Bil-Jax 36XT User Manual

PARTS AND SERVICE

MANUAL

36XT

BOOM

TM

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[phone]
	[phone]
		Fax [phone]
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	25
Lift Cylinder Replacement	26
Outrigger Cylinder Replacement	27
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

1 — SAFETY

BEFORE OPERATION

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.

DURING OPERATION

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.

DANGER

This machine is NOT insulated for use near electrical power lines and DOES NOT provide protection from contact with or close proximity to any electrically charged conductor. Operator must maintain safe clearances at all times (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	Minimum Safe Approach Distance
(Phase to Phase)	(Feet)		(Meters)
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

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/cm2 (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 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.

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 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.

6

1 — SAFETY

MAINTENANCE 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 drying 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	43 ft 6 in
	13.4 m
Maximum Platform Height	37 ft 6 in
	11.4 m
Maximum Horizontal Outreach
From Centerline	32 ft
	9.8 m
From Outrigger Footpad Edge	27 ft
	8.2 m
Rated Platform Capacity
Without Platform Rotation	500 lbs
	227 kg
With Platform Rotation	440 lbs
	200 kg
Maximum Occupants	2
Total Weight	4,680 lbs
	2,123 kg
Turntable Rotation	700º Non-Continuous
Leveling Capability	12.5º
Gradeability	45%
Wheel Base	8 ft 8 in
	2.7 m
Turning Radius
Inside	10 ft
	3 m
Outside	18 ft
	5.5 m
Platform Dimensions
Height	3 ft 7 in
	1.1 m
Length	2 ft 6 in
	0.8 m
Width – US/CE	5 ft/4 ft
	1.5 m/1.2 m
Stowed Dimensions
Height	6 ft 6 in
	2.0 m
Length (Platform stowed)	20 ft 10 in
	6.4 m
Width	5 ft 5 in
	1.7 m

Outrigger Footprint
Length	12 ft 2 in
	3.7 m
Width	11 ft 4 in
	3.4 m
Footpad Diameter	12.5 in
	0.3 m
Brake	Spring Applied
Speed
Gas Power	1.5 mph
	5.6 km/h
DC Power	1.75 mph
	2.8 km/h
Tire Size	26 x 12 bar lug tires
Tire Pressure	20 psi
	140 kPa
Control System	24V DC
Battery	4 x 6V 245 amp-hr
Battery Charger	110/120 Volt
Gas Engine	Kawasaki 21 HP
Hydraulic Pressure	3,000 PSI
	20,684 kPa
Reservoir Capacity	4.8 Gallons
	18.2 L
Hydraulic System Capacity	7 Gallons
	26.5 L
Hydraulic Oil (Standard)	Dexron III/Mercon ATF
Platform Rotation/Type (Optional)	90º/Manual
Maximum Decibel Level
DC Mode – Ground	60 dB
DC Mode – Platform	55 dB
Gas Mode – Ground	70 dB
Gas Mode - Platform	65 dB
Localized Pressure per Outrigger	25 PSI
	1.8 kg/cm2
	176.5 kPa
Operation Temperature Range	-20º to 110º Fahrenheit
	-29º to 43º Celsius
Max. Pressure Per Tire – Floor	35 PSI
Loading	2.5 bar

11

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.

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.

12

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 contained 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.

Check engine oil level.

Add oil as needed.

Manufacturer recommends engine oil type 5W-30.

Check engine fuel level.

Add fuel as needed.

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 lift level. Raise one outrigger until the footpad is not in contact with the ground.

Verify that boom functions are unresponsive when one outrigger is raised.

Repeat this procedure for each outrigger.

Raise all outriggers until the footpads are not in contact with the ground. Verify that all outrigger status LEDs on the ground control panel are unlit.

Lower one outrigger until the footpad makes contact with the ground and the outrigger begins lifting the trailer.

If the LED is lit before the footpad makes contact with the ground or if the LED remains unlit after the weight is transferred to the outrigger, the position switch or wiring is faulty.

