Beruflich Dokumente
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MANUAL
B33-01-0111-04
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 manufacturers 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.
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 Replacement Parts 47
Ordering Replacement Parts 97
7 Material Safety 99
M S D S For Lead Acid Batteries, wet, filled with acid 99
M S D S For Powerflow AW HVI Hydraulic Oil 101
1
LIST 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
LIST 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
2
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.
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HAULOTTE | BILJAX ESP 19 Electric Stock Picker
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.
4
1 SAFETY
ALWAYS cordon off area around the base to keep NEVER operate this equipment when exposed to
personnel and other equipment away from it while in high winds, thunderstorms, ice, or any other weather
use. conditions that would compromise the safety of the
operator.
ALWAYS stay clear of wires, cables, and other
overhead obstructions. NEVER climb up or down masts.
ALWAYS disconnect power at the batteries when NEVER allow ropes, electric cords, hoses, etc. to
not in use to guard against unauthorized use. become entangled in the equipment when the
platform is being raised or lowered.
NEVER allow electrode contact with any part of the
platform if welding is being performed from the NEVER exceed manufacturer's platform load limits
platform. and make sure all materials are evenly distributed
over the entire platform.
NEVER override or by-pass manufacturer's safety
devices. NEVER exceed platform load ratings by transferring
loads to platform at elevated heights.
NEVER release the travel brake or tow the lift
vehicle while a person or materials are on board. NEVER use guard rails to carry materials and never
allow overhang of materials when raising or lowering
NEVER stand or sit on guard rails. Work only within
platform.
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.
6
1 SAFETY
MAINTENANCE SAFETY
Ensure the following general safety precautions are Ensure the following general safety precautions are
followed while performing maintenance on the ESP followed when performing battery maintenance on
19: the ESP 19.
General Maintenance Battery Maintenance
Read and observe the following general safety ALWAYS wear safety glasses when working with or
precautions when performing maintenance on the near batteries.
ESP 19.
ALWAYS avoid contact with battery acid. Battery
ALWAYS perform maintenance procedures acid causes serious burns and should be kept away
according to manufacturer's requirements. NEVER from skin or eyes. If contact occurs, flush with water
short change maintenance procedures. and consult a physician immediately.
ALWAYS check hydraulic system. Make sure all ALWAYS disconnect ground cable first when
lines, connectors, and fittings are tight and in good removing battery.
condition.
ALWAYS connect ground cable last when installing
ALWAYS keep all mechanisms properly adjusted battery.
and lubricated according to maintenance schedule
ALWAYS charge batteries in open, well-ventilated
and manufacturers specifications.
areas.
ALWAYS perform a function check of operating
ALWAYS replace batteries using only parts
controls before each use and after repairs have
recommended by manufacturer. ALWAYS use only
been made.
batteries with sealed caps over cells.
ALWAYS locate and protect against possible pinch
NEVER smoke while servicing batteries.
points prior to performing maintenance and repairs.
NEVER charge batteries near flammable materials.
ALWAYS use only factory-approved parts to repair
or maintain this equipment. If this equipment is NEVER allow batteries to overcharge and boil.
rebuilt, retesting is required in accordance with
NEVER short across battery posts to check for
factory instructions.
current. NEVER break a live circuit at the battery.
NEVER add unauthorized fluids to the hydraulic
NEVER disconnect battery from charger while
system or battery. Check manufacturers
charger is connected to a live power source.
specifications.
NEVER jumpstart other vehicles using the ESP 19
NEVER exceed the manufacturer's recommended
batteries.
relief valve settings.
NEVER attempt repairs you do not understand.
Consult manufacturer if you have any questions
regarding proper maintenance, specifications, or
repair.
7
HAULOTTE | BILJAX ESP 19 Electric Stock Picker
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.
8
2 SPECIFICATIONS
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.
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HAULOTTE | BILJAX ESP 19 Electric Stock Picker
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
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2 SPECIFICATIONS
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.
11
HAULOTTE | BILJAX ESP 19 Electric Stock Picker
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.
12
3 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 manufacturers 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.
13
HAULOTTE | BILJAX ESP 19 Electric Stock Picker
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.
14
3 EQUIPMENT MAINTENANCE
15
HAULOTTE | BILJAX ESP 19 Electric Stock Picker
16
3 EQUIPMENT MAINTENANCE
17
HAULOTTE | BILJAX ESP 19 Electric Stock Picker
After any actual, suspected or potential damage is Check for air in the hydraulic system if the machine has
sustained that could affect the structural integrity or been stored without use for a period exceeding thirty days,
stability of the aerial platform. or if the machine was stored without use during a
seasonal climate change. Air trapped in the hydraulic
After a change in ownership. Owners should provide system will affect machine performance. Follow
a complete service history when reselling the unit. procedures for bleeding air from the hydraulic system.
