Bil-Jax XLB-4725A User Manual

AERIAL WORK PLATFORMS

AERIAL WORK PLATFORMS

AERIAL WORK PLATFORMSAERIAL WORK PLATFORMS

XLB-4725A

Proportional

Hydraulic Boom Lift

Operation and
Maintenance Manual

B33-01-0072-01

XLB-4725A

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 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......................................................................... 3-7

3-4 Manual Boom Rotation.................................................................... 3-7

3-5 Battery Recharge (DC Model Only)............................................... 3-8

3-6 Boom Lift Transport....................................................................... 3-10

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 Leveling System.............................................................................. 4-11

4-6 Troubleshooting ............................................................................... 4-14

4-7 Material Safety Data Sheets .......................................................... 4-23

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 Upper Cylinder Parts List................................................................ 6-6

6-4 Lower Cylinder Parts List................................................................ 6-8

6-5 DC Model Bat t ery Com p a rtm ent P a r t s Li st.................................... 6-10

6- 6 Ga s M o d e l Eng i n e Comp a r t me n t P a rts L i s t .......................................6-14

6-7 DC Model Power Compartment Parts List.................................. 6-18

6- 8 Ga s M o d e l Po we r C o mp a r t me n t P a r t s L i s t....................................... 6-22

6-9 Frame and Rotation Unit List....................................................... 6-26

6-10 Hitch and Jack Assembly Parts List ............................................ 6-28

6-11 Square Tube Axle and Wheel Assembly Parts List................... 6-32

6-12 Hex Tube Axle and Wheel Assembly Parts List........................ 6-34

6-13 Tail Lights and Junction Box Parts List ..................................... 6-36

6-14 Front Outriggers Parts List............................................................ 6-38

6-15 Rear Outrigger Parts List............................................................... 6-40

6-16 Basket Parts List............................................................................. 6-42

6-16A Basket Parts List, Early Model..................................................... 6-46

6-17 Upper Control Box – External Parts List...................................... 6-50

6-18 Upper Control Box – Internal Parts List....................................... 6-51

6-19 Lower Control Box Parts List....................................................... 6-52

6-20 Proportional Valve Assembly Parts List....................................... 6-54

6-21 Surge Brakes Parts List................................................................. 6-55

6-22 DC Model Hydraulic System Parts List ...................................... 6-56

6-23 Gas Model Hydraulic System Parts List...................................... 6-58

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....................................................................3-7

Figure 3-5. Boom Rotation........................................................................................ 3-7

Figure 3-6. Battery Charger and Receptacle..............................................................3-8

Figure 3-7. Battery Charger....................................................................................... 3-9

Figure 3-8. Breakaway Safety Cable.......................................................................3-10

Figure 3-9. Jack Travel Position.............................................................................. 3-10

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

Figure 3-11. Backup Lever Position.......................................................................... 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. Checking Outrigger Bushings............................................................... 4-11

Figure 4-8. Outrigger Bushing Replacement........................................................... 4-12

Figure 4-9. Adjusting Axle Position Switches.........................................................4-13

Figure 4-10. Lower Controller Board........................................................................ 4-16

Figure 4-11. Level Sensor .........................................................................................4-18

Figure 4-12. DC Model Hydraulic Diagram..............................................................4-19

Figure 4-13. Gas Model Hydraulic Diagram.............................................................4-20

Figure 4-14. PC Logic Diagram, DC Model..............................................................4-21

Figure 4-15. PC Logic Diagram, Gas Model.............................................................4-22

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, Trailer and Boom........................................................ 5-5

Figure 5-3. Decal Locations, Power Compartments Exterior.................................... 5-6

Figure 5-4. Decal Locations, Power Compartment Interior....................................... 5-6

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

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

Figure 6-3. Upper Cylinder .......................................................................................6-6

Figure 6-4. Lower Cylinder.......................................................................................6-8

Figure 6-5. DC Model Battery Compartment.......................................................... 6-10

Figure 6-6. Gas Model Engine Compartment..........................................................6-14

Figure 6-7. DC Model Power Compartment............................................................6-18

Figure 6-8. Gas Model Power Compartment...........................................................6-22

Figure 6-9. Frame and Rotation Unit.......................................................................6-26

Figure 6-10. Hitch and Jack Assembly...................................................................... 6-28

Figure 6-11. Square Tube Axle and Wheel Assembly...............................................6-32

Figure 6-12. Hex Tube Axle and Wheel Assembly...................................................6-34

Figure 6-13. Tail Lights and Junction Box................................................................ 6-36

Figure 6-14. Front Outriggers....................................................................................6-38

Figure 6-15. Rear Outrigger ......................................................................................6-40

Figure 6-16. Basket ...................................................................................................6-42

Figure 6-16A. Basket, Early Model..............................................................................6-46

Figure 6-17. Upper Control Box (DC Model) – External..........................................6-50

Figure 6-18. Upper Control Box (DC Model) – Internal...........................................6-51

Figure 6-19. Lower Control Box (Gas Model).......................................................... 6-52

Figure 6-20. Proportional Valve Assembly............................................................... 6-54

Figure 6-21. Surge Brakes.........................................................................................6-55

Figure 6-22. DC Model Hydraulic System................................................................ 6-56

Figure 6-23. Gas Model Hydraulic System ...............................................................6-58

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.......................................................................... 4-14

Table 4-4. Error Codes........................................................................................... 4-15

Table 4-5. LED Indicators ..................................................................................... 4-17

Table 4-6. Upper Control Box Specifications........................................................ 4-17

Table 4-7. Level Sensor LEDs............................................................................... 4-18

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. Upper Cylinder Parts List....................................................................... 6-7

Table 6-4. Lower Cylinder Parts List....................................................................... 6-9

Table 6-5. DC Model Battery Compartment Parts List.......................................... 6-11

Table 6-6. Gas Model Engine Compartment Parts List.......................................... 6-15

Table 6-7. DC Model Power Compartment Parts List........................................... 6-19

Table 6-8. Gas Model Power Compartment Parts List........................................... 6-23

Table 6-9. Frame and Rotation Unit Parts List ...................................................... 6-27

Table 6-10. Hitch and Jack Assembly Parts List...................................................... 6-29

Table 6-11. Square Tube Axle and Wheel Assembly Parts List.............................. 6-33

Table 6-12. Hex Tube Axle and Wheel Assembly Parts List................................... 6-35

Table 6-13. Tail Lights and Junction Box Parts List................................................ 6-37

Table 6-14. Front Outriggers Parts List ................................................................... 6-39

Table 6-15. Rear Outrigger Parts List...................................................................... 6-41

Table 6-16. Basket Parts List................................................................................... 6-43

Table 6-16A. Basket Parts List, Early Model............................................................. 6-46

Table 6-17. Upper Control Box – External Parts List.............................................. 6-50

Table 6-18. Upper Control Box – Internal Parts List............................................... 6-51

Table 6-19. Lower Control Box Parts List............................................................... 6-53

Table 6-20. Proportional Valve Assembly Parts List............................................... 6-54

Table 6-21. Surge Brakes Parts List......................................................................... 6-55

Table 6-22. DC Model Hydraulic System Parts List................................................ 6-57

Table 6-23. Gas Model Hydraulic System Parts List.............................................. 6-59

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

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

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
Bil-Jax equipment only.

For any questions concerning the safe use of this equipment, call 419.445.9675 before
operating.

1-1

XLB-4725A

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-4725A 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 o perating area.

• ALWAYS read, understand, and follow the procedures in this manual before at-

tempting 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 re-

quired 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 equip-

ment 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 no t 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-4725A

1-3 DURING OPERATION

Ensure the following general safety precautions are followed during the operation of the
XLB-4725A 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 be-

fore 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 struc-

ture, 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-4725A

1-4 MAINTENANCE SAFETY

Ensure the following safety precautions are observed whenever maintenance is performed
on the XLB-4725A Boom Lift.

General Maintenance

• ALWAYS perform maintenance procedures according to manufacturer's re-

quirements. 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 discon-

necting 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. In-

gestion 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 origi-

nal manufacturer specifications.

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

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

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

• NEVER tamper with cylinder counter balance valves. Contact the Bil-Jax Ser-

vice 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-4725A 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 cir-

cuit 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

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-4725A

1-8

2

2

22

Introduction

2-1 GENERAL DESCRIPTION

The XLB-4725A 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 450 lbs. (The older basket model capacity is 400 lbs. Refer to figures 6-16 and
6-16A for illustrations of the basket models). Basket elevation is by two hydraulic cylin­ders acting on upper and lower 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, a 24 Volt, 39 Amp, one horsepower, DC
electric motor drives 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, on-board
battery charger is provided for recharging the batteries at the end of each work
period.

On the gasoline engine powered (Gas Model) boom lift, a 4-cycle, 8 horsepower, gasoline
engine drives the hydraulic pump. A 12 volt DC storage battery powers the engine starter
circuit. An auxiliary voltage regulator/rectifier provides 18 amps maximum charge current
while the engine is running.

Two control panels use directional selector switches, rheostats, and proportional 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 adjustable from zero to 8 inches per second (0 to 40 ft/min). 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 pl unger on the front end of the
power compartment. Firmly pulling out and holding the valve plunger manually retrac t s
the upper boom lift cylinder.

The XLB-4725A 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-4725A

2-2 SPECIFICATIONS

Boom Lift Work Platform

Model Number XLB-4725A Serial Number ________________
Manufactured by: Bil-Jax, Inc.

125 Taylor Parkway
Archbold, Ohio 43502

419.445.9675

Table 2-1. Specifications

Feature Battery Powered Model Gasoline Powered Model

Rated Platform Load 450 lbs (204.1 kg) total

[400 lbs (181.6 kg) total for early

version basket ]*
Maximum Work Height 47 ft (14.34 m) 47 ft (14.34 m)
Extended Basket Height 40.5 ft (12.35 m) 40.5 ft (12.35 m)
Elevation Rate,
Maximum
Horizontal Reach 25 ft (7.6 m) 25 ft (7.6 m)
Boom Rotation 360° Continuous 360° Continuous
Rotation Speed 8 in. p er Second, Maximum 8 in. per Second, Maximum
Basket Dimensions 45 in. W x 30 in. D x 42 in. H

Power Source 24 Volt DC, Deep Cycle,

Battery Charger 110/120 Volt, 40 Amp N/A
Hydraulic Pressure 2000 psi (13,790 kPa) 2000 psi (13,790 kPa)
Reservoir Capacity 5 Gallons (18.9 Liters) 5 Gallons (18.9 Liters)
Hydraulic Capacity 7 Gallons (26.5 Liters) 7 Gallons (26.5 Liters)
Hydraulic Oil Energol HLP-HD46 (BP Oil) Energol HLP-HD46 (BP Oil)
Gross Vehicle Weight 4,950 lbs (2247.3 kg) 4,750 lbs (2156.5 kg)
Tongue Wei ght 350 lbs (158.8 kg) 350 lbs (158.8 kg)
Trailer Brakes Hydraulic Surge Hydraulic Surge

*Refer to figures 6-16 and 6-16A for basket views.

