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Bil-Jax XLB-4725A Operation And Maintenance Manual

Proportional hydraulic boom lift
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AERIAL WORK PLATFORMS
AERIAL WORK PLATFORMS
AERIAL WORK PLATFORMS
AERIAL WORK PLATFORMS
B33-01-0072-01
XLB-4725A
Proportional
Hydraulic Boom Lift
Operation and
Maintenance Manual

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Summary of Contents for Bil-Jax XLB-4725A

  • Page 1 Operation and Maintenance Manual AERIAL WORK PLATFORMS AERIAL WORK PLATFORMS AERIAL WORK PLATFORMS AERIAL WORK PLATFORMS XLB-4725A Proportional Hydraulic Boom Lift B33-01-0072-01...
  • 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 1 1 1 1 Safety ....................... 1-1 Introduction ..................1-1 Before Operation ................1-3 During Operation................1-4 Maintenance Safety ................1-6 Damaged Equipment Policy ............. 1-7 2 2 2 2 Introduction ....................2-1 General Description................2-1 Specifications ..................2-2 Warranty.....................
  • Page 4 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.
  • Page 5 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.

  • Page 7: 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 to procedures that may be of concern to them.
  • Page 8 XLB-4725A 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.

  • Page 9: Before Operation

    1 — SAFETY 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.

  • Page 10: During Operation

    XLB-4725A 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.
  • Page 11 1 — SAFETY • 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. •...

  • Page 12: 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 419.445.9675 if the cylinder counter balance valves need ad- justing.

  • Page 13: Damaged Equipment Policy

    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.
  • Page 14 XLB-4725A...

  • Page 15: Introduction

    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...

  • Page 16: Specifications

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

  • Page 17: Operation

    Operation 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.
  • Page 18 XLB-4725A 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).
  • Page 19 3 — OPERATION 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.
  • Page 20 XLB-4725A 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.
  • Page 21 3 — OPERATION 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.

  • Page 22: Normal Operating Procedure

    XLB-4725A NORMAL OPERATING PROCEDURE Perform the following procedures to operate the XLB-4725A 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 manual.

  • Page 23: Emergency Lowering

    3 — OPERATION 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.

  • Page 24: Battery Recharge (Dc Model Only)

    XLB-4725A 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.

  • Page 25: Figure 3-7. Battery Charger

    3 — OPERATION Plug the power cord into a grounded 120 VAC receptacle. Verify that the red ON-CHARGING indicator LED lights up on the battery charger. To determine the charge rate at any time during the charge cycle, observe the DC ammeter (Figure 3-7).

  • Page 26: Boom Lift Transport

    XLB-4725A 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 27: Figure 3-10. Trailer Hitching Checkpoints

    3 — OPERATION 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. Attach the trailer safety chains to the tow vehicle. Make sure the chains cross under the trailer tongue as shown in (Figure 3-10).

  • Page 28: Figure 3-11. Backup Lever Position

    XLB-4725A 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. Before towing the trailer, check the following and make all necessary adjust- ments, corrections, or repairs: Check that trailer jack and outriggers are locked in travel positions.

  • Page 29: Maintenance

    4 4 4 4 Maintenance 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 Daily Service Check before use Weekly Check battery electrolyte level. If battery charge is low, add water to bring electrolyte just above plates.

  • Page 30: Table 4-2. Monthly Service Checks

    XLB-4725A 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 emergency lower- ing valve.

  • Page 31: Wheel Nut Torque Requirements

    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. Lubricate trailer and outrigger jack posts and all grease fittings labeled LUBRICATE WEEKLY with NLGI Grade 2 multi-purpose grease.

  • Page 32: Figure 4-3. Lubricate Semi-Annually

    XLB-4725A 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.

  • Page 33: Figure 4-4. Lubrication Of Dexter Axles

    4 — MAINTENANCE Lubricate a Dexter axle according to the following procedure: Remove the rubber plug to expose the grease fitting. 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.

