Bil-Jax XLB-4319, B33-01-0080 User Manual

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AERIAL WORK PLATFORMS

XLB-4319

Hydraulic Boom Lift

Operation and Maintenance Manual

B33-01-0080

XLB-4319

BOOM PERSONNEL LIFT

This equipment is designed and manufactured in compliance with the duties, responsibilities, and standards set forth for manufacturers in the ANSI 92.2 standard in effect at the time of manufacture.

This equipment will meet or exceed applicable OSHA codes and ANSI A92.2 standards when used in accordance with sections 7, 8, 9, 10 & 11 of ANSI A92.2 and all other manufacturer’s recommendations.

It is the responsibility of the user of this equipment to follow all applicable ANSI, OSHA, Federal, State, and local codes and regulations that govern the safe operation of this equipment.

Table of Contents

Preface................................................................................................................ v

1 Safety................................................................................................................1-1

1-1 Introduction.........................................................................................1-1

1-2 Before Operation ................................................................................1-2

1-3 During Operation................................................................................1-3

1-4 Maintenance Safety.............................................................................1-5

General Maintenance......................................................................1-5

Battery Maintenance.......................................................................1-6

1-5 Damaged Equipment Policy ...............................................................1-6

Safety Statement.............................................................................1-6

Damage Policy................................................................................1-6

Damage Repair Notice....................................................................1-6

Reporting Safety Defects................................................................1-7

2 Introduction.....................................................................................................2-1

2-1 General Description............................................................................2-1

2-2 Specifications......................................................................................2-4

Boom Lift Work Platform..............................................................2-4

2-3 Warranty.............................................................................................2-5

3 Operation.........................................................................................................3-1

3-1 Operator Controls ...............................................................................3-1

Ground Control Station.......................................................................3-1

Basket Control Station....................................................................3-4

3-2 Normal Operating Procedure..............................................................3-6

3-3 Emergency Lowering..........................................................................3-8

3-4 Manual Boom Rotation.......................................................................3-9

3-5 Battery Recharge (DC MODEL ONLY)..........................................3-10

3-6 Boom Lift Transport.........................................................................3-11

Trailer Hitching............................................................................3-11

4 Maintenance ....................................................................................................4-1

4-1 Scheduled Service Checks..................................................................4-1

Daily/Weekly Service Checks........................................................4-1

Monthly Service Checks.................................................................4-2

4-2 Wheel Nut Torque Requirements .......................................................4-3

4-3 Lubrication..........................................................................................4-4

4-4 Hydraulic System................................................................................4-5

Hydraulic System Inspection..........................................................4-5

Fluid Check and Replacement........................................................4-5

Return Filter Replacement..............................................................4-6

Air Bleeding ...................................................................................4-6

Hydraulic Pressure Checks and Adjustments.................................4-7

Hydraulic Cylinder Replacement .................................................4-10

4-5 SLEW RING BEARING..................................................................4-17

Check Free Play............................................................................4-17

4-6 Limit Switch checks and adjustments...............................................4-18

Adjusting Boom Down Limit Switch...........................................4-18

Adjusting Outrigger Position Switches ........................................4-19

4-7 Troubleshooting................................................................................4-20

Troubleshooting Aids...................................................................4-22

4-8 Material Safety Data Sheets..............................................................4-31

5 Replacement Decals........................................................................................ 5-1

6 Parts List......................................................................................................... 6-1

6-1 Upper Boom Parts List....................................................................... 6-2

6-2 Lower Boom Parts List...................................................................... 6-4

6-3 Jib Boom Parts List............................................................................ 6-6

6-4 Compartment Covers Parts List......................................................... 6-8

6-5 Reservoir Compartment Parts List, Gas model................................ 6-10

6-6 Pump Compartment Parts List, DC Model ...................................... 6-12

6-7 Chassis and Rotation Unit Parts List................................................ 6-16

6-8 Hitch and Jack Assembly Parts List................................................. 6-18

6-9 Axle and Wheel Assembly Parts List.............................................. 6-20

6-10 Rear Lights and Junction Box Parts List.......................................... 6-23

6-11 Outriggers Parts List ........................................................................ 6-25

6-12 Basket Parts List............................................................................... 6-27

6-13 Outrigger Hydraulic Controls Parts List .......................................... 6-29

6-14 Lower Controls Parts List ................................................................ 6-31

6-15 Upper Controls Parts List................................................................. 6-33

6-16 Engine Compartment Parts List, Gas Model.................................... 6-35

6-17 Boom Control Hydraulics Parts List, Basket................................... 6-39

6-18 Boom Control Hydraulics Parts List, Ground, Gas Model.............. 6-41

6-19 Boom Control Hydraulics Parts List, Ground, DC Model............... 6-43

6-20 Lower Boom Cylinder Hydraulics Parts List................................... 6-45

6-21 Upper Boom Cylinder Hydraulics Parts List ................................... 6-46

6-22 Pushbutton Panel Parts List, Basket................................................. 6-47

6-23 Pushbutton Panel Parts List, Ground Controls................................. 6-49

7 ANSI Reprint.................................................................................................. 7-1

List of Illustrations

Figure 2-1. XLB-4319 Hydraulic Boom Lift.............................................................2-1

Figure 2-2. Basket and Ground Station Controls.......................................................2-2

Figure 2-3. Safe Operating Zone ...............................................................................2-3

Figure 3-1. Ground Control Station Access...............................................................3-1

Figure 3-2. Ground Control Station...........................................................................3-2

Figure 3-3. Engine Keyswitch ...................................................................................3-3

Figure 3-4. Basket Control Station ............................................................................3-4

Figure 3-5. Outrigger Controls ..................................................................................3-6

Figure 3-6. Manual Lowering Valve .........................................................................3-8

Figure 3-7. Basket Control Station ............................................................................3-8

Figure 3-8. Emergency Rotation................................................................................3-9

Figure 3-9. Battery Charger .....................................................................................3-10

Figure 3-10. Trailer Hitching .....................................................................................3-11

Figure 4-1. Wheel Bolt Tightening Sequence............................................................4-3

Figure 4-2. Lubricate Monthly...................................................................................4-4

Figure 4-3. Lubricate Semi-Annually........................................................................4-4

Figure 4-4. Hydraulic Reservoir ................................................................................4-5

Figure 4-5. Main Bypass Valve and Pressu re Test Port (Gas Engine Model)...........4-7

Figure 4-6. Outriggers Bypass Valve ........................................................................4-8

Figure 4-7. Boom Control Bypass Valve, Basket Station..........................................4-9

Figure 4-8. Hydraulic Cylinder Removal ................................................................4-11

Figure 4-9. Jib Boom Components..........................................................................4-14

Figure 4-10. Basket Swivel Cylinder.........................................................................4-16

Figure 4-11. Slew Ring Position Measurement.........................................................4-17

Figure 4-12. Boom Down Limit Switch....................................................................4-18

Figure 4-13. Outrigger Position Switch.....................................................................4-19

Figure 4-14. Simplified Electrical Diagram, DC Model............................................4-22

Figure 4-15. Detailed Electrical Diagram, DC Model...............................................4-23

Figure 4-16. Simplified Electrical Diagram, Gas Model...........................................4-24

Figure 4-17. Detailed Electrical Diagram, Gas Model ..............................................4-25

Figure 4-18. Hydraulic Diagram, DC Model.............................................................4-26

Figure 4-19. Hydraulic Diagram, Gas Model............................................................4-28

Figure 4-20. Level Sensor..........................................................................................4-30

Figure 5-1. Replacement Decals................................................................................5-2

Figure 5-2. Decal Locations, Trailer and Boom ........................................................5-5

Figure 5-3. Decal Locations, Control Compartment Exterior....................................5-6

Figure 5-4. Lubri cate Monthly Decal ........................................................................5-6

Figure 5-5. Lubricate Semi-Annually Decal..............................................................5-6

Figure 6-1. Upper Boom............................................................................................6-2

Figure 6-2. Lower Boom ...........................................................................................6-4

Figure 6-3. Jib Boom .................................................................................................6-6

Figure 6-4. Compartment Covers ..............................................................................6-8

Figure 6-5. Reservoir Compartment, Gas Model....................................................6-10

Figure 6-6. Pump Compartment, DC Model............................................................6-12

Figure 6-7. Chassis and Rotation Unit.....................................................................6-16

Figure 6-8. Hitch and Jack Assembly......................................................................6-18

Figure 6-9. Axle and Wheel Assembly....................................................................6-20

Figure 6-10. Rear Lights and Junction Box...............................................................6-23

iii

Figure 6-11. Outriggers............................................................................................. 6-25

Figure 6-12. Basket................................................................................................... 6-27

Figure 6-13. Outrigger Hydraulic Controls............................................................... 6-29

Figure 6-14. Lower Controls..................................................................................... 6-31

Figure 6-15. Upper Controls..................................................................................... 6-33

Figure 6-16. Engine Compartment Parts List, Gas Model........................................ 6-35

Figure 6-17. Boom Control Hydraulics, Basket........................................................ 6-39

Figure 6-18. Gas Model Boom Control Hydraulics, Ground.................................... 6-41

Figure 6-19. DC Model Boom Control Hydraulics, Ground .................................... 6-43

Figure 6-20. Lower Boom Cylinder Hydraulics ....................................................... 6-45

Figure 6-21. Upper Boom Cylinder Hydraulics........................................................ 6-46

Figure 6-22. Basket Pushbutton Panel, Gas Model................................................... 6-47

Figure 6-23. Pushbutton Panel, Ground Controls..................................................... 6-49

List of Tables

Table 1-1. Minimum Safe Approach Distances....................................................... 1-3

Table 2-1. Specifications ......................................................................................... 2-4

Table 4-1. Daily/Weekly Service Checks................................................................ 4-1

Table 4-2. Monthly Service Checks ........................................................................ 4-2

Table 4-3. Troubleshooting Chart.......................................................................... 4-20

Table 4-4. Level Sensor LEDs............................................................................... 4-30

Table 5-1. Replacement Decals............................................................................... 5-1

Table 6-1. Upper Boom Parts List........................................................................... 6-3

Table 6-2. Lower Boom Parts List........................................................................... 6-5

Table 6-3. Jib Boom Parts List ................................................................................ 6-7

Table 6-4. Compartment Covers Parts List.............................................................. 6-9

Table 6-5. Reservoir Compartment Parts List, Gas Model.................................... 6-11

Table 6-6. Pump Compartment Parts List, DC Model........................................... 6-13

Table 6-7. Chassis and Rotation Unit Parts List.................................................... 6-17

Table 6-8. Hitch and Jack Assembly Parts List..................................................... 6-19

Table 6-9. Axle and Wheel Assembly Parts List................................................... 6-21

Table 6-10. Rear Lights and Junction Box Parts List.............................................. 6-24

Table 6-11. Outriggers Parts List............................................................................. 6-26

Table 6-12. Basket Parts List................................................................................... 6-28

Table 6-13. Outrigger Hydraulic Controls Parts List............................................... 6-30

Table 6-14. Lower Controls Parts List..................................................................... 6-32

Table 6-15. Upper Controls Parts List..................................................................... 6-34

Table 6-16. Engine Compartment Parts List, Gas Model........................................ 6-36

Table 6-17. Boom Control Hydraulics Parts List, Basket........................................ 6-40

Table 6-18. Gas Model Boom Control Hydraulics Parts List, Ground.................... 6-42

Table 6-19. DC Model Boom Control Hydraulics Parts List, Ground.................... 6-44

Table 6-20. Lower Boom Cylinder Hydraulics Parts List....................................... 6-45

Table 6-21. Upper Boom Cylinder Hydraulics Parts List........................................ 6-46

Table 6-22. Basket Pushbutton Panel Parts List...................................................... 6-48

Table 6-23. Pushbutton Panel Parts List, Ground Controls..................................... 6-49

Table 7-1. Minimum Safe Approach Distance (M.S.A.D.)

to energized (exposed or insulated) power lines and parts........................................... 7-11

PREFACE

The purpose of this manual is to provide a thorough understanding of the XLB-4319 Hydraulic Boom Lift operation and controls. Read the safety and operating instructions in this manual and become familiar with the location and use of all controls.

Follow all warnings, cautions, and instructions in this manual and any attached to and supplied with the boom lift. All OSHA, ANSI, state, and local codes and regulations concerning this equipment should obtained, read, and thoroughly understood before attempting to operate this equipment.

To ensure proper and safe use of this equipment, only trained and qualified personnel should operate and maintain the boom lift.

SAFETY NOTES

This manual contains DANGERS, WARNINGS, CAUTIONS, and NOTES that must be followed to prevent the possibility of improper service, personnel injury or death, and damage to equipment.

DANGER

Dangers warn of equipment operation near electrical power lines that could lead to personal injury or death.

WARNING

Warnings describe conditions or practices that could lead to personal injury or death.

CAUTION

Cautions provide information important to prevent errors that could damage machine or components.

NOTE: Notes contain additional information important to a procedure.

Safety

1-1

INTRODUCTION

Familiarity and proper training are required for the safe operation of mechanical equ ment. Equipment operated improperly or by untrained personnel can be dangerous. Read the operating instructions in this manual and become familiar with the location and proper use of all controls. Inexperienced operators should receive instruction from so one familiar with the equipment before being allowed to operate the machine. The use of intelligence and common practice in any safety policy. Be professional and always observe the safety procedure set forth in this manual.

All OSHA, ANSI, state, and local codes and regulations pertaining to this equipment should be obtained, read, and thoroughly understood before attempting to operate this equipment. Persons under the influence of drugs, alcohol, or prescription medication should not be on or near this equipment. Common sense should be times during the use of this equipment. Do not operate this equipment in areas where the equipment or user may come in contact with a live power source.

The information contained herein is not to be for informational purposes only. This information is offered to alert Bil-Jax customers procedures that may be of concern to them.

This information is not intended to be all inclusive and is to b e followed in the use of Bil-Jax equipment only.

For any questions concerning the safe use of this equipment, call 800-937-0540 before operating.

sense in the operation of mechanical equipment is the best

implemented at all

considered as legal advice and is intended

ip-

me-

1-1

XLB-4319

1-2 BEFORE OPERATION

Ensure the following general safety precautions are followed before operating the XLB-4319 Hydraulic Boom Lift.

• ALWAYS survey the usage area for potential hazards such as untamped earth fills, unlevel surfaces, overhead obstructions, and electrically charged conductors or wires. Be aware of any potential hazards and always consider what could happen. Watch for moving vehicles in the operating area.

• ALWAYS read, understand, and follow the procedures in this manual before attempting to operate equipment.

• ALWAYS inspect the equipment for damaged or worn parts. Check for cracked welds, hydraulic leaks, damaged wiring, loose wire connectors, damaged outriggers, low tire pressure, uneven tire wear, or tire damage. Also check for any improper operation. NEVER operate equipment if damaged in any way. Improperly operating equipment must be repaired before using.

• ALWAYS wear proper clothing for the job. Wear protective equipment as required by federal, state, or local regulations. The operator MUST wear a safety harness and lanyard.

• ALWAYS locate, read, and follow all directions and warnings displayed on the equipment.

• ALWAYS inspect the equipment for “DO NOT USE” tags. NEVER use equipment tagged in this way until all repairs are made and all “DO NOT USE” tags are removed by authorized maintenance personnel.

• ALWAYS make sure the basket and outrigger shoes are free of mud, grease, or other slippery material to reduce the possibility of slipping.

• NEVER allow improperly trained personnel to operate this equipment. Only trained and authorized personnel shall be allowed to operate this equipment.

• NEVER operate this equipment if you are under the influence of alcohol or drugs, or if you feel ill, dizzy, or unsteady in any way. Operators must be physically fit, thoroughly trained, and not easily excitable.

• NEVER modify, alter, or change the equipment in any way that would affect its original design or operation in any way.

• NEVER operate this equipment in ways for which it is not intended.

1-2

1 — SAFETY

1-3 DURING OPERATION

Ensure the following general safety precautions are followed during the operation of the XLB-4319 Hydraulic Boom Lift.

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 (10 feet minimum) and always allow for platform movement such as wind induced sway. Always contact the power company before performing work near power lines. Assume every line is hot. Remember, power lines can be blown by the wind.

Refer to Table 1-1 for minimum safe approach distances between machine and electrical power lines.

Table 1-1. Minimum Safe Approach Distances

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)

• ALWAYS position lift far enough away from power sources to ensure that no part of the lift can accidentally reach into an unsafe area. This includes full extension of the boom through 360 degrees rotation.

• ALWAYS operate only on a firm and level surface. NEVER use on surfaces that do not support the equipment with its rated load capacity and the resulting force exerted on the outriggers during boom extension and rotation.

• ALWAYS keep yourself and all personnel away from potential pinch or shear points.

• ALWAYS report any misuse of equipment to the proper authorities. Horseplay is prohibited.

• ALWAYS maintain good footing on the work platform. NEVER wear slippery soled shoes.

• ALWAYS make certain all personnel are clear and there are no obstructions before repositioning basket.

• ALWAYS cordon off area around the outriggers to keep personnel and other equipment away from it while in use.

• ALWAYS stay clear of wires, cables, and other overhead obstructions.

• ALWAYS engage the boom travel locking pins before towing the trailer.

1-3

XLB-4319

• NEVER allow electrode contact with any part of the basket if welding is being performed from the platform.

• NEVER use without the outriggers fully extended and firmly based.

• NEVER override or by-pass manufacturer's safety devices.

• NEVER attach a safety harness to an adjacent structure, pole, or equipment

while working from the boom platform.

• NEVER move unit with a person or materials on board.

• NEVER try to move the trailer with the boom extended.

