AERIAL WORK PLATFORMS
AERIAL WORK PLATFORMS
AERIAL WORK PLATFORMSAERIAL WORK PLATFORMS
XLB-4232 DC
Hydraulic Boom Lift
Operation and
Maintenance Manual
B33-01-0088
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
1111 Safety ............................................................................................................... 1-1
1-1 Introduction........................................................................................ 1-1
1-2 Before Operation............................................................................... 1-3
1-3 During Operation............................................................................... 1-4
1-4 Maintenance Safety........................................................................... 1-6
1-5 Damaged Equipment Policy............................................................. 1-7
2222 Introduction .................................................................................................... 2-1
2-1 General Description........................................................................... 2-1
2-2 Specifications..................................................................................... 2-2
2-3 Warranty............................................................................................. 2-2
3333 Operation ........................................................................................................ 3-1
3-1 Operator Controls.............................................................................. 3-1
3-2 Normal Operating Procedure............................................................ 3-6
3-3 Emergency Lowering.........................................................................3-8
3-4 Manual Boom Rotation.................................................................... 3-8
3-5 Battery Recharge (DC Model Only)............................................... 3-9
3-6 Boom Lift Transport....................................................................... 3-11
4444 Maintenance.................................................................................................... 4-1
4-1 Scheduled Service Checks................................................................ 4-1
4-2 Wheel Nut Torque Requirements.................................................... 4-3
4-3 Lubrication......................................................................................... 4-3
4-4 Hydraulic System.............................................................................. 4-6
4-5 Axle Switches Adjustment..............................................................4-11
4-6 Troubleshooting ............................................................................... 4-12
4-7 Material Safety Data Sheets .......................................................... 4-17
5555 Replacement Decals........................................................................................ 5-1
6666 Parts List ......................................................................................................... 6-1
6-1 Upper Boom Parts List.................................................................... 6-2
6-2 Lower Boom Parts List.................................................................... 6-4
6-3 Turntable Parts List.......................................................................... 6-6
6-4 DC Model Bat t ery Co mpa r tment P a rts Lis t...................................... 6-8
6-5 DC Model Power Compartment Parts List.................................. 6-10
6- 6 Ter mi na l E n cl o s u r e Par t s L is t............................................................ 6-14
6-7 Frame and Rotation Unit List....................................................... 6-16
6-8 Hitch and Jack Assembly Parts List............................................ 6-18
6-9 Square Tube Axle and Wheel Assembly Parts List................... 6-22
6-10 Hex Tube Axle and Wheel Assembly Parts List........................ 6-26
6-11 Tail Lights and Outrigger Display Transmitter Box Parts List. 6-28
6-12 Right Front/Left Rear Outriggers Parts List................................ 6-30
6-13 Left Front/Right Rear Outriggers Parts List................................ 6-32
6-14 Basket Parts List............................................................................. 6-34
6-15 Upper Control Box – External Parts List...................................... 6-38
6-16 Lower Control Box – Internal Parts List...................................... 6-39
6-17 Combination Valve Assembly Parts List...................................... 6-40
6-18 Surge Brakes Parts List................................................................. 6-41
6-19 DC Model Hydraulic System Parts List ...................................... 6-42
6-20 Power Unit Parts List ...................................................................... 6-44
7777 ANSI Reprint................................................................................................. 7-1
i
List of Illustrations
Figure 3-1. Battery ON/OFF Switch..........................................................................3-1
Figure 3-2. Lower Control Panel ............................................................................... 3-2
Figure 3-3. Upper Control Panel...............................................................................3-4
Figure 3-4. Emergency Lowering Valve....................................................................3-8
Figure 3-5. Boom Rotation........................................................................................ 3-8
Figure 3-6. Battery Charger and Receptacle..............................................................3-9
Figure 3-7. Battery Charger..................................................................................... 3-10
Figure 3-8. Breakaway Safety Cable.......................................................................3-11
Figure 3-9. Jack Travel Position.............................................................................. 3-11
Figure 3-10. Trailer Hitching Checkpoints................................................................3-12
Figure 4-1. Wheel Nut Tightening Sequence.............................................................4-3
Figure 4-2. Lubricate Monthly...................................................................................4-3
Figure 4-3. Lubricate Semi-Annually........................................................................4-4
Figure 4-4. Lubrication of Dexter Axles....................................................................4-5
Figure 4-5. Hydraulic Cylinder Removal ..................................................................4-7
Figure 4-6. Hydraulic Cylinder Repair...................................................................... 4-9
Figure 4-7. Adjusting Axle Position Switches.........................................................4-11
Figure 4-8. Electrical Layout................................................................................... 4-14
Figure 4-9. Level Sensor .........................................................................................4-15
Figure 4-10. DC Model Hydraulic Diagram..............................................................4-16
Figure 5-1. Replacement Decals, Sheet 1 of 3...........................................................5-2
Figure 5-1. Replacement Decals, Sheet 2 of 3...........................................................5-3
Figure 5-1. Replacement Decals, Sheet 3 of 3...........................................................5-4
Figure 5-2. Decal Locations, Top View ....................................................................5-5
Figure 5-3. Decal Locations, Passenger Side.............................................................5-6
Figure 5-4. Decal Locations, Driver Side..................................................................5-7
Figure 6-1. Upper Boom............................................................................................6-2
Figure 6-2. Lower Boom........................................................................................... 6-4
Figure 6-3. Turntable................................................................................................. 6-6
Figure 6-4. DC Model Battery Compartment............................................................ 6-8
Figure 6-5. DC Model Power Compartment............................................................6-10
Figure 6-6. Terminal Enclosure............................................................................... 6-14
Figure 6-7. Frame and Rotation Unit.......................................................................6-16
Figure 6-8. Hitch and Jack Assembly......................................................................6-18
Figure 6-9. Square Tube Axle and Wheel Assembly...............................................6-22
Figure 6-10. Hex Tube Axle and Wheel Assembly...................................................6-26
Figure 6-11. Tail Lights and Outrigger Display Transmitter Box .............................6-28
Figure 6-12. Right Front/Left Rear Outriggers..........................................................6-30
Figure 6-13. Left Front/Right Rear Outriggers..........................................................6-32
Figure 6-14. Basket ...................................................................................................6-34
Figure 6-15. Upper Control Box................................................................................6-38
Figure 6-16. Lower Control Box...............................................................................6-39
Figure 6-17. Combination Valve Assembly...............................................................6-40
Figure 6-18. Surge Brakes.........................................................................................6-41
Figure 6-19. DC Model Hydraulic System................................................................ 6-42
Figure 6-20. Power Unit............................................................................................6-44
ii
List of Tables
Table 1-1. Minimum Safe Approach Distances....................................................... 1-4
Table 2-1. Specifications.......................................................................................... 2-2
Table 4-1. Daily/Weekly Service Checks ................................................................ 4-1
Table 4-2. Monthly Service Checks......................................................................... 4-2
Table 4-3. Troubleshooting Chart.......................................................................... 4-12
Table 4-7. Level Sensor LEDs............................................................................... 4-15
Table 5-1. Replacement Decals, DC Model............................................................. 5-1
Table 6-1. Upper Boom Parts List........................................................................... 6-3
Table 6-2. Lower Boom Parts List........................................................................... 6-5
Table 6-3. Turntable Parts List ................................................................................ 6-7
Table 6-4. DC Model Battery Compartment Parts List............................................ 6-9
Table 6-5. DC Model Power Compartment Parts List........................................... 6-11
Table 6-6. Terminal Enclosure Parts List...............................................................6-15
Table 6-7. Frame and Rotation Unit Parts List ...................................................... 6-17
Table 6-8. Hitch and Jack Assembly Parts List...................................................... 6-19
Table 6-9. Square Tube Axle and Wheel Assembly Parts List .............................. 6-23
Table 6-10. Hex Tube Axle and Wheel Assembly Parts List................................... 6-27
Table 6-11. Tail Lights and Outrigger Display Transmitter Box Parts List............. 6-29
Table 6-12. Right Front/Left Rear Outriggers Parts List.......................................... 6-31
Table 6-13. Left Front/Right Rear Outriggers Parts List.......................................... 6-33
Table 6-14. Basket Parts List................................................................................... 6-35
Table 6-15. Upper Control Box Parts List............................................................... 6-38
Table 6-16. Lower Control Box Parts List............................................................... 6-39
Table 6-17. Combination Valve Assembly Parts List.............................................. 6-40
Table 6-18. Surge Brakes Parts List......................................................................... 6-41
Table 6-19. DC Model Hydraulic System Parts List................................................ 6-43
Table 6-20. Power Unit Parts List............................................................................ 6-45
Table 7-1. Minimum Safe Approach Distance (M.S.A.D.) to energized
(exposed or insulated) power lines and parts........................................ 7-10
iii
iv
1
1
11
Safety
1-1 INTRODUCTION
Familiarity and proper training are required for the safe operation of mechanical
equipment. 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
someone familiar with the equipment before being allowed to operate the machine. The
use of intelligence and common sense in the operation of mechanical equipment is the
best practice in any safety policy. Be professional and always observe the safety
procedures set forth in this manual.
All OSHA, ANSI, state, and local codes and regulations pertaining to this equipment
should be ob tained, read, a nd 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 implemented at all
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 considered as legal advice and is intended
for informational purposes only. This information is offered to alert Bil-Jax customers to
procedures that may be of concern to them.
This information is not intended to be all inclusive and is to be followed in the use of BilJax equipment only.
For any questions concerning the safe use of this equipment, call 419.445.9675 before
operating.
1-1
XLB-4232 DC
Safety Notes
This manual contains DANGERS, WARNINGS, CAUTIONS, and NOTES that must be
followed to prevent the possibility of improper service, damage to the equipment, or
personal injury.
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.
1-2
1 — SAFETY
1-2 BEFORE OPERATION
Ensure the following general safety precautions are followed before operating the
XLB-4232 DC 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 t he operating are a.
• 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.
1-3
XLB-4232 DC
1-3 DURING OPERATION
Ensure the following general safety precautions are followed during the operation of the
XLB-4232 DC 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 sourc es 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 pin before towing the trailer.
1-4
1 — SAFETY
• 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, locked, and firmly based.
When on soft surfaces, ALWAYS use outrigger base plates.
• 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 release outrigger locks or move unit with a person or materials on
board.
• NEVER release the outriggers or 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 oper ate 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.
1-5
XLB-4232 DC
1-4 MAINTENANCE SAFETY
Ensure the following safety precautions are observed whenever maintenance is performed
on the XLB-4232 DC 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 MASTER POWER switch OFF before connecting or
disconnecting wiring to or from valve soleno i ds 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 manufact urer for drying instruct ions.
• 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
electronic components. ALWAYS use static discharge prevention mats and
grounding devices when handling electro ni c components.
• NEVER tamper with cylinder counter balance valves. Contact the Bil-Jax
Service Department at 419.445.9675 if the cylinder counter balance valves need
adjusting.
• NEVER attempt repairs you do not unde rstand. Consult manufacturer if you
have any questions regarding proper maintenance, specific ations, or repa ir.
1-6
1 — SAFETY
Battery Maintenance
Ensure the following general safety precautions are followed whenever performing
battery maintenance on the XLB-4232 DC Boom Lift.
• ALWAYS check battery acid level daily. 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 BilJax 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 419.445.9675.
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.
1-7
XLB-4232 DC
1-8
2
2
22
Introduction
2-1 GENERAL DESCRIPTION
The XLB-4232 DC Boom Lift is designed and manufactured for positioning personnel
with their tools and equipment at overhead work locations. The rated work basket load
capacity is 300 lbs. for the XLB-4232. Basket elevation is by two hydraulic cylinders
acting on the boom sections. A hydraulic powered motor and worm gear rotates the boom
360° around a vertical axis. The hydraulic power unit includes a reservoir, pump, and
control valves.
On the battery powered (DC Model) boom lift, dual 24 Volt, 39 Amp, one horsepower,
DC electric motors 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.
Two control panels use directional selector switches and hydraulic valves to control the
direction and speed of boom lift and rotation. One set of operator controls is provided for
ground operation and another set is provided for operation from the basket. Elevation and
rotation controls are operational only when the moving boom section is within a
programmed safe operating zone. Only one boom motion is permitted at a time, and only
as long as the boom is within the safe operating zone. When a selected boom motion
reaches a safe operating limit, the motion ceases and another motion must be selected
within the safe operating zone.
Outrigger and wheel position interlock safety switches prevent lifting operations until the
four outriggers are properly deployed and the full weight of the boom lift is loaded onto
the outriggers.
Boom elevation speeds are selected from low to high by a toggle switch. A hydraulic hose
failure at either retract-cylinder port will cause a velocity fuse to close and 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 detailed instructions.
Emergency lowering of the basket is by a manual valve on the base of the lift cylinder.
Pushing in and turning 1/4 turn manually retracts the upper boom lift cylinder. The boom
may need to be manually rotated to a clear area before lowering.
The 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.
2-1
XLB-4232 DC
2-2 SPECIFICATIONS
Boom Lift Work Platform
Model Number XLB-4232 DC Serial Number ________________
Manufactured by: Bil-Jax, Inc.
125 Taylor Parkway
Archbold, Ohio 43502
419.445.9675
Table 2-1. Specifications
Feature XLB-4232 DC Model
Rated Platform Load 300 lbs (136.1 kg) total (1 man plus tools)
Maximum Work Height 42 ft (12.80 m)
Extended Basket Height 35 ft-5 in. (10.80 m)
Elevation Rate,
Maximum
Horizontal Reach 32.0 ft (9.8 m)
Boom Rotation 360° Continuous
Rotation Speed 8 in. per Second, Maximum
Basket Dimensions 36 in. W x 24 in. D x 42 in. H
Power Source 24 Volt DC, Deep Cycle, 245 Amp-hour Battery
Battery Charger 110/120 Volt, 40 Amp
Hydraulic Pressure 2000 psi (13,790 kPa)
Reservoir Capacity 6 Gallons (22.7 Liters)
Hydraulic Capacity 8 Gallons (30.3 Liters)
Hydraulic Oil AW-46
Gross Vehicle Weight 4760 lbs (2159 kg)
Tongue Wei ght 275 lbs (124.7 kg)
Trailer Brakes Hydraulic Surge; Optional – Electric
8 in./sec (203 mm/sec)
[40 ft/min (12.2 m/min)]
(91.4 cm x 61.0 cm x 106.7 cm)
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; structural components are
warranted for three years. 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.
2-2
3
3
33
Operation
3-1 OPERATOR CONTROLS
The XLB-4232 DC Boom Lift is equipped with multiple operator controls. Electrical
boom lift and rotation control panels are located at ground level and in the basket. Manual
boom rotation and lowering controls are at the ground level.