Repeat this procedure for each outrigger.

Repair or replace as needed. Refer to Figure 2-1.

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.

14

3 — EQUIPMENT MAINTENANCE

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

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 in 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

3

2 5

Figure 3-3. Wheel Nut Tightening Sequence

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.

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.

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

18

3 — EQUIPMENT MAINTENANCE

STRUCTURAL INSPECTION

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.

ADDITIONAL SERVICE INFORMATION

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	a.	Emergency STOP engaged.	a.	Disengage Emergency STOP buttons.
	key switch is turned to the
	on position.	b.	Battery charge is low.	b.	Recharge as needed.
		c.	Battery ground or in-series cable is loose.	c.	Inspect and repair battery connections.
		d.	Battery main disconnect unplugged.	d.	Plug in main disconnect.
	Hydraulic function does not	a.	Fault detected by safety interlock	a.	Refer to Table 4-2 for error code
	work and display window		microprocessor.		definition and correction.
	shows an error message	b.	Boom Lift electric or electronic failure	b.	Refer to Table 4-2 for error code
					definition and correction.
	Outrigger indicator LED	a.	Key switch turned to the OFF or platform	a.	Turn key switch to ground controls
	lights do not function.		controls position.		position.
		b.	Emergency STOP engaged.	b.	Disengage emergency STOP buttons.
		c.	Outriggers not deployed.	c.	Deploy all outriggers.
	One or more boom controls	a.	Key switch is turned to the OFF or	a.	Turn key switch to ground or platform
	do not function		incorrect control position.		controls position.
	OR	b.	Battery charge is low.	b.	Recharge battery.
	One or more boom controls	c.	Emergency STOP engaged.	c.	Disengage Emergency STOP buttons.
	function improperly
	OR	d.	Battery ground or in-series cable loose.	d.	Inspect and repair battery connections.
	One or more boom controls	e.	All outriggers not properly deployed.	e.	Deploy all outriggers and level boom lift.
	function intermittently.
		f.	Hydraulic pump inoperative.	f.	Inspect pump; replace or repair as
					needed.
		g.	Loose wiring connector.	g.	Check wiring terminals in control box
					and at valve manifold; replace or repair
					as needed.
		h.	Valve solenoid not operating properly.	h.	Clean valve solenoid and recheck
					function(s); replace or repair as needed.
		i.	Fault detected by system interlock.	i.	Check display for system status. Refer
					to Table 4-2 for error code definitions
					and correction.
		j.	Broken or loose wire.	j.	Inspect wiring in control box and 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
001	MACHINE IS IN DOWN ONLY	Machine was either never leveled, outriggers not
	MODE	lowered, or machine went out of level with use.
002	LOSS OF PLATFORM	Ground control lost communication with platform
	COMMUNICATION	control.
005	PLATFORM CONTROL HAS	Platform control detected a stuck or pressed key
	STUCK KEY	on power up.
008	GROUND CONTROL HAS	Ground control detected a stuck or pressed key
	STUCK KEY	on power up.
009	BOOM UP WITHOUT	Ground control detected the boom is up and all
	OUTRIGGERS ON GROUND	outriggers are not on the ground
010	LEVEL SENSOR HAS	The ground control detected an erratic output
	ERRATIC OUTPUT	from the level sensor.
015	MACHINE IS NOT LEVEL	Machine has gone out of level with use.
016	LIFT BOOM	A boom rotate, extend, or retract function
		requested with boom down.
017	STOW BOOM	An outrigger function requested with boom up.
021	OPEN CIRCUIT PRIMARY UP	A load of less than 70mA detected in primary up
		circuit on power-up.
022	SHORTED CIRCUIT	Excessive load detected in primary up circuit on
	PRIMARY UP	power-up.
023	OPEN CIRCUIT PRIMARY	A load of less than 70mA was detected when
	DOWN	primary down circuit was energized
024	SHORTED CIRCUIT	Excessive load detected when primary down
	PRIMARY DOWN	circuit was energized.
025	OPEN CIRCUIT SECONDARY	A load of less than 70mA detected in secondary
	UP	up circuit on power-up.
026	SHORTED CIRCUIT	Excessive load detected in secondary up circuit
	SECONDARY UP	on power-up.
027	OPEN CIRCUIT SECONDARY	A load of less than 70mA detected when
	DOWN	secondary down circuit was energized
028	SHORTED CIRCUIT	Excessive load detected when secondary down
	SECONDARY DOWN	circuit was energized.
029	OPEN CIRCUIT JIB UP	A load of less than 70mA detected in jib up circuit
		on power-up.
030	SHORTED CIRCUIT JIB UP	Excessive load detected in jib up circuit on
		power-up.