  • Page 34: Hydraulic System

    XLB-4725A 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 35: Figure 4-5. Hydraulic Cylinder Removal

    4 — MAINTENANCE Hydraulic Cylinder Repair Cylinder Removal and Installation Lower boom onto travel supports, turn off the main power switch, and remove the PLATFORM/OFF/GROUND key. 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.
  • Page 36 Power up the hydraulic system and check for leakage. Tighten hydraulic fittings as needed. 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.

  • Page 37: Figure 4-6. Hydraulic Cylinder Repair

    4 — MAINTENANCE 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. Check bearings (1, Figure 4-6) for wear and excess play.
  • Page 38 XLB-4725A Remove headstock (2). Remove and discard o-ring (11), backup ring (12), and seal (13). Remove bushing (14) and wiper (15). Discard wiper. 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.

  • Page 39: Leveling System

    4 — MAINTENANCE LEVELING SYSTEM Check and Replace Outrigger Bushings Check outrigger bushings every six months according to the following procedure: 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. Lower the outrigger jack to raise the trailer wheel.

  • Page 40: Figure 4-8. Outrigger Bushing Replacement

    XLB-4725A Perform the following procedure to replace outrigger bushings. Refer to Figure 4-8. Remove three screws (5), lock washers (4), and flat washers (3). Unscrew and remove fluted knob (2). Remove pin cap (1). Remove nylon lock hex nut (9) and cap screw (6). Remove outrigger (8).

  • Page 41: Figure 4-9. Adjusting Axle Position Switches

    4 — MAINTENANCE 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.

  • Page 42: Troubleshooting

    XLB-4725A TROUBLESHOOTING Table 4-3. Troubleshooting Chart Problem Cause Correction Outriggers indicator lamp Master power switch turned off. Turn on master power switch. will not light up. Emergency stop or power button Rotate emergency stop buttons clock- engaged (pushed in). wise to disengage.
  • Page 43 4 — MAINTENANCE Table 4-3. Troubleshooting Chart, Continued Problem Cause Correction No operation of all functions Master power switch turned off. Turn on master power switch. when the trigger or speed Short circuit burned out the power Check fuse status indicator D67 in control knob and a function fuse.

  • Page 44: Figure 4-10. Lower Controller Board

    XLB-4725A Figure 4-10. Lower Controller Board 4-16...

  • Page 45: Table 4-5. Led Indicators

    4 — MAINTENANCE 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.

  • Page 46: Figure 4-11. Level Sensor

    XLB-4725A YELLOW LED GREEN LED RED LED OUT OF LEVEL INPUT POWER OUTPUT SIGNAL (MOMENTARY) (ON WHEN LEVEL) 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.

  • Page 47: Figure 4-12. Dc Model Hydraulic Diagram

    4 — MAINTENANCE LOWER BOOM UPPER BOOM LIFT CYLINDER LIFT CYLINDER BOOM ROTATION GEAR MOTOR PROP. VALVE HYDRAULIC MANIFOLD FILTER HYDRAULIC PUMP Figure 4-12. DC Model Hydraulic Diagram 4-19...

  • Page 48: Figure 4-13. Gas Model Hydraulic Diagram

    XLB-4725A LOWER BOOM UPPER BOOM LIFT CYLINDER LIFT CYLINDER BOOM ROTATION GEAR MOTOR PROP. VALVE HYDRAULIC MANIFOLD HYDRAULIC PUMP FILTER Figure 4-13. Gas Model Hydraulic Diagram 4-20...

  • Page 49: Figure 4-14. Pc Logic Diagram, Dc Model

    4 — MAINTENANCE (PBS) INPUT PRIMARY BUCKET SWITCH UPPER LOWER (SBS) INPUT CONTROL BOX CONTROL BOX SECONDARY BUCKET SWITCH E-DOWN E-DOWN LEVEL OUTRIGGER PROP. SENSOR VALVE SPEED TRIGGER CONTROL SWITCH (SBS) MOTOR START SOLENOID (PBS) (SBS) LEVEL UPPER UPPER OUTRIGGER UPPER SENSOR CYL UP...

