operation, maintenance & parts manual · 1 safety 3 legend: safety advisories 4 before...

OPERATION, MAINTENANCE & PARTS MANUAL

B33-01-0111-02

ESP 19 ELECTRIC STOCK PICKER

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

This equipment will meet or exceed applicable ANSI codes and standards when operated in accordance with manufacturer’s recommendations.

It is the responsibility of the user to follow all regional codes and regulations that govern the safe operation of this equipment.

Obtain, read and obey all safety precautions before performing maintenance or repairs or attempting to operate this equipment. This includes all manufacturer recommendations as well as those directives set forth by government and local authorities.

To ensure proper and safe use of this equipment, it is strongly recommended that only trained and authorized personnel attempt to operate and maintain the lift.

This manual shall be considered a permanent and necessary component of the machine and shall be kept with the ESP 19 at all times.

Owners and Lessors should complete a full inspection of all components and perform a test of all functions, including brake functions, before commissioning or reselling the machine. Repair or replace all damaged or malfunctioning components.

Haulotte | BilJax is dedicated to the continuous improvement of this and all Haulotte | BilJax products. Therefore, equipment information is subject to change without notice. Direct any questions or concerns regarding errors or discrepancies in this manual to the Haulotte | BilJax Service Department.

Copyright © Haulotte | BilJax, Inc. 2009. All Rights Reserved.

“Haulotte | BilJax” is a registered trademark of Haulotte | BilJax, a member of the Haulotte Group. Contact Haulotte | BilJax for replacement manuals.

125 Taylor Parkway Archbold, Ohio 43502 Phone (800) 537-0540 (419) 445-8915 Fax (419) 445-0367

P/N: B33-01-0111-02

1

TABLE OF CONTENTS

Table of Contents 1 Illustrations 2 Tables 2 1 Safety 3

Legend: Safety Advisories 4 Before Operation 5 During Operation 5 Maintenance Safety 7 Damaged Equipment Policy 8

2 Specifications 9

Specifications 10 Warranty 11

3 Equipment Maintenance 13

Daily Service Checks 14 Weekly Service Check 15 Biannual Service Checks 16 Annual Service Checks 17 Structural Inspection 18 Pressure Relief Valve Adjustment 19 Flow Restriction Valve Replacement 20 Valve Operation 21 Hydraulic Cylinder Repair 22 Lift Chain Adjustment 23 Slide Block Adjustment 23 Battery Recharge 24 Troubleshooting 28

4 Operation 35

Lower Control Box 36 Upper Control Box 37 Normal Operating Procedure 38 Emergency Lowering Procedure 39 Lift Vehicle Transport 40

5 Replacement Decals 41 6 ANSI Reprint 47 7 Replacement Parts 57

Ordering Replacement Parts 104

8 Material Safety 105 M S D S For Lead Acid Batteries, wet, filled with acid 105 M S D S For Powerflow™ AW HVI Hydraulic Oil 107

Appendix: Torque-Hub Manual 115

2

LIST OF ILLUSTRATIONSLIST OF ILLUSTRATIONSLIST OF ILLUSTRATIONSLIST OF ILLUSTRATIONS

Figure 3-1 Chain Elongation Inspection 16

Figure 3-2 Pressure Relief Valve Adjustment 19

Figure 3-3 Flow Restriction Valve Replacement 20

Figure 3-4 Valve Operation 21

Figure 3-5 Hydraulic Cylinder Disassembly 22

Figure 3-6 Lift Chain Adjustment 23

Figure 3-7 Slide Block Adjustment 23

Figure 3-8 Battery Charger Faceplate 24

Figure 4-1 Lower Control Box 36

Figure 4-2 Upper Control Box 37

Figure 4-3 Battery On/Off Switch 38

Figure 4-4 Emergency Lowering Valve 39

Figure 4-5 Fork Lift Pockets 40

Figure 5-1 Decal Locations 42

Figure 6-1 Minimum Safe Approach Distances 56

LIST OF TABLESLIST OF TABLESLIST OF TABLESLIST OF TABLES

Table 1-1 Minimum Safe Approach Distances 5

Table 2-1 Specifications 10

Table 3-1 Anpat Charger Fault Codes 25

Table 3-2 Iota LED Codes 25

Table 3-3 Troubleshooting Chart 28

Table 3-4 Motor Controller Fault Codes 32

Table 5-1 Replacement Decal Descriptions 43

3

1 SAFETY

DANGER Proper training is required for the safe operation of any mechanical device. Failure to follow all instructions and safety precautions in this manual and attached to the ESP 19 will result in death or serious injury.

Prior to Operation: � Read, understand and obey all instructions and safety precautions in this manual and

attached to the ESP 19.

� Read, understand and obey all applicable government regulations.

� Become familiar with the proper use of all controls.

� Inexperienced users should receive instruction before attempting to operate or maintain the machine.

The use of intelligence and common sense is the best practice when following any safety policy.

HAULOTTE | BILJAX ESP 19 Electric Stock Picker

4

LEGEND: SAFETY ADVISORIES

The following safety advisories are used throughout this manual to indicate specific hazards when operating or maintaining the machine. Read, understand and obey all safety advisories to prevent improper service, damage to equipment, personal injury or death.

DANGER Indicates a hazardous situation which, if not avoided, will result in death or serious injury .

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury .

CAUTION Indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.

NOTICE Contains information important in the prevention of errors that could damage the machine or its components .

1 — SAFETY

5

BEFORE OPERATION DURING OPERATION

Ensure the following general safety precautions are followed 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.

Ensure the following general safety precautions are followed while operating the ESP 19:

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

Table 1-1. Minimum Safe Approach Distances

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.

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, 3.05 meters minimum) and must always allow for platform movement due to gusty winds. Always contact power company before working near power lines. Assume every power line is live. Power lines can be blown by the wind. Refer to Table 1-1 for minimum safe approach distances between the machine and electrical power lines.

Minimum Safe Approach Distance Voltage Range

(Phase to Phase) (Feet) (Meters)

0 to 300V Avoid Contact

Over 300V to 50KV 10 3.05

Over 50KV to 200KV 15 4.60

Over 200KV to 350KV 20 6.10

Over 350KV to 500KV 25 7.62

Over 500KV to 750KV 35 10.67

Over 750KV to 1000KV 45 13.72


6

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

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

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

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

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

NEVER release the travel brake or tow the lift vehicle while a person or materials are on board.

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

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

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

NEVER climb up or down masts.

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

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

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

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

1 — SAFETY

7

MAINTENANCE SAFETY

Ensure the following general safety precautions are followed while performing maintenance on the ESP 19:

General Maintenance

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 manufacturer’s 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.

Ensure the following general safety precautions are followed when performing battery maintenance on the ESP 19.

Battery Maintenance

ALWAYS wear safety glasses when working with or near batteries.

ALWAYS avoid contact with battery acid. Battery acid causes serious burns and should be kept away from skin or eyes. If 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.

ALWAYS replace batteries using only parts recommended by manufacturer. ALWAYS use only batteries with sealed caps over cells.

NEVER smoke while servicing batteries.

NEVER charge batteries near flammable materials.

NEVER allow batteries to overcharge and boil.

NEVER short across battery posts to check for current. NEVER break a live circuit at the battery.

NEVER disconnect battery from charger while charger is connected to a live power source.

NEVER jumpstart other vehicles using the ESP 19 batteries.


8

DAMAGED EQUIPMENT POLICY

Safety Statement

At Haulotte | BilJax, we are dedicated to the safety of all users of our products. All Haulotte | 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 Haulotte | BilJax lift is involved in an incident that results in structural damage to the lift. Such damage can seriously compromise the ability of the lift to perform in a safe manner. Therefore, whenever a Haulotte | BilJax lift is damaged structurally or when there is suspected internal damage to the structure, Haulotte | BilJax may require that the lift be returned to our facility for reconditioning. For any questions concerning structural damage or the Damaged Equipment Policy, please contact the Haulotte | BilJax Service Department at 800-537-0540.

Damage Repair Notice

There may be occasions when a Haulotte | BilJax lift is involved in an accident resulting in damage to non-structural components. When such damage occurs and repairs are made by the owner or area distributor, please notify Haulotte | BilJax of these non-maintenance repairs and request a repair form to be filled out and returned to Haulotte | BilJax.

9

2 2 2 2 SPECIFICATIONSSPECIFICATIONSSPECIFICATIONSSPECIFICATIONS

Haulotte | BilJax, Inc. is dedicated to the continuous improvement of this and all Haulotte | BilJax products. Therefore, equipment information is subject to change without notice.

The following information is based on ideal working conditions. Machine performance may vary based on work environment and on machine options.

Direct any questions or concerns regarding equipment specifications to your regional Haulotte | BilJax representative or to the Haulotte | BilJax Service Department.


10

SPECIFICATIONS ESP 19 Electric Stock Picker Model Number: ESP 19 Serial Number: ________________

Manufactured by: Haulotte | BilJax, Inc. 125 Taylor Parkway Archbold, Ohio 43502 800-537-0540

Table 2-1. Specifications

Rated Platform Load 450 lb (204 kg) total including operator [1 person + materials not to exceed 450 lb (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 2900 lb (1315 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 — SPECIFICATIONS

11

WARRANTY

Haulotte US Inc (Haulotte) warrants its new products made by it to be free from defects in material or workmanship for twelve (12) months under normal operational conditions from the warranty start date (delivery date). In addition, Haulotte further warrants the structural elements of each new product made by it, as defined in its then current warranty policies and procedures, to be free from defects in material or workmanship for five (5) years from the warranty start date (delivery date). Haulotte agrees to repair or replace at its own expense; at its facility in Frederick MD, or at an authorized repair facility designated by Haulotte, any part or parts of the product found to be defective in material or workmanship, provided Haulotte is notified of such defect or defects within the applicable warranty period and given a reasonable time to correct the defect. In no case shall any warranty extend to defects in materials, components, or services furnished by third parties. Defects caused by chemical action or the presence of abrasive materials and defects arising following the operation beyond rated capacity or the improper use or application of any products shall not be considered defects within the scope of this warranty. If any repairs or alterations are made or any parts are replaced during the applicable warranty periods by anyone other than Haulotte or an entity authorized by Haulotte for use in its products, customer shall pay for such repairs or parts without recourse against Haulotte, and Haulotte should be relieved of responsibility for fulfillment of this warranty with respect to such repairs, alterations, or replacement so made. Haulotte obligations under this warranty shall at all times be subject to its current warranty policies and procedures. The above mentioned warranty shall not apply to replacement or service parts made and sold by Haulotte. Periodic maintenance, periodic maintenance items (including paint and decals), and minor adjustments are excluded from this warranty. Certain components, including, but not limited to, engines, tires and batteries, which may be part of the product are not manufactured or warranted by Haulotte. Any applicable warranty for such component is provided through the original manufacturer of the component or its distributor organization. Haulotte warranty does not apply to defects caused by negligence, misuse, accidental damage, inadequate or improper use or maintenance, acts of nature and normal wear and tear of the products. Under no circumstances shall Haulotte be liable for any consequential or special damages which any person or entity may incur or claim to incur as a result of any defect in the product or in any correction or alteration thereof made or furnished by Haulotte or others. Consequential or special damage includes, but not limited to cost of transportation, lost sales, lost orders, lost profits, lost income, increased over head, labor and material costs, and cost of manufacturing variances and operational inefficiencies. Haulotte maximum liability under this warranty shall be the purchase price paid to Haulotte with respect to the product to which such warranty is claimed. This warranty constitutes Haulotte entire and exclusive warranty as to the product and is the sole and exclusive remedy for the product defects in material and workmanship. Haulotte does not assume (and has not authorized any other person to assume on its behalf) any other warranty or liability in connection with any product covered by this warranty. Haulotte expressly disclaims any and all other warranties of any kind whatsoever as to the product furnished hereunder, including but not limited to any express warranties, except for the exclusive warranty provided herein, or implied warranties as to merchantability, or fitness for any particular purpose. This warranty shall be void, if, upon the occurrence of any incident involving any product made by Haulotte and resulting in any personal injury or property damage, customer shall fail to notify Haulotte within 48 hours of such occurrence or permit Haulotte and its representatives to have immediate access to such product and all records of or within the control of the customer relating to the product and occurrence. For the procedure to apply for warranty please refer to the warranty claims procedure on the following page.


12

WARRANTY CLAIMS PROCEDURE

In order to qualify for warranty coverage, the following conditions must be met:

1) Return of completed “Warranty Registration” form to Haulotte | BilJax within 15 days of receipt of product;

2) Notification to Haulotte | BilJax Service within 48 hours of any claimed defect, or damage resulting from the claimed defect;

3) Warranty is limited to parts that are determined to be defective by an authorized service dealership in conjunction with Haulotte | BilJax Service. This does not include parts worn out due to normal wear and tear.

