Bil-Jax 45XA Operator's Manual

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45XA

OPERATOR’S

MANUAL

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.

BilJax, Inc. is dedicated to the continuous improvement of this and all BilJax products. Therefore, equipment information is subject to change without notice. Direct any questions or concerns regarding errors or discrepancies in this manual to the BilJax Service Department.

“BilJax” and “X-Boom” are trademarks of BilJax, Inc., a member of the Haulotte Group. Contact BilJax for replacement manuals.

P/N B33

-01-0104 - 01 http://www.

125 Taylor Parkway Archbold, Ohio 43502 Phone (800) 537-0540 (419) 445-8915 Fax (419) 445-0367

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 Before Operation 9

Daily Service Checks 10 Weekly Service Checks 12 Monthly Service Checks 12 Workplace Inspection 13

3 Operation 15

Ground Control Station 16 Platform Control Station 18 Platform Controls Joystick 20 Operation: Set Up 21 Operation: Ground Controls 22 Operation: Platform Controls 23 Operation: Drive Functions 23 Manual Boom Operation 24 Battery Recharge 26 Boom Lift Transport 27

4 Troubleshooting 29

Troubleshooting 30 Error Code Definitions 31

5 Replacement Decals 35

6 Specifications 41

7 Equipment Options 45

Material Lifting Hook 46 Platform Rotator 47

LIST OF ILLUSTRATIONS

Figure 2-1 Outrigger Position Switches 9

Figure 2-2 Hydraulic Reservoir 10

Figure 2-3 Wheel Nut Tightening Sequence 10

Figure 3-1 Ground Control Panel 16

Figure 3-2 Platform Control Panel 18

Figure 3-3 Platform Controls Joystick 20

Figure 3-4 Outrigger Controls 21

Figure 3-5 Boom Travel Latch 21

Figure 3-6 Manual Brake Release 21

Figure 3-7 Hand Pump and Controls for Manual Operation 24

Figure 3-8 Manual Lowering Valve 25

Figure 3-9 Battery Charger Faceplate 26

Figure 3-10 Boom Lift and Transport Instructions 27

Figure 5-1 Decal Placements 37

Figure 5-2 Decal Placements – CE 39

Figure 6-1 Range of Motion 43

Figure 7-1 Material Lifting Hook Configuration 46

Figure 7-2 Material Lifting Hook Installation 46

Figure 7-3 Manual Platform Rotator 47

LIST OF TABLES

Table 1-1 Minimum Safe Approach Distances 4

Table 3-1 Charger Fault Codes 26

Table 4-1 Troubleshooting Steps 30

Table 4-2 Error Code Definitions 31

Table 5-1 Decal Descriptions 36

Table 5-2 Decal Descriptions – CE 38

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.

BILJAX 45XA

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.

BEFORE OPERATION DURING OPERATION

DANGER

Ensu

Ensure the following general safety precautions are followed before operating the Aerial Work Platform:

re the following general safety precautions are

followed while operating the Aerial Work Platform:

1 – SAFETY

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 c

onduct 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 s

afety harness and energy-

absorbing lanyard.

ALWAYS inspect platform floor and outri

gger 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 Bulle

tins distributed by the manufacturer. Bulletins may contain critical procedures that supersede the information contained in manuals.

NEVER operate this equi

pment 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 whi

it is not intended.

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 machin

e 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 k

eep 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

(25 psi) to

ensure safe operation.

ALWAYS k

eep personnel away from potential pinch and shear points and from potential crush hazards as indicated by decals attached to the machine.

ALWAYS k

eep 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.

BILJAX 45XA

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 BilJax, 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

ALWAYS limit travel speed accordi

when operating drive functions.

ng 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 be

havior considered unsafe according to

employer, job site and/or government regulations.

NEVER operate the internal combustion engine in

a that is not properly ventilated.

an are

NEVER fuel the internal combustion engine while

king, or while near spark or open flame.

smo

MAINTENANCE SAFETY

1 – SAFETY

Ensure the following general safety precautions are followed while performing maintenance on the Aerial Work Platform:

General Maintenance

ALWAYS perform maintenance proc

edures according to manufacturer’s guidelines. NEVER disregard or bypass proper maintenance procedures.

ALWAYS inspect hydraulic system to ensure that all lines, connectors and fittings are properly fastened and in good condition.

ALWAYS turn the key switch OFF and remove key before performing maintenance.

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.

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 BilJax technician if repairs are necessary.

NEVER modify, alter or change the equipment without first consulting an authorized BilJax technician, and NEVER in any way that would affect its original design or operation.

Battery Maintenance

re the following general safety precautions are

Ensu followed when performing battery maintenance on the Aerial Work Platform.

ALWAYS wear safety glasses when working with or near batteries.

ALWAYS check the battery fluid level daily.

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

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.

BILJAX 45XA

NEVER jumpstart other vehicles using the boom lift batteries.

1 – SAFETY

DAMAGED EQUIPMENT POLICY

Safety Statement

At BilJax, we are dedicated to the safety of all users of our products. All BilJax lifts are designed, manufactured and tested to comply with current applicable ANSI and/or CE codes and regulations.