• NEVER stand or sit on cage bars. Work only within the work cage and do not

lean out over the cage to perform work.

• NEVER attempt to increase working height with boxes, ladders, or other means.

• NEVER operate this equipment when exposed to high winds, thunderstorms,

ice, or any other weather conditions that would compromise operator safety.

• NEVER allow ropes, electric cords, hoses, etc. to become entangled in the equipment when the basket is being raised or lowered.

• NEVER exceed manufacturer's load limits or use the lift as a crane for lifting heavy materials. Make sure all tools and equipment are safely stowed.

• NEVER exceed load ratings by transferring loads to the basket at elevated heights.

• NEVER use cage to carry materials and never allow overhang of materials when raising or lowering the basket.

• NEVER push or pull with the boom or basket and NEVER use the boom to lift any part of the trailer.

• NEVER use the boom or basket to place a “dead man” load against any structure, materials, or equipment.

• NEVER climb up or down boom.

• NEVER leave the keys in the boom lift while unattended or not in use.

1-4

1 — SAFETY

1-4 MAINTENANCE SAFETY

Ensure the following safety precautions are observed whenever maintenance is performed on the XLB-4319 Hydraulic Boom Lift.

General Maintenance

• ALWAYS perform maintenance procedures according to manufacturer's requirements. NEVER short change maintenance procedures.

• ALWAYS check hydraulic system. Make sure all lines, connectors, and fittings are tight and in good condition.

• ALWAYS turn the key switch off before connecting or disconnecting wiring to or from valve solenoids or other load devices.

• ALWAYS disconnect power to the hydraulic pump drive motor before making electrical checks of the hydraulic valves.

• ALWAYS keep all mechanisms properly adjusted and lubricated according to maintenance schedule and manufacturer’s specifications.

• ALWAYS perform a function check of operating controls before each use and after repairs have been made.

• ALWAYS locate and protect against possible pinch points prior to performing maintenance and repairs.

• ALWAYS use factory-approved parts to repair or maintain this equipment. If this equipment is rebuilt, retesting is required in accordance with factory instructions.

• NEVER allow water or foreign particles into the DC electric motor housing. Ingestion of water or foreign particles may cause serious damage to the motor. If the motor gets wet, oven dry the motor to remove all moisture before operating; consult motor manufacturer for drying instructions.

• NEVER test or operate the hydraulic components when another person is near the equipment.

• NEVER add unauthorized fluids to the hydraulic system or battery. Check original manufacturer specifications.

• NEVER exceed the manufacturer's recommended relief valve settings.

• NEVER touch or allow metal tools to contact static discharge sensitive elec-

tronic components. ALWAYS use static discharge prevention mats and grounding devices when handling electronic components.

• NEVER tamper with cylinder counter balance valves. Contact the Bil-Jax Service Department at 800-537-0540 if the cylinder counter balance valves need adjusting.

• NEVER attempt repairs you do not understand. Consult manufacturer if you have any questions regarding proper maintenance, specifications, or repair.

1-5

XLB-4319

Battery Maintenance

Ensure the following general safety precautions are followed whenever performing battery maintenance on the XLB-4319 Hydraulic Boom Lift.

• ALWAYS check battery acid level daily on the DC model boom lift. Check battery test indicator for proper state of charge on maintenance free batteries before using lift.

• ALWAYS wear safety glasses when working near battery.

• ALWAYS avoid contact with battery acid. Battery acid causes serious burns.

Avoid contact with skin or eyes. If accidental 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.

• NEVER smoke when servicing battery.

• NEVER allow batteries to overcharge and boil.

• NEVER short across battery posts to check for current. NEVER break a live

circuit at battery.

• NEVER jump start other vehicles using boom lift battery.

1-5 DAMAGED EQUIPMENT POLICY

Safety Statement

At Bil-Jax, we are dedicated to the safety of all users of our products. Therefore, all Bil-Jax lifts are designed, manufactured and tested to comply with current applicable Federal OSHA and ANSI codes and regulations.

Damage Policy

There may be occasions when a Bil-Jax lift is involved in an incident that results in structural damage to the lift. This can seriously compromise the ability of the lift to perform in a safe manner. Therefore, whenever a Bil-Jax lift is damaged structurally or when there is the possibility of structural damage (this damage may be internal and is not always visible to the naked eye), Bil-Jax requires that the lift be returned to our facility at 125 Taylor Parkway, Archbold, Ohio, for reconditioning. If you have any questions concerning what constitutes structural damage, please call the Bil-Jax Service Department at 800-537-0540.

Damage Repair Notice

There may be occasions when a Bil-Jax lift is involved in an incident resulting in nonstructural damage. When this occurs and repairs are made by the owner or area distributor, please notify Bil-Jax of these non-maintenance repairs and request a repair form to be filled out and returned to Bil-Jax.

1-6

1 — SAFETY

Bil-Jax, Inc.

125 Taylor Parkway

Archbold, Ohio 43502

Reporting Safety Defects

If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Bil-Jax, Inc.

If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in any individual problems between you, your dealer, or Bil-Jax, Inc.

To contact NHTSA you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (366-0123 in Washington, DC area) or write to:

NHTSA U.S. DEPARTMENT of TRANSPORTATION

Street SW, (NSA-11)

400 7 Washington, DC 20590

You can also obtain other information about motor vehicle safety from the Hotline.

1-7

XLB-4319

1-8

Introduction

2-1

GENERAL DESCRIPTION

The XLB-4319 Hydraulic Boom Lift (Figure 2-1) is designed to position personnel with their tools and equipment at overhead work locations. The work basket load capacity i 450 lbs. During all boom operations, the unit is supported by four extended outriggers.

Two versions of the XLB-4319 boom lift are available – gasoline powered or battery powered. On both versions the hydraulic power unit includes a reservoir, pump, and con trol valves. Three hydraulic cylinders elevate the lower boom, upper boom, and jib boom. A hydraulic motor and worm gear rotates the boom 360° around a vertical axis.

UPPER

BOOM

LOWER

BOOM

WORK

BASKET

JIB

BOOM

XLB-4319

OUTRIGGER

Figure 2-1. XLB-4319 Hydraulic Boom Lift

2-1

XLB-4319

The gasoline powered boom lift (gas model) uses a 4-cycle, 8-horsepower Honda engine. The engine drive shaft is directly coupled to the hydraulic pump. A 12 Volt DC storage battery powers the engine starter circuit. An auxiliary voltage regulator/rectifier provides up to 18 Amps charge current while the engine is running.

The battery powered boom lift (DC model) uses a 24 Volt, 39 Amp, one horsepower, DC motor to drive the hydraulic pump. The DC motor is powered by four 6 Volt DC, 245 Amp-hour, deep charge batteries connected in series. A 40 Amp, automatic, onboard battery charger is provided for recharging the batteries at the end of each work period.

The boom lift is equipped with basket and ground station control panels (Figure 2-2). The control panels include motion enable pushbuttons and proportional hydraulic valves for controlling the direction and speed of boom lift and rotation. The gas model basket station control panel includes an engine start pushbutton. Boom elevation and rotation controls are operational only when the outriggers are correctly extended and the moving boom sections are within a programmed safe operating zone.

GROUND STATION CONTROLS BASKET STATION CONTROLS

Figure 2-2. Basket and Ground Station Controls

2-2

2 — INTRODUCTION

Only one boom motion is permitted at a time, and only as long as the boom is within the safe operating zone (Figure 2-3). When a selected boom motion reaches a safe operating limit, the boom motion ceases and another boom motion must be selected within the safe operating zone.

XLB-4319 SPECIFICATIONS

45.9

42.6

39.4 36

32.8

24.5

26.3 23

19.7

16.4 13

9.8

6.5

3.2 0

9.8 6.5 3.2 0 3.2 6.5 9.8 1 3 16.4 19.7 23

CAPACITY.......................................... 450 LB.

MAXIMUM PLATFORM HEIGHT ....... 37 FT.

WORK HEIGHT .................................. 43 FT.

POWER SOURCE.............................. 24V DC BATTERY OR GAS

FTC

B06-00-0430

Figure 2-3. Safe Operating Zone

Outrigger load sensing interlocks and interlock safety switches prevent all boom lifting operations until the four outriggers are properly extended, the trailer is level, and the full weight of the boom lift is loaded onto the outriggers. An interlock prevents the retracting of any outrigger while the upper or lower boom is raised two inches (50 mm) or more.

Boom elevation speeds are adjustable from zero to 5.3 inches per second (0 to 27 ft/min). A hydraulic hose failure at either retract-cylinder port will cause a counterbalance valve to stop the return oil flow. It is strongly recommended that no one adjust or tamper with these safety devices. If service is required, please notify Bil-Jax for instructions.

Emergency lowering of the basket is by manual valve plungers on the upper and lower boom lift cylinders or by manual operation of a hand pump in the basket. Firmly pushing in and holding a valve plunger manually retracts the boom lift cylinder. Smooth pumping of the hand pump while engaging a single hydraulic valve lever enables boom operation in case of a hydraulic power failure.

The XLB-4319 Hydraulic Boom Lift cylinders will not rust or corrode during storage since the cylinder rod is fully immersed in oil. It is important that the cylinder rods be kept clean and undamaged for the protection of the cylinder head packings.

2-3

XLB-4319

2-2 SPECIFICATIONS

Boom Lift Work Platform

Model Number: XLB-4319 Serial Number ________________ Manufactured by: Bil-Jax, Inc.

125 Taylor Parkway Archbold, Ohio 43502 800-537-0540

Table 2-1. Specifications

Feature Data

Rated Platform Load 450 lbs (204 kg) total Maximum Work Height 43 ft (13.1 m) Extended Basket Height 37 ft (11.3 m) Maximum Outreach 19 ft (9.8 m) Elevation Rate, Nominal Horizontal Reach 19 ft (5.9 m) Boom Rotation 700° Rotation Speed 318° per minute, nominal Basket Dimensions 51 in. W x 30 in. D x 45 in. H

Power Source, Gas Model 8 Horsepower, 4-Cycle,

Storage Battery, Gas Model 12 Volt DC, 195 Amp Storage

Power Source, DC Model 24 Volt DC, 4 Deep Cycle,

Battery Charger, DC Model 110/120 Volt, 40 Amp Hydraulic Pressure 2756 psi (19,000 kPa) Reservoir Capacity 2.75 Gallons (10.4 Liters) Hydraulic Capacity 7 Gallons (26.5 Liters) Hydraulic Oil Energol HLP-HD46 (BP Oil) Gross Vehicle Weight, DC Model 2860 lbs (1297 kg) Gross Vehicle Weight, Gas Model 3200 lbs (1452 kg) Tongue Weight, DC Model 100 lbs (45.4 kg) Tongue Weight, Gas Model 160 lbs (72.6 kg) Trailer Brakes Mechanical Surge

5.3 in./sec (135 mm/sec) [26.7 ft/min (8.14 m/min)]

(129.5 cm x 76 cm x 114.3 cm)

Gasoline Engine with Remote Start Control and Alternator Circuit

Battery, NAPA P/N 5022NF

245 Amp-hour Batteries

2-4

2 — INTRODUCTION

2-3 WARRANTY

Bil-Jax warrants its boom lifts for one year from the date of delivery against all defects of material and workmanship, provided the unit is operated and maintained in compliance with Bil-Jax’s operating and maintenance instructions. Bil-Jax will, at its option, repair or replace any unit or component part which fails to function properly in normal use.

This warranty does not apply if the lift and/or its component parts have been altered, changed, or repaired without the consent of bil-jax or by anyone other than Bil-Jax or its factory trained personnel, nor if the lift and/or its components have been subjected to misuse, negligence, accident or any conditions deemed other than those considered as occurring during normal use.

Components not manufactured by Bil-Jax are covered by their respective manufacturer’s warranties. A list of those components and their warranties is available upon written request to Bil-Jax.

Bil-Jax shall not in any event be liable for the cost of any special, indirect, or consequential damages to anyone, product, or thing. This warranty is in lieu of all other warranties expressed or implied. We neither assume nor authorize any representative, or other person, to assume for us any other liability in connection with the sale, rental, or use of this product.

2-5

XLB-4319

2-6

Operation

3-1

OPERATOR CONTROLS

The XLB-4319 Hydraulic Boom Lift is equipped with ment power and outrigger controls are located at ground level. Boom lift and rotation controls are located at ground leve

Ground Control Station

The ground control station (Figure 3-1) operates the outriggers and lift booms. To access the boom controls, reach into the cover latch port and release the cover latch according to the latch decal. Open the control compartment cover. Unhook the support rod behind the front edge of the cover and place the rod end into the mating hole in the battery bracket.

GROUND

CONTROL

STATION

l and in the basket.

multiple operator controls. Equip-

CONTROL

COMPARTMENT

COVER

LATCH

DECAL

COVER

LATCH

PORT

Figure 3-1. Ground Control Station Access

3-1

XLB-4319

The ground control station (Figure 3-2) includes the following electrical and hydraulic controls.

BOOM OPERATOR

LEVERS

Key Switch

OUTRIGGER INDICATORS

KEY

SWITCH

EMERGENCY

STOP

PUSHBUTTON

OUTRIGGER

OPERATOR

LEVERS

Figure 3-2. Ground Control Station

OUTRIGGERS

RUN

PUSHBUTTON

BOOM

RUN

PUSHBUTTON

Turning the key switch to the left selects o

peration from the basket control station. Turning the key switch to the right selects operation from the ground control station. The center (Off) position disables electrical and

hydraulic operations. Removing the key protects

against unauthorized boom lift operation.

EMERGENCY STOP Pushbutton

When pressed, the EMERGENCY STOP pushbutton disconnects electrical powe

r from the upper and lower control stations. Pressing the EMERGENCY STOP pushbutton also shuts off the gasoline eng

ine or DC motor to interrupt hydraulic power. Before you can

restore power, you must rotate the EMERGENCY STOP pushbutton clockwise.

Outrigger Indicators

Four green OUTRIGGER indicators l and the boom weight is removed f

ight up when the boom lift outriggers are extended

rom the trailer axle. All four indicators must be lit and

the trailer must be level to enable operation of the lift booms.

3-2

3 — OPERATION

Outriggers Run Pushbutton

Holding the black outriggers run pushbutton in enables operation of the outrigger cylinders. The outrigger cylinders can only be operated when the lift boom cylinders are retracted.

Boom Run Pushbutton

Holding the green boom run pushbutton in enables operation of the lift boom cylinders. The lift boom cylinders can only be operated when the outrigger cylinders are extend

ed,

the boom weight is removed from the trailer axle, and the trailer is level.

Outrigger Operator Levers

Four outrigger operator levers position the hydr rigger cylinders. Lifting an o Pushing down on an operato

perator lever retracts the cylinder to raise the outrigger.

r lever lowers the related outrigger. When released, the op-

erator levers return to the center (valve-off) position. Starting on your left, the outrigger

aulic valves to extend and retract the out-

s are numbered 1 through 4. A decal located below the outrigger valve manifold indicates which operator lever controls which outrigger.

Boom Operator Levers

Four boom operator levers position proportional hydraulic valves to extend and retract the boom lift cylinders

and the boom rotation drive motor. Pulling a boom operator lever extends the cylinder to raise the boom. Pushing a boom operator lever lowers the related boom. How far the lever is pushed or pulled controls the boom lift speed.

Pulling the boom

rotation operator lever turns the boom clockwise. Pushing the operator lever turns the boom counterclockwise. How far the lever is pushed or pulled controls the boom rotation speed.

When released, the boom operator levers return to the center (valve-off) position. A dec

al located in front of the valve manifold shows which boom motion is controlled by each operator lever.

Engine Keyswitch (Gas M

On the gas model start and stop

boom lift, the engine keyswitch (Figure 3-3) is used to

the gasoline engine from ust be in the ON position

odel only)

the ground position. The keyswitch m

(as shown) to enable engine start-up from the work basket control station.

ENGINE

KEYSWITCH

Figure 3-3. Engine Keyswitch

3-3

XLB-4319

Basket Control Station

The basket control station (Figure 3-3) operates the hydraulic boom lift, boom rotation. and basket rotation motions. The basket control station includes the following electrical and hydraulic controls.

ENGINE START

BOOM RUN

PUSHBUTTON

HYDRAULIC

HAND PUMP

EMERGENCY

STOP PUSHBUTTON

PUSHBUTTON

(GAS MODEL ONLY)

AUDIBLE

ALARM

BOOM

OPERATOR LEVERS

115 VOLT

OUTLET

Figure 3-4. Basket Control Station

EMERGENCY STOP Pushbutton

When pressed, the EMERGENC

Y STOP pushbutton disconnects electrical power from the upper and lower control stations. Pressing the EMERGENCY STOP pushbutton also shuts off the gasoline engine or DC motor to interrupt hydraulic power. Before you can restore power, you must rotate the EMERGENCY STOP pushbutton clockwise.

Boom Run Pushbutton

Holding the green boom run pushbutton in enables operation of the boom lift and rotation functions. Boom lift and rotation can only be operated when the outrigger cylinders are extended, the boom weight is supported by all four outriggers, and the trailer is level.

3-4

3 — OPERATION

Boom Operator Levers

Five boom operator levers position proportional hydraulic valves to extend and retract three boom lift cylinders, the boom rotation drive motor, and the basket swivel cylinder. Pulling a boom operator lever extends the cylinder to raise the boom. Pushing a boom lift operator lever lowers the related boom. How far the lever is pushed or pulled controls the boom lift speed.

Pulling the boom rotation or basket rotation operator lever turns the boom or basket clockwise. Pushing the operator lever turns the boom or basket counterclockwise. How far the lever is pushed or pulled controls the rotation speed.

