MARK INDUSTRIES THE MARKLIFTS J25EP (01) PDF Document

The following are the nominal specifications for the MARK INDUSTRIES THE MARKLIFTS J25EP:

Specifications are nominal and are subject to change due to continuous design improvements.

Every operator of the MARK INDUSTRIES THE MARKLIFTS J25EP must read, understand and follow the safety rules set forth herein. It is essential that it be properly maintained and operated to perform all functions with maximum safety and efficiency.

1. Inspect the machine periodically as specified in the Inspection and Checkout, and Preventive Maintenance sections and as required by ANSI, OSHA, local safety boards and the owner. All unsafe items must be corrected by a qualified service person before use of the machine.

2. Only trained operators must be assigned to operate the machine.

3. It is the responsibility of the operator to read and understand this manual and to follow all recommendations made.

4. Never exceed manufacturer’s recommended platform load capacity. Remember, the load capacity of the machine is the total combined weight of personnel and tools, fixtures, accessories, etc.

5. Always distribute the load evenly over the platform floor area.

6. It is recommended that head gear (hard hats) be worn by all personnel on the work platform.

7. Do Not change, alter, or vary the equipment in any way.

8. Do Not override any hydraulic, mechanical, or electrical safety devices.

9. Do Not store loose material in the work platform such as pipe, rope, extension cords, wire or miscellaneous boxes. If it is necessary to store such items, they must be positioned in such a way that no one will trip over them when operating or working in the platform.

10. Do Not work on the platform if your physical condition is such that you feel dizzy or unsteady in any way.

11. The MARK INDUSTRIES THE MARKLIFTS J25EP is a non-insulated personnel carrier and must not be operated within 10 feet of a 50,000 volt line. (See Division Of Industrial Safety for required clearances from overhead high voltage lines.)

12. Under no circumstances should horse play be tolerated on the machine.

13. Do Not drive on uneven, sloping or soft terrain that sets the unit in an out-of-level condition of more than 6 degrees fore and aft, or 3 degrees side to side.

14. Do Not drive the platform into objects.

15. Do Not lean over platform guard railings to perform work.

16. Do Not use ladders or scaffolding on the platform to obtain greater height.

17. Do Not raise or lower scissor into objects.

18. The machine structure must not be used as a welding ground. Disconnect both battery leads prior to performing any welding operations.

19. Do Not jump start other vehicles using the machine’s battery.

20. When a machine is not in use, remove the key from the ground control panel to prevent unauthorized use.

21. When working under the elevated platform, always remember to raise the Safety Support Arm to prevent accidental platform descent.

When operating or transporting the MARK INDUSTRIES THE MARKLIFTS J25EP near energized high-voltage lines, the following minimum clearances must be maintained. Unless electrical distribution and transmission lines have been de-energized and visibly grounded or effective barriers have been erected to prevent physical and arcing contacts, these provisions apply.

TABLE X – Required Clearances from Overhead High-Voltage Lines

TABLE Y – Required Clearances from Energized High-Voltage Conductors (While in Transit)

Before unloading the MARK INDUSTRIES THE MARKLIFTS J25EP, inspect it for any physical damage. Note any damage on the freight bill and report it to the carrier.

When a loading dock is unavailable and a forklift must be used, make sure that the forklift used has forks sufficiently long for the forklift boots at the ends of the unit. Do Not attempt to lift the machine from the side.

Short Distance Transport:

The MARK INDUSTRIES THE MARKLIFTS J25EP may be freewheeled for loading and unloading or for towing a very short distance (maximum of one (1) mile), at a speed no greater than five (5) mph. To enable freewheeling, you must open the Freewheeling valve to set the brakes back into the normal mode (refer to brake adjustment procedure).

Long Distance Transport:

To transport the MARK INDUSTRIES THE MARKLIFTS J25EP over long distances, a truck or trailer must be used. If a rollback truck with a winch is used, attach the winch cable to the tiedown brackets and pull the machine onto the truck. Keep the winch cable taut at all times.

Securing for Transport:

When securing the machine to the truck, put the chains or straps through the tiedown brackets only. DO NOT CHAIN OR STRAP OVER THE THE PLATFORM OR GUARD RAILS. Severe damage to the unit will result from excess pressure caused by improperly securing the machine.

The MARK INDUSTRIES THE MARKLIFTS J25EP is equipped with both dynamic (hydro-static) and parking brakes. The parking brake is adjusted by turning the large red knob, located on the control valve, clockwise or counter-clockwise to regulate the speed at which the brake cylinder rod engages the brake sprocket on the rear wheel.

