Bil Jax Personal Lift Aerial Work Platforms Hydraulic Boom Users Manual Introduction

Bil-Jax Personal Lift XLB-4319 Biljax_XLB-4319_operator_manual

2015-02-02

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Operation and
Maintenance Manual
AERIAL WORK PLATFORMS

XLB-4319
Hydraulic Boom Lift

3
B-4

B33-01-0080

BOOM PERSONNEL LIFT
This equipment is designed and manufactured in compliance with the duties, responsibilities, and standards set forth for manufacturers in the ANSI 92.2 standard
in effect at the time of manufacture.
This equipment will meet or exceed applicable OSHA codes and ANSI A92.2 standards when used in accordance with sections 7, 8, 9, 10 & 11 of ANSI A92.2 and all
other manufacturer’s recommendations.
It is the responsibility of the user of this equipment to follow all applicable ANSI,
OSHA, Federal, State, and local codes and regulations that govern the safe operation of this equipment.

Table of Contents
Preface................................................................................................................ v
1

Safety................................................................................................................1-1
1-1
Introduction.........................................................................................1-1
1-2
Before Operation ................................................................................1-2
1-3
During Operation ................................................................................1-3
1-4
Maintenance Safety.............................................................................1-5
General Maintenance......................................................................1-5
Battery Maintenance.......................................................................1-6
1-5
Damaged Equipment Policy ...............................................................1-6
Safety Statement .............................................................................1-6
Damage Policy................................................................................1-6
Damage Repair Notice....................................................................1-6
Reporting Safety Defects................................................................1-7

Introduction.....................................................................................................2-1
2-1
General Description ............................................................................2-1
2-2
Specifications......................................................................................2-4
Boom Lift Work Platform ..............................................................2-4
2-3
Warranty .............................................................................................2-5

Operation .........................................................................................................3-1
3-1
Operator Controls ...............................................................................3-1
Ground Control Station.......................................................................3-1
Basket Control Station....................................................................3-4
3-2
Normal Operating Procedure ..............................................................3-6
3-3
Emergency Lowering..........................................................................3-8
3-4
Manual Boom Rotation.......................................................................3-9
3-5
Battery Recharge (DC MODEL ONLY) ..........................................3-10
3-6
Boom Lift Transport .........................................................................3-11
Trailer Hitching ............................................................................3-11

Maintenance ....................................................................................................4-1
4-1
Scheduled Service Checks ..................................................................4-1
Daily/Weekly Service Checks ........................................................4-1
Monthly Service Checks.................................................................4-2
4-2
Wheel Nut Torque Requirements .......................................................4-3
4-3
Lubrication..........................................................................................4-4
4-4
Hydraulic System................................................................................4-5
Hydraulic System Inspection..........................................................4-5
Fluid Check and Replacement........................................................4-5
Return Filter Replacement..............................................................4-6
Air Bleeding ...................................................................................4-6
Hydraulic Pressure Checks and Adjustments .................................4-7
Hydraulic Cylinder Replacement .................................................4-10
4-5
SLEW RING BEARING ..................................................................4-17
Check Free Play............................................................................4-17
4-6
Limit Switch checks and adjustments...............................................4-18
Adjusting Boom Down Limit Switch ...........................................4-18
Adjusting Outrigger Position Switches ........................................4-19
4-7
Troubleshooting................................................................................4-20
Troubleshooting Aids ...................................................................4-22
4-8
Material Safety Data Sheets..............................................................4-31

Replacement Decals........................................................................................ 5-1

Parts List ......................................................................................................... 6-1
6-1
Upper Boom Parts List....................................................................... 6-2
6-2
Lower Boom Parts List ...................................................................... 6-4
6-3
Jib Boom Parts List ............................................................................ 6-6
6-4
Compartment Covers Parts List ......................................................... 6-8
6-5
Reservoir Compartment Parts List, Gas model ................................ 6-10
6-6
Pump Compartment Parts List, DC Model ...................................... 6-12
6-7
Chassis and Rotation Unit Parts List................................................ 6-16
6-8
Hitch and Jack Assembly Parts List................................................. 6-18
6-9
Axle and Wheel Assembly Parts List.............................................. 6-20
6-10
Rear Lights and Junction Box Parts List.......................................... 6-23
6-11
Outriggers Parts List ........................................................................ 6-25
6-12
Basket Parts List............................................................................... 6-27
6-13
Outrigger Hydraulic Controls Parts List .......................................... 6-29
6-14
Lower Controls Parts List ................................................................ 6-31
6-15
Upper Controls Parts List................................................................. 6-33
6-16
Engine Compartment Parts List, Gas Model.................................... 6-35
6-17
Boom Control Hydraulics Parts List, Basket ................................... 6-39
6-18
Boom Control Hydraulics Parts List, Ground, Gas Model .............. 6-41
6-19
Boom Control Hydraulics Parts List, Ground, DC Model ............... 6-43
6-20
Lower Boom Cylinder Hydraulics Parts List ................................... 6-45
6-21
Upper Boom Cylinder Hydraulics Parts List ................................... 6-46
6-22
Pushbutton Panel Parts List, Basket................................................. 6-47
6-23
Pushbutton Panel Parts List, Ground Controls................................. 6-49

ANSI Reprint .................................................................................................. 7-1

List of Illustrations
Figure 2-1.
Figure 2-2.
Figure 2-3.
Figure 3-1.
Figure 3-2.
Figure 3-3.
Figure 3-4.
Figure 3-5.
Figure 3-6.
Figure 3-7.
Figure 3-8.
Figure 3-9.
Figure 3-10.
Figure 4-1.
Figure 4-2.
Figure 4-3.
Figure 4-4.
Figure 4-5.
Figure 4-6.
Figure 4-7.
Figure 4-8.
Figure 4-9.
Figure 4-10.
Figure 4-11.
Figure 4-12.
Figure 4-13.
Figure 4-14.
Figure 4-15.
Figure 4-16.
Figure 4-17.
Figure 4-18.
Figure 4-19.
Figure 4-20.
Figure 5-1.
Figure 5-2.
Figure 5-3.
Figure 5-4.
Figure 5-5.
Figure 6-1.
Figure 6-2.
Figure 6-3.
Figure 6-4.
Figure 6-5.
Figure 6-6.
Figure 6-7.
Figure 6-8.
Figure 6-9.
Figure 6-10.

XLB-4319 Hydraulic Boom Lift.............................................................2-1
Basket and Ground Station Controls.......................................................2-2
Safe Operating Zone ...............................................................................2-3
Ground Control Station Access...............................................................3-1
Ground Control Station...........................................................................3-2
Engine Keyswitch ...................................................................................3-3
Basket Control Station ............................................................................3-4
Outrigger Controls ..................................................................................3-6
Manual Lowering Valve .........................................................................3-8
Basket Control Station ............................................................................3-8
Emergency Rotation................................................................................3-9
Battery Charger .....................................................................................3-10
Trailer Hitching.....................................................................................3-11
Wheel Bolt Tightening Sequence............................................................4-3
Lubricate Monthly...................................................................................4-4
Lubricate Semi-Annually ........................................................................4-4
Hydraulic Reservoir ................................................................................4-5
Main Bypass Valve and Pressure Test Port (Gas Engine Model)...........4-7
Outriggers Bypass Valve ........................................................................4-8
Boom Control Bypass Valve, Basket Station..........................................4-9
Hydraulic Cylinder Removal ................................................................4-11
Jib Boom Components ..........................................................................4-14
Basket Swivel Cylinder.........................................................................4-16
Slew Ring Position Measurement .........................................................4-17
Boom Down Limit Switch ....................................................................4-18
Outrigger Position Switch .....................................................................4-19
Simplified Electrical Diagram, DC Model............................................4-22
Detailed Electrical Diagram, DC Model ...............................................4-23
Simplified Electrical Diagram, Gas Model ...........................................4-24
Detailed Electrical Diagram, Gas Model ..............................................4-25
Hydraulic Diagram, DC Model.............................................................4-26
Hydraulic Diagram, Gas Model ............................................................4-28
Level Sensor..........................................................................................4-30
Replacement Decals ................................................................................5-2
Decal Locations, Trailer and Boom ........................................................5-5
Decal Locations, Control Compartment Exterior....................................5-6
Lubricate Monthly Decal ........................................................................5-6
Lubricate Semi-Annually Decal..............................................................5-6
Upper Boom............................................................................................6-2
Lower Boom ...........................................................................................6-4
Jib Boom .................................................................................................6-6
Compartment Covers ..............................................................................6-8
Reservoir Compartment, Gas Model....................................................6-10
Pump Compartment, DC Model............................................................6-12
Chassis and Rotation Unit.....................................................................6-16
Hitch and Jack Assembly ......................................................................6-18
Axle and Wheel Assembly....................................................................6-20
Rear Lights and Junction Box ...............................................................6-23

iii

Figure 6-11.
Figure 6-12.
Figure 6-13.
Figure 6-14.
Figure 6-15.
Figure 6-16.
Figure 6-17.
Figure 6-18.
Figure 6-19.
Figure 6-20.
Figure 6-21.
Figure 6-22.
Figure 6-23.

Outriggers............................................................................................. 6-25
Basket ................................................................................................... 6-27
Outrigger Hydraulic Controls............................................................... 6-29
Lower Controls..................................................................................... 6-31
Upper Controls ..................................................................................... 6-33
Engine Compartment Parts List, Gas Model ........................................ 6-35
Boom Control Hydraulics, Basket........................................................ 6-39
Gas Model Boom Control Hydraulics, Ground.................................... 6-41
DC Model Boom Control Hydraulics, Ground .................................... 6-43
Lower Boom Cylinder Hydraulics ....................................................... 6-45
Upper Boom Cylinder Hydraulics........................................................ 6-46
Basket Pushbutton Panel, Gas Model................................................... 6-47
Pushbutton Panel, Ground Controls ..................................................... 6-49

List of Tables
Table 1-1.
Minimum Safe Approach Distances....................................................... 1-3
Table 2-1.
Specifications ......................................................................................... 2-4
Table 4-1.
Daily/Weekly Service Checks................................................................ 4-1
Table 4-2.
Monthly Service Checks ........................................................................ 4-2
Table 4-3.
Troubleshooting Chart.......................................................................... 4-20
Table 4-4.
Level Sensor LEDs............................................................................... 4-30
Table 5-1.
Replacement Decals ............................................................................... 5-1
Table 6-1.
Upper Boom Parts List ........................................................................... 6-3
Table 6-2.
Lower Boom Parts List........................................................................... 6-5
Table 6-3.
Jib Boom Parts List ................................................................................ 6-7
Table 6-4.
Compartment Covers Parts List.............................................................. 6-9
Table 6-5.
Reservoir Compartment Parts List, Gas Model.................................... 6-11
Table 6-6.
Pump Compartment Parts List, DC Model........................................... 6-13
Table 6-7.
Chassis and Rotation Unit Parts List .................................................... 6-17
Table 6-8.
Hitch and Jack Assembly Parts List ..................................................... 6-19
Table 6-9.
Axle and Wheel Assembly Parts List................................................... 6-21
Table 6-10. Rear Lights and Junction Box Parts List .............................................. 6-24
Table 6-11. Outriggers Parts List............................................................................. 6-26
Table 6-12. Basket Parts List................................................................................... 6-28
Table 6-13. Outrigger Hydraulic Controls Parts List............................................... 6-30
Table 6-14. Lower Controls Parts List..................................................................... 6-32
Table 6-15. Upper Controls Parts List ..................................................................... 6-34
Table 6-16. Engine Compartment Parts List, Gas Model ........................................ 6-36
Table 6-17. Boom Control Hydraulics Parts List, Basket........................................ 6-40
Table 6-18. Gas Model Boom Control Hydraulics Parts List, Ground.................... 6-42
Table 6-19. DC Model Boom Control Hydraulics Parts List, Ground .................... 6-44
Table 6-20. Lower Boom Cylinder Hydraulics Parts List ....................................... 6-45
Table 6-21. Upper Boom Cylinder Hydraulics Parts List........................................ 6-46
Table 6-22. Basket Pushbutton Panel Parts List ...................................................... 6-48
Table 6-23. Pushbutton Panel Parts List, Ground Controls ..................................... 6-49
Table 7-1.
Minimum Safe Approach Distance (M.S.A.D.)
to energized (exposed or insulated) power lines and parts. .......................................... 7-11

PREFACE
The purpose of this manual is to provide a thorough understanding of the XLB-4319
Hydraulic Boom Lift operation and controls. Read the safety and operating instructions
in this manual and become familiar with the location and use of all controls.
Follow all warnings, cautions, and instructions in this manual and any attached to and
supplied with the boom lift. All OSHA, ANSI, state, and local codes and regulations
concerning this equipment should obtained, read, and thoroughly understood before
attempting to operate this equipment.
To ensure proper and safe use of this equipment, only trained and qualified personnel
should operate and maintain the boom lift.

SAFETY NOTES
This manual contains DANGERS, WARNINGS, CAUTIONS, and NOTES that must be
followed to prevent the possibility of improper service, personnel injury or death, and
damage to equipment.

DANGER
Dangers warn of equipment operation near electrical power lines that could lead to
personal injury or death.

WARNING
Warnings describe conditions or practices that could lead to personal injury or
death.

CAUTION
Cautions provide information important to prevent errors that could damage
machine or components.

NOTE:

Notes contain additional information important to a procedure.

Safety
1-1

INTRODUCTION
Familiarity and proper training are required for the safe operation of mechanical equipment. Equipment operated improperly or by untrained personnel can be dangerous. Read
the operating instructions in this manual and become familiar with the location and
proper use of all controls. Inexperienced operators should receive instruction from someone familiar with the equipment before being allowed to operate the machine. The use of
intelligence and common sense in the operation of mechanical equipment is the best
practice in any safety policy. Be professional and always observe the safety procedures
set forth in this manual.
All OSHA, ANSI, state, and local codes and regulations pertaining to this equipment
should be obtained, read, and thoroughly understood before attempting to operate this
equipment. Persons under the influence of drugs, alcohol, or prescription medication
should not be on or near this equipment. Common sense should be implemented at all
times during the use of this equipment. Do not operate this equipment in areas where the
equipment or user may come in contact with a live power source.
The information contained herein is not to be considered as legal advice and is intended
for informational purposes only. This information is offered to alert Bil-Jax customers to
procedures that may be of concern to them.
This information is not intended to be all inclusive and is to be followed in the use of
Bil-Jax equipment only.
For any questions concerning the safe use of this equipment, call 800-937-0540 before
operating.

1-1

XLB-4319

1-2

BEFORE OPERATION
Ensure the following general safety precautions are followed before operating the
XLB-4319 Hydraulic Boom Lift.

1-2

•

ALWAYS survey the usage area for potential hazards such as untamped earth
fills, unlevel surfaces, overhead obstructions, and electrically charged conductors or wires. Be aware of any potential hazards and always consider what could
happen. Watch for moving vehicles in the operating area.

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

1 — SAFETY

1-3

DURING OPERATION
Ensure the following general safety precautions are followed during the operation of the
XLB-4319 Hydraulic Boom Lift.

DANGER
This machine is not insulated for use near electrical power lines and DOES NOT
provide protection from contact with or close proximity to any electrically
charged conductor. Operator must maintain safe clearances at all times (10 feet
minimum) and always allow for platform movement such as wind induced sway.
Always contact the power company before performing work near power lines. Assume every line is hot. Remember, power lines can be blown by the wind.
Refer to Table 1-1 for minimum safe approach distances between machine and electrical
power lines.
Table 1-1. Minimum Safe Approach Distances
Voltage Range
(Phase to Phase)

Minimum Safe Approach Distance
(Feet)

0 to 300V

(Meters)
Avoid Contact

Over 300V to 50KV

3.05

Over 50KV to 200KV

4.60

Over 200KV to 350KV

6.10

Over 350KV to 500KV

7.62

Over 500KV to 750KV

10.67

Over 750KV to 1000KV

13.72

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

ALWAYS engage the boom travel locking pins before towing the trailer.
1-3

XLB-4319

1-4

•

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

•

NEVER use without the outriggers fully extended and firmly based.

•

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

•

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

•

NEVER move unit with a person or materials on board.

•

NEVER try to move the trailer with the boom extended.

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

NEVER climb up or down boom.

•

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

1 — SAFETY

1-4

MAINTENANCE SAFETY
Ensure the following safety precautions are observed whenever maintenance is performed on the XLB-4319 Hydraulic Boom Lift.

General Maintenance
•

ALWAYS perform maintenance procedures according to manufacturer's requirements. NEVER short change maintenance procedures.

•

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

•

ALWAYS turn the key switch off before connecting or disconnecting wiring to
or from valve solenoids or other load devices.

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

NEVER exceed the manufacturer's recommended relief valve settings.

•

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

•

NEVER tamper with cylinder counter balance valves. Contact the Bil-Jax Service Department at 800-537-0540 if the cylinder counter balance valves need
adjusting.

•

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

1-5

XLB-4319

Battery Maintenance
Ensure the following general safety precautions are followed whenever performing battery maintenance on the XLB-4319 Hydraulic Boom Lift.

1-5

•

ALWAYS check battery acid level daily on the DC model boom lift. Check
battery test indicator for proper state of charge on maintenance free batteries
before using lift.

•

ALWAYS wear safety glasses when working near battery.

•

ALWAYS avoid contact with battery acid. Battery acid causes serious burns.
Avoid contact with skin or eyes. If accidental contact occurs, flush with water
and consult a physician immediately.

•

ALWAYS disconnect ground cable first when removing battery.

•

ALWAYS connect ground cable last when installing battery.

•

ALWAYS charge batteries in open, well-ventilated areas.

•

NEVER smoke when servicing battery.

•

NEVER allow batteries to overcharge and boil.

•

NEVER short across battery posts to check for current. NEVER break a live
circuit at battery.

•

NEVER jump start other vehicles using boom lift battery.

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

Damage Policy
There may be occasions when a Bil-Jax lift is involved in an incident that results in structural damage to the lift. This can seriously compromise the ability of the lift to perform in
a safe manner. Therefore, whenever a Bil-Jax lift is damaged structurally or when there is
the possibility of structural damage (this damage may be internal and is not always visible to the naked eye), Bil-Jax requires that the lift be returned to our facility at 125 Taylor Parkway, Archbold, Ohio, for reconditioning. If you have any questions concerning
what constitutes structural damage, please call the Bil-Jax Service Department at
800-537-0540.

Damage Repair Notice
There may be occasions when a Bil-Jax lift is involved in an incident resulting in nonstructural damage. When this occurs and repairs are made by the owner or area distributor, please notify Bil-Jax of these non-maintenance repairs and request a repair form to
be filled out and returned to Bil-Jax.

1-6

1 — SAFETY

Bil-Jax, Inc.
125 Taylor Parkway

Archbold, Ohio 43502
Reporting Safety Defects
If you believe that your vehicle has a defect which could cause a crash or could cause injury or
death, you should immediately inform the National Highway Traffic Safety Administration
(NHTSA) in addition to notifying Bil-Jax, Inc.
If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety
defect exists in a group of vehicles, it may order a recall and remedy campaign. However,
NHTSA cannot become involved in any individual problems between you, your dealer, or
Bil-Jax, Inc.
To contact NHTSA you may either call the Auto Safety Hotline toll-free at 1-800-424-9393
(366-0123 in Washington, DC area) or write to:
NHTSA
U.S. DEPARTMENT of TRANSPORTATION
400 7th Street SW, (NSA-11)
Washington, DC 20590
You can also obtain other information about motor vehicle safety from the Hotline.

1-7

XLB-4319

1-8

Introduction
2-1

GENERAL DESCRIPTION
The XLB-4319 Hydraulic Boom Lift (Figure 2-1) is designed to position personnel with
their tools and equipment at overhead work locations. The work basket load capacity is
450 lbs. During all boom operations, the unit is supported by four extended outriggers.
Two versions of the XLB-4319 boom lift are available – gasoline powered or battery
powered. On both versions the hydraulic power unit includes a reservoir, pump, and control valves. Three hydraulic cylinders elevate the lower boom, upper boom, and jib
boom. A hydraulic motor and worm gear rotates the boom 360° around a vertical axis.

UPPER
BOOM
LOWER
BOOM

WORK
BASKET

JIB
BOOM

-43

B
XL

OUTRIGGER

Figure 2-1. XLB-4319 Hydraulic Boom Lift

2-1

XLB-4319

The gasoline powered boom lift (gas model) uses a 4-cycle, 8-horsepower Honda engine.
The engine drive shaft is directly coupled to the hydraulic pump. A 12 Volt DC storage
battery powers the engine starter circuit. An auxiliary voltage regulator/rectifier provides
up to 18 Amps charge current while the engine is running.
The battery powered boom lift (DC model) uses a 24 Volt, 39 Amp, one horsepower,
DC motor to drive the hydraulic pump. The DC motor is powered by four 6 Volt DC,
245 Amp-hour, deep charge batteries connected in series. A 40 Amp, automatic, onboard battery charger is provided for recharging the batteries at the end of each work period.
The boom lift is equipped with basket and ground station control panels (Figure 2-2).
The control panels include motion enable pushbuttons and proportional hydraulic valves
for controlling the direction and speed of boom lift and rotation. The gas model basket
station control panel includes an engine start pushbutton. Boom elevation and rotation
controls are operational only when the outriggers are correctly extended and the moving
boom sections are within a programmed safe operating zone.

GROUND STATION CONTROLS

BASKET STATION CONTROLS

Figure 2-2. Basket and Ground Station Controls

2-2

2 — INTRODUCTION

Only one boom motion is permitted at a time, and only as long as the boom is within the
safe operating zone (Figure 2-3). When a selected boom motion reaches a safe operating
limit, the boom motion ceases and another boom motion must be selected within the safe
operating zone.