Haulotte | BilJax authorized dealers or distributors are responsible for filing claims under warranty. Listed below is the warranty claims process.

1) Contact Haulotte | BilJax Service at 567.444.4466 to report the claim and verify warranty coverage. Machine serial number and machine hours must be provided when call is placed. A call ID number will be created when the call is placed. The service representative will issue the call ID number to you at the end of the call.

2) Identify the components to be claimed under warranty along with description of failure. An RMA number will be issued from Haulotte | BilJax to return warranty parts at the time the parts order is placed.

3) Replacement parts will then be sent by Haulotte | BilJax to the dealer or distributor. All parts are invoiced at dealer/distributor list price. Credits will be issued when defective parts are returned to Haulotte | BilJax under the proper RMA number and found to be defective under warranty.

4) After completing repairs, submit warranty application form and return the defective parts to Haulotte | BilJax. Warranty application form and parts must be received within 30 days of claim in order to be eligible for credit. Returned parts are to be sent prepaid and will be credited when part is received and verified. Warranty labor rate will be paid at current rate set by Haulotte | BilJax. The amount of labor hours reimbursed will be determined by Haulotte | BilJax and will be limited to 4 hours unless approved by Haulotte | BilJax Service.

5) The warranty application must include; the issued RMA number, the invoice number for the associated parts, the machine serial number, the machine hours on the date of failure, the issued call ID, failure and repair description, and requested customer information.

Failure to follow the warranty claims process may result in delay in processing claim or denial of the claim. Haulotte | BilJax reserves the right to limit or adjust warranty claims with regard to parts, labor, and travel time. Replacement components purchased from suppliers other than Haulotte | BilJax are not covered under the terms of this warranty.

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3 3 3 3 EQUIPMENT MAINTENANCE EQUIPMENT MAINTENANCE EQUIPMENT MAINTENANCE EQUIPMENT MAINTENANCE

Performing the appropriate maintenance procedures will extend the life of the ESP 19 and will help ensure the safety of personnel operating the equipment.

Repair, replacement or adjustment of any hydraulic or electrical control device should be performed only by fully trained and authorized personnel. These include, but are not limited to, hydraulic load valves, hydraulic flow control valves, solenoid valves and limit switches. These are safety related controls. Improper adjustment or tampering with these devices may impair machine function and result in safety or damage hazards.

Persons performing maintenance or repairs on the machine, including weld repairs, should be trained in accordance with the manufacturer’s recommendations. Contact your regional Haulotte | BilJax representative if additional information is needed.

Critical or suspect areas identified during any scheduled inspection of the machine shall be examined by qualified personnel in accordance with applicable government regulations.

Never operate the machine if a defect or malfunction is identified or suspected. All defects and malfunctions must be repaired, and all maintenance performed, before returning a machine to service.

This manual contains a list of recommended maintenance procedures to be performed daily, weekly, biannually and annually.

It is the practice of Haulotte | BilJax to issue Service and/or Safety Bulletins, which may include updates to the information contained in this manual. In such instances, procedures contained in Haulotte | BilJax Service Bulletins or Safety Bulletins supersede the information contained in manuals.

Always follow maintenance schedule, regardless of use.


14

DAILY SERVICE CHECKS

The following service checks should be performed daily or before each operation.

Verify that all decals are correctly applied and in plain view.

� Refer to Section 5 for decal locations.

Verify that all controls and indicators at ground and platform control stations operate properly.

Inspect hydraulic pump, hydraulic cylinder and hydraulic lines for leaks or damage.

Inspect structural components and platform for obvious damage or debris.

� Repair or replace as necessary.

Inspect machine for missing, loose or damaged fasteners, including pins and bolts.

� Tighten loose fasteners as necessary.

Verify that cage gate is secure.

Verify that Operation and Maintenance Manual is stored inside Manual Box.

Inspect hydraulic system and fluid levels.

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

� The hydraulic oil level should be checked with the platform fully lowered.

� Hydraulic oil level should be at the MAXIMUM level mark (approx. 1.5 inches from top of reservoir).

� If the hydraulic oil level is not at the MAXIMUM level mark, add clean hydraulic fluid as necessary while platform is fully lowered. Pour slowly to avoid creating air pockets in the reservoir. Do not fill above the MAXIMUM level mark. Overfilling the hydraulic reservoir may cause damage to hydraulic lines and may result in equipment malfunction.

� The hydraulic reservoir is originally filled with AW HVI 32 hydraulic oil.

� Manufacturer recommends a higher viscosity hydraulic oil when operating routinely in extreme climates.

NOTICE Do not mix hydraulic oils. Do not add any fluid to the hydraulic system that is not expressly recommended by the manufacturer. Adding unauthorized fluids to the hydraulic system may cause equipment damage.

3 — EQUIPMENT MAINTENANCE

15

WEEKLY SERVICE CHECKS

Perform the following service checks at least once each week in addition to all recommended Daily Service Checks:

Verify proper operation of underguard safety switches.

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

� Place a weight of at least 15 lb on the underguard.

� Using the lower control box with power ON, attempt to lower platform. MAKE SURE AREA UNDERNEATH AND AROUND THE CAGE/PLATFORM IS CLEAR OF PERSONNEL A warning beeper should sound and the platform should not lower. The lift should still be able to raise.

� Repeat procedure with personnel in the platform and using upper control box. Attempt to actuate drive functions. A warning beeper should sound and the ESP 19 should not drive.

� If the lowering or drive functions are still operable with weight applied to the underguard, the switches below the underguard may need to be adjusted or replaced. To adjust or replace underguard switches, turn power OFF, then remove two of the underguard clamps from one side of the underguard. The switches below the underguard can be adjusted by loosening the screws or removed for replacement.

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


16

BIANNUAL SERVICE CHECKS

Perform the following service checks at least once every six months in addition to all recommended Daily Service Checks:

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

� 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 3-1. Chain Elongation Inspection

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

Check casters, caster axle and swivel bolts for cracks or wear.

Verify that cage is securely bolted to lift mast.

Clean all battery terminals.

Check battery for loose connections or damaged wires.

� Check for cuts, loose terminals, broken wires, chaffing and corrosion.

� Repair all damage, remove corrosion and seal exposed connections.

Verify proper operation of emergency lowering valve and manual valve operation.

� Refer to Section 4 for emergency lowering procedures.

Lubricate lift chains.

� Use 40-weight oil

Verify that slide blocks and slide block paths are clean and lubricated.

� Plastic slide blocks 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.


17

ANNUAL SERVICE CHECKS

Perform the following service checks at least once each year:

Replace Hydraulic Oil and Oil Filter.

� Drain hydraulic reservoir, clean and replace oil.

� Wipe away dirt and excess oil from around filter using cleaning cloths and alcohol solvent.

� Loosen and remove filter. Use absorbent cloths to keep excess oil from leaking onto the machine. Discard used filter.

� Wipe away dirt and excess oil from around filter housing.

� Install new filter. Do not over-tighten.

� With the fill port cap on but not tightened, completely raise and lower platform to bleed trapped air from the lift cylinder. Repeat as necessary.

� Replace yearly, or whenever filter or oil contamination has a noticeable effect on function.

Inspect slide blocks for wear.

Check for mast sway.

Load test lift operations with 450 lb (204 kg) load.


18

STRUCTURAL INSPECTION ADDITIONAL SERVICE INFORMATION

A comprehensive structural inspection of the unit shall be performed under any of the following conditions.

� Ten years from the date of manufacture and every five years thereafter.

� After any actual, suspected or potential damage is sustained that could affect the structural integrity or stability of the aerial platform.

� After a change in ownership. Owners should provide a complete service history when reselling the unit.

The structural inspection shall include the following considerations.

� The service history of the unit, including hours of service, work performed and environmental conditions.

� The inspection and maintenance record of the unit.

� The effectiveness of all controls and components.

� A visual inspection of the unit for wear or damage.

� Manufacturer recommendations.

� A visual weld inspection, to be performed by qualified personnel in accordance with applicable government regulations.

Seals on hydraulic cylinders should be replaced every five years or as indicated by machine performance.

All service checks should be performed on a machine that has been stored without use for a period exceeding thirty days.

Check for air in the hydraulic system if the machine has been stored without use for a period exceeding thirty days, or if the machine was stored without use during a seasonal climate change. Air trapped in the hydraulic system will affect machine performance. Follow procedures for bleeding air from the hydraulic system.

Owners and lessors should complete a full inspection of all components and perform a test of all functions, including brake functions, before commissioning or reselling machine. Always repair or replace all damaged or malfunctioning components before commissioning or reselling machine.

When a change in ownership occurs, it is the responsibility of the seller to provide the new owner with all manuals for the machine. It is the responsibility of the buyer to notify the manufacturer of the unit model and serial number and the name and address of the new owner within 60 days.

Use the Service Checklists as well as any maintenance, repairs or alterations performed on the machine.

Records of frequent safety checks need not be made. However, where a safety hazard is found, it shall be reported in writing to the owner of the machine, and a record of any corrective action shall be maintained for five years or as required by the authority having jurisdiction.

Testing Machine Stability

The ESP 19 has been tested for stability in accordance with applicable ANSI standards. Stability tests should be conducted only by trained personnel.


19

Pressure Relief Valve Adjustment

Perform the following procedure to adjust the pressure relief valve. Refer to Figure 3-2.

� Move the ESP 19 lift platform to the fully DOWN position.

� Center 450 pounds of weight on the lift platform.

� Remove the cap (Delta Power) or loosen the jam nut (Bucher) on the pressure relief valve.

� 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.

� Place the key switch in the LOWER CONTROL position and press the UP pushbutton. The pump should run, bypassing oil to the hydraulic reservoir.

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

� With the platform lift function enabled (pump running), turn the pressure relief valve adjust screw clockwise just enough to smoothly raise the platform without bypassing oil to the hydraulic reservoir.

� Retighten the jam nut or replace and tighten cap as applicable.

Delta Power Pump Unit Bucher Pump Unit

Figure 3-2. Pressure Relief Valve Adjustment


20

Flow Restriction 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 could result in serious injury or death to personnel or damage to the equipment.

The flow restriction valve, Figure 3-3, is located inside the base of the hydraulic lift cylinder. If the flow restriction valve needs to be removed or replaced, it is important that it be properly reinstalled.

� Raise the platform and masts high enough to access the fitting. Support the raised platform using a forklift or hoist to prevent it from lowering.

WARNING Never work under the lift while it is raised unless the platform is fully supported to prevent it from lowering. Failure to properly support a raised platform could result in serious crushing injury or death.

� Remove cartridge and replace with new cartridge.

Figure 3-3. Flow Restriction Valve


21

Valve Operation

Refer to Figure 3-4 for valve locations. The valves are labeled on the valve manifold as C1, C2 and C3. The platform down valve is located at the base of the lift cylinder.

Lift Valve (C1): Pressing the ENABLE and UP pushbuttons energizes the platform lift valve, causing the lift cylinder to extend.

Steering Valve (C2): Pressing the ENABLE and the thumb steering switch on the joystick to the left energizes the steering valve, causing the steering cylinder to retract and execute a left turn.

Steering Valve (C3): Pressing the ENABLE and the thumb steering switch on the joystick to the right energizes the steering valve, causing the steering cylinder to extend and execute a right turn.

Platform Down Valve: Pressing the ENABLE and DOWN pushbuttons energizes the platform down valve. Oil flows back into the reservoir, causing the lift cylinder to retract.

Delta Pump Unit Bucher Pump Unit

Figure 3-4. Valve Operation


22

Hydraulic Cylinder Repair

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

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

� Remove the plexiglass cover from the base.

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

� Disconnect the two lift chains from the base mast.

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

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

Hydraulic Cylinder Repair Procedure

Perform the following procedure to repair the hydraulic lift cylinder. Refer to Figure 3-5.

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

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

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

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

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

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

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

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

� Refill the hydraulic reservoir.

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

� Bleed all trapped air from the hydraulic system.

2

3

4

1

5

7

6

Figure 3-5. Hydraulic Cylinder Disassembly

CAUTION Hydraulic cylinder removal requires extensive disassembly of the ESP 19 lift vehicle. Contact Haulotte | BilJax for assistance before removing the hydraulic cylinder.

1. Gland Nut 2. Cylinder Jacket 3. O-ring 4. Packing Ring 5. Rod Wiper 6. Piston Rod 7. Wear Ring


23

Lift Chain Adjustment Slide Block Adjustment

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

� Remove the Plexiglass cover from the base.

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

� If a lift chain is loose, tighten the related clevis, Figure 3-6. Tighten the clevis lock nut until the lift chain just becomes snug. Do not over-tighten any lift chain. (An over-tightened lift chain will raise the platform from its rest position at the bottom of the base slide ways).

