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

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PARTS AND SERVICE

MANUAL

36XT

AERIAL WORK PLATFORMS

BOOM

TM

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

Phone (800) 537-0540

(419) 445-8915

Fax (419) 445-0367

B33-01-0103 http://www.biljax.com

1

TABLE OF CONTENTS

Table of Contents 1

Illustrations 2

Tables 2

1 Safety 3

Legend: Safety Advisories 4

Before Operation 5

During Operation 5

Maintenance Safety 7

Damaged Equipment Policy 8

2 Specifications 9

Range of Motion 10

Specifications 11

Warranty 12

3 Equipment Maintenance 13

Daily Service Checks 14

Weekly Service Checks 16

Monthly Service Checks 17

Annual Service Checks 18

Structural Inspection 19

Additional Service Information 19

Troubleshooting 20

Error Code Definitions 21

4 Cylinder Replacement 25

Lift Cylinder Replacement 26

Outrigger Cylinder Replacement 27

5 Replacement Decals 29

6 Material Safety Data 35

Appendix: Replacement Parts 39

Ordering Replacement Parts 101

2

LIST OF ILLUSTRATIONS

Figure 2-1 Range of Motion 10

Figure 3-1 Outrigger Position Switch 14

Figure 3-2 Hydraulic Reservoir 15

Figure 3-3 Wheel Nut Tightening Sequence 17

Figure 3-4 Slew Ring Position Measurement 18

Figure 4-1 Lift Cylinder Replacement 26

Figure 4-2 Outrigger Cylinder Replacement 27

Figure 5-1 Decal Locations 31

Figure 5-2 Decal Locations – CE 33

LIST OF TABLES

Table 1-1 Minimum Safe Approach Distances 5

Table 3-2 Troubleshooting Steps 20

Table 3-3 Error Code Definitions 21

Table 5-1 Replacement Decal Descriptions 30

Table 5-2 Replacement Decal Descriptions – CE 32

3

1 SAFETY

Proper training is required for the safe operation of any mechanical device.

Failure to follow all instructions and safety precautions in this manual and

attached to the lift will result in death or personal injury.

Prior to Operation:

 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

4

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

5

BEFORE OPERATION DURING OPERATION

Ensure the following general safety precautions are

followed before operating the articulating boom lift:

ALWAYS inspect the usage area for potential

hazards, such as unstable or unlevel surfaces,

overhead obstructions and electrically charged wires

or conductors. ALWAYS watch for moving vehicles

in the operating area.

ALWAYS conduct a thorough inspection of the

machine before operation. Check for damaged or

worn parts, hydraulic leaks, damaged wiring, loose

wiring conductors, damaged outriggers, low tire

pressure, uneven tire wear or tire damage. Check for

any improperly operating components. NEVER

operate equipment if any damage is observed or

suspected. Repair damaged or malfunctioning

equipment before operation.

ALWAYS wear proper clothing and footgear. Wear

protective equipment as required by government

regulations. Keep loose clothing, jewelry, gloves and

hair away from moving parts.

ALWAYS wear a safety harness and energy-

absorbing lanyard, such as a safety harness and

lanyard provided by Bil-Jax.

ALWAYS inspect platform floor and outrigger

footpads for mud, grease, debris or other foreign

material. ALWAYS remove any such material from

the equipment before operation.

ALWAYS tag any part of the equipment known or

suspected to be damaged or malfunctioning.

ALWAYS remove a malfunctioning, damaged or

defective machine from service. NEVER operate a

machine that has any known or suspected defect.

ALWAYS comply with the instructions found in

Safety and/or Service Bulletins distributed by the

manufacturer. Bulletins may contain critical

procedures that supersede the information

contained in manuals.

NEVER operate this equipment while under the

influence of drugs or alcohol, while taking

prescription medications that may leave the operator

drowsy or prone to dizziness, or while feeling ill.

NEVER modify the equipment in any way that would

affect its original design or operation.

NEVER deface, modify or obscure any decals or

markings on equipment.

NEVER operate the equipment in any way for which

it is not intended.

Ensure the following general safety precautions are

followed while operating the articulating boom lift:

ALWAYS position lift away from power lines to

ensure that no part of the lift can accidentally reach

into an unsafe area. This includes full extension of

the boom through 700º rotation.

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.

Table 1-1. Minimum Safe Approach Distances

ALWAYS keep away from a machine that is

exposed to energized power lines. If the machine

contacts energized power lines, NEVER touch or

operate the machine until power lines are shut off.

ALWAYS operate only on a firm and level surface.

NEVER operate on surfaces that do not support the

equipment with its rated load capacity or on surfaces

that do not support force exerted by the outriggers

during boom operation. Operate only on surfaces

that can support a pressure of 1.8 kg/cm2 (25 psi) to

ensure safe operation.

ALWAYS keep personnel away from potential pinch

and shear points and from potential crush hazards

as indicated by decals attached to the machine.

ALWAYS keep the safety bar lowered unless

personnel are entering or exiting the work platform.

ALWAYS keep personnel and obstructions clear of

the machine when repositioning boom or basket.

Minimum Safe Approach Distance

Voltage Range

(Phase to Phase) (Feet) (Meters)

0 to 300V Avoid Contact

Over 300V to 50KV 10 3.05

Over 50KV to 200KV 15 4.60

Over 200KV to 350KV 20 6.10

Over 350KV to 500KV 25 7.62

Over 500KV to 750KV 35 10.67

Over 750KV to 1000KV 45 13.72

BIL-JAX 36XT

6

ALWAYS cordon the area surrounding the

outriggers to keep personnel, vehicles and moving

equipment away from the machine while in use.

ALWAYS stay clear of overhead obstructions,

including wires and cables.

ALWAYS engage boom travel latches before towing

trailer.

ALWAYS exercise caution when rotating the boom

from the ground control station. ALWAYS watch for

personnel inside the radius of the turntable and

boom arm when rotating the boom lift from the

ground or platform controls.

ALWAYS remove personnel from the boom lift

before attempting to free an elevated platform that

has become caught or snagged on an adjacent

structure or obstacle.

NEVER operate the machine on any surface other

than firm and level ground. NEVER operate the

machine from a position on truckbeds, trailers,

floating vessels or scaffolding without written

approval from the manufacturer.

NEVER operate lift functions on slopes exceeding

12.5º.

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 allow ropes, electric cords, hoses or other

equipment to become entangled in the machine

while raising or lowering platform.

NEVER exceed the load limits set by the

manufacturer. Use only the Material Lifting Hook,

supplied as an option and manufactured by Bil-Jax,

when lifting materials. Safely stow all tools and

equipment.

NEVER exceed load ratings by transferring loads to

the lift at elevated heights.

NEVER use the platform to lift a load that exceeds

the platform dimensions. NEVER lift a load in such a

way that the center of gravity is higher than the top

guardrail of the platform.

NEVER modify the platform or carry materials that

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

7

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 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 Bil-

Jax service technician for proper drying instructions.

NEVER add unauthorized fluids to the hydraulic

system or battery. NEVER mix hydraulic oils.

Consult manufacturer specifications. Refer to

Section 4 for hydraulic system maintenance

procedures.

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 charge batteries near spark or open flame.

NEVER allow batteries to overcharge and boil.

NEVER short across battery posts to check for

current. NEVER break a live circuit at the battery.

NEVER disconnect battery from charger while

charger is connected to a live power source.

NEVER jumpstart other vehicles using the boom lift

batteries.

BIL-JAX 36XT

8

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 800-537-

0540.

Damage Repair Notice

There may be occasions when a Bil-Jax lift is involved in an accident resulting in

damage to non-structural components. When such damage occurs and repairs

are made by the owner or area distributor, please notify Bil-Jax of these non-

maintenance repairs and request a repair form to be filled out and returned to Bil-

Jax.

9

2 SPECIFICATIONS

Bil-Jax, Inc. is dedicated to the continuous improvement of this and all

Bil-Jax products. Therefore, equipment information is subject to change

without notice.

The following information is based on ideal working conditions. Machine

performance may vary based on work environment and on machine

options.

Direct any questions or concerns regarding equipment specifications to your

regional Bil-Jax representative or to the Bil-Jax Service Department.

BIL-JAX 36XT

10

RANGE OF MOTION

Figure 2-1. Range of Motion

2 — SPECIFICATIONS

11

SPECIFICATIONS SERIAL NUMBER____________________________

Working Height

43 ft 6 in

13.4 m

Maximum Platform Height

37 ft 6 in

11.4 m

Maximum Horizontal Outreach

From Centerline

From Outrigger Footpad Edge

32 ft

9.8 m

27 ft

8.2 m

Rated Platform Capacity

Without Platform Rotation

With Platform Rotation

500 lbs

227 kg

440 lbs

200 kg

Maximum Occupants 2

Total Weight

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

10 ft

3 m

18 ft

5.5 m

Platform Dimensions

Height

Length

Width – US/CE

3 ft 7 in

1.1 m

2 ft 6 in

0.8 m

5 ft/4 ft

1.5 m/1.2 m

Stowed Dimensions

Height

Length (Platform stowed)

Width

6 ft 6 in

2.0 m

20 ft 10 in

6.4 m

5 ft 5 in

1.7 m

Outrigger Footprint

Length

Width

Footpad Diameter

12 ft 2 in

3.7 m

11 ft 4 in

3.4 m

12.5 in

0.3 m

Brake Spring Applied

Speed

Gas Power

DC Power

1.5 mph

5.6 km/h

1.75 mph

2.8 km/h

Tire Size 26 x 12 bar lug tires

Tire Pressure

20 psi

140 kPa

Control System 24V DC

Battery 4 x 6V 245 amp-hr

Battery Charger 110/120 Volt

Gas Engine Kawasaki 21 HP

Hydraulic Pressure

3,000 PSI

20,684 kPa

Reservoir Capacity

4.8 Gallons

18.2 L

Hydraulic System Capacity

7 Gallons

26.5 L

Hydraulic Oil (Standard) Dexron III/Mercon ATF

Platform Rotation/Type (Optional) 90º/Manual

Maximum Decibel Level

DC Mode – Ground

DC Mode – Platform

Gas Mode – Ground

Gas Mode - Platform

60 dB

55 dB

70 dB

65 dB

Localized Pressure per Outrigger

25 PSI

1.8 kg/cm2

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

BIL-JAX 36XT

12

WARRANTY

Bil-Jax, Inc. warrants this product for one year, beginning on the date of delivery,

to be free from defects of material and workmanship provided the unit is operated

and maintained in compliance with the guidelines established in the Operations

and Maintenance Manuals. Major structural components, including trailer tongue

and boom weldments, are warranted for five years against defects due to

material or workmanship. Bil-Jax will, at its option, repair or replace any unit or

component part that fails to function properly during normal use.

The warranty does not apply if the lift and/or its components have been altered,

changed, or repaired without the consent of Bil-Jax. Repairs, damage, or defects

resulting from the following are not covered under the terms of the warranty:

negligence, misuse, accidental damage, inadequate or improper maintenance,

acts of nature, damage caused by chemicals or abrasive materials, and normal

wear and tear, such as rust or corrosion. Components not covered under this

warranty include tires, filters, covers, and routine maintenance items.

Components not manufactured by Bil-Jax are covered be their respective

manufacturer’s warranties. A list of those components and their warranties is

available upon written request to Bil-Jax.

Bil-Jax shall not in any event be liable for the cost of any special, indirect, or

consequential damages to any person, product, or thing. Bil-Jax’s maximum

liability under this warranty is limited to the amount paid to Bil-Jax for the product.

This warranty is in lieu of all other warranties expressed or implied. Bil-Jax

neither assumes nor authorizes any or other entity to assume on its behalf any

other liability in connection with the sale, rental, or use of this product.

