Bil-Jax ESP 19 User Manual

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AERIAL WORK PLATFORMS

ESP 19

Electric Stock Picker

Operation and Maintenance Manual

800-225-3765

CTG

B06-00-0380

ACITY

LBS.

MAXIMUMCAP

450

CCTT

DONOT

1 6

-0 0

-0

6 0 B

OPERATIONINSTRUCTIONSFORESP19

1.Readandfollowsafety precautions and all responsibilitiessectionssetforthinthe operators manual obstructionsorelectricallychargedconductors, usetheliftwheresuchhazards exist.

2.Makesurethelift is onafirmandlevelsurfaceand thattherearenopotentialhazards such as overhead

3.Checktheliftfordamaged orwornpartsandrepairor replace as necessary.

4.Checktobesurethat the cageisproperlyattachedtothe lift.

5.Turnmasterpowerswitch to on.

6.Checktobesureall safety devices arefunctioningproperly. oystick).

eitherupordownfunction.

orbackward)thatyouwishtotravel.

7.Tooperateliftfrom the ground turn andholdlowercontrolswitchto "lower control" setting thenselect topofthejoystickinthedirection youwishthelifttoturn (either

8.Tooperateliftfrom the platform, turn lowercontrolswitchto"uppercontrol" setting.

latched.LIFTWILLNOTOPERATE IF LID IS NOT CLOSED SECURELY.

hold

9.Makesurebatterycharger cord is disconnected from outlet, placedbackintoitsboxand lid is closed and

ENTRYGATEISNOTCLOSEDCOMPLETELY.

oneofthe"enable"buttons(one“enable”buttonison the front of the joystickhandle,

SEORLOWER

10.Enterplatformandbe certain thattheentrygateisclosedcompletely. LIFT WILL NOTOPERATEIF

ssand oneofthe"enable" buttons (one“enable”buttonisonthefront of the joystick handle, rislocatedtotheleftofthejoystick). ertheraiseorlowerbutton.

hold

458 0-0

06-0

Electric

Stock

Picke

B06-00-0380

ACITY

LBS.

MAXIMUMCAP

450

CCTT

B06-00-0380

ACITY

LBS.

MAXIMUMCAP

450

CCTT

STAYCLEAR

WHILE RAISING

C C F

OR LOWERING

B 06

-0 0-0

2 2 5

TG C

B33-01-0086-02

TELESCOPIC PERSONNEL LIFT

This equipment is designed and manufactured in compliance with the duties, responsibilities, and standards set forth for manufacturers in the ANSI 92.6 standard in effect at the time of manufacture.

This equipment will meet or exceed applicable OSHA codes and ANSI A92.6 standards when used in accordance with sections 5, 6, 7, 8, 9, 10, and 11 of ANSI A92.6 and all other manufacturer’s recommendations.

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 operation of this equipment.

Table of Contents

1 Safety................................................................................................................1-1

1-1 Introduction.............................................................................................1-1

1-2 Before Operation....................................................................................1-3

1-3 During Operation....................................................................................1-4

1-4 Maintenance Safety ................................................................................1-6

1-5 Damaged Equipment Policy..................................................................1-7

2 Introduction.....................................................................................................2-1

2-1 General Description ...............................................................................2-1

2-2 Specifications..........................................................................................2-2

2-3 Warranty .................................................................................................2-2

3 Operation.........................................................................................................3-1

3-1 Operator Controls...................................................................................3-1

3-2 Normal Operating Procedure................................................................3-3

3-3 Emergency Lowering Procedures.........................................................3-5

3-4 Lift Vehicle Transport...........................................................................3-6

4 Maintenance ....................................................................................................4-1

4-1 Scheduled Service Checks....................................................................4-1

4-2 Underguard Service Check ...................................................................4-3

4-3 Lubrication..............................................................................................4-4

4-4 Hydraulic System...................................................................................4-6

4-5 Electrical System..................................................................................4-12

4-6 Lift Chains And Slide Blocks ...........................................................4-13

4-7 Troubleshooting....................................................................................4-16

5 Replacement Decals ........................................................................................5-1

6 Parts List..........................................................................................................6-1

6-1 First Moving Mast Parts List ..........................................................6-2

6-2 Second Moving Mast Parts List......................................................6-4

6-3 Third Moving Mast Parts List.........................................................6-6

6-4 Fourth Moving (Platform) Mast Parts List ....................................6-8

6-5 Battery Compartment Parts List.....................................................6-10

6-6 Hydraulic Pump Compartment Parts List.....................................6-12

6-7 Base Parts List ................................................................................6-14

6-8 Base Mast Parts List ......................................................................6-16

6-9 Drive Axle Parts List .....................................................................6-18

6-10 Steering Parts List...........................................................................6-20

6-11 Platform Parts List..........................................................................6-22

6-12 Upper Control Box Parts List .......................................................6-24

6-13 Hydraulic Unit Parts List...............................................................6-26

6-14 Hydraulic Cylinder, Fittings, and Hoses Parts List......................6-28

7 ANSI Reprint..................................................................................................7-1

List of Illustrations

Figure 3-1. Lower Control Box................................................................................. 3-1

Figure 3-2. Upper Control Box................................................................................. 3-2

Figure 3-3. Battery On/Off Switch............................................................................ 3-3

Figure 3-4. Emergency Lowering Valve................................................................... 3-5

Figure 3-5. Lifting Pockets ....................................................................................... 3-6

Figure 3-6. Travel Brake and Steering Linkage........................................................ 3-6

Figure 4-1. Figure 4-2.

Figure 4-3. Mast Slide Ways Lubrication................................................................. 4-4

Figure 4-4. Rear Casters Lubrication........................................................................ 4-5

Figure 4-5. Front Caster Pillow Blocks Lubrication................................................. 4-5

Figure 4-6. Pressure Relief Valve Adjustment.......................................................... 4-7

Figure 4-7. Flow Restrictor Valve ............................................................................ 4-8

Figure 4-8. Valve Operation .................................................................................... 4-9

Figure 4-9. Hydraulic Cylinder Disassembly.......................................................... 4-12

Figure 4-10. Battery Charger Cord ........................................................................... 4-12

Figure 4-11. Chain Elongation Inspection ................................................................ 4-13

Figure 4-12. Lift Chains Adjustment ........................................................................ 4-14

Figure 4-13. Slide Blocks Adjustment...................................................................... 4-15

Figure 4-14. Main Controller Board ......................................................................... 4-19

Figure 4-15. Hydraulic Diagram............................................................................... 4-26

Figure 4-16. PC Logic Diagram................................................................................ 4-27

Figure 4-17. Electrical Layout .................................................................................. 4-28

Figure 4-18. Drive Wiring Diagram.......................................................................... 4-29

Figure 4-19. Upper Control Wiring Diagram ........................................................... 4-30

Figure 5-1. Replacement Decals............................................................................... 5-2

Figure 5-2. Decal Locations, Side View................................................................... 5-4

Figure 5-3. Decal Locations, Rear View................................................................... 5-5

Figure 6-1. First Moving Mast.................................................................................. 6-2

Figure 6-2. Second Moving Mast ............................................................................. 6-4

Figure 6-3. Third Moving Mast ................................................................................ 6-6

Figure 6-4. Fourth Moving (Platform) Mast............................................................. 6-8

Figure 6-5. Battery Compartment........................................................................... 6-10

Figure 6-6. Hydraulic Pump Compartment............................................................. 6-12

Figure 6-7. Base...................................................................................................... 6-14

Figure 6-8. Base Mast............................................................................................. 6-16

Figure 6-9. Drive Axle............................................................................................ 6-18

Figure 6-10. Figure 6-11. Figure 6-12. Figure 6-13. Figure 6-14.

Underguard............................................................................................. 4-3

Lift Chains Lubrication.......................................................................... 4-4

Steering ................................................................................................ 6-20

Platform................................................................................................ 6-22

Upper Control Box............................................................................... 6-24

Hydraulic Unit Assembly..................................................................... 6-26

Hydraulic Cylinder, Fittings, and Hoses .............................................. 6-28

List of Tables

Table 1-1. Minimum Safe Approach Distances .......................................................1-4

Table 2-1. Specifications..........................................................................................2-2

Table 4-1. Daily/Weekly Service Checks.................................................................4-1

Table 4-2. Monthly Service Checks......................................................................... 4-2

Table 4-3. Troubleshooting Chart ..........................................................................4-16

Table 4-4. Main Controller LED Indicators...........................................................4-20

Table 5-1. Replacement Decals................................................................................5-1

Table 6-1. First Moving Mast Parts List...................................................................6-3

Table 6-2. Second Moving Mast Parts List..............................................................6-5

Table 6-3. Third Moving Mast Parts List.................................................................6-7

Table 6-4. Fourth Moving (Platform) Mast Parts List..............................................6-9

Table 6-5. Battery Compartment Parts List............................................................6-11

Table 6-6. Hydraulic Pump Compartment Parts List .............................................6-13

Table 6-7. Base Parts List.......................................................................................6-15

Table 6-8. Base Mast Parts List..............................................................................6-17

Table 6-9. Drive Axle Parts List.............................................................................6-19

Table 6-10. Steering Parts List.................................................................................6-21

Table 6-11. Platform Parts List.................................................................................6-23

Table 6-12. Upper Control Box Parts List................................................................6-25

Table 6-13. Hydraulic Unit Parts List ......................................................................6-27

Table 6-14. Hydraulic Cylinder, Fittings, and Hoses Parts List...............................6-29

Table 7-1. Minimum Safe Approach Distance (M.S.A.D.) to energized

(exposed or insulated) power lines and parts........................................7-15

iii

Safety

1-1

INTRODUCTION

Familiarity and proper training are required for the safe operation of mechanical equ ment. Equipment operated improperly or by untrained personnel can be dangerous. Rea the operating instructions in this manual and become familiar with the location and proper use of all controls. Inexperienced operators should receive instruction from persons who are familiar with the equipment before operating the machine. The use of intelligence and com in any safety policy. Be professional and always observe the safety procedures set for in this manual.

All OSHA, 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 b 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 for informational purposes only. This information is offered to alert Bil-Jax customers procedures that may be of concern to them.

This information is not intended to be all-inclusive and is to b e 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.

mon sense in the operation of mechanical equipment is the best practice

e implemented at all

considered as legal advice and is intended

ip-

1-1

ESP 19

Safety Notes

This manual contains DANGERS, WARNINGS, CAUTIONS, and NOTES that must be followed to prevent the possibility of improper service, damage to the equipment, or personal injury.

DANGER

Dangers warn of equipment operation near electrical power lines that could lead to personal injury or death.

WARNING

Warnings describe conditions or practices that could lead to personal injury or death.

CAUTION

Cautions provide information important to prevent errors that could damage machine or components.

NOTE: Notes contain additional information important to a procedure.

1-2

1 — SAFETY

1-2 BEFORE OPERATION

Read and observe the following general safety precautions before operating the ESP 19.

• ALWAYS survey the usage area for potential hazards such as untampered earth fills, unlevel surfaces, overhead obstructions, and electrically charged conductors or wires. Be aware of any potential hazards and always consider what could happen. Watch for moving vehicles in the operating area.

• ALWAYS read, understand, and follow the procedures in this manual before attempting to operate equipment.

• ALWAYS inspect the equipment for damaged or worn parts. Check for cracked welds, hydraulic leaks, damaged wiring, loose wire connectors, damaged casters, and damaged pothole guards. Also check for any improper operation. NEVER operate equipment if damaged in any way. Improperly operating equipment must be repaired before using.

• ALWAYS wear proper clothing for the job. Wear protective equipment as required by federal, state, or local regulations.

• ALWAYS locate, read, and follow all directions and warnings displayed on the equipment.

• ALWAYS inspect the equipment for “DO NOT USE” tags installed by maintenance personnel. NEVER use tagged equipment until repairs are made and all tags are removed by authorized maintenance personnel.

• ALWAYS make sure the platform is free of mud, grease, or other foreign material. This will reduce the possibility of slipping.

• NEVER allow improperly trained personnel to operate this equipment. Only trained and authorized personnel shall be allowed to operate this equipment.

• NEVER operate this equipment if you are under the influence of alcohol or drugs or if you feel ill, dizzy, or unsteady in any way. Operators must be physically fit, thoroughly trained, and not easily excitable.

• NEVER modify, alter, or change the equipment in any way that would affect its original design or operation in any way.

• NEVER operate this equipment in ways for which it is not intended.

1-3

ESP 19

1-3 DURING OPERATION

Read and observe the following general safety precautions at all times during operation of the ESP 19.

DANGER

This machine is not insulated for use near electrical power lines and DOES NOT provide protection from contact with or close proximity to any electrically charged conductor. Operator must maintain safe clearances at all times (10 feet minimum) and always allow for platform movement such as wind induced sway. Always contact the power company before performing work near power lines. Assume 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

(Phase to Phase)

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

Minimum Safe Approach Distance

(Feet) (Meters)

• ALWAYS position lift far enough away from power sources to ensure that no part of the lift can accidentally reach into an unsafe area.

• ALWAYS operate only on a firm and level surface. NEVER use on surfaces that do not support the weight of the equipment and its rated load capacity.

• ALWAYS keep yourself and all personnel away from potential pinch or shear points.

• ALWAYS report any misuse of equipment to the proper authorities. Horseplay is prohibited.

• ALWAYS maintain good footing on the platform. NEVER wear slippery soled shoes.

• ALWAYS make certain all personnel are clear and there are no obstructions before repositioning platform.

• ALWAYS cordon off area around the base to keep personnel and other equipment away from it while in use.

• ALWAYS stay clear of wires, cables, and other overhead obstructions.

• ALWAYS disconnect power at the batteries when not in use to guard against

unauthorized use.

