Bil-Jax ESP 19 User Manual

Operation and

Maintenance Manual

AERIAL WORK PLATFORMS

ESP 19

Electric Stock Picker

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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

i

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.	Underguard.............................................................................................	4-3
Figure 4-2.	Lift Chains Lubrication ..........................................................................	4-4
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.	Steering ................................................................................................	6-20
Figure 6-11.	Platform................................................................................................	6-22
Figure 6-12.	Upper Control Box ...............................................................................	6-24
Figure 6-13.	Hydraulic Unit Assembly.....................................................................	6-26
Figure 6-14.	Hydraulic Cylinder, Fittings, and Hoses ..............................................	6-28

ii

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

iv

1

Safety

1-1 INTRODUCTION

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

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 be implemented at all times during the use of this equipment. Do not operate this equipment in areas where equipment or user may come in contact with live power source.

The information contained herein is not to be considered as legal advice and is intended for informational purposes only. This information is offered to alert Bil-Jax customers to procedures that may be of concern to them.

This information is not intended to be all-inclusive and is to be followed in the use of Bil-Jax equipment only.

For any questions concerning the safe use of this equipment, call 800-537-0540 before operating.

1-1

ESP 19

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	Minimum Safe Approach Distance
(Phase to Phase)	(Feet)		(Meters)
0 to 300V		Avoid Contact
Over 300V to 50KV	10		3.05
Over 50KV to 200KV	15		4.60
Over 200KV to 350KV	20		6.10
Over 350KV to 500KV	25		7.62
Over 500KV to 750KV	35		10.67
Over 750KV to 1000KV	45		13.72

•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 materials are on board.

•NEVER stand or sit on guard rails. Work only within the platform guard rail area and do not lean out over guard rails to perform work.

•NEVER attempt to increase working height with boxes, ladders, or other means.

•NEVER operate this equipment when exposed to high winds, thunderstorms, ice, or any other weather conditions that would compromise the safety of the operator.

•NEVER climb up or down masts.

•NEVER allow ropes, electric cords, hoses, etc. to become entangled in the equipment when the platform is being raised or lowered.

•NEVER exceed manufacturer's platform load limits and make sure all materials are evenly distributed over the entire platform.

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

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

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 circuit 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

2

Introduction

2-1 GENERAL DESCRIPTION

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

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

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

Other electrically powered functions include a two-wheel drive transaxle for floor travel and pushbutton steering. The maximum travel speed is enabled only when the lift platform is down. When the platform is raised, the travel speed is limited. The transaxle includes an electric brake that locks the drive wheels whenever forward or reverse travel is halted. The electric brake is normally applied; the brake disengages when forward or reverse travel is enabled with the joystick. In case of a loss of battery power, a manual free wheel lever can be used to disengage the electric brake, allowing the lift vehicle to be towed.

Floor travel and platform lift functions are controlled from an upper control box located on the lift platform. Floor travel is by joystick control with pushbutton steering. Lift functions are by pushbutton control. Platform lift can also be controlled from a lower control box mounted on the vehicle base. An electronic level sensor disables all lift and travel functions except platform lowering if the lift vehicle base is more than one degree out of level. While out of level, travel can be resumed after the lift platform is fully lowered.

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

Proper lift vehicle operation and safety are assured by performing the scheduled inspection and maintenance procedures set forth in this manual. The risk of platform free-fall is eliminated by proper maintenance of the chains, sheaves and sheave pins, a properly installed flow restrictor valve, and a clean mast. The restrictor valve (non-adjustable) fixes the maximum rate of platform descent to approximately 0.6 feet per second, whether the platform is empty or fully loaded. With the restrictor valve properly installed, a hydraulic hose failure will result in the same maximum rate of descent.

Carefully read and understand all of the safety instructions in Section 1 and all operating instructions in Section 3 of this manual before operating the lift vehicle.

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

3

Operation

3-1 OPERATOR CONTROLS

Most of the operator controls for the ESP 19 are located on the upper and lower control boxes. Other operator controls include the BATTERY ON/OFF switch and the emergency lowering valve. The BATTERY ON/OFF switch, located on the left side of the lift base, is the main power disconnect switch for the lift vehicle. The location and operation of the emergency lowering valve is described in paragraph 3-3.

Lower Control Box

The lower control box, Figure 3-1, is located on the lift base and contains three controls:

UP/DOWN, EMERGENCY STOP, and UPPER CONTROL/OFF/LOWER CONTROL. The lower con-

trol box enables lift operations from floor level.

The UPPER CONTROL/OFF/LOWER CONTROL key switch selects the active (upper or lower) control location. To enable an UP or DOWN lift motion from the floor, turn and hold the key switch in the LOWER CONTROL position. To enable lift vehicle travel or platform elevation from the upper control box, turn the key switch to the UPPER CONTROL position. To disable lift vehicle operations, turn the key switch to the OFF position and remove the key.

Turn the UP/DOWN selector switch to the UP position to raise the lift platform or to the DOWN position to lower the platform. (The key switch must be held in the LOWER CONTROL position to enable the UP/DOWN selector switch).

