Foster On-A-Roll Lifter Power Jumbo (63" Lift Height) - 61599 User Manual, page 1
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On-A-Roll Lifter®

Service Guide for Power Jumbo Models

This guide provides information on some common problems that may occur and steps to resolve them.

It is the user’s responsibility to exercise good judgment, common sense, safety measures and reasonable limits regarding the use of the On-A-Roll Lifter® so as not to incur risk to the user or damage to the materials being carried. In order to obtain maximum benefit from your machine, please read these instructions carefully before using the On-A-Roll Lifter®.

204 B Progress Drive, Montgomeryville, PA

Toll Free: 800-523-4855 information@go-foster.com

mybinding.com 1-800-944-4573

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Foster On-A-Roll Lifter Power Jumbo (63" Lift Height) - 61599 User Manual, page 2
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Contents

Parts Diagram 1.1 Complete Parts Diagram 1.2 Fork Assembly & Media Lifter Assembly 1.3 Hydraulic Pump Assembly & Push Bar Assembly 1.4 Electric Control Box Assembly

Diagram of Hydraulic System

Diagram of Electric System

On-A-Roll Lifter® Wheels Not Turning Properly

Opening & Closing the Electric Control Box

Oil Change and Filling

Oil Leaking and Prevention

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Parts Diagram

Parts diagram and list of components

Item # 63006 63040 63041 63050 63087 63088 63090 63091 63092 63093 63187 63205 63207 63208 63209 63210 63211 63212 63213 63214 63216 63217 63219 63220 63221 63222 63223 63225 63226 63228 63229 63230 63248 63249 63250 63293 63294 63295 63296

Contact Foster before replacing any components or performing any adjustments that aren’t currently mentioned in this instruction manual.

Description Support/caster frame nut Hydraulic pump chain cotter pin Hydraulic pump chain bolt Hydraulic pump chain guard screw Allen key bolt nut Allen key bolt washer Media tray strap clamp Media tray strap bolt Media tray strap nut M6 x 12mm Bolt Pull Bar Long Bolts M6 x 45mm Front Caster Wheel Assembly Wire Shield Protector Chain wheel cover 5cm wide Strap Pin 8cm wide strap clamp Support Strap with buckle Jumbo Media Tray Jumbo Media Tray Assembly Jumbo Push Bar Assembly Hydraulic Pump Double Chain Wheel Hydraulic pump chain guard washer Jumbo Fork Frame Roller Bearing Thread Screw for Jumbo Roller Bearing for Jumbo Snap Ring Nylon Cap Rear Caster Wheel Assembly Thread Screw for Rear Caster Wheel Front Caster Wheel Mounting Bolt Front Caster Wheel Mounting Washer Front Caster Wheel Mounting Nut Wire Shield Protector Bolt Wire Shield Protector Washer Wire Shield Protector Bracket Charger- 110V/60HZ, US Plug Fuse for Power Unit- All Lifters Battery for Power Unit- All Lifters Charger- 220V/50HZ/1PH, Euro plug

Item # Description 63297 EU Power Cord for 220V/50HZ/1PH 63298 US Power Cord for 110V/60HZ 63299 Complete pump assembly 63300 Power Jumbo Chain & Fork Assembly 63301 Chain Assembly- connected 63302 Complete Electric Control Box 63303 Power Jumbo Case 63304 Battery Connector 63305 Battery Connector Nut 63306 Battery Clamper 63307 Electric Box Cover 63308 Electric Pump 63309 Oil Pipe Adapter 63310 O Ring for Electric Pump 63311 Plug for Electric Pump 63312 Key Switch for Electric Box 63313 Coulometer 63314 Charging Status Indicator 63315 Control Faceplate 63316 Lower Operating Button 63317 Raise Operating Button 63318 Faceplace Screw 63319 Electric Box Cover Screw 63320 Electric Box Cover Washer 63321 Battery Clamper Lower Bolt 63322 Battery Clamper Lower Washer 63323 Battery Clamper Lower Nut 63324 Mounting Bracket for Electric Box 63325 Power Jumbo Frame 63326 Pump Rest Block 63327 "U" Bolt for Power Jumbo 63328 "U" bolt nut 63329 "U" bolt washer 63330 Bolt for Mounting Bracket 63331 Washer for Mounting Bracket 63332 Large Washer for Mounting Bracket 63333 Nut for Mounting Bracket 63334 Oil tube & Union for Hydraulic Pump

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Parts Diagram

Parts diagram and list of components

Contact Foster before replacing any components or performing any adjustments that aren’t currently mentioned in this instruction manual.

