Home

Bil-Jax AERIAL WORK PLATFORMS Hydraulic Boom Lift Personal Lift User Manual

1. PUMP COMPARTMENT GROUND CONTROL BOX KEY qu SWITCH BATTERY ALARM CHARGER RELAY OUT 6 6 RIGGERS E STOP e RL2 Indy ah 2 PB2 GND Cr BOOM gt 22 21 20 19 3 3 8 7 6 5 4 19 3 12 1 1523 MCB BOOM DOWN LIMIT SWITCH HHH L 1 CONTACTOR BATTERIES i 3 sws SW4 POSITION SWITCHES Figure 4 15 Detailed Electrical Diagram DC Model 4 23 XLB 4319 STARTER RELAY STARTER e MOTOR ENGINE KEYSWITCH 9 CIRCUIT dene i Lopes Mello ri 242225052 Ost i IGNITION UNIT _ E STOP LEVEL o
2. 4 34 Replacement Decals Refer to Table 5 1 and Figure 5 1 through Figure 5 5 for descriptions and locations of decals on the XLB 4319 Hydraulic Boom Lift Table 5 1 Replacement Decals Decal No Description of Decal Qty Description of Decal Qty B06 00 0033 CAUTION THIS UNIT SHALL B06 00 0334 DANGER HIGH VOLTAGE 2 ONLY BE TOWED WHEN OPERATION B06 00 0034 DANGER DURING B06 00 0363B Bil Jax SMALL LABLE CHARGING EXPLOSIVE B06 00 0380 MAXIMUM CAPACITY 450 LBS OXYHYDROGEN GAS B06 00 0056 LUBRICATE WEEKLY 22 B06 00 0393 Basket Station Valve Numbers B06 00 0037 _ LUBRICATE SEME ANNUALLY B06 00 0394 Basket Station Valve Motions B06 00 0043 MANUAL PUMP HANDLE B06 00 0395 Ground Station Valve Numbers 06 00 0060 STOP READ OPERATING B06 00 0396 Ground Station Valve Motions B06 00 0062_ THIS PLUG 115 VOLT 06 00 0397 LATCHED UNLATCHED B06 00 0068 THE HYDRAULIC SYSTEM B06 00 0398 OUTRIGGER INSTRUCTIONS decal on hydraulic reservoir B06 00 0399 ABBREVIATED OPERATING B06 00 0115 1500 WATT LOAD LIMIT STRONG 06 00 0130 LUBRICATE MONTHLY B06 00 0400 DANGER BEFORE USING 5 B06 00 0151 DANGER 110 VOLT LOWER ALL 4 OUTRIGGERS B06 00 0161B Bil Jax LARGE LABLE B06 00 0401 DANGER BOOM SAFETY B06 00 01
3. 4 17 Check Free Play ett e eet 4 17 4 6 Limit Switch checks and adjustments esee 4 18 Adjusting Boom Down Limit 4 18 Adjusting Outrigger Position Switches 4 19 4 7 Troubleshooting ete aet de ete 4 20 Troubleshooting 4 22 4 8 Material Safety Data 4 31 Replacement Decals eese eese esee 5 1 List 6 1 6 1 Upper Boom Parts 6 2 6 2 Lower Boom Parts 6 4 6 3 Jib Boom Parts L3st ser been ORE 6 6 6 4 Compartment Covers Parts 6 8 6 5 Reservoir Compartment Parts List Gas 6 10 6 6 Pump Compartment Parts List DC 6 12 6 7 Chassis and Rotation Unit Parts List esee 6 16 6 8 Hitch and Jack Assembly Parts 6 18 6 9 Axle and Wheel Assembly Parts 6 20 6 10 Rear Lights and Junction Box Parts 6 23 6 11 Outriggers Parts List oie des 6 25 6 12 Basket Parts List ceres 6 27 6 13 Outrigger Hydraulic Controls Parts 6 29 6 14 Lower Controls Parts 4 6 6 31 6 15 Upper Controls Parts List prO treten 6 33 6 16 Engine Compartment Parts List Gas 6 35 6 17 Boom Control Hydraulics Parts List Basket ss
4. Hose Assembly merorori Hydrate Hose Assembly CH s meroror Hydrate Hose Assembly 6mm C27 9 faye Hos sey co 1 1 1 1 1 2 1 1 BO2 14 0068 Lever Pivot Box With Gaiter 4 4 4 1 1 1 2 108 wicewispm 106 02 14 0053 Handle Con Yans 02 01 0183 Hydrate Hose Assembly 10mm C28 rie seb B02 02 0207 Tee Fitting 1 4 BSP Female Swivel 1 4 BSP Male 1 4 BSP Male 21 B02 02 0212 Tee Fitting 1 4 BSP Male 1 4 BSP Female Swivel 1 4 BSP Male 6 43 XLB 4319 6 20 LOWER BOOM CYLINDER HYDRAULICS PARTS LIST Refer to Table 6 20 for the lower boom cylinder hydraulics parts list 2 Figure 6 20 Lower Boom Cylinder Hydraulics Table 6 20 Lower Boom Cylinder Hydraulics Parts List B02 01 0180 Hydraulic Hose Assembly 6mm C21 B02 02 0210 Adapter Straight 1 4 BSP Male 1 4 BSP Male B02 00 0044 1 4 Dowty Washer B02 01 0181 Hydraulic Hose Assembly 6mm C22 2 B02 02 0203 Elbow 90 1 4 BSP Male 1 4 BSP Male 6 44 6 21 UPPER BOOM CYLINDER HYDRAULICS PARTS LIST Refer to Table 6 21 for the upper boom cylinder parts list Figure 6 21 Upper Boom Cylinder Hydraulics Table 6 21 Upper Boom Cylinder Hydraulics Parts List 3 Hose 050958 Hose Assembly on Cs 1 5 meroror
5. 5 2 6 19 XLB 4319 6 9 AXLE AND WHEEL ASSEMBLY PARTS LIST Refer to Table 6 9 for the axle and wheel assembly parts list Figure 6 9 Axle and Wheel Assembly 6 20 6 PARTS LIST Table 6 9 Axle and Wheel Assembly Parts List a1 __ ex Nar Locking 822 00 0026 Kit Fender includes items 2 3 amp 6 10 B29 00 0154 Bracket Fender B18 00 0109 Fender Top Mount Flat Washer Cap Screw 0090 0033 Cap Screw 5 16 18 x 1 3 4 B07 06 5772 Fender Mount 0090 0420 Flat Washer 5 16 9 0090 0185 Nut Lock 5 16 18 10 0090 0645 Cap Screw 5 16 18 x 1 2 11 B08 02 0012 Tire 11A B08 02 0013 Rim Only 12 B10 00 0062 Bolt Wheel Lug Conical M12 x 1 5 13 B10 00 0063 Dust Cap 4 B10 00 0061 Flange Nut Spindle 5 B21 00 0025 Brake Drum with Bearings Nut Mount Spindle B21 00 0025B Brake Drum with Bearings Bolt Mount Spindle B25 00 0077 Wheel Bearing Nut Mount Spindle B25 00 0077B Wheel Bearing Bolt Mount Spindle B10 00 0083 Retaining Ring Nut Mount Spindle B10 00 0083B Retaining Ring Bolt Mount Spindle B10 00 0077 Pull off Spring B10 00 0078 Expanding Clutch B21 00 0024 Brake Shoe pair B10 00 0079 Spindle Nut Mount B10 00 0079B Spindle Bolt Mount B10 00 0080 Cable Eye B12 00 0126 Brake Cable 24 B10 00 0081 Spring Reverse Lever 25 B10 00 0076 Bearing Bolt 26 B10 00 0075 Spring Shoe Retaining 27 B10 00 0074 Cotter Pin 28 B10 00 0072 Reverse Lever LH Side 28A B10 00 007
6. VALVE E TEE BANK ZONE 2 2755 PSI Ma peal pace Mapas hae E age EE al 5 VALVE VALVE BOOMLIFT in SV1 SV2 CYLINDER LOWER CYLINDER LA LA BOOM LIFT CYLINDER 7 gt gt a Z BOOM SLEW MN ee CS ER gt FILTER I MANIFOLD 3045 PSI 1 1 EE ba 227 4 28 SUCTION FILTER RETURN FILTER OUTRIGGER CONTROL VALVE BANK JACK CYL 2 JACK CYL 3 Figure 4 19 Hydraulic Diagram Gas Model Sheet 1 of 2 4 BASKET CONTROL VALVE BANK 1 bd 1 AQ 1 WDR OE zi ES 51 gt lt HOL H H x H FROM EM EK me GROUND C VALVE CHECK 1
7. 3 4 OQut gger Controls n entem ete Gee ite manent 3 6 Manual Lowering Valve 3 8 Basket Control 3 8 Emergency 3 9 Battery ioco erbe bete t tee a netter 3 10 Trailer tree tete 3 11 Wheel Bolt Tightening Sequence eee 4 3 Lubricate Monthly sess 4 4 Lubricate Semi Annually eese enne 4 4 Hydraulic Reservoir nae HERE gn D D teresa 4 5 Main Bypass Valve and Pressure Test Port Gas Engine Model 4 7 Outriggers Bypass 4 8 Boom Control Bypass Valve Basket 4 0 Hydraulic Cylinder Removal 4 11 Jib Boom Component 4 14 Basket Swivel Cylhnder needed 4 16 Slew Ring Position Measurement 4 17 Boom Down Limit 4 18 Outrigger Position 4 19 Simplified Electrical Diagram DC 4 22 Detailed Electrical Diagram DC Model 4 23 Simplified Electrical Diagram Gas 4 24 Detailed Electrical Diagram Gas Model 4 25 Hydraulic Diagram DC 4 26 Hydraulic Diagram Gas Model 4 28 Level Sensor uet ee mtb tt eo peteret 4 30 Replacement 5 2 n otia 5 2 Decal Locations Trailer and Boom 5 5 Decal Locations Control Compartment 5 6 Lubricate Monthly Decal 5 6 Lubricat
8. B02140070 Valve Replacement 2 Hydric Hose Assembly 6mm CH __ 01 01 Hydraulic Hose Assembly 6mm C24 1 7 9 30 01 0162 Hydraulic Hose Assembly 6mm 25 2 _______ Hydrate Hose Assembly 1 Bo201 0183 Hydraulic Hose Assembly 10mm C28 1 s perro pte Hose 3 B02 02 0207 Tee Fitting 1 4 BSP Female Bund 1 4 BSP Male 1 4 BSP Male i 2 m wee 23 B02 02 0212 Tee Fitting 1 4 BSP Male 1 4 BSP Female 2 Swivel 1 4 BSP Male 2 2 2 2 Hydraulic Hose Assembly 6 mm 2 1 Valve Hose Assembly CH mem 1 1 34 Hydraulic Hose Assembly 6 mm C35 6 41 XLB 4319 6 19 BOOM CONTROL HYDRAULICS PARTS LIST GROUND DC MODEL Refer to Table 6 19 for the DC model boom control hydraulics parts list 1 9 9 e 0 Figure 6 19 DC Model Boom Control Hydraulics Ground 6 42 6 PARTS LIST Table 6 19 DC Model Boom Control Hydraulics Parts List Ground B02 01 0179 Hydraulic Hose Assembly 6 mm C20 02 00 0043 3 8 Dowty Washer 02 02 0205 Adapter 1 4 BSP Male 3 8 BSP 14 z War Sonst Beam Enae B02 14 0056 Coil For Valve SV1 24V DC
9. lt gt Lu pig ea tabu MI gt gt 222 UNE 512755 8 TRE MR i OUTRIGGER f X X XX OUTRIGGER ae CYL 1 CYL 4 OUTRIGGER OUTRIGGER cu CYL 2 CYL 3 Figure 4 18 Hydraulic Diagram DC Model Sheet 1 of 2 4 26 4 HAND PUMP BASKET CONTROL VALVE BANK pe eq qu e e ee ee ee Fg ze Lj 1 221 af x ad ad GROUND i CONTROL 5 49 34 H H H H TI H VALVE CHECK it 4 it BANK VALVE M 1951 1 111 2755 PSI Ic 3 5 8 CYLINDER T CYLINDER WH LOWER BOOM LIFT CYLINDER amp gt JIB BOOM LIFT CYLINDER Figure 4 18 Hydraulic Diagram DC Model Sheet 2 of 2 4 27 XLB 4319 GROUND CONTROL VALVE BANK 1 5 E H AH gt CONTROL
10. PARKING L 7 a BRAKE JACK IN 212 RAISED PIN POSITION BREAKAWAY CHAINS Figure 3 10 Trailer Hitching 3 11 XLB 4319 3 12 3 Hold ball hitch release lever open and lower the hitch onto the ball Let go of the release lever to secure the ball 4 Crank the jack down to check for secure coupling If jacking will raise the tow vehicle bumper two or three inches the ball hitch coupling is secure 5 Release the trailer parking brake 6 Pull the pivot locking pin Swivel the jack 90 degrees to the travel position and release the pivot locking pin Always cross and attach the safety chains before towing Failure to attach safety chains properly will allow tongue to drop in case of ball hitch failure resulting in serious damage to the trailer and equipment 7 Attach the trailer safety chains to the tow vehicle Make sure the chains cross under the trailer tongue If needed cross the chains over then under the tow bar to prevent dragging 8 Connect the trailer lights to the tow vehicle power plug 9 Check the breakaway safety cable If the safety cable does not have adequate slack the brakes may drag 10 Before towing the trailer check the following and make all necessary adjust ments corrections or repairs a Check that the trailer jack and outriggers are in their travel positions b Verify that the transport
11. 5 Inspect the charge indicator LEDs near the end of the expected charge cycle If all indicator LEDs are off the battery is fully charged The DC ammeter needle should point to the left NOTE yellow 80 CHARGE indicator lights up when the battery voltage is nearing full charge At full charge 3 1 2 hours after the 80 CHARGE indicator lights up the charger turns off the battery voltage does not reach the 80 CHARGE level in 14 hours the charger turns off and the red CHECK BATTERY indicator LED lights up This prevents extended charging of a faulty battery 6 Unplug the power cord from the 120 VAC receptacle and the charger recepta cle Properly store the power cord for next use BOOM LIFT TRANSPORT The boom lift trailer is a single axle trailer fitted with a two inch ball hitch surge brakes breakaway safety cable safety chains brake lights and side marker lights Proper boom lift transport requires the correct hookup and inspection of these trailer components be fore towing Use the following procedures to hitch tow and back the boom lift trailer Trailer Hitching Trailer hitching requires a second person to give tow vehicle backing instructions 1 Back the tow vehicle to the trailer Verify that the ball and hitch are in line and that the trailer hitch will clear the ball Jack up the tongue as needed 2 Align the ball and hitch Figure 3 10 Fasten the breakaway safety cable to the tow vehicle
12. N DANGER Dangers warn of equipment operation near electrical power lines that could lead to personal injury or death WARNING Warnings describe conditions or practices that could lead to personal injury or death CAUTION Cautions provide information important to prevent errors that could damage machine or components NOTE Notes contain additional information important to a procedure Safety INTRODUCTION Familiarity and proper training are required for the safe operation of mechanical equip ment Equipment operated improperly or by untrained personnel can be dangerous Read the operating instructions in this manual and become familiar with the location and proper use of all controls Inexperienced operators should receive instruction from some one familiar with the equipment before being allowed to operate the machine The use of intelligence and common sense in the operation of mechanical equipment is the best practice in any safety policy Be professional and always observe the safety procedures set forth in this manual All OSHA ANSI state and local codes and regulations pertaining to this equipment should be obtained read and thoroughly understood before attempting to operate this equipment Persons under the influence of drugs alcohol or prescription medication should not be on or near this equipment Common sense should be implemented at all times during the use of this equipment Do not operat
13. 2 3 10 Fully retract lower the lift booms Go to the hydraulic reservoir side of the boom lift Open the power cabinet Access the top surface of the slew ring gear near the front end trailer tow end of the gear This area is below and behind the hydraulic pump reservoir Insert a 2 inch 50 mm caliper or bore micrometer at the top front surface of the slew ring gear Measure the distance from the top of the slew ring gear to the horizontal plate above the gear Figure 4 11 Record the measurement Place a 175 Ib 80 kg load in the boom lift basket Raise the lower boom until the front of the boom is about 11 5 ft 3 5 m from the ground Slowly raise the upper boom and extend the jib boom until both are horizontal Repeat the measurement in step 5 Record the measurement If the difference between the measurements in step 5 and step 9 is greater than 0 25 inch 6 35 mm the slew ring bearing should be replaced Notify Bil Jax for bearing replacement instructions or assistance HN HEE SLEW MEASURE RING TOW END OF TRAILER a ms Figure 4 11 Slew Ring Position Measurement 4 17 XLB 4319 4 18 4 6 LIMIT SWITCH CHECKS AND ADJUSTMENTS Adjusting Boom Down Limit Switch When the upper and lower booms are retracted the boom down limit s
14. 8 3 8 4 7 ANSI REPRINT 9 Hydraulic and pneumatic cylinders and holding valves for malfunction and visible damage 10 Hydraulic and pneumatic filters for cleanliness and the presence of foreign ma terial in the system indicating other component deterioration 11 Electrical systems and components for deterioration or wear including those not readily visible on a frequent inspection 12 Performance test of all boom movements 13 Condition and tightness of bolts and other fasteners 14 Welds as specified by the manufacturer 15 Legible and proper identification operational and instructional markings 16 If the aerial device is rated as an insulated device the electrical insulating components and system s shall be thoroughly inspected for lack of cleanliness and other conditions that compromise insulation Then these components and system s shall be tested for compliance with the rating of the aerial device in accordance with one of the applicable methods and procedures as outlined in section 5 4 3 of this standard a If the aerial device is used for AC bare hand work the unit shall undergo a 60 Hz test as shown in Table 2 at least every three years b If the aerial device is used for DC bare hand work the unit shall undergo a DC test as shown in Table 2 at least every three years c After repair or modification of any component that crosses the insulating system s or the repair or replacement of an i
15. 2 Figure 6 6 Pump Compartment Model 6 14 6 PARTS LIST Table 6 6 Pump Compartment Parts List DC Model continued 38 01 39 B02 02 0205 Adapter Straight 1 4 BSP Male 3 8 BSP Male B02 00 0043 3 8 Dowty Washer PwmsniReenerAsemy verano tot showny Hose Pump B02 02 0213 Adapter Straight 1 4 BSP Female Swivel 3 8 BSP Male B02 01 0185 Hydraulic Hose Assembly 13mm C31 Start Contact 24V 41 41A 41B 41C 41D 42 43 44 45 47 48 6 15 XLB 4319 6 7 CHASSIS AND ROTATION UNIT PARTS LIST Refer to Table 6 7 for the chassis and rotation unit parts list Figure 6 7 Chassis and Rotation Unit Table 6 7 Chassis and Rotation Unit Parts List Boom Support Bracket Cap Screw B02 06 0009 Slew Motor 3A B02 06 0010 Seal Kit Slew Motor 3B B02 06 0011 Slew Motor End Seal Taper Roller Bearing Cap Screw Lock Washer 6 813 00 0007 Worm Gearbox With Slew Ring B12 00 0140 Trailer Chassis Socket Head Screw Hex Nut Flat Washer Level Sensor Machine Screw Lock Washer Level Sensor Cover Machine Screw 17 B11 03 0047 Slew Restrictor 18 B46 00 0035 Handle Manual Rotation 6 PARTS LIST Q lt lt 6 17 XLB 4319 6 8 HITCH AND JACK ASSEMBLY PARTS LIST Refer
16. 3 Lower trailer tongue jack 4 Release trailer hitch from vehicle SETTING UP 1 Read Operation Manual and all decals prior to operation 2 Check to be sure all personnel are clear of outriggers Select ground controls with key swilch Make sure emergency stop buttons are re leased Using outrigger levers lower each outrigger to within 6 from ground Lower the two outriggers closest to the trailer hitch until trailer tongue jack is clear of ground Level machine using two remaining outriggers while referring to bubble level Check to be sure both wheels are clear of ground Check all outrigger lights show green and buzzer has stopped Check to be sure each outrigger foot is in firm contact with the ground 11 Do not place boards concrete blocks or any other object under the outrigger foot to obtain greater height adjustment BOOM OPERATING 1 Remove transport stowing pins 2 Select ground controls with key switch 3 Press green enable button and operate levers as required 4 Check all lift functions for proper operation 5 Return all boom arms to stowed position Move key switch to basket controls Lift is now ready for operation from the basket STOWING MACHINE 1 2 3 Fully lower each boom into transport position Using outrigger levers raise outriggers full start ing at the cage end Install boom locking pins TOWING MACHINE Do not tow machine unless booms are full lowere