When released, the boom operator levers return to the center (valve-off) position. A decal located in front of the valve manifold shows which boom motion is controlled by each operator lever.

Hydraulic Hand Pump

The basket control station is equipped with a hydraulic hand pump. In case lift boom operating power is lost, the hand pump is available to manually lower the lift boom. Holding the related operator lever in position and smoothly operating the hand pump lowers the lift boom or swivels the work basket to another position.

Engine Start Pushbutton (Gas Model only)

Pressing the engine start pushbutton restarts the gasoline engine while in the work basket. The pushbutton should only be pressed until the engine starts. The engine should not be cranked longer than 15 seconds at a time. Over-cranking will burn up the starter motor.

Audible Alarm

An audible alarm is located in the basket station control panel. The audible alarm sounds whenever the key switch is on and the boom lift is out of level.

115 Volt Outlet

The 115 Volt AC outlet is provided for running electrical power tools in the work basket. A connecting power cord must be plugged in to a suitable power source. The power plug is located on the inside of the trailer frame, near the tow end of the trailer. The o utlet is rated for a 15-ampere load. Do not overload the accessory power circuit.

3-5

XLB-4319

3-2 NORMAL OPERATING PROCEDURE

Perform the following procedures to operate the XLB-4319 Hydraulic Boom Lift.

1. Read and follow all safety precautions contained in Section 1 and all responsibilities outlined in the ANSI A92.2 reprint contained in Section 7 of this manual.

2. Position the lift at the work area. Make sure the lift is on a firm and level surface and that there are no potential hazards such as overhead obstructions or electrically charged conductors. Do not operate the lift if such hazards exist.

3. Check the tow trailer and boom lift for damaged or worn parts. Repair or replace parts as necessary. Do not use a damaged boom lift.

4. Apply the trailer parking brake.

5. Lower the trailer tongue jack and unhitch the trailer from the tow vehicle. The trailer must be unhitched before the outriggers are lowered.

6. See Figure 3-4 and lower the boom lift outriggers as follows: a. Start the engine or motor. b. Turn the key switch to the ground control position. c. Press and hold in the black outrigger run pushbutton.

KEY

SWITCH

BUBBLE

LEVEL

INDICATOR

OUTRIGGERS

RUN

PUSHBUTTON

OUTRIGGER

OPERATOR

LEVERS

Figure 3-5. Outrigger Controls

3-6

3 — OPERATION

WARNING

Always verify that the green outrigger LEDs light up when the outrigger feet become loaded. If an outrigger LED fails to light up or lights up before the outrigger foot becomes loaded, the limit switch or switch setting is faulty. Using the boom lift with a faulty limit switch or switch setting can cause severe injury, death, or damage to the equipment.

d. Push down on the rear outrigger levers (1 & 2) to lower the rear outriggers.

Lower the rear outriggers only until the rear outrigger LEDs light up on the control panel.

e. Push down on the front outrigger levers (3 & 4) to lower the front outrig-

gers. Raise the trailer wheels off the ground. Verify that the front outrigger LEDs light up on the control panel.

f. Watch the bubble level indicator and adjust the outriggers as needed to

level the trailer.

NOTE: An LED level switch and four outrigger position switches prevent boom

motions if the trailer is not level or if one or more outriggers is not supporting the vehicle load. The load of the boom lift vehicle must be placed on all four outriggers and the trailer must be level to enable motorpowered boom lift operations.

7. Remove the keeper pins and transport pins that secure the upper and lower booms. Stow the transport pins in the retainer clips provided.

8. Use the ground control station to operate the boom lift controls. Raise, lower, and rotate the boom to get familiar with the controls. Learn to smoothly start and stop all boom motions.

9. Lower the boom sections to position the basket for boarding. Turn the key switch to the basket control position.

10. Raise the safety bar and enter the basket. Put on the safety harness and attach the lanyard to the attachment position on the basket railing. Operate the boom lift carefully.

11. When boom lift operations are complete, retract the boom and outriggers for trailer towing according to the following procedure:

a. Using the basket control station, rotate the basket to the center position. b. Fully retract the jib boom, the upper boom, and the lower boom. c. Exit the basket and turn the key switch to the ground control position. d. Retract the two rear outriggers until the trailer tires touch. Do not fully re-

tract the rear outriggers. e. Retract the front outriggers until fully raised. f. Retract the rear outriggers until fully raised. g. Prior to towing, install the transport pins and keeper pins to secure the up-

per and lower booms. Refer to paragraph 3-6 for towing instructions.

3-7

XLB-4319

3-3 EMERGENCY LOWERING

The XLB-4319 Boom Lift is equipped with two manual lowering valves and a hydraulic hand pump. These devices can be used to lower the basket in case of a power failure, a load shift, or other emergency situation.

The manual lowering valves are located on the upper and lower boom lift cylinders and are manually operated from the ground. The hydraulic hand pump is located in the work basket. Use the hand pump in case an assistant is not available on the ground.

To lower the work basket from the ground, push in the valve plunger (Figure 3-6) on the lower boom lift cylinder. Continue pushing the valve plunger to fully retract the lower boom. Push in and hold the valve plunger on the upper boom lift cylinder until the upper boom is retracted.

VALVE

PLUNGER

Figure 3-6. Manual Lowering Valve

To manually lower the boom lift from the work basket, push the upper or lower boom operator lever (Figure 3-7) down and use the hand pump to lower the boom. Apply a steady up-and-down pumping action. The hydraulic cylinders are dual acting; boom motion will continue throughout pump handle operation.

BOOM OPERATOR

LEVERS

HAND PUMP

Figure 3-7. Basket Control Station

3-8

3 — OPERATION

3-4 MANUAL BOOM ROTATION

The hydraulic boom lift is equipped with an emergency rotation handle (crank) that can be used to rotate the boom in case of a power failure or other emergency situation.

Use the following procedure to manually rotate the boom:

1. Remove the crank from its stowage rack and install the crank on the hex end of the worm gear drive screw (Figure 3-8).

2. Hold the boom rotation valve lever in the correct position for boom rotation and turn the crank to rotate the boom.

BOOM ROTATION

VALVE LEVER

BOOM ROTATION

CRANK

Figure 3-8. Emergency Rotation

3-9

XLB-4319

3-5 BATTERY RECHARGE (DC MODEL ONLY)

The DC model boom lift batteries should be recharged after each 8-hour work shift or more often if needed. When the boom lift is not in use, the batteries should be recharged at least once per week.

The normal charge time is 10 to 12 hours. If the battery charge is extremely low, a full recharge may take up to 24 hours.

Recharge the DC model boom lift batteries as follows:

WARNING

Recharge the batteries in a well ventilated area only. Do not charge batteries near fire, flame, or other ignition sources. Batteries being charged may emit highly explosive hydrogen gas. Failure to properly ventilate the charge gases may result in serious injury or death.

1. Move the boom lift to a well ventilated area with direct access to a grounded 120 VAC electrical outlet. Make sure the recharge area is not near fire, flames or other ignition sources.

2. Plug a short, heavy-duty power cord into the battery charger receptacle on the electrical cord connected to the charger. The recommended power cord should be an 12 AWG multi-strand, grounded cord no longer than 50 feet (16 meters).

NOTE: Using an underrated or long power cord will reduce the output of the

battery charger, resulting in longer charge time.

3. Plug the power cord into a grounded 120 VAC receptacle. Verify that the red ON-CHARGING indicator LED lights up on the battery charger.

4. To determine the charge rate at any time during the charge cycle, observe the DC ammeter (Figure 3-9). The ammeter needle moves to the right at the start of the charge cycle. As the battery charge rises, the needle moves farther left.

Figure 3-9. Battery Charger

3-10

3 — OPERATION

CAUTION

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

5. Inspect the charge indicator LEDs near the end of the expected charge cycle. If all indicator LEDs are off, the battery is fully charged. (The DC ammeter needle should point to the left.)

NOTE: The yellow 80% CHARGE indicator lights up when the battery voltage is

nearing full indicator lig

If the battery voltage does not reach the 80% CHARGE level in 14 hours,

the charger turns off and the red CHECK BATTERY indicator LED lights up. This prevents extended charging of a faulty battery.

6. Unplug the power cord from the 120 VAC receptacle and the charger receptacle. Properly store the power cord for next

charge. At full charge (3-1/2 hours after the 80% CHARGE

hts up), the charger turns off.

3-6 BOOM LIFT TRA

The boom lift trailer is a single axle trailer fitted with a two-inch ball hitch, surge brakes, brea

kaway safety cable, safety chains, brake lights, and side marker lights. Proper boom

lift t

ransport requires the correct hookup and inspection of these trailer components be-

fore towi hitch, tow, and back the boom lift trailer:

ng. Use the following procedures to

use.

NSPORT

Traile

Trai give tow vehicle backing instructions.

r Hitching

ler hitching requires a second person to

1. Back the tow vehicle to the trailer. Verify that the ball and hitch are in lin e and that the trailer hitch will clear

2. Align the ball and hitch (Figure 3-10). Fasten the breakaway safety cable to the tow vehicle.

PARKING

BRAKE

BALL AND

HITCH

PO E

W R

PLUG

SAFETY

CHAINS

the ball. Jack up the tongue as needed.

JACK IN

PIVOT

LOCKING

BREAKAWAY

SAFETY CABLE

JACK IN

RAISED

POSITION

Figure 3-10. Trailer Hitching

3-11

XLB-4319

3. l

Ho d ball hitch release lever open and lower the hitch onto the ball. Let go of the release lever to secure the ball.

4. the tow

Crank the jack down to check for secure coupling. If jacking will raise vehicle bumper two or three inches, the ball hitch coupling is secure.

5. Release the trailer parking brake.

6. Pull the pivot locking pin. Swivel the jack 90 degrees to the travel position and release the pivot locking pin.

CAUTION

Always cross and attach the safety chains before towing. Failure to attach safety chains properly will allow tongue to drop in case of ball hitch failure, resulting in serious damage to the trailer and equipment.

7. Attach the trailer safety chains to the tow vehicle. Make sure the chains cross under the trailer tongue. If needed, cross the chains over then under the tow bar to prevent dragging.

8. Connect the trailer lights to the tow vehicle power plug.

9. Check the breakaway safety cable. If the safety cable does not have adequate slack, the brakes may drag.

10. Before towing the trailer, check the following and make all necessary adjustments, corrections, or repairs:

a. Check that the trailer jack and outriggers are in their travel positions. b. Verify that the transport pins and pin keepers secure the upper and lower

booms. If the booms are not secured, install the transport pins and pin keep-

ers at this time. c. Verify that the basket is centered and that all onboard equipment is secured. d. Check that the key switch is in the OFF position. Remove the key. e. Verify that trailer brake lights and marker lights work properly. f. Check that the trailer tires are evenly inflated and not low on air.

WARNING

Improper tightening of boom lift trailer wheel nuts can cause wheel lugs to shear, causing serious injury or damage to equipment. Check and maintain the proper wheel nut torque according to the maintenance instructions in this manual.

Periodically check the wheel nut torque according to the instructions in Section 4 of this manual. More frequent torque checks are required when a wheel is recently installed.

Prior to towing, while the trailer wheels are elevated for boom lift operation, check for loose wheels and for wheel lug wear indications. If a loose wheel mounting is indicated, remove and inspect the wheel lugs for damage. Do not tow the boom lift with worn or damaged wheel lugs.

3-12

Maintenance

4-1 ECKS

SCHEDULED SERVICE CH

Daily/Weekly Service Checks

Perform the following -1.

Check to see that all decals are present.

Check that controls and indicators at ground and basket control stations operate properly.

Raise booms and press emergency stop pushbutton. Verify that booms remain elevated and do not drift down.

Check that boom down limyit switch and outrigger position

Check/add hydraulic oil.

Check/add engine oil.

Check engine air filter element. Clean or replace dirty or damaged air filter element.

Check trailer tires for proper inflation. When cold, tires should be inflated to 55 psi (3.8 bar).

Check trailer running lights for proper operation.

Check battery electrolyte level. If battery charge is low, add water to bring electrolyte just above plates. If batteries a fully charged, raise electrolyte to full mark in each cell.

Check trailer hitch components for damage and proper operation. Refer to Trailer Hitching in paragraph 3-6.

Check electrical wiring for cuts, loose terminals, broken wires, chaffing, corrosion, or other damage. Repair all damage, remove corrosion, and seal exposed connections.

Lubricate grease fittings labeled LUBRICATE WEEKLY with NLGI Grade 2 multi-purpose grease.

Check trailer and boom lift for missing or loose hardware. Replace or tighten missing or loose hardware as needed.

daily/weekly service checks as listed in Table 4

Table 4-1. Daily ks

Service Check

. switches operate properl

/Weekly Service Chec

Daily

before use Weekly

4-1

XLB-4319

Monthly Service Checks

Perform the following monthly service checks as listed in Table 4-2.

Table 4-2. Monthly Service Checks

Service Check

month

Check/add hydraulic oil per paragraph 4-4.

Clean battery terminals and battery charger operation.

Check operation of manual lowering valves and hand pump.

Check wheel nut torque per paragraph 4-2.

Lubricate compartment hinges and latches with light weight machine oil.

Lubricate grease fittings labeled LUBRICATE MONTHLY per paragraph 4-3.2.

Lubricate trailer tongue jack (2 places) with NLGI Grade 2 multi-purpose grease.

Lubricate grease fittings labeled LUBRICATE SEMI-ANNUALLY per paragraph 4-3. 3.

Change engine oil.

Check battery cables and wiring for loose connections and damaged wires.

Replace spark plug.

Replace hydraulic oil and oil filter.

Check boom pivot pin and sleeve bearings for wear. Replace worn or damaged pivot pins and sleeve bearings.

Check slew bearing for wear or damage per paragraph 4-5.

Inspect and adjust trailer brakes.

Load test boom lift operations with 450 pounds (204 kg).

Every

6 months

Every

12 months

4-2

4 — MAINTENANCE

4-2 WHEEL NUT TORQUE REQUIREMENTS

It is very important to apply and maintain the correct wheel bolt torque on the boom lift trailer. The wheel bolts must be evenly tightened to the following specified torque increments whenever a trailer wheel is removed and installed. Use the following tightening procedure:

1. Evenly tighten the wheel bolts to 25 lb-ft (34 N shown in Figure 4-1.

·m) in the tightening sequence

Figure 4-1. Wheel Bolt Tightening Sequence

2. Evenly tighten the wheel bolts to 60 lb-ft (81,4 N quence shown.

3. Evenly tighten the wheel bolts to 100 lb-ft (135,6 N quence shown.

·m) using the tightening se-

4-3

XLB-4319

4-3 LUBRICATION

Lubrication makes operation of the XLB-4319 Boom Lift more efficient and extends the equipment life. Use the following procedures to lubricate the boom lift components.

1. Lubricate trailer jack post and all grease fittings labeled LUBRICATE WEEKLY with NLGI Grade 2 multi-purpose grease.

2. Lubricate all LUBRICATE MONTHLY grease fittings with NLGI Grade 2 multi-purpose grease. Wipe off dirt and grease residue. Add approximately ½ ounce (15 cc) of grease to each fitting. See Figure 4-2 for grease fitting locations.

GREASE

FITTINGS

Figure 4-2. Lubricate Monthly

3. Lubricate the slew ring bearing grease fitting (Figure 4-3) with NLGI Grade 2 multi-purpose grease. Wipe off dirt and grease residue. Rotate the boom and add approximately ½ ounce (15 cc) of grease to each bearing quadrant.

GREASE

FITTING

GREASE

FITTINGS

Figure 4-3. Lubricate Semi-Annually

4-4

4 — MAINTENANCE

4-4 HYDRAULIC SYSTEM

Hydraulic system maintenance varies with equipment use and the environment in which the boom lift is used. Constant attention to keep the oil clean and the reservoir properly filled will help prevent possible damage to the system. Hydraulic diagrams are provided in this section for general reference.

WARNING

Hydraulic system pressure settings are factory settings and should not need readjustment. The only time readjustment is needed is when a component in the hydraulic control circuit is replaced. Only the adjustments covered in this manual are permitted. If you believe that any other hydraulic component needs adjustment, notify Bil-Jax for additional instruction. Hydraulic motions are quiet, quick, and can be dangerous to persons on or near the lift vehicle. Failure to heed this warning can result in serious injury or death.

Hydraulic System Inspection

Check the hydraulic hose and fittings for leaks and damage daily. Tighten or replace as necessary to prevent hydraulic oil loss. Secure hoses and lines as needed to prevent rubbing and chafing.

Fluid Check and Replacement

The oil level should be checked with the engine or motor off, the boom down, and the trailer on a level surface. Pull the dipstick out of the reservoir (Figure 4-4) and wipe off any oil with a clean shop cloth, then reinsert the dipstick. Pull the dipstick to check the oil level. The oil level should be between the full and add oil marks on the dipstick.

DIPSTICK

HYDRAULIC RESERVOIR

Figure 4-4. Hydraulic Reservoir

4-5

XLB-4319

Do not mix hydraulic oils. The reservoir is originally filled with Energol HLP-HD46, a high-grade, non-foaming hydraulic oil designed for temperatures as low as -20°F (- 33°C). For temperatures reaching -40°F (-40°C), use Dextron Automatic Transmission Fluid Type A.

If either oil is not available, a good grade SAE 10W hydraulic oil may be used where the low temperature is above 32°F (0°C). SAE 5W hydraulic oil may be used where low temperatures reach 0°F (-18°C).

Once a year or whenever the oil becomes contaminated, drain the reservoir, clean the sump strainer, and replace the hydraulic oil and return filter.

