Operation and Maintenance Manual AERIAL WORK PLATFORMS XLB-4232 DC Hydraulic Boom Lift B33-01-0088
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 & 11 of ANSI A92.2 and all other manufacturer’s recommendations.
Table of Contents 1 Safety ............................................................................................................... 1-1 1-1 Introduction ........................................................................................ 1-1 1-2 Before Operation ............................................................................... 1-3 1-3 During Operation............................................................................... 1-4 1-4 Maintenance Safety ..........................
List of Illustrations Figure 3-1. Figure 3-2. Figure 3-3. Figure 3-4. Figure 3-5. Figure 3-6. Figure 3-7. Figure 3-8. Figure 3-9. Figure 3-10. Figure 4-1. Figure 4-2. Figure 4-3. Figure 4-4. Figure 4-5. Figure 4-6. Figure 4-7. Figure 4-8. Figure 4-9. Figure 4-10. Figure 5-1. Figure 5-1. Figure 5-1. Figure 5-2. Figure 5-3. Figure 5-4. Figure 6-1. Figure 6-2. Figure 6-3. Figure 6-4. Figure 6-5. Figure 6-6. Figure 6-7. Figure 6-8. Figure 6-9. Figure 6-10. Figure 6-11. Figure 6-12. Figure 6-13. Figure 6-14.
List of Tables Table 1-1. Table 2-1. Table 4-1. Table 4-2. Table 4-3. Table 4-7. Table 5-1. Table 6-1. Table 6-2. Table 6-3. Table 6-4. Table 6-5. Table 6-6. Table 6-7. Table 6-8. Table 6-9. Table 6-10. Table 6-11. Table 6-12. Table 6-13. Table 6-14. Table 6-15. Table 6-16. Table 6-17. Table 6-18. Table 6-19. Table 6-20. Table 7-1. Minimum Safe Approach Distances ....................................................... 1-4 Specifications.......................................................................
iv
1 Safety 1-1 INTRODUCTION Familiarity and proper training are required for the safe operation of mechanical equipment. Equipment operated improperly or by untrained personnel can be dangerous. Read the operating 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.
XLB-4232 DC Safety Notes This manual contains DANGERS, WARNINGS, CAUTIONS, and NOTES that must be followed to prevent the possibility of improper service, damage to the equipment, or personal injury. 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.
1 — SAFETY 1-2 BEFORE OPERATION Ensure the following general safety precautions are followed before operating the XLB-4232 DC 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.
XLB-4232 DC 1-3 DURING OPERATION Ensure the following general safety precautions are followed during the operation of the XLB-4232 DC 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.
1 — SAFETY • NEVER allow electrode contact with any part of the basket if welding is being performed from the platform. • NEVER use without the outriggers fully extended, locked, and firmly based. When on soft surfaces, ALWAYS use outrigger base plates. • NEVER override or by-pass manufacturer's safety devices. • NEVER attach a safety harness to an adjacent structure, pole, or equipment while working from the boom platform.
XLB-4232 DC 1-4 MAINTENANCE SAFETY Ensure the following safety precautions are observed whenever maintenance is performed on the XLB-4232 DC Boom Lift. General Maintenance 1-6 • ALWAYS perform maintenance procedures according to manufacturer's requirements. NEVER short change maintenance procedures. • ALWAYS check hydraulic system. Make sure all lines, connectors, and fittings are tight and in good condition.
1 — SAFETY Battery Maintenance Ensure the following general safety precautions are followed whenever performing battery maintenance on the XLB-4232 DC Boom Lift. 1-5 • ALWAYS check battery acid level daily. Check battery test indicator for proper state of charge on maintenance free batteries before using lift. • ALWAYS wear safety glasses when working near battery. • ALWAYS avoid contact with battery acid. Battery acid causes serious burns. Avoid contact with skin or eyes.
XLB-4232 DC 1-8
2 Introduction 2-1 GENERAL DESCRIPTION The XLB-4232 DC Boom Lift is designed and manufactured for positioning personnel with their tools and equipment at overhead work locations. The rated work basket load capacity is 300 lbs. for the XLB-4232. Basket elevation is by two hydraulic cylinders acting on the boom sections. A hydraulic powered motor and worm gear rotates the boom 360° around a vertical axis. The hydraulic power unit includes a reservoir, pump, and control valves.
XLB-4232 DC 2-2 SPECIFICATIONS Boom Lift Work Platform Model Number XLB-4232 DC Serial Number ________________ Manufactured by: Bil-Jax, Inc. 125 Taylor Parkway Archbold, Ohio 43502 419.445.9675 Table 2-1.
3 Operation 3-1 OPERATOR CONTROLS The XLB-4232 DC Boom Lift is equipped with multiple operator controls. Electrical boom lift and rotation control panels are located at ground level and in the basket. Manual boom rotation and lowering controls are at the ground level. Battery ON/OFF Switch A battery ON/OFF switch (Figure 3-1) is mounted on the front end of the hydraulic power compartment. Turn the switch to the ON position to turn battery power on to the boom lift electrical system.
XLB-4232 DC Lower Control Panel The lower control panel (Figure 3-2) is located on the side of the hydraulic power compartment. The following controls and indicators are on the lower control panel. Figure 3-2. Lower Control Panel (DC Model) EMERGENCY STOP Pushbutton When pressed, the EMERGENCY STOP pushbutton disconnects electrical power to the upper and lower control panels. The EMERGENCY STOP pushbutton should only be pressed to immediately stop all boom motion.
3 — OPERATION BOOM IN/OUT Selector Switch Holding the BOOM IN/OUT selector switch in the OUT position extends the boom out. Holding the selector switch in the IN position retracts the boom. The in or out boom motion continues until the selector switch is released, or the boom reaches a hard stop or a safe travel limit. BOOM FAST/SLOW Selector Switch The BOOM FAST/SLOW selector switch controls the speed of the selected boom motion.
