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Bil-Jax XLB-4016 Operation And Maintenance Manual

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AERIAL WORK PLATFORMS
B33-01-0081
XLB-4016
Hydraulic Boom Lift
Operation and
Maintenance Manual

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Summary of Contents for Bil-Jax XLB-4016

  • Page 1 Operation and Maintenance Manual AERIAL WORK PLATFORMS XLB-4016 Hydraulic Boom Lift B33-01-0081...
  • Page 2 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 &...

  • Page 3: Table Of Contents

    Table of Contents Preface....................... v Safety........................1-1 Introduction................1-1 Before Operation..............1-2 During Operation ..............1-3 Maintenance Safety ..............1-5 General Maintenance..............1-5 Battery Maintenance...............1-6 Damaged Equipment Policy ........... 1-6 Safety Statement ................1-6 Damage Policy................1-6 Damage Repair Notice..............1-6 Reporting Safety Defects..............1-7 Introduction.....................2-1 General Description ..............
  • Page 4 Parts List ......................6-1 Upper Boom................6-2 Lower Boom................6-4 Chassis and Rotation Unit ............. 6-6 Hitch, Jack, and Emergency Brake ........6-10 Axle and Wheel Assembly ...........6-12 Pump Compartment and Cover ...........6-14 Outriggers ................6-16 Basket ..................6-18 Basket Controls..............6-20 6-10 Lower Controls...............6-22 6-11 Upper and Lower Control Box ..........6-24 6-12 Outrigger Controls..............6-26...
  • Page 5 List of Illustrations Figure 3-1. Ground Control Station................3-1 Figure 3-2. Outrigger Control Station................3-3 Figure 3-3. Basket Control Station ................3-4 Figure 3-4. Outrigger Controls ..................3-6 Figure 3-5. Manual Lowering Valve Plungers ............3-9 Figure 3-6. Emergency Ball Valves.................3-10 Figure 3-7. Hydraulic Rotation Motor Bypass Valve ..........3-11 Figure 3-8.
  • Page 6 List of Tables Table 1-1. Minimum Safe Approach Distances............1-3 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................4-12 Table 4-4. Level Sensor LEDs................4-17 Table 5-1. Replacement Decals ................

  • Page 7: Preface

    PREFACE The purpose of this manual is to provide a thorough understanding of the XLB-4016 Hy- draulic Boom Lift operation and controls. Read the safety and operating instructions in this manual and become familiar with the location and use of all controls.

  • Page 9: Safety

    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 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.

  • Page 10: Before Operation

    XLB-4016 BEFORE OPERATION Ensure the following general safety precautions are followed before operating the XLB-4016 Hydraulic Boom Lift. • ALWAYS survey the usage area for potential hazards such as untamped earth fills, unlevel surfaces, overhead obstructions, and electrically charged conduc- tors or wires.

  • Page 11: During Operation

    1 — SAFETY DURING OPERATION Ensure the following general safety precautions are followed during the operation of the XLB-4016 Hydraulic 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.
  • Page 12 XLB-4016 • 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 and firmly based. • NEVER override or by-pass manufacturer's safety devices. •...

  • Page 13: Maintenance Safety

    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 800-537-0540 if the cylinder counter balance valves need adjusting.

  • Page 14: Battery Maintenance

    (this damage may be internal and is not always visi- ble to the naked eye), Bil-Jax requires that the lift be returned to our facility at 125 Tay- lor Parkway, Archbold, Ohio, for reconditioning. If you have any questions concerning what constitutes structural damage, please call the Bil-Jax Service Department at 800-537-0540.

  • Page 15: Reporting Safety Defects

    If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Bil-Jax, Inc. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.
  • Page 16 XLB-4016...

  • Page 17: Introduction

    70 seconds. It is strongly recom- mended that no one adjust these speeds. If service is required, please notify Bil-Jax for detailed instructions. Emergency lowering of the basket is by manual valve plungers on the upper and lower boom lift cylinders.

  • Page 18: Specifications

    Mechanical Surge 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. Bil-Jax will, at its option, repair or replace any unit or component part which fails to function properly in normal use.