Battery ON/OFF Switch
A battery ON/OFF switch (Figure 3-1) is mounted on the front end of the hydraulic power
compartment. Turn the switch to the ON position to turn battery power on to the boom lift
electrical system. Turn the switch to the OFF position to conserve battery power when the
lift is not in use.
BATTERY
ON/OFF
SWITCH
Figure 3-1. Battery ON/OFF Switch
3-1
XLB-4232 DC
Lower Control Panel
The lower control panel (Figure 3-2) is located on the side of the hydraulic power
compartment. The following controls and indicators are on the lower control panel.
Figure 3-2. Lower Control Panel (DC Model)
EMERGENCY STOP Pushbutton
When pressed, the EMERGENCY STOP pushbutton disconnects electrical power to the
upper and lower control panels. The EMERGENCY STOP pushbutton should only be
pressed to immediately stop all boom motion. To resume control, pull to disengage the
emergency stop switch contacts.
BOOM UP/DOWN Selector Switch
Holding the BOOM UP/DOWN selector switch in the UP position enables the boom to
rise. Holding the selector switch in the DOWN position enables the boom to descend.
The up or down boom motion continues until the selector switch is released, or the boom
reaches a hard stop or a safe travel limit.
UPPER/OFF/LOWER Controls Selector Switch
The UPPER/OFF/LOWER controls selector switch enables boom lift control from either
the lower control panel or the work platform. When operating the boom lift from ground
level, hold the switch in the LOWER position while simultaneously selecting a motion
function.
3-2
3 — OPERATION
BOOM IN/OUT Selector Switch
Holding the BOOM IN/OUT selector switch in the OUT position extends the boom out.
Holding the selector switch in the IN position retracts the boom. The in or out boom
motion continues until the selector switch is released, or the boom reaches a hard stop or
a safe travel limit.
BOOM FAST/SLOW Selector Switch
The BOOM FAST/SLOW selector switch controls the speed of the selected boom
motion. Generally, the switch is set on FAST to position the boom in the general
proximity of the work area. Then, the switch is set on SLOW to fine tune the position of
the boom to get closer to the work area.
ROTATION CW/CCW Selector Switch
Holding the ROTATION CW/CCW selector switch in the CW position enables the boom
to rotate in the clockwise direction. Holding the selector switch in the CCW position
enables the boom to rotate in the counterclockwise direction.
OUTRIGGERS Indicator
The OUTRIGGERS indicator lights up when the boom outriggers are properly deployed
and the boom weight is removed from the trailer axle.
3-3
XLB-4232 DC
Upper Control Panel
The upper control panel (Figure 3-3) is mounted in the work basket. The following
controls and indicators are available on the upper control panel.
BATTERY CHARGE
INDICATOR
Figure 3-3. Upper Control Panel (DC Model)
BUCKET TILT COMPENSATOR Switch (DC Model Only)
A BUCKET TILT COMPENSATOR switch allows for slight adjustment to the level of
the work basket. Adjustment is limited to 3 degrees in either direction.
Battery Charge Indicator (DC model only)
Indicator LEDs light up to indicate the level of charge remaining in the batteries. Lighted
green LEDs indicate a good charge level. Lighted yellow LEDs indicate the need for
charging soon. Lighted red LEDs warn that the battery charge level is low; boom
operations should be halted until the batteries are recharged.
BOOM FAST/SLOW Selector Switch
The BOOM FAST/SLOW selector switch controls the speed of the selected boom
motion. Generally, the switch is set on FAST to position the boom in the general
proximity of the work area. Then, the switch is set on SLOW to fine tune the position of
the boom to get closer to the work area.
EMERGENCY STOP Pushbutton
When pressed, the EMERGENCY STOP pushbutton disconnects electrical power to the
upper and lower control panels. The EMERGENCY STOP pushbutton should only be
pressed to immediately stop all boom motion. To resume control, pull to disengage the
emergency stop switch contacts.
3-4
3 — OPERATION
UPPER CONTROLS ON/OFF Deadman Switch
The UPPER CONTROLS ON/OFF deadman switch must be held in the ON position
simultaneously with any other boom motion function. This prevents accidental movement
of the work basket.
ROTATION CW/CCW Selector Switch
Holding the ROTATION CW/CCW selector switch in the CW position enables the boom
to rotate in the clockwise direction. Holding the selector switch in the CCW position
enables the boom to rotate in the counterclockwise direction.
BOOM IN/OUT Selector Switch
Holding the BOOM IN/OUT selector switch in the OUT position extends the boom out.
Holding the selector switch in the IN position retracts the boom. The in or out boom
motion continues until the selector switch is released, or the boom reaches a hard stop or
a safe travel limit.
BOOM UP/DOWN Selector Switch
Holding the BOOM UP/DOWN selector switch in the UP position enables the boom to
rise. Holding the selector switch in the DOWN position enables the boom to descend.
The up or down boom motion continues until the selector switch is released, or the boom
reaches a hard stop or a safe travel limit.
3-5
XLB-4232 DC
3-2 NORMAL OPERATING PROCEDURE
Perform the following procedures to operate the XLB-4232 DC 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. Lower the t railer tongue jack and unhitch the tra iler from the tow vehicle . The
trailer must be unhitched before the outriggers are deployed.
5. Deploy the boom lift outriggers as follows:
a. Lift up on the locking pin and slide each outrigger out from the trailer frame.
Slide the outriggers out until the locking pins engage again.
b. P ull out the quick-adjust jack pins and lower the jack feet. With the jack feet
near the ground, reinstall the jack pins at the lowest available setting.
c. Turn the BATTERY ON/OFF switch to the ON position. Lift the bubble
level cover plate in front of the boom rotation housing (slew ring housing).
d. Jack up the outriggers to evenly raise the trailer; refer to the bubble level.
Raise the boom lift evenly until at least one trailer wheel is off the ground
and all outrigger LED’s are lit.
e. Flip outrigger jack handles over to keep them from being damaged by
falling objects or bent by lowering the boom onto them.
NOTE: An axle position switch will prevent boom operation if at least one wheel
is not lifted off the ground. The load o f the boom lift must be placed on
the outriggers to enable power.
6. Remove the pin keeper and transport pin that secures the boom to the trailer
frame. Stow the transport pin in its storage tube.
7. Unlock and open the base controls door.
8. Toggle the UPPER/OFF/LOWER controls switch to the LOWER position.
9. Use the lower control panel to operate the lift controls. Raise, lower, extend, and
rotate the boom in slow speed to get familiar with the controls. Learn to
smoothly start and stop the boom lift.
10. To place the basket at an easier entry height:
a. Raise the boom clear of its support post by holding the controls selector
switch to LOWER position and also activating the UP function.
b. Rotate the boom clockwise from its transport position by holding the
controls selector switch to LOWER position and also activate CW function.
Rotate until there is clearance between the support post and the boom.
c. Lower the boom until the basket just touches the ground by holding the
controls selector switch to LOWER position and also activate the DOWN
function.
11. Switch the controls selector switch to UPPER controls. Control of the boom is
now directed to the basket control panel.
3-6
3 — OPERATION
12. Raise the safety bar and enter the basket. Put on the safety harness and attach the
lanyard to the basket railing.
13. The lift is now ready for operation from the basket. Operate in slow speed to get
familiar with the controls. The UPPER CONTROLS ON/OFF deadman switch
must be held in the ON position simultaneously with any other boom motion
function.
14. Should the basket become tilted out of the normal vertical axis, adjustment can
be made using the BUCKET TILT COMPENSATOR switch. This function is
protected with a 3 degree limit safety switch in either direction.
15. Monitor the BATTERY CHARGE INDICATOR during operation and charge
the batteries as necessary. (See Section 3-5)
3-7
XLB-4232 DC
3-3 EMERGENCY LOWERING
The XLB-4232 DC Boom Lift is equipped with a manual emergency lowering valve that
can lower the basket in case of a power failure or an emergency situation. The emergency
lowering valve is located at the base of the lift cylinder.
Before lowering, it may be necessary to manually rotate the boom if it is over hanging an
obstruction. See the following section for this procedure.
To lower the work basket, push and turn the knurled knob counter-clockwise to desired
speed of descent (Figure 3-4). After lowering, press and turn the knob clockwise to close
the valve.
EMERGENCY
LOWERING
KNOB
Figure 3-4. Emergency Lowering Valve
3-4 MANUAL BOOM ROTATION
The 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. Loosen the crank stowage tube thumbscrew (Figure 3-5).
2. Remove the crank.
3. Install the crank on the hex end of the worm gear drive screw as shown.
4. Turn the crank handle to rotate the boom.
CRANK
STOWAGE
TUBE
THUMBSCREW
CRANK
IN USE
Figure 3-5. Boom Rotation
3-8
3 — OPERATION
3-5 BATTERY RECHARGE (DC MODEL ONLY)
The DC 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 t o 24 hours.
Recharge the DC 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, flame or
other ignition sources.
2. Turn the BATTERY ON/OFF switch to the OFF position.
3. Plug a short, heavy-duty power cord into the battery charger receptacle on the
front of the battery compartment. The recommended power cord should be an
12 AWG multi-strand, grounded cord no longer than 20 feet (6 meters).
NOTE: Using an underrated or lo ng power cord will reduce the output of the
battery charger, resulting in longer charge time.
BATTERY
CHARGER
RECEPTACLE
BATTERY
CHARGER
Figure 3-6. Battery Charger and Receptacle
4. Plug the power cord into a grounded 120 VAC receptacle. Verify that the red
ON-CHARGING indicator LED lights up on the battery charger.
3-9
XLB-4232 DC
5. To determine the charge rate at any time during the charge cycle, observe the
DC ammeter (Figure 3-7). 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 3-7. Battery Charger
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.
6. 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 charge. At full charge (3-1/2 hours after the 80% CHARGE
indicator lights up), the charger turns off.
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.
7. Unplug the power cord from the 120 VAC receptacle and the charger receptacle.
Properly store the power cord for next use.
3-10
3 — OPERATION
3-6 BOOM LIFT TRANSPORT
The boom lift trailer is a single axle trailer fitted with a two-inch ball hitch, surge brakes,
breakaway safety cable, safety chains, brake lights, and side marker lights. Proper boom
lift transport requires the correct hookup and inspection of these trailer components
before towing. Use the following procedures to hitch, tow, and back the boom lift trailer:
Trailer Hitching
Trailer hitching requires a sec ond person to give t ow vehicle backing instructions.
1. Back the tow vehicle to the trailer. Verify that the ball and hitch are in line and
that the trailer hitch will clear the ball. Jack up the tongue as needed.
2. Align the ball and hitch. Wrap and fasten the breakaway safety cable around the
ball hitch (Figure 3-8).
HITCH
RELEASE
HANDLE
BREAKAWAY
SAFETY CABLE
Figure 3-8. Breakaway Safety Cable
3. Hold ball hitch release lever open and lower the hitch onto the ball. Let go of the
release lever to secure the ball.
4. Crank the jack down to check for secure coupling. If jacking will raise the tow
vehicle bumper two or three inches, the ball hitch coupling is secure.
5. Pull the pin keeper and pivot locking pin, raise the jack to the travel position as
shown in Figure 3-9, and reinstall the pivot locking pin and pin keeper.
Figure 3-9. Jack Travel Position
3-11
XLB-4232 DC
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.
6. Attach the trailer safety chains to the tow vehicle. Make sure the chains cross
under the trailer tongue as shown in (Figure 3-10). If needed , cross the chains
over then under the tow bar to prevent dragging.
BREAKAWAY
SAFETY CABLE
SAFETY
CHAINS
Figure 3-10. Trailer Hitching Checkpoints
7. Connect the trailer lights to the tow vehicle power plug.
8. Before towing the trailer, check the following and make all necessary
adjustments, corrections, or repairs:
a. Check that trailer jack and outriggers are locked in travel positions.
b. Verify that the transport pin secures the lower boom to the trailer frame. If
the boom is not secured, install the transport pin and pin keeper at this time.
c. Verify that all onboard equipment is secured.
d. Check that the BATTERY ON/OFF switch is in the OFF position.
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.
3-12
3 — OPERATION
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 4-2 of this
manual. More frequent torque checks are required when a wheel is recently installed.
After 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.
3-13
XLB-4232 DC
3-14
4
4
44
Maintenance
4-1 SCHEDULED SERVICE CHECKS
Daily/Weekly Service Checks
Perform the following daily/weekly service checks as listed in Table 4-1.
Table 4-1. Daily/Weekly Service Checks
Service Check
Check battery electrolyte level. If battery charge is low, add
water to bring electrolyte just above plates. If batteries are
fully charged, raise electrolyte to full mark in each cell.
Check and retighten all nuts and bolts.
Check that cage gate is secure.
Check to see that all decals are present.
Check that controls and indicators on upper and lower
control panels operate properly.
Check/add hydraulic oil.
Check trailer tires for proper inflation. When cold, tires
should be inflated to 65 psi.
Check trailer running lights for proper operation.
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.
Use small diameter probe to check upper control box drain
holes for clogging. If clogged, open box and remove debris.
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
before use Weekly
4-1
XLB-4232 DC
Monthly Service Checks
Perform the following monthly service checks as listed in Table 4-2.
Table 4-2. Monthly Service Checks
Service Check
Clean battery terminals and check battery
charger operation.
Check operat ion of manual emergency
lowering valve.
Check wheel nut torque per paragrap h 4-2.
Check for excess wear, free play, or binding in
outrigger screws. Replace damaged parts.
Lubricate power 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.
Lubricate wheel bearings per paragraph 4-3.4.
Check battery cables and wiring for loose
connections and damaged wires.
Check outrigger bushings and replace if
necessary per paragraph 4-5.
Replace hydraulic oil and oil filter.
Check boom pivot points for bearing wear.
Replace worn or damaged bearings.
Check slew bearing for wear or damage; torque
bearing bolts to 200 lb-ft (271 N
Inspect and adjust trailer brakes.
Load test boom with 300 pounds.
·m).
month
Every
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 nut torque on the boom lift
trailer. The wheel nuts 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 lug nuts to 25 lb-ft (34 N
shown in Figure 4-1.
Figure 4-1. Wheel Nut Tightening Sequence
2. Evenly tighten the wheel lug nuts to 60 lb-ft (81.4 N
sequence shown.
3. Evenly tighten the wheel lug nuts to 100 lb-ft (135.6 N
tightening sequence shown.
4-3 LUBRICATION
Lubrication makes operation of the XLB-4232 DC Boom Lift more efficient and extends
the equipment life. Use the following procedures to lubricate the boom lift components.
1. Lubricate trailer and outrigger jack posts and all grease fittings labeled
LUBRICATE WEEKLY with NLGI Grade 2 multi-purpose grease.
