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Operator`s Manual - Robinsons Hardware

1. Item No Part No Description Qty 1 A 01063 Cover Front 1 2 0096 0014 Cap Screw M10 x 20 14 3 0096 0041 Hex Nut Self Locking M10 22 4 A 01064 Cover Top 1 5 A 01067 Cover Side Left 1 6 A 01069 Cover Side Right 1 7 0096 0001 Cap Screw M6 x 16 20 8 0096 0039 Hex Nut Self Locking M6 33 9 B42 01 1006 Hinge 72 Continuous 2 10 A 01045 Latch Paddle Style 2 11 0096 0113 Cap Screw M4 x 16 8 12 0096 0073 Hex Nut Self Locking M4 8 13 A 01052 Cover Rear 1 14 B01 06 0053 Relay 24V DC w Bracket 5 15 0096 0002 Cap Screw M6 x 20 13 16 A A 01059 Cover Pad 2 17 0096 0068 Flat Head Cap Screw M10 x 45 4 18 A 03048 Relay Cover 1 19 A 03040 Switcher Box Assembly 1 B01 06 0056 Relay 30 Amp 1 B01 10 0354 Circuit Breaker 20 Amp 1 A 01015 Switcher Box 1 20 A 01072 Cover Latch Stop 2 21 0096 0098 Cap Screw M8 x 35 4 22 0096 0040 Hex Nut Self Locking M8 4 23 A 01047 Fuel Tank 1 24 A 01089 Fuel Gauge 1 25 0096 0016 Cap Screw M10 x 25 2 45 ENGINE ASSEMBLY II 29 12 12 6 0 6963 B 9 6 9 12 46 ENGINE ASSEMBLY PARTS LIST
2. 12 3 SO Or Equivilant 0625 H A B 36 2 B B w W G As 1 2 Grommet OD i Delphi Weather Pack 12010717 i 3 Pin Male Housing i 12124582 i i Male Terminal 12 14ga i 12010293 i Seal 12 14ga OIL SWITCH ASSEMBLY A 03044A i Delphi Weather Pack B00 00 0170 i 12010973 B01 09 0109 Wire Casing i 2 Pin Male Housing i 044 i 16 PVC i 12089040 B01 09 0110 i OIL PRESSURE SWITCH 4WD i i i i Male Terminal i i TRANSDUCER DIRECT TDPS211A8FW i i 12015323 B01 09 0093 i EE i Green Seal i Wires should be 17 18 Long 94 CORD ASSEMBLY 110V GENERATOR B01 01 0178 lt 24 4 Female Spade 4 Female Spade 10 Ring Terminal Rev l w 14 3 SO or Equivalent 9 4 8 p i lt gt 12015793 i 4 i Female Housing i i 12124580 i Label i Female Terminal 12 14ga H 12010293 H Seal 12 14ga CORD ASSEMBLV GENERATOR SWITCH BO1 01 0179 7 Female Spade Rev Female Spade 18 2 SO or Equivalent lt gt i 12010973 I 4 i 2 Pin Male Housing Label 12089040 i Male Terminal 12015323 Green Seal Delphi Weather Pack
3. Item No Part No Description Qty 1 A 01046 Engine 21HP See Manufacturer s Literature 1 2 0096 0098 Cap Screw M8 x 35 4 3 0096 0040 Hex Nut Self Locking M8 18 4 A 01048 Pump Dual 4 5 GPM 1 5 A 01055 Dual Pump Mount 1 6 0096 0110 Cap Screw M10 x 110 2 7 0096 0093 Washer M10 2 8 0096 0041 Hex Nut Self Locking M10 2 9 A 01081 Oil Cooler 1 10 0096 0010 Cap Screw M8 x 20 4 11 A 01071 Solenoid Bracket 1 12 0096 0001 Cap Screw M6 x 16 12 13 0096 0039 Hex Nut Self Locking M6 10 14 A 01074 Throttle Solenoid Assembly 2 A 03045 Linkage Spring 1 15 A 00761 Generator 1 16 A 01060 Spacer 4 17 0096 0053 Cap Screw M8 x 50 4 18 A 01038 Brake Release Hand Pump 1 19 0096 0108 Cap Screw M8 x 70 2 20 B02 00 0071 Oil Filter Assembly 1 21 B29 00 0016 Oil Filter Bracket 1 22 A 00783 Exhaust Assembly 1 23 A 01061 Belt 1 24 A 01051 Pulley ANSI 2 24 A 03060 Pulley CE 2 25 0090 0363 Set Screw 1 4 20 x 3 4 6 26 A 01036 Pulley 1 27 A 01088 Idler Roller 1 28 0096 0022 Cap Screw M12x 75 1 29 0096 0076 Washer M12 3 30 0096 0041 Hex Nut Self Locking M12 1 31 A 01095 Tension Arm 1 32 A 01086 Spacer Tension Arm 1 33 0090 0210 Washer 3 8 1 34 0096 0069 Cap Screw M10 x 75 1 47 FRONT REST ASSEMBLY 48 FRONT REST ASSEMBLY PARTS LIST Item
4. EZESLOZL i Kud 0EEOLOZL uuo ojew B l uuo Wa 9 006808021 H 02 1 0250 92602021 uuo 9 i 3990 WA dwy 98202021 i gLuld less u9919 10 ors i EZESLOZL pE Uld sa ea f H SOYIMS Y wel Wd saum pajoxoe i 1109 Ja6 IJNO 88168021 ZL uuo LL i Mojeanba 40 1XL 62SLOZL i SZ Zi Xx Olud i 5 y 1295 a uid ZESLOZL sus Wd 88168021 S 2 prs spue ujog 10 TXL kr SM 1 0ZS022 yoeo qe7 62 ZL x e68L uuo W4 duy BuisnoH 26191021 JO SUOIJEJOJ pajeubisaq BuisnoH W4 Ea 1109 189Y S J9AUQ EZESLOZL EE SJJOEJUO9 3Jesu 1285 oT 88168020 E uuo W4 Jaygeam Ig s pue yo dno16 2601021 uisnoH ae ZESLOZL La 7919277 1295 lqeS zesvan 2 ___ Y gt eos pue Lv yumg 3134013 5 Z 8L yo as lds 19qe7 981 1 025011 uuo W4 ul lt N e681 9e Md 160L0ZL 2629102 Bueno af BuisnoH aew ZESLOZL EZESLOZL 1295 lqeS eas 21429 gt
5. Check for cuts loose terminals broken wires chaffing and corrosion Q Repair all damage remove corrosion and seal exposed connections Inspect boom lift for missing loose or damaged hardware Repair or replace as necessary Inspect all hydraulic system components including pump and motor and cylinders for damage leaks loss of pressure or speed and unusual noise or vibration Q Repair or replace as necessary 16 MONTHLY SERVICE CHECKS Perform the following service checks at least once each month Clean all battery terminals Check battery for loose connections or damaged wires Verify proper operation of manual lowering valves and hand pump Refer to Section 3 for manual boom operating procedures Lubricate all compartment hinges and latches slew ring and mating gear Q Use NLGI Grade 2 multi purpose grease Check wheel nut torque Q Refer to Figure 4 3 for correct wheel nut tightening sequence Q Evenly tighten wheel nuts to 34 N m in the tightening sequence shown Repeat sequence tightening wheel nuts to 81 N m and to 136 N m NOTE Follow this procedure each time the wheel is removed and reinstalled Figure 3 3 Wheel Nut Tightening Sequence 3 EQUIPMENT MAINTENANCE 17 BIL JAX 45XA ANNUAL SERVICE CHECKS Perform the following service checks at least once each year Replace Hydraulic Oil and Oil Filter Q Drain hydraulic reservoir clean and replace
6. Error Message Displayed 019 BOOM FUNCTION DISABLED 30 LOSS OF LOAD CELL CONNECTION 021 OPEN CIRCUIT PRIMARY UP 022 SHORTED CIRCUIT PRIMARY UP 023 OPEN CIRCUIT PRIMARY DOWN Error Explanation amp Possible Causes The Load Sense Module has detected an overloaded 1 boom condition which caused the Lower Control to 2 disable all boom functions 3 4 This is a self clearing error When error condition is 5 removed error is cleared 6 NOTE This error only occurs on machines equipped with the Load Sense option Possible causes include Too much weight in basket or on hook Lower Control incorrectly configured Faulty Load Cell Faulty Load Cell wiring Faulty Load Sense Module Faulty Lower Control The Load Sense Module has detected a loss of 1 connection to the Load Cell 2 3 This is a self clearing error When error condition is removed error is cleared NOTE This error only occurs on machines equipped with the Load Sense option Possible causes include 1 Faulty Load Cell 2 Faulty Load Cell wiring 3 Faulty Load Sense Module The Lower Control has detected an open circuit on the T Primary Up solenoid output when it was energized 2 during startup self diagnostics 3 NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Primary Up solenoid wiring 2 Faulty Primary Up solenoid 3 Faulty Lowe
7. B02 01 0220 6 x 28 Hydraulic Hose B02 01 0327 6 x 46 Hydraulic Hose B02 01 0328 6 x 46 Hydraulic Hose o O O N B02 02 0258 Fitting Tee 6 MORFS o B02 02 0259 Fitting 6 MORFS 6 MORB RT gt TRAILER HYDRAULIC LINES 4WD A 01075 609234 991 SIUONF vr 108944 v v 108943 06 54 2 06 SUONF SIUOWFE Z 01 9 007933 OL 9 00v944 ALS SUOWOL SAUOW9 2 MIS gHOWOLI SJHOWOs Z DAY seu N IP A rrrE 09244 U 991 SAHOMbH wonog Al 35v3134 p s 3 vua VANN C INIonuoo ALT 9 9 108944 9 9 108944 06 HOW9 SAHONW9A Z 06 S 3HOWOKZ 9 01 0199 9 01 10198 77209944 BUONA SHO MOL Z u Sb IUOWF SIUONFE Z 2 n W 81 8 06 L2 Cw EH d L gt 06 ONO lO 9 9 0079141 99009944 9 9 007944 9 9 007944 9 9 007933 Oo 9 9 007914 9 9 00 9 44 9 9 00p943 ae m un o 2 vr 000944 01 8 208933 St SUONOL SAUOWNS 2 RY lt ofueg 01 H 80v9 199 Z1 01 108944 dung ans 06 GYOZI S4YOWOL E 9 9 009944 MIS BYOWS HSAYONS Q db 8 8 8 209244 9 9 108944 991 S3HON8S 06 Sid 106 vid 9
8. 12 A 01025 Tie Rod 4WD 13 A 01096 Bushing 1 25 OD x 1 0 ID 14 A 01085 Pin Front Axle 15 0090 0155 Cotter Pin 3 16 x 1 3 4 16 A 01030 Steering Cylinder 4WD 17 A 01005 Front Axle Mount Weldment 18 0096 0038 Cap Screw M20 x 120 19 0096 0045 Hex Nut Self Locking M20 A lt I N NI Hl HR ER BR CO N oO HR 20 A 01029 Pad Front Axle 21 0096 0091 Flat Head Cap Screw M10 x 25 22 A 01009 Pin 1 0 x 5 5 23 A 00018 Pin Retainer 1 0 24 0096 0014 Cap Screw M10 x 20 mk 51 REAR AXLE ASSEMBLY L 52 REAR AXLE ASSEMBLY PARTS LIST Item No Part No Description Qty 1 A 00175 Hydraulic Cover 1 2 0096 0010 Cap Screw M8 x 20 12 3 0096 0067 Clip Nut M8 12 4 A 01032 Hydraulic Motor Rear 2 5 0096 0024 Cap Screw M12 x 100 8 6 0096 0042 Hex Nut Self Locking M12 8 7 A 01037 Axle Cover 2 53 54 SLEW RING ASSEMBLY SISIS SLEW RING ASSEMBLY PARTS LIST Item No Part No Description Qty 1 A 02189 Slew Assembly and Adapter 1 2 Slew Ring 1 3 Slew Ring Drive 1 4 A 00149 Base Ring Adapter 1 5 0090 0461 Cap Screw 1 2 13 x 2 2 6 0090 0212 Lock Washer 1 2 2 7 0096 0033 Flat Head Cap Screw M16 x 35 16 8 0096 0054 Flat Head Cap Screw M16 x 50 18 9 0090 0643 C
9. ALWAYS inspect platform floor and outrigger footpads for mud grease debris or other foreign material ALWAYS remove any such material from the equipment before operation ALWAYS tag any part of the equipment known or suspected to be damaged or malfunctioning ALWAYS remove a malfunctioning damaged or defective machine from service NEVER operate a machine that has any known or suspected defect ALWAYS comply with the instructions found in Safety and or Service Bulletins distributed by the manufacturer Bulletins may contain critical procedures that supersede the information contained in manuals NEVER operate this equipment while under the influence of drugs or alcohol while taking prescription medications that may leave the operator drowsy or prone to dizziness or while feeling ill NEVER modify the equipment in any way that would affect its original design or operation NEVER deface modify or obscure any decals or markings on equipment NEVER operate the equipment in any way for which it is not intended 1 SAFETY DURING OPERATION Ensure the following general safety precautions are followed while operating the articulating boom lift ALWAYS position lift away from power lines to ensure that no part of the lift can accidentally reach into an unsafe area This includes full extension of the boom through 700 rotation DANGER This machine is NOT insulated for use near electrical power lines and DOES NOT
10. CORD ASSEMBLY SWITCH JUMPER B01 01 0180 e 1 4 Female Spade L I A Ya Female Spade 14ga Black TXL or Equivalent Label All Measurements are 0 250 In CORD ASSEMBLY 110V AC PLUG FM 01 01 0181 12 lt gt AO HL Female Spade Female Spade 14 3 0 SO or Equivalent North America 110V Female Plug 95 SWITCHER BOX ASSEMBLY CE MODELS 03040 Box A 01015 B01 06 0056 a Bu ARR 30 Amp Relay B01 10 0354 i DPST NO i 20 Amp Circuit Breaker Allied Electronics i W 250 Male Spade Terminal i 1850 0345 i Allied Electronics i Or Equivilant 886 0036 4 20 mmm Or Equivilant Cord Grip Heyco 3231 Or Equivilant Delphi Weather Pack i 2 Pin Male Housing 12010973 B WXG Male Terminal 12089040 i i Green Seal 12015323 i Delphi Weather Pack i i 3 Pin Male Housing 12015793 Male Terminal 12010293 i lt lallo 220V GENERATOR WIRE HARNESS CE A 03043CE 14 3 SO e Or Equivilant 0625 i i H LES 24 2 us i Generator p P Wire Colors Delphi Weather Pack ROT SCT j 12015793 i 1 2 Grommet OD 3 Pin Female Housing i 12124580 i Female Terminal 12 14ga 1201
11. Clean valve solenoid and recheck function s replace or repair as needed Check display for system status Refer to Table 4 2 for error code definitions and correction Inspect wiring in control box and at valve manifold and valve coil repair or replace as needed 20 3 EQUIPMENT MAINTENANCE ERROR CODE DEFINITIONS he DISPLAY PANEL located on the ground control panel indicates the present operating status of the boom lift If an error condition is detected by the control processor during start up or operation the appropriate error code will be displayed on this panel Refer to Table 3 2 for a list of common error codes and their definitions A comprehensive list of Error Codes can be found in the Appendix Table 3 2 Error Code Definitions ERROR MESSAGE DEFINITION OF ERROR COMMENTS 001 MACHINE IS IN DOWN ONLY Machine was either never leveled outriggers not Retract boom to travel position lowered or machine went out of level with use and extend outriggers using AUTO LEVEL button 002 LOSS OF PLATFORM Ground control lost communication with platform Check for unplugged or damaged COMMUNICATION control platform control cable 005 PLATFORM CONTROL HAS Platform control detected a stuck or pressed key Turn key switch off and on again STUCK KEY on power up without pressing any buttons 008 GROUND CONTROL HAS Ground control detected a stuck or pressed key Turn key switch off and on again STUCK KEY on powe
12. If repair or replacement of a boom lift or outrigger hydraulic cylinder or its component parts becomes necessary observe the following procedures in accordance with the safety precautions established in Section 1 of this manual Removing the hydraulic cylinder from the boom lift may require the use of specialized tools and lifting equipment NEVER attempt to operate overhead hoists or cranes or related equipment without proper training authorization and supervision Perform all maintenance procedures only in an area that is well lit and well ventilated Bil Jax Inc is not responsible for personal injury or property damage resulting from the improper use of equipment or failure to follow all procedures and related safety precautions Direct all questions regarding cylinder removal and replacement to your regional Bil Jax representative or to the Bil Jax Service Department at 800 537 0540 25 BIL JAX 45XA LIFT CYLINDER REPLACEMENT Use the following procedure to remove and replace faulty or damaged hydraulic cylinders on the boom lift WARNING Repair and removal of the hydraulic cylinders requires the use of lifting straps and an overhead crane or lifting gear to support the boom lift and hydraulic cylinders Personnel should be thoroughly trained in the operation of these devices before attempting installation or removal Hydraulic cylinders are heavy and may have hydraulic oil on their surface Failure to use proper equi
13. Repair or replace Drive PWM valve solenoid wiring Replace Drive PWM valve Replace Lower Control Repair or replace Drive PWM valve solenoid wiring Replace Drive PWM valve Replace Lower Control Repair or replace Drive Enable solenoid wiring Replace Drive Enable solenoid Replace Lower Control Repair or replace Drive Enable solenoid wiring Replace Drive Enable solenoid Replace Lower Control 123 Error Message Displayed 083 OPEN CIRCUIT DRIVE ENGAGE 084 SHORTED CIRCUIT DRIVE ENGAGE 085 OPEN CIRCUIT LEFT WHEEL FORWARD 086 SHORTED CIRCUIT LEFT WHEEL FORWARD 087 OPEN CIRCUIT LEFT WHEEL REVERSE 088 SHORTED CIRCUIT LEFT WHEEL REVERSE Error Explanation amp Possible Causes The Lower Control has detected an open circuit on the Drive Engage solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800 Possible causes include 1 Faulty Drive Engage solenoid wiring 2 Faulty Drive Engage solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the Drive Enable solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Drive Engage solenoid wiring 2 Faulty Drive Engage solenoid 3 Faulty Lower Control The Lower Control has detected an open circuit on the Left Wheel Forward solenoid output whe
14. Verify that outrigger safety interlocks operate correctly Q Begin with the outriggers fully extended and the boom lift level Raise one outrigger until the footpad is not in contact with the ground Q Verify that boom functions are unresponsive when one outrigger is raised Q Repeat this procedure for each outrigger Q Raise all outriggers until the footpads are not in contact with the ground Verify that all outrigger status LEDs on the ground control panel are unlit Q Lower one outrigger until the footpad makes contact with the ground and the outrigger begins lifting the trailer If the LED is lit before the footpad makes contact with the ground or if the LED remains unlit after the weight is transferred to the outrigger the position switch or wiring is faulty Q Repeat this procedure for each outrigger Repair or replace as needed Refer to Figure 2 1 Figure 3 1 Outrigger Position Switches Repair and replacement of machine components should be performed only by trained and certified personnel in accordance with government regulations and manufacturer recommendations Inspect hydraulic system and fluid levels a Check all hydraulic hoses and fittings for leaks and damage Tighten or replace as necessary to prevent hydraulic oil or pressure loss The hydraulic oil level should be checked with the booms down all outriggers raised and the trailer wheels on a level surface Hydraulic o
15. Buniesul 0 609 91pi20 jo doup Alddy 3791 52 02 0 anbio i WAI 62 12 0 enbio L juejess peasy Ajdde pue einsus oj USJU I L Ajqwasse Buunp yal 29 86 o Wal 8LL EOL 0 anbloL DW yal 27 8 0 22 nbio uoneJedo yea 9 A VA G yal SL 77 SjnN 1 er Wal 8 0 al Jauajse4 nbio spealy o 219007 Jodoup Alddy yal go Syog Jojoyy anbio WAI 8 2 0 anbio a 78 PUMP ASSEMBLY PARTS LIST CONTINUED Item No Part No Description Qty 1 02 15 0513 Reservoir 1 2 B02 15 0470 Pump Assembly 2 09CCM 1 3 B02 15 0471 Motor Pump 24 V DC 1 4 B02 15 0500 Coupling 875 x 2 795 1 5 B02 15 0501 Filter Hydraulic 1 6 B02 15 0476 Sight Glass 1 7 B02 15 0477 Socket Head Cap Screw M8 x 85 2 8 B02 02 0247 Fitting Plug M14 x 1 5 x 5 8 1 9 B02 15 0478 Seal Ring 1 10 B02 15 0485 Clamp Band 10 16 2 11 B02 15 0480 Filter Suction Pump 1 12 B02 15 0504 Allen Nut 1 4 20 4 13 B02 02 0255 Fitting M18 x HB 90 MxHB 90 1 14 B02 15 0503 O Ring 110 72 x 3 53 NBR 70D 1 15 B02 02 0279 Fitting JIC 8 x Push On FsxPO 2 16 B02 15 0505 Hose Black 1 2 x 6 1 17 B02 02 0280 Fitti
16. Gu 7 JIB Wire OO PLATFORM GROUND COMMUNICATION CABLE A 03714 Amp ITT CA3101F18 12SF80 Connector Kit 66100 7 or 66101 2 Amp AMP Pins Part of Kit FM 207008 2 206708 1 53 Terminal Strain Relief Plug Pin A Orange 18 6 Cable Orange PinB Pin 3 FI Pin C i Pin 9 Fina Pin 8 LI Pin E Pin4 Pin F l Jacket of cable must be in strain relief 100 Pin 7 For Cable Track Pin 6 A 03714 Rev Jacket of cable must be in strain relief Fill Strain Relief with Black RTV and wipe off excess WATER LINE TO PLATFORM OPTION A 03701 Part No Description B09 00 0044 6 x 142 W 1 6 6FMP 1 6 6MP 3000 PSI Pressure Washer Hose B09 00 0045 6 x 516 W 2 6 6MPSW 3000 PSI Pressure Washer Hose B09 00 0041 6 x 78 W 1 6 6FMP 1 6 6MP 3000 PSI Pressure Washer Hose B09 00 0032 Fitting QD E Series FM 6FMNPT B09 00 0033 Fitting QD E Series M 6FMNPT AIR LINE TO PLATFORM OPTION A 03700 Part No Description B09 00 0046 6 x 142 W 1 6 6FMPSW 1 6 6MP 300 PSI Air Hose B09 00 0047 6 x 516 W 2 6 6MP 300 PSI Air Hose B09 00 0036 6 x 78 W 1 6 6FMPSW 1 6 6MP 300 PSI Air Hose B02 02 0108 Fitting 6FMNPT 4FMNPT STR B09 00 0025 Fitting Univ QD FM 4MNPT B09 00 0026 Fitting QD IND Series M 4MNPT B09 00 0027 Fitting QD ARO Series M 4MNPT B09 00 0028 Fitting
