or malfunction s Any problems or malfunctions that affect the safety of operations shall be repaired prior to use of the aerial platform 32 Carrying materials larger than the platform The operator shall ensure 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 operator shall not permit personnel on the platform to exceed the manufacturer s horizontal
73. llating axles or other stability enhancing means shall be deployed and locked into place as required by the manufacturer 4 Guardrail system Guardrails shall be installed and positioned and access gates or openings shall be closed per the manufacturer s instructions 5 Distribution of load The load and its distribution on the platform and any platform extension s shall be in accordance with manufacturer s rated capacity for that specific configuration 6 Maintaining overhead clearance The operator shall be instructed to ensure that adequate clearance is maintained from overhead obstructions and energized electrical conductors and parts 7 Electrocution hazard The user shall direct the operator to maintain and provide the means to maintain the minimum safe approach distance MSAD from energized power lines and parts as listed in Table 7 1 on pages 7 14 amp 7 15 Electrical equipment and lines shall be considered energized until determined to be de energized by tests or other appropriate methods or means and properly grounded If energized power lines or parts are within the area in which the aerial platform is to be used the user shall define and explain to the operator specific means to maintain the minimum safe approach distance required 8 Personal protective equipment The user shall direct the operator to ensure all personnel on the platform wear personal protective equipment as required 9 Personnel footing Personnel shall maint
74. n 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 Front Caster Pillow Blocks Lubrication ESP 19 4 6 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 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 29 Dextron Automatic Transmission Fluid Type 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 tempera
75. on with the aerial platform upon each delivery unless this individual has been provided with familiarization on the same model or one having characteristics consistent with the one being delivered within the prior 90 days 5 11 2 Proof of training The dealer should provide trainees who successfully complete training a means to evidence they are trained The dealer shall provide such proof if requested by the trainee The document evidencing the training shall include the following information 1 Name of entity providing training or retraining 2 Name of trainer s 3 Clear identification that training covered Self Propelled Elevating Work Platforms 4 Date of training 5 11 3 Record dissemination Upon request the dealer shall provide the following information 1 To the owner of the aerial platform a copy of frequent or annual inspections performed 2 To the owner of the aerial platform a copy of repairs accomplished 3 To a user proof of training for an operator including name of trainer and date of training 4 To a user the name of the person s receiving familiarization upon delivery of the aerial platform 5 12 Modifications Modification alteration or remanufacture of an aerial platform shall be made only with prior written permission of the manufacturer 5 13 Manufacturer s Safety Bulletins The dealer shall comply with safety related bulletins as received from the manufacturer 5 14 Responsibilities Upon Sale When th
76. ontal Side Force 0 Ibs um Bil Jax Inc 2005 06 00 0500 Tool Tray 150 Ib max Bike Rack 50 Ib max Platform 30016 max Platform 400 Ib max 206 00 0297 806 00 0532 LOW BATTERY ALARM 06 00 0500 LOWERING VALVE When audible alarm sounds continuously lift ie ZONE 22 NOT PICK MACHINE UP FROM THIS _ 8 m nien B06 00 0464 06 00 0470 06 00 0463 Tip Over Hazard Battery weight is critical for lift stability This lift must be equipped with two batteries having a total combined minimum 1 Turn master power switch off when not in use THIS IS NOT A WORK PLATFORM OR A SHELF DO stand or sit on this mast cover Failure to turn power off will drain batteries DO NOT use this mast cover as a work platform Turn control box off before DO NOT use this mast cover as a shelf or workbench by placing A turning master power tools equipment merchandise or any other objects on it weight of 165 Ibs DO NOT replace with FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY CAUSE THE switch on batteries of lesser weight MAST COVER TO FAIL AND RESULT IN SERIOUS INJURY OR DEATH Bil Jax Inc 2005 0800400 Use only Bil Jax horized replacement 806 00 0492 06 00 0469 e parts Bil Jax Inc 2005 06 00 0501 06 00 0501 Full Body Harness and Lanyard must be used at all tim
