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Bil-Jax 36XT User's Manual

Contents

1. 68 k 1 029024 apeds uuo z 2 yds ui 3nd eb ZL uuo N4 duy se BuisnoH JO suone5o1 pajeubisag 0301 53203002 1465 1a 9881 8 lees pue seil jo 67048 sond q gt el 1 02901 uuo Nd dwy YY 1294 SSEd lt 991 EL 991 jM 1 43 SSEd 08L 3130014 ela 2 du 899 pue 190900 SOJIM 6 600 V 97 2 uuo Nd duy S U3JAS woog 8L epeds leuu d 7 02 8 A gt 95 ANALOG HARNESS A 00715 Amp 770680 Individual Label les AMP 770520 1 Wire Labels a 4 Pin Pump Speed Signal FM Spade LL 9 36 18 ga Green gt Insulated Pin Motor Cntrl Enab FM Spade Fo 4 4 Y 86 18 Yellow Insulated 15 boom Amp Pin Ground Weather Pack Housing 9 4 12 18 ga Black gt 12010973 2 Pin Housing 4 770680 1 Pin Engine Run A 12089040 Male Term
2. a 76 PUMP ASSEMBLY PARTS LIST Item No Part No Description Qty 1 B02 15 0496 Manifold Valve Housing 1 2 B02 14 0108 Valve Counterbalance 2 3 02 15 0472 Manual Pump Extend Retract Rotate 1 4 B02 14 0089 Valve Cartridge Outrigger Check 1 5 02 14 0109 Valve Cartridge Outrigger 2 6 B02 14 0091 1 7 B02 14 0110 1 8 B02 14 0094 Valve Proportional 1 9 B02 14 0095 Coil Sterling Proportional Valve 1 10 B02 14 0111 1 11 B02 14 0097 1 12 B02 14 0098 Valve Shuttle 1 13 B02 14 0099 Valve Cartridge Rotator 1 14 B02 14 0100 Valve Counterbalance 1 15 B02 14 0101 Valve Cartridge Basket Compensate 1 16 B02 14 0114 Valve Flow Control Rotator 1 17 B02 02 0245 Fitting Plug 2 ORB 11 18 B02 02 0246 Fitting Hex Plug 1 19 B02 02 0248 Fitting Plug 4 ORB 5 20 B02 14 0112 Coil 20 VDC 8 5 21 B02 14 0113 Coil 20 VDC 10 5 22 B02 15 0497 Stud 1 4 20 x 5 8 4 23 02 15 0498 Expansion Plug 1 24 B02 02 0235 Fitting Plug 6 ORB 2 25 8 1 7 PUMP ASSEMBLY CONTINUED Beye 41 SI y 415 0 Bun uay L 01 N 0 04611 PUEH Jeules USJUDI L syog nbio 1 WO 2 2 OF 2401 Alqwesse Buunp Buu o jou oq lquu sse
3. Item No Part No Description Qty 1 A 01063 Cover Front 1 2 0096 0014 Cap Screw M10 x 20 14 3 0096 0041 Hex Nut Self Locking M10 22 4 A 01064 Cover Top 1 5 A 01067 Cover Side Left 1 6 A 01069 Cover Side Right 1 7 0096 0001 Cap Screw M6 x 16 20 8 0096 0039 Hex Nut Self Locking M6 33 9 B42 01 1006 Hinge 72 Continuous 2 10 A 01045 Latch Paddle Style 2 11 0096 0113 Cap Screw 04 x 16 8 12 0096 0073 Hex Nut Self Locking M4 8 13 A 01052 Cover Rear 1 14 B01 06 0053 Relay 24V DC w Bracket 5 15 0096 0002 Cap Screw M6 x 20 13 16 A A 01059 Cover Pad 2 17 0096 0068 Flat Head Cap Screw M10 x 45 4 18 A 03048 Relay Cover 1 19 A 03040 Switcher Box Assembly 1 B01 06 0056 Relay 30 Amp 1 B01 10 0354 Circuit Breaker 20 Amp 1 A 01015 Switcher Box 1 20 A 01072 Cover Latch Stop 2 21 0096 0098 Cap Screw M8 x 35 4 22 0096 0040 Hex Nut Self Locking M8 4 23 A 01047 Fuel Tank 1 24 A 01089 Fuel Gauge 1 25 0096 0016 Cap Screw M10 x 25 2 45 ENGINE ASSEMBLY Il 12 2 3 6 16 13 1 12 46 ENGINE ASSEMBLY PARTS LIST Item No Part No Description Qty
4. gt Bi PE 1 60 SO or Equivalent lt 4 North America 110V Female Plug 92 SWITCHER BOX ASSEMBLY CE MODELS A 03040CE Box A 01015 B01 06 0056 30 Amp Relay B01 10 0354 i DPST NO i 20 Amp Circuit Breaker Allied Electronics 250 Male Spade Terminal 850 0345 Allied Electronics i Or Equivilant 8860036 a 1 e Or Equivilant Cord Grip Heyco 3231 Or Equivilant i Delphi Weather Pack i 1 2 Pin Male Housing 12010973 i BAWAG 1 Male Terminal 12089040 i Green Seal 12015323 1 Delphi Weather Pack 1 Pin Male Housing 12015793 i Male Terminal 12010293 i lt lallo iG i 220V GENERATOR WIRE HARNESS CE A 03043CE 14 3 SO Or Equivilant 24 2 Generator Wire Colors en 1 2 Grommet OD 3 Pin Female Housing 12124580 Female Terminal 12 14ga i 12010293 i Seal 12 14ga CORD ASSEMBLY 220V AC PLUG CE B01 01 0181 12 Ya Female Spade Ya Female Spade InterPower 88010390 16A Socket or Equiliviant POR AENA 93 PUMP AND CYLINDER WIRE HARNESS 00716 111180 O EOLOZL 22802021 udi q BnId Slew 62802021 1
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6. 005944 06 0 01 5 001 01 01 01 908944 991 SJHONWOLFNSOWOLFSJHONWO Lit 21 8 007933 MIS SUYONZI SIUONS 01 21 0199 MIS 3 0 31002 0 3 84 TRAILER HYDRAULIC LINES PARTS LISTS Item No Part No Description 1 B02 01 0402 10 28 Hydraulic Hose 2 B02 01 0401 8 x 154 Hydraulic Hose 3 B02 01 0398 8 x 16 Hydraulic Hose 4 B02 01 0400 8 24 Hydraulic Hose 5 9 8 x 18 Hydraulic Hose 6 B02 01 0386 6 x 30 Hydraulic Hose 7 B02 01 0387 6 x 30 Hydraulic Hose 8 B02 01 0397 6 x 166 Hydraulic Hose 9 B02 01 0396 6 150 Hydraulic Hose 10 B02 01 0385 4 x 118 Hydraulic Hose 11 59 4 16 Hydraulic Hose 12 2 4 x 30 Hydraulic Hose 13 B02 01 0383 4 40 Hydraulic Hose 14 B02 01 0393 6 x 138 Hydraulic Hose 15 B02 01 0392 6 138 Hydraulic Hose 16 B02 01 0388 6 x 38 Hydraulic Hose 17 B02 01 0389 6 38 Hydraulic Hose 18 B02 01 0395 6 x 138 Hydraulic Hose 19 B02 01 0394 6 138 Hydraulic Hose 20 B02 01 0390 6 x 62 Hydraulic Hose 21 B02 01 0391 6 x 62 Hydraulic Hose 22 B02 01 0380 4 21 Hydraulic Hose 23 4 4 x 105 Hydraulic Hose 24 B02 01 0381 4 x 25 Hydraulic Hose FITTINGS Pa
7. A visual inspection of the unit for wear or damage Manufacturer recommendations Oooo A visual weld inspection to be performed by qualified personnel in accordance with applicable government regulations 3 EQUIPMENT MAINTENANCE ADDITIONAL SERVICE INFORMATION Seals on hydraulic cylinders should be replaced every five years or as indicated by machine performance All service checks should be performed on a machine that has been stored without use for a period exceeding thirty days Check for air in the hydraulic system if the machine has been stored without use for a period exceeding thirty days or if the machine was stored without use during a seasonal climate change Air trapped in the hydraulic system will affect machine performance Follow procedures for bleeding air from the hydraulic system found in Section 4 Owners and lessors should complete a full inspection of all components and perform a test of all functions including brake functions before commissioning or reselling machine Always repair or replace all damaged or malfunctioning components before commissioning or reselling machine When a change in ownership occurs it is the responsibility of the seller to provide the new owner with all manuals for the machine It is the responsibility of the buyer to notify the manufacturer of the unit model and serial number and the name and address of the new owner within 60 days Use the Service Checklist
8. Assembly Description Outrigger Engine Front Rest Front Axle Rear Axle Slew Ring Counterweight Control Compartment Pump Compartment Battery Compartment Cover Boom Cable Track Boom Nose Platform Hydraulic Pump Assembly Description Boom and Rotation Hydraulic Lines Outrigger Hydraulic Lines Trailer Hydraulic Lines 4WD Wire Harnesses Manifold Wire Harness Gas Engine Wire Harness Choke Throttle Solenoid Wire Harness Engine Relays Wire Harness ATC Fuse Holder Start Stop Run Wire Harness Generator Switcher Box Wire Assembly Fan IEC Cord Male US Markets Generator 110V Wire Harness Oil Switch Cord Assembly 110V Generator Cord Assembly Generator Switch Cord Assembly Switch Jumper Cord Assembly 110V AC Plug Female Switcher Box CE Models 220V Generator Wire Harness CE Models Cord Assembly 220V AC Plug Female CE Models Pump And Cylinder Wire Harnesses Outrigger Coil and Switches Wire Harness Analog Harness Power Harness 110 VAC Tower Platform Harness Platform Ground Communication Cable Material Hook Battery Layout 100 41 OUTRIGGER ASSEMBLY KD 290909 6 W 6969 9 42 OUTRIGGER ASSEMBLY PARTS LIST Item No Part No Description Qty 1 A 00120 Outrigger Weldment 1 2 A 00046 Grommet 1 5 x 1 25
9. m Check for cuts loose terminals broken wires chaffing and corrosion Q Repair all damage remove corrosion and seal exposed connections Inspect boom lift for missing loose or damaged hardware Repair or replace as necessary Inspect all hydraulic system components including pump and motor and cylinders for damage leaks loss of pressure or speed and unusual noise or vibration Repair or replace as necessary 16 MONTHLY SERVICE CHECKS Perform the following service checks at least once each month Clean all battery terminals Check battery for loose connections or damaged wires Verify proper operation of manual lowering valves and hand pump Refer to Section for manual boom operating procedures Lubricate all compartment hinges and latches slew ring and mating gear Use NLGI Grade 2 multi purpose grease Check wheel nut torque u Refer to Figure 4 3 for correct wheel nut tightening sequence Q Evenly tighten wheel nuts to 34 N m in the tightening sequence shown Repeat sequence tightening wheel nuts to 81 N m and to 136 N m NOTE Follow this procedure each time the wheel is removed and reinstalled Figure 3 3 Wheel Nut Tightening Sequence 3 EQUIPMENT MAINTENANCE 17 BIL JAX 36XT ANNUAL SERVICE CHECKS Perform the following service checks at least once each year Replace Hydraulic Oil and Oil Filter u Drain hydraulic reservoir clean
10. BIL JAX 36XT 12 WARRANTY Bil Jax Inc warrants this product for one year beginning on the date of delivery to be free from defects of material and workmanship provided the unit is operated and maintained in compliance with the guidelines established in the Operations and Maintenance Manuals Major structural components including trailer tongue and boom weldments are warranted for five years against defects due to material or workmanship Bil Jax will at its option repair or replace any unit or component part that fails to function properly during normal use The warranty does not apply if the lift and or its components have been altered changed or repaired without the consent of Bil Jax Repairs damage or defects resulting from the following are not covered under the terms of the warranty negligence misuse accidental damage inadequate or improper maintenance acts of nature damage caused by chemicals or abrasive materials and normal wear and tear such as rust or corrosion Components not covered under this warranty include tires filters covers and routine maintenance items Components not manufactured by Bil Jax are covered be their respective manufacturer s warranties A list of those components and their warranties is available upon written request to Bil Jax Bil Jax shall not in any event be liable for the cost of any special indirect or consequential damages to any person product or thing Bil Jax s maximum liabi
11. Bn d anbio 9 ES 72 62 0 anbioL NOLLO3S 1 41 2 61 0 Gnid 970 10 8 S 0 amen 010 1 41 6 6 97010 wage INN 1140 WAI oz 0 anbiol 8 2 0 1 60 S00 ON3 Jed Japuedx3 9154 wage INN 2401 yal 66 80 0 1209 wage INN 04 1 WI 60 86 0 amen SnbJoL WAL vz ez 0 Snia nid 1240 nid vos Q Id vz PL LL I T 22 578 0 na Aia BAJBA 970 0 3 yal 22 558 o BAJBA 91240 ai ZA 00 yal 208 NEA 970 10 1 41 5 6 97010 9 D INN 9401 WAI 60 86 0 D BAJBA enbiol T 0281 Wd 8 2 0 A 4 anbio 6 L WO 22 82 0 9 010 6 wage 97020 1162 Wl 66 86 0 6 8A E 11240 t 02 y y 898 c OR wal 61 2 0 X WL 8A E anbioL 2 12416 00 0401 ecol yal 6 0 0 97010 97010 TN m 5 6 INN 0401 yal 02 58 0 BAJBA 9 010 ne
12. NEVER disregard or bypass proper maintenance procedures ALWAYS inspect hydraulic system to ensure that all lines connectors and fittings are properly fastened and in good condition ALWAYS turn the key switch OFF and remove key before performing maintenance ALWAYS perform maintenance with the boom and platform in a fully lowered stowed position when possible ALWAYS secure the boom before performing maintenance on hydraulic cylinders ALWAYS disconnect power to the hydraulic pump drive motor before making electrical checks to the hydraulic valves ALWAYS keep all mechanical parts properly adjusted and lubricated according to maintenance schedule and manufacturer s specifications ALWAYS perform a function check of operating controls before each use and after repairs have been made ALWAYS locate and protect against possible pinch points before performing any maintenance or repairs ALWAYS use only manufacturer approved parts to repair or maintain equipment If any portion of this equipment is rebuilt or repaired retesting is required in accordance with factory instructions ALWAYS maintain a safe distance while testing the hydraulic components ALWAYS relieve hydraulic pressure before loosening or removing hydraulic components NEVER test or operate the hydraulic components while personnel are near the equipment NEVER allow water or foreign particles into the DC electric motor housing Inclusion of water or for
13. safety hazards related to these chemicals Material Safety Data Sheets are included here in accordance with applicable federal and state regulations Read and observe all safety precautions Maintain awareness of potential health and safety hazards MATERIAL SAFETY DATA SHEET FOR LEAD ACID BATTERIES WET FILLED WITH ACID SECTION GENERAL INFORMATION Manufacturer s Name Crown Battery Mfg Company EMERGENCY NO 800 487 2879 Street Address 1445 Majestic Drive OR 800 OIL TANK City State Zip Fremont Ohio 43420 Phone Number 419 334 7181 REVISION DATE 5 18 2000 SECTION II MATERIAL IDENTIFICATION AND INFORMATION COMPONENTS PERCENT OSHA ACGIH OTHER LIMITS CAS NUMBER Hazardous Components PEL TLV 1 or greater Carcinogens 0 01 or greater METALLIC LEAD METAL 25 5 0 05 mg m3 0 05 mg m3 NONE 7439 92 1 LEAD SULFATES 18 2 0 05 mg m3 0 05 mg m3 NONE 7439 92 1 LEAD OXIDES 18 0 0 05 mg m3 0 05 mg m3 NONE 7439 92 1 POLYPROPYLENE CASE MTL 6 496 SEPARATORS 3 5 SULFURIC ACID 2504 5 2 1 0mg 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 Ill of the Superfund Amendments and Reauthorization Act The items are covered in an exemption as a Manufactured Article 372 30 b SECTION III PHYSICAL CHEMICAL CHARACTERISTICS Boiling Point Approximately 203F Vapor Density Greater Than 1 Vapor P
14. 1 A 01046 Engine 21HP See Manufacturer s Literature 1 2 0096 0098 Cap Screw M8 x 35 4 3 0096 0040 Hex Nut Self Locking M8 18 4 A 01048 Pump Dual 4 5 GPM 1 5 A 01055 Dual Pump Mount 1 6 0096 0110 Cap Screw M10 x 110 2 7 0096 0093 Washer M10 2 8 0096 0041 Hex Nut Self Locking M10 2 9 A 01081 Oil Cooler 1 10 0096 0010 Cap Screw M8 x 20 4 11 A 01071 Solenoid Bracket 1 12 0096 0001 Cap Screw M6 x 16 12 13 0096 0039 Hex Nut Self Locking M6 10 14 A 01074 Throttle Solenoid Assembly 2 15 A 00761 Generator 1 16 A 01060 Spacer 4 17 0096 0053 Cap Screw M8 x 50 4 18 A 01038 Brake Release Hand Pump 1 19 0096 0108 Cap Screw M8 x 70 2 20 B02 00 0071 Oil Filter Assembly 1 21 B29 00 0016 Oil Filter Bracket 1 22 A 00783 Exhaust Assembly 1 23 A 01061 Belt 1 24 A 01051 Pulley 2 25 0090 0363 Set Screw 1 4 20 x 3 4 6 26 A 01036 Pulley 1 27 A 01088 Idler Roller 1 28 0096 0022 Cap Screw M12 x 75 1 29 0096 0076 Washer M12 3 30 0096 0041 Hex Nut Self Locking M12 1 31 A 01095 Tension Arm 1 32 A 01086 Spacer Tension Arm 1 33 0090 0210 Washer 3 8 1 34 0096 0069 Cap Screw M10 x 75 1 47 FRONT REST ASSEMBLY 48 FRONT REST ASSEMBLY PARTS LIST Item No Part No Description Qty 1 A 03145 Front Rest Weldment 1 2 0096 0024 Cap Screw M12 x 100 2 3 0096 0042 Hex Nut Self Locking M12 2 4 A 0
15. CG 2 Switch is forced open AC when Boon is lifted GFCI Plug AC Switch Plug DU IEC Recp i I 5 i OROROROZCA Drive N Manifold OR Fuel Start Sol A O Fuel Sol 5 Fan Generator 12020786 6 Pin Male Conn 1208089040 Male Term 12015323 Green Wire Seal 3 Pin Male Conn 12089040 Male Term 12015323 12020926 6 Pin FM Conn 12089188 FM Term 12015323 Pin Female Conn 12089188 Female Term 12015323 Label Wires Both Ends Stripe wire to 4 12020827 3 Pin Male Conn 12089040 Male Term 12015323 12020829 Pin Female Conn 12089188 Female Term 12015323 Strip Wires 3 7 A 01034 Wire Color A 00785 Rev SOOW or Equivalent 120 10 18ga 10 Cond Wire SOOW or Equivalent A 01034 Rev Ends A 00785 Rev 156 13 2 16 Cond 18ga Wire Label Both MANIFOLD WIRE HARNESS A 00785 Wires 8 Sealed Deutsch Term 0462 201 16141 Deutsch DT06 2S 2 Pin Plug W2s Wedge ai N ail a Wires ER Connected amp Se
16. D D hoses to prevent leakage Plug or cap exposed hose fittings and cylinder ports At the base of the cylinder unbolt and remove retainer plate from each side of the pivot pin Remove the pivot pin using a hammer and a brass or hardwood drift Lift and remove the cylinder using an overhead hoist and lifting straps Replace or reinstall the cylinder by following the above instructions in the reverse order of removal Actuate the hydraulic system and check for leakage Tighten hydraulic fittings as needed Bleed trapped air from the hydraulic system by raising and lowering the boom with the reservoir fill port cap on but not tightened Allow several minutes for trapped air to escape Repeat as needed RETAINING PLATE 5 AL CYLINDER BASE END PISTON END Figure 4 1 Lift Cylinder Replacement OUTRIGGER CYLINDER REPLACEMENT Use the following procedure to remove and replace faulty or damaged hydraulic cylinders on the outriggers a Lower the outrigger until the footpad is touching the ground Do not transfer the weight of the boom lift onto the outrigger Leave the weight of the boom on the trailer wheels Remove the bolts securing the outrigger cylinder rod guard Figure 4 2 Remove the guard At the piston rod end of the cylinder unbolt and remove the retainer plate from each side of the pivot pin Place a block o
17. Excessive load detected in secondary up circuit Check for faulty boom up SECONDARY UP on power up solenoid coil and wiring 027 OPEN CIRCUIT SECONDARY A load of less than 70mA detected when Check for faulty boom down DOWN secondary down circuit was energized solenoid coil and wiring 028 SHORTED CIRCUIT Excessive load detected when secondary down Check for faulty boom down SECONDARY DOWN circuit was energized solenoid coil and wiring 029 OPEN CIRCUIT JIB UP A load of less than 70mA detected in jib up circuit Check for faulty jib up solenoid on power up coil and wiring 030 SHORTED CIRCUIT JIB UP Excessive load detected in jib up circuit on Check for faulty jib up solenoid power up coil and wiring 21 BIL JAX 36XT ERROR MESSAGE DEFINITION OF ERROR COMMENTS 031 OPEN CIRCUIT JIB DOWN A load of less than 70mA detected when jib down Check for faulty jib down solenoid circuit was energized coil and wiring 032 SHORTED CIRCUIT JIB Excessive load detected when jib down circuit Check for faulty jib down solenoid DOWN was energized coil and wiring 033 OPEN CIRCUIT EXTEND A load of less than 70mA detected in extend Check for faulty boom extend circuit on power up solenoid coil wiring 034 SHORTED CIRCUIT EXTEND Excessive load detected in extend circuit on Check for faulty boom extend power up solenoid coil wiring 035 OPEN CIRCUIT RETRACT A load of less than 70mA detected in retract Check for faulty boom retract circuit on power up solen
18. INGESTION CARCINOGENIC NO SYMPTOMS INGESTION CONTACT INHALATION MILD TRANSIENT SKIN OR EYE IRRITATION MAY OCCUR EYES FLUSH WITH WATER FOR 15 MINUTES SKIN WASH THOROUGHLY WITH WARM SOAPY WATER INGESTION DO NOT INDUCE VOMITTING SEEK MEDICAL ATTENTION CONDITIONS AGGRAVATED BY EXPOSURE NONE KNOWN AIR EXPOSURE LIMITS P E L 5 mg m3 OSHA T L V 10073 ACGIH HEALTH 0 FIRE 1 SPECIFIC X REACTIVITY 0 SECTION III PHYSICAL DATA BOILING POINT FREEZING POINT N A VAPOR PRESSURE PSIA N A SPECIFIC GRAVITY H20 1 0 86 SOLUBILITY IN WATER NEGLIGIBLE INSOLUBLE IN COLD WATER PH OF CONCENTRATE N A APPEARANCE AND ODOR RED LIQUID MILD PETROLEUM ODOR SECTION IV FIRE AND EXPLOSION HAZARD DATA FLASH POINT METHOD USED CLOSED 339 F Pensky Martens OPEN 3902 F Cleveland FLAMMABLE LIMITS NOT DETERMINED LEL N A UEL EXTINGUISHING MEDIA DRY CHEMICAL FOAM CO2 WATER FOG TREAT AS CLASS B FIRE UNUSUAL FIRE AND EXPLOSION HAZARDS PRODUCES COMBUSTIBLE VAPOR AT TEMPERATURES ABOVE FLASH POINT SECTION V REACTIVITY DATA STABILITY STABLE CONDITIONS TO AVOID AVOID EXTREMES OF HEAT IGNITION SOURCES INCOMPATIBILITY MATERIALS TO AVOID STRONG OXIDIZING MATERIALS HAZARDOUS DECOMPOSITION PRODUCTS INCOMPLETE COMBUSTION MAY CAUSE CARBON OXIDES HAZARDOUS POLYMERIZATION WILL NOT OCCUR SECTION VI SPECIAL PROTECTION INFORMATION RESPIRATORY PROTECTION SPECIFIC TYPE NONE R
19. Outrigger Position Switch 14 Figure 3 2 Hydraulic Reservoir 15 Figure 3 3 Wheel Nut Tightening Sequence 17 Figure 3 4 Slew Ring Position Measurement 18 Figure 4 1 Lift Cylinder Replacement 26 Figure 4 2 Outrigger Cylinder Replacement 27 Figure 5 1 Decal Locations 31 Figure 5 2 Decal Locations CE 33 LIST OF TABLES Table 1 1 Minimum Safe Approach Distances 5 Table 3 2 Troubleshooting Steps 20 Table 3 3 Error Code Definitions 21 Table 5 1 Replacement Decal Descriptions 30 Table 5 2 Replacement Decal Descriptions CE 32 1 SAFETY Proper training is required for the safe operation of any mechanical device Failure to follow all instructions and safety precautions in this manual and attached to the lift will result in death or personal injury Prior to Operation Q Read understand and obey all instructions and safety precautions in this manual and attached to the lift Q Read understand and obey all applicable government regulations Become familiar with the proper use of all controls Inexperienced users should receive instruction before attempting to operate or maintain the machine D The use of intelligence and common sense is the best practice when following any safety policy BIL JAX 36XT LEGEND SAFETY ADVISORIES The following safety advisories are used throughout this manual to indicate specific hazards when operating or maintaining the machine Read understand and obey all safety advisories to prevent im
20. Part No Description Qty 1 A 00268 Tire Iron Jack Handle 1 2 B04 07 0033 Clamp 2 3 0096 0001 Cap Screw M6 x 16 2 4 0096 0039 Hex Nut Self Locking M6 4 5 A 00290 Cover Stop Bracket 1 6 0096 0002 Cap Screw M6 x 20 2 7 0096 0014 Cap Screw M10 x 20 2 61 BATTERY COMPARTMENT ASSEMBLY amp B BATTERY COMPARTMENT ASSEMBLY PARTS LIST Item No Part No Description Qty 1 A 00215 Battery Box Weldment Left 1 2 A 00220 Battery Box Weldment Right 1 3 A 00278 Battery Hinge Pin 2 4 0096 0050 Washer Flat M16 8 5 0090 0147 Cotter Pin 4 6 A 00271 Battery Clamp 4 7 0096 0010 Cap Screw M8 x 20 4 8 0096 0040 Hex Nut Self Locking M8 8 9 A 00219 Battery Box Latch 2 10 A 00256 Motor Cover 1 11 A 00229 Latch Plate 2 12 A 00234 Spacer 2 13 0096 0011 Cap Screw M8 x 25 6 14 A 00244 Tension Spring 2 15 A 00225 Nose Weldment 1 16 0096 0014 Cap Screw M10 x 20 10 17 0096 0041 Hex Nut Self Locking M10 10 18 A 00037 Ramp Short 4 19 0096 0002 Flat Head Cap Screw M6 x 20 4 20 0096 0039 Hex Nut Self Locking M6 4 21 A 00046 Grommet 4 22 B04 07 0036 Clamp 2 23 801 09 0132 A Frame Handle Connector 1 24 B01 09 0131 Plug Connector 1 25 A 03272 Battery Cable Kit 1 26 B01 09 0133 Terminal Boot Black 4 27 B01 09 0134 Terminal Boot Red 4 28
21. Part No Description Qty 1 A 00510 Telescopic Boom Tube 1 2 A 00550 Hydraulic Extension Cylinder 1 3 A 00535 Slider 2 4 0096 0018 Cap Screw M10 x 40 4 5 0096 0041 Hex Nut Self Locking M10 6 A 00032 Bearing 2 7 0096 0033 Flat Head Cap Screw M16 x 35 4 8 A 00027 Pin 75 0 1 9 7 Retainer 75 1 10 0096 0016 Cap Screw M10 x 25 1 11 00533 1 Wear Pad Green 5 12 A 00533 2 Wear Pad Grey 7 13 A 00534 Wear Pad Shim 6 14 0096 0013 Nylon Cap Screw M10 x 16 24 15 A 00537 Boom Switch Block 1 16 0096 0098 Cap Screw M8 x 35 2 17 0096 0040 Hex Nut Self Locking M8 2 18 A 00469 Cage Latch Pad 1 19 A 00470 Cage Storage Pad 1 20 A 00471 Cage Latch Plate 1 21 A 00473 Cage Latch 1 22 0096 0001 Cap Screw M6 x 16 4 23 0096 0049 Cap Screw M8 x 50 1 24 0096 0040 Hex Nut Self Locking M8 3 25 801 10 0275 Strobe Light Option 1 26 0090 0236 Machine Screw 10 24 x 3 4 2 27 0090 0415 Washer Flat 0 2 28 0090 0182 Hex Nut Self Locking 10 24 2 69 CABLE TRACK ASSEMBLY 70 CABLE TRACK ASSEMBLY PARTS LIST Item No Part No Description Qty 1 A 00531 Slide Tube 1 2 0096 0010 Cap Screw M8 x 20 16 3 0096 0040 Hex Nut Self Locking M8 18 4 A 00532 Tube Slider 1 5 A 00529 Tube Slider Back 1 6 0096 0018 Cap Screw M10 x 40 2 7 0096 0017 Cap Screw M10 x 0 2 8 0096 0041 Hex Nut Self Locking M10 8 9 B00 00 0031 Cable Track 41 Link
22. hydraulic cylinder or its component parts becomes necessary observe the following procedures in accordance with the safety precautions established in Section 1 of this manual Removing the hydraulic cylinder from the boom lift may require the use of specialized tools and lifting equipment NEVER attempt to operate overhead hoists or cranes or related equipment without proper training authorization and supervision Perform all maintenance procedures only in an area that is well lit and well ventilated Bil Jax Inc is not responsible for personal injury or property damage resuliing from the improper use of equipment or failure to follow all procedures and related safety precautions Direct all questions regarding cylinder removal and replacement to your regional Bil Jax representative or to the Bil Jax Service Department at 800 537 0540 25 BIL JAX 36XT LIFT CYLINDER REPLACEMENT Use the following procedure to remove and replace faulty or damaged hydraulic cylinders on the boom lift WARNING Repair and removal of the hydraulic cylinders requires the use of lifting straps and an overhead crane or lifting gear to support the boom Iift and hydraulic cylinders Personnel should be thoroughly trained in the operation of these devices before attempting installation or removal Hydraulic cylinders are heavy and may have hydraulic oil on their surface Failure to use proper equipment or to securely support boom and boom cylinders ca
23. o Joud pue Buu o Aiddy Wal SL 0 SINN 970 0 Buueeq Gumasul 0 40144 609 9101007 Jo doup Alddy cz 5 4 Ajdde pue uonejedo 9 yea 9 91 509 oj U9JU I L dl 27 66 o 24 1 e 871 601 0 0 nbio Wal EZL ZLL or 9 010 OC 17418 0 8 Jauajse4 enbJo speelu oj 911901 Jodoup Alddy Ad yy slog Joyo 8 2 0 9 0 0 0 an 970 0 D 78 PUMP ASSEMBLY PARTS LIST CONTINUED Item No Part No Description Qty 1 B02 15 0513 Reservoir 1 2 02 15 0470 Pump Assembly 2 09 1 3 B02 15 0471 Motor Pump 24 VDC 1 4 B02 15 0500 Coupling 875 x 2 795 1 5 B02 15 0501 Filter Hydraulic 1 6 02 15 0476 Sight Glass 1 7 02 15 0477 Socket Head Cap Screw M8 x 85 2 8 B02 02 0247 Fitting Plug M14 1 5 8 1 9 B02 15 0478 Seal Ring 1 10 B02 15 0485 Clamp Band 10 16 2 11 B02 15 0480 Filter Suction 1 12 B02 15 0504 Allen Nut 1 4 20 4 13 B02 02 0255 Fitting M18 x HB 90M x HB 90 1 14 B02 15 0503 O Ring 110 72 x 3 53 NBR 70 D 1 15 B02 02 0279 Fitting JIC 8 x Push On FS PO 2 16 B02 15 0505 Hose Black 1 2 x 6 1 17 B02 02 0280 Fitting JIC 8 x 46
24. or repair as needed Clean valve solenoid and recheck function s replace or repair as needed Check display for system status Refer to Table 4 2 for error code definitions and correction Inspect wiring in control box and at valve manifold and valve coil repair or replace as needed 20 3 EQUIPMENT MAINTENANCE ERROR CODE DEFINITIONS The DISPLAY PANEL located on the ground control panel indicates the present operating status of the boom lift If an error condition is detected by the control processor during start up or operation the appropriate error code will be displayed on this panel Refer to Table 3 2 for a comprehensive list of Error Code Definitions and solutions Table 3 2 Error Code Definitions ERROR MESSAGE DEFINITION OF ERROR COMMENTS 001 MACHINE IS IN DOWN ONLY Machine was either never leveled outriggers not Retract boom to travel position lowered or machine went out of level with use and extend outriggers using AUTO LEVEL button 002 LOSS OF PLATFORM Ground control lost communication with platform Check for unplugged or damaged COMMUNICATION control platform control cable 005 PLATFORM CONTROL HAS Platform control detected a stuck or pressed key Turn key switch off and on again STUCK KEY on power up without pressing any buttons 008 GROUND CONTROL HAS Ground control detected a stuck or pressed key Turn key switch off and on again STUCK KEY on power up without pressing any button
25. swift service always have the part number available as well as the equipment model and serial number When ordering parts by fax or email always provide the above information See Page 12 for Equipment Warranty information QUICK REFERENCE Equipment Model Bil Jax 4527A Articulating Boom Lift Serial Number NOTES 101 102 125 Taylor Parkway Archbold OH 43502 Phone 419 445 8915 800 537 0540 Fax 419 445 0367 http www biljax com Distributed bv
26. under warranty 4 After completing repairs submit warranty claim form and defective parts to Bil Jax Warranty claim form and parts must be received within 30 days of claim in order to be eligible for credit RMA number must be referenced on warranty claim form Returned parts are to be sent prepaid and will be credited when part is received and verified Warranty labor rate will be paid at current rate set by Bil Jax The amount of labor hours reimbursed will be determined by Bil Jax and will be limited to 4 hours unless approved by Bil Jax Failure to follow the warranty claims process may result in delay in processing claim or denial of the claim Bil Jax reserves the right to limit or adjust warranty claims with regard to parts labor and travel time Components purchased from suppliers other than Bil Jax are not covered under the terms of this warranty 3 EQUIPMENT MAINTENANCE Performing the appropriate maintenance procedures will extend the life of the boom lift and will help ensure the safety of personnel operating the equipment Repair replacement or adjustment of any hydraulic or electrical control device should be performed only by fully trained and authorized personnel These include but are not limited to hydraulic load valves hydraulic flow control valves solenoid valves and limit switches These are safety related controls adjustment or tampering with these devices may impair boom lift function and res
27. x 1 75 1 3 A 00032 Bearing 2 4 A 00020 Pin 1 25 x 5 5 2 5 A 00019 Pin Retainer 1 25 3 6 0096 0016 Cap Screw M10 x 25 3 7 0096 0041 Hex Nut Self Locking 0 3 8 A 00060 Pin 1 25 x 4 25 1 9 A 00138 Outrigger Hydraulic Cylinder 1 10 A 00141 Outrigger Cylinder Guard 1 11 0096 0009 Cap Screw M8 x 10 2 12 A 00142 Guard Slide 1 13 0096 0010 Cap Screw M8 x 20 6 14 0096 0040 Hex Nut Self Locking M8 10 15 A 00154 Spring Outrigger Sensor 1 16 0096 0036 Cap Screw M16 x 150 1 17 0096 0044 Hex Nut Self Locking M16 2 18 A 00128 Pad Mount Weldment 1 19 0096 0051 Cap Screw M16 x 100 1 20 B01 03 0078 Limit Switch Assembly 1 21 0090 0232 Slotted Machine Screw 10 24 x 5 8 2 22 0090 0182 Hex Nut Self Locking 10 24 2 23 A 00136 Foot Pad Aluminum 12 1 24 A 00137 Foot Pad Bottom 12 1 25 0096 0121 Flat Head Cap Screw M8 x 30 4 26 A 00135 Foot Pad Ball 1 27 A 00195 O Ring 1 1 4 OD x 1 ID 1 28 0096 0045 Hex Nut Self Locking M20 1 29 A 00127 Foot Pad Lock 2 30 A 00139 Foot Pad Lock Cap 1 Quantities listed reflect the number of parts needed for each outrigger NOTE Unless otherwise noted high strength Grade 5 Class 8 8 fasteners are used in the assembly of this equipment 43 ENGINE ASSEMBLY 44 ENGINE ASSEMBLY 1 PARTS LIST
28. 0 0034 GFI Outlet 1 30 B01 10 0035 Outlet Box Cover 1 31 0096 0001 Cap Screw M6 x 16 2 73 PLATFORM ASSEMBLY PLATFORM ASSEMBLY PARTS LIST Item No Part No Description Qty 1 A 03350 Platform Weldment 5 1 2 A 03359 Platform Floor 1 3 0096 0102 Cap Screw M8 x 25 26 4 0096 0040 Hex Nut Self Locking M8 26 5 A 03361 Upper Control Box Mount 1 6 0096 0016 Cap Screw M10 x 25 4 7 0096 0041 Hex Nut Self Locking M10 4 8 A 00466 Control Box Latch 1 9 A 00463 Midrail End 4 10 0096 0115 Slotted Head Cap Screw M6 x 20 2 11 A 00464 Midrail 1 12 0096 0052 Cap Screw M6 x 40 2 13 0096 0039 Hex Nut Self Locking M6 6 14 A 00468 Manual Storage Mount Plate 1 15 0096 0017 Cap Screw M10 x 0 2 16 A 00475 Manual Storage Box 1 17 0096 0001 Cap Screw M6 x 16 4 18 A 00474 Cord Wrap Bracket 1 19 A 00071 Platform Pin 1 20 0090 0147 Cotter Pin 1 8 x 1 4 2 21 A 00028 Pin Platform to End Weldment 1 22 A 00779 Upper Control Box 4WD Articulating 1 23 A 00462 Spool 7 24 0096 0003 Flat Head Cap Screw M6 x 40 7 75 PUMP ASSEMBLY 00254 1 41 82 52 0 enbiol 2 1 41 8 2 0 4 1 AN 61 yal 6 6 0 anbioL UL 0 WHEL 8 2 01
29. 0157 Front Rest Pad 5 0096 0017 Cap Screw M10 x 0 16 6 0096 0041 Hex Nut Self Locking M10 20 7 A 00159 Boom Latch 1 8 0096 0016 Cap Screw M10 x 25 4 9 A 00169 Switch Bracket 1 10 0096 0002 Cap Screw M6 x 20 2 11 0096 0039 Hex Nut Self Locking M6 2 12 A 00188 Switch Cam 2 13 0090 1104 Machine Screw 44 40 x 1 3 14 0090 0525 Hex Nut Self Locking 44 40 3 15 B01 03 0078 Limit Switch Assembly NO Female 1 16 B01 03 0079 Limit Switch Assembly NC Male 1 17 0090 0709 Machine Screw 46 32 x 1 1 4 2 18 0090 0180 Hex Nut Self Locking 46 32 2 19 A 00158 Tension Spring 1 20 0096 0038 Cap Screw M20 x 120 4 21 0096 0045 Hex Nut Self Locking M20 4 22 A 01082 Tie Weldment 4WD 1 49 FRONT AXLE ASSEMBLY 50 FRONT AXLE ASSEMBLY PARTS LIST Item No Part No Description Qty 1 A 01010 Front Axle Weldment 4WD 2 A 01097 Bushing 1 5 OD 1 25 ID 3 A 01020 Front Yoke Left 4 A 01021 Front Yoke Right 5 A 01070 Pin 1 25 x 1 625 6 A 00019 Pin Retainer 1 25 7 0096 0016 Cap Screw M10 x 25 8 0096 0041 Hex Nut Self Locking M10 9 A 01022 Hydraulic Motor 4WD 10 0096 0024 Cap Screw M12 x 100 11 0096 0042 Hex Nut Self Locking M12 12 A 01025 Tie Rod 4WD 13 A 01096 Bushing 1 25 OD x 1 0 ID 14 A 01085 Pin Front Axle 15 0090 0155 Cotter Pin 3 16 x 1 3 4 16 A 01030 Steeri
30. 28 5 REPLACEMENT DECALS Decals contain information that is required for the safe and proper use of the aerial work platform Decals should be considered necessary components of the machine and should be checked before each use to verify that they are correctly attached and legible Use the following guides to find the correct location of all decals 29 BIL JAX 36XT Decal No 0202 0523 B06 00 0034 B06 00 0037 B06 00 0062 B06 00 0068 B06 00 0161B B06 00 0404 B06 00 0405 806 00 0471 806 00 0473 806 00 0474 806 00 0475 806 00 0476 806 00 0477 806 00 0481 806 00 0482 30 Table 5 1 Decal Descriptions Decal Description Made in USA DANGER Electric Shock Lubricate Semi Annually NOTICE AC Power NOTICE Hydraulic System Oil Bil Jax Logo Black Transfer WARNING Outrigger Crush Toe WARNING Pinch Point DANGER Before Use Main Instruction Hazards Platform NOTICE Operator s Manual Missing NOTICE Max Load WARNING Read Understand Operator s Manual NOTICE Range of Motion WARNING Forklift Pockets CAUTION Transport Safety Latch DANGER Electrocution Hazard Qty Decal No Decal Description Qty 4 DANGER Battery Charger Safety 1 B06 00 0494 NOTICE Hazardous Materials 1 806 00 0495 CAUTION Compartment Access 2 Restricted B06 00 0503 NOTICE Handle Applications 1 B06 00 0504 NOTICE Emergency Hand Pump 1 DANGER Before Use Main 06 00 0505 jnstruciion Hazards grou
31. 582 i i Male Terminal 12 14ga i 12010293 i Seal 12 14ga Delphi Weather Pack B00 00 0170 12010973 01 09 0109 A Wire Casing 2 Pin Male Housing i A 03044 i 16 PVC 1 12089040 01 09 0110 OIL PRESSURE SWITCH 4WD H 1 Male Terminal i RANSDUCER DIRECT 810 321168 i 12015323 B01 09 0088 i Green Seal Wires should be 17 18 Long 91 CORD ASSEMBLY 110V GENERATOR 01 01 0178 24 L Female Spade Female Spade O 10 Ring Terminal Rev 14 3 SO or Equivalent Delphi Weather Pack i 12015793 i 3 Pin Female Housing i 124580 i SW H 12 Label Female Terminal 12 14ga 12010293 i Seal 12 14ga CORD ASSEMBLY GENERATOR SWITCH B01 01 0179 Female Spade Female Spade 18 2 Delphi Weather Pack SO or Equivalent ee i 12010973 i 4 i 2Pin Male Housing i 12089040 i Male Terminal 12015323 Green Seal w Female Spade DH 80 01 0180 w Female Spade 7 14 Black TXL or Equivalent Label All Measurements are 0 250 In CORD ASSEMBLY 110V AC PLUG FM B01 01 0181 42 gt Female Spade Female Spade
32. 6 FFORX 4 6 FFORX 9 1 4 10 Hydraulic Hose 4 4 FFORX 90S 4 4 FFORX 10 42 4 420 Hydraulic Hose 4 4 FFORX 4 4 FFORX 11 93 4 420 Hydraulic Hose 4 4 FFORX 4 4 FFORX 12 4 4 16 Hydraulic Hose 4 4 MFFOR 4 4 FFORX 13 B02 01 0235 4 x 16 Hydraulic Hose 4 4 MFFOR 4 4 FFORX 14 B02 01 0204 3 x 32 Hydraulic Hose 2 MNPT 2 MNPT 90SW FITTINGS Part No Description Qty B02 02 0259 6 MORFS 6 MORB STR 6 B02 02 0264 46 MORFS 6 MORB 45 8 B02 02 0263 44 MORFS Tee 1 B02 02 0237 44 MORFS 6 MORB STR 2 B02 02 0262 6 MORFS 10 MORB 45 2 B02 02 0196 34 MORB 2 MNPT STR 1 B02 02 0241 32 NPTFM Coupling 1 B02 02 0242 42 QD Plug 1 B02 02 0229 44 MORFS 446 MORB 90 3 81 82 OUTRIGGER HYDRAULIC LINES amp 03182 OUTRIGGER HYDRAULIC LINES PARTS LIST Item Part No Description Qty B02 01 0213 44 x 28 Hydraulic Hose B02 01 0214 4 x 28 Hydraulic Hose B02 01 0215 6 x 56 Hydraulic Hose B02 01 0216 6 x 56 Hydraulic Hose B02 01 0219 6 x 28 Hydraulic Hose B02 01 0220 6 x 28 Hydraulic Hose B02 01 0327 6 x 46 Hydraulic Hose B02 01 0328 6 x 46 Hydraulic Hose 4 B02 02 0258 Fitting Tee 6 MORFS B02 02 0259 Fitting 6 MORFS 46 MORB R R TRAILER HYDRAULIC LINES 4WD 010
33. 75 09244 991 930 0893 1089 06 SUOWF SIUOWFE Z 06 0 9 Z 01 9 007933 01 9 007933 ALS 5 1018 93 00198 2 MIS 01 5 09 IP aa U 5092 7 991 930 0 38V43134 epis 3 xvua D 6 N 1onuo9 AS 9 9 108944 9 9 108944 06 09 098 2 06 09 9 09 2 9 01 70199 9 01 T 0Lp9 77209944 9 01 a s 9 00 8 2 Sy SHOWbirSHHOWY Z o CES 81 8 06 L2 Cw Da d 06 m mere onc 9 9 00y933 9 9 9 00 9 9 9 00 _ 934 9 9 00 9 9 9 00 ON 9 9 007933 9 9 00 9 44 9 9 007911 s m o o u 2 0099 01 8 2089 Sv 01 9 RY ofueg 01 14 8079 67 4 00 1 9 Z1 01 08944 dung ans 06 SUOZI SAHOWOL ns zal 9 9 0944 ALS 09 5 9 Edl db 8 8 8 09744 9 9 108911 991 5 06 Sid 106 9 9 1 108944 MIS 9 9 007944 06 Vid 9 9 108933 vr 108933 06 0 9 1089 06 SHOWY S 3 0 1 01 0
34. 96 ITT CA3101F18 12SF80 Connector Kit PLATFORM GROUND COMMUNICATION CABLE A 00714 Jacket of cable must be in strain relief I Pins Part of Kit 416 18 6 Cable For Cable Track S A 00714 Rev A Pins Part of Kit Orange PinA PinB Pin Pin Pin ITT CA3106F18 12PF80 Connector Kit N Jacket of cable must be in strain relief jl 97 98 lt A gt 650 lt Po a DE PW j MATERIAL LIFT HOOK ASSEMBLY OPTION A 00846 MATERIAL LIFT HOOK PARTS LIST Item No Part No Description Qty 1 A 00977 Platform Mount Weldment LS 1 2 A 00982 Load Sense Weldment 1 3 0096 0055 Cap Screw M12 x 190 1 4 0096 0042 Hex Nut Self Locking M12 3 5 A 00988 1 Load Cell 1 6 0096 0089 Cap Screw M12 x 65 2 7 A 00990A Load Sense Spacer A 1 8 A 00990B Load Sense Spacer B 2 9 0096 0069 Cap Screw M10 x 75 1 10 0096 0041 Hex Nut Self Locking M10 1 11 A 00033 Bearing 4 12 A 00994 LS Roller Bar 1 13 A 00995 LS Roller 2 14 0096 0046 Washer Flat M12 2 15 0090 0147 Cotter Pin 2 16 0096 0009 Cap Screw M8 x 10 2 17 A 00038 Ramp 4 18 0096 0003 Fla
35. A 00242 Battery 4 29 0090 0162 Hex Nut 3 8 16 8 30 A 00235 Power Unit 4WD 1 B02 15 0528 3KW 24V DC Motor 1 B02 15 0529 Gear Pump 2 0 1 B02 02 0301 Fitting M14 x 6 ORFS 1 B02 02 0302 Fitting M18 8 ORFS 1 O COVER ASSEMBLY 1 gt COVER ASSEMBLY PARTS LIST Item No Part No Description Qty 1 A 03240 Cover Left 1 2 A 03239 Cover Right 1 3 A 00228 Cover Brace 2 4 A 00252 Hinge 4 5 0096 0002 Cap Screw M6 x 20 12 6 0096 0039 Hex Nut Self Locking M6 12 7 0090 1080 Pop Rivet 22 8 A 00258 Controls Cover Left Side 1 9 B42 01 1002 Hinge Controls Cover 1 10 A 00292 Cover Latch Assembly 2 65 BOOM ASSEMBLY l 66 BOOM ASSEMBLY PARTS LIST Item No Part No Description Qty 1 A 00552 Hydraulic Master Cylinder 1 2 A 00024 Pin 75 x 8 5 1 3 A 00017 Pin Retainer 75 2 4 0096 0016 Cap Screw M10 x 25 7 5 0096 0041 Hex Nut Self Locking M10 7 6 A 00026 Pin 75 x 7 0 1 7 00551 Hydraulic Boom Cylinder 1 8 A 00021 Pin 1 25 x 8 5 2 9 A 00019 Pin Retainer 1 25 5 10 A 00023 Pin 1 25 x 7 25 1 67 BOOM ASSEMBLY 0 3 68 BOOM ASSEMBLY PARTS LIST Item No
36. EQUIRED VENTILATION NORMAL LOCAL EXHAUST NORMAL MECHANICAL EXHAUST GENERAL X PROTECTIVE GLOVES OIL IMPERVIOUS GLOVES RECOMMENDED EYE PROTECTION SAFETY GLASSES RECOMMENDED OTHER PROTECTIVE EQUIPMENT PROTECTIVE CLOTHING RECOMMENDED SPECIAL LABELLING INSTRUCTIONS NOT REQUIRED SPECIAL PACKAGING RECOMMENDATIONS NONE HANDLING AND STORAGE RECOMMENDATIONS AVOID EXTREMES OF COLD OR HEAT STORE IN CLEAN DRY AREA SPILL OR LEAK PROCEDURES IN CASE OF LEAK OR SPILL DIKE AND ABSORB WITH INERT MATERIAL FOLLOW ALL LOCAL STATE AND FEDERAL REGULATIONS FOR DISPOSAL DISCLAIMER THE INFORMATION CONTAINED HEREIN HAS BEEN COMPILED FROM SOURCES CONSIDERED TO BE DEPENDABLE AND IS ACCURATE TO THE BEST OF THE SELLER S KNOWLEDGE THE SELLER MAKES NO WARRANTY WHATSOEVER EXPRESSED OR IMPLIED REGARDING THE ACCURACY OF SUCH DATA OR THE RESULTS TO BE OBTAINED FROM THE USE THEREOF 37 38 APPENDIX REPLACEMENT PARTS Use only parts manufactured and or authorized by Bil Jax Inc when replacing damaged components See page 89 for replacement part ordering information Only personnel properly trained and authorized to operate all equipment and familiar with all boom functions should attempt to repair or replace any part of the boom lift Always read understand and obey all safety precautions included in this manual as well as those precautions attached to the lift and dictated by federal state and local regulations 39 40
37. MxM 1 18 B02 15 0506 Cap Screw 5 16 18 1 1 4 2 19 B02 02 0283 Fitting JIC 8 x G 3 4 MxM 1 20 B02 02 0281 Fitting Plug 12 ORB 2 21 B02 02 0282 Fitting 3 8 NPT x 1 2 MxHB 1 22 B02 15 0507 Hose Black 1 2 x 15 1 B02 02 0276 Fitting Plug 8 ORB Under Reservoir 1 79 BOOM AND ROTATION HYDRAULIC LINES A 00269 0237 Slave RET DT Basket Level EXT D Master 0237 Basket Level Telescopic RET RET 209 0259 U CU EXT HZ Lift CH RET s 0259 _ 0263 CD EXT 8 O 0229 9 ll 00100 ZE Top Port CE e t Port 0262 D Rotation Kinematics Slew Drive 0264 45 EXT 0241 u 80 BOOM AND ROTATION HYDRAULIC LINES PARTS LISTS Item No Part No Description Fittings 1 B02 01 0274 4 x 42 Hydraulic Hose 4 6 FFORX 4 4 FFORX 2 B02 01 0275 4 x 42 Hydraulic Hose 4 6 FFORX 4 4 FFORX 3 B02 01 0276 46 66 Hydraulic Hose 6 6 FFORX 6 6 FFORX 4 B02 01 0277 6 x 66 Hydraulic Hose 6 6 FFORX 6 6 FFORX 5 B02 01 0278 4 x 48 Hydraulic Hose 4 6 FFORX 46 45 6 B02 01 0279 4 x 48 Hydraulic Hose 4 6 FFORX 46FFORX 45 7 0 4 x 36 Hydraulic Hose 4 6 FFORX 4 6 FFORX 8 1 4 x 36 Hydraulic Hose 4
38. ND 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 SECTION VIII CONTROL AND PROTECTIVE MEASURES Respiratory Protection ABOVE P E L NIOSH APPROVED FITTED FULL FACE RESPIRATOR Protective Gloves ACID RESISTANT Eye Protection FULL FACE PROTECTION Ventilation LOCAL EXHAUST VENTILATED AREA PREFERRED MECHANICAL IF BELOW P E L SPECIAL MUST BE ACID amp EXPLOSIVE RESISTANT OTHER MUST BE ACID amp EXPLOSIVE RESISTANT Other Protective Equipment ACID RESISTANT CLOTHING AND BOOTS Hygienic Work Practices N A 36 6 MATERIAL SAFETY DATA MATERIAL SAFETY DATA SHEET DEXRON III MERCON AUTOMATIC TRANSMISSION FLUID HYDRAULIC OIL SECTION GENERAL INFORMATION TRADE NAME CITGO TRANSGARD ATF DEXRON III MERCON EMERGENCY TELEPHONE NUMBERS 918 495 4700 medical 800 424 9300 chemical CHEMICAL FAMILY AUTOMATIC TRANSMISSION FLUID LUBRICATING OIL CAS NUMBER MIXTURE REVISION DATE 10 29 98 HAZARDOUS INGREDIENTS CONTAINS NO INGREDIENTS NOW KNOWN TO BE HAZARDOUS AS DEFINED IN OSHA 29 CFR 1910 1000 AND OSHA 29 CFR 1910 1200 SECTION II HEALTH HAZARD DATA PRIMARY ROUTES OF ENTRY INHALATION SKIN ABRASION AND
39. OSED 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 Stability STABLE Conditions to Avoid N A Incompatibility AVOID COMBUSTIBLES ORGANIC MATERIALS AND STRONG REDUCING AGENTS Hazardous Decomposition Products SULFUR TRIOXIDE CARBON MONOXIDE SULFURIC ACID FUMES amp SULFUR DIOXIDE Hazardous Polymerization MAY OCCUR Conditions to Avoid N A SECTION VII SPILL OR LEAK PROCEDURES Steps to be taken in case material is released or spilled CONTAIN SPILL USING NON COMBUSTIBLE MATERIALS VERMICULITE DRY SAND amp EARTH NEUTRALIZE WITH LIME SODA ASH SODIUM BICARBONATE ETC Waste disposal method CONSULT STATE ENVIRONMENTAL AGENCY INDIVIDUAL STATE REGULATIONS VARY Precautions to be taken in Handling amp Storage SEPARATE FROM INCOMPATIBLE MATERIALS KEEP AWAY FROM FIRE SPARKS A
40. PARTS AND SERVICE MANUAL ES RE AERIAL WORK PLATFORMS SELF PROPELLED AERIAL WORK PLATFORM This equipment is designed and manufactured in compliance with the duties responsibilities and standards set forth in the ANSI CE CSA and or AS standards in effect at the time of manufacture This equipment will meet or exceed applicable ANSI CE CSA and or AS codes and standards when operated in accordance with manufacturer s recommendations It is the responsibility of the user to follow all regional codes and regulations that govern the safe operation of this equipment Obtain read and obey all safety precautions before performing maintenance or repairs or attempting to operate this equipment This includes all manufacturer recommendations as well as those directives set forth by government and local authorities To ensure proper and safe use of this equipment it is strongly recommended that only trained and authorized personnel attempt to operate and maintain the boom lift This manual shall be considered a permanent and necessary component of the machine and shall be kept with the boom lift at all times Owners and Lessors should complete a full inspection of all components and perform a test of all functions including brake functions before commissioning or reselling the machine Repair or replace all damaged or malfun
41. aled i Stripe wire to 12 GAS ENGINE WIRE HARNESS A 01034 RBL Oil Press Sw OFIBL C Press Sw Gen Switch CWRIBI Black Choke L Strip Wires 6 Delphi Weather Pack Pin Female Conn i 12089188 Female Term 12015323 1 Green Wire Seal Delphi Weather Pack 12010973 7777 2 Pin Male Conn 12089040 Male Term 12015323 Green Wire Seal Delphi Weather Pack 12020830 4 Pin Male Conn 12089040 Male Term 12015323 87 THROTTLE SOLENOID WIRE HARNESS 01042 Weather Pack FM Term 12089188 Cable Seal 12015323 FM Housing 12015792 20 18ga TXL Or Equivalent Put Wires in 16 Split tubing Heat Seal Both ends ENGINE RELAYS WIRE HARNESS 01044 Tube Wrap Female Spade Tape At Delphi Weather Pack Each End Male Term 12089040 Green Seal 12015323 8 Solder inline Resistor Wire Color Wire Length Red U 4 Female Spade HO Y Male Spade xx Y Female Spade Female Spade gt gt Black 15 Y Male Spade Yellow St gt Female Spade Female Spade D gt gt Female 88 O 5 16 Ring Term Labels All wires 18 ga TXL or E
42. and replace oil Wipe away dirt and excess oil from around filter using cleaning cloths and alcohol solvent Q Loosen and remove filter Use absorbent cloths to keep excess oil from leaking onto the machine Discard used filter a Wipe away dirt and excess oil from around filter housing a Install new filter Do not over tighten With the fill port cap on but not tightened completely raise and lower all booms to bleed trapped air from the lift cylinders Repeat as necessary u Replace yearly or whenever filter or oil contamination has a noticeable effect on boom functions Inspect pivot pins and cylinders including rod ends for wear or damage Replace as necessary Visually inspect welds and structural components for wear damage and corrosion Q Follow all manufacturer s recommendations when making repairs to critical components u Personnel making repairs to welds should be certified in accordance with applicable government regulations Inspect outriggers for wear or damage Repair or replace as necessary Verify that Level Sensor is operating correctly Fully deploy outriggers until all Outrigger LEDs and AUTO LEVEL LED are lit and buzzer sounds Q Verify that machine is level and that level sensor is giving an accurate reading Repair or replace as necessary Inspect and adjust axles and brakes Load test boom lift operations with 500 Ib 187 kg load 18 Check slew b
43. ant i Cord Grip 34 3231 Or Equivilant i Delphi Weather Pack i 2 Pin Male Housing 12010973 i i Male Terminal 12089040 i i Green Seal 12015323 i Delphi Weather Pack 1 3 Pin Male Housing 12015793 1 Male Terminal 12010293 Gray Seal 12010293 WIRE ASSEMBLY FAN A 03041 40 Loom Tape each End 8 Middle Weather Pack Weather Pack FM Term FM Term 12089188 12089188 Cable Seal e Cable Seal 12015323 Svo 12015323 FM Housing FM Housing 12015792 12015792 All wires 18 ga TXL or Equivalent All Measurements are 0 250 In 90 IEC CORD MALE US MARKETS A 03042 18 03042 Rev SO cable or Label Equivalent North America Minimum Requirements 120V Male Plug C 90 Degree Plug Interpower Current 15 AMP IEC 60320 C19 Mold 012 i Voltage 120 240VAC GENERATOR 110V WIRE HARNESS A 03043 12 3 SO Or Equivilant 0625 U H A B 36 2 B w 8 een 1 2 Grommet OD i Delphi Weather Pack 1 12010717 i 3 Pin Male Housing i 12124
44. anual NOTICE Range of Motion Qty Decal No B06 00 0482 B06 00 0495 B06 00 0505 B06 00 0506 B06 00 0541 B06 00 0545 B06 00 0561 B06 00 0562 B06 00 0563 B06 00 0568 B06 00 0572 Decal Description DANGER Electrocution Hazard CAUTION Compartment Access Restricted DANGER Before Use Main Instruction Hazards ground NOTICE Emergency Lowering CAUTION Manual Boom Functions Bil Jax Website Transfer WARNING Operating Instructions Ground WARNING Operating Instructions Platform 36XT 6 Black Transfer WARNING Outrigger Pressure WARNING Read Understand Parts and Service Manual Identification Plates Qty B06 00 0499 CE CE Serial ID Plate B06 00 0526 Key Tag 5 REPLACEMENT DECALS 4 A Ver 05621 0474 0471 0476 Figure 5 2 Decal Placement CE 33 BIL JAX 36XT 34 MATERIAL SAFETY DATA The following Material Safety Data Sheets describe the correct procedures for the safe handling of chemical components within the Model 45XA Articulating Boom Lift as well as any potential health and
45. be kept away from skin or eyes If contact occurs flush with water and consult a physician immediately ALWAYS disconnect ground cable first when removing battery ALWAYS connect ground cable last when installing battery ALWAYS charge batteries in open well ventilated areas ALWAYS replace batteries using only parts recommended by manufacturer ALWAYS use only batteries with sealed caps over cells NEVER smoke while servicing batteries NEVER charge batteries near spark or open flame NEVER allow batteries to overcharge and boil NEVER short across battery posts to check for current NEVER break a live circuit at the battery NEVER disconnect battery from charger while charger is connected to a live power source NEVER jumpstart other vehicles using the boom lift batteries BIL JAX 36XT DAMAGED EQUIPMENT POLICY Safety Statement At Bil Jax we are dedicated to the safety of all users of our products All Bil Jax lifts are designed manufactured and tested to comply with current applicable federal OSHA and ANSI codes and regulations Damage Policy There may be occasions when a Bil Jax lift is involved in an incident that results in structural damage to the lift Such damage can seriously compromise the ability of the lift to perform in a safe manner Therefore whenever Bil Jax lift is damaged structurally or when there is suspected internal damage to the structure Bil Jax may require that the lift be returned t
46. ctioning components Bil Jax Inc is dedicated to the continuous improvement of this and all Bil Jax products Therefore equipment information is subject to change without notice Direct any questions or concerns regarding errors or discrepancies in this manual to the Bil Jax Service Department B33 01 0103 Copyright Bil Jax Inc 2008 Rights Reserved Bil Jax is a registered trademark and A Step Above and X Boom are trademarks of Bil Jax Inc Contact Bil Jax for replacement manuals BIL JAX 125 Taylor Parkway Archbold Ohio 43502 A STEP ABOVE Phone 800 537 0540 419 445 8915 Fax 419 445 0367 http www biljax com TABLE OF CONTENTS Table of Contents 1 Illustrations 2 Tables 2 1 Safety 3 Legend Safety Advisories 4 Before Operation 5 During Operation 5 Maintenance Safety 7 Damaged Equipment Policy 8 2 Specifications 9 Range of Motion 10 Specifications 11 Warranty 12 3 Equipment Maintenance 13 Daily Service Checks 14 Weekly Service Checks 16 Monthly Service Checks 17 Annual Service Checks 18 Structural Inspection 19 Additional Service Information 19 Troubleshooting 20 Error Code Definitions 21 4 Cylinder Replacement 25 Lift Cylinder Replacement 26 Outrigger Cylinder Replacement 27 5 Replacement Decals 29 6 Material Safety Data 35 Appendix Replacement Parts 39 Ordering Replacement Parts 101 LIST OF ILLUSTRATIONS Figure 2 1 Range of Motion 10 Figure 3 1
47. dify the platform or carry materials that would increase the surface area of the platform Increasing the area exposed to the wind may decrease machine stability NEVER attach overhanging loads when raising or lowering the platform NEVER use the boom or platform to push or pull or to lift any part of the machine NEVER use the boom or platform to place a load against any structure materials or equipment NEVER climb on the boom NEVER leave an elevated platform unattended NEVER leave the keys in the boom lift while unattended or not in use Drive Safety ALWAYS maintain an awareness of limited sight and blind spots when operating drive functions ALWAYS limit travel speed according to surface conditions slope location of personnel and obstructions and any other factors which may result in collision NEVER operate drive functions on slopes exceeding 20 NEVER engage in stunt driving horseplay or any other behavior considered unsafe according to employer job site and or government regulations NEVER operate the internal combustion engine in an area that is not properly ventilated NEVER fuel the internal combustion engine while smoking or while near spark or open flame MAINTENANCE SAFETY Ensure the following general safety precautions are followed while performing maintenance on the articulating boom lift General Maintenance ALWAYS perform maintenance procedures according to manufacturer s guidelines
48. earing for wear or damage a Check bolts for wear or damage Q With the boom lift fully retracted measure the distance between the slew ring gear and the horizontal plate above Use a 2 inch B0 mm caliper or bore micrometer Record the measurement Figure 3 4 Place a 175 lb 65 kg load on the boom lift platform Measure the distance between the slew ring and the horizontal plate above Record the measurement Ifthe difference in measurements is greater than 25 in 6 35 mm the slew ring bearing should be replaced Contact manufacturer for replacement instructions and assistance MEASURE HERE SLEW RING Figure 3 4 Slew Ring Position Measurement STRUCTURAL INSPECTION A comprehensive structural inspection of the unit shall be performed under any of the following conditions Q Ten years from the date of manufacture and every five years thereafter Q After any actual suspected or potential damage is sustained that could affect the structural integrity or stability of the aerial platform Q After a change in ownership Owners should provide a complete service history when reselling the unit The structural inspection shall include the following considerations u The service history of the unit including hours of service work performed and environmental conditions The inspection and maintenance record of the unit The effectiveness of all controls and components
49. eign particles may cause serious damage to the motor If the motor becomes wet consult an authorized Bil Jax service technician for proper drying instructions NEVER add unauthorized fluids to the hydraulic system or battery NEVER mix hydraulic oils Consult manufacturer specifications Refer to Section 4 for hydraulic system maintenance procedures 1 SAFETY NEVER exceed the manufacturer s recommended relief valve settings NEVER touch or allow metal tools to contact any components that are sensitive to static discharge ALWAYS use static discharge prevention mats and grounding devices when handling electronic components NEVER adjust repair replace or bypass any hydraulic or electrical control or safety device These include but are not limited to hydraulic load control and flow control valves solenoid valves and limit switches ALWAYS consult an authorized Bil Jax technician if repairs are necessary NEVER modify alter or change the equipment without first consulting an authorized Bil Jax technician and NEVER in any way that would affect its original design or operation Battery Maintenance Ensure the following general safety precautions are followed when performing battery maintenance on the Aerial Work Platform ALWAYS wear safety glasses when working with or near batteries ALWAYS check the battery fluid level daily ALWAYS avoid contact with battery acid Battery acid causes serious burns and should
50. f wood shoring between the outrigger beam and cylinder Remove the pivot pin using a hammer and a brass or hardwood drift Fully retract the cylinder Turn key to the off position and remove the key Tag and number all hydraulic hoses that attach to the cylinder valve block Use a marker to label the valve block ports with the appropriate hose numbers 4 CYLINDER REPLACEMENT Unplug the cylinder valve solenoid Place absorbent cloths below the cylinder ports and detach hydraulic hoses from the cylinder Elevate hoses to prevent leakage Plug or cap exposed hose fittings and cylinder ports At the base of the cylinder unbolt and remove retainer plate from each side of the pivot pin Remove the pivot pin using a hammer and a brass or hardwood drift Lift and remove the cylinder using an overhead hoist and lifting straps Replace or reinstall the cylinder by following the above instructions in the reverse order of removal Actuate the hydraulic system and check for leakage Tighten hydraulic fittings as needed Bleed trapped air from the hydraulic system by raising and lowering the boom with the reservoir fill port cap on but not tightened Allow several minutes for trapped air to escape Repeat as needed CYLINDER ROD PIN GUARD CYLINDER ROD GUARD BOLTS CYLINDER RETAINING PLATES Figure 4 2 Outrigger Cylinder Replacement 27 BIL JAX 36XT
51. ht Length Width US CE Stowed Dimensions Height Length Platform stowed Width 43 ft 6 in 13 4 m 37 ft 6 in 11 4m 32 ft 9 8m 27 ft 8 2 500 Ibs 227 kg 440 Ibs 200 kg 2 4 680 lbs 2 123 kg 7002 Non Continuous 12 52 45 8 ft 8 in 2 7 10 ft 3m 18 ft 5 5 3 ft 7 in 111m 2 ft 6 in 0 8m 5 ft 4 ft 1 5 1 2 6 ft 6 in 2 0m 20 ft 10 in 6 4 m 5 ft 5 in 1 7 SERIAL NUMBER 2 SPECIFICATIONS Outrigger Footprint Length Width Footpad Diameter Brake Speed Gas Power DC Power Tire Size Tire Pressure Control System Battery Battery Charger Gas Engine Hydraulic Pressure Reservoir Capacity Hydraulic System Capacity Hydraulic Oil Standard Platform Rotation Type Optional Maximum Decibel Level DC Mode Ground DC Mode Platform Gas Mode Ground Gas Mode Platform Localized Pressure per Outrigger Operation Temperature Range Max Pressure Per Tire Floor Loading 12 ft 2 in 3 7m 11 ft 4 in 3 4 m 12 5 in 0 3 m Spring Applied 1 5 mph 5 6 km h 1 75 mph 2 8 kmh 26 x 12 bar lug tires 20 psi 140 kPa 24V DC 4 x eV 245 amp hr 110 120 Volt Kawasaki 21 HP 3 000 PSI 20 684 kPa 4 8 Gallons 18 2 L 7 Gallons 26 5 L Dexron ATF 90 Manual 60 dB 55 dB 70 dB 65 dB 25 PSI 1 8 kg cm 176 5 kPa 20 to 1102 Fahrenheit 29 to 43 Celsius 35 PSI 2 5 bar 11
52. ify that outrigger safety interlocks operate correctly Q Begin with the outriggers fully extended and the boom lift level Raise one outrigger until the footpad is not in contact with the ground Q Verify that boom functions are unresponsive when one outrigger is raised Q Repeat this procedure for each outrigger Q Raise all outriggers until the footpads are not in contact with the ground Verify that all outrigger status LEDs on the ground control panel are unlit Q Lower one outrigger until the footpad makes contact with the ground and the outrigger begins lifting the trailer If the LED is lit before the footpad makes contact with the ground or if the LED remains unlit after the weight is transferred to the outrigger the position switch or wiring is faulty Q Repeat this procedure for each outrigger Repair or replace as needed Refer to Figure 2 1 Figure 3 1 Outrigger Position Switches Repair and replacement of machine components should be performed only by trained and certified personnel in accordance with government regulations and manufacturer recommendations Inspect hydraulic system and fluid levels a Check all hydraulic hoses and fittings for leaks and damage Tighten or replace as necessary to prevent hydraulic oil or pressure loss The hydraulic oil level should be checked with the booms down all outriggers raised and the trailer wheels on a level surface Hydraulic oil leve
53. inal Black 10 TENA yu 12015323 Wire Seal x 10 Loom 18 18ga Red V FM Spade Insulated 18 18ga Black FM Spade Splice amp Heat xd UT insulated Shrink Seal Pin Level Sensor 24 lt F gt lt 10 18 ga Red gt i Level 5 GND 8 Loom Au mine lt 10 8 Weather Pack 1 gt gt 18 Blaci leather XL or Equivalent i 8 B 12020830 4 Pos housing All Measurements i Pin Level Sensor X Mates With 12020832 4 Lr 9 12089040 Male Terminal 0 250 In 2 lt 18 18 ga Orange gt 12015323 Wire Seal Pump Speed Signal D Motor Enab Pin Level Sensor Y 23 lt 18 18 ga Brown gt POWER HARNESS A 00718 AMP 1 66740 1 Or 12ga Red 66740 6 lt 32 gt AMP 3 Pin Housing 206037 2 AMP Cable Clamp 206070 1 00718 Fill Strain Relief with RTV then put cable clamp and wipe off excess Delphi Weather Pack 3 Pin Male Housing 12010717 B01 09 0123 Male Terminal 12124582 B01 09 0120 Gray cable seal 12010293 B01 09 0121 Ge CB Ceo CW c Gus 6 SDN SJO 5 16 Ring Terminal Batt Pos Pin1 1 66740 1 1293 Black 66740 6 I Batt Neg Pin 2 8 Z DD 5 16 Ring Terminal Bundle wires in 28 of loom Tape both ends if split loom is used 110 VAC TOWER PLATFORM HARNESS A 00722 462 2 14 3 SDN SJO Label or Equivalent A 00722 Rev
54. l should be visible in but not above the sight gauge If the hydraulic oil level is not visible to at least half way up the sight gauge Figure 3 2 add clean hydraulic fluid as necessary while all booms and outriggers are fully retracted and stowed Pour slowly to avoid creating air pockets in the reservoir Do not fill above sight gauge Overfilling the hydraulic reservoir may cause damage to hydraulic lines and may result in equipment malfunction A CAUTION Do not mix hydraulic oils Do not add any fluid to the hydraulic system that is not expressly recommended by the manufacturer Adding unauthorized fluids to the hydraulic system may cause damage to equipment a a The hydraulic reservoir is originally filled with Dexron ATF with a viscosity rating of 175 Manufacturer recommends a higher viscosity hydraulic oil when operating equipment routinely in extreme climates 1 Filter Element Fill Port 3 Sight Gauge Figure 3 2 Hydraulic Reservoir 3 EQUIPMENT MAINTENANCE 15 BIL JAX 36XT WEEKLY SERVICE CHECKS Perform the following service checks at least once each week in addition to all recommended Daily Service Checks Check Battery electrolyte level a If electrolyte level is low add enough water to bring the electrolyte level to the top of the plates a If batteries are fully charged raise electrolyte level to full mark in each cell Inspect all electrical wiring
55. lity under this warranty is limited to the amount paid to Bil Jax for the product This warranty is in lieu of all other warranties expressed or implied Bil Jax neither assumes nor authorizes any or other entity to assume on its behalf any other liability in connection with the sale rental or use of this product Warranty Claims Process In order to qualify for warranty coverage the following conditions must be met 1 Return of completed Warranty Registration form to Bil Jax within 15 days of receipt of product 2 Notification Bil Jax within 72 hours of any claimed defect injury or damage resulting from the claimed the defect and 3 Warranty is limited to parts that are determined to be defective This does not include parts worn out due to normal use Bil Jax authorized dealers or distributors are responsible for filing claims under warranty Listed below is the warranty claims procedure 1 Contact Bil Jax Service Department at 800 537 0540 to report the claim and verify warranty coverage Machine serial number must be provided 2 Identify the components to be claimed under warranty along with description of failure A Returned Merchandise Authorization RMA number will be issued by Bil Jax 3 Replacement parts will then be sent by Bil Jax to the dealer or distributor All parts are invoiced at dealer distributor list price Credits will be issued when defective parts are returned to Bil Jax and found to be defective
56. lty rotate CW CW circuit on power up solenoid coil wiring 046 SHORTED CIRCUIT Excessive load detected in rotate CW circuit on Check for faulty rotate CW TURNTABLE CW power up solenoid coil wiring 047 OPEN CIRCUIT TURNTABLE A load of less than 70mA detected in rotate CCW Check for faulty rotate CCW CCW circuit on power up solenoid coil wiring 048 SHORTED CIRCUIT Excessive load detected in rotate CCW circuit on Check for faulty rotate CCW TURNTABLE CCW power up solenoid coil wiring 049 OPEN CIRCUIT OUTRIGGER A load of less than 70mA detected in outrigger Check for faulty outrigger retract RETRACT retract circuit on power up solenoid coil wiring 050 SHORTED CIRCUIT Excessive load was detected when Outrigger Check for faulty outrigger retract OUTRIGGER RETRACT Retract circuit was energized solenoid coil wiring 051 OPEN CIRCUIT OUTRIGGER A load of less than 70mA detected in outrigger Check for faulty outrigger extend EXTEND retract circuit on power up solenoid coil wiring 052 SHORTED CIRCUIT Excessive load was detected in outrigger extend Check for faulty outrigger extend OUTRIGGER EXTEND circuit on power up solenoid coil wiring 053 OPEN CIRCUIT A load of less than 70mA detected in left front Check for faulty solenoid LF OUTRIGGER outrigger circuit on power up coil wiring at outrigger 054 SHORTED CIRCUIT Excessive load was detected in left front Check for faulty solenoid LF OUTRIGGER outrigger circuit on power up coil wiring at out
57. m potential crush hazards as indicated by decals attached to the machine ALWAYS keep the safety bar lowered unless personnel are entering or exiting the work platform ALWAYS keep personnel and obstructions clear of the machine when repositioning boom or basket BIL JAX 36XT ALWAYS cordon the area surrounding the outriggers to keep personnel vehicles and moving equipment away from the machine while in use ALWAYS stay clear of overhead obstructions including wires and cables ALWAYS engage boom travel latches before towing trailer ALWAYS exercise caution when rotating the boom from the ground control station ALWAYS watch for personnel inside the radius of the turntable and boom arm when rotating the boom lift from the ground or platform controls ALWAYS remove personnel from the boom lift before attempiing to free an elevated platform that has become caught or snagged on an adjacent structure or obstacle NEVER operate the machine on any surface other than firm and level ground NEVER operate the machine from a position on truckbeds trailers floating vessels or scaffolding without written approval from the manufacturer NEVER operate lift functions on slopes exceeding 12 52 NEVER allow electrode contact with any part of the machine while welding from the platform NEVER use the machine as a ground for welding NEVER operate without the outriggers fully extended or when the machine is not level NEVER posi
58. n result in damage to lift components serious injury or death Q Lower the boom until it is resting in a stowed position When removing the slave cylinder extend the articulating boom section until all pivot pins are exposed approximately two feet Press and hold the emergency lowering valve on the back of the jib boom section to relieve all hydraulic pressure to the cylinder Repeat this process for the upper and lower boom sections Refer to the 4527A Operator s Manual for emergency lowering valve locations and operating procedures Q Turn key switch to the OFF position and remove the key Q Locate the piston rod end of the cylinder to be removed Figure 4 1 Unbolt and remove the retainer plate from each side of the pivot pin Verify that the cylinder is supported by lifting straps and an overhead hoist Remove the pivot pin using a hammer a brass or hardwood drift Q Use an overhead crane or lifting gear to raise the boom section Adequate clearance is necessary to reach the cylinder valve block and hydraulic hose ports Q Unplug the appropriate emergency lowering valve solenoid Q Tag and number all hydraulic hoses that attach to the cylinder valve block Use a marker to label the valve block ports with the appropriate hose numbers Place absorbent cloths below the cylinder ports and detach hydraulic hoses from the cylinder Elevate 26 D D
59. nd B06 00 0506 NOTICE Emergency Lowering 2 06 00 0521 DANGER Tip Over Hazard 5 B06 00 0541 CAUTION Manual Boom 1 Functions B06 00 0545 Bil Jax Website Transfer 2 NOTICE Fall Protection Attach B06 00 0552 ment points 1 B06 00 0561 WARNING Operating Instructions 2 Ground B06 00 0562 WARNING Operating Instructions 1 Platform B06 00 0563 6 Black Transfer 2 Identification Plates B06 00 0490 VIN Plate 1 B06 00 0499 ANSI ID Plate 1 B06 00 0524 Annual Inspection Plate 1 B06 00 0526 Key 1 5 DECAL PLACEMENT coso is Figure 5 1 Decal Locations 31 BIL JAX 36XT Decal No 0202 0523 B06 00 0034 B06 00 0037 B06 00 0062 B06 00 0068 B06 00 0161B B06 00 0173 B06 00 0404 B06 00 0405 B06 00 0471 B06 00 0474 B06 00 0475 B06 00 0476 32 Table 5 2 Decal Descriptions CE Decal Description Made in USA DANGER Electric Shock Lubricate Semi Annually NOTICE AC Power NOTICE Hydraulic System Oil Bil Jax Logo Black Transfer Fall Protection Attachment Points WARNING Outrigger Crush Toe WARNING Pinch Point DANGER Before Use Main Instruction Hazards Platform NOTICE Max Load WARNING Read Understand Operator s M
60. ng Cylinder 4WD 17 A 01005 Front Axle Mount Weldment 18 0096 0038 Cap Screw M20 x 120 19 0096 0045 Hex Nut Self Locking M20 R NP NP INP lt lt R R R 0O 0O PIO AR R R A 20 A 01029 Pad Front Axle 21 0096 0091 Flat Head Cap Screw M10 x 25 22 A 01009 Pin 1 0 x 5 5 23 A 00018 Pin Retainer 1 0 24 0096 0014 Cap Screw M10 x 20 51 REAR AXLE ASSEMBLY 52 REAR AXLE ASSEMBLY PARTS LIST Item No Part No Description Qty 1 A 00175 Hydraulic Cover 1 2 0096 0010 Cap Screw M8 x 20 12 3 0096 0067 Clip Nut M8 12 4 A 01032 Hydraulic Motor Rear 2 5 0096 0024 Cap Screw M12 x 100 8 6 0096 0042 Hex Nut Self Locking M12 8 7 01037 Axle Cover 2 53 SLEW RING ASSEMBLY lt l III a 9 19 54 SLEW RING ASSEMBLY PARTS LIST Item No Part No Description Qty 1 A 02189 Slew Assembly and Adapter 1 2 Slew Ring 1 3 Slew Ring Drive 1 4 A 00149 Base Ring Adapter 1 5 0090 0461 Cap Screw 1 2 13 x 2 2 6 0090 0212 Lock Washer 1 2 2 7 0096 0033 Flat Head Cap Screw M16 x 35 16 8 0096 0054 Flat Head Cap Screw M16 x 50 18 9 0090 0643 Cap Screw 5 8 11 x 2 3 4 Grade 8 19 10 0096 0044 Hex Nut Self Locking M16 16 11 A 00350 Rotation Stop Assembly 1 12 0096 0021 Cap Scre
61. o our facility for reconditioning For any questions concerning structural damage or the Damaged Equipment Policy please contact the Bil Jax Service Department at 800 537 0540 Damage Repair Notice There may be occasions when a Bil Jax lift is involved in an accident resulting in damage to non structural components When such damage occurs and 5 are made by the owner or area distributor please notify Bil Jax of these non maintenance repairs and request a repair form to be filled out and returned to Bil Jax 2 SPECIFICATIONS Bil Jax Inc is dedicated to the continuous improvement of this and all Bil Jax products Therefore equipment information is subject to change without notice The following information is based on ideal working conditions Machine performance may vary based on work environment and on machine options Direct any questions or concerns regarding equipment specifications to your regional Bil Jax representative or to the Bil Jax Service Department BIL JAX 36XT RANGE OF MOTION Figure 2 1 Range of Motion SPECIFICATIONS Working Height Maximum Platform Height Maximum Horizontal Outreach From Centerline From Outrigger Footpad Edge Rated Platform Capacity Without Platform Rotation With Platform Rotation Maximum Occupants Total Weight Turntable Rotation Leveling Capability Gradeability Wheel Base Turning Radius Inside Outside Platform Dimensions Heig
62. oid coil wiring 036 SHORTED CIRCUIT Excessive load detected in retract circuit on Check for faulty boom retract RETRACT power up solenoid coil wiring 037 OPEN CIRCUIT PLATFORM A load of less than 70mA detected in platform Check for faulty level up solenoid LEVEL UP level up circuit on power up coil wiring 038 SHORTED CIRCUIT Excessive load detected in platform level up Check for faulty level up solenoid PLATFORM LEVEL UP circuit on power up coil wiring 039 OPEN CIRCUIT PLATFORM A load of less than 70mA detected in platform Check for faulty level down LEVEL DOWN level down circuit on power up solenoid coil wiring 040 SHORTED CIRCUIT Excessive load detected in platform level down Check for faulty level down PLATFORM LEVEL DOWN circuit on power up solenoid coil wiring 041 OPEN CIRCUIT PLATFORM load of less than 7OmA detected in platform Check for faulty boom rotate CW CW circuit on power up solenoid coil wiring 042 SHORTED CIRCUIT Excessive load detected in platform CW circuit Check for faulty boom rotate PLATFORM CW power up solenoid coil wiring 043 OPEN CIRCUIT PLATFORM A load of less than 7OmA detected in platform Check for faulty boom rotate CCW CCW circuit on power up solenoid coil wiring 044 SHORTED CIRCUIT Excessive load detected in platform CCW circuit Check for faulty boom rotate PLATFORM CCW power up solenoid coil wiring 045 OPEN CIRCUIT TURNTABLE A load of less than 70mA detected in rotate CW Check for fau
63. onnections Plug in main disconnect Hydraulic function does not work and display window shows an error message Fault detected by safety interlock microprocessor Boom Lift electric or electronic failure Refer to Table 4 2 for error code definition and correction Refer to Table 4 2 for error code definition and correction Outrigger indicator LED lights do not function Key switch turned to the OFF or platform controls position Emergency STOP engaged Outriggers not deployed Turn key switch to ground controls position Disengage emergency STOP buttons Deploy all outriggers One or more boom controls do not function OR One or more boom controls function improperly OR One or more boom controls function intermittently Key switch is turned to the OFF or incorrect control position Battery charge is low Emergency STOP engaged Battery ground or in series cable loose All outriggers not properly deployed Hydraulic pump inoperative Loose wiring connector Valve solenoid not operating properly Fault detected by system interlock Broken or loose wire Turn key switch to ground or platform controls position Recharge battery Disengage Emergency STOP buttons Inspect and repair battery connections Deploy all outriggers and level boom lift Inspect pump replace or repair as needed Check wiring terminals in control box and at valve manifold replace
64. proper service damage to equipment personal injury or death N DANGER Warns of operation near electrical power sources that could lead to personal injury or death WARNING Describes conditions or practices that could lead to personal injury or death A CAUTION Contains information important in the prevention of errors that could damage machine or components NOTE Contains additional information important for performing a procedure BEFORE OPERATION Ensure the following general safety precautions are followed before operating the articulating boom lift ALWAYS inspect the usage area for potential hazards such as unstable or unlevel surfaces overhead obstructions and electrically charged wires or conductors ALWAYS watch for moving vehicles in the operating area ALWAYS conduct a thorough inspection of the machine before operation Check for damaged or worn parts hydraulic leaks damaged wiring loose wiring conductors damaged outriggers low tire pressure uneven tire wear or tire damage Check for any improperly operating components NEVER operate equipment if any damage is observed or suspected Repair damaged or malfunctioning equipment before operation ALWAYS wear proper clothing and footgear Wear protective equipment as required by government regulations Keep loose clothing jewelry gloves and hair away from moving parts ALWAYS wear a safety harness and energy absorbing lanyard such as a safe
65. quivalent All Measurements are 0 250 In Wire Color Split Tube Wrap 8 Heat Shrink Each of Drop Out 48 12010973 2 Pin Male Housing i 12089040 Female Spade Ins ATC FUSE HOLDER A 01049 ATC Fuse Holder Waytek 46278 or Equivalent 5 16 Ring Term Label End Tape Both Sides Delphi Weather Pack i 4 Pin Female Conn i 12089188 4 6 Leads 4 6 Leads 12 ga Wire 12 ga Wire START STOP RUN WIRE HARNESS A 01098 Wire Label Male Spade Insulated emale Term Wire Color Length gt 27 26 Blue 207 Green 20 12015192 Pin Female Conn 2 12089188 Female Term 12015323 Black gt 28 Female Spade Insulated Orange 28 287 gt Male Terminal 12015323 Green Wire Seal Ring Terminal Delphi Weather Pack 12010973 i 2 Pin Male Housing TXL or Equivalent 42089040 i All Measurements Male Terminal are 0 250 In 12018323 Seal 89 GENERATOR SWITCHER BOX ASSEMBLY A 03040 Box A 01015 B01 06 0056 30 Amp Relay DPST NO Allied Electronics i 850 0345 i Or Equivilant 20 Amp Circuit Breaker W 250 Male Spade Termina i Allied Electronics 886 0036 Or Equivil
66. ressure 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 Flammability Limits in Air by Volume N A Extinguishing Media Dry Chemical Carbon Dioxide Water Fog Water Special Fire Fighting Procedures Sulfuric Acid Fumes Sulfur Dioxide Gas or Carbon Monoxide may be released when acid decomposes Wear NIOSH approved self contained breathing apparatus Unusual Hazards Water applied to sulfuric acid generates heat and causes acid to splatter Wear full cover acid resistant clothing Sulfuric acid reacts violently with metals nitrates chlorates carbides fulminates picrates and other organic materials Reacts with most metals to yield explosive flammable hydrogen gas This reaction is intensified when sulfuric acid is diluted with water to form battery electrolyte 35 BIL JAX 36XT MATERIAL SAFETY DATA SHEET FOR LEAD ACID BATTERIES WET FILLED WITH ACID Continued SECTION V HEALTH HAZARD DATA Primary Routes of Entry Inhalation YES Skin YES Ingestion YES Health Hazards Acute EYES SKIN RESPIRATORY SYSTEM 8 DIGESTIVE SYSTEM Chronic EYES SKIN RESPIRATORY SYSTEM 8 DIGESTIVE SYSTEM Signs and Symptoms of Exposure IRRITATION OF EXP
67. rigger 055 OPEN CIRCUIT A load of less than 70mA detected in right front Check for faulty solenoid RF OUTRIGGER outrigger circuit on power up coil wiring at outrigger 22 3 EQUIPMENT MAINTENANCE ERROR MESSAGE DEFINITION OF ERROR COMMENTS 056 SHORTED CIRCUIT Excessive load detected in right front outrigger Check for faulty solenoid RF OUTRIGGER circuit on power up coil wiring at outrigger 057 OPEN CIRCUIT A load of less than 70mA detected in left rear Check for faulty solenoid LR OUTRIGGER outrigger circuit on power up coil wiring at outrigger 058 SHORTED CIRCUIT Excessive load detected in left rear outrigger Check for faulty solenoid LR OUTRIGGER circuit on power up coil wiring at outrigger 059 OPEN CIRCUIT A load of less than 70mA detected in right rear Check for faulty solenoid RR OUTRIGGER outrigger circuit on power up coil wiring at outrigger 060 SHORTED CIRCUIT Excessive load detected in right rear outrigger Check for faulty solenoid RR OUTRIGGER circuit on power up coil wiring at outrigger 069 OPEN CIRCUIT A load of less than 70mA detected in proportional Check for faulty solenoid PROPORTIONAL valve circuit on power up coil wiring at proportional valve 070 SHORTED CIRCUIT Excessive load detected in proportional valve Check for faulty solenoid PROPORTIONAL circuit on power up coil wiring at proportional valve 23 BIL JAX 36XT 24 4 CYLINDER REPLACEMENT If repair or replacement of a boom lift or outrigger
68. rt No Description Qty B02 02 0259 46 MORFS 46 MORB STR 10 B02 02 0293 48 MORFS 48 MORB STR 1 B02 02 0260 46 MORFS 6 MORB 90 6 B02 02 0287 44 MORFS 44 MORB STR 2 B02 02 0288 44 MORFS 4 MORB 90 6 B02 02 0289 44 MORFS Tee 2 B02 02 0294 6 MORFS 6 MORB 90 L 1 5 12 MORB 10 FMORB 1 B02 02 0296 10 MORFS 10 MORB 10 MORFS Tee 1 B02 02 0297 10 MORFS 10 FMORFS 90 1 B02 02 0298 48 MORFS 12 MORB STR 1 B02 02 0299 48 MORFS 10 MORB 457 2 B02 02 0300 10 MORFS 12 MORB 905 1 B02 02 0303 10 MORB Plug 1 B02 02 0304 10 MORB 6 FMORB 4 B02 02 0305 46 MORFS 10 MORB STR 4 B02 02 0237 44 MORFS 6 MORB STR 2 B02 02 0307 48 MORFS Tee 1 B02 02 0308 44 MORB Plug 1 B02 02 0309 8MORFS 12 MORB 90 2 4WD MANIFOLD A 01033 85 WIRE HARNESSES Platform Plug Motor Cntl P48 P5 Connector P3 P1 Turntable Connector J4 Platform Connector P2 Analog Connector Lift Engine Connector 23 16 00000000 0000000 0000000 1 Level Sensor Motor Controller Motor Controller HH NO NO Boom Down Relay NG EE i Za cg OQ CG
69. s 009 BOOM UP WITHOUT Ground control detected the boom is up and all Retract boom to travel position OUTRIGGERS ON GROUND outriggers are not on the ground and extend outriggers using AUTO LEVEL button 010 LEVEL SENSOR HAS The ground control detected an erratic output Retract and extend outriggers ERRATIC OUTPUT from the level sensor using AUTO LEVEL button 015 MACHINE IS NOT LEVEL Machine has gone out of level with use Retract and extend outriggers using AUTO LEVEL 016 LIFT BOOM A boom rotate extend or retract function Raise boom from travel position requested with boom down 017 STOW BOOM An outrigger function requested with boom up Retract and lower boom to travel position 021 OPEN CIRCUIT PRIMARY UP A load of less than 70mA detected in primary up Check for faulty boom up circuit on power up solenoid coil and wiring 022 SHORTED CIRCUIT Excessive load detected in primary up circuit on Check for faulty boom up PRIMARY UP power up solenoid coil and wiring 023 OPEN CIRCUIT PRIMARY A load of less than 70mA was detected when Check for faulty boom down DOWN primary down circuit was energized solenoid coil and wiring 024 SHORTED CIRCUIT Excessive load detected when primary down Check for faulty boom down PRIMARY DOWN circuit was energized solenoid coil and wiring 025 OPEN CIRCUIT SECONDARY A load of less than 70mA detected in secondary Check for faulty boom up UP up circuit on power up solenoid coil and wiring 026 SHORTED CIRCUIT
