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 at the time of manufacture. This equipment will meet or exceed applicable OSHA and ANSI codes and standards when operated in accordance with sections 7, 8, 9 and 10 of ANSI A92.2 and all other manufacturer’s recommendations.
TABLE OF CONTENTS Table of Contents 1 Illustrations 2 Tables 2 1 Safety 3 Before Operation During Operation Maintenance Safety Damaged Equipment Policy Reporting Safety Defects 2 General Introduction Specifications Warranty 3 Operations Ground Control Station Platform Control Station Normal Operating Procedure Manual Boom Operations Battery Recharge Boom Lift Transport 4 Operator Service 4 4 5 7 8 9 11 12 13 14 16 18 20 22 23 25 Daily Service Checks Weekly Service Checks Monthly Service Chec
LIST OF ILLUSTRATIONS Figure 2-1 Bil-Jax Model 3522A 9 Figure 2-2 Boom Lift Control Panel 10 Figure 2-3 Range of Motion 10 Figure 3-1 Ground Control Station 14 Figure 3-2 Platform Control Station 16 Figure 3-3 Outrigger Controls 18 Figure 3-4 Boom Travel Latch 18 Figure 3-5 Hand Pump and Controls for Manual Operation 20 Figure 3-6 Manual Lowering Valve 21 Figure 3-7 Manual Lowering Valve Locations 21 Figure 3-8 Battery Charger Faceplate 22 Figure 3-9 Trailer Hitching 23 F
1 SAFETY Familiarity with all equipment and proper training are required for the safe operation of any mechanical device. Attempting to operate any mechanical equipment improperly or without training creates a situation that is potentially hazardous. Prior to operation, read the instructions and safety precautions included in this manual and attached to the lift. Become familiar with the proper use of all controls.
BIL-JAX 3522A BEFORE OPERATION DURING OPERATION Ensure the following general safety precautions are followed before operating the Bil-Jax Model 3522A Articulating Boom Lift: Ensure the following general safety precautions are followed during the operation of the Bil-Jax Model 3522A Articulating 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.
1 — SAFETY ALWAYS stay clear of wires, cables and other overhead obstructions. MAINTENANCE SAFETY ALWAYS engage the boom travel latches before towing the trailer. Ensure the following safety precautions are observed whenever maintenance is performed on the Bil-Jax 3522A Articulating Boom Lift. NEVER allow electrode contact with any part of the machine while welding from the platform. General Maintenance NEVER use without the outriggers fully extended and firmly based.
BIL-JAX 3522A NEVER adjust, repair, replace or bypass any hydraulic or electrical control or safety device. These include, but are not limited to, hydraulic load control and flow control valves, solenoid valves and limit switches. Contact the Bil-Jax Service Department at 800-537-0540 if these components require maintenance. NEVER attempt repairs or maintenance without first consulting manufacturer regarding proper procedures.
1 — SAFETY DAMAGED EQUIPMENT POLICY Safety Statement At Bil-Jax, we are dedicated to the safety of all users of our products. All Bil-Jax lifts are designed, manufactured and tested to comply with current applicable federal OSHA and ANSI codes and regulations. 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.
BIL-JAX 3522A Bil-Jax, Inc. 125 Taylor Parkway Archbold, Ohio 43502 800-537-0540 REPORTING SAFETY DEFECTS If you believe that your vehicle has a defect that could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Bil-Jax, Inc.
2 GENERAL INTRODUCTION The Bil-Jax 3522A Articulating Boom Lift (Figure 2-1) is a Summit Series™ Trailer-Mounted Boom, designed and manufactured to position personnel with their tools and equipment at overhead work locations. The work platform load capacity is rated at 500 pounds. During all boom operations, four extended outriggers support the unit. The boom lift is battery powered and operated with electronic pushbutton controls, a hydraulic power unit, a hydraulic gear motor and hydraulic cylinders.
BIL-JAX 3522A The hydraulic power unit uses a 24 Volt, one horsepower DC motor to drive the hydraulic pump. The DC motor is powered by four 6 Volt DC, 245 Amp-hour deep charge batteries connected in series. A 25 Amp, automatic onboard battery charger is provided with standard models for recharging the batteries at the end of each work period. Two control panels (Figure 2-2) use pushbutton switches and hydraulic valves to control the direction and speed of boom lift and rotation.