8 in./sec (203 mm/sec)

[40 ft/min (12.2 m/min)]

(114.3 cm x 76 cm x 107 cm)

245 Amp-hour Battery

450 lbs (204.1 kg) total
[400 lbs (181.6 kg) total for early

version basket ]*

8 in./sec (203 mm/sec)
[40 ft/min (12.2 m/min)]

45 in. W x 30 in. D x 42 in. H
(114.3 cm x 76 cm x 107 cm)
8 Horsepower Gasoline Engine

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-4725A 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-4725A

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)

HOUR Meter

The HOUR meter displays the elapsed time that the boom lift has been in operation
(UP/DOWN or ROTATION switches engaged). Display units are i n hours and tenths.

PLATFORM/OFF/GROUND Key Switch

The PLATFORM/OFF/GROUND key switch enables boom lift control from either the
lower control panel or the work platform. Removing the key disables lift operation.

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 lift motion. To resume control, rotate the pushbut­ton clockwise to d i sengage the emergency stop switch contacts.

OUTRIGGERS Indicator

The OUTRIGGERS indicator lights up when the boom outriggers are properly deployed
and the boom weight is removed from the trailer axle.

3-2

3 — OPERATION

UPPER BOOM UP/DOWN Selector Switch

Holding the UPPER BOOM UP/DOWN selector switch in the UP position enables the
upper boom to rise. Holding the selector switch in the DOWN position enables the upper
boom to descend. Turning the SPEED CONTROL rheostat clockwise starts the boom
motion. The up or down boom motion continues until the rheostat is released, the selector
switch is released, or the upper boom reaches a hard stop or a safe travel limit.

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. Turning the SPEED
CONTROL rheostat clockwise starts the boom motion. Rotation continues until the rheo­stat or the selector switch is released.

LOWER BOOM UP/DOWN Selector Switch

Holding the LOWER BOOM UP/DOWN selector switch in the UP position raises the
lower boom. Holding the selector switch in the DOWN position lowers the lower boom.
Turning the SPEED CONTROL rheostat clockwise starts the selected boom motion. The
up or down boom motion continues until the rheostat is released, the selector switch is re­leased, or the lower boom reaches a hard stop or a safe travel limit.

SPEED CONTROL Rheostat

A BOOM UP/DOWN or ROTATION selector switch must be held in a motion-enable
position to enable the SPEED CONTROL rheostat. Turn the SPEED CONTROL rheo­stat clockwise to start boom motion. All boom motion speeds ramp up electronically.
Turn the rheostat farther clockwise to increase the boom motion speed.

Lower Control Panel – Gas Model Only

The following engine controls are included on the lower control panel of the gas model
boom lift. These controls are not shown.

CHOKE Pushbutton

Pressing the CHOKE pushbutton engages the choke solenoid. For cold starting, press the
CHOKE pushbutton in for about 5 seconds while cranking the engine.

ENGINE START/STOP Selector Switch

Holding the START/STOP selector switch in the START position cranks the engine. The
engine should not be cranked longer than 15 seconds at a time. Over-cranking will burn
up the starter motor.

Holding the START/STOP selector switch in the STOP position stops the engine. The se­lector switch must be held down until the engine stops running.

3-3

XLB-4725A

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.

Figure 3-3. Upper Control Panel (DC Model)

UPPER BOOM UP/DOWN Pushbuttons

Pressing the UPPER BOOM UP pushbutton enables the upper boom to rise. Pressing the
UPPER BOOM DOWN pushbutton enables the upper boom to descend. Squeezing the
hand grip trigger starts the boom motion. The up or down boom motion continues until
the trigger is released, the pushbutton is released, or the upper boom reaches a hard stop
or a safe travel limit.

ROTATION CW/CCW Pushbuttons

Pressing the ROTATION CW pushbutton enables the boom to rotate in the clockwise di­rection. Pressing the ROTATION CCW pushbutton enables the boom to rotate in the
counterclockwise direction. Squeezing the hand grip trigger starts the boom motion. Rota­tion continues until the trigger is released or the pushbutton is released.

LOWER BOOM UP/DOWN Pushbuttons

Pressing the LOWER BOOM UP pushbutton enables the lower boom to rise. Pressing
the LOWER BOOM DOWN pushbutton enables the lower boom to descend. Squeezing
the hand grip trigger starts the boom motion. The up or down boom motion continues un­til the trigger is released, the pushbutton is released, or the lower boom reaches a hard
stop or a safe travel limit.

3-4

3 — OPERATION

Hand Grip and Trigger

A BOOM UP/DOWN or ROTATION pushbutton must be depressed to enable the hand
grip trigger. Pull the trigger up slowly to start boom motion. All boom motion speeds
ramp up electronically. Pull the trigger higher to speed up the boom motion.

POWER Pushbutton

When pressed, the POWER pushbutton disconnects electrical power to the upper control
panel. The POWER pushbutton should only be pressed to immediately stop all boom lift
motion. To resume control, rotate the pushbutton clockwise to disengage the switch.

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.

EMERGENCY DOWN Pushbutton

When pressed, the EMERGENCY DOWN pushbutton opens the upper cylinder retract
solenoid valve to allow a controlled basket descent. Limited battery power is required to
open the retract cylinder solenoid valve. This method of boom lowering should only be
used when the BOOM DOWN pushbutton or trigger control fails.

Upper Control Panel – Gas Model Only

The following engine controls are included on the upper control panel of the gas model
boom lift. These controls are not shown.

CHOKE Pushbutton

Pressing the CHOKE pushbutton engages the choke solenoid. For cold starting, press the
CHOKE pushbutton down for about 5 seconds while cranking the engine.

ENGINE START Pushbutton

Pressing the ENG INE START pushbutton cranks the engine. The engine should not be
cranked longer than 15 seconds at a time. Over-cranking will burn up the starter motor.

ENGINE STOP Pushbutton

Pressing the ENGINE STOP pushbutton stops the engine. The ENGINE STOP pushbut­ton must be held down until the engine stops r unning.

3-5

XLB-4725A

3-2 NORMAL OPERATING PROCEDURE

Perform the following procedures to operate the XLB-4725A 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 j ack 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 pull each outrigger away from the trailer

frame. Swing the outriggers away 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.

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 lower boom to the
trailer frame. Stow the transport pin in its storage tube.

7. Turn the PLATFORM/OFF/GROUND key switch to the GROUND position.

CAUTION

Do not crank the engine for more than 15 seconds at a time. Extended engine
cranking may overheat and damage the starter motor.

8. (Gas Model Only) Toggle the ENGINE START switch to start the engine. If
the engine is cold, hold the CHOKE switch down for about five seconds while
cranking. Allow the e ngi ne to idle for at least five minutes before operating the
boom lift hydraulics.

9. Use the lower control panel to operate the lift controls. Raise, lower, and rotate
the boom to get familiar with the controls. Learn to smoothly start and stop the
boom lift.

10. With the upper boom fully down, raise the lower boom to upper limit to position
the basket for boarding. Turn the key switch to the PLATFORM position.

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

3-6

3 — OPERATION

3-3 EMERGENCY LOWERING

The XLB-4725A 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 front of the hydraulic power compartment.

To lower the work basket, pull out the valve plunger knob (Figure 3-4). Continue to pull
out on the plunger to lower the basket. Only the upper boom lift cylinder will retract.

PLUNGER

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

3-7

XLB-4725A

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. 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
8 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 bat-

tery charger, resulting in longer charge time.

Figure 3-6. Battery Charger and Receptacle

3-8

3 — OPERATION

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

4. To determine the charge rate at any time during the charge cycle, observe the DC
ammeter (Figure 3-7). 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.

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

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

nearing full 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.

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

3-9

XLB-4725A

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).

Figure 3-8. Breakaway Safety Cable

3. Hold b a ll 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

3-10

3 — OPERATION

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.

INDICATOR BLOCK

IN BRAKE - RELEASED

POSITION

BREAKAWAY

SAFETY CABLE

SAFETY
CHAINS

Figure 3-10. Trailer Hitching Checkpoints

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

8. Check the position of the breakaway safety cable indicator block. If the indicator
block is not in the brakes-released position shown in Figure 3-10, the brakes may
drag. Position the breakaway safety cable and indicator block as shown.

3-11

XLB-4725A

9. Check the position of the trailer backup lever (Figure 3-11). The lever must be in
the TOWING position (up) to enable operation of the surge brakes.

10. 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.
g. Check that the indicator block and backup lever are in their correct

positions as shown in Figures 3–10 and 3–11.

Trailer Towing and Backing

After backing and before towing the boom lift on the open road, always check the posi­tion of the backup lever. Make sure the backup lever is in the TOWING position (up).
See Figure 3-11.

Figure 3-11. Backup Lever Position

WARNING

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

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

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.

3-12

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/add engine oil.
Check/add transmission oil.
Check air filter for dirty or damaged elements. Clean or

replace dirty filter elements. Replace all damaged elements.
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-4725A

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.
Change engine oil.
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.
Clean spark plug and readjust if necessary.
Check outrigger bushings and replace if neces-

sary per paragraph 4-5.
Replace paper air filter element.
Replace hydraulic oil and oil filter.
Replace spark plug.
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 450 pounds. Load early

version basket with 400 pounds. See figures
6-16 and 6-16A for basket views.

·m).

Every

month

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
ing sequence shown.

4-3 LUBRICATION

Lubrication makes operation of the XLB-4725A 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 tighten-

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-4725A

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

4. 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.

5. 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 spin-

dle 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

6. 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

7. 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 spin-

dle 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-4725A

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 Energol HLP-HD46, a high-grade, non­foaming 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 through 3 as needed. Add oil slowly and only when the boom is
lowered to prevent adding more air to the system.

4-6

4 — MAINTENANCE

Hydraulic Cylinder Repair

Cylinder Removal and Installation

1. Lower boom onto travel supports, 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. Place 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-4725A

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. P ower 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.

NOTE: Do not tamper with the cylinder counterbalance valves. If the

counterbalance valves need adjustment, contact the Bil-Jax Service
Department at 419.445.9675.

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-4725A

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 tube 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 cylind er 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 fit of the wiper
(15) on the cylinder rod (3).