·m) in the tightening sequence
·m) using the nut tightening
·m) using the nut
2. Lubricate all LUBRICATE MONTHLY grease fittings with NLGI Grade 2
multi-purpose grease. Wipe off dirt and grease residue. Add approximately ½
ounce of fresh grease to each fitting. See Figure 4-2 for grease fitting locations.
Figure 4-2. Lubricate Monthly
4-3
XLB-4232 DC
3. Lubricate the slew ring bearing grease fitting labeled LUBRICATE SEMIANNUALLY with NLGI Grade 2 multi-purpose grease. Wipe off dirt and
grease residue. Rotate the boom and add approximately ½ ounce of grease to
each bearing quadrant. See Figure 4-3 for the location of the slew ring bearing
grease fitting.
Figure 4-3. Lubricate Semi-Annually
16. Determine whether the boom lift is equipped with an Al-Ko axle (hex tube) or
Dexter axle (square tube). Lubricate the boom lift axle per the applicable
procedure in step 5 or 6.
17. Clean and repack Al-Ko axle wheel bearings according to the following
general instructions:
a. Use the outriggers to raise the trailer wheels.
b. Remove the spindle caps, cotter pins, spindle nuts, washers, outer wheel
bearings, and wheels. Remove inner wheel bearings.
c. Clean wheel bearings, bearing races, and spindle with solvent and lint-free
cleaning cloths.
d. Repack inner and outer wheel bearings with a reputable NLGI Grade 2
polyurea type, lithium-based, high-temperature, wheel bearing grease
(minimum 440°F dropping point).
e. Apply a thin film of grease to the bearing races and spindles.
f. At each wheel, install inner bearing, wheel, outer bearing, washer, and
spindle nut. Turn wheel and tighten spindle nut until wheel hub binds.
g. Hold the wheel stationary and loosen the spindle nut. Finger tighten the
spindle nut, then back off as needed to align the cotter pin hole. The wheel
should be free to spin without binding or excess free play.
h. Install cotter pin and spindle cap.
4-4
4 — MAINTENANCE
18. Lubricate a Dexter axle according to the following procedure:
a. Remove the rubber plug to expose the grease fitting.
b. Grease the bearings with an NLGI Grade 2 polyurea type, lithium-based,
high-temperature, wheel bearing grease (minimum 440°F dropping point).
Rotate the hub while applying grease.
c. Continue to apply fresh grease until all the old grease is purged. When new
grease starts to flow from the front bea ring, remove the grease gun. Remove
the excess grease and reinstall the rubber plug.
INNER
BEARING
RUBBER
OUTER
BEARING
PLUG
GREASE
FLOW
GREASE
FITTING
METAL
END CAP
Figure 4-4. Lubrication of Dexter Axles
19. When installing the hub of a Dexter axle or if a wheel bearing adjustment is
necessary, use the following instructions:
a. Install the inner bearing, wheel, outer bearing, washer, and spindle nut.
While rotating the hub, tighten the spindle nut to 50 lb-ft.
b. Hold the hub stationary and loosen the spindle nut. Finger tighten the
spindle nut, then back off the nut to align the cotter key hole. The wheel hub
should be free to spin without binding or excess free play.
c. Install the locking tang and end cap.
d. Lubricate the bearings according to the instructions in step 6.
4-5
XLB-4232 DC
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
at the end of this section for general reference.
Hydraulic System Inspection
Check the hydraulic hose and fittings for leaks and damage daily. Tighten or replace as
necessary to prevent hydraulic oil loss.
Fluid Check and Replacement
The oil level sight gage should be checked with the boom down and the trailer on a level
surface. The reservoir is originally filled with AW-46, a high-grade, non-foaming
hydraulic oil designed for temperatures as low as -20°F (-33°C).
Use Dextron Automatic Transmission Fluid Type A for low temperatures reaching -40°F
(-40°C). 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 reaching 0°F (-18°C).
Do not mix hydraulic oils. Clean the reservoir sump strainer and replace the hydraulic oil
once a year or whenever the oil becomes contaminated.
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 thr ough 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 Cylinder Repair
Cylinder Removal and Installation
1. Lower boom onto travel support, turn off the main power switch, and remove the
PLATFORM/OFF/GROUND key.
2. Support lift cylinder with wood shoring between cylinder and boom. Secure both
ends of lower boom lift cylinder with lifting straps and overhead lifting device.
Support upper boom lift cylinder with padded lift truck forks.
3. P lace absorbent drip cloths below cylinder ports. Remove hydraulic hoses from
lift cylinder. Elevate hoses above hydraulic reservoir and protect exposed hose
fittings and cylinder ports with protective caps.
4. Refer to Figure 4-5. Remove screws (1), lock washers (2), and locking plate (3)
from elevated end of cylinder (6).
3
2
1
5
5
5
6
5
4
3
2
1
1. Screws 4. Pivot Pin
2. Lock Washers 5. Spacer
3. Locking Plate 6. Cylinder
Figure 4-5. Hydraulic Cylinder Removal
4
4-7
XLB-4232 DC
5. Using a pry bar and shoring, unweight the cylinder end. Remove pivot pin (4)
and spacers (5).
6. Lower the free end of cylinder (6) onto support shoring or a lifting strap.
7. Repeat steps 4 through 6 at the opposite end of the cylinder.
8. Lift the lower end of the cylinder from its pivot block. Use an overhead lifting
device and lifting straps and/or a lift truck to remove the cylinder.
9. After repairing the hydraulic cylinder, reinstall the cylinder in the reverse order
of removal.
10. Power up the hydraulic system and check for leakage. Tighten hydraulic fittings
as needed.
11. Bleed entrapped air from the hydraulic cylinder according to instructions in
paragraph 4-4.
4-8
4 — MAINTENANCE
Cylinder Disassembly and Inspection
Perform the following procedure to disassemble the upper or lower hydraulic lift cylinder.
Whenever the hydraulic cylinder is disassembled, all seals must be replaced. Refer to
replacement seal kit, Figure 6-3 or 6-4.
1. Check bearings (1, Figure 4-6) for wear and excess play. Replace bearings if
necessary.
2. Unscrew headstock (2) and slide cylinder rod (3) from housing (4).
3. Remove slotted nut (5) and piston (6). Remove and discard wear ring (7), o-rings
(8 and 9). Remove sleeve (10).
1. Bearings
2. Headstock
3. Cylinder Rod
4. Housing
5. Slotted Nut
6. Piston
7. Wear Ring
8. O-Ring
9. O-Ring
10. Sleeve
11. O-Ring
12. Backup Ring
13. Seal
14. Bushing
15. Wiper
Figure 4-6. Hydraulic Cylinder Repair
4-9
XLB-4232 DC
4. Remove headstock (2). Remove and discard o-ring (11), backup ring (12), and
seal (13). Remove bushing (14) and wiper (15). Discard wiper.
5. Inspect the cylinder rod (3) for scratches or pits. Pitting in the base metal is not
acceptable. Wear indications that catch the fingernail, but do not extend into the
base metal nor extend more than 1/2 inch along the rod length are acceptable if
they will not cut the seal material. The chromium plating must not be worn
through. Replace the cylinder rod if not acceptable by these inspection criter ia.
6. Inspect the headstock (2). Check the inside bore for scratches; deep scratches or
cracks are unacceptable. Check the bore for polished wear surfaces. Polishing
indicates uneven loading. Check the bore for out-of-roundness. If the bore is
more than 0.007 inch out-of-round, replace the head. Seal groove damage is
unacceptable. Replace the headstock if these conditions are not met.
7. Inspect piston (6). Check the outside surface for scratches; deep scratches are
unacceptable. Check the outside surface for polished wear surfaces. If polishing
is noticed, check the piston for out-of-roundness. If out-of roundness exceeds
0.007 inch, replace the piston. Seal groove damage is unacceptable. Replace the
piston if these conditions are not met.
8. Inspect cylinder housing (4) for scratches or pits. Pits or scratches that are deep
enough to catch the fingernail are not acceptable. Scratches that catch the
fingernail, but extend less than 1/2 inch along the tube length, are acceptable
providing they are not sharp enough to cut the seals. Replace the cylinder tub e if
these conditions are not met.
Cylinder Assembly
1. Lubricate headstock (2, Figure 4-6), wiper (15), seal (13), backup ring (12), and
o-ring (11) with hydraulic fluid.
2. Twist seal (13) into a ‘C’ shape and seat it in mating groove of headstock (2).
3. Seat wiper (15), backup ring (12), and o-ring (11) in mating groove of headstock
(2). Make sure the back-up ring is installed above the o-ring. Use brass tools or
plastic tools to avoid seal groove damage during installation. Scratching the seal
grooves may cause by-pass leakage. Allow the assembled headstock to sit one
hour for the seals to regain their original shape.
4. Lubricate piston (6) and o-rings (8 and 9) with hydraulic fluid.
5. Install wear ring (7). Allow the assembled cylinder head to sit one hour for the
seals to regain their original shape.
6. Thoroughly rinse the inside of cylinder housing (4) with a high-pressure rinse
and wipe with lint free cleaning cloths.
7. Install the headstock (2), bushing (14), stop sleeve (10), piston (6) and nut (5 )
onto the cylinder rod (3). Tighten the nut from 100 to 120 lb-ft (136 to 162
N
·m).
8. Apply anti-seize to the headstock threads and installed o-ring (11).
9. Coat the cylinder rod with hydraulic fluid and insert the rod into the cylinder
housing. When insert i ng headstock (2) make sure t hat static o-ring (11) does not
extrude from the o-ring groove. Be careful not to nick the seals as they enter the
cylinder housing.
10. Screw headstock into the cylinder housing and tighten for a snug fi t of the wiper
(15) on the cylinder rod (3).
11. Pr ess in new bearings (1).
4-10
4 — MAINTENANCE
4-5 ADJUSTING AXLE POSITION SWITCHES
The axle position switches are set up to detect when the boom lift load is transferred from
the trailer wheels to the outriggers. After the first 100 miles of road travel the axle torque
arms wear in. Torque arm wear-in causes the wheels to ride higher in relation to the trailer
frame. Following wear-in, the axle position switches need to be readjusted. Use the
following procedure to readjust the axle position switches:
1. Deploy the outriggers and raise the trailer wheels off the ground. The wheels
should spin freely.
2. Loosen the switch bracket, Figure 4-7.
3. Adjust the switch position to where the roller just touches the upper edge of the
torque arm. Tighten the switch bracket.
4. Repeat the adjustment procedure for the axle position switch at the opposite
wheel.
Figure 4-7. Adjusting Axle Position Switches
4-11
XLB-4232 DC
4-6 TROUBLESHOOTING
Table 4-3. Troubleshooting Chart
Problem Cause Correction
1. Outriggers indicator lamp
will not light up.
a. Master power switch turned off.
b. Emergency stop or power button
engaged (pushed in).
c. All outriggers not deployed.
d. At least one wheel not raised.
a. Turn on master power switch.
b. Rotate emergency stop buttons
clockwise to dise ngage.
c. Deploy all outriggers.
d. Raise at least one wheel off the
ground.
2. Boom UP/DOWN and
ROTATION functions do not
work.
3. Single boom lift or rotation
function does not work.
4. Boom lift and rotate
functions do not operate
properly.
a. Master power switch turned off.
b. Low battery power.
c. Boom lift is out of level.
d. Emergency stop or power button
engaged (pushed in).
e. Battery ground or in-series cable
loose.
f. All outriggers not deployed
g. At least one wheel is not raised.
h. Battery cable or equipment ground
lead loose or corroded.
i. Hydraulic pump not pumping.
a. Loose wiring connector.
b. Valve solenoid not operating
properly.
c. System interlock fault.
d. Broken or loose wire.
a. Valve solenoid not operating
properly.
b. Loose solenoid wiring.
a. Turn on master power switch.
b. Check battery charge LEDs on upper
control panel. Recharge batteries if
yellow or red LED is lighted.
c. Level boom lift with outrigger jacks.
d. Rotate emergency stop button
clockwise to dise ngage.
e. Check for and repair loose battery
connections or ground fault.
f. Check outrigger display. Lower
outrigger ja cks to engage switches.
g. Check outrigger display. Raise at
least one wheel off the ground.
h. Clean and reconnect loose or corroded
battery cable or ground lead.
i. Check pump motor operation; repair
or replace if not running. Check gear
pump; replace if hot to touch.
a. Check wiring terminals in control box
and at valve manifold; repair loose
wiring terminal.
b. Swab out valve solenoids and recheck
function; replace solenoid if faulty.
c. Check display for system status.
Correct indicated fault conditions.
d. Repair or replace wire.
a. Swab out valve solenoids and recheck
function; replace solenoid if faulty.
b. Check wiring terminals in control box
and at valve manifold; repair loose
wiring terminal.
4-12
4 — MAINTENANCE
Table 4-3. Troubleshooting Chart, Continued
Problem Cause Correction
5. Boom lift and rotate
functions operate
intermittently.
a. Loose connection.
b. Loose connector at valve coil.
a. Reconnect wiring.
b. Check wiring connection to valve coil;
repair loose wiring.
4-13
XLB-4232 DC
T2
T1
T4
T3
T5
T6
Rotate
Battery
Charger
B
R
110v AC
(-)
(-)
-
Tel e
+
-
+
+
-
-
+
+
-
Power
Switch
Master
L1
L2
R2
R1
T2
T1
BL2
BL1
R1-5
T8
T6
T4
Lift UP
Hi/
CCW
Tele
T12
T11
05
Low
6
In
Comp
Bucket
Comp
Bucket
4
8
CCW
CW
2
T-2
Lift DN
5
T5
CW
06
Out
Tele
R1-6
12
11
Beeper
Outrigger
Lift
-
W
B
+
Light
Cylinder
(-)
1
R1
Hi/Low
W
B
W
R
B
T9T8T7
(-)
T2
B
R1
7
R1
A
R1
T10T
Level Sensor
789
6
T
18
13
Outrigger
Display
514
1
3
0
W
Rot.
