TABLE OF CONTENTS Table of Contents Illustrations Tables 1 Safety Legend: Safety Advisories Before Operation During Operation Maintenance Safety Damaged Equipment Policy 2 Specifications Range of Motion Specifications Warranty 3 Equipment Maintenance Daily Service Checks Weekly Service Checks Monthly Service Checks Annual Service Checks Structural Inspection Additional Service Information...
SAFETY Proper training is required for the safe operation of any mechanical device. Failure to follow all instructions and safety precautions in this manual and attached to the lift will result in death or personal injury. Prior to Operation: Read, understand and obey all instructions and safety precautions in this manual and attached to the lift.
BIL-JAX 36XT LEGEND: SAFETY ADVISORIES The following safety advisories are used throughout this manual to indicate specific hazards when operating or maintaining the machine. Read, understand and obey all safety advisories to prevent improper service, damage to equipment, personal injury or death.
ALWAYS wear a safety harness and energy- absorbing lanyard, such as a safety harness and Minimum Safe Approach Distance Voltage Range lanyard provided by Bil-Jax. (Feet) (Meters) (Phase to Phase) ALWAYS inspect platform floor and outrigger...
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NEVER exceed the load limits set by the including wires and cables. manufacturer. Use only the Material Lifting Hook, supplied as an option and manufactured by Bil-Jax, ALWAYS engage boom travel latches before towing when lifting materials. Safely stow all tools and trailer.
BIL-JAX 36XT DAMAGED EQUIPMENT POLICY Safety Statement At Bil-Jax, we are dedicated to the safety of all users of our products. All Bil-Jax lifts are designed, manufactured and tested to comply with current applicable federal OSHA and ANSI codes and regulations.
SPECIFICATIONS Bil-Jax, Inc. is dedicated to the continuous improvement of this and all Bil-Jax products. Therefore, equipment information 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.
2 — SPECIFICATIONS SPECIFICATIONS SERIAL NUMBER____________________________ Working Height 43 ft 6 in Outrigger Footprint 13.4 m Length 12 ft 2 in 3.7 m Maximum Platform Height 37 ft 6 in Width 11 ft 4 in 11.4 m 3.4 m Maximum Horizontal Outreach Footpad Diameter 12.5 in From Centerline...
A list of those components and their warranties is available upon written request to Bil-Jax. Bil-Jax shall not in any event be liable for the cost of any special, indirect, or consequential damages to any person, product, or thing. Bil-Jax’s maximum liability under this warranty is limited to the amount paid to Bil-Jax for the product.
It is the practice of Bil-Jax, Inc. to issue Service and/or Safety Bulletins, which may include updates to the information contained in this manual. In such instances, procedures contained in Bil-Jax Service Bulletins or Safety Bulletins supersede the information contained in manuals.
BIL-JAX 36XT DAILY SERVICE CHECKS The following maintenance procedures should be Verify that boom down limit switches operate performed daily or before each operation. correctly. Verify that all decals are correctly applied and in Down limit switches are actuated when the boom is in a fully lowered, stowed position.
3 — EQUIPMENT MAINTENANCE Inspect hydraulic system and fluid levels. Check all hydraulic hoses and fittings for leaks and damage. Tighten or replace as necessary to prevent hydraulic oil or pressure loss. The hydraulic oil level should be checked with the booms down, all outriggers raised and the trailer wheels on a level surface.
BIL-JAX 36XT WEEKLY SERVICE CHECKS Perform the following service checks at least once each week in addition to all recommended Daily Service Checks: Check Battery electrolyte level. If electrolyte level is low, add enough water to bring the electrolyte level to the top of the plates.
3 — EQUIPMENT MAINTENANCE MONTHLY SERVICE CHECKS Perform the following service checks at least once each month: Clean all battery terminals. Check battery for loose connections or damaged wires. Verify proper operation of manual lowering valves and hand pump Refer to Section 3 for manual boom operating procedures.
BIL-JAX 36XT ANNUAL SERVICE CHECKS Perform the following service checks at least once Check slew bearing for wear or damage. each year: Check bolts for wear or damage. Replace Hydraulic Oil and Oil Filter. With the boom lift fully retracted, measure the distance between the slew ring gear and the Drain hydraulic reservoir, clean and replace oil.
3 — EQUIPMENT MAINTENANCE STRUCTURAL INSPECTION ADDITIONAL SERVICE INFORMATION A comprehensive structural inspection of the unit shall be performed under any of the following Seals on hydraulic cylinders should be replaced every five conditions. years or as indicated by machine performance. Ten years from the date of manufacture and every All service checks should be performed on a machine that five years thereafter.
