PARTS AND SERVICE

MANUAL
 SELF-PROPELLED
AERIAL WORK PLATFORM
This equipment is designed and manufactured in
compliance with the duties, responsibilities and
standards set forth in the ANSI, CE, CSA and/or AS
standards in effect at the time of manufacture.
This equipment will meet or exceed applicable ANSI,
CE, CSA and/or AS codes and standards when operated
in accordance with manufacturer’s recommendations.
It is the responsibility of the user to follow all regional
codes and regulations that govern the safe operation of
this equipment.
Obtain, read and obey all safety precautions before
performing maintenance or repairs or attempting to
operate this equipment. This includes all manufacturer
recommendations as well as those directives set forth by
government and local authorities.
To ensure proper and safe use of this equipment, it is
strongly recommended that only trained and authorized
personnel attempt to operate and maintain the boom lift.
This manual shall be considered a permanent and
necessary component of the machine and shall be kept
with the boom lift at all times.
Owners and Lessors should complete a full inspection of
all components and perform a test of all functions,
including brake functions, before commissioning or
reselling the machine. Repair or replace all damaged or
malfunctioning components.

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

of this and all Bil-Jax products. Therefore, equipment
information is subject to change without notice. Direct
any questions or concerns regarding errors or
discrepancies in this manual to the Bil-Jax Service
Department.
Copyright © Bil-Jax, Inc. 2009. All Rights Reserved.

“Bil-Jax” and “X-Boom” are registered trademarks of

Bil-Jax, Inc., a member of the Haulotte Group. Contact
Bil-Jax for replacement manuals.

125 Taylor Parkway

Archbold, Ohio 43502

Phone (800) 537-0540

(419) 445-8915
Fax (419) 445-0367
B33-01-0105-01 http://www.biljax.com
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 11
Warranty 12

3 Equipment Maintenance 13
Daily Service Checks 14
Weekly Service Checks 16
Monthly Service Checks 17
Annual Service Checks 18
Structural Inspection 19
Additional Service Information 19
Troubleshooting 20
Error Code Definitions 21

4 Cylinder Replacement 25
Lift Cylinder Replacement 26
Outrigger Cylinder Replacement 27

5 Replacement Decals 29

6 Material Safety Data 35

Appendix: Replacement Parts 39

Ordering Replacement Parts 108

Appendix: Error Codes 109

1
 LIST OF ILLUSTRATIONS
Figure 2-1 Range of Motion 10
Figure 3-1 Outrigger Position Switch 14
Figure 3-2 Hydraulic Reservoir 15
Figure 3-3 Wheel Nut Tightening Sequence 17
Figure 3-4 Slew Ring Position Measurement 18
Figure 4-1 Lift Cylinder Replacement 26
Figure 4-2 Outrigger Cylinder Replacement 27
Figure 5-1 Decal Locations 31
Figure 5-2 Decal Locations – CE 33

LIST OF TABLES
Table 1-1 Minimum Safe Approach Distances 5
Table 3-2 Troubleshooting Steps 20
Table 3-3 Error Code Definitions 21
Table 5-1 Replacement Decal Descriptions 30
Table 5-2 Replacement Decal Descriptions – CE 32

2
1 SAFETY
Proper training is required for the safe operation of any mechanical device.
Failure to follow all instructions and safety precautions in this manual and
attached to the lift will result in death or personal injury.

Prior to Operation:
 Read, understand and obey all instructions and safety precautions in this
manual and attached to the lift.
 Read, understand and obey all applicable government regulations.
 Become familiar with the proper use of all controls.
 Inexperienced users should receive instruction before attempting to
operate or maintain the machine.

The use of intelligence and common sense is the best practice when
following any safety policy.

3
BIL-JAX 45XA

LEGEND: SAFETY ADVISORIES

The following safety advisories are used throughout
this manual to indicate specific hazards when
operating or maintaining the machine. Read,
understand and obey all safety advisories to prevent
improper service, damage to equipment, personal
injury or death.

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.

4
 1 — SAFETY

BEFORE OPERATION DURING OPERATION

Ensure the following general safety precautions are Ensure the following general safety precautions are
followed before operating the articulating boom lift: followed while operating the articulating boom lift:
ALWAYS inspect the usage area for potential ALWAYS position lift away from power lines to
hazards, such as unstable or unlevel surfaces, ensure that no part of the lift can accidentally reach
overhead obstructions and electrically charged wires into an unsafe area. This includes full extension of
or conductors. ALWAYS watch for moving vehicles the boom through 700º rotation.
in the operating area.
ALWAYS conduct a thorough inspection of the DANGER
machine before operation. Check for damaged or This machine is NOT insulated for use near
worn parts, hydraulic leaks, damaged wiring, loose electrical power lines and DOES NOT provide
wiring conductors, damaged outriggers, low tire protection from contact with or close proximity
pressure, uneven tire wear or tire damage. Check for to any electrically charged conductor. Operator
any improperly operating components. NEVER must maintain safe clearances at all times (3.05
operate equipment if any damage is observed or meters minimum) and must always allow for
suspected. Repair damaged or malfunctioning platform movement due to gusty winds. Always
equipment before operation. contact power company before working near
ALWAYS wear proper clothing and footgear. Wear power lines. Assume every power line is live.
protective equipment as required by government Power lines can be blown by the wind. Refer to
regulations. Keep loose clothing, jewelry, gloves and Table 1-1 for minimum safe approach distances
hair away from moving parts. between the machine and electrical power lines.

ALWAYS wear a safety harness and energy-

absorbing lanyard, such as a safety harness and Minimum Safe Approach Distance
Voltage Range
lanyard provided by Bil-Jax. (Phase to Phase) (Feet) (Meters)
ALWAYS inspect platform floor and outrigger 0 to 300V Avoid Contact
footpads for mud, grease, debris or other foreign Over 300V to 50KV 10 3.05
material. ALWAYS remove any such material from Over 50KV to 200KV 15 4.60
the equipment before operation.
Over 200KV to 350KV 20 6.10
ALWAYS tag any part of the equipment known or Over 350KV to 500KV 25 7.62
suspected to be damaged or malfunctioning. Over 500KV to 750KV 35 10.67
ALWAYS remove a malfunctioning, damaged or
Over 750KV to 1000KV 45 13.72
defective machine from service. NEVER operate a
machine that has any known or suspected defect. Table 1-1. Minimum Safe Approach Distances

ALWAYS comply with the instructions found in ALWAYS keep away from a machine that is
Safety and/or Service Bulletins distributed by the exposed to energized power lines. If the machine
manufacturer. Bulletins may contain critical contacts energized power lines, NEVER touch or
procedures that supersede the information operate the machine until power lines are shut off.
contained in manuals. ALWAYS operate only on a firm and level surface.
NEVER operate this equipment while under the NEVER operate on surfaces that do not support the
influence of drugs or alcohol, while taking equipment with its rated load capacity or on surfaces
prescription medications that may leave the operator that do not support force exerted by the outriggers
drowsy or prone to dizziness, or while feeling ill. during boom operation. Operate only on surfaces
that can support a pressure of 1.8 kg/cm2 (25 psi) to
NEVER modify the equipment in any way that would ensure safe operation.
affect its original design or operation.
ALWAYS keep personnel away from potential pinch
NEVER deface, modify or obscure any decals or and shear points and from potential crush hazards
markings on equipment. as indicated by decals attached to the machine.
NEVER operate the equipment in any way for which ALWAYS keep the safety bar lowered unless
it is not intended. personnel are entering or exiting the work platform.
ALWAYS keep personnel and obstructions clear of
the machine when repositioning boom or basket.

5
BIL-JAX 45XA

ALWAYS cordon the area surrounding the NEVER allow ropes, electric cords, hoses or other
outriggers to keep personnel, vehicles and moving equipment to become entangled in the machine
equipment away from the machine while in use. while raising or lowering platform.
ALWAYS stay clear of overhead obstructions, NEVER exceed the load limits set by the
including wires and cables. manufacturer. Use only the Material Lifting Hook,
supplied as an option and manufactured by Bil-Jax,
ALWAYS engage boom travel latches before towing
when lifting materials. Safely stow all tools and
trailer.
equipment.
ALWAYS exercise caution when rotating the boom
NEVER exceed load ratings by transferring loads to
from the ground control station. ALWAYS watch for
the lift at elevated heights.
personnel inside the radius of the turntable and
boom arm when rotating the boom lift from the NEVER use the platform to lift a load that exceeds
ground or platform controls. the platform dimensions. NEVER lift a load in such a
way that the center of gravity is higher than the top
ALWAYS remove personnel from the boom lift
guardrail of the platform.
before attempting to free an elevated platform that
has become caught or snagged on an adjacent NEVER modify the platform or carry materials that
structure or obstacle. would increase the surface area of the platform.
Increasing the area exposed to the wind may
NEVER operate the machine on any surface other
decrease machine stability. NEVER attach
than firm and level ground. NEVER operate the
overhanging loads when raising or lowering the
machine from a position on truckbeds, trailers,
platform.
floating vessels or scaffolding without written
approval from the manufacturer. NEVER use the boom or platform to push or pull or
to lift any part of the machine.
NEVER operate lift functions on slopes exceeding
12.5º. NEVER use the boom or platform to place a load
against any structure, materials or equipment.
NEVER allow electrode contact with any part of the
machine while welding from the platform. NEVER NEVER climb on the boom.
use the machine as a ground for welding.
NEVER leave an elevated platform unattended.
NEVER operate without the outriggers fully
NEVER leave the keys in the boom lift while
extended or when the machine is not level.
unattended or not in use.
NEVER position an elevated platform against
another object to steady the platform
Drive Safety
NEVER override or bypass the manufacturer’s
safety devices.
ALWAYS maintain an awareness of limited sight and
NEVER attach a safety harness to an adjacent blind spots when operating drive functions.
structure, pole, or to nearby equipment while
ALWAYS limit travel speed according to surface
working from the boom platform.
conditions, slope, location of personnel and
NEVER raise the outriggers while boom is raised or obstructions and any other factors which may result
extended. in collision.
NEVER sit, stand or climb on cage bars. ALWAYS NEVER operate drive functions on slopes exceeding
keep both feet firmly on the work cage floor when 20º.
working from an elevated platform.
NEVER engage in stunt driving, horseplay or any
NEVER attempt to increase the working height with other behavior considered unsafe according to
boxes, ladders, stools or any other materials. employer, job site and/or government regulations.
NEVER operate this equipment when exposed to NEVER operate the internal combustion engine in
high winds, thunderstorms, ice or any weather an area that is not properly ventilated.
conditions that would compromise operator safety.
NEVER fuel the internal combustion engine while
NEVER operate boom lift in conditions where wind smoking, or while near spark or open flame.
speeds exceed 12.5 m/sec (45 km/h or 28 mph).
High winds may affect stability and boom operation.