1-4

1 — SAFETY

• NEVER allow electrode contact with any part of the platform if welding is being performed from the platform.

• NEVER override or by-pass manufacturer's safety devices.

• NEVER release the travel brake or tow the lift vehicle while a person or 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 distributed over the entire platform.

• NEVER exceed platform load ratings by transferring loads to platform at elevated heights.

• NEVER use guard rails to carry materials and never allow overhang of materials when raising or lowering platform.

1-5

ESP 19

1-4 MAINTENANCE SAFETY

Read and observe the following general safety precautions when performing maintenance on the ESP 19.

• ALWAYS perform maintenance procedures according to manufacturer's requirements. NEVER short change maintenance procedures.

• ALWAYS check hydraulic system. Make sure all lines, connectors, and fittings are tight and in good condition.

• ALWAYS keep all mechanisms properly adjusted and lubricated according to maintenance schedule and manufacturers specifications.

• ALWAYS perform a function check of operating controls before each use and after repairs have been made.

• ALWAYS locate and protect against possible pinch points prior to performing maintenance and repairs.

• ALWAYS use only factory-approved parts to repair or maintain this equipment. If this equipment is rebuilt, retesting is required in accordance with factory instructions.

• NEVER add unauthorized fluids to the hydraulic system or battery. Check manufacturers specifications.

• NEVER exceed the manufacturer's recommended relief valve settings.

• NEVER attempt repairs you do not understand. Consult manufacturer if you

have any questions regarding proper maintenance, specifications, or repair.

Battery Maintenance

Read and observe the following general safety precautions when performing battery maintenance on the ESP 19.

• Check battery charge indicator for proper state of charge on maintenance free batteries before using lift.

• ALWAYS wear safety glasses when working near battery.

• ALWAYS avoid contact with battery acid. Battery acid causes serious burns.

Avoid contact with skin or eyes. If accidental contact occurs, flush with water and consult a physician immediately.

• ALWAYS disconnect ground cable first when removing battery.

• ALWAYS connect ground cable last when installing battery.

• ALWAYS charge batteries in open, well-ventilated areas.

• NEVER smoke when servicing battery.

• NEVER allow batteries to overcharge and boil.

• NEVER short across battery posts to check for current. NEVER break a live cir-

cuit at battery.

• NEVER jump start other vehicles using lift battery.

1-6

1 — SAFETY

1-5 DAMAGED EQUIPMENT POLICY

Safety Statement

At Bil-Jax, we are dedicated to the safety of all users of our products. Therefore, all BilJax lifts are designed, manufactured, and tested to comply with current applicable Federal OSHA and ANSI codes and regulations.

Damage Policy

There may be occasions when a Bil-Jax lift is involved in an incident that results in structural damage to the lift. This can seriously compromise the ability of the lift to perform in a safe manner. Therefore, whenever a Bil-Jax lift is damaged structurally or when there is the possibility of structural damage (this damage may be internal and is not always visible to the naked eye), Bil-Jax requires that the lift be returned to our facility at 125 Taylor Parkway, Archbold, Ohio, for reconditioning. If you have any questions concerning what constitutes structural damage, please call the Bil-Jax Service Department at 800-537-0540.

Damage Repair Notice

There may be occasions when a Bil-Jax lift is involved in an incident resulting in nonstructural damage. When this occurs and repairs are made by the owner or area distributor, please notify Bil-Jax of these non-maintenance repairs and request a repair form to be filled out and returned to Bil-Jax.

1-7

ESP 19

1-8

Introduction

2-1

GENERAL DESCRIPTION

The ESP 19 hydraulic lift is designed and manufactured for use as a warehouse stocking and order picking vehicle. Its guard rail design permits the operat form with the load, while transferring parts to and from multiple overhead storage locations. The maximum platform load is limited to 450 lbs.

All ESP 19 operations are powered by a 24-Volt DC battery package. A 40-amp battery charger and plug-in receptacle are included in the system for recharging the batteries the end of each work period. A charge level indicator displays the battery charge status.

The platform lift function is hydraulic, including a hydraulic cylinder, reservoir, and pump. The hydraulic pump motor is driven by a 24-Volt DC electric motor. Elevation is by a 1-3/4 inch linear-displacement hydraulic cylinder and four telescoping mast sections. The lower mast section is raised by hydraulic cylinder. The raised mechanically by connecting sets of chains and sheaves (pulleys). The lift platform rises four inches for each inch of hydraulic cylinder extension.

Other electrically powered functions include a two-wheel drive transaxle for floor travel and pushbutton steering. The maximum travel speed is enabled only when the lift platform is down. When the platform is raised, the travel speed is limited. The transaxle includes an electric brake that locks the drive wheels whenever forward or reverse travel is halted. The electric brake is normally applied; the brake disengages when forward or re verse tra 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 f out of level. While out of level, travel can be resumed after the lift platform is fully lowered.

vel is enabled with the joystick. In case of a loss of battery power, a manual free

unctions except platform lowering if the lift vehicle base is more than one degree

or to ride on the plat-

upper mast sections are

With equipment power on or lift platform at a controlled, safe speed. The lowering valve knob is visible and readily accessible from floor level.

Proper lift vehicle operation and safety are assured by performing the scheduled inspection and maintenance procedures set forth in this manual. The risk of platform free-fall is eliminated by proper maintenance of the chains, sheaves and sheave pins, a properly installed flow restrictor valve, and a clean mast. The restrictor valve (non-adjustable) fixes the maximum rate of platform descent to approximately 0.6 fe 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.

off, turning an emergency lowering valve knob lowers the

et per second, whether the

2-1

ESP 19

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 lbs (204 kg) total including operator

[1 person + materials not to exceed 450 lbs (204 kg)] Extended Platform Height 19 ft 3 in (5.9 m) Retracted Platform Height 20 in. (50.8 cm) Platform Dimensions 30 in. W x 30 in. L x 42 in. H

(0.76 m x 0.76 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

2-3 WARRANTY

Bil-Jax warrants its telescopic lifts for one year from the date of delivery against all defects of material and workmanship, provided the unit is operated and maintained in compliance with Bil-Jax’s operating and maintenance instructions; structural components are warranted for three years. Bil-Jax will, at its option, repair or replace any unit or component part which fails to function properly in normal use.

This warranty does not apply if the lift and/or its component parts have been altered, changed, or repaired without the consent of Bil-Jax or by anyone other than Bil-Jax or its factory trained personnel, nor if the lift and/or its components have been subjected to misuse, negligence, accident or any conditions deemed other than those considered as occurring during normal use.

Components not manufactured by Bil-Jax are covered by their respective manufacturer’s warranties. A list of those components and their warranties is available upon written request to Bil-Jax.

Bil-Jax shall not in any event be liable for the cost of any special, indirect, or consequential damages to anyone, product, or thing. This warranty is in lieu of all other warranties expressed or implied. We neither assume nor authorize any representative, or other person, to assume for us any other liability in connection with the sale, rental, or use of this product.

2-2

Operation

3-1

OPERATOR CONTROLS

Most of the operator controls for the ESP 19 are located on the upper and lower control boxes. Other operator controls include the lowering valve. main power disconnect switch for the lift vehicle. The location and operation of the emergency lowering valve is

The BATTERY ON/OFF switch, located on th

described in paragraph 3-3.

BATTERY ON/OFF switch and the emergenc

e left side of the lift base, is the

Lower Control Box

The lower control box, Figure 3-1, is located on th

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 switch selects the active (upper or lower)

control location. To enable an key switch in the vation

from the upper control box, turn the key switch to the To disable lift vehicle operations, turn the key switch to the key.

Turn the

DOWN position to lower the platform. (The key switch must be held in the LOWER CONTROL

Press the moving forward or back causing travel to stop quickly. To resume lift vehicle operation, turn the

STOP

UP/DOWN selector switch to the UP position to raise

position to enable the UP/DOWN selector switch).

EMERGENCY STOP button to stop all equipment motion. If the lift vehicle is

butt

on clockwise.

LOWER CONTROL position. To enable lift vehicle travel or platform ele-

UP or DOWN lift motion from the floor, turn and hold the

, pressing the

EMERGENCY STOP button engages the travel brake

e lift base and contains three controls:

UPPER CONTROL position.

OFF position and remove th

the lift platform or to the

EMERGENCY

Figure 3-1. Lower Control Box

3-1

ESP 19

Upper Control Box

The upper control box, Figure 3-2, is in the lift cage. The upper control box enables lift and travel operations whenever the lower control box key switch is in the

Upper control box controls include four pushbuttons and a forward/reverse floor-travel joystick with thumb-switch steering.

ENABLE

PUSHBUTTONS

BATTERY ON/OFF switch is in the ON position and the

UPPER CONTROL position.

STEERING

THUMB

SWITCH

PUSHBUTTON

DOWN

PUSHBUTTON

TRAVEL

EMERGENCY

JOYSTICK

STOP

PUSHBUTTON

Figure 3-2. Upper Control Box

Press and hold either one of the

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 platform or press the

With one of the

ENABLE pushbuttons depressed, press the UP [] pushbutton to raise the

DOWN [

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.

ENABLE pushbuttons to enable a control function. An

] pushbutton to lower the platform.



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.

3-2

3 — OPERATION

3-2 NORMAL OPERATING PROCEDURE

Perform the following procedures to operate the ESP 19 platform lift vehicle.

1. Read and follow all safety precautions contained in Section 1 and all responsibilities outlined in the ANSI A92.3 reprint in Section 7 of this manual.

2. Check the lift vehicle for damage or worn parts. If damage or part wear is found, do not operate the vehicle until the problem is corrected.

3. Make sure battery charger cord is disconnected from wall outlet. Place cord back into its box and close and latch lid. LIFT WILL NOT OPERATE IF LID IS NOT CLOSED SECURELY.

4. Turn the

BATTERY ON/OFF switch, Figure 3-3, to the ON position.

5. Observe the battery charge level indicator. Verify that the battery charge level is 3/4 or more.

Figure 3-3. Battery On/Off Switch

6. Turn the to the

UPPER CONTROL/OFF/LOWER CONTROL key switch, Figures 3-1 & 3-3,

UPPER CONTROL position.

7. Enter the platform cage and close the entry gate. LIFT WILL NOT OPERATE IF THE GATE IS NOT CLOSED COMPLETELY.

8. Use the upper control box controls to operate the lift vehicle.

9. Position the lift vehicle at the work area. Make sure the vehicle is on a firm and level surface and that there are no potential hazards such as speed bumps, open floor drains, potholes, overhead obstructions or electrically charged conductors. Do not operate the lift vehicle if such hazards exist in the immediate area.

NOTE: The lift vehicle is equipped with a level sensor. When the vehicle is on a

slope greater than 1 degree, the level sensor disables all functions other than platform lowering and 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

10. During floor travel and lift operations, the alarm beeper should sound. If the alarm beeper does not work properly, do not operate the lift vehicle.

11. During lift platform descent, the amber caution light should blink on and off. If the caution light does not blink on and off, do not use the lift vehicle.

12. If any equipment motion continues after the pushbutton, joystick, or selector switch is released, press the

EMERGENCY STOP pushbutton, Figure 3-2. All

equipment motion should stop immediately.

13. At the end of each workday and whenever a low battery alarm sounds, transport the lift vehicle to the recharge site and plug in the charge cord. Verify that the

ON-CHARGING indicator lights up on the battery charger.

NOTE: For more information on battery charging operations, refer to the bat-

tery charging procedure in paragraph 4-4.

14. To shut down the equipment, turn the switch and the

BATTERY ON/OFF switch to OFF. Remove the key to prevent unau-

thorized equipment operation.

UPPER CONTROL/OFF/LOWER CONTROL key

3-4

3 — OPERATION

3-3 EMERGENCY LOWERING PROCEDURES

In an emergency, a person at floor level can lower the platform by holding the UPPER

CONTROL/OFF/LOWER CONTROL

UP/DOWN selector switch to the DOWN position. (If the upper control box emergency

the stop pushbutton is depressed, the platform will not lower.)

An emergency lowering valve is shown in Figure 3-4. In case of a total loss of battery power, a person at floor level can safely lower the platform by opening the emergency lowering valve.

key switch in the LOWER CONTROL position and turning

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. age shelves.

To lower the platform, pull and hold the red valve knob until the platform starts to descend. When the platform is fully lowered, release the knob to close the valve.

Do not leave the cage to climb down the lift mast or stor-

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 following instructions before using these features to lift or tow the vehicle.

Figure 3-5. Lifting Pockets

CAUTION

Do not attempt to push the lift vehicle or use the lift vehicle to pull another vehicle or object. Pushing the lift vehicle or using the vehicle for towing may cause serious equipment damage.

The forks of a lift truck (2-ton minimum capacity) can be used to raise the ESP 19 for loading onto a trailer or for blocking up the lift vehicle for maintenance. Forks must be inserted a minimum of 32 inches before raising the ESP 19.

Before towing the ESP 19 lift vehicle, you must manually disengage the travel brake and disconnect the steering cylinder from the steering linkage. Refer to the illustratio ns in Figure 3-6.

Figure 3-6. Travel Brake and Steering Linkage

3-6

Maintenance

4-1 HECKS

SCHEDULED SERVICE C

Daily/Weekly Service Checks

Perform the daily and

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.

weekly service checks listed in Table 4-1.

able 4-1. Daily ks

T /Weekly Service Chec

Service Check

Daily

before use Weekly



    



4-1

ESP 19

6 Month/Yearly Service Checks

Perform the service checks in Table 4-2 every 6 months or every 12 months, as indicated.

Table 4-2. 6 Month/Yearly Service Checks

Service Check

Every

6 months

Check chain assemblies for split leaves, loose pins, excessive wear, or elongation.

Verify that cage is securely bolted to lift mast.