XLB-4319 SPECIFICATIONS
45.9
42.6
39.4
36
32.8
24.5
26.3
23
19.7
16.4
13
9.8
6.5
3.2
0

9.8

6.5

3.2

6.5

9.8

13 16.4 19.7

CAPACITY .......................................... 450 LB.
MAXIMUM PLATFORM HEIGHT ....... 37 FT.
WORK HEIGHT .................................. 43 FT.
POWER SOURCE .............................. 24V DC BATTERY OR GAS
FTC

B06-00-0430

Figure 2-3. Safe Operating Zone
Outrigger load sensing interlocks and interlock safety switches prevent all boom lifting
operations until the four outriggers are properly extended, the trailer is level, and the full
weight of the boom lift is loaded onto the outriggers. An interlock prevents the retracting
of any outrigger while the upper or lower boom is raised two inches (50 mm) or more.
Boom elevation speeds are adjustable from zero to 5.3 inches per second (0 to 27 ft/min).
A hydraulic hose failure at either retract-cylinder port will cause a counterbalance valve
to stop the return oil flow. It is strongly recommended that no one adjust or tamper with
these safety devices. If service is required, please notify Bil-Jax for instructions.
Emergency lowering of the basket is by manual valve plungers on the upper and lower
boom lift cylinders or by manual operation of a hand pump in the basket. Firmly pushing
in and holding a valve plunger manually retracts the boom lift cylinder. Smooth pumping
of the hand pump while engaging a single hydraulic valve lever enables boom operation
in case of a hydraulic power failure.
The XLB-4319 Hydraulic Boom Lift cylinders will not rust or corrode during storage
since the cylinder rod is fully immersed in oil. It is important that the cylinder rods be
kept clean and undamaged for the protection of the cylinder head packings.

2-3

XLB-4319

2-2

SPECIFICATIONS
Boom Lift Work Platform
Model Number:
Manufactured by:

XLB-4319
Serial Number ________________
Bil-Jax, Inc.
125 Taylor Parkway
Archbold, Ohio 43502
800-537-0540
Table 2-1. Specifications

Feature
Rated Platform Load
Maximum Work Height
Extended Basket Height
Maximum Outreach
Elevation Rate,
Nominal
Horizontal Reach
Boom Rotation
Rotation Speed
Basket Dimensions

Data
450 lbs (204 kg) total
43 ft (13.1 m)
37 ft (11.3 m)
19 ft (9.8 m)
5.3 in./sec (135 mm/sec)
[26.7 ft/min (8.14 m/min)]
19 ft (5.9 m)
700°
318° per minute, nominal
51 in. W x 30 in. D x 45 in. H
(129.5 cm x 76 cm x 114.3 cm)
Power Source, Gas Model
8 Horsepower, 4-Cycle,
Gasoline Engine with Remote Start
Control and Alternator Circuit
Storage Battery, Gas Model
12 Volt DC, 195 Amp Storage
Battery, NAPA P/N 5022NF
Power Source, DC Model
24 Volt DC, 4 Deep Cycle,
245 Amp-hour Batteries
Battery Charger, DC Model
110/120 Volt, 40 Amp
Hydraulic Pressure
2756 psi (19,000 kPa)
Reservoir Capacity
2.75 Gallons (10.4 Liters)
Hydraulic Capacity
7 Gallons (26.5 Liters)
Hydraulic Oil
Energol HLP-HD46 (BP Oil)
Gross Vehicle Weight, DC Model 2860 lbs (1297 kg)
Gross Vehicle Weight, Gas Model 3200 lbs (1452 kg)
Tongue Weight, DC Model
100 lbs (45.4 kg)
Tongue Weight, Gas Model
160 lbs (72.6 kg)
Trailer Brakes
Mechanical Surge

2-4

2 — INTRODUCTION

2-3

WARRANTY
Bil-Jax warrants its boom lifts for one year from the date of delivery against all defects of
material and workmanship, provided the unit is operated and maintained in compliance
with Bil-Jax’s operating and maintenance instructions. Bil-Jax will, at its option, repair
or replace any unit or component part which fails to function properly in normal use.
This warranty does not apply if the lift and/or its component parts have been altered,
changed, or repaired without the consent of bil-jax or by anyone other than Bil-Jax or its
factory trained personnel, nor if the lift and/or its components have been subjected to
misuse, negligence, accident or any conditions deemed other than those considered as
occurring during normal use.
Components not manufactured by Bil-Jax are covered by their respective manufacturer’s
warranties. A list of those components and their warranties is available upon written request to Bil-Jax.
Bil-Jax shall not in any event be liable for the cost of any special, indirect, or consequential damages to anyone, product, or thing. This warranty is in lieu of all other warranties
expressed or implied. We neither assume nor authorize any representative, or other person, to assume for us any other liability in connection with the sale, rental, or use of this
product.

2-5

XLB-4319

2-6

Operation
3-1

OPERATOR CONTROLS
The XLB-4319 Hydraulic Boom Lift is equipped with multiple operator controls. Equipment power and outrigger controls are located at ground level. Boom lift and rotation
controls are located at ground level and in the basket.

Ground Control Station
The ground control station (Figure 3-1) operates the outriggers and lift booms. To access
the boom controls, reach into the cover latch port and release the cover latch according to
the latch decal. Open the control compartment cover. Unhook the support rod behind the
front edge of the cover and place the rod end into the mating hole in the battery bracket.

CONTROL
COMPARTMENT
COVER

GROUND
CONTROL
STATION

LATCH
DECAL
COVER
LATCH
PORT

Figure 3-1. Ground Control Station Access
3-1

XLB-4319

The ground control station (Figure 3-2) includes the following electrical and hydraulic
controls.

BOOM OPERATOR
LEVERS

OUTRIGGER
INDICATORS

OUTRIGGERS
RUN
PUSHBUTTON

KEY
SWITCH

BOOM
EMERGENCY
RUN
STOP
PUSHBUTTON
PUSHBUTTON

OUTRIGGER
OPERATOR
LEVERS

Figure 3-2. Ground Control Station
Key Switch
Turning the key switch to the left selects operation from the basket control station. Turning the key switch to the right selects operation from the ground control station. The center (Off) position disables electrical and hydraulic operations. Removing the key protects
against unauthorized boom lift operation.
EMERGENCY STOP Pushbutton
When pressed, the EMERGENCY STOP pushbutton disconnects electrical power from
the upper and lower control stations. Pressing the EMERGENCY STOP pushbutton also
shuts off the gasoline engine or DC motor to interrupt hydraulic power. Before you can
restore power, you must rotate the EMERGENCY STOP pushbutton clockwise.
Outrigger Indicators
Four green OUTRIGGER indicators light up when the boom lift outriggers are extended
and the boom weight is removed from the trailer axle. All four indicators must be lit and
the trailer must be level to enable operation of the lift booms.

3-2

3 — OPERATION

Outriggers Run Pushbutton
Holding the black outriggers run pushbutton in enables operation of the outrigger cylinders. The outrigger cylinders can only be operated when the lift boom cylinders are retracted.
Boom Run Pushbutton
Holding the green boom run pushbutton in enables operation of the lift boom cylinders.
The lift boom cylinders can only be operated when the outrigger cylinders are extended,
the boom weight is removed from the trailer axle, and the trailer is level.
Outrigger Operator Levers
Four outrigger operator levers position the hydraulic valves to extend and retract the outrigger cylinders. Lifting an operator lever retracts the cylinder to raise the outrigger.
Pushing down on an operator lever lowers the related outrigger. When released, the operator levers return to the center (valve-off) position. Starting on your left, the outriggers
are numbered 1 through 4. A decal located below the outrigger valve manifold indicates
which operator lever controls which outrigger.
Boom Operator Levers
Four boom operator levers position proportional hydraulic valves to extend and retract
the boom lift cylinders and the boom rotation drive motor. Pulling a boom operator lever
extends the cylinder to raise the boom. Pushing a boom operator lever lowers the related
boom. How far the lever is pushed or pulled controls the boom lift speed.
Pulling the boom rotation operator lever turns the boom clockwise. Pushing the operator
lever turns the boom counterclockwise. How far the lever is pushed or pulled controls the
boom rotation speed.
When released, the boom operator levers return to the center (valve-off) position. A decal
located in front of the valve manifold shows which boom motion is controlled by each
operator lever.
Engine Keyswitch (Gas Model only)
On the gas model boom lift, the engine keyswitch (Figure 3-3) is used to start and stop
the gasoline engine from the ground position. The keyswitch must be in the ON position
(as shown) to enable engine start-up from the work basket control station.

ENGINE
KEYSWITCH

Figure 3-3. Engine Keyswitch
3-3

XLB-4319

Basket Control Station
The basket control station (Figure 3-3) operates the hydraulic boom lift, boom rotation.
and basket rotation motions. The basket control station includes the following electrical
and hydraulic controls.
ENGINE START
PUSHBUTTON
(GAS MODEL ONLY)

BOOM RUN
PUSHBUTTON

HYDRAULIC
HAND PUMP

AUDIBLE
ALARM

EMERGENCY
STOP PUSHBUTTON

BOOM
OPERATOR LEVERS

115 VOLT
OUTLET

Figure 3-4. Basket Control Station
EMERGENCY STOP Pushbutton
When pressed, the EMERGENCY STOP pushbutton disconnects electrical power from
the upper and lower control stations. Pressing the EMERGENCY STOP pushbutton also
shuts off the gasoline engine or DC motor to interrupt hydraulic power. Before you can
restore power, you must rotate the EMERGENCY STOP pushbutton clockwise.
Boom Run Pushbutton
Holding the green boom run pushbutton in enables operation of the boom lift and rotation functions. Boom lift and rotation can only be operated when the outrigger cylinders
are extended, the boom weight is supported by all four outriggers, and the trailer is level.

3-4

3 — OPERATION

Boom Operator Levers
Five boom operator levers position proportional hydraulic valves to extend and retract
three boom lift cylinders, the boom rotation drive motor, and the basket swivel cylinder.
Pulling a boom operator lever extends the cylinder to raise the boom. Pushing a boom lift
operator lever lowers the related boom. How far the lever is pushed or pulled controls the
boom lift speed.
Pulling the boom rotation or basket rotation operator lever turns the boom or basket
clockwise. Pushing the operator lever turns the boom or basket counterclockwise. How
far the lever is pushed or pulled controls the rotation speed.
When released, the boom operator levers return to the center (valve-off) position. A decal
located in front of the valve manifold shows which boom motion is controlled by each
operator lever.
Hydraulic Hand Pump
The basket control station is equipped with a hydraulic hand pump. In case lift boom operating power is lost, the hand pump is available to manually lower the lift boom. Holding the related operator lever in position and smoothly operating the hand pump lowers
the lift boom or swivels the work basket to another position.
Engine Start Pushbutton (Gas Model only)
Pressing the engine start pushbutton restarts the gasoline engine while in the work basket. The pushbutton should only be pressed until the engine starts. The engine should not
be cranked longer than 15 seconds at a time. Over-cranking will burn up the starter motor.
Audible Alarm
An audible alarm is located in the basket station control panel. The audible alarm sounds
whenever the key switch is on and the boom lift is out of level.
115 Volt Outlet
The 115 Volt AC outlet is provided for running electrical power tools in the work basket.
A connecting power cord must be plugged in to a suitable power source. The power plug
is located on the inside of the trailer frame, near the tow end of the trailer. The outlet is
rated for a 15-ampere load. Do not overload the accessory power circuit.

3-5

XLB-4319

3-2

NORMAL OPERATING PROCEDURE
Perform the following procedures to operate the XLB-4319 Hydraulic Boom Lift.
1.

Read and follow all safety precautions contained in Section 1 and all responsibilities outlined in the ANSI A92.2 reprint contained in Section 7 of this manual.

Position the lift at the work area. Make sure the lift is on a firm and level surface
and that there are no potential hazards such as overhead obstructions or electrically charged conductors. Do not operate the lift if such hazards exist.

Check the tow trailer and boom lift for damaged or worn parts. Repair or replace parts as necessary. Do not use a damaged boom lift.

Apply the trailer parking brake.

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

See Figure 3-4 and lower the boom lift outriggers as follows:
a.

Start the engine or motor.

Turn the key switch to the ground control position.

Press and hold in the black outrigger run pushbutton.

KEY
SWITCH
BUBBLE
LEVEL
INDICATOR

OUTRIGGERS
RUN
PUSHBUTTON
OUTRIGGER
OPERATOR
LEVERS

Figure 3-5. Outrigger Controls

3-6

3 — OPERATION

WARNING
Always verify that the green outrigger LEDs light up when the outrigger feet become loaded. If an outrigger LED fails to light up or lights up before the outrigger
foot becomes loaded, the limit switch or switch setting is faulty. Using the boom
lift with a faulty limit switch or switch setting can cause severe injury, death, or
damage to the equipment.
d.

Push down on the rear outrigger levers (1 & 2) to lower the rear outriggers.
Lower the rear outriggers only until the rear outrigger LEDs light up on the
control panel.

Push down on the front outrigger levers (3 & 4) to lower the front outriggers. Raise the trailer wheels off the ground. Verify that the front outrigger
LEDs light up on the control panel.

Watch the bubble level indicator and adjust the outriggers as needed to
level the trailer.

NOTE:

An LED level switch and four outrigger position switches prevent boom
motions if the trailer is not level or if one or more outriggers is not supporting the vehicle load. The load of the boom lift vehicle must be placed
on all four outriggers and the trailer must be level to enable motorpowered boom lift operations.

Remove the keeper pins and transport pins that secure the upper and lower
booms. Stow the transport pins in the retainer clips provided.

Use the ground control station to operate the boom lift controls. Raise, lower,
and rotate the boom to get familiar with the controls. Learn to smoothly start
and stop all boom motions.

Lower the boom sections to position the basket for boarding. Turn the key
switch to the basket control position.

10.

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

11.

When boom lift operations are complete, retract the boom and outriggers for
trailer towing according to the following procedure:
a.

Using the basket control station, rotate the basket to the center position.

Fully retract the jib boom, the upper boom, and the lower boom.

Exit the basket and turn the key switch to the ground control position.

Retract the two rear outriggers until the trailer tires touch. Do not fully retract the rear outriggers.

Retract the front outriggers until fully raised.

Retract the rear outriggers until fully raised.

Prior to towing, install the transport pins and keeper pins to secure the upper and lower booms. Refer to paragraph 3-6 for towing instructions.

3-7

XLB-4319

3-3

EMERGENCY LOWERING
The XLB-4319 Boom Lift is equipped with two manual lowering valves and a hydraulic
hand pump. These devices can be used to lower the basket in case of a power failure, a
load shift, or other emergency situation.
The manual lowering valves are located on the upper and lower boom lift cylinders and
are manually operated from the ground. The hydraulic hand pump is located in the work
basket. Use the hand pump in case an assistant is not available on the ground.
To lower the work basket from the ground, push in the valve plunger (Figure 3-6) on the
lower boom lift cylinder. Continue pushing the valve plunger to fully retract the lower
boom. Push in and hold the valve plunger on the upper boom lift cylinder until the upper
boom is retracted.

VALVE
PLUNGER

Figure 3-6. Manual Lowering Valve
To manually lower the boom lift from the work basket, push the upper or lower boom
operator lever (Figure 3-7) down and use the hand pump to lower the boom. Apply a
steady up-and-down pumping action. The hydraulic cylinders are dual acting; boom
motion will continue throughout pump handle operation.
BOOM OPERATOR
LEVERS
HAND
PUMP

Figure 3-7. Basket Control Station

3-8

3 — OPERATION

3-4

MANUAL BOOM ROTATION
The hydraulic boom lift is equipped with an emergency rotation handle (crank) that can
be used to rotate the boom in case of a power failure or other emergency situation.
Use the following procedure to manually rotate the boom:
1.

Remove the crank from its stowage rack and install the crank on the hex end of
the worm gear drive screw (Figure 3-8).

Hold the boom rotation valve lever in the correct position for boom rotation and
turn the crank to rotate the boom.

BOOM ROTATION
VALVE LEVER

BOOM ROTATION
CRANK

Figure 3-8. Emergency Rotation

3-9

XLB-4319

3-5

BATTERY RECHARGE (DC MODEL ONLY)
The DC model boom lift batteries should be recharged after each 8-hour work shift or
more often if needed. When the boom lift is not in use, the batteries should be recharged
at least once per week.
The normal charge time is 10 to 12 hours. If the battery charge is extremely low, a full
recharge may take up to 24 hours.
Recharge the DC model boom lift batteries as follows:

WARNING
Recharge the batteries in a well ventilated area only. Do not charge batteries near
fire, flame, or other ignition sources. Batteries being charged may emit highly explosive hydrogen gas. Failure to properly ventilate the charge gases may result in
serious injury or death.
1.

Move the boom lift to a well ventilated area with direct access to a grounded
120 VAC electrical outlet. Make sure the recharge area is not near fire, flames
or other ignition sources.

Plug a short, heavy-duty power cord into the battery charger receptacle on the
electrical cord connected to the charger. The recommended power cord should
be an 12 AWG multi-strand, grounded cord no longer than 50 feet (16 meters).

NOTE:

Using an underrated or long power cord will reduce the output of the
battery charger, resulting in longer charge time.

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

To determine the charge rate at any time during the charge cycle, observe the
DC ammeter (Figure 3-9). The ammeter needle moves to the right at the start of
the charge cycle. As the battery charge rises, the needle moves farther left.

Figure 3-9. Battery Charger

3-10

3 — OPERATION

CAUTION
Always remember to unplug the battery charger power cord before moving the
boom lift. Failure to unplug the power cord will cause damage to the equipment.
5.

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

NOTE:

The yellow 80% CHARGE indicator lights up when the battery voltage is
nearing full charge. At full charge (3-1/2 hours after the 80% CHARGE
indicator lights up), the charger turns off.
If the battery voltage does not reach the 80% CHARGE level in 14 hours,
the charger turns off and the red CHECK BATTERY indicator LED
lights up. This prevents extended charging of a faulty battery.

3-6

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

BOOM LIFT TRANSPORT
The boom lift trailer is a single axle trailer fitted with a two-inch ball hitch, surge brakes,
breakaway safety cable, safety chains, brake lights, and side marker lights. Proper boom
lift transport requires the correct hookup and inspection of these trailer components before towing. Use the following procedures to hitch, tow, and back the boom lift trailer:

Trailer Hitching
Trailer hitching requires a second person to give tow vehicle backing instructions.
1.

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

Align the ball and hitch (Figure 3-10). Fasten the breakaway safety
cable to the tow vehicle.

PARKING
BRAKE

BALL AND
HITCH
PIVOT
LOCKING
PIN

POWER
PLUG

SAFETY
CHAINS

JACK IN
RAISED
POSITION

BREAKAWAY
SAFETY CABLE

Figure 3-10. Trailer Hitching
3-11

XLB-4319

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

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

Release the trailer parking brake.

Pull the pivot locking pin. Swivel the jack 90 degrees to the travel position and
release the pivot locking pin.

CAUTION
Always cross and attach the safety chains before towing. Failure to attach safety
chains properly will allow tongue to drop in case of ball hitch failure, resulting in
serious damage to the trailer and equipment.
7.

Attach the trailer safety chains to the tow vehicle. Make sure the chains cross
under the trailer tongue. If needed, cross the chains over then under the tow bar
to prevent dragging.

Connect the trailer lights to the tow vehicle power plug.

Check the breakaway safety cable. If the safety cable does not have adequate
slack, the brakes may drag.

10.

Before towing the trailer, check the following and make all necessary adjustments, corrections, or repairs:
a.

Check that the trailer jack and outriggers are in their travel positions.

Verify that the transport pins and pin keepers secure the upper and lower
booms. If the booms are not secured, install the transport pins and pin keepers at this time.

Verify that the basket is centered and that all onboard equipment is secured.

Check that the key switch is in the OFF position. Remove the key.

Verify that trailer brake lights and marker lights work properly.

Check that the trailer tires are evenly inflated and not low on air.

WARNING
Improper tightening of boom lift trailer wheel nuts can cause wheel lugs to shear,
causing serious injury or damage to equipment. Check and maintain the proper
wheel nut torque according to the maintenance instructions in this manual.
Periodically check the wheel nut torque according to the instructions in Section 4 of this
manual. More frequent torque checks are required when a wheel is recently installed.
Prior to towing, while the trailer wheels are elevated for boom lift operation, check for
loose wheels and for wheel lug wear indications. If a loose wheel mounting is indicated,
remove and inspect the wheel lugs for damage. Do not tow the boom lift with worn or
damaged wheel lugs.

3-12

Maintenance
4-1

SCHEDULED SERVICE CHECKS
Daily/Weekly Service Checks
Perform the following daily/weekly service checks as listed in Table 4-1.
Table 4-1. Daily/Weekly Service Checks
Service Check

Daily
before use

Weekly

Check to see that all decals are present.
Check that controls and indicators at ground and basket
control stations operate properly.
Raise booms and press emergency stop pushbutton. Verify
that booms remain elevated and do not drift down.
Check that boom down limit switch and outrigger position
switches operate properly.
Check/add hydraulic oil.
Check/add engine oil.
Check engine air filter element. Clean or replace dirty or
damaged air filter element.

Check trailer tires for proper inflation. When cold, tires
should be inflated to 55 psi (3.8 bar).

Check trailer running lights for proper operation.

Check battery electrolyte level. If battery charge is low, add
water to bring electrolyte just above plates. If batteries are
fully charged, raise electrolyte to full mark in each cell.

Check trailer hitch components for damage and proper
operation. Refer to Trailer Hitching in paragraph 3-6.

Check electrical wiring for cuts, loose terminals, broken
wires, chaffing, corrosion, or other damage. Repair all
damage, remove corrosion, and seal exposed connections.

Lubricate grease fittings labeled LUBRICATE WEEKLY
with NLGI Grade 2 multi-purpose grease.

Check trailer and boom lift for missing or loose hardware.
Replace or tighten missing or loose hardware as needed.

4-1

XLB-4319

Monthly Service Checks
Perform the following monthly service checks as listed in Table 4-2.
Table 4-2. Monthly Service Checks
Service Check
Check/add hydraulic oil per paragraph 4-4.
Clean battery terminals and battery charger
operation.
Check operation of manual lowering valves
and hand pump.
Check wheel nut torque per paragraph 4-2.
Lubricate compartment hinges and latches with
light weight machine oil.
Lubricate grease fittings labeled LUBRICATE
MONTHLY per paragraph 4-3.2.
Lubricate trailer tongue jack (2 places) with
NLGI Grade 2 multi-purpose grease.