� After making a lift chain adjustment, verify that at least 1/8 in. (3 mm) of the threaded clevis rod extends beyond the lock nut. Also recheck the slack of all lift chains at mid-span; verify that all lift chains are equally snug.

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

� Replace the Plexiglass cover.

1. Lift Chain 2. Clevis Assembly 3. Lock Nut

Figure 3-6. Lift Chains Adjustment

If the ESP 19 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 3-7.

Start with the slide blocks on one side of the inner mast. Adjust the upper and lower slide blocks on one side, followed by the upper and lower slide blocks on the opposite side. Repeat the adjustments for the center mast slide blocks, followed by the outer mast slide blocks. The adjustment procedure is the same for all slide blocks:

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

� Use an Allen wrench to turn the set screws clockwise. This will push the block in against the next mast. Do not overtighten. Tighten the slotted hex head screw to secure the slide block in position.

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

1. Slide Block 2. Set Screw 3. Slotted Hex Screw

Figure 3-7. Slide Block 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.


24

BATTERY RECHARGE

Recharge ESP 19 batteries after each 8-hour work shift or as needed. When ESP 19 is not in use, batteries should be recharged at least once per week. Under normal circumstances, battery recharge should take approximately 10-12 hours. However, a full recharge may take up to 24 hours, if the battery charge is extremely low.

To recharge the batteries:

� Move the ESP 19 to a well-ventilated area with direct access to 120V electrical outlet. Keep the ESP 19 and batteries away from open flame or other potential ignition sources.

� Remove power cord from covered enclosure on the ESP 19 console, located next to the lower control panel.

NOTE: Using an underrated or long power cord will reduce the output of the battery charger and may extend charge time.

� Plug the cord into outlet. Verify that the green CHARGING indicator LED is lit on the battery charger faceplate (Figure 3-8).

CHARGING

80% CHARGED

CHECK BATTERY

Linear Battery Charger

CHARGE CURRENT

PUSH

FOR

BATTERY VOLTAGE

FUSE 15A

SLO BLO

Figure 3-8. Anpat Battery Charger Faceplate

� The CHARGING indicator LED remains lit continuously during the first stage of the charge cycle. The bulk mode CHARGE CURRENT will be displayed on the battery charger faceplate.

� Press and hold the BATTERY VOLTAGE button to display the detected battery voltage.

� If a battery fault is detected, the appropriate fault code will appear on the CHARGE CURRENT display. The red CHECK BATTERY indicator LED will become lit. See Table 3-1 for battery charger fault codes.

� When the battery charge reaches 80% of capacity, the yellow 80% CHARGED indicator LED will become lit and the green CHARGING indicator LED will begin to flash.

� When the batteries have reached a full charge, the green and yellow indicator LEDs will turn themselves off. CC (Charge Complete) will appear on the CHARGE CURRENT display. After two hours, this display will fade and the CHARGE CURRENT will read 00.

WARNING Recharge batteries in a well-ventilated area only. Do not charge batteries near fire, spark or other potential ignition sources. Batteries may emit highly explosive hydrogen gas while charging. Failure to properly ventilate the charge gases could result in death or serious injury. Always charge batteries away from flammable materials.

WARNING Do not disconnect any output leads or connectors between the batteries and the charger when the charger is on. To stop a charge in progress, always unplug the battery charger power cord from the AC outlet.

CAUTION Always unplug the battery charger power cord before moving the ESP 19. Failure to disconnect power cord may result in injury and damage the equipment.


25

Table 3-1. Anpat Charger Fault Code

Code Description Limits Cause

F0 No Battery <10 volts Loose connection or battery missing

F1 Over Voltage >112% charge voltage Connected to wrong battery voltage

F2 Over Current >60 amperes Operating machine while charging

F3 Bulk Mode Timeout <80% charge at 16 hrs. Battery fault

F4 ARD Mode Timeout >80% and <full charge after 6 hrs Max.

Battery fault

F9 Current Measurement Error Standby

Board fault or charger exposed to extreme cold

FA Triac Error Board shorted

FF Full Power to Transformer, No Current Output

Battery shorted or low AC line voltage or charger fault

CO Charger Off Charger resting between pulses (AGM batteries only)

CC Charge Mode Complete Batteries charged

Table 3-2. Iota LED Codes

Cell Indication

6 Flashes 12V Battery (6 Cells)




Charge Phase LED Status Voltage Rate

Float On 2.26 per cell

Absorption Slow Flashing 2.36 per cell

Bulk Rapid Flashing 2.46 per cell


26

P/N: B01-05-0067


27


28

TROUBLESHOOTING

Refer to Table 3-3 for basic troubleshooting operations. Contact the Haulotte | BilJax Service Department with any questions or before attempting any advanced troubleshooting operations.

Table 3-3. Troubleshooting Chart

1 Lift vehicle will not power up. Cause Correction

a Low battery power or faulty battery circuit.

Recharge batteries to (min 12.6 volts per battery or 25.2 volts per system to reset BDI), load test batteries, and check for faulty cables.

b Battery ground or in-series battery cable loose.

Check for and repair loose and /or corroded battery connections or ground fault.

c Master power switch turned off. Turn on master power switch. d 250 amp fuse blown. Check for and repair fuse. e 10 amp fuse blown. Check for and repair fuse.

f Emergency stop button (upper & lower) engaged (pushed in).

Rotate emergency stop buttons clockwise to disengage.

g Gate switch open circuit or improperly adjusted.

Check wire harness for short and/or adjust switch to actuate when gate is closed.

h Charging cord box door switch open circuit or improperly adjusted.

Check wire harness for short and/or adjust switch to actuate when door is closed.

i No (24V+) signal at Relay post (85) Check Mast wire for damage.

j No (24V-) ground at Relay post (86) Check (B-) side of terminal strip and wiring leading to post.

k No (24V+) hot at Relay post (30) Check wiring from 10 amp fuse to post.

l No (24V+) to Terminal strip (B+) Check wiring from terminal strip to Relay post (87)

2 Lift vehicle will not function at upper and lower control box.

Cause Correction

a Error code Controller (Green flashing light) Record flashes and find code on Motor Controller Fault Codes (Table 3-3). Read and repair as needed.

b CAN communication lost between upper and lower I/O modules (No Green light)

Check and repair wires and/or wire connections that are creating an open circuit.

c Bad Connection and/or damaged wiring Check and repair connectors and wiring from arm rest controls to upper I/O module and from Module to Mast wiring.

d Key switch (lower controls) not turned to appropriate position.

Turn key switch to Upper or Lower controls.


29

Table 3-3. Troubleshooting Chart (Continued)

3 Lift vehicle will not drive or raise/lower from upper control box. Cause Correction

a Underguard switch open circuit with no load applied to underguard. Beeper tone will change also.

Check wiring and switch adjustment. Vehicle will raise with this condition.

b Stowed mast switch open, level sensor led is red, and beeper tone change.

Vehicle is out of level, lower machine until stowed mast switch is closed and drive to a level location for raising.

c Function selected before selecting enable (trigger or button)

Select enable before function.

4 Lift vehicle will not drive from upper control box. Cause Correction

a Enable circuit not making connection to upper I/O module.

Check for damaged wires and connectors.

b Joystick pot out of adjustment. Adjust pot to center voltage of 2.5V.

c Faulty joystick wire or wire connection to upper I/O module and/or 24V-.

Check and repair damaged connections or wires.

d Something blocking the wheels. Remove blockage.

5 Lift vehicle will not raise from upper and lower control box. Cause Correction

a Stowed mast switch open, level sensor led is red, and beeper tone change.

Vehicle is out of level, lower machine until stowed mast switch is closed and drive to a level location for raising.

b 100 Amp fuse blown Check and Replace. c Bad connection to (P) on motor controller Check for loose connection or bad wiring.

d Up coil not receiving input, faulty wiring, bad coil.

Check for at least 18 volts at coil, if not present check wiring for damage and/or output from lower I/O module.

e Down valve sticking open or leaking Repair or replace down valve. f Hydraulic oil level low in reservoir. Check reservoir level.

g Emergency lowering valve open. Close emergency lowering valve.

h Trying to lift more than rated capacity. Ensure load trying to lift does not exceed rated capacity.

i Mast sections dirty; slide blocks binding. Clean and lubricate masts with dry silicone. If adjustment needed refer to slide block adjustment.

j Internal leakage in hydraulic cylinder. Check cylinder housing for heat buildup due to leakage. If leakage is indicated, repair or replace hydraulic cylinder.


30


6 Lift vehicle will not raise from upper control box.

Cause Correction



b Up switch not making connection to upper I/O module.


7 Lift vehicle will not raise from lower control box.

Cause Correction

a Poor or no ground to Key Switch from (B-) Check for damaged/unconnected wires and connectors.

b Key switch (with lower controls selected) not providing ground (B-) to Up switch contactor.

c Up switch contactor to lower I/O module not making connection.

Check for damaged/unconnected wires and connectors.

8 Lift vehicle will not lower from upper and lower control box.

Cause Correction

a Underguard switch open circuit with no load applied to underguard. Beeper tone will change also.

Check wiring and switch adjustment. Vehicle will raise with this condition.

b Down coil not receiving input, faulty wiring, bad coil.


c Down valve sticking; does not open Repair or replace down valve.

d Mast sections dirty; slide blocks binding. Clean and lubricate masts with dry silicone. If adjustment needed refer to slide block adjustment.

9 Lift vehicle will not lower from upper control box.

Cause Correction



b Down switch not making connection to upper I/O module.



31


10 Lift vehicle will not lower from lower control box.

Cause Correction

a Poor or no ground to Key Switch from (B-) Check for damaged/unconnected wires and connectors.

b Key switch (with lower controls selected) not providing ground (B-) to Up switch contactor.


c Down switch contactor to lower I/O module not making connection.


11 Lift vehicle will not steer from upper control box. Cause Correction a Wheel turned to steering limit. Turn wheel in opposite direction. b 100 Amp fuse blown Check and Replace. c Bad connection to (P) on motor controller Check for loose connection or bad wiring.

d Steer coil (right or left) not receiving input, faulty wiring, bad coil.


e Steering one direction only. Replace stuck valve. f Hydraulic oil level low in reservoir. Check reservoir level.

g Thumb switches not making connection to upper I/O module.


h Thumb switch faulty. Replace Joystick.

i Enable circuit not making connection to upper I/O module.


j Steering linkage pin snapped. Replace pin.


32

Table 3-4. Sevcon Motor Controller Fault Codes

Fault Code Name Flashes Severity

Checked When Solution

1 Unit over temperature 8 1 Runtime

Remove power and allow controller to cool. If fault repeatedly occurs, look for binding on the hydraulic cylinders or sticking valves. Otherwise, the pump motor may be failing.

2 Traction Power Limit 8 1 Runtime

Recycle power. If fault repeatedly occurs, look for faulty drive motor wiring. Otherwise, the traction motors may be failing.

3 Pump Power Limit 8 1 Runtime

Recycle power. If fault repeatedly occurs, look for binding on the hydraulic cylinders or sticking valves. Otherwise, the pump motor may be failing.

4 Two Direction Input Fault 2 2 Runtime

Forward and Reverse input commands both active. Faulty or damage wiring between controller and traction motors, between joystick and upper I/O module or Joystick pot out of adjustment.

5 Sequence Fault 2 2 Power up Command to drive or lift is active at power up. Check enable line, B- wiring, and Molex Connector.

6 CAN Input Fault 2 2 Runtime

CAN command input is invalid or illegal. Check CAN wiring and connectors. Refer to beep codes for safety signal inputs.

7 Low Battery Fault 7 2 Runtime Recharge the batteries. Make sure battery connections are not reversed.

8 High Battery Fault 7 2 Runtime

Make sure battery charger is off. Check for poor or corroded battery connections.

9 CAN Fault 10 2 Runtime

CAN communications lost or CAN controller reporting excessive transmission failures. Check CAN wiring and connectors.

10 High Battery w/o Line Contactor 7 3 Runtime

Make sure battery charger is off or that the batteries are not over charged.

11 Configuration Range Fault 1 3 Power up

Use Sevcon calibrator to enter correct settings from latest Personality Sheet.

12 Configuration CRC Fault 1 3 Power up

Use Sevcon calibrator to enter correct settings from latest Personality Sheet. Otherwise, replace motor controller.

13 Motor Setup Error 1 3 Power up

Use Sevcon calibrator to enter correct settings from latest Personality Sheet. Otherwise, replace motor controller.

14 Line Contactor Welded 4 3 Power up

Check line contactor wiring. If OK, then replace line contactor.

15 Line Contactor Did Not Close 4 3 Runtime

Check line contactor wiring and Molex connector. If OK, then replace line contactor.

16 Motor Open Circuit 5 3 Runtime

Check traction motor wiring and connections for damaged or disconnected wiring. If OK, replace motor controller.