Check that slide blocks and their paths are clean and lightly lubricated with a dry silicone lubricant.

Verify that all safety decals are present and legible.

Check for wear on chain sheaves, sheave axles, and bearings.

Check caster axle and swivel bolts for wear.

Check casters for cracks or excessive wear.

Lubricate lift chains with 40-weight oil.

Check hydraulic UP and DOWN valves operation.

Clean battery terminals. Check operation of emergency

lowering valve. Grease rear caster swivel bolts, axles

and wheels. Grease steering linkage pivot bolts. Grease front caster pillow blocks. Check battery cables and wiring for

loose connections and damaged wires.

Replace hydraulic oil. Check slide blocks for wear. Check for mast sway. Load test with 450 pounds.

Every

12 months



 



   

4-2

4 — MAINTENANCE

4-2 UNDERGUARD SERVICE CHECK

The underguard is a safety device located under the cage/platform that shuts down operation of the lift when weight is applied. Perform the following procedure weekly to verify the underguard is working properly.

1. Turn power to lift ON and raise cage/platform using the lower control box a minimum of 3 feet above the underguard.

2. Place a weight of at least 15 lbs. on the underguard. Refer to Figure 4-1.

15 LB. WEIGHT

UNDERGUARD

CLAMP

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 lower control box

with power ON, attempt to lower lift. A warning beeper should sound and the lift should not lower. The lift should still be able to raise. With someone in the cage, switch to upper controls and attempt to drive. A warning beeper should sound and the lift should not drive.

4. If the lift lowers or drives, the switches below the underguard may need to be adjusted or replaced. To adjust or replace underguard switches, shut power OFF to lift, then remove two of the underguard clamps from one side of the lift. The switches below the underguard can be adjusted by loosening the screws or removed for replacement.

5. Retest whenever underguard is removed and switches are adjusted or replaced.

4-3

ESP 19

4-3 LUBRICATION

Lubrication makes operation of the ESP 19 more efficient and extends the life of the lift vehicle. Perform the following lubrication procedures.

1. Lubricate lift chains with clean 40-weight oil. Refer to Figure 4-2.

LIFT

CHAINS

LIFT

CHAINS

Figure 4-2. Lift Chains Lubrication

2. Clean the mast slide ways, Figure 4-3, and lightly spray the slide ways with a dry silicone lubricant.

NOTE: The slide blocks have a high level of lubricity and need only be kept

clean. To reduce wear and extend service life, the slide ways should be cleaned and lightly lubricated with a dry type silicon lubricant.

Figure 4-3. Mast Slide Ways Lubrication

4-4

4 — MAINTENANCE

Figure 4-4. Rear Casters Lubrication

3. See Figure 4-4. Grease rear caster axles and swivel bolts at the grease fittings provided. Add about 1/2 ounce of clean #2 NGLI grease to each fitting.

4. Remove, clean, and lubricate steering linkage with wheel bearing grease.

5. Apply about 1/2 ounce of clean #2 NGLI grease to the fitting on each front wheel pillow block, Figure 4-5. Do not over-grease the pillow block bearings.

Figure 4-5. Front Caster Pillow Blocks Lubrication

4-5

ESP 19

4-4 HYDRAULIC SYSTEM

Hydraulic system maintenance varies by the amount of use and the environment in which the lift vehicle is used. Keeping the hydraulic oil clean and the reservoir properly filled will help prevent possible damage to the system.

Hydraulic System Inspection

Check all hydraulic hoses and fittings for leaks and damage daily. Tighten or replace as necessary to prevent hydraulic oil loss.

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, nonfoaming hydraulic oil. This oil is recommended for use in climatic temperatures as low as -20°F/-29°C. Dextron Automatic Transmission Fluid Type A is recommended for use in temperatures as low as -40°F/-40°C.

If either of these oils is not available, a good grade SAE 10W hydraulic oil may be used where the minimum climatic temperature is above 32°F/0°C. An SAE 5W hydraulic oil may be used where temperatures are as low as 0°F/-18°C.

Do not mix different hydraulic oils. Clean the reservoir and sump strainer and replace the hydraulic oil at least once a year. Clean the reservoir and sump strainer and replace the oil whenever contamination is suspected.

Hydraulic System Air Bleeding Procedure

Delayed response or uneven movement of the hydraulic cylinder may indicate trapped air in the hydraulic oil.

NOTE: Whenever the upper control box emergency stop pushbutton is engaged,

lift operation remains enabled at the lower control box. However, the

DOWN lift motion will be intermittent. Intermittent lift motion should

or not be mistaken as trapped air in the hydraulic system.

Perform the following procedure to bleed trapped air from the hydraulic system.

1. Fill the reservoir to the

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.

MAXIMUM level with the proper hydraulic fluid.

4-6

4 — MAINTENANCE

Pressure Relief Valve Adjustment

Perform the following procedure to adjust the pressure relief valve. Refer to Figure 4-6.

1. Move the ESP 19 lift platform to the fully

DOWN position.

2. Center 450 pounds of weight on the lift platform.

3. Loosen the jam nut. The pressure relief valve is on the back side of the pump.

4. Turn the pressure relief valve adjust screw 1/8

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.

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 without bypassing oil to the hydraulic reservoir.

7. Retighten the jam nut.

Figure 4-6. Pressure Relief Valve Adjustment

4-7

ESP 19

Flow Restrictor Valve Replacement

WARNING

Closely read and adhere to the following instructions whenever you remove and install the flow restrictor valve. Failure to properly install the flow restrictor valve can result in serious injury or death to personnel or damage to the equipment.

The flow restrictor valve, Figure 4-7, is located inside the base of the hydraulic lift cylinder. If the flow restrictor valve needs to be removed or replaced, it is important that it be properly reinstalled.

1. 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 th e 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 o il 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.

Figure 4-7. Flow Restrictor Valve

4-8

4 — MAINTENANCE

Valve Operation

Refer to Figure 4-8 for valve locations and the hydraulic diagram in Figure 4-15. The valves are labeled on the valve manifold as A, B, C, FA and FB. The platform down valve is located at the base of the lift cylinder.

Steering Valve Right (A): Pressing the

ENABLE and the thumb steering switch to the

right energizes the steering valve, causing the steering cylinder to extend and execute a right turn.

Steering Valve Left (B): Pressing the

ENABLE and the thumb steering switch to the left

energizes the steering valve, causing the steering cylinder to retract and execute a right turn.

Lift Valve (C): Pressing the

ENABLE and UP pushbuttons energizes the platform lift

valve, causing the lift cylinder to extend. Down Valve (D): Pressing the

ENABLE and DOWN pushbuttons energizes the platform

down valve. Oil flows back into the reservoir, causing the lift cylinder to retract. Steering Speed Adjust Valve (FA): Adjust to control left turn – steering cylinder

retraction rate. Steering Speed Adjust Valve (FB): Adjust to control right turn – steering cylinder

extension rate.

Figure 4-8. Valve Operation

4-9

ESP 19

Hydraulic Cylinder Repair

CAUTION

Hydraulic cylinder removal requires extensive disassembly of the ESP 19 lift vehicle. Contact Bil-Jax for assistance before removing the hydraulic cylinder.

Hydraulic Cylinder Removal

It is recommended that Bil-Jax be contacted for assistance before removing the hydraulic cylinder.

1. Make sure hydraulic cylinder is completely retracted and pressure is released from the system. Place a pan underneath the cylinder to catch the hydraulic oil.

2. Disconnect the hydraulic hose from the flow restrictor valve and drain the hydraulic oil from the cylinder. Remove the two bolts, washers, and nuts securing the hydraulic cylinder to the base.

3. Remove the plexiglass cover from the base.

4. Remove the mounting bolt, washer, and nut securing hydraulic cylinder to the lower mast.

5. Disconnect the two lift chains from the base mast.

6. Using a crane with at least one ton of lifting capacity, lift the lower mast section high enough to remove the clamp securing the cylinder to the base. Remove the clamp and cylinder from the unit.

7. After hydraulic cylinder maintenance is completed, reinstall the cylinder in the reverse order of removal.

4-10

4 — MAINTENANCE

Hydraulic Cylinder Repair Procedure

Perform the following procedure to repair the hydraulic lift cylinder. Refer to Figure 4-

1. Remove gland nut (1) from cylinder jacket (2). If worn, replace gland nut (1), o-ring (3), packing ring (4), and rod wiper (5) with a new gland nut assembly.

2. Remove piston rod (6) and wear ring (7).

3. Inspect piston rod (6) and wear ring (7) for gouges, scratches, and wear. Replace worn or damaged components.

4. Thoroughly clean the inside surface of cylinder jacket (2).

5. Lubricate wear ring (7) with clean hydraulic oil or petrolatum. Slide piston rod (6) with wear ring (7) into cylinder jacket (2).

6. Lubricate o-ring (3), packing ring (4), and rod wiper (5) with clean hydraulic oil or petrolatum.

7. Slide gland nut (1) onto piston rod (6). Fully thread the gland nut into cylinder jacket (2).

8. Reinstall the hydraulic cylinder in the lift vehicle and reconnect the hydraulic hose.

9. Refill the hydraulic reservoir.

10. Stroke the cylinder to seat and align packing ring (4) and wear ring (7).

11. Bleed all trapped air from the hydraulic system.

1. Gland Nut

2. Cylinder Jacket

3. O-ring

4. Packing Ring

5. Rod Wiper

6. Piston Rod

7. Wear Ring

4-11

ESP 19

Figure 4-9. Hydraulic Cylinder Disassembly

4-5 ELECTRICAL SYSTEM

Regular maintenance is necessary to keep the electrical system in proper working order. Check daily all electrical wires for cuts, broken wires, potential short circuits, and any other damage.

Battery Care and Charging

The electric system is designed to provide power for a normal work shift. However, the charge life of the battery pack depends on machine usage. Plan your work to prevent unnecessary use of electrical power.

Since the power source for the machine is a battery pack, proper battery care is important. Recharge the batteries after each work shift. When the machine is not being used, the batteries should be charged at least once a week. Normal battery charging time should be 10 to 12 hours. If the battery is extremely low, charging time may be as long as 24 hours.

Clean the battery terminals every 6 months. Remove the cables from the battery posts, clean the battery posts and cable ends to shiny metal, and replace the cables. Always connect the insulated cable from the starter solenoid to the most positive post. Lubricate the outside of the battery post connections with petroleum jelly or grease.

Battery Charging Procedure

1. Remove the battery charger cord from its box and plug into a 3-prong 115V outlet, Figure 4-10.

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.

4-12

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.

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, disconnect the battery charger cord from the wall outlet, place it back into its box, and close and latch the lid. LIFT WILL NOT OPERATE IF THE LID IS NOT CLOSED SECURELY.

4-6 LIFT CHAINS AND SLIDE BLOCKS

WARNING

Do not operate a unit on which any chain assembly is damaged or in need of replacement. Operating a unit with a damaged chain can cause severe injury or death to personnel and damage to equipment.

Inspect all lift chains every 6 months. Inspect for signs of wear, split leaves, loose pins, clevis damage, and elongation. Replace any chain that is damaged in any way. Chain assemblies may be ordered from your dealer or direct from the factory. Do not operate a unit on which any chain assembly is damaged and in need of replacement.

Chain Elongation Inspection

Refer to Figure 4-11. Measure 20 pitches of chain. Twenty pitches of new chain should measure 12.5 in. (31.75 cm). Replace the chain if a 20-pitch length measures over 12.75 in. (32.385 cm).

Figure 4-11. Chain Elongation Inspection

4-13

ESP 19

Lift Chain Adjustment

1. Raise the platform to the maximum height. Then, lower the platform while someone verifies that all sheaves (pulleys) are turning and that the chains are not visibly damaged or worn.

2. Remove the plexiglass cover from the base.

3. When the platform is fully lowered, the lift chains should be equally tight. Check each lift chain at mid-span. The lift chains should flex about 1/2 to 3/4 inch (12 to 19 mm), but there should be no loose play.

4. 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).

5. 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.

6. If a single lift chain requires frequent adjustment, the clevis lock nut is probably worn. Replace any clevis lock nut that does not hold position during use.

7. Replace the plexiglass cover.

LOCK

NUT

LIFT

CHAINS

CLEVIS

LIFT

CHAINS

CLEVIS

Figure 4-12. Lift Chains Adjustment

LOCK

NUT

4-14

4 — MAINTENANCE

Slide Block Adjustment

Annually check for wear on the slide blocks and replace or retighten as necessary. If the lift exhibits excessive mast sway, it is probable that the slide blocks need adjustment. The slide blocks should be adjusted so that there is no air gap between the slide block and the mast the slide block is moving against. There are 16 slide blocks, - 8 upper and 8 lower. Three upper slide blocks are shown in Figure 4-13.

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. Loosen, but do not remove the slotted hex screw securing the slide block.

2. 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.

3. After all adjustments are made, fully extend the lift. If the platform can be raised and lowered without hesitation or stopping, the blocks are properly adjusted.

Figure 4-13. Slide Blocks Adjustment

NOTE: The plastic slide blocks in the mast are made of a bearing material

which has a high degree of lubricity and need only be kept clean. However, precautions should be taken to ensure that the paths along which the blocks move are kept clean and lightly lubricated with a dry type silicon lubricant.

4-15

ESP 19

4-7 TROUBLESHOOTING

Table 4-3. Troubleshooting Chart

Problem Cause Correction

1. Lift vehicle controls do not work at upper or lower control box.

a. Master power switch turned off. b. Low battery power or faulty battery

circuit.

c. Emergency stop button engaged

(pushed in).

d. Battery ground or in-series battery

cable loose.

e. Circuit breaker tripped.

f. Battery cable or equipment ground

lead loose or corroded.

a. Turn on master power switch. b. Recharge batteries per paragraph 4-4.

