Operator manual

Operator manual

SUMMIT SERIES EN

24203 4138 0 E 06 09 EN
2 24203 4138 0 E 06 09 EN
 Operator manual

CONTENTS

1 - Boom Personnel Lift . . . . . . . . . . . . . . . . . . . . . 7

2 - WARRANTY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 - Warranty Claims Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

A
SAFETY
1 - Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 - Before operation . . . . . . . . . . . . . . . . . . . . . . . . 12
3 - During operation. . . . . . . . . . . . . . . . . . . . . . . . 13
4 - MAINTENANCE SAFETY . . . . . . . . . . . . . . . . . 15
5 - General Maintenance . . . . . . . . . . . . . . . . . . . . 15
6 - Battery Maintenance . . . . . . . . . . . . . . . . . . . . 16
7 - DAMAGED EQUIPMENT POLICY . . . . . . . . . . 17
7.1 - Safety Statement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.2 - Damage Policy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.3 - Damage Repair Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

B
CONTENTS

BEFORE OPERATION
1 - Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2 - Before operation instructions . . . . . . . . . . . . . 19
3 - DAILY SERVICE CHECKS . . . . . . . . . . . . . . . . 20
4 - WEEKLY SERVICE CHECKS . . . . . . . . . . . . . . 23
5 - MONTHLY SERVICE CHECKS . . . . . . . . . . . . . 24
6 - ADDITIONAL SERVICE INFORMATION . . . . . 26

C
OPERATION
1 - Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2 - GROUND CONTROL STATION . . . . . . . . . . . . 28
3 - PLATFORM CONTROL STATION . . . . . . . . . . 32
4 - PLATFORM CONTROLS JOYSTICK . . . . . . . . 36
5 - Normal Operating Procedure . . . . . . . . . . . . . 36
6 - OperationSet up . . . . . . . . . . . . . . . . . . . . . . . . 37
7 - OperationGROUND CONTROLS . . . . . . . . . . . 39
8 - OperationPLATFORM CONTROLS . . . . . . . . . 40
9 - DRIVE AND SET CONTROLS. . . . . . . . . . . . . . 41

3
 Operator manual

10 - MANUAL BOOM OPERATION . . . . . . . . . . . . 42

10.1 - Manual Retraction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
10.2 - Manual Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
10.3 - Manual Lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
11 - BATTERY RECHARGE . . . . . . . . . . . . . . . . . . 45
12 - BOOM LIFT TRANSPORT . . . . . . . . . . . . . . . 47
12.1 - LIFTING INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
12.2 - LIFTING INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
12.3 - TRANSPORT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

D
TROUBLESHOOTING
1 - Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2 - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 51
3 - Error code definitions . . . . . . . . . . . . . . . . . . . 52

E
DECAL REPLACEMENT
1 - Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2 - Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.1 - REPLACEMENT DECALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

F
SPECIFICATIONS
1 - Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2 - Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3 - RANGE OF MOTION . . . . . . . . . . . . . . . . . . . . 103

G
EQUIPMENT OPTIONS
1 - Foreword . . . . . . . . . . . . . . . .. . . . . . . . . . . . . 109
2 - MATERIAL LIFTING HOOK .. . . . . . . . . . . . . 109
3 - PLATFORM ROTATOR . . . . .. . . . . . . . . . . . . 110
4 - DRIVE AND SET . . . . . . . . . .. . . . . . . . . . . . . 111
5 - DRIVE AND SET SAFETY. . .. . . . . . . . . . . . . 112

4
 Operator manual

H
OTHER
1 - Inspection Form for BilJax Summit Series®
Aerial Work Platforms113
2 - REPORTING SAFETY DEFECTS . . . . . . . . . . 113
3 - BIL-JAX SUMMIT SERIES QUICK START GUIDE
114
4 - Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

CONTENTS

5
Operator manual

6
Boom Personnel Lift
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.

24203 4138 0 E 06 09 EN 7
1 - 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 5 years against defects due to material
or workmanship. Bil-Jax will, at its option, repair or replace any unit or component part that fails to
function properly during normal use.

The warranty does not apply if the lift and/or its components have been altered, changed, or repaired
without the consent of Bil-Jax. Repairs, damage, or defects resulting from the following are not covered
under the terms of the warranty : negligence, misuse, accidental damage, inadequate or improper
maintenance, acts of nature, damage caused by chemicals or abrasive materials, and normal wear and
tear, such as rust or corrosion. Components not covered under this warranty include tires, filters,
covers, and routine maintenance items. Components not manufactured by Bil-Jax are covered by their
respective manufacturer’s warranties. A list of those components and their warranties is available upon
written request to Bil-Jax.

Bil-Jax shall not in any event be liable for the cost of any special, indirect, or consequential damages
to any person, product, or thing. Bil-Jax's maximum liability under this warranty is limited to the amount
paid to Bil-Jax for the product. This warranty is in lieu of all other warranties expressed or implied. Bil-
Jax neither assumes nor authorizes any or other entity to assume on its behalf any other liability in
connection with the sale, rental, or use of this product.

8 24203 4138 0 E 06 09 EN
 1.1 - WARRANTY CLAIMS PROCESS

In order to qualify for warranty coverage, the following conditions must be met :
1. Return of completed "Warranty Registration" form to Bil-Jax within 15 days of receipt of product.
2. Notification to Bil-Jax within 72 hours of any claimed defect, injury, or damage resulting from the
claimed defect; and
3. Warranty is limited to parts that are determined to be defective. This does not include parts worn
out due to normal use.
4. Bil-Jax authorized dealers or distributors are responsible for filing claims under warranty. Listed be-
low is the warranty claims procedure.
5. Contact Bil-Jax Service Department at 800-537-0540 to report the claim and verify warranty cove-
rage. Machine serial number must be provided.
6. Identify the components to be claimed under warranty along with description of failure. A Returned
Merchandise Authorization (RMA) number will be issued by Bil-Jax.
7. Replacement parts will then be sent by Bil-Jax to the dealer or distributor. All parts are invoiced at
dealer/distributor list price. Credits will be issued when defective parts are returned to Bil-Jax and
found to be defective under warranty.
8. After completing repairs, submit warranty claim form and defective parts to Bil-Jax. Warranty claim
form and parts must be received within 30 days of claim in order to be eligible for credit. RMA num-
ber must be referenced on warranty claim form. Returned parts are to be sent prepaid and will be
credited when part is received and verified. Warranty labor rate will be paid at current rate set by
Bil-Jax. . The amount of labor hours reimbursed will be determined by Bil-Jax and will be limited to
4 hours unless approved by Bil-Jax.
Failure to follow the warranty claims process may result in delay in processing claim or denial
of the claim. Bil-Jax reserves the right to limit or adjust warranty claims with regard to parts,
labor and travel time. Components purchased from suppliers other than Bil-Jax are not
covered under the terms of this warranty.

24203 4138 0 E 06 09 EN 9
10 24203 4138 0 E 06 09 EN
A - Safety
A
Safety
1 - Foreword
Proper training is required for the safe operation of any mechanical device. Failure to follow all
B
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.
C
• 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. D
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.
E
Warns of operation near electrical power sources that could lead to personal injury or death.

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

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

N.B.-:-CONTAINS ADDITIONAL INFORMATION IMPORTANT FOR PERFORMING A PROCEDURE.

G

24203 4138 0 E 06 09 EN 11
A - Safety

2 - Before operation
Ensure the following general safety precautions are followed before operating the telescoping boom lift
:

ALWAYS inspect the usage area for potential hazards, such as unstable or unlevel surfaces, overhead
obstructions and electrically charged wires or conductors. ALWAYS watch for moving vehicles in the
operating area.

ALWAYS conduct a thorough inspection of the machine before operation. Check for damaged or worn
parts, hydraulic leaks, damaged wiring, loose wiring conductors, damaged outriggers, low tire
pressure, uneven tire wear or tire damage. Check for any improperly operating components. NEVER
operate equipment if any damage is observed or suspected. Repair damaged or malfunctioning
equipment before operation.

ALWAYS wear proper clothing and footgear. Wear protective equipment as required by government
regulations. Keep loose clothing, jewelry, gloves and hair away from moving parts.

ALWAYS wear a safety harness and energy-absorbing lanyard, such as the safety harness and
lanyard provided by Bil-Jax.

ALWAYS inspect platform floor and outrigger footpads for mud, grease, debris or other foreign
material. ALWAYS remove any such material from the equipment before operation.

ALWAYS tag any part of the equipment known or suspected to be damaged or malfunctioning.
ALWAYS remove a malfunctioning, damaged or defective machine from service. NEVER operate a
machine that has any known or suspected defect.

ALWAYS comply with the instructions found in Safety and/or Service Bulletins distributed by the
manufacturer. Bulletins may contain critical procedures that supersede the information contained in
manuals.

NEVER operate this equipment while under the influence of drugs or alcohol, while taking prescription
medications that may leave the operator drowsy or prone to dizziness, or while feeling ill.

NEVER modify the equipment in any way that would affect its original design or operation.

NEVER deface, modify or obscure any decals or markings on equipment.

NEVER operate the equipment in any way for which it is not intended.

12 24203 4138 0 E 06 09 EN
A - Safety
A
3 - During operation
Ensure the following general safety precautions are followed while operating the telescoping boom lift : B
ALWAYS position lift away from power lines to ensure that no part of the lift can accidentally reach into
an unsafe area. This includes full extension of the boom through 700 ° rotation.

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 ( 3,05 m (10 ft 0 in) minimum) and must always allow for platform movement due
to gusty winds. Always contact power company before working near power lines. Assume every power
C
line is live. Power lines can be blown by the wind. Refer to Table below for minimum safe approach
distances between the machine and electrical power lines.

Minimum Safe Approach Distances

Voltage range (Phase to Phase) Minimum Safe Approach Distances

Feet Meters
D
0 - 300 V Avoid contact
300 V - 50 kV 10 3,05
50 - 200 kV 15 4,60
200 - 350 kV 20 6,10
350 - 500 kV
500 - 750 kV
25
35
7,62
10,67
E
750 - 1000 kV 45 13,72

ALWAYS keep away from a machine that is exposed to energized power lines. If the machine contacts
energized power lines, NEVER touch or operate the machine until power lines are shut off.

ALWAYS operate only on a firm and level surface. NEVER operate on surfaces that do not support
F
the equipment with its rated load capacity or on surfaces that do not support force exerted by the
outriggers during boom operation. Operate only on surfaces that can support a pressure of 1,8 kg/cm²
(25 psi) to ensure safe operation.

ALWAYS keep personnel away from potential pinch and shear points and from potential crush hazards
as indicated by decals attached to the machine. G
ALWAYS keep the safety bar lowered unless personnel are entering or exiting the work platform.

ALWAYS keep personnel and obstructions clear of the machine when repositioning boom or basket.

ALWAYS cordon the area surrounding the outriggers to keep personnel, vehicles and moving
equipment away from the machine while in use.
H
ALWAYS stay clear of overhead obstructions, including wires and cables.

For 45XA and SUMMIT SERIES only : ALWAYS engage boom travel latches before towing trailer.

ALWAYS exercise caution when rotating the boom from the ground control station. ALWAYS watch
for personnel inside the radius of the turntable and boom arm when rotating the boom lift from the
I
ground or platform controls.

ALWAYS remove personnel from the boom lift before attempting to free an elevated platform that has
become caught or snagged on an adjacent structure or obstacle.

24203 4138 0 E 06 09 EN 13
A - Safety

NEVER operate the machine on any surface other than firm and level ground. NEVER operate the
machine from a position on truckbeds, trailers, floating vessels or scaffolding without written approval
from the manufacturer.

NEVER operate lift functions on slopes exceeding 12,5 ° .

NEVER allow electrode contact with any part of the machine while welding from the platform. NEVER
use the machine as a ground for welding.

NEVER operate without the outriggers fully extended or when the machine is not level.

NEVER position an elevated platform against another object to steady the platform.

NEVER override or bypass the manufacturer's safety devices.

NEVER attach a safety harness to an adjacent structure, pole, or to nearby equipment while working
from the boom platform.

NEVER raise the outriggers (or move the trailer) while boom is raised or extended. (Please see
machine configuration)

NEVER sit, stand or climb on cage bars. ALWAYS keep both feet firmly on the work cage floor when
working from an elevated platform.

NEVER attempt to increase the working height with boxes, ladders, stools or any other materials.

NEVER operate this equipment when exposed to high winds, thunderstorms, ice or any weather
conditions that would compromise operator safety.
NEVER operate boom lift in conditions where wind speeds exceed 12,5 m/s (41 ft/s) ( 45 km/h (28
mph) ). High winds may affect stability and boom operation.
NEVER allow ropes, electric cords, hoses or other equipment to become entangled in the machine
while raising or lowering platform.
NEVER exceed the load limits set by the manufacturer. Use only the Material Lifting Hook, supplied
as an option and manufactured by Bil-Jax, when lifting materials. Safely stow all tools and equipment.

NEVER exceed load ratings by transferring loads to the lift at elevated heights.

NEVER use the platform to lift a load that exceeds the platform dimensions. NEVER lift a load in such
a way that the center of gravity is higher than the top guardrail of the platform.

NEVER modify the platform or carry materials that would increase the surface area of the platform.
Increasing the area exposed to the wind may decrease machine stability. NEVER attach overhanging
loads when raising or lowering the platform.

NEVER use the boom or platform to push or pull or to lift any part of the machine ( or of trailer).

NEVER use the boom or platform to place a load against any structure, materials or equipment.

NEVER climb on the boom.

NEVER leave an elevated platform unattended.

NEVER leave the keys in the boom lift while unattended or not in use.

14 24203 4138 0 E 06 09 EN
A - Safety
A
4 - MAINTENANCE SAFETY
Ensure the following general safety precautions are followed while performing maintenance on the
telescoping boom lift.
B
5 - General Maintenance
ALWAYS perform maintenance procedures according to manufacturer's guidelines. NEVER disregard
or bypass proper maintenance procedures. C
ALWAYS inspect hydraulic system to ensure that all lines, connectors and fittings are properly fastened
and in good condition.

ALWAYS turn the key switch OFF and remove key before performing maintenance.

ALWAYS perform maintenance with the boom and platform in a fully lowered, stowed position, when D
possible. ALWAYS secure the boom before performing maintenance on hydraulic cylinders.
ALWAYS disconnect power to the hydraulic pump drive motor before making electrical checks to the
hydraulic valves.
ALWAYS keep all mechanical parts properly adjusted and lubricated according to maintenance
schedule and manufacturer's specifications. E
ALWAYS perform a function check of operating controls before each use and after repairs have been
made.
ALWAYS locate and protect against possible pinch points before performing any maintenance or
repairs.
ALWAYS use only manufacturer-approved parts to repair or maintain equipment. If any portion of this
F
equipment is rebuilt or repaired, retesting is required in accordance with factory instructions.

ALWAYS maintain a safe distance while testing the hydraulic components. ALWAYS relieve hydraulic
pressure before loosening or removing hydraulic components. NEVER test or operate the hydraulic
components while personnel are near the equipment.
G
NEVER allow water or foreign particles into the DC electric motor housing. Inclusion of water or foreign
particles may cause serious damage to the motor. If the motor becomes wet, consult an authorized
Bil-Jax service technician for proper drying instructions.

NEVER add unauthorized fluids to the hydraulic system or battery. NEVER mix hydraulic oils. Consult
manufacturer specifications.
H
NEVER exceed the manufacturer's recommended relief valve settings.

NEVER touch or allow metal tools to contact any components that are sensitive to static discharge.
ALWAYS use static discharge prevention mats and grounding devices when handling electronic
components.

NEVER adjust, repair, replace or bypass any hydraulic or electrical control or safety device. These
I
include, but are not limited to, hydraulic load control and flow control valves, solenoid valves and limit
switches. ALWAYS consult an authorized Bil-Jax technician if repairs are necessary.

24203 4138 0 E 06 09 EN 15
A - Safety

NEVER modify, alter or change the equipment without first consulting an authorized Bil-Jax technician,
and NEVER in any way that would affect its original design or operation.

6 - Battery Maintenance
Ensure the following general safety precautions are followed when performing battery maintenance on
the Aerial Work Platform.

ALWAYS wear safety glasses when working with or near batteries.

ALWAYS check the battery fluid level daily.

ALWAYS avoid contact with battery acid. Battery acid causes serious burns and should be kept away
from skin or eyes. If contact occurs, flush with water and consult a physician immediately.

ALWAYS disconnect ground cable first when removing battery.

ALWAYS connect ground cable last when installing battery.

ALWAYS charge batteries in open, well-ventilated areas.

ALWAYS replace batteries using only parts recommended by manufacturer. ALWAYS use only
batteries with sealed caps over cells.

NEVER smoke while servicing batteries.

NEVER charge batteries near spark or open flame.

NEVER allow batteries to overcharge and boil.

NEVER short across battery posts to check for current. NEVER break a live circuit at the battery.
NEVER disconnect battery from charger while charger is connected to a live power source.

NEVER jumpstart other vehicles using the boom lift batteries.

16 24203 4138 0 E 06 09 EN
A - Safety
A
7 - DAMAGED EQUIPMENT POLICY
7.1 - SAFETY STATEMENT
B
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.
7.2 - DAMAGE POLICY

There may be occasions when a Bil-Jax lift is involved in an incident that results in structural C
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-

7.3 -
Jax dealer.
DAMAGE REPAIR NOTICE
D
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.
E

24203 4138 0 E 06 09 EN 17
A - Safety

18 24203 4138 0 E 06 09 EN
B - Before operation
A
Before operation
1 - Foreword
Performing the appropriate maintenance procedures will extend the life of the boom lift and will help
B
ensure the safety of personnel operating the equipment.

Repair, replacement or adjustment of any hydraulic or electrical control device should be performed
only by fully trained and authorized personnel. These include, but are not limited to, hydraulic load
valves, hydraulic flow control valves, solenoid valves and limit switches. These are safety related
controls. Improper adjustment or tampering with these devices may impair boom lift function and result
in safety or damage hazards.
C
Persons performing maintenance or repairs on the machine should be trained in accordance with the
manufacturer's recommendations. Contact your regional Bil-Jax representative if additional
information is needed.

Critical or suspect areas identified during any scheduled inspection of the machine shall be examined
by qualified personnel in accordance with applicable government regulations.
D
Never operate the machine if a defect or malfunction is identified or suspected. All defects and
malfunctions must be repaired, and all maintenance performed, before returning a machine to service.

This manual contains a list of recommended maintenance procedures to be performed daily, weekly
and monthly. Refer to the appropriate Summit Series Parts and Service Manual for a list of annual
service checks.
E
It is the practice of Bil-Jax, Inc. to issue Service and/or Safety Bulletins, which may include updates to
the information contained in this manual. In such instances, procedures contained in Bil-Jax Service
Bulletins or Safety Bulletins supersede the information contained in manuals.

Always follow maintenance schedule, regardless of use. F

2 - Before operation instructions
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 :
G
• 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 H
Manual. Annual service checks and structural inspections should be performed only by personnel
trained and certified in accordance with applicable government regulations.