11. Press in new bearings (1).

4-10

4 — MAINTENANCE

4-5 LEVELING SYSTEM

Check and Replace Outrigger Bushings

Check outrigger bushings every six months according to the following procedure:

1. Extend the outrigger (Figure 4-7). With the jack raised, draw a pencil line where
the outrigger arm lines up with the latch pin mounting plate.

2. Lower the outrigger jack to raise the trailer wheel. Mark a second line where the
outrigger arm lines up with the latch pin mounting plate.

3. Lower the trailer. Measure the distance between the two marks. If the distance
exceeds 1/16 in., replace the outrigger bushings.

MARK FIRST LINE

WITH OUTRIGGER

JACK RAISED

WITH OUTRIGGER JACK LOWERED

MARK SECOND LINE

(WHEEL RAISED)

1/16 IN. MAX.

BETWEEN MARKS

OUTRIGGER

JACK RAISED

TOP VIEW

Figure 4-7. Checking Outrigger Bushings

4-11

XLB-4725A

Perform the following procedure to replace outrigger bushings. Refer to Figure 4-8.

1. Remove three screws (5), lock washers (4), and flat washers (3).

2. Unscrew and remove fluted knob (2). Remove pin cap (1).

3. Remove nylon lock hex nut (9) and cap screw (6). Remove outrigger ( 8).

4. Remove and replace bushings (7).

5. Reinstall the outrigger in reverse order of removal.

1

2

3

4

5

6

8

7

9

7

1. Pin Cap 6. Cap Screw

2. Fluted Knob 7. Bushings

3. Flat Washers 8. Outrigger

4. Lock Washers 9. Nylon Lock Hex Nut

5. Screws

Figure 4-8. Outrigger Bushing Replacement

4-12

4 — MAINTENANCE

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 4-9.

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 4-9. Adjusting Axle Position Switches

4-13

XLB-4725A

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 clock-

wise to disengage.
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. Short circuit burned out the power

fuse.

g. Battery cable or equi pment ground

lead loose or corroded.

h. System interlock fault.

i. Hydraulic pump not pumping.

a. Loose wiring connector.

b. Valve solenoid failed.

c. System interlock fault.

d. Broken or loose wire.

a. Rheostat or rheostat wiring failure.

b. Valve solenoid not proportional type.

c. Loose solenoid wiring.

d. System interlock fault.

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 clock-

wise to disengage.
e. Check for and repair loose battery

connections or ground fault.
f. Check fuse status indicator D67 in

lower control box. If LED is not on,

replace fuse with spare and retry. If

spare burns out, locate and correct

short circuit in wiring.
g. Clean and reconnect loose or corroded

battery cable or ground lead.
h. Check display for system status.

Correct indicated fault conditions.
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. Check rheostat; replace rheostat or

repair wiring if loose or damaged.
b. Swab out valve solenoids and recheck

function; replace solenoid if faulty.
c. Check wiring terminals in control box

and at valve manifold; repair loose

wiring terminal.
d. Check display for system status.

Correct indicated fault conditions.

4-14

4 — MAINTENANCE

Table 4-3. Troubleshooting Chart, Continued

Problem Cause Correction

5. No operation of all functions
when the trigger or speed
control knob and a function
switch is activated.

a. Master power switch turned off.
b. Short circuit burned out the power

fuse.

c. System interlock fault.

d. Battery cable or equipment ground

lead loose or corroded.

e. Hydraulic pump not pumping.

a. Turn on master power switch.
b. Check fuse status indicator D67 in

lower control box. If LED is not on,
replace fuse with spare and retry. If
spare burns out, locate and correct
short circuit in wiring.

c. Check display for system status.

Correct indicated fault conditions.

d. Clean and reconnect loose or corroded

battery cable or ground lead.

e. Check pump motor operation; repair

or replace if not running. Check gear
pump; replace if hot to touch.

6. Boom lift and rotate func­tions operate intermittently.

a. Loose connection at trigger or speed

control knob.

b. Loose connector at valve coil.

c. System interlock fault.

a. Check display reading for status.

Reconnect wiring.

b. Check wiring connection to valve coil;

repair loose wiring.

c. Check display for system status.

Correct indicated fault conditions.

Troubleshooting Aids

A controller board with fault display LEDs and an error code display is inside the lower
control panel. When a problem arises, open the lower control panel. Turn power on and
observe the control board indicators. See Tables 4-4 and 4-5 for interpreting error codes
and LED indicators on the controller board. Table 4-7 defines the level sensor LEDs in
Figure 4-11. Hydr aulic and electrical diagrams are provide d in Figures 4-12 through 4-15.

Table 4-4. Error Codes

Code Error Description

EC01 Data Communications Error Communication failure during self-test.
EC02 Proportional Control Out of Range Boom lift function outside of programmed safe operating zone.
EC03 Upper Cylinder Down Output Upper cylinder down circuit wiring or valve solenoid faulty.
EC04 Upper Cylinder Up Output Upper cylinder up circuit wiring or valve solenoid faulty.
EC05 Motor/Run/Throttle Solenoid Output Engine stop or throttle control circuit wiring or control device faulty.
EC06 Tilt Alarm Output (Beeper) Alarm output circuit wiring or alarm beeper faulty.
EC08 Lower Cylinder Down Output Lower cylinder down circuit wiring or valve solenoid faulty.
EC09 Lower Cylinder Up Output Lower cylinder up circuit wiring or valve solenoid faulty.
EC10 Rotate CCW Output Rotate CCW circuit wiring or valve solenoid faulty.
EC11 Rotate CW Output Rotate CW circuit wiring or valve solenoid faulty.
EC12 Emergency Down Output Emergency down circuit wiring or valve solenoid faulty.
EC13 Choke Output Choke control circuit wiring or choke solenoid faulty.
EC14 Motor Start Output Engine start circuit wiring or control device faulty.
EC15 Primary Bucket Switch Input Primary bucket switch or switch circuit wiring faulty.
EC16 Secondary Bucket Switch Input Secondary bucket switch or switch circuit wiring faulty.

Note: The related switch must be functionally sound to produce an error code other than EC01, EC06, EC15, or EC16.

4-15

XLB-4725A

Figure 4-10. Lower Controller B oard

4-16

4 — MAINTENANCE

CAUTION

Integrated circuits can be damaged by static electrical discharge. When touching
or handling circuit boards, wear a n anti-static wristband grounded to a boom lift
ground lug. When replacing a circuit board, st and on a grounded anti-static floor
mat. Always seal circuit boards in static shield bags for storage and transport.
Failure to use anti-static discharge protection can cause permanent damage to in­tegrated circuit components.

Table 4-5. LED Indicators

Indicator Function Color

D12 +5 Volt Regulated Supply Red
D16 Communications Active Green
D49 Upper Boom Down Output Red
D50 Upper Boom Up Output Red
D51 Motor Run Output Red
D52 Tilt Alarm Output Red
D53 Spare Red
D54 Lower Boom Down Output Red
D55 Lower Boom Up Output Red
D56 Rotate CCW Output Red
D57 Rotate CW Output Red
D58 Emergency Down Output Red
D59 Outrigger Light Out put Red
D60 Hour Meter Output Red
D61 Proportional Flow Output Red
D62 Engine Choke Output Red
D63 Engine Start Output Red
D64 Engine Stop Output Red
D65 Accessory Power Output Red
D67 Fuse Light Red

Note: D16 should light when power is first turned on (following
the control system self-test). A lighted red LED indicates a fault.

Table 4-6. Upper Control Box Specifications

Power Supply Voltage 12V/24V nominal, 7V to 35V transient
Operating Temperature -40°C to +85°C
Storing Temperature -40°C to +100°C
Digital Inputs 12/24V DC, 60V transient
Analog Inputs 0 to 5V DC, 60V transient

4-17

XLB-4725A

YELLOW LED
OUT OF LEVEL
(MOMENTARY)

GREEN LED

INPUT POWER

RED LED

OUTPUT SIGNAL

(ON WHEN LEVEL)

Figure 4-11. Level Sensor

Table 4-7. 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.

4-18

4 — MAINTENANCE

A1

UPPER BOOM

LIFT CYLINDER

B1 A2 B2

LOWER BOOM

LIFT CYLINDER

BOOM ROTATION

GEAR MOTOR

A3 B3

FILTER

PROP.
VALVE

HYDRAULIC MANIFOLD

HYDRAULIC

PUMP

Figure 4-12. DC Model Hydraulic Diagram

4-19

XLB-4725A

A1

UPPER BOOM

LIFT CYLINDER

B1

LOWER BOOM

LIFT CYLINDER

A2 B2

BOOM ROTATION

GEAR MOTOR

A3 B3

PROP.

VALVE

TP

FILTER

HYDRAULIC MANIFOLD

HYDRAULIC

PUMP

Figure 4-13. Gas Model Hydraulic Diagram

4-20

4 — MAINTENANCE

UPPER

CONTROL BOX

E-DOWN

TRIGGER

SWITCH

UPPER

CYL UP

UPPER

CYL

DOWN

LOWER
CYL UP

LOWER

CYL

DOWN

LOWER

CONTROL BOX

SPEED

CONTROL

UPPER
CYL UP

UPPER

CYL

DOWN

LOWER
CYL UP

LOWER

CYL

DOWN

PRIMARY BUCKET SWITCH

SECONDARY BUCKET SWITCH

OUTRIGGER

OUTRIGGER

OUTRIGGER

OUTRIGGER

OUTRIGGER

(PBS)

(PBS)

(SBS)

(SBS)

(SBS)

LEVEL

SENSOR

MOTOR START

LEVEL

SENSOR

LEVEL

SENSOR

LEVEL

SENSOR

(PBS) INPUT

(SBS) INPUT

SOLENOID

CYL DOWN

CYL DOWN

E-DOWN

PROP.
VALVE

UPPER

CYL UP

UPPER

LOWER
CYL UP

LOWER

KEY

SWITCH

20 AMP

FUSE

ROTATE

CW

ROTATE

CCW

E-STOP

–

+

24V

UPPER

CONTROLS

LOWER

CONTROLS

MASTER

POWER
SWITCH

ROTATE

CW

ROTATE

CCW

E-STOP

MOTOR

SOLENOID

OUTRIGGER

SWITCHES

START

OUTRIGGER

OUTRIGGER

M

AXLE

SWITCHES

LEVEL

SENSOR

OUTRIGGER

SENSOR

Figure 4-14. PC Logic Diagram, DC Model

LAMP

LEVEL

LEVEL

SENSOR

LEVEL

SENSOR

OUTRIGGER

INPUT

LEVEL

SENSOR

INPUT

ROTATE

CW

ROTATE

CCW

LEVEL

SENSOR

WARNING

4-21

XLB-4725A

UPPER

CONTROL BOX

E-DOWN

TRIGGER

SWITCH

UPPER
CYL UP

UPPER

CYL

DOWN

LOWER
CYL UP

LOWER

CYL

DOWN

LOWER

CONTROL BOX

SPEED

CONTROL

UPPER

CYL UP

UPPER

CYL

DOWN

LOWER
CYL UP

LOWER

CYL

DOWN

PRIMARY BUCKET SWITCH

SECONDARY BUCKET SWITCH

OUTRIGGER

OUTRIGGER

OUTRIGGER

OUTRIGGER

OUTRIGGER

(PBS)