17. 6 40 Table 6 18 Gas Model Boom Control Hydraulics Parts List Ground 6 42 Table 6 19 Model Boom Control Hydraulics Parts List Ground 6 44 Table 6 20 Lower Boom Cylinder Hydraulics Parts 6 45 Table 6 21 Upper Boom Cylinder Hydraulics Parts 6 46 Table 6 22 Basket Pushbutton Panel Parts 6 48 Table 6 23 Pushbutton Panel Parts List Ground 5 400 4211 6 49 Table 7 1 Minimum Safe Approach Distance M S A D to energized exposed or insulated power lines and 7 11 PREFACE The purpose of this manual is to provide a thorough understanding of the XLB 4319 Hydraulic Boom Lift operation and controls Read the safety and operating instructions in this manual and become familiar with the location and use of all controls Follow all warnings cautions and instructions in this manual and any attached to and supplied with the boom lift All OSHA ANSI state and local codes and regulations concerning this equipment should obtained read and thoroughly understood before attempting to operate this equipment To ensure proper and safe use of this equipment only trained and qualified personnel should operate and maintain the boom lift SAFETY NOTES This manual contains DANGERS WARNINGS CAUTIONS and NOTES that must be followed to prevent the possibility of improper service personnel injury or death and damage to equipment
18. BANK VALVE 1 MI 1 111 2755 PSI _____ ___ 1 3 54 84 2 4 4 6 n UPPER X BOOM gt SLEW KALINDER 1 Lb CYLINDER A E LOWER Pam oe m BOOM LIFT OE CYLINDER E JIB BOOM LIFT CYLINDER Figure 4 19 Hydraulic Diagram Gas Model Sheet 2 of 2 4 29 XLB 4319 YELLOW LED GREEN LED RED LED OUT OF LEVEL INPUT POWER OUTPUT SIGNAL MOMENTARY ON WHEN LEVEL Figure 4 20 Level Sensor Table 4 4 Level Sensor LEDs Color Description Yellow Boom lift out of level Signals alarm after 2 second delay Green Boom lift power is on Red Boom lift level Goes out after time delay 4 30 4 MAINTENANCE 4 8 MATERIAL SAFETY DATA SHEETS 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 MATERIAL IDENTIFICATION AND INFORMATION COMPONENTS PERCENT OSHA ACGIH OTHER LIMITS CAS NUMBER Hazardous Components PEL TLV 1 or greater Carcinogens 0 0
19. ALL LOCAL STATE AND ATIONS FOR DISPOSAL OF COLLECTED MATERIAL MATERIAL IS RELEASED OR I 4 33 4 MAINTENANCE MATERIAL SAFETY DATA SHEET FOR AW 46 HYDRAULIC OIL Continued SPECIAL PROTECTION INFORMATION RESPIRATORY PROTECTION SPECIFIC REQUIRED ILATION NORMAL EXHAUST NORMAL HANICAL EXHAUST GENERAL X ECTIVE GLOVES OIL IMPERVIOUS GLOVES RECOMMENDED PROTECTION SAFETY GLASSES RECOMMENDED R PROTECTIVE EQUIPMENT NONE REQUIRED Gl OQZZz m E SPECIAL INSTRUCTIONS SPECIAL LABELLING INSTRUCTIONS REQUIRED SPECIAL PACKAGING RECOMMENDATIONS NONE HANDLING AND STORAGE RECOMMENDATIONS DO NOT CUT OR WELD ON EMPTY CONTAINERS AVOID EXTREMES OF COLD OR HEAT STORE IN CLEAN DRY AR Dp DISCLAIMER THE R FROM SOURCES CONSIDERED TO BE DEPENDABLE AND IS ACCURATE TO THE BEST OF THE SELLERS KNOWLEDGE THE SELLER MAKES NO WARRANTY WHATSOEVER EXPRESSED IMPLIED OR OF MERCHANTABILITY REGARDING THE ACCURACY OF SUCH DATA OR THE RESULTS TO BE OBTAINED FROM THE USE THEREOF MATION CONTAINED HEREIN HAS BEEN COMPILED
20. DC motor is powered by four 6 Volt DC 245 Amp hour deep charge batteries connected in series A 40 Amp automatic on board battery charger is provided for recharging the batteries at the end of each work pe riod The boom lift is equipped with basket and ground station control panels Figure 2 2 The control panels include motion enable pushbuttons and proportional hydraulic valves for controlling the direction and speed of boom lift and rotation The gas model basket station control panel includes an engine start pushbutton Boom elevation and rotation controls are operational only when the outriggers are correctly extended and the moving boom sections are within a programmed safe operating zone GROUND STATION CONTROLS BASKET STATION CONTROLS Figure 2 2 Basket and Ground Station Controls 2 2 2 INTRODUCTION Only one boom motion is permitted at a time and only as long as the boom is within the safe operating zone Figure 2 3 When a selected boom motion reaches a safe operating limit the boom motion ceases and another boom motion must be selected within the safe operating zone XLB 4319 SPECIFICATIONS 459 426 LU m E 3x Le CAPACITY MAXIMUM PLATFORM HEIGHT WORK HEIGHT POWER SOURCE B06 00 0430 Figure 2 3 Safe Operating Zone Outrigger load sensing interlocks and interlock safety switches prevent all boom lifting operations until the four outriggers are properly extend
21. OL ims 4 9 us bd 24 HOLIMS asnd Figure 4 17 Detailed Electrical Diagram Gas Model 4 25 XLB 4319 GROUND CONTROL VALVE BANK i j e 7 1 HOLH H H H H TO D gt CONTROL gt gt gt VALVE 7 s 2 2 gt 1 111 2755 PSI DIVERTER E VALVE UPPER BOOM 5 7 LA CYLINDER 2 4 6 8 BOOM LIFT LOWER CYLINDER BOOM LIFT T i CYLINDER et go ee 1 E PRESSURE eo MERI lt gt FILTER E mE MANIFOLD p BOOM SLEW FS MOTOR OUTRIGGER CONTROL VALVE BANK ee eta EXEC ee E Ze gt 5 H H H H H H COHEN Ud amp 2rLTER gt
22. PB1 SENSOR ALARM LA RELAY 4 a RL2 RUN L N AUDIBLE Q9 ALARM BASKET ESTOP 20 CONTROLS OUTRIGGER POSITION SWITCHES BASKET OFF GROUND KEYSWITCH SW1 OUTRIGGER DOWN LEDs IBASKET OUTRIGGERS OUTRIGGERS BOOM DOWN ENABLE ENABLE VALVE OFF LIMIT SWITCH 9 oA SW3 PB3 SV2 Figure 4 16 Simplified Electrical Diagram Gas Model 4 24 4 1109 qm Naw as 32018 T ps 2 6 4 3ATVA Is qayna LZ 235 _ 62 3ATVA GION3 10S J18VN3 ualuvis 6 121 INDOS 3NION3 OL a sqa1u395luino 5 ND lt 318vN3 m amp 62 Sua3o5IH1no cc 3 d 3 1 edd d 6 Te A bad 5 318vN3 dolsa LYVLS T 98d oL 6 4013 94 4 Sad H A HOLIMSASD Z t 1449 11 lt 0 1912 1081 09 13598
23. Seal Kit hk Vat B02 01 0174 Hydraulic Hose Assembly 6 mm C15 B02 01 0175 Hydraulic Hose Assembly 6 mm C16 B02 01 0176 Hydraulic Hose Assembly 6 mm C17 B02 01 0177 Hydraulic Hose Assembly 6 mm C18 776 80 IA BSP BSP Nate s saena 71 ews y O n Waster m e Stocking 5 waster 71 sin 025 ain in 6 25 XLB 4319 6 12 BASKET PARTS LIST Refer to Table 6 12 for the basket parts list 3 LA 2 5 5 12 Figure 6 12 Basket 6 26 6 PARTS LIST Table 6 12 Basket Parts List n AM B02 03 0030 Hydraulic Cylinder Cage E B25 00 0087 Bushing Cage Cylinder Cylinder End B25 00 0085 Bushing Cage Cylinder Rod End B02 13 0110 Seal Kit Cage Cylinder End Cap With Groove B02 13 0116 Seal Kit Cage Cylinder End Cap Without Groove ing 2 1 3 B36 00 0065 Pivot Pin 16mm dia x 102mm Flat Washer 3 ccc waster i eea O ee O 5 1 1 1 2 2 1 ON B02 01 0171 Hose Assembly 6 mm C12 Lu p memes is 020510 Adare BSP Male 14 BSP Casing Wire Slit 5 16 Dia x 8 1 2 Long 2 Wire Tie 3 32 x 7 6 6 27 XLB 4319 6 13 OUTRIGGER HYDR
24. 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 dilluted with water to form battery electrolyte 4 31 XLB 4319 4 32 MATERIAL SAFETY DATA SHEET FOR LEAD ACID BATTERIES WET FILLED WITH ACID Continued SECTION 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 LUNG 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 St
25. an aerial device occurs it shall be the responsibility of the seller to provide the manufacturer s manual s for that aerial device to the purchaser It is the responsibility of the purchaser to notify the manufacturer of the unit model and serial number and the name and address of the new owner within 60 days 8 8 Markings The markings on the aerial device shall not be removed defaced or al tered All missing or illegible markings shall be promptly replaced 8 9 Parts When parts or components are replaced they shall be identical in specifica tion and function to the original aerial device parts or components or shall provide an equal or greater factor of safety 8 10 Safety Bulletins Owners shall comply with safety related bulletins as received from the manufacturer dealer or installer 8 11 Manuals The owner shall insure that the operating manual s is stored on the mo bile unit 8 12 Training Retraining and Familiarization of Operators 8 12 1 Owner as a Renter or Lessor When an owner functions as a renter or lessor he shall have the same responsibilities as specified under Section 11 of this standard 8 12 2 General Training Only personnel who have received general instructions regard ing the inspection application and operation of aerial devices including recogni tion and avoidance of hazards associated with their operation shall operate an ae rial device Such items covered shall include but not necessarily be limited
26. area or write to NHTSA U S DEPARTMENT of TRANSPORTATION 400 7 Street SW NSA 11 Washington DC 20590 You can also obtain other information about motor vehicle safety from the Hotline 1 7 XLB 4319 1 8 Introduction 2 1 GENERAL DESCRIPTION The XLB 4319 Hydraulic Boom Lift Figure 2 1 is designed to position personnel with their tools and equipment at overhead work locations The work basket load capacity is 450 Ibs During all boom operations the unit is supported by four extended outriggers Two versions of the XLB 4319 boom lift are available gasoline powered or battery powered On both versions the hydraulic power unit includes a reservoir pump and con trol valves Three hydraulic cylinders elevate the lower boom upper boom and jib boom A hydraulic motor and worm gear rotates the boom 360 around a vertical axis WORK BASKET Figure 2 1 XLB 4319 Hydraulic Boom Lift 2 1 XLB 4319 The gasoline powered boom lift gas model uses a 4 cycle 8 horsepower Honda engine The engine drive shaft is directly coupled to the hydraulic pump A 12 Volt DC storage battery powers the engine starter circuit An auxiliary voltage regulator rectifier provides up to 18 Amps charge current while the engine is running The battery powered boom lift DC model uses a 24 Volt 39 Amp one horsepower DC motor to drive the hydraulic pump The
27. floor and supports only the out rigger beam Leave the weight of the boom lift on the trailer wheels At the piston rod end of the cylinder unscrew and remove the keeper pins from both sides of the boom pivot pin Thread the removed keeper pin screws and keeper pins to the outrigger beam for use during cylinder installation Place a block of wood shoring between the outrigger beam and cylinder 10 11 12 13 14 4 Drive out the pivot pin with a hammer and brass or hardwood drift Do not al low the free end of the cylinder to fall Fully retract the cylinder Turn off the key switch and remove the key Tag the hydraulic hoses that connect to the cylinder valve block Each valve block port is stamped with an identity number Place absorbent drip cloths below the cylinder ports Remove the hydraulic hoses from the lift cylinder Plug the hose fittings to prevent fluid leakage Pro tect exposed cylinder ports with plugs and caps At the base of the cylinder unscrew and remove the keeper pins from both sides of the pivot pin Thread the removed keeper pin screws and keeper pins to the mating beam for use during cylinder installation Drive out the pivot pin with a hammer and a brass or hardwood drift Lift and remove the cylinder using an overhead hoist and lifting straps After repairing the hydraulic cylinder reinstall the cylinder in the reverse order of removal Power up the hydraulic
28. moron B01020102 Double NO Gas deen Panel sure 1 Conair 1 s erin lek Segment sse Tum Conois 6 ANSI Reprint The following sections are reprinted from the ANSI A92 2 2001 code in effect at the time of manufacture Permission to reprint has been granted by the Scaffold Industry Association 7 71 7 2 7 3 7 4 7 5 7 6 7 7 7 8 Responsibilities of Dealers and Installers General Responsibilities Each dealer or installer as applicable shall comply with the requirements of this section Vehicle Specifications Each dealer or installer or both who sells an aerial device shall inform the owner or user or both of the manufacturer s minimum vehicle specifications Vehicle Weight Distribution The installer shall be responsible for the weight dis tribution of the completed mobile unit in accordance with the requirements of the aerial device and the applicable regulations Allowance shall be made for the weight of readily removable tools and material specified by the user Manuals Upon delivery of the equipment to the owner or user the dealer or in staller shall provide the manuals as required by Paragraph 6 4 of this standard and manuals for auxiliary equipment added by the installer Installations The installer shall comply with Sections 5 and 6 of this sta
29. related boom How far the lever is pushed or pulled controls the boom lift speed Pulling the boom rotation operator lever turns the boom clockwise Pushing the operator lever turns the boom counterclockwise How far the lever is pushed or pulled controls the boom rotation speed When released the boom operator levers return to the center valve off position A decal located in front of the valve manifold shows which boom motion is controlled by each operator lever Engine Keyswitch Gas Model only On the gas model boom lift the engine keyswitch Figure 3 3 is used to start and stop the gasoline engine from the ground position The keyswitch must be in the ON position as shown to enable engine start up from the work basket control station ENGINE KEYSWITCH Figure 3 3 Engine Keyswitch 3 3 XLB 4319 3 4 Basket Control Station The basket control station Figure 3 3 operates the hydraulic boom lift boom rotation and basket rotation motions The basket control station includes the following electrical and hydraulic controls ENGINE START PUSHBUTTON PUSHBUTTON i 4 E P 4 1 P HYDRAULIC y HAND PUMP 5 cH aL SN AUDIBLE ALARM 2 14 STOP PUSHBUTTON M 4 oe Figure 3 4 Basket Control Station EMERGENCY STOP Pushb
30. shall be inspected for defects prior to each day s operation The following tests and inspections shall be performed by the operator once daily prior to first use 1 Operating controls and associated mechanisms for conditions interfering with proper operation 2 Visual and audible safety devices for malfunction 3 Hydraulic or pneumatic systems for observable deterioration or excessive leakage 4 Fiberglass and other insulating components for visible damage or contami nation 5 Missing or illegible operational and instructional markings 6 Electrical systems of or related to the aerial device for malfunction signs of excessive deterioration dirt and moisture accumulation 7 Visual inspection of bolts pins and other fasteners for loose deformed or missing fasteners and other locking devices Any suspected items shall be carefully examined or tested and a determination made by a qualified per son as to whether they constitute a safety hazard All unsafe items shall be replaced or repaired before use 10 7 Worksite Before the aerial device is used the worksite shall be surveyed for haz ards such as 1 Untamped earth fills 2 Ditches 3 Dropoffs and floor obstructions 4 Debris 5 Overhead obstructions and electrical conductors 6 Weather conditions 7 Presence of unauthorized persons 10 8 Precautions Before and during each use the operator shall 1 Check for overhead obstructions and electri
31. temperatures reaching 40 F 40 C use Dextron Automatic Transmission Fluid Type A If either oil is not available a good grade SAE 10W hydraulic oil may be used where the low temperature is above 32 F 0 SAE 5W hydraulic oil may be used where low temperatures reach 0 F 18 C Once a year or whenever the oil becomes contaminated drain the reservoir clean the sump strainer and replace the hydraulic oil and return filter Return Filter Replacement The hydraulic oil filter should be replaced yearly or whenever filter contamination has a noticeable effect on the beam lift functions If return filter clogging is suspected check the system hydraulic pressure With engine or motor running and no controls actuated hydraulic system pressure should be near 0 zero or minimal If the pressure exceeds 30 psig 2 bar 200 kPa gage the return filter should be replaced as follows 1 Usecleaning cloths and alcohol solvent to clean away dirt on filter cover and housing Figure 4 4 Be sure to place reusable components on new cleaning cloths Do not allow filter parts to become contaminated 2 Usea wrench to loosen filter cover 3 Remove filter cover Place reusable filter parts on new cleaning cloths Lift filter element and element holder above reservoir oil level Drain residual oil back into filter housing Remove and discard used filter element Locate OUT marking on one end of new filter element With OUT end u
32. to the following issues and requirements 1 The purpose and use of manuals 2 That operating manuals are an integral part of the aerial device and must be properly stored on the vehicle when not in use 3 A pre start inspection 4 Responsibilities associated with problems or malfunctions affecting the op eration of the aerial device 5 Factors affecting stability 6 The purpose of placards and decals 7 Workplace inspection 8 Applicable safety rules and regulations such as Part 4 ANSI C2 1997 Na tional Electrical Safety Code applies to utility workers as defined in ANSI C2 The above standard is an example other industries using aerial devices have safety rules pertinent to that industry 9 Authorization to operate 10 Operator warnings and instructions 11 Actual operation of the aerial device Under the direction of a qualified per son the trainee shall operate the aerial device for a sufficient period of time to demonstrate proficiency in the actual operation of the aerial device 12 Proper use of personal fall protection equipment 8 12 3 Retraining The operator shall be retrained when so directed by the user based on the user s observation and evaluation of the operator 8 12 4 Familiarization When an operator is directed to operate an aerial device he she is not familiar with the operator prior to operating shall be instructed regarding the following items and issues 1 The location of the man
33. to 60 lb ft 81 4 N m using the tightening se quence shown 3 Evenly tighten the wheel bolts to 100 lb ft 135 6 N m using the tightening se quence shown 4 3 XLB 4319 4 3 LUBRICATION Lubrication makes operation of the XLB 4319 Boom Lift more efficient and extends the equipment life Use the following procedures to lubricate the boom lift components 1 Lubricate trailer jack post and all grease fittings labeled LUBRICATE WEEKLY with NLGI Grade 2 multi purpose grease 2 Lubricate all LUBRICATE MONTHLY grease fittings with NLGI Grade 2 multi purpose grease Wipe off dirt and grease residue Add approximately 1 2 ounce 15 cc of grease to each fitting See Figure 4 2 for grease fitting loca tions 1 MONTHLY GREASE FITTINGS Figure 4 2 Lubricate Monthly 3 Lubricate the slew ring bearing grease fitting Figure 4 3 with NLGI Grade 2 multi purpose grease Wipe off dirt and grease residue Rotate the boom and add approximately 1 2 ounce 15 cc of grease to each bearing quadrant Figure 4 3 Lubricate Semi Annually 4 HYDRAULIC SYSTEM Hydraulic system maintenance varies with equipment use and the environment in which the boom lift is used Constant attention to keep the oil clean and the reservoir properly filled will help prevent possible damage to the system Hydraulic diagrams are provided in this section for general referen
