B PARTS MANUAL

Transcription

1 B PARTS MANUAL

2 BOOM PERSONNEL LIFT This equipment is designed and manufactured in compliance with the duties, responsibilities and standards set forth in the ANSI, CSA, AS and/or CE standards in effect at the time of manufacture. This equipment will meet or exceed applicable ANSI, CSA, AS and/or CE 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. Haulotte Group BilJax, Inc. is dedicated to the continuous improvement of this and all Haulotte Group BilJax products. Therefore, equipment information is subject to change without notice. Direct any questions or concerns regarding errors or discrepancies in this manual to the Haulotte Group BilJax Service Department. Copyright Haulotte Group BilJax, Inc All Rights Reserved. Haulotte Group BilJax is a registered trademark and A Step Above and Summit Series are trademarks of Haulotte Group BilJax, Inc. Contact Haulotte Group BilJax for replacement manuals. 125 Taylor Parkway Archbold, Ohio P/N: B Phone (800) (419) Fax (419)

3 TABLE OF CONTENTS Table of Contents 1 1 Replacement Decals 3 2 Replacement Parts 17 Outrigger 18 Towing 20 Front Rest 22 Brake And Axle 24 Slew Ring 26 Limit Switch 28 Control Compartment 30 Pump Compartment 32 Battery Compartment 34 Cover Assembly 36 Lower Boom 38 Triangle Weldment 40 Upper Boom 42 Jib Boom 44 Platform 46 Hydraulic Pump 48 Boom and Rotation Hydraulic Lines 52 Outrigger Hydraulic Lines 54 Wire Harnesses 55 Platform Wire Harness 56 Analog Wire Harness 56 Pump and Cylinder Wire Harness 57 Outrigger Coil Wire Harness 58 Power Harness VAC Tower-Platform Wire Harness 59 Tail Light Turntable-Platform Wire Harness 59 Secondary Cylinder Wire 60 Jib Wire VAC Trailer-Tower Wire Harness 60 Marker Light Wire Harness 61 Tail Light Wire Harness 61 Material Lift Hook 62 Water Line to Platform 63 Air Line to Platform 63 DC/Gas Hybrid Wire Harness 64 Battery Layout, Standard 65 Battery Layout, Auxiliary 66 Brake Cable CE 67 Trailer Light Wire Harness CE 67 Ordering Replacement Parts 69 1

4 2

5 1 REPLACEMENT DECALS Decals contain information that is required for the safe and proper use of the aerial work platform. Decals should be considered necessary components of the machine and should be checked before each use to verify that they are correctly attached and legible. Use the following guides to find the correct location of all decals. 3

6 4 Decal Locations - ANSI

7 1 REPLACEMENT DECALS Replacement Decal Descriptions - ANSI B DECAL KIT - Includes the following: ITEM NO. PART NUMBER DESCRIPTION QTY. 1 B Decal - Warning - Unhitch To Operate 2 2 B Decal - Caution - Latch / Jack / Brake 1 3 B Decal - Warning - Hand Pinch Point 17 4 B Decal - Emergency Lower Valve 4 5 B Decal - Danger - Tip Over Hazard 7 6 B Decal - Warning - Outrigger Crush Foot 8 7 B B Decal - 'Haulotte BilJax' - 5in Black / Red on Clear 2 8 B Decal - Warning - Fork Lift Use 2 9 B Decal A Transfer - Black 2 10 B Decal - Caution - Transport Latch 2 11 B Decal - Notice - Range of Motion A 2 12 B Decal - Danger - Electrocution 2 13 B Decal - "Lubricate Semi - Annually" 1 14 B Decal - Danger - Main Instruction / Hazard - Platform 1 15 B Decal - Warning - Read / Understand Manual 1 16 B Decal - Notice - Operator Manual Missing 1 17 B Decal - Warning - Platform Operation - Articulating 1 18 B Decal - Notice - AC Power 2 19 B Decal - Air PSI 2 20 B Decal - Water PSI 2 21 B Decal - Notice - Lanyard Attachment 1 22 B Decal - Notice - Platform Maximum Load Decal - Flag, Made In USA 1 24 B Decal - Notice - Handle Applications 1 25 B Decal - Notice - Emergency Hand Pump 1 26 B Decal - Notice - Low Foam Hydraulic Oil 1 27 B Decal - Notice - Contains Hazardous Material 1 28 B Decal - Caution - Manual Rotate / Retract 1 29 B Decal - Caution - Compartment Access 2 30 B Decal - Danger - Main Instruction / Hazard - Base 1 31 B Decal - Danger - Battery / Charger Safety 1 32 B Decal - Warning, Ground Operation Instructions - Articulating 2 33 B Decal - Danger - Battery / Charger Instruction 1 34 B Decal - Warning - Crush Hazard 2 35 B Decal - Caution - Generator Plate Maximum B Decal - Notice - AC Power Connection 1 37 B Decal - Warning - Maximum Tow Speed B Decal - Warning - Tow Hazard 65 mph 2 5