Damage Policy

There may be occasions when a BilJax 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 BilJax lift is damaged structurally or when there is suspected internal damage to the structure, BilJax may require that the lift be returned to our facility for reconditioning. For any questions concerning structural damage or the Damaged Equipment Policy, please contact an authorized BilJax representative or your regional BilJax dealer

Damage Repair Notice

There may be occasions when a BilJax 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 BilJax of these nonmaintenance repairs and request a repair form to be filled out and returned to BilJax.

2 BEFORE OPERATION

Inspections of the aerial work platform and the intended work area should be performed daily before operation. Failure to inspect machine and work area may result in death or personal injury.

Prior to Operation:

 Conduct a pre-operation inspection of the aerial work platform by

performing all daily service checks as explained in this manual, as well as all weekly and/or monthly service checks, if applicable.

 Inspect the work area.

A comprehensive schedule of service checks and maintenance can be found in the Parts and Service Manual. Annual service checks and structural inspections should be performed only by personnel trained and certified in accordance with applicable government regulations.

BILJAX 45XA

DAILY SERVICE CHECKS

The following maintenance procedures should be performed daily or before each operation.

Verify that all decals are correctly applied and in plain view.

 Refer to Section 5 for decal locations.

Verify that all controls and indicators at ground and platform control stations operate properly.

 Lower outriggers to level the boom lift.

 Raise and extend all booms.

 Press emergency STOP button.

 Verify that booms remain elevated and do not drift.

 Pull out STOP button and lower the booms.

 If either control station is unresponsive, refer to Table

4-1 for troubleshooting procedures.

 If display panel displays an error code, refer to Table

4-2 for error code definitions.

Verify 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.

Figure 2-1. 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.

BILJAX 45XA

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 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 2-2), 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 2-2. Hydraulic Reservoir

2 – BEFORE OPERATION

WEEKLY SERVICE CHECKS MONTHLY SERVICE CHECKS

Perform the following service checks at least once each week in addition to all recommended daily service checks:

Check Battery electrolyte level.

 If battery electrolyte level is low, add enough distilled

water to bring the electrolyte level to the top of the plates.

 If batteries are fully charged, raise electrolyte level to

full mark in each cell.

Inspect all electrical wiring.

 Check for cuts, loose terminals, broken wires, chaffing

and corrosion.

 Repair all damage, remove corrosion and seal

exposed connections.

Inspect transport hitch components for damage.

Inspect boom lift for missing, loose or damaged hardware.

 Repair or replace as necessary.

Inspect all hydraulic system components including pump and motor and cylinders for damage, leaks, loss of pressure or speed, and unusual noise or vibration.

 Repair or replace as necessary.

Perform the following service checks at least once each month in addition to all recommended daily service checks:

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 2-3 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.

Figure 2-3. Wheel Nut Tightening Sequence

BILJAX 45XA

WORKPLACE INSPECTION

Before operating the machine, be aware of and avoid the following:

 Drop-offs

 Holes

 Floor obstructions or debris

 Sloped surfaces outside the capabilities of the

boom lift

 Unstable or slippery surfaces

 Surfaces that will not support the load forces

imposed by the machine or outriggers

 Overhead obstructions and high voltage

conductors

 Sinkholes and untamped earth fills

 Personnel

 Unsafe weather conditions

 Other vehicles and equipment

 Other unsafe conditions

2 – BEFORE OPERATION

3 OPERATION

The Model 45XA Aerial Work Platform is equipped with multiple operator control stations. Operators can use boom and outrigger functions from both the platform and ground control panels. Drive functions are found on the platform control panel.

Before attempting boom lift operation, Operators should:

 Attend a training program as required by government regulations.

 Obtain, read and obey all safety precautions as indicated by

manufacturer’s recommendations and all federal, state and local regulations.

 Become familiar with the location and use of all controls.

 Verify that there are no overhead obstructions or live power sources

in the work area that could interfere with the safe operation of the boom lift.

 Position the boom lift on a firm and level surface.

 Conduct a Pre-Operation inspection by performing all recommended

Daily Service Checks. Refer to Section 2.

BILJAX 45XA

GROUND CONTROL STATION

The ground control station is used to operate outriggers and control boom motion. To access the ground control station, open the control panel access cover found on the turntable. Turn the key switch to the ground controls setting.

1. Key Switch

1a. Ground Controls Position

1b. Platform Controls Position

2. Battery Condition Indicator

3. Engine Start

4. Engine Choke

5. Display Panel

6. Emergency Stop

7. Boom Extend

8. Boom Retract

9. Lower Boom Raise

10. Lower Boom Down

11. Upper Boom Raise

Figure 3-1. Ground Control Panel

12. Upper Boom Down

13. Jib Raise

14. Jib Down

15. Speed Buttons

16. Platform Tilt – Up

17. Platform Tilt – Down

18. Boom Rotation – Clockwise

19. Boom Rotation – Counterclockwise

20. Outrigger Status Indicator LED

21. Outrigger Extend

22. Outrigger Retract

23. Auto Level

24. Outrigger Button

BILJAX 45XA

The ground control station includes the following controls and Indicators. Refer to Figure 3-1 for control locations.