34. valve and pressure test port are mounted on the hydraulic manifold located between the hydraulic pump and reservoir To prevent tampering the main bypass valve cap is secured with locking wire and a seal If a pres sure adjustment is required call Bil Jax and request a replacement lock wire and seal The boom lift has four bypass valves that regulate hydraulic operating pressures These include 1 the main bypass valve 2 the outriggers bypass valve 3 the basket station boom controls bypass valve and 4 the ground station boom controls bypass valve Check Adjust System and Outriggers Hydraulic Pressures The system hydraulic pressure pump output pressure is regulated by the main bypass valve The system hydraulic pressure is used to power all hydraulic operations The main bypass valve and pressure test port for the gas model boom lift are shown in Figure 4 5 Figure 4 5 Main Bypass Valve and Pressure Test Port Gas Engine Model 4 7 XLB 4319 To adjust the system hydraulic pressure we must first set the outriggers bypass pressure very high This ensures that you are reading system pressure when fully retracting an outrigger cylinder After adjusting the system pressure we must readjust the outriggers bypass pressure to specification Adjust System Pressure 1 2 Connect a hydraulic pressure gage to the pressure test port Remove the cap from the outriggers bypass valve Figure 4 6 Turn the adjust screw to th
35. vovo SHADDIH LNO Tv SHSDDIYLNO 11 6070 S IVO3Q LNAWLYVdNOO HOA 5 9 33S gt T c AQ b L saas 2 X 222 345 9070 Figure 5 2 Decal Locations Trailer and Boom 5 5 XLB 4319 0334 0034 ON END PANEL 0033 RE 0399 0401 4 0397 0395 0396 ON OF CONTROL BOX 0261 0430 Figure 5 3 Decal Locations Control Compartment Exterior 0037 Figure 5 5 Lubricate Semi Annually Decal 5 6 6 Parts List XLB 4319 6 1 UPPER BOOM PARTS LIST Refer to Table 6 1 for the upper boom parts list Figure 6 1 Upper Boom 6 2 6 PARTS LIST Table 6 1 Upper Boom Parts List Description Qty Vertical 1 Pivot Pin 30mm dia x 221mm 3 Locking Pin 10 3 Flat Washer 10 _ 5 Lock Washer 10 6 Cap Screw 10 71 Flat Washer 2 HEC n Flat Washer 2 Trimlock 1 4 in x 30 in 1 Trimlock 1 4 in x 7 in 1 B02 03 0027 Hydraulic Cylinder Upper Boom 1 es Bushing Cylinder Pivot 4 B02 13 0107 Seal Kit End Cap With Groove 1 p Seal Kit End Cap With Groove 16C B02 04 0082 Counter Balance Valve End Cap With Groove B02 04 0064 Counter Balance Valve End Cap Without Groove 16D B02 14 0059 Emergency Lowering Valve End Cap With Groove B02 14 0055 Em
36. 076 Valve Control Basket B02 14 0068 Lever Pivot Box With Gaiter 1B B02 14 0069 End Cap With Spring 5 B02 14 0052 Handle Valve Control 2 B02 00 0043 3 8 Dowty Washer B02 02 0206 Adapter Straight 3 8 BSP Male 3 8 BSP Male 4 B02 02 0209 Tee Adapter 3 8 BSP Female Swivel 1 4 BSP Male 3 8 BSP Male B02 01 0160 Hose Assembly 6 mm C7 sen Gm 77 serorors Hydrate Hose Assembly 6mm C8 9 Hose Assembly 6mm CI Lu merororsr Hydraulic Hose Assembly 10mm C2 Los sonar ts Spiral NAE ee 1s merorors Hose Assembly 6mm C27 23 B02 02 0208 Tee Adapter 3 8 BSP Female Swivel 3 8 BSP Male 3 8 BSP Male cede o gency Dom 28 B02 02 0207 Tee Adapter 1 4 BSP Female Swivel 1 4 BSP Male 1 4 BSP Male 6 39 XLB 4319 6 18 BOOM CONTROL HYDRAULICS PARTS LIST GROUND GAS MODEL Refer to Table 6 18 for the gas model boom control hydraulics parts list N 6 6B Figure 6 18 Gas Model Boom Control Hydraulics Ground 6 40 6 PARTS LIST Table 6 18 Gas Model Boom Control Hydraulics Parts List Ground 4 mr mieHoseAsemby 6mm 36 11 5s Harale Hose Assembly 6mm 38 3 6 8005086 Solenoid Valve SV2 Outriggers Enable 1
37. 1 or greater METALLIC LEAD METAL 25 5 0 05 mg m3 0 05mg m3 NONE 7439 92 1 LEAD SULFATES 18 2 0 05 mg m3 0 05 mg m3 NONE 7439 92 1 LEAD OXIDES 18 0 0 05 mg m3 0 05 mg m3 NONE 7439 92 1 POLYPROPYLENE CASE MTL 6 4 SEPARATORS 3 5 SULFURIC ACID H2SO4 5 2 1 0 mg m3 1 0 mg m3 NONE 7664 93 9 WATER 19 2 REGULATORY INFORMATION Those ingredients listed above are not subject to the reporting requirements of 313 of Title of the Superfund Amendments Reauthorization Act The items are covered in an exemption as a Manufactured Article 372 30 b SECTION 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 Sharp Pungent Odor SECTION IV FIRE AND EXPLOSION HAZARD DATA Flash Point Not Combustible Auto Ignition Temperature N A Flammabiltiy 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
38. 3 8 4 4 4 4 4 4 6 6 2 2 1 1 1 4 4 4 1 1 1 1 4 4 4 4 4 2 2 2 1 1 1 4 4 2 4 1 1 6 35 XLB 4319 6 16 ENGINE COMPARTMENT PARTS LIST GAS MODEL Refer to Table 6 16 for the gas model engine compartment parts list S cece to Figure 6 16 Engine Compartment Parts List Gas Model 6 36 6 PARTS LIST Table 6 16 Engine Compartment Parts List Gas Model continued ee B20 00 0009 Engine Honda 8 Horsepower Coupling Half Engine Shaft rr Washer ss 0000 0008 Ca Co a Pump Stat 50 Woodruff oe Lm na OOOO O e __________ eese Waster 6 37 XLB 4319 6 17 BOOM CONTROL HYDRAULICS PARTS LIST BASKET Refer to Table 6 17 for the boom control hydraulics parts list 22 etu C1 0 190 ES 0 C7 5 Cr T re zug 9 C6 o z C27 C8 17 Figure 6 17 Boom Control Hydraulics Basket 6 38 6 PARTS LIST Table 6 17 Boom Control Hydraulics Parts List Basket B02 04 0
39. 3 Reverse Lever RH Side 29 B10 00 0065 Brake Adjuster Assembly 30 B10 00 0071 Plug Plastic 31 10 00 0070 Cover Plate B10 00 0069 Lock Nut Nut Mount Spindle B10 00 0082 Bolt M20 x 60mm Bolt Mount Spindle not shown ele 6 7 8 19 20 21 22 23 N 33 Cover Spindle Lock Nut Nut Mount Spindle Only 34 Backplate Cap 35 Brake Cable Shell 36 Hex Nut Self Locking 37 PF Flat Washer 38 Axle Assembly 9 fF Cap Screw Order fender kit B22 00 0026 when replacing original side mounted fender XLB 4319 6 10 REAR LIGHTS AND JUNCTION BOX PARTS LIST Refer to Table 6 10 for the rear lights and junction box parts list Figure 6 10 Rear Lights and Junction Box 6 PARTS LIST Table 6 10 Rear Lights and Junction Box Parts List qu 3 0090 0934 Screw Self Tapping 1 4 20 x 3 4 01 10 0069 Lens Replacement 1 2 1 2 Poroa anchor Pate were 3 1 1 1 1 Wire Tie 3 32 x 6 1 4 01 09 0010 Cord 6 23 XLB 4319 6 11 OUTRIGGERS PARTS LIST Refer to Table 6 11 for the outriggers parts list bw 3 A Figure 6 11 Outriggers 6 24 6 PARTS LIST Table 6 11 Outriggers Parts List B02 03 0026 Hydraulic Cylinder Outrigger B25 00 0084 Bushing Cylinder Pivot B02 13 0109
40. 4070121 Latch Cover Washer Internal Lock 1 4 in x 30 5 in ARS I xx Hex Nut Self Locking 4 B42 00 0020 Support Rod Socket Head Screw Flat Head 15 B04 07 0118 Clamp Support Rod 1 Hex Nut Self Locking 6 PARTS LIST Qty gt NOTE Quantities shown for one cover There two covers the machine control compartment and pump compartment The pump compartment does not have an opening and does not require a trim lock item 11 6 9 XLB 4319 6 5 RESERVOIR COMPARTMENT PARTS LIST GAS MODEL Refer to Table 6 5 for the pump compartment parts list for the gas model boom lift TO HYDRAULIC PUMP 14 Figure 6 5 Reservoir Compartment Gas Model 6 10 6 PARTS LIST Table 6 5 Reservoir Compartment Parts List Gas Model Reservoir Assembly Hydraulic Filter not shown B02 01 0185 Hydraulic Hose Assembly 13mm C31 Cap Screw Lock Washer Flat Washer Hydraulic Hose Assembly Pump Supply 5 Hex Nut Self Locking 02 02 0205 Adapter Straight 1 4 BSP Male 3 8 BSP Male B02 00 0043 3 8 Dowty Washer pes 9 Return Manifold Assembly _ Socket Head Screw 12 02 00 0042 1 2 Dowty Washer NN 3 d ERE CER B02 02 0220 1 2 BSP Male Plug B02 02 0206 Adapter Straight 3 8 BSP Male 3 8 BSP Male Hydraulic Hose
41. 67 Caution Tape Black and Yellow INSTRUCTIONS B06 00 0173 SAFETY HARNESS LANYARD 06 00 0402 BOOM LIFT INSTRUCTIONS 1 ATTACHMENT POINT BASKET B06 00 0403 PUSH TO LOWER B06 00 0404 WARNING STAND CLEAR OF OUTRIGGER B06 00 0405 WARNING PINCH POINT 06 00 0406 XLB 4319 TRANSFER 06 00 0409 EMERGENCY ROTATION 1 GEAR B06 00 0430 XLB 4319 SPECIFICATIONS B06 00 0189 WARNING LEVEL MACHINE BEFORE USE B06 00 0192 OPERATION AND SERVICE MANUAL INSIDE B06 00 0225 WARNING STAY CLEAR WHILE RAISING B06 00 0261 CAUTION ANSI DECAL B06 00 0268 EMERGENCY ROTATION HANDLE 5 1 XLB 4319 LUBRICATE EMERGENCY A DANGER FAILURE TO COMPLY WITH THE FOLLOWING INSTRUCTIONS B06 00 0036 OR ANY OTHER IMPROPER USE OR MAINTENANCE OF THIS B06 00 0409 EQUIPMENT WILL RESULT IN INJURY OR DEATH WEEKLY 06 00 0036 ROTATION GEAR f Risk of Electric Shock f MAXI M U M CAPACI TY MONTHLY DO NOT expose charger to rain power wash detergents or spray DO NOT use frayed or damaged electric cords when 450LBs 30600 0130 charging B06 00 0380 B06 00 0130 During charging explosive oxyhydrogen gas is generated DO NOT smoke or allow open fire sparks or embers near battery when charging Connect input cord only to properly grounded three wire outlet with specified voltage and frequency LUBRICATE Always wear safety goggles and fac
42. AULIC CONTROLS PARTS LIST Refer to Table 6 13 for the outrigger hydraulic controls parts list Figure 6 13 Outrigger Hydraulic Controls 6 28 6 PARTS LIST Table 6 13 Outrigger Hydraulic Controls Parts List B02 01 0173 Hydraulic Hose Assembly 6 mm C14 1 B02 01 0174 Hydraulic Hose Assembly 6 mm C15 3 2 B02 01 0175 OHIO URS TT Hose Assembly 6 mm C16 2 B02 01 0176 Hydraulic Hose Assembly 6mm C17 Hose Assembly 6 mm C17 2 B02 01 0177 Hydraulic Hose Assembly 6 mm C18 2 a Joon Mage Sei 14 BSP Mal BSP s hororo mme 1 Self Locking Hex Nut 13 Hydraulic Hose Assembly 6 mm C38 Gas Model Only 14 B02 02 0204 Adapter Straight With Orifice 1 4 BSP Male 3 8 BSP Male 6 29 XLB 4319 6 14 LOWER CONTROLS PARTS LIST Refer to Table 6 14 for the lower controls parts list N 10 Figure 6 14 Lower Controls 6 30 6 PARTS LIST Table 6 14 Lower Controls Parts List Battery Charger 1 z Washer 2 ZEE ZZ B02 04 0074 Valve Control Boom ET NNNM 7 __ Strain Relief m OOOO Ca omm This item
43. Assembly 10 mm C28 Hydraulic Hose Assembly 6 mm C14 Hydraulic Hose Assembly 10 mm 19 Hydraulic Hose Assembly 6 mm C37 Hydraulic Hose Assembly 6 mm C34 21 02 01 0163 Hydraulic Hose Assembly 6 mm C26 22 02 01 0182 Hydraulic Hose Assembly 6 mm C23 B02 02 0218 Adapter Straight 3 8 BSP Male 1 2 BSP Male 7 10 11 12 13 14 15 16 17 18 23 02 02 0215 3 8 BSP Male Plug 24 ap 20 21 22 23 24 XLB 4319 6 6 PUMP COMPARTMENT PARTS LIST DC MODEL Refer to Table 6 6 for the pump compartment parts list for the DC model boom lift Figure 6 6 Pump Compartment DC Model 6 12 6 PARTS LIST Table 6 6 Pump Compartment Parts List DC Model F ab 0090 0787 Fender Washer gae Sd C ewe Cable Connector Plug and Receptacle dl EE B02 02 0218 Adapter Straight 3 8 BSP Male 1 2 BSP Male Hydraulic Return Manifold 02 02 0220 1 2 BSP Male Plug B02 02 0206 Adapter Straight 3 8 BSP Male 3 8 BSP Male B02 01 0183 Hydraulic Hose Assembly 10 mm C28 B02 01 0156 Hydraulic Hose Assembly 10 mm 6 EE 1 e 16 6 13 XLB 4319 6 6 PUMP COMPARTMENT PARTS LIST DC MODEL Refer to Table 6 6 for the pump compartment parts list for the DC model boom lift 3 Sx 5 b dins
44. Hand Pump The basket control station is equipped with a hydraulic hand pump In case lift boom op erating power is lost the hand pump is available to manually lower the lift boom Hold ing the related operator lever in position and smoothly operating the hand pump lowers the lift boom or swivels the work basket to another position Engine Start Pushbutton Gas Model only Pressing the engine start pushbutton restarts the gasoline engine while in the work bas ket The pushbutton should only be pressed until the engine starts The engine should not be cranked longer than 15 seconds at a time Over cranking will burn up the starter mo tor Audible Alarm An audible alarm is located in the basket station control panel The audible alarm sounds whenever the key switch is on and the boom lift is out of level 115 Volt Outlet The 115 Volt AC outlet is provided for running electrical power tools in the work basket A connecting power cord must be plugged in to a suitable power source The power plug is located on the inside of the trailer frame near the tow end of the trailer The outlet is rated for a 15 ampere load Do not overload the accessory power circuit 3 5 XLB 4319 3 2 NORMAL OPERATING PROCEDURE Perform the following procedures to operate the XLB 4319 Hydraulic Boom Lift 1 3 6 Read and follow all safety precautions contained in Section 1 and all responsi bilities outlined in the ANSI A92 2 reprint contained in Secti
45. IONS OR ANY OTHER IMPROPER USE OF THIS EQUIPMENT WILL RESULT IN SERIOUS INJURY OR DEATH BEFORE USE Operator must read and understand owners manual and all decals on machine before operating Itis operators ity to comply with all warnings and instructions Survey the job site and identify all potential hazards Inspect lift for proper maintenance and any damaged or worn components DO NOT operate until proper maintenance has been performed and all damaged or worn parts have been replaced See owners manual for proper maintenance procedures NEVER TAKE CHANCES DO NOT use this lift if you are under the influence of drugs or alcohol or if you feel dizzy ill or unsteady in any way OPERATE ON FIRM AND LEVEL SURFACE ONL Y f used on loose gravel or other soft surfaces additional base support under each outrigger foot pad may be necessary Properly deploy all 4 outriggers by lowering each outrigger until it is in firm contact with the ground Level machine before use if buzzer sounds lift is not level and the necessary outrigger adjustment should be made to level machine before continuing All occupants must wear full body harness and lanyard Check safety devices daily before use see owners manual for proper check procedures When working on public roads warnings and barriers must be setup in accordance with all local state and federal traffic codes Cordon off area around base to keep personnel and other equipment away from unit while in
46. K K K 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 XLB 4319 1 2 MATERIAL SAFETY DATA SHEET FOR AW 46 HYDRAULIC OIL SITE SP GENERAL ECIFIC INFORMATION AW 46 HYDRAULIC OIL INFORMATION TRADE NAME AW 46 HYDRAULIC OIL EM ERGENCY TEI HONE NUMBERS 517 849 2144 CH EMICAL FAMI ies JUBRICATING OIL CAS NUMBI HAZARDOUS INGR ER MIXTURE ISSUE DATE 12 15 96 EDIENTS CONTAINS NO INGR 1910 1000 AND OS EDIENTS NOW KNOWN TO BE HAZARDOUS AS DEFINED IN OSHA 29 CFR HA 29 CFR 1910 1200 HEALTH HAZARD DATA THRESHHOLD LIMIT VAL
47. Maintenance Manual Operation and STEP ABOVE 9 JAX AERIAL WORK PLATFORMS BIL XLB 4319 Hydraulic Boom Lift B33 01 0080 BOOM PERSONNEL LIFT This equipment is designed and manufactured in compliance with the duties re sponsibilities and standards set forth for manufacturers in the ANSI 92 2 standard in effect at the time of manufacture This equipment will meet or exceed applicable OSHA codes and ANSI A92 2 stan dards when used in accordance with sections 7 8 9 10 amp 11 of ANSI A92 2 and all other manufacturer s recommendations It is the responsibility of the user of this equipment to follow all applicable ANSI OSHA Federal State and local codes and regulations that govern the safe opera tion of this equipment Table of Contents jn v 1 NOISE ERN 1 1 1 1 Introduction nihi atate die d ER ee 1 1 1 2 Before Operation oni 1 2 1 3 Operation oo petere ge bg e 1 3 1 4 Maintenance Safety ete rre de et Ide Bere te retener 1 5 General 2 1 5 Battery Maintenance 5e 1 6 1 5 Damaged Equipment Policy 1 6 Safety Statement hdd efe edes 1 6 Damage 1 6 Damage Repair 1 6 Reporting Safety 1 1 7 2 linn 2 1 2 1 General D
48. Make sure all tools and equipment are safely stowed NEVER exceed load ratings by transferring loads to the basket at elevated heights NEVER use cage to carry materials and never allow overhang of materials when raising or lowering the basket NEVER push or pull with the boom or basket and NEVER use the boom to lift any part of the trailer NEVER use the boom or basket to place a dead man load against any struc ture materials or equipment NEVER climb up or down boom NEVER leave the keys in the boom lift while unattended or not in use 1 4 1 MAINTENANCE SAFETY Ensure the following safety precautions are observed whenever maintenance is per formed on the XLB 4319 Hydraulic Boom Lift General Maintenance ALWAYS perform maintenance procedures according to manufacturer s re quirements NEVER short change maintenance procedures ALWAYS check hydraulic system Make sure all lines connectors and fittings are tight and in good condition ALWAYS turn the key switch off before connecting or disconnecting wiring to or from valve solenoids or other load devices ALWAYS disconnect power to the hydraulic pump drive motor before making electrical checks of the hydraulic valves ALWAYS keep all mechanisms properly adjusted and lubricated according to maintenance schedule and manufacturer s specifications ALWAYS perform a function check of operating controls before each use and after repairs have
49. Outrigger Position Switches The outrigger position switches are set up to detect when the boom lift load is transferred from the trailer wheels to the outriggers When the load is transferred to each outrigger the related position switch is engaged and the related LED lights up on the control panel All four position switch circuits must be engaged to enable lift boom operation Use the following procedure to check and adjust the outrigger position switches 1 Inspect the outrigger position switches for loose mounting or visible damage If the mounting hardware is loose tighten the hardware If a position switch is damaged replace the switch 2 Lower the outriggers and raise the trailer wheels off the ground Verify that all four outrigger LEDs light up 3 If an LED is lit before the outrigger is lowered or if an LED fails to light when the outrigger is lowered check the adjustment of the related outrigger position switch as follows a Measure the distance between the actuator roller and the outrigger pivot Figure 4 13 The roller should be 1 8 inch 3 mm from the outrigger pivot Adjust the actuator as needed b Ifthe actuator is correctly adjusted but the LED fails to light up or go dim check the switch LED and wiring Repair or replace the faulty component Refer to the detailed electrical diagram in Figure 4 15 OUTRIGGER POSITION SWITCH ACTUATOR ROLLER 7 POSITION SWITCH TRIP POINT Figure 4 13 Out