17. 1 5 x 1 25 x 1 75 1 3 A 00032 Bearing 2 4 A 00020 Pin 1 25 x 5 5 2 5 A 00019 Pin Retainer 1 25 3 6 0096 0016 Cap Screw M10 x 25 3 7 0096 0041 Hex Nut Self Locking M10 3 8 A 00060 Pin 1 25 x 4 25 1 9 A 00138 Outrigger Hydraulic Cylinder 1 10 A 00141 Outrigger Cylinder Guard 1 11 0096 0009 Cap Screw M8 x 10 2 12 A 00142 Guard Slide 1 13 0096 0010 Cap Screw M8 x 20 6 14 0096 0040 Hex Nut Self Locking M8 10 15 A 00154 Spring Outrigger Sensor 1 16 0096 0036 Cap Screw M16 x 150 1 17 0096 0044 Hex Nut Self Locking M16 2 18 A 00128 Pad Mount Weldment 1 19 0096 0051 Cap Screw M16 x 100 1 20 B01 03 0078 Limit Switch Assembly 1 21 0090 0232 Slotted Machine Screw 10 24 x 5 8 2 22 0090 0182 Hex Nut Self Locking 10 24 2 23 A 00136 Foot Pad Aluminum 12 1 24 A 00137 Foot Pad Bottom 12 1 25 0096 0121 Flat Head Cap Screw M8 x 30 4 26 A 00135 Foot Pad Ball 1 27 A 00195 O Ring 1 1 4 OD x 1 ID 1 28 0096 0045 Hex Nut Self Locking M20 1 29 A 00127 Foot Pad Lock 2 30 A 00139 Foot Pad Lock Cap 1 Quantities listed reflect the number of parts needed for each outrigger NOTE Unless otherwise noted high strength Grade 5 Class 8 8 fasteners are used in the assembly of this equipment 43 ENGINE ASSEMBLY I 44 ENGINE ASSEMBLY I PARTS LIST
18. 3 A 00290 Cover Stop Bracket 1 4 0096 0016 Cap Screw M10 x 25 2 5 0096 0041 Hex Nut Self Locking M10 2 6 A 00295 Level Sensor 1 7 0096 0002 Cap Screw M6 x 20 16 8 0096 0039 Hex Nut Self Locking M6 20 9 A 00287 Mount Plate GFI Outlet 1 10 A 00255 Motor Controller 2 11 B01 05 0056 Battery Charger 1 12 A 00274 Gas Spring 1 13 0090 0920 Stud Ball 10mm 2 14 0090 0185 Hex Nut Self Locking 5 16 18 2 15 A 03200 Turntable Weldment 1 16 B01 10 0046 Outlet Box 1 17 B01 10 0034 GFI Outlet 1 18 B01 10 0035 Outlet Box Cover 1 19 0096 0001 Cap Screw M6 x 16 2 20 A 00288 Plastic Cover 1 21 0096 0004 Cap Screw M6 x 25 8 22 A 00935 Dual Motor Controller Bracket 1 59 60 PUMP COMPARTMENT ASSEMBLY PUMP COMPARTMENT PARTS LIST Item No Part No Description Qty 1 A 00268 Tire Iron Jack Handle 1 2 B04 07 0033 Clamp 2 3 0096 0001 Cap Screw M6 x 16 2 4 0096 0039 Hex Nut Self Locking M6 4 5 A 00290 Cover Stop Bracket 1 6 0096 0002 Cap Screw M6 x 20 2 7 0096 0014 Cap Screw M10 x 20 2 61 BATTERY COMPARTMENT ASSEMBLY BATTERY COMPARTMENT ASSEMBLY PARTS LIST Item No Part No Description Qty 1 A 00215 Battery Box Weldment Left 1 2 A 00220 Battery Box Weldment Right 1 3 A 00278 Ba
19. Faulty Lower Control The Lower Control has detected excessive current on the LR Outrigger solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty LR Outrigger solenoid wiring 2 Faulty LR Outrigger solenoid 3 Faulty Lower Control The Lower Control has detected an open circuit on the RR Outrigger solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty RR Outrigger solenoid wiring 2 Faulty RR Outrigger solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the RR Outrigger solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty RR Outrigger solenoid wiring 2 Faulty RR Outrigger solenoid 3 Faulty Lower Control What To Check amp Corrective Action To Clear Error Repair or replace RF Outrigger solenoid wiring Replace RF Outrigger solenoid Replace Lower Control Repair or replace RF Outrigger solenoid wiring Replace RF Outrigger solenoid Replace Lower Control Repair or replace LR Outrigger solenoid wiring Replace LR Outrigger solenoid Replace Lower Control Repair or replace LR Outrigger solenoid wiring Replace LR Outrigger solenoid Replace Lower Control Repair or replace RR Outrigger solenoid wiring Replace RR Outrigge
20. Q Refer to Section 5 for decal locations Verify that all controls and indicators at ground and platform control stations operate properly Lower outriggers to level the boom lift Raise and extend all booms Press emergency sToP button Verify that booms remain elevated and do not drift Pull out sToP button and lower the booms D D D D D D If either control station is unresponsive refer to Table 3 1 for troubleshooting procedures If display panel displays an error code refer to Table 3 2 for error code definitions Verifv correct tire inflation Inflate tires to 20 psi 140 kPa Inspect tires for damage or loose or missing lug nuts a Repair or replace as necessary Inspect structural components and platform for obvious damage or debris a Repair or replace as necessary Inspect machine for missing loose or damaged fasteners including pins and bolts Check engine oil level Add oil as needed a Manufacturer recommends engine oil type 5W 30 Check engine fuel level Q Add fuel as needed 14 Verify that boom down limit switches operate correctly a Down limit switches are actuated when the boom is in a fully lowered stowed position Limit switches must be operational to raise or lower outriggers a If outrigger controls are unresponsive when boom is fully lowered and stowed inspect down limit switches for loose mounting or visible damage Q Repair or replace as needed
21. The Lower Control has detected excessive current on the Outrigger Extend solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Outrigger Extend solenoid wiring 2 Faulty Outrigger Extend solenoid 3 Faulty Lower Control The Lower Control has detected an open circuit on the LF Outrigger solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty LF Outrigger solenoid wiring 2 Faulty LF Outrigger solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the LF Outrigger solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty LF Outrigger solenoid wiring 2 Faulty LF Outrigger solenoid 3 Faulty Lower Control What To Check amp Corrective Action To Clear Error Repair or replace Outrigger Retract solenoid wiring Replace Outrigger Retract solenoid Replace Lower Control Repair or replace Outrigger Retract solenoid wiring Replace Outrigger Retract solenoid Replace Lower Control Repair or replace Outrigger Extend solenoid wiring Replace Outrigger Extend solenoid Replace Lower Control Repair or replace Outrigger Extend solenoid wiring Replace Outrigger Extend solenoid Replace Lower Control Repair or replace LF Outrigger
22. injury or death AN DANGER Warns of operation near electrical power sources that could lead to personal injury or death WARNING Describes conditions or practices that could lead to personal injury or death AN CAUTION Contains information important in the prevention of errors that could damage machine or components NOTE Contains additional information important for performing a procedure BEFORE OPERATION Ensure the following general safety precautions are followed before operating the articulating boom lift ALWAYS inspect the usage area for potential hazards such as unstable or unlevel surfaces overhead obstructions and electrically charged wires or conductors ALWAYS watch for moving vehicles in the operating area ALWAYS conduct a thorough inspection of the machine before operation Check for damaged or worn parts hydraulic leaks damaged wiring loose wiring conductors damaged outriggers low tire pressure uneven tire wear or tire damage Check for any improperly operating components NEVER operate equipment if any damage is observed or suspected Repair damaged or malfunctioning equipment before operation ALWAYS wear proper clothing and footgear Wear protective equipment as required by government regulations Keep loose clothing jewelry gloves and hair away from moving parts ALWAYS wear a safety harness and energy absorbing lanyard such as a safety harness and lanyard provided by Bil Jax
23. procedures ALWAYS inspect hydraulic system to ensure that all lines connectors and fittings are properly fastened and in good condition ALWAYS turn the key switch OFF and remove key before performing maintenance ALWAYS perform maintenance with the boom and platform in a fully lowered stowed position when possible ALWAYS secure the boom before performing maintenance on hydraulic cylinders ALWAYS disconnect power to the hydraulic pump drive motor before making electrical checks to the hydraulic valves ALWAYS keep all mechanical parts 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 before performing any maintenance or repairs ALWAYS use only manufacturer approved parts to repair or maintain equipment If any portion of this equipment is rebuilt or repaired retesting is required in accordance with factory instructions ALWAYS maintain a safe distance while testing the hydraulic components ALWAYS relieve hydraulic pressure before loosening or removing hydraulic components NEVER test or operate the hydraulic components while personnel are near the equipment NEVER allow water or foreign particles into the DC electric motor housing Inclusion of water or foreign particles may cause serious damage to the
24. 00651 End Pivot Weldment 1 3 A 00660 Jib Cylinder 1 4 A 01553 Slave Cylinder 1 5 A 00662 Jib End Weldment 1 6 A 01979 Bulkhead Left 1 7 0096 0016 Cap Screw M10 x 25 7 8 0096 0041 Hex Nut Self Locking M10 12 9 0096 0091 Flat Head Cap Screw M10 x 25 2 10 A 00054 Pin Retainer 1 0 Flat Head 2 11 A 00052 Pin 1 0 x 5 25 1 12 A 00018 Pin Retainer 1 0 2 13 A 00061 Pin 1 0x 7 375 2 14 A 00925 Pin Retainer 0 75 4 15 A 00050 Pin 0 75 x 7 375 4 16 A 00672 Valve Guard 1 17 A 00667 Jib Bumper 1 18 0096 0068 Flat Head Cap Screw M10 x 45 5 19 B01 10 0046 Outlet Box 1 20 B01 10 0034 GFI Outlet 1 21 B01 10 0035 Outlet Box Cover 1 22 0096 0001 Cap Screw M6 x 16 2 23 0096 0039 Hex Nut Self Locking M6 10 24 A 00522 Boom End Weldment 1 25 A 00031 Bearing 2 26 A 00038 Ramp 0 25 4 27 0096 0002 Flat Head Cap Screw M6 x 20 8 28 0096 0019 Cap Screw M12 x 25 8 29 0096 0042 Hex Nut Self Locking M12 8 30 0096 0018 Cap Screw M10 x 40 2 31 A 00056 Bushing 4 73 PLATFORM ASSEMBLY PLATFORM ASSEMBLY PARTS LIST Item No Part No Description Qty 1 A 03350 Platform Weldment 5 1 1 A 03365 Platform Weldment 4 1 2 A 03359 Platform Floor 1 3 0096 0102 Cap Screw M8 x 25 26 4 0096 0040 Hex Nut Self Locking M8 26 5 A 03361 Upper Control Box Mount 1 6 0096 0
25. 8816801 AAA uue eje m NA Da yoed ayom Yd 34M i y a lt 4 081 gt 98 Amp Housing 770680 1 Black i TXL or Equivalent i i All Measurements are 0 250 In AMP 3 Pin Housing AMP Cable Clamp 206037 2 Pin Pin 15 Pin 22 Pin 23 206070 1 A 00718 Rev Fill Strain Relief with RTV then put on cable clamp and wipe off excess Delphi Weather Pack 3 Pin Male Housing 12020827 Male Terminal 12089040 Green cable seal 12015323 ANALOG HARNESS A 00715 Amp 770680 i Label A 00715 due AMP 770520 1 Wire Labels 1 Pin Pump Speed Signal FM Spade 1 lt O 3 36 18 ga _ gt Insulated i Motor Cntrl Enab AS Pin FM Spade m da 3 36 18 Yellow gt Insulated dodo Pin Ground Weather Pack lt 12 18 ga Black gt 12010973 2 Pin Housing Pin Engine Run A 12089040 Male Terminal 10 12015323 Wire Seal lt 12 18 ga ei gt 18 18ga Red FM Spade Insulated 18 18ga Black FM Spade Splice amp Heat aa UT insulated Shrink Seal A N Le
26. 9 T 108943 MIS 92 9 9 007944 06 Vid 9 9 108944 06 4 vr 108943 vr 108943 06 4 01 01 005944 06 SIYONJ0L SIJUOWOL 01 01 01 908944 991 SIUOWOLFUSOWOLHF SIUOWOL 21 8 007933 MIS SUYONZI SIUONS O 01 21 0199 MIS WASHO0L WENOZL Op 31009 Lu 83 84 TRAILER HYDRAULIC LINES PARTS LISTS ltem No Part No Description 1 B02 01 0402 10 x 28 Hydraulic Hose 2 B02 01 0401 8 x 154 Hydraulic Hose 3 B02 01 0398 8 x 16 Hydraulic Hose 4 B02 01 0400 8 x 24 Hydraulic Hose 5 B02 01 0399 8 x 18 Hydraulic Hose 6 B02 01 0386 6 x 30 Hydraulic Hose 7 B02 01 0387 6 x 30 Hydraulic Hose 8 B02 01 0397 6 x 166 Hydraulic Hose 9 B02 01 0396 6 x 150 Hydraulic Hose 10 B02 01 0385 4 x 118 Hydraulic Hose 11 B02 01 0379 4 x 16 Hydraulic Hose 12 B02 01 0382 4 x 30 Hydraulic Hose 13 B02 01 0383 4 x 40 Hydraulic Hose 14 B02 01 0393 6 x 138 Hydraulic Hose 15 B02 01 0392 6 x 138 Hydraulic Hose 16 B02 01 0388 6 x 38 Hydraulic Hose 17 B02 01 0389 6 x 38 Hydraulic Hose 18 B02 01 0395 6 x 138 Hydraulic Hose 19 B02 01 0394 6 x 138 Hydraulic Hose 20 B02 01 0390 6 x 62 Hydraulic Hose 21 B02 01 0391 6 x 62 Hydraulic Hose 22 B02 01 0380 4 x 21 Hydraulic Hose 23 B02 01 0384 4 x 105 Hydraulic Hos
27. C23 solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Turn Right C23 solenoid wiring 2 Faulty Turn Right C23 solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the Turn Right C23 solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Turn Right C23 solenoid wiring 2 Faulty Turn Right C23 solenoid 3 Faulty Lower Control What To Check amp Corrective Action To Clear Error Repair or replace Drive Dump C21 solenoid wiring Replace Drive Dump C21 solenoid Replace Lower Control Repair or replace Drive Dump C21 solenoid wiring Replace Drive Dump C21 solenoid Replace Lower Control Repair or replace Turn Left C22 solenoid wiring Replace Turn Left C22 solenoid Replace Lower Control Repair or replace Turn Left C22 solenoid wiring Replace Turn Left C22 solenoid Replace Lower Control Repair or replace Turn Right C23 solenoid wiring Replace Turn Right C23 solenoid Replace Lower Control Repair or replace Turn Right C23 solenoid wiring Replace Turn Right C23 solenoid Replace Lower Control 126 Error Message Displayed 089 OPEN CIRCUIT FORWARD 1 C24 090 SHORTED CIRCUIT FORWARD 1 C24 091 OPEN CIRGUIT R
28. Control The Lower Control has detected an open circuit on the Right Wheel Reverse solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Right Wheel Reverse solenoid wiring 2 Faulty Right Wheel Reverse solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the Right Wheel Reverse solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Right Wheel Reverse solenoid wiring 2 Faulty Right Wheel Reverse solenoid 3 Faulty Lower Control What To Check amp Corrective Action To Clear Error Repair or replace Right Wheel Forward solenoid wiring Replace Right Wheel Forward solenoid Replace Lower Control Repair or replace Right Wheel Forward solenoid wiring Replace Right Wheel Forward solenoid Replace Lower Control Repair or replace Right Wheel Reverse solenoid wiring Replace Right Wheel Reverse solenoid Replace Lower Control Repair or replace Right Wheel Reverse solenoid wiring Replace Right Wheel Reverse solenoid Replace Lower Control 125 Error Message Displayed 083 OPEN CIRCUIT DRIVE DUMP C21 084 SHORTED CIRCUIT DRIVE DUMP C21 085 OPEN CIRCUIT TURN LEFT C22 086 SHORTED CIRCUIT TURN LEFT C22 087 OPEN CIRCUIT TURN RIGHT C23 088 SH
29. Extend boom solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Extend boom solenoid wiring 2 Faulty Extend boom solenoid 3 Faulty Lower Control The Lower Control has detected an open circuit on the Retract boom solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Retract boom solenoid wiring 2 Faulty Retract boom solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the Retract boom solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Retract boom solenoid wiring 2 Faulty Retract boom solenoid 3 Faulty Lower Control What To Check amp Corrective Action To Clear Error Repair or replace Jib Down solenoid wiring Replace Jib Down solenoid Replace Lower Control Repair or replace Jib Down solenoid wiring Replace Jib Down solenoid Replace Lower Control Repair or replace Extend boom solenoid wiring Replace Extend solenoid Replace Lower Control Repair or replace Extend boom solenoid wiring Replace Extend solenoid Replace Lower Control Repair or replace Retract boom solenoid wiring Replace Retract boom solenoid Replace Lower Control Repair or replace Retract boom solenoid wiring Replace Retract boom solenoid
30. Hydraulic Hose 9 B02 01 0291 4 x 15 Hydraulic Hose 10 B02 01 0320 4 x 310 Hydraulic Hose 11 B02 01 0321 4 x 310 Hydraulic Hose 12 B02 01 0234 4 x 16 Hydraulic Hose 13 B02 01 0235 4 x 16 Hydraulic Hose 14 B02 01 0294 6 x 20 Hydraulic Hose 15 B02 01 0295 4 x 20 Hydraulic Hose 16 B02 01 0322 6 x 183 Hydraulic Hose 17 B02 01 0323 4 x 183 Hydraulic Hose 18 B02 01 0298 6 x 20 Hydraulic Hose 19 B02 01 0299 4 x 20 Hydraulic Hose 20 B02 01 0324 6 x 316 Hydraulic Hose 21 B02 01 0301 6 x 54 Hydraulic Hose 22 B02 01 0346 4 x 316 Hydraulic Hose 23 B02 01 0343 4 x 54 Hydraulic Hose 24 B02 01 0282 x 20 Hydraulic Hose FITTINGS Part No Description Qty B02 02 0259 6 MORFS 6 MORB STR 11 B02 02 0264 6 MORFS 6 MORB 45 8 B02 02 0260 6 MORFS 6 MORB 90 1 B02 02 0237 4 MORFS 6 MORB STR 2 B02 02 0262 6 MORFS 10 MORB 45 2 B02 02 0258 6 MORFS Tee 5 B02 02 0270 6 MORFS 6 MORFS 6 MORB Tee 1 B02 02 0196 4 MORB 2 MNPT STR 1 B02 02 0241 2 NPTFM Coupling 1 B02 02 0242 2 QD Plug 1 81 82 OUTRIGGER HYDRAULIC LINES A 03182 OUTRIGGER HYDRAULIC LINES PARTS LIST Item No Part No Description Qty B02 01 0213 4 x 28 Hydraulic Hose B02 01 0214 4 x 28 Hydraulic Hose B02 01 0215 6 x 56 Hydraulic Hose B02 01 0216 6 x 56 Hydraulic Hose B02 01 0219 6 x 28 Hydraulic Hose
31. Jax s maximum liability under this warranty is limited to the amount paid to Bil Jax for the product This warranty is in lieu of all other warranties expressed or implied Bil Jax neither assumes nor authorizes any or other entity to assume on its behalf any other liability in connection with the sale rental or use of this product Warranty Claims Process In order to qualify for warranty coverage the following conditions must be met 1 Return of completed Warranty Registration form to Bil Jax within 15 days of receipt of product 2 Notification to Bil Jax within 72 hours of any claimed defect injury or damage resulting from the claimed the defect and 3 Warranty is limited to parts that are determined to be defective This does not include parts worn out due to normal use Bil Jax authorized dealers or distributors are responsible for filing claims under warranty Listed below is the warranty claims procedure 1 Contact Bil Jax Service Department at 800 537 0540 to report the claim and verify warranty coverage Machine serial number must be provided 2 Identify the components to be claimed under warranty along with description of failure A Returned Merchandise Authorization RMA number will be issued by Bil Jax 3 Replacement parts will then be sent by Bil Jax to the dealer or distributor All parts are invoiced at dealer distributor list price Credits will be issued when defective parts are returned to Bil Jax and fou
