EKKO ES100E Operator'S And Service Manual Download

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Electric Scissor Lift Work Platform

erator’s and Service Manual

Applies to

ES40E/ES60E/ES80E/ES100E/ES120E

Frist Edition January 2022

Summary of Contents for ES100E

Page 1: ...Electric Scissor Lift Work Platform Operator s and Service Manual Applies to ES40E ES60E ES80E ES100E ES120E Frist Edition January 2022 ...

Page 2: ...will be very helpful for safe use of the equipment 1 Comply with the user rules workplace rules and government rules 2 Read understand and comply with the manual and other instructions in manuals 3 Routinel perform good safety work practices 4 Only trained certified operator or under the guidance of a supervisors who has the certificate can run the machine If there are any ambiguous in the manual ...

Page 3: ...re properly trained to safely operate the machine Hazard Classification products use symbols color coding and signal words to identify the following Safety alert symbol used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Red Indicates a hazardous situation which if not avoided will result in death or serious inju...

Page 4: ... 12 A11000021 Lifting Point 4 13 A11000032 Forklift Pocket 2 14 A11000029 Safety Arm 1 15 A11000031 Tip over Hazard Tilting Switch 1 16 A11000028 Brake Release Safety and Operating Instructions 1 17 A11000012 Data Plate 1 18 A11000017 Directional Arrows 2 19 A11000039 Wheel Load 4 20 A11000015 Crushing Hazard 2 21 A11000016 Crushing Hazard 2 22 A11000025 Electrocution Hazard 2 23 A11000027 Tip ove...

Page 5: ...Decals 3 ...

Page 6: ...Tie down 4 12 A11000021 Lifting Point 4 13 A11000032 Forklift Pocket 2 14 A11000029 Safety Arm 1 15 A11000031 Tip over Hazard Tilting Switch 1 16 A11000028 Brake Release Safety and Operating Instructions 1 17 A11000012 Data Plate 1 18 A11000017 Directional Arrows 2 19 A11000151 Wheel Load ES0607W 4 20 A11000145 Crushing Hazard 2 21 A11000146 Crushing Hazard 2 22 A11000025 Electrocution Hazard 2 23...

Page 7: ...Decals 5 ...

Page 8: ...ctive Band 2 11 A11000020 Transport Tie down 4 12 A11000021 Lifting Point 4 13 A11000032 Forklift Pocket 2 14 A11000012 Data Plate 1 15 A11000031 Tip over Hazard Tilting Switch 1 16 A11000028 Brake Release Safety and Operating Instructions 1 17 A11000017 Directional Arrows 2 18 A11000152 Wheel Load ES80E 4 A11000148 Wheel Load ES100E 4 A11000149 Wheel Load ES120E 4 19 A11000145 Crushing Hazard 2 2...

Page 9: ...Decals 7 ...

Page 10: ...vernmental regulations regarding required clearance from electrical power lines At a minimum the required clearance contained in the chart below must be followed Line Voltage Required Clearance 0 to 300V Don t touch 300V to 50KV 120 Inch 50KV to 200KV 181 Inch 200KV to 350KV 240 Inch 350KV to 500KV 300 Inch 500KV to 750KV 420 Inch 750KV to 1000KV 540 Inch Allow for platform movement electrical lin...

Page 11: ...t alarm sounds on the chassis only when the machine is on a severe slope If the tilt alarm sounds Lower the platform Move the machine to a firm level surface If the tilt alarm sounds when the platform is raised use extreme caution to lower the platform Outdoor Use Do not raise the platform when wind speeds may exceed 12 5 m s If wind speeds exceed 12 5 m s when the platform is raised lower the pla...

Page 12: ... ES80E 400N Indoor 2P 200N Outdoor 2P ES100E 400N Indoor 2P 200N Outdoor 1P ES120E 400N Indoor 2P Do not alter or disable the limit switches Do not alter or disable machine components that in any way affect safety and stability Do not replace items critical to machine stability with items of different weight or specification Do not modify or alter an aerial work platform without prior written perm...