17 Mosfet Failure 3 3 Runtime

Check traction motor wiring and connections for damaged or disconnected wiring. If OK, replace motor controller.

18 Autozero Out Of Range OFF 3 Runtime

Check Translation board for fault or trouble shooting table #1. If OK, replace motor controller.


33

Fault Code Name Flashes Severity

Checked When Solution

19 Armature Mosfet Always Off OFF 3 Power up


20 Armature Mosfet Always On OFF 3 Power up


21 Power-up Mosfet Failure 3 3 Power up

M2 terminal voltage < 2.5V. If OK, replace motor controller.

22 Contactor Driver Always Off OFF 3 Power up


23 Contactor Driver Always On OFF 3 Power up


24 System Monitor Tripped 11 3 Runtime

Check Translation board for fault. If OK, replace motor controller.

Table 3-4. Sevcon Motor Controller Fault Codes (Continued)


34


35

4 4 4 4 OPERATIONOPERATIONOPERATIONOPERATION

The ESP 19 Electric Stock Picker is equipped with multiple operator control stations. 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.

Before attempting operation, Operators should:

� Attend a training program as required by government regulations.

� Obtain, read and obey all safety precautions as indicated by manufacturer’s recommendations and all federal, state and local regulations.

� Become familiar with the location and use of all controls.

� Verify that there are no overhead obstructions or live power sources in the work area that could interfere with the safe operation of the lift.

� Position the ESP 19 on a firm and level surface.

� Conduct a Pre-Operation inspection by performing all recommended Daily Service Checks. Refer to Section 3.


36

Lower Control Box

The lower control box, Figure 4-1, is located on the lift base and contains three controls: UP/DOWN (1), EMERGENCY STOP (2), and UPPER CONTROL/OFF/LOWER CONTROL (3). The lower control box enables lift operations from floor level.

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

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

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

1. UP/DOWN Selector Switch

2. EMERGENCY STOP

3. UPPER Control/Off/LOWER Control Key switch

Figure 4-1. Lower Control Box

4 — OPERATION

37

Upper Control Box

The upper control box, Figure 4-2, 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.

1. ENABLE Pushbutton 4.Thumb Switch 2. UP Pushbutton 5. EMERGENCY STOP 3. DOWN Pushbutton

Figure 4-2. Upper Control Box

Press and hold either one of the ENABLE pushbuttons (1) 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 (2) to raise the platform or press the DOWN pushbutton (3) 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 (4) to steer the rear wheels to the left or right. The steering can be adjusted before or during floor travel.

Press the EMERGENCY STOP (5) 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, pull out EMERGENCY STOP button.


38

NORMAL OPERATING PROCEDURE

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

Read and follow all safety precautions contained in Section 1 and all responsibilities outlined in the ANSI A92.6 reprint in Section 6 of this manual.

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

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

Turn the MASTER POWER SWITCH, Figure 4-3, to the ON position.

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

Figure 4-3. Battery On/Off Switch

Turn the UPPER CONTROL/OFF/LOWER CONTROL key switch, Figure 4-1, to the UPPER CONTROL position.

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

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

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

NOTE: The lift vehicle is equipped with a level sensor. When the vehicle is on a slope greater than 1 degree, the level sensor disables all functions other than platform lowering and sounds an alarm beeper. Once the platform is lowered, floor travel is again enabled to allow travel to a level area.

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

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

If any equipment motion continues after the pushbutton, joystick, or selector switch is released, press the EMERGENCY STOP pushbutton, Figure 4-2. All equipment motion should stop immediately.

At the end of each workday and whenever a low battery alarm sounds, transport the lift vehicle to the recharge site and plug in the charge cord. Verify that the ON-CHARGING indicator lights up on the battery charger.

NOTE: For more information on battery charging operations, refer to the battery recharge procedure in Section 3.

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.

4 — OPERATION

39

Emergency Lowering Procedure

In an emergency, a person at floor level can lower the platform by holding the UPPER CONTROL/OFF/LOWER CONTROL key switch in the LOWER CONTROL position and turning the UP/DOWN selector switch to the DOWN position. (If the upper control box emergency stop pushbutton is depressed, the platform will not lower.)

An emergency lowering valve is shown in Figure 4-4. 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.

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 4-4. 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 could cause death or severe injury and equipment damage.


40

LIFT VEHICLE TRANSPORT The ESP 19 is equipped with fork lift pockets, Figure 4-5. Read the following instructions before lifting the machine.

Figure 4-5. Fork Lift Pockets

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 (81 cm) before raising the ESP 19.

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.


41

5555 REPLACEMENT DECALSREPLACEMENT DECALSREPLACEMENT DECALSREPLACEMENT DECALS

WARNING Decals contain information that is required for the safe and proper use of the ESP 19.

Decals should be considered necessary components of the machine and should be checked before each use to verify that they are correctly attached and legible.

Promptly replace decals that are no longer legible .

Use the following guides to find the correct location of all decals.


42

Figure 5-1. Decal Locations

4 — OPERATION

43

Table 5-1. Replacement Decal Descriptions

Decal No. Decal Description Qty

B06-00-0009 WARNING: Moving Telescopic Masts 1

B06-00-0146 DANGER: Electrocution Hazard 1

B06-00-0173 NOTICE: Lanyard Attachment 2

B06-00-0192 WARNING: Manual Enclosed 1

B06-00-0225 WARNING: Stay Clear 2

B06-00-0289 Check Level with Cage Down 1

B06-00-0297 Forklift Pockets 1

B06-00-0457 WARNING: Stay Clear While Work Platform is Raised 1

B06-00-0458 Max. Capacity 150 lb 2

B06-00-0459 For Bicycles Only 2

B06-00-0460 CAUTION TAPE 2

B06-00-0469 WARNING: Not a Work Platform or Shelf 1


B06-00-0509 Wheel Loading 2

B06-00-0617 WARNING: Tool Tray for Material Only 1


44

Figure 5-1. Decal Locations (Continued)

4 — OPERATION

45

Table 5-1. Replacement Decal Descriptions (Continued)

Decal No. Decal Description Qty

B06-00-0009 WARNING: Moving Telescopic Masts 1

B06-00-0034 DANGER: Battery/Charger Safety Hazards 1

B06-00-0037 Lubricate Semi-Annually 1

B06-00-0068 Notice: SAE 10W Hydraulic Oil 1

B06-00-0138 WARNING: Maintenance Requirements 1

B06-00-0289 Check Level with Cage Down 1

B06-00-0382 CAUTION: ANSI 92.6 1

B06-00-0383 DANGER: Failure to Comply 1

B06-00-0453 ESP 19 Horizontal Logo 1

B06-00-0454 ESP 19 Vertical Logo 2

B06-00-0455 Haulotte | BilJax Vertical Logo 2

B06-00-0456 800-225-3765 For Service 1

B06-00-0461 WARNING: Operation Instructions 2

B06-00-0462 Battery Charger Cord Box 1

B06-00-0463 Do Not Lift Machine From This End 1

B06-00-0464 Emergency Lowering Valve 1

B06-00-0470 Low Battery Alarm 1

B06-00-0492 NOTICE: Turn Master Power Switch Off 1


B06-00-0589 Operating Instructions for Battery Charger 2

B06-00-0590 WARNING: Tip Over Hazard 1

Identification Plate

B06-00-0359 Serial Number Tag 1

Decal Kit

B06-01-1400 Decal Set (Does Not Include Serial Number Tag)


46


47

6 6 6 6 ANSI REPRINTANSI REPRINTANSI REPRINTANSI REPRINT

The following sections are reprinted from the ANSI A92.6 code in effect at the time of manufacture and govern the safe use of the ESP 19.

Permission to reprint this material has been granted by the Scaffold Industry Association.

5. Responsibilities of Dealers

5.1 Basic Principles. Sound principles of safety, training, inspection, maintenance, application, and operation consistent with all data available regarding the parameters intended use and expected environment shall be applied in the training of operators, in maintenance, application, safety provisions and operation of the aerial platform with due consideration of the knowledge that the aerial platform will be carrying personnel.

5.2 Manuals. 5.2.1 Machine manual(s). Dealers shall keep and

maintain copy(s) of the (1) Operating manual. (2) Maintenance manual. (3) Parts manual. (4) Repair manual. The operating manual and maintenance manual shall be provided with each rental, lease or sale delivery and shall be stored in the weather resistant storage compartment on the aerial platform. Manual(s) are considered an integral part of the aerial platform and are vital to communicate necessary safety information to owners, users and operators. In addition, repair and parts manuals should be provided with each sale delivery.

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

5.3 Pre-delivery Preparation. Aerial platforms shall be inspected, serviced, and adjusted to manufacturer's requirements prior to each delivery by sale, lease, or rental.

5.4 Maintenance, Inspection And Repair. 5.4.1 Maintenance. When a dealer accomplishes

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

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

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

5.5 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) Hydraulic oil pressure relieved from all hydraulic circuits before loosening or removing hydraulic components; (5) Safety props or latches installed where applicable as prescribed by the manufacturer.

5.6 Replacement Parts. When parts or components are replaced, they shall be identical or equivalent to original aerial platform parts or components

5.7 Training. The dealer shall offer appropriate training to facilitate owners, users, and operators to comply with requirements set forth in this standard regarding the inspection, maintenance, use, application, and operation of the aerial platform.

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.


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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 having characteristics consistent with the one being delivered, within the prior 90 days.

5.11.2 Proof of training. The dealer should provide trainees who successfully complete training a means to evidence they are trained. The dealer shall provide such proof if requested by the trainee. The document evidencing the training shall include the following information: (1) Name of entity providing training or retraining. (2) Name of trainer(s). (3) Clear identification that training covered Self-Propelled Elevating Work Platforms. (4) Date of training.

5.11.3 Record dissemination. Upon request, the dealer shall provide the following information: (1) To the owner of the aerial platform, a copy of frequent or annual inspections performed. (2) To the owner of the aerial platform, a copy of repairs accomplished. (3) To a user, proof of training for an operator, including name of trainer and date of training. (4) To a user, the name of the person(s) receiving familiarization upon delivery of the aerial platform.

5.12 Modifications. Modification, alteration or remanufacture of an aerial platform shall be made only with prior written permission of the manufacturer.

5.13 Manufacturer's Safety Bulletins. The dealer shall comply with safety-related bulletins as received from the manufacturer.

5.14 Responsibilities Upon Sale. When 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.

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.


6.4 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

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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 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.

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


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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.


6.17 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 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.

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7.6.1 Trainee records. A record of the trainee's aerial platform instruction shall be maintained by the user for at least 4 years.

7.7 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 considered energized until determined to be de-energized by tests or other appropriate methods or means and properly grounded. If energized power lines or parts are within the area in which the aerial platform is to be used, the user shall define and explain to the operator specific means to maintain the minimum safe approach distance required. (8) Personal protective equipment. The user shall direct the operator to ensure all personnel on the platform wear personal protective equipment as required. (9) Personnel footing. Personnel shall 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 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


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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 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

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Self-Propelled Elevating Work Platforms. (4) Date of training.


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.

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.


8.3 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 operate an aerial platform he/she is not familiar with, the operator shall receive instructions regarding the following items: (1) The location of the weather resistant compartment (for manual storage). (2) The purpose and function of all controls. (3) Safety devices and operating characteristics specific to the aerial platform.

8.6 Before Operation. Before operation, the operator shall: (1) Read and understand the manufacturer's operating instruction(s) and user’s safety rules or have them explained. (2) Understand all labels, warnings, and instructions displayed on the aerial platform or have them explained. (3) Ensure all occupants of the aerial platform wear appropriate personal safety equipment for the conditions, including the environment in which the aerial platform will be operated.

8.7 Workplace Inspection. Before the aerial platform is used and during use, the operator shall check the area in which the aerial platform is to be used for possible 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.

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.


54

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 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 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 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)

6 — ANSI REPRINT

55

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.

9. Responsibilities Of Lessors

9.1 Basic Principles. Sound principles of safety, training, inspections, maintenance, application, and operation consistent with all data available regarding the parameters of intended use and expected environment shall be applied in the performance of responsibilities of lessors with due consideration of the knowledge that the aerial platform will be carrying personnel.

9.2 Lessor As A Dealer. When a lessor uses the aerial platform as a dealer, the lessor shall have the responsibilities of dealers as specified in Section 5 of this standard.

9.3 Lessor As An Owner. When a lessor uses the aerial platform as an owner, the lessor shall have responsibilities of owners as specified in Section 6 of this standard.

9.4 Lessor As A User. When a lessor uses the aerial platform as a user, the lessor shall have the responsibilities of users as specified in Section 7 of this standard.

9.5 Lessor As An Operator. When a lessor uses the aerial platform as an operator, he shall have the responsibilities of operators as specified in Section 8 of this standard.