32. NOTICE Max Load WARNING Read Understand Operator s Manual Qty Decal No Decal Description Qty B06 00 0482 DANGER Electrocution Hazard 2 06 00 0495 CAUTION Compartment Access 2 Restricted DANGER Before Use Main B06 00 0505 etruction Hazards ground 1 B06 00 0536 NOTICE Range of Motion 2 B06 00 0541 CAUTION Manual Boom 1 Functions B06 00 0545 Bil Jax Website Transfer 2 WARNING Operating Instructions B06 00 0561 Ground 2 06 00 0562 WARNING Operating Instructions 1 Platform B06 00 0564 45XA 6 Black Transfer 2 BO6 00 0568 WARNING Outrigger Pressure 4 WARNING Read Understand B06 00 0572 Barts and Service Manual Identification Plates B06 00 0499 ANSI ID Plate 1 B06 00 0526 Key Tag 1 5 REPLACEMENT DECALS Figure 5 2 Decal Placement CE 33 BIL JAX 45XA 34 6 MATERIAL SAFETY DATA The following Material Safety Data Sheets describe the correct procedures for the safe handling of chemical components within the Model 45XA Articulating Boom Lift as well as any potential health and safety hazards related to these chemicals Material Safety Data Sheets are included here in accordance with applicable federal and state regulations Read and observe all safety precautions Maintain awaren
33. Ring 5 16 Ring 105 MANUAL PLATFORM ROTATE ASSEMBLY OPTION A 00300 Y eem Fu 02000 a LE I 1 8 I 0 orc eS 3 cor gt 106 MANUAL PLATFORM ROTATE ASSEMBLY PARTS LIST Item No Part No Description Qty 1 A 00301 Platform Mount A Weldment 1 2 A 00308 Platform Mount Weldment 1 3 A 00315 Gearbox Platform Rotate 1 4 A 00330 Bearing 75 ID 2 5 A 00329 Pin 0 75 x 10 25 DB 1 6 A 00017 Pin Retainer 0 75 2 7 0096 0014 Cap Screw M10 x 20 6 8 0096 0041 Hex Nut Self Locking M10 2 9 0096 0019 Cap Screw M12 x 25 2 10 0096 0042 Hex Nut Self Locking M12 2 11 A 00071 Pin Platform 1 12 0090 0147 Cotter Pin 2 13 0096 0103 Cap Screw M8 x 140 2 14 0096 0040 Hex Nut Self Locking M8 2 107 108 ORDERING REPLACEMENT PARTS To order replacement parts contact the Bil Jax Service Department by phone at 800 537 0540 by fax at 419 446 8202 or by email at techsupport biljax com For swift service always have the part number available as well as the equipment model and serial number When ordering parts by fax or email always provide the above information See Page 12 for Equipment Warranty information QUICK REFERENCE Equipment Model Bil Jax 45XA Articulating Boom Lift Serial Number NOTES APPENDIX ERROR CODES The
34. and wiring 026 SHORTED CIRCUIT Excessive load detected in secondary up circuit Check for faulty boom up SECONDARY UP on power up solenoid coil and wiring 027 OPEN CIRCUIT SECONDARY A load of less than 70mA detected when Check for faulty boom down DOWN secondary down circuit was energized solenoid coil and wiring 028 SHORTED CIRCUIT Excessive load detected when secondary down Check for faulty boom down SECONDARY DOWN circuit was energized solenoid coil and wiring 029 OPEN CIRCUIT JIB UP A load of less than 70mA detected in jib up circuit Check for faulty jib up solenoid on power up coil and wiring 030 SHORTED CIRCUIT JIB UP Excessive load detected in jib up circuit on Check for faulty jib up solenoid power up coil and wiring 21 BIL JAX 45XA ERROR MESSAGE DEFINITION OF ERROR COMMENTS 031 OPEN CIRCUIT JIB DOWN A load of less than 70mA detected when jib down Check for faulty jib down solenoid circuit was energized coil and wiring 032 SHORTED CIRCUIT JIB Excessive load detected when jib down circuit Check for faulty jib down solenoid DOWN was energized coil and wiring 033 OPEN CIRCUIT EXTEND A load of less than 70mA detected in extend Check for faulty boom extend circuit on power up solenoid coil wiring 034 SHORTED CIRCUIT EXTEND Excessive load detected in extend circuit on Check for faulty boom extend power up solenoid coil wiring 035 OPEN CIRCUIT RETRACT A load of less than 70mA detected in retr
35. error codes listed below may not be applicable to all machines and configurations Error Message Displayed 001 MACHINE IS IN DOWN ONLY MODE 002 LOSS OF PLATFORM COMMUNICATION 003 LOSS OF DRIVE COMMUNICATION 004 LOSS OF PC COMMUNICATION Error Explanation amp Possible Causes The Machine has gone into DOWN ONLY mode 1 This is a self clearing error When error condition is 2 removed error is cleared 3 NOTE This error will not be displayed when boom is down or if so equipped when the Load Sense Module has detected an overloaded condition Possible causes include 1 Machine went out of level during use 2 Load sense has detected an overload condition 3 Moment sense has detected an overload condition The Lower Control has lost communication with the 1 Platform Control 2 3 This is a latched error To clear this error first the error 4 condition must be removed and second the power must be cycled off then back on NOTE During this error condition the Platform Control Engine On LED will blink a 2 blink error code and the Lower Control Power LED will blink a 2 blink error code Possible causes include 1 Lower control incorrectly configured 2 Faulty Boom Cable 3 Faulty Upper Control 4 Faulty Lower Control The Lower Control has lost communication with the 1 Drive Control 2 3 This is a latched error To clear this error first the error 4
36. include 1 Faulty Torque C29 solenoid wiring 2 Faulty Torque C29 solenoid 3 Faulty Lower Control The Lower Control has detected an open circuit on the Torque H L C30 solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Torque C30 solenoid wiring 2 Faulty Torque C30 solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the Torque H L C30 solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Torque C30 solenoid wiring 2 Faulty Torque H L C30 solenoid 3 Faulty Lower Control What To Check amp Corrective Action To Clear Error Repair or replace Reverse 2 C28 solenoid wiring Replace Reverse 2 C28 solenoid Replace Lower Control Repair or replace Reverse 2 C28 solenoid wiring Replace Reverse 2 C28 solenoid Replace Lower Control Repair or replace Torque H L C29 solenoid wiring Replace Torque H L C29 solenoid Replace Lower Control Repair or replace Torque H L C29 solenoid wiring Replace Torque H L C29 solenoid Replace Lower Control Repair or replace Torque H L C30 solenoid wiring Replace Torque H L C30 solenoid Replace Lower Control Repair or replace Torque H L C30 solenoid wiring
37. main disconnect Hydraulic function does not work and display window shows an error message Fault detected by safety interlock microprocessor Boom Lift electric or electronic failure Refer to Table 4 2 for error code definition and correction Refer to Table 4 2 for error code definition and correction Outrigger indicator LED lights do not function Key switch turned to the OFF or platform controls position Emergency sToP engaged Outriggers not deployed Turn key switch to ground controls position Disengage emergency STOP buttons Deploy all outriggers One or more boom controls do nat function OR One or more boom controls function improperly OR One or more boom controls function intermittently Key switch is turned to the OFF or incorrect control position Battery charge is low Emergency STOP engaged Battery ground or in series cable loose All outriggers not properly deployed Hydraulic pump inoperative Loose wiring connector Valve solenoid not operating properly Fault detected by system interlock Broken or loose wire Turn key switch to ground or platform controls position Recharge battery Disengage Emergency STOP buttons Inspect and repair battery connections Deploy all outriggers and level boom lift Inspect pump replace or repair as needed Check wiring terminals in control box and at valve manifold replace or repair as needed
38. motor If the motor becomes wet consult an authorized Bil Jax service technician for proper drying instructions NEVER add unauthorized fluids to the hydraulic system or battery NEVER mix hydraulic oils Consult manufacturer specifications Refer to Section 4 for hydraulic system maintenance procedures 1 SAFETY NEVER exceed the manufacturer s recommended relief valve settings NEVER touch or allow metal tools to contact any components that are sensitive to static discharge ALWAYS use static discharge prevention mats and grounding devices when handling electronic components NEVER adjust repair replace or bypass any hydraulic or electrical control or safety device These include but are not limited to hydraulic load control and flow control valves solenoid valves and limit switches ALWAYS consult an authorized Bil Jax technician if repairs are necessary NEVER modify alter or change the equipment without first consulting an authorized Bil Jax technician and NEVER in any way that would affect its original design or operation Battery Maintenance Ensure the following general safety precautions are followed when performing battery maintenance on the Aerial Work Platform ALWAYS wear safety glasses when working with or near batteries ALWAYS check the battery fluid level daily ALWAYS avoid contact with battery acid Battery acid causes serious burns and should be kept away from skin or eyes If contact oc
39. of the unit for wear or damage Manufacturer recommendations Oooo A visual weld inspection to be performed by qualified personnel in accordance with applicable government regulations 3 EQUIPMENT MAINTENANCE ADDITIONAL SERVICE INFORMATION Seals on hydraulic cylinders should be replaced every five years or as indicated by machine performance All service checks should be performed on a machine that has been stored without use for a period exceeding thirty days Check for air in the hydraulic system if the machine has been stored without use for a period exceeding thirty days or if the machine was stored without use during a seasonal climate change Air trapped in the hydraulic system will affect machine performance Follow procedures for bleeding air from the hydraulic system found in Section 4 Owners and lessors should complete a full inspection of all components and perform a test of all functions including brake functions before commissioning or reselling machine Always repair or replace all damaged or malfunctioning components before commissioning or reselling machine When a change in ownership occurs it is the responsibility of the seller to provide the new owner with all manuals for the machine It is the responsibility of the buyer to notify the manufacturer of the unit model and serial number and the name and address of the new owner within 60 days Use the Service Checklists found at the back of
40. outreach setting NOTE This error only occurs on machines equipped with the Moment Sense option Possible causes include 1 much weight on boom 2 extended too far for weight on boom 3 lowered too far for weight on boom 4 Lower Control incorrectly configured 5 Faulty Lower Control The Lower Control has detected the boom has reached the maximum outreach setting NOTE This error only occurs on machines equipped with the Moment Sense option Possible causes include Too much weight on boom Boom extended too far for weight on boom Boom lowered too far for weight on boom Lower Control incorrectly configured Faulty Lower Control The Lower Control has detected the primary boom cylinder has reached or exceeded the maximum pressure setting NOTE This error only occurs on machines equipped with the Moment Sense option Possible causes include Too much weight on boom Boom extended too far for weight on boom Boom lowered too far for weight on boom Lower Control incorrectly configured Faulty Lower Control The Primary boom cylinder pressure safety switch has detected the primary cylinder has reached or exceeded the maximum pressure setting and disabled all boom functions If this error occurs one or more of the three sensors responsible for determining the moment are not reading correctly The angle sensor the pressure sensor and the pressure switch must be examined to determine which
41. sensor or sensors have failed NOTE This error only occurs on machines equipped with the Moment Sense option Possible causes include Faulty angle sensor Faulty angle sensor wiring Faulty pressure sensor Faulty pressure sensor wiring Faulty Primary cylinder pressure switch Faulty Primary cylinder pressure switch wiring Lower Control incorrectly configured Faulty Lower Control D NOR ED MEANS ALAN What To Check amp Corrective Action To Clear Error Reduce weight in basket or on hook Retract boom Raise boom Correctly configure Lower Control Replace Lower Control Reduce weight in basket or on hook Retract boom Raise boom Correctly configure Lower Control Replace Lower Control Reduce weight in basket or on hook Retract boom Raise boom Correctly configure Lower Control Replace Lower Control Check angle sensor Repair or replace angle sensor wiring Check pressure sensor Repair or replace pressure wiring Check and repair Primary boom cylinder pressure switch Repair or replace Primary boom cylinder pressure switch wiring Correctly configure Lower Control Replace Lower Control 130 Lower Control Blink Error Codes The Power led blinks to indicate the following error conditions 1 Blink Stuck key on Lower Control 2 Blinks Loss of communication with Platform Control 3 Blinks Loss of communication with Drive Control 4 Blinks L
42. solenoid wiring Replace LF Outrigger solenoid Replace Lower Control Repair or replace LF Outrigger solenoid wiring Replace LF Outrigger solenoid Replace Lower Control 118 Error Message Displayed 055 OPEN CIRCUIT RF OUTRIGGER 056 SHORTED CIRCUIT RF OUTRIGGER 057 OPEN CIRCUIT LR OUTRIGGER 058 SHORTED CIRCUIT LR OUTRIGGER 059 OPEN CIRCUIT RR OUTRIGGER 060 SHORTED CIRCUIT RR OUTRIGGER Error Explanation amp Possible Causes The Lower Control has detected an open circuit on the RF Outrigger solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty RF Outrigger solenoid wiring 2 Faulty RF Outrigger solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the RF Outrigger solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty RF Outrigger solenoid wiring 2 Faulty RF Outrigger solenoid 3 Faulty Lower Control The Lower Control has detected an open circuit on the LR Outrigger solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty LR Outrigger solenoid wiring 2 Faulty LR Outrigger solenoid 3
43. the Operator s Manual to record all Service Checks as well as any maintenance repairs or alterations performed on the machine Records of frequent safety checks need not be made However where a safety hazard is found it shall be reported in writing to the owner of the machine anda record of any corrective action shall be maintained for five years or as required b y the authority having jurisdiction Testing Machine Stability The Summit Series aerial work platform has been tested for stability using a load equal to 150 of the rated capacity of the machine and placed at the center of the platform with the boom fully extended Stability tests should be conducted only by trained personnel and only when the machine is properly anchored to safeguard against tipping 19 BIL JAX 45XA TROUBLESHOOTING Refer to Table 3 2 for basic troubleshooting operations Additional information can be found in the Bil Jax Model 45XA Operator s Manual Contact the Bil Jax Service Department with any questions or before attempting any advanced troubleshooting operations Table 3 1 Troubleshooting Steps PROBLEM CAUSE SOLUTION No lights on panel when key switch is turned to the on position Emergency sToP engaged Battery charge is low Battery ground or in series cable is loose Battery main disconnect unplugged Disengage Emergency stop buttons Recharge as needed Inspect and repair battery connections Plug in
44. this error first the error condition must be removed and second the power must be cycled off then back on NOTE During this error condition the Lower Control Power LED will blink a 1 blink error code Possible causes include 1 Lower Control has a stuck key 2 Faulty Lower Control The Lower Control has detected the boom is up without all four outriggers on the ground This is a self clearing error When error condition is removed error is cleared NOTE Alarm will sound during this error condition Possible causes include 1 Faulty boom down or outrigger limit switches 2 Faulty boom down or outrigger limit switch wiring 3 Faulty Lower Control 1 What To Check amp Corrective Action To Clear Error Free stuck or pressed key on Platform Control Replace Platform Control Free stuck or pressed key on Drive Control Replace Drive Control Free or replace stuck joystick on Drive Control Replace Drive Control Free stuck or pressed key on Lower Control Replace Lower Control Check and repair boom and outrigger limit switches Repair or replace boom and outrigger limit switch wiring Replace Lower Control 110 Error Message Displayed 010 LEVEL SENSOR HAS ERRATIC OUTPUT 011 TRYING TO DRIVE W TRAILER BRAKE OFF 012 ANGLE SENSOR IS DISCONNECTED OR BAD 013 PRESSURE SENSOR IS DISCONNECTED OR BAD 014 CHECK ENGINE LOW OIL PRESSURE Error Explanation 8 Possible Causes T
45. 0 x 7 0 DB 1 15 A 00032 Bearing 4 16 A 00023 Pin 1 25 x 7 25 1 17 0096 0091 Flat Head Cap Screw M10 x 25 1 69 UPPER BOOM ASSEMBLY 70 UPPER BOOM ASSEMBLY PARTS LIST Item No Part No Description Qty 1 A 03502 Upper Boom Weldment 1 2 A 03510 Telescopic Boom Tube 1 3 A 03550 Extension Cylinder 1 4 A 00535 Slider 2 5 0096 0017 Cap Screw M10 x 30 4 6 0096 0041 Hex Nut Self Locking M10 16 7 0096 0033 Flat Head Cap Screw M16 x 35 4 8 A 00533 Wear Pad 12 9 A 00534 Wear Pad Shim 20 10 0096 0013 UHMW Bolts M10 x 15 24 11 A 00532 Tube Slider 1 12 A 00529 Tube Slider Back 1 13 0096 0018 Cap Screw M10 x 40 4 14 A 01554 Boom Latch Hook 1 15 A 01531 Cable Track Tube 1 16 A 03536 Cable Track Tray 1 17 A 03530 Cable Track 1 18 0096 0010 Cap Screw M8 x 20 12 19 0096 0040 Hex Nut Self Locking M8 12 20 A 00026 Pin 75 x 7 0 1 21 A 00925 Pin Retainer 75 1 22 0096 0016 Cap Screw M10 x 25 8 71 JIB BOOM ASSEMBLY es NEL es 8 E 3 H 9 72 JIB ASSEMBLY PARTS LIST Item No Part No Description Qty 1 A 00657 Jib Link Weldment 2 2 A
46. 00 0521 DANGER Tip Over Hazard 5 B06 00 0536 NOTICE Range of Motion 2 B06 00 0541 CAUTION Manual Boom 1 Functions B06 00 0545 Bil Jax Website Transfer 2 NOTICE Fall Protection Attach B06 00 0552 ment Points 1 06 00 0561 WARNING Operating Instructions 2 Ground 06 00 0562 WARNING Operating Instructions 1 Platform B06 00 0564 45XA 6 Black Transfer 2 Identification Plates B06 00 0490 VIN Plate 1 B06 00 0499 ANSI ID Plate 1 B06 00 0524 Annual Inspection Plate 1 B06 00 0526 Key Tag 1 5 DECAL PLACEMENT RN umi oso J soro 0 L870 5790 Figure 5 1 Locations 31 BIL JAX 45XA Decal No 0202 0523 B06 00 0034 B06 00 0037 B06 00 0062 B06 00 0068 B06 00 0161B B06 00 0173 B06 00 0403 B06 00 0404 B06 00 0405 B06 00 0471 B06 00 0474 06 00 0475 32 Table 5 2 Decal Descriptions Decal Description Made in USA DANGER Electric Shock Lubricate Semi Annually NOTICE AC Power NOTICE Hydraulic System Oil Bil Jax Logo Black Transfer Fall Protection Attachment Points NOTICE Emergency Lowering WARNING Outrigger Crush Toe WARNING Pinch Point DANGER Before Use Main Instruction Hazards Platform
