Bil-Jax 36XT User Manual

PARTS AND SERVICE

MANUAL
36XT
BOOM
AERIAL WORK PLATFORMS

SELF-PROPELLED

AERIAL WORK PLATFORM

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.
Copyright © Bil-Jax, Inc. 2008. All Rights Reserved.
“Bil-Jax” is a registered trademark and “A Step Above” and “X-Boom” are trademarks of Bil-Jax, Inc. Contact Bil-Jax for replacement manuals.
125 Taylor Parkway Archbold, Ohio 43502
Phone (800) 537-0540 (419) 445-8915 Fax (419) 445-0367
B33-01-0103 http://www.
biljax.com
TABLE OF CONTENTS
Table of Contents 1 Illustrations 2 Tables 2
1 Safety 3
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 Equipment Maintenance 13
Daily Service Checks 14 Weekly Service Checks 16 Monthly Service Checks 17 Annual Service Checks 18 Structural Inspection 19 Additional Service Information 19 Troubleshooting 20 Error Code Definitions 21
4 Cylinder Replacement
Lift Cylinder Replacement 26 Outrigger Cylinder Replacement 27
25
5 Replacement Decals 29
6 Material Safety Data 35
Appendix: Replacement Parts 39
Ordering Replacement Parts 101
1
LIST OF ILLUSTRATIONS
Figure 2-1 Range of Motion 10 Figure 3-1 Outrigger Position Switch 14 Figure 3-2 Hydraulic Reservoir 15 Figure 3-3 Wheel Nut Tightening Sequence 17 Figure 3-4 Slew Ring Position Measurement 18 Figure 4-1 Lift Cylinder Replacement 26 Figure 4-2 Outrigger Cylinder Replacement 27 Figure 5-1 Decal Locations 31 Figure 5-2 Decal Locations – CE 33

LIST OF TABLES

Table 1-1 Minimum Safe Approach Distances 5 Table 3-2 Troubleshooting Steps 20 Table 3-3 Error Code Definitions 21 Table 5-1 Replacement Decal Descriptions 30 Table 5-2 Replacement Decal Descriptions – CE 32
2
1 SAFETY
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 36XT
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 articulating 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 and footgear. 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 a 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 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 articulating 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 keep the safety bar lowered unless personnel are entering or exiting the work platform.
ALWAYS keep personnel and obstructions clear of the machine when repositioning boom or basket.
5
BIL-JAX 36XT
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 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 functions 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 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 while boom is raised or extended.
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 machine.
NEVER use the boom or platform to place a load against any structure, materials or equipment.
NEVER climb on the boom. NEVER leave an elevated platform unattended. NEVER leave the keys in the boom lift while
unattended or not in use.

Drive Safety

ALWAYS maintain an awareness of limited sight and blind spots when operating drive functions.

ALWAYS limit travel speed according to surface conditions, slope, location of personnel and obstructions and any other factors which may result in collision.

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.
NEVER operate boom lift in conditions where wind speeds exceed 12.5 m/sec (45 km/h or 28 mph). High winds may affect stability and boom operation.
6
NEVER operate drive functions on slopes exceeding 20º.

NEVER engage in stunt driving, horseplay or any other behavior considered unsafe according to employer, job site and/or government regulations.

NEVER operate the internal combustion engine in an area that is not properly ventilated.

NEVER fuel the internal combustion engine while smoking, or while near spark or open flame.
MAINTENANCE SAFETY
1 — SAFETY
Ensure the following general safety precautions are followed while performing maintenance on the articulating boom lift:

General Maintenance

ALWAYS perform maintenance procedures 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.
ALWAYS perform maintenance with the boom and platform in a fully lowered, stowed position, when possible. 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 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 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

Ensure the following general safety precautions are followed when performing battery maintenance on the Aerial Work Platform.
ALWAYS wear safety glasses when working with or near batteries.
ALWAYS check the battery fluid level daily. 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 charge batteries near spark or open flame. 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 36XT

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 federal OSHA and ANSI 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 the Bil-Jax Service Department at 800-537-
0540.

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 36XT
RANGE OF MOTION
Figure 2-1. Range of Motion
10
2 — SPECIFICATIONS