77. ope electric cords and hoses etc from becoming entangled in the aerial platform 15 Capacity limitations Rated capacities shall not be exceeded when loads are transferred to the platform at any height 16 Work area The operator shall ensure the area surrounding the aerial platform is clear of personnel and equipment before lowering the platform 17 Fueling The engine if applicable shall be shut down while fuel tanks are being filled Fueling shall be done in a well ventilated area 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 The aerial platform shall not be operated from a position on trucks trailers railway cars floating vessels scaffolds or similar equipment unless the application is approved in writing by the manufacturer or a qualified person 22 Travel speeds The operator shall limit travel speed according to conditions including the condition of the support surface congestion visibility slope location of personnel and other factors leading to hazards which may cause collision s or result in potential
78. operate equipment ALWAYS inspect the equipment for damaged or worn parts Check for cracked welds hydraulic leaks damaged wiring loose wire connectors damaged cast ers 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 re quired by federal state or local regulations ALWAYS locate read and follow all directions and warnings displayed on the equipment ALWAYS inspect the equipment for NOT tags installed by mainte nance 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 mate rial 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 physi cally 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 1 3 ESP 1
79. operators as outlined in Section 8 of this standard 6 11 2 Assistance to user Upon request of the user when an owner sells leases rents or provides an aerial platform for any form of beneficial use the owner at that time shall offer to do training or advise the user where training may be reasonably secured 6 12 Familiarization Upon Delivery Upon delivery for lease rental or any form of beneficial use the owner 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 with the operator or person s designated by the user 4 Review safety devices specific to the model aerial platform being delivered 6 13 Operation When an owner operates an aerial platform the owner shall have the responsibilities of users as specified in Section 7 of this standard and the operating personnel shall have responsibilities of operators as specified in Section 8 of this standard 6 14 Assistance To Users And Operators If an owner is unable to answer a user s or operator s question s relating to rated capacity intended use maintenance repair inspection or operation of the aerial platform the owner shall obtain the proper information from the dealer or manufacturer and provide that information to user or operator
80. or means and properly grounded If energized power lines or parts are within the area in which the aerial platform is to be used the operator shall maintain the minimum safe approach distance required 8 Personal protective equipment The user operator shall ensure all occupants of the platform wear personal protective equipment as required 9 Personnel footing Personnel shall maintain firm footing on the platform floor while working thereon Climbing by occupants on the midrail or toprail of the aerial platform is prohibited The use of planks ladders or any other device on the aerial platform for achieving additional height or 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 The operator shall immediately report to a supervisor any problem s or malfunction s that become evident during operation The operator shall ensure all problems and malfunctions that affect the safety of operations are repaired prior to continued use 12 Reporting potentially hazardous locations The operator shall immediately report to a supervisor any potentially hazardous location s one having potentially flammable or expl
81. osive gases or particles that become evident during operation 13 Hazardous location operation Operation of aerial platforms not approved and marked for operation in a hazardous location one having potentially flammable or explosive gases or particles shall be prohibited 14 Entanglement Care shall be taken to prevent rope electric cords and hoses etc from becoming entangled in the aerial platform 15 Capacity limitations Rated capacities shall not be exceeded when loads are transferred to the platform at any height 16 Work area The operator shall ensure the area surrounding the aerial platform is clear of personnel and equipment before lowering the platform 17 Fueling The engine if applicable shall be shut down while fuel tanks are being filled Fueling shall be done in a well ventilated area 7 11 ESP 19 7 12 free of flame sparks or other hazards that may cause fire 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 The aerial platform shall not be operated from a position on trucks trailers railway cars floating vessels scaffolds or similar equipment unle
82. ower 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 4 Ifthe 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 5 Retest whenever underguard is removed and switches are adjusted or replaced 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 l Lubricate lift chains with clean 40 weight oil Refer to Figure 4 2 LIFT CHAINS Figure 4 2 Lift Chains Lubrication 2 Clean the mast slide ways Figure 4 3 and lightly spray the slide ways with a dry silicone lubricant NOTE Theslide 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 1 Figure 4 3 Mast Slide Ways Lubrication 4 MAINTENANCE LUDBHICA M MONT HL Figure 4 4 Rear Casters Lubricatio
