Bil Jax Wheelchair Xlb 4725A Users Manual

Bil-Jax Personal Lift AERIAL WORK PLATFORMS Hydraulic Boom Lift B33-01-0072_XLB-4725A

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Operation and

Maintenance Manual

XLB-4725A

Proportional

Hydraulic Boom Lift

XLB-4725A

B33-01-0072-01

AERIAL WORK PLATFORMS

AERIAL WORK PLATFORMSAERIAL WORK PLATFORMS

AERIAL WORK PLATFORMS

BOOM PERSONNEL LIFT

This equipment is designed and manufactured in compliance with the duties, re-

sponsibilities, and standards set forth for manufacturers in the ANSI 92.2 standard

in effect at the time of manufacture.

This equipment will meet or exceed applicable OSHA codes and ANSI A92.2 stan-

dards when used in accordance with sections 7, 8, 9 & 10 of ANSI A92.2 and all

other manufacturer’s recommendations.

It is the responsibility of the user of this equipment to follow all applicable ANSI,

OSHA, Federal, State, and local codes and regulations that govern the safe opera-

tion of this equipment.

Table of Contents

1 Safety ............................................................................................................... 1-1

1-1 Introduction........................................................................................ 1-1

1-2 Before Operation............................................................................... 1-3

1-3 During Operation............................................................................... 1-4

1-4 Maintenance Safety ........................................................................... 1-6

1-5 Damaged Equipment Policy............................................................. 1-7

2 Introduction .................................................................................................... 2-1

2-1 General Description........................................................................... 2-1

2-2 Specifications ..................................................................................... 2-2

2-3 Warranty............................................................................................. 2-2

3 Operation ........................................................................................................ 3-1

3-1 Operator Controls.............................................................................. 3-1

3-2 Normal Operating Procedure............................................................ 3-6

3-3 Emergency Lowering......................................................................... 3-7

3-4 Manual Boom Rotation .................................................................... 3-7

3-5 Battery Recharge (DC Model Only)............................................... 3-8

3-6 Boom Lift Transport....................................................................... 3-10

4 Maintenance.................................................................................................... 4-1

4-1 Scheduled Service Checks................................................................ 4-1

4-2 Wheel Nut Torque Requirements.................................................... 4-3

4-3 Lubrication ......................................................................................... 4-3

4-4 Hydraulic System .............................................................................. 4-6

4-5 Leveling System .............................................................................. 4-11

4-6 Troubleshooting ............................................................................... 4-14

4-7 Material Safety Data Sheets .......................................................... 4-23

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

6 Parts List ......................................................................................................... 6-1

6-1 Upper Boom Parts List.................................................................... 6-2

6-2 Lower Boom Parts List.................................................................... 6-4

6-3 Upper Cylinder Parts List................................................................ 6-6

6-4 Lower Cylinder Parts List................................................................ 6-8

6-5 DC Model Battery Compartment Parts List.................................... 6-10

6-6 Gas Model Engine Compartment Parts List....................................... 6-14

6-7 DC Model Power Compartment Parts List.................................. 6-18

6-8 Gas Model Power Compartment Parts List ....................................... 6-22

6-9 Frame and Rotation Unit List ....................................................... 6-26

6-10 Hitch and Jack Assembly Parts List ............................................ 6-28

6-11 Square Tube Axle and Wheel Assembly Parts List ................... 6-32

6-12 Hex Tube Axle and Wheel Assembly Parts List........................ 6-34

6-13 Tail Lights and Junction Box Parts List ..................................... 6-36

6-14 Front Outriggers Parts List ............................................................ 6-38

6-15 Rear Outrigger Parts List............................................................... 6-40

6-16 Basket Parts List............................................................................. 6-42

6-16A Basket Parts List, Early Model..................................................... 6-46

6-17 Upper Control Box – External Parts List...................................... 6-50

6-18 Upper Control Box – Internal Parts List....................................... 6-51

6-19 Lower Control Box Parts List....................................................... 6-52

6-20 Proportional Valve Assembly Parts List....................................... 6-54

6-21 Surge Brakes Parts List ................................................................. 6-55

6-22 DC Model Hydraulic System Parts List ...................................... 6-56

6-23 Gas Model Hydraulic System Parts List...................................... 6-58

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

List of Illustrations

Figure 3-1. Battery ON/OFF Switch.......................................................................... 3-1

Figure 3-2. Lower Control Panel............................................................................... 3-2

Figure 3-3. Upper Control Panel ............................................................................... 3-4

Figure 3-4. Emergency Lowering Valve.................................................................... 3-7

Figure 3-5. Boom Rotation........................................................................................ 3-7

Figure 3-6. Battery Charger and Receptacle.............................................................. 3-8

Figure 3-7. Battery Charger....................................................................................... 3-9

Figure 3-8. Breakaway Safety Cable ....................................................................... 3-10

Figure 3-9. Jack Travel Position.............................................................................. 3-10

Figure 3-10. Trailer Hitching Checkpoints................................................................ 3-11

Figure 3-11. Backup Lever Position.......................................................................... 3-12

Figure 4-1. Wheel Nut Tightening Sequence............................................................. 4-3

Figure 4-2. Lubricate Monthly................................................................................... 4-3

Figure 4-3. Lubricate Semi-Annually ........................................................................ 4-4

Figure 4-4. Lubrication of Dexter Axles.................................................................... 4-5

Figure 4-5. Hydraulic Cylinder Removal .................................................................. 4-7

Figure 4-6. Hydraulic Cylinder Repair...................................................................... 4-9

Figure 4-7. Checking Outrigger Bushings ............................................................... 4-11

Figure 4-8. Outrigger Bushing Replacement ........................................................... 4-12

Figure 4-9. Adjusting Axle Position Switches......................................................... 4-13

Figure 4-10. Lower Controller Board........................................................................ 4-16

Figure 4-11. Level Sensor .........................................................................................4-18

Figure 4-12. DC Model Hydraulic Diagram.............................................................. 4-19

Figure 4-13. Gas Model Hydraulic Diagram............................................................. 4-20

Figure 4-14. PC Logic Diagram, DC Model..............................................................4-21

Figure 4-15. PC Logic Diagram, Gas Model............................................................. 4-22

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

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

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

Figure 5-2. Decal Locations, Trailer and Boom........................................................5-5

Figure 5-3. Decal Locations, Power Compartments Exterior .................................... 5-6

Figure 5-4. Decal Locations, Power Compartment Interior....................................... 5-6

Figure 6-1. Upper Boom............................................................................................6-2

Figure 6-2. Lower Boom ........................................................................................... 6-4

Figure 6-3. Upper Cylinder .......................................................................................6-6

Figure 6-4. Lower Cylinder ....................................................................................... 6-8

Figure 6-5. DC Model Battery Compartment.......................................................... 6-10

Figure 6-6. Gas Model Engine Compartment.......................................................... 6-14

Figure 6-7. DC Model Power Compartment............................................................ 6-18

Figure 6-8. Gas Model Power Compartment........................................................... 6-22

Figure 6-9. Frame and Rotation Unit....................................................................... 6-26

Figure 6-10. Hitch and Jack Assembly......................................................................6-28

Figure 6-11. Square Tube Axle and Wheel Assembly............................................... 6-32

Figure 6-12. Hex Tube Axle and Wheel Assembly...................................................6-34

Figure 6-13. Tail Lights and Junction Box................................................................ 6-36

Figure 6-14. Front Outriggers.................................................................................... 6-38

Figure 6-15. Rear Outrigger ......................................................................................6-40

Figure 6-16. Basket ................................................................................................... 6-42

Figure 6-16A. Basket, Early Model..............................................................................6-46

Figure 6-17. Upper Control Box (DC Model) – External.......................................... 6-50

Figure 6-18. Upper Control Box (DC Model) – Internal........................................... 6-51

Figure 6-19. Lower Control Box (Gas Model).......................................................... 6-52

Figure 6-20. Proportional Valve Assembly............................................................... 6-54

Figure 6-21. Surge Brakes.........................................................................................6-55

Figure 6-22. DC Model Hydraulic System................................................................ 6-56

Figure 6-23. Gas Model Hydraulic System ............................................................... 6-58

iii

List of Tables

Table 1-1. Minimum Safe Approach Distances ....................................................... 1-4

Table 2-1. Specifications.......................................................................................... 2-2

Table 4-1. Daily/Weekly Service Checks ................................................................ 4-1

Table 4-2. Monthly Service Checks......................................................................... 4-2

Table 4-3. Troubleshooting Chart.......................................................................... 4-14

Table 4-4. Error Codes........................................................................................... 4-15

Table 4-5. LED Indicators ..................................................................................... 4-17

Table 4-6. Upper Control Box Specifications........................................................ 4-17

Table 4-7. Level Sensor LEDs............................................................................... 4-18

Table 5-1. Replacement Decals, DC Model............................................................. 5-1

Table 6-1. Upper Boom Parts List ........................................................................... 6-3

Table 6-2. Lower Boom Parts List........................................................................... 6-5

Table 6-3. Upper Cylinder Parts List....................................................................... 6-7

Table 6-4. Lower Cylinder Parts List....................................................................... 6-9

Table 6-5. DC Model Battery Compartment Parts List.......................................... 6-11

Table 6-6. Gas Model Engine Compartment Parts List.......................................... 6-15

Table 6-7. DC Model Power Compartment Parts List ........................................... 6-19

Table 6-8. Gas Model Power Compartment Parts List........................................... 6-23

Table 6-9. Frame and Rotation Unit Parts List ...................................................... 6-27

Table 6-10. Hitch and Jack Assembly Parts List...................................................... 6-29

Table 6-11. Square Tube Axle and Wheel Assembly Parts List .............................. 6-33

Table 6-12. Hex Tube Axle and Wheel Assembly Parts List................................... 6-35

Table 6-13. Tail Lights and Junction Box Parts List................................................ 6-37

Table 6-14. Front Outriggers Parts List ................................................................... 6-39

Table 6-15. Rear Outrigger Parts List...................................................................... 6-41

Table 6-16. Basket Parts List................................................................................... 6-43

Table 6-16A. Basket Parts List, Early Model............................................................. 6-46

Table 6-17. Upper Control Box – External Parts List.............................................. 6-50

Table 6-18. Upper Control Box – Internal Parts List............................................... 6-51

Table 6-19. Lower Control Box Parts List............................................................... 6-53

Table 6-20. Proportional Valve Assembly Parts List............................................... 6-54

Table 6-21. Surge Brakes Parts List......................................................................... 6-55

Table 6-22. DC Model Hydraulic System Parts List................................................ 6-57

Table 6-23. Gas Model Hydraulic System Parts List.............................................. 6-59

Table 7-1. Minimum Safe Approach Distance (M.S.A.D.) to energized

(exposed or insulated) power lines and parts.......................................... 7-7

1-1

Safety

1-1 INTRODUCTION

Familiarity and proper training are required for the safe operation of mechanical equip-

ment. Equipment operated improperly or by untrained personnel can be dangerous. Read

the operating instructions in this manual and become familiar with the location and proper

use of all controls. Inexperienced operators should receive instruction from someone fa-

miliar with the equipment before being allowed to operate the machine. The use of intelli-

gence and common sense in the operation of mechanical equipment is the best practice in

any safety policy. Be professional and always observe the safety procedures set forth in

this manual.

All OSHA, ANSI, state, and local codes and regulations pertaining to this equipment

should be obtained, read, and thoroughly understood before attempting to operate this

equipment. Persons under the influence of drugs, alcohol, or prescription medication

should not be on or near this equipment. Common sense should be implemented at all

times during the use of this equipment. Do not operate this equipment in areas where the

equipment or user may come in contact with a live power source.

The information contained herein is not to be considered as legal advice and is intended

for informational purposes only. This information is offered to alert Bil-Jax customers to

procedures that may be of concern to them.

This information is not intended to be all inclusive and is to be followed in the use of

Bil-Jax equipment only.

For any questions concerning the safe use of this equipment, call 419.445.9675 before

operating.

XLB-4725A

1-2

Safety Notes

This manual contains DANGERS, WARNINGS, CAUTIONS, and NOTES that must be

followed to prevent the possibility of improper service, damage to the equipment, or per-

sonal injury.

DANGER

Dangers warn of equipment operation near electrical power lines that could lead

to personal injury or death.

WARNING

Warnings describe conditions or practices that could lead to personal injury or

death.

CAUTION

Cautions provide information important to prevent errors that could damage ma-

chine or components.

NOTE: Notes contain additional information important to a procedure.

1 — SAFETY

1-3

1-2 BEFORE OPERATION

Ensure the following general safety precautions are followed before operating the

XLB-4725A Boom Lift.

• ALWAYS survey the usage area for potential hazards such as untamped earth

fills, unlevel surfaces, overhead obstructions, and electrically charged conductors

or wires. Be aware of any potential hazards and always consider what could hap-

pen. Watch for moving vehicles in the operating area.

• ALWAYS read, understand, and follow the procedures in this manual before at-

tempting to operate equipment.

• ALWAYS inspect the equipment for damaged or worn parts. Check for cracked

welds, hydraulic leaks, damaged wiring, loose wire connectors, damaged outrig-

gers, low tire pressure, uneven tire wear, or tire damage. Also check for any im-

proper operation. NEVER operate equipment if damaged in any way. Improperly

operating equipment must be repaired before using.

• ALWAYS wear proper clothing for the job. Wear protective equipment as re-

quired by federal, state, or local regulations. The operator MUST wear a safety

harness and lanyard.

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

equipment.

• ALWAYS inspect the equipment for “DO NOT USE” tags. NEVER use equip-

ment tagged in this way until all repairs are made and all “DO NOT USE” tags

are removed by authorized maintenance personnel.

• ALWAYS make sure the basket and outrigger shoes are free of mud, grease, or

other slippery material to reduce the possibility of slipping.

• NEVER allow improperly trained personnel to operate this equipment. Only

trained and authorized personnel shall be allowed to operate this equipment.

• NEVER operate this equipment if you are under the influence of alcohol or

drugs, or if you feel ill, dizzy, or unsteady in any way. Operators must be physi-

cally fit, thoroughly trained, and not easily excitable.

• NEVER modify, alter, or change the equipment in any way that would affect its

original design or operation in any way.

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

XLB-4725A

1-4

1-3 DURING OPERATION

Ensure the following general safety precautions are followed during the operation of the

XLB-4725A Boom Lift.

DANGER

This machine is not insulated for use near electrical power lines and DOES NOT

provide protection from contact with or close proximity to any electrically charged

conductor. Operator must maintain safe clearances at all times (10 feet minimum)

and always allow for platform movement such as wind induced sway. Always con-

tact the power company before performing work near power lines. Assume every

line is hot. Remember, power lines can be blown by the wind.

Refer to Table 1-1 for minimum safe approach distances between machine and electrical

power lines.

Table 1-1. Minimum Safe Approach Distances

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

• ALWAYS position lift far enough away from power sources to ensure that no

part of the lift can accidentally reach into an unsafe area. This includes full ex-

tension of the boom through 360 degrees rotation.

• ALWAYS operate only on a firm and level surface. NEVER use on surfaces that

do not support the equipment with its rated load capacity and the resulting force

exerted on the outriggers during boom extension and rotation.

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

points.

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

prohibited.

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

soled shoes.

• ALWAYS make certain all personnel are clear and there are no obstructions be-

fore repositioning basket.

• ALWAYS cordon off area around the outriggers to keep personnel and other

equipment away from it while in use.

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

• ALWAYS engage the boom travel locking pin before towing the trailer.

1 — SAFETY

1-5

• NEVER allow electrode contact with any part of the basket if welding is being

performed from the platform.

• NEVER use without the outriggers fully extended, locked, and firmly based.

When on soft surfaces, ALWAYS use outrigger base plates.

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

• NEVER attach a safety harness to an adjacent structure, pole, or equipment

while working from the boom platform.

• NEVER release outrigger locks or move unit with a person or materials on

board.

• NEVER release the outriggers or move the trailer with the boom extended.

• NEVER stand or sit on cage bars. Work only within the work cage and do not

lean out over the cage to perform work.

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

• NEVER operate this equipment when exposed to high winds, thunderstorms, ice,

or any other weather conditions that would compromise operator safety.

• NEVER allow ropes, electric cords, hoses, etc. to become entangled in the

equipment when the basket is being raised or lowered.

• NEVER exceed manufacturer's load limits or use the lift as a crane for lifting

heavy materials. Make sure all tools and equipment are safely stowed.

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

heights.

• NEVER use cage to carry materials and never allow overhang of materials when

raising or lowering the basket.

• NEVER push or pull with the boom or basket and NEVER use the boom to lift

any part of the trailer.

• NEVER use the boom or basket to place a “dead man” load against any struc-

ture, materials, or equipment.

• NEVER climb up or down boom.

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

XLB-4725A

1-6

1-4 MAINTENANCE SAFETY

Ensure the following safety precautions are observed whenever maintenance is performed

on the XLB-4725A Boom Lift.

General Maintenance

• ALWAYS perform maintenance procedures according to manufacturer's re-

quirements. NEVER short change maintenance procedures.

• ALWAYS check hydraulic system. Make sure all lines, connectors, and fittings

are tight and in good condition.

• ALWAYS turn the MASTER POWER switch OFF before connecting or discon-

necting wiring to or from valve solenoids or other load devices.

• ALWAYS disconnect power to the hydraulic pump drive motor before making

electrical checks of the hydraulic valves.

• ALWAYS keep all mechanisms properly adjusted and lubricated according to

maintenance schedule and manufacturer’s specifications.

• ALWAYS perform a function check of operating controls before each use and

after repairs have been made.

• ALWAYS locate and protect against possible pinch points prior to performing

maintenance and repairs.

• ALWAYS use factory-approved parts to repair or maintain this equipment. If

this equipment is rebuilt, retesting is required in accordance with factory

instructions.

• NEVER allow water or foreign particles into the DC electric motor housing. In-

gestion of water or foreign particles may cause serious damage to the motor. If

the motor gets wet, oven dry the motor to remove all moisture before operating;

consult motor manufacturer for drying instructions.

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

the equipment.

• NEVER add unauthorized fluids to the hydraulic system or battery. Check origi-

nal manufacturer specifications.

• NEVER exceed the manufacturer's recommended relief valve settings.

• NEVER touch or allow metal tools to contact static discharge sensitive elec-

tronic components. ALWAYS use static discharge prevention mats and ground-

ing devices when handling electronic components.

• NEVER tamper with cylinder counter balance valves. Contact the Bil-Jax Ser-

vice Department at 419.445.9675 if the cylinder counter balance valves need ad-

justing.

• NEVER attempt repairs you do not understand. Consult manufacturer if you

have any questions regarding proper maintenance, specifications, or repair.

1 — SAFETY

1-7

Battery Maintenance

Ensure the following general safety precautions are followed whenever performing bat-

tery maintenance on the XLB-4725A Boom Lift.

• ALWAYS check battery acid level daily. Check battery test indicator for proper

state of charge on maintenance free batteries before using lift.

• ALWAYS wear safety glasses when working near battery.

• ALWAYS avoid contact with battery acid. Battery acid causes serious burns.

Avoid contact with skin or eyes. If accidental contact occurs, flush with water

and consult a physician immediately.

• ALWAYS disconnect ground cable first when removing battery.

• ALWAYS connect ground cable last when installing battery.

• ALWAYS charge batteries in open, well-ventilated areas.

• NEVER smoke when servicing battery.

• NEVER allow batteries to overcharge and boil.

• NEVER short across battery posts to check for current. NEVER break a live cir-

cuit at battery.

• NEVER jump start other vehicles using boom lift battery.

1-5 DAMAGED EQUIPMENT POLICY

Safety Statement

At Bil-Jax, we are dedicated to the safety of all users of our products. Therefore, all

Bil-Jax lifts are designed, manufactured and tested to comply with current applicable

Federal OSHA and ANSI codes and regulations.

Damage Policy

There may be occasions when a Bil-Jax lift is involved in an incident that results in struc-

tural damage to the lift. This can seriously compromise the ability of the lift to perform in

a safe manner. Therefore, whenever a Bil-Jax lift is damaged structurally or when there is

the possibility of structural damage (this damage may be internal and is not always visible

to the naked eye), Bil-Jax requires that the lift be returned to our facility at 125 Taylor

Parkway, Archbold, Ohio, for reconditioning. If you have any questions concerning what

constitutes structural damage, please call the Bil-Jax Service Department at

419.445.9675.

Damage Repair Notice

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

structural damage. When this occurs and repairs are made by the owner or area distribu-

tor, please notify Bil-Jax of these non-maintenance repairs and request a repair form to be

filled out and returned to Bil-Jax.

XLB-4725A

1-8

2-1

Introduction

2-1 GENERAL DESCRIPTION

The XLB-4725A Boom Lift is designed and manufactured for positioning personnel with

their tools and equipment at overhead work locations. The rated work basket load capac-

ity is 450 lbs. (The older basket model capacity is 400 lbs. Refer to figures 6-16 and

6-16A for illustrations of the basket models). Basket elevation is by two hydraulic cylin-

ders acting on upper and lower boom sections. A hydraulic powered motor and worm

gear rotates the boom 360° around a vertical axis. The hydraulic power unit includes a

reservoir, pump, and control valves.