  • Page 19: Operation

    Operation OPERATOR CONTROLS The XLB-4016 Hydraulic Boom Lift is equipped w ith multiple operator controls. Equip- ment power, outrigger controls, and boom lift controls are located at ground level. Boom lift and rotation controls are locate d in the basket.
  • Page 20 XLB-4016 Boom Raise Pushbutton Holding the green boom run pushbutton in starts the hydraulic motor and enables the boom lift function. The lift boom cylinders can only be operated when the outrigger cyl- inders are extended and the trailer is level.

  • Page 21: Outrigger Control Station

    3 — OPERATION LEVEL OUTRIGGER INDICATOR OPERATOR LEVERS OUTRIGGER RUN PUSHBUTTON Figure 3-2. Outrigger Control Station Outrigger Control Station The outrigger control station (Figure 3-2) operates the outriggers. The outrigger control station includes the following electrical and hydraulic controls. Outrigger Run Pushbutton Holding the black outrigger run pushbutton in starts the hydraulic pump and enables op- eration of the outrigger cylinders.

  • Page 22: Basket Control Station

    XLB-4016 EMERGENCY BOOM OPERATE STOP PUSHBUTTON PUSHBUTTON BOOM LOWER PUSHBUTTON 115 VOLT OUTLET BOOM OPERATE LEVERS Figure 3-3. Basket Control Station Basket Control Station The basket control station (Figure 3-3) operates the hydraulic boom lift and boom rota- tion. The basket control station includes the following electrical and hydraulic controls.
  • Page 23 3 — OPERATION Boom Operator Levers Three boom operator levers position proportional hydraulic valves to extend and retract three boom lift cylinders and the boom rotation drive motor. Pulling a boom operator lever up extends the cylinder to raise the boom. Pushing a boom lift operator lever down lowers the related boom.

  • Page 24: Normal Operating Procedure

    XLB-4016 NORMAL OPERATING PROCEDURE Perform the following procedures to operate the XLB-4016 Hydraulic Boom Lift. 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 man- ual.
  • Page 25 3 — OPERATION WARNING Always verify that the green outrigger LEDs light up when the outriggers are low- ered and the trailer is level. If an outrigger LED fails to light up, or lights up be- fore the outrigger foot is fully lowered, the limit switch or switch setting is faulty. Using the boom lift with a faulty limit switch or switch setting can cause severe in- jury, death, or damage to the equipment.

  • Page 26: Emergency Lowering

    XLB-4016 EMERGENCY LOWERING The XLB-4016 Hydraulic Boom Lift is equipped with manual lowering valves. These devices can be used to lower the basket in case of a power failure, a load shift, or other emergency situation. Manually lowering the work basket can be accomplished in two different ways. The first method requires two people.

  • Page 27: Manually Lowering The Work Basket With Two People

    3 — OPERATION Manually Lowering the Work Basket with Two People Have an assistant pull out and hold the valve plunger (Figure 3-5) on the lower boom lift cylinder. Press down on the boom operator lever at the ground control station, or push down on the upper boom operator lever at the basket control station.

  • Page 28: Manually Lowering The Work Basket With One Person

    XLB-4016 Manually Lowering the Work Basket with One Person Open the two emergency ball valves located next to the ground station boom operator lever, Figure 3-6. These valves are open when the handles are vertical. Slowly pull out the valve plunger on the lower boom cylinder, Figure 3-5, to lower the lower boom.

  • Page 29: Manual Boom Rotation

    3 — OPERATION MANUAL BOOM ROTATION The hydraulic boom lift is equipped with an emergency rotation feature that allows the boom to be rotated in case of a power failure or other emergency situation. Use the following procedure to manually rotate the boom: Turn the hydraulic rotation motor bypass valve (Figure 3-7) counterclockwise to bypass the hydraulic rotation motor.

  • Page 30: Battery Recharge

    XLB-4016 BATTERY RECHARGE 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.
  • Page 31 3 — OPERATION 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. Inspect the charge indicator LEDs near the end of the expected charge cycle. If all indicator LEDs are on, the battery is fully charged.

  • Page 32: Boom Lift Transport

    XLB-4016 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.
  • Page 33 3 — OPERATION Pull pivot locking pin. Swivel the jack 90 degrees to the travel position and release the pivot locking pin. Ensure that the jack is locked in the travel position. 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.
  • Page 34 XLB-4016 3-16...