Push Bar Assembly 63214

63299 Complete Hydraulic Pump Assembly

63302 Complete Electric Control Box Includes all internal components and mounting brackets.

Chain & Fork Assembly 63300 63220 63221 63222 63223

Jumbo Media Tray Assembly 63213

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Foster On-A-Roll Lifter Power Jumbo (63" Lift Height) - 61599 User Manual, page 5
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Parts Diagram

1.2 Parts diagram: Chain & Media Tray Assembly

Chain & Fork Assembly 63300

Jumbo Media Tray Assembly 63213 (Contains: parts: 63091, 63092, 63209, 63210, 63211, 63212)

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Foster On-A-Roll Lifter Power Jumbo (63" Lift Height) - 61599 User Manual, page 6
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Parts Diagram

1.3 Parts diagram: Hydraulic & Handle Bar Assembly

Push Bar Assembly 63214

63299 Complete Hydraulic Pump Assembly includes: complete Hyraulic pump assembly, double chain wheel, chain assembly, chain cover, cover bolts and washers

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Foster On-A-Roll Lifter Power Jumbo (63" Lift Height) - 61599 User Manual, page 7
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Parts Diagram

1.4 Parts diagram: Electric Control Box Assembly

Charger 63293 110V/60HZ 63296 220V/50HZ/1PH

63302 Complete Electric Control Box Includes all internal components and mounting brackets.

Power Cord 63297 EU Power Cord 63298 US Power Cord

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Diagram of Hydraulic System

DF TF YF M

Magnet Valve Speed Control Valve Discharge Valve Electric Pump

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Foster On-A-Roll Lifter Power Jumbo (63" Lift Height) - 61599 User Manual, page 9
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Diagram of Electric System

If unfamiliar with electric, have a trained Electrician service this unit.

JD RD M E CZ YK SA XA DF DL

Relay Fuse DC Motor Battery Charger Socket Switch LIFT- Button LOWER- Button Magnet Valve Coulometer

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Foster On-A-Roll Lifter Power Jumbo (63" Lift Height) - 61599 User Manual, page 10
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On-A-Roll Lifter® Wheels Not Turning Properly

Lift the front side to ensure the front wheels are intact and turning. Replace if damaged. Lift the back side to ensure the steering wheels are intact and turning. Replace if damaged. Ensure the bottom cross bar on the frame is straight and not bowed. If the cross bar is bowed, the likely cause is that the user has dropped the roll media onto the tray or the roll weight is in excess of the recommended weight. Replace if damaged.

Opening & Closing the Electric Control Box

Using a Phillips Head Screwdriver, remove the 6 screws on the side of the Electric Control Box Cover. There will be 3 on each side. Using a Phillips Head Screwdriver, remove the 2 screws located on the Electric Control Box Faceplate on top. Gently remove the Cover and Faceplate being mindful of the electrical connections to leave intact.

To install the cover, line up the cover and faceplate back in position. The screw holes should match the holes on the unit. Using a Phillips Head Screwdriver insert the top 2 faceplate screws followed by the 6 side screws until the cover is securely in place.

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Foster On-A-Roll Lifter Power Jumbo (63" Lift Height) - 61599 User Manual, page 11
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Oil Change and Filling

Lower the lifter tray to the lowest position. Remove the Electric Control Box cover as instructed in the previous step 5. Using a flathead screwdriver or 8mm socket wrench, loosen the clamp ring that secures the oil tank to the pump. Remove the tank. *** Drain the old oil, clean the valve plate and the oil tank. Fill the pump unit 80% of the tank with type L-HM46 Hydraulic oil (equivalent to ISO VG46). Inspect the connections to avoid oil leaks. Reassemble the pump section and ensure all parts are securely tight and in place.