Check for faulty battery or cables if red battery charger LED is lit.

c. Rotate emergency stop buttons clock-

wise to disengage.

d. Check for and repair loose battery

connections or ground fault.

e. Reset breaker. If breaker trips again,

locate and correct short to ground in power circuit wiring.

f. Clean and reconnect loose or cor-

roded battery cable or ground lead.

2. Lift vehicle controls do not work at upper control box, but do work at lower control box.

3. When UP function is se- lected, pump motor runs but will not raise the platform.

a. Emergency stop button engaged

(pushed in) on upper control box.

b. Upper control box cable connectors

unplugged.

c. Upper control box cable connectors

plugged into wrong receptacles.

d. Enable pushbutton switch or wiring

faulty.

a. Hydraulic oil level low in reservoir.

b. More than 450 lbs. on lift platform. c. Emergency lowering valve open. d. Up valve solenoid or solenoid wiring

faulty.

e. Down valve sticking open or leaking. f. UP switch or UP switch wiring faulty.

g. Mast sections dirty; slide blocks

binding.

h. Internal leakage in hydraulic cylinder.

a. Rotate emergency stop buttons clock-

wise to disengage.

b. Plug in cable connectors at front of

upper control box.

c. Plug in cable connectors in opposite

receptacles at upper control box.

d. Repair wire break or replace faulty

switch.

a. Check reservoir level. If low, check

for oil system leakage. Refill reservoir and bleed air from hydraulic system

per instructions in paragraph 4-3. b. Ensure load is 450 lbs. or less. c. Close emergency lowering valve. d. Check voltage at up valve solenoid. If

no voltage, check wiring. If voltage,

exchange solenoids and recheck func-

tion; replace solenoid if faulty. e. Repair or replace down valve. f. Check for lighted UP LED when up

switch is engaged. If LED does not

light, signal is not reaching main con-

troller; repair wire break or replace

faulty switch. g. Clean and lubricate masts with dry

silicone. If needed, adjust slide bocks

per paragraph 4-5. h. Check cylinder housing for heat

buildup due to leakage. If leakage is

indicated, repair or replace hydraulic

cylinder.

4-16

4 — MAINTENANCE

Table 4-3. Troubleshooting Chart (Continued)

Problem Cause Correction

4. ENABLE pushbutton blinks when pressed.

a. ENABLE pushbutton has been

pressed down for longer than 5

a. Release ENABLE pushbutton and

press again. seconds without a function being selected.

b. Joystick potentiometer out of adjust-

ment (will not return to center).

b. Adjust joystick forward/reverse travel

potentiometer for null drive signal

with joystick at center.

c. Did not press ENABLE pushbutton

first before moving joystick to for-

c. Release ENABLE pushbutton and

press again before moving joystick. ward or reverse drive.

5. When DOWN function is selected, lift platform will not descend.

d. Tried to drive forward or reverse and

raise or lower the platform at the same time.

a. Down valve solenoid or solenoid

wiring faulty.

b. Down valve sticking; does not open. c. DOWN switch or DOWN switch

wiring faulty.

d. Underguard switches activated

d. Release ENABLE pushbutton and run

only one function (drive or lift) at a time.

a. Check voltage at down valve sole-

noid. If no voltage, check wiring. If voltage, exchange solenoids and recheck function; replace solenoid if

faulty. b. Repair or replace down valve. c. Check for lighted DOWN LED when

down switch is engaged. If LED does

not light, signal is not reaching main

controller; repair wire break or re-

place faulty switch. d. Remove object from underguard or

readjust/replace switches.

6. Alarm is sounding; lift UP and travel functions stopped

a. Lift vehicle more than 1 degree out of

level.

a. Lower lift platform and drive lift

vehicle to level area.

working.

7. When joystick is moved, lift vehicle will not travel.

a. Wheels blocked.

b. Free wheel lever in free wheel (tow)

position.

c. Joystick or joystick wiring faulty.

d. Main controller or main controller

signal wiring faulty.

e. Motor controller 24-volt power cable

disconnected.

a. Check wheels for blocking; remove

travel obstacle.

b. Move free wheel lever back to drive

position.

c. Check for lighted travel LED when

joystick is engaged. If travel LED does not light, travel signal is not reaching main controller; repair wire break or replace faulty joystick.

d. Check for output voltage to motor

controller when joystick is engaged. If travel signal is not present at main controller, contact Bil-Jax for assistance. If travel signal is not present at motor controller, repair wire break.

e. Check connection of 24-volt power

cable to motor controller; repair faulty power cable connection.

4-17

ESP 19

Table 4-3. Troubleshooting Chart (Continued)

Problem Cause Correction

7. When joystick is moved, lift vehicle will not travel. (cont)

f. Motor controller, motor controller

output wiring, or transaxle drive motor faulty.

g. Transaxle drive train damaged.

f. Check for output voltage to drive

motor when joystick is engaged. If drive voltage is not present at motor controller, replace motor controller. If drive voltage does not reach drive motor, repair wire break. If drive voltage is present at drive motor, replace drive motor.

g. If transaxle drive motor runs, inspect

drive train components for damage. Repair or replace transaxle gearhouse, if damaged.

8. Wh en steering thumb switch is pressed, steering wheels do not swivel.

9. When BATTERY ON/OFF switch is turned ON, hydraulic pump starts up.

a. Wheels turned to steering limit. b. 10 Amp Motors fuse burned out on

main controller board. c. Internal steering actuator fuse. d. Thumb switch or thumb switch wiring

faulty.

e. Actuator or actuator wiring faulty.

f. Steering linkage failed.

g. Main controller faulty.

a. Motor start relay failure; relay con-

tacts fused shut.

a. Turn wheels in opposite direction. b. Replace 10 Amp Motors fuse.

c. Replace steering actuator fuse. d. Check for lighted steering LED when

thumb switch is engaged. If LED does not light, signal is not reaching main controller; repair wire break or replace faulty joystick.

e. Check actuator wiring for operating

voltage. If voltage is present, replace faulty actuator. If voltage is not present, check actuator wiring for continuity; repair wire breaks.

f. Check steering linkage for damage;

replace damaged parts. g. Contact Bil-Jax for assistance. a. Replace motor start relay.

4-18

4 — MAINTENANCE

Troubleshooting Aids

See Table 4-4 for interpreting LED indicators located on the main controller board shown in Figure 4-14. Hydraulic and PC logic diagrams are shown in Figures 4-15 and 4-16. An electrical wiring diagram is shown in Figure 4-17.

2 AMP FUSE

PWR GND

PWR POS

EASI-TXD

10 AMP FUSE

EASI-RXD

EASI-24V

EASI-GND

RS232-RXD

RS232-TXD

RS232-GND

CANH

CANL

CAN P5V

CAN GND

PUMP

PWR

RIGHT

PWR

LEFT

PWR

DOUT1

PWR

DOUT2

PWR

DOWN

PWR

HORN

PWR

HOUR METER

PWR

BUZZER

PUMP ON

RIGHT ON

LEFT ON

DOUT1 ON

DOUT2 ON

DOWN ON

UP ON

HORN ON

HRMTR ON

BUZZER ONBUZZER

MAST SWITCH

MAST DOWN

UP CTRL SELECTED

LOWERING

RAISING

MACHINE LEVEL

UNDERCAGE SAFETY

UNDERCAGE OK

DIN1 ON

DIN2 ON

JTAG DB-9

DIAG LEDS

PWR

UPPER CONTROLS

PWR

LOWER DOWN

PWR

LOWER UP

PWR

TILT SENSOR

PWR

DIN1

PWR

DIN2

PWR

SPARE +5V

AGND

AIN1

STEERING +5V

STEERING GND

STEERING IN

Figure 4-14. Main Controller Board

4-19

ESP 19

Table 4-4. Main Controller LED Indicators

Indicator Function Color

Main

Controller

Diagnostics

Error Codes

Flashes 1: Main Controller OK Flashes 2: Short or open at hydraulic pump output Flashes 3: Short circuit on the Up, Down, Horn, Buzzer, or

Red

Hour Meter outputs Flashes 4: Short circuit on one of the Steering outputs Flashes 5: Error reading/writing NVM-using default values

System

Diagnostics

Error Codes

Flashes 1: System OK Flashes 2: Tilt limit exceeded

Green

Flashes 3: Transaxle brake error Flashes 4: Unable to Communicate with Motor Controller

Flashes 5: Unable to Communicate with Joystick EASI-TXD Upper Control Transmitting 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.

4-20

4 — MAINTENANCE

Main Controller Troubleshooting

Lower Control Mode

• Up Command Does Not Work

1. Ch eck 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. Wh ile holding “UP” command switch ON,

a. Check LED labeled “RISING” on the main controller. It

should be ON, indicating the UP command switch is OK. If the LED is OFF, the UP/DOWN command switch on the machine or the wiring may be faulty.

b. LED’s labeled “PUMP ON” and “UP ON” should be ON. If

LED “RISING” is ON, but LED’s “PUMP ON” or “UP ON” are OFF, the main controller may be faulty.

• Down Command Does Not Work

1. Ch eck 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. Wh ile holding “DOWN” command switch ON,

a. Check LED labeled “LOWERING” on the main controller.

It should be ON, indicating the DOWN command switch is OK. If the LED is OFF, the UP/DOWN command switch on the machine or the wiring may be faulty.

b. LED labeled “DOWN ON” should be ON. If LED

“LOWERING” is ON, but LED “DOWN ON” is OFF, the main controller may be faulty.

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. Wh en in Upper Control Mode, LED “UP CTRL SEL” should be ON. If it’s OFF, check the Upper/Lower selector switch and make sure it’s set to Upper Control.

2. Make sure the joystick is connected to EASI POS and EASI NEG terminals of the main controller.

3. Make sure E-STOP switch on the joystick is OFF.

4. Make sure LED’s EASI-TXD and RXD on the main controller are blinking at high frequency. If not, Check Fuse F1 located on the main controller. If all of the above are O.K, the joystick may be faulty.

Joystick Does Not Drive The Motor

•

-Moving the joystick forward or reverse does not drive the machine.

1. Check if there is communication between the main controller and the joystick. If L1 and L2 LED’s on the joystick are not blinking rapidly, there is no communication. Refer to the previous step to troubleshoot "No Communication".

2. L1 and L2 on the joystick are blinking rapidly, but unit still does not drive, then:

a. Press "ENABLE" on the joystick, move the joystick forward,

Check if LED "HRMTR ON" turns on. If not on, the main controller may be faulty. Check fuse F2 on the main controller.

b. If the LED turns on, but unit still doesn't drive, the motor

controller may be faulty. Refer to the Motor Controller Troubleshooting section.

UP/DOWN, LEFT/RIGHT Commands Do Not Work

•

-When pressing UP, DOWN, LEFT, or RIGHT switches on the joystick, the machine does not respond.

2. For faulty UP command:

a. Hold "UP" switch on the joystick, make sure it lights up. If

it doesn't, the internal bulb may be blown or the switch may be faulty.

b. Press "UP" and "ENABLE" on the joystick. Make sure that

LED's "PUMP ON", "UP ON" and "HRMTR ON" turn ON. If not, the main controller may be faulty.

3. For faulty DOWN command:

4-22

4 — MAINTENANCE

a. Hold "DOWN" switch on the joystick, make sure it lights up.

If it doesn't, the internal bulb may be blown or the switch may be faulty.

b. Press "DOW N" and "ENABLE" on the Joystick. Make sure

LED's "DOWN ON" and "HRMTR ON" turn ON. If not, the main controller may be faulty.

4. For faulty LEFT/RIGHT command: a. Hold "ENABLE" & "LEFT" switch on the joystick, check

LED’s "PUMP ON" & "LEFT ON" turn ON. If not, the "LEFT" switch on the joystick or the main controller may be faulty.

b. Ho ld "ENABLE" & "RIGHT" switch on the joystick, check

LED’s "PUMP ON" & "RIGHT ON" turn ON. If not, the "RIGHT" switch on the joystick or the main controller may be faulty.

Joystick Switches Work But Do Not Light Up

•

-"ENABLE", "UP", "DOWN", steering LED’s do not light up, but the functionality is fine.

1. "ENABLE", "UP", "DOWN" switches work but the bulbs inside the

switches won't turn ON possibly because of internal bulbs being blown or the wiring to the bulb may be loose.

2. Steering angle LED display won't turn ON due to possible following

reasons:

a. Blown LED's (very unlikely that all LED's are blown), if

none turn ON, the joystick may not be providing proper signal.

b. Faulty wiring between the LED board and the joystick board

or a loose connection.

c. The wiring between the steering angle sensor to the main

controller (Steering IN) may be faulty.

4-23

ESP 19

Motor Controller Troubleshooting

1. Mak e sure there is Power present on the Motor Controller unit. L2 should be ON, if not ON, check to see if the power cable is properly connected to the unit. If still no power to the un it, please check resistances between the following terminals. If any resistance fails, the motor controller is faulty.

a. GND and POWER Very High ~ M ohms b. GND and MOTOR + Very High c. GND and MOTOR - Very High d. POW ER and MOTOR + Very High e. POWER and MOTOR - Very High

2. Mak e sure the unit is communicating with the main controller (refer to the Blink Codes). L7 and LED1 on the motor controller should be blinking at high frequency. If not, check wiring between J12 of the motor controller to the main controller. Check fuse on the motor controller.

3. Make sure the brake is ok.

a. L5 on the Motor Controller is ON and L6 is OFF. If L5 is

OFF, it means that the brake's manual override system is activated. In such case, the motor controller will not drive the motor. Manual override lever situated on the brake should be disengaged in order for the motor controller to drive the motor.

4. L6 should only turn ON when the joystick is moved either forward or reverse. If L6 remains ON or OFF regardless of the position of the joystick, the motor controller may be faulty.