10. Responsibilities Of Lessees

10.1 Basic Principles. Sound principles of safety, training, inspections, maintenance, application, and operation consistent with all data available regarding the parameters of intended use and expected environment shall be applied in the performance of responsibilities of lessees with due consideration of the knowledge that the aerial platform will be carrying personnel.

10.2 Lessee As A Dealer. When a lessee uses the aerial platform as a dealer, he shall have the responsibilities of dealers as specified in Section 5 of this standard.

10.3 Lessee As An Owner. When a lessee uses the aerial platform as an owner, the lessee shall have the responsibilities of owners as specified in Section 6 of this standard.

10.4 Lessee As A User. When a lessee uses the aerial platform as a user, the lessee shall have the responsibilities of users as specified in Section 7 of this standard.

10.5 Lessee As An Operator. When a lessee uses the aerial platform as an operator, the lessee shall have the responsibilities of operators as specified in Section 8 of this standard.

11. Responsibilities Of Brokers

11.1 Responsibilities Upon Sale. The broker shall: (1) Upon delivery, ensure the operating and maintenance manuals are provided to the new owner. (2) Upon delivery, provide a copy of the ANSI/SIA A92.6-1999 Manual of Responsibilities for Dealers, Owners, Users, Operators, Lessors, Lessees, and Brokers of Self-Propelled Elevating Work Platforms. (3) Maintain records of the sale for a minimum of 4 years.

11.2 Responsibilities With Re-rents, Leases, Or Any Other Form Of Beneficial Use. When compensation is received as a result of a re-rent, lease or any form of beneficial use of an aerial platform, the broker shall: (1) Upon delivery, ensure the operating and maintenance manuals are provided to the user. (2) Upon delivery, provide a copy of the ANSI/SIA A92.6-1999 Manual of Responsibilities for Dealers, Owners, Users, Operators, Lessors, Lessees, and Brokers of Self-Propelled Elevating Work Platforms. (3) Ensure operating personnel are familiarized with the aerial platform prior to use. (4) Retain records of the transaction for a minimum of 4 years.


56

Figure 6-1. Minimum Safe Approach Distances

Minimum Safe Approach Distances

Minimum Safe Approach Distance Voltage Range

(Phase to Phase) (Feet) (Meters)

0 to 300V Avoid Contact

Over 300V to 50KV 10 3.05

Over 50KV to 200KV 15 4.60

Over 200KV to 350KV 20 6.10

Over 350KV to 500KV 25 7.62

Over 500KV to 750KV 35 10.67

Over 750KV to 1000KV 45 13.72

DANGER Do not allow machine, personnel, or conductive materials inside prohibited zone. Maintain M.S.A.D. from all energized lines and parts as well as those shown. Assume all electrical parts and wires are energized unless known otherwise.

CAUTION Diagrams shown are only for purposes of illustrating M.S.A.D. work positions, not all work positions.

DENOTES PROHIBITED

ZONE

57

7 7 7 7 REPLACEMENT PARTSREPLACEMENT PARTSREPLACEMENT PARTSREPLACEMENT PARTS

Use only parts manufactured and/or authorized by Haulotte | BilJax, Inc. when replacing damaged components. See page 103 for replacement part ordering information.

Only personnel properly trained and authorized to operate all equipment and familiar with all functions should attempt to repair or replace any part of the lift.

Always read, understand and obey all safety precautions included in this manual, as well as those precautions attached to the lift and dictated by federal, state and local regulations.

Assembly Description Page

Mast (Complete) 58

First Moving Mast 60

Second Moving Mast 62

Third Moving Mast 64

Fourth Moving Mast 66

Chain 68

Base and Mast (Complete) 70

Base (I) 72

Base (II) 74

Underguard 76

Console 78

Platform 80

Steering 82

I/O Module Upper 84

Lower Control Box 86

Upper Controls Box 88

Electrical Diagram – ESP 19 90

Control Panel 96

Hydraulic Pump Unit 98

Hydraulic Valve Block 100

Hydraulic Schematic 101

58

MAST ASSEMBLY

59

MAST ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 E-00205 Mast Assembly, First Moving 1

2 E-00202 Mast Assembly, Second Moving 1

3 E-00203 Mast Assembly, Third Moving 1

4 E-00204 Mast Assembly, Fourth Moving 1

5 E-00412 Mast Hood, Plastic, Black 1

60

FIRST MOVING MAST ASSEMBLY

61

FIRST MOVING MAST ASSEMBLY PARTS LIST


1 E-00205 Mast, First Moving Section 1

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

3 B36-01-0002 Sheave Pin 3

4 0090-0425 Washer, Flat, 5/8” 6

5 B26-00-0009 Sheave Assembly, Chain 2

6 0090-0188 Hex Nut, Self-Locking, 3/8-16” 1

7 0090-0422 Washer, Flat, 3/8” 1

8 B40-00-0003 Cable, 3/16” 1

9 0090-0389 Set Screw, 1/2-20 x 1/2" 8

10 0090-0403 Sheet Metal Screw, #10 x 1” 4

11 B31-00-0001 Slide Block, Plastic, 8” 4

12 0090-0042 Cap Screw, 3/8-16 x 1” 6

13 0090-0210 Washer, Lock, Split, 3/8” 6

14 0090-0162 Hex Nut, 3/8-16 6

15 B24-01-0008 Mounting Bracket 1

16 B29-00-0033 Mast Stop 1

17 B29-00-0078 Bracket Weldment 1

18 B26-00-0001 Sheave Assembly, Cable 1

19 0090-0147 Cotter Pin, 1/8” x 1-1/4” 1

20 B02-03-0048 Lift Cylinder 1

21 0090-0071 Cap Screw, 1/2-13 x 2-1/2” 1

22 0090-0212 Washer, Lock, Split, 1/2" 1

23 0090-0166 Hex Nut, 1/2-13 1

62

SECOND MOVING MAST ASSEMBLY

63

SECOND MOVING MAST ASSEMBLY PARTS LIST


1 E-00202 Mast, Second Moving Section 1

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

3 B36-01-0002 Sheave Pin 3

4 0090-0425 Washer, Flat, 5/8” 6


6 0090-0188 Hex Nut, Self-Locking, 3/8-16” 1

7 0090-0422 Washer, Flat, 3/8” 1

8 B40-00-0003 Cable, 3/16” 1

9 0090-0389 Set Screw, 1/2-20 x 1/2" 8



12 0090-0042 Cap Screw, 3/8-16 x 1” 6


14 0090-0162 Hex Nut, 3/8-16 6


16 B29-00-0033 Mast Stop 1



19 0090-0147 Cotter Pin, 1/8” x 1-1/4” 1

64

THIRD MOVING MAST ASSEMBLY

65

THIRD MOVING MAST ASSEMBLY PARTS LIST


1 E-00203 Mast, Third Moving Section 1

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

3 B36-01-0002 Sheave Pin 3

4 0090-0425 Washer, Flat, 5/8” 6



7 0090-0147 Cotter Pin, 1/8” x 1-1/4” 1

8 B40-00-0003 Cable, 3/16” 1

9 0090-0389 Set Screw, 1/2-20 x 1/2" 8



12 0090-0042 Cap Screw, 3/8-16 x 1” 4


14 0090-0162 Hex Nut, 3/8-16 4


16 B29-00-0033 Mast Stop 1


66

FOURTH MOVING MAST ASSEMBLY

67

FOURTH MOVING MAST ASSEMBLY PARTS LIST


1 E-00204 Mast, Fourth Moving Section 1

2 E-00414 Top Angle Weldment 2

3 0090-0014 Cap Screw, 1/4-20 x 2-1/2 4

4 0090-0206 Washer, Lock, Split, 1/4" 4

5 0090-0159 Hex Nut, Self-Locking, 1/4-20 4

6 E-00419 Hood Spacer 4

7 E-00228 Quick Release Pin, Threaded, 5/16-18 2

8 0090-0033 Cap Screw, 5/16-18 x 1-3/4 2

9 E-00417 Rear Safety Window 1

10 E-00445 Washer, Rubber, 3/8” 8

11 E-00504 Acorn Nut, 1/4-20 4


13 0090-0389 Set Screw, 1/2-20 x 1/2" 8


15 B01-10-0275 Strobe Light, Amber 1

16 0090-0802 Machine Screw, #10-24 x 7/8 2

17 0090-0182 Hex Nut, Self-Locking, #10-24 2

68

CHAIN ASSEMBLY

69

CHAIN ASSEMBLY PARTS LIST


B40-01-0010 Chain Assembly w/ Clevis Attachments 6

1 B40-01-0008 Lift Chain 1

2 B04-07-0088 Upper Clevis Attachment 1

3 B04-07-0078 Clevis Pin 2

4 B04-07-0087 Lower Clevis Attachment 1

5 0090-0860 Cotter Pin, 1.6mm x 7mm 12

6 0090-0192 Hex Nut, 1/2-13 6

70

BASE AND MAST ASSEMBLY

71

BASE AND MAST ASSEMBLY PARTS LIST


1 E-00201 Base and Mast Assembly 1

2 E-00402 Console Assembly, Complete 1

3 E-00006 Rear Window Assembly 1

E-00410 Safety Window 1

E-00445 Washer, Rubber, 3/8” 8

E-00504 Acorn Nut, 1/4-20 4

4 B02-03-0048 Lift Cylinder 1

5 0090-0654 U-Bolt 1


7 0090-0043 Cap Screw, 3/8-16 x 1-1/4” 4

8 B07-06-1060 Extension Rod, Emergency Lowering Valve 1

9 B46-00-0031 Knob, Emergency Lowering Valve 1

10 B29-00-0049 Retainer, Plastic Tube 2

11 B00-00-0007 Tube, Plastic, 2-1/8” OD x 66” 1

12 B00-00-0008 Plug, 2” 1

13 0090-0679 Pop Rivet, 5/32” 4

14 0090-0498 Washer, 3/16” 4

15 E-00034 Power Unit – 24v 1


17 0090-0389 Set Screw, 1/2-20 x 1/2" 8

18 0090-0403 Sheet Metal Screw, #10-24 x 1” 6

19 B40-01-0010 Chain Assembly 2


21 B40-00-0003 Cable, Steel, 3/16” Diameter 1

22 0090-0422 Washer, Flat, 3/8” SAE 1


24 0090-0344 Thread Cut Screw, 1/2" 2

25 B03-00-0219 Switch Assembly, Upper Mast (Not Shown) 1

26 B03-00-0218 Switch Assembly, Lower Mast (Not Shown) 1

72

BASE (I) ASSEMBLY

73

BASE (I) ASSEMBLY PARTS LIST



2 A-00056 Bushing, 3/4" 4

3 E-00413 Wheel, 10” Diameter 2

4 0090-0428 Washer, Flat, 3/4” SAE 10

5 0090-1083 Jam Hex Nut, Self-Locking, 3/4” 4

6 E-00418 Skid Pad 2

7 0090-1135 Flat-Head Cap Screw, 5/16-18 x 1” 14

8 E-00513 Round Head, Square Neck Bolt, 3/4-10 x 8” 4

9 E-00213 Counterweight 2

10 E-00467 Battery Clamp Assembly 2

11 0090-0425 Washer, 5/8” SAE 2

12 E-00530 Socket-Head, Cap Screw, 5/8-11 2

13 E-00459 Fork Pocket Bracket 1

14 B01-04-0017 Battery 2

15 E-00512 Pin 6-1/2” x 3/4" 2

16 0090-0150 Hairpin – 3/4" 2

74

BASE (II) ASSEMBLY

75

BASE (II) ASSEMBLY PARTS LIST



2 B39-00-0049 Spring 4

3 B01-03-0061 Limit Switch Assembly, Underguard 2

A-03631 Switch Body 1

A-03632 Switch Head 1

A-03627 Switch Harness 1

B01-09-0091 Terminal, Female 2

B01-09-0092 Connector Assembly, Female 1

B01-09-0093 Seal, Wire 2

4 0090-0232 Machine Screw, #19-24 x 1 1/2” 4

5 0090-0498 Washer, Flat, 3/16” SAE 4


7 B01-10-0331 Fuse Holder, 200 AMP 1

B01-10-0330 Fuse, 200 AMP 1

8 0090-0010 Cap Screw, 1/4-20 x 1 1/2" 2


76

UNDERGUARD ASSEMBLY

77

UNDERGUARD ASSEMBLY PARTS LIST


1 E-00446 Underguard, Aluminum 1

2 B07-06-5953 Underguard Clamp 4

3 0090-0001 Cap Screw, 1/4-20 x 1/2" 8

78

CONSOLE ASSEMBLY

79

CONSOLE ASSEMBLY PARTS LIST


1 E-00488 Console Housing Weldment 1

2 E-00404 Power Cord Tube 1

3 E-00405 Cushion Strip 9

4 B01-02-0060 Master Power Switch 1

5 B01-02-0076 Control Box, 3 Position w/Key 1

6 B01-05-0056 or

B01-05-0067

Battery Charger 24V/40 Amp (Anpat) or Battery Charger 24V/100 Amp (Iota) – This charger also requires (1) E-00456-24 Red Output Wire and (1) E-00456-25 Black Output Wire