  • Page 35: Maintenance

    Maintenance SCHEDULED SERVICE C HECKS Daily/Weekly Service Checks Perform the following daily/weekly service checks as listed in Table 4 Table 4-1. Daily /Weekly Service Chec Daily Service Check before use Weekly Check to see that all decals are present. Check that controls and indicators at ground, outrigger, a basket control stations operate properly.

  • Page 36: Monthly Service Checks

    XLB-4016 Monthly Service Checks Perform the following monthly service checks as listed in Table 4-2. Table 4-2. Monthly Service Checks Every Every Every Service Check month 6 months 12 months Clean battery terminals and check battery charger operation. Check operation of manual lowering valves.

  • Page 37: Lubrication

    4 — MAINTENANCE LUBRICATION Lubrication makes operation of the XLB-4016 Boom Lift more efficient and extends the equipment life. Use the following procedures to lubricate the boom lift components. Lubricate trailer jack post and all grease fittings labeled LUBRICATE WEEKLY with NLGI Grade 2 multi-purpose grease.

  • Page 38: Hydraulic System

    XLB-4016 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.

  • Page 39: Figure 4-3. Hydraulic Cylinder Removal

    Bleed entrapped air from the hydraulic cylinder according to instructions in paragraph 4-4. NOTE: Do not tamper with the cylinder counterbalance or manual lowering valves. If the valves need adjustment, contact the Bil-Jax Service Department at 800-537-0540. PIVOT PIN PIVOT PIN...

  • Page 40: Figure 4-4. Outrigger Cylinder Removal

    XLB-4016 Outrigger Cylinder Removal and Installation Lower the outrigger until the foot pad meets the floor and supports only the out- rigger beam. Leave the weight of the boom lift on the trailer wheels. At the piston rod end of the cylinder, unscrew and remove the pin keepers, Figure 4-4, from both sides of the pivot pin.
  • Page 41 4 — MAINTENANCE Drive out the pivot pin with a hammer and a brass or hardwood drift. Do not al- low the free end of the cylinder to fall. Fully retract the cylinder. Turn off the key switch and remove the key. Lift the outrigger cylinder so it is in a vertical position.

  • Page 42: Hydraulic Pressure Checks And Adjustments

    XLB-4016 Hydraulic Pressure Checks and Adjustments Hydraulic pressures are set at the factory and should not be adjusted unless a hydraulic component such as a cylinder or control valve has been replaced. Boom lift operating pressure is regulated by a pressure regulating valve. The valve regu- lates the output pressure of the hydraulic pump.

  • Page 43: Limit Switch Checks And Adjustments

    4 — MAINTENANCE LIMIT SWITCH CHECKS AND ADJUSTMENTS Adjusting Boom Down Limit Switch When the upper and lower booms are retracted, the boom down limit switch is actuated. The boom down limit switch must be actuated to lower or raise the outriggers. The boom down limit switch should trip when the lower boom is within 1 inch (25,4 mm) of seating on the boom rest.
  • Page 44 XLB-4016 If the pump motor runs, the limit switch may need to be adjusted, or the limit switch or switch wiring is damaged. Repair or replace a damaged limit switch or wiring, as needed. The limit switch may be adjusted as follows: Raise the lower boom to allow free access to the limit switch.

  • Page 45: Adjusting Outrigger Position Switches

    4 — MAINTENANCE Adjusting Outrigger Position Switches The outrigger position switches, Figure 4-7, are set up to detect when the boom lift load is transferred from the trailer wheels to the outriggers. When the load is transferred to each outrigger, the related position switch is engaged and the related LED lights up on the control panel.

  • Page 46: Troubleshooting

    XLB-4016 TROUBLESHOOTING Table 4-3. Troubleshooting Chart Problem Cause Correction 1. Hydraulic pump motor will Key switch in wrong position. Turn key switch to correct position. not start from any control b. Emergency stop engaged (pushed in). b. Rotate emergency stop buttons clock- station.
  • Page 47 4 — MAINTENANCE Table 4-3. Troubleshooting Chart, Continued Problem Cause Correction 4. Boom slew function fails to Key switch in wrong position. Turn key switch to basket run posi- work. tion. b. Trailer out of level. b. Operate outriggers to level trailer. Outrigger not under load.