1. Key Switch

ng the key switch to the

Turni

PLATFORM (1A) icon

selects operation from the platform. Turning the key switch to the

GROUND (1B) icon selects operation

from the ground control panel. The center (power off) position interrupts all electric and hydraulic power operations except emergency lowering. Removing the key protects against operation by unauthorized persons. The key may be removed with the key switch in any selected position.

2. Battery Condition Indicator

Indicato

r LEDs light up to indicate the level of charge remaining in the batteries. A lighted green LED indicates an adequate charge level. Lighted yellow LEDs indicate the need for charging soon. A lighted red LED warns that the battery charge level is low; boom operations should be halted until the batteries are recharged.

3-4. Engine Start and Choke

Start a cold e

ngine by pressing the Engine button while pressing and holding the To start/restart a warm engine, press the

START

CHOKE button.

START

button only.

5. Display Panel

The DISPLAY PANEL is a lighted text window that displays the present operating status or an existing error condition when the key switch is on.

6. Emergency Stop Button

n pushed in, the emergency

Whe

STOP button

disconnects electrical power to the ground and platform control stations. The emergency

STOP

pushbutton should only be pressed to immediately stop all boom motion. To resume control, pull out the emergency

STOP button.

7-8. Boom Extend/Retract Buttons

Pressing and holding a desired

BOOM EXTEND button at the same time extends the

SPEED button and the

telescopic boom. Pressing and holding a desired

SPEED button and the BOOM RETRACT button at the

same time retracts the boom. Boom motion

continues until the buttons are released or until the boom reaches a hard stop or a safe travel limit.

9-14. Boom Raise/Down Buttons

Pressing and holding a desired

UPPER/LOWER/JIB BOOM RAISE button at the same

SPEED button and the

time will raise the chosen boom. Pressing a desired

SPEED button and the UPPER/LOWER/JIB BOOM DOWN

button at the same time will lower the chosen boom. Boom motion continues until the buttons are released or until the boom reaches a hard stop or a safe travel limit.

15. Speed Buttons

SPEED buttons along the lower right side of the

The control panel must be pressed and held while selecting a boom function. Four speeds are available to control the positioning of the boom lift.

16-17. Platform Tilt Buttons

Press and hold any

PLATFORM TILT button at the same time to level the

SPEED button and the desired

work platform (levels the platform only, not the boom lift).

18-19. Boom Rotation Buttons

Pressing and holding a desired

BOOM ROTATION CLOCKWISE or COUNTERCLOCKWISE

SPEED button and the

button at the same time enables the boom to rotate in the direction selected. The boom will rotate through 700 degrees until the buttons are released or the stop is reached.

20-24. Outrigger Controls

For automatic outrigger extension/retraction: Select

EXTEND or RETRACT outrigger button and the AUTO

button at the same time. To manually extend

LEVEL

or retract the outriggers: Select outrigger button and one of the

EXTEND or RETRACT OUTRIGGER buttons

at the same time. The outrigger indicator LEDs light up when the outriggers are properly deployed and the boom weight is on the outriggers. Each of the outer outrigger LEDs indicates load is on the outrigger footpad. Each of the inner outrigger LEDs, when flashing, indicate that side is low and needs to be further raised for leveling. The Auto Level LED lights up and a buzzer sounds when the boom is level.

3 – OPERATION

PLATFORM CONTROL STATION

The platform control station is used to control boom motion. To access the platform control station, turn the key switch at the ground control station to the platform controls setting and enter the work cage.

1. Engine Start

2. Engine Choke

3. Engine Stop

4. Generator On/Off

5. Fuel Toggle

6. Horn

7. Drive Speed Selector

8. Battery Condition Indicator

9. Diagnostic Indicators

10. Emergency Stop

11. Auto Level

Figure 3-2. Platform Control Panel

12. Outrigger Buttons

13. Outrigger Extend

14. Outrigger Retract

15. Outrigger Condition Status LED

16. Lower Boom Raise/Down

17. Boom Rotation

18. Boom Extend/Retract

19. Platform Tilt

20. Upper Boom Raise/Down

21. Jib Raise/Down

22. Jib Rotation (Option)

3 – OPERATION

The platform control station includes the following controls and Indicators. Refer to Figure 3-2 for control locations.

1-2. Engine Start and Choke

Start a cold e then press the engine

ngine by pressing the

START button (1) to start the

CHOKE button (2),

engine. To start/restart a warm engine, press the

START button only.

3. Engine Stop

Press to stop

the engine. If charged, batteries will

still provide power to the lift.

4. Gnerator On/Off

Press

GENERATOR ON/OFF button to activate

generator. Generator provides power to battery charger and to GFI outlets found adjacent to the ground and platform control stations.

5. Fuel Toggle

FUEL TOGGLE button to change between fuel

Press types. Option is not currently available on selfpropelled machines.

6. Horn

Press to sound the horn. Use the horn button to warn personnel in the area of a falling object hazard, impending boom motions or the need for assistance.

7. Drive Speed Selector

Press

DRIVE SPEED SELECTOR to switch between low

speed/high torque and high speed/low torque settings. The low speed/high torque setting is recommended when operating on inclines.