Warranty Claims Process

In order to qualify for warranty coverage, the following conditions must be met:

1) Return of completed “Warranty Registration” form to Bil-Jax within 15 days of

receipt of product;

2) Notification to Bil-Jax within 72 hours of any claimed defect, injury, or damage

resulting from the claimed the defect; and

3) Warranty is limited to parts that are determined to be defective. This does not

include parts worn out due to normal use.

Bil-Jax authorized dealers or distributors are responsible for filing claims under

warranty. Listed below is the warranty claims procedure.

1) Contact Bil-Jax Service Department at 800-537-0540 to report the claim and

verify warranty coverage. Machine serial number must be provided.

2) Identify the components to be claimed under warranty along with description of

failure. A Returned Merchandise Authorization (RMA) number will be issued by

Bil-Jax.

3) Replacement parts will then be sent by Bil-Jax to the dealer or distributor. All

parts are invoiced at dealer/distributor list price. Credits will be issued when

defective parts are returned to Bil-Jax and found to be defective under warranty.

4) After completing repairs, submit warranty claim form and defective parts to Bil-

Jax. Warranty claim form and parts must be received within 30 days of claim in

order to be eligible for credit. RMA number must be referenced on warranty claim

form. Returned parts are to be sent prepaid and will be credited when part is

received and verified. Warranty labor rate will be paid at current rate set by Bil-

Jax. The amount of labor hours reimbursed will be determined by Bil-Jax and will

be limited to 4 hours unless approved by Bil-Jax.

Failure to follow the warranty claims process may result in delay in processing

claim or denial of the claim. Bil-Jax reserves the right to limit or adjust warranty

claims with regard to parts, labor and travel time. Components purchased from

suppliers other than Bil-Jax are not covered under the terms of this warranty.

13

3 EQUIPMENT MAINTENANCE

Performing the appropriate maintenance procedures will extend the life

of the boom lift and will help ensure the safety of personnel operating the

equipment.

Repair, replacement or adjustment of any hydraulic or electrical control

device should be performed only by fully trained and authorized

personnel. These include, but are not limited to, hydraulic load valves,

hydraulic flow control valves, solenoid valves and limit switches. These

are safety related controls. Improper adjustment or tampering with these

devices may impair boom lift 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

14

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 booms remain elevated and do not drift.

 Pull out STOP button and lower the booms.

 If either control station is unresponsive, refer to Table

3-1 for troubleshooting procedures.

 If display panel displays an error code, refer to Table

3-2 for error code definitions.

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.

Check engine oil level.

 Add oil as needed.

 Manufacturer recommends engine oil type 5W-30.

Check engine fuel level.

 Add fuel as needed.

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.

 Begin with the outriggers fully extended and the boom

lift level. Raise one outrigger until the footpad is not in

contact with the ground.

 Verify that boom functions are unresponsive when

one outrigger is raised.

 Repeat this procedure for each outrigger.

 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.

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

15

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. Filter Element

2. Fill Port

3. Sight Gauge

Figure 3-2. Hydraulic Reservoir

BIL-JAX 36XT

16

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

17

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.

4

5

1

2

3

Figure 3-3. Wheel Nut Tightening Sequence

BIL-JAX 36XT

18

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.

 Replace yearly, or whenever filter or oil contamination

has a noticeable effect on boom functions.

Inspect pivot pins and cylinders, including rod

ends, for wear or damage. Replace as necessary.

Visually inspect welds and structural

components for wear, damage and corrosion.

 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.

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.

MEASURE

HERE

SLEW RING

Figure 3-4. Slew Ring Position Measurement

3 — EQUIPMENT MAINTENANCE

19

STRUCTURAL INSPECTION ADDITIONAL SERVICE INFORMATION

A comprehensive structural inspection of the unit

shall be performed under any of the following

conditions.

 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.

Seals on hydraulic cylinders should be replaced every five

years or as indicated by machine performance.

All service checks should be performed on a machine that

has been stored without use for a period exceeding thirty

days.

Check for air in the hydraulic system if the machine has

been stored without use for a period exceeding thirty days,

or if the machine was stored without use during a

seasonal climate change. Air trapped in the hydraulic

system will affect machine performance. Follow

procedures for bleeding air from the hydraulic system,

found in Section 4.

Owners and lessors should complete a full inspection of all

components and perform a test of all functions, including

brake functions, before commissioning or reselling

machine. Always repair or replace all damaged or

malfunctioning components before commissioning or

reselling machine.

When a change in ownership occurs, it is the responsibility

of the seller to provide the new owner with all manuals for

the machine. It is the responsibility of the buyer to notify

the manufacturer of the unit model and serial number and

the name and address of the new owner within 60 days.

Use the Service Checklists found at the back of 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

20

TROUBLESHOOTING

Refer to Table 3-2 for basic troubleshooting operations. Additional information

can be found in the Bil-Jax Model 45XA Operator’s Manual. Contact the Bil-Jax

Service Department with any questions or before attempting any advanced

troubleshooting operations.

Table 3-1. Troubleshooting Steps

PROBLEM CAUSE SOLUTION

No lights on panel when

key switch is turned to the

on position.

a. Emergency STOP engaged.

b. Battery charge is low.

c. Battery ground or in-series cable is loose.

d. Battery main disconnect unplugged.

a. Disengage Emergency STOP buttons.

b. Recharge as needed.

c. Inspect and repair battery connections.

d. Plug in main disconnect.

Hydraulic function does not

work and display window

shows an error message

a. Fault detected by safety interlock

microprocessor.

b. Boom Lift electric or electronic failure

a. Refer to Table 4-2 for error code

definition and correction.

b. Refer to Table 4-2 for error code

definition and correction.

Outrigger indicator LED

lights do not function. a. Key switch turned to the OFF or platform

controls position.

b. Emergency STOP engaged.

c. Outriggers not deployed.

a. Turn key switch to ground controls

position.

b. Disengage emergency STOP buttons.

c. Deploy all outriggers.

One or more boom controls

do not function

OR

One or more boom controls

function improperly

OR

One or more boom controls

function intermittently.

a. Key switch is turned to the OFF or

incorrect control position.

b. Battery charge is low.

c. Emergency

STOP engaged.

d. Battery ground or in-series cable loose.

e. All outriggers not properly deployed.

f. Hydraulic pump inoperative.

g. Loose wiring connector.

h. Valve solenoid not operating properly.

i. Fault detected by system interlock.

j. Broken or loose wire.

a. Turn key switch to ground or platform

controls position.

b. Recharge battery.

c. Disengage Emergency STOP buttons.

d. Inspect and repair battery connections.

e. Deploy all outriggers and level boom lift.

f. Inspect pump; replace or repair as

needed.

g. Check wiring terminals in control box

and at valve manifold; replace or repair

as needed.

h. Clean valve solenoid and recheck

function(s); replace or repair as needed.

i. Check display for system status. Refer

to Table 4-2 for error code definitions

and correction.

j. Inspect wiring in control box and at

valve manifold and valve coil; repair or

replace as needed.

3 — EQUIPMENT MAINTENANCE

21

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

MODE Machine was either never leveled, outriggers not

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

UP A load of less than 70mA detected in secondary

up circuit on power-up. Check for faulty boom up

solenoid coil and wiring.

026 SHORTED CIRCUIT

SECONDARY UP Excessive load detected in secondary up circuit

on power-up. Check for faulty boom up

solenoid coil and wiring.

027 OPEN CIRCUIT SECONDARY

DOWN A load of less than 70mA detected when

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.

BIL-JAX 36XT

22

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

RETRACT A load of less than 70mA detected in outrigger

retract circuit on power-up. Check for faulty outrigger retract

solenoid coil/wiring.

050 SHORTED CIRCUIT

OUTRIGGER RETRACT Excessive load was detected when Outrigger

Retract circuit was energized. Check for faulty outrigger retract

solenoid coil/wiring.

051 OPEN CIRCUIT OUTRIGGER

EXTEND A load of less than 70mA detected in outrigger

retract circuit on power-up. Check for faulty outrigger extend

solenoid coil/wiring.

052 SHORTED CIRCUIT

OUTRIGGER EXTEND 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.

3 — EQUIPMENT MAINTENANCE

23

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

24

25

4 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

26

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.

 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.

 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.

 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

hoses to prevent leakage. Plug or cap exposed hose

fittings and cylinder ports.

 At the base of the cylinder, unbolt and remove

retainer plate from each side of the pivot pin.

 Remove the pivot pin using a hammer and a brass or

hardwood drift.

 Lift and remove the cylinder using an overhead hoist

and lifting straps.

 Replace or reinstall the cylinder by following the

above instructions in the reverse order of removal.

 Actuate the hydraulic system and check for leakage.

Tighten hydraulic fittings as needed.

 Bleed trapped air from the hydraulic system by raising

and lowering the boom with the reservoir fill port cap

on but not tightened. Allow several minutes for

trapped air to escape. Repeat as needed.

RETAINING

PLATE

CYLINDER

PIN

PISTON ENDBASE END

Figure 4-1. Lift Cylinder Replacement

4 — CYLINDER REPLACEMENT

27

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.

 Remove the bolts securing the outrigger cylinder rod

guard (Figure 4-2). Remove the guard.

 At the piston rod end of the cylinder, unbolt and

remove the retainer plate from each side of the pivot

pin.

 Place a block of wood shoring between the outrigger

beam and cylinder.

 Remove the pivot pin using a hammer and a brass or

hardwood drift.

 Fully retract the cylinder.

 Turn key to the off position and remove the key.

 Tag and number all hydraulic hoses that attach to the

cylinder valve block. Use a marker to label the valve

block ports with the appropriate hose numbers.

 Unplug the cylinder valve solenoid.

 Place absorbent cloths below the cylinder ports and

detach hydraulic hoses from the cylinder. Elevate

hoses to prevent leakage. Plug or cap exposed hose

fittings and cylinder ports.

 At the base of the cylinder, unbolt and remove

retainer plate from each side of the pivot pin.

 Remove the pivot pin using a hammer and a brass or

hardwood drift.

 Lift and remove the cylinder using an overhead hoist

and lifting straps.

 Replace or reinstall the cylinder by following the

above instructions in the reverse order of removal.

 Actuate the hydraulic system and check for leakage.

Tighten hydraulic fittings as needed.

 Bleed trapped air from the hydraulic system by raising

and lowering the boom with the reservoir fill port cap

on but not tightened. Allow several minutes for

trapped air to escape. Repeat as needed.