  • Page 48: Troubleshooting Aids

    XLB-4016 Troubleshooting Aids Electrical diagrams are provided in Figure 4-8 and Figure 4-9. A hydraulic diagram is provided in Figure 4-10. Level sensor LED indications are provided in Table 4-4. Outrigger Limit Switches Basket Control Station Outrigger Control Station Upper...

  • Page 49: Figure 4-9. Detailed Electrical Diagram

    4 — MAINTENANCE Keyswitch Emergency Stop Basket Ground Diverter Level Valve Sensor Relay Outrigger Boom Limit Switch Outrigger Limit Switches Outrigger Indicators Boom Lower Upper Lift Cylinder Blocking Valve Boom Boom Raise Operate Lower Lift Cylinder Blocking Valve Boom Lowering Emergency Basket Control Stop...

  • Page 50: Figure 4-10. Hydraulic Diagram

    XLB-4016 Figure 4-10. Hydraulic Diagram 4-16...

  • Page 51: Figure 4-11. Level Sensor

    4 — MAINTENANCE YELLOW LED GREEN LED RED LED OUT OF LEVEL INPUT POWER OUTPUT SIGNAL (MOMENTARY) (ON WHEN LEVEL) Figure 4-11. Level Sensor Table 4-4. Level Sensor LEDs Color Description Yellow Boom lift out of level. Signals alarm after 2 second delay. Green Boom lift power is on.

  • Page 52: Material Safety Data Sheets

    XLB-4016 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 800 OIL-TANK City, State, Zip...
  • Page 53 4 — MAINTENANCE LEAD ACID BATTERIES, WET, FILLED WITH ACID (continued) ******************************************************************************************** ***** SECTION V -- HEALTH HAZARD DATA ******************************************************************************************** ***** Primary Routes of Entry: Inhalation: Skin: Ingestion: 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.
  • Page 54 XLB-4016 MATERIAL SAFETY DATA SHEET FOR AW-46 HYDRAULIC OIL 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.
  • Page 55 4 — MAINTENANCE AW-46 HYDRAULIC OIL (continued) PAGE 2 SPECIAL PROTECTION INFORMATION RESPIRATORY PROTECTION (SPECIFIC TYPE) NONE REQUIRED VENTILATION: NORMAL LOCAL EXHAUST: NORMAL MECHANICAL EXHAUST (GENERAL) PROTECTIVE GLOVES: OIL IMPERVIOUS GLOVES RECOMMENDED EYE PROTECTION: SAFETY GLASSES RECOMMENDED OTHER PROTECTIVE EQUIPMENT: NONE REQUIRED ---------------------------------------------------------------------------- SPECIAL INSTRUCTIONS SPECIAL LABELLING INSTRUCTIONS: NOT REQUIRED...
  • Page 56 XLB-4016 4-22...

  • Page 57: Replacement Decals

    THE HYDRAULIC SYSTEM … B06-00-0405 PINCH POINT (decal on hydraulic reservoir) B06-00-0407 XLB-4016 B06-00-0115 1500 WATT LOAD LIMIT B06-00-0410 BASKET CONTROLS B 06-00-0161B Bil-Jax – LARGE LABEL B06-00-0411 BOOM OPER ATING B06-00-0173 SAFETY HARNESS LANYARD INSTRUCTIONS GROUND ATTACHMENT POINT CONTROLS B06-00-0189...
  • Page 58 XLB-4016 BEFORE USING, LOWER ALL 4 OUTRIGGERS UNTIL DANGER THE HYDRAULIC SYSTEM OF EACH OUTRIGGER IS IN FIRM CONTACT WITH THE THIS MACHINE IS DESIGNED TO USE GROUND, THEN LEVEL THE MACHINE. B06-00-0400 ENERGOL HLP-46 HYDRAULIC OIL B06-00-0400 B06-00-0068 B06-00-0068 MAXIMUM CAPACITY •...
  • Page 59 B06-00-0261 B06-00-0261 13 16.4 19.7 BOOM OPERATING INSTRUCTIONS FOR XLB-4016 CAPACITY ......... 450 LB. MAXIMUM PLATFORM HEIGHT ..33 FT. WORK HEIGHT ......... 40 FT. 1. Read Operation Manual and all decals 5.
  • Page 60 STAY CLEAR • During charging, explosive oxyhydrogen gas is generated. DO NOT smoke or allow open fire, sparks, or embers near © Bil-Jax, Inc. 2004 B06-00-0405 battery when charging. B06-00-0405 • Connect input cord only to properly grounded three wire outlet with specified voltage and frequency.

