Bishamon UNILIFT UNI-20, Service Manual

Page 1: ...SERVICE MANUAL MANUAL SERVICE MANUAL MANUAL Model UNI 20 UNILIFT PA L L E T T R A N S P O R T E R P O S I T I O N E R TM Patents Pending For Serial Numbers 1110803 and Earlier ...

Page 2: ...BISHAMON INDUSTRIES CORPORATION 5651 East Francis Street Ontario California 91761 USA 909 390 0055 800 231 3187 Date Placed in Service Serial Number Dealer ...

Page 3: ... Lift Points 7 Figure 6 Installation Components 7 Figure 7 Operator Console 8 Figure 8 Outriggers Fully Retracted LED Indicators 8 Figure 9 Right Outrigger Extending LED Indicators 8 Figure 10 Right Outrigger Extended LED Indicators 9 Figure 11 Left Outrigger Extending LED Indicators 9 Figure 12 Outriggers Fully Extended LED Indicators 9 Figure 13 Left Outrigger Retracting LED Indicators 9 Figure ...

Page 4: ...igure 31 Outrigger Inspection Points 18 Figure 32 Outrigger Linkage 19 List of Charts Chart 1 Daily Inspection Items 17 Chart 2 Weekly Inspection Items 18 Chart 3 Detailed Inspection and Maintenance 20 Chart 4 Recommended Hydraulic Fluids 20 Chart 5 2 Year 5000 Cycle Maintenance Items 21 Chart 6 Troubleshooting 22 ...

Page 5: ...e UniLift unless you have been trained and authorized to do so All operators must understand and be familiar with the operation and function of all controls and indicators 2 A falling load can cause SEVERE PERSONAL INJURY or DEATH NEVER go under the loaded or unloaded forks All maintenance should be performed with the unloaded forks in the fully lowered position or securely blocked in a raised pos...

Page 6: ...valve is installed to protect the operator and the UniLift Changing the relief valve setting may cause the forks to suddenly fall SEVERE PERSONAL INJURY and PROPERTY DAMAGE could result 7 ALL lift servicing must be performed by qualified personnel only Unauthorized modifications to the UniLift its hydraulic power unit or its control system may compromise the performance and safety of the system re...

Page 7: ...3 CRUSH AND PINCH POINT HAZARDS Figure 1 Hazard Locations ...

Page 8: ...4 Figure 2 Safety Warning Label Locations SAFETY WARNING LABEL LOCATIONS ...

Page 9: ...ners bent or cracked structural members cut or freyed hydraulic lines and damaged or malfunctioning controls or safety devices Ensure all repairs are made by qualified personnel in conformance with the instructions provided by Bishamon Industries Corporation Ensure the UniLift is used in accordance with the guidelines provided in this manual Ensure modifications or alterations of any UniLift are m...

Page 10: ... lighting 2 Next using the strap cutter remove the bands securing the UniLift to the pallet Remove all packing material and place it off to the side 3 The UniLift is stabilized on the pallet with two 2 shipping blocks secured to the top of the pallet on the left and right side of the UniLift Remove the screw securing each block to the pallet then tap the side of the blocks to remove them from the ...

Page 11: ... and gently pull the power cord out of the recess The cord will extend 2 to 3 inches to allow a 120 VAC extension cord to be attached After charging disconnect the extension cord and push the plug back into the recess Universal Key Switch All UniLifts are supplied with a universal key battery disconnect switch Turning the key to the OFF position disconnects all battery power from the UniLift The k...

Page 12: ...isconnect Switch Turning the key to the OFF position disconnects all battery power from the UniLift Turn the key to the ON position to connect battery power to the UniLift s control system Outrigger Position LEDs The position of each deployable outrigger is indicated by 5 LEDs 2 green and 3 red LEDs A green LED indicates the outrigger is in either the fully retracted or the fully extended position...

Page 13: ...tinue to depress the UP button Figure 14 Right Outrigger Retracting LED Indicators Outriggers Fully Extended The two upper green LEDs will be illuminated when both outriggers are fully extended The UniLift is now in STACKER mode and is capable of lifting and positioning a palletized load Left Outrigger Retracting As the UniLift transitions from a stacker to a pallet jack the forks will automatical...

Page 14: ...igger s direction CAREFULLY remove the obstruction or reposition the UniLift to allow the outriggers to rotate as required For additional information refer to the OPERATING INSTRUCTIONS Stacker Mode Pallet Obstruction section of this manual Battery Charger LEDs The battery charger has 2 LEDs to indicate the charger s status The left CHARGER POWER LED will illuminate when the charger is plugged int...