SPECIFICATIONS SERIAL NUMBER____________________________

Working Height
Maximum Platform Height
Maximum Horizontal Outreach
From Centerline
From Outrigger Footpad Edge
Rated Platform Capacity
Without Platform Rotation
With Platform Rotation
Maximum Occupants Total Weight
Turntable Rotation Leveling Capability Gradeability Wheel Base
Turning Radius
Inside
Outside
Platform Dimensions
Height
Length
Width – US/CE
43 ft 6 in
13.4 m
37 ft 6 in
11.4 m
32 ft
9.8 m
27 ft
8.2 m
500 lbs
227 kg
440 lbs
200 kg
4,680 lbs
2,123 kg
700º Non-Continuous
12.5º 45%
8 ft 8 in
2.7 m
10 ft
3 m
18 ft
5.5 m
3 ft 7 in
1.1 m
2 ft 6 in
0.8 m
5 ft/4 ft
1.5 m/1.2 m
Outrigger Footprint
Length
Width
2
Footpad Diameter
Brake Speed
Gas Power
DC Power
Tire Size Tire Pressure
Control System Battery Battery Charger Gas Engine Hydraulic Pressure
Reservoir Capacity
Hydraulic System Capacity
Hydraulic Oil (Standard) Platform Rotation/Type (Optional) Maximum Decibel Level
DC Mode – Ground DC Mode – Platform Gas Mode – Ground Gas Mode - Platform
12 ft 2 in
3.7 m
11 ft 4 in
3.4 m
12.5 in
0.3 m
Spring Applied
1.5 mph
5.6 km/h
1.75 mph
2.8 km/h
26 x 12 bar lug tires
20 psi
140 kPa
24V DC
4 x 6V 245 amp-hr
110/120 Volt
Kawasaki 21 HP
3,000 PSI
20,684 kPa
4.8 Gallons
18.2 L
7 Gallons
26.5 L
Dexron III/Mercon ATF
90º/Manual
60 dB 55 dB 70 dB 65 dB
Stowed Dimensions
Height
Length (Platform stowed)
Width
6 ft 6 in
2.0 m
20 ft 10 in
6.4 m
5 ft 5 in
1.7 m
Localized Pressure per Outrigger
Operation Temperature Range
Max. Pressure Per Tire – Floor Loading
25 PSI
1.8 kg/cm
176.5 kPa
-20º to 110º Fahrenheit
-29º to 43º Celsius
35 PSI
2.5 bar
11
2
BIL-JAX 36XT
WARRANTY
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 be 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 the 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.
Bil-Jax authorized dealers or distributors are responsible for filing claims under warranty. Listed below is the warranty claims procedure.
1) Contact Bil-Jax Service Department at 800-537-0540 to report the claim and verify warranty coverage. Machine serial number must be provided.
2) Identify the components to be claimed under warranty along with description of failure. A Returned Merchandise Authorization (RMA) number will be issued by Bil-Jax.
3) 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.
4) After completing repairs, submit warranty claim form and defective parts to Bil­Jax. 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 Bil­Jax. 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 EQUIPMENT MAINTENANCE
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, including weld repairs, 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, monthly and annually.
When servicing the internal combustion engine installed on this machine, always follow the guidelines specified by the engine manufacturer.
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.
13
BIL-JAX 36XT
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
3-1 for troubleshooting procedures.
If display panel displays an error code, refer to Table
3-2 for error code definitions.
Verify correct tire inflation.
Inflate tires to 20 psi (140 kPa).
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 2-1.
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.
Check engine oil level.
Add oil as needed. Manufacturer recommends engine oil type 5W-30.
Check engine fuel level.
Add fuel as needed.
14
Figure 3-1. Outrigger Position Switches
*Repair and replacement of machine components should be performed only by trained and certified personnel in accordance with government regulations and manufacturer recommendations.
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 3-2), 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
3 — EQUIPMENT MAINTENANCE
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 3-2. Hydraulic Reservoir
15
BIL-JAX 36XT
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 electrolyte level 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 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.
16
3 — EQUIPMENT MAINTENANCE
MONTHLY SERVICE CHECKS
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: Follow this procedure each time the
wheel is removed and reinstalled.
1
4
2
Figure 3-3. Wheel Nut Tightening Sequence
3
5
17
BIL-JAX 36XT
ANNUAL SERVICE CHECKS
Perform the following service checks at least once each year:
Replace Hydraulic Oil and Oil Filter.
Drain hydraulic reservoir, clean and replace oil. Wipe away dirt and excess oil from around filter using
cleaning cloths and alcohol solvent.
Loosen and remove filter. Use absorbent cloths to
keep excess oil from leaking onto the machine. Discard used filter.
Wipe away dirt and excess oil from around filter
housing.
Install new filter. Do not over-tighten. With the fill port cap on but not tightened, completely
raise and lower all booms to bleed trapped air from the lift cylinders. Repeat as necessary.
Replace yearly, or whenever filter or oil contamination
has a noticeable effect on boom functions.
Inspect pivot pins and cylinders, including rod ends, for wear or damage. Replace as necessary.
Visually inspect welds and structural components for wear, damage and corrosion.
Follow all manufacturer’s recommendations when
making repairs to critical components.
Personnel making repairs to welds should be certified
in accordance with applicable government regulations.
Inspect outriggers for wear or damage. Repair or replace as necessary.
Check slew bearing for wear or damage.
Check bolts for wear or damage. With the boom lift fully retracted, measure the
distance between the slew ring gear and the horizontal plate above. Use a 2-inch (50 mm) caliper or bore micrometer. Record the measurement (Figure 3-4).
Place a 175 lb (65 kg) load on the boom lift platform. Measure the distance between the slew ring and the
horizontal plate above. Record the measurement.
If the difference in measurements is greater than .25
in (6.35 mm) the slew ring bearing should be replaced. Contact manufacturer for replacement instructions and assistance.
MEASURE
HERE
SLEW RING
Figure 3-4. Slew Ring Position Measurement
Verify that Level Sensor is operating correctly.
Fully deploy outriggers until all Outrigger LEDs and
AUTO LEVEL LED are lit, and buzzer sounds.
Verify that machine is level, and that level sensor is
giving an accurate reading.
Repair or replace as necessary.
Inspect and adjust axles and brakes. Load test boom lift operations with 500 lb (187
kg) load.
18
3 — EQUIPMENT MAINTENANCE
STRUCTURAL INSPECTION ADDITIONAL SERVICE INFORMATION
A comprehensive structural inspection of the unit shall be performed under any of the following conditions.
Ten years from the date of manufacture and every
five years thereafter.
After any actual, suspected or potential damage is
sustained that could affect the structural integrity or stability of the aerial platform.
After a change in ownership. Owners should provide
a complete service history when reselling the unit.
The structural inspection shall include the following considerations.
The service history of the unit, including hours of
service, work performed and environmental conditions.
The inspection and maintenance record of the unit. The effectiveness of all controls and components. A visual inspection of the unit for wear or damage. Manufacturer recommendations. A visual weld inspection, to be performed by qualified
personnel in accordance with applicable government regulations.
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 Section 4.
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 the Operator’s 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.
Testing Machine Stability
The Summit Series aerial work platform has been tested for stability using a load equal to 150% of the rated capacity of the machine and placed at the center of the platform with the boom fully extended. Stability tests should be conducted only by trained personnel and only when the machine is properly anchored to safeguard against tipping.
19
BIL-JAX 36XT
TROUBLESHOOTING
Refer to Table 3-2 for basic troubleshooting operations. Additional information can be found in the Bil-Jax Model 45XA Operator’s Manual. Contact the Bil-Jax Service Department with any questions or before attempting any advanced troubleshooting operations.
Table 3-1. Troubleshooting Steps
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.
a. Emergency STOP engaged. b. Battery charge is low. c. Battery ground or in-series cable is loose. d. Battery main disconnect unplugged.
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 OFF or
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.
STOP engaged.
a. Disengage Emergency STOP buttons. b. Recharge as needed. c. Inspect and repair battery connections. d. Plug in main disconnect.
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.
20
3 — EQUIPMENT MAINTENANCE
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 by the control processor during start-up or operation, the appropriate error code will be displayed on this panel.
Refer to Table 3-2 for a comprehensive list of Error Code Definitions and solutions.
Table 3-2. Error Code Definitions
ERROR MESSAGE DEFINITION OF ERROR COMMENTS
MACHINE IS IN DOWN ONLY
001
MODE
LOSS OF PLATFORM
002
COMMUNICATION PLATFORM CONTROL HAS
005
STUCK KEY GROUND CONTROL HAS
008
STUCK KEY BOOM UP WITHOUT
009
OUTRIGGERS ON GROUND
LEVEL SENSOR HAS
010
ERRATIC OUTPUT
015 MACHINE IS NOT LEVEL Machine has gone out of level with use.
016 LIFT BOOM
017 STOW BOOM An outrigger function requested with boom up.
021 OPEN CIRCUIT PRIMARY UP
SHORTED CIRCUIT
022
PRIMARY UP OPEN CIRCUIT PRIMARY
023
DOWN SHORTED CIRCUIT
024
PRIMARY DOWN OPEN CIRCUIT SECONDARY
025
UP SHORTED CIRCUIT
026
SECONDARY UP OPEN CIRCUIT SECONDARY
027
DOWN SHORTED CIRCUIT
028
SECONDARY DOWN
029 OPEN CIRCUIT JIB UP
030 SHORTED CIRCUIT JIB UP
Machine was either never leveled, outriggers not lowered, or machine went out of level with use.
Ground control lost communication with platform control.
Platform control detected a stuck or pressed key on power up.
Ground control detected a stuck or pressed key on power up.
Ground control detected the boom is up and all outriggers are not on the ground
The ground control detected an erratic output from the level sensor.
A boom rotate, extend, or retract function requested with boom down.
A load of less than 70mA detected in primary up circuit on power-up.
Excessive load detected in primary up circuit on power-up.
A load of less than 70mA was detected when primary down circuit was energized
Excessive load detected when primary down circuit was energized.
A load of less than 70mA detected in secondary up circuit on power-up.
Excessive load detected in secondary up circuit on power-up.
A load of less than 70mA detected when secondary down circuit was energized
Excessive load detected when secondary down circuit was energized.
A load of less than 70mA detected in jib up circuit on power-up.
Excessive load detected in jib up circuit on power-up.
Retract boom to travel position and extend outriggers using
LEVEL
button.
Check for unplugged or damaged platform control cable.
Turn key switch off and on again without pressing any buttons.
Turn key switch off and on again without pressing any buttons.
Retract boom to travel position and extend outriggers using
button.
LEVEL
Retract and extend outriggers using
AUTO LEVEL button.
Retract and extend outriggers using
AUTO LEVEL.
Raise boom from travel position.
Retract and lower boom to travel position.
Check for faulty boom up solenoid coil and wiring.
Check for faulty boom up solenoid coil and wiring.
Check for faulty boom down solenoid coil and wiring.
Check for faulty boom down solenoid coil and wiring.
Check for faulty boom up solenoid coil and wiring.
Check for faulty boom up solenoid coil and wiring.
Check for faulty boom down solenoid coil and wiring.
Check for faulty boom down solenoid coil and wiring.
Check for faulty jib up solenoid coil and wiring.
Check for faulty jib up solenoid coil and wiring.
AUTO
AUTO
21
BIL-JAX 36XT
ERROR MESSAGE DEFINITION OF ERROR COMMENTS
031 OPEN CIRCUIT JIB DOWN
SHORTED CIRCUIT JIB
032
DOWN
033 OPEN CIRCUIT EXTEND
034 SHORTED CIRCUIT EXTEND
035 OPEN CIRCUIT RETRACT
SHORTED CIRCUIT
036
RETRACT OPEN CIRCUIT PLATFORM
037
LEVEL UP SHORTED CIRCUIT
038
PLATFORM LEVEL UP OPEN CIRCUIT PLATFORM
039
LEVEL DOWN SHORTED CIRCUIT
040
PLATFORM LEVEL DOWN OPEN CIRCUIT PLATFORM
041
CW SHORTED CIRCUIT
042
PLATFORM CW OPEN CIRCUIT PLATFORM
043
CCW SHORTED CIRCUIT
044
PLATFORM CCW OPEN CIRCUIT TURNTABLE
045
CW SHORTED CIRCUIT
046
TURNTABLE CW OPEN CIRCUIT TURNTABLE
047
CCW SHORTED CIRCUIT
048
TURNTABLE CCW OPEN CIRCUIT OUTRIGGER
049
RETRACT SHORTED CIRCUIT
050
OUTRIGGER RETRACT OPEN CIRCUIT OUTRIGGER
051
EXTEND SHORTED CIRCUIT
052
OUTRIGGER EXTEND OPEN CIRCUIT
053
LF OUTRIGGER SHORTED CIRCUIT
054
LF OUTRIGGER OPEN CIRCUIT
055
RF OUTRIGGER
A load of less than 70mA detected when jib down circuit was energized