Page 13: ...The guard rail system provides fall protection If occupant s of the platform are required to wear personal fall protection equipment PFPE due to job site or employer rules PFPE and its use shall be in accordance with the PFPE manufacturer s instructions and applicable governmental requirements Do not sit stand or climb on the platform guard rails Maintain a firm footing on the platform floor at al...

Page 14: ...explosive gases or particles may be present Damaged Machine Hazards Do not use a damaged or malfunctioning machine Conduct a thorough pre operation inspection of the machine and test all functions before each work shift Immediately tag and remove from service a damaged or malfunctioning machine Be sure all maintenance has been performed as specified in this manual and the appropriate service manua...

Page 15: ...erating Avoid electrical shock from contact with battery terminals Remove all rings watches and other jewelry Tip over Hazards Batteries are used as counterweight and are critical to machine stability Do not use batteries that weigh less than the original equipment Each battery must weigh 61 5lbs ES120 battery is 80 lbs Battery tray including batteries must weigh a minimum of the following require...

Page 16: ...m controls 5 Platform extension 6 Platform socket and air pipes optional 7 Scissor arm 8 Transport tie down 9 Steering wheel 10 Pothole guard 11 Ground controls 12 Timer 13 Non steering wheel 14 Brake release pump 15 Entry ladder 16 Emergency lowering line 17 Lift cylinder 18 Safety arm 19 Platform entry chain or gate 20 Platform extension release pedal ...

Page 17: ...nd air pipes optional 7 Scissor arm 8 Transport tie down 9 Steering wheel 10 Pothole guard 11 Ground controls 12 Timer 13 Non steering wheel 14 Brake release pump 15 Entry ladder 16 Emergency lowering line 17 Lift cylinder 18 Safety arm 19 Platform entry chain or gate 20 Platform extension release pedal 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 ...

Page 18: ...Platform controls 5 Platform extension 6 Platform socket and air pipes optional 7 Scissor arm 8 Transport tie down 9 Steering wheel 10 Pothole guard 11 Timer 12 Ground controls 13 Non steering wheel 14 Brake release pump 15 Entry ladder 16 Emergency lowering line 17 Lift cylinder 18 Safety arm 19 Platform entry chain or gate 20 Platform extension release pedal ...

Page 19: ...will operate Press and hold the lifting key and the platform rising key at the same time can operate the ascending function Press and hold the lifting key and the platform 2 Red Emergency Stop button lowering key at the same time can operate the ascending function Push in the red Emergency Stop button to the off position to stop all functions Pull out the red Emergency Stop button to the on positi...

Page 20: ...anel 1 Thumb rocker switch for steer function 5 Horn button 2 Drive function button 6 Lift function button 3 Drive speed select button 7 LED 4 Red Emergency Stop button 8 Proportional control handle and function enable switch for drive and lift functions ...

Page 21: ...e indicator and lift drive mode indicator 8 Proportional control handle and function enable switch for drive and lift functions Lift function Press and hold the function enable switch to enable the lift function on the platform control handle Move the control handle in the direction indicated by the blue arrow and the platform will raise Move the control handle in the direction indicated by the ye...

Page 22: ...g is apparently wrong with a machine before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance procedures are required Only routine maintenance items specified in this manual may be performed by the operator Refer to the list on the next page and check each of the items If damage or any unauthorized variation from factory delivered...

Page 23: ... and manifolds Battery pack and connections Drive motors Wear pads Tires and wheels Limit switches alarms and horn Nuts bolts and other fasteners Platform entry gate Alarms and beacons if equipped Safety arm Platform extension Scissor pins and retaining fasteners Platform control joystick Brake release components Pothole protection device Check entire machine for Cracks in welds or structural comp...

Page 24: ... should display CH Test Emergency Stop 6 Push in the ground red Emergency Stop button to the off position Result No functions should operate 7 Pull out the red Emergency Stop button to the on position Test the Up Down Functions The audible warnings on this machine and the standard horn all come from the same central alarm The horn is a constant tone The descent alarm sounds at 60 beeps per minute ...