8. Battery Condition Indicator

Indicato

r LEDs light up to indicate the level of charge remaining in the batteries. A lighted green LED indicates a good charge level. Lighted yellow LEDs indicate the need for charging soon. A lighted red LED warns that the battery charge level is low; boom operations should be halted until the batteries are recharged.

9. Diagnostic Indicators

Indicator LEDs warn of machine or engine issues. Refer to the display panel on the ground control panel and the troubleshooting section of this manual for fault code explanations.

10. Emergency Stop

When pushed in, the emergency

STOP button

disconnects electrical power to the ground and platform control stations. The emergency

STOP

pushbutton should only be pressed to immediately stop all boom motion. To resume control, pull out the emergency

STOP button.

11-15. Outrigger Controls

Outrigger controls on the platform are identical to the outrigger controls on the ground control panel.

16. Lower Boom Raise/Down

Press the

LOWER BOOM RAISE/DOWN button until the

adjacent LED indicator becomes lit. Depress the trigger on the platform controls joystick and move the joystick off center in the appropriate direction to raise and lower the boom.

17. Boom Rotation

Press the

BOOM ROTATION button until the adjacent

LED indicator becomes lit. Press and hold the toggle button on top of the platform controls joystick, using the color-coded direction arrows to determine direction the machine will rotate. Depress the trigger on the platform controls joystick and move the joystick off center to rotate the boom.

18. Boom Extend/Retract

Press the

BOOM EXTEND/RETRACT button until the

adjacent LED indicator becomes lit. Depress the trigger on the platform controls joystick and move the joystick off center in the appropriate direction to extend and retract the boom.

19. Platform Tilt

Press the

PLATFORM TILT button until the adjacent

LED indicator becomes lit. Depress the trigger on the platform controls joystick and move the joystick off center in the appropriate direction to extend and retract the boom.

20. Upper Boom Raise/Down

Press the

UPPER BOOM RAISE/DOWN button until the

adjacent LED indicator becomes lit. Depress the trigger on the platform controls joystick and move the joystick off center in the appropriate direction to raise and lower the boom.

21. Jib Boom Raise/Down

Press the

JIB BOOM RAISE/DOWN button until the

adjacent LED indicator becomes lit. Depress the trigger on the platform controls joystick and move the joystick off center in the appropriate direction to raise and lower the boom.

22. Jib Rotation (Option)

Press the

JIB ROTATION button until the adjacent LED

indicator becomes lit. Press and hold the toggle button on top of the platform controls joystick, using the color-coded direction arrows to determine direction the jib boom will rotate. Depress the trigger on the platform controls joystick and move the joystick off center to rotate the jib boom.

3 – OPERATION

PLATFORM CONTROLS JOYSTICK

Use the Joystick to operate drive and boom functions from the platform control station.

1. Joystick Trigger

2. Toggle Switch

Figure 3-3. Platform Controls Joystick

1. Joystick Trigger

Depress the trigger after selecting a boom function and move the joystick in the desired direction to operate boom functions.

2. Toggle Switch

Use the toggle switch to control direction of boom rotation and to steer the machine when using drive functions.

BILJAX 45XA

OPERATION: SET UP

 Turn the key switch on the ground controls to

select the desired control station. If power does not come on, make sure both emergency

STOP

buttons (ground and platform) are pulled out and the main power disconnect is plugged in.

 The control microprocessor will perform self-

diagnostics to test the operating system. After several seconds, the DISPLAY PANEL window will read:

BIL – JAX

A STEP ABOVE

 Verify that the control status indicator LED is lit.

If the control status indicator LED is not lit or is flashing, the outrigger buttons will not work. A flashing control status LED indicates that one or more of the booms is raised and needs to be stowed. Refer to Figure 3-1 and Figure 3-4.

 Extend the outriggers manually or using the

AUTO LEVEL button. When the boom is leveled

properly, a buzzer will sound and two LEDs at

OUTRIGGER button and the LED at the AUTO

each

button will be lit.

LEVEL

Auto Level: Press and hold the

AUTO LEVEL

buttons at the same time.

EXTEND and

Manual Level: Extend the two outriggers closest to the trailer coupler first. Lower each pair of outriggers by pressing the and the two appropriate

OUTRIGGER buttons at

EXTEND button

the same time.

 Verify that the auto level indicator LED is lit. If

the auto level indicator is not lit, the boom may not be level.

 Pull the latch release on the boom travel latches,

raise the latch handle and swing the latch U-bolt down. Refer to figure 3-5.

Figure 3-5. Boom Travel Latch

Manual Brake Release

The brake release is located in the engine compartment. Refer to Figure 3-6.

To release brakes:

 Depress the black knob.

 Pump the red knob 3-5 times to release brakes.

Activate drive function on the platform control panel to resume normal brake operation.

Figure 3-4. Outrigger Controls

NOTE: The safety interlock system prevents all

boom operations if the boom is not level or if one or more outriggers are not supporting the vehicle load.

Figure 3-6. Manual Brake Release

OPERATION: GROUND CONTROLS

 Turn the key switch to ground control position.