BIL-JAX 36XT TROUBLESHOOTING Refer to Table 3-2 for basic troubleshooting operations. Additional information can be found in the Bil-Jax Model 45XA Operator’s Manual. Contact the Bil-Jax Service Department with any questions or before attempting any advanced troubleshooting operations. Table 3-1. Troubleshooting Steps...
3 — EQUIPMENT MAINTENANCE ERROR CODE DEFINITIONS The DISPLAY PANEL located on the ground control panel indicates the present operating status of the boom lift. If an error condition is detected by the control processor during start-up or operation, the appropriate error code will be displayed on this panel.
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BIL-JAX 36XT ERROR MESSAGE DEFINITION OF ERROR COMMENTS 031 OPEN CIRCUIT JIB DOWN A load of less than 70mA detected when jib down Check for faulty jib down solenoid circuit was energized coil and wiring. 032 SHORTED CIRCUIT JIB Excessive load detected when jib down circuit...
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3 — EQUIPMENT MAINTENANCE ERROR MESSAGE DEFINITION OF ERROR COMMENTS 056 SHORTED CIRCUIT Excessive load detected in right front outrigger Check for faulty solenoid RF OUTRIGGER circuit on power-up. coil/wiring at outrigger. 057 OPEN CIRCUIT A load of less than 70mA detected in left rear Check for faulty solenoid LR OUTRIGGER outrigger circuit on power-up.
Perform all maintenance procedures only in an area that is well-lit and well-ventilated. Bil-Jax, Inc. is not responsible for personal injury or property damage resulting from the improper use of equipment or failure to follow all procedures and related safety precautions.
BIL-JAX 36XT LIFT CYLINDER REPLACEMENT Use the following procedure to remove and replace hoses to prevent leakage. Plug or cap exposed hose fittings and cylinder ports. faulty or damaged hydraulic cylinders on the boom lift: At the base of the cylinder, unbolt and remove retainer plate from each side of the pivot pin.
4 — CYLINDER REPLACEMENT OUTRIGGER CYLINDER REPLACEMENT Unplug the cylinder valve solenoid. Use the following procedure to remove and replace faulty or damaged hydraulic cylinders on the Place absorbent cloths below the cylinder ports and outriggers: detach hydraulic hoses from the cylinder. Elevate hoses to prevent leakage.
REPLACEMENT DECALS Decals contain information that is required for the 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.
B06-00-0062 NOTICE: AC Power B06-00-0503 NOTICE: Handle Applications B06-00-0068 NOTICE: Hydraulic System Oil B06-00-0504 NOTICE: Emergency Hand Pump B06-00-0161B Bil-Jax Logo, Black Transfer DANGER: Before Use/Main B06-00-0505 B06-00-0404 WARNING: Outrigger Crush Toe Instruction/Hazards (ground) B06-00-0405 WARNING: Pinch Point B06-00-0506 NOTICE: Emergency Lowering...
MATERIAL SAFETY DATA The following Material Safety Data Sheets describe the correct procedures for the safe handling of chemical components within the Model 45XA Articulating Boom Lift, as well as any potential health and safety hazards related to these chemicals. Material Safety Data Sheets are included here in accordance with applicable federal and state regulations.
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BIL-JAX 36XT MATERIAL SAFETY DATA SHEET FOR LEAD ACID BATTERIES, WET, FILLED WITH ACID (Continued) SECTION V -- HEALTH HAZARD DATA Primary Routes of Entry: Inhalation: YES Skin: Ingestion: Health Hazards: Acute EYES, SKIN, RESPIRATORY SYSTEM & DIGESTIVE SYSTEM Chronic: EYES, SKIN, RESPIRATORY SYSTEM &...
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6 – MATERIAL SAFETY DATA MATERIAL SAFETY DATA SHEET DEXRON III/MERCON AUTOMATIC TRANSMISSION FLUID (HYDRAULIC OIL) SECTION I -- GENERAL INFORMATION TRADE NAME: CITGO TRANSGARD™ ATF, DEXRON III/MERCON EMERGENCY TELEPHONE NUMBERS: 918.495.4700 (medical); 800.424.9300 (chemical) CHEMICAL FAMILY: AUTOMATIC TRANSMISSION FLUID, LUBRICATING OIL CAS NUMBER: MIXTURE.
REPLACEMENT PARTS APPENDIX: Use only parts manufactured and/or authorized by Bil-Jax, Inc. when replacing damaged components. See page 89 for replacement part ordering information. Only personnel properly trained and authorized to operate all equipment and familiar with all boom functions should attempt to repair or replace any part of the boom lift.