  • ** If not able to remove the tank easily with loosening the clamp ring: A. Using a 17mm wrench remove the Union from the Oil Tube. Note that if oil is in the line it will start to leak out on removal and you will need to have something to collect the oil while removing the Union and Oil Tube connection. B. Draining the Oil Tank from the drain screw. Place an oil pan to collect the oil. Using an 8mm Allen Key, remove the drain screw and allow the oil to drain into the pan. C. Oil can be checked and refilled from the Oil Cap on the top of the tank.

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Hydraulic Pump Check

Regularly changing your hydraulic fluid is the best way to prevent hydraulic pump leaks. If a leak has occurred, check all connections to the hydraulic pump to make sure everything is properly tightened.

Check Piston Valve. Check both union connections on the Oil Tube. Check top connection where Double Chain Roller attaches to Hydraulic Pump.

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Foster On-A-Roll Lifter Power Jumbo (63" Lift Height) - 61599 User Manual, page 13
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Oil Leaking and Prevention

If any of the connection points are loose in Step 7, tighten them to prevent leaking. If any connection point is damaged, those parts will need to be replaced. If all 3 connections appear fine then the Hydraulic Pump will need to be replaced.

Remove the nuts and cotter pins from both chains attaching to the top section of the chain assembly.

Remove 2 washers and nuts from the U bolt.

Lift the hydraulic pump. Pack it properly into thick packaging material to avoid the oil spilling. Replace with new hydraulic pump. Tighten 2 washer and nuts from the U bolt. Reattach the nuts and cotter pins to each chain.

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Foster On-A-Roll Lifter Power Jumbo (63" Lift Height) - 61599 User Manual, page 14
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Troubleshooting & Maintenance

Problem / Description Cause / Reason Coulometer doesn't indicate when 1. Terminals and inserts are loose. key switch is ON.

  1. Switch is out of order.

Solution

  1. Check terminals and all connections to ensure nothing is loose or damaged.
  2. Check and change the switch or damaged wires.

Roll tray does not lift up when pushing the LIFT button.

  1. Terminals and inserts are loose.
  2. Oil is low on Hydraulic Pump.
  3. Fuse is broken.
  4. Lift Button is broken.

Lifting speed is too slow when pushing LIFT button.

1. Battery does not have enough power.

2. Relief valve is not in proper position.

3. Roll weight exceeds lifting capability.

1. Oil is low on Hydraulic Pump.

2. Other object blocking.

1. Check terminals and all connections to ensure nothing is loose or damaged.

2. Fill oil to proper level.

3. Replace Fuse.

4. Check and replace lift button.

1. Recharge the battery.

2. Adjust the relief valve.

3. Check roll weight to ensure it is 990lbs (450kg) or less.

Roll tray can't lift to the top.

Electric pump does not work.

1. Battery does not have enough power.

2. Terminals and connector are loose.

3. Electric pump is broken.

1. Recharge the battery.

2. Check terminals and connector.

3. Check and replace.

Roll tray does not lower when pushing LOWER button.

1. Fuse is broken.

2. Lower button is broken.

3. Magnet contactor is broken.

4. Other object blocking.

1. Check and replace Fuse.

2. Check and replace button.

3. Check and replace magnet.

4. Remove object that is blocking the lifter from lowering.

Coulmeter shows nothing, red light is flashing or the battery doesn't have enough power.

1. Terminals and inserts are loose.

2. Hasn't been charged long enough.

3. Local electric doesn't match the charger.

4. Battery is worn out.

1. Check terminals and all connections to ensure nothing is loose or damaged.

2. Charge the unit longer.

3. Connect charger to match electric requirements. Or have a certified electrician correct the outlet.

4. Check and replace the battery.

Hydraulic system has oil leaks.

1. Oil seals are broken or loose.

1. Replace oil seals or tighten those that are loose.

1. Fill oil to proper level.

2. Remove object that is blocking the lifter from raising.

After recharge, Coulometer shows 1. Battery hasn't been charged long low electricity and lifting speed is enough. slow.