  • Page 61: Figure 5-2. Decal Locations, Trailer And Boom

    5 — REPLACEMENT DECALS 0161B 0036 0036 0415 0060 0115 0192 0062 0400 0428 0380 0392 0405 0410 0428 0034 0225 0429 0400 0401 0405 0401 0334 0173 0068 0414 0411 0404 0334 0036 0036 0037 0431 0261 0407 0400 0036 0405 0363B...
  • Page 62 XLB-4016...

  • Page 63: Parts List

    Parts List...

  • Page 64: Upper Boom

    XLB-4016 UPPER BOOM Refer to Table 6-1 for the upper boom parts list. Figure 6-1. Upper Boom...

  • Page 65: Table 6-1. Upper Boom Parts List

    6 — PARTS LIST Table 6-1. Upper Boom Parts List Item No. Part No. Description Boom, Upper Cap Screw Washer, Lock Washer, Flat Plate, Retainer Seal Cap Screw Washer, Flat Bar, Upper Leveling Cap Screw Pivot Pin Grease Fitting Trim Weldment, Vertical Beam Pivot Pin Decal...

  • Page 66: Lower Boom

    XLB-4016 LOWER BOOM Refer to Table 6-2 for the lower boom parts list. Figure 6-2. Lower Boom...

  • Page 67: Table 6-2. Lower Boom Parts List

    6 — PARTS LIST Table 6-2. Lower Boom Parts List Item No. Part No. Description Cap Screw Washer, Lock Washer, Flat Pivot Pin Pivot Pin Pivot Pin Grease Fitting Boom, Lower Grease Fitting Bar, Lower Leveling Cylinder, Hydraulic, Lower Boom Lift Hydraulic Hose Assembly, Lower Boom Lift Cylinder Return to Tank Wire Tie...

  • Page 68: Chassis And Rotation Unit

    XLB-4016 CHASSIS AND ROTATION UNIT Refer to Table 6-3 for the chassis and rotation unit parts list. Figure 6-3. Chassis and Rotation Unit...

  • Page 69: Table 6-3. Chassis And Rotation Unit Parts List

    6 — PARTS LIST Table 6-3. Chassis and Rotation Unit Parts List Item No. Part No. Description Boom Rotation Weldment Trim Nut, Self-locking Washer, Flat Button, Emergency Stop Bolt, Socket Head Wire Grip Cap Screw Washer, Flat Motor, Hydraulic Rotation Cap Screw Washer, Lock Washer, Flat...

  • Page 70: Figure 6-3. Chassis And Rotation Unit

    XLB-4016 6-3. CHASSIS AND ROTATION UNIT Figure 6-3. Chassis and Rotation Unit...
  • Page 71 6 — PARTS LIST Table 6-3. Chassis and Rotation Unit Parts List (continued) Item No. Part No. Description Nut, Self Locking Grease Fitting Bolt, Socket Head Switch, Boom Down Limit Wire Grip Bracket, Mounting Nut, Self Locking Washer, Flat Washer, Lock Cap Screw Tape, Non-Skid Pad, Upper Boom Rest...

  • Page 72: Hitch, Jack, And Emergency Brake

    XLB-4016 HITCH, JACK, AND EMERGENCY BRAKE Refer to Table 6-4 for the hitch, jack, and emergency brake parts list. 13 12 Figure 6-4. Hitch, Jack, and Emergency Brake 6-10...

  • Page 73: Table 6-4. Hitch, Jack, And Emergency Brake Parts List

    6 — PARTS LIST Table 6-4. Hitch, Jack, and Emergency Brake Parts List Item No. Part No. Description 0090-0188 Nut, Self Locking, 3/8-16 0090-0042 Cap Screw, 3/8-16 x 1 Emergency Brake Assembly Cap Screw Washer, Flat Wire Tie Wire Clip, Adhesive Nut, Self Locking B01-10-0021 Side Marker, Amber...

  • Page 74: Axle And Wheel Assembly

    XLB-4016 AXLE AND WHEEL ASSEMBLY Refer to Table 6-5 for the axle and wheel assembly parts list. Figure 6-5. Axle and Wheel Assembly 6-12...