  • Page 50: Figure 4-15. Pc Logic Diagram, Gas Model

    XLB-4725A (PBS) INPUT PRIMARY BUCKET SWITCH UPPER LOWER (SBS) INPUT CONTROL BOX CONTROL BOX SECONDARY BUCKET SWITCH E-DOWN E-DOWN LEVEL OUTRIGGER PROP. SENSOR VALVE SPEED TRIGGER CONTROL SWITCH (SBS) THROTTLE SOLENOID RELAY UPPER UPPER (PBS) LEVEL (SBS) OUTRIGGER UPPER CYL UP...

  • Page 51: Material Safety Data Sheets

    4 — MAINTENANCE 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 Fremont, Ohio 43420 Phone Number:...
  • Page 52 XLB-4725A ************************************************************************************************* 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 53 4 — MAINTENANCE 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.
  • Page 54 XLB-4725A 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 55: Replacement Decals

    5 5 5 5 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 Decal No. Description of Decal...
  • Page 56 XLB-4725A BEFORE USING: EXTEND, LOCK, STABILIZE DANGER !! ATTENTION !! OUTRIGGERS; AND LEVEL MACHINE. To prevent premature motor failure, it is imperative that the fiberglass cover be CFT/RFC B06-00-0139 kept in the closed position to protect B06-00-0139 against direct contact with any foreign particles and/or moisture.
  • Page 57 5 — REPLACEMENT DECALS Figure 5-1. Replacement Decals, Sheet 2 of 3...
  • Page 58 XLB-4725A ® bil -jax ® bil -jax ® ® EMERGENCY A Member of the plettac Group DOWN A Member of the plettac Group ROTATION UPPER LOWER BOOM BOOM UPPER LOWER BOOM BOOM DOWN DOWN PLATFORM GROUND POWER EMERGENCY STOP B06-00-0372...
  • Page 59 0036 Both Ends Both Booms 0036 0161B (Both Sides) (Both Sides) 0036 Both Ends/ Both Cylinders 0192 (Opposite Side) 0033 (Opposite Side) 0335 (Both Sides) 0321 0036 0372 (Opposite Side) 0380 0374 0173 0139 0145 (Both Sides) 0016 0167 0373 or 0375 0036 0036...

  • Page 60: Figure 5-3. Decal Locations, Power Compartments Exterior

    XLB-4725A Figure 5-3. Decal Locations, Power Compartments Exterior Figure 5-4. Decal Locations, Power Compartment Interior...

  • Page 61: Parts List

    6 6 6 6 Parts List...

  • Page 62: Upper Boom Parts List

    XLB-4725A UPPER BOOM PARTS LIST Refer to Table 6-1 for the upper boom parts list. Figure 6-1. Upper Boom...

  • Page 63: Table 6-1. Upper Boom Parts List

    6 — PARTS LIST Table 6-1. Upper Boom Parts List Item No. Part No. Description B14-00-0006 Boom, Upper B29-00-0005 Plate, Lift Pin Locking 0090-0208 Washer, Lock, Split, 5/16 in. 0090-0028 Screw, Cap, 5/16-18 x 3/4 in. B36-01-0022 Pin, Boom, Pivot B29-00-0118 Leveling Bar Knuckle 0090-0485...

  • Page 64: Lower Boom Parts List

    XLB-4725A LOWER BOOM PARTS LIST Refer to Table 6-2 for the lower boom parts list. Figure 6-2. Lower Boom...

  • Page 65: Table 6-2. Lower Boom Parts List

    6 — PARTS LIST Table 6-2. Lower Boom Parts List Item No. Part No. Description B14-00-0008 Boom, Lower B25-00-0023 Bearing, Bronze, 1.75 OD x 1.5 ID B34-00-0007 Trimlock, 1/4 in. 2 ft. 0090-0005 Screw, Cap, 1/4-20 x 3/4 in. B04-07-0034 Clamp, Cable/Hose, DG 12 0090-0183 Nut, Hex, Nylon Lock, 1/4-20...