The structural inspection shall include the following Owners and lessors should complete a full inspection of all
considerations. components and perform a test of all functions, including
brake functions, before commissioning or reselling
The service history of the unit, including hours of machine. Always repair or replace all damaged or
service, work performed and environmental malfunctioning components before commissioning or
conditions. reselling machine.
The inspection and maintenance record of the unit. When a change in ownership occurs, it is the responsibility
The effectiveness of all controls and components. of the seller to provide the new owner with all manuals for
the machine. It is the responsibility of the buyer to notify
A visual inspection of the unit for wear or damage. the manufacturer of the unit model and serial number and
the name and address of the new owner within 60 days.
Manufacturer recommendations.
Use the Service Checklists as well as any maintenance,
A visual weld inspection, to be performed by qualified
repairs or alterations performed on the machine.
personnel in accordance with applicable government
regulations. 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.
18
3 EQUIPMENT MAINTENANCE
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.
19
HAULOTTE | BILJAX ESP 19 Electric Stock Picker
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.
20
3 EQUIPMENT MAINTENANCE
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.
21
HAULOTTE | BILJAX ESP 19 Electric Stock Picker
2
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 7
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 Figure 3-5. Hydraulic Cylinder Disassembly
gouges, scratches, and wear. Replace worn or
damaged components.
Thoroughly clean the inside surface of cylinder
jacket (2).
22
3 EQUIPMENT MAINTENANCE
1. Slide Block
2. Set Screw
3. Slotted Hex Screw
Figure 3-7. Slide Block Adjustment
1. Lift Chain
2. Clevis Assembly NOTE: The plastic slide blocks in the mast are
3. Lock Nut made of a bearing material which has a high
degree of lubricity and need only be kept clean.
Figure 3-6. Lift Chains Adjustment 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.
23
HAULOTTE | BILJAX ESP 19 Electric Stock Picker
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 Linear Battery Charger
week. Under normal circumstances, battery
recharge should take approximately 10-12 hours. CHARGING
PUSH
WARNING FOR
24
3 EQUIPMENT MAINTENANCE
Cell Indication
Charge
LED Status Voltage Rate
Phase
25
HAULOTTE | BILJAX ESP 19 Electric Stock Picker
P/N: B01-05-0067
26
3 EQUIPMENT MAINTENANCE
27
HAULOTTE | BILJAX ESP 19 Electric Stock Picker
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.
Cause Correction
Recharge batteries to (min 12.6 volts per
battery or 25.2 volts per system to reset BDI),
a Low battery power or faulty battery circuit.
load test batteries, and check for faulty
cables.
Battery ground or in-series battery cable Check for and repair loose and /or corroded
b
loose. 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.
Emergency stop button (upper & lower) Rotate emergency stop buttons clockwise to
f
engaged (pushed in). disengage.
Gate switch open circuit or improperly Check wire harness for short and/or adjust
g
adjusted. switch to actuate when gate is closed.
Charging cord box door switch open circuit or Check wire harness for short and/or adjust
h
improperly adjusted. switch to actuate when door is closed.
i No (24V+) signal at Relay post (85) Check Mast wire for damage.
Check (B-) side of terminal strip and wiring
j No (24V-) ground at Relay post (86)
leading to post.
k No (24V+) hot at Relay post (30) Check wiring from 10 amp fuse to post.
Check wiring from terminal strip to Relay post
l No (24V+) to Terminal strip (B+)
(87)
2 Lift vehicle will not function at upper and lower control box.
Cause Correction
Record flashes and find code on Motor
a Error code Controller (Green flashing light) Controller Fault Codes (Table 3-3). Read
and repair as needed.
CAN communication lost between upper and Check and repair wires and/or wire
b
lower I/O modules (No Green light) connections that are creating an open circuit.
Check and repair connectors and wiring from
c Bad Connection and/or damaged wiring arm rest controls to upper I/O module and
from Module to Mast wiring.
Key switch (lower controls) not turned to
d Turn key switch to Upper or Lower controls.
appropriate position.
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3 EQUIPMENT MAINTENANCE
3 Lift vehicle will not drive or raise/lower from upper control box.
Cause Correction
Underguard switch open circuit with no load
Check wiring and switch adjustment. Vehicle
a applied to underguard. Beeper tone will
will raise with this condition.
change also.