Lift
Selector
1
1
1
2
G
Cond
B
E-Stop
Lower Control box
Drive Rear
Pass Front
Drive Front
2
2
1
2
1
B
Pass Axle
G
W
6
514
3
1
0
789
1
Pass Rear
Drive Axle
Upper Control
Lift
Tele
Rotate
Box
T1
T3
T6
1
1
2
2
1
1
3
1
(-)
14
Panel
Bucket
Transport
Hour Meter
Limit Switch
E
+
-
N
N0N
-
Side
Protected
+
T
16
T
18
(-)
20
0
N
-
+
Low
Pump
Speed
-
+
+
-
T9
+
-
High
Pump
Speed
GRD
White
Bl B
R
Hot
3 Deg
B
T7
Switch
Mercury
Y
R
T
Comp/switch
Surge
Suppressor
T
20
T
19
AMP
c
C
E
-
Line Side
+
T
12
T
11
T
G
15
T
R
11
T
W
18
T
B
14
7
A
R1
Level
Outrigger
9B8
246
135
Sensor
123
456
Display
R2
Outriggers
0
4
9
5
8
6
7
-
-
-
-
-
BW
G
20
19
18
17
16
15
14
13
12
11
10
9
8
7
TR2
(-)
6
14
6
5
4
T2
T4
T5
Dead Man
B
(-)
R
Gauge
Battery
T
10
E-Stop
Comp
Bucket
T
T
12
Hi/Low
T9
T7
T8
20
T
T
19
11
T1Black
T2Blue
T3Brown
T4Orange
T5Yellow
T6Pink
T7Blue/Black
T8Brown/Red
T9Pink/Black
T10Orange/Black
T11Yellow/Red
T12Orange/Red
T19Black/Red
T20Yellow/Black
(-)Blue/Red
Extend
Hi Speed
4
3
2
1
R3
7
8
5
6
Red
Black
3
2
1
Blue
110v
Figure 4-8. Electrical Layout
4-14
4 — MAINTENANCE
YELLOW LED
OUT OF LEVEL
(MOMENTARY)
GREEN LED
INPUT POWER
RED LED
OUTPUT SIGNAL
(ON WHEN LEVEL)
Figure 4-9. 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.
4-15
XLB-4232 DC
8
L2
L1
Dual Pump Unit
Manifold Combo Valve
Piloted Operated Check Valve
Extention Cylinder
Master/Slave Cylinder
Double Piloted Operated Check Valve
Rotation Motor
Lift Cylinder
7
5
C2
C1
V2
V1
6
5
R2
R1
T2
T1
BL1
B02-05-0017 1
B02-04-0069 1
B02-04-0009 1
B02-03-0020 1
B02-03-0007 2
B02-04-0068 1
B02-06-0006 1
B02-03-0024 1
1
2
3
4
5
6
7
8
2
1
1.6
GPM
BL2
3
4
2.5
GPM
Figure 4-10. DC Model Hydraulic Diagram
4-16
4 — MAINTENANCE
4-7 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 NONE 7439-92-1
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 ingredients listed above are not subject to
the reporting requirements of 313 of Title III of the Superf und Amendments and
Reauthorization Act. The items are covered in an exemption as a “ Manufact ured
Article”. 372.30(b)
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 E l ectrolyte
Appearance & Odor Clear Liquid with Sharp Pungent Odor
SECTION IV: FIRE AND EXPLOSION HAZARD DATA:
Flash Point: Not Combustible
Auto Ignition Temperature N/A Flammability Limits in Air % by Volume: N/A
Extinguishing Media: Dry Chemical Carbon Di oxide, Water Fog, Wat er
Special Fire Fighting Procedures
released when acid decomposes. Wear NIOSH approved self-contained breathing apparatus.
Unusual Hazards
acid resistant cl ot hi ng. Sulfuric acid reacts violently with metals, nitrates, chlorates, carbides, fulminates,
picrates and other organic m a t eri al s. Reacts with most m etals to yield explosive/flamm abl e hydrogen gas.
This reaction is intensified when sulfuric acid is diluted with water to f orm battery electrolyte.
: Water applied t o sulfuric acid generates heat and causes acid to splatter. Wear full-cover
: Sulfuric Acid Fumes, Sulfur Dioxide Gas or Carbon Monoxide may be
4-17
XLB-4232 DC
*************************************************************************************************
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 WATE R FOR AT LEAST 15 MINUTES
Inhalation: REMOVE TO FRESH AIR, IF BREATHING IS DIFFICULT - GIVE OXYGEN
Ingestion: GIVE MILK TO DRINK, DO NOT
INDU CE VOMITTING. CA L L PHYSICIAN
*************************************************************************************************
SECTION VI -- REACTIVITY DATA
*************************************************************************************************
Stability: STABLE Condition s to Avoid: N/A
Incompatibility: AVOID COMBUSTIBLES, ORGANIC MATERIALS, AND STRONG REDUCING AGENTS
Hazardous Decompositi on 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
HYD ROGE N GAS. THIS REACT ION IS IN TENSIFIED WHEN DILUTED.
NFPA Rating: HEALTH: 3 FLAMMABILITY: 0 REACTIVITY: 2 SPECIAL: 0
HMIS Rating: HEALTH: 3 FLAMMABILITY: 0 REACTIVITY: 2 PERSO NAL 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
MECH ANICAL: 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
4-18
4 — MAINTENANCE
MATERIAL SAFETY DATA SHEET
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
---------------------------------------------------------------------------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 DATAFLASH POINT(METHOD USED): 425 DEG F.
FLAMMABLE LIMITS: NOT DETERMINED LEL: N/AUEL: 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.
----------------------------------------------------------------------------
HEALTH: 1FIRE: 1SPECIFIC: XREACTIVITY: 0
4-19
XLB-4232 DC
PAGE 2
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.
4-20
5
5
55
Replacement Decals
Refer to Table 5-1 and Figures 5-1 through 5-6 for descriptions and locations of decals on
the XLB-4232 DC Boom Lift.
Table 5-1. Replacement Decals, DC Model
Decal No. Description of Decal Qty
B06-00-0006 EMERGENCY CONTROL
VALVE
B06-00-0015 MAXIMUM CAPACITY…300
LBS. OR 1 OCCUPANT…
B06-00-0033 CAUTION: THIS UNIT SHALL
ONLY BE TOWED WHEN…
B06-00-0034 DANGER: …DURING
CHARGING, EXPLOSIVE
OXYHYDROGEN GAS…
B06-00-0036 LUBRICATE WEEKLY 13
B06-00-0037 LUBRICATE SEMI-ANNUALLY 1
B06-00-0041 MASTER POWER SWITCH 1
B06-00-0058 SAFETY TREAD 1
B06-00-0060 STOP…READ OPERATING… 2
B06-00-0062 THIS PLUG 115 VOLT 2
B06-00-0068 THE HYDRAULIC SYSTEM… 1
B06-00-0114 XLB-4232 (TRANSFER) 2
B06-00-0115 1500 WATT LOAD LIMIT 1
B06-00-0116 OPERATE WITH FULLY
CHARGED BATTERIES…
B06-00-0117 BUCKET TILT COMPENSATOR 2
B06-00-0118 BUCKET CONTROLS 1
B06-00-0129 OIL LEVEL – TRANSPORT
POSITION
B06-00-0130 LUBRICATE MONTHLY 10
B06-00-0139 DANGER: BEFORE USING:
EXTEND, LOCK, STABILIZE…
B06-00-0144 XLB-4232 SPECIFICATIONS 2
1
2
2
1
1
1
5
Decal No. Description of Decal Qty
B06-00-0145 DANGER: BOOM SAFETY
INSTRUCTIONS
B06-00-0146 DANGER: HIGH VOLTAGE
OPERAT ION – LARGE LABE L
B06-00-0151 DANGER: 110 VOLT 1
B06-00-0161B BIL-JAX TRANSFER, BLACK 2
B06-00-0161Y BIL-JAX TRANSFER, YELLOW 1
B06-00-0167 Caution Tape, Black and Yellow
B06-00-0173 SAFETY HARNESS LANYARD
ATTACHMENT POINT
B06-00-0189 WARNING: LEVEL MACHINE
BEFORE USE…
B06-00-0192 OPERATION AND SERVICE
MANUAL INSIDE
B06-00-0225 WARNING: STAY CLEAR
WHILE RAISING …
B06-00-0261 CAUTION: ANSI DECAL 1
B06-00-0266 SAFETY STRIPE-YELLOW
(TRANSFER)
B06-00-0268 EMERGENCY ROTATION
HANDLE
B06-00-0272 CAUTION ROTATE BUCKET 2
B06-00-0276 BASE CONTROLS 1
B06-00-0290 ATTENTION: DC MOTOR
FAILURE WARNING
B06-00-0359 SERIAL NO. TAG (NOT
AVAILABLE AS A
REPLACEMENT ITEM)
2
1
35’6”
1
1
1
1
1
1
1
1
5-1
XLB-4232 DC
XLB-4232
DANGER
OUTRIGGERS; AND LEVEL MACHINE.
CFT/RFC B06-00-0139
DANGER
IT IS UNLAWFULTO 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.
BEFORE USING: EXTEND, LOCK, STABILIZE
This machine is NOT insulated. Do not use within 10 ft. of power lines
or other electrically charged sources. This machine
protection for personnel from contact with or close proximity to any live
electrical power source and by allshould be considered energized
CFT/RFC B06-00-0146
personnel coming in contact with machine.
CAUTION
This machine is designed and manufactured in compliwith 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 be A92.2 and the owners
m
anual.
Alterations, modifications, or changes to this machine
without the written authorization of Workforce Products,
Inc. as well as any unauthorized adjustment of values,
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.
DOES NOT provide
COIA/RFT
B06-00-0261FFU
!! ATTENTION !!
To prevent premature motor failure, it is
imperative that the fiberglass cover be
kept in the closed position to protect
against direct contact with any foreign
particles and/or moisture. Should the
hydraulic power unit need to be cleaned,
it is very important to cover or shield the
motor. The DC motor must not comeinto
direct contact with foreign particles and/
or moisture. See Operator’s Manual for
details.
B06-00-0290
OPERATIONAND SERVICE
MANUAL INSIDE
COFC B06-00-0192
EMERGENCY ROTATION HANDLE
THIS PLUG 115 VOLT
RIL
B06-00-0268OFA
B06-00-0062
CAUTION
THIS UNIT SHALL ONLY BE TOWED
WHEN ALL BOOM SECTIONS ARE
FULLY DOWN AND LOCKED WITH
TRANSPORT SAFETY PINS.
B06-00-0033
FAILURE TO COMLYWITH THE FOLLOWING SAFETYINSTRUCTIONS OR ANY OTHER USE
BEFORE USE
• Operator must read and understand ownersmanual and alldecals onmachine before operating. Itis
operatorsresponsibility to complywith allwarnings and instructions.
• Survey thejob site andidentify allpotential hazards.
• Inspect liftfor proper maintenanceand anydamaged or worncomponents. DO NOToperate untilproper
maintenancehas been performedand alldamaged or wornparts havebeen replaced. Seeowners manual for
propermaintenance procedures.
• NEVER TAKECHANCES—DO NOTuse this liftif youare under theinfluence ofdrugs or alcohol,or if youfeel
dizzy,ill, orunsteady in anyway.
• OPERATE ONFIRM ANDLEVEL SURFACEONLY—if usedon loose gravelor othersoft surfaces, thelarge
squaresupport pads shouldbe addedto the baseof theoutriggers. Additionalbase supportmay be
necessaryon excessively softfooting.
• Extend, lock,and stabilize allfour outriggers.
• Level machinebefore use—if buzzersounds, liftis not leveland thenecessary outrigger adjustmentshould
bemade to levelmachine beforecontinuing.
• All occupantsmust wear fullbody harnessand lanyard.
• Check safetydevices daily beforeuse—see ownersmanual for propercheck procedures.
• When workingon public roads,warnings andbarriers must beset upin accordance withall local, state,and
federaltraffic codes.
• Cordon offarea around baseto keeppersonnel and otherequipment awayfrom unit whilein use.
DURINGUSE
• To avoidhand injuries,always keep handsinside basketarea during boommovement.
• DO NOTuse without allfour outriggersfully extended, lockedand stabilized.
• DO NOTrelease outriggers withboom extendedor operator inbasket.
• DO NOTmove or repositiontrailer whileoperator occupies basket.
• DO NOTuse when exposedto highwinds, rain, snow,or ice.
R
OF THIS EQUIPMENT WILL RESULTIN SERIOUS INJURY OR DEATH.
DANGER
SAFETY
HARNESS
LANYARD
ATTACHMENT
POINT
• DO NOTuse where liftoperator cancome in contactwith overheadobstructions such aselectric wires,cables,
ropes,overhangs, etc.
• DO NOToperate without fullbody harnessand lanyard inuse byall basket occupants.
• DO NOTstand orsit on guardrails or topedge ofbasket.
• DO NOTlean out overtop edgeof basket toperform work.
• DO NOTuse boxes, ladders,scaffolding, orany other
meansto increase workingheight.
• DO NOTclimb up ordown boom.
• DO NOTexceed rated liftcapacity.
• DO NOTallow ropes, electriccords, hoses,etc. to become
entangledin the liftwhile platformis being raisedor lowered.
• DO NOToverride, alter,or bypass safetydevices.
• DO NOTuse boom rotationfor pushingor pulling.
• DO NOTexceed platformcapacity when transferringloads to theplatform whileelevated.
• DO NOTuse as acrane forlifting materials.
• DO NOTleave keys inmachine whileunattended.
• Plug chargerin at theend ofeach day.
• When usingthe lift withthe 110Vpower cordplugged into thebase ofthe unit, caremust be takento ensurethat
thecord is notdamaged orentangled during rotation.
• DO NOTallow flames, sparks,or embersnear batteries andDO NOTsmoke near batteries. Batteriesproduce a
hydrogen,oxygen gas mixturewhich canexplode.
OWNERS& OPERATORSARE RESPONSIBLE FORINSPECTION, MAINTENANCE, TRAINING,
ANDOPERATION ASREQUIRED BY THEOWNERS MANUAL .
IFYOU HAVENOT BEEN PROVIDEDWITH SAFETYLITERATURE,
ORFOR ANYQUESTIONS CONCERNING THESAFE USEOF THIS
EQUIPMENT,CALL 419/445-9675.
Figure 5-1. Replacement Decals, Sheet 1 of 3
3
B06-00-0173UFC
LUBRICATE
MONTHLY
RIF
LUBRICATE
SEMI-ANNUALLY
COIA B06-00-0037
EMERGENCY CONTROL VALVE
B06-00-0015
B06-00-0114
B06-00-0130
B06-00-0006
LUBRICATE
WEEKLY
COIA B06-00-0036
DANGER
110 V OLT
B06-00-0151GFT/LFG
5
5-2
5 — REPLACEMENT DECALS
CCW
.
CW
COMPENSATOR
BUCKET TILT
AIF B06-00-0117
© Bil-Jax, Inc. 2004
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
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 gogglesand 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.
RIR/OFG
B06-00-0034
MASTER
POWER
SWITCH
RFT B06-00-0041
B06-00-0041
STAY CLEAR
WARNING
B06-00-0225
WHILE RAISING
OR LOWERING
CCFO B06-00-0225
STOP
READ OPERATING
INSTRUCTIONS BEFORE
OPERATING
MACHINE
RIL
B06-00-0060
B06-00-0060
XLB-4232 SPECIFICATIONS
CAPACITY 300 LB.