  • Page 66: Upper Cylinder Parts List

    XLB-4725A UPPER CYLINDER PARTS LIST Refer to Table 6-3 for the upper cylinder parts list. Figure 6-3. Upper Cylinder...

  • Page 67: Table 6-3. Upper Cylinder Parts List

    6 — PARTS LIST Table 6-3. Upper Cylinder Parts List Item No. Part No. Description Rod, Cylinder B00-00-0061 Fitting, Grease, Straight B02-13-0103 Bearing, Spherical Wiper, Rod Headstock Bushing, Bronze Seal Ring, Backup O-Ring B00-00-0106 Fitting, Grease, 90° Cylinder Housing Nut, Slotted Ring, Wear Piston O-Ring...

  • Page 68: Lower Cylinder Parts List

    XLB-4725A LOWER CYLINDER PARTS LIST Refer to Table 6-4 for lower cylinder parts list. Figure 6-4. Lower Cylinder...

  • Page 69: Table 6-4. Lower Cylinder Parts List

    6 — PARTS LIST Table 6-4. Lower Cylinder Parts List Item No. Part No. Description Rod, Cylinder B00-00-0061 Fitting, Grease, Straight B02-13-0103 Bearing, Spherical Wiper, Rod Headstock Ring, Backup O-Ring B02-04-0064 Valve, Counterbalance Cylinder Housing Nut, Slotted Ring, Wear Piston O-Ring Seal Sleeve, Stop...

  • Page 70: Dc Model Battery Compartment Parts List

    XLB-4725A 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 36, 36A 15 31 Figure 6-5. DC Model Battery Compartment 6-10...

  • Page 71: Table 6-5. Dc Model Battery Compartment Parts List

    6 — PARTS LIST Table 6-5. DC Model Battery Compartment Parts List Item No. Part No. Description B18-00-0014 Lid, Compartment Cover B18-00-0135 Vent Louver, 2-1/2 in. B42-00-0006 Clip, Latch 0090-0225 Screw, Machine, #8-32 x 1/2 in. 0090-0181 Nut, Hex, Nylon Lock, #8-32 B18-00-0132 Frame, Compartment Cover 0090-0182...
  • Page 72 XLB-4725A 14 15 22, 22A 36, 36A 15 31 Figure 6-5. DC Model Battery Compartment 6-12...
  • Page 73 6 — PARTS LIST Table 6-5. DC Model Battery Compartment Parts List, Continued Item No. Part No. Description 0090-0814 Screw, Machine, #8-32 x 7/8 in. B30-00-0040 Spacer 0090-0042 Screw, Cap, 3/8-16 x 1 in. 0090-0005 Screw, Cap, 1/4-20 x 3/4 in. 0090-0409 Screw, Thumb, 3/8-16 x 3/4 in.

  • Page 74: Gas Model Engine Compartment Parts List

    XLB-4725A GAS MODEL ENGINE COMPARTMENT PARTS LIST Refer to Table 6-6 for the gas model boom lift engine compartment parts list. 18 17 22 21 3, 3A 29 36 Figure 6-6. Gas Model Engine Compartment 6-14...

  • Page 75: Table 6-6. Gas Model Engine Compartment Parts List

    6 — PARTS LIST Table 6-6. Gas Model Engine Compartment Parts List Item No. Part No. Description B18-00-0052 Lid, Compartment Cover B18-00-0129 Plate, Top, Engine Cover B01-04-0004 Battery, 12 Volt B01-04-0012 Battery, Dry Cell, 12 Volt B01-01-0110 Cable, Battery, 2 Ga. x 45 in. B29-00-0001 Strap, Battery Hold-Down B04-07-0003...
  • Page 76 XLB-4725A 18 17 22 21 3, 3A 29 36 Figure 6-6. Gas Model Engine Compartment 6-16...
  • Page 77 6 — PARTS LIST Table 6-6. Gas Model Engine Compartment Parts List, Continued Item No. Part No. Description 0090-0787 Washer, Fender 0090-0014 Screw, 1/4-20 x 2-1/2 B07-10-1026 Spacer, Isolation Mount Ring B20-00-0006 Ring, Isolation Mount B20-00-0013 Regulator/Rectifier, Voltage, 12 Volt, 18 Amp 0090-0183 Nut, Nylon Lock, 1/4 in.

