Bil Jax Satellite Tv System 36Xt Users Manual Operator’s

2015-02-02

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PARTS AND SERVICE
MANUAL

36XT

BOOM

AERIAL WORK PLATFORMS

SELF-PROPELLED
AERIAL WORK PLATFORM
This equipment is designed and manufactured in
compliance with the duties, responsibilities and
standards set forth in the ANSI, CE, CSA and/or AS
standards in effect at the time of manufacture.
This equipment will meet or exceed applicable ANSI,
CE, CSA and/or AS codes and standards when operated
in accordance with manufacturer’s recommendations.
It is the responsibility of the user to follow all regional
codes and regulations that govern the safe operation of
this equipment.
Obtain, read and obey all safety precautions before
performing maintenance or repairs or attempting to
operate this equipment. This includes all manufacturer
recommendations as well as those directives set forth by
government and local authorities.
To ensure proper and safe use of this equipment, it is
strongly recommended that only trained and authorized
personnel attempt to operate and maintain the boom lift.
This manual shall be considered a permanent and
necessary component of the machine and shall be kept
with the boom lift at all times.
Owners and Lessors should complete a full inspection of
all components and perform a test of all functions,
including brake functions, before commissioning or
reselling the machine. Repair or replace all damaged or
malfunctioning components.

Bil-Jax, Inc. is dedicated to the continuous improvement
of this and all Bil-Jax products. Therefore, equipment
information is subject to change without notice. Direct
any questions or concerns regarding errors or
discrepancies in this manual to the Bil-Jax Service
Department.
Copyright © Bil-Jax, Inc. 2008. All Rights Reserved.
“Bil-Jax” is a registered trademark and “A Step Above”
and “X-Boom” are trademarks of Bil-Jax, Inc. Contact
Bil-Jax for replacement manuals.

125 Taylor Parkway
Archbold, Ohio 43502

B33-01-0103

Phone (800) 537-0540
(419) 445-8915
Fax (419) 445-0367
http://www.biljax.com

TABLE OF CONTENTS
Table of Contents

Illustrations

Tables

1 Safety

Legend: Safety Advisories
Before Operation
During Operation
Maintenance Safety
Damaged Equipment Policy

4
5
5
7
8

2 Specifications

Range of Motion
Specifications
Warranty

10
11
12

3 Equipment Maintenance
Daily Service Checks
Weekly Service Checks
Monthly Service Checks
Annual Service Checks
Structural Inspection
Additional Service Information
Troubleshooting
Error Code Definitions

4 Cylinder Replacement
Lift Cylinder Replacement
Outrigger Cylinder Replacement

13
14
16
17
18
19
19
20
21

25
26
27

5 Replacement Decals

6 Material Safety Data

Appendix: Replacement Parts

Ordering Replacement Parts

101

LIST OF ILLUSTRATIONS
Figure 2-1

Range of Motion

Figure 3-1

Outrigger Position Switch

Figure 3-2

Hydraulic Reservoir

Figure 3-3

Wheel Nut Tightening Sequence

Figure 3-4

Slew Ring Position Measurement

Figure 4-1

Lift Cylinder Replacement

Figure 4-2

Outrigger Cylinder Replacement

Figure 5-1

Decal Locations

Figure 5-2

Decal Locations – CE

LIST OF TABLES

Table 1-1

Minimum Safe Approach Distances

Table 3-2

Troubleshooting Steps

Table 3-3

Error Code Definitions

Table 5-1

Replacement Decal Descriptions

Table 5-2

Replacement Decal Descriptions – CE

SAFETY

Proper training is required for the safe operation of any mechanical device.
Failure to follow all instructions and safety precautions in this manual and
attached to the lift will result in death or personal injury.
Prior to Operation:
Read, understand and obey all instructions and safety precautions in this
manual and attached to the lift.
Read, understand and obey all applicable government regulations.
Become familiar with the proper use of all controls.
Inexperienced users should receive instruction before attempting to
operate or maintain the machine.
The use of intelligence and common sense is the best practice when
following any safety policy.

BIL-JAX 36XT

LEGEND: SAFETY ADVISORIES
The following safety advisories are used throughout
this manual to indicate specific hazards when
operating or maintaining the machine. Read,
understand and obey all safety advisories to prevent
improper service, damage to equipment, personal
injury or death.

DANGER
Warns of operation near electrical power
sources that could lead to personal injury or
death.

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

CAUTION
Contains information important in the prevention
of errors that could damage machine or
components.

NOTE: Contains additional information
important for performing a procedure.

1 — SAFETY

BEFORE OPERATION

DURING OPERATION

Ensure the following general safety precautions are
followed before operating the articulating boom lift:

Ensure the following general safety precautions are
followed while operating the articulating boom lift:

ALWAYS inspect the usage area for potential
hazards, such as unstable or unlevel surfaces,
overhead obstructions and electrically charged wires
or conductors. ALWAYS watch for moving vehicles
in the operating area.

ALWAYS position lift away from power lines to
ensure that no part of the lift can accidentally reach
into an unsafe area. This includes full extension of
the boom through 700º rotation.

ALWAYS conduct a thorough inspection of the
machine before operation. Check for damaged or
worn parts, hydraulic leaks, damaged wiring, loose
wiring conductors, damaged outriggers, low tire
pressure, uneven tire wear or tire damage. Check for
any improperly operating components. NEVER
operate equipment if any damage is observed or
suspected. Repair damaged or malfunctioning
equipment before operation.
ALWAYS wear proper clothing and footgear. Wear
protective equipment as required by government
regulations. Keep loose clothing, jewelry, gloves and
hair away from moving parts.
ALWAYS wear a safety harness and energyabsorbing lanyard, such as a safety harness and
lanyard provided by Bil-Jax.

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 (3.05
meters minimum) and must always allow for
platform movement due to gusty winds. Always
contact power company before working near
power lines. Assume every power line is live.
Power lines can be blown by the wind. Refer to
Table 1-1 for minimum safe approach distances
between the machine and electrical power lines.

Voltage Range
(Phase to Phase)

Minimum Safe Approach Distance
(Feet)

(Meters)

ALWAYS inspect platform floor and outrigger
footpads for mud, grease, debris or other foreign
material. ALWAYS remove any such material from
the equipment before operation.

0 to 300V

ALWAYS tag any part of the equipment known or
suspected to be damaged or malfunctioning.
ALWAYS remove a malfunctioning, damaged or
defective machine from service. NEVER operate a
machine that has any known or suspected defect.
ALWAYS comply with the instructions found in
Safety and/or Service Bulletins distributed by the
manufacturer. Bulletins may contain critical
procedures that supersede the information
contained in manuals.

ALWAYS keep away from a machine that is
exposed to energized power lines. If the machine
contacts energized power lines, NEVER touch or
operate the machine until power lines are shut off.

NEVER operate this equipment while under the
influence of drugs or alcohol, while taking
prescription medications that may leave the operator
drowsy or prone to dizziness, or while feeling ill.
NEVER modify the equipment in any way that would
affect its original design or operation.

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

Table 1-1. Minimum Safe Approach Distances

ALWAYS operate only on a firm and level surface.
NEVER operate on surfaces that do not support the
equipment with its rated load capacity or on surfaces
that do not support force exerted by the outriggers
during boom operation. Operate only on surfaces
that can support a pressure of 1.8 kg/cm2 (25 psi) to
ensure safe operation.

NEVER deface, modify or obscure any decals or
markings on equipment.

ALWAYS keep personnel away from potential pinch
and shear points and from potential crush hazards
as indicated by decals attached to the machine.

NEVER operate the equipment in any way for which
it is not intended.

ALWAYS keep the safety bar lowered unless
personnel are entering or exiting the work platform.
ALWAYS keep personnel and obstructions clear of
the machine when repositioning boom or basket.
5

BIL-JAX 36XT

ALWAYS cordon the area surrounding the
outriggers to keep personnel, vehicles and moving
equipment away from the machine while in use.

NEVER allow ropes, electric cords, hoses or other
equipment to become entangled in the machine
while raising or lowering platform.

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

NEVER exceed the load limits set by the
manufacturer. Use only the Material Lifting Hook,
supplied as an option and manufactured by Bil-Jax,
when lifting materials. Safely stow all tools and
equipment.

ALWAYS engage boom travel latches before towing
trailer.
ALWAYS exercise caution when rotating the boom
from the ground control station. ALWAYS watch for
personnel inside the radius of the turntable and
boom arm when rotating the boom lift from the
ground or platform controls.
ALWAYS remove personnel from the boom lift
before attempting to free an elevated platform that
has become caught or snagged on an adjacent
structure or obstacle.
NEVER operate the machine on any surface other
than firm and level ground. NEVER operate the
machine from a position on truckbeds, trailers,
floating vessels or scaffolding without written
approval from the manufacturer.
NEVER operate lift functions on slopes exceeding
12.5º.
NEVER allow electrode contact with any part of the
machine while welding from the platform. NEVER
use the machine as a ground for welding.
NEVER operate without the outriggers fully
extended or when the machine is not level.
NEVER position an elevated platform against
another object to steady the platform
NEVER override or bypass the manufacturer’s
safety devices.
NEVER attach a safety harness to an adjacent
structure, pole, or to nearby equipment while
working from the boom platform.
NEVER raise the outriggers while boom is raised or
extended.
NEVER sit, stand or climb on cage bars. ALWAYS
keep both feet firmly on the work cage floor when
working from an elevated platform.
NEVER attempt to increase the working height with
boxes, ladders, stools or any other materials.
NEVER operate this equipment when exposed to
high winds, thunderstorms, ice or any weather
conditions that would compromise operator safety.
NEVER operate boom lift in conditions where wind
speeds exceed 12.5 m/sec (45 km/h or 28 mph).
High winds may affect stability and boom operation.

NEVER exceed load ratings by transferring loads to
the lift at elevated heights.
NEVER use the platform to lift a load that exceeds
the platform dimensions. NEVER lift a load in such a
way that the center of gravity is higher than the top
guardrail of the platform.
NEVER modify the platform or carry materials that
would increase the surface area of the platform.
Increasing the area exposed to the wind may
decrease machine stability. NEVER attach
overhanging loads when raising or lowering the
platform.
NEVER use the boom or platform to push or pull or
to lift any part of the machine.
NEVER use the boom or platform to place a load
against any structure, materials or equipment.
NEVER climb on the boom.
NEVER leave an elevated platform unattended.
NEVER leave the keys in the boom lift while
unattended or not in use.
Drive Safety
ALWAYS maintain an awareness of limited sight and
blind spots when operating drive functions.
ALWAYS limit travel speed according to surface
conditions, slope, location of personnel and
obstructions and any other factors which may result
in collision.
NEVER operate drive functions on slopes exceeding
20º.
NEVER engage in stunt driving, horseplay or any
other behavior considered unsafe according to
employer, job site and/or government regulations.
NEVER operate the internal combustion engine in
an area that is not properly ventilated.
NEVER fuel the internal combustion engine while
smoking, or while near spark or open flame.

1 — SAFETY

MAINTENANCE SAFETY
Ensure the following general safety precautions are
followed while performing maintenance on the
articulating boom lift:
General Maintenance
ALWAYS perform maintenance procedures
according to manufacturer’s guidelines. NEVER
disregard or bypass proper maintenance
procedures.
ALWAYS inspect hydraulic system to ensure that all
lines, connectors and fittings are properly fastened
and in good condition.
ALWAYS turn the key switch OFF and remove key
before performing maintenance.
ALWAYS perform maintenance with the boom and
platform in a fully lowered, stowed position, when
possible. ALWAYS secure the boom before
performing maintenance on hydraulic cylinders.
ALWAYS disconnect power to the hydraulic pump
drive motor before making electrical checks to the
hydraulic valves.
ALWAYS keep all mechanical parts properly
adjusted and lubricated according to maintenance
schedule and manufacturer’s specifications.
ALWAYS perform a function check of operating
controls before each use and after repairs have
been made.
ALWAYS locate and protect against possible pinch
points before performing any maintenance or
repairs.
ALWAYS use only manufacturer-approved parts to
repair or maintain equipment. If any portion of this
equipment is rebuilt or repaired, retesting is required
in accordance with factory instructions.
ALWAYS maintain a safe distance while testing the
hydraulic components. ALWAYS relieve hydraulic
pressure before loosening or removing hydraulic
components. NEVER test or operate the hydraulic
components while personnel are near the
equipment.

NEVER exceed the manufacturer’s recommended
relief valve settings.
NEVER touch or allow metal tools to contact any
components that are sensitive to static discharge.
ALWAYS use static discharge prevention mats and
grounding devices when handling electronic
components.
NEVER adjust, repair, replace or bypass any
hydraulic or electrical control or safety device. These
include, but are not limited to, hydraulic load control
and flow control valves, solenoid valves and limit
switches. ALWAYS consult an authorized Bil-Jax
technician if repairs are necessary.
NEVER modify, alter or change the equipment
without first consulting an authorized Bil-Jax
technician, and NEVER in any way that would affect
its original design or operation.
Battery Maintenance
Ensure the following general safety precautions are
followed when performing battery maintenance on
the Aerial Work Platform.
ALWAYS wear safety glasses when working with or
near batteries.
ALWAYS check the battery fluid level daily.
ALWAYS avoid contact with battery acid. Battery
acid causes serious burns and should be kept away
from skin or eyes. If contact occurs, flush with water
and consult a physician immediately.
ALWAYS disconnect ground cable first when
removing battery.
ALWAYS connect ground cable last when installing
battery.
ALWAYS charge batteries in open, well-ventilated
areas.
ALWAYS replace batteries using only parts
recommended by manufacturer. ALWAYS use only
batteries with sealed caps over cells.
NEVER smoke while servicing batteries.

NEVER allow water or foreign particles into the DC
electric motor housing. Inclusion of water or foreign
particles may cause serious damage to the motor. If
the motor becomes wet, consult an authorized BilJax service technician for proper drying instructions.

NEVER charge batteries near spark or open flame.

