BilJax 5031A Guía de inicio rápido

Parts and

Service Manual

AERIAL WORK PLATFORMS

5031A

Hydraulic Boom Lift

BIL- AX

B33-01-0092

BOOM PERSONNEL LIFT

This equipment is designed and manufactured in compliance with the duties,

responsibilities, 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

standards when used in accordance with sections 7, 8, 9 & 10 of ANSI A92.2 and all

other manufacturer’s recommendations.

It is the responsibility of the user of this equipment to follow all applicable ANSI,

OSHA, Federal, State, and local codes and regulations that govern the safe

operation of this equipment.

Table of Contents

PREFACE.................................................................................................iv

1Safety................................................................................................................1-1

1-1 Introduction.............................................................................................1-1

1-2 Before Operation.....................................................................................1-3

1-3 During Operation....................................................................................1-4

1-4 Maintenance Safety.................................................................................1-5

1-5 Damaged Equipment Policy....................................................................1-7

2Introduction.....................................................................................................2-1

2-1 General Description ................................................................................2-1

2-2 Specifications..........................................................................................2-4

2-3 Warranty .................................................................................................2-5

3Operation.........................................................................................................3-1

3-1 Operator Controls....................................................................................3-1

3-2 Normal Operating Procedure..................................................................3-7

3-3 Emergency Lowering..............................................................................3-9

3-4 Manual Boom Operations.....................................................................3-10

3-5 Manual Boom Rotation.........................................................................3-11

3-6 Battery Recharge (DC Model Only) .....................................................3-12

3-7 Boom Lift Transport .............................................................................3-14

4Operator Service.............................................................................................4-1

4-1 Scheduled Service Checks......................................................................4-1

4-2 Wheel Nut Torque Requirements............................................................4-3

4-3 Lubrication..............................................................................................4-4

4-4 Hydraulic System....................................................................................4-5

4-5 Slew Ring Bearing................................................................................4-16

4-6 Limit Switch checks and adjustments...................................................4-17

4-7 Troubleshooting....................................................................................4-19

4-8 Material Safety Data Sheets..................................................................4-26

5Replacement Decals ........................................................................................5-1

6Parts List..........................................................................................................6-1

6-1 Towing Assemblies.................................................................................6-2

6-2 Fender, Axle, and Wheel Assemblies.....................................................6-4

6-3 Turntable and Slew Components............................................................6-6

6-4 Outrigger Components............................................................................6-8

6-5 Lower Controls .....................................................................................6-10

6-6 Lower Control Box Components..........................................................6-12

6-7 Pump Compartment ..............................................................................6-14

6-8 Battery Compartment............................................................................6-16

6-9 Compartment Covers ............................................................................6-18

6-10 Lower Boom Components....................................................................6-20

6-11 Upper Boom Components....................................................................6-22

6-12 Telescopic Boom Components.............................................................6-24

6-13 Cable/Hose Track Components............................................................6-26

6-14 Jib Boom Components .........................................................................6-28

6-15 Platform Components...........................................................................6-30

6-16 Upper Controls.....................................................................................6-32

6-17 Hydraulic Pump Unit Components ......................................................6-34

6-18 Upper Control Panel Components........................................................6-36

7ANSI Reprint...................................................................................................7-1

List of Illustrations

Figure 2-1. Bil-Jax 5031A Hydraulic Boom Lift...................................................... 2-1

Figure 2-2. Platform and Ground Station Controls................................................... 2-2

Figure 2-3. Safe Operating Zone............................................................................... 2-3

Figure 3-1. Pump Compartment Access ................................................................... 3-1

Figure 3-2. Ground Station Controls......................................................................... 3-3

Figure 3-3. Pump Compartment................................................................................ 3-4

Figure 3-4. Engine Key Switch................................................................................. 3-4

Figure 3-5. Platform Control Station ........................................................................ 3-5

Figure 3-6. Outrigger Controls.................................................................................. 3-7

Figure 3-7. Emergency Descent (Lowering) Switches ............................................. 3-9

Figure 3-8. Emergency Lowering Valve................................................................. 3-10

Figure 3-9. Manual Pump Operation ...................................................................... 3-10

Figure 3-10. Slew Motor Bypass Valve.................................................................... 3-11

Figure 3-11. Battery Charger .................................................................................... 3-12

Figure 3-12. Trailer Hitching.................................................................................... 3-14

Figure 4-1. Wheel Nut Tightening Sequence............................................................ 4-3

Figure 4-2. Lubricate Monthly.................................................................................. 4-4

Figure 4-3. Lubricate Semi-Annually ....................................................................... 4-4

Figure 4-4. Hydraulic Reservoir ............................................................................... 4-5

Figure 4-5. Main Relief Valve and Pressure Test Port (Gas Engine Model)........... 4-7

Figure 4-6. Outriggers Relief Valve.......................................................................... 4-8

Figure 4-7. Boom Control Relief Valve, Platform Station........................................ 4-9

Figure 4-8. Hydraulic Cylinder Removal................................................................ 4-11

Figure 4-9. Jib Boom Components ......................................................................... 4-14

