This equipment is designed and manufactured in
compliance with the duties, responsibilities and
standards set forth in the ANSI, CE CSA and/or AS
standards in effect at the time of manufacture.
This equipment will meet or exceed applicable ANSI,
CE, CSA and/or AS codes and standards when
operated in accordance with manufacturer’s
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 boom lift.
This manual shall be considered a permanent and
necessary component of the machine and shall be kept
with the boom lift 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.
Bil-Jax, Inc. is dedicated to the continuous improvement
of this and all Bil-Jax products. Therefore, equipment
information is subject to change without notice. Direct
any questions or concerns regarding errors or
discrepancies in this manual to the Bil-Jax Service
Department.
Legend: Safety Advisories 4
Before Operation 5
During Operation 5
Maintenance Safety 7
Damaged Equipment Policy 8
2 Specifications 9
Range of Motion 10
Specifications 11
Warranty 12
3 Operations 13
Ground Control Station 14
Platform Control Station 16
Normal Operating Procedure 18
Manual Boom Operations 20
Battery Recharge 22
Boom Lift Transport 23
4 Operator Service 25
Daily Service Checks 26
Weekly Service Checks 28
Monthly Service Checks 29
Troubleshooting 30
Error Code Definitions 31
5 Replacement Decals 49
6 ANSI Reprint 53
7 Material Safety Data 59
8 Equipment Options 63
Material Lifting Hook 64
Platform Rotator 65
Replacement Decals 66
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 lift will result in death or personal injury.
Prior to Operation:
Read, understand and obey all instructions and safety precautions in this
manual and attached to the lift.
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.
3
BIL-JAX 2622T
LEGEND: SAFETY ADVISORIES
The following safety advisories are used throughout
this manual to indicate specific hazards when
operating or maintaining the machine. Read,
understand and obey all safety advisories to prevent
improper service, damage to equipment, personal
injury or death.
DANGER
Warns of operation near electrical power
sources that could lead to personal injury or
death.
WARNING
Describes conditions or practices that could lead
to personal injury or death.
CAUTION
Contains information important in the prevention
of errors that could damage machine or
components.
NOTE: Contains additional information
important for performing a procedure.
4
BEFORE OPERATION DURING OPERATION
DANGER
1 – SAFETY
Ensure the following general safety precautions are
followed before operating the telescoping boom lift:
ALWAYS inspect the usage area for potential
hazards, such as unstable or unlevel surfaces,
overhead obstructions and electrically charged wires
or conductors. ALWAYS watch for moving vehicles
in the operating area.
ALWAYS conduct a thorough inspection of the
machine before operation. Check for damaged or
worn parts, hydraulic leaks, damaged wiring, loose
wiring conductors, damaged outriggers, low tire
pressure, uneven tire wear or tire damage. Check for
any improperly operating components. NEVER
operate equipment if any damage is observed or
suspected. Repair damaged or malfunctioning
equipment before operation.
ALWAYS wear proper clothing. Wear protective
equipment as required by government regulations.
Keep loose clothing, jewelry, gloves and hair away
from moving parts.
ALWAYS wear a safety harness and energyabsorbing lanyard, such as the safety harness and
lanyard provided by Bil-Jax.
ALWAYS inspect platform floor and outrigger
footpads for mud, grease, debris or other foreign
material. ALWAYS remove any such material from
the equipment before operation.
ALWAYS tag any part of the equipment known or
suspected to be damaged or malfunctioning.
ALWAYS remove a malfunctioning, damaged or
defective machine from service. NEVER operate a
machine that has any known or suspected defect.
ALWAYS comply with the instructions found in
Safety and/or Service Bulletins distributed by the
manufacturer. Bulletins may contain critical
procedures that supersede the information
contained in manuals.
NEVER operate this equipment while under the
influence of drugs or alcohol, while taking
prescription medications that may leave the operator
drowsy or prone to dizziness, or while feeling ill.
NEVER modify, alter or change the equipment in
any way that would affect its original design or
operation.
NEVER deface, modify or obscure any decals or
markings on equipment.
NEVER operate the equipment in any way for which
it is not intended.
Ensure the following general safety precautions are
followed while operating the telescoping boom lift:
ALWAYS position lift away from power lines to
ensure that no part of the lift can accidentally reach
into an unsafe area. This includes full extension of
the boom through 700º rotation.
This machine is NOT insulated for use near
electrical power lines and DOES NOT provide
protection from contact with or close proximity
to any electrically charged conductor. Operator
must maintain safe clearances at all times (3.05
meters minimum) and must always allow for
platform movement due to gusty winds. Always
contact power company before working near
power lines. Assume every power line is live.
Power lines can be blown by the wind. Refer to
Table 1-1 for minimum safe approach distances
between the machine and electrical power lines.
Voltage Range
(Phase to Phase)
0 to 300V Avoid Contact
Over 300V to 50KV 10 3.05
Over 50KV to 200KV 15 4.60
Over 200KV to 350KV 20 6.10
Over 350KV to 500KV 25 7.62
Over 500KV to 750KV 35 10.67
Over 750KV to 1000KV 45 13.72
Minimum Safe Approach Distance
(Feet) (Meters)
Table 1-1. Minimum Safe Approach Distances
ALWAYS keep away from a machine that is
exposed to energized power lines. If the machine
contacts energized power lines, NEVER touch or
operate the machine until power lines are shut off.
ALWAYS operate only on a firm and level surface.
NEVER operate on surfaces that do not support the
equipment with its rated load capacity or on surfaces
that do not support force exerted by the outriggers
during boom operation. Operate only on surfaces
that can support a pressure of 1.8 kg/cm
2
(25 psi) to
ensure safe operation.
ALWAYS keep personnel away from potential pinch
and shear points and from potential crush hazards
as indicated by decals attached to the machine.
ALWAYS maintain sure footing on the work platform.
ALWAYS keep the safety bar lowered unless
personnel are entering or exiting the work platform.
5
BIL-JAX 2622T
ALWAYS wear proper footgear. ALWAYS keep the
platform free of debris.
ALWAYS keep personnel and obstructions clear of
the machine when repositioning boom or basket.
ALWAYS cordon the area surrounding the
outriggers to keep personnel, vehicles and moving
equipment away from the machine while in use.
ALWAYS stay clear of overhead obstructions,
including wires and cables.
ALWAYS engage boom travel latches before towing
trailer.
ALWAYS exercise caution when rotating the boom
(slew) from the ground control station. ALWAYS
watch for personnel inside the radius of the turntable
and boom arm when rotating the boom lift from the
ground or platform controls.
ALWAYS remove personnel from the boom lift
before attempting to free an elevated platform that
has become caught or snagged on an adjacent
structure or obstacle.
NEVER operate the machine on any surface other
than firm and level ground. NEVER operate the
machine from a position on truckbeds, trailers,
floating vessels or scaffolding without written
approval from the manufacturer.
NEVER operate lift on slopes exceeding 12.5º.
NEVER allow electrode contact with any part of the
machine while welding from the platform. NEVER
use the machine as a ground for welding.
NEVER operate without the outriggers fully
extended or when the machine is not level.
NEVER position an elevated platform against
another object to steady the platform
NEVER operate boom lift in conditions where wind
speeds exceed 12.5 m/sec (45 km/h or 28 mph).
Steady or gusty winds that exceed 12.5 m/sec (45
km/h) may affect stability and boom operation.
NEVER allow ropes, electric cords, hoses or other
equipment to become entangled in the machine
while raising or lowering platform.
NEVER exceed the load limits set by the
manufacturer. Use only the Material Lifting Hook,
supplied as an option and manufactured by Bil-Jax,
when lifting materials. Safely stow all tools and
equipment.
NEVER exceed load ratings by transferring loads to
the lift at elevated heights.
NEVER use the platform to lift a load that exceeds
the platform dimensions. NEVER lift a load in such a
way that the center of gravity is higher than the top
guardrail of the platform.
NEVER modify the platform or carry materials that
would increase the surface area of the platform.
Increasing the area exposed to the wind may
decrease machine stability. NEVER attach
overhanging loads when raising or lowering the
platform.
NEVER use the boom or platform to push or pull or
to lift any part of the trailer.
NEVER use the boom or platform to place a load
against any structure, materials or equipment.
NEVER climb on the boom. Refer to Section 3 for
the instructions for manual operation.
NEVER leave an elevated platform unattended.
NEVER leave the keys in the boom lift while
unattended or not in use.
NEVER override or bypass the manufacturer’s
safety devices.
NEVER attach a safety harness to an adjacent
structure, pole, or to nearby equipment while
working from the boom platform.
NEVER raise the outriggers or move the trailer with
materials or personnel on board, or while boom is
raised or extended.
NEVER sit, stand or climb on cage bars. ALWAYS
keep both feet firmly on the work cage floor when
working from an elevated platform.
NEVER attempt to increase the working height with
boxes, ladders, stools or any other materials.
NEVER operate this equipment when exposed to
high winds, thunderstorms, ice or any weather
conditions that would compromise operator safety.
6
MAINTENANCE SAFETY
1 – SAFETY
Ensure the following general safety precautions are
followed while performing maintenance on the
telescoping boom lift:
General Maintenance
ALWAYS perform maintenance proc
edures
according to manufacturer’s guidelines. NEVER
disregard or bypass proper maintenance
procedures.
ALWAYS inspect hydraulic system to ensure that all
lines, connectors and fittings are properly fastened
and in good condition.
ALWAYS turn the key switch OFF and remove key
before performing maintenance.
Whenever possible, ALWAYS perform maintenance
with the boom and platform in a fully lowered,
stowed position. ALWAYS secure the boom before
performing maintenance on hydraulic cylinders.
ALWAYS disconnect power to the hydraulic pump
drive motor before making electrical checks to the
hydraulic valves.
ALWAYS keep all mechanical parts properly
adjusted and lubricated according to maintenance
schedule and manufacturer’s specifications.
ALWAYS perform a function check of operating
controls before each use and after repairs have
been made.
ALWAYS locate and protect against possible pinch
points before performing any maintenance or
repairs.
ALWAYS use only manufacturer-approved parts to
repair or maintain equipment. If any portion of this
equipment is rebuilt or repaired, retesting is required
in accordance with factory instructions.
ALWAYS maintain a safe distance while testing the
hydraulic components. ALWAYS relieve hydraulic
pressure before loosening or removing hydraulic
components. NEVER test or operate the hydraulic
components while personnel are near the
equipment.
NEVER exceed the manufacturer’s recommended
relief valve settings.
NEVER touch or allow metal tools to contact any
components that are sensitive to static discharge.
ALWAYS use static discharge prevention mats and
grounding devices when handling electronic
components.
NEVER adjust, repair, replace or bypass any
hydraulic or electrical control or safety device. These
include, but are not limited to, hydraulic load control
and flow control valves, solenoid valves and limit
switches. ALWAYS consult an authorized Bil-Jax
technician if repairs are necessary.
NEVER modify, alter or change the equipment
without first consulting an authorized Bil-Jax
technician, and NEVER in any way that would affect
its original design or operation.
Battery Maintenance
re the following general safety precautions are
Ensu
followed when performing battery maintenance on
the telescoping boom lift.
ALWAYS check the battery fluid level daily.
ALWAYS wear safety glasses when working with or
near batteries.
ALWAYS avoid contact with battery acid. Battery
acid causes serious burns and should be kept away
from skin or eyes. If contact occurs, flush with water
and consult a physician immediately.
ALWAYS disconnect ground cable first when
removing battery.
ALWAYS connect ground cable last when installing
battery.
ALWAYS charge batteries in open, well-ventilated
areas.
ALWAYS replace batteries using only parts
recommended by manufacturer. ALWAYS use only
batteries with sealed caps over cells.
NEVER smoke while servicing batteries.
NEVER allow water or foreign particles into the DC
electric motor housing. Inclusion of water or foreign
particles may cause serious damage to the motor. If
the motor becomes wet, consult an authorized BilJax service technician for proper dry i ng instructions.
NEVER add unauthorized fluids to the hydraulic
system or battery. NEVER mix hydraulic oils.
Consult manufacturer specifications. Refer to
Section 4 for hydraulic system maintenance
procedures.
NEVER charge batteries near flammable materials.
NEVER allow batteries to overcharge and boil.
NEVER short across battery posts to check for
current. NEVER break a live circuit at the battery.
NEVER disconnect battery from charger while
charger is connected to a live power source.
NEVER jumpstart other vehicles using the boom lift
batteries.
7
BIL-JAX 2622T
DAMAGED EQUIPMENT POLICY
Safety Statement
At Bil-Jax, we are dedicated to the safety of all users of our products. All Bil-Jax
lifts are designed, manufactured and tested to comply with current applicable
ANSI and/or CE codes and regulations.
Damage Policy
There may be occasions when a Bil-Jax 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 Bil-Jax lift is
damaged structurally or when there is suspected internal damage to the
structure, Bil-Jax 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 an authorized Bil-Jax representative or your
regional Bil-Jax dealer
Damage Repair Notice
There may be occasions when a Bil-Jax 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 Bil-Jax of these nonmaintenance repairs and request a repair form to be filled out and returned to BilJax.
8
2 SPECIFICATIONS
Bil-Jax, Inc. is dedicated to the continuous improvement of this and all
Bil-Jax 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 Bil-Jax representative or to the Bil-Jax Service Department.
9
BIL-JAX 2622T
RANGE OF MOTION
40 ft
12.2m
30 ft
9.1m
20 ft
6.1m
10 ft
3m
15 ft
4.6m
5ft
1.5m
5ft
0
1.5m
15 ft
4.6m
25 ft
7.6m
0
Figure 2-1. Range of Motion
10
2 – INTRODUCTION
SPECIFICATIONS SERIAL NUMBER_____________________________
Bil-Jax, Inc. warrants this product for one year, beginning on the date of delivery,
to be free from defects of material and workmanship provided the unit is operated
and maintained in compliance with the guidelines established in the Operations
and Maintenance Manuals. Major structural components, including trailer tongue
and boom weldments, are warranted for five years against defects due to
material or workmanship. Bil-Jax will, at its option, repair or replace any unit or
component part that fails to function properly during normal use.
The warranty does not apply if the lift and/or its components have been altered,
changed, or repaired without the consent of Bil-Jax. Repairs, damage, or defects
resulting from the following are not covered under the terms of the warranty:
negligence, misuse, accidental damage, inadequate or improper maintenance,
acts of nature, damage caused by chemicals or abrasive materials, and normal
wear and tear, such as rust or corrosion. Components not covered under this
warranty include tires, filters, covers, and routine maintenance items.
Components not manufactured by Bil-Jax are covered by their respective
manufacturer’s warranties. A list of those components and their warranties is
available upon written request to Bil-Jax.
Bil-Jax shall not in any event be liable for the cost of any special, indirect, or
consequential damages to any person, product, or thing. Bil-Jax’s maximum
liability under this warranty is limited to the amount paid to Bil-Jax for the product.
This warranty is in lieu of all other warranties expressed or implied. Bil-Jax
neither assumes nor authorizes any or other entity to assume on its behalf any
other liability in connection with the sale, rental, or use of this product.
Warranty Claims Process
In order to qualify for warranty coverage, the following conditions must be met:
1. Return of completed “Warranty Registration” form to Bil-Jax within 15 days of receipt
of product;
2. Notification to Bil-Jax within 72 hours of any claimed defect, injury, or damage
resulting from the claimed defect; and
3. Warranty is limited to parts that are determined to be defective. This does not include
parts worn out due to normal use.
4. Bil-Jax authorized dealers or distributors are responsible for filing claims
under warranty. Listed below is the warranty claims procedure.
5. Contact Bil-Jax Service Department at 800-537-0540 to report the claim and verify
warranty coverage. Machine serial number must be provided.
6. Identify the components to be claimed under warranty along with description of
failure. A Returned Merchandise Authorization (RMA) number will be issued by BilJax.
7. Replacement parts will then be sent by Bil-Jax to the dealer or distributor. All parts
are invoiced at dealer/distributor list price. Credits will be issued when defective parts
are returned to Bil-Jax and found to be defective under warranty.
8. After completing repairs, submit warranty claim form and defective parts to Bil-Jax.
Warranty claim form and parts must be received within 30 days of claim in order to be
eligible for credit. RMA number must be referenced on warranty claim form. 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 Bil-Jax. The amount of labor
hours reimbursed will be determined by Bil-Jax and will be limited to 4 hours unless
approved by Bil-Jax.
12
Failure to follow the warranty claims process may result in delay in processing
claim or denial of the claim. Bil-Jax reserves the right to limit or adjust warranty
claims with regard to parts, labor and travel time. Components purchased from
suppliers other than Bil-Jax are not covered under the terms of this warranty.
3 OPERATION
The Bil-Jax Telescoping Boom Lift is equipped with multiple operator
control stations. Equipment power and outrigger controls are located at
ground level. Boom lift and rotation controls are located at ground level
and on the work platform.
Before attempting boom lift operation, Operators should:
Attend a training program as required by government regulations.
Obtain, read and obey all safety precautions as indicated by
manufacturer’s recommendations and all federal, state and local
regulations.
Become familiar with the location and use of all controls.
Verify that there are no overhead obstructions or live power sources
in the work area that could interfere with the safe operation of the
boom lift.