47. 0092 Proportional Valve 1 6 B02 14 0119 Valve Directional Steering 4WD 1 7 B02 14 0098 Shuttle Valve 1 8 B02 15 0518 Cartridge Valve NO 1 9 B02 14 0120 Orifice Brake 1 10 B02 14 0121 Cartridge Valve NO 2 11 B02 14 0122 Valve Directional Drive 4WD 2 12 B02 14 0123 Flow Control Valve 1 13 02 14 0112 Coil 20v DC Deutsch Connector 11 14 B02 15 0524 Coil Proportional 20v DC Deutsch Conn 1 87 88 WIRE HARNESSES ANSI Platform Plug Boom Down Relay NC X a Motor Cntl P4 amp P5 P3 Turntable Connector Connector J4 P1 Analog Connector 23 16 00000000 9000000 1 Platform Connector 5 600000000000 00000000000 000000000009 1 1 P2 Lift Engine Connector 3 24 NO NO N Level Sensor Motor Controller Motor Controller GFCI Plug 00 100 20 50 Manifold AC Plug AC Switch T 4 Generator Switch is forced Closed Switch is forced open when Boom is lifted Engine Spark OR Start
48. 016 Cap Screw M10 x 25 4 7 0096 0041 Hex Nut Self Locking M10 4 8 A 00466 Control Box Latch 1 9 A 00463 Midrail End 4 10 0096 0115 Slotted Head Cap Screw M6 x 20 2 11 A 00464 Midrail 1 12 0096 0052 Cap Screw M6 x 40 2 13 0096 0039 Hex Nut Self Locking M6 6 14 A 00468 Manual Storage Mount Plate 1 15 0096 0017 Cap Screw M10 x 30 2 16 A 00475 Manual Storage Box 1 17 0096 0001 Cap Screw M6 x 16 4 18 A 00474 Cord Wrap Bracket 1 19 A 00071 Platform Pin 1 20 0090 0147 Cotter Pin 1 8 x 1 1 4 2 21 A 00028 Pin Platform to End Weldment 1 22 A 00779 Upper Control Box 4WD Articulating 1 23 A 00462 Spool 7 24 0096 0003 Flat Head Cap Screw M6 x 40 7 75 PUMP ASSEMBLY A 03254 1 41 82 52 04 an ey lt 1 41 8 2 0 anbioy 61 4 2 yal 6 0 nbio WAI 8 2 0 9 N Y ql ve ec 0 anbioL bey 9 NOILO3S Gaia LL 213 jT Ij 1 ED UI E 2 E ch sz O BAJBA enbio 8 amp 6 9 enbiol p 1 41 8 201 ya ez anbi
49. 0293 i Seal 12 14ga CORD ASSEMBLY 220V AC PLUG CE B01 01 0181 12 Ya Female Spade Ya Female Spade InterPower 88010390 16A Socket or Equiliviant PHA ee 96 PUMP AND CYLINDER WIRE HARNESS A 03716 e6gL Zi leas U9919 261021 9 2 AHMED 00601021 0r0680ZL 1 025022 ul 0SZ 0 WA 62802021 a l gusno ejem 22802021 ETAT vor H fid udi q tudi q ut juejeAmb3 10 XL 12028022 02 ud leas U9919 EZESLOZL mE Bnid 00601021 uL W3 88168021 BuisnoH WA 62802021 22802021 1udjeq xoed yd aq e6gL 21 rmn dd 1295 6266102 D w 72 Bnid Ay neg OOEOLOZL Ca AVW 07068021 a 02501 GZ ui Wa 62802021 BursnoH 22802021 SE d tudi q V 92 10250227 SZM T 8L Bnid Z sul peds leuu 3d A 1025077 Uld woog SZ 90 10 yasmag su apeds V L Z 304908 7191 102 2970 YISINSQ epees 9 d fi 1025072 el PPLSL LOZ ZOPO 968 9 roar ud 19497 Jeld A Sod 9JeJ0y V 19191 102 29 0 ED TIT ae SHUN sod MO 9163034 BE 17191
50. 096 0002 Cap Screw M6 x 20 12 6 0096 0039 Hex Nut Self Locking M6 12 7 0090 1080 Pop Rivet 22 8 A 00258 Controls Cover Left Side 1 9 B42 01 1002 Hinge Controls Cover 1 10 A 00292 Cover Latch Assembly 2 65 LOWER BOOM ASSEMBLY n 6 LOWER BOOM ASSEMBLY PARTS LIST Item No Part No Description Qty 1 A 03300 Lower Boom Weldment 1 2 A 03314 Lower Link Weldment 1 3 A 02551 Lift Cylinder 1 4 A 00159 Boom Latch 1 5 0096 0016 Cap Screw M10 x 25 11 6 0096 0041 Hex Nut Self Locking M10 17 7 A 00157 Rest Pad 3 8 0096 0017 Cap Screw M10 x 30 6 9 A 00021 Pin 1 25 x 8 5 3 10 A 00019 Pin Retainer 1 25 7 11 A 00023 Pin 1 25 x 7 25 2 12 A 00032 Bearing 2 67 TRIANGLE WELDMENT ASSEMBLY 68 TRIANGLE WELDMENT ASSEMBLY PARTS LIST Item No Part No Description Qty 1 A 02320 Triangle Weldment 1 2 A 01552 Master Cylinder 1 3 A 02551 Lift Cylinder 1 4 A 00021 Pin 1 25 x 8 5 4 5 A 00019 Pin Retainer 1 25 9 6 0096 0016 Cap Screw M10 x 25 10 7 0096 0041 Hex Nut Self Locking M10 11 8 A 00018 Pin Retainer 1 0 1 9 A 00049 Pin 1 0 x 8 5 1 10 A 00537 Switch Block 1 11 0096 0098 Cap Screw M8 x 35 2 12 0096 0040 Hex Nut Self Locking M8 2 13 A 00054 Pin Retainer 1 0 FH 1 14 A 00051 Pin 1
51. 102 2970 T 1 025044 l z v9 1922 LVLOL LOZ Z9VO wood Buisno ecl mds or mE mbrtorzayo Li 5 H as 0 g A yeu e68 SL 87 Gand IvL9L LOZ Z9VO 1 025022 2n e6gL 9E voz 7 Pu z 268 OL E sod JOS 921304 sod 106 pu xa sog 3195 OL Sog 1x3 186611n0 saM Jay 1966LJNO uondo pue je aqe7 SIAM 319UM JO opis ade umoys se sdno16 uj WOO JO no SAJIM udi q Bnid AHAED 00601021 9jew 12802021 a 1 0250 1295 U8919 62551021 6 W4 88168021 BuisnoH WA Z 26 6102 A98d tudi q Jees U9919 EZESLOZL w131 W 07068021 22 BuisnoH W Z 260LOZL tudi q 8 Uld 1 0250 vl 1 029022 1 0750Z2 1 029022 932304 gt 029022 a i e9s U9919 EZESLOZL uuo Wd 88168021 BuisnoH WA 62802021 19yjeam yd oq ZUd 1 025022 Ce y 1025022 Uld 0250 E 7 68 21 E 22 E 9 EL 3 97 OUTRIGGER COIL 4 SWITCHES WIRE HARNESS A 03039 f 5 uo AN IE9S au m U9919 6
52. 58 0 anbio 102 AN 61 WAI 8 2 0 anbioL 76 PUMP ASSEMBLY PARTS LIST Item No Part No Description Qty 1 B02 15 0496 Manifold Valve Housing 1 2 B02 14 0108 Valve Cartridge Telescope 2 3 B02 15 0472 Manual Pump Extend Retract Rotate 1 4 B02 14 0089 Valve Cartridge Outrigger Check 1 5 B02 14 0109 Valve Cartridge Outrigger 2 6 B02 14 0091 1 7 B02 14 0110 1 8 B02 14 0094 Valve Proportional 1 9 B02 14 0095 Coil Sterling Proportional Valve 1 10 B02 14 0111 1 11 B02 14 0097 1 12 B02 14 0098 Valve Shuttle 1 13 B02 14 0099 Valve Cartridge Rotator 1 14 B02 14 0100 Valve Counterbalance 2 15 B02 14 0101 Valve Cartridge Basket Compensate 1 16 B02 14 0114 Valve Flow Control Rotator 1 17 B02 02 0245 Fitting Plug 2 ORB 11 18 B02 02 0246 Fitting Hex Plug 1 19 B02 02 0248 Fitting Plug 4 ORB 5 20 B02 14 0112 Coil 20 VDC 8 5 21 B02 14 0113 Coil 20 VDC 10 4 22 B02 15 0497 Stud 1 4 20 x 5 8 4 23 B02 15 0498 Expansion Plug 1 24 B02 02 0235 Fitting Plug 6 ORB 2 25 B02 15 0478 1 77 PUMP ASSEMBLY CONTINUED UBIL pueH JSUIEJJS USJUDI L b Jo jou lquu sse soud xuej He pue uea Ajddy bl Beye 1J SI 3 eunsu o uay iL
53. A 00028 Pin 1 5 A 00485 Lift Hook Assembly 1 6 A 00037 Ramp Short 4 7 0096 0003 Flat Head Cap Screw M6 x 20 4 8 0096 0039 Hex Nut Self Locking M6 4 9 0096 0016 Cap Screw M10 x 25 2 10 0096 0041 Hex Nut Self Locking M10 2 11 0096 0029 Cap Screw M12 x 220 1 12 0096 0042 Hex Nut Self Locking M12 1 A 01976 Load Sense Module Not Pictured 1 BATTERY LAYOUT Motor Controller Contactor 24VDC 100AMP B01 06 0058 Contactor 24VDC 100AMP B01 06 0058 Item No Kit No A 00272 1 30 Red 2 Gauge 5 16 Ring Lug 45 Black 2 Gauge 5 16 Ring 5 16 Ring 8 Black 2 Gauge 5 16 Ring 5 16 Ring 22 Black 2 Gauge 5 16 Ring Lug 24 Red 2 Gauge 5 16 Ring Lug 48 Black 2 Gauge 5 16 Ring Lug 22 Red 2 Gauge 5 16 Ring Lug 48 Red 2 Gauge 5 16 Ring 5 16 Ring O N 45 Black 2 Gauge 5 16 Ring 5 16 Ring 19 Black 2 Gauge 5 16 Ring 5 16 Ring O 13 Red 2 Gauge 5 16 Ring 5 16 Ring ltem No Kit No A 00934 D1 6 Red 2 Gauge 5 16 Ring 5 16 Ring D2 30 Red 2 Gauge 5 16 Ring 5 16 Ring D3 13 Black 2 Gauge 5 16 Ring 5 16 Ring D4 40 Red 2 Gauge 5 16 Ring 5 16 Ring D5 40 Black 2 Gauge 5 16 Ring 5 16 Ring D6 20 Red 2 Gauge 5 16
54. CHINE IS NOT LEVEL 016 LIFT BOOM 017 STOW BOOM 018 LOSS OF LOAD SENSE COMMUNICATION Error Explanation 8 Possible Causes The Lower Control has detected the machine has all four outriggers on the ground but is not level This is a self clearing error When error condition is removea error is cleared Possible causes include 1 Machine has gone out of level with use 2 Faulty level sensor 3 Faulty level sensor wiring 4 Faulty Lower Control The Lower Control has detected the Boom must be raised before the requested function can be performed This is a self clearing error When error condition is removed error is cleared Possible causes include Trying to rotate boom while boom is down Trying to extend boom while boom is down Trying to retract boom while boom is down Faulty boom down limit switch Faulty boom down limit switch wiring Faulty Lower Control The Lower Control has detected the boom must be lowered before the requested function can be performed This is a self clearing error When error condition is removed error is cleared Possible causes include Trying to auto level machine while boom is raised Trying to extend outriggers while boom is raised Trying to retract outriggers while boom is raised Faulty boom down limit switch Faulty boom down limit switch wiring Faulty Lower Control The Lower Control has lost communication with the Load Sense Module This is a latched error T
55. CK 008 GROUND CONTROL HAS STUCK KEY 009 BOOM UP WITHOUT OUTRIGGERS ON GROUND Error Explanation 8 Possible Causes The Platform Control has detected a stuck or pressed key on power up This is a latched error To clear this error first the error condition must be removed and second the power must be cycled off then back on NOTE During this error condition the Platform Control Engine On LED will blink a 1 blink error code Possible causes include 1 Platform Control has a stuck key 2 Faulty Platform Control The Drive Control has detected a stuck or pressed key on power up This is a latched error To clear this error first the error condition must be removed and second the power must be cycled off then back on NOTE During this error condition the Drive Control Engine On LED will blink a 1 blink error code Possible causes include 1 Drive Control has a stuck key 2 Faulty Drive Control The Drive Control has detected a stuck joystick on power up This is a latched error To clear this error first the error condition must be removed and second the power must be cycled off then back on NOTE During this error condition the Drive Control Engine On LED will blink a 2 blink error code Possible causes include 1 Drive Control has a stuck joystick 2 Faulty Drive Control The Lower Control has detected a stuck or pressed key on power up This is a latched error To clear
56. ECTIVE EQUIPMENT PROTECTIVE CLOTHING RECOMMENDED SPECIAL LABELLING INSTRUCTIONS NOT REQUIRED SPECIAL PACKAGING RECOMMENDATIONS NONE HANDLING AND STORAGE RECOMMENDATIONS AVOID EXTREMES OF COLD OR HEAT STORE IN CLEAN DRY AREA SPILL OR LEAK PROCEDURES IN CASE OF LEAK OR SPILL DIKE AND ABSORB WITH INERT MATERIAL FOLLOW ALL LOCAL STATE AND FEDERAL REGULATIONS FOR DISPOSAL DISCLAIMER THE INFORMATION CONTAINED HEREIN HAS BEEN COMPILED FROM SOURCES CONSIDERED TO BE DEPENDABLE AND IS ACCURATE TO THE BEST OF THE SELLER S KNOWLEDGE THE SELLER MAKES NO WARRANTY WHATSOEVER EXPRESSED OR IMPLIED REGARDING THE ACCURACY OF SUCH DATA OR THE RESULTS TO BE OBTAINED FROM THE USE THEREOF 37 38 APPENDIX REPLACEMENT PARTS Use only parts manufactured and or authorized by Bil Jax Inc when replacing damaged components See page 89 for replacement part ordering information Only personnel properly trained and authorized to operate all equipment and familiar with all boom functions should attempt to repair or replace any part of the boom lift Always read understand and obey all safety precautions included in this manual as well as those precautions attached to the lift and dictated by federal state and local regulations 39 40 Assembly Description Outrigger Engine Front Rest Front Axle Rear Axle Slew Ring Limit Switch Control Compartment Pump Compartment Battery Compartment Cover Lower Boom Triangle
57. ER INGESTION DO NOT INDUCE VOMITTING SEEK MEDICAL ATTENTION CONDITIONS AGGRAVATED BY EXPOSURE NONE KNOWN AIR EXPOSURE LIMITS P E L 5 mg m3 OSHA T L V 10mg m3 ACGIH HEALTH 0 FIRE 1 SPECIFIC x REACTIVITY 0 SECTION III PHYSICAL DATA BOILING POINT FREEZING POINT N A VAPOR PRESSURE PSIA N A SPECIFIC GRAVITY H20 1 0 86 SOLUBILITY IN WATER NEGLIGIBLE INSOLUBLE IN COLD WATER PH OF CONCENTRATE N A APPEARANCE AND ODOR RED LIQUID MILD PETROLEUM ODOR SECTION IV FIRE AND EXPLOSION HAZARD DATA FLASH POINT METHOD USED CLOSED 339 F Pensky Martens OPEN 3902 F Cleveland FLAMMABLE LIMITS NOT DETERMINED LEL N A UEL N A EXTINGUISHING MEDIA DRY CHEMICAL FOAM CO2 WATER FOG TREAT AS CLASS B FIRE UNUSUAL FIRE AND EXPLOSION HAZARDS PRODUCES COMBUSTIBLE VAPOR AT TEMPERATURES ABOVE FLASH POINT SECTION V REACTIVITY DATA STABILITY STABLE CONDITIONS TO AVOID AVOID EXTREMES OF HEAT IGNITION SOURCES INCOMPATIBILITY MATERIALS TO AVOID STRONG OXIDIZING MATERIALS HAZARDOUS DECOMPOSITION PRODUCTS INCOMPLETE COMBUSTION MAY CAUSE CARBON OXIDES HAZARDOUS POLYMERIZATION WILL NOT OCCUR SECTION VI 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 PROT
58. EVERSE 1 C25 092 SHORTED CIRCUIT REVERSE 1 C25 093 OPEN CIRCUIT FORWARD 2 C27 094 SHORTED CIRCUIT FORWARD 2 C27 Error Explanation amp Possible Causes The Lower Control has detected an open circuit on the Forward 1 C24 solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Forward 1 C24 solenoid wiring 2 Faulty Forward 1 C24 solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the Forward 1 C24 solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Forward 1 C24 solenoid wiring 2 Faulty Forward 1 C24 solenoid 3 Faulty Lower Control The Lower Control has detected an open circuit on the Reverse 1 C25 solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Reverse 1 C25 solenoid wiring 2 Faulty Reverse 1 C25 solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the Reverse 1 C24 solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Reverse 1 C25 solenoid wiring 2 Faulty Reverse 1 C25 solen
59. Electronics 886 0036 Or Equivilant i Delphi Weather Pack i 3 Pin Male Housing i Male Terminal i Gray Seal GENERATOR SWITCHER BOX ASSEMBLY A 03040 Box A 01015 B01 06 0056 30 Amp Relay i DPST NO i i Allied Electronics i i 8850 0345 Or Equivilant Cord Grip Heyco 3231 Or Equivilant i Delphi Weather Pack 2 Pin Male Housing i Male Terminal Green Seal 12010973 i 12089040 i 12015323 12015793 12010293 12010293 WIRE ASSEMBLY FAN A 03041 V A 3041 Label E eee 2 40 Loom Tape each End 8 Label Middle abel Weather Pack Wires Wire Weather Pack FM Term FM Term 12089188 Cable Seal Cable Seal 12015323 Rev H 12015323 FM Housing FM Housing 12015792 12015792 All wires 18 ga TXL or Equivalent All Measurements are 0 250 In mam 93 IEC CORD MALE ANSI A 03042 18 SO cable or Equivalent North America Inn Minimum Requirements 120V Male Plug i IEC 90 Degree Plug i Interpower B Current 15 AMP IEC 60320 C19 Mold 012 i Voltage 120 240VAC GENERATOR 110V WIRE HARNESS A 03043
60. HORTED CIRCUIT SECONDARY DOWN 029 OPEN CIRCUIT JIB UP 030 SHORTED CIRCUIT JIB UP Error Explanation amp Possible Causes The Lower Control has detected excessive current on the Primary Down solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Primary Down solenoid wiring 2 Faulty Primary Down solenoid 3 Faulty Lower Control The Lower Control has detected an open circuit on the Secondary Up solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Secondary Up solenoid wiring 2 Faulty Secondary Up solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the Secondary Up solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Secondary Up solenoid wiring 2 Faulty Secondary Up solenoid 3 Faulty Lower Control The Lower Control has detected an open circuit on the Secondary Down solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Secondary Down solenoid wiring 2 Faulty Secondary Down solenoid 3 Faulty Lower Control The Lower Control has detected excess
61. IVE ENABLE 082 SHORTED CIRCUIT DRIVE ENABLE Error Explanation 8 Possible Causes The Lower Control has detected an open circuit on the Drive PWM valve solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800 at 100 Possible causes include 1 Faulty Drive PWM valve solenoid wiring 2 Faulty Drive PWM valve solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the Drive PWM valve solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Drive PWM valve solenoid wiring 2 Faulty Drive PWM valve solenoid 3 Faulty Lower Control The Lower Control has detected an open circuit on the Drive Enable solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Drive Enable solenoid wiring 2 Faulty Drive Enable solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the Drive Enable solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Drive Enable solenoid wiring 2 Faulty Drive Enable solenoid 3 Faulty Lower Control on gt What To Check amp Corrective Action To Clear Error
62. K 873 3 Black s gn gt Spade 2 Yellow Cm CS Female Spade All wires 18 ga N TXL or Equivalent Labels Wire Color All Measurements are 0 250 In 91 ATC FUSE HOLDER A 01049 ATC Fuse Holder Waytek 46278 or Equivalent 5 16 Ring Female Spade Ins Term 9 lt gt lt gt 4 6 Leads 4 6 Leads 12 ga Wire 12 ga Wire START STOP RUN WIRE HARNESS A 01098 f Split Tube Wrap i amp Heat Shrink Each End Tape Both Sides Wire Label of Drop Out Delphi Pack 4 Pin Female Conn r Male Spad 12089188 i insulated Female Term i x 12015323 Wire N Color Length 18 Red White 12015792 Delphi Weather Pack 2 Pin Female Conn 12089188 i Female Term 12015323 Green Wire Seal Y A Black 4 28 Orange 28 Yellow 28 15 Black 12010973 i 2 Pin Male Housing i i 12089040 i Male Terminal i Y Ring 12015323 Terminal Green Wire Seal Delphi Weather Pack All wires i TXL or Equivalent i All Measurements are 0 250 In 12010973 Pin Male Housing 12089040 Male Terminal 12015323 Green Wire Seal 92 20 Amp Circuit Breaker W 250 Male Spade Termina i Allied
63. No Part No Description Qty 1 A 03145 Front Rest Weldment 1 2 0096 0024 Cap Screw M12 x 100 2 3 0096 0042 Hex Nut Self Locking M12 2 4 A 00157 Front Rest Pad 5 0096 0017 Cap Screw M10 x 30 16 6 0096 0041 Hex Nut Self Locking M10 20 7 A 00159 Boom Latch 1 8 0096 0016 Cap Screw M10 x 25 4 9 A 00169 Switch Bracket 1 10 0096 0002 Cap Screw M6 x 20 2 11 0096 0039 Hex Nut Self Locking M6 2 12 A 00188 Switch Cam 2 13 0090 1104 Machine Screw 4 40 x 1 3 14 0090 0525 Hex Nut Self Locking 4 40 3 15 B01 03 0078 Limit Switch Assembly NO Female 1 16 B01 03 0079 Limit Switch Assembly NC Male 1 17 0090 0709 Machine Screw 6 32 x 1 1 4 2 18 0090 0180 Hex Nut Self Locking 6 32 2 19 A 00158 Tension Spring 1 20 0096 0038 Cap Screw M20 x 120 4 21 0096 0045 Hex Nut Self Locking M20 4 22 A 01082 Tie Weldment 4WD 1 49 FRONT AXLE ASSEMBLY 59 06066 ace 50 FRONT AXLE ASSEMBLY PARTS LIST Item No Part No Description Qty 1 A 01010 Front Axle Weldment 4WD 2 A 01097 Bushing 1 5 OD x 1 25 ID 3 A 01020 Front Yoke Left 4 A 01021 Front Yoke Right 5 A 01070 Pin 1 25 x 1 625 6 A 00019 Pin Retainer 1 25 7 0096 0016 Cap Screw M10 x 25 8 0096 0041 Hex Nut Self Locking M10 9 A 01022 Hydraulic Motor 4WD 10 0096 0024 Cap Screw M12 x 100 11 0096 0042 Hex Nut Self Locking M12