24203 4138 0 E 06 09 EN 19
B - Before operation

3 - DAILY SERVICE CHECKS

The following maintenance procedures should be performed daily or before each operation.

Verify that all decals are correctly applied and in plain view :

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.
• Verify that booms remain elevated and do not drift.
• Pull out STOP button and lower the booms.
• If either control station is unresponsive, refer to troubleshooting procedures.
• If display panel displays an error code, refer to error code definitions.
• Verify operation of running and brake lights.

Verify correct tire inflation :

• For X_Boom : Inflate tires to 1,4 bar (20 psi) .
• For Summit Series : In cold climates, inflate tires to 3,8 bar (55 psi) .

Inspect tires for damage or loose or missing lug nuts :

• Repair or replace as necessary.
N.B.-:-REPAIR AND REPLACEMENT OF MACHINE COMPONENTS SHOULD BE PERFORMED ONLY BY TRAINED
AND CERTIFIED PERSONNEL IN ACCORDANCE WITH GOVERNMENT REGULATIONS AND MANUFACTURER
RECOMMENDATIONS.

Inspect structural components and platform for obvious damage or debris :

• Repair or replace as necessary.

Inspect machine for missing, loose or damaged fasteners, including pins and bolts.

Verify that boom down limit switches operate correctly :

• Down limit switches are actuated when the boom is in a fully lowered, stowed position. Limit switches
must be operational to raise or lower outriggers.
• If outrigger controls are unresponsive when boom is fully lowered and stowed, inspect down limit
switches for loose mounting or visible damage.
• Repair or replace as needed.

Verify that outrigger safety interlocks operate correctly :

• Begin with the outriggers fully extended and the boom lift level. Raise one outrigger until the footpad
is not in contact with the ground.
• Verify that boom functions are unresponsive when one outrigger is raised.
• Repeat this procedure for each outrigger.

20 24203 4138 0 E 06 09 EN
B - Before operation
A
• Raise all outriggers until the footpads are not in contact with the ground. Verify that all outrigger status
LEDs on the ground control panel are unlit.
• Lower one outrigger until the footpad makes contact with the ground and the outrigger begins lifting
the trailer. B
• If the LED is lit before the footpad makes contact with the ground or if the LED remains unlit after the
weight is transferred to the outrigger, the position switch or wiring is faulty.
• Repeat this procedure for each outrigger.
• Repair or replace as needed.
O u t r i g g e r P o s i t i o n S w i t c h e s C

E
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.
F
• 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, 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. G
• 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. H
• Manufacturer recommends a higher viscosity hydraulic oil when operating equipment routinely in
extreme climates.

24203 4138 0 E 06 09 EN 21
B - Before operation

H y d r a u l i c R e s e r v o i r

Reference Description of the components

1 Filter Element
2 Fill Port
3 Sight Gauge

22 24203 4138 0 E 06 09 EN
B - Before operation
A
4 - WEEKLY SERVICE CHECKS
Perform the following service checks at least once each week in addition to all recommended daily
service checks.
B
Check Battery electrolyte level :
• If electrolyte level is low, add enough distilled water to bring the electrolyte level to the top of the
plates.
• If batteries are fully charged, raise electrolyte level to full mark in each cell. C
Inspect all electrical wiring :
• Check for cuts, loose terminals, broken wires, chaffing and corrosion.
• Repair all damage, remove corrosion and seal exposed connections.

Inspect transport hitch components for damage. D

Inspect boom lift for missing, loose or damaged hardware :
• Repair or replace as necessary.

Inspect all hydraulic system components including pump and motor and cylinders for damage, leaks,
loss of pressure or speed, and unusual noise or vibration :
• Repair or replace as necessary.
E

24203 4138 0 E 06 09 EN 23
B - Before operation

5 - MONTHLY SERVICE CHECKS

Perform the following service checks at least once each month in addition to all recommended daily
service checks.

Clean all battery terminals.

Check battery for loose connections or damaged wires.

• Verify proper operation of manual lowering valves and hand pump.
• Refer to section for manual boom operating procedures.

Lubricate all compartment hinges and latches, slew ring and mating gear :
• Use NLGI Grade 2 multi-purpose grease.

Check wheel nut torque :

• Refer to Figure below for correct wheel nut tightening sequence.
• Evenly tighten wheel nuts to 34 Nm in the tightening sequence shown.
• Repeat sequence, tightening wheel nuts to 81 Nm and to 136 Nm.

N.B.-:-WHEN WHEELS ARE NEWLY INSTALLED OR REPLACED, VERIFY WHEEL NUT TORQUE AFTER 75 AND 150
KM OF TRAVEL AND MONTHLY THEREAFTER. FOLLOW THIS PROCEDURE EACH TIME THE WHEEL IS REMOVED
AND REINSTALLED.

W h e e l N u t T i g h t e n i n g S e q u e n c e - 3 5 2 2 A - 4 5 2 7 A -
5 5 3 3 A

1 1

6 3
4 3

4 5
2 5
2

24 24203 4138 0 E 06 09 EN
B - Before operation
A
W h e e l N u t T i g h t e n i n g S e q u e n c e - 2 6 2 2 T

1
B

4 3 C

D
2 5

W h e e l N u t T i g h t e n i n g S e q u e n c e - 4 6 4 2 T
E
1

6 3 F

G
4 5

2 H

24203 4138 0 E 06 09 EN 25
B - Before operation

6 - ADDITIONAL SERVICE INFORMATION

Refer to the Bil-Jax Parts and Service Manual for a comprehensive list of Annual service checks.

Seals on hydraulic cylinders should be replaced every five years or as indicated by machine
performance.

All service checks should be performed on a machine that has been stored without use for a period
exceeding thirty days.

Check for air in the hydraulic system if the machine has been stored without use for a period exceeding
thirty days, or if the machine was stored without use during a seasonal climate change. Air trapped in
the hydraulic system will affect machine performance. Follow procedures for bleeding air from the
hydraulic system, found in the Bil-Jax Parts and Service manual.
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 machine. Always repair or
replace all damaged or malfunctioning components before commissioning or reselling machine.

When a change in ownership occurs, it is the responsibility of the seller to provide the new owner with
all manuals for the machine. It is the responsibility of the buyer to notify the manufacturer of the unit
model and serial number and the name and address of the new owner within 60 days. Use the Service
Checklists found at the back of this manual to record all Service Checks as well as any maintenance,
repairs or alterations performed on the machine.

Use the Service Checklists found at the back of this manual to record all Service Checks as well as any
maintenance, repairs or alterations performed on the machine.

Records of frequent safety checks need not be made. However, where a safety hazard is found, it shall
be reported in writing to the owner of the machine, and a record of any corrective action shall be
maintained for five years or as required b y the authority having jurisdiction.

Refer to the Bil-Jax Parts and Service Manual for a comprehensive list of Annual service checks.

26 24203 4138 0 E 06 09 EN
C - Operation
A
Operation
1 - Foreword
The machine are equipped with multiple operator control stations. Operators can use boom and
B
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
C
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.
D
• Conduct a Pre-Operation inspection by performing all recommended Daily Service Checks. .
• For SUMMIT SERIES only : Unhitch equipment trailer from the tow vehicle.

24203 4138 0 E 06 09 EN 27
C - Operation

2 - 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.

G r o u n d C o n t r o l P a n e l - 2 6 2 2 T - 4 6 4 2 T

N.B.-:-THE GROUND CONTROL STATION INCLUDES THE FOLLOWING CONTROLS AND INDICATORS.

Ground Control Panel - 2622T - 4642T

Marking Description Function

1 Key Switch Turning the key switch to the PLATFORM (1a) icon selects operation
1a Platform Controls Position from the platform. Turning the key switch to the GROUND (1b) icon
selects operation from the ground control panel. The center (power
off) position interrupts all electric and hydraulic power operations
1b Ground Controls Position except emergency lowering. Removing the key protects against
operation by unauthorized persons. The key may be removed with the
key switch in any selected position.
Indicator LEDs light up to indicate the level of charge remaining in the
batteries. A lighted green LED indicates an adequate charge level.
2 Battery Condition Indicator Lighted yellow LEDs indicate the need for charging soon. A lighted
red LED warns that the battery charge level is low; boom operations
should be halted until the batteries are recharged.

28 24203 4138 0 E 06 09 EN
C - Operation
A
Marking Description Function
Engine Start (DC / Gas option
3 Start a cold engine by pressing the Engine START (3) button while

4
only)
Engine Choke (DC / Gas option
only)
pressing and holding the CHOKE (4) button. To start/restart a warm
engine, press the START button only.
B
The DISPLAY PANEL is a lighted text window that displays the
5 Display Panel present operating status or an existing error condition when the key
switch is on.
When pushed in, the emergency STOP button disconnects electrical

6 Emergency Stop
power to the ground and platform control stations. The emergency
STOP pushbutton should only be pressed to immediately stop all C
boom motion. To resume control, pull out the emergency STOP
button.
7 Boom Extend Pressing and holding a desired SPEED button and the BOOM
EXTEND (7) button at the same time extends the telescopic boom.
Pressing and holding a desired SPEED button and the BOOM
8 Boom Retract RETRACT (8) button at the same time retracts the boom. Boom
motion continues until the buttons are released or until the boom
D
reaches a hard stop or a safe travel limit.
9 Boom Raise Boom Raise / Down ButtonsPressing and holding a desired SPEED
button and the BOOM RAISE ( 9 ) button at the same time will raise
the boom. Pressing a desired SPEED button and the BOOM
10 Boom Down DOWN ( 10 ) button at the same time will lower the boom. Boom
motion continues until the buttons are released or until the boom
reaches a hard stop or a safe travel limit. E
11 Boom Rotation - Clockwise Pressing and holding a desired SPEED button and the BOOM
ROTATION CLOCKWISE or COUNTERCLOCKWISE button at the
Boom Rotation - same time enables the boom to rotate in the direction selected. The
12
Counterclockwise boom will rotate through 700 ° until the buttons are released or the
stop is reached.
13
14
Platform Tilt - Up
Platform Tilt - Down
Press and hold any SPEED button and the desired PLATFORM TILT
button at the same time to level the work platform (Levels the platform
F
only, not the boom lift).
The SPEED buttons along the lower right side of the control panel
15 Speed Buttons must be pressed and held while selecting a boom function. Four
speeds are available to control the positioning of the boom lift.
16
17
18
Outrigger Extend
Outrigger Retract
Auto Level
Outrigger ControlsFor automatic outrigger extension/retraction :
Select EXTEND 16 or RETRACT 17 outrigger button and the AUTO
LEVEL 18 button at the same time. To manually extend or retract the
G
19 Outrigger Buttons outriggers : Select EXTEND or RETRACT outrigger button and one
of the OUTRIGGER buttons 19 at the same time. The outrigger
indicator LEDs light up when the outriggers are properly deployed and
the boom weight is on the outriggers. Each of the outer outrigger
20 Outrigger Status Indicator LED LEDs indicates load is on the outrigger footpad. Each of the inner
outrigger LEDs, when flashing, indicate that side is low and needs to
be further raised for leveling. The Auto Level LED lights up and a
H
buzzer sounds when the boom is level
21 Power Indicator LED

24203 4138 0 E 06 09 EN 29
C - Operation

G r o u n d C o n t r o l P a n e l - 3 5 2 2 A - 4 5 2 7 A - 5 5 3 3 A

N.B.-:-THE GROUND CONTROL STATION INCLUDES THE FOLLOWING CONTROLS AND INDICATORS.

Ground Control Panel - 3522A - 4527A - 5533A

Marking Description Function

1 Key Switch Turning the key switch to the PLATFORM (1a) icon selects operation
1a Platform Controls Position from the platform. Turning the key switch to the GROUND (1b) icon
selects operation from the ground control panel. The center (power
off) position interrupts all electric and hydraulic power operations
1b Ground Controls Position except emergency lowering. Removing the key protects against
operation by unauthorized persons. The key may be removed with the
key switch in any selected position.
Indicator LEDs light up to indicate the level of charge remaining in the
batteries. A lighted green LED indicates an adequate charge level.
2 Battery Condition Indicator Lighted yellow LEDs indicate the need for charging soon. A lighted red
LED warns that the battery charge level is low; boom operations
should be halted until the batteries are recharged.
3 Engine Start Start a cold engine by pressing the Engine START (3) button while
pressing and holding the CHOKE (4) button. To start/restart a warm
4 Engine Choke
engine, press the START button only.
The DISPLAY PANEL is a lighted text window that displays the present
5 Display Panel operating status or an existing error condition when the key switch is
on.

30 24203 4138 0 E 06 09 EN
C - Operation
A
Marking Description Function
When pushed in, the emergency STOP button disconnects electrical

6 Emergency Stop
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
B
button.
7 Boom Extend Pressing and holding a desired SPEED button and the BOOM
EXTEND (7) button at the same time extends the telescopic boom.
Pressing and holding a desired SPEED button and the BOOM
8 Boom Retract RETRACT (8) button at the same time retracts the boom. Boom
motion continues until the buttons are released or until the boom
reaches a hard stop or a safe travel limit.
C
9 Lower Boom Raise Boom Raise / Down ButtonsPressing and holding a desired SPEED
10 Lower Boom Down button and the UPPER/LOWER/JIB BOOM RAISE button at the same
11 Upper Boom Raise time will raise the chosen boom. Pressing a desired SPEED button
12 Upper Boom Down and the UPPER/LOWER/JIB BOOM DOWN button at the same time
13
14
Jib Raise
Jib Down
will lower the chosen boom. Boom motion continues until the buttons
are released or until the boom reaches a hard stop or a safe travel
limit.
D
The SPEED buttons along the lower right side of the control panel
15 Speed Buttons must be pressed and held while selecting a boom function. Four
speeds are available to control the positioning of the boom lift.
16 Platform Tilt - Down Press and hold any SPEED button and the desired PLATFORM TILT
17 Platform Tilt - Up
button at the same time to level the work platform (Levels the platform
only, not the boom lift). E
18 Boom Rotation - Clockwise Pressing and holding a desired SPEED button and the BOOM
ROTATION CLOCKWISE or COUNTERCLOCKWISE button at the
Boom Rotation - same time enables the boom to rotate in the direction selected. The
19
Counterclockwise boom will rotate through 700 ° until the buttons are released or the
stop is reached.
20
21
Outrigger Status Indicator LED
Outrigger Extend
Outrigger ControlsFor automatic outrigger extension/retraction :
Select EXTEND (21) or RETRACT (22) outrigger button and the F
22 Outrigger Retract AUTO LEVEL (23) button at the same time. To manually extend or
23 Auto Level retract the outriggers : Select EXTEND or RETRACT outrigger button
and one of the OUTRIGGER buttons (24) at the same time. The
outrigger indicator LEDs light up when the outriggers are properly
deployed and the boom weight is on the outriggers. Each of the outer
24 Outrigger Buttons outrigger LEDs indicates load is on the outrigger footpad. Each of the
inner outrigger LEDs, when flashing, indicate that side is low and
G
needs to be further raised for leveling. The Auto Level LED lights up
and a buzzer sounds when the boom is level

24203 4138 0 E 06 09 EN 31
C - Operation

3 - 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.

P l a t f o r m C o n t r o l P a n e l - 3 5 2 2 A - 4 5 2 7 A - 5 5 3 3 A

N.B.-:-THE PLATFORM CONTROL STATION INCLUDES THE FOLLOWING CONTROLS AND INDICATORS.

32 24203 4138 0 E 06 09 EN
C - Operation
A
Platfor m Control Panel - 3522A - 4527A - 5533A

Marking Description Function

1
Engine Start (DC / Gas Model
only)
Engine Start and Choke : Start a cold engine by pressing the CHOKE
B
button , then press the engine START button to start the engine. To
Engine Choke (DC / Gas Model
2 start/restart a warm engine, press the START button only.
only)
Press to sound the horn. Use the horn button to warn personnel in the
3 Horn area of a falling object hazard, impending boom motions or the need
for assistance.
Indicator LEDs light up to indicate the level of charge remaining in the
batteries. A lighted green LED indicates a good charge level. Lighted
C
4 Battery Condition Indicator yellow LEDs indicate the need for charging soon. A lighted red LED
warns that the battery charge level is low; boom operations should be
halted until the batteries are recharged.
When pushed in, the emergency STOP button disconnects electrical

5 Emergency Stop
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
D
button.
The SPEED buttons along the lower right side of the control panel
6 Speed Buttons must be pressed and held while selecting boom functions. Four
speeds are available to control the positioning of the boom lift.
7 Boom Rotation - Clockwise

Boom Rotation -
Pressing and holding a desired SPEED button and the BOOM
ROTATION CLOCKWISE or COUNTERCLOCK-WISE button at the
same time enables the boom to rotate in the direction selected. The
E
8
Counterclockwise boom will rotate through 700° until the buttons are released or the
stop is reached.
9 Lower Boom Raise Boom Raise / Down ButtonsPressing and holding a desired SPEED
10 Lower Boom Down button and the UPPER, LOWER or JIB BOOM RAISE button at the
11
12
Upper Boom Raise
Upper Boom Down
same time will raise the boom. Pressing a desired SPEED button and
the UPPER, LOWER or JIB BOOM DOWN button at the same time
F
13 Jib Boom Raise will lower the boom. Boom motion continues until the buttons are
14 Jib Boom Down released or until each boom reaches a hard stop or a safe travel limit.
15 Boom Extend Boom Extend / Retract ButtonsPressing and holding a desired
SPEED button and the BOOM EXTEND button at the same time

16 Boom Retract
extends the telescopic boom. Pressing and holding a desired SPEED
button and the BOOM RETRACT button at the same time retracts the
boom. Boom motion continues until the buttons are released or until
G
the boom reaches a hard stop or a safe travel limit.
17 Platform Tilt - Up Press and hold any SPEED button and the desired PLATFORM TILT
button at the same time to level the work platform (levels the platform
18 Platform Tilt - Down
only, not the boom lift).

Outlet
The outlet is provided for running electrical power tools from the work
platform. A connecting power cord must be plugged into a suitable
power source. The power plug is located on the trailer frame, in front
H
of the accessory equipment stowage plate. The outlet is rated for a
15 A load. Do not overload the accessory power circuit.

24203 4138 0 E 06 09 EN 33
C - Operation

P l a t f o r m C o n t r o l P a n e l - 2 6 2 2 T - 4 6 4 2 T

N.B.-:-THE PLATFORM CONTROL STATION INCLUDES THE FOLLOWING CONTROLS AND INDICATORS.

34 24203 4138 0 E 06 09 EN
C - Operation
A
Platfor m Control Panel - 2622T - 4642T

Marking Description Function

1
Engine Start (DC / Gas Model
only)
Engine Start and Choke : Start a cold engine by pressing the CHOKE
B
button , then press the engine START button to start the engine. To
Engine Choke (DC / Gas Model
2 start/restart a warm engine, press the START button only.
only)
Press to sound the horn. Use the horn button to warn personnel in the
3 Horn area of a falling object hazard, impending boom motions or the need
for assistance.
Indicator LEDs light up to indicate the level of charge remaining in the
batteries. A lighted green LED indicates a good charge level. Lighted
C
4 Battery Condition Indicator yellow LEDs indicate the need for charging soon. A lighted red LED
warns that the battery charge level is low; boom operations should be
halted until the batteries are recharged.
When pushed in, the emergency STOP button disconnects electrical

5 Emergency Stop
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
D
button.
The SPEED buttons along the lower right side of the control panel
6 Speed Buttons must be pressed and held while selecting boom functions. Four
speeds are available to control the positioning of the boom lift.
7 Boom Rotation - Clockwise

Boom Rotation -
Pressing and holding a desired SPEED button and the BOOM
ROTATION CLOCKWISE or COUNTERCLOCK-WISE button at the
same time enables the boom to rotate in the direction selected. The
E
8
Counterclockwise boom will rotate through 700° until the buttons are released or the
stop is reached.
9 Boom Raise Boom Raise / Down ButtonsPressing and holding a desired SPEED
button and the BOOM RAISE button at the same time will raise the

10 Boom Down
boom. Pressing a desired SPEED button and the BOOM DOWN
button at the same time will lower the boom. Boom motion continues
until the buttons are released or until each boom reaches a hard stop
F
or a safe travel limit.
11 Boom Extend Boom Extend / Retract ButtonsPressing and holding a desired
SPEED button and the BOOM EXTEND button at the same time
extends the telescopic boom. Pressing and holding a desired SPEED
12 Boom Lower button and the BOOM RETRACT button at the same time retracts the
boom. Boom motion continues until the buttons are released or until
G
the boom reaches a hard stop or a safe travel limit.
13 Platform Tilt - Up Press and hold any SPEED button and the desired PLATFORM TILT
button at the same time to level the work platform (levels the platform
14 Platform Tilt - Down
only, not the boom lift).

Outlet
The outlet is provided for running electrical power tools from the work
platform. A connecting power cord must be plugged into a suitable
power source. The power plug is located on the trailer frame, in front
H
of the accessory equipment stowage plate. The outlet is rated for a
15 A load. Do not overload the accessory power circuit.

24203 4138 0 E 06 09 EN 35
C - Operation

4 - PLATFORM CONTROLS JOYSTICK

Use the Joystick to operate drive and boom functions from the platform control station. .
P l a t f o r m C o n t r o l s J o y s t i c k

Platfor m Controls Joystick

Marking Description Function

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

5 - Normal Operating Procedure

Perform the following procedures to operate the Bil-Jax Telescoping Boom Lift :
• Read and obey all safety precautions and operating instructions, as well as all applicable government
regulations.
• Conduct a Pre-Operation Inspection by performing all recommended Daily Service Checks.
• Position the boom lift at the work area. Make sure the boom lift is on a firm and level surface and
there are no potential hazards such as overhead obstructions or electrically charged conductors. Do
not operate the boom lift if such hazards exist.
• Apply the boom lift parking brake or chock the wheels.
• Lower the tongue jack and unhitch the boom lift from the tow vehicle.

Failing to unhitch the boom lift before operation may lead to damage to equipment or tow vehicle and
makes the boom lift unstable, which can cause personnel injury or death.

36 24203 4138 0 E 06 09 EN
C - Operation
A
6 - Operation : Set up
• Turn the key switch on the ground controls to select the desired control station. If power does not
come on, make sure both emergency STOP buttons (ground and platform) are pulled out and the
main power disconnect is plugged in.
B
• The control microprocessor will perform self-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 A and B. C
• Extend the outriggers manually or using the 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 LEVEL buttons 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.
D
A - O u t r i g g e r C o n t r o l s

N.B.-:-THE SAFETY INTERLOCK SYSTEM PREVENTS ALL BOOM OPERATIONS IF THE BOOM IS NOT LEVEL OR IF
G
ONE OR MORE OUTRIGGERS ARE NOT SUPPORTING THE VEHICLE LOAD.

N.B.-:-THE RANGE OF MOTION DIAGRAMS AT THE GROUND AND PLATFORM CONTROL STATIONS DISPLAY THE
RANGE OF PLATFORM MOTION (SAFE OPERATING ZONE) FACING AWAY FROM THE TRAILER TONGUE. VERIFY
THAT THE OPERATING ZONE IS CLEAR OF OBSTRUCTIONS THROUGH 700 ° OF TURNTABLE ROTATION. H
• Verify that the auto level indicator LED is lit. If the auto level indicator is not lit, the boom may not be
level.
• Pull the latch release on the boom travel latch, raise the latch handle and swing the latch U-bolt down.
Refer to B
I

24203 4138 0 E 06 09 EN 37
C - Operation

B - B o o m T r a v e l L a t c h

• Open the platform travel latch (Figure C) and pivot the platform upright. Platform locking pins will
engage in the pivot locking holes when the platform is in a full upright position. Verify that the platform
is locked into place.
C - P l a t f o r m T r a v e l L a t c h

• Verify that the platform is properly attached to the mounting bracket on the boom end. The Retaining
Pin should be fully inserted through the platform and the mounting bracket on the boom end.

Failure to verify proper attachment of the platform to the boom end could cause the platform to separate
from the boom, resulting in death or serious injury.

• Verify that the platform is properly attached to the mounting bracket on the boom end. The Retaining
Pin should be fully inserted through the platform and the mounting bracket on the boom end.

Failure to verify proper attachment of the platform to the boom end could cause the platform to separate
from the boom, resulting in serious injury or death to the operator.
• Use the ground control panel to operate the boom lift functions. Raise, lower, extend and rotate the
boom 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 the boom onto the boom rest to position the platform for boarding. Turn the key switch to
the platform control position.

38 24203 4138 0 E 06 09 EN
C - Operation
A
• Raise the safety bar and enter the work platform. Put on the safety harness and attach the lanyard
to the Fall Protection Attachment Point on the side of the platform support beam.
• Use the platform control panel to operate the boom lift functions. Raise, lower, extend and rotate the
boom by pressing 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.
B
• Should the platform become tilted out of the normal vertical axis, press and hold the desired SPEED
button and one of the PLATFORM TILT buttons at the same time 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. C
• When all boom lift operations are complete, fully retract the telescoping boom extension. Center
boom over the boom rest and fully lower boom until seated in the stowed position for transport.
Safety switches prevent outrigger retraction until boom is completely lowered and stowed for
transport.
• Unfasten the safety harness and exit platform.
• Turn the key switch to the ground controls position. D
• 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 and trailer for obstructions
before retracting outriggers.
• Turn the key switch to the OFF position and remove key.
N.B.-:-THE N/A (4642T) IS EQUIPPED WITH A MOMENT SENSE OPTION THAT MONITORS PLATFORM POSITION
AND LOAD. IF THE PLATFORM MOVES OUTSIDE OF ITS UNRESTRICTED RANGE OF MOTION AND THE LOAD IS
E
GREATER THAN 160 KG (350 LB) , BOOM FUNCTIONS (OTHER THAN THE RETRACT FUNCTION) WILL CEASE.
RETRACT THE BOOM UNTIL THE PLATFORM IS WITHIN THE UNRESTRICTED RANGE OF MOTION TO RESUME
BOOM FUNCTIONS.

N.B.-:-LIFT FUNCTIONS MAY OPERATE MORE SLOWLY IN COLD CLIMATES. TO LOWER OUTRIGGERS IN COLD
TEMPERATURES, USE THE INDIVIDUAL OUTRIGGER BUTTONS TO LOWER EACH OUTRIGGER UNTIL THE FOOT
PAD TOUCHES THE GROUND. WHEN ALL FOUR OUTRIGGER FOOTPADS TOUCH THE GROUND, PRESS AND HOLD
F
EXTEND AND AUTO LEVEL BUTTONS TO LEVEL THE MACHINE.

7 - Operation : GROUND CONTROLS

• Turn the key switch to ground control position.
• Raise, lower, extend, retract and rotate the boom by pressing and holding the desired SPEED and
G
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 boom until seated in the stowed position for transport.
Safety switches prevent outrigger retraction until boom is completely lowered and stowed for
transport.
• Disengage platform locking pins and return platform to a stowed position. Engage the boom and
H
platform 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. I

24203 4138 0 E 06 09 EN 39
C - Operation

8 - Operation : PLATFORM CONTROLS

• Fully lower the boom 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. Put on the safety harness and attach the lanyard
to the Fall Protection Attachment Point on the side of the platform support beam.

Use the platform control panel to operate the boom lift functions :
• To raise, lower, extend and rotate the boom, press the desired function button.
• An LED adjacent to the function button will become lit, indicating that the function is active.
• 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.

40 24203 4138 0 E 06 09 EN
C - Operation
A
9 - DRIVE AND SET CONTROLS
The platform control station of a Drive and Set equipped machine includes the following controls and
indicators. .
B
D R I V E A N D S E T C O N T R O L S

DRIVE AND SET CONTROLS

Marking Description Function

F
Move the joystick in the desired direction while pressing and holding
1 Drive and Set Joystick
the DRIVE ENABLE ( 2 ) button to drive the fully retracted boom lift
Press and hold the DRIVE ENABLE button while using the joystick ( 1 )
2 Drive Enable Button to drive the fully retracted boom lift. Release the DRIVE ENABLE
button or joystick to stop
Diagnostic Indicator LEDs will light to indicate an error in boom lift or G
3 Diagnostic Indicators drive function. When lit, check the display panel on the ground control
station and the ERROR CODE DEFINITIONS chart in this manual.
Outriggers can be deployed from either the ground or platform control
4 Outrigger Controls
station on drive and set machines.
Press and hold the ENABLE button and the outrigger EXTEND or
5

6
Outrigger Enable Button

Machine Level Indicator

RETRACT button to deploy or retract outriggers.
Indicator LED will light to indicate that the machine is level and boom
H
functions can be performed.
When flashing, boom must be fully stowed before resuming outrigger
7 Platform Position LED
control or Drive and Set operations.

24203 4138 0 E 06 09 EN 41
C - Operation

10 - MANUAL BOOM OPERATION

Manual retraction, rotation and lowering functions allow the aerial work platform (or Telescoping Boom
Lift) to be moved and lowered during hydraulic power interruption or failure. In each instance, refer to
Figure A.

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. In case of a power failure, the hand
pump and selected hydraulic valve settings can be used to manually retract the Telescoping boom or
rotate the boom turntable.

To begin manual retraction or rotation, turn Proportional Valve counterclockwise until it stops, and
insert pump handle into the pump handle fitting.

A - H a n d P u m p a n d C o n t r o l s f o r M a n u a l L i f t
O p e r a t i o n

Marking Description
1 Hand pump
2 Proportional Valve
3 Rotation Button
4 Retract Button

42 24203 4138 0 E 06 09 EN
C - Operation
A
10.1 - MANUAL RETRACTION

Pushing and holding the Retract button while simultaneously actuating Hand Pump will retract
the extension boom section. B
10.2 - MANUAL ROTATION

To rotate the turntable clockwise :

• Push and hold the Rotation button and simultaneously actuate Hand Pump.
To rotate the turntable counterclockwise :
• Pull the Rotation button out and simultaneously actuate Hand Pump.
C
N.B.-:-RETURN PROPORTIONAL VALVE TO ITS ORIGINAL POSITION BEFORE LOWERING THE LIFT OR RESUMING
NORMAL OPERATION.

10.3 - MANUAL LOWERING

D
Each Manual Lowering Valve is equipped with a plunger, found at the base of the lift cylinder(
Figure B). Use the plunger to lower the platform in case of a complete electrical power failure,
a load shift, or other emergency. To lower the work platform, pull the valve plunger forward.
Continue pulling the plunger to completely lower the boom.
B - M a n u a l L o w e r i n g V a l v e - 3 6 X T - 2 6 2 2 T - 4 6 4 2 T
E

24203 4138 0 E 06 09 EN 43
C - Operation

C - M a n u a l L o w e r i n g V a l v e - 4 5 X A - 3 5 2 2 A - 4 5 2 7 A -
5 5 3 3 A

44 24203 4138 0 E 06 09 EN
C - Operation
A
11 - BATTERY RECHARGE
Recharge batteries as needed. When using the gas engine, press the GENERATOR button on the
platform control station to charge the batteries. Charge daily under normal use. When machine is not
B
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.

• Recharge batteries in a well-ventilated area only.

• Do no charge batteries near fire, spark or other potential ignition sources.
C
• Batteries may emit highly explosive hydrogen gas while charging.
• Failure to properly ventilate the charge gases may result in serious injury or death.
• Always charge boom lift batteries away from flammable materials.

To recharge the boom lift batteries : D

• Move the boom lift to a well-ventilated area with direct access to 120 V electrical outlet (CE : 220 V).
Keep the boom lift and batteries away from open flame or other potential ignition sources.
• Attach a 12 AWG multi-strand, grounded extension cord with a maximum length of 15 m (50 ft 0 in)
to the receptacle located inside the engine compartment. The generator may need to be
disconnected from the receptacle.
N.B.-:-USING AN UNDERRATED OR LONG POWER CORD WILL REDUCE THE OUTPUT OF THE BATTERY CHARGER
E
AND MAY EXTEND CHARGE TIME.

• Plug the extension cord into outlet. Verify that the green CHARGING indicator LED is lit on the battery
charger faceplate (A).
A - B a t t e r y C h a r g e r F a c e p l a t e
F

H
• The CHARGING indicator LED remains lit continuously during the first stage of the charge cycle. The
bulk mode =CHARGE CURRENT will be displayed on the battery charger faceplate.
• Press and hold the BATTERY VOLTAGE button to display the detected battery voltage.
• If a battery fault is detected, the appropriate fault code will appear on the CHARGE CURRENT
I
display. The red CHECK BATTERY indicator LED will become lit. See Table B for battery charger
fault codes.

24203 4138 0 E 06 09 EN 45
C - Operation

• Do not disconnect any output leads or connectors between the batteries and the charger when the
charger is on.
• To stop a charge in progress, always unplug the extension cord from the AC power source.
• When the battery charge reaches 80 % of capacity, the yellow 80% CHARGED indicator LED will
become lit and the green CHARGING indicator LED will begin to flash.
• When the batteries have reached a full charge, the green and yellow indicator LEDs will turn
themselves off. CC (Charge Complete) will appear on the CHARGE CURRENT display. After 2
hours, this display will fade and the CHARGE CURRENT will read 00.
• Unplug the extension cord from the outlet and the charger receptacle on the boom lift. Store the
extension cord for next use.

Always unplug the battery charger power cord before moving the boom lift. Failure to disconnect power
cord will cause damage to the equipment.

Code Description Limits Cause

More than 112 % charge Loose battery or charger
F1 Over Voltage
voltage connection
F2 Over Current More than 60 amperes Battery Fault
F3 Bulk Mode Timeout 14 h Max. Battery Fault
F4 ARD Mode Timeout 6 h Max. Battery Fault
F5 FCT Mode Timeout 2.5 h Max. Battery Fault
F6 Self-Test Error Charger Fault

46 24203 4138 0 E 06 09 EN
C - Operation
A
12 - BOOM LIFT TRANSPORT
The boom lift trailer includes a single axle, two-inch ball hitch, hydraulic surge brakes, mechanical
parking brake, safety chains, brake lights and side marker lights. Proper boom transport requires the
B
proper attachment and inspection of these components before towing.

A - T r a i l e r H i t c h i n g

1
Marking
Trailer Hitch
Description
F
2 Trailer Parking Brake
3 Release Lever
4 Safety Chains
5 Trailer-to-Vehicle Power Plug
G
Use the following procedure to hitch and tow the boom lift.
• Back the tow vehicle to the trailer. Verify that the ball and hitch are aligned and that the trailer hitch
has proper clearance above the ball. Use the tongue jack as needed.

Obtain, read and obey all recommendations set forth by the tow vehicle manufacturer before attempting
to transport equipment. Verify that equipment weight does not exceed the vehicle’s towing capacity.
H
Exceeding the tow vehicle's rated capacity may result in damage to tow vehicle or boom lift.
• Lift release lever and lower the hitch onto the ball using the tongue jack. Push down the release lever
to secure the ball.
• Use the tongue jack to verify secure coupling. If using the jack will raise the bumper of the tow
vehicle 0,05 - 0,07 m (0 ft 2 - 3 in) , the ball hitch coupling is secure. I
• Release the trailer parking brake.
• On the tongue jack, pull the pivot locking pin and swivel jack 90 ° to the travel position. Reengage
pivot locking pin.

24203 4138 0 E 06 09 EN 47
C - Operation

• Attach the safety chains to the tow vehicle. Verify that the chains cross under the trailer tongue. If
necessary, cross the chains first over then under the tow bar to prevent dragging.

Failure to attach safety chains properly before towing will allow trailer tongue to drop in case of ball hitch
failure, resulting in damage to trailer and equipment.
• If equipped, connect the breakaway cable to the tow vehicle. Leave adequate slack to prevent brakes
from dragging.
• Connect the trailer lights to the tow vehicle power plug.

Verify the following before towing the lift. Make adjustments as necessary.
• The trailer jack and outriggers are in their travel positions.
• Boom travel latches are engaged, securing the booms in their fully stowed positions.
• All on-board equipment is secured.
• The key switch is in the OFF position. Remove the key.
• The parking brake is disengaged.
• The trailer tires are adequately and evenly inflated.

Periodically check the wheel nut torque according to manufacturer's recommendations. Frequent
torque checks are required when a wheel is recently installed.

Prior to towing, while the trailer wheels are elevated for boom lift operation, inspect for loose wheels
and for wheel lug wear. If a loose wheel mounting is suspected, remove and inspect wheel lugs for
damage. NEVER tow a boom lift with worn or damaged wheel components.
12.1 - LIFTING INSTRUCTIONS

L i f t a n d T r a n s p o r t I n s t r u c t i o n s - 3 5 2 2 A - 4 5 2 7 A -
5 5 3 3 A

48 24203 4138 0 E 06 09 EN
C - Operation
A
12.2 - LIFTING INSTRUCTIONS

L i f t a n d T r a n s p o r t I n s t r u c t i o n s - 2 6 2 2 T - 4 6 4 2 T
B

• Completely lower and retract boom.

• Secure boom and platform travel latches. E
• Remove all loose materials from machine.
• Retract all outriggers to fully stowed position.
• Attach rigging only to the designated forklift pockets (A).
• Adjust rigging to keep the machine level and to minimize the risk of damage to machine.
• When using a forklift, use only the designated forklift pockets. Follow all forklift operating instructions
F
as indicated by the forklift manufacturer.
• Only trained and authorized personnel should attempt to lift the boom using a crane or forklift.
12.3 - TRANSPORT INSTRUCTIONS
• Verify that truck or trailer is parked on a firm and level surface. G
• Completely lower and retract boom.
• Secure boom and platform travel latches.
• Retract all outriggers to fully stowed position.
• Load boom onto truck or trailer.
• Chock the wheels ( B ) and apply parking brake.
H
• Place a wooden block under the tongue, near the trailer hitch ( C ).
• Lower jack until trailer tongue rests on the wooden block. Swing up and lock the jack ( D ) so that the
weight of the tongue now rests on the wooden block.
• Secure the boom lift to the trailer bed using straps or chains. Use only the two attachment points I
beneath the machine, adjacent to the outriggers (E).
• Adjust as necessary to prevent damage to rigging or machine.