(PBS)

(SBS)

(SBS)

(SBS)

LEVEL

SENSOR

LEVEL

SENSOR

LEVEL

SENSOR

LEVEL

SENSOR

(PBS) INPUT

(SBS) INPUT

THROTTLE
SOLENOID

RELAY

CYL DOWN

CYL DOWN

E-DOWN

PROP.
VALVE

UPPER
CYL UP

UPPER

LOWER
CYL UP

LOWER

SWITCH

ENGINE

18 AMP

CHARGING

SYSTEM

KEY

20

AMP

FUSE

ROTATE

CW

ROTATE

CCW

CHOKE

START

ENGINE

KILL

E-STOP

UPPER

CONTROLS

LOWER

CONTROLS

–

+

12V

25

AMP

FUSE

MASTER

POWER
SWITCH

ROTATE

CW

ROTATE

CCW

CHOKE

START

ENGINE

KILL

E-STOP

OUTRIGGER SWITCHES

THROTTLE
SOLENOID

RELAY

THROTTLE
SOLENOID

OUTRIGGER

OUTRIGGER

ENGINE

KILL

SWITCHES

ENGINE

START

AXLE

LEVEL

SENSOR

SENSOR

SENSOR

ENGINE

IGNITION

MODULE

OUTRIGGER

LAMP

LEVEL

SENSOR

LEVEL

LEVEL

OUTRIGGER

INPUT

LEVEL

SENSOR

INPUT

ROTATE

CW

ROTATE

CCW

CHOKE

ENGINE

KILL

LEVEL

SENSOR

WARNING

Figure 4-15. PC Logic Diagram, Gas Model

4-22

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 Electrolyte
Appearance & Odor Clear Liquid with Sharp Pungent Odor

SECTION IV: FIRE AND EXPLOSION HAZARD DATA:

Flash Point: Not Combustible
Auto Ignition Temperature N/A Flammabil tiy Limits in Air % by Volume: N/A
Extinguishing Media: Dry Chemical CarbonDi 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 ac id is dilluted with water to form 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

4-23

XLB-4725A

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

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 Conditions 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 PERSONAL PROTECTION: X

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

SECTION VIII -- CONTROL AND PROTECTIVE MEASURES

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

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

4-24

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: [phone]
CHEMICAL FAMILY: LUBRICATING OIL
CAS NUMBER: MIXTURE: ISSUE DATE 12/15/96
HAZARDOUS INGREDIENTS:

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

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

1910.1000 AND OSHA 29 CFR 1910.1200.

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

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

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

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

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

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

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

4-25

XLB-4725A

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.

4-26

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-4725A Boom Lift.

Table 5-1. Replacement Decals, DC Model

Decal No.

B06-00-0006 EMERGENCY CONTROL

B06-00-0033 CAUTION: THIS UNIT SHALL

B06-00-0034 DANGER: …DURING

B06-00-0036 LUBRICATE WEEKLY 36
B06-00-0037 LUBRICATE SEMI-ANNUALLY 1
B06-00-0041 MASTER POWER SWITCH 1
B06-00-0060 STOP…READ OPERATING… 2
B06-00-0062 THIS PLUG 115 VOLT 2
B06-00-0068 THE HYDRAULIC SYSTEM… 1
B06-00-0115 1500 WATT LOAD LIMIT 1
B06-00-0116 OPERATE WITH FULLY

B06-00-0129 OIL LEVEL – TRANSPORT

B06-00-0130 LUBRICATE MONTHLY 5
B06-00-0139 DANGER: BEFORE USING:

B06-00-0145 DANGER: BOOM SAFETY

B06-00-0146 DANGER: HIGH VOLTAGE

B06-00-0151 DANGER: 110 VOLT 1

B06-00-0161B Bil-Jax TRANSFER 2

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

Description of Decal

VALVE

ONLY BE TOWED WHEN…

CHARGING, EXPLOSIVE
OXYHYDROGEN GAS…

CHARGED BATTERIES…

POSITION

EXTEND, LOCK, STABILIZE…

INSTRUCTIONS

OPERAT ION – LARGE LABE L

ATTACHMENT POINT

Qty

1

2

1

1

1

5

2

1

2

Decal No. Description of Decal Qty

B06-00-0189 WARNING: LEVEL MACHINE

BEFORE USE…

B06-00-0192 OPERATION AND SERVICE

MANUAL INSIDE

B06-00-0225 WARNING: STAY CLEAR

WHILE RAISING …
B06-00-0243 GASOLINE FILL 1
B06-00-0261 CAUTION: ANSI DECAL 1
B06-00-0268 EMERGENCY ROTATION

HANDLE
B06-00-0290 ATTENTION: DC MOTOR

FAILURE WARNING
B06-00-0321

or

B06-00-0380
B06-00-0328

or

B06-00-0328-A

B06-00-0334 DANGER: HIGH VOLTAGE

B06-00-0335 XLB-4725A TRANSFER 2
B06-00-0371 ERROR CODES 1
B06-00-0372 UPPER CONTROLS DECALS,

B06-00-0373 LOWER CONTROLS DECALS,

B06-00-0374 UPPER CONTROLS DECALS,

B06-00-0375 LOWER CONTROLS DECALS,

B06-00-0376 OPERATING INSTRUCTIONS –

MAXIMUM CAPACITY 400 LBS

(early model basket)

MAXIMUM CAPACITY 450 LBS

XLB-4725A SPECIFICATIONS 2

OPERATION – SMALL LAB EL

DC MODEL

DC MODEL

GAS MODEL

GAS MODEL

PROPORTIONAL CONTROLS

1

1

1

1

1

2

1

1

1

1

1

2

5-1

XLB-4725A

D ANGER

OUTRIGGERS; AND LEVEL MACHINE.

CFT/RFC B06-00-0139

B06-00-0139

D ANGER

IT IS UN L AWFULT O OPERATE
THIS EQUIPMENT WITHIN 10
FEET OF HIGH VO LTAGE LINES
OF 50,000 VO LTS OR LESS.

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

This machine is NOT insulated. Do not use within 10 ft. of power lines

BEFORE USING: EXTEND, LOCK, ST ABILIZE

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.

B06-00-0146

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.

B06-00-0261

D ANGER

B06-00-0334

SAFETY
HARNESS
LANYARD

ATTA CHMENT

POINT

B06-00-0173

DOES NOT provide

B06-00-0261FFU

B06-00-0173UFC

COIA/RFT

BOOM OPERATING INSTRUCTIONS (PROPORTIONAL CONTROLS)

1. Read and follow all manuals and
decals.

2. Disconnect the boom hitch from the
towing vehicle.

3. Extend lock and base all four (4)
outriggers.

4. Level the lift using the four (4)
outriggers and by referencing the T­level located at the front of the boom
power base. Remove as much
weight as possible from the trailer
tires.

5. Always wear safety harness and
attach lanyard when operating from
the basket.

ITT

!! AT T ENTION !!

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 f oreign
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 mo to r must not come into
direct contact with foreign particles and/
or moisture. See Operator’s Manual for
details.

B06-00-0290

B06-00-0290

OPERA TION AND SERVICE

MANUAL INSIDE

COFC B06-00-0192

B06-00-0192

EMERGENCY ROTATION HANDLE

B06-00-0268

THIS P LUG 1 15V O LT

RIL

B06-00-0062

GASOLINE FILL

B06-00-0243

CAUTION

THIS UNIT SHALL ONLY BETOW ED
WHEN ALL BOOM SECTIONS ARE
FULLY DOWN AND LOCKED WITH
TRANSPORT SAFETY PINS.

B06-00-0033

6. If using gas model, start engine from either
the lower or upper control box. It may be
necessary to hold the choke for a short
time when engine is cold. If using DC
model, turn master power switch to “on”.
Familiarize yourself with the operation of
the lift, using the ground controls before
operating the lift from the platform.

7. On the lower control panel, position
“control selector” switch to “upper ”.
The lift is now ready to operate from the
basket.

8. Select function by pressing and holding
button. Grasp the handle and slowly
squeeze the trigger. Boom speed
increases the harder the trigger is
squeezed.

B06-00-0376

B06-00-0033

B06-00-0268OFA

B06-00-0062

B06-00-0376

FAILURETO COMLYWITH THE FOLLOWING SAFETY INSTRUCTIONS OR ANY OTHER USE

BEFORE USE

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

• Survey the job site and identify all potential hazards.

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

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

• OPERATE ON FIRM AND LEVEL SURFACE ONLY—if used on loose gravel or other soft surfaces,the large
square support pads should be added to the base of the outriggers. Additional base support may be
necessary on excessively soft footing.

• Extend, lock,and stabilize all four outriggers.

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

• All occupants must wear full body harness and lanyard.

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

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

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

DURING USE

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

• DO NOT use without all four outriggers fully extended, locked and stabilized.

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

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

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

CFT/RFT B06-00-0145

OFTHIS EQUIPMENTWILL RESULT IN SERIOUS INJURY OR DEATH.

D ANGER

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

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

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

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

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

• DO NOT climb up or down boom.

• DO NOT exceed rated lift capacity.

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

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

• DO NOT use boom rotation for pushing or pulling.

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

• DO NOT use as a crane for lifting materials.

• DO NOT leave keys in machine while unattended.

• Plug charger in at the end of each day.

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

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

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

AND OPERATION AS REQUIRED BYTHE OWNERS MANUAL .

®

IFYOU HAVE NOT BEEN PROVIDEDWITH SAFETY LITERATURE,
OR FOR ANY QUESTIONS CONCERNINGTHE SAFE USE OF THIS
EQUIPMENT,CALL 419/445-9675.