2. Battery is worn out.

3. Charger is warn out.

1. Recharge the battery.

2. Check and replace the battery.

3. Check and replace the charger.

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Troubleshooting & Maintenance

Battery Charger & Hydraulic Oil

Maintenance free lead acid battery 10” L x 6.7”W x 8”H (255 x 170 x 205mm)

Built-in 110V AC charger

L-HM46 Hydraulic oil (equivalent to ISO VG46)

H x 8” ) 7”W 05mm . L x 10” x 170 x (2

Replacing the Battery.

  1. Using a 5mm Allen Key and a 10mm Wrench, remove both the top and bottom bolts and nuts from the battery clamper.
  2. Disconnect the old battery.
  3. Install the new 12V maintenance free lead acid battery.
  4. Reconnect the battery and clamper.

Replacing the Fuse.

  1. On the fuse box, open the door to get access to the fuse.
  2. Slide the fuse out of its holder.
  3. Insert new fuse and line up both ends on the connectors.
  4. Close the fuse box.

Replacing the Key Switch, LIFT, or LOWER buttons. If unfamiliar with electric, have a trained Electrician service this unit.

  1. Use a screwdriver to remove the 2 screws holding the button in place.
  2. Disconnect the wires keeping them separated from each other.
  3. Install the new button and reconnect the wires.

Key Switch

mybinding.com 1-800-944-4573

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Troubleshooting

ProblemLikely causeFix (from the manual)
Coulometer does not indicate when the key switch is ONLoose terminals or inserts, or the switch is out of order.Check all terminals and connections. Check and change the switch or any damaged wires. Page 14
Roll tray does not lift when pushing LIFTLoose terminals or inserts, low hydraulic oil, a broken fuse or a broken LIFT button.Check terminals and connections, fill oil to the proper level, replace the fuse, or check and replace the LIFT button. Page 14
Lifting speed is too slowBattery does not have enough power, the relief valve is out of position, or the roll exceeds the lifting capability.Recharge the battery, adjust the relief valve, and make sure the roll weighs 990 lbs (450 kg) or less. Page 14
Roll tray cannot lift to the topLow hydraulic oil or an object blocking the lifter.Fill oil to the proper level and remove any blocking object. Page 14
Electric pump does not workBattery is low, terminals or connector are loose, or the pump is broken.Recharge the battery, check terminals and connector, or check and replace the pump. Page 14
Roll tray does not lower when pushing LOWERBroken fuse, LOWER button or magnet contactor, or an object blocking.Check and replace the fuse, button or magnet, or remove the blocking object. Page 14
Coulometer shows nothing, red light flashes, or the battery is lowLoose terminals, not charged long enough, charger does not match the local power, or a worn-out battery.Check connections, charge longer, use a charger that matches the outlet (or have an electrician correct it), or replace the battery. Page 14
Low charge and slow lifting after rechargingBattery not charged long enough, or a worn-out battery or charger.Recharge the battery, or check and replace the battery or charger. Page 14
Hydraulic oil leaksOil seals are broken or loose.Replace or tighten the oil seals. Check the piston valve, both oil tube unions and the double chain roller connection; replace the pump if all are fine. Page 13
Wheels not turning properlyDamaged wheels, or a bowed bottom cross bar from dropping a roll onto the tray or overloading.Lift each side to check the front and steering wheels, and check the cross bar. Replace damaged parts. Page 10

Frequently asked questions

How do I change the hydraulic oil?

Lower the tray, remove the electric control box cover, loosen the clamp ring and remove the tank. Drain the old oil, clean the valve plate and tank, and fill 80% of the tank with L-HM46 (ISO VG46) oil. See page 11.

What battery does the Power Jumbo use?

A 12V maintenance-free lead acid battery, 10 x 6.7 x 8 in (255 x 170 x 205 mm), with a built-in 110V AC charger. See page 15.

How do I replace the fuse?

Open the fuse box door, slide the fuse out of its holder, insert the new fuse lined up on both connectors and close the box. See page 15.

What is the maximum roll weight?

The troubleshooting guide says the roll should weigh 990 lbs (450 kg) or less. See page 14.