Lubricate grease fittings labeled LUBRICATE
SEMI-ANNUALLY per paragraph 4-3. 3.

Change engine oil.

Check battery cables and wiring for loose
connections and damaged wires.

Replace spark plug.

Replace hydraulic oil and oil filter.

Check boom pivot pin and sleeve bearings for
wear. Replace worn or damaged pivot pins and
sleeve bearings.

Check slew bearing for wear or damage per
paragraph 4-5.
Inspect and adjust trailer brakes.
Load test boom lift operations with 450
pounds (204 kg).

4-2

Every
month

Every
6 months

Every
12 months

4 — MAINTENANCE

4-2

WHEEL NUT TORQUE REQUIREMENTS
It is very important to apply and maintain the correct wheel bolt torque on the boom lift
trailer. The wheel bolts must be evenly tightened to the following specified torque increments whenever a trailer wheel is removed and installed. Use the following tightening
procedure:
1.

Evenly tighten the wheel bolts to 25 lb-ft (34 N·m) in the tightening sequence
shown in Figure 4-1.

1
4

3
2

Figure 4-1. Wheel Bolt Tightening Sequence
2.

Evenly tighten the wheel bolts to 60 lb-ft (81,4 N·m) using the tightening sequence shown.

Evenly tighten the wheel bolts to 100 lb-ft (135,6 N·m) using the tightening sequence shown.

4-3

XLB-4319

4-3

LUBRICATION
Lubrication makes operation of the XLB-4319 Boom Lift more efficient and extends the
equipment life. Use the following procedures to lubricate the boom lift components.
1.

Lubricate trailer jack post and all grease fittings labeled LUBRICATE
WEEKLY with NLGI Grade 2 multi-purpose grease.

Lubricate all LUBRICATE MONTHLY grease fittings with NLGI Grade 2
multi-purpose grease. Wipe off dirt and grease residue. Add approximately ½
ounce (15 cc) of grease to each fitting. See Figure 4-2 for grease fitting locations.

GREASE
FITTINGS

Figure 4-2. Lubricate Monthly
3.

Lubricate the slew ring bearing grease fitting (Figure 4-3) with NLGI Grade 2
multi-purpose grease. Wipe off dirt and grease residue. Rotate the boom and add
approximately ½ ounce (15 cc) of grease to each bearing quadrant.

GREASE
FITTING

Figure 4-3. Lubricate Semi-Annually

4-4

4 — MAINTENANCE

4-4

HYDRAULIC SYSTEM
Hydraulic system maintenance varies with equipment use and the environment in which
the boom lift is used. Constant attention to keep the oil clean and the reservoir properly
filled will help prevent possible damage to the system. Hydraulic diagrams are provided
in this section for general reference.

WARNING
Hydraulic system pressure settings are factory settings and should not need readjustment. The only time readjustment is needed is when a component in the hydraulic control circuit is replaced. Only the adjustments covered in this manual
are permitted. If you believe that any other hydraulic component needs adjustment, notify Bil-Jax for additional instruction. Hydraulic motions are quiet,
quick, and can be dangerous to persons on or near the lift vehicle. Failure to heed
this warning can result in serious injury or death.

Hydraulic System Inspection
Check the hydraulic hose and fittings for leaks and damage daily. Tighten or replace as
necessary to prevent hydraulic oil loss. Secure hoses and lines as needed to prevent rubbing and chafing.

Fluid Check and Replacement
The oil level should be checked with the engine or motor off, the boom down, and the
trailer on a level surface. Pull the dipstick out of the reservoir (Figure 4-4) and wipe off
any oil with a clean shop cloth, then reinsert the dipstick. Pull the dipstick to check the
oil level. The oil level should be between the full and add oil marks on the dipstick.

DIPSTICK

HYDRAULIC
RESERVOIR

Figure 4-4. Hydraulic Reservoir
4-5

XLB-4319

Do not mix hydraulic oils. The reservoir is originally filled with Energol HLP-HD46, a
high-grade, non-foaming hydraulic oil designed for temperatures as low as -20°F (33°C). For temperatures reaching -40°F (-40°C), use Dextron Automatic Transmission
Fluid Type A.
If either oil is not available, a good grade SAE 10W hydraulic oil may be used where the
low temperature is above 32°F (0°C). SAE 5W hydraulic oil may be used where low
temperatures reach 0°F (-18°C).
Once a year or whenever the oil becomes contaminated, drain the reservoir, clean the
sump strainer, and replace the hydraulic oil and return filter.

Return Filter Replacement
The hydraulic oil filter should be replaced yearly or whenever filter contamination has a
noticeable effect on the beam lift functions. If return filter clogging is suspected, check
the system hydraulic pressure.
With engine or motor running and no controls actuated, hydraulic system pressure should
be near 0 (zero), or minimal. If the pressure exceeds 30 psig (2 bar) (200 kPa gage), the
return filter should be replaced as follows:
1.

Use cleaning cloths and alcohol solvent to clean away dirt on filter cover and
housing (Figure 4-4). Be sure to place reusable components on new cleaning
cloths. Do not allow filter parts to become contaminated.

Use a wrench to loosen filter cover.

Remove filter cover. Place reusable filter parts on new cleaning cloths.

Lift filter element and element holder above reservoir oil level. Drain residual
oil back into filter housing.

Remove and discard used filter element.

Locate OUT marking on one end of new filter element.

With OUT end up, seat new filter element in center of filter holder.

Seat filter holder and element in filter housing.

Wipe o-ring and mating seal surface of cover with cleaning cloth. If o-ring is cut
or gouged, replace o-ring.

10.

Install and hand tighten filter cover. Do not over-tighten filter cover.

Air Bleeding
Delayed response or sporadic boom lift motions may indicate air in the lift cylinders. Use
the following procedure to bleed entrapped air from the hydraulic system.

4-6

Fill the reservoir with the proper hydraulic fluid. Replace, but do not tighten the
reservoir fill cap.

Fully raise and lower the boom to return oil with entrapped air to the reservoir.

Allow several minutes for air to escape the reservoir oil.

Repeat steps 1 through 3 as needed. Add oil slowly and only when the boom is
lowered to prevent adding more air to the system.

4 — MAINTENANCE

Hydraulic Pressure Checks and Adjustments
Hydraulic pressures are set at the factory and should not be adjusted unless a hydraulic
component has been replaced in the regulated circuit.
On the gas engine model a pressure test port (Figure 4-5) is located at the ground station
boom control valves. A hydraulic pressure gage [0-6000 psig (0-400 bar) (41 000 kPa
gage) minimum range] must be connected to the test port when adjusting hydraulic pressures. This is the only pressure test port on the boom lift.
On the DC model boom lift, the main bypass valve and pressure test port are mounted on
the hydraulic manifold located between the hydraulic pump and reservoir. To prevent
tampering, the main bypass valve cap is secured with locking wire and a seal. If a pressure adjustment is required, call Bil-Jax and request a replacement lock wire and seal.
The boom lift has four bypass valves that regulate hydraulic operating pressures. These
include (1) the main bypass valve, (2) the outriggers bypass valve, (3) the basket station
boom controls bypass valve, and (4) the ground station boom controls bypass valve.
Check/Adjust System and Outriggers Hydraulic Pressures
The system hydraulic pressure (pump output pressure) is regulated by the main bypass
valve. The system hydraulic pressure is used to power all hydraulic operations. The main
bypass valve and pressure test port for the gas model boom lift are shown in (Figure 4-5).

MAIN
BYPASS
VALVE

PRESSURE
TEST PORT

Figure 4-5. Main Bypass Valve and Pressure Test Port
(Gas Engine Model)

4-7

XLB-4319

To adjust the system hydraulic pressure, we must first set the outriggers bypass pressure
very high. This ensures that you are reading system pressure when fully retracting an
outrigger cylinder. After adjusting the system pressure, we must readjust the outriggers
bypass pressure to specification.
Adjust System Pressure
1.

Connect a hydraulic pressure gage to the pressure test port.

Remove the cap from the outriggers bypass valve (Figure 4-6). Turn the adjust
screw to the right exactly two turns. This adjustment will allow the main bypass
valve to regulate the test pressure.

Reinstall and tighten the cap to prevent oil leakage. Do not over tighten the cap.

OUTRIGGERS
BYPASS VALVE

Figure 4-6. Outriggers Bypass Valve
4.

Start the gasoline engine or DC motor. Run the engine or motor for at least five
minutes to warm the hydraulic oil to the normal operating temperature.

Pull up one outrigger control lever to fully retract the outrigger. While the outrigger control lever is pulled up, read the pressure gage. If the pressure is rising,
allow the pressure to reach its highest reading.

On the gas model boom lift, if the pressure gage reading is 3045 psig [210 bar
(21 000 kPa)] nominal, no adjustment is required. If an adjustment is required,
proceed with step 8.

On the DC model boom lift, if the pressure gage reading is 2750 psig [190 bar
(19 000 kPa)] nominal, no adjustment is required. If an adjustment is required,
proceed with step 8.

NOTE:

4-8

Loosening the adjust lock nut will cause hydraulic oil to leak from the
main bypass valve. It is recommended that you shut the engine off before
making adjustments to the main bypass valve.

Press the emergency stop pushbutton to turn off the hydraulic pump.

Loosen the adjust lock nut for the main bypass valve.

4 — MAINTENANCE

10.

Use hex wrench to turn the pressure adjust screw. Turn the adjust screw right
for higher pressure or left for lower pressure. Turning the adjust screw 1/4 turn
will adjust the pressure about 150 psig [10,4 bar (1 037 kPa gage)].

11.

Tighten the adjust lock nut.

12.

Reset the emergency stop pushbutton and restart the engine or motor.

13.

Pull up one outrigger control lever and recheck the system pressure. If the pressure is still too high or too low, repeat the adjustment starting with step 6.

14.

When the system pressure is properly adjusted, remove the cap from the outriggers bypass valve (Figure 4-6). Turn the adjust screw to the left two turns.

15.

Reinstall and tighten the adjust screw cap. Do not over tighten the cap.

Check/Adjust Outriggers Pressure
1.

Pull up one outrigger control lever and read the pressure at the gage. If the gage
reading is 2750 psig [190 bar (19 000 kPa)] nominal, no adjustment is required.

If the outriggers pressure is too high or too low, remove the cap (Figure 4-6)
and adjust the pressure. Turning the adjust screw to the right 1/4 turn will raise
the pressure about 150 psig [10,4 bar (1 037 kPa gage)].

Reinstall and tighten the adjust screw cap. Do not over tighten the cap.

Repeat steps 1 through 3 as needed to properly adjust outrigger pressure.

If no other hydraulic pressures are to be checked, shut down the engine or motor
and remove the pressure gage.

Check/Adjust Boom Hydraulic Pressure
The hydraulic pressure for the basket station boom controls is regulated by a bypass
valve (Figure 4-7) at the front of the basket station valve bank. The hydraulic pressure
for the ground station boom controls is regulated by an identical valve at the back of the
ground station boom controls. The regulated pressure is used to extend and retract all
basket and boom positioning cylinders.

VALVE
CAP

BYPASS VALVE
ADJUST SCREW

Figure 4-7. Boom Control Bypass Valve, Basket Station
4-9

XLB-4319

Check and adjust the hydraulic bypass pressure for the basket or ground station boom
controls as follows:
1.

Connect a hydraulic pressure gage to the pressure test port.

Start the gasoline engine or DC motor. Run the engine or motor for at least five
minutes to warm the hydraulic oil to the normal operating temperature.

Extend the outriggers to fully support and level the boom lift.

Turn the ground control station key switch to basket or ground position, according to which bypass pressure (basket or ground control) is to be adjusted.

NOTE:

When adjusting the bypass pressure for the basket station boom controls,
the basket station boom controls must be used. When adjusting the bypass pressure for the ground station boom controls, the ground station
boom controls must be used.

Push down the lower beam control lever at the basket or ground station and read
the pressure gage. If the pressure gage reading is 2750 psig [190 bar (19 000
kPa)] nominal, no adjustment is required. If an adjustment is required, proceed
with step 6.

Press the emergency stop pushbutton to turn off the hydraulic pump.

NOTE:

Removing the adjust screw cap while the hydraulic pump is running will
cause oil to leak from the bypass valve. It is recommended that you shut
the engine off before removing the adjust screw cap.

Locate the bypass valve for the selected boom control valve bank. Remove the
adjust screw cap.

Use screwdriver to turn the adjust screw. Turning the adjust screw 1/4 turn to
the right will increase the pressure about 150 psig [10,4 bar (1 037 kPa gage)].

Reinstall and tighten the adjust screw cap. Do not over tighten the cap.

10.

Reset the emergency stop pushbutton and restart the engine or motor.

11.

Push the upper or lower beam control lever down at the basket or ground station
controls and read the pressure gage. If the bypass pressure is still too high or too
low, repeat the adjustment starting with step 6.

12.

If no other hydraulic pressures are to be checked, shut down the engine or motor
and remove the pressure gage.

Hydraulic Cylinder Replacement

WARNING
Hydraulic cylinders are heavy and may have hydraulic oil on the surface. Hydraulic cylinders must be secured with lifting straps or tie-downs when removing, installing, and handling. Failure to heed this warning can result in serious injury.

4-10

4 — MAINTENANCE

Boom Lift Cylinder Removal and Installation

WARNING
Make sure the boom and boom cylinder are securely supported before removing
the boom cylinder. Failure to do so may cause the boom or boom cylinder to fall.
This may cause severe injury or damage to the boom lift.
1.

If removing the lower boom lift cylinder, raise the lower boom to just above
horizontal and stand a 36 inch (90 cm) long length of 4x4 hardwood shoring on
the trailer tongue directly below the lower boom rest plate. Lower the boom
onto the shoring. Manually check the stability of the shoring.

If removing the upper boom lift cylinder, raise the lower boom about two inches
(50 mm) above the boom rest position.

Press in and hold the manual lowering valve at the boom lift cylinder that is to
be replaced. Bleed off all hydraulic pressure to the cylinder.

Refer to Figure 4-8. At the piston rod end of the cylinder, unscrew and remove
the keeper pins from both sides of the pivot pin. Thread the removed keeper pin
hardware to the boom for use during cylinder installation.

Drive out the pivot pin with a hammer and a brass or hardwood drift. Do not allow the free end of the cylinder to fall.

PIVOT
PIN

UPPER
BOOM

PIVOT
PIN

PIN
KEEPER

HYDRAULIC
CYLINDER

VALVE
BLOCK

MANUAL
LOWERING
VALVE

Figure 4-8. Hydraulic Cylinder Removal

4-11

XLB-4319

If removing the lower boom lift cylinder, fully retract the cylinder. Use the pivot
pin to turn the piston rod pivot boss 90°. Lower the cylinder through the relief
slot in the stabilizer beam (not shown).

Turn off the key switch and remove the key.

Tag the hydraulic hoses that connect to the cylinder valve block. Each valve
block port is stamped with an identity number.

Place absorbent drip cloths below the cylinder ports. Remove the hydraulic
hoses from the lift cylinder. Elevate the hoses to help prevent fluid leakage. Protect exposed hose fittings and cylinder ports with plugs and caps.

10.

At the base of the cylinder, unscrew and remove the keeper pins from both sides
of the boom pivot pin. Thread the removed keeper pin hardware to the boom for
use during cylinder installation.

11.

Drive out the pivot pin with a hammer and a brass or hardwood drift.

12.

Lift and remove the cylinder using an overhead hoist and lifting straps.

13.

After repairing the hydraulic cylinder, reinstall the cylinder in the reverse order
of removal.

14.

Power up the hydraulic system and check for leakage. Tighten the hydraulic fittings as needed.
Bleed entrapped air from the hydraulic cylinder according to instructions in
paragraph 4-4.

15.
NOTE:

Do not tamper with the cylinder counterbalance or manual lowering
valves. If the valves need adjustment, contact the Bil-Jax Service
Department at 800-537-0540.

Outrigger Cylinder Removal and Installation

4-12

Lower the outrigger until the foot pad meets the floor and supports only the outrigger beam. Leave the weight of the boom lift on the trailer wheels.

At the piston rod end of the cylinder, unscrew and remove the keeper pins from
both sides of the boom pivot pin. Thread the removed keeper pin screws and
keeper pins to the outrigger beam for use during cylinder installation.

Place a block of wood shoring between the outrigger beam and cylinder.

4 — MAINTENANCE

Drive out the pivot pin with a hammer and a brass or hardwood drift. Do not allow the free end of the cylinder to fall.

Fully retract the cylinder.

Turn off the key switch and remove the key.

Tag the hydraulic hoses that connect to the cylinder valve block. Each valve
block port is stamped with an identity number.

Place absorbent drip cloths below the cylinder ports. Remove the hydraulic
hoses from the lift cylinder. Plug the hose fittings to prevent fluid leakage. Protect exposed cylinder ports with plugs and caps.

At the base of the cylinder, unscrew and remove the keeper pins from both sides
of the pivot pin. Thread the removed keeper pin screws and keeper pins to the
mating beam for use during cylinder installation.

10.

Drive out the pivot pin with a hammer and a brass or hardwood drift.

11.

Lift and remove the cylinder using an overhead hoist and lifting straps.

12.

After repairing the hydraulic cylinder, reinstall the cylinder in the reverse order
of removal.

13.

Power up the hydraulic system and check for leakage. Tighten the hydraulic fittings as needed.
Bleed entrapped air from the hydraulic cylinder according to instructions in
paragraph 4-4.

14.

Jib Boom Cylinder Removal and Installation
1.

Fully lower the outriggers and the upper and lower boom.

Extend the jib beam to raise the basket a few inches.

Place shoring under the jib beam. Lower the beam onto the shoring to support
the weight of the basket.

Place shoring under both rear corners of the basket. Adjust the shoring to relieve
any binding torque load on the upper jib beam pivot pins.

Remove the four keeper pins from the upper jib beam pivot pins (Figure 4-9).
Secure the keeper pins to the mating beam for use during cylinder installation.

4-13

XLB-4319

PIVOT
PIN
KEEPER
PINS
(2 PER SIDE)

KEEPER
PIN

UPPER JIB
BEAM

BEAM
PIVOT PIN

JIB BEAM
CYLINDER

PIVOT
PIN
KEEPER
PINS
(2 PER SIDE)

Figure 4-9. Jib Boom Components
6.

4-14

Try to rotate one of the upper jib beam pivot pins with a keeper pin. Adjust the
rear basket shoring as needed to enable pivot pin movement.

4 — MAINTENANCE

Remove the upper jib beam pivot pin at the top end of the beam. If needed,
drive out the pivot pin with a hammer and a brass or hardwood drift.

Before removing the bottom pivot pin, insert a long blade screwdriver through
the top pivot pin bores.

Remove the pivot pin at the bottom end of the upper jib beam. If needed, drive
out the pivot pin with a hammer and a brass or hardwood drift. Remove the upper jib beam.

10.

Fully retract the jib beam cylinder. Turn off the key switch and remove the key.

11.

Tag the hydraulic hoses that connect to the left and right ports of the cylinder
valve block.

12.

Sketch the location of wire ties that secure the hydraulic hoses at the cylinder.
The hoses must be properly secured to prevent pinching during jib boom operation. Cut the wire ties from the jib boom cylinder hydraulic lines.

13.

Place absorbent drip cloths below the cylinder ports. Remove the hydraulic
hoses from the jib boom cylinder. Plug the hose fittings to prevent fluid leakage.
Protect exposed cylinder ports with plugs and caps.

14.

At the top of the cylinder, unscrew and remove the keeper pins from both sides
of the boom pivot pin. Secure the keeper pins to the mating beam for use during
cylinder installation.

15.

Support the weight of the jib boom cylinder using an overhead hoist and lifting
straps.

16.

Drive out the pivot pin with a hammer and a brass or hardwood drift and remove the jib boom cylinder.

17.

After repairing the hydraulic cylinder, reinstall the cylinder in the reverse order
of removal.

18.

Power up the hydraulic system and check for leakage. Tighten the hydraulic fittings as needed.
Bleed entrapped air from the hydraulic cylinder according to instructions in
paragraph 4-4.

19.

4-15

XLB-4319

Basket Swivel Cylinder Removal and Installation
1.

Fully lower the outriggers and raise the upper boom. Position the basket for easy
access to the hydraulic cylinder (Figure 4-10) mounted on the bottom of the
work basket.

HYDRAULIC
CYLINDER

KEEPER
PIN

Figure 4-10. Basket Swivel Cylinder

4-16

Remove the keeper pins from both ends of the cylinder. Remove the hydraulic
cylinder.

Secure the keeper pins to the mating beam for use during cylinder installation.

After repairing the hydraulic cylinder, reinstall the cylinder in the reverse order
of removal.

Power up the hydraulic system and check for leakage. Tighten the hydraulic fittings as needed.

Bleed entrapped air from the hydraulic cylinder according to instructions in
paragraph 4-4.

4 — MAINTENANCE

4-5

SLEW RING BEARING
Check Free Play
Check the free play of the slew ring bearing every six months. If the recommended maintenance schedule is followed, there should be little or no wear of the slew ring bearing.
Check the slew ring bearing free play according to the following procedure:
1.

Fully retract (lower) the lift booms.

Go to the hydraulic reservoir side of the boom lift. Open the power cabinet.

Access the top surface of the slew ring gear near the front end (trailer tow end)
of the gear. This area is below and behind the hydraulic pump reservoir.

Insert a 2-inch (50 mm) caliper or bore micrometer at the top front surface of the
slew ring gear.

Measure the distance from the top of the slew ring gear to the horizontal plate
above the gear (Figure 4-11). Record the measurement.

Place a 175 lb (80 kg) load in the boom lift basket.

Raise the lower boom until the front of the boom is about 11.5 ft (3,5 m) from
the ground.

Slowly raise the upper boom and extend the jib boom until both are horizontal.

Repeat the measurement in step 5. Record the measurement.

10.

If the difference between the measurements in step 5 and step 9 is greater than
0.25 inch (6,35 mm) the slew ring bearing should be replaced. Notify Bil-Jax for
bearing replacement instructions or assistance.