2 — GENERAL INTRODUCTION SPECIFICATIONS Boom Lift Work Platform Feature Model Number: 3522A Serial Number______________________ Manufactured by: Bil-Jax, Inc. 125 Taylor Parkway Archbold, Ohio 43502 800-537-0540 Model 3522A Working Height 43 ft 2 in (13.3 m) Maximum Platform Height 37 ft 2 in (11.3 m) Maximum Horizontal Outreach From Centerline 22 ft 6 in (6.9 m) From Outrigger Footpad Edge 17 ft 6 in (5.3 m) Up and Over Height 19 ft (5.
BIL-JAX 3522A WARRANTY Bil-Jax, Inc. warrants this product for one year, beginning on the date of delivery, to be free from defects of material and workmanship provided the unit is operated and maintained in compliance with the guidelines established in the Operations and Maintenance Manuals. Major structural components, including trailer tongue and boom weldments, are warranted for five years against defects due to material or workmanship.
3 OPERATION The Model 3522A Articulating Boom Lift is equipped with multiple operator control stations. Equipment power and outrigger controls are located at ground level. Boom lift and rotation controls are located at ground level and on the work platform. Before attempting boom lift operation, Operators should: Obtain, read and obey all safety precautions as indicated by manufacturer’s recommendations and all federal, state and local regulations.
BIL-JAX 3522A 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 Station. The ground control station includes the following controls and Indicators. Refer to Figure 3-1 for control locations.
3 — OPERATION Display Panel The DISPLAY PANEL is a lighted text window that displays the present operating status or an existing error condition when the key switch is on. Emergency Stop Button When pushed in, the emergency STOP button disconnects electrical power to the ground and platform control stations. The emergency STOP pushbutton should only be pressed to immediately stop all boom motion. To resume control, pull out the emergency STOP button.
BIL-JAX 3522A 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 Station The platform control station includes the following controls and Indicators. Refer to Figure 3-2 for control locations.
3 — OPERATION Speed Buttons The SPEED buttons along the lower right side of the control panel must be pressed and held while selecting boom functions. Four speeds are available to control the positioning of the boom lift. Boom Rotation CW/CCW Buttons Pressing and holding a desired SPEED button and the BOOM ROTATION CW or CCW button at the same time enables the boom to rotate in the direction selected. The boom will rotate through 700 degrees until the buttons are released or the stop is reached.
BIL-JAX 3522A NORMAL OPERATING PROCEDURE Perform the following procedures to operate the BilJax Model 3522A Articulating Boom Lift. Read and obey all safety precautions and operating instructions, as well as all applicable portions of ANSI A92.2, reprinted in Section 6. pair of outriggers by pressing the EXTEND button and the two appropriate OUTRIGGER buttons at the same time. Position the boom lift at the work area.
3 — OPERATION Use the ground control panel to operate the boom lift functions. Raise, lower, extend and rotate the booms by pressing and holding the desired SPEED and function buttons at the same time. Become familiar with the location and function of all controls. Learn to smoothly start and stop all boom motions. Fully lower both booms onto the boom rest to position the platform for boarding. Turn the key switch to the platform control position. Raise the safety bar and enter the work platform.
BIL-JAX 3522A MANUAL BOOM OPERATION Manual retraction, rotation and lowering functions allow the Model 3522A Articulating Boom Lift to be moved and lowered during hydraulic power interruption or failure. In each instance, refer to Figure 3-5. The following procedures for manual retraction, rotation and lowering require a person on the ground to operate the manual controls and hand pump. The hydraulic hand pump is located in the pump compartment.
3 — OPERATION Manual Lowering Each Manual Lowering Valve (Figure 3-6) is equipped with a plunger, found at the base of the lift cylinders and on the back side of the jib boom (Figure 3-7). Use the plungers to lower the platform in case of a complete electrical power failure, a load shift, or other emergency situation. To lower the work platform, push the valve plungers. Continue pushing the plungers to completely lower the booms. Figure 3-6.
BIL-JAX 3522A BATTERY RECHARGE Recharge boom lift batteries after each 8-hour work shift or as needed. When boom lift is not in use, batteries should be recharged at least once per week. Under normal circumstances, battery recharge should take approximately 10-12 hours. However, a full recharge may take up to 24 hours, if the battery charge is extremely low. The battery charger is located on the turntable behind the ground control panel. WARNING Recharge batteries in a well-ventilated area only.
3 — OPERATION BOOM LIFT TRANSPORT The boom lift trailer includes a single axle, two-inch ball hitch, hydraulic surge brakes, mechanical parking brake, breakaway safety cable, safety chains, brake lights and side marker lights. Proper boom transport requires the proper attachment and inspection of these components before towing. Refer to Figure 3-9. Release the trailer parking brake. On the tongue jack, pull the pivot locking pin and swivel jack 90 degrees to the travel position.
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4 OPERATOR SERVICE Performing the appropriate daily, weekly and monthly service checks and scheduled maintenance procedures will extend the life of the boom lift and will help ensure the safety of personnel operating the equipment. Additional annual and semi-annual maintenance and repair procedures can be found in the Bil-Jax Model 3522A Parts and Service Manual. Do not attempt to adjust, repair or replace any hydraulic or electrical control device.
BIL-JAX 3522A DAILY SERVICE CHECKS The following Maintenance Procedures should be performed daily before operation. Verify that all decals are correctly applied and in plain view. Refer to Section 5 for decal locations. Verify that all controls and indicators at ground and platform control stations operate properly. Lower outriggers to level the boom lift. Raise and extend all booms. Press emergency STOP button. Figure 4-1. Outrigger Position Switches Verify that booms remain elevated and do not drift.
4 — OPERATOR SERVICE WEEKLY SERVICE CHECKS MONTHLY SERVICE CHECKS Perform the following service checks at least once each week: Perform the following service checks at least once each month: Check Battery electrolyte level. Clean all battery terminals. If battery charge is low, add enough water to bring the electrolyte level to the top of the plates. Check battery for loose connections or damaged wires. If batteries are fully charged, raise electrolyte level to full mark in each cell.
BIL-JAX 3522A TROUBLESHOOTING Refer to Table 4-1 for basic troubleshooting operations. Additional information can be found in the Bil-Jax Model 3522A 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 No lights on panel when key switch is turned to the on position. CAUSE SOLUTION a. Emergency STOP engaged. a. Disengage Emergency STOP buttons. b.
4 — OPERATOR SERVICE 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.
BIL-JAX 3522A ERROR MESSAGE DEFINITION OF ERROR COMMENTS 031 OPEN CIRCUIT JIB DOWN A load of less than 70mA detected when jib down circuit was energized Check for faulty jib down solenoid coil and wiring. 032 SHORTED CIRCUIT JIB DOWN Excessive load detected when jib down circuit was energized. Check for faulty jib down solenoid coil and wiring. 033 OPEN CIRCUIT EXTEND A load of less than 70mA detected in extend circuit on power-up. Check for faulty boom extend solenoid coil/wiring.
4 — OPERATOR SERVICE ERROR MESSAGE DEFINITION OF ERROR COMMENTS 056 SHORTED CIRCUIT RF OUTRIGGER Excessive load detected in right front outrigger circuit on power-up. Check for faulty solenoid coil/wiring at outrigger. 057 OPEN CIRCUIT LR OUTRIGGER A load of less than 70mA detected in left rear outrigger circuit on power-up. Check for faulty solenoid coil/wiring at outrigger. 058 SHORTED CIRCUIT LR OUTRIGGER Excessive load detected in left rear outrigger circuit on power-up.
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5 REPLACEMENT DECALS Refer to Table 5-1 and Figure 5-1 for descriptions and locations of decals on the Bil-Jax Model 3522A Articulating Boom Lift. Table 5-1. Replacement Decal Descriptions Decal No. Decal Description Qty 0202-0523 Made in USA 1 B06-00-0034 DANGER: Electric Shock 1 B06-00-0037 Lubricate Semi-Annually 1 B06-00-0062 NOTICE: AC Power B06-00-0068 Decal No.
BIL-JAX 3522A Figure 5-1.
6 ANSI REPRINT The following sections are reprinted from the ANSI A92.2-2001 code in effect at the time of manufacture and govern the safe use of the Bil-Jax Model 3522A Articulating Boom Lift. Permission to reprint this material 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.
BIL-JAX 3522A locking devices. Any suspected items shall be carefully examined or tested and a determination made by a qualified person as to whether they constitute a safety hazard. All unsafe items shall be replaced or repaired before use. 8.2.4 36 Periodic Inspection or Test. An inspection of the mobile unit shall be performed at the intervals defined in 8.2.2 depending upon its activity, severity of service, and environment, or as specifically indicated below.
6 — ANSI REPRINT 8.12 Training, Retraining, and Familiarization of Operators. (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. (8) Applicable safety rules and regulations, such as Part 4, ANSI C2-1997, National Electrical Safety Code. (Applies to utility workers as defined in ANSI C2).
BIL-JAX 3522A 10.4 Brakes. The vehicle parking brake(s) shall be set at all times that the boom is elevated except when the aerial device is being used in accordance with 9.5. 10.5 Loading. Any loading which includes a horizontal load shall be avoided unless the mobile unit is designed for that application. 10.6 Observations. Observations during operation for any defects shall be conducted on an ongoing basis. 10.6.1 Pre-start Inspection.
6 — ANSI REPRINT Elevating and Rotating Aerial Devices. These manuals shall be stored on the mobile unit. 11.4 (applies to utility workers as defined in ANSI C2). The above standard is an example; other industries using aerial devices have safety rules pertinent to that industry. (9) Authorization to operate. (10) Operator warnings and instructions. (11) Actual operation of the aerial device.
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7 MATERIAL SAFETY DATA The following Material Safety Data Sheets describe the correct procedures for the safe handling of chemical components within the Model 3522A Articulating Boom Lift, as well as any potential health and safety hazards related to these chemicals. Material Safety Data Sheets are included here in accordance with applicable federal and state regulations. Read and observe all safety precautions. Maintain awareness of potential health and safety hazards.
BIL-JAX 3522A MATERIAL SAFETY DATA SHEET FOR LEAD ACID BATTERIES, WET, FILLED WITH ACID (Continued) SECTION V -- HEALTH HAZARD DATA Primary Routes of Entry: Inhalation: YES Skin: YES Ingestion: YES Acute EYES, SKIN, RESPIRATORY SYSTEM & DIGESTIVE SYSTEM Chronic: EYES, SKIN, RESPIRATORY SYSTEM & DIGESTIVE SYSTEM IRRITATION OF EXPOSED AREA, BURNS AND RESPIRATORY PROBLEMS NO POSSIBILITY OF EXPOSURE OF LEAD WILL OCCUR UNLESS BATTERY IS DESTROYED.
7 — MATERIAL SAFETY DATA MATERIAL SAFETY DATA SHEET DEXRON III/MERCON AUTOMATIC TRANSMISSION FLUID (HYDRAULIC OIL) SECTION I -- GENERAL INFORMATION TRADE NAME: EMERGENCY TELEPHONE NUMBERS: CHEMICAL FAMILY: CAS NUMBER: MIXTURE. HAZARDOUS INGREDIENTS: CITGO TRANSGARD™ ATF, DEXRON III/MERCON 918.495.4700 (medical); 800.424.9300 (chemical) AUTOMATIC TRANSMISSION FLUID, LUBRICATING OIL REVISION DATE: 10/29/98 CONTAINS NO INGREDIENTS NOW KNOWN TO BE HAZARDOUS AS DEFINED IN OSHA 29 CFR 1910.
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8 EQUIPMENT OPTIONS The Bil-Jax Model 3522A 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.
BIL-JAX 3522A 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.
8 — EQUIPMENT OPTIONS HORIZONTAL JIB ROTATOR PLATFORM ROTATOR The optional jib rotator allows the jib boom and work platform to be rotated clockwise or counterclockwise around a vertical axis. Boom lifts equipped with jib rotator option will have additional controls on the ground and platform control panels (Figure 8-3). 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.
BIL-JAX 3522A COMBINATION HITCH Observe the following procedure to change the hitch coupler on lifts equipped with an optional combination hitch: Choose the desired hitch coupler from among the following: 2-inch ball hitch, 2 5/16-inch ball hitch, 2 ½-inch Pintle Ring, or Clevis hitch. Insert the hitch coupler into the hitch bracket found at the end of the trailer tongue (Figure 86). Figure 8-6.
8 — EQUIPMENT OPTIONS REPLACEMENT DECALS Refer to Table 8-1 and Figure 8-7 to Figure 8-8 for a descriptions and locations of replacement decals for optional components. Refer to Section 5 for a comprehensive list of standard decals on the Bil-Jax Model 3522A Articulating Boom Lift. All decals related to optional equipment have a quantity of one (1) unless otherwise noted. Table 8-1. Replacement Decals Decal No. Description of Decal B06-00-0474 NOTICE: Max.
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BIL-JAX MODEL 3522A QUICK START GUIDE Obtain, read and obey all Safety Guidelines: In this manual Attached to the boom lift Indicated by federal, state and local regulations Position the boom lift in work area Unhitch from the tow vehicle and disengage all boom travel latches Turn Key Switch to ground control station for outrigger extension and leveling Extend outriggers and level the boom Press and hold the outrigger EXTEND and AUTO LEVEL buttons A buzzer will sound and all LEDs will become lit on the Out
Distributed by: 125 Taylor Parkway Archbold, OH 43502 Phone (419) 445-8915 (800) 537-0540 Fax (419) 445-0367 http://www.biljax.