NEVER add unauthorized fluids to the hydraulic
system or battery. NEVER mix hydraulic oils.
Consult manufacturer specifications. Refer to
Section 4 for hydraulic system maintenance
procedures.

NEVER disconnect battery from charger while
charger is connected to a live power source.

NEVER allow batteries to overcharge and boil.
NEVER short across battery posts to check for
current. NEVER break a live circuit at the battery.

NEVER jumpstart other vehicles using the boom lift
batteries.
7

BIL-JAX 36XT

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

Damage Policy
There may be occasions when a Bil-Jax lift is involved in an incident that results
in structural damage to the lift. Such damage can seriously compromise the
ability of the lift to perform in a safe manner. Therefore, whenever a Bil-Jax lift is
damaged structurally or when there is suspected internal damage to the
structure, Bil-Jax may require that the lift be returned to our facility for
reconditioning. For any questions concerning structural damage or the Damaged
Equipment Policy, please contact the Bil-Jax Service Department at 800-5370540.

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

SPECIFICATIONS

Bil-Jax, Inc. is dedicated to the continuous improvement of this and all
Bil-Jax products. Therefore, equipment information is subject to change
without notice.
The following information is based on ideal working conditions. Machine
performance may vary based on work environment and on machine
options.
Direct any questions or concerns regarding equipment specifications to your
regional Bil-Jax representative or to the Bil-Jax Service Department.

BIL-JAX 36XT

RANGE OF MOTION

Figure 2-1. Range of Motion

2 — SPECIFICATIONS

SPECIFICATIONS

Working Height
Maximum Platform Height
Maximum Horizontal Outreach
From Centerline
From Outrigger Footpad Edge
Rated Platform Capacity
Without Platform Rotation
With Platform Rotation
Maximum Occupants
Total Weight

SERIAL NUMBER____________________________

43 ft 6 in
13.4 m
37 ft 6 in
11.4 m
32 ft
9.8 m
27 ft
8.2 m
500 lbs
227 kg
440 lbs
200 kg
2
4,680 lbs
2,123 kg

Turntable Rotation

700º Non-Continuous

Leveling Capability

12.5º

Gradeability

45%

Wheel Base

8 ft 8 in
2.7 m

Turning Radius
Inside
Outside
Platform Dimensions
Height
Length
Width – US/CE
Stowed Dimensions
Height
Length (Platform stowed)
Width

10 ft
3m
18 ft
5.5 m

Outrigger Footprint
Length
Width
Footpad Diameter
Brake
Speed
Gas Power
DC Power
Tire Size

1.5 mph
5.6 km/h
1.75 mph
2.8 km/h
26 x 12 bar lug tires
20 psi
140 kPa

Control System

24V DC

Battery
Battery Charger
Gas Engine

4 x 6V 245 amp-hr
110/120 Volt
Kawasaki 21 HP

Hydraulic Pressure

3,000 PSI
20,684 kPa

Reservoir Capacity

4.8 Gallons
18.2 L

Hydraulic System Capacity

Platform Rotation/Type (Optional)
Maximum Decibel Level
DC Mode – Ground
DC Mode – Platform
Gas Mode – Ground
Gas Mode - Platform
Localized Pressure per Outrigger

6 ft 6 in
2.0 m
20 ft 10 in
6.4 m
5 ft 5 in
1.7 m

Spring Applied

Tire Pressure

Hydraulic Oil (Standard)
3 ft 7 in
1.1 m
2 ft 6 in
0.8 m
5 ft/4 ft
1.5 m/1.2 m

12 ft 2 in
3.7 m
11 ft 4 in
3.4 m
12.5 in
0.3 m

7 Gallons
26.5 L
Dexron III/Mercon ATF
90º/Manual
60 dB
55 dB
70 dB
65 dB
25 PSI
2
1.8 kg/cm
176.5 kPa

Operation Temperature Range

-20º to 110º Fahrenheit
-29º to 43º Celsius

Max. Pressure Per Tire – Floor
Loading

35 PSI
2.5 bar
11

BIL-JAX 36XT

WARRANTY
Bil-Jax, Inc. warrants this product for one year, beginning on the date of delivery,
to be free from defects of material and workmanship provided the unit is operated
and maintained in compliance with the guidelines established in the Operations
and Maintenance Manuals. Major structural components, including trailer tongue
and boom weldments, are warranted for five years against defects due to
material or workmanship. Bil-Jax will, at its option, repair or replace any unit or
component part that fails to function properly during normal use.
The warranty does not apply if the lift and/or its components have been altered,
changed, or repaired without the consent of Bil-Jax. Repairs, damage, or defects
resulting from the following are not covered under the terms of the warranty:
negligence, misuse, accidental damage, inadequate or improper maintenance,
acts of nature, damage caused by chemicals or abrasive materials, and normal
wear and tear, such as rust or corrosion. Components not covered under this
warranty include tires, filters, covers, and routine maintenance items.
Components not manufactured by Bil-Jax are covered be their respective
manufacturer’s warranties. A list of those components and their warranties is
available upon written request to Bil-Jax.
Bil-Jax shall not in any event be liable for the cost of any special, indirect, or
consequential damages to any person, product, or thing. Bil-Jax’s maximum
liability under this warranty is limited to the amount paid to Bil-Jax for the product.
This warranty is in lieu of all other warranties expressed or implied. Bil-Jax
neither assumes nor authorizes any or other entity to assume on its behalf any
other liability in connection with the sale, rental, or use of this product.
Warranty Claims Process
In order to qualify for warranty coverage, the following conditions must be met:
1)
2)
3)

Return of completed “Warranty Registration” form to Bil-Jax within 15 days of
receipt of product;
Notification to Bil-Jax within 72 hours of any claimed defect, injury, or damage
resulting from the claimed the defect; and
Warranty is limited to parts that are determined to be defective. This does not
include parts worn out due to normal use.

Bil-Jax authorized dealers or distributors are responsible for filing claims under
warranty. Listed below is the warranty claims procedure.
1)
2)

Contact Bil-Jax Service Department at 800-537-0540 to report the claim and
verify warranty coverage. Machine serial number must be provided.
Identify the components to be claimed under warranty along with description of
failure. A Returned Merchandise Authorization (RMA) number will be issued by
Bil-Jax.
Replacement parts will then be sent by Bil-Jax to the dealer or distributor. All
parts are invoiced at dealer/distributor list price. Credits will be issued when
defective parts are returned to Bil-Jax and found to be defective under warranty.
After completing repairs, submit warranty claim form and defective parts to BilJax. Warranty claim form and parts must be received within 30 days of claim in
order to be eligible for credit. RMA number must be referenced on warranty claim
form. Returned parts are to be sent prepaid and will be credited when part is
received and verified. Warranty labor rate will be paid at current rate set by BilJax. The amount of labor hours reimbursed will be determined by Bil-Jax and will
be limited to 4 hours unless approved by Bil-Jax.

Failure to follow the warranty claims process may result in delay in processing
claim or denial of the claim. Bil-Jax reserves the right to limit or adjust warranty
claims with regard to parts, labor and travel time. Components purchased from
suppliers other than Bil-Jax are not covered under the terms of this warranty.

EQUIPMENT MAINTENANCE

Performing the appropriate maintenance procedures will extend the life
of the boom lift and will help ensure the safety of personnel operating the
equipment.
Repair, replacement or adjustment of any hydraulic or electrical control
device should be performed only by fully trained and authorized
personnel. These include, but are not limited to, hydraulic load valves,
hydraulic flow control valves, solenoid valves and limit switches. These
are safety related controls. Improper adjustment or tampering with these
devices may impair boom lift function and result in safety or damage
hazards.
Persons performing maintenance or repairs on the machine, including
weld repairs, should be trained in accordance with the manufacturer’s
recommendations. Contact your regional Bil-Jax representative if
additional information is needed.
Critical or suspect areas identified during any scheduled inspection of the
machine shall be examined by qualified personnel in accordance with
applicable government regulations.
Never operate the machine if a defect or malfunction is identified or
suspected. All defects and malfunctions must be repaired, and all
maintenance performed, before returning a machine to service.
This manual contains a list of recommended maintenance procedures to
be performed daily, weekly, monthly and annually.
When servicing the internal combustion engine installed on this
machine, always follow the guidelines specified by the engine
manufacturer.
It is the practice of Bil-Jax, Inc. to issue Service and/or Safety Bulletins,
which may include updates to the information contained in this manual.
In such instances, procedures contained in Bil-Jax Service Bulletins or
Safety Bulletins supersede the information contained in manuals.
Always follow maintenance schedule, regardless of use.

BIL-JAX 36XT

DAILY SERVICE CHECKS
The following maintenance procedures should be
performed daily or before each operation.
Verify that all decals are correctly applied and in
plain view.
Refer to Section 5 for decal locations.

Verify that all controls and indicators at ground
and platform control stations operate properly.
Lower outriggers to level the boom lift.
Raise and extend all booms.
Press emergency STOP button.

Verify that boom down limit switches operate
correctly.
Down limit switches are actuated when the boom is in
a fully lowered, stowed position. Limit switches must
be operational to raise or lower outriggers.
If outrigger controls are unresponsive when boom is
fully lowered and stowed, inspect down limit switches
for loose mounting or visible damage.
Repair or replace as needed.

Verify that outrigger safety interlocks operate
correctly.

Pull out STOP button and lower the booms.

Begin with the outriggers fully extended and the boom
lift level. Raise one outrigger until the footpad is not in
contact with the ground.

If either control station is unresponsive, refer to Table
3-1 for troubleshooting procedures.

Verify that boom functions are unresponsive when
one outrigger is raised.

If display panel displays an error code, refer to Table
3-2 for error code definitions.

Repeat this procedure for each outrigger.

Verify that booms remain elevated and do not drift.

Verify correct tire inflation.
Inflate tires to 20 psi (140 kPa).

Inspect tires for damage or loose or missing lug
nuts.
Repair or replace as necessary.*

Inspect structural components and platform for
obvious damage or debris.
Repair or replace as necessary.

Inspect machine for missing, loose or damaged
fasteners, including pins and bolts.

Raise all outriggers until the footpads are not in
contact with the ground. Verify that all outrigger status
LEDs on the ground control panel are unlit.
Lower one outrigger until the footpad makes contact
with the ground and the outrigger begins lifting the
trailer.
If the LED is lit before the footpad makes contact with
the ground or if the LED remains unlit after the weight
is transferred to the outrigger, the position switch or
wiring is faulty.
Repeat this procedure for each outrigger.
Repair or replace as needed. Refer to Figure 2-1.

Check engine oil level.
Add oil as needed.
Manufacturer recommends engine oil type 5W-30.

Check engine fuel level.
Add fuel as needed.

Figure 3-1. Outrigger Position Switches

*Repair and replacement of machine components should
be performed only by trained and certified personnel in
accordance with government regulations and
manufacturer recommendations.

3 — EQUIPMENT MAINTENANCE

Inspect hydraulic system and fluid levels.
Check all hydraulic hoses and fittings for leaks and
damage. Tighten or replace as necessary to prevent
hydraulic oil or pressure loss.
The hydraulic oil level should be checked with the
booms down, all outriggers raised and the trailer
wheels on a level surface.
Hydraulic oil level should be visible in, but not above,
the sight gauge.
If the hydraulic oil level is not visible to at least half
way up the sight gauge (Figure 3-2), add clean
hydraulic fluid as necessary while all booms and
outriggers are fully retracted and stowed. Pour slowly
to avoid creating air pockets in the reservoir. Do not
fill above sight gauge. Overfilling the hydraulic
reservoir may cause damage to hydraulic lines and
may result in equipment malfunction.

CAUTION

Do not mix hydraulic oils. Do not add any fluid to
the hydraulic system that is not expressly
recommended by the manufacturer. Adding
unauthorized fluids to the hydraulic system may
cause damage to equipment
The hydraulic reservoir is originally filled with Dexron
III/Mercon ATF with a viscosity rating of 175.
Manufacturer recommends a higher viscosity
hydraulic oil when operating equipment routinely in
extreme climates.

1.
2.

Filter Element
Fill Port

Sight Gauge

Figure 3-2. Hydraulic Reservoir

BIL-JAX 36XT

WEEKLY SERVICE CHECKS
Perform the following service checks at least once
each week in addition to all recommended Daily
Service Checks:
Check Battery electrolyte level.
If electrolyte level is low, add enough water to bring
the electrolyte level to the top of the plates.
If batteries are fully charged, raise electrolyte level to
full mark in each cell.

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

Inspect boom lift for missing, loose or damaged
hardware.
Repair or replace as necessary.

Inspect all hydraulic system components
including pump and motor and cylinders for
damage, leaks, loss of pressure or speed, and
unusual noise or vibration.
Repair or replace as necessary.

3 — EQUIPMENT MAINTENANCE

MONTHLY SERVICE CHECKS
Perform the following service checks at least once
each month:
Clean all battery terminals.
Check battery for loose connections or damaged
wires.
Verify proper operation of manual lowering
valves and hand pump
Refer to Section 3 for manual boom operating
procedures.

Lubricate all compartment hinges and latches,
slew ring and mating gear.
Use NLGI Grade 2 multi-purpose grease.

Check wheel nut torque.
Refer to Figure 4-3 for correct wheel nut tightening
sequence.
Evenly tighten wheel nuts to 34 N*m in the tightening
sequence shown.
Repeat sequence, tightening wheel nuts to 81 N*m
and to 136 N*m.

NOTE: Follow this procedure each time the
wheel is removed and reinstalled.

Figure 3-3. Wheel Nut Tightening Sequence

BIL-JAX 36XT

ANNUAL SERVICE CHECKS
Perform the following service checks at least once
each year:
Replace Hydraulic Oil and Oil Filter.
Drain hydraulic reservoir, clean and replace oil.
Wipe away dirt and excess oil from around filter using
cleaning cloths and alcohol solvent.
Loosen and remove filter. Use absorbent cloths to
keep excess oil from leaking onto the machine.
Discard used filter.
Wipe away dirt and excess oil from around filter
housing.
Install new filter. Do not over-tighten.
With the fill port cap on but not tightened, completely
raise and lower all booms to bleed trapped air from
the lift cylinders. Repeat as necessary.