Excessive load detected when jib down circuit was energized.
A load of less than 70mA detected in extend circuit on power-up.
Excessive load detected in extend circuit on power-up.
A load of less than 70mA detected in retract circuit on power-up.
Excessive load detected in retract circuit on power-up.
A load of less than 70mA detected in platform level up circuit on power-up.
Excessive load detected in platform level up circuit on power-up.
A load of less than 70mA detected in platform level down circuit on power-up.
Excessive load detected in platform level down circuit on power-up.
A load of less than 70mA detected in platform CW circuit on power-up.
Excessive load detected in platform CW circuit on power-up.
A load of less than 70mA detected in platform CCW circuit on power-up.
Excessive load detected in platform CCW circuit on power-up.
A load of less than 70mA detected in rotate CW circuit on power-up.
Excessive load detected in rotate CW circuit on power-up.
A load of less than 70mA detected in rotate CCW circuit on power-up.
Excessive load detected in rotate CCW circuit on power-up.
A load of less than 70mA detected in outrigger retract circuit on power-up.
Excessive load was detected when Outrigger Retract circuit was energized.
A load of less than 70mA detected in outrigger retract circuit on power-up.
Excessive load was detected in outrigger extend circuit on power-up.
A load of less than 70mA detected in left front outrigger circuit on power-up.
Excessive load was detected in left front outrigger circuit on power-up.
A load of less than 70mA detected in right front outrigger circuit on power-up.
Check for faulty jib down solenoid coil and wiring.
Check for faulty jib down solenoid coil and wiring.
Check for faulty boom extend solenoid coil/wiring.
Check for faulty boom extend solenoid coil/wiring.
Check for faulty boom retract solenoid coil/wiring.
Check for faulty boom retract solenoid coil/wiring.
Check for faulty level up solenoid coil/wiring.
Check for faulty level up solenoid coil/wiring.
Check for faulty level down solenoid coil/wiring.
Check for faulty level down solenoid coil/wiring.
Check for faulty boom rotate solenoid coil/wiring.
Check for faulty boom rotate solenoid coil/wiring.
Check for faulty boom rotate solenoid coil/wiring.
Check for faulty boom rotate solenoid coil/wiring.
Check for faulty rotate CW solenoid coil/wiring.
Check for faulty rotate CW solenoid coil/wiring.
Check for faulty rotate CCW solenoid coil/wiring.
Check for faulty rotate CCW solenoid coil/wiring.
Check for faulty outrigger retract solenoid coil/wiring.
Check for faulty outrigger retract solenoid coil/wiring.
Check for faulty outrigger extend solenoid coil/wiring.
Check for faulty outrigger extend solenoid coil/wiring.
Check for faulty solenoid coil/wiring at outrigger.
Check for faulty solenoid coil/wiring at outrigger.
Check for faulty solenoid coil/wiring at outrigger.
22
3 — EQUIPMENT MAINTENANCE
ERROR MESSAGE DEFINITION OF ERROR COMMENTS
SHORTED CIRCUIT
056
RF OUTRIGGER OPEN CIRCUIT
057
LR OUTRIGGER SHORTED CIRCUIT
058
LR OUTRIGGER OPEN CIRCUIT
059
RR OUTRIGGER SHORTED CIRCUIT
060
RR OUTRIGGER OPEN CIRCUIT
069
PROPORTIONAL SHORTED CIRCUIT
070
PROPORTIONAL
Excessive load detected in right front outrigger circuit on power-up.
A load of less than 70mA detected in left rear outrigger circuit on power-up.
Excessive load detected in left rear outrigger circuit on power-up.
A load of less than 70mA detected in right rear outrigger circuit on power-up.
Excessive load detected in right rear outrigger circuit on power-up.
A load of less than 70mA detected in proportional valve circuit on power-up.
Excessive load detected in proportional valve circuit on power-up.
Check for faulty solenoid coil/wiring at outrigger.
Check for faulty solenoid coil/wiring at outrigger.
Check for faulty solenoid coil/wiring at outrigger.
Check for faulty solenoid coil/wiring at outrigger.
Check for faulty solenoid coil/wiring at outrigger.
Check for faulty solenoid coil/wiring at proportional valve.
Check for faulty solenoid coil/wiring at proportional valve.
23
BIL-JAX 36XT
24
4 CYLINDER REPLACEMENT
If repair or replacement of a boom lift or outrigger hydraulic cylinder or its component parts becomes necessary, observe the following procedures in accordance with the safety precautions established in Section 1 of this manual.
Removing the hydraulic cylinder from the boom lift may require the use of specialized tools and lifting equipment. NEVER attempt to operate overhead hoists or cranes or related equipment without proper t raining, authorization and supervision. Perform all maintenance procedures only in an area that is well-lit and well-ventilated. Bil-Jax, Inc. is not responsible for personal injury or property damage resulting from the improper use of equipment or failure to follow all procedures and related safety precautions.
Direct all questions regarding cylinder removal and replacement to your regional Bil-Jax representative or to the Bil-Jax Service Department at 800-537-0540.
25
BIL-JAX 36XT
LIFT CYLINDER REPLACEMENT
Use the following procedure to remove and replace faulty or damaged hydraulic cylinders on the boom lift:
WARNING
Repair and removal of the hydraulic cylinders requires the use of lifting straps and an overhead crane or lifting gear to support the boom lift and hydraulic cylinders. Personnel should be thoroughly trained in the operation of these devices before attempting installation or removal. Hydraulic cylinders are heavy and may have hydraulic oil on their surface. Failure to use proper equipment or to securely support boom and boom cylinders can result in damage to lift components, serious injury or death.
Lower the boom until it is resting in a stowed position.
When removing the slave cylinder, extend the articulating boom section until all pivot pins are exposed (approximately two feet).
Press and hold the emergency lowering valve on the
back of the jib boom section to relieve all hydraulic pressure to the cylinder. Repeat this process for the upper and lower boom sections. Refer to the 4527A Operator’s Manual for emergency lowering valve locations and operating procedures.
Turn key switch to the OFF position and remove the
key.
Locate the piston rod end of the cylinder to be
removed (Figure 4-1). Unbolt and remove the retainer plate from each side of the pivot pin.
Verify that the cylinder is supported by lifting straps
and an overhead hoist.
Remove the pivot pin using a hammer and a brass or
hardwood drift.
Use an overhead crane or lifting gear to raise the
boom section. Adequate clearance is necessary to reach the cylinder valve block and hydraulic hose ports.
Unplug the appropriate emergency lowering valve
solenoid.
Tag and number all hydraulic hoses that attach to the
cylinder valve block. Use a marker to label the valve block ports with the appropriate hose numbers.
Place absorbent cloths below the cylinder ports and
detach hydraulic hoses from the cylinder. Elevate
hoses to prevent leakage. Plug or cap exposed hose fittings and cylinder ports.
At the base of the cylinder, unbolt and remove
retainer plate from each side of the pivot pin.
Remove the pivot pin using a hammer and a brass or
hardwood drift.
Lift and remove the cylinder using an overhead hoist
and lifting straps.
Replace or reinstall the cylinder by following the
above instructions in the reverse order of removal.
Actuate the hydraulic system and check for leakage.
Tighten hydraulic fittings as needed.
Bleed trapped air from the hydraulic system by raising
and lowering the boom with the reservoir fill port cap on but not tightened. Allow several minutes for trapped air to escape. Repeat as needed.
RETAINING
PLATE
PIN
CYLINDER
PISTON ENDBASE END
Figure 4-1. Lift Cylinder Replacement
26
OUTRIGGER CYLINDER REPLACEMENT
Use the following procedure to remove and replace faulty or damaged hydraulic cylinders on the outriggers:
Lower the outrigger until the footpad is touching the
Remove the bolts securing the outrigger cylinder rod
At the piston rod end of the cylinder, unbolt and
Place a block of wood shoring between the outrigger
Remove the pivot pin using a hammer and a brass or
Fully retract the cylinder. Turn key to the off position and remove the key. Tag and number all hydraulic hoses that attach to the
ground. Do not transfer the weight of the boom lift onto the outrigger. Leave the weight of the boom on the trailer wheels.
guard (Figure 4-2). Remove the guard.
remove the retainer plate from each side of the pivot pin.
beam and cylinder.
hardwood drift.
cylinder valve block. Use a marker to label the valve block ports with the appropriate hose numbers.
4 — CYLINDER REPLACEMENT
Unplug the cylinder valve solenoid. Place absorbent cloths below the cylinder ports and
detach hydraulic hoses from the cylinder. Elevate hoses to prevent leakage. Plug or cap exposed hose fittings and cylinder ports.
At the base of the cylinder, unbolt and remove
retainer plate from each side of the pivot pin.
Remove the pivot pin using a hammer and a brass or
hardwood drift.
Lift and remove the cylinder using an overhead hoist
and lifting straps.
Replace or reinstall the cylinder by following the
above instructions in the reverse order of removal.
Actuate the hydraulic system and check for leakage.
Tighten hydraulic fittings as needed.
Bleed trapped air from the hydraulic system by raising
and lowering the boom with the reservoir fill port cap on but not tightened. Allow several minutes for trapped air to escape. Repeat as needed.
CYLINDER ROD
GUARD
PIN
CYLINDER
CYLINDER ROD
GUARD BOLTS
RETAINING
PLATES
Figure 4-2. Outrigger Cylinder Replacement
27
BIL-JAX 36XT
28
5 REPLACEMENT DECALS
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.
29
BIL-JAX 36XT
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, Black Transfer 2 B06-00-0404 WARNING: Outrigger Crush Toe 8 B06-00-0405 WARNING: Pinch Point 14
B06-00-0471
B06-00-0473
B06-00-0474 NOTICE: Max. Load 1
B06-00-0475
B06-00-0476 NOTICE: Range of Motion 2 B06-00-0477 WARNING: Forklift Pockets 2 B06-00-0481 CAUTION: Transport Safety Latch 1 B06-00-0482 DANGER: Electrocution Hazard 2
DANGER: Before Use/Main Instruction/Hazards (Platform)
NOTICE: Operator’s Manual Missing
WARNING: Read/Understand Operator’s Manual
1
1
1
Decal No. Decal Description Qty B06-00-0484 DANGER: Battery/Charger Safety 1 B06-00-0494 NOTICE: Hazardous Materials 1
B06-00-0495
B06-00-0503 NOTICE: Handle Applications 1 B06-00-0504 NOTICE: Emergency Hand Pump 1
B06-00-0505
B06-00-0506 NOTICE: Emergency Lowering 2 B06-00-0521 DANGER: Tip Over Hazard 5
B06-00-0541
B06-00-0545 Bil-Jax Website Transfer 2
B06-00-0552
B06-00-0561
B06-00-0562
B06-00-0563 36XT, 6” Black Transfer 2
CAUTION: Compartment Access Restricted
DANGER: Before Use/Main Instruction/Hazards (ground)
CAUTION: Manual Boom Functions
NOTICE: Fall Protection Attach­ment points
WARNING: Operating Instructions (Ground)
WARNING: Operating Instructions (Platform)
2
1
1
1
2
1
Identification Plates
30
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
5 – DECAL PLACEMENT
4x
0405
0482
0506
0521
0476
0404
0037
0494
0068
0541
0503
0504
0477
0545
0495
0561
0505
0563
05520405
0493
0473
0161B
0475
0062
0552
0202-0523
0405
05520405
05520521
0481
0495
0484
0034
0562
0471
0474
0476
Figure 5-1. Decal Locations
31
BIL-JAX 36XT
Table 5-2. Decal Descriptions – CE
Decal No. Decal Description Qty
0202-0523 Made in USA 1 B06-00-0034 DANGER: Electric Shock 2 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, B lack Transfer 2 B06-00-0173 Fall Protection Attachment Points 1 B06-00-0404 WARNING: Outrigger Crush Toe 8 B06-00-0405 WARNING: Pinch Point 14
B06-00-0471
B06-00-0474 NOTICE: Max. Load 1
B06-00-0475
B06-00-0476 NOTICE: Range of Motion 2
DANGER: Before Use/Main Instruction/Hazards (Platform)
WARNING: Read/Understand Operator’s Manual
1
2
Decal No. Decal Description Qty
B06-00-0482 DANGER: Electrocution Hazard 2
B06-00-0495
B06-00-0505
B06-00-0506 NOTICE: Emergency Lowering 2
B06-00-0541
B06-00-0545 Bil-Jax Website Transfer 2
B06-00-0561
B06-00-0562
B06-00-0563 36XT, 6” Black Transfer 2 B06-00-0568 WARNING: Outrigger Pressure 4
B06-00-0572
CAUTION: Compartment Access Restricted
DANGER: Before Use/Main Instruction/Hazards (ground)
CAUTION: Manual Boom Functions
WARNING: Operating Instructions (Ground)
WARNING: Operating Instructions (Platform)
WARNING: Read/Understand Parts and Service Manual
2
1
1
2
1
1
Identification Plates
B06-00-0499-CE CE Serial ID Plate 1 B06-00-0526 Key Tag 1
32
0405
0482
0506
0037
5 — REPLACEMENT DECALS
0068
0541
4x
05520405
0568
0405
0404
0545
0563
0161B
0405
0495
0505
0495
0572
0475
0034
0561
0476
0034
05520405
0062
0475
0562
0474
0471
0202-0523
0476
0173
Figure 5-2. Decal Placement – CE
33
BIL-JAX 36XT
34
6 MATERIAL SAFETY DATA
The following Material Safety Data Sheets describe the correct procedures for the safe handling of chemical components within the Model 45XA Articulating 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
35
BIL-JAX 36XT