MEASURE
HERE

SLEW
RING

TOW END
OF TRAILER

Figure 4-11. Slew Ring Position Measurement

4-17

XLB-4319

4-6

LIMIT SWITCH CHECKS AND ADJUSTMENTS
Adjusting Boom Down Limit Switch
When the upper and lower booms are retracted, the boom down limit switch is actuated.
The boom down limit switch must be actuated to lower or raise the outriggers. The boom
down limit switch should trip when the lower boom is within 2 inches (50 mm) of seating
on the trailer tongue. You may not be able to extend or retract the outriggers if the boom
down limit switch is loose, damaged, or not adjusted properly.
Use the following procedure to readjust the boom down limit switch:
1.

Lower the outriggers and raise the lower boom for free access to the limit
switch, Figure 4-12.

Inspect the limit switch for loose mounting or visible damage. If the mounting
hardware is loose, tighten the hardware. If the limit switch is damaged, replace
the limit switch.

Measure the free height of the limit switch actuator roller. The top of the roller
should be 0.75 inch (19 mm) above the limit switch mounting plate. Adjust the
actuator position as needed.

Fully lower the upper and lower booms.

Press the outrigger run pushbutton to verify that the boom down limit switch is
engaged. The hydraulic pump motor should run when the outrigger run pushbutton is pressed.

If the pump motor does not run, the limit switch or switch wiring is damaged.
Repair or replace a damaged limit switch or wiring, as needed.

Figure 4-12. Boom Down Limit Switch

4-18

4 — MAINTENANCE

Adjusting Outrigger Position Switches
The outrigger position switches are set up to detect when the boom lift load is transferred
from the trailer wheels to the outriggers. When the load is transferred to each outrigger,
the related position switch is engaged and the related LED lights up on the control panel.
All four position switch circuits must be engaged to enable lift boom operation. Use the
following procedure to check and adjust the outrigger position switches.
1.

Inspect the outrigger position switches for loose mounting or visible damage. If
the mounting hardware is loose, tighten the hardware. If a position switch is
damaged, replace the switch.

Lower the outriggers and raise the trailer wheels off the ground. Verify that all
four outrigger LEDs light up.

If an LED is lit before the outrigger is lowered or if an LED fails to light when
the outrigger is lowered, check the adjustment of the related outrigger position
switch as follows:
a.

Measure the distance between the actuator roller and the outrigger pivot,
Figure 4-13. The roller should be 1/8 inch (3 mm) from the outrigger pivot.
Adjust the actuator as needed.

If the actuator is correctly adjusted, but the LED fails to light up or go dim,
check the switch, LED, and wiring. Repair or replace the faulty component.
Refer to the detailed electrical diagram in Figure 4-15.

OUTRIGGER
POSITION SWITCH

ACTUATOR
ROLLER

OUTRIGGER
PIVOT

POSITION SWITCH
TRIP POINT

Figure 4-13. Outrigger Position Switch

4-19

XLB-4319

4-7

TROUBLESHOOTING
Table 4-3. Troubleshooting Chart

Problem
1.

Engine or motor will not
start.

Emergency stop engaged (pushed in).

Rotate emergency stop buttons clockwise to disengage.

Battery charge is low.

Check charge level. Recharge battery
if needed.

Battery ground or in-series cable
loose.

Check for and repair loose battery
connections or ground fault.

Main circuit breaker tripped or
switched off.

Reset main circuit breaker inside
ground control panel.

Main disconnect unplugged.

Plug in main disconnect.

Fuse F2 burned out. Fuse is mounted
on front inner wall of boom pivot
weldment, in series with the positive
battery cable.

Correct cause of short circuit and
replace fuse.

Motor contactor failed.

Replace motor contactor.

Pump motor failed.

Check pump motor operation; repair
or replace motor if faulty.

Engine key switch in wrong position.

Turn key switch to run position.

Fuel tank empty.

Refill fuel tank.

Engine oil level low.

Check/add engine oil.

Spark plug fouled or damaged.

Check/replace spark plug.

Fuse F2 burned out. Fuse is mounted
inside engine key switch housing.

Correct cause of short circuit and
replace fuse.

Starter relay or starter motor failed.

Replace failed starter relay or motor.

Basket/ground key switch in wrong
position.

Turn key switch to ground position.

Hydraulic oil level low.

Check hydraulic oil level in reservoir.
Add oil as needed.

Boom down limit switch or switch
wiring failed.

Check boom down limit switch and
wiring operation per paragraph 4-6.

Hydraulic gear pump failed.

Check pump; replace if hot to touch.

DC model only

Boom enable valve SV1 faulty (sticking open) (see item 4, Figure 6-19).

Repair or replace faulty valve.

Gas model only

Outrigger enable valve solenoid SV2
failed (see item 6, Figure 6-18).

Replace faulty wiring or solenoid.

Boom enable valve SV1 faulty (sticking open) (see item 1, Figure 6-18).

Repair or replace faulty valve.

Gas model only

4-20

Correction

DC model only

Cause

Pump motor runs, but outriggers will not extend.

4 — MAINTENANCE

Table 4-3. Troubleshooting Chart, Continued
3.

Pump motor runs, but upper
and lower boom lift functions do not work.

Pump motor runs, but the
upper and lower booms will
not retract.

Pump motor runs, but the
boom rotate function does
not work.

One hydraulic boom or
outrigger function fails to
work.

Basket/ground key switch in wrong
position.

Turn key switch to enable basket or
ground controls.

Boom lift out of level.

Operate outriggers to level boom lift.

Outrigger not under load.

Check that all outriggers support a
load; adjust outriggers as needed.

Hydraulic oil level low.

Check hydraulic oil level per paragraph 4-4. Add oil as needed.

Boom enable valve solenoid SV1
failed (see item 1, Figure 6-18 or
item 4, Figure 6-19).

Replace faulty wiring or solenoid.

Hydraulic output filter dirty.

Check pump output pressure, no load.
Replace filter if pump output pressure
reaches 30 psig (206 kPa gage) with
no hydraulic function selected.

Hydraulic gear pump failed.

Check pump; replace if hot to touch.

Obstruction below basket or boom.

Raise and reposition the boom to
avoid the obstruction.

Basket/ground key switch in wrong
position.

Turn key switch to ground or basket
run position.

Boom lift shifted out of level.

If out of level alarm is sounding,
manually lower boom.

Outrigger not under load.

Check that all outriggers support a
load. If not, manually lower boom.

Hydraulic oil level low.

Manually lower boom. Check oil
level in reservoir; add oil as needed.

Boom enable valve solenoid SV1
failed (see item 1, Figure 6-18 or
item 4, Figure 6-19).

Manually lower boom. Repair faulty
wiring or replace failed solenoid.

Basket/ground key switch in wrong
position.

Turn key switch to ground or basket
position.

Boom lift out of level.

Operate outriggers to level boom lift.

Outrigger not under load.

Check that all outriggers are supporting a load; adjust as needed.

Hydraulic oil level low.

Check hydraulic oil level in reservoir.
Add oil as needed.

Rotate obstruction or hard stop
reached.

Rotate boom in opposite direction.

Slew ring bearing worn and binding.

Retract boom and retry rotation.
Replace slew ring bearing if worn.

Control valve failed; leaking.

Repair or replace control valve if hot
to touch.

Cylinder counterbalance valve failed;
leaking.

Counterbalance valves are in cylinder
manifold blocks. Repair or replace
valve if hot to touch.

Cylinder failed; leaking.

Touch cylinder wall near piston; repair or replace cylinder if hot touch.

4-21

XLB-4319

Troubleshooting Aids
Electrical diagrams are provided in Figure 4-14 through Figure 4-17. Hydraulic diagrams
are provided in Figure 4-18 and Figure 4-19. Level sensor LED indications are shown in
Table 4-4.
MAIN DISCONNECT
12 VDC
BATTERY

–

MOTOR
CONTACTOR

FUSE

PUMP
MOTOR

F2
E-STOP
PB1

MCB

CIRCUIT
BREAKER

PB4

OUTRIGGERS
ENABLE

SW3
BOOM DOWN
LIMIT SWITCH
AUDIBLE
ALARM

LEVEL
SENSOR

ALARM
RELAY
RL2

GROUND

OFF

BASKET

PB2

BOOM
ENABLE

BOOM
ENABLE
VALVE
SV1

BOOM
ENABLE
PB7
PB6

E-STOP

BASKET
CONTROLS

OUTRIGGER
POSITION
SWITCHES
BASKET/OFF/
GROUND
KEYSWITCH
SW2

OUTRIGGER
DOWN LEDs

Figure 4-14. Simplified Electrical Diagram, DC Model
4-22

4 — MAINTENANCE

PLATFORM
CONTROL BOX
E-STOP
PB6

PB 7
BOOM

AUDIBLE
ALARM

8 14 23 0

PUMP COMPARTMENT
GROUND CONTROL BOX
KEY
SWITCH

SW 2
PB 4
P B1
OUTRIGGERS E-STOP

BASKET
PB2
BOOM

BATTERY
CHARGER

ALARM
RELAY

RL 2

GND

LEDS
22 21 20 19 3

8 7

6 5 4

0 12 1 15 23

MCB

S W3

SV1

BOOM DOWN
LIMIT SWITCH

MOTOR
CONTACTOR
CT1

PUMP
MOTOR

–

BATTERIES

M
S W5

S W6

S W4

OUTRIGGER
POSITION
SWITCHES

S W7

Figure 4-15. Detailed Electrical Diagram, DC Model

4-23

XLB-4319

STARTER
RELAY

–

12 VDC
BATTERY

CB1

FUSE

ENGINE
KEYSWITCH

CIRCUIT
BREAKER

STARTER
MOTOR

SW2

IGNITION UNIT
LEVEL
SENSOR

E-STOP
PB1

BASKET/OFF/GROUND KEYSWITCH SW1

SPARK PLUG
G

RUN
LED

ENGINE BASKET
START CONTROLS

ALARM
RELAY
RL2
AUDIBLE
ALARM

BOOM
ENABLE
PB2
PB5

BOOM
ENABLE
VALVE
SV1

PB6
BOOM ENABLE
BASKET
CONTROLS

E-STOP

OUTRIGGER
POSITION
SWITCHES
OUTRIGGER
DOWN LEDs

BASKET
OFF
GROUND

BOOM DOWN
LIMIT SWITCH

SW3

OUTRIGGERS
ENABLE
PB3

Figure 4-16. Simplified Electrical Diagram, Gas Model

4-24

OUTRIGGERS
ENABLE VALVE

SV2

LP3

LP4

LP5

LEVEL
SENSOR

BLACK

ALARM
RELAY
RL2

WHITE

LP2

TERMINAL BLOCK NUMBER

OUTRIGGER LEDs

RED

TO
ENGINE
IGNITION
COIL

BOOM
ENABLE
VALVE
SV1

OUTRIGGERS
ENABLE
VALVE
SV2

PB3
OUTRIGGERS
ENABLE

OFF

AUDIBLE
ALARM

PB2
BOOM
ENABLE

OUTRIGGER LIMIT SWITCHES

BASKET

PB6
BOOM
ENABLE

GROUND

TO ENGINE
STARTER
SOLENOID

ENGINE
START

PB5
E-STOP

BASKET CONTROLS

BOOM DOWN
LIMIT SWITCH

RUN
LED

E-STOP
PB1

SW1
BASKET/ 112
OFF/
GROUND
KEYSWITCH

CIRCUIT
BREAKER

12VDC
BATTERY

TO ENGINE
KEYSWITCH

15 A

FUSE
F2

4 — MAINTENANCE

LP1

Figure 4-17. Detailed Electrical Diagram, Gas Model

4-25

XLB-4319

GROUND CONTROL VALVE BANK

TO
BASKET
CONTROL
VALVE
BANK
2755 PSI

DIVERTER
VALVE

TO UPPER
BOOM LIFT
CYLINDER

1
3

5
6
TO LOWER
BOOM LIFT
CYLINDER

7 TO JIB
8 BOOM LIFT
CYLINDER

FROM
RETURN
MANIFOLD

PRESSURE
FILTER
2755 PSI

BOOM SLEW
MOTOR

M
SUCTION
FILTER

RETURN
FILTER

OUTRIGGER CONTROL VALVE BANK

2755 PSI
OUTRIGGER
CYL. 1

=
RET.
CYL.

EXT.
CYL.

OUTRIGGER
CYL. 2

Figure 4-18. Hydraulic Diagram, DC Model, Sheet 1 of 2

4-26

OUTRIGGER
CYL. 4

OUTRIGGER
CYL. 3

4 — MAINTENANCE

EMERGENCY
HAND PUMP
BASKET CONTROL VALVE BANK

FROM
GROUND
CONTROL
VALVE CHECK
BANK VALVE
2755 PSI

UPPER
BOOM LIFT
CYLINDER

BASKET
SLEW
CYLINDER

2
LOWER
BOOM LIFT
CYLINDER

6
JIB
BOOM LIFT
CYLINDER

Figure 4-18. Hydraulic Diagram, DC Model, Sheet 2 of 2

4-27

XLB-4319

GROUND CONTROL VALVE BANK

TO
BASKET
CONTROL
VALVE
BANK
2755 PSI
DIVERTER DIVERTER TO UPPER
BOOM LIFT
VALVE
VALVE
CYLINDER
SV1
SV2

FROM
RETURN
MANIFOLD

PRESSURE
FILTER
3045 PSI

1
3

5
6
TO LOWER
BOOM LIFT
CYLINDER

7 TO JIB
8 BOOM LIFT
CYLINDER

BOOM SLEW
MOTOR

OUTRIGGER CONTROL VALVE BANK
ENGINE
SUCTION
FILTER

RETURN
FILTER

2755 PSI

JACK CYL. 1
JACK CYL. 2

JACK CYL. 4
JACK CYL. 3

Figure 4-19. Hydraulic Diagram, Gas Model, Sheet 1 of 2

4-28

4 — MAINTENANCE

EMERGENCY
HAND PUMP
BASKET CONTROL VALVE BANK

FROM
GROUND
CONTROL
VALVE CHECK
BANK VALVE
2755 PSI

1
2

UPPER
BOOM LIFT
CYLINDER

BASKET
SLEW
CYLINDER

LOWER
BOOM LIFT
CYLINDER

JIB
BOOM LIFT
CYLINDER

Figure 4-19. Hydraulic Diagram, Gas Model, Sheet 2 of 2

4-29

XLB-4319

YELLOW LED
GREEN LED
RED LED
OUT OF LEVEL INPUT POWER OUTPUT SIGNAL
(MOMENTARY)
(ON WHEN LEVEL)

Figure 4-20. Level Sensor

Table 4-4. Level Sensor LEDs
Color

4-30

Description

Yellow

Boom lift out of level. Signals alarm after 2 second delay.

Green

Boom lift power is on.

Red

Boom lift level. Goes out after time delay.

4 — MAINTENANCE

4-8

MATERIAL SAFETY DATA SHEETS
MATERIAL SAFETY DATA SHEET

FOR LEAD ACID BATTERIES, WET, FILLED WITH ACID
SECTION I: GENERAL INFORMATION
Manufacturer’s Name:
Street Address:
City, State, Zip
Phone Number:

Crown Battery Mfg. Company
1445 Majestic Drive
Fremont, Ohio 43420
419 334-7181

EMERGENCY NO: 800 487-2879
OR
800 OIL-TANK
REVISION DATE:

5/18/2000

SECTION II: MATERIAL IDENTIFICATION AND INFORMATION
COMPONENTS
Hazardous Components
1% or greater
Carcinogens 0.01% or greater

PERCENT

METALLIC LEAD METAL
LEAD SULFATES
LEAD OXIDES
POLYPROPYLENE CASE MTL
SEPARATORS
SULFURIC ACID(H2SO4)
WATER

25.5%
18.2%
18.0%
6.4%
3.5%
5.2%
19.2%

OSHA

ACGIH

PEL

TLV

OTHER LIMITS CAS NUMBER

0.05 mg/m3 0.05 mg/m3
0.05 mg/m3 0.05 mg/m3
0.05 mg/m3 0.05 mg/m3

NONE
NONE
NONE

7439-92-1
7439-92-1
7439-92-1

1.0 mg/m3

NONE

7664-93-9

1.0 mg/m3

REGULATORY INFORMATION: Those ingredients listed above are not subject to
the reporting requirements of 313 of Title III 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
Vapor Pressure
Solubility in Water
Specific Gravity
Appearance & Odor

Approximately 203F
Vapor Density:
14 @ 37% @ 80 F
Melting Point:
100%
Water Reactive:
1.245 - 1.295 Battery Electrolyte
Clear Liquid with Sharp Pungent Odor

Greater Than 1
-36 F to -10.6 F
Yes, Produces Heat

SECTION IV: FIRE AND EXPLOSION HAZARD DATA:
Flash Point: Not Combustible
Auto Ignition Temperature N/A
Flammabiltiy Limits in Air % by Volume:
N/A
Extinguishing Media: Dry Chemical Carbon Dioxide, Water Fog, Water
Special Fire Fighting Procedures: Sulfuric Acid Fumes, Sulfur Dioxide Gas or Carbon Monoxide may be
released when acid decomposes. Wear NIOSH approved self contained breathing apparatus.
Unusual Hazards: Water applied to sulfuric acid generates heat and causes acid to splatter. Wear full-cover
acid resistant clothing. Sulfuric acid reacts violently with metals, nitrates, chlorates, carbides, fulminates,
picrates and other organic materials. Reacts with most metals to yield explosive/flammable hydrogen gas.
This reaction is intensified when sulfuric acid is dilluted with water to form battery electrolyte.

4-31

XLB-4319

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 & DIGESTIVE SYSTEM
Chronic:
EYES, SKIN, RESPIRATORY SYSTEM & DIGESTIVE SYSTEM
Signs and Symptoms of Exposure: IRRITATION OF EXPOSED AREA, BURNS AND RESPIRATORY PROBLEMS
NO POSSIBILITY OF EXPOSURE OF LEAD WILL OCCUR UNLESS
BATTERY IS DESTROYED.
Medical Conditions Generally
Aggravated By Exposure:
EXPOSURE TO MIST MAY CAUSE LUNG DAMAGE & AGGRAVATE
PULMONARY CONDITION.
Emergency First Aid Procedures: SEEK MEDICAL ASSISTANCE FOR FURTHER TREATMENT, OBSERVATION
AND SUPPORT IF NECESSARY.
Eye Contact:
WASH WITH COPIOUS QUANTITIES OF COOL WATER FOR AT LEAST 15 MINUTES
Skin Contact:
FLUSH AREA WITH LARGE AMOUNTS OF COOL 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, &
SULFUR DIOXIDE
Hazardous Polymerization: MAY OCCUR
Conditions to Avoid: N/A

********************************************************************************************
SECTION VII -- SPILL OR LEAK PROCEDURES
********************************************************************************************
Steps to be taken in case material is released or spilled:
CONTAIN SPILL, USING NON-COMBUSTIBLE MATERIALS: VERMICULITE, DRY SAND & EARTH. NEUTRALIZE WITH
LIME, SODA ASH, SODIUM BICARBONATE, ETC.
Waste disposal method: CONSULT STATE ENVIRONMENTAL AGENCY. INDIVIDUAL STATE REGULATIONS
VARY
Precautions to be taken in Handling & Storage:
SEPARATE FROM INCOMPATIBLE MATERIALS, KEEP AWAY
FROM FIRE, SPARKS AND HEAT
Other Precautions and/or Special Hazards:
CONTACT WITH METALS MAY PRODUCE TOXIC SULFUR DIOXIDE FUMES & MAY ALSO RELEASE FLAMMABLE
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:
Protective Gloves:
Eye Protection:
Ventilation:

Other Protective Equipment:
Hygienic Work Practices:

4-32

ABOVE P.E.L.: NIOSH APPROVED, FITTED, FULL FACE RESPIRATOR
ACID RESISTANT
FULL FACE PROTECTION
LOCAL EXHAUST: VENTILATED AREA PREFERRED
MECHANICAL:
IF BELOW P.E.L.
SPECIAL:
MUST BE ACID & EXPLOSIVE RESISTANT
OTHER:
MUST BE ACID & EXPLOSIVE RESISTANT
ACID RESISTANT CLOTHING AND BOOTS
N/A

XLB-4319

MATERIAL SAFETY DATA SHEET
FOR AW–46 HYDRAULIC OIL
1-SITE SPECIFIC INFORMATION: AW-46 HYDRAULIC OIL
2-GENERAL INFORMATION TRADE NAME: AW-46 HYDRAULIC OIL
EMERGENCY TELEPHONE NUMBERS: (517) 849-2144
CHEMICAL FAMILY: LUBRICATING OIL
CAS NUMBER: MIXTURE: ISSUE DATE 12/15/96
HAZARDOUS INGREDIENTS:
---------------------------------------------------------------------------CONTAINS NO INGREDIENTS NOW KNOWN TO BE HAZARDOUS AS DEFINED IN OSHA 29 CFR
1910.1000 AND OSHA 29 CFR 1910.1200.
---------------------------------------------------------------------------HEALTH HAZARD DATA
THRESHHOLD LIMIT VALUE: 5mg/m3 AS OIL MIST 8 hr, TWA
PRIMARY ROUTES OF ENTRY: INHALATION, SKIN ABRASION AND INGESTION.
CARCINOGENIC: NO
SYMPTOMS IF INGESTED, CONTACTED WITH SKIN, OR VAPOR INHALED: NO ADVERSE
EFFECTS EXPECTED.
EYES: FLUSH WITH WATER FOR 15 MINUTES SKIN: WASH THOROUGHLY WITH WARM
SOAPY WATER.
INGESTION: DO NOT INDUCE VOMITTING-SEEK MEDICAL ATTENTION.
MEDICAL CONDITIONS AGGRAVATED BY EXPOSURE: NONE KNOWN
AIR EXPOSURE LIMITS: P.E.L.
NOT ESTABLISHED
T.L.V.5mg/m3 OSHA 29 CFR
1910.1000
HEALTH: 1FIRE: 1SPECIFIC: XREACTIVITY: 0
---------------------------------------------------------------------------PHYSICAL DATA: BOILING POINT: 400+ DEG F.
VAPOR PRESSURE (PSIA): N/A
SPECIFIC GRAVITY (H20=1): 0.87
SOULUBILITY IN WATER: NEGLIGIBLE
PH OF CONCENTRATE: N/A
APPEARANCE AND ODOR: PALE YELLOW, PETROLEUM ODOR
---------------------------------------------------------------------------FIRE AND EXPLOSION HAZARD DATA FLASH POINT(METHOD USED): 425 DEG F.
FLAMMABLE LIMITS: NOT DETERMINED
LEL: N/AUEL: N/A
EXTINGUISHING MEDIA: SAND, DRY CHEMICAL, FOAM, CO2. TREAT AS CLASS B FIRE.
UNUSUAL FIRE AND EXPLOSION HAZARDS: NONE
---------------------------------------------------------------------------REACTIVIYY DATA
STABILITY: STABLE
CONDITIONS TO AVOID: AVOID EXTREMES
OF HEAT.
INCOMPATIBILITY (MATERIALS TO AVOID): STRONG OXIDIZING MATERIALS.
HAZARDOUS DECOMPOSITION PRODUCTS: INCOMPLETE COMBUSTION MAY CAUSE CARBON
OXIDES.
HAZARDOUS POLYMERIZATION: WILL NOT OCCUR.
---------------------------------------------------------------------------SPILL OR LEAK PROCEDURES: STEPS TO BE TAKEN IN CASE MATERIAL IS RELEASED OR
SPILLED. DIKE AND ABSORB ON INERT MATERIAL. FOLLOW ALL LOCAL, STATE, AND
FEDERAL REGULATIONS FOR DISPOSAL OF COLLECTED MATERIAL.
----------------------------------------------------------------------------

4-33

4 — MAINTENANCE

MATERIAL SAFETY DATA SHEET
FOR AW–46 HYDRAULIC OIL (Continued)
SPECIAL PROTECTION INFORMATION
RESPIRATORY PROTECTION (SPECIFIC TYPE)
NONE REQUIRED
VENTILATION: NORMAL
LOCAL EXHAUST: NORMAL
MECHANICAL EXHAUST (GENERAL) X
PROTECTIVE GLOVES: OIL IMPERVIOUS GLOVES RECOMMENDED
EYE PROTECTION: SAFETY GLASSES RECOMMENDED
OTHER PROTECTIVE EQUIPMENT: NONE REQUIRED
---------------------------------------------------------------------------SPECIAL INSTRUCTIONS SPECIAL LABELLING INSTRUCTIONS: NOT REQUIRED
SPECIAL PACKAGING RECOMMENDATIONS: NONE
HANDLING AND STORAGE RECOMMENDATIONS: DO NOT CUT OR WELD ON EMPTY
CONTAINERS, AVOID EXTREMES OF COLD OR HEAT. STORE IN CLEAN DRY AREA.
DISCLAIMER: THE INFORMATION CONTAINED HEREIN HAS BEEN COMPILED FROM SOURCES
CONSIDERED TO BE DEPENDABLE AND IS ACCURATE TO THE BEST OF THE SELLERS
KNOWLEDGE. THE SELLER MAKES NO WARRANTY WHATSOEVER, EXPRESSED, IMPLIED OR OF
MERCHANTABILITY REGARDING THE ACCURACY OF SUCH DATA OR THE RESULTS TO
BE OBTAINED FROM THE USE THEREOF.