83. r s recommendations and be compatible with operating conditions and the severity of the operating environment Aerial platforms that are not in proper operating condition shall be immediately removed from service until repaired Repairs shall be made by a qualified person and the repairs shall be in conformance with the manufacturer s recommendations 7 3 1 Frequent Inspection Users of an aerial platform shall ensure that frequent inspections are conducted as outlined in section 6 6 of this standard 7 3 2 Annual Inspection Users of an aerial platform shall ensure that annual inspections are conducted as outlined in section 6 7 of this standard 7 3 3 Pre start Inspection Before use each day or at the beginning of each shift the aerial platform shall be given a visual inspection and functional test including but not limited to the following 1 Operating and emergency controls 2 Safety devices 3 Personal protective devices 4 Air hydraulic and fuel system leaks 5 Cables and wiring harness 6 Loose or missing parts 7 Tires and wheels 8 Placards warnings control markings and operating manual s 9 Outriggers stabilizers and other structures 10 Guardrail system 11 Items specified by the manufacturer 7 3 4 Maintenance Safety Precautions Before adjustments and repairs are started on an aerial platform the following precautions shall be taken as applicable 1 Powerplant stopped and starting means rendered inoperative
84. rects personnel to operate an aerial platform loading unloading inspecting sales demonstrations or any form of use the dealer shall assume the responsibilities of users as specified in Section 7 of this standard personnel authorized to operate the aerial platform shall have been 1 Trained 2 Familiarized with the aerial platform to be operated 3 Made aware of the responsibilities of the operators as outlined in Section 8 of this standard 5 10 Assistance To Owners And Users If a dealer is unable to answer an owner s or user s question s relating to rated capacity intended use maintenance repair inspection or operation of the aerial platform the dealer shall obtain the proper information from the manufacturer or a qualified person if the manufacturer is no longer in business and provide that information to the owner or user 5 11 Record Retention And Dissemination 5 11 1 Record retention The dealer 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 the date of delivery 2 Records of the pre delivery preparation performed prior to each delivery 3 Records of frequent and annual machine inspections accomplished 4 Records of repairs accomplished to correct malfunctions and problems 5 Name of the person s trained 6 Name of the person s providing the training 7 Date of training 8 Name of person s receiving familiarizati
85. 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 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 2 Remove the hydraulic line from the fitting Then remove the fitting 3 Remove the flow restrictor valve using a 3 16 allen wrench 4 When reinstalling the flow restrictor valve make sure it is tightened in all the way against the bottom 5 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 6 Finally reconnect the hydraulic line to the fitting Make sure the o ring seal on the face of the fitting is not cut or tore HYDRAULIC LINE HYDRAULIC CYLINDER FLOW RESTRICTOR VALVE INSIDE Figure 4 7 Flow Restrictor Valve 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 th
86. ried 36 Leveling the aerial platform Outriggers and leveling devices supplied by the manufacturer shall be utilized to level the aerial platform when provided 37 Protecting against unauthorized use The user shall direct the operator not to use rent lease or provide the aerial platform for any form of beneficial use unless so authorized 7 11 User As Operator If a user is also the operator of an aerial platform the user shall have the responsibilities of operators specified in Section 8 of this standard as well as responsibilities of users as specified in Section 7 of this standard 7 12 Shutdown Of Aerial Platform The user shall authorize and direct the operating personnel to cease operation of the aerial platform in case of any suspected malfunctions of the aerial platform or any hazard or potentially unsafe condition that may be encountered and to request further information as to safe operation from the owner dealer or manufacturer before further operation of the aerial platform 7 13 Record Retention And Dissemination 7 13 1 Record retention The user shall retain the following records for at least 4 years 1 Names of the operator s trained and retrained 2 Names of operator s provided familiarization 3 The owner or entity designated by the owner is responsible to ensure frequent and annual inspections are conducted and written records are maintained The records shall include the date of the inspection any deficienc
87. rting means rendered inoperative 2 controls in the Off position and all operating features secured from inadvertent motion by brakes blocks or other means 3 Elevating assembly and platform lowered down to the full down position if possible or otherwise secured by blocking or cribbing to prevent dropping 4 Hydraulic oil pressure relieved from all hydraulic circuits before loosening or removing hydraulic components 5 Safety props or latches installed where applicable as prescribed by the manufacturer 5 6 Replacement Parts When parts or components are replaced they shall be identical or equivalent to original aerial platform parts or components 5 7 Training The dealer shall offer appropriate training to facilitate owners users and operators to comply with requirements set forth in this standard regarding the inspection maintenance use application and operation of the aerial platform 7 1 ESP 19 7 2 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 Whenever a dealer di