  • Page 78: Dc Model Power Compartment Parts List

    XLB-4725A DC MODEL POWER COMPARTMENT PARTS LIST Refer to Table 6-7 for the DC model power compartment parts list. 13 12 33 34 61, 62 Figure 6-7. DC Model Power Compartment 6-18...

  • Page 79: Table 6-7. Dc Model Power Compartment Parts List

    6 — PARTS LIST Table 6-7. DC Model Power Compartment Parts List Item No. Part No. Description B18-00-0013 Lid, Compartment Cover B18-00-0135 Vent, Louver, 2-1/2 in. 0090-0232 Screw, Machine, #10-24 x 5/8 in. 0090-0684 Rivet, Pop, 3/16 x 1/2 in. B42-01-1002 Hinge 0090-0182...
  • Page 80 XLB-4725A 13 12 33 34 61, 62 Figure 6-7. DC Model Power Compartment 6-20...
  • Page 81 6 — PARTS LIST Table 6-7. DC Model Power Compartment Parts List, Continued Item No. Part No. Description B01-09-0001 Ring, Wire, 3/8 B05-01-0009 Wire, 16 Ga. 6 in. B02-04-0066 Manifold, Proportional Valve, 24 Volt 0090-0420 Washer, Flat, 5/16 in. 0090-0926 Screw, Cap, 5/16-18 x 4-1/2 in.

  • Page 82: Gas Model Power Compartment Parts List

    XLB-4725A 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 6-22...

  • Page 83: Table 6-8. Gas Model Power Compartment Parts List

    6 — PARTS LIST Table 6-8. Gas Model Power Compartment Parts List Item No. Part No. Description B18-00-0013 Lid, Compartment Cover B18-00-0135 Vent, Louver, 2-1/2 in. 0090-0232 Screw, Machine, #10-24 x 5/8 in. 0090-0684 Rivet, Pop, 3/16 x 1/2 in. B42-01-1002 Hinge 0090-0182...
  • Page 84 XLB-4725A Figure 6-8. Gas Model Power Compartment 6-24...
  • Page 85 6 — PARTS LIST Table 6-8. Gas Model Power Compartment Parts List, Continued Item No. Part No. Description 0090-0688 Screw, 1/4-20 x 1 in. 0090-0206 Washer, Lock, Split, 1/4 in. B34-00-0006 Trimlock, 1/8 in. 37 in. B18-00-0143 Cover, Side 0090-0814 Screw, Machine, #8-32 x 7/8 in.

  • Page 86: Frame And Rotation Unit List

    XLB-4725A 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 6-26...

  • Page 87: Table 6-9. Frame And Rotation Unit Parts List

    6 — PARTS LIST Table 6-9. Frame and Rotation Unit Parts List Item No. Part No. Description B11-03-0036 Turntable Weldment 0090-0710 Screw, Machine, #8-32 x 2-3/4 in. B18-00-0021 Cover, Level Housing 0090-0181 Nut, Hex, Nylon Lock, #8-32 B00-00-0001 Level, Bubble 0090-0643 Screw, Cap, 5/8-11 x 2-3/4 in.

  • Page 88: 6-10 Hitch And Jack Assembly Parts List

    XLB-4725A 6-10 HITCH AND JACK ASSEMBLY PARTS LIST Refer to Table 6-10 for the hitch and jack assembly parts list. 17 18 44, 45 4 36 22, 22A Figure 6-10. Hitch and Jack Assembly 6-28...

