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

Name: Bil-Jax XLB-4319
Brand: Bil-Jax
SKU: 997236
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Bil-Jax XLB-4319, B33-01-0080 User Manual

Operation and

Maintenance Manual

AERIAL WORK PLATFORMS

XLB-4319

Hydraulic Boom Lift

-4319 XLB

B33-01-0080

BOOM PERSONNEL LIFT

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

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

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

Table of Contents

	Preface	................................................................................................................	v
1	Safety................................................................................................................		1-1
	1-1 .........................................................................................	Introduction	1-1
	1-2 ................................................................................	Before Operation	1-2
	1-3 ................................................................................	During Operation	1-3
	1-4 .............................................................................	Maintenance Safety	1-5
	......................................................................	General Maintenance	1-5
	.......................................................................	Battery Maintenance	1-6
	1-5 ...............................................................	Damaged Equipment Policy	1-6
	.............................................................................	Safety Statement	1-6
	................................................................................	Damage Policy	1-6
	....................................................................	Damage Repair Notice	1-6
	................................................................	Reporting Safety Defects	1-7

2	Introduction.....................................................................................................		2-1
	2-1	General Description ............................................................................	2-1
	2-2	Specifications......................................................................................	2-4
		Boom Lift Work Platform ..............................................................	2-4
	2-3	Warranty .............................................................................................	2-5

3	Operation .........................................................................................................		3-1
	3-1	Operator Controls ...............................................................................	3-1
		Ground Control Station.......................................................................	3-1
		Basket Control Station....................................................................	3-4
	3-2	Normal Operating Procedure ..............................................................	3-6
	3-3	Emergency Lowering..........................................................................	3-8
	3-4	Manual Boom Rotation.......................................................................	3-9
	3-5	Battery Recharge (DC MODEL ONLY) ..........................................	3-10
	3-6	Boom Lift Transport .........................................................................	3-11
		Trailer Hitching ............................................................................	3-11

4	Maintenance ....................................................................................................		4-1
	4-1	Scheduled Service Checks ..................................................................	4-1
		Daily/Weekly Service Checks ........................................................	4-1
		Monthly Service Checks.................................................................	4-2
	4-2	Wheel Nut Torque Requirements .......................................................	4-3
	4-3	Lubrication..........................................................................................	4-4
	4-4	Hydraulic System................................................................................	4-5
		Hydraulic System Inspection..........................................................	4-5
		Fluid Check and Replacement........................................................	4-5
		Return Filter Replacement..............................................................	4-6
		Air Bleeding ...................................................................................	4-6
		Hydraulic Pressure Checks and Adjustments.................................	4-7
		Hydraulic Cylinder Replacement .................................................	4-10
	4-5	SLEW RING BEARING..................................................................	4-17
		Check Free Play............................................................................	4-17
	4-6	Limit Switch checks and adjustments...............................................	4-18
		Adjusting Boom Down Limit Switch...........................................	4-18
		Adjusting Outrigger Position Switches ........................................	4-19
	4-7	Troubleshooting................................................................................	4-20
		Troubleshooting Aids ...................................................................	4-22
	4-8	Material Safety Data Sheets..............................................................	4-31

5	Replacement Decals........................................................................................		5-1
6	Parts List .........................................................................................................		6-1
	6-1	Upper Boom Parts List.......................................................................	6-2
	6-2	Lower Boom Parts List ......................................................................	6-4
	6-3	Jib Boom Parts List ............................................................................	6-6
	6-4	Compartment Covers Parts List .........................................................	6-8
	6-5	Reservoir Compartment Parts List, Gas model ................................	6-10
	6-6	Pump Compartment Parts List, DC Model ......................................	6-12
	6-7	Chassis and Rotation Unit Parts List................................................	6-16
	6-8	Hitch and Jack Assembly Parts List.................................................	6-18
	6-9	Axle and Wheel Assembly Parts List..............................................	6-20
	6-10	Rear Lights and Junction Box Parts List..........................................	6-23
	6-11	Outriggers Parts List ........................................................................	6-25
	6-12	Basket Parts List...............................................................................	6-27
	6-13	Outrigger Hydraulic Controls Parts List ..........................................	6-29
	6-14	Lower Controls Parts List ................................................................	6-31
	6-15	Upper Controls Parts List.................................................................	6-33
	6-16	Engine Compartment Parts List, Gas Model....................................	6-35
	6-17	Boom Control Hydraulics Parts List, Basket ...................................	6-39
	6-18	Boom Control Hydraulics Parts List, Ground, Gas Model ..............	6-41
	6-19	Boom Control Hydraulics Parts List, Ground, DC Model...............	6-43
	6-20	Lower Boom Cylinder Hydraulics Parts List...................................	6-45
	6-21	Upper Boom Cylinder Hydraulics Parts List ...................................	6-46
	6-22	Pushbutton Panel Parts List, Basket.................................................	6-47
	6-23	Pushbutton Panel Parts List, Ground Controls.................................	6-49
7	ANSI Reprint ..................................................................................................		7-1