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 pause, long beep, long pause…)

Be__Be__Be__Be__ (short beep, pause, short beep, pause…)

B_B_Be_B_B_Be_ (very short beep, short pause, very short beep,

short pause, short beep, short pause…) B_Beeeeep_B_Beeeeep_B_Beeeeep_

(very short beep, short pause, very long beep, short pause, very short beep, short pause…)

Beeeeeeeeep (continuous beep)

Normal Motion Indicator – Machine operating properly.

Machine Out of Level With Platform Down – Platform will not raise.

Machine Out of Level With Platform Raised – Platform will not raise and machine will not drive.

Object On Underguard – Platform will not lower and machine will not drive.

Low Battery Warning – Immediately drive machine to recharging area and plug-in to wall outlet.

4-25

ESP 19

B02-03-0038 Steering Cylinder

B02-03-0040 Lift Cylinder

C2C1

FB FA

B02-05-0034

Pump Unit

Figure 4-15. Hydraulic Diagram

4-26

4 — MAINTENANCE

Raise

Switch

1.5 Deg Level

Sensor

1 Deg

Level

Sensor

15’

LSI

Main

Control

Board

2 Amp

Gate

Switch

E-Stop

Enable

Platform Raise

Right Turn

LSI

UCIPlatform Lower

Lower

Drive FWD

Drive REV

Steer Right

Steer Left

FWI

Upper Control Box

Beacon Lamp

Start Solenoid

Up Valve

Down Valve

Start Solenoid

Steering

Sensor

Under

Cage

Mast

Switch

110v Box

Switch

110v Switch

Box Relay

SSI

UCI

MSI

Master

Power

Amp

Left Turn

Forward

Reverse

LSI

Free Wheel Switch

MSI

FWI

SSI

Controller

Start

Solenoid

FWI

Motor

Right Solenoid

Start Solenoid

Left Solenoid

Parking

Brake

Transaxle

Motor

Hydraulic

Pump Motor

Figure 4-16. PC Logic Diagram

4-27

ESP 19

Cntls

Lower

Cntls

Upper

E-Stop

Down

Protection

Under Cage

Beeper

EASI RXD

Buzzer (-)

PWR

Hour M (-)

PWR

Horn (-)

PWR

Down

PWR

DOUT 2

PWR

DOUT 1

PWR

LEFT

PWR

Right

PWR

PUMP

10 AMP

Converter

24V DC-DC

G B

Rotary

Steering

1.0 W

1.5

15'

Switch

Cut Out

Mast

Switch

STEERING GND STEERING +5V AINI AGND SPARE +5V

PWR DIN 2 PWR

DIN 1 PWR UNDER CAGE

PWR TILT SENSOR PWR L CNTLS UP PWR L CNTLS DN

PWR UPPER CNTLS PWR MAST SW

CAN GND CAN P5V CAN L CAN H

EASI TXD

MOTOR

CAN P5V

Y/Gr

CAN HI

CAN GND

(-)

CAN LO

Power

BATTERY

Upper Control Box

BRAKE

(+)

Comm

Light

Gate Switch

+ 24V

FW SWITCH

MOTOR

+ 24V

(+)

Free

Com

NO NC

Wheel

Switch

Brake

8586

87a

Beeper

EASI GND EASI 24V

5 6 7

2 AMP

1 2 3

Battery

Gage

W B

Flashing

Light

RWB

To Batteries

Master

Power

Gate Switch

Switch

PWR POS

PWR GND

Cord Box

Switch

Pump

Left

Right

8586

87a

Down

Valve

Lift Cylinder

Figure 4-17. Electrical Layout

4-28

4 — MAINTENANCE

BATTERY

18-5

MOTOR CONTROLLER

Motor

BATTERY

(-)

(+)

CAN P5V

CAN GND

CAN-HI

CAN-L0

Power

(+)

Brake

+24V

FW SWITCH

+24V

Y/Gr

2 1 2

COM

WIRE

TRANSAXLE

BRAKE

FREEWHEEL

SWITCH

MASTER

POWER

SWITCH

START

SOLENOID

R B

24 VOLT

BATTERY

CHARGER

Figure 4-18. Drive Wiring Diagram

110 VOLT

CHARGING

CORD

PUMP UNIT

4-29

ESP 19

Steering Display

Right

Left Turn

Turn

Enable

E-Stop

R B

Figure 4-19. Upper Control Wiring Diagram

Down

4-30

Replacement Decals

Refer to Table 5-1, and Figures 5-1, 5-2, and 5-3 for descriptions and locations of decals on the ES

P 19.

Table 5-1. Replacement Decals

Decal No. Description of Decal

B06-00-0009 Warning...Moving telescopic

masts will create...

B06-00-0034 Danger...During charging, explo-

sive oxyhydrogen gas... B06-00-0037 Lubricate Semi-Annually 4 B06-00-0066 Insert Forks Minimum 32”… 2 B06-00-0068 SAE 10W Hydraulic Oil 1 B06-00-0138 Warning...(Maintenance decal) 1 B06-00-0146 Danger...(High voltage line warn-

ing) B06-00-0173 Safety harness lanyard attachm

point B06-00-0192 Operation and service manual

inside B06-00-0225 Warning...Stay clear when raising

or lowering B06-00-0289 Check level with cage fully down 1 B06-00-0297 Forklift Pockets 1 B06-00-0339 ness and 1 Warning…Full Body Har

Lanyard…(Not used on lifts with

fully enclosed platform) B06-00-0349 Operation Instructions for Battery

Charger B06-00-0359 Serial Number Tag (Not available

as replacement part) B06-00-0382 Caution...This machine designed

and manufactured...

Qty

ent 2

Decal No. Description of Decal Qty

B06-00-0383 Danger...Failure To Comply With

The Following... B06-00-0390 Trans Axle Instruction 2 B06-00-0453 ESP 19 Horizontal Logo 1 B06-00-0454 ESP 19 Vertical Logo 2 B06-00-0455 Bil-Jax (Vertical transfer type

decal) B06-00-0456 800-225-3765 For Service 1 B06-00-0457 Warning...Stay clear while wo

platform is raised B06-00-0458 Maximum Capacity 150 lbs. 2 B06-00-0459 For Bicycles Only 2 B06-00-0460 Caution (Black on Yellow) 2 B06-00-0461 Operation Instructions for ESP 19 4 B06-00-0462 Battery Charger Cord Box 1 B06-00-0463 Do Not Pick Machine Up From

This End B06-00-0464 Emergency Lowering 1 B06-00-0469 Warning...This is not a work

platform or a shelf B06-00-0470 Low battery alarm 1 B06-00-0492 Turn Master Power Switch Off… 1 B06-00-0500 Maximum Capacity...450 lb. 4 B06-00-0501 Tip Over Hazard 2 B06-00-0509 Wheel Loading 2 B06-00-0532 Slope Warning 2

rk 1

5-1

ESP 19

OPERATION INSTRUCTIONS FOR ESP 19

1. Read and follow safety precautions and all responsibilities sections set forth in the operators manual

2. Make sure the lift is on a firm and level surface and that there are no potential hazards such as overhead obstructions or electrically charged conductors, use the lift where such hazards exist.

3. Check the lift for damaged or worn parts and repair or replace as necessary.

4. Check to be sure that the cage is properly attached to the lift.

5. Turn master power switch to on.

6. Check to be sure all safety devices are functioning properly.

7. To operate lift from the ground turn and hold lower control switch to "lower control" setting then select either up or down function.

8. To operate lift from the platform, turn lower control switch to "upper control" setting.

9. 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 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 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.

Pressthesteeringthumbswitchonthetopofthejoystickinthedirectionyouwishthelifttoturn(either right or left).

The joystick and steering thumb switch may be operated simultaneously for smooth maneuvering.

DO NOT

This lift is equipped with a level sensor that will prevent the lift from raising or driving with platform elevated while on an unlevel surface. If the lift fails to raise or drive while elevated, lower platform immediately.

CTG

hold

attempt to operate the drive function and the raise/lower function at the same time.

DO NOT

B06-00-0461

FAILURE TO COMPLY WITH THE FOLLOWING SAFETY INSTRUCTIONS OR ANY OTHER IMPROPER

USE OF THIS EQUIPMENT WILL RESULT IN SERIOUS INJURYOR DEATH.

BEFORE USE:

This equipment to be used by competent, fully trained, and authorized personnel only.

Operator must read and understand owner's manual and all decals before operating. It is the operator's responsibility to comply with all warnings and instructions. NEVER TAKE CHANCES - DO NOT operate this lift if you are under the influence of

drugs or alcohol, or if you fell dizzy,ill or unsteady in any way. ALWAYSsurvey the job site and identify all potential hazards.

DO NOT override or alter any safety devices or make any modifications that would

affect the original design of the lift. Inspect unit for damaged or worn

parts. DO NOT use until such parts are replaced. DO NOT use if lift is not working properly. DO NOT use when exposed to

wind, rain, snow or ice. Check all safety devices for

proper function prior to each use. DO NOT use without entry gate in

the closed position unless operator is wearing a full body harness and lanyard and with the lanyard attached to factory provided attachment point.

DURING USE:

DO NOT raise platform while on uneven, soft, or sloped surfaces.

DO NOT DRIVE lift onto uneven,

soft, or sloped surfaces while elevated. DO NOT climb up or down masts.

Work only within the platform guard rail area and do not attempt to increase working height with boxes, ladders, scaffolding or any other means.

DONOT drivenear loading docks, ditches, holes, unguarded openings,open elevatedshafts or drop-offs.

DONOT usewhere lift cancome into contact with overhead obstructions such as electrical wires,cables, ropesor overor overhangs, etc..

DO NOT exert horizontal force to platform while performing work.

DO NOT move lift if you do not have a clear view of the path of travel.

DO NOT exceed manufacturer's recommended load capacity.

DO NOT stand or sit on guard rails..

DO NOT lean out over guard rails to perform work.

DO NOT raise or lower lift until you are certain all personnel are clear.

DO NOT use near cranes or other moving vehicles.

DO NOT leave keys in machine while unattended.

DO NOT allow flames, sparks or embers near batteries and do not smoke near batteries. Batteries produce highly flammable gases which can explode.

OWNERS & OPERATORS ARE RESPONSIBLE FOR INSPECTION, MAINTENANCE, TRAINING, AND OPERATION AS REQUIRED BY THE OWNERS MANUAL AND THE

ANSI A92.6 STANDARD (IN EFFECT AT DATE OF MANUFACTURE).

AERIAL WORK PLATFORMS

IF YOU HAVE NOT BEEN PROVIDED WITH SAFETY LITERATURE, OR FOR ANY QUESTIONS CONCERNING THE SAFE USE OF THIS EQUIPMENT, CALL 419/445-9675.

B06-00-0383

OPERATION AND SERVICE

MANUAL INSIDE

COFC B06-00-0192

B06-00-0192

B06-00-0461

B06-00-0383UOT

E.S.P. 19

ESP-

19’6

24V DC

Patents Pending

B06-00-0359

El ectr ic

St oc k

Pi cke r

800-225-3765

CTG

B06-00-0454

This machine is designed and manufactured in compliance with the ANSI A92.6 standard in force on the date of manufacture. Dealers, owners, users, operators, lessors, and lessees are responsible for inspection, maintenance, training, and operation as required by A92.6 and the owners manual.

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 improper use of this machine shall exempt bil-jax, inc. from any liability for any resulting injuries or damage.

B06-00-0382UOT

B06-00-0382

B06-00-0034

B06-00-0289

B06-00-0349

B06-00-0173

B06-00-0138

B06-00-0453

B06-00-0037

Normal Drive

B06-00-0146

FreeWheel

B06-00-0390

Transaxle

B06-00-0009

STAY CLEAR

WHILE RAISING

OR LOWERING

CCFO

B06-00-0225

Figure 5-1. Replacement Decals

5-2

5 — REPLACEMENT DECALS

CTG © Bil-Jax, Inc. 2004 B06-00-0462

BATTERY CHARGER CORD BOX

 To charge batteries, plug cord

into 3-prong 115V outlet only.

 Cord must be placed into box

and lid closed and latched or lift will not operate.

WARNING

STAY CLEAR WHILE WORK PLATFORM IS RAISED

• DO NOT work, stand, sit or place any part of your body under the work platform while platform is raised.

• DO NOT allow children to stand, sit or play on this lift.

• DO NOT place any objects on the base of the lift while the platform is raised.

FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN SERIOUS CRUSHING INJURY OR DEATH.

CTG/CTA B06-00-0457 © Bil-Jax, Inc. 2005

B06-00-0457

B06-00-0462

CTG

B06-00-0458

CTG

B06-00-0456

B06-00-0455

B06-00-0068

ARNINGARNING

ARNING

ARNINGARNING

Tip Over Hazard

DO NOT exceed rated capacity. 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.

UTA B06-00-0500

Rated Number of Occupants: One (1) Maximum Capacity: 450 lbs. / 204 kg

ToolTray (150 lb. max) Platform (300 lb. max)

450 lbs. / 204 kg

Bike Rack (50 lb. max) Platform (400 lb. max)

450 lbs. / 204 kg

Rated Horizontal Side Force: 0 lbs.

B06-00-0500

DO NOT PICK MACHINE UP FROM THIS END

GTG B06-00-0463© Bil-Jax, Inc. 2004

B06-00-0463

NOTICE

WARNING

THIS IS NOT A WORK PLATFORM OR A SHELF

• DO NOT stand or sit on this mast cover.

• DO NOT use this mast cover as a work platform.

DO NOT use this mast cover as a shelf or workbench by placing

•

tools, equipment, merchandise or any other objects on it.

FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY CAUSE THE MAST COVER TO FAIL AND RESULT IN SERIOUS INJURY OR DEATH.