Page 25: ...ing the steer end of the machine 26 Press the drive function button 27 Press and hold the function enable switch on the control handle 28 Press the switch on top of the control handle in the direction indicated by the left triangle on the control panel Result The steer wheels should turn in the direction indicated by the left triangle 29 Press the switch on top of the control handle in the directi...

Page 26: ... stop The tilt alarm should sound 180 times each minute 40 Move the control handle in the direction indicated by the up arrow then move it by the down arrow Result The drive function should not work in either direction 41 Lower the platform and remove both pieces of wood Test the pothole guards Note The pothole guards should automatically deploy when the platform is raised The pothole guards activ...

Page 27: ...le for safe machine operation It should be performed by the operator prior to moving the machine to the workplace It is the operator s responsibility to read and remember the workplace hazards then watch for and avoid them while moving setting up and operating the machine Workplace inspection checklist Be aware of and avoid the following hazardous situations drop offs or holes bumps floor obstruct...

Page 28: ...s and a workplace inspection before using the machine Emergency Stop Push in the red Emergency Stop button to the off position at the ground controls or the platform controls to stop all functions Repair any function that operates when either red Emergency Stop button is pushed in Emergency Lowering 1 Pull the emergency lowering knob to lower the platform Operation from Ground 1 Be sure the batter...

Page 29: ...drive speed Drive on a slope Determine the slope and side slope ratings for the machine and determine the slope grade Slope at Stowed Position Side Slope at Stowed Position ES40E 60E ES80E ES100E ES120E Max slope rating stowed position 25 Max side slope rating stowed position 25 ES80E Max slope rating stowed position 30 Max side slope rating stowed position 30 Note Slope rating is subject to groun...

Page 30: ...om the middle of the extension deck railing fold down the extension deck rail assembly toward the rear of the unit 5 Replace the two removed pins back into each side of bracket 6 At the rear of the main deck remove the two main deck lock pins 7 Fold down the rear gate and entry side rails as one unit Keep hands clear of pinch points 8 Replace the two removed pins back into each side of bracket 9 F...

Page 31: ...r Fault 32 Angle Sensor Fault 42 Platform Left Turn Switch ON at power up Message 43 Platform Right Turn Switch ON at power up Message 46 Platform Joystick Enable Switch ON at power up Fault 47 Platform Joystick not in neutral at power up Message 52 Forward Coil Fault 53 Reverse Coil Fault 54 Lift Up Coil Fault 55 Lift Down Coil Fault 56 Right Turn Coil Fault 57 Left Turn Coil Fault 58 General Bra...

Page 32: ...o the bottom of the fill tube Do not overfill Dry Battery Filling and Charging Instructions 1 Remove the battery vent caps and permanently remove the plastic seal from the battery vent openings 2 Fill each cell with battery acid electrolyte until the level is sufficient to cover the plates Do not fill to maximum level until the battery charge cycle is complete Overfilling can cause the battery aci...

Page 33: ...t allow the rails to fall when the snap pins are removed Maintain a firm grasp on the rails when the rails are lowered Do not drive the machine on a slope that exceeds the uphill downhill or side slope rating See Driving on a Slope in the Operating Instructions section If the slope of the transport vehicle bed exceeds the maximum slope rating the machine must be loaded and unloaded using a winch a...

Page 34: ...with a forklift Be sure the crane capacity loading surfaces and straps or lines are sufficient to withstand the machine weight See the serial label for the machine weight Lifting the Machine with a Forklift Be sure the extension deck controls and component trays are secure Remove all loose items on the machine Fully lower the platform The platform must remain lowered during all loading and transpo...

Page 35: ... points on the machine There are two lifting holes int each end of the machine Adjust the rigging to prevent damage to the machine and to keep the machine level core X SHAFT YSHAFT ES40E 19 64 Inch 18 93 Inch ES60E 25 35 Inch 20 75 Inch ES80E 33 66 Inch 23 54 Inch ES100E 32 80 Inch 25 43 Inch ES120E 33 46 Inch 28 90 Inch A 1 1 000019 A 1 1 000019 G R M E E Y C N E O P T S Chassis Lifting Points 2 ...

