Bil Jax 2622T_manual

8/8/2019 Bil Jax 2622T_manual

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OPERATORSMANUAL


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BOOM PERSONNEL LIFT

This equipment is designed and manufactured incompliance with the duties, responsibilities andstandards set forth in the ANSI, CE CSA and/or ASstandards in effect at the time of manufacture.

This equipment will meet or exceed applicable ANSI,

CE, CSA and/or AS codes and standards whenoperated in accordance with manufacturersrecommendations.

It is the responsibility of the user to follow all regionalcodes and regulations that govern the safe operation ofthis equipment.

Obtain, read and obey all safety precautions beforeperforming maintenance or repairs or attempting tooperate this equipment. This includes all manufacturerrecommendations as well as those directives set forth bygovernment and local authorities.

To ensure proper and safe use of this equipment, it is

strongly recommended that only trained and authorizedpersonnel attempt to operate and maintain the boom lift.

This manual shall be considered a permanent andnecessary component of the machine and shall be keptwith the boom lift at all times.

Owners and Lessors should complete a full inspection ofall components and perform a test of all functions,including brake functions, before commissioning orreselling the machine. Repair or replace all damaged ormalfunctioning components.

Bil-Jax, Inc. is dedicated to the continuous improvement

of this and all Bil-Jax products. Therefore, equipmentinformation is subject to change without notice. Directany questions or concerns regarding errors ordiscrepancies in this manual to the Bil-Jax ServiceDepartment.

Copyright Bil-Jax, Inc. 2007. All Rights Reserved.

Bil-Jax is a registered trademark and A Step Aboveand Summit Series are trademarks of Bil-Jax, Inc.Contact Bil-Jax for replacement manuals.

125 Taylor ParkwayArchbold, Ohio 43502

Phone (800) 537-0540(419) 445-8915

Fax (419) 445-0367

P/N B33-01-0099 http://www.biljax.com


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1

TABLE OF CONTENTS

Table of Contents 1

Illustrations 2

Tables 2

1 Safety 3

Legend: Safety Advisories 4

Before Operation 5

During Operation 5

Maintenance Safety 7

Damaged Equipment Policy 8

2 Specifications 9

Range of Motion 10

Specifications 11Warranty 12

3 Operations 13

Ground Control Station 14

Platform Control Station 16

Normal Operating Procedure 18

Manual Boom Operations 20

Battery Recharge 22

Boom Lift Transport 23

4 Operator Service 25

Daily Service Checks 26

Weekly Service Checks 28

Monthly Service Checks 29

Troubleshooting 30

Error Code Definitions 31

5 Replacement Decals 33

6 ANSI Reprint 37

7 Material Safety Data 43

8 Equipment Options 47

Material Lifting Hook 48

Platform Rotator 49

Replacement Decals 50

Service Checklists 52


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2

LIST OF ILLUSTRATIONSFigure 2-1 Range of Motion 10

Figure 3-1 Ground Control Panel 14

Figure 3-2 Platform Control Panel 16

Figure 3-3 Outrigger Controls 18

Figure 3-4 Boom Travel Latch 18

Figure 3-5 Platform Travel Latch 19

Figure 3-6 Hand Pump and Controls for Manual Operation 20

Figure 3-7 Manual Lowering Valve 21

Figure 3-8 Battery Charger Faceplate 22

Figure 3-9 Trailer Hitching 23

Figure 3-10 Boom Lift and Transport Instructions 24

Figure 4-1 Outrigger Position Switches 26Figure 4-2 Hydraulic Reservoir 27

Figure 4-3 Wheel Nut Tightening Sequence 29

Figure 5-1 Decal Placements 35

Figure 6-1 Minimum Safe Approach Distances 41

Figure 8-1 Material Lifting Hook Configuration 48

Figure 8-2 Material Lifting Hook Installation 48

Figure 8-3 Manual Platform Rotator 49

Figure 8-6 Material Lift Decal Placement 50

Figure 8-7 Optional Components Decal Placement 50

LIST OF TABLES Table 1-1 Minimum Safe Approach Distances 5

Table 3-1 Charger Fault Codes 22

Table 4-1 Troubleshooting Steps 30

Table 4-2 Error Code Definitions 31

Table 5-1 Replacement Decal Descriptions 34

Table 8-1 Replacement Decals Optional Components 50


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3

1 SAFETYProper training is required for the safe operation of any mechanical device.Failure to follow all instructions and safety precautions in this manual andattached to the lift will result in death or personal injury.

Prior to Operation:

Read, understand and obey all instructions and safety precautions in thismanual and attached to the lift.

Read, understand and obey all applicable government regulations.

Become familiar with the proper use of all controls.

Inexperienced users should receive instruction before attempting tooperate or maintain the machine.

The use of intelligence and common sense is the best practice when

following any safety policy.


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BIL-JAX 2622T

LEGEND: SAFETY ADVISORIES

The following safety advisories are used throughoutthis manual to indicate specific hazards whenoperating or maintaining the machine. Read,understand and obey all safety advisories to preventimproper service, damage to equipment, personalinjury or death.

DANGER

Warns of operation near electrical powersources that could lead to personal injury ordeath.

WARNING

Describes conditions or practices that could leadto personal injury or death.

CAUTION

Contains information important in the preventionof errors that could damage machine orcomponents.

NOTE: Contains additional informationimportant for performing a procedure.

4


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1 SAFETY

BEFORE OPERATION DURING OPERATION

Ensure the following general safety precautions arefollowed before operating the telescoping boom lift:

ALWAYS inspect the usage area for potentialhazards, such as unstable or unlevel surfaces,overhead obstructions and electrically charged wiresor conductors. ALWAYS watch for moving vehiclesin the operating area.

ALWAYS conduct a thorough inspection of themachine before operation. Check for damaged orworn parts, hydraulic leaks, damaged wiring, loosewiring conductors, damaged outriggers, low tirepressure, uneven tire wear or tire damage. Check forany improperly operating components. NEVERoperate equipment if any damage is observed orsuspected. Repair damaged or malfunctioningequipment before operation.

ALWAYS wear proper clothing. Wear protectiveequipment as required by government regulations.Keep loose clothing, jewelry, gloves and hair awayfrom moving parts.

5

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

ALWAYS inspect platform floor and outriggerfootpads for mud, grease, debris or other foreignmaterial. ALWAYS remove any such material fromthe equipment before operation.

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

ALWAYS comply with the instructions found inSafety and/or Service Bulletins distributed by themanufacturer. Bulletins may contain criticalprocedures that supersede the informationcontained in manuals.

NEVER operate this equipment while under theinfluence of drugs or alcohol, while takingprescription medications that may leave the operator

drowsy or prone to dizziness, or while feeling ill.

NEVER modify, alter or change the equipment inany way that would affect its original design oroperation.

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

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

Ensure the following general safety precautions arefollowed while operating the telescoping boom lift:

ALWAYS position lift away from power lines toensure that no part of the lift can accidentally reachinto an unsafe area. This includes full extension ofthe boom through 700 rotation.

DANGER

This machine is NOT insulated for use nearelectrical power lines and DOES NOT provideprotection from contact with or close proximityto any electrically charged conductor. Operatormust maintain safe clearances at all times (3.05meters minimum) and must always allow forplatform movement due to gusty winds. Alwayscontact power company before working near

power lines. Assume every power line is live.Power lines can be blown by the wind. Refer toTable 1-1 for minimum safe approach distancesbetween the machine and electrical power lines.

Table 1-1. Minimum Safe Approach Distances

ALWAYS keep away from a machine that isexposed to energized power lines. If the machinecontacts energized power lines, NEVER touch oroperate 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 theequipment with its rated load capacity or on surfacesthat do not support force exerted by the outriggers

during boom operation. Operate only on surfacesthat can support a pressure of 1.8 kg/cm

2(25 psi) to

ensure safe operation.

ALWAYS keep personnel away from potential pinchand shear points and from potential crush hazardsas indicated by decals attached to the machine.

ALWAYS maintain sure footing on the work platform

ALWAYS keep the safety bar lowered unlesspersonnel are entering or exiting the work platform.

Minimum Safe Approach DistanceVoltage Range

(Phase to Phase) (Feet) (Meters)

0 to 300V Avoid Contact

Over 300V to 50KV 10 3.05

Over 50KV to 200KV 15 4.60

Over 200KV to 350KV 20 6.10

Over 350KV to 500KV 25 7.62Over 500KV to 750KV 35 10.67

Over 750KV to 1000KV 45 13.72


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BIL-JAX 2622T

6

ALWAYS wear proper footgear. ALWAYS keep theplatform free of debris.

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

ALWAYS cordon the area surrounding theoutriggers to keep personnel, vehicles and movingequipment away from the machine while in use.

ALWAYS stay clear of overhead obstructions,including wires and cables.

ALWAYS engage boom travel latches before towingtrailer.

ALWAYS exercise caution when rotating the boom(slew) from the ground control station. ALWAYSwatch for personnel inside the radius of the turntableand boom arm when rotating the boom lift from theground or platform controls.