88. ss the application is approved in writing by the manufacturer or a qualified person 22 Travel speeds The operator shall limit travel speed according to conditions including the condition of the support surface congestion visibility slope location of personnel and other factors leading to hazards which may cause collision s or result in potential injury s to personnel 23 Elevated driving requirements Before and during driving while the platform is elevated the operator shall a Maintain a clear view of the support surface and route of travel b Ensure personnel in the worksite area that may be affected are aware of the movement communicating and maneuvering the aerial platform as required to protect against personal injury c Maintain a safe distance from obstacles debris drop offs holes depressions ramps and other hazards to ensure safe travel d Maintain a safe distance from overhead obstacles 24 Stunt driving Stunt driving and horseplay are prohibited 25 Securing the aerial platform The operator shall implement means provided to protect against use by unauthorized person s 26 Altering safety devices Interlocks or other safety devices shall not be altered or disabled 27 Snagged platform If the platform basket or supporting assembly becomes caught snagged or otherwise prevented from normal motion by adjacent structures or other obstacles such that control reversal does not free the platform all personnel sha
89. t vehicle base is more than one degree out of level While out of level travel can be resumed after the lift platform is fully low ered 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 inspec tion 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 in stalled 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 2 1 ESP 19 2 2 2 2 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 450 Ibs 204 kg total including operator 1 person materials not to exceed 450 Ibs
90. ted over the entire platform NEVER exceed platform load ratings by transferring loads to platform at ele vated heights NEVER use guard rails to carry materials and never allow overhang of materials when raising or lowering platform 1 5 ESP 19 1 4 MAINTENANCE SAFETY Read and observe the following general safety precautions when performing maintenance on the ESP 19 e ALWAYS perform maintenance procedures according to manufacturer s re quirements NEVER short change maintenance procedures e ALWAYS check hydraulic system Make sure all lines connectors and fittings are tight and in good condition e ALWAYS keep all mechanisms properly adjusted and lubricated according to maintenance schedule and manufacturers specifications e ALWAYS perform a function check of operating controls before each use and after repairs have been made e ALWAYS locate and protect against possible pinch points prior to performing maintenance and repairs e ALWAYS use only factory approved parts to repair or maintain this equipment If this equipment is rebuilt retesting is required in accordance with factory in structions e NEVER add unauthorized fluids to the hydraulic system or battery Check manufacturers specifications e NEVER exceed the manufacturer s recommended relief valve settings e NEVER attempt repairs you do not understand Consult manufacturer if you have any questions regarding proper maintenance specifications or repair
91. tee eet tests 3 1 3 2 Normal Operating Procedure 3 3 3 3 Emergency Lowering Procedures 3 5 39 4 aft Velucle Transport donee Detur 3 6 MAMENANG 1 4 1 4 1 Scheduled Service Checks 2 4 1 4 2 Underguard Service 4 3 4 3 L bricati n Rer nnb nete Repente 4 4 4 4 Hydraulic System 4 6 4 5 Electrical 5 he ERRORS 4 12 4 6 Lift Chains And Slide Blocks eene 4 13 A T Troubleshooting RR NERO 4 16 Replacement Decals eee ee eee esee eene eene etant 5 1 Parts 6 1 6 1 First Moving Mast Parts List 6 2 6 2 Second Moving Mast Parts List essere 6 4 6 3 Third Moving Mast Parts 8 6 6 6 4 Fourth Moving Platform Mast Parts 115 6 8 6 5 Battery Compartment Parts List sess 6 10 6 6 Hydraulic Pump Compartment Parts List eese 6 12 6 7 Parts ted 6 14 6 8 Base Mast Parts Lister Me etti 6 16 6 9 Drive Axle Parts 1842 uero eere pectet wie 6 18 6 10 Steering Parts List res terrre debe tet det 6
92. 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 re quest to Bil Jax Bil Jax shall not in any event be liable for the cost of any special indirect or consequen tial 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 per son to assume for us any other liability in connection with the sale rental or use of this product 3 1 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 con trol box enables lift operations from floor level The UPPER CONTROL OFF LOWER CONTROL key sw