XLB-4232 DC Upper Control Panel The upper control panel (Figure 3-3) is mounted in the work basket. The following controls and indicators are available on the upper control panel. BATTERY CHARGE INDICATOR Figure 3-3. Upper Control Panel (DC Model) BUCKET TILT COMPENSATOR Switch (DC Model Only) A BUCKET TILT COMPENSATOR switch allows for slight adjustment to the level of the work basket. Adjustment is limited to 3 degrees in either direction.
3 — OPERATION UPPER CONTROLS ON/OFF Deadman Switch The UPPER CONTROLS ON/OFF deadman switch must be held in the ON position simultaneously with any other boom motion function. This prevents accidental movement of the work basket. ROTATION CW/CCW Selector Switch Holding the ROTATION CW/CCW selector switch in the CW position enables the boom to rotate in the clockwise direction. Holding the selector switch in the CCW position enables the boom to rotate in the counterclockwise direction.
XLB-4232 DC 3-2 NORMAL OPERATING PROCEDURE Perform the following procedures to operate the XLB-4232 DC Boom Lift. 1. Read and follow all safety precautions contained in Section 1 and all responsibilities outlined in the ANSI A92.2 reprint contained in Section 7 of this manual. 2. Position the lift at the work area. Make sure the lift is on a firm and level surface and that there are no potential hazards such as overhead obstructions or electrically charged conductors.
3 — OPERATION 12. Raise the safety bar and enter the basket. Put on the safety harness and attach the lanyard to the basket railing. 13. The lift is now ready for operation from the basket. Operate in slow speed to get familiar with the controls. The UPPER CONTROLS ON/OFF deadman switch must be held in the ON position simultaneously with any other boom motion function. 14. Should the basket become tilted out of the normal vertical axis, adjustment can be made using the BUCKET TILT COMPENSATOR switch.
XLB-4232 DC 3-3 EMERGENCY LOWERING The XLB-4232 DC Boom Lift is equipped with a manual emergency lowering valve that can lower the basket in case of a power failure or an emergency situation. The emergency lowering valve is located at the base of the lift cylinder. Before lowering, it may be necessary to manually rotate the boom if it is over hanging an obstruction. See the following section for this procedure.
3 — OPERATION 3-5 BATTERY RECHARGE (DC MODEL ONLY) The DC boom lift batteries should be recharged after each 8-hour work shift or more often if needed. When the boom lift is not in use, the batteries should be recharged at least once per week. The normal charge time is 10 to 12 hours. If the battery charge is extremely low, a full recharge may take up to 24 hours. Recharge the DC boom lift batteries as follows: WARNING Recharge the batteries in a well ventilated area only.
XLB-4232 DC 5. To determine the charge rate at any time during the charge cycle, observe the DC ammeter (Figure 3-7). The ammeter needle moves to the right at the start of the charge cycle. As the battery charge rises, the needle moves farther left. Figure 3-7. Battery Charger CAUTION Always remember to unplug the battery charger power cord before moving the boom lift. Failure to unplug the power cord will cause damage to the equipment. 6.
3 — OPERATION 3-6 BOOM LIFT TRANSPORT The boom lift trailer is a single axle trailer fitted with a two-inch ball hitch, surge brakes, breakaway safety cable, safety chains, brake lights, and side marker lights. Proper boom lift transport requires the correct hookup and inspection of these trailer components before towing. Use the following procedures to hitch, tow, and back the boom lift trailer: Trailer Hitching Trailer hitching requires a second person to give tow vehicle backing instructions. 1.
XLB-4232 DC CAUTION Always cross and attach the safety chains before towing. Failure to attach safety chains properly will allow tongue to drop in case of ball hitch failure, resulting in serious damage to the trailer and equipment. 6. Attach the trailer safety chains to the tow vehicle. Make sure the chains cross under the trailer tongue as shown in (Figure 3-10). If needed, cross the chains over then under the tow bar to prevent dragging. BREAKAWAY SAFETY CABLE SAFETY CHAINS Figure 3-10.
3 — OPERATION WARNING Improper tightening of boom lift trailer wheel nuts can cause wheel lugs to shear, causing serious injury or damage to equipment. Check and maintain the proper wheel nut torque according to the maintenance instructions in this manual. Periodically check the wheel nut torque according to the instructions in Section 4-2 of this manual. More frequent torque checks are required when a wheel is recently installed.
XLB-4232 DC 3-14
4 Maintenance 4-1 SCHEDULED SERVICE CHECKS Daily/Weekly Service Checks Perform the following daily/weekly service checks as listed in Table 4-1. Table 4-1. Daily/Weekly Service Checks Service Check Daily before use Weekly Check battery electrolyte level. If battery charge is low, add water to bring electrolyte just above plates. If batteries are fully charged, raise electrolyte to full mark in each cell. Check and retighten all nuts and bolts. Check that cage gate is secure.
XLB-4232 DC Monthly Service Checks Perform the following monthly service checks as listed in Table 4-2. Table 4-2. Monthly Service Checks Service Check Clean battery terminals and check battery charger operation. Check operation of manual emergency lowering valve. Check wheel nut torque per paragraph 4-2. Check for excess wear, free play, or binding in outrigger screws. Replace damaged parts. Lubricate power compartment hinges and latches with light weight machine oil.
4 — MAINTENANCE 4-2 WHEEL NUT TORQUE REQUIREMENTS It is very important to apply and maintain the correct wheel nut torque on the boom lift trailer. The wheel nuts must be evenly tightened to the following specified torque increments whenever a trailer wheel is removed and installed. Use the following tightening procedure: 1. Evenly tighten the wheel lug nuts to 25 lb-ft (34 N·m) in the tightening sequence shown in Figure 4-1. Figure 4-1. Wheel Nut Tightening Sequence 4-3 2.
XLB-4232 DC 3. Lubricate the slew ring bearing grease fitting labeled LUBRICATE SEMIANNUALLY with NLGI Grade 2 multi-purpose grease. Wipe off dirt and grease residue. Rotate the boom and add approximately ½ ounce of grease to each bearing quadrant. See Figure 4-3 for the location of the slew ring bearing grease fitting. Figure 4-3. Lubricate Semi-Annually 16. Determine whether the boom lift is equipped with an Al-Ko axle (hex tube) or Dexter axle (square tube).