24203 4138 0 E 06 09 EN 49
C - Operation

50 24203 4138 0 E 06 09 EN
D - Troubleshooting
A
Troubleshooting
1 - Foreword
The following section contains information for solving basic diagnostic issues associated with the
B
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.
C
2 - Troubleshooting
Refer to Table below for basic troubleshooting operations. Additional information can be found in the
Bil-Jax Model 36XT Parts and Service Manual. Contact the Bil-Jax Service Department with any D
questions or before attempting any advanced troubleshooting operations.

Tr o u b l e s h o o t i n g S t e p s

Problem Cause
Emergency STOP engaged
Solution
Disengage Emergency stop buttons E
No lights on panel when Battery charge is low Recharge as needed
key switch is turned to Battery ground or in-series cable is loose Inspect and repair battery connections
the on position Battery main disconnect unplugged Plug in main disconnect
Blown fuse Replace fuse
Fault detected by safety interlock Refer to Table below for error code definition
Hydraulic function does
not work and display
window shows an error
microprocessor
Boom Lift electric or electronic failure
and correction
Refer to Table below for error code definition
F
message and correction
Key switch turned to the off or platform
Turn key switch to ground controls position
Outrigger indicator LED controls position
lights do not function Emergency STOP engaged Disengage emergency stop buttons
Outriggers not deployed
Key switch is turned to the off or incorrect
control position
Deploy all outriggers
Turn key switch to ground or platform
controls position
G
Battery charge is low Recharge battery
Emergency STOP engaged Disengage Emergency stop buttons
Battery ground or in-series cable is loose Inspect and repair battery connections

One or more boom

controls do not
functionOrOne or more
All outriggers not properly deployed
Hydraulic pump inoperative
Deploy all outriggers and level boom lift
Inspect pump. Repair or replace as needed.
Check wiring terminals in control box and at
H
boom controls function Loose wiring connector valve manifold. Repair or replace as
improperlyOrOne or needed.
more boom controls Clean valve solenoid and recheck
Valve solenoid not operating properly
function intermittently function(s). Repair or replace as needed.

Fault detected by system interlock

Check display for system status. Refer to
Table below for error code definition and
correction.
I
j.Inspect wiring in control box and at valve
Broken or loose wire manifold and valve coil. Repair or replace
as needed.

24203 4138 0 E 06 09 EN 51
D - Troubleshooting

3 - 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 below for a comprehensive list of Error Code Definitions and solutions.

Error code definitions

Error Message What To Check and Corrective Action To Clear

Error Explanation and Possible Causes
Displayed Error
The Machine has gone into DOWN ONLY 1. Check outrigger and level LED indicators
modeThis is a self clearing error. When and if required re-level machine
error condition is removed, error is 2. Reduce boom load
cleared. Note : This error will not be
displayed when boom is down or if so 3. Reduce boom load
equipped, when the Load Sense Module
001MACHINE IS IN has detected an overloaded condition.
DOWN ONLY MODE Possible causes include :
1. Machine went out of level during
use.
2. Load sense has detected an over-
load condition.
3. Moment sense has detected an
overload condition.
The Lower Control has lost communication 1. Correctly configure Lower Control
with the Platform ControlThis is a latched
2. Replace Boom Cable
error. To clear this error, first the error
condition must be removed and second 3. Replace Upper Control
the power must be cycled off then back on. 4. Replace Lower Control
Note : During this error condition, the
Platform Control "Engine On" LED will
002LOSS OF blink a " 2 blink" error code and the Lower
PLATFORM Control "Power" LED will blink a " 2 blink"
COMMUNICATION error code.
Possible causes include :
1. Lower control incorrectly configu-
red.
2. Faulty Boom Cable.
3. Faulty Upper Control.
4. Faulty Lower Control.

52 24203 4138 0 E 06 09 EN
D - Troubleshooting
A
Error Message What To Check and Corrective Action To Clear
Error Explanation and Possible Causes
Displayed Error
The Lower Control has lost communication
with the Drive ControlThis is a latched
error. To clear this error, first the error
1. Correctly configure Lower Control
2. Replace Boom Cable
B
condition must be removed and second 3. Replace Upper Control
the power must be cycled off then back on. 4. Replace Lower Control
Note : During this error condition, the
Platform Control "Engine On" LED will
003 LOSS OF DRIVE
COMMUNICATION
blink a " 2 blink" error code and the Lower
Control "Power" LED will blink a " 2 blink"
error code.
C
Possible causes include :
1. Lower Control incorrectly configu-
red.
2. Faulty Boom Cable.
3. Faulty Upper Control.
4. Faulty Lower Control.
D
The Lower Control has lost communication 1. Replace cable between laptop and
with the laptop. This is a self clearing error. Lower Control
When error condition is removed, error is 2. Disconnect laptop or run laptop's pro-
cleared. Note : During this error condition, gram

004 LOSS OF PC
the Lower Control "Power" LED will blink a
" 4 blink" error code.
Possible causes include :
3. Replace laptop
4. Replace Lower Control
E
COMMUNICATION
1. Faulty cable between laptop and
Lower Control.
2. Laptop's program is not running.
3. Faulty laptop.
4. Faulty Lower Control. F
The Platform Control has detected a stuck 1. Free stuck or pressed key on Platform
or pressed key on power upThis is a Control
latched error. To clear this error, first the 2. Replace Platform Control
error condition must be removed and
second the power must be cycled off then
005PLATFORM
CONTROL HAS
STUCK KEY
back on. Note : During this error condition,
the Platform Control "Engine On" LED will
G
blink a " 1 blink" error code.
Possible causes include :
1. Platform Control has a stuck key.
2. Faulty Platform Control.
The Drive Control has detected a stuck or
pressed key on power upThis is a latched
error. To clear this error, first the error
1. Free stuck or pressed key on Drive Con-
trol H
2. Replace Drive Control
condition must be removed and second
006 DRIVE the power must be cycled off then back on.
CONTROL HAS Note : During this error condition, the Drive
STUCK KEY Control "Engine On" LED will blink a " 1
blink" error code.
Possible causes include : I
1. Drive Control has a stuck key.
2. Faulty Drive Control.

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D - Troubleshooting

Error Message What To Check and Corrective Action To Clear

Error Explanation and Possible Causes
Displayed Error
The Drive Control has detected a stuck 1. Free or replace stuck joystick on Drive
joystick on power upThis is a latched error. Control
To clear this error, first the error condition 2. Replace Drive Control
must be removed and second the power
007 DRIVE must be cycled off then back on. Note :
CONTROL HAS During this error condition, the Drive
STUCK JOYSTICK Control "Engine On" LED will blink a " 2
blink" error code.
Possible causes include :
1. Drive Control has a stuck joystick.
2. Faulty Drive Control.
The Lower Control has detected a stuck or 1. Free stuck or pressed key on Lower Con-
pressed key on power upThis is a latched trol
error. To clear this error, first the error 2. Faulty Lower Control
condition must be removed and second
008GROUND the power must be cycled off then back on.
CONTROL HAS Note : During this error condition, the
STUCK KEY Lower Control "Power" LED will blink a " 1
blink" error code.
Possible causes include :
1. Lower Control has a stuck key.
2. Faulty Lower Control.
The Lower Control has detected the boom 1. Check and repair boom and outrigger li-
is up without all four outriggers on the mit switches
groundThis is a self clearing error. When 2. Repair or replace boom and outrigger li-
error condition is removed, error is mit switch wiring
009BOOM UP cleared. Note : Alarm will sound during this
error condition. 3. Replace Lower Control
WITHOUT
OUTRIGGERS ON Possible causes include :
GROUND 1. Faulty boom down or outrigger li-
mit switches.
2. Faulty boom down or outrigger li-
mit switch wiring.
3. Faulty Lower Control
The Lower Control has detected a rapidly 1. Check Level Sensor
changing output from the level sensorThis 2. Repair or replace Level Sensor wiring
is a self clearing error. When error
010LEVEL SENSOR condition is removed, error is cleared. 3. Replace Lower Control
HAS ERRATIC Possible causes include : Note : With machine powered and level, Level
OUTPUT 1. Faulty Level Sensor. Sensor should have a steady approximately 24 V
supply voltage and a steady approximately 2.50
2. Faulty Level Sensor wiring.
V output on both X and Y outputs with respect to
3. Faulty Lower Control the Level Sensor ground connection.

54 24203 4138 0 E 06 09 EN
D - Troubleshooting
A
Error Message What To Check and Corrective Action To Clear
Error Explanation and Possible Causes
Displayed Error
An attempt was made to drive machine
without engaging the trailer brakeThis is a
self clearing error. When error condition is
1. Engage trailer brake
2. Check and repair trailer brake switch
B
removed, error is cleared. Note : This error 3. Repair or replace trailer brake switch wi-
only occurs on machines equipped with ring
011 TRYING TO the Drive and Set option. 4. Replace Lower Control
DRIVE W/ TRAILER Possible causes include :
BRAKE OFF
1. Trailer brake not engaged.
2. Faulty trailer brake switch.
C
3. Faulty trailer brake switch wiring
4. Faulty Lower Control
The Lower Control has detected the angle 1. Check angle sensor
sensor output is out of rangeThis is a self
clearing error. When error condition is
removed, error is cleared. Note : This error
2. Repair or replace angle sensor wiring
3. Correctly configure Lower Control D
only occurs on machines equipped with 4. Replace Lower Control
012 ANGLE SENSOR the Moment Sense option.
IS DISCONNECTED Possible causes include :
OR BAD 1. Faulty angle sensor.
2. Faulty angle sensor wiring.
3. Lower Control incorrectly configu-
red
E
4. Faulty Lower Control
The Lower Control has detected the 1. Check pressure sensor
pressure sensor output is out of rangeThis
2. Repair or replace pressure sensor wiring
is a self clearing error. When error

013 PRESSURE
condition is removed, error is cleared.
Note : This error only occurs on machines
3. Correctly configure Lower Control
4. Replace Lower Control
F
equipped with the Moment Sense option.
SENSOR IS
Possible causes include :
DISCONNECTED OR
BAD
1. Faulty pressure sensor.
2. Faulty pressure sensor wiring.
3. Lower Control incorrectly configu-
red G
4. Faulty Lower Control

24203 4138 0 E 06 09 EN 55
D - Troubleshooting

Error Message What To Check and Corrective Action To Clear

Error Explanation and Possible Causes
Displayed Error
The Lower Control has detected the 1. Check engine oil level
engine had low oil pressure while
2. Check oil pressure sensor
runningThis is a latched error. To clear
this error, first the error condition must be 3. Repair or replace oil pressure sensor wi-
removed and second the power must be ring
cycled off then back on. Note : This error 4. Correctly configure Lower Control
only occurs on machines equipped with
5. Replace Lower Control
014 CHECK ENGINE the X-Boom option.
LOW OIL PRESSURE Possible causes include :
1. Engine oil low.
2. Faulty oil pressure sensor.
3. Faulty oil pressure sensor wiring
4. Lower Control incorrectly configu-
red
5. Faulty Lower Control
The Lower Control has detected the 1. Check outrigger and level LED indicators
machine has all 4 outriggers on the and if required re-level machine
ground but is not levelThis is a self clearing 2. Check level sensor
error. When error condition is removed,
error is cleared. 3. Repair or replace level sensor wiring
015MACHINE IS NOT Possible causes include : 4. Replace Lower Control
LEVEL 1. Machine has gone out of level with
use.
2. Faulty level sensor.
3. Faulty level sensor wiring
4. Faulty Lower Control
The Lower Control has detected the Boom 1. Check that boom is raised before trying
must be raised before the requested to rotate boom
function can be performedThis is a self 2. Check that boom is raised before trying
clearing error. When error condition is to extend boom
removed, error is cleared.
Possible causes include : 3. Check that boom is raised before trying
to retract boom
1. Trying to rotate boom while boom
is down. 4. Check and repair boom down limit switch
016 LIFT BOOM 2. Trying to extend boom while boom 5. Repair or replace boom down limit switch
is down. wiring
3. Trying to retract boom while boom 6. Replace Lower Control
is down.
4. Faulty boom down limit switch.
5. Faulty boom down limit switch wi-
ring.
6. Faulty Lower Control

56 24203 4138 0 E 06 09 EN
D - Troubleshooting
A
Error Message What To Check and Corrective Action To Clear
Error Explanation and Possible Causes
Displayed Error
The Lower Control has detected the boom
must be lowered before the requested
function can be performedThis is a self
1. Check that boom is down before trying to
auto level machine B
2. Check that boom is down before trying to
clearing error. When error condition is extend outriggers
removed, error is cleared.
Possible causes include : 3. Check that boom is down before trying to
retract outriggers
1. Trying to auto level machine while

017STOW BOOM
boom is raised.
2. Trying to extend outriggers while
4. Check and repair boom down limit switch
5. Repair or replace boom down limit switch
wiring
C
boom is raised.
3. Trying to retract outriggers while 6. Replace Lower Control
boom is raised
4. Faulty boom down limit switch
5. Faulty boom down limit switch wi-
ring D
6. Faulty Lower Control
The Lower Control has lost communication 1. Correctly configure Lower Control
with the Load Sense ModuleThis is a
2. Replace Boom Cable
latched error. To clear this error, first the
error condition must be removed and 3. Replace Load Sense Module
second the power must be cycled off then
back on. Note : During this error condition,
4. Replace Lower Control E
the Load Sense Module "Status" LED will
blink a red " 2 blink" error code and the
018 LOSS OF LOAD Lower Control "Power" LED will blink a " 5
SENSE blink" error code. Note : This error only
COMMUNICATION occurs on machines equipped with the
Load Sense option.
Possible causes include :
F
1. Lower control incorrectly configu-
red.
2. Faulty Boom Cable.
3. Faulty Load Sense Module
4. Faulty Lower Control G

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D - Troubleshooting

Error Message What To Check and Corrective Action To Clear

Error Explanation and Possible Causes
Displayed Error
The Load Sense Module has detected an 1. Reduce weight in basket or on hook
overloaded boom condition which caused
2. Correctly configure Lower Control
the Lower Control to disable all boom
functionsThis is a self clearing error. 3. Replace load cell
When error condition is removed, error is 4. Repair or replace Load Cell wiring
cleared. Note : This error only occurs on
5. Replace Load Sense Module
machines equipped with the Load Sense
option. 6. Replace Lower Control
019 BOOM Possible causes include :
FUNCTION 1. Too much weight in basket or on
DISABLED hook.
2. Lower control incorrectly configu-
red.
3. Faulty Load Cell
4. Faulty Load Cell wiring
5. Faulty Load Sense Module
6. Faulty Lower Control
The Lower Control has detected a rapidly 1. Replace load cell
changing output from the level sensorThis
2. Repair or replace Load Cell wiring
is a self clearing error. When error
condition is removed, error is cleared. 3. Replace Load Sense Module
Note : Alarm will sound during this error
020 LOSS OF LOAD condition.
CELL CONNECTION Possible causes include :
1. Faulty boom down or outrigger li-
mit switches.
2. Faulty boom down or outrigger li-
mit switch wiring.
3. Faulty Lower Control
The Load Sense Module has detected a 1. Repair or replace Primary Up solenoid
loss of connection to the Load CellNote : A wiring
load of less than 70 mA will be detected 2. Replace Primary Up solenoid
as an open circuit. The typical load is
021OPEN CIRCUIT approximately 800 mA. 3. Replace Lower Control
PRIMARY UP Possible causes include :
1. Faulty Primary Up solenoid wiring.
2. Faulty Primary Up solenoid.
3. Faulty Lower Control
The Lower Control has detected excessive 1. Repair or replace Primary Up solenoid
current on the Primary Up solenoid output wiring
when it was energized during startup self 2. Replace Primary Up solenoid
022SHORTED diagnostics
CIRCUIT PRIMARY Possible causes include : 3. Replace Lower Control
UP 1. Faulty Primary Up solenoid wiring.
2. Faulty Primary Up solenoid.
3. Faulty Lower Control

58 24203 4138 0 E 06 09 EN
D - Troubleshooting
A
Error Message What To Check and Corrective Action To Clear
Error Explanation and Possible Causes
Displayed Error
The Lower Control has detected an open
circuit on the Primary Down solenoid
output when it was energized during
1. Repair or replace Primary Down solenoid
wiring B
2. Replace Primary Down solenoid
startup self diagnosticsNote : A load of
less than 70 mA will be detected as an 3. Replace Lower Control
023OPEN CIRCUIT open circuit. The typical load is
approximately 800 mA.
PRIMARY DOWN
Possible causes include :
1. Faulty Primary Down solenoid wi-
ring.
C
2. Faulty Primary Down solenoid.
3. Faulty Lower Control
The Lower Control has detected an open 1. Repair or replace Primary Down solenoid
circuit on the Primary Down solenoid
output when it was energized during
startup self diagnostics
wiring
2. Replace Primary Down solenoid D
024SHORTED 3. Replace Lower Control
CIRCUIT PRIMARY Possible causes include :
DOWN 1. Faulty Primary Down solenoid wi-
ring.
2. Faulty Primary Down solenoid.
3. Faulty Lower Control
The Lower Control has detected an open 1. Repair or replace Secondary Up solenoid
E
circuit on the Secondary Up solenoid wiring
output when it was energized during 2. Replace Secondary Up solenoid
startup self diagnosticsNote : A load of
less than 70 mA will be detected as an 3. Replace Lower Control
open circuit. The typical load is
025OPEN CIRCUIT
SECONDARY UP approximately 800 mA.
Possible causes include :
F
1. Faulty Secondary Up solenoid wi-
ring.
2. Faulty Secondary Up solenoid.
3. Faulty Lower Control
The Lower Control has detected an open
circuit on the Secondary Up solenoid
1. Repair or replace Secondary Up solenoid
wiring
G
output when it was energized during 2. Replace Secondary Up solenoid
startup self diagnostics
026SHORTED 3. Replace Lower Control
Possible causes include :
CIRCUIT
SECONDARY UP 1. Faulty Secondary Up solenoid wi-
ring.
2. Faulty Secondary Up solenoid. H
3. Faulty Lower Control

24203 4138 0 E 06 09 EN 59
D - Troubleshooting

Error Message What To Check and Corrective Action To Clear

Error Explanation and Possible Causes
Displayed Error
The Lower Control has detected an open 1. Repair or replace Secondary Down sole-
circuit on the Secondary Down solenoid noid wiring
output when it was energized during 2. Replace Secondary Down solenoid
startup self diagnosticsNote : A load of
less than 70 mA will be detected as an 3. Replace Lower Control
027OPEN CIRCUIT open circuit. The typical load is
SECONDARY DOWN approximately 800 mA.
Possible causes include :
1. Faulty Secondary Down solenoid
wiring.
2. Faulty Secondary Down solenoid.
3. Faulty Lower Control
The Lower Control has detected excessive 1. Repair or replace Secondary Down sole-
current on the Secondary Down solenoid noid wiring
output when it was energized during 2. Replace Secondary Down solenoid
028SHORTED startup self diagnostics
Possible causes include : 3. Replace Lower Control
CIRCUIT
SECONDARY DOWN 1. Faulty Secondary Down solenoid
wiring.
2. Faulty Secondary Down solenoid.
3. Faulty Lower Control
The Lower Control has detected an open 1. Repair or replace Jib Up solenoid wiring
circuit on the Jib Up solenoid output when
2. Replace Jib Up solenoid
it was energized during startup self
diagnosticsNote : A load of less than 70 3. Replace Lower Control
mA will be detected as an open circuit.
029OPEN CIRCUIT
The typical load is approximately 800 mA.
JIB UP
Possible causes include :
1. Faulty Jib Up solenoid wiring.
2. Faulty Jib Up solenoid.
3. Faulty Lower Control
The Lower Control has detected excessive 1. Repair or replace Jib Up solenoid wiring
current on the Jib Up solenoid output when
2. Replace Jib Up solenoid
it was energized during startup self
diagnostics 3. Replace Lower Control
030SHORTED
Possible causes include :
CIRCUIT JIB UP
1. Faulty Jib Up solenoid wiring.
2. Faulty Jib Up solenoid.
3. Faulty Lower Control
The Lower Control has detected an open 1. Repair or replace Jib Down solenoid wi-
circuit on the Jib Down solenoid output ring
when it was energized during startup self 2. Replace Jib Down solenoid
diagnosticsNote : A load of less than 70
mA will be detected as an open circuit. 3. Replace Lower Control
031OPEN CIRCUIT
The typical load is approximately 800 mA.
JIB DOWN
Possible causes include :
1. Faulty Jib Down solenoid wiring.
2. Faulty Jib Down solenoid.
3. Faulty Lower Control

60 24203 4138 0 E 06 09 EN
D - Troubleshooting
A
Error Message What To Check and Corrective Action To Clear
Error Explanation and Possible Causes
Displayed Error
The Lower Control has detected excessive
current on the Jib Down solenoid output
when it was energized during startup self
1. Repair or replace Jib Down solenoid wi-
ring B
2. Replace Jib Down solenoid
diagnostics
032SHORTED 3. Replace Lower Control
Possible causes include :
CIRCUIT JIB DOWN
1. Faulty Jib Down solenoid wiring.
2. Faulty Jib Down solenoid.
3. Faulty Lower Control
The Lower Control has detected an open 1. Repair or replace Extend boom solenoid
C
circuit on the Extend boom solenoid output wiring
when it was energized during startup self 2. Replace Extend solenoid
diagnosticsNote : A load of less than 70
mA will be detected as an open circuit. 3. Replace Lower Control
033OPEN CIRCUIT
EXTEND
The typical load is approximately 800 mA.
Possible causes include :
1. Faulty Extend boom solenoid wi-
D
ring.
2. Faulty Extend boom solenoid.
3. Faulty Lower Control
The Lower Control has detected excessive
current on the Extend boom solenoid
output when it was energized during
1. Repair or replace Extend boom solenoid
wiring
2. Replace Extend solenoid
E
startup self diagnostics
034SHORTED Possible causes include : 3. Replace Lower Control
CIRCUIT EXTEND 1. Faulty Extend boom solenoid wi-
ring.
2. Faulty Extend boom solenoid.
3. Faulty Lower Control
F
The Lower Control has detected an open 1. Repair or replace Retract boom solenoid
circuit on the Retract boom solenoid output wiring
when it was energized during startup self 2. Replace Retract boom solenoid
diagnosticsNote : A load of less than 70
3. Replace Lower Control
035OPEN CIRCUIT
RETRACT
mA will be detected as an open circuit.
The typical load is approximately 800 mA.
Possible causes include :
G
1. Faulty Retract boom solenoid wi-
ring.
2. Faulty Retract boom solenoid.
3. Faulty Lower Control
The Lower Control has detected excessive
current on the Retract boom solenoid
1. Repair or replace Retract boom solenoid
wiring
H
output when it was energized during 2. Replace Retract boom solenoid
startup self diagnostics
036SHORTED Possible causes include : 3. Replace Lower Control
CIRCUIT RETRACT 1. Faulty Retract boom solenoid wi-
ring.
2. Faulty Retract boom solenoid. I
3. Faulty Lower Control

24203 4138 0 E 06 09 EN 61
D - Troubleshooting

Error Message What To Check and Corrective Action To Clear

Error Explanation and Possible Causes
Displayed Error
The Lower Control has detected an open 1. Repair or replace Platform Level Up so-
circuit on the Platform Level Up solenoid lenoid wiring
output when it was energized during 2. Replace Platform Level Up solenoid
startup self diagnosticsNote : A load of
less than 70 mA will be detected as an 3. Replace Lower Control
037OPEN CIRCUIT open circuit. The typical load is
PLATFORM LEVEL approximately 800 mA.
UP Possible causes include :
1. Faulty Platform Level Up solenoid
wiring.
2. Faulty Platform Level Up solenoid.
3. Faulty Lower Control
The Lower Control has detected excessive 1. Repair or replace Platform Level Up so-
current on the Platform Level Up solenoid lenoid wiring
output when it was energized during 2. Replace Platform Level Up solenoid
038SHORTED startup self diagnostics
Possible causes include : 3. Replace Lower Control
CIRCUIT PLATFORM
LEVEL UP 1. Faulty Platform Level Up solenoid
wiring.
2. Faulty Platform Level Up solenoid.
3. Faulty Lower Control
The Lower Control has detected an open 1. Repair or replace Platform Level Down
circuit on the Platform Level Down solenoid wiring
solenoid output when it was energized 2. Replace Platform Level Down solenoid
during startup self diagnosticsNote : A
load of less than 70 mA will be detected 3. Replace Lower Control
039OPEN CIRCUIT as an open circuit. The typical load is
PLATFORM LEVEL approximately 800 mA.
DOWN Possible causes include :
1. Faulty Platform Level Down sole-
noid wiring.
2. Faulty Platform Level Down sole-
noid.
3. Faulty Lower Control
The Lower Control has detected excessive 1. Repair or replace Platform Level Down
current on the Platform Level Down solenoid wiring
solenoid output when it was energized 2. Replace Platform Level Down solenoid
during startup self diagnostics
040SHORTED Possible causes include : 3. Replace Lower Control
CIRCUIT PLATFORM 1. Faulty Platform Level Down sole-
LEVEL DOWN noid wiring.
2. Faulty Platform Level Down sole-
noid.
3. Faulty Lower Control

62 24203 4138 0 E 06 09 EN
D - Troubleshooting
A
Error Message What To Check and Corrective Action To Clear
Error Explanation and Possible Causes
Displayed Error
The Lower Control has detected an open
circuit on the Platform clockwise solenoid
output when it was energized during
1. Faulty Platform clockwise solenoid
2. Repair or replace Platform countercloc-
B
kwise solenoid wiringReplace Platform
startup self diagnosticsNote : A load of counterclockwise solenoid
less than 70 mA will be detected as an
open circuit. The typical load is 3. Replace Lower Control
041OPEN CIRCUIT
PLATFORM CW approximately 800 mA.
Possible causes include :
1. Faulty Platform clockwise solenoid
wiring.
C
2. .
3. Faulty Lower Control
The Lower Control has detected excessive 1. Faulty Platform clockwise solenoid
current on the Platform clockwise solenoid
output when it was energized during
startup self diagnostics
2. Repair or replace Platform countercloc-
kwise solenoid wiringReplace Platform
counterclockwise solenoid
D
042SHORTED Possible causes include :
CIRCUIT PLATFORM 3. Replace Lower Control
1. Faulty Platform clockwise solenoid
CW wiring.
2. Faulty Platform counter clockwise
solenoid.
3. Faulty Lower Control
E
The Lower Control has detected an open 1. Repair or replace Platform counter cloc-
circuit on the Platform counter clockwise kwise solenoid wiring
solenoid output when it was energized 2. Replace Platform counter clockwise so-
during startup self diagnosticsNote : A lenoid
load of less than 70 mA will be detected

043OPEN CIRCUIT
as an open circuit. The typical load is
approximately 800 mA.
3. Replace Lower Control
F
PLATFORM CCW Possible causes include :
1. Faulty Platform counter clockwise
solenoid wiring.
2. Faulty Platform counter clockwise
solenoid.
3. Faulty Lower Control G
The Lower Control has detected excessive 1. Repair or replace Platform counter cloc-
current on the Platform clockwise solenoid kwise solenoid wiring
output when it was energized during 2. Replace Platform counter clockwise so-
startup self diagnostics lenoid
044SHORTED Possible causes include :
CIRCUIT PLATFORM
CCW
1. Faulty Platform counter clockwise
solenoid wiring.
3. Replace Lower Control
H
2. Faulty Platform counter clockwise
solenoid.
3. Faulty Lower Control

24203 4138 0 E 06 09 EN 63
D - Troubleshooting

Error Message What To Check and Corrective Action To Clear

Error Explanation and Possible Causes
Displayed Error
The Lower Control has detected an open 1. Repair or replace Turntable clockwise
circuit on the Turntable clockwise solenoid solenoid wiring
output when it was energized during 2. Replace Turntable clockwise solenoid
startup self diagnosticsNote : A load of
less than 70 mA will be detected as an 3. Replace Lower Control
open circuit. The typical load is
045OPEN CIRCUIT approximately 800 mA.
TURNTABLE CW Possible causes include :
1. Faulty Turntable clockwise sole-
noid wiring.
2. Faulty Turntable clockwise sole-
noid.
3. Faulty Lower Control
The Lower Control has detected excessive 1. Repair or replace Turntable clockwise
current on the Turntable clockwise solenoid wiring
solenoid output when it was energized 2. Replace Turntable clockwise solenoid
during startup self diagnostics
046SHORTED Possible causes include : 3. Replace Lower Control
CIRCUIT 1. Faulty Turntable clockwise sole-
TURNTABLE CW noid wiring.
2. Faulty Turntable clockwise sole-
noid.
3. Faulty Lower Control
The Lower Control has detected excessive 1. Repair or replace Turntable counter cloc-
current on the Turntable counter clockwise kwise solenoid wiring
solenoid output when it was energized 2. Replace Turntable counter clockwise so-
during startup self diagnosticsNote : A lenoid
load of less than 70 mA will be detected
as an open circuit. The typical load is 3. Replace Lower Control
047OPEN CIRCUIT approximately 800 mA.
TURNTABLE CCW Possible causes include :
1. Faulty Turntable counter clockwi-
se solenoid wiring.
2. Faulty Turntable counter clockwi-
se solenoid.
3. Faulty Lower Control
The Lower Control has detected an open 1. Repair or replace Turntable counter cloc-
circuit on the Turntable counter clockwise kwise solenoid wiring
solenoid output when it was energized 2. Replace Turntable counter clockwise so-
during startup self diagnostics lenoid
048SHORTED Possible causes include :
CIRCUIT 3. Replace Lower Control
1. Faulty Turntable counter clockwi-
TURNTABLE CCW se solenoid wiring.
2. Faulty Turntable counter clockwi-
se solenoid.
3. Faulty Lower Control

64 24203 4138 0 E 06 09 EN
D - Troubleshooting
A
Error Message What To Check and Corrective Action To Clear
Error Explanation and Possible Causes
Displayed Error
The Lower Control has detected an open
circuit on the Outrigger Retract solenoid
output when it was energized during
1. Repair or replace Outrigger Retract sole-
noid wiring B
2. Replace Outrigger Retract solenoid
startup self diagnosticsNote : A load of
less than 70 mA will be detected as an 3. Replace Lower Control
049OPEN CIRCUIT open circuit. The typical load is
OUTRIGGER approximately 800 mA.
RETRACT Possible causes include :
1. Faulty Outrigger Retract solenoid
wiring
C
2. Faulty Outrigger Retract solenoid.
3. Faulty Lower Control
The Lower Control has detected excessive 1. Repair or replace Outrigger Retract sole-

050SHORTED
current on the Outrigger Retract solenoid
output when it was energized during
startup self diagnostics
noid wiring
2. Replace Outrigger Retract solenoid D
CIRCUIT Possible causes include : 3. Replace Lower Control
OUTRIGGER 1. Faulty Outrigger Retract solenoid
RETRACT wiring
2. Faulty Outrigger Retract solenoid.
3. Faulty Lower Control
The Lower Control has detected an open 1. Repair or replace Outrigger Extend sole-
E
circuit on the Outrigger Extend solenoid noid wiring
output when it was energized during 2. Replace Outrigger Extend solenoid
startup self diagnosticsNote : A load of
less than 70 mA will be detected as an 3. Replace Lower Control
051OPEN CIRCUIT open circuit. The typical load is
OUTRIGGER
EXTEND
approximately 800 mA.
Possible causes include :
F
1. Faulty Outrigger Extend solenoid
wiring
2. Faulty Outrigger Extend solenoid.
3. Faulty Lower Control
The Lower Control has detected excessive
current on the Outrigger Extend solenoid
1. Repair or replace Outrigger Extend sole-
noid wiring
G
output when it was energized during 2. Replace Outrigger Extend solenoid
052 SHORTED startup self diagnostics
CIRCUIT Possible causes include : 3. Replace Lower Control
OUTRIGGER 1. Faulty Outrigger Extend solenoid
EXTEND wiring
2. Faulty Outrigger Extend solenoid. H
3. Faulty Lower Control

24203 4138 0 E 06 09 EN 65
D - Troubleshooting

Error Message What To Check and Corrective Action To Clear

Error Explanation and Possible Causes
Displayed Error
The Lower Control has detected excessive 1. Repair or replace Left Front Outrigger so-
current on the Left Front Outrigger lenoid wiring
solenoid output when it was energized 2. Replace Left Front Outrigger solenoid
during startup self diagnosticsNote : A
load of less than 70 mA will be detected 3. Replace Lower Control
as an open circuit. The typical load is
053OPEN CIRCUIT approximately 800 mA.
LF OUTRIGGER Possible causes include :
1. Faulty Left Front Outrigger sole-
noid wiring
2. Faulty Left Front Outrigger sole-
noid.
3. Faulty Lower Control
The Lower Control has detected an open 1. Repair or replace Left Front Outrigger so-
circuit on the Left front Outrigger solenoid lenoid wiring
output when it was energized during 2. Replace Left Front Outrigger solenoid
startup self diagnostics
054SHORTED Possible causes include : 3. Replace Lower Control
CIRCUIT LF 1. Faulty Left Front Outrigger sole-
OUTRIGGER noid wiring
2. Faulty Left Front Outrigger sole-
noid.
3. Faulty Lower Control
The Lower Control has detected an open 1. Repair or replace Right Front Outrigger
circuit on the Right Front Outrigger solenoid wiring
solenoid output when it was energized 2. Replace Right Front Outrigger solenoid
during startup self diagnosticsNote : A
load of less than 70 mA will be detected 3. Replace Lower Control
as an open circuit. The typical load is
055OPEN CIRCUIT approximately 800 mA.
RF OUTRIGGER Possible causes include :
1. Faulty Right Front Outrigger sole-
noid wiring
2. Faulty Right Front Outrigger sole-
noid.
3. Faulty Lower Control
The Lower Control has detected excessive 1. Repair or replace Right Front Outrigger
current on the Right Front Outrigger solenoid wiring
solenoid output when it was energized 2. Replace Right Front Outrigger solenoid
during startup self diagnostics
056SHORTED Possible causes include : 3. Replace Lower Control
CIRCUIT RF 1. Faulty Right Front Outrigger sole-
OUTRIGGER noid wiring
2. Faulty Right Front Outrigger sole-
noid.
3. Faulty Lower Control

66 24203 4138 0 E 06 09 EN
D - Troubleshooting
A
Error Message What To Check and Corrective Action To Clear
Error Explanation and Possible Causes
Displayed Error
The Lower Control has detected an open
circuit on the Left Rear Outrigger solenoid
output when it was energized during
1. Repair or replace Left Rear Outrigger so-
lenoid wiring B
2. Replace Left Rear Outrigger solenoid
startup self diagnosticsNote : A load of
less than 70 mA will be detected as an 3. Replace Lower Control
open circuit. The typical load is
057OPEN CIRCUIT approximately 800 mA.
LR OUTRIGGER Possible causes include :
1. Faulty Left Rear Outrigger sole-
noid wiring
C
2. Faulty Left Rear Outrigger sole-
noid.
3. Faulty Lower Control
The Lower Control has detected excessive
current on the Left Rear Outrigger
solenoid output when it was energized
1. Repair or replace Left Rear Outrigger so-
lenoid wiring
2. Replace Left Rear Outrigger solenoid
D
during startup self diagnostics
058SHORTED Possible causes include : 3. Replace Lower Control
CIRCUIT LR 1. Faulty Left Rear Outrigger sole-
OUTRIGGER noid wiring
2. Faulty Left Rear Outrigger sole-
noid. E
3. Faulty Lower Control
The Lower Control has detected an open 1. Repair or replace Right Rear Outrigger
circuit on the Right Rear Outrigger solenoid wiring
solenoid output when it was energized 2. Replace Right Rear Outrigger solenoid
during startup self diagnosticsNote : A

059OPEN CIRCUIT
load of less than 70 mA will be detected
as an open circuit. The typical load is
3. Replace Lower Control
F
approximately 800 mA.
RR OUTRIGGER Possible causes include :
1. Faulty Right Rear Outrigger sole-
noid wiring
2. Faulty Right Rear Outrigger sole-
noid
3. Faulty Lower Control
G
The Lower Control has detected excessive 1. Repair or replace Right Rear Outrigger
current on the Right Rear Outrigger solenoid wiring
solenoid output when it was energized 2. Replace Right Rear Outrigger solenoid
during startup self diagnostics
060SHORTED
CIRCUIT RR
Possible causes include :
1. Faulty Right Rear Outrigger sole-
3. Replace Lower Control
H
OUTRIGGER noid wiring
2. Faulty Right Rear Outrigger sole-
noid
3. Faulty Lower Control
I