50. UE 5mg m3 AS OIL MIST 8 hr TWA PRIMARY ROUTES OF ENTRY INHALATION SKIN ABRASION AND INGESTION CARCINOGENIC NO SYMPTOMS IF INGESTED CONTACTED WITH SKIN OR VAPOR INHALED NO ADVERSE EFFECTS EXPECTED EYES FLUSH WITH WATER FOR 15 MINUTES SKIN WASH THOROUGHLY WITH WARM SOAPY WATER INGESTION DO NOT INDUCE VOMITTING SEEK MEDICAL ATTENTION MEDICAL CONDITIONS AGGRAVATED BY EXPOSURE NONE KNOWN AIR EXPOSURE LIMITS P E L NOT ESTABLISHED T L V 5mg m3 OSHA 29 CFR 1910 1000 HEALTH lFIRE 1SPECIFIC XREACTIVITY 0 PHYSICAL DATA BOILING POINT 400 DEG F VAPOR PRESSURE PSIA N A SPECIFIC GRAVITY H20 1 0 87 SOULUBILITY IN WATER NEGLIGIBLE PH OF CONCENTRATE N A APPEARANCE AND ODOR PALE YELLOW PETROLEUM ODOR FIRE AND EXPLOSION HAZARD DATAFLASH POINT METHOD USED 425 DEG FLAMMABLE LIMITS NOT DETERMINED EL N AUEL N A EXTINGUISHING MEDIA SAND DRY CHEMICAL FOAM CO2 TREAT AS CLASS B FIRE UNUSUAL FIRE AND EXPLOSION HAZARDS NONE REACTIVIYY DATA STABILITY STABLE CONDITIONS TO AVOID AVOID EXTREMES OF HEAT INCOMPATIBILITY MATERIALS TO AVOID STRONG OXIDIZING MATERIALS OX IDES HAZARDOUS PO HAZARDOUS DECOMPOSITION PRODUCTS INCOMPLETE COMBUSTION MAY CAUSE CARBON 2 WILL NOT OCCUR SP SP ILL OR Ll ILLED FEDERAL REGU EAK P ROCEDURES STEPS TO BE TAKEN IN CAS DIKE AND ABSORB ON INERT MATERIAL FOLLOW
51. Washer PF Flat Washer B36 00 0040 Transport Pin Flat Head Screw 5 5 XLB 4319 6 3 JIB BOOM PARTS LIST Refer to Table 6 3 for the jib boom parts list Figure 6 3 Jib Boom 6 6 6 PARTS LIST Table 6 3 Boom Parts List Description Jib Boom Knuckle Pivot Pin 25mm dia x 208mm Locking Pin ey Flat Washer Item No Cap Screw Jib Boom Bushing Jib Boom Full Boss Bushing Jib Boom Short Boss 2228 Grease Fitting Cage Support Hydraulic Cylinder Jib Boom Bushing Cylinder Pivot B02 13 0107 Seal Kit End Cap With Groove Seal Kit End Cap Without Groove B02 04 0082 Counter Balance Valve End Cap With Groove B02 04 0064 Counter Balance Valve End Cap Without Groove Hydraulic Hose Assembly 6mm C8 Adapter Straight 1 4 BSP Male 1 4 BSP Male 1 4 Dowty Washer Wire Tie Pivot Pin 25mm dia x 201mm Qty HR 6 7 XLB 4319 6 4 COMPARTMENT COVERS PARTS LIST Refer to Table 6 4 for the control and power compartment covers parts list 4 6 Figure 6 4 Compartment Covers 6 8 Table 6 4 Compartment Covers Parts List B42 01 1015 Hinge Cover Fender Washer Hex Nut Lock Washer 6 Cover Control Compartment Cover Pump Compartment not shown 8 80
52. YS wear proper clothing for the job Wear protective equipment as re quired by federal state or local regulations The operator MUST wear a safety harness and lanyard e ALWAYS locate read and follow all directions and warnings displayed on the equipment e ALWAYS inspect the equipment for DO NOT USE tags NEVER use equip ment tagged in this way until all repairs are made and all DO NOT USE tags are removed by authorized maintenance personnel e ALWAYS make sure the basket and outrigger shoes are free of mud grease or other slippery material to reduce the possibility of slipping e NEVER allow improperly trained personnel to operate this equipment Only trained and authorized personnel shall be allowed to operate this equipment e NEVER operate this equipment if you are under the influence of alcohol or drugs or if you feel ill dizzy or unsteady in any way Operators must be physi cally fit thoroughly trained and not easily excitable e NEVER modify alter or change the equipment in any way that would affect its original design or operation in any way e NEVER operate this equipment in ways for which it is not intended 1 2 1 3 1 DURING OPERATION Ensure the following general safety precautions are followed during the operation of the XLB 4319 Hydraulic Boom Lift N DANGER This machine is not insulated for use near electrical power lines and DOES NOT provide protection from conta
53. ability 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 SPILL OR LEAK PROCEDURES Steps to be taken 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 NFPA Rating HEALTH 3 FLAMMABILITY 0 REACTIVITY 2 SPECIAL 0 HMIS Rating HEALTH 3 FLAMMABILITY 0 REACTIVITY 2 PERSONAL PROTECTION X ote IC SE SECTION VIII CONTROL AND PROTECTIVE MEASURES KKK K K K K K K K K
54. ances eese 1 3 Table 2 1 Specifications auras 2 4 Table 4 1 Daily Weekly Service Checks 4 1 Table 4 2 Monthly Servic Checks tete eoe Reset 4 2 Table 4 3 Troubleshooting 4 20 Table 4 4 Level Sensor 4 30 Table 5 1 Replacement eet tee 5 1 6 1 Upper Boom Parts List iore egre tee matre 6 3 Table 6 2 Lower Boom Parts Last iie eco eee titer se tees HH 6 5 Table 6 3 Jib Boom List eno tmd eed e dettes 6 7 Table 6 4 Compartment Covers Parts 6 9 Table 6 5 Reservoir Compartment Parts List Gas 6 11 Table 6 6 Pump Compartment Parts List DC 6 13 Table 6 7 Chassis and Rotation Unit Parts 6 17 Table 6 8 Hitch and Jack Assembly Parts 6 19 Table 6 9 Axle and Wheel Assembly Parts 6 21 Table 6 10 Rear Lights and Junction Box Parts 6 24 Table 6 11 Outriggers Parts List 6 26 Table 6 12 Basket Parts rH predetto 6 28 Table 6 13 Outrigger Hydraulic Controls Parts 6 30 Table 6 14 Lower Controls Parts 8 6 32 Table 6 15 Upper Controls Parts 6 34 Table 6 16 Engine Compartment Parts List Gas Model 6 36 Table 6 17 Boom Control Hydraulics Parts List
55. been made ALWAYS locate and protect against possible pinch points prior to performing maintenance and repairs ALWAYS use factory approved parts to repair or maintain this equipment If this equipment is rebuilt retesting is required in accordance with factory instructions NEVER allow water or foreign particles into the DC electric motor housing In gestion of water or foreign particles may cause serious damage to the motor If the motor gets wet oven dry the motor to remove all moisture before operating consult motor manufacturer for drying instructions NEVER test or operate the hydraulic components when another person is near the equipment NEVER add unauthorized fluids to the hydraulic system or battery Check origi nal manufacturer specifications NEVER exceed the manufacturer s recommended relief valve settings NEVER touch or allow metal tools to contact static discharge sensitive elec tronic components ALWAYS use static discharge prevention mats and ground ing devices when handling electronic components NEVER tamper with cylinder counter balance valves Contact the Bil Jax Ser vice Department at 800 537 0540 if the cylinder counter balance valves need adjusting NEVER attempt repairs you do not understand Consult manufacturer if you have any questions regarding proper maintenance specifications or repair 1 5 XLB 4319 Battery Maintenance Ensure the following general safety precautions are followed when
56. boom and boom cylinder are securely supported before removing the boom cylinder Failure to do so may cause the boom or boom cylinder to fall This may cause severe injury or damage to the boom lift 1 If removing the lower boom lift cylinder raise the lower boom to just above horizontal and stand a 36 inch 90 cm long length of 4x4 hardwood shoring on the trailer tongue directly below the lower boom rest plate Lower the boom onto the shoring Manually check the stability of the shoring 2 If removing the upper boom lift cylinder raise the lower boom about two inches 50 mm above the boom rest position 3 Press in and hold the manual lowering valve at the boom lift cylinder that is to be replaced Bleed off all hydraulic pressure to the cylinder 4 Refer to Figure 4 8 At the piston rod end of the cylinder unscrew and remove the keeper pins from both sides of the pivot pin Thread the removed keeper pin hardware to the boom for use during cylinder installation 5 Drive out the pivot pin with a hammer and a brass or hardwood drift Do not al low the free end of the cylinder to fall gt 27 e P PN UPPER f BOOM M p 26 Q 1 Qh PIN 2 M HYDRAULIC CYLINDER LOWERING VALVE BLOCK Figure 4 8 Hydraulic Cylinder Removal 4 11 XLB 4319 4 12 10 11 12 13 14 15 NOTE If removing the lower boo
57. cal conductors 2 Insure that the load on the platform and or load lifting devices are in accor dance with the manufacturer s rated capacity 3 Insure that outriggers and stabilizers are used if the manufacturer s instruc tions require their use 4 Insure that guardrails are properly installed and the gates are closed 5 Use outrigger pads when necessary to provide firm footing 10 9 Mobile Operation Before engaging in mobile operation the operator shall deter mine that the aerial device is specifically designed for mobile operation 10 10 Personnel Only trained and authorized personnel shall be permitted to operate the aerial device 10 11 Training Retraining and Familiarization of Operators 10 11 1 General Training Only personnel who have received general instructions re garding the inspection application and operation of aerial devices including recognition and avoidance of hazards associated with their operation shall op 7 ANSI REPRINT erate an aerial device Such items covered shall include but not necessarily be limited to the following issues and requirements 1 The purpose and use of manuals 2 That operating manuals are an integral part of the aerial device and must be properly stored on the vehicle when not in use 3 A pre start inspection 4 Responsibilities associated with problems or malfunctions affecting the operation of the aerial device 5 Factors affecting stability 6 The purpos
58. ce WARNING Hydraulic system pressure settings are factory settings and should not need read justment The only time readjustment is needed is when a component in the hy draulic control circuit is replaced Only the adjustments covered in this manual are permitted If you believe that any other hydraulic component needs adjust ment notify Bil Jax for additional instruction Hydraulic motions are quiet quick and can be dangerous to persons on or near the lift vehicle Failure to heed this warning can result in serious injury or death Hydraulic System Inspection Check the hydraulic hose and fittings for leaks and damage daily Tighten or replace as necessary to prevent hydraulic oil loss Secure hoses and lines as needed to prevent rub bing and chafing Fluid Check and Replacement The oil level should be checked with the engine or motor off the boom down and the trailer on a level surface Pull the dipstick out of the reservoir Figure 4 4 and wipe off any oil with a clean shop cloth then reinsert the dipstick Pull the dipstick to check the oil level The oil level should be between the full and add oil marks on the dipstick DIPSTICK HYDRAULIC RESERVOIR Figure 4 4 Hydraulic Reservoir 4 5 XLB 4319 4 6 Do not mix hydraulic oils The reservoir is originally filled with Energol HLP HD46 a high grade non foaming hydraulic oil designed for temperatures as low as 20 F 33 C For
59. ct with or close proximity to any electrically charged conductor Operator must maintain safe clearances at all times 10 feet minimum and always allow for platform movement such as wind induced sway Always contact the power company before performing work near power lines As sume every line is hot Remember power lines can be blown by the wind Refer to Table 1 1 for minimum safe approach distances between machine and electrical power lines Table 1 1 Minimum Safe Approach Distances Voltage Range Minimum Safe Approach Distance 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 500 25 7 62 Over 500KV to 750KV 35 10 67 Over 750KV to 1000KV 45 13 72 e ALWAYS position lift far enough away from power sources to ensure that part of the lift can accidentally reach into an unsafe area This includes full ex tension of the boom through 360 degrees rotation e ALWAYS operate only on a firm and level surface NEVER use surfaces that do not support the equipment with its rated load capacity and the resulting force exerted on the outriggers during boom extension and rotation e ALWAYS keep yourself and all personnel away from potential pinch or shear points e ALWAYS report any misuse of equipment to the proper authorities Horseplay is prohibited e ALWAYS maintain good footing on the w
60. d The boom locking pins are in place outriggers are fully retracted 7 1 Secure trailer hitch to ball on towing vehicle 2 3 Attach lighting plugs Check to make sure lighting Attach safety wire wire cannot be damaged in transit 4 Check to make sure lights are working properly 5 Fully raise trailer tongue jack and release hand brake The trailer weight must not exceed the vehicle towing capacity Do not exceed maximum towing speed EMERGENCY LOWERING PROCEDURE From Basket if fitted In the event of power failure the basket may be lowered using the emergency hand pump The procedure is as follows 1 2 3 Attach hand pump handle Select function required with control lever s Pump hand pump From Ground 1 2 Press red emergency lowering valve on base of bottom boom lift cylinder Stand clear of descend ing structure Press red emergency lowering valve on top of boom cylinder Stand clear of descending struc ture Emergency Rotation Install emergency rotation handle red hex shaft on rotation gearbox Turn handle to rotate structure B06 00 0399 BOOM OPERATING INSTRUCTIONS XLB 4319 1 Read Operation Manual and all decals prior to operating 2 Follow the instructions on the lower controls for Unhitching Setting Up and Boom Operating This will ensure proper boom set up and also help you familiarize y
61. e Semi Annually Decal 5 6 Upper Boom ette ette ete ero Lt ttp 6 2 Lower Bom ener etie ie ete eet ER e ento 6 4 Boomi Rune ERU EBORE HR HN 6 6 Compartment Covers 6 8 Reservoir Compartment Gas 6 10 Pump Compartment DC 6 12 Chassis and Rotation 6 16 Hitch and Jack Assembly 6 18 Axle and Wheel Assembly essen 6 20 Rear Lights and Junction 6 23 Figure 6 11 Figure 6 12 Figure 6 13 Figure 6 14 Figure 6 15 Figure 6 16 Figure 6 17 Figure 6 18 Figure 6 19 Figure 6 20 Figure 6 21 Figure 6 22 Figure 6 23 QUES LO PRU PO Ue Ee eed 6 25 6 27 Outrigger Hydraulic esee 6 29 Lower 6 31 Upper Controls ure ee het a eerie 6 33 Engine Compartment Parts List Gas Model 6 35 Boom Control Hydraulics Basket essen 6 39 Gas Model Boom Control Hydraulics 6 41 DC Model Boom Control Hydraulics 6 43 Lower Boom Cylinder Hydraulics 6 45 Upper Boom Cylinder Hydraulics eene 6 46 Basket Pushbutton Panel Gas Model sse 6 47 Pushbutton Panel Ground Controls eee 6 49 List of Tables Table 1 1 Minimum Safe Approach Dist
62. e of placards and decals 7 Workplace inspection 8 Applicable safety rules and regulations such as Part 4 ANSI C2 1997 National Electrical Safety Code applies to utility workers as defined in ANSI C2 The above standard is an example other industries using ae rial devices have safety rules pertinent to that industry 9 Authorization to operate 10 Operator warnings and instructions 11 Actual operation of the aerial device Under the direction of a qualified person the trainee shall operate the aerial device for a sufficient period of time to demonstrate proficiency in the actual operation of the aerial de vice 12 Proper use of personal fall protection equipment 10 11 2 Retraining The operator shall be retrained when so directed by the user based on the user s observation and evaluation of the operator 10 11 3 Familiarization When an operator is directed to operate an aerial device he she is not familiar with the operator prior to operating shall be instructed regard ing the following items and issues 1 The location of the manuals 2 The purpose and function of all controls 3 Safety devices and operating characteristics specific to the aerial device 11 Responsibilities of Renters Lessors or Lessees 11 1 General Responsibilities Each renter or lessor or lessee shall comply with the re quirements of the applicable section or sections below 7 7 XLB 4319 7 8 11 1 1 Lessor or Lessee as Deale
63. e right exactly two turns This adjustment will allow the main bypass valve to regulate the test pressure Reinstall and tighten the cap to prevent oil leakage Do not over tighten the cap NOTE Figure 4 6 Outriggers Bypass Valve Start the gasoline engine or DC motor Run the engine or motor for at least five minutes to warm the hydraulic oil to the normal operating temperature Pull up one outrigger control lever to fully retract the outrigger While the out rigger control lever is pulled up read the pressure gage If the pressure is rising allow the pressure to reach its highest reading On the gas model boom lift if the pressure gage reading is 3045 psig 210 bar 21 000 kPa nominal no adjustment is required If an adjustment is required proceed with step 8 On the DC model boom lift if the pressure gage reading is 2750 psig 190 bar 19 000 kPa nominal no adjustment is required If an adjustment is required proceed with step 8 Loosening the adjust lock nut will cause hydraulic oil to leak from the main bypass valve It is recommended that you shut the engine off before making adjustments to the main bypass valve Press the emergency stop pushbutton to turn off the hydraulic pump Loosen the adjust lock nut for the main bypass valve 10 11 12 13 14 15 4 Use hex wrench to turn the pressure adjust screw Turn the adjust screw right for higher pressure or left for lo