Return Filter Replacement

The hydraulic oil filter should be replaced yearly or whenever filter contamination has a noticeable effect on the beam lift functions. If return filter clogging is suspected, check the system hydraulic pressure.

With engine or motor running and no controls actuated, hydraulic system pressure should be near 0 (zero), or minimal. If the pressure exceeds 30 psig (2 bar) (200 kPa gage), the return filter should be replaced as follows:

1. Use cleaning cloths and alcohol solvent to clean away dirt on filter cover and housing (Figure 4-4). Be sure to place reusable components on new cleaning cloths. Do not allow filter parts to become contaminated.

2. Use a wrench to loosen filter cover.

3. Remove filter cover. Place reusable filter parts on new cleaning cloths.

4. Lift filter element and element holder above reservoir oil level. Drain residual oil back into filter housing.

5. Remove and discard used filter element.

6. Locate OUT marking on one end of new filter element.

7. With OUT end up, seat new filter element in center of filter holder.

8. Seat filter holder and element in filter housing.

9. Wipe o-ring and mating seal surface of cover with cleaning cloth. If o-ring is cut or gouged, replace o-ring.

10. Install and hand tighten filter cover. Do not over-tighten filter cover.

Air Bleeding

Delayed response or sporadic boom lift motions may indicate air in the lift cylinders. Use the following procedure to bleed entrapped air from the hydraulic system.

1. Fill the reservoir with the proper hydraulic fluid. Replace, but do not tighten the reservoir fill cap.

2. Fully raise and lower the boom to return oil with entrapped air to the reservoir.

3. Allow several minutes for air to escape the reservoir oil.

4. Repeat steps 1 through 3 as needed. Add oil slowly and only when the boom is lowered to prevent adding more air to the system.

4-6

4 — MAINTENANCE

Hydraulic Pressure Checks and Adjustments

Hydraulic pressures are set at the factory and should not be adjusted unless a hydraulic component has been replaced in the regulated circuit.

On the gas engine model a pressure test port (Figure 4-5) is located at the ground station boom control valves. A hydraulic pressure gage [0-6000 psig (0-400 bar) (41 000 kPa gage) minimum range] must be connected to the test port when adjusting hydraulic pressures. This is the only pressure test port on the boom lift.

On the DC model boom lift, the main bypass valve and pressure test port are mounted on the hydraulic manifold located between the hydraulic pump and reservoir. To prevent tampering, the main bypass valve cap is secured with locking wire and a seal. If a pressure adjustment is required, call Bil-Jax and request a replacement lock wire and seal.

The boom lift has four bypass valves that regulate hydraulic operating pressures. These include (1) the main bypass valve, (2) the outriggers bypass valve, (3) the basket station boom controls bypass valve, and (4) the ground station boom controls bypass valve.

Check/Adjust System and Outriggers Hydraulic Pressures

The system hydraulic pressure (pump output pressure) is regulated by the main bypass valve. The system hydraulic pressure is used to power all hydraulic operations. The main bypass valve and pressure test port for the gas model boom lift are shown in (Figure 4-5).

MAIN

BYPASS

VALVE

PRESSURE

TEST PORT

Figure 4-5. Main Bypass Valve and Pressure Test Port

(Gas Engine Model)

4-7

XLB-4319

To adjust the system hydraulic pressure, we must first set the outriggers bypass pressure very high. This ensures that you are reading system pressure when fully retracting an outrigger cylinder. After adjusting the system pressure, we must readjust the outriggers bypass pressure to specification.

Adjust System Pressure

1. Connect a hydraulic pressure gage to the pressure test port.

2. Remove the cap from the outriggers bypass valve (Figure 4-6). Turn the adjust screw to the right exactly two turns. This adjustment will allow the main bypass valve to regulate the test pressure.

3. Reinstall and tighten the cap to prevent oil leakage. Do not over tighten the cap.

OUTRIGGERS

BYPASS VALVE

Figure 4-6. Outriggers Bypass Valve

4. Start the gasoline engine or DC motor. Run the engine or motor for at least five minutes to warm the hydraulic oil to the normal operating temperature.

5. Pull up one outrigger control lever to fully retract the outrigger. While the outrigger control lever is pulled up, read the pressure gage. If the pressure is rising, allow the pressure to reach its highest reading.

6. On the gas model boom lift, if the pressure gage reading is 3045 psig [210 bar (21 000 kPa)] nominal, no adjustment is required. If an adjustment is required, proceed with step 8.

7. On the DC model boom lift, if the pressure gage reading is 2750 psig [190 bar (19 000 kPa)] nominal, no adjustment is required. If an adjustment is required, proceed with step 8.

NOTE: Loosening the adjust lock nut will cause hydraulic oil to leak from the

main bypass valve. It is recommended that you shut the engine off before making adjustments to the main bypass valve.

8. Press the emergency stop pushbutton to turn off the hydraulic pump.

9. Loosen the adjust lock nut for the main bypass valve.

4-8

4 — MAINTENANCE

10. Use hex wrench to turn the pressure adjust screw. Turn the adjust screw right for higher pressure or left for lower pressure. Turning the adjust screw 1/4 turn will adjust the pressure about 150 psig [10,4 bar (1 037 kPa gage)].

11. Tighten the adjust lock nut.

12. Reset the emergency stop pushbutton and restart the engine or motor.

13. Pull up one outrigger control lever and recheck the system pressure. If the pressure is still too high or too low, repeat the adjustment starting with step 6.

14. When the system pressure is properly adjusted, remove the cap from the outriggers bypass valve (Figure 4-6). Turn the adjust screw to the left two turns.

15. Reinstall and tighten the adjust screw cap. Do not over tighten the cap.

Check/Adjust Outriggers Pressure

1. Pull up one outrigger control lever and read the pressure at the gage. If the gage reading is 2750 psig [190 bar (19 000 kPa)] nominal, no adjustment is required.

2. If the outriggers pressure is too high or too low, remove the cap (Figure 4-6) and adjust the pressure. Turning the adjust screw to the rig ht 1/4 turn will raise the pressure about 150 psig [10,4 bar (1 037 kPa gage)].

3. Reinstall and tighten the adjust screw cap. Do not over tighten the cap.

4. Repeat steps 1 through 3 as needed to properly adjust outrigger pressure.

5. If no other hydraulic pressures are to be checked, shut down the engine or motor and remove the pressure gage.

Check/Adjust Boom Hydraulic Pressure

The hydraulic pressure for the basket station boom controls is regulated by a bypass valve (Figure 4-7) at the front of the basket station valve bank. The hydraulic pressure for the ground station boom controls is regulated by an identical valve at the back of the ground station boom controls. The regulated pressure is used to extend and retract all basket and boom positioning cylinders.

VALVE

CAP

BYPASS VALVE

ADJUST SCREW

Figure 4-7. Boom Control Bypass Valve, Basket Station

4-9

XLB-4319

Check and adjust the hydraulic bypass pressure for the basket or ground station boom controls as follows:

1. Connect a hydraulic pressure gage to the pressure test port.

2. Start the gasoline engine or DC motor. Run the engine or motor for at least five minutes to warm the hydraulic oil to the normal operating temperature.

3. Extend the outriggers to fully support and level the boom lift.

4. Turn the ground control station key switch to basket or ground position, according to which bypass pressure (basket or ground control) is to be adjusted.

NOTE: When adjusting the bypass pressure for the basket station boom controls,

the basket station boom controls must be used. When adjusting the bypass pressure for the ground station boom controls, the ground station boom controls must be used.

5. Push down the lower beam control lever at the basket or ground station and read the pressure gage. If the pressure gage reading is 2750 psig [190 bar (19 000 kPa)] nominal, no adjustment is required. If an adjustment is required, proceed with step 6.

6. Press the emergency stop pushbutton to turn off the hydraulic pump.

NOTE: Removing the adjust screw cap while the hydraulic pump is running will

cause oil to leak from the bypass valve. It is recommended that you shut the engine off before removing the adjust screw cap.

7. Locate the bypass valve for the selected boom control valve bank. Remove the adjust screw cap.

8. Use screwdriver to turn the adjust screw. Turning the adjust screw 1/4 turn to the right will increase the pressure about 150 psig [10,4 bar (1 037 kPa gage)].

9. Reinstall and tighten the adjust screw cap. Do not over tighten the cap.

10. Reset the emergency stop pushbutton and restart the engine or motor.

11. Push the upper or lower beam control lever down at the basket or ground station controls and read the pressure gage. If the bypass pressure is still too high o r too low, repeat the adjustment starting with step 6.

12. If no other hydraulic pressures are to be checked, shut down the engine or motor and remove the pressure gage.

Hydraulic Cylinder Replacement

WARNING

Hydraulic cylinders are heavy and may have hydraulic oil on the surface. Hydraulic cylinders must be secured with lifting straps or tie-downs when removing, installing, and handling. Failure to heed this warning can result in serious injury.

4-10

4 — MAINTENANCE

Boom Lift Cylinder Removal and Installation

WARNING

Make sure the boom and boom cylinder are securely supported before removing the boom cylinder. Failure to do so may cause the boom or boom cylinder to fall. This may cause severe injury or damage to the boom lift.

1. If removing the lower boom lift cylinder, raise the lower boom to just above horizontal and stand a 36 inch (90 cm) long length of 4x4 hardwood shoring on the trailer tongue directly below the lower boom rest plate. Lower the boom onto the shoring. Manually check the stability of the shoring.

2. If removing the upper boom lift cylinder, raise the lower boom about two inches (50 mm) above the boom rest position.

3. Press in and hold the manual lowering valve at the boom lift cylinder that is to be replaced. Bleed off all hydraulic pressure to the cylinder.

4. Refer to Figure 4-8. At the piston rod end of the cylinder, unscrew and remove the keeper pins from both sides of the pivot pin. Thread the removed keeper pin hardware to the boom for use during cylinder installation.

5. Drive out the pivot pin with a hammer and a brass or hardwood drift. Do not allow the free end of the cylinder to fall.

PIVOT

KEEPER

PIVOT

KEEPER

UPPER

BOOM

BLOCK

VALVE

HYDRAULIC

CYLINDER

MANUAL

LOWERING

VALVE

Figure 4-8. Hydraulic Cylinder Removal

4-11

XLB-4319

6. If removing the lower boom lift cylinder, fully retract the cylinder. Use the pivot pin to turn the piston rod pivot boss 90°. Lower the cylinder through the relief slot in the stabilizer beam (not shown).

7. Turn off the key switch and remove the key.

8. Tag the hydraulic hoses that connect to the cylinder valve block. Each valve block port is stamped with an identity number.

9. Place absorbent drip cloths below the cylinder ports. Remove the hydraulic hoses from the lift cylinder. Elevate the hoses to help prevent fluid leakage. Protect exposed hose fittings and cylinder ports with plugs and caps.

10. At the base of the cylinder, unscrew and remove the keeper pins from both sides of the boom pivot pin. Thread the removed keeper pin hardware to the boom for use during cylinder installation.

11. Drive out the pivot pin with a hammer and a brass or hardwood drift.

12. Lift and remove the cylinder using an overhead hoist and lifting straps.

13. After repairing the hydraulic cylinder, reinstall the cylinder in the reverse order of removal.

14. Power up the hydraulic system and check for leakage. Tighten the hydraulic fittings as needed.

15. Bleed entrapped air from the hydraulic cylinder according to instructions in paragraph 4-4.

NOTE: Do not tamper with the cylinder counterbalance or manual lowering

valves. If the valves need adjustment, contact the Bil-Jax Service Department at 800-537-0540.

Outrigger Cylinder Removal and Installation

1. Lower the outrigger until the foot pad meets the floor and supports only the outrigger beam. Leave the weight of the boom lift on the trailer wheels.

2. At the piston rod end of the cylinder, unscrew and remove the keeper pins from both sides of the boom pivot pin. Thread the removed keeper pin screws and keeper pins to the outrigger beam for use during cylinder installation.

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

4-12

4 — MAINTENANCE

4. Drive out the pivot pin with a hammer and a brass or hardwood drift. Do not allow the free end of the cylinder to fall.

5. Fully retract the cylinder.

6. Turn off the key switch and remove the key.

7. Tag the hydraulic hoses that connect to the cylinder valve block. Each valve block port is stamped with an identity number.

8. Place absorbent drip cloths below the cylinder ports. Remove the hydraulic hoses from the lift cylinder. Plug the hose fittings to prevent flu id leakage. Protect exposed cylinder ports with plugs and caps.

9. At the base of the cylinder, unscrew and remove the keeper pins from both sides of the pivot pin. Thread the removed keeper pin screws and keeper pins to the mating beam for use during cylinder installation.

10. Drive out the pivot pin with a hammer and a brass or hardwood drift.

11. Lift and remove the cylinder using an overhead hoist and lifting straps.

12. After repairing the hydraulic cylinder, reinstall the cylinder in the reverse order of removal.

13. Power up the hydraulic system and check for leakage. Tighten the hydraulic fittings as needed.

14. Bleed entrapped air from the hydraulic cylinder according to instructions in paragraph 4-4.

Jib Boom Cylinder Removal and Installation

1. Fully lower the outriggers and the upper and lower boom.

2. Extend the jib beam to raise the basket a few inches.

3. Place shoring under the jib beam. Lower the beam onto the shoring to support the weight of the basket.

4. Place shoring under both rear corners of the basket. Adjust the shoring to relieve any binding torque load on the upper jib beam pivot pins.

5. Remove the four keeper pins from the upper jib beam pivot pins (Figure 4-9). Secure the keeper pins to the mating beam for use during cylinder installation.

4-13

XLB-4319

PIVOT

KEEPER

PINS

KEEPER

(2 PER SIDE)

UPPER JIB

BEAM

PIVOT PIN

JIB BEAM

CYLINDER

PIVOT

KEEPER

PINS

(2 PER SIDE)

Figure 4-9. Jib Boom Components

6. Try to rotate one of the upper jib beam pivot pins with a keeper pin. Adjust the rear basket shoring as needed to enable pivot pin movement.

4-14

4 — MAINTENANCE

7. Remove the upper jib beam pivot pin at the top end of the beam. If needed, drive out the pivot pin with a hammer and a brass or hardwood drift.

8. Before removing the bottom pivot pin, insert a long blade screwdriver through the top pivot pin bores.

9. Remove the pivot pin at the bottom end of the upper jib beam. If needed, drive out the pivot pin with a hammer and a brass or hardwood drift. Remove the upper jib beam.

10. Fully retract the jib beam cylinder. Turn off the key switch and remove the key.

11. Tag the hydraulic hoses that connect to the left and right ports of the cylinder valve block.

12. Sketch the location of wire ties that secure the hydraulic hoses at the cylinder. The hoses must be properly secured to prevent pinching during jib boom operation. Cut the wire ties from the jib boom cylinder hydraulic lines.

13. Place absorbent drip cloths below the cylinder ports. Remove the hydraulic hoses from the jib boom cylinder. Plug the hose fittings to prevent fluid leakage. Protect exposed cylinder ports with plugs and caps.

14. At the top of the cylinder, unscrew and remove the keeper pins from both sides of the boom pivot pin. Secure the keeper pins to the mating beam for use during cylinder installation.

15. Support the weight of the jib boom cylinder using an overhead hoist and lifting straps.

16. Drive out the pivot pin with a hammer and a brass or hardwood drift and remove the jib boom cylinder.

17. After repairing the hydraulic cylinder, reinstall the cylinder in the reverse order of removal.

18. Power up the hydraulic system and check for leakage. Tighten the hydraulic fittings as needed.

19. Bleed entrapped air from the hydraulic cylinder according to instructions in paragraph 4-4.

4-15

XLB-4319

Basket Swivel Cylinder Removal and Installation

1. Fully lower the outriggers and raise the upper boom. Position the basket for easy access to the hydraulic cylinder (Figure 4-10) mounted on the bottom of the work basket.

HYDRAULIC

CYLINDER

KEEPER

Figure 4-10. Basket Swivel Cylinder

2. Place absorbent drip cloths below the cylinder ports. Remove the hydraulic hoses from the jib boom cylinder. Plug the hose fittings to prevent fluid leakage. Protect exposed cylinder ports with plugs and caps.

3. Remove the keeper pins from both ends of the cylinder. Remove the hydraulic cylinder.

4. Secure the keeper pins to the mating beam for use during cylinder installation.

5. After repairing the hydraulic cylinder, reinstall the cylinder in the reverse o rder of removal.

6. Power up the hydraulic system and check for leakage. Tighten the hydraulic fittings as needed.

7. Bleed entrapped air from the hydraulic cylinder according to instructions in paragraph 4-4.

4-16

4 — MAINTENANCE

4-5 SLEW RING BEARING

Check Free Play

Check the free play of the slew ring bearing every six months. If the recommended maintenance schedule is followed, there should be little or no wear of the slew ring bearing. Check the slew ring bearing free play according to the following procedure:

1. Fully retract (lower) the lift booms.

2. Go to the hydraulic reservoir side of the boom lift. Open the power cabinet.

3. Access the top surface of the slew ring gear near the front end (trailer tow end) of the gear. This area is below and behind the hydraulic pump reservoir.

4. Insert a 2-inch (50 mm) caliper or bore micrometer at the top front surface of the slew ring gear.

5. Measure the distance from the top of the slew ring gear to the horizontal plate above the gear (Figure 4-11). Record the measurement.

6. Place a 175 lb (80 kg) load in the boom lift basket.

7. Raise the lower boom until the front of the boom is about 11.5 ft (3,5 m) from the ground.

8. Slowly raise the upper boom and extend the jib boom until both are horizontal.

TOW E

OF TRA

9. Repeat the measurement in step 5. Record the measurement.

10. If the difference between the measurements in step 5 and step 9 is greater than

0.25 inch (6,35 mm) the slew ring bearing should be replaced. Notify Bil-Jax for bearing replacement instructions or assistance.

MEASURE

HERE

ILER

SLEW

RING

Figure 4-11. Slew Ring Position Measurement

4-17

XLB-4319

4-6 LIM

Adjusting Boom Down Limit Switch

When th The boom ggers. The boom down limit switch should trip when the lower boom is within 2 inches (50 mm) of seating on the trailer tongue. You may not be able to extend or retract the outriggers if the boom down limit switch is loose, damaged, or not adjusted properly.

Use the following procedure to readjust the boom down limit switch:

IT SWITCH CHECKS AND ADJUSTMENTS

e upper and lower booms are retracted, the boom down limit switch is actuated.

down limit switch must be actuated to lower or raise the outri

1. Lower the outriggers and raise the lower boom for free access to the limit switch, Figure 4-12.

2. Inspect the limit switch for loose mounting or visible damage. If the mounting hardware is loose, tighten the hardware. If the limit switch is damaged, replace the limit switch.

3. Measure the free height of the limit switch actuator roller. The top of the roller should be 0.75 inch (19 mm) above the limit switch mounting plate. Adjust the actuator position as needed.

4. Fully lower the upper and lower booms.

5. Press the outrigger run pushbutton to verify that the boom down limit switch is engaged. The hydraulic pump motor should run when the outrigger run pushbut ton is pressed.

6. If the pump motor does not run, the limit switch or switch wiring is damaged. Repair or replace a damaged limit switch or wiring, as needed.

Figure 4-12. Boom Down Limit Switch

4-18

4 — MAINTENANCE

Adjusting Outrigger Position Switches

The outrigger position switches are set up to detect when the boom lift load is transferred from the trailer wheels to the outriggers. When the load is transferred to each outrigger, the related position switch is engaged and the related LED lights up on the control panel. All four position switch circuits must be engaged to enable lift boom operation. Use the following procedure to check and adjust the outrigger position switches.

1. Inspect the outrigger position switches for loose mounting or visible damage. If the mounting hardware is loose, tighten the hardware. If a position switch is damaged, replace the switch.

2. Lower the outriggers and raise the trailer wheels off the ground. Verify that all four outrigger LEDs light up.

3. If an LED is lit before the outrigger is lowered or if an LED fails to light when the outrigger is lowered, check the adjustment of the related outrigger position switch as follows:

a. Measure the distance between the actuator roller and the outrigger pivot,

Figure 4-13. The roller should be 1/8 inch (3 mm) from the outrigger pivot. Adjust the actuator as needed.

b. If the actuator is correctly adjusted, but the LED fails to light up or go dim,

check the switch, LED, and wiring. Repair or replace the faulty component. Refer to the detailed electrical diagram in Figure 4-15.

OUTRIGGER

POSITION SWITCH

ACTUATOR

ROLLER

OUTRIGGER

PIVOT

POSITION SWITCH

TRIP POINT

Figure 4-13. Outrigger Position Switch

4-19

XLB-4319

4-7 TROUBLESHOOTING

Table 4-3. Troubleshooting Chart

Problem Cause Correction

1. En gine or motor will not start.

DC model only

Gas model only

2. Pump motor runs, but outriggers will not extend.

DC model only

Gas model only

a. Emergency stop engaged (pushed in).

b. Battery ch arge is low.

c. Battery ground or in-series cable

loose.

d. Main circuit breaker tripped or

switched off.

a. Main disconnect unplugged. b. Fuse F2 burned out. Fuse is mounted

on front inner wall of boom pivot weldment, in series with the positive

battery cable. c. Motor contactor failed. d. Pu mp motor failed.

a. Engine key switch in wrong position. b. Fuel tank empty. c. Engine oil level low. d. Spark plug fouled or damaged. e. Fuse F2 burned out. Fuse is mounted

inside engine key switch housing. f. Starter relay or starter motor failed. a. Basket/ground key switch in wrong

position. b. Hydraulic oil level low.

c. Boom down limit switch or switch

wiring failed. d. Hydraulic gear pump failed.

a. Boom enable valve SV1 faulty (stick-

ing open) (see item 4, Figure 6-19). a. Outrigger enable valve solenoid SV2

failed (see item 6, Figure 6-18). b. Boom enable valve SV1 faulty (stick-

ing open) (see item 1, Figure 6-18).

a. Rotate emergency stop buttons clock-

wise to disengage.

b. Check charge level. Recharge battery

if needed.

c. Check for and repair loose battery

connections or ground fault.

d. Reset main circuit b reaker inside

ground control panel.

a. Plug in main disconnect. b. Correct cause of short circuit and

replace fuse.

c. Replace motor contactor. d. Check pump motor operation; repair

or replace motor if faulty. a. Turn key switch to run position. b. Refill fuel tank. c. Check/add engine oil. d. Check/replace spark plug. e. Correct cause of short circuit and

replace fuse. f. Replace failed starter relay or motor. a. Turn key switch to ground position.

b. Check hydraulic oil level in reservoir.

Add oil as needed. c. Check boom down limit switch and

wiring operation per paragraph 4-6. d. Check pump; replace if hot to touch.

a. Repair or replace faulty valve.

a. Replace faulty wiring or solenoid.

b. Repair or replace faulty valve.

4-20

4 — MAINTENANCE

Table 4-3. Troubleshooting Chart, Continued

3. Pump motor runs, but upper and lower boom lift functions do not work.

4. Pump motor runs, but the upper and lower booms will not retract.

5. Pump motor runs, but the boom rotate function does not work.

a. Basket/ground key switch in wrong

position. b. Boom lift out of level. c. Outrigger not under load.

d. Hydraulic oil level low.

e. Boom enable valve solenoid SV1

failed (see item 1, Figure 6-18 or

item 4, Figure 6-19). f. Hydraulic outp ut filter dirty.

g. Hydraulic gear pump failed. a. Obstruction below basket or boom.

b. Basket/ground key switch in wrong

position. c. Boom lift shifted out of level.

d. Outrigger not under load.

e. Hydraulic oil level low.

f. Boom enable valve solenoid SV1

failed (see item 1, Figure 6-18 or

item 4, Figure 6-19). a. Basket/ground key switch in wrong

position. b. Boom lift out of level. c. Outrigger not under load.

d. Hydraulic oil level low.

e. Rotate obstruction or hard stop

reached. f. Slew ring bearing worn and binding.

a. Turn key switch to enable basket or

ground controls. b. Operate outriggers to level boom lift. c. Check that all outriggers support a

load; adjust outriggers as needed. d. Check hydraulic oil level per para-

graph 4-4. Add oil as needed. e. Replace faulty wiring or solenoid.

f. Check pump output pressure, no load.

Replace filter if pump output pressure

reaches 30 psig (206 kPa gage) with

no hydraulic function selected. g. Check pump; replace if hot to touch.

a. Raise and reposition the boom to

avoid the obstruction. b. Turn key switch to ground or basket

run position. c. If out of level alarm is sounding,

manually lower boom. d. Check that all outriggers support a

load. If not, manually lower boom. e. Manually lower boom. Check oil

level in reservoir; add oil as needed. f. Manually lower boom. Repair faulty

wiring or replace failed solenoid.

a. Turn key switch to ground or basket

position. b. Operate outriggers to level boom lift. c. Check that all outriggers are support-

ing a load; adjust as needed. d. Check hydraulic oil level in reservoir.

Add oil as needed. e. Rotate boom in opposite direction.

f. Retract boom and retry rotation.

Replace slew ring bearing if worn.

6. One hydraulic boom or outrigger function fails to work.

a. Control valve failed; leaking.

b. Cylinder counterbalance valve failed;

leaking.

c. Cylinder failed; leaking.

a. Repair or replace control valve if hot

to touch.

b. Counterbalance valves are in cylinder

manifold blocks. Repair or replace valve if hot to touch.

c. Touch cylinder wall near piston; re-

pair or replace cylinder if hot touch.

4-21

XLB-4319

Troubleshooting Aids

Electrical diagrams are provided in Figure 4-14 through Figure 4-17. Hydraulic diagrams are provided in Figure 4-18 and Figure 4-19. Level sensor LED indications are shown in Table 4-4.

MAIN DISCONNECT

12 VDC

BATTERY

–

E-STOP

PB1

FUSE

MCB

CIRCUIT

BREAKER

PB4

OUTRIGGERS

ENABLE

LEVEL

SENSOR

PB2

MOTOR

CONTACTOR

SW3

BOOM DOWN

LIMIT SWITCH

ALARM

RELAY

RL2

PUMP

MOTOR

AUDIBLE

ALARM

BOOM

ENABLE

VALVE

SV1

BASKET

OFF

GROUND

BASKET/OFF/

GROUND

KEYSWITCH

SW2

Figure 4-14. Simplified Electrical Diagram, DC Model

4-22

BOOM

ENABLE

BOOM

ENABLE

PB7

PB6

E-STOP

BASKET CONTROLS

OUTRIGGER

POSITION

SWITCHES

OUTRIGGER

DOWN LEDs

4 — MAINTENANCE

PLATFORM

CONTROL BOX

BOOM

E-STOP

67814230

AUDIBLE

ALARM

PUMP COMPARTMENT

GROUND CONTROL BOX

KEY

SWITCH

ALARM

OUT-

RIGGERS

E-STOP

RELAY

BATTERY

CHARGER

BOOM DOWN

LIMIT SWITCH

BASKET

GND

BOOM

LEDS

22 21 20 19 3 3 8 7 6 5 4 9 3 0 0 12 1 15 23

MCB

MOTOR

CONTACTOR

PUMP

MOTOR

+–

BATTERIES

OUTRIGGER

POSITION

SWITCHES

Figure 4-15. Detailed Electrical Diagram, DC Model

4-23

XLB-4319

STARTER

–

12 VDC

BATTERY

FUSE

ENGINE

KEYSWITCH

SW2

RELAY

STARTER

MOTOR

CIRCUIT

CB1

BREAKER

ENGINE

START

BASKET CONTROLS

IGNITION UNIT

SPARK PLUG

SW1

KEYSWITCH

BASKET/OFF/GROUND

RUN

LED

E-STOP

PB1

BOOM

ENABLE

PB2

PB5

E-STOP

LEVEL

SENSOR

PB6

BOOM ENABLE

ALARM

RELAY

RL2

AUDIBLE

ALARM

BOOM

ENABLE

VALVE

SV1

BASKET CONTROLS

OUTRIGGER

POSITION

SWITCHES

OUTRIGGER

DOWN LEDs

BASKET

OFF

GROUND

Figure 4-16. Simplified Electrical Diagram, Gas Model

4-24

BOOM DOWN

LIMIT SWITCH

SW3

OUTRIGGERS

ENABLE

PB3

OUTRIGGERS

ENABLE VALVE

SV2

4 — MAINTENANCE

15 A

FUSE

CIRCUIT

BREAKER

BOOM DO

LIMIT SWITCH

ENGINE TO

KEYSWITCH

112

TTERY

12VDC

SW1

OFF/

BASKET/

GROUND

KEYSWITCH

PB1

E-ST

LP1

LED

GROUND

OFF

BASKET

PB3

ENABLE

OUTRIGGERS

RED

1211

WHITE

LEVEL

SENSOR

BLACK

ALARM

E V

SV2

ENABLE

OUTRIGGERS

RL2

RELA

LP2

LP3

OUTRIGGER LIMIT SWITCHES

LP4

LP5

OUTRIGGER LEDs

TERMINAL BLOCK NUMBER

SV1

UDIBLE A

ALARM

ENGINE

COIL

IGNITION

PB5

OLS

E-ST

BASKET CONTR

PB6

ENGINE

PB2

BOOM

ENABLE

STAR

ENABLE

L VA

BOOM

ENABLE

ARTER

ENGINE O

SOLENOID

Figure 4-17. Detailed Electrical Diagram, Gas Model

4-25

XLB-4319

GROUND CONTROL VALVE BANK

TO BASKET CONTROL VALVE BANK

DIVERTER

VALVE

PRESSURE

FILTER

2755 PSI

SUCTION

FILTER

TER FIL

RETURN

2755 PSI

TO UPPER

BOOM LIFT

CYLINDER

FROM RETURN MANIFOLD

OUTRIGGER CONTROL VALVE BANK

BOOM SLEW

TO LOWER BOOM LIFT

CYLINDER

MOTOR

TO JIB

BOOM LIFT

CYLINDER

2755 PSI

OUTRIGGER

CYL. 1

OUTRIGGER

CYL. 4

RET. CYL.

4-26

EXT. CYL.

Figure 4-18. Hydraulic Diagram, DC Model, Sheet 1 of 2

OUTRIGGER

CYL. 2

OUTRIGGER

CYL. 3

4 — MAINTENANCE

EMERGENCY

HAND PUMP

BASKET CONTROL VALVE BANK

FROM

GROUND

CONTROL

VALVE

BANK

CHECK

VALVE

2755 PSI

UPPER

BOOM LIFT

CYLINDER

Figure 4-18. Hydraulic Diagram, DC Model, Sheet 2 of 2

BASKET

SLEW

CYLINDER

LOWER

BOOM LIFT

CYLINDER

JIB

BOOM LIFT

CYLINDER

4-27

XLB-4319

GROUND CONTROL VALVE BANK

TO BASKET CONTROL VALVE BANK

2755 PSI

DIVERTER

VALVE

SV1

PRESSURE

FILTER

3045 PSI

ENGINE

SUCTION

FILTER

RETURN

FILTER

DIVERTER

VALVE

SV2

TO UPPER

BOOM LIFT

CYLINDER

FROM RETURN MANIFOLD

TO LOWER

BOOM LIFT

CYLINDER

BOOM SLEW

MOTOR

OUTRIGGER CONTROL VALVE BANK

TO JIB

BOOM LIFT

CYLINDER

2755 PSI

JACK CYL. 1 JACK CYL. 4

JACK CYL. 2

JACK CYL. 3

Figure 4-19. Hydraulic Diagram, Gas Model, Sheet 1 of 2

4-28

4 — MAINTENANCE

EMERGENCY

HAND PUMP

BASKET CONTROL VALVE BANK

FROM

GROUND

CONTROL

VALVE

BANK

CHECK

VALVE

2755 PSI

UPPER

BOOM LIFT

CYLINDER

LOWER

BOOM LIFT

CYLINDER

BOOM LIFT

CYLINDER

Figure 4-19. Hydraulic Diagram, Gas Model, Sheet 2 of 2

BASKET

SLEW

CYLINDER

JIB

4-29

XLB-4319

YELLOW LED

OUT OF LEVEL

(MOMENTARY)

GREEN LED

INPUT POWER

RED LED

OUTPUT SIGNAL

(ON WHEN LEVEL)

Figure 4-20. Level Sensor

Table 4-4. Level Sensor LEDs

Color Description

Yellow Boom lift out of level. Signals alarm after 2 second delay. Green Boom lift power is on. Red Boom lift level. Goes out after time delay.

4-30

4 — MAINTENANCE

4-8 MATERIAL SAFETY DATA SHEETS

MATERIAL SAFETY DATA SHEET

FOR LEAD ACID BATTERIES, WET, FILLED WITH ACID

SECTION I: GENERAL INFORMATION

Manufacturer’s Name: Crown Battery Mfg. Company EMERGENCY NO: 800 487-2879 Street Address: 1445 Majestic Drive OR 800 OIL-TANK City, State, Zip Fremont, Ohio 43420 Phone Number: 419 334-7181 REVISION DATE: 5/18/2000

SECTION II: MATERIAL IDENTIFICATION AND INFORMATION

COMPONENTS PERCENT OSHA ACGIH OTHER LIMITS CAS NUMBER Hazardous Components PEL TLV 1% or greater Carcinogens 0.01% or greater

METALLIC LEAD METAL 25.5% 0.05 mg/m3 0.05 mg/m3 LEAD SULFATES 18.2% 0.05 mg/m3 0.05 mg/m3 NONE 7439-92-1 LEAD OXIDES 18.0% 0.05 mg/m3 0.05 mg/m3 NONE 7439-92-1 POLYPROPYLENE CASE MTL 6.4% SEPARATORS 3.5% SULFURIC ACID(H2SO4) 5.2% 1.0 mg/m3 1.0 mg/m3 NONE 7664-93-9 WATER 19.2%

REGULATORY INFORMATION: Those ingredi ents listed above are not subject to the reporting requirements of 313 of Title III of the Superfund Amendments and Reauthorization Act. The items are covered in an exemption as a “Manufactured Article”. 372.30(b)

NONE 7439-92-1

SECTION III: PHYSICAL / CHEMICAL CHARACTERISTICS

Boiling Point Approximately 203F Vapor Density: Greater Than 1 Vapor Pressure 14 @ 37% @ 80 F Melting Point: -36 F to -10.6 F Solubility in Water 100% Water Reactive: Yes, Produces Heat Specific Gravity 1.245 - 1.295 Battery Electrolyte Appearance & Odor Clear Liquid with Sharp Pungent Odor

SECTION IV: FIRE AND EXPLOSION HAZARD DATA:

Flash Point: Not Combustible Auto Ignition Temperature N/A Flammabiltiy Limits in Air % by Volume: N/A Extinguishing Media: Dry Chemical Carbon Dioxide, Water Fog, Water Special Fire Fighting Procedures: Sulfuric Acid Fumes, Sulfur Dioxide Gas or Carbon Monoxide may be released when acid decomposes. Wear NIOSH approved self contained breathing apparatus.

Unusual Hazards: Water applied to sulfuric acid generates heat and causes acid to splatter. Wear full-cover acid resistant clothing. Sulfuric acid reacts violently with metals, nitrates, chlorates, carbides, fulminates, picrates and other organic materials. Reacts with most metals to yield explosive/flammable hydrogen gas. This reaction is intensified when sulfuric acid is dilluted with water to form battery electrolyte.

4-31

XLB-4319

MATERIAL SAFETY DATA SHEET

FOR LEAD ACID BATTERIES, WET, FILLED WITH ACID (Continued)

********************************************************************************************

SECTION V -- HEALTH HAZARD DATA

********************************************************************************************

Primary Routes of Entry: Inhalation: YES Skin: YES Ingestion: YES Health Hazards: Acute EYES, SKIN, RESPIRATORY SYSTEM & DIGESTIVE SYSTEM Chronic: EYES, SKIN, RESPIRATORY SYSTEM & DIGESTIVE SYSTEM Signs and Symptoms of Exposure: IRRITATION OF EXPOSED AREA, BURNS AND RESPIRATORY PROBLEMS NO POSSIBILITY OF EXPOSURE OF LEAD WILL OCCUR UNLESS BATTERY IS DESTROYED. Medical Conditions Generally Aggravated By Exposure: EXPOSURE TO MIST MAY CAUSE LUNG DAMAGE & AGGRAVATE PULMONARY CONDITION. Emergency First Aid Procedures: SEEK MEDICAL ASSISTANCE FOR FURTHER TREATMENT, OBSERVATION AND SUPPORT IF NECESSARY. Eye Contact: WASH WITH COPIOUS QUANTITIES OF COOL WATER FOR AT LEAST 15 MINUTES Skin Contact: FLUSH AREA WITH LARGE AMOUNTS OF COOL WATER FOR AT LEAST 15 MINUTES Inhalation: REMOVE TO FRESH AIR, IF BREATHING IS DIFFICULT - GIVE OXYGEN Ingestion: GIVE MILK TO DRINK,

********************************************************************************************

DO NOT INDUCE VOMITTING. CALL PHYSICIAN

SECTION VI -- REACTIVITY DATA

********************************************************************************************

Stability: STABLE Conditions to Avoid: N/A Incompatibility: AVOID COMBUSTIBLES, ORGANIC MATERIALS, AND STRONG REDUCING AGENTS Hazardous Decomposition Products: SULFUR TRIOXIDE, CARBON MONOXIDE, SULFURIC ACID FUMES, & SULFUR DIOXIDE Hazardous Polymerization: MAY OCCUR Conditions to Avoid: N/A

********************************************************************************************

SECTION VII -- SPILL OR LEAK PROCEDURES

********************************************************************************************

Steps to be taken in case material is released or spilled: CONTAIN SPILL, USING NON-COMBUSTIBLE MATERIALS: VERMICULITE, DRY SAND & EARTH. NEUTRALIZE WITH LIME, SODA ASH, SODIUM BICARBONATE, ETC. Waste disposal method: CONSULT STATE ENVIRONMENTAL AGENCY. INDIVIDUAL STATE REGULATIONS VARY Precautions to be taken in Handling & Storage: SEPARATE FROM INCOMPATIBLE MATERIALS, KEEP AWAY FROM FIRE, SPARKS AND HEAT Other Precautions and/or Special Hazards: CONTACT WITH METALS MAY PRODUCE TOXIC SULFUR DIOXIDE FUMES & MAY ALSO RELEASE FLAMMABLE HYDROGEN GAS. THIS REACTION IS INTENSIFIED WHEN DILUTED. NFPA Rating: HEALTH: 3 FLAMMABILITY: 0 REACTIVITY: 2 SPECIAL: 0 HMIS Rating: HEALTH: 3 FLAMMABILITY: 0 REACTIVITY: 2 PERSONAL PROTECTION: X

********************************************************************************************

SECTION VIII -- CONTROL AND PROTECTIVE MEASURES

********************************************************************************************

Respiratory Protection: ABOVE P.E.L.: NIOSH APPROVED, FITTED, FULL FACE RESPIRATOR Protective Gloves: ACID RESISTANT Eye Protection: FULL FACE PROTECTION Ventilation: LOCAL EXHAUST: VENTILATED AREA PREFERRED MECHANICAL: IF BELOW P.E.L. SPECIAL: MUST BE ACID & EXPLOSIVE RESISTANT OTHER: MUST BE ACID & EXPLOSIVE RESISTANT Other Protective Equipment: ACID RESISTANT CLOTHING AND BOOTS Hygienic Work Practices: N/A

4-32

XLB-4319

MATERIAL SAFETY DATA SHEET

FOR AW–46 HYDRAULIC OIL

1-SITE SPECIFIC INFORMATION: AW-46 HYDRAULIC OIL

2-GENERAL INFORMATION TRADE NAME: AW-46 HYDRAULIC OIL EMERGENCY TELEPHONE NUMBERS: (517) 849-2144 CHEMICAL FAMILY: LUBRICATING OIL CAS NUMBER: MIXTURE: ISSUE DATE 12/15/96 HAZARDOUS INGREDIENTS:

----------------------------------------------------------------------------

CONTAINS NO INGREDIENTS NOW KNOWN TO BE HAZARDOUS AS DEFINED IN OSHA 29 CFR

1910.1000 AND OSHA 29 CFR 1910.1200.

---------------------------------------------------------------------------HEALTH HAZARD DATA THRESHHOLD LIMIT VALUE: 5mg/m3 AS OIL MIST 8 hr, TWA PRIMARY ROUTES OF ENTRY: INHALATION, SKIN ABRASION AND INGESTION. CARCINOGENIC: NO SYMPTOMS IF INGESTED, CONTACTED WITH SKIN, OR VAPOR INHALED: NO ADVERSE EFFECTS EXPECTED. EYES: FLUSH WITH WATER FOR 15 MINUTES SKIN: WASH THOROUGHLY WITH WARM SOAPY WATER. INGESTION: DO NOT INDUCE VOMITTING-SEEK MEDICAL ATTENTION. MEDICAL CONDITIONS AGGRAVATED BY EXPOSURE: NONE KNOWN AIR EXPOSURE LIMITS: P.E.L. NOT ESTABLISHED T.L.V. 5mg/m3 OSHA 29 CFR

1910.1000 HEALTH: 1 FIRE: 1 SPECIFIC: X REACTIVITY: 0

---------------------------------------------------------------------------PHYSICAL DATA: BOILING POINT: 400+ DEG F. VAPOR PRESSURE (PSIA): N/A SPECIFIC GRAVITY (H20=1): 0.87 SOULUBILITY IN WATER: NEGLIGIBLE PH OF CONCENTRATE: N/A APPEARANCE AND ODOR: PALE YELLOW, PETROLEUM ODOR

---------------------------------------------------------------------------FIRE AND EXPLOSION HAZARD DATA FLASH POINT(METHOD USED): 425 DEG F. FLAMMABLE LIMITS: NOT DETERMINED LEL: N/A UEL: N/A EXTINGUISHING MEDIA: SAND, DRY CHEMICAL, FOAM, CO2. TREAT AS CLASS B FIRE. UNUSUAL FIRE AND EXPLOSION HAZARDS: NONE

---------------------------------------------------------------------------REACTIVIYY DATA STABILITY: STABLE CONDITIONS TO AVOID: AVOID EXTREMES OF HEAT. INCOMPATIBILITY (MATERIALS TO AVOID): STRONG OXIDIZING MATERIALS. HAZARDOUS DECOMPOSITION PRODUCTS: INCOMPLETE COMBUSTION MAY CAUSE CARBON OXIDES. HAZARDOUS POLYMERIZATION: WILL NOT OCCUR.

---------------------------------------------------------------------------SPILL OR LEAK PROCEDURES: STEPS TO BE TAKEN IN CASE MATERIAL IS RELEASED OR SPILLED. DIKE AND ABSORB ON INERT MATERIAL. FOLLOW ALL LOCAL, STATE, AND FEDERAL REGULATIONS FOR DISPOSAL OF COLLECTED MATERIAL.

----------------------------------------------------------------------------

4-33

4 — MAINTENANCE

MATERIAL SAFETY DATA SHEET

FOR AW–46 HYDRAULIC OIL (Continued)

SPECIAL PROTECTION INFORMATION RESPIRATORY PROTECTION (SPECIFIC TYPE) NONE REQUIRED VENTILATION: NORMAL LOCAL EXHAUST: NORMAL MECHANICAL EXHAUST (GENERAL) X PROTECTIVE GLOVES: OIL IMPERVIOUS GLOVES RECOMMENDED EYE PROTECTION: SAFETY GLASSES RECOMMENDED OTHER PROTECTIVE EQUIPMENT: NONE REQUIRED

----------------------------------------------------------------------------

SPECIAL INSTRUCTIONS SPECIAL LABELLING INSTRUCTIONS: NOT REQUIRED SPECIAL PACKAGING RECOMMENDATIONS: NONE HANDLING AND STORAGE RECOMMENDATIONS: DO NOT CUT OR WELD ON EMPTY CONTAINERS, AVOID EXTREMES OF COLD OR HEAT. STORE IN CLEAN DRY AREA.

DISCLAIMER: THE INFORMATION CONTAINED HEREIN HAS BEEN COMPILED FROM SOURCES CONSIDERED TO BE DEPENDABLE AND IS ACCURATE TO THE BEST OF THE SELLERS KNOWLEDGE. THE SELLER MAKES NO WARRANTY WHATSOEVER, EXPRESSED, IMPLIED OR OF MERCHANTABILITY REGARDING THE ACCURACY OF SUCH DATA OR THE RESULTS TO BE OBTAINED FROM THE USE THEREOF.

4-34

Replacement Decals

Refer to Table 5-1 and Figure 5-1 through Figure 5-5 for descriptions and locations of decals on ft.

the XLB-4319 Hydraulic Boom Li

able 5- placem

T 1. Re ent Decals

Decal No. Description of Decal

B06-00-0033 CAUTION: THIS UNIT

ONLY BE TOWED WHEN…

B06-00-0034

B06-00-0036 LUBRICATE WEEKLY 22 B06-00-0037 LUBRICATE SEMI-ANNUALLY 1 B06-00-0043 MANUAL PUMP HANDLE 1 B06-00-0060 STOP…READ OPERATING… 1 B06-00-0062 THIS PLUG 115 VOLT 2 B06-00-0068 THE HYDRAULIC SYSTEM…

B06-00-0115 1500 WATT LOAD LIMIT 1 B06-00-0130 LUBRICATE MONTHLY 1 B06-00-0151 DANGER: 110 VOLT 1

B 2 06-00-0161B Bil-Jax – LARGE LABLE

B06-00-0167 Caution Tape, Black and Yellow B06-00-0173 SAFETY HARNESS LANYARD

B06-00-0189 WARNING: LEVEL MACHINE

B06-00-0192 OPERATION AND SERVICE

B06-00-0225 WARNING: STAY CLEAR

B06-00-0261 CAUTION: ANSI DECAL 1 B06-00-0268 EMERGENCY R TATION

DANGER: …DURING CHARGING, EXPLOSIV OXYHYDROGEN GAS…

(decal on hydraulic reservoir)

ATTACHMENT POINT

BEFORE USE

MANUAL INSIDE

WHILE RAISING …

HANDLE

SHALL 2

Qty

1 O

Decal No. Description of Decal Qty

B06-00-0334 DANGER: HIGH VOLTAG

OPERATION

B06-00-0363B Bil-Jax – SMALL LABLE 2

B06-00-0380 MAXIMUM CAPACITY 450

LBS B06-00-0393 Basket Station Valve Numbers 1 B06-00-0394 Basket Station Valve Motions 1 B06-00-0395 Ground Station Valve Numbers 1 B06-00-0396 Ground Station Valve Motions 1 B06-00-0397 LATCHED UNLATCHED 1 B06-00-0398 OUTRIGGER INSTRUCTIONS 1 B06-00-0399 ABBREVIATED OPERATING

INSTRUCTIONS B06-00-0400 DANGER: BEFORE USING,

LOWER ALL 4 OUTRIGGER B06-00-0401 DANGER: BOOM SAFETY

INSTRUCTIONS B06-00-0402 BOOM LIFT INSTRUCTIONS

BASKET B06-00-0403 PUSH TO LOWER 2 B06-00-0404 W A RNING: STAND CLEAR OF

OUTRIGGER… B06-00-0405 WARNING: PINCH POINT… 10 B06-00-0406 XLB-4319 TRANSFER 2 B06-00-0409 EMERGENCY ROTATION

GEAR B06-00-0430 XLB–4319 SPECIFICATIONS 1

E 2

5-1

XLB-4319

EMERGENCY RO T A TION GEAR

FTC B06-00-0409

B06-00-0409

COIA B06-00-0036

MAXIMUM CAPACITY

CCTT B06-00-0380

450

B06-00-0380

LUBRICATE

SEMI-ANNUALLY

COIA B06-00-0037

B06-00-0037

THIS PLUG 115 VOLT

RIL

B06-00-0062

EMERGENCY ROTATION HANDLE

OFA B06-00-0268

B06-00-0268

LBS.

MANUAL PUMP HANDLE

COIA B06-00-0043

B06-00-0043

B06-00-0062

CAUTION

THIS UNIT SHALL ONLY BE TOWED WHEN ALL BOOM SECTIONS ARE FULL Y DOWN AND LOCKED WITH TRANSPORT SAFETY PINS.

COIA/RFT B06-00-0033

B06-00-0033

DANGER

IT IS UNLAWFUL TO OPERATE THIS EQUIPMENT WITHIN 10 FEET OF HIGH VOLTAGE LINES OF 50,000 VOLTS OR LESS.

For safe clearance of lines in excess of 50,000 volts, see owners manual.

This machine is NOT insulated. Do not use within 10 ft. of power lines or other electrically charged sources. This machine NOT provide protection for personnel from contact with or close proximity to any live electrical power source and ered energized by all personnel coming in contact with machine.

FFL

B06-00-0334

LUBRICATE

WEEKLY

B06-00-0036

LUBRICATE

MONTHLY

RIF

B06-00-0130

WARNING

PINCH POINT

Y CLEAR

FTC B06-00-0405

B06-00-0405

SAFETY HARNESS LANYARD

ATTACHMENT

POINT

B06-00-0173UFC

B06-00-0173

DOES

should be consid-

B06-00-0334

DANGER

FAILURE TO COMPLY WITH THE FOLLOWING INSTRUCTIONS OR ANY OTHER IMPROPER USE OR MAINTENANCE OF THIS EQUIPMENT WILL RESULT IN INJURY OR DEATH.

• Risk of Electric Shock DO NOT expose charger to rain, power wash detergents or

B06-00-0130

spray - DO NOT use frayed or damaged electric cords when charging.

• During charging, explosive oxyhydrogen gas is generated. DO NOT smoke or allow open fire, sparks, or embers near battery when charging.

• Connect input cord only to properly grounded three wire outlet with specified voltage and frequency.

Always wear safety goggles and face shield when working

• on or near battery.

• Check battery acid level at the start of each day. If acid does not cover the plates, add only enough distilled or demineralized water to completely cover the plates.

• Keep terminals and terminal connections clean.

• Consult Operation and Maintenance Manual for additional information on battery maintenance.

B06-00-0034

CAUTION

This machine is designed and manufactured in compliance with the ANSI A92.2 standard in force on the date of manufacture. Dealers, owners, users, operators, lessors, and lessees are responsible for inspection, maintenance, training, and operation as required by A92.2 and the o wners manual.

Alterations, modifications, or changes to this machine without the written authorization of Workforce Products, Inc. as well as any unauthorized adjustment of valves, disabling or by-passing of safety devices or the improper use of this machine shall exempt Workforce Products, Inc. from any liability for any resulting injuries or damage.

FFU

B06-00-0261

OPERATION AND SERVICE

MANUAL INSIDE

COFC B06-00-0192

B06-00-0192

• Level machine before use.

WARNING

• Failure to level this machine could result in serious injury or death!

LFC B06-00-0189

B06-00-0189

DANGER

110 VOL T

GFT/LFC B06-00-0151

B06-00-0151

RIR/OFG

B06-00-0261

STA Y CLEAR

B06-00-0161B

WARNING

WHILE RAISING

OR LOWERING

CCFO

B06-00-0225

Figure 5-1. Replacement Decals, Sheet 1 of 3

5-2

XLB-4319

B06-00-0406

B06-00-0363B

5 — REPLACEMENT DECALS

ABBREVIATED OPERATING INSTRUCTIONS

W ARNING

UNHITCHING

Machine must be unhitched from vehicle before setting up.

1. Apply hand brake.

2. Remove lighting plug and safety wire from vehicle.

3. Lower trailer tongue jack.

4. Release trailer hitch from vehicle.

SETTING UP

1. Read Operation Manual and all decals prior to operation.

2. Check to be sure all personnel are clear of outriggers.

3. Select ground controls with key switch.

4. Make sure emergency stop buttons are released.

5. Using outrigger levers, lower each outrigger to within 6” from ground.

6. Lower the two outriggers closest to the trailer hitch until trailer tongue jack is clear of ground.

7. Level machine using two remaining outriggers while referring to bubble level.

8. Check to be sure both wheels are clear of ground.

9. Check all outrigger lights show green and buzzer has stopped.

10. Check to be sure each outrigger foot is in firm contact with the ground.

11. Do not place boards, concrete blocks, or any other object under the outrigger foot to obtain greater height adjustment.

BOOM OPERATING

1. Remove transport stowing pins.

2. Select ground controls with key switch.

3. Press green “enable” button and operate levers as required.

4. Check all lift functions for proper operation.

5. Return all boom arms to stowed position. Move key switch to basket controls. Lift is now ready for operation from the basket.

