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OPERATOR’S

MANUAL

45XA

BOOM
AERIAL WORK PLATFORMS
TM
SELF-PROPELLED
AERIAL WORK PLATFORM
This equipment is designed and manufactured in
compliance with the duties, responsibilities and
standards set forth in the ANSI, CE, CSA and/or AS
standards in effect at the time of manufacture.
This equipment will meet or exceed applicable ANSI,
CE, CSA and/or AS codes and standards when
operated in accordance with manufacturer’s
recommendations.
It is the responsibility of the user to follow all regional
codes and regulations that govern the safe operation of
this equipment.
Obtain, read and obey all safety precautions before
performing maintenance or repairs or attempting to
operate this equipment. This includes all manufacturer
recommendations as well as those directives set forth by
government and local authorities.
To ensure proper and safe use of this equipment, it is
strongly recommended that only trained and authorized
personnel attempt to operate and maintain the boom lift.
This manual shall be considered a permanent and
necessary component of the machine and shall be kept
with the boom lift at all times.
Owners and Lessors should complete a full inspection of
all components and perform a test of all functions,
including brake functions, before commissioning or
reselling the machine. Repair or replace all damaged or
malfunctioning components.

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. Direct
any questions or concerns regarding errors or
discrepancies in this manual to the Bil-Jax Service
Department.
Copyright © Bil-Jax, Inc. 2007. All Rights Reserved.

“Bil-Jax” is a registered trademark and “A Step Above”


and “X-Boom” are trademarks of Bil-Jax, Inc. Contact
Bil-Jax for replacement manuals.

125 Taylor Parkway


Archbold, Ohio 43502
Phone (800) 537-0540
(419) 445-8915
Fax (419) 445-0367

P/N B33-01-0104 http://www.biljax.com


TABLE OF CONTENTS
Table of Contents 1
Illustrations 2
Tables 2

1 Safety 3
Legend: Safety Advisories 4
Before Operation 5
During Operation 5
Maintenance Safety 7
Damaged Equipment Policy 8

2 Before Operation 9
Daily Service Checks 10
Weekly Service Checks 12
Monthly Service Checks 12
Workplace Inspection 13

3 Operation 15
Ground Control Station 16
Platform Control Station 18
Platform Controls Joystick 20
Operation: Set Up 21
Operation: Ground Controls 22
Operation: Platform Controls 23
Operation: Drive Functions 23
Manual Boom Operation 24
Battery Recharge 26
Boom Lift Transport 27

4 Troubleshooting 29
Troubleshooting 30
Error Code Definitions 31

5 Replacement Decals 35

6 Specifications 41

7 Equipment Options 45
Material Lifting Hook 46
Platform Rotator 47

1
LIST OF ILLUSTRATIONS
Figure 2-1 Outrigger Position Switches 9
Figure 2-2 Hydraulic Reservoir 10
Figure 2-3 Wheel Nut Tightening Sequence 10
Figure 3-1 Ground Control Panel 16
Figure 3-2 Platform Control Panel 18
Figure 3-3 Platform Controls Joystick 20
Figure 3-4 Outrigger Controls 21
Figure 3-5 Boom Travel Latch 21
Figure 3-6 Hand Pump and Controls for Manual Operation 24
Figure 3-7 Manual Lowering Valve 25
Figure 3-8 Battery Charger Faceplate 26
Figure 3-9 Boom Lift and Transport Instructions 27
Figure 5-1 Decal Placements 37
Figure 5-2 Decal Placements – CE 39
Figure 6-1 Range of Motion 43
Figure 7-1 Material Lifting Hook Configuration 46
Figure 7-2 Material Lifting Hook Installation 46
Figure 7-3 Manual Platform Rotator 47

LIST OF TABLES
Table 1-1 Minimum Safe Approach Distances 4
Table 3-1 Charger Fault Codes 26
Table 4-1 Troubleshooting Steps 30
Table 4-2 Error Code Definitions 31
Table 5-1 Decal Descriptions 36
Table 5-2 Decal Descriptions – CE 38

2
1 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.
Read, understand and obey all applicable government regulations.
Become familiar with the proper use of all controls.
Inexperienced users should receive instruction before attempting to
operate or maintain the machine.

The use of intelligence and common sense is the best practice when
following any safety policy.

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BIL-JAX 45XA

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.

DANGER
Warns of operation near electrical power
sources that could lead to personal injury or
death.

WARNING
Describes conditions or practices that could lead
to personal injury or death.

CAUTION
Contains information important in the prevention
of errors that could damage machine or
components.

NOTE: Contains additional information


important for performing a procedure.

4
1 – SAFETY

BEFORE OPERATION DURING OPERATION


Ensure the following general safety precautions are Ensure the following general safety precautions are
followed before operating the Aerial Work Platform: followed while operating the Aerial Work Platform:
ALWAYS inspect the usage area for potential ALWAYS position lift away from power lines to
hazards, such as unstable or unlevel surfaces, ensure that no part of the lift can accidentally reach
overhead obstructions and electrically charged wires into an unsafe area. This includes full extension of
or conductors. ALWAYS watch for moving vehicles the boom through 700º rotation.
in the operating area.
ALWAYS conduct a thorough inspection of the DANGER
machine before operation. Check for damaged or This machine is NOT insulated for use near
worn parts, hydraulic leaks, damaged wiring, loose electrical power lines and DOES NOT provide
wiring conductors, damaged outriggers, low tire protection from contact with or close proximity
pressure, uneven tire wear or tire damage. Check for to any electrically charged conductor. Operator
any improperly operating components. NEVER must maintain safe clearances at all times (3.05
operate equipment if any damage is observed or meters minimum) and must always allow for
suspected. Repair damaged or malfunctioning platform movement due to gusty winds. Always
equipment before operation. contact power company before working near
ALWAYS wear proper clothing and footgear. Wear power lines. Assume every power line is live.
protective equipment as required by government Power lines can be blown by the wind. Refer to
regulations. Keep loose clothing, jewelry, gloves and Table 1-1 for minimum safe approach distances
hair away from moving parts. between the machine and electrical power lines.

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. (Phase to Phase) (Feet) (Meters)
ALWAYS inspect platform floor and outrigger 0 to 300V Avoid Contact
footpads for mud, grease, debris or other foreign Over 300V to 50KV 10 3.05
material. ALWAYS remove any such material from Over 50KV to 200KV 15 4.60
the equipment before operation.
Over 200KV to 350KV 20 6.10
ALWAYS tag any part of the equipment known or Over 350KV to 500KV 25 7.62
suspected to be damaged or malfunctioning. Over 500KV to 750KV 35 10.67
ALWAYS remove a malfunctioning, damaged or
Over 750KV to 1000KV 45 13.72
defective machine from service. NEVER operate a
machine that has any known or suspected defect. Table 1-1. Minimum Safe Approach Distances

ALWAYS comply with the instructions found in ALWAYS keep away from a machine that is
Safety and/or Service Bulletins distributed by the exposed to energized power lines. If the machine
manufacturer. Bulletins may contain critical contacts energized power lines, NEVER touch or
procedures that supersede the information operate the machine until power lines are shut off.
contained in manuals. ALWAYS operate only on a firm and level surface.
NEVER operate this equipment while under the NEVER operate on surfaces that do not support the
influence of drugs or alcohol, while taking equipment with its rated load capacity or on surfaces
prescription medications that may leave the operator that do not support force exerted by the outriggers
drowsy or prone to dizziness, or while feeling ill. during boom operation. Operate only on surfaces
that can support a pressure of 1.8 kg/cm2 (25 psi) to
NEVER modify the equipment in any way that would ensure safe operation.
affect its original design or operation.
ALWAYS keep personnel away from potential pinch
NEVER deface, modify or obscure any decals or and shear points and from potential crush hazards
markings on equipment. as indicated by decals attached to the machine.
NEVER operate the equipment in any way for which ALWAYS keep the safety bar lowered unless
it is not intended. personnel are entering or exiting the work platform.
ALWAYS keep personnel and obstructions clear of
the machine when repositioning boom or basket.
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BIL-JAX 45XA