Figure 4-10. Platform Rotation Cylinder .................................................................. 4-15

Figure 4-11. Slew Ring Position Measurement ........................................................ 4-16

Figure 4-12. Boom Down Limit Switch.................................................................... 4-17

Figure 4-13. Outrigger Position Switch.................................................................... 4-18

Figure 4-14. Simplified Electrical Diagram, DC Model........................................... 4-21

Figure 4-15. Detailed Electrical Diagram, DC Model .............................................. 4-22

Figure 4-16. Hydraulic Diagram, Sheet 1 of 2.......................................................... 4-23

Figure 4-17. Level Sensor......................................................................................... 4-25

Figure 5-1. Replacement Decals, Sheet 1 of 4.......................................................... 5-2

Figure 5-2. Decal Locations, Trailer and Boom........................................................ 5-6

Figure 5-3. Decal Locations, Platform...................................................................... 5-7

Figure 5-4. Lubricate Monthly Decal........................................................................ 5-7

Figure 5-5. Lubricate Semi-Annually Decal............................................................. 5-7

Figure 6-1. Towing Assemblies................................................................................ 6-2

Figure 6-2. Fender, Axle, and Wheel Assemblies .................................................... 6-4

Figure 6-3. Turntable and Slew Components ........................................................... 6-6

Figure 6-4. Outrigger Components........................................................................... 6-8

Figure 6-5. Lower Controls..................................................................................... 6-10

Figure 6-6. Lower Control Box Components, Sheet 1 of 2 .................................... 6-12

Figure 6-7. Pump Compartment.............................................................................. 6-14

Figure 6-8. Battery Compartment ........................................................................... 6-16

Figure 6-9. Compartment Covers............................................................................ 6-18

Figure 6-10. Lower Boom Components.................................................................... 6-20

Figure 6-11. Upper Boom Components.................................................................... 6-22

Figure 6-12. Telescopic Boom Components............................................................. 6-24

Figure 6-13. Cable/Hose Track Components............................................................ 6-26

Figure 6-14. Jib Boom Components ......................................................................... 6-28

Figure 6-15. Platform Components........................................................................... 6-30

Figure 6-16. Upper Controls..................................................................................... 6-32

Figure 6-17. Hydraulic Pump Unit Components ...................................................... 6-34

Figure 6-18. Upper Control Panel Components........................................................ 6-36

iii

List of Tables

Table 1-1. Minimum Safe Approach Distances.........................................................1-4

Table 2-1. Specifications...........................................................................................2-4

Table 3-1. Charger Fault Codes...............................................................................3-13

Table 4-1. Daily/Weekly Service Checks..................................................................4-1

Table 4-2. Monthly Service Checks ..........................................................................4-2

Table 4-3. Troubleshooting Chart ...........................................................................4-19

Table 4-4. Level Sensor LEDs ................................................................................4-25

Table 5-1. Replacement Decals.................................................................................5-1

Table 6-1. Towing Assemblies Parts List..................................................................6-3

Table 6-2. Fender, Axle, and Wheel Assemblies Parts List ......................................6-5

Table 6-3. Turntable and Slew Components Parts List.............................................6-7

Table 6-4. Outrigger Components Parts List.............................................................6-9

Table 6-5. Lower Controls Parts List ......................................................................6-11

Table 6-6. Lower Control Box Parts List ................................................................6-13

Table 6-7. Pump Compartment Parts List ...............................................................6-15

Table 6-8. Battery Compartment Parts List.............................................................6-17

Table 6-9. Compartment Covers Parts List .............................................................6-19

Table 6-10. Lower Boom Parts List ..........................................................................6-21

Table 6-11. Upper Boom Parts List...........................................................................6-23

Table 6-12. Telescopic Boom Parts List....................................................................6-25

Table 6-13. Cable/Hose Track Parts List...................................................................6-27

Table 6-14. Jib Boom Parts List................................................................................6-29

Table 6-15. Platform Parts List..................................................................................6-31

Table 6-16. Upper Controls Parts List.......................................................................6-33

Table 6-17. Hydraulic Pump Unit Parts List .............................................................6-35

Table 6-18. Upper Control Panel Parts List ..............................................................6-36

Table 6-19. Hydraulic Hose Listing ..........................................................................6-37

Table 7-1. Minimum Safe Approach Distance (M.S.A.D.) to energized

(exposed or insulated) power lines and parts. ........................................7-11

PREFACE

The purpose of this manual is to provide a thorough understanding of the

Bil-Jax 5031A Hydraulic Boom Lift operation and maintenance procedures.

Read the safety, operating and maintenance instructions in this manual and

become familiar with the location and use of all controls.

Follow all warnings, cautions, and instructions in this manual and any

attached to and supplied with the boom lift. All OSHA, ANSI, state, and

local codes and regulations concerning this equipment should be obtained,

read, and thoroughly understood before attempting to operate or service this

equipment.

To ensure proper and safe use of this equipment, only trained and qualified

personnel should operate and maintain the boom lift.

1-1

Safety

1-1

ned

ety

al.

implemented at all

considered as legal advice and is intended

For any questions concerning the safe use of this equipment, call 800-537-0540 before

operating.