64. e shield when working SEMLANNUATUY MANUAL PUMP HANDLE PINCH POINT 06 00 0037 B06 00 0037 Consult Operation and Maintenance Manual for additional THIS PLUG 1 1 5 VO LT information on battery maintenance B06 00 0062 STAY CLEAR amore FTC Bil Jax Inc 2004 06 00 0405 B06 0 0 0034 B06 00 0405 Check battery acid level atthe start of each day If acid does not cover the plates add only enough distilled or demineral ized water to completely cover the plates B06 00 0043 Keep terminals and terminal connections clean EMERGENCY ROTATION HANDLE OFA 806 00 0268 55 This machine is designed and manufactured in compli LANYARD ance with the ANSI A92 2 standard in force on the date of THIS UNIT SHALL ONLY BE TOWED manufacture Dealers owners users operators lessors WHEN ALL BOOMSECTIONS ARE FULLY ATTACHMENT and lessees are responsible for inspection maintenance DOWN AND LOCKEDWITHTRANSPORT POINT training and operation as required by A92 2 and the owners SAFETY PINS manual COIAIRFT 06 00 0033 06 00 0173 Alterations modifications or changes to this machine B06 00 0033 without the written authorization of Workforce Products Inc as well as any unauthorized adjustment of valves disabling or by passing of safety devices or the improper use of this machine shall exempt Workforce Products Inc from any liability for any resulting injur
65. e this equipment in areas where the equipment or user may come in contact with a live power source The information contained herein is not to be considered as legal advice and is intended for informational purposes only This information is offered to alert Bil Jax customers to procedures that may be of concern to them This information is not intended to be all inclusive and is to be followed in the use of Bil Jax equipment only For any questions concerning the safe use of this equipment call 800 937 0540 before operating 1 1 XLB 4319 1 2 BEFORE OPERATION Ensure the following general safety precautions are followed before operating the XLB 4319 Hydraulic Boom Lift e ALWAYS survey the usage area for potential hazards such as untamped earth fills unlevel surfaces overhead obstructions and electrically charged conduc tors or wires Be aware of any potential hazards and always consider what could happen Watch for moving vehicles in the operating area e ALWAYS read understand and follow the procedures in this manual before at tempting to operate equipment e ALWAYS inspect the equipment for damaged or worn parts Check for cracked welds hydraulic leaks damaged wiring loose wire connectors damaged out riggers low tire pressure uneven tire wear or tire damage Also check for any improper operation NEVER operate equipment if damaged in any way Im properly operating equipment must be repaired before using e ALWA
66. eature Data Rated Platform Load 450 Ibs 204 kg total Maximum Work Height 43 ft 13 1 m Extended Basket Height 37 ft 11 3 m Maximum Outreach 19 ft 9 8 m Elevation Rate 5 3 in sec 135 mm sec Nominal 26 7 ft min 8 14 m min Horizontal Reach 19 ft 5 9 m Boom Rotation 700 Rotation Speed 318 per minute nominal Basket Dimensions 51 in W x 30in D x 45 in H 129 5 cm x 76 cm x 114 3 cm Power Source Gas Model 8 Horsepower 4 Cycle Gasoline Engine with Remote Start Control and Alternator Circuit Storage Battery Gas Model 12 Volt DC 195 Amp Storage Battery NAPA P N 5022NF Power Source DC Model 24 Volt DC 4 Deep Cycle 245 Amp hour Batteries Battery Charger DC Model 110 120 Volt 40 Amp Hydraulic Pressure 2756 psi 19 000 kPa Reservoir Capacity 2 75 Gallons 10 4 Liters Hydraulic Capacity 7 Gallons 26 5 Liters Hydraulic Oil Energol HLP HD46 BP Oil Gross Vehicle Weight DC Model 2860 lbs 1297 kg Gross Vehicle Weight Gas Model 3200 lbs 1452 kg Tongue Weight DC Model 100 165 45 4 kg Tongue Weight Gas Model 160 165 72 6 kg Trailer Brakes Mechanical Surge 2 3 2 INTRODUCTION WARRANTY Bil Jax warrants its boom lifts for one year from the date of delivery against all defects of material and workmanship provided the unit is operated and maintained in compliance with Bil Jax s operating and maintenance instructions Bil Jax will at its o
67. ed the trailer is level and the full weight of the boom lift is loaded onto the outriggers An interlock prevents the retracting of any outrigger while the upper or lower boom is raised two inches 50 mm or more Boom elevation speeds are adjustable from zero to 5 3 inches per second 0 to 27 ft min A hydraulic hose failure at either retract cylinder port will cause a counterbalance valve to stop the return oil flow It is strongly recommended that no one adjust or tamper with these safety devices If service is required please notify Bil Jax for instructions Emergency lowering of the basket is by manual valve plungers on the upper and lower boom lift cylinders or by manual operation of a hand pump in the basket Firmly pushing in and holding a valve plunger manually retracts the boom lift cylinder Smooth pumping of the hand pump while engaging a single hydraulic valve lever enables boom operation in case of a hydraulic power failure The XLB 4319 Hydraulic Boom Lift cylinders will not rust or corrode during storage since the cylinder rod is fully immersed in oil It is important that the cylinder rods be kept clean and undamaged for the protection of the cylinder head packings 2 3 XLB 4319 2 4 2 2 SPECIFICATIONS Boom Lift Work Platform Model Number XLB 4319 Serial Number Manufactured by Bil Jax Inc 125 Taylor Parkway Archbold Ohio 43502 800 537 0540 Table 2 1 Specifications F
68. eets this requirement 8 2 2 Regular Inspection and Tests The inspection procedure for mobile units is di vided into two classifications based upon the intervals at which inspections and tests shall be performed Intervals shall be set by the owner in accordance with the manufacturer s recommendations Such intervals are dependent upon component function and exposure to wear deterioration and other agents which adversely af fect component life Two classifications are designated 1 Frequent Inspection and Test Daily to monthly intervals 2 Periodic Inspection and Test One to twelve month intervals 8 2 3 Frequent Inspection and Test Items determined by the owner in accordance with the manufacturer s recommendations for each specific aerial device shall be in spected for defects The following tests and inspections shall be performed by the operator once daily prior to first use 1 Operating controls and associated mechanisms for conditions interfering with proper operation 2 Visual and audible safety devices for malfunction 3 Hydraulic or pneumatic systems for observable deterioration or excessive leakage 4 Fiberglass and other insulating components for visible damage or contami nation 5 Missing or illegible operational and instructional markings 6 Electrical systems of or related to the aerial device for malfunction signs of excessive deterioration dirt and moisture accumulation 7 Visual inspect
69. entrapped air from the hydraulic cylinder according to instructions in paragraph 4 4 4 15 XLB 4319 Basket Swivel Cylinder Removal and Installation 1 Fully lower the outriggers and raise the upper boom Position the basket for easy access to the hydraulic cylinder Figure 4 10 mounted on the bottom of the work basket F HYDRAULIC lt 22242 CYLINDER 52277 KEEPER 44 Figure 4 10 Basket Swivel Cylinder 2 Place absorbent drip cloths below the cylinder ports Remove the hydraulic hoses from the jib boom cylinder Plug the hose fittings to prevent fluid leakage Protect exposed cylinder ports with plugs and caps 3 Remove the keeper pins from both ends of the cylinder Remove the hydraulic cylinder 4 Secure the keeper pins to the mating beam for use during cylinder installation 5 After repairing the hydraulic cylinder reinstall the cylinder in the reverse order of removal 6 Power up the hydraulic system and check for leakage Tighten the hydraulic fit tings as needed 7 Bleed entrapped air from the hydraulic cylinder according to instructions in paragraph 4 4 4 16 4 4 5 SLEW RING BEARING Che ck Free Play Check the free play of the slew ring bearing every six months If the recommended main tenance schedule is followed there should be little or no wear of the slew ring bearing Check the slew ring bearing free play according to the following procedure 1
70. equently on request 11 4 1 General training Only personnel who have received general instructions regard ing the inspection application and operation of aerial devices including recogni tion and avoidance of hazards associated with their operation shall operate an ae rial device Such items covered shall include but not necessarily be limited to the following issues and requirements 1 The purpose and use of manuals 2 That operating manuals are an integral part of the aerial device and must be properly stored on the vehicle when not in use 3 A pre start inspection 4 Responsibilities associated with problems or malfunctions affecting the operation of the aerial device 5 Factors affecting stability 6 The purpose of placards and decals 7 Workplace inspection 8 Applicable safety rules and regulations such as Part 4 ANSI C2 1997 National Electrical Safety Code applies to utility workers as defined in ANSI C2 The above standard is an example other industries using aerial devices have safety rules pertinent to that industry 9 Authorization to operate 10 Operator warnings and instructions 11 Actual operation of the aerial device Under the direction of a qualified person the trainee shall operate the aerial device for a sufficient period of time to demonstrate proficiency in the actual operation of the aerial device 12 Proper use of personal fall protection equipment 11 4 2 Familiarization When an op
71. erator is directed to operate an aerial device he she is not familiar with the operator prior to operating shall be instructed regarding the following items and issues 1 The location of the manuals 2 The purpose and function of all controls 3 Safety devices and operating characteristics specific to the aerial device 11 5 Communications In the event the manufacturer or installer provides the renter or lessor manuals bulletins or other materials for the information of the user of an ae rial device the renter or lessor shall pass them on to the user without any undue de lay 7 ANSI REPRINT 7 9 XLB 4319 BUS BARS 7 moy NUN ARD 5 C ND M S A D Minimum Safe Approach Distance See Table 7 1 DENOTES PROHIBITED ZONE NDANGER Do not allow machine personnel or conductive materials inside prohibited zone Maintain M S A D from all energized lines and parts as well as those shown Assume all electrical parts and wires are energized unless known otherwise CAUTION Diagrams shown are only for purposes of illustrating M S A D work positions not all work positions 7 10 Table 7 1 Minimum Safe Approach Distance M S A D to energized exposed or insulated power lines and parts 7 ANSI REPRINT Minimum Safe Approach Distance Voltage Range Phase to Phase Feet Meters 0 to 300V Avoid Contact Over 300V
72. ergency Lowering Valve End Cap Without Groove Grease Fitting B11 03 0040 Upper Boom Bushing Upper Boom Upper Boom Stabilizer Bushing Upper Boom Stabilizer Pivot Pin 30mm dia x 179mm Flat Washer Knuckle Jib Boom NM Self Locking Nut Pivot Pin 30mm dia x 201mm Pivot Pin 30mm dia x 216mm 6 3 XLB 4319 6 2 LOWER BOOM PARTS LIST Refer to Table 6 2 for the lower boom parts list Figure 6 2 Lower Boom 6 4 6 PARTS LIST Table 6 2 Lower Boom Parts List Item No Description Qty B11 03 0039 Lower Boom 1 1A B25 00 0084 Bushing Lower Boom 4 PF Grease Fitting 6 B36 00 0042 Locking Pin 8 Flat Washer Cap Screw Lower Boom Stabilizer Bushing Lower Boom Stabilizer Pivot Pin 30mm dia x 179mm Hydraulic Cylinder Lower Boom Bushing Cylinder Pivot B02 13 0107 Seal Kit End Cap With Groove Seal Kit End Cap With Groove B02 04 0082 Counter Balance Valve End Cap With Groove Counter Balance Valve End Cap Without Groove B02 14 0059 Emergency Lowering Valve End Cap With Groove B02 14 0055 Emergency Lowering Valve End Cap Without Groove Boom Support Bracket Pivot Pin 30mm dia x 221mm Self Locking Hex Nut Limit Switch Head Limit Switch Roller Arm Plug Adapter Wire Tie 15 B01 03 0064 Cable Limit Switch Socket Head Screw Flat Head Screw M8 x 1 25 x 20mm B31 00 0037 Boom Wear Pad o Socket Head Screw Lock
73. escriptions nse nate 2 1 2 2 SpecifICAatlons e DP 2 4 Boom Lift Work Platform 2 4 2 3 Warranty Ate e Ie RE UR 2 5 3 Operation E 3 1 3 1 Operator Controls trm e eR e tures 3 1 Ground Control Station eese eene 3 1 Basket Control 3 4 3 2 Normal Operating Procedure sese 3 6 3 3 Emergency 3 8 3 4 Manual Boom 3 9 3 5 Battery Recharge DC MODEL ONLY 3 10 3 6 Boom Lift Transport ecce rrt 3 11 Trailer Pitching 3 uni don to porch ps 3 11 4 Maintenance eese eere esee enne tn o ee iaee r ST S ee aens 4 1 4 1 Scheduled Service Checks 4 1 Daily Weekly Service Checks 4 1 8 4 2 4 2 Wheel Nut Torque Requirements 4 3 4 3 Lubrication 3 rae RU quete rede 4 4 4 4 Hydraulic Systems REUS terree HR ut eg 4 5 Hydraulic System Inspection eee 4 5 Fluid Check and Replacement 4 5 Return Filter 4 6 Bleeding e rete eet 4 6 Hydraulic Pressure Checks and 4 7 Hydraulic Cylinder Replacement 4 10 4 5 SLEW RING
74. ever performing bat tery maintenance on the XLB 4319 Hydraulic Boom Lift e ALWAYS check battery acid level daily on the DC model boom lift Check battery test indicator for proper state of charge on maintenance free batteries before using lift e ALWAYS wear safety glasses when working near battery e ALWAYS avoid contact with battery acid Battery acid causes serious burns Avoid contact with skin or eyes If accidental contact occurs flush with water and consult a physician immediately e ALWAYS disconnect ground cable first when removing battery e ALWAYS connect ground cable last when installing battery e ALWAYS charge batteries in open well ventilated areas e NEVER smoke when servicing battery e NEVER allow batteries to overcharge and boil e NEVER short across battery posts to check for current NEVER break a live circuit at battery e NEVER jump start other vehicles using boom lift battery 1 5 DAMAGED EQUIPMENT POLICY Safety Statement At Bil Jax we are dedicated to the safety of all users of our products Therefore all Bil Jax lifts are designed manufactured and tested to comply with current applicable Federal OSHA and ANSI codes and regulations Damage Policy There may be occasions when a Bil Jax lift is involved in an incident that results in struc tural damage to the lift This can seriously compromise the ability of the lift to perform in a safe manner Therefore whenever a Bil Jax lift is damaged struc
75. ght up on the control panel e Push down on the front outrigger levers 3 amp 4 to lower the front outrig gers Raise the trailer wheels off the ground Verify that the front outrigger LEDs light up on the control panel f Watch the bubble level indicator and adjust the outriggers as needed to level the trailer An LED level switch and four outrigger position switches prevent boom motions if the trailer is not level or if one or more outriggers is not sup porting the vehicle load The load of the boom lift vehicle must be placed on all four outriggers and the trailer must be level to enable motor powered boom lift operations Remove the keeper pins and transport pins that secure the upper and lower booms Stow the transport pins in the retainer clips provided Use the ground control station to operate the boom lift controls Raise lower and rotate the boom to get familiar with the controls Learn to smoothly start and stop all boom motions Lower the boom sections to position the basket for boarding Turn the key switch to the basket control position Raise the safety bar and enter the basket Put on the safety harness and attach the lanyard to the attachment position on the basket railing Operate the boom lift carefully When boom lift operations are complete retract the boom and outriggers for trailer towing according to the following procedure a Using the basket control station rotate the basket to the center posit
76. he boom controls reach into the cover latch port and release the cover latch according to the latch decal Open the control compartment cover Unhook the support rod behind the front edge of the cover and place the rod end into the mating hole in the battery bracket d gt CONTROL COMPARTMENT COVER gt GROUND CONTROL STATION 4 rdi Figure 3 1 Ground Control Station Access 3 1 XLB 4319 3 2 The ground control station Figure 3 2 includes the following electrical and hydraulic controls EMERGENCY STOP PUSHBUTTON OUTRIGGER OPERATOR LEVERS Figure 3 2 Ground Control Station Key Switch Turning the key switch to the left selects operation from the basket control station Turn ing the key switch to the right selects operation from the ground control station The cen ter Off position disables electrical and hydraulic operations Removing the key protects against unauthorized boom lift operation EMERGENCY STOP Pushbutton When pressed the EMERGENCY STOP pushbutton disconnects electrical power from the upper and lower control stations Pressing the EMERGENCY STOP pushbutton also shuts off the gasoline engine or DC motor to interrupt hydraulic power Before you can restore power you must rotate the EMERGENCY STOP pushbutton clockwise Outrigger Indicators Four green OUTRIGGER indicators light up when the boom lift outriggers are extended a
77. he hand pump to lower the boom Apply a steady up and down pumping action The hydraulic cylinders are dual acting boom motion will continue throughout pump handle operation BOOM OPERATOR LEVERS Figure 3 7 Basket Control Station 3 8 3 MANUAL BOOM ROTATION The hydraulic boom lift is equipped with an emergency rotation handle crank that can be used to rotate the boom in case of a power failure or other emergency situation Use the following procedure to manually rotate the boom 1 Remove the crank from its stowage rack and install the crank on the hex end of the worm gear drive screw Figure 3 8 2 Hold the boom rotation valve lever in the correct position for boom rotation and turn the crank to rotate the boom Figure 3 8 Emergency Rotation 3 9 XLB 4319 3 10 3 5 BATTERY RECHARGE DC MODEL ONLY The DC model boom lift batteries should be recharged after each 8 hour work shift or more often if needed When the boom lift is not in use the batteries should be recharged at least once per week The normal charge time is 10 to 12 hours If the battery charge is extremely low a full recharge may take up to 24 hours Recharge the DC model boom lift batteries as follows WARNING Recharge the batteries in well ventilated area only Do not charge batteries near fire flame or other ignition sources Batteries being charged may emit highly ex plosive hydr