CYLINDER

CYLINDER ROD

GUARD PIN

CYLINDER ROD

GUARD BOLTS

RETAINING

PLATES

Figure 4-2. Outrigger Cylinder Replacement

BIL-JAX 36XT

28

29

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

30

Table 5-1. Decal Descriptions

Decal No. Decal Description Qty

0202-0523 Made in USA 1

B06-00-0034 DANGER: Electric Shock 1

B06-00-0037 Lubricate Semi-Annually 1

B06-00-0062 NOTICE: AC Power 2

B06-00-0068 NOTICE: Hydraulic System Oil 1

B06-00-0161B Bil-Jax Logo, Black Transfer 2

B06-00-0404 WARNING: Outrigger Crush Toe 8

B06-00-0405 WARNING: Pinch Point 14

B06-00-0471 DANGER: Before Use/Main

Instruction/Hazards (Platform) 1

B06-00-0473 NOTICE: Operator’s Manual

Missing 1

B06-00-0474 NOTICE: Max. Load 1

B06-00-0475 WARNING: Read/Understand

Operator’s Manual 1

B06-00-0476 NOTICE: Range of Motion 2

B06-00-0477 WARNING: Forklift Pockets 2

B06-00-0481 CAUTION: Transport Safety Latch 1

B06-00-0482 DANGER: Electrocution Hazard 2

Decal No. Decal Description Qty

B06-00-0484 DANGER: Battery/Charger Safety 1

B06-00-0494 NOTICE: Hazardous Materials 1

B06-00-0495 CAUTION: Compartment Access

Restricted 2

B06-00-0503 NOTICE: Handle Applications 1

B06-00-0504 NOTICE: Emergency Hand Pump 1

B06-00-0505 DANGER: Before Use/Main

Instruction/Hazards (ground) 1

B06-00-0506 NOTICE: Emergency Lowering 2

B06-00-0521 DANGER: Tip Over Hazard 5

B06-00-0541 CAUTION: Manual Boom

Functions 1

B06-00-0545 Bil-Jax Website Transfer 2

B06-00-0552 NOTICE: Fall Protection Attach-

ment points 1

B06-00-0561 WARNING: Operating Instructions

(Ground) 2

B06-00-0562 WARNING: Operating Instructions

(Platform) 1

B06-00-0563 36XT, 6” Black Transfer 2

Identification Plates

B06-00-0490 VIN Plate 1

B06-00-0499 ANSI ID Plate 1

B06-00-0524 Annual Inspection Plate 1

B06-00-0526 Key Tag 1

5 – DECAL PLACEMENT

31

0545

0476

0474

0552

0202-0523

0062

0475

0495

0034

0484

0495

0068

0504

0494

0541

0476

0037

0493

0503

0506

0405

0482

0404

0521

4x

0481

05520405

05520521

0477

0405

0473

0471

0562

0561

0505

0161B

05520405

0563

Figure 5-1. Decal Locations

BIL-JAX 36XT

32

Table 5-2. Decal Descriptions – CE

Decal No. Decal Description Qty

0202-0523 Made in USA 1

B06-00-0034 DANGER: Electric Shock 2

B06-00-0037 Lubricate Semi-Annually 1

B06-00-0062 NOTICE: AC Power 2

B06-00-0068 NOTICE: Hydraulic System Oil 1

B06-00-0161B Bil-Jax Logo, Black Transfer 2

B06-00-0173 Fall Protection Attachment Points 1

B06-00-0404 WARNING: Outrigger Crush Toe 8

B06-00-0405 WARNING: Pinch Point 14

B06-00-0471 DANGER: Before Use/Main

Instruction/Hazards (Platform) 1

B06-00-0474 NOTICE: Max. Load 1

B06-00-0475 WARNING: Read/Understand

Operator’s Manual 2

B06-00-0476 NOTICE: Range of Motion 2

Decal No. Decal Description Qty

B06-00-0482 DANGER: Electrocution Hazard 2

B06-00-0495 CAUTION: Compartment Access

Restricted 2

B06-00-0505 DANGER: Before Use/Main

Instruction/Hazards (ground) 1

B06-00-0506 NOTICE: Emergency Lowering 2

B06-00-0541 CAUTION: Manual Boom

Functions 1

B06-00-0545 Bil-Jax Website Transfer 2

B06-00-0561 WARNING: Operating Instructions

(Ground) 2

B06-00-0562 WARNING: Operating Instructions

(Platform) 1

B06-00-0563 36XT, 6” Black Transfer 2

B06-00-0568 WARNING: Outrigger Pressure 4

B06-00-0572 WARNING: Read/Understand

Parts and Service Manual 1

Identification Plates

B06-00-0499-CE CE Serial ID Plate 1

B06-00-0526 Key Tag 1

5 — REPLACEMENT DECALS

33

0563

0545

0476

0474

0173

0202-0523

0062

0475

0495

0034

0495

0068

0541

0476

0037

0506

0405

0482

0405

0404

4x

05520405

0405

0568

0471

0562

0505

0161B

05520405

0561

0475

0572

0034

Figure 5-2. Decal Placement – CE

BIL-JAX 36XT

34

35

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: Crown Battery Mfg. Company EMERGENCY NO: 800 487-2879

Street Address: 1445 Majestic Drive OR 800 OIL-TANK

City, State, Zip Fremont, Ohio 43420

Phone Number: 419 334-7181 REVISION DATE: 5/18/2000

SECTION II -- MATERIAL IDENTIFICATION AND INFORMATION

COMPONENTS PERCENT OSHA ACGIH OTHER LIMITS CAS NUMBER

Hazardous Components PEL TLV

1% or greater

Carcinogens 0.01% or greater

METALLIC LEAD METAL 25.5% 0.05 mg/m3 0.05 mg/m3 NONE 7439-92-1

LEAD SULFATES 18.2% 0.05 mg/m3 0.05 mg/m3 NONE 7439-92-1

LEAD OXIDES 18.0% 0.05 mg/m3 0.05 mg/m3 NONE 7439-92-1

POLYPROPYLENE CASE MTL 6.4%

SEPARATORS 3.5%

SULFURIC ACID (H2SO4) 5.2% 1.0 mg/m3 1.0 mg/m3 NONE 7664-93-9

WATER 19.2%

REGULATORY INFORMATION: Those ingredients listed above are not subject to the reporting requirements of 313

of Title 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 Approximately 203F Vapor Density: Greater Than 1

Vapor Pressure 14 @ 37% @ 80 F Melting Point: -36 F to -10.6 F

Solubility in Water 100% Water Reactive: Yes, Produces Heat

Specific Gravity 1.245 - 1.295 Battery Electrolyte

Appearance & Odor Clear Liquid with Sharp Pungent Odor

SECTION IV -- FIRE AND EXPLOSION HAZARD DATA

Flash Point: Not Combustible

Auto Ignition Temperature N/A Flammability Limits in Air % by Volume: N/A

Extinguishing Media: Dry Chemical Carbon Dioxide, Water Fog, Water

Special Fire Fighting Procedures: Sulfuric Acid Fumes, Sulfur Dioxide Gas or Carbon Monoxide may be

released when acid decomposes. Wear NIOSH approved self-contained breathing apparatus.

Unusual Hazards: Water applied to sulfuric acid generates heat and causes acid to splatter. Wear full-cover

acid resistant clothing. Sulfuric acid reacts violently with metals, nitrates, chlorates, carbides, fulminates,

picrates and other organic materials. Reacts with most metals to yield explosive/flammable hydrogen gas.

This reaction is intensified when sulfuric acid is diluted with water to form battery electrolyte.

BIL-JAX 36XT

36

MATERIAL SAFETY DATA SHEET

FOR LEAD ACID BATTERIES, WET, FILLED WITH ACID (Continued)

SECTION V -- HEALTH HAZARD DATA

Primary Routes of Entry: Inhalation: YES

Skin: YES

Ingestion: YES

Health Hazards: Acute EYES, SKIN, RESPIRATORY SYSTEM & DIGESTIVE SYSTEM

Chronic: EYES, SKIN, RESPIRATORY SYSTEM & DIGESTIVE SYSTEM

Signs and Symptoms of Exposure: IRRITATION OF EXPOSED AREA, BURNS AND RESPIRATORY PROBLEMS

NO POSSIBILITY OF EXPOSURE OF LEAD WILL OCCUR UNLESS

BATTERY IS DESTROYED.

Medical Conditions Generally

Aggravated By Exposure: EXPOSURE TO MIST MAY CAUSE LUNG DAMAGE & AGGRAVATE

PULMONARY CONDITION.

Emergency First Aid Procedures: SEEK MEDICAL ASSISTANCE FOR FURTHER TREATMENT, OBSERVATION

AND SUPPORT IF NECESSARY.

Eye Contact: WASH WITH COPIOUS QUANTITIES OF COOL WATER FOR AT LEAST 15 MINUTES

Skin Contact: FLUSH AREA WITH LARGE AMOUNTS OF COOL WATER FOR AT LEAST 15 MINUTES

Inhalation: REMOVE TO FRESH AIR, IF BREATHING IS DIFFICULT - GIVE OXYGEN

Ingestion: GIVE MILK TO DRINK, DO NOT INDUCE VOMITTING. CALL PHYSICIAN

SECTION VI -- REACTIVITY DATA

Stability: STABLE Conditions to Avoid: N/A

Incompatibility: AVOID COMBUSTIBLES, ORGANIC MATERIALS, AND STRONG REDUCING AGENTS

Hazardous Decomposition Products: SULFUR TRIOXIDE, CARBON MONOXIDE, SULFURIC ACID FUMES, &

SULFUR DIOXIDE

Hazardous Polymerization: MAY OCCUR Conditions to Avoid: N/A

SECTION VII -- SPILL OR LEAK PROCEDURES

Steps to be taken in case material is released or spilled:

CONTAIN SPILL, USING NON-COMBUSTIBLE MATERIALS: VERMICULITE, DRY SAND & EARTH. NEUTRALIZE

WITH LIME, SODA ASH, SODIUM BICARBONATE, ETC.

Waste disposal method: CONSULT STATE ENVIRONMENTAL AGENCY. INDIVIDUAL STATE REGULATIONS VARY

Precautions to be taken in Handling & Storage: SEPARATE FROM INCOMPATIBLE MATERIALS, KEEP AWAY

FROM FIRE, SPARKS AND HEAT

Other Precautions and/or Special Hazards:

CONTACT WITH METALS MAY PRODUCE TOXIC SULFUR DIOXIDE FUMES & MAY ALSO RELEASE FLAMMABLE

HYDROGEN GAS. THIS REACTION IS INTENSIFIED WHEN DILUTED.

NFPA Rating: HEALTH: 3 FLAMMABILITY: 0 REACTIVITY: 2 SPECIAL: 0

HMIS Rating: HEALTH: 3 FLAMMABILITY: 0 REACTIVITY: 2 PERSONAL PROTECTION: X

SECTION VIII -- CONTROL AND PROTECTIVE MEASURES

Respiratory Protection: ABOVE P.E.L.: NIOSH APPROVED, FITTED, FULL FACE RESPIRATOR

Protective Gloves: ACID RESISTANT

Eye Protection: FULL FACE PROTECTION

Ventilation: LOCAL EXHAUST: VENTILATED AREA PREFERRED

MECHANICAL: IF BELOW P.E.L.

SPECIAL: MUST BE ACID & EXPLOSIVE RESISTANT

OTHER: MUST BE ACID & EXPLOSIVE RESISTANT

Other Protective Equipment: ACID RESISTANT CLOTHING AND BOOTS

Hygienic Work Practices: N/A

6 – MATERIAL SAFETY DATA

37

MATERIAL SAFETY DATA SHEET

DEXRON III/MERCON AUTOMATIC TRANSMISSION FLUID (HYDRAULIC OIL)

SECTION I -- GENERAL INFORMATION

TRADE NAME: CITGO TRANSGARD™ ATF, DEXRON III/MERCON

EMERGENCY TELEPHONE NUMBERS: 918.495.4700 (medical); 800.424.9300 (chemical)

CHEMICAL FAMILY: AUTOMATIC TRANSMISSION FLUID, LUBRICATING OIL

CAS NUMBER: MIXTURE. REVISION DATE: 10/29/98

HAZARDOUS INGREDIENTS: CONTAINS NO INGREDIENTS NOW KNOWN TO BE HAZARDOUS AS

DEFINED IN OSHA 29 CFR 1910.1000 AND OSHA 29 CFR 1910.1200.

SECTION II -- HEALTH HAZARD DATA

PRIMARY ROUTES OF ENTRY: INHALATION, SKIN ABRASION AND INGESTION.

CARCINOGENIC: NO

SYMPTOMS (INGESTION, CONTACT, INHALATION): MILD, TRANSIENT SKIN OR EYE IRRITATION MAY OCCUR.

EYES: FLUSH WITH WATER FOR 15 MINUTES

SKIN: WASH THOROUGHLY WITH WARM SOAPY 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: N/A

VAPOR PRESSURE (PSIA): N/A

SPECIFIC GRAVITY (H20=1): 0.86

SOLUBILITY IN WATER: NEGLIGIBLE; INSOLUBLE IN COLD WATER

PH OF CONCENTRATE: N/A

APPEARANCE AND ODOR: RED LIQUID, MILD PETROLEUM ODOR

SECTION IV -- FIRE AND EXPLOSION HAZARD DATA

FLASH POINT (METHOD USED): CLOSED: 339º F (Pensky-Martens); OPEN: 390º F (Cleveland).

FLAMMABLE LIMITS: NOT DETERMINED

LEL: N/A UEL: N/A

EXTINGUISHING MEDIA: DRY CHEMICAL, FOAM, CO2, WATER FOG. TREAT AS CLASS B FIRE.

UNUSUAL FIRE AND EXPLOSION HAZARDS: PRODUCES COMBUSTIBLE VAPOR AT TEMPERATURES ABOVE FLASH POINT

SECTION V -- REACTIVITY DATA

STABILITY: STABLE

CONDITIONS TO AVOID: AVOID EXTREMES OF HEAT; IGNITION SOURCES.

INCOMPATIBILITY (MATERIALS TO AVOID): STRONG OXIDIZING MATERIALS.

HAZARDOUS DECOMPOSITION PRODUCTS: INCOMPLETE COMBUSTION MAY CAUSE CARBON OXIDES.

HAZARDOUS POLYMERIZATION: WILL NOT OCCUR.

SECTION VI -- SPECIAL PROTECTION INFORMATION

RESPIRATORY PROTECTION (SPECIFIC TYPE): NONE REQUIRED

VENTILATION: NORMAL

LOCAL EXHAUST: NORMAL

MECHANICAL EXHAUST (GENERAL): X

PROTECTIVE GLOVES: OIL IMPERVIOUS GLOVES RECOMMENDED

EYE PROTECTION: SAFETY GLASSES RECOMMENDED

OTHER PROTECTIVE EQUIPMENT: PROTECTIVE CLOTHING RECOMMENDED

SPECIAL LABELLING INSTRUCTIONS: NOT REQUIRED

SPECIAL PACKAGING RECOMMENDATIONS: NONE

HANDLING AND STORAGE RECOMMENDATIONS: AVOID EXTREMES OF COLD OR HEAT. STORE IN CLEAN DRY AREA.

SPILL OR LEAK PROCEDURES: IN CASE OF LEAK OR SPILL, DIKE AND ABSORB WITH INERT MATERIAL. FOLLOW

ALL LOCAL, STATE AND FEDERAL REGULATIONS FOR DISPOSAL.

DISCLAIMER: THE INFORMATION CONTAINED HEREIN HAS BEEN COMPILED FROM SOURCES

CONSIDERED TO BE DEPENDABLE AND IS ACCURATE TO THE BEST OF THE SELLER’S

KNOWLEDGE. THE SELLER MAKES NO WARRANTY WHATSOEVER, EXPRESSED OR IMPLIED, REGARDING THE ACCURACY

OF SUCH DATA OR THE RESULTS TO BE OBTAINED FROM THE USE THEREOF.

38

39

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.

40

Assembly Description Page

Outrigger 42

Engine 44

Front Rest 48

Front Axle 50

Rear Axle 52

Slew Ring 54

Counterweight 56

Control Compartment 58

Pump Compartment 60

Battery Compartment 62

Cover 64

Boom 66

Cable Track 70

Boom Nose 72

Platform 74

Hydraulic Pump 76

41

Assembly Description Page

Boom and Rotation Hydraulic Lines 80

Outrigger Hydraulic Lines 82

Trailer Hydraulic Lines – 4WD 83

Wire Harnesses 86

Manifold Wire Harness 87

Gas Engine Wire Harness 87

Choke/Throttle Solenoid Wire Harness 88

Engine Relays Wire Harness 88

ATC Fuse Holder 89

Start/Stop/Run Wire Harness 89

Generator Switcher Box 90

Wire Assembly – Fan 90

IEC Cord – Male – US Markets 91

Generator 110V Wire Harness 91

Oil Switch 91

Cord Assembly – 110V Generator 92

Cord Assembly – Generator Switch 92

Cord Assembly – Switch Jumper 92

Cord Assembly – 110V AC Plug – Female 92

Switcher Box – CE Models 93

220V Generator Wire Harness – CE Models 93

Cord Assembly – 220V AC Plug – Female – CE Models 93

Pump And Cylinder Wire Harnesses 94

Outrigger Coil and Switches Wire Harness 95

Analog Harness 96

Power Harness 96

110 VAC Tower-Platform Harness 96

Platform-Ground Communication Cable 97

Material Hook 98

Battery Layout 100

42

OUTRIGGER ASSEMBLY

1

2

3

4

5

6

8

10

11 12 13

14

15

19

20

21

22

23

24

25

26

28 4

5

5

6

6

7

7

7

17

18 16

17

9

27

13

14

14

29

30

43

OUTRIGGER ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-00120 Outrigger Weldment 1*

2 A-00046 Grommet – 1.5 x 1.25 x 1.75 1

3 A-00032 Bearing 2

4 A-00020 Pin, 1.25 x 5.5 2

5 A-00019 Pin Retainer, 1.25 3

6 0096-0016 Cap Screw, M10 x 25 3

7 0096-0041 Hex Nut, Self-Locking, M10 3

8 A-00060 Pin, 1.25 x 4.25 1

9 A-00138 Outrigger Hydraulic Cylinder 1

10 A-00141 Outrigger Cylinder Guard 1

11 0096-0009 Cap Screw, M8 x 10 2

12 A-00142 Guard Slide 1

13 0096-0010 Cap Screw, M8 x 20 6

14 0096-0040 Hex Nut, Self-Locking, M8 10

15 A-00154 Spring, Outrigger Sensor 1

16 0096-0036 Cap Screw, M16 x 150 1

17 0096-0044 Hex Nut, Self-Locking, M16 2

18 A-00128 Pad Mount Weldment 1

19 0096-0051 Cap Screw, M16 x 100 1

20 B01-03-0078 Limit Switch Assembly 1

21 0090-0232 Slotted Machine Screw, #10-24 x 5/8 2

22 0090-0182 Hex Nut, Self-Locking, #10-24 2

23 A-00136 Foot Pad, Aluminum, 12” 1

24 A-00137 Foot Pad Bottom, 12” 1

25 0096-0121 Flat Head Cap Screw, M8 x 30 4

26 A-00135 Foot Pad Ball 1

27 A-00195 O-Ring, 1 1/4” OD x 1” ID 1

28 0096-0045 Hex Nut, Self-Locking, M20 1

29 A-00127 Foot Pad Lock 2

30 A-00139 Foot Pad Lock Cap 1

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

NOTE: Unless otherwise noted, high-strength Grade 5/Class 8.8 fasteners

are used in the assembly of this equipment.

44

ENGINE ASSEMBLY (I)

1

2

3

4

56

78

9

10

11

12

14

15

16 17

18

19

20

21

22

23

24

25

7

8

8

8

15

15

3

2

13

3

2

45

ENGINE ASSEMBLY (I) PARTS LIST

Item No. Part No. Description Qty.

1 A-01063 Cover Front 1

2 0096-0014 Cap Screw, M10 x 20 14

3 0096-0041 Hex Nut, Self-Locking, M10 22

4 A-01064 Cover Top 1

5 A-01067 Cover Side – Left 1

6 A-01069 Cover Side – Right 1

7 0096-0001 Cap Screw, M6 x 16 20

8 0096-0039 Hex Nut, Self-Locking, M6 33

9 B42-01-1006 Hinge – 72” Continuous 2

10 A-01045 Latch, Paddle-Style 2

11 0096-0113 Cap Screw, M4 x 16 8

12 0096-0073 Hex Nut, Self-Locking, M4 8

13 A-01052 Cover Rear 1

14 B01-06-0053 Relay 24V DC w/ Bracket 5

15 0096-0002 Cap Screw, M6 x 20 13

16 A-A-01059 Cover Pad 2

17 0096-0068 Flat Head Cap Screw, M10 x 45 4

18 A-03048 Relay Cover 1

19 A-03040 Switcher Box Assembly 1

B01-06-0056 Relay – 30 Amp 1

B01-10-0354 Circuit Breaker – 20 Amp 1

A-01015 Switcher Box 1

20 A-01072 Cover Latch Stop 2

21 0096-0098 Cap Screw, M8 x 35 4

22 0096-0040 Hex Nut, Self-Locking, M8 4

23 A-01047 Fuel Tank 1

24 A-01089 Fuel Gauge 1

25 0096-0016 Cap Screw, M10 x 25 2

46

ENGINE ASSEMBLY (II)

1

2

3

4

5

67

9

10

26

11

12

13

14

15

16

17

18

1920

21

22

23

24

25

12 1212 3

13 3

28 29

27

33

31 32

34

47

ENGINE ASSEMBLY (II) PARTS LIST

Item No. Part No. Description Qty.

1 A-01046 Engine 21HP (See Manufacturer’s Literature) 1

2 0096-0098 Cap Screw, M8 x 35 4

3 0096-0040 Hex Nut, Self-Locking, M8 18

4 A-01048 Pump – Dual – 4.5 GPM 1

5 A-01055 Dual Pump Mount 1

6 0096-0110 Cap Screw, M10 x 110 2

7 0096-0093 Washer, M10 2

8 0096-0041 Hex Nut, Self-Locking, M10 2

9 A-01081 Oil Cooler 1

10 0096-0010 Cap Screw, M8 x 20 4

11 A-01071 Solenoid Bracket 1

12 0096-0001 Cap Screw, M6 x 16 12

13 0096-0039 Hex Nut, Self-Locking, M6 10

14 A-01074 Throttle Solenoid Assembly 2

15 A-00761 Generator 1

16 A-01060 Spacer 4

17 0096-0053 Cap Screw, M8 x 50 4

18 A-01038 Brake Release – Hand Pump 1

19 0096-0108 Cap Screw, M8 x 70 2

20 B02-00-0071 Oil Filter Assembly 1

21 B29-00-0016 Oil Filter Bracket 1

22 A-00783 Exhaust Assembly 1

23 A-01061 Belt 1

24 A-01051 Pulley 2

25 0090-0363 Set Screw – 1/4 - 20 x 3/4 6

26 A-01036 Pulley 1

27 A-01088 Idler Roller 1

28 0096-0022 Cap Screw, M12 x 75 1

29 0096-0076 Washer, M12 3

30 0096-0041 Hex Nut, Self-Locking, M12 1

31 A-01095 Tension Arm 1

32 A-01086 Spacer – Tension Arm 1

33 0090-0210 Washer – 3/8” 1

34 0096-0069 Cap Screw, M10 x 75 1

48

FRONT REST ASSEMBLY

1

2

3

4

5

6

7

8

9

10

11

12

13

14

16

17

18

19

20

21

6

15

20

22

21

49

FRONT REST ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-03145 Front Rest Weldment 1

2 0096-0024 Cap Screw, M12 x 100 2

3 0096-0042 Hex Nut, Self-Locking, M12 2

4 A-00157 Front Rest Pad 6

5 0096-0017 Cap Screw, M10 x 30 16

6 0096-0041 Hex Nut, Self-Locking, M10 20

7 A-00159 Boom Latch 1

8 0096-0016 Cap Screw, M10 x 25 4

9 A-00169 Switch Bracket 1

10 0096-0002 Cap Screw, M6 x 20 2

11 0096-0039 Hex Nut, Self-Locking, M6 2

12 A-00188 Switch Cam 2

13 0090-1104 Machine Screw, #4-40 x 1 3

14 0090-0525 Hex Nut, Self-Locking, #4-40 3

15 B01-03-0078 Limit Switch Assembly, NO (Female) 1

16 B01-03-0079 Limit Switch Assembly, NC (Male) 1

17 0090-0709 Machine Screw, #6-32 x 1 1/4 2

18 0090-0180 Hex Nut, Self-Locking, #6-32 2

19 A-00158 Tension Spring 1

20 0096-0038 Cap Screw, M20 x 120 4

21 0096-0045 Hex Nut, Self-Locking, M20 4

22 A-01082 Tie Weldment – 4WD 1

50

FRONT AXLE ASSEMBLY

12

3

4

5

6

7

8

9

20

10

11

12

13

14 15

16

17

18

19

21

22

23

24

8

13

51

FRONT AXLE ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-01010 Front Axle Weldment – 4WD 1

2 A-01097 Bushing, 1.5” OD x 1.25” ID 4

3 A-01020 Front Yoke – Left 1

4 A-01021 Front Yoke – Right 1

5 A-01070 Pin – 1.25” x 1.625” 4

6 A-00019 Pin Retainer – 1.25” 4

7 0096-0016 Cap Screw, M10 x 25 4

8 0096-0041 Hex Nut, Self-Locking, M10 9

9 A-01022 Hydraulic Motor – 4WD 2

10 0096-0024 Cap Screw, M12 x 100 8

11 0096-0042 Hex Nut, Self-Locking, M12 8

12 A-01025 Tie Rod – 4WD 1

13 A-01096 Bushing, 1.25” OD x 1.0” ID 4

14 A-01085 Pin – Front Axle 4

15 0090-0155 Cotter Pin – 3/16” x 1 3/4" 4

16 A-01030 Steering Cylinder – 4WD 1

17 A-01005 Front Axle Mount Weldment 1

18 0096-0038 Cap Screw, M20 x 120 2

19 0096-0045 Hex Nut, Self-Locking, M20 2

20 A-01029 Pad – Front Axle 2

21 0096-0091 Flat Head Cap Screw, M10 x 25 4

22 A-01009 Pin – 1.0” x 5.5” 1

23 A-00018 Pin Retainer – 1.0” 1

24 0096-0014 Cap Screw, M10 x 20 1

52

REAR AXLE ASSEMBLY

12 45

6

7

2

53

REAR AXLE ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-00175 Hydraulic Cover 1

2 0096-0010 Cap Screw, M8 x 20 12

3 0096-0067 Clip Nut, M8 12

4 A-01032 Hydraulic Motor – Rear 2

5 0096-0024 Cap Screw, M12 x 100 8

6 0096-0042 Hex Nut, Self-Locking, M12 8

7 A-01037 Axle Cover 2

54

SLEW RING ASSEMBLY

3

1

25

6

7

8

9

10

11

12

13

4

55

SLEW RING ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-02189 Slew Assembly and Adapter 1

2 Slew Ring 1

3 Slew Ring Drive 1

4 A-00149 Base Ring Adapter 1

5 0090-0461 Cap Screw, 1/2-13 x 2 2

6 0090-0212 Lock Washer, 1/2 2

7 0096-0033 Flat Head Cap Screw, M16 x 35 16

8 0096-0054 Flat Head Cap Screw, M16 x 50 18

9 0090-0643 Cap Screw, 5/8-11 x 2-3/4, Grade 8 19

10 0096-0044 Hex Nut, Self-Locking, M16 16

11 A-00350 Rotation Stop Assembly 1

12 0096-0021 Cap Screw, M12 x 45 2

13 0096-0042 Hex Nut, Self-Locking, M12 2

56

COUNTERWEIGHT ASSEMBLY

57

COUNTERWEIGHT ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-00270 Counterweight 1

2 0096-0065 Cap Screw, M20 x 80 4

3 0096-0045 Hex Nut, Self-Locking, M20 4

58

CONTROL COMPARTMENT ASSEMBLY

1

3

4

25

6

7

8

9

10

11

12

13

14

15

7

13

8 7 17 18 19 2016

7

7

8

8

21

21

8

22

59

CONTROL COMPARTMENT ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-00712 Lower Control Box 1

2 A-00233 Lower Control Mount 1

3 A-00290 Cover Stop Bracket 1

4 0096-0016 Cap Screw, M10 x 25 2

5 0096-0041 Hex Nut, Self-Locking, M10 2

6 A-00295 Level Sensor 1

7 0096-0002 Cap Screw, M6 x 20 16

8 0096-0039 Hex Nut, Self-Locking, M6 20

9 A-00287 Mount Plate – GFI Outlet 1

10 A-00255 Motor Controller 2

11 B01-05-0056 Battery Charger 1

12 A-00274 Gas Spring 1

13 0090-0920 Stud Ball, 10mm 2

14 0090-0185 Hex Nut, Self-Locking, 5/16-18 2

15 A-03200 Turntable Weldment 1

16 B01-10-0046 Outlet Box 1

17 B01-10-0034 GFI Outlet 1

18 B01-10-0035 Outlet Box Cover 1

19 0096-0001 Cap Screw, M6 x 16 2

20 A-00288 Plastic Cover 1

21 0096-0004 Cap Screw, M6 x 25 8

22 A-00935 Dual Motor Controller Bracket 1

60

PUMP COMPARTMENT ASSEMBLY

1

2

3

4

5

6

7

4

61

PUMP COMPARTMENT PARTS LIST

Item No. Part No. Description Qty.

1 A-00268 Tire Iron/Jack Handle 1

2 B04-07-0033 Clamp 2

3 0096-0001 Cap Screw, M6 x 16 2

4 0096-0039 Hex Nut, Self-Locking, M6 4

5 A-00290 Cover Stop Bracket 1

6 0096-0002 Cap Screw, M6 x 20 2

7 0096-0014 Cap Screw, M10 x 20 2

62

BATTERY COMPARTMENT ASSEMBLY

1

3

4

5

6

7

11

14

17

2

89

10

13

12

8

22

24

23

21

25

20

26 27

29

28

16

16

17

15

19

18

30

16

63

BATTERY COMPARTMENT ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-00215 Battery Box Weldment – Left 1

2 A-00220 Battery Box Weldment – Right 1

3 A-00278 Battery Hinge Pin 2

4 0096-0050 Washer, Flat, M16 8

5 0090-0147 Cotter Pin 4

6 A-00271 Battery Clamp 4

7 0096-0010 Cap Screw, M8 x 20 4

8 0096-0040 Hex Nut, Self-Locking, M8 8

9 A-00219 Battery Box Latch 2

10 A-00256 Motor Cover 1

11 A-00229 Latch Plate 2

12 A-00234 Spacer 2

13 0096-0011 Cap Screw, M8 x 25 6

14 A-00244 Tension Spring 2

15 A-00225 Nose Weldment 1

16 0096-0014 Cap Screw, M10 x 20 10

17 0096-0041 Hex Nut, Self-Locking, M10 10

18 A-00037 Ramp, Short 4

19 0096-0002 Flat Head Cap Screw, M6 x 20 4

20 0096-0039 Hex Nut, Self-Locking, M6 4

21 A-00046 Grommet 4

22 B04-07-0036 Clamp 2

23 B01-09-0132 A-Frame Handle, Connector 1

24 B01-09-0131 Plug, Connector 1

25 A-03272 Battery Cable Kit 1

26 B01-09-0133 Terminal Boot – Black 4

27 B01-09-0134 Terminal Boot – Red 4

28 A-00242 Battery 4

29 0090-0162 Hex Nut, 3/8-16” 8

30 A-00235 Power Unit, 4WD 1

B02-15-0528 3KW 24V DC Motor 1

B02-15-0529 Gear Pump 2.0 ccm 1

B02-02-0301 Fitting M14 x –6 ORFS 1

B02-02-0302 Fitting, M18 x –8 ORFS 1

64

COVER ASSEMBLY

12

3

4

5

6

7

89

10

7

65

COVER ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-03240 Cover – Left 1

2 A-03239 Cover – Right 1

3 A-00228 Cover Brace 2

4 A-00252 Hinge 4

5 0096-0002 Cap Screw, M6 x 20 12

6 0096-0039 Hex Nut, Self-Locking, M6 12

7 0090-1080 Pop Rivet 22

8 A-00258 Controls Cover – Left Side 1

9 B42-01-1002 Hinge, Controls Cover 1

10 A-00292 Cover Latch Assembly 2

66

BOOM ASSEMBLY (I)

1

2

3

4

5

6

789

10

8

9

9

4

4

3

5

4

67

BOOM ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-00552 Hydraulic Master Cylinder 1

2 A-00024 Pin, .75 x 8.5 1

3 A-00017 Pin Retainer – .75 2

4 0096-0016 Cap Screw, M10 x 25 7

5 0096-0041 Hex Nut, Self-Locking, M10 7

6 A-00026 Pin, .75 x 7.0 1

7 A-00551 Hydraulic Boom Cylinder 1

8 A-00021 Pin, 1.25 x 8.5 2

9 A-00019 Pin Retainer – 1.25 5

10 A-00023 Pin, 1.25 x 7.25 1

68

BOOM ASSEMBLY (II)

12

3

4

5

6

7

8

9

10

11

12

13

14

15 16

17 18 19 20

21

22

23

24

25

26

27

24

14

13

5

28

69

BOOM ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-00510 Telescopic Boom Tube 1

2 A-00550 Hydraulic Extension Cylinder 1

3 A-00535 Slider 2

4 0096-0018 Cap Screw, M10 x 40 4

5 0096-0041 Hex Nut, Self-Locking, M10

6 A-00032 Bearing 2

7 0096-0033 Flat Head Cap Screw, M16 x 35 4

8 A-00027 Pin, .75 x 7.0 1

9 A-00017 Retainer – .75 1

10 0096-0016 Cap Screw, M10 x 25 1

11 A-00533-1 Wear Pad – Green 5

12 A-00533-2 Wear Pad – Grey 7

13 A-00534 Wear Pad Shim 6

14 0096-0013 Nylon Cap Screw, M10 x 16 24

15 A-00537 Boom Switch Block 1

16 0096-0098 Cap Screw, M8 x 35 2

17 0096-0040 Hex Nut, Self-Locking, M8 2

18 A-00469 Cage Latch Pad 1

19 A-00470 Cage Storage Pad 1

20 A-00471 Cage Latch Plate 1

21 A-00473 Cage Latch 1

22 0096-0001 Cap Screw, M6 x 16 4

23 0096-0049 Cap Screw, M8 x 50 1

24 0096-0040 Hex Nut, Self-Locking, M8 3

25 B01-10-0275 Strobe Light (Option) 1

26 0090-0236 Machine Screw, #10-24 x 3/4 2

27 0090-0415 Washer, Flat, #10 2

28 0090-0182 Hex Nut, Self-Locking, #10-24 2

70

CABLE TRACK ASSEMBLY

1

2

3

4567

8

910

11

13

12

14

2

2

3

3

3

8

71

CABLE TRACK ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-00531 Slide Tube 1

2 0096-0010 Cap Screw, M8 x 20 16

3 0096-0040 Hex Nut, Self-Locking, M8 18

4 A-00532 Tube Slider 1

5 A-00529 Tube Slider Back 1

6 0096-0018 Cap Screw, M10 x 40 2

7 0096-0017 Cap Screw, M10 x 30 2

8 0096-0041 Hex Nut, Self-Locking, M10 8

9 B00-00-0031 Cable Track – 41 Links 1

10 A-00536 Cable Track Tray 1

11 0096-0014 Cap Screw, M10 x 20 4

12 A-00538 Cable Support Tube 1

13 A-00539 Cable Slide Block 1

14 0096-0056 Cap Screw, M8 x 30 2

72

BOOM NOSE ASSEMBLY

1

2

3

4

5

67

8

910 1112

13

14

15

16

17

18

19 20

21 22

23

24

25 26

27

28

29

30

31

8

13

2

73

BOOM NOSE ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-00979 Bulkhead Mount 1

2 0096-0016 Cap Screw, M10 x 25 4

3 A-00601 Platform Pivot Weldment 1

4 A-00025 Pin, 1.0 x 6.5 1

5 A-00018 Pin Retainer – 1.0 1

6 0096-0041 Hex Nut, Self-Locking, M10 6

7 0096-0015 Socket Head Cap Screw, M10 x 20 2

8 A-00033 Bearing 4

9 A-00606 Snap Pin 2

10 A-00608 Compression Spring 1

11 A-00609 Knob, Platform Latch 2

12 0096-0055 Cap Screw, M12 x 190 1

13 0096-0042 Hex Nut, Self-Locking, M12 10

14 A-00553 Hydraulic Slave Cylinder 1

15 A-00027 Pin, .75 x 5.25 DB 1

16 A-00034 Pin Retainer – .75 FH 2

17 0096-0012 Flat Head Cap Screw, M8 x 25 2

18 0096-0040 Hex Nut, Self-Locking, M8 2

19 A-00035 Pin, .75 x 6.5 1

20 A-00017 Pin Retainer – .75 1

21 A-00522 Boom End Weldment 1

22 0096-0020 Cap Screw, M12 x 30 9

23 A-00031 Bearing 2

24 A-00610 Platform Mount Weldment 1

25 A-00038 Ramp 4

26 0096-0003 Flat Head Cap Screw, M6 x 20 8

27 0096-0039 Hex Nut, Self-Locking, M6 10

28 B01-10-0046 Outlet Box 1

29 B01-10-0034 GFI Outlet 1

30 B01-10-0035 Outlet Box Cover 1

31 0096-0001 Cap Screw, M6 x 16 2

74

PLATFORM ASSEMBLY

1

2

5

6

7

9

10

11

12

13 14

1516

17

18

19

20

21

22

24

13

7

23

75

PLATFORM ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-03350 Platform Weldment – 5’ 1

2 A-03359 Platform Floor 1

3 0096-0102 Cap Screw, M8 x 25 26

4 0096-0040 Hex Nut, Self-Locking, M8 26

5 A-03361 Upper Control Box Mount 1

6 0096-0016 Cap Screw, M10 x 25 4

7 0096-0041 Hex Nut, Self-Locking, M10 4

8 A-00466 Control Box Latch 1

9 A-00463 Midrail End 4

10 0096-0115 Slotted Head Cap Screw, M6 x 20 2

11 A-00464 Midrail 1

12 0096-0052 Cap Screw, M6 x 40 2

13 0096-0039 Hex Nut, Self-Locking, M6 6

14 A-00468 Manual Storage Mount Plate 1

15 0096-0017 Cap Screw, M10 x 30 2

16 A-00475 Manual Storage Box 1

17 0096-0001 Cap Screw, M6 x 16 4

18 A-00474 Cord Wrap Bracket 1

19 A-00071 Platform Pin 1

20 0090-0147 Cotter Pin – 1/8 x 1 1/4 2

21 A-00028 Pin – Platform to End Weldment 1

22 A-00779 Upper Control Box – 4WD Articulating 1

23 A-00462 Spool 7

24 0096-0003 Flat Head Cap Screw, M6 x 40 7

76

PUMP ASSEMBLY (A-00254)

1

2

3

5

6

7

89

10

11

12

13

14

15

21

21

24

19

17 17 17

24 17

19

22

17

19

23

17 17

20 4

19

17 20

19

17

16

20

25

18

77

PUMP ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 B02-15-0496 Manifold, Valve Housing 1

2 B02-14-0108 Valve, Counterbalance 2

3 B02-15-0472 Manual Pump, Extend/Retract/Rotate 1

4 B02-14-0089 Valve, Cartridge (Outrigger Check) 1

5 B02-14-0109 Valve, Cartridge (Outrigger) 2

6 B02-14-0091 Valve, Check 1

7 B02-14-0110 Valve, Check 1

8 B02-14-0094 Valve, Proportional 1

9 B02-14-0095 Coil Sterling, Proportional Valve 1

10 B02-14-0111 Valve, Relief 1

11 B02-14-0097 Valve, Relief 1

12 B02-14-0098 Valve, Shuttle 1

13 B02-14-0099 Valve, Cartridge (Rotator) 1

14 B02-14-0100 Valve, Counterbalance 1

15 B02-14-0101 Valve, Cartridge (Basket Compensate) 1

16 B02-14-0114 Valve, Flow Control (Rotator) 1

17 B02-02-0245 Fitting, Plug, #2 ORB 11

18 B02-02-0246 Fitting, Hex Plug 1

19 B02-02-0248 Fitting, Plug, #4 ORB 5

20 B02-14-0112 Coil, 20 VDC, #8 5

21 B02-14-0113 Coil, 20 VDC, #10 5

22 B02-15-0497 Stud, #1/4-20 x 5/8 4

23 B02-15-0498 Expansion Plug 1

24 B02-02-0235 Fitting, Plug, #6 ORB 2

25 B02-15-0478 Seal Ring 1

78

PUMP ASSEMBLY, CONTINUED

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

15

19

20

21

22

79

PUMP ASSEMBLY PARTS LIST, CONTINUED

Item No. Part No. Description Qty.

1 B02-15-0513 Reservoir 1

2 B02-15-0470 Pump Assembly, 2.09 CCM 1

3 B02-15-0471 Motor, Pump, 24 VDC 1

4 B02-15-0500 Coupling, .875 x 2.795 1

5 B02-15-0501 Filter, Hydraulic 1

6 B02-15-0476 Sight Glass 1

7 B02-15-0477 Socket Head Cap Screw, M8 x 85 2

8 B02-02-0247 Fitting, Plug, M14 x 1.5 x 5.8 1

9 B02-15-0478 Seal Ring 1

10 B02-15-0485 Clamp, Band, #10-16 2

11 B02-15-0480 Filter, Suction 1

12 B02-15-0504 Allen Nut, 1/4-20 4

13 B02-02-0255 Fitting, M18 x HB-90M x HB-90 1

14 B02-15-0503 O-Ring, 110.72 x 3.53 NBR 70 D 1

15 B02-02-0279 Fitting, JIC-8 x Push On FS x PO 2

16 B02-15-0505 Hose, Black, 1/2 x 6” 1

17 B02-02-0280 Fitting, JIC-8 x #6 MxM 1

18 B02-15-0506 Cap Screw, #5/16-18 x 1 1/4 2

19 B02-02-0283 Fitting, JIC-8 x G 3/4 MxM 1

20 B02-02-0281 Fitting, Plug, #12 ORB 2

21 B02-02-0282 Fitting, 3/8 NPT x 1/2 MxHB 1

22 B02-15-0507 Hose, Black, 1/2 x 15” 1

B02-02-0276 Fitting, Plug, #8 ORB (Under Reservoir) 1

80

BOOM AND ROTATION HYDRAULIC LINES (A-00269)

81

BOOM AND ROTATION HYDRAULIC LINES PARTS LISTS

Item No. Part No. Description Fittings

1 B02-01-0274 #4 x 42” Hydraulic Hose 4-6 FFORX 4-4 FFORX

2 B02-01-0275 #4 x 42” Hydraulic Hose 4-6 FFORX 4-4 FFORX

3 B02-01-0276 #6 x 66” Hydraulic Hose 6-6 FFORX 6-6 FFORX

4 B02-01-0277 #6 x 66” Hydraulic Hose 6-6 FFORX 6-6 FFORX

5 B02-01-0278 #4 x 48” Hydraulic Hose 4-6 FFORX 4-6 FFORX 45

6 B02-01-0279 #4 x 48” Hydraulic Hose 4-6 FFORX 4-6 FFORX 45

7 B02-01-0280 #4 x 36” Hydraulic Hose 4-6 FFORX 4-6 FFORX

8 B02-01-0281 #4 x 36” Hydraulic Hose 4-6 FFORX 4-6 FFORX

9 B02-01-0231 #4 x 10” Hydraulic Hose 4-4 FFORX 90S 4-4 FFORX

10 B02-01-0232 #4 x 420” Hydraulic Hose 4-4 FFORX 4-4 FFORX

11 B02-01-0233 #4 x 420” Hydraulic Hose 4-4 FFORX 4-4 FFORX

12 B02-01-0234 #4 x 16” Hydraulic Hose 4-4 MFFOR 4-4 FFORX

13 B02-01-0235 #4 x 16” Hydraulic Hose 4-4 MFFOR 4-4 FFORX

14 B02-01-0204 #3 x 32” Hydraulic Hose 2 MNPT 2 MNPT 90SW

FITTINGS

Part No. Description Qty.

B02-02-0259 #6 MORFS - #6 MORB, STR 6

B02-02-0264 #6 MORFS - # 6 MORB, 45º 8

B02-02-0263 #4 MORFS, Tee 1

B02-02-0237 #4 MORFS - #6 MORB, STR 2

B02-02-0262 #6 MORFS - #10 MORB, 45º 2

B02-02-0196 #4 MORB - #2 MNPT, STR 1

B02-02-0241 #2 NPTFM Coupling 1

B02-02-0242 #2 QD Plug 1

B02-02-0229 #4 MORFS - #6 MORB 90 3

82

OUTRIGGER HYDRAULIC LINES (A-03182)

EXT

RET

RET

EXT

RET

EXT

EXT

RET

EXT

RET

2

1

4

6

1

99

10

10 10

10

1

3

5

2

2

12

7

8

OUTRIGGER HYDRAULIC LINES PARTS LIST

Item No. Part No. Description Qty.

1 B02-01-0213 #4 x 28” Hydraulic Hose 4

2 B02-01-0214 #4 x 28” Hydraulic Hose 4

3 B02-01-0215 #6 x 56” Hydraulic Hose 1

4 B02-01-0216 #6 x 56” Hydraulic Hose 1

5 B02-01-0219 #6 x 28” Hydraulic Hose 1

6 B02-01-0220 #6 x 28” Hydraulic Hose 1

7 B02-01-0327 #6 x 46” Hydraulic Hose 1

8 B02-01-0328 #6 x 46” Hydraulic Hose 1

9 B02-02-0258 Fitting, Tee, #6 MORFS 6

10 B02-02-0259 Fitting, #6 MORFS - #6 MORB 8

83

TRAILER HYDRAULIC LINES – 4WD (A-01075)

P1A

P2B

P1B

P2A

S1A

S1B

TB M2A

M2B

M3A

M3B

M1A

M1B

M4A

M4B

TA

B1

Aux

Pump

P

T

8-18 Metric

90

6-14 Metric

90

TP2

TP3

ORB

SMA

SMB

Banjo

Bolt

Pump

Side

Rear

Control

Side

Front

Control

Side

Rear

Pump

Side

Front

OIL

COOLER

Dual

Pump

5GPM

Driver

Top Top

Bottom

Front

Rear

Front

Rear

Bottom

6

7

1

4

8

9

5

13

12

10

14

11

MANUAL

BRAKE

RELEASE

2

3

11

15

16

17

18

19

20

21

22

23

24

24

#12ORBM-#10ORBFM STR

6410-12-10

#10MORFS-#10MOBR-#10MORFS Tee

FF6804-10-10-10

#8MORFS-#12MORB STR

FF6400-8-12

(2) #8MORFS-#10MORB 45

FF6802-8-10

10MORB Plug

6408-H-10

#10MORFS-#12ORB 90

FF6801-10-12

#4MORFS-#4MORB 90

FF6801-4-4

#4MORFS-#4MORB 90

FF6801-4-4

(2)#10MORB-#6FMORB

6410-L-10-6

(2)#6MORFS-#6MORB 90

FF6801-6-6

(2)#10MORB-#6FMORB

6410-L-10-6

(2)#6MORFS-#6MORB 90

FF6801-6-6

(2) #6MORFS-#10MORB STR

FF6400-6-10

(2) #4MORFS-#4MORB 90

FF6801-4-4

#4MORFS Tee

FF2603-4-4-4

#4MORFS Tee

FF2603-4-4-4

#8MORFS Tee

FF2603-8-8-8

#6MORFS-#6MORB STR

FF6400-6-6

(2) #6MORFS-#10MORB STR

FF6400-6-10

(2) #4MORFS-#4MORB 90

FF6801-4-4

FF6801-6-6

FF6400-4-6

FF6400-6-6

FF6400-4-6

FF6400-6-6

FF6400-6-6 FF6400-6-6

FF6400-6-6 FF6400-6-6

FF6400-6-6

FF6400-6-6

FF6400-6-6

FF6400-8-8

FF6400-4-4

FF6400-4-4

(2) #4MORFS-#4MORB 45

FF6802-4-4

#10MORFS-#10FMORFS 90

FF6500-10-10

B1

Brake

FF6801-L-6-6

FF6801-6-6

90

90L

90

STR

14

15

18

19

1A

2A

2B

3B

4B

3A

1B

7A

6A

4A

5

Oil Filter

84

TRAILER HYDRAULIC LINES PARTS LISTS

Item No. Part No. Description

1 B02-01-0402 #10 x 28” Hydraulic Hose

2 B02-01-0401 #8 x 154” Hydraulic Hose

3 B02-01-0398 #8 x 16” Hydraulic Hose

4 B02-01-0400 #8 x 24” Hydraulic Hose

5 B02-01-0399 #8 x 18” Hydraulic Hose

6 B02-01-0386 #6 x 30” Hydraulic Hose

7 B02-01-0387 #6 x 30” Hydraulic Hose

8 B02-01-0397 #6 x 166” Hydraulic Hose

9 B02-01-0396 #6 x 150” Hydraulic Hose

10 B02-01-0385 #4 x 118” Hydraulic Hose

11 B02-01-0379 #4 x 16” Hydraulic Hose

12 B02-01-0382 #4 x 30” Hydraulic Hose

13 B02-01-0383 #4 x 40” Hydraulic Hose

14 B02-01-0393 #6 x 138” Hydraulic Hose

15 B02-01-0392 #6 x 138” Hydraulic Hose

16 B02-01-0388 #6 x 38” Hydraulic Hose

17 B02-01-0389 #6 x 38” Hydraulic Hose

18 B02-01-0395 #6 x 138” Hydraulic Hose

19 B02-01-0394 #6 x 138” Hydraulic Hose

20 B02-01-0390 #6 x 62” Hydraulic Hose

21 B02-01-0391 #6 x 62” Hydraulic Hose

22 B02-01-0380 #4 x 21” Hydraulic Hose

23 B02-01-0384 #4 x 105” Hydraulic Hose

24 B02-01-0381 #4 x 25” Hydraulic Hose

85

FITTINGS

Part No. Description Qty.

B02-02-0259 #6 MORFS - #6 MORB, STR 10

B02-02-0293 #8 MORFS - #8 MORB, STR 1

B02-02-0260 #6 MORFS - #6 MORB, 90º 6

B02-02-0287 #4 MORFS - #4 MORB, STR 2

B02-02-0288 #4 MORFS - #4 MORB, 90º 6

B02-02-0289 #4 MORFS, Tee 2

B02-02-0294 #6 MORFS - #6 MORB, 90ºL 1

B02-02-0295 #12 MORB - #10 FMORB 1

B02-02-0296 #10 MORFS - #10 MORB - #10 MORFS, Tee 1

B02-02-0297 #10 MORFS - #10 FMORFS, 90º 1

B02-02-0298 #8 MORFS - #12 MORB, STR 1

B02-02-0299 #8 MORFS - #10 MORB, 45º 2

B02-02-0300 #10 MORFS - #12 MORB, 90º 1

B02-02-0303 #10 MORB Plug 1

B02-02-0304 #10 MORB - #6 FMORB 4

B02-02-0305 #6 MORFS - #10 MORB, STR 4

B02-02-0237 #4 MORFS - #6 MORB, STR 2

B02-02-0307 #8 MORFS, Tee 1

B02-02-0308 #4 MORB Plug 1

B02-02-0309 #8MORFS - #12 MORB, 90º 2

4WD MANIFOLD (A-01033)

86

WIRE HARNESSES

111

12 3

5

Prim

Cyl

C5

Sec

Cyl

C16

Jib

Cyl

C17

1

12

2436

1

12

2435

18

23 16

LF

C1

LR

C3

RF

C2

RR

C4

LF

LR

RF

RR

24

1

3

2

4

27

26

13

15

14

16

22

23

Strobe

1

16

31

B- B+

M-

Main

Pump

Motor

A2E2

D1E1

EnableSpeed

R B O Br

+ -

X Y

8

15

22

23

Motor

Controller

Main

Level

Sensor

Front

Boom

Switches

Boom

Down

Relay NC

C22C23C24C25 C20C21C26

3334 11 10 9876

12

31

B- B+

M-

EnableSpeed

20

Motor

Controller

Aux

Aux

Pump

Motor

A2E2

D1E1

Drive

Manifold

200

Amp

Fuses

C27C28C29C30C31

1718192021

1 2

Motor

Cntl

B+

Motor

Cntl

B-

3

4

6

7

8

9

Wh

Blu

Bla

Or

Re

Gr

B

E

F

A

D

C

Upper

Control

Box

IEC Recp.

35

PLT

DN

C14

PLT

UP

C13

Rot

CCW

C9

Rot

CW

C10

Boom

RET

C12

Boom

EXT

C11

Prop

Coil

C8

Chk

Valve

C6A

OR

EXT

C6

OR

RET

C7

+ -

Pump

10

Throttle

Sol

Choke

Sol

Engine

Start

Fuel

Switch

Engine

Stop

Fan

Engine

Run

242725 269

M

Fan

Fuel Sol

Start Sol

Engine Spark

LN

Platform Plug

Engine Stop

Start

Fuel

Fan

NO

Jib

Switches

##NO

#NC

#NC

#

Switch is forced open

when Boom is lifted

##

Switch is forced Closed

when Boom is Stowed

##NO

**

NO

**

NO

**

NO

**

Switch is forced Closed

when outrigger is loaded

**

GFCI

Plug

P4 & P5

Connector

P3

Turntable Connector P1

Analog Connector

J4

Platform Connector

P2

Lift/Engine Connector

20

31

21

7

8

13

14

23

9

10

34

17

18

35

32

32

Oil

Press

Switch

AC

Switch

Generator

AC Switch

AC

Plug

Engine

Start

87

MANIFOLD WIRE HARNESS (A-00785)

A

B

C

D

E

F

A

B

C

A

B

C

D

E

F

C20

C21

C22

C23

C24

C25

GND

C27

C28

C29

C30

C31

GND

C26(+)

C26(-)

C22

C25

Deutsch Term.

0462-201-16141

C20

C24

C21

C23

Wires

Connected

& Sealed

Stripe wire

to 12"

1

2

1

2

1

2

1

2

1

2

1

2

C27 1

2

C28 1

2

C29 1

2

C30 1

2

C31 1

2

C26 + 1

2

C26 -

GND 2

GND 1

3"

3"

9"

9"

Deutsch

DT06-2S

2PinPlug

W2S Wedge

12020926

6 Pin FM Conn

12089188

FM Term

12015323

Green Wire Seal

12010717

3 Pin Male Conn

12089040

Male Term

12015323

Green Wire Seal

12020786

6 Pin Male Conn

1208089040

Male Term

12015323

Green Wire Seal

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

SOOW or Equivalent

Stripe wire

to 4"

Label Wires

Both Ends

Wires

Connected

& Sealed

Orange

White

Green

Red

Blue

White/B

Black

Red/B

Green/B

Orange/B

Blue/B

Green/W

Red/W

Blue/W

Black/W

Wire Color

Orange

White

Green

Red

Blue

White/B

Black

Red/B

Green/B

Orange/B

Blue/B

Green/W

Red/W

Blue/W

Black/W

A-00785

Rev-

Label

A-00785

Rev-

Label

GAS ENGINE WIRE HARNESS (A-01034)

Engine Stop

Engine Start

Throttle

Choke

Engine RunRed

Red

Green

Black

Blue

White

Orange

White

Blue

Orange

Green

Black

Strip Wires 6"

120" (10')

18ga-10 Cond Wire

SOOW or Equivalent

Strip Wires 3"

A

B

C

D

GND

12010973

2 Pin Male Conn

12089040

Male Term

12015323

Green Wire Seal

12020830

4 Pin Male Conn

12089040

Male Term

12015323

Green Wire Seal

A

B

1"

5"

Delphi

Weather Pack

Delphi

Weather Pack

12020829

3 Pin Female Conn

12089188

Female Term

12015323

Green Wire Seal

C

B

A

Throttle

Engine Start

Engine Stop

C

B

A

Engine Run

GND

Choke

12020827

3 Pin Male Conn

12089040

Male Term

12015323

Green Wire Seal

C

B

AGen Switch

Oil Press Sw (+)

Oil Press Sw

B

A

A

B

GND

Oil Press Sw (+)

Oil Press Sw

Gen Switch

12015792

2 Pin Female Conn

12089188

Female Term

12015323

Green Wire Seal

Delphi

Weather Pack

12020829

3 Pin Female Conn

12089188

Female Term

12015323

Green Wire Seal

A-01034

Rev-

A-01034

Rev-

Label Both

Ends

R/BL

Or/BL

Wh/Bl

R/BL

Or/BL

Wh/Bl

Label Wire

Color

Label

Wire

Color

Green

Green

5"

Splice &

Heat Sealed

88

CHOKE /THROTTLE SOLENOID WIRE HARNESS (A-01042)

Weather Pack

FM Term

12089188

Cable Seal

12015323

FM Housing

12015792

B

A

B

W

20" 18ga TXL

Or Equivalent

A-01042

Rev- Label

Put Wires

in 16"

Split

tubing

Heat Seal

Both

ends

1"

ENGINE RELAYS WIRE HARNESS (A-01044)

Starter S 87 Starter20"

15"Ign K 87a Ign Coil

Fuel Sw

¼” Female Spade

15"

5/16" Ring Term

¼” Female Spade

18"

All wires 18 ga

TXL or Equivalent

All Measurements

are +/- 0.250 In

+12V

Labels

A-01044

Rev-

10" Split

Tube Wrap

Tape At

Each End

Engine

Run

Engine Run 10"

Resistor

2.2k-Ohm

.5Watt

Solder inline &

Heat Shrink

4"

¼” Female Spade

¼” Male Spade

Red

Black

Yellow

Orange

Wire

Color

¼” Male Spade

Wire

Length

¼” Female

Spade

4" RedFAN Green

Fuel F 87

¼” Female Spade

¼” Female Spade

¼” Female Spade

8"

8"

6"

6"F30

3"

3"

3"

8"

6"

O

Y

B G R

Heat

Shrink

Label

Delphi Weather Pack

Male Term 12089040

Green Seal 12015323

S30

C30

T30

Wire Color

12v +

89

ATC FUSE HOLDER (A-01049)

¼” Female Spade Ins

5/16" Ring

Term

4"- 6" Leads

12 ga Wire

4"- 6" Leads

12 ga Wire

ATC Fuse Holder

Waytek # 46278

or Equivalent

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

A

B

C

D

12020832

4 Pin Female Conn

12089188

Female Term

12015323

Green Wire Seal

¼” Male Spade

Insulated

¼” Female Spade Insulated

Start S 86

Engine Run

Wire Label

All wires

TXL or Equivalent

All Measurements

are +/- 0.250 In

24"

26"

20"

20"

Split Tube Wrap

& Heat Shrink

Each End

Fuel F 86

6"

4"

6"

Splice & Heat

Shrink Seal

¼” Ring

Terminal

7"

10"

2"

11"

5"