FTC B06-00-0399

IMPROPER USE OF THIS EQUIPMENT WILL RESULT IN SERIOUS INJURY OR DEATH.

THIS MACHINE MUST NOT BE OPERATED UNLESS YOU ARE COMPLETELY FAMILIAR WITH THE INSTRUCTIONS CONTAINED IN THE OPERATING MANUAL

STOWING MACHINE

1. Fully lower each boom into transport position.

2. Using outrigger levers, raise outriggers full starting at the cage end.

3. Install boom locking pins.

TOWING MACHINE

Do not tow machine unless: * The booms are full lowered * The boom locking pins are in place * All outriggers are fully retracted

1. Secure trailer hitch to ball on towing vehicle.

2. Attach safety wire.

3. Attach lighting plugs. Check to make sure lighting wire cannot be damaged in transit.

4. Check to make sure lights are working properly.

5. Fully raise trailer tongue jack and release hand brake.

6. The trailer weight must not exceed the vehicle towing capacity.

7. Do not exceed maximum towing speed.

EMERGENCY LOWERING PROCEDURE

From Basket (if fitted)

In the event of power failure, the basket may be lowered using the emergency hand pump. The procedure is as follows:

1. Attach hand pump handle.

2. Select function required with control lever(s).

3. Pump hand pump.

From Ground

1. Press red emergency lowering valve on base of bottom boom lift cylinder. Stand clear of descending structure.

2. Press red emergency lowering valve on top of boom cylinder. Stand clear of descending structure.

Emergency Rotation

on red hex-shaft on rotation gearbox. Turn handle to rotate structure.

- Install emergency rotation handle

B06-00-0399

BOOM OPERATING INSTRUCTIONS FOR XLB-4319

1. Read Operation Manual and all

decals prior to operating.

2. Follow the instructions on the lower controls for “Unhitching”, “Setting Up” and “Boom Operating”. This will ensure proper boom set up and also help you familiarize yourself with the operation of the lift.

3. Check again to be sure all outriggers are properly set and the lift is level.

4. Always wear full body harness and attach lanyard to the provided attachment when operating from the basket.

5. Check the emergency stop button to make sure it is in the released position.

6. Press and hold the green enable button with one hand while operating the control levers with the other hand. Each lever is clearly marked for function and direction.

B06-00-0402FTC

B06-00-0402

BEFORE USING, LOWER ALL 4 OUTRIGGERS UNTIL

DANGER

EACH OUTRIGGER IS IN FIRM CONTACT WITH THE GROUND, THEN LEVEL THE MACHINE.

FTC B06-00-0400

B06-00-0400

WARNING

Stand clear of outrigger while it is being lowered. Contact with outrigger foot pad will cause serious crushing injury.

B06-00-0404FTC

B06-00-0404

THE HYDRAULIC SYSTEM OF

THIS MACHINE IS DESIGNED TO USE

ENERGOL HLP-46 HYDRAULIC OIL

OII B06-00-0068

B06-00-0068

FTC B06-00-0395

B06-00-0395

FTC B06-00-0393

B06-00-0393

EMERGENCY

LOWERING VALVE

PUSH TO LOWER

FTC B06-00-0403

B06-00-0403

FTC B06-00-0397

B06-00-0397

• Use only tools equipped with 3 prong grounded plug.

• 1500 Watt maximum load.

• 15 Amp maximum circuit.

AIF/RFC

B06-00-0115

STOP

READ OPERA TING

INSTRUCTIONS BEFORE

OPERATING

MACHINE

RIL

B06-00-0060

DANGER

FAILURE TO COMPLY WITH THE FOLLOWING SAFETY INSTRUCTIONS OR ANY OTHER IMPROPER USE

BEFORE USE

• Operator must read and understand owners manual and all decals on machine before operating. It is operators responsibility to comply with all warnings and instructions.

• Survey the job site and identify all potential hazards.

• Inspect lift for proper maintenance and any damaged or worn components. DO NOT operate until proper maintenance has been performed and all damaged or worn parts have been replaced. See owners manual for proper maintenance procedures.

• NEVER TAKE CHANCES—DO NOT use this lift if you are under the influence of drugs or alcohol, or if you feel dizzy, ill, or unsteady in any way.

• OPERATE ON FIRM AND LEVEL SURFACE ONLY—if used on loose gravel or other soft surfaces, additional base support under each outrigger foot pad may be necessary.

• Properly deploy

• Level machine before use—if buzzer sounds, lift is not level and the necessary outrigger adjustment should be made to level machine before continuing.

• All occupants must wear full body harness and lanyard.

• Check safety devices daily before use—see owners manual for proper check procedures.

• When working on public roads, warnings and barriers must be set up in accordance with all local, state, and federal traffic codes.

• Cordon off area around base to keep personnel and other equipment away from unit while in use.

DURING USE

• To avoid hand injuries, always keep hands inside basket area during boom movement.

• DO NOT use without all four outriggers in firm contact with the ground and the lift level.

• DO NOT release outriggers with boom extended or operator in basket.

• DO NOT move or reposition trailer while operator occupies basket.

• DO NOT use when exposed to high winds, rain, snow, or ice.

FTC B06-00-0401

all 4 outriggers by lowering each outrigger until it is in firm contact with the ground.

5-3

OF THIS EQUIPMENT WILL RESULT IN SERIOUS INJURY OR DEATH.

• DO NOT use where lift operator can come in contact with overhead obstructions such as electric wires, cables, ropes, overhangs, etc.

• DO NOT operate without full body harness and lanyard in use by all basket occupants.

• DO NOT stand or sit on guard rails or top edge of basket.

• DO NOT lean out over top edge of basket to perform work.

• DO NOT use boxes, ladders, scaffolding, or any other means to increase working height.

• DO NOT climb up or down boom.

• DO NOT exceed rated lift capacity.

• DO NOT allow ropes, electric cords, hoses, etc. to become entangled in the lift while platform is being raised or lowered.

• DO NOT override, alter, or bypass safety devices.

• DO NOT use boom rotation or basket rotation (if so equipped) for pushing or pulling.

• DO NOT exceed platform capacity when transferring loads to the platform while elevated.

• DO NOT use as a crane for lifting materials.

• DO NOT leave keys in machine while unattended.

• Plug charger in at the end of each day.

• When using the lift with the 110V power cord plugged into the base of the unit, care must be taken to ensure that the cord is not damaged or entangled during rotation.

• DO NOT allow flames, sparks, or embers near batteries and DO NOT smoke near batteries. Batteries produce a hydrogen, oxygen gas mixture which can explode.

OWNERS & OPERATORS ARE RESPONSIBLE FOR INSPECTION, MAINTENANCE, TRAINING,

AND OPERATION AS REQUIRED BY THE OWNERS MANUAL .

IF YOU HAVE NOT BEEN PROVIDED WITH SAFETY LITERATURE, OR FOR ANY QUESTIONS CONCERNING THE SAFE USE OF THIS EQUIPMENT, CALL 419/445-9675.

B06-00-0401

Figure 5-1. Replacement Decals, Sheet 2 of 3

XLB-4319

1) Ensure Emergency Stop buttons are released.

2) Turn key to Ground Controls.

3) Press and hold black button.

4) Operate Outrigger Levers to level unit (refer to Bubble Level).

5) Lower outriggers 3 and 4 first to ensure tongue jack is clear of ground.

6) Check to be sure each outrigger foot is in firm contact with ground.

7) Check to be sure all outriggers are showing a green light and buzzer has stopped.

FTC B06-00-0394

FTC B06-00-0398

B06-00-0398

B06-00-0394

FTC B06-00-0396

B06-00-0396

XLB-4319 SPECIFICATIONS

45.9

42.6

39.4 36

32.8

24.5

26.3 23

19.7

16.4 13

9.8

6.5

3.2 0

9.8 6.5 3.2 0 3.2 6.5 9.8 13 16.4 19.7 23

CAPACITY.......................................... 450 LB.

MAXIMUM PLATFORM HEIGHT ....... 37 FT.

WORK HEIGHT .................................. 43 FT.

POWER SOURCE.............................. 24V DC BATTERY OR GAS

FTC

B06-00-0430

Figure 5-1. Replacement Decals, Sheet 3 of 3

5-4

B06-00-0430

5 — REPLACEMENT DECALS

4 40

0036

TH BO

0161B

SIDES

0033

0130

0036

0403

0036

0405

0062

0268

0225

0405

BOTH

0225

BOTH

SIDES

0403

SIDES

0405

0036

0400

(ALL OUTRIGGERS)

TMENT AR

VER DECALS

SEE FIGURE 5-3

FOR COMP

0405

(ALL OUTRIGGERS)

0036

(ALL OUTRIGGERS)

0404

(ALL OUTRIGGERS)

0406

BOTH

SIDES

XLB-4319

0036

0225

SIDES

0043

0380

0036

0402

0060

0334

0033

0393

0192

0394

0173

0400

0401

0151

0115

0062

0189

0409

0404

BOTH

0363B

SIDES

Figure 5-2. Decal Locations, Trailer and Boom

5-5

XLB-4319

0334, 0034

ON END

PANEL

0033 0398

0399

0401

0397

0395

0395, 0396

ON TOP OF

CONTROL BOX

0261

0430

Figure 5-3. Decal Locations, Control Compartment Exterior

Figure 5-4. Lubricate Monthly Decal

0037

Figure 5-5. Lubricate Semi-Annually Decal

5-6

Parts List

6-1

XLB-4319

6-1 UPPER BOOM PARTS LIST

Refer to Table 6-1 for the upper boom parts list.

19, 19A

18, 18A

16, 16A, 16B,

16C, 16D

11 2

22 24

19, 19A

18, 18A

Figure 6-1. Upper Boom

6-2

6 — PARTS LIST

Table 6-1. Upper Boom Parts List

Item No. Part No. Description Qty

1 B11-03-0043 Vertical Boom 1 2 B36-00-0059 Pivot Pin, 30mm dia. x 221mm 3 3 B36-00-0042 Locking Pin 10 4 Flat Washer 10 5 Lock Washer 10 6 Cap Screw 10 7 Cap Screw 2 8 Flat Washer 2

9 Hose Clamp 1 10 Flat Washer 2 11 Hex Nut 2 12 B31-00-0036 Wear Pad 1 13 Cap Screw 2 14 Trimlock, 1/4 in. x 30 in. 1 15 Trimlock, 1/4 in. x 7 in. 1 16 B02-03-0027 Hydraulic Cylinder, Upper Boom 1

16A B25-00-0084 Bushing, Cylinder Pivot 4 16B B02-13-0107

B02-13-0106

16C B02-04-0082

B02-04-0064

Seal Kit, End Cap With Groove Seal Kit, End Cap With Groove Counter-Balance Valve, End Cap With Groove Counter-Balance Valve, End Cap Without

Groove

16D B02-14-0059

B02-14-0055

Emergency Lowering Valve, End Cap With Groove

Emergency Lowering Valve, End Cap Without Groove

17 Grease Fitting 6 18 B11-03-0040 Upper Boom 1

18A B25-00-0084 Bushing, Upper Boom 4

19 B11-03-0042 Upper Boom Stabilizer 1

19A B25-00-0084 Bushing, Upper Boom Stabilizer 4

20 B36-00-0062 Pivot Pin, 30mm dia. x 179mm 1 21 Cap Screw 2 22 Flat Washer 4 23 B11-03-0045 Knuckle, Jib Boom 1 24 Self Locking Nut 2 25 B36-00-0058 Pivot Pin, 30mm dia. x 201mm 1 26 B36-00-0060 Pivot Pin, 30mm dia. x 216mm 1

6-3

XLB-4319

6-2 LOWER BOOM PARTS LIST

Refer to Table 6-2 for the lower boom parts list.

13, 13A,

13B, 13C

2264

9A, 9B,

C, 9D

1, 1A

7, 7A

oweFigure 6-2. L r Boom

6-4

6 — PARTS LIST

Tabl ower Boom Parts List

e 6-2. L

Item No. Part No. Description Qty

1 B11-03-0039 Lower Boom 1

1A B25-00-0084 Bushing, Lower Boom 4

2 Grease Fitting 6

3 B36-00-0042 Locking Pin 8

4 Flat Washer 8

5 Lock Washer 8

6 Cap Screw 8

7 B11-03-0041 Lower Boom Stabilizer 1

7A B25-00-0084 Bushing, Lower Boom Stabilizer 4

8 B36-00-0062 Pivot Pin, 30mm dia. x 179mm 1

9 B02-03-0028 Hydraulic Cylinder, Lower Boom 1

9A B25-00-0084 Bushing, Cylinder Pivot 4

9B B02-13-0107

B02-13-0106

9C B02-04-0082

B02-04-0064

9D B02-14-0059

B02-14-0055

10 Boom Support Bracket 1 11 B36-00-0059 Pivot Pin, 30mm dia. x 221mm 3 12 Self Locking Hex Nut 4

13 B01-03-0056 Limit Switch 1 13A B01-03-0003 Head, Limit Switch 1 13B B01-03-0054 Roller Arm 1 13C B01-03-0055 Plug Adapter 1

14 Wire Tie AR

15 B01-03-0064 Cable, Limit Switch 1

16 Socket Head Screw 4

17 Flat Washer 4

18 Flat Head Screw, M8 x 1.25 x 20mm 2

19 B31-00-0037 Boom Wear Pad 1

20 Socket Head Screw 1

21 Lock Washer 1

22 Flat Washer 1

23 Chain 1

24 B36-00-0040 Transport Pin 1

25 Clamp 1

26 Flat Head Screw 1

Seal Kit, End Cap With Groove Seal Kit, End Cap With Groove Counter-Balance Valve, End Cap With Groove Counter-Balance Valve, End Cap Without Groove Emergency Lowering Valve, End Cap With Groove Emergency Lowering Valve, End Cap Without

Groove

6-5

XLB-4319

6-3 JIB BOOM PARTS LIST

Refer to Table 6-3 for the jib boom parts list.

10, 10A,

10B, 10C

Figure 6-3. Jib Boom

6-6

6 — PARTS LIST

Table 6-3. Jib Boom Parts List

Item No. Part No. Description Qty

1 B11-03-0045 Jib Boom Knuckle 1 2 B36-00-0067 Pivot Pin, 25mm dia. x 208mm 2 3 B36-00-0042 Locking Pin 8 4 Flat Washer 8 5 Lock Washer 8 6 Cap Screw 8

7 B11-03-0044 Jib Boom 2 7A B25-00-0081 Bushing, Jib Boom, Full Boss 2 7B B25-00-0086 Bushing, Jib Boom, Short Boss 4

8 Grease Fitting 4

9 B11-03-0046 Cage Support 1

10 B02-03-0029 Hydraulic Cylinder, Jib Boom 1 10A B25-00-0081 Bushing, Cylinder Pivot 4 10B B02-13-0107

B02-13-0106

10C B02-04-0082

B02-04-0064

Seal Kit, End Cap With Groove Seal Kit, End Cap Without Groove Counter-Balance Valve, End Cap With Groove Counter-Balance Valve, End Cap Without

Groove 11 B02-01-0168 Hydraulic Hose Assembly, 6mm, C8 2 12 B02-02-0210 Adapter, Straight, 1/4 BSP Male-1/4 BSP Male 2 13 B02-00-0044 1/4 Dowty Washer 2 14 Wire Tie AR 15 B36-00-0066 Pivot Pin, 25mm dia. x 201mm 2

6-7

XLB-4319

6-4 COMPARTMENT COVERS PARTS LIST

Refer to Table 6-4 for the control and power compartment covers parts list.

7,7A

15 16

Figure 6-4. Compartment Covers

5 3

6-8

6 — PARTS LIST

Table 6-4. Compartment Covers Parts List

Item No. Part No. Description Qty

1 B42-01-1015 Hinge, Cover 2 2 Cap Screw 8 3 Flat Washer 10 4 Fender Washer 4 5 Hex Nut 6 6 Lock Washer 4 7 B18-00-0156 Cover, Control Compartment 1 7A B18-00-0155 Cover, Pump Compartment (not shown) 1 8 B04-07-0121 Latch, Cover 1

9 Washer, Internal Lock 2 10 Hex Nut 1 11 Trimlock, 1/4 in. x 30.5 in. 1 12 Hex Nut, Self Locking 1 13 B42-00-0020 Support Rod 1 14 Socket Head Screw, Flat Head 1 15 B04-07-0118 Clamp, Support Rod 1 16 Hex Nut, Self Locking 1

NOTE: Quantities shown are for one cover. There are two covers on the machine,

control compartment and pump compartment. The pump compartment does not have an opening and does not require a trim lock, item 11.

6-9

XLB-4319

6-5 RESERVOIR COMPARTMENT PARTS LIST,

GAS MODEL

Refer to Table 6-5 for the pump compartment parts list for the gas model boom lift.