Important: THE PARKING BRAKE IS NOT DESIGNED FOR DYNAMIC APPLICATION (WHILE THE MACHINE IS STILL IN MOTION). Adjust the brake control valve so that the cylinder rod engages the brake sprocket after the wheel has stopped turning. Mis-adjustment of the parking brake (cylinder rod engages brake sprocket while the wheel is still turning) WILL result in damage to the parking brake cylinder.

After the MARK INDUSTRIES THE MARKLIFTS J25EP is delivered and unloaded, some minor inspections must be made before putting the unit into service. The following must be checked:

1. Visually inspect all exposed parts of the machine. Secure any loose bolts and nuts. Replace any damaged hydraulic lines or broken wires. Check for any structural damage, including cut or damaged tires.

2. Check the hydraulic oil level – sight gauge shows full when the scissor stack is fully lowered.

3. Check the battery for a 1200 ± 50 on the hydrometer. Charge the battery if its reading is below 1100. If the battery requires water, fill to the proper level AFTER charging. Do Not overfill.

4. Check the hydraulic valve manifold for leaks, loose fittings or loose electrical connections.

5. Check hoses for leaks.

6. Make sure that the brakes will hold the unit on an incline of up to 3 degrees.

7. Test switches: Position the selector switch to ‘ground’, then raise the platform up and down. Position the selector switch to ‘aerial’ and test the ‘drive’, ‘steering’, and ‘raise platform’ switches.

To start the MARK INDUSTRIES THE MARKLIFTS J25EP, follow these steps:

1. Turn power switch at ground control station to “ON”.

2. Position selector switch to “AERIAL”.

3. Enter the platform.

4. MAKE SURE THE ENTRANCE SLIDE BAR ASSEMBLY IS IN THE PROPER POSITION.

5. Pull the emergency ON/OFF switch out to activate the aerial controls and warning devices.

Forward and reverse drive are operated from the aerial control box only. The MARK INDUSTRIES THE MARKLIFTS J25EP is equipped with a high and low speed for both forward and reverse drive.

For forward drive, rotate the knob forward; the first position is low speed, the second position is high speed.

For reverse drive, rotate the knob reverse; the first position is low speed, the second position is high speed. Low speed is automatically selected whenever the platform is raised 7 feet.

The MARK INDUSTRIES THE MARKLIFTS J25EP may be steered from the aerial control panel only. Push the toggle switch to the left to turn the front wheels to the left. Pushing the switch to the right will cause the wheels to turn to the right. The toggle switch is a momentary switch which will automatically return to the ‘off’ position when released. The wheels will remain at a steering direction until the toggle switch is activated again.

To operate from the aerial control box:

Position the selector switch to the “Aerial” position. Raise or lower the platform by operating the “Lift/Lower” toggle switch.

To raise or lower the scissor from the ground control:

Set the selector switch to the “Ground Control” position, then push the toggle switch up or down. The toggle switch is self-centering. When it is released it will automatically set itself to center (the neutral position). The unit will remain stationary.

The platform on the MARK INDUSTRIES THE MARKLIFTS J25EP may be manually extended from the aerial platform.

To extend: Raise the handles up from the lock position. Using the handles, push forward until the platform is fully extended. Lower the handles to the lock position.

To retract: Raise the handles from the lock position, then pull the platform inward until fully retracted. Lower the handles into the lock position.

As a special safety feature, the MARK INDUSTRIES THE MARKLIFTS J25EP is equipped with an “out-of-level” sensor that will automatically lower the scissor whenever the machine is in an unsafe out-of-level position.

An unsafe out-of-level condition is sensed by the mercury switches, located within the ground control box, when the machine is tilted 3° or more on either side or 6° front or rear. The unsafe condition is indicated by a red warning light and buzzer, located on the top center of the aerial control box. When the warning light and buzzer are on, “Lift: UP/DOWN will not operate but the drive and steer functions will. Should the warning signals come on, maneuver the machine until it is on a safe operating surface and all functions will be restored.

The following items should be checked daily on the MARK INDUSTRIES THE MARKLIFTS J25EP:

1. Make sure that operation and safety decals are in place and easy to read.

2. Check hydraulic tank level.

3. Check the water level in the batteries.

4. Check for loose or worn hardware.

5. Inspect the controls for proper operation.

6. Check for and correct any hydraulic leaks.

7. Check for and correct any structural damage.

The following items should be checked weekly on the MARK INDUSTRIES THE MARKLIFTS J25EP:

1. Check the condition of the tires. Make sure they are free of serious cuts or defects.

2. Check that operation and safety decals are in place and are easy to read.

3. Check for proper brake operation.

4. Record hour meter reading. (Optional)

5. Clean unit by removing all dirt, oil, and grease. The machine may be washed with soap and water. (Keep clear of the electrical panels and charging units.)

