45XA
OPERATOR’S
MANUAL
BOOM
AERIAL WORK PLATFORMS
TM
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.
Copyright © BilJax, Inc. 2009. All Rights Reserved.
“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
1
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
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
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.
4
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
ch
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
2
(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.
5
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
6
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.
7
BILJAX 45XA
NEVER jumpstart other vehicles using the boom lift
batteries.
8
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.
9
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.
10
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.
11
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
12
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.
1
4
3
2
5
Figure 2-3. Wheel Nut Tightening Sequence
13
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
14
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