Vehicle is out of level, lower machine until
Stowed mast switch open, level sensor led is
b stowed mast switch is closed and drive to a
red, and beeper tone change.
level location for raising.
Function selected before selecting enable
c Select enable before function.
(trigger or button)
4 Lift vehicle will not drive from upper control box.
Cause Correction
Enable circuit not making connection to upper
a Check for damaged wires and connectors.
I/O module.
b Joystick pot out of adjustment. Adjust pot to center voltage of 2.5V.
Faulty joystick wire or wire connection to Check and repair damaged connections or
c
upper I/O module and/or 24V-. wires.
d Something blocking the wheels. Remove blockage.
5 Lift vehicle will not raise from upper and lower control box.
Cause Correction
Vehicle is out of level, lower machine until
Stowed mast switch open, level sensor led is
a stowed mast switch is closed and drive to a
red, and beeper tone change.
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.
Check for at least 18 volts at coil, if not
Up coil not receiving input, faulty wiring, bad
d present check wiring for damage and/or
coil.
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.
Ensure load trying to lift does not exceed
h Trying to lift more than rated capacity.
rated capacity.
Clean and lubricate masts with dry silicone. If
i Mast sections dirty; slide blocks binding. adjustment needed refer to slide block
adjustment.
Check cylinder housing for heat buildup due
j Internal leakage in hydraulic cylinder. to leakage. If leakage is indicated, repair or
replace hydraulic cylinder.
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HAULOTTE | BILJAX ESP 19 Electric Stock Picker
Cause Correction
Enable circuit not making connection to upper
a Check for damaged wires and connectors.
I/O module.
Up switch not making connection to upper I/O
b Check for damaged wires and connectors.
module.
7 Lift vehicle will not raise from lower control box.
Cause Correction
Check for damaged/unconnected wires and
a Poor or no ground to Key Switch from (B-)
connectors.
Key switch (with lower controls selected) not
b
providing ground (B-) to Up switch contactor.
Up switch contactor to lower I/O module not Check for damaged/unconnected wires and
c
making connection. connectors.
8 Lift vehicle will not lower from upper and lower control box.
Cause Correction
Underguard switch open circuit with no load
Check wiring and switch adjustment. Vehicle
a applied to underguard. Beeper tone will
will raise with this condition.
change also.
Check for at least 18 volts at coil, if not
Down coil not receiving input, faulty wiring,
b present check wiring for damage and/or
bad coil.
output from lower I/O module.
c Down valve sticking; does not open Repair or replace down valve.
Clean and lubricate masts with dry silicone. If
d Mast sections dirty; slide blocks binding. adjustment needed refer to slide block
adjustment.
Cause Correction
Enable circuit not making connection to upper
a Check for damaged wires and connectors.
I/O module.
Down switch not making connection to upper
b Check for damaged wires and connectors.
I/O module.
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3 EQUIPMENT MAINTENANCE
Cause Correction
Check for damaged/unconnected wires and
a Poor or no ground to Key Switch from (B-)
connectors.
Key switch (with lower controls selected) not Check for damaged/unconnected wires and
b
providing ground (B-) to Up switch contactor. connectors.
Down switch contactor to lower I/O module Check for damaged/unconnected wires and
c
not making connection. connectors.
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.
Check for at least 18 volts at coil, if not
Steer coil (right or left) not receiving input,
d present check wiring for damage and/or
faulty wiring, bad coil.
output from lower I/O module.
e Steering one direction only. Replace stuck valve.
f Hydraulic oil level low in reservoir. Check reservoir level.
Thumb switches not making connection to Check for damaged/unconnected wires and
g
upper I/O module. connectors.
h Thumb switch faulty. Replace Joystick.
Enable circuit not making connection to upper
i Check for damaged wires and connectors.
I/O module.
j Steering linkage pin snapped. Replace pin.
31
HAULOTTE | BILJAX ESP 19 Electric Stock Picker
Fault Checked
Code Name Flashes Severity When Solution
Remove power and allow controller to cool. If fault
repeatedly occurs, look for binding on the hydraulic
Unit over cylinders or sticking valves. Otherwise, the pump
1 temperature 8 1 Runtime motor may be failing.
Recycle power. If fault repeatedly occurs, look for
Traction Power faulty drive motor wiring. Otherwise, the traction
2 Limit 8 1 Runtime motors may be failing.
Recycle power. If fault repeatedly occurs, look for
Pump Power binding on the hydraulic cylinders or sticking valves.
3 Limit 8 1 Runtime Otherwise, the pump motor may be failing.
Forward and Reverse input commands both active.