1

7 B01-10-0194 Alarm 1

8 B42-00-0025 Latch 2

9 B01-02-0117 Switch, Snap Action W/ Roller 1

10 B01-01-0143 Retractable Cord 1

11 B01-10-0344 Level Sensor 1

12 0090-0679 Pop Rivet, 5/32 x 1/4" 4

13 0090-0498 Washer, 3/16” Rivet Backup 4

14 0090-0104 Washer, Flat, #6 6

15 0090-0005 Cap Screw, 1/4-20 x 3/4" 4


17 E-00011 Battery Charger Window Assembly 1

E-00487 Battery Charger Window 1

0090-0415 Washer, Flat, #10 SAE 8

0090-0205 Washer, Split, Lock, #10 4

0090-0231 Machine Screw, #10-24 x 1/2" 4

0090-0182 Hex Nut, Self-Locking, #10-24 4

18 0090-0691 Machine Screw, #6-32 x 3/4" 2


20 0090-0231 Machine Screw, #10-24 x 1/2” 2


22 E-00534 Power Gauge 1

23 E-00537 Lower Box Mount Plate 1

24 0096-0106 Cap Screw, M4 x 40 4

25 0096-0067 Nut Clip, M8 4

26 0096-0010 Cap Screw, M8 x 20 4

27 E-00536 Sevcon Lower Panel 1

28 0090-0893 Washer, Flat, 5/16” 4

29 0090-0030 Cap Screw, 5/16-18 x 1” 4


31 B00-00-0008 Plug for Power Cord Tube, 2” Dia. 1

80

PLATFORM ASSEMBLY

81

PLATFORM ASSEMBLY PARTS LIST


1 E-00302 Platform Weldment 1

2 E-00303 Shelf Weldment 1

3 B17-00-0138 Gate Weldment 1

4 B36-00-0038 Plunger Pin, Spring 2

5 0090-0771 Washer, Flat, 1/2" 2

6 E-00502 Washer, Flat 2

7 B01-03-0065 Limit Switch 1

8 E-00309 Shoulder Bolt, 1/2" x 2” 2

9 E-00503 Hex Nut, Self-Locking, 3/8-16 2

10 B11-00-0052-1 Bike Rack Arm, Left 1

11 B11-00-0052-2 Bike Rack Arm, Right 1

12 B00-00-0154 Bike Rack Cap Sleeve, Black, 1/2” x 5” 2

B39-00-0034 Gas Shock, Shelf 1

13 B39-00-0048 Gas Shock, Gate 1

14 B25-00-0094 Bearing 1

15 0090-0574 Washer, Flat, 1/2” SAE 3

16 0090-0076 Cap Screw, 1/2-13 x 3-1/2” 1

17 0090-0893 Washer, Flat, 5/16 4


19 0090-0033 Cap Screw, 5/16-18 x 1-3/4” 2

20 0090-0419 Washer, Flat, 1/4" SAE 1


22 E-00035 Upper Control Assembly 1

23 E-00012 Upper I/O Module Enclosure Assembly 1

24 0090-0231 Machine Screw 10-24 x 1/2” 4


26 A-00475 Manual Storage Box 1

27 0090-0005 Cap Screw, 1/4-20 x 3/4" 4

28 0090-0066 Cap Screw, 1/2-13 x 1-1/4” 2


82

STEERING ASSEMBLY

83

STEERING ASSEMBLY PARTS LIST


1 E-00420 Pivot Weldment, Steering 1

2 E-00425 Wheel Assembly, Right 1

3 E-00433 Wheel Assembly, Left 1

4 E-00438 Linkage, Drive Wheel 2

5 E-00328 Shoulder Bolt, 5/8 x 1-1/2” 2

6 E-00452 Bearing, 5/8” ID x 1/2" 4

7 0090-0425 Washer, Flat, 5/8” SAE 8

8 E-00320 Shoulder Bolt, 8/8 x 1-3/4” 2


10 0090-0574 Washer, Flat, 1/2" SAE 4

11 E-00036 Steering Cylinder 1


13 0090-0420 Washer, Flat, 5/16” 5

14 E-00455 Shoulder Bolt, 5/16 x 1-3/4” 1

15 E-00451 Bearing, 1-1/4” ID x 2-7/16” 1

16 E-00448 Bearing, Thrust, 1-1/4” ID 2

17 E-00508 Jam Nut, 1-1/2-6 2

18 E-00447 Bearing, Thrust, 1-1/2” ID 4

19 E-00229 Bearing, Flanged, Bunting, 5/16” ID x 3/8” 2

20 0090-0893 Washer, Flat, 5/16” 2

21 E-00458 Shoulder Bolt, 5/16 x 2” 1


23 0090-1133 Washer, 1-1/2” SAE 2

24 0090-1134 Washer, Flat, 1-1/4” SAE 1

25 E-00482 Hex Bolt, 1-1/4-7 x 1/2" 1

26 E-00529 Hex Nut, Self-Locking, 1-1/4-7 1

27 E-00460 Spacer 2

84

I/O MODULE ASSEMBLY

85

I/O MODULE ASSEMBLY PARTS LIST


1 E-00545 Upper I/O Module Box 1

2 B01-09-0087 9 Pin Flange Receptacle 2

3 B01-09-0084 4 Pin Flange Receptacle 1

4 E-00462 Sevcon Control Board, Upper 1

5 E-00543 Brass Standoff #6-32 x 5/8” 4

6 0090-0104 Washer, Flat, #6 8

7 0090-0218 Machine Screw, #6-32 x 1/2” 8

0090-0499 Sheetmetal Screw, #4 x 1/2" 20

86

LOWER CONTROL BOX ASSEMBLY

87

LOWER CONTROL BOX ASSEMBLY PARTS LIST


1 B01-02-0076 Lower Control Box Assembly W/ Key 1

2 B01-09-0003 Strain Relief Cable 1

3 B19-00-0040 Control Box 1

4 B01-02-0078 Contacts Switch, Normally OPEN 4

5 B01-02-0079 Contacts Switch, Normally CLOSED 1

6 B01-02-0082 Selector Switch 1

7 B01-02-0081 Emergency Stop Pushbutton Switch 1

8 B01-02-0080 Selector Switch, Up/Down 1

9 B00-00-0131 Legend Plate, Upper/Off/Lower 1

10 B00-00-0130 Legend Plate, Emergency Stop 1

11 B00-00-0129 Legend Plate, Up/Down 1

12 B38-00-0001 Replacement Key 1

13 0090-0232 Machine Screw, #10-24 x 5/8” 2

88

UPPER CONTROL BOX ASSEMBLY

89

UPPER CONTROL BOX ASSEMBLY PARTS LIST


E-00035 Upper Control Box Assembly 1

1 E-00553 Joystick 1

2 E-00554 Emergency Stop Pushbutton 1

3 E-00555 9-Pin Control Harness 1

4 E-00556 Emergency Stop Harness 1

5 E-00557 Machine Screw, #8-32 6

6 E-00558 Enable Button 1

7 E-00559 Top Plate 1

8 E-00560 Side Plate, Inside 1

9 E-00561 Side Plate, Outside 1

10 E-00562 Enclosure with Armrest 1

11 E-00563 Machine Screw, 1/4-20 4

12 E-00564 Mounting Nut 1

13 E-00565 Faceplate Decal 1

14 E-00566 Screw 6

15 E-00567 Nylon Hole Plug 1

16 E-00568 Directional Pushbutton, Green 2

17 E-00569 Washer 6

90

ELECTRICAL DIAGRAMS – ESP 19

SEVCON CONTROL PANEL ASSEMBLY

98

SEVCON CONTROL PANEL ASSEMBLY PARTS LIST


E-00536 SEVCON Lower Panel 1

1 E-00608 Baseplate 1

2 E-00609 Motor Controller 1

3 E-00463 I/O Module 1

4 E-00570 Contactor Mounting Kit 1

5 E-00571 Contactor 1

6 E-00572 Product ID Tag 1

7 E-00573 Power Cable 1

8 E-00574 Panel Harness 1

9 E-00575 14-Way Terminal Block 1

10 E-00576 24v Relay 1

11 E-00577 Fuse Terminal 4

12 E-00578 Link, Copper 2

13 E-00579 250 amp Fuse 1

14 E-00580 50 amp Fuse 1

15 E-00581 Socket Head Cap Screw, M6 x 20 4

16 E-00582 Washer, Flat, M6 4

17 E-00583 Washer, Spring, M6 4

18 E-00584 Cap Screw, Washer Head, M5 x 10 1

19 E-00585 Cap Screw, Washer Head, M3 x 12 8

20 E-00586 Cap Screw, M8 x 35 4


22 E-00588 Half Nut, M8 4

23 E-00589 Washer, Flat, M8, Large ID 8

24 E-00590 Hex Nut, Self-Locking, M8 4




28 E-00594 Cap Screw, M4 x 35 4

29 E-00595 Washer, Shakeproof, M4 4

30 E-00596 Slotted Channel Screw, M4 x 12 4

99

HYDRAULIC PUMP UNIT (BUCHER)

100

HYDRAULIC PUMP UNIT (MTE)

101

HYDRAULIC VALVE BLOCK

102

HYDRAULIC SCHEMATIC (DELTA)

103

HYDRAULIC SCHEMATIC (BUCHER)

104

ORDERING REPLACEMENT PARTS

To order replacement parts, contact the Haulotte | BilJax Service Department by phone at 800-537-0540, by fax at 419-446-8202 or by email at [email protected].

For swift service, always have the part number available, as well as the equipment model and serial number. When ordering parts by fax or email, always provide the above information.

See Page 11 for Equipment Warranty information.

QUICK REFERENCE

Equipment Model: ESP 19 Electric Stock Picker

Serial Number: ______________________________________________

NOTES

105

8 8 8 8 MATERIAL SAFETYMATERIAL SAFETYMATERIAL SAFETYMATERIAL SAFETY

The following Material Safety Data Sheets describe the correct procedures for the safe handling of chemical components within the Model 4527A HTA / 16 P Telescoping Boom Lift, as well as any potential health and safety hazards related to these chemicals. Material Safety Data Sheets are included here in accordance with all Federal State and Local codes and regulations. Read and observe all safety precautions. Maintain awareness of potential health and safety hazards.

MATERIAL SAFETY DATA SHEET FOR LEAD ACID BATTERIES, WET, FILLED WITH ACID

SECTION I – GENERAL INFORMATION

Manufacturer’s Name: Crown Battery Mfg. Company EMERGENCY NO: 800 487-2879 Street Address: 1445 Majestic Drive OR 800 OIL-TANK City, State, Zip Fremont, Ohio 43420 Phone Number: 419 334-7181 REVISION DATE: 5/18/2000

SECTION II -- MATERIAL IDENTIFICATION AND INFORMATION

COMPONENTS PERCENT OSHA ACGIH OTHER LIMITS CAS NUMBER Hazardous Components PEL TLV 1% or greater Carcinogens 0.01% or greater

METALLIC LEAD METAL 25.5% 0.05 mg/m3 0.05 mg/m3 NONE 7439-92-1 LEAD SULFATES 18.2% 0.05 mg/m3 0.05 mg/m3 NONE 7439-92-1 LEAD OXIDES 18.0% 0.05 mg/m3 0.05 mg/m3 NONE 7439-92-1 POLYPROPYLENE CASE MTL 6.4% SEPARATORS 3.5% SULFURIC ACID (H2SO4) 5.2% 1.0 mg/m3 1.0 mg/m3 NONE 7664-93-9 WATER 19.2%

REGULATORY INFORMATION: Those ingredients listed above are not subject to the reporting requirements of 313 of Title III of the Superfund Amendments and Reauthorization Act. The items are covered in an exemption as a “Manufactured Article”. 372.30(b)

SECTION III -- PHYSICAL / CHEMICAL CHARACTERISTICS

Boiling Point Approximately 203F Vapor Density: Greater Than 1 Vapor Pressure 14 @ 37% @ 80 F Melting Point: -36 F to -10.6 F Solubility in Water 100% Water Reactive: Yes, Produces Heat Specific Gravity 1.245 - 1.295 Battery Electrolyte Appearance & Odor Clear Liquid with Sharp Pungent Odor

SECTION IV -- FIRE AND EXPLOSION HAZARD DATA

Flash Point: Not Combustible Auto Ignition Temperature N/A Flammability Limits in Air % by Volume: N/A Extinguishing Media: Dry Chemical Carbon Dioxide, Water Fog, Water Special Fire Fighting Procedures: Sulfuric Acid Fumes, Sulfur Dioxide Gas or Carbon Monoxide may be released when acid decomposes. Wear NIOSH approved self-contained breathing apparatus. Unusual Hazards: Water applied to sulfuric acid generates heat and causes acid to splatter. Wear full-cover acid resistant clothing. Sulfuric acid reacts violently with metals, nitrates, chlorates, carbides, fulminates, picrates and other organic materials. Reacts with most metals to yield explosive/flammable hydrogen gas. This reaction is intensified when sulfuric acid is diluted with water to form battery electrolyte.