CTA B06-00-0469

B06-00-0469

UTIONUTION

UTION

UTIONUTION

MAXIMUMWHEEL LOADING

Front 950 lbs (431 kg) per wheel Rear 900 lbs (408 kg) per wheel

GTA B06-00-0509

B06-00-0509

FRONT REAR

1. Turn master power switch off when not in use.

Failure to turn power off will drain batteries.

2. Turn control box off before turning master power switch on.

B06-00-0456

CTG

CAUTION

CTG

B06-00-0460

B06-00-0066

B06-00-0297

EMERGENCY

LOWERING VALVE

PULL AND HOLD

TO LOWE R

ATG B06-00-0464

B06-00-0464

B06-00-0492

B06-00-0339

B06-00-0460

B06-00-0492

B06-00-0458

B06-00-0459

WARNING

This machine must not be operated on any slope greater than 5 degrees.

Failure to follow these instructions will result in serious injury or death.

ITA B06-00-0532

©Bil-Jax, Inc. 2005

B06-00-0532

LOW BATTERY ALARM

When audible alarm sounds continuously, lift batteries must be recharged immediately.

CTA B06-00-0470

B06-00-0470

ARNINGARNING

ARNING

ARNINGARNING

Tip Over Hazard

Battery weight is critical for lift stability.

This lift must be equipped with two batteries having a total combined minimum weight of 165 lbs.

DO NOT replace with batteries of lesser weight.

Use only Bil-Jax authorized replacement parts.

UTA B06-00-0501

B06-00-0501

B06-00-0459

5-3

Figure 5-1. Replacement Decals

ESP 19

0469

0500

0532

0461

0455

0454

800-225-3765

CTG

B06-00-0469

WARNING

THISIS NOTA WORKPLATFORM ORA SHELF

•DONOT standorsit onthismast cover. DONOT usethismast coverasa workplatform.

tools,equipment,merchandise oranyotherobjects onit.

DONOT usethismast coverasa shelforworkbenchby placing

FAILURETOCOMPLYWITH THESEINSTRUCTIONSMAYCAUSE THE

MASTCOVERTO FAILANDRESULTIN SERIOUSINJURYOR DEATH.

CTA

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IFTWILLNOTOPERATE

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OTCLOSED

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OPERATIONINSTRUCTIONSFORESP 19

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IFTWILLNOTOPERATE

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8.To t

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9.Make

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Elec

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Stock

Picke

TipOverHazard

DONOTexceedratedcapacity. DONOTexerthorizontalsideforceto theplatformwhileelevated. Failuretocomplywiththe preceding instructionsmayresultinthe machine tippingovercausingserious injuryor deathtotheoperator.

UTA B06-00-0500

0009

0146

0173

BikeRack(50lb.max) Platform(400lb.max)

450lbs./204kg

Or RatedNumberof Occupants:One(1) MaximumCapacity:450 lbs./204kg

ToolTray(150lb.max) Platform(300lb.max)

450lbs./204kg

ARNINGARNING ARNING

ARNINGARNING

reater

RatedHorizontalSide Force:0lbs.

tnotbe

WW WW

2 3

-05 0

-0

WARNING

06 B

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these chine on

illresultin

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degrees.

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than

injuryo ailure F instructio serious

ITA

0500

0532

0458

(Top of Bike Rack Arms)

0459

0461

B06-00-0458

CTG

0458

0192 (Manual Tube)

0460 (Both Sides)

0500

0390

BikeRack(50lb.max) Platform(400lb.max)

450lbs./204kg

RatedNumberof Occupants:One(1) MaximumCapacity:450 lbs./204kg

ToolTray(150lb.max) Platform(300lb.max) 450lbs./204kg

ARNINGARNING ARNINGARNING

ARNING

RatedHorizontalSide Force:0lbs.

WW WW

0509

MAXIMUMWHEEL

UTIONUTION

UTION

UTIONUTION

Front950lbs (431kg)perwheel Rear900lbs (408kg) perwheel

GTA B06-00-0509

TipOverHazard

DONOTexceedratedcapacity. DONOTexerthorizontalsideforceto theplatformwhileelevated.

overcausingserious injuryor

Failuretocomplywiththepreceding

instructionsmayresultinthemachine tipping deathtotheoperator.

UTA B06-00-0500

FRONT REAR

WHILE RAISING

C C F

OR LOWERING

STAY C LEAR

B 0 6

0 2 2 5

0297

0066

0501

Between Fork Pockets

(

Below Underguard

)

(Both Sides)

0457

0225

0066

(On Underguard)

0037

(On Pillow Blocks)

Figure 5-2. Decal Locations, Side View

5-4

5 — REPLACEMENT DECALS



charge

batteries,

plug

cord

into

-prong

15V

outlet

only



ord

must

placed

into

box

and

lid

closed

and

latched

lift

will

not

operate.

0009

WARNING

0138

0470

0359

0464

0492

0390

0461

0455

0454

800-225-3

CTG

WARNING

NOTICE

1.Turnmaster powerswitch offwhennot inuse.

Failuretoturn poweroff willdrainbatteries.

2.Turncontrol boxoffbefore turningmasterpower

switchon.

CAUTION

B06-00-0492

0382

0462

0383

ARNINGARNING

ARNING

ARNINGARNING

ightiscritical

TipOver Hazard

nimum

atteryw

i B forliftstability.

inedm b

Thisliftmust beequipped

ight.

with

thtwobatterieshaving

i w atotalcom

ightof165lbs.

lesserw

Treplace

acement D batteriesof Useonly Bil-Jax authorizedrepl

parts.

Electr ic

Stock

Picke

DANGER

765

UTA B06-00-0501

B06-00-0456

CTG

0501

0453

0456

0037

DO NOT PICK MACHINE UP FROM THIS END

ON STEERING

(

PIVOT BLOCK

0289

ON RESERVOIR

(

INSIDE

)

0068

0349

INSIDE

(

DOOR

)

0034

INSIDE

(

DOOR

ON FRAME BEHIND

(

DOOR BY RESERVOIR

)

0463

)

Figure 5-3. Decal Locations, Rear View

5-5

ESP 19

5-6

Parts List

6-1

ESP 19

6-1 FIRST MOVING MAST PARTS LIST

Refer to Table 6-1 for the parts list for the first moving mast.

Figure 6-1. First Moving Mast

6-2

6 — PARTS LIST

Table 6-1. First Moving Mast Parts List

Item No. Part No. Description Qty

1 B16-01-0044 First Moving Mast Weldment 1 2 0090-0770 Pin, Cotter 3/16 x 1-1/2 in. 2 3 B36-01-0002 Axle, Sheave 3 4 0090-0425 Washer, Flat, 5/8 in. 6 5 B26-00-0009 Sheave Assembly, Chain 2 6 0090-0188 Nut, Nylon Lock, 3/8-16 1 7 0090-0422 Washer, Flat, 3/8 in. 1 8 B40-00-0003 Cable, Steel, 3/16 in. 1

9 0090-0389 Screw, Set, 1/2-20 x 1/2 in. 8 10 0090-0403 Screw, Sheet Metal, #10 x 1 4 11 B31-00-0001 Slide Block, Plastic 4 12 B40-01-0008 Chain, Lift 2 13 0090-0860 Pin, Cotter 2 14 B04-07-0078 Pin, Clevis 2 15 B04-07-0088 Clevis, Upper 2 16 0090-0192 Nut, Nylon Lock, 1/2-13 2 17 0090-0042 Screw, Cap, 3/8-16 x 1 in. 6 18 0090-0210 Washer, Lock, Split, 3/8 in. 6 19 0090-0162 Nut, Hex, 3/8-16 6 20 B24-01-0008 Mounting Bracket 1 21 B29-00-0033 Mast Stop 1 22 B29-00-0078 Bracket, Weldment 1 23 B26-00-0001 Sheave, Cable 1 24 0090-0147 Pin, Cotter 1

* 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

6-2 SECOND MOVING MAST PARTS LIST

Refer to Table 6-2 for the parts list for the second moving mast.

Chain from Base Mast

Figure 6-2. Second Moving Mast

6-4

6 — PARTS LIST

Table 6-2. Second Moving Mast Parts List

Item No. Part No. Description Qty

1 B16-01-0040 Second Moving Mast Weldment 1

2 0090-0770 Pin, Cotter, 3/16 x 1-1/2 in. 2

3 B36-01-0002 Axle, Sheave 3

4 0090-0425 Washer, Flat, 5/8 in. 6

5 B26-00-0009 Sheave Assembly, Chain 2

6 0090-0389 Screw, Set, 1/2-20 x 1/2 in. 8

7 0090-0403 Screw, Sheet Metal, #10 x 1 in. 4

8 B31-00-0001 Slide Block, Plastic 4

9 B40-00-0003 Cable, Steel, 3/16 in. 1 10 B40-01-0008 Chain, Lift 4 11 B04-07-0078 Pin, Clevis 4 12 B04-07-0087 Clevis, Lower 2 13 0090-0042 Screw, Cap, 3/8-16 x 1 in. 6 14 B29-00-0033 Mast Stop 1 15 0090-0210 Washer, Lock, Split, 3/8 in. 6 16 0090-0162 Nut, Hex, 3/8-16 6 17 0090-0860 Pin, Cotter 4 18 B29-00-0078 Bracket, Weldment 1 19 0090-0147 Pin, Cotter, 1/8 x 1-1/4 in. 1 20 B24-01-0008 Mounting Bracket 1 21 B26-00-0001 Sheave, Cable 1 22 B04-07-0088 Clevis, Upper 2 23 0090-0192 Nut, Nylon Lock, 1/2-13 2 24 0090-0422 Washer, Flat, 3/8 in. 1 25 0090-0188 Nut, Nylon Lock, 3/8-16 1

* B03-00-0009 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

6-3 THIRD MOVING MAST PARTS LIST

Refer to Table 6-3 for the parts list for the third moving mast.

Chain from 1 Mast

Figure 6-3. Third Moving Mast

6-6

6 — PARTS LIST

Table 6-3. Third Moving Mast Parts List

Item No. Part No. Description Qty

1 B16-01-0041 Third Moving Mast Weldment 1

2 0090-0770 Pin, Cotter, 3/16 x 1-1/2 in. 2

3 B36-01-0002 Axle, Sheave 3

4 0090-0425 Washer, Flat, 5/8 in. 6

5 B26-00-0009 Sheave Assembly, Chain 2

6 0090-0389 Screw, Set, 1/2-20 x 1/2 in. 8

7 0090-0403 Screw, Sheet Metal, #10 x 1 in. 4

8 B31-00-0001 Slide Block, Plastic 4

9 B40-00-0003 Cable, Steel, 3/16 in. 1 10 B40-01-0008 Chain, Lift 2 11 B04-07-0078 Pin, Clevis 2 12 B04-07-0087 Clevis, Lower 2 13 0090-0042 Screw, Cap, 3/8-16 x 1 in. 6 14 B29-00-0033 Mast Stop 1 15 0090-0210 Washer, Lock, Split, 3/8 in. 6 16 0090-0162 Nut, Hex, 3/8-16 6 17 0090-0860 Pin, Cotter 2 18 B29-00-0078 Bracket, Weldment 1 19 0090-0147 Pin, Cotter, 1/8 x 1-1/4 in. 1 20 B24-01-0008 Mounting Bracket 1 21 B26-00-0001 Sheave, Cable 1

* B03-00-0009 Chain Assy, includes items 10, 11, 12, 17 and

Upper Clevis & 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 the forth moving (platform) mast.

Chain from 2 Mast

Figure 6-4. Fourth Moving (Platform) Mast

6-8

6 — PARTS LIST

Table 6-4. Fourth Moving (Platform) Mast Parts List

Item No. Part No. Description Qty

1 B16-01-0042 Fourth Moving (Platform) Mast Weldment 1

2 0090-0014 Screw, Cap, 1/4-20 x 2-1/4 in. 2

3 B01-09-0026 Grommet, Plastic 2

4 B29-00-0160 Bracket, Outreach 1

5 0090-0206 Washer, Lock, Split, 1/4 in. 2

6 0090-0159 Nut, Hex, 1/4-20 2

7 B31-00-0001 Slide Block, Plastic 2

8 0090-0389 Screw, Set, 1/2-20 x 1/2 in. 4

9 0090-0403 Screw, Sheet Metal, #10 x 1 in. 2 10 B01-10-0275 Light, Caution 1 11 0090-0802 Screw, Machine, #10-24 x 7/8 in. 2 12 0090-0182 Nut, Nylon Lock, #10-24 2 13 B04-07-0087 Clevis, Lower 2 14 B04-07-0078 Pin, Clevis 2 15 0090-0860 Pin, Cotter 2 16 B40-01-0008 Chain, Lift 2 17 B40-00-0003 Cable, Steel, 3/16 in. 1 18 B07-01-2033 Edge, Top Cover 1 19 0090-0344 Screw, Threadcutting, #10-24 x 1/2 in. 4 20 B18-00-0178 Plexiglass, 1/8 in. 1 21 B24-00-0011 Frame, Aluminum, 11-1/2 in 1

* B03-00-0009 Chain Assy, includes items 13, 14, 15, 16 and

Upper Clevis & Lock Nut (shown on page 6-4)

*NOTE: It is recommended that chain parts be purchased as an assembly.

6-9

ESP 19

6-5 BATTERY COMPARTMENT PARTS LIST

Refer to Table 6-5 for the parts list for the battery compartment.