78. i Hydrate Hose Assembly Ca 71 Hose Assembly 1 7 noo 0r 0162 Hydrate Hose Assembly Cos 77 0 0200 dapes BSP Male gt 6 PARTS LIST 6 45 XLB 4319 6 22 PUSHBUTTON PANEL PARTS LIST BASKET Refer to Table 6 22 for the basket pushbutton panel parts list Emergency Enavie Stop Figure 6 22 Basket Pushbutton Panel 6 46 Table 6 22 Basket Pushbutton Panel Parts List B19 00 0042 Enclosure Upper Control Box DC Model i i B01 02 0084 Pushbutton Switch Emergency Stop Red 06 00 0441 Decal Upper Controls B01 10 0002 Audible Warning Device Alarm B01 02 0098 Pushbutton Switch Engine Start SW2 Yellow 1 Gas Model 01 09 0021 Nut Electric Lock NO Contact Gas Model NO Contact Gas Model mau n B01 10 0031 3 Position Terminal Strip DC Model 5 Position Terminal Strip Gas Model 01 10 0090 5 Position Marker Strip Gas Model Only 0090 0813 Screw Machine 8 32 x 3 4 0090 0181 Nut Lock 8 32 6 PARTS LIST 6 47 XLB 4319 6 48 6 23 PUSHBUTTON PANEL PARTS LIST GROUND CONTROLS Refer to Table 6 23 for the pushbutton panel parts list 9 8 7 6 5 Figure 6 23 Pushbutton Panel Ground Controls Table 6 23 Pushbutton Panel Parts List Ground Controls
79. ies or damage Re FFU 06 00 0261 E B06 00 0261 IT IS UNLAWFUL TO OPERATE THIS EQUIPMENT WITHIN 10 OPERATION AND SERVICE FEET OF HIGH VOLTAGE MANUAL INSIDE LINES OF 50 000 VOLTS OR COFC 806 00 0192 ADANG ER LESS 806 00 0192 For safe clearance of lines in excess of 50 000 volts see owners manual 1 1 0 VO LT This machine is NOT insulated Do not use within 10 ft of power Level machine before use lines or other electrically charged sources This machine DOES Failure ts level this maching could S NOT provide protection for personnel from contact with or close result in serious injury or death proximity to any live electrical power source and should consid dii 80500188 06 00 0151 1 ing i ith hine ered energized by all personnel coming in contact wit machine 806 00 0189 806 00 0334 L JAX B06 00 0161B STAY CLEAR WHILE RAISING c OR LOWERING AA BIL JAX 06 00 0225 06 00 0225 06 00 0363 Figure 5 1 Replacement Decals Sheet 1 of 3 ABBREVIATED OPERATING INSTRUCTIONS IMPROPER USE OF THIS EQUIPMENT WILL RESULT IN SERIOUS INJURY OR DEATH THIS MACHINE MUST NOT OPERATED UNLESS YOU ARE COMPLETELY FAMILIAR WITH THE INSTRUCTIONS CONTAINED IN THE OPERATING MANUAL UNHITCHING Machine must be unhitched from vehicle before setting up 1 Apply hand brake 2 Remove lighting plug and safety wire from vehicle
80. ion b Fully retract the jib boom the upper boom and the lower boom c Exitthe basket and turn the key switch to the ground control position d Retract the two rear outriggers until the trailer tires touch Do not fully re tract the rear outriggers e Retract the front outriggers until fully raised f Retract the rear outriggers until fully raised g Prior to towing install the transport pins and keeper pins to secure the up per and lower booms Refer to paragraph 3 6 for towing instructions 3 7 XLB 4319 3 3 EMERGENCY LOWERING The XLB 4319 Boom Lift is equipped with two manual lowering valves and a hydraulic hand pump These devices can be used to lower the basket in case of a power failure a load shift or other emergency situation The manual lowering valves are located on the upper and lower boom lift cylinders and are manually operated from the ground The hydraulic hand pump is located in the work basket Use the hand pump in case an assistant is not available on the ground To lower the work basket from the ground push in the valve plunger Figure 3 6 on the lower boom lift cylinder Continue pushing the valve plunger to fully retract the lower boom Push in and hold the valve plunger on the upper boom lift cylinder until the upper boom is retracted Figure 3 6 Manual Lowering Valve To manually lower the boom lift from the work basket push the upper or lower boom operator lever Figure 3 7 down and use t
81. ion of bolts pins and other fasteners for loose deformed or missing fasteners and other locking devices Any suspected items shall be carefully examined or tested and a determination made by a qualified per son as to whether they constitute a safety hazard All unsafe items shall be replaced or repaired before use 8 2 4 Periodic Inspection or Test An inspection of the mobile unit shall be performed at the intervals defined in 8 2 2 depending upon its activity severity of service and environment or as specifically indicated below These inspections shall include the requirements of 8 2 3 1 Structural members for deformation cracks or corrosion 2 Parts such as pins bearings shafts gears rollers locking devices chains chain sprockets wire and synthetic ropes and sheaves for wear cracks or distortion 3 Hydraulic and pneumatic relief valve settings 4 Hydraulic system for proper oil level 5 Hydraulic and pneumatic fittings hoses and tubing for evidence of leak age abnormal deformation or excessive abrasion 6 Compressors pumps motors and generators for loose fasteners leaks un usual noises or vibrations loss of operating speed and excessive heating 7 Hydraulic and pneumatic valves for malfunction and visible cracks in the external valve housing leaks and sticking spools 8 Visually inspect any vacuum prevention systems and verify function of such systems on Category A aerial devices
82. is required If an adjustment is required proceed with step 6 Press the emergency stop pushbutton to turn off the hydraulic pump Removing the adjust screw cap while the hydraulic pump is running will cause oil to leak from the bypass valve It is recommended that you shut the engine off before removing the adjust screw cap Locate the bypass valve for the selected boom control valve bank Remove the adjust screw cap Use screwdriver to turn the adjust screw Turning the adjust screw 1 4 turn to the right will increase the pressure about 150 psig 10 4 bar 1 037 kPa gage Reinstall and tighten the adjust screw cap Do not over tighten the cap Reset the emergency stop pushbutton and restart the engine or motor Push the upper or lower beam control lever down at the basket or ground station controls and read the pressure gage If the bypass pressure is still too high or too low repeat the adjustment starting with step 6 If no other hydraulic pressures are to be checked shut down the engine or motor and remove the pressure gage Hydraulic Cylinder Replacement WARNING Hydraulic cylinders are heavy and may have hydraulic oil on the surface Hydrau lic cylinders must be secured with lifting straps or tie downs when removing in stalling and handling Failure to heed this warning can result in serious injury 4 10 4 Boom Lift Cylinder Removal and Installation WARNING Make sure the
83. l per paragraph 4 4 o Clean battery terminals and battery charger operation Check operation of manual lowering valves and hand pump Check wheel nut torque per paragraph 4 2 Lubricate compartment hinges and latches with light weight machine oil Lubricate grease fittings labeled LUBRICATE MONTHLY per paragraph 4 3 2 Lubricate trailer tongue jack 2 places with NLGI Grade 2 multi purpose grease Lubricate grease fittings labeled LUBRICATE SEMI ANNUALLY per paragraph 4 3 3 Change engine oil Check battery cables and wiring for loose connections and damaged wires Replace spark plug Replace hydraulic oil and oil filter Check boom pivot pin and sleeve bearings for wear Replace worn or damaged pivot pins and sleeve bearings Check slew bearing for wear or damage per paragraph 4 5 Inspect and adjust trailer brakes Load test boom lift operations with 450 pounds 204 kg 4 2 4 2 4 MAINTENANCE WHEEL NUT TORQUE REQUIREMENTS It is very important to apply and maintain the correct wheel bolt torque on the boom lift trailer The wheel bolts must be evenly tightened to the following specified torque incre ments whenever a trailer wheel is removed and installed Use the following tightening procedure 1 Evenly tighten the wheel bolts to 25 lb ft 34 N m in the tightening sequence shown in Figure 4 1 Figure 4 1 Wheel Bolt Tightening Sequence 2 Evenly tighten the wheel bolts
84. m lift cylinder fully retract the cylinder Use the pivot pin to turn the piston rod pivot boss 90 Lower the cylinder through the relief slot in the stabilizer beam not shown Turn off the key switch and remove the key Tag the hydraulic hoses that connect to the cylinder valve block Each valve block port is stamped with an identity number Place absorbent drip cloths below the cylinder ports Remove the hydraulic hoses from the lift cylinder Elevate the hoses to help prevent fluid leakage Pro tect exposed hose fittings and cylinder ports with plugs and caps At the base of the cylinder unscrew and remove the keeper pins from both sides of the boom pivot pin Thread the removed keeper pin hardware to the boom for use during cylinder installation Drive out the pivot pin with a hammer and a brass or hardwood drift Lift and remove the cylinder using an overhead hoist and lifting straps After repairing the hydraulic cylinder reinstall the cylinder in the reverse order of removal Power up the hydraulic system and check for leakage Tighten the hydraulic fit tings as needed Bleed entrapped air from the hydraulic cylinder according to instructions in paragraph 4 4 Do not tamper with the cylinder counterbalance or manual lowering valves If the valves need adjustment contact the Bil Jax Service Department at 800 537 0540 Outrigger Cylinder Removal and Installation 1 Lower the outrigger until the foot pad meets the
85. mmendations Should the original manufacturer no longer exist an equivalent entity may determine the re quired procedure 8 4 1 Maintenance Training The owner shall train their maintenance personnel in in 8 5 8 6 spection and maintenance of the aerial device in accordance with manufac turer s recommendations and Section 8 of this standard Modifications No modifications or additions which affect the stability mechani cal hydraulic or electrical integrity or the safe operation of the aerial device shall be made without the written approval of the manufacturer If such modifications or changes are made the capacity operation and maintenance instruction markings shall be changed accordingly In no case shall the safety factors be reduced below those specified in this standard or below the manufacturers design safety factors whichever are greater Should the original manufacturer no longer exist an equiva lent entity may approve required modification Weight Distribution Changes in loading or additions made to the mobile unit after the final acceptance that affect weight distribution shall meet applicable regulations 7 3 XLB 4319 7 4 by governmental agencies In no case shall axle loads of the fully loaded vehicle exceed the Gross Axle Weight Ratings GAWR assigned by the manufacturer Note Any change in weight distribution may adversely affect stability 8 7 Transfer of Ownership When a change in ownership of
86. n accordance with conditions of the ground surface congestion and slope 9 6 Alterations Altering or disabling of safety devices guards or interlocks if so equipped shall be prohibited 9 7 Bare Hand Work For bare hand work a Category aerial device shall be used 9 8 Lower Controls The lower controls of aerial devices shall not be used for con tinuous operation with personnel in the platform 10 Responsibilities of Operators 7 5 XLB 4319 7 6 10 1 General Responsibilities Each operator shall comply with the requirements of this section 10 2 Operation During operation of the aerial device all platform occupants shall use appropriate fall protection connected to the aerial device at the platform position 10 3 Work Platform The operator shall not use railings planks ladders or any other device in or on the work platform for achieving additional working height or reach 10 4 Brakes The vehicle parking brake s shall be set at all times that the boom is ele vated except when the aerial device is being used in accordance with 9 5 10 5 Loading Any loading which includes a horizontal load shall be avoided unless the mobile unit is designed for that application 10 6 Observations Observations during operation for any defects shall be conducted on an ongoing basis 10 6 1 Pre start Inspection Items determined by the owner in accordance with the manufacturer s recommendations for each specific aerial device
87. nd the boom weight is removed from the trailer axle All four indicators must be lit and the trailer must be level to enable operation of the lift booms 3 Outriggers Run Pushbutton Holding the black outriggers run pushbutton in enables operation of the outrigger cylin ders The outrigger cylinders can only be operated when the lift boom cylinders are re tracted Boom Run Pushbutton Holding the green boom run pushbutton in enables operation of the lift boom cylinders The lift boom cylinders can only be operated when the outrigger cylinders are extended the boom weight is removed from the trailer axle and the trailer is level Outrigger Operator Levers Four outrigger operator levers position the hydraulic valves to extend and retract the out rigger cylinders Lifting an operator lever retracts the cylinder to raise the outrigger Pushing down on an operator lever lowers the related outrigger When released the op erator levers return to the center valve off position Starting on your left the outriggers are numbered 1 through 4 A decal located below the outrigger valve manifold indicates which operator lever controls which outrigger Boom Operator Levers Four boom operator levers position proportional hydraulic valves to extend and retract the boom lift cylinders and the boom rotation drive motor Pulling a boom operator lever extends the cylinder to raise the boom Pushing a boom operator lever lowers the
88. ndard re lating to proper installation and shall follow the instructions of the manufacturer In the event the original manufacturer no longer exists an equivalent entity may pro vide these instructions The installer of an aerial device shall before the mobile unit is placed in operation perform stability tests in accordance with the requirements of 4 5 1 and 4 5 2 the operational and visual tests in accordance with the requirements of 6 6 1 and 6 6 2 and the appropriate electrical tests required in 5 4 3 of this stan dard The installer shall when installing an aerial device on a chassis which is a highway vehicle comply with all requirements of the applicable Federal Motor Ve hicle Safety Standards in effect at the time of installation Certification as a manu facturer alteration intermediate or final of a motor vehicle under the Federal Mo tor Vehicle Safety Standards is required The travel height of the mobile unit shall be posted in a location that is readily visible to the vehicle operator For insulated aerial devices the installer shall assure conformance to the Qualification test re quirements of 5 3 2 by either obtaining certification of the test and performing a pe riodic test after installation or by performing the Qualification test Quality Assurance The installer shall have a documented quality assurance pro gram which will ensure compliance with this standard Welding All welds made by the installer whose failure c
89. nsulating component s the unit shall be dielectrically tested in accordance with section 5 4 3 d An insulated replacement boom shall be tested to insure conformance to 5 3 3 by the supplier e Bare hand work units shall be tested as shown in Table after any major repair to the insulated boom or any insulated boom replacement Any sus pected items shall be carefully examined or tested and a determination made by a qualified person as to whether they constitute a safety hazard All unsafe items shall be replaced or repaired before use Inspection and Test Records 1 Items to be inspected shall be designated to the operator or other authorized per son making frequent inspections Records of frequent inspections need not be made However where a safety hazard is found it shall be reported in writing to a person responsible for the corrective action and that report and a record of the cor rection shall be maintained for five years or as required by applicable regulations 2 Written dated and signed reports and records shall be made of periodic inspec tions and tests and retained for a period of five years or as required by applicable regulations Maintenance Maintenance and frequency of maintenance shall be determined by the owner in accordance with the manufacturer s recommendations Welding re pairs of components or welds designated as critical in the manufacturers manual shall be made in accordance with the manufacturers reco
90. ogen gas Failure to properly ventilate the charge gases may result in serious injury or death 1 Move the boom lift to a well ventilated area with direct access to a grounded 120 VAC electrical outlet Make sure the recharge area is not near fire flames or other ignition sources 2 Pluga short heavy duty power cord into the battery charger receptacle on the electrical cord connected to the charger The recommended power cord should be an 12 AWG multi strand grounded cord no longer than 50 feet 16 meters NOTE Using an underrated or long power cord will reduce the output of the battery charger resulting in longer charge time 3 Plug the power cord into a grounded 120 VAC receptacle Verify that the red ON CHARGING indicator LED lights up on the battery charger 4 determine the charge rate at any time during the charge cycle observe the DC ammeter Figure 3 9 The ammeter needle moves to the right at the start of the charge cycle As the battery charge rises the needle moves farther left AMIE frau DC ON CHARGING AMMETER COMPLETED 80 CHARGE INDICATOR LEDs CHECK BATTERY SEE MANUAL ASSOCIATED MARKETING PROFESSIONALS PHOENIX AZ U S A bem Figure 3 9 Battery Charger 3 6 3 OPERATION CAUTION Always remember to unplug the battery charger power cord before moving the boom lift Failure to unplug the power cord will cause damage to the equipment