4-34

Replacement Decals
Refer to Table 5-1 and Figure 5-1 through Figure 5-5 for descriptions and locations of
decals on the XLB-4319 Hydraulic Boom Lift.
Table 5-1. Replacement Decals
Decal No.

Description of Decal

Qty

Decal No.
B06-00-0334

B06-00-0033

CAUTION: THIS UNIT SHALL
ONLY BE TOWED WHEN…

B06-00-0034

DANGER: …DURING
CHARGING, EXPLOSIVE
OXYHYDROGEN GAS…

B06-00-0036

LUBRICATE WEEKLY

B06-00-0037

Description of Decal
DANGER: HIGH VOLTAGE
OPERATION

B06-00-0363B Bil-Jax – SMALL LABLE

Qty
2
2

B06-00-0380

MAXIMUM CAPACITY 450
LBS

B06-00-0393

Basket Station Valve Numbers

LUBRICATE SEMI-ANNUALLY

B06-00-0394

Basket Station Valve Motions

B06-00-0043

MANUAL PUMP HANDLE

B06-00-0395

Ground Station Valve Numbers

B06-00-0060

STOP…READ OPERATING…

B06-00-0396

Ground Station Valve Motions

B06-00-0062

THIS PLUG 115 VOLT

B06-00-0397

LATCHED UNLATCHED

B06-00-0068

THE HYDRAULIC SYSTEM…
(decal on hydraulic reservoir)

B06-00-0398

OUTRIGGER INSTRUCTIONS

B06-00-0115

1500 WATT LOAD LIMIT

B06-00-0399

ABBREVIATED OPERATING
INSTRUCTIONS

B06-00-0130

LUBRICATE MONTHLY

B06-00-0400

DANGER: 110 VOLT

DANGER: BEFORE USING,
LOWER ALL 4 OUTRIGGERS

B06-00-0151

B06-00-0401

DANGER: BOOM SAFETY
INSTRUCTIONS

B06-00-0161B Bil-Jax – LARGE LABLE
B06-00-0167

Caution Tape, Black and Yellow

B06-00-0173

SAFETY HARNESS LANYARD
ATTACHMENT POINT

B06-00-0402

BOOM LIFT INSTRUCTIONS
BASKET

B06-00-0189

WARNING: LEVEL MACHINE
BEFORE USE

B06-00-0403

PUSH TO LOWER

B06-00-0404

OPERATION AND SERVICE
MANUAL INSIDE

WARNING: STAND CLEAR OF
OUTRIGGER…

B06-00-0405

WARNING: PINCH POINT…

B06-00-0225

WARNING: STAY CLEAR
WHILE RAISING …

B06-00-0406

XLB-4319 TRANSFER

B06-00-0409

CAUTION: ANSI DECAL

EMERGENCY ROTATION
GEAR

B06-00-0261
B06-00-0268

EMERGENCY ROTATION
HANDLE

B06-00-0430

XLB–4319 SPECIFICATIONS

B06-00-0192

5-1

XLB-4319

LUBRICATE
WEEKLY

EMERGENCY
ROTATION GEAR

COIA

FTC

DANGER

B06-00-0036

FAILURE TO COMPLY WITH THE FOLLOWING INSTRUCTIONS
OR ANY OTHER IMPROPER USE OR MAINTENANCE OF THIS
EQUIPMENT WILL RESULT IN INJURY OR DEATH.

B06-00-0036

B06-00-0409

MAXIMUM CAPACITY

450 LBS.

CCTT

B06-00-0130

RIF

B06-00-0130

WARNING

COIA

MANUAL PUMP HANDLE
COIA

Risk of Electric Shock
DO NOT expose charger to rain, power wash detergents or
spray - DO NOT use frayed or damaged electric cords when
charging.

• During charging, explosive oxyhydrogen gas is generated.
DO NOT smoke or allow open fire, sparks, or embers near
battery when charging.

B06-00-0380

LUBRICATE
SEMI-ANNUALLY

•

LUBRICATE
MONTHLY

PINCH POINT

• Connect input cord only to properly grounded three wire
outlet with specified voltage and frequency.
• Always wear safety goggles and face shield when working
on or near battery.

B06-00-0043

B06-00-0037

• Check battery acid level at the start of each day. If acid does
not cover the plates, add only enough distilled or demineralized water to completely cover the plates.

B06-00-0043

B06-00-0037

• Keep terminals and terminal connections clean.

THIS PLUG 115 VOLT

RIL

B06-00-0062

STAY CLEAR

B06-00-0062

FTC

RIR/OFG

B06-00-0034

B06-00-0405

EMERGENCY ROTATION HANDLE
OFA

• Consult Operation and Maintenance Manual for additional
information on battery maintenance.

B06-00-0268

CAUTION
THIS UNIT SHALL ONLY BE TOWED
WHEN ALL BOOM SECTIONS ARE FULLY
DOWN AND LOCKED WITH TRANSPORT
SAFETY PINS.
COIA/RFT

B06-00-0033

CAUTION

SAFETY
HARNESS
LANYARD
ATTACHMENT
POINT
UFC

This machine is designed and manufactured in compliance with the ANSI A92.2 standard in force on the date of
manufacture. Dealers, owners, users, operators, lessors,
and lessees are responsible for inspection, maintenance,
training, and operation as required by A92.2 and the owners
manual.
Alterations, modifications, or changes to this machine
without the written authorization of Workforce Products,
Inc. as well as any unauthorized adjustment of valves,
disabling or by-passing of safety devices or the improper
use of this machine shall exempt Workforce Products, Inc.
from any liability for any resulting injuries or damage.

B06-00-0173

DANGER
IT IS UNLAWFUL TO OPERATE
THIS EQUIPMENT WITHIN 10
FEET OF HIGH VOLTAGE
LINES OF 50,000 VOLTS OR
LESS.

FFU

B06-00-0261

B06-00-0261
OPERATION AND SERVICE
MANUAL INSIDE
COFC

B06-00-0192

110 VOLT

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

This machine is NOT insulated. Do not use within 10 ft. of power
lines or other electrically charged sources. This machine DOES
NOT provide protection for personnel from contact with or close
proximity to any live electrical power source and should be considered energized by all personnel coming in contact with machine.
B06-00-0334

FFL

DANGER

• Level machine before use.
to level this machine could
WARNING • Failure
result in serious injury or death!
LFC

B06-00-0189

GFT/LFC

B06-00-0189

B06-00-0334

STAY CLEAR
WHILE RAISING
OR LOWERING

WARNING
CCFO

B06-00-0161B

XLB-4319
B06-00-0406

B06-00-0225

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

B06-00-0151

B06-00-0363B

5 — REPLACEMENT DECALS

ABBREVIATED OPERATING INSTRUCTIONS

WARNING
UNHITCHING

STOWING MACHINE

Machine must be unhitched from vehicle before
setting up.
1. Apply hand brake.
2. Remove lighting plug and safety wire from
vehicle.
3. Lower trailer tongue jack.
4. Release trailer hitch from vehicle.

1. Fully lower each boom into transport position.
2. Using outrigger levers, raise outriggers full starting at the cage end.
3. Install boom locking pins.

Do not tow machine unless:
* The booms are full lowered
* The boom locking pins are in place
* All outriggers are fully retracted
1. Secure trailer hitch to ball on towing vehicle.
2. Attach safety wire.
3. Attach lighting plugs. Check to make sure lighting
wire cannot be damaged in transit.
4. Check to make sure lights are working properly.
5. Fully raise trailer tongue jack and release hand
brake.
6. The trailer weight must not exceed the vehicle
towing capacity.
7. Do not exceed maximum towing speed.

1. Read Operation Manual and all decals prior to
operation.
2. Check to be sure all personnel are clear of
outriggers.
3. Select ground controls with key switch.
4. Make sure emergency stop buttons are released.
5. Using outrigger levers, lower each outrigger to
within 6” from ground.
6. Lower the two outriggers closest to the trailer
hitch until trailer tongue jack is clear of ground.
7. Level machine using two remaining outriggers
while referring to bubble level.
8. Check to be sure both wheels are clear of
ground.
9. Check all outrigger lights show green and
buzzer has stopped.
10. Check to be sure each outrigger foot is in firm
contact with the ground.
11. Do not place boards, concrete blocks, or any
other object under the outrigger foot to obtain
greater height adjustment.

PUSH TO LOWER
FTC

B06-00-0403

EMERGENCY LOWERING PROCEDURE

From Basket (if fitted)
In the event of power failure, the basket may be
lowered using the emergency hand pump. The
procedure is as follows:
1. Attach hand pump handle.
2. Select function required with control lever(s).
3. Pump hand pump.
FTC

From Ground
1. Press red emergency lowering valve on base of
bottom boom lift cylinder. Stand clear of descending structure.
2. Press red emergency lowering valve on top of
boom cylinder. Stand clear of descending structure.

BOOM OPERATING
1. Remove transport stowing pins.
2. Select ground controls with key switch.
3. Press green “enable” button and operate levers
as required.
4. Check all lift functions for proper operation.
5. Return all boom arms to stowed position. Move
key switch to basket controls. Lift is now ready
for operation from the basket.

FTC

Stand clear of outrigger while it
is being lowered. Contact with
outrigger foot pad will cause
serious crushing injury.

TOWING MACHINE

SETTING UP

EMERGENCY
LOWERING VALVE

WARNING

IMPROPER USE OF THIS EQUIPMENT WILL RESULT IN SERIOUS INJURY OR DEATH.
THIS MACHINE MUST NOT BE OPERATED UNLESS YOU ARE COMPLETELY FAMILIAR
WITH THE INSTRUCTIONS CONTAINED IN THE OPERATING MANUAL

FTC

B06-00-0404

Emergency Rotation - Install emergency rotation handle
on red hex-shaft on rotation gearbox. Turn handle to
rotate structure.
B06-00-0399

THE HYDRAULIC SYSTEM OF
THIS MACHINE IS DESIGNED TO USE
ENERGOL HLP-46 HYDRAULIC OIL

B06-00-0399

B06-00-0397

B06-00-0404

OII

B06-00-0068

• Use only tools equipped with
3 prong grounded plug.
• 1500 Watt maximum load.
• 15 Amp maximum circuit.
B06-00-0115

AIF/RFC

B06-00-0068

BOOM OPERATING INSTRUCTIONS FOR XLB-4319
1. Read Operation Manual and all
decals prior to operating.
2. Follow the instructions on the lower
controls for “Unhitching”, “Setting
Up” and “Boom Operating”. This
will ensure proper boom set up and
also help you familiarize yourself
with the operation of the lift.
3. Check again to be sure all outriggers are properly set and the lift is
level.

4. Always wear full body harness and
attach lanyard to the provided
attachment when operating from
the basket.
5. Check the emergency stop button
to make sure it is in the released
position.
6. Press and hold the green enable
button with one hand while operating the control levers with the other
hand. Each lever is clearly marked
for function and direction.

FTC

READ OPERATING
INSTRUCTIONS BEFORE
FTC

B06-00-0393

OPERATING

B06-00-0393

B06-00-0402

FTC

STOP

B06-00-0395

B06-00-0402

DANGER

B06-00-0115

MACHINE

BEFORE USING, LOWER ALL 4 OUTRIGGERS UNTIL
EACH OUTRIGGER IS IN FIRM CONTACT WITH THE
GROUND, THEN LEVEL THE MACHINE.

RIL

B06-00-0060

B06-00-0400

B06-00-0060

B06-00-0400

DANGER
FAILURE TO COMPLY WITH THE FOLLOWING SAFETY INSTRUCTIONS OR ANY OTHER IMPROPER USE
OF THIS EQUIPMENT WILL RESULT IN SERIOUS INJURY OR DEATH.
BEFORE USE
• Operator must read and understand owners manual and all decals on machine before operating. It is operators
responsibility to comply with all warnings and instructions.
• Survey the job site and identify all potential hazards.
• Inspect lift for proper maintenance and any damaged or worn components. DO NOT operate until proper
maintenance has been performed and all damaged or worn parts have been replaced. See owners manual for
proper maintenance procedures.
• NEVER TAKE CHANCES—DO NOT use this lift if you are under the influence of drugs or alcohol, or if you feel
dizzy, ill, or unsteady in any way.
• OPERATE ON FIRM AND LEVEL SURFACE ONLY—if used on loose gravel or other soft surfaces, additional base
support under each outrigger foot pad may be necessary.
• Properly deploy all 4 outriggers by lowering each outrigger until it is in firm contact with the ground.
• Level machine before use—if buzzer sounds, lift is not level and the necessary outrigger adjustment should be
made to level machine before continuing.
• All occupants must wear full body harness and lanyard.
• Check safety devices daily before use—see owners manual for proper check procedures.
• When working on public roads, warnings and barriers must be set up in accordance with all local, state, and federal
traffic codes.
• Cordon off area around base to keep personnel and other equipment away from unit while in use.

DURING USE
•
•
•
•
•

To avoid hand injuries, always keep hands inside basket area during boom movement.
DO NOT use without all four outriggers in firm contact with the ground and the lift level.
DO NOT release outriggers with boom extended or operator in basket.
DO NOT move or reposition trailer while operator occupies basket.
DO NOT use when exposed to high winds, rain, snow, or ice.

• DO NOT use where lift operator can come in contact with overhead obstructions such as electric wires, cables, ropes,
overhangs, etc.
• DO NOT operate without full body harness and lanyard in use by all basket occupants.
• DO NOT stand or sit on guard rails or top edge of basket.
• DO NOT lean out over top edge of basket to perform work.
• DO NOT use boxes, ladders, scaffolding, or any other
means to increase working height.
• DO NOT climb up or down boom.
• DO NOT exceed rated lift capacity.
• DO NOT allow ropes, electric cords, hoses, etc. to become
entangled in the lift while platform is being raised or lowered.
• DO NOT override, alter, or bypass safety devices.
• DO NOT use boom rotation or basket rotation (if so equipped) for pushing or pulling.
• DO NOT exceed platform capacity when transferring loads to the platform while elevated.
• DO NOT use as a crane for lifting materials.
• DO NOT leave keys in machine while unattended.
• Plug charger in at the end of each day.
• When using the lift with the 110V power cord plugged into the base of the unit, care must be taken to ensure that the
cord is not damaged or entangled during rotation.
• DO NOT allow flames, sparks, or embers near batteries and DO NOT smoke near batteries. Batteries produce a
hydrogen, oxygen gas mixture which can explode.

OWNERS & OPERATORS ARE RESPONSIBLE FOR INSPECTION, MAINTENANCE, TRAINING,
AND OPERATION AS REQUIRED BY THE OWNERS MANUAL .
IF YOU HAVE NOT BEEN PROVIDED WITH SAFETY LITERATURE,
OR FOR ANY QUESTIONS CONCERNING THE SAFE USE OF THIS
EQUIPMENT, CALL 419/445-9675.
B06-00-0401

FTC

B06-00-0401

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

XLB-4319

1)
2)
3)
4)

FTC
FTC

B06-00-0398

B06-00-0394

FTC

B06-00-0396

XLB-4319 SPECIFICATIONS
45.9
42.6
39.4
36
32.8
24.5
26.3
23
19.7
16.4
13
9.8
6.5
3.2
0

9.8

6.5

3.2

6.5

9.8

13 16.4 19.7

B06-00-0430

Figure 5-1. Replacement Decals, Sheet 3 of 3
5-4

Ensure Emergency Stop buttons are released.
Turn key to Ground Controls.
Press and hold black button.
Operate Outrigger Levers to level unit (refer to
Bubble Level).
5) Lower outriggers 3 and 4 first to ensure tongue
jack is clear of ground.
6) Check to be sure each outrigger foot is in firm
contact with ground.
7) Check to be sure all outriggers are showing a
green light and buzzer has stopped.
B06-00-0398

0404

0060
0334
0033

0043
0402

0409

0189

0400
0401

0393
0394

0036

0363B
BOTH
SIDES

0173
0151
0062 0115

0192

0380

0225
BOTH
SIDES

0334

0036

0403

0404
(ALL OUTRIGGERS)

0036
(ALL OUTRIGGERS)

0405

0036

0225
BOTH
SIDES

0225

0403

0036
0400
(ALL OUTRIGGERS)

0405

0268 0062

SEE FIGURE 5-3
FOR COMPARTMENT
COVER DECALS

0405
BOTH
SIDES

0405
(ALL OUTRIGGERS)

3
B-4

0406
BOTH
SIDES

0036

0161B
BOTH
SIDES

0033

0036

0130

0036

0404

5 — REPLACEMENT DECALS

Figure 5-2. Decal Locations, Trailer and Boom

5-5

XLB-4319

0334, 0034
ON END
PANEL
0033
0398
0399
0401
0397
0395

0395, 0396
ON TOP OF
CONTROL BOX

0261
0430

Figure 5-3. Decal Locations, Control Compartment Exterior

Figure 5-4. Lubricate Monthly Decal

0037

Figure 5-5. Lubricate Semi-Annually Decal
5-6

Parts List

6-1

XLB-4319

6-1

UPPER BOOM PARTS LIST
Refer to Table 6-1 for the upper boom parts list.
17

1
2
3

19, 19A

4 5
3

18, 18A
17

10
11

2
2

3
16, 16A, 16B,
16C, 16D

12
13

21
22

19, 19A

4
17

18, 18A

26
23
22
24

Figure 6-1. Upper Boom
6-2

6 — PARTS LIST

Table 6-1. Upper Boom Parts List
Item No.

Part No.

Description

Qty

B11-03-0043

Vertical Boom

B36-00-0059

Pivot Pin, 30mm dia. x 221mm

B36-00-0042

Locking Pin

Flat Washer

Lock Washer

Cap Screw

Flat Washer

Hose Clamp

Flat Washer

Hex Nut

Wear Pad

Cap Screw

Trimlock, 1/4 in. x 30 in.

Trimlock, 1/4 in. x 7 in.

B31-00-0036

B02-03-0027

Hydraulic Cylinder, Upper Boom

16A

B25-00-0084

Bushing, Cylinder Pivot

16B

B02-13-0107

Seal Kit, End Cap With Groove

B02-13-0106

Seal Kit, End Cap With Groove

B02-04-0082

Counter-Balance Valve, End Cap With Groove

B02-04-0064

Counter-Balance Valve, End Cap Without
Groove

B02-14-0059

Emergency Lowering Valve, End Cap With
Groove

B02-14-0055

Emergency Lowering Valve, End Cap Without
Groove

16C

16D

Grease Fitting

B11-03-0040

Upper Boom

18A

B25-00-0084

Bushing, Upper Boom

B11-03-0042

Upper Boom Stabilizer

19A

B25-00-0084

Bushing, Upper Boom Stabilizer

B36-00-0062

Pivot Pin, 30mm dia. x 179mm

Cap Screw

Flat Washer

Knuckle, Jib Boom

Self Locking Nut

B11-03-0045

24
25

B36-00-0058

Pivot Pin, 30mm dia. x 201mm

B36-00-0060

Pivot Pin, 30mm dia. x 216mm

6-3

XLB-4319

6-2

LOWER BOOM PARTS LIST
Refer to Table 6-2 for the lower boom parts list.
18
19

15
14
13, 13A,
13B, 13C

2
17

12
22
23

1, 1A
24

20
21

25
26

2
8
9, 9A, 9B,
9C, 9D

11
3

11
6

3
4

5 6

Figure 6-2. Lower Boom
6-4

7, 7A

6 — PARTS LIST

Table 6-2. Lower Boom Parts List
Item No.