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Assembly Description Page Outrigger Engine Front Rest Front Axle Rear Axle Slew Ring Counterweight Control Compartment Pump Compartment Battery Compartment Cover Boom Cable Track Boom Nose Platform Hydraulic Pump...
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ENGINE ASSEMBLY (I) PARTS LIST Item No. Part No. Description Qty. A-01063 Cover Front 0096-0014 Cap Screw, M10 x 20 0096-0041 Hex Nut, Self-Locking, M10 A-01064 Cover Top A-01067 Cover Side – Left A-01069 Cover Side – Right 0096-0001 Cap Screw, M6 x 16 0096-0039 Hex Nut, Self-Locking, M6 B42-01-1006...
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ENGINE ASSEMBLY (II) PARTS LIST Item No. Part No. Description Qty. A-01046 Engine 21HP (See Manufacturer’s Literature) 0096-0098 Cap Screw, M8 x 35 0096-0040 Hex Nut, Self-Locking, M8 A-01048 Pump – Dual – 4.5 GPM A-01055 Dual Pump Mount 0096-0110 Cap Screw, M10 x 110 0096-0093 Washer, M10...
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FRONT REST ASSEMBLY PARTS LIST Item No. Part No. Description Qty. A-03145 Front Rest Weldment 0096-0024 Cap Screw, M12 x 100 0096-0042 Hex Nut, Self-Locking, M12 A-00157 Front Rest Pad 0096-0017 Cap Screw, M10 x 30 0096-0041 Hex Nut, Self-Locking, M10 A-00159 Boom Latch 0096-0016...
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FRONT AXLE ASSEMBLY PARTS LIST Item No. Part No. Description Qty. A-01010 Front Axle Weldment – 4WD A-01097 Bushing, 1.5” OD x 1.25” ID A-01020 Front Yoke – Left A-01021 Front Yoke – Right A-01070 Pin – 1.25” x 1.625” A-00019 Pin Retainer –...
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SLEW RING ASSEMBLY PARTS LIST Item No. Part No. Description Qty. A-02189 Slew Assembly and Adapter Slew Ring Slew Ring Drive A-00149 Base Ring Adapter 0090-0461 Cap Screw, 1/2-13 x 2 0090-0212 Lock Washer, 1/2 0096-0033 Flat Head Cap Screw, M16 x 35 0096-0054 Flat Head Cap Screw, M16 x 50 0090-0643...
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COUNTERWEIGHT ASSEMBLY PARTS LIST Item No. Part No. Description Qty. A-00270 Counterweight 0096-0065 Cap Screw, M20 x 80 0096-0045 Hex Nut, Self-Locking, M20...
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CONTROL COMPARTMENT ASSEMBLY 17 18 19 20...
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CONTROL COMPARTMENT ASSEMBLY PARTS LIST Item No. Part No. Description Qty. A-00712 Lower Control Box A-00233 Lower Control Mount A-00290 Cover Stop Bracket 0096-0016 Cap Screw, M10 x 25 0096-0041 Hex Nut, Self-Locking, M10 A-00295 Level Sensor 0096-0002 Cap Screw, M6 x 20 0096-0039 Hex Nut, Self-Locking, M6 A-00287...
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PUMP COMPARTMENT PARTS LIST Item No. Part No. Description Qty. A-00268 Tire Iron/Jack Handle B04-07-0033 Clamp 0096-0001 Cap Screw, M6 x 16 0096-0039 Hex Nut, Self-Locking, M6 A-00290 Cover Stop Bracket 0096-0002 Cap Screw, M6 x 20 0096-0014 Cap Screw, M10 x 20...
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COVER ASSEMBLY PARTS LIST Item No. Part No. Description Qty. A-03240 Cover – Left A-03239 Cover – Right A-00228 Cover Brace A-00252 Hinge 0096-0002 Cap Screw, M6 x 20 0096-0039 Hex Nut, Self-Locking, M6 0090-1080 Pop Rivet A-00258 Controls Cover – Left Side B42-01-1002 Hinge, Controls Cover A-00292...
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BOOM NOSE ASSEMBLY PARTS LIST Item No. Part No. Description Qty. A-00979 Bulkhead Mount 0096-0016 Cap Screw, M10 x 25 A-00601 Platform Pivot Weldment A-00025 Pin, 1.0 x 6.5 A-00018 Pin Retainer – 1.0 0096-0041 Hex Nut, Self-Locking, M10 0096-0015 Socket Head Cap Screw, M10 x 20 A-00033 Bearing...