91. on 7 of this man ual Position the lift at the work area Make sure the lift is on a firm and level surface and that there are no potential hazards such as overhead obstructions or electri cally charged conductors Do not operate the lift if such hazards exist Check the tow trailer and boom lift for damaged or worn parts Repair or re place parts as necessary Do not use a damaged boom lift Apply the trailer parking brake Lower the trailer tongue jack and unhitch the trailer from the tow vehicle The trailer must be unhitched before the outriggers are lowered See Figure 3 4 and lower the boom lift outriggers as follows a Start the engine or motor b Turn the key switch to the ground control position c Press and hold in the black outrigger run pushbutton BUBBLE LEVEL INDICATOR RUN PUSHBUTTON OUTRIGGER OPERATOR LEVERS Figure 3 5 Outrigger Controls 3 WARNING Always verify that the green outrigger LEDs light when the outrigger feet be come loaded If an outrigger LED fails to light up or lights up before the outrigger foot becomes loaded the limit switch or switch setting is faulty Using the boom lift with a faulty limit switch or switch setting can cause severe injury death or damage to the equipment NOTE 10 11 d Push down on the rear outrigger levers 1 amp 2 to lower the rear outriggers Lower the rear outriggers only until the rear outrigger LEDs li
92. on valve bank The hydraulic pressure for the ground station boom controls is regulated by an identical valve at the back of the ground station boom controls The regulated pressure is used to extend and retract all basket and boom positioning cylinders a ok a MCA t id 7 4 2 qc 3 J UPPER d BEAM Figure 4 7 Boom Control Bypass Valve Basket Station 4 9 XLB 4319 Check and adjust the hydraulic bypass pressure for the basket or ground station boom controls as follows 1 2 10 11 12 Connect a hydraulic pressure gage to the pressure test port Start the gasoline engine or DC motor Run the engine or motor for at least five minutes to warm the hydraulic oil to the normal operating temperature Extend the outriggers to fully support and level the boom lift Turn the ground control station key switch to basket or ground position accord ing to which bypass pressure basket or ground control is to be adjusted When adjusting the bypass pressure for the basket station boom controls the basket station boom controls must be used When adjusting the by pass pressure for the ground station boom controls the ground station boom controls must be used Push down the lower beam control lever at the basket or ground station and read the pressure gage If the pressure gage reading is 2750 psig 190 bar 19 000 kPa nominal no adjustment
93. ork platform NEVER wear slippery soled shoes e ALWAYS make certain all personnel are clear and there are no obstructions be fore repositioning basket e ALWAYS cordon off area around the outriggers to keep personnel and other equipment away from it while in use e ALWAYS stay clear of wires cables and other overhead obstructions e ALWAYS engage the boom travel locking pins before towing the trailer 1 3 XLB 4319 1 4 NEVER allow electrode contact with any part of the basket if welding is being performed from the platform NEVER use without the outriggers fully extended and firmly based NEVER override or by pass manufacturer s safety devices NEVER attach a safety harness to an adjacent structure pole or equipment while working from the boom platform NEVER move unit with a person or materials on board NEVER try to move the trailer with the boom extended NEVER stand or sit on cage bars Work only within the work cage and do not lean out over the cage to perform work NEVER attempt to increase working height with boxes ladders or other means NEVER operate this equipment when exposed to high winds thunderstorms ice or any other weather conditions that would compromise operator safety NEVER allow ropes electric cords hoses etc to become entangled in the equipment when the basket is being raised or lowered NEVER exceed manufacturer s load limits or use the lift as a crane for lifting heavy materials
94. ould result in motion of the platform s shall meet the Structural Welding Code AWS D1 1 98 and AWS D1 2 98 The installer shall establish applicable welding quality assurance proce dures for all weldments Training The dealer or installer shall offer training or training materials that aid owners and users in the operation inspection testing and maintenance of the aerial device This training shall be offered initially and subsequently on request 7 8 1 Dealer or Installer as User Whenever a dealer or installer directs personnel to op erate an aerial device inspecting sales demonstrations or any form of use the dealer or installer shall assume the responsibilities of users as specified in Section 9 of this standard personnel authorized to operate the aerial device shall have been trained 7 1 XLB 4319 7 2 8 2 Responsibilities of Owners General Responsibilities Each owner shall comply with the requirements of this section The following responsibilities pertain to the owner s inspection testing maintenance modification training and transfer of ownership These activities shall be performed by qualified person s Inspection and Testing Classifications 8 2 1 Initial Inspection and Test Prior to initial use all new or modified mobile units shall be inspected and tested to ensure compliance with the provisions of this stan dard Verification by the manufacturer the installer or an equivalent entity s m
95. ourself with the operation of the lift 3 Check again to be sure all outrig gers are properly set and the lift is level 4 Always wear full body harness and attach lanyard to the provided attachment when operating from the basket 5 Check the emergency stop button to make sure it is in the released position 6 Press and hold the green enable button with one hand while operat ing the control levers with the other hand Each lever is clearly marked Stand clear of outrigger while it is being lowered Contact with outrigger foot pad will cause serious crushing injury THE HYDRAULIC SYSTEM OF THIS MACHINE IS DESIGNED USE ENERGOL HLP 46 HYDRAULIC OIL for function and direction FTC B06 00 0402 806 00 0402 5 REPLACEMENT DECALS EMERGENCY LOWERING VALVE PUSH TO LOWER 06 00 0403 B06 00 0403 cie LATCHED UNLATCHED B06 00 0397 B06 00 0404 POR POMADA Use only tools equipped with 3 prong grounded plug 1500 Watt maximum load 15 Amp maximum circuit AIFIRFC B06 00 0115 806 00 0115 STOP READ OPERATING INSTRUCTIONS BEFORE OPERATING MACHINE B06 00 0068 B06 00 0068 B06 00 0393 BEFORE USING LOWER ALL 4 OUTRIGGERS UNTIL EACH OUTRIGGER IS IN FIRM CONTACT WITH THE G E R GROUND THEN LEVEL THE MACHINE 06 00 0400 806 00 0400 FAILURE TO COMPLY WITH THE FOLLOWING SAFETY INSTRUCT
96. p seat new filter element in center of filter holder Seat filter holder and element in filter housing 000 d Ug Wipe o ring and mating seal surface of cover with cleaning cloth If o ring is cut or gouged replace o ring 10 Install and hand tighten filter cover Do not over tighten filter cover Air Bleeding Delayed response or sporadic boom lift motions may indicate air in the lift cylinders Use the following procedure to bleed entrapped air from the hydraulic system Fillthe reservoir with the proper hydraulic fluid Replace but do not tighten the reservoir fill cap 2 Fully raise and lower the boom to return oil with entrapped air to the reservoir 3 Allow several minutes for air to escape the reservoir oil 4 Repeat steps 1 through 3 as needed Add oil slowly and only when the boom 15 lowered to prevent adding more air to the system 4 Hydraulic Pressure Checks and Adjustments Hydraulic pressures are set at the factory and should not be adjusted unless a hydraulic component has been replaced in the regulated circuit On the gas engine model a pressure test port Figure 4 5 is located at the ground station boom control valves A hydraulic pressure gage 0 6000 psig 0 400 bar 41 000 kPa gage minimum range must be connected to the test port when adjusting hydraulic pres sures This is the only pressure test port on the boom lift On the DC model boom lift the main bypass
97. pins and pin keepers secure the upper and lower booms If the booms are not secured install the transport pins and pin keep ers at this time c Verify that the basket is centered and that all onboard equipment is secured d Check that the key switch is in the OFF position Remove the key e Verify that trailer brake lights and marker lights work properly f Check that the trailer tires are evenly inflated and not low on air WARNING Improper tightening of boom lift trailer wheel nuts can cause wheel lugs to shear causing serious injury or damage to equipment Check and maintain the proper wheel nut torque according to the maintenance instructions in this manual Periodically check the wheel nut torque according to the instructions in Section 4 of this manual More frequent torque checks are required when a wheel is recently installed Prior to towing while the trailer wheels are elevated for boom lift operation check for loose wheels and for wheel lug wear indications If a loose wheel mounting is indicated remove and inspect the wheel lugs for damage Do not tow the boom lift with worn or damaged wheel lugs Maintenance 4 1 SCHEDULED SERVICE CHECKS Daily Weekly Service Checks Perform the following daily weekly service checks as listed in Table 4 1 Table 4 1 Daily Weekly Service Checks Daily Service Check before use Check to see that all decals are present Check that controls and indicators at ground and ba
98. ption repair or replace any unit or component part which fails to function properly in normal use This warranty does not apply if the lift and or its component parts have been altered changed or repaired without the consent of bil jax or by anyone other than Bil Jax or its factory trained personnel nor if the lift and or its components have been subjected to misuse negligence accident or any conditions deemed other than those considered as occurring during normal use Components not manufactured by Bil Jax are covered by their respective manufacturer s warranties A list of those components and their warranties is available upon written re quest to Bil Jax Bil Jax shall not in any event be liable for the cost of any special indirect or consequen tial damages to anyone product or thing This warranty is in lieu of all other warranties expressed or implied We neither assume nor authorize any representative or other per son to assume for us any other liability in connection with the sale rental or use of this product 2 5 XLB 4319 2 6 3 1 Operation OPERATOR CONTROLS The XLB 4319 Hydraulic Boom Lift is equipped with multiple operator controls Equip ment power and outrigger controls are located at ground level Boom lift and rotation controls are located at ground level and in the basket Ground Control Station The ground control station Figure 3 1 operates the outriggers and lift booms To access t
99. r or Installer When a lessor or lessee uses the aerial device as a dealer or installer he shall have the same responsibilities as specified under Section 7 of this standard 11 1 2 Lessor or Lessee as Owner When a lessor or lessee uses the aerial device as an owner he shall have the same responsibilities as specified under Section 8 of this standard 11 1 3 Lessor or Lessee as User When a lessor or lessee uses the aerial device as a user he shall have the same responsibilities as specified under Section 9 of this stan dard 11 1 4 Lessor or Lessee as Operator When a lessor or lessee uses the aerial device as an operator he shall have the same responsibilities as specified under Section 10 of this standard 11 2 Ownership Duties The renter or lessor shall carry out the duties of ownership specified in this standard which are not assigned to the renting entity or lessee as the user 11 3 Obligations Upon delivery each renter or lessor of an aerial device shall provide the operators manual and the ANSI SIA A92 2 xxxx Manual of Responsibilities for dealers owners users operators lessors and lessees of Vehicle Mounted Elevating and Rotating Aerial Devices These manuals shall be stored on the mobile unit 11 4 Training The renter or lessor shall offer training or training materials that aid the renting entity or lessee in the operation inspection testing and maintenance of the aerial device This training shall be offered initially and subs
100. removing the bottom pivot pin insert a long blade screwdriver through the top pivot pin bores Remove the pivot pin at the bottom end of the upper jib beam If needed drive out the pivot pin with a hammer and a brass or hardwood drift Remove the up per jib beam Fully retract the jib beam cylinder Turn off the key switch and remove the key Tag the hydraulic hoses that connect to the left and right ports of the cylinder valve block Sketch the location of wire ties that secure the hydraulic hoses at the cylinder The hoses must be properly secured to prevent pinching during jib boom opera tion Cut the wire ties from the jib boom cylinder hydraulic lines Place absorbent drip cloths below the cylinder ports Remove the hydraulic hoses from the jib boom cylinder Plug the hose fittings to prevent fluid leakage Protect exposed cylinder ports with plugs and caps At the top of the cylinder unscrew and remove the keeper pins from both sides of the boom pivot pin Secure the keeper pins to the mating beam for use during cylinder installation Support the weight of the jib boom cylinder using an overhead hoist and lifting straps Drive out the pivot pin with a hammer and a brass or hardwood drift and re move the jib boom cylinder After repairing the hydraulic cylinder reinstall the cylinder in the reverse order of removal Power up the hydraulic system and check for leakage Tighten the hydraulic fit tings as needed Bleed
101. rigger Position Switch 4 19 XLB 4319 4 7 TROUBLESHOOTING Table 4 3 Troubleshooting Chart Problem Cause Correction 1 Engine or motor will not a Emergency stop engaged pushed in a Rotate emergency stop buttons clock start wise to disengage b Battery charge is low b Check charge level Recharge battery if needed c Battery ground or in series cable c Check for and repair loose battery loose connections or ground fault d Main circuit breaker tripped or d Reset main circuit breaker inside switched off ground control panel DC model onl Main disconnect unplugged a Plug in main disconnect b Fuse F2 burned Fuse is mounted b Correct cause of short circuit and on front inner wall of boom pivot replace fuse weldment in series with the positive battery cable c Motor contactor failed c Replace motor contactor d Pump motor failed d Check pump motor operation repair or replace motor if faulty Gas model only a Engine key switch in wrong position a Turn key switch to run position b Fueltank empty b Refill fuel tank c Engineoillevel low c Check add engine oil d Spark plug fouled or damaged d Check replace spark plug e Fuse F2 burned out Fuse is mounted Correct cause of short circuit and inside engine key switch housing replace fuse f Starter relay or starter motor failed f Replace failed starter relay or motor 2 Pump motor runs but out a Basket ground key s
102. rules pertinent to that industry 9 Authorization to operate 10 Operator warnings and instructions 11 Actual operation of the aerial device Under the direction of a qualified per son the trainee shall operate the aerial device for a sufficient period of time to demonstrate proficiency in the actual operation of the aerial device 12 Proper use of personal fall protection equipment 9 3 2 Retraining The operator shall be retrained when so directed by the user based on the user s observation and evaluation of the operator 9 3 3 Familiarization When an operator is directed to operate an aerial device he she is not familiar with the operator prior to operating shall be instructed regarding the following items and issues 1 The location of the manuals 2 The purpose and function of all controls 3 Safety devices and operating characteristics specific to the aerial device 9 4 Application The employer and assigned operator shall insure that the aerial device is used only for intended applications as defined in the operating manual and that recognized safety practices are observed 9 5 Mobile Operation Before and during driving the driver shall 1 Avoid traveling on any surface that adversely affects vehicle stability 2 Maintain a safe distance from obstacles and overhead lines 3 Maintain communications between the driver and the operator 4 Under all travel conditions the driver shall limit travel speed i
103. s 6 39 6 18 Boom Control Hydraulics Parts List Ground Gas Model 6 41 6 19 Boom Control Hydraulics Parts List Ground DC Model 6 43 6 20 Lower Boom Cylinder Hydraulics Parts 6 45 6 21 Upper Boom Cylinder Hydraulics Parts List 6 46 6 22 Pushbutton Panel Parts List Basket 6 47 6 23 Pushbutton Panel Parts List Ground Controls 6 49 ANSE REPPIN 7 1 List of Illustrations Figure 2 1 Figure 2 2 Figure 2 3 Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 3 5 Figure 3 6 Figure 3 7 Figure 3 8 Figure 3 9 Figure 3 10 Figure 4 1 Figure 4 2 Figure 4 3 Figure 4 4 Figure 4 5 Figure 4 6 Figure 4 7 Figure 4 8 Figure 4 9 Figure 4 10 Figure 4 11 Figure 4 12 Figure 4 13 Figure 4 14 Figure 4 15 Figure 4 16 Figure 4 17 Figure 4 18 Figure 4 19 Figure 4 20 Figure 5 1 Figure 5 2 Figure 5 3 Figure 5 4 Figure 5 5 Figure 6 1 Figure 6 2 Figure 6 3 Figure 6 4 Figure 6 5 Figure 6 6 Figure 6 7 Figure 6 8 Figure 6 9 Figure 6 10 XLB 4319 Hydraulic 2 1 Basket and Ground Station 2 2 Safe Operating a roi tea eee 2 3 Ground Control Station 3 1 Ground Control Station 3 2 Engine Keyswitch nsi eerte atte teret tee rH Heer 3 3 Basket Control Stations neos rete nh
