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TABLE OF CONTENTS
Table of Contents
Illustrations
Tables
1
2
2
1 Safety
3
Before Operation
4
4
5
7
8
During Operation
Maintenance Safety
Damaged Equipment Policy
Reporting Safety Defects
2 General Introduction
9
Specifications
Warranty
11
12
3 Operations
13
Ground Control Station
Platform Control Station
Normal Operating Procedure
Manual Boom Operations
Battery Recharge
14
16
18
20
22
23
Boom Lift Transport
4 Operator Service
25
Daily Service Checks
Weekly Service Checks
Monthly Service Checks
Troubleshooting
26
27
27
28
29
Error Code Definitions
5 Replacement Decals
6 ANSI Reprint
33
35
41
45
7 Material Safety Data
8 Equipment Options
Material Lifting Hook
Horizontal Jib Rotator
Platform Rotator
46
47
47
48
49
Combination Hitch
Replacement Decals
1
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LIST OF ILLUSTRATIONS
Figure 2-1
Figure 2-2
Figure 2-3
Figure 3-1
Figure 3-2
Figure 3-3
Figure 3-4
Figure 3-5
Figure 3-6
Figure 3-7
Figure 3-8
Figure 3-9
Figure 4-1
Figure 4-2
Figure 4-3
Figure 5-1
Figure 6-1
Figure 8-1
Figure 8-2
Figure 8-3
Figure 8-4
Figure 8-5
Figure 8-6
Figure 8-7
Figure 8-8
Bil-Jax Model 3522A
9
10
10
14
16
18
18
20
21
21
22
23
26
26
27
34
39
46
46
47
47
47
48
49
49
Boom Lift Control Panel
Range of Motion
Ground Control Station
Platform Control Station
Outrigger Controls
Boom Travel Latch
Hand Pump and Controls for Manual Operation
Manual Lowering Valve
Manual Lowering Valve Locations
Battery Charger Faceplate
Trailer Hitching
Outrigger Position Switches
Hydraulic Reservoir
Wheel Nut Tightening Sequence
Decal Locations
Minimum Safe Approach Distances
Material Lifting Hook Configuration
Material Lifting Hook Installation
Ground Controls with Jib Rotator
Jib Rotate Buttons
Manual Platform Rotator
Combination Hitch Installation
Material Lifting Hook Decals
Optional Component Decal Locations
LIST OF TABLES
Table 1-1
Table 4-1
Table 4-2
Table 5-1
Table 8-1
Minimum Safe Approach Distances
4
28
29
33
49
Troubleshooting Steps
Error Code Definitions
Replacement Decal Descriptions
Replacement Decals
2
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1
SAFETY
Familiarity with all equipment and proper training are required for the
safe operation of any mechanical device. Attempting to operate any
mechanical equipment improperly or without training creates a situation
that is potentially hazardous. Prior to operation, read the instructions and
safety precautions included in this manual and attached to the lift.
Become familiar with the proper use of all controls. Inexperienced
operators should receive instruction before attempting to operate or
maintain the machine.
Always follow the safety procedures set forth in this manual as well as all
applicable ANSI, OSHA, state and local regulations. Persons under the
influence of drugs, alcohol or prescription medications should not be
allowed on or near this equipment. Do not operate in areas where the
machine or its operator may come into contact with a live power source.
The information contained herein is provided to alert Bil-Jax customers to
the normal procedures for the operation and maintenance of the Bil-Jax
Model 3522A Articulating Boom Lift. This information is not intended to
be all-inclusive, nor is it to be considered legal advice. These procedures
are to be followed in the care and maintenance of the named Bil-Jax
equipment only.
For any questions concerning the safe use of this equipment, contact the
Bil-Jax Service Department at 800-537-0540 before attempting
operation.
The use of intelligence and common sense is the best practice in
following any safety policy.
SAFETY NOTICES
This manual contains a variety of notices that must be observed to
prevent the possibility of improper service, personnel injury or death, or
damage to the equipment.
DANGER
Warns of operation near electrical power sources that could lead to
personal injury or death.
WARNING
Describes conditions or practices that could lead to personal injury
or death.
CAUTION
Contains information important in the prevention of errors that
could damage machine or components.
NOTE: Contains additional information important for performing a
procedure.