On the battery powered (DC Model) boom lift, a 24 Volt, 39 Amp, one horsepower, DC

electric motor drives the hydraulic pump. The DC motor is powered by four 6 Volt DC,

245 Amp-hour, deep charge batteries connected in series. A 40 amp, automatic, on-board

battery charger is provided for recharging the batteries at the end of each work

period.

On the gasoline engine powered (Gas Model) boom lift, a 4-cycle, 8 horsepower, gasoline

engine drives the hydraulic pump. A 12 volt DC storage battery powers the engine starter

circuit. An auxiliary voltage regulator/rectifier provides 18 amps maximum charge current

while the engine is running.

Two control panels use directional selector switches, rheostats, and proportional hydraulic

valves to control the direction and speed of boom lift and rotation. One set of operator

controls is provided for ground operation and another set is provided for operation from

the basket. Elevation and rotation controls are operational only when the moving boom

section is within a programmed safe operating zone. Only one boom motion is permitted

at a time, and only as long as the boom is within the safe operating zone. When a selected

boom motion reaches a safe operating limit, the motion ceases and another motion must

be selected within the safe operating zone.

Outrigger and wheel position interlock safety switches prevent lifting operations until the

four outriggers are properly deployed and the full weight of the boom lift is loaded onto

the outriggers.

Boom elevation speeds are adjustable from zero to 8 inches per second (0 to 40 ft/min). A

hydraulic hose failure at either retract-cylinder port will cause a velocity fuse to close and

stop the return oil flow. It is strongly recommended that no one adjust or tamper with

these safety devices. If service is required, please notify Bil-Jax for detailed instructions.

Emergency lowering of the basket is by a manual valve plunger on the front end of the

power compartment. Firmly pulling out and holding the valve plunger manually retracts

the upper boom lift cylinder.

The XLB-4725A Boom Lift cylinders will not rust or corrode during storage since the

cylinder rod is fully immersed in oil. It is important that the cylinder rods be kept clean

and undamaged for the protection of the cylinder head packings.

XLB-4725A

2-2

2-2 SPECIFICATIONS

Boom Lift Work Platform

Model Number XLB-4725A Serial Number ________________

Manufactured by: Bil-Jax, Inc.

125 Taylor Parkway

Archbold, Ohio 43502

419.445.9675

Table 2-1. Specifications

Feature Battery Powered Model Gasoline Powered Model

Rated Platform Load 450 lbs (204.1 kg) total

[400 lbs (181.6 kg) total for early

version basket]*

450 lbs (204.1 kg) total

[400 lbs (181.6 kg) total for early

version basket]*

Maximum Work Height 47 ft (14.34 m) 47 ft (14.34 m)

Extended Basket Height 40.5 ft (12.35 m) 40.5 ft (12.35 m)

Elevation Rate,

Maximum 8 in./sec (203 mm/sec)

[40 ft/min (12.2 m/min)] 8 in./sec (203 mm/sec)

[40 ft/min (12.2 m/min)]

Horizontal Reach 25 ft (7.6 m) 25 ft (7.6 m)

Boom Rotation 360° Continuous 360° Continuous

Rotation Speed 8 in. per Second, Maximum 8 in. per Second, Maximum

Basket Dimensions 45 in. W x 30 in. D x 42 in. H

(114.3 cm x 76 cm x 107 cm) 45 in. W x 30 in. D x 42 in. H

(114.3 cm x 76 cm x 107 cm)

Power Source 24 Volt DC, Deep Cycle,

245 Amp-hour Battery 8 Horsepower Gasoline Engine

Battery Charger 110/120 Volt, 40 Amp N/A

Hydraulic Pressure 2000 psi (13,790 kPa) 2000 psi (13,790 kPa)

Reservoir Capacity 5 Gallons (18.9 Liters) 5 Gallons (18.9 Liters)

Hydraulic Capacity 7 Gallons (26.5 Liters) 7 Gallons (26.5 Liters)

Hydraulic Oil Energol HLP-HD46 (BP Oil) Energol HLP-HD46 (BP Oil)

Gross Vehicle Weight 4,950 lbs (2247.3 kg) 4,750 lbs (2156.5 kg)

Tongue Weight 350 lbs (158.8 kg) 350 lbs (158.8 kg)

Trailer Brakes Hydraulic Surge Hydraulic Surge

*Refer to figures 6-16 and 6-16A for basket views.

2-3 WARRANTY

Bil-Jax warrants its boom lifts for one year from the date of delivery against all defects of

material and workmanship, provided the unit is operated and maintained in compliance

with Bil-Jax’s operating and maintenance instructions; structural components are war-

ranted for three years. Bil-Jax will, at its option, repair or replace any unit or component

part which fails to function properly in normal use.

This warranty does not apply if the lift and/or its component parts have been altered,

changed, or repaired without the consent of Bil-Jax or by anyone other than Bil-Jax or its

factory trained personnel, nor if the lift and/or its components have been subjected to

misuse, negligence, accident or any conditions deemed other than those considered as oc-

curring during normal use.

Components not manufactured by Bil-Jax are covered by their respective manufacturer’s

warranties. A list of those components and their warranties is available upon written re-

quest to Bil-Jax.

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

tial damages to anyone, product, or thing. This warranty is in lieu of all other warranties

expressed or implied. We neither assume nor authorize any representative, or other per-

son, to assume for us any other liability in connection with the sale, rental, or use of this

product.

3-1

Operation

3-1 OPERATOR CONTROLS

The XLB-4725A Boom Lift is equipped with multiple operator controls. Electrical boom

lift and rotation control panels are located at ground level and in the basket. Manual boom

rotation and lowering controls are at the ground level.

BATTERY ON/OFF Switch

A BATTERY ON/OFF switch (Figure 3-1) is mounted on the front end of the hydraulic

power compartment. Turn the switch to the ON position to turn battery power on to the

boom lift electrical system. Turn the switch to the OFF position to conserve battery power

when the lift is not in use.

BATTERY

ON/OFF

SWITCH

Figure 3-1. Battery ON/OFF Switch

XLB-4725A

3-2

Lower Control Panel

The lower control panel (Figure 3-2) is located on the side of the hydraulic power com-

partment. The following controls and indicators are on the lower control panel.

Figure 3-2. Lower Control Panel (DC Model)

HOUR Meter

The HOUR meter displays the elapsed time that the boom lift has been in operation

(UP/DOWN or ROTATION switches engaged). Display units are in hours and tenths.

PLATFORM/OFF/GROUND Key Switch

The PLATFORM/OFF/GROUND key switch enables boom lift control from either the

lower control panel or the work platform. Removing the key disables lift operation.

EMERGENCY STOP Pushbutton

When pressed, the EMERGENCY STOP pushbutton disconnects electrical power to the

upper and lower control panels. The EMERGENCY STOP pushbutton should only be

pressed to immediately stop all boom lift motion. To resume control, rotate the pushbut-

ton clockwise to disengage the emergency stop switch contacts.

OUTRIGGERS Indicator

The OUTRIGGERS indicator lights up when the boom outriggers are properly deployed

and the boom weight is removed from the trailer axle.

3 — OPERATION

3-3

UPPER BOOM UP/DOWN Selector Switch

Holding the UPPER BOOM UP/DOWN selector switch in the UP position enables the

upper boom to rise. Holding the selector switch in the DOWN position enables the upper

boom to descend. Turning the SPEED CONTROL rheostat clockwise starts the boom

motion. The up or down boom motion continues until the rheostat is released, the selector

switch is released, or the upper boom reaches a hard stop or a safe travel limit.

ROTATION CW/CCW Selector Switch

Holding the ROTATION CW/CCW selector switch in the CW position enables the boom

to rotate in the clockwise direction. Holding the selector switch in the CCW position en-

ables the boom to rotate in the counterclockwise direction. Turning the SPEED

CONTROL rheostat clockwise starts the boom motion. Rotation continues until the rheo-

stat or the selector switch is released.

LOWER BOOM UP/DOWN Selector Switch

Holding the LOWER BOOM UP/DOWN selector switch in the UP position raises the

lower boom. Holding the selector switch in the DOWN position lowers the lower boom.

Turning the SPEED CONTROL rheostat clockwise starts the selected boom motion. The

up or down boom motion continues until the rheostat is released, the selector switch is re-

leased, or the lower boom reaches a hard stop or a safe travel limit.

SPEED CONTROL Rheostat

A BOOM UP/DOWN or ROTATION selector switch must be held in a motion-enable

position to enable the SPEED CONTROL rheostat. Turn the SPEED CONTROL rheo-

stat clockwise to start boom motion. All boom motion speeds ramp up electronically.

Turn the rheostat farther clockwise to increase the boom motion speed.

Lower Control Panel – Gas Model Only

The following engine controls are included on the lower control panel of the gas model

boom lift. These controls are not shown.

CHOKE Pushbutton

Pressing the CHOKE pushbutton engages the choke solenoid. For cold starting, press the

CHOKE pushbutton in for about 5 seconds while cranking the engine.

ENGINE START/STOP Selector Switch

Holding the START/STOP selector switch in the START position cranks the engine. The

engine should not be cranked longer than 15 seconds at a time. Over-cranking will burn

up the starter motor.

Holding the START/STOP selector switch in the STOP position stops the engine. The se-

lector switch must be held down until the engine stops running.

XLB-4725A

3-4

Upper Control Panel

The upper control panel (Figure 3-3) is mounted in the work basket. The following con-

trols and indicators are available on the upper control panel.

Figure 3-3. Upper Control Panel (DC Model)

UPPER BOOM UP/DOWN Pushbuttons

Pressing the UPPER BOOM UP pushbutton enables the upper boom to rise. Pressing the

UPPER BOOM DOWN pushbutton enables the upper boom to descend. Squeezing the

hand grip trigger starts the boom motion. The up or down boom motion continues until

the trigger is released, the pushbutton is released, or the upper boom reaches a hard stop

or a safe travel limit.

ROTATION CW/CCW Pushbuttons

Pressing the ROTATION CW pushbutton enables the boom to rotate in the clockwise di-

rection. Pressing the ROTATION CCW pushbutton enables the boom to rotate in the

counterclockwise direction. Squeezing the hand grip trigger starts the boom motion. Rota-

tion continues until the trigger is released or the pushbutton is released.

LOWER BOOM UP/DOWN Pushbuttons

Pressing the LOWER BOOM UP pushbutton enables the lower boom to rise. Pressing

the LOWER BOOM DOWN pushbutton enables the lower boom to descend. Squeezing

the hand grip trigger starts the boom motion. The up or down boom motion continues un-

til the trigger is released, the pushbutton is released, or the lower boom reaches a hard

stop or a safe travel limit.

3 — OPERATION

3-5

Hand Grip and Trigger

A BOOM UP/DOWN or ROTATION pushbutton must be depressed to enable the hand

grip trigger. Pull the trigger up slowly to start boom motion. All boom motion speeds

ramp up electronically. Pull the trigger higher to speed up the boom motion.

POWER Pushbutton

When pressed, the POWER pushbutton disconnects electrical power to the upper control

panel. The POWER pushbutton should only be pressed to immediately stop all boom lift

motion. To resume control, rotate the pushbutton clockwise to disengage the switch.

Battery Charge Indicator (DC model only)

Indicator LEDs light up to indicate the level of charge remaining in the batteries. Lighted

green LEDs indicate a good charge level. Lighted yellow LEDs indicate the need for

charging soon. Lighted red LEDs warn that the battery charge level is low; boom opera-

tions should be halted until the batteries are recharged.

EMERGENCY DOWN Pushbutton

When pressed, the EMERGENCY DOWN pushbutton opens the upper cylinder retract

solenoid valve to allow a controlled basket descent. Limited battery power is required to

open the retract cylinder solenoid valve. This method of boom lowering should only be

used when the BOOM DOWN pushbutton or trigger control fails.

Upper Control Panel – Gas Model Only

The following engine controls are included on the upper control panel of the gas model

boom lift. These controls are not shown.

CHOKE Pushbutton

Pressing the CHOKE pushbutton engages the choke solenoid. For cold starting, press the

CHOKE pushbutton down for about 5 seconds while cranking the engine.

ENGINE START Pushbutton

Pressing the ENGINE START pushbutton cranks the engine. The engine should not be

cranked longer than 15 seconds at a time. Over-cranking will burn up the starter motor.

ENGINE STOP Pushbutton

Pressing the ENGINE STOP pushbutton stops the engine. The ENGINE STOP pushbut-

ton must be held down until the engine stops running.

XLB-4725A

3-6

3-2 NORMAL OPERATING PROCEDURE

Perform the following procedures to operate the XLB-4725A Boom Lift.

1. Read and follow all safety precautions contained in Section 1 and all responsi-

bilities outlined in the ANSI A92.2 reprint contained in Section 7 of this manual.

2. Position the lift at the work area. Make sure the lift is on a firm and level surface

and that there are no potential hazards such as overhead obstructions or electri-

cally charged conductors. Do not operate the lift if such hazards exist.

3. Check the tow trailer and boom lift for damaged or worn parts. Repair or replace

parts as necessary. Do not use a damaged boom lift.

4. Lower the trailer tongue jack and unhitch the trailer from the tow vehicle. The

trailer must be unhitched before the outriggers are deployed.

5. Deploy the boom lift outriggers as follows:

a. Lift up on the locking pin and pull each outrigger away from the trailer

frame. Swing the outriggers away until the locking pins engage again.

b. Pull out the quick-adjust jack pins and lower the jack feet. With the jack feet

near the ground, reinstall the jack pins at the lowest available setting.

c. Turn the BATTERY ON/OFF switch to the ON position. Lift the bubble

level cover plate in front of the boom rotation housing (slew ring housing).

d. Jack up the outriggers to evenly raise the trailer; refer to the bubble level.

Raise the boom lift evenly until at least one trailer wheel is off the ground.

NOTE: An axle position switch will prevent boom operation if at least one wheel

is not lifted off the ground. The load of the boom lift must be placed on

the outriggers to enable power.

6. Remove the pin keeper and transport pin that secures the lower boom to the

trailer frame. Stow the transport pin in its storage tube.

7. Turn the PLATFORM/OFF/GROUND key switch to the GROUND position.

CAUTION

Do not crank the engine for more than 15 seconds at a time. Extended engine

cranking may overheat and damage the starter motor.

8. (Gas Model Only) Toggle the ENGINE START switch to start the engine. If

the engine is cold, hold the CHOKE switch down for about five seconds while

cranking. Allow the engine to idle for at least five minutes before operating the

boom lift hydraulics.

9. Use the lower control panel to operate the lift controls. Raise, lower, and rotate

the boom to get familiar with the controls. Learn to smoothly start and stop the

boom lift.

10. With the upper boom fully down, raise the lower boom to upper limit to position

the basket for boarding. Turn the key switch to the PLATFORM position.

11. Raise the safety bar and enter the basket. Put on the safety harness and attach the

lanyard to the basket railing. Operate the boom lift carefully.

3 — OPERATION

3-7

3-3 EMERGENCY LOWERING

The XLB-4725A Boom Lift is equipped with a manual emergency lowering valve that

can lower the basket in case of a power failure or an emergency situation. The emergency

lowering valve is located at the front of the hydraulic power compartment.

To lower the work basket, pull out the valve plunger knob (Figure 3-4). Continue to pull

out on the plunger to lower the basket. Only the upper boom lift cylinder will retract.

PLUNGER

Figure 3-4. Emergency Lowering Valve

3-4 MANUAL BOOM ROTATION

The boom lift is equipped with an emergency rotation handle (crank) that can be used to

rotate the boom in case of a power failure or other emergency situation.

Use the following procedure to manually rotate the boom:

1. Loosen the crank stowage tube thumbscrew (Figure 3-5).

2. Remove the crank.

3. Install the crank on the hex end of the worm gear drive screw as shown.

4. Turn the crank handle to rotate the boom.

CRANK

STOWAGE

TUBE

CRANK

IN USE

THUMBSCREW

Figure 3-5. Boom Rotation

XLB-4725A

3-8

3-5 BATTERY RECHARGE (DC MODEL ONLY)

The DC boom lift batteries should be recharged after each 8-hour work shift or more of-

ten if needed. When the boom lift is not in use, the batteries should be recharged at least

once per week.

The normal charge time is 10 to 12 hours. If the battery charge is extremely low, a full re-

charge may take up to 24 hours.

Recharge the DC boom lift batteries as follows:

WARNING

Recharge the batteries in a well ventilated area only. Do not charge batteries near

fire, flame, or other ignition sources. Batteries being charged may emit highly ex-

plosive hydrogen gas. Failure to properly ventilate the charge gases may result in

serious injury or death.

1. Move the boom lift to a well ventilated area with direct access to a grounded

120 VAC electrical outlet. Make sure the recharge area is not near fire, flame or

other ignition sources.

2. Plug a short, heavy-duty power cord into the battery charger receptacle on the

front of the battery compartment. The recommended power cord should be an

8 AWG multi-strand, grounded cord no longer than 20 feet (6 meters).

NOTE: Using an underrated or long power cord will reduce the output of the bat-

tery charger, resulting in longer charge time.

Figure 3-6. Battery Charger and Receptacle

3 — OPERATION

3-9

3. Plug the power cord into a grounded 120 VAC receptacle. Verify that the red

ON-CHARGING indicator LED lights up on the battery charger.

4. To determine the charge rate at any time during the charge cycle, observe the DC

ammeter (Figure 3-7). The ammeter needle moves to the right at the start of the

charge cycle. As the battery charge rises, the needle moves farther left.

Figure 3-7. Battery Charger

CAUTION

Always remember to unplug the battery charger power cord before moving the

boom lift. Failure to unplug the power cord will cause damage to the equipment.

5. Inspect the charge indicator LEDs near the end of the expected charge cycle. If

all indicator LEDs are off, the battery is fully charged. (The DC ammeter needle

should point to the left.)

NOTE: The yellow 80% CHARGE indicator lights up when the battery voltage is

nearing full charge. At full charge (3-1/2 hours after the 80% CHARGE

indicator lights up), the charger turns off.

If the battery voltage does not reach the 80% CHARGE level in 14 hours,

the charger turns off and the red CHECK BATTERY indicator LED

lights up. This prevents extended charging of a faulty battery.

6. Unplug the power cord from the 120 VAC receptacle and the charger receptacle.

Properly store the power cord for next use.

XLB-4725A

3-10

3-6 BOOM LIFT TRANSPORT

The boom lift trailer is a single axle trailer fitted with a two-inch ball hitch, surge brakes,

breakaway safety cable, safety chains, brake lights, and side marker lights. Proper boom

lift transport requires the correct hookup and inspection of these trailer components be-

fore towing. Use the following procedures to hitch, tow, and back the boom lift trailer:

Trailer Hitching

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

1. Back the tow vehicle to the trailer. Verify that the ball and hitch are in line and

that the trailer hitch will clear the ball. Jack up the tongue as needed.

2. Align the ball and hitch. Wrap and fasten the breakaway safety cable around the

ball hitch (Figure 3-8).

Figure 3-8. Breakaway Safety Cable

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

release lever to secure the ball.

4. Crank the jack down to check for secure coupling. If jacking will raise the tow

vehicle bumper two or three inches, the ball hitch coupling is secure.

5. Pull the pin keeper and pivot locking pin, raise the jack to the travel position as

shown in Figure 3-9, and reinstall the pivot locking pin and pin keeper.

Figure 3-9. Jack Travel Position

3 — OPERATION

3-11

CAUTION

Always cross and attach the safety chains before towing. Failure to attach safety

chains properly will allow tongue to drop in case of ball hitch failure, resulting in

serious damage to the trailer and equipment.

6. Attach the trailer safety chains to the tow vehicle. Make sure the chains cross

under the trailer tongue as shown in (Figure 3-10). If needed, cross the chains

over then under the tow bar to prevent dragging.

SAFETY

CHAINS

BREAKAWAY

SAFETY CABLE

INDICATOR BLOCK

IN BRAKE - RELEASED

POSITION

Figure 3-10. Trailer Hitching Checkpoints

7. Connect the trailer lights to the tow vehicle power plug.

8. Check the position of the breakaway safety cable indicator block. If the indicator

block is not in the brakes-released position shown in Figure 3-10, the brakes may

drag. Position the breakaway safety cable and indicator block as shown.

XLB-4725A

3-12

9. Check the position of the trailer backup lever (Figure 3-11). The lever must be in

the TOWING position (up) to enable operation of the surge brakes.

10. Before towing the trailer, check the following and make all necessary adjust-

ments, corrections, or repairs:

a. Check that trailer jack and outriggers are locked in travel positions.

b. Verify that the transport pin secures the lower boom to the trailer frame. If

the boom is not secured, install the transport pin and pin keeper at this time.

c. Verify that all onboard equipment is secured.

d. Check that the BATTERY ON/OFF switch is in the OFF position.

e. Verify that trailer brake lights and marker lights work properly.

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

g. Check that the indicator block and backup lever are in their correct

positions as shown in Figures 3–10 and 3–11.

Trailer Towing and Backing

After backing and before towing the boom lift on the open road, always check the posi-

tion of the backup lever. Make sure the backup lever is in the TOWING position (up).