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 VOMITTING. 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
36
6 – MATERIAL SAFETY DATA
MATERIAL SAFETY DATA SHEET
DEXRON III/MERCON AUTOMATIC TRANSMISSION FLUID (HYDRAULIC OIL)
SECTION I -- GENERAL INFORMATION
TRADE NAME: CITGO TRANSGARD™ ATF, DEXRON III/MERCON EMERGENCY TELEPHONE NUMBERS: 918.495.4700 (medical); 800.424.9300 (chemical) CHEMICAL FAMILY: AUTOMATIC TR ANSMISSION F LUID, LUBRICA TING 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.
37
38
APPENDIX:REPLACEMENT PARTS
Use only parts manufactured and/or authorized by Bil-Jax, Inc. when replacing damaged components. See page 89 for replacement part ordering information.
Only personnel properly trained and authorized to operate all equipment and familiar with all boom functions should attempt to repair or replace any part of the boom lift.
Always read, understand and obey all safety precautions included in this manual, as well as those precautions attached to the lift and dictated by federal, state and local regulations.
39
Assembly Description Page
Outrigger 42 Engine 44 Front Rest 48 Front Axle 50 Rear Axle 52 Slew Ring 54 Counterweight 56 Control Compartment 58 Pump Compartment 60 Battery Compartment 62 Cover 64 Boom 66 Cable Track 70 Boom Nose 72 Platform 74 Hydraulic Pump 76
40
Assembly Description Page
Boom and Rotation Hydraulic Lines 80 Outrigger Hydraulic Lines 82 Trailer Hydraulic Lines – 4WD 83 Wire Harnesses 86 Manifold Wire Harness 87 Gas Engine Wire Harness 87 Choke/Throttle Solenoid Wire Harness 88 Engine Relays Wire Harness 88 ATC Fuse Holder 89 Start/Stop/Run Wire Harness 89 Generator Switcher Box 90 Wire Assembly – Fan 90 IEC Cord – Male – US Markets 91 Generator 110V Wire Harness 91 Oil Switch 91 Cord Assembly – 110V Generator 92 Cord Assembly – Generator Switch 92 Cord Assembly – Switch Jumper 92 Cord Assembly – 110V AC Plug – Female 92 Switcher Box – CE Models 93 220V Generator Wire Harness – CE Models 93 Cord Assembly – 220V AC Plug – Female – CE Models 93 Pump And Cylinder Wire Harnesses 94 Outrigger Coil and Switches Wire Harness 95 Analog Harness 96 Power Harness 96 110 VAC Tower-Platform Harness 96 Platform-Ground Communication Cable 97 Material Hook 98 Battery Layout 100
41
OUTRIGGER ASSEMBLY
13
30
14
29
14
26
27
23
24
25
18
28
21
15
16
17
11 12
10
14
13
9
4
5
6
7
2
6
5
7
4
22
20
19
17
5
7
6
8
1
3
42
OUTRIGGER ASSEMBLY PARTS LIST
Item No. Part No. Description Qty.
1 A-00120 Outrigger Weldment 1* 2 A-00046 Grommet – 1.5 x 1.25 x 1.75 1 3 A-00032 Bearing 2 4 A-00020 Pin, 1.25 x 5.5 2 5 A-00019 Pin Retainer, 1.25 3 6 0096-0016 Cap Screw, M10 x 25 3 7 0096-0041 Hex Nut, Self-Locking, M10 3 8 A-00060 Pin, 1.25 x 4.25 1
9 A-00138 Outrigger Hydraulic Cylinder 1 10 A-00141 Outrigger Cylinder Guard 1 11 0096-0009 Cap Screw, M8 x 10 2 12 A-00142 Guard Slide 1 13 0096-0010 Cap Screw, M8 x 20 6 14 0096-0040 Hex Nut, Self-Locking, M8 10 15 A-00154 Spring, Outrigger Sensor 1 16 0096-0036 Cap Screw, M16 x 150 1 17 0096-0044 Hex Nut, Self-Locking, M16 2 18 A-00128 Pad Mount Weldment 1 19 0096-0051 Cap Screw, M16 x 100 1 20 B01-03-0078 Limit Switch Assembly 1 21 0090-0232 Slotted Machine Screw, #10-24 x 5/8 2 22 0090-0182 Hex Nut, Self-Locking, #10-24 2 23 A-00136 Foot Pad, Aluminum, 12” 1 24 A-00137 Foot Pad Bottom, 12” 1 25 0096-0121 Flat Head Cap Screw, M8 x 30 4 26 A-00135 Foot Pad Ball 1 27 A-00195 O-Ring, 1 1/4” OD x 1” ID 1 28 0096-0045 Hex Nut, Self-Locking, M20 1 29 A-00127 Foot Pad Lock 2 30 A-00139 Foot Pad Lock Cap 1
*Quantities listed reflect the number of parts needed for each outrigger.
NOTE: Unless otherwise noted, high-strength Grade 5/Class 8.8 fasteners
are used in the assembly of this equipment.
43
ENGINE ASSEMBLY (I)
11
10
5
6
7
8
9
7
12
25
24
21
4
16
2
17
3
19
8
8
15
8
20
22
14
15
13
2
2
3
1
23
15
3
18
44
ENGINE ASSEMBLY (I) PARTS LIST
Item No. Part No. Description Qty.
1 A-01063 Cover Front 1
2 0096-0014 Cap Screw, M10 x 20 14
3 0096-0041 Hex Nut, Self-Locking, M10 22
4 A-01064 Cover Top 1
5 A-01067 Cover Side – Left 1
6 A-01069 Cover Side – Right 1
7 0096-0001 Cap Screw, M6 x 16 20
8 0096-0039 Hex Nut, Self-Locking, M6 33
9 B42-01-1006 Hinge – 72” Continuous 2 10 A-01045 Latch, Paddle-Style 2 11 0096-0113 Cap Screw, M4 x 16 8 12 0096-0073 Hex Nut, Self-Locking, M4 8 13 A-01052 Cover Rear 1 14 B01-06-0053 Relay 24V DC w/ Bracket 5 15 0096-0002 Cap Screw, M6 x 20 13 16 A-A-01059 Cover Pad 2 17 0096-0068 Flat Head Cap Screw, M10 x 45 4 18 A-03048 Relay Cover 1 19 A-03040 Switcher Box Assembly 1
B01-06-0056 Relay – 30 Amp 1 B01-10-0354 Circuit Breaker – 20 Amp 1
A-01015 Switcher Box 1 20 A-01072 Cover Latch Stop 2 21 0096-0098 Cap Screw, M8 x 35 4 22 0096-0040 Hex Nut, Self-Locking, M8 4 23 A-01047 Fuel Tank 1 24 A-01089 Fuel Gauge 1 25 0096-0016 Cap Screw, M10 x 25 2
45
ENGINE ASSEMBLY (II)
10
3
21
9
17
15
14
12 1212
3
67
1
2
4
5
18
12
46
22
13
16
13 3
11
25
24
27
33
31
32
34
1920
28
29
26
23
ENGINE ASSEMBLY (II) PARTS LIST
Item No. Part No. Description Qty.
1 A-01046 Engine 21HP (See Manufacturer’s Literature) 1 2 0096-0098 Cap Screw, M8 x 35 4 3 0096-0040 Hex Nut, Self-Locking, M8 18 4 A-01048 Pump – Dual – 4.5 GPM 1 5 A-01055 Dual Pump Mount 1 6 0096-0110 Cap Screw, M10 x 110 2 7 0096-0093 Washer, M10 2 8 0096-0041 Hex Nut, Self-Locking, M10 2
9 A-01081 Oil Cooler 1 10 0096-0010 Cap Screw, M8 x 20 4 11 A-01071 Solenoid Bracket 1 12 0096-0001 Cap Screw, M6 x 16 12 13 0096-0039 Hex Nut, Self-Locking, M6 10 14 A-01074 Throttle Solenoid Assembly 2 15 A-00761 Generator 1 16 A-01060 Spacer 4 17 0096-0053 Cap Screw, M8 x 50 4 18 A-01038 Brake Release – Hand Pump 1 19 0096-0108 Cap Screw, M8 x 70 2 20 B02-00-0071 Oil Filter Assembly 1 21 B29-00-0016 Oil Filter Bracket 1 22 A-00783 Exhaust Assembly 1 23 A-01061 Belt 1 24 A-01051 Pulley 2 25 0090-0363 Set Screw – 1/4 - 20 x 3/4 6 26 A-01036 Pulley 1 27 A-01088 Idler Roller 1 28 0096-0022 Cap Screw, M12 x 75 1 29 0096-0076 Washer, M12 3 30 0096-0041 Hex Nut, Self-Locking, M12 1 31 A-01095 Tension Arm 1 32 A-01086 Spacer – Tension Arm 1 33 0090-0210 Washer – 3/8” 1 34 0096-0069 Cap Screw, M10 x 75 1
47
FRONT REST ASSEMBLY
13
19
17
15
11
12
14
5
6
6
4
9
16
18
10
21
8
21
2
1
3
22
20
20
7
48
FRONT REST ASSEMBLY PARTS LIST
Item No. Part No. Description Qty.
1 A-03145 Front Rest Weldment 1
2 0096-0024 Cap Screw, M12 x 100 2
3 0096-0042 Hex Nut, Self-Locking, M12 2
4 A-00157 Front Rest Pad 6
5 0096-0017 Cap Screw, M10 x 30 16
6 0096-0041 Hex Nut, Self-Locking, M10 20
7 A-00159 Boom Latch 1
8 0096-0016 Cap Screw, M10 x 25 4
9 A-00169 Switch Bracket 1 10 0096-0002 Cap Screw, M6 x 20 2 11 0096-0039 Hex Nut, Self-Locking, M6 2 12 A-00188 Switch Cam 2 13 0090-1104 Machine Screw, #4-40 x 1 3 14 0090-0525 Hex Nut, Self-Locking, #4-40 3 15 B01-03-0078 Limit Switch Assembly, NO (Female) 1 16 B01-03-0079 Limit Switch Assembly, NC (Male) 1 17 0090-0709 Machine Screw, #6-32 x 1 1/4 2 18 0090-0180 Hex Nut, Self-Locking, #6-32 2 19 A-00158 Tension Spring 1 20 0096-0038 Cap Screw, M20 x 120 4 21 0096-0045 Hex Nut, Self-Locking, M20 4 22 A-01082 Tie Weldment – 4WD 1