64. ORTED CIRCUIT TURN RIGHT C23 Error Explanation 8 Possible Causes The Lower Control has detected an open circuit on the Drive Dump C21 solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Drive Dump C21 solenoid wiring 2 Faulty Drive Dump C21 solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the Drive Dump C21 solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Drive Dump C21 solenoid wiring 2 Faulty Drive Dump C21 solenoid 3 Faulty Lower Control The Lower Control has detected an open circuit on the Turn Left C22 solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Turn Left C22 solenoid wiring 2 Faulty Turn Left C22 solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the Turn Left C22 solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Turn Left C22 solenoid wiring 2 Faulty Turn Left C22 solenoid 3 Faulty Lower Control The Lower Control has detected an open circuit on the Turn Right
65. PA 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 amp EXPLOSIVE RESISTANT OTHER MUST BE ACID amp EXPLOSIVE RESISTANT Other Protective Equipment ACID RESISTANT CLOTHING AND BOOTS Hygienic Work Practices N A 36 6 MATERIAL SAFETY DATA MATERIAL SAFETY DATA SHEET DEXRON III MERCON AUTOMATIC TRANSMISSION FLUID HYDRAULIC OIL SECTION GENERAL INFORMATION TRADE NAME CITGO TRANSGARD ATF DEXRON III MERCON EMERGENCY TELEPHONE NUMBERS 918 495 4700 medical 800 424 9300 chemical CHEMICAL FAMILY AUTOMATIC TRANSMISSION FLUID LUBRICATING OIL CAS NUMBER MIXTURE REVISION DATE 10 29 98 HAZARDOUS INGREDIENTS CONTAINS NO INGREDIENTS NOW KNOWN TO BE HAZARDOUS AS DEFINED IN OSHA 29 CFR 1910 1000 AND OSHA 29 CFR 1910 1200 SECTION II HEALTH HAZARD DATA PRIMARY ROUTES OF ENTRY INHALATION SKIN ABRASION AND INGESTION CARCINOGENIC NO SYMPTOMS INGESTION CONTACT INHALATION MILD TRANSIENT SKIN OR EYE IRRITATION MAY OCCUR EYES FLUSH WITH WATER FOR 15 MINUTES SKIN WASH THOROUGHLY WITH WARM SOAPY WAT
66. PARTS AND SERVICE MANUAL DILJAX AA E C AN AERIAL WORK PLATFORMS SELF PROPELLED AERIAL WORK PLATFORM This equipment is designed and manufactured in compliance with the duties responsibilities and standards set forth in the ANSI CE CSA and or AS standards in effect at the time of manufacture This equipment will meet or exceed applicable ANSI CE CSA and or AS codes and standards when operated in accordance with manufacturer s recommendations It is the responsibility of the user to follow all regional codes and regulations that govern the safe operation of this equipment Obtain read and obey all safety precautions before performing maintenance or repairs or attempting to operate this equipment This includes all manufacturer recommendations as well as those directives set forth by government and local authorities To ensure proper and safe use of this equipment it is strongly recommended that only trained and authorized personnel attempt to operate and maintain the boom lift This manual shall be considered a permanent and necessary component of the machine and shall be kept with the boom lift at all times Owners and Lessors should complete a full inspection of all components and perform a test of all functions including brake functions before commissioning or reselling the machine Repair or replace all damaged or malfunctioning components Bil Jax Inc is dedicated to the continuous improvement
67. Proportional valve solenoid wiring Replace Proportional valve solenoid Replace Lower Control Repair or replace Motor Control Enable wiring Replace Motor Control Replace Lower Control Repair or replace Motor Control Enable wiring Replace Motor Control Replace Lower Control 121 Error Message Displayed 073 OPEN CIRCUIT SPARE OUTPUT 074 SHORTED CIRCUIT SPARE OUTPUT 075 OPEN CIRCUIT AC SWITCH 076 SHORTED CIRCUIT AC SWITCH 077 OPEN CIRCUIT STROBE 078 SHORTED CIRCUIT STROBE Error Explanation amp Possible Causes The Lower Control has detected an open circuit on the Spare solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit This output is not used and this error is suppressed to avoid false errors Possible causes include 1 Faulty Lower Control The Lower Control has detected excessive current on the Motor Control Enable output when it was energized during startup self diagnostics NOTE This output is not used and this error is suppressed to avoid false errors Possible causes include 1 Faulty Lower Control The Lower Control has detected an open circuit on the AC Switch output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit This load is less than 70mA and this error is suppressed to avoid false errors Possible causes
68. RIGGER outrigger circuit on power up coil wiring at outrigger 055 OPEN CIRCUIT A load of less than 70mA detected in right front Check for faulty solenoid RF OUTRIGGER outrigger circuit on power up coil wiring at outrigger 22 3 EQUIPMENT MAINTENANCE ERROR MESSAGE DEFINITION OF ERROR COMMENTS 056 SHORTED CIRCUIT Excessive load detected in right front outrigger Check for faulty solenoid RF OUTRIGGER circuit on power up coil wiring at outrigger 057 OPEN CIRCUIT A load of less than 70mA detected in left rear Check for faulty solenoid LR OUTRIGGER outrigger circuit on power up coil wiring at outrigger 058 SHORTED CIRCUIT Excessive load detected in left rear outrigger Check for faulty solenoid LR OUTRIGGER circuit on power up coil wiring at outrigger 059 OPEN CIRCUIT A load of less than 70mA detected in right rear Check for faulty solenoid RR OUTRIGGER outrigger circuit on power up coil wiring at outrigger 060 SHORTED CIRCUIT Excessive load detected in right rear outrigger Check for faulty solenoid RR OUTRIGGER circuit on power up coil wiring at outrigger 069 OPEN CIRCUIT A load of less than 70mA detected in proportional Check for faulty solenoid PROPORTIONAL valve circuit on power up coil wiring at proportional valve 070 SHORTED CIRCUIT Excessive load detected in proportional valve Check for faulty solenoid PROPORTIONAL circuit on power up coil wiring at proportional valve 23 BIL JAX 45XA 24 4 CYLINDER REPLACEMENT
69. Replace Lower Control 115 Error Message Displayed 037 OPEN CIRCUIT PLATFORM LEVEL UP 038 SHORTED CIRCUIT PLATFORM LEVEL UP 039 OPEN CIRCUIT PLATFORM LEVEL DOWN 040 SHORTED CIRCUIT PLATFORM LEVEL DOWN 041 OPEN CIRCUIT PLATFORM CW 042 SHORTED CIRCUIT PLATFORM CW Error Explanation 8 Possible Causes The Lower Control has detected an open circuit on the Platform Level Up solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Platform Level Up solenoid wiring 2 Faulty Platform Level Up solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the Platform Level Up solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Platform Level Up solenoid wiring 2 Faulty Platform Level Up solenoid 3 Faulty Lower Control The Lower Control has detected an open circuit on the Platform Level Down solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Platform Level Down solenoid wiring 2 Faulty Platform Level Down solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on th
70. Replace Torque H L C30 solenoid Replace Lower Control 128 Error Message Displayed 101 OPEN CIRCUIT TORQUE H L C31 102 SHORTED CIRCUIT TORQUE H L C31 Error Explanation 8 Possible Causes The Lower Control has detected an open circuit on the Torque H L C31 solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Torque C31 solenoid wiring 2 Faulty Torque C31 solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the Torque H L C31 solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Torque H L C31 solenoid wiring 2 Faulty Torque C31 solenoid 3 Faulty Lower Control What To Check amp Corrective Action To Clear Error Repair or replace Torque H L C31 solenoid wiring Replace Torque H L C31 solenoid Replace Lower Control Repair or replace Torque H L C31 solenoid wiring Replace Torque H L C31 solenoid Replace Lower Control 129 Error Message Displayed 103 OUTREACH NEAR MAXIMUM 104 OUTREACH AT MAXIMUM 105 OVER MAXIMUM CYLINDER PRESSURE 106 OUTREACH SENSING FAULT Error Explanation 8 Possible Causes The Lower Control has detected the boom has reached or exceeded 95 of maximum
71. SI 2 5 bar 11 BIL JAX 45XA 12 WARRANTY Bil Jax Inc warrants this product for one year beginning on the date of delivery to be free from defects of material and workmanship provided the unit is operated and maintained in compliance with the guidelines established in the Operations and Maintenance Manuals Major structural components including trailer tongue and boom weldments are warranted for five years against defects due to material or workmanship Bil Jax will at its option repair or replace any unit or component part that fails to function properly during normal use The warranty does not apply if the lift and or its components have been altered changed or repaired without the consent of Bil Jax Repairs damage or defects resulting from the following are not covered under the terms of the warranty negligence misuse accidental damage inadequate or improper maintenance acts of nature damage caused by chemicals or abrasive materials and normal wear and tear such as rust or corrosion Components not covered under this warranty include tires filters covers and routine maintenance items Components not manufactured by Bil Jax are covered be 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 any person product or thing Bil
72. Sol C t Fuel Sol Fan Platform Plug Amp Housing 770680 1 A 00716 WIRE HARNESSES CE a Down Relay NC EX amp A Motor Controller Motor Controller Aux Plug Manifold Start Engine Stop Engine Spark Start Sol Fuel Sol 89 Label Wires Both Ends 12020786 6 Pin Male Conn 1208089040 Male Term 12015323 Green Wire Seal 3 Pin Male Conn 12089040 Male Term 12015323 12020926 6 Pin FM Conn 12089188 FM Term 12015323 Stripe wire to 4 3 Pin Female Conn 12089188 Female Term 12015323 12020827 3 Pin Male Conn 12089040 Male Term 12015323 Green Wire Seal 12020829 3 Pin Female Conn 12089188 Female Term 12015323 Strip Wires 3 90 MANIFOLD WIRE HARNESS A 00785 Re A 00785 A 00785 Rev 156 13 2 16 Cond 18ga Wire SOOW or Equivalent Deutsch Term 0462 201 16141 GAS ENGINE WIRE HARNESS A 01034 A 01034 Rev Deutsch B DT06 2S Wir
73. UNG DAMAGE amp 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 WATER FOR AT LEAST 15 MINUTES Inhalation REMOVE TO FRESH AIR IF BREATHING IS DIFFICULT GIVE OXYGEN Ingestion GIVE MILK TO DRINK DO NOT INDUCE VOMITTING CALL PHYSICIAN SECTION VI REACTIVITY DATA Stability STABLE Conditions to Avoid N A Incompatibility AVOID COMBUSTIBLES ORGANIC MATERIALS AND STRONG REDUCING AGENTS Hazardous Decomposition Products SULFUR TRIOXIDE CARBON MONOXIDE SULFURIC ACID FUMES amp 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 amp 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 amp 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 amp MAY ALSO RELEASE FLAMMABLE HYDROGEN GAS THIS REACTION IS INTENSIFIED WHEN DILUTED NF
74. Univ QD FM 6FMNPT B09 00 0029 Fitting QD DF Series M 6FMNPT B09 00 0030 Fitting QD J Series M 6FMNPT 101 102 LOAD SENSE ASSEMBLY OPTION A 01846 LOAD SENSE ASSEMBLY PARTS LIST Item No Part No Description Qty 1 A 01977 Platform Mount Weldment LS 1 2 A 00982 Load Sense Weldment 1 3 0096 0055 Cap Screw M12 x 190 1 4 0096 0042 Hex Nut Self Locking M12 3 5 A 00988 1 Load Cell 1 6 0096 0089 Cap Screw M12 x 65 2 7 A 00990A Load Sense Spacer A 1 8 A 00990B Load Sense Spacer B 2 9 0096 0069 Cap Screw M10x 75 1 10 0096 0041 Hex Nut Self Locking M10 1 11 A 00033 Bearing 4 12 A 00994 LS Roller Bar 1 13 A 00995 LS Roller 2 14 0096 0046 Washer Flat M12 4 15 0090 0147 Cotter Pin 2 16 0096 0009 Cap Screw M8 x 10 2 17 A 00038 Ramp 4 18 0096 0003 Flat Head Cap Screw M6 x 20 8 19 0096 0039 Hex Nut Self Locking M6 8 20 A 00992 Load Sense Interface Not Pictured 1 21 0096 0085 Cap Screw M6 x 60 22 0096 0039 Hex Nut Self Locking M6 103 MATERIAL LIFT HOOK ASSEMBLY OPTION A 01846 3 O E MATERIAL LIFT HOOK PARTS LIST Item No Part No Description Qty 1 A 00480 Material Lift Weldment 1 2 A 00155 Lift Hook Storage Bracket 1 3 A 01156 Bracket Clamp 1 4
75. VERSE 2 C28 096 SHORTED CIRCUIT REVERSE 2 C28 097 OPEN CIRCUIT TORQUE H L C29 098 SHORTED CIRCUIT TORQUE H L C29 099 OPEN CIRCUIT TORQUE H L C30 100 SHORTED CIRCUIT TORQUE H L C30 Error Explanation amp Possible Causes The Lower Control has detected an open circuit on the Reverse 2 C28 solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Reverse 2 C28 solenoid wiring 2 Faulty Reverse 2 C28 solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the Reverse 2 C28 solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Reverse 2 C28 solenoid wiring 2 Faulty Reverse 2 C28 solenoid 3 Faulty Lower Control The Lower Control has detected an open circuit on the Torque H L C29 solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Torque C29 solenoid wiring 2 Faulty Torque C29 solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the Torque H L C29 solenoid output when it was energized during startup self diagnostics Possible causes
76. Weldment Upper Boom Jib Boom Platform Hydraulic Pump Boom and Rotation Hydraulic Lines Outrigger Hydraulic Lines Trailer Hydraulic Lines 4WD Manifold Assembly 4WD Assembly Description Wire Harnesses ANSI Wire Harnesses CE Manifold Wire Harness Gas Engine Wire Harness Choke Throttle Solenoid Wire Harness Engine Relays Wire Harness ATC Fuse Holder Start Stop Run Wire Harness Generator Switcher Box Wire Assembly Fan IEC Cord Male ANSI Generator 110V Wire Harness Oil Switch Cord Assembly 110V Generator Cord Assembly Generator Switch Cord Assembly Switch Jumper Cord Assembly 110V AC Plug Female Switcher Box CE Models 220V Generator Wire Harness CE Models Cord Assembly 220V AC Plug Female CE Models Pump And Cylinder Wire Harnesses Outrigger Coil and Switches Wire Harness Analog Harness Power Harness 110 VAC Tower Platform Harness Secondary Cylinder Wire Jib Wire Platform Ground Communication Cable Water Line to Platform Air Line to Platform Load Sense Material Lift Hook Battery Layout Manual Platform Rotate 100 100 100 101 101 102 104 105 106 41 OUTRIGGER ASSEMBLY 42 OUTRIGGER ASSEMBLY PARTS LIST Item No Part No Description Qty 1 A 00120 Outrigger Weldment 1 2 A 00046 Grommet
77. act Check for faulty boom retract circuit on power up solenoid coil wiring 036 SHORTED CIRCUIT Excessive load detected in retract circuit on Check for faulty boom retract RETRACT power up solenoid coil wiring 037 OPEN CIRCUIT PLATFORM A load of less than 70mA detected in platform Check for faulty level up solenoid LEVEL UP level up circuit on power up coil wiring 038 SHORTED CIRCUIT Excessive load detected in platform level up Check for faulty level up solenoid PLATFORM LEVEL UP circuit on power up coil wiring 039 OPEN CIRCUIT PLATFORM A load of less than 70mA detected in platform Check for faulty level down LEVEL DOWN level down circuit on power up solenoid coil wiring 040 SHORTED CIRCUIT Excessive load detected in platform level down Check for faulty level down PLATFORM LEVEL DOWN circuit on power up solenoid coil wiring 041 OPEN CIRCUIT PLATFORM A load of less than 70mA detected in platform Check for faulty boom rotate CW CW circuit on power up solenoid coil wiring 042 SHORTED CIRCUIT Excessive load detected in platform CW circuit Check for faulty boom rotate PLATFORM CW on power up solenoid coil wiring 043 OPEN CIRCUIT PLATFORM A load of less than 70mA detected in platform Check for faulty boom rotate CCW CCW circuit on power up solenoid coil wiring 044 SHORTED CIRCUIT Excessive load detected in platform CCW circuit Check for faulty boom rotate PLATFORM CCW on power up solenoid coil wiring 045 OPEN CIRCUIT TURNTABLE A lo
78. ad of less than 70mA detected in rotate CW Check for faulty rotate CW CW circuit on power up solenoid coil wiring 046 SHORTED CIRCUIT Excessive load detected in rotate CW circuit on Check for faulty rotate CW TURNTABLE CW power up solenoid coil wiring 047 OPEN CIRCUIT TURNTABLE A load of less than 70mA detected in rotate CCW Check for faulty rotate CCW CCW circuit on power up solenoid coil wiring 048 SHORTED CIRCUIT Excessive load detected in rotate CCW circuit on Check for faulty rotate CCW TURNTABLE CCW power up solenoid coil wiring 049 OPEN CIRCUIT OUTRIGGER A load of less than 70mA detected in outrigger Check for faulty outrigger retract RETRACT retract circuit on power up solenoid coil wiring 050 SHORTED CIRCUIT Excessive load was detected when Outrigger Check for faulty outrigger retract OUTRIGGER RETRACT Retract circuit was energized solenoid coil wiring 051 OPEN CIRCUIT OUTRIGGER A load of less than 70mA detected in outrigger Check for faulty outrigger extend EXTEND retract circuit on power up solenoid coil wiring 052 SHORTED CIRCUIT Excessive load was detected in outrigger extend Check for faulty outrigger extend OUTRIGGER EXTEND circuit on power up solenoid coil wiring 053 OPEN CIRCUIT A load of less than 70mA detected in left front Check for faulty solenoid LF OUTRIGGER outrigger circuit on power up coil wiring at outrigger 054 SHORTED CIRCUIT Excessive load was detected in left front Check for faulty solenoid LF OUT
79. age a Check bolts for wear or damage a With the boom lift fully retracted measure the distance between the slew ring gear and the horizontal plate above Use a 2 inch 50 mm caliper or bore micrometer Record the measurement Figure 3 4 Place a 175 Ib 65 kg load on the boom lift platform Measure the distance between the slew ring and the horizontal plate above Record the measurement a If the difference in measurements is greater than 25 in 6 35 mm the slew ring bearing should be replaced Contact manufacturer for replacement instructions and assistance MEASURE i HERE SLEW RING Figure 3 4 Slew Ring Position Measurement STRUCTURAL INSPECTION A comprehensive structural inspection of the unit shall be performed under any of the following conditions a Ten years from the date of manufacture and every five years thereafter Q After any actual suspected or potential damage is sustained that could affect the structural integrity or stability of the aerial platform Q After a change in ownership Owners should provide a complete service history when reselling the unit The structural inspection shall include the following considerations a service history of the unit including hours of service work performed and environmental conditions The inspection and maintenance record of the unit The effectiveness of all controls and components A visual inspection