Part No.

Description

Qty

B11-03-0039

Lower Boom

B25-00-0084

Bushing, Lower Boom

Grease Fitting

2
3

Locking Pin

B36-00-0042

Flat Washer

Lock Washer

Cap Screw

B11-03-0041

Lower Boom Stabilizer

B25-00-0084

Bushing, Lower Boom Stabilizer

B36-00-0062

Pivot Pin, 30mm dia. x 179mm

B02-03-0028

Hydraulic Cylinder, Lower Boom

B25-00-0084

Bushing, Cylinder Pivot

B02-13-0107

Seal Kit, End Cap With Groove

B02-13-0106

Seal Kit, End Cap With Groove

B02-04-0082

Counter-Balance Valve, End Cap With Groove

B02-04-0064

Counter-Balance Valve, End Cap Without Groove

B02-14-0059

Emergency Lowering Valve, End Cap With Groove

B02-14-0055

Emergency Lowering Valve, End Cap Without
Groove

9C
9D

10
11

B36-00-0059

1
1

Boom Support Bracket

Pivot Pin, 30mm dia. x 221mm

Self Locking Hex Nut

B01-03-0056

Limit Switch

13A

B01-03-0003

Head, Limit Switch

13B

B01-03-0054

Roller Arm

13C

B01-03-0055

Plug Adapter

14
15

Wire Tie
Cable, Limit Switch

Socket Head Screw

Flat Washer

Flat Head Screw, M8 x 1.25 x 20mm

Boom Wear Pad

Socket Head Screw

Lock Washer

Flat Washer

Chain

Transport Pin

Clamp

Flat Head Screw

B01-03-0064

B31-00-0037

B36-00-0040

6-5

XLB-4319

6-3

JIB BOOM PARTS LIST
Refer to Table 6-3 for the jib boom parts list.
1

2
10, 10A,
10B, 10C

13
11 12

7
7
8

6
5

9
5
3

Figure 6-3. Jib Boom
6-6

4
5 6

6 — PARTS LIST

Table 6-3. Jib Boom Parts List
Item No.

Part No.

Description

Qty

B11-03-0045

Jib Boom Knuckle

B36-00-0067

Pivot Pin, 25mm dia. x 208mm

B36-00-0042

Locking Pin

Flat Washer

Lock Washer

Cap Screw

B11-03-0044

Jib Boom

B25-00-0081

Bushing, Jib Boom, Full Boss

B25-00-0086

Bushing, Jib Boom, Short Boss

Grease Fitting

8
9

B11-03-0046

Cage Support

B02-03-0029

Hydraulic Cylinder, Jib Boom

10A

B25-00-0081

Bushing, Cylinder Pivot

10B

B02-13-0107

Seal Kit, End Cap With Groove

B02-13-0106

Seal Kit, End Cap Without Groove

B02-04-0082

Counter-Balance Valve, End Cap With Groove

B02-04-0064

Counter-Balance Valve, End Cap Without
Groove

B02-01-0168

Hydraulic Hose Assembly, 6mm, C8

B02-02-0210

Adapter, Straight, 1/4 BSP Male-1/4 BSP Male

B02-00-0044

1/4 Dowty Washer

10C

14
15

Wire Tie
B36-00-0066

Pivot Pin, 25mm dia. x 201mm

AR
2

6-7

XLB-4319

6-4

COMPARTMENT COVERS PARTS LIST
Refer to Table 6-4 for the control and power compartment covers parts list.
1

3
3

7,7A

4
5

8
9
10
5
3
13

14
15
16

Figure 6-4. Compartment Covers

6-8

6 — PARTS LIST

Table 6-4. Compartment Covers Parts List
Item No.
1

Part No.
B42-01-1015

Description

Qty

Hinge, Cover

Cap Screw

Flat Washer

Fender Washer

Hex Nut

Lock Washer

B18-00-0156

Cover, Control Compartment

B18-00-0155

Cover, Pump Compartment (not shown)

B04-07-0121

Latch, Cover

Washer, Internal Lock

Hex Nut

Trimlock, 1/4 in. x 30.5 in.

Hex Nut, Self Locking

Support Rod

Socket Head Screw, Flat Head

Clamp, Support Rod

Hex Nut, Self Locking

B42-00-0020

14
15
16

B04-07-0118

NOTE: Quantities shown are for one cover. There are two covers on the machine,
control compartment and pump compartment. The pump compartment does
not have an opening and does not require a trim lock, item 11.

6-9

XLB-4319

6-5

RESERVOIR COMPARTMENT PARTS LIST,
GAS MODEL
Refer to Table 6-5 for the pump compartment parts list for the gas model boom lift.

12
1, 1A

7
24

6
9
23
22
21
19

4 26
C3 C C23

20
8

18
17
16

TO
HYDRAULIC
PUMP

10
C3
1

9
15

13 12

Figure 6-5. Reservoir Compartment, Gas Model

6-10

6 — PARTS LIST

Table 6-5. Reservoir Compartment Parts List, Gas Model
Item No.

Part No.

Description

Qty

Reservoir Assembly

Hydraulic Filter (not shown)

Hydraulic Hose Assembly, 13mm, C31

Cap Screw

Lock Washer

Flat Washer

Hydraulic Hose Assembly, Pump Supply

Hex Nut, Self Locking

B02-01-0185

B02-02-0205

Adapter, Straight, 1/4 BSP Male-3/8 BSP
Male

B02-00-0043

3/8 Dowty Washer

Return Manifold Assembly

Socket Head Cap Screw

B02-00-0042

1/2 Dowty Washer

B02-02-0218

Adapter, Straight, 3/8 BSP Male-1/2 BSP
Male

B02-02-0220

1/2 BSP Male Plug

B02-02-0206

Adapter, Straight, 3/8 BSP Male-3/8 BSP
Male

B02-01-0183

Hydraulic Hose Assembly, 10 mm, C28

B02-01-0173

Hydraulic Hose Assembly, 6 mm, C14

B02-01-0156

Hydraulic Hose Assembly, 10 mm, C1

Hydraulic Hose Assembly, 6 mm, C37

Hydraulic Hose Assembly, 6 mm, C34

B02-01-0163

Hydraulic Hose Assembly, 6 mm, C26

B02-01-0182

Hydraulic Hose Assembly, 6 mm, C23

B02-02-0215

3/8 BSP Male Plug

Cap

6-11

XLB-4319

6-6

PUMP COMPARTMENT PARTS LIST, DC MODEL
Refer to Table 6-6 for the pump compartment parts list for the DC model boom lift.
4
5

2
7

9
10
11
12
3

14
13

15
20
36

16
19

17
44

45
46

39
40
41, 41A,
41B, 41C,
41D

4
C1 C26 23
C

38
36

48
39

34
33

8
C2
C1

35
40
C3

26
25

24
23

40
32

22
30 29

Figure 6-6. Pump Compartment, DC Model
6-12

6 — PARTS LIST

Table 6-6. Pump Compartment Parts List, DC Model
Item No.
1

Part No.
B01-04-0001

Description

Qty

Battery, Dry Cell, 6 Volt DC

Cable, Battery, 2 Ga. x 8 in.

Terminal Boot

0090-0185

Hex Nut, Self Locking, 5/16 in.-18

0090-0420

Flat Washer, 5/16 in.

0090-0787

Fender Washer

B04-07-0081

Threaded Rod, 5/16 in. x 10 in.

Cable, Battery, 2 Ga. x 12 in.

Flat Washer

Socket Head Cap Screw

Flat Washer

Flange Nut

B01-10-0245

Fuse, 200 Amp, FS2

B01-10-0246

Insulator

Cable, Battery, 2 Ga. x 21 in.

Cable Connector, Plug and Receptacle

Cable, Battery, 2 Ga. x 12 in.

Cable, Battery, 2 Ga. x 14 in.

Machine Screw, Flat Head

Cable, Battery, 2 Ga. x 38 in.

Hex Nut, Self Locking

Cap Screw

Lock Washer

Flat Washer

Hex Nut

Fender Washer

Hydraulic Return Manifold

Socket Head Cap Screw

B02-00-0042

1/2 Dowty Washer

B02-02-0218

Adapter, Straight, 3/8 BSP Male-1/2 BSP
Male

B02-02-0220

1/2 BSP Male Plug

B02-02-0206

Adapter, Straight, 3/8 BSP Male-3/8 BSP
Male

B02-01-0183

Hydraulic Hose Assembly, 10 mm, C28

B02-01-0156

Hydraulic Hose Assembly, 10 mm, C1

B02-02-0215

3/8 BSP Male Plug

6-13

XLB-4319

6-6

PUMP COMPARTMENT PARTS LIST, DC MODEL
Refer to Table 6-6 for the pump compartment parts list for the DC model boom lift.
4
5

2
7

9
10
11
12
3

14
13

15
20
36

16
19

17
44

45
46

39
40
41, 41A,
41B, 41C,
41D

4
C1 C26 23
C

38
36

48
39

34
33

35
40
C3

26
25

24
23

40
32

22
30 29

Figure 6-6. Pump Compartment, DC Model
6-14

6 — PARTS LIST

Table 6-6. Pump Compartment Parts List, DC Model (continued)
Item No.

Part No.

Description

Qty

B02-01-0173

Hydraulic Hose Assembly, 6 mm, C14

B02-01-0163

Hydraulic Hose Assembly, 6 mm, C26

B02-01-0182

Hydraulic Hose Assembly, 6 mm, C23

B02-02-0205

Adapter, Straight, 1/4 BSP Male-3/8 BSP
Male

B02-00-0043

3/8 Dowty Washer

Pump and Reservoir Assembly

Pump Assembly Without Reservoir

Hydraulic Filter (not shown)

41
41A

B02-15-0419

41B
41C

B02-15-0389

Motor, 24V

41D

B02-15-0390

Brush Kit, 24V Motor

B02-02-0216

Fitting, Test Gauge

B02-00-0043

1/4 Dowty Washer

Hydraulic Hose Assembly, Pump Output

44
45

B02-02-0214

Fitting, Tee, 1/4 BSP Male

B02-02-0213

Adapter, Straight, 1/4 BSP Female Swivel3/8 BSP Male

B02-01-0185

Hydraulic Hose Assembly, 13mm, C31

Start Contact, 24V

6-15

XLB-4319

6-7

CHASSIS AND ROTATION UNIT PARTS LIST
Refer to Table 6-7 for the chassis and rotation unit parts list.
1

3, 3A, 3B, 3C
17
4
5
7

16
11

8
15

13
14
12

11
10

Figure 6-7. Chassis and Rotation Unit

6-16

6 — PARTS LIST

Table 6-7. Chassis and Rotation Unit Parts List
Item No.

Part No.

Description

Qty

Boom Support Bracket

Cap Screw

B02-06-0009

Slew Motor

B02-06-0010

Seal Kit, Slew Motor

B02-06-0011

Slew Motor End Seal

B25-00-0078

Taper Roller Bearing

Cap Screw

Lock Washer

Worm Gearbox With Slew Ring

Grease Fitting

Trailer Chassis

Socket Head Screw

Hex Nut

Flat Washer

Level Sensor

Machine Screw

Lock Washer

Level Sensor Cover

Machine Screw

B13-00-0007

7
8

B12-00-0140

B01-10-0016

B11-03-0047

Slew Restrictor

B46-00-0035

Handle, Manual Rotation

6-17

XLB-4319

6-8

HITCH AND JACK ASSEMBLY PARTS LIST
Refer to Table 6-8 for the hitch and jack assembly parts list.

4
1, 1A

5
37

6
7
10

35 36

17
13
34

40
28

14
16

22
12

23
12

18
19

15
24

20
30

27
26

39
28

Figure 6-8. Hitch and Jack Assembly

6-18

6 — PARTS LIST

Table 6-8. Hitch and Jack Assembly Parts List
Item No.
1
1A
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

Part No.
B12-00-0122
B12-00-0123
B01-10-0179
0090-0344

B12-00-0125

B36-00-0040

0090-0188
B23-02-0063
B12-00-0173

B23-02-0061

B03-00-0017
0090-0959
0090-1032
B01-01-0137
B12-00-0120
0090-0960
0090-0042
B12-00-0172
B12-00-0171
B12-00-0124
B12-00-0135

Description
Parking/Surge Brake Control Assembly
Hand Brake Only
Cap Screw
Lamp, Side Marker, Amber
Screw, Self Tapping, #10-24 x 1/2"
Hex Nut, Self Locking
Spacer
Bracket, Brake Cable
Brake Rod
Clamp
Socket Head Screw, Flat Head
Transport Pin
Flat Washer
Cap Screw
Chain
Keeper pin
Hex Nut
Hex Nut, Self Locking
Hex Nut, Self Locking, 3/8”-16
Swivel Plate
Breakaway Safety Cable
Cotter Key
Flat Washer
Spring
Swivel Pin
Jack Assembly
Hex Nut, Self Locking
Bushing
Safety Chain
Cap Screw, M12 x 1.75 x 100mm
Flat Washer
Cap Screw, M12 x 1.75 x 80mm
Wiring Harness
Ball Hitch
Hex Nut, Self Locking, M12 x 1.75
Hex Nut, Self Locking
Cap Screw, 3/8”-16 x 1”
Housing, Coupler With Bearings
Overrun Shaft
Damper, Gas Shock
Rubber Boot, Hitch

Qty
1
1
2
2
4
2
1
1
1
2
2
1
2
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
2
1
2
1
1
1
2
2
2
1
1
1
1

6-19

XLB-4319

6-9

AXLE AND WHEEL ASSEMBLY
PARTS LIST
Refer to Table 6-9 for the axle and wheel assembly parts list.

39
9

7
8

10
30

31
32
37
36

33
28,28A

27
26

25
35

17
24

16
23

11, 11A

Figure 6-9. Axle and Wheel Assembly

6-20

6 — PARTS LIST

Table 6-9. Axle and Wheel Assembly Parts List

Item No.
1
*
2
3
4
5
6
7
8
9
10
11
11A
12
13
14
15

Part No.

Description

Hex Nut, Self Locking
Kit, Fender (includes items 2, 3, & 6-10)
Bracket, Fender
Fender, Top Mount
Flat Washer
Cap Screw
0090-0033
Cap Screw, 5/16”-18 x 1-3/4”
B07-06-5772
Fender Mount
0090-0420
Flat Washer, 5/16”
0090-0185
Nut, Lock, 5/16”-18
0090-0645
Cap Screw, 5/16”-18 x 1/2”
B08-02-0012
Tire
B08-02-0013
Rim Only
B10-00-0062
Bolt, Wheel Lug, Conical, M12 x 1.5
B10-00-0063
Dust Cap
B10-00-0061
Flange Nut, Spindle
B21-00-0025
Brake Drum with Bearings, Nut Mount Spindle
B21-00-0025B
Brake Drum with Bearings, Bolt Mount Spindle
16
B25-00-0077
Wheel Bearing, Nut Mount Spindle
B25-00-0077B
Wheel Bearing, Bolt Mount Spindle
17
B10-00-0083
Retaining Ring, Nut Mount Spindle
B10-00-0083B
Retaining Ring, Bolt Mount Spindle
18
B10-00-0077
Pull-off Spring
19
B10-00-0078
Expanding Clutch
20
B21-00-0024
Brake Shoe (pair)
21
B10-00-0079
Spindle, Nut Mount
B10-00-0079B
Spindle, Bolt Mount
22
B10-00-0080
Cable Eye
23
B12-00-0126
Brake Cable
24
B10-00-0081
Spring, Reverse Lever
25
B10-00-0076
Bearing Bolt
26
B10-00-0075
Spring, Shoe Retaining
27
B10-00-0074
Cotter Pin
28
B10-00-0072
Reverse Lever LH Side
28A
B10-00-0073
Reverse Lever RH Side
29
B10-00-0065
Brake Adjuster Assembly
30
B10-00-0071
Plug, Plastic
31
B10-00-0070
Cover Plate
32
B10-00-0069
Lock Nut, Nut Mount Spindle
B10-00-0082
Bolt, M20 x 60mm, Bolt Mount Spindle (not
shown)
33
B10-00-0068
Cover, Spindle Lock Nut, Nut Mount Spindle Only
34
B10-00-0067
Backplate Cap
35
B10-00-0066
Brake Cable Shell
36
Hex Nut, Self Locking
37
Flat Washer
38
B10-00-0064
Axle Assembly
39
Cap Screw
* Order fender kit B22-00-0026 when replacing original side mounted fender.
B22-00-0026
B29-00-0154
B18-00-0109

Qty
4
2
2
2
4
4
4
4
16
4
8
2
2
8
2
2
2
4
2
2
2
2
2
2
2
2
2
2
2
1
1
2
4
2
2

2
2
2
4
4
1
4
6-21

XLB-4319

6-10 REAR LIGHTS AND JUNCTION BOX PARTS LIST
Refer to Table 6-10 for the rear lights and junction box parts list.

5
2
7
4

8
6
11

5
1

Figure 6-10. Rear Lights and Junction Box

6-22

6 — PARTS LIST

Table 6-10. Rear Lights and Junction Box Parts List
Item No.

Part No.

Description

Qty

B01-10-0023

Tail Light Assembly, Right

B01-10-0024

Tail Light Assembly, Left

0090-0934

Screw, Self Tapping, 1/4"-20 x 3/4"

B29-00-0037

Bracket, License Plate

B01-10-0069

Lens, Replacement

B01-09-0023

Anchor Plate, Wire Tie

B01-09-0030

Wire Tie, 3/32” x 6 1/4"

B01-10-0014

Junction Box

B01-10-0049

Cover, Junction Box

B01-09-0029

Cord Grip

B01-09-0010

Cord Cap

6-23

XLB-4319

6-11 OUTRIGGERS PARTS LIST
Refer to Table 6-11 for the outriggers parts list.
1
2
3, 3A,
3B, 3C
4

5
20

7
8

9
10, 10A, 10B

19
22

11, 11A

19 18

17
16
12

15
14
13

Figure 6-11. Outriggers
6-24

6 — PARTS LIST

Table 6-11. Outriggers Parts List
Item No.

Part No.

Description

Qty

Dust Shield

Grease Fitting

B02-03-0026

Hydraulic Cylinder, Outrigger

B25-00-0084

Bushing, Cylinder Pivot

B02-13-0109

Seal Kit, Outrigger

B02-14-0060

Check Valve, Outrigger

B02-01-0174

Hydraulic Hose Assembly, 6 mm, C15

B02-01-0175

Hydraulic Hose Assembly, 6 mm, C16

B02-01-0176

Hydraulic Hose Assembly, 6 mm, C17

B02-01-0177

Hydraulic Hose Assembly, 6 mm, C18

B02-00-0044

1/4 Dowty Washer

B02-02-0203

Adapter, 90°, 1/4 BSP Male-1/4 BSP Male

B01-03-0059

Cable, Limit Switch

Socket Head Cap Screw

Flat Washer

B01-03-0051

Limit Switch, Body With 2 NC Contacts

10A

B01-03-0003

Head, Limit Switch

10B

B01-03-0057

Contact Only, 2 NC

B23-01-0099

Outrigger

11A

B25-00-0084

Bushing, Outrigger

B23-02-0064

Outrigger Footpad

B23-02-0065

Hinge Pin, 16mm dia. x 102mm

Split Pin, 0.19 in. dia. x 1 in.

Trimlock

Sleeve, Hinge Pin

7 in.

B36-00-0057

Pivot Pin, 30mm dia. x 167mm

B36-00-0042

Locking Pin

Cap Screw

Lock Washer

Flat Washer

Hex Nut, Self Locking

Pivot Pin, 30mm dia. x 211mm

Flat Washer

Split Pin, 0.25 in. dia. x 2 in.

Pivot Pin, 30mm dia. x 201mm

B36-00-0055

B36-00-0058

6-25

XLB-4319

6-12 BASKET PARTS LIST
Refer to Table 6-12 for the basket parts list.

17
16
15
14

1
C1

18
19
2

18
19
1, 1C

7
6

4
5
6
7
8

5
9
10
23

13
6
5
6

Figure 6-12. Basket
6-26

6 — PARTS LIST

Table 6-12. Basket Parts List
Item No.

Part No.

Description

Qty

B02-03-0030

Hydraulic Cylinder, Cage

B25-00-0087

Bushing, Cage Cylinder, Cylinder End

B25-00-0085

Bushing, Cage Cylinder, Rod End

B02-13-0110

Seal Kit, Cage Cylinder End Cap With Groove

B02-13-0116

Seal Kit, Cage Cylinder End Cap Without
Groove

Grease Fitting

Spacer

B36-00-0065

Pivot Pin, 16mm dia. x 102mm

B36-00-0042

Locking Pin

Flat Washer

Lock Washer

Cap Screw

Spacer

B36-00-0061

Pivot Pin, 25mm dia. x 330mm

B17-00-0126

Basket Weldment

B36-00-0064

Pivot Pin, 16mm dia. x 108mm

Hex Nut

Hydraulic Hose Assembly, 6 mm, C11

Flexible Sleeve

Hydraulic Hose Assembly, 6 mm, C12

Flexible Sleeve

13
14

B02-01-0165

15
16

B02-01-0171

17
18

B02-02-0210

Adapter, Straight 1/4 BSP Male-1/4 BSP Male

B02-00-0044

1/4 Dowty Washer

B05-00-0001

Tube, Foam, 21 1/2" Long

B06-00-0167

Caution Tape, Black and Yellow

B00-00-0086

Casing, Wire, Slit, 5/16” Dia. x 8 1/2" Long

B01-09-0030

Wire Tie, 3/32” x 7”

1 Roll

6-27

XLB-4319

6-13 OUTRIGGER HYDRAULIC CONTROLS PARTS LIST
Refer to Table 6-13 for the outrigger hydraulic controls parts list.