4 — MAINTENANCE 18. Lubricate a Dexter axle according to the following procedure: a. Remove the rubber plug to expose the grease fitting. b. Grease the bearings with an NLGI Grade 2 polyurea type, lithium-based, high-temperature, wheel bearing grease (minimum 440°F dropping point). Rotate the hub while applying grease. c. Continue to apply fresh grease until all the old grease is purged. When new grease starts to flow from the front bearing, remove the grease gun.
XLB-4232 DC 4-4 HYDRAULIC SYSTEM Hydraulic system maintenance varies with equipment use and the environment in which the boom lift is used. Constant attention to keep the oil clean and the reservoir properly filled will help prevent possible damage to the system. Hydraulic diagrams are provided at the end of this section for general reference. Hydraulic System Inspection Check the hydraulic hose and fittings for leaks and damage daily. Tighten or replace as necessary to prevent hydraulic oil loss.
4 — MAINTENANCE Hydraulic Cylinder Repair Cylinder Removal and Installation 1. Lower boom onto travel support, turn off the main power switch, and remove the PLATFORM/OFF/GROUND key. 2. Support lift cylinder with wood shoring between cylinder and boom. Secure both ends of lower boom lift cylinder with lifting straps and overhead lifting device. Support upper boom lift cylinder with padded lift truck forks. 3. Place absorbent drip cloths below cylinder ports. Remove hydraulic hoses from lift cylinder.
XLB-4232 DC 5. Using a pry bar and shoring, unweight the cylinder end. Remove pivot pin (4) and spacers (5). 6. Lower the free end of cylinder (6) onto support shoring or a lifting strap. 7. Repeat steps 4 through 6 at the opposite end of the cylinder. 8. Lift the lower end of the cylinder from its pivot block. Use an overhead lifting device and lifting straps and/or a lift truck to remove the cylinder. 9. After repairing the hydraulic cylinder, reinstall the cylinder in the reverse order of removal. 10.
4 — MAINTENANCE Cylinder Disassembly and Inspection Perform the following procedure to disassemble the upper or lower hydraulic lift cylinder. Whenever the hydraulic cylinder is disassembled, all seals must be replaced. Refer to replacement seal kit, Figure 6-3 or 6-4. 1. Check bearings (1, Figure 4-6) for wear and excess play. Replace bearings if necessary. 2. Unscrew headstock (2) and slide cylinder rod (3) from housing (4). 3. Remove slotted nut (5) and piston (6).
XLB-4232 DC 4. Remove headstock (2). Remove and discard o-ring (11), backup ring (12), and seal (13). Remove bushing (14) and wiper (15). Discard wiper. 5. Inspect the cylinder rod (3) for scratches or pits. Pitting in the base metal is not acceptable. Wear indications that catch the fingernail, but do not extend into the base metal nor extend more than 1/2 inch along the rod length are acceptable if they will not cut the seal material. The chromium plating must not be worn through.
4 — MAINTENANCE 4-5 ADJUSTING AXLE POSITION SWITCHES The axle position switches are set up to detect when the boom lift load is transferred from the trailer wheels to the outriggers. After the first 100 miles of road travel the axle torque arms wear in. Torque arm wear-in causes the wheels to ride higher in relation to the trailer frame. Following wear-in, the axle position switches need to be readjusted. Use the following procedure to readjust the axle position switches: 1.
XLB-4232 DC 4-6 TROUBLESHOOTING Table 4-3. Troubleshooting Chart Problem 1. 2. 3. 4. 4-12 Outriggers indicator lamp will not light up. Cause a. Master power switch turned off. a. Turn on master power switch. b. Emergency stop or power button engaged (pushed in). b. Rotate emergency stop buttons clockwise to disengage. c. All outriggers not deployed. c. Deploy all outriggers. d. At least one wheel not raised. d. Raise at least one wheel off the ground. Master power switch turned off.
4 — MAINTENANCE Table 4-3. Troubleshooting Chart, Continued Problem 5. Boom lift and rotate functions operate intermittently. Cause Correction a. Loose connection. a. Reconnect wiring. b. Loose connector at valve coil. b. Check wiring connection to valve coil; repair loose wiring.
4-14 T 11 T 19 Hi/Low T 12 T 20 Bucket Comp E-Stop T 10 Figure 4-8.
4 — MAINTENANCE YELLOW LED GREEN LED RED LED OUT OF LEVEL INPUT POWER OUTPUT SIGNAL (MOMENTARY) (ON WHEN LEVEL) Figure 4-9. Level Sensor Table 4-4. Level Sensor LEDs Color Description Yellow Boom lift out of level. Signals alarm after 2 second delay. Green Boom lift power is on. Red Boom lift level. Goes out after time delay.
4-16 2.5 GPM 4 3 BL2 Figure 4-10. DC Model Hydraulic Diagram 1.
4 — MAINTENANCE 4-7 MATERIAL SAFETY DATA SHEETS MATERIAL SAFETY DATA SHEET FOR LEAD ACID BATTERIES, WET, FILLED WITH ACID SECTION I: GENERAL INFORMATION Manufacturer’s Name: Street Address: City, State, Zip Phone Number: Crown Battery Mfg. Company 1445 Majestic Drive Fremont, Ohio 43420 419 334-7181 EMERGENCY NO: 800 487-2879 OR 800 OIL-TANK REVISION DATE: 5/18/2000 SECTION II: MATERIAL IDENTIFICATION AND INFORMATION COMPONENTS Hazardous Components 1% or greater Carcinogens 0.
XLB-4232 DC ************************************************************************************************* SECTION V -- HEALTH HAZARD DATA ************************************************************************************************* Primary Routes of Entry: Inhalation: YES Skin: YES Ingestion: YES Health Hazards: Acute EYES, SKIN, RESPIRATORY SYSTEM & DIGESTIVE SYSTEM Chronic: EYES, SKIN, RESPIRATORY SYSTEM & DIGESTIVE SYSTEM Signs and Symptoms of Exposure: IRRITATION OF EXPOSED AREA, BURNS AND RES
4 — MAINTENANCE MATERIAL SAFETY DATA SHEET 1-SITE SPECIFIC INFORMATION: AW-46 HYDRAULIC OIL 2-GENERAL INFORMATION TRADE NAME: AW-46 HYDRAULIC OIL EMERGENCY TELEPHONE NUMBERS: (517) 849-2144 CHEMICAL FAMILY: LUBRICATING OIL CAS NUMBER: MIXTURE: ISSUE DATE 12/15/96 HAZARDOUS INGREDIENTS: ---------------------------------------------------------------------------CONTAINS NO INGREDIENTS NOW KNOWN TO BE HAZARDOUS AS DEFINED IN OSHA 29 CFR 1910.1000 AND OSHA 29 CFR 1910.1200.
XLB-4232 DC PAGE 2 SPECIAL PROTECTION INFORMATION RESPIRATORY PROTECTION (SPECIFIC TYPE) NONE REQUIRED VENTILATION: NORMAL LOCAL EXHAUST: NORMAL MECHANICAL EXHAUST (GENERAL) X PROTECTIVE GLOVES: OIL IMPERVIOUS GLOVES RECOMMENDED EYE PROTECTION: SAFETY GLASSES RECOMMENDED OTHER PROTECTIVE EQUIPMENT: NONE REQUIRED ---------------------------------------------------------------------------SPECIAL INSTRUCTIONS SPECIAL LABELLING INSTRUCTIONS: NOT REQUIRED SPECIAL PACKAGING RECOMMENDATIONS: NONE HANDLING AND STO
5 Replacement Decals Refer to Table 5-1 and Figures 5-1 through 5-6 for descriptions and locations of decals on the XLB-4232 DC Boom Lift. Table 5-1. Replacement Decals, DC Model Decal No. Description of Decal Qty Decal No. Description of Decal Qty B06-00-0006 EMERGENCY CONTROL VALVE 1 B06-00-0145 DANGER: BOOM SAFETY INSTRUCTIONS 2 B06-00-0015 MAXIMUM CAPACITY…300 LBS.
XLB-4232 DC DANGER BEFORE USING: EXTEND, LOCK, STABILIZE OUTRIGGERS; AND LEVEL MACHINE. CFT/RFC !! ATTENTION !! To prevent premature motor failure, it is imperative that the fiberglass cover be kept in the closed position to protect against direct contact with any foreign particles and/or moisture. Should the hydraulic power unit need to be cleaned, it is very important to cover or shield the motor. The DC motor must not come into direct contact with foreign particles and/ or moisture.
5 — REPLACEMENT DECALS DANGER FAILURE TO COMPLY WITH THE FOLLOWING INSTRUCTIONS OR ANY OTHER IMPROPER USE OR MAINTENANCE OF THIS EQUIPMENT WILL RESULT IN INJURY OR DEATH. • Risk of Electric Shock DO NOT expose charger to rain, power wash detergents or spray - DO NOT use frayed or damaged electric cords when charging. • During charging, explosive oxyhydrogen gas is generated. DO NOT smoke or allow open fire, sparks, or embers near battery when charging.
XLB-4232 DC FAST . SLOW CCW C O N T R O L S ON . . PULL PUSH OFF ON OUT OFF PULL ON PUSH OFF UP UP . . AIF/AFL CW . . . IN DOWN © Bil-Jax, Inc. 2004 DOWN OUT UPPER B06-00-0118 OFF B06-00-0118 CONTROLS SELECTOR . . IN LOWER FAST CCW . . SLOW OFA CW © Bil-Jax, Inc. 2004 B06-00-0276 . Model - XLB 4232 DC VIN Max. Plat. HT. 35 ft 5in Max Reach 32ft 0in SYSTEM PRESSURE 1900 PSI OUTRIGGERS PROPERLY SET B06-00-0276 MANUFACTURED IN G.V.W. - 4740 LBS.
B06-00-0139 B06-00-0161Y (WORM GEAR) B06-00-0130 B06-00-0139 B06-00-0037 B06-00-0139 B06-00-0130 B06-00-0060 B06-00-0192 B06-00-0015 B06-00-0173 (OUTSIDE OF DOOR) B06-00-0145 B06-00-0116 B06-00-0115 B06-00-0118 B06-00-0117 B06-00-0144 5 — REPLACEMENT DECALS Figure 5-2.
5-6 (BOTH ENDS) Figure 5-3.
B06-00-0033 B06-00-0130 B06-00-0036 B06-00-0130 B06-00-0272 B06-00-0114 B06-00-0130 B06-00-0130 B06-00-0268 B06-00-0062 B06-00-0161 B06-00-0036 (EACH JACK) (STRIPED TRANSFER) B06-00-0266 B06-00-0034 B06-00-0036 B06-00-0006 5 — REPLACEMENT DECALS Figure 5-4.
XLB-4232 DC 5-8
6 Parts List 6-1
XLB-4232 DC 6-1 UPPER BOOM PARTS LIST Refer to Table 6-1 for the upper boom parts list. 15 14 1 13 22 23 21 10, 10A 12 5 4 7 22 3 20 2 2 8 17A 6 3 11 9 20 4 5 19 24 7 17 20 8 18 Figure 6-1.
6 — PARTS LIST Table 6-1. Upper Boom Parts List Item No. Part No. Description Qty 1 B14-00-0002 Boom, Upper 1 2 B30-00-0004 Spacer, Extension Cylinder, Ram End 2 3 B04-06-0001 Washer, Flat, 2 in. OD 2 4 0090-0210 Washer, Lock, Split, 3/8 in. 2 5 0090-0480 Screw, Cap, 3/8-16 x 1 in. w/Loctite Patch 2 6 B36-01-0004 Pin, Extension Cylinder, Ram End 1 7 B25-00-0003 Bushing, Bronze, 1-1/2 in. ID 2 8 0090-0344 Screw, Threadcutting, #10-24 x 1/2 in.
XLB-4232 DC 6-2 LOWER BOOM PARTS LIST Refer to Table 6-2 for the lower boom parts list. 18 17 16 13 20 11 11 12 13 14 14 15 16 17 19, 19A 1 18 27 28 2 27 2 28 2 2 3 4 27 5 6 21 27 28 22, 22A 28 2 8 7A 10 24 7 7A 6 5 23A 25 9 26 23 Figure 6-2.
6 — PARTS LIST Table 6-2. Lower Boom Parts List Item No. Part No. Description Qty 1 B14-00-0001 Boom, Lower 1 2 0090-0510 Screw, Cap, Nylon, 3/8-16 x 1/2 in. 30 3 B31-00-0004 Shim, Side 4 4 0090-0429 Washer, Flat, 1 in. 2 5 B30-00-0003 Cam, Support Roller 2 6 0090-0363 Screw, Set, Socket, 1/4-20 x 3/4 in.
XLB-4232 DC 6-3 TURNTABLE PARTS LIST Refer to Table 6-3 for the turntable parts list. 1, 1A LOWER BOOM 10 4 2 5 6 8 15 3 7 2 9, 9A, 9B, 9C 11 16 17 12 13 3 6 4 7 5 14 10 21 22 8 5 6 24 7 23 22 25 26 Figure 6-3.
6 — PARTS LIST Table 6-3. Turntable Parts List Item No. Part No. Description Qty 1 B02-03-0007 Cylinder, Master Leveling, 2 in. Bore x 13-1/4 in. Stroke 1 1A B02-13-0037 Kit, Seal Replacement, Leveling Cylinder 1 2 0090-0103 Screw, Cap, 3/4-10 x 2-1/2 in. 2 3 0090-0428 Washer, Flat, 3/4 in. 2 4 0090-0195 Nut, Hex, Nylon Lock, 3/4-10 2 5 B29-00-0005 Plate, Pin 6 6 0090-0208 Washer, Lock, Split, 5/16 in. 12 7 0090-0028 Screw, Cap, 5/16-18 x 3/4 in.
XLB-4232 DC 6-4 DC MODEL BATTERY COMPARTMENT PARTS LIST Refer to Table 6-4 for the DC model boom lift battery compartment parts list. 1 2 10 13 12 10 3 10 8 7 5 7 9 14 15 4 11 6 16 17 35 32 36 37 11 34 14 33 20 18 18 19 21 7 22, 22A 30, 30A 28 31 29 5 14 24 15 25 26 25 27 c Figure 6-4.
6 — PARTS LIST Table 6-4. DC Model Battery Compartment Parts List Item No. Part No. Description Qty 1 B18-00-0014 Lid, Compartment Cover 1 2 B18-00-0135 Vent Louver, 2-1/2 in. 4 3 B42-00-0006 Clip, Latch 1 4 0090-0225 Screw, Machine, #8-32 x 1/2 in.
XLB-4232 DC 6-5 DC MODEL POWER COMPARTMENT PARTS LIST Refer to Table 6-5 for the DC model power compartment parts list. 3 2 1 4 3 5 3 13 12 10 11 8 6 6 7 16 9 14 15 17 19 18 57 58 59 62 61 6 63 64 21 27 22 23 3 60 37 36 56 55 11 24 20 41 38 61 54 21 42 53 41 43 28 40 45 28 49 21 48 22 47 Figure 6-5.
6 — PARTS LIST Table 6-5. DC Model Power Compartment Parts List Item No. Part No. Description Qty 1 B18-00-0013 Lid, Compartment Cover 1 2 B18-00-0135 Vent, Louver, 2-1/2 in. 2 3 0090-0232 Screw, Machine, #10-24 x 5/8 in. 16 4 0090-0684 Rivet, Pop, 3/16 x 1/2 in.
XLB-4232 DC 3 2 1 4 3 5 3 13 12 10 11 8 6 6 7 16 9 14 15 17 19 18 57 58 59 62 61 6 63 64 21 27 22 23 3 60 37 36 56 55 11 24 20 41 38 61 54 21 42 53 41 43 28 40 45 28 49 21 48 22 47 Figure 6-5.
6 — PARTS LIST Table 6-5. DC Model Power Compartment Parts List, Continued Item No. Part No. Description Qty 33 B01-10-0271 Display, Outrigger /Axle 1 34 0090-0001 Screw, Cap, 1/4-20 x 1/2 in. 2 35 B07-06-5589 Plate, Outrigger /Axle Display 1 36 B29-00-0152 Bracket, Outrigger /Axle Display 1 37 0090-0834 Nut, Jam, Nylon Lock, 1/4-20 4 38 0090-0627 Screw, Thread Cutting, #4-40 x 1/2 in.
XLB-4232 DC 6-6 TERMINAL ENCLOSURE PARTS LIST Refer to Table 6-6 for the terminal enclosure parts list. 1 2, 3 5 25 2, 3 10 2, 3 7 6 4 8 26 9, 10 24 11, 12 1 15 7 23 22 21 16 17, 18 6 14 19, 20 14 Figure 6-6.
6 — PARTS LIST Table 6-6. Terminal Enclosure Parts List Item No. Part No. Description Qty 1 B19-00-0007 Terminal Enclosure w/Cover 1 2 B01-09-0020 Cord Grip, 3/4 in. 3 3 B01-09-0021 Plastic Nut, 3/4 in. Cord Grip 3 4 B00-00-0102 Plug, Plastic 1 5 0090-0708 Screw, Machine, #6-32 x 3/8 in. 2 6 0090-0690 Screw, Machine, #6-32 x 5/8 in. 5 7 0090-0218 Screw, Machine, #6-32 x 1/2 in. 3 8 0090-0688 Screw, Cap, 1/4-20 x 1 in. 4 9 B01-09-0029 Cord Grip, 1/2 in.
XLB-4232 DC 6-7 FRAME AND ROTATION UNIT LIST Refer to Table 6-7 for the frame and rotation unit parts list. 2 3 4 1 8 7 5 6 9 10 12 13 15 11 18 14 16 17 22 20 21 23 19 24 25 26 27 28, 28A 30 31 11 29 33 34 Figure 6-7.
6 — PARTS LIST Table 6-7. Frame and Rotation Unit Parts List Item No. Part No. Description Qty 1 B03-00-0078 Handle Assembly, Manual Rotation (includes items 54 through 59) 1 2 B11-03-0018 Tube, Manual Boom Rotation 1 3 0090-0834 Nut, Nylon Lock, 1/4-20 1 4 0090-0011 Screw, Cap, 1/4-20 x 1-3/4 in.
XLB-4232 DC 6-8 HITCH AND JACK ASSEMBLY PARTS LIST Refer to Table 6-8 for the hitch and jack assembly parts list. 10 1 2 9 8 3 7 4 6 5 13 4 11 10 4 24 4 19 22 9 21 23 36 32 33 41 12 39, 40 22, 22A, 22B 42 38 8 18 24 24 31 28 27 39 7 16 24 39 26 47 46 34 Figure 6-8.
6 — PARTS LIST Table 6-8. Hitch and Jack Assembly Parts List Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 22A 22B 23 Part No.
XLB-4232 DC 10 1 2 9 8 3 7 4 6 5 13 4 11 10 4 24 4 19 22 9 21 23 36 32 33 41 12 39, 40 22, 22A, 22B 42 38 8 18 24 24 31 28 27 39 7 16 24 39 26 47 46 34 Figure 6-8.
6 — PARTS LIST Table 6-8. Hitch and Jack Assembly Parts List, Continued Item No. 24 25 26 27 28 29 Part No. 0090-0574 0090-0081 B03-00-0017 B01-01-0121 0090-0080 Description Washer, Flat, 1/2 in. Screw, Cap, 1/2-13 x 5 in. Chain, Safety Harness, Tail Light Screw, Cap, 1/2-13 x 4-1/2 in. B12-00-0169 Hitch, Tow (includes items 30-33) 30 B12-00-0182 Clamp Kit, 2 in.
XLB-4232 DC 6-9 SQUARE TUBE AXLE AND WHEEL ASSEMBLY PARTS LIST Refer to Table 6-9 for the square tube axle and wheel assembly parts list. 8 1 2 3 4 6 5 7 51 9 10 48 47 49 50 13,13A, 35,35A 11 37 39 38 40 41 42 43 47 14, 14A 17 36 21, 21A 16 46 30 26 29 15,15A 24 12 18 33 28 25 21, 21A 32,32A 21, 21A 34 22 20 31 23 21, 21A Figure 6-9.
6 — PARTS LIST Table 6-9. Square Tube Axle and Wheel Assembly Parts List Item No. Part No. Description Qty 1 B10-00-0041 Axle, Square Tube 1 2 0090-0938 Nut, Hex, Lock, 5/8-18 4 3 0090-0612 Washer, Flat 5/8 in. 4 4 0090-0937 Screw, Cap, 5/8-18 x 1-1/2 in. 4 5 0090-0032 Screw, Cap, 5/16-18 x 1-1/2 in. 8 6 0090-0208 Washer, Lock, 5/16 in. 8 7 0090-0420 Washer, Flat, 5/16 in.
XLB-4232 DC 8 1 2 3 4 6 5 7 51 9 10 48 47 49 50 13,13A, 35,35A 11 37 39 38 40 41 42 43 47 14, 14A 17 36 21, 21A 16 46 30 26 29 15,15A 24 12 18 28 25 33 21, 21A 32,32A 21, 21A 34 22 20 31 23 21, 21A 27 Figure 6-9.
6 — PARTS LIST Table 6-9. Square Tube Axle and Wheel Assembly Parts List, Continued Item No. Part No.
XLB-4232 DC 6-10 HEX TUBE AXLE AND WHEEL ASSEMBLY PARTS LIST Refer to Table 6-10 for the early version axle and wheel assembly parts list. 4 5 9 1 6 10 11 3 13, 13A 14 2 26 8 7 12 15 27 16 17 18 19 21 25 24 23 22 28 20 Figure 6-10.
6 — PARTS LIST Table 6-10. Hex Tube Axle and Wheel Assembly Parts List Item No. Part No. Description Qty 1 Not Procurable Axle, Hex Tube 1 2 0090-0192 Nut, Lock, 1/2-13 4 3 0090-0574 Washer, Flat 1/2 in. 8 4 0090-0461 Screw, Cap, 1/2-13 x 2 in. 4 5 0090-0648 Washer, Bevel, 1/2 in. 4 6 0090-0032 Screw, Cap, 5/16-18 x 1-1/2 in. 8 7 0090-0208 Washer, Lock, 5/16 in. 8 8 0090-0420 Washer, Flat, 5/16 in.
XLB-4232 DC 6-11 TAIL LIGHTS AND OUTRIGGER DISPLAY TRANSMITTER BOX PARTS LIST Refer to Table 6-11 for the tail lights and outrigger display transmitter box parts list. 12 16 2 12 14 13 1 3 10 12 6 11 7 12 11 3 8 5 7 8 9 4 15, 15A, 15B Figure 6-11.
6 — PARTS LIST Table 6-11. Tail Lights and Outrigger Display Transmitter Box Parts List Item No. Part No.
XLB-4232 DC 6-12 RIGHT FRONT/LEFT REAR OUTRIGGERS PARTS LIST Refer to Table 6-12 for the right front/left rear outriggers parts list. 6 5 7 2 25 1, 1A 24 23 27 22 3 8 R FO S T ER AC ILIZ NT AB CO ST EL ND HE W TE EX AST LE 3” 20 21 9 4 26 18 10 19 18 17 11 28 29 30, 30A 16 15 14 Figure 6-12.
6 — PARTS LIST Table 6-12. Right Front/Left Rear Outriggers Parts List Item No. Part No. Description Qty 1 B23-01-0087 Outrigger, Front, Passenger Side 1 1A B23-01-0087 Outrigger, Rear, Driver Side 1 2 B00-00-0085 Fitting, Grease, Straight, 1/4-28 1 3 B06-00-0167 Caution Tape, Black and Yellow 1 Roll 4 B23-02-0048 Assembly, Outrigger Jack (includes items 5 through 11) 5 B46-00-0028 6 0090-0183 Nut, Hex, Nylon Lock, 1/4-20 1 7 0090-0007 Screw, Cap, 1/4-20 x 1-1/4 in.
XLB-4232 DC 6-13 LEFT FRONT/RIGHT REAR OUTRIGGERS PARTS LIST Refer to Table 6-13 for the left front/right rear outriggers parts list. 25 27 24 26 23 22 21 19 30, 30A 18 29 28 19 20 6 1, 1A 18 17 5 EX LE TEN AS D S T W TA HE BIL EL IZE CO RS NT FO AC R T 7 2 3 8 3/4” 4 9 10 11 12 16 15 13 Figure 6-13.
6 — PARTS LIST Table 6-13. Left Front/Right Rear Outriggers Parts List Item No. Part No. Description Qty 1 B23-01-0092 Outrigger, Rear, Passenger Side 1 1A B23-01-0092 Outrigger, Front, Driver Side 1 2 B00-00-0085 Fitting, Grease, Straight, 1/4-28 1 3 B06-00-0167 Caution Tape, Black and Yellow 1 Roll 4 B23-02-0048 Assembly, Outrigger Jack (includes items 5 through 11) 5 B46-00-0028 6 0090-0183 Nut, Hex, Nylon Lock, 1/4-20 1 7 0090-0007 Screw, Cap, 1/4-20 x 1-1/4 in.
XLB-4232 DC 6-14 BASKET PARTS LIST 1 Refer to Table 6-14 for the basket parts list. 2 4 5 6 3 8 7 14 13 9 UPPER BOOM 17 15 16 18 10 11 18 12 19 3A 20 21 22 23, 23A 25 24 4 26 27 24 V 1600 DC PS I C AP M AC AX W I M IT Y O UM HY RK SY DRAU HEI PLAT G ST EM LIC HT FO RM VO SY HE 30 LTA STEM IG 0 G HT LB E PR ES SU 42 RE FT 35 FT 5 IN XL B42 32 31 SP EC IF IC AT IO NS 32 C AU 38 150 TION 0W ATT LO AD L IMIT 39 30 40 4 36 Figure 6-14.
6 — PARTS LIST Table 6-14. Basket Parts List Item No. Part No. Description Qty 1 B44-00-0016 Plywood, Cage 1 2 0090-0128 Bolt, Carriage, 5/16-18 x 1-1/4 in. 4 3 B17-00-0045 Cage Weldment 1 3A B17-00-0041 Bucket, Fiberglass – Option 1 4 0090-0344 Screw, Threadcutting, #10-24 x 1/2 in. 14 5 B07-05-0007 Plate, Decal 1 6 0090-0461 Screw, Cap, 1/2-13 x 2 in. 4 7 B05-00-0001 Tube, Foam, 16-1/2 in.
XLB-4232 DC 1 2 4 5 6 3 8 7 14 13 9 UPPER BOOM 17 15 16 18 10 11 18 12 19 3A 20 21 22 23, 23A 25 24 4 26 27 24 V 1600 DC PS I C AP M AC AX W IM I T Y O UM HY RK SY DRAU HEI PLAT G ST EM LIC HT FO RM VO SY HE 30 LTA STEM IG 0 G HT LB E PR ES SU 42 RE FT 35 FT 5 IN XL B42 32 31 SP EC IF IC AT IO NS 32 C AU 38 150 TION 0W ATT LO AD L IMIT 39 30 40 4 36 Figure 6-14.
6 — PARTS LIST Table 6-14. Basket Parts List, Continued Item No. Part No. Description Qty 23 B02-03-0007 Cylinder, Slave Leveling, 2 in. Bore x 13-1/4 in. Stroke 1 23A B02-13-0037 Kit, Seal Replacement, Leveling Cylinder 1 24 0090-0428 Washer, Flat, 3/4 in. 2 25 0090-0195 Nut, Hex, Nylon Lock, 3/4-10 2 26 B19-00-0003 Panel, Upper Control Box 1 27 B19-00-0005 Door, Upper Control Box 1 28 B32-00-0005 Weather Strip, 1/2 x 26-1/2 in.
XLB-4232 DC 6-15 UPPER CONTROL BOX PARTS LIST Refer to Table 6-15 for the upper control box parts list. 2 1 9 3 5, 6, 7 8 10 4 12 2 11 Figure 6-15. Upper Control Box Table 6-15. Upper Control Box Item No. 6-38 Part No.
6 — PARTS LIST 6-16 LOWER CONTROL BOX PARTS LIST Refer to the Table 6-16 for the lower control box parts list. 2, 3, 4 1 6 5 11, 12 7 13 8, 9, 10 Figure 6-16. Lower Control Box Table 6-16. Lower Control Box Parts List Item No. Part No.
XLB-4232 DC 6-17 COMBINATION VALVE ASSEMBLY PARTS LIST Refer to Table 6-17 for the proportional valve assembly parts list. 2 3 4 5, 6 1 7 8 5, 9 11 5, 10 5, 10 5, 6 Figure 6-17. Combination Valve Assembly Table 6-17. Combination Valve Assembly Parts List Item No. 6-40 Part No.
6 — PARTS LIST 6-18 SURGE BRAKES PARTS LIST Refer to Table 6-18 for the surge brakes parts list. 10 1 3 6 4 7 5 8 6 9 2 7 5 Figure 6-18. Surge Brakes Table 6-18. Surge Brakes Parts List Item No. 1 Part No. Description Qty B12-00-0169 Surge Brake Coupler Assembly 1 B21-00-0001 Brake Line Kit (includes items 3 through 9) 1 2 ** Brake Line, 3/16 x 17 in. 1 3 ** Brake Line, 3/16 x 45 in. 1 4 ** Brake Line, 3/16 x 15-3/4 ft. 1 5 ** Hose, 18-7/8 in.