6. Check for and correct any hydraulic leaks.

7. Check for and correct any structural damage.

8. Check overall performance.

9. Check for wear on electrical cables and hoses.

The following maintenance should be performed monthly (or after the first 50 hours) on the MARK INDUSTRIES THE MARKLIFTS J25EP:

1. Check and lubricate, if necessary.

2. Check battery condition.

3. Change the hydraulic oil return filter.

The following maintenance should be performed every six months (or 100 hours) on the MARK INDUSTRIES THE MARKLIFTS J25EP:

1. Check and lubricate, if necessary.

2. Change the hydraulic oil return filter.

The following maintenance should be performed every year on the MARK INDUSTRIES THE MARKLIFTS J25EP:

1. Re-pack all wheel bearings.

2. Change the hydraulic oil.

3. Change the hydraulic oil return filter.

Battery Fill Instructions

Water loss from the battery is mainly due to evaporation brought on by temperature rises during heavy charging cycles. A very small amount of water is lost due to hydrogen and oxygen formed during charging. Acid is lost if the case becomes cracked or if the battery is allowed to tip over. Therefore, acid is seldom needed.

Checking the Water Level

When checking the water level, don’t allow dirt to enter into the battery cells once the caps have been removed. Take particular care to avoid setting the caps down on a dirty surface. Replace the caps immediately after checking the water level.

Materials and Equipment Required

1. Battery Filler Bottle

2. Distilled Water (if available)

3. Hydrometer

Filling the Battery

Use a hydrometer to see how much charge the battery has. A reading of 1.260 and above in all cells indicates fully charged. If the battery is fully charged, add water up to the level indicator. If the battery’s water level is far below the lead plates, add only enough water to barely cover the plates.

Avoid Battery Hazards

Batteries produce flammable and explosive gasses. Keep arcs, sparks, flames and lighted tobacco away from batteries.

Battery acid will damage eyes or skin on contact. Always wear a face shield during battery maintenance to avoid acid in eyes. Also wear rubber gloves and protective clothing to keep acid off skin.

Never check the battery by placing a metal object across the posts. Serious burns or an explosion can result.

Charge batteries only in a well ventilated area.

The following table shows the actual hydrometer reading at various temperatures, which corresponds to the approximate state of charge for the batteries.

The freezing point of the battery electrolyte depends on its specific gravity. Note that cold temperatures have a numbing effect on the electromechanical action of the battery, greatly reducing its capacity. It is highly recommended that the battery be kept in an almost fully charged condition during cold weather.

Whenever troubleshooting any problem, begin by checking the basics. This means checking to make sure that the batteries are in good shape and have at least a three quarter charge, determined by using a hydrometer and battery maintenance instructions. A large percentage of electrical problems are often due to poorly charged or defective batteries.

ELECTRICAL

A. If a problem seems to be electrical, refer the schematic section for more information and use a volt/ohm meter to trace power flow (electrical current) starting at the battery and continuing through the system until the problem is located.

B. Keep in mind, if you DO NOT have a good ground to a valve coil, relay, etc., (even if you have enough electrical power to operate the coil or relay), these items will not operate properly.

C. Diodes can be thought of as “One way electrical check valves” they permit current to flow in one direction and stop it in the opposite direction.

D. The basic purpose of the relay is to remotely switch other electrical devices.

HYDRAULIC

A. The various hydraulic functions are controlled by electric solenoid valves. When a slower drive speed is needed, a portion of the hydraulic fluid is routed to the tank by the low speed priority valve, thus reducing the speed.

B. Directional valves (steering, drive, etc.) have two electrical coils with a moveable spool between the coils.

C. One way valves (lift, descent, and dump) are normally opened or closed to prevent or permit passage of fluid when electrically energized.

If the drive motor will not run, check the following:

A. Check ground control box circuit breaker.

B. Check for low battery reading.

C. Refer to your local service facility.

If the unit will not go into high speed, refer to your local service facility.