 Raise, lower, extend and rotate the boom by

pressing and holding the desired function buttons at the same time.

 When all boom lift operations are complete, fully

retract the telescoping boom extension. Center boom over the boom rest and fully lower all booms until seated in the stowed position for transport. Safety switches prevent outrigger retraction until boom is completely lowered and stowed for transport.

 Engage the boom travel latches.

 Press and hold the outrigger RETRACT button

and the

AUTO LEVEL button until all outriggers are

fully retracted to their upright positions. Inspect the area beneath lift for obstructions before retracting outriggers.

 Turn the key switch to the OFF position and

remove key.

SPEED and

3 – OPERATION

BILJAX 45XA

OPERATION: PLATFORM CONTROLS OPERATION: DRIVE FUNCTIONS

 Fully lower the boom onto the boom rest to

position the platform for boarding. Turn the key switch to the platform control position.

 Raise the safety bar and enter the work

platform. Put on the safety harness and attach the lanyard to the Fall Protection Attachment Point on the side of the platform support beam.

Use the platform control panel to operate the boom lift functions.

 To raise, lower, extend and rotate the boom,

press the desired function button.

 An LED adjacent to the function button will

become lit, indicating that the function is active.

 Depress the trigger on the platform controls

joystick and move the joystick off center. Moving the joystick further off center will increase function speed. Moving the joystick toward center will decrease function speed. Returning the joystick to center and/or releasing the trigger will stop boom functions.

 Use the color-coded direction arrows to

determine the direction the boom will move.

 To drive machine, use the platform controls to

raise all outriggers to a fully stowed position.

 Verify that the drive mode LED is lit.

 Depress the trigger on the platform controls

joystick and move the joystick off center. Moving the joystick further off center will increase drive speed. Moving the joystick toward center will decrease drive speed. Returning the joystick to center and/or releasing the trigger will stop drive functions.

 To steer, use the toggle switch on the top of the

platform controls joystick.

 Use the color-coded direction arrow to

determine the direction the machine will move.

 To rotate the turntable, depress the trigger on

the platform controls joystick and use the toggle switch located on top of the platform controls joystick. While pressing the toggle switch and the trigger, move the joystick off center to adjust function speed.

 Use the toggle switch and the color-coded

direction arrows to determine the direction the turntable will rotate. The turntable will rotate in the desired direction regardless of which direction the joystick is moved off center.

 Should the platform become tilted out of the

normal vertical axis, use the

PLATFORM TILT

function to adjust.

 Monitor the Battery Condition Indicator during

operation and charge the batteries as necessary.

 Always fully retract, rotate and lower the boom

to the stowed position before exiting the platform.

MANUAL BOOM OPERATION

3 – OPERATION

Manual retraction, rotation and lowering functions allow the aerial work platform to be moved and lowered during hydraulic power interruption or failure. In each instance, refer to Figure 3-7.

The following procedures for manual retraction, rotation and lowering require a person on the ground to operate the manual controls and hand pump.

The hydraulic hand pump is located in the pump compartment. In case of a power failure, the hand pump and selected hydraulic valve settings can be used to manually retract the Telescoping boom or rotate the boom turntable.

To begin manual retraction or rotation, turn Proportional Valve counterclockwise until it stops, and insert pump handle into the pump handle fitting.

Manual Retraction

Pushing and holding the Retract button while simultaneously actuating Hand Pump will retract the extension boom section.

Manual Rotation

To rotate the turntable clockwise: Push and hold the Rotation button and simultaneously actuate Hand Pump.

To rotate the turntable counterclockwise: Pull the Rotation button out and simultaneously actuate Hand Pump.

NOTE: Return proportional valve to its original

position before lowering the lift or resuming normal operation.

1. Hand Pump

2. Proportional Valve

Figure 3-7. Hand Pump and Controls for Manual Lift Operation

3. Rotation Button

4. Retract Button

BILJAX 45XA

Manual Lowering

Each Manual Lowering Valve is equipped with a plunger, found at the base of the lift cylinder (Figure 3-8). Depress the plunger to lower the platform in case of a complete electrical power failure, a load shift, or other emergency. Continue pressing the plunger to completely lower the boom.

Figure 3-8. Manual Lowering Valve

BATTERY RECHARGE

WARNING

CAUTION

3 – OPERATION

Recharge batteries as needed. When using the gas engine, press the

GENERATOR button on the platform

control station to charge the batteries. Charge daily under normal use. When machine is not in use, batteries should be recharged at least once per week. Under normal circumstances, battery recharge should take approximately 10-12 hours. However, a full recharge may take up to 24 hours if the battery charge is extremely low.

WARNING

Recharge batteries in a well-ventilated area only. Do no charge batteries near fire, spark or other potential ignition sources. Batteries may emit highly explosive hydrogen gas while charging. Failure to properly ventilate the charge gases may result in serious injury or death. Always charge boom lift batteries away from flammable materials.

To recharge the boom lift batteries:

 Move the boom lift to a well-ventilated area with

direct access to 120 V electrical outlet. Keep the boom lift and batteries away from open flame or other potential ignition sources.