70. s 1 10 A 00536 Cable Track Tray 1 11 0096 0014 Screw M10 x 20 4 12 A 00538 Cable Support Tube 1 13 A 00539 Cable Slide Block 1 14 0096 0056 Cap Screw M8 x 30 2 71 BOOM NOSE ASSEMBLY 9 9 6 8 6 O 6969669 69 69 6 72 BOOM NOSE ASSEMBLY PARTS LIST Item No Part No Description Qty 1 A 00979 Bulkhead Mount 1 2 0096 0016 Cap Screw M10 x 25 4 3 A 00601 Platform Pivot Weldment 1 4 A 00025 Pin 1 0 x 6 5 1 5 A 00018 Pin Retainer 1 0 1 6 0096 0041 Hex Nut Self Locking M10 6 7 0096 0015 Socket Head Cap Screw M10 x 20 2 8 A 00033 Bearing 4 9 A 00606 Snap Pin 2 10 A 00608 Compression Spring 1 11 A 00609 Knob Platform Latch 2 12 0096 0055 Cap Screw M12 x 190 1 13 0096 0042 Hex Nut Self Locking M12 10 14 A 00553 Hydraulic Slave Cylinder 1 15 A 00027 Pin 75 x 5 25 DB 1 16 A 00034 Pin Retainer 75 FH 2 17 0096 0012 Flat Head Cap Screw M8 x 25 2 18 0096 0040 Hex Nut Self Locking M8 2 19 A 00035 Pin 75 5 1 20 A 00017 Pin Retainer 75 1 21 A 00522 Boom End Weldment 1 22 0096 0020 Cap Screw M12 x 0 9 23 A 00031 Bearing 2 24 A 00610 Platform Mount Weldment 1 25 A 00038 Ramp 4 26 0096 0003 Flat Head Cap Screw M6 x 20 8 27 0096 0039 Hex Nut Self Locking M6 10 28 B01 10 0046 Outlet Box 1 29 B01 1
71. s found at the back of the Operator s Manual to record all Service Checks as well as any maintenance repairs or alterations performed on the machine Records of frequent safety checks need not be made However where a safety hazard is found it shall be reported in writing to the owner of the machine anda record of any corrective action shall be maintained for five years or as required b y the authority having jurisdiction Testing Machine Stability The Summit Series aerial work platform has been tested for stability using a load equal to 150 of the rated capacity of the machine and placed at the center of the platform with the boom fully extended Stability tests should be conducted only by trained personnel and only when the machine is properly anchored to safeguard against tipping 19 BIL JAX 36XT TROUBLESHOOTING Refer to Table 3 2 for basic troubleshooting operations Additional information can be found in the Bil Jax Model 45XA Operator s Manual Contact the Bil Jax Service Department with any questions or before attempting any advanced troubleshooting operations Table 3 1 Troubleshooting Steps PROBLEM CAUSE SOLUTION No lights on panel when key switch is turned to the on position Emergency STOP engaged Battery charge is low Battery ground or in series cable is loose Battery main disconnect unplugged Disengage Emergency stop buttons Recharge as needed Inspect and repair battery c
72. se near electrical power lines and DOES NOT provide protection from contact with or close proximity to any electrically charged conductor Operator must maintain safe clearances at all times 3 05 meters minimum and must always allow for platform movement due to gusty winds Always contact power company before working near power lines Assume every power line is live Power lines can be blown by the wind Refer to Table 1 1 for minimum safe approach distances between the machine and electrical power lines Voltage Range Minimum Safe Approach Distance Phase to Phase Feet Meters 0 to 300V Avoid Contact Over 300V to 50KV 10 3 05 Over 50KV to 200KV 15 4 60 Over 200KV to 350KV 20 6 10 Over 350KV to 500KV 25 7 62 Over 500KV to 750KV 35 10 67 Over 750KV to 1000KV 45 13 72 Table 1 1 Minimum Safe Approach Distances ALWAYS keep away from a machine that is exposed to energized power lines If the machine contacts energized power lines NEVER touch or operate the machine until power lines are shut off ALWAYS operate only on a firm and level surface NEVER operate on surfaces that do not support the equipment with its rated load capacity or on surfaces that do not support force exerted by the outriggers during boom operation Operate only on surfaces that can support a pressure of 1 8 kg cm 25 psi to ensure safe operation ALWAYS keep personnel away from potential pinch and shear points and fro
73. t Head Cap Screw M6 x 20 8 19 0096 0039 Hex Nut Self Locking M6 8 20 A 00992 Load Sense Interface Not Pictured 1 21 0096 0085 Cap Screw M6 x 60 3 22 0096 0039 Hex Nut Self Locking M6 3 99 100 BATTERY LAYOUT 03 0 24 06 100AMP 801 06 0058 Contactor 24VDC 100AMP B01 06 0058 Item No Kit No A 00272 1 30 Red 2 Gauge 5 16 Ring Lug 2 45 Black 2 Gauge 5 16 Ring 5 16 Ring 3 8 Black 2 Gauge 5 16 Ring 5 16 Ring 4 22 Black 2 Gauge 5 16 Ring Lug 5 24 Red 2 Gauge 5 16 Ring Lug 6 48 Black 2 Gauge 5 16 Ring Lug 7 22 Red 2 Gauge 5 16 Ring Lug 8 48 Red 2 Gauge 5 16 Ring 5 16 Ring 9 45 Black 2 Gauge 5 16 Ring 5 16 Ring 10 19 Black 2 Gauge 5 16 Ring 5 16 Ring 11 13 Red 2 Gauge 5 16 Ring 5 16 Ring Item No Kit No A 00934 D1 6 Red 2 Gauge 5 16 Ring 5 16 Ring D2 30 Red 2 Gauge 5 16 Ring 5 16 Ring D3 13 Black 2 Gauge 5 16 Ring 5 16 Ring D4 40 Red 2 Gauge 5 16 Ring 5 16 Ring D5 40 Black 2 Gauge 5 16 Ring 5 16 Ring D6 20 Red 2 Gauge 5 16 Ring 5 16 Ring ORDERING REPLACEMENT PARTS To order replacement parts contact the Bil Jax Service Department by phone at 800 537 0540 by fax at 419 446 8202 or by email at techsupport biljax com For
74. tion an elevated platform against another object to steady the platform NEVER override or bypass the manufacturer s safety devices NEVER attach a safety harness to an adjacent structure pole or to nearby equipment while working from the boom platform NEVER raise the outriggers while boom is raised or extended NEVER sit stand or climb on cage bars ALWAYS keep both feet firmly on the work cage floor when working from an elevated platform NEVER attempt to increase the working height with boxes ladders stools or any other materials NEVER operate this equipment when exposed to high winds thunderstorms ice or any weather conditions that would compromise operator safety NEVER operate boom lift in conditions where wind speeds exceed 12 5 m sec 45 km h or 28 mph High winds may affect stability and boom operation NEVER allow ropes electric cords hoses or other equipment to become entangled in the machine while raising or lowering platform NEVER exceed the load limits set by the manufacturer Use only the Material Lifting Hook supplied as an option and manufactured by Bil Jax when lifting materials Safely stow all tools and equipment NEVER exceed load ratings by transferring loads to the lift at elevated heights NEVER use the platform to lift a load that exceeds the platform dimensions NEVER lift a load such a way that the center of gravity is higher than the top guardrail of the platform NEVER mo
75. to Section 5 for decal locations Verify that all controls and indicators at ground and platform control stations operate properly Lower outriggers to level the boom lift Raise and extend all booms Press emergency STOP button Verify that booms remain elevated and do not drift Pull out STOP button and lower the booms OOO 0 00 If either control station is unresponsive refer to Table 3 1 for troubleshooting procedures u If display panel displays an error code refer to Table 3 2 for error code definitions Verify correct tire inflation a Inflate tires to 20 psi 140 kPa Inspect tires for damage or loose or missing lug nuts a Repair or replace as necessary Inspect structural components and platform for obvious damage or debris Repair or replace as necessary Inspect machine for missing loose or damaged fasteners including pins and bolts Check engine oil level Add oil as needed a Manufacturer recommends engine oil type 5W 30 Check engine fuel level Q Add fuel as needed 14 Verify that boom down limit switches operate correctly a Down limit switches are actuated when the boom is in a fully lowered stowed position Limit switches must be operational to raise or lower outriggers u If outrigger controls are unresponsive when boom is fully lowered and stowed inspect down limit switches for loose mounting or visible damage Q Repair or replace as needed Ver
76. ty harness and lanyard provided by Bil Jax ALWAYS inspect platform floor and outrigger footpads for mud grease debris or other foreign material ALWAYS remove any such material from the equipment before operation ALWAYS tag any part of the equipment known or suspected to be damaged or malfunctioning ALWAYS remove a malfunctioning damaged or defective machine from service NEVER operate a machine that has any known or suspected defect ALWAYS comply with the instructions found in Safety and or Service Bulletins distributed by the manufacturer Bulletins may contain critical procedures that supersede the information contained in manuals NEVER operate this equipment while under the influence of drugs or alcohol while taking prescription medications that may leave the operator drowsy or prone to dizziness or while feeling ill NEVER modify the equipment in any way that would affect its original design or operation NEVER deface modify or obscure any decals or markings on equipment NEVER operate the equipment in any way for which it is not intended 1 SAFETY DURING OPERATION Ensure the following general safety precautions are followed while operating the articulating boom lift ALWAYS position lift away from power lines to ensure that no part of the lift can accidentally reach into an unsafe area This includes full extension of the boom through 700 rotation ZA DANGER This machine is NOT insulated for u
77. ult in safety or damage hazards Persons performing maintenance or repairs on the machine including weld repairs should be trained in accordance with the manufacturer s recommendations Contact your regional Bil Jax representative if additional information is needed Critical or suspect areas identified during any scheduled inspection of the machine shall be examined by qualified personnel in accordance with applicable government regulations Never operate the machine if a defect or malfunction is identified or suspected All defects and malfunctions must be repaired and all maintenance performed before returning a machine to service This manual contains a list of recommended maintenance procedures to be performed daily weekly monthly and annually When servicing the internal combustion engine installed on this machine always follow the guidelines specified by the engine manufacturer It is the practice of Bil Jax Inc to issue Service and or Safety Bulletins which may include updates to the information contained in this manual In such instances procedures contained in Bil Jax Service Bulletins or Safety Bulletins supersede the information contained in manuals Always follow maintenance schedule regardless of use 13 BIL JAX 36XT DAILY SERVICE CHECKS The following maintenance procedures should be performed daily or before each operation Verify that all decals are correctly applied and in plain view u Refer
78. w M12 x 45 2 13 0096 0042 Hex Nut Self Locking M12 2 55 COUNTERWEIGHT ASSEMBLY COUNTERWEIGHT ASSEMBLY PARTS LIST Item No Part No Description Qty 1 A 00270 Counterweight 1 2 0096 0065 Screw M20 80 3 0096 0045 Hex Nut Self Locking M20 4 57 CONTROL COMPARTMENT ASSEMBLY 58 CONTROL COMPARTMENT ASSEMBLY PARTS LIST Item No Part No Description Qty 1 A 00712 Lower Control Box 1 2 A 00233 Lower Control Mount 1 3 A 00290 Cover Stop Bracket 1 4 0096 0016 Cap Screw M10 x 25 2 5 0096 0041 Hex Nut Self Locking M10 2 6 A 00295 Level Sensor 1 7 0096 0002 Cap Screw M6 x 20 16 8 0096 0039 Hex Nut Self Locking M6 20 9 A 00287 Mount Plate GFI Outlet 1 10 A 00255 Motor Controller 2 11 B01 05 0056 Battery Charger 1 12 A 00274 Gas Spring 1 13 0090 0920 Stud Ball 10mm 2 14 0090 0185 Hex Nut Self Locking 5 16 18 2 15 A 03200 Turntable Weldment 1 16 B01 10 0046 Outlet Box 1 17 B01 10 0034 GFI Outlet 1 18 B01 10 0035 Outlet Box Cover 1 19 0096 0001 Cap Screw M6 x 16 2 20 A 00288 Plastic Cover 1 21 0096 0004 Cap Screw M6 x 25 8 22 A 00935 Dual Motor Controller Bracket 1 59 PUMP COMPARTMENT ASSEMBLY 60 PUMP COMPARTMENT PARTS LIST Item No
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