Check slew bearing for wear or damage.
Check bolts for wear or damage.
With the boom lift fully retracted, measure the
distance between the slew ring gear and the
horizontal plate above. Use a 2-inch (50 mm) caliper
or bore micrometer. Record the measurement (Figure
3-4).
Place a 175 lb (65 kg) load on the boom lift platform.
Measure the distance between the slew ring and the
horizontal plate above. Record the measurement.
If the difference in measurements is greater than .25
in (6.35 mm) the slew ring bearing should be
replaced. Contact manufacturer for replacement
instructions and assistance.

Replace yearly, or whenever filter or oil contamination
has a noticeable effect on boom functions.

Inspect pivot pins and cylinders, including rod
ends, for wear or damage. Replace as necessary.

MEASURE
HERE

SLEW RING

Visually inspect welds and structural
components for wear, damage and corrosion.
Follow all manufacturer’s recommendations when
making repairs to critical components.
Personnel making repairs to welds should be certified
in accordance with applicable government
regulations.

Inspect outriggers for wear or damage. Repair or
replace as necessary.
Verify that Level Sensor is operating correctly.
Fully deploy outriggers until all Outrigger LEDs and
AUTO LEVEL LED are lit, and buzzer sounds.
Verify that machine is level, and that level sensor is
giving an accurate reading.
Repair or replace as necessary.

Inspect and adjust axles and brakes.
Load test boom lift operations with 500 lb (187
kg) load.

Figure 3-4. Slew Ring Position Measurement

3 — EQUIPMENT MAINTENANCE

STRUCTURAL INSPECTION

ADDITIONAL SERVICE INFORMATION

A comprehensive structural inspection of the unit
shall be performed under any of the following
conditions.

Seals on hydraulic cylinders should be replaced every five
years or as indicated by machine performance.

Ten years from the date of manufacture and every
five years thereafter.
After any actual, suspected or potential damage is
sustained that could affect the structural integrity or
stability of the aerial platform.
After a change in ownership. Owners should provide
a complete service history when reselling the unit.

The structural inspection shall include the following
considerations.
The service history of the unit, including hours of
service, work performed and environmental
conditions.
The inspection and maintenance record of the unit.
The effectiveness of all controls and components.
A visual inspection of the unit for wear or damage.
Manufacturer recommendations.
A visual weld inspection, to be performed by qualified
personnel in accordance with applicable government
regulations.

All service checks should be performed on a machine that
has been stored without use for a period exceeding thirty
days.
Check for air in the hydraulic system if the machine has
been stored without use for a period exceeding thirty days,
or if the machine was stored without use during a
seasonal climate change. Air trapped in the hydraulic
system will affect machine performance. Follow
procedures for bleeding air from the hydraulic system,
found in Section 4.
Owners and lessors should complete a full inspection of all
components and perform a test of all functions, including
brake functions, before commissioning or reselling
machine. Always repair or replace all damaged or
malfunctioning components before commissioning or
reselling machine.
When a change in ownership occurs, it is the responsibility
of the seller to provide the new owner with all manuals for
the machine. It is the responsibility of the buyer to notify
the manufacturer of the unit model and serial number and
the name and address of the new owner within 60 days.
Use the Service Checklists found at the back of the
Operator’s Manual to record all Service Checks as well as
any maintenance, repairs or alterations performed on the
machine.
Records of frequent safety checks need not be made.
However, where a safety hazard is found, it shall be
reported in writing to the owner of the machine, and a
record of any corrective action shall be maintained for five
years or as required b y the authority having jurisdiction.

Testing Machine Stability
The Summit Series aerial work platform has been tested
for stability using a load equal to 150% of the rated
capacity of the machine and placed at the center of the
platform with the boom fully extended. Stability tests
should be conducted only by trained personnel and only
when the machine is properly anchored to safeguard
against tipping.

BIL-JAX 36XT

TROUBLESHOOTING
Refer to Table 3-2 for basic troubleshooting operations. Additional information
can be found in the Bil-Jax Model 45XA Operator’s Manual. Contact the Bil-Jax
Service Department with any questions or before attempting any advanced
troubleshooting operations.

Table 3-1. Troubleshooting Steps
PROBLEM
No lights on panel when
key switch is turned to the
on position.

CAUSE

SOLUTION

Emergency STOP engaged.

Disengage Emergency STOP buttons.

Battery charge is low.

Recharge as needed.

Battery ground or in-series cable is loose.

Inspect and repair battery connections.

Battery main disconnect unplugged.

Plug in main disconnect.

Fault detected by safety interlock
microprocessor.

Refer to Table 4-2 for error code
definition and correction.

Boom Lift electric or electronic failure

Refer to Table 4-2 for error code
definition and correction.

Key switch turned to the OFF or platform
controls position.

Turn key switch to ground controls
position.

Emergency STOP engaged.

Disengage emergency STOP buttons.

Outriggers not deployed.

Deploy all outriggers.

One or more boom controls
do not function

Key switch is turned to the OFF or
incorrect control position.

Turn key switch to ground or platform
controls position.

Battery charge is low.

Recharge battery.

One or more boom controls
function improperly

Emergency STOP engaged.

Disengage Emergency STOP buttons.

Battery ground or in-series cable loose.

Inspect and repair battery connections.

One or more boom controls
function intermittently.

All outriggers not properly deployed.

Deploy all outriggers and level boom lift.

Hydraulic pump inoperative.

Inspect pump; replace or repair as
needed.

Loose wiring connector.

Check wiring terminals in control box
and at valve manifold; replace or repair
as needed.

Valve solenoid not operating properly.

Clean valve solenoid and recheck
function(s); replace or repair as needed.

Fault detected by system interlock.

Check display for system status. Refer
to Table 4-2 for error code definitions
and correction.

Broken or loose wire.

Inspect wiring in control box and at
valve manifold and valve coil; repair or
replace as needed.

Hydraulic function does not
work and display window
shows an error message

Outrigger indicator LED
lights do not function.

3 — EQUIPMENT MAINTENANCE

ERROR CODE DEFINITIONS
The DISPLAY PANEL located on the ground control panel indicates the present
operating status of the boom lift. If an error condition is detected by the control
processor during start-up or operation, the appropriate error code will be
displayed on this panel.
Refer to Table 3-2 for a comprehensive list of Error Code Definitions and
solutions.

Table 3-2. Error Code Definitions
ERROR MESSAGE

DEFINITION OF ERROR

COMMENTS

001 MACHINE IS IN DOWN ONLY Machine was either never leveled, outriggers not
MODE
lowered, or machine went out of level with use.

Retract boom to travel position
and extend outriggers using AUTO
LEVEL button.

002 LOSS OF PLATFORM
COMMUNICATION

Ground control lost communication with platform
control.

Check for unplugged or damaged
platform control cable.

005 PLATFORM CONTROL HAS
STUCK KEY

Platform control detected a stuck or pressed key
on power up.

Turn key switch off and on again
without pressing any buttons.

008 GROUND CONTROL HAS
STUCK KEY

Ground control detected a stuck or pressed key
on power up.

Turn key switch off and on again
without pressing any buttons.

009 BOOM UP WITHOUT
OUTRIGGERS ON GROUND

Ground control detected the boom is up and all
outriggers are not on the ground

Retract boom to travel position
and extend outriggers using AUTO
LEVEL button.

010 LEVEL SENSOR HAS
ERRATIC OUTPUT

The ground control detected an erratic output
from the level sensor.

Retract and extend outriggers
using AUTO LEVEL button.

015 MACHINE IS NOT LEVEL

Machine has gone out of level with use.

Retract and extend outriggers
using AUTO LEVEL.

016 LIFT BOOM

A boom rotate, extend, or retract function
requested with boom down.

Raise boom from travel position.

017 STOW BOOM

An outrigger function requested with boom up.

Retract and lower boom to travel
position.

021 OPEN CIRCUIT PRIMARY UP A load of less than 70mA detected in primary up
circuit on power-up.

Check for faulty boom up
solenoid coil and wiring.

022 SHORTED CIRCUIT
PRIMARY UP

Excessive load detected in primary up circuit on
power-up.

Check for faulty boom up
solenoid coil and wiring.

023 OPEN CIRCUIT PRIMARY
DOWN

A load of less than 70mA was detected when
primary down circuit was energized

Check for faulty boom down
solenoid coil and wiring.

024 SHORTED CIRCUIT
PRIMARY DOWN

Excessive load detected when primary down
circuit was energized.

Check for faulty boom down
solenoid coil and wiring.

025 OPEN CIRCUIT SECONDARY A load of less than 70mA detected in secondary
UP
up circuit on power-up.

Check for faulty boom up
solenoid coil and wiring.

026 SHORTED CIRCUIT
SECONDARY UP

Check for faulty boom up
solenoid coil and wiring.

Excessive load detected in secondary up circuit
on power-up.

027 OPEN CIRCUIT SECONDARY A load of less than 70mA detected when
DOWN
secondary down circuit was energized

Check for faulty boom down
solenoid coil and wiring.

028 SHORTED CIRCUIT
SECONDARY DOWN

Excessive load detected when secondary down
circuit was energized.

Check for faulty boom down
solenoid coil and wiring.

029 OPEN CIRCUIT JIB UP

A load of less than 70mA detected in jib up circuit
on power-up.

Check for faulty jib up solenoid
coil and wiring.

030 SHORTED CIRCUIT JIB UP

Excessive load detected in jib up circuit on
power-up.

Check for faulty jib up solenoid
coil and wiring.
21

BIL-JAX 36XT

ERROR MESSAGE

DEFINITION OF ERROR

COMMENTS

031 OPEN CIRCUIT JIB DOWN

A load of less than 70mA detected when jib down
circuit was energized

Check for faulty jib down solenoid
coil and wiring.

032 SHORTED CIRCUIT JIB
DOWN

Excessive load detected when jib down circuit
was energized.

Check for faulty jib down solenoid
coil and wiring.

033 OPEN CIRCUIT EXTEND

A load of less than 70mA detected in extend
circuit on power-up.

Check for faulty boom extend
solenoid coil/wiring.

034 SHORTED CIRCUIT EXTEND Excessive load detected in extend circuit on
power-up.

Check for faulty boom extend
solenoid coil/wiring.

035 OPEN CIRCUIT RETRACT

A load of less than 70mA detected in retract
circuit on power-up.

Check for faulty boom retract
solenoid coil/wiring.

036 SHORTED CIRCUIT
RETRACT

Excessive load detected in retract circuit on
power-up.

Check for faulty boom retract
solenoid coil/wiring.

037 OPEN CIRCUIT PLATFORM
LEVEL UP

A load of less than 70mA detected in platform
level up circuit on power-up.

Check for faulty level up solenoid
coil/wiring.

038 SHORTED CIRCUIT
PLATFORM LEVEL UP

Excessive load detected in platform level up
circuit on power-up.

Check for faulty level up solenoid
coil/wiring.

039 OPEN CIRCUIT PLATFORM
LEVEL DOWN

A load of less than 70mA detected in platform
level down circuit on power-up.

Check for faulty level down
solenoid coil/wiring.

040 SHORTED CIRCUIT
PLATFORM LEVEL DOWN

Excessive load detected in platform level down
circuit on power-up.

Check for faulty level down
solenoid coil/wiring.

041 OPEN CIRCUIT PLATFORM
CW

A load of less than 70mA detected in platform
CW circuit on power-up.

Check for faulty boom rotate
solenoid coil/wiring.

042 SHORTED CIRCUIT
PLATFORM CW

Excessive load detected in platform CW circuit
on power-up.

Check for faulty boom rotate
solenoid coil/wiring.

043 OPEN CIRCUIT PLATFORM
CCW

A load of less than 70mA detected in platform
CCW circuit on power-up.

Check for faulty boom rotate
solenoid coil/wiring.

044 SHORTED CIRCUIT
PLATFORM CCW

Excessive load detected in platform CCW circuit
on power-up.

Check for faulty boom rotate
solenoid coil/wiring.

045 OPEN CIRCUIT TURNTABLE
CW

A load of less than 70mA detected in rotate CW
circuit on power-up.

Check for faulty rotate CW
solenoid coil/wiring.

046 SHORTED CIRCUIT
TURNTABLE CW

Excessive load detected in rotate CW circuit on
power-up.

Check for faulty rotate CW
solenoid coil/wiring.

047 OPEN CIRCUIT TURNTABLE
CCW

A load of less than 70mA detected in rotate CCW
circuit on power-up.

Check for faulty rotate CCW
solenoid coil/wiring.

048 SHORTED CIRCUIT
TURNTABLE CCW

Excessive load detected in rotate CCW circuit on
power-up.

Check for faulty rotate CCW
solenoid coil/wiring.

049 OPEN CIRCUIT OUTRIGGER A load of less than 70mA detected in outrigger
RETRACT
retract circuit on power-up.

Check for faulty outrigger retract
solenoid coil/wiring.

050 SHORTED CIRCUIT
OUTRIGGER RETRACT

Check for faulty outrigger retract
solenoid coil/wiring.

Excessive load was detected when Outrigger
Retract circuit was energized.

051 OPEN CIRCUIT OUTRIGGER A load of less than 70mA detected in outrigger
EXTEND
retract circuit on power-up.
Excessive load was detected in outrigger extend
circuit on power-up.

Check for faulty outrigger extend
solenoid coil/wiring.

053 OPEN CIRCUIT
LF OUTRIGGER

A load of less than 70mA detected in left front
outrigger circuit on power-up.

Check for faulty solenoid
coil/wiring at outrigger.

054 SHORTED CIRCUIT
LF OUTRIGGER

Excessive load was detected in left front
outrigger circuit on power-up.

Check for faulty solenoid
coil/wiring at outrigger.

055 OPEN CIRCUIT
RF OUTRIGGER

A load of less than 70mA detected in right front
outrigger circuit on power-up.

Check for faulty solenoid
coil/wiring at outrigger.

052

SHORTED CIRCUIT
OUTRIGGER EXTEND

Check for faulty outrigger extend
solenoid coil/wiring.