List of Illustrations

Figure 2-1.	XLB-4319 Hydraulic Boom Lift.............................................................	2-1
Figure 2-2.	Basket and Ground Station Controls.......................................................	2-2
Figure 2-3.	Safe Operating Zone ...............................................................................	2-3
Figure 3-1.	Ground Control Station Access...............................................................	3-1
Figure 3-2.	Ground Control Station...........................................................................	3-2
Figure 3-3.	Engine Keyswitch ...................................................................................	3-3
Figure 3-4.	Basket Control Station ............................................................................	3-4
Figure 3-5.	Outrigger Controls ..................................................................................	3-6
Figure 3-6.	Manual Lowering Valve .........................................................................	3-8
Figure 3-7.	Basket Control Station ............................................................................	3-8
Figure 3-8.	Emergency Rotation................................................................................	3-9
Figure 3-9.	Battery Charger .....................................................................................	3-10
Figure 3-10.	Trailer Hitching.....................................................................................	3-11
Figure 4-1.	Wheel Bolt Tightening Sequence............................................................	4-3
Figure 4-2.	Lubricate Monthly...................................................................................	4-4
Figure 4-3.	Lubricate Semi-Annually ........................................................................	4-4
Figure 4-4.	Hydraulic Reservoir ................................................................................	4-5
Figure 4-5.	Main Bypass Valve and Pressure Test Port (Gas Engine Model)...........	4-7
Figure 4-6.	Outriggers Bypass Valve ........................................................................	4-8
Figure 4-7.	Boom Control Bypass Valve, Basket Station..........................................	4-9
Figure 4-8.	Hydraulic Cylinder Removal ................................................................	4-11
Figure 4-9.	Jib Boom Components ..........................................................................	4-14
Figure 4-10.	Basket Swivel Cylinder.........................................................................	4-16
Figure 4-11.	Slew Ring Position Measurement .........................................................	4-17
Figure 4-12.	Boom Down Limit Switch ....................................................................	4-18
Figure 4-13.	Outrigger Position Switch.....................................................................	4-19
Figure 4-14. Simplified Electrical Diagram, DC Model............................................		4-22
Figure 4-15. Detailed Electrical Diagram, DC Model ...............................................		4-23
Figure 4-16. Simplified Electrical Diagram, Gas Model ...........................................		4-24
Figure 4-17. Detailed Electrical Diagram, Gas Model ..............................................		4-25
Figure 4-18.	Hydraulic Diagram, DC Model.............................................................	4-26
Figure 4-19.	Hydraulic Diagram, Gas Model ............................................................	4-28
Figure 4-20.	Level Sensor..........................................................................................	4-30
Figure 5-1.	Replacement Decals ................................................................................	5-2
Figure 5-2.	Decal Locations, Trailer and Boom ........................................................	5-5
Figure 5-3.	Decal Locations, Control Compartment Exterior....................................	5-6
Figure 5-4.	Lubricate Monthly Decal ........................................................................	5-6
Figure 5-5.	Lubricate Semi-Annually Decal..............................................................	5-6
Figure 6-1.	Upper Boom............................................................................................	6-2
Figure 6-2.	Lower Boom ...........................................................................................	6-4
Figure 6-3.	Jib Boom .................................................................................................	6-6
Figure 6-4.	Compartment Covers ..............................................................................	6-8
Figure 6-5.	Reservoir Compartment, Gas Model....................................................	6-10
Figure 6-6.	Pump Compartment, DC Model............................................................	6-12
Figure 6-7.	Chassis and Rotation Unit.....................................................................	6-16
Figure 6-8.	Hitch and Jack Assembly ......................................................................	6-18
Figure 6-9.	Axle and Wheel Assembly....................................................................	6-20
Figure 6-10.	Rear Lights and Junction Box...............................................................	6-23