  • Page 89: Table 6-10. Hitch And Jack Assembly Parts List

    6 — PARTS LIST Table 6-10. Hitch and Jack Assembly Parts List Item No. Part No. Description B29-00-0119 Post, Support B30-00-0009 Pad, Rubber 0022-01-03 Brace, Guard Rail 0090-0192 Nut, Hex, Nylon Lock, 1/2-13 0090-0045 Screw, Cap, 3/8-16 x 1-1/2 in. 0090-0188 Nut, Hex, Nylon Lock, 3/8-16 0090-0344...
  • Page 90 XLB-4725A 17 18 44, 45 4 36 22, 22A Figure 6-10. Hitch and Jack Assembly 6-30...
  • Page 91 6 — PARTS LIST Table 6-10. Hitch and Jack Assembly Parts List, Continued Item No. Part No. Description 0090-0080 Screw, Cap, 1/2-13 x 4-1/2 in. 0090-0081 Screw, Cap, 1/2-13 x 5 in. 0090-0574 Washer, Flat, 1/2 in. B03-00-0017 Chain, Safety B01-01-0121 Harness, Tail Light B12-00-0013...

  • Page 92: Square Tube Axle And Wheel Assembly Parts List

    XLB-4725A 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. 13,13A, 14,14A 20 21 22 23 15, 15A, Figure 6-11. Square Tube Axle and Wheel Assembly...

  • Page 93: Table 6-11. Square Tube Axle And Wheel Assembly Parts List

    6 — PARTS LIST Table 6-11. Square Tube Axle and Wheel Assembly Parts List Item No. Part No. Description B10-00-0041 Axle, Square Tube 0090-0938 Nut, Hex, Lock, 5/8-18 0090-0612 Washer, Flat 5/8 in. 0090-0937 Screw, Cap, 5/8-18 x 1-1/2 in. 0090-0032 Screw, Cap, 5/16-18 x 1-1/2 in.

  • Page 94: Hex Tube Axle And Wheel Assembly Parts List

    XLB-4725A 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. 12, 12A 16 17 Figure 6-12. Hex Tube Axle and Wheel Assembly 6-34...

  • Page 95: Table 6-12. Hex Tube Axle And Wheel Assembly Parts List

    6 — PARTS LIST Table 6-12. Hex Tube Axle and Wheel Assembly Parts List Item No. Part No. Description Not Procurable Axle, Hex Tube 0090-0192 Nut, Lock, 1/2-13 0090-0574 Washer, Flat 1/2 in. 0090-0877 Screw, Cap, 1/2-13 x 8-1/2 0090-0032 Screw, Cap, 5/16-18 x 1-1/2 in.

  • Page 96: 6-13 Tail Lights And Junction Box Parts List

    XLB-4725A 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 6-36...

  • Page 97: Table 6-13. Tail Lights And Junction Box Parts List

    6 — PARTS LIST Table 6-13. Tail Lights and Junction Box Parts List Item No. Part No. Description B01-10-0024 Tail Light Assembly, Left B29-00-0037 Bracket, License Plate Mounting B01-10-0069 Lens, Replacement B04-07-0032 Clamp, Cable/Hose, DG 6 0090-0183 Nut, Hex, Nylon Lock, 1/4-20 0090-0182 Nut, Hex, Nylon Lock, #10-24 B01-09-0009...

  • Page 98: 6-14 Front Outriggers Parts List

    XLB-4725A 6-14 FRONT OUTRIGGERS PARTS LIST Refer to Table 6-14 for the front outriggers parts list. 19, 20 30 31 1, 2 Figure 6-14. Front Outriggers 6-38...

  • Page 99: Table 6-14. Front Outriggers Parts List

    6 — PARTS LIST Table 6-14. Front Outriggers Parts List Item No. Part No. Description B23-01-0088 Outrigger, Front, Passenger Side B23-01-0089 Outrigger, Front, Driver side B06-00-0167 Caution Tape, Black and Yellow 1 Roll B23-02-0048 Assembly, Outrigger Jack (includes items 5 through 11) B46-00-0028 Kit, Handle Replacement 0090-0183...