3
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BIL-JAX 3522A
BEFORE OPERATION
DURING OPERATION
Ensure the following general safety precautions are
followed before operating the Bil-Jax Model 3522A
Articulating Boom Lift:
Ensure the following general safety precautions are
followed during the operation of the Bil-Jax Model
3522A Articulating Boom Lift:
ALWAYS survey the usage area for potential
hazards, such as untamped earth fills, unlevel
surfaces, overhead obstructions and electrically
charged conductors or wires. Maintain awareness of
any potential hazards. ALWAYS watch for moving
vehicles in the operating area.
ALWAYS position lift away from power sources to
ensure that no part of the lift can accidentally reach
into an unsafe area. This includes full extension of
the boom through 700 degrees rotation.
DANGER
This machine is not insulated for use near
electrical power lines and DOES NOT provide
protection from contact with or close proximity
to any electrically charged conductor. Operator
must maintain safe clearances at all times (10
feet/3.05 meters minimum) and always allow for
platform movement such as wind-induced sway.
Always contact the power company before
performing work near power lines. Assume every
power line is live. Remember, power lines can be
blown by the wind. Refer to Table 1-1 for
ALWAYS read, understand and obey the procedures
set forth in this manual before attempting to operate
equipment.
ALWAYS inspect the equipment for damaged or
worn parts. Check for cracked welds, hydraulic
leaks, damaged wiring, loose wire connectors,
damaged outriggers, low tire pressure, uneven tire
wear or tire damage. Check for any improperly
operating components. NEVER operate equipment if
any damage is present or suspected. Damaged or
malfunctioning equipment must be repaired before
operation.
minimum safe approach distances between the
machine and electrical power lines.
ALWAYS wear proper clothing. Wear protective
equipment as required by federal, state and local
regulations. Keep loose clothing, jewelry, gloves and
hair away from moving parts.
Table 1-1. Minimum Safe Approach Distances
Minimum Safe Approach Distance
Voltage Range
(Phase to Phase)
0 to 300V
(Feet)
(Meters)
Avoid Contact
ALWAYS wear a safety harness and lanyard.
Over 300V to 50KV
10
15
20
25
35
45
3.05
4.60
ALWAYS locate, read and obey all directions and
warnings displayed on the equipment.
Over 50KV to 200KV
Over 200KV to 350KV
Over 350KV to 500KV
Over 500KV to 750KV
Over 750KV to 1000KV
6.10
ALWAYS inspect the equipment for DO NOT USE tags
placed by previous operators or maintenance
personnel. NEVER use equipment tagged in this
way until all repairs are made and all DO NOT USE
tags are removed by authorized personnel.
7.62
10.67
13.72
ALWAYS operate only on a firm and level surface.
NEVER operate equipment on surfaces that do not
support the equipment with its rated load capacity or
on surfaces that do not support force exerted on the
outriggers during boom extension and rotation.
ALWAYS inspect the platform and the outrigger
footpads for mud, grease, or other slippery material.
ALWAYS remove any such material from the
equipment to reduce the possibility of slippage.
NEVER allow improperly trained personnel to
operate this equipment. Only trained and authorized
personnel shall operate this equipment.
ALWAYS keep personnel away from potential pinch
or shear points.
ALWAYS report any misuse of equipment to the
proper authorities.
NEVER operate this equipment while under the
influence of drugs or alcohol, while taking
prescription medications, while feeling ill or prone to
dizziness. Operators must be physically fit and
thoroughly trained.
ALWAYS maintain sure footing on the work platform.
ALWAYS wear proper footgear. NEVER wear shoes
with slippery or slick soles.
NEVER modify, alter or change the equipment in
any way that would affect its original design or
operation.
ALWAYS keep personnel and obstructions clear of
the machine when repositioning basket.
ALWAYS cordon the area surrounding the
outriggers to keep personnel and other equipment
away from the machine while in use.
NEVER operate equipment in any way for which it is
not intended.
4
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1 — SAFETY
ALWAYS stay clear of wires, cables and other
overhead obstructions.
MAINTENANCE SAFETY
Ensure the following safety precautions are
observed whenever maintenance is performed on
the Bil-Jax 3522A Articulating Boom Lift.
ALWAYS engage the boom travel latches before
towing the trailer.