If the motor dies under load, check the following:

A. Check hydraulic pressure.

B. Refer to your local service facility.

If you suspect a hydraulic pressure issue, check the following:

A. Make sure hydraulic system is up to recommended pressure.

B. Refer to your local service facility.

If the hydraulic pump is making excessive noise, check the following:

A. Check suction hose from tank to pump for kinks.

B. Check hydraulic oil level (sight gauge on tank.)

C. Check suction line fittings for tightness.

D. Check oil. See hydraulic fluid table.

E. Refer to your local service facility.

If the lift functions fail to operate from the aerial controls, check the following:

A. Check “Aerial/Ground” selector switch.

B. Check for loose wire in aerial control box.

C. Solenoid dump valve.

If the lift functions fail to operate from the ground controls, check the following:

A. Check position of “Aerial/Ground” box selector switch.

B. Check for loose wire in ground control box.

C. Refer to your local service facility.

Prior to disassembly, clean off the exterior of the motor. Remove key and snap ring from shaft. It may be helpful for later reference to use a felt marker to note the “top” and “bottom” of each piece with respect to the piece next to it, as proper reassembly is critical in this regard. There is no internal timing and radial location is unimportant.

Disassembly Steps:

1. Place motor in vise with shaft down, clamping around motor ports.

2. Remove bolts (19) and end cover (15).

3. Remove balance plate taking care not to drop the 4-3/8″ balls (16) located in 4 holes on balance plate (15).

4. Remove motor assembly (13), manifold boot (12), manifold (11), drive link (9), spacer (14), and thrust bearing (7).

5. Remove shaft (8) up through housing (5).

6. Turn housing over and pry out the dust seal (1).

7. Push the seal carrier (6) and thrust bearing (7) down toward the roller bearing located in housing bore. Remove snap ring (2), steel back-up shim (3), and lathe cut seal (4) from inner bore groove with small screwdriver.

8. Lift out the seal carrier (6) and thrust bearing (7).

Reassembly Steps:

1. Place housing in vise with flange up.

2. Place thrust bearing on shaft.

3. Place thrust washer (5) on shaft.

4. Place the protective shaft seal installation sleeve with the shaft seal still on its overshaft end. (Apply oil to teflon back-up (3) and seal (4) prior to installation). Install seal (4) over the sleeve and onto the shaft down to the thrust washer (5) (oriented as shown).

5. Remove installation sleeve.

6. Install the teflon back-up (3) onto the shaft oriented as shown. The lip on the teflon back-up (3) should engage with the shaft seal (4).

7. Install back-up ring (2) onto shaft and down against the teflon back-up (3).

8. Place seal carrier (1) onto the shaft. We recommend using the seal carrier installation guide (PE444501) to push the seal carrier straight down over the shaft seal assembly, taking care not to cock the carrier while installing.

9. If a seal carrier installation guide is not available, you may use your fingers or a short piece of pipe to carefully and very gently push seal carrier over the seal.

10. If applicable, install .062 dia. wire ring onto the shaft being used.

11. Slide shaft assembly (8) into the housing so that seal carrier (6) is beyond the inner bore seal groove.

12. Install lathe cut seal (4) into groove.

13. Install the steel back-up shim (3) next to seal shim must be folded and bent slightly and worked into place with a small screwdriver.

14. Install wire retaining ring.

15. Place housing (5) and shaft assembly (8) in vise with shaft (8) down.

16. Install drive link (9), tap lightly on drive link end to seat the shaft assembly into the retaining ring. (See revision A)

17. Place thrust bearing on shaft end, make sure the bearing sits inside the housing bore with rollers flush or slightly below face of housing.

18. Install body seal (10) into groove in housing (5).

19. Place manifold (11) on housing (5), aligning bolt holes. Note: Manifold side with only 1 valving holes goes toward housing.

20. Place manifold boot (12) around manifold.

21. Install body seal (10) in groove in the “bottom” side of rotor assembly, bottom side has 1 deep groove in rotor. Place rotor assembly on manifold, engaging the drive link splines (9). Turn rotor assembly (13) to align bolt holes.

22. If model requires a spacer (14), place spacer on drive link end.

23. Place balance plate (15) onto rotor assembly (13) and install 4-3/16″ check balls (16) into holes provided. Note: only motors with date codes later than 030-5 have the ball check balance plates (15).

24. Install 3.125″ O.D. body seal (10) into seal groove in end cover. Note: one extra 1.782″ O.D. body seal (17) is included in seal kits for motors built prior to June, 1984, 17. Place end cover on balance plate and align bolt holes.

25. Insert bolts (19) and torque in a crisscross manner to 60 FT. LBS. Remove motor from vise and place on work bench with shaft up.

26. Install dust seal (1) to flush with pilot face.