  • Page 100: 6-15 Rear Outrigger Parts List

    XLB-4725A 6-15 REAR OUTRIGGER PARTS LIST Refer to Table 6-15 for the rear outrigger parts list. 19, 20 30 31 1, 2 Figure 6-15. Rear Outrigger 6-40...

  • Page 101: Table 6-15. Rear Outrigger Parts List

    6 — PARTS LIST Table 6-15. Rear Outrigger Parts List Item No. Part No. Description B23-01-0090 Outrigger, Rear, Passenger Side B23-01-0091 Outrigger, Rear, Driver side B06-00-0167 Caution Tape, Black and Yellow 1 Roll B23-02-0048 Assembly, Outrigger Jack (includes items 5 through 11) B46-00-0028 Kit, Handle Replacement 0090-0183...

  • Page 102: 6-16 Basket Parts List

    XLB-4725A 6-16 BASKET PARTS LIST Refer to Table 6-16 for the basket parts list. 12, 13 17, 17A Figure 6-16. Basket 6-42...

  • Page 103: Table 6-16. Basket Parts List

    6 — PARTS LIST Table 6-16. Basket Parts List Item No. Part No. Description 0090-0344 Screw, Threadcutting, #10-24 x 1/2 in. B17-00-0102 Guard, Hand B01-03-0006 Switch, Limit B01-03-0008 Roller Lever, Limit Switch B01-03-0007 Head, Side Rotary, Limit Switch 0090-0238 Screw, Machine, #10-24 x 1 in. B01-03-0016 Head, Roller Plunger, Limit Switch B01-09-0029...
  • Page 104 XLB-4725A 12, 13 17, 17A Figure 6-16. Basket 6-44...
  • Page 105 6 — PARTS LIST Table 6-16. Basket Parts List, Continued Item No. Part No. Description B01-09-0088 Cable Housing, 9 Contact Plug B01-09-0085 Cable Housing, 4 Contact Plug B01-10-0046 Junction Box, 110 Vac Outlet B01-10-0034 Receptacle, 120 Vac, GFI B01-10-0035 Cover, GFI B17-00-0103 Cage Weldment B06-00-0167...

  • Page 106: 6-16A Basket Parts List, Early Model

    XLB-4725A 6-16A BASKET PARTS LIST, EARLY MODEL Refer to Table 6-16A for the early model basket parts list. 13, 14 18, 18A Figure 6-16A. Basket, Early Model 6-46...

  • Page 107: Table 6-16A. Basket Parts List, Early Model

    6 — PARTS LIST Table 6-16A. Basket Parts List, Early Model Item No. Part No. Description B44-00-0029 Platform, Basket 0090-0128 Bolt, Carriage, 5/16-18 x 1-1/4 in. B01-03-0006 Switch, Limit B01-03-0008 Roller Lever, Limit Switch B01-03-0007 Head, Side Rotary, Limit Switch 0090-0238 Screw, Machine, #10-24 x 1 in.
  • Page 108 XLB-4725A 13, 14 18, 18A Figure 6-16A. Basket, Early Model 6-48...
  • Page 109 6 — PARTS LIST Table 6-16A. Basket Parts List, Early Model, Continued Item No. Part No. Description B01-09-0088 Cable Housing, 9 Contact Plug B01-09-0085 Cable Housing, 4 Contact Plug B01-10-0046 Junction Box, 110 Vac Outlet B01-10-0034 Receptacle, 120 Vac, GFI B01-10-0035 Cover, GFI B17-00-0093...

  • Page 110: 6-17 Upper Control Box - External Parts List

    XLB-4725A 6-17 UPPER CONTROL BOX – EXTERNAL PARTS LIST Refer to Table 6-17 for the upper control box parts list. 1, 1A 2, 2A Figure 6-17. Upper Control Box (DC Model) – External Table 6-17. Upper Control Box – External Parts List Item No.

  • Page 111: 6-18 Upper Control Box - Internal Parts List

    6 — PARTS LIST 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.