iii

Figure 6-11.	Outriggers.............................................................................................	6-25
Figure 6-12.	Basket ...................................................................................................	6-27
Figure 6-13. Outrigger Hydraulic Controls...............................................................		6-29
Figure 6-14.	Lower Controls.....................................................................................	6-31
Figure 6-15.	Upper Controls .....................................................................................	6-33
Figure 6-16. Engine Compartment Parts List, Gas Model ........................................		6-35
Figure 6-17. Boom Control Hydraulics, Basket........................................................		6-39
Figure 6-18. Gas Model Boom Control Hydraulics, Ground....................................		6-41
Figure 6-19. DC Model Boom Control Hydraulics, Ground ....................................		6-43
Figure 6-20. Lower Boom Cylinder Hydraulics .......................................................		6-45
Figure 6-21. Upper Boom Cylinder Hydraulics........................................................		6-46
Figure 6-22. Basket Pushbutton Panel, Gas Model...................................................		6-47
Figure 6-23.	Pushbutton Panel, Ground Controls .....................................................	6-49

List of Tables

Table 1-1.	Minimum Safe Approach Distances.......................................................	1-3
Table 2-1.	Specifications .........................................................................................	2-4
Table 4-1.	Daily/Weekly Service Checks................................................................	4-1
Table 4-2.	Monthly Service Checks ........................................................................	4-2
Table 4-3.	Troubleshooting Chart..........................................................................	4-20
Table 4-4.	Level Sensor LEDs...............................................................................	4-30
Table 5-1.	Replacement Decals ...............................................................................	5-1
Table 6-1.	Upper Boom Parts List ...........................................................................	6-3
Table 6-2.	Lower Boom Parts List...........................................................................	6-5
Table 6-3.	Jib Boom Parts List ................................................................................	6-7
Table 6-4.	Compartment Covers Parts List..............................................................	6-9
Table 6-5.	Reservoir Compartment Parts List, Gas Model....................................	6-11
Table 6-6.	Pump Compartment Parts List, DC Model...........................................	6-13
Table 6-7.	Chassis and Rotation Unit Parts List ....................................................	6-17
Table 6-8.	Hitch and Jack Assembly Parts List .....................................................	6-19
Table 6-9.	Axle and Wheel Assembly Parts List...................................................	6-21
Table 6-10.	Rear Lights and Junction Box Parts List ..............................................	6-24
Table 6-11.	Outriggers Parts List.............................................................................	6-26
Table 6-12.	Basket Parts List...................................................................................	6-28
Table 6-13.	Outrigger Hydraulic Controls Parts List...............................................	6-30
Table 6-14.	Lower Controls Parts List.....................................................................	6-32
Table 6-15.	Upper Controls Parts List .....................................................................	6-34
Table 6-16.	Engine Compartment Parts List, Gas Model ........................................	6-36
Table 6-17.	Boom Control Hydraulics Parts List, Basket........................................	6-40
Table 6-18.	Gas Model Boom Control Hydraulics Parts List, Ground....................	6-42
Table 6-19.	DC Model Boom Control Hydraulics Parts List, Ground ....................	6-44
Table 6-20.	Lower Boom Cylinder Hydraulics Parts List .......................................	6-45
Table 6-21.	Upper Boom Cylinder Hydraulics Parts List........................................	6-46
Table 6-22.	Basket Pushbutton Panel Parts List ......................................................	6-48
Table 6-23.	Pushbutton Panel Parts List, Ground Controls.....................................	6-49
Table 7-1.	Minimum Safe Approach Distance (M.S.A.D.)
to energized (exposed or insulated) power lines and parts. ..........................................		7-11

PREFACE

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

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

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

SAFETY NOTES

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

DANGER

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

WARNING

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

CAUTION

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

NOTE: Notes contain additional information important to a procedure.

Safety

1-1 INTRODUCTION

Familiarity and proper training are required for the safe operation of mechanical 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 Bil-Jax equipment only.