MAXIMUM PLATFORM HEIGHT 35 FT. 5 IN.
WORK HEIGHT 42 FT.
POWER SOURCE 24V DC BATTERY
CFT/OFG
© Bil-Jax, Inc. 2004
B06-00-0144
• Level machine before use.
WARNING
• Failure to level this machine could
result in serious injury or death!
LFC B06-00-0189
B06-00-0189
THE HYDRAULIC SYSTEM OF
THIS MACHINE IS DESIGNED TO USE
ENERGOL HLP-46 HYDRAULIC OIL
OII B06-00-0068
TRANSPORT
POSITION
MAX
MIN
RIF B06-00-0129
B06-00-0129
B06-00-0144
CAUTION
Right- hand corne ring is
limited due to bucket
position.
© Bil-Jax, Inc. 2004
COFG
B06-00-0272
OPERATE WITH FULLY CHARGED BATTERIES
REDUCED ELECTRICAL COMPONENT LIFE MAY
RESULT IF OPERATED WHEN BATTERYCONDI-
TION IS BELOW YELLOW LINE INDICATOR.
B06-00-0116
B06-00-0068
Figure 5-1. Replacement Decals, Sheet 2 of 3
B06-00-0117
B06-00-0266
Rotate bucket to
transport position
before towing.
B06-00-0272
B06-00-0116
• Use only tools equipped with
3 prong grounded plug.
• 1500Watt maximum load.
15 Amp maximum circuit.
•
AIF/RFC
B06-00-0115
B06-00-0115
5-3
XLB-4232 DC
UP
OUT
CCW
UPPER
LOWER
CW
.
.
SLOW
FAST
DOWN
.
.
.
OFF
CONTROLS
SELECTOR
IN
PULL
ON
PUSH
OFF
.
.
B06-00-0276OFA
OUTRIGGERS PROPERLY SET
© Bil-Jax, Inc. 2004
FAST
.
.
SLOW
PUL L
ON
CCW
.
CW IN DOWN
PUSH
OFF
OUT UP
.
© Bil-Jax, Inc. 2004
ON
.
OFF
.
B06-00-0118
C
O
N
T
R
O
L
S
B06-00-0118AIF/AFL
Model - XLB 4232 DC
VIN
Max. Plat. HT. 35 ft5in
Max Reach 32ft 0in
SYSTEM PRESSURE 1900 PSI
MANUFACTURED IN
G.V.W. - 4740 LBS.
B06-00-0359
B06-00-0167
B06-00-0276
5-4
Figure 5-1. Replacement Decals, Sheet 3 of 3
5 — REPLACEMENT DECALS
B06-00-0115
B06-00-0118
B06-00-0117
B06-00-0116
B06-00-0145
B06-00-0144
(OUTSIDE OF DOOR)
B06-00-0173
B06-00-0060
B06-00-0015
B06-00-0192
B06-00-0139
B06-00-0130
B06-00-0139
B06-00-0130
(WORM GEAR)
B06-00-0161Y
B06-00-0037
B06-00-0139
Figure 5-2. Decal Locations, Top View
5-5
XLB-4232 DC
B06-00-0167
B06-00-0146
B06-00-0145
B06-00-0139
B06-00-0015
B06-00-0192
B06-00-0272
B06-00-0058
B06-00-0114
B06-00-0161B
B06-00-0036
(BOTH ENDS)
B06-00-0144
B06-00-0225
B06-00-0130
(BOTH ENDS)
B06-00-0130
B06-00-0189
B06-00-0146
B06-00-0192 (ON MANUAL TUBE)
)
B06-00-0167
(STRIPED TAPE 3 OUTER
FACES EACH JACK
B06-00-0276
B06-00-0033
B06-00-0359
B06-00-0041
B06-00-0261
B06-00-0117
B06-00-0036
B06-00-0290
B06-00-0145
B06-00-0068
(INSIDE)
B06-00-0151
B06-00-0129
(INSIDE)
(INSIDE SILVER
JUNCTION BOX)
(INSIDE)
Figure 5-3. Decal Locations, Passenger Side
5-6
5 — REPLACEMENT DECALS
B06-00-0006
B06-00-0161
B06-00-0036
B06-00-0034
B06-00-0268
B06-00-0062
B06-00-0266
(STRIPED TRANSFER)
B06-00-0036
(EACH JACK)
B06-00-0130
B06-00-0272
B06-00-0114
B06-00-0130
B06-00-0130
B06-00-0036
B06-00-0130
Figure 5-4. Decal Locations, Driver Side
B06-00-0033
5-7
XLB-4232 DC
5-8
6
6
66
Parts List
6-1
XLB-4232 DC
6-1 UPPER BOOM PARTS LIST
Refer to Table 6-1 for the upper boom parts list.
15
17
20
14
13
12
16, 16A
1
22
23
21
5
4
22
7
8
9
8
3
2
7
11
10, 10A
24
20
20
2
6
3
4
19
5
17A
18
Figure 6-1. Upper Boom
6-2
6 — PARTS LIST
Table 6-1. Upper Boom Parts List
Item No. Part No. Description Qty
1 B14-00-0002 Boom, Upper 1
2 B30-00-0004 Spacer, Extension Cylinder, Ram End 2
3 B04-06-0001 Washer, Flat, 2 in. OD 2
4 0090-0210 Washer, Lock, Split, 3/8 in. 2
5 0090-0480 Screw, Cap, 3/8-16 x 1 in. w/Loctite Patch 2
6 B36-01-0004 Pin, Extension Cylinder, Ram End 1
7 B25-00-0003 Bushing, Bronze, 1-1/2 in. ID 2
8 0090-0344 Screw, Threadcutting, #10-24 x 1/2 in. 2
9 B18-00-0017 End Cover, Upper Boom 1
10 B02-03-0020 Cylinder, Boom Extension,
1
2-1/2 in. Bore x 168 in. Stroke
10A B02-13-0098 Kit, Seal Replacement, Extension Cylinder 1
11 B25-00-0002 Roller Bearing, 1-3/4 in. OD 2
12 B31-00-0007 Shim, Bottom 1
13 0090-0509 Screw, Cap, Nylon, 3/8-16 x 3/8 in. 6
14 0090-0510 Screw, Cap, Nylon, 3/8-16 x 1/2 in. 6
15 B31-00-0005 Shim, Top 1
16 B00-00-0031 Cable Track, 41 Link w/Mounting Brackets 1
16A B00-00-0074 Link, Replacement, Cable Track
17 B29-00-0165-1 Bracket, Cable Track, Driven, Left Hand 1
17A B29-00-0165-2 Bracket, Cable Track, Driven, Right Hand 1
18 B29-00-0012 Carrier Tube Arm 1
19 0090-0419 Washer, Flat, 1/4 in. 4
20 0090-0183 Nut, Nylon Lock, 1/4-20 6
21 0090-0422 Washer, Flat, 3/8 in. 4
22 0090-0188 Nut, Nylon Lock, 3/8-16 4
23 B00-00-0014 Cap, Black Plastic 2
24 B02-04-0068 Valve, P.O. Check 1
6-3
XLB-4232 DC
6-2 LOWER BOOM PARTS LIST
Refer to Table 6-2 for the lower boom parts list.
11
11
20
13
18
17
16
14
15
1
27
2
27
2
2
27
28
28
19, 19A
16
21
12
13
14
17
18
7A
28
2
23A
28
22, 22A
24
25
23
3
4
5
6
8
7
7A
5
6
9
27
2
10
26
Figure 6-2. Lower Boom
6-4
6 — PARTS LIST
Table 6-2. Lower Boom Parts List
Item No. Part No. Description Qty
1 B14-00-0001 Boom, Lower 1
2 0090-0510 Screw, Cap, Nylon, 3/8-16 x 1/2 in. 30
3 B31-00-0004 Shim, Side 4
4 0090-0429 Washer, Flat, 1 in. 2
5 B30-00-0003 Cam, Support Roller 2
6 0090-0363 Screw, Set, Socket, 1/4-20 x 3/4 in. 4
7 B25-00-0001 Roller, Boom Support 1
7A B25-00-0021 Bearing, Replacement 2
8 B31-00-0005 Shim, Top 1
9 B36-01-0006 Axle, Boom Support Roller 1
10 0090-0320 Pin, Roll, 1/4 x 1-1/2 in. 2
11 0090-0344 Screw, Threadcutting, #10-24 x 1/2 in. 4
12 B18-00-0015 End Cover, Lower Boom 1
13 B25-00-0023 Bushing, Bronze, 1.5 in. ID 2
14 B30-00-0001 Spacer, Extension Cylinder, Dead End 2
15 B36-01-0003 Pin, Extension Cylinder, Dead End 1
16 B04-06-0001 Washer, Flat, 2 in. OD 2
17 0090-0210 Washer, Lock, Split, 3/8 in. 2
18 0090-0480 Screw, Cap, 3/8-16 x 1 in. w/Loctite Patch 2
19 B02-03-0020 Cylinder, Boom Extension,
1
2-1/2 in. Bore x 168 in. Stroke
19A B02-13-0098 Kit, Seal Replacement, Extension Cylinder 1
20 B18-00-0016 Cover, Top, Lower Boom 1
21 B29-00-0009 Carrier Tube 1
22 B00-00-0031 Cable Track, 41 Link w/Mounting Brackets 1
22A B00-00-0074 Link, Replacement, Cable Track
23 B29-00-0166-1 Bracket, Cable Track, Fixed, Left Hand 1
23A B29-00-0166-2 Bracket, Cable Track, Fixed, Right Hand 1
24 0090-0005 Screw, Cap, 1/4-20 x 3/4 in. 4
25 0090-0419 Washer, Flat, 1/4 in. 4
26 0090-0183 Nut, Nylon Lock, 1/4-20 4
27 0090-0422 Washer, Flat, 3/8 in. 4
28 0090-0188 Nut, Nylon Lock, 3/8-16 4
6-5
XLB-4232 DC
6-3 TURNTABLE PARTS LIST
Refer to Table 6-3 for the turntable parts list.
1, 1A
LOWER
BOOM
10
10
22
24
8
23
2
21
7
14
4
5
6
3
9, 9A,
9B, 9C
11
2
12
13
15
16
17
18
19
3
4
5
8
5
6
7
20
6
7
22
25
26
Figure 6-3. Turntable
6-6
6 — PARTS LIST
Table 6-3. Turntable Parts List
Item No. Part No. Description Qty
1 B02-03-0007 Cylinder, Master Leveling,
2 in. Bore x 13-1/4 in. Stroke
1A B02-13-0037 Kit, Seal Replacement, Leveling Cylinder 1
2 0090-0103 Screw, Cap, 3/4-10 x 2-1/2 in. 2
3 0090-0428 Washer, Flat, 3/4 in. 2
4 0090-0195 Nut, Hex, Nylon Lock, 3/4-10 2
5 B29-00-0005 Plate, Pin 6
6 0090-0208 Washer, Lock, Split, 5/16 in. 12
7 0090-0028 Screw, Cap, 5/16-18 x 3/4 in. 12
8 B36-01-0005 Pin, Lift Cylinder 2
9 B02-03-0024 Cylinder, Boom Lift,
4 in. Bore x 31 in. Stroke
9A B02-13-0124 Kit, Seal Replacement, Lift Cylinder 1
9B B02-14-0061 Valve, NC Cartridge 1
9C B01-08-0001 Coil, 24V 1
10 B30-00-0002 Spacer, Lift Cylinder 4
11 0090-0005 Screw, Cap, 1/4-20 x 3/4 in. 4
12 0090-0206 Washer, Lock, Split, 1/4 in. 4
13 0090-0419 Washer, Flat, 1/4 in. 12
14 B18-00-0083 Cover, Turntable 1
15 B11-03-0002 Turntable Weldment 1
16 B36-01-0007 Pin, Lower Boom Pivot 1
17 B04-06-0001 Washer, Flat, 2 in. OD 2
18 0090-0210 Washer, Lock, Split, 3/8 in. 2
19 B04-05-0001 Screw, Cap, 3/8-16 x 1 in. Drilled for Zerk 2
20 B00-00-0009 Fitting, Grease, Straight, 3/16 in. 2
21 B05-00-0005 Tape, Foam Adhesive Back, 3/16 x 1/4 in. 66 in.
22 B00-00-0014 Cap, Black Plastic 2
23 B18-00-0021 Cover, Bubble Level 1
24 0090-0181 Nut, Hex, Nylon Lock, #8-32 1
25 0090-0710 Screw, Machine, #8-32 x 2-3/4 in. 1
26 B00-00-0001 Level, Bubble 1
1
1
6-7
XLB-4232 DC
6-4 DC MODEL BATTERY COMPARTMENT PARTS LIST
Refer to Table 6-4 for the DC model boom lift battery compartment parts list.
1
2
10
10
32
33
13
12
11
3
4
10
7
8
7
14
9
15
5
6
16
17
35
34
14
36
37
11
20
18
18
19
21
7
22, 22A
30, 30A
29
31
28
5
14
23
24
25
15
26
25
27
c
Figure 6-4. DC Mo del Battery Compartment
6-8
6 — PARTS LIST
Table 6-4. DC Model Battery Compartment Parts List
Item No. Part No. Description Qty
1 B18-00-0014 Lid, Compartment Cover 1
2 B18-00-0135 Vent Louver, 2-1/2 in. 4
3 B42-00-0006 Clip, Latch 1
4 0090-0225 Screw, Machine, #8-32 x 1/2 in. 1
5 0090-0181 Nut, Hex, Nylon Lock, #8-32 3
6 B18-00-0132 Frame, Compartment Cover 1
7 0090-0182 Nut, Hex, Nylon Lock, #10-24 15
8 B29-00-0073 Bracket, Ball Mounting 1
9 B39-00-0034 Spring, Gas 1
10 0090-0232 Screw, Machine, #10-24 x 5/8 in. 15
11 0090-0415 Washer, Flat, #10 7
12 B42-01-1002 Hinge 1
13 0090-0684 Rivet, Pop, 3/16 x 1/2 in. 3
14 0090-0183 Nut, Hex, Nylon Lock, 1/4-20 8
15 0090-0419 Washer, Flat, 1/4 in. 6
16 B04-07-0005 Rod, Threaded, Battery Retaining, 1/4 in. 2
17 B29-00-0017 Retainer Angle, Battery 1
18 B05-04-0001 Wrap, Spiral Black, 3/8 x 0.27 in.
19 B01-01-0028 Cable, Battery, 2 Ga. x 33 in. 1
20 B01-01-0012 Cable, Battery, 2 Ga. x 45 in. 1
21 B01-01-0014 Cable, Battery, 2 Ga. x 8 in. 3
22 B01-04-0003 Battery, 6 Volt DC, 250 Amp 4
22A B01-04-0009 Battery, Dry Cell, 6 Volt DC 4
23 B42-00-0005 Latch, Lid 1
24 0090-0814 Screw, Machine, #8-32 x 7/8 in. 2
25 0090-0005 Screw, Cap, 1/4-20 x 3/4 in. 8
26 0090-0206 Washer, Lock, Split, 1/4 in. 4
27 B18-00-0010 Cover, Side 1
28 B05-00-0007 Tape, Foam Adhesive Back, 1/16 x 1/2 in. 32 in.
29 B18-00-0018 Plexiglass, 1/8 in. x 8 in. x 8 in. 1
30 B01-05-0006 Charger, Battery, 40 Amp, 110 Volt AC, 60 Hz 1
30A B01-05-0027 Charger, Battery, 40 Amp, 220 Volt AC, 50 Hz 1
31 B18-00-0026 Cover 1
32 0090-0344 Screw, Threadcutting, #10-24 x 1/2 in. 2
33 B01-10-0003 Receptacle, Flush Mount 1
34 B29-00-0021 Bracket, Level Sensor Mounting 1
35 B01-10-0016 Sensor, Slope, 3°, 0.5 Second Delay 1
36 0090-0231 Screw, Machine, #10-24 x 1/2 in. 4
37 0090-0205 Washer, Lock, #10 4
6-9
XLB-4232 DC
6-5 DC MODEL POWER COMPARTMENT PARTS LIST
Refer to Table 6-5 for the DC model power compartment parts list.