8 6 Identification Plates & Optional Equipment - ANSI

9 1 REPLACEMENT DECALS IDENTIFICATION PLATES & OPTIONAL EQUIPMENT ANSI IDENTIFICATION PLATES (Used on all standard equipment) ITEM NO. PART NUMBER DESCRIPTION QTY. 39 B Key Ring Tag 1 40 B Annual Inspection Plate 1 41 B VIN Plate 1 42 B ANSI ID Plate 1 REPLACEMENT DECALS FOR OPTIONAL EQUIPMENT ANSI ITEM NO. PART NUMBER DESCRIPTION QTY. 43 B Decal - Notice - Platform Rotate (Manual Rotation Option) 1 44 B Decal - Warning - Drive and Set (Drive and Set Option) 1 45 B Decal - Notice - Drive and Set (Drive and Set Option) 1 46 B Decal - Warning - Jockey Wheel (Drive and Set Option) 1 47 B Decal - Notice - Material Lift Set - up (Material Lift Option) 1 48 B Decal - Notice - Material Lift Max 500 (Material Lift Option) 1 49 B Decal - Notice - Unleaded Fuel Only (Gas Engine Option) 1 50 B Decal - Caution - Component Damage (Gas Engine Option) 1 51 B Decal - Notice - Engine Specifics (Gas Engine Option) 1 52 B Decal - Warning - Eng Operate - Hot (Gas Engine Option) 1 7

10 8 Decal Locations - CE

11 1 REPLACEMENT DECALS DECAL KIT - CE B DECAL KIT - Includes the following: ITEM NO. PART NUMBER DESCRIPTION QTY. 1 B CE Decal - Warning - Hand Pinch Point 15 2 B CE Decal - Notice - Emergency Lower 4 3 B CE Decal - Caution - Outrigger Pressure 4 4 B CE Decal - Warning - Outrigger Crush Foot 10 5 B B Decal - 'Haulotte BilJax' - 5in Black / Red on Clear 2 8 B CE Decal - Danger - Electrocution 2 11 B CE Decal - Warning - Read / Understand Manual 2 13 B CE Decal - Notice - AC Power 2 14 B CE Decal - Notice - Lanyard Attachment 1 15 B CE Decal - Notice - Platform Maximum Load Decal - Flag, Made In USA 1 17 B CE Decal - Notice - Low Foam Hydraulic Oil 1 19 B CE Decal - Caution - Compartment Access 2 20 B CE Decal - Caution - Read Parts and Service Manual 1 21 B CE Decal - Danger - Battery / Charger Safety 2 24 B CE Decal - Caution - Generator Plate Maximum B CE Decal - Warning - Maximum Tow Speed 65 1 B DECAL KIT - Includes the following: ITEM NO. PART NUMBER DESCRIPTION QTY. 6 B CE Decal - HTA 19 P - Black Clear Vinyl with Black Letters 2 7 B CE Decal - Notice - Range of Motion A 2 B DU DECAL KIT - Dutch - Includes the following: B EN DECAL KIT - English International - Includes the following: B FC DECAL KIT - French (Canadian) - Includes the following: B FR DECAL KIT - French (European) - Includes the following: B GE DECAL KIT - German - Includes the following: B IT DECAL KIT - Italian - Includes the following: B KO DECAL KIT - Korean - Includes the following: B RU DECAL KIT - Russian - Includes the following: B SW DECAL KIT - Swedish - Includes the following: ITEM NO. PART NUMBER DESCRIPTION QTY. 9 B Decal - "Lubricate Semi - Annually" 1 10 B Decal - Danger - Main Instruction / Hazard - Platform 1 12 B Decal - Warning - Platform Operation A 1 18 B Decal - Caution - Manual Rotate / Retract 1 22 B Decal - Danger - Main Instruction / Hazard - Base 1 23 B Decal - Warning - Ground Operation 2 25 B Decal - Notice - AC Power Connection 1 Note: Decals without the CE suffix are available in the following languages: -DE = German, -DU = Dutch, -FC = French (Canadian), -FR = French (European), -IT = Italian, -KO = Korean, RU = Russian, -SP = Spanish, -SW = Swedish To order add the appropriate suffix to the end of the part number. 9

12 10 Identification Plates & Optional Equipment - CE

13 1 REPLACEMENT DECALS IDENTIFICATION PLATES & OPTIONAL EQUIPMENT - CE IDENTIFICATION PLATES (Used on all standard CE equipment) ITEM NO. PART NUMBER DESCRIPTION QTY. 27 B CE ID Plate 1 28 B VIN Plate 1 DECALS FOR OPTIONAL EQUIPMENT - CE ITEM NO. PART NUMBER DESCRIPTION QTY. 29 B Decal - Notice - Platform Rotate (Manual Rotation Option) 1 30 B Decal - Warning - Drive and Set (Drive and Set Option) 1 31 B Decal - Notice - Drive and Set (Drive and Set Option) 1 32 B Decal - Air PSI (Air Line to Platform Option) 2 33 B Decal - Water PSI (Water Line to Platform Option) 2 34 B Decal - Warning - Jockey Wheel (Drive and Set Option) 1 35 B Decal - Notice - Unleaded Fuel Only (Gas Engine Option) 1 11