24203 4138 0 E 06 09 EN 67
D - Troubleshooting

Error Message What To Check and Corrective Action To Clear

Error Explanation and Possible Causes
Displayed Error
The Lower Control has detected an open 1. Repair or replace Engine Throttle relay
circuit on the Engine Throttle relay output wiring
when it was energized during startup self 2. Replace Engine Throttle relay
diagnosticsNote : A load of less than 70
mA will be detected as an open circuit. 3. Replace Lower Control
061 OPEN CIRCUIT This load is less than 70 mA and this error
ENGINE THROTTLE is suppressed to avoid false errors.
Possible causes include :
1. Faulty Engine Throttle relay wiring
2. Faulty Engine Throttle relay
3. Faulty Lower Control
The Lower Control has detected excessive 1. Repair or replace Engine Throttle relay
current on the Engine Throttle relay output wiring
when it was energized during startup self 2. Replace Engine Throttle relay
062 SHORTED diagnostics
CIRCUIT ENGINE Possible causes include : 3. Replace Lower Control
THROTTLE 1. Faulty Engine Throttle relay wiring
2. Faulty Engine Throttle relay
3. Faulty Lower Control
The Lower Control has detected an open 1. Repair or replace Engine Starter relay wi-
circuit on the Engine Starter relay output ring
when it was energized during startup self 2. Replace Engine Starter relay
diagnosticsNote : A load of less than 70
mA will be detected as an open circuit. 3. Replace Lower Control
063 OPEN CIRCUIT This load is less than 70 mA and this error
ENGINE STARTER is suppressed to avoid false errors.
Possible causes include :
1. Faulty Engine Starter relay wiring
2. Faulty Engine Starter relay
3. Faulty Lower Control
The Lower Control has detected excessive 1. Repair or replace Engine Starter relay wi-
current on the Engine Starter relay output ring
when it was energized during startup self 2. Replace Engine Starter relay
064 SHORTED diagnostics
CIRCUIT ENGINE Possible causes include : 3. Replace Lower Control
STARTER 1. Faulty Engine Starter relay wiring
2. Faulty Engine Starter relay
3. Faulty Lower Control
The Lower Control has detected an open 1. Repair or replace Engine Choke relay wi-
circuit on the Engine Choke relay output ring
when it was energized during startup self 2. Replace Engine Choke relay
diagnosticsNote : A load of less than 70
mA will be detected as an open circuit. 3. Replace Lower Control
065 OPEN CIRCUIT This load is less than 70 mA and this error
ENGINE CHOKE is suppressed to avoid false errors.
Possible causes include :
1. Faulty Engine Choke relay wiring
2. Faulty Engine Choke relay
3. Faulty Lower Control

68 24203 4138 0 E 06 09 EN
D - Troubleshooting
A
Error Message What To Check and Corrective Action To Clear
Error Explanation and Possible Causes
Displayed Error
The Lower Control has detected an open
circuit on the Engine Choke relay output
when it was energized during startup self
1. Repair or replace Engine Choke relay wi-
ring B
2. Replace Engine Choke relay
066 SHORTED diagnostics
CIRCUIT ENGINE Possible causes include : 3. Replace Lower Control
CHOKE 1. Faulty Engine Choke relay wiring
2. Faulty Engine Choke relay
3. Faulty Lower Control
The Lower Control has detected an open 1. Repair or replace Engine Stop relay wi-
C
circuit on the Engine Stop relay output ring
when it was energized during startup self 2. Replace Engine Stop relay
diagnosticsNote : A load of less than 70
mA will be detected as an open circuit. 3. Replace Lower Control
067 OPEN CIRCUIT
ENGINE STOP
This load is less than 70 mA and this error
is suppressed to avoid false errors.
Possible causes include :
D
1. Faulty Engine Stop relay wiring
2. Faulty Engine Stop relay
3. Faulty Lower Control
The Lower Control has detected excessive
current on the Engine Stop relay output
when it was energized during startup self
1. Repair or replace Engine Stop relay wi-
ring
2. Replace Engine Stop relay
E
068 SHORTED diagnostics
CIRCUITENGINE Possible causes include : 3. Replace Lower Control
STOP 1. Faulty Engine Stop relay wiring
2. Faulty Engine Stop relay
3. Faulty Lower Control
The Lower Control has detected an open 1. Repair or replace Proportional valve so-
F
circuit on the Proportional valve solenoid lenoid wiring
output when it was energized during 2. Replace Proportional valve solenoid
startup self diagnosticsNote : A load of
less than 70 mA will be detected as an 3. Replace Lower Control

069OPEN CIRCUIT
PROPORTIONAL
open circuit. This load is less than 70 mA
and this error is suppressed to avoid false
errors.
G
Possible causes include :
1. Faulty Proportional valve solenoid
wiring
2. Faulty Proportional valve solenoid
3. Faulty Lower Control H

24203 4138 0 E 06 09 EN 69
D - Troubleshooting

Error Message What To Check and Corrective Action To Clear

Error Explanation and Possible Causes
Displayed Error
The Lower Control has detected an open 1. Repair or replace Proportional valve so-
circuit on the Proportional valve solenoid lenoid wiring
output when it was energized during 2. Replace Proportional valve solenoid
startup self diagnosticsNote : A load of
less than 70 mA will be detected as an 3. Replace Lower Control
open circuit. This load is less than 70 mA
069OPEN CIRCUIT and this error is suppressed to avoid false
PROPORTIONAL errors.
Possible causes include :
1. Faulty Proportional valve solenoid
wiring
2. Faulty Proportional valve solenoid
3. Faulty Lower Control
The Lower Control has detected excessive 1. Repair or replace Proportional valve so-
current on the Proportional valve solenoid lenoid wiring
output when it was energized during 2. Replace Proportional valve solenoid
070SHORTED startup self diagnostics
Possible causes include : 3. Replace Lower Control
CIRCUIT
PROPORTIONAL 1. Faulty Proportional valve solenoid
wiring
2. Faulty Proportional valve solenoid
3. Faulty Lower Control
The Lower Control has detected an open 1. Repair or replace Motor Control Enable
circuit on the Motor Control Enable output wiring
when it was energized during startup self 2. Replace Motor Control
diagnosticsNote : A load of less than 70
mA will be detected as an open circuit. 3. Replace Lower Control
071 OPEN CIRCUIT
This load is less than 70 mA and this error
MOTOR CONTROL
is suppressed to avoid false errors.
ENABLE
Possible causes include :
1. Faulty Motor Control Enable wiring
2. Faulty Motor Control
3. Faulty Lower Control
The Lower Control has detected excessive 1. Repair or replace Motor Control Enable
current on the Motor Control Enable output wiring
when it was energized during startup self 2. Replace Motor Control
072 SHORTED diagnostics
CIRCUIT MOTOR Possible causes include : 3. Replace Lower Control
CONTROL ENABLE 1. Faulty Motor Control Enable wiring
2. Faulty Motor Control
3. Faulty Lower Control
The Lower Control has detected an open 1. Replace Lower Control
circuit on the Spare solenoid output when
it was energized during startup self
diagnosticsNote : A load of less than 70
073 OPEN CIRCUIT
mA will be detected as an open circuit.
SPARE OUTPUT
This output is not used and this error is
suppressed to avoid false errors.
Possible causes include :
1. Faulty Lower Control

70 24203 4138 0 E 06 09 EN
D - Troubleshooting
A
Error Message What To Check and Corrective Action To Clear
Error Explanation and Possible Causes
Displayed Error
The Lower Control has detected excessive
current on the Motor Control Enable output
when it was energized during startup self
1. Replace Lower Control
B
074 SHORTED
diagnosticsNote : This output is not used
CIRCUIT SPARE
and this error is suppressed to avoid false
OUTPUT
errors.
Possible causes include :
1. Faulty Lower Control
The Lower Control has detected an open 1. Repair or replace Alternative Current
Switch wiring
C
circuit on the Alternative Current Switch
output when it was energized during 2. Replace Alternative Current Switch
startup self diagnosticsNote : A load of
less than 70 mA will be detected as an 3. Replace Lower Control
open circuit. This load is less than 70 mA
075 OPEN CIRCUIT
AC SWITCH
and this error is suppressed to avoid false
errors. D
Possible causes include :
1. Faulty Alternative Current Switch
wiring
2. Faulty Alternative Current Switch
3. Faulty Lower Control
The Lower Control has detected excessive
current on the Alternative Current Switch
1. Repair or replace Alternative Current
Switch wiring
E
output when it was energized during 2. Replace Alternative Current Switch
startup self diagnostics
076 SHORTED Possible causes include : 3. Replace Lower Control
CIRCUIT AC SWITCH 1. Faulty Alternative Current Switch
wiring
2. Faulty Alternative Current Switch F
3. Faulty Lower Control
The Lower Control has detected an open 1. Repair or replace Strobe wiring
circuit on the Strobe output when it was
2. Replace Strobe
energized during startup self

077 OPEN CIRCUIT

diagnosticsNote : A load of less than 70
mA will be detected as an open circuit.
This load is less than 70 mA and this error
3. Replace Lower Control
G
STROBE is suppressed to avoid false errors.
Possible causes include :
1. Faulty Strobe wiring
2. Faulty Strobe
3. Faulty Lower Control
The Lower Control has detected excessive 1. Repair or replace Strobe wiring
H
current on the Strobe output when it was
2. Replace Strobe
energized during startup self diagnostics
078 SHORTED Possible causes include : 3. Replace Lower Control
CIRCUIT STROBE 1. Faulty Strobe wiring
2. Faulty Strobe
3. Faulty Lower Control
I

24203 4138 0 E 06 09 EN 71
D - Troubleshooting

Error Message What To Check and Corrective Action To Clear

Error Explanation and Possible Causes
Displayed Error
The Lower Control has detected an open 1. Repair or replace Drive PWM (Pulse
circuit on the Drive PWM (Pulse With With Modulation) valve solenoid wiring
modulation) valve solenoid output when it 2. Replace Drive PWM (Pulse With Modula-
was energized during startup self tion) valve
diagnosticsNote : A load of less than 70
mA will be detected as an open circuit. 3. Replace Lower Control
079 OPEN CIRCUIT The typical load is approximately 800 mA
DRIVE PWM at 100 % .
Possible causes include :
1. Faulty Drive PWM (Pulse With Mo-
dulation) valve solenoid wiring
2. Faulty Drive PWM (Pulse With Mo-
dulation) valve solenoid
3. Faulty Lower Control
The Lower Control has detected excessive 1. Repair or replace Drive PWM (Pulse
current on the Drive PWM (Pulse With With Modulation) valve solenoid wiring
Modulation) valve solenoid output when it 2. Replace Drive PWM (Pulse With Modula-
was energized during startup self tion) valve
080 SHORTED diagnostics
Possible causes include : 3. Replace Lower Control
CIRCUIT DRIVE
PWM 1. Faulty Drive PWM (Pulse With Mo-
dulation) valve solenoid wiring
2. Faulty Drive PWM (Pulse With Mo-
dulation) valve solenoid
3. Faulty Lower Control
The Lower Control has detected an open 1. Repair or replace Drive Enable solenoid
circuit on the Drive Enable solenoid output wiring
when it was energized during startup self 2. Replace Drive Enable solenoid
diagnosticsNote : A load of less than 70
mA will be detected as an open circuit. 3. Replace Lower Control
081 OPEN CIRCUIT The typical load is approximately 800 mA.
DRIVE ENABLE Possible causes include :
1. Faulty Drive Enable solenoid wi-
ring
2. Faulty Drive Enable solenoid
3. Faulty Lower Control
The Lower Control has detected excessive 1. Repair or replace Drive Enable solenoid
current on the Drive Enable solenoid wiring
output when it was energized during 2. Replace Drive Enable solenoid
082 SHORTED startup self diagnostics
Possible causes include : 3. Replace Lower Control
CIRCUIT DRIVE
ENABLE 1. Faulty Drive Enable solenoid wi-
ring
2. Faulty Drive Enable solenoid
3. Faulty Lower Control

72 24203 4138 0 E 06 09 EN
D - Troubleshooting
A
Error Message What To Check and Corrective Action To Clear
Error Explanation and Possible Causes
Displayed Error
The Lower Control has detected an open
circuit on the Drive Engage solenoid
output when it was energized during
1. Repair or replace Drive Engage solenoid
wiring B
2. Replace Drive Engage solenoid
startup self diagnosticsNote : A load of
less than 70 mA will be detected as an 3. Replace Lower Control
083 OPEN CIRCUIT open circuit. The typical load is
DRIVE ENGAGE approximately 800 mA.
Possible causes include :
1. Faulty Drive Engage solenoid wi-
ring
C
2. Faulty Drive Engage solenoid
3. Faulty Lower Control
The Lower Control has detected excessive 1. Repair or replace Drive Engage solenoid
current on the Drive Enable solenoid
output when it was energized during
startup self diagnostics
wiring
2. Replace Drive Engage solenoid D
084 SHORTED 3. Replace Lower Control
CIRCUIT DRIVE Possible causes include :
ENGAGE 1. Faulty Drive Engage solenoid wi-
ring
2. Faulty Drive Engage solenoid
3. Faulty Lower Control
The Lower Control has detected an open 1. Repair or replace Left Wheel Forward so-
E
circuit on the Left Wheel Forward solenoid lenoid wiring
output when it was energized during 2. Replace Left Wheel Forward solenoid
startup self diagnosticsNote : A load of
less than 70 mA will be detected as an 3. Replace Lower Control
open circuit. The typical load is
085 OPEN CIRCUIT
LEFT WHEEL
FORWARD
approximately 800 mA.
Possible causes include :
F
1. Faulty Left Wheel Forward sole-
noid wiring
2. Faulty Left Wheel Forward sole-
noid
3. Faulty Lower Control
The Lower Control has detected excessive 1. Repair or replace Left Wheel Forward so-
G
current on the Left Wheel Forward lenoid wiring
solenoid output when it was energized 2. Replace Left Wheel Forward solenoid
during startup self diagnostics
086 SHORTED Possible causes include : 3. Replace Lower Control
CIRCUIT LEFT
WHEEL FORWARD
1. Faulty Left Wheel Forward sole-
noid wiring
2. Faulty Left Wheel Forward sole-
H
noid
3. Faulty Lower Control

24203 4138 0 E 06 09 EN 73
D - Troubleshooting

Error Message What To Check and Corrective Action To Clear

Error Explanation and Possible Causes
Displayed Error
The Lower Control has detected an open 1. Repair or replace Left Wheel Reverse
circuit on the Left Wheel Reverse solenoid solenoid wiring
output when it was energized during 2. Replace Left Wheel Reverse solenoid
startup self diagnosticsNote : A load of
less than 70 mA will be detected as an 3. Replace Lower Control
087 OPEN CIRCUIT open circuit. The typical load is
LEFT WHEEL approximately 800 mA.
REVERSE Possible causes include :
1. Faulty Left Wheel Reverse sole-
noid wiring
2. Faulty Left Wheel Reverse sole-
noid
3. Faulty Lower Control
The Lower Control has detected excessive 1. Repair or replace Left Wheel Reverse
current on the Left Wheel Reverse solenoid wiring
solenoid output when it was energized 2. Replace Left Wheel Reverse solenoid
during startup self diagnostics
088 SHORTED Possible causes include : 3. Replace Lower Control
CIRCUIT LEFT 1. Faulty Left Wheel Reverse sole-
WHEEL REVERSE noid wiring
2. Faulty Left Wheel Reverse sole-
noid
3. Faulty Lower Control
The Lower Control has detected an open 1. Repair or replace Right Wheel Forward
circuit on the Right Wheel Forward solenoid wiring
solenoid output when it was energized 2. Replace Right Wheel Forward solenoid
during startup self diagnosticsNote : A
load of less than 70 mA will be detected 3. Replace Lower Control
089 OPEN CIRCUIT as an open circuit. The typical load is
RIGHT WHEEL approximately 800 mA.
FORWARD Possible causes include :
1. Faulty Right Wheel Forward sole-
noid wiring
2. Faulty Right Wheel Forward sole-
noid
3. Faulty Lower Control
The Lower Control has detected excessive 1. Repair or replace Right Wheel Forward
current on the Right Wheel Forward solenoid wiring
solenoid output when it was energized 2. Replace Right Wheel Forward solenoid
during startup self diagnostics
090 SHORTED Possible causes include : 3. Replace Lower Control
CIRCUIT RIGHT 1. Faulty Right Wheel Forward sole-
WHEEL FORWARD noid wiring
2. Faulty Right Wheel Forward sole-
noid
3. Faulty Lower Control

74 24203 4138 0 E 06 09 EN
D - Troubleshooting
A
Error Message What To Check and Corrective Action To Clear
Error Explanation and Possible Causes
Displayed Error
The Lower Control has detected excessive
current on the Right Wheel Forward
solenoid output when it was energized
1. Repair or replace Right Wheel Reverse
solenoid wiring B
2. Replace Right Wheel Reverse solenoid
during startup self diagnosticsNote : A
load of less than 70 mA will be detected 3. Replace Lower Control
091 OPEN CIRCUIT as an open circuit. The typical load is
RIGHT WHEEL approximately 800 mA.
REVERSE Possible causes include :
1. Faulty Right Wheel Reverse sole-
noid wiring
C
2. Faulty Right Wheel Reverse sole-
noid
3. Faulty Lower Control
The Lower Control has detected excessive
current on the Right Wheel Reverse
solenoid output when it was energized
1. Repair or replace Right Wheel Reverse
solenoid wiring
2. Replace Right Wheel Reverse solenoid
D
during startup self diagnostics
092 SHORTED Possible causes include : 3. Replace Lower Control
CIRCUIT RIGHT 1. Faulty Right Wheel Reverse sole-
WHEEL REVERSE noid wiring
2. Faulty Right Wheel Reverse sole-
noid E
3. Faulty Lower Control
For N/A (4642T) only
The Lower Control has detected the boom 1. Reduce weight in basket or on hook
has reached or exceeded 95 % of
2. Retract boom
maximum outreach settingNote : This error
only occurs on machines equipped with
the Moment Sense option.
3. Raise boom
4. Correctly configure Lower Control
F
Possible causes include :
5. Replace Lower Control
1. Too much weight on boom
103 OUTREACH
NEAR MAXIMUM 2. Boom extended too far for weight
on boom
3. Boom lowered too far for weight on
boom
G
4. Lower Control incorrectly configu-
red
5. Faulty Lower Control

24203 4138 0 E 06 09 EN 75
D - Troubleshooting

Error Message What To Check and Corrective Action To Clear

Error Explanation and Possible Causes
Displayed Error
The Lower Control has detected the boom 1. Reduce weight in basket or on hook
has reached the maximum outreach
2. Retract boom
settingNote : This error only occurs on
machines equipped with the Moment 3. Raise boom
Sense option. 4. Correctly configure Lower Control
Possible causes include :
5. Replace Lower Control
1. Too much weight on boom
104 OUTREACH AT
MAXIMUM 2. Boom extended too far for weight
on boom
3. Boom lowered too far for weight on
boom
4. Lower Control incorrectly configu-
red
5. Faulty Lower Control
The Lower Control has detected the 1. Reduce weight in basket or on hook
primary boom cylinder has reached or
2. Retract boom
exceeded the maximum pressure
settingNote : This error only occurs on 3. Raise boom
machines equipped with the Moment 4. Correctly configure Lower Control
Sense option.
5. Replace Lower Control
Possible causes include :
105 OVER MAXIMUM
1. Too much weight on boom
CYLINDER
PRESSURE 2. Boom extended too far for weight
on boom
3. Boom lowered too far for weight on
boom
4. Lower Control incorrectly configu-
red
5. Faulty Lower Control

76 24203 4138 0 E 06 09 EN
D - Troubleshooting
A
Error Message What To Check and Corrective Action To Clear
Error Explanation and Possible Causes
Displayed Error
The Primary boom cylinder pressure
safety switch has detected the primary
cylinder has reached or exceeded the
1. Check angle sensor
2. Repair or replace angle sensor wiring
B
maximum pressure setting and disabled all 3. Check pressure sensor
boom functionsIf this error occurs one or 4. Repair or replace pressure wiring
more of the three sensors responsible for
5. Check and repair Primary boom cylinder
determining the moment are not reading
pressure switch
correctly. The angle sensor, the pressure
sensor and the pressure switch must be
examined to determine which sensor or
6. Repair or replace Primary boom cylinder
pressure switch wiring
C
sensors have failedNote : This error only 7. Correctly configure Lower Control
occurs on machines equipped with the
8. Replace Lower Control
Moment Sense option.
106 OUTREACH Possible causes include :
SENSING FAULT
1. Faulty angle sensor
2. Faulty angle sensor wiring
D
3. Faulty pressure sensor
4. Faulty pressure sensor wiring
5. Faulty Primary cylinder pressure
switch
6. Faulty Primary cylinder pressure
switch wiring
E
7. Lower control incorrectly configu-
red
8. Faulty Lower Control

24203 4138 0 E 06 09 EN 77
D - Troubleshooting

78 24203 4138 0 E 06 09 EN
E - Decal replacement
A
Decal replacement
1 - Foreword
Decals contain information that is required for the safe and proper use of the aerial work platform.
B
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.