B06-00-0145

LUBRICATE

MONTHLY

RIF

B06-00-0130

LUBRICATE

SEMI-ANNUALLY

COIA B06-00-0037

B06-00-0037

EMERGENCY CONTROLVALVE

B06-00-0130

B06-00-0006

LUBRICATE

WEEKLY

COIA B06-00-0036

B06-00-0036

DANGER

110 VOLT

B06-00-0151GFT/LFG

B06-00-0151

B06-00-0006

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

5-2

5 — REPLACEMENT DECALS

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

5-3

XLB-4725A

®

PLATFORM GROUND

OFF

EMERGENCY STOP

OUTRIGGERS

UP UP

CW CCW

DOWN DOWN

UPPER BOOM SPEED

ROTATION

LOWER BOOM

B06-00-0373

®

bil-jax

A Member of the plettac Group

CONTROL

bil-jax

A Member of the plettac Group

®

UPPER

BOOM

UP

UPPER
BOOM
DOWN

®

ROTATION

CCW

A Member of the plettac Group

POWER

bil-jax

CCW

®

LOWER

BOOM

UP

LOWER

BOOM

DOWN

EMERGENCY

DOWN

B06-00-0372

®

A Member of the plettac Group

ROTATION

CCW

UPPER

BOOM

UP

®

UPPER

BOOM
DOWN

bil-jax

CCW

®

LOWER
BOOM

UP

LOWER
BOOM
DOWN

EMERGENCY

DOWN

PLATFORM GROUND

OFF

EMERGENCY STOP

OUTRIGGERS

UP UP

CW CCW

DOWN DOWN

UPPER BOOM LOWER BOOM

ROTATION

B06-00-0375

B06-00-0161B

MAXIMUM CAPACITY

CHOKE

START

STOP

ENGINE

SPEED

CONTROL

XLB-4725A

B06-00-0335

POWER

CHOKE ENGINE

STOP

ENGINE

START

B06-00-0374

ERROR CODE CHART

EC01 Data Communication Error
EC02 Proportional Control out of Range
EC03 Upper Cylinder Down Output
EC04 Upper Cylinder Up Output
EC05 Motor/Run/Throttle Solenoid Output
EC06 Tilt Alarm Output (Beeper)
EC08 Lower Cylinder Down Output
EC09 Lower Cylinder Up Output
EC10 Rotate CCW Output
EC11 Rotate CW Output
EC12 Emergency Down Output
EC13 Choke Output
EC14 Motor Start Output
EC15 Primary Bucket Switch Input
EC16 Secondary Bucket Switch Input

RTT

B06-00-0371

MAXIMUM CAPACITY

B06-00-0371

AFL B06-00-0321

400

B06-00-0321

LBS.

CCTT

450

B06-00-0380

LBS.

B06-00-0380

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

5-4

5-5

0036

Both Ends

(

Both Booms

5 — REPLACEMENT DECALS

(

Figure 5-2. Decal Locations, Trailer and Boom

0173

(Both Sides)

0060

0334

0328

0145

0321

or

0380

0139

0372

or

0374

0016

XLB-4725A

0335

(Both Sides)

0036

2 Places

(

Both Sides

0192

(Opposite Side)

0373 or

(

Both Ends/

(

Both Cylinders

0375

0328

0036

(

0167

0139

(Both Sides)

0036

(Both Sides)

0161B

(Both Sides)

(4 Outriggers)

0036

(Both Sides)

0033

(Opposite Side)

0036

(Opposite Side)

0036

0290

0167

0321

or

0380

0115

0036

2 Places

(

Both Sides

(

0036

(Both Sides)

0139

(Both Sides)

0146

0261

0145

0041

0033

XLB-4725A

Figure 5-3. Decal Locations, Power Compartments Exterior

Figure 5-4. Decal Locations, Power Compartment Interior

5-6

6

6

66

Parts List

6-1

XLB-4725A

6-1 UPPER BOOM PARTS LIST

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

Figure 6-1. Upper Boom

6-2

6 — PARTS LIST

Table 6-1. Upper Boom Parts List

Item No. Part No. Description Qty

1 B14-00-0006 Boom, Upper 1
2 B29-00-0005 Plate, Lift Pin Locking 6
3 0090-0208 Washer, Lock, Split, 5/16 in. 12
4 0090-0028 Screw, Cap, 5/16-18 x 3/4 in. 16
5 B36-01-0022 Pin, Boom, Pivot 1
6 B29-00-0118 Leveling Bar Knuckle 2
7 0090-0485 Nut, Hex, 1/2-13 4
8 0090-0574 Washer, Flat, 1/2 in. 12

9 B25-00-0014 Bearing, Tie Rod End, 1/2 in. R.H. Thread 4
10 0090-0461 Screw, Cap, 1/2-13 x 2 in. 4
11 B04-06-0028 Washer, Shim 4
12 B04-07-0090 Ring, Retaining 4
13 B04-06-0001 Washer, Flat, 2 in. OD 2
14 0090-0210 Washer, Lock, Split, 3/8 in. 2
15 B04-05-0001 Screw, Cap, 3/8-16 x 1 in. 2
16 B00-00-0009 Fitting, Grease, Straight, 3/16 in. 2
17 B11-03-0028 Bar, Lower Leveling 2
18 0090-0167 Nut, Jam, 1/2-20 4
19 B11-03-0027 Bar, Upper Leveling 2
20 0090-0191 Nut, Nylon Lock, 1/2-13 4
21 B25-00-0053 Bushing, Bronze, 1-1/2 in. ID 2
22 B36-01-0005 Pin, Lift Cylinder 2
23 B30-00-0002 Spacer, Lift Pin 4
24 B02-03-0022 Cylinder, Upper Boom Lift,

1

3 in. Bore x 54 in. Stroke (See Figure 6-3)
25 0090-0185 Nut, Nylon Lock, 5/16-18 12
26 0090-0285 Pin, Roll, 3/16 x 1 in. 4
27 0090-0662 U-Bolt 4
28 B29-00-0125 Bracket, U-Bolt 2
29 B29-00-0124 Support, Upper Leveling Bar 1
30 B25-00-0023 Bearing, Bronze 2

6-3

XLB-4725A

6-2 LOWER BOOM PARTS LIST

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

4

3

2

1

6

23

24

26

25

6

23

7

2

2

20

22

11

12

8

9

10

11

2

5
7

6

13

3

19

18

17

21

20

14

15

16

7

8

9

10

Figure 6-2. Lower Boom

11

12

8

9

10

6-4

6 — PARTS LIST

Table 6-2. Lower Boom Parts List

Item No. Part No. Description Qty

1 B14-00-0008 Boom, Lower 1
2 B25-00-0023 Bearing, Bronze, 1.75 OD x 1.5 ID 4
3 B34-00-0007 Trimlock, 1/4 in. 2 ft.
4 0090-0005 Screw, Cap, 1/4-20 x 3/4 in. 3
5 B04-07-0034 Clamp, Cable/Hose, DG 12 3
6 0090-0183 Nut, Hex, Nylon Lock, 1/4-20 5
7 B00-00-0009 Fitting, Grease, 3/16 in. Drive 4
8 B29-00-0005 Plate 6

9 0090-0208 Washer, Lock, Split, 5/16 in. 12
10 0090-0028 Screw, Cap, 5/16-18 x 3/4 in. 12
11 B30-00-0002 Spacer, Lift Cylinder Pin 4
12 B36-01-0005 Pin, Lift Cylinder 2
13 B02-03-0013 Cylinder, Lower Boom Lift,

1

4 in. Bore x 25 in. Stroke (See Figure 6-4)
14 B04-06-0001 Washer, Flat, 2 in. OD 2
15 0090-0210 Washer, Lock, Split, 3/8 in. 2
16 B04-05-0001 Screw, Cap, 3/8-16 x 1 in. 2
17 B36-01-0007 Pin, Lower Boom Pivot 1
18 0090-0392 Screw, Socket, 1/2-13 x 2-1/2 in. 2
19 B25-00-0013 Bearing, Tie Rod End, 1/2 in. L.H. Thread 2
20 B30-00-0038 Spacer, Levering Bar Stanchion 4
21 0090-0168 Nut, 1/2-20 LH 2
22 B11-03-0028 Bar, Lower Leveling 2
23 B04-07-0036 Clamp, Cable/Hose, DG 16 2
24 B34-00-0006 Trimlock, 1/8 in. 1 ft.
25 B00-00-0014 Cap, Black Plastic 2
26 B30-00-0044 Pad, Rubber, Upper Boom Support 1

6-5

XLB-4725A

6-3 UPPER CYLINDER PARTS LIST

Refer to Table 6-3 for the upper cylinder parts list.

Figure 6-3. Upper Cylinder

6-6

6 — PARTS LIST

Table 6-3. Upper Cylinder Parts List

Item No. Part No. Description Qty

1 ** Rod, Cylinder 1
2 B00-00-0061 Fitting, Grease, Straight 1
3 B02-13-0103 Bearing, Spherical 2
4 * Wiper, Rod 1
5 ** Headstock 1
6 ** Bushing, Bronze 1
7 * Seal 1
8 * Ring, Backup 1

9 * O-Ring 1
10 B00-00-0106 Fitting, Grease, 90° 1
11 ** Cylinder Housing 1
12 ** Nut, Slotted 1
13 * Ring, Wear 1
14 ** Piston 1
15 * O-Ring 1
16 * Seal 1
17 ** Sleeve, Stop 1
18 B02-03-0022 Cylinder, Upper Boom Lift,

1

3 in. Bore x 54 in. Stroke

19 B22-00-0010 Kit, Seal (Not Illustrated)

1

(includes items 4, 7, 8, 9, 13, 15, and 16)

*Part of Seal Kit, item 19.
** Not procurable; order Upper Boom Lift Cylinder, item 18.

6-7

XLB-4725A

6-4 LOWER CYLINDER PARTS LIST

Refer to T a b le 6 -4 for lower cylinder parts list.

1

16

12

9

11

15

14

13

10

2

3

4

8

2

Figure 6-4. Lower Cylinder

3

5

6

7

6-8

6 — PARTS LIST

Table 6-4. Lower Cylinder Parts List

Item No. Part No. Description Qty

1 ** Rod, Cylinder 1

2 B00-00-0061 Fitting, Grease, Straight 2

3 B02-13-0103 Bearing, Spherical 2

4 * Wiper, Rod 1

5 ** Headstock 1

6 * Ring, Backup 1

7 * O-Ring 1

8 B02-04-0064 Valve, Counterbalance 2

9 ** Cylinder Housing 1
10 ** Nut, Slotted 1
11 * Ring, Wear 1
12 ** Piston 1
13 * O-Ring 1
14 * Seal 1
15 ** Sleeve, Stop 1
16 B02-03-0013 Cylinder, Lower Boom Lift,

1

4 in. Bore x 25 in. Stroke

17 B22-00-0011 Kit, Seal (Not Illustrated)

1

(includes items 4, 6, 7, and 12)

*Part of Seal Kit, item 17.
**Not procurable; order Lower Boom Lift Cylinder, item 16.