14 12 Decal Locations - Australia

15 1 REPLACEMENT DECALS DECAL KIT AUSTRALIA B DECAL KIT - Includes the following: ITEM NO. PART NUMBER DESCRIPTION QTY. 1 B CE Decal - Warning - Hand Pinch Point 15 2 B CE Decal - Notice - Emergency Lower 4 3 B CE Decal - Caution - Outrigger Pressure 4 4 B CE Decal - Warning - Outrigger Crush Foot 10 5 B B Decal - 'Haulotte BilJax' - 5in Black / Red on Clear 2 8 B CE Decal - Danger - Electrocution 2 11 B CE Decal - Warning - Read / Understand Manual 2 13 B CE Decal - Notice - AC Power 2 14 B CE Decal - Notice - Lanyard Attachment 1 15 B CE Decal - Notice - Platform Maximum Load Decal - Flag, Made In USA 1 17 B CE Decal - Notice - Low Foam Hydraulic Oil 1 19 B CE Decal - Caution - Compartment Access 2 20 B CE Decal - Caution - Read Parts and Service Manual 1 21 B CE Decal - Danger - Battery / Charger Safety 2 24 B CE Decal - Caution - Generator Plate Maximum B CE Decal - Warning - Maximum Tow Speed 65 1 B DECAL KIT - Includes the following: ITEM NO. PART NUMBER DESCRIPTION QTY. 6 B CE Decal - HTA 19 P - Black Clear Vinyl with Black Letters 2 7 B CE Decal - Notice - Range of Motion A 2 B EN DECAL KIT - English International - Includes the following: ITEM NO. PART NUMBER DESCRIPTION QTY. 9 B Decal - "Lubricate Semi - Annually" 1 10 B Decal - Danger - Main Instruction / Hazard - Platform 1 12 B Decal - Warning - Platform Operation A 1 18 B Decal - Caution - Manual Rotate / Retract 1 22 B Decal - Danger - Main Instruction / Hazard - Base 1 23 B Decal - Warning - Ground Operation 2 25 B Decal - Notice - AC Power Connection 1 13

16 14 Identification Plates & Optional Equipment - Australia

17 1 REPLACEMENT DECALS IDENTIFICATION PLATES & OPTIONAL EQUIPMENT - AUSTRALIA IDENTIFICATION PLATES (Used on all standard equipment) ITEM NO. PART NUMBER DESCRIPTION QTY. 27 B Annual Inspection Plate 1 28 B VIN Plate 1 29 B ANSI ID Plate 1 REPLACEMENT DECALS FOR OPTIONAL EQUIPMENT - AUSTRALIA ITEM NO. PART NUMBER DESCRIPTION QTY. 30 B Decal - Notice - Platform Rotate (Manual Rotation Option) 1 31 B Decal - Warning - Drive and Set (Drive and Set Option) 1 32 B Decal - Notice - Drive and Set (Drive and Set Option) 1 33 B Decal - Air PSI (Air Line to Platform Option) 2 34 B Decal - Water PSI (Water Line to Platform Option) 2 35 B Decal - Warning - Jockey Wheel (Drive and Set Option) 1 36 B or Decal - Notice - Unleaded Fuel Only (Gas Engine Option)or 1 B Decal - Notice - Diesel Fuel Only (Gas Engine Options) 37 B Decal - Warning - Eng Operate - Hot (Gas Engine Option) 1 15

18 16

19 2 REPLACEMENT PARTS Use only parts manufactured and/or authorized by Haulotte Group BilJax, Inc. when replacing damaged components. See page 69 for replacement part ordering information. Only personnel properly trained and authorized to operate all equipment and familiar with all boom functions should attempt to repair or replace any part of the boom lift. Always read, understand and obey all safety precautions included in this manual, as well as those precautions attached to the lift and dictated by federal, state and local regulations. 17

20 OUTRIGGER ASSEMBLY

21 OUTRIGGER ASSEMBLY PARTS LIST Item No. Part No. Description Qty. 1 A Outrigger Weldment 1* 2 A Grommet 1.5 x 1.25 x A Bearing 2 4 A Pin, 1.25 X A Pin Retainer, Cap Screw, M10 x Hex Nut, Self-Locking, M A Pin, 1.25 X A Outrigger Hydraulic Cylinder 1 10 A Outrigger Cylinder Guard Cap Screw, M8 x A Guard Slide Cap Screw, M8 x Hex Nut, Self-Locking, M A Spring, Outrigger Sensor Cap Screw, M16 x Hex Nut, Self-Locking, M A Pad Mount Weldment Cap Screw, M16 x B Limit Switch Assembly Slotted Machine Screw, #10-24 x 5/ Hex Nut, Self-Locking, # A Foot Pad, Aluminum, A Foot Pad Bottom, Flat Head Cap Screw, M8 x A Foot Pad Ball 1 27 A Retaining Ring, Foot Pad Hex Nut, Self-Locking, M20 1 *Quantities listed reflect the number of parts needed for each outrigger. NOTE: Unless otherwise noted, high-strength Grade 5/Class 8.8 fasteners are used in the assembly of this equipment. 19

22 TOWING ASSEMBLY

23 TOWING ASSEMBLY PARTS LIST Item No. Part No. Description Qty. 1 Adjustable Hitch 1 1 A Bradley Hitch Coupler CE 1 2 B Adjustable Coupler 2 Ball 1 3 A Tongue Handle 1 3 A Tongue Handle CE 1 4 B Safety Chain Assembly 2 5 A Brake Bracket 1 6 A Brake Lever Cap Screw, M8 x Hex Nut, Self-Locking, M Cap Screw, M12 x Washer, Flat, M Hex nut, Self-Locking, M Cap Screw, #5/8-11 x 4 3/ Washer, 5/ Hex Nut, Self-Locking, 5/ B Grommet, Marker Light 2 16 B Marker Light, Amber 2 16 A Marker Light, Square, White CE 2 17 B Washer, Flat, Brake Lever 1 18 B Clevis Pin, Brake Lever 1 19 B Cotter Pin, Brake Lever 1 21