 Attach a 12 AWG multi-strand, grounded

extension cord with a maximum length of 15 meters to the receptacle located inside the engine compartment. The generator may need to be disconnected from the receptacle.

NOTE: Using an underrated or long power cord

will reduce the output of the battery charger and may extend charge time.

 The CHARGING indicator LED remains lit

continuously during the first stage of the charge cycle. The bulk mode CHARGE CURRENT will be displayed on the battery charger faceplate.

 Press and hold the BATTERY VOLTAGE button to

display the detected battery voltage.

 If a battery fault is detected, the appropriate fault

code will appear on the CHARGE CURRENT display. The red CHECK BATTERY indicator LED will become lit. See Table 3-1 for battery charger fault codes.

Do not disconnect any output leads or connectors between the batteries and the charger when the charger is on. To stop a charge in progress, always unplug the extension cord from the AC power source.

 When the battery charge reaches 80% of

capacity, the yellow 80% CHARGED indicator LED will become lit and the green CHARGING indicator LED will begin to flash.

 When the batteries have reached a full charge,

the green and yellow indicator LEDs will turn themselves off. CC (Charge Complete) will appear on the CHARGE CURRENT display. After two hours, this display will fade and the CHARGE CURRENT will read 00.

 Unplug the extension cord from the outlet and

the charger receptacle on the boom lift. Store the extension cord for next use.

 Plug the extension cord into outlet. Verify that

the green CHARGING indicator LED is lit on the battery charger faceplate (Figure 3-9).

Linear Battery Charger

CHARGING

CHARGE CURRENT

PUSH

FOR

BATTERYVOLTAGE

FUSE 15A SLO BLO

Figure 3-9. Battery Charger Faceplate

80% CHARGED

CHECK BATTERY

Always unplug the battery charger power cord before moving the boom lift. Failure to disconnect power cord will cause damage to the equipment.

Table 3-1. Charger Fault Codes

Code Description Limits Cause

F1 Over Voltage

F2 Over Current >60 amperes Battery Fault

F3 Bulk Mode Timeout 14 hrs Max. Battery Fault

F5 FCT Mode Timeout 2.5 hrs Max. Battery Fault

F6 Self-Test Error Charger Fault

ARD Mode

Timeout

>112% charge

voltage

6 hrs Max. Battery Fault

Loose battery or

charger

connection

BILJAX 45XA

BOOM LIFT TRANSPORT

LIFTING INSTRUCTIONS TRANSPORT INSTRUCTIONS

Refer to Figure 3-10.

 Completely lower and retract booms.

 Secure boom and platform travel latches.

 Remove all loose materials from machine.

 Retract all outriggers to fully stowed position.

 Attach rigging only to the designated forklift

pockets (A).

 Adjust rigging to keep the machine level and to

minimize the risk of damage to machine.

 When using a forklift, use only the designated

forklift pockets. Follow all forklift operating instructions as indicated by the forklift manufacturer.

 Only trained and authorized personnel should

attempt to lift the boom using a crane or forklift.

Refer to Figure 3-10.

 Verify that truck or trailer is parked on a firm and

level surface.

 Completely lower and retract boom.

 Secure boom travel latches.

 Retract all outriggers to fully stowed position.

 Load boom onto truck or trailer.

 Secure the boom lift to the trailer bed using

straps or chains. Use only the two attachment points beneath the machine, adjacent to the outriggers (B).

 Adjust as necessary to prevent damage to

rigging or machine.

Figure 3-10. Lift and Transport Instructions

3 – OPERATION

4 TROUBLESHOOTING

The following section contains information for solving basic diagnostic issues associated with the machine. If any issue or malfunction is encountered during the correct and proper operation of the aerial work platform that is not covered by the troubleshooting steps covered in this manual, contact your regional BilJax representative or the BilJax Service Department.

 All maintenance and repairs should be performed by qualified

personnel in accordance with manufacturer specifications and government regulations.

 Follow recommended maintenance safety guidelines when

performing maintenance on the machine.

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

One or more boom controls function improperly

One or more boom controls function intermittently.

4 – TROUBLESHOOTING

TROUBLESHOOTING

Refer to Table 4-1 for basic troubleshooting operations. Additional information can be found in the BilJax Model 45XA Parts and Service Manual. Contact the BilJax Service Department with any questions or before attempting any advanced troubleshooting operations.

Table 4-1. Troubleshooting Steps

a. Emergency STOP engaged.

b. Battery charge is low.

c. Battery ground or in-series cable is loose.

d. Battery main disconnect unplugged.

e. Blown fuse.

a. Fault detected by safety interlock

microprocessor.

b. Boom Lift electric or electronic failure

a. Key switch turned to the OFF or platform

controls position.

b. Emergency

c. Outriggers not deployed.

a. Key switch is turned to the

incorrect control position.

b. Battery charge is low.

c. Emergency

d. Battery ground or in-series cable loose.

e. All outriggers not properly deployed.

f. Hydraulic pump inoperative.

g. Loose wiring connector.

h. Valve solenoid not operating properly.

i. Fault detected by system interlock.

j. Broken or loose wire.

STOP engaged.