ALWAYS cordon the area surrounding the NEVER allow ropes, electric cords, hoses or other
outriggers to keep personnel, vehicles and moving equipment to become entangled in the machine
equipment away from the machine while in use. while raising or lowering platform.
ALWAYS stay clear of overhead obstructions, 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.
equipment.
ALWAYS exercise caution when rotating the boom
NEVER exceed load ratings by transferring loads to
from the ground control station. ALWAYS watch for
the lift at elevated heights.
personnel inside the radius of the turntable and
boom arm when rotating the boom lift from the NEVER use the platform to lift a load that exceeds
ground or platform controls. the platform dimensions. NEVER lift a load in such a
way that the center of gravity is higher than the top
ALWAYS remove personnel from the boom lift
guardrail of the platform.
before attempting to free an elevated platform that
has become caught or snagged on an adjacent NEVER modify the platform or carry materials that
structure or obstacle. would increase the surface area of the platform.
Increasing the area exposed to the wind may
NEVER operate the machine on any surface other
decrease machine stability. NEVER attach
than firm and level ground. NEVER operate the
overhanging loads when raising or lowering the
machine from a position on truckbeds, trailers,
platform.
floating vessels or scaffolding without written
approval from the manufacturer. NEVER use the boom or platform to push or pull or
to lift any part of the machine.
NEVER operate lift functions on slopes exceeding
12.5º. NEVER use the boom or platform to place a load
against any structure, materials or equipment.
NEVER allow electrode contact with any part of the
machine while welding from the platform. NEVER NEVER climb on the boom.
use the machine as a ground for welding.
NEVER leave an elevated platform unattended.
NEVER operate without the outriggers fully
NEVER leave the keys in the boom lift while
extended or when the machine is not level.
unattended or not in use.
NEVER position an elevated platform against
another object to steady the platform
Drive Safety
NEVER override or bypass the manufacturer’s
safety devices. ALWAYS maintain an awareness of limited sight and
blind spots when operating drive functions.
NEVER attach a safety harness to an adjacent
structure, pole, or to nearby equipment while ALWAYS limit travel speed according to surface
working from the boom platform. conditions, slope, location of personnel and
obstructions and any other factors which may result
NEVER raise the outriggers while boom is raised or
in collision.
extended.
NEVER operate drive functions on slopes exceeding
NEVER sit, stand or climb on cage bars. ALWAYS
20º.
keep both feet firmly on the work cage floor when
working from an elevated platform. NEVER engage in stunt driving, horseplay or any
other behavior considered unsafe according to
NEVER attempt to increase the working height with
employer, job site and/or government regulations.
boxes, ladders, stools or any other materials.
NEVER operate the internal combustion engine in
NEVER operate this equipment when exposed to
an area that is not properly ventilated.
high winds, thunderstorms, ice or any weather
conditions that would compromise operator safety. NEVER fuel the internal combustion engine while
smoking, or while near spark or open flame.
NEVER operate boom lift in conditions where wind
speeds exceed 12.5 m/sec (45 km/h or 28 mph).
High winds may affect stability and boom operation.

6
1 – SAFETY

MAINTENANCE SAFETY
Ensure the following general safety precautions are NEVER exceed the manufacturer’s recommended
followed while performing maintenance on the Aerial relief valve settings.
Work Platform:
NEVER touch or allow metal tools to contact any
General Maintenance components that are sensitive to static discharge.
ALWAYS use static discharge prevention mats and
ALWAYS perform maintenance procedures
grounding devices when handling electronic
according to manufacturer’s guidelines. NEVER
components.
disregard or bypass proper maintenance
procedures. NEVER adjust, repair, replace or bypass any
hydraulic or electrical control or safety device. These
ALWAYS inspect hydraulic system to ensure that all
include, but are not limited to, hydraulic load control
lines, connectors and fittings are properly fastened
and flow control valves, solenoid valves and limit
and in good condition.
switches. ALWAYS consult an authorized Bil-Jax
ALWAYS turn the key switch OFF and remove key technician if repairs are necessary.
before performing maintenance.
NEVER modify, alter or change the equipment
ALWAYS perform maintenance with the boom and without first consulting an authorized Bil-Jax
platform in a fully lowered, stowed position, when technician, and NEVER in any way that would affect
possible. ALWAYS secure the boom before its original design or operation.
performing maintenance on hydraulic cylinders.
Battery Maintenance
ALWAYS disconnect power to the hydraulic pump
Ensure the following general safety precautions are
drive motor before making electrical checks to the
followed when performing battery maintenance on
hydraulic valves.
the Aerial Work Platform.
ALWAYS keep all mechanical parts properly
ALWAYS wear safety glasses when working with or
adjusted and lubricated according to maintenance
near batteries.
schedule and manufacturer’s specifications.
ALWAYS check the battery fluid level daily.
ALWAYS perform a function check of operating
controls before each use and after repairs have ALWAYS avoid contact with battery acid. Battery
been made. acid causes serious burns and should be kept away
from skin or eyes. If contact occurs, flush with water
ALWAYS locate and protect against possible pinch
and consult a physician immediately.
points before performing any maintenance or
repairs. ALWAYS disconnect ground cable first when
removing battery.
ALWAYS use only manufacturer-approved parts to
repair or maintain equipment. If any portion of this ALWAYS connect ground cable last when installing
equipment is rebuilt or repaired, retesting is required battery.
in accordance with factory instructions.
ALWAYS charge batteries in open, well-ventilated
ALWAYS maintain a safe distance while testing the areas.
hydraulic components. ALWAYS relieve hydraulic
ALWAYS replace batteries using only parts
pressure before loosening or removing hydraulic
recommended by manufacturer. ALWAYS use only
components. NEVER test or operate the hydraulic
batteries with sealed caps over cells.
components while personnel are near the
equipment. NEVER smoke while servicing batteries.
NEVER allow water or foreign particles into the DC NEVER charge batteries near spark or open flame.
electric motor housing. Inclusion of water or foreign
NEVER allow batteries to overcharge and boil.
particles may cause serious damage to the motor. If
the motor becomes wet, consult an authorized Bil- NEVER short across battery posts to check for
Jax service technician for proper drying instructions. current. NEVER break a live circuit at the battery.
NEVER add unauthorized fluids to the hydraulic NEVER disconnect battery from charger while
system or battery. NEVER mix hydraulic oils. charger is connected to a live power source.
Consult manufacturer specifications. Refer to
Section 4 for hydraulic system maintenance NEVER jumpstart other vehicles using the boom lift
procedures. batteries.

7
BIL-JAX 45XA

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
ANSI and/or CE codes and regulations.
Damage Policy
There may be occasions when a Bil-Jax lift is involved in an incident that results
in structural damage to the lift. Such damage can seriously compromise the
ability of the lift to perform in a safe manner. Therefore, whenever a Bil-Jax lift is
damaged structurally or when there is suspected internal damage to the
structure, Bil-Jax may require that the lift be returned to our facility for
reconditioning. For any questions concerning structural damage or the Damaged
Equipment Policy, please contact an authorized Bil-Jax representative or your
regional Bil-Jax dealer
Damage Repair Notice
There may be occasions when a Bil-Jax lift is involved in an accident resulting in
damage to non-structural components. When such damage occurs and repairs
are made by the owner or area distributor, please notify Bil-Jax of these non-
maintenance repairs and request a repair form to be filled out and returned to Bil-
Jax.

8
2 BEFORE OPERATION
Inspections of the aerial work platform and the intended work area should be
performed daily before operation. Failure to inspect machine and work area
may result in death or personal injury.

Prior to Operation:
Conduct a pre-operation inspection of the aerial work platform by
performing all daily service checks as explained in this manual, as well
as all weekly and/or monthly service checks, if applicable.
Inspect the work area.

A comprehensive schedule of service checks and maintenance can be


found in the Parts and Service Manual. Annual service checks and
structural inspections should be performed only by personnel trained and
certified in accordance with applicable government regulations.

9
BIL-JAX 45XA

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
plain view. a fully lowered, stowed position. Limit switches must
be operational to raise or lower outriggers.
Refer to Section 5 for decal locations.
If outrigger controls are unresponsive when boom is
Verify that all controls and indicators at ground fully lowered and stowed, inspect down limit switches
and platform control stations operate properly. for loose mounting or visible damage.
Lower outriggers to level the boom lift. Repair or replace as needed.
Raise and extend all booms. Verify that outrigger safety interlocks operate
Press emergency STOP button. correctly.

Verify that booms remain elevated and do not drift. Begin with the outriggers fully extended and the boom
lift level. Raise one outrigger until the footpad is not in
Pull out STOP button and lower the booms. contact with the ground.
If either control station is unresponsive, refer to Table Verify that boom functions are unresponsive when
4-1 for troubleshooting procedures. one outrigger is raised.
If display panel displays an error code, refer to Table Repeat this procedure for each outrigger.
4-2 for error code definitions.
Raise all outriggers until the footpads are not in
Verify correct tire inflation. contact with the ground. Verify that all outrigger status
LEDs on the ground control panel are unlit.
Inflate tires to 20 psi (140 kPa).
Lower one outrigger until the footpad makes contact
Inspect tires for damage or loose or missing lug with the ground and the outrigger begins lifting the
nuts. trailer.
Repair or replace as necessary.* If the LED is lit before the footpad makes contact with
the ground or if the LED remains unlit after the weight
Inspect structural components and platform for is transferred to the outrigger, the position switch or
obvious damage or debris. wiring is faulty.
Repair or replace as necessary. Repeat this procedure for each outrigger.
Inspect machine for missing, loose or damaged Repair or replace as needed. Refer to Figure 2-1.
fasteners, including pins and bolts.
Check engine oil level.
Add oil as needed.
Manufacturer recommends engine oil type 5W-30.
Check engine fuel level.
Add fuel as needed.

Figure 2-1. Outrigger Position Switches

* Repair and replacement of machine components


should be performed only by trained and certified
personnel in accordance with government regulations
and manufacturer recommendations.

10
2 – BEFORE OPERATION

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 wheels on
a level surface.
Hydraulic oil level should be visible in, but not above,
the sight gauge.
If the hydraulic oil level is not visible to at least half
way up the sight gauge (Figure 2-2), add clean
hydraulic fluid as necessary while all booms and
outriggers are fully retracted and stowed. Pour slowly
to avoid creating air pockets in the reservoir. Do not
fill above sight gauge. Overfilling the hydraulic
reservoir may cause damage to hydraulic lines and
may result in equipment malfunction.

CAUTION
Do not mix hydraulic oils. Do not add any fluid to
the hydraulic system that is not expressly
recommended by the manufacturer. Adding
unauthorized fluids to the hydraulic system may
cause damage to equipment
The hydraulic reservoir is originally filled with Dexron
III/Mercon ATF with a viscosity rating of 175.
Manufacturer recommends a higher viscosity
hydraulic oil when operating equipment routinely in
extreme climates.

1. Filter Element
2. Fill Port
3. Sight Gauge

Figure 2-2. Hydraulic Reservoir

11
BIL-JAX 45XA

WEEKLY SERVICE CHECKS MONTHLY SERVICE CHECKS


Perform the following service checks at least once Perform the following service checks at least once
each week in addition to all recommended daily each month in addition to all recommended daily
service checks: service checks:
Check Battery electrolyte level. Clean all battery terminals.
If battery electrolyte level is low, add enough distilled Check battery for loose connections or damaged
water to bring the electrolyte level to the top of the wires.
plates.
Verify proper operation of manual lowering
If batteries are fully charged, raise electrolyte level to valves and hand pump
full mark in each cell.
Refer to Section 3 for manual boom operating
Inspect all electrical wiring. procedures.
Check for cuts, loose terminals, broken wires, chaffing Lubricate all compartment hinges and latches,
and corrosion.
slew ring and mating gear.
Repair all damage, remove corrosion and seal
Use NLGI Grade 2 multi-purpose grease.
exposed connections.
Inspect transport hitch components for damage. Check wheel nut torque.
Refer to Figure 2-3 for correct wheel nut tightening
Inspect boom lift for missing, loose or damaged sequence.
hardware.
Evenly tighten wheel nuts to 34 N*m in the tightening
Repair or replace as necessary. sequence shown.
Inspect all hydraulic system components Repeat sequence, tightening wheel nuts to 81 N*m
including pump and motor and cylinders for and to 136 N*m.
damage, leaks, loss of pressure or speed, and
unusual noise or vibration. NOTE: Follow this procedure each time the
wheel is removed and reinstalled.
Repair or replace as necessary.

4 3

2 5

Figure 2-3. Wheel Nut Tightening Sequence

12
2 – BEFORE OPERATION

WORKPLACE INSPECTION
Before operating the machine, be aware of and
avoid the following:
Drop-offs
Holes
Floor obstructions or debris
Sloped surfaces outside the capabilities of the
boom lift
Unstable or slippery surfaces
Surfaces that will not support the load forces
imposed by the machine or outriggers
Overhead obstructions and high voltage
conductors
Sinkholes and untamped earth fills
Personnel
Unsafe weather conditions
Other vehicles and equipment
Other unsafe conditions

13
BIL-JAX 45XA

14
3 OPERATION
The Model 45XA Aerial Work Platform is equipped with multiple operator
control stations. Operators can use boom and outrigger functions from
both the platform and ground control panels. Drive functions are found
on the platform control panel.

Before attempting boom lift operation, Operators should:


Attend a training program as required by government regulations.
Obtain, read and obey all safety precautions as indicated by
manufacturer’s recommendations and all federal, state and local
regulations.
Become familiar with the location and use of all controls.
Verify that there are no overhead obstructions or live power sources
in the work area that could interfere with the safe operation of the
boom lift.
Position the boom lift on a firm and level surface.
Conduct a Pre-Operation inspection by performing all recommended
Daily Service Checks. Refer to Section 2.

15
BIL-JAX 45XA

GROUND CONTROL STATION

The ground control station is used to operate outriggers and control


boom motion. To access the ground control station, open the control
panel access cover found on the turntable. Turn the key switch to the
ground controls setting.

Figure 3-1. Ground Control Panel

1. Key Switch 12. Upper Boom Down


1a. Ground Controls Position 13. Jib Raise
1b. Platform Controls Position 14. Jib Down
2. Battery Condition Indicator 15. Speed Buttons
3. Engine Start 16. Platform Tilt – Up
4. Engine Choke 17. Platform Tilt – Down
5. Display Panel 18. Boom Rotation – Clockwise
6. Emergency Stop 19. Boom Rotation – Counterclockwise
7. Boom Extend 20. Outrigger Status Indicator LED
8. Boom Retract 21. Outrigger Extend
9. Lower Boom Raise 22. Outrigger Retract
10. Lower Boom Down 23. Auto Level
11. Upper Boom Raise 24. Outrigger Button

16
3 – OPERATION

The ground control station includes the following continues until the buttons are released or until the
controls and Indicators. Refer to Figure 3-1 for boom reaches a hard stop or a safe travel limit.
control locations.
9-14. Boom Raise/Down Buttons
1. Key Switch
Pressing and holding a desired SPEED button and the
Turning the key switch to the PLATFORM (1A) icon UPPER/LOWER/JIB BOOM RAISE button at the same
selects operation from the platform. Turning the key time will raise the chosen boom. Pressing a desired
switch to the GROUND (1B) icon selects operation SPEED button and the UPPER/LOWER/JIB BOOM DOWN
from the ground control panel. The center (power button at the same time will lower the chosen boom.
off) position interrupts all electric and hydraulic Boom motion continues until the buttons are
power operations except emergency lowering. released or until the boom reaches a hard stop or a
Removing the key protects against operation by safe travel limit.
unauthorized persons. The key may be removed
15. Speed Buttons
with the key switch in any selected position.
The SPEED buttons along the lower right side of the
2. Battery Condition Indicator
control panel must be pressed and held while
Indicator LEDs light up to indicate the level of charge selecting a boom function. Four speeds are
remaining in the batteries. A lighted green LED available to control the positioning of the boom lift.
indicates an adequate charge level. Lighted yellow
16-17. Platform Tilt Buttons
LEDs indicate the need for charging soon. A lighted
red LED warns that the battery charge level is low; Press and hold any SPEED button and the desired
boom operations should be halted until the batteries PLATFORM TILT button at the same time to level the
are recharged. work platform (levels the platform only, not the boom
lift).
3-4. Engine Start and Choke
18-19. Boom Rotation Buttons
Start a cold engine by pressing the Engine START
button while pressing and holding the CHOKE button. Pressing and holding a desired SPEED button and the
To start/restart a warm engine, press the START BOOM ROTATION CLOCKWISE or COUNTERCLOCKWISE
button only. button at the same time enables the boom to rotate
in the direction selected. The boom will rotate
5. Display Panel
through 700 degrees until the buttons are released
The DISPLAY PANEL is a lighted text window that or the stop is reached.
displays the present operating status or an existing
20-24. Outrigger Controls
error condition when the key switch is on.
For automatic outrigger extension/retraction: Select
6. Emergency Stop Button
EXTEND or RETRACT outrigger button and the AUTO
When pushed in, the emergency STOP button LEVEL button at the same time. To manually extend
disconnects electrical power to the ground and or retract the outriggers: Select EXTEND or RETRACT
platform control stations. The emergency STOP outrigger button and one of the OUTRIGGER buttons
pushbutton should only be pressed to immediately at the same time. The outrigger indicator LEDs light
stop all boom motion. To resume control, pull out the up when the outriggers are properly deployed and
emergency STOP button. the boom weight is on the outriggers. Each of the
outer outrigger LEDs indicates load is on the
7-8. Boom Extend/Retract Buttons
outrigger footpad. Each of the inner outrigger LEDs,
Pressing and holding a desired SPEED button and the when flashing, indicate that side is low and needs to
BOOM EXTEND button at the same time extends the be further raised for leveling. The Auto Level LED
telescopic boom. Pressing and holding a desired lights up and a buzzer sounds when the boom is
SPEED button and the BOOM RETRACT button at the level.
same time retracts the boom. Boom motion

17
BIL-JAX 45XA

PLATFORM CONTROL STATION


The platform control station is used to control boom motion. To access the
platform control station, turn the key switch at the ground control station to the
platform controls setting and enter the work cage.

Figure 3-2. Platform Control Panel

1. Engine Start 12. Outrigger Buttons


2. Engine Choke 13. Outrigger Extend
3. Engine Stop 14. Outrigger Retract
4. Generator On/Off 15. Outrigger Condition Status LED
5. Fuel Toggle 16. Lower Boom Raise/Down
6. Horn 17. Boom Rotation
7. Drive Speed Selector 18. Boom Extend/Retract
8. Battery Condition Indicator 19. Platform Tilt
9. Diagnostic Indicators 20. Upper Boom Raise/Down
10. Emergency Stop 21. Jib Raise/Down
11. Auto Level 22. Jib Rotation (Option)

18
3 – OPERATION

The platform control station includes the following 11-15. Outrigger Controls
controls and Indicators. Refer to Figure 3-2 for
Outrigger controls on the platform are identical to the
control locations.
outrigger controls on the ground control panel.
1-2. Engine Start and Choke
16. Lower Boom Raise/Down
Start a cold engine by pressing the CHOKE button (2),
Press the LOWER BOOM RAISE/DOWN button until the
then press the engine START button (1) to start the
adjacent LED indicator becomes lit. Depress the
engine. To start/restart a warm engine, press the
trigger on the platform controls joystick and move
START button only.
the joystick off center in the appropriate direction to
3. Engine Stop raise and lower the boom.
Press to stop the engine. If charged, batteries will 17. Boom Rotation
still provide power to the lift.
Press the BOOM ROTATION button until the adjacent
4. Gnerator On/Off LED indicator becomes lit. Press and hold the toggle
button on top of the platform controls joystick, using
Press GENERATOR ON/OFF button to activate
the color-coded direction arrows to determine
generator. Generator provides power to battery
direction the machine will rotate. Depress the trigger
charger and to GFI outlets found adjacent to the
on the platform controls joystick and move the
ground and platform control stations.
joystick off center to rotate the boom.
5. Fuel Toggle
18. Boom Extend/Retract
Press FUEL TOGGLE button to change between fuel
Press the BOOM EXTEND/RETRACT button until the
types. Option is not currently available on self-
adjacent LED indicator becomes lit. Depress the
propelled machines.
trigger on the platform controls joystick and move
6. Horn the joystick off center in the appropriate direction to
extend and retract the boom.
Press to sound the horn. Use the horn button to
warn personnel in the area of a falling object hazard, 19. Platform Tilt
impending boom motions or the need for assistance.
Press the PLATFORM TILT button until the adjacent
7. Drive Speed Selector LED indicator becomes lit. Depress the trigger on
the platform controls joystick and move the joystick
Press DRIVE SPEED SELECTOR to switch between low
off center in the appropriate direction to extend and
speed/high torque and high speed/low torque retract the boom.
settings. The low speed/high torque setting is
recommended when operating on inclines. 20. Upper Boom Raise/Down
8. Battery Condition Indicator Press the UPPER BOOM RAISE/DOWN button until the
adjacent LED indicator becomes lit. Depress the
Indicator LEDs light up to indicate the level of charge
trigger on the platform controls joystick and move
remaining in the batteries. A lighted green LED the joystick off center in the appropriate direction to
indicates a good charge level. Lighted yellow LEDs raise and lower the boom.
indicate the need for charging soon. A lighted red
LED warns that the battery charge level is low; boom 21. Jib Boom Raise/Down
operations should be halted until the batteries are
Press the JIB BOOM RAISE/DOWN button until the
recharged.
adjacent LED indicator becomes lit. Depress the
9. Diagnostic Indicators trigger on the platform controls joystick and move
the joystick off center in the appropriate direction to
Indicator LEDs warn of machine or engine issues. raise and lower the boom.
Refer to the display panel on the ground control
panel and the troubleshooting section of this manual 22. Jib Rotation (Option)
for fault code explanations.
Press the JIB ROTATION button until the adjacent LED
10. Emergency Stop indicator becomes lit. Press and hold the toggle
button on top of the platform controls joystick, using
When pushed in, the emergency STOP button the color-coded direction arrows to determine
disconnects electrical power to the ground and direction the jib boom will rotate. Depress the trigger
platform control stations. The emergency STOP
on the platform controls joystick and move the
pushbutton should only be pressed to immediately joystick off center to rotate the jib boom.
stop all boom motion. To resume control, pull out the
emergency STOP button.

19
BIL-JAX 45XA

PLATFORM CONTROLS JOYSTICK


Use the Joystick to operate drive and boom
functions from the platform control station.

1. Joystick Trigger
2. Toggle Switch
Figure 3-3. Platform Controls Joystick

1. Joystick Trigger
Depress the trigger after selecting a boom function
and move the joystick in the desired direction to
operate boom functions.
2. Toggle Switch
Use the toggle switch to control direction of boom
rotation and to steer the machine when using drive
functions.

20
3 – OPERATION

OPERATION: SET UP
Turn the key switch on the ground controls to Verify that the auto level indicator LED is lit. If
select the desired control station. If power does the auto level indicator is not lit, the boom may
not come on, make sure both emergency STOP not be level.
buttons (ground and platform) are pulled out and
Pull the latch release on the boom travel latches,
the main power disconnect is plugged in.
raise the latch handle and swing the latch U-bolt
The control microprocessor will perform self- down. Refer to figure 3-5.
diagnostics to test the operating system. After
several seconds, the DISPLAY PANEL window
will read:
BIL – JAX
A STEP ABOVE
Verify that the control status indicator LED is lit.
If the control status indicator LED is not lit or is
flashing, the outrigger buttons will not work. A
flashing control status LED indicates that one or
more of the booms is raised and needs to be
stowed. Refer to Figure 3-1 and Figure 3-4.
Extend the outriggers manually or using the Figure 3-5. Boom Travel Latch
AUTO LEVEL button. When the boom is leveled
properly, a buzzer will sound and two LEDs at
each OUTRIGGER button and the LED at the AUTO
LEVEL button will be lit.