49
FRONT AXLE ASSEMBLY
19
17
22
23
24
20
21
13
8
8
3
18
14
15
12
16
7
6
5
50
13
4
9
10
12
11
FRONT AXLE ASSEMBLY PARTS LIST
Item No. Part No. Description Qty.
1 A-01010 Front Axle Weldment – 4WD 1
2 A-01097 Bushing, 1.5” OD x 1.25” ID 4
3 A-01020 Front Yoke – Left 1
4 A-01021 Front Yoke – Right 1
5 A-01070 Pin – 1.25” x 1.625” 4
6 A-00019 Pin Retainer – 1.25” 4
7 0096-0016 Cap Screw, M10 x 25 4
8 0096-0041 Hex Nut, Self-Locking, M10 9
9 A-01022 Hydraulic Motor – 4WD 2 10 0096-0024 Cap Screw, M12 x 100 8 11 0096-0042 Hex Nut, Self-Locking, M12 8 12 A-01025 Tie Rod – 4WD 1 13 A-01096 Bushing, 1.25” OD x 1.0” ID 4 14 A-01085 Pin – Front Axle 4 15 0090-0155 Cotter Pin – 3/16” x 1 3/4" 4 16 A-01030 Steering Cylinder – 4WD 1 17 A-01005 Front Axle Mount Weldment 1 18 0096-0038 Cap Screw, M20 x 120 2 19 0096-0045 Hex Nut, Self-Locking, M20 2 20 A-01029 Pad – Front Axle 2 21 0096-0091 Flat Head Cap Screw, M10 x 25 4 22 A-01009 Pin – 1.0” x 5.5” 1 23 A-00018 Pin Retainer – 1.0” 1 24 0096-0014 Cap Screw, M10 x 20 1
51
REAR AXLE ASSEMBLY
2
7
52
12
6
4
5
REAR AXLE ASSEMBLY PARTS LIST
Item No. Part No. Description Qty.
1 A-00175 Hydraulic Cover 1
2 0096-0010 Cap Screw, M8 x 20 12
3 0096-0067 Clip Nut, M8 12
4 A-01032 Hydraulic Motor – Rear 2
5 0096-0024 Cap Screw, M12 x 100 8
6 0096-0042 Hex Nut, Self-Locking, M12 8
7 A-01037 Axle Cover 2
53
SLEW RING ASSEMBLY
13
12
11
9
2
8
1
3
6
5
7
4
54
10
SLEW RING ASSEMBLY PARTS LIST
Item No. Part No. Description Qty.
1 A-02189 Slew Assembly and Adapter 1
2 Slew Ring 1
3 Slew Ring Drive 1
4 A-00149 Base Ring Adapter 1
5 0090-0461 Cap Screw, 1/2-13 x 2 2
6 0090-0212 Lock Washer, 1/2 2
7 0096-0033 Flat Head Cap Screw, M16 x 35 16
8 0096-0054 Flat Head Cap Screw, M16 x 50 18
9 0090-0643 Cap Screw, 5/8-11 x 2-3/4, Grade 8 19 10 0096-0044 Hex Nut, Self-Locking, M16 16 11 A-00350 Rotation Stop Assembly 1 12 0096-0021 Cap Screw, M12 x 45 2 13 0096-0042 Hex Nut, Self-Locking, M12 2
55
COUNTERWEIGHT ASSEMBLY
56
COUNTERWEIGHT ASSEMBLY PARTS LIST
Item No. Part No. Description Qty.
1 A-00270 Counterweight 1
2 0096-0065 Cap Screw, M20 x 80 4
3 0096-0045 Hex Nut, Self-Locking, M20 4
57
CONTROL COMPARTMENT ASSEMBLY
21
22
13
12
13
14
21
10
8
7
6
1
8
15
7
7
4
3
2
8 7
5
8
8
11
17
18
19 2016
7
9
58
CONTROL COMPARTMENT ASSEMBLY PARTS LIST
Item No. Part No. Description Qty.
1 A-00712 Lower Control Box 1
2 A-00233 Lower Control Mount 1
3 A-00290 Cover Stop Bracket 1
4 0096-0016 Cap Screw, M10 x 25 2
5 0096-0041 Hex Nut, Self-Locking, M10 2
6 A-00295 Level Sensor 1
7 0096-0002 Cap Screw, M6 x 20 16
8 0096-0039 Hex Nut, Self-Locking, M6 20
9 A-00287 Mount Plate – GFI Outlet 1 10 A-00255 Motor Controller 2 11 B01-05-0056 Battery Charger 1 12 A-00274 Gas Spring 1 13 0090-0920 Stud Ball, 10mm 2 14 0090-0185 Hex Nut, Self-Locking, 5/16-18 2 15 A-03200 Turntable Weldment 1 16 B01-10-0046 Outlet Box 1 17 B01-10-0034 GFI Outlet 1 18 B01-10-0035 Outlet Box Cover 1 19 0096-0001 Cap Screw, M6 x 16 2 20 A-00288 Plastic Cover 1 21 0096-0004 Cap Screw, M6 x 25 8 22 A-00935 Dual Motor Controller Bracket 1
59
PUMP COMPARTMENT ASSEMBLY
4
2
3
6
5
4
1
60
7
PUMP COMPARTMENT PARTS LIST
Item No. Part No. Description Qty.
1 A-00268 Tire Iron/Jack Handle 1
2 B04-07-0033 Clamp 2
3 0096-0001 Cap Screw, M6 x 16 2
4 0096-0039 Hex Nut, Self-Locking, M6 4
5 A-00290 Cover Stop Bracket 1
6 0096-0002 Cap Screw, M6 x 20 2
7 0096-0014 Cap Screw, M10 x 20 2
61
BATTERY COMPARTMENT ASSEMBLY
30
17
16
20
18
19
26
29
27
16
16
15
17
3
22
24
23
21
25
8
28
14
11
891013
12
6
7
4
1
2
5
62
BATTERY COMPARTMENT ASSEMBLY PARTS LIST
Item No. Part No. Description Qty.
1 A-00215 Battery Box Weldment – Left 1
2 A-00220 Battery Box Weldment – Right 1
3 A-00278 Battery Hinge Pin 2
4 0096-0050 Washer, Flat, M16 8
5 0090-0147 Cotter Pin 4
6 A-00271 Battery Clamp 4
7 0096-0010 Cap Screw, M8 x 20 4
8 0096-0040 Hex Nut, Self-Locking, M8 8
9 A-00219 Battery Box Latch 2 10 A-00256 Motor Cover 1 11 A-00229 Latch Plate 2 12 A-00234 Spacer 2 13 0096-0011 Cap Screw, M8 x 25 6 14 A-00244 Tension Spring 2 15 A-00225 Nose Weldment 1 16 0096-0014 Cap Screw, M10 x 20 10 17 0096-0041 Hex Nut, Self-Locking, M10 10 18 A-00037 Ramp, Short 4 19 0096-0002 Flat Head Cap Screw, M6 x 20 4 20 0096-0039 Hex Nut, Self-Locking, M6 4 21 A-00046 Grommet 4 22 B04-07-0036 Clamp 2 23 B01-09-0132 A-Frame Handle, Connector 1 24 B01-09-0131 Plug, Connector 1 25 A-03272 Battery Cable Kit 1 26 B01-09-0133 Terminal Boot – Black 4 27 B01-09-0134 Terminal Boot – Red 4 28 A-00242 Battery 4 29 0090-0162 Hex Nut, 3/8-16” 8 30 A-00235 Power Unit, 4WD 1
B02-15-0528 3KW 24V DC Motor 1 B02-15-0529 Gear Pump 2.0 ccm 1 B02-02-0301 Fitting M14 x –6 ORFS 1 B02-02-0302 Fitting, M18 x –8 ORFS 1
63
COVER ASSEMBLY
5
7
3
4
6
89
10
7
2
1
64
COVER ASSEMBLY PARTS LIST
Item No. Part No. Description Qty.
1 A-03240 Cover – Left 1
2 A-03239 Cover – Right 1
3 A-00228 Cover Brace 2
4 A-00252 Hinge 4
5 0096-0002 Cap Screw, M6 x 20 12
6 0096-0039 Hex Nut, Self-Locking, M6 12
7 0090-1080 Pop Rivet 22
8 A-00258 Controls Cover – Left Side 1
9 B42-01-1002 Hinge, Controls Cover 1 10 A-00292 Cover Latch Assembly 2
65
BOOM ASSEMBLY (I)
3
10
6
4
8
9
4
5
2
3
4
5
4
789
1
9
66
BOOM ASSEMBLY PARTS LIST
Item No. Part No. Description Qty.
1 A-00552 Hydraulic Master Cylinder 1
2 A-00024 Pin, .75 x 8.5 1
3 A-00017 Pin Retainer – .75 2
4 0096-0016 Cap Screw, M10 x 25 7
5 0096-0041 Hex Nut, Self-Locking, M10 7
6 A-00026 Pin, .75 x 7.0 1
7 A-00551 Hydraulic Boom Cylinder 1
8 A-00021 Pin, 1.25 x 8.5 2
9 A-00019 Pin Retainer – 1.25 5 10 A-00023 Pin, 1.25 x 7.25 1
67
BOOM ASSEMBLY (II)
7
4
3
5
12
13
11
14
6
8
5
10
9
28
25
27
26
24
14
13
12
17
15 16
18 19 20
24
23
22
21
68
BOOM ASSEMBLY PARTS LIST
Item No. Part No. Description Qty.
1 A-00510 Telescopic Boom Tube 1
2 A-00550 Hydraulic Extension Cylinder 1
3 A-00535 Slider 2
4 0096-0018 Cap Screw, M10 x 40 4
5 0096-0041 Hex Nut, Self-Locking, M10
6 A-00032 Bearing 2
7 0096-0033 Flat Head Cap Screw, M16 x 35 4
8 A-00027 Pin, .75 x 7.0 1
9 A-00017 Retainer – .75 1 10 0096-0016 Cap Screw, M10 x 25 1 11 A-00533-1 Wear Pad – Green 5 12 A-00533-2 Wear Pad – Grey 7 13 A-00534 Wear Pad Shim 6 14 0096-0013 Nylon Cap Screw, M10 x 16 24 15 A-00537 Boom Switch Block 1 16 0096-0098 Cap Screw, M8 x 35 2 17 0096-0040 Hex Nut, Self-Locking, M8 2 18 A-00469 Cage Latch Pad 1 19 A-00470 Cage Storage Pad 1 20 A-00471 Cage Latch Plate 1 21 A-00473 Cage Latch 1 22 0096-0001 Cap Screw, M6 x 16 4 23 0096-0049 Cap Screw, M8 x 50 1 24 0096-0040 Hex Nut, Self-Locking, M8 3 25 B01-10-0275 Strobe Light (Option) 1 26 0090-0236 Machine Screw, #10-24 x 3/4 2 27 0090-0415 Washer, Flat, #10 2 28 0090-0182 Hex Nut, Self-Locking, #10-24 2
69
CABLE TRACK ASSEMBLY
5
4
3
8
67
8
3
2
2
3
12
2
1
11
910
3
14
13
70
CABLE TRACK ASSEMBLY PARTS LIST
Item No. Part No. Description Qty.