White

Red

Blue

Green

Black

Length

Wire

Color

K30

Fan

A

B

A

B

Yellow

Orange/Bl

Choke C 87

Throttle T 87

28"

28"

Black

Black15"

15"

9"

12010973

2 Pin Male Housing

12089040

Male Terminal

12015323

Green Wire Seal

Throttle

Choke

18"

A-01098

Rev - Label

Tape Both Sides

of Drop Out

A

B

Choke C 86

Throttle T 8628"

28"

Orange

Black

12015792

2 Pin Female Conn

12089188

Female Term

12015323

Green Wire Seal

Black

GND 85

A

B

A–Leave

Open

12010973

2 Pin Male Housing

12089040

Male Terminal

12015323

Green Wire Seal

Delphi Weather Pack

Delphi Weather Pack

Delphi Weather Pack

Delphi Weather Pack

Frame

Gnd

4" GND 85

GND 85

GND 85

6"

8"

8"

GND 85

Stop K 86

Choke

Throttle

90

GENERATOR SWITCHER BOX ASSEMBLY (A-03040)

20

Amp

B W GB W G B W

B W G

A

B

C

A

B

B

W

B01-01-0179

B01-01-0178

Ground

Stud

Br

Bl Y/

g

B01-06-0056

30 Amp Relay

DPST – NO

Allied Electronics

#850-0345

Or Equivilant

B01-10-0354

20 Amp Circuit Breaker

W/.250 Male Spade Terminal

Allied Electronics

#886-0036

Or Equivilant

Cord Grip

Heyco #3231

Or Equivilant

Delphi Weather Pack

2 Pin Male Housing 12010973

Male Terminal 12089040

Green Seal 12015323

Delphi Weather Pack

3 Pin Male Housing 12015793

Male Terminal 12010293

Gray Seal 12010293

Box-A-01015

B01-01-0181

B01-01-0180

WIRE ASSEMBLY – FAN (A-03041)

Weather Pack

FM Term

12089188

Cable Seal

12015323

FM Housing

12015792

B

A

Black

Red

All wires 18 ga

TXL or Equivalent

All Measurements

are +/- 0.250 In

36"

GND

Relay

Label

Wires Wire

Color

B

A

40" Loom

Tape each End &

Middle

A-3041

Rev.

Label

B

A

Weather Pack

FM Term

12089188

Cable Seal

12015323

FM Housing

12015792

B

A

A-03041

Rev.

91

IEC CORD MALE – US MARKETS (A-03042)

North America

120V Male Plug

Current 15 AMP

Voltage 120/240VAC

SO cable or

Equivalent

18"

A-03042

Rev

Label

IEC90DegreePlug

Interpower

IEC 60320 C19

Mold 012

Minimum Requirements

GENERATOR 110V WIRE HARNESS (A-03043)

W B

W B

3"

3"

3"

3"

2"

2" B

B

B

WW

W

1/2” Grommet OD

Delphi Weather Pack

12010717

3 Pin Male Housing

12124582

Male Terminal 12/14ga

12010293

Seal 12/14ga

B

C

A

B

W

G

.0625"

12-3 SO

Or Equivilant

36" (+/- 2")

OIL SWITCH ASSEMBLY (A-03044A)

A

B

Delphi Weather Pack

12010973 (B01-09-0109)

2 Pin Male Housing

12089040 (B01-09-0110)

Male Terminal

12015323 (B01-09-0093)

Green Seal

R

B

Wires should be 17-18" Long

B00-00-0170

Wire Casing

16"

A-03044

OIL PRESSURE SWITCH 4WD

TRANSDUCER DIRECT #TDPS211A8FW

PVC

Tape

92

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

B W G

A

B

C

B01-01-0178

Rev

BWG

¼” Female Spade

¼” Female Spade

#10 Ring Terminal

24"

14-3

SO or Equivalent

4"

Delphi Weather Pack

12015793

3 Pin Female Housing

12124580

Female Terminal 12/14ga

12010293

Seal 12/14ga

Label

CORD ASSEMBLY GENERATOR SWITCH (B01-01-0179)

A

B

B

WB01-01-0179

Rev

¼” Female Spade

¼” Female Spade

4"

28"

18-2

SO or Equivalent

Label

Delphi Weather Pack

12010973

2 Pin Male Housing

12089040

Male Terminal

12015323

Green Seal

CORD ASSEMBLY SWITCH JUMPER (B01-01-0180)

¼” Female Spade¼” Female Spade

14ga Black

TXL or Equivalent

All Measurements

are +/- 0.250 In

B01-01-0180

Rev

Label

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

North America

110V Female Plug

BWG

¼” Female Spade

¼” Female Spade

4"

12"

14-3

SO or Equivalent

B01-01-0181

Rev

93

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

20

Amp

G W BB W G B W

B W G

A

B

C

A

B

B

W

B01-01-0179

B01-01-0178

Br

Bl Y/

g

B01-06-0056

30 Amp Relay

DPST – NO

Allied Electronics

#850-0345

Or Equivilant

B01-10-0354

20 Amp Circuit Breaker

W/.250 Male Spade Terminal

Allied Electronics

#886-0036

Or Equivilant

Cord Grip

Heyco #3231

Or Equivilant

Delphi Weather Pack

2 Pin Male Housing 12010973

Male Terminal 12089040

Green Seal 12015323

Delphi Weather Pack

3 Pin Male Housing 12015793

Male Terminal 12010293

Gray Seal 12010293

Box-A-01015

B01-01-0181CE

B01-01-0180

20

Amp

B01-09-0005

Blue Wire Nut

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

G G

W B

4"

2"

2"

1/2” Grommet OD

.0625"

14-3 SO

Or Equivilant

24" (+/- 2")

White

4"Black

B W G

A

B

C

Delphi Weather Pack

12015793

3 Pin Female Housing

12124580

Female Terminal 12/14ga

12010293

Seal 12/14ga

Green 2" Y W

G R

Generator

Wire Colors

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

BWG

¼” Female Spade

¼” Female Spade

4"

12"

14-3

SO or Equivalent

B01-01-0181CE

Rev

InterPower

# 88010390

16A Socket or

Equiliviant

94

PUMP AND CYLINDER WIRE HARNESS (A-00716)

95

OUTRIGGER SWITCH & COIL WIRE HARNESS (A-00746)

96

ANALOG HARNESS (A-00715)

Amp

Housing

770680-1

Black

Pin

1

¼” FM Spade

Insulated

Pump Speed Signal

3' (36") 18 ga Green

Pin

16

Motor Cntrl Enab

3' (36") 18 ga Yellow

¼” FM Spade

Insulated

Pin

810" 18 ga Red

Level Sensor +24

Pin

15 10" 18 ga Black

Level Sensor GND

Pin

22 18" 18 ga Orange

Level Sensor X

Pin

23 18" 18 ga Brown

Level Sensor Y

A

B

C

D

A

B

C

D

Weather Pack

12020830 4 Pos housing

Mates With 12020832

12089040 Male Terminal

12015323 Wire Seal

Amp

770680

A

B

C

D

Level

Sensor

Pump Speed Signal

Motor Cntrl Enab

32" Loom

AMP 770520-1

A-00715

Rev

Label

B

A

10" Loom

Pin

10 12" 18 ga Red

Pin

912" 18 ga Black

Engine Run +

Ground

B

A

Weather Pack

12010973 2 Pin Housing

12089040 Male Terminal

12015323 Wire Seal

18

2316

8"

8"

18" 18ga Red

18" 18ga Black

Splice & Heat

Shrink Seal

15" Loom

8" Loom

All wires

TXL or Equivalent

All Measurements

are +/- 0.250 In

Start

Contactor

Label

1"

¼” FM Spade

Insulated

¼” FM Spade

Insulated

Label

Motor

Control

Label

Engine

Run

Label

Individual

Wire Labels

POWER HARNESS (A-00718)

AMP

5/16" Ring Terminal

AMP

1-66740-1

Or

66740-6

5/16" Ring Terminal

AMP

1-66740-1

Or

66740-6

12ga Red

32"

32"

12ga

Black

Pin 2

Pin 1

Fill Strain Relief with RTV then put on

cable clamp and wipe off excess Bundle wires in 28" of loom.

Tape both ends if split loom is used

Batt Pos

Batt Neg

AMP 3 Pin Housing

206037-2

AMP Cable Clamp

206070-1

A-00718

Rev.

110 VAC TOWER-PLATFORM HARNESS (A-00722)

97

PLATFORM-GROUND COMMUNICATION CABLE (A-00714)

98

MATERIAL LIFT HOOK ASSEMBLY (OPTION A-00846)

1

2

3

4

5

6

7

8

9

10

11

12

13

15

16

17

18

4

14

19

99

MATERIAL LIFT HOOK PARTS LIST

Item No. Part No. Description Qty.

1 A-00977 Platform Mount Weldment – LS 1

2 A-00982 Load Sense Weldment 1

3 0096-0055 Cap Screw, M12 x 190 1

4 0096-0042 Hex Nut, Self-Locking, M12 3

5 A-00988-1 Load Cell 1

6 0096-0089 Cap Screw, M12 x 65 2

7 A-00990A Load Sense Spacer A 1

8 A-00990B Load Sense Spacer B 2

9 0096-0069 Cap Screw, M10 x 75 1

10 0096-0041 Hex Nut, Self-Locking, M10 1

11 A-00033 Bearing 4

12 A-00994 LS Roller Bar 1

13 A-00995 LS Roller 2

14 0096-0046 Washer, Flat, M12 2

15 0090-0147 Cotter Pin 2

16 0096-0009 Cap Screw, M8 x 10 2

17 A-00038 Ramp 4

18 0096-0003 Flat Head Cap Screw, M6 x 20 8

19 0096-0039 Hex Nut, Self-Locking, M6 8

20 A-00992 Load Sense Interface (Not Pictured) 1

21 0096-0085 Cap Screw, M6 x 60 3

22 0096-0039 Hex Nut, Self-Locking, M6 3

100

BATTERY LAYOUT

+

- +

- +

- +

-

-

+-

+

B+

B- M-

Drive

Motor

Pump

2

3 3

4

Motor

Controller

Enable0-5V

A2E2

D1E1

6

10

200 AMP

Fuse

1

531

Main

Pump

Motor

A2E2

D1E1

B+ M-

Enable 0-5V

31

B-

200 AMP

Fuse

D1

D3

D5

D4

8

9

Contactor

24VDC 100AMP

B01-06-0058

Contactor

24VDC 100AMP

B01-06-0058

7

D6 D2

11

Item No. Kit No. A-00272

1 30” Red, 2 Gauge, 5/16 Ring – Lug

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

3 8” Black, 2 Gauge, 5/16 Ring – 5/16 Ring

4 22” Black, 2 Gauge, 5/16 Ring – Lug

5 24” Red, 2 Gauge, 5/16 Ring – Lug

6 48” Black, 2 Gauge, 5/16 Ring – Lug

7 22” Red, 2 Gauge, 5/16 Ring – Lug

8 48” Red, 2 Gauge, 5/16 Ring – 5/16 Ring

9 45” Black, 2 Gauge, 5/16 Ring – 5/16 Ring

10 19” Black, 2 Gauge, 5/16 Ring – 5/16 Ring

11 13” Red, 2 Gauge, 5/16 Ring – 5/16 Ring

Item No. Kit No. A-00934

D1 6” Red, 2 Gauge, 5/16 Ring – 5/16 Ring

D2 30” Red, 2 Gauge, 5/16 Ring – 5/16 Ring

D3 13” Black, 2 Gauge, 5/16 Ring – 5/16 Ring

D4 40” Red, 2 Gauge, 5/16 Ring – 5/16 Ring

D5 40” Black, 2 Gauge, 5/16 Ring – 5/16 Ring

D6 20” Red, 2 Gauge, 5/16 Ring – 5/16 Ring

101

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

102

NOTES

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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