See Figure 3-11.

Figure 3-11. Backup Lever Position

WARNING

Improper tightening of boom lift trailer wheel nuts can cause wheel lugs to shear,

causing serious injury or damage to equipment. Check and maintain the proper

wheel nut torque according to the maintenance instructions in this manual.

Periodically check the wheel nut torque according to the instructions in Section 4 of this

manual. More frequent torque checks are required when a wheel is recently installed.

After towing, while the trailer wheels are elevated for boom lift operation, check for loose

wheels and for wheel lug wear indications. If a loose wheel mounting is indicated, remove

and inspect the wheel lugs for damage. Do not tow the boom lift with worn or damaged

wheel lugs.

4-1

Maintenance

4-1 SCHEDULED SERVICE CHECKS

Daily/Weekly Service Checks

Perform the following daily/weekly service checks as listed in Table 4-1.

Table 4-1. Daily/Weekly Service Checks

Service Check Daily

before use Weekly

Check battery electrolyte level. If battery charge is low, add

water to bring electrolyte just above plates. If batteries are

fully charged, raise electrolyte to full mark in each cell.

Check and retighten all nuts and bolts.

Check that cage gate is secure.

Check to see that all decals are present.

Check that controls and indicators on upper and lower

control panels operate properly.

Check/add hydraulic oil.

Check/add engine oil.

Check/add transmission oil.

Check air filter for dirty or damaged elements. Clean or

replace dirty filter elements. Replace all damaged elements.

Check trailer tires for proper inflation. When cold, tires

should be inflated to 65 psi.

Check trailer running lights for proper operation.

Check trailer hitch components for damage and proper

operation. Refer to Trailer Hitching in paragraph 3-6.

Check electrical wiring for cuts, loose terminals, broken

wires, chaffing, corrosion, or other damage. Repair all

damage, remove corrosion, and seal exposed connections.

Use small diameter probe to check upper control box drain

holes for clogging. If clogged, open box and remove debris.

Lubricate grease fittings labeled LUBRICATE WEEKLY

with NLGI Grade 2 multi-purpose grease.

Check trailer and boom lift for missing or loose hardware.

Replace or tighten missing or loose hardware as needed.

XLB-4725A

4-2

Monthly Service Checks

Perform the following monthly service checks as listed in Table 4-2.

Table 4-2. Monthly Service Checks

Service Check Every

month Every

6 months Every

12 months

Clean battery terminals and check battery

charger operation.

Check operation of manual emergency lower-

ing valve.

Check wheel nut torque per paragraph 4-2.

Check for excess wear, free play, or binding in

outrigger screws. Replace damaged parts.

Lubricate power compartment hinges and

latches with light weight machine oil.

Lubricate grease fittings labeled LUBRICATE

MONTHLY per paragraph 4-3.2.

Lubricate trailer tongue jack (2 places) with

NLGI Grade 2 multi-purpose grease.

Change engine oil.

Lubricate grease fittings labeled LUBRICATE

SEMI-ANNUALLY per paragraph 4-3.3.

Lubricate wheel bearings per paragraph 4-3.4.

Check battery cables and wiring for loose

connections and damaged wires.

Clean spark plug and readjust if necessary.

Check outrigger bushings and replace if neces-

sary per paragraph 4-5.

Replace paper air filter element.

Replace hydraulic oil and oil filter.

Replace spark plug.

Check boom pivot points for bearing wear.

Replace worn or damaged bearings.

Check slew bearing for wear or damage; torque

bearing bolts to 200 lb-ft (271 N·m).

Inspect and adjust trailer brakes.

Load test boom with 450 pounds. Load early

version basket with 400 pounds. See figures

6-16 and 6-16A for basket views.

4 — MAINTENANCE

4-3

4-2 WHEEL NUT TORQUE REQUIREMENTS

It is very important to apply and maintain the correct wheel nut torque on the boom lift

trailer. The wheel nuts must be evenly tightened to the following specified torque incre-

ments whenever a trailer wheel is removed and installed. Use the following tightening

procedure:

1. Evenly tighten the wheel lug nuts to 25 lb-ft (34 N·m) in the tightening sequence

shown in Figure 4-1.

Figure 4-1. Wheel Nut Tightening Sequence

2. Evenly tighten the wheel lug nuts to 60 lb-ft (81.4 N·m) using the nut tightening

sequence shown.

3. Evenly tighten the wheel lug nuts to 100 lb-ft (135.6 N·m) using the nut tighten-

ing sequence shown.

4-3 LUBRICATION

Lubrication makes operation of the XLB-4725A Boom Lift more efficient and extends the

equipment life. Use the following procedures to lubricate the boom lift components.

1. Lubricate trailer and outrigger jack posts and all grease fittings labeled

LUBRICATE WEEKLY with NLGI Grade 2 multi-purpose grease.

2. Lubricate all LUBRICATE MONTHLY grease fittings with NLGI Grade 2

multi-purpose grease. Wipe off dirt and grease residue. Add approximately ½

ounce of fresh grease to each fitting. See Figure 4-2 for grease fitting locations.

Figure 4-2. Lubricate Monthly

XLB-4725A

4-4

3. Lubricate the slew ring bearing grease fitting labeled LUBRICATE SEMI-

ANNUALLY with NLGI Grade 2 multi-purpose grease. Wipe off dirt and

grease residue. Rotate the boom and add approximately ½ ounce of grease to

each bearing quadrant. See Figure 4-3 for the location of the slew ring bearing

grease fitting.

Figure 4-3. Lubricate Semi-Annually

4. Determine whether the boom lift is equipped with an Al-Ko axle (hex tube) or

Dexter axle (square tube). Lubricate the boom lift axle per the applicable proce-

dure in step 5 or 6.

5. Clean and repack Al-Ko axle wheel bearings according to the following general

instructions:

a. Use the outriggers to raise the trailer wheels.

b. Remove the spindle caps, cotter pins, spindle nuts, washers, outer wheel

bearings, and wheels. Remove inner wheel bearings.

c. Clean wheel bearings, bearing races, and spindle with solvent and lint-free

cleaning cloths.

d. Repack inner and outer wheel bearings with a reputable NLGI Grade 2

polyurea type, lithium-based, high-temperature, wheel bearing grease

(minimum 440°F dropping point).

e. Apply a thin film of grease to the bearing races and spindles.

f. At each wheel, install inner bearing, wheel, outer bearing, washer, and spin-

dle nut. Turn wheel and tighten spindle nut until wheel hub binds.

g. Hold the wheel stationary and loosen the spindle nut. Finger tighten the

spindle nut, then back off as needed to align the cotter pin hole. The wheel

should be free to spin without binding or excess free play.

h. Install cotter pin and spindle cap.

4 — MAINTENANCE

4-5

6. Lubricate a Dexter axle according to the following procedure:

a. Remove the rubber plug to expose the grease fitting.

b. Grease the bearings with an NLGI Grade 2 polyurea type, lithium-based,

high-temperature, wheel bearing grease (minimum 440°F dropping point).

Rotate the hub while applying grease.

c. Continue to apply fresh grease until all the old grease is purged. When new

grease starts to flow from the front bearing, remove the grease gun. Remove

the excess grease and reinstall the rubber plug.

INNER

BEARING

OUTER

BEARING

GREASE

FLOW

RUBBER

PLUG

METAL

END CAP

GREASE

FITTING

Figure 4-4. Lubrication of Dexter Axles

7. When installing the hub of a Dexter axle or if a wheel bearing adjustment is nec-

essary, use the following instructions:

a. Install the inner bearing, wheel, outer bearing, washer, and spindle nut.

While rotating the hub, tighten the spindle nut to 50 lb-ft.

b. Hold the hub stationary and loosen the spindle nut. Finger tighten the spin-

dle nut, then back off the nut to align the cotter key hole. The wheel hub

should be free to spin without binding or excess free play.

c. Install the locking tang and end cap.

d. Lubricate the bearings according to the instructions in step 6.

XLB-4725A

4-6

4-4 HYDRAULIC SYSTEM

Hydraulic system maintenance varies with equipment use and the environment in which

the boom lift is used. Constant attention to keep the oil clean and the reservoir properly

filled will help prevent possible damage to the system. Hydraulic diagrams are provided

at the end of this section for general reference.

Hydraulic System Inspection

Check the hydraulic hose and fittings for leaks and damage daily. Tighten or replace as

necessary to prevent hydraulic oil loss.

Fluid Check and Replacement

The oil level sight gage should be checked with the boom down and the trailer on a level

surface. The reservoir is originally filled with Energol HLP-HD46, a high-grade, non-

foaming hydraulic oil designed for temperatures as low as -20°F (-33°C).

Use Dextron Automatic Transmission Fluid Type A for low temperatures reaching -40°F

(-40°C). If either oil is not available, a good grade SAE 10W hydraulic oil may be used

where the low temperature is above 32°F (0°C). SAE 5W hydraulic oil may be used

where low temperatures reaching 0°F (-18°C).

Do not mix hydraulic oils. Clean the reservoir sump strainer and replace the hydraulic oil

once a year or whenever the oil becomes contaminated.

Air Bleeding

Delayed response or sporadic boom lift motions may indicate air in the lift cylinders. Use

the following procedure to bleed entrapped air from the hydraulic system.

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

reservoir fill cap.

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

3. Allow several minutes for air to escape the reservoir oil.

4. Repeat steps 1 through 3 as needed. Add oil slowly and only when the boom is

lowered to prevent adding more air to the system.

4 — MAINTENANCE

4-7

Hydraulic Cylinder Repair

Cylinder Removal and Installation

1. Lower boom onto travel supports, turn off the main power switch, and remove

the PLATFORM/OFF/GROUND key.

2. Support lift cylinder with wood shoring between cylinder and boom. Secure both

ends of lower boom lift cylinder with lifting straps and overhead lifting device.

Support upper boom lift cylinder with padded lift truck forks.

3. Place absorbent drip cloths below cylinder ports. Remove hydraulic hoses from

lift cylinder. Elevate hoses above hydraulic reservoir and protect exposed hose

fittings and cylinder ports with protective caps.

4. Refer to Figure 4-5. Remove screws (1), lock washers (2), and locking plate (3)

from elevated end of cylinder (6).

321

4321

Figure 4-5. Hydraulic Cylinder Removal

1. Screws 4. Pivot Pin

2. Lock Washers 5. Spacer

3. Locking Plate 6. Cylinder

XLB-4725A

4-8

5. Using a pry bar and shoring, unweight the cylinder end. Remove pivot pin (4)

and spacers (5).

6. Lower the free end of cylinder (6) onto support shoring or a lifting strap.

7. Repeat steps 4 through 6 at the opposite end of the cylinder.

8. Lift the lower end of the cylinder from its pivot block. Use an overhead lifting

device and lifting straps and/or a lift truck to remove the cylinder.

9. After repairing the hydraulic cylinder, reinstall the cylinder in the reverse order

of removal.

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

as needed.

11. Bleed entrapped air from the hydraulic cylinder according to instructions in

paragraph 4-4.

NOTE: Do not tamper with the cylinder counterbalance valves. If the

counterbalance valves need adjustment, contact the Bil-Jax Service

Department at 419.445.9675.

4 — MAINTENANCE

4-9

Cylinder Disassembly and Inspection

Perform the following procedure to disassemble the upper or lower hydraulic lift cylinder.

Whenever the hydraulic cylinder is disassembled, all seals must be replaced. Refer to re-

placement seal kit, Figure 6-3 or 6-4.

1. Check bearings (1, Figure 4-6) for wear and excess play. Replace bearings if

necessary.

2. Unscrew headstock (2) and slide cylinder rod (3) from housing (4).

3. Remove slotted nut (5) and piston (6). Remove and discard wear ring (7), o-rings

(8 and 9). Remove sleeve (10).

Figure 4-6. Hydraulic Cylinder Repair

1. Bearings

2. Headstock

3. Cylinder Rod

4. Housing

5. Slotted Nut

6. Piston

7. Wear Ring

8. O-Ring

9. O-Ring

10. Sleeve

11. O-Ring

12. Backup Ring

13. Seal

14. Bushing

15. Wiper

XLB-4725A

4-10

4. Remove headstock (2). Remove and discard o-ring (11), backup ring (12), and

seal (13). Remove bushing (14) and wiper (15). Discard wiper.

5. Inspect the cylinder rod (3) for scratches or pits. Pitting in the base metal is not

acceptable. Wear indications that catch the fingernail, but do not extend into the

base metal nor extend more than 1/2 inch along the rod length are acceptable if

they will not cut the seal material. The chromium plating must not be worn

through. Replace the cylinder rod if not acceptable by these inspection criteria.

6. Inspect the headstock (2). Check the inside bore for scratches; deep scratches or

cracks are unacceptable. Check the bore for polished wear surfaces. Polishing

indicates uneven loading. Check the bore for out-of-roundness. If the bore is

more than 0.007 inch out-of-round, replace the head. Seal groove damage is un-

acceptable. Replace the headstock if these conditions are not met.

7. Inspect piston (6). Check the outside surface for scratches; deep scratches are

unacceptable. Check the outside surface for polished wear surfaces. If polishing

is noticed, check the piston for out-of-roundness. If out-of roundness exceeds

0.007 inch, replace the piston. Seal groove damage is unacceptable. Replace the

piston if these conditions are not met.

8. Inspect cylinder housing (4) for scratches or pits. Pits or scratches that are deep

enough to catch the fingernail are not acceptable. Scratches that catch the finger-

nail, but extend less than 1/2 inch along the tube length, are acceptable providing

they are not sharp enough to cut the seals. Replace the cylinder tube if these

conditions are not met.

Cylinder Assembly

1. Lubricate headstock (2, Figure 4-6), wiper (15), seal (13), backup ring (12), and

o-ring (11) with hydraulic fluid.

2. Twist seal (13) into a ‘C’ shape and seat it in mating groove of headstock (2).

3. Seat wiper (15), backup ring (12), and o-ring (11) in mating groove of headstock

(2). Make sure the back-up ring is installed above the o-ring. Use brass tools or

plastic tools to avoid seal groove damage during installation. Scratching the seal

grooves may cause by-pass leakage. Allow the assembled headstock to sit one

hour for the seals to regain their original shape.

4. Lubricate piston (6) and o-rings (8 and 9) with hydraulic fluid.

5. Install wear ring (7). Allow the assembled cylinder head to sit one hour for the

seals to regain their original shape.

6. Thoroughly rinse the inside of cylinder housing (4) with a high-pressure rinse

and wipe with lint free cleaning cloths.

7. Install the headstock (2), bushing (14), stop sleeve (10), piston (6) and nut (5 )

onto the cylinder rod (3). Tighten the nut from 100 to 120 lb-ft (136 to 162

N·m).

8. Apply anti-seize to the headstock threads and installed o-ring (11).

9. Coat the cylinder rod with hydraulic fluid and insert the rod into the cylinder

housing. When inserting headstock (2) make sure that static o-ring (11) does not

extrude from the o-ring groove. Be careful not to nick the seals as they enter the

cylinder housing.

10. Screw headstock into the cylinder housing and tighten for a snug fit of the wiper

(15) on the cylinder rod (3).

11. Press in new bearings (1).

4 — MAINTENANCE

4-11

4-5 LEVELING SYSTEM

Check and Replace Outrigger Bushings

Check outrigger bushings every six months according to the following procedure:

1. Extend the outrigger (Figure 4-7). With the jack raised, draw a pencil line where

the outrigger arm lines up with the latch pin mounting plate.

2. Lower the outrigger jack to raise the trailer wheel. Mark a second line where the

outrigger arm lines up with the latch pin mounting plate.

3. Lower the trailer. Measure the distance between the two marks. If the distance

exceeds 1/16 in., replace the outrigger bushings.

MARK FIRST LINE

WITH OUTRIGGER

JACK RAISED

MARK SECOND LINE

WITH OUTRIGGER JACK LOWERED

(WHEEL RAISED)

OUTRIGGER

JACK RAISED

1/16 IN. MAX.

BETWEEN MARKS

TOP VIEW

Figure 4-7. Checking Outrigger Bushings

XLB-4725A

4-12

Perform the following procedure to replace outrigger bushings. Refer to Figure 4-8.

1. Remove three screws (5), lock washers (4), and flat washers (3).

2. Unscrew and remove fluted knob (2). Remove pin cap (1).

3. Remove nylon lock hex nut (9) and cap screw (6). Remove outrigger (8).

4. Remove and replace bushings (7).

5. Reinstall the outrigger in reverse order of removal.

345

Figure 4-8. Outrigger Bushing Replacement

1. Pin Cap 6. Cap Screw

2. Fluted Knob 7. Bushings

3. Flat Washers 8. Outrigger

4. Lock Washers 9. Nylon Lock Hex Nut

5. Screws

4 — MAINTENANCE

4-13

Adjusting Axle Position Switches

The axle position switches are set up to detect when the boom lift load is transferred from

the trailer wheels to the outriggers. After the first 100 miles of road travel the axle torque

arms wear in. Torque arm wear-in causes the wheels to ride higher in relation to the trailer

frame. Following wear-in, the axle position switches need to be readjusted. Use the fol-

lowing procedure to readjust the axle position switches:

1. Deploy the outriggers and raise the trailer wheels off the ground. The wheels

should spin freely.

2. Loosen the switch bracket, Figure 4-9.

3. Adjust the switch position to where the roller just touches the upper edge of the

torque arm. Tighten the switch bracket.

4. Repeat the adjustment procedure for the axle position switch at the opposite

wheel.

Figure 4-9. Adjusting Axle Position Switches

XLB-4725A

4-14

4-6 TROUBLESHOOTING

Table 4-3. Troubleshooting Chart

Problem Cause Correction

1. Outriggers indicator lamp

will not light up. a. Master power switch turned off.

b. Emergency stop or power button

engaged (pushed in).

c. All outriggers not deployed.

d. At least one wheel not raised.

a. Turn on master power switch.

b. Rotate emergency stop buttons clock-

wise to disengage.

c. Deploy all outriggers.

d. Raise at least one wheel off the

ground.

2. Boom UP/DOWN and

ROTATION functions do not

work.

a. Master power switch turned off.

b. Low battery power.

c. Boom lift is out of level.

d. Emergency stop or power button

engaged (pushed in).

e. Battery ground or in-series cable

loose.

f. Short circuit burned out the power

fuse.

g. Battery cable or equipment ground

lead loose or corroded.

h. System interlock fault.

i. Hydraulic pump not pumping.

a. Turn on master power switch.

b. Check battery charge LEDs on upper

control panel. Recharge batteries if

yellow or red LED is lighted.

c. Level boom lift with outrigger jacks.

d. Rotate emergency stop button clock-

wise to disengage.

e. Check for and repair loose battery

connections or ground fault.

f. Check fuse status indicator D67 in

lower control box. If LED is not on,

replace fuse with spare and retry. If

spare burns out, locate and correct

short circuit in wiring.

g. Clean and reconnect loose or corroded

battery cable or ground lead.

h. Check display for system status.

Correct indicated fault conditions.

i. Check pump motor operation; repair

or replace if not running. Check gear

pump; replace if hot to touch.

3. Single boom lift or rotation

function does not work. a. Loose wiring connector.

b. Valve solenoid failed.

c. System interlock fault.

d. Broken or loose wire.

a. Check wiring terminals in control box

and at valve manifold; repair loose

wiring terminal.

b. Swab out valve solenoids and recheck

function; replace solenoid if faulty.

c. Check display for system status.

Correct indicated fault conditions.

d. Repair or replace wire.

4. Boom lift and rotate func-

tions do not operate properly. a. Rheostat or rheostat wiring failure.

b. Valve solenoid not proportional type.

c. Loose solenoid wiring.

d. System interlock fault.

a. Check rheostat; replace rheostat or

repair wiring if loose or damaged.

b. Swab out valve solenoids and recheck

function; replace solenoid if faulty.

c. Check wiring terminals in control box

and at valve manifold; repair loose

wiring terminal.

d. Check display for system status.

Correct indicated fault conditions.

4 — MAINTENANCE

4-15

Table 4-3. Troubleshooting Chart, Continued

Problem Cause Correction

5. No operation of all functions

when the trigger or speed

control knob and a function

switch is activated.

a. Master power switch turned off.

b. Short circuit burned out the power

fuse.

c. System interlock fault.

d. Battery cable or equipment ground

lead loose or corroded.

e. Hydraulic pump not pumping.

a. Turn on master power switch.

b. Check fuse status indicator D67 in

lower control box. If LED is not on,

replace fuse with spare and retry. If

spare burns out, locate and correct

short circuit in wiring.

c. Check display for system status.

Correct indicated fault conditions.

d. Clean and reconnect loose or corroded

battery cable or ground lead.

e. Check pump motor operation; repair

or replace if not running. Check gear

pump; replace if hot to touch.

6. Boom lift and rotate func-

tions operate intermittently. a. Loose connection at trigger or speed

control knob.

b. Loose connector at valve coil.

c. System interlock fault.

a. Check display reading for status.

Reconnect wiring.

b. Check wiring connection to valve coil;

repair loose wiring.

c. Check display for system status.

Correct indicated fault conditions.

Troubleshooting Aids

A controller board with fault display LEDs and an error code display is inside the lower

control panel. When a problem arises, open the lower control panel. Turn power on and

observe the control board indicators. See Tables 4-4 and 4-5 for interpreting error codes

and LED indicators on the controller board. Table 4-7 defines the level sensor LEDs in

Figure 4-11. Hydraulic and electrical diagrams are provided in Figures 4-12 through 4-15.

Table 4-4. Error Codes

Code Error Description

EC01 Data Communications Error Communication failure during self-test.

EC02 Proportional Control Out of Range Boom lift function outside of programmed safe operating zone.

EC03 Upper Cylinder Down Output Upper cylinder down circuit wiring or valve solenoid faulty.

EC04 Upper Cylinder Up Output Upper cylinder up circuit wiring or valve solenoid faulty.

EC05 Motor/Run/Throttle Solenoid Output Engine stop or throttle control circuit wiring or control device faulty.

EC06 Tilt Alarm Output (Beeper) Alarm output circuit wiring or alarm beeper faulty.

EC08 Lower Cylinder Down Output Lower cylinder down circuit wiring or valve solenoid faulty.

EC09 Lower Cylinder Up Output Lower cylinder up circuit wiring or valve solenoid faulty.

EC10 Rotate CCW Output Rotate CCW circuit wiring or valve solenoid faulty.

EC11 Rotate CW Output Rotate CW circuit wiring or valve solenoid faulty.

EC12 Emergency Down Output Emergency down circuit wiring or valve solenoid faulty.

EC13 Choke Output Choke control circuit wiring or choke solenoid faulty.

EC14 Motor Start Output Engine start circuit wiring or control device faulty.

EC15 Primary Bucket Switch Input Primary bucket switch or switch circuit wiring faulty.

EC16 Secondary Bucket Switch Input Secondary bucket switch or switch circuit wiring faulty.

Note: The related switch must be functionally sound to produce an error code other than EC01, EC06, EC15, or EC16.

XLB-4725A

4-16

Figure 4-10. Lower Controller Board

4 — MAINTENANCE

4-17

CAUTION

Integrated circuits can be damaged by static electrical discharge. When touching

or handling circuit boards, wear an anti-static wristband grounded to a boom lift

ground lug. When replacing a circuit board, stand on a grounded anti-static floor

mat. Always seal circuit boards in static shield bags for storage and transport.

Failure to use anti-static discharge protection can cause permanent damage to in-

tegrated circuit components.

Table 4-5. LED Indicators

Indicator Function Color

D12 +5 Volt Regulated Supply Red

D16 Communications Active Green

D49 Upper Boom Down Output Red

D50 Upper Boom Up Output Red

D51 Motor Run Output Red

D52 Tilt Alarm Output Red

D53 Spare Red

D54 Lower Boom Down Output Red

D55 Lower Boom Up Output Red

D56 Rotate CCW Output Red

D57 Rotate CW Output Red

D58 Emergency Down Output Red

D59 Outrigger Light Output Red

D60 Hour Meter Output Red

D61 Proportional Flow Output Red

D62 Engine Choke Output Red

D63 Engine Start Output Red

D64 Engine Stop Output Red

D65 Accessory Power Output Red

D67 Fuse Light Red

Note: D16 should light when power is first turned on (following

the control system self-test). A lighted red LED indicates a fault.

Table 4-6. Upper Control Box Specifications

Power Supply Voltage 12V/24V nominal, 7V to 35V transient

Operating Temperature -40°C to +85°C

Storing Temperature -40°C to +100°C

Digital Inputs 12/24V DC, 60V transient

Analog Inputs 0 to 5V DC, 60V transient

XLB-4725A

4-18

YELLOW LED

OUT OF LEVEL

(MOMENTARY)

RED LED

OUTPUT SIGNAL

(ON WHEN LEVEL)

GREEN LED

INPUT POWER

Figure 4-11. Level Sensor

Table 4-7. Level Sensor LEDs

Color Description

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

Green Boom lift power is on.

Red Boom lift level. Goes out after time delay.

4 — MAINTENANCE

4-19

LOWER BOOM

LIFT CYLINDER

BOOM ROTATION

GEAR MOTOR

UPPER BOOM

LIFT CYLINDER

PROP.

VALVE

B1 A2 B2 A3 B3

HYDRAULIC MANIFOLD

FILTER

HYDRAULIC

PUMP

Figure 4-12. DC Model Hydraulic Diagram

XLB-4725A

4-20

LOWER BOOM

LIFT CYLINDER

BOOM ROTATION

GEAR MOTOR

UPPER BOOM

LIFT CYLINDER

PROP.

VALVE

B1 A3 B3

HYDRAULIC MANIFOLD

FILTER

HYDRAULIC

PUMP

A2 B2

Figure 4-13. Gas Model Hydraulic Diagram

4 — MAINTENANCE

4-21

TRIGGER

SWITCH

SPEED

CONTROL

UPPER

CYL UP

UPPER

CYL UP UPPER

CYL UP

UPPER

CYL

DOWN

UPPER

CYL DOWN

UPPER

CYL

DOWN

LOWER

CYL UP

LOWER

CYL UP LOWER

CYL UP

LOWER

CYL

DOWN

LOWER

CYL

DOWN

LOWER

CYL DOWN

ROTATE

CW ROTATE

ROTATE

CCW

ROTATE

CCW

UPPER

CONTROLS

LOWER

CONTROLS

E-STOP E-STOP

ROTATE

CCW

PRIMARY BUCKET SWITCH

SECONDARY BUCKET SWITCH

E-DOWN

(PBS) INPUT

(SBS) INPUT

OUTRIGGER

LAMP

OUTRIGGER

INPUT

LEVEL

SENSOR

INPUT

LEVEL

SENSOR

WARNING

(SBS)

(PBS)

LEVEL

SENSOR

LEVEL

SENSOR

LEVEL

SENSOR

LEVEL

SENSOR

LEVEL

SENSOR

LEVEL

SENSOR

AXLE

SWITCHES

OUTRIGGER

SWITCHES

LEVEL

SENSOR

LEVEL

SENSOR

MOTOR START

SOLENOID

PROP.

VALVE

E-DOWN

LOWER

CONTROL BOX

UPPER

CONTROL BOX

20 AMP

FUSE

–

KEY

SWITCH

MASTER

POWER

SWITCH

MOTOR

START

SOLENOID

24V

Figure 4-14. PC Logic Diagram, DC Model

XLB-4725A

4-22

TRIGGER

SWITCH

SPEED

CONTROL

UPPER

CYL UP

UPPER

CYL UP UPPER

CYL UP

UPPER

CYL

DOWN

UPPER

CYL DOWN

UPPER

CYL

DOWN

LOWER

CYL UP

LOWER

CYL UP LOWER

CYL UP

LOWER

CYL

DOWN

LOWER

CYL

DOWN

LOWER

CYL DOWN

ROTATE

CW ROTATE

ROTATE

CCW

ROTATE

CCW

CHOKE CHOKE CHOKE

START ENGINE

START

ENGINE

KILL ENGINE

KILL

ENGINE

KILL

ENGINE

KILL

UPPER

CONTROLS

LOWER

CONTROLS

E-STOP E-STOP

ROTATE

CCW

PRIMARY BUCKET SWITCH

SECONDARY BUCKET SWITCH

E-DOWN

(PBS) INPUT

(SBS) INPUT

OUTRIGGER

LAMP

OUTRIGGER

INPUT

LEVEL

SENSOR

INPUT

LEVEL

SENSOR

WARNING

(SBS)

(PBS)

LEVEL

SENSOR

LEVEL

SENSOR

LEVEL

SENSOR

LEVEL

SENSOR

LEVEL

SENSOR

LEVEL

SENSOR

AXLE

SWITCHES

OUTRIGGER SWITCHES

LEVEL

SENSOR

LEVEL

SENSOR

THROTTLE

SOLENOID

RELAY

PROP.

VALVE

E-DOWN

LOWER

CONTROL BOX

UPPER

CONTROL BOX

AMP

FUSE

AMP

FUSE

–

KEY

SWITCH

MASTER

POWER

SWITCH

ENGINE

18 AMP

CHARGING

SYSTEM THROTTLE

SOLENOID

RELAY

THROTTLE

SOLENOID

12V

ENGINE

IGNITION

MODULE

Figure 4-15. PC Logic Diagram, Gas Model

4 — MAINTENANCE

4-23

4-7 MATERIAL SAFETY DATA SHEETS

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 Flammabiltiy Limits in Air % by Volume: N/A

Extinguishing Media: Dry Chemical CarbonDioxide, Water Fog, Water

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

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

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

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

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

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

XLB-4725A

4-24

*************************************************************************************************

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

4 — MAINTENANCE

4-25

MATERIAL SAFETY DATA SHEET

1-SITE SPECIFIC INFORMATION: AW-46 HYDRAULIC OIL

2-GENERAL INFORMATION TRADE NAME: AW-46 HYDRAULIC OIL

EMERGENCY TELEPHONE NUMBERS: (517) 849-2144

CHEMICAL FAMILY: LUBRICATING OIL

CAS NUMBER: MIXTURE: ISSUE DATE 12/15/96

HAZARDOUS INGREDIENTS:

----------------------------------------------------------------------------

CONTAINS NO INGREDIENTS NOW KNOWN TO BE HAZARDOUS AS DEFINED IN OSHA 29 CFR

1910.1000 AND OSHA 29 CFR 1910.1200.

----------------------------------------------------------------------------

HEALTH HAZARD DATA THRESHHOLD LIMIT VALUE: 5mg/m3 AS OIL MIST 8 hr, TWA

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

CARCINOGENIC: NO

SYMPTOMS IF INGESTED, CONTACTED WITH SKIN, OR VAPOR INHALED: NO ADVERSE

EFFECTS EXPECTED.

EYES: FLUSH WITH WATER FOR 15 MINUTES SKIN: WASH THOROUGHLY WITH WARM

SOAPY WATER.

INGESTION: DO NOT INDUCE VOMITTING-SEEK MEDICAL ATTENTION.

MEDICAL CONDITIONS AGGRAVATED BY EXPOSURE: NONE KNOWN

AIR EXPOSURE LIMITS: P.E.L. NOT ESTABLISHED T.L.V. 5mg/m3 OSHA 29 CFR

1910.1000

HEALTH: 1 FIRE: 1 SPECIFIC: X REACTIVITY: 0

----------------------------------------------------------------------------

PHYSICAL DATA: BOILING POINT: 400+ DEG F. VAPOR PRESSURE (PSIA): N/A

SPECIFIC GRAVITY (H20=1): 0.87 SOULUBILITY IN WATER: NEGLIGIBLE

PH OF CONCENTRATE: N/A

APPEARANCE AND ODOR: PALE YELLOW, PETROLEUM ODOR

----------------------------------------------------------------------------

FIRE AND EXPLOSION HAZARD DATA FLASH POINT(METHOD USED): 425 DEG F.

FLAMMABLE LIMITS: NOT DETERMINED LEL: N/A UEL: N/A

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

UNUSUAL FIRE AND EXPLOSION HAZARDS: NONE

----------------------------------------------------------------------------

REACTIVIYY DATA STABILITY: STABLE CONDITIONS TO AVOID: AVOID EXTREMES

OF HEAT.

INCOMPATIBILITY (MATERIALS TO AVOID): STRONG OXIDIZING MATERIALS.

HAZARDOUS DECOMPOSITION PRODUCTS: INCOMPLETE COMBUSTION MAY CAUSE CARBON

OXIDES.

HAZARDOUS POLYMERIZATION: WILL NOT OCCUR.

----------------------------------------------------------------------------

SPILL OR LEAK PROCEDURES: STEPS TO BE TAKEN IN CASE MATERIAL IS RELEASED OR

SPILLED. DIKE AND ABSORB ON INERT MATERIAL. FOLLOW ALL LOCAL, STATE, AND

FEDERAL REGULATIONS FOR DISPOSAL OF COLLECTED MATERIAL.

----------------------------------------------------------------------------

XLB-4725A

4-26

PAGE 2

SPECIAL PROTECTION INFORMATION RESPIRATORY PROTECTION (SPECIFIC TYPE)

NONE REQUIRED

VENTILATION: NORMAL LOCAL EXHAUST: NORMAL

MECHANICAL EXHAUST (GENERAL) X

PROTECTIVE GLOVES: OIL IMPERVIOUS GLOVES RECOMMENDED

EYE PROTECTION: SAFETY GLASSES RECOMMENDED

OTHER PROTECTIVE EQUIPMENT: NONE REQUIRED

----------------------------------------------------------------------------

SPECIAL INSTRUCTIONS SPECIAL LABELLING INSTRUCTIONS: NOT REQUIRED

SPECIAL PACKAGING RECOMMENDATIONS: NONE

HANDLING AND STORAGE RECOMMENDATIONS: DO NOT CUT OR WELD ON EMPTY

CONTAINERS, AVOID EXTREMES OF COLD OR HEAT. STORE IN CLEAN DRY AREA.

DISCLAIMER: THE INFORMATION CONTAINED HEREIN HAS BEEN COMPILED FROM SOURCES

CONSIDERED TO BE DEPENDABLE AND IS ACCURATE TO THE BEST OF THE SELLERS

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

MERCHANTABILITY REGARDING THE ACCURACY OF SUCH DATA OR THE RESULTS TO

BE OBTAINED FROM THE USE THEREOF.

5-1

Replacement Decals

Refer to Table 5-1 and Figures 5-1 through 5-6 for descriptions and locations of decals on

the XLB-4725A Boom Lift.

Table 5-1. Replacement Decals, DC Model

Decal No. Description of Decal Qty

B06-00-0006 EMERGENCY CONTROL

VALVE 1

B06-00-0033 CAUTION: THIS UNIT SHALL

ONLY BE TOWED WHEN… 2

B06-00-0034 DANGER: …DURING

CHARGING, EXPLOSIVE

OXYHYDROGEN GAS…

B06-00-0036 LUBRICATE WEEKLY 36

B06-00-0037 LUBRICATE SEMI-ANNUALLY 1

B06-00-0041 MASTER POWER SWITCH 1

B06-00-0060 STOP…READ OPERATING… 2

B06-00-0062 THIS PLUG 115 VOLT 2

B06-00-0068 THE HYDRAULIC SYSTEM… 1

B06-00-0115 1500 WATT LOAD LIMIT 1

B06-00-0116 OPERATE WITH FULLY

CHARGED BATTERIES… 1

B06-00-0129 OIL LEVEL – TRANSPORT

POSITION 1

B06-00-0130 LUBRICATE MONTHLY 5

B06-00-0139 DANGER: BEFORE USING:

EXTEND, LOCK, STABILIZE… 5

B06-00-0145 DANGER: BOOM SAFETY

INSTRUCTIONS 2

B06-00-0146 DANGER: HIGH VOLTAGE

OPERATION – LARGE LABEL 1

B06-00-0151 DANGER: 110 VOLT 1

B06-00-0161B Bil-Jax TRANSFER 2

B06-00-0167 Caution Tape, Black and Yellow

B06-00-0173 SAFETY HARNESS LANYARD

ATTACHMENT POINT 2

Decal No. Description of Decal Qty

B06-00-0189 WARNING: LEVEL MACHINE

BEFORE USE… 1

B06-00-0192 OPERATION AND SERVICE

MANUAL INSIDE 1

B06-00-0225 WARNING: STAY CLEAR

WHILE RAISING … 1

B06-00-0243 GASOLINE FILL 1

B06-00-0261 CAUTION: ANSI DECAL 1

B06-00-0268 EMERGENCY ROTATION

HANDLE 1

B06-00-0290 ATTENTION: DC MOTOR

FAILURE WARNING 1

B06-00-0321

B06-00-0380

MAXIMUM CAPACITY 400 LBS

(early model basket)

MAXIMUM CAPACITY 450 LBS

B06-00-0328

B06-00-0328-A

XLB-4725A SPECIFICATIONS 2

B06-00-0334 DANGER: HIGH VOLTAGE

OPERATION – SMALL LABEL 1

B06-00-0335 XLB-4725A TRANSFER 2

B06-00-0371 ERROR CODES 1

B06-00-0372 UPPER CONTROLS DECALS,

DC MODEL 1

B06-00-0373 LOWER CONTROLS DECALS,

DC MODEL 1

B06-00-0374 UPPER CONTROLS DECALS,

GAS MODEL 1

B06-00-0375 LOWER CONTROLS DECALS,

GAS MODEL 1

B06-00-0376 OPERATING INSTRUCTIONS –

PROPORTIONAL CONTROLS 2

XLB-4725A

5-2

B06-00-0334

THIS PLUG 115 VOLT

RIL

B06-00-0062

B06-00-0130

LUBRICATE

MONTHLY

B06-00-0130

RIF

B06-00-0268OFA

B06-00-0268

EMERGENCY ROTATION HANDLE

COFC B06-00-0192

B06-00-0192

OPERATION AND SERVICE

MANUAL INSIDE

DANGER

FAILURE TO COMLY WITH THE FOLLOWING SAFETY INSTRUCTIONS OR ANY OTHER USE

OFTHIS EQUIPMENTWILL RESULT IN SERIOUS INJURY OR DEATH.

BEFORE USE

•Operatormust read and understand owners manual and all decals on machine before operating. It is

operators responsibility to comply with all warnings and instructions.

• Survey the job site and identify all potential hazards.

• Inspect lift for proper maintenance and any damaged or worn components. DO NOT operate until proper

maintenance has been performed and all damaged or worn parts have been replaced. See owners manual for

proper maintenance procedures.

• NEVER TAKE CHANCES—DO NOT use this lift if you are under the influence of drugs or alcohol, or if you feel

dizzy,ill, or unsteady in any way.

• OPERATE ON FIRM AND LEVEL SURFACE ONLY—if used on loose gravel or other soft surfaces, the large

square support pads should be added to the base of the outriggers. Additional base support may be

necessary on excessively soft footing.

• Extend, lock, and stabilize all four outriggers.

• Level machine before use—if buzzer sounds, lift is not level and the necessary outrigger adjustment should

be made to level machine before continuing.

• All occupants must wear full body harness and lanyard.

• Check safety devices daily before use—see owners manual for proper check procedures.

• When working on public roads, warnings and barriers must be set up in accordance with all local, state, and

federal traffic codes.

• Cordon off area around base to keep personnel and other equipment away from unit while in use.

DURING USE

• To avoid hand injuries, always keep hands inside basket area during boom movement.

• DO NOT use without all four outriggers fully extended, locked and stabilized.

• DO NOT release outriggers with boom extended or operator in basket.

• DO NOT move or reposition trailer while operator occupies basket.

• DO NOT use when exposed to high winds, rain, snow, or ice.

• DO NOT use where lift operator can come in contact with overhead obstructions such as electric wires, cables,

ropes, overhangs, etc.

• DO NOT operate without full body harness and lanyard in use by all basket occupants.

• DO NOT stand or sit on guard rails or top edge of basket.

• DO NOT lean out over top edge of basket to perform work.

• DO NOT use boxes, ladders,scaffolding, or any other

means to increase working height.

• DO NOT climb up or down boom.

• DO NOT exceed rated lift capacity.

• DO NOT allow ropes, electric cords, hoses,etc. to become

entangled in the lift while platform is being raised or lowered.

• DO NOT override, alter,or bypass safety devices.

• DO NOT use boom rotation for pushing or pulling.

• DO NOT exceed platform capacity when transferring loads to the platform while elevated.

• DO NOT use as a crane for lifting materials.

• DO NOT leave keys in machine while unattended.

• Plug charger in at the end of each day.

• When using the lift with the 110V power cord plugged into the base of the unit, care must be taken to ensure that

the cord is not damaged or entangled during rotation.

• DO NOT allow flames, sparks, or embers near batteries and DO NOT smoke near batteries. Batteries produce a

hydrogen, oxygen gas mixture which can explode.

OWNERS & OPERATORS ARE RESPONSIBLE FOR INSPECTION, MAINTENANCE, TRAINING,

AND OPERATION AS REQUIRED BYTHE OWNERS MANUAL .

IF YOU HAVE NOT BEEN PROVIDED WITH SAFETY LITERATURE,

OR FOR ANY QUESTIONS CONCERNING THE SAFE USE OFTHIS

EQUIPMENT,CALL 419/445-9675.

CFT/RFT B06-00-0145

B06-00-0145

COIA/RFT B06-00-0033

B06-00-0033

THIS UNIT SHALL ONLY BE TOWED

WHEN ALL BOOM SECTIONS ARE

FULLY DOWN AND LOCKED WITH

TRANSPORT SAFETY PINS.

CAUTION

This machine is NOT insulated. Do not use within 10 ft. of power lines

or other electrically charged sources. This machine DOES NOT provide

protection for personnel from contact with or close proximity to any live

electrical power source and by allshould be considered energized

personnel coming in contact with machine.

IT IS UNLAWFUL TO OPERATE

THIS EQUIPMENT WITHIN 10

FEET OF HIGH VOLTAGE LINES

OF 50,000 VOLTS OR LESS.

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

CFT/RFC B06-00-0146

B06-00-0146

DANGER

B06-00-0290

!! ATTENTION !!

To prevent premature motor failure, it is

imperative that the fiberglass cover be

kept in the closed position to protect

against direct contact with any foreign

particles and/or moisture. Should the

hydraulic power unit need to be cleaned,

it is very important to cover or shield the

motor. The DC motor must not come into

direct contact with foreign particles and/

or moisture. See Operator’s Manual for

details.

B06-00-0261FFU

B06-00-0261

This machine is designed and manufactured in compli-

with the ANSI A92.2 standard in force on the date of

manufacture. Dealers, owners, users, operators, lessors,

and lessees are responsible for inspection, maintenance,

training, and operation as required be A92.2 and the owners

Alterations, modifications, or changes to this machine

without the written authorization of Workforce Products,

Inc. as well as any unauthorized adjustment of values,

disabling or by-passing of safety devices or the improper

use of this machine shall exempt Workforce Products, Inc.

from any liability for any resulting injuries or damage.

CAUTION

anual.

B06-00-0243

GASOLINE FILL

DANGER

BEFORE USING: EXTEND, LOCK, STABILIZE

OUTRIGGERS; AND LEVEL MACHINE.

DANGER

CFT/RFC B06-00-0139

B06-00-0139

1. Read and follow all manuals and

decals.

2. Disconnect the boom hitch from the

towing vehicle.

3. Extend lock and base all four (4)

outriggers.

4. Level the lift using the four (4)

outriggers and by referencing the T-

level located at the front of the boom

power base. Remove as much

weight as possible from the trailer

tires.

5. Always wear safety harness and

attach lanyard when operating from

the basket.

BOOM OPERATING INSTRUCTIONS (PROPORTIONAL CONTROLS)

B06-00-0376

ITT

6. If using gas model, start engine from either

the lower or upper control box. It may be

necessary to hold the choke for a short

time when engine is cold. If using DC

model, turn master power switch to “on”.

Familiarize yourself with the operation of

the lift, using the ground controls before

operating the lift from the platform.

7. On the lower control panel, position

“control selector” switch to “upper”.

The lift is now ready to operate from the

basket.

8. Select function by pressing and holding

button. Grasp the handle and slowly

squeeze the trigger. Boom speed

increases the harder the trigger is

squeezed.

EMERGENCY CONTROL VALVE

B06-00-0006

LUBRICATE

SEMI-ANNUALLY

COIA B06-00-0037

LUBRICATE

WEEKLY

COIA B06-00-0036

B06-00-0037

B06-00-0036

SAFETY

HARNESS

LANYARD

ATTACHMENT

POINT

B06-00-0173UFC

B06-00-0173

B06-00-0151

B06-00-0151GFT/LFG

DANGER

110 VOLT

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

5 — REPLACEMENT DECALS

5-3

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

XLB-4725A

5-4

B06-00-0335

XLB-4725A

B06-00-0161B

B06-00-0371

RTT

ERROR CODE CHART

EC01 Data Communication Error

EC02 Proportional Control out of Range

EC03 Upper Cylinder Down Output

EC04 Upper Cylinder Up Output

EC05 Motor/Run/Throttle Solenoid Output

EC06 Tilt Alarm Output (Beeper)

EC08 Lower Cylinder Down Output

EC09 Lower Cylinder Up Output

EC10 Rotate CCW Output

EC11 Rotate CW Output

EC12 Emergency Down Output

EC13 Choke Output

EC14 Motor Start Output

EC15 Primary Bucket Switch Input

EC16 Secondary Bucket Switch Input

400 LBS.

MAXIMUM CAPACITY

AFL B06-00-0321

B06-00-0321

450 LBS.

MAXIMUM CAPACITY

B06-00-0380

B06-00-0374

B06-00-0372

B06-00-0373

B06-00-0375

PLATFORM GROUND

OFF

EMERGENCY STOP

OUTRIGGERS

UPPER BOOM SPEED

CONTROL

ROTATION

DOWN DOWN

UP UP

CW CCW

A Member of the plettac Group

bil

jax

PLATFORM GROUND

OFF

EMERGENCY STOP

OUTRIGGERS

UPPER BOOM LOWER BOOM

LOWER BOOM

SPEED

CONTROL

ROTATION

STOP

ENGINE

CHOKE

START

DOWN DOWN

UP UP

CW CCW

A Member of the plettac Group

bil

jax

LOWER

BOOM

UPPER

BOOM

LOWER

BOOM

DOWN

UPPER

BOOM

DOWN

CHOKE ENGINE

STOP

ENGINE

START

ROTATION

CCW

POWER

CCW

EMERGENCY

DOWN

A Member of the plettac Group

bil

jax

LOWER

BOOM

UPPER

BOOM

LOWER

BOOM

DOWN

UPPER

BOOM

DOWN

ROTATION

CCW

POWER

CCW

EMERGENCY

DOWN

A Member of the plettac Group

bil

jax

CCTT

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

5 — REPLACEMENT DECALS

5-5

XLB-4725A

0033

(Opposite Side)

0192

(Opposite Side)

0036

(Opposite Side)

0036

(4 Outriggers)

0139

(Both Sides)

0173

(Both Sides)

0139

(Both Sides)

0146

0321

0380

0145

0321

0380 0372

0374

0139

0016

0167

0328

0334

0060

0261

0145

0033

0041

0290

0328

0036

(Both Sides)

0036

(Both Sides)

0335

(Both Sides)

0036

2 Places

Both Sides

0036

Both Ends/

Both Cylinders

0036

(Both Sides)

0161B

(Both Sides)

0167

(

0115

0036

2 Places

Both Sides

(

0036

Both Ends

Both Booms

(

0373 or

0375

(

Figure 5-2. Decal Locations, Trailer and Boom

XLB-4725A

5-6

Figure 5-3. Decal Locations, Power Compartments Exterior

Figure 5-4. Decal Locations, Power Compartment Interior

6-1

Parts List

XLB-4725A

6-2

6-1 UPPER BOOM PARTS LIST

Refer to Table 6-1 for the upper boom parts list.

Figure 6-1. Upper Boom

6 — PARTS LIST

6-3

Table 6-1. Upper Boom Parts List

Item No. Part No. Description Qty

1 B14-00-0006 Boom, Upper 1

2 B29-00-0005 Plate, Lift Pin Locking 6

3 0090-0208 Washer, Lock, Split, 5/16 in. 12

4 0090-0028 Screw, Cap, 5/16-18 x 3/4 in. 16

5 B36-01-0022 Pin, Boom, Pivot 1

6 B29-00-0118 Leveling Bar Knuckle 2

7 0090-0485 Nut, Hex, 1/2-13 4

8 0090-0574 Washer, Flat, 1/2 in. 12

9 B25-00-0014 Bearing, Tie Rod End, 1/2 in. R.H. Thread 4

10 0090-0461 Screw, Cap, 1/2-13 x 2 in. 4

11 B04-06-0028 Washer, Shim 4

12 B04-07-0090 Ring, Retaining 4

13 B04-06-0001 Washer, Flat, 2 in. OD 2

14 0090-0210 Washer, Lock, Split, 3/8 in. 2

15 B04-05-0001 Screw, Cap, 3/8-16 x 1 in. 2

16 B00-00-0009 Fitting, Grease, Straight, 3/16 in. 2

17 B11-03-0028 Bar, Lower Leveling 2

18 0090-0167 Nut, Jam, 1/2-20 4

19 B11-03-0027 Bar, Upper Leveling 2

20 0090-0191 Nut, Nylon Lock, 1/2-13 4

21 B25-00-0053 Bushing, Bronze, 1-1/2 in. ID 2

22 B36-01-0005 Pin, Lift Cylinder 2

23 B30-00-0002 Spacer, Lift Pin 4

24 B02-03-0022 Cylinder, Upper Boom Lift,

3 in. Bore x 54 in. Stroke (See Figure 6-3) 1

25 0090-0185 Nut, Nylon Lock, 5/16-18 12

26 0090-0285 Pin, Roll, 3/16 x 1 in. 4

27 0090-0662 U-Bolt 4

28 B29-00-0125 Bracket, U-Bolt 2

29 B29-00-0124 Support, Upper Leveling Bar 1

30 B25-00-0023 Bearing, Bronze 2

XLB-4725A

6-4

6-2 LOWER BOOM PARTS LIST

Refer to Table 6-2 for the lower boom parts list.

8910

11 8910

16 7

8910

Figure 6-2. Lower Boom

6 — PARTS LIST

6-5

Table 6-2. Lower Boom Parts List

Item No. Part No. Description Qty

1 B14-00-0008 Boom, Lower 1

2 B25-00-0023 Bearing, Bronze, 1.75 OD x 1.5 ID 4

3 B34-00-0007 Trimlock, 1/4 in. 2 ft.

4 0090-0005 Screw, Cap, 1/4-20 x 3/4 in. 3

5 B04-07-0034 Clamp, Cable/Hose, DG 12 3

6 0090-0183 Nut, Hex, Nylon Lock, 1/4-20 5

7 B00-00-0009 Fitting, Grease, 3/16 in. Drive 4

8 B29-00-0005 Plate 6

9 0090-0208 Washer, Lock, Split, 5/16 in. 12

10 0090-0028 Screw, Cap, 5/16-18 x 3/4 in. 12

11 B30-00-0002 Spacer, Lift Cylinder Pin 4

12 B36-01-0005 Pin, Lift Cylinder 2

13 B02-03-0013 Cylinder, Lower Boom Lift,

4 in. Bore x 25 in. Stroke (See Figure 6-4) 1

14 B04-06-0001 Washer, Flat, 2 in. OD 2

15 0090-0210 Washer, Lock, Split, 3/8 in. 2

16 B04-05-0001 Screw, Cap, 3/8-16 x 1 in. 2

17 B36-01-0007 Pin, Lower Boom Pivot 1

18 0090-0392 Screw, Socket, 1/2-13 x 2-1/2 in. 2

19 B25-00-0013 Bearing, Tie Rod End, 1/2 in. L.H. Thread 2

20 B30-00-0038 Spacer, Levering Bar Stanchion 4

21 0090-0168 Nut, 1/2-20 LH 2

22 B11-03-0028 Bar, Lower Leveling 2

23 B04-07-0036 Clamp, Cable/Hose, DG 16 2

24 B34-00-0006 Trimlock, 1/8 in. 1 ft.

25 B00-00-0014 Cap, Black Plastic 2

26 B30-00-0044 Pad, Rubber, Upper Boom Support 1

XLB-4725A

6-6

6-3 UPPER CYLINDER PARTS LIST

Refer to Table 6-3 for the upper cylinder parts list.

Figure 6-3. Upper Cylinder

6 — PARTS LIST

6-7

Table 6-3. Upper Cylinder Parts List

Item No. Part No. Description Qty

1 ** Rod, Cylinder 1

2 B00-00-0061 Fitting, Grease, Straight 1

3 B02-13-0103 Bearing, Spherical 2

4 * Wiper, Rod 1

5 ** Headstock 1

6 ** Bushing, Bronze 1

7 * Seal 1

8 * Ring, Backup 1

9 * O-Ring 1

10 B00-00-0106 Fitting, Grease, 90° 1

11 ** Cylinder Housing 1

12 ** Nut, Slotted 1

13 * Ring, Wear 1

14 ** Piston 1

15 * O-Ring 1

16 * Seal 1

17 ** Sleeve, Stop 1

18 B02-03-0022 Cylinder, Upper Boom Lift,

3 in. Bore x 54 in. Stroke 1

19 B22-00-0010 Kit, Seal (Not Illustrated)

(includes items 4, 7, 8, 9, 13, 15, and 16) 1

*Part of Seal Kit, item 19.

** Not procurable; order Upper Boom Lift Cylinder, item 18.

XLB-4725A

6-8

6-4 LOWER CYLINDER PARTS LIST

Refer to Table 6-4 for lower cylinder parts list.

Figure 6-4. Lower Cylinder

6 — PARTS LIST

6-9

Table 6-4. Lower Cylinder Parts List

Item No. Part No. Description Qty

1 ** Rod, Cylinder 1

2 B00-00-0061 Fitting, Grease, Straight 2

3 B02-13-0103 Bearing, Spherical 2

4 * Wiper, Rod 1

5 ** Headstock 1

6 * Ring, Backup 1

7 * O-Ring 1

8 B02-04-0064 Valve, Counterbalance 2

9 ** Cylinder Housing 1

10 ** Nut, Slotted 1

11 * Ring, Wear 1

12 ** Piston 1

13 * O-Ring 1

14 * Seal 1

15 ** Sleeve, Stop 1

16 B02-03-0013 Cylinder, Lower Boom Lift,

4 in. Bore x 25 in. Stroke 1

17 B22-00-0011 Kit, Seal (Not Illustrated)

(includes items 4, 6, 7, and 12) 1

*Part of Seal Kit, item 17.

**Not procurable; order Lower Boom Lift Cylinder, item 16.

XLB-4725A

6-10

6-5 DC MODEL BATTERY COMPARTMENT PARTS LIST

Refer to Table 6-5 for the DC model boom lift battery compartment parts list.

14 15

22, 22A

15 3138

15 31 32

36, 36A

43 44

43 45

Figure 6-5. DC Model Battery Compartment

6 — PARTS LIST

6-11

Table 6-5. DC Model Battery Compartment Parts List

Item No. Part No. Description Qty

1 B18-00-0014 Lid, Compartment Cover 1

2 B18-00-0135 Vent Louver, 2-1/2 in. 4

3 B42-00-0006 Clip, Latch 1

4 0090-0225 Screw, Machine, #8-32 x 1/2 in. 1

5 0090-0181 Nut, Hex, Nylon Lock, #8-32 3

6 B18-00-0132 Frame, Compartment Cover 1

7 0090-0182 Nut, Hex, Nylon Lock, #10-24 15

8 B29-00-0073 Bracket, Ball Mounting 1

9 B39-00-0034 Spring, Gas 1

10 0090-0232 Screw, Machine, #10-24 x 5/8 in. 15

11 0090-0415 Washer, Flat, #10 7

12 B42-01-1002 Hinge 1

13 0090-0684 Rivet, Pop, 3/16 x 1/2 in. 3

14 0090-0183 Nut, Hex, Nylon Lock, 1/4-20 7

15 0090-0419 Washer, Flat, 1/4 in. 6

16 B04-07-0005 Rod, Threaded, Battery Retaining, 1/4 in. 1

17 B29-00-0135 Hold Down Bracket, Battery 1

18 B05-04-0001 Wrap, Spiral Black, 3/8 x 0.27 in.

19 B01-01-0028 Cable, Battery, 2 Ga. x 33 in. 1

20 B01-01-0012 Cable, Battery, 2 Ga. x 45 in. 1

21 B01-01-0014 Cable, Battery, 2 Ga. x 8 in. 3

22 B01-04-0003 Battery, 6 Volt DC, 250 Amp 4

22A B01-04-0009 Battery, Dry Cell, 6 Volt DC 4

23 0090-0188 Nut, Hex, Nylon Lock, 3/8-16 4

24 B42-00-0005 Latch, Lid 1

XLB-4725A

6-12

14 15

22, 22A

15 3138

15 31 32

36, 36A

43 44

43 45

Figure 6-5. DC Model Battery Compartment

6 — PARTS LIST

6-13

Table 6-5. DC Model Battery Compartment Parts List, Continued

Item No. Part No. Description Qty

25 0090-0814 Screw, Machine, #8-32 x 7/8 in. 2

26 B30-00-0040 Spacer 2

27 0090-0042 Screw, Cap, 3/8-16 x 1 in. 4

28 0090-0005 Screw, Cap, 1/4-20 x 3/4 in. 8

29 0090-0409 Screw, Thumb, 3/8-16 x 3/4 in. 1

30 B18-00-0026 Cover 1

31 0090-0206 Washer, Lock, Split, 1/4 in. 5

32 0090-0688 Bolt, Hex, 1/4-20 x 1 in. 1

33 B18-00-0010 Cover, Side 1

34 B05-00-0007 Tape, Foam Adhesive Back, 1/16 x 1/2 in. 32 in.

35 B18-00-0018 Plexiglass, 1/8 in. x 8 in. x 8 in. 1

36 B01-05-0006 Charger, Battery, 40 Amp, 110 Volt AC, 60 Hz 1

36A B01-05-0027 Charger, Battery, 40 Amp, 220 Volt AC, 50 Hz 1

37 B03-00-0078 Handle Assembly, Manual Rotation

(includes items 38 through 42) 1

38 B11-03-0018 Tube, Manual Boom Rotation 1

39 0090-0834 Nut, Nylon Lock, 1/4-20 1

40 0090-0011 Screw, Cap, 1/4-20 x 1-3/4 in. 1

41 B07-10-1042 Handle, Manual Boom Rotation 1

42 B46-00-0018 Grip, Rubber 1

43 0090-0344 Screw, Threadcutting, #10-24 x 1/2 in. 3

44 B04-07-0062 Clip, Gripper 1

45 B01-10-0003 Receptacle, Flush Mount 1

46 B29-00-0021 Bracket, Level Sensor Mounting 1

47 B01-10-0016 Sensor, Slope, 3°, 0.5 Second Delay 1

48 0090-0231 Screw, Machine, #10-24 x 1/2 in. 4

49 0090-0205 Washer, Lock, #10 4

XLB-4725A

6-14

6-6 GAS MODEL ENGINE COMPARTMENT PARTS LIST

Refer to Table 6-6 for the gas model boom lift engine compartment parts list.

910 11

44 60

44 59

29 36 35

46 3629

3, 3A

42 43

22 21

18 17

c Figure 6-6. Gas Model Engine Compartment

6 — PARTS LIST

6-15

Table 6-6. Gas Model Engine Compartment Parts List

Item No. Part No. Description Qty

1 B18-00-0052 Lid, Compartment Cover 1

2 B18-00-0129 Plate, Top, Engine Cover 1

3 B01-04-0004 Battery, 12 Volt 1

3A B01-04-0012 Battery, Dry Cell, 12 Volt 1

4 B01-01-0110 Cable, Battery, 2 Ga. x 45 in. 1

5 B29-00-0001 Strap, Battery Hold-Down 1

6 B04-07-0003 Rod, Threaded, Battery Hold-Down 2

7 0090-0232 Screw, Machine, #10-24 x 5/8 in. 15

8 0090-0415 Washer, Flat, #10 7

9 0090-0225 Screw, Machine, #8-32 x 1/2 in. 3

10 B42-00-0006 Clip, Latch 1

11 0090-0182 Nut, Hex, Nylon Lock, #10-24 15

12 B29-00-0073 Bracket, Ball Mounting 1

13 B39-00-0034 Spring, Gas 1

14 B18-00-0132 Frame, Compartment Cover 1

15 B42-01-1002 Hinge 1

16 0090-0684 Rivet, Pop, 3/16 x 1/2 1

17 0090-0030 Screw, Machine, 5/16-18 x 1 in. 4

18 0090-0208 Washer, Lock, 5/16 4

19 0090-0420 Washer, Flat, 5/16 4

20 0090-0043 Screw, Machine, 3/8-16 x 1-1/4 in. 4

21 0090-0210 Washer, Lock, 3/8 4

22 0090-0422 Washer, Flat, 3/8 4

23 0192-0030 Housing, Coupler 1

24 0192-0026 Coupler Body, Modified 1

25 0192-0028 Insert, Coupler 1

26 B00-00-0045 Coupler Body 1

27 B20-00-0009 Engine, Gasoline, 8 HP 1

28 0090-0183 Nut, Hex, Nylon Lock, 1/4 4

29 0090-0419 Washer, Flat, 1/4 in. 8

30 B01-01-0067 Cable, Battery, 2 Ga. x 45 in. 1

31 B07-06-5198 Plate, Engine Isolation Mount 1

32 B20-00-0007 Bushing, Isolation Mount 4

33 0090-0007 Screw, 1/4-20 x 1-1/4 2

34 B18-00-0128 Cover, Engine Panel, Rear 1

35 0090-0010 Screw, 1/4-20 x 1-1/2 3

36 0090-0206 Washer, Lock, 1/4 in. 5

XLB-4725A

6-16

910 11

44 60

44 59

29 36 35

46 3629

3, 3A

42 43

22 21

18 17

Figure 6-6. Gas Model Engine Compartment

6 — PARTS LIST

6-17

Table 6-6. Gas Model Engine Compartment Parts List, Continued

Item No. Part No. Description Qty

37 0090-0787 Washer, Fender 4

38 0090-0014 Screw, 1/4-20 x 2-1/2 4

39 B07-10-1026 Spacer, Isolation Mount Ring 4

40 B20-00-0006 Ring, Isolation Mount 4

41 B20-00-0013 Regulator/Rectifier, Voltage, 12 Volt, 18 Amp 1

42 0090-0183 Nut, Nylon Lock, 1/4 in. 6

43 0090-0028 Screw, Machine, 5/16-18 x 3/4 1

44 0090-0344 Screw, Threadcutting, #10-24 x 1/2 in. 6

45 B18-00-0127 Cover, Engine Panel, Front 1

46 0090-0005 Screw, Cap, 1/4-20 x 3/4 in. 4

47 B42-00-0005 Latch, Lid 1

48 B18-00-0054 Cover, Side 1

49 B42-00-0011 Latch, Draw, Flexible 1

50 0090-0185 Nut, Nylon Lock, 5/16-18 2

51 0090-0420 Washer, Flat, 5/16 in. 2

52 0090-0409 Screw, Thumb, 3/8-16 x 3/4 in. 1

53 B03-00-0078 Handle Assembly, Manual Rotation

(includes items 54 through 59)

54 B11-03-0018 Tube, Manual Boom Rotation 1

55 0090-0834 Nut, Nylon Lock, 1/4-20 1

56 0090-0011 Screw, Cap, 1/4-20 x 1-3/4 in. 1

57 B07-10-1042 Handle, Manual Boom Rotation 1

58 B46-00-0018 Grip, Rubber 1

59 B04-07-0062 Clip, Gripper 1

60 B01-10-0003 Receptacle, Flush Mount 1

61 B29-00-0021 Bracket, Level Sensor Mounting 1

62 B01-10-0016 Sensor, Slope, 3°, 0.5 Second Delay 1

63 0090-0231 Screw, Machine, #10-24 x 1/2 in. 4

64 0090-0205 Washer, Lock, #10 4

65 B01-10-0084 Solenoid, Choke, 12 Volt 1

66 0090-0708 Screw, Machine, #6-32 x 3/8 in. 4

67 B29-00-0095 Bracket, Solenoid 1

68 0090-0180 Nut, Nylon Lock, #6-32 4

69 B01-01-0006 Cable, Battery, 2 Ga. x 16 in. 1

70 0090-0188 Nut, Nylon Lock, 3/8-16 1

71 B18-00-0026 Cover 1

72 0090-0472 Screw, Sheet Metal, #10 x 1/2 2

XLB-4725A

6-18

6-7 DC MODEL POWER COMPARTMENT PARTS LIST

Refer to Table 6-7 for the DC model power compartment parts list.

61, 62

676

13 12 11

1415 16 17

19 20

33 34

24 25

25 45

Figure 6-7. DC Model Power Compartment

6 — PARTS LIST

6-19

Table 6-7. DC Model Power Compartment Parts List

Item No. Part No. Description Qty

1 B18-00-0013 Lid, Compartment Cover 1

2 B18-00-0135 Vent, Louver, 2-1/2 in. 2

3 0090-0232 Screw, Machine, #10-24 x 5/8 in. 15

4 0090-0684 Rivet, Pop, 3/16 x 1/2 in. 3

5 B42-01-1002 Hinge 1

6 0090-0182 Nut, Hex, Nylon Lock, #10-24 15

7 B39-00-0034 Spring, Gas 1

8 B29-00-0073 Bracket, Ball Mounting 1

9 B18-00-0132 Frame, Compartment Cover 1

10 0090-0415 Washer, Flat, #10 5

11 0090-0181 Nut, Hex, Nylon Lock, #8-32 3

12 B42-00-0006 Clip, Latch 1

13 0090-0225 Screw, Machine, #8-32 x 1/2 in. 1

14 B02-15-0216 Clamp, Hose 1

15 0090-0231 Screw, Machine, #10-24 x 1/2 in. 2

16 B01-01-0028 Cable, Battery, 2 Ga. x 33 in. 1

17 B01-09-0018 Boot, Terminal 4

18 0090-0157 Nut, Hex, #10-24 2

19 B02-15-0345 Solenoid, Motor 1

20 B02-15-0346 Wiring Assembly, 4 Pin 1

21 B01-09-0050 Wire, Butt Splice Crimp 18/22A 1

22 B01-01-0010 Cable, Battery, 2 Ga. x 13 in. 1

23 B01-01-0027 Cable, Battery, 2 Ga. x 19 in. 1

24 0090-0188 Nut, Hex, Nylon Lock, 3/8-16 2

25 0090-0419 Washer, Flat, 1/4 in. 13

26 0090-0206 Washer, Lock, Split, 1/4 in. 2

27 0090-0159 Nut, Hex, 1/4 –20 2

28 B29-00-0126 Bracket, Pump/Motor 2

29 0090-0183 Nut, Hex, Nylon Lock, 1/4-20 11

30 B02-05-0021 Pump and Motor Assembly 1

31 B01-07-0004 Motor, Pump 1

32 B02-05-0020 Pump, Gear, Fixed Displacement,

1.4 gal. per min. 1

XLB-4725A

6-20

61, 62

676

13 12 11

1415 16 17

19 20

33 34

24 25

25 45

Figure 6-7. DC Model Power Compartment

6 — PARTS LIST

6-21

Table 6-7. DC Model Power Compartment Parts List, Continued

Item No. Part No. Description Qty

33 B01-09-0001 Ring, Wire, 3/8 1

34 B05-01-0009 Wire, 16 Ga. 6 in.

35 B02-04-0066 Manifold, Proportional Valve, 24 Volt 1

36 0090-0420 Washer, Flat, 5/16 in. 2

37 0090-0926 Screw, Cap, 5/16-18 x 4-1/2 in. 2

38 0090-0185 Nut, Hex, Nylon Lock, 5/16-18 2

39 0090-0344 Screw, Thread Cutting, #10-24 x 1/2 in. 1

40 B00-00-0112 Faceplate, Master Power Switch 1

41 B01-02-0060 Switch, Master Power 1

42 B29-00-0143 Bracket, Lower Control Box 1

43 0090-0042 Screw, Cap, 3/8-16 x 1 1

44 B01-02-0066 Box, Lower Control (DC Model) 1

45 0090-0005 Screw, Cap, 1/4-20 x 3/4 in. 8

46 B01-09-0076 Insert, 8 Pin 1

47 B01-09-0075 Connector, 8 Pin 1

48 B01-09-0074 Insert, 6 Pin 1

49 B01-09-0073 Connector, 6 Pin 1

50 B01-09-0078 Insert, 12 Pin 2

51 B01-09-0077 Connector, 12 Pin, Gray 1

52 B01-09-0080 Socket, Female 26

53 B01-09-0079 Connector, 12 Pin, Black 1

54 B34-00-0006 Trimlock, 1/8 in. 37 in.

55 B18-00-0143 Cover, Side 1

56 0090-0206 Washer, Lock, Split, 1/4 in. 4

57 0090-0688 Screw, 1/4-20 x 1 in. 7

58 0090-0814 Screw, Machine, #8-32 x 7/8 in. 2

59 B42-00-0005 Latch, Lid 1

60 B03-00-0103 Assembly, Reservoir 1

61 B02-00-0025 Assembly, Filter Head 1

62 B02-00-0026 Element, Filter 1

63 B02-15-0025 Cap, Breather 1

64 B07-06-1039 Rod, Emergency Lowering Valve Actuator 1

65 B46-00-0031 Pull Knob, Valve Actuator 1

XLB-4725A

6-22

6-8 GAS MODEL POWER COMPARTMENT PARTS LIST

Refer to Table 6-8 for the gas model power compartment parts list.

Figure 6-8. Gas Model Power Compartment

6 — PARTS LIST

6-23

Table 6-8. Gas Model Power Compartment Parts List

Item No. Part No. Description Qty

1 B18-00-0013 Lid, Compartment Cover 1

2 B18-00-0135 Vent, Louver, 2-1/2 in. 2

3 0090-0232 Screw, Machine, #10-24 x 5/8 in. 15

4 0090-0684 Rivet, Pop, 3/16 x 1/2 in. 3

5 B42-01-1002 Hinge 1

6 0090-0182 Nut, Hex, Nylon Lock, #10-24 15

7 B39-00-0034 Spring, Gas 1

8 B29-00-0073 Bracket, Ball Mounting 1

9 B18-00-0132 Frame, Compartment Cover 1

10 0090-0415 Washer, Flat, #10 3

11 0090-0181 Nut, Hex, Nylon Lock, #8-32 3

12 B42-00-0006 Clip, Latch 1

13 0090-0225 Screw, Machine, #8-32 x 1/2 in. 1

14 B01-10-0167 Kit, Solenoid, Engine Throttle 1

15 B01-10-0191 Control Module, Throttle Solenoid 1

16 0090-0737 Screw, Machine, #10-24 x 1-/14 in. 2

17 B02-04-0067 Manifold, Proportional Valve, 24 Volt 1

18 B07-06-1039 Rod, Emergency Lowering Valve Actuator 1

19 B46-00-0031 Pull Knob, Valve Actuator 1

20 0090-0420 Washer, Flat, 5/16 in. 2

21 0090-0926 Screw, Cap, 5/16-18 x 4-1/2 in. 2

22 0090-0185 Nut, Hex, Nylon Lock, 5/16-18 2

23 0090-0344 Screw, Threadcutting, #10-24 x 1/2 in. 2

24 B00-00-0112 Faceplate, Master Power Switch 1

25 B01-02-0060 Switch, Master Power 1

26 B01-02-0064 Box, Lower Control (Gas Model) 1

27 0090-0419 Washer, Flat, 1/4 in. 11

28 0090-0005 Screw, Cap, 1/4-20 x 3/4 in. 12

29 B29-00-0143 Bracket, Lower Control Box 1

30 0090-0422 Washer, Flat, 3/16 in. 1

31 0090-0188 Nut, Hex, Nylon Lock, 3/8-16 1

32 0090-0183 Nut, Hex, Nylon Lock, 1/4-20 8

33 0090-0042 Screw, Cap, 3/8-16 x 1 1

XLB-4725A

6-24

Figure 6-8. Gas Model Power Compartment

6 — PARTS LIST

6-25

Table 6-8. Gas Model Power Compartment Parts List, Continued

Item No. Part No. Description Qty

34 0090-0688 Screw, 1/4-20 x 1 in. 3

35 0090-0206 Washer, Lock, Split, 1/4 in. 4

36 B34-00-0006 Trimlock, 1/8 in. 37 in.

37 B18-00-0143 Cover, Side 1

38 0090-0814 Screw, Machine, #8-32 x 7/8 in. 2

39 B42-00-0005 Latch, Lid 1

40 B03-00-0103 Assembly, Reservoir 1

41 B02-00-0025 Assembly, Filter Head 1

42 B02-00-0026 Element, Filter 1

43 B02-15-0025 Cap, Breather 1

44 B01-09-0076 Insert, 8 Pin 1

45 B01-09-0075 Connector, 8 Pin 1

46 B01-09-0074 Insert, 6 Pin 1

47 B01-09-0073 Connector, 6 Pin 1

48 B01-09-0078 Insert, 12 Pin 2

49 B01-09-0077 Connector, 12 Pin, Gray 1

50 B01-09-0080 Socket, Female 26

51 B01-09-0079 Connector, 12 Pin, Black 1

XLB-4725A

6-26

6-9 FRAME AND ROTATION UNIT LIST

Refer to Table 6-9 for the frame and rotation unit parts list.

23, 23A

Figure 6-9. Frame and Rotation Unit

6 — PARTS LIST

6-27

Table 6-9. Frame and Rotation Unit Parts List

Item No. Part No. Description Qty

1 B11-03-0036 Turntable Weldment 1

2 0090-0710 Screw, Machine, #8-32 x 2-3/4 in. 1

3 B18-00-0021 Cover, Level Housing 1

4 0090-0181 Nut, Hex, Nylon Lock, #8-32 1

5 B00-00-0001 Level, Bubble 1

6 0090-0643 Screw, Cap, 5/8-11 x 2-3/4 in. 12

7 0090-0612 Washer, Flat, 5/8 in. 30

8 B13-00-0001 Ring, Worm Gear 1

9 B02-02-0025 Fitting, 90° Elbow 2

10 B02-06-0006 Motor, Hydraulic 1

11 0090-0461 Screw, Cap, 1/2-13 x 2 in. 2

12 0090-0212 Washer, Lock, Split, 1/2 in. 2

13 B13-00-0006 Slew Ring Assembly (includes items 8 and 14) 1

14 B25-00-0031 Slew Ring 1

15 B00-00-0061 Fitting, Grease, 1/8 in. NPT Straight 1

16 B00-00-0106 Fitting, Grease, 90° 3

17 B07-04-1006 Plate, Tread 1

18 B03-00-0122 Kit, Rotary Conductor 1

19 B01-09-0032 Spade, Female, 16/14 Ga. 4

20 B00-00-0060 Support, Rotary Conductor 2

21 B01-10-0107 Conductor, Rotary 1

22 0090-0355 Screw, Set, 1/4-20 x 1/4 in. 2

23 B12-00-0088 Trailer Weldment (accommodates later model

trailer axle and jack) 1

23A B12-00-0059 Trailer Weldment (accommodates early model

trailer axle and jack) 1

24 0090-0633 Screw, Cap, 5/8-11 x 1-1/2 in. 18

25 0090-0160 Nut, Hex, 5/16-18 14

26 0090-0208 Washer, Lock, Split, 5/16 in. 14

27 0090-0420 Washer, Flat, 5/16 in. 14

28 0090-0127 Bolt, Carriage, 5/16-18 x 1 in. 14

XLB-4725A

6-28

6-10 HITCH AND JACK ASSEMBLY PARTS LIST

Refer to Table 6-10 for the hitch and jack assembly parts list.

20 21

17 18

25A

22, 22A

38 36

36 34

436

43612

10 4

44, 45

Figure 6-10. Hitch and Jack Assembly

6 — PARTS LIST

6-29

Table 6-10. Hitch and Jack Assembly Parts List

Item No. Part No. Description Qty

1 B29-00-0119 Post, Support 1

2 B30-00-0009 Pad, Rubber 1

3 0022-01-03 Brace, Guard Rail 2

4 0090-0192 Nut, Hex, Nylon Lock, 1/2-13 8

5 0090-0045 Screw, Cap, 3/8-16 x 1-1/2 in. 6

6 0090-0188 Nut, Hex, Nylon Lock, 3/8-16 6

7 0090-0344 Screw, Threadcutting, #10-24 x 1/2 in. 3

8 B40-00-0012 Chain, #3 x 10 in. 2

9 0090-0552 Ring, Key 2

10 B36-00-0033 Pin, Transport Safety 2

11 B03-00-0092 Assembly, Jack Handle, Early Version 1

12 0090-0005 Screw, Cap, 1/4-20 x 3/4 in. 2

13 0090-0206 Washer, Lock, 1/4 in. 1

14 0090-0875 Washer, Flat, 1/4 in. 1

15 B46-00-0014 Grip, Handle 1

16 B46-00-0003 Handle, Jack 1

17 B46-00-0004 Mount, Jack Handle 1

18 0090-0010 Screw, Cap, 1/4-20 x 1-1/2 in. 2

19 0090-0834 Nut, Lock, 1/4-20 2

20 B04-07-0032 Clamp, Cable/Hose, DG 6 2

21 0090-0183 Nut, Hex, Nylon Lock, 1/4-20 9

22 B01-10-0021 Marker, Side, Amber 2

22A B01-10-0066 Lens, Replacement 2

23 B23-02-0039 Weldment, Outer Jack Tube 1

24 0090-0428 Washer, Flat, 3/4 in. 1

25 B00-00-0085 Fitting, Grease, 1/4-28 1

25A B00-00-0009 Fitting, Grease, 3/16 in. Drive 1

26 B25-00-0011 Bearing, Thrust 1

27 B04-02-8006 Nut, Jack, 1-1/4 in. 1

28 B23-02-0038 Screw, Jack, 1/4 x 15 in. 1

29 B23-02-0040 Weldment, Inner Jack Tube 1

30 0090-0042 Screw, Cap, 3/8-16 x 1 in. 4

31 B03-00-0148 Caster Assembly 1

32 0090-0360 Screw, Socket, 1/4-20 x 1/2 in. 2

33 0090-0319 Pin, Roll, 1/4 x 1-1/4 in. 1

XLB-4725A

6-30

20 21

17 18

25A

22, 22A

38 36

36 34

436

43612

10 4

44, 45

Figure 6-10. Hitch and Jack Assembly

6 — PARTS LIST

6-31

Table 6-10. Hitch and Jack Assembly Parts List, Continued

Item No. Part No. Description Qty

34 0090-0080 Screw, Cap, 1/2-13 x 4-1/2 in. 2

35 0090-0081 Screw, Cap, 1/2-13 x 5 in. 1

36 0090-0574 Washer, Flat, 1/2 in. 6

37 B03-00-0017 Chain, Safety 2

38 B01-01-0121 Harness, Tail Light 1

39 B12-00-0013 Hitch, Tow 1

40 B21-00-0001 Kit, Brake Line 1

41 0090-0712 Screw, Cap, 1/2-13 x 4-3/4 in. 1

*42 B03-00-0105 Assembly, Jack

(includes items 6, 25, 30, 31 and 43 through

49)

43 B23-02-0058 Weldment, Outer Jack Tube 1

44 B23-02-0057 Assembly, Inner Jack Tube

(includes items 45 through 49) 1

45 B46-00-0028 Kit, Handle Replacement

(includes items 46 and 47) 1

46 0090-0183 Nut, Hex, Nylon Lock, 1/4-20 1

47 0090-0007 Screw, Cap, 1/4-20 x 1-1/4 in. 1

48 B04-06-0030 Washer, 2.18 in. Square 1

49 B25-00-0068 Bearing Assembly 1

*Item 42 replaces early version jack, items 6, 11, 17 through 19, and 23 through 33.

XLB-4725A

6-32

6-11 SQUARE TUBE AXLE AND WHEEL ASSEMBLY

PARTS LIST

Refer to Table 6-11 for the square tube axle and wheel assembly parts list.

15, 15A,

20 21

22 23

567

13,13A,

14,14A

Figure 6-11. Square Tube Axle and Wheel Assembly

6 — PARTS LIST

6-33

Table 6-11. Square Tube Axle and Wheel Assembly Parts List

Item No. Part No. Description Qty

1 B10-00-0041 Axle, Square Tube 1

2 0090-0938 Nut, Hex, Lock, 5/8-18 4

3 0090-0612 Washer, Flat 5/8 in. 4

4 0090-0937 Screw, Cap, 5/8-18 x 1-1/2 in. 4

5 0090-0032 Screw, Cap, 5/16-18 x 1-1/2 in. 8

6 0090-0208 Washer, Lock, 5/16 in. 8

7 0090-0420 Washer, Flat, 5/16 in. 8

8 B12-00-0082 Fender 2

9 B10-00-0052 Seal, Grease 2

10 B10-00-0053 Cone, Inner Bearing 2

11 B10-00-0055 Cup, Inner Bearing 2

12 B10-00-0049 Assembly, Wheel Hub

(includes bearings, grease seal, and studs) 2

13 B10-00-0042 Brake Assembly, Left Hand, Hydraulic 1

13A B10-00-0043 Brake Assembly, Right Hand, Hydraulic 1

*14 B10-00-0044 Brake Assembly, Right Hand, Electric

(Not Illustrated) 1

*14A B10-00-0045 Brake Assembly, Left Hand, Electric

(Not Illustrated) 1

15 B10-00-0048 Kit, Hydraulic Brake Shoe/Lining, Right Hand 1

15A B10-00-0047 Kit, Hydraulic Brake Shoe/Lining, Left Hand 1

*16 B10-00-0046 Kit, Electric Brake Shoe/Lining

(Not Illustrated) 2

17 B10-00-0056 Cup, Outer Bearing 2

18 B10-00-0054 Cone, Outer Bearing 2

19 B10-00-0059 Washer, Spindle 2

20 B10-00-0051 Washer, Tang, EZ Lube 2

21 B10-00-0060 Nut, Spindle, EZ Lube 2

22 B10-00-0057 Cap, Grease, EZ Lube 2

23 B10-00-0058 Plug, Rubber, EZ Lube Grease Cap 2

24 0090-0624 Nut, Wheel Lug, 1/2-20 12

25 B10-00-0050 Stud, Wheel, 1/2-20 12

26 0090-0182 Nut, Hex, Nylon Lock, #10-24 8

27 B07-01-1081 Bracket, Limit Switch 2

28 B01-02-0075 Switch, Limit, Axle Position 2

29 0090-0232 Screw, Machine, #10-24 x 5/8 in. 4

30 B08-02-0003 Tire, ST225/75D-15 2

31 0090-0236 Screw, Machine 4

*Optional equipment on original boom lift order only.

XLB-4725A

6-34

6-12 HEX TUBE AXLE AND WHEEL ASSEMBLY

PARTS LIST

Refer to Table 6-12 for the early version axle and wheel assembly parts list.

15 16 17

12, 12A

Figure 6-12. Hex Tube Axle and Wheel Assembly

6 — PARTS LIST

6-35

Table 6-12. Hex Tube Axle and Wheel Assembly Parts List

Item No. Part No. Description Qty

1 Not Procurable Axle, Hex Tube 1

2 0090-0192 Nut, Lock, 1/2-13 4

3 0090-0574 Washer, Flat 1/2 in. 8

4 0090-0877 Screw, Cap, 1/2-13 x 8-1/2 4

5 0090-0032 Screw, Cap, 5/16-18 x 1-1/2 in. 8

6 0090-0208 Washer, Lock, 5/16 in. 8

7 0090-0420 Washer, Flat, 5/16 in. 8

8 B12-00-0082 Fender 2

9 B32-00-0014 Seal, Grease 2

10 B25-00-0060 Assembly, Inner Bearing

11 B12-00-0071 Assembly, Wheel Hub

(Includes bearings, grease seal, and studs) 2

12 B10-00-0031 Brake Assembly, Left Hand, Hydraulic 1

12A B10-00-0030 Brake Assembly, Right Hand, Hydraulic 1

13 B10-00-0016 Brakes Pads, Set (left and right wheel) 1

14 B25-00-0061 Assembly, Outer Bearing 2

15 B10-00-0059 Washer, Spindle 2

16 0090-0880 Nut, Spindle 2

17 0090-0881 Pin, Cotter, 5/32 x 2 in. 2

18 B32-00-0013 Cap, Dust 2

19 0090-0624 Nut, Wheel Lug, 1/2-20 12

20 B04-07-0107 Stud, Wheel, 1/2-20 x 2-1/2 in. 12

21 0090-0182 Nut, Hex, Nylon Lock, #10-24 8

22 B01-09-0051 Fitting, Cable Grip, 90º, 1/2 in. 2

23 B01-03-0006 Switch Body, Limit, Axle Position 2

24 0090-0236 Screw, Machine, #10-24 x 3/4 in. 4

25 B01-03-0014 Actuator, Limit Switch 2

26 B01-03-0007 Head, Limit Switch 2

27 B08-02-0003 Tire, ST225/75D-15 2

XLB-4725A

6-36

6-13 TAIL LIGHTS AND JUNCTION BOX PARTS LIST

Refer to Table 6-13 for the tail lights and junction box parts list.

Figure 6-13. Tail Lights and Junction Box

6 — PARTS LIST

6-37

Table 6-13. Tail Lights and Junction Box Parts List

Item No. Part No. Description Qty

1 B01-10-0024 Tail Light Assembly, Left 1

2 B29-00-0037 Bracket, License Plate Mounting 1

3 B01-10-0069 Lens, Replacement 2

4 B04-07-0032 Clamp, Cable/Hose, DG 6 4

5 0090-0183 Nut, Hex, Nylon Lock, 1/4-20 4

6 0090-0182 Nut, Hex, Nylon Lock, #10-24 1

7 B01-09-0009 Fitting, Cable Grip, 3/8 in. 1

8 B01-10-0023 Tail Light Assembly, Right 1

9 B01-09-0029 Fitting, Cable Grip, 1/2 in. 3

10 B01-10-0026 Junction 1

11 B01-09-0007 Fitting, Cable Grip, 3/4 in. 1

12 0090-0236 Screw, Machine, #10-24 x 3/4 in. 1

13 B01-10-0027 Cover and Gasket, Junction Box 1

XLB-4725A

6-38

6-14 FRONT OUTRIGGERS PARTS LIST

Refer to Table 6-14 for the front outriggers parts list.

1, 2

14 13

18 30 31

22 23 24

19, 20

Figure 6-14. Front Outriggers

6 — PARTS LIST

6-39

Table 6-14. Front Outriggers Parts List

Item No. Part No. Description Qty

1 B23-01-0088 Outrigger, Front, Passenger Side 1

2 B23-01-0089 Outrigger, Front, Driver side 1

3 B06-00-0167 Caution Tape, Black and Yellow 1 Roll

4 B23-02-0048 Assembly, Outrigger Jack

(includes items 5 through 11) 1

5 B46-00-0028 Kit, Handle Replacement 1

6 0090-0183 Nut, Hex, Nylon Lock, 1/4-20 1

7 0090-0007 Screw, Cap, 1/4-20 x 1-1/4 in. 1

8 B04-06-0030 Washer, 2.18 in. Square 1

9 B25-00-0068 Bearing Kit 1

10 B36-00-0039 Pin 1

11 B23-02-0053 Drop Tube, Quick Adjust 1

12 0090-0909 Screw, Cap, 5/8-11 x 3-1/4 in. 1

13 B00-00-0009 Fitting, Grease, Straight, 3/16 in. 2

14 B23-02-0047 Weldment, Footpad 1

15 0090-0194 Nut, Hex, Nylon Lock, 5/8-11 1

16 B25-00-0052 Bushing, Bronze 2

17 0090-0889 Nut, Hex, Nylon Lock, 1-1/4-7 1

18 0090-0888 Screw, Cap, 1-1/4-7 x 16 in. 1

19 B11-03-0032 Cap, Driver Side, Outrigger Locator Pin 1

20 B11-03-0031 Cap, Passenger Side, Outrigger Locator Pin 1

21 B46-00-0024 Knob, Fluted 1

22 0090-0420 Washer, Flat, 5/16 in. 3

23 0090-0208 Washer, Lock, 5/16 in. 3

24 0090-0028 Screw, Cap, 5/16-18 x 3/4 in. 3

25 B30-00-0037 Spacer, Outrigger Locator Pin 1

26 B39-00-0028 Spring, 1.13 OD x 0.915 ID 1

27 B11-03-0030 Pin, Outrigger Locator 1

28 B01-03-0007 Head, Side Rotary, Limit Switch 1

29 B01-03-0006 Body, Limit Switch 1

30 B01-09-0051 Cable Grip, 90°, 1/2 in. 1

31 0090-0232 Screw, Machine, #10-24 x 5/8 in. 2

32 B01-03-0008 Roller Lever, Limit Switch 1

33 B00-00-0085 Fitting, Grease, Straight, 1/4-28 1

XLB-4725A

6-40

6-15 REAR OUTRIGGER PARTS LIST

Refer to Table 6-15 for the rear outrigger parts list.

1, 2

30 31

29 28

19, 20 21

22 23 24

Figure 6-15. Rear Outrigger

6 — PARTS LIST

6-41

Table 6-15. Rear Outrigger Parts List

Item No. Part No. Description Qty

1 B23-01-0090 Outrigger, Rear, Passenger Side 1

2 B23-01-0091 Outrigger, Rear, Driver side 1

3 B06-00-0167 Caution Tape, Black and Yellow 1 Roll

4 B23-02-0048 Assembly, Outrigger Jack

(includes items 5 through 11) 1

5 B46-00-0028 Kit, Handle Replacement 1

6 0090-0183 Nut, Hex, Nylon Lock, 1/4-20 1

7 0090-0007 Screw, Cap, 1/4-20 x 1-1/4 in. 1

8 B04-06-0030 Washer, 2.18 in. Square 1

9 B25-00-0068 Bearing Kit 1

10 B36-00-0039 Pin 1

11 B23-02-0053 Slide, Quick Adjust 1

12 0090-0909 Screw, Cap, 5/8-11 x 3-1/4 in. 1

13 B00-00-0009 Fitting, Grease, Straight, 3/16 in. 2

14 B23-02-0047 Weldment, Footpad 1

15 0090-0194 Nut, Hex, Nylon Lock, 5/8-11 1

16 B25-00-0052 Bushing, Bronze 2

17 0090-0889 Nut, Hex, Nylon Lock, 1-1/4-7 1

18 0090-0888 Screw, Cap, 1-1/4-7 x 16 in. 1

19 B11-03-0032 Cap, Driver Side, Outrigger Locator Pin 1

20 B11-03-0031 Cap, Passenger Side, Outrigger Locator Pin 1

21 B46-00-0024 Knob, Fluted 1

22 0090-0420 Washer, Flat, 5/16 in. 3

23 0090-0208 Washer, Lock, 5/16 in. 3

24 0090-0028 Screw, Cap, 5/16-18 x 3/4 in. 3

25 B30-00-0037 Spacer, Outrigger Locator Pin 1

26 B39-00-0028 Spring, 1.13 OD x 0.915 ID 1

27 B11-03-0030 Pin, Outrigger Locator 1

28 B01-03-0007 Head, Side Rotary, Limit Switch 1

29 B01-03-0006 Body, Limit Switch 1

30 B01-09-0029 Cable Grip, 1/2 in. 1

31 0090-0232 Screw, Machine, #10-24 x 5/8 in. 2

32 B01-03-0008 Roller Lever, Limit Switch 1

33 B00-00-0085 Fitting, Grease, Straight, 1/4-28 1

XLB-4725A

6-42

6-16 BASKET PARTS LIST

Refer to Table 6-16 for the basket parts list.

43 45

4347

3738

17, 17A

12, 13

28 48

Figure 6-16. Basket

6 — PARTS LIST

6-43

Table 6-16. Basket Parts List

Item No. Part No. Description Qty

1 0090-0344 Screw, Threadcutting, #10-24 x 1/2 in. 8

2 B17-00-0102 Guard, Hand 1

3 B01-03-0006 Switch, Limit 2

4 B01-03-0008 Roller Lever, Limit Switch 1

5 B01-03-0007 Head, Side Rotary, Limit Switch 1

6 0090-0238 Screw, Machine, #10-24 x 1 in. 4

7 B01-03-0016 Head, Roller Plunger, Limit Switch 1

8 B01-09-0029 Cable Grip, 1/2 in. 3

9 0090-0182 Nut, Hex, Nylon Lock, #10-24 10

10 B04-07-0034 Clamp, Cable/Hose, DG 12 1

11 0090-0183 Nut, Hex, Nylon Lock, 1/4-20 1

12 B01-02-0065 Control, Proportional (DC Model) 1

13 B01-02-0063 Control, Proportional (Gas Model) 1

14 0090-0232 Screw, Machine, #10-24 x 5/8 in. 6

15 0090-0415 Washer, Flat, #10 4

16 B05-01-0039 Wire, 18-5 54 ft.

17 B05-01-0038 Wire, 20-2 43 in.

17A B05-01-0038 Wire, 20-2 39 in.

18 B05-04-0001 Wrap, Black Spiral 3.5 ft.

19 B01-09-0083 Plug, Socket, 4 Terminal 1

20 B01-09-0086 Plug, Socket, 9 Terminal 1

21 B01-09-0089 Terminal, 18-14 SG 9

XLB-4725A

6-44

43 45

4347

3738

17, 17A

12, 13

28 48

Figure 6-16. Basket

6 — PARTS LIST

6-45

Table 6-16. Basket Parts List, Continued

Item No. Part No. Description Qty

22 B01-09-0088 Cable Housing, 9 Contact Plug 1

23 B01-09-0085 Cable Housing, 4 Contact Plug 1

24 B01-10-0046 Junction Box, 110 Vac Outlet 1

25 B01-10-0034 Receptacle, 120 Vac, GFI 1

26 B01-10-0035 Cover, GFI 1

27 B17-00-0103 Cage Weldment 1

28 B06-00-0167 Caution Tape, Black and Yellow 1 Roll

29 B05-00-0001 Tube, Foam, 21-1/2 in. 1

30 B00-00-0086 Casing, Wire, Slit, 5/16 in. dia. x 8.5 in. long 2

31 B01-09-0030 Wire, Tie, 7 x 3/32 in. 6

32 0090-0208 Washer, Lock, Split, 5/16 in. 4

33 B36-01-0007 Pin, Boom Pivot 1

34 B29-00-0005 Plate 2

35 0090-0028 Screw, Cap, 5/16-18 x 3/4 in. 4

36 B00-00-0009 Fitting, Grease, Straight, 3/16 in. 2

37 B04-05-0001 Screw, Cap, 3/8-16 x 1 in. 2

38 0090-0210 Washer, Lock, Split, 3/8 in. 2

39 B04-06-0001 Washer, Retaining 2

40 B34-00-0006 Trimlock, 1/8 in. 16 in.

41 B34-00-0006 Trimlock, 1/8 in. 5 in.

42 B39-00-0041 Spring, Extension 2

43 0090-0574 Washer, Flat, 1/2 in. 4

44 B25-00-0013 Bearing, Tie Rod End, 1/2 in. L.H. Thread 2

45 0090-0168 Nut, Jam, 1/2-20, L.H. Thread 2

46 B11-03-0027 Bar, Upper Leveling 2

47 0090-0461 Screw, Cap, 1/2-13 x 2 in. 2

48 B05-01-0028 Wire, 14-3, SDN 55 ft.

XLB-4725A

6-46

6-16A BASKET PARTS LIST, EARLY MODEL

Refer to Table 6-16A for the early model basket parts list.

13, 14 15

18, 18A

40 39

44 50

40 51

4045

4948

Figure 6-16A. Basket, Early Model

6 — PARTS LIST

6-47

Table 6-16A. Basket Parts List, Early Model

Item No. Part No. Description Qty

1 B44-00-0029 Platform, Basket 1

2 0090-0128 Bolt, Carriage, 5/16-18 x 1-1/4 in. 6

3 B01-03-0006 Switch, Limit 2

4 B01-03-0008 Roller Lever, Limit Switch 1

5 B01-03-0007 Head, Side Rotary, Limit Switch 1

6 0090-0238 Screw, Machine, #10-24 x 1 in. 2

7 B01-03-0016 Head, Roller Plunger, Limit Switch 1

8 0090-0702 Screw, Machine, #10-24 x 2 in. 2

9 B01-09-0029 Cable Grip, 1/2 in. 3

10 0090-0182 Nut, Hex, Nylon Lock, #10-24 10

11 B4-07-0034 Clamp, Cable/Hose, DG 12 1

12 0090-0183 Nut, Hex, Nylon Lock, 1/4-20 1

13 B01-02-0065 Control, Proportional (DC Model) 1

14 B01-02-0063 Control, Proportional (Gas Model) 1

15 0090-0232 Screw, Machine, #10-24 x 5/8 in. 6

16 0090-0415 Washer, Flat, #10 4

17 B05-01-0039 Wire, 18-5 54 ft.

18 B05-01-0038 Wire, 20-2 44 in.

18A B05-01-0038 Wire, 20-2 39 in.

19 B05-04-0001 Wrap, Black Spiral 3 ft.

20 B01-09-0083 Plug, Socket, 4 Terminal 1

21 B01-09-0086 Plug, Socket, 9 Terminal 1

22 B01-09-0089 Terminal, 18-14 SG 9

XLB-4725A

6-48

13, 14 15

18, 18A

40 39

44 50

40 51

4045

4948

Figure 6-16A. Basket, Early Model

6 — PARTS LIST

6-49

Table 6-16A. Basket Parts List, Early Model, Continued

Item No. Part No. Description Qty

23 B01-09-0088 Cable Housing, 9 Contact Plug 1

24 B01-09-0085 Cable Housing, 4 Contact Plug 1

25 B01-10-0046 Junction Box, 110 Vac Outlet 1

26 B01-10-0034 Receptacle, 120 Vac, GFI 1

27 B01-10-0035 Cover, GFI 1

28 B17-00-0093 Cage Weldment 1

29 B06-00-0167 Caution Tape, Black and Yellow 1 Roll

30 0090-0160 Nut, Hex, 5/16-18 6

31 0090-0208 Washer, Lock, Split, 5/16 in. 10

32 B05-00-0001 Tube, Foam, 14 in. 2

33 B00-00-0086 Casing, Wire, Slit, 5/16 in. dia. x 8.5 in. long 4

34 B01-09-0030 Wire, Tie, 7 x 3/32 in. 12

35 B36-01-0007 Pin, Boom Pivot 1

36 B29-00-0005 Plate 2

37 0090-0028 Screw, Cap, 5/16-18 x 3/4 in. 4

38 B00-00-0009 Fitting, Grease, Straight, 3/16 in. 2

39 0090-0153 Cotter Pin 2

40 0090-0574 Washer, Flat, 1/2 in. 6

41 B36-00-0032 Rod, Pinch Point Cover 1

42 B18-00-0113 Guard, Hand 1

43 B34-00-0006 Trimlock, 1/8 in. x 16 in. long 2

44 0089-151 Spring, Torsion 1

45 0090-0461 Screw, Cap, 1/2-13 x 2 in. 2

46 B11-03-0027 Bar, Upper Leveling 2

47 B04-06-0001 Washer, Retaining 2

48 0090-0210 Washer, Lock, Split, 3/8 in. 2

49 B04-05-0001 Screw, Cap, 3/8-16 x 1 in. 2

50 B25-00-0013 Bearing, Tie Rod End, 1/2 in. L.H. Thread 2

51 0090-0168 Nut, 1/4-20, L.H. Thread 2

52 B05-01-0028 Wire, 14-3 SDN 55 ft.

XLB-4725A

6-50

6-17 UPPER CONTROL BOX – EXTERNAL PARTS LIST

Refer to Table 6-17 for the upper control box parts list.

1, 1A 2, 2A 3

Figure 6-17. Upper Control Box (DC Model) – External

Table 6-17. Upper Control Box – External Parts List

Item No. Part No. Description Qty

1 B01-02-0065 Control Box Assembly, Upper (DC Model) 1

1A B01-02-0063 Control Box Assembly, Upper (Gas Model)

(Not Illustrated) 1

2 B06-00-0372 Decal, Upper Control Box (DC Model) 1

2A B06-00-0374 Decal, Upper Control Box (Gas Model)

(Not Illustrated) 1

*3 B01-10-0017 Gage, Battery 1

4 B01-02-0069 Switch, Pushbutton, Red 1

5 B01-10-0185 Switch, Trigger 1

6 B01-10-0186 Handle, Grip 1

**7 B01-02-0068 Switch, Pushbutton, Yellow 6

8 B01-02-0072 Switch, Emergency Stop 1

*Equipped on DC model boom lift only.

**Three additional switches included on gas model boom lift.

6 — PARTS LIST

6-51

6-18 UPPER CONTROL BOX – INTERNAL PARTS LIST

Refer to the Table 6-18 for the internal upper control box parts list.

1, 1A

8, 9

9, 10

Figure 6-18. Upper Control Box (DC Model) – Internal

Table 6-18. Upper Control Box – Internal Parts List

Item No. Part No. Description Qty

1 B01-02-0065 Control Box, Upper (DC Model) 1

1A B01-02-0063 Control Box, Upper (Gas Model)

(Not Illustrated) 1

2 B01-02-0068 Switch, Pushbutton, Yellow 6

3 B01-02-0072 Switch, Emergency Stop 1

*4 B01-10-0017 Gage, Battery 1

5 B01-02-0069 Switch, Pushbutton, Red 1

6 B01-10-0185 Switch, Trigger 1

7 B01-10-0186 Handle, Grip 1

8 B01-09-0084 Flange Receptacle, 4 Contact 1

9 B01-09-0090 Pin, 18-14 SG 9

10 B01-09-0087 Flange Receptacle, 9 Contact 1

11 B01-10-0184 Circuit Board 1

*Equipped on DC model boom lift only.

XLB-4725A

6-52

6-19 LOWER CONTROL BOX PARTS LIST

Refer to Table 6-19 for the lower control box parts list.

Figure 6-19. Lower Control Box (Gas Model)

6 — PARTS LIST

6-53

Table 6-19. Lower Control Box Parts List

Item No. Part No. Description Qty

1 B01-02-0066 Control Box, Lower (DC Model)

(Not Illustrated) 1

1A B01-02-0064 Control Box, Lower (Gas Model) 1

2 B06-00-0373 Decal, Lower Control Box (DC Model)

(Not Illustrated) 1

2A B06-00-0375 Decal, Lower Control Box (Gas Model) 1

3 B01-10-0181 Meter, Hour 1

4 B01-02-0068 Switch, Pushbutton, Yellow 1

5 B01-02-0072 Stop Switch, Emergency 1

6 B01-02-0070 Switch, Toggle 4

7 B01-10-0183 Sensor, Speed Control 1

8 B46-00-0032 Knob, Speed Control 1

9 B01-10-0182 Socket, Lamp 1

10 B01-10-0112 Lens, Green 1

11 B01-10-0042 Bulb, 12 Volt (Gas Model) 1

11A B01-10-0056 Bulb, 24 Volt (DC Model) 1

12 B01-02-0073 Switch, Key 1

13 B38-00-0010 Key 1

XLB-4725A

6-54

6-20 PROPORTIONAL VALVE ASSEMBLY PARTS LIST

Refer to Table 6-20 for the proportional valve assembly parts list.

36, 7

9, 7

8, 11,

12, 12A

6, 7

14, 15, 16

1, 1A

Figure 6-20. Proportional Valve Assembly

Table 6-20. Proportional Valve Assembly Parts List

Item No. Part No. Description Qty

1 B02-04-0066 Valve Ass’y, Proportional, 24 Volt (DC Model) 1

1A B02-04-0067 Valve Ass’y, Proportional, 12 Volt (Gas Model) 1

2 B02-02-0084 Fitting, Hex Nipple, 6 JIC, 6 ORM 6

3 B02-04-0064 Valve, Counterbalance 1

4 B02-02-0070 Fitting, 90° Elbow, 6 JIC, 6 ORM 1

5 B02-02-0195 Fitting, 90° Elbow, 6 JIC, 6 ORM LL 1

6 B02-14-0042 Valve, 4 - Way Cartridge 3

6 B01-08-0002 Coil, 12 Volt (Gas Model) 7

7 B01-08-0014 Coil, 18 Volt (DC Model) 7

8 B02-14-0045 Disc, Orifice 1

9 B02-14-0043 Valve, Emergency Lowering 1

10 B46-00-0031 Knob, Emergency Down 1

11 B02-14-0044 Proportional, Valve 1

12 B01-08-0012 Proportional, Coil, 12 Volt (Gas Model) 1

12A B01-08-0013 Proportional, Coil, 24 Volt (DC Model) 1

13 B02-14-0041 Valve, Relief, Bi-directional 1

14 B02-02-0196 Nipple, 4 ORM, 2 NPTM 1

15 B02-02-0018 Coupler, Male, 2 NPTFM 1

16 B02-14-0047 Plug, Orifice 1

6 — PARTS LIST

6-55

6-21 SURGE BRAKES PARTS LIST

Refer to Table 6-21 for the surge brakes parts list.