XLB-4232 DC 6-19 DC MODEL HYDRAULIC SYSTEM PARTS LIST 40 23 C1 V1 R2 R1 23 7 26 8 23 1 17 37 14 15 18 2 19 20 3 21 22 35 4 38 16 1 BL2 BL1 30 31 15 5 T2 T1 14 32 33 6 36 8 L2 L1 28 24 25 42 27 9 41 10 39 29 13 21 11 V2 C2 29 33 21 12 Refer to Table 6-19 for the DC model boom lift hydraulic system parts list. Figure 6-19.
6 — PARTS LIST Table 6-19. DC Model Hydraulic System Parts List Item No. Part No.
Figure 6-20. Power Unit 12 14 5,32 2.5 2 13,23 15 P T 6 36 G.P.M. CUSTOMER Fenner Fluid Power Inc., Rockford, IL P.S.I. PERFORMANCE DATE CODE AMPS 10 22,28 9 19 8,18 16 + SERIAL NUMBER PART NUMBER 25 27 P.S.I. RELIEF MODEL NUMBER - 6-44 21 P 33 41 E F LG 50 100 150 200 1.6 L 3T 0 20 40 60 80 100 C E S A T 37 7 10 24 34 11 8,18 17 5 3 30 1 19 + - 26 13,23 ENDHEAD SECTION BOTH ENDHEADS 35 38 4 14,15 36 31 12 20 29 3/8 N.P.S.C.
6 — PARTS LIST Table 6-20. Power Unit Parts List Item No. Part No. Description Qty B02-05-0017 Power Unit, 24V DC, Dual Pump and Motor 1 1 B02-15-0088 Bolt, Torx, 5/16-24 x 2-3/4 in. 2 2 B02-15-0089 Bolt, Torx, 5/16-24 x 3 in. 2 3 B02-15-0119 Coupling, SAE 9T-20/40 2 4 B02-15-0128 Steel Ball, 3/8 in. 2 5 B02-15-0091 Seal, Shaft 2 6 B02-15-0025 Cap, Breather 1 7 B02-15-0230 Screw, Taptite, 1/4-20 x 1/2 in. 8 8 B02-15-0093 Washer, Flat, .338 ID x .645 OD x .060 Thk.
XLB-4232 DC 6-46
7 ANSI Reprint The following sections are reprinted from the ANSI A92.2-2001 code in effect at the time of manufacture. Permission to reprint has been granted by the Scaffold Industry Association. 7. Responsibilities of Dealers and Installers 7.1 General Responsibilities. Each dealer or installer as applicable shall comply with the requirements of this section. 7.2 Vehicle Specifications.
XLB-4232 DC 8. 8.1 Responsibilities of Owners General Responsibilities. Each owner shall comply with the requirements of this section. The following responsibilities pertain to the owner’s inspection, testing, maintenance, modification, training, and transfer of ownership. These activities shall be performed by qualified person(s). 8.2 Inspection and Testing Classifications. 8.2.1 Initial Inspection and Test.
7 — ANSI REPRINT (10) Hydraulic and pneumatic filters for cleanliness and the presence of foreign material in the system indicating other component deterioration. (11) Electrical systems and components for deterioration or wear including those not readily visible on a frequent inspection. (12) Performance test of all boom movements. (13) Condition and tightness of bolts and other fasteners. (14) Welds, as specified by the manufacturer.
XLB-4232 DC by governmental agencies. In no case shall axle loads of the fully loaded vehicle exceed the Gross Axle Weight Ratings (GAWR) assigned by the manufacturer. Note: Any change in weight distribution may adversely affect stability. 8.7 Transfer of Ownership. When a change in ownership of an aerial device occurs, it shall be the responsibility of the seller to provide the manufacturer's manual(s) for that aerial device to the purchaser.
7 — ANSI REPRINT 9. Responsibility of Users. 9.1 General Responsibilities. Each User shall comply with the requirements of this section. 9.2 Personnel. Only trained and authorized personnel shall be permitted to operate the aerial device. 9.3 Training, Retraining, and Familiarization of Operators. 9.3.1 General Training.
XLB-4232 DC 10.2 Operation. During operation of the aerial device all platform occupants shall use appropriate fall protection connected to the aerial device at the platform position. 10.3 Work Platform. The operator shall not use railings, planks, ladders or any other device in or on the work platform for achieving additional working height or reach. 10.4 Brakes.
7 — ANSI REPRINT (2) That operating manuals are an integral part of the aerial device and must be properly stored on the vehicle when not in use. (3) A pre-start inspection. (4) Responsibilities associated with problems or malfunctions affecting the operation of the aerial device. (5) Factors affecting stability. (6) The purpose of placards and decals. (7) Workplace inspection.
XLB-4232 DC operate an aerial device. Such items covered shall include, but not necessarily be limited to, the following issues and requirements: (1) The purpose and use of manuals. (2) That operating manuals are an integral part of the aerial device and must be properly stored on the vehicle when not in use. (3) A pre-start inspection. (4) Responsibilities associated with problems or malfunctions affecting the operation of the aerial device. (5) Factors affecting stability.
7 — ANSI REPRINT M.S.A.D. = Minimum Safe Approach Distance (See Table 7-1). DENOTES PROHIBITED ZONE • Do not allow machine, personnel, or conductive materials inside prohibited zone. • Maintain M.S.A.D. from all energized lines and parts as well as those shown. • Assume all electrical parts and wires are energized unless known otherwise. Diagrams shown are only for purposes of illustrating M.S.A.D. work positions, not all work positions.
XLB-4232 DC Table 7-1. Minimum Safe Approach Distance (M.S.A.D.) to energized (exposed or insulated) power lines and parts. Voltage Range (Phase to Phase) Minimum Safe Approach Distance (Feet) 0 to 300V 7-10 (Meters) 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.
125 Taylor Parkway Archbold, OH 43502 Phone (419) 445-9675 (800) 527-5333 Fax (419) 445-0367