6-9

XLB-4725A

6-5 DC MODEL BATTERY COMPARTMENT PARTS LIST

Refer to Table 6-5 for the DC model boom lift battery compartment parts list.

1

2

37

41

39

38

42

36, 36A

43

40

44

10

10

43

45

13

12

11

3

4

10

7

8

7

14

9

15

5

6

16

17

47

48

49

46

11

14

7

20

18

18

19

21

22, 22A

23

35

30

34

5

14

24

25

26

29

28

15

31

27

15

31

32

38

33

c

Figure 6-5. DC Model Battery Compartment

6-10

6 — PARTS LIST

Table 6-5. 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 7
15 0090-0419 Washer, Flat, 1/4 in. 6
16 B04-07-0005 Rod, Threaded, Battery Retaining, 1/4 in. 1
17 B29-00-0135 Hold Down Bracket, 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 0090-0188 Nut, Hex, Nylon Lock, 3/8-16 4
24 B42-00-0005 Latch, Lid 1

6-11

XLB-4725A

1

2

37

41

39

38

42

36, 36A

43

40

44

10

10

43

45

13

12

11

3

4

10

7

8

7

14

9

15

5

6

16

17

47

48

49

46

11

14

7

20

18

18

19

21

22, 22A

23

35

30

34

5

14

24

25

26

29

28

15

31

27

15

31

32

38

33

Figure 6-5. DC Model Battery Compartment

6-12

6 — PARTS LIST

Table 6-5. DC Model Battery Compartment Parts List, Continued

Item No. Part No. Description Qty

25 0090-0814 Screw, Machine, #8-32 x 7/8 in. 2
26 B30-00-0040 Spacer 2
27 0090-0042 Screw, Cap, 3/8-16 x 1 in. 4
28 0090-0005 Screw, Cap, 1/4-20 x 3/4 in. 8
29 0090-0409 Screw, Thumb, 3/8-16 x 3/4 in. 1
30 B18-00-0026 Cover 1
31 0090-0206 Washer, Lock, Split, 1/4 in. 5
32 0090-0688 Bolt, Hex, 1/4-20 x 1 in. 1
33 B18-00-0010 Cover, Side 1
34 B05-00-0007 Tape, Foam Adhesive Back, 1/16 x 1/2 in. 32 in.
35 B18-00-0018 Plexiglass, 1/8 in. x 8 in. x 8 in. 1
36 B01-05-0006 Charger, Battery, 40 Amp, 110 Volt AC, 60 Hz 1
36A B01-05-0027 Charger, Battery, 40 Amp, 220 Volt AC, 50 Hz 1
37 B03-00-0078 Handle Assembly, Manual Rotation

1

(includes items 38 through 42)
38 B11-03-0018 Tube, Manual Boom Rotation 1
39 0090-0834 Nut, Nylon Lock, 1/4-20 1
40 0090-0011 Screw, Cap, 1/4-20 x 1-3/4 in. 1
41 B07-10-1042 Handle, Manual Boom Rotation 1
42 B46-00-0018 Grip, Rubber 1
43 0090-0344 Screw, Threadcutting, #10-24 x 1/2 in. 3
44 B04-07-0062 Clip, Gripper 1
45 B01-10-0003 Receptacle, Flush Mount 1
46 B29-00-0021 Bracket, Level Sensor Mounting 1
47 B01-10-0016 Sensor, Slope, 3°, 0.5 Second Delay 1
48 0090-0231 Screw, Machine, #10-24 x 1/2 in. 4
49 0090-0205 Washer, Lock, #10 4

6-13

XLB-4725A

6-6 GAS MODEL ENGINE COMPAR TMENT PARTS LIST

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

53

1

49

72

2

7

7

16

15

18

6

11

10

9

7

8

5

22

26

20

21

17

19

24

11

12

11

4

3, 3A

23

25

14

13

27

66

58

44

59

61

62

63

65

64

28

29

30

44

60

42

57

70

56

9

72

67

68

31

32

29

33

34

46

55

36

29

54

12

49

50

51

12

52

71

69

29

42

41

48

44

42

43

40

29

36

35

10

47

42

39

29

46

45

38

c

37

Figure 6-6. Gas Model Engine Compartment

6-14

6 — PARTS LIST

Table 6-6. Gas Model Engine Compartment Parts List

Item No. Part No. Description Qty

1 B18-00-0052 Lid, Compartment Cover 1
2 B18-00-0129 Plate, Top, Engine Cover 1
3 B01-04-0004 Battery, 12 Volt 1

3A B01-04-0012 Battery, Dry Cell, 12 Volt 1
4 B01-01-0110 Cable, Battery, 2 Ga. x 45 in. 1
5 B29-00-0001 Strap, Battery Hold-Down 1
6 B04-07-0003 Rod, Threaded, Battery Hold-Down 2
7 0090-0232 Screw, Machine, #10-24 x 5/8 in. 15
8 0090-0415 Washer, Flat, #10 7
9 0090-0225 Screw, Machine, #8-32 x 1/2 in. 3

10 B42-00-0006 Clip, Latch 1
11 0090-0182 Nut, Hex, Nylon Lock, #10-24 15
12 B29-00-0073 Bracket, Ball Mounting 1
13 B39-00-0034 Spring, Gas 1
14 B18-00-0132 Frame, Compartment Cover 1
15 B42-01-1002 Hinge 1
16 0090-0684 Rivet, Pop, 3/16 x 1/2 1
17 0090-0030 Screw, Machine, 5/16-18 x 1 in. 4
18 0090-0208 Washer, Lock, 5/16 4
19 0090-0420 Washer, Flat, 5/16 4
20 0090-0043 Screw, Machine, 3/8-16 x 1-1/4 in. 4
21 0090-0210 Washer, Lock, 3/8 4
22 0090-0422 Washer, Flat, 3/8 4
23 0192-0030 Housing, Coupler 1
24 0192-0026 Coupler Body, Modified 1
25 0192-0028 Insert, Coupler 1
26 B00-00-0045 Coupler Body 1
27 B20-00-0009 Engine, Gasoline, 8 HP 1
28 0090-0183 Nut, Hex, Nylon Lock, 1/4 4
29 0090-0419 Washer, Flat, 1/4 in. 8
30 B01-01-0067 Cable, Battery, 2 Ga. x 45 in. 1
31 B07-06-5198 Plate, Engine Isolation Mount 1
32 B20-00-0007 Bushing, Isolation Mount 4
33 0090-0007 Screw, 1/4-20 x 1-1/4 2
34 B18-00-0128 Cover, Engine Panel, Rear 1
35 0090-0010 Screw, 1/4-20 x 1-1/2 3
36 0090-0206 Washer, Lock, 1/4 in. 5

6-15

XLB-4725A

53

1

49

72

2

7

7

16

15

18

6

11

10

9

7

8

5

22

26

20

21

17

19

24

11

12

11

4

3, 3A

23

25

14

13

27

66

58

44

59

61

62

63

65

64

28

29

30

44

60

42

57

70

56

9

72

67

68

31

32

29

33

34

46

55

36

29

54

12

49

50

51

12

52

71

69

29

42

41

48

44

42

43

40

29

36

35

10

47

42

39

29

46

45

38

37

Figure 6-6. Gas Model Engine Compartment

6-16

6 — PARTS LIST

Table 6-6. Gas Model Engine Compartment Parts List, Continued

Item No. Part No. Description Qty

37 0090-0787 Washer, Fender 4
38 0090-0014 Screw, 1/4-20 x 2-1/2 4
39 B07-10-1026 Spacer, Isolation Mount Ring 4
40 B20-00-0006 Ring, Isolation Mount 4
41 B20-00-0013 Regulator/Rectifier, Voltage, 12 Volt, 18 Amp 1
42 0090-0183 Nut, Nylon Lock, 1/4 in. 6
43 0090-0028 Screw, Machine, 5/16-18 x 3/4 1
44 0090-0344 Screw, Threadcutting, #10-24 x 1/2 in. 6
45 B18-00-0127 Cover, Engine Panel, Front 1
46 0090-0005 Screw, Cap, 1/4-20 x 3/4 in. 4
47 B42-00-0005 Latch, Lid 1
48 B18-00-0054 Cover, Side 1
49 B42-00-0011 Latch, Draw, Flexible 1
50 0090-0185 Nut, Nylon Lock, 5/16-18 2
51 0090-0420 Washer, Flat, 5/16 in. 2
52 0090-0409 Screw, Thumb, 3/8-16 x 3/4 in. 1
53 B03-00-0078 Handle Assembly, Manual Rotation

(includes items 54 through 59)
54 B11-03-0018 Tube, Manual Boom Rotation 1
55 0090-0834 Nut, Nylon Lock, 1/4-20 1
56 0090-0011 Screw, Cap, 1/4-20 x 1-3/4 in. 1
57 B07-10-1042 Handle, Manual Boom Rotation 1
58 B46-00-0018 Grip, Rubber 1
59 B04-07-0062 Clip, Gripper 1
60 B01-10-0003 Receptacle, Flush Mount 1
61 B29-00-0021 Bracket, Level Sensor Mounting 1
62 B01-10-0016 Sensor, Slope, 3°, 0.5 Second Delay 1
63 0090-0231 Screw, Machine, #10-24 x 1/2 in. 4
64 0090-0205 Washer, Lock, #10 4
65 B01-10-0084 Solenoid, Choke, 12 Volt 1
66 0090-0708 Screw, Machine, #6-32 x 3/8 in. 4
67 B29-00-0095 Bracket, Solenoid 1
68 0090-0180 Nut, Nylon Lock, #6-32 4
69 B01-01-0006 Cable, Battery, 2 Ga. x 16 in. 1
70 0090-0188 Nut, Nylon Lock, 3/8-16 1
71 B18-00-0026 Cover 1
72 0090-0472 Screw, Sheet Metal, #10 x 1/2 2

6-17

XLB-4725A

6-7 DC MODEL POWER COMPARTMENT PARTS LIST

Refer to Table 6-7 for the DC model power compartment parts list.