ALWAYS remove personnel from the boom liftbefore attempting to free an elevated platform that

has become caught or snagged on an adjacentstructure or obstacle.

NEVER operate the machine on any surface otherthan firm and level ground. NEVER operate themachine from a position on truckbeds, trailers,floating vessels or scaffolding without writtenapproval from the manufacturer.

NEVER operate lift on slopes exceeding 12.5.

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

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

NEVER position an elevated platform againstanother object to steady the platform

NEVER override or bypass the manufacturerssafety devices.

NEVER attach a safety harness to an adjacentstructure, pole, or to nearby equipment whileworking from the boom platform.

NEVER raise the outriggers or move the trailer withmaterials or personnel on board, or while boom is

raised or extended.NEVER sit, stand or climb on cage bars. ALWAYSkeep both feet firmly on the work cage floor whenworking from an elevated platform.

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

NEVER operate this equipment when exposed tohigh winds, thunderstorms, ice or any weatherconditions that would compromise operator safety.

NEVER operate boom lift in conditions where windspeeds exceed 12.5 m/sec (45 km/h or 28 mph).Steady or gusty winds that exceed 12.5 m/sec (45km/h) may affect stability and boom operation.

NEVER allow ropes, electric cords, hoses or otherequipment to become entangled in the machinewhile raising or lowering platform.

NEVER exceed the load limits set by themanufacturer. Use only the Material Lifting Hook,supplied as an option and manufactured by Bil-Jax,when lifting materials. Safely stow all tools andequipment.

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

NEVER use the platform to lift a load that exceedsthe platform dimensions. NEVER lift a load in such away that the center of gravity is higher than the topguardrail of the platform.

NEVER modify the platform or carry materials thatwould increase the surface area of the platform.Increasing the area exposed to the wind maydecrease machine stability. NEVER attachoverhanging loads when raising or lowering theplatform.

NEVER use the boom or platform to push or pull orto lift any part of the trailer.

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

NEVER climb on the boom. Refer to Section 3 forthe instructions for manual operation.

NEVER leave an elevated platform unattended.

NEVER leave the keys in the boom lift whileunattended or not in use.


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1 SAFETY

7

MAINTENANCE SAFETY

Ensure the following general safety precautions arefollowed while performing maintenance on thetelescoping boom lift:

General Maintenance

ALWAYS perform maintenance proceduresaccording to manufacturers guidelines. NEVERdisregard or bypass proper maintenanceprocedures.

ALWAYS inspect hydraulic system to ensure that alllines, connectors and fittings are properly fastenedand in good condition.

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

Whenever possible, ALWAYS perform maintenancewith the boom and platform in a fully lowered,

stowed position. ALWAYS secure the boom beforeperforming maintenance on hydraulic cylinders.

ALWAYS disconnect power to the hydraulic pumpdrive motor before making electrical checks to thehydraulic valves.

ALWAYS keep all mechanical parts properlyadjusted and lubricated according to maintenanceschedule and manufacturers specifications.

ALWAYS perform a function check of operatingcontrols before each use and after repairs havebeen made.

ALWAYS locate and protect against possible pinchpoints before performing any maintenance orrepairs.

ALWAYS use only manufacturer-approved parts torepair or maintain equipment. If any portion of thisequipment is rebuilt or repaired, retesting is requiredin accordance with factory instructions.

ALWAYS maintain a safe distance while testing thehydraulic components. ALWAYS relieve hydraulicpressure before loosening or removing hydrauliccomponents. NEVER test or operate the hydrauliccomponents while personnel are near the

equipment.NEVER allow water or foreign particles into the DCelectric motor housing. Inclusion of water or foreignparticles may cause serious damage to the motor. Ifthe motor becomes wet, consult an authorized Bil-Jax service technician for proper drying instructions.

NEVER add unauthorized fluids to the hydraulicsystem or battery. NEVER mix hydraulic oils.Consult manufacturer specifications. Refer toSection 4 for hydraulic system maintenanceprocedures.

NEVER exceed the manufacturers recommendedrelief valve settings.

NEVER touch or allow metal tools to contact anycomponents that are sensitive to static discharge.ALWAYS use static discharge prevention mats andgrounding devices when handling electroniccomponents.

NEVER adjust, repair, replace or bypass anyhydraulic or electrical control or safety device. Theseinclude, but are not limited to, hydraulic load controland flow control valves, solenoid valves and limitswitches. ALWAYS consult an authorized Bil-Jaxtechnician if repairs are necessary.

NEVER modify, alter or change the equipmentwithout first consulting an authorized Bil-Jaxtechnician, and NEVER in any way that would affect

its original design or operation.

Battery Maintenance

Ensure the following general safety precautions arefollowed when performing battery maintenance onthe telescoping boom lift.

ALWAYS check the battery fluid level daily.

ALWAYS wear safety glasses when working with ornear batteries.

ALWAYS avoid contact with battery acid. Batteryacid causes serious burns and should be kept awayfrom skin or eyes. If contact occurs, flush with waterand consult a physician immediately.

ALWAYS disconnect ground cable first whenremoving battery.

ALWAYS connect ground cable last when installingbattery.

ALWAYS charge batteries in open, well-ventilatedareas.

ALWAYS replace batteries using only partsrecommended by manufacturer. ALWAYS use onlybatteries with sealed caps over cells.

NEVER smoke while servicing batteries.NEVER charge batteries near flammable materials.

NEVER allow batteries to overcharge and boil.

NEVER short across battery posts to check forcurrent. NEVER break a live circuit at the battery.

NEVER disconnect battery from charger whilecharger is connected to a live power source.

NEVER jumpstart other vehicles using the boom liftbatteries.


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BIL-JAX 2622T

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DAMAGED EQUIPMENT POLICY

Safety Statement

At Bil-Jax, we are dedicated to the safety of all users of our products. All Bil-Jaxlifts are designed, manufactured and tested to comply with current applicable

ANSI and/or CE codes and regulations.

Damage Policy

There may be occasions when a Bil-Jax lift is involved in an incident that resultsin structural damage to the lift. Such damage can seriously compromise theability of the lift to perform in a safe manner. Therefore, whenever a Bil-Jax lift isdamaged structurally or when there is suspected internal damage to thestructure, Bil-Jax may require that the lift be returned to our facility forreconditioning. For any questions concerning structural damage or the DamagedEquipment Policy, please contact an authorized Bil-Jax representative or yourregional Bil-Jax dealer

Damage Repair Notice

There may be occasions when a Bil-Jax lift is involved in an accident resulting indamage to non-structural components. When such damage occurs and repairsare 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.


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9

2 SPECIFICATIONS Bil-Jax, Inc. is dedicated to the continuous improvement of this and all

Bil-Jax products. Therefore, equipment information is subject to changewithout notice.

The following information is based on ideal working conditions. Machineperformance may vary based on work environment and on machineoptions.

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


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BIL-JAX 2622T

RANGE OF MOTION

0

10 ft3m

20 ft6.1m

30 ft9.1m

40 ft12.2m

15 ft4.6m

5 ft1.5m

5 ft1.5m

0 15 ft4.6m

25 ft7.6m

Figure 2-1. Range of Motion

10


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2 INTRODUCTION

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SPECIFICATIONS SERIAL NUMBER_____________________________

Working Height 31 ft 7 in

10.1 m

Maximum Platform Height 25 ft 7 in

8.1 m

Maximum Horizontal Outreach

From Centerline

From Outrigger Footpad Edge

19 ft 11 in

6.1 m

14 ft

4.3 m

Rated Platform Capacity 440 lbs

200 kg

Maximum Occupants 2

Tongue Weight 120 lbs54 kg

Total Weight 2,560 lbs

1,160 kg

Turntable Rotation 700 Non-Continuous

Leveling Capability 12.5

Platform Dimensions

Height

Length

Width

3 ft 7 in

1.1 m

2 ft 6 in

0.8 m4 ft

1.2 m

Stowed Dimensions

Height

Length

Width

6 ft 6 in

2.0 m

16 ft 4 in

5.0 m

5 ft 3 in

1.7 m

Outrigger Footprint

Length

Width

Footpad Diameter

11 ft3.7 m

11 ft

3.4 m

10 in

0.3 m

Parking Brake Standard, Mechanical

Towing Brake Mechanical Surge

Rated Towing Speed 65 m

105 k

Tire Size ST 225/75 R1

Control System 24V

Battery 4 x 6V 245 am

Charger

Standard

CE

110/120

220

Hydraulic Pressure 3,000

206

Reservoir Capacity 3.1 Gall

11

Hydraulic System Capacity 5.1 Gall

19

Hydraulic Oil (Standard) Dexron III/Mercon A

Platform Rotation/Type (Optional) 90/Man

Maximum Decibel Level

Standard DC Mode Ground

Standard DC Mode Platform

DC/Gas Option Ground

DC/Gas Option - Platform

60

55

70

65

Function SpeedsBoom Raise (Fast)

Boom Raise (Slow)

Boom Lower (Fast)

Boom Lower (Slow)

Boom Extend (Fast)

Boom Extend (Slow)

Boom Retract (Fast)

Boom Retract (Slow)

Turntable Rotation (Fast)

Turntable Rotation (Slow)

Platform Level (Fast)

Platform Level (Slow)

Outrigger Extend

Outrigger Retract

30-35 Seco

50-55 Seco

45-50 Seco

120-150 Seco

30-35 Seco

75-90 Seco

40-45 Seco

100-110 Seco

82-90 Seco

240-270 Seco

8-10 Seco

12-16 Seco

15-20 Seco

25-30 Seco

Localized Pressure per Outrigger 25

1.8 kg/

176.5

Operation Temperature Range -20 to 110 Fahren

-29 to 43 Cel


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BIL-JAX 2622T

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WARRANTYBil-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 operatedand maintained in compliance with the guidelines established in the Operationsand Maintenance Manuals. Major structural components, including trailer tongueand boom weldments, are warranted for five years against defects due tomaterial 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 defectsresulting 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 normalwear and tear, such as rust or corrosion. Components not covered under thiswarranty include tires, filters, covers, and routine maintenance items.Components not manufactured by Bil-Jax are covered by their respectivemanufacturers warranties. A list of those components and their warranties isavailable upon written request to Bil-Jax.