OFF or

STOP engaged.

a. Disengage Emergency STOP buttons.

b. Recharge as needed.

c. Inspect and repair battery connections.

d. Plug in main disconnect.

e. Replace fuse.

a. Refer to Table 4-2 for error code

definition and correction.

b. Refer to Table 4-2 for error code

definition and correction.

a. Turn key switch to ground controls

position.

b. Disengage emergency STOP buttons.

c. Deploy all outriggers.

a. Turn key switch to ground or platform

controls position.

b. Recharge battery.

c. Disengage Emergency STOP buttons.

d. Inspect and repair battery connections.

e. Deploy all outriggers and level boom lift.

f. Inspect pump; replace or repair as

needed.

g. Check wiring terminals in control box

and at valve manifold; replace or repair as needed.

h. Clean valve solenoid and recheck

function(s); replace or repair as needed.

i. Check display for system status. Refer

to Table 4-2 for error code definitions and correction.

j. Inspect wiring in control box and at

valve manifold and valve coil; repair or replace as needed.

BILJAX 45XA

ERROR MESSAGE DEFINITION OF ERROR COMMENTS

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 4-2 for a comprehensive list of Error Code Definitions and solutions.

Table 4-2. Error Code Definitions

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

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.

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.

SHORTED CIRCUIT

022

PRIMARY UP

OPEN CIRCUIT PRIMARY

023

DOWN

SHORTED CIRCUIT

024

PRIMARY DOWN

OPEN CIRCUIT SECONDARY

025

SHORTED CIRCUIT

026

SECONDARY UP

OPEN CIRCUIT SECONDARY

027

DOWN

SHORTED CIRCUIT

028

SECONDARY DOWN

029 OPEN CIRCUIT JIB 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.

030 SHORTED CIRCUIT JIB UP

Excessive load detected in jib up circuit on power-up.

Retract boom to travel position and extend outriggers using

LEVEL

button.

AUTO

Check for unplugged or damaged platform control cable.

Turn key switch off and on again without pressing any buttons.

Retract boom to travel position and extend outriggers using

button.

LEVEL

AUTO

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 down 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 jib up solenoid coil and wiring.

4 – TROUBLESHOOTING

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

SHORTED CIRCUIT

042

PLATFORM CW

OPEN CIRCUIT PLATFORM

043

CCW

SHORTED CIRCUIT

044

PLATFORM CCW

OPEN CIRCUIT TURNTABLE

045

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 boom extend solenoid coil/wiring.

Check for faulty boom retract solenoid coil/wiring.

Check for faulty level up solenoid coil/wiring.

Check for faulty level down solenoid coil/wiring.

Check for faulty boom rotate solenoid coil/wiring.

Check for faulty rotate CW solenoid coil/wiring.

Check for faulty rotate CCW solenoid coil/wiring.

Check for faulty outrigger retract solenoid coil/wiring.

Check for faulty outrigger extend solenoid coil/wiring.

Check for faulty solenoid coil/wiring at outrigger.

BILJAX 45XA

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 proportional valve.

4 – TROUBLESHOOTING

5 DECAL REPLACEMENT

Decals contain information that is required for the safe and proper use of the aerial work platform. Decals should be considered necessary components of the machine and should be checked before each use to verify that they are correctly attached and legible.

Use the following guides to find the correct location of all decals.

Table 5-1. Decal Descriptions

4 – TROUBLESHOOTING

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 BilJax Logo, Black Transfer 2

B06-00-0403 NOTICE: Emergency Lowering 4

B06-00-0404 WARNING: Outrigger Crush Toe 8

B06-00-0405 WARNING: Pinch Point 16

B06-00-0471

B06-00-0473

B06-00-0474 NOTICE: Max. Load 1

B06-00-0475

B06-00-0477 WARNING: Forklift Pockets 2

B06-00-0481 CAUTION: Transport Safety Latch 2

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

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

B06-00-0521 DANGER: Tip Over Hazard 5

B06-00-0536 NOTICE: Range of Motion 2

B06-00-0541

B06-00-0545 BilJax Website Transfer 2

B06-00-0552

B06-00-0561

B06-00-0562

B06-00-0564 45XA, 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)

Identification Plates

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

0405

0482

0403

0037

0405

0403

0481

0473

0475

0562

0062

0471

0552

0474

0202-0523

0536

0521

0504

0495

0505

0068

0503

0494

0541

0561

0405

0521

0404

0536

0403

0564

0545

0161B

0477

0481

0495

0484

0034

0405

Figure 5-1. Decal Placement

0405

0521

Table 5-2. Decal Descriptions – CE

5 – DECAL PLACEMENT

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 BilJax Logo, Black Transfer 2

B06-00-0173 Fall Protection Attachment Points 1

B06-00-0403 NOTICE: Emergency Lowering 4

B06-00-0404 WARNING: Outrigger Crush Toe 8

B06-00-0405 WARNING: Pinch Point 15

B06-00-0471

B06-00-0474 NOTICE: Max. Load 1

B06-00-0475

DANGER: Before Use/Main Instruction/Hazards (Platform)