Auto Level: Press and hold the EXTEND and


AUTO LEVELbuttons at the same time.
Manual Level: Extend the two outriggers
closest to the trailer coupler first. Lower each
pair of outriggers by pressing the EXTEND button
and the two appropriate OUTRIGGER buttons at
the same time.

Figure 3-4. Outrigger Controls


NOTE: The safety interlock system prevents all
boom operations if the boom is not level
or if one or more outriggers are not
supporting the vehicle load.

21
BIL-JAX 45XA

OPERATION: GROUND CONTROLS


Turn the key switch to ground control position.
Raise, lower, extend and rotate the boom by
pressing and holding the desired SPEED and
function buttons at the same time.
When all boom lift operations are complete, fully
retract the telescoping boom extension. Center
boom over the boom rest and fully lower all
booms until seated in the stowed position for
transport. Safety switches prevent outrigger
retraction until boom is completely lowered and
stowed for transport.
Engage the boom travel latches.
Press and hold the outrigger RETRACT button
and the AUTO LEVEL button until all outriggers are
fully retracted to their upright positions. Inspect
the area beneath lift for obstructions before
retracting outriggers.
Turn the key switch to the OFF position and
remove key.

22
3 – OPERATION

OPERATION: PLATFORM CONTROLS OPERATION: DRIVE FUNCTIONS


Fully lower the boom onto the boom rest to To drive machine, use the platform controls to
position the platform for boarding. Turn the key raise all outriggers to a fully stowed position.
switch to the platform control position.
Verify that the drive mode LED is lit.
Raise the safety bar and enter the work
Depress the trigger on the platform controls
platform. Put on the safety harness and attach
joystick and move the joystick off center. Moving
the lanyard to the Fall Protection Attachment
the joystick further off center will increase drive
Point on the side of the platform support beam.
speed. Moving the joystick toward center will
Use the platform control panel to operate the boom decrease drive speed. Returning the joystick to
lift functions. center and/or releasing the trigger will stop drive
functions.
To raise, lower, extend and rotate the boom,
press the desired function button. To steer, use the toggle switch on the top of the
platform controls joystick.
An LED adjacent to the function button will
become lit, indicating that the function is active. Use the color-coded direction arrow to
determine the direction the machine will move.
Depress the trigger on the platform controls
joystick and move the joystick off center. Moving
the joystick further off center will increase
function speed. Moving the joystick toward
center will decrease function speed. Returning
the joystick to center and/or releasing the trigger
will stop boom functions.
Use the color-coded direction arrows to
determine the direction the boom will move.
To rotate the turntable, depress the trigger on
the platform controls joystick and use the toggle
switch located on top of the platform controls
joystick. While pressing the toggle switch and
the trigger, move the joystick off center to adjust
function speed.
Use the toggle switch and the color-coded
direction arrows to determine the direction the
turntable will rotate. The turntable will rotate in
the desired direction regardless of which
direction the joystick is moved off center.
Should the platform become tilted out of the
normal vertical axis, use the PLATFORM TILT
function to adjust.
Monitor the Battery Condition Indicator during
operation and charge the batteries as
necessary.
Always fully retract, rotate and lower the boom
to the stowed position before exiting the
platform.

23
BIL-JAX 45XA

MANUAL BOOM OPERATION


Manual retraction, rotation and lowering functions Manual Retraction
allow the aerial work platform to be moved and
Pushing and holding the Retract button while
lowered during hydraulic power interruption or
simultaneously actuating Hand Pump will retract the
failure. In each instance, refer to Figure 3-6.
extension boom section.
The following procedures for manual retraction,
Manual Rotation
rotation and lowering require a person on the ground
to operate the manual controls and hand pump. To rotate the turntable clockwise: Push and hold
the Rotation button and simultaneously actuate
The hydraulic hand pump is located in the pump
Hand Pump.
compartment. In case of a power failure, the hand
pump and selected hydraulic valve settings can be To rotate the turntable counterclockwise: Pull the
used to manually retract the Telescoping boom or Rotation button out and simultaneously actuate
rotate the boom turntable. Hand Pump.
To begin manual retraction or rotation, turn NOTE: Return proportional valve to its original
Proportional Valve counterclockwise until it stops, position before lowering the lift or
and insert pump handle into the pump handle fitting. resuming normal operation.

1. Hand Pump 3. Rotation Button


2. Proportional Valve 4. Retract Button

Figure 3-6. Hand Pump and Controls for Manual Lift Operation

24
3 – OPERATION

Manual Lowering
Each Manual Lowering Valve is equipped with a
plunger, found at the base of the lift cylinder (Figure
3-7). Depress the plunger to lower the platform in
case of a complete electrical power failure, a load
shift, or other emergency. Continue pressing the
plunger to completely lower the boom.

Figure 3-7. Manual Lowering Valve

25
BIL-JAX 45XA

BATTERY RECHARGE
Recharge batteries as needed. When using the gas The CHARGING indicator LED remains lit
engine, press the GENERATOR button on the platform continuously during the first stage of the charge
control station to charge the batteries. Charge daily cycle. The bulk mode CHARGE CURRENT will
under normal use. When machine is not in use, be displayed on the battery charger faceplate.
batteries should be recharged at least once per
Press and hold the BATTERY VOLTAGE button to
week. Under normal circumstances, battery
display the detected battery voltage.
recharge should take approximately 10-12 hours.
However, a full recharge may take up to 24 hours if If a battery fault is detected, the appropriate fault
the battery charge is extremely low. code will appear on the CHARGE CURRENT
display. The red CHECK BATTERY indicator
WARNING LED will become lit. See Table 3-1 for battery
Recharge batteries in a well-ventilated area only. charger fault codes.
Do no charge batteries near fire, spark or other
potential ignition sources. Batteries may emit WARNING
highly explosive hydrogen gas while charging. Do not disconnect any output leads or
Failure to properly ventilate the charge gases connectors between the batteries and the
may result in serious injury or death. Always charger when the charger is on. To stop a charge
charge boom lift batteries away from flammable in progress, always unplug the extension cord
materials. from the AC power source.
To recharge the boom lift batteries: When the battery charge reaches 80% of
capacity, the yellow 80% CHARGED indicator
Move the boom lift to a well-ventilated area with
LED will become lit and the green CHARGING
direct access to 120 V electrical outlet. Keep the
indicator LED will begin to flash.
boom lift and batteries away from open flame or
other potential ignition sources. When the batteries have reached a full charge,
the green and yellow indicator LEDs will turn
Attach a 12 AWG multi-strand, grounded
themselves off. CC (Charge Complete) will
extension cord with a maximum length of 15
appear on the CHARGE CURRENT display.
meters to the receptacle located inside the
After two hours, this display will fade and the
engine compartment. The generator may need
CHARGE CURRENT will read 00.
to be disconnected from the receptacle.
Unplug the extension cord from the outlet and
NOTE: Using an underrated or long power cord
the charger receptacle on the boom lift. Store
will reduce the output of the battery
the extension cord for next use.
charger and may extend charge time.
Plug the extension cord into outlet. Verify that CAUTION
the green CHARGING indicator LED is lit on the Always unplug the battery charger power cord
battery charger faceplate (Figure 3-8). before moving the boom lift. Failure to
disconnect power cord will cause damage to the
equipment.
Linear Battery Charger Table 3-1. Charger Fault Codes
CHARGING
Code Description Limits Cause
Loose battery or
>112% charge
F1 Over Voltage charger
voltage
connection
CHARGE CURRENT 80% CHARGED
F2 Over Current >60 amperes Battery Fault
PUSH
FOR F3 Bulk Mode Timeout 14 hrs Max. Battery Fault
BATTERY VOLTAGE CHECK BATTERY
ARD Mode
F4 6 hrs Max. Battery Fault
Timeout

FUSE 15A
F5 FCT Mode Timeout 2.5 hrs Max. Battery Fault
SLO BLO

F6 Self-Test Error Charger Fault

Figure 3-8. Battery Charger Faceplate

26
3 – OPERATION

BOOM LIFT TRANSPORT

LIFTING INSTRUCTIONS TRANSPORT INSTRUCTIONS


Refer to Figure 3-9. Refer to Figure 3-9.
Completely lower and retract booms. Verify that truck or trailer is parked on a firm and
level surface.
Secure boom and platform travel latches.
Completely lower and retract boom.
Remove all loose materials from machine.
Secure boom travel latches.
Retract all outriggers to fully stowed position.
Retract all outriggers to fully stowed position.
Attach rigging only to the designated forklift
pockets (A). Load boom onto truck or trailer.
Adjust rigging to keep the machine level and to Secure the boom lift to the trailer bed using
minimize the risk of damage to machine. straps or chains. Use only the two attachment
points beneath the machine, adjacent to the
When using a forklift, use only the designated
outriggers (B).
forklift pockets. Follow all forklift operating
instructions as indicated by the forklift Adjust as necessary to prevent damage to
manufacturer. rigging or machine.
Only trained and authorized personnel should
attempt to lift the boom using a crane or forklift.

Figure 3-9. Lift and Transport Instructions

27
BIL-JAX 45XA

28
4 TROUBLESHOOTING
The following section contains information for solving basic diagnostic
issues associated with the machine. If any issue or malfunction is
encountered during the correct and proper operation of the aerial work
platform that is not covered by the troubleshooting steps covered in this
manual, contact your regional Bil-Jax representative or the Bil-Jax
Service Department.

All maintenance and repairs should be performed by qualified


personnel in accordance with manufacturer specifications and
government regulations.
Follow recommended maintenance safety guidelines when
performing maintenance on the machine.

29
BIL-JAX 45XA

TROUBLESHOOTING
Refer to Table 4-1 for basic troubleshooting operations. Additional information
can be found in the Bil-Jax Model 45XA Parts and Service Manual. Contact the
Bil-Jax Service Department with any questions or before attempting any
advanced troubleshooting operations.

Table 4-1. Troubleshooting Steps

PROBLEM CAUSE SOLUTION


No lights on panel when a. Emergency STOP engaged. a. Disengage Emergency STOP buttons.
key switch is turned to the
on position. b. Battery charge is low. b. Recharge as needed.

c. Battery ground or in-series cable is loose. c. Inspect and repair battery connections.

d. Battery main disconnect unplugged. d. Plug in main disconnect.

e. Blown fuse. e. Replace fuse.

Hydraulic function does not a. Fault detected by safety interlock a. Refer to Table 4-2 for error code
work and display window microprocessor. definition and correction.
shows an error message
b. Boom Lift electric or electronic failure b. Refer to Table 4-2 for error code
definition and correction.

Outrigger indicator LED a. Key switch turned to the OFF or platform a. Turn key switch to ground controls
lights do not function. controls position. position.

b. Emergency STOP engaged. b. Disengage emergency STOP buttons.

c. Outriggers not deployed. c. Deploy all outriggers.

One or more boom controls a. Key switch is turned to the OFF or a. Turn key switch to ground or platform
do not function incorrect control position. controls position.
OR b. Battery charge is low. b. Recharge battery.
One or more boom controls
function improperly c. Emergency STOP engaged. c. Disengage Emergency STOP buttons.
OR d. Battery ground or in-series cable loose. d. Inspect and repair battery connections.
One or more boom controls
function intermittently. e. All outriggers not properly deployed. e. Deploy all outriggers and level boom lift.

f. Hydraulic pump inoperative. f. Inspect pump; replace or repair as


needed.

g. Loose wiring connector. g. Check wiring terminals in control box


and at valve manifold; replace or repair
as needed.

h. Valve solenoid not operating properly. h. Clean valve solenoid and recheck
function(s); replace or repair as needed.

i. Fault detected by system interlock. i. Check display for system status. Refer
to Table 4-2 for error code definitions
and correction.

j. Broken or loose wire. j. Inspect wiring in control box and at


valve manifold and valve coil; repair or
replace as needed.

30
4 – TROUBLESHOOTING

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.
Refer to Table 4-2 for a comprehensive list of Error Code Definitions and
solutions.

Table 4-2. Error Code Definitions

ERROR MESSAGE DEFINITION OF ERROR COMMENTS


001 MACHINE IS IN DOWN ONLY Machine was either never leveled, outriggers not Retract boom to travel position
MODE lowered, or machine went out of level with use. and extend outriggers using AUTO
LEVEL button.

002 LOSS OF PLATFORM Ground control lost communication with platform Check for unplugged or damaged
COMMUNICATION control. platform control cable.
005 PLATFORM CONTROL HAS Platform control detected a stuck or pressed key Turn key switch off and on again
STUCK KEY on power up. without pressing any buttons.
008 GROUND CONTROL HAS Ground control detected a stuck or pressed key Turn key switch off and on again
STUCK KEY on power up. without pressing any buttons.
009 BOOM UP WITHOUT Ground control detected the boom is up and all Retract boom to travel position
OUTRIGGERS ON GROUND outriggers are not on the ground and extend outriggers using AUTO
LEVEL button.

010 LEVEL SENSOR HAS The ground control detected an erratic output Retract and extend outriggers
ERRATIC OUTPUT from the level sensor. using AUTO LEVEL button.
015 MACHINE IS NOT LEVEL Machine has gone out of level with use. Retract and extend outriggers
using AUTO LEVEL.
016 LIFT BOOM A boom rotate, extend, or retract function Raise boom from travel position.
requested with boom down.
017 STOW BOOM An outrigger function requested with boom up. Retract and lower boom to travel
position.
021 OPEN CIRCUIT PRIMARY UP A load of less than 70mA detected in primary up Check for faulty boom up
circuit on power-up. solenoid coil and wiring.
022 SHORTED CIRCUIT Excessive load detected in primary up circuit on Check for faulty boom up
PRIMARY UP power-up. solenoid coil and wiring.
023 OPEN CIRCUIT PRIMARY A load of less than 70mA was detected when Check for faulty boom down
DOWN primary down circuit was energized solenoid coil and wiring.
024 SHORTED CIRCUIT Excessive load detected when primary down Check for faulty boom down
PRIMARY DOWN circuit was energized. solenoid coil and wiring.
025 OPEN CIRCUIT SECONDARY A load of less than 70mA detected in secondary Check for faulty boom up
UP up circuit on power-up. solenoid coil and wiring.
026 SHORTED CIRCUIT Excessive load detected in secondary up circuit Check for faulty boom up
SECONDARY UP on power-up. solenoid coil and wiring.
027 OPEN CIRCUIT SECONDARY A load of less than 70mA detected when Check for faulty boom down
DOWN secondary down circuit was energized solenoid coil and wiring.
028 SHORTED CIRCUIT Excessive load detected when secondary down Check for faulty boom down
SECONDARY DOWN circuit was energized. solenoid coil and wiring.
029 OPEN CIRCUIT JIB UP A load of less than 70mA detected in jib up circuit Check for faulty jib up solenoid
on power-up. coil and wiring.
030 SHORTED CIRCUIT JIB UP Excessive load detected in jib up circuit on Check for faulty jib up solenoid
power-up. coil and wiring.

31
BIL-JAX 45XA

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 Check for faulty jib down solenoid
DOWN was energized. coil and wiring.
033 OPEN CIRCUIT EXTEND A load of less than 70mA detected in extend Check for faulty boom extend
circuit on power-up. solenoid coil/wiring.
034 SHORTED CIRCUIT EXTEND Excessive load detected in extend circuit on Check for faulty boom extend
power-up. solenoid coil/wiring.
035 OPEN CIRCUIT RETRACT A load of less than 70mA detected in retract Check for faulty boom retract
circuit on power-up. solenoid coil/wiring.
036 SHORTED CIRCUIT Excessive load detected in retract circuit on Check for faulty boom retract
RETRACT power-up. solenoid coil/wiring.
037 OPEN CIRCUIT PLATFORM A load of less than 70mA detected in platform Check for faulty level up solenoid
LEVEL UP level up circuit on power-up. coil/wiring.
038 SHORTED CIRCUIT Excessive load detected in platform level up Check for faulty level up solenoid
PLATFORM LEVEL UP circuit on power-up. coil/wiring.
039 OPEN CIRCUIT PLATFORM A load of less than 70mA detected in platform Check for faulty level down
LEVEL DOWN level down circuit on power-up. solenoid coil/wiring.
040 SHORTED CIRCUIT Excessive load detected in platform level down Check for faulty level down
PLATFORM LEVEL DOWN circuit on power-up. solenoid coil/wiring.
041 OPEN CIRCUIT PLATFORM A load of less than 70mA detected in platform Check for faulty boom rotate
CW CW circuit on power-up. solenoid coil/wiring.
042 SHORTED CIRCUIT Excessive load detected in platform CW circuit Check for faulty boom rotate
PLATFORM CW on power-up. solenoid coil/wiring.
043 OPEN CIRCUIT PLATFORM A load of less than 70mA detected in platform Check for faulty boom rotate
CCW CCW circuit on power-up. solenoid coil/wiring.
044 SHORTED CIRCUIT Excessive load detected in platform CCW circuit Check for faulty boom rotate
PLATFORM CCW on power-up. solenoid coil/wiring.
045 OPEN CIRCUIT TURNTABLE A load of less than 70mA detected in rotate CW Check for faulty rotate CW
CW circuit on power-up. solenoid coil/wiring.
046 SHORTED CIRCUIT Excessive load detected in rotate CW circuit on Check for faulty rotate CW
TURNTABLE CW power-up. solenoid coil/wiring.
047 OPEN CIRCUIT TURNTABLE A load of less than 70mA detected in rotate CCW Check for faulty rotate CCW
CCW circuit on power-up. solenoid coil/wiring.
048 SHORTED CIRCUIT Excessive load detected in rotate CCW circuit on Check for faulty rotate CCW
TURNTABLE CCW power-up. solenoid coil/wiring.
049 OPEN CIRCUIT OUTRIGGER A load of less than 70mA detected in outrigger Check for faulty outrigger retract
RETRACT retract circuit on power-up. solenoid coil/wiring.
050 SHORTED CIRCUIT Excessive load was detected when Outrigger Check for faulty outrigger retract
OUTRIGGER RETRACT Retract circuit was energized. solenoid coil/wiring.
051 OPEN CIRCUIT OUTRIGGER A load of less than 70mA detected in outrigger Check for faulty outrigger extend
EXTEND retract circuit on power-up. solenoid coil/wiring.
052 SHORTED CIRCUIT Excessive load was detected in outrigger extend Check for faulty outrigger extend
OUTRIGGER EXTEND circuit on power-up. solenoid coil/wiring.
053 OPEN CIRCUIT A load of less than 70mA detected in left front Check for faulty solenoid
LF OUTRIGGER outrigger circuit on power-up. coil/wiring at outrigger.
054 SHORTED CIRCUIT Excessive load was detected in left front Check for faulty solenoid
LF OUTRIGGER outrigger circuit on power-up. coil/wiring at outrigger.
055 OPEN CIRCUIT A load of less than 70mA detected in right front Check for faulty solenoid
RF OUTRIGGER outrigger circuit on power-up. coil/wiring at outrigger.

32
4 – TROUBLESHOOTING

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. coil/wiring at outrigger.
058 SHORTED CIRCUIT Excessive load detected in left rear outrigger Check for faulty solenoid
LR OUTRIGGER circuit on power-up. coil/wiring at outrigger.
059 OPEN CIRCUIT A load of less than 70mA detected in right rear Check for faulty solenoid
RR OUTRIGGER outrigger circuit on power-up. coil/wiring at outrigger.
060 SHORTED CIRCUIT Excessive load detected in right rear outrigger Check for faulty solenoid
RR OUTRIGGER circuit on power-up. coil/wiring at outrigger.
069 OPEN CIRCUIT A load of less than 70mA detected in proportional Check for faulty solenoid
PROPORTIONAL valve circuit on power-up. coil/wiring at proportional valve.
070 SHORTED CIRCUIT Excessive load detected in proportional valve Check for faulty solenoid
PROPORTIONAL circuit on power-up. coil/wiring at proportional valve.

33
BIL-JAX 45XA

34
5 DECAL REPLACEMENT
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.

35
BIL-JAX 45XA

Table 5-1. Decal Descriptions

Decal No. Decal Description Qty Decal No. Decal Description Qty
0202-0523 Made in USA 1 B06-00-0484 DANGER: Battery/Charger Safety 1
B06-00-0034 DANGER: Electric Shock 1 B06-00-0494 NOTICE: Hazardous Materials 1
B06-00-0037 Lubricate Semi-Annually 1 CAUTION: Compartment Access
B06-00-0495 2
Restricted
B06-00-0062 NOTICE: AC Power 2
B06-00-0503 NOTICE: Handle Applications 1
B06-00-0068 NOTICE: Hydraulic System Oil 1
B06-00-0504 NOTICE: Emergency Hand Pump 1
B06-00-0161B Bil-Jax Logo, Black Transfer 2
DANGER: Before Use/Main
B06-00-0403 NOTICE: Emergency Lowering 4 B06-00-0505 1
Instruction/Hazards (ground)
B06-00-0404 WARNING: Outrigger Crush Toe 8 B06-00-0521 DANGER: Tip Over Hazard 5
B06-00-0405 WARNING: Pinch Point 16 B06-00-0536 NOTICE: Range of Motion 2
DANGER: Before Use/Main CAUTION: Manual Boom
B06-00-0471 1 B06-00-0541 1
Instruction/Hazards (Platform) Functions
NOTICE: Operator’s Manual B06-00-0545 Bil-Jax Website Transfer 2
B06-00-0473 1
Missing
NOTICE: Fall Protection Attach-
B06-00-0474 NOTICE: Max. Load 1 B06-00-0552 1
ment Points
WARNING: Read/Understand WARNING: Operating Instructions
B06-00-0475 1 B06-00-0561 2
Operator’s Manual (Ground)
B06-00-0477 WARNING: Forklift Pockets 2 WARNING: Operating Instructions
B06-00-0562 1
B06-00-0481 CAUTION: Transport Safety Latch 2 (Platform)

B06-00-0482 DANGER: Electrocution Hazard 2 B06-00-0564 45XA, 6” Black Transfer 2

Identification Plates
B06-00-0490 VIN Plate 1
B06-00-0499 ANSI ID Plate 1
B06-00-0524 Annual Inspection Plate 1
B06-00-0526 Key Tag 1

36
4x
0405

0521 0405

0405 0404 0482

0536

0403
0403
0037

0161B 0545 0564


0481 0403 0405
0477

0473

0562
0475

0471
0062

0552
0474

Figure 5-1. Decal Placement


0405 0536 0202-0523
0521

0521

0481 0505 0495 0504


0503 0068

0494
0495

0034

0484 0561 0541

37
5 – DECAL PLACEMENT
BIL-JAX 45XA

Table 5-2. Decal Descriptions – CE

Decal No. Decal Description Qty Decal No. Decal Description Qty
0202-0523 Made in USA 1 B06-00-0482 DANGER: Electrocution Hazard 2
B06-00-0034 DANGER: Electric Shock 2 CAUTION: Compartment Access
B06-00-0495 2
Restricted
B06-00-0037 Lubricate Semi-Annually 1
DANGER: Before Use/Main
B06-00-0062 NOTICE: AC Power 2 B06-00-0505 1
Instruction/Hazards (ground)
B06-00-0068 NOTICE: Hydraulic System Oil 1 B06-00-0536 NOTICE: Range of Motion 2
B06-00-0161B Bil-Jax Logo, Black Transfer 2 CAUTION: Manual Boom
B06-00-0541 1
B06-00-0173 Fall Protection Attachment Points 1 Functions

B06-00-0403 NOTICE: Emergency Lowering 4 B06-00-0545 Bil-Jax Website Transfer 2

B06-00-0404 WARNING: Outrigger Crush Toe 8 WARNING: Operating Instructions


B06-00-0561 2
(Ground)
B06-00-0405 WARNING: Pinch Point 15
WARNING: Operating Instructions
B06-00-0562 1
DANGER: Before Use/Main (Platform)
B06-00-0471 1
Instruction/Hazards (Platform)
B06-00-0564 45XA, 6” Black Transfer 2
B06-00-0474 NOTICE: Max. Load 1
B06-00-0568 WARNING: Outrigger Pressure 4
WARNING: Read/Understand
B06-00-0475 2 WARNING: Read/Understand
Operator’s Manual B06-00-0572 1
Parts and Service Manual

Identification Plates
B06-00-0499 ANSI ID Plate 1
B06-00-0526 Key Tag 1

38
4x
0405

0405

0568
0405 0482

0404 0403
0403
0037

0161B 0545 0564


0403 0405

0562
0475
0474

0471
0062

0536
0202-0523

0405 0173

Figure 5-2. Decal Placement – CE


0495 0505
0495
0068
0572

0475

0034

0536 0561 0541


0034

39
5 – DECAL PLACEMENT
BIL-JAX 45XA

40
6 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.
Direct any questions or concerns regarding equipment specifications to
your regional Bil-Jax representative or to the Bil-Jax Service Department.

41
BIL-JAX 45XA

SPECIFICATIONS
SERIAL NUMBER__________________

Working Height 51 ft Outrigger Footprint


15.7 m Length 12 ft 2 in
Maximum Platform Height 45 ft 3.7 m
13.7 m Width 11 ft 4 in
3.4 m
Maximum Horizontal Outreach
Footpad Diameter 12.5 in
From Centerline 27 ft
0.3 m
8.2 m
From Outrigger Footpad Edge 21 ft Brake Spring Applied
6.4 m Speed
Rated Platform Capacity Gas Power 3.75 mph
Without Platform Rotation 500 lbs 6 km/h
227 kg DC Power 2 mph
With Platform Rotation 440 lbs 3.2 km/h
200 kg Tire Size 26 x 12 bar lug tires
Maximum Occupants 2 Tire Pressure 20 PSI
Total Weight 4,300 lbs 140 kPa
1,950 kg Control System 24V DC
Turntable Rotation 700º Non-Continuous Battery 4 x 6V 245 amp-hr
Leveling Capability 12.5º Battery Charger 110/120 Volt
Gradeability 48% Gas Engine Kawasaki 21 HP
Wheel Base 8 ft 8 in Hydraulic Pressure 3,000 psi
2.7 m 20,684 kPa
Turning Radius Reservoir Capacity 4.3 Gallons
Inside 11 ft 16.3 L
3.35 m
Hydraulic System Capacity 6.3 Gallons
Outside 16 ft 8 in
23.9 L
5m
Hydraulic Oil (Standard) Dexron III/Mercon ATF
Platform Dimensions
Height 3 ft 7 in Platform Rotation/Type (Optional) 90º/Manual
1.1 m Maximum Decibel Level
Length 2 ft 6 in DC Mode – Ground 60 dB
0.8 m DC Mode – Platform 55 dB
Width – US/CE 5 ft/4 ft Gas Mode – Ground 70 dB
1.5 m/1.2 m Gas Mode - Platform 65 dB
Stowed Dimensions Localized Pressure per Outrigger 25 PSI
Height 6 ft 4 in 1.8 kg/cm2
2.0 m 176.5 kPa
Length 19 ft 2 in Operation Temperature Range -20º to 110º Fahrenheit
5.8 m -29º to 43º Celsius
Width 5 ft 5 in
Max. Pressure Per Tire – Floor 35 PSI
1.7 m
Loading 2.5 bar

42
6 — SPECIFICATIONS

RANGE OF MOTION

Figure 7-1. Range of Motion

43
BIL-JAX 45XA

44
7 EQUIPMENT OPTIONS
The Bil-Jax Model 45XA may be equipped with one or more
optional components designed for the convenience and safety of
operators when using the equipment to accomplish specific
tasks.
Always use only those components manufactured and/or
authorized by Bil-Jax, Inc. Never make any adjustments or
modifications or otherwise alter the equipment in any way that is
not expressly recommended by the manufacturer.
When operating a machine equipped with optional components,
observe all safety precautions set forth by the manufacturer, as
well as all government codes and regulations regarding this
equipment and its components.
Consult rental agency or equipment manufacturer regarding
which optional components may be installed on the boom lift. For
questions regarding safe use, contact your regional Bil-Jax
dealer before attempting operation

45
BIL-JAX 45XA

MATERIAL LIFTING HOOK


If the boom lift is equipped with a material lifting
hook, observe the following procedure for material
lift operation:
Remove platform controls from the work
platform by releasing the latch on the back of the
platform control box.
Disconnect platform control box from the load
sense module located on the boom lift bulkhead.
Remove the electric loopback plug from the Figure 8-2. Material Lifting Hook Installation
receptacle on the bottom right of the ground
control panel (Figure 8-1) and insert the platform Operate the material lifting hook remotely, using
control cable into the open receptacle. the platform control box for optimal control.

WARNING
Always observe the manufacturer’s weight lifting
limitations when using the material lifting hook.
Always use lifting straps or wire rope slings that
are rated at a minimum 500 lbs lifting capacity.
Never stand beneath an elevated load or position
an elevated load above personnel. Falling
objects can cause serious injury or death.

1. To Boom Cable. DANGER


This machine is not insulated for use near
Do Not Remove.
electrical power lines and DOES NOT provide
2. To Platform Controls. protection from contact with or close proximity
to any electrically charged conductor. Operator
a. Disconnect platform controls.
must maintain safe clearances at all times and
b. Replace with loopback plug from ground always allow for platform movement such as
controls. wind-induced sway. Refer to Table 1-1 for
minimum safe approach distances between the
c. Plug platform controls into open receptacle machine and electrical power lines.
on the bottom right of ground control panel.
Reverse the procedure to reattach the work
Figure 8-1. Material Lifting Hook Configuration platform.

Insert the removed electric loopback plug into


the open receptacle on the load sense module,
replacing the platform control cable.
Remove the retaining pin holding the platform to
boom lift. Firmly secure platform to prevent
equipment damage.
Remove the platform from the boom by lifting
cage up and away from the mounting bracket on
the boom nose.
Attach the material lifting hook to the mounting
bracket on the boom nose and insert the
retaining pin (Figure 8-2).

46
7 — EQUIPMENT OPTIONS

PLATFORM ROTATOR
The optional platform rotator allows the operator to
rotate the elevated work platform 90º around a
vertical axis by actuating a rotator handle found
below the platform control panel.
To operate manual platform rotator, turn the rotator
handle in the direction of desired rotation (clockwise
or counterclockwise). Motion continues in the
desired direction until rotator handle is released or
the platform reaches a safe travel limit.

WARNING
Installation of a manual platform rotator may
reduce the rated load limit of the work platform.
Follow all manufacturer’s recommendations and
safety precautions when operating a boom lift
equipped for platform rotation.

Figure 8-3. Manual Platform Rotator

47
BIL-JAX 45XA

48
NOTES
Distributed by:

125 Taylor Parkway


Archbold, OH 43502
Phone (419) 445-8915
(800) 537-0540
Fax (419) 445-0367

http://www.biljax.com