2 - Identification C
Decal Descriptions - 3522A

Decal No. Decal description Quantity

0202-0523
B06-00-0034
Made in USA
DANGER: Electric Shock
1
1
D
B06-00-0037 Lubricate Semi-Annually 1
B06-00-0062 NOTICE: AC Power 2
B06-00-0068 NOTICE: Hydraulic System Oil 1
B06-00-0161B Bil-Jax Logo, Black Transfer 2
B06-00-0173
B06-00-0403
B06-00-0404
NOTICE: Fall Protection Attachment Point
NOTICE: Emergency Lowering
WARNING: Outrigger Crush Toe
2
4
8
E
B06-00-0405 WARNING: Pinch Point 17
B06-00-0471 DANGER: Before Use/Main Instruction/Hazards (Platform) 1
B06-00-0473 NOTICE: Operator's Manual Missing 1
B06-00-0474 NOTICE: Max. Load 1
B06-00-0475
B06-00-0477
WARNING: Read/Understand Operator’s Manual
WARNING: Forklift Pockets
1
2
F
B06-00-0478 NOTICE: Platform Charger/Power Plug Here 1
B06-00-0481 CAUTION: Transport Safety Latch 3
B06-00-0482 DANGER: Electrocution Hazard 2
B06-00-0484 DANGER: Battery/Charger Safety 1
B06-00-0494
B06-00-0495
NOTICE: Hazardous Materials
CAUTION: Compartment Access Restricted
1
2 G
B06-00-0496 CAUTION: Generator Plate Capacity 1
B06-00-0503 NOTICE: Handle Applications 1
B06-00-0504 NOTICE: Emergency Hand Pump 1
B06-00-0505 DANGER: Before Use/Main Instruction/Hazards (ground) 1
B06-00-0521
B06-00-0533
B06-00-0534
DANGER: Tip Over Hazard
WARNING: Operating Instructions (Ground)
WARNING: Operating Instructions (Platform)
7
2
1
H
B06-00-0535 NOTICE: Range of Motion 2
B06-00-0538 3522A, 6" Black Transfer 2
B06-00-0541 CAUTION: Manual Boom Functions 1
B06-00-0542 WARNING: Max. Towing Speed 2
B06-00-0543
B06-00-0544
WARNING: Wheel Crush Toe
WARNING: Towing Hazards
2
2
I
B06-00-0545 Bil-Jax Website Transfer 2
B06-00-0550 WARNING: Unhitch Lift Before Use 2
B06-00-0551 CAUTION: Prior to Towing 1

24203 4138 0 E 06 09 EN 79
E - Decal replacement

Identification Plates - 3522A

Decal No. Decal description Quantity

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

- - - 3522A

Decal No. Decal description Quantity

B06-00-0167 Black/Yellow Hazard 4
B06-00-0568 WARNING: Tip Over Hazard 4

80 24203 4138 0 E 06 09 EN
E - Decal replacement
A
D e c a l l o c a t i o n s - 3 5 2 2 A

24203 4138 0 E 06 09 EN 81
E - Decal replacement

Decal Descriptions - 4527A

Decal No. Decal description Quantity

B06-00-0034 DANGER: Electric Shock 1
B06-00-0037 Lubricate Semi-Annually 1
B06-00-0062 NOTICE: AC Power 2
B06-00-0068 NOTICE: Hydraulic System Oil 1
B06-00-0161B Bil-Jax Logo, Black Transfer 2
B06-00-0173 NOTICE: Fall Protection Attachment Point 2
B06-00-0403 NOTICE: Emergency Lowering 4
B06-00-0404 WARNING: Outrigger Crush Toe 8
B06-00-0405 WARNING: Pinch Point 17
B06-00-0471 DANGER: Before Use/Main Instruction/Hazards (Platform) 1
B06-00-0473 NOTICE: Operator's Manual Missing 1
B06-00-0474 NOTICE: Max. Load 1
B06-00-0475 WARNING: Read/Understand Operator’s Manual 1
B06-00-0477 WARNING: Forklift Pockets 2
B06-00-0478 NOTICE: Platform Charger/Power Plug Here 1
B06-00-0481 CAUTION: Transport Safety Latch 3
B06-00-0482 DANGER: Electrocution Hazard 2
B06-00-0484 DANGER: Battery/Charger Safety 1
B06-00-0494 NOTICE: Hazardous Materials 1
B06-00-0495 CAUTION: Compartment Access Restricted 2
B06-00-0496 CAUTION: Generator Plate Capacity 1
B06-00-0503 NOTICE: Handle Applications 1
B06-00-0504 NOTICE: Emergency Hand Pump 1
B06-00-0505 DANGER: Before Use/Main Instruction/Hazards (ground) 1
B06-00-0521 DANGER: Tip Over Hazard 7
B06-00-0533 WARNING: Operating Instructions (Ground) 2
B06-00-0534 WARNING: Operating Instructions (Platform) 1
B06-00-0536 NOTICE: Range of Motion 2
B06-00-0539 4527A, 6" Black Transfer 2
B06-00-0541 CAUTION: Manual Boom Functions 1
B06-00-0542 WARNING: Max. Towing Speed 2
B06-00-0543 WARNING: Wheel Crush Toe 2
B06-00-0544 WARNING: Towing Hazards 2
B06-00-0545 Bil-Jax Website Transfer 2
B06-00-0550 WARNING: Unhitch Lift Before Use 2
B06-00-0551 CAUTION: Prior to Towing 1

Identification Plates - 4527A

Decal No. Decal description Quantity

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

82 24203 4138 0 E 06 09 EN
E - Decal replacement
A
- - - 4527A

Decal No. Decal description Quantity B

B06-00-0167 Black/Yellow Hazard 4
B06-00-0568 WARNING: Tip Over Hazard 4

D e c a l l o c a t i o n s - 4 5 2 7 A
C

24203 4138 0 E 06 09 EN 83
E - Decal replacement

Decal Descriptions - 5533A

Decal No. Decal description Quantity

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 2
B06-00-0068 NOTICE: Hydraulic System Oil 1
B06-00-0161B Bil-Jax Logo, Black Transfer 2
B06-00-0173 NOTICE: Fall Protection Attachment Point 2
B06-00-0403 NOTICE: Emergency Lowering 4
B06-00-0404 WARNING: Outrigger Crush Toe 8
B06-00-0405 WARNING: Pinch Point 17
B06-00-0471 DANGER: Before Use/Main Instruction/Hazards (Platform) 1
B06-00-0473 NOTICE: Operator's Manual Missing 1
B06-00-0474 NOTICE: Max. Load 1
B06-00-0475 WARNING: Read/Understand Operator’s Manual 1
B06-00-0477 WARNING: Forklift Pockets 2
B06-00-0478 NOTICE: Platform Charger/Power Plug Here 1
B06-00-0481 CAUTION: Transport Safety Latch 3
B06-00-0482 DANGER: Electrocution Hazard 2
B06-00-0484 DANGER: Battery/Charger Safety 1
B06-00-0494 NOTICE: Hazardous Materials 1
B06-00-0495 CAUTION: Compartment Access Restricted 2
B06-00-0496 CAUTION: Generator Plate Capacity 1
B06-00-0503 NOTICE: Handle Applications 1
B06-00-0504 NOTICE: Emergency Hand Pump 1
B06-00-0505 DANGER: Before Use/Main Instruction/Hazards (ground) 1
B06-00-0521 DANGER: Tip Over Hazard 7
B06-00-0533 WARNING: Operating Instructions (Ground) 2
B06-00-0534 WARNING: Operating Instructions (Platform) 1
B06-00-0537 NOTICE: Range of Motion 2
B06-00-0540 5533A, 6" Black Transfer 2
B06-00-0541 CAUTION: Manual Boom Functions 1
B06-00-0542 WARNING: Max. Towing Speed 2
B06-00-0543 WARNING: Wheel Crush Toe 2
B06-00-0544 WARNING: Towing Hazards 2
B06-00-0545 Bil-Jax Website Transfer 2
B06-00-0550 WARNING: Unhitch Lift Before Use 2
B06-00-0551 CAUTION: Prior to Towing 1

Identification Plates - 5533A

Decal No. Decal description Quantity

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

84 24203 4138 0 E 06 09 EN
E - Decal replacement
A
- - - 5533A

Decal No. Decal description Quantity B

B06-00-0167 Black/Yellow Hazard 4
B06-00-0568 WARNING: Tip Over Hazard 4

D e c a l l o c a t i o n s - 5 5 3 3 A
C

24203 4138 0 E 06 09 EN 85
E - Decal replacement

Decal Descriptions - 2622T

Decal No. Decal description Quantity

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 2
B06-00-0068 NOTICE: Hydraulic System Oil 1
B06-00-0161B Bil-Jax Logo, Black Transfer 2
B06-00-0173 NOTICE: Fall Protection Attachment Point 2
B06-00-0403 NOTICE: Emergency Lowering 4
B06-00-0404 WARNING: Outrigger Crush Toe 8
B06-00-0405 WARNING: Pinch Point 17
B06-00-0468 WARNING: Operating Instructions (Ground) 2
B06-00-0471 DANGER: Before Use/Main Instruction/Hazards (Platform) 1
B06-00-0473 NOTICE: Operator's Manual Missing 1
B06-00-0475 WARNING: Read/Understand Operator’s Manual 1
B06-00-0477 WARNING: Forklift Pockets 2
B06-00-0478 NOTICE: Platform Charger/Power Plug Here 1
B06-00-0481 CAUTION: Transport Safety Latch 3
B06-00-0482 DANGER: Electrocution Hazard 2
B06-00-0484 DANGER: Battery/Charger Safety 1
B06-00-0491 WARNING: Operating Instructions (Platform) 1
B06-00-0493 CAUTION: Prior to Towing 1
B06-00-0494 NOTICE: Hazardous Materials 1
B06-00-0495 CAUTION: Compartment Access Restricted 2
B06-00-0496 CAUTION: Generator Plate Capacity 1
B06-00-0503 NOTICE: Handle Applications 1
B06-00-0504 NOTICE: Emergency Hand Pump 1
B06-00-0505 DANGER: Before Use/Main Instruction/Hazards (ground) 1
B06-00-0521 DANGER: Tip Over Hazard 7
B06-00-0541 CAUTION: Manual Boom Functions 1
B06-00-0542 WARNING: Max. Towing Speed 2
B06-00-0543 WARNING: Wheel Crush Toe 2
B06-00-0544 WARNING: Towing Hazards 2
B06-00-0545 Bil-Jax Website Transfer 2
B06-00-0550 WARNING: Unhitch Lift Before Use 2
B06-00-0555 NOTICE: Range of Motion 2
B06-00-0556 2622T, 6" Black Transfer 2
B06-00-0557 NOTICE: Max. Load 1

Identification Plates - 2622T

Decal No. Decal description Quantity

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

86 24203 4138 0 E 06 09 EN
E - Decal replacement
A
- - 2622T

Decal No. Decal description Quantity B

B06-00-0167 Black/Yellow Hazard 4
B06-00-0568 WARNING: Tip Over Hazard 4

D e c a l l o c a t i o n s - 2 6 2 2 T
C

24203 4138 0 E 06 09 EN 87
E - Decal replacement

Decal Descriptions - 4642T

Decal No. Decal description Quantity

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 2
B06-00-0068 NOTICE: Hydraulic System Oil 1
B06-00-0161B Bil-Jax Logo, Black Transfer 2
B06-00-0167 Yellow and black adhesive tape 4
B06-00-0404 WARNING: Outrigger Crush Toe 8
B06-00-0405 WARNING: Pinch Point 17
B06-00-0468 WARNING: Operating Instructions (Ground) 2
B06-00-0471 DANGER: Before Use/Main Instruction/Hazards (Platform) 1
B06-00-0473 NOTICE: Operator's Manual Missing 1
B06-00-0475 WARNING: Read/Understand Operator’s Manual 1
B06-00-0477 WARNING: Forklift Pockets 2
B06-00-0478 NOTICE: Platform Charger/Power Plug Here 1
B06-00-0481 CAUTION: Transport Safety Latch 3
B06-00-0482 DANGER: Electrocution Hazard 2
B06-00-0484 DANGER: Battery/Charger Safety 1
B06-00-0491 WARNING: Operating Instructions (Platform) 1
B06-00-0493 CAUTION: Prior to Towing 1
B06-00-0494 NOTICE: Hazardous Materials 1
B06-00-0495 CAUTION: Compartment Access Restricted 2
B06-00-0496 CAUTION: Generator Plate Capacity 1
B06-00-0503 NOTICE: Handle Applications 1
B06-00-0504 NOTICE: Emergency Hand Pump 1
B06-00-0505 DANGER: Before Use/Main Instruction/Hazards (ground) 1
B06-00-0506 NOTICE: Emergency Lowering 2
B06-00-0521 DANGER: Tip Over Hazard 7
B06-00-0541 CAUTION: Manual Boom Functions 1
B06-00-0542 WARNING: Max. Towing Speed 2
B06-00-0543 WARNING: Wheel Crush Toe 2
B06-00-0544 WARNING: Towing Hazards 2
B06-00-0545 Bil-Jax Website Transfer 2
B06-00-0550 WARNING: Unhitch Lift Before Use 2
B06-00-0552 NOTICE: Lanyard Attach Points 1
B06-00-0586 NOTICE: Range of Motion 2
B06-00-0587 4642T, 6" Black Transfer 2
B06-00-0588 NOTICE: Max. Load 1

Identification Plates - 4642T

Decal No. Decal description Quantity

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

88 24203 4138 0 E 06 09 EN
E - Decal replacement
A
- - 4642T

Decal No. Decal description Quantity B

B06-00-0167 Black/Yellow Hazard 4
B06-00-0568 WARNING: Tip Over Hazard 4

D e c a l l o c a t i o n s - 4 6 4 2 T
C

24203 4138 0 E 06 09 EN 89
E - Decal replacement

2.1 - REPLACEMENT DECALS

Refer to Table and Figure in this document for a descriptions and locations of replacement
decals for optional components. Refer to Section in this document for a comprehensive list of
standard decals on the Bil-Jax Model.

REPLACEMENT DECALS

Decal No. Decal description

B06-00-0474 NOTICE: Max. Load (All Configurations)
B06-00-0485 NOTICE: Material/Lifting Configuration Set-Up (Material Lift Option Only)
B06-00-0497 NOTICE: Load Capacity for Material Lifting Hook (Material Lift Option Only)
B06-00-0527 WARNING: Drive and Set Hazards
B06-00-0528 NOTICE: Drive and Set Instruction
B06-00-0529 NOTICE: Manual Platform Rotation (Manual Rotation Option Only)
B06-00-0553 WARNING: Jockey Wheel

N.B.-:-ALL DECALS RELATED TO OPTIONAL EQUIPMENT HAVE A QUANTITY OF 1 UNLESS OTHERWISE NOTED.

M a t e r i a l L i f t D e c a l P l a c e m e n t

90 24203 4138 0 E 06 09 EN
E - Decal replacement
A
D e c a l L o c a t i o n s

24203 4138 0 E 06 09 EN 91
E - Decal replacement

92 24203 4138 0 E 06 09 EN
F - Specifications
A
Specifications
1 - Foreword
• Bil-Jax, Inc.. is dedicated to the continuous improvement of this and all Bil-Jax products. Therefore,
B
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. C
2 - Specifications
Serial number :

Te c h n i c a l c h a r a c t e r i s t i c s - F o r 3522A
D
Machine 3522A
Metric
Characteristics
Imperial
Working Height
Maximum Platform Height
13,3 m (43 ft 2 in)
11,3 m (37 ft 2 in)
E
Maximum Horizontal Outreach
• 6,9 m (22 ft 6 in)
• From Centerline
• 5,3 m (17 ft 6 in)
• From Outrigger Footpad Edge
Rated Platform Capacity
• 227 kg (500 lb)
• Without Platform Rotation
• With Platform Rotation
Maximum Occupants
• 200 kg (440 lb)
2
F
Tongue Weight 86 kg (190 lb)
Total Weight 1397 kg (3,080 lb)
Turntable Rotation 700 °Non continuous
Leveling Capability 12,5 °
Platform Dimensions
• Height
• 1,1 m (3 ft 7 in)
• 0,8 m (2 ft 6 in)
G
• Length
• 1,5 m (4 ft 0 in)
• Width
Stowed Dimensions
• 2 m (6 ft 5 in)
• Height
• 5 m (16 ft 3 in)
• Length
• Width
Outrigger Footprint
• 1,7 m (5 ft 6 in)
H
• 3,4 m (11 ft 1 in)
• Length
• 3 m (9 ft 11 in)
• Width
• 0,3 m (0 ft 10 in)
• Footpad Diameter
Parking brake Standard - Mechanical
Towing brake
Rated Towing speed
Mechanical Surge
105 km/h (65 mph) I
Tire Size ST 205/75 R14C
Control System 24 V DC
Battery 4 x 6 V 245 amp-hr

24203 4138 0 E 06 09 EN 93
F - Specifications

Machine 3522A
Metric
Characteristics
Imperial
Charger type
• 110 / 120 Volt
• Standard
• 220 Volt
• CE
Hydraulic Pressure 206 bar (3,000 psi)
Reservoir Capacity 11,7 l (3.1 gal US)
Hydraulic System Capacity 19,3 l (5.1 gal US)
Hydraulic Oil (Standard) Dexron III / Mercon ATF
Maximum Decibel Level
• Standard DC Mode - Ground 60 dB
• Standard DC Mode - Platform 55 dB
• DC / Gas Option - Ground 70 dB
• DC / Gas Option - Platform 65 dB
Maximum Decibel LevelFunction Speed
• Boom Raise (Fast) 30 - 35 s
• Boom Raise (Slow) 50 - 55 s
• Boom Lower (Fast) 45 - 50 s
• Boom Lower (Slow) 120 - 150 s
• Boom Extend (Fast) 30 - 35 s
• Boom Extend (Slow) 75 - 90 s
• Boom Retract (Fast) 40 - 45 s
• Boom Retract (Slow) 100 - 110 s
• Turntable rotation (Fast) 82 - 90 s
• Turntable rotation (Slow) 240 - 270 s
• Platform Level (Fast) 8 - 10 s
• Platform Level (Slow) 12 - 16 s
• Outrigger Extend 15 - 20 s
• Outrigger Retract 25 - 30 s
Localized Pressure per Outrigger 1,7237 bar (25 psi)
Operation Temperature Range - 29 °C (-20 °F) to 43 °C (110 °F)
Max. Pressure Per Tire - Floor Loading 2,5 bar (35 psi)

94 24203 4138 0 E 06 09 EN
F - Specifications
A
Te c h n i c a l c h a r a c t e r i s t i c s - F o r 3522A

Machine 4527A

Characteristics
Metric
Imperial
B
Working Height 15,7 m (51 ft 0 in)
Maximum Platform Height 13,7 m (45 ft 0 in)
Maximum Horizontal Outreach
• 8,2 m (27 ft 0 in)
• From Centerline
• From Outrigger Footpad Edge
Rated Platform Capacity
• 6,4 m (21 ft 0 in)

• 227 kg (500 lb)

C
• Without Platform Rotation
• 200 kg (440 lb)
• With Platform Rotation
Maximum Occupants 2
Tongue Weight 77 kg (170 lb)
Total Weight
Turntable Rotation
Leveling Capability
1760 kg (3,880 lb)
700 °Non continuous
12,5 °
D
Platform Dimensions
• 1,1 m (3 ft 7 in)
• Height
• 0,8 m (2 ft 6 in)
• Length
• 1,2 m (4 ft 0 in)
• Width
Stowed Dimensions
• Height
• Length
• 2 m (6 ft 5 in)
• 5,9 m (19 ft 6 in)
E
• 1,7 m (5 ft 6 in)
• Width
Outrigger Footprint
• 3,8 m (12 ft 4 in)
• Length
• 3,5 m (11 ft 4 in)
• Width
• 0,3 m (12 ft 5 in)
• Footpad Diameter
Parking brake
Towing brake
Standard - Mechanical
Mechanical Surge
F
Rated Towing speed 105 km/h (65 mph)
Tire Size ST 225/75 R15D
Control System 24 V DC
Battery
Charger type
• Standard
4 x 6 V 245 amp-hr
• 110 / 120 Volt
G
• 220 Volt
• CE
Hydraulic Pressure 206 bar (3,000 psi)
Reservoir Capacity 16,3 l (4.3 gal US)
Hydraulic System Capacity 23,9 l (6.3 gal US)
Hydraulic Oil (Standard)
Maximum Decibel Level
Dexron III / Mercon ATF
H
• Standard DC Mode - Ground 60 dB
• Standard DC Mode - Platform 55 dB
• DC / Gas Option - Ground 70 dB
• DC / Gas Option - Platform 65 dB

24203 4138 0 E 06 09 EN 95
F - Specifications

Machine 4527A
Metric
Characteristics
Imperial
Maximum Decibel LevelFunction Speed
• Boom Raise (Fast) 30 - 35 s
• Boom Raise (Slow) 50 - 55 s
• Boom Lower (Fast) 45 - 50 s
• Boom Lower (Slow) 120 - 150 s
• Boom Extend (Fast) 30 - 35 s
• Boom Extend (Slow) 75 - 90 s
• Boom Retract (Fast) 40 - 45 s
• Boom Retract (Slow) 100 - 110 s
• Turntable rotation (Fast) 82 - 90 s
• Turntable rotation (Slow) 240 - 270 s
• Platform Level (Fast) 8 - 10 s
• Platform Level (Slow) 12 - 16 s
• Outrigger Extend 15 - 20 s
• Outrigger Retract 25 - 30 s
Localized Pressure per Outrigger 1,7237 bar (25 psi)
Operation Temperature Range - 29 °C (-20 °F) to 43 °C (110 °F)

96 24203 4138 0 E 06 09 EN
F - Specifications
A
Te c h n i c a l c h a r a c t e r i s t i c s - F o r 5533A

Machine 5533A

Characteristics
Metric
Imperial
B
Working Height 18,8 m (61 ft 3 in)
Maximum Platform Height 16,8 m (55 ft 3 in)
Maximum Horizontal Outreach
• 10,2 m (33 ft 5 in)
• From Centerline
• From Outrigger Footpad Edge
Rated Platform Capacity
• 8,2 m (27 ft 4 in)

• 227 kg (500 lb)

C
• Without Platform Rotation
• 200 kg (440 lb)
• With Platform Rotation
Maximum Occupants 2
Tongue Weight 122 kg (270 lb)
Total Weight
Turntable Rotation
Leveling Capability
1996 kg (4,400 lb)
700 °Non continuous
12,5 °
D
Platform Dimensions
• 1,1 m (3 ft 7 in)
• Height
• 0,8 m (2 ft 6 in)
• Length
• 1,5 m (4 ft 0 in)
• Width
Stowed Dimensions
• Height
• Length
• 2 m (6 ft 6 in)
• 7 m (22 ft 11 in)
E
• 1,7 m (5 ft 7 in)
• Width
Outrigger Footprint
• 3,9 m (12 ft 11 in)
• Length
• 3,9 m (12 ft 9 in)
• Width
• 0,3 m (12 ft 5 in)
• Footpad Diameter
Parking brake
Towing brake
Standard - Mechanical
Mechanical Surge
F
Rated Towing speed 105 km/h (65 mph)
Tire Size ST 225/75 R15D
Control System 24 V DC
Battery
Charger type
• Standard
4 x 6 V 245 amp-hr
• 110 / 120 Volt
G
• 220 Volt
• CE
Hydraulic Pressure 206 bar (3,000 psi)
Reservoir Capacity 21,2 l (5.6 gal US)
Hydraulic System Capacity 32,2 l (8.5 gal US)
Hydraulic Oil (Standard)
Platform (Standard)
Dexron III / Mercon ATF
90 ° - Manual
H
Maximum Decibel Level
• Standard DC Mode - Ground 60 dB
• Standard DC Mode - Platform 55 dB
• DC / Gas Option - Ground 70 dB
• DC / Gas Option - Platform 65 dB
I

24203 4138 0 E 06 09 EN 97
F - Specifications

Machine 5533A
Metric
Characteristics
Imperial
Maximum Decibel LevelFunction Speed
• Boom Raise (Fast) 30 - 35 s
• Boom Raise (Slow) 50 - 55 s
• Boom Lower (Fast) 45 - 50 s
• Boom Lower (Slow) 120 - 150 s
• Boom Extend (Fast) 30 - 35 s
• Boom Extend (Slow) 75 - 90 s
• Boom Retract (Fast) 40 - 45 s
• Boom Retract (Slow) 100 - 110 s
• Turntable rotation (Fast) 82 - 90 s
• Turntable rotation (Slow) 240 - 270 s
• Platform Level (Fast) 8 - 10 s
• Platform Level (Slow) 12 - 16 s
• Outrigger Extend 15 - 20 s
• Outrigger Retract 25 - 30 s
Localized Pressure per Outrigger 1,7237 bar (25 psi)
Operation Temperature Range - 29 °C (-20 °F) to 43 °C (110 °F)

98 24203 4138 0 E 06 09 EN
F - Specifications
A
Te c h n i c a l c h a r a c t e r i s t i c s - F o r 2622T

Machine 2622T

Characteristics
Metric
Imperial
B
Working Height 10,1 m (31 ft 7 in)
Maximum Platform Height 8,1 m (25 ft 7 in)
Maximum Horizontal Outreach
• 6,1 m (19 ft 11 in)
• From Centerline
• From Outrigger Footpad Edge
Rated Platform Capacity
• 4,3 m (14 ft 0 in)
200 kg (440 lb)
C
Maximum Occupants 2
Tongue Weight 54 kg (120 lb)
Total Weight 1160 kg (2,560 lb)
Turntable Rotation 700 °Non continuous
Leveling Capability
Platform Dimensions
• Height
12,5 °
• 1,1 m (3 ft 7 in)
D
• 0,8 m (2 ft 6 in)
• Length
• 1,5 m (4 ft 0 in)
• Width
Stowed Dimensions
• 2 m (6 ft 6 in)
• Height
• 5 m (16 ft 4 in)
• Length
• Width
Outrigger Footprint
• 1,7 m (5 ft 3 in) E
• 3,7 m (11 ft 0 in)
• Length
• 3,4 m (11 ft 0 in)
• Width
• 0,3 m (0 ft 10 in)
• Footpad Diameter
Parking brake Standard - Mechanical
Towing brake
Rated Towing speed
Mechanical Surge
105 km/h (65 mph) F
Tire Size ST 225/75 R15D
Control System 24 V DC
Battery 4 x 6 V 245 amp-hr
Charger type
• 110 / 120 Volt
• Standard
• CE
Hydraulic Pressure
• 220 Volt
206 bar (3,000 psi)
G
Reservoir Capacity 11,7 l (3.1 gal US)
Hydraulic System Capacity 19,3 l (5.1 gal US)
Hydraulic Oil (Standard) Dexron III / Mercon ATF
Platform (Standard) 90 ° - Manual
Maximum Decibel Level
• Standard DC Mode - Ground 60 dB
H
• Standard DC Mode - Platform 55 dB
• DC / Gas Option - Ground 70 dB
• DC / Gas Option - Platform 65 dB

24203 4138 0 E 06 09 EN 99
F - Specifications

Machine 2622T
Metric
Characteristics
Imperial
Maximum Decibel LevelFunction Speed
• Boom Raise (Fast) 30 - 35 s
• Boom Raise (Slow) 50 - 55 s
• Boom Lower (Fast) 45 - 50 s
• Boom Lower (Slow) 120 - 150 s
• Boom Extend (Fast) 30 - 35 s
• Boom Extend (Slow) 75 - 90 s
• Boom Retract (Fast) 40 - 45 s
• Boom Retract (Slow) 100 - 110 s
• Turntable rotation (Fast) 82 - 90 s
• Turntable rotation (Slow) 240 - 270 s
• Platform Level (Fast) 8 - 10 s
• Platform Level (Slow) 12 - 16 s
• Outrigger Extend 15 - 20 s
• Outrigger Retract 25 - 30 s
Localized Pressure per Outrigger 1,7237 bar (25 psi)
Operation Temperature Range - 29 °C (-20 °F) to 43 °C (110 °F)

100 24203 4138 0 E 06 09 EN

F - Specifications
A
Te c h n i c a l c h a r a c t e r i s t i c s - F o r 4642T

Machine 4642T

Characteristics
Metric
Imperial
B
Working Height 16,1 m (52 ft 4 in)
Maximum Platform Height 14,1 m (46 ft 4 in)
Maximum Horizontal Outreach
• 12,6 m (41 ft 6 in)
• From Centerline
• From Outrigger Footpad Edge
Rated Platform Capacity
• 10,7 m (35 ft 1 in)

• 227 kg (500 lb)

C
• Without Platform Rotation
• (160 kg (350 lb) )
• (Restricted load)
• 200 kg (440 lb)
• With Platform Rotation
• (160 kg (350 lb) )
• (Restricted load)
Maximum Occupants
Tongue Weight(With all options)
2
• 100 kg (220 lb)
• (136 kg (300 lb) )
D
• 2585 kg (5700 lb)
Total Weight(With all options)
• (2767 kg (6100 lb) )
Turntable Rotation 700 °Non continuous
Leveling Capability 12,5 °
Platform Dimensions
• Height
• Length
• 1,1 m (3 ft 7 in)
• 0,8 m (2 ft 6 in)
E
• 1,5 m (4 ft 0 in)
• Width
Stowed Dimensions
• 2 m (6 ft 6 in)
• Height
• 6,6 m (21 ft 8 in)
• Length
• 1,7 m (5 ft 3 in)
• Width
Outrigger Footprint
• Length
• 4 m (12 ft 11 in)
F
• 4,1 m (12 ft 9 in)
• Width
• 0,3 m (0 ft 10 in)
• Footpad Diameter
Parking brake Standard - Mechanical
Towing brake Mechanical Surge
Rated Towing speed
Tire Size
105 km/h (65 mph)
ST 225/75 R15D
G
Control System 24 V DC
Battery 4 x 6 V 245 amp-hr
Charger type
• 110 / 120 Volt
• Standard
• 220 Volt
• CE
Hydraulic Pressure
Reservoir Capacity
206 bar (3,000 psi)
21,2 l (5.6 gal US)
H
Hydraulic System Capacity 32,2 l (8.5 gal US)
Hydraulic Oil (Standard) Dexron III / Mercon ATF
Platform (Standard) 75 ° - Manual
Maximum Decibel Level
• Standard DC Mode - Ground
• Standard DC Mode - Platform
60 dB
55 dB
I
• DC / Gas Option - Ground 70 dB
• DC / Gas Option - Platform 65 dB

24203 4138 0 E 06 09 EN 101

F - Specifications

Machine 4642T
Metric
Characteristics
Imperial
Maximum Decibel LevelFunction Speed
• Boom Raise (Fast) 30 - 35 s
• Boom Raise (Slow) 50 - 55 s
• Boom Lower (Fast) 45 - 50 s
• Boom Lower (Slow) 120 - 150 s
• Boom Extend (Fast) 30 - 35 s
• Boom Extend (Slow) 75 - 90 s
• Boom Retract (Fast) 40 - 45 s
• Boom Retract (Slow) 100 - 110 s
• Turntable rotation (Fast) 82 - 90 s
• Turntable rotation (Slow) 240 - 270 s
• Platform Level (Fast) 8 - 10 s
• Platform Level (Slow) 12 - 16 s
• Outrigger Extend 15 - 20 s
• Outrigger Retract 25 - 30 s
Localized Pressure per Outrigger 1,7237 bar (25 psi)
Operation Temperature Range - 29 °C (-20 °F) to 43 °C (110 °F)

102 24203 4138 0 E 06 09 EN

F - Specifications
A
3 - RANGE OF MOTION
3 5 2 2 A B

24203 4138 0 E 06 09 EN 103

F - Specifications

4 5 2 7 A

104 24203 4138 0 E 06 09 EN

F - Specifications
A
5 5 3 3 A

24203 4138 0 E 06 09 EN 105

F - Specifications

2 6 2 2 T

106 24203 4138 0 E 06 09 EN

F - Specifications
A
4 6 4 2 T

24203 4138 0 E 06 09 EN 107

F - Specifications

108 24203 4138 0 E 06 09 EN

G - Equipment options
A
Equipment options
1 - Foreword
The Bil-Jax Model may be equipped with one or more optional components designed for the
B
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
C
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. D
2 - 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
E
control box.
• Disconnect platform control box from the load sense module (Figure below) located on the boom lift
bulkhead.
• Remove the electric loopback plug from the receptacle on the bottom right of the ground control panel
and insert the platform control cable into the open receptacle.
M a t e r i a l L i f t i n g H o o k C o n f i g u r a t i o n
F

Marking Description H
1 To Boom Cable. Do Not Remove
To Platform Controls.
• Disconnect platform controls.
2
• Replace with loopback plug from ground controls
• Plug platform controls into open receptacle on the bottom right of ground control panel.
I

24203 4138 0 E 06 09 EN 109

G - Equipment options

• 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 below).
• Operate the material lifting hook remotely, using the platform
control box for optimal control.

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.

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 and always allow for platform movement such as wind-induced sway. Refer to
manual for minimum safe approach distances between the machine and electrical power lines.
• Reverse the procedure to reattach the work platform.

3 - PLATFORM ROTATOR
The optional platform rotator allows the operator to rotate the elevated work platform 90 ° 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.

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.
M a n u a l P l a t f o r m R o t a t o r

110 24203 4138 0 E 06 09 EN

G - Equipment options
A
4 - DRIVE AND SET
Use the following procedure to operate a boom lift equipped with the Drive and Set option. B
Set parking brake. Drive function will not operate unless parking brake is set.

Lower jack stand and unhitch lift from tow vehicle.

If unit is equipped with a jockey wheel, remove lock pin and swing jockey wheel into lowered position.

Reinsert lock pin to secure jockey wheel in lowered (drive) position.

C
J o c k e y W h e e l I n s t r u c t i o n

E
Raise jack stand and swing into stowed position.

Completely lower platform. Drive function will not operate unless platform is completely lowered and
fully stowed.
F
Fully retract outriggers.

Press and hold the DRIVE ENABLE button. Move joystick in the desired direction.

Machine will continue in the desired direction until joystick or drive enable button is released. G
To resume platform operation, lower outriggers and level the lift using either the ground or platform
controls and following the instructions found in this manual. Boom functions are not available until
outriggers are fully deployed and machine is level.

24203 4138 0 E 06 09 EN 111

G - Equipment options

5 - DRIVE AND SET SAFETY

NEVER drive machine unless parking brake is set.

NEVER drive machine without platform fully lowered or without operator securely inside the platform.

ALWAYS watch for personnel and obstructions in the path of the machine. Be aware of limited visibility
and blind spots.

112 24203 4138 0 E 06 09 EN

H - Other
A
Other
1 - Inspection Form for BilJax Summit Series® Aerial Work
Platforms B
Machine Model No Serial No

Date of Manufacture
Inspection Performed
by
C
Date of Inspection Inspection Location

2 - REPORTING SAFETY DEFECTS

D
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.
E
If the NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect
exists in a group of vehicles, it may order a recall and remedy campaign. However, the NHTSA cannot
become involved in any individual problems between operators, users, or lessors, and Bil-Jax, Inc.

To contact the NHTSA you may either call the Auto Safety Hotline toll-free at 800-424-9393 ( 366-
0123 in the Washington, DC area) or write to : F
NHTSA

U.S. DEPARTMENT of TRANSPORTATION

G
400 7th Street SW (NSA-11)

Washington, DC 20590

You can also obtain other information regarding motor vehicle safety by calling the Hotline. H

24203 4138 0 E 06 09 EN 113

H - Other

3 - BIL-JAX SUMMIT SERIES 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 Outrigger Control Panel when the boom is level

Turn Key Switch to platform control station

Enter the work platform and attach safety harness to the Fall Protection Attachment Point

Press and hold the desired SPEED and function buttons to operate boom lift

114 24203 4138 0 E 06 09 EN

H - Other
A
4 - Notes
Date Comments
B

24203 4138 0 E 06 09 EN 115

H - Other

Date Comments

116 24203 4138 0 E 06 09 EN