93. 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 LOW BATTERY ALARM Figure 3 3 Battery On Off Switch Turn the UPPER CONTROL OFF LOWER CONTROL key switch Figures 3 1 amp 3 3 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 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 sounds an alarm beeper Once the platform is lowered floor travel is again enabled to allow travel to a level area 3 3 ESP 19 3 4 10 11
94. ther means Operator must read and understand owner s manual and all decals before operating MAX MIN B06 00 0289 Operation Instructions for Battery Charger Since batteries are the power source for the machine proper batlery care cannot be overemphasized Recharge batteries after each work shift When the machine is not being used batteries should be charged at least once a week The normal charging time should be 10 to 12 hours If batteries are extremely low charging time may be as long as 24 hours Charge batteries as follows A an extension cord from a 110V AC 60 Hz DO NOT ever e cr alt any safely devi tak cud outlet to the flush mount receptacle The extension override or alter any safety devices or make any modifications that woul affect the original design of the lit cord to be used should be as short and large as Inspect unit for damaged or wom possible A small long cord will decrease the output o m 800 225 3765 dete pe e s pont DO NOT use DO NOT ceni manufactures recommended load capacty m 08 00 0854 stand or sit on guard rails 1 there is power in the line the on charging red DO NOT use when exposed to 8 DO NOT lean out over guard rails to perform work Wind rain snow or ce E B06 00 0454 light will indicate charge current is flowing and the Check safety d
95. there is no communication Refer to the previous step to troubleshoot No Communication L1 and L2 on the joystick are blinking rapidly but unit still does not drive then a Press 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 Ifthe LED turns on but unit still doesn t drive the motor controller may be faulty Refer to the Motor Controller Troubleshooting section e 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 4 22 Check if there is communication between the main controller and 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 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 turn ON If not the main controller may be faulty For faulty DOWN command 4 MAINTENANCE 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 Press DOWN and ENABLE on the Joystick Make sure LED s DOWN ON
96. tick forward reverse travel ment will not return to center potentiometer for null drive signal with joystick at center Did not press ENABLE pushbutton c Release ENABLE pushbutton and first before moving joystick to for press again before moving joystick ward or reverse drive Tried to drive forward or reverse and d Release ENABLE pushbutton and run raise or lower the platform at the only one function drive or lift at a same time time 5 When DOWN function is Down valve solenoid or solenoid a Check voltage at down valve sole selected lift platform will wiring faulty noid If no voltage check wiring If not descend voltage exchange solenoids and re check function replace solenoid if Down valve sticking does not open faulty DOWN switch or DOWN switch b Repair or replace down valve wiring faulty c Check for lighted DOWN LED when Underguard switches activated down switch 15 engaged If LED does not light signal is not reaching main controller repair wire break or re place faulty switch d Remove object from underguard or readjust replace switches 6 Alarm is sounding lift UP Lift vehicle more than 1 degree out of a Lower lift platform and drive lift and travel functions stopped level vehicle to level area working 7 When joystick is moved lift Wheels blocked a Check wheels for blocking remove vehicle will not travel travel obstacle Free wheel lever in free wheel tow b Move free wheel le
97. tting Green EASI RXD Upper Control Receiving Green Mast Down Mast Down Switch Output Green Lower Down Lower Mast Down Output Green Lower Raise Lower Mast Up Output Green Upper Controls Upper Controls Activated Green Steer Left Steer Left Output Green Steer Right Steer Right Output Green Down Valve Platform Down Output Green Up Valve Platform Up Output Green Horn ON Horn Output Green Hour Meter Hour Meter On Output 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 4 MAINTENANCE Main Controller Troubleshooting Lower Control Mode e 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 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 C
98. ture 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 1 the reservoir to the MAXIMUM level with the proper hydraulic fluid 2 Fully raise the lift platform 3 Lower the lift platform to allow oil with entrapped air to return to the reservoir Be careful not to overflow the hydraulic reservoir 4 Leave the lift platform down and the lift vehicle at rest for 10 to 15 minutes while air escapes the hydraulic oil 5 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 4 MAINTENANCE Pressure Relief Valve Adjustment Perform the following procedure to adjust the pr
