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1 – SAFETY  

 

7

MAINTENANCE SAFETY

Ensure the following general safety precautions are 
followed while performing maintenance on the Aerial 
Work Platform: 

General Maintenance 

ALWAYS perform maintenance procedures 
according to manufacturer’s guidelines. NEVER 
disregard or bypass proper maintenance 
procedures. 

ALWAYS inspect hydraulic system to ensure that all 
lines, connectors and fittings are properly fastened 
and in good condition. 

ALWAYS turn the key switch OFF and remove key 
before performing maintenance. 

ALWAYS perform maintenance with the boom and 
platform in a fully lowered, stowed position, when 
possible. ALWAYS secure the boom before 
performing maintenance on hydraulic cylinders. 

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

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

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

ALWAYS locate and protect against possible pinch 
points before performing any maintenance or 
repairs. 

ALWAYS use only manufacturer-approved parts to 
repair or maintain equipment. If any portion of this 
equipment is rebuilt or repaired, retesting is required 
in accordance with factory instructions. 

ALWAYS maintain a safe distance while testing the 
hydraulic components. ALWAYS relieve hydraulic 
pressure before loosening or removing hydraulic 
components. NEVER test or operate the hydraulic 
components while personnel are near the 
equipment. 

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

NEVER add unauthorized fluids to the hydraulic 
system or battery. NEVER mix hydraulic oils. 
Consult manufacturer specifications. Refer to 

Section 4 for hydraulic system maintenance 
procedures. 

NEVER exceed the manufacturer’s recommended 
relief valve settings. 

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

NEVER adjust, repair, replace or bypass any 
hydraulic or electrical control or safety device. These 
include, but are not limited to, hydraulic load control 
and flow control valves, solenoid valves and limit 
switches. ALWAYS consult an authorized BilJax 
technician if repairs are necessary. 

NEVER modify, alter or change the equipment 
without first consulting an authorized BilJax 
technician, and NEVER in any way that would affect 
its original design or operation. 

Battery Maintenance 

Ensure the following general safety precautions are 
followed when performing battery maintenance on 
the Aerial Work Platform. 

ALWAYS wear safety glasses when working with or 
near batteries.  

ALWAYS check the battery fluid level daily. 

ALWAYS avoid contact with battery acid. Battery 
acid causes serious burns and should be kept away 
from skin or eyes. If contact occurs, flush with water 
and consult a physician immediately. 

ALWAYS disconnect ground cable first when 
removing battery. 

ALWAYS connect ground cable last when installing 
battery. 

ALWAYS charge batteries in open, well-ventilated 
areas. 

ALWAYS replace batteries using only parts 
recommended by manufacturer. ALWAYS use only 
batteries with sealed caps over cells. 

NEVER smoke while servicing batteries. 

NEVER charge batteries near spark or open flame. 

NEVER allow batteries to overcharge and boil. 

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

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

Содержание 45XA

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

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

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

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 17: ...2 BEFORE OPERATION 15 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 31: ...3 OPERATION 29 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 37: ...4 TROUBLESHOOTING 35 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 43: ...5 DECAL PLACEMENT 41 ...

Страница 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 ...

Страница 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...

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

Страница 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 ...

Страница 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...

Страница 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...

Страница 50: ...BILJAX 45XA 48 ...

Страница 51: ...NOTES ...

Страница 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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