Position the boom lift on a firm and level surface.
Conduct a Pre-Operation inspection by performing all recommended
Daily Service Checks. Refer to Section 4.
Unhitch equipment trailer from the tow vehicle.
13
BIL-JAX 2622T
GROUND CONTROL STATION
The ground control station is used to operate outriggers and control
boom motion. To access the ground control station, open the control
panel access cover found on the turntable. Turn the key switch to the
ground controls setting.
1. Key Switch
1a. Platform Controls Position
1b. Ground Controls Position
2. Battery Condition Indicator
3. Engine Start (DC/Gas Option Only)
4. Engine Choke (DC Gas Option Only)
5. Display Panel
6. Emergency Stop
7. Boom Extend
8. Boom Retract
9. Boom Raise
10. Boom Down
Figure 3-1. Ground Control Panel
11. Boom Rotation – Clockwise
12. Boom Rotation – Counterclockwise
13. Platform Tilt – Up
14. Platform Tilt – Down
15. Speed Buttons
16. Outrigger Extend
17. Outrigger Retract
18. Auto Level
19. Outrigger Buttons
20. Outrigger Status Indicator LED
21. Power Indicator LED
14
3 – OPERATION
The ground control station includes the following
controls and Indicators. Refer to Figure 3-1 for
control locations.
1. Key Switch
ng the key switch to the
Turni
PLATFORM (1A) icon
selects operation from the platform. Turning the key
switch to the
GROUND (1B) icon selects operation
from the ground control panel. The center (power
off) position interrupts all electric and hydraulic
power operations except emergency lowering.
Removing the key protects against operation by
unauthorized persons. The key may be removed
with the key switch in any selected position.
2. Battery Condition Indicator
Indicato
r LEDs light up to indicate the level of charge
remaining in the batteries. A lighted green LED
indicates an adequate charge level. Lighted yellow
LEDs indicate the need for charging soon. A lighted
red LED warns that the battery charge level is low;
boom operations should be halted until the batteries
are recharged.
3-4. Engine Start and Choke (Hybrid Model only)
Start a cold e
ngine by pressing the Engine
button while pressing and holding the
START (3)
CHOKE (4)
button. To start/restart a warm engine, press the
START button only.
5. Display Panel
The DISPLAY PANEL is a lighted text window that
displays the present operating status or an existing
error condition when the key switch is on.
6. Emergency Stop Button
Whe
n pushed in, the emergency
STOP button
disconnects electrical power to the ground and
platform control stations. The emergency
STOP
pushbutton should only be pressed to immediately
stop all boom motion. To resume control, pull out the
emergency
STOP button.
7-8. Boom Extend/Retract Buttons
Pressing and holding a desired
BOOM EXTEND (7) button at the same time extends
SPEED button and the
the telescopic boom. Pressing and holding a desired
SPEED button and the BOOM RETRACT (8)button at the
same time retracts the boom. Boom motion
continues until the buttons are released or until the
boom reaches a hard stop or a safe travel limit.
9-10. Boom Raise/Down Buttons
Pressing and holding a desired
BOOM RAISE (9) button at the same time will raise the
boom. Pressing a desired
BOOM DOWN (10) button at the same time will lower
SPEED button and the
SPEED button and the
the boom. Boom motion continues until the buttons
are released or until the boom reaches a hard stop
or a safe travel limit.
11-12. Boom Rotation Buttons
Pressing and holding a desired
BOOM ROTATIONCLOCKWISE (11)or COUNTERCLOCK-
WISE (12) button at the same time enables the boom
SPEED button and the
to rotate in the direction selected. The boom will
rotate through 700 degrees until the buttons are
released or the stop is reached.
13-14. Platform Tilt Buttons
Press and hold any
PLATFORM TILT (13 and 14) button at the same time
SPEED button and the desired
to level the work platform (levels the platform only,
not the boom lift).
15. Speed Buttons
The
SPEED buttons along the lower right side of the
control panel must be pressed and held while
selecting a boom function. Four speeds are
available to control the positioning of the boom lift.
16-20. Outrigger Controls
For automatic outrigger extension/retraction: Select
EXTEND (16) or RETRACT (17) outrigger button and
AUTO LEVEL (18) button at the same time. To
the
manually extend or retract the outriggers: Select
EXTEND or RETRACT outrigger button and one of the
OUTRIGGER buttons (19) at the same time. The
outrigger indicator LEDs light up when the outriggers
are properly deployed and the boom weight is on the
outriggers. Each of the outer outrigger LEDs
indicates load is on the outrigger footpad. Each of
the inner outrigger LEDs, when flashing, indicate
that side is low and needs to be further raised for
leveling. The Auto Level LED lights up and a buzzer
sounds when the boom is level.
15
BIL-JAX 2622T
PLATFORM CONTROL STATION
The platform control station is used to control boom motion. To access the
platform control station, turn the key switch at the ground control station to the
platform controls setting and enter the work cage.
1. Engine Start (DC/Gas Model Only)
2. Engine Choke (DC/Gas Model Only)
3. Horn Button
4. Battery Condition Indicator
5. Emergency Stop Button
6. Speed Buttons
7. Boom Rotation – Clockwise
16
Figure 3-2. Ground Control Panel
8. Boom Rotation – Counterclockwise
9. Boom Raise
10. Boom Down
11. Boom Extend
12. Boom Lower
13. Platform Tilt – Up
14. Platform Tilt – Down
3 – OPERATION
The platform control station includes the following
controls and Indicators. Refer to Figure 3-2 for
control locations.
1-2. Engine Start and Choke (DC/Gas Model only)
Start a cold e
ngine by pressing the
then press the engine
START button (2) to start the
CHOKE button (1),
engine. To start/restart a warm engine, press the
START button only.
3. Horn Button
Pressin
HORN button to warn personnel in the area of a
g the button will sound the horn. Use the
falling object hazard, impending boom motions, or
the need for assistance.
4. Battery Condition Indicator
Indicato
r LEDs light up to indicate the level of charge
remaining in the batteries. A lighted green LED
indicates a good charge level. Lighted yellow LEDs
indicate the need for charging soon. A lighted red
LED warns that the battery charge level is low; boom
operations should be halted until the batteries are
recharged.
5. Emergency Stop Button
n pushed in, the emergency
Whe
STOP button
disconnects electrical power to the ground and
platform control stations. The emergency
STOP
pushbutton should only be pressed to immediately
stop all boom motion. To resume control, pull out the
emergency
STOP button.
6. Speed Buttons
The
SPEED buttons along the lower right side of the
control panel must be pressed and held while
selecting boom functions. Four speeds are available
to control the positioning of the boom lift.
7-8. Boom Rotation Buttons
Pressing and holding a desired
BOOM ROTATIONCLOCKWISE (7) or COUNTERCLOCK-
WISE (8) button at the same time enables the boom
SPEED button and the
to rotate in the direction selected. The boom will
rotate through 700 degrees until the buttons are
released or the stop is reached.
9-10. Boom Raise/Down Buttons
Pressing and holding a desired
BOOM RAISE (9) button at the same time will raise the
boom. Pressing a desired
BOOM DOWN (10) button at the same time will lower
SPEED button and the
SPEED button and the
the boom. Boom motion continues until the buttons
are released or until each boom reaches a hard stop
or a safe travel limit.
11-12. Boom Extend/Retract Buttons
Pressing and holding a desired
BOOM EXTEND (11) button at the same time extends
SPEED button and the
the telescopic boom. Pressing and holding a desired
SPEED button and the BOOMRETRACT (12) button at
the same time retracts the boom. Boom motion
continues until the buttons are released or until the
boom reaches a hard stop or a safe travel limit.
13-14. Platform Tilt Buttons
Press and hold any
PLATFORM TILT button at the same time to level the
SPEED button and the desired
work platform (levels the platform only, not the boom
lift).
Outlet
The outlet is provided for running electrical power
tools from the work platform. A connecting power
cord must be plugged into a suitable power source.
The power plug is located on the trailer frame, in
front of the accessory equipment stowage plate. The
outlet is rated for a 15-ampere load. Do not overload
the accessory power circuit.
17
BIL-JAX 2622T
NORMAL OPERATING PROCEDURE
Perform the following procedures to operate the BilJax Telescoping Boom Lift.
Read and obey all safety precautions and
operating instructions, as well as all applicable
government regulations.
Conduct a Pre-Operation Inspection by
performing all recommended Daily Service
Checks. Refer to Section 4.
Position the boom lift at the work area. Make
sure the boom lift is on a firm and level surface
and there are no potential hazards such as
overhead obstructions or electrically charged
conductors. Do not operate the boom lift if such
hazards exist.
Apply the boom lift parking brake or chock the
wheels.
Lower the tongue jack and unhitch the boom lift
from the tow vehicle.
WARNING
Failing to unhitch the boom lift before operation
may lead to damage to equipment or tow vehicle
and makes the boom lift unstable, which can
cause personnel injury or death.
Turn the key switch on the ground control station
to operate ground controls. If power does not
come on, make sure both emergency
buttons (ground and platform) are pulled out and
the main power disconnect is plugged in.
The control microprocessor will perform self-
diagnostics to test the operating system. After
several seconds, the DISPLAY PANEL window
will read:
BIL – JAX
A STEP ABOVE
Verify that the control status indicator LED is lit.
If the control status indicator LED is not lit or is
flashing, the outrigger buttons will not work. A
flashing control status LED indicates that one or
more of the booms is raised and needs to be
stowed. Refer to Figure 3-1 and Figure 3-3.
STOP
and the two appropriate
OUTRIGGER buttons at
the same time.
Figure 3-3. Outrigger Controls
NOTE: The safety interlock system prevents all
boom operations if the boom is not level
or if one or more outriggers are not
supporting the vehicle load.
NOTE: The Range of Motion Diagrams at the
ground and platform control stations
display the range of platform motion
(safe operating zone) facing away from
the trailer tongue. Verify that the
operating zone is clear of obstructions
through 700º of turntable rotation.
Verify that the auto level indicator LED is lit. If
the auto level indicator is not lit, the boom may
not be level.
Pull the latch release on the boom travel latch,
raise the latch handle and swing the latch U-bolt
down. Refer to figure 3-4.
Extend the outriggers manually or using the
AUTO LEVEL button. When the boom is leveled
properly, a buzzer will sound and two LEDs at
OUTRIGGER button and the LED at the AUTO
each
button will be lit.
LEVEL
Auto Level: Press and hold the
AUTO LEVEL
buttons at the same time.
EXTEND and
Manual Level: Extend the two outriggers
closest to the trailer coupler first. Lower each
pair of outriggers by pressing the
18
EXTEND button
Figure 3-4. Boom Travel Latch
3 – OPERATION
Open the platform travel latch (Figure 3-5) and
pivot the platform upright. Platform locking pins
will engage in the pivot locking holes when the
platform is in a full upright position. Verify that
the platform is locked into place.
Figure 3-5. Platform Travel Latch
Verify that the platform is properly attached to
the mounting bracket on the boom end. The
Retaining Pin should be fully inserted through
the platform and the mounting bracket on the
boom end.
WARNING
Failure to verify proper attachment of the
platform to the boom end could cause the
platform to separate from the boom, resulting in
serious injury or death to the operator.
Should the platform become tilted out of the
normal vertical axis, press and hold the desired
SPEED button and one of the PLATFORM TILT
buttons at the same time to adjust.
Monitor the Battery Condition Indicator during
operation and charge the batteries as
necessary.
Always fully retract, rotate and lower the boom
to the stowed position before exiting the
platform.
When all boom lift operations are complete, fully
retract the telescoping boom extension. Center
boom over the boom rest and fully lower boom
until seated in the stowed position for transport.
Safety switches prevent outrigger retraction until
boom is completely lowered and stowed for
transport.
Unfasten the safety harness and exit platform.
Disengage platform locking pins and return
platform to a stowed position. Engage the boom
and platform travel latches.
Turn the key switch to the ground controls
position.
Press and hold the outrigger RETRACT button
and the
AUTO LEVEL button until all outriggers are
fully retracted to their upright positions. Inspect
the area beneath lift and trailer for obstructions
before retracting outriggers.
Turn the key switch to the OFF position and
remove key.
Use the ground control panel to operate the
boom lift functions. Raise, lower, extend and
rotate the boom by pressing and holding the
desired
SPEED and function buttons at the same
time. Become familiar with the location and
function of all controls. Learn to smoothly start
and stop all boom motions.
Fully lower the boom onto the boom rest to
position the platform for boarding. Turn the key
switch to the platform control position.
Raise the safety bar and enter the work
platform. Put on the safety harness and attach
the lanyard to the Fall Protection Attachment
Point on the side of the platform support beam.
Use the platform control panel to operate the
boom lift functions. Raise, lower, extend and
rotate the boom by pressing the desired
SPEED
and function buttons at the same time. Become
familiar with the location and function of all
controls. Learn to smoothly start and stop all
boom motions.
19
BIL-JAX 2622T
MANUAL BOOM OPERATION
Manual retraction, rotation and lowering functions
allow the Telescoping Boom Lift to be moved and
lowered during hydraulic power interruption or
failure. In each instance, refer to Figure 3-6.
The following procedures for manual retraction,
rotation and lowering require a person on the ground
to operate the manual controls and hand pump.
The hydraulic hand pump is located in the pump
compartment. In case of a power failure, the hand
pump and selected hydraulic valve settings can be
used to manually retract the Telescoping boom or
rotate the boom turntable.
To begin manual retraction or rotation, turn
Proportional Valve counterclockwise until it stops,
and insert pump handle into the pump handle fitting.
Manual Retraction
Pushing and holding the Retract button while
simultaneously actuating Hand Pump will retract the
extension boom section.
Manual Rotation
To rotate the turntable counterclockwise: Push
and hold the Rotation button and simultaneously
actuate Hand Pump.
To rotate the turntable clockwise: Pull the
Rotation button out and simultaneously actuate
Hand Pump.
NOTE: Return proportional valve to its original
position before lowering the lift or
resuming normal operation.
20
1. Hand Pump
2. Proportional Valve
3. Rotation Button
4. Retract Button
Figure 3-6. Hand Pump and Controls for Manual Lift Operation
3 – OPERATION
Manual Lowering
Each Manual Lowering Valve is equipped with a
plunger, found at the base of the lift cylinder (Figure
3-7). Use the plunger to lower the platform in case of
a complete electrical power failure, a load shift, or
other emergency. To lower the work platform, pull
the valve plunger forward. Continue pulling the
plunger to completely lower the boom.
Figure 3-7. Manual Lowering Valve
21
BIL-JAX 2622T
BATTERY RECHARGE
Recharge boom lift batteries after each 8-hour work
shift or as needed. When boom lift is not in use,
batteries should be recharged at least once per
week. Under normal circumstances, battery
recharge should take approximately 10-12 hours.
However, a full recharge may take up to 24 hours, if
the battery charge is extremely low.
WARNING
Recharge batteries in a well-ventilated area only.
Do no charge batteries near fire, spark or other
potential ignition sources. Batteries may emit
highly explosive hydrogen gas while charging.
Failure to properly ventilate the charge gases
may result in serious injury or death. Always
charge boom lift batteries away from flammable
materials.
To recharge the boom lift batteries:
Move the boom lift to a well-ventilated area with
direct access to 120v (CE: 220v) electrical
outlet. Keep the boom lift and batteries away
from open flame or other potential ignition
sources.
Attach a 12 AWG multi-strand, grounded
extension cord with a maximum length of 15
meters to the receptacle located on the cargo
plate in front of the turntable.
NOTE: Using an underrated or long power cord
will reduce the output of the battery
charger and may extend charge time.
Plug the extension cord into outlet. Verify that
the green CHARGING indicator LED is lit on the
battery charger faceplate (Figure 3-8).
Linear Battery Charger
CHARGING
CHARGE CURRENT
PUSH
FOR
BATTERYVOLTAGE
FUSE 15A
SLO BLO
Figure 3-8. Battery Charger Faceplate
80% CHARGED
CHECK BATTERY
The CHARGING indicator LED remains lit
continuously during the first stage of the charge
cycle. The bulk mode CHARGE CURRENT will
be displayed on the battery charger faceplate.
Press and hold the BATTERY VOLTAGE button to
display the detected battery voltage.
If a battery fault is detected, the appropriate fault
code will appear on the CHARGE CURRENT
display. The red CHECK BATTERY indicator
LED will become lit. See Table 3-1 for battery
charger fault codes.
WARNING
Do not disconnect any output leads or
connectors between the batteries and the
charger when the charger is on. To stop a charge
in progress, always unplug the extension cord
from the AC power source.
When the battery charge reaches 80% of
capacity, the yellow 80% CHARGED indicator
LED will become lit and the green CHARGING
indicator LED will begin to flash.
When the batteries have reached a full charge,
the green and yellow indicator LEDs will turn
themselves off. CC (Charge Complete) will
appear on the CHARGE CURRENT display.
After two hours, this display will fade and the
CHARGE CURRENT will read 00.
Unplug the extension cord from the outlet and
the charger receptacle on the boom lift. Store
the extension cord for next use.
CAUTION
Always unplug the battery charger power cord
before moving the boom lift. Failure to
disconnect power cord will cause damage to the
equipment.