54
13
55
56
12
64
17
3
19
42
41
3
6
23
24
20
46
28
41
44
38
40
21
22
39
43
37
25
36
45
35
34
28
26
33
22
32
27
28
20
29
30, 31
2
1
4
5
3
10
11
9
11
8
59
62
7
15
6
16
18
63
3
61
20
53
21
50
51
6
14
57
60
52
58
61
48
20
49
22
48
21
47
Figure 6-5. DC Mo del Power Compartment
6-10
6 — PARTS LIST
Table 6-5. DC Model Power Compartment Parts List
Item No. Part No. Description Qty
1 B18-00-0013 Lid, Compartment Cover 1
2 B18-00-0135 Vent, Louver, 2-1/2 in. 2
3 0090-0232 Screw, Machine, #10-24 x 5/8 in. 16
4 0090-0684 Rivet, Pop, 3/16 x 1/2 in. 3
5 B42-01-1002 Hinge 1
6 0090-0182 Nut, Hex, Nylon Lock, #10-24 16
7 B39-00-0034 Spring, Gas 1
8 B29-00-0073 Bracket, Ball Mounting 1
9 B18-00-0132 Frame, Compartment Cover 1
10 0090-0415 Washer, Flat, #10 5
11 0090-0181 Nut, Hex, Nylon Lock, #8-32 3
12 B42-00-0006 Clip, Latch 1
13 0090-0225 Screw, Machine, #8-32 x 1/2 in. 1
14 B02-04-0069 Valve, Combination, 24 Volt (for
1
component parts see page 6-40)
15 B02-02-0196 Fitting, Hex Nipple, 4 ORM-2 NPTM 1
16 B02-02-0018 Fitting, Quick Connect Male 1
17 0090-0420 Washer, Flat, 5/16 in. 2
18 0090-0879 Screw, Cap, 5/16-18 x 4 in. 2
19 B19-00-0007 Terminal Enclosure w/Cover (for
1
component parts see pages 6-14, 15)
20 0090-0183 Nut, Hex, Nylon Lock, 1/4-20 14
21 0090-0005 Screw, Cap, 1/4-20 x 3/4 in. 12
22 0090-0419 Washer, Flat, 1/4 in. 10
23 B00-00-0112 Faceplate, Master Power Switch 1
24 B01-02-0060 Switch, Master Power 1
25 B18-00-0011 Door, Lower Control Box 1
26 0090-0235 Screw, Machine, Flat Head, 10-24 x 3/4 in. 4
27 B37-00-0002 Lock w/Key (Key only B38-00-0003) 1
28 B05-00-0007 Tape, Foam Adhesive Back, 1/16 x 1/2 in. Roll
29 B19-00-0009 Lower Control Box Assembly (for
1
component parts see pages 6-39)
30 B01-09-0029 Cord Grip, 1/2 in. 1
31 B04-07-0030 Plastic Nut, 1/2 in. Cord Grip 1
32 0090-0007 Screw, Cap, 1/4-20 x 1-1/4 in. 2
6-11
XLB-4232 DC
54
13
55
56
12
2
3
1
4
3
5
3
10
11
8
6
6
7
16
58
15
18
17
19
9
14
57
59
61
62
63
3
64
6
21
27
23
22
28
25
20
11
60
52
48
21
61
50
51
20
53
42
41
46
24
20
41
28
44
38
40
39
43
37
36
45
35
34
28
26
33
22
32
29
30, 31
20
49
22
48
21
47
Figure 6-5. DC Mo del Power Compartment
6-12
6 — PARTS LIST
Table 6-5. DC Model Power Compartment Parts List, Continued
Item No. Part No. Description Qty
33 B01-10-0271 Display, Outrigger /Axle 1
34 0090-0001 Screw, Cap, 1/4-20 x 1/2 in. 2
35 B07-06-5589 Plate, Outrigger /Axle Display 1
36 B29-00-0152 Bracket, Outrigger /Axle Display 1
37 0090-0834 Nut, Jam, Nylon Lock, 1/4-20 4
38 0090-0627 Screw, Thread Cutting, #4-40 x 1/2 in. 2
39 B01-10-0007 Hourmeter 1
40 B01-02-0010 Switch, Toggle, Tilt 1
41 B01-10-0008 Circuit Breaker, 20 Amp 1
42 B29-00-0018 Bracket, Switch-Fuse-Hour Meter 1
43 B01-09-0105 Connector, 12 Pin, Outrigger Display 1
44 B01-09-0107 Insert, 12 Pin, Outrigger Display 1
45 B01-09-0108 Pin, Outrigger Display 6
46 B18-00-0019 Plexiglass, 1/8 in. x 4 in. x 6 in. 1
47 B18-00-0009 Cover, Control Side 1
48 0090-0206 Washer, Lock, Split, 1/4 in. 6
49 B02-00-0003 Assembly, Return Filter (includes head and
1
items 50-51)
50 B02-00-0004 Indicator 1
51 B02-00-0005 Element, Filter 1
52 B29-00-0016 Bracket, Oil Filter 1
53 0090-0042 Screw, Cap, 3/8-16 x 1-1/2 in. 2
54 0090-0814 Screw, Machine, #8-32 x 7/8 in. 2
55 B42-00-0005 Latch, Lid 1
56 B02-05-0017 Pump and Motor Assembly (for component
1
parts see pages 6-44, 45)
57 0090-0188 Nut, Hex, Nylon Lock, 3/8-16 2
58 0090-0210 Washer, Lock, Split, 3/8 in. 2
59 0090-0422 Washer, Flat, 3/8 in. 2
60 0090-0185 Nut, Hex, Nylon Lock, 5/16-18 2
61 B01-10-0002 Beeper 1
62 B01-10-0258 Surge Suppressor, 24VDC 1
63 B01-10-0260 End Clip 1
64 B01-10-0261 Din Rail 1
6-13
XLB-4232 DC
6-6 TERMINAL ENCLOSURE PA RTS LIST
Refer to Table 6-6 for the terminal enclosure parts list.
1
2, 3
25
5
7
2, 3
4
6
8
26
2, 3
10
24
9, 10
11, 12
1
13
15
7
23
22
21
6
14
19, 20
17, 18
14
16
14
Figure 6-6. Terminal Enclosure
6-14
6 — PARTS LIST
Table 6-6. Terminal Enclosure Parts List
Item No. Part No. Description Qty
1 B19-00-0007 Terminal Enclosure w/Cover 1
2 B01-09-0020 Cord Grip, 3/4 in. 3
3 B01-09-0021 Plastic Nut, 3/4 in. Cord Grip 3
4 B00-00-0102 Plug, Plastic 1
5 0090-0708 Screw, Machine, #6-32 x 3/8 in. 2
6 0090-0690 Screw, Machine, #6-32 x 5/8 in. 5
7 0090-0218 Screw, Machine, #6-32 x 1/2 in. 3
8 0090-0688 Screw, Cap, 1/4-20 x 1 in. 4
9 B01-09-0029 Cord Grip, 1/2 in. 1
10 B04-07-0030 Plastic Nut, 1/2 in. Cord Grip 1
11 B01-10-0090 Marker, 5 Position Terminal Strip 1
12 B01-10-0030 Terminal Strip, 5 Position 1
13 0090-0183 Nut, Hex, Nylon Lock, 1/4-20 4
14 0090-0180 Nut, Hex, Nylon Lock, #6-32 12
15 B01-06-0028 Relay, 24VDC, Quick Connect 1
16 B01-06-0013 Relay, 24VDC 1
17 B01-10-0089 Marker, 20 Position Terminal Strip 1
18 B01-10-0029 Terminal Strip, 20 Position 1
19 B01-10-0091 Marker, 3 Position Terminal Strip 1
20 B01-10-0031 Terminal Strip, 3 Position 1
21 0090-0220 Screw, Machine, #6-32 x 1 in. 2
22 B01-06-0007 Socket, Snap Mount Screw Terminal 1
23 B01-06-0008 Relay, 24VDC, Blade Terminal 1
24 B01-10-0032 Cover w/Latches 1
25 B06-00-0151 Decal, Danger 110V 1
26 B01-06-0012 Socket, 24V Relay 1
6-15
XLB-4232 DC
6-7 FRAME AND ROTATION UNIT LIST
Refer to Table 6-7 for the frame and rotation unit parts list.
2
3
1
4
7
10
5
12
11
13
6
9
8
11
29
15
16
17
14
24
25
26
27
18
20
21
19
34
33
22
23
28, 28A
30
31
32
Figure 6-7. Frame and Rotation Unit
6-16
6 — PARTS LIST
Table 6-7. Frame and Rotation Unit Parts List
Item No. Part No. Description Qty
1 B03-00-0078 Handle Assembly, Manual Rotation
1
(includes items 54 through 59)
2 B11-03-0018 Tube, Manual Boom Rotation 1
3 0090-0834 Nut, Nylon Lock, 1/4-20 1
4 0090-0011 Screw, Cap, 1/4-20 x 1-3/4 in. 1
5 B07-10-1042 Handle, Manual Boom Rotation 1
6 B46-00-0018 Grip, Rubber 1
7 B11-03-0015 Bracket, Upper Rotary Contact 1
8 B11-03-0002 Turntable Weldment 1
9 0090-0409 Screw, Thumb, 3/8-16 x 3/4 in. 1
10 B04-07-0062 Clip, Gripper 1
11 0090-0344 Screw, Threadcutting, #10-24 x 1/2 in. 1
12 0090-0643 Screw, Cap, 5/8-11 x 2-3/4 in. 12
13 0090-0612 Washer, Flat, 5/8 in. 30
14 B02-02-0025 Fitting, 90° Elbow 2
15 B02-06-0006 Motor, Hydraulic 1
16 0090-0461 Screw, Cap, 1/2-13 x 2 in. 2
17 0090-0212 Washer, Lock, Split, 1/2 in. 2
18 B00-00-0106 Fitting, Grease, 90° 3
19 B13-00-0006 Slew Ring Assembly (includes items 20 and
1
21)
20 B13-00-0001 Ring, Worm Gear 1
21 B25-00-0031 Slew Ring 1
22 0090-0127 Bolt, Carriage, 5/16-18 x 1 in. 14
23 B07-04-1001 Plate, Tread 1
24 B00-00-0061 Fitting, Grease, 1/8 in. NPT Straight 1
25 0090-0420 Washer, Flat, 5/16 in. 14
26 0090-0208 Washer, Lock, Split, 5/16 in. 14
27 0090-0160 Nut, Hex, 5/16-18 14
28 B12-00-0089 Trailer Weldment (accommodates later model
1
trailer axle and jack)
28A B12-00-0002 Trailer Weldment (accommodates early model
1
trailer axle and jack)
29 0090-0633 Screw, Cap, 5/8-11 x 1-1/2 in. 18
30 B01-09-0103 Spade, Female, .110 in. 4
31 B01-09-0095 Spade, Female, 1/4 in. 2
32 B00-00-0060 Support, Rotary Conductor 2
33 B01-10-0219 Conductor, Rotary 1
34 0090-0355 Screw, Set, 1/4-20 x 1/4 in. 2
6-17
XLB-4232 DC
6-8 HITCH AND JACK ASSEMBLY PARTS LIST
Refer to Table 6-8 for the hitch and jack assembly parts list.