NEVER allow electrode contact with any part of the
machine while welding from the platform.
General Maintenance
ALWAYS perform maintenance procedures
according too manufacturer's guidelines. NEVER
disregard or bypass proper maintenance
procedures.
NEVER use without the outriggers fully extended
and firmly based.
NEVER override or bypass the manufacturer's
safety devices.
ALWAYS inspect hydraulic system to ensure that all
lines, connectors and fittings are properly fastened
and in good condition.
NEVER attach a safety harness to an adjacent
structure, pole, or to nearby equipment while
working from the boom platform.
ALWAYS turn the key switch OFF before performing
maintenance on valve solenoids or other electric and
electronic devices.
NEVER raise the outriggers or move the trailer with
materials or personnel on board, or while the boom
is raised or extended.
ALWAYS disconnect power to the hydraulic pump
drive motor before making electrical checks of the
hydraulic valves.
NEVER sit, stand or climb on cage bars. ALWAYS
keep both feet firmly on work cage floor when
working from the elevated platform.
ALWAYS keep all mechanical parts properly
adjusted and lubricated according to maintenance
schedule and manufacturer’s specifications.
NEVER attempt to increase working height with
boxes, ladders, stools or any other materials.
ALWAYS perform a function check of operating
controls before each use and after repairs have
been made.
NEVER operate this equipment when exposed to
high winds, thunderstorms, ice or any other weather
conditions that would compromise operator safety.
ALWAYS locate and protect against possible pinch
points prior to performing maintenance and repairs.
NEVER allow ropes, electric cords, hoses or other
equipment to become entangled in the machine
while raising or lowering the platform.
ALWAYS use factory-approved parts to repair or
maintain equipment. If any portion of this equipment
is rebuilt or repaired, retesting is required in
accordance with factory instructions.
NEVER exceed the load limits set by the
manufacturer. Use only the Material Lifting Hook,
supplied as an option and manufactured by Bil-Jax,
when lifting materials. Safely stow all tools and
equipment.
ALWAYS maintain a safe distance while testing the
hydraulic components. NEVER test or operate the
hydraulic components while personnel are near the
equipment.
NEVER exceed load ratings by transferring loads to
the lift at elevated heights.
NEVER allow water or foreign particles into the DC
electric motor housing. Inclusion of water or foreign
particles may cause serious damage to the motor. If
the motor becomes wet, consult Bil-Jax Service
Department for proper drying instructions.
NEVER use cage to carry materials. NEVER allow
overhang of materials when raising or lowering the
platform.
NEVER use the boom or platform to push or pull or
to lift any part of the trailer.
NEVER add unauthorized fluids to the hydraulic
system or battery. NEVER mix hydraulic oils.
Consult manufacturer specifications. Refer to
Section 4 for hydraulic system maintenance
instructions.
NEVER use the boom or platform to place a load
against any structure, materials, or equipment.
NEVER climb on the boom. In the case of power
failure or equipment malfunction, refer to the
instructions for manual operation.
NEVER exceed the manufacturer's recommended
relief valve settings.
NEVER leave the keys in the boom lift while
unattended or not in use.
NEVER touch or allow metal tools to contact any
electronic components that are sensitive to static
discharge. ALWAYS use static discharge prevention
mats and grounding devices when handling
electronic components.
5
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BIL-JAX 3522A
NEVER adjust, repair, replace or bypass any
hydraulic or electrical control or safety device. These
include, but are not limited to, hydraulic load control
and flow control valves, solenoid valves and limit
switches. Contact the Bil-Jax Service Department at
800-537-0540 if these components require
maintenance.
NEVER attempt repairs or maintenance without first
consulting manufacturer regarding proper
procedures.
Battery Maintenance
Ensure the following general safety precautions are
followed whenever performing battery maintenance
on the Bil-Jax Model 3522A Articulating Boom Lift:
ALWAYS check battery acid level daily.
ALWAYS wear safety glasses when working with or
near batteries.
ALWAYS avoid contact with battery acid. Battery
acid causes serious burns and should be kept away
from skin and eyes. If contact occurs, flush with
water and consult a physician immediately.
ALWAYS disconnect ground cable first when
removing battery.
ALWAYS connect ground cable last when installing
battery.
ALWAYS charge batteries in open, well-ventilated
areas.
NEVER smoke while servicing battery.
NEVER charge batteries near flammable materials.
NEVER allow batteries to overcharge and boil.
NEVER short across battery posts to check for
current. NEVER break a live circuit at the battery.
NEVER disconnect battery from charger while
charger is connected to a live power source.
NEVER jumpstart other vehicles using boom lift
battery.
6
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1 — SAFETY
DAMAGED EQUIPMENT POLICY
Safety Statement
At Bil-Jax, we are dedicated to the safety of all users of our products. All Bil-Jax
lifts are designed, manufactured and tested to comply with current applicable
federal OSHA and ANSI codes and regulations.
Damage Policy
There may be occasions when a Bil-Jax lift is involved in an incident that results
in structural damage to the lift. Such damage can seriously compromise the
ability of the lift to perform in a safe manner. Therefore, whenever a Bil-Jax lift is
damaged structurally or when there is suspected internal damage to the
structure, Bil-Jax may require that the lift be returned to our facility for
reconditioning. For any questions concerning structural damage or the Damaged
Equipment Policy, please contact the Bil-Jax Service Department at 800-537-
0540.
Damage Repair Notice
There may be occasions when a Bil-Jax lift is involved in an accident resulting in
damage to non-structural components. When such damage occurs and repairs
are made by the owner or area distributor, please notify Bil-Jax of these non-
maintenance repairs and request a repair form to be filled out and returned to Bil-
Jax.
7
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BIL-JAX 3522A
Bil-Jax, Inc.
125 Taylor Parkway
Archbold, Ohio 43502
800-537-0540
REPORTING SAFETY DEFECTS
If you believe that your vehicle has a defect that could cause a crash or could
cause injury or death, you should immediately inform the National Highway
Traffic Safety Administration (NHTSA) in addition to notifying Bil-Jax, Inc.
If the NHTSA receives similar complaints, it may open an investigation, and if it
finds that a safety defect exists in a group of vehicles, it may order a recall and
remedy campaign. However, the NHTSA cannot become involved in any
individual problems between operators, users, or lessors, and Bil-Jax, Inc.
To contact the NHTSA you may either call the Auto Safety Hotline toll-free at
800-424-9393 (366-0123 in the Washington, DC area) or write to:
NHTSA
U.S. DEPARTMENT of TRANSPORTATION
400 7th Street SW (NSA-11)
Washington, DC 20590
You can also obtain other information regarding motor vehicle safety by calling
the Hotline.
8
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2
GENERAL INTRODUCTION
The Bil-Jax 3522A Articulating Boom Lift (Figure 2-1) is a Summit
Series™ Trailer-Mounted Boom, designed and manufactured to position
personnel with their tools and equipment at overhead work locations.
The work platform load capacity is rated at 500 pounds. During all boom
operations, four extended outriggers support the unit.
The boom lift is battery powered and operated with electronic pushbutton
controls, a hydraulic power unit, a hydraulic gear motor and hydraulic
cylinders. The hydraulic power unit includes a reservoir, pump and
control valves. Three hydraulic cylinders elevate the lower boom, upper
boom and jib boom. A fourth cylinder extends a telescopic boom. A
master and slave cylinder maintain the work platform at level while
raising and lowering the boom. The hydraulic motor and mating worm
gear allow the boom to rotate 700º around a vertical axis.
TELESCOPIC
BOOM
UPPER BOOM
TRAILER HITCH
ASSEMBLY
JIB BOOM
3522A
LOWER
BOOM
TURNTABLE
PUMP COMPARTMENT
BATTERY COMPARTMENT
GROUND CONTROLS
Figure 2-1. Model 3522A Articulating Boom Lift
9
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BIL-JAX 3522A
The hydraulic power unit uses a 24 Volt, one
horsepower DC motor to drive the hydraulic pump.
The DC motor is powered by four 6 Volt DC, 245
Amp-hour deep charge batteries connected in
series. A 25 Amp, automatic onboard battery
charger is provided with standard models for
recharging the batteries at the end of each work
period.
Two control panels (Figure 2-2) use pushbutton
switches and hydraulic valves to control the direction
and speed of boom lift and rotation. One set of
operator controls is provided for ground operation
and another set is provided for operation from the
platform. Elevation and rotation controls are
operational only when the outriggers are correctly
extended and the moving boom section is within a
programmed safe operating zone.
Figure 2-3. Range of Motion
Outrigger load sensing switches and level sensing
interlocks prevent all platform boom operations until
the four outriggers are properly extended, the trailer
is level and the full weight of the boom lift is loaded
onto the outriggers. A boom-raised interlock
Figure 2-2. Boom Lift Control Panel (Ground)
prevents outrigger operation until the platform boom
is fully lowered to the stowed position.
The ground and platform control panels include
CHOKE and START buttons for use with boom models
equipped with an optional DC/gasoline hybrid
generator for continuous duty. Battery condition
indicators show the charge state of the batteries.
When pressed, a STOP button at each control panel
immediately stops all boom motions. The ground
control panel includes a lighted text window that
displays the present operating status or an existing
error condition. The platform control panel includes a
horn button that sounds an audible alarm when
pressed.
Safety devices prevent the boom from retracting
suddenly in the event of a hydraulic hose or system
failure. It is strongly recommended that no one
adjust or tamper with these safety devices. If service
is required, please notify Bil-Jax for instructions.
Each cylinder rod is fully immersed in oil to prevent
rust or corrosion of the cylinders during storage. It is
important that the cylinder rods be kept clean and
undamaged for the protection of the cylinder head
packings.
Boom elevation, extension and rotation speeds are
selected from low to high by SPEED buttons. The lift
and extension cylinders have load-holding valves in
the base of each cylinder in case of a hydraulic hose
failure.
In the event of power loss, control system failure or
other malfunction, all boom movement functions may
be accomplished by manual operations.
Manual lowering of the platform is performed by
actuating valve plungers found on the base of each
boom lift cylinder. Pushing and holding each valve
retracts the corresponding boom lift cylinder. The
boom may need to be rotated to a clear area before
lowering.
Only one boom motion is permitted at a time and
only as long as the boom is within the safe operating
zone (Figure 2-3). When a selected boom motion
exceeds a safe operating limit, the boom motion
ceases and another boom motion must be selected
within the safe operating zone.
Manual boom retraction and turntable rotation are
accessed inside the pump compartment. The hand
pump and selected valves on the hydraulic pump
unit are used for these functions.
10
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2 — GENERAL INTRODUCTION
SPECIFICATIONS
Boom Lift Work Platform
Model Number:
3522A
Serial Number______________________
Manufactured by: Bil-Jax, Inc.
125 Taylor Parkway
Archbold, Ohio 43502
800-537-0540
Feature
Model 3522A
43 ft 2 in (13.3 m)
37 ft 2 in (11.3 m)
Feature
Model 3522A
Working Height
Outrigger Footprint
Length
Maximum Platform Height
Maximum Horizontal Outreach
From Centerline
11 ft 1 in (3.4 m)
9 ft 11 in (3 m)
10 in (0.3 m)
Width
22 ft 6 in (6.9 m)
Footpad Diameter
From Outrigger Footpad Edge 17 ft 6 in (5.3 m)
Parking Brake
Towing Brake
Standard, Mechanical
Hydraulic Surge
Up and Over Height
19 ft (5.8 m)
Rated Platform Capacity
Tongue Weight
Total Weight
Turntable Rotation
Leveling Capability
Platform Dimensions
Height
500 lbs (227 kg)
190 lbs (86 kg)
3,080 lbs (1,397 kg)
700º Non-Continuous
12.5º
Rated Towing Speed
65 mph (105 km/h)
Tire Size
ST 205/75 R14C
24V DC
Control System
Battery
4 x 6V 245 amp-hr
Charger
110/120 Volt, 25 Amp
3,000 psi (20,684 kPa)
3.1 Gallons (11.7 L)
5.1 Gallons (19.3 L)
Dexron III/Mercon ATF
3 ft 7 in (1.1 m)
2 ft 6 in (0.8 m)
4 ft (1.2 m)
Hydraulic Pressure
Reservoir Capacity
Hydraulic System Capacity
Hydraulic Oil (Standard)
Length
Width
Stowed Dimensions
Height
6 ft 5 in (2.0 m)
16 ft 3 in (5.0 m)
5 ft 6 in (1.7 m)
Length
Platform Rotation/Type (Optional) 90º/Manual
Width
WARNING
The installation of some optional components may affect the
performance and capacities of the boom lift. Failure to obtain, read
and observe the safety precautions and rated capacities associated
with any optional component may result in damage to equipment,
serious injury or death.
11
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BIL-JAX 3522A
WARRANTY
Bil-Jax, Inc. warrants this product for one year, beginning on the date of delivery,
to be free from defects of material and workmanship provided the unit is operated
and maintained in compliance with the guidelines established in the Operations
and Maintenance Manuals. Major structural components, including trailer tongue
and boom weldments, are warranted for five years against defects due to
material or workmanship. Bil-Jax will, at its option, repair or replace any unit or
component part that fails to function properly during normal use.
The warranty does not apply if the lift and/or its components have been altered,
changed, or repaired without the consent of Bil-Jax. Repairs, damage, or defects
resulting from the following are not covered under the terms of the warranty:
negligence, misuse, accidental damage, inadequate or improper maintenance,
acts of nature, damage caused by chemicals or abrasive materials, and normal
wear and tear, such as rust or corrosion. Components not covered under this
warranty include tires, filters, covers, and routine maintenance items.
Components not manufactured by Bil-Jax are covered be their respective
manufacturer’s warranties. A list of those components and their warranties is
available upon written request to Bil-Jax.
Bil-Jax shall not in any event be liable for the cost of any special, indirect, or
consequential damages to any person, product, or thing. Bil-Jax’s maximum
liability under this warranty is limited to the amount paid to Bil-Jax for the product.
This warranty is in lieu of all other warranties expressed or implied. Bil-Jax
neither assumes nor authorizes any or other entity to assume on its behalf any
other liability in connection with the sale, rental, or use of this product.
Warranty Claims Process
In order to qualify for warranty coverage, the following conditions must be met:
1)
2)
3)
Return of completed “Warranty Registration” form to Bil-Jax within 15 days of
receipt of product;
Notification to Bil-Jax within 72 hours of any claimed defect, injury, or damage
resulting from the claimed the defect; and
Warranty is limited to parts that are determined to be defective. This does not
include parts worn out due to normal use.
Bil-Jax authorized dealers or distributors are responsible for filing claims under
warranty. Listed below is the warranty claims procedure.
1)
Contact Bil-Jax Service Department at 800-537-0540 to report the claim and
verify warranty coverage. Machine serial number must be provided.
Identify the components to be claimed under warranty along with description of
failure. A Returned Merchandise Authorization (RMA) number will be issued by
Bil-Jax.
2)
3)
4)
Replacement parts will then be sent by Bil-Jax to the dealer or distributor. All
parts are invoiced at dealer/distributor list price. Credits will be issued when
defective parts are returned to Bil-Jax and found to be defective under warranty.
After completing repairs, submit warranty claim form and defective parts to Bil-
Jax. Warranty claim form and parts must be received within 30 days of claim in
order to be eligible for credit. RMA number must be referenced on warranty claim
form. Returned parts are to be sent prepaid and will be credited when part is
received and verified. Warranty labor rate will be paid at current rate set by Bil-
Jax. The amount of labor hours reimbursed will be determined by Bil-Jax and will
be limited to 4 hours unless approved by Bil-Jax.
Failure to follow the warranty claims process may result in delay in processing
claim or denial of the claim. Bil-Jax reserves the right to limit or adjust warranty
claims with regard to parts, labor and travel time. Components purchased from
suppliers other than Bil-Jax are not covered under the terms of this warranty.
12
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3
OPERATION
The Model 3522A Articulating Boom Lift is equipped with multiple
operator control stations. Equipment power and outrigger controls are
located at ground level. Boom lift and rotation controls are located at
ground level and on the work platform.
Before attempting boom lift operation, Operators should:
ꢀ
Obtain, read and obey all safety precautions as indicated by
manufacturer’s recommendations and all federal, state and local
regulations.
ꢀ
ꢀ
Become familiar with the location and use of all controls.
Verify that there are no overhead obstructions or live power sources
in the work area that could interfere with the safe operation of the
boom lift.
ꢀ
ꢀ
Position the boom lift on a firm and level surface.
Unhitch equipment trailer from the tow vehicle.
13
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