3 — EQUIPMENT MAINTENANCE

ERROR MESSAGE

DEFINITION OF ERROR

COMMENTS

056 SHORTED CIRCUIT
RF OUTRIGGER

Excessive load detected in right front outrigger
circuit on power-up.

Check for faulty solenoid
coil/wiring at outrigger.

057 OPEN CIRCUIT
LR OUTRIGGER

A load of less than 70mA detected in left rear
outrigger circuit on power-up.

Check for faulty solenoid
coil/wiring at outrigger.

058 SHORTED CIRCUIT
LR OUTRIGGER

Excessive load detected in left rear outrigger
circuit on power-up.

Check for faulty solenoid
coil/wiring at outrigger.

059 OPEN CIRCUIT
RR OUTRIGGER

A load of less than 70mA detected in right rear
outrigger circuit on power-up.

Check for faulty solenoid
coil/wiring at outrigger.

060 SHORTED CIRCUIT
RR OUTRIGGER

Excessive load detected in right rear outrigger
circuit on power-up.

Check for faulty solenoid
coil/wiring at outrigger.

069 OPEN CIRCUIT
PROPORTIONAL

A load of less than 70mA detected in proportional
valve circuit on power-up.

Check for faulty solenoid
coil/wiring at proportional valve.

070 SHORTED CIRCUIT
PROPORTIONAL

Excessive load detected in proportional valve
circuit on power-up.

Check for faulty solenoid
coil/wiring at proportional valve.

BIL-JAX 36XT

CYLINDER REPLACEMENT

If repair or replacement of a boom lift or outrigger hydraulic cylinder or its
component parts becomes necessary, observe the following procedures in
accordance with the safety precautions established in Section 1 of this manual.
Removing the hydraulic cylinder from the boom lift may require the use of
specialized tools and lifting equipment. NEVER attempt to operate overhead
hoists or cranes or related equipment without proper training, authorization and
supervision. Perform all maintenance procedures only in an area that is well-lit
and well-ventilated. Bil-Jax, Inc. is not responsible for personal injury or property
damage resulting from the improper use of equipment or failure to follow all
procedures and related safety precautions.
Direct all questions regarding cylinder removal and replacement to your regional
Bil-Jax representative or to the Bil-Jax Service Department at 800-537-0540.

BIL-JAX 36XT

LIFT CYLINDER REPLACEMENT
Use the following procedure to remove and replace
faulty or damaged hydraulic cylinders on the boom
lift:

WARNING
Repair and removal of the hydraulic cylinders
requires the use of lifting straps and an
overhead crane or lifting gear to support the
boom lift and hydraulic cylinders. Personnel
should be thoroughly trained in the operation of
these devices before attempting installation or
removal. Hydraulic cylinders are heavy and may
have hydraulic oil on their surface. Failure to use
proper equipment or to securely support boom
and boom cylinders can result in damage to lift
components, serious injury or death.

hoses to prevent leakage. Plug or cap exposed hose
fittings and cylinder ports.
At the base of the cylinder, unbolt and remove
retainer plate from each side of the pivot pin.
Remove the pivot pin using a hammer and a brass or
hardwood drift.
Lift and remove the cylinder using an overhead hoist
and lifting straps.
Replace or reinstall the cylinder by following the
above instructions in the reverse order of removal.
Actuate the hydraulic system and check for leakage.
Tighten hydraulic fittings as needed.
Bleed trapped air from the hydraulic system by raising
and lowering the boom with the reservoir fill port cap
on but not tightened. Allow several minutes for
trapped air to escape. Repeat as needed.

Lower the boom until it is resting in a stowed position.
When removing the slave cylinder, extend the
articulating boom section until all pivot pins are
exposed (approximately two feet).
Press and hold the emergency lowering valve on the
back of the jib boom section to relieve all hydraulic
pressure to the cylinder. Repeat this process for the
upper and lower boom sections. Refer to the 4527A
Operator’s Manual for emergency lowering valve
locations and operating procedures.

RETAINING
PLATE

Turn key switch to the OFF position and remove the
key.
Locate the piston rod end of the cylinder to be
removed (Figure 4-1). Unbolt and remove the retainer
plate from each side of the pivot pin.

CYLINDER

BASE END

PISTON END

Verify that the cylinder is supported by lifting straps
and an overhead hoist.
Remove the pivot pin using a hammer and a brass or
hardwood drift.
Use an overhead crane or lifting gear to raise the
boom section. Adequate clearance is necessary to
reach the cylinder valve block and hydraulic hose
ports.
Unplug the appropriate emergency lowering valve
solenoid.
Tag and number all hydraulic hoses that attach to the
cylinder valve block. Use a marker to label the valve
block ports with the appropriate hose numbers.
Place absorbent cloths below the cylinder ports and
detach hydraulic hoses from the cylinder. Elevate

Figure 4-1. Lift Cylinder Replacement

4 — CYLINDER REPLACEMENT

OUTRIGGER CYLINDER REPLACEMENT
Use the following procedure to remove and replace
faulty or damaged hydraulic cylinders on the
outriggers:
Lower the outrigger until the footpad is touching the
ground. Do not transfer the weight of the boom lift
onto the outrigger. Leave the weight of the boom on
the trailer wheels.

Unplug the cylinder valve solenoid.
Place absorbent cloths below the cylinder ports and
detach hydraulic hoses from the cylinder. Elevate
hoses to prevent leakage. Plug or cap exposed hose
fittings and cylinder ports.
At the base of the cylinder, unbolt and remove
retainer plate from each side of the pivot pin.

Remove the bolts securing the outrigger cylinder rod
guard (Figure 4-2). Remove the guard.

Remove the pivot pin using a hammer and a brass or
hardwood drift.

At the piston rod end of the cylinder, unbolt and
remove the retainer plate from each side of the pivot
pin.

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

Place a block of wood shoring between the outrigger
beam and cylinder.
Remove the pivot pin using a hammer and a brass or
hardwood drift.
Fully retract the cylinder.
Turn key to the off position and remove the key.

Replace or reinstall the cylinder by following the
above instructions in the reverse order of removal.
Actuate the hydraulic system and check for leakage.
Tighten hydraulic fittings as needed.
Bleed trapped air from the hydraulic system by raising
and lowering the boom with the reservoir fill port cap
on but not tightened. Allow several minutes for
trapped air to escape. Repeat as needed.

Tag and number all hydraulic hoses that attach to the
cylinder valve block. Use a marker to label the valve
block ports with the appropriate hose numbers.

CYLINDER ROD
GUARD

CYLINDER

CYLINDER ROD
GUARD BOLTS

RETAINING
PLATES

Figure 4-2. Outrigger Cylinder Replacement
27

BIL-JAX 36XT

5 REPLACEMENT DECALS
Decals contain information that is required for the safe and proper use of
the aerial work platform. Decals should be considered necessary
components of the machine and should be checked before each use to
verify that they are correctly attached and legible.
Use the following guides to find the correct location of all decals.

BIL-JAX 36XT

Table 5-1. Decal Descriptions
Decal No.

Decal Description

Qty

Decal No.

Decal Description

Qty

0202-0523

Made in USA

B06-00-0484

DANGER: Battery/Charger Safety

B06-00-0034

DANGER: Electric Shock

B06-00-0494

NOTICE: Hazardous Materials

B06-00-0037

Lubricate Semi-Annually

B06-00-0495

B06-00-0062

NOTICE: AC Power

CAUTION: Compartment Access
Restricted

B06-00-0068

NOTICE: Hydraulic System Oil

B06-00-0503

NOTICE: Handle Applications

B06-00-0161B

Bil-Jax Logo, Black Transfer

B06-00-0504

NOTICE: Emergency Hand Pump

B06-00-0404

WARNING: Outrigger Crush Toe

B06-00-0505

DANGER: Before Use/Main
Instruction/Hazards (ground)

B06-00-0405

WARNING: Pinch Point

B06-00-0506

NOTICE: Emergency Lowering

B06-00-0471

DANGER: Before Use/Main
Instruction/Hazards (Platform)

B06-00-0521

DANGER: Tip Over Hazard

B06-00-0473

NOTICE: Operator’s Manual
Missing

B06-00-0541

CAUTION: Manual Boom
Functions

B06-00-0474

NOTICE: Max. Load

B06-00-0545

Bil-Jax Website Transfer

B06-00-0475

WARNING: Read/Understand
Operator’s Manual

B06-00-0552

NOTICE: Fall Protection Attachment points

B06-00-0476

NOTICE: Range of Motion

B06-00-0561

WARNING: Operating Instructions
(Ground)

B06-00-0477

WARNING: Forklift Pockets

2
B06-00-0562

CAUTION: Transport Safety Latch

WARNING: Operating Instructions
(Platform)

B06-00-0481
B06-00-0482

DANGER: Electrocution Hazard

B06-00-0563

36XT, 6” Black Transfer

Identification Plates

B06-00-0490

VIN Plate

B06-00-0499

ANSI ID Plate

B06-00-0524

Annual Inspection Plate

B06-00-0526

Key Tag

0476

0474

0471

0562

0552

0062

0475

0202-0523

0473

0405
0552
0521
0552

0481

0405

0493

0034

0484

0495

0161B

0405
0552

0563

0505

0561

0404

0521

0495

0545

0477

0476

0506

0405

0504

0503

0541

0494

0068

0037

0482

5 – DECAL PLACEMENT

Figure 5-1. Decal Locations

BIL-JAX 36XT

Table 5-2. Decal Descriptions – CE
Decal No.

Decal Description

Qty

Decal No.
B06-00-0482

DANGER: Electrocution Hazard

B06-00-0495

CAUTION: Compartment Access
Restricted

Decal Description

Qty

0202-0523

Made in USA

B06-00-0034

DANGER: Electric Shock

B06-00-0037

Lubricate Semi-Annually

B06-00-0062

NOTICE: AC Power

B06-00-0505

DANGER: Before Use/Main
Instruction/Hazards (ground)

B06-00-0068

NOTICE: Hydraulic System Oil

B06-00-0506

NOTICE: Emergency Lowering

B06-00-0161B

Bil-Jax Logo, Black Transfer

2
B06-00-0541

CAUTION: Manual Boom
Functions

B06-00-0173

Fall Protection Attachment Points

B06-00-0404

WARNING: Outrigger Crush Toe

B06-00-0545

Bil-Jax Website Transfer

B06-00-0405

WARNING: Pinch Point

B06-00-0561

WARNING: Operating Instructions
(Ground)

B06-00-0471

DANGER: Before Use/Main
Instruction/Hazards (Platform)

B06-00-0562

WARNING: Operating Instructions
(Platform)

B06-00-0474

NOTICE: Max. Load

B06-00-0563

36XT, 6” Black Transfer

B06-00-0475

WARNING: Read/Understand
Operator’s Manual

B06-00-0568

WARNING: Outrigger Pressure

B06-00-0476

NOTICE: Range of Motion

B06-00-0572

WARNING: Read/Understand
Parts and Service Manual

Identification Plates

B06-00-0499-CE

CE Serial ID Plate

B06-00-0526

Key Tag

0476

0471

0474

0562

0173

0202-0523

0062

0475

0405
0552

0405

0034

0475

0476

0495

0161B

0405
0568

0405
0552

0505

0563

0561

0572

0404

0034

0495

0545

0506

0405

0541

0068

0037

0482

5 — REPLACEMENT DECALS

Figure 5-2. Decal Placement – CE

BIL-JAX 36XT

6 MATERIAL SAFETY DATA
The following Material Safety Data Sheets describe the correct
procedures for the safe handling of chemical components within the
Model 45XA Articulating Boom Lift, as well as any potential health and
safety hazards related to these chemicals. Material Safety Data Sheets
are included here in accordance with applicable federal and state
regulations. Read and observe all safety precautions. Maintain
awareness of potential health and safety hazards.

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

OTHER LIMITS

CAS NUMBER

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

PERCENT

OSHA
PEL

ACGIH
TLV

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%

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

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
Flammability Limits in Air % by Volume:
N/A
Extinguishing Media: Dry Chemical Carbon Dioxide, Water Fog, Water
Special Fire Fighting Procedures: Sulfuric Acid Fumes, Sulfur Dioxide Gas or Carbon Monoxide may be
released when acid decomposes. Wear NIOSH approved self-contained breathing apparatus.
Unusual Hazards: Water applied to sulfuric acid generates heat and causes acid to splatter. Wear full-cover
acid resistant clothing. Sulfuric acid reacts violently with metals, nitrates, chlorates, carbides, fulminates,
picrates and other organic materials. Reacts with most metals to yield explosive/flammable hydrogen gas.
This reaction is intensified when sulfuric acid is diluted with water to form battery electrolyte.

BIL-JAX 36XT

MATERIAL SAFETY DATA SHEET
FOR LEAD ACID BATTERIES, WET, FILLED WITH ACID (Continued)
SECTION V -- HEALTH HAZARD DATA
Primary Routes of Entry:

Inhalation: YES
Skin:
YES
Ingestion: YES
Acute
EYES, SKIN, RESPIRATORY SYSTEM & DIGESTIVE SYSTEM
Chronic:
EYES, SKIN, RESPIRATORY SYSTEM & DIGESTIVE SYSTEM
IRRITATION OF EXPOSED AREA, BURNS AND RESPIRATORY PROBLEMS
NO POSSIBILITY OF EXPOSURE OF LEAD WILL OCCUR UNLESS
BATTERY IS DESTROYED.