6
 1 — SAFETY

MAINTENANCE SAFETY
Ensure the following general safety precautions are NEVER exceed the manufacturer’s recommended
followed while performing maintenance on the relief valve settings.
articulating boom lift:
NEVER touch or allow metal tools to contact any
General Maintenance components that are sensitive to static discharge.
ALWAYS use static discharge prevention mats and
ALWAYS perform maintenance procedures
grounding devices when handling electronic
according to manufacturer’s guidelines. NEVER
components.
disregard or bypass proper maintenance
procedures. NEVER adjust, repair, replace or bypass any
hydraulic or electrical control or safety device. These
ALWAYS inspect hydraulic system to ensure that all
include, but are not limited to, hydraulic load control
lines, connectors and fittings are properly fastened
and flow control valves, solenoid valves and limit
and in good condition.
switches. ALWAYS consult an authorized Bil-Jax
ALWAYS turn the key switch OFF and remove key technician if repairs are necessary.
before performing maintenance.
NEVER modify, alter or change the equipment
ALWAYS perform maintenance with the boom and without first consulting an authorized Bil-Jax
platform in a fully lowered, stowed position, when technician, and NEVER in any way that would affect
possible. ALWAYS secure the boom before its original design or operation.
performing maintenance on hydraulic cylinders.
Battery Maintenance
ALWAYS disconnect power to the hydraulic pump
Ensure the following general safety precautions are
drive motor before making electrical checks to the
followed when performing battery maintenance on
hydraulic valves.
the Aerial Work Platform.
ALWAYS keep all mechanical parts properly
ALWAYS wear safety glasses when working with or
adjusted and lubricated according to maintenance
near batteries.
schedule and manufacturer’s specifications.
ALWAYS check the battery fluid level daily.
ALWAYS perform a function check of operating
controls before each use and after repairs have ALWAYS avoid contact with battery acid. Battery
been made. acid causes serious burns and should be kept away
from skin or eyes. If contact occurs, flush with water
ALWAYS locate and protect against possible pinch
and consult a physician immediately.
points before performing any maintenance or
repairs. ALWAYS disconnect ground cable first when
removing battery.
ALWAYS use only manufacturer-approved parts to
repair or maintain equipment. If any portion of this ALWAYS connect ground cable last when installing
equipment is rebuilt or repaired, retesting is required battery.
in accordance with factory instructions.
ALWAYS charge batteries in open, well-ventilated
ALWAYS maintain a safe distance while testing the areas.
hydraulic components. ALWAYS relieve hydraulic
ALWAYS replace batteries using only parts
pressure before loosening or removing hydraulic
recommended by manufacturer. ALWAYS use only
components. NEVER test or operate the hydraulic
batteries with sealed caps over cells.
components while personnel are near the
equipment. NEVER smoke while servicing batteries.
NEVER allow water or foreign particles into the DC NEVER charge batteries near spark or open flame.
electric motor housing. Inclusion of water or foreign
NEVER allow batteries to overcharge and boil.
particles may cause serious damage to the motor. If
the motor becomes wet, consult an authorized Bil- NEVER short across battery posts to check for
Jax service technician for proper drying instructions. current. NEVER break a live circuit at the battery.
NEVER add unauthorized fluids to the hydraulic NEVER disconnect battery from charger while
system or battery. NEVER mix hydraulic oils. charger is connected to a live power source.
Consult manufacturer specifications. Refer to
Section 4 for hydraulic system maintenance NEVER jumpstart other vehicles using the boom lift
procedures. batteries.

7
BIL-JAX 45XA

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.

8
2 SPECIFICATIONS
Bil-Jax, Inc. is dedicated to the continuous improvement of this and all
Bil-Jax products. Therefore, equipment information is subject to change
without notice.
The following information is based on ideal working conditions. Machine
performance may vary based on work environment and on machine
options.
Direct any questions or concerns regarding equipment specifications to your
regional Bil-Jax representative or to the Bil-Jax Service Department.

9
BIL-JAX 45XA

RANGE OF MOTION

Figure 2-1. Range of Motion

10
 2 — SPECIFICATIONS

SPECIFICATIONS SERIAL NUMBER____________________________

Working Height 51 ft Outrigger Footprint

15.7 m Length 12 ft 2 in
Maximum Platform Height 45 ft 3.7 m
13.7 m Width 11 ft 4 in
3.4 m
Maximum Horizontal Outreach
Footpad Diameter 12.5 in
From Centerline 27 ft
0.3 m
8.2 m
From Outrigger Footpad Edge 21 ft Brake Spring Applied
6.4 m Speed
Rated Platform Capacity Gas Power 3.75 mph
Without Platform Rotation 500 lbs 6 km/h
227 kg DC Power 2 mph
With Platform Rotation 440 lbs 3.2 km/h
200 kg Tire Size 26 x 12 bar lug tires
Maximum Occupants 2 Tire Pressure 20 PSI
Total Weight 4,300 lbs 140 kPa
1,950 kg Control System 24V DC
Turntable Rotation 700º Non-Continuous Battery 4 x 6V 245 amp-hr
Leveling Capability 12.5º Battery Charger 110/120 Volt
Gradeability 48% Gas Engine Kawasaki 21 HP
Wheel Base 8 ft 8 in Hydraulic Pressure 3,000 psi
2.7 m 20,684 kPa
Turning Radius Reservoir Capacity 4.3 Gallons
Inside 11 ft 16.3 L
3.35 m
Hydraulic System Capacity 6.3 Gallons
Outside 16 ft 8 in
23.9 L
5m
Hydraulic Oil (Standard) Dexron III/Mercon ATF
Platform Dimensions
Height 3 ft 7 in Platform Rotation/Type (Optional) 90º/Manual
1.1 m Maximum Decibel Level
Length 2 ft 6 in DC Mode – Ground 60 dB
0.8 m DC Mode – Platform 55 dB
Width – US/CE 5 ft/4 ft Gas Mode – Ground 70 dB
1.5 m/1.2 m Gas Mode - Platform 65 dB
Stowed Dimensions Localized Pressure per Outrigger 25 PSI
2
Height 6 ft 4 in 1.8 kg/cm
2.0 m 176.5 kPa
Length 19 ft 2 in Operation Temperature Range -20º to 110º Fahrenheit
5.8 m -29º to 43º Celsius
Width 5 ft 5 in
Max. Pressure Per Tire – Floor 35 PSI
1.7 m
Loading 2.5 bar
11
BIL-JAX 45XA

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) Return of completed “Warranty Registration” form to Bil-Jax within 15 days of
receipt of product;
2) Notification to Bil-Jax within 72 hours of any claimed defect, injury, or damage
resulting from the claimed the 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.
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.
2) 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.
3) 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.
4) 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
3 EQUIPMENT MAINTENANCE
Performing the appropriate maintenance procedures will extend the life
of the boom lift and will help ensure the safety of personnel operating the
equipment.
Repair, replacement or adjustment of any hydraulic or electrical control
device should be performed only by fully trained and authorized
personnel. These include, but are not limited to, hydraulic load valves,
hydraulic flow control valves, solenoid valves and limit switches. These
are safety related controls. Improper adjustment or tampering with these
devices may impair boom lift function and result in safety or damage
hazards.
Persons performing maintenance or repairs on the machine, including
weld repairs, should be trained in accordance with the manufacturer’s
recommendations. Contact your regional Bil-Jax representative if
additional information is needed.
Critical or suspect areas identified during any scheduled inspection of the
machine shall be examined by qualified personnel in accordance with
applicable government regulations.
Never operate the machine if a defect or malfunction is identified or
suspected. All defects and malfunctions must be repaired, and all
maintenance performed, before returning a machine to service.
This manual contains a list of recommended maintenance procedures to
be performed daily, weekly, monthly and annually.

When servicing the internal combustion engine installed on this

machine, always follow the guidelines specified by the engine
manufacturer.

It is the practice of Bil-Jax, Inc. to issue Service and/or Safety Bulletins,

which may include updates to the information contained in this manual.
In such instances, procedures contained in Bil-Jax Service Bulletins or
Safety Bulletins supersede the information contained in manuals.

Always follow maintenance schedule, regardless of use.

13
BIL-JAX 45XA

DAILY SERVICE CHECKS

The following maintenance procedures should be Verify that boom down limit switches operate
performed daily or before each operation. correctly.
Verify that all decals are correctly applied and in  Down limit switches are actuated when the boom is in
plain view. a fully lowered, stowed position. Limit switches must
be operational to raise or lower outriggers.
 Refer to Section 5 for decal locations.
 If outrigger controls are unresponsive when boom is
Verify that all controls and indicators at ground fully lowered and stowed, inspect down limit switches
and platform control stations operate properly. for loose mounting or visible damage.
 Lower outriggers to level the boom lift.  Repair or replace as needed.
 Raise and extend all booms. Verify that outrigger safety interlocks operate
 Press emergency STOP button. correctly.

 Verify that booms remain elevated and do not drift.  Begin with the outriggers fully extended and the boom
lift level. Raise one outrigger until the footpad is not in
 Pull out STOP button and lower the booms. contact with the ground.
 If either control station is unresponsive, refer to Table  Verify that boom functions are unresponsive when
3-1 for troubleshooting procedures. one outrigger is raised.
 If display panel displays an error code, refer to Table  Repeat this procedure for each outrigger.
3-2 for error code definitions.
 Raise all outriggers until the footpads are not in
Verify correct tire inflation. contact with the ground. Verify that all outrigger status
LEDs on the ground control panel are unlit.
 Inflate tires to 20 psi (140 kPa).
 Lower one outrigger until the footpad makes contact
Inspect tires for damage or loose or missing lug with the ground and the outrigger begins lifting the
nuts. trailer.
 Repair or replace as necessary.*  If the LED is lit before the footpad makes contact with
the ground or if the LED remains unlit after the weight
Inspect structural components and platform for is transferred to the outrigger, the position switch or
obvious damage or debris. wiring is faulty.
 Repair or replace as necessary.  Repeat this procedure for each outrigger.
Inspect machine for missing, loose or damaged  Repair or replace as needed. Refer to Figure 2-1.
fasteners, including pins and bolts.
Check engine oil level.
 Add oil as needed.
 Manufacturer recommends engine oil type 5W-30.
Check engine fuel level.
 Add fuel as needed.

Figure 3-1. Outrigger Position Switches

*Repair and replacement of machine components should

be performed only by trained and certified personnel in
accordance with government regulations and
manufacturer recommendations.

14
 3 — EQUIPMENT MAINTENANCE

Inspect hydraulic system and fluid levels.

 Check all hydraulic hoses and fittings for leaks and
damage. Tighten or replace as necessary to prevent
hydraulic oil or pressure loss.
 The hydraulic oil level should be checked with the
booms down, all outriggers raised and the trailer
wheels 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 half
way up the sight gauge (Figure 3-2), add clean
hydraulic fluid as necessary while all booms and
outriggers are fully retracted and stowed. Pour slowly
to avoid creating air pockets in the reservoir. Do not
fill above sight gauge. Overfilling the hydraulic
reservoir may cause damage to hydraulic lines and
may result in equipment malfunction.

CAUTION
Do not mix hydraulic oils. Do not add any fluid to
the hydraulic system that is not expressly
recommended by the manufacturer. Adding
unauthorized fluids to the hydraulic system may
cause damage to equipment
 The hydraulic reservoir is originally filled with Dexron
III/Mercon ATF with a viscosity rating of 175.
 Manufacturer recommends a higher viscosity
hydraulic oil when operating equipment routinely in
extreme climates.

1. Filter Element
2. Fill Port
3. Sight Gauge

Figure 3-2. Hydraulic Reservoir

15
BIL-JAX 45XA

WEEKLY SERVICE CHECKS

Perform the following service checks at least once
each week in addition to all recommended Daily
Service Checks:
Check Battery electrolyte level.
 If electrolyte level is low, add enough water to bring
the electrolyte level to the top of the plates.
 If batteries are fully charged, raise electrolyte level to
full mark in each cell.
Inspect all electrical wiring.
 Check for cuts, loose terminals, broken wires, chaffing
and corrosion.
 Repair all damage, remove corrosion and seal
exposed connections.
Inspect boom lift for missing, loose or damaged
hardware.
 Repair or replace as necessary.
Inspect all hydraulic system components
including pump and motor and cylinders for
damage, leaks, loss of pressure or speed, and
unusual noise or vibration.
 Repair or replace as necessary.

16
 3 — EQUIPMENT MAINTENANCE

MONTHLY SERVICE CHECKS

Perform the following service checks at least once
each month:
Clean all battery terminals.
Check battery for loose connections or damaged
wires.
Verify proper operation of manual lowering
valves and hand pump
 Refer to Section 3 for manual boom operating
procedures.
Lubricate all compartment hinges and latches,
slew ring and mating gear.
 Use NLGI Grade 2 multi-purpose grease.
Check wheel nut torque.
 Refer to Figure 4-3 for correct wheel nut tightening
sequence.
 Evenly tighten wheel nuts to 34 N*m in the tightening
sequence shown.
 Repeat sequence, tightening wheel nuts to 81 N*m
and to 136 N*m.
NOTE: Follow this procedure each time the
wheel is removed and reinstalled.

4 3

2 5

Figure 3-3. Wheel Nut Tightening Sequence

17
BIL-JAX 45XA

ANNUAL SERVICE CHECKS

Perform the following service checks at least once Check slew bearing for wear or damage.
each year:
 Check bolts for wear or damage.
Replace Hydraulic Oil and Oil Filter.  With the boom lift fully retracted, measure the
 Drain hydraulic reservoir, clean and replace oil. distance between the slew ring gear and the
horizontal plate above. Use a 2-inch (50 mm) caliper
 Wipe away dirt and excess oil from around filter using or bore micrometer. Record the measurement (Figure
cleaning cloths and alcohol solvent. 3-4).
 Loosen and remove filter. Use absorbent cloths to  Place a 175 lb (65 kg) load on the boom lift platform.
keep excess oil from leaking onto the machine.
Discard used filter.  Measure the distance between the slew ring and the
horizontal plate above. Record the measurement.
 Wipe away dirt and excess oil from around filter
housing.  If the difference in measurements is greater than .25
in (6.35 mm) the slew ring bearing should be
 Install new filter. Do not over-tighten. replaced. Contact manufacturer for replacement
 With the fill port cap on but not tightened, completely instructions and assistance.
raise and lower all booms to bleed trapped air from
the lift cylinders. Repeat as necessary.
 Replace yearly, or whenever filter or oil contamination
has a noticeable effect on boom functions.
MEASURE
HERE
Inspect pivot pins and cylinders, including rod
ends, for wear or damage. Replace as necessary.
SLEW RING

Visually inspect welds and structural

components for wear, damage and corrosion.
 Follow all manufacturer’s recommendations when
making repairs to critical components. Figure 3-4. Slew Ring Position Measurement

 Personnel making repairs to welds should be certified

in accordance with applicable government
regulations.
Inspect outriggers for wear or damage. Repair or
replace as necessary.
Verify that Level Sensor is operating correctly.
 Fully deploy outriggers until all Outrigger LEDs and
AUTO LEVEL LED are lit, and buzzer sounds.

 Verify that machine is level, and that level sensor is

giving an accurate reading.
 Repair or replace as necessary.
Inspect and adjust axles and brakes.
Load test boom lift operations with 500 lb (187
kg) load.

18
 3 — EQUIPMENT MAINTENANCE

STRUCTURAL INSPECTION ADDITIONAL SERVICE INFORMATION

A comprehensive structural inspection of the unit
shall be performed under any of the following Seals on hydraulic cylinders should be replaced every five
conditions. years or as indicated by machine performance.
 Ten years from the date of manufacture and every All service checks should be performed on a machine that
five years thereafter. has been stored without use for a period exceeding thirty
 After any actual, suspected or potential damage is days.
sustained that could affect the structural integrity or Check for air in the hydraulic system if the machine has
stability of the aerial platform. been stored without use for a period exceeding thirty days,
 After a change in ownership. Owners should provide or if the machine was stored without use during a
a complete service history when reselling the unit. seasonal climate change. Air trapped in the hydraulic
system will affect machine performance. Follow
The structural inspection shall include the following procedures for bleeding air from the hydraulic system,
considerations. found in Section 4.
 The service history of the unit, including hours of Owners and lessors should complete a full inspection of all
service, work performed and environmental components and perform a test of all functions, including
conditions. brake functions, before commissioning or reselling
machine. Always repair or replace all damaged or
 The inspection and maintenance record of the unit. malfunctioning components before commissioning or
 The effectiveness of all controls and components. reselling machine.

 A visual inspection of the unit for wear or damage. When a change in ownership occurs, it is the responsibility
of the seller to provide the new owner with all manuals for
 Manufacturer recommendations. the machine. It is the responsibility of the buyer to notify
the manufacturer of the unit model and serial number and
 A visual weld inspection, to be performed by qualified
the name and address of the new owner within 60 days.
personnel in accordance with applicable government
regulations. Use the Service Checklists found at the back of the
Operator’s Manual to record all Service Checks as well as
any maintenance, repairs or alterations performed on the
machine.
Records of frequent safety checks need not be made.
However, where a safety hazard is found, it shall be
reported in writing to the owner of the machine, and a
record of any corrective action shall be maintained for five
years or as required b y the authority having jurisdiction.

Testing Machine Stability

The Summit Series aerial work platform has been tested
for stability using a load equal to 150% of the rated
capacity of the machine and placed at the center of the
platform with the boom fully extended. Stability tests
should be conducted only by trained personnel and only
when the machine is properly anchored to safeguard
against tipping.

19
BIL-JAX 45XA

TROUBLESHOOTING
Refer to Table 3-2 for basic troubleshooting operations. Additional information
can be found in the Bil-Jax Model 45XA Operator’s Manual. Contact the Bil-Jax
Service Department with any questions or before attempting any advanced
troubleshooting operations.

Table 3-1. Troubleshooting Steps

PROBLEM CAUSE SOLUTION
No lights on panel when a. Emergency STOP engaged. a. Disengage Emergency STOP buttons.
key switch is turned to the
on position. b. Battery charge is low. b. Recharge as needed.

c. Battery ground or in-series cable is loose. c. Inspect and repair battery connections.

d. Battery main disconnect unplugged. d. Plug in main disconnect.

Hydraulic function does not a. Fault detected by safety interlock a. Refer to Table 4-2 for error code
work and display window microprocessor. definition and correction.
shows an error message
b. Boom Lift electric or electronic failure b. Refer to Table 4-2 for error code
definition and correction.

Outrigger indicator LED a. Key switch turned to the OFF or platform a. Turn key switch to ground controls
lights do not function. controls position. position.

b. Emergency STOP engaged. b. Disengage emergency STOP buttons.

c. Outriggers not deployed. c. Deploy all outriggers.

One or more boom controls a. Key switch is turned to the OFF or a. Turn key switch to ground or platform
do not function incorrect control position. controls position.
OR b. Battery charge is low. b. Recharge battery.
One or more boom controls
function improperly c. Emergency STOP engaged. c. Disengage Emergency STOP buttons.
OR d. Battery ground or in-series cable loose. d. Inspect and repair battery connections.
One or more boom controls
function intermittently. e. All outriggers not properly deployed. e. Deploy all outriggers and level boom lift.

f. Hydraulic pump inoperative. f. Inspect pump; replace or repair as

needed.

g. Loose wiring connector. g. Check wiring terminals in control box

and at valve manifold; replace or repair
as needed.

h. Valve solenoid not operating properly. h. Clean valve solenoid and recheck
function(s); replace or repair as needed.

i. Fault detected by system interlock. i. Check display for system status. Refer
to Table 4-2 for error code definitions
and correction.

j. Broken or loose wire. j. Inspect wiring in control box and at

valve manifold and valve coil; repair or
replace as needed.

20
 3 — EQUIPMENT MAINTENANCE

ERROR CODE DEFINITIONS

he DISPLAY PANEL located on the ground control panel indicates the present
operating status of the boom lift. If an error condition is detected by the control
processor during start-up or operation, the appropriate error code will be
displayed on this panel.
Refer to Table 3-2 for a list of common error codes and their definitions. A
comprehensive list of Error Codes can be found in the Appendix.

Table 3-2. Error Code Definitions

ERROR MESSAGE DEFINITION OF ERROR COMMENTS

001 MACHINE IS IN DOWN ONLY Machine was either never leveled, outriggers not Retract boom to travel position
MODE lowered, or machine went out of level with use. and extend outriggers using AUTO
LEVEL button.

002 LOSS OF PLATFORM Ground control lost communication with platform Check for unplugged or damaged
COMMUNICATION control. platform control cable.
005 PLATFORM CONTROL HAS Platform control detected a stuck or pressed key Turn key switch off and on again
STUCK KEY on power up. without pressing any buttons.
008 GROUND CONTROL HAS Ground control detected a stuck or pressed key Turn key switch off and on again
STUCK KEY on power up. without pressing any buttons.
009 BOOM UP WITHOUT Ground control detected the boom is up and all Retract boom to travel position
OUTRIGGERS ON GROUND outriggers are not on the ground and extend outriggers using AUTO
LEVEL button.