80. age solenoid wiring Replace Drive Engage solenoid Replace Lower Control Repair or replace Left Wheel Forward solenoid wiring Replace Left Wheel Forward solenoid Replace Lower Control Repair or replace Left Wheel Forward solenoid wiring Replace Left Wheel Forward solenoid Replace Lower Control Repair or replace Left Wheel Reverse solenoid wiring Replace Left Wheel Reverse solenoid Replace Lower Control Repair or replace Left Wheel Reverse solenoid wiring Replace Left Wheel Reverse solenoid Replace Lower Control 124 Error Message Displayed 089 OPEN CIRCUIT RIGHT WHEEL FORWARD 090 SHORTED CIRCUIT RIGHT WHEEL FORWARD 091 OPEN CIRGUIT RIGHT WHEEL REVERSE 092 SHORTED CIRCUIT RIGHT WHEEL REVERSE Error Explanation 8 Possible Causes The Lower Control has detected an open circuit on the Right Wheel Forward solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Right Wheel Forward solenoid wiring 2 Faulty Right Wheel Forward solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the Right Wheel Forward solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Right Wheel Forward solenoid wiring 2 Faulty Right Wheel Forward solenoid 3 Faulty Lower
81. ap Screw 5 8 11 x 2 3 4 Grade 8 19 10 0096 0044 Hex Nut Self Locking M16 16 11 A 00350 Rotation Stop Assembly 1 12 0096 0021 Cap Screw M12 x 45 2 13 0096 0042 Hex Nut Self Locking M12 2 55 LIMIT SWITCH ASSEMBLY 56 LIMIT SWITCH ASSEMBLY PARTS LIST Item No Part No Description Qty 1 A 01190L Switch Plate Left 1 2 A 01190R Switch Plate Right 1 3 0096 0016 Cap Screw M10 x 25 4 4 B01 03 0078 Limit Switch NO 1 5 B01 03 0079 Limit Switch NC 1 6 A 01191 Switch Cam Weldment 1 7 A 01195 Switch Cam Top Slide 1 8 0096 0012 Flat Head Cap Screw M8 x 25 6 9 A 01196 Tension Spring 3 10 0096 0078 Cap Screw M6 x 80 1 11 0096 0039 Hex Nut Self Locking M6 2 12 0096 0085 Cap Screw M6 x 60 1 13 0090 0232 Machine Screw 10 24 x 5 8 4 14 0090 0182 Hex Nut Self Locking 10 24 4 15 0096 0081 Cap Screw M8 x 80 2 16 A 01157 Switch Slide Not Pictured 2 17 0096 0040 Hex Nut Self Locking M8 8 18 0096 0017 Cap Screw M10 x 30 4 19 A 01197 Jib Slide Pad 2 20 0096 0041 Hex Nut Self Locking M10 8 57 CONTROL COMPARTMENT ASSEMBLY 58 CONTROL COMPARTMENT ASSEMBLY PARTS LIST Item No Part No Description Qty 1 A 00712 Lower Control Box 1 2 A 00233 Lower Control Mount 1
82. arp Pungent Odor SECTION IV FIRE AND EXPLOSION HAZARD DATA Flash Point Not Combustible Auto Ignition Temperature N A Flammability Limits in Air by Volume N A Extinguishing Media Dry Chemical Carbon Dioxide Water Fog Water Special Fire Fighting Procedures Sulfuric Acid Fumes Sulfur Dioxide Gas or Carbon Monoxide may be released when acid decomposes Wear NIOSH approved self contained breathing apparatus Unusual Hazards Water applied to sulfuric acid generates heat and causes acid to splatter Wear full cover acid resistant clothing Sulfuric acid reacts violently with metals nitrates chlorates carbides fulminates picrates and other organic materials Reacts with most metals to yield explosive flammable hydrogen gas This reaction is intensified when sulfuric acid is diluted with water to form battery electrolyte 35 BIL JAX 45XA MATERIAL SAFETY DATA SHEET FOR LEAD ACID BATTERIES WET FILLED WITH ACID Continued SECTION V HEALTH HAZARD DATA Primary Routes of Entry Inhalation YES Skin YES Ingestion YES Health Hazards Acute EYES SKIN RESPIRATORY SYSTEM amp DIGESTIVE SYSTEM Chronic EYES SKIN RESPIRATORY SYSTEM amp 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 L
83. cals attached to the machine ALWAYS keep the safety bar lowered unless personnel are entering or exiting the work platform ALWAYS keep personnel and obstructions clear of the machine when repositioning boom or basket BIL JAX 45XA ALWAYS cordon the area surrounding the outriggers to keep personnel vehicles and moving equipment away from the machine while in use ALWAYS stay clear of overhead obstructions including wires and cables ALWAYS engage boom travel latches before towing trailer ALWAYS exercise caution when rotating the boom from the ground control station ALWAYS watch for personnel inside the radius of the turntable and boom arm when rotating the boom lift from the ground or platform controls ALWAYS remove personnel from the boom lift before attempting to free an elevated platform that has become caught or snagged on an adjacent structure or obstacle NEVER operate the machine on any surface other than firm and level ground NEVER operate the machine from a position on truckbeds trailers floating vessels or scaffolding without written approval from the manufacturer NEVER operate lift functions on slopes exceeding 12 52 NEVER allow electrode contact with any part of the machine while welding from the platform NEVER use the machine as a ground for welding NEVER operate without the outriggers fully extended or when the machine is not level NEVER position an elevated platform against another ob
84. condition must be removed and second the power must be cycled off then back on NOTE During this error condition the Platform Control Engine On LED will blink a 2 blink error code and the Lower Control Power LED will blink a 2 blink error code Possible causes include 1 Lower Control incorrectly configured 2 Faulty Boom Cable 3 Faulty Upper Control 4 Faulty Lower Control The Lower Control has lost communication with the 1 PC 2 3 This is a self clearing error When error condition is 4 removed error is cleared NOTE During this error condition the Lower Control Power LED will blink a 4 blink error code Possible causes include 1 Faulty cable between PC and Lower Control 2 PC s program is not running 3 Faulty PC 4 Faulty Lower Control What To Check amp Corrective Action To Clear Error Check outrigger and level LED indicators and if required re level machine Reduce boom load Reduce boom load Correctly configure Lower Control Replace Boom Cable Replace Upper Control Replace Lower Control Correctly configure Lower Control Replace Boom Cable Replace Upper Control Replace Lower Control Replace cable between PC and Lower Control Disconnect PC or run PC s program Replace PC Replace Lower Control 109 Error Message Displayed 005 PLATFORM CONTROL HAS STUCK KEY 006 DRIVE CONTROL HAS STUCK KEY 007 DRIVE CONTROL HAS STUCK JOYSTI
85. cted excessive current on the Turntable CW solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Turntable CW solenoid wiring 2 Faulty Turntable CW solenoid 3 Faulty Lower Control The Lower Control has detected an open circuit on the Turntable CCW solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Turntable CCW solenoid wiring 2 Faulty Turntable CCW solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the Turntable CCW solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Turntable CCW solenoid wiring 2 Faulty Turntable CCW solenoid 3 Faulty Lower Control What To Check amp Corrective Action To Clear Error Repair or replace Platform CCW solenoid wiring Replace Platform CCW solenoid Replace Lower Control Repair or replace Platform CCW solenoid wiring Replace Platform CCW solenoid Replace Lower Control Repair or replace Turntable CW solenoid wiring Replace Turntable CW solenoid Replace Lower Control Repair or replace Turntable CW solenoid wiring Replace Turntable CW solenoid Replace Lower Control Repair or replace Turntable CCW solenoid wiring Replace Turntable CCW solenoid Replace Lower Control Repair
86. curs 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 ALWAYS replace batteries using only parts recommended by manufacturer ALWAYS use only batteries with sealed caps over cells NEVER smoke while servicing batteries NEVER charge batteries near spark or open flame NEVER allow batteries to overcharge and boil NEVER short across battery posts to check for current NEVER break a live circuit at the battery NEVER disconnect battery from charger while charger is connected to a live power source NEVER jumpstart other vehicles using the boom lift batteries BIL JAX 45XA DAMAGED EQUIPMENT POLICY Safety Statement At Bil Jax we are dedicated to the safety of all users of our products 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 Such damage 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 suspected internal damage to the structure Bil Jax may require that the lift be returned to our facility for reconditioning For any que
87. d Replace Lower Control Repair or replace Platform CW solenoid wiring Replace Platform CW solenoid Replace Lower Control 116 Error Message Displayed 043 OPEN CIRCUIT PLATFORM CCW 044 SHORTED CIRCUIT PLATFORM CCW 045 OPEN CIRCUIT TURNTABLE CW 046 SHORTED CIRCUIT TURNTABLE CW 047 OPEN CIRCUIT TURNTABLE CCW 048 SHORTED CIRCUIT TURNTABLE CCW Error Explanation 8 Possible Causes The Lower Control has detected an open circuit on the Platform CCW solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Platform CCW solenoid wiring 2 Faulty Platform CCW solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the Platform CW solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Platform CCW solenoid wiring 2 Faulty Platform CCW solenoid 3 Faulty Lower Control The Lower Control has detected an open circuit on the Turntable CW solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Turntable CW solenoid wiring 2 Faulty Turntable CW solenoid 3 Faulty Lower Control The Lower Control has dete
88. d increase the surface area of the platform Increasing the area exposed to the wind may decrease machine stability NEVER attach overhanging loads when raising or lowering the platform NEVER use the boom or platform to push or pull or to lift any part of the machine NEVER use the boom or platform to place a load against any structure materials or equipment NEVER climb on the boom NEVER leave an elevated platform unattended NEVER leave the keys in the boom lift while unattended or not in use Drive Safety ALWAYS maintain an awareness of limited sight and blind spots when operating drive functions ALWAYS limit travel speed according to surface conditions slope location of personnel and obstructions and any other factors which may result in collision NEVER operate drive functions on slopes exceeding 20 NEVER engage in stunt driving horseplay or any other behavior considered unsafe according to employer job site and or government regulations NEVER operate the internal combustion engine in an area that is not properly ventilated NEVER fuel the internal combustion engine while smoking or while near spark or open flame MAINTENANCE SAFETY Ensure the following general safety precautions are followed while performing maintenance on the articulating boom lift General Maintenance ALWAYS perform maintenance procedures according to manufacturer s guidelines NEVER disregard or bypass proper maintenance
89. de 1 Faulty Proportional valve solenoid wiring 2 Faulty Proportional valve solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the Proportional valve solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Proportional valve solenoid wiring 2 Faulty Proportional valve solenoid 3 Faulty Lower Control The Lower Control has detected an open circuit on the Motor Control Enable output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit This load is less than 70mA and this error is suppressed to avoid false errors Possible causes include 1 Faulty Motor Control Enable wiring 2 Faulty Motor Control 3 Faulty Lower Control The Lower Control has detected excessive current on the Motor Control Enable output when it was energized during startup self diagnostics Possible causes include 1 Faulty Motor Control Enable wiring 2 Faulty Motor Control 3 Faulty Lower Control 1 2 3 What To Check amp Corrective Action To Clear Error Repair or replace Engine Stop relay wiring Replace Engine Stop relay Replace Lower Control Repair or replace Engine Stop relay wiring Replace Engine Stop relay Replace Lower Control Repair or replace Proportional valve solenoid wiring Replace Proportional valve solenoid Replace Lower Control Repair or replace
90. e 24 B02 01 0381 4 x 25 Hydraulic Hose FITTINGS Part No Description Qty B02 02 0259 6 MORFS 6 MORB STR 10 B02 02 0293 8 MORFS 8 MORB STR 1 B02 02 0260 6 MORFS 6 MORB 90 6 B02 02 0287 4 MORFS 4 MORB STR 2 B02 02 0288 4 MORFS 4 MORB 90 6 B02 02 0289 4 MORFS Tee 2 B02 02 0294 6 MORFS 6 MORB 90 L 1 B02 02 0295 12 MORB 10 FMORB 1 B02 02 0296 10 MORFS 10 MORB 10 MORFS Tee 1 B02 02 0297 10 MORFS 10 FMORFS 90 1 B02 02 0298 8 MORFS 12 MORB STR 1 B02 02 0299 8 MORFS 10 MORB 45 2 B02 02 0300 10 MORFS 12 MORB 90 1 B02 02 0303 10 MORB Plug 1 B02 02 0304 10 MORB 6 FMORB 4 B02 02 0305 6 MORFS 10 MORB STR 4 B02 02 0237 4 MORFS 6 MORB STR 2 B02 02 0307 8 MORFS Tee 1 B02 02 0308 4 MORB Plug 1 B02 02 0309 8MORFS 12 MORB 90 2 85 MANIFOLD ASSEMBLY 4WD A 01033 o ILI FAO DER a q AEZ 2 Lo N NS Ni Z lt I ech Lt NA 5 22 ip LT T A Ee Fi y m p S 60004 OF CLO 86 MANIFOLD ASSEMBLY PARTS LIST Item No Part No Description Qty 1 02 15 0516 Valve Cartridge NC 2 2 B02 14 0111 Relief Valve 3000 psi 1 3 B02 14 0118 Relief Valve 600 psi 1 4 B02 14 0092 Check Valve 8 5 B02 15
91. e Platform Level Down solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Platform Level Down solenoid wiring 2 Faulty Platform Level Down solenoid 3 Faulty Lower Control The Lower Control has detected an open circuit on the Platform CW solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Platform CW solenoid wiring 2 Faulty Platform CW solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the Platform CW solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Platform CW solenoid wiring 2 Faulty Platform CW solenoid 3 Faulty Lower Control What To Check amp Corrective Action To Clear Error Repair or replace Platform Level Up solenoid wiring Replace Platform Level Up solenoid Replace Lower Control Repair or replace Platform Level Up solenoid wiring Replace Platform Level Up solenoid Replace Lower Control Repair or replace Platform Level Down solenoid wiring Replace Platform Level Down solenoid Replace Lower Control Repair or replace Platform Level Down solenoid wiring Replace Platform Level Down solenoid Replace Lower Control Repair or replace Platform CW solenoid wiring Replace Platform CW solenoi
92. er Remove the pivot pin using a hammer and a brass or hardwood drift Fully retract the cylinder Turn key to the off position and remove the key Tag and number all hydraulic hoses that attach to the cylinder valve block Use a marker to label the valve block ports with the appropriate hose numbers 4 CYLINDER REPLACEMENT Unplug the cylinder valve solenoid Place absorbent cloths below the cylinder ports and detach hydraulic hoses from the cylinder Elevate hoses to prevent leakage Plug or cap exposed hose fittings and cylinder ports At the base of the cylinder unbolt and remove retainer plate from each side of the pivot pin Remove the pivot pin using a hammer and a brass or hardwood drift Lift and remove the cylinder using an overhead hoist and lifting straps Replace or reinstall the cylinder by following the above instructions in the reverse order of removal Actuate the hydraulic system and check for leakage Tighten hydraulic fittings as needed Bleed trapped air from the hydraulic system by raising and lowering the boom with the reservoir fill port cap on but not tightened Allow several minutes for trapped air to escape Repeat as needed CYLINDER ROD PIN GUARD CYLINDER ROD GUARD BOLTS CYLINDER RETAINING PLATES Figure 4 2 Outrigger Cylinder Replacement 27 BIL JAX 45XA 28 D REPLACEMENT DECALS Decals contain informat
93. es 2 Pin Plug Connected W2S Wedge amp Sealed LT ET pr E B pr B Fn Connected C C26 xi amp Sealed i 1 Stripe wire to 12 Delphi Weather Pack CRIBL HOI Press Sw z gt gt 120 10 18ga 10 Cond Wire r OrBL Oil Press 5 f COEL Of Press Sw 2 Pin Female Conn 12089188 Female Term CWRIBI Gen Switch 12015323 r Green Wire Seal Delphi Weather Pack 12010973 2 Pin Male Conn 12089040 Male Term SOOW or Equivalent Label Both Ends Black Choke 12015323 Green Wire Seal Delphi Weather Pack 12020830 4 Pin Male Conn 12089040 Strip Wires 6 Male Term 12015323 CHOKE THROTTLE SOLENOID WIRE HARNESS A 01042 Weather Pack Put Wires FM Term i 12089188 16 Cable Seal Split 12015323 tubing FM Housing 12015792 ps zt ends 20 18ga TXL Or Equivalent ENGINE RELAYS WIRE HARNESS A 01044 Solderinline amp i Resistor i 22k Ohm i i Wire NE S SR 4 ee Se Color Wire 7 10 Split Length y pe i Tube Wrap OO DO n Ya Male Spade Run yo Tape At i Delphi Weather Pack I Female Spade Each End i Male Term 12089040 i Green Seal 12015323 al Female Spade 52 7 Pua Sw ex 1 2 Female Spade
94. ess of potential health and safety hazards MATERIAL SAFETY DATA SHEET FOR LEAD ACID BATTERIES WET FILLED WITH ACID SECTION 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 2504 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 of the Superfund Amendments and Reauthorization Act The items are covered in an exemption as a Manufactured 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 amp Odor Clear Liquid with Sh
95. he Lower Control has detected a rapidly changing output from the level sensor This is a self clearing error When error condition is removed error is cleared Possible causes include 1 Faulty Level Sensor 2 Faulty Level Sensor wiring 3 Faulty Lower Control An attempt was made to drive machine without engaging the trailer brake This is a self clearing error When error condition is removed error is cleared NOTE This error only occurs on machines equipped with the Drive amp Set option Possible causes include 1 Trailer brake not engaged 2 Faulty trailer brake switch 3 Faulty trailer brake switch wiring 4 Faulty Lower Control The Lower Control has detected the angle sensor output is out of range This is a self clearing error When error condition is removed error is cleared NOTE This error only occurs on machines equipped with the Moment Sense option Possible causes include 1 Faulty angle sensor 2 Faulty angle sensor wiring 3 Lower Control incorrectly configured 4 Faultv Lower Control The Lower Control has detected the pressure sensor output is out of range This is a self clearing error When error condition is removed error is cleared NOTE This error only occurs on machines equipped with the Moment Sense option Possible causes include 1 Faulty pressure sensor 2 Faulty pressure sensor wiring 3 Lower Control incorrectly configured 4 Faulty Lower Control The Lo