Health Hazards:
Signs and Symptoms of Exposure:

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
Incompatibility:
Hazardous Decomposition Products:
Hazardous Polymerization:

Conditions to Avoid: N/A
AVOID COMBUSTIBLES, ORGANIC MATERIALS, AND STRONG REDUCING AGENTS
SULFUR TRIOXIDE, CARBON MONOXIDE, SULFURIC ACID FUMES, &
SULFUR DIOXIDE
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:

SECTION VIII -- CONTROL AND PROTECTIVE MEASURES
Respiratory Protection:
Protective Gloves:
Eye Protection:
Ventilation:

Other Protective Equipment:
Hygienic Work Practices:

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

6 – MATERIAL SAFETY DATA

MATERIAL SAFETY DATA SHEET
DEXRON III/MERCON AUTOMATIC TRANSMISSION FLUID (HYDRAULIC OIL)
SECTION I -- GENERAL INFORMATION
TRADE NAME:
EMERGENCY TELEPHONE NUMBERS:
CHEMICAL FAMILY:
CAS NUMBER: MIXTURE.
HAZARDOUS INGREDIENTS:

CITGO TRANSGARD™ ATF, DEXRON III/MERCON
918.495.4700 (medical); 800.424.9300 (chemical)
AUTOMATIC TRANSMISSION FLUID, LUBRICATING OIL
REVISION DATE: 10/29/98
CONTAINS NO INGREDIENTS NOW KNOWN TO BE HAZARDOUS AS
DEFINED IN OSHA 29 CFR 1910.1000 AND OSHA 29 CFR 1910.1200.

SECTION II -- HEALTH HAZARD DATA
PRIMARY ROUTES OF ENTRY:
INHALATION, SKIN ABRASION AND INGESTION.
CARCINOGENIC:
NO
SYMPTOMS (INGESTION, CONTACT, INHALATION):
MILD, TRANSIENT SKIN OR EYE IRRITATION MAY OCCUR.
EYES:
FLUSH WITH WATER FOR 15 MINUTES
SKIN:
WASH THOROUGHLY WITH WARM SOAPY WATER.
INGESTION:
DO NOT INDUCE VOMITTING-SEEK MEDICAL ATTENTION.
CONDITIONS AGGRAVATED BY EXPOSURE:
NONE KNOWN
AIR EXPOSURE LIMITS:
P.E.L. 5 mg/m3 (OSHA) T.L.V. 10mg/m3 (ACGIH)
HEALTH:
0
FIRE:
1
SPECIFIC:
X
REACTIVITY:
0

SECTION III -- PHYSICAL DATA
BOILING POINT/FREEZING POINT:
VAPOR PRESSURE (PSIA):
SPECIFIC GRAVITY (H20=1):
SOLUBILITY IN WATER:
PH OF CONCENTRATE:
APPEARANCE AND ODOR:

N/A
N/A
0.86
NEGLIGIBLE; INSOLUBLE IN COLD WATER
N/A
RED LIQUID, MILD PETROLEUM ODOR

SECTION IV -- FIRE AND EXPLOSION HAZARD DATA
FLASH POINT (METHOD USED):
FLAMMABLE LIMITS:
LEL: N/A
UEL:
EXTINGUISHING MEDIA:
UNUSUAL FIRE AND EXPLOSION HAZARDS:

CLOSED: 339º F (Pensky-Martens); OPEN: 390º F (Cleveland).
NOT DETERMINED
N/A
DRY CHEMICAL, FOAM, CO2, WATER FOG. TREAT AS CLASS B FIRE.
PRODUCES COMBUSTIBLE VAPOR AT TEMPERATURES ABOVE FLASH POINT

SECTION V -- REACTIVITY DATA
STABILITY:
CONDITIONS TO AVOID:
INCOMPATIBILITY (MATERIALS TO AVOID):
HAZARDOUS DECOMPOSITION PRODUCTS:
HAZARDOUS POLYMERIZATION:

STABLE
AVOID EXTREMES OF HEAT; IGNITION SOURCES.
STRONG OXIDIZING MATERIALS.
INCOMPLETE COMBUSTION MAY CAUSE CARBON OXIDES.
WILL NOT OCCUR.

SECTION VI -- SPECIAL PROTECTION INFORMATION
RESPIRATORY PROTECTION (SPECIFIC TYPE):
VENTILATION:
LOCAL EXHAUST:
MECHANICAL EXHAUST (GENERAL):
PROTECTIVE GLOVES:
EYE PROTECTION:
OTHER PROTECTIVE EQUIPMENT:

NONE REQUIRED
NORMAL
NORMAL
X
OIL IMPERVIOUS GLOVES RECOMMENDED
SAFETY GLASSES RECOMMENDED
PROTECTIVE CLOTHING RECOMMENDED

SPECIAL LABELLING INSTRUCTIONS:
SPECIAL PACKAGING RECOMMENDATIONS:
HANDLING AND STORAGE RECOMMENDATIONS:
SPILL OR LEAK PROCEDURES:

NOT REQUIRED
NONE
AVOID EXTREMES OF COLD OR HEAT. STORE IN CLEAN DRY AREA.

IN CASE OF LEAK OR SPILL, DIKE AND ABSORB WITH INERT MATERIAL. FOLLOW
ALL LOCAL, STATE AND FEDERAL REGULATIONS FOR DISPOSAL.

DISCLAIMER: THE INFORMATION CONTAINED HEREIN HAS BEEN COMPILED FROM SOURCES
CONSIDERED TO BE DEPENDABLE AND IS ACCURATE TO THE BEST OF THE SELLER’S
KNOWLEDGE. THE SELLER MAKES NO WARRANTY WHATSOEVER, EXPRESSED OR IMPLIED, REGARDING THE ACCURACY
OF SUCH DATA OR THE RESULTS TO BE OBTAINED FROM THE USE THEREOF.

APPENDIX:REPLACEMENT

PARTS

Use only parts manufactured and/or authorized by Bil-Jax, Inc. when replacing
damaged components. See page 89 for replacement part ordering information.
Only personnel properly trained and authorized to operate all equipment and
familiar with all boom functions should attempt to repair or replace any part of the
boom lift.
Always read, understand and obey all safety precautions included in this
manual, as well as those precautions attached to the lift and dictated by
federal, state and local regulations.

Assembly Description

Page

Outrigger

Engine

Front Rest

Front Axle

Rear Axle

Slew Ring

Counterweight

Control Compartment

Pump Compartment

Battery Compartment

Cover

Boom

Cable Track

Boom Nose

Platform

Hydraulic Pump

Assembly Description

Page

Boom and Rotation Hydraulic Lines

Outrigger Hydraulic Lines

Trailer Hydraulic Lines – 4WD

Wire Harnesses

Manifold Wire Harness

Gas Engine Wire Harness

Choke/Throttle Solenoid Wire Harness

Engine Relays Wire Harness

ATC Fuse Holder

Start/Stop/Run Wire Harness

Generator Switcher Box

Wire Assembly – Fan

IEC Cord – Male – US Markets

Generator 110V Wire Harness

Oil Switch

Cord Assembly – 110V Generator

Cord Assembly – Generator Switch

Cord Assembly – Switch Jumper

Cord Assembly – 110V AC Plug – Female

Switcher Box – CE Models

220V Generator Wire Harness – CE Models

Cord Assembly – 220V AC Plug – Female – CE Models

Pump And Cylinder Wire Harnesses

Outrigger Coil and Switches Wire Harness

Analog Harness

Power Harness

110 VAC Tower-Platform Harness

Platform-Ground Communication Cable

Material Hook

Battery Layout

100

OUTRIGGER ASSEMBLY

21 15 16

4
5

13
30
6

29
14
26
27

6
5

7
25
4

OUTRIGGER ASSEMBLY PARTS LIST

Item No.

Part No.

Description

Qty.

A-00120

Outrigger Weldment

A-00046

Grommet – 1.5 x 1.25 x 1.75

A-00032

Bearing

A-00020

Pin, 1.25 x 5.5

A-00019

Pin Retainer, 1.25

0096-0016

Cap Screw, M10 x 25

0096-0041

Hex Nut, Self-Locking, M10

A-00060

Pin, 1.25 x 4.25

A-00138

Outrigger Hydraulic Cylinder

A-00141

Outrigger Cylinder Guard

0096-0009

Cap Screw, M8 x 10

A-00142

Guard Slide

0096-0010

Cap Screw, M8 x 20

0096-0040

Hex Nut, Self-Locking, M8

A-00154

Spring, Outrigger Sensor

0096-0036

Cap Screw, M16 x 150

0096-0044

Hex Nut, Self-Locking, M16

A-00128

Pad Mount Weldment

0096-0051

Cap Screw, M16 x 100

B01-03-0078

Limit Switch Assembly

0090-0232

Slotted Machine Screw, #10-24 x 5/8

0090-0182

Hex Nut, Self-Locking, #10-24

A-00136

Foot Pad, Aluminum, 12”

A-00137

Foot Pad Bottom, 12”

0096-0121

Flat Head Cap Screw, M8 x 30

A-00135

Foot Pad Ball

A-00195

O-Ring, 1 1/4” OD x 1” ID

0096-0045

Hex Nut, Self-Locking, M20

A-00127

Foot Pad Lock

A-00139

Foot Pad Lock Cap

*Quantities listed reflect the number of parts needed for each outrigger.
NOTE:

Unless otherwise noted, high-strength Grade 5/Class 8.8 fasteners
are used in the assembly of this equipment.
43

ENGINE ASSEMBLY (I)
5

16 17

3
11
10

8
15
8

20
22
14

15
13
2

ENGINE ASSEMBLY (I) PARTS LIST

Item No.

Part No.

Description

Qty.

A-01063

Cover Front

0096-0014

Cap Screw, M10 x 20

0096-0041

Hex Nut, Self-Locking, M10

A-01064

Cover Top

A-01067

Cover Side – Left

A-01069

Cover Side – Right

0096-0001

Cap Screw, M6 x 16

0096-0039

Hex Nut, Self-Locking, M6

B42-01-1006

Hinge – 72” Continuous

A-01045

Latch, Paddle-Style

0096-0113

Cap Screw, M4 x 16

0096-0073

Hex Nut, Self-Locking, M4

A-01052

Cover Rear

B01-06-0053

Relay 24V DC w/ Bracket

0096-0002

Cap Screw, M6 x 20

A-A-01059

Cover Pad

0096-0068

Flat Head Cap Screw, M10 x 45

A-03048

Relay Cover

A-03040

Switcher Box Assembly

B01-06-0056

Relay – 30 Amp

B01-10-0354

Circuit Breaker – 20 Amp

A-01015

Switcher Box

A-01072

Cover Latch Stop

0096-0098

Cap Screw, M8 x 35

0096-0040

Hex Nut, Self-Locking, M8

A-01047

Fuel Tank

A-01089

Fuel Gauge

0096-0016

Cap Screw, M10 x 25

ENGINE ASSEMBLY (II)
3

12 17

2
4
5
18

16 13

24
26

23
33
31 32
34
28

ENGINE ASSEMBLY (II) PARTS LIST

Item No.

Part No.

Description

Qty.

A-01046

Engine 21HP (See Manufacturer’s Literature)

0096-0098

Cap Screw, M8 x 35

0096-0040

Hex Nut, Self-Locking, M8

A-01048

Pump – Dual – 4.5 GPM

A-01055

Dual Pump Mount

0096-0110

Cap Screw, M10 x 110

0096-0093

Washer, M10

0096-0041

Hex Nut, Self-Locking, M10

A-01081

Oil Cooler

0096-0010

Cap Screw, M8 x 20

A-01071

Solenoid Bracket

0096-0001

Cap Screw, M6 x 16

0096-0039

Hex Nut, Self-Locking, M6

A-01074

Throttle Solenoid Assembly

A-00761

Generator

A-01060

Spacer

0096-0053

Cap Screw, M8 x 50

A-01038

Brake Release – Hand Pump

0096-0108

Cap Screw, M8 x 70

B02-00-0071

Oil Filter Assembly

B29-00-0016

Oil Filter Bracket

A-00783

Exhaust Assembly

A-01061

Belt

A-01051

Pulley

0090-0363

Set Screw – 1/4 - 20 x 3/4

A-01036

Pulley

A-01088

Idler Roller

0096-0022

Cap Screw, M12 x 75

0096-0076

Washer, M12

0096-0041

Hex Nut, Self-Locking, M12

A-01095

Tension Arm

A-01086

Spacer – Tension Arm

0090-0210

Washer – 3/8”

0096-0069

Cap Screw, M10 x 75

1
47

FRONT REST ASSEMBLY
12

19
17

15
11

5
6
10
6
21

FRONT REST ASSEMBLY PARTS LIST

Item No.

Part No.

Description

Qty.

A-03145

Front Rest Weldment

0096-0024

Cap Screw, M12 x 100

0096-0042

Hex Nut, Self-Locking, M12

A-00157

Front Rest Pad

0096-0017

Cap Screw, M10 x 30

0096-0041

Hex Nut, Self-Locking, M10

A-00159

Boom Latch

0096-0016

Cap Screw, M10 x 25

A-00169

Switch Bracket

0096-0002

Cap Screw, M6 x 20

0096-0039

Hex Nut, Self-Locking, M6

A-00188

Switch Cam

0090-1104

Machine Screw, #4-40 x 1

0090-0525

Hex Nut, Self-Locking, #4-40

B01-03-0078

Limit Switch Assembly, NO (Female)

B01-03-0079

Limit Switch Assembly, NC (Male)

0090-0709

Machine Screw, #6-32 x 1 1/4

0090-0180

Hex Nut, Self-Locking, #6-32

A-00158

Tension Spring

0096-0038

Cap Screw, M20 x 120

0096-0045

Hex Nut, Self-Locking, M20

A-01082

Tie Weldment – 4WD

FRONT AXLE ASSEMBLY

19
17
22
8
23
24
20

21
16

6
5

13
4
9

FRONT AXLE ASSEMBLY PARTS LIST

Item No.

Part No.

Description

Qty.

A-01010

Front Axle Weldment – 4WD

A-01097

Bushing, 1.5” OD x 1.25” ID

A-01020

Front Yoke – Left

A-01021

Front Yoke – Right

A-01070

Pin – 1.25” x 1.625”

A-00019

Pin Retainer – 1.25”

0096-0016

Cap Screw, M10 x 25

0096-0041

Hex Nut, Self-Locking, M10

A-01022

Hydraulic Motor – 4WD

0096-0024

Cap Screw, M12 x 100

0096-0042

Hex Nut, Self-Locking, M12

A-01025

Tie Rod – 4WD

A-01096

Bushing, 1.25” OD x 1.0” ID

A-01085

Pin – Front Axle

0090-0155

Cotter Pin – 3/16” x 1 3/4"

A-01030

Steering Cylinder – 4WD

A-01005

Front Axle Mount Weldment

0096-0038

Cap Screw, M20 x 120

0096-0045

Hex Nut, Self-Locking, M20

A-01029

Pad – Front Axle

0096-0091

Flat Head Cap Screw, M10 x 25

A-01009

Pin – 1.0” x 5.5”

A-00018

Pin Retainer – 1.0”

0096-0014

Cap Screw, M10 x 20

REAR AXLE ASSEMBLY

REAR AXLE ASSEMBLY PARTS LIST

Item No.

Part No.

Description

Qty.

A-00175

Hydraulic Cover

0096-0010

Cap Screw, M8 x 20

0096-0067

Clip Nut, M8

A-01032

Hydraulic Motor – Rear

0096-0024

Cap Screw, M12 x 100

0096-0042

Hex Nut, Self-Locking, M12

A-01037

Axle Cover

SLEW RING ASSEMBLY

13
12
11

3
6
2

SLEW RING ASSEMBLY PARTS LIST

Item No.
1

Part No.
A-02189

Description
Slew Assembly and Adapter

Qty.
1

Slew Ring

Slew Ring Drive

A-00149

Base Ring Adapter

0090-0461

Cap Screw, 1/2-13 x 2

0090-0212

Lock Washer, 1/2

0096-0033

Flat Head Cap Screw, M16 x 35

0096-0054

Flat Head Cap Screw, M16 x 50

0090-0643

Cap Screw, 5/8-11 x 2-3/4, Grade 8

0096-0044

Hex Nut, Self-Locking, M16

A-00350

Rotation Stop Assembly

0096-0021

Cap Screw, M12 x 45

0096-0042

Hex Nut, Self-Locking, M12

COUNTERWEIGHT ASSEMBLY

COUNTERWEIGHT ASSEMBLY PARTS LIST

Item No.

Part No.

Description

Qty.

A-00270

Counterweight

0096-0065

Cap Screw, M20 x 80

0096-0045

Hex Nut, Self-Locking, M20

CONTROL COMPARTMENT ASSEMBLY
8

10
21

22
21
8
13
12

7
6
13
14

16 17 18 19 20

CONTROL COMPARTMENT ASSEMBLY PARTS LIST

Item No.

Part No.

Description

Qty.

A-00712

Lower Control Box

A-00233

Lower Control Mount

A-00290

Cover Stop Bracket

0096-0016

Cap Screw, M10 x 25

0096-0041

Hex Nut, Self-Locking, M10

A-00295

Level Sensor

0096-0002

Cap Screw, M6 x 20

0096-0039

Hex Nut, Self-Locking, M6

A-00287

Mount Plate – GFI Outlet

A-00255

Motor Controller

B01-05-0056

Battery Charger

A-00274

Gas Spring

0090-0920

Stud Ball, 10mm

0090-0185

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

A-03200

Turntable Weldment

B01-10-0046

Outlet Box

B01-10-0034

GFI Outlet

B01-10-0035

Outlet Box Cover

0096-0001

Cap Screw, M6 x 16

A-00288

Plastic Cover

0096-0004

Cap Screw, M6 x 25

A-00935

Dual Motor Controller Bracket

PUMP COMPARTMENT ASSEMBLY

4
1

PUMP COMPARTMENT PARTS LIST

Item No.

Part No.

Description

Qty.

A-00268

Tire Iron/Jack Handle

B04-07-0033

Clamp

0096-0001

Cap Screw, M6 x 16

0096-0039

Hex Nut, Self-Locking, M6

A-00290

Cover Stop Bracket

0096-0002

Cap Screw, M6 x 20

0096-0014

Cap Screw, M10 x 20

BATTERY COMPARTMENT ASSEMBLY
16

30
22

16
20

23
18
21
19

26 27
29

8
6
7

28
4

14
11

BATTERY COMPARTMENT ASSEMBLY PARTS LIST

Item No.

Part No.

Description

Qty.

A-00215

Battery Box Weldment – Left

A-00220

Battery Box Weldment – Right

A-00278

Battery Hinge Pin

0096-0050

Washer, Flat, M16

0090-0147

Cotter Pin

A-00271

Battery Clamp

0096-0010

Cap Screw, M8 x 20

0096-0040

Hex Nut, Self-Locking, M8

A-00219

Battery Box Latch

A-00256

Motor Cover

A-00229

Latch Plate

A-00234

Spacer

0096-0011

Cap Screw, M8 x 25

A-00244

Tension Spring

A-00225

Nose Weldment

0096-0014

Cap Screw, M10 x 20

0096-0041

Hex Nut, Self-Locking, M10

A-00037

Ramp, Short

0096-0002

Flat Head Cap Screw, M6 x 20

0096-0039

Hex Nut, Self-Locking, M6

A-00046

Grommet

B04-07-0036

Clamp

B01-09-0132

A-Frame Handle, Connector

B01-09-0131

Plug, Connector

A-03272

Battery Cable Kit

B01-09-0133

Terminal Boot – Black

B01-09-0134

Terminal Boot – Red

A-00242

Battery

0090-0162

Hex Nut, 3/8-16”

A-00235

Power Unit, 4WD

B02-15-0528

3KW 24V DC Motor

B02-15-0529

Gear Pump 2.0 ccm

B02-02-0301

Fitting M14 x –6 ORFS

B02-02-0302

Fitting, M18 x –8 ORFS

1
63

COVER ASSEMBLY
5

9
10

COVER ASSEMBLY PARTS LIST

Item No.

Part No.

Description

Qty.

A-03240

Cover – Left

A-03239

Cover – Right

A-00228

Cover Brace

A-00252

Hinge

0096-0002

Cap Screw, M6 x 20

0096-0039

Hex Nut, Self-Locking, M6

0090-1080

Pop Rivet

A-00258

Controls Cover – Left Side

B42-01-1002

Hinge, Controls Cover

A-00292

Cover Latch Assembly

BOOM ASSEMBLY (I)
10

8
9
4
5
2
3

BOOM ASSEMBLY PARTS LIST

Item No.

Part No.

Description

Qty.

A-00552

Hydraulic Master Cylinder

A-00024

Pin, .75 x 8.5

A-00017

Pin Retainer – .75

0096-0016

Cap Screw, M10 x 25

0096-0041

Hex Nut, Self-Locking, M10

A-00026

Pin, .75 x 7.0

A-00551

Hydraulic Boom Cylinder

A-00021

Pin, 1.25 x 8.5

A-00019

Pin Retainer – 1.25

A-00023

Pin, 1.25 x 7.25

BOOM ASSEMBLY (II)
7

13 14

6
8
5
10
9
28
4

25
27
26
24

17 15

20 22

BOOM ASSEMBLY PARTS LIST

Item No.

Part No.

Description

Qty.

A-00510

Telescopic Boom Tube

A-00550

Hydraulic Extension Cylinder

A-00535

Slider

0096-0018

Cap Screw, M10 x 40

0096-0041

Hex Nut, Self-Locking, M10

A-00032

Bearing

0096-0033

Flat Head Cap Screw, M16 x 35

A-00027

Pin, .75 x 7.0

A-00017

Retainer – .75

0096-0016

Cap Screw, M10 x 25

A-00533-1

Wear Pad – Green

A-00533-2

Wear Pad – Grey

A-00534

Wear Pad Shim

0096-0013

Nylon Cap Screw, M10 x 16

A-00537

Boom Switch Block

0096-0098

Cap Screw, M8 x 35

0096-0040

Hex Nut, Self-Locking, M8

A-00469

Cage Latch Pad

A-00470

Cage Storage Pad

A-00471

Cage Latch Plate

A-00473

Cage Latch

0096-0001

Cap Screw, M6 x 16

0096-0049

Cap Screw, M8 x 50

0096-0040

Hex Nut, Self-Locking, M8

B01-10-0275

Strobe Light (Option)

0090-0236

Machine Screw, #10-24 x 3/4

0090-0415

Washer, Flat, #10

0090-0182

Hex Nut, Self-Locking, #10-24

CABLE TRACK ASSEMBLY
4

2
3
3

12
2

CABLE TRACK ASSEMBLY PARTS LIST

Item No.

Part No.

Description

Qty.

A-00531

Slide Tube

0096-0010

Cap Screw, M8 x 20

0096-0040

Hex Nut, Self-Locking, M8

A-00532

Tube Slider

A-00529

Tube Slider Back

0096-0018

Cap Screw, M10 x 40

0096-0017

Cap Screw, M10 x 30

0096-0041

Hex Nut, Self-Locking, M10

B00-00-0031

Cable Track – 41 Links

A-00536

Cable Track Tray

0096-0014

Cap Screw, M10 x 20

A-00538

Cable Support Tube

A-00539

Cable Slide Block

0096-0056

Cap Screw, M8 x 30

BOOM NOSE ASSEMBLY
31

2
15

28
29

30
17
18
3
23
4

5
2

25 26

8 10 11

BOOM NOSE ASSEMBLY PARTS LIST

Item No.

Part No.

Description

Qty.

A-00979

Bulkhead Mount

0096-0016

Cap Screw, M10 x 25

A-00601

Platform Pivot Weldment

A-00025

Pin, 1.0 x 6.5

A-00018

Pin Retainer – 1.0

0096-0041

Hex Nut, Self-Locking, M10

0096-0015

Socket Head Cap Screw, M10 x 20

A-00033

Bearing

A-00606

Snap Pin

A-00608

Compression Spring

A-00609

Knob, Platform Latch

0096-0055

Cap Screw, M12 x 190

0096-0042

Hex Nut, Self-Locking, M12

A-00553

Hydraulic Slave Cylinder

A-00027

Pin, .75 x 5.25 DB

A-00034

Pin Retainer – .75 FH

0096-0012

Flat Head Cap Screw, M8 x 25

0096-0040

Hex Nut, Self-Locking, M8

A-00035

Pin, .75 x 6.5

A-00017

Pin Retainer – .75

A-00522

Boom End Weldment

0096-0020

Cap Screw, M12 x 30

A-00031

Bearing

A-00610

Platform Mount Weldment

A-00038

Ramp

0096-0003

Flat Head Cap Screw, M6 x 20

0096-0039

Hex Nut, Self-Locking, M6

B01-10-0046

Outlet Box

B01-10-0034

GFI Outlet

B01-10-0035

Outlet Box Cover

0096-0001

Cap Screw, M6 x 16

PLATFORM ASSEMBLY
17

22
23
24
7
5

18
7

9
11
12

21
2

20
19
13

PLATFORM ASSEMBLY PARTS LIST

Item No.

Part No.

Description

Qty.

A-03350

Platform Weldment – 5’

A-03359

Platform Floor

0096-0102

Cap Screw, M8 x 25

0096-0040

Hex Nut, Self-Locking, M8

A-03361

Upper Control Box Mount

0096-0016

Cap Screw, M10 x 25

0096-0041

Hex Nut, Self-Locking, M10

A-00466

Control Box Latch

A-00463

Midrail End

0096-0115

Slotted Head Cap Screw, M6 x 20

A-00464

Midrail

0096-0052

Cap Screw, M6 x 40

0096-0039

Hex Nut, Self-Locking, M6

A-00468

Manual Storage Mount Plate

0096-0017

Cap Screw, M10 x 30

A-00475

Manual Storage Box

0096-0001

Cap Screw, M6 x 16

A-00474

Cord Wrap Bracket

A-00071

Platform Pin

0090-0147

Cotter Pin – 1/8 x 1 1/4

A-00028

Pin – Platform to End Weldment

A-00779

Upper Control Box – 4WD Articulating

A-00462

Spool

0096-0003

Flat Head Cap Screw, M6 x 40

20 4

2 21

15 20

5 21

20 13

8 9

PUMP ASSEMBLY (A-00254)

PUMP ASSEMBLY PARTS LIST

Item No.

Part No.

Description

Qty.

B02-15-0496

Manifold, Valve Housing

B02-14-0108

Valve, Counterbalance

B02-15-0472

Manual Pump, Extend/Retract/Rotate

B02-14-0089

Valve, Cartridge (Outrigger Check)

B02-14-0109

Valve, Cartridge (Outrigger)

B02-14-0091

Valve, Check

B02-14-0110

Valve, Check

B02-14-0094

Valve, Proportional

B02-14-0095

Coil Sterling, Proportional Valve

B02-14-0111

Valve, Relief

B02-14-0097

Valve, Relief

B02-14-0098

Valve, Shuttle

B02-14-0099

Valve, Cartridge (Rotator)

B02-14-0100

Valve, Counterbalance

B02-14-0101

Valve, Cartridge (Basket Compensate)

B02-14-0114

Valve, Flow Control (Rotator)

B02-02-0245

Fitting, Plug, #2 ORB

B02-02-0246

Fitting, Hex Plug

B02-02-0248

Fitting, Plug, #4 ORB

B02-14-0112

Coil, 20 VDC, #8

B02-14-0113

Coil, 20 VDC, #10

B02-15-0497

Stud, #1/4-20 x 5/8

B02-15-0498

Expansion Plug

B02-02-0235

Fitting, Plug, #6 ORB

B02-15-0478

Seal Ring

PUMP ASSEMBLY, CONTINUED

PUMP ASSEMBLY PARTS LIST, CONTINUED

Item No.

Part No.

Description

Qty.

B02-15-0513

Reservoir

B02-15-0470

Pump Assembly, 2.09 CCM

B02-15-0471

Motor, Pump, 24 VDC

B02-15-0500

Coupling, .875 x 2.795

B02-15-0501

Filter, Hydraulic

B02-15-0476

Sight Glass

B02-15-0477

Socket Head Cap Screw, M8 x 85

B02-02-0247

Fitting, Plug, M14 x 1.5 x 5.8

B02-15-0478

Seal Ring

B02-15-0485

Clamp, Band, #10-16

B02-15-0480

Filter, Suction

B02-15-0504

Allen Nut, 1/4-20

B02-02-0255

Fitting, M18 x HB-90M x HB-90

B02-15-0503

O-Ring, 110.72 x 3.53 NBR 70 D

B02-02-0279

Fitting, JIC-8 x Push On FS x PO

B02-15-0505

Hose, Black, 1/2 x 6”

B02-02-0280

Fitting, JIC-8 x #6 MxM

B02-15-0506

Cap Screw, #5/16-18 x 1 1/4

B02-02-0283

Fitting, JIC-8 x G 3/4 MxM

B02-02-0281

Fitting, Plug, #12 ORB

B02-02-0282

Fitting, 3/8 NPT x 1/2 MxHB

B02-15-0507

Hose, Black, 1/2 x 15”

B02-02-0276

Fitting, Plug, #8 ORB (Under Reservoir)

BOOM AND ROTATION HYDRAULIC LINES (A-00269)

BOOM AND ROTATION HYDRAULIC LINES PARTS LISTS
Item No.

Part No.

Description

Fittings

B02-01-0274

#4 x 42” Hydraulic Hose

4-6 FFORX

4-4 FFORX

B02-01-0275

#4 x 42” Hydraulic Hose

4-6 FFORX

4-4 FFORX

B02-01-0276

#6 x 66” Hydraulic Hose

6-6 FFORX

B02-01-0277

#6 x 66” Hydraulic Hose

6-6 FFORX

B02-01-0278

#4 x 48” Hydraulic Hose

4-6 FFORX

4-6 FFORX 45

B02-01-0279

#4 x 48” Hydraulic Hose

4-6 FFORX

4-6 FFORX 45

B02-01-0280

#4 x 36” Hydraulic Hose

4-6 FFORX

B02-01-0281

#4 x 36” Hydraulic Hose

4-6 FFORX

B02-01-0231

#4 x 10” Hydraulic Hose

4-4 FFORX 90S

4-4 FFORX

B02-01-0232

#4 x 420” Hydraulic Hose

4-4 FFORX

B02-01-0233

#4 x 420” Hydraulic Hose

4-4 FFORX

B02-01-0234

#4 x 16” Hydraulic Hose

4-4 MFFOR

4-4 FFORX

B02-01-0235

#4 x 16” Hydraulic Hose

4-4 MFFOR

4-4 FFORX

B02-01-0204

#3 x 32” Hydraulic Hose

2 MNPT

2 MNPT 90SW

FITTINGS
Part No.

Description

Qty.

B02-02-0259

#6 MORFS - #6 MORB, STR

B02-02-0264

#6 MORFS - # 6 MORB, 45º

B02-02-0263

#4 MORFS, Tee

B02-02-0237

#4 MORFS - #6 MORB, STR

B02-02-0262

#6 MORFS - #10 MORB, 45º

B02-02-0196

#4 MORB - #2 MNPT, STR

B02-02-0241

#2 NPTFM Coupling

B02-02-0242

#2 QD Plug

B02-02-0229

#4 MORFS - #6 MORB 90

OUTRIGGER HYDRAULIC LINES (A-03182)

RET

7
9

EXT
5

3
1

R
ET

EX
T

T
RE

T
EX

OUTRIGGER HYDRAULIC LINES PARTS LIST

Item No.

Part No.

Description

Qty.

B02-01-0213

#4 x 28” Hydraulic Hose

B02-01-0214

#4 x 28” Hydraulic Hose

B02-01-0215

#6 x 56” Hydraulic Hose

B02-01-0216

#6 x 56” Hydraulic Hose

B02-01-0219

#6 x 28” Hydraulic Hose

B02-01-0220

#6 x 28” Hydraulic Hose

B02-01-0327

#6 x 46” Hydraulic Hose

B02-01-0328

#6 x 46” Hydraulic Hose

B02-02-0258

Fitting, Tee, #6 MORFS

B02-02-0259

Fitting, #6 MORFS - #6 MORB

(2) #8MORFS-#10MORB 45
FF6802-8-10

#10MORFS-#10MOBR-#10MORFS Tee
FF6804-10-10-10
#10MORFS-#10FMORFS 90
FF6500-10-10

#12ORBM-#10ORBFM STR
6410-12-10

OIL
COOLER

Dual
Pump
5GPM

Banjo
Bolt

10MORB Plug
6408-H-10

#8MORFS Tee
FF2603-8-8-8

Driver

ORB

#4MORFS-#4MORB 90
FF6801-4-4

3B
#10MORFS-#12ORB 90
FF6801-10-12

#8MORFS-#12MORB STR
FF6400-8-12

SMB

SMA

#6MORFS-#6MORB STR
FF6400-6-6

#4MORFS-#4MORB 90
FF6801-4-4

TP3

P1A
90

FF6801-6-6

P1B
90

FF6801-L-6-6

TP2

P2A
90L

P2B
STR

FF6400-6-6

FF6801-6-6

Oil Filter

S1B

Rear

Front

Bottom

Top

M2B

FF6400-6-6

(2) #6MORFS-#10MORB STR
FF6400-6-10
(2) #4MORFS-#4MORB 90
FF6801-4-4

Control
Side
Rear

Control
Side
Front

M2A
FF6400-6-6

FF6400-4-4

(2)#10MORB-#6FMORB
6410-L-10-6
(2)#6MORFS-#6MORB 90
FF6801-6-6

FF6400-4-6

S1A

M3B

20
21

M1B

FF6400-6-6

M4A

Bottom

Pump
Side
Rear

Pump
Side
Front
24

(2) #6MORFS-#10MORB STR
FF6400-6-10
(2) #4MORFS-#4MORB 90
FF6801-4-4

Rear

Front

Aux
Pump

(2)#10MORB-#6FMORB
6410-L-10-6
(2)#6MORFS-#6MORB 90
FF6801-6-6

Top

B1
FF6400-4-4

FF6400-8-8

8-18 Metric
90

6-14 Metric
90

M4B

FF6400-6-6

M1A

#4MORFS Tee
FF2603-4-4-4

FF6400-6-6

M3A

#4MORFS Tee
FF2603-4-4-4

MANUAL
BRAKE
RELEASE

Brake

(2) #4MORFS-#4MORB 45
FF6802-4-4

TRAILER HYDRAULIC LINES – 4WD (A-01075)

TRAILER HYDRAULIC LINES PARTS LISTS
Item No.

Part No.

Description

B02-01-0402

#10 x 28” Hydraulic Hose

B02-01-0401

#8 x 154” Hydraulic Hose

B02-01-0398

#8 x 16” Hydraulic Hose

B02-01-0400

#8 x 24” Hydraulic Hose

B02-01-0399

#8 x 18” Hydraulic Hose

B02-01-0386

#6 x 30” Hydraulic Hose

B02-01-0387

#6 x 30” Hydraulic Hose

B02-01-0397

#6 x 166” Hydraulic Hose

B02-01-0396

#6 x 150” Hydraulic Hose

B02-01-0385

#4 x 118” Hydraulic Hose

B02-01-0379

#4 x 16” Hydraulic Hose

B02-01-0382

#4 x 30” Hydraulic Hose

B02-01-0383

#4 x 40” Hydraulic Hose

B02-01-0393

#6 x 138” Hydraulic Hose

B02-01-0392

#6 x 138” Hydraulic Hose

B02-01-0388

#6 x 38” Hydraulic Hose

B02-01-0389

#6 x 38” Hydraulic Hose

B02-01-0395

#6 x 138” Hydraulic Hose

B02-01-0394

#6 x 138” Hydraulic Hose

B02-01-0390

#6 x 62” Hydraulic Hose

B02-01-0391

#6 x 62” Hydraulic Hose

B02-01-0380

#4 x 21” Hydraulic Hose

B02-01-0384

#4 x 105” Hydraulic Hose

B02-01-0381

#4 x 25” Hydraulic Hose

FITTINGS
Part No.

Description

Qty.

B02-02-0259

#6 MORFS - #6 MORB, STR

B02-02-0293

#8 MORFS - #8 MORB, STR

B02-02-0260

#6 MORFS - #6 MORB, 90º

B02-02-0287

#4 MORFS - #4 MORB, STR

B02-02-0288

#4 MORFS - #4 MORB, 90º

B02-02-0289

#4 MORFS, Tee

B02-02-0294

#6 MORFS - #6 MORB, 90ºL

B02-02-0295

#12 MORB - #10 FMORB

B02-02-0296

#10 MORFS - #10 MORB - #10 MORFS, Tee

B02-02-0297

#10 MORFS - #10 FMORFS, 90º

B02-02-0298

#8 MORFS - #12 MORB, STR

B02-02-0299

#8 MORFS - #10 MORB, 45º

B02-02-0300

#10 MORFS - #12 MORB, 90º

B02-02-0303

#10 MORB Plug

B02-02-0304

#10 MORB - #6 FMORB

B02-02-0305

#6 MORFS - #10 MORB, STR

B02-02-0237

#4 MORFS - #6 MORB, STR

B02-02-0307

#8 MORFS, Tee

B02-02-0308

#4 MORB Plug

B02-02-0309

#8MORFS - #12 MORB, 90º

4WD MANIFOLD (A-01033)

WIRE HARNESSES
Upper
Control
Box

Platform Plug

Motor
Cntl
B+

Motor
Cntl
B-

Bla
Blu

Re
Or

3
1

6
4

8
7

J4
Platform Connector

P4 & P5
Connector
P3
Turntable Connector
36

P1
Analog Connector

P2
Lift/Engine Connector
35

11
24

3
1

4
2

22
15

1
23

5
12

7
20

32
32

+ -

+
Jib
Cyl
C17

Strobe

Prop
Coil
C8

Sec
Cyl
C16
Level
Sensor

PLT
DN
C14
PLT
UP
C13

Prim
Cyl
C5

Motor
Controller
Main

Chk
Valve
C6A

Rot
CCW
C9

Boom
RET
C12

OR
EXT
C6

Rot
CW
C10

Boom
EXT
C11

OR
RET
C7

Motor
Controller
Aux

Pump

LF
LF
C1

LR
C3

RF
C2

3
Speed

**NO

RR
C4

B-

1
Enable
M-

3
Speed
B-

B+

1
Enable
M-

Oil
Press
Switch

B+

AC
Switch

**NO
# # NO # # NO
RF

Boom
Down
Relay NC
34

C26

Jib
Switches

Front
Boom
Switches

# NC

**NO

D
A 2 E2 1 E1

Aux
Pump
Motor

RR
NO

200
Amp
Fuses

C25

C24

C23

C22

C21

C20

A 2E

Throttle
Sol

Fuel
Switch

Choke
Sol

Engine
Stop

Main
Pump
Motor

Engine
Start

Fan

Engine
Run

IEC Recp.

C31

C30

C29

C28

C27

Engine
Start

Engine Stop

Start

Drive
Manifold

Switch is forced Closed
when outrigger is loaded
#

GFCI
Plug

AC
Plug

Switch is forced open
when Boom is lifted
AC Switch

Switch is forced Closed
when Boom is Stowed

Generator

2 D 1 E1

Engine Spark

Fuel

Start Sol

Fan

Fuel Sol

M
Fan

MANIFOLD WIRE HARNESS (A-00785)

Deutsch Term.
0462-201-16141

Label Wires
Both Ends

12020786
6 Pin Male Conn
1208089040
Male Term
12015323
Green Wire Seal
12010717
3 Pin Male Conn
12089040
Male Term
12015323
Green Wire Seal
12020926
6 Pin FM Conn
12089188
FM Term
12015323
Green Wire Seal

Wires
Connected
& Sealed

Wire Color

Orange

C20

C21

White

C22

Green
Red

C23

C24

Blue

C25

White/B

Black

GND
C26(+)

C26(-)

Green/B

Red/B

C27

Orange/B

C28

Blue/B

C29

Green/W

C30

Red/W

C31

Blue/W

GND

Black/W

Label
A-00785
Rev-

GND 1
3"

C20

White

C21

Green

C22

Red

C23

Blue

C24

White/B

C25

Orange/B

C27

Blue/B

C28

Green/W

C29

Red/W

C30

1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2

Black

3"
Black/W
GND 2

156" (13')(+/- 2") 16 Cond 18ga Wire
SOOW or Equivalent

Orange

Blue/W

Wires
Connected
& Sealed

C31

Red/B

C26 +

Green/B

C26 -

Deutsch
DT06-2S
2 Pin Plug
W2S Wedge

Stripe wire
to 12"

Stripe wire
to 4"

GAS ENGINE WIRE HARNESS (A-01034)

12020829
3 Pin Female Conn
12089188
Female Term
12015323
Green Wire Seal
C

Wire
Color

Label

Oil Press Sw
Oil Press Sw (+)

Or/BL

B
A

Gen Switch

Wh/Bl

Engine Run

Red

Wire
Color

Label

R/BL

Oil Press Sw (+)

Or/BL

Oil Press Sw

R/BL
Gen Switch

Wh/Bl
Green
C
B

GND

Green

Choke

Black

120" (10')
18ga-10 Cond Wire
SOOW or Equivalent
A-01034
Rev-

A-01034
Rev-

Throttle

White

Engine Stop

Blue

Choke
Throttle

A
B

Splice &
Heat Sealed

Red

Engine Run

White

Engine Start

Blue

Engine Stop

Green

GND

12010973
2 Pin Male Conn
12089040
Male Term
12015323
Green Wire Seal

Delphi
Weather Pack

Orange

Engine Start

Black
Orange
Green

Label Both
Ends

12015792
2 Pin Female Conn
12089188
Female Term
12015323
Green Wire Seal

Delphi
Weather Pack

12020827
3 Pin Male Conn
12089040
Male Term
12015323
Green Wire Seal

12020829
3 Pin Female Conn
12089188
Female Term
12015323
Green Wire Seal

GND

Delphi
Weather Pack

12020830
4 Pin Male Conn
12089040
Male Term
12015323
Green Wire Seal

Strip Wires 6"

Strip Wires 3"

CHOKE /THROTTLE SOLENOID WIRE HARNESS (A-01042)