010 LEVEL SENSOR HAS The ground control detected an erratic output Retract and extend outriggers
ERRATIC OUTPUT from the level sensor. using AUTO LEVEL button.
015 MACHINE IS NOT LEVEL Machine has gone out of level with use. Retract and extend outriggers
using AUTO LEVEL.
016 LIFT BOOM A boom rotate, extend, or retract function Raise boom from travel position.
requested with boom down.
017 STOW BOOM An outrigger function requested with boom up. Retract and lower boom to travel
position.
021 OPEN CIRCUIT PRIMARY UP A load of less than 70mA detected in primary up Check for faulty boom up
circuit on power-up. solenoid coil and wiring.
022 SHORTED CIRCUIT Excessive load detected in primary up circuit on Check for faulty boom up
PRIMARY UP power-up. solenoid coil and wiring.
023 OPEN CIRCUIT PRIMARY A load of less than 70mA was detected when Check for faulty boom down
DOWN primary down circuit was energized solenoid coil and wiring.
024 SHORTED CIRCUIT Excessive load detected when primary down Check for faulty boom down
PRIMARY DOWN circuit was energized. solenoid coil and wiring.
025 OPEN CIRCUIT SECONDARY A load of less than 70mA detected in secondary Check for faulty boom up
UP up circuit on power-up. solenoid coil and wiring.
026 SHORTED CIRCUIT Excessive load detected in secondary up circuit Check for faulty boom up
SECONDARY UP on power-up. solenoid coil and wiring.
027 OPEN CIRCUIT SECONDARY A load of less than 70mA detected when Check for faulty boom down
DOWN secondary down circuit was energized solenoid coil and wiring.
028 SHORTED CIRCUIT Excessive load detected when secondary down Check for faulty boom down
SECONDARY DOWN circuit was energized. solenoid coil and wiring.
029 OPEN CIRCUIT JIB UP A load of less than 70mA detected in jib up circuit Check for faulty jib up solenoid
on power-up. coil and wiring.
030 SHORTED CIRCUIT JIB UP Excessive load detected in jib up circuit on Check for faulty jib up solenoid
power-up. coil and wiring.

21
BIL-JAX 45XA

ERROR MESSAGE DEFINITION OF ERROR COMMENTS

031 OPEN CIRCUIT JIB DOWN A load of less than 70mA detected when jib down Check for faulty jib down solenoid
circuit was energized coil and wiring.
032 SHORTED CIRCUIT JIB Excessive load detected when jib down circuit Check for faulty jib down solenoid
DOWN was energized. coil and wiring.
033 OPEN CIRCUIT EXTEND A load of less than 70mA detected in extend Check for faulty boom extend
circuit on power-up. solenoid coil/wiring.
034 SHORTED CIRCUIT EXTEND Excessive load detected in extend circuit on Check for faulty boom extend
power-up. solenoid coil/wiring.
035 OPEN CIRCUIT RETRACT A load of less than 70mA detected in retract Check for faulty boom retract
circuit on power-up. solenoid coil/wiring.
036 SHORTED CIRCUIT Excessive load detected in retract circuit on Check for faulty boom retract
RETRACT power-up. solenoid coil/wiring.
037 OPEN CIRCUIT PLATFORM A load of less than 70mA detected in platform Check for faulty level up solenoid
LEVEL UP level up circuit on power-up. coil/wiring.
038 SHORTED CIRCUIT Excessive load detected in platform level up Check for faulty level up solenoid
PLATFORM LEVEL UP circuit on power-up. coil/wiring.
039 OPEN CIRCUIT PLATFORM A load of less than 70mA detected in platform Check for faulty level down
LEVEL DOWN level down circuit on power-up. solenoid coil/wiring.
040 SHORTED CIRCUIT Excessive load detected in platform level down Check for faulty level down
PLATFORM LEVEL DOWN circuit on power-up. solenoid coil/wiring.
041 OPEN CIRCUIT PLATFORM A load of less than 70mA detected in platform Check for faulty boom rotate
CW CW circuit on power-up. solenoid coil/wiring.
042 SHORTED CIRCUIT Excessive load detected in platform CW circuit Check for faulty boom rotate
PLATFORM CW on power-up. solenoid coil/wiring.
043 OPEN CIRCUIT PLATFORM A load of less than 70mA detected in platform Check for faulty boom rotate
CCW CCW circuit on power-up. solenoid coil/wiring.
044 SHORTED CIRCUIT Excessive load detected in platform CCW circuit Check for faulty boom rotate
PLATFORM CCW on power-up. solenoid coil/wiring.
045 OPEN CIRCUIT TURNTABLE A load of less than 70mA detected in rotate CW Check for faulty rotate CW
CW circuit on power-up. solenoid coil/wiring.
046 SHORTED CIRCUIT Excessive load detected in rotate CW circuit on Check for faulty rotate CW
TURNTABLE CW power-up. solenoid coil/wiring.
047 OPEN CIRCUIT TURNTABLE A load of less than 70mA detected in rotate CCW Check for faulty rotate CCW
CCW circuit on power-up. solenoid coil/wiring.
048 SHORTED CIRCUIT Excessive load detected in rotate CCW circuit on Check for faulty rotate CCW
TURNTABLE CCW power-up. solenoid coil/wiring.
049 OPEN CIRCUIT OUTRIGGER A load of less than 70mA detected in outrigger Check for faulty outrigger retract
RETRACT retract circuit on power-up. solenoid coil/wiring.
050 SHORTED CIRCUIT Excessive load was detected when Outrigger Check for faulty outrigger retract
OUTRIGGER RETRACT Retract circuit was energized. solenoid coil/wiring.
051 OPEN CIRCUIT OUTRIGGER A load of less than 70mA detected in outrigger Check for faulty outrigger extend
EXTEND retract circuit on power-up. solenoid coil/wiring.
052 SHORTED CIRCUIT Excessive load was detected in outrigger extend Check for faulty outrigger extend
OUTRIGGER EXTEND circuit on power-up. solenoid coil/wiring.
053 OPEN CIRCUIT A load of less than 70mA detected in left front Check for faulty solenoid
LF OUTRIGGER outrigger circuit on power-up. coil/wiring at outrigger.
054 SHORTED CIRCUIT Excessive load was detected in left front Check for faulty solenoid
LF OUTRIGGER outrigger circuit on power-up. coil/wiring at outrigger.
055 OPEN CIRCUIT A load of less than 70mA detected in right front Check for faulty solenoid
RF OUTRIGGER outrigger circuit on power-up. coil/wiring at outrigger.

22
 3 — EQUIPMENT MAINTENANCE

ERROR MESSAGE DEFINITION OF ERROR COMMENTS

056 SHORTED CIRCUIT Excessive load detected in right front outrigger Check for faulty solenoid
RF OUTRIGGER circuit on power-up. coil/wiring at outrigger.
057 OPEN CIRCUIT A load of less than 70mA detected in left rear Check for faulty solenoid
LR OUTRIGGER outrigger circuit on power-up. coil/wiring at outrigger.
058 SHORTED CIRCUIT Excessive load detected in left rear outrigger Check for faulty solenoid
LR OUTRIGGER circuit on power-up. coil/wiring at outrigger.
059 OPEN CIRCUIT A load of less than 70mA detected in right rear Check for faulty solenoid
RR OUTRIGGER outrigger circuit on power-up. coil/wiring at outrigger.
060 SHORTED CIRCUIT Excessive load detected in right rear outrigger Check for faulty solenoid
RR OUTRIGGER circuit on power-up. coil/wiring at outrigger.
069 OPEN CIRCUIT A load of less than 70mA detected in proportional Check for faulty solenoid
PROPORTIONAL valve circuit on power-up. coil/wiring at proportional valve.
070 SHORTED CIRCUIT Excessive load detected in proportional valve Check for faulty solenoid
PROPORTIONAL circuit on power-up. coil/wiring at proportional valve.

23
BIL-JAX 45XA

24
4 CYLINDER REPLACEMENT
If repair or replacement of a boom lift or outrigger hydraulic cylinder or its
component parts becomes necessary, observe the following procedures in
accordance with the safety precautions established in Section 1 of this manual.
Removing the hydraulic cylinder from the boom lift may require the use of
specialized tools and lifting equipment. NEVER attempt to operate overhead
hoists or cranes or related equipment without proper training, authorization and
supervision. Perform all maintenance procedures only in an area that is well-lit
and well-ventilated. Bil-Jax, Inc. is not responsible for personal injury or property
damage resulting from the improper use of equipment or failure to follow all
procedures and related safety precautions.
Direct all questions regarding cylinder removal and replacement to your regional
Bil-Jax representative or to the Bil-Jax Service Department at 800-537-0540.

25
BIL-JAX 45XA

LIFT CYLINDER REPLACEMENT

Use the following procedure to remove and replace  At the base of the cylinder, unbolt and remove
faulty or damaged hydraulic cylinders on the boom retainer plate from each side of the pivot pin.
lift:  Remove the pivot pin using a hammer and a brass or
hardwood drift.
WARNING  Lift and remove the cylinder using an overhead hoist
Repair and removal of the hydraulic cylinders and lifting straps.
requires the use of lifting straps and an  Replace or reinstall the cylinder by following the
overhead crane or lifting gear to support the above instructions in the reverse order of removal.
boom lift and hydraulic cylinders. Personnel
 Actuate the hydraulic system and check for leakage.
should be thoroughly trained in the operation of Tighten hydraulic fittings as needed.
these devices before attempting installation or
removal. Hydraulic cylinders are heavy and may  Bleed trapped air from the hydraulic system by raising
have hydraulic oil on their surface. Failure to use and lowering the boom with the reservoir fill port cap
proper equipment or to securely support boom on but not tightened. Allow several minutes for
trapped air to escape. Repeat as needed.
and boom cylinders can result in damage to lift
components, serious injury or death.

 Lower the boom until it is resting in a stowed position.

When removing the slave cylinder, extend the
articulating boom section until all pivot pins are
RETAINING
exposed (approximately two feet). PLATE

 Press and hold the emergency lowering valve on the

back of the jib boom section to relieve all hydraulic
pressure to the cylinder. Repeat this process for the PIN
upper and lower boom sections. Refer to the 4527A
Operator’s Manual for emergency lowering valve CYLINDER
locations and operating procedures.
BASE END PISTON END
 Turn key switch to the OFF position and remove the
key.
 Locate the piston rod end of the cylinder to be
removed (Figure 4-1). Unbolt and remove the retainer
plate from each side of the pivot pin.
 Verify that the cylinder is supported by lifting straps
and an overhead hoist.
 Remove the pivot pin using a hammer and a brass or
hardwood drift.
 Use an overhead crane or lifting gear to raise the
boom section. Adequate clearance is necessary to
reach the cylinder valve block and hydraulic hose
ports.
 Unplug the appropriate emergency lowering valve
solenoid.
 Tag and number all hydraulic hoses that attach to the
cylinder valve block. Use a marker to label the valve
block ports with the appropriate hose numbers.
 Place absorbent cloths below the cylinder ports and Figure 4-1. Lift Cylinder Replacement
detach hydraulic hoses from the cylinder. Elevate
hoses to prevent leakage. Plug or cap exposed hose
fittings and cylinder ports.