106

MATERIAL SAFETY DATA SHEET FOR LEAD ACID BATTERIES, WET, FILLED WITH ACID (CONTINUED)

SECTION V -- HEALTH HAZARD DATA

Primary Routes of Entry: Inhalation: YES Skin: YES Ingestion: YES Health Hazards: Acute EYES, SKIN, RESPIRATORY SYSTEM & DIGESTIVE SYSTEM Chronic: EYES, SKIN, RESPIRATORY SYSTEM & DIGESTIVE SYSTEM Signs and Symptoms of Exposure: IRRITATION OF EXPOSED AREA, BURNS AND RESPIRATORY PROBLEMS NO POSSIBILITY OF EXPOSURE OF LEAD WILL OCCUR UNLESS BATTERY IS DESTROYED. Medical Conditions Generally Aggravated By Exposure: EXPOSURE TO MIST MAY CAUSE LUNG DAMAGE & AGGRAVATE PULMONARY CONDITION. Emergency First Aid Procedures: SEEK MEDICAL ASSISTANCE FOR FURTHER TREATMENT, OBSERVATION AND SUPPORT IF NECESSARY. Eye Contact: WASH WITH COPIOUS QUANTITIES OF COOL WATER FOR AT LEAST 15 MINUTES Skin Contact: FLUSH AREA WITH LARGE AMOUNTS OF COOL WATER FOR AT LEAST 15 MINUTES Inhalation: REMOVE TO FRESH AIR, IF BREATHING IS DIFFICULT - GIVE OXYGEN Ingestion: GIVE MILK TO DRINK, DO NOT INDUCE VOMITING. CALL PHYSICIAN

SECTION VI -- REACTIVITY DATA

Stability: STABLE Conditions to Avoid: N/A Incompatibility: AVOID COMBUSTIBLES, ORGANIC MATERIALS, AND STRONG REDUCING AGENTS Hazardous Decomposition Products: SULFUR TRIOXIDE, CARBON MONOXIDE, SULFURIC ACID FUMES, & SULFUR DIOXIDE Hazardous Polymerization: MAY OCCUR Conditions to Avoid: N/A

SECTION VII -- SPILL OR LEAK PROCEDURES

Steps to be taken in case material is released or spilled: CONTAIN SPILL, USING NON-COMBUSTIBLE MATERIALS: VERMICULITE, DRY SAND & EARTH. NEUTRALIZE WITH LIME, SODA ASH, SODIUM BICARBONATE, ETC.

Waste disposal method: CONSULT STATE ENVIRONMENTAL AGENCY. INDIVIDUAL STATE REGULATIONS VARY Precautions to be taken in Handling & Storage: SEPARATE FROM INCOMPATIBLE MATERIALS, KEEP AWAY FROM FIRE, SPARKS AND HEAT Other Precautions and/or Special Hazards: CONTACT WITH METALS MAY PRODUCE TOXIC SULFUR DIOXIDE FUMES & MAY ALSO RELEASE FLAMMABLE HYDROGEN GAS. THIS REACTION IS INTENSIFIED WHEN DILUTED. NFPA Rating: HEALTH: 3 FLAMMABILITY: 0 REACTIVITY: 2 SPECIAL: 0 HMIS Rating: HEALTH: 3 FLAMMABILITY: 0 REACTIVITY: 2 PERSONAL PROTECTION: X

SECTION VIII -- CONTROL AND PROTECTIVE MEASURES

Respiratory Protection: ABOVE P.E.L.: NIOSH APPROVED, FITTED, FULL FACE RESPIRATOR Protective Gloves: ACID RESISTANT Eye Protection: FULL FACE PROTECTION Ventilation: LOCAL EXHAUST: VENTILATED AREA PREFERRED MECHANICAL: IF BELOW P.E.L. SPECIAL: MUST BE ACID & EXPLOSIVE RESISTANT OTHER: MUST BE ACID & EXPLOSIVE RESISTANT Other Protective Equipment: ACID RESISTANT CLOTHING AND BOOTS Hygienic Work Practices: N/A

107

MATERIAL SAFETY DATA SHEET POWERFLOW™ AW HVI HYDRAULIC OIL

108

MATERIAL SAFETY DATA SHEET POWERFLOW™ AW HVI HYDRAULIC OIL (CONTINUED)

109


110


111


112


113


115

APPENDIX:APPENDIX:APPENDIX:APPENDIX:TORQUETORQUETORQUETORQUE----HUB MANUAL HUB MANUAL HUB MANUAL HUB MANUAL The following materials have been provided by Fairfield Manufacturing Company, Inc. for the purpose of maintaining and servicing the torque-hub units attached to the ESP 19 Electric Stock Picker. These materials are reprinted here by permission.

E035C3A Service Manual

REV DESCRIPTION DATE -- Initial Release 4/14/08

116

TABLE OF CONTENTS

Introduction ..................................................................................................................107 Roll and Leak Testing ..................................................................................................108 Tightening and Torquing Bolts .....................................................................................109 Oil Type and Capacity, Oil Check Procedure...............................................................110 Manual Disengage Procedure......................................................................................111 Motor Disassembly ......................................................................................................113 Gearbox Main Disassembly .........................................................................................114 Input Carrier Disassembly............................................................................................115 Hub Disassembly .........................................................................................................116 Spindle Disassembly....................................................................................................117 Spindle Sub-Assembly.................................................................................................118 Hub Sub-Assembly ......................................................................................................120 Input Carrier Sub-Assembly .........................................................................................121 Gearbox Main Assembly ..............................................................................................123 Motor Assembly ...........................................................................................................125 Assembly Drawing .......................................................................................................126 Service Parts List .........................................................................................................127 Assembly Tools............................................................................................................129

Fairfield Manufacturing Company, Inc. P.O. Box 7940 U.S. 52 South

Lafayette, Indiana 47903 Phone 765-772-4000 Fax 765-772-4001

www.fairfieldmfg.com

117

INTRODUCTION This manual is a step-by-step guide to servicing the E035C3A Torque-Hub units. It is designed for the customer or shop mechanic who is repairing this particular model of Torque-Hub. Users of this manual should note that each part mentioned is followed by an identification number enclosed in parentheses. These part numbers may be referred to in the Parts List section of this manual and on the illustrated parts breakdown of this unit. Any specialized tools normally used to assemble this unit are noted in the assembly procedures and diagrammed in the assembly tools section. Users should familiarize themselves with the procedures for roll and leak testing and bolt tightening and torquing found on the following two pages before any servicing of the assembly. Standard safety practices should be followed during the procedures described. Safety glasses and safety shoes should be worn. Be especially alert when you see the word CAUTION. This indicates that a particular operation could cause personal injury if not performed properly or if certain safety procedures are not followed. The word NOTE is used to bring attention to the user of certain procedures or helpful hints that will aid in the disassembly and assembly steps. DISCLAIMER: This manual will cover how to completely assemble and disassemble this Torque-Hub unit. However, if the unit is under warranty you should contact your Fairfield customer service representative for a replacement unit. The warranty will no longer be valid if the unit is disassembled by non-Fairfield personnel.

118

ROLL AND LEAK TESTING Torque-Hub units should always be roll and leak tested before disassembly and after assembly to make sure that the unit's gears, bearings and seals are working properly. The following information briefly outlines what to look for when performing these tests. NOTE: The brake must be released before performing the roll test. This can be accomplished by supplying 24 Volts D.C. to the brake connector. THE ROLL TEST The purpose of the roll test is to determine if the unit's gears are rotating freely and properly. You should be able to rotate the wheel or hub of the gearbox by hand. If you feel more drag in the gears only at certain points, then the gears are not rolling freely and should be examined for improper installation or defects. Some gear packages roll with more difficulty than others. Do not be concerned if the gears in your unit seem to roll hard as long as they roll with consistency. THE LEAK TEST The purpose of a leak test is to make sure the unit is air tight. You can tell if your unit has a leak if the pressure gauge reading on your leak checking fitting starts to fall after the unit has been pressurized and allowed to equalize. Leaks will most likely occur at the pipe plugs, the main seal or wherever o-rings are located. The exact location of a leak can usually be detected by brushing a soap and water solution around the main seal and where the o-rings or gaskets meet on the exterior of the unit, then checking for air bubbles. If a leak is detected in a seal, o-ring or gasket, the part must be replaced, and the unit rechecked. Leak test at 10 psi for 20 minutes. NOTE: Due the small air volume inside this Torque-Hub, it will pressurize to 10 psi very quickly. If the pressure becomes excessive in the unit the seals will be destroyed.

119

TIGHTENING AND TORQUING BOLTS If an air impact wrench is used to tighten bolts, extreme care should be taken to ensure that the bolts are not tightened beyond their specified torque. The following steps describe how to tighten and torque bolts or socket head cap screws in a bolt circle. 1. Tighten (but do not torque) bolt “A” until snug. 2. Go to the opposite side of the bolt circle and tighten bolt “B” until equally snug. 3. Crisscross around the bolt circle and tighten remaining bolts. 4. Now use a torque wrench to apply the specified torque to bolt “A”. 5. Using the same sequence, crisscross around the bolt circle and apply an equal torque to

the remaining bolts.

120

OIL TYPE & CAPACITY This torque hub unit is shipped with ISO 68 viscosity oil (hydraulic fluid). It is designed to utilize the same oil throughout its service life. However, should it need to be serviced the oil will need to be drained and replaced. In the event of servicing, fill the unit with ISO grade 68 oil or oil of a similar viscosity (80W gear oil or 20W engine oil). The gearbox will need to be filled with 10 oz of oil.

OIL FILLING INSTRUCTIONS 10 oz of gearbox oil will fill the gearbox cavity approximately half full. To check the oil level, rotate the wheel so that the cover plugs are at 12 o-clock and 3 o-clock. Allow the oil to settle. Slowly loosen the 3 o-clock plug. If oil begins to come out then the oil level is sufficient. If no oil is noticed at the 3 o-clock plug location, then remove both plugs. Slowly add oil at the 12 o-clock plug location until oil begins to seep out of the 3-clock plug location. Reinstall and tighten plugs to 40 in-lbs.

121

MANUAL DISENGAGE PROCEDURE

In the event of a power loss to the Torque-Hub, the parking brake will engage as a safety precaution. Should the unit need to be towed or pushed to an area where it can be serviced or recharged the operator will need to manually disengage the parking brakes. The following procedure outlines how this is to be done.

CAUTION: If the machine is on any incline, the wheels must be adequately blocked prior to manually disengaging the brakes. Failure to do so may result in injury or even death. 1. Make sure the E-stop plunger is pushed in and the key is removed from the ignition switch. 2. Remove the 2 Brake Cover Bolts (B1). The Brake Cover Bolts are also the release bolts

for the brake. The size of the back cover bolts is M5 x 0.8 x 20mm long. 3. Remove the Brake Cover (M1). 4. Insert the Back Cover Bolts (B1) into the two Manual Release holes in the brake housing.

122

5. Tighten down bolts and the brake will disengage. 6. Repeat this procedure for the other wheel drive. CAUTION: The disengage bolts MUST be removed from the brake housing after the machine is towed or pushed to its servicing location. The brakes can not be engaged with the disengage bolts in the brake housing. This WILL cause the machine to roll when parked on an incline.

123

MOTOR DISASSEMBLY

1. Make sure the E-stop plunger is pushed in and the key is removed from the ignition switch.

2. Disconnect the cable from the power controller.

3. Drain the oil out of the unit by removing Cover Plug (G29) (see page 11), note the condition of the oil

4. Remove the 2 Motor Mounting Bolts (M7) and Washers (M8)

5. Gently remove the Motor (13).

NOTE: Reference Appendix A for maintenance procedures internal to the motor.

124

GEARBOX MAIN DISASSEMBLY

1. Using a screwdriver, pry the end of the Retaining Ring (G19) out of the groove in the Hub Subassembly, then grasp the loose end of the Retaining Ring (G19) and pull the rest of the way out.