1 A-00531 Slide Tube 1
2 0096-0010 Cap Screw, M8 x 20 16
3 0096-0040 Hex Nut, Self-Locking, M8 18
4 A-00532 Tube Slider 1
5 A-00529 Tube Slider Back 1
6 0096-0018 Cap Screw, M10 x 40 2
7 0096-0017 Cap Screw, M10 x 30 2
8 0096-0041 Hex Nut, Self-Locking, M10 8
9 B00-00-0031 Cable Track – 41 Links 1 10 A-00536 Cable Track Tray 1 11 0096-0014 Cap Screw, M10 x 20 4 12 A-00538 Cable Support Tube 1 13 A-00539 Cable Slide Block 1 14 0096-0056 Cap Screw, M8 x 30 2
71
BOOM NOSE ASSEMBLY
31
8
1
2
21 22
13
28
29
30
13
24
27
15
16
17
18
3
23
4
5
2
72
25 26
8
910
1112
67
19 20
14
BOOM NOSE ASSEMBLY PARTS LIST
Item No. Part No. Description Qty.
1 A-00979 Bulkhead Mount 1
2 0096-0016 Cap Screw, M10 x 25 4
3 A-00601 Platform Pivot Weldment 1
4 A-00025 Pin, 1.0 x 6.5 1
5 A-00018 Pin Retainer – 1.0 1
6 0096-0041 Hex Nut, Self-Locking, M10 6
7 0096-0015 Socket Head Cap Screw, M10 x 20 2
8 A-00033 Bearing 4
9 A-00606 Snap Pin 2 10 A-00608 Compression Spring 1 11 A-00609 Knob, Platform Latch 2 12 0096-0055 Cap Screw, M12 x 190 1 13 0096-0042 Hex Nut, Self-Locking, M12 10 14 A-00553 Hydraulic Slave Cylinder 1 15 A-00027 Pin, .75 x 5.25 DB 1 16 A-00034 Pin Retainer – .75 FH 2 17 0096-0012 Flat Head Cap Screw, M8 x 25 2 18 0096-0040 Hex Nut, Self-Locking, M8 2 19 A-00035 Pin, .75 x 6.5 1 20 A-00017 Pin Retainer – .75 1 21 A-00522 Boom End Weldment 1 22 0096-0020 Cap Screw, M12 x 30 9 23 A-00031 Bearing 2 24 A-00610 Platform Mount Weldment 1 25 A-00038 Ramp 4 26 0096-0003 Flat Head Cap Screw, M6 x 20 8 27 0096-0039 Hex Nut, Self-Locking, M6 10 28 B01-10-0046 Outlet Box 1 29 B01-10-0034 GFI Outlet 1 30 B01-10-0035 Outlet Box Cover 1 31 0096-0001 Cap Screw, M6 x 16 2
73
PLATFORM ASSEMBLY
17
13
6
1516
14
22
23
24
7
5
18
11
12
7
9
21
2
1
20
74
19
13
10
PLATFORM ASSEMBLY PARTS LIST
Item No. Part No. Description Qty.
1 A-03350 Platform Weldment – 5’ 1
2 A-03359 Platform Floor 1
3 0096-0102 Cap Screw, M8 x 25 26
4 0096-0040 Hex Nut, Self-Locking, M8 26
5 A-03361 Upper Control Box Mount 1
6 0096-0016 Cap Screw, M10 x 25 4
7 0096-0041 Hex Nut, Self-Locking, M10 4
8 A-00466 Control Box Latch 1
9 A-00463 Midrail End 4 10 0096-0115 Slotted Head Cap Screw, M6 x 20 2 11 A-00464 Midrail 1 12 0096-0052 Cap Screw, M6 x 40 2 13 0096-0039 Hex Nut, Self-Locking, M6 6 14 A-00468 Manual Storage Mount Plate 1 15 0096-0017 Cap Screw, M10 x 30 2 16 A-00475 Manual Storage Box 1 17 0096-0001 Cap Screw, M6 x 16 4 18 A-00474 Cord Wrap Bracket 1 19 A-00071 Platform Pin 1 20 0090-0147 Cotter Pin – 1/8 x 1 1/4 2 21 A-00028 Pin – Platform to End Weldment 1 22 A-00779 Upper Control Box – 4WD Articulating 1 23 A-00462 Spool 7 24 0096-0003 Flat Head Cap Screw, M6 x 40 7
75
PUMP ASSEMBLY (A-00254)
7
25
13
20
12
18
17
24
17
3
19
17
10
16
17
24
19
89
22
6
1
17
76
17
11
14
20
15
17
19
21 2
19
4
20
21 5
17
17
19
23
PUMP ASSEMBLY PARTS LIST
Item No. Part No. Description Qty.
1 B02-15-0496 Manifold, Valve Housing 1
2 B02-14-0108 Valve, Counterbalance 2
3 B02-15-0472 Manual Pump, Extend/Retract/Rotate 1
4 B02-14-0089 Valve, Cartridge (Outrigger Check) 1
5 B02-14-0109 Valve, Cartridge (Outrigger) 2
6 B02-14-0091 Valve, Check 1
7 B02-14-0110 Valve, Check 1
8 B02-14-0094 Valve, Proportional 1
9 B02-14-0095 Coil Sterling, Proportional Valve 1 10 B02-14-0111 Valve, Relief 1 11 B02-14-0097 Valve, Relief 1 12 B02-14-0098 Valve, Shuttle 1 13 B02-14-0099 Valve, Cartridge (Rotator) 1 14 B02-14-0100 Valve, Counterbalance 1 15 B02-14-0101 Valve, Cartridge (Basket Compensate) 1 16 B02-14-0114 Valve, Flow Control (Rotator) 1 17 B02-02-0245 Fitting, Plug, #2 ORB 11 18 B02-02-0246 Fitting, Hex Plug 1 19 B02-02-0248 Fitting, Plug, #4 ORB 5 20 B02-14-0112 Coil, 20 VDC, #8 5 21 B02-14-0113 Coil, 20 VDC, #10 5 22 B02-15-0497 Stud, #1/4-20 x 5/8 4 23 B02-15-0498 Expansion Plug 1 24 B02-02-0235 Fitting, Plug, #6 ORB 2 25 B02-15-0478 Seal Ring 1
77
PUMP ASSEMBLY, CONTINUED
12
1
8
14
2
21
11
16
7
10
9
13
78
19
20
18
5
15
6
22
15
17
4
3
PUMP ASSEMBLY PARTS LIST, CONTINUED
Item No. Part No. Description Qty.
1 B02-15-0513 Reservoir 1
2 B02-15-0470 Pump Assembly, 2.09 CCM 1
3 B02-15-0471 Motor, Pump, 24 VDC 1
4 B02-15-0500 Coupling, .875 x 2.795 1
5 B02-15-0501 Filter, Hydraulic 1
6 B02-15-0476 Sight Glass 1
7 B02-15-0477 Socket Head Cap Screw, M8 x 85 2
8 B02-02-0247 Fitting, Plug, M14 x 1.5 x 5.8 1
9 B02-15-0478 Seal Ring 1 10 B02-15-0485 Clamp, Band, #10-16 2 11 B02-15-0480 Filter, Suction 1 12 B02-15-0504 Allen Nut, 1/4-20 4 13 B02-02-0255 Fitting, M18 x HB-90M x HB-90 1 14 B02-15-0503 O-Ring, 110.72 x 3.53 NBR 70 D 1 15 B02-02-0279 Fitting, JIC-8 x Push On FS x PO 2 16 B02-15-0505 Hose, Black, 1/2 x 6” 1 17 B02-02-0280 Fitting, JIC-8 x #6 MxM 1 18 B02-15-0506 Cap Screw, #5/16-18 x 1 1/4 2 19 B02-02-0283 Fitting, JIC-8 x G 3/4 MxM 1 20 B02-02-0281 Fitting, Plug, #12 ORB 2 21 B02-02-0282 Fitting, 3/8 NPT x 1/2 MxHB 1 22 B02-15-0507 Hose, Black, 1/2 x 15” 1
B02-02-0276 Fitting, Plug, #8 ORB (Under Reservoir) 1
79
BOOM AND ROTATION HYDRAULIC LINES (A-00269)
80
BOOM AND ROTATION HYDRAULIC LINES PARTS LISTS
Item No. Part No. Description Fittings
1 B02-01-0274 #4 x 42” Hydraulic Hose 4-6 FFORX 4-4 FFORX
2 B02-01-0275 #4 x 42” Hydraulic Hose 4-6 FFORX 4-4 FFORX
3 B02-01-0276 #6 x 66” Hydraulic Hose 6-6 FFORX 6-6 FFORX
4 B02-01-0277 #6 x 66” Hydraulic Hose 6-6 FFORX 6-6 FFORX
5 B02-01-0278 #4 x 48” Hydr aulic Hose 4-6 FFORX
6 B02-01-0279 #4 x 48” Hydr aulic Hose 4-6 FFORX
7 B02-01-0280 #4 x 36” Hydraulic Hose 4-6 FFORX 4-6 FFORX
8 B02-01-0281 #4 x 36” Hydraulic Hose 4-6 FFORX 4-6 FFORX
9 B02-01-0231 #4 x 10” Hydr aulic Hose
10 B02-01-0232 #4 x 420” Hydraulic Hose 4-4 FFORX 4-4 FFORX 11 B02-01-0233 #4 x 420” Hydraulic Hose 4-4 FFORX 4-4 FFORX 12 B02-01-0234 #4 x 16” Hydraulic Hose 4-4 MFFOR 4-4 FFORX 13 B02-01-0235 #4 x 16” Hydraulic Hose 4-4 MFFOR 4-4 FFORX 14 B02-01-0204 #3 x 32” Hydraulic Hose 2 MNPT
4-4 FFORX 90S
4-6 FFORX 45 4-6 FFORX 45
4-4 FFORX
2 MNPT 90SW
FITTINGS
Part No. Description Qty.
B02-02-0259 #6 MORFS - #6 MORB, STR 6 B02-02-0264 #6 MORFS - # 6 MORB, 45º 8 B02-02-0263 #4 MORFS, Tee 1 B02-02-0237 #4 MORFS - #6 MORB, STR 2 B02-02-0262 #6 MORFS - #10 MORB, 45º 2 B02-02-0196 #4 MORB - #2 MNPT, STR 1 B02-02-0241 #2 NPTFM Coupling 1 B02-02-0242 #2 QD Plug 1 B02-02-0229 #4 MORFS - #6 MORB 90 3
81
OUTRIGGER HYDRAULIC LINES (A-03182)
E
X
T
R
E
T
2
1
T
X
E
T
E
R
10
10
1
6
9
2
5
RET
8
7
EXT
4
3
10
2
9
1
10
T
RE
T
X
E
1
2
R
E
T
E
X
T
OUTRIGGER HYDRAULIC LINES PARTS LIST
Item No. Part No. Description Qty.
1 B02-01-0213 #4 x 28” Hydraulic Hose 4 2 B02-01-0214 #4 x 28” Hydraulic Hose 4 3 B02-01-0215 #6 x 56” Hydraulic Hose 1 4 B02-01-0216 #6 x 56” Hydraulic Hose 1 5 B02-01-0219 #6 x 28” Hydraulic Hose 1 6 B02-01-0220 #6 x 28” Hydraulic Hose 1 7 B02-01-0327 #6 x 46” Hydraulic Hose 1 8 B02-01-0328 #6 x 46” Hydraulic Hose 1
82
9 B02-02-0258 Fitting, Tee, #6 MORFS 6
10 B02-02-0259 Fitting, #6 MORFS - #6 MORB 8
Oil Filter
TRAILER HYDRAULIC LINES – 4WD (A-01075)
BRAKE
MANUAL
RELEASE
B1
Brake