Bil-Jax shall not in any event be liable for the cost of any special, indirect, orconsequential damages to any person, product, or thing. Bil-Jaxs maximumliability 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-Jaxneither assumes nor authorizes any or other entity to assume on its behalf anyother liability in connection with the sale, rental, or use of this product.

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 receiptof product;

2. Notification to Bil-Jax within 72 hours of any claimed defect, injury, or damageresulting 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 claimsunder warranty. Listed below is the warranty claims procedure.

5. Contact Bil-Jax Service Department at 800-537-0540 to report the claim and verifywarranty coverage. Machine serial number must be provided.

6. Identify the components to be claimed under warranty along with description offailure. 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 partsare invoiced at dealer/distributor list price. Credits will be issued when defective partsare 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 beeligible for credit. RMA number must be referenced on warranty claim form. Returnedparts 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 laborhours reimbursed will be determined by Bil-Jax and will be limited to 4 hours unlessapproved by Bil-Jax.

Failure to follow the warranty claims process may result in delay in processingclaim or denial of the claim. Bil-Jax reserves the right to limit or adjust warrantyclaims with regard to parts, labor and travel time. Components purchased fromsuppliers other than Bil-Jax are not covered under the terms of this warranty.


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13

3 OPERATION The Bil-Jax Telescoping Boom Lift is equipped with multiple operatorcontrol stations. Equipment power and outrigger controls are located atground level. Boom lift and rotation controls are located at ground leveland on the work platform.

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 bymanufacturers recommendations and all federal, state and localregulations.

Become familiar with the location and use of all controls.

Verify that there are no overhead obstructions or live power sourcesin the work area that could interfere with the safe operation of theboom lift.

Position the boom lift on a firm and level surface.

Conduct a Pre-Operation inspection by performing all recommendedDaily Service Checks. Refer to Section 4.

Unhitch equipment trailer from the tow vehicle.


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BIL-JAX 2622T

GROUND CONTROL STATION

The ground control station is used to operate outriggers and controlboom motion. To access the ground control station, open the controlpanel access cover found on the turntable. Turn the key switch to theground controls setting.

Figure 3-1. Ground Control Panel

1. Key Switch

1a. Platform Controls Position

1b. Ground Controls Position

2. Battery Condition Indicator

3. Engine Start (DC/Gas Option Only)4. Engine Choke (DC Gas Option Only)

5. Display Panel

6. Emergency Stop

7. Boom Extend

8. Boom Retract

9. Boom Raise

10. Boom Down

11. Boom Rotation Clockwise

12. Boom Rotation Counterclockwise

13. Platform Tilt Up

14. Platform Tilt Down

15. Speed Buttons16. Outrigger Extend

17. Outrigger Retract

18. Auto Level

19. Outrigger Buttons

20. Outrigger Status Indicator LED

21. Power Indicator LED

14


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3 OPERATION

15

The ground control station includes the followingcontrols and Indicators. Refer to Figure 3-1 forcontrol locations.

1. Key Switch

Turning the key switch to the PLATFORM (1A) iconselects operation from the platform. Turning the keyswitch to the GROUND (1B) icon selects operationfrom the ground control panel. The center (poweroff) position interrupts all electric and hydraulicpower operations except emergency lowering.Removing the key protects against operation byunauthorized persons. The key may be removedwith the key switch in any selected position.


Indicator LEDs light up to indicate the level of charge

remaining in the batteries. A lighted green LEDindicates an adequate charge level. Lighted yellowLEDs indicate the need for charging soon. A lightedred LED warns that the battery charge level is low;boom operations should be halted until the batteriesare recharged.

3-4. Engine Start and Choke (Hybrid Model only)

Start a cold engine by pressing the Engine START (3)button while pressing and holding the CHOKE (4)button. To start/restart a warm engine, press theSTART button only.

5. Display Panel

The DISPLAY PANEL is a lighted text window thatdisplays the present operating status or an existingerror condition when the key switch is on.

6. Emergency Stop Button

When pushed in, the emergency STOP buttondisconnects electrical power to the ground andplatform control stations. The emergency STOPpushbutton should only be pressed to immediatelystop all boom motion. To resume control, pull out theemergency STOP button.

7-8. Boom Extend/Retract Buttons

Pressing and holding a desired SPEED button and theBOOM EXTEND (7) button at the same time extendsthe telescopic boom. Pressing and holding a desired

SPEED button and the BOOM RETRACT (8) button at thesame time retracts the boom. Boom motioncontinues until the buttons are released or until theboom reaches a hard stop or a safe travel limit.

9-10. Boom Raise/Down Buttons

Pressing and holding a desired SPEED button and theBOOM RAISE (9) button at the same time will raise theboom. Pressing a desired SPEED button and theBOOM DOWN (10) button at the same time will lowerthe boom. Boom motion continues until the buttonsare released or until the boom reaches a hard stopor a safe travel limit.

11-12. Boom Rotation Buttons

Pressing and holding a desired SPEED button and theBOOM ROTATIONCLOCKWISE (11) or COUNTERCLOCK-WISE (12) button at the same time enables the boomto rotate in the direction selected. The boom will

rotate through 700 degrees until the buttons arereleased or the stop is reached.

13-14. Platform Tilt Buttons

Press and hold any SPEED button and the desiredPLATFORM TILT (13 and 14) button at the same timeto level the work platform (levels the platform only,not the boom lift).

15. Speed Buttons

The SPEED buttons along the lower right side of thecontrol panel must be pressed and held whileselecting a boom function. Four speeds are

available to control the positioning of the boom lift.

16-20. Outrigger Controls

For automatic outrigger extension/retraction: SelectEXTEND (16) or RETRACT (17) outrigger button andthe AUTO LEVEL (18) button at the same time. Tomanually extend or retract the outriggers: SelectEXTEND or RETRACT outrigger button and one of theOUTRIGGER buttons (19) at the same time. Theoutrigger indicator LEDs light up when the outriggersare properly deployed and the boom weight is on theoutriggers. Each of the outer outrigger LEDsindicates load is on the outrigger footpad. Each of

the inner outrigger LEDs, when flashing, indicatethat side is low and needs to be further raised forleveling. The Auto Level LED lights up and a buzzersounds when the boom is level.


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BIL-JAX 2622T

PLATFORM CONTROL STATION

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

Figure 3-2. Ground Control Panel

1. Engine Start (DC/Gas Model Only)

2. Engine Choke (DC/Gas Model Only)

3. Horn Button



6. Speed Buttons

7. Boom Rotation Clockwise

8. Boom Rotation Counterclockwise

9. Boom Raise

10. Boom Down

11. Boom Extend

12. Boom Lower

13. Platform Tilt Up

14. Platform Tilt Down

16


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3 OPERATION

17

The platform control station includes the followingcontrols and Indicators. Refer to Figure 3-2 forcontrol locations.

1-2. Engine Start and Choke (DC/Gas Model only)

Start a cold engine by pressing the CHOKE button (1),then press the engine START button (2) to start theengine. To start/restart a warm engine, press theSTART button only.

3. Horn Button

Pressing the button will sound the horn. Use theHORN button to warn personnel in the area of afalling object hazard, impending boom motions, orthe need for assistance.


Indicator LEDs light up to indicate the level of charge

remaining in the batteries. A lighted green LEDindicates a good charge level. Lighted yellow LEDsindicate the need for charging soon. A lighted redLED warns that the battery charge level is low; boomoperations should be halted until the batteries arerecharged.


When pushed in, the emergency STOP buttondisconnects electrical power to the ground andplatform control stations. The emergency STOPpushbutton should only be pressed to immediatelystop all boom motion. To resume control, pull out the

emergency STOP button.