96. il level should be visible in but not above the sight gauge If the hydraulic oil level is not visible to at least half way up the sight gauge Figure 3 2 add clean hydraulic fluid as necessary while all booms and outriggers are fully retracted and stowed Pour slowly to avoid creating air pockets in the reservoir Do not fill above sight gauge Overfilling the hydraulic reservoir may cause damage to hydraulic lines and may result in equipment malfunction A CAUTION Do not mix hydraulic oils Do not add any fluid to the hydraulic system that is not expressly recommended by the manufacturer Adding unauthorized fluids to the hydraulic system may cause damage to equipment a a The hydraulic reservoir is originally filled with Dexron II Mercon ATF with a viscosity rating of 175 Manufacturer recommends a higher viscosity hydraulic oil when operating equipment routinely in extreme climates 1 Filter Element Fill Port 3 Sight Gauge Figure 3 2 Hydraulic Reservoir 3 EQUIPMENT MAINTENANCE 15 BIL JAX 45XA WEEKLY SERVICE CHECKS Perform the following service checks at least once each week in addition to all recommended Daily Service Checks Check Battery electrolyte level a If electrolyte level is low add enough water to bring the electrolyte level to the top of the plates a If batteries are fully charged raise electrolyte level to full mark in each cell Inspect all electrical wiring
97. include 1 Faulty AC Switch wiring 2 Faulty AC Switch 3 Faulty Lower Control The Lower Control has detected excessive current on the AC Switch output when it was energized during startup self diagnostics Possible causes include 1 Faulty AC Switch wiring 2 Faulty AC Switch 3 Faulty Lower Control The Lower Control has detected an open circuit on the Strobe output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit This load is less than 70mA and this error is suppressed to avoid false errors Possible causes include 1 Faulty Strobe wiring 2 Faulty Strobe 3 Faulty Lower Control The Lower Control has detected excessive current on the Strobe output when it was energized during startup self diagnostics Possible causes include 1 Faulty Strobe wiring 2 Faulty Strobe 3 Faulty Lower Control 1 1 2 3 What To Check amp Corrective Action To Clear Error Replace Lower Control Replace Lower Control Repair or replace AC Switch wiring Replace AC Switch Replace Lower Control Repair or replace AC Switch wiring Replace AC Switch Replace Lower Control Repair or replace Strobe wiring Replace Strobe Replace Lower Control Repair or replace Strobe wiring Replace Strobe Replace Lower Control 122 Error Message Displayed 079 OPEN CIRCUIT DRIVE PWM 080 SHORTED CIRCUIT DRIVE PWM 081 OPEN CIRCUIT DR
98. ing Radius Inside Outside Platform Dimensions Height Length Width US CE Stowed Dimensions Height Length Width 51 ft 15 7m 45 ft 13 7m 27 ft 82m 21 ft 6 4 m 500 Ibs 227 kg 440 Ibs 200 kg 2 4 300 lbs 1 950 kg 7002 Non Continuous 12 52 48 8 ft 8 in 27m 11 ft 3 35 16 ft 8 in 5m 3 ft 7 in 1 1m 2ft6in 0 8 m 5 ft 4 ft 1 5 m 1 2 m 6 ft 4 in 2 0 m 19 ft 2 in 5 8 m 5 ft 5 in 1 7m SERIAL NUMBER 2 SPECIFICATIONS Outrigger Footprint Length Width Footpad Diameter Brake Speed Gas Power DC Power Tire Size Tire Pressure Control System Battery Battery Charger Gas Engine Hydraulic Pressure Reservoir Capacity Hydraulic System Capacity Hydraulic Oil Standard Platform Rotation Type Optional Maximum Decibel Level DC Mode Ground DC Mode Platform Gas Mode Ground Gas Mode Platform Localized Pressure per Outrigger Operation Temperature Range Max Pressure Per Tire Floor Loading 12 ft 2 in 3 7m 11 ft 4 in 3 4m 12 5 in 0 3 m Spring Applied 3 75 mph 6 km h 2 mph 3 2 km h 26 x 12 bar lug tires 20 PSI 140 kPa 24V DC 4 x 6V 245 amp hr 110 120 Volt Kawasaki 21 HP 3 000 psi 20 684 kPa 4 3 Gallons 16 3 L 6 3 Gallons 23 9 L Dexron ATF 90 Manual 60 dB 55 dB 70 dB 65 dB 25 PSI 1 8 kg cm 176 5 kPa 20 to 110 Fahrenheit 29 to 43 Celsius 35 P
99. ion that is required for the safe and proper use of the aerial work platform Decals should be considered necessary components of the machine and should be checked before each use to verify that they are correctly attached and legible Use the following guides to find the correct location of all decals 29 BIL JAX 45XA Decal No 0202 0523 B06 00 0034 B06 00 0037 B06 00 0062 B06 00 0068 B06 00 0161B B06 00 0403 B06 00 0404 B06 00 0405 B06 00 0471 B06 00 0473 B06 00 0474 06 00 0475 06 00 0477 06 00 0481 06 00 0482 30 Table 5 1 Decal Descriptions Decal Description Made in USA DANGER Electric Shock Lubricate Semi Annually NOTICE AC Power NOTICE Hydraulic System Oil Bil Jax Logo Black Transfer NOTICE Emergency Lowering WARNING Outrigger Crush Toe WARNING Pinch Point DANGER Before Use Main Instruction Hazards Platform NOTICE Operator s Manual Missing NOTICE Max Load WARNING Read Understand Operator s Manual WARNING Forklift Pockets CAUTION Transport Safety Latch DANGER Electrocution Hazard Qty _ O o PM Decal No Decal Description Qty B06 00 0484 DANGER Battery Charger Safety 1 B06 00 0494 NOTICE Hazardous Materials 1 B06 00 0495 CAUTION Compartment Access 2 Restricted B06 00 0503 NOTICE Handle Applications 1 B06 00 0504 NOTICE Emergency Hand Pump 1 DANGER Before Use Main B06 00 0505 hstruction Hazards ground B06
100. ive current on the Secondary Down solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Secondary Down solenoid wiring 2 Faulty Secondary Down solenoid 3 Faulty Lower Control The Lower Control has detected an open circuit on the Jib Up solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Jib Up solenoid wiring 2 Faulty Jib Up solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the Jib Up solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Jib Up solenoid wiring 2 Faulty Jib Up solenoid 3 Faulty Lower Control jh on What To Check amp Corrective Action To Clear Error Repair or replace Primary Down solenoid wiring Replace Primary Down solenoid Replace Lower Control Repair or replace Secondary Up solenoid wiring Replace Secondary Up solenoid Replace Lower Control Repair or replace Secondary Up solenoid wiring Replace Secondary Up solenoid Replace Lower Control Repair or replace Secondary Down solenoid wiring Replace Secondary Down solenoid Replace Lower Control Repair or replace Secondary Down solenoid wiring Replace Secondary Down solenoid Replace Lower Control Repair or replace Jib Up sole
101. ject to steady the platform NEVER override or bypass the manufacturer s safety devices NEVER attach a safety harness to an adjacent structure pole or to nearby equipment while working from the boom platform NEVER raise the outriggers while boom is raised or extended NEVER sit stand or climb on cage bars ALWAYS keep both feet firmly on the work cage floor when working from an elevated platform NEVER attempt to increase the working height with boxes ladders stools or any other materials NEVER operate this equipment when exposed to high winds thunderstorms ice or any weather conditions that would compromise operator safety NEVER operate boom lift in conditions where wind speeds exceed 12 5 m sec 45 km h or 28 mph High winds may affect stability and boom operation NEVER allow ropes electric cords hoses or other equipment to become entangled in the machine while raising or lowering platform NEVER exceed the load limits set by the manufacturer Use only the Material Lifting Hook supplied as an option and manufactured by Bil Jax when lifting materials Safely stow all tools and equipment NEVER exceed load ratings by transferring loads to the lift at elevated heights NEVER use the platform to lift a load that exceeds the platform dimensions NEVER lift a load in such a way that the center of gravity is higher than the top guardrail of the platform NEVER modify the platform or carry materials that woul
102. lic Reservoir 15 Figure 3 3 Wheel Nut Tightening Sequence 17 Figure 3 4 Slew Ring Position Measurement 18 Figure 4 1 Lift Cylinder Replacement 26 Figure 4 2 Outrigger Cylinder Replacement 27 Figure 5 1 Decal Locations 31 Figure 5 2 Decal Locations CE 33 LIST OF TABLES Table 1 1 Minimum Safe Approach Distances 5 Table 3 2 Troubleshooting Steps 20 Table 3 3 Error Code Definitions 21 Table 5 1 Replacement Decal Descriptions 30 Table 5 2 Replacement Decal Descriptions CE 32 1 SAFETY Proper training is required for the safe operation of any mechanical device Failure to follow all instructions and safety precautions in this manual and attached to the lift will result in death or personal injury Prior to Operation Q Read understand and obey all instructions and safety precautions in this manual and attached to the lift Q Read understand and obey all applicable government regulations Become familiar with the proper use of all controls a Inexperienced users should receive instruction before attempting to operate or maintain the machine D The use of intelligence and common sense is the best practice when following any safety policy BIL JAX 45XA LEGEND SAFETY ADVISORIES The following safety advisories are used throughout this manual to indicate specific hazards when operating or maintaining the machine Read understand and obey all safety advisories to prevent improper service damage to equipment personal
103. n it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Left Wheel Forward solenoid wiring 2 Faulty Left Wheel Forward solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the Left Wheel Forward solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Left Wheel Forward solenoid wiring 2 Faulty Left Wheel Forward solenoid 3 Faulty Lower Control The Lower Control has detected an open circuit on the Left Wheel Reverse solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Left Wheel Reverse solenoid wiring 2 Faulty Left Wheel Reverse solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the Left Wheel Reverse solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Left Wheel Reverse solenoid wiring 2 Faulty Left Wheel Reverse solenoid 3 Faulty Lower Control 1 on What To Check amp Corrective Action To Clear Error Repair or replace Drive Engage solenoid wiring Replace Drive Engage solenoid Replace Lower Control Repair or replace Drive Eng
104. nd to be defective under warranty 4 After completing repairs submit warranty claim form and defective parts to Bil Jax Warranty claim form and parts must be received within 30 days of claim in order to be eligible for credit RMA number must be referenced on warranty claim form Returned parts are to be sent prepaid and will be credited when part is received and verified Warranty labor rate will be paid at current rate set by Bil Jax The amount of labor hours reimbursed will be determined by Bil Jax and will be limited to 4 hours unless approved by Bil Jax Failure to follow the warranty claims process may result in delay in processing claim or denial of the claim Bil Jax reserves the right to limit or adjust warranty claims with regard to parts labor and travel time Components purchased from suppliers other than Bil Jax are not covered under the terms of this warranty 3 EQUIPMENT MAINTENANCE Performing the appropriate maintenance procedures will extend the life of the boom lift and will help ensure the safety of personnel operating the equipment Repair replacement or adjustment of any hydraulic or electrical control device should be performed only by fully trained and authorized personnel These include but are not limited to hydraulic load valves hydraulic flow control valves solenoid valves and limit switches These are safety related controls Improper adjustment or tampering with these devices may impair boom lift functi
105. ng JIC 8 x 6 90 MxM 1 18 B02 15 0506 Cap Screw 5 16 18 x 1 1 4 2 19 B02 02 0283 Fitting JIC 8 x G 3 4 MxM 1 20 B02 02 0281 Fitting Plug 12 ORB 2 21 B02 02 0282 Fitting 3 8 NPT x 1 2 MxHB 1 22 B02 15 0507 Hose Black 1 2 x 15 1 B02 02 0276 Fitting Plug 8 ORB Under Reservoir 1 79 BOOM AND ROTATION HYDRAULIC LINES A 03269 a ma 5 Slave RET Basket Level EXT DA Master Basket Level 0259 Cti 4 0259 E gt Telescopic b M 0259 L 0260 20 yy OFT O or Lower Lift Upper Lift EXT EXT 0258 0258 EXT 0259 02 Rotation Kinematics Slew Drive Outrigger Ret 0241 a Outrigger EXT 80 BOOM AND ROTATION HYDRAULIC LINES PARTS LISTS ltem No Part No Description 1 B02 01 0281 4 x 36 Hydraulic Hose 2 B02 01 0280 4 x 36 Hydraulic Hose 3 B02 01 0313 4 x 204 Hydraulic Hose 4 B02 01 0314 4 x 204 Hydraulic Hose 5 B02 01 0315 6 x 237 Hydraulic Hose 6 B02 01 0316 6 x 237 Hydraulic Hose 7 B02 01 0289 6 x 20 Hydraulic Hose 8 B02 01 0290 4 x 20
106. noid wiring Replace Jib Up solenoid Replace Lower Control Repair or replace Jib Up solenoid wiring Replace Jib Up solenoid Replace Lower Control 114 Error Message Displayed 031 OPEN CIRCUIT JIB DOWN 032 SHORTED CIRCUIT JIB DOWN 033 OPEN CIRCUIT EXTEND 034 SHORTED CIRCUIT EXTEND 035 OPEN CIRCUIT RETRACT 036 SHORTED CIRCUIT RETRACT Error Explanation amp Possible Causes The Lower Control has detected an open circuit on the Jib Down solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Jib Down solenoid wiring 2 Faulty Jib Down solenoid 3 Fault Lower Control The Lower Control has detected excessive current on the Jib Down solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Jib Down solenoid wiring 2 Faulty Jib Down solenoid 3 Faulty Lower Control The Lower Control has detected an open circuit on the Extend boom solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Extend boom solenoid wiring 2 Faulty Extend boom solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the
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108. o clear this error first the error condition must be removed and second the power must be cycled off then back on NOTE During this error condition the Load Sense Module Status LED will blink a red 2 blink error code and the Lower Control Power LED will blink a 5 blink error code NOTE This error only occurs on machines equipped with the Load Sense option Possible causes include 1 Lower control incorrectly configured 2 Faulty Boom Cable 3 Faultv Load Sense Module 4 Faulty Lower Control Pons What To Check amp Corrective Action To Clear Error Check outrigger and level LED indicators and if required re level machine Check level sensor Repair or replace level sensor wiring Replace Lower Control Check that boom is raised before trying to rotate boom Check that boom is raised before trying to extend boom Check that boom is raised before trying to retract boom Check and repair boom down limit switch Repair or replace boom down limit switch wiring Replace Lower Control Check that boom is down before trying to auto level machine Check that boom is down before trying to extend outriggers Check that boom is down before trying to retract outriggers Check and repair boom down limit switch Repair or replace boom down limit switch wiring Replace Lower Control Correctly configure Lower Control Replace Boom Cable Replace Load Sense Module Replace Lower Control 112
109. of this and all Bil Jax products Therefore equipment information is subject to change without notice Direct any questions or concerns regarding errors or discrepancies in this manual to the Bil Jax Service Department B33 01 0105 01 Copyright O Bil Jax Inc 2009 All Rights Reserved Bil Jax and are registered trademarks of Bil Jax Inc a member of the Haulotte Group Contact Bil Jax for replacement manuals BIL JAX Haulotte gt gt 125 Taylor Parkway Archbold Ohio 43502 Phone 800 537 0540 419 445 8915 Fax 419 445 0367 http www biljax com TABLE OF CONTENTS Table of Contents 1 Illustrations 2 Tables 2 1 Safety 3 Legend Safety Advisories 4 Before Operation 5 During Operation 5 Maintenance Safety 7 Damaged Equipment Policy 8 2 Specifications 9 Range of Motion 10 Specifications 11 Warranty 12 3 Equipment Maintenance 13 Daily Service Checks 14 Weekly Service Checks 16 Monthly Service Checks 17 Annual Service Checks 18 Structural Inspection 19 Additional Service Information 19 Troubleshooting 20 Error Code Definitions 21 4 Cylinder Replacement 25 Lift Cylinder Replacement 26 Outrigger Cylinder Replacement 27 5 Replacement Decals 29 6 Material Safety Data 35 Appendix Replacement Parts 39 Ordering Replacement Parts 108 Appendix Error Codes 109 LIST OF ILLUSTRATIONS Figure 2 1 Range of Motion 10 Figure 3 1 Outrigger Position Switch 14 Figure 3 2 Hydrau
110. oid 3 Faulty Lower Control The Lower Control has detected an open circuit on the Forward 2 C27 solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800 Possible causes include 1 Faulty Forward 2 C27 solenoid wiring 2 Faulty Forward 2 C27 solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the Forward 2 C27 solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Forward 2 C27 solenoid wiring 2 Faulty Forward 2 C27 solenoid 3 Faulty Lower Control What To Check amp Corrective Action To Clear Error Repair or replace Forward 1 C24 solenoid wiring Replace Forward 1 C24 solenoid Replace Lower Control Repair or replace Forward 1 C24 solenoid wiring Replace Forward 1 C24 solenoid Replace Lower Control Repair or replace Reverse 1 C25 solenoid wiring Replace Reverse 1 C25 solenoid Replace Lower Control Repair or replace Reverse 1 C25 solenoid wiring Replace Reverse 1 C25 solenoid Replace Lower Control Repair or replace Forward 2 C27 solenoid wiring Replace Forward 2 C27 solenoid Replace Lower Control Repair or replace Forward 2 C27 solenoid wiring Replace Forward 2 C27 solenoid Replace Lower Control 127 Error Message Displayed 095 OPEN CIRCUIT RE
111. oil a Wipe away dirt and excess oil from around filter using cleaning cloths and alcohol solvent Q Loosen and remove filter Use absorbent cloths to keep excess oil from leaking onto the machine Discard used filter a Wipe away dirt and excess oil from around filter housing a Install new filter Do not over tighten a With the fill port cap on but not tightened completely raise and lower all booms to bleed trapped air from the lift cylinders Repeat as necessary Q Replace yearly or whenever filter or oil contamination has a noticeable effect on boom functions Inspect pivot pins and cylinders including rod ends for wear or damage Replace as necessary Visually inspect welds and structural components for wear damage and corrosion a Follow all manufacturer s recommendations when making repairs to critical components Q Personnel making repairs to welds should be certified in accordance with applicable government regulations Inspect outriggers for wear or damage Repair or replace as necessary Verify that Level Sensor is operating correctly a Fully deploy outriggers until all Outrigger LEDs and AUTO LEVEL LED are lit and buzzer sounds Q Verify that machine is level and that level sensor is giving an accurate reading a Repair or replace as necessary Inspect and adjust axles and brakes Load test boom lift operations with 500 Ib 187 kg load 18 Check slew bearing for wear or dam