INTRODUCTION

Familiarity and proper training are required for the safe operation and maintenance of

mechanical equipment. Equipment operated or serviced improperly or by untrai

personnel can be dangerous. Read the operating and maintenance instructions in this

manual and become familiar with the location and proper use of all controls.

Inexperienced operators should receive instruction from someone familiar with the

equipment before being allowed to operate the machine. The use of intelligence and

common sense in the operation of mechanical equipment is the best practice in any saf

policy. Be professional and always observe the safety procedures set forth in this manu

All OSHA, ANSI, state, and local codes and regulations pertaining to this equipment

should be obtained, read, and thoroughly understood before attempting to operate this

equipment. Persons under the influence of drugs, alcohol, or prescription medication

should not be on or near this equipment. Common sense should be

times during the use of this equipment. Do not operate this equipment in areas where the

equipment or user may come in contact with a live power source.

The information contained herein is not to be

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.

BIL-JAX 5031A

1-2

SAFETY NOTES

This manual contains DANGERS, WARNINGS, CAUTIONS, and NOTES that

must be followed to prevent the possibility of improper service, personnel injury

or death, and damage to equipment.

DANGER

Dangers warn of equipment operation near electrical power lines that could

lead to personal injury or death.

WARNING

Warnings describe conditions or practices that could lead to personal injury

or death.

CAUTION

Cautions provide information important to prevent errors that could damage

machine or components.

NOTE: Notes contain additional information important to a procedure.

1 — SAFETY

1-3

1-2 BEFORE OPERATION

Ensure the following general safety precautions are followed before operating the

Bil-Jax 5031A Hydraulic 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. Be aware of any potential hazards and always consider

what could happen. Watch for moving vehicles in the operating area.

• ALWAYS read, understand, and follow the procedures in this manual before

attempting to operate equipment.

• ALWAYS inspect the equipment for damaged or worn parts. Check for cracked

welds, hydraulic leaks, damaged wiring, loose wire connectors, damaged

outriggers, low tire pressure, uneven tire wear, or tire damage. Also check for

any improper operation. NEVER operate equipment if damaged in any way.

Improperly operating equipment must be repaired before using.

• ALWAYS wear proper clothing for the job. Wear protective equipment as

required by federal, state, or local regulations. The operator MUST wear a

safety harness and lanyard.

• ALWAYS locate, read, and follow all directions and warnings displayed on the

equipment.

• ALWAYS inspect the equipment for “DO NOT USE” tags. NEVER use

equipment tagged in this way until all repairs are made and all “DO NOT USE”

tags are removed by authorized maintenance personnel.

• ALWAYS make sure the platform and outrigger pads are free of mud, grease, or

other slippery material to reduce the possibility of slipping.

• NEVER allow improperly trained personnel to operate this equipment. Only

trained and authorized personnel shall be allowed to operate this equipment.

• NEVER operate this equipment if you are under the influence of alcohol or

drugs, or if you feel ill, dizzy, or unsteady in any way. Operators must be

physically fit, thoroughly trained, and not easily excitable.

• NEVER modify, alter, or change the equipment in any way that would affect its

original design or operation in any way.

• NEVER operate this equipment in ways for which it is not intended.

BIL-JAX 5031A

1-4

1-3 DURING OPERATION

Ensure the following general safety precautions are followed during the operation of the

Bil-Jax 5031A 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. Operator must maintain safe clearances at all times (10 feet

minimum) and always allow for platform movement such as wind induced sway.

Always contact the power company before performing work near power lines.

Assume every line is hot. Remember, power lines can be blown by the wind.

Refer to Table 1-1 for minimum safe approach distances between machine and electrical

power lines.

Table 1-1. Minimum Safe Approach Distances

Minimum Safe Approach Distance

Voltage Range

(Phase to Phase) (Feet) (Meters)

0 to 300V Avoid Contact

Over 300V to 50KV 10 3.05

Over 50KV to 200KV 15 4.60

Over 200KV to 350KV 20 6.10

Over 350KV to 500KV 25 7.62

Over 500KV to 750KV 35 10.67

Over 750KV to 1000KV 45 13.72

• ALWAYS position lift far enough away from power sources to ensure that no

part of the lift can accidentally reach into an unsafe area. This includes full

extension of the boom through 360 degrees rotation.

• ALWAYS operate only on a firm and level surface. NEVER use on surfaces

that do not support the equipment with its rated load capacity and the resulting

force exerted on the outriggers during boom extension and rotation.

• ALWAYS keep yourself and all personnel away from potential pinch or shear

points.

• ALWAYS report any misuse of equipment to the proper authorities. Horseplay

is prohibited.

• ALWAYS maintain good footing on the work platform. NEVER wear slippery

soled shoes.

• ALWAYS make certain all personnel are clear and there are no obstructions

before repositioning platform.

• ALWAYS cordon off area around the outriggers to keep personnel and other

equipment away from it while in use.

• ALWAYS stay clear of wires, cables, and other overhead obstructions.

• ALWAYS engage the boom travel locking pins before towing the trailer.

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