Page 15: ...capable of lifting most skids including postal skids Figure 18 GMA Pallet Dimensions 1 Turn the ON OFF switch to the ON position The PLC is similar to a computer and requires approximately 5 seconds to initialize before operation 2 Check the status of the outrigger position LEDs Both outriggers should be in the fully retracted positions If not depress the DOWN button to fully retract both outrigge...

Page 16: ...evate the palletized load Release the UP button when the bottom of the pallet clears the floor If a squealing sound is heard coming from the UniLift immediately release the UP button The pressure relief valve is operating due to an overload Reduce the load to 2000 lbs or less before attempting to lift it DANGER ALWAYS travel with the outriggers retracted and the forks in the lowest position possib...

Page 17: ...ove the UniLift from service Contact a supervisor or maintenance personnel to inspect the UniLift for damage 5 When the palletized load is properly positioned depress the DOWN button to lower the load onto the elevated surface Continue to lower the forks until they completely disengage the pallet and release the DOWN button Carefully pull the UniLift rearward to remove the forks from the pallet 6 ...

Page 18: ...d under high pressure can be dangerous ALWAYS disconnect the battery before servicing the electrical system Not doing so could result in a SEVERE ELECTRICAL SHOCK Blocking the Forks in a Raised Position Blocking the unloaded forks in an elevated position may be required for certain periodic inspections or maintenance operations There are many acceptable methods to block or secure the unloaded fork...

Page 19: ...er finish removing the cover and set it off to the side Inspection and or maintenance can now be performed on the UniLift Figure 23 Upper Console Cover Removal Figure 24 Lower Battery Cover Removal 7 To reinstall the covers install the lower battery cover first then the upper console cover Disconnecting the Batteries 1 Lower the forks completely and turn the key switch to the OFF position 2 Follow...

Page 20: ...ey switch is turned to OFF Carefully gasp each lever arm and rotate it rearward until it stops Release each arm and watch for smooth movement and complete load wheel retraction There should be a definite audible knock when the load wheel fully retracts and strikes the travel stop in the fork If the load wheels fail to retract completely or any binding is present the lift MUST be repaired before co...

Page 21: ...er wheel engagement 3 Visually inspect the mast channels cylinder and lifting sling Lower the forks completely and turn the key to the OFF position As demonstrated in Figure 29 gently pull the mast cover to the side and inspect the cylinder area The channels should be smooth free of filings and lightly coated with lubricant The cylinder area should be free of leaks and excess hydraulic fluid Visua...

Page 22: ...d and DEPRESS THE DOWN BUTTON for several seconds to release the hydraulic pressure before servicing the lift The release of hydraulic fluid under high pressure can be dangerous ALWAYS disconnect the battery before servicing the electrical system Not doing so could result in a SEVERE ELECTRICAL SHOCK The UniLift s upper console cover lower battery cover and mast cover must be removed to perform ma...

Page 23: ...sure the terminals are clean and tight Next check the battery straps to ensure they are tight and the batteries are not free to move 5 Check the level and appearance of the hydraulic oil The oil level is visible through the reservoir With the forks completely lowered the oil level should be 1 to 2 inches below the filler Add hydraulic oil if required Next check the hydraulic oil for contamination ...

Page 24: ...nual However detailed instructions are available from your local Bishamon dealer or Bishamon Industries Corporation The following maintenance operations must be performed by a qualified service person Hydraulic Oil Bishamon recommends the hydraulic oil be replaced every twentyfour 24 months of service or more often if conditions warrant The frequency of oil changes will depend upon the general wor...

Page 25: ...000 Cycle Maintenance Items Cylinder Seal Replacement In the event the pump or cylinder seals are leaking detailed instructions and replacement part kits are available Contact your local dealer or Bishamon Industries Corporation to obtain service kits and instructions for these items Electrical and Hydraulic Schematic Electrical and hydraulic schematics are available upon request Contact your loca...

Page 26: ...e valve Replace switch and or check wiring Replace spring Clean repair replace valve Replace pallet Outriggers will not deploy Outrigger obstruction Faulty outrigger actuator Non standard or damaged pallet Remove obstruction Replace actuator Replace pallet Outriggers will not retract Outrigger obstruction Faulty outrigger actuator Defective batteries Remove obstruction Replace actuator Replace bat...