COMMENTS

Retract boom to travel position and extend outriggers using AUTO 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 AUTO LEVEL button.

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.

21

BIL-JAX 36XT

	ERROR MESSAGE	DEFINITION OF ERROR	COMMENTS
031	OPEN CIRCUIT JIB DOWN	A load of less than 70mA detected when jib down	Check for faulty jib down solenoid
		circuit was energized	coil and wiring.
032	SHORTED CIRCUIT JIB	Excessive load detected when jib down circuit	Check for faulty jib down solenoid
	DOWN	was energized.	coil and wiring.
033	OPEN CIRCUIT EXTEND	A load of less than 70mA detected in extend	Check for faulty boom extend
		circuit on power-up.	solenoid coil/wiring.
034	SHORTED CIRCUIT EXTEND	Excessive load detected in extend circuit on	Check for faulty boom extend
		power-up.	solenoid coil/wiring.
035	OPEN CIRCUIT RETRACT	A load of less than 70mA detected in retract	Check for faulty boom retract
		circuit on power-up.	solenoid coil/wiring.
036	SHORTED CIRCUIT	Excessive load detected in retract circuit on	Check for faulty boom retract
	RETRACT	power-up.	solenoid coil/wiring.
037	OPEN CIRCUIT PLATFORM	A load of less than 70mA detected in platform	Check for faulty level up solenoid
	LEVEL UP	level up circuit on power-up.	coil/wiring.
038	SHORTED CIRCUIT	Excessive load detected in platform level up	Check for faulty level up solenoid
	PLATFORM LEVEL UP	circuit on power-up.	coil/wiring.
039	OPEN CIRCUIT PLATFORM	A load of less than 70mA detected in platform	Check for faulty level down
	LEVEL DOWN	level down circuit on power-up.	solenoid coil/wiring.
040	SHORTED CIRCUIT	Excessive load detected in platform level down	Check for faulty level down
	PLATFORM LEVEL DOWN	circuit on power-up.	solenoid coil/wiring.
041	OPEN CIRCUIT PLATFORM	A load of less than 70mA detected in platform	Check for faulty boom rotate
	CW	CW circuit on power-up.	solenoid coil/wiring.
042	SHORTED CIRCUIT	Excessive load detected in platform CW circuit	Check for faulty boom rotate
	PLATFORM CW	on power-up.	solenoid coil/wiring.
043	OPEN CIRCUIT PLATFORM	A load of less than 70mA detected in platform	Check for faulty boom rotate
	CCW	CCW circuit on power-up.	solenoid coil/wiring.
044	SHORTED CIRCUIT	Excessive load detected in platform CCW circuit	Check for faulty boom rotate
	PLATFORM CCW	on power-up.	solenoid coil/wiring.
045	OPEN CIRCUIT TURNTABLE	A load of less than 70mA detected in rotate CW	Check for faulty rotate CW
	CW	circuit on power-up.	solenoid coil/wiring.
046	SHORTED CIRCUIT	Excessive load detected in rotate CW circuit on	Check for faulty rotate CW
	TURNTABLE CW	power-up.	solenoid coil/wiring.
047	OPEN CIRCUIT TURNTABLE	A load of less than 70mA detected in rotate CCW	Check for faulty rotate CCW
	CCW	circuit on power-up.	solenoid coil/wiring.
048	SHORTED CIRCUIT	Excessive load detected in rotate CCW circuit on	Check for faulty rotate CCW
	TURNTABLE CCW	power-up.	solenoid coil/wiring.
049	OPEN CIRCUIT OUTRIGGER	A load of less than 70mA detected in outrigger	Check for faulty outrigger retract
	RETRACT	retract circuit on power-up.	solenoid coil/wiring.
050	SHORTED CIRCUIT	Excessive load was detected when Outrigger	Check for faulty outrigger retract
	OUTRIGGER RETRACT	Retract circuit was energized.	solenoid coil/wiring.
051	OPEN CIRCUIT OUTRIGGER	A load of less than 70mA detected in outrigger	Check for faulty outrigger extend
	EXTEND	retract circuit on power-up.	solenoid coil/wiring.
052	SHORTED CIRCUIT	Excessive load was detected in outrigger extend	Check for faulty outrigger extend
	OUTRIGGER EXTEND	circuit on power-up.	solenoid coil/wiring.
053	OPEN CIRCUIT	A load of less than 70mA detected in left front	Check for faulty solenoid
	LF OUTRIGGER	outrigger circuit on power-up.	coil/wiring at outrigger.
054	SHORTED CIRCUIT	Excessive load was detected in left front	Check for faulty solenoid
	LF OUTRIGGER	outrigger circuit on power-up.	coil/wiring at outrigger.
055	OPEN CIRCUIT	A load of less than 70mA detected in right front	Check for faulty solenoid
	RF OUTRIGGER	outrigger circuit on power-up.	coil/wiring at outrigger.