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

1-1

XLB-4319

1-2 BEFORE OPERATION

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

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

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

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

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

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

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

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

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

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

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

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

1-2

1 — SAFETY

1-3 DURING OPERATION

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

DANGER

This machine is not insulated for use near electrical power lines and DOES NOT provide protection from contact with or close proximity to any electrically charged conductor. Operator must maintain safe clearances at all times (10 feet minimum) and always allow for platform movement such as wind induced sway. Always contact the power company before performing work near power lines. Assume every line is hot. Remember, power lines can be blown by the wind.

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

Table 1-1. Minimum Safe Approach Distances

Voltage Range	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 pins before towing the trailer.

1-3

XLB-4319

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

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

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

•NEVER attach a safety harness to an adjacent structure, pole, or equipment while working from the boom platform.

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

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

•NEVER stand or sit on cage bars. Work only within the work cage and do not lean out over the cage to perform work.

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

•NEVER operate this equipment when exposed to high winds, thunderstorms, ice, or any other weather conditions that would compromise operator safety.

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

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

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

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

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

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

•NEVER climb up or down boom.

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

1-4

1 — SAFETY

1-4 MAINTENANCE SAFETY

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

General Maintenance

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

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

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

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

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

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

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

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

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

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

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

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

•NEVER touch or allow metal tools to contact static discharge sensitive 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 800-537-0540 if the cylinder counter balance valves need adjusting.

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

1-5

XLB-4319

Battery Maintenance

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

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

•ALWAYS wear safety glasses when working near battery.

•ALWAYS avoid contact with battery acid. Battery acid causes serious burns. Avoid contact with skin or eyes. If accidental contact occurs, flush with water and consult a physician immediately.

•ALWAYS disconnect ground cable first when removing battery.

•ALWAYS connect ground cable last when installing battery.

•ALWAYS charge batteries in open, well-ventilated areas.

•NEVER smoke when servicing battery.

•NEVER allow batteries to overcharge and boil.

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

•NEVER jump start other vehicles using boom lift battery.

1-5 DAMAGED EQUIPMENT POLICY

Safety Statement

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

Damage Policy

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

Damage Repair Notice

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

1-6

1 — SAFETY

Bil-Jax, Inc.

125 Taylor Parkway

Archbold, Ohio 43502

Reporting Safety Defects

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

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

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

NHTSA

U.S. DEPARTMENT of TRANSPORTATION

400 7th Street SW, (NSA-11)

Washington, DC 20590

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

1-7

XLB-4319

1-8

Introduction

2-1 GENERAL DESCRIPTION

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

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

JIB WORK BOOM BASKET

UPPER

BOOM

LOWER

BOOM

-4319 XLB

OUTRIGGER

Figure 2-1. XLB-4319 Hydraulic Boom Lift

2-1

XLB-4319

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

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

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

GROUND STATION CONTROLS

BASKET STATION CONTROLS

Figure 2-2. Basket and Ground Station Controls

2-2

2 — INTRODUCTION

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

XLB-4319 SPECIFICATIONS

45.9
42.6
39.4
36
32.8
24.5
26.3
23
19.7
16.4
13
9.8
6.5
3.2
0	6.5	3.2	0	3.2	6.5	9.8	13	16.4	19.7	23
9.8	6.5	3.2	0	3.2	6.5	9.8	13	16.4	19.7	23

CAPACITY ..........................................	450 LB.
MAXIMUM PLATFORM HEIGHT .......	37 FT.
WORK HEIGHT ..................................	43 FT.
POWER SOURCE ..............................	24V DC BATTERY OR GAS
FTC	B06-00-0430

Figure 2-3. Safe Operating Zone

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

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

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

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

2-3

XLB-4319

2-2 SPECIFICATIONS

Boom Lift Work Platform

Model Number:	XLB-4319	Serial Number ________________
Manufactured by:	Bil-Jax, Inc.
	125 Taylor Parkway
	Archbold, Ohio 43502
	800-537-0540