10
1
2
24
9
8
7
6
5
13
14, 15
4
10
19
21
24
4
36
33
32
4
8
9
36
20
11
22
12
22, 22A,
23
18
17
7
22B
20
21
41
39, 40
42
45
39
4
38
43
44
37
3
29,30
31
35
24
28
34
26
27
24
25
16
46
39
47
48
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 B29-00-0010 Post, Support 1
2 B30-00-0009 Pad, Rubber 1
3 B28-00-0011 Brace, Support Post 2
4 0090-0192 Nut, Hex, Nylon Lock, 1/2-13 9
5 0090-0045 Screw, Cap, 3/8-16 x 1-1/2 in. 6
6 0090-0188 Nut, Hex, Nylon Lock, 3/8-16 6
7 0090-0344 Screw, Threadcutting, #10-24 x 1/2 in. 3
8 B40-00-0012 Chain, #3 x 10 in. 2
9 0090-0552 Ring, Key 2
10 B36-00-0033 Pin, Transport Safety 2
11 B03-00-0021 Assembly, Jack, Early Version
1
(includes items 12-18)
12 B23-02-0039 Weldment, Jack (includes items 13-15 1
13 B22-00-0002 Handle, Jack 1
14 B18-00-0001 Cover, Gear w/Clip 1
15 B22-00-0001 Bevel Gear Kit 1
16 0029-952 Caster Assembly 1
17 0090-0050 Screw, Cap, 3/8-16 x 2 1/2 in. 1
18 0090-0188 Nut, Hex, Nylon Lock, 3/8-16 1
19 0090-0005 Screw, Cap, 1/4-20 x 3/4 in. 1
20 B04-07-0032 Clamp, Cable/Hose, DG 6 5
21 0090-0183 Nut, Hex, Nylon Lock, 1/4-20 9
22 B01-10-0021 Marker, Side, Amber 2
22A B01-10-0066 Lens, Replacement 2
22B B01-10-0068 Bulb, Side Marker 2
23 0090-0712 Screw, Cap, 1/2-13 x 4-3/4 in. 1
6-19
XLB-4232 DC
10
1
2
24
9
8
7
6
5
13
14, 15
4
10
19
21
24
4
36
33
32
4
8
9
36
20
11
22
12
22, 22A,
23
18
17
7
22B
20
21
41
39, 40
42
45
39
4
38
43
44
37
3
29,30
31
35
24
28
34
26
27
24
25
16
46
39
47
48
Figure 6-8. Hitch and Jack Assembly
6-20
6 — PARTS LIST
Table 6-8. Hitch and Jack Assembly Parts List, Continued
Item No. Part No. Description Qty
24 0090-0574 Washer, Flat, 1/2 in. 8
25 0090-0081 Screw, Cap, 1/2-13 x 5 in. 1
26 B03-00-0017 Chain, Safety 2
27 B01-01-0121 Harness, Tail Light 1
28 0090-0080 Screw, Cap, 1/2-13 x 4-1/2 in. 3
29
30
31
32
33
34
35
B12-00-0169 Hitch, Tow (includes items 30-33) 1
B12-00-0182 Clamp Kit, 2 in. Ball 1
B12-00-0181 Push Rod w/Breakaway Cable 1
B12-00-0180 Cap, Replacement 1
B02-02-0227 Fitting, Brake Line Adapter 1
B12-00-0013 Hitch, Tow, Early Version (includes item 35) 1
B12-00-0033 Cap, Replacement, Early Version Hitch 1
36 B21-00-0001 Kit, Brake Line 1
37
B03-00-0105 Assembly, Jack
1
(includes items 38-48)
38
39
B23-02-0058 Weldment, Outer Jack Tube 1
B23-02-0057
Assembly, Inner Jack Tube
1
(includes items 40-44)
40
B46-00-0028 Kit, Handle Replacement
1
(includes items 41 and 42)
41
42
43
44
45
0090-0183 Nut, Hex, Nylon Lock, 1/4-20 1
0090-0007 Screw, Cap, 1/4-20 x 1-1/4 in. 1
B04-06-0030 Washer, 2.18 in. Square 1
B25-00-0068 Bearing Assembly 1
B00-00-0085 Fitting, Grease, 1/4-28 1
46 B03-00-0148 Caster Assembly 1
47 0090-0188 Nut, Hex, Nylon Lock, 3/8-16 4
48 0090-0042 Screw, Cap, 3/8-16 x 1 in. 4
6-21
XLB-4232 DC
6-9 SQUARE TUBE AXLE AND WHEEL ASSEMBLY
PARTS LIST
Refer to Table 6-9 for the square tube axle and wheel assembly parts list.
50
51
49
47
21, 21A
24
48
17
47
25
14, 14A
15,15A
32,32A
8
1
16
2
5
3
4
9
10
11
36
30
29
28
34
31
26
6
18
7
13,13A,
35,35A
46
33
37
12
38
39
45
40
21, 21A
41
42
43
44
20
21, 21A
22
23
21, 21A
27
19
Figure 6-9. Square Tube Axle and Wheel Assembly
6-22
6 — PARTS LIST
Table 6-9. Square Tube Axle and Wheel Assembly Parts List
Item No. Part No. Description Qty
1 B10-00-0041 Axle, Square Tube 1
2 0090-0938 Nut, Hex, Lock, 5/8-18 4
3 0090-0612 Washer, Flat 5/8 in. 4
4 0090-0937 Screw, Cap, 5/8-18 x 1-1/2 in. 4
5 0090-0032 Screw, Cap, 5/16-18 x 1-1/2 in. 8
6 0090-0208 Washer, Lock, 5/16 in. 8
7 0090-0420 Washer, Flat, 5/16 in. 8
8 B12-00-0010 Fender 2
9 B10-00-0052 Seal, Grease 2
10 B10-00-0053 Cone, Inner Bearing 2
11 B10-00-0055 Cup, Inner Bearing 2
12 B10-00-0049 Assembly, Wheel Hub
2
(includes bearings, grease seal, and studs)
13 B10-00-0043 Brake Assembly, Right Hand, Hydraulic
1
(includes items 14, 15, 16-20, 21, 22-31, 32,
33 & 34)
13A B10-00-0042 Brake Assembly, Left Hand, Hydraulic
1
(includes items 14A, 15A, 16-20, 21A, 22-31,
32A, 33 & 34)
14 B10-00-0088 Backing Plate Assembly, Right Hand 1
14A B10-00-0087 Backing Plate Assembly, Left Hand 1
15 B10-00-0090 Cylinder, Uni-Servo, Right Hand 1
15A B10-00-0089 Cylinder, Uni-Servo, Left Hand 1
16 B10-00-0091 Push Rod, Cylinder 1
17 B10-00-0092 Screw/Washer Assembly 2
18 B10-00-0093 Travel Link 1
19 B10-00-0094 Spring, Retractor 1
20 B10-00-0095 Spring, Shoe Lever Return 1
21 B10-00-0048 Kit, Hydraulic Brake Shoe/Lining, Right Hand 1
21A B10-00-0047 Kit, Hydraulic Brake Shoe/Lining, Left Hand 1
22 B10-00-0096 Adjuster Assembly 1
23 B10-00-0097 Spring, Adjusting Screw 1
24 B10-00-0098 Plug, Adjuster Slot 1
25 B10-00-0099 Nut/Washer Assembly 5
26 B10-00-0100 Shoe Lever 1
27 B10-00-0101 Nut, Lock 1
28 B10-00-0102 Screw 1
29 B10-00-0103 Washer 1
Items 14-34 are for hydraulic surge brakes only.
6-23
XLB-4232 DC
50
51
49
47
21, 21A
24
48
17
47
25
14, 14A
15,15A
32,32A
8
1
16
2
5
3
4
9
10
11
36
30
29
28
34
31
26
6
18
7
13,13A,
35,35A
46
33
37
12
38
39
45
40
21, 21A
41
42
43
44
20
21, 21A
22
23
21, 21A
27
19
Figure 6-9. Square Tube Axle and Wheel Assembly
6-24
6 — PARTS LIST
Table 6-9. Square Tube Axle and Wheel Assembly Parts List, Continued
Item No. Part No. Description Qty
30 B10-00-0104 Spring, Primary Shoe Return 1
31 B10-00-0105 Retainer 1
32 B10-00-0108 Parking Lever & Pin, Right Hand 1
32A B10-00-0107 Parking Lever & Pin, Left Hand 1
33 B10-00-0106 Strut, Parking Brake 1
34 B10-00-0109 Washer 1
*35 B10-00-0044 Brake Assembly, Right Hand, Electric
1
(includes item 36, Not Illustrated)
*35A B10-00-0045 Brake Assembly, Left Hand, Electric
1
(includes item 36, Not Illustrated)
*36 B10-00-0046 Kit, Electric Brake Shoe/Lining
2
(Not Illustrated)
37 B10-00-0056 Cup, Outer Bearing 2
38 B10-00-0054 Cone, Outer Bearing 2
39 B10-00-0059 Washer, Spindle 2
40 B10-00-0051 Washer, Tang, EZ Lube 2
41 B10-00-0060 Nut, Spindle, EZ Lube 2
42 B10-00-0057 Cap, Grease, EZ Lube 2
43 B10-00-0058 Plug, Rubber, EZ Lube Grease Cap 2
44 0090-0624 Nut, Wheel Lug, 1/2-20 12
45 B08-02-0003 Tire, ST225/75D-15 2
46 B10-00-0050 Stud, Wheel, 1/2-20 12
47 0090-0182 Nut, Hex, Nylon Lock, #10-24 8
48 B07-01-1081 Bracket, Limit Switch 2
49 B01-02-0075 Switch, Limit, Axle Position 2
50 0090-0232 Screw, Machine, #10-24 x 5/8 in. 4
51 0090-0236 Screw, Machine 4
Items 14-34 are for hydraulic surge brakes only.
*Optional equipment on original boom lift order only.
6-25
XLB-4232 DC
6-10 HEX TUBE AXLE AND WHEEL ASSEMBLY
PARTS LIST
Refer to Table 6-10 for the early version axle and wheel assembly parts list.
4
5
26
25
24
23
22
27
9
1
8
7
6
11
13, 13A
14
21
12
15
28
16
17
18
19
20
10
3
2
Figure 6-10. Hex Tube Axle and Wheel Assembly
6-26
6 — PARTS LIST
Table 6-10. Hex Tube Axle and Wheel Assembly Parts List
Item No. Part No. Description Qty
1 Not Procurable Axle, Hex Tube 1
2 0090-0192 Nut, Lock, 1/2-13 4
3 0090-0574 Washer, Flat 1/2 in. 8
4 0090-0461 Screw, Cap, 1/2-13 x 2 in. 4
5 0090-0648 Washer, Bevel, 1/2 in. 4
6 0090-0032 Screw, Cap, 5/16-18 x 1-1/2 in. 8
7 0090-0208 Washer, Lock, 5/16 in. 8
8 0090-0420 Washer, Flat, 5/16 in. 8
9 B12-00-0010 Fender 2
10 B32-00-0014 Seal, Grease 2
11 B25-00-0060 Assembly, Inner Bearing
12 B12-00-0071 Assembly, Wheel Hub
2
(Includes bearings, grease seal, and studs)
13 B10-00-0031 Brake Assembly, Left Hand, Hydraulic 1
13A B10-00-0030 Brake Assembly, Right Hand, Hydraulic 1
14 B10-00-0016 Brakes Pads, Set (left and right wheel) 1
15 B25-00-0061 Assembly, Outer Bearing 2
16 B10-00-0059 Washer, Spindle 2
17 0090-0880 Nut, Spindle 2
18 0090-0881 Pin, Cotter, 5/32 x 2 in. 2
19 B32-00-0013 Cap, Dust 2
20 0090-0624 Nut, Wheel Lug, 1/2-20 12
21 B04-07-0107 Stud, Wheel, 1/2-20 x 2-1/2 in. 12
22 0090-0182 Nut, Hex, Nylon Lock, #10-24 8
23 B01-09-0051 Fitting, Cable Grip, 90º, 1/2 in. 2
24 B01-03-0006 Switch Body, Limit, Axle Position 2
25 0090-0236 Screw, Machine, #10-24 x 3/4 in. 4
26 B01-03-0014 Actuator, Limit Switch 2
27 B01-03-0007 Head, Limit Switch 2
28 B08-02-0003 Tire, ST225/75D-15 2
6-27
XLB-4232 DC
6-11 TAIL LIGHTS AND OUTRIGGER DISPLAY
TRANSMITTER BOX PARTS LIST
Refer to Table 6-11 for the tail lights and outrigger display transmitter box parts list.
12
16
2
14
12
13
10
12
11
1
6
12
11
7
8
5
7
9
8
3
4
15, 15A,
15B
3
Figure 6-11. Tail Lights and Outrigger Display Transmitter Box
6-28
6 — PARTS LIST
Table 6-11. Tail Lights and Outrigger Display Transmitter Box Parts List
Item No. Part No. Description Qty
1 B01-10-0024 Tail Light Assembly, Left 1
2 B29-00-0037 Bracket, License Plate Mounting 1
3 B01-10-0069 Lens, Replacement 2
4 B01-10-0023 Tail Light Assembly, Right 1
5 B01-10-0270 Transmitter, Outrigger Display 1
6 B01-09-0105 Connector, 12 Pin, Outrigger Display, Gray 1
7 B01-09-0107 Insert, 12 Pin, Outrigger Display 2
8 B01-09-0108 Pin, Outrigger Display (3 in gray connector, 12
15
in black connector)
9 B01-09-0106 Connector, 12 Pin, Outrigger Display, Black 1
10 B18-00-0153 Cover, Outrigger Display Transmitter 1
11 0090-0419 Washer, Flat, 1/4 in. 4
12 0090-0183 Nut, Hex, Nylon Lock, 1/4-20 8
13 B04-07-0035 Clamp, Cable/Hose, DG 14 1
14 B04-07-0034 Clamp, Cable/Hose, DG 12 1
15
15A
15B
B01-10-0022 Marker, Side, Red 2
B01-10-0067 Lens, Replacement 2
B01-10-0068 Bulb, Side Marker 2
16 B04-07-0032 Clamp, Cable/Hose, DG 6 2
6-29
XLB-4232 DC
6-12 RIGHT FRONT/LEFT REAR OUTRIGGERS PARTS LIST
Refer to Table 6-12 for the right front/left rear outriggers parts list.
6
5
7
2
3
26
27
21
23
18
24
19
30, 30A
22
28
25
29
17
20
18
1, 1A
EXTEND
LEAST W
ST
HEEL
ABILIZERS
CO
R
FO
ACT
NT
3”
8
9
4
10
11
16
15
12
13
14
Figure 6-12. Right Front/Left Rear Outriggers
6-30
6 — PARTS LIST
Table 6-12. Right Front/Left Rear Outriggers Parts List
Item No. Part No. Description Qty
1 B23-01-0087 Outrigger, Front, Passenger Side 1
1A B23-01-0087 Outrigger, Rear, Driver Side 1
2 B00-00-0085 Fitting, Grease, Straight, 1/4-28 1
3 B06-00-0167 Caution Tape, Black and Yellow 1 Roll
4 B23-02-0048 Assembly, Outrigger Jack
1
(includes items 5 through 11)
5 B46-00-0028 Kit, Handle Replacement 1
6 0090-0183 Nut, Hex, Nylon Lock, 1/4-20 1
7 0090-0007 Screw, Cap, 1/4-20 x 1-1/4 in. 1
8 B04-06-0030 Washer, 2.18 in. Square 1
9 B25-00-0068 Bearing Kit 1
10 B36-00-0039 Pin 1
11 B23-02-0053 Drop Tube, Quick Adjust 1
12 0090-0909 Screw, Cap, 5/8-11 x 3-1/4 in. 1
13 B00-00-0009 Fitting, Grease, Straight, 3/16 in. 1
14 B23-02-0047 Weldment, Footpad 1
15 0090-0194 Nut, Hex, Nylon Lock, 5/8-11 1
16 B06-00-0036 Decal, Lube Weekly 1
17 B01-03-0031 Magnet, Proximity 1
18 0090-0813 Screw, Machine, #8-32 x 3/4 in. 4
19 0090-0181 Nut, Hex, Nylon Lock, #8-32 4
20 B31-00-0006
B31-00-0027
Plate, Guide, 5/16” Thick or
Plate, Guide, 1/4” Thick
1
21 B36-00-0004 Pin, Plunger 1
22 0090-0319 Pin, Roll, 1/4 x 1-1/4 in. 1
23 B39-00-0004 Spring 1
24 B46-00-0005 Handle, Outrigger Pin 1
25 B46-00-0008 Knob, Ball 1
26 0090-0476 Washer, External Tooth Star, 1/2 in. 3
27 0090-0387 Screw, Socket Head Cap, 1/2-13 x 1/2 in. 3
28 B04-07-0032 Clamp, Cable/Hose, DG-6 3
29 0090-0183 Nut, Hex, Nylon Lock, 1/4-20 2
30 B01-03-0029 Switch, Magnetic Reed w/72” SJO Cord, Front
1
Outrigger – Pa ssenger Side
30A B01-03-0030 Switch, Magnetic Reed w/45” SJO Cord, Rear
1
Outrigger – Driver Side
Note: Quantities shown for Items 2-29 are per outrigger.