2. Remove Cover (G11). Thrust Washer (G21) should remain in the inner counterbore of the

Cover (G11) when removed. NOTE: To remove the cover the motor must be removed. Slide a rod through the motor shaft hole and gently tap with a rubber hammer to force the cover out. 3. Remove Input Sun Gear (G4). 4. Remove Input Carrier Sub-assembly. 5. Remove Cover (G11) O-ring (G20). . 6. Remove Input Ring Gear (G3). NOTE: The Input Ring Gear (G3) is held in with a press fit on its outside diameter. Insert jacking screws (1/4-20UNC, grade 8) with at least 1.5 inches of thread length into each of the three tapped holes to force the ring gear out. Be sure and alternate between the jacking screws to keep the ring gear from becoming misaligned in the bore. The screws will push against the outer race of the main bearing. This bearing will have to be replaced afterwards. 7. Using a screwdriver, remove Spiral Retaining Ring (G27). 8. Pull Hub Sub-assembly off of the Spindle Sub-assembly.

125

INPUT CARRIER DISASSEMBLY

1. Remove Retaining Rings (G18) from each of the three Planet Shafts (G6). NOTE: Do not overstress these Retaining Rings when removing them. 2. Remove Thrust Plate (G23). 3. Remove Thrust Washer (G25) from each Planet Shaft (G6). 4. Slide each Input Planet Gear (G5) off the Planet Shaft (G6). 5. Press out Bushing (G26) from the bore of each Planet Gear (G5). Bushings cannot be

reused when removed. 6. Remove the other Thrust Washer (G25) from each Planet Shaft (G6). 7. Remove Retaining Ring (G24) from Output Sun Gear (G8). 8. Slide Output Sun Gear (G8) out from the center of the Input Carrier (G7). 9. Remove the three Planet Shafts (G6) from the Input Carrier. NOTE: The Planet Shafts (G6) are held in with a press fit. To avoid damage to the parts, use an arbor or hydraulic press to remove the Planet Shafts (G6).

126

HUB DISASSEMBLY

1. Remove Main Wheel Bearing (G14). NOTE: This part is held in the hub with a press fit. To remove have the hub setting seal side up. Use a plate or rod with a large enough diameter push in the inner race of the bearing. Apply force to the push the bearing out. This bearing will need to be replaced upon reassembly. 2. Remove main Lip Seal (G16). NOTE: This Lip Seal (G16) is also held in with a press fit. Remove the Lip Seal only if the hub or seal needs to be replaced. The Lip Seal will most likely become damaged during removal. Try not to damage the hub bore.

127

SPINDLE DISASSEMBLY

1. Place Spindle Sub-Assembly on bench with Planet Gears (G9) facing up. NOTE: Do not damage or scratch the seal surface of the spindle (G1) during disassembly. 2. Remove three Output Planet Shafts (G10) NOTE: These Planet Shafts are held in with a press fit. Use the tapped hole in the end of the pin in conjunction with a slide hammer or similar tool to remove them. 3. Remove the Output Planet Gear (G9), Thrust Washer (G25), and Tanged Washer (G32)

out each of gear “window” of the Spindle (G1). NOTE: The Output Planet Gears (G9) are very similar in size to the Input Planet Gears (5), tag or label the Planet Gears to avoid confusion. 4. Press out Bushing (G26) from the bore of each Planet Gear (G9). Bushings cannot be

reused when removed 5. Remove the Main Bearing (G14) from the outside diameter of the Spindle (G1). NOTE: This bearing is held in with a press fit. You will need to pry against the Spindle (1) to remove it. A new bearing should be used when the unit is reassembled. 6. Remove the Bearing Retaining Ring (G15) from the bore of the Spindle (G1) 7. Remove the shaft Ball Bearing (G15) from the center bore. 8. Press out the Motor Shaft Seal (G17) from the center bore. The seal cannot be reused

when removed.

128

SPINDLE SUB-ASSEMBLY

1. Place the spindle (G1) on the bench with the carrier portion facing up.

NOTE: Do not damage or scratch the seal surface of the spindle (G1) during assembly.

2. Install Input Ball Bearing (G15) into the spindle bore.

3. Using Retaining Ring Pliers, install Retaining Ring (G28) into the groove in the Spindle (G1) bore.

4. Using the appropriate pressing tool (T-182377), press on Main Bearing (G14) until it is

fully seated.

5. Use the Output Planet Pin (G10) as a pressing tool to install the Planet Bushing (G26) into the bore of each Planet Gear (G9). The shaft will help guide the bushing into the bore as well as prevent damage from the press.

6. Place Tanged Thrust Washer (G32) into each planet “window” of the Spindle (G1).

Make sure the tang sits in the cast groove on the inside of the window.

7. Place a Thrust Washer (G25) onto the Output Planet Gear (G9). Line up the bores as best as you can. Use grease to hold the Thrust Washer in place.

8. Slide the Output Planet Gear (G9) into the window with the Tanged Thrust Washer

(G32) until the bores line up.

129

9. Insert Output Planet Shaft (G10) into the Planet Shaft hole of the Spindle (1) and

through the bores of the Thrust Washers (G25) & (G32) and the Planet Gear (G9).

10. Before pressing the Output Planet Shaft (G10) into the Spindle (G1), make sure the Output Planet Gear (G9) spins freely.

11. Press the Output Planet Shaft (G10) into the Spindle (G1) until it bottoms out. Make

sure the Output Planet Gear (G9) spins freely after the Planet Shaft is pressed in.

12. Repeat Steps 5-11 for the other two Output Planet Gears (G9). 13. Turn the Spindle (G1) over so that the carrier end is down. 14. Using a flat plate or rod, press the Motor Shaft Seal (G17) into the center bore so that it

is flush with the face of the Spindle (G1).

130

HUB SUB-ASSEMBLY

1. Put Hub (G2) on a table with the tapped holes facing down.

2. Using a flat plate in conjunction with a pressing tool, press in the Seal (G16) so it is

.060” inside thee edge of the hub.

NOTE: The Seal has a thin outer shell that can be easily damaged if not installed with care. It is a good idea to start the Seal into the bore with a rubber mallet before pressing.

3. Flip the Hub (G2) over

4. Using the appropriate pressing tool (T-174356), press the Main Bearing (G15) into the

bore until it bottoms out.

131

INPUT CARRIER SUB-ASSEMBLY

1. Use the Input Planet Shaft (G6) as a pressing tool to install the Planet Bushing (G26) into the bore of each Planet Gear (G5). The shaft will help guide the bushing into the bore as well as prevent damage from the press.

2. Press three Input Planet Shafts (G6) into the three holes of the Input Carrier (7). The

head of the Input Planet Shaft (G6) needs to sit flush in the counter bore of the Input Carrier (G7) holes

3. Insert Output Sun Gear (G8) into the splined bore of the Input Carrier (G7). The gear

tooth end of the Output Sun Gear (G8) should protrude in the opposite direction of the Input Planet Shafts (G6).

4. Using retaining ring pliers, install the Retaining Ring (G24) into the groove of the Output

Sun Gear (G8). Make sure that the Retaining Ring (G24) is correctly seated in the groove and that the Output Sun Gear (G8) cannot be pulled out of the Input Carrier (G7).

5. Place a Thrust Washer (G25) on each side of the Input Planet Gear (5). Line up the

bores as well as you can visually.

6. Place the Input Planet Gear (G5) and Thrust Washers (G25) onto the Input Planet Shaft (G6) sticking out from the Input Carrier (G7).

132

7. Repeat 5 & 6 for the other 2 Planet Gears (G5).

8. Put the Thrust Plate (G23) onto the three Input Planet Shafts (G6). Use the three holes on the outermost bolt circle. The other three holes are for a different gear ratio.

9. Using the appropriate retaining ring pliers put a Retaining Ring (G18) into the groove of

each Input Planet Shaft (G6).

NOTE: Do not overstress the Retaining Rings (G18).

133

MAIN GEARBOX ASSEMBLY

1. Inspect seal surface of Spindle Sub-Assembly. Remove any debris or burrs that may be present.

2. Apply a coating of grease to the Lip Seal (not shown) in the Hub Sub-Assembly. 3. Place Spindle (G1) Sub-Assembly on table with carrier side up. 4. Carefully install the Hub Subassembly (seal side down) onto the Spindle Sub-Assembly.

This installation should be a slip fit and takes place in 3 stages.

Stage 1: The hub slides together until the gear teeth of the hub hit the gear teeth of the 3 Output Planet Gears (G9). Stage 2: Find the Output Planet Gear (G9) that is tight and turn it until you feel it go into mesh with the hub gear teeth, apply slight downward pressure to the hub and then find the next gear that is tight and do the same. Stage 3: Once all the Output Planet Gears (G9) are in mesh apply pressure to the hub, it should push on the rest of the way.

5. Install Retaining Ring (G27) into the groove on the OD of the Spindle (G1) carrier. This

is a Spiral Retaining Ring so it will not require pliers. You will need to pull the Retaining Ring (G27) apart and work it into the groove.

6. Using the appropriate pressing tool (T-174356), press in the Input Ring Gear (G3) into

the bore of Hub Subassembly.

NOTE: Do not use excessive pressing force because it will be reacted by the main wheel bearings.

134

7. Install the Input Carrier Subassembly into mesh. The Output Sun Gear (G8) portion of

the Input Carrier Subassembly will mesh with the Output Planet Gears (G9) and the Input Planet Gears (G5) mounted on the Input Carrier Subassembly will mesh with the Input Ring Gear (G3).

8. Install the Input Sun Gear (G4) into the area between the three Input Planet Gears (G5). 9. Apply a coating of grease to the Cover O-ring (G20) and install it into the o-ring groove

of the Hub Subassembly. NOTE: It may be helpful to stretch the O-ring (G20) out prior to assembly to avoid pinching or shearing when the Cover (G11) is assembled. 10. Apply Loctite 380 or 480 glue to Cover Thrust Washer (G21) and place it in the center

counter bore of the Cover (G11) so that the steel face of the washer is out of the bore.

NOTE: Make sure that both the Cover Thrust Washer (G21) and the Cover (G11) have good clean surfaces for the Loctite to properly adhere. 11. Center the Cover (G11) in the hub bore. Push it into the bore. 12. Install the Cover Retaining Ring (G19) into the groove of the Hub Sub-assembly.

135

MOTOR ASSEMBLY

1. Insert motor (13) into back of the gearbox. Motor will pilot on the 4 bosses in the gearbox.

Try to keep the end of the motor shaft from causing damage to the lip seal in the gearbox. NOTE: The motor may need to be rotated to line up the sun gear splines with the motor shaft splines. 2. Install the 2 Motor Mounting Bolts (M7) and Washers (M8). Tighten to 9-11 ft-lbs. 3. Connect the end of the cable to the power controller. 4. Fill the gearbox with oil per the type & capacity specified on Page 7.

136

ASSEMBLY DRAWING

137

PARTS LIST

Item No. Part No. Includes Description Qty G2 E-00622 Hub 1 G3 E-00623 Input Ring 1 G4 E-00624 Input Sun 1 G5 E-00625 Input Plant Gear 3 G6 E-00626 Input Plant Pins 3 G7 E-00627 Carrier 1 G8 E-00628 Output Sun 1 G11 E-00629 Cover 1 G14 E-00630 Main Bearing 3 G16 E-00631 Main Lip Seal 2 G18 E-00632 Planet Pin Retaining Rings 3 G19 E-00633 Cover Snap Ring 1 G20 E-00634 Cover O-Ring 5 G21 E-00637 Cover Thrust Washer 1 G23 E-00638 Thrust Plate 1 G24 E-00639 Output Sun Retaining Ring 1 G25 E-00640 Planet Thrust Washer 6 G26 E-00641 Planet Bushing 3 G27 E-00642 Main Bearing Retaining Ring 2 G29 E-00643 O-Ring Cover Plug 2

E-00644 Cover Kit G11 1 G20 1 G21 1 G19 1 G29 2 E-00645 Input Carrier Kit G5 3 G26 3 G25 6 G18 3 G6 3 G23 1 G24 1 G8 1 G4 1 G7 1 G20 1 E-00646 Hub Kit G16 1 G20 1 G2 1 G14 1 G27 1 E-00647 Input Ring Kit G3 1 G20 1 G27 1 G14 1

138

PARTS LIST CONTINUED Item No. Part No. Includes Description Qty

E-00615 Motor & Brake Replacement E-00616 Motor & Brake 1 B01-09-0111 Spade Connector 2 E-00551 Spade Connector 2 E-00617 Brake Kit w/ Gasket and Filler Strip E-00618 Brake Disc E-00619 Motor Brush & Bearing Kit E-00620 Motor Hardware Kit E-00621 Motor Terminal Cover Kit E-00546 Cable Clamp (Motor Terminal Cover)

139

ASSEMBLY TOOLS

141

Fairfield Manufacturing Company, Inc. P.O. Box 7940 U.S. 52 South

Lafayette, Indiana 47903 Phone 765-772-4000 Fax 765-772-4001

www.fairfieldmfg.com

125 Taylor Parkway Archbold, OH 43502 Phone (419) 445-8915 (800) 537-0540 Fax (419) 445-0367

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