Table 3-1. Charger Fault Codes
CodeDescription Limits Cause
F1 Over Voltage
F2 Over Current >60 amperes Battery Fault
F3 Bulk Mode Timeout 14 hrs Max. Battery Fault
The boom lift trailer includes a single axle, two-inch
ball hitch, hydraulic surge brakes, mechanical
parking brake, safety chains, brake lights and side
marker lights. Proper boom transport requires the
proper attachment and inspection of these
components before towing. Refer to Figure 3-9.
1. Trailer Hitch
2. Trailer Parking Brake
3. Release Lever
4. Safety Chains
5. Trailer-to-Vehicle Power Plug
Figure 3-9. Trailer Hitching
Use the following procedure to hitch and tow the
boom lift.
Back the tow vehicle to the trailer. Verify that the
ball and hitch are aligned and that the trailer
hitch has proper clearance above the ball. Use
the tongue jack as needed.
CAUTION
Obtain, read and obey all recommendations set
forth by the tow vehicle manufacturer before
attempting to transport equipment. Verify that
equipment weight does not exceed the vehicle’s
towing capacity. Exceeding the tow vehicle’s
rated capacity may result in damage to tow
vehicle or boom lift.
On the tongue jack, pull the pivot locking pin and
swivel jack 90 degrees to the travel position.
Reengage pivot locking pin.
Attach the safety chains to the tow vehicle.
Verify that the chains cross under the trailer
tongue. If necessary, cross the chains first over
then under the tow bar to prevent dragging.
Failure to attach safety chains properly before
towing will allow trailer tongue to drop in case of
ball hitch failure, resulting in damage to trailer
and equipment.
If equipped, connect the breakaway cable to the
tow vehicle. Leave adequate slack to prevent
brakes from dragging.
Connect the trailer lights to the tow vehicle
power plug.
Verify the following before towing the lift. Make
adjustments as necessary.
The trailer jack and outriggers are in their travel
positions.
Boom travel latches are engaged, securing the
booms in their fully stowed positions.
All on-board equipment is secured.
The key switch is in the OFF position. Remove
the key.
The parking brake is disengaged.
The trailer tires are adequately and evenly
inflated.
Periodically check the wheel nut torque according to
manufacturer’s recommendations. Frequent torque
checks are required when a wheel is recently
installed.
Prior to towing, while the trailer wheels are elevated
for boom lift operatio
n, inspect for loose wheels and
for wheel lug wear. If a loose wheel mounting is
suspected, remove and inspect wheel lugs for
damage. NEVER tow a boom lift with worn or
damaged wheel components.
Lift release lever and lower the hitch onto the
Use the tongue jack to verify secure coupling. If
Release the trailer parking brake.
ball using the tongue jack. Push down the
release lever to secure the ball.
using the jack will raise the bumper of the tow
vehicle 2-3 inches, the ball hitch coupling is
secure.
23
BIL-JAX 2622T
BOOM LIFT TRANSPORT
LIFTING INSTRUCTIONS TRANSPORT INSTRUCTIONS
Refer to Figure 3-10.
Completely lower and retract boom.
Secure boom and platform travel latches.
Remove all loose materials from machine.
Retract all outriggers to fully stowed position.
Attach rigging only to the designated forklift
pockets (A).
Adjust rigging to keep the machine level and to
minimize the risk of damage to machine.
When using a forklift, use only the designated
forklift pockets. Follow all forklift operating
instructions as indicated by the forklift
manufacturer.
Only trained and authorized personnel should
attempt to lift the boom using a crane or forklift.
Refer to Figure 3-10.
Verify that truck or trailer is parked on a firm and
level surface.
Completely lower and retract boom.
Secure boom and platform travel latches.
Retract all outriggers to fully stowed position.
Load boom onto truck or trailer.
Chock the wheels (B) and apply parking brake.
Place a wooden block under the tongue, near
the trailer hitch (C).
Lower jack until trailer tongue rests on the
wooden block. Swing up and lock the jack (D) so
that the weight of the tongue now rests on the
wooden block.
Secure the boom lift to the trailer bed using
straps or chains. Use only the two attachment
points beneath the machine, adjacent to the
outriggers (E).
Adjust as necessary to prevent damage to
rigging or machine.
Figure 3-10. Lift and Transport Instruction
24
4 OPERATOR SERVICE
Performing the appropriate maintenance procedures will extend the life
of the boom lift 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 boom lift function and result in safety or damage
hazards.
Persons performing maintenance or repairs on the machine should be
trained in accordance with the manufacturer’s recommendations.
Contact your regional Bil-Jax 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 and monthly. Refer to the appropriate
Summit Series Parts and Service Manual for a list of annual service
checks.
It is the practice of Bil-Jax, Inc. to issue Service and/or Safety Bulletins,
which may include updates to the information contained in this manual.
In such instances, procedures co nt ained in Bil-Jax Service Bulletins or
Safety Bulletins supersede the information contained in manuals.
Always follow maintenance schedule, regardless of use
.
25
BIL-JAX 2622T
DAILY SERVICE CHECKS
The following Maintenance Procedures should be
performed daily or before each operation.
Verify that all decals are correctly applied and in
plain view.
Refer to Section 5 for decal locations.
Verify that all controls and indicators at ground
and platform control stations operate properly.
Lower outriggers to level the boom lift.
Raise and extend all booms.
Press emergency STOP button.
Verify that booms remain elevated and do not drift.
Pull out STOP button and lower the booms.
If either control station is unresponsive, refer to Table
4-1 for troubleshooting procedures.
If display panel displays an error code, refer to Table
4-2 for error code definitions.
Verify operation of running and brake lights.
Verify correct tire inflation.
In cold climates, inflate tires to 55 psi.
Inspect tires for damage or loose or missing lug
nuts.
Repair or replace as necessary.
Inspect structural components and platform for
obvious damage or debris.
Repair or replace as necessary.
Inspect machine for missing, loose or damaged
fasteners, including pins and bolts.
Verify that boom down limit switches operate
correctly.
Down limit switches are actuated when the boom is in
a fully lowered, stowed position. Limit switches must
be operational to raise or lower outriggers.
If outrigger controls are unresponsive when boom is
fully lowered and stowed, inspect down limit switches
for loose mounting or visible damage.
Repair or replace as needed.
Verify that outrigger safety interlocks operate
correctly.
Begin with the outriggers fully extended and the boom
Verify that boom functions are unresponsive when
Repeat this procedure for each outrigger.
Raise all outriggers until the footpads are not in
Lower one outrigger until the footpad makes contact
If the LED is lit before the footpad makes contact with
Repeat this procedure for each outrigger.
Repair or replace as needed. Refer to Figure 4-1.
lift level. Raise one outrigger until the footpad is not in
contact with the ground.
one outrigger is raised.
contact with the ground. Verify that all outrigger status
LEDs on the ground control panel are unlit.
with the ground and the outrigger begins lifting the
trailer.
the ground or if the LED remains unlit after the weight
is transferred to the outrigger, the position switch or
wiring is faulty.
26
Figure 4-1. Outrigger Position Switches
4 – OPERATOR SERVICE
Inspect hydraulic system and fluid levels.
Check all hydraulic hoses and fittings for leaks and
damage. Tighten or replace as necessary to prevent
hydraulic oil or pressure loss.
The hydraulic oil level should be checked with the
booms down, all outriggers raised and the trailer
wheels on a level surface.
Hydraulic oil level should be visible in, but not above,
the sight gauge.
If the hydraulic oil level is not visible to at least half
way up the sight gauge (Figure 4-2), add clean
hydraulic fluid as necessary while all booms and
outriggers are fully retracted and stowed. Pour slowly
to avoid creating air pockets in the reservoir. Do not
fill above sight gauge. Overfilling the hydraulic
reservoir may cause damage to hydraulic lines and
may result in equipment malfunction.
CAUTION
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 damage to equipment
The hydraulic reservoir is originally filled with Dexron
III/Mercon ATF with a viscosity rating of 175.
Manufacturer recommends a higher viscosity
hydraulic oil when operating equipment routinely i n
extreme climates.
1. Filter Element
2. Fill Port
3. Sight Gauge
Figure 4-2. Hydraulic Reservoir
27
BIL-JAX 2622T
WEEKLY SERVICE CHECKS
Perform the following service checks at least once
each week in addition to all recommended Daily
Service Checks:
Check Battery electrolyte level.
If battery charge is low, add enough water to bring the
electrolyte level to the top of the plates.
If batteries are fully charged, raise electrolyte level to
full mark in each cell.
Inspect all electrical wiring.
Check for cuts, loose terminals, broken wires, chaffing
and corrosion.
Repair all damage, remove corrosion and seal
exposed connections.
Inspect transport hitch components for damage.
Inspect boom lift for missing, loose or damaged
hardware.
Repair or replace as necessary.
Inspect all hydraulic system components
including pump and motor and cylinders for
damage, leaks, loss of pressure or speed, and
unusual noise or vibration.
Repair or replace as necessary.
28
4 – OPERATOR SERVICE
MONTHLY SERVICE CHECKS ADDITIONAL SERVICE INFORMATION
Perform the following service checks at least once
each month:
Clean all battery terminals.
Check battery for loose connections or damaged
wires.
Verify proper operation of manual lowering
valves and hand pump
Refer to Section 3 for manual boom operating
procedures.
Lubricate all compartment hinges and latches,
slew ring and mating gear.
Use NLGI Grade 2 multi-purpose grease.
Check wheel nut torque.
Refer to Figure 4-3 for correct wheel nut tightening
sequence.
Evenly tighten wheel nuts to 34 N*m in the tightening
sequence shown.
Repeat sequence, tightening wheel nuts to 81 N*m
and to 136 N*m.
NOTE: When wheels are newly installed or
replaced, verify wheel nut torque after 75
and 150 km of travel and monthly
thereafter. Follow this procedure each
time the wheel is removed and
reinstalled.
1
4
3
Refer to the Bil-Jax Parts and Service Manual for a
comprehensive list of Annual service checks.
Seals on hydraulic cylinders should be replaced every five
years or as indicated by machine performance.
All service checks should be performed on a machine that
has been stored without use for a period exceeding thirty
days.
Check for air in the hydraulic system if the machine has
been stored without use for a period exceeding thirty days,
or if the machine was stored without use during a
seasonal climate change. Air trapped in the hydraulic
system will affect machine performance. Follow
procedures for bleeding air from the hydraulic system,
found in the Bil-Jax Parts and Service manual.
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
machine. Always repair or replace all damaged or
malfunctioning components before commissioning or
reselling machine.
When a change in ownership occurs, it is the responsibility
of the seller to provide the new owner with all manuals for
the machine. It is the responsibility of the buyer to notify
the manufacturer of the unit model and serial number and
the name and address of the new owner within 60 days.
Use the Service Checklists found at the back of this
manual to record all Service Checks as well as any
maintenance, repairs or alterations performed on the
machine.
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 b y the authority having jurisdiction.
Refer to the Bil-Jax Parts and Service Manual for a
comprehensive list of Annual service checks.
2
5
Figure 4-3. Wheel Nut Tightening Sequence
29
BIL-JAX 2622T
PROBLEM CAUSE SOLUTION
No lights on panel when
key switch is turned to the
on position.
Hydraulic function does not
work and display window
shows an error message
Outrigger indicator LED
lights do not function.
One or more boom controls
do not function
OR
One or more boom controls
function improperly
OR
One or more boom controls
function intermittently.
TROUBLESHOOTING
Refer to Table 4-1 for basic troubleshooting operations. Additional information
can be found in the Bil-Jax Parts and Service Manual. Contact the Bil-Jax
Service Department with any questions or before attempting any advanced
troubleshooting operations.
Table 4-1. Troubleshooting Steps
a. Emergency STOP engaged.
b. Battery charge is low.
c. Battery ground or in-series ca ble is loose.
d. Battery main disconnect unplugged.
e. Blown Fuse.
a. Fault detected by safety interlock
microprocessor.
b. Boom Lift electric or electronic failure
a. Key switch turned to the OFF or platform
controls position.
b. Emergency
c. Outriggers not deployed.
a. Key switch is turned to the
incorrect control position.
b. Battery charge is low.
c. Emergency
d. Battery ground or in-series cable loose.
e. All outriggers not properly deployed.
f. Hydraulic pump inoperative.
g. Loose wiring connector.
h. Valve solenoid not operating properly.
i. Fault detected by system interlock.
j. Broken or loose wire.
STOP engaged.
OFF or
STOP engaged.
a. Disengage Emergency STOP buttons.
b. Recharge as needed.
c. Inspect and repair battery connections.
d. Plug in main disconnect.
e. Check and replace fuse.
a. Refer to Table 4-2 for error code
definition and correction.
b. Refer to Table 4-2 for error code
definition and correction.
a. Turn key switch to ground controls
position.
b. Disengage emergency STOP buttons.
c. Deploy all outriggers.
a. Turn key switch to ground or platform
controls position.
b. Recharge battery.
c. Disengage Emergency STOP buttons.
d. Inspect and repair battery connections.
e. Deploy all outriggers and level boom lift.
f. Inspect pump; replace or repair as
needed.
g. Check wiring terminals in control box
and at valve manifold; replace or repair
as needed.
h. Clean valve solenoid and recheck
function(s); replace or repair as needed.
i. Check display for system status. Refer
to Table 4-2 for error code definitions
and correction.
j. Inspect wiring in control box a nd at
valve manifold and valve coil; repair or
replace as needed.
30
4 – OPERATOR SERVICE
ERROR CODE DEFINITIONS
The DISPLAY PANEL located on the ground control panel indicates the present
operating status of the boom lift. If an error condition is detected, the appropriate
error code will be displayed on this panel. Refer to Table 4-2 for a list of Error
Code Definitions and solutions.
Table 4-2. Error Code Definitions
Error Message
Displayed
001 MACHINE IS IN
DOWN ONLY MODE
002 LOSS OF PLATFORM
COMMUNICATION
003 LOSS OF DRIVE
COMMUNICATION
004 LOSS OF PC
COMMUNICATION
Error Explanation &
Possible Causes
The Machine has gone into DOWN ONLY mode.
When error condition is removed, error is cleared.
NOTE: This error will not be displayed when boom is
down or if so equipped, when the Load Sense Module
has detected an overloaded condition.
Possible causes include:
1. Machine went out of level during use
2. Load sense has detected an overload condition
3. Moment sense has detected an overload
condition
The Lower Control has lost communication with the
Platform Control. To clear this error, the error
condition must be removed and the power must be
cycled off then back on.
NOTE: During this error condition, the Platform
Control "Engine On" LED will blink a “2 blink” error
code and the Lower Control “Power” LED will blink a
“2 blink” error code.
Possible causes include:
1. Lower control incorrectly configured
2. Faulty Boom Cable
3. Faulty Upper Control
4. Faulty Lower Control
The Lower Control has lost communication with the
Drive Control.
This is a latched error. To clear this error, first the
error condition must be removed and second the
power must be cycled off then back on.
NOTE: During this error condition, the Platform
Control "Engine On" LED will blink a “2 blink” error
code and the Lower Control “Power” LED will blink a
“2 blink” error code.
Possible causes include:
1. Lower Control incorrectly configured
2. Faulty Boom Cable
3. Faulty Upper Control
4. Faulty Lower Control
The Lower Control has lost communication with the
PC. When error condition is removed, error is cleared.
NOTE: During this error condition, the Lower Control
“Power” LED will blink a “4 blink” error code.
Possible causes include:
1. Faulty cable between PC and Lower Control
2. PC’s program is not running
3. Faulty PC
4. Faulty Lower Control
What To Check &
Corrective Action To Clear
Error
1. Check outrigger and level LED indicators and if
required re-level machine
2. Reduce boom load
3. Reduce boom load
1. Correctly configure Lower Control
2. Replace Boom Cable
3. Replace Upper Control
4. Replace Lower Control
1. Correctly configure Lower Control
2. Replace Boom Cable
3. Replace Upper Control
4. Replace Lower Control
1. Replace cable between PC and Lower Control
2. Disconnect PC or run PC’s program
3. Replace PC
4. Replace Lower Control
31
BIL-JAX 2622T
Error Message
Displayed
005 PLATFORM
CONTROL
HAS STUCK KEY
006 DRIVE CONTROL
HAS STUCK KEY
007 DRIVE CONTROL
HAS STUCK JOYSTICK
008 GROUND CONTROL
HAS STUCK KEY
009 BOOM UP WITHOUT
OUTRIGGERS ON
GROUND
Error Explanation &
Possible Causes
The Platform Control has detected a stuck or pressed
key on power up.
This is a latched error. To clear this error, first the
error condition must be removed and second the
power must be cycled off then back on.
NOTE: During this error condition, the Platform
Control “Engine On” LED will blink a “1 blink” error
code.
Possible causes include:
1. Platform Control has a stuck key
2. Faulty Platform Control
The Drive Control has detected a stuck or pressed key
on power up.
This is a latched error. To clear this error, first the
error condition must be removed and second the
power must be cycled off then back on.
NOTE: During this error condition, the Drive Control
“Engine On” LED will blink a “1 blink” error code.
Possible causes include:
1. Drive Control has a stuck key
2. Faulty Drive Control
The Drive Control has detected a stuck joystick on
power up.