1"
A-01042
Rev-

Put Wires
in 16"
Split
tubing
Heat Seal
Both
ends

Weather Pack
FM Term
12089188
Cable Seal
12015323
FM Housing
12015792

Label

20" 18ga TXL
Or Equivalent

ENGINE RELAYS WIRE HARNESS (A-01044)

A-01044
Rev-

Solder inline &
Heat Shrink

Label

10" Split
Tube Wrap
Tape At
Each End

¼” Female Spade

Engine Run

Red

3"
R

FAN

4" Red

Fuel F 87

15"

Ign K 87a

Black

15"

¼” Female Spade

Starter S 87

Yellow

20"

Orange

18"

F 30

S 30

6"
12v +

C 30

T 30

Wire Color

10"

¼” Female Spade

Heat
Shrink

Wire
Length
Engine
Run

¼” Male Spade

¼” Female Spade

Delphi Weather Pack
Male Term 12089040
Green Seal 12015323

¼” Female
Spade

Resistor
2.2k-Ohm
.5Watt

Wire
Color

Green

All wires 18 ga
TXL or Equivalent
All Measurements
are +/- 0.250 In

Fuel Sw
Ign Coil

¼” Female Spade

¼” Male Spade
Starter

+ 12V

Labels

¼” Female Spade

5/16" Ring Term

ATC FUSE HOLDER (A-01049)

ATC Fuse Holder
Waytek # 46278
or Equivalent
5/16" Ring
Term

¼” Female Spade Ins

4"- 6" Leads
12 ga Wire

START/STOP/RUN WIRE HARNESS (A-01098)

A-01098
Rev 10"

Label

Split Tube Wrap
& Heat Shrink
Each End
Wire Label

Tape Both Sides
of Drop Out

18"

Delphi Weather Pack
12020832
4 Pin Female Conn
12089188
Female Term
12015323
Green Wire Seal

Start S 86
Length

Red

24"

White

26"

Blue

20"

GND 85

Green

20"

GND 85

C
D
Delphi Weather Pack

¼” Male Spade
Insulated

Engine Run
Wire
Color

6"
4"

12015792
2 Pin Female Conn
12089188
Female Term
12015323
Green Wire Seal

Stop K 86
Fuel F 86

Choke

Black

28"

Choke C 86

Throttle

Orange

28"

Throttle T 86

Yellow

28"

Choke C 87

Orange/Bl

28"

Throttle T 87

Choke
15"

B
A

12010973
2 Pin Male Housing
12089040
Male Terminal
12015323
Green Wire Seal
Delphi Weather Pack

Black

Throttle
15"

Frame
Gnd

¼” Female Spade Insulated

Black

K 30

11"

¼” Ring
Terminal
Delphi Weather Pack

5"
Fan

Splice & Heat
Shrink Seal

12010973
2 Pin Male Housing
12089040
Male Terminal
12015323
Green Wire Seal

All wires
TXL or Equivalent
All Measurements
are +/- 0.250 In

A – Leave
Open

GENERATOR SWITCHER BOX ASSEMBLY (A-03040)
Box-A-01015

B01-06-0056
30 Amp Relay
DPST – NO
Allied Electronics
#850-0345
Or Equivilant

B01-01-0180

B01-10-0354
20 Amp Circuit Breaker
W/.250 Male Spade Terminal
Allied Electronics
#886-0036
Or Equivilant

20
Amp

Ground
Stud
Bl
Br

Y/
g

B W G

B W

Cord Grip
Heyco #3231
Or Equivilant

B01-01-0181

B01-01-0179
B01-01-0178

Delphi Weather Pack
2 Pin Male Housing
Male Terminal
Green Seal

12015793
12010293
12010293

12010973
12089040
12015323

Delphi Weather Pack
3 Pin Male Housing
Male Terminal
Gray Seal

B W G

Label

Weather Pack
FM Term
12089188
Cable Seal
12015323
FM Housing
12015792

WIRE ASSEMBLY – FAN (A-03041)

A-3041
Rev.

40" Loom
Tape each End &
Middle

Label
Wires

Wire
Color

GND

Black

Relay

Red

A-03041
Rev.

B
A

Weather Pack
FM Term
12089188
Cable Seal
12015323
FM Housing
12015792

36"

All wires 18 ga
TXL or Equivalent
All Measurements
are +/- 0.250 In

IEC CORD MALE – US MARKETS (A-03042)

18"

A-03042
Rev
SO cable or
Equivalent

Label
North America
120V Male Plug

Minimum Requirements
IEC 90 Degree Plug
Interpower
IEC 60320 C19
Mold 012

Current 15 AMP
Voltage 120/240VAC

GENERATOR 110V WIRE HARNESS (A-03043)

12-3 SO
Or Equivilant
36" (+/- 2")

.0625"
2"
B
W

1/2” Grommet OD
Delphi Weather Pack
12010717
3 Pin Male Housing
12124582
Male Terminal 12/14ga
12010293
Seal 12/14ga

OIL SWITCH ASSEMBLY (A-03044A)

A-03044
OIL PRESSURE SWITCH 4WD
TRANSDUCER DIRECT #TDPS211A8FW

B00-00-0170
Wire Casing
16"

Delphi Weather Pack
12010973 (B01-09-0109)
2 Pin Male Housing
12089040 (B01-09-0110)
Male Terminal
12015323 (B01-09-0093)
Green Seal

PVC
Tape

Wires should be 17-18" Long

CORD ASSEMBLY 110V GENERATOR (B01-01-0178)

14-3
SO or Equivalent

Delphi Weather Pack
12015793
3 Pin Female Housing
12124580
Female Terminal 12/14ga
12010293
Seal 12/14ga

B01-01-0178
Rev

¼” Female Spade

B W G

¼” Female Spade

24"
A

#10 Ring Terminal

4"
Label

CORD ASSEMBLY GENERATOR SWITCH (B01-01-0179)
28"
A

¼” Female Spade
B01-01-0179
Rev
¼” Female Spade

18-2
SO or Equivalent

Delphi Weather Pack
12010973
2 Pin Male Housing
12089040
Male Terminal
12015323
Green Seal

Label

CORD ASSEMBLY SWITCH JUMPER (B01-01-0180)
B01-01-0180
Rev

¼” Female Spade

¼” Female Spade
14ga Black

Label

TXL or Equivalent
All Measurements
are +/- 0.250 In

CORD ASSEMBLY 110V AC PLUG – FM (B01-01-0181)

14-3
SO or Equivalent
North America
110V Female Plug

¼” Female Spade
¼” Female Spade

B01-01-0181
Rev

12"

SWITCHER BOX ASSEMBLY – CE MODELS (A-03040CE)
Box-A-01015

B01-01-0180

B01-10-0354
20 Amp Circuit Breaker
W/.250 Male Spade Terminal
Allied Electronics
#886-0036
Or Equivilant

B01-06-0056
30 Amp Relay
DPST – NO
Allied Electronics
#850-0345
Or Equivilant

20
Amp

Bl
Br

Y/
g

B W G

G W B

B W

Cord Grip
Heyco #3231
Or Equivilant

B01-09-0005
Blue Wire Nut

B01-01-0181CE

B01-01-0179
B01-01-0178

Delphi Weather Pack
2 Pin Male Housing
Male Terminal
Green Seal

12015793
12010293
12010293

12010973
12089040
12015323

Delphi Weather Pack
3 Pin Male Housing
Male Terminal
Gray Seal

B W G

220V GENERATOR WIRE HARNESS – CE (A-03043CE)

2"
Green

Delphi Weather Pack
12015793
3 Pin Female Housing
12124580
Female Terminal 12/14ga
12010293
Seal 12/14ga

White

Black

Generator
Wire Colors

1/2” Grommet OD

CORD ASSEMBLY 220V AC PLUG – CE (B01-01-0181)

B01-01-0181CE
Rev

14-3
SO or Equivalent

12"
¼” Female Spade

.0625"

¼” Female Spade

B W G

14-3 SO
Or Equivilant
24" (+/- 2")

InterPower
# 88010390
16A Socket or
Equiliviant

PUMP AND CYLINDER WIRE HARNESS (A-00716)

OUTRIGGER SWITCH & COIL WIRE HARNESS (A-00746)

ANALOG HARNESS (A-00715)
Amp
770680
Label

Individual
Wire Labels

AMP 770520-1

A-00715
Rev

Amp
Housing
770680-1
Black

Pump Speed Signal

Pin
1

3' (36") 18 ga Green

Pin
16

3' (36") 18 ga Yellow

Motor Cntrl Enab

Ground

Pin
9

12" 18 ga Black
Engine Run +

Pin
10

¼” FM Spade
Insulated

15" Loom

Weather Pack
12010973 2 Pin Housing
12089040 Male Terminal
12015323 Wire Seal

B
A

12" 18 ga Red

10" Loom
Engine
Run

18" 18ga Red

¼” FM Spade
Insulated
¼” FM Spade
Insulated

18" 18ga Black

Splice & Heat
Shrink Seal

A
B
C
D

Label
B
A

Level
Sensor
Level Sensor +24

Pin
8

32" Loom

10" 18 ga Red

Level Sensor GND

Pin
15

All wires
TXL or Equivalent
All Measurements
are +/- 0.250 In

10" 18 ga Black

A
B

Level Sensor X

Pin
22

18" 18 ga Orange

C
D

Level Sensor Y

Pin
23

Motor
Control
Weather Pack
12020830 4 Pos housing
Mates With 12020832
12089040 Male Terminal
12015323 Wire Seal

Label
8" Loom

Label
Pump Speed Signal
Motor Cntrl Enab
Start
Contactor

18" 18 ga Brown

Label

POWER HARNESS (A-00718)
AMP
1-66740-1
Or
66740-6

12ga Red
32"
Batt Pos

Pin 1

AMP 3 Pin Housing
206037-2

5/16" Ring Terminal

AMP Cable Clamp
206070-1

AMP

A-00718
Rev.

Fill Strain Relief with RTV then put on
cable clamp and wipe off excess

AMP
1-66740-1
Or
66740-6

12ga
Black
32"
Batt Neg

Pin 2

5/16" Ring Terminal

Bundle wires in 28" of loom.
Tape both ends if split loom is used

110 VAC TOWER-PLATFORM HARNESS (A-00722)

PLATFORM-GROUND COMMUNICATION CABLE (A-00714)

MATERIAL LIFT HOOK ASSEMBLY (OPTION A-00846)
5

1
3

4
2

19
18
15

13 14 12

MATERIAL LIFT HOOK PARTS LIST

Item No.

Part No.

Description

Qty.

A-00977

Platform Mount Weldment – LS

A-00982

Load Sense Weldment

0096-0055

Cap Screw, M12 x 190

0096-0042

Hex Nut, Self-Locking, M12

A-00988-1

Load Cell

0096-0089

Cap Screw, M12 x 65

A-00990A

Load Sense Spacer A

A-00990B

Load Sense Spacer B

0096-0069

Cap Screw, M10 x 75

0096-0041

Hex Nut, Self-Locking, M10

A-00033

Bearing

A-00994

LS Roller Bar

A-00995

LS Roller

0096-0046

Washer, Flat, M12

0090-0147

Cotter Pin

0096-0009

Cap Screw, M8 x 10

A-00038

Ramp

0096-0003

Flat Head Cap Screw, M6 x 20

0096-0039

Hex Nut, Self-Locking, M6

A-00992

Load Sense Interface (Not Pictured)

0096-0085

Cap Screw, M6 x 60

0096-0039

Hex Nut, Self-Locking, M6

BATTERY LAYOUT
-

2
1

+
-

4
D4

Motor
Controller

5
6

BD6

0-5V Enable

M-

B+
E2
A2

D3
Contactor
24VDC 100AMP
B01-06-0058

200 AMP
Fuse

D1
E1

Drive
Motor
Pump

200 AMP
Fuse

8
9

B+
1
11

M- B3

Enable 0-5V
7

E2
A2

D1
E1

Main
Pump
Motor
Contactor
24VDC 100AMP
B01-06-0058

Item No.
1

30” Red, 2 Gauge, 5/16 Ring – Lug

45” Black, 2 Gauge, 5/16 Ring – 5/16 Ring

8” Black, 2 Gauge, 5/16 Ring – 5/16 Ring

22” Black, 2 Gauge, 5/16 Ring – Lug

24” Red, 2 Gauge, 5/16 Ring – Lug

48” Black, 2 Gauge, 5/16 Ring – Lug

22” Red, 2 Gauge, 5/16 Ring – Lug

48” Red, 2 Gauge, 5/16 Ring – 5/16 Ring

45” Black, 2 Gauge, 5/16 Ring – 5/16 Ring

19” Black, 2 Gauge, 5/16 Ring – 5/16 Ring

13” Red, 2 Gauge, 5/16 Ring – 5/16 Ring

Item No.

100

Kit No. A-00272

Kit No. A-00934

6” Red, 2 Gauge, 5/16 Ring – 5/16 Ring

30” Red, 2 Gauge, 5/16 Ring – 5/16 Ring

13” Black, 2 Gauge, 5/16 Ring – 5/16 Ring

40” Red, 2 Gauge, 5/16 Ring – 5/16 Ring

40” Black, 2 Gauge, 5/16 Ring – 5/16 Ring

20” Red, 2 Gauge, 5/16 Ring – 5/16 Ring

ORDERING REPLACEMENT PARTS
To order replacement parts, contact the Bil-Jax Service Department by phone at
800-537-0540, by fax at 419-446-8202 or by email at techsupport@biljax.com.
For swift service, always have the part number available, as well as the
equipment model and serial number. When ordering parts by fax or email, always
provide the above information.
See Page 12 for Equipment Warranty information.

QUICK REFERENCE
Equipment Model: Bil-Jax 4527A Articulating Boom Lift

Serial Number: ______________________________________________

NOTES

101

102

NOTES

Distributed by:
125 Taylor Parkway
Archbold, OH 43502
Phone (419) 445-8915
(800) 537-0540
Fax
(419) 445-0367
http://www.biljax.com

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Author                          : Eric Palicki

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Bil Jax Satellite Tv System 36Xt Users Manual Operator’s

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