Faulty or damage wiring between controller and
Two Direction traction motors, between joystick and upper I/O
4 Input Fault 2 2 Runtime module or Joystick pot out of adjustment.
Command to drive or lift is active at power up. Check
5 Sequence Fault 2 2 Power up enable line, B- wiring, and Molex Connector.
CAN command input is invalid or illegal. Check CAN
wiring and connectors. Refer to beep codes for
6 CAN Input Fault 2 2 Runtime safety signal inputs.
Recharge the batteries. Make sure battery
7 Low Battery Fault 7 2 Runtime connections are not reversed.
High Battery Make sure battery charger is off. Check for poor or
8 Fault 7 2 Runtime corroded battery connections.
CAN communications lost or CAN controller reporting
excessive transmission failures. Check CAN wiring
9 CAN Fault 10 2 Runtime and connectors.
High Battery w/o Make sure battery charger is off or that the batteries
10 Line Contactor 7 3 Runtime are not over charged.
Configuration Use Sevcon calibrator to enter correct settings from
11 Range Fault 1 3 Power up latest Personality Sheet.
Use Sevcon calibrator to enter correct settings from
Configuration latest Personality Sheet. Otherwise, replace motor
12 CRC Fault 1 3 Power up controller.
Use Sevcon calibrator to enter correct settings from
Motor Setup latest Personality Sheet. Otherwise, replace motor
13 Error 1 3 Power up controller.
Line Contactor Check line contactor wiring. If OK, then replace line
14 Welded 4 3 Power up contactor.
Line Contactor Check line contactor wiring and Molex connector. If
15 Did Not Close 4 3 Runtime OK, then replace line contactor.
Check traction motor wiring and connections for
Motor Open damaged or disconnected wiring. If OK, replace
16 Circuit 5 3 Runtime motor controller.
Check traction motor wiring and connections for
damaged or disconnected wiring. If OK, replace
17 Mosfet Failure 3 3 Runtime motor controller.
Autozero Out Of Check Translation board for fault or trouble shooting
18 Range OFF 3 Runtime table #1. If OK, replace motor controller.
32
3 EQUIPMENT MAINTENANCE
Fault Checked
Code Name Flashes Severity When Solution
33
HAULOTTE | BILJAX ESP 19 Electric Stock Picker
34
HAULOTTE | BILJAX ESP 19 Electric Stock Picker
4 OPERATION
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.
35
HAULOTTE | BILJAX ESP 19 Electric Stock Picker
36
4 OPERATION
37
HAULOTTE | BILJAX ESP 19 Electric Stock Picker
38
4 OPERATION
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.
39
HAULOTTE | BILJAX ESP 19 Electric Stock Picker
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.
40
HAULOTTE | BILJAX ESP 19 Electric Stock Picker
5 REPLACEMENT 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.
41
HAULOTTE | BILJAX ESP 19 Electric Stock Picker
42
4 OPERATION
43
HAULOTTE | BILJAX ESP 19 Electric Stock Picker
44
4 OPERATION
Identification Plate
B06-00-0359 Serial Number Tag 1
Decal Kit
B06-01-1400 Decal Set (Does Not Include Serial Number Tag)
45
HAULOTTE | BILJAX ESP 19 Electric Stock Picker
46
6 REPLACEMENT PARTS
Use only parts manufactured and/or authorized by Haulotte | BilJax, Inc. when replacing
damaged components. See page 97 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) 48
First Moving Mast 50
Second Moving Mast 52
Third Moving Mast 54
Fourth Moving Mast 56
Chain 58
Base and Mast (Complete) 60
Base (I) 62
Base (II) 64
Underguard 66
Console 68
Platform 72
Steering 74
I/O Module Upper 76
Lower Control Box 78
Upper Controls Box 80
Electrical Diagram ESP 19 82
Control Panel 84
Hydraulic Pump Unit 92
Hydraulic Valve Block 94
Hydraulic Schematic 95
47
MAST ASSEMBLY
48
MAST ASSEMBLY PARTS LIST
49
FIRST MOVING MAST ASSEMBLY
50
FIRST MOVING MAST ASSEMBLY PARTS LIST
51
SECOND MOVING MAST ASSEMBLY
52
SECOND MOVING MAST ASSEMBLY PARTS LIST
53
THIRD MOVING MAST ASSEMBLY
54
THIRD MOVING MAST ASSEMBLY PARTS LIST
55
FOURTH MOVING MAST ASSEMBLY
56
FOURTH MOVING MAST ASSEMBLY PARTS LIST
57
CHAIN ASSEMBLY
58
CHAIN ASSEMBLY PARTS LIST
59
BASE AND MAST ASSEMBLY
60
BASE AND MAST ASSEMBLY PARTS LIST
61
BASE (I) ASSEMBLY
62
BASE (I) ASSEMBLY PARTS LIST
63
BASE (II) ASSEMBLY
64
BASE (II) ASSEMBLY PARTS LIST
65
UNDERGUARD ASSEMBLY
66
UNDERGUARD ASSEMBLY PARTS LIST
67
CONSOLE ASSEMBLY (PRIOR TO APRIL 2012)
68
CONSOLE ASSEMBLY PARTS LIST (PRIOR TO APRIL 2012)
69
CONSOLE ASSEMBLY
70
CONSOLE ASSEMBLY PARTS LIST
71
PLATFORM ASSEMBLY
72
PLATFORM ASSEMBLY PARTS LIST
73
STEERING ASSEMBLY
74
STEERING ASSEMBLY PARTS LIST