2

1

13

12

11

59

4

5

3

10

8

6

9

63

60

29
25

61, 62

11

6

7

31

30

32

29
25

28

38

3

3

28

14

33

15

17

34

39

19

24

40

17

16

23

25
26
27

21

17

41

22

44

10

18

20

35

64

46

48

50

65

36

37

47

49

51

53

58

57

45

56

43

25

29
24
36

25

42

55

50

52

45

54

Figure 6-7. DC Model Power Compartment

6-18

6 — PARTS LIST

Table 6-7. 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. 15
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 15
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 B02-15-0216 Clamp, Hose 1
15 0090-0231 Screw, Machine, #10-24 x 1/2 in. 2
16 B01-01-0028 Cable, Battery, 2 Ga. x 33 in. 1
17 B01-09-0018 Boot, Terminal 4
18 0090-0157 Nut, Hex, #10-24 2
19 B02-15-0345 Solenoid, Motor 1
20 B02-15-0346 Wiring Assembly, 4 Pin 1
21 B01-09-0050 Wire, Butt Splice Crimp 18/22A 1
22 B01-01-0010 Cable, Battery, 2 Ga. x 13 in. 1
23 B01-01-0027 Cable, Battery, 2 Ga. x 19 in. 1
24 0090-0188 Nut, Hex, Nylon Lock, 3/8-16 2
25 0090-0419 Washer, Flat, 1/4 in. 13
26 0090-0206 Washer, Lock, Split, 1/4 in. 2
27 0090-0159 Nut, Hex, 1/4 –20 2
28 B29-00-0126 Bracket, Pump/Motor 2
29 0090-0183 Nut, Hex, Nylon Lock, 1/4-20 11
30 B02-05-0021 Pump and Motor Assembly 1
31 B01-07-0004 Motor, Pump 1
32 B02-05-0020 Pump, Gear, Fixed Displacement,

1

1.4 gal. per min.

6-19

XLB-4725A

2

1

13

12

11

59

4

3

5

3

10

8

6

6

7

31

30

9

61, 62

32

14

15

3

16

17

18

65

33

34

10

19

21

17

20

64

35

36

37

17

63

60

29
25

28

38

29
25

28

24

39

40

23

25
26
27

22

46

48

47

49

51

53

41

11

44

50

58

29

25

50

52

45

24
36

43

42

25

57

45

56

55

54

Figure 6-7. DC Model Power Compartment

6-20

6 — PARTS LIST

Table 6-7. DC Model Power Compartment Parts List, Continued

Item No. Part No. Description Qty

33 B01-09-0001 Ring, Wire, 3/8 1
34 B05-01-0009 Wire, 16 Ga. 6 in.
35 B02-04-0066 Manifold, Proportional Valve, 24 Volt 1
36 0090-0420 Washer, Flat, 5/16 in. 2
37 0090-0926 Screw, Cap, 5/16-18 x 4-1/2 in. 2
38 0090-0185 Nut, Hex, Nylon Lock, 5/16-18 2
39 0090-0344 Screw, Thread Cutting, #10-24 x 1/2 in. 1
40 B00-00-0112 Faceplate, Master Power Switch 1
41 B01-02-0060 Switch, Master Power 1
42 B29-00-0143 Bracket, Lower Control Box 1
43 0090-0042 Screw, Cap, 3/8-16 x 1 1
44 B01-02-0066 Box, Lower Control (DC Model) 1
45 0090-0005 Screw, Cap, 1/4-20 x 3/4 in. 8
46 B01-09-0076 Insert, 8 Pin 1
47 B01-09-0075 Connector, 8 Pin 1
48 B01-09-0074 Insert, 6 Pin 1
49 B01-09-0073 Connector, 6 Pin 1
50 B01-09-0078 Insert, 12 Pin 2
51 B01-09-0077 Connector, 12 Pin, Gray 1
52 B01-09-0080 Socket, Female 26
53 B01-09-0079 Connector, 12 Pin, Black 1
54 B34-00-0006 Trimlock, 1/8 in. 37 in.
55 B18-00-0143 Cover, Side 1
56 0090-0206 Washer, Lock, Split, 1/4 in. 4
57 0090-0688 Screw, 1/4-20 x 1 in. 7
58 0090-0814 Screw, Machine, #8-32 x 7/8 in. 2
59 B42-00-0005 Latch, Lid 1
60 B03-00-0103 Assembly, Reservoir 1
61 B02-00-0025 Assembly, Filter Head 1
62 B02-00-0026 Element, Filter 1
63 B02-15-0025 Cap, Breather 1
64 B07-06-1039 Rod, Emergency Lowering Valve Actuator 1
65 B46-00-0031 Pull Knob, Valve Actuator 1

6-21

XLB-4725A

6-8 GAS MODEL POWER COMPAR TMENT PARTS LIST

Refer to Table 6-8 for the gas model power compartment parts list.

Figure 6-8. Gas Model Power Compartment

6-22

6 — PARTS LIST

Table 6-8. Gas 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. 15

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 15

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 3
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 B01-10-0167 Kit, Solenoid, Engine Throttle 1
15 B01-10-0191 Control Module, Throttle Solenoid 1
16 0090-0737 Screw, Machine, #10-24 x 1-/14 in. 2
17 B02-04-0067 Manifold, Proportional Valve, 24 Volt 1
18 B07-06-1039 Rod, Emergency Lowering Valve Actuator 1
19 B46-00-0031 Pull Knob, Valve Actuator 1
20 0090-0420 Washer, Flat, 5/16 in. 2
21 0090-0926 Screw, Cap, 5/16-18 x 4-1/2 in. 2
22 0090-0185 Nut, Hex, Nylon Lock, 5/16-18 2
23 0090-0344 Screw, Threadcutting, #10-24 x 1/2 in. 2
24 B00-00-0112 Faceplate, Master Power Switch 1
25 B01-02-0060 Switch, Master Power 1
26 B01-02-0064 Box, Lower Control (Gas Model) 1
27 0090-0419 Washer, Flat, 1/4 in. 11
28 0090-0005 Screw, Cap, 1/4-20 x 3/4 in. 12
29 B29-00-0143 Bracket, Lower Control Box 1
30 0090-0422 Washer, Flat, 3/16 in. 1
31 0090-0188 Nut, Hex, Nylon Lock, 3/8-16 1
32 0090-0183 Nut, Hex, Nylon Lock, 1/4-20 8
33 0090-0042 Screw, Cap, 3/8-16 x 1 1

6-23

XLB-4725A

Figure 6-8. Gas Model Power Compartment

6-24

6 — PARTS LIST

Table 6-8. Gas Model Power Co mpartment Parts List, Continued

Item No. Part No. Description Qty

34 0090-0688 Screw, 1/4-20 x 1 in. 3
35 0090-0206 Washer, Lock, Split, 1/4 in. 4
36 B34-00-0006 Trimlock, 1/8 in. 37 in.
37 B18-00-0143 Cover, Side 1
38 0090-0814 Screw, Machine, #8-32 x 7/8 in. 2
39 B42-00-0005 Latch, Lid 1
40 B03-00-0103 Assembly, Reservoir 1
41 B02-00-0025 Assembly, Filter Head 1
42 B02-00-0026 Element, Filter 1
43 B02-15-0025 Cap, Breather 1
44 B01-09-0076 Insert, 8 Pin 1
45 B01-09-0075 Connector, 8 Pin 1
46 B01-09-0074 Insert, 6 Pin 1
47 B01-09-0073 Connector, 6 Pin 1
48 B01-09-0078 Insert, 12 Pin 2
49 B01-09-0077 Connector, 12 Pin, Gray 1
50 B01-09-0080 Socket, Female 26
51 B01-09-0079 Connector, 12 Pin, Black 1

6-25

XLB-4725A

6-9 FRAME AND ROTATION UNIT LIST

Refer to Table 6-9 for the frame and rotation unit parts list.

2

1

16

8

13

14

15

12

11

3

4

5

6

7

9

10

17

27

26

28

25

7

24

21

22

23, 23A

19

20

18

Figure 6-9. Frame and Rotation Unit

6-26

6 — PARTS LIST

Table 6-9. Frame and Rotation Unit Parts List

Item No. Part No. Description Qty

1 B11-03-0036 Turntable Weldment 1
2 0090-0710 Screw, Machine, #8-32 x 2-3/4 in. 1
3 B18-00-0021 Cover, Level Housing 1
4 0090-0181 Nut, Hex, Nylon Lock, #8-32 1
5 B00-00-0001 Level, Bubble 1
6 0090-0643 Screw, Cap, 5/8-11 x 2-3/4 in. 12
7 0090-0612 Washer, Flat, 5/8 in. 30
8 B13-00-0001 Ring, Worm Gear 1

9 B02-02-0025 Fitting, 90° Elbow 2
10 B02-06-0006 Motor, Hydraulic 1
11 0090-0461 Screw, Cap, 1/2-13 x 2 in. 2
12 0090-0212 Washer, Lock, Split, 1/2 in. 2
13 B13-00-0006 Slew Ring Assembly (includes items 8 and 14) 1
14 B25-00-0031 Slew Ring 1
15 B00-00-0061 Fitting, Grease, 1/8 in. NPT Straight 1
16 B00-00-0106 Fitting, Grease, 90° 3
17 B07-04-1006 Plate, Tread 1
18 B03-00-0122 Kit, Rotary Conductor 1
19 B01-09-0032 Spade, Female, 16/14 Ga. 4
20 B00-00-0060 Support, Rotary Conductor 2
21 B01-10-0107 Conductor, Rotary 1
22 0090-0355 Screw, Set, 1/4-20 x 1/4 in. 2
23 B12-00-0088 Trailer Weldment (accommodates later model

1

trailer axle and jack)

23A B12-00-0059 Trailer Weldment (accommodates early model

1

trailer axle and jack)
24 0090-0633 Screw, Cap, 5/8-11 x 1-1/2 in. 18
25 0090-0160 Nut, Hex, 5/16-18 14
26 0090-0208 Washer, Lock, Split, 5/16 in. 14
27 0090-0420 Washer, Flat, 5/16 in. 14
28 0090-0127 Bolt, Carriage, 5/16-18 x 1 in. 14

6-27

XLB-4725A

6-10 HITCH AND JACK ASSEMBLY PARTS LIST

Refer to Table 6-10 for the hitch and jack assembly parts list.