C31

1, 1A

HYDRAULIC

PUMP

C28

C14

C37

C34

C26

C23

Figure 6-5. Reservoir Compartment, Gas Model

6-10

6 — PARTS LIST

Table 6-5. Reservoir Compartment Parts List, Gas Model

Item No. Part No. Description Qty

1 Reservoir Assembly 1 1A Hydraulic Filter (not shown) 1 2 B02-01-0185 Hydraulic Hose Assembly, 13mm, C31 1 3 Cap Screw 2 4 Lock Washer 2 5 Flat Washer 2 6 Hydraulic Hose Assembly, Pump Supply 1 7 Hex Nut, Self Locking 2 8 B02-02-0205 Adapter, Straight, 1/4 BSP Male-3/8 BSP

Male 9 B02-00-0043 3/8 Dowty Washer 8 10 Return Manifold Assembly 1 11 Socket Head Cap Screw 2 12 B02-00-0042 1/2 Dowty Washer 4 13 B02-02-0218 Adapter, Straight, 3/8 BSP Male-1/2 BSP

Male 14 B02-02-0220 1/2 BSP Male Plug 2 15 B02-02-0206 Adapter, Straight, 3/8 BSP Male-3/8 BSP

Male 16 B02-01-0183 Hydraulic Hose Assembly, 10 mm, C28 1 17 B02-01-0173 Hydraulic Hose Assembly, 6 mm, C14 1 18 B02-01-0156 Hydraulic Hose Assembly, 10 mm, C1 1 19 Hydraulic Hose Assembly, 6 mm, C37 1 20 Hydraulic Hose Assembly, 6 mm, C34 1 21 B02-01-0163 Hydraulic Hose Assembly, 6 mm, C26 1 22 B02-01-0182 Hydraulic Hose Assembly, 6 mm, C23 1 23 B02-02-0215 3/8 BSP Male Plug 1 24 Cap 1

6-11

XLB-4319

6-6 PUMP COMPARTMENT PARTS LIST, DC MODEL

Refer to Table 6-6 for the pump compartment parts list for the DC model boom lift.

C31

41B, 41C,

41, 41A,

41D

C28

C14

C26

C23

Figure 6-6. Pump Compartment, DC Model

24 23

6-12

6 — PARTS LIST

Table 6-6. Pump Compartment Parts List, DC Model

Item No. Part No. Description Qty

1 B01-04-0001 Battery, Dry Cell, 6 Volt DC 4 2 Cable, Battery, 2 Ga. x 8 in. 3 3 Terminal Boot 12 4 0090-0185 Hex Nut, Self Locking, 5/16 in.-18 2 5 0090-0420 Flat Washer, 5/16 in. 2 6 0090-0787 Fender Washer 2 7 B04-07-0081 Threaded Rod, 5/16 in. x 10 in. 2 8 Cable, Battery, 2 Ga. x 12 in. 1

9 Flat Washer 2 10 Socket Head Cap Screw 2 11 Flat Washer 6 12 Flange Nut 2 13 B01-10-0245 Fuse, 200 Amp, FS2 1 14 B01-10-0246 Insulator 1 15 Cable, Battery, 2 Ga. x 21 in. 1 16 Cable Connector, Plug and Receptacle 1 17 Cable, Battery, 2 Ga. x 12 in. 1 18 Cable, Battery, 2 Ga. x 14 in. 1 19 Machine Screw, Flat Head 2 20 Cable, Battery, 2 Ga. x 38 in. 1 21 Hex Nut, Self Locking 2 22 Cap Screw 2 23 Lock Washer 2 24 Flat Washer 2 25 Hex Nut 4 26 Fender Washer 2 27 Hydraulic Return Manifold 1 28 Socket Head Cap Screw 2 29 B02-00-0042 1/2 Dowty Washer 4 30 B02-02-0218 Adapter, Straight, 3/8 BSP Male-1/2 BSP

Male 31 B02-02-0220 1/2 BSP Male Plug 2 32 B02-02-0206 Adapter, Straight, 3/8 BSP Male-3/8 BSP

Male 33 B02-01-0183 Hydraulic Hose Assembly, 10 mm, C28 1 34 B02-01-0156 Hydraulic Hose Assembly, 10 mm, C1 1 35 B02-02-0215 3/8 BSP Male Plug 3

6-13

XLB-4319

6-6 PUMP COMPARTMENT PARTS LIST, DC MODEL

Refer to Table 6-6 for the pump compartment parts list for the DC model boom lift.

C31

41B, 41C,

41, 41A,

41D

C28

C14

C26

C23

Figure 6-6. Pump Compartment, DC Model

26 25

6-14

6 — PARTS LIST

Table 6-6. Pump Compartment Parts List, DC Model (continued)

Item No. Part No. Description Qty

36 B02-01-0173 Hydraulic Hose Assembly, 6 mm, C14 1 37 B02-01-0163 Hydraulic Hose Assembly, 6 mm, C26 1 38 B02-01-0182 Hydraulic Hose Assembly, 6 mm, C23 1 39 B02-02-0205 Adapter, Straight, 1/4 BSP Male-3/8 BSP

Male 40 B02-00-0043 3/8 Dowty Washer 9 41 Pump and Reservoir Assembly 1

41A B02-15-0419 Pump Assembly Without Reservoir 1 41B Hydraulic Filter (not shown) 1 41C B02-15-0389 Motor, 24V 1 41D B02-15-0390 Brush Kit, 24V Motor 1

42 B02-02-0216 Fitting, Test Gauge 1

43 B02-00-0043 1/4 Dowty Washer 1 44 Hydraulic Hose Assembly, Pump Output 1 45 B02-02-0214 Fitting, Tee, 1/4 BSP Male 1 46 B02-02-0213 Adapter, Straight, 1/4 BSP Female Swivel-

3/8 BSP Male 47 B02-01-0185 Hydraulic Hose Assembly, 13mm, C31 1 48 Start Contact, 24V 1

6-15

XLB-4319

6-7 CHASSIS AND ROTATION UNIT PARTS LIST

Refer to Table 6-7 for the chassis and rotation unit parts list.

3, 3A, 3B, 3C

Figure 6-7. Chassis and Rotation Unit

6-16

6 — PARTS LIST

Table 6-7. Chassis and Rotation Unit Parts List

Item No. Part No. Description Qty

1 Boom Support Bracket 1 2 Cap Screw 12

3 B02-06-0009 Slew Motor 1 3A B02-06-0010 Seal Kit, Slew Motor 1 3B B02-06-0011 Slew Motor End Seal 1 3C B25-00-0078 Taper Roller Bearing 2

4 Cap Screw 2

5 Lock Washer 2

6 B13-00-0007 Worm Gearbox With Slew Ring 1

7 Grease Fitting 4

8 B12-00-0140 Trailer Chassis 1

9 Socket Head Screw 16

10 Hex Nut 4 11 Flat Washer 8 12 B01-10-0016 Level Sensor 1 13 Machine Screw 3 14 Lock Washer 3 15 Level Sensor Cover 1 16 Machine Screw 4 17 B11-03-0047 Slew Restrictor 1 18 B46-00-0035 Handle, Manual Rotation 1

6-17

XLB-4319

6-8 HITCH AND JACK ASSEMBLY PARTS LIST

Refer to Table 6-8 for the hitch and jack assembly parts list.

3428

1, 1A

10 8

Figure 6-8. Hitch and Jack Assembly

6-18

6 — PARTS LIST

Table 6-8. Hitch and Jack Assembly Parts List

Item No. Part No. Description Qty

1 B12-00-0122 Parking/Surge Brake Control Assembly 1

1A B12-00-0123 Hand Brake Only 1

2 Cap Screw 2

3 B01-10-0179 Lamp, Side Marker, Amber 2

4 0090-0344 Screw, Self Tapping, #10-24 x 1/2" 4

5 Hex Nut, Self Locking 2

6 Spacer 1

7 Bracket, Brake Cable 1

8 B12-00-0125 Brake Rod 1

9 Clamp 2

10 Socket Head Screw, Flat Head 2 11 B36-00-0040 Transport Pin 1 12 Flat Washer 2 13 Cap Screw 1 14 Chain 1 15 Keeper pin 1 16 Hex Nut 1 17 Hex Nut, Self Locking 2 18 0090-0188 Hex Nut, Self Locking, 3/8”-16 2 19 B23-02-0063 Swivel Plate 1 20 B12-00-0173 Breakaway Safety Cable 1 21 Cotter Key 1 22 Flat Washer 1 23 Spring 1 24 Swivel Pin 1 25 B23-02-0061 Jack Assembly 1 26 Hex Nut, Self Locking 1 27 Bushing 1 28 B03-00-0017 Safety Chain 2 29 0090-0959 Cap Screw, M12 x 1.75 x 100mm 1 30 Flat Washer 2 31 0090-1032 Cap Screw, M12 x 1.75 x 80mm 1 32 B01-01-0137 Wiring Harness 1 33 B12-00-0120 Ball Hitch 1 34 0090-0960 Hex Nut, Self Locking, M12 x 1.75 2 35 Hex Nut, Self Locking 2 36 0090-0042 Cap Screw, 3/8”-16 x 1” 2 37 B12-00-0172 Housing, Coupler With Bearings 1 38 B12-00-0171 Overrun Shaft 1 39 B12-00-0124 Damper, Gas Shock 1 40 B12-00-0135 Rubber Boot, Hitch 1

6-19

XLB-4319

6-9 AXLE AND WHEEL ASSEMBLY

PARTS LIST

Refer to Table 6-9 for the axle and wheel assembly parts list.

28,28A

11, 11 A

Figure 6-9. Axle and Wheel Assembly

6-20

6 — PARTS LIST

Table 6-9. Axle and Wheel Assembly Parts List

Item No. Part No. Description Qty

1 Hex Nut, Self Locking 4 * B22-00-0026 Kit, Fender (includes items 2, 3, & 6-10) 2 2 B29-00-0154 Bracket, Fender 2 3 B18-00-0109 Fender, Top Mount 2 4 Flat Washer 4 5 Cap Screw 4 6 0090-0033 Cap Screw, 5/16”-18 x 1-3/4” 4 7 B07-06-5772 Fender Mount 4 8 0090-0420 Flat Washer, 5/16” 16

9 0090-0185 Nut, Lock, 5/16”-18 4 10 0090-0645 Cap Screw, 5/16”-18 x 1/2” 8 11 B08-02-0012 Tire 2

11A B08-02-0013 Rim Only 2

12 B10-00-0062 Bolt, Wheel Lug, Conical, M12 x 1.5 8 13 B10-00-0063 Dust Cap 2 14 B10-00-0061 Flange Nut, Spindle 2 15 B21-00-0025

B21-00-0025B

16 B25-00-0077

B25-00-0077B

17 B10-00-0083

B10-00-0083B 18 B10-00-0077 Pull-off Spring 2 19 B10-00-0078 Expanding Clutch 2 20 B21-00-0024 Brake Shoe (pair) 2 21 B10-00-0079

B10-00-0079B 22 B10-00-0080 Cable Eye 2 23 B12-00-0126 Brake Cable 2 24 B10-00-0081 Spring, Reverse Lever 2 25 B10-00-0076 Bearing Bolt 2 26 B10-00-0075 Spring, Shoe Retaining 2 27 B10-00-0074 Cotter Pin 2 28 B10-00-0072 Reverse Lever LH Side 1

28A B10-00-0073 Reverse Lever RH Side 1

29 B10-00-0065 Brake Adjuster Assembly 2 30 B10-00-0071 Plug, Plastic 4 31 B10-00-0070 Cover Plate 2 32 B10-00-0069

B10-00-0082

33 B10-00-0068 Cover, Spindle Lock Nut, Nut Mount Spindle Only 2 34 B10-00-0067 Backplate Cap 2 35 B10-00-0066 Brake Cable Shell 2 36 Hex Nut, Self Locking 4 37 Flat Washer 4 38 B10-00-0064 Axle Assembly 1 39

* Order

fender kit B22-00-0026 when replacing original side mounted fender.

6-21

Brake Drum with Bearings, Nut Mount Spindle Brake Drum with Bearings, Bolt Mount Spindle Wheel Bearing, Nut Mount Spindle Wheel Bearing, Bolt Mount Spindle Retaining Ring, Nut Mount Spindle Retaining Ring, Bolt Mount Spindle

Spindle, Nut Mount Spindle, Bolt Mount

Lock Nut, Nut Mount Spindle Bolt, M20 x 60mm, Bolt Mount Spindle (not

shown)

Cap Screw 4

XLB-4319

6-10 REAR LIGHTS AND JUNCTION BOX PARTS LIST

Refer to Table 6-10 for the rear lights and junction box parts list.

Figure 6-10. Rear Lights and Junction Box

6-22

6 — PARTS LIST

Table 6-10. Rear Lights and Junction Box Parts List

Item No. Part No. Description Qty

1 B01-10-0023 Tail Light Assembly, Right 1

2 B01-10-0024 Tail Light Assembly, Left 1

3 0090-0934 Screw, Self Tapping, 1/4"-20 x 3/4" 2 4 B29-00-0037 Bracket, License Plate 1 5 B01-10-0069 Lens, Replacement 2 6 B01-09-0023 Anchor Plate, Wire Tie 3 7 B01-09-0030 Wire Tie, 3/32” x 6 1/4" 3 8 B01-10-0014 Junction Box 1

9 B01-10-0049 Cover, Junction Box 1 10 B01-09-0029 Cord Grip 1 11 B01-09-0010 Cord Cap 1

6-23

XLB-4319

6-11 OUTRIGGERS PARTS LIST

Refer to Table 6-11 for the outriggers parts list.

3, 3A,

3B, 3C

9 10, 10A, 10B

11, 11 A

6-24

19 18

Figure 6-11. Outriggers

6 — PARTS LIST

Table 6-11. Outriggers Parts List

Item No. Part No. Description Qty

1 Dust Shield 1 2 Grease Fitting 2

3 B02-03-0026 Hydraulic Cylinder, Outrigger 1 3A B25-00-0084 Bushing, Cylinder Pivot 4 3B B02-13-0109 Seal Kit, Outrigger 1 3C B02-14-0060 Check Valve, Outrigger 2

B02-01-0174

B02-01-0175 B02-01-0176 B02-01-0177

Hydraulic Hose Assembly, 6 mm, C15 Hydraulic Hose Assembly, 6 mm, C16 Hydraulic Hose Assembly, 6 mm, C17 Hydraulic Hose Assembly, 6 mm, C18

5 B02-00-0044 1/4 Dowty Washer 2

6 B02-02-0203 Adapter, 90°, 1/4 BSP Male-1/4 BSP Male 2

7 B01-03-0059 Cable, Limit Switch 1

8 Socket Head Cap Screw 4

9 Flat Washer 4

10 B01-03-0051 Limit Switch, Body With 2 NC Contacts 1 10A B01-03-0003 Head, Limit Switch 1 10B B01-03-0057 Contact Only, 2 NC 1

11 B23-01-0099 Outrigger 1

11A B25-00-0084 Bushing, Outrigger 2

12 B23-02-0064 Outrigger Footpad 1

13 B23-02-0065 Hinge Pin, 16mm dia. x 102mm 1

14 Split Pin, 0.19 in. dia. x 1 in. 2

15 Trimlock 7 in.

16 Sleeve, Hinge Pin 1

17 B36-00-0057 Pivot Pin, 30mm dia. x 167mm 1

18 B36-00-0042 Locking Pin 4

19 Cap Screw 4

20 Lock Washer 4

21 Flat Washer 4

22 Flat Washer 4

23 Hex Nut, Self Locking 4

24 B36-00-0055 Pivot Pin, 30mm dia. x 211mm 1

25 Flat Washer 2

26 Split Pin, 0.25 in. dia. x 2 in. 2

27 B36-00-0058 Pivot Pin, 30mm dia. x 201mm 1

6-25

XLB-4319

6-12 BASKET PARTS LIST

Refer to Table 6-12 for the basket parts list.

C12

1, 1C

1A 2

5 6 7 8

6 5

6-26

Figure 6-12. Basket

Bil-Jax XLB-4319, B33-01-0080 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Safety

INTRODUCTION

General Maintenance

Battery Maintenance

1-5 DAMAGED EQUIPMENT POLICY

Safety Statement

Damage Policy

Damage Repair Notice

Introduction

GENERAL DESCRIPTION

Boom Lift Work Platform

Operation

OPERATOR CONTROLS

Ground Control Station

Key Switch

OUTRIGGER INDICATORS

EMERGENCY STOP Pushbutton

Outriggers Run Pushbutton

Boom Run Pushbutton

Outrigger Operator Levers

Boom Operator Levers

Basket Control Station

EMERGENCY STOP Pushbutton

Boom Run Pushbutton

Boom Operator Levers

Hydraulic Hand Pump

Engine Start Pushbutton (Gas Model only)

Audible Alarm

115 Volt Outlet

3-2 NORMAL OPERATING PROCEDURE

3-4 MANUAL BOOM ROTATION

3-5 BATTERY RECHARGE (DC MODEL ONLY)

Maintenance

Daily/Weekly Service Checks

Monthly Service Checks

4-2 WHEEL NUT TORQUE REQUIREMENTS

Hydraulic System Inspection

Fluid Check and Replacement

Return Filter Replacement

Air Bleeding

Hydraulic Pressure Checks and Adjustments

Check/Adjust System and Outriggers Hydraulic Pressures

Check/Adjust Boom Hydraulic Pressure

Hydraulic Cylinder Replacement

Boom Lift Cylinder Removal and Installation

Outrigger Cylinder Removal and Installation

Jib Boom Cylinder Removal and Installation

Basket Swivel Cylinder Removal and Installation

4-5 SLEW RING BEARING

Check Free Play

Adjusting Boom Down Limit Switch

Adjusting Outrigger Position Switches

Troubleshooting Aids

4-8 MATERIAL SAFETY DATA SHEETS

Replacement Decals

Parts List

6-1 UPPER BOOM PARTS LIST

6-2 LOWER BOOM PARTS LIST

6-3 JIB BOOM PARTS LIST

6-4 COMPARTMENT COVERS PARTS LIST

6-6 PUMP COMPARTMENT PARTS LIST, DC MODEL

6-7 CHASSIS AND ROTATION UNIT PARTS LIST

6-8 HITCH AND JACK ASSEMBLY PARTS LIST