WARNING: Read/Understand Operator’s Manual

Decal No. Decal Description Qty

B06-00-0482 DANGER: Electrocution Hazard 2

B06-00-0495

B06-00-0505

B06-00-0536 NOTICE: Range of Motion 2

B06-00-0541

B06-00-0545 BilJax Website Transfer 2

B06-00-0561

B06-00-0562

B06-00-0564 45XA, 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

Identification Plates

B06-00-0499 ANSI ID Plate 1

B06-00-0526 Key Tag 1

BILJAX 45XA

0562

0475

0474

0062

0471

0202-0523

0536

0173

0068

0495

0541

0034

0405

0568

0482

0403

0404

0037

0405

0403

0564

0545

0161B

0505

0495

0572

0475

0561

0536

0034

0403

0405

Figure 5-2. Decal Placement – CE

5 – DECAL PLACEMENT

6 SPECIFICATIONS

BilJax, Inc. is dedicated to the continuous improvement of this and all BilJax 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 BilJax representative or to the BilJax Service Department.

BILJAX 45XA

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

51 ft

15.7 m

45 ft

13.7 m

27 ft

8.2 m

21 ft

6.4 m

500 lbs

227 kg

440 lbs

200 kg

4,300 lbs

1,950 kg

700º Non-Continuous

12.5º

48%

8 ft 8 in

2.7 m

11 ft

3.35 m

16 ft 8 in

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

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

3.75 mph

6 km/h

2 mph

3.2 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

4.3 Gallons

16.3 L

6.3 Gallons

23.9 L

Dexron III/Mercon ATF

90º/Manual

60 dB

55 dB

70 dB

65 dB

Stowed Dimensions

Height

Length

Width

6 ft 4 in

2.0 m

19 ft 2 in

5.8 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

BILJAX 45XA

RANGE OF MOTION

Figure 7-1. Range of Motion

7 EQUIPMENT OPTIONS

The BilJax Model 45XA may be equipped with one or more optional components designed for the convenience and safety of operators when using the equipment to accomplish specific tasks.

Always use only those components manufactured and/or authorized by BilJax, Inc. Never make any adjustments or modifications or otherwise alter the equipment in any way that is not expressly recommended by the manufacturer.

When operating a machine equipped with optional components, observe all safety precautions set forth by the manufacturer, as well as all government codes and regulations regarding this equipment and its components.

Consult rental agency or equipment manufacturer regarding which optional components may be installed on the boom lift. For questions regarding safe use, contact your regional BilJax dealer before attempting operation

BILJAX 45XA

MATERIAL LIFTING HOOK

If the boom lift is equipped with a material lifting hook, observe the following procedure for material lift operation:

 Remove platform controls from the work

platform by releasing the latch on the back of the platform control box.

 Disconnect platform control box from the load

sense module located on the boom lift bulkhead.

 Remove the electric loopback plug from the

receptacle on the bottom right of the ground control panel (Figure 8-1) and insert the platform control cable into the open receptacle.

To Boom Cable.

Do Not Remove.

2. To Platform Controls.

a. Disconnect platform controls.

b. Replace with loopback plug from ground

controls.

c. Plug platform controls into open receptacle

on the bottom right of ground control panel.

Figure 8-1. Material Lifting Hook Configuration

Figure 8-2. Material Lifting Hook Installation

 Operate the material lifting hook remotely, using

the platform control box for optimal control.

WARNING

Always observe the manufacturer’s weight lifting limitations when using the material lifting hook. Always use lifting straps or wire rope slings that are rated at a minimum 500 lbs lifting capacity. Never stand beneath an elevated load or position an elevated load above personnel. Falling objects can cause serious injury or death.

DANGER

This machine is not insulated for use near electrical power lines and DOES NOT provide protection from contact with or close proximity to any electrically charged conductor. Operator must maintain safe clearances at all times and always allow for platform movement such as wind-induced sway. Refer to Table 1-1 for minimum safe approach distances between the machine and electrical power lines.

 Reverse the procedure to reattach the work

platform.

 Insert the removed electric loopback plug into

the open receptacle on the load sense module, replacing the platform control cable.

 Remove the retaining pin holding the platform to

boom lift. Firmly secure platform to prevent equipment damage.

 Remove the platform from the boom by lifting

cage up and away from the mounting bracket on the boom nose.

 Attach the material lifting hook to the mounting

bracket on the boom nose and insert the retaining pin (Figure 8-2).

PLATFORM ROTATOR

The optional platform rotator allows the operator to rotate the elevated work platform 90º around a vertical axis by actuating a rotator handle found below the platform control panel.

To operate manual platform rotator, turn the rotator handle in the direction of desired rotation (clockwise or counterclockwise). Motion continues in the desired direction until rotator handle is released or the platform reaches a safe travel limit.

WARNING

Installation of a manual platform rotator may reduce the rated load limit of the work platform. Follow all manufacturer’s recommendations and safety precautions when operating a boom lift equipped for platform rotation.

7 — EQUIPMENT OPTIONS

Figure 8-3. Manual Platform Rotator

BILJAX 45XA

NOTES

125 Ta

ylor Parkway Archbold, OH 43502 Phone (419) 445-8915 (800) 537-0540 Fax (419) 445-0367

http://www.biljax.com

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Bil-Jax 45XA Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual