Bil-Jax 45XA Operator'S Manual Download | Manualshive

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4

TROUBLESHOOTING

The following section contains information for solving basic diagnostic
issues associated with the machine. If any issue or malfunction is
encountered during the correct and proper operation of the aerial work
platform that is not covered by the troubleshooting steps covered in this
manual, contact your regional BilJax representative or the BilJax Service
Department.



All maintenance and repairs should be performed by qualified
personnel in accordance with manufacturer specifications and
government regulations.



Follow recommended maintenance safety guidelines when
performing maintenance on the machine.

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Summary of Contents for 45XA

Page 1: ...OPERATOR S MANUAL 45XA AERIAL WORK PLATFORMS BOOMTM ...

Page 2: ...mended that only trained and authorized personnel attempt to operate and maintain the boom lift This manual shall be considered a permanent and necessary component of the machine and shall be kept with the boom lift at all times Owners and Lessors should complete a full inspection of all components and perform a test of all functions including brake functions before commissioning or reselling the ...

Page 3: ...s 12 Workplace Inspection 13 3 Operation 15 Ground Control Station 16 Platform Control Station 18 Platform Controls Joystick 20 Operation Set Up 21 Operation Ground Controls 22 Operation Platform Controls 23 Operation Drive Functions 23 Manual Boom Operation 24 Battery Recharge 26 Boom Lift Transport 27 4 Troubleshooting 29 Troubleshooting 30 Error Code Definitions 31 5 Replacement Decals 35 6 Spe...

Page 4: ...Operation 24 Figure 3 8 Manual Lowering Valve 25 Figure 3 9 Battery Charger Faceplate 26 Figure 3 10 Boom Lift and Transport Instructions 27 Figure 5 1 Decal Placements 37 Figure 5 2 Decal Placements CE 39 Figure 6 1 Range of Motion 43 Figure 7 1 Material Lifting Hook Configuration 46 Figure 7 2 Material Lifting Hook Installation 46 Figure 7 3 Manual Platform Rotator 47 LIST OF TABLES Table 1 1 Mi...

Page 5: ...or to Operation Read understand and obey all instructions and safety precautions in this manual and attached to the lift Read understand and obey all applicable government regulations Become familiar with the proper use of all controls Inexperienced users should receive instruction before attempting to operate or maintain the machine The use of intelligence and common sense is the best practice wh...

Page 6: ... improper service damage to equipment personal injury or death DANGER Warns of operation near electrical power sources that could lead to personal injury or death WARNING Describes conditions or practices that could lead to personal injury or death CAUTION Contains information important in the prevention of errors that could damage machine or components NOTE Contains additional information importa...

Page 7: ...ris or other foreign material ALWAYS remove any such material from the equipment before operation ALWAYS tag any part of the equipment known or suspected to be damaged or malfunctioning ALWAYS remove a malfunctioning damaged or defective machine from service NEVER operate a machine that has any known or suspected defect Table 1 1 Minimum Safe Approach Distances Minimum Safe Approach Distance Volta...

Page 8: ...y weather conditions that would compromise operator safety NEVER operate boom lift in conditions where wind speeds exceed 12 5 m sec 45 km h or 28 mph High winds may affect stability and boom operation NEVER allow ropes electric cords hoses or other equipment to become entangled in the machine while raising or lowering platform NEVER exceed the load limits set by the manufacturer Use only the Mate...

Page 9: ...cian for proper drying instructions NEVER add unauthorized fluids to the hydraulic system or battery NEVER mix hydraulic oils Consult manufacturer specifications Refer to Section 4 for hydraulic system maintenance procedures NEVER exceed the manufacturer s recommended relief valve settings NEVER touch or allow metal tools to contact any components that are sensitive to static discharge ALWAYS use ...

Page 10: ...BILJAX 45XA 8 NEVER jumpstart other vehicles using the boom lift batteries ...

Page 11: ...never a BilJax lift is damaged structurally or when there is suspected internal damage to the structure BilJax may require that the lift be returned to our facility for reconditioning For any questions concerning structural damage or the Damaged Equipment Policy please contact an authorized BilJax representative or your regional BilJax dealer Damage Repair Notice There may be occasions when a BilJ...

Page 12: ...nspection of the aerial work platform by performing all daily service checks as explained in this manual as well as all weekly and or monthly service checks if applicable Inspect the work area A comprehensive schedule of service checks and maintenance can be found in the Parts and Service Manual Annual service checks and structural inspections should be performed only by personnel trained and cert...

Page 13: ...rrectly Down limit switches are actuated when the boom is in a fully lowered stowed position Limit switches must be operational to raise or lower outriggers If outrigger controls are unresponsive when boom is fully lowered and stowed inspect down limit switches for loose mounting or visible damage Repair or replace as needed Verify that outrigger safety interlocks operate correctly Begin with the ...

Page 14: ...s are fully retracted and stowed Pour slowly to avoid creating air pockets in the reservoir Do not fill above sight gauge Overfilling the hydraulic reservoir may cause damage to hydraulic lines and may result in equipment malfunction CAUTION Do not mix hydraulic oils Do not add any fluid to the hydraulic system that is not expressly recommended by the manufacturer Adding unauthorized fluids to the...

Page 15: ...stem components including pump and motor and cylinders for damage leaks loss of pressure or speed and unusual noise or vibration Repair or replace as necessary Perform the following service checks at least once each month in addition to all recommended daily service checks Clean all battery terminals Check battery for loose connections or damaged wires Verify proper operation of manual lowering va...

Page 16: ... Sloped surfaces outside the capabilities of the boom lift Unstable or slippery surfaces Surfaces that will not support the load forces imposed by the machine or outriggers Overhead obstructions and high voltage conductors Sinkholes and untamped earth fills Personnel Unsafe weather conditions Other vehicles and equipment Other unsafe conditions ...

Page 17: ...2 BEFORE OPERATION 15 ...

Page 18: ...m as required by government regulations Obtain read and obey all safety precautions as indicated by manufacturer s recommendations and all federal state and local regulations Become familiar with the location and use of all controls Verify that there are no overhead obstructions or live power sources in the work area that could interfere with the safe operation of the boom lift Position the boom l...

Page 19: ... Ground Controls Position 1b Platform Controls Position 2 Battery Condition Indicator 3 Engine Start 4 Engine Choke 5 Display Panel 6 Emergency Stop 7 Boom Extend 8 Boom Retract 9 Lower Boom Raise 10 Lower Boom Down 11 Upper Boom Raise 12 Upper Boom Down 13 Jib Raise 14 Jib Down 15 Speed Buttons 16 Platform Tilt Up 17 Platform Tilt Down 18 Boom Rotation Clockwise 19 Boom Rotation Counterclockwise ...

Page 20: ...n and the BOOM RETRACT button at the same time retracts the boom Boom motion continues until the buttons are released or until the boom reaches a hard stop or a safe travel limit 9 14 Boom Raise Down Buttons Pressing and holding a desired SPEED button and the UPPER LOWER JIB BOOM RAISE button at the same time will raise the chosen boom Pressing a desired SPEED button and the UPPER LOWER JIB BOOM D...

Page 21: ...tform Control Panel 1 Engine Start 2 Engine Choke 3 Engine Stop 4 Generator On Off 5 Fuel Toggle 6 Horn 7 Drive Speed Selector 8 Battery Condition Indicator 9 Diagnostic Indicators 10 Emergency Stop 11 Auto Level 12 Outrigger Buttons 13 Outrigger Extend 14 Outrigger Retract 15 Outrigger Condition Status LED 16 Lower Boom Raise Down 17 Boom Rotation 18 Boom Extend Retract 19 Platform Tilt 20 Upper ...

Page 22: ... STOP button 11 15 Outrigger Controls Outrigger controls on the platform are identical to the outrigger controls on the ground control panel 16 Lower Boom Raise Down Press the LOWER BOOM RAISE DOWN button until the adjacent LED indicator becomes lit Depress the trigger on the platform controls joystick and move the joystick off center in the appropriate direction to raise and lower the boom 17 Boo...

Page 23: ... Trigger 2 Toggle Switch Figure 3 3 Platform Controls Joystick 1 Joystick Trigger Depress the trigger after selecting a boom function and move the joystick in the desired direction to operate boom functions 2 Toggle Switch Use the toggle switch to control direction of boom rotation and to steer the machine when using drive functions 21 ...

Page 24: ... LED at the AUTO LEVEL button will be lit Auto Level Press and hold the EXTEND and AUTO LEVEL buttons at the same time Manual Level Extend the two outriggers closest to the trailer coupler first Lower each pair of outriggers by pressing the EXTEND button and the two appropriate OUTRIGGER buttons at the same time Figure 3 4 Outrigger Controls NOTE The safety interlock system prevents all boom opera...

Page 25: ... boom over the boom rest and fully lower all booms until seated in the stowed position for transport Safety switches prevent outrigger retraction until boom is completely lowered and stowed for transport Engage the boom travel latches Press and hold the outrigger RETRACT button and the AUTO LEVEL button until all outriggers are fully retracted to their upright positions Inspect the area beneath li...

Page 26: ... the toggle switch located on top of the platform controls joystick While pressing the toggle switch and the trigger move the joystick off center to adjust function speed Use the toggle switch and the color coded direction arrows to determine the direction the turntable will rotate The turntable will rotate in the desired direction regardless of which direction the joystick is moved off center Sho...

Page 27: ...he boom turntable To begin manual retraction or rotation turn Proportional Valve counterclockwise until it stops and insert pump handle into the pump handle fitting Manual Retraction Pushing and holding the Retract button while simultaneously actuating Hand Pump will retract the extension boom section Manual Rotation To rotate the turntable clockwise Push and hold the Rotation button and simultane...

Page 28: ... plunger found at the base of the lift cylinder Figure 3 8 Depress the plunger to lower the platform in case of a complete electrical power failure a load shift or other emergency Continue pressing the plunger to completely lower the boom Figure 3 8 Manual Lowering Valve 26 ...

Page 29: ...FOR BATTERY VOLTAGE FUSE 15A SLO BLO Figure 3 9 Battery Charger Faceplate The CHARGING indicator LED remains lit continuously during the first stage of the charge cycle The bulk mode CHARGE CURRENT will be displayed on the battery charger faceplate Press and hold the BATTERY VOLTAGE button to display the detected battery voltage If a battery fault is detected the appropriate fault code will appear...

Page 30: ...ts Follow all forklift operating instructions as indicated by the forklift manufacturer Only trained and authorized personnel should attempt to lift the boom using a crane or forklift Refer to Figure 3 10 Verify that truck or trailer is parked on a firm and level surface Completely lower and retract boom Secure boom travel latches Retract all outriggers to fully stowed position Load boom onto truc...

Page 31: ...3 OPERATION 29 ...

Page 32: ...of the aerial work platform that is not covered by the troubleshooting steps covered in this manual contact your regional BilJax representative or the BilJax Service Department All maintenance and repairs should be performed by qualified personnel in accordance with manufacturer specifications and government regulations Follow recommended maintenance safety guidelines when performing maintenance o...

Page 33: ...r platform controls position b Emergency STOP engaged c Outriggers not deployed a Turn key switch to ground controls position b Disengage emergency STOP buttons c Deploy all outriggers One or more boom controls do not function OR One or more boom controls function improperly OR One or more boom controls function intermittently a Key switch is turned to the OFF or incorrect control position b Batte...

Page 34: ...th use Retract and extend outriggers using AUTO LEVEL 016 LIFT BOOM A boom rotate extend or retract function requested with boom down Raise boom from travel position 017 STOW BOOM An outrigger function requested with boom up Retract and lower boom to travel position 021 OPEN CIRCUIT PRIMARY UP A load of less than 70mA detected in primary up circuit on power up Check for faulty boom up solenoid coi...

Page 35: ... wiring 043 OPEN CIRCUIT PLATFORM CCW A load of less than 70mA detected in platform CCW circuit on power up Check for faulty boom rotate solenoid coil wiring 044 SHORTED CIRCUIT PLATFORM CCW Excessive load detected in platform CCW circuit on power up Check for faulty boom rotate solenoid coil wiring 045 OPEN CIRCUIT TURNTABLE CW A load of less than 70mA detected in rotate CW circuit on power up Ch...

Page 36: ...r faulty solenoid coil wiring at outrigger 059 OPEN CIRCUIT RR OUTRIGGER A load of less than 70mA detected in right rear outrigger circuit on power up Check for faulty solenoid coil wiring at outrigger 060 SHORTED CIRCUIT RR OUTRIGGER Excessive load detected in right rear outrigger circuit on power up Check for faulty solenoid coil wiring at outrigger 069 OPEN CIRCUIT PROPORTIONAL A load of less t...

Page 37: ...4 TROUBLESHOOTING 35 ...

Page 38: ...e safe and proper use of the aerial work platform Decals should be considered necessary components of the machine and should be checked before each use to verify that they are correctly attached and legible Use the following guides to find the correct location of all decals ...

Page 39: ... Transport Safety Latch 2 B06 00 0482 DANGER Electrocution Hazard 2 Decal No Decal Description Qty B06 00 0484 DANGER Battery Charger Safety 1 B06 00 0494 NOTICE Hazardous Materials 1 B06 00 0495 CAUTION Compartment Access Restricted 2 B06 00 0503 NOTICE Handle Applications 1 B06 00 0504 NOTICE Emergency Hand Pump 1 B06 00 0505 DANGER Before Use Main Instruction Hazards ground 1 B06 00 0521 DANGER...

Page 40: ...02 0523 0062 0475 0495 0034 0484 0495 0068 0504 0494 0541 0403 0405 0403 0037 0521 0503 0536 0536 0481 0481 0405 0405 0405 0482 0403 0477 0405 0521 0521 0404 0161B 0545 0473 4x 0564 0505 0561 0562 0471 Figure 5 1 Decal Placement 38 ...

Page 41: ...atform 1 B06 00 0474 NOTICE Max Load 1 B06 00 0475 WARNING Read Understand Operator s Manual 2 Decal No Decal Description Qty B06 00 0482 DANGER Electrocution Hazard 2 B06 00 0495 CAUTION Compartment Access Restricted 2 B06 00 0505 DANGER Before Use Main Instruction Hazards ground 1 B06 00 0536 NOTICE Range of Motion 2 B06 00 0541 CAUTION Manual Boom Functions 1 B06 00 0545 BilJax Website Transfer...

Page 42: ... 0474 0173 0202 0523 0062 0475 0475 0034 0495 0068 0541 0403 0405 0403 0037 0536 0536 0405 0405 0405 0482 0403 0405 0404 0161B 0545 4x 0564 0505 0561 0562 0471 0568 0495 0034 0572 Figure 5 2 Decal Placement CE 40 ...

Page 43: ...5 DECAL PLACEMENT 41 ...

Page 44: ...formation is subject to change without notice The following information is based on ideal working conditions Machine performance may vary based on work environment and on machine options Direct any questions or concerns regarding equipment specifications to your regional BilJax representative or to the BilJax Service Department ...

Page 45: ... 4 in 2 0 m 19 ft 2 in 5 8 m 5 ft 5 in 1 7 m Outrigger Footprint Length Width Footpad Diameter 12 ft 2 in 3 7 m 11 ft 4 in 3 4 m 12 5 in 0 3 m Brake Spring Applied Speed Gas Power DC Power 3 75 mph 6 km h 2 mph 3 2 km h Tire Size 26 x 12 bar lug tires Tire Pressure 20 PSI 140 kPa Control System 24V DC Battery 4 x 6V 245 amp hr Battery Charger 110 120 Volt Gas Engine Kawasaki 21 HP Hydraulic Pressu...

Page 46: ...BILJAX 45XA RANGE OF MOTION Figure 7 1 Range of Motion 44 ...

Page 47: ...s or otherwise alter the equipment in any way that is not expressly recommended by the manufacturer When operating a machine equipped with optional components observe all safety precautions set forth by the manufacturer as well as all government codes and regulations regarding this equipment and its components Consult rental agency or equipment manufacturer regarding which optional components may ...

Page 48: ...irmly secure platform to prevent equipment damage Remove the platform from the boom by lifting cage up and away from the mounting bracket on the boom nose Attach the material lifting hook to the mounting bracket on the boom nose and insert the retaining pin Figure 8 2 Figure 8 2 Material Lifting Hook Installation Operate the material lifting hook remotely using the platform control box for optimal...

Page 49: ... rotator handle in the direction of desired rotation clockwise or counterclockwise Motion continues in the desired direction until rotator handle is released or the platform reaches a safe travel limit WARNING Installation of a manual platform rotator may reduce the rated load limit of the work platform Follow all manufacturer s recommendations and safety precautions when operating a boom lift equ...

Page 50: ...BILJAX 45XA 48 ...

Page 51: ...NOTES ...

Page 52: ...Distributed by 125 Taylor Parkway Archbold OH 43502 Phone 419 445 8915 800 537 0540 Fax 419 445 0367 http www biljax com ...

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