Figure 6-5. Battery Compartment

6-10

6 — PARTS LIST

Table 6-5. Battery Compartment Parts List

Item No. Part No. Description Qty

1 0090-0183 Nut, Nylon Lock, 1/4-20 7

2 B04-07-0036 Clamp, Cable/Hose, DG 16 1

3 B01-01-0144 Cable, Battery, 2 Ga. x 104 in. 1

4 B01-01-0027 Cable, Battery, 2 Ga. x 19 in. 1

5 B01-01-0130 Cable, Battery, 4 Ga. x 68 in. 1

6 0090-0188 Nut, Nylon Lock, 3/8-16 1

7 B01-10-0282 Controller, Motor 1

8 0090-0028 Screw, Cap, 5/16-18 x 3/4 in. 2

9 0090-0208 Washer, Lock, 5/16 in. 2 10 B01-01-0131 Cable, Battery, 8 Ga. x 16 in 1 11 B01-01-0014 Cable, Battery, 2 Ga. x 8 in. 1 12 B01-04-0015 Battery, Maintenance-Free, 12 Volt 2 13 B07-01-1144 Bracket, Battery Clamp 2 14 0090-0419 Washer, Flat, 1/4 in. 8 15 0090-0005 Screw, Cap, 1/4-20 x 3/4 in. 6 16 B18-00-0179 Underguard 1 17 B01-06-0053 Relay, 24 Volt DC, 20 Amp 1 18 B01-10-0135 Sensor, Level, 1.5 Degree 1 19 B01-01-0113 Plug, Level Sensor 1 20 B01-03-0061 Switch, Limit, Underguard 2 21 B01-01-0122 Cable Assembly, Underguard Switch 2 22 B07-06-5953 Clamp, Underguard 4 23 0090-0001 Screw, Cap, 1/4-20 x 1/2 in. 8 24 B39-00-0049 Spring 4 25 0090-0415 Washer, Flat, #10 8 26 0090-0182 Nut, Nylon Lock, #10-24 4 27 B04-07-0015 Clamp, Cable 1 28 0090-0232 Screw, Machine, #10-24 x 5/8 in. 4 29 B11-01-0148 Front Guard 1 30 0090-0048 Screw, Cap, 3/8-16 x 2 in. 2 31 0090-0210 Washer, Lock, Split, 3/8 in. 2 32 0090-0422 Washer, Flat, 3/8 in. 2

6-11

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

6-12

6 — PARTS LIST

Table 6-6. Hydraulic Pump Compartment Parts List

Item No. Part No. Description Qty

1 B01-10-0291 Converter, 24 Volt DC-DC 1

2 0090-0183 Nut, Nylon Lock, 1/4-20 22

3 0090-0419 Washer, Flat, 1/4 in. 6

4 0090-0005 Screw, Cap, 1/4-20 x 3/4 in. 16

5 0090-0210 Washer, Lock, Split, 3/8 in. 5

6 0090-0162 Nut, Hex, 3/8-16 1

7 B04-07-0036 Clamp, Cable/Hose, DG 16 4

8 0090-0232 Screw, Machine, #10-24 x 5/8 in. 1

9 0090-0001 Screw, Cap, 1/4-20 x 1/2 in. 2 10 0090-0415 Washer, Flat, #10 1 11 B01-06-0053 Relay, 24 Volt DC, 20 Amp 1 12 0090-0182 Nut, Nylon Lock, #10-24 1 13 B02-15-0425 Solenoid, Start, 24VDC 1 14 B01-05-0056 Charger, Battery, 40 Amp, 110 Volt AC, 60 1 15 B04-07-0015 Clamp, Tie Wrap 3 16 B01-10-0280 Control Board, Main 1 17 B01-10-0194 Alarm, Audible 1 18 0090-0422 Washer, Flat, 3/8 in. 4 19 0090-0040 Screw, Cap, 3/8-16 x 3/4 in. 2 20 B01-10-0247 Sensor, Level, 1.0 Degree 1 21 B29-00-0021 Bracket, Level Sensor Mount 1 22 B11-01-0147 Rear Guard 1 23 B30-00-0061 Bumper, Corner 2 24 0090-0344 Screw, Threadcutting, #10-24 x 1/2 in. 8 25 0090-0048 Screw, Cap, 3/8-16 x 2 in. 2 26 B02-05-0034 Pump, Hydraulic (see pages 6-26 & 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.

UP DO

LOWER CONTR

OFF

UPPER CONTR

STOP

EMERGENCY

13,14

Figure 6-7. Base

6-14

6 — PARTS LIST

Table 6-7. Base Parts List

Item No. Part No. Description Qty

1 B07-01-2003 Edge, Top Cover 1 2 0090-0344 Screw, Threadcutting, #10-24 x 1/2 in. 8 3 B05-00-0005 Tape, Foam Adhesive 32 in. 4 B18-00-0177 Plexiglass, 1/8 in. 1 5 B24-01-0013 Frame, Aluminum, 18-1/4 in. 2 6 B24-01-0009 Frame, Aluminum, 20 in. 1 7 B37-00-0006 Lock Assembly, Utility 2 8 B01-10-0194 Alarm, Audible 1

9 0090-0182 Nut, Nylon Lock, #10-24 2 10 B01-09-0003 Strain Relief, Cable 1 11 B01-02-0076 Control Box Assembly, Lower 1 12 B19-00-0040 Box, Switch, 3 Position 1 13 B01-02-0078 Contacts, Switch, Normally Open 4 14 B01-02-0079 Contacts, Switch, Normally Closed 1 15 B01-02-0082 Switch, Selector, Keyed 1 16 B01-02-0081 Switch, Pushbutton, Emergency Stop 1 17 B01-02-0080 Switch, Selector, Up/Down 1 18 B00-00-0131 Legend Plate, Upper/Off/Lower 1 19 B00-00-0130 Legend Plate, Emergency Stop 1 20 B00-00-0129 Legend Plate, Up/Down 1 21 B38-00-0001 Key, Replacement 1 22 0090-0232 Screw, Machine, #10-24 x 5/8 in. 2 23 B11-01-0146 Weldment, Base and Mast 1 24 B01-02-0060 Switch, Master Power 1 25 B00-00-0112 Faceplate, Master Power Switch 1 26 B01-10-0294 Battery Gauge/Hour Meter 1 27 B01-03-0065 Switch, Battery Charger Cord Box 1 28 B19-00-0045 Box, Battery Charger Cord 1 29 B01-01-0143 Cord, Retractable, 16-3 1 30 B04-07-0032 Clamp, Cord, DG-6 1 31 0090-0005 Screw, Cap, 1/4-20 x 3/4 in. 3 32 0090-0183 Nut, Nylon Lock, 1/4-20 3

6-15

ESP 19

6-8 BASE MAST PARTS LIST

Refer to Table 6-8 for the parts list for the base mast.

6-16

Figure 6-8. Base Mast

6 — PARTS LIST

Table 6-8. Base Mast Parts List

Item No. Part No. Description Qty

1 0090-0188 Nut, Nylon Lock, 3/8-16 1

2 0090-0422 Washer, Flat, 3/8 in. 1

3 B40-00-0003 Cable, Steel, 3/16 in. 1

4 0090-0389 Screw, Set, 1/2-20 x 1/2 in. 4

5 0090-0403 Screw, Sheet Metal, #10-24 x 1 in. 2

6 B31-00-0001 Slide Block, Plastic 2

7 B01-01-0142 Cord, Coiled, 16-2 1

8 0090-0684 Rivet, Pop, 3/16 x 1/2 in. 2

9 B40-01-0008 Chain, Lift 2 10 0090-0860 Pin, Cotter, 1.6 mm 2 11 B04-07-0078 Pin, Clevis 2 12 B04-07-0088 Clevis, Upper 2 13 0090-0192 Nut, Nylon Lock, 1/2-13 2 14 0090-0071 Screw, Cap, 1/2-13 x 2-1/2 in. 1 15 0090-0212 Washer, Lock, Split, 1/2 in. 1 16 0090-0166 Nut, Hex, 1/2-13 1 17 B02-03-0040 Cylinder, Hydraulic Lift, 1.75 in. Diameter 1 18 0090-0654 Clamp, U-bolt, 5/16-18 x 2-1/2 x 2-5/8 in. 1 19 0090-0185 Nut, Nylon Lock, 5/16-18 2 20 0090-0344 Screw, Thread Cutting, #10-24 x 1/2 in. 2 21 B29-00-0049 Retainer, Tube 2 22 B00-00-0007 Tube, Plastic 1 23 B46-00-0031 Knob, Manual Lowering Valve 1 24 B07-06-1060 Extension Rod, Manual Lowering Valve 1 25 0090-0042 Screw, Cap, 3/8-16 x 1 in. 2 26 0090-0210 Washer, Lock, Split, 3/8 in. 2 27 0090-0422 Washer, Flat, 3/8 in. 2 28 B00-00-0008 Plug, Plastic 1 29 0090-0498 Washer, Flat, 3/16 in. 2 30 B01-03-0040 Switch, Limit, Mast 1 31 0090-0182 Nut, Nylon Lock, #10-24 4 32 B01-01-0129 Cable Assembly, Mast Limit Switch 1 33 B04-07-0015 Clamp, Cable 2 34 0090-0231 Screw, Machine, #10-24 x 1/2 2 35 B01-03-0066 Switch, Limit, Level Sensor 1

* 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.

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

Item No. Part No. Description Qty

1 0090-0049 Screw, Cap, 3/8-16 x 2-1/4 in. 1

2 B30-00-0050 Pad Assembly, Torsion 1

3 0090-0188

ut, Nylon Lock, 3/8-16 2 4 0090-0065 Screw, Cap, 1/2-13 x 1 in. 1 5 B07-06-5995 Bracket, Torsion 1 6 B01-07-0015 Transaxle Assembl

6A B01-07-0012 Transaxle Subassembly 1

6B B01-07-0011 Motor Subassembly 1 6C B01-07-0013 Brake Subassembly, Electric 1

7 B07-07-5022 Key, Square, 1/4 x 2-1/4 in. 2 8 B30-00-0049 Mount, Rubbe

9 B07-06-5946 Plate, Transaxle Clamp 2

10 B25-00-0073 Pillow Bloc

2 11 0090-0422 Washer, Flat, 3/8 in. 4 12 0090-1096 Screw, Cap, 3/8-16 x 2 in. – Grade 8 4 13 0090-0367 Screw, Set, 1/4-28 x 1/4 in. 4 14 0090-1071 Screw, Set, 5/16-18 x 5/8 in. 4 15 B08-02-0015 Caster, 10 in. Drive 2 16 0090-0776 Washer, Flat, 7/16 in. 2 17 0090-0617 Screw, Cap, 7/16-14 x 1 in. 2

6-19

ESP 19

6-10 STEERING PARTS LIST

Refer to Table 6-10 for the parts list for the steering components.

4 7

29, 29A

Figure 6-10. Steering

6-20

6 — PARTS LIST

Table 6-10. Steering Parts List

Item No. Part No. Description Qty

1 0090-0239 Screw, Machine, #10-24 x 1-1/2 in. 2 2 B01-02-0105 Switch, Rotary, Steering Indicator 1 3 0090-0182

ut, Nylon Lock, #10-24 2 4 B24-01-0015 Adapter Shaft, Rotary Switch 1 5 0090-0824 Screw, Set, #10-32 x 3/16 in. 1 6 0090-0035 Screw, Cap, 5/16-18 x 3 in. 1 7 0090-0188

ut, Nylon Lock, 3/8-16 6 8 0090-0422 Washer, Flat, 3/8 in. 15 9 0090-0420 Washer, Flat, 5/16 in. 7

10 0090-0185 11 0090-0192

ut, Nylon Lock, 5/16-18 4

ut, Nylon Lock, 1/2-13 1

12 0090-0574 Washer, Flat, 1/2 in. 6 13 B00-00-0009 Fitting, Zerk, Drive-In 2 14 B11-01-0149 Support Arm, Tie Rod 1 15 0090-0881 Pin, Cotter, 5/32 x 2 in. 2 16 0090-1072

ut, Castle, 1-8 2

17 0090-0429 Washer, Flat, 1 in. 8 18 B25-00-0096 Bearing, Thrus

4 19 0090-0046 Screw, Cap, 3/8-16 x 1-3/4 in. 4 20 B07-08-0037 Knuckle, Tie Rod 4 21 B11-01-0138 Tie Rod 1 22 B07-06-5826 Support Linkage, Tie Rod 1 23 0090-0045 Screw, Cap, 3/8-16 x 1-1/2 in. 1 24 0090-1061 Screw, Cap, 5/16-18 x 2 in. – Grade 8 3 25 B11-01-0100 Linkage, Steerin

1 26 0090-0080 Screw, Cap, 1/2-13 x 4-1/2 in. 1 27 B02-03-0038 Cylinder, Hydraulic Steering, 1.5 in. Bore x 4

in. Stroke

28 0063-0492 Bushin

2 29 B11-01-0137 Bracket, Wheel, Right 1

29A B11-01-0105 Bracket, Wheel, Left 1

30 0090-0112 Bolt, Steering Axle, 3/4-10 x 5 in. 2 31 0090-0428 Washer, Flat, 3/4 in. 4 32 0090-0195 33 B08-02-0011 Caster, Steerin

ut, Nylon Lock, 3/4-10 2

6-21

ESP 19

6-11 PLATFORM PARTS LIST

Refer to Table 6-11 for the parts list for the platform.