6-31
XLB-4232 DC
6-13 LEFT FRONT/RIGHT REAR OUTRIGGERS PARTS LIST
Refer to Table 6-13 for the left front/right rear outriggers parts list.
30, 30A
18
29
28
26
19
27
18
21
23
24
17
19
22
25
20
1, 1A
6
5
E
X
T
E
L
N
E
D
A
S
S
T
T
A
W
B
H
I
L
E
I
E
Z
L
E
R
C
S
O
F
N
O
T
A
R
C
T
7
2
3
8
3/4”
4
9
10
11
16
12
15
13
14
Figure 6-13. Left Front/Right Rear Outriggers
6-32
6 — PARTS LIST
Table 6-13. Left Front/Right Rear Outriggers Parts List
Item No. Part No. Description Qty
1 B23-01-0092 Outrigger, Rear, Passenger Side 1
1A B23-01-0092 Outrigger, Front, Driver Side 1
2 B00-00-0085 Fitting, Grease, Straight, 1/4-28 1
3 B06-00-0167 Caution Tape, Black and Yellow 1 Roll
4 B23-02-0048 Assembly, Outrigger Jack
1
(includes items 5 through 11)
5 B46-00-0028 Kit, Handle Replacement 1
6 0090-0183 Nut, Hex, Nylon Lock, 1/4-20 1
7 0090-0007 Screw, Cap, 1/4-20 x 1-1/4 in. 1
8 B04-06-0030 Washer, 2.18 in. Square 1
9 B25-00-0068 Bearing Kit 1
10 B36-00-0039 Pin 1
11 B23-02-0053 Slide, Quick Adjust 1
12 0090-0909 Screw, Cap, 5/8-11 x 3-1/4 in. 1
13 B00-00-0009 Fitting, Grease, Straight, 3/16 in. 1
14 B23-02-0047 Weldment, Footpad 1
15 0090-0194 Nut, Hex, Nylon Lock, 5/8-11 1
16 B06-00-0036 Decal, Lube Weekly 1
17 B01-03-0031 Magnet, Proximity 1
18 0090-0813 Screw, Machine, #8-32 x 3/4 in. 4
19 0090-0181 Nut, Hex, Nylon Lock, #8-32 4
20 B30-00-0006
B31-00-0027
Plate, Guide, 5/16” Thick or
Plate, Guide, 1/4” Thick
1
21 B36-00-0004 Pin, Plunger 1
22 0090-0319 Pin, Roll, 1/4 x 1-1/4 in. 1
23 B39-00-0004 Spring 1
24 B46-00-0005 Handle, Outrigger Pin 1
25 B46-00-0008 Knob, Ball 1
26 0090-0476 Washer, External Tooth Star, 1/2 in. 3
27 0090-0387 Screw, Socket Head Cap, 1/2-13 x 1/2 in. 3
28 B04-07-0032 Clamp, Cable/Hose, DG-6 3
29 0090-0183 Nut, Hex, Nylon Lock, 1/4-20 2
30 B01-03-0030 Switch, Magnetic Reed w/45” SJO Cord, Rear
1
Outrigger – Pa ssenger Side
30A B01-03-0029 Switch, Magnetic Reed w/72” SJO Cord, Front
1
Outrigger – Driver Side
Note: Quantities shown for Items 2-29 are per outrigger.
6-33
XLB-4232 DC
6-14 BASKET PARTS LIST
1
2
4
5
6
8
7
Refer to Table 6-14 for the basket parts list.
3
14
UPPER BOOM
17
9
13
15
16
10
11
12
3A
18
19
21
18
20
22
25
23, 23A
24
4
31
26
SY
S
T
H
E
Y
M
D
R
V
W
A
O
O
U
L
L
TA
R
M
IC
K
A
G
H
X
S
C
E
E
Y
IM
A
IG
S
TE
P
U
A
H
M
M
C
T
P
IT
P
L
Y
R
A
E
T
S
F
S
O
U
R
R
2
M
E
4
V
H
D
E
IG
C
4
2
H
1
T
F
6
T
0
3
0
0
0
P
S
LB
I
3
5
F
T
5
IN
27
XLB-4232 SPECIFICATIONS
28
29
33
29
38
39
C
A
U
TIO
1500 WATT LOAD LIMIT
N
32
30
40
34
35
41
37
4
36
Figure 6-14. Basket
6-34
6 — PARTS LIST
Table 6-14. Ba sket Parts List
Item No. Part No. Description Qty
1 B44-00-0016 Plywood, Cage 1
2 0090-0128 Bolt, Carriage, 5/16-18 x 1-1/4 in. 4
3 B17-00-0045 Cage Weldment 1
3A B17-00-0041 Bucket, Fiberglass – Option 1
4 0090-0344 Screw, Threadcutting, #10-24 x 1/2 in. 14
5 B07-05-0007 Plate, Decal 1
6 0090-0461 Screw, Cap, 1/2-13 x 2 in. 4
7 B05-00-0001 Tube, Foam, 16-1/2 in. 1
8 B06-00-0167 Caution Tape, Black and Yellow 1 Roll
9 B01-09-0030 Wire, Tie, 7 x 3/32 in. 6
10 B00-00-0086 Casing, Wire, Slit, 5/16 in. dia. x 8.5 in. long 2
11 0090-0208 Washer, Lock, Split, 5/16 in. 4
12 0090-0160 Nut, Hex, 5/16-18 4
13 B30-00-0015 Bumper, Lid 1
14 B29-00-0011 Cage Mount Weldment 1
15 0090-0574 Washer, Flat, 1/2 in. 4
16 0090-0192 Nut, Hex, Nylon Lock, 1/2-13 4
17 0090-0108 Screw, Cap, 3/4-10 x 3-1/2 in. 1
18 B25-00-0004 Bearing, Bronze Thrust, 1-1/2 ID x 2-1/2 OD 2
19 B04-06-0001 Washer, Flat, 2 in. OD 1
20 0090-0210 Washer, Lock, Split, 3/8 in. 1
21 B04-05-0001 Screw, Cap, 3/8-16 x 1 in. Drilled for Zerk 1
22 B00-00-0009 Fitting, Grease, Straight, 3/16 in. 1
6-35
XLB-4232 DC
1
2
4
5
6
3
8
7
14
UPPER BOOM
17
9
13
15
16
10
11
12
3A
18
19
21
18
20
22
25
23, 23A
24
4
31
26
S
Y
S
TE
H
Y
M
D
R
V
W
A
O
O
U
L
L
TA
R
M
IC
K
A
G
H
X
S
C
E
E
Y
IM
A
IG
S
T
P
U
E
A
H
M
M
C
T
P
ITY
P
L
R
A
E
TF
SS
O
U
R
R
2
M
E
4
V
H
D
E
IG
C
4
2
H
1
T
F
6
T
0
3
0
0
0
P
S
L
I
B
3
5
F
T
5
IN
27
XLB-4232 SPECIFICATIONS
28
29
33
29
38
39
C
A
U
TIO
1500 WATT LOAD LIMIT
N
32
30
40
34
35
41
37
4
36
Figure 6-14. Basket
6-36
6 — PARTS LIST
Table 6-14. Basket Parts List, Continued
Item No. Part No. Description Qty
23 B02-03-0007 Cylinder, Slave Leveling,
2 in. Bore x 13-1/4 in. Stroke
23A B02-13-0037 Kit, Seal Replacement, Leveling Cylinder 1
24 0090-0428 Washer, Flat, 3/4 in. 2
25 0090-0195 Nut, Hex, Nylon Lock, 3/4-10 2
26 B19-00-0003 Panel, Upper Control Box 1
27 B19-00-0005 Door, Upper Control Box 1
28 B32-00-0005 Weather Strip, 1/2 x 26-1/2 in. 1
29 0090-0181 Nut, Hex, Nylon Lock, 8-32 6
30 0090-0225 Screw, Machine, #8-32 x 1/2 in. 2
31 B19-00-0002 Upper Control Box 1
32 0090-0679 Rivet, Pop, 5/32 x 1/2 in. 2
33 0090-0414 Washer, Flat, #8 2
34 B01-10-0040 Switch, Mercury, 3 Degree Cage Level 1
35 B01-09-0023 Cord Grip, 90 Degree 1
36 B19-00-0004 Panel, Bottom, Upper Control Box 1
37 B01-10-0035 Cover, GFI 1
38 0090-0690 Screw, Machine, #6-32 x 5/8 in. 2
39 B01-10-0034 Receptacle, 120 Vac, GFI 1
40 0090-0180 Nut, Hex, Nylon Lock, 6-32 2
41 B42-00-0005 Latch 1
1
6-37
XLB-4232 DC
6-15 UPPER CONTROL BOX PARTS LIST
Refer to Table 6-15 for the upper control box parts list.
9
1
2
3
5, 6, 7
8
10
12
4
2
11
Figure 6-15. Upper Control Box
Table 6-15. Upper Control B ox
Item No. Part No. Description Qty
B19-00-0010 Switch Panel Assembly, Upper Control Box
1
(includes items 1-11)
1 B19-00-0003 Panel, Upper Control Box 1
2 B01-02-0010 Switch, Toggle, Lift/Telescope/Rotate/Tilt 4
3 B01-10-0017 Gage, Battery 1
4 B01-02-0013 Switch, Toggle, Speed 1
5 B01-02-0031 Button, Emergency Stop 1
6 B01-02-0032 NC Contact, Emergency Stop 1
7 B01-10-0055 Block, NC Contact Mount 1
8 B01-02-0012 Switch, Toggle, Controls On/Off 1
9 B06-00-0117 Decal, Bucket Tilt 1
10 B06-00-0118 Decal, Upper Control Box 1
11 B06-00-0116 Decal, “OPERATE WITH FULLY…” 1
12 B06-00-0144 Decal, Specifications 1
6-38
6 — PARTS LIST
6-16 LOWER CONTROL BOX PARTS LIST
Refer to the Table 6-16 for the lower control box parts list.
2, 3, 4
1
6
5
11, 12
7
13
8, 9, 10
Figure 6-16. Lower Control Box
Table 6-16. Low er Control Box Parts List
Item No. Part No. Description Qty
B19-00-0009 Control Box Assembly, Lower (includes items
1
1-13)
1 B19-00-0006 Box, Lower Control 1
2 B01-02-0031 Button, Emergency Stop 1
3 B01-02-0032 NC Contact, Emergency Stop 1
4 B01-10-0055 Block, NC Contact Mount 1
5 B01-02-0010 Switch, Toggle, Lift/Telescope/Rotate 3
6 B01-02-0011 Switch, Toggle, Controls Selector 1
7 B01-02-0013 Switch, Toggle, Speed 1
8 B01-10-0111 Socket, Lamp 1
9 B01-10-0112 Lens, Green 1
10 B01-10-0056 Bulb, 24 Volt 1
11 B01-09-0029 Cord Grip, 1/2 in. 1
12 B04-07-0030 Plastic Nut, 1/2 in. Cord Grip 1
13 B06-00-0119 Decal, Lower Control Box 1
6-39
XLB-4232 DC
6-17 COMBINATION VALVE ASSEMBLY PARTS LIST
Refer to Table 6-17 for the proportional valve assembly parts list.
3
4
2
5, 6
1
8
7
5, 9
5, 6
5, 10
5, 10
11
Figure 6-17. Combination Valve Assembly
Table 6-17. Combination Valve Assembly Parts List
Item No. Part No. Description Qty
1 B02-04-0069 Valve Assembly, Combination, 24 Volt DC 1
2 B02-14-0078 Valve, Cartridge Relief, Basket Rotation 1
3 B02-14-0063 Valve, Cartridge, Crossover Relief 1
4 B02-14-0077 Valve, Cartridge, Crossover Relief, Rotation 1
5 B01-08-0001 Coil, 24 Volt 9
6 B02-14-0042 Valve, Cartridge, 4 - Way 2
7 B02-14-0064 Valve, Cartridge, Flow Control, 1.25 1
8 B02-14-0065 Valve, Cartridge, Flow Control, 1.0 1
9 B02-14-0067 Valve, Cartridge, NC, High Down 1
10 B02-14-0066 Valve, Cartridge, 4 – Way, Telescoping and
Basket Leveling
11 B02-14-0079 Valve, Cartridge Relief, Basket Rotation 1
2
6-40
6 — PARTS LIST
6-18 SURGE BRAKES PARTS LIST
Refer to Table 6-18 for the surge brakes parts list.
10
1
3
6
4
7
5
6
7
5
8
9
2
Figure 6-18. Surge Brakes
Table 6-18. Surge Brakes Parts List
Item No. Part No. Description Qty
1 B12-00-0169 Surge Brake Coupler Assembly 1
B21-00-0001 Brake Line Kit (includes items 3 through 9) 1
2 ** Brake Line, 3/16 x 17 in. 1
3 ** Brake Line, 3/16 x 45 in. 1
4 ** Brake Line, 3/16 x 15-3/4 ft. 1
5 ** Hose, 18-7/8 in. 2
6 ** Bracket, Hose 2
7 ** Clip, Hose 2
8 ** Tee 1
9 0090-0183 Nut, Lock, 1/4-20 1
10 B12-00-0013 Surge Brake Coupler Assembly, Early Version 1
**Not procurable, order brake line kit.
6-41
XLB-4232 DC
6-19 DC MODEL HYDRAULIC SYSTEM PARTS LIST
Refer to Table 6-19 for the DC model boom lift hydraulic system parts list.
12
21
33
23
40
31
32
30
33
13
42
14
11
41
29
28
10
15
29
4
C2
C1
V2
V1
21
39
9
27
25
24
L2
R2
T2
BL2
23
8
36
26
8
38
1
16
35
L1
6
7
5
23
R1
T1
BL1
22
21
3
20
19
2
37
18
17
1
15
14
Figure 6-19. DC Model Hydraulic System
6-42
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