6. Speed Buttons

The SPEED buttons along the lower right side of thecontrol panel must be pressed and held whileselecting boom functions. Four speeds are availableto control the positioning of the boom lift.

7-8. Boom Rotation Buttons

Pressing and holding a desired SPEED button and theBOOM ROTATIONCLOCKWISE (7) or COUNTERCLOCK-WISE (8) button at the same time enables the boomto rotate in the direction selected. The boom will

rotate through 700 degrees until the buttons arereleased or the stop is reached.

9-10. Boom Raise/Down Buttons

Pressing and holding a desired SPEED button and theBOOM RAISE (9) button at the same time will raise theboom. Pressing a desired SPEED button and theBOOM DOWN (10) button at the same time will lowerthe boom. Boom motion continues until the buttonsare released or until each boom reaches a hard stopor a safe travel limit.

11-12. Boom Extend/Retract Buttons

Pressing and holding a desired SPEED button and theBOOM EXTEND (11) button at the same time extendsthe telescopic boom. Pressing and holding a desiredSPEED button and the BOOMRETRACT (12) button atthe same time retracts the boom. Boom motioncontinues until the buttons are released or until theboom reaches a hard stop or a safe travel limit.

13-14. Platform Tilt Buttons

Press and hold any SPEED button and the desiredPLATFORM TILT button at the same time to level thework platform (levels the platform only, not the boomlift).

Outlet

The outlet is provided for running electrical powertools from the work platform. A connecting powercord must be plugged into a suitable power source.

The power plug is located on the trailer frame, infront of the accessory equipment stowage plate. Theoutlet is rated for a 15-ampere load. Do not overloadthe accessory power circuit.


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BIL-JAX 2622T

NORMAL OPERATING PROCEDURE

Perform the following procedures to operate the Bil-Jax Telescoping Boom Lift.

Read and obey all safety precautions andoperating instructions, as well as all applicablegovernment regulations.

Conduct a Pre-Operation Inspection byperforming all recommended Daily ServiceChecks. Refer to Section 4.

Position the boom lift at the work area. Makesure the boom lift is on a firm and level surfaceand there are no potential hazards such asoverhead obstructions or electrically chargedconductors. Do not operate the boom lift if suchhazards exist.

Apply the boom lift parking brake or chock thewheels.

Lower the tongue jack and unhitch the boom liftfrom the tow vehicle.

WARNINGFailing to unhitch the boom lift before operationmay lead to damage to equipment or tow vehicleand makes the boom lift unstable, which cancause personnel injury or death.

18

Turn the key switch on the ground control stationto operate ground controls. If power does notcome on, make sure both emergency STOPbuttons (ground and platform) are pulled out andthe main power disconnect is plugged in.

The control microprocessor will perform self-diagnostics to test the operating system. Afterseveral seconds, the DISPLAY PANEL windowwill read:

BIL JAXA STEP ABOVE

Verify that the control status indicator LED is lit.If the control status indicator LED is not lit or isflashing, the outrigger buttons will not work. Aflashing control status LED indicates that one ormore of the booms is raised and needs to bestowed.Refer to Figure 3-1 and Figure 3-3.

Extend the outriggers manually or using theAUTO LEVEL button. When the boom is leveledproperly, a buzzer will sound and two LEDs ateach OUTRIGGER button and the LED at the AUTOLEVEL button will be lit.

Auto Level: Press and hold the EXTEND andAUTO LEVEL buttons at the same time.

Manual Level: Extend the two outriggersclosest to the trailer coupler first. Lower eachpair of outriggers by pressing the EXTEND button

and the two appropriate OUTRIGGER buttons atthe same time.

Figure 3-3. Outrigger Controls

NOTE: The safety interlock system prevents allboom operations if the boom is not levelor if one or more outriggers are notsupporting the vehicle load.

NOTE: The Range of Motion Diagrams at theground and platform control stationsdisplay the range of platform motion(safe operating zone) facing away fromthe trailer tongue. Verify that theoperating zone is clear of obstructionsthrough 700 of turntable rotation.

Verify that the auto level indicator LED is lit. Ifthe auto level indicator is not lit, the boom maynot be level.

Pull the latch release on the boom travel latch,raise the latch handle and swing the latch U-boltdown. Refer to figure 3-4.

Figure 3-4. Boom Travel Latch


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3 OPERATION

Open the platform travel latch (Figure 3-5) andpivot the platform upright. Platform locking pinswill engage in the pivot locking holes when theplatform is in a full upright position. Verify thatthe platform is locked into place.

Figure 3-5. Platform Travel Latch

Verify that the platform is properly attached tothe mounting bracket on the boom end. TheRetaining Pin should be fully inserted throughthe platform and the mounting bracket on theboom end.

WARNINGFailure to verify proper attachment of theplatform to the boom end could cause the

platform to separate from the boom, resulting inserious injury or death to the operator.

19

Use the ground control panel to operate theboom lift functions. Raise, lower, extend androtate the boom by pressing and holding thedesired SPEED and function buttons at the sametime. Become familiar with the location andfunction of all controls. Learn to smoothly startand stop all boom motions.

Fully lower the boom onto the boom rest toposition the platform for boarding. Turn the keyswitch to the platform control position.

Raise the safety bar and enter the workplatform. Put on the safety harness and attachthe lanyard to the Fall Protection AttachmentPoint on the side of the platform support beam.

Use the platform control panel to operate theboom lift functions. Raise, lower, extend androtate the boom by pressing the desired SPEEDand function buttons at the same time. Becomefamiliar with the location and function of allcontrols. Learn to smoothly start and stop allboom motions.

Should the platform become tilted out of thenormal vertical axis, press and hold the desiredSPEED button and one of the PLATFORM TILTbuttons at the same time to adjust.

Monitor the Battery Condition Indicator duringoperation and charge the batteries asnecessary.

Always fully retract, rotate and lower the boomto the stowed position before exiting theplatform.

When all boom lift operations are complete, fullyretract the telescoping boom extension. Centerboom over the boom rest and fully lower boomuntil seated in the stowed position for transport.Safety switches prevent outrigger retraction untilboom is completely lowered and stowed fortransport.

Unfasten the safety harness and exit platform.

Disengage platform locking pins and returnplatform to a stowed position. Engage the boomand platform travel latches.

Turn the key switch to the ground controlsposition.

Press and hold the outrigger RETRACT buttonand the AUTO LEVEL button until all outriggers arefully retracted to their upright positions. Inspectthe area beneath lift and trailer for obstructionsbefore retracting outriggers.

Turn the key switch to the OFF position andremove key.


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BIL-JAX 2622T

MANUAL BOOM OPERATION

Manual retraction, rotation and lowering functionsallow the Telescoping Boom Lift to be moved andlowered during hydraulic power interruption orfailure. In each instance, refer to Figure 3-6.

The following procedures for manual retraction,

rotation and lowering require a person on the groundto operate the manual controls and hand pump.

The hydraulic hand pump is located in the pumpcompartment. In case of a power failure, the handpump and selected hydraulic valve settings can beused to manually retract the Telescoping boom orrotate the boom turntable.

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

Manual Retraction

Pushing and holding the Retract button whilesimultaneously actuating Hand Pump will retract theextension boom section.

Manual Rotation

To rotate the turntable clockwise: Push and holdthe Rotation button and simultaneously actuateHand Pump.

To rotate the turntable counterclockwise: Pull theRotation button out and simultaneously actuateHand Pump.

NOTE: Return proportional valve to its originalposition before lowering the lift orresuming normal operation.

1. Hand Pump2. Proportional Valve

3. Rotation Button4. Retract Button

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

20


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3 OPERATION

Manual Lowering

Each Manual Lowering Valve is equipped with aplunger, found at the base of the lift cylinder (Figure3-7). Use the plunger to lower the platform in case ofa complete electrical power failure, a load shift, orother emergency. To lower the work platform, pullthe valve plunger forward. Continue pulling the

plunger to completely lower the boom.

Figure 3-7. Manual Lowering Valve

21


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BIL-JAX 2622T

BATTERY RECHARGE

Recharge boom lift batteries after each 8-hour workshift or as needed. When boom lift is not in use,batteries should be recharged at least once perweek. Under normal circumstances, batteryrecharge should take approximately 10-12 hours.However, a full recharge may take up to 24 hours, if

the battery charge is extremely low.

WARNINGRecharge batteries in a well-ventilated area only.Do no charge batteries near fire, spark or otherpotential ignition sources. Batteries may emithighly explosive hydrogen gas while charging.Failure to properly ventilate the charge gasesmay result in serious injury or death. Alwayscharge boom lift batteries away from flammablematerials.

22

To recharge the boom lift batteries:

Move the boom lift to a well-ventilated area withdirect access to 120v (CE: 220v) electricaloutlet. Keep the boom lift and batteries awayfrom open flame or other potential ignitionsources.

Attach a 12 AWG multi-strand, groundedextension cord with a maximum length of 15meters to the receptacle located on the cargoplate in front of the turntable.

NOTE: Using an underrated or long power cordwill reduce the output of the batterycharger and may extend charge time.

Plug the extension cord into outlet. Verify thatthe green CHARGING indicator LED is lit on thebattery charger faceplate (Figure 3-8).

CHARGING

80% CHARGED

CHECK BATTERY

Linear Battery Charger

CHARGE CURRENT

PUSH

FOR

BATTERYVOLTAGE

FUSE 15A

SLO BLO

Figure 3-8. Battery Charger Faceplate

The CHARGING indicator LED remains litcontinuously during the first stage of the chargecycle. The bulk mode CHARGE CURRENT willbe 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 CURRENTdisplay. The red CHECK BATTERY indicatorLED will become lit. See Table 3-1 for batterycharger fault codes.

WARNINGDo not disconnect any output leads orconnectors between the batteries and thecharger when the charger is on. To stop a chargein progress, always unplug the extension cordfrom the AC power source.

When the battery charge reaches 80% ofcapacity, the yellow 80% CHARGED indicatorLED will become lit and the green CHARGINGindicator LED will begin to flash.

When the batteries have reached a full charge,the green and yellow indicator LEDs will turnthemselves off. CC (Charge Complete) willappear on the CHARGE CURRENT display.After two hours, this display will fade and theCHARGE CURRENT will read 00.

Unplug the extension cord from the outlet andthe charger receptacle on the boom lift. Storethe extension cord for next use.

CAUTIONAlways unplug the battery charger power cordbefore moving the boom lift. Failure todisconnect power cord will cause damage to theequipment.

Table 3-1. Charger Fault Codes

Code Description Limits Cause

F1 Over Voltage>112% charge

voltage

Loose battery orcharger

connection

F2 Over Current >60 amperes Battery Fault

F3 Bulk Mode Timeout 14 hrs Max. Battery Fault

F4ARD Mode

Timeout6 hrs Max. Battery Fault

F5 FCT Mode Timeout 2.5 hrs Max. Battery Fault

F6 Self-Test Error Charger Fault


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3 OPERATION

BOOM LIFT TRANSPORT

The boom lift trailer includes a single axle, two-inchball hitch, hydraulic surge brakes, mechanicalparking brake, safety chains, brake lights and sidemarker lights. Proper boom transport requires theproper attachment and inspection of thesecomponents before towing. Refer to Figure 3-9.

23

1. Trailer Hitch

2. Trailer Parking Brake

3. Release Lever

4. Safety Chains

5. Trailer-to-Vehicle Power Plug

Figure 3-9. Trailer Hitching

Use the following procedure to hitch and tow the

boom lift.

Back the tow vehicle to the trailer. Verify that theball and hitch are aligned and that the trailerhitch has proper clearance above the ball. Usethe tongue jack as needed.

CAUTIONObtain, read and obey all recommendations setforth by the tow vehicle manufacturer beforeattempting to transport equipment. Verify thatequipment weight does not exceed the vehiclestowing capacity. Exceeding the tow vehiclesrated capacity may result in damage to towvehicle or boom lift.

Lift release lever and lower the hitch onto theball using the tongue jack. Push down therelease lever to secure the ball.

Use the tongue jack to verify secure coupling. Ifusing the jack will raise the bumper of the towvehicle 2-3 inches, the ball hitch coupling issecure.

Release the trailer parking brake.

On the tongue jack, pull the pivot locking pin andswivel jack 90 degrees to the travel position.Reengage pivot locking pin.

Attach the safety chains to the tow vehicle.Verify that the chains cross under the trailer

tongue. If necessary, cross the chains first overthen under the tow bar to prevent dragging.

CAUTIONFailure to attach safety chains properly beforetowing will allow trailer tongue to drop in case ofball hitch failure, resulting in damage to trailerand equipment.

If equipped, connect the breakaway cable to thetow vehicle. Leave adequate slack to preventbrakes from dragging.

Connect the trailer lights to the tow vehicle

power plug.Verify the following before towing the lift. Makeadjustments as necessary.

The trailer jack and outriggers are in their travelpositions.

Boom travel latches are engaged, securing thebooms in their fully stowed positions.

All on-board equipment is secured.

The key switch is in the OFF position. Removethe key.

The parking brake is disengaged. The trailer tires are adequately and evenly

inflated.Periodically check the wheel nut torque according tomanufacturers recommendations. Frequent torquechecks are required when a wheel is recentlyinstalled.

Prior to towing, while the trailer wheels are elevatedfor boom lift operation, inspect for loose wheels andfor wheel lug wear. If a loose wheel mounting issuspected, remove and inspect wheel lugs fordamage. NEVER tow a boom lift with worn or

damaged wheel components.


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BIL-JAX 2622T

BOOM LIFT TRANSPORT

LIFTING INSTRUCTIONS TRANSPORT INSTRUCTIONS

Refer to Figure 3-10.

Completely lower and retract boom.

Secure boom and platform travel latches.

Remove all loose materials from machine.

Retract all outriggers to fully stowed position.

Attach rigging only to the designated forkliftpockets (A).

Adjust rigging to keep the machine level and tominimize the risk of damage to machine.

When using a forklift, use only the designatedforklift pockets. Follow all forklift operatinginstructions as indicated by the forklift

manufacturer.

Only trained and authorized personnel shouldattempt to lift the boom using a crane or forklift.

Refer to Figure 3-10.

Verify that truck or trailer is parked on a firm and

level surface.

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.

Place a wooden block under the tongue, nearthe trailer hitch (C).

Lower jack until trailer tongue rests on thewooden block. Swing up and lock the jack (D) sothat the weight of the tongue now rests on thewooden block.

Secure the boom lift to the trailer bed usingstraps or chains. Use only the two attachmentpoints beneath the machine, adjacent to theoutriggers (E).

Adjust as necessary to prevent damage torigging or machine.

Figure 3-10. Lift and Transport Instruction

24


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25

4 OPERATOR SERVICE Performing the appropriate maintenance procedures will extend the lifeof the boom lift and will help ensure the safety of personnel operating theequipment.

Repair, replacement or adjustment of any hydraulic or electrical controldevice should be performed only by fully trained and authorizedpersonnel. These include, but are not limited to, hydraulic load valves,hydraulic flow control valves, solenoid valves and limit switches. Theseare safety related controls. Improper adjustment or tampering with thesedevices may impair boom lift function and result in safety or damagehazards.

Persons performing maintenance or repairs on the machine should betrained in accordance with the manufacturers recommendations.

Contact your regional Bil-Jax representative if additional information isneeded.

Critical or suspect areas identified during any scheduled inspection of themachine shall be examined by qualified personnel in accordance withapplicable government regulations.

Never operate the machine if a defect or malfunction is identified orsuspected. All defects and malfunctions must be repaired, and allmaintenance performed, before returning a machine to service.

This manual contains a list of recommended maintenance procedures tobe performed daily, weekly and monthly. Refer to the appropriateSummit Series Parts and Service Manual for a list of annual servicechecks.

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 orSafety Bulletins supersede the information contained in manuals.

Always follow maintenance schedule, regardless of use.


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BIL-JAX 2622T

DAILY SERVICE CHECKS

The following Maintenance Procedures should beperformed daily or before each operation.

Verify that all decals are correctly applied and inplain view.

Refer to Section 5 for decal locations.

Verify that all controls and indicators at groundand 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 Table4-1 for troubleshooting procedures.

If display panel displays an error code, refer to Table

4-2 for error code definitions.

Verify operation of running and brake lights.

Verify correct tire inflation.

In cold climates, inflate tires to 55 psi.

Inspect tires for damage or loose or missing lugnuts.

Repair or replace as necessary.

Inspect structural components and platform forobvious damage or debris.


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

Verify that boom down limit switches operatecorrectly.

Down limit switches are actuated when the boom is ina fully lowered, stowed position. Limit switches mustbe operational to raise or lower outriggers.

If outrigger controls are unresponsive when boom isfully lowered and stowed, inspect down limit switchesfor loose mounting or visible damage.

Repair or replace as needed.

Verify that outrigger safety interlocks operatecorrectly.

Begin with the outriggers fully extended and the boomlift level. Raise one outrigger until the footpad is not incontact with the ground.

Verify that boom functions are unresponsive whenone outrigger is raised.

Repeat this procedure for each outrigger.

Raise all outriggers until the footpads are not incontact with the ground. Verify that all outrigger statusLEDs on the ground control panel are unlit.

Lower one outrigger until the footpad makes contactwith the ground and the outrigger begins lifting thetrailer.

If the LED is lit before the footpad makes contact withthe ground or if the LED remains unlit after the weightis transferred to the outrigger, the position switch orwiring is faulty.

Repeat this procedure for each outrigger.

Repair or replace as needed. Refer to Figure 4-1.

Figure 4-1. Outrigger Position Switches

26


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4 OPERATOR SERVICE

Inspect hydraulic system and fluid levels.

Check all hydraulic hoses and fittings for leaks anddamage. Tighten or replace as necessary to preventhydraulic oil or pressure loss.

The hydraulic oil level should be checked with thebooms down, all outriggers raised and the trailerwheels on a level surface.

Hydraulic oil level should be visible in, but not above,the sight gauge.

If the hydraulic oil level is not visible to at least halfway up the sight gauge (Figure 4-2), add cleanhydraulic fluid as necessary while all booms andoutriggers are fully retracted and stowed. Pour slowlyto avoid creating air pockets in the reservoir. Do notfill above sight gauge. Overfilling the hydraulicreservoir may cause damage to hydraulic lines andmay result in equipment malfunction.

CAUTIONDo not mix hydraulic oils. Do not add any fluid to

the hydraulic system that is not expresslyrecommended by the manufacturer. Addingunauthorized fluids to the hydraulic system maycause damage to equipment

27

The hydraulic reservoir is originally filled with DexronIII/Mercon ATF with a viscosity rating of 175.

Manufacturer recommends a higher viscosityhydraulic oil when operating equipment routinely inextreme climates.

1. Filter Element

2. Fill Port

3. Sight Gauge

Figure 4-2. Hydraulic Reservoir


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BIL-JAX 2622T

28

WEEKLY SERVICE CHECKS

Perform the following service checks at least onceeach week in addition to all recommended DailyService Checks:

Check Battery electrolyte level.

If battery charge is low, add enough water to bring theelectrolyte level to the top of the plates.

If batteries are fully charged, raise electrolyte level tofull mark in each cell.

Inspect all electrical wiring.

Check for cuts, loose terminals, broken wires, chaffingand corrosion.

Repair all damage, remove corrosion and sealexposed connections.

Inspect transport hitch components for damage.

Inspect boom lift for missing, loose or damagedhardware.


Inspect all hydraulic system componentsincluding pump and motor and cylinders fordamage, leaks, loss of pressure or speed, andunusual noise or vibration.



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4 OPERATOR SERVICE

MONTHLY SERVICE CHECKS ADDITIONAL SERVICE INFORMATION

Perform the following service checks at least onceeach month:

Clean all battery terminals.

Check battery for loose connections or damagedwires.

Verify proper operation of manual loweringvalves and hand pump

Refer to Section 3 for manual boom operatingprocedures.

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 4-3 for correct wheel nut tightening

sequence.

Evenly tighten wheel nuts to 34 N*m in the tighteningsequence shown.

Repeat sequence, tightening wheel nuts to 81 N*mand to 136 N*m.

NOTE: When wheels are newly installed orreplaced, verify wheel nut torque after 75and 150 km of travel and monthlythereafter. Follow this procedure eachtime the wheel is removed andreinstalled.

4

5

1

2

3

Figure 4-3. Wheel Nut Tightening Sequence

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

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

All service checks should be performed on a machine thathas been stored without use for a period exceeding thirtydays.

Check for air in the hydraulic system if the machine hasbeen stored without use for a period exceeding thirty daysor if the machine was stored without use during aseasonal climate change. Air trapped in the hydraulicsystem will affect machine performance. Followprocedures 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 alcomponents and perform a test of all functions, includingbrake functions, before commissioning or reselling

machine. Always repair or replace all damaged ormalfunctioning components before commissioning orreselling machine.

When a change in ownership occurs, it is the responsibilityof the seller to provide the new owner with all manuals forthe machine. It is the responsibility of the buyer to notifythe manufacturer of the unit model and serial number andthe name and address of the new owner within 60 days.

Use the Service Checklists found at the back of thismanual to record all Service Checks as well as anymaintenance, repairs or alterations performed on themachine.

Records of frequent safety checks need not be made.

However, where a safety hazard is found, it shall bereported in writing to the owner of the machine, and arecord of any corrective action shall be maintained for fiveyears or as required b y the authority having jurisdiction.

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

29


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BIL-JAX 2622T

30

TROUBLESHOOTING

Refer to Table 4-1 for basic troubleshooting operations. Additional informationcan be found in the Bil-Jax Parts and Service Manual. Contact the Bil-JaxService Department with any questions or before attempting any advancedtroubleshooting operations.

Table 4-1. Troubleshooting Steps

PROBLEM CAUSE SOLUTION

No lights on panel whenkey switch is turned to theon position.

a. Emergency STOP engaged.

b. Battery charge is low.

c. Battery ground or in-series cable is loose.

d. Battery main disconnect unplugged.

e. Blown Fuse.

a. Disengage Emergency STOP buttons.

b. Recharge as needed.

c. Inspect and repair battery connections.

d. Plug in main disconnect.

e. Check and replace fuse.

Hydraulic function does not

work and display windowshows an error message

a. Fault detected by safety interlock

microprocessor.

b. Boom Lift electric or electronic failure

a. Refer to Table 4-2 for error code

definition and correction.

b. Refer to Table 4-2 for error codedefinition and correction.

Outrigger indicator LEDlights do not function.

a. Key switch turned to the OFF or platformcontrols position.

b. Emergency STOP engaged.

c. Outriggers not deployed.

a. Turn key switch to ground controlsposition.

b. Disengage emergency STOP buttons.

c. Deploy all outriggers.

One or more boom controlsdo not function

OROne or more boom controlsfunction improperly

OR

One or more boom controlsfunction intermittently.

a. Key switch is turned to the OFF orincorrect control position.

b. Battery charge is low.

c. Emergency STOP engaged.

d. Battery ground or in-series cable loose.

e. All outriggers not properly deployed.

f. Hydraulic pump inoperative.

g. Loose wiring connector.

h. Valve solenoid not operating properly.

i. Fault detected by system interlock.

j. Broken or loose wire.

a. Turn key switch to ground or platformcontrols position.

b. Recharge battery.

c. Disengage Emergency STOP buttons.

d. Inspect and repair battery connections.

e. Deploy all outriggers and level boom lift.

f. Inspect pump; replace or repair asneeded.

g. Check wiring terminals in control boxand at valve manifold; replace or repairas needed.

h. Clean valve solenoid and recheckfunction(s); replace or repair as needed.

i. Check display for system status. Referto Table 4-2 for error code definitionsand correction.

j. Inspect wiring in control box and atvalve manifold and valve coil; repair orreplace as needed.


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4 OPERATOR SERVICE

31

ERROR CODE DEFINITIONS

The DISPLAY PANEL located on the ground control panel indicates the presentoperating status of the boom lift. If an error condition is detected by the controlprocessor during start-up or operation, the appropriate error code will bedisplayed on this panel.

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

solutions.

Table 4-2. Error Code Definitions

ERROR MESSAGE DEFINITION OF ERROR COMMENTS

001 MACHINE IS IN DOWN ONLYMODE

Machine was either never leveled, outriggers notlowered, or machine went out of level with use.

Retract boom to travel positionand extend outriggers using AUTOLEVEL button.

002 LOSS OF PLATFORMCOMMUNICATION

Ground control lost communication with platformcontrol.

Check for unplugged or damagedplatform control cable.

005 PLATFORM CONTROL HASSTUCK KEY

Platform control detected a stuck or pressed keyon power up.

Turn key switch off and on againwithout pressing any buttons.

008 GROUND CONTROL HASSTUCK KEY

Ground control detected a stuck or pressed keyon power up.

Turn key switch off and on againwithout pressing any buttons.

009 BOOM UP WITHOUTOUTRIGGERS ON GROUND

Ground control detected the boom is up and alloutriggers are not on the ground

Retract boom to travel positionand extend outriggers using AUTOLEVEL button.

010 LEVEL SENSOR HASERRATIC OUTPUT

The ground control detected an erratic outputfrom the level sensor.

Retract and extend outriggersusing AUTO LEVEL button.

015 MACHINE IS NOT LEVEL Machine has gone out of level with use. Retract and extend outriggersusing AUTO LEVEL.

016 LIFT BOOM A boom rotate, extend, or retract functionrequested with boom down.

Raise boom from travel position.

017 STOW BOOM An outrigger function requested with boom up. Retract and lower boom to travelposition.

021 OPEN CIRCUIT PRIMARY UP A load of less than 70mA detected in primary upcircuit on power-up.

Check for faulty boom upsolenoid coil and wiring.

022 SHORTED CIRCUITPRIMARY UP

Excessive load detected in primary up circuit onpower-up.

Check for faulty boom upsolenoid coil and wiring.

033 OPEN CIRCUIT EXTEND A load of less than 70mA detected in extendcircuit on power-up.

Check for faulty boom extendsolenoid coil/wiring.

034 SHORTED CIRCUIT EXTEND Excessive load detected in extend circuit onpower-up.

Check for faulty boom extendsolenoid coil/wiring.

035 OPEN CIRCUIT RETRACT A load of less than 70mA detected in retractcircuit on power-up.

Check for faulty boom retractsolenoid coil/wiring.

036 SHORTED CIRCUITRETRACT Excessive load detected in retract circuit onpower-up. Check for faulty boom retractsolenoid coil/wiring.

037 OPEN CIRCUIT PLATFORMLEVEL UP

A load of less than 70mA detected in platformlevel up circuit on power-up.

Check for faulty level up solenoidcoil/wiring.

038 SHORTED CIRCUITPLATFORM LEVEL UP

Excessive load detected in platform level upcircuit on power-up.

Check for faulty level up solenoidcoil/wiring.

039 OPEN CIRCUIT PLATFORMLEVEL DOWN

A load of less than 70mA detected in platformlevel down circuit on power-up.

Check for faulty level downsolenoid coil/wiring.

040 SHORTED CIRCUITPLATFORM LEVEL DOWN

Excessive load detected in platform level downcircuit on power-up.

Check for faulty level downsolenoid coil/wiring.


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BIL-JAX 2622T

32

ERROR MESSAGE DEFINITION OF ERROR COMMENTS

045 OPEN CIRCUIT TURNTABLECW

A load of less than 70mA detected in rotate CWcircuit on power-up.

Check for faulty rotate CWsolenoid coil/wiring.

046 SHORTED CIRCUITTURNTABLE CW

Excessive load detected in rotate CW circuit onpower-up.

Check for faulty rotate CWsolenoid coil/wiring.

047 OPEN CIRCUIT TURNTABLE

CCW

A load of less than 70mA detected in rotate CCW

circuit on power-up.

Check for faulty rotate CCW

solenoid coil/wiring.048 SHORTED CIRCUIT

TURNTABLE CCWExcessive load detected in rotate CCW circuit onpower-up.

Check for faulty rotate CCWsolenoid coil/wiring.

049 OPEN CIRCUIT OUTRIGGERRETRACT

A load of less than 70mA detected in outriggerretract circuit on power-up.

Check for faulty outrigger retractsolenoid coil/wiring.

050 SHORTED CIRCUITOUTRIGGER RETRACT

Excessive load was detected when OutriggerRetract circuit was energized.

Check for faulty outrigger retractsolenoid coil/wiring.

051 OPEN CIRCUIT OUTRIGGEREXTEND

A load of less than 70mA detected in outriggerretract circuit on power-up.

Check for faulty outrigger extendsolenoid coil/wiring.

052 SHORTED CIRCUITOUTRIGGER EXTEND

Excessive load was detected in outrigger extendcircuit on power-up.

Check for faulty outrigger extendsolenoid coil/wiring.

053 OPEN CIRCUIT

LF OUTRIGGER

A load of less than 70mA detected in left front

outrigger circuit on power-up.

Check for faulty solenoid

coil/wiring at outrigger.

054 SHORTED CIRCUITLF OUTRIGGER

Excessive load was detected in left frontoutrigger circuit on power-up.

Check for faulty solenoidcoil/wiring at outrigger.

055 OPEN CIRCUITRF OUTRIGGER

A load of less than 70mA detected in right frontoutrigger circuit on power-up.


056 SHORTED CIRCUITRF OUTRIGGER

Excessive load detected in right front outriggercircuit on power-up.


057 OPEN CIRCUITLR OUTRIGGER

A load of less than 70mA detected in left rearoutrigger circuit on power-up.


058 SHORTED CIRCUITLR OUTRIGGER

Excessive load detected in left rear outriggercircuit on power-up.


059 OPEN CIRCUITRR OUTRIGGER

A load of less than 70mA detected in right rearoutrigger circuit on power-up.


060 SHORTED CIRCUITRR OUTRIGGER

Excessive load detected in right rear outriggercircuit on power-up.


069 OPEN CIRCUITPROPORTIONAL

A load of less than 70mA detected in proportionalvalve circuit on power-up.

Check for faulty solenoidcoil/wiring at proportional valve.

070 SHORTED CIRCUITPROPORTIONAL

Excessive load detected in proportional valvecircuit on power-up.

Check for faulty solenoidcoil/wiring at proportional valve.


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5 DECAL REPLACEMENT

Decals contain information that is required for the safe and proper use ofthe aerial work platform. Decals should be considered necessarycomponents of the machine and should be checked before each use toverify that they are correctly attached and legible.

Use the following guides to find the correct location of all decals.


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Table 5-1. Decal Descriptions

Decal No. Decal Description Qty

0202-0523 Made in USA 1

B06-00-0034 DANGER: Electric Shock 1

B06-00-0037 Lubricate Semi-Annually 1

B06-00-0062 NOTICE: AC Power 2

B06-00-0068 NOTICE: Hydraulic System Oil 1

B06-00-0161B Bil-Jax Logo, 6 Black Transfer 2

B06-00-0173NOTICE: Fall ProtectionAttachment Point

2

B06-00-0403 NOTICE: Emergency Lowering 2

B06-00-0404 WARNING: Outrigger Crush Toe 8

B06-00-0405 WARNING: Pinch Point 16

B06-00-0468 WARNING: Operating Instructions(Ground)

2

B06-00-0471DANGER: Before Use/MainInstruction/Hazards (Platform)

1

B06-00-0473NOTICE: Operators ManualMissing

1

B06-00-0475WARNING: Read/UnderstandOperators Manual

1

B06-00-0477 WARNING: Forklift Pockets 2

B06-00-0478NOTICE: Platform Charger/PowerPlug Here

1

B06-00-0481 CAUTION: Transport Safety Latch 1

B06-00-0482 DANGER: Electrocution Hazard 2

Decal No. Decal Description Qty

B06-00-0484 DANGER: Battery/Charger Safety 1

B06-00-0491WARNING: Operating Instructions(Platform) 1

B06-00-0493 CAUTION: Prior to Towing 1

B06-00-0494 NOTICE: Hazardous Materials 1

B06-00-0495CAUTION: Compartment AccessRestricted

2

B06-00-0496CAUTION: Generator PlateCapacity 200 lbs.

1

B06-00-0503 NOTICE: Handle Applications 1

B06-00-0504 NOTICE: Emergency Hand Pump 1

B06-00-0505DANGER: Before Use/Main

Instruction/Hazards (ground)1

B06-00-0521 DANGER: Tip Over Hazard 5

B06-00-0541CAUTION: Manual BoomFunctions

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

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

CE/CAN/AUS Machines

B06-00-0167 Black/Yellow Hazard - 2 Wide 4

B06-00-0568 WARNING: Tip Over Hazard 4


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6 ANSI REPRIN T The following sections are reprinted from the ANSI A92.2-2001 code ineffect at the time of manufacture and govern the safe use of the Bil-JaxModel 2622T Telescoping Boom Lift. It is the responsibility of allowners and operators of this machine to read, understand and obeythe recommendations set forth by the ANSI code.

Permission to reprint this material has been granted by the ScaffoldIndustry Association.

7. Responsibilities of Dealers and Installers

7.1 General Responsibilities. Each dealer or installer asapplicable shall comply with the requirements of thissection.

7.2 Vehicle Specifications. Each dealer or installer, or both,who sells an aerial device shall inform the owner or user, orboth, of the manufacturers minimum vehicle specifications.

7.3 Vehicle Weight Distribution. The installer shall be

responsible for the weight distribution of the completedmobile unit in accordance with the requirements of theaerial device and the applicable regulations. Allowanceshall be made for the weight of readily removable tools andmaterial specified by the user.

7.4 Manuals. Upon delivery of the equipment to the owner oruser, the dealer or installer shall provide the manuals asrequired by Paragraph 6.4 of this standard and manuals forauxiliary equipment added by the installer.

7.5 Installations. The installer shall comply with Sections 5 and6 of this standard relating to proper installation and shallfollow the instructions of the manufacturer. In the event theoriginal manufacturer no longer exists, an equivalent entitymay provide these instructions. The installer of an aerialdevice shall, before the mobile unit is placed in operation,

perform stability tests in accordance with the requirementsof 4.5.1 and 4.5.2, the operational and visual tests inaccordance with the requirements of 6.6.1 and 6.6.2 a, andthe appropriate electrical tests required in 5.4.3 of thisstandard. The installer shall, when installing an aerialdevice on a chassis which is a highway vehicle, comply withall requirements of the Federal Motor Vehicle SafetyStandards in effect at the time of installation. Certification asa manufacturer (alteration, intermediate or final) of a motorvehicle under the Federal Motor Vehicle Safety Standardsis required. The travel height of a mobile unit shall beposted in a location that is readily visible to the vehicleoperator. For insulated aerial devices, the installer shallassure conformance to the Qualification test requirementsof 5.3.2 by either obtaining certification of the test andperforming a periodic test after insulation, or by performingthe Qualification test.

7.5.1 Quality Assurance. The installer shall have a documentedquality assurance program which will ensure compliancewith this standard.

7.6 Welding. All welds made by the installer, whose failurecould result in motion of the platform(s) shall meet theStructural Welding Code AWS D1.1-98 and AWS D1.2-98.The installer shall establish applicable welding qualityassurance procedures for all weldments.

7.7 Training. The dealer or installer shall offer training ortraining materials that aid owners and users in theoperation, inspection, testing and maintenance of the aerial

device. The training shall be offered initially andsubsequently on request.

7.7.1 Dealer or Installer as User. Whenever a dealer or installerdirects personnel to operate the aerial device (inspecting,sales demonstrations, or any form of use), the dealer orinstaller shall assume the responsibilities of users asspecified in Section 9 of this standard. All personnelauthorized to operate this aerial device shall have beentrained.

8. Responsibilities of Owners

8.1 General Responsibilities. Each owner shall comply with therequirements of this section. The following responsibilitiespertain to the owners inspection, testing, maintenance,modification, training and transfer of ownership. Theseactivities shall be performed by qualified person(s).

8.2 Inspection and Testing Classifications.

8.2.1 Initial Inspection and Test. Prior to initial use, all new ormodified mobile units shall be inspected and tested to ensurecompliance with the provisions of this standard. Verificationby the manufacturer, the installer, or an equivalent entity(s)meets this requirement.

8.2.2 Regular Inspection and Tests. The inspection procedure for

mobile units is divided into two classifications based upon theintervals at which inspections and tests shall be performed.Intervals shall be set by the owner in accordance with themanufacturers recommendations. Such intervals aredependant upon component function and exposure to wear,deterioration and other agents which adversely affectcomponent life. Two classifications are designated:(1) Frequent Inspection and Test: Daily to Monthly intervals(2) Periodic Inspection and Test: One to Twelve Month

intervals.

8.2.3 Frequent Inspection and Test. Items determined to by theowner in accordance with the manufacturersrecommendations for each specific aerial device shall beinspected for defects. The following tests and inspectionsshall be performed by the operator once daily, prior to firstuse:(1) Operating controls and associated mechanisms for

conditions interfering with proper operation.(2) Visual and audible safety devices for malfunction.(3) Hydraulic and pneumatic systems for observable

deterioration or excessive leakage.(4) Fiberglass and other insulating components for visible

damage or contamination.(5) Missing or illegible operational and instructional

markings.(6) Electrical systems of/or related to the aerial device for

malfunction, signs of excessive deterioration, dirt andmoisture accumulation.

(7) Visual inspection of bolts, pins and other fasteners forloose, deformed or missing fasteners and other locking


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devices. Any suspected items shall be carefullyexamined or tested and a determination made by aqualified person as to whether they constitute a safetyhazard. All unsafe items shall be replaced or repairedbefore use.

8.2.4 Periodic Inspection or Test. An inspection of the mobile unitshall be performed at the intervals defined in 8.2.2 dependingupon its activity, severity of service, and environment, or asspecifically indicated below. (These inspections shall includethe requirements of 8.2.3):(1) Structural members for deformation, cracks or corrosion.(2) Parts, such as pins, bearings, shafts, gears, rollers,

locking devices, chains, chain sprockets, wire andsynthetic ropes and sheaves, for wear, cracks ordistortion.

(3) Hydraulic and pneumatic relief valve settings.(4) Hydraulic system for proper oil level.(5) Hydraulic and pneumatic fittings, hoses and tubing for

evidence of leakage, abnormal deformation or excessiveabrasion.

(6) Compressors, pumps, motors and generators for loosefasteners, leaks, unusual noises or vibrations, loss ofoperating speed and excessive heating.

(7) Hydraulic and pneumatic valves for malfunction andvisible cracks in the external valve housing, for leaks

and sticking spools.(8) Visually inspect any vacuum prevention systems and

verify function of such systems on Category A aerialdevices.

(9) Hydraulic and pneumatic cylinders and holding valvesfor malfunction and visible damage.

(10) Hydraulic and pneumatic filters for cleanliness and thepresence of foreign material in the system indicatingother component deterioration.

(11) Electrical systems and components for deterioration orwear including those not readily visible on a frequentinspection.

(12) Performance test of all boom movements.(13) Condition and tightness of bolts and other fasteners.(14) Welds, as specified by the manufacturer.(15) Legible and proper identification, operational and

instructional markings.

(16) If the aerial device is rated as an insulated device, theelectrical insulating components and system(s) shall bethoroughly inspected for lack of cleanliness and othercomponents that compromise insulation. Then thesecomponents and system(s) shall be tested forcompliance with the rating of the aerial device inaccordance with one of the applicable methods andprocedures as outlined in Section 5.4.3 of this standard:(a) If the aerial device is used for AC bare-hand work,

the unit shall undergo a 60 Hz test as shown inTable 2 at least every three years;

(b) If the aerial device is used for DC bare-hand work,the unit shall undergo a DC test as shown in Table2 at least every three years.

(c) After repair or modification of any component thatcrosses the insulating system(s), or the repair or

replacement of an insulating component(s), the unitshall be dielectrically tested in accordance withsection 5.4.3;

(d) An insulated replacement boom shall be tested toinsure conformance to 5.3.3 by the supplier;

(e) Bare-hand work units shall be tested as shown inTable l after any major repair to the insulated boomor any insulated boom replacement. Any suspecteditems shall be carefully examined or tested and adetermination made by a qualified person as towhether they constitute a safety hazard. All unsafeitems shall be replaced or repaired before use.

8.3 Inspection and Test Records.

(1) Items to be inspected shall be designated to theoperator or other authorized person making frequentinspections. Records of frequent inspections need notbe made. However, where a safety hazard is found, itshall be reported in writing to a person responsible forthe corrective action and that report and a record ofthe correction shall be maintained for five years, or asrequired by applicable regulations.

(2) Written, dated and signed reports and records shall bemade of periodic inspections and tests and retained fora period of five years or as required by applicableregulations.

8.4.1.1 Maintenance. Maintenance and frequency of maintenanceshall be determined by the owner in accordance with themanufacturers recommendations. Welding repairs ofcomponents or welds, designated as critical in themanufacturers manual, shall be made in accordance withthe manufacturers recommendations. Should the originalmanufacturer no longer exist an equivalent entity maydetermine the required procedure.

8.4.1.2 Maintenance Training. The owner shall train theirmaintenance personnel in inspection and maintenance ofthe aerial device in accordance with the manufacturersrecommendations and Section 8 of this standard.

8.4.1.3 Modifications. No modifications or additions which affectthe stability, mechanical, hydraulic, or electrical integrity orthe safe operation of the aerial device shall be madewithout the written approval of the manufacturer. If suchmodifications or changes are made, the capacity, operation,and maintenance instruction markings shall be changedaccordingly. In no case shall the safety factors be reducedbelow those specified in this standard or below themanufacturers design safety factors, whichever are greater.Should the original manufacturer no longer exist, anequivalent entity may approve required modification.

8.6 Weight Distribution. Changes in loading or additions madeto the mobile unit after the final acceptance that affectweight distribution shall meet applicable regulations bygovernmental agencies. In no case shall axle loads of the

fully loaded vehicle exceed the Gross Axle Weight Ratings(GAWR) assigned by the manufacturer. Note: Any changein weight distribution may adversely affect stability.

8.7 Transfer of Ownership. When a change in ownership of anaerial device occurs, it shall be the responsibility of theseller to provide the manufacturer's manual(s) for that aerialdevice to the purchaser. It is the responsibility of thepurchaser to notify the manufacturer of the unit model andserial number and the name and address of the new ownerwithin 60 days.

8.8 Markings. The markings on the aerial device shall not beremoved, defaced, or altered. All missing or illegiblemarkings shall be promptly replaced.

8.9 Parts. When parts or components are replaced they shallbe identical in specification and function to the originalaerial device parts or components or shall provide an equalor greater factor of safety.

8.10 Safety Bulletins. Owners shall comply with safety relatedbulletins as received from the manufacturer, dealer orinstaller.

8.11 Manuals. The owner shall insure that the operatingmanual(s) is stored on the mobile unit.

8.12 Training, Retraining, and Familiarization of Operators.


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8.12.1 Owner as a Renter or Lessor. When an owner functionsas a renter or lessor he shall have the same responsibilitiesas specified under Section 11 of this standard.

8.12.2 General Training. Only personnel who have receivedgeneral instructions regarding the inspection, applicationand operation of aerial devices, including recognition andavoidance of hazards associated with their operation, shalloperate an aerial device. Such items covered shall include,but not necessarily be limited to, the following issues andrequirements:(1) The purpose and use of manuals.(2) That operating manuals are an integral part of the

aerial device and must be properly stored on thevehicle when not in use.

(3) A pre-start inspection.(4) Responsibilities associated with problems or

malfunctions affecting the operation of the aerialdevice.

(5) Factors affecting stability.(6) The purpose of placards and decals.(7) Workplace inspection.(8) Applicable safety rules and regulations, such as Part 4,

ANSI C2-1997, National Electrical Safety Code(applies to utility workers as defined in ANSI C2). Theabove standard is an example; other industries using

aerial devices have safety rules pertinent to thatindustry.

(9) Authorization to operate.(10) Operator warnings and instructions.(11) Actual operation of the aerial device. Under the

direction of a qualified person, the trainee shall operatethe aerial device for a sufficient period of time todemonstrate proficiency in the actual operation of theaerial device.

(12) Proper use of personal fall protection equipment.

8.12.3 Retraining. The operator shall be retrained, when sodirected by the user, based on the

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