  • Page 75: Table 6-5. Axle And Wheel Assembly Parts List

    6 — PARTS LIST Table 6-5. Axle and Wheel Assembly Parts List Item No. Part No. Description Cap Screw Washer, Flat Cap Screw Washer, Flat Bracket, Fender Fender Washer, Flat Nut, Self Locking Bolt, Wheel Lug Tire Nut, Axle Rotor Bearing, Sealed Snap Ring Axle Assembly...

  • Page 76: Pump Compartment And Cover

    XLB-4016 PUMP COMPARTMENT AND COVER Refer to Table 6-6 for the pump compartment and cover parts list. Figure 6-6. Pump Compartment and Cover 6-14...

  • Page 77: Table 6-6. Pump Compartment And Cover Parts List

    6 — PARTS LIST Table 6-6. Pump Compartment and Cover Parts List Item No. Part No. Description Cable, Battery Cable, Battery Cap, Terminal Washer, Wave Washer, Flat Fuse, 200A Fuse Holder Bolt, Socket Head Washer, Flat Nut, Self Locking Screw, Cap Washer, Flat Cable, Battery Wire Tie...

  • Page 78: Outriggers

    XLB-4016 OUTRIGGERS Refer to Table 6-7 or the outriggers parts list. Figure 6-7. Outriggers 6-16...

  • Page 79: Table 6-7. Outriggers Parts List

    6 — PARTS LIST Table 6-7. Outriggers Parts List Item No. Part No. Description Hydraulic Hose, Outrigger to Outrigger Con- trol Station Adapter, Elbow Grease Fitting Cylinder, Hydraulic, Outrigger Cap, Grease Fitting Bolt, Socket Head Washer, Flat Switch, Outrigger Limit Outrigger Cap Screw Washer, Lock...

  • Page 80: Basket

    XLB-4016 BASKET Refer to Table 6-8 for the basket parts list. 14 15 32 33 Figure 6-8. Basket 6-18...

  • Page 81: Figure 6-8. Basket

    6 — PARTS LIST Table 6-8. Basket Parts List Item No. Part No. Description Tube, Manual Holder Clamp Screw Basket Weldment Nut, Self Locking Washer, Flat Cap Screw Tape, Non-skid Cap Screw Washer, Falt Clamp Tape, red/white striped B01-10-0023 Tail Light, Right Side B01-10-0014 Conduit Box B01-09-0037...

  • Page 82: Basket Controls

    XLB-4016 BASKET CONTROLS Refer to Table 6-9 for the Basket controls parts list. Figure 6-9. Basket Controls 6-20...

  • Page 83: Table 6-9. Basket Controls Parts List

    6 — PARTS LIST Table 6-9. Basket Controls Parts List Item No. Part No. Description Screw, part of 2 B01-10-0035 Cover, Receptacle Gasket, part of 2 Screw, part of 5 B01-10-0034 Receptacle, GFI B01-10-0046 Junction Box, 110V Cap Screw Wire Grip 0090-0232 Cap Screw, 10-24 x 5/8 Electrical Box, Upper Controls...

  • Page 84: 6-10 Lower Controls

    XLB-4016 6-10 LOWER CONTROLS Refer to Table 6-10 for the lower controls parts list. Figure 6-10. Lower Controls 6-22...

  • Page 85: Table 6-10. Lower Controls Parts List

    6 — PARTS LIST Table 6-10. Lower Controls Parts List Item No. Part No. Description Cap Screw Cap Screw Washer, Flat Nut, Self Locking Washer, Flat Wire Grip Bolt, Socket Head Main Electrical Box Wire Grip Box, Ground Control Station Valve, Hydraulic, Boom Control Nut, Self Locking Valve, Diverter Solenoid...

  • Page 86: 6-11 Upper And Lower Control Box

    XLB-4016 6-11 UPPER AND LOWER CONTROL BOX Refer to Table 6-11 for the upper and lower control box parts list. BASKET CONTROL PANEL GROUND CONTROL MAIN ELECTRICAL PANEL Figure 6-11. Upper and Lower Control Box 6-24...