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WIRE HARNESSES Upper Control Platform Plug Motor Motor Cntl Cntl P4 & P5 Platform Connector Connector Turntable Connector Analog Connector Lift/Engine Connector Prop Coil Strobe Valve Level Prim Sensor Boom Boom Motor Motor Pump Controller Controller Main Speed Enable Speed Enable Press Switch...
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MANIFOLD WIRE HARNESS (A-00785) Deutsch Term. 0462-201-16141 Deutsch Orange DT06-2S Wires Label Wires 2 Pin Plug White W2S Wedge Connected Both Ends Wire Color & Sealed Green Orange 12020786 Blue 6 Pin Male Conn White 1208089040 Green White/B Male Term 12015323 9"...
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CHOKE /THROTTLE SOLENOID WIRE HARNESS (A-01042) 1" A-01042 Label Rev- Put Wires Weather Pack FM Term in 16" 12089188 Split Cable Seal tubing 12015323 FM Housing Heat Seal 12015792 Both ends 20" 18ga TXL Or Equivalent ENGINE RELAYS WIRE HARNESS (A-01044) Solder inline &...
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ATC FUSE HOLDER (A-01049) ATC Fuse Holder Waytek # 46278 or Equivalent 5/16" Ring ¼” Female Spade Ins Term 4"- 6" Leads 4"- 6" Leads 12 ga Wire 12 ga Wire START/STOP/RUN WIRE HARNESS (A-01098) 2" A-01098 Label Rev - Split Tube Wrap 10"...
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GENERATOR SWITCHER BOX ASSEMBLY (A-03040) Box-A-01015 B01-06-0056 B01-01-0180 30 Amp Relay B01-10-0354 DPST – NO 20 Amp Circuit Breaker Allied Electronics W/.250 Male Spade Terminal #850-0345 Allied Electronics Or Equivilant #886-0036 Or Equivilant Ground Stud B W G B W G Cord Grip Heyco #3231 Or Equivilant...
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IEC CORD MALE – US MARKETS (A-03042) 18" A-03042 SO cable or Label Equivalent North America Minimum Requirements 120V Male Plug IEC 90 Degree Plug Current 15 AMP Interpower IEC 60320 C19 Voltage 120/240VAC Mold 012 GENERATOR 110V WIRE HARNESS (A-03043) 12-3 SO Or Equivilant .0625"...
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SWITCHER BOX ASSEMBLY – CE MODELS (A-03040CE) Box-A-01015 B01-01-0180 B01-06-0056 30 Amp Relay DPST – NO B01-10-0354 Allied Electronics 20 Amp Circuit Breaker W/.250 Male Spade Terminal #850-0345 Allied Electronics Or Equivilant #886-0036 Or Equivilant B W G G W B Cord Grip Heyco #3231 Or Equivilant...
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ANALOG HARNESS (A-00715) 770680 Label Individual A-00715 Wire Labels AMP 770520-1 1" Pump Speed Signal ¼” FM Spade Insulated 3' (36") 18 ga Green Motor Cntrl Enab ¼” FM Spade Insulated 15" Loom 3' (36") 18 ga Yellow Ground Weather Pack Housing 12010973 2 Pin Housing 12"...
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PLATFORM-GROUND COMMUNICATION CABLE (A-00714)
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MATERIAL LIFT HOOK ASSEMBLY (OPTION A-00846)
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MATERIAL LIFT HOOK PARTS LIST Item No. Part No. Description Qty. A-00977 Platform Mount Weldment – LS A-00982 Load Sense Weldment 0096-0055 Cap Screw, M12 x 190 0096-0042 Hex Nut, Self-Locking, M12 A-00988-1 Load Cell 0096-0089 Cap Screw, M12 x 65 A-00990A Load Sense Spacer A A-00990B...
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BATTERY LAYOUT Motor 0-5V Enable Controller Drive 200 AMP Fuse Motor Pump Contactor 24VDC 100AMP B01-06-0058 200 AMP Fuse B+ M- Enable 0-5V Main Pump Motor Contactor 24VDC 100AMP B01-06-0058 Item No. Kit No. A-00272 30” Red, 2 Gauge, 5/16 Ring – Lug 45”...
ORDERING REPLACEMENT PARTS To order replacement parts, contact the Bil-Jax Service Department by phone at 800-537-0540, by fax at 419-446-8202 or by email at techsupport@biljax.com. For swift service, always have the part number available, as well as the equipment model and serial number. When ordering parts by fax or email, always provide the above information.
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