3, 10

Figure 6-21. Surge Brakes

Table 6-21. Surge Brakes Parts List

Item No. Part No. Description Qty

1 B12-00-0013 Surge Break Coupler Assembly 1

B21-00-0001 Brake Line Kit (includes items 3 through 9) 1

2 ** Brake Line, 3/16 x 17 in. 1

3 ** Brake Line, 3/16 x 45 in. 1

4 ** Brake Line, 3/16 x 15-3/4 ft. 1

5 ** Hose, 18-7/8 in. 2

6 ** Bracket, Hose 2

7 ** Clip, Hose 2

8 ** Tee 1

9 0090-0183 Nut, Lock, 1/4-20 1

10 B01-09-0012 Clamp, Hose, Insulated, 5/16 in. 1

11 B12-00-0033 Cap, Replacement 1

**Not procurable, order brake line kit.

XLB-4725A

6-56

6-22 DC MODEL HYDRAULIC SYSTEM PARTS LIST

Refer to Table 6-22 for the DC model boom lift hydraulic system parts list.

RESERVOIR

ASSEMBLY

FILTER

PUMP

SLEW RING

LOWER LIFT CYLINDER

UPPER LIFT CYLINDER

PUMP

PORT

CONTROL

PORT

TOP

BOTTOM

123

6, 6A, 6B

19 8

(UNDER FITTING)

23, 24

Figure 6-22. DC Model Hydraulic System

6 — PARTS LIST

6-57

Table 6-22. DC Model Hydraulic System Parts List

Item No. Part No. Description Qty

1 B03-00-0103 Reservoir Assembly 1

2 B02-15-0025 Cap, Breather 1

3 B02-02-0096 Elbow, 90°, 6 JIC-8 NPT 1

4 B02-02-0175 Adapter, 8 Bead, 12 NPT 1

5 B02-02-0029 Fitting, 90° Elbow, 6 JIC-6 NPT 1

6 B02-05-0021 Pump and Motor Assembly, Hydraulic 1

6A B01-07-0004 Motor, DC, Hydraulic Pump 1

6B B02-05-0020 Pump, Hydraulic 1

7 B02-02-0174 Elbow, 90°, 8 NPT, 8 Bead 1

8 B02-02-0195 Elbow, 90°, 6 JIC-6 ORM LL 1

9 B02-02-0070 Elbow, 90°, 6 JIC-6 ORM 1

10 B02-04-0066 Valve Manifold, Proportional, DC 1

11 B02-02-0084 Hex Nipple, Fitting, 6 JIC, 6 ORM 6

12 B02-06-0006 Motor, Hydraulic Gear 1

13 B02-02-0025 Elbow, 90°, 6 JIC-10 ORM 2

14 B02-03-0013 Cylinder, Lower Lift, 4 in. Bore x 25 in. Stroke 1

15 B02-03-0022 Cylinder, Upper Lift, 3 in. Bore x 54 in. Stroke 1

16 B02-02-0032 Elbow, 90°, 6 JIC-8 ORM 4

17 B02-04-0004 Valve, Velocity Fuse, 10 GPM 1

B02-16-0001 Hose Kit (includes items 18-22) 1

18 B02-01-0043 Hose, 6 M3K x 23.5 in., W2 6-6 FJX 3

19 B02-01-0140 Hose, 6 M3K x 20 in., W2 6-6 FJX 1

20 B05-02-0002 Hose, 8 LOLA x 4 in. 1

21 B02-01-0082 Hose, 6 M3K x 55 in., W2 6-6 FJX 2

22 B02-01-0125 Hose, 6 M3K x 204 in., W2 6-6 FJX 2

23 B02-00-0025 Assembly, Filter Head 1

24 B02-00-0026 Element, Filter 1

XLB-4725A

6-58

6-23 GAS MODEL HYDRAULIC SYSTEM PARTS LIST

Refer to Table 6-23 for the gas model boom lift hydraulic system parts list.

HYDRAULIC

RESERVOIR

FILTER

SLEW RING

LOWER LIFT CYLINDER

UPPER LIFT CYLINDER

PUMP

PORT

CONTROL

PORT

TOP

BOTTOM

123

25 13

21 20

(UNDER FITTING)

PUMP

28, 29

Figure 6-23. Gas Model Hydraulic System

6 — PARTS LIST

6-59

Table 6-23. Gas Model Hydraulic System Parts List

Item No. Part No. Description Qty

1 B03-00-0103 Reservoir Assembly 1

2 B02-15-0025 Cap, Breather 1

3 B02-02-0065 Tee, 8 NPT-8 NPTFM-8 NPTFM 1

4 B02-02-0035 Adapter, 6 JIC-8 NPTM 1

5 B02-02-0062 Elbow, 90°, 8 NPT 90 1

6 B02-04-0061 Valve, Pressure Relief 1

7 B02-02-0096 Elbow, 90°, 6 JIC-8 NPT 1

8 B02-02-0180 Elbow, 90°, 8 JIC-8 NPT 1

9 B02-05-0015 Pump, Hydraulic, 0.15 cu. in./rev. 1

10 B02-02-0188 Elbow, 90°, 10 JIC-6 NPT 1

11 B02-02-0187 Elbow, 90°, 10 JIC-12 NPT 1

12 B02-02-0157 Elbow, 90°, 8 JIC-6 NPT 1

13 B02-02-0195 Elbow, 90°, 6 JIC-6 ORM LL 1

14 B02-04-0067 Valve Manifold, Proportional (Gas Model) 1

15 B02-02-0070 Fitting, 90° Elbow, 6 JIC-6 ORM 1

16 B02-02-0084 Hex Nipple, Fitting, 6 JIC, 6 ORM 6

17 B02-06-0006 Motor, Hydraulic Gear 1

18 B02-02-0025 Fitting, 90° Elbow, 6 JIC-10 ORM 2

19 B02-03-0013 Cylinder, Lower Lift, 4 in. Bore x 25 in. Stroke 1

20 B02-02-0032 Fitting, 90° Elbow, 6 JIC-8 ORM 4

21 B02-03-0022 Cylinder, Upper Lift, 3 in. Bore x 54 in. Stroke 1

22 B02-04-0004 Valve, Velocity Fuse, 10 GPM 1

B02-16-0002 Hose Kit (includes items 23-27) 1

23 B02-01-0125 Hose, 6M3K x 204 in. w/2ea.

6-6FJX fittings 2

24 B02-01-0082 Hose, 6M3K x 55 in. w/2ea. 6-6FJX fittings 2

25 B02-01-0043 Hose, 6M3K x 23.5 in. w/2ea.

6-6FJX fittings 4

26 B02-01-0134 Hose, 10M3K x 26 in. w/2ea.

10-10FJX fittings 1

27 B02-01-0129 Hose, 8M3K x 27 in. w/2ea. 8-8FJX fittings 1

28 B02-00-0025 Assembly, Filter Head 1

29 B02-00-0026 Element, Filter 1

XLB-4725A

6-60

7-1

ANSI Reprint

The following sections are reprinted from the ANSI A92.2-1990 code in effect at the

time of manufacture. Permission to reprint has been granted by the Scaffold

Industry Association.

7. Responsibilities of Dealers and Installers

7.1 General Responsibilities. Each dealer or installer as applicable shall comply with

the requirements of this section.

7.2 Vehicle Specifications. Each dealer or installer, or both, who sells an aerial device

shall inform the owner or user, or both, of the manufacturer's minimum vehicle

specifications.

7.3 Vehicle Weight Distribution. The installer shall be responsible for the weight dis-

tribution of the completed mobile unit in accordance with the requirements of the

aerial device and the applicable regulations. Allowance shall be made for the

weight of readily removable tools and materials specified by the user.

7.4 Manuals. Upon delivery of the equipment to the owner or user, the dealer or in-

staller shall provide the manuals as required by Paragraph 6.4 of this standard and

manuals for its auxiliary equipment added by the installer.

7.5 Installations. The installer shall comply with Sections 5 and 6 of this standard re-

lating to proper installation and shall follow the instructions of the manufacturer. In

the event the original manufacturer no longer exists, an equivalent entity may pro-

vide these instructions.

The installer of an aerial device shall, before the mobile unit is placed in operation,

perform stability tests in accordance with the requirements of 4.5.1 and 4.5.2, the

operational and visual tests in accordance with the requirements of 6.6.1 and 6.6.2,

and the appropriate electrical tests required in 5.4.3 of this standard. The installer

shall comply with all requirements of the applicable Federal Motor Vehicle Safety

Standards in effect at the time of installation. Certification as a manufacturer (al-

teration, intermediate or final) of a motor vehicle under the Federal Motor Vehicle

Safety Standards is required. The travel height of the mobile unit shall be posted in

a location that is readily visible to the vehicle operator.

For insulated aerial devices, the installer shall assure conformance to the Qualifica-

tion test requirements of 5.3.2 by either obtaining certification of the test and per-

forming a periodic test after installation, or by performing the Qualification test.

7.6 Quality Assurance. The installer shall have a quality assurance program which

will ensure compliance with this standard.

7.7 Welding. All welds made by the installer, whose failure could result in motion of

the platform(s) shall meet the Structural Welding Code ANSI/AWS D1.1-90 and

ANSI/AWS D1.2-90. The installer shall establish applicable welding quality assur-

ance procedures for all weldments.

7.8 Training. The dealer or installer shall offer operator training initially in the opera-

tion of the aerial device(s) to the purchaser.

XLB-4725A

7-2

8. Responsibilities of the Owners and Users

8.1 General Responsibilities. Each owner or user shall comply with the requirements

of this section.

The following responsibilities pertain to owner and user inspection, testing, mainte-

nance and modification. These activities shall be performed by qualified person(s).

8.2 Inspection and Testing Classifications.

8.2.1 Initial Inspection and Test. Prior to initial use, all new or modified mobile

units shall be inspected and tested to ensure compliance with the provisions of this

standard. Verification by the manufacturer, the installer or an equivalent entity(s),

meets this requirement.

8.2.2 Regular Inspection and Tests. The inspection procedure for mobile units is

divided into two classifications based upon the intervals at which inspections and

test shall be performed. Safe intervals shall be set by the user based on the recom-

mendations that shall be supplied by the manufacturer.

Such intervals are dependent upon component function and exposure to wear, dete-

rioration and other agents which adversely affect component life. Two classifica-

tions are designated:

(1) Frequent Inspection and Test: Daily to monthly intervals

(2) Periodic Inspection and Test: One to twelve month intervals

8.2.3 Frequent Inspection and Test. Items determined by the user based on rec-

ommendations by the manufacturer for each specific aerial device shall be inspected

for defects.

Inspection and tests referred to as critical in the manufacturer's manual shall be

strictly adhered to.

The following tests and inspections shall be performed by the operator once daily,

prior to first use:

(1) Operating controls and associated mechanisms for conditions interfering with

proper operation

(2) Visual and audible safety devices for malfunction

(3) Hydraulic or pneumatic systems for observable deterioration or excessive leak-

age

(4) Fiberglass and other insulating components of visible damage or contamination

(5) Missing illegible operational markings

(6) Electrical apparatus for malfunction, signs or excessive deterioration, dirt, and

moisture accumulation

Any suspected items shall be carefully examined and a determination made by a

qualified person as to whether they constitute a safety hazard. All unsafe items shall

be replace or repaired before use.

8.2.4 Periodic Inspection and Test. An inspection of the mobile unit shall be per-

formed at the intervals defined in 8.2.2 depending upon its activity, severity of ser-

vice, and environment, or as specifically indicated below. (These inspections shall

include the requirements of 8.2.3).

(1) Structural members for deformation, cracks or corrosion

(2) Parts, such as pins, bearings, shafts, gears, rollers, locking devices, chains,

chain sprockets, wire ropes, and sheaves for wear, cracks or distortion

(3) Hydraulic and pneumatic relief valve settings

(4) Hydraulic system for proper oil level

(5) Hydraulic and pneumatic fittings, hoses, and tubing for evidence of leakage,

abnormal deformation, or excessive abrasion

(6) Compressors, pumps, motors and generators for loose fasteners, leaks, unusual

noises or vibrations, loss of operating speed, and excessive heating

7 — ANSI REPRINT

7-3

(7) Hydraulic and pneumatic valves for malfunction and visible cracks in the exter-

nal valve housing, leaks, and sticking spools

(8) Hydraulic and pneumatic cylinders and holding valves for malfunction and

visible damage

(9) Hydraulic and pneumatic filters for cleanliness and the presence of foreign ma-

terial in the system indicating other component deterioration

(10) Electrical systems and components for deterioration or wear including those not

readily visible on frequent inspection

(11) Performance test of all boom movements

(12) Condition and tightness of bolts and other fasteners

(13) Welds, as specified by the manufacturer

(14) Legible and proper markings of controls, ratings, and instructions

(15) If the aerial device is rated and used as an insulated device, the electrical insu-

lating components and system(s), after a thorough inspection for lack of cleanliness

and other hazards, shall be tested for compliance with the rating of the aerial device

in accordance with one of the applicable methods and procedures as outlined in sec-

tion 5.4.3 of this standard.

(a) If the aerial device is used for A.C. bare-hand work, the unit shall undergo a 60

hertz test as shown in Table 2 at least every three years.

(b) If the aerial device is used for D.C. bare-hand work, the unit shall undergo a

D.C. test as shown in Table 2 at least every three years.

tem(s), or the repair or replacement of an insulating component(s), the unit shall be

dielectrically tested in accordance with section5.4.3.

(d) An insulated replacement boom shall be tested to insure conformance to 5.3.3

by the supplier.

(e) Bare-hand work units shall be tested as shown in Table 1 after any major repair

to the insulated boom or any insulated boom replacement.

Any suspected items shall be carefully examined and a determination made by a

qualified person as to whether they constitute a safety hazard. All unsafe items shall

be replaced or repaired before use.

8.3 Inspection and Test Records.

(1) Items to be inspected shall be designated to the operator or other authorized

person making frequent inspections. Records of frequent inspections need not be

made. However, where a safety hazard is found, it shall be reported in writing to a

person responsible for the corrective action and that report and a record of the cor-

rection shall be maintained for five years, or as required by applicable regulations.

(2) Written, dated and signed reports and records shall be made of periodic inspec-

tions and tests and retained for a period of five years or as required by applicable

regulations.

8.4 Maintenance. Maintenance and frequency of maintenance shall be determined by

the user based on the recommendation of the manufacturer.

Maintenance referred to as critical in the manufacturer's manual shall be strictly ad-

hered to.

Welding repairs or components or welds, designated as critical in the manufacturer's

manual, shall be made in accordance with the manufacturer's recommendations.

Should the original manufacturer no longer exist an equivalent entity may determine

the required procedure.

XLB-4725A

7-4

8.5 Modifications. No modifications or additions which affect the stability, mechani-

cal, hydraulic, or electrical integrity or the safe operation of the aerial device shall

be made without the written approval of the manufacturer. If such modifications or

changes are made, the capacity, operation, and maintenance instruction markings

shall be changed accordingly. In no case shall the safety factors be reduced below

those specified in this standard or below the manufacturer's design safety factors,

whichever are greater.

Should the original manufacturer no longer exist, an equivalent entity may approve

required modification.

8.6 Weight Distribution. Changes in loading or additions made to the mobile unit af-

ter the final acceptance that affect weight distribution shall meet applicable regula-

tions by governmental agencies. In no case shall axle loads of the fully loaded vehi-

cle exceed the Gross Axle Weight Ratings (G.A.W.R.) assigned by the manufac-

turer.

8.7 Transfer of Ownership. When a change in ownership of an aerial device occurs, it

shall be the responsibility of the seller to provide the manufacturer's manual(s) for

that aerial device to the purchaser. It is the responsibility of the purchaser to notify

the manufacturer of the unit model and serial number and the name and address of

the new owner within 60 days.

8.8 Markings. The markings on the aerial device shall not be removed, defaced, or al-

tered. All missing or illegible markings shall be promptly replaced.

8.9 Parts. When parts or components are replaced they shall be identical in specifica-

tion and function to the original aerial device parts or components.

8.10 Safety Bulletins. Owner and user shall comply with safety related bulletins as re-

ceived from the manufacturer, dealer or installer.

8.11 Manuals. The owner and user shall insure that the operating manuals(s) is stored

on the mobile unit.

8.12 Training of Operators. Each trainee shall be instructed in the safe and proper op-

eration of the aerial device utilizing the manufacturer's operator's manual, the user's

work instructions, and the appropriate standards referenced in Section 2.

Such training shall include "hands-on" use to successfully demonstrate the trainee's

proficiency to the satisfaction of the qualified person designated to administrate the

user's training program.

8.13 Operation.

8.13.1 Personnel. Only trained and authorized personnel shall be permitted to op-

erate the aerial device.

8.13.2 Application. The employer and assigned operator shall insure that the ae-

rial device is used only for intended applications as defined in the operating manual,

and that recognized safety practices are observed.

8.13.3 Mobile Operation. Before and during driving, the driver shall:

(1) Avoid traveling on any surface that adversely effects vehicle stability

(2) Maintain a safe distance from obstacles

(3) Maintain communications between the driver and the operator

(4) Under all travel conditions, the driver shall limit travel speed in accordance

with conditions of the ground surface, congestion, and slope

8.13.4 Alterations. Altering or disabling safety devices, guards, or interlocks if so

equipped, shall be prohibited.

8.13.5 Bare-Hand Work. For bare-hand work, a Category A aerial device shall be

used.

8.13.6 Lower Controls. On aerial devices having both upper and lower controls,

the lower controls shall not be used for continuous operation of the aerial device

with individual(s) in the platform.

7 — ANSI REPRINT

7-5

9. Responsibilities of Renters or Lessors

9.1 General Responsibilities. Each renter or lessor shall comply with the requirements

of this section.

9.2 Ownership Duties. The renter or lessor shall carry out the duties of ownership

specified in this standard which are not assumed by the renting entity of lessee as the

user.

9.3 Obligations. Each renter or lessor of an aerial device shall provide a copy of user

responsibilities within this standard.

9.4 Training. The renter or lessor shall offer operator training initially to the renting

entity or lessee.

9.5 Communications. In the event the manufacturer or installer provides the renter or

lessor manuals, bulletins, or other materials for the information of the user of an ae-

rial device, the renter or lessor shall pass them on to the user without any undue de-

lay.

10. Responsibilities of Operators.

10.1 General Responsibilities. Each operator shall comply with the requirements of this

section.

10.2 Operation. During operation of the aerial device the operator shall wear a body

belt or harness and be connected to the aerial device with a lanyard at the platform

position.

10.3 Work Platform. The operator shall not use railings, planks, ladders or any other

device in or on the work platform for achieving additional working height or reach.

10.4 Brakes. The vehicle parking brake(s) shall be set at all times that the boom is ele-

vated except when the aerial device is being used in accordance with 8.13.3.

10.5 Loading. Any loading which includes a horizontal load shall be avoided unless the

mobile unit is designed for that application.

10.6 Observations. Observations during operation for any defects shall be conducted on

an ongoing basis.

10.7 Worksite. Before the aerial device is used, the worksite shall be surveyed for haz-

ards such as:

(1) Untamped earth fills

(2) Ditches

(3) Dropoffs and floor obstructions

(4) Debris

(5) Overhead obstructions and electrical conductors

(6) Weather conditions

(7) Presence of unauthorized persons

10.8 Precautions. Before and during each use the operator shall:

(1) Check for overhead obstructions and electrical conductors

(2) Insure that the load on the platform and/or load lifting devices are in accor-

dance with the manufacturer's rated capacity

(3) Insure that outriggers and stabilizers are used if the manufacturer's instructions

require their use

(4) Insure that guardrails are properly installed, and the gates are closed

(5) Use outrigger pads when necessary to provide firm footing

10.9 Mobile Operation. Before engaging in mobile operation the operator shall deter-

mine that the aerial device is specifically designed for mobile operation.

XLB-4725A

7-6

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

• Do not allow machine, personnel, or conductive materials inside prohibited zone.

• Maintain M.S.A.D. from all energized lines and parts as well as those shown.

• Assume all electrical parts and wires are energized unless known otherwise.

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

all work positions.

DENOTES PROHIBITED ZONE

7 — ANSI REPRINT

7-7

Table 7-1. Minimum Safe Approach Distance (M.S.A.D.) to energized

(exposed or insulated) power lines and parts.

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

XLB-4725A

7-8

125 Taylor Parkway

Archbold, OH 43502

Phone (419) 445-9675

(800) 527-5333

Fax (419) 445-0367

Bil Jax Wheelchair Xlb 4725A Users Manual

Bil-Jax Personal Lift AERIAL WORK PLATFORMS Hydraulic Boom Lift B33-01-0072_XLB-4725A

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