75
I/O MODULE ASSEMBLY
76
I/O MODULE ASSEMBLY PARTS LIST
77
LOWER CONTROL BOX ASSEMBLY
78
LOWER CONTROL BOX ASSEMBLY PARTS LIST
79
UPPER CONTROL BOX ASSEMBLY
80
UPPER CONTROL BOX ASSEMBLY PARTS LIST
81
ELECTRICAL DIAGRAMS ESP 19
82
83
84
85
86
87
HAULOTTE | BILJAX ESP 19 Electric Stock Picker
96
SEVCON CONTROL PANEL ASSEMBLY PARTS LIST (PRIOR TO APRIL 2012)
89
SEVCON CONTROL PANEL ASSEMBLY
90
SEVCON CONTROL PANEL ASSEMBLY PARTS LIST
91
HYDRAULIC PUMP UNIT (BUCHER)
92
HYDRAULIC PUMP UNIT (MTE)
93
HYDRAULIC VALVE BLOCK
94
HYDRAULIC SCHEMATIC (DELTA)
95
HYDRAULIC SCHEMATIC (BUCHER)
96
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
techsupport@haulotte.com.
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
NOTES
97
98
7 MATERIAL 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.
Manufacturers 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
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)
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.
99
MATERIAL SAFETY DATA SHEET
FOR LEAD ACID BATTERIES, WET, FILLED WITH ACID (CONTINUED)
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
100
MATERIAL SAFETY DATA SHEET
POWERFLOW AW HVI HYDRAULIC OIL
101
MATERIAL SAFETY DATA SHEET
POWERFLOW AW HVI HYDRAULIC OIL (CONTINUED)
102
MATERIAL SAFETY DATA SHEET
POWERFLOW AW HVI HYDRAULIC OIL (CONTINUED)
103
MATERIAL SAFETY DATA SHEET
POWERFLOW AW HVI HYDRAULIC OIL (CONTINUED)
104
MATERIAL SAFETY DATA SHEET
POWERFLOW AW HVI HYDRAULIC OIL (CONTINUED)
105
MATERIAL SAFETY DATA SHEET
POWERFLOW AW HVI HYDRAULIC OIL (CONTINUED)
106
MATERIAL SAFETY DATA SHEET
POWERFLOW AW HVI HYDRAULIC OIL (CONTINUED)
107
108
APPENDIX:TORQUE-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.
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.
111
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.
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.
112
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.
2. Go to the opposite side of the bolt circle and tighten bolt B until equally snug.
5. Using the same sequence, crisscross around the bolt circle and apply an equal torque to
the remaining bolts.
113
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).
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.
114
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.
4. Insert the Back Cover Bolts (B1) into the two Manual Release holes in the brake housing.
115
5. Tighten down bolts and the brake will disengage.
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.
116
MOTOR DISASSEMBLY
1. Make sure the E-stop plunger is pushed in and the key is removed from the ignition switch.
3. Drain the oil out of the unit by removing Cover Plug (G29) (see page 11), note the condition
of the oil
117
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.
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.
1. Remove Retaining Rings (G18) from each of the three Planet Shafts (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).
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).
119
HUB DISASSEMBLY
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.
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.
120
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.
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.
121
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.
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.
122
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).
123
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.
4. Using the appropriate pressing tool (T-174356), press the Main Bearing (G15) into the
bore until it bottoms out.
124
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).
125
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).
126
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.
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.
127
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.
128
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.
4. Fill the gearbox with oil per the type & capacity specified on Page 7.
129
ASSEMBLY DRAWING
130
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
131
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)
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ASSEMBLY TOOLS
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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
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