5
C1 16 7
C C1
C1

3
6

2
1

5
C1 16 7
C 1
C
C1

10
9

11
12

Figure 6-13. Outrigger Hydraulic Controls

6-28

6 — PARTS LIST

Table 6-13. Outrigger Hydraulic Controls Parts List
Item No.

Part No.

B02-01-0173

Hydraulic Hose Assembly, 6 mm, C14

B02-01-0174

Hydraulic Hose Assembly, 6 mm, C15

B02-01-0175

Hydraulic Hose Assembly, 6 mm, C16

B02-01-0176

Hydraulic Hose Assembly, 6 mm, C17

B02-01-0177

Hydraulic Hose Assembly, 6 mm, C18

B02-02-0205

Adapter, Straight, 1/4 BSP Male-3/8 BSP Male

B02-00-0043

3/8 Dowty Washer

B02-04-0075

Valve Control

B02-14-0068

Lever Pivot Box With Gaiter

B02-14-0069

End Cap With Spring

B02-14-0053

Handle, Valve Control

Flat Washer

Self Locking Hex Nut

Flat Washer

Cap Screw

Hydraulic Hose Assembly, 6 mm, C38 (Gas
Model Only)

Adapter, Straight With Orifice, 1/4 BSP Male3/8 BSP Male

B02-02-0204

Description

Qty

6-29

XLB-4319

6-14 LOWER CONTROLS PARTS LIST
Refer to Table 6-14 for the lower controls parts list.
5B
5C

2
1*

3
5A

6
7
8

9
5
17

10
14

22*

21*
20* 19*
18*

13
14
16
15

Figure 6-14. Lower Controls

6-30

6 — PARTS LIST

Table 6-14. Lower Controls Parts List
Item No.

Part No.

Description

Qty

Battery Charger

Cap Screw

Flat Washer

Standoff, Hex

B02-04-0074

Valve Control, Boom Lift

B02-14-0068

Lever Pivot Box With Gaiter

B02-14-0069

End Cap With Spring

B02-14-0053

Handle, Valve Control

Hex Nut, Self Locking

Flat Washer

Support Bracket, Control Box

Lower Control Box

Strain Relief

Screw, 1/4 Turn, Control Box

Strain Relief

Hex Nut, Self Locking

Flat Washer

Hex Nut, Self Locking

Flat Washer

Cap Screw

18*

Cap Screw

19*

Lock Washer

20*

Cap Screw

21*

Lock Washer

22*

Support Bracket

10
11

B04-07-0130

* This item used on DC model boom lift only.

6-31

XLB-4319

6-15 UPPER CONTROLS PARTS LIST
Refer to Table 6-15 for the upper controls parts list.
15
15

17
1

5
14

19
13

3
4

12
9
8
10
11

Figure 6-15. Upper Controls
6-32

6 — PARTS LIST

Table 6-15. Upper Controls Parts List
Item No.

Part No.

Description

Qty

B17-00-0129

Cover, Basket Hydraulics

B02-04-0076

Valve Control

B02-14-0068

Lever Pivot Box With Gaiter

B02-14-0069

End Cap With Spring

B02-14-0052

Handle, Valve Control

0090-0420

Flat Washer, 5/16”

0090-0185

Hex Nut, Self-locking, 5/16”-18

0090-0182

Hex Nut, Self-locking, 10-24

0090-0419

Flat Washer, 1/4”

0090-0183

Hex Nut, Self-locking, 1/4”-20

0090-0415

Flat Washer, #10

B01-10-0046

Junction Box, 110 Vac Outlet

0090-0232

Machine Screw, 10-24 x 3/8

B01-10-0034

Receptacle, 120 Vac, GFI

B01-10-0035

Cover, Junction Box

Manual Hydraulic Pump

13
14

B04-07-0120

Clamp

0090-0344

Screw, Self Tapping, #10-24 x 1/2

B40-00-0033

Chain

B07-10-1200

Handle, Hydraulic Pump

0090-0456

Cap Screw, 1/4"-20 x 3”

0090-0037

Cap Screw, 5/16”-18 x 2 1/2"

Control Box, Upper

10 in.

0090-0232

Machine Screw, #10-24 x 5/8”

B00-00-0014

Cap, Manual Tube

6-33

XLB-4319

6-16 ENGINE COMPARTMENT PARTS LIST,
GAS MODEL
Refer to Table 6-16 for the gas model engine compartment parts list.

7
8

9
10

62
2

61
60

3
11

12
5

54
55

46
47

49
48

19
20

37
36
33

34
35

28
31
25
29

57
30

27
26

24
23
22
21

Figure 6-16. Engine Compartment Parts List, Gas Model
6-34

6 — PARTS LIST

Table 6-16. Engine Compartment Parts List, Gas Model
Item No.

Part No.

Description

Qty

Engine Cover

Lock Washer

Cap Screw

Lock Washer

Flat Washer

Cap Screw

Socket Head Cap Screw

Lock Washer

Flange Adapter

O-ring

Seal Ring

Adapter, M/M

Hydraulic Hose Assembly, Pump Supply

0090-0420

Flat Washer, 5/16”

0090-0208

Lock Washer, 5/16”

0090-0030

Machine Screw, 5/16”-18 x 1”

Seal Ring

Adapter, M/M

Hydraulic Hose Assembly, 6mm, C33

Spiral Wrap

0090-0714

Cap Screw, 1/4"-20 x 2 3/4"

0090-0787

Washer, Fender

B07-10-1026

Spacer, Isolation Mount Ring

B20-00-0006

Ring, Isolation Mount

B20-00-0007

Bushing, Isolation Mount

0090-0010

Cap Screw, 1/4"-20 x 1 1/2"

0090-0419

Flat Washer, 1/4"

0090-0183

Nut, Lock, 1/4"-20

B20-00-0013

Rectifier/Regulator, Voltage, 12 Volt, 18 Amp

Rectifier/Regulator Harness

30
31

B07-06-5198

Engine Mount Plate

0090-0875

Flat Washer, USS, 1/4"

0090-0183

Nut, Lock, 1/4"-20

0090-0472

Sheet Metal Screw, #10 x 1/2"

0090-0180

Nut, Lock, #6-32

B29-00-0095

Bracket, Solenoid

B01-10-0084

Solenoid, Choke, 12 Volt

0090-0708

Machine Screw, #6-32 x 3/8”

6-35

XLB-4319

6-16 ENGINE COMPARTMENT PARTS LIST,
GAS MODEL
Refer to Table 6-16 for the gas model engine compartment parts list.

7
8

9
10

61
60

3
11

12
5

54
55

46
47

49
48

19
20

37
36
33

34
35

28
31

25
29

27
26

24
23
22
21

Figure 6-16. Engine Compartment Parts List, Gas Model
6-36

6 — PARTS LIST

Table 6-16. Engine Compartment Parts List, Gas Model (continued)
Item No.
39

Part No.
B20-00-0009

Description

Qty

Engine, Honda, 8 Horsepower

Square Key

Coupling Half, Engine Shaft

Damper, Coupler

Bell Housing

0090-0420

Flat Washer, 5/16”

0090-0208

Lock Washer, 5/16”

0090-0974

Cap Screw, 5/16”-24 x 1”

Hex Nut

Flat Washer

Coupling Half, Pump Shaft

Washer

Woodruff Key

Hydraulic Pump, Gas Engine

Flange Adapter

B02-05-0033

53
54

B01-04-0013

Battery, 12 Volt DC

B07-06-5110

Hold-Down Strap, Battery

B04-07-0003

Hold-Down Rod, Battery

0090-0183

Nut, Lock, 1/4"-20

B01-01-0005

Battery Cable, 22”, Positive To Starter

B01-01-0006

Battery Cable, 16”, Negative To Bell Housing

Side Access Cover

Cap Screw

Flat Washer

Self Locking Hex Nut

6-37

XLB-4319

6-17 BOOM CONTROL HYDRAULICS PARTS LIST,
BASKET
Refer to Table 6-17 for the boom control hydraulics parts list.

2
2
13

C6
C27

C27

C12

9
C8
C11

4
19

18
8

12
2
13

17
C2

Figure 6-17. Boom Control Hydraulics, Basket
6-38

6 — PARTS LIST

Table 6-17. Boom Control Hydraulics Parts List, Basket
Item No.

Part No.

Description

Qty

B02-04-0076

Valve Control, Basket

B02-14-0068

Lever Pivot Box With Gaiter

B02-14-0069

End Cap With Spring

B02-14-0052

Handle, Valve Control

B02-00-0043

3/8 Dowty Washer

B02-02-0206

Adapter, Straight, 3/8 BSP Male-3/8 BSP Male

B02-02-0209

Tee Adapter, 3/8 BSP Female Swivel-1/4 BSP
Male-3/8 BSP Male

B02-01-0159

Hydraulic Hose Assembly, 6 mm, C4

B02-01-0160

Hydraulic Hose Assembly, 6 mm, C7

B02-01-0166

Hydraulic Hose Assembly, 6 mm, C5

B02-01-0168

Hydraulic Hose Assembly, 6 mm, C8

B02-01-0165

Hydraulic Hose Assembly, 6 mm, C11

B02-01-0164

Hydraulic Hose Assembly, 6 mm, C27

Spiral Wrap

Check Valve

B02-02-0205

Adapter, Straight, 1/4 BSP Male-3/8 BSP Male

B02-01-0157

Hydraulic Hose Assembly, 10 mm, C2

B02-01-0171

Hydraulic Hose Assembly, 6 mm, C12

Spiral Wrap

16
17

B02-01-0169

Hydraulic Hose Assembly, 6 mm, C9

B02-01-0164

Hydraulic Hose Assembly, 6 mm, C27

B02-01-0167

Hydraulic Hose Assembly, 6 mm, C6

B02-01-0158

Hydraulic Hose Assembly, 6 mm, C3

B02-01-0156

Hydraulic Hose Assembly, 10 mm, C1

B02-01-0170

Hydraulic Hose Assembly, 10 mm, C10

B02-02-0208

Tee Adapter, 3/8 BSP Female Swivel-3/8 BSP
Male-3/8 BSP Male

B02-02-0044

1/4 Dowty Washer

B02-02-0210

Adapter, Straight, 1/4 BSP Male-1/4 BSP Male

Wire Tie

Pump, Emergency Down

Tee Adapter, 1/4 BSP Female Swivel-1/4 BSP
Male-1/4 BSP Male

Cable Sleeve

28
29

B02-02-0207

6-39

XLB-4319

6-18 BOOM CONTROL HYDRAULICS PARTS LIST,
GROUND, GAS MODEL
Refer to Table 6-18 for the gas model boom control hydraulics parts list.
C3

1, 1A, 1B
2

3
2

2
3

6, 6A, 6B
C

7
30

16
2 3

32
33

11
8

25
23

C21

24
19

C22

12C

C28

12B
26

12A

2
13
14

Figure 6-18. Gas Model Boom Control Hydraulics, Ground
6-40

C32

24 C29

C27

C24

C27
C3

C29

21
20

C29

C35

C34

C25

6 — PARTS LIST

Table 6-18. Gas Model Boom Control Hydraulics Parts List, Ground
Item No.
1
1A
1B
2
3
4
5
6
6A
6B
7
8
9
10
11
12
12A
12B
12C
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34

Part No.
B02-04-0086
B02-04-0072
B02-14-0070
B02-00-0043
B02-02-0205

B02-04-0086
B02-04-0072
B02-14-0070
B02-01-0161
B02-01-0162
B02-01-0164
B02-04-0074
B02-14-0068
B02-14-0069
B02-14-0053
B02-02-0206
B02-01-0183
B02-01-0157
B02-02-0207
B02-01-0181
B02-01-0180
B02-01-0184
B02-01-0159
B02-01-0158
B02-02-0212
B02-02-0211
B02-00-0042
B02-06-0009
B02-01-0160

Description

Qty

2-Way Solenoid Valve, SV1, Boom Enable
Coil For Valve, SV1, 12V DC
Valve Replacement, SV1
3/8 Dowty Washer
Adapter, Straight, 1/4 BSP Male-3/8 BSP Male
Hydraulic Hose Assembly, 6 mm, C36
Hydraulic Hose Assembly, 6 mm, C38
2-Way Solenoid Valve, SV2, Outriggers Enable
Coil For Valve, SV2, 12V DC
Valve Replacement, SV2
Hydraulic Hose Assembly, 6 mm, C37
Hydraulic Hose Assembly, 6 mm, C24
Hydraulic Hose Assembly, 6 mm, C25
Hydraulic Hose Assembly, 6 mm, C27
Hydraulic Hose Assembly, 6 mm, C32
Valve Control, Ground Station Boom
Lever Pivot Box With Gaiter
End Cap With Spring
Handle, Control Valve
Adapter, Straight, 3/8 BSP Male-3/8 BSP Male
Hydraulic Hose Assembly, 10 mm, C28
Hydraulic Hose Assembly, 6 mm, C2
Tee Fitting, 1/4 BSP Female Swivel-1/4 BSP
Male-1/4 BSP Male
Hydraulic Hose Assembly, 6 mm, C22
Hydraulic Hose Assembly, 6 mm, C21
Hydraulic Hose Assembly, 6 mm, C29
Hydraulic Hose Assembly, 6 mm, C4
Hydraulic Hose Assembly, 6 mm, C3
Wire Tie
Tee Fitting, 1/4 BSP Male-1/4 BSP Female
Swivel-1/4 BSP Male
Adapter, Straight, 1/4 BSP Male-1/2 BSP Male
1/2 Dowty Washer
Gear Motor, Boom Rotation
Hydraulic Hose Assembly, 6 mm, C7
Hydraulic Hose Assembly, 6 mm, C34
Pressure Valve, Hydraulic
Hydraulic Hose Assembly, 6 mm, C33
Tee Fitting, M/M/F
Seal Ring
Pressure Tap
Hydraulic Hose Assembly, 6 mm, C35

1
1
1
19
18
1
1
1
1
1
1
1
1
2
1
1
4
4
4
1
1
1
3
1
1
2
1
1
AR
2
2
2
1
2
1
1
1
1
1
1
1

6-41

XLB-4319

6-19 BOOM CONTROL HYDRAULICS PARTS LIST,
GROUND, DC MODEL
Refer to Table 6-19 for the DC model boom control hydraulics parts list.
1

3
2

4, 4A, 4B

9
C1
3

3
5

9
8
6

21
25

C25

C22

C24

C21

22
23

C29

21
25

C29

C27

10C

C28

10B
24

10A

2
11
12

Figure 6-19. DC Model Boom Control Hydraulics, Ground
6-42

C27

6 — PARTS LIST

Table 6-19. DC Model Boom Control Hydraulics Parts List, Ground
Item No.

Part No.

Description

Qty

B02-01-0179

Hydraulic Hose Assembly, 6 mm, C20

B02-00-0043

3/8 Dowty Washer

B02-02-0205

Adapter, Straight, 1/4 BSP Male-3/8 BSP Male

B02-04-0085

2-Way Solenoid Valve, SV1, Boom Enable

B02-14-0056

Coil For Valve, SV1, 24V DC

B02-14-0070

Valve Replacement, SV1

B02-01-0172

Hydraulic Hose Assembly, 6 mm, C13

B02-01-0161

Hydraulic Hose Assembly, 6 mm, C24

B02-01-0162

Hydraulic Hose Assembly, 6 mm, C25

B02-01-0164

Hydraulic Hose Assembly, 6 mm, C27

B02-01-0178

Hydraulic Hose Assembly, 6 mm, C19

B02-04-0074

Valve Control, Ground Station Boom

10A

B02-14-0068

Lever Pivot Box With Gaiter

10B

B02-14-0069

End Cap With Spring

10C

B02-14-0053

Handle, Control Valve

B02-02-0206

Adapter, Straight, 3/8 BSP Male-3/8 BSP Male

B02-01-0183

Hydraulic Hose Assembly, 10 mm, C28

B02-01-0157

Hydraulic Hose Assembly, 6 mm, C2

B02-02-0207

Tee Fitting, 1/4 BSP Female Swivel-1/4 BSP
Male-1/4 BSP Male

B02-01-0181

Hydraulic Hose Assembly, 6 mm, C22

B02-01-0180

Hydraulic Hose Assembly, 6 mm, C21

B02-01-0184

Hydraulic Hose Assembly, 6 mm, C29

B02-01-0159

Hydraulic Hose Assembly, 6 mm, C4

B02-01-0158

Hydraulic Hose Assembly, 6 mm, C3

Wire Tie

B02-02-0212

Tee Fitting, 1/4 BSP Male-1/4 BSP Female
Swivel-1/4 BSP Male

B02-02-0211

Adapter, Straight, 1/4 BSP Male-1/2 BSP Male

B02-00-0042

1/2 Dowty Washer

B02-06-0009

Gear Motor, Boom Rotation

B02-01-0160

Hydraulic Hose Assembly, 6 mm, C7

6-43

XLB-4319

6-20 LOWER BOOM CYLINDER HYDRAULICS
PARTS LIST
Refer to Table 6-20 for the lower boom cylinder hydraulics parts list.

C
21

2
C2

3
2
3
3

Figure 6-20. Lower Boom Cylinder Hydraulics
Table 6-20. Lower Boom Cylinder Hydraulics Parts List

6-44

Item No.

Part No.

Description

Qty

B02-01-0180

Hydraulic Hose Assembly, 6mm, C21

B02-02-0210

Adapter, Straight, 1/4 BSP Male-1/4 BSP Male

B02-00-0044

1/4 Dowty Washer

B02-01-0181

Hydraulic Hose Assembly, 6mm, C22

B02-02-0203

Elbow, 90°, 1/4 BSP Male-1/4 BSP Male

6 — PARTS LIST

6-21 UPPER BOOM CYLINDER HYDRAULICS
PARTS LIST
Refer to Table 6-21 for the upper boom cylinder parts list.

2
3

2
8

1 C24
C26
5

C25

6
7

Figure 6-21. Upper Boom Cylinder Hydraulics
Table 6-21. Upper Boom Cylinder Hydraulics Parts List
Item No.

Part No.

Description

Qty

B02-02-0203

Elbow, 90°, 1/4 BSP Male-1/4 BSP Male

B02-00-0044

1/4 Dowty Washer

B02-01-0166

Hydraulic Hose Assembly, 6mm, C5

B02-01-0158

Hydraulic Hose Assembly, 6mm, C3

B02-01-0161

Hydraulic Hose Assembly, 6mm, C24

B02-01-0163

Hydraulic Hose Assembly, 6mm, C26

B02-01-0162

Hydraulic Hose Assembly, 6mm, C25

B02-02-0210

Adapter, Straight, 1/4 BSP Male-1/4 BSP Male

6-45

XLB-4319

6-22 PUSHBUTTON PANEL PARTS LIST, BASKET
Refer to Table 6-22 for the basket pushbutton panel parts list.
4

3
1

5
8

2
6

12
11
10

17, 18
13
15, 16
14
9

Figure 6-22. Basket Pushbutton Panel

6-46

6 — PARTS LIST

Table 6-22. Basket Pushbutton Panel Parts List
Item No.

Part No.

Description

Qty

B19-00-0042

Enclosure, Upper Control Box, DC Model

B19-00-0043

Enclosure, Upper Control Box, Gas Model

B01-09-0023

Cord Grip

B01-02-0085

Pushbutton Switch, Boom Enable, Green

B01-02-0084

Pushbutton Switch, Emergency Stop, Red

B06-00-0441

Decal, Upper Controls

B01-10-0002

Audible Warning Device (Alarm)

B01-02-0098

Pushbutton Switch, Engine Start, SW2, Yellow
(Gas Model Only)

B06-00-0442

Decal, Engine Start (Gas Model Only)

B01-09-0021

Nut, Electric Lock

B01-02-0086

NC Contact

B01-02-0087

NO Contact (Gas Model Only)

B01-02-0087

NO Contact, DC Model

NO Contact, Gas Model

B01-09-0050

Butt Splice

B01-09-0032

Female Spade

B01-10-0031

3-Position Terminal Strip, DC Model

B01-10-0030

5-Position Terminal Strip, Gas Model

B01-10-0090

5-Position Marker Strip (Gas Model Only)

0090-0813

Screw, Machine, 8-32 x 3/4"

0090-0181

Nut, Lock, 8-32

6-47

XLB-4319

6-23 PUSHBUTTON PANEL PARTS LIST,
GROUND CONTROLS
Refer to Table 6-23 for the pushbutton panel parts list.
3

Figure 6-23. Pushbutton Panel, Ground Controls
Table 6-23. Pushbutton Panel Parts List, Ground Controls
Item No.

6-48

Part No.

Description

Qty

B01-02-0085

Pushbutton Switch, Boom Enable, PB2

B01-02-0089

Pushbutton Switch, Outriggers Enable, PB3

B01-02-0084

Pushbutton Switch, Emergency Stop, PB1

B01-02-0088

Key Switch, Basket/Off/Ground, SW1

B01-02-0101

5-Contact Mount Adapter

B01-02-0102

Double NO Contact (Gas model only)

Control Panel Closure

Alarm Relay, RL2

Motor Contactor (DC model only)

Circuit Breaker

Terminal Block Segment

B01-10-0243

LED, Green

B04-07-0130

Screw, 1/4 Turn, Control Box

B01-02-0086

NC Contact

B01-02-0087

NO Contact

ANSI Reprint
The following sections are reprinted from the ANSI A92.2-2001 code in effect at the
time of manufacture. Permission to reprint has been granted by the Scaffold
Industry Association.