Press the EMERGENCY STOP button to stop all equipment motion. If the lift vehicle is moving forward or back, pressing the EMERGENCY STOP button engages the travel brake causing travel to stop quickly. To resume lift vehicle operation, turn the EMERGENCY STOP button clockwise.

Figure 3-1. Lower Control Box

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 BATTERY ON/OFF switch is in the ON position and the lower control box key switch is in the UPPER CONTROL position.

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

ENABLE

PUSHBUTTONS

STEERING

THUMB

SWITCH

UP

PUSHBUTTON

DOWN

PUSHBUTTON

TRAVEL

EMERGENCY JOYSTICK

STOP

PUSHBUTTON

Figure 3-2. Upper Control Box

Press and hold either one of the ENABLE pushbuttons to enable a control function. An ENABLE pushbutton must be pressed to enable the lift, steering, and travel functions. The ENABLE pushbutton must be held down to continue the equipment function.

With one of the ENABLE pushbuttons depressed, press the UP [ ] pushbutton to raise the platform or press the DOWN [ ] pushbutton to lower the platform.

With one of the ENABLE pushbuttons depressed, move the travel joystick forward or back to move the lift vehicle in the forward or reverse direction. For slow speeds, move the joystick forward or back just a little. For faster speeds, move the joystick more.

With one of the ENABLE pushbuttons depressed, press the left or right side of the thumb switch to steer the rear wheels to the left or right. The steering can be adjusted before or during floor travel.

Press the EMERGENCY STOP button to stop all equipment motion. If the lift vehicle is moving forward or back, a travel brake is applied causing travel to stop. To resume lift vehicle operations, turn EMERGENCY STOP button clockwise.

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 UPPER CONTROL/OFF/LOWER CONTROL key switch, Figures 3-1 & 3-3, to the 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 battery charging procedure in paragraph 4-4.

14.To shut down the equipment, turn the UPPER CONTROL/OFF/LOWER CONTROL key switch and the BATTERY ON/OFF switch to OFF. Remove the key to prevent unauthorized equipment operation.

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 key switch in the LOWER CONTROL position and turning

the UP/DOWN selector switch to the DOWN position. (If the upper control box emergency stop pushbutton is depressed, the platform will not lower.)

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

WARNING

Do not climb out of the lift cage while the lift platform is elevated. The lift mast cannot be climbed safely. An elevated lift platform has a high center of gravity and can be tipped easily. Standing on or leaning out from the outside of a cage rail may cause the lift vehicle to tip over. Tipping the lift vehicle over can cause severe injury or death and equipment damage.

If you lose power while elevated in the cage, instruct someone on ground level to open the emergency lowering valve. Do not leave the cage to climb down the lift mast or storage shelves.

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

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 illustrations in Figure 3-6.

Figure 3-6. Travel Brake and Steering Linkage

3-6

4

Maintenance

4-1 SCHEDULED SERVICE CHECKS

Daily/Weekly Service Checks

Perform the daily and weekly service checks listed in Table 4-1.

Table 4-1. Daily/Weekly Service Checks

Service Check	Daily
	before use	Weekly
Check that all upper and lower control box controls work
properly.
Check for hydraulic oil leaks.
Check for loose or missing parts.
Check for and retighten loose nuts and bolts.
Check that cage gate is secure.
Ensure Operation Manual is in manual tube.
Verify that underguard shuts down operation when weight is
applied.

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

	Every	Every
Service Check	6 months	12 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.

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

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 UP or DOWN lift motion will be intermittent. Intermittent lift motion should not be mistaken as trapped air in the hydraulic system.

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

1.Fill the reservoir to the MAXIMUM level with the proper hydraulic fluid.

2.Fully raise the lift platform.

3.Lower the lift platform to allow oil with entrapped air to return to the reservoir. Be careful not to overflow the hydraulic reservoir.

4.Leave the lift platform down and the lift vehicle at rest for 10 to 15 minutes while air escapes the hydraulic oil.

5.Repeat steps 2 through 4 as needed. Each time the platform is lowered, refill the reservoir to prevent pumping more air into the hydraulic cylinder.

4-6

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 1/8th 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 pushbutton. The pump should run, bypassing oil to the hydraulic reservoir.

CAUTION

Do not adjust the pressure relief valve for a bypass pressure higher than needed to raise the 450 pound load. Hydraulic system overload may occur at a higher bypass pressure, causing hydraulic failures or damage to the equipment.

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 the hydraulic line from the fitting. Then, remove the fitting.

3.Remove the flow restrictor valve using a 3/16” allen wrench.

4.When reinstalling the flow restrictor valve, make sure it is tightened in all the way against the bottom.

5.When reinstalling the fitting, do not tighten it against the flow restrictor. If the fitting is turned in too far, it can reduce or stop the oil flow to the cylinder.

6.Finally, reconnect the hydraulic line to the fitting. Make sure the o-ring seal on the face of the fitting is not cut or tore.

Figure 4-7. Flow Restrictor Valve

4-8