Table 2-1.	Specifications

Feature	Data
Rated Platform Load	450 lbs (204 kg) total
Maximum Work Height	43 ft (13.1 m)
Extended Basket Height	37 ft (11.3 m)
Maximum Outreach	19 ft (9.8 m)
Elevation Rate,	5.3 in./sec (135 mm/sec)
Nominal	[26.7 ft/min (8.14 m/min)]
Horizontal Reach	19 ft (5.9 m)
Boom Rotation	700°
Rotation Speed	318° per minute, nominal
Basket Dimensions	51 in. W x 30 in. D x 45 in. H
	(129.5 cm x 76 cm x 114.3 cm)
Power Source, Gas Model	8 Horsepower, 4-Cycle,
	Gasoline Engine with Remote Start
	Control and Alternator Circuit
Storage Battery, Gas Model	12 Volt DC, 195 Amp Storage
	Battery, NAPA P/N 5022NF
Power Source, DC Model	24 Volt DC, 4 Deep Cycle,
	245 Amp-hour Batteries
Battery Charger, DC Model	110/120 Volt, 40 Amp
Hydraulic Pressure	2756 psi (19,000 kPa)
Reservoir Capacity	2.75 Gallons (10.4 Liters)
Hydraulic Capacity	7 Gallons (26.5 Liters)
Hydraulic Oil	Energol HLP-HD46 (BP Oil)
Gross Vehicle Weight, DC Model	2860 lbs (1297 kg)
Gross Vehicle Weight, Gas Model	3200 lbs (1452 kg)
Tongue Weight, DC Model	100 lbs (45.4 kg)
Tongue Weight, Gas Model	160 lbs (72.6 kg)
Trailer Brakes	Mechanical Surge

2-4

2 — INTRODUCTION

2-3 WARRANTY

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

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

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

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

2-5

XLB-4319

2-6

Operation

3-1 OPERATOR CONTROLS

The XLB-4319 Hydraulic Boom Lift is equipped with multiple operator controls. Equipment power and outrigger controls are located at ground level. Boom lift and rotation controls are located at ground level and in the basket.

Ground Control Station

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

CONTROL

COMPARTMENT

COVER

GROUND

CONTROL

STATION

LATCH

DECAL

COVER

LATCH

PORT

Figure 3-1. Ground Control Station Access

3-1

XLB-4319

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

BOOM OPERATOR

LEVERS

OUTRIGGER OUTRIGGERS

INDICATORS RUN

PUSHBUTTON

KEY

SWITCH

BOOM

EMERGENCY RUN

STOP PUSHBUTTON

PUSHBUTTON

OUTRIGGER

OPERATOR

LEVERS

Figure 3-2. Ground Control Station

Key Switch

Turning the key switch to the left selects operation from the basket control station. Turning the key switch to the right selects operation from the ground control station. The center (Off) position disables electrical and hydraulic operations. Removing the key protects against unauthorized boom lift operation.

EMERGENCY STOP Pushbutton

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

Outrigger Indicators

Four green OUTRIGGER indicators light up when the boom lift outriggers are extended and the boom weight is removed from the trailer axle. All four indicators must be lit and the trailer must be level to enable operation of the lift booms.

3-2

3 — OPERATION

Outriggers Run Pushbutton

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

Boom Run Pushbutton

Holding the green boom run pushbutton in enables operation of the lift boom cylinders. The lift boom cylinders can only be operated when the outrigger cylinders are extended, the boom weight is removed from the trailer axle, and the trailer is level.

Outrigger Operator Levers

Four outrigger operator levers position the hydraulic valves to extend and retract the outrigger cylinders. Lifting an operator lever retracts the cylinder to raise the outrigger. Pushing down on an operator lever lowers the related outrigger. When released, the operator levers return to the center (valve-off) position. Starting on your left, the outriggers are numbered 1 through 4. A decal located below the outrigger valve manifold indicates which operator lever controls which outrigger.

Boom Operator Levers

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

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

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

Engine Keyswitch (Gas Model only)

On the gas model boom lift, the engine keyswitch (Figure 3-3) is used to start and stop the gasoline engine from the ground position. The keyswitch must be in the ON position (as shown) to enable engine start-up from the work basket control station.

ENGINE

KEYSWITCH

Figure 3-3. Engine Keyswitch

3-3

XLB-4319

Basket Control Station

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

		ENGINE START
BOOM RUN		PUSHBUTTON
PUSHBUTTON		(GAS MODEL ONLY)

HYDRAULIC

HAND PUMP

AUDIBLE

ALARM

EMERGENCY

STOP PUSHBUTTON

BOOM

OPERATOR LEVERS

115 VOLT OUTLET

Figure 3-4. Basket Control Station