Bil-Jax XLB-4725A User Manual

Operation and

Maintenance Manual

AERIAL WORK PLATFORMS

XLB-4725A

Proportional

Hydraulic Boom Lift

-4725A XLB

B33-01-0072-01

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

1	Safety	...............................................................................................................		1-1
	1-1	Introduction ........................................................................................		1-1
	1-2	Before	Operation...............................................................................	1-3
	1-3	During	Operation...............................................................................	1-4
	1-4 ...........................................................................	Maintenance Safety		1-6
	1-5 .............................................................	Damaged Equipment Policy		1-7

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

3	Operation ........................................................................................................		3-1
	3-1	Operator Controls..............................................................................	3-1
	3-2	Normal Operating Procedure............................................................	3-6
	3-3	Emergency Lowering.........................................................................	3-7
	3-4	Manual Boom Rotation ....................................................................	3-7
	3-5	Battery Recharge (DC Model Only)...............................................	3-8
	3-6	Boom Lift Transport.......................................................................	3-10

4	Maintenance....................................................................................................								4-1
	4-1	Scheduled Service Checks................................................................							4-1
	4-2	Wheel Nut Torque Requirements ....................................................							4-3
	4-3	Lubrication .........................................................................................							4-3
	4-4	Hydraulic System ..............................................................................							4-6
	4-5	Leveling System ..............................................................................							4-11
	4-6	Troubleshooting ...............................................................................							4-14
	4-7	Material Safety			Data	Sheets ..........................................................			4-23
5	Replacement Decals........................................................................................								5-1
6	Parts List .........................................................................................................								6-1
	6-1	Upper Boom Parts List....................................................................							6-2
	6-2	Lower Boom Parts List....................................................................							6-4
	6-3	Upper		Cylinder	Parts	List................................................................			6-6
	6-4	Lower		Cylinder	Parts	List................................................................			6-8
	6-5	DC Model Battery Compartment Parts List....................................							6-10
	6-6	Gas Model Engine Compartment Parts List.......................................							6-14
	6-7	DC Model Power Compartment Parts List ..................................							6-18
	6-8	Gas Model Power Compartment Parts List .......................................							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
7	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

Safety

1-1 INTRODUCTION

Familiarity and proper training are required for the safe operation of mechanical equipment. Equipment operated improperly or by untrained personnel can be dangerous. Read the operating instructions in this manual and become familiar with the location and proper use of all controls. Inexperienced operators should receive instruction from someone familiar with the equipment before being allowed to operate the machine. The use of intelligence and common sense in the operation of mechanical equipment is the best practice in any safety policy. Be professional and always observe the safety procedures set forth in this manual.

All OSHA, ANSI, state, and local codes and regulations pertaining to this equipment should be obtained, read, and thoroughly understood before attempting to operate this equipment. Persons under the influence of drugs, alcohol, or prescription medication should not be on or near this equipment. Common sense should be implemented at all times during the use of this equipment. Do not operate this equipment in areas where the equipment or user may come in contact with a live power source.

The information contained herein is not to be considered as legal advice and is intended for informational purposes only. This information is offered to alert Bil-Jax customers to procedures that may be of concern to them.

This information is not intended to be all inclusive and is to be followed in the use of Bil-Jax equipment only.

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

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

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

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

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

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

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

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

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

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

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

1-3

XLB-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	Minimum Safe Approach Distance
	(Feet)		(Meters)
(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

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

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

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

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

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

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

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

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

•ALWAYS engage the boom travel locking pin before towing the trailer.

1-4

1 — SAFETY

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

•NEVER use without the outriggers fully extended, locked, and firmly based. When on soft surfaces, ALWAYS use outrigger base plates.

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

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

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

•NEVER release the outriggers or move the trailer with the boom extended.

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

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

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

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

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

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

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

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

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

•NEVER climb up or down boom.

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

1-5

XLB-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 requirements. NEVER short change maintenance procedures.

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

•ALWAYS turn the MASTER POWER switch OFF before connecting or disconnecting wiring to or from valve solenoids or other load devices.

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

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

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

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

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

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

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

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

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

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

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

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

1-6

1 — SAFETY

Battery Maintenance

Ensure the following general safety precautions are followed whenever performing battery maintenance on the XLB-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 circuit at battery.

•NEVER jump start other vehicles using boom lift battery.

1-5 DAMAGED EQUIPMENT POLICY

Safety Statement

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

Damage Policy

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

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 plunger on the front end of the power compartment. Firmly pulling out and holding the valve plunger manually retracts 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		450 lbs (204.1 kg) total
	[400 lbs (181.6 kg) total for early		[400 lbs (181.6 kg) total for early
	version basket]*		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,	8 in./sec (203 mm/sec)		8 in./sec (203 mm/sec)
Maximum	[40 ft/min (12.2 m/min)]		[40 ft/min (12.2 m/min)]
Horizontal Reach	25 ft (7.6 m)		25 ft (7.6 m)
Boom Rotation	360° Continuous		360° Continuous
Rotation Speed	8 in. per Second, Maximum		8 in. per Second, Maximum
Basket Dimensions	45 in. W x 30 in. D x 42 in. H		45 in. W x 30 in. D x 42 in. H
	(114.3 cm x 76 cm x 107 cm)		(114.3 cm x 76 cm x 107 cm)
Power Source	24 Volt DC, Deep Cycle,		8 Horsepower Gasoline Engine
	245 Amp-hour Battery
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 Weight	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.

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

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 in 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 disengage 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.

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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.

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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 ENGINE 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 running.

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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 jack and unhitch the trailer from the tow vehicle. The trailer must be unhitched before the outriggers are deployed.

5.Deploy the boom lift outriggers as follows:

a.Lift up on the locking pin and 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 of 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 engine 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

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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 long power cord will reduce the output of the battery 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 second person to give tow vehicle backing instructions.

1.Back the tow vehicle to the trailer. Verify that the ball and hitch are in line and that the trailer hitch will clear the ball. Jack up the tongue as needed.

2.Align the ball and hitch. Wrap and fasten the breakaway safety cable around the ball hitch (Figure 3-8).

Figure 3-8. Breakaway Safety Cable

3.Hold ball hitch release lever open and lower the hitch onto the ball. Let go of the release lever to secure the ball.

4.Crank the jack down to check for secure coupling. If jacking will raise the tow vehicle bumper two or three inches, the ball hitch coupling is secure.

5.Pull the pin keeper and pivot locking pin, raise the jack to the travel position as shown in Figure 3-9, and reinstall the pivot locking pin and pin keeper.

Figure 3-9. Jack Travel Position

3-10

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

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

	Daily
Service Check	before use Weekly

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.

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XLB-4725A

Monthly Service Checks

Perform the following monthly service checks as listed in Table 4-2.

Table 4-2. Monthly Service Checks

	Every	Every	Every
Service Check	month	6 months	12 months

Clean battery terminals and check battery charger operation.

Check operation of manual emergency lowering valve.

Check wheel nut torque per paragraph 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 necessary 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·m).

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.

4-2