FF6802-4-4
(2) #4MORFS-#4MORB 45
22
B1
FF6400-4-4
TA
FF6400-8-8
M4A
M1A
M3A
M2A
TB
FF6400-4-4
5
S1A
FF6400-4-6
90
P1A
FF6801-6-6
12
M4B
FF6400-6-6
FF6400-6-6
M1B
FF6400-6-6
FF6400-6-6
M3B
FF6400-6-6
M2B
FF6400-6-6
FF6400-6-6 FF6400-6-6
S1B
FF6400-4-6
90
P1B
FF6801-L-6-6
P2B
STR
FF6400-6-6
FF6801-6-6
90L
P2A
Aux
Pump
FF6801-6-6
T
P
90
6-14 Metric
4A
6410-L-10-6
90
(2)#10MORB-#6FMORB
8-18 Metric
(2)#6MORFS-#6MORB 90
Top
21
20
19
18
17
16
15
14
Top
FF6801-6-6
6410-L-10-6
Control
(2)#10MORB-#6 FMORB
(2)#6MORFS-#6 MORB 90
10
9
8
23
Side
Pump
Side
#4MORFS Tee
Front
Bottom
Bottom
Front
FF2603-4-4-4
24
24
Side
Rear
Pump
Front
15
14
19
Front
Side
Control
TP2
TP3
Rear
18
Rear
Rear
FF6801-4-4
FF6400-6-10
11
(2) #4MORFS-#4MORB 90
(2) #6MORFS-#10MORB STR
FF2603-4-4-4
#4MORFS Tee
11
FF6801-4-4
FF6400-6-10
(2) #4MORFS-#4MORB 90
(2) #6MORFS-#10MORB STR
FF6801-4-4
13
#4MORFS-#4MORB 90
SMA
FF6400-6-6
#6MORFS-#6MORB STR
SMB
4
Driver
FF6801-4-4
#4MORFS-#4MORB 90
5
7
6
FF6400-8-12
#8MORFS-#12MORB STR
OIL
COOLER
FF6804-10-10-10
FF6500-10-10
6410-12-10
#10MORFS-#10FMORFS 90
#10MORFS-#10MOBR-#10MORFS Tee
#12ORBM-#10ORBFMSTR
2A
1A
1
2B
4B
3
FF2603-8-8-8
#8MORFS Tee
3B
1B
A
7
FF6801-10-12
6408-H-10
10MORB Plug
#10MORFS-#12ORB 90
Dual
Pump
5GPM
A
6
FF6802-8-10
(2) #8MORFS-#10MORB 45
ORB
3A
Bolt
Banjo
2
83
TRAILER HYDRAULIC LINES PARTS LISTS
Item No. Part No. Description
1 B02-01-0402 #10 x 28” Hydraulic Hose 2 B02-01-0401 #8 x 154” Hydraulic Hose 3 B02-01-0398 #8 x 16” Hydr aulic Hose 4 B02-01-0400 #8 x 24” Hydr aulic Hose 5 B02-01-0399 #8 x 18” Hydr aulic Hose 6 B02-01-0386 #6 x 30” Hydr aulic Hose 7 B02-01-0387 #6 x 30” Hydr aulic Hose 8 B02-01-0397 #6 x 166” Hydraulic Hose
9 B02-01-0396 #6 x 150” Hydraulic Hose 10 B02-01-0385 #4 x 118” Hydraulic Hose 11 B02-01-0379 #4 x 16” Hydraulic Hose 12 B02-01-0382 #4 x 30” Hydraulic Hose 13 B02-01-0383 #4 x 40” Hydraulic Hose 14 B02-01-0393 #6 x 138” Hydraulic Hose 15 B02-01-0392 #6 x 138” Hydraulic Hose 16 B02-01-0388 #6 x 38” Hydraulic Hose 17 B02-01-0389 #6 x 38” Hydraulic Hose 18 B02-01-0395 #6 x 138” Hydraulic Hose 19 B02-01-0394 #6 x 138” Hydraulic Hose 20 B02-01-0390 #6 x 62” Hydraulic Hose 21 B02-01-0391 #6 x 62” Hydraulic Hose 22 B02-01-0380 #4 x 21” Hydraulic Hose 23 B02-01-0384 #4 x 105” Hydraulic Hose 24 B02-01-0381 #4 x 25” Hydraulic Hose
84
Part No. Description Qty.
B02-02-0259 #6 MORFS - #6 MORB, STR 10 B02-02-0293 #8 MORFS - #8 MORB, STR 1 B02-02-0260 #6 MORFS - #6 MORB, 90º 6 B02-02-0287 #4 MORFS - #4 MORB, STR 2 B02-02-0288 #4 MORFS - #4 MORB, 90º 6 B02-02-0289 #4 MORFS, Tee 2 B02-02-0294 #6 MORFS - #6 MORB, 90ºL 1 B02-02-0295 #12 MORB - #10 FMORB 1 B02-02-0296 #10 MORFS - #10 MORB - #10 MORFS, Tee 1 B02-02-0297 #10 MORFS - #10 F M ORFS, 90º 1 B02-02-0298 #8 MORFS - #12 MORB, ST R 1 B02-02-0299 #8 MORFS - #10 MORB, 45º 2 B02-02-0300 #10 MORFS - #12 MORB, 90 º 1 B02-02-0303 #10 MORB Plug 1 B02-02-0304 #10 MORB - #6 FM ORB 4 B02-02-0305 #6 MORFS - #10 MORB, ST R 4 B02-02-0237 #4 MORFS - #6 MORB, STR 2 B02-02-0307 #8 MORFS, Tee 1 B02-02-0308 #4 MORB Plug 1 B02-02-0309 #8MORFS - #12 MORB, 90º 2
FITTINGS
4WD MANIFOLD (A-01033)
85
WIRE HARNESSES
Upper
Control
Box
Platform Plug
Motor
Cntl
B+
Motor
Cntl
B-
BEFAD
Wh
BlaOrRe
Blu
C
Gr
1 2
Turntable Connector
12
2413242726131514162223
Boom Down
Relay NC
N
L
LFC1LRC3RFC2RR
C4
##NO
##NO
Jib
Switches
#NC
3334 11 10 9 8 7 6
IEC Recp.
AC
Plug
GFCI
Plug
AC Switch
P3
Front Boom
Switches
#NC
Manifold
Strobe
Drive
P4 & P5
Connector
2436
1
LF NO
**
LR
NO
**
RF
NO
**
RR
NO
**
C22C23C24C25 C20C21C26
34678
Analog Connector
23
81522
12
35
C27C28C29C30C31
1718192021
Switch is forced Closed
**
when outrigger is loaded
#
Switch is forced open
when Boom is lifted
##
Switch is forced Closed
when Boom is Stowed
9
Platform Connector
P1
16
18
1
20
16
23
X Y
+ -
R B O Br
Level
Sensor
Motor
Controller
Main
31
B-B+M-
J4
EnableSpeed
200
Amp
Fuses
P2
Lift/Engine Connector
12
2435
5
12 3
Jib Cyl C17
Sec Cyl C16
Prim
Cyl
C5
Motor
Controller
Aux
31
B-B+M-
D
2
1
E
E
2
1
A
Main Pump Motor
Engine
Start
1
111
7
203121
81314239103417183532
PLT
DN
C14
PLT
UP
C13
Rot
CCW
C9
Rot CW C10
Boom
RET
C12
Boom
EXT
C11
32
+ -
Prop
Coil
C8
Chk
Valve
C6A
OR
EXT
C6
OR
RET
C7
Pump
EnableSpeed
2
A
2
E
Aux Pump Motor
10
D
1
E
1
Engine Stop
Start
Fuel
Fan
Oil
Press
Switch
242725 269
Throttle
Sol
Choke
Sol
Engine
Start
Engine
Run
Engine Spark
Start Sol
Fuel Sol
AC
Switch
Fuel
Switch
Engine
Stop
Fan
M
Fan
86
Generator
12020786
6 Pin Male Conn
1208089040
Male Term
12015323
Green Wire Seal
12010717
3 Pin Male Conn
12089040
Male Term
12015323
Green Wire Seal
12020926
6 Pin FM Conn
12089188 FM Term 12015323
Green Wire Seal
Label Wires
Both Ends
C20
A
C21
B
C22
C
C23
D
C24
E
C25
F
GND
A
C26(+)
B
C26(-)
C
A
C27
B
C28
C
C29
D
C30
E
C31
F
GND
Stripe wire
to 4"
Orange
White
Green
Red
Blue
White/B
Black
Red/B
Green/B
Orange/B
Blue/B
Green/W
Red/W
Blue/W
Black/W
Wire Color
Label A-00785 Rev-
156" (13')(+/- 2") 16 Cond 18ga Wire
SOOW or Equivalent
Label A-00785 Rev-
MANIFOLD WIRE HARNESS (A-00785)
Deutsch Term.
3"
3"
Wires
Connected
& Sealed
GND 1
Black
Black/W
GND 2
Wires
Connected
& Sealed
9"
9"
Stripe wire
to 12"
Orange
White
Green
Red
Blue
White/B
Orange/B
Blue/B
Green/W
Red/W
Blue/W
Red/B
Green/B
C20
C21
C22
C23
C24
C25
C27
C28
C29
C30
C31
C26 +
C26 -
0462-201-16141
1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2
Deutsch DT06-2S
2PinPlug
W2S Wedge
GAS ENGINE WIRE HARNESS (A-01034)
12020829
3 Pin Female Conn
12089188
Female Term
12015323
Green Wire Seal
C
Oil Press Sw
B
Oil Press Sw (+)
A Gen Switch
Engine Run
C
B
A
12020827
3 Pin Male Conn
12089040
Male Term
12015323
Green Wire Seal
12020829
3 Pin Female Conn
12089188
Female Term
12015323
Green Wire Seal
C
B
A
Throttle
Engine Start
Engine Stop
Strip Wires 3"
GND
Choke
Label
Or/BL
R/BL
Wh/Bl
Red
Green
Black
Orange
White
Blue
Wire
Color
18ga-10 Cond Wire
SOOW or Equivalent
A-01034
Rev-
120" (10')
A-01034
Rev-
Label Both
Ends
Green
1"
Strip Wires 6"
Wire
Color
5"
5"
R/BL
Or/BL
Wh/Bl Green
White
Blue
Green
Black
Orange
Label
Oil Press Sw (+)
Oil Press Sw
Gen Switch
GND
Choke
Throttle
Splice &
Heat Sealed
Engine RunRed
Engine Start
Engine Stop
GND
A
B
C
D
A B
A
B
B
A
Delphi
Weather Pack
12015792
2 Pin Female Conn
12089188
Female Term
12015323
Green Wire Seal
Delphi
Weather Pack
12010973
2 Pin Male Conn
12089040
Male Term
12015323
Green Wire Seal
Delphi
Weather Pack
12020830
4 Pin Male Conn
12089040
Male Term
12015323
Green Wire Seal
87
CHOKE /THROTTLE SOLENOID WIRE HARNESS (A-01042)
Weather Pack
FM Term 12089188
Cable Seal
12015323
FM Housing
12015792
B
A
1"
Put Wires
Heat Seal
B
W
20" 18ga TXL
Or Equivalent
in 16"
Split
tubing
Both ends
A-01042 Rev-
Label
ENGINE RELAYS WIRE HARNESS (A-01044)
A-01044 Rev-
Label
10" Split
Tube Wrap
Tape At
Each End
O
6"
¼” Female
3"
B G R
8"
Y
Spade
Heat
Shrink
3"
3"
¼” Female Spade
Delphi Weather Pack Male Term 12089040 Green Seal 12015323
¼” Female Spade
¼” Female Spade
S30
C30
T30
Solder inline &