19, 19A

Figure 6-11. Platform

6-22

6 — PARTS LIST

Table 6-11. Platform Parts List

Item No. Part No. Description Qty

1 B17-00-0137 Weldment, Platform 1 2 0090-0053 Screw, Cap, 3/8-16 x 3 in. 2 3 0090-0422 Washer, Flat, 3/8 in. 4 4 0090-0188 Nut, Nylon Lock, 3/8-16 4 5 B17-00-0138 Gate 1 6 B39-00-0048 Gas Shock, Gate 1 7 0090-0076 Screw, Cap, 1/2-13 x 3-1/2 in. 1 8 0090-0574 Washer, Flat, 1/2 in. 5

9 0090-0033 Screw, Cap, 5/16-18 x 1-3/4 in. 2 10 0090-0420 Washer, Flat, 5/16 in 4 11 0090-0185 Nut, Nylon Lock, 5/16-18 2 12 B01-10-0281 Joystick Switch Plate Assembly,

Includes Circuit Board

13 0090-0224 Screw, Machine, #8-32 x 3/8 in. 6

14 0090-0007 Screw, Cap, 1/4-20 x1-1/4 in. 4 15 B07-06-5549 Plate, Clamp, Upper Control Box 1 16 B18-00-0144 Control Box, Upper Enclosure 1 17 B07-06-5552 Plate, Threaded, Control Box 1 18 0090-0183 Nut, Nylon Lock, 1/4-20 6 19 B11-00-0052-1 Bike Rack Arm, Left 1

19A B11-00-0052-2 Bike Rack Arm, Right 1

20 0090-0001 Screw, Cap, 1/4-20 x 1/2 in. 2 21 0090-0419 Washer, Flat, 1/4 in. 4 22 B39-00-0034 Gas Shock, Shelf 1 23 B17-00-0139 Shelf, Cage 1 24 B36-00-0038 Pin, Spring Plunger, Shelf 2 25 B00-00-0014 Cap, Manual Tube 2 26 0090-0920 Ball, Swivel 2 27 0090-0074 Screw, Cap, 1/2-13 x 3 in. 2 28 0090-0191 Nut, Jam, Nylon Lock, 1/2-13 2 29 B01-03-0065 Switch, Gate 1 30 B18-00-0183 Mast Cover 1 31 0090-0042 Screw, Cap, 3/8-16 x 1 in. 2 32 B00-00-0154 Sleeve, Heat Shrink, 1/2 x 5 in. 2 33 B00-00-0144 Bumper 2 34 0090-1052 Screw, Machine, #10-24 x 3/4 in. 4

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.

5,7

4,7

6,7

Figure 6-12. Upper Control Box

6-24

6 — PARTS LIST

Table 6-12. Upper Control Box Parts List

Item No. Part No. Description Qty

B01-10-0273 Joystick Assembly 1 1 B01-10-0198 Circuit Board, Joystick (Not Shown) 1 2 B01-10-0201 Stop Switch, Emergency 1 3 B01-10-0205 Protection Skin, Push Button 3 4 B01-10-0202 Push Button, Arrow Up 1 5 B01-10-0203 Push Button, Arrow Down 1 6 B01-10-0204 Push Button, Enable 1 7 B01-10-0207 Mini Lamp, 6.3 volt 3 8 B01-10-0206 Switch, Cherry, Water/Dust Proof 3 9 B01-10-0317 Plate, Top Control 1

10 B01-10-0264 Joystick 1 11 B01-10-0318 Plate, Drive Direction 1 12 B01-10-0311 Rubber Cup, Thumb Switch 1 13 B01-10-0312-1 Handle, Joystick, Left Half 1 14 B01-10-0313 Rubber Cord 2 15 B01-10-0312-2 Handle, Joystick, Right Half 1 16 B01-10-0315 Switch, Thumb Actuator 1 17 B01-10-0314 Lever, Enable Switch 1 18 B01-10-0305 Pin, Dowel, 1/8 x 3/4 in. 1 19 B01-10-0316 Pushbutton, Enable Switch 1 20 0090-0500 Screw, Machine, #4-40 x 3/4 in. 2 21 B01-10-0218 Clamp 1 22 B01-10-0217 Screw, Machine, Torx, #6-32 x 3/8 in. 2 23 B01-10-0210 Boot, Rubber 1 24 0090-0243 Screw, Machine, #10-32 x 1/2 in. 2 25 B01-10-0209 Washer, Plastic 2 26 B01-10-0208 Gasket, Foam 1 27 B01-10-0306 Pin, Dowel, 3/16 x 3/4 in. 1 28 B01-10-0308 Spring, Torsion 1 29 B01-10-0307 Gear, 24 Tooth, Switch Activation 1 30 B01-10-0310 Bushing, Flanged 1 31 B01-10-0309 Standoff, Hex 2 32 0090-1087 Screw, Machine, Panhead, #6-32 x 1/4 in. 2

6-25

ESP 19

6-13 HYDRAULIC UNIT PARTS LIST

Figure 6-13. Hydraulic Unit Assembly

6-26

6 — PARTS LIST

Table 6-13. Hydraulic Unit Parts List

Item No. Part No. Description Qty

B02-05-0034 Pump Unit Complete 1 1 B02-15-0423 Reservoir, Plastic 1 2 B02-15-0412 Clamp, Reservoir 1 3 B02-15-0418 Breather Cap 1 4 B02-15-0438 Valve Assembly, 24VDC 1 5 0090-1060 Screw, Socket Head Cap, 1/4-20 x 2-3/4 in. 7 6 B02-15-0444 Cap, Cartridge Valve 2 7 B02-15-0440 Valve, Pilot Operated Check 1 8 B02-15-0441 Valve, Flow Control 2 9 B02-15-0442 Valve, Cartridge, 3 Way-2 Position 3

10 B02-15-0439 Valve Manifold 1 11 B02-15-0443 Valve, Cartridge Relief 1 12 B02-15-0425 Solenoid, Start, 24VDC 1 13 B02-15-0490 Plug, Nylon, Motor 2 14 B02-15-0424 Motor, Electric, 12VDC 1 15 B02-15-0491 Bearing, Motor 1 16 B02-15-0420 Base Assembly, Pump 1 17 B02-15-0433 Screw, Spring Retainer, 9/16-18 1 18 B02-15-0432 Spring, Check Valve 1 19 B02-15-0431 Poppet, Ball Retainer 1 20 B02-15-0430 Ball, 5/16 in. Diameter 1 21 B02-15-0426 Base, End Head 1 22 B02-15-0429 Seal, Shaft 1 23 B02-15-0427 Bearing, Needle 2 24 B02-15-0434 Spring, Retaining, Port Filter 1 25 B02-15-0435 Filter, Screen 1 26 B02-15-0436 Valve, Cartridge Relief 1 27 B02-15-0437 Seal, O-Ring, 3-7/8 x 1/8 in. 1 28 B02-15-0428 Seal, O-Ring, 5/8 x 1/16 in. 1 29 B02-15-0401

Tube, Return, 1/8 NPT, 90°

1 30 B02-15-0421 Pump Assembly 1 31 B02-15-0403

Tube, Return, 3/8 NPT, 90°

1 32 B02-15-0404 Filter, Screen (Suction) 1

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6-14 HYDRAULIC CYLINDER, FITTINGS, AND HOSES

PARTS LIST

16, 17

Figure 6-14. Hydraulic Cylinder, Fittings, and Hoses

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6 — PARTS LIST

. Stroke

Table 6-14. Hydraulic Cylinder, Fittings, and Hoses Parts List

Item No. Part No. Description Qty

1 B02-03-0040 Cylinder, Hydraulic Lift, 1.75 in. Bore x 54 in.

Stroke

2 Wiper, Rod 1 3 B02-13-0096 Nut, Gland 1 4 Packing 1 5 O-Ring 1 6 NSS Piston Rod 1 7 Ring, Wear 1 8 NSS Jacket, Cylinder 1 9 B02-02-0230

Fitting, 4MFS-4ORM 90°

10 B02-03-0038 Cylinder, Hydraulic Steering, 1.5 in. Bore x 4

12 B02-04-0094 Valve, Flow Control, 1.25 gpm 1 11 B02-02-0237 Fitting, Straight, 4ORFS-6ORB 1 13 B02-01-0186 Hose, Hydraulic, #4 x 22 in.

w/2 - #4FMFS fittings

14 B02-02-0229

Fitting, 4MFS-6ORM 90°

3 15 B02-05-0034 Pump, Hydraulic 1 16 B02-15-0445 Valve 1 17 B01-08-0018 Coil 1

* B02-13-0097 Seal Kit (Includes items 2, 4, 5, and 7

NSS – Not Sold Separately

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6-30

ANSI Reprint

The following sections are reprinted from the ANSI A92.6-1999 code in effect at the time of manufacture. Permissi 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, maintenance, app

ideration of the knowledge that the aerial platform will be carrying personnel.

cons

Manuals.

5.2

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 m The operating manual and maintenance manual shall be provided with each rental, lease or sale delivery and shall be stored in the weather resistant storage compartment on the aerial platform. Manual(s) are considered an integral part of the aerial platform and a users and operators. In addition, repair and parts manuals should be provid each sale delivery.

5.2.2 Manual of responsibilities. The ANSI/SIA A92.6-1999 Manual of Responsibilities for Dealers, Owners, Users, Brokers of Self-Propelled Elevating Work Platforms shall be provided and stor the weather resistant storage compartment.

lication, safety provisions and operation of the aerial platform with due

on to reprint has been granted by the Scaffold

anual.

re vital to communicate necessary safety information to owners,

ed with

Operators, Lessors, Lessees, and

ed in

5.3 Pre-delivery Preparation. Aerial platfo

sted to manufacturer's requirements prior to each delivery by sale, lease, or rental.

adju

aintenance, Inspection And Repair.

5.4 M

5.4.1 Maintenance. When a dealer accomplishes pr

aerial platform, it shall be in accordance with the manufacturer’s recommendations and based on the environment and severity of use.

5.4.2 Inspection. When the dealer accomplishes frequent and annual inspections, they shall be accomplished in accordance with the manufacturer’s

5.4.3 Repairs. Repairs accomplished to correct malfunctions and problems shall be in accordance with the manufacturer’s manuals and instructions.

5.5 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; (2) All 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) Hydrauli oil pressure reli 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 facilitat operators to comply with requirements set forth in this standard regarding the inspection, maintenance, use, application, and operation of the aerial platform.

eved from all hydraulic circuits before loosening or removing hydraulic

rms shall be inspected, serviced, and

eventative maintenance on the

manuals.

e owners, users, and

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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 directs 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. All 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 familiarization with the aerial platform upon each delivery unless this individual has been provided with familiarization on the same model, or one h aving characteristics consistent with the one being delivered, within th e 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 SelfPropelled 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 the 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.

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6. Responsibilities of Owners

6.1 Basic 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 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 a copy(s) 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.

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 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) All chain and cable mechanisms for adjustment and worn or damaged parts; (4) All

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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.

6.7 Annual 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 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) All 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 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.

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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 identification 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 principles 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 a 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

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Brokers of Self-Propelled Elevating Work Platforms shall be provided and stored in the weather resistant storage compartment.

7.3 Inspection And Maintenance. Users shall inspect and maintain the aerial platform as required to ensure proper operation. The frequency of inspection and maintenance shall be determined by the manufacturer's recommendations and be compatible with operating conditions and the severity of the operating environment. 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; (2) All 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.

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7 — ANSI REPRINT

7.7 Familiarization Before Use. The user shall permit only properly trained personnel to operate an aerial platform. The user shall ensure that before use the operator is familiar with the model of the aerial platform to be operated, and specifically: (1) Knows where the weather resistant compartment for manual storage is located. (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 flammable 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, 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 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 & 7-15. Electrical equipment and lines shall be consid ered 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 maintain 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

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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 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 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 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) 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

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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 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 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 deficiencies 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 related 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.

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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 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) 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 op erate 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 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.

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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 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, 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 & 7-15. Electrical equipment and lines shall be considered energized until determined to b e 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 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 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 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

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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 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 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) 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 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.

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Bil-Jax ESP 19 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Safety

INTRODUCTION

Safety Notes

1-2 BEFORE OPERATION

1-3 DURING OPERATION

1-4 MAINTENANCE SAFETY

Battery Maintenance

1-5 DAMAGED EQUIPMENT POLICY

Safety Statement

Damage Policy

Damage Repair Notice

Introduction

GENERAL DESCRIPTION

2-2 SPECIFICATIONS

ESP 19 Electric Hydraulic Lift Platform

2-3 WARRANTY

Operation

OPERATOR CONTROLS

Lower Control Box

Upper Control Box

3-2 NORMAL OPERATING PROCEDURE

3-3 EMERGENCY LOWERING PROCEDURES

3-4 LIFT VEHICLE TRANSPORT

Maintenance

Daily/Weekly Service Checks

6 Month/Yearly Service Checks

4-2 UNDERGUARD SERVICE CHECK

4-3 LUBRICATION

4-4 HYDRAULIC SYSTEM

Hydraulic System Inspection

Fluid Check and Replacement

Hydraulic System Air Bleeding Procedure

Flow Restrictor Valve Replacement

Valve Operation

Hydraulic Cylinder Repair

Hydraulic Cylinder Removal

Hydraulic Cylinder Repair Procedure

4-5 ELECTRICAL SYSTEM

Battery Care and Charging

Battery Charging Procedure

4-6 LIFT CHAINS AND SLIDE BLOCKS

Chain Elongation Inspection

Lift Chain Adjustment

Slide Block Adjustment

4-7 TROUBLESHOOTING

Troubleshooting Aids

Replacement Decals

Parts List

6-1 FIRST MOVING MAST PARTS LIST

6-2 SECOND MOVING MAST PARTS LIST

6-3 THIRD MOVING MAST PARTS LIST

6-4 FOURTH MOVING (PLATFORM) MAST PARTS LIST

6-5 BATTERY COMPARTMENT PARTS LIST

6-6 HYDRAULIC PUMP COMPARTMENT PARTS LIST

6-7 BASE PARTS LIST

6-8 BASE MAST PARTS LIST

6-9 DRIVE AXLE PARTS LIST

6-10 STEERING PARTS LIST

6-11 PLATFORM PARTS LIST

6-12 UPPER CONTROL BOX PARTS LIST

6-13 HYDRAULIC UNIT PARTS LIST

ANSI Reprint