  • Page 112: 6-19 Lower Control Box Parts List

    XLB-4725A 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) 6-52...

  • Page 113: Table 6-19. Lower Control Box Parts List

    6 — PARTS LIST Table 6-19. Lower Control Box Parts List Item No. Part No. Description B01-02-0066 Control Box, Lower (DC Model) (Not Illustrated) B01-02-0064 Control Box, Lower (Gas Model) B06-00-0373 Decal, Lower Control Box (DC Model) (Not Illustrated) B06-00-0375 Decal, Lower Control Box (Gas Model) B01-10-0181 Meter, Hour...

  • Page 114: 6-20 Proportional Valve Assembly Parts List

    XLB-4725A 6-20 PROPORTIONAL VALVE ASSEMBLY PARTS LIST Refer to Table 6-20 for the proportional valve assembly parts list. 6, 7 9, 7 14, 15, 16 1, 1A 8, 11, 12, 12A 6, 7 6, 7 Figure 6-20. Proportional Valve Assembly Table 6-20.

  • Page 115: 6-21 Surge Brakes Parts List

    6 — PARTS LIST 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 B12-00-0013 Surge Break Coupler Assembly B21-00-0001 Brake Line Kit (includes items 3 through 9) Brake Line, 3/16 x 17 in.

  • Page 116: 6-22 Dc Model Hydraulic System Parts List

    XLB-4725A 6-22 DC MODEL HYDRAULIC SYSTEM PARTS LIST Refer to Table 6-22 for the DC model boom lift hydraulic system parts list. 23, 24 FILTER RESERVOIR ASSEMBLY 6, 6A, 6B PUMP SLEW RING PUMP PORT LOWER LIFT CYLINDER CONTROL PORT...

  • Page 117: Table 6-22. Dc Model Hydraulic System Parts List

    6 — PARTS LIST Table 6-22. DC Model Hydraulic System Parts List Item No. Part No. Description B03-00-0103 Reservoir Assembly B02-15-0025 Cap, Breather B02-02-0096 Elbow, 90°, 6 JIC-8 NPT B02-02-0175 Adapter, 8 Bead, 12 NPT B02-02-0029 Fitting, 90° Elbow, 6 JIC-6 NPT B02-05-0021 Pump and Motor Assembly, Hydraulic B01-07-0004...

  • Page 118: 6-23 Gas Model Hydraulic System Parts List

    XLB-4725A 6-23 GAS MODEL HYDRAULIC SYSTEM PARTS LIST Refer to Table 6-23 for the gas model boom lift hydraulic system parts list. 28, 29 FILTER HYDRAULIC RESERVOIR PUMP SLEW RING PUMP PORT LOWER LIFT CYLINDER CONTROL PORT UPPER LIFT CYLINDER...

  • Page 119: Table 6-23. Gas Model Hydraulic System Parts List

    6 — PARTS LIST Table 6-23. Gas Model Hydraulic System Parts List Item No. Part No. Description B03-00-0103 Reservoir Assembly B02-15-0025 Cap, Breather B02-02-0065 Tee, 8 NPT-8 NPTFM-8 NPTFM B02-02-0035 Adapter, 6 JIC-8 NPTM B02-02-0062 Elbow, 90°, 8 NPT 90 B02-04-0061 Valve, Pressure Relief B02-02-0096...
  • Page 120 XLB-4725A 6-60...

  • Page 121: Ansi Reprint

    7 7 7 7 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.
  • Page 122 XLB-4725A 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).
  • Page 123 7 — ANSI REPRINT (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...
  • Page 124 XLB-4725A 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 125 7 — ANSI REPRINT 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.
  • Page 126 XLB-4725A 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 127: 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 (Phase to Phase) (Feet) (Meters) 0 to 300V Avoid Contact Over 300V to 50KV 3.05 Over 50KV to 200KV 4.60...
  • Page 128 XLB-4725A...
  • Page 130 125 Taylor Parkway Archbold, OH 43502 Phone (419) 445-9675 (800) 527-5333 (419) 445-0367...

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