Heat Shrink
Resistor
2.2k-Ohm
Wire
Color
Engine Run 10"
Red
¼” Female Spade
4" RedFAN
6"F30
6"
8"
8"
Starter S 87 Starter20"
12v +
Wire Color
Fuel F 87
Black
Yellow
Orange
All wires 18 ga TXL or Equivalent All Measurements
are +/- 0.250 In
.5Watt
Wire
Length
15"Ign K 87a Ign Coil
18"
4"
15"
Green
Engine
Run
¼” Male Spade
¼” Male Spade
+12V
Labels
Fuel Sw
¼” Female Spade
5/16" Ring Term
¼” Female Spade
88
¼” Female Spade Ins
ATC Fuse Holder
Waytek # 46278
or Equivalent
ATC FUSE HOLDER (A-01049)
5/16" Ring
Term
4"- 6" Leads
12 ga Wire
4"- 6" Leads
12 ga Wire
START/STOP/RUN WIRE HARNESS (A-01098)
2"
10"
7"
A-01098 Rev -
Split Tube Wrap
& Heat Shrink
Each End
Tape Both Sides
of Drop Out
18"
2 Pin Male Housing
Male Terminal
Green Wire Seal
Delphi Weather Pack
A
B
C
D
Delphi Weather Pack
A
B
12010973
12089040
12015323
Label
Delphi Weather Pack
A
B
A
B
12020832
4 Pin Female Conn
12089188
Female Term
12015323
Green Wire Seal
12015792
2 Pin Female Conn
12089188
Female Term
12015323
Green Wire Seal
Choke
Throttle
Choke
Throttle
¼” Ring
Terminal
Frame
Gnd
Wire Label
Start S 86
5"
Fan
A
B
¼” Male Spade
Insulated
A–Leave
Open
¼” Female Spade Insulated
4"
12010973
12089040
12015323
Engine Run
6"
Stop K 86
Fuel F 86
GND 85
GND 85
6"
4" GND 85
6"
GND 85
8"8"GND 85
Choke C 87
Throttle T 87
K30
Choke C 86
Throttle T 8628"
Wire
Color
Red
White
Blue
Green
Black15"
Black
15"
Black
9"
All wires TXL or Equivalent All Measurements
are +/- 0.250 In
Black
Orange
Yellow
Orange/Bl
Length
24"
26"
20"
20"
28"
28"
28"
Black
Splice & Heat
Shrink Seal
11"
Delphi Weather Pack
2 Pin Male Housing
Male Terminal
Green Wire Seal
89
GENERATOR SWITCHER BOX ASSEMBLY (A-03040)
Box-A-01015
B01-10-0354
20 Amp Circuit Breaker
W/.250 Male Spade Terminal
Allied Electronics
#886-0036
Or Equivilant
B01-01-0181
Delphi Weather Pack 3 Pin Male Housing 12015793 Male Terminal 12010293 Gray Seal 12010293
B01-01-0180
20
Amp
Ground
Stud
Bl
Y/
Br
g
B W GB W G B W
B01-01-0178
B W G
A
B
C
WIRE ASSEMBLY – FAN (A-03041)
B01-06-0056
30 Amp Relay
DPST – NO
Allied Electronics
#850-0345
Or Equivilant
Cord Grip Heyco #3231 Or Equivilant
B01-01-0179
W
B
Delphi Weather Pack
2 Pin Male Housing 12010973
Male Terminal 12089040
Green Seal 12015323
A
B
Weather Pack
FM Term
12089188
Cable Seal
12015323
FM Housing
12015792
B
A
A-3041
Label
Label Wires
B
GND
A
Relay
TXL or Equivalent All Measurements
Wire
Color
Black
Red
36"
All wires 18 ga
are +/- 0.250 In
A-03041
Rev.
Weather Pack
FM Term
B
A
12089188
Cable Seal
12015323
FM Housing
12015792
Rev.
40" Loom
Tape each End &
Middle
B
A
90
IEC90DegreePlug
Interpower
IEC 60320 C19
Mold 012
SO cable or
Equivalent
Minimum Requirements
Current 15 AMP
Voltage 120/240VAC
IEC CORD MALE – US MARKETS (A-03042)
18"
A-03042
Rev
Label
North America
120V Male Plug
GENERATOR 110V WIRE HARNESS (A-03043)
A
B
C
Delphi Weather Pack
12010717
3 Pin Male Housing
12124582
Male Terminal 12/14ga
12010293
Seal 12/14ga
OIL PRESSURE SWITCH 4WD
TRANSDUCER DIRECT #TDPS211A8FW
B
W
G
A-03044
Or Equivilant
36" (+/- 2")
B00-00-0170 Wire Casing
16"
12-3 SO
.0625"
B
W
3"
2"
2"
B
3"
B
3"
W
3"
W
W B
W B
1/2” Grommet OD
OIL SWITCH ASSEMBLY (A-03044A)
Delphi Weather Pack 12010973 (B01-09-0109) 2 Pin Male Housing
PVC
Tape
12089040 (B01-09-0110) Male Terminal 12015323 (B01-09-0093) Green Seal
R
B
A
B
Wires should be 17-18" Long
91
CORD ASSEMBLY 110V GENERATOR (B01-01-0178)
24"
A
B
C
Delphi Weather Pack
12015793
3 Pin Female Housing
12124580
Female Terminal 12/14ga
12010293
Seal 12/14ga
B W G
B01-01-0178
Rev
BWG
14-3
SO or Equivalent
4"
Label
¼” Female Spade
¼” Female Spade
#10 Ring Terminal
CORD ASSEMBLY GENERATOR SWITCH (B01-01-0179)
28"
A
B
Delphi Weather Pack
12010973
2 Pin Male Housing
12089040
Male Terminal
12015323
Green Seal
W
B01-01-0179
B
Rev
18-2
SO or Equivalent
Label
4"
¼” Female Spade
¼” Female Spade
CORD ASSEMBLY SWITCH JUMPER (B01-01-0180)
B01-01-0180
Rev
14ga Black
Label
TXL or Equivalent
All Measurements
are +/- 0.250 In
¼” Female Spade¼” Female Spade
CORD ASSEMBLY 110V AC PLUG – FM (B01-01-0181)
12"
¼” Female Spade
¼” Female Spade
North America
110V Female Plug
B01-01-0181
Rev
14-3
SO or Equivalent
BWG
4"
92
SWITCHER BOX ASSEMBLY – CE MODELS (A-03040CE)
Box-A-01015
B01-10-0354
20 Amp Circuit Breaker
W/.250 Male Spade Terminal
Allied Electronics
#886-0036
Or Equivilant
B01-01-0180
20
Amp
20
Amp
Bl
Y/
Br
g
Blue Wire Nut
B01-01-0181CE
Delphi Weather Pack 3 Pin Male Housing 12015793 Male Terminal 12010293 Gray Seal 12010293
B01-06-0056
30 Amp Relay
DPST – NO
Allied Electronics
#850-0345
Or Equivilant
G W BB W G B W
Cord Grip
Heyco #3231
B01-09-0005
B01-01-0178
B W G
A
B
C
Or Equivilant
B01-01-0179
W
B
Delphi Weather Pack 2 Pin Male Housing 12010973 Male Terminal 12089040 Green Seal 12015323
A
B
220V GENERATOR WIRE HARNESS – CE (A-03043CE)
A
B
C
Delphi Weather Pack
3 Pin Female Housing
Female Terminal 12/14ga
B W G
12015793
12124580
12010293
Seal 12/14ga
B01-01-0181CE
Rev
14-3 SO
Or Equivilant
24" (+/- 2")
CORD ASSEMBLY 220V AC PLUG – CE (B01-01-0181)
14-3
SO or Equivalent
12"
.0625"
1/2” Grommet OD
BWG
Green
4"
2"
White
2"
2"
4"
4"Black
G G
W B
Y W
G R
Generator
Wire Colors
¼” Female Spade
¼” Female Spade
InterPower # 88010390
16A Socket or
Equiliviant
93
PUMP AND CYLINDER WIRE HARNESS (A-00716)
94
OUTRIGGER SWITCH & COIL WIRE HARNESS (A-00746)
95
ANALOG HARNESS (A-00715)
Amp
770680
Label
A-00715
Rev
1"
15" Loom
AMP 770520-1
Pin
1
Pin
16
3' (36") 18 gaGreen
3' (36") 18 ga Yellow
Individual
Wire Labels
Pump Speed Signal
Motor Cntrl Enab
¼” FM Spade
Insulated
¼” FM Spade
Insulated
Amp
Housing
770680-1
Black
2316
All wires TXL or Equivalent All Measurements
are +/- 0.250 In
AMP 3 Pin Housing
206037-2
1
8
AMP Cable Clamp
206070-1
Engine Run +
Level Sensor +24
10" 18 ga Re
Level Sensor GND
10" 18 ga Black
Level Sensor X
Level Sensor Y
Ground
d
B
A
18" 18ga Red
18" 18ga Black
A
B
C
D
Weather Pack 12010973 2 Pin H ousing 12089040 M ale Terminal 12015323 W ire Seal
A
Weather Pack 12020830 4 Pos housing
B
Mates With 12020832 12089040 Male Terminal
C
12015323 Wire Seal
D
¼” FM Spade
Insulated
¼” FM Spade
Insulated
10" Loom
Engine
Run
Label
B
A
Pump Speed Signal Motor Cntrl Enab
32" Loom
Motor
Control
Label
A B C D
Label
8" Loom
Start
Contactor
Label
Level
Sensor
Pin
9
Pin
10
Splice & Heat
Shrink Seal
Pin
8
Pin 15
Pin 22
Pin 23
12" 18 ga Black
12" 18 ga Red
8"
8"
18" 18 ga Orange
18" 18 ga Brown
POWER HARNESS (A-00718)
AMP
1-66740-1
Or
66740-6
Pin 1
12ga Red
32"
Batt Pos
5/16" Ring Terminal
AMP
A-00718
Rev.
Fill Strain Relief with RTV then put on
cable clamp and wipe off excess
96
AMP
1-66740-1
Or
66740-6
Pin 2
Bundle wires in 28" of loom.
Tape both ends if split loom is used
12ga
Black
32"
Batt Neg
5/16" Ring Terminal
110 VAC TOWER-PLATFORM HARNESS (A-00722)
PLATFORM-GROUND COMMUNICATION CABLE (A-00714)
97
MATERIAL LIFT HOOK ASSEMBLY (OPTION A-00846)
5
8
4
10
4
1
3
11
2
17
18
7
16
13
14
12
9
6
19
15
98
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