  • Page 87: Table 6-11. Upper And Lower Control Box Parts List

    6 — PARTS LIST Table 6-11. Upper and Lower Control Box Parts List Item No. Part No. Description Pushbutton, Green Pushbutton, Black Pushbutton, Emergency Stop Key Switch Pushbutton, Green Pushbutton, Black End Block Terminal Block Breaker, 4A Terminal Mounting Strip B01-06-0019 Relay, 12 VDC (inside ground control panel) B01-06-0007...

  • Page 88: 6-12 Outrigger Controls

    XLB-4016 6-12 OUTRIGGER CONTROLS Refer to Table 6-12 for the outrigger controls parts list. Figure 6-12. Outrigger Controls 6-26...

  • Page 89: Table 6-12. Outrigger Controls Parts List

    6 — PARTS LIST Table 6-12. Outrigger Controls Parts List Item No. Part No. Description Cap Screw Washer, Flat Box, Outrigger Enable Pushbutton Wire Grip Bubble Level Cap Screw Washer, Flat Valve, Hydraulic, Outrigger Control Wire Tie Hydraulic Hose, Diverter Valve to Outrigger Controls Hydraulic Hose, Outrigger Controls to Left Rear Outrigger (#4)

  • Page 90: 6-13 Ground Control And Pump Hydraulics

    XLB-4016 6-13 GROUND CONTROL AND PUMP HYDRAULICS Refer to Table 6-13 for the ground control and pump hydraulics parts list. Figure 6-13. Ground Control and Pump Hydraulics 6-28...

  • Page 91: Table 6-13. Ground Control And Pump Hydraulics Parts List

    6 — PARTS LIST Table 6-13. Ground Control and Pump Hydraulics Parts List Item No. Part No. Description Hydraulic Hose, Outrigger Control Valve Return to Tank Hydraulic Hose, Basket Control Valve Return to Tank Adapter, Tee Adapter Washer, Seal Hydraulic Hose, Upper Boom Lift Cylinder Return to Tank Adapter, Tee Hydraulic Hose, Lower Boom Lift Cylinder...

  • Page 92: 6-14 Rotation Hydraulics

    XLB-4016 6-14 ROTATION HYDRAULICS Refer to Table 6-14 for the rotation hydraulics parts list. Figure 6-14. Rotation Hydraulics 6-30...

  • Page 93: Table 6-14. Rotation Hydraulics Parts List

    6 — PARTS LIST Table 6-14. Rotation Hydraulics Parts List Item No. Part No. Description Hydraulic Hose, Rotation Pump Bypass Valve to Rotation Pump Adapter Washer, Seal Valve, Bypass, Rotation Pump Washer, Flat Bolt, Socket Head Hydraulic Hose, Rotation Pump Bypass Valve to Basket Controls Wire Tie Adapter...
  • Page 94 XLB-4016 6-32...

  • Page 95: Ansi Reprint

    ANSI Reprint The following sections are reprinted from the ANSI A92.2-1990 code in effect at the time of manufacture. Permission to reprint h as been granted by the Scaffold Industry Association. 7. R esponsibilities of Dealers and In stallers 7.1 General Responsibilities. Each dealer or installer as applicable shall comply with the requirements of this section.
  • Page 96 XLB-4016 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, main- tenance and modification. These activities shall be performed by qualified per- son(s).
  • Page 97 7 — ANSI REPRINT (6) Compressors, pumps, motors and generators for loose fasteners, leaks, unusual noises or vibrations, loss of operating speed, and excessive heating (7) Hydraulic and pneumatic valves for malfunction and visible cracks in the ex- ternal 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-...
  • Page 98 XLB-4016 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.
  • Page 99 7 — ANSI REPRINT 9. Responsibilities of Renters or Lessors 9.1 General Responsibilities. Each renter or lessor shall comply with the require- ments 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.
  • Page 100 XLB-4016 M.S.A.D. = Minimum Safe Approach Distance (See Table 7-1). DENOTES PROHIBITED ZONE • 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.

  • Page 101: Table 7-1. Minimum Safe Approach Distance (M.s.a.d.) To Energized

    7 — ANSI REPRINT 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 (Feet) (Meters) (Phase to Phase) 0 to 300V Avoid Contact Over 300V to 50KV 3.05 Over 50KV to 200KV 4.60...
  • Page 102 XLB-4016...
  • Page 104 125 Taylor Parkway Archbold, OH 43502 Phone (419) 445-8915 (800) 537-0540 (419) 445-0367...

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