26
 4 — CYLINDER REPLACEMENT

OUTRIGGER CYLINDER REPLACEMENT

Use the following procedure to remove and replace  Unplug the cylinder valve solenoid.
faulty or damaged hydraulic cylinders on the  Place absorbent cloths below the cylinder ports and
outriggers: detach hydraulic hoses from the cylinder. Elevate
 Lower the outrigger until the footpad is touching the hoses to prevent leakage. Plug or cap exposed hose
ground. Do not transfer the weight of the boom lift fittings and cylinder ports.
onto the outrigger. Leave the weight of the boom on  At the base of the cylinder, unbolt and remove
the trailer wheels. retainer plate from each side of the pivot pin.
 Remove the bolts securing the outrigger cylinder rod  Remove the pivot pin using a hammer and a brass or
guard (Figure 4-2). Remove the guard. hardwood drift.
 At the piston rod end of the cylinder, unbolt and  Lift and remove the cylinder using an overhead hoist
remove the retainer plate from each side of the pivot and lifting straps.
pin.
 Replace or reinstall the cylinder by following the
 Place a block of wood shoring between the outrigger above instructions in the reverse order of removal.
beam and cylinder.
 Actuate the hydraulic system and check for leakage.
 Remove the pivot pin using a hammer and a brass or Tighten hydraulic fittings as needed.
hardwood drift.
 Bleed trapped air from the hydraulic system by raising
 Fully retract the cylinder. and lowering the boom with the reservoir fill port cap
 Turn key to the off position and remove the key. on but not tightened. Allow several minutes for
trapped air to escape. Repeat as needed.
 Tag and number all hydraulic hoses that attach to the
cylinder valve block. Use a marker to label the valve
block ports with the appropriate hose numbers.

CYLINDER ROD PIN

GUARD

CYLINDER

CYLINDER ROD
GUARD BOLTS

RETAINING
PLATES

Figure 4-2. Outrigger Cylinder Replacement

27
BIL-JAX 45XA

28
5 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.

29
BIL-JAX 45XA

Table 5-1. Decal Descriptions

Decal No. Decal Description Qty Decal No. Decal Description Qty
0202-0523 Made in USA 1 B06-00-0484 DANGER: Battery/Charger Safety 1
B06-00-0034 DANGER: Electric Shock 1 B06-00-0494 NOTICE: Hazardous Materials 1
B06-00-0037 Lubricate Semi-Annually 1 CAUTION: Compartment Access
B06-00-0495 2
Restricted
B06-00-0062 NOTICE: AC Power 2
B06-00-0503 NOTICE: Handle Applications 1
B06-00-0068 NOTICE: Hydraulic System Oil 1
B06-00-0504 NOTICE: Emergency Hand Pump 1
B06-00-0161B Bil-Jax Logo, Black Transfer 2
DANGER: Before Use/Main
B06-00-0403 NOTICE: Emergency Lowering 4 B06-00-0505 1
Instruction/Hazards (ground)
B06-00-0404 WARNING: Outrigger Crush Toe 8 B06-00-0521 DANGER: Tip Over Hazard 5
B06-00-0405 WARNING: Pinch Point 16 B06-00-0536 NOTICE: Range of Motion 2
DANGER: Before Use/Main CAUTION: Manual Boom
B06-00-0471 1 B06-00-0541 1
Instruction/Hazards (Platform) Functions
NOTICE: Operator’s Manual B06-00-0545 Bil-Jax Website Transfer 2
B06-00-0473 1
Missing
NOTICE: Fall Protection Attach-
B06-00-0474 NOTICE: Max. Load 1 B06-00-0552 1
ment Points
WARNING: Read/Understand WARNING: Operating Instructions
B06-00-0475 1 B06-00-0561 2
Operator’s Manual (Ground)
B06-00-0477 WARNING: Forklift Pockets 2 WARNING: Operating Instructions
B06-00-0562 1
B06-00-0481 CAUTION: Transport Safety Latch 2 (Platform)

B06-00-0482 DANGER: Electrocution Hazard 2 B06-00-0564 45XA, 6” Black Transfer 2

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

30
 4x
0405

0521 0405

0405 0404 0482

0536

0403
0403 4x
0037

0161B 0564 0167*

0545
0481 0403 0405
0477
0568*

0473
0562
0475
0474

0471
0062

0536
0202-0523

0405 0552

Figure 5-1. Decal Locations

0521

0521

0481 0505 0495 0504

0503 0068

0494
0495

0034

0484 0561 0541

31
5 – DECAL PLACEMENT
BIL-JAX 45XA

Table 5-2. Decal Descriptions – CE

Decal No. Decal Description Qty Decal No. Decal Description Qty
0202-0523 Made in USA 1 B06-00-0482 DANGER: Electrocution Hazard 2
B06-00-0034 DANGER: Electric Shock 2 CAUTION: Compartment Access
B06-00-0495 2
Restricted
B06-00-0037 Lubricate Semi-Annually 1
DANGER: Before Use/Main
B06-00-0062 NOTICE: AC Power 2 B06-00-0505 1
Instruction/Hazards (ground)
B06-00-0068 NOTICE: Hydraulic System Oil 1 B06-00-0536 NOTICE: Range of Motion 2
B06-00-0161B Bil-Jax Logo, Black Transfer 2 CAUTION: Manual Boom
B06-00-0541 1
B06-00-0173 Fall Protection Attachment Points 1 Functions

B06-00-0403 NOTICE: Emergency Lowering 4 B06-00-0545 Bil-Jax Website Transfer 2

B06-00-0404 WARNING: Outrigger Crush Toe 8 WARNING: Operating Instructions

B06-00-0561 2
(Ground)
B06-00-0405 WARNING: Pinch Point 15
WARNING: Operating Instructions
B06-00-0562 1
DANGER: Before Use/Main (Platform)
B06-00-0471 1
Instruction/Hazards (Platform)
B06-00-0564 45XA, 6” Black Transfer 2
B06-00-0474 NOTICE: Max. Load 1
B06-00-0568 WARNING: Outrigger Pressure 4
WARNING: Read/Understand
B06-00-0475 2 WARNING: Read/Understand
Operator’s Manual B06-00-0572 1
Parts and Service Manual

Identification Plates
B06-00-0499 ANSI ID Plate 1
B06-00-0526 Key Tag 1

32
 4x
0405

0405

0568
0405 0482

0404 0403
0403
0037

0161B 0545 0564

0403 0405

0562
0475
0474

0471
0062

0536
0202-0523

0405 0173

Figure 5-2. Decal Placement – CE

0495 0505
0495
0068
0572

0475

0034

0536 0561 0541

0034
5 — REPLACEMENT DECALS

33
BIL-JAX 45XA

34
 6 MATERIAL SAFETY DATA
The following Material Safety Data Sheets describe the correct
procedures for the safe handling of chemical components within the
Model 45XA Articulating Boom Lift, as well as any potential health and
safety hazards related to these chemicals. Material Safety Data Sheets
are included here in accordance with applicable federal and state
regulations. Read and observe all safety precautions. Maintain
awareness of potential health and safety hazards.

MATERIAL SAFETY DATA SHEET

FOR LEAD ACID BATTERIES, WET, FILLED WITH ACID
SECTION I -- GENERAL INFORMATION

Manufacturer’s Name: Crown Battery Mfg. Company EMERGENCY NO: 800 487-2879
Street Address: 1445 Majestic Drive OR 800 OIL-TANK
City, State, Zip Fremont, Ohio 43420
Phone Number: 419 334-7181 REVISION DATE: 5/18/2000

SECTION II -- MATERIAL IDENTIFICATION AND INFORMATION

COMPONENTS PERCENT OSHA ACGIH OTHER LIMITS CAS NUMBER

Hazardous Components PEL TLV
1% or greater
Carcinogens 0.01% or greater

METALLIC LEAD METAL 25.5% 0.05 mg/m3 0.05 mg/m3 NONE 7439-92-1
LEAD SULFATES 18.2% 0.05 mg/m3 0.05 mg/m3 NONE 7439-92-1
LEAD OXIDES 18.0% 0.05 mg/m3 0.05 mg/m3 NONE 7439-92-1
POLYPROPYLENE CASE MTL 6.4%
SEPARATORS 3.5%
SULFURIC ACID (H2SO4) 5.2% 1.0 mg/m3 1.0 mg/m3 NONE 7664-93-9
WATER 19.2%

REGULATORY INFORMATION: Those ingredients listed above are not subject to the reporting requirements of 313
of Title III of the Superfund Amendments and Reauthorization Act. The items are
covered in an exemption as a “Manufactured Article”. 372.30(b)

SECTION III -- PHYSICAL / CHEMICAL CHARACTERISTICS

Boiling Point Approximately 203F Vapor Density: Greater Than 1

Vapor Pressure 14 @ 37% @ 80 F Melting Point: -36 F to -10.6 F
Solubility in Water 100% Water Reactive: Yes, Produces Heat
Specific Gravity 1.245 - 1.295 Battery Electrolyte
Appearance & Odor Clear Liquid with Sharp Pungent Odor

SECTION IV -- FIRE AND EXPLOSION HAZARD DATA

Flash Point: Not Combustible

Auto Ignition Temperature N/A Flammability Limits in Air % by Volume: N/A
Extinguishing Media: Dry Chemical Carbon Dioxide, Water Fog, Water
Special Fire Fighting Procedures: Sulfuric Acid Fumes, Sulfur Dioxide Gas or Carbon Monoxide may be
released when acid decomposes. Wear NIOSH approved self-contained breathing apparatus.

Unusual Hazards: Water applied to sulfuric acid generates heat and causes acid to splatter. Wear full-cover
acid resistant clothing. Sulfuric acid reacts violently with metals, nitrates, chlorates, carbides, fulminates,
picrates and other organic materials. Reacts with most metals to yield explosive/flammable hydrogen gas.
This reaction is intensified when sulfuric acid is diluted with water to form battery electrolyte.

35
BIL-JAX 45XA

MATERIAL SAFETY DATA SHEET

FOR LEAD ACID BATTERIES, WET, FILLED WITH ACID (Continued)
SECTION V -- HEALTH HAZARD DATA

Primary Routes of Entry: Inhalation: YES

Skin: YES
Ingestion: YES
Health Hazards: Acute EYES, SKIN, RESPIRATORY SYSTEM & DIGESTIVE SYSTEM
Chronic: EYES, SKIN, RESPIRATORY SYSTEM & DIGESTIVE SYSTEM
Signs and Symptoms of Exposure: IRRITATION OF EXPOSED AREA, BURNS AND RESPIRATORY PROBLEMS
NO POSSIBILITY OF EXPOSURE OF LEAD WILL OCCUR UNLESS
BATTERY IS DESTROYED.
Medical Conditions Generally
Aggravated By Exposure: EXPOSURE TO MIST MAY CAUSE LUNG DAMAGE & AGGRAVATE
PULMONARY CONDITION.
Emergency First Aid Procedures: SEEK MEDICAL ASSISTANCE FOR FURTHER TREATMENT, OBSERVATION
AND SUPPORT IF NECESSARY.
Eye Contact: WASH WITH COPIOUS QUANTITIES OF COOL WATER FOR AT LEAST 15 MINUTES
Skin Contact: FLUSH AREA WITH LARGE AMOUNTS OF COOL WATER FOR AT LEAST 15 MINUTES
Inhalation: REMOVE TO FRESH AIR, IF BREATHING IS DIFFICULT - GIVE OXYGEN
Ingestion: GIVE MILK TO DRINK, DO NOT INDUCE VOMITTING. CALL PHYSICIAN

SECTION VI -- REACTIVITY DATA

Stability: STABLE Conditions to Avoid: N/A

Incompatibility: AVOID COMBUSTIBLES, ORGANIC MATERIALS, AND STRONG REDUCING AGENTS
Hazardous Decomposition Products: SULFUR TRIOXIDE, CARBON MONOXIDE, SULFURIC ACID FUMES, &
SULFUR DIOXIDE
Hazardous Polymerization: MAY OCCUR Conditions to Avoid: N/A

SECTION VII -- SPILL OR LEAK PROCEDURES

Steps to be taken in case material is released or spilled:

CONTAIN SPILL, USING NON-COMBUSTIBLE MATERIALS: VERMICULITE, DRY SAND & EARTH. NEUTRALIZE
WITH LIME, SODA ASH, SODIUM BICARBONATE, ETC.
Waste disposal method: CONSULT STATE ENVIRONMENTAL AGENCY. INDIVIDUAL STATE REGULATIONS VARY
Precautions to be taken in Handling & Storage: SEPARATE FROM INCOMPATIBLE MATERIALS, KEEP AWAY
FROM FIRE, SPARKS AND HEAT
Other Precautions and/or Special Hazards:
CONTACT WITH METALS MAY PRODUCE TOXIC SULFUR DIOXIDE FUMES & MAY ALSO RELEASE FLAMMABLE
HYDROGEN GAS. THIS REACTION IS INTENSIFIED WHEN DILUTED.
NFPA Rating: HEALTH: 3 FLAMMABILITY: 0 REACTIVITY: 2 SPECIAL: 0
HMIS Rating: HEALTH: 3 FLAMMABILITY: 0 REACTIVITY: 2 PERSONAL PROTECTION: X

SECTION VIII -- CONTROL AND PROTECTIVE MEASURES

Respiratory Protection: ABOVE P.E.L.: NIOSH APPROVED, FITTED, FULL FACE RESPIRATOR
Protective Gloves: ACID RESISTANT
Eye Protection: FULL FACE PROTECTION
Ventilation: LOCAL EXHAUST: VENTILATED AREA PREFERRED
MECHANICAL: IF BELOW P.E.L.
SPECIAL: MUST BE ACID & EXPLOSIVE RESISTANT
OTHER: MUST BE ACID & EXPLOSIVE RESISTANT
Other Protective Equipment: ACID RESISTANT CLOTHING AND BOOTS
Hygienic Work Practices: N/A

36
 6 – MATERIAL SAFETY DATA

MATERIAL SAFETY DATA SHEET

DEXRON III/MERCON AUTOMATIC TRANSMISSION FLUID (HYDRAULIC OIL)

SECTION I -- GENERAL INFORMATION

TRADE NAME: CITGO TRANSGARD™ ATF, DEXRON III/MERCON
EMERGENCY TELEPHONE NUMBERS: 918.495.4700 (medical); 800.424.9300 (chemical)
CHEMICAL FAMILY: AUTOMATIC TRANSMISSION FLUID, LUBRICATING OIL
CAS NUMBER: MIXTURE. REVISION DATE: 10/29/98
HAZARDOUS INGREDIENTS: CONTAINS NO INGREDIENTS NOW KNOWN TO BE HAZARDOUS AS
DEFINED IN OSHA 29 CFR 1910.1000 AND OSHA 29 CFR 1910.1200.

SECTION II -- HEALTH HAZARD DATA

PRIMARY ROUTES OF ENTRY: INHALATION, SKIN ABRASION AND INGESTION.

CARCINOGENIC: NO
SYMPTOMS (INGESTION, CONTACT, INHALATION): MILD, TRANSIENT SKIN OR EYE IRRITATION MAY OCCUR.
EYES: FLUSH WITH WATER FOR 15 MINUTES
SKIN: WASH THOROUGHLY WITH WARM SOAPY WATER.
INGESTION: DO NOT INDUCE VOMITTING-SEEK MEDICAL ATTENTION.
CONDITIONS AGGRAVATED BY EXPOSURE: NONE KNOWN
AIR EXPOSURE LIMITS: P.E.L. 5 mg/m3 (OSHA) T.L.V. 10mg/m3 (ACGIH)
HEALTH: 0 FIRE: 1 SPECIFIC: X REACTIVITY: 0

SECTION III -- PHYSICAL DATA

BOILING POINT/FREEZING POINT: N/A
VAPOR PRESSURE (PSIA): N/A
SPECIFIC GRAVITY (H20=1): 0.86
SOLUBILITY IN WATER: NEGLIGIBLE; INSOLUBLE IN COLD WATER
PH OF CONCENTRATE: N/A
APPEARANCE AND ODOR: RED LIQUID, MILD PETROLEUM ODOR

SECTION IV -- FIRE AND EXPLOSION HAZARD DATA

FLASH POINT (METHOD USED): CLOSED: 339º F (Pensky-Martens); OPEN: 390º F (Cleveland).
FLAMMABLE LIMITS: NOT DETERMINED
LEL: N/A UEL: N/A
EXTINGUISHING MEDIA: DRY CHEMICAL, FOAM, CO2, WATER FOG. TREAT AS CLASS B FIRE.
UNUSUAL FIRE AND EXPLOSION HAZARDS: PRODUCES COMBUSTIBLE VAPOR AT TEMPERATURES ABOVE FLASH POINT

SECTION V -- REACTIVITY DATA

STABILITY: STABLE
CONDITIONS TO AVOID: AVOID EXTREMES OF HEAT; IGNITION SOURCES.
INCOMPATIBILITY (MATERIALS TO AVOID): STRONG OXIDIZING MATERIALS.
HAZARDOUS DECOMPOSITION PRODUCTS: INCOMPLETE COMBUSTION MAY CAUSE CARBON OXIDES.
HAZARDOUS POLYMERIZATION: WILL NOT OCCUR.

SECTION VI -- SPECIAL PROTECTION INFORMATION

RESPIRATORY PROTECTION (SPECIFIC TYPE): NONE REQUIRED

VENTILATION: NORMAL
LOCAL EXHAUST: NORMAL
MECHANICAL EXHAUST (GENERAL): X
PROTECTIVE GLOVES: OIL IMPERVIOUS GLOVES RECOMMENDED
EYE PROTECTION: SAFETY GLASSES RECOMMENDED
OTHER PROTECTIVE EQUIPMENT: PROTECTIVE CLOTHING RECOMMENDED
SPECIAL LABELLING INSTRUCTIONS: NOT REQUIRED
SPECIAL PACKAGING RECOMMENDATIONS: NONE
HANDLING AND STORAGE RECOMMENDATIONS: AVOID EXTREMES OF COLD OR HEAT. STORE IN CLEAN DRY AREA.
SPILL OR LEAK PROCEDURES: IN CASE OF LEAK OR SPILL, DIKE AND ABSORB WITH INERT MATERIAL. FOLLOW
ALL LOCAL, STATE AND FEDERAL REGULATIONS FOR DISPOSAL.

DISCLAIMER: THE INFORMATION CONTAINED HEREIN HAS BEEN COMPILED FROM SOURCES
CONSIDERED TO BE DEPENDABLE AND IS ACCURATE TO THE BEST OF THE SELLER’S
KNOWLEDGE. THE SELLER MAKES NO WARRANTY WHATSOEVER, EXPRESSED OR IMPLIED, REGARDING THE ACCURACY
OF SUCH DATA OR THE RESULTS TO BE OBTAINED FROM THE USE THEREOF.

37
38
APPENDIX:REPLACEMENT PARTS
Use only parts manufactured and/or authorized by Bil-Jax, Inc. when replacing
damaged components. See page 89 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.

39
 Assembly Description Page
Outrigger 42
Engine 44
Front Rest 48
Front Axle 50
Rear Axle 52
Slew Ring 54
Limit Switch 56
Control Compartment 58
Pump Compartment 60
Battery Compartment 62
Cover 64
Lower Boom 66
Triangle Weldment 68
Upper Boom 70
Jib Boom 72
Platform 74
Hydraulic Pump 76
Boom and Rotation Hydraulic Lines 80
Outrigger Hydraulic Lines 82
Trailer Hydraulic Lines – 4WD 83
Manifold Assembly – 4WD 86

40
Assembly Description Page

Wire Harnesses – ANSI 88

Wire Harnesses – CE 89
Manifold Wire Harness 90
Gas Engine Wire Harness 90
Choke/Throttle Solenoid Wire Harness 91
Engine Relays Wire Harness 91
ATC Fuse Holder 92
Start/Stop/Run Wire Harness 92
Generator Switcher Box 93
Wire Assembly – Fan 93
IEC Cord – Male – ANSI 94
Generator 110V Wire Harness 94
Oil Switch 94
Cord Assembly – 110V Generator 95
Cord Assembly – Generator Switch 95
Cord Assembly – Switch Jumper 95
Cord Assembly – 110V AC Plug – Female 95
Switcher Box – CE Models 96
220V Generator Wire Harness – CE Models 96
Cord Assembly – 220V AC Plug – Female – CE Models 96
Pump And Cylinder Wire Harnesses 97
Outrigger Coil and Switches Wire Harness 98
Analog Harness 99
Power Harness 99
110 VAC Tower-Platform Harness 99
Secondary Cylinder Wire 100
Jib Wire 100
Platform-Ground Communication Cable 100
Water Line to Platform 101
Air Line to Platform 101
Load Sense 102
Material Lift Hook 104
Battery Layout 105
Manual Platform Rotate 106

41
 OUTRIGGER ASSEMBLY

18 28 21 15 16 17 11 10 14 12 13 9 4

13

30

14 7
29

14
26
27 2

23 6

5
24
7

25

22 20 19 17 6 5 7 8 1 3

42
 OUTRIGGER ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-00120 Outrigger Weldment 1*
2 A-00046 Grommet – 1.5 x 1.25 x 1.75 1
3 A-00032 Bearing 2
4 A-00020 Pin, 1.25 x 5.5 2
5 A-00019 Pin Retainer, 1.25 3
6 0096-0016 Cap Screw, M10 x 25 3
7 0096-0041 Hex Nut, Self-Locking, M10 3
8 A-00060 Pin, 1.25 x 4.25 1
9 A-00138 Outrigger Hydraulic Cylinder 1
10 A-00141 Outrigger Cylinder Guard 1
11 0096-0009 Cap Screw, M8 x 10 2
12 A-00142 Guard Slide 1
13 0096-0010 Cap Screw, M8 x 20 6
14 0096-0040 Hex Nut, Self-Locking, M8 10
15 A-00154 Spring, Outrigger Sensor 1
16 0096-0036 Cap Screw, M16 x 150 1
17 0096-0044 Hex Nut, Self-Locking, M16 2
18 A-00128 Pad Mount Weldment 1
19 0096-0051 Cap Screw, M16 x 100 1
20 B01-03-0078 Limit Switch Assembly 1
21 0090-0232 Slotted Machine Screw, #10-24 x 5/8 2
22 0090-0182 Hex Nut, Self-Locking, #10-24 2
23 A-00136 Foot Pad, Aluminum, 12” 1
24 A-00137 Foot Pad Bottom, 12” 1
25 0096-0121 Flat Head Cap Screw, M8 x 30 4
26 A-00135 Foot Pad Ball 1
27 A-00195 O-Ring, 1 1/4” OD x 1” ID 1
28 0096-0045 Hex Nut, Self-Locking, M20 1
29 A-00127 Foot Pad Lock 2
30 A-00139 Foot Pad Lock Cap 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.

43
 ENGINE ASSEMBLY (I)
5 6 12 25 24 21 4 2 16 17

3
11

10 19

8
7
8
15
8 8

9 20

22
14
7
15

13

2 1 3 23 3 15 18

44
 ENGINE ASSEMBLY (I) PARTS LIST

Item No. Part No. Description Qty.

1 A-01063 Cover Front 1
2 0096-0014 Cap Screw, M10 x 20 14
3 0096-0041 Hex Nut, Self-Locking, M10 22
4 A-01064 Cover Top 1
5 A-01067 Cover Side – Left 1
6 A-01069 Cover Side – Right 1
7 0096-0001 Cap Screw, M6 x 16 20
8 0096-0039 Hex Nut, Self-Locking, M6 33
9 B42-01-1006 Hinge – 72” Continuous 2
10 A-01045 Latch, Paddle-Style 2
11 0096-0113 Cap Screw, M4 x 16 8
12 0096-0073 Hex Nut, Self-Locking, M4 8
13 A-01052 Cover Rear 1
14 B01-06-0053 Relay 24V DC w/ Bracket 5
15 0096-0002 Cap Screw, M6 x 20 13
16 A-A-01059 Cover Pad 2
17 0096-0068 Flat Head Cap Screw, M10 x 45 4
18 A-03048 Relay Cover 1
19 A-03040 Switcher Box Assembly 1
B01-06-0056 Relay – 30 Amp 1
B01-10-0354 Circuit Breaker – 20 Amp 1
A-01015 Switcher Box 1
20 A-01072 Cover Latch Stop 2
21 0096-0098 Cap Screw, M8 x 35 4
22 0096-0040 Hex Nut, Self-Locking, M8 4
23 A-01047 Fuel Tank 1
24 A-01089 Fuel Gauge 1
25 0096-0016 Cap Screw, M10 x 25 2

45
 ENGINE ASSEMBLY (II)
3 21 12 17 15 14 12 12 3 6 7 1

9 18

10

12

22

13 20 16 13 11 19 3

25

24
26
27

23
33
31 32

34
28 29

46
 ENGINE ASSEMBLY (II) PARTS LIST

Item No. Part No. Description Qty.

1 A-01046 Engine 21HP (See Manufacturer’s Literature) 1
2 0096-0098 Cap Screw, M8 x 35 4
3 0096-0040 Hex Nut, Self-Locking, M8 18
4 A-01048 Pump – Dual – 4.5 GPM 1
5 A-01055 Dual Pump Mount 1
6 0096-0110 Cap Screw, M10 x 110 2
7 0096-0093 Washer, M10 2
8 0096-0041 Hex Nut, Self-Locking, M10 2
9 A-01081 Oil Cooler 1
10 0096-0010 Cap Screw, M8 x 20 4
11 A-01071 Solenoid Bracket 1
12 0096-0001 Cap Screw, M6 x 16 12
13 0096-0039 Hex Nut, Self-Locking, M6 10
14 A-01074 Throttle Solenoid Assembly 2
A-03045 Linkage Spring 1
15 A-00761 Generator 1
16 A-01060 Spacer 4
17 0096-0053 Cap Screw, M8 x 50 4
18 A-01038 Brake Release – Hand Pump 1
19 0096-0108 Cap Screw, M8 x 70 2
20 B02-00-0071 Oil Filter Assembly 1
21 B29-00-0016 Oil Filter Bracket 1
22 A-00783 Exhaust Assembly 1
23 A-01061 Belt 1
24 A-01051 Pulley - ANSI 2
24 A-03060 Pulley – CE 2
25 0090-0363 Set Screw – 1/4 - 20 x 3/4 6
26 A-01036 Pulley 1
27 A-01088 Idler Roller 1
28 0096-0022 Cap Screw, M12 x 75 1
29 0096-0076 Washer, M12 3
30 0096-0041 Hex Nut, Self-Locking, M12 1
31 A-01095 Tension Arm 1
32 A-01086 Spacer – Tension Arm 1
33 0090-0210 Washer – 3/8” 1
34 0096-0069 Cap Screw, M10 x 75 1

47
 FRONT REST ASSEMBLY
12 14 9

13

19

17 16
15

11 18
5

6
10
6
21

4 8

2 7

21

22 20 20

48
 FRONT REST ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-03145 Front Rest Weldment 1
2 0096-0024 Cap Screw, M12 x 100 2
3 0096-0042 Hex Nut, Self-Locking, M12 2
4 A-00157 Front Rest Pad 8
5 0096-0017 Cap Screw, M10 x 30 16
6 0096-0041 Hex Nut, Self-Locking, M10 20
7 A-00159 Boom Latch 1
8 0096-0016 Cap Screw, M10 x 25 4
9 A-00169 Switch Bracket 1
10 0096-0002 Cap Screw, M6 x 20 2
11 0096-0039 Hex Nut, Self-Locking, M6 2
12 A-00188 Switch Cam 2
13 0090-1104 Machine Screw, #4-40 x 1 3
14 0090-0525 Hex Nut, Self-Locking, #4-40 3
15 B01-03-0078 Limit Switch Assembly, NO (Female) 1
16 B01-03-0079 Limit Switch Assembly, NC (Male) 1
17 0090-0709 Machine Screw, #6-32 x 1 1/4 2
18 0090-0180 Hex Nut, Self-Locking, #6-32 2
19 A-00158 Tension Spring 1
20 0096-0038 Cap Screw, M20 x 120 4
21 0096-0045 Hex Nut, Self-Locking, M20 4
22 A-01082 Tie Weldment – 4WD 1

49
 FRONT AXLE ASSEMBLY

8 18 14 15

19

17

22

8
23
24

20 12
21

13 16

7
3
6
5

13
4
9

10

1 11 2

50
 FRONT AXLE ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-01010 Front Axle Weldment – 4WD 1
2 A-01097 Bushing, 1.5” OD x 1.25” ID 4
3 A-01020 Front Yoke – Left 1
4 A-01021 Front Yoke – Right 1
5 A-01070 Pin – 1.25” x 1.625” 4
6 A-00019 Pin Retainer – 1.25” 4
7 0096-0016 Cap Screw, M10 x 25 4
8 0096-0041 Hex Nut, Self-Locking, M10 9
9 A-01022 Hydraulic Motor – 4WD 2
10 0096-0024 Cap Screw, M12 x 100 8
11 0096-0042 Hex Nut, Self-Locking, M12 8
12 A-01025 Tie Rod – 4WD 1
13 A-01096 Bushing, 1.25” OD x 1.0” ID 4
14 A-01085 Pin – Front Axle 4
15 0090-0155 Cotter Pin – 3/16” x 1 3/4" 4
16 A-01030 Steering Cylinder – 4WD 1
17 A-01005 Front Axle Mount Weldment 1
18 0096-0038 Cap Screw, M20 x 120 2
19 0096-0045 Hex Nut, Self-Locking, M20 2
20 A-01029 Pad – Front Axle 2
21 0096-0091 Flat Head Cap Screw, M10 x 25 4
22 A-01009 Pin – 1.0” x 5.5” 1
23 A-00018 Pin Retainer – 1.0” 1
24 0096-0014 Cap Screw, M10 x 20 1

51
 REAR AXLE ASSEMBLY

1 2 6 4 5

52
 REAR AXLE ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-00175 Hydraulic Cover 1
2 0096-0010 Cap Screw, M8 x 20 12
3 0096-0067 Clip Nut, M8 12
4 A-01032 Hydraulic Motor – Rear 2
5 0096-0024 Cap Screw, M12 x 100 8
6 0096-0042 Hex Nut, Self-Locking, M12 8
7 A-01037 Axle Cover 2

53
 SLEW RING ASSEMBLY

13

12

11

9 1

2 5

10

54
 SLEW RING ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-02189 Slew Assembly and Adapter 1
2 Slew Ring 1
3 Slew Ring Drive 1
4 A-00149 Base Ring Adapter 1
5 0090-0461 Cap Screw, 1/2-13 x 2 2
6 0090-0212 Lock Washer, 1/2 2
7 0096-0033 Flat Head Cap Screw, M16 x 35 16
8 0096-0054 Flat Head Cap Screw, M16 x 50 18
9 0090-0643 Cap Screw, 5/8-11 x 2-3/4, Grade 8 19
10 0096-0044 Hex Nut, Self-Locking, M16 16
11 A-00350 Rotation Stop Assembly 1
12 0096-0021 Cap Screw, M12 x 45 2
13 0096-0042 Hex Nut, Self-Locking, M12 2