Page 36: ...d 0 78 Inch Weight 1960 Lbs Machine weights vary with option configurations See serial label for specific machine weight Power source 2Batterys12V 100Ah System voltage 24V Controls Proportional AC outlet in platform Standard Maximum hydraulic pressure functions 240Bar Tire size Φ230 80 Sound pressure level 70 dB The maximum noise level normally A level detection Total vibration value is subjected ...

Page 37: ...or specific machine weight Power source 4Batterys 6V 180Ah Lithium battery 25 6V 150Ah System voltage 24V Controls Proportional AC outlet in platform Standard Maximum hydraulic pressure functions 240Bar Tire size Φ323 100 Sound pressure level 70 dB The maximum noise level normally A level detection Total vibration value is subjected does not exceed 2 5 m s2 Maximum slope rating stowed position 25 ...

Page 38: ... for specific machine weight Power source 4Batterys 6V 180Ah Lithium battery 25 6V 180Ah System voltage 24V Controls Proportional AC outlet in platform Standard Maximum hydraulic pressure functions 240Bar Tire size Φ381 129 Sound pressure level 70 dB The maximum noise level normally A level detection Total vibration value is subjected does not exceed 2 5 m s2 Maximum slope rating stowed position 3...

Page 39: ...abel for specific machine weight Power source 4Batterys 6V 180Ah Lithium battery 25 6V 220Ah System voltage 24V Controls Proportional AC outlet in platform Standard Maximum hydraulic pressure functions 240Bar Tire size Φ381 129 Sound pressure level 70 dB The maximum noise level normally A level detection Total vibration value is subjected does not exceed 2 5 m s2 Maximum slope rating stowed positi...

Page 40: ...l for specific machine weight Power source 4Batterys 6V 240Ah Lithium battery 25 6V 220Ah System voltage 24V Controls Proportional AC outlet in platform Standard Maximum hydraulic pressure functions 240Bar Tire size Φ381 129 Sound pressure level 70 dB The maximum noise level normally A level detection Total vibration value is subjected does not exceed 2 5 m s2 Maximum slope rating stowed position ...

Page 41: ... safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions Note Sealed battery or maintenance free batteries machine do not need to check this matter Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries contain aci...

Page 42: ...s as required Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly semi annually annually and two years The Scheduled Maintenance Procedures section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are required to...

Page 43: ...according to the manufacturer s specifications and the requirements listed in the responsibilities manual Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the ...

Page 44: ...ervice repair and re inspect it After repair place a check in the R box Checklist A Y N R A 1 Inspect the manuals and decals A 2 Pre operation inspection A 3 Function tests After 40 hours A 4 30 day service After 100hours A 5 Grease steer yokes Checklist B Y N R B 1 Batteries B 2 Electrical wiring B 3 Electrical contactor B 4 Tires and wheels B 5 Emergency stop B 6 Key switch B 7 Horn B 8 Drive br...

Page 45: ...required decals and all decals are legible and in good condition Result The machine is not equipped with all required decals or one or more decals are illegible or in poor condition Remove the machine from service until the decals are replaced 4 Always return the manuals to the storage container after use Note Contact your authorized distributor or if replacement manuals or decals are needed A 2 P...

Page 46: ... damaged cables and connections can result in component damage and hazardous conditions Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Put on protective c...

Page 47: ...ry acid level If needed replenish with distilled water to 1 8 inch 3 mm below the bottom of the battery fill tube Do not overfill 12 Install the vent caps and neutralize any electrolyte that may have spilled a Batteries b Quick disconnect c 300A fuse d Charger Suitable for all models 13 Check each battery pack and verify that the batteries are wired correctly 14 Inspect the battery charger plug an...

Page 48: ...ed position and turn the machine off B 3 Inspect the Tires and Wheels This procedure should be performed every 250 hours or quarterly whichever comes first Maintaining the tires and wheels in good condition is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may also result if problems are not discovered and repaired in ...

