Bil-Jax XLB-4232 DC User Manual

Name: Bil-Jax XLB-4232 DC
Brand: Bil-Jax
SKU: 997220
Rating: 4.4 (8 reviews)

4.4 (8)

Operation and

Maintenance Manual

AERIAL WORK PLATFORMS

XLB-4232 DC

Hydraulic Boom Lift

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

1	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

2	Introduction ....................................................................................................		2-1
	2-1	General Description...........................................................................	2-1
	2-2	Specifications .....................................................................................	2-2
	2-3	Warranty.............................................................................................	2-2

3	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

4	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
5	Replacement Decals........................................................................................						5-1
6	Parts List .........................................................................................................						6-1
	6-1	Upper Boom Parts List....................................................................					6-2
	6-2	Lower Boom Parts List....................................................................					6-4
	6-3	Turntable Parts		List ..........................................................................			6-6
	6-4	DC Model Battery Compartment Parts List......................................					6-8
	6-5	DC Model Power Compartment Parts List ..................................					6-10
	6-6	Terminal Enclosure Parts List............................................................					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
7	ANSI Reprint		.................................................................................................				7-1

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

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

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 obtained, read, and thoroughly understood before attempting to operate this equipment. Persons under the influence of drugs, alcohol, or prescription medication should not be on or near this equipment. Common sense should be 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 the operating area.

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

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

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

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

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

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

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

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

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

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

1-3

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	Minimum Safe Approach Distance
Voltage Range	(Feet)		(Meters)
(Phase to Phase)	(Feet)		(Meters)
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

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

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

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

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

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

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

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

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

•ALWAYS engage the boom travel locking 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 operate this equipment when exposed to high winds, thunderstorms, ice, or any other weather conditions that would compromise operator safety.

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

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

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

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

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

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

•NEVER climb up or down boom.

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

1-5

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 solenoids or other load devices.

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

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

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

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

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

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

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

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

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

•NEVER touch or allow metal tools to contact static discharge sensitive electronic components. ALWAYS use static discharge prevention mats and grounding devices when handling electronic components.

•NEVER tamper with cylinder counter balance valves. Contact the Bil-Jax Service Department at 419.445.9675 if the cylinder counter balance valves need adjusting.

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

1-6

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

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,	8 in./sec (203 mm/sec)
Maximum	[40 ft/min (12.2 m/min)]
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
	(91.4 cm x 61.0 cm x 106.7 cm)
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 Weight	275 lbs (124.7 kg)
Trailer Brakes	Hydraulic Surge; Optional – Electric

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

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

EMERGENCY STOP Pushbutton

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

BOOM IN/OUT Selector Switch

BOOM UP/DOWN Selector Switch

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 trailer tongue jack and unhitch the trailer 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.Pull 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 of 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.

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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)

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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

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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 to 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 long 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.

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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.

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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 second person to give tow 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

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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.

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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.

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