22

				3 — EQUIPMENT MAINTENANCE
		ERROR MESSAGE	DEFINITION OF ERROR	COMMENTS
	056	SHORTED CIRCUIT	Excessive load detected in right front outrigger	Check for faulty solenoid
		RF OUTRIGGER	circuit on power-up.	coil/wiring at outrigger.
	057	OPEN CIRCUIT	A load of less than 70mA detected in left rear	Check for faulty solenoid
		LR OUTRIGGER	outrigger circuit on power-up.	coil/wiring at outrigger.
	058	SHORTED CIRCUIT	Excessive load detected in left rear outrigger	Check for faulty solenoid
		LR OUTRIGGER	circuit on power-up.	coil/wiring at outrigger.
	059	OPEN CIRCUIT	A load of less than 70mA detected in right rear	Check for faulty solenoid
		RR OUTRIGGER	outrigger circuit on power-up.	coil/wiring at outrigger.
	060	SHORTED CIRCUIT	Excessive load detected in right rear outrigger	Check for faulty solenoid
		RR OUTRIGGER	circuit on power-up.	coil/wiring at outrigger.
	069	OPEN CIRCUIT	A load of less than 70mA detected in proportional	Check for faulty solenoid
		PROPORTIONAL	valve circuit on power-up.	coil/wiring at proportional valve.
	070	SHORTED CIRCUIT	Excessive load detected in proportional valve	Check for faulty solenoid
		PROPORTIONAL	circuit on power-up.	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 training, 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

BASE END

PISTON END

Figure 4-1. Lift Cylinder Replacement

26

4 — CYLINDER REPLACEMENT

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 ground. Do not transfer the weight of the boom lift onto the outrigger. Leave the weight of the boom on the trailer wheels.

Remove the bolts securing the outrigger cylinder rod guard (Figure 4-2). Remove the guard.

At the piston rod end of the cylinder, unbolt and remove the retainer plate from each side of the pivot pin.

Place a block of wood shoring between the outrigger beam and cylinder.

Remove the pivot pin using a hammer and a brass or hardwood drift.

Fully retract the cylinder.

Turn key to the off position and remove the key.

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.

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				PIN
GUARD
			CYLINDER

CYLINDER ROD

GUARD BOLTS

RETAINING

PLATES

Figure 4-2. Outrigger Cylinder Replacement

27

BIL-JAX 36XT

28