99. ual recommendations Do not overtighten slide blocks Slide block paths must be kept clean free of dit grease and other foreign material DO NOT use grease oil any similar lubricant masts or slide Electric ock icker blocks For additional lubrication use dry silicone only 206 00 0158 B06 00 0138 DANGER IT IS UNLAWFUL TO OPERATE THIS EQUIPMENT WITHIN 10 Pree Wheel FEET OF HIGH VOLTAGE LINES OF 50 000 VOLTS OR LESS T B06 00 0009 For safe clearance of lines in excess of 50 000 volts see owners manual STAY CLEAR WHILE RAISING _ OR LOWERING B06 00 0146 B06 00 0390 06 00 0225 Bindax Ino 2004 06 00 0453 806 00 0453 LUBRICATE SEMI ANNUALLY Bil Jax Inc 2003 B06 00 0037 B06 00 0037 Moving telescopic masts will create pinch points Keep fingers hands arms and feet clear of all telescopic mast sections at all times This machine is NOT insulated Do not use within 10 ft of power lines or other electrically charged sources This machine DOES NOT provide protection for personnel from contact with or close proximity to any live electrical power source and should be considered energized by all personnel coming in contact with machine 06 00 0146 CFTREC Figure 5 1 Replacement Decals 5 REPLACEMENT DECALS BATTERY CHARGER CORD BOX DO NOT work stand sit or place any part of your
100. urposes only This information is offered to alert Bil Jax customers to procedures that may be of concern to them This information is not intended to be all inclusive and is to be followed in the use of Bil Jax equipment only For any questions concerning the safe use of this equipment call 800 537 0540 before operating 1 1 ESP 19 1 2 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 per sonal injury N 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 CAUTION Cautions provide information important to prevent errors that could damage ma chine or components NOTE Notes contain additional information important to a procedure 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 conduc tors 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 at tempting to
101. ver back to drive position position Joystick or joystick wiring faulty 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 Main controller or main controller d Check for output voltage to motor signal wiring faulty controller when joystick is engaged If travel signal is not present at main controller contact Bil Jax for assis tance If travel signal is not present at motor controller repair wire break Motor controller 24 volt power cable Check connection of 24 volt power disconnected cable to motor controller repair faulty power cable connection 4 17 ESP 19 Table 4 3 Troubleshooting Chart Continued Problem Cause Correction 7 When joystick is moved lift f Motor controller motor controller f Check for output voltage to drive vehicle will not travel cont output wiring or transaxle drive mo motor when joystick is engaged If tor faulty drive voltage is not present at motor controller replace motor controller If drive voltage does not reach drive motor repair wire break If drive volt age is present at drive motor replace drive motor g Transaxle drive train damaged g If transaxle drive motor runs inspect drive train components for damage Repair or replace transaxle gearhouse if damaged 8 When steering thumb switch a Wheels turne
102. x lift is damaged structurally or when there is the possibility of structural damage this damage may be internal and is not always visi ble to the naked eye Bil Jax requires that the lift be returned to our facility at 125 Tay lor 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 non structural damage When this occurs and repairs are made by the owner or area distribu tor please notify Bil Jax of these non maintenance repairs and request a repair form to be filled out and returned to Bil Jax 1 7 ESP 19 1 8 2 1 Introduction 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 plat form with the load while transferring parts to and from multiple overhead storage loca tions The maximum platform load is limited to 450 165 ESP 19 operations are powered by a 24 Volt DC battery package 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
103. y misuse of equipment to the proper authorities Horseplay 15 prohibited e ALWAYS maintain good footing on the platform NEVER wear slippery soled shoes e ALWAYS make certain all personnel are clear and there are no obstructions be fore repositioning platform e ALWAYS cordon off area around the base to keep personnel and other equip ment away from it while in use e ALWAYS stay clear of wires cables and other overhead obstructions e ALWAYS disconnect power at the batteries when not in use to guard against unauthorized use 1 SAFETY NEVER allow electrode contact with any part of the platform if welding is be ing 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 materi als 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 distribu
104. years 7 13 ESP 19 BUS BARS 7 moy NUN ARD 3 C ND M S A D Minimum Safe Approach Distance See Table 7 1 DENOTES PROHIBITED ZONE NDANGER 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 CAUTION Diagrams shown are only for purposes of illustrating M S A D work positions not all work positions 7 14 Table 7 1 Minimum Safe Approach Distance M S A D to energized exposed or insulated power lines and parts 7 ANSI REPRINT Minimum Safe Approach Distance Voltage Range Phase to Phase Feet Meters 0 to 300V 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 72 7 15 ESP 19 7 16 A STEP ABOVE 125 Taylor Parkway Archbold OH 43502 Phone 419 445 8915 800 537 0540 Fax 419 445 0367

Bil-Jax ESP 19 Personal Lift User Manual

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