10

1

2

9

8

7

4

6

12
13

11

14

18

33

41

17

25A

22

26

27

28

22, 22A

20

5

21

25

46

44, 45

47

48

15

16

19

24

10

12

21

36

4

40

4

36

8

4

23

9

3

43

39

36

34

40

37

38

20

36

7

35

32

31

30

29

44

6

31

49

42

44

6

30

Figure 6-10. Hitch and Jack Assembly

6-28

6 — PARTS LIST

Table 6-10. Hitch and Jack Assembly Parts List

Item No. Part No. Description Qty

1 B29-00-0119 Post, Support 1
2 B30-00-0009 Pad, Rubber 1
3 0022-01-03 Brace, Guard Rail 2
4 0090-0192 Nut, Hex, Nylon Lock, 1/2-13 8
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 B03-00-0092 Assembly, Jack Handle, Early Version 1
12 0090-0005 Screw, Cap, 1/4-20 x 3/4 in. 2
13 0090-0206 Washer, Lock, 1/4 in. 1
14 0090-0875 Washer, Flat, 1/4 in. 1
15 B46-00-0014 Grip, Handle 1
16 B46-00-0003 Handle, Jack 1
17 B46-00-0004 Mount, Jack Handle 1
18 0090-0010 Screw, Cap, 1/4-20 x 1-1/2 in. 2
19 0090-0834 Nut, Lock, 1/4-20 2
20 B04-07-0032 Clamp, Cable/Hose, DG 6 2
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

23 B23-02-0039 Weldment, Outer Jack Tube 1
24 0090-0428 Washer, Flat, 3/4 in. 1
25 B00-00-0085 Fitting, Grease, 1/4-28 1
25A B00-00-0009 Fitting, Grease, 3/16 in. Drive 1
26 B25-00-0011 Bearing, Thrust 1
27 B04-02-8006 Nut, Jack, 1-1/4 in. 1
28 B23-02-0038 Screw, Jack, 1/4 x 15 in. 1
29 B23-02-0040 Weldment, Inner Jack Tube 1
30 0090-0042 Screw, Cap, 3/8-16 x 1 in. 4
31 B03-00-0148 Caster Assembly 1
32 0090-0360 Screw, Socket, 1/4-20 x 1/2 in. 2
33 0090-0319 Pin, Roll, 1/4 x 1-1/4 in. 1

6-29

XLB-4725A

10

1

2

9

3

8

7

4

6

12
13

11

14

18

33

41

17

25A

22

26

27

20

5

21

46

44, 45

47

43

15

16

19

24

10

4

23

12

21

36

4

40

4

36

8

9

22, 22A

28

25

48

39

36

34

40

38

20

36

7

35

32

29

44

6

49

42

44

30

37

6

31

31

30

Figure 6-10. Hitch and Jack Assembly

6-30

6 — PARTS LIST

Table 6-10. Hitch and Jack Assembly Parts List, Continued

Item No. Part No. Description Qty

34 0090-0080 Screw, Cap, 1/2-13 x 4-1/2 in. 2
35 0090-0081 Screw, Cap, 1/2-13 x 5 in. 1
36 0090-0574 Washer, Flat, 1/2 in. 6
37 B03-00-0017 Chain, Safety 2
38 B01-01-0121 Harness, Tail Light 1
39 B12-00-0013 Hitch, Tow 1
40 B21-00-0001 Kit, Brake Line 1
41 0090-0712 Screw, Cap, 1/2-13 x 4-3/4 in. 1

*42

B03-00-0105 Assembly, Jack

1

(includes items 6, 25, 30, 31 and 43 through

49)

43
44

B23-02-0058 Weldment, Outer Jack Tube 1
B23-02-0057

Assembly, Inner Jack Tube

1

(includes items 45 through 49)

45

B46-00-0028 Kit, Handle Replacement

1

(includes items 46 and 47)

46
47
48
49

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

*Item 42 replaces early version jack, items 6, 11, 17 through 19, and 2 3 through 33.

6-31

XLB-4725A

6-11 SQUARE TUBE AXLE AND WHEEL ASSEMBLY

PARTS LIST

Refer to Table 6-11 for the square tube axle and wheel assembly parts list.

29

31

28

26

27

26

8

1

2

4

9

10

15, 15A,

5

11

16

3

6

7

13,13A,

14,14A

25

17

12

18

19

20

21

22

23

30

Figure 6-11. Square Tube Axle and Wheel Assembly

6-32

24

6 — PARTS LIST

Table 6-11. 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 B12-00-0082 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 B10-00-0042 Brake Assembly, Left Hand, Hydraulic 1
13A B10-00-0043 Brake Assembly, Right Hand, Hydraulic 1

*14 B10-00-0044 Brake Assembly, Right Hand, Electric

1

(Not Illustrated)

*14A B10-00-0045 Brake Assembly, Left Hand, Electric

1

(Not Illustrated)
15 B10-00-0048 Kit, Hydraulic Brake Shoe/Lining, Right Hand 1
15A B10-00-0047 Kit, Hydraulic Brake Shoe/Lining, Left Hand 1

*16 B10-00-0046 Kit, Electric Brake Shoe/Lining

2

(Not Illustrated)
17 B10-00-0056 Cup, Outer Bearing 2
18 B10-00-0054 Cone, Outer Bearing 2
19 B10-00-0059 Washer, Spindle 2
20 B10-00-0051 Washer, Tang, EZ Lube 2
21 B10-00-0060 Nut, Spindle, EZ Lube 2
22 B10-00-0057 Cap, Grease, EZ Lube 2
23 B10-00-0058 Plug, Rubber, EZ Lube Grease Cap 2
24 0090-0624 Nut, Wheel Lug, 1/2-20 12
25 B10-00-0050 Stud, Wheel, 1/2-20 12
26 0090-0182 Nut, Hex, Nylon Lock, #10-24 8
27 B07-01-1081 Bracket, Limit Switch 2
28 B01-02-0075 Switch, Limit, Axle Position 2
29 0090-0232 Screw, Machine, #10-24 x 5/8 in. 4
30 B08-02-0003 Tire, ST225/75D-15 2
31 0090-0236 Screw, Machine 4

*Optional equipment on original boom lift order only.

6-33

XLB-4725A

6-12 HEX TUBE AXLE AND WHEEL ASSEMBLY

PARTS LIST

Refer to Table 6-12 for the early version axle and wheel assembly parts list.

4

3

25

24

23

22

21

26

8

1

7

6

5

9

10

3

2

12, 12A

13

20

11

14

27

15

16

17

18

19

Figure 6-12. Hex Tube Axle and Wheel Assembly

6-34

6 — PARTS LIST

Table 6-12. 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 0090-0877 Screw, Cap, 1/2-13 x 8-1/2 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 B12-00-0082 Fender 2

9 B32-00-0014 Seal, Grease 2
10 B25-00-0060 Assembly, Inner Bearing
11 B12-00-0071 Assembly, Wheel Hub

2

(Includes bearings, grease seal, and studs)
12 B10-00-0031 Brake Assembly, Left Hand, Hydraulic 1
12A B10-00-0030 Brake Assembly, Right Hand, Hydraulic 1
13 B10-00-0016 Brakes Pads, Set (left and right wheel) 1
14 B25-00-0061 Assembly, Outer Bearing 2
15 B10-00-0059 Washer, Spindle 2
16 0090-0880 Nut, Spindle 2
17 0090-0881 Pin, Cotter, 5/32 x 2 in. 2
18 B32-00-0013 Cap, Dust 2
19 0090-0624 Nut, Wheel Lug, 1/2-20 12
20 B04-07-0107 Stud, Wheel, 1/2-20 x 2-1/2 in. 12
21 0090-0182 Nut, Hex, Nylon Lock, #10-24 8
22 B01-09-0051 Fitting, Cable Grip, 90º, 1/2 in. 2
23 B01-03-0006 Switch Body, Limit, Axle Position 2
24 0090-0236 Screw, Machine, #10-24 x 3/4 in. 4
25 B01-03-0014 Actuator, Limit Switch 2
26 B01-03-0007 Head, Limit Switch 2
27 B08-02-0003 Tire, ST225/75D-15 2

6-35

XLB-4725A

6-13 TAIL LIGHTS AND JUNCTION BOX PARTS LIST

Refer to Table 6-13 for the tail lights and junction box parts list.

7

2

1

1

4

5

6

3

9

10

11

9

12

13

Figure 6-13. Tail Lights and Junction Box

3

8

6-36

6 — PARTS LIST

Table 6-13. Tail Lights and Junction 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 B04-07-0032 Clamp, Cable/Hose, DG 6 4
5 0090-0183 Nut, Hex, Nylon Lock, 1/4-20 4
6 0090-0182 Nut, Hex, Nylon Lock, #10-24 1
7 B01-09-0009 Fitting, Cable Grip, 3/8 in. 1
8 B01-10-0023 Tail Light Assembly, Right 1

9 B01-09-0029 Fitting, Cable Grip, 1/2 in. 3
10 B01-10-0026 Junction 1
11 B01-09-0007 Fitting, Cable Grip, 3/4 in. 1
12 0090-0236 Screw, Machine, #10-24 x 3/4 in. 1
13 B01-10-0027 Cover and Gasket, Junction Box 1

6-37

XLB-4725A

6-14 FRONT OUTRIGGERS PARTS LIST

Refer to Table 6-14 for the front outriggers parts list.

18

30

19, 20

31

29

32

28

21

22

27

25
26

23

24

16

13

1, 2

33

6

5

7

3

8

4

9

10

17

16

Figure 6-14. Front Outriggers

15

14

13

11

12

6-38

6 — PARTS LIST

Table 6-14. Front Outriggers Parts List

Item No. Part No. Description Qty

1 B23-01-0088 Outrigger, Front, Passenger Side 1
2 B23-01-0089 Outrigger, Front, Driver side 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. 2
14 B23-02-0047 Weldment, Footpad 1
15 0090-0194 Nut, Hex, Nylon Lock, 5/8-11 1
16 B25-00-0052 Bushing, Bronze 2
17 0090-0889 Nut, Hex, Nylon Lock, 1-1/4-7 1
18 0090-0888 Screw, Cap, 1-1/4-7 x 16 in. 1
19 B11-03-0032 Cap, Driver Side, Outrigger Locator Pin 1
20 B11-03-0031 Cap, Passenger Side, Outrigger Locator Pin 1
21 B46-00-0024 Knob, Fluted 1
22 0090-0420 Washer, Flat, 5/16 in. 3
23 0090-0208 Washer, Lock, 5/16 in. 3
24 0090-0028 Screw, Cap, 5/16-18 x 3/4 in. 3
25 B30-00-0037 Spacer, Outrigger Locator Pin 1
26 B39-00-0028 Spring, 1.13 OD x 0.915 ID 1
27 B11-03-0030 Pin, Outrigger Locator 1
28 B01-03-0007 Head, Side Rotary, Limit Switch 1
29 B01-03-0006 Body, Limit Switch 1
30 B01-09-0051 Cable Grip, 90°, 1/2 in. 1
31 0090-0232 Screw, Machine, #10-24 x 5/8 in. 2
32 B01-03-0008 Roller Lever, Limit Switch 1
33 B00-00-0085 Fitting, Grease, Straight, 1/4-28 1

6-39

XLB-4725A

6-15 REAR OUTRIGGER PARTS LIST

Refer to Table 6-15 for the rear outrigger parts list.

18

29

30

19, 20

31

32

28

21

25

26

27

22

23

24

16

6

5

7

33

3

1, 2

8

9

4

17

13

16

Figure 6-15. Rear Outrigger

15

14

13

10

11

12

6-40