104. sket control stations operate properly Raise booms and press emergency stop pushbutton Verify that booms remain elevated and do not drift down Check that boom down limit switch and outrigger position switches operate properly Check add hydraulic oil Check add engine oil Check engine air filter element Clean or replace dirty or damaged air filter element Check trailer tires for proper inflation When cold tires should be inflated to 55 psi 3 8 Check trailer running lights for proper operation Check battery electrolyte level If battery charge is low add water to bring electrolyte just above plates If batteries are a fully charged raise electrolyte to full mark in each cell Check trailer hitch components for damage and proper operation Refer to Trailer Hitching in paragraph 3 6 Check electrical wiring for cuts loose terminals broken wires chaffing corrosion or other damage Repair all damage remove corrosion and seal exposed connections Lubricate grease fittings labeled LUBRICATE WEEKLY with NLGI Grade 2 multi purpose grease Check trailer and boom lift for missing or loose hardware Replace tighten missing or loose hardware as needed 4 1 XLB 4319 Monthly Service Checks Perform the following monthly service checks as listed in Table 4 2 Table 4 2 Monthly Service Checks Every Every Every Service Check month 6 months 12 months Check add hydraulic oi
105. system and check for leakage Tighten the hydraulic fit tings as needed Bleed entrapped air from the hydraulic cylinder according to instructions in paragraph 4 4 Jib Boom Cylinder Removal and Installation 1 2 3 Fully lower the outriggers and the upper and lower boom Extend the jib beam to raise the basket a few inches Place shoring under the jib beam Lower the beam onto the shoring to support the weight of the basket Place shoring under both rear corners of the basket Adjust the shoring to relieve any binding torque load on the upper jib beam pivot pins Remove the four keeper pins from the upper jib beam pivot pins Figure 4 9 Secure the keeper pins to the mating beam for use during cylinder installation 4 13 XLB 4319 PIVOT PIN KEEPER PINS 2 PER SIDE UPPER JIB BEAM 1 4 JIB BEAM CYLINDER IE mA 5 4 Wi P KEEPER 8 Pins LLLI e PER SIDE Figure 4 9 Jib Boom Components 6 Try to rotate one of the upper jib beam pivot pins with a keeper pin Adjust the rear basket shoring as needed to enable pivot pin movement 4 14 10 11 12 13 14 15 16 17 18 19 4 MAINTENANCE Remove the upper jib beam pivot pin at the top end of the beam If needed drive out the pivot pin with a hammer and a brass or hardwood drift Before
106. to SOKV 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 XLB 4319 7 12 125 Taylor Parkway Archbold OH 43502 Phone 419 445 8915 800 537 0540 419 445 0367
107. to Table 6 8 for the hitch and jack assembly parts list 28 Figure 6 8 Hitch and Jack Assembly 6 18 Table 6 8 Hitch and Jack Assembly Parts List Description Parking Surge Brake Control Assembly Hand Brake Only Cap Screw 3 __ 1 10 0179 Lamp Side Marker Amber Screw Self Tapping 10 24 x 1 2 5 Hex Nut Self Locking Bracket Brake Cable o ae Socket Head Screw Flat Head 11 B36 00 0040 Transport Pin Flat Washer Cap Screw Chain Keeper pin Hex Nut Hex Nut Self Locking 18 0090 0188 Hex Nut Self Locking 3 8 16 19 B23 02 0063 Swivel Plate 20 B12 00 0173 Breakaway Safety Cable Flat Washer 24 Swivel Pin 25 B23 02 0061 Jack Assembly Hex Nut Self Locking Bushing 28 B03 00 0017 Safety Chain 29 0090 0959 Cap Screw M12 x 1 75 x 100mm Flat Washer 0090 1032 Cap Screw 12 x 1 75 x 80mm Wiring Harness Ball Hitch Hex Nut Self Locking M12 x 1 75 3 Hex Nut Self Locking 36 Cap Screw 3 87 16 x 1 Housing Coupler With Bearings 12 00 0171 Overrun Shaft Damper Gas Shock Rubber Boot Hitch NIN gt ga Q x lt N 30 31 32 33 34 6 PARTS LIST lt lt 52 NUTR 2 LR 2 52 2
108. turally or when there is the possibility of structural damage this damage may be internal and is not always visi ble to the naked eye Bil Jax requires that the lift be returned to our facility at 125 Tay lor Parkway Archbold Ohio for reconditioning If you have any questions concerning what constitutes structural damage please call the Bil Jax Service Department at 800 537 0540 Damage Repair Notice There may be occasions when a Bil Jax lift is involved in an incident resulting in non structural damage When this occurs and repairs are made by the owner or area distribu tor please notify Bil Jax of these non maintenance repairs and request a repair form to be filled out and returned to Bil Jax 1 6 1 Inc 125 Taylor Parkway Archbold Ohio 43502 Reporting Safety Defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying Bil Jax Inc If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in any individual problems between you your dealer or Bil Jax Inc To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 366 0123 in Washington DC
109. uals 2 The purpose and function of all controls 3 Safety devices and operating characteristics specific to the aerial device 9 Responsibility of Users 9 1 General Responsibilities Each User shall comply with the requirements of this section 7 ANSI REPRINT 9 2 Personnel Only trained and authorized personnel shall be permitted to operate the aerial device 9 3 Training Retraining and Familiarization of Operators 9 3 1 General Training Only personnel who have received general instructions regard ing the inspection application and operation of aerial devices including recogni tion and avoidance of hazards associated with their operation shall operate an ae rial device Such items covered shall include but not necessarily be limited to the following issues and requirements 1 The purpose and use of manuals 2 That operating manuals are an integral part of the aerial device and must be properly stored on the vehicle when not in use 3 A pre start inspection 4 Responsibilities associated with problems or malfunctions affecting the op eration of the aerial device 5 Factors affecting stability 6 The purpose of placards and decals 7 Workplace inspection 8 Applicable safety rules and regulations such as Part 4 ANSI C2 1997 Na tional Electrical Safety Code applies to utility workers as defined in ANSI C2 The above standard is an example other industries using aerial devices have safety
110. ure that the cord is not damaged or entangled during rotation DO NOT allow flames sparks or embers near batteries and DO NOT smoke near batteries Batteries produce a hydrogen oxygen gas mixture which can explode OWNERS amp OPERATORS ARE RESPONSIBLE FOR INSPECTION MAINTENANCE TRAINING AND OPERATION AS REQUIRED BY THE OWNERS MANUAL IF YOU HAVE NOT BEEN PROVIDED WITH SAFETY LITERATURE WORKFORCE OR FOR ANY QUESTIONS CONCERNING THE SAFE USE OF THIS EQUIPMENT CALL 419 445 9675 06 00 0401 B06 00 0401 Figure 5 1 Replacement Decals Sheet 2 of 3 XLB 4319 OUTRIGGER OPERATING INSTRUCTIONS 1 Ensure Emergency Stop buttons are released 2 Turn key to Ground Controls 3 Press and hold black button 4 Operate Outrigger Levers to level unit refer to Bubble Level 5 Lower outriggers 3 and 4 first to ensure tongue jack is clear of ground 6 Check to be sure each outrigger foot is in firm contact with ground 7 Check to be sure all outriggers are ae a green light and buzzer has stopped gt Rotation KI BASE AM B06 00 0398 B06 00 0394 we BASE Os TET 00 0396 XLB 4319 SPECIFICATIONS 98 65 32 0 32 6 98 B 164 197 2 CAPACITY MAXIMUM PLATFORM HEIGHT WORK HEIGHT POWER SOURCE B06 00 0430 B06 00 0430 Figure 5 1 Replacement Decals Sheet 3 of 3 5 4 5 REPLACEMENT DECALS SHADDIHLNO mv
111. use DURINGUSE To avoid hand injuries always keep hands inside basket area during boom movement DO NOT use without all four outriggers in firm contact with the ground and the lift level DO NOT release outriggers with boom extended or operator in basket DO NOT move or reposition trailer while operator occupies basket DO NOT use when exposed to high winds rain snow or ice DO use where lift operator can come in contact with overhead obstructions such as electric wires cables ropes overhangs etc DO NOT operate without full body harness and lanyard in use by all basket occupants DO NOT stand or sit on guard rails or top edge of basket DO NOT lean out over top edge of basket to perform work DO NOT use boxes ladders scaffolding or any other means to increase working height DO NOT climb up or down boom DO NOT exceed rated lift capacity DO NOT allow ropes electric cords hoses etc to become entangled in the lift while platform is being raised or lowered DO NOT override alter or bypass safety devices DO NOT use boom rotation or basket rotation if so equipped for pushing or pulling DO NOT exceed platform capacity when transferring loads to the platform while elevated DO NOT use as a crane for lifting materials DO NOT leave keys in machine while unattended Plug charger in at the end of each day When using the lift with the 110V power cord plugged into the base of the unit care must be taken to ens
112. used on DC model boom lift only 6 31 XLB 4319 6 15 UPPER CONTROLS PARTS LIST Refer to Table 6 15 for the upper controls parts list Figure 6 15 Upper Controls 6 32 6 PARTS LIST Table 6 15 Upper Controls Parts List 02 14 0068 Lever Pivot Box With pene 71 5 fase ni 5 B02 14 0052 acap Wi Spe Valve Control Hex Nut Self locking 5 16 18 5 4 2 4 4 1 2 1 1 1 1 8 3 0090 0232 Machine Screw 10 24 3 8 5 over uncon Box 5 3 Yon Box Upper 1 6 33 XLB 4319 6 16 ENGINE COMPARTMENT PARTS LIST GAS MODEL Refer to Table 6 16 for the gas model engine compartment parts list T Figure 6 16 Engine Compartment Parts List Gas Model 6 34 6 PARTS LIST Table 6 16 Engine Compartment Parts List Gas Model Engine Cover 3 Cap Screw 5 Flat Washer IUE Hose Assembly Pump Supply aoa Ls oem ook Waser si Machine Screw 5 167 18 x 1 E Ls eiie Lm Screw 1 4 20 x 1 1 2 ea Nut Lock 1 4 20 Le freon tsi Se B01 10 0084 Solenoid Choke 12 Volt 0090 0708 Machine Screw 46 32 x
113. utput pressure no load Replace filter if pump output pressure reaches 30 psig 206 kPa gage with no hydraulic function selected Hydraulic gear pump failed g Check pump replace if hot to touch Pump motor runs but the Obstruction below basket or boom a Raise and reposition the boom to upper and lower booms will avoid the obstruction Basket ground key switch in wrong b Turn key switch to ground or basket position run position Boom lift shifted out of level c If out of level alarm is sounding manually lower boom Outrigger not under load d Check that all outriggers support a load If not manually lower boom Hydraulic oil level low e Manually lower boom Check oil level in reservoir add oil as needed Boom enable valve solenoid SV1 f Manually lower boom Repair faulty failed see item 1 Figure 6 18 or wiring or replace failed solenoid item 4 Figure 6 19 Pump motor runs but the Basket ground key switch in wrong a Turn key switch to ground or basket boom rotate function does position position not work Boom lift out of level b Operate outriggers to level boom lift Outrigger not under load c Check that all outriggers are support ing a load adjust as needed Hydraulic oil level low d Check hydraulic oil level in reservoir Add oil as needed Rotate obstruction or hard stop e Rotate boom in opposite direction reached Slew ring bearing worn and binding f Retract boom and retry rotation Replace sle
114. utton When pressed the EMERGENCY STOP pushbutton disconnects electrical power from the upper and lower control stations Pressing the EMERGENCY STOP pushbutton also shuts off the gasoline engine or DC motor to interrupt hydraulic power Before you can restore power you must rotate the EMERGENCY STOP pushbutton clockwise Boom Run Pushbutton Holding the green boom run pushbutton in enables operation of the boom lift and rota tion functions Boom lift and rotation can only be operated when the outrigger cylinders are extended the boom weight is supported by all four outriggers and the trailer is level 3 OPERATION Boom Operator Levers Five boom operator levers position proportional hydraulic valves to extend and retract three boom lift cylinders the boom rotation drive motor and the basket swivel cylinder Pulling a boom operator lever extends the cylinder to raise the boom Pushing a boom lift operator lever lowers the related boom How far the lever is pushed or pulled controls the boom lift speed Pulling the boom rotation or basket rotation operator lever turns the boom or basket clockwise Pushing the operator lever turns the boom or basket counterclockwise How far the lever is pushed or pulled controls the rotation speed When released the boom operator levers return to the center valve off position A decal located in front of the valve manifold shows which boom motion is controlled by each operator lever Hydraulic
115. w ring bearing if worn One hydraulic boom or Control valve failed leaking a Repair or replace control valve if hot outrigger function fails to to touch work Cylinder counterbalance valve failed b Counterbalance valves are in cylinder leaking manifold blocks Repair or replace valve if hot to touch Cylinder failed leaking c Touch cylinder wall near piston re pair or replace cylinder if hot touch 4 21 XLB 4319 4 22 Troubleshooting Aids Electrical diagrams are provided in Figure 4 14 through Figure 4 17 Hydraulic diagrams are provided in Figure 4 18 and Figure 4 19 Level sensor LED indications are shown in Table 4 4 MAIN DISCONNECT ME CONTACTOR CIRCUIT PB4 BREAKER SW3 O OUTRIGGERS BOOM DOWN LIMIT SWITCH 9 AUDIBLE ALARM 1 ALARM BOOM LEVEL RELAY ENABLE SENSOR RL2 VALVE SV1 PB2 P A O BOOM BOOM JO ENABLE ENABLE PB7 BASKET CONTROLS SWITCHES BASKET OFF GROUND KEYSWITCH SW2 OUTRIGGER DOWN LEDs ZEN A Figure 4 14 Simplified Electrical Diagram DC Model 4 PLATFORM CONTROL BOX E STOP AUDIBLE PB7 PB6 ALARM BOOM O T Pe
116. wer pressure Turning the adjust screw 1 4 turn will adjust the pressure about 150 psig 10 4 bar 1 037 kPa gage Tighten the adjust lock nut Reset the emergency stop pushbutton and restart the engine or motor Pull up one outrigger control lever and recheck the system pressure If the pres sure is still too high or too low repeat the adjustment starting with step 6 When the system pressure is properly adjusted remove the cap from the outrig gers bypass valve Figure 4 6 Turn the adjust screw to the left two turns Reinstall and tighten the adjust screw cap Do not over tighten the cap Check Adjust Outriggers Pressure 1 Pull up one outrigger control lever and read the pressure at the gage If the gage reading is 2750 psig 190 bar 19 000 kPa nominal no adjustment is required If the outriggers pressure is too high or too low remove the cap Figure 4 6 and adjust the pressure Turning the adjust screw to the right 1 4 turn will raise the pressure about 150 psig 10 4 bar 1 037 kPa gage Reinstall and tighten the adjust screw cap Do not over tighten the cap Repeat steps through 3 as needed to properly adjust outrigger pressure If no other hydraulic pressures are to be checked shut down the engine or motor and remove the pressure gage Check Adjust Boom Hydraulic Pressure The hydraulic pressure for the basket station boom controls is regulated by a bypass valve Figure 4 7 at the front of the basket stati
117. witch in wrong a Turn key switch to ground position riggers will not extend position b Hydraulic oil level low b Check hydraulic oil level in reservoir Add oil as needed c Boom down limit switch or switch Check boom down limit switch and wiring failed wiring operation per paragraph 4 6 d Hydraulic gear pump failed d Check pump replace if hot to touch DC model a Boom enable valve SV1 faulty stick a Repair or replace faulty valve ing open see item 4 Figure 6 19 Outrigger enable valve solenoid SV2 a Replace faulty wiring or solenoid failed see item 6 Figure 6 18 b Boom enable valve SV1 faulty stick b Repair or replace faulty valve ing open see item 1 Figure 6 18 4 20 4 Table 4 3 Troubleshooting Chart Continued Pump motor runs but upper Basket ground key switch in wrong a Turn key switch to enable basket or and lower boom lift func position ground controls tions do not work Boom lift out of level b Operate outriggers to level boom lift Outrigger not under load c Check that all outriggers support a load adjust outriggers as needed Hydraulic oil level low d Check hydraulic oil level per para graph 4 4 Add oil as needed Boom enable valve solenoid SV1 e Replace faulty wiring or solenoid failed see item 1 Figure 6 18 or item 4 Figure 6 19 Hydraulic output filter dirty f Check pump o
118. witch is actuated The boom down limit switch must be actuated to lower or raise the outriggers The boom down limit switch should trip when the lower boom is within 2 inches 50 mm of seating on the trailer tongue You may not be able to extend or retract the outriggers if the boom down limit switch is loose damaged or not adjusted properly Use the following procedure to readjust the boom down limit switch 1 Lower the outriggers and raise the lower boom for free access to the limit switch Figure 4 12 Inspect the limit switch for loose mounting or visible damage If the mounting hardware is loose tighten the hardware If the limit switch is damaged replace the limit switch Measure the free height of the limit switch actuator roller The top of the roller should be 0 75 inch 19 mm above the limit switch mounting plate Adjust the actuator position as needed Fully lower the upper and lower booms Press the outrigger run pushbutton to verify that the boom down limit switch is engaged The hydraulic pump motor should run when the outrigger run pushbut ton is pressed If the pump motor does not run the limit switch or switch wiring is damaged Repair or replace a damaged limit switch or wiring as needed ACTUATOR ROLLER FREE HEIGHT J Q SWITCH BOOM DOWN LIMIT SWITCH Figure 4 12 Boom Down Limit Switch 4 Adjusting

Bil-Jax AERIAL WORK PLATFORMS Hydraulic Boom Lift Personal Lift User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents