Bil-Jax XLB-4319, B33-01-0080 User Manual
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
i
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
ii
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
iv
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.
v
vi
1
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-
s
to
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
th
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
2
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
s
-
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
3
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
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