24 FRONT REST ASSEMBLY

25 FRONT REST ASSEMBLY PARTS LIST Item No. Part No. Description Qty. 1 A Front Rest Weldment Cap Screw, M12 x Hex Nut, Self-Locking, M A Front Rest Pad Cap Screw, M10 x Hex Nut, Self-Locking, M A Boom Latch Cap Screw, M10 x A Switch Bracket Cap Screw, M6 x Hex Nut, Self-Locking, M A Switch Cam Machine Screw, #4-40 x Hex Nut, Self-Locking, # B Limit Switch Assembly, NO (Female) 1 16 B Limit Switch Assembly, NC (Male) Machine Screw, #6-32 x 1 1/ Hex Nut, Self-Locking, # A Tension Spring 1 20 A Jack Assembly 1 21 A Attach Plate Cap Screw, M10 x A Axle Cotter Pin, 1/8 1 1/ Washer, Flat, M A Tire and Wheel Assembly 2 27 A Jack Weldment Cap Screw, M12 x 75 1 A Tongue Tube Weldment CE 2 A Bike Catcher Weldment CE Cap Screw, M12 x Cap Screw, M12 x Hex Nut, Self-Locking, M

26 BRAKE AND AXLE ASSEMBLY

27 BRAKE AND AXLE ASSEMBLY PARTS LIST Item No. Part No. Description Qty. 1 A Axle US/CAN 1 1 A Axle CE 1 2 A Fender 2 3 A Equalizer Bracket 1 4 A Fender Mount Left 1 5 A Fender Mount Right Cap Screw, M10 x Hex Nut, Self-Locking, M Cap Screw, M10 x Cap Screw, M8 x A Brake Cable Mount Hex Nut, Self-Locking, M A Cable Assembly Parking Brake Cap Screw, M16 x Washer, M Hex Nut, Self-Locking, M B Brake Assembly Left 1 17 B Brake Assembly Right 1 18 B Brake Drum and Wheel Hub Assembly 2 19 B Wheel Assembly 75 R15D 2 19 A Wheel Assembly ST R16C CE Lug Nut, 1/2-20, Chrome Lug Nut CE 10 MECHANICAL BRAKE ASSEMBLY CE A Brake Link Weldment CE 1 A Brake Link Rod CE 2 A Brake Link Coupler CE 1 A Brake Cable Guide 1 A Bolt, M10 x 50 1 A Brake Cable CE 1 A Brake Slide 2 25

28 SLEW RING ASSEMBLY

29 SLEW RING ASSEMBLY PARTS LIST Item No. Part No. Description Qty. 1 A Slew Assembly and Adapter 1 2 Slew Ring 1 3 Slew Ring Drive 1 4 A Base Ring Adapter Cap Screw, 1/2-13 x Lock Washer, 1/ Flat Head Cap Screw, M16 x Flat Head Cap Screw, M16 x Cap Screw, 5/8-11 x 2-3/4, Grade Hex Nut, Self-Locking, M A Rotation Stop Assembly Cap Screw, M12 x Hex Nut, Self-Locking, M

30 LIMIT SWITCH ASSEMBLY

31 LIMIT SWITCH ASSEMBLY PARTS LIST Item No. Part No. Description Qty. 1 A-01190L Switch Plate Left 1 2 A-01190R Switch Plate Right Cap Screw, M10 x B Limit Switch NO 1 5 B Limit Switch NC 1 6 A Switch Cam Weldment 1 7 A Switch Cam Top Slide Flat Head Cap Screw, M8 x A Tension Spring Cap Screw, M6 x Hex Nut, Self-Locking, M Cap Screw, M6 x Machine Screw, #10-24 x 5/ Hex Nut, Self-Locking, # Cap Screw, M8 x A Switch Slide (Not Pictured) Hex Nut, Self-Locking, M Cap Screw, M10 x A Jib Slide Pad Hex Nut, Self-Locking, M

32 CONTROL COMPARTMENT ASSEMBLY

33 CONTROL COMPARTMENT ASSEMBLY PARTS LIST Item No. Part No. Description Qty. 1 A Lower Control Box 1 2 A Lower Control Mount 1 3 A Cover Stop Bracket Cap Screw, M10 x Hex Nut, Self-Locking, M A Level Sensor Cap Screw, M6 x Hex Nut, Self-Locking, M A Mount Plate GFI Outlet 1 10 A Motor Controller 1 11 B Battery Charger 1 12 A Gas Spring Stud Ball, 10mm Hex Nut, Self-Locking, 5/ A Turntable Weldment 1 16 B Outlet Box 1 17 B GFI Outlet 1 18 B Outlet Box Cover Cap Screw, M6 x A Plastic Cover 1 31

34 PUMP COMPARTMENT ASSEMBLY

35 PUMP COMPARTMENT PARTS LIST Item No. Part No. Description Qty. 1 A Tire Iron/Jack Handle 1 2 B Clamp Cap Screw, M6 x Hex Nut, Self-Locking, M6 4 5 A Cover Stop Bracket Cap Screw, M6 x Cap Screw, M10 x

36 BATTERY COMPARTMENT ASSEMBLY

37 BATTERY COMPARTMENT ASSEMBLY PARTS LIST Item No. Part No. Description Qty. 1 A Battery Box Weldment Left 1 2 A Battery Box Weldment Right 1 3 A Battery Hinge Pin Washer, Flat, M Cotter Pin 4 6 A Battery Clamp Cap Screw, M8 x Hex Nut, Self-Locking, M8 8 9 A Battery Box Latch 2 10 A Motor Cover 1 11 A Latch Plate 2 12 A Spacer Cap Screw, M8 x A Tension Spring 2 15 A Nose Weldment Cap Screw, M10 x Hex Nut, Self-Locking, M A Ramp, Short Flat Head Cap Screw, M6 x Hex Nut, Self-Locking, M A Grommet 4 22 B Clamp 2 23 B A-Frame Handle, Connector 1 24 B Plug, Connector 1 25 A Battery Cable Kit 1 26 B Terminal Boot Black 4 27 B Terminal Boot Red 4 28 A Battery Hex Nut, 3/

38 COVER ASSEMBLY

39 COVER ASSEMBLY PARTS LIST Item No. Part No. Description Qty. 1 A Cover Left 1 2 A Cover Right 1 3 A Cover Brace 2 4 A Hinge Cap Screw, M6 x Hex Nut, Self-Locking, M Pop Rivet 22 8 A Controls Cover Left Side w/hinge 1 9 A Cover Latch Assembly 2 37

40 LOWER BOOM ASSEMBLY

41 LOWER BOOM ASSEMBLY PARTS LIST Item No. Part No. Description Qty. 1 A Lower Boom Weldment 1 2 A Lower Link Weldment 1 3 A Lift Cylinder 1 4 A Boom Latch Cap Screw, M10 x Hex Nut, Self-Locking, M A Rest Pad Cap Screw, M10 x A Pin, 1.25 x A Pin Retainer, A Pin, 1.5 x A Bearing 2 39

42 TRIANGLE WELDMENT ASSEMBLY

43 TRIANGLE WELDMENT ASSEMBLY PARTS LIST Item No. Part No. Description Qty. 1 A Triangle Weldment 1 2 A Master Cylinder 1 3 A Lift Cylinder 1 4 A Pin, 1.25 x A Pin Retainer, Cap Screw, M10 x Hex Nut, Self-Locking, M A Pin Retainer, A Pin, 1.0 x A Switch Block Cap Screw, M8 x Hex Nut, Self-Locking, M A Pin Retainer, 1.0 FH 1 14 A Pin, 1.0 x 7.0, DB 1 15 A Bearing 4 16 A Pin, 1.25 x Flat Head Cap Screw, M10 x

44 42 UPPER BOOM ASSEMBLY

45 UPPER BOOM ASSEMBLY PARTS LIST Item No. Part No. Description Qty. 1 A Upper Boom Weldment 1 2 A Telescopic Boom Tube 1 3 A Extension Cylinder 1 4 A Slider Cap Screw, M10 x Hex Nut, Self-Locking, M Flat Head Cap Screw, M16 x A Wear Pad 12 9 A Wear Pad Shim UHMW Bolts, M10 x A Tube Slider 1 12 A Tube Slider Back Cap Screw, M10 x A Boom Latch Hook 1 15 A Cable Track Tube 1 16 A Cable Track Tray 1 17 A Cable Track, Dual Piece Mounting, Both Ends (Prior to June 2010) 1 17A A Cable Track, Single Piece Mounting, Both Ends (June 2010 onwards). Also uses: M8 x 25 Flat Head Cap Screw (Qty of 2) to attach to Item Cap Screw, M8 x 20 (Qty used decreases by 6 when 17A is used) Hex Nut, Self-Locking, M8 (Qty used decreases by 4 when 17A is used) 20 A Pin, 0.75 x A Pin Retainer, Cap Screw, M10 x A Cable Support Tube 1 24 A Cable Slide Block

46 JIB BOOM ASSEMBLY

47 JIB ASSEMBLY PARTS LIST Item No. Part No. Description Qty. 1 A Jib Link Weldment 2 2 A End Pivot Weldment 1 3 A Jib Cylinder 1 4 A Slave Cylinder 1 5 A Jib End Weldment 1 6 A Bulkhead Left Cap Screw, M10 x Hex Nut, Self-Locking, M Flat Head Cap Screw, M10 x A Pin Retainer, 1.0, Flat Head 2 11 A Pin, 1.0 x A Pin Retainer, A Pin, 1.0 x A Pin Retainer, A Pin, 0.75 x A Valve Guard 1 17 A Jib Bumper Flat Head Cap Screw, M10 x B Outlet Box 1 20 B GFI Outlet 1 21 B Outlet Box Cover Cap Screw, M6 x Hex Nut, Self-Locking, M A Boom End Weldment 1 25 A Bearing 2 26 A Ramp, Flat Head Cap Screw, M6 x Cap Screw, M12 x Hex Nut, Self-Locking, M

48 PLATFORM ASSEMBLY

49 PLATFORM ASSEMBLY PARTS LIST Item No. Part No. Description Qty. 1 A Platform Weldment 1 2 A Platform Control Box 1 3 A Upper Control Box Mount Cap Screw, M10 x Hex Nut, Self-Locking, M A Control Box Latch Rivet 2 8 A Spool Flat Head Cap Screw, M6 x A Midrail End Cap Screw, M6 x Socket Head Cap Screw, M6 x Hex Nut, Self-Locking, M A Midrail 1 15 A Manual Mounting Plate 1 16 A Manual Storage Box 1 17 A Pin 1 18 A License Bracket 1 19 A Tail Light Box 2 20 B Grommet, Marker Light 2 21 B Marker Light, Red 2 22 B Grommet, Tail Light 2 23 B Tail Light 2 24 B License Plate Lamp Cap Screw, M6 x Cap Screw. M6 x TAIL LIGHT ASSEMBLY CE A Light Bracket Articulating Lift CE 1 A Light Package CE 1 47

50 48 PUMP ASSEMBLY (A-02254)

51 PUMP ASSEMBLY PARTS LIST Item No. Part No. Description Qty. 1 B Manifold, Valve Housing 1 2 B Valve, Cartridge 2 3 B Manual Pump, Extend/Retract/Rotate 1 4 B Valve, Cartridge 1 5 B Valve, Cartridge 2 6 B Valve, Check 1 7 B Valve, Check 1 8 B Valve, Proportional 1 9 B Coil Sterling, Proportional Valve 1 10 B Valve, Counterbalance 1 11 B Valve, Relief 1 12 B Valve, Shuttle 1 13 B Valve, Cartridge 1 14 B Valve, Counterbalance 2 15 B Valve, Cartridge 1 16 B Valve, Relief 1 17 B Fitting, Plug, #2 ORB B Fitting, Hex Plug 1 19 B Fitting, Plug, #4 ORB 5 20 B Coil, 20 VDC 5 21 B Coil, 20 VDC 4 22 B Stud, #1/4-20 x 5/ B Expansion Plug 1 24 B Fitting, Plug, #6 ORB 2 25 B Seal Ring 1 49

52 50 PUMP ASSEMBLY, CONTINUED

53 PUMP ASSEMBLY PARTS LIST, CONTINUED Item No. Part No. Description Qty. 1 B Reservoir 1 2 B Pump Assembly, 3.15CCM 1 3 B Motor, Pump, 24 V DC 1 4 B Coupling,.875 x B Filter, Hydraulic 1 6 B Sight Glass 1 7 B Socket Head Cap Screw, M8 x B Fitting, Plug, M14 x 1.5 x B Seal Ring 1 10 B Clamp, Band, # B Filter, Suction, Pump 1 12 B Allen Nut, 1/ B Fitting, M18 x HB-90 MxHB B O-Ring, x 3.53 NBR 70D 1 15 B Fitting, JIC-8 x Push On FsxPO 2 16 B Hose, Black, 1/2 x B Fitting JIC-8 x #6 90 MxM 1 18 B Cap Screw, #5/16-18 x 1 1/ B Fitting, JIC-8 x G 3/4 MxM 1 20 B Fitting, Plug, #12 ORB 2 21 B Fitting, 3/8 NPT x 1/2 MxHB 1 22 B Hose, Black, 1/2 x

54 BOOM AND ROTATION HYDRAULIC LINES 12 Slave Basket Level RET EXT Master Basket Level EXT RET Telescopic Jib RET RET EXT RET EXT Lower Lift RET EXT Upper Lift EXT PRA TP SMA 45 PRB SMB 45 BCB ECA 45 BCA 2 Top Port Bottom Port 45 ECB Rotation Kinematics Slew Drive 45 ORA ORB 45 Outrigger Ret Outrigger EXT

55 BOOM AND ROTATION HYDRAULIC LINES PARTS LISTS Item No. Part No. Description 1 B #4 x 36 Hydraulic Hose 2 B #4 x 36 Hydraulic Hose 3 B #4 x 240 Hydraulic Hose 4 B #4 x 240 Hydraulic Hose 5 B #6 x 276 Hydraulic Hose 6 B #6 x 276 Hydraulic Hose 7 B #6 x 22 Hydraulic Hose 8 B #4 x 22 Hydraulic Hose 9 B #4 x 15 Hydraulic Hose 10 B #4 x 384 Hydraulic Hose 11 B #4 x 384 Hydraulic Hose 12 B #4 x 16 Hydraulic Hose 13 B #4 x 16 Hydraulic Hose 14 B #6 x 20 Hydraulic Hose 15 B #4 x 20 Hydraulic Hose 16 B #6 x 222 Hydraulic Hose 17 B #4 x 222 Hydraulic Hose 18 B #6 x 20 Hydraulic Hose 19 B #4 x 20 Hydraulic Hose 20 B #6 x 390 Hydraulic Hose 21 B #6 x 54 Hydraulic Hose 22 #4 x 390 Hydraulic Hose 23 #4 x 54 Hydraulic Hose 24 B #3 x 32 Hydraulic Hose FITTINGS Part No. Description Qty. B #6 MORFS - #6 MORB, STR 9 B #6 MORFS - # 6 MORB, 45º 6 B #6 MORFS - #6 MORB, 90º 3 B #4 MORFS - #6 MORB, STR 2 B #6 MORFS - #10 MORB, 45º 2 B #6 MORFS, Tee 4 B #6 MORFS - #6 MORFS - #6 MORB, Tee 1 B #4 MORB - #2 MNPT, STR 1 B #6 MORFS - #6 MORFS, 90º 1 B #2 QD Plug 1 B #2NPTFM Coupling 1 53

56 OUTRIGGER HYDRAULIC LINES EX T RET RET RET EX T EX T RET EXT RET EX T 2 OUTRIGGER HYDRAULIC LINES PARTS LIST Item No. Part No. Description Qty. 1 B #4 x 40 Hydraulic Hose 4 2 B #4 x 40 Hydraulic Hose 4 3 B #6 x 55 Hydraulic Hose 1 4 B #6 x 55 Hydraulic Hose 1 5 B #6 x 31 Hydraulic Hose 1 6 B #6 x 31 Hydraulic Hose 1 7 B #6 x 54 Hydraulic Hose 1 8 B #6 x 54 Hydraulic Hose 1 9 B Fitting, Tee, #6 MORFS 6 10 B Fitting, #6 MORFS - #6 MORB 8 54

57 WIRE HARNESSES ML RH Tailight G Y B W LH Tailight LP ML Load Hot Line White Platform GFI Load Hot Line Base GFI White B Upper Control Box F D E A C Motor Cntl B+ Motor Cntl B- Wh Bla Re Blu Or Gr A A Amp Housing Black A A Amp Housing Black A Amp Housing White X Y R B O Br + - Strobe Level Sensor + Prim Cyl Coil - PLT DN PLT UP Prop Coil Chk Valve Sec Cyl Coil Rot CCW Rot CW Boom RET Boom EXT OR EXT OR RET Jib Cyl Coil Pump W B Y G LF Coil LR Coil RF Coil RR Coil LF NO 3 1 Speed Enable B- M- B+ Motor Controller ML RF NO ML Tail Lights L N IEC Recp. Boom Down Relay NC Jib Down NO Jib Down NC LR NO RR NO A2E2 D1E1 Pump Motor Boom Down NO Boom Down NC 55

58 PLATFORM WIRE HARNESS (A-02714) ITT CA3101F18-12SF80 Connector Kit Pins Part of Kit Pin A Pin B Pin C Pin D Pin E Pin F Orange White Green Red Blue Black 61' 18/6 Cable For Cable Track Amp or FM Terminal Orange Pin 7 White Pin 3 Green Pin 9 Red Pin 8 Blue Pin 4 Black Pin 6 Amp Strain Relief AMP Plug Jacket of cable must be in strain relief A Rev Jacket of cable must be in strain relief Fill Strain Relief with Black RTV and wipe off excess ANALOG HARNESS (A-02715) Pin 1 AMP " 18 ga Pump Speed Signal ¼ FM Spade Insulated Label Part # & Rev Level Amp Pin 16 36" 18 ga Motor Cntrl Enab ¼ FM Spade Insulated Amp Housing Black Pin 9 Pin 10 12" 18 ga 12" 18 ga Pin 8 18" 18 ga Pin 15 18" 18 ga Pin 22 18" 18 ga Pin 23 18" 18 ga Ground Engine Run + Level Sensor +24 Level Sensor GND Level Sensor X Level Sensor Y A B C D Weather Pack B A Weather Pack M Term Green Seal Weather Pack M 4 Pos housing Mates With A B C D 10" Loom B A A B C D Level Sensor 22" Loom Pump Speed Signal Motor Cntrl Enab 15" Loom Weather Pack M Term Green Seal 56

59 PUMP AND CYLINDER WIRE HARNESS (A-02716) 57

60 58 OUTRIGGER COIL WIRE HARNESS (A-02717)

61 POWER HARNESS (A-02718) AMP Or Pin 1 12ga Red 40" Batt Pos 5/16" Ring Terminal AMP 3 Pin Housing AMP Cable Clamp A Rev. AMP AMP Or Pin 2 12ga Black 40" Batt Neg 5/16" Ring Terminal Fill Strain Relief with RTV then put on cable clamp and wipe off excess Bundle wires in 30" of loom. Tape both ends if split loom is used 110 VAC TOWER-PLATFORM HARNESS (A-02722) Delphi Weather Pack 3 Pin Male Housing Male Terminal Green cable seal A B SDN Color Code Red Black Hot Neutral Label 110V AC 60' 14-3 SDN or Equivalent Label 110V AC C Blue GND TAIL LIGHT TURNTABLE-PLATFORM HARNESS (A-02723) Weather Pack 4 pin Male Housing Male Terminal Green Cable Seal Weather Pack 4 pin Male Housing Male Terminal Green Cable Seal A-White B-Black C-Red D-Green Label Tail Light 60' 18-4 SJO or Equivalent Label Tail Light A-White B-Black C-Red D-Green 59

62 SECONDARY CYLINDER WIRE (A-02724) Delphi Weather Pack 2 Pin Female Housing Female Terminal Green Wire Seal A B W B Sec Cyl Wire 23'6" 18-2 SJO or Equivalent Label Both ends Sec Cyl Wire Delphi Weather Pack 2 Pin Male Housing Male Terminal Green Wire Seal W B A B JIB WIRE (A-02725) Delphi Weather Pack 2 Pin Female Housing Female Terminal Green Wire Seal A B W B JIB Wire 60' 18-2 SJO or Equivalent Label Both ends JIB Wire W B Delphi Weather Pack 2 Pin Male Housing Male Terminal Green Wire Seal A B 110 VAC TRAILER-TOWER HARNESS (A-02726) Delphi Weather Pack Female Terminal B Delphi Weather Pack Gray seal B ¼ Female Spade Blue A Red White B Black Black 8'6" 14-3 SDN or SJO C Blue Green SDN SJO Trailer End Assy A ICE Rec. L N Blue Red Black W G B 60

63 MARKER LIGHT WIRE HARNESS (A-02153) (62") 5' 0" Braided Loom & Heat Seal 6" Westbar Wire Plug Delphi Weather Pack Cable Seal Green Delphi Weather Pack Female Terminal Lower Harness 4Pin Flat Plug W Br Y G Wires need to be Molded together 22' 0" Label Tail Lights A B C D Delphi Weather Pack Pos Female Housing TAIL LIGHT WIRE HARNESS (A-01246) 61

64 MATERIAL LIFT HOOK ASSEMBLY (OPTION A-01846) MATERIAL LIFT HOOK PARTS LIST Item No. Part No. Description Qty. 1 A Material Lift Weldment 1 2 A Lift Hook Storage Bracket 1 3 A Bracket Clamp 1 4 A Pin 1 5 A Lift Hook Assembly 1 6 A Ramp, Short Flat Head Cap Screw, M6 x Hex Nut, Self-Locking, M Cap Screw, M10 x Hex Nut, Self-Locking, M Cap Screw, M12 x Hex Nut, Self-Locking, M12 1 A Load Sense Module (Not Pictured) 1 62

65 WATER LINE TO PLATFORM (OPTION A-02701) Part No. B B B B B Description #6 x 146 W/1-6-6FMP, 1-6-6MP 3000 PSI Pressure Washer Hose #6 x 628 W/2-6-6MPSW 3000 PSI Pressure Washer Hose #6 x 78 W/1-6-6FMP, 1-6-6MP 3000 PSI Pressure Washer Hose Fitting, QD E Series FM-#6FMNPT Fitting, QD E Series M-#6FMNPT AIR LINE TO PLATFORM (OPTION A-02700) Part No. B B B B B B B B B B Description #6 x 146 W/1-6-6FMPSW, 1-6-6MP 300 PSI Air Hose #6 x 628 W/2-6-6MP 300 PSI Air Hose #6 x 78 W/1-6-6FMPSW, 1-6-6MP 300 PSI Air Hose Fitting, #6FMNPT-#4FMNPT STR Fitting, Univ QD FM-#4MNPT Fitting, QD IND Series M-#4MNPT Fitting,QD ARO Series M-#4MNPT Fitting, Univ QD FM-#6FMNPT Fitting, QD DF Series M-#6FMNPT Fitting, QD J Series M-#6FMNPT 63

66 64 DC/GAS HYBRID WIRE HARNESS (OPTION)

67 BATTERY LAYOUT Motor Controller 0-5V Enable 3 1 B- M- B AMP Fuse Motor 5533A BATTERY LAYOUT (Kit A-02272) Item No. Description 1 32 Red, 2 Gauge, 5/16 Ring Lug 2 45 Black, 2 Gauge, 5/16 Ring 5/16 Ring 3 8 Black, 2 Gauge, 5/16 Ring 5/16 Ring 4 20 Black, 2 Gauge, 5/16 Ring Lug 5 28 Black, 2 Gauge, 5/16 Ring Lug 6 60 Black, 2 Gauge, 5/16 Ring Lug 7 30 Red, 2 Gauge, 5/16 Ring 5/16 Ring 8 48 Red, 2 Gauge, 5/16 Ring 5/16 Ring 9 45 Black, 2 Gauge, 5/16 Ring 5/16 Ring Black, 2 Gauge, 5/16 Ring 5/16 Ring 65

68 66 AUXILIARY BATTERY PACK LAYOUT (OPTION A-03413)

69 BRAKE CABLE CE " (+.25/-.00) M10x1.5 Threaded Stud End Thread length 5" 5" Thread Strand 1/8 124" (+.00/-.25) 5" Thread M10x1.5 Threaded Stud End Thread length 5" TRAILER LIGHT WIRE HARNESS CE UK & Europe Trailer Plug Auto Warehouse (autow.co.uk) MP247Pin Metal Plug Pin 1 White w/bl Pin 2 Blue Pin 3 White Pin 4 Green ¼ Female Spade Deutsch 8 Pin Receptacle DT06-8S Wedge W8S Socket Jacket must be tightened under Strain Relief A Rev. Pin 5 Pin 6 Pin 7 Extra Red w/bl Red Black Orange Red w/bl White Black 8" 18-8 White w/bl Blue White Green Red w/bl Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Label Strip 6" of jacket to access wires 8" Red Pin 6 Black Pin 7 Orange Pin 8 62" ¼ Female Spade Strip wires 2" 268" TAIL LIGHT WIRE HARNESS CE Deutsch 8 Pin Receptacle DT04-8P Wedge W8P Pin Deutsch 8 Pin Receptacle DT04-8P Wedge W8P Pin Pin 1 White w/bl White w/bl Pin 1 Pin 2 Blue Blue Pin 2 Pin 3 White White Pin 3 Pin 4 Pin 5 Green Red w/bl A Rev 16-8 A Rev Green Red w/bl Pin 4 Pin 5 Pin 6 Red Red Pin 6 Pin 7 Pin 8 Black Orange Label Both ends Black Pin 7 Orange Pin 8 Strip wires 2" Strip wires 2" 720" 67

70 68

71 ORDERING REPLACEMENT PARTS To order replacement parts, contact the Haulotte Group BilJax Service Department by phone at , by fax at or by at For swift service, always have the part number available, as well as the equipment model and serial number. When ordering parts by fax or , always provide the above information. QUICK REFERENCE Equipment Model: Haulotte Group BilJax 5533A Articulating Boom Lift Serial Number: NOTES 69

72

73 HAULOTTE GROUP BILJAX MODEL 5533A 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 NOTES 71

74 Distributed by: 125 Taylor Parkway Archbold, OH Phone (419) (800) Fax (419)