Page 49: ...lt The machine functions should not operate 6 Turn the key switch to the off position Result No function should operate B 6 Test the Automotive style Horn This procedure should be performed every 250 hours or quarterly whichever comes first The horn is activated at the platform controls and sounds at the ground as a warning to ground personal An improperly functioning horn will prevent the operato...

Page 50: ...m control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Lower the platform to the stowed position 4 Press the drive function select button a Drive function select button 5 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line 6 Move the control handle to drive at the maximum spe...

Page 51: ...2 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Lower the platform to the stowed position 4 Press the drive speed select button a drive speed select button 5 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line 6 Move the control handle t...

Page 52: ...ents for wear Tighten any loose fasteners 2 Lubricate each module tray rotary latch Using light oil apply a few drops to each of the springs and to the sides of the rotary latch mechanism B 14 Test the Down Limit Switch Level Sensor and Pothole Limit Switches This procedure should be performed every 250 hours or quarterly whichever comes first Maintaining the limit switches is essential to safe op...

Page 53: ...safety arm when lowering the platform 19 Turn the key switch to the off position 20 Disconnect the platform controls from the ECU cable 21 Securely install the connector of the ECU cable into the platform control cable 22 Install the connector of the platform controls 23 Connect the two wires in the down limit switch correctly and safely 24 Install the cover of down limit switch 25 Turn the key sw...

Page 54: ...lty limit switch could result in reduced machine performance and a potentially unsafe operating condition Perform this procedure with the machine on a firm level surface that is free of obstructions 1 Turn the key switch to ground control and raise the platform approximately 2 5 m from the ground 2 While raising the platform from the ground controls push the arm of the up limit switch Result The p...

Page 55: ...orm to the highest position and continue to press the up function select button Result The motor does not operate The machine is functioning properly Result The motor continue to operate Calibration the platform overload system 9 Lower the platform to the stowed position by manually drop function 10 Lift the safety arm move it to the center of the scissor arm and rotate up to a vertical position 1...

Page 56: ...ween the number one inner arm cross tube and the chassis deck at the ground controls side of the non steer end of the machine a inner arm cross tube b wear pad c chassis deck Result The measurement is not less than x mm ZS07 x 34 5 ZS12 x 38 Refer to Step2 Result The measurement is less than x mm Replace the Scissor Arm Wear Pads 2 Measure the distance between the number one inner arm cross tube a...

Page 57: ...butor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Note This performed should under the state of stowed 1 Disconnect the battery pack from the machine Electrocution burn hazard Contact with electrically charged circuits could result in d...

Page 58: ...ner 2 9 Nm 12 Link hydraulic pump inlet pipe into the tank 13 Link hydraulic pump return pipe with the return filter 14 Fill the tank with hydraulic oil until the fluid is at Max Indicator Do not over fill 15 Activate the pump to fill the hydraulic system with oil and bleed the system of air Component damage Component damage hazard The pump can be damaged if operated without oil Be careful not to ...

Page 59: ...Electrical Schematic Diagram 57 ES40E ...

Page 60: ...Electrical Schematic Diagram 58 ES60E ES80E ES100E ES120E ...

Page 61: ...2 L A R SAE R L B1 B1 28 35bar 28 35bar 11 2L min 11 2L min 2950rpm 2950rpm 10 10μm 1 5bar 1 5bar 4cc 4cc T1 T1 P M 2 3 1 BR BR CSE CSE BS BS AS AS 3 1 2 4 241bar 207bar 109bar 2 5L Min 3 1 2 4 1 3 8 2 7 4 6 1 1 11 B2 B2 B1 B1 3 1 2 4 6 2 T C ...

Page 62: ...Hydraulic Schematic Diagram 60 ES80E Y7 Y7 G1 4 19 Y1 Y1 Y2 Y2 Y3 Y3 Y4 Y4 Y5 Y5 Y6 Y6 ...

Page 63: ...Hydraulic Schematic Diagram 61 ES100E ES120E Y7 Y7 G1 4 19 Y1 Y1 Y2 Y2 Y3 Y3 Y4 Y4 Y5 Y5 Y6 Y6 ...

Page 64: ...Hydraulic Schematic Diagram 62 Maintenance Record Date Note ...

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