Responsibilities of Dealers and Installers

7.1 General Responsibilities. Each dealer or installer as applicable shall comply with
the requirements of this section.
7.2 Vehicle Specifications. Each dealer or installer, or both, who sells an aerial device
shall inform the owner or user, or both, of the manufacturer’s minimum vehicle
specifications.
7.3 Vehicle Weight Distribution. The installer shall be responsible for the weight distribution of the completed mobile unit in accordance with the requirements of the
aerial device and the applicable regulations. Allowance shall be made for the
weight of readily removable tools and material specified by the user.
7.4 Manuals. Upon delivery of the equipment to the owner or user, the dealer or installer shall provide the manuals as required by Paragraph 6.4 of this standard and
manuals for auxiliary equipment added by the installer.
7.5 Installations. The installer shall comply with Sections 5 and 6 of this standard relating to proper installation and shall follow the instructions of the manufacturer. In
the event the original manufacturer no longer exists, an equivalent entity may provide these instructions. The installer of an aerial device shall, before the mobile unit
is placed in operation, perform stability tests in accordance with the requirements of
4.5.1 and 4.5.2, the operational and visual tests in accordance with the requirements
of 6.6.1 and 6.6.2, and the appropriate electrical tests required in 5.4.3 of this standard. The installer shall, when installing an aerial device on a chassis which is a
highway vehicle, comply with all requirements of the applicable Federal Motor Vehicle Safety Standards in effect at the time of installation. Certification as a manufacturer (alteration, intermediate or final) of a motor vehicle under the Federal Motor Vehicle Safety Standards is required. The travel height of the mobile unit shall
be posted in a location that is readily visible to the vehicle operator. For insulated
aerial devices, the installer shall assure conformance to the Qualification test requirements of 5.3.2 by either obtaining certification of the test and performing a periodic test after installation, or by performing the Qualification test.
7.6 Quality Assurance. The installer shall have a documented quality assurance program which will ensure compliance with this standard.
7.7 Welding. All welds made by the installer, whose failure could result in motion of
the platform(s) shall meet the Structural Welding Code AWS D1.1-98 and AWS
Dl.2-98. The installer shall establish applicable welding quality assurance procedures for all weldments.
7.8 Training. The dealer or installer shall offer training or training materials that aid
owners and users in the operation, inspection, testing and maintenance of the aerial
device. This training shall be offered initially and subsequently on request.
7.8.1 Dealer or Installer as User. Whenever a dealer or installer directs personnel to operate an aerial device (inspecting, sales demonstrations, or any form of use), the
dealer or installer shall assume the responsibilities of users as specified in Section 9
of this standard. All personnel authorized to operate the aerial device shall have
been trained.

7-1

XLB-4319

Responsibilities of Owners

8.1 General Responsibilities. Each owner shall comply with the requirements of this
section. The following responsibilities pertain to the owner’s inspection, testing,
maintenance, modification, training, and transfer of ownership. These activities
shall be performed by qualified person(s).
8.2 Inspection and Testing Classifications.
8.2.1 Initial Inspection and Test. Prior to initial use, all new or modified mobile units
shall be inspected and tested to ensure compliance with the provisions of this standard. Verification by the manufacturer, the installer or an equivalent entity(s),
meets this requirement.
8.2.2 Regular Inspection and Tests. The inspection procedure for mobile units is divided into two classifications based upon the intervals at which inspections and
tests shall be performed. Intervals shall be set by the owner in accordance with the
manufacturer’s recommendations. Such intervals are dependent upon component
function and exposure to wear, deterioration and other agents which adversely affect component life. Two classifications are designated:
(1) Frequent Inspection and Test: Daily to monthly intervals.
(2) Periodic Inspection and Test: One to twelve month intervals.
8.2.3 Frequent Inspection and Test. Items determined by the owner in accordance with
the manufacturer’s recommendations for each specific aerial device shall be inspected for defects. The following tests and inspections shall be performed by the
operator once daily, prior to first use:
(1) Operating controls and associated mechanisms for conditions interfering
with proper operation.
(2) Visual and audible safety devices for malfunction.
(3) Hydraulic or pneumatic systems for observable deterioration or excessive
leakage.
(4) Fiberglass and other insulating components for visible damage or contamination.
(5) Missing or illegible operational and instructional markings.
(6) Electrical systems of/or related to the aerial device for malfunction, signs of
excessive deterioration, dirt and moisture accumulation.
(7) Visual inspection of bolts, pins, and other fasteners for loose, deformed or
missing fasteners and other locking devices. Any suspected items shall be
carefully examined or tested and a determination made by a qualified person as to whether they constitute a safety hazard. All unsafe items shall be
replaced or repaired before use.
8.2.4 Periodic Inspection or Test. An inspection of the mobile unit shall be performed
at the intervals defined in 8.2.2 depending upon its activity, severity of service, and
environment, or as specifically indicated below. (These inspections shall include
the requirements of 8.2.3):
(1) Structural members for deformation, cracks or corrosion
(2) Parts, such as pins, bearings, shafts, gears, rollers, locking devices, chains,
chain sprockets, wire and synthetic ropes, and sheaves for wear, cracks or
distortion.
(3) Hydraulic and pneumatic relief valve settings.
(4) Hydraulic system for proper oil level.
(5) Hydraulic and pneumatic fittings, hoses, and tubing for evidence of leakage, abnormal deformation or excessive abrasion.
(6) Compressors, pumps, motors, and generators for loose fasteners, leaks, unusual noises or vibrations, loss of operating speed, and excessive heating.
(7) Hydraulic and pneumatic valves for malfunction and visible cracks in the
external valve housing, leaks, and sticking spools.
(8) Visually inspect any vacuum prevention systems and verify function of
such systems on Category “A” aerial devices.

7-2

7 — ANSI REPRINT

(9) Hydraulic and pneumatic cylinders and holding valves for malfunction and
visible damage.
(10) Hydraulic and pneumatic filters for cleanliness and the presence of foreign material in the system indicating other component deterioration.
(11) Electrical systems and components for deterioration or wear including those
not readily visible on a frequent inspection.
(12) Performance test of all boom movements.
(13) Condition and tightness of bolts and other fasteners.
(14) Welds, as specified by the manufacturer.
(15) Legible and proper identification, operational, and instructional markings.
(16) If the aerial device is rated as an insulated device, the electrical insulating
components and system(s) shall be thoroughly inspected for lack of cleanliness
and other conditions that compromise insulation. Then these components and
system(s) shall be tested for compliance with the rating of the aerial device in
accordance with one of the applicable methods and procedures as outlined in
section 5.4.3 of this standard:
(a) If the aerial device is used for AC bare-hand work, the unit shall undergo a
60 Hz test as shown in Table 2 at least every three years;
(b) If the aerial device is used for DC bare-hand work, the unit shall undergo a
DC test as shown in Table 2 at least every three years;
(c) After repair or modification of any component that crosses the insulating
system(s), or the repair or replacement of an insulating component(s), the
unit shall be dielectrically tested in accordance with section 5.4.3;
(d) An insulated replacement boom shall be tested to insure conformance to
5.3.3 by the supplier;
(e) Bare-hand work units shall be tested as shown in Table l after any major
repair to the insulated boom or any insulated boom replacement. Any suspected items shall be carefully examined or tested and a determination
made by a qualified person as to whether they constitute a safety hazard.
All unsafe items shall be replaced or repaired before use.
8.3 Inspection and Test Records.
(l) Items to be inspected shall be designated to the operator or other authorized person making frequent inspections. Records of frequent inspections need not be
made. However, where a safety hazard is found, it shall be reported in writing to a
person responsible for the corrective action and that report and a record of the correction shall be maintained for five years, or as required by applicable regulations.
(2) Written, dated and signed reports and records shall be made of periodic inspections and tests and retained for a period of five years or as required by applicable
regulations.
8.4 Maintenance. Maintenance and frequency of maintenance shall be determined by
the owner in accordance with the manufacturer’s recommendations. Welding repairs of components or welds, designated as critical in the manufacturers manual,
shall be made in accordance with the manufacturers recommendations. Should the
original manufacturer no longer exist an equivalent entity may determine the required procedure.
8.4.1 Maintenance Training. The owner shall train their maintenance personnel in inspection and maintenance of the aerial device in accordance with the manufacturer’s recommendations and Section 8 of this standard.
8.5 Modifications. No modifications or additions which affect the stability, mechanical, hydraulic, or electrical integrity or the safe operation of the aerial device shall
be made without the written approval of the manufacturer. If such modifications or
changes are made, the capacity, operation, and maintenance instruction markings
shall be changed accordingly. In no case shall the safety factors be reduced below
those specified in this standard or below the manufacturers design safety factors,
whichever are greater. Should the original manufacturer no longer exist, an equivalent entity may approve required modification.
8.6 Weight Distribution. Changes in loading or additions made to the mobile unit after
the final acceptance that affect weight distribution shall meet applicable regulations
7-3

XLB-4319

by governmental agencies. In no case shall axle loads of the fully loaded vehicle
exceed the Gross Axle Weight Ratings (GAWR) assigned by the manufacturer.
Note: Any change in weight distribution may adversely affect stability.
8.7 Transfer of Ownership. When a change in ownership of an aerial device occurs, it
shall be the responsibility of the seller to provide the manufacturer's manual(s) for
that aerial device to the purchaser. It is the responsibility of the purchaser to notify
the manufacturer of the unit model and serial number and the name and address of
the new owner within 60 days.
8.8 Markings. The markings on the aerial device shall not be removed, defaced, or altered. All missing or illegible markings shall be promptly replaced.
8.9 Parts. When parts or components are replaced they shall be identical in specification and function to the original aerial device parts or components or shall provide
an equal or greater factor of safety.
8.10 Safety Bulletins. Owners shall comply with safety related bulletins as received
from the manufacturer, dealer or installer.
8.11 Manuals. The owner shall insure that the operating manual(s) is stored on the mobile unit.
8.12 Training, Retraining, and Familiarization of
Operators.
8.12.1 Owner as a Renter or Lessor. When an owner functions as a renter or lessor he
shall have the same responsibilities as specified under Section 11 of this standard.
8.12.2 General Training. Only personnel who have received general instructions regarding the inspection, application and operation of aerial devices, including recognition and avoidance of hazards associated with their operation, shall operate an aerial device. Such items covered shall include, but not necessarily be limited to,
the following issues and requirements:
(1) The purpose and use of manuals.
(2) That operating manuals are an integral part of the aerial device and must be
properly stored on the vehicle when not in use.
(3) A pre-start inspection.
(4) Responsibilities associated with problems or malfunctions affecting the operation of the aerial device.
(5) Factors affecting stability.
(6) The purpose of placards and decals.
(7) Workplace inspection.
(8) Applicable safety rules and regulations, such as Part 4, ANSI C2-1997, National Electrical Safety Code (applies to utility workers as defined in ANSI
C2). The above standard is an example; other industries using aerial devices
have safety rules pertinent to that industry.
(9) Authorization to operate.
(10) Operator warnings and instructions.
(11) Actual operation of the aerial device. Under the direction of a qualified person, the trainee shall operate the aerial device for a sufficient period of time
to demonstrate proficiency in the actual operation of the aerial device.
(12) Proper use of personal fall protection equipment
8.12.3 Retraining. The operator shall be retrained, when so directed by the user, based
on the user’s observation and evaluation of the operator.
8.12.4 Familiarization. When an operator is directed to operate an aerial device he/she
is not familiar with, the operator, prior to operating, shall be instructed regarding
the following items and issues :
(1) The location of the manuals.
(2) The purpose and function of all controls.
(3) Safety devices and operating characteristics specific to the aerial device.

Responsibility of Users.

9.1 General Responsibilities. Each User shall comply with the requirements of this
section.
7-4

7 — ANSI REPRINT

9.2 Personnel. Only trained and authorized personnel shall be permitted to operate the
aerial device.
9.3 Training, Retraining, and Familiarization of Operators.
9.3.1 General Training. Only personnel who have received general instructions regarding the inspection, application and operation of aerial devices, including recognition and avoidance of hazards associated with their operation, shall operate an aerial device. Such items covered shall include, but not necessarily be limited to, the
following issues and requirements:
(1) The purpose and use of manuals.
(2) That operating manuals are an integral part of the aerial device and must be
properly stored on the vehicle when not in use.
(3) A pre-start inspection.
(4) Responsibilities associated with problems or malfunctions affecting the operation of the aerial device.
(5) Factors affecting stability.
(6) The purpose of placards and decals.
(7) Workplace inspection.
(8) Applicable safety rules and regulations, such as Part 4, ANSI C2-1997, National Electrical Safety Code. (applies to utility workers as defined in ANSI
C2). The above standard is an example; other industries using aerial devices
have safety rules pertinent to that industry.
(9) Authorization to operate.
(10) Operator warnings and instructions.
(11) Actual operation of the aerial device. Under the direction of a qualified person, the trainee shall operate the aerial device for a sufficient period of time
to demonstrate proficiency in the actual operation of the aerial device.
(12) Proper use of personal fall protection equipment
9.3.2 Retraining. The operator shall be retrained, when so directed by the user, based on
the user’s observation and evaluation of the operator.
9.3.3 Familiarization. When an operator is directed to operate an aerial device he/she is
not familiar with, the operator, prior to operating, shall be instructed regarding the
following items and issues:
(1) The location of the manuals.
(2) The purpose and function of all controls.
(3) Safety devices and operating characteristics specific to the aerial device.
9.4 Application. The employer and assigned operator shall insure that the aerial device
is used only for intended applications as defined in the operating manual, and that
recognized safety practices are observed.
9.5 Mobile Operation. Before and during driving, the driver shall:
(1) Avoid traveling on any surface that adversely affects vehicle stability.
(2) Maintain a safe distance from obstacles and overhead lines.
(3) Maintain communications between the driver and the operator.
(4) Under all travel conditions, the driver shall limit travel speed in accordance
with conditions of the ground surface, congestion, and slope.
9.6 Alterations. Altering or disabling of safety devices, guards, or interlocks if so
equipped shall be prohibited.
9.7 Bare-Hand Work. For bare-hand work, a Category “A” aerial device shall be
used.
9.8 Lower Controls. The lower controls of aerial devices shall not be used for continuous operation with personnel in the platform.

10. Responsibilities of Operators
7-5

XLB-4319

10.1 General Responsibilities. Each operator shall comply with the requirements of this
section.
10.2 Operation. During operation of the aerial device all platform occupants shall use
appropriate fall protection connected to the aerial device at the platform position.
10.3 Work Platform. The operator shall not use railings, planks, ladders or any other
device in or on the work platform for achieving additional working height or reach.
10.4 Brakes. The vehicle parking brake(s) shall be set at all times that the boom is elevated except when the aerial device is being used in accordance with 9.5.
10.5 Loading. Any loading which includes a horizontal load shall be avoided unless the
mobile unit is designed for that application.
10.6 Observations. Observations during operation for any defects shall be conducted on
an ongoing basis.
10.6.1 Pre-start Inspection. Items determined by the owner in accordance with the
manufacturer’s recommendations for each specific aerial device shall be inspected
for defects prior to each day’s operation. The following tests and inspections shall
be performed by the operator once daily, prior to first use:
(1) Operating controls and associated mechanisms for conditions interfering
with proper operation.
(2) Visual and audible safety devices for malfunction.
(3) Hydraulic or pneumatic systems for observable deterioration or excessive
leakage.
(4) Fiberglass and other insulating components for visible damage or contamination.
(5) Missing or illegible operational and instructional markings.
(6) Electrical systems of/or related to the aerial device for malfunction, signs of
excessive deterioration, dirt and moisture accumulation.
(7) Visual inspection of bolts, pins, and other fasteners for loose, deformed or
missing fasteners and other locking devices. Any suspected items shall be
carefully examined or tested and a determination made by a qualified person as to whether they constitute a safety hazard. All unsafe items shall be
replaced or repaired before use.
10.7 Worksite. Before the aerial device is used the worksite shall be surveyed for hazards such as:
(1) Untamped earth fills.
(2) Ditches.
(3) Dropoffs and floor obstructions.
(4) Debris.
(5) Overhead obstructions and electrical conductors.
(6) Weather conditions.
(7) Presence of unauthorized persons.
10.8 Precautions. Before and during each use the operator shall:
(1) Check for overhead obstructions and electrical conductors.
(2) Insure that the load on the platform and/or load lifting devices are in accordance with the manufacturer's rated capacity.
(3) Insure that outriggers and stabilizers are used if the manufacturer's instructions require their use.
(4) Insure that guardrails are properly installed, and the gates are closed.
(5) Use outrigger pads when necessary to provide firm footing.
10.9 Mobile Operation. Before engaging in mobile operation the operator shall determine that the aerial device is specifically designed for mobile operation.
10.10 Personnel. Only trained and authorized personnel shall be permitted to operate the
aerial device.
10.11 Training, Retraining, and Familiarization of Operators.

10.11.1 General Training. Only personnel who have received general instructions regarding the inspection, application and operation of aerial devices, including
recognition and avoidance of hazards associated with their operation, shall op7-6

7 — ANSI REPRINT

erate an aerial device. Such items covered shall include, but not necessarily be
limited to, the following issues and requirements:
(1) The purpose and use of manuals.
(2) That operating manuals are an integral part of the aerial device and must
be properly stored on the vehicle when not in use.
(3) A pre-start inspection.
(4) Responsibilities associated with problems or malfunctions affecting the
operation of the aerial device.
(5) Factors affecting stability.
(6) The purpose of placards and decals.
(7) Workplace inspection.
(8) Applicable safety rules and regulations, such as Part 4, ANSI C2-1997,
National Electrical Safety Code (applies to utility workers as defined in
ANSI C2). The above standard is an example; other industries using aerial devices have safety rules pertinent to that industry.
(9) Authorization to operate.
(10) Operator warnings and instructions.
(11) Actual operation of the aerial device. Under the direction of a qualified
person, the trainee shall operate the aerial device for a sufficient period of
time to demonstrate proficiency in the actual operation of the aerial device.
(12) Proper use of personal fall protection equipment
10.11.2 Retraining. The operator shall be retrained, when so directed by the user, based
on the user’s observation and evaluation of the operator.
10.11.3 Familiarization. When an operator is directed to operate an aerial device he/she
is not familiar with, the operator, prior to operating, shall be instructed regarding the following items and issues:
(1) The location of the manuals.
(2) The purpose and function of all controls.
(3) Safety devices and operating characteristics specific to the aerial device.

11. Responsibilities of Renters, Lessors or Lessees
11.1 General Responsibilities. Each renter or lessor or lessee shall comply with the requirements of the applicable section or sections below.
7-7

XLB-4319

11.1.1 Lessor or Lessee as Dealer or Installer. When a lessor or lessee uses the aerial
device as a dealer or installer he shall have the same responsibilities as specified
under Section 7 of this standard.
11.1.2 Lessor or Lessee as Owner. When a lessor or lessee uses the aerial device as an
owner he shall have the same responsibilities as specified under Section 8 of this
standard.
11.1.3 Lessor or Lessee as User. When a lessor or lessee uses the aerial device as a user
he shall have the same responsibilities as specified under Section 9 of this standard.
11.1.4 Lessor or Lessee as Operator. When a lessor or lessee uses the aerial device as
an operator he shall have the same responsibilities as specified under Section 10 of
this standard.
11.2 Ownership Duties. The renter or lessor shall carry out the duties of ownership
specified in this standard which are not assigned to the renting entity or lessee as
the user.
11.3 Obligations. Upon delivery each renter or lessor of an aerial device shall provide
the operators manual and the ANSI/SIA A92.2-xxxx Manual of Responsibilities for
dealers, owners, users, operators, lessors and lessees of Vehicle Mounted Elevating
and Rotating Aerial Devices. These manuals shall be stored on the mobile unit.
11.4 Training. The renter or lessor shall offer training or training materials that aid the
renting entity or lessee in the operation, inspection, testing and maintenance of the
aerial device. This training shall be offered initially and subsequently on request.
11.4.1 General training. Only personnel who have received general instructions regarding the inspection, application and operation of aerial devices, including recognition and avoidance of hazards associated with their operation, shall operate an aerial device. Such items covered shall include, but not necessarily be limited to,
the following issues and requirements:
(1) The purpose and use of manuals.
(2) That operating manuals are an integral part of the aerial device and must
be properly stored on the vehicle when not in use.
(3) A pre-start inspection.
(4) Responsibilities associated with problems or malfunctions affecting the
operation of the aerial device.
(5) Factors affecting stability.
(6) The purpose of placards and decals.
(7) Workplace inspection.
(8) Applicable safety rules and regulations, such as Part 4, ANSI C2-1997,
National Electrical Safety Code (applies to utility workers as defined in
ANSI C2). The above standard is an example; other industries using aerial
devices have safety rules pertinent to that industry.
(9) Authorization to operate.
(10) Operator warnings and instructions.
(11) Actual operation of the aerial device. Under the direction of a qualified
person, the trainee shall operate the aerial device for a sufficient period of
time to demonstrate proficiency in the actual operation of the aerial device.
(12) Proper use of personal fall protection equipment
11.4.2 Familiarization. When an operator is directed to operate an aerial device he/she
is not familiar with, the operator, prior to operating, shall be instructed regarding
the following items and issues:
(1) The location of the manuals.
(2) The purpose and function of all controls.
(3) Safety devices and operating characteristics specific to the aerial device.

11.5 Communications. In the event the manufacturer or installer provides the renter or
lessor manuals, bulletins, or other materials for the information of the user of an aerial device, the renter or lessor shall pass them on to the user without any undue delay.
7-8

7 — ANSI REPRINT

7-9

XLB-4319

M.S.A.D. = Minimum Safe Approach Distance (See Table 7-1).

DENOTES PROHIBITED ZONE

• Do not allow machine, personnel, or conductive materials inside prohibited zone.
• Maintain M.S.A.D. from all energized lines and parts as well as those shown.
• Assume all electrical parts and wires are energized unless known otherwise.

Diagrams shown are only for purposes of illustrating M.S.A.D. work positions, not
all work positions.

7-10

7 — ANSI REPRINT

Table 7-1. Minimum Safe Approach Distance (M.S.A.D.) to energized
(exposed or insulated) power lines and parts.
Voltage Range
(Phase to Phase)

Minimum Safe Approach Distance
(Feet)

0 to 300V

(Meters)
Avoid Contact

Over 300V to 50KV

3.05

Over 50KV to 200KV

4.60

Over 200KV to 350KV

6.10

Over 350KV to 500KV

7.62

Over 500KV to 750KV

10.67

Over 750KV to 1000KV

13.72

7-11

XLB-4319

7-12

125 Taylor Parkway
Archbold, OH 43502
Phone (419) 445-8915
(800) 537-0540
Fax
(419) 445-0367

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Bil Jax Personal Lift Aerial Work Platforms Hydraulic Boom Users Manual Introduction

Bil-Jax Personal Lift XLB-4319 Biljax_XLB-4319_operator_manual

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