This is a latched error. To clear this error, first the
error condition must be removed and second the
power must be cycled off then back on.
NOTE: During this error condition, the Drive Control
“Engine On” LED will blink a “2 blink” error code.
Possible causes include:
1. Drive Control has a stuck joystick
2. Faulty Drive Control
The Lower Control has detected a stuck or pressed
key on power up.
This is a latched error. To clear this error, first the
error condition must be removed and second the
power must be cycled off then back on.
NOTE: During this error condition, the Lower Control
“Power” LED will blink a “1 blink” error code.
Possible causes include:
1. Lower Control has a stuck key
2. Faulty Lower Control
The Lower Control has detected the boom is up
without all four outriggers on the ground.
This is a self clearing error. When error condition is
removed, error is cleared.
NOTE: Alarm will sound during this error condition.
Possible causes include:
1. Faulty boom down or outrigger limit switches
2. Faulty boom down or outrigger limit switch wiring
3. Faulty Lower Control
What To Check &
Corrective Action To Clear
Error
1. Free stuck or pressed key on Platform Control
2. Replace Platform Control
1. Free stuck or pressed key on Drive Control
2. Replace Drive Control
1. Free or replace stuck joystick on Drive Control
2. Replace Drive Control
1. Free stuck or pressed key on Lower Control
2. Replace Lower Control
1. Check and repair boom and outrigger limit
switches
2. Repair or replace boom and outrigger limit
switch wiring
3. Replace Lower Control
32
4 – OPERATOR SERVICE
Error Message
Displayed
010 LEVEL SENSOR HAS
ERRATIC OUTPUT
011 TRYING TO DRIVE
W/ TRAILER BRAKE OFF
012 ANGLE SENSOR IS
DISCONNECTED OR BAD
013 PRESSURE SENSOR IS
DISCONNECTED OR BAD
014 CHECK ENGINE
LOW OIL PRESSURE
Error Explanation &
Possible Causes
The Lower Control has detected a rapidly changing
output from the level sensor.
This is a self clearing error. When error condition is
removed, error is cleared.
Possible causes include:
1. Faulty Level Sensor
2. Faulty Level Sensor wiring
3. Faulty Lower Control
An attempt was made to drive machine without
engaging the trailer brake.
This is a self clearing error. When error condition is
removed, error is cleared.
NOTE: This error only occurs on machines equipped
with the Drive & Set option.
Possible causes include:
1. Trailer brake not engaged
2. Faulty trailer brake switch
3. Faulty trailer brake switch wiring
4. Faulty Lower Control
The Lower Control has detected the angle sensor
output is out of range.
This is a self clearing error. When error condition is
removed, error is cleared.
NOTE: This error only occurs on machines equipped
with the Moment Sense option.
Possible causes include:
1. Faulty angle sensor
2. Faulty angle sensor wiring
3. Lower Control incorrectly configured
4. Faulty Lower Control
The Lower Control has detected the pressure sensor
output is out of range.
This is a self clearing error. When error condition is
removed, error is cleared.
NOTE: This error only occurs on machines equipped
with the Moment Sense option.
Possible causes include:
1. Faulty pressure sensor
2. Faulty pressure sensor wiring
3. Lower Control incorrectly configured
4. Faulty Lower Control
The Lower Control has detected the engine had low
oil pressure while running.
This is a latched error. To clear this error, first the
error condition must be removed and second the
power must be cycled off then back on.
NOTE: This error only occurs on machines equipped
with the X-Boom option.
Possible causes include:
1. Engine oil low
2. Faulty oil pressure sensor
3. Faulty oil pressure sensor wiring
4. Lower Control incorrectly configured
5. Faulty Lower Control
What To Check &
Corrective Action To Clear Error
1. Check Level Sensor
2. Repair or replace Level Sensor wiring
3. Replace Lower Control
NOTE: With machine powered and level, Level
Sensor should have a steady approximately 24 volt
supply voltage and a steady approximately 2.50 volt
output on both X and Y outputs with respect to the
Level Sensor ground connection.
1. Engage trailer brake
2. Check and repair trailer brake switch
3. Repair or replace trailer brake switch wiring
4. Replace Lower Control
1. Check angle sensor
2. Repair or replace angle sensor wiring
3. Correctly configure Lower Control
4. Replace Lower Control
1. Check pressure sensor
2. Repair or replace pressure sensor wiring
3. Correctly configure Lower Control
4. Replace Lower Control
1. Check engine oil level
2. Check oil pressure sensor
3. Repair or replace oil pressure sensor wiring
4. Correctly configure Lower Control
5. Replace Lower Control
33
BIL-JAX 2622T
Error Message
Displayed
015 MACHINE IS
NOT LEVEL
016 LIFT BOOM
017 STOW BOOM
018 LOSS OF LOAD SENSE
COMMUNICATION
Error Explanation &
Possible Causes
The Lower Control has detected the machine has all
four outriggers on the ground but is not level.
This is a self clearing error. When error condition is
removed, error is cleared.
Possible causes include:
1. Machine has gone out of level with use
2. Faulty level sensor
3. Faulty level sensor wiring
4. Faulty Lower Control
The Lower Control has detected the Boom must be
raised before the requested function can be
performed.
This is a self clearing error. When error condition is
removed, error is cleared.
Possible causes include:
1. Trying to rotate boom while boom is down
2. Trying to extend boom while boom is down
3. Trying to retract boom while boom is down
4. Faulty boom down limit switch
5. Faulty boom down limit switch wiring
6. Faulty Lower Control
The Lower Control has detected the boom must be
lowered before the requested function can be
performed.
This is a self clearing error. When error condition is
removed, error is cleared.
Possible causes include:
1. Trying to auto level machine while boom is
raised
2. Trying to extend outriggers while boom is raised
3. Trying to retract outriggers while boom is raised
4. Faulty boom down limit switch
5. Faulty boom down limit switch wiring
6. Faulty Lower Control
The Lower Control has lost communication with the
Load Sense Module.
This is a latched error. To clear this error, first the
error condition must be removed and second the
power must be cycled off then back on.
NOTE: During this error condition, the Load Sense
Module "Status" LED will blink a red “2 blink” error
code and the Lower Control “Power” LED will blink a
“5 blink” error code.
NOTE: This error only occurs on machines equipped
with the Load Sense option.
Possible causes include:
1. Lower control incorrectly configured
2. Faulty Boom Cable
3. Faulty Load Sense Module
4. Faulty Lower Control
What To Check &
Corrective Action To Clear Error
1. Check outrigger and level LED indicators and if
required re-level machine
2. Check level sensor
3. Repair or replace level sensor wiring
4. Replace Lower Control
1. Check that boom is raised before trying to rotate
boom
2. Check that boom is raised before trying to extend
boom
3. Check that boom is raised before trying to retract
boom
4. Check and repair boom down limit switch
5. Repair or replace boom down limit switch wiring
6. Replace Lower Control
1. Check that boom is down before trying to auto
level machine
2. Check that boom is down before trying to extend
outriggers
3. Check that boom is down before trying to retract
outriggers
4. Check and repair boom down limit switch
5. Repair or replace boom down limit switch wiring
6. Replace Lower Control
1. Correctly configure Lower Control
2. Replace Boom Cable
3. Replace Load Sense Module
4. Replace Lower Control
34
Error Message
Displayed
019 BOOM FUNCTION
DISABLED
020 LOSS OF LOAD
CELL CONNECTION
021 OPEN CIRCUIT
PRIMARY UP
022 SHORTED CIRCUIT
PRIMARY UP
023 OPEN CIRCUIT
PRIMARY DOWN
Error Explanation &
Possible Causes
The Load Sense Module has detected an overloaded
boom condition which caused the Lower Control to
disable all boom functions.
This is a self clearing error. When error condition is
removed, error is cleared.
NOTE: This error only occurs on machines equipped
with the Load Sense option.
Possible causes include:
1. Too much weight in basket or on hook
2. Lower Control incorrectly configured
3. Faulty Load Cell
4. Faulty Load Cell wiring
5. Faulty Load Sense Module
6. Faulty Lower Control
The Load Sense Module has detected a loss of
connection to the Load Cell.
This is a self clearing error. When error condition is
removed, error is cleared.
NOTE: This error only occurs on machines equipped
with the Load Sense option.
Possible causes include:
1. Faulty Load Cell
2. Faulty Load Cell wiring
3. Faulty Load Sense Module
The Lower Control has detected an open circuit on the
Primary Up solenoid output when it was energized
during startup self diagnostics.
NOTE: A load of less than 70mA will be detected as an
open circuit. The typical load is approximately 800mA.
Possible causes include:
1. Faulty Primary Up solenoid wiring
2. Faulty Primary Up solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on
the Primary Up solenoid output when it was energized
during startup self diagnostics.
Possible causes include:
1. Faulty Primary Up solenoid wiring
2. Faulty Primary Up solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the
Primary Down solenoid output when it was energized
during startup self diagnostics.
NOTE: A load of less than 70mA will be detected as an
open circuit. The typical load is approximately 800mA.
Possible causes include:
1. Faulty Primary Down solenoid wiring
2. Faulty Primary Down solenoid
3. Faulty Lower Control
4 – OPERATOR SERVICE
What To Check &
Corrective Action To Clear
Error
1. Reduce weight in basket or on hook
2. Correctly configure Lower Control
3. Replace Load Cell
4. Repair or replace Load Cell wiring
5. Replace Load Sense Module
6. Replace Lower Control
1. Replace Load Cell
2. Repair or replace Load Cell wiring
3. Replace Load Sense Module
1. Repair or replace Primary Up solenoid
wiring
2. Replace Primary Up solenoid
3. Replace Lower Control
1. Repair or replace Primary Up solenoid
wiring
2. Replace Primary Up solenoid
3. Replace Lower Control
1. Repair or replace Primary Down solenoid
wiring
2. Replace Primary Down solenoid
3. Replace Lower Control
35
BIL-JAX 2622T
Error Message
Displayed
024 SHORTED CIRCUIT
PRIMARY DOWN
025 OPEN CIRCUIT
SECONDARY UP
026 SHORTED CIRCUIT
SECONDARY UP
027 OPEN CIRCUIT
SECONDARY DOWN
028 SHORTED CIRCUIT
SECONDARY DOWN
029 OPEN CIRCUIT
JIB UP
030 SHORTED CIRCUIT
JIB UP
Error Explanation &
Possible Causes
The Lower Control has detected excessive current on
the Primary Down solenoid output when it was
energized during startup self diagnostics.
Possible causes include:
1. Faulty Primary Down solenoid wiring
2. Faulty Primary Down solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the
Secondary Up solenoid output when it was energized
during startup self diagnostics.
NOTE: A load of less than 70mA will be detected as an
open circuit. The typical load is approximately 800mA.
Possible causes include:
1. Faulty Secondary Up solenoid wiring
2. Faulty Secondary Up solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on
the Secondary Up solenoid output when it was
energized during startup self diagnostics.
Possible causes include:
1. Faulty Secondary Up solenoid wiring
2. Faulty Secondary Up solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the
Secondary Down solenoid output when it was
energized during startup self diagnostics.
NOTE: A load of less than 70mA will be detected as an
open circuit. The typical load is approximately 800mA.
Possible causes include:
1. Faulty Secondary Down solenoid wiring
2. Faulty Secondary Down solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on
the Secondary Down solenoid output when it was
energized during startup self diagnostics.
Possible causes include:
1. Faulty Secondary Down solenoid wiring
2. Faulty Secondary Down solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the
Jib Up solenoid output when it was energized during
startup self diagnostics.
NOTE: A load of less than 70mA will be detected as an
open circuit. The typical load is approximately 800mA.
Possible causes include:
1. Faulty Jib Up solenoid wiring
2. Faulty Jib Up solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on
the Jib Up solenoid output when it was energized
during startup self diagnostics.
Possible causes include:
1. Faulty Jib Up solenoid wiring
2. Faulty Jib Up solenoid
3. Faulty Lower Control
What To Check &
Corrective Action To Clear
Error
1. Repair or replace Primary Down solenoid
wiring
2. Replace Primary Down solenoid
3. Replace Lower Control
1. Repair or replace Secondary Up solenoid
wiring
2. Replace Secondary Up solenoid
3. Replace Lower Control
1. Repair or replace Secondary Up solenoid
wiring
2. Replace Secondary Up solenoid
3. Replace Lower Control
1. Repair or replace Secondary Down solenoid
wiring
2. Replace Secondary Down solenoid
3. Replace Lower Control
1. Repair or replace Secondary Down solenoid
wiring
2. Replace Secondary Down solenoid
3. Replace Lower Control
1. Repair or replace Jib Up solenoid wiring
2. Replace Jib Up solenoid
3. Replace Lower Control
1. Repair or replace Jib Up solenoid wiring
2. Replace Jib Up solenoid
3. Replace Lower Control
36
4 – OPERATOR SERVICE
Error Message
Displayed
031 OPEN CIRCUIT
JIB DOWN
032 SHORTED CIRCUIT
JIB DOWN
033 OPEN CIRCUIT
EXTEND
034 SHORTED CIRCUIT
EXTEND
035 OPEN CIRCUIT
RETRACT
036 SHORTED CIRCUIT
RETRACT
Error Explanation &
Possible Causes
The Lower Control has detected an open circuit on the Jib
Down solenoid output when it was energized during
startup self diagnostics.
NOTE: A load of less than 70mA will be detected as an
open circuit. The typical load is approximately 800mA.
Possible causes include:
1. Faulty Jib Down solenoid wiring
2. Faulty Jib Down solenoid
3. Fault Lower Control
The Lower Control has detected excessive current on the
Jib Down solenoid output when it was energized during
startup self diagnostics.
Possible causes include:
1. Faulty Jib Down solenoid wiring
2. Faulty Jib Down solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the
Extend boom solenoid output when it was energized
during startup self diagnostics.
NOTE: A load of less than 70mA will be detected as an
open circuit. The typical load is approximately 800mA.
Possible causes include:
1. Faulty Extend boom solenoid wiring
2. Faulty Extend boom solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on the
Extend boom solenoid output when it was energized
during startup self diagnostics.
Possible causes include:
1. Faulty Extend boom solenoid wiring
2. Faulty Extend boom solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the
Retract boom solenoid output when it was energized
during startup self diagnostics.
NOTE: A load of less than 70mA will be detected as an
open circuit. The typical load is approximately 800mA.
Possible causes include:
1. Faulty Retract boom solenoid wiring
2. Faulty Retract boom solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on the
Retract boom solenoid output when it was energized
during startup self diagnostics.
Possible causes include:
1. Faulty Retract boom solenoid wiring
2. Faulty Retract boom solenoid
3. Faulty Lower Control
What To Check &
Corrective Action To Clear
Error
1. Repair or replace Jib Down solenoid wiring
2. Replace Jib Down solenoid
3. Replace Lower Control
1. Repair or replace Jib Down solenoid wiring
2. Replace Jib Down solenoid
3. Replace Lower Control
1. Repair or replace Extend boom solenoid
wiring
2. Replace Extend solenoid
3. Replace Lower Control
1. Repair or replace Extend boom solenoid
wiring
2. Replace Extend solenoid
3. Replace Lower Control
1. Repair or replace Retract boom solenoid
wiring
2. Replace Retract boom solenoid
3. Replace Lower Control
1. Repair or replace Retract boom solenoid
wiring
2. Replace Retract boom solenoid
3. Replace Lower Control
37
BIL-JAX 2622T
Error Message
Displayed
037 OPEN CIRCUIT
PLATFORM LEVEL UP
038 SHORTED CIRCUIT
PLATFORM LEVEL UP
039 OPEN CIRCUIT
PLATFORM LEVEL
DOWN
040 SHORTED CIRCUIT
PLATFORM LEVEL
DOWN
041 OPEN CIRCUIT
PLATFORM CW
042 SHORTED CIRCUIT
PLATFORM CW
Error Explanation &
Possible Causes
The Lower Control has detected an open circuit on the
Platform Level Up solenoid output when it was
energized during startup self diagnostics.
NOTE: A load of less than 70mA will be detected as an
open circuit. The typical load is approximately 800mA.
Possible causes include:
1. Faulty Platform Level Up solenoid wiring
2. Faulty Platform Level Up solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on
the Platform Level Up solenoid output when it was
energized during startup self diagnostics.
Possible causes include:
1. Faulty Platform Level Up solenoid wiring
2. Faulty Platform Level Up solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the
Platform Level Down solenoid output when it was
energized during startup self diagnostics.
NOTE: A load of less than 70mA will be detected as an
open circuit. The typical load is approximately 800mA.
Possible causes include:
1. Faulty Platform Level Down solenoid wiring
2. Faulty Platform Level Down solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on
the Platform Level Down solenoid output when it was
energized during startup self diagnostics.
Possible causes include:
1. Faulty Platform Level Down solenoid wiring
2. Faulty Platform Level Down solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the
Platform CW solenoid output when it was energized
during startup self diagnostics.
NOTE: A load of less than 70mA will be detected as an
open circuit. The typical load is approximately 800mA.
Possible causes include:
1. Faulty Platform CW solenoid wiring
2. Faulty Platform CW solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on
the Platform CW solenoid output when it was energized
during startup self diagnostics.
Possible causes include:
1. Faulty Platform CW solenoid wiring
2. Faulty Platform CW solenoid
3. Faulty Lower Control
What To Check &
Corrective Action To Clear
Error
1. Repair or replace Platform Level Up solenoid
wiring
2. Replace Platform Level Up solenoid
3. Replace Lower Control
1. Repair or replace Platform Level Up solenoid
wiring
2. Replace Platform Level Up solenoid
3. Replace Lower Control
1. Repair or replace Platform Level Down
solenoid wiring
2. Replace Platform Level Down solenoid
3. Replace Lower Control
1. Repair or replace Platform Level Down
solenoid wiring
2. Replace Platform Level Down solenoid
3. Replace Lower Control
1. Repair or replace Platform CW solenoid
wiring
2. Replace Platform CW solenoid
3. Replace Lower Control
1. Repair or replace Platform CW solenoid
wiring
2. Replace Platform CW solenoid
3. Replace Lower Control
38
Error Message
Displayed
043 OPEN CIRCUIT
PLATFORM CCW
044 SHORTED CIRCUIT
PLATFORM CCW
045 OPEN CIRCUIT
TURNTABLE CW
046 SHORTED CIRCUIT
TURNTABLE CW
047 OPEN CIRCUIT
TURNTABLE CCW
048 SHORTED CIRCUIT
TURNTABLE CCW
Error Explanation &
Possible Causes
The Lower Control has detected an open circuit on the
Platform CCW solenoid output when it was energized
during startup self diagnostics.
NOTE: A load of less than 70mA will be detected as
an open circuit. The typical load is approximately
800mA.
Possible causes include:
1. Faulty Platform CCW solenoid wiring
2. Faulty Platform CCW solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on
the Platform CW solenoid output when it was
energized during startup self diagnostics.
Possible causes include:
1. Faulty Platform CCW solenoid wiring
2. Faulty Platform CCW solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the
Turntable CW solenoid output when it was energized
during startup self diagnostics.
NOTE: A load of less than 70mA will be detected as
an open circuit. The typical load is approximately
800mA.
Possible causes include:
1. Faulty Turntable CW solenoid wiring
2. Faulty Turntable CW solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on
the Turntable CW solenoid output when it was
energized during startup self diagnostics.
Possible causes include:
1. Faulty Turntable CW solenoid wiring
2. Faulty Turntable CW solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the
Turntable CCW solenoid output when it was energized
during startup self diagnostics.
NOTE: A load of less than 70mA will be detected as
an open circuit. The typical load is approximately
800mA.
Possible causes include:
1. Faulty Turntable CCW solenoid wiring
2. Faulty Turntable CCW solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on
the Turntable CCW solenoid output when it was
energized during startup self diagnostics.
Possible causes include:
1. Faulty Turntable CCW solenoid wiring
2. Faulty Turntable CCW solenoid
3. Faulty Lower Control
4 – OPERATOR SERVICE
What To Check &
Corrective Action To Clear
Error
1. Repair or replace Platform CCW solenoid
wiring
2. Replace Platform CCW solenoid
3. Replace Lower Control
1. Repair or replace Platform CCW solenoid
wiring
2. Replace Platform CCW solenoid
3. Replace Lower Control
1. Repair or replace Turnta ble CW solenoid wiring
2. Replace Turntable CW solenoid
3. Replace Lower Control
1. Repair or replace Turnta ble CW solenoid wiring
2. Replace Turntable CW solenoid
3. Replace Lower Control
1. Repair or replace Turntable CCW solenoid
wiring
2. Replace Turntable CCW solenoid
3. Replace Lower Control
1. Repair or replace Turntable CCW solenoid
wiring
2. Replace Turntable CCW solenoid
3. Replace Lower Control
39
BIL-JAX 2622T
Error Message
Displayed
049 OPEN CIRCUIT
OUTRIGGER RETRACT
050 SHORTED CIRCUIT
OUTRIGGER RETRACT
051 OPEN CIRCUIT
OUTRIGGER EXTEND
052 SHORTED CIRCUIT
OUTRIGGER EXTEND
053 OPEN CIRCUIT
LF OUTRIGGER
054 SHORTED CIRCUIT
LF OUTRIGGER
Error Explanation &
Possible Causes
The Lower Control has detected an open circuit on
the Outrigger Retract solenoid output when it was
energized during startup self diagnostics.
NOTE: A load of less than 70mA will be detected as
an open circuit. The typical load is approximately
800mA.
Possible causes include:
1. Faulty Outrigger Retract solenoid wiring
2. Faulty Outrigger Retract solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on
the Outrigger Retract solenoid output when it was
energized during startup self diagnostics.
Possible causes include:
1. Faulty Outrigger Retract solenoid wiring
2. Faulty Outrigger Retract solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on
the Outrigger Extend solenoid output when it was
energized during startup self diagnostics.
NOTE: A load of less than 70mA will be detected as
an open circuit. The typical load is approximately
800mA.
Possible causes include:
1. Faulty Outrigger Extend solenoid wiring
2. Faulty Outrigger Extend solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on
the Outrigger Extend solenoid output when it was
energized during startup self diagnostics.
Possible causes include:
1. Faulty Outrigger Extend solenoid wiring
2. Faulty Outrigger Extend solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on
the LF Outrigger solenoid output when it was
energized during startup self diagnostics.
NOTE: A load of less than 70mA will be detected as
an open circuit. The typical load is approximately
800mA.
Possible causes include:
1. Faulty LF Outrigger solenoid wiring
2. Faulty LF Outrigger solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on
the LF Outrigger solenoid output when it was
energized during startup self diagnostics.
Possible causes include:
1. Faulty LF Outrigger solenoid wiring
2. Faulty LF Outrigger solenoid
3. Faulty Lower Control
What To Check &
Corrective Action To Clear
Error
1. Repair or replace Outrigger Retract solenoid
wiring
2. Replace Outrigger Retract solenoid
3. Replace Lower Control
1. Repair or replace Outrigger Retract solenoid
wiring
2. Replace Outrigger Retract solenoid
3. Replace Lower Control
1. Repair or replace Outrigger Extend solenoid
wiring
2. Replace Outrigger Extend solenoid
3. Replace Lower Control
1. Repair or replace Outrigger Extend solenoid
wiring
2. Replace Outrigger Extend solenoid
3. Replace Lower Control
1. Repair or replace LF Outrigger solenoid
wiring
2. Replace LF Outrigger solenoid
3. Replace Lower Control
1. Repair or replace LF Outrigger solenoid
wiring
2. Replace LF Outrigger solenoid
3. Replace Lower Control
40
Error Message
Displayed
055 OPEN CIRCUIT
RF OUTRIGGER
056 SHORTED CIRCUIT
RF OUTRIGGER
057 OPEN CIRCUIT
LR OUTRIGGER
058 SHORTED CIRCUIT
LR OUTRIGGER
059 OPEN CIRCUIT
RR OUTRIGGER
060 SHORTED CIRCUIT
RR OUTRIGGER
Error Explanation &
Possible Causes
The Lower Control has detected an open circuit on the
RF Outrigger solenoid output when it was energized
during startup self diagnostics.
NOTE: A load of less than 70mA will be detected as an
open circuit. The typical load is approximately 800mA.
Possible causes include:
1. Faulty RF Outrigger solenoid wiring
2. Faulty RF Outrigger solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on
the RF Outrigger solenoid output when it was
energized during startup self diagnostics.
Possible causes include:
1. Faulty RF Outrigger solenoid wiring
2. Faulty RF Outrigger solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the
LR Outrigger solenoid output when it was energized
during startup self diagnostics.
NOTE: A load of less than 70mA will be detected as an
open circuit. The typical load is approximately 800mA.
Possible causes include:
1. Faulty LR Outrigger solenoid wiring
2. Faulty LR Outrigger solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on
the LR Outrigger solenoid output when it was energized
during startup self diagnostics.
Possible causes include:
1. Faulty LR Outrigger solenoid wiring
2. Faulty LR Outrigger solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the
RR Outrigger solenoid output when it was energized
during startup self diagnostics.
NOTE: A load of less than 70mA will be detected as an
open circuit. The typical load is approximately 800mA.
Possible causes include:
1. Faulty RR Outrigger solenoid wiring
2. Faulty RR Outrigger solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on
the RR Outrigger solenoid output when it was
energized during startup self diagnostics.
Possible causes include:
1. Faulty RR Outrigger solenoid wiring
2. Faulty RR Outrigger solenoid
3. Faulty Lower Control
4 – OPERATOR SERVICE
What To Check &
Corrective Action To Clear
Error
1. Repair or replace RF Outrigger solenoid
wiring
2. Replace RF Outrigger solenoid
3. Replace Lower Control
1. Repair or replace RF Outrigger solenoid
wiring
2. Replace RF Outrigger solenoid
3. Replace Lower Control
1. Repair or replace LR Outrigger solenoid
wiring
2. Replace LR Outrigger solenoid
3. Replace Lower Control
1. Repair or replace LR Outrigger solenoid
wiring
2. Replace LR Outrigger solenoid
3. Replace Lower Control
1. Repair or replace RR Outrigger solenoid
wiring
2. Replace RR Outrigger solenoid
3. Replace Lower Control
1. Repair or replace RR Outrigger solenoid
wiring
2. Replace RR Outrigger solenoid
3. Replace Lower Control
41
BIL-JAX 2622T
Error Message
Displayed
061 OPEN CIRCUIT
ENGINE THROTTLE
062 SHORTED CIRCUIT
ENGINE THROTTLE
063 OPEN CIRCUIT
ENGINE STARTER
064 SHORTED CIRCUIT
ENGINE STARTER
065 OPEN CIRCUIT
ENGINE CHOKE
066 SHORTED CIRCUIT
ENGINE CHOKE
Error Explanation &
Possible Causes
The Lower Control has detected an open circuit on the
Engine Throttle relay output when it was energized during
startup self diagnostics.
NOTE: A load of less than 70mA will be detected as an
open circuit. This load is less than 70mA and this error is
suppressed to avoid false errors.
Possible causes include:
1. Faulty Engine Throttle relay wiring
2. Faulty Engine Throttle relay
3. Faulty Lower Control
The Lower Control has detected excessive current on the
Engine Throttle relay output when it was energized during
startup self diagnostics.
Possible causes include:
1. Faulty Engine Throttle relay wiring
2. Faulty Engine Throttle relay
3. Faulty Lower Control
The Lower Control has detected an open circuit on the
Engine Starter relay output when it was energized during
startup self diagnostics.
NOTE: A load of less than 70mA will be detected as an
open circuit. This load is less than 70mA and this error is
suppressed to avoid false errors.
Possible causes include:
1. Faulty Engine Starter relay wiring
2. Faulty Engine Starter relay
3. Faulty Lower Control
The Lower Control has detected excessive current on the
Engine Starter relay output when it was energized during
startup self diagnostics.
Possible causes include:
1. Faulty Engine Starter relay wiring
2. Faulty Engine Starter relay
3. Faulty Lower Control
The Lower Control has detected an open circuit on the
Engine Choke relay output when it was energized during
startup self diagnostics.
NOTE: A load of less than 70mA will be detected as an
open circuit. This load is less than 70mA and this error is
suppressed to avoid false errors.
Possible causes include:
1. Faulty Engine Choke relay wiring
2. Faulty Engine Choke relay
3. Faulty Lower Control
The Lower Control has detected excessive current on the
Engine Choke relay output when it was energized during
startup self diagnostics.
Possible causes include:
1. Faulty Engine Choke relay wiring
2. Faulty Engine Choke relay
3. Faulty Lower Control
What To Check &
Corrective Action To Clear
Error
1. Repair or replace Engine Throttle relay
wiring
2. Replace Engine Throttle relay
3. Replace Lower Control
1. Repair or replace Engine Throttle relay
wiring
2. Replace Engine Throttle relay
3. Replace Lower Control
1. Repair or replace Engine Starter relay
wiring
2. Replace Engine Starter relay
3. Replace Lower Control
1. Repair or replace Engine Starter relay
wiring
2. Replace Engine Starter relay
3. Replace Lower Control
1. Repair or replace Engine Choke relay
wiring
2. Replace Engine Choke relay
3. Replace Lower Control
1. Repair or replace Engine Choke relay
wiring
2. Replace Engine Choke relay
3. Replace Lower Control
42
Error Message
Displayed
067 OPEN CIRCUIT
ENGINE STOP
068 SHORTED CIRCUIT
ENGINE STOP
069 OPEN CIRCUIT
PROPORTIONAL
070 SHORTED CIRCUIT
PROPORTIONAL
071 OPEN CIRCUIT
MOTOR CONTROL
ENABLE
072 SHORTED CIRCUIT
MOTOR CONTROL
ENABLE
Error Explanation &
Possible Causes
The Lower Control has detected an open circuit on the
Engine Stop relay output when it was energized
during startup self diagnostics.
NOTE: A load of less than 70mA will be detected as
an open circuit. This load is less than 70mA and this
error is suppressed to avoid false errors.
Possible causes include:
1. Faulty Engine Stop relay wiring
2. Faulty Engine Stop relay
3. Faulty Lower Control
The Lower Control has detected excessive current on
the Engine Stop relay output when it was energized
during startup self diagnostics.
Possible causes include:
1. Faulty Engine Stop relay wiring
2. Faulty Engine Stop relay
3. Faulty Lower Control
The Lower Control has detected an open circuit on the
Proportional valve solenoid output when it was
energized during startup self diagnostics.
NOTE: A load of less than 70mA will be detected as
an open circuit. The typical load is approximately
800mA at 100%.
Possible causes include:
1. Faulty Proportional valve solenoid wiring
2. Faulty Proportional valve solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on
the Proportional valve solenoid output when it was
energized during startup self diagnostics.
Possible causes include:
1. Faulty Proportional valve solenoid wiring
2. Faulty Proportional valve solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the
Motor Control Enable output when it was energized
during startup self diagnostics.
NOTE: A load of less than 70mA will be detected as
an open circuit. This load is less than 70mA and this
error is suppressed to avoid false errors.
Possible causes include:
1. Faulty Motor Control Enable wiring
2. Faulty Motor Control
3. Faulty Lower Control
The Lower Control has detected excessive current on
the Motor Control Enable output when it was
energized during startup self diagnostics.
Possible causes include:
1. Faulty Motor Control Enable wiring
2. Faulty Motor Control
3. Faulty Lower Control
4 – OPERATOR SERVICE
What To Check &
Corrective Action To Clear
Error
1. Repair or replace Engine Stop relay wiring
2. Replace Engine Stop relay
3. Replace Lower Control
1. Repair or replace Engine Stop relay wiring
2. Replace Engine Stop relay
3. Replace Lower Control
1. Repair or replace Proportional valve solenoid
wiring
2. Replace Proportional valve solenoid
3. Replace Lower Control
1. Repair or replace Proportional valve solenoid
wiring
2. Replace Proportional valve solenoid
3. Replace Lower Control
1. Repair or replace Motor Control Enable wiring
2. Replace Motor Control
3. Replace Lower Control
1. Repair or replace Motor Control Enable wiring
2. Replace Motor Control
3. Replace Lower Control
43
BIL-JAX 2622T
Error Message
Displayed
073 OPEN CIRCUIT
SPARE OUTPUT
074 SHORTED CIRCUIT
SPARE OUTPUT
075 OPEN CIRCUIT
AC SWITCH
076 SHORTED CIRCUIT
AC SWITCH
077 OPEN CIRCUIT
STROBE
078 SHORTED CIRCUIT
STROBE
Error Explanation &
Possible Causes
The Lower Control has detected an open circuit on the
Spare solenoid output when it was energized during startup
self diagnostics.
NOTE: A load of less than 70mA will be detected as an
open circuit. This output is not used and this error is
suppressed to avoid false errors.
Possible causes include:
1. Faulty Lower Control
The Lower Control has detected excessive current on the
Motor Control Enable output when it was energized during
startup self diagnostics.
NOTE: This output is not used and this error is suppressed
to avoid false errors.
Possible causes include:
1. Faulty Lower Control
The Lower Control has detected an open circuit on the AC
Switch output when it was energized during startup self
diagnostics.
NOTE: A load of less than 70mA will be detected as an
open circuit. This load is less than 70mA and this error is
suppressed to avoid false errors.
Possible causes include:
1. Faulty AC Switch wiring
2. Faulty AC Switch
3. Faulty Lower Control
The Lower Control has detected excessive current on the
AC Switch output when it was energized during startup self
diagnostics.
Possible causes include:
1. Faulty AC Switch wiring
2. Faulty AC Switch
3. Faulty Lower Control
The Lower Control has detected an open circuit on the
Strobe output when it was energized during startup self
diagnostics.
NOTE: A load of less than 70mA will be detected as an
open circuit. This load is less than 70mA and this error is
suppressed to avoid false errors.
Possible causes include:
1. Faulty Strobe wiring
2. Faulty Strobe
3. Faulty Lower Control
The Lower Control has detected excessive current on the
Strobe output when it was energized during startup self
diagnostics.
Possible causes include:
1. Faulty Strobe wiring
2. Faulty Strobe
3. Faulty Lower Control
What To Check &
Corrective Action To Clear
Error
1. Replace Lower Control
1. Replace Lower Control
1. Repair or replace AC Switch wiring
2. Replace AC Switch
3. Replace Lower Control
1. Repair or replace AC Switch wiring
2. Replace AC Switch
3. Replace Lower Control
1. Repair or replace Strobe wiring
2. Replace Strobe
3. Replace Lower Control
1. Repair or replace Strobe wiring
2. Replace Strobe
3. Replace Lower Control
44
Error Message
Displayed
079 OPEN CIRCUIT
DRIVE PWM
080 SHORTED CIRCUIT
DRIVE PWM
081 OPEN CIRCUIT
DRIVE ENABLE
082 SHORTED CIRCUIT
DRIVE ENABLE
Error Explanation &
Possible Causes
The Lower Control has detected an open circuit on the
Drive PWM valve solenoid output when it was
energized during startup self diagnostics.
NOTE: A load of less than 70mA will be detected as
an open circuit. The typical load is approximately
800mA at 100%.
Possible causes include:
1. Faulty Drive PWM valve solenoid wiring
2. Faulty Drive PWM valve solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on
the Drive PWM valve solenoid output when it was
energized during startup self diagnostics.
Possible causes include:
1. Faulty Drive PWM valve solenoid wiring
2. Faulty Drive PWM valve solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the
Drive Enable solenoid output when it was energized
during startup self diagnostics.
NOTE: A load of less than 70mA will be detected as
an open circuit. The typical load is approximately
800mA.
Possible causes include:
1. Faulty Drive Enable solenoid wiring
2. Faulty Drive Enable solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on
the Drive Enable solenoid output when it was
energized during startup self diagnostics.
Possible causes include:
1. Faulty Drive Enable solenoid wiring
2. Faulty Drive Enable solenoid
3. Faulty Lower Control
4 – OPERATOR SERVICE
What To Check &
Corrective Action To Clear
Error
1. Repair or replace Drive PWM valve solenoid
wiring
2. Replace Drive PWM valve
3. Replace Lower Control
1. Repair or replace Drive PWM valve solenoid
wiring
2. Replace Drive PWM valve
3. Replace Lower Control
1. Repair or replace Drive Enable solenoid wiring
2. Replace Drive Enable solenoid
3. Replace Lower Control
1. Repair or replace Drive Enable solenoid wiring
2. Replace Drive Enable solenoid
3. Replace Lower Control
45
BIL-JAX 2622T
Error Message
Displayed
083 OPEN CIRCUIT
DRIVE ENGAGE
084 SHORTED
CIRCUIT
DRIVE ENGAGE
085 OPEN CIRCUIT
LEFT WHEEL
FORWARD
086 SHORTED
CIRCUIT
LEFT WHEEL
FORWARD
087 OPEN CIRCUIT
LEFT WHEEL REVERSE
088 SHORTED
CIRCUIT
LEFT WHEEL REVERSE
Error Explanation &
Possible Causes
The Lower Control has detected an open circuit on the
Drive Engage solenoid output when it was energized
during startup self diagnostics.
NOTE: A load of less than 70mA will be detected as an
open circuit. The typical load is approximately 800mA.
Possible causes include:
1. Faulty Drive Engage solenoid wiring
2. Faulty Drive Engage solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on the
Drive Enable solenoid output when it was energized
during startup self diagnostics.
Possible causes include:
1. Faulty Drive Engage solenoid wiring
2. Faulty Drive Engage solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the
Left Wheel Forward solenoid output when it was
energized during startup self diagnostics.
NOTE: A load of less than 70mA will be detected as an
open circuit. The typical load is approximately 800mA.
Possible causes include:
1. Faulty Left Wheel Forward solenoid wiring
2. Faulty Left Wheel Forward solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on the
Left Wheel Forward solenoid output when it was
energized during startup self diagnostics.
Possible causes include:
1. Faulty Left Wheel Forward solenoid wiring
2. Faulty Left Wheel Forward solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the
Left Wheel Reverse solenoid output when it was
energized during startup self diagnostics.
NOTE: A load of less than 70mA will be detected as an
open circuit. The typical load is approximately 800mA.
Possible causes include:
1. Faulty Left Wheel Reverse solenoid wiring
2. Faulty Left Wheel Reverse solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on the
Left Wheel Reverse solenoid output when it was
energized during startup self diagnostics.
Possible causes include:
1. Faulty Left Wheel Reverse solenoid wiring
2. Faulty Left Wheel Reverse solenoid
3. Faulty Lower Control
What To Check &
Corrective Action To Clear
Error
1. Repair or replace Drive Engage solenoid
wiring
2. Replace Drive Engage solenoid
3. Replace Lower Control
1. Repair or replace Drive Engage solenoid
wiring
2. Replace Drive Engage solenoid
3. Replace Lower Control
1. Repair or replace Left Wheel Forward
solenoid wiring
2. Replace Left Wheel Forward solenoid
3. Replace Lower Control
1. Repair or replace Left Wheel Forward
solenoid wiring
2. Replace Left Wheel Forward solenoid
3. Replace Lower Control
1. Repair or replace Left Wheel Reverse
solenoid wiring
2. Replace Left Wheel Reverse solenoid
3. Replace Lower Control
1. Repair or replace Left Wheel Reverse
solenoid wiring
2. Replace Left Wheel Reverse solenoid
3. Replace Lower Control
46
Error Message
Displayed
089 OPEN CIRCUIT
RIGHT WHEEL FORWARD
090 SHORTED CIRCUIT
RIGHT WHEEL FORWARD
091 OPEN CIRCUIT
RIGHT WHEEL REVERSE
092 SHORTED CIRCUIT
RIGHT WHEEL REVERSE
Error Explanation &
Possible Causes
The Lower Control has detected an open circuit on
the Right Wheel Forward solenoid output when it
was energized during startup self diagnostics.
NOTE: A load of less than 70mA will be detected as
an open circuit. The typical load is approximately
800mA.
Possible causes include:
1. Faulty Right Wheel Forward solenoid wiring
2. Faulty Right Wheel Forward solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current
on the Right Wheel Forward solenoid output when it
was energized during startup self diagnostics.
Possible causes include:
1. Faulty Right Wheel Forward solenoid wiring
2. Faulty Right Wheel Forward solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on
the Right Wheel Reverse solenoid output when it
was energized during startup self diagnostics.
NOTE: A load of less than 70mA will be detected as
an open circuit. The typical load is approximately
800mA.
Possible causes include:
1. Faulty Right Wheel Reverse solenoid wiring
2. Faulty Right Wheel Reverse solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current
on the Right Wheel Reverse solenoid output when it
was energized during startup self diagnostics.
Possible causes include:
1. Faulty Right Wheel Reverse solenoid wiring
2. Faulty Right Wheel Reverse solenoid
3. Faulty Lower Control
4 – OPERATOR SERVICE
What To Check &
Corrective Action To Clear
Error
1. Repair or replace Right Wheel Forward
solenoid wiring
2. Replace Right Wheel Forward solenoid
3. Replace Lower Control
1. Repair or replace Right Wheel Forward
solenoid wiring
2. Replace Right Wheel Forward solenoid
3. Replace Lower Control
1. Repair or replace Right Wheel Reverse
solenoid wiring
2. Replace Right Wheel Reverse solenoid
3. Replace Lower Control
1. Repair or replace Right Wheel Reverse
solenoid wiring
2. Replace Right Wheel Reverse solenoid
3. Replace Lower Control
47
BIL-JAX 2622T
48
5 DECAL REPLACEMENT
Decals contain information that is required for the safe and proper use of
the aerial work platform. 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.
Use the following guides to find the correct location of all decals.
49
BIL-JAX 2622T
Table 5-1. Decal Descriptions
Decal No. Decal Description Qty
0202-0523 Made in USA 1
B06-00-0034 DANGER: Electric Shock 1
B06-00-0037 Lubricate Semi-Annually 1
B06-00-0062 NOTICE: AC Power 2
B06-00-0068 NOTICE: Hydraulic System Oil 1
B06-00-0161B Bil-Jax Logo, 6” Black Transfer 2
B06-00-0504 NOTICE: Emergency Hand Pump 1
B06-00-0505
B06-00-0521 DANGER: Tip Over Hazard 5
B06-00-0541
B06-00-0542 WARNING: Max. Towing Speed 2
B06-00-0543 WARNING: Wheel Crush Toe 2
B06-00-0544 WARNING: Towing Hazards 2
B06-00-0545 Bil-Jax Website Transfer 2
B06-00-0550 WARNING: Unhitch Lift Before Use 2
B06-00-0555 NOTICE: Range of Motion 2
B06-00-0556 2622T, 6” Black Transfer 2
B06-00-0557 NOTICE: Max Load 1
WARNING: Operating Instructions
(Platform)
CAUTION: Compartment Access
Restricted
CAUTION: Generator Plate
Capacity 200 lbs.
DANGER: Before Use/Main
Instruction/Hazards (ground)
CAUTION: Manual Boom
Functions
1
2
1
1
1
Identification Plates
50
B06-00-0490 VIN Plate 1
B06-00-0499 ANSI ID Plate 1
B06-00-0524 Annual Inspection Plate 1
B06-00-0526 Key Tag 1
CE/CAN/AUS Machines
B06-00-0167 Black/Yellow Hazard - 2” Wide 4
B06-00-0568 WARNING: Tip Over Hazard 4
BIL-JAX 2622T
0482
4x
0405
4x
0506
0568
0521
0555
0167
0404
0037
0477
0545
0556
0478
2x
0543
0503
0504
0495
0505
0068
0560
0405
0405
0494
0541
0468
0062
0405
0493
0473
0550
0491
0475
0557
0062
0471
0496
0161B
0542
0481
0405
0202-0523
0552
05520405
05520521
0555
0560
0544
0495
0550
0484
0034
Figure 5-1. Decal Placement
51
BIL-JAX 2622T
52
6 ANSI REPRINT
The following sections are reprinted from the ANSI A92.2-2001 code in
effect at the time of manufacture and govern the safe use of the Bil-Jax
Model 2622T Telescoping Boom Lift. It is the responsibility of all
owners and operators of this machine to read, understand and obey
the recommendations set forth by the ANSI code.
Permission to reprint this material has been granted by the Scaffold
Industry Association.
7. Responsibilities of Dealers and Installers
7.1 General Responsibilities. Each dealer or installer as
applicable shall comply with the requirements of this
section.
7.2 Vehicle Specifications. Each dealer or installer, or both,
who sells an aerial device shall inform the owner or user, or
both, of the manufacturer’s minimum vehicle specifications.
7.3 Vehicle Weight Distribution. The installer shall be
responsible for the weight distribution of the completed
mobile unit in accordance with the requirements of the
aerial device and the applicable regulations. Allowance
shall be made for the weight of readily removable tools and
material specified by the user.
7.4 Manuals. Upon delivery of the equipment to the owner or
user, the dealer or installer shall provide the manuals as
required by Paragraph 6.4 of this standard and manuals for
auxiliary equipment added by the installer.
7.5 Installations. The installer shall comply with Sections 5 and
6 of this standard relating to proper installation and shall
follow the instructions of the manufacturer. In the event the
original manufacturer no longer exists, an equivalent entity
may provide these instructions. The installer of an aerial
device shall, before the mobile unit is placed in operation,
perform stability tests in accordance with the requirements
of 4.5.1 and 4.5.2, the operational and visual tests in
accordance with the requirements of 6.6.1 and 6.6.2 a, and
the appropriate electrical tests required in 5.4.3 of this
standard. The installer shall, when installing an aerial
device on a chassis which is a highway vehicle, comply with
all requirements of the Federal Motor Vehicle Safety
Standards in effect at the time of installation. Certification as
a manufacturer (alteration, intermediate or final) of a motor
vehicle under the Federal Motor Vehicle Safety Standards
is required. The travel height of a mobile unit shall be
posted in a location that is readily visible to the vehicle
operator. For insulated aerial devices, the installer shall
assure conformance to the Qualification test requirements
of 5.3.2 by either obtaining certification of the test and
performing a periodic test after insulation, or by performing
the Qualification test.
7.5.1 Quality Assurance. The installer shall have a documented
quality assurance program which will ensure compliance
with this standard.
7.6 Welding. All welds made by the installer, whose failure
could result in motion of the platform(s) shall meet the
Structural Welding Code AWS D1.1-98 and AWS D1.2-98.
The installer shall establish applicable welding quality
assurance procedures for all weldments.
7.7 Training. The dealer or installer shall offer training or
training materials that aid owners and users in the
operation, inspection, testing and maintenance of the aerial
device. The training shall be offered initially and
subsequently on request.
7.7.1 Dealer or Installer as User. Whenever a dealer or installer
directs personnel to operate the aerial device (inspecting,
sales demonstrations, or any form of use), the dealer or
installer shall assume the responsibilities of users as
specified in Section 9 of this standard. All personnel
authorized to operate this aerial device shall have been
trained.
8. Responsibilities of Owners
8.1 General Responsibilities. Each owner shall comply with the
requirements of this section. The following responsibilities
pertain to the owner’s inspection, testing, maintenance,
modification, training and transfer of ownership. These
activities shall be performed by qualified person(s).
8.2 Inspection and Testing Classifications.
8.2.1 Initial Inspection and Test. Prior to initial use, all new or
modified mobile units shall be inspected and tested to ensure
compliance with the provisions of this standard. Verification
by the manufacturer, the installer, or an equivalent entity(s)
meets this requirement.
8.2.2 Regular Inspection and Tests. The inspection procedure for
mobile units is divided into two classifications based upon the
intervals at which inspections and tests shall be performed.
Intervals shall be set by the owner in accordance with the
manufacturer’s recommendations. Such intervals are
dependant upon component function and exposure to wear,
deterioration and other agents which adversely affect
component life. Two classifications are designated:
(1) Frequent Inspection and Test: Daily to Monthly intervals.
(2) Periodic Inspection and Test: One to Twelve Month
intervals.
8.2.3 Frequent Inspection and Test. Items determined to by the
owner in accordance with the manufacturer’s
recommendations for each specific aerial device shall be
inspected for defects. The following tests and inspections
shall be performed by the operator once daily, prior to first
use:
(1) Operating controls and associated mechanisms for
conditions interfering with proper operation.
(2) Visual and audible safety devices for malfunction.
(3) Hydraulic and pneumatic systems for observable
deterioration or excessive leakage.
(4) Fiberglass and other insulating components for visible
damage or contamination.
(5) Missing or illegible operational and instructional
markings.
(6) Electrical systems of/or related to the aerial device for
malfunction, signs of excessive deterioration, dirt and
moisture accumulation.
(7) Visual inspection of bolts, pins and other fasteners for
loose, deformed or missing fasteners and other locking
53
BIL-JAX 2622T
devices. Any suspected items shall be carefully
examined or tested and a determination made by a
qualified person as to whether they constitute a safety
hazard. All unsafe items shall be replaced or repaired
before use.
8.2.4 Periodic Inspection or Test. An inspection of the mobile unit
shall be performed at the intervals defined in 8.2.2 depending
upon its activity, severity of service, and environment, or as
specifically indicated below. (These inspections shall include
the requirements of 8.2.3):
(1) Structural members for deformation, cracks or corrosion.
(2) Parts, such as pins, bearings, shafts, gears, rollers,
locking devices, chains, chain sprockets, wire and
synthetic ropes and sheaves, for wear, cracks or
distortion.
(3) Hydraulic and pneumatic relief valve settings.
(4) Hydraulic system for proper oil level.
(5) Hydraulic and pneumatic fittings, hoses and tubing for
evidence of leakage, abnormal deformation or excessive
abrasion.
(6) Compressors, pumps, motors and generators for loose
fasteners, leaks, unusual noises or vibrations, loss of
operating speed and excessive heating.
(7) Hydraulic and pneumatic valves for malfunction and
visible cracks in the external valve housing, for leaks
and sticking spools.
(8) Visually inspect any vacuum prevention systems and
verify function of such systems on Category “A” aerial
devices.
(9) Hydraulic and pneumatic cylinders and holding valves
for malfunction and visible damage.
(10) Hydraulic and pneumatic filters for cleanliness and the
presence of foreign material in the system indicating
other component deterioration.
(11) Electrical systems and components for deterioration or
wear including those not readily visible on a frequent
inspection.
(12) Performance test of all boom movements.
(13) Condition and tightness of bolts and other fasteners.
(14) Welds, as specified by the manufacturer.
(15) Legible and proper identification, operational and
instructional markings.
(16) If the aerial device is rated as an insulated device, the
electrical insulating components and system(s) shall be
thoroughly inspected for lack of cleanliness and other
components that compromise insulation. Then these
components and system(s) shall be tested for
compliance with the rating of the aerial device in
accordance with one of the applicable methods and
procedures as outlined in Section 5.4.3 of this standard:
(a) If the aerial device is used for AC bare-hand work,
the unit shall undergo a 60 Hz test as shown in
Table 2 at least every three years;
(b) If the aerial device is used for DC bare-hand work,
the unit shall undergo a DC test as shown in Table
2 at least every three years.
(c) After repair or modification of any component that
crosses the insulating system(s), or the repair or
replacement of an insulating component(s), the unit
shall be dielectrically tested in accordance with
section 5.4.3;
(d) An insulated replacement boom shall be tested to
insure conformance to 5.3.3 by the supplier;
(e) Bare-hand work units shall be tested as shown in
Table l after any major repair to the insulated boom
or any insulated boom replacement. Any suspected
items shall be carefully examined or tested and a
determination made by a qualified person as to
whether they constitute a safety hazard. All unsafe
items shall be replaced or repaired before use.
8.3 Inspection and Test Records.
(1) Items to be inspected shall be designated to the
operator or other authorized person making frequent
inspections. Records of frequent inspections need not
be made. However, where a safety hazard is found, it
shall be reported in writing to a person responsible for
the corrective action and that report and a record of
the correction shall be maintained for five years, or as
required by applicable regulations.
(2) Written, dated and signed reports and records shall be
made of periodic inspections and tests and retained for
a period of five years or as required by applicable
8.4.1.1 Maintenance. Maintenance and frequency of maintenance
8.4.1.2 Maintenance Training. The owner shall train their
8.4.1.3 Modifications. No modifications or additions which affect
8.6 Weight Distribution. Changes in loading or additions made
8.7 Transfer of Ownership. When a change in ownership of an
8.8 Markings. The markings on the aerial device shall not be
8.9 Parts. When parts or components are replaced they shall
8.10 Safety Bulletins. Owners shall comply with safety related
8.11 Manuals. The owner shall insure that the operating
8.12 Training, Retraining, and Famili ariz ation of Ope rators.
regulations.
shall be determined by the owner in accordance with the
manufacturer’s recommendations. Welding repairs of
components or welds, designated as critical in the
manufacturers manual, shall be made in accordance with
the manufacturers recommendations. Should the original
manufacturer no longer exist an equivalent entity may
determine the required procedure.
maintenance personnel in inspection and maintenance of
the aerial device in accordance with the manufacturer’s
recommendations and Section 8 of this standard.
the stability, mechanical, hydraulic, or electrical integrity or
the safe operatio
without the written approval of the manufacturer. If such
modifications or changes are made, the capacity, operation,
and maintenance instruction markings shall be changed
accordingly. In no case shall the safety factors be reduced
below those specified in this standard or below the
manufacturers design safety factors, whichever are greater.
Should the original manufacturer no longer exist, an
equivalent entity may approve required modification.
to the mobile unit after the final acceptance that affect
weight distribution shall meet applicable regulations by
governmental agencies. In no case shall axle loads of the
fully loaded vehicle exceed the Gross Axle Weight Ratings
(GAWR) assigned by the manufacturer. Note: Any change
in weight distribution may adversely affect stability.
aerial device occurs, it shall be the responsibility of the
seller to provide the manufacturer's manual(s) for that aerial
device to the purchaser. It is the responsibility of the
purchaser to notify the manufacturer of the unit model and
serial number and the name and address of the new owner
within 60 days.
removed, defaced, or altered. All missing or illegible
markings shall be promptly replaced.
be identical in specification and function to the original
aerial device parts or components or shall provide an equal
or greater factor of safety.
bulletins as received from the manufacturer, dealer or
installer.
manual(s) is stored on the mobile unit.
n of the aerial device shall be made
54
6 — ANSI REPRINT
8.12.1 Owner as a Renter or Lessor. When an owner functions
as a renter or lessor he shall have the same responsibilities
as specified under Section 11 of this standard.
8.12.2 General Training. Only personnel who have received
general instructions regarding the inspection, application
and operation of aerial devices, including recognition and
avoidance of hazards associated with their operation, shall
operate an aerial device. Such items covered shall include,
but not necessarily be limited to, the following issues and
requirements:
(1) The purpose and use of manuals.
(2) That operating manuals are an integral part of the
aerial device and must be properly stored on the
vehicle when not in use.
(3) A pre-start inspection.
(4) Responsibilities associated with problems or
malfunctions affecting the operation of the aerial
device.
(5) Factors affecting stability.
(6) The purpose of placards and decals.
(7) Workplace inspection.
(8) Applicable safety rules and regulations, such as Part 4,
ANSI C2-1997, National Electrical Safety Code
(applies to utility workers as defined in ANSI C2). The
above standard is an example; other industries using
aerial devices have safety rules pertinent to that
industry.
(9) Authorization to operate.
(10) Oper ator warnin gs and instructions.
(11) Actual operation of the aerial device. Under the
direction of a qualified person, the trainee shall operate
the aerial device for a sufficient period of time to
demonstrate proficiency in the actual operation of the
aerial device.
(12) Proper use of personal fall protection equipment.
8.12.3 Retraining. The operator shall be retrained, when so
directed by the user, based on the user’s observation and
evaluation of the operator.
8.12.4 Familiarization. When an operator is directed to operate an
aerial device he/she is not familiar with, the operator, prior
to operating, shall be instructed regarding the following
items and issues:
(1) The location of the manuals.
(2) The purpose and function of all controls.
(3) Safety devices and operating characteristics specific to
the aerial device.
9. Responsibility of Users.
9.1 General Responsibilities. Each User shall comply with the
requirements of this section.
9.2 Personnel. Only trained and authorized personnel shall be
permitted to operate the aerial device.
9.3 Training, Retraining, and Familiarization of Operators.
9.3.1 General Training. Only personnel who have received
general instructions regarding the inspection, application
and operation of aerial devices, including recognition and
avoidance of hazards associated with their operation, shall
operate an aerial device. Such items covered shall include,
but not necessarily be limited to, the following issues and
requirements:
(1) The purpose and use of manuals.
(2) That operating manuals are an integral part of the
aerial device and must be properly stored on the
vehicle when not in use.
(3) A pre-start inspection.
(4) Responsibilities associated with problems or
malfunctions affecting the operation of the aerial
device.
(5) Factors affecting stability.
(6) The purpose of placards and decals.
(7) Workplace inspection.
(8) Applicable safety rules and regulations, such as Part 4,
ANSI C2-1997, National Electrical Safety Code.
(Applies to utility workers as defined in ANSI C2). The
above standard is an example; other industries using
aerial devices have safety rules pertinent to that
industry.
(9) Authorization to operate.
(10) Oper ator warnin gs and instructions.
(11) Actual operation of the aerial device. Under the
direction of a qualified person, the trainee shall operate
the aerial device for a sufficient period of time to
demonstrate proficiency in the actual operation of the
aerial device.
(12) Proper use of personal fall protection equipment.
9.3.2 Retraining. The operator shall be retrained, when so
directed by the user, based on the user’s observation and
evaluation of the operator.
9.3.3 Familiarization. When an operator is directed to operate an
aerial device he/she is not familiar with, the operator, prior
to operating, shall be instructed regarding the following
items and issues:
(1) The location of the manuals.
(2) The purpose and function of all controls.
(3) Safety devices and operating characteristics specific to
the aerial device.
9.4 Application. The employer and assigned operator shall
9.5 Mobile Operation. Before and during driving, the driver
9.6 Alterations. Altering or disabling of safety devices, guards,
9.7.1 Bare-Hand Work. For bare-hand work, a Category “A”
9.8 Lower Controls. The lower controls of aerial devices shall
10. Responsibilities of Operators
10.1 General Responsibilities. Each operator shall comply with
10.2 Operation. During operation of the aerial device all platform
10.3 Work Platform. The operator shall not use railings, planks,
insure that the aerial device is used only for intended
applications as defined in the operating manual, and that
recognized safety practices are observed.
shall:
(1) Avoid traveling on any surface that adversely affects
vehicle stability.
(2) Maintain a safe distance from obstacles and overhead
lines.
(3) Maintain communications between the driver and the
(4) Under all travel conditions, the driver shall limit travel
or interlocks if so equipped shall be prohibited.
aerial device shall be used.
not be used for continuous operation with personnel in the
platform.
the requirements of this section.
occupants shall use appropriate fall protection connected to
the aerial device at the platform position.
ladders or any other device in or on the work platform for
achieving additional working height or reach.
operator.
speed in accordance with conditions of the ground
surface, congestion, and slope.
55
BIL-JAX 2622T
10.4 Brakes. The vehicle parking brake(s) shall be set at all
times that the boom is elevated except when the aerial
device is being used in accordance with 9.5.
10.5 Loading. Any loading which includes a horizontal load shall
be avoided unless the mobile unit is designed for that
application.
10.6 Observations. Observations during operation for any
defects shall be conducted on an ongoing basis.
10.6.1 Pre-start Inspection. Items determined by the owner in
accordance with the manufacturer’s recommendations for
each specific aerial device shall be inspected for defects
prior to each day’s operation. The following tests and
inspections shall be performed by the operator once daily,
prior to first use:
(1) Operating controls and associated mechanisms for
conditions interfering with proper operation.
(2) Visual and audible safety devices for malfunction.
(3) Hydraulic or pneumatic systems for observable
deterioration or excessive leakage.
(4) Fiberglass and other insulating components for visible
damage or contamination.
(5) Missing or illegible operational and instructional
markings.
(6) Electrical systems of/or related to the aerial device for
malfunction, signs of excessive deterioration, dirt and
moisture accumulation.
(7) Visual inspection of bolts, pins, and other fasteners for
loose, deformed or missing fasteners and other locking
devices. Any suspected items shall be carefully
examined or tested and a determination made by a
qualified person as to whether they constitute a safety
hazard. All unsafe items shall be replaced or repaired
before use.
10.7 Worksite. Before the aerial device is used the worksite shall
10.8 Precautions. Before and during each use the operator shall:
10.9 Mobile Operation. Before engaging in mobile operation the
10.10 Personnel. Only trained and authorized personnel shall be
10.11 Training, Retraining, and Familiarization of Operators.
10.11.1 General Training. Only personnel who have received
56
be surveyed for hazards such as:
(1) Untamped earth fills.
(2) Ditches.
(3) Drop-offs and floor obstructions.
(4) Debris.
(5) Overhead obstructions and electrical conductors.
(6) Weather conditions.
(7) Presence of unauthorized persons.
(1) Check for overhe ad obstructions and electrical
conductors.
(2) Insure that the load on the platform and/or load lifting
devices are in accordance with the manufacturer's
rated capacity.
(3) Insure that outriggers and stabilizers are used if the
manufacturer's instructions require their use.
(4) Insure that gua rdrails are properly installed, and the
gates are closed.
(5) Use outrigger pads when necessary to provide firm
footing.
operator shall determine that the aerial device is specifically
designed for mobile operation.
permitted to operate the aerial device.
general instructions regarding the inspection, application
and operation of aerial devices, including recognition and
avoidance of hazards associated with their operation, shall
operate an aerial device. Such items covered shall include,
but not necessarily be limited to, the following issues and
requirements:
(1)
The purpose and use of manuals.
(2) That operating manuals are an integral part of the
aerial device and must be properly stored on the
vehicle when not in use.
(3) A pre-start inspection.
(4) Responsibilities associated with problems or
malfunctions affecting the operation of the aerial
device.
(5) Factors affecting stability.
(6) The purpose of placards and decals.
(7) Workplace inspection.
(8) Applicable safety rules and regulations, such as Part 4,
ANSI C2-1997, National Electrical Safety Code
(applies to utility workers as defined in ANSI C2). The
above standard is an example; other industries using
aerial devices have safety rules pertinent to that
industry.
(9) Authorization to operate.
(10) Operator warnings and instructions.
(11) Actual operation of the aerial device. Under the
direction of a qualified person, the trainee shall operate
the aerial device for a sufficient period of time to
demonstrate proficiency in the actual operation of the
aerial device.
(12) Proper use of personal fall protection equipment.
10.11.2 Retraining. The operator shall be retrained, when so
10.11.3 Familiarization. When an operator is directed to operate an
directed by the user, based on the user’s observation and
evaluation of the operator.
aerial device he/she is not familiar with, the operator, prior
to operating, shall be instructed regarding the following
items and issues:
(1) The location of the manuals.
(2) The purpose and function of all controls.
(3) Safety devices and operating characteristics specific to
the aerial device.
Responsibilities of Renters, Lessors or Lessees
11.1 General Responsibilities. Each renter or lessor or lessee
11.1.1 Lessor or Lessee as Dealer or Installer. When a lessor or
11.1.2 Lessor or Lessee as Owner. When a lessor or lessee
11.1.3 Lessor or Lessee as User. When a lessor or lessee uses
11.1.4 Lessor or Lessee as Operator. When a lessor or lessee
11.2 Ownership Duties. The renter or lessor shall carry out the
shall comply with the requirements of the applicable section
or sections below.
lessee uses the aerial device as a dealer or installer he
shall have the same responsibilities as specified under
Section 7 of this standard.
uses the aerial device as an owner he shall have the same
responsibilities as specified under Section 8 of this
standard.
the aerial device as a user he shall have the same
responsibilities as specified under Section 9 of this
standard.
uses the aerial device as an operator he shall have the
same responsibilities as specified under Section 10 of this
standard.
duties of ownership specified in this standard which are not
assigned to the renting entity or lessee as the user.
6 — ANSI REPRINT
11.3 Obligations. Upon delivery each renter or lessor of an
aerial device shall provide the operators manual and the
ANSI/SIA A92.2-xxxx Manual of Responsibilities for dealers,
owners, users, operators, lessors and lessees of Vehicle
Mounted Elevating and Rotating Aerial Devices. These
manuals shall be stored on the mobile unit.
11.4 Training. The renter or lessor shall offer training or training
materials that aid the renting entity or lessee in the
operation, inspection, testing and maintenance of the aerial
device. This training shall be offered initially and
subsequently on request.
11.4.1 General Training. Only personnel who have received
general instructions regarding the inspection, application
and operation of aerial devices, including recognition and
avoidance of hazards associated with their operation, shall
operate an aerial device. Such items covered shall include,
but not necessarily be limited to, the following issues and
requirements:
(1) The purpose and use of manuals.
(2) That operating manuals are an integral part of the
aerial device and must be properly stored on the
vehicle when not in use.
(3) A pre-start inspection.
(4) Responsibilities associated with problems or
malfunctions affecting the operation of the aerial
device.
(5) Factors affecting stability.
(6) The purpose of placards and decals.
(7) Workplace inspection.
(8) Applicable safety rules and regulations, such as Part 4,
ANSI C2-1997, National Electrical Safety Code
(applies to utility workers as defined in ANSI C2). The
above standard is an example; other industries using
aerial devices have safety rules pertinent to that
industry.
(9) Authorization to operate.
(10) Operator warnings and instructions.
(11) Actual operation of the aerial device. Under the
direction of a qualified person, the trainee shall operate
the aerial device for a sufficient period of time to
demonstrate proficiency in the actual operation of the
aerial device.
(12) Proper use of personal fall protection equipment.
11.4.2 Familiarization. When an operator is directed to operate an
aerial device he/she is not familiar with, the operator, prior to
operating, shall be instructed regarding the following items
and issues:
(1) The location of the manuals.
(2) The purpose and function of all controls.
(4) Safety devices and operating characteristics specific to
the aerial device.
11.5 Communications. In the event the manufacturer or installer
provides the renter or lessor manuals, bulletins, or other
materials for the information of the user of an aerial device,
the renter or lessor shall pass them on to the user without
any undue delay.
Figure 6-1. Minimum Safe Approach Distances
Do not allow machine, personnel, or conductive
materials inside prohibited zone. Maintain
M.S.A.D. from all energized lines and parts as
well as those shown. Assume all electrical parts
and wires are energized unless known
otherwise.
Diagrams shown are only for purposes of
illustrating M.S.A.D. work positions, not all work
positions.
DENOTES
PROHIBITED
Voltage Range
(Phase to Phase)
0 to 300V Avoid Contact
Over 300V to 50KV 10 3.05
Over 50KV to 200KV 15 4.60
Over 200KV to 350KV 20 6.10
Over 350KV to 500KV 25 7.62
Over 500KV to 750KV 35 10.67
Over 750KV to 1000KV 45 13.72
Minimum Safe Approach Distance
ZONE
(Feet) (Meters)
Minimum Safe Approach Distances
57
BIL-JAX 2622T
58
7 MATERIAL SAFETY
The following Material Safety Data Sheets describe the correct
procedures for the safe handling of chemical components within the
Model 2622T 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 applicable federal and state
regulations. Read and observe all safety precautions. Maintain
awareness of potential health and safety hazards.
MATERIAL SAFETY DATA SHEET
FOR LEAD ACID BATTERIES, WET, FILLED WITH ACID
SECTION I – GENERAL INFORMATION
Manufacturer’s 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
SECTION II -- MATERIAL IDENTIFICATION AND INFORMATION
COMPONENTS PERCENT OSHA ACGIH OTHER LIMITS CAS NUMBER
Hazardous Components PEL TLV
1% or greater
Carcinogens 0.01% or greater
METALLIC LEAD METAL 25.5% 0.05 mg/m3 0.05 mg/m3
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)
NONE 7439-92-1
SECTION III -- PHYSICAL / CHEMICAL CHARACTERISTICS
Boiling Point Approximately 203F Vapor Density: Greater Than 1
Vapor Pressure 14 @ 37% @ 80 F Melting Point: -36 F to -10.6 F
Solubility in Water 100% Water Reactive: Yes, Produces Heat
Specific Gravity 1.245 - 1.295 Battery Electrolyte
Appearance & Odor Clear Liquid with Sharp Pungent Odor
SECTION IV -- FIRE AND EXPLOSION HAZARD DATA
Flash Point: Not Combustible
Auto Ignition Temperature N/A Flammability Limits in Air % by Volume: N/A
Extinguishing Media: Dry Chemical Carbon Dioxide, Water Fog, Water
Special Fire Fighting Procedures
released when acid decomposes. Wear NIOSH approved self-contained breathing apparatus.
Unusual Hazards
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.
: Water applied to sulfuric acid generates heat and causes acid to splatter. Wear full-cover
: Sulfuric Acid Fumes, Sulfur Dioxide Gas or Carbon Monoxide may be
59
BIL-JAX 2622T
MATERIAL SAFETY DATA SHEET
FOR LEAD ACID BATTERIES, WET, FILLED WITH ACID (Continued)
SECTION V -- HEALTH HAZARD DATA
Primary Routes of Entry: Inhalation: YES
Skin: YES
Ingestion: YES
Health Hazards: Acute EYES, SKIN, RESPIRATORY SYSTEM & DIGESTIVE SYSTEM
Chronic: EYES, SKIN, RESPIRATORY SYSTEM & DIGESTIVE SYSTEM
Signs and Symptoms of Exposure: IRRITATION OF EXPOSED AREA, BURNS AND RESPIRATORY PROBLEMS
NO POSSIBILITY OF EXPOSURE OF LEAD WILL OCCUR UNLESS
BATTERY IS DESTROYED.
Medical Conditions Generally
Aggravated By Exposure: EXPOSURE TO MIST MAY CAUSE LUNG DAMAGE & AGGRAVATE
PULMONARY CONDITION.
Emergency First Aid Procedures: SEEK MEDICAL ASSISTANCE FOR FURTHER TREATMENT, OBSERVATION
AND SUPPORT IF NECESSARY.
Eye Contact: WASH WITH COPIOUS QUANTITIES OF COOL WATER FOR AT LEAST 15 MINUTES
Skin Contact: FLUSH AREA WITH LARGE AMOUNTS OF COOL WATER FOR AT LEAST 15 MINUTES
Inhalation: REMOVE TO FRESH AIR, IF BREATHING IS DIFFICULT - GIVE OXYGEN
Ingestion: GIVE MILK TO DRINK, DO NOT
SECTION VI -- REACTIVITY DATA
Stability: STABLE Conditions to Avoid: N/A
Incompatibility: AVOID COMBUSTIBLES, ORGANIC MATERIALS, AND STRONG REDUCING AGENTS
Hazardous Decomposition Products: SULFUR TRIOXIDE, CARBON MONOXIDE, SULFURIC ACID FUMES, &
SULFUR DIOXIDE
Hazardous Polymerization: MAY OCCUR Conditions to Avoid: N/A
INDUCE VOMITING. CALL PHYSICIAN
SECTION VII -- SPILL OR LEAK PROCEDURES
Steps to be taken in case material is released or spilled:
Waste disposal method: CONSULT STATE ENVIRONMENTAL AGENCY. INDIVIDUAL STATE REGULATIONS VARY
Precautions to be taken in Handling & Storage: SEPARATE FROM INCOMPATIBLE MATERIALS, KEEP AWAY
FROM FIRE, SPARKS AND HEAT
Other Precautions and/or Special Hazards:
CONTACT WITH METALS MAY PRODUCE TOXIC SULFUR DIOXIDE FUMES & MAY ALSO RELEASE FLAMMABLE
HYDROGEN GAS. THIS REACTION IS INTENSIFIED WHEN DILUTED.
NFPA Rating: HEALTH: 3 FLAMMABILITY: 0 REACTIVITY: 2 SPECIAL: 0
HMIS Rating: HEALTH: 3 FLAMMABILITY: 0 REACTIVITY: 2 PERSONAL PROTECTION: X
CONTAIN SPILL, USING NON-COMBUSTIBLE MATERIALS: VERMICULITE, DRY SAND & EARTH. NEUTRALIZE
WITH LIME, SODA ASH, SODIUM BICARBONATE, ETC.
SECTION VIII -- CONTROL AND PROTECTIVE MEASURES
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
TRADE NAME: CITGO TRANSGARD™ ATF, DEXRON III/MERCON
EMERGENCY TELEPHONE NUMBERS: 918.495.4700 (medical); 800.424.9300 (chemical)
CHEMICAL FAMILY: AUTOMATIC TRANSMISSION FLUID, LUBRICATING OIL
CAS NUMBER: MIXTURE. REVISION DATE: 10/29/98
HAZARDOUS INGREDIENTS: CONTAINS NO INGREDIENTS NOW KNOWN TO BE HAZARDOUS AS
SECTION II -- HEALTH HAZARD DATA
PRIMARY ROUTES OF ENTRY: INHALATION, SKIN ABRASION AND INGESTION.
CARCINOGENIC: NO
SYMPTOMS (INGESTION, CONTACT, INHALATION):
EYES: FLUSH WITH WATER FOR 15 MINUTES
SKIN: WASH THOROUGHLY WITH WARM SOAPY WATER.
INGESTION: DO NOT INDUCE VOMITTING-SEEK MEDICAL ATTENTION.
CONDITIONS AGGRAVATED BY EXPOSURE: NONE KNOWN
AIR EXPOSURE LIMITS: P.E.L. 5 mg/m3 (OSHA) T.L.V. 10mg/m3 (ACGIH)
HEALTH: 0 FIRE: 1 SPECIFIC: X REACTIVITY: 0
SECTION III -- PHYSICAL DATA
BOILING POINT/FREEZING POINT: N/A
VAPOR PRESSURE (PSIA): N/A
SPECIFIC GRAVITY (H20=1): 0.86
SOLUBILITY IN WATER: NEGLIGIBLE; INSOLUBLE IN COLD WATER
PH OF CONCENTRATE: N/A
APPEARANCE AND ODOR: RED LIQUID, MILD PETROLEUM ODOR
DEFINED IN OSHA 29 CFR 1910.1000 AND OSHA 29 CFR 1910.1200.
MILD, TRANSIENT SKIN OR EYE IRRITATION MAY OCCUR.
SECTION IV -- FIRE AND EXPLOSION HAZARD DATA
FLASH POINT (METHOD USED): CLOSED: 339º F (Pensky-Martens); OPEN: 390º F (Cleveland).
FLAMMABLE LIMITS: NOT DETERMINED
LEL: N/A UEL: N/A
EXTINGUISHING MEDIA: DRY CHEMICAL, FOAM, CO2, WATER FOG. TREAT AS CLASS B FIRE.
UNUSUAL FIRE AND EXPLOSION HAZARDS: PRODUCES COMBUSTIBLE VAPOR AT TEMPERATURES ABOVE FLASH POINT
SECTION V -- REACTIVITY DATA
STABILITY: STABLE
CONDITIONS TO AVOID: AVOID EXTREMES OF HEAT; IGNITION SOURCES.
INCOMPATIBILITY (MATERIALS TO AVOID): STRONG OXIDIZING MATERIALS.
HAZARDOUS DECOMPOSITION PRODUCTS: INCOMPLETE COMBUSTION MAY CAUSE CARBON OXIDES.
HAZARDOUS POLYMERIZATION: WILL NOT OCCUR.
SECTION VI -- SPECIAL PROTECTION INFORMATION
RESPIRATORY PROTECTION (SPECIFIC TYPE): NONE REQUIRED
VENTILATION: NORMAL
LOCAL EXHAUST: NORMAL
MECHANICAL EXHAUST (GENERAL): X
PROTECTIVE GLOVES: OIL IMPERVIOUS GLOVES RECOMMENDED
EYE PROTECTION: SAFETY GLASSES RECOMMENDED
OTHER PROTECTIVE EQUIPMENT: PROTECTIVE CLOTHING RECOMMENDED
SPECIAL LABELLING INSTRUCTIONS: NOT REQUIRED
SPECIAL PACKAGING RECOMMENDATIONS: NONE
HANDLING AND STORAGE RECOMMENDATIONS: AVOID EXTREMES OF COLD OR HEAT. STORE IN CLEAN DRY AREA.
SPILL OR LEAK PROCEDURES: IN CASE OF LEAK OR SPILL, DIKE AND ABSORB WITH INERT MATERIAL. FOLLOW
DISCLAIMER: THE INFORMATION CONTAINED HEREIN HAS BEEN COMPILED FROM SOURCES
CONSIDERED TO BE DEPENDABLE AND IS ACCURATE TO THE BEST OF THE SELLER’S
KNOWLEDGE. THE SELLER MAKES NO WARRANTY WHATSOEVER, EXPRESSED OR IMPLIED, REGARDING THE ACCURACY
OF SUCH DATA OR THE RESULTS TO BE OBTAINED FROM THE USE THEREOF.
ALL LOCAL, STATE AND FEDERAL REGULATIONS FOR DISPOSAL.
61
BIL-JAX 2622T
62
8 EQUIPMENT OPTIONS
The Bil-Jax lift may be equipped with one or more optional
components designed for the convenience and safety of
operators when using the equipment to accomplish specific
tasks.
Always use only those components manufactured and/or
authorized by Bil-Jax, Inc. Never make any adjustments or
modifications or otherwise alter the equipment in any way that is
not expressly recommended by the manufacturer.
When operating a machine equipped with optional components,
observe all safety precautions set forth by the manufacturer, as
well as all government codes and regulations regarding this
equipment and its components.
Consult rental agency or equipment manufacturer regarding
which optional components may be installed on the boom lift. For
questions regarding safe use, contact your regional Bil-Jax
dealer before attempting operation
63
BIL-JAX 2622T
MATERIAL LIFTING HOOK
If the boom lift is equipped with a material lifting
hook, observe the following procedure for material
lift operation:
Remove platform controls from the work
platform by releasing the latch on the back of the
platform control box.
Disconnect platform control box from the load
sense module located on the boom lift bulkhead.
Remove the electric loopback plug from the
receptacle on the bottom right of the ground
control panel (Figure 8-1) and insert the platform
control cable into the open receptacle.
1. To Boom Cable.
Do Not Remove.
2. To Platform Controls.
a. Disconnect platform controls.
b. Replace with loopback plug from ground
controls.
c. Plug platform controls into open receptacle
on the bottom right of ground control panel.
Figure 8-1. Material Lifting Hook Configuration
Figure 8-2. Material Lifting Hook Installation
Operate the material lifting hook remotely, using
the platform control box for optimal control.
WARNING
Always observe the manufacturer’s weight lifting
limitations when using the material lifting hook.
Always use lifting straps or wire rope slings that
are rated at a minimum 500 lbs lifting capacity.
Never stand beneath an elevated load or position
an elevated load above personnel. Falling
objects can cause serious injury or death.
DANGER
This machine is not insulated for use near
electrical power lines and DOES NOT provide
protection from contact with or close proximity
to any electrically charged conductor. Operator
must maintain safe clearances at all times and
always allow for platform movement such as
wind-induced sway. Refer to Table 1-1 for
minimum safe approach distances between the
machine and electrical power lines.
Reverse the procedure to reattach the work
platform.
Insert the removed electric loopback plug into
the open receptacle on the load sense module,
replacing the platform control cable.
Remove the retaining pin holding the platform to
boom lift. Firmly secure platform to prevent
equipment damage.
Remove the platform from the boom by lifting
cage up and away from the mounting bracket on
the boom nose.
Attach the material lifting hook to the mounting
bracket on the boom nose and insert the
retaining pin (Figure 8-2).
64
PLATFORM ROTATOR
The optional platform rotator allows the operator to
rotate the elevated work platform 90º around a
vertical axis by actuating a rotator handle found
below the platform control panel.
To operate manual platform rotator, turn the rotator
handle in the direction of desired rotation (clockwise
or counterclockwise). Motion continues in the
desired direction until rotator handle is released or
the platform reaches a safe travel limit.
WARNING
Installation of a manual platform rotator may
reduce the rated load limit of the work platform.
Follow all manufacturer’s recommendations and
safety precautions when operating a boom lift
equipped for platform rotation.
8 — EQUIPMENT OPTIONS
Figure 8-3. Manual Platform Rotator
65
BIL-JAX 2622T
REPLACEMENT DECALS
Refer to Table 8-1 and Figure 8-6 to Figure 8-7 for a
descriptions and locations of replacement decals for
optional components. Refer to Section 5 for a
comprehensive list of standard decals on the Bil-Jax
Model 2622T Telescoping Boom Lift.
Table 8-1. Replacement Decals
Decal No. Description of Decal
B06-00-0474 NOTICE: Max. Load (All
Configurations)
B06-00-0485 NOTICE: Material/Lifting
Configuration Set-Up (Material Lift
Option Only)
B06-00-0497 NOTICE: Load Capacity for Material
Lifting Hook (Material Lift Option
Only)
B06-00-0527 WARNING: Drive and Set Hazards
B06-00-0528 NOTICE: Drive and Set Instruction
B06-00-0529 NOTICE: Manual Platform Rotation
(Manual Rotation Option Only)
All decals related to optional equipment have a
quantity of one (1) unless otherwise noted.
Figure 8-6. Material Lift Decal Placement
Figure 8-7. Decal Locations
66
8 — EQUIPMENT OPTIONS
67
Inspection Form for BilJax Summit Series® Aerial Work Platforms
Machine Model No. Serial No.
Date of Manufacture: Inspection Performed by:
Date of Inspection: Inspection Location:
Inspection and Maintenance of the above listed machine shall be performed only b y fully trained, authorized and, where
applicable, certified personnel. All service checks shall be performed in accordance with manufacturer’s recommendations
(see the appropriate BilJax Parts and Service Manual) and ANSI/SIA A92.2-2001. Copy this form as needed. Direct any
questions to the BilJax Customer Service Department: 1.800.537.0540 or visit BilJax online at www.biljax.com.
Inspector: Initial in the space provided beside each service check as it is completed. Sign and date form after
Inspection. Owner: Keep this form for your records.
Frequency Key: D=Daily (or before each use); W=Weekly; M=Monthly; A=Annually
Service Check Description Frequency Initials
Verify that all decals are correctly applied and in plain view. D
Verify that all controls and indicators at ground and platform control stations
D
operate properly.
Verify operation of running and brake lights. D
Verify proper tire inflation. D
Inspect tires for damage or loose or missing lug nuts. D
Inspect structural components for obvious damage or debris. D
Inspect machine for loose, damaged or missing fasteners, including pins and bolts. D
Verify that boom down limit switches operate correctly. D
Verify that outrigger safety interlocks operate correctly. D
Inspect hydraulic system and fluid levels. D
Check battery electrolyte level. W
Inspect electrical wiring W
Inspect transport hitch for damage W
Inspect boom for missing, loose or damaged hardware. W
Inspect all hydraulic system components including pump and motor and cylinders
W
for damage, leaks, loss of pressure or speed, and unusual noise or vibration.
Clean all battery terminals. M
Check battery connections. M
Verify proper operation of manual lowering valves and hand pump. M
Lubricate all compartment hinges and latches, slew ring and mating gear using
M
NLGI Grade 2 multi-purpose grease.
Check Wheel Nut torque. M
Replace Hydraulic Oil and Hydraulic Filter. A
Inspect pivot pins and cylinders, including rod ends for wear or damage. A
Visually inspect all welds for wear, damage or corrosion. A
Inspect outriggers for wear or damage. A
Verify proper level sensor operation A
Inspect and adjust axle and parking brake. A
Load test all boom functions with a 500lb (227kg) load (440lb/200kg load if
A
machine is equipped with jib/platform rotate).
Check slew ring for wear or damage. A
125 Taylor Parkway
Archbold, Ohio 43502
800-537-0540
REPORTING SAFETY DEFECTS
If you believe that your vehicle has a defect that could cause a crash or could
cause injury or death, you should immediately inform the National Highway
Traffic Safety Administration (NHTSA) in addition to notifying Bil-Jax, Inc.
If the NHTSA receives similar complaints, it may open an investigation, and if it
finds that a safety defect exists in a group of vehicles, it may order a recall and
remedy campaign. However, the NHTSA cannot become involved in any
individual problems between operators, users, or lessors, and Bil-Jax, Inc.
To contact the NHTSA you may either call the Auto Safety Hotline toll-free at
800-424-9393 (366-0123 in the Washington, DC area) or write to:
NHTSA
U.S. DEPARTMENT of TRANSPORTATION
400 7th Street SW (NSA-11)
Washington, DC 20590
You can also obtain other information regarding motor vehicle
safety by calling the Hotline.
69
70
BIL-JAX SUMMIT SERIES QUICK START GUIDE
Obtain, read and obey all Safety Guidelines:
In this manual
Attached to the boom lift
Indicated by federal, state and local regulations
Position the boom lift in work area
Unhitch from the tow vehicle and disengage all boom travel latches
Turn Key Switch to ground control station for outrigger extension and leveling
Extend outriggers and level the boom
Press and hold the outrigger EXTEND and AUTO LEVEL buttons
A buzzer will sound and all LEDs will become lit on the Outrigger Control Panel
when the boom is level
Turn Key Switch to platform control station.
Enter the work platform and attach safety harness to the Fall Protection
Attachment Point
Press and hold the desired SPEED and function buttons to operate boom lift