112. on and result in safety or damage hazards Persons performing maintenance or repairs on the machine including weld repairs should be trained in accordance with the manufacturer s recommendations Contact your regional Bil Jax representative if additional information is needed Critical or suspect areas identified during any scheduled inspection of the machine shall be examined by qualified personnel in accordance with applicable government regulations Never operate the machine if a defect or malfunction is identified or suspected All defects and malfunctions must be repaired and all maintenance performed before returning a machine to service This manual contains a list of recommended maintenance procedures to be performed daily weekly monthly and annually When servicing the internal combustion engine installed on this machine always follow the guidelines specified by the engine manufacturer It is the practice of Bil Jax Inc to issue Service and or Safety Bulletins which may include updates to the information contained in this manual In such instances procedures contained in Bil Jax Service Bulletins or Safety Bulletins supersede the information contained in manuals Always follow maintenance schedule regardless of use 13 BIL JAX 45XA DAILY SERVICE CHECKS The following maintenance procedures should be performed daily or before each operation Verify that all decals are correctly applied and in plain view
113. or replace Turntable CCW solenoid wiring Replace Turntable CCW solenoid Replace Lower Control 117 Error Message Displayed 049 OPEN CIRCUIT OUTRIGGER RETRACT 050 SHORTED CIRCUIT OUTRIGGER RETRACT 051 OPEN CIRCUIT OUTRIGGER EXTEND 052 SHORTED CIRCUIT OUTRIGGER EXTEND 053 OPEN CIRCUIT LF OUTRIGGER 054 SHORTED CIRCUIT LF OUTRIGGER Error Explanation 8 Possible Causes The Lower Control has detected an open circuit on the Outrigger Retract solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Outrigger Retract solenoid wiring 2 Faulty Outrigger Retract solenoid 3 Faulty Lower Control The Lower Control has detected excessive current on the Outrigger Retract solenoid output when it was energized during startup self diagnostics Possible causes include 1 Faulty Outrigger Retract solenoid wiring 2 Faulty Outrigger Retract solenoid 3 Faulty Lower Control The Lower Control has detected an open circuit on the Outrigger Extend solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Outrigger Extend solenoid wiring 2 Faulty Outrigger Extend solenoid 3 Faulty Lower Control
114. oss of communication with PC 5 Blinks Loss of communication with Load Sense Module Upper Control Blink Error Codes The Engine led blinks to indicate the following error conditions 1 Blink Stuck key on Upper Control 2 Blinks Loss of communication with Lower Control 3 Blinks Stuck Joystick 131 132 125 Taylor Parkway Archbold OH 43502 Phone 419 445 8915 800 537 0540 Fax 419 445 0367 http www biljax com Distributed bv
115. place Lower Control Repair or replace Engine Choke relay wiring Replace Engine Choke relay Replace Lower Control Repair or replace Engine Choke relay wiring Replace Engine Choke relay Replace Lower Control 120 Error Message Displayed 067 OPEN CIRCUIT ENGINE STOP 068 SHORTED CIRCUIT ENGINE STOP 069 OPEN CIRCUIT PROPORTIONAL 070 SHORTED CIRCUIT PROPORTIONAL 071 OPEN CIRCUIT MOTOR CONTROL ENABLE 072 SHORTED CIRCUIT MOTOR CONTROL ENABLE Error Explanation 8 Possible Causes The Lower Control has detected an open circuit on the Engine Stop relay output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit This load is less than 70mA and this error is suppressed to avoid false errors Possible causes include 1 Faulty Engine Stop relay wiring 2 Faulty Engine Stop relay 3 Faulty Lower Control The Lower Control has detected excessive current on the Engine Stop relay output when it was energized during startup self diagnostics Possible causes include 1 Faulty Engine Stop relay wiring 2 Faulty Engine Stop relay 3 Faulty Lower Control The Lower Control has detected an open circuit on the Proportional valve solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA at 100 Possible causes inclu
116. pment or to securely support boom and boom cylinders can result in damage to lift components serious injury or death Q Lower the boom until it is resting in a stowed position When removing the slave cylinder extend the articulating boom section until all pivot pins are exposed approximately two feet Q Press and hold the emergency lowering valve on the back of the jib boom section to relieve all hydraulic pressure to the cylinder Repeat this process for the upper and lower boom sections Refer to the 4527A Operator s Manual for emergency lowering valve locations and operating procedures a Turn key switch to the OFF position and remove the key Q Locate the piston rod end of the cylinder to be removed Figure 4 1 Unbolt and remove the retainer plate from each side of the pivot pin a Verify that the cylinder is supported by lifting straps and an overhead hoist Q Remove the pivot pin using a hammer and a brass or hardwood drift Q Use an overhead crane or lifting gear to raise the boom section Adequate clearance is necessary to reach the cylinder valve block and hydraulic hose ports Q Unplug the appropriate emergency lowering valve solenoid Q Tag and number all hydraulic hoses that attach to the cylinder valve block Use a marker to label the valve block ports with the appropriate hose numbers Q Place absorbent cloths below the cylinder ports and detach hydraulic hoses from the cylinder Elevate hoses to
117. prevent leakage Plug or cap exposed hose fittings and cylinder ports 26 At the base of the cylinder unbolt and remove retainer plate from each side of the pivot pin Remove the pivot pin using a hammer and a brass or hardwood drift Lift and remove the cylinder using an overhead hoist and lifting straps Replace or reinstall the cylinder by following the above instructions in the reverse order of removal Actuate the hydraulic system and check for leakage Tighten hydraulic fittings as needed Bleed trapped air from the hydraulic system by raising and lowering the boom with the reservoir fill port cap on but not tightened Allow several minutes for trapped air to escape Repeat as needed RETAINING PLATE p Y AS CYLINDER BASE END PISTON END Figure 4 1 Lift Cylinder Replacement OUTRIGGER CYLINDER REPLACEMENT Use the following procedure to remove and replace faulty or damaged hydraulic cylinders on the outriggers Q Lower the outrigger until the footpad is touching the ground Do not transfer the weight of the boom lift onto the outrigger Leave the weight of the boom on the trailer wheels Remove the bolts securing the outrigger cylinder rod guard Figure 4 2 Remove the guard At the piston rod end of the cylinder unbolt and remove the retainer plate from each side of the pivot pin Place a block of wood shoring between the outrigger beam and cylind
118. provide protection from contact with or close proximity to any electrically charged conductor Operator must maintain safe clearances at all times 3 05 meters minimum and must always allow for platform movement due to gusty winds Always contact power company before working near power lines Assume every power line is live Power lines can be blown by the wind Refer to Table 1 1 for minimum safe approach distances between the machine and electrical power lines Voltage Range Minimum Safe Approach Distance Phase to Phase Feet Meters 0 to 300V Avoid Contact Over 300V to 50KV 10 3 05 Over 50KV to 200KV 15 4 60 Over 200KV to 350KV 20 6 10 Over 350KV to 500KV 25 7 62 Over 500KV to 750KV 35 10 67 Over 750KV to 1000KV 45 13 72 Table 1 1 Minimum Safe Approach Distances ALWAYS keep away from a machine that is exposed to energized power lines If the machine contacts energized power lines NEVER touch or operate the machine until power lines are shut off ALWAYS operate only on a firm and level surface NEVER operate on surfaces that do not support the equipment with its rated load capacity or on surfaces that do not support force exerted by the outriggers during boom operation Operate only on surfaces that can support a pressure of 1 8 kg cm 25 psi to ensure safe operation ALWAYS keep personnel away from potential pinch and shear points and from potential crush hazards as indicated by de
119. r Control The Lower Control has detected excessive current on 1 the Primary Up solenoid output when it was energized 2 during startup self diagnostics 3 Possible causes include 1 Faulty Primary Up solenoid wiring 2 Faulty Primary Up solenoid 3 Faulty Lower Control The Lower Control has detected an open circuit on the Primary Down solenoid output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit The typical load is approximately 800mA Possible causes include 1 Faulty Primary Down solenoid wiring 2 Faulty Primary Down solenoid 3 Faulty Lower Control What To Check amp Corrective Action To Clear Error Reduce weight in basket or on hook Correctly configure Lower Control Replace Load Cell Repair or replace Load Cell wiring Replace Load Sense Module Replace Lower Control Replace Load Cell Repair or replace Load Cell wiring Replace Load Sense Module Repair or replace Primary Up solenoid wiring Replace Primary Up solenoid Replace Lower Control Repair or replace Primary Up solenoid wiring Replace Primary Up solenoid Replace Lower Control Repair or replace Primary Down solenoid wiring Replace Primary Down solenoid Replace Lower Control 113 Error Message Displayed 024 SHORTED CIRCUIT PRIMARY DOWN 025 OPEN CIRCUIT SECONDARY UP 026 SHORTED CIRCUIT SECONDARY UP 027 OPEN CIRCUIT SECONDARY DOWN 028 S
120. r solenoid Replace Lower Control Repair or replace RR Outrigger solenoid wiring Replace RR Outrigger solenoid Replace Lower Control 119 Error Message Displayed 061 OPEN CIRCUIT ENGINE THROTTLE 062 SHORTED CIRCUIT ENGINE THROTTLE 063 OPEN CIRCUIT ENGINE STARTER 064 SHORTED CIRCUIT ENGINE STARTER 065 OPEN CIRCUIT ENGINE CHOKE 066 SHORTED CIRCUIT ENGINE CHOKE Error Explanation amp Possible Causes The Lower Control has detected an open circuit on the Engine Throttle relay output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit This load is less than 70mA and this error is suppressed to avoid false errors Possible causes include 1 Faulty Engine Throttle relay wiring 2 Faulty Engine Throttle relay 3 Faulty Lower Control The Lower Control has detected excessive current on the Engine Throttle relay output when it was energized during startup self diagnostics Possible causes include 1 Faulty Engine Throttle relay wiring 2 Faulty Engine Throttle relay 3 Faulty Lower Control The Lower Control has detected an open circuit on the Engine Starter relay output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit This load is less than 70mA and this error is suppressed to avoid false errors Possible causes include 1 Faulty Engine Starter
121. r up without pressing any buttons 009 BOOM UP WITHOUT Ground control detected the boom is up and all Retract boom to travel position OUTRIGGERS ON GROUND outriggers are not on the ground and extend outriggers using AUTO LEVEL button 010 LEVEL SENSOR HAS The ground control detected an erratic output Retract and extend outriggers ERRATIC OUTPUT from the level sensor using AUTO LEVEL button 015 MACHINE IS NOT LEVEL Machine has gone out of level with use Retract and extend outriggers using AUTO LEVEL 016 LIFT BOOM A boom rotate extend or retract function Raise boom from travel position requested with boom down 017 STOW BOOM An outrigger function requested with boom up Retract and lower boom to travel position 021 OPEN CIRCUIT PRIMARY UP A load of less than 70mA detected in primary up Check for faulty boom up circuit on power up solenoid coil and wiring 022 SHORTED CIRCUIT Excessive load detected in primary up circuit on Check for faulty boom up PRIMARY UP power up solenoid coil and wiring 023 OPEN CIRCUIT PRIMARY A load of less than 70mA was detected when Check for faulty boom down DOWN primary down circuit was energized solenoid coil and wiring 024 SHORTED CIRCUIT Excessive load detected when primary down Check for faulty boom down PRIMARY DOWN circuit was energized solenoid coil and wiring 025 OPEN CIRCUIT SECONDARY A load of less than 70mA detected in secondary Check for faulty boom up UP up circuit on power up solenoid coil
122. relay wiring 2 Faulty Engine Starter relay 3 Faulty Lower Control The Lower Control has detected excessive current on the Engine Starter relay output when it was energized during startup self diagnostics Possible causes include 1 Faulty Engine Starter relay wiring 2 Faulty Engine Starter relay 3 Faulty Lower Control The Lower Control has detected an open circuit on the Engine Choke relay output when it was energized during startup self diagnostics NOTE A load of less than 70mA will be detected as an open circuit This load is less than 70mA and this error is suppressed to avoid false errors Possible causes include 1 Faulty Engine Choke relay wiring 2 Faulty Engine Choke relay 3 Faulty Lower Control The Lower Control has detected excessive current on the Engine Choke relay output when it was energized during startup self diagnostics Possible causes include 1 Faulty Engine Choke relay wiring 2 Faulty Engine Choke relay 3 Faulty Lower Control 1 2 3 on gt What To Check amp Corrective Action To Clear Error Repair or replace Engine Throttle relay wiring Replace Engine Throttle relay Replace Lower Control Repair or replace Engine Throttle relay wiring Replace Engine Throttle relay Replace Lower Control Repair or replace Engine Starter relay wiring Replace Engine Starter relay Replace Lower Control Repair or replace Engine Starter relay wiring Replace Engine Starter relay Re
123. stions concerning structural damage or the Damaged Equipment Policy please contact the Bil Jax Service Department at 800 537 0540 Damage Repair Notice There may be occasions when a Bil Jax lift is involved in an accident resulting in damage to non structural components When such damage 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 2 SPECIFICATIONS Bil Jax Inc is dedicated to the continuous improvement of this and all Bil Jax products Therefore equipment information is subject to change without notice The following information is based on ideal working conditions Machine performance may vary based on work environment and on machine options Direct any questions or concerns regarding equipment specifications to your regional Bil Jax representative or to the Bil Jax Service Department BIL JAX 45XA RANGE OF MOTION 15 ft 25 ft 35 ft 1 5m 4 6m 7 6m 10 7m Figure 2 1 Range of Motion 10 SPECIFICATIONS Working Height Maximum Platform Height Maximum Horizontal Outreach From Centerline From Outrigger Footpad Edge Rated Platform Capacity Without Platform Rotation With Platform Rotation Maximum Occupants Total Weight Turntable Rotation Leveling Capability Gradeability Wheel Base Turn
124. ttery Hinge Pin 2 4 0096 0050 Washer Flat M16 8 5 0090 0147 Cotter Pin 4 6 A 00271 Battery Clamp 4 7 0096 0010 Cap Screw M8 x 20 4 8 0096 0040 Hex Nut Self Locking M8 8 9 A 00219 Battery Box Latch 2 10 A 00256 Motor Cover 1 11 A 00229 Latch Plate 2 12 A 00234 Spacer 2 13 0096 0011 Cap Screw M8 x 25 6 14 A 00244 Tension Spring 2 15 A 00225 Nose Weldment 1 16 0096 0014 Cap Screw M10 x 20 10 17 0096 0041 Hex Nut Self Locking M10 10 18 A 00037 Ramp Short 4 19 0096 0002 Flat Head Cap Screw M6 x 20 4 20 0096 0039 Hex Nut Self Locking M6 4 21 A 00046 Grommet 4 22 B04 07 0036 Clamp 2 23 B01 09 0132 A Frame Handle Connector 1 24 B01 09 0131 Plug Connector 1 25 A 03272 Battery Cable Kit 1 26 01 09 0133 Terminal Boot Black 4 27 01 09 0134 Terminal Boot Red 4 28 A 00242 Battery 4 29 0090 0162 Hex Nut 3 8 16 8 30 A 00235 Power Unit 4WD 1 B02 15 0528 3KW 24V DC Motor 1 B02 15 0529 Gear Pump 2 0 ccm 1 B02 02 0301 Fitting M14 x 6 ORFS 1 B02 02 0302 Fitting M18 x 8 ORFS 1 COVER ASSEMBLY s 72 a A xs V 4 AA Ex 1 1 1 1 3 X 2 gt 122 AA COVER ASSEMBLY PARTS LIST Item No Part No Description Qty 1 A 03240 Cover Left 1 2 A 03239 Cover Right 1 3 A 00228 Cover Brace 2 4 A 00252 Hinge 4 5 0
125. vel Sensor 24 x n 9 32 Loom gt lt 10 48 ga Red gt Level Sensor GND _ A gt lt 10 48 ga Black gt Weather Label B 12020830 4 Pos housing Level Sensor X Mates With 12020832 Lr c 12089040 Male Terminal 2 lt 18 18 ga Orang 12015323 Wire Seal Pump Speed Signal D Motor Cntrl Enab Level Sensor Y a lt rg _______ gt POWER HARNESS A 00718 AMP 1 66740 1 Or 12ga Red 66740 6 lt 32 gt Batt Pos Pin 1 5 16 Ring Terminal AMP 1 66740 1 12ga Or Black 66740 6 Batt Neg Pin 2 2 5 16 Ring Terminal Bundle wires in 28 of loom Tape both ends if split loom is used 110 VAC TOWER PLATFORM HARNESS A 03722 49 14 3 SDN or Equivalent A 03722 Rev 99 SECONDARY CYLINDER WIRE A 03724 Delphi Weather Pack 2 Pin Female Housing 12025792 Female Terminal 12089188 Green Wire Seal 12015323 20 18 2 SJO or Equivalent Delphi Weather Pack 2 Pin Male Housing O Sec Cyl Wire JIB WIRE A 03725 Delphi Weather Pack 2 Pin Female Housing 12025792 Female Terminal 12089188 Green Wire Seal 12015323 50 6 18 2 SJO or Equivalent OC JIB Wire 12010973 Male Terminal 12124582 Green Wire Seal 12015323 Label Both ends Sec Cyl Wire Delphi Weather Pack 2 Pin Male Housing 12010973 Male Terminal 12124582 Green Wire Seal 12015323 Label Both ends J
126. wer Control has detected the engine had low oil pressure while running This is a latched error To clear this error first the error condition must be removed and second the power must be cycled off then back on NOTE This error only occurs on machines equipped with the X Boom option Possible causes include Engine oil low Faulty oil pressure sensor Faulty oil pressure sensor wiring Lower Control incorrectly configured Faulty Lower Control OV BON What To Check amp Corrective Action To Clear Error 1 Check Level Sensor 2 Repair or replace Level Sensor wiring 3 Replace Lower Control NOTE With machine powered and level Level Sensor should have a steady approximately 24 volt supply voltage and a steady approximately 2 50 volt output on both X and Y outputs with respect to the Level Sensor ground connection Engage trailer brake Check and repair trailer brake switch Repair or replace trailer brake switch wiring Replace Lower Control Pe eo Ne Check angle sensor Repair or replace angle sensor wiring Correctly configure Lower Control Replace Lower Control Check pressure sensor Repair or replace pressure sensor wiring Correctly configure Lower Control Replace Lower Control Check engine oil level Check oil pressure sensor Repair or replace oil pressure sensor wiring Correctly configure Lower Control Replace Lower Control MAD 111 Error Message Displayed 015 MA

Operator`s Manual - Robinsons Hardware

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