55
 LIMIT SWITCH ASSEMBLY

18 1 19 20 9

10

15
13 2

11
7

12

11 17 5 14 4 3

56
 LIMIT SWITCH ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-01190L Switch Plate – Left 1
2 A-01190R Switch Plate – Right 1
3 0096-0016 Cap Screw, M10 x 25 4
4 B01-03-0078 Limit Switch NO 1
5 B01-03-0079 Limit Switch NC 1
6 A-01191 Switch Cam Weldment 1
7 A-01195 Switch Cam Top Slide 1
8 0096-0012 Flat Head Cap Screw, M8 x 25 6
9 A-01196 Tension Spring 3
10 0096-0078 Cap Screw, M6 x 80 1
11 0096-0039 Hex Nut, Self-Locking, M6 2
12 0096-0085 Cap Screw, M6 x 60 1
13 0090-0232 Machine Screw, #10-24 x 5/8 4
14 0090-0182 Hex Nut, Self-Locking, #10-24 4
15 0096-0081 Cap Screw, M8 x 80 2
16 A-01157 Switch Slide (Not Pictured) 2
17 0096-0040 Hex Nut, Self-Locking, M8 8
18 0096-0017 Cap Screw, M10 x 30 4
19 A-01197 Jib Slide Pad 2
20 0096-0041 Hex Nut, Self-Locking, M10 8

57
 CONTROL COMPARTMENT ASSEMBLY

10 8
21

22

21
8

13

12
15
7

13

14

1 7

4 9

2 3 8 7 8 5 8 11 16 17 18 19 20 7

58
 CONTROL COMPARTMENT ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-00712 Lower Control Box 1
2 A-00233 Lower Control Mount 1
3 A-00290 Cover Stop Bracket 1
4 0096-0016 Cap Screw, M10 x 25 2
5 0096-0041 Hex Nut, Self-Locking, M10 2
6 A-00295 Level Sensor 1
7 0096-0002 Cap Screw, M6 x 20 16
8 0096-0039 Hex Nut, Self-Locking, M6 20
9 A-00287 Mount Plate – GFI Outlet 1
10 A-00255 Motor Controller 2
11 B01-05-0056 Battery Charger 1
12 A-00274 Gas Spring 1
13 0090-0920 Stud Ball, 10mm 2
14 0090-0185 Hex Nut, Self-Locking, 5/16-18 2
15 A-03200 Turntable Weldment 1
16 B01-10-0046 Outlet Box 1
17 B01-10-0034 GFI Outlet 1
18 B01-10-0035 Outlet Box Cover 1
19 0096-0001 Cap Screw, M6 x 16 2
20 A-00288 Plastic Cover 1
21 0096-0004 Cap Screw, M6 x 25 8
22 A-00935 Dual Motor Controller Bracket 1

59
 PUMP COMPARTMENT ASSEMBLY

60
 PUMP COMPARTMENT PARTS LIST

Item No. Part No. Description Qty.

1 A-00268 Tire Iron/Jack Handle 1
2 B04-07-0033 Clamp 2
3 0096-0001 Cap Screw, M6 x 16 2
4 0096-0039 Hex Nut, Self-Locking, M6 4
5 A-00290 Cover Stop Bracket 1
6 0096-0002 Cap Screw, M6 x 20 2
7 0096-0014 Cap Screw, M10 x 20 2

61
 BATTERY COMPARTMENT ASSEMBLY
16 10 16 15 17 3

30

17 22

24
16

20

23
18
21
19
25
26 27

29 8

28
4

14

11

8 12 9 13 1 2 5

62
 BATTERY COMPARTMENT ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-00215 Battery Box Weldment – Left 1
2 A-00220 Battery Box Weldment – Right 1
3 A-00278 Battery Hinge Pin 2
4 0096-0050 Washer, Flat, M16 8
5 0090-0147 Cotter Pin 4
6 A-00271 Battery Clamp 4
7 0096-0010 Cap Screw, M8 x 20 4
8 0096-0040 Hex Nut, Self-Locking, M8 8
9 A-00219 Battery Box Latch 2
10 A-00256 Motor Cover 1
11 A-00229 Latch Plate 2
12 A-00234 Spacer 2
13 0096-0011 Cap Screw, M8 x 25 6
14 A-00244 Tension Spring 2
15 A-00225 Nose Weldment 1
16 0096-0014 Cap Screw, M10 x 20 10
17 0096-0041 Hex Nut, Self-Locking, M10 10
18 A-00037 Ramp, Short 4
19 0096-0002 Flat Head Cap Screw, M6 x 20 4
20 0096-0039 Hex Nut, Self-Locking, M6 4
21 A-00046 Grommet 4
22 B04-07-0036 Clamp 2
23 B01-09-0132 A-Frame Handle, Connector 1
24 B01-09-0131 Plug, Connector 1
25 A-03272 Battery Cable Kit 1
26 B01-09-0133 Terminal Boot – Black 4
27 B01-09-0134 Terminal Boot – Red 4
28 A-00242 Battery 4
29 0090-0162 Hex Nut, 3/8-16” 8
30 A-00235 Power Unit, 4WD 1
B02-15-0528 3KW 24V DC Motor 1
B02-15-0529 Gear Pump 2.0 ccm 1
B02-02-0301 Fitting M14 x –6 ORFS 1
B02-02-0302 Fitting, M18 x –8 ORFS 1

63
 COVER ASSEMBLY
5 3

8 9

10 1 2

64
 COVER ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-03240 Cover – Left 1
2 A-03239 Cover – Right 1
3 A-00228 Cover Brace 2
4 A-00252 Hinge 4
5 0096-0002 Cap Screw, M6 x 20 12
6 0096-0039 Hex Nut, Self-Locking, M6 12
7 0090-1080 Pop Rivet 22
8 A-00258 Controls Cover – Left Side 1
9 B42-01-1002 Hinge, Controls Cover 1
10 A-00292 Cover Latch Assembly 2

65
 LOWER BOOM ASSEMBLY
1 6 7 8 5 4

11

6
10
12

10 9

6
10

5 6 5 5 10 6

66
 LOWER BOOM ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-03300 Lower Boom Weldment 1
2 A-03314 Lower Link Weldment 1
3 A-02551 Lift Cylinder 1
4 A-00159 Boom Latch 1
5 0096-0016 Cap Screw, M10 x 25 11
6 0096-0041 Hex Nut, Self-Locking, M10 17
7 A-00157 Rest Pad 3
8 0096-0017 Cap Screw, M10 x 30 6
9 A-00021 Pin, 1.25 x 8.5 3
10 A-00019 Pin Retainer, 1.25 7
11 A-00023 Pin, 1.25 x 7.25 2
12 A-00032 Bearing 2

67
 TRIANGLE WELDMENT ASSEMBLY

7 14 15 2 5 16

13

17

7
7
5
6 6

9 7

8
4
6
7
3
5
6
4

15
6

7 4 1 12 10 11

68
 TRIANGLE WELDMENT ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-02320 Triangle Weldment 1
2 A-01552 Master Cylinder 1
3 A-02551 Lift Cylinder 1
4 A-00021 Pin, 1.25 x 8.5 4
5 A-00019 Pin Retainer, 1.25 9
6 0096-0016 Cap Screw, M10 x 25 10
7 0096-0041 Hex Nut, Self-Locking, M10 11
8 A-00018 Pin Retainer, 1.0 1
9 A-00049 Pin, 1.0 x 8.5 1
10 A-00537 Switch Block 1
11 0096-0098 Cap Screw, M8 x 35 2
12 0096-0040 Hex Nut, Self-Locking, M8 2
13 A-00054 Pin Retainer, 1.0 FH 1
14 A-00051 Pin, 1.0 x 7.0, DB 1
15 A-00032 Bearing 4
16 A-00023 Pin, 1.25 x 7.25 1
17 0096-0091 Flat Head Cap Screw, M10 x 25 1

69
 UPPER BOOM ASSEMBLY
7 2 6 8 9

10

20

6
4
22
21
5
6

19
11

17
10
18
6

9
22
8

14

22

12 13 18 19 15 18 19

70
 UPPER BOOM ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-03502 Upper Boom Weldment 1
2 A-03510 Telescopic Boom Tube 1
3 A-03550 Extension Cylinder 1
4 A-00535 Slider 2
5 0096-0017 Cap Screw, M10 x 30 4
6 0096-0041 Hex Nut, Self-Locking, M10 16
7 0096-0033 Flat Head Cap Screw, M16 x 35 4
8 A-00533 Wear Pad 12
9 A-00534 Wear Pad Shim 20
10 0096-0013 UHMW Bolts, M10 x 15 24
11 A-00532 Tube Slider 1
12 A-00529 Tube Slider Back 1
13 0096-0018 Cap Screw, M10 x 40 4
14 A-01554 Boom Latch Hook 1
15 A-01531 Cable Track Tube 1
16 A-03536 Cable Track Tray 1
17 A-03530 Cable Track 1
18 0096-0010 Cap Screw, M8 x 20 12
19 0096-0040 Hex Nut, Self-Locking, M8 12
20 A-00026 Pin, .75 x 7.0 1
21 A-00925 Pin Retainer, .75 1
22 0096-0016 Cap Screw, M10 x 25 8

71
 JIB BOOM ASSEMBLY
14 7 8 7 12 13 25 24 28 8

11

10

9
15 29
2 13

31

30 15
8
1
14
3
7
31

8
7
8 16

18
5

17
22
8
15
6
27
26
7

21 20 23 19

72
 JIB ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-00657 Jib Link Weldment 2
2 A-00651 End Pivot Weldment 1
3 A-00660 Jib Cylinder 1
4 A-01553 Slave Cylinder 1
5 A-00662 Jib End Weldment 1
6 A-01979 Bulkhead – Left 1
7 0096-0016 Cap Screw, M10 x 25 7
8 0096-0041 Hex Nut, Self-Locking, M10 12
9 0096-0091 Flat Head Cap Screw, M10 x 25 2
10 A-00054 Pin Retainer, 1.0, Flat Head 2
11 A-00052 Pin, 1.0 x 5.25 1
12 A-00018 Pin Retainer, 1.0 2
13 A-00061 Pin, 1.0 x 7.375 2
14 A-00925 Pin Retainer, 0.75 4
15 A-00050 Pin, 0.75 x 7.375 4
16 A-00672 Valve Guard 1
17 A-00667 Jib Bumper 1
18 0096-0068 Flat Head Cap Screw, M10 x 45 5
19 B01-10-0046 Outlet Box 1
20 B01-10-0034 GFI Outlet 1
21 B01-10-0035 Outlet Box Cover 1
22 0096-0001 Cap Screw, M6 x 16 2
23 0096-0039 Hex Nut, Self-Locking, M6 10
24 A-00522 Boom End Weldment 1
25 A-00031 Bearing 2
26 A-00038 Ramp, 0.25 4
27 0096-0002 Flat Head Cap Screw, M6 x 20 8
28 0096-0019 Cap Screw, M12 x 25 8
29 0096-0042 Hex Nut, Self-Locking, M12 8
30 0096-0018 Cap Screw, M10 x 40 2
31 A-00056 Bushing 4

73
 PLATFORM ASSEMBLY

17 16 13 15 14

22

23
24

7
5

6 18

11

12

21
2
1

20

19
13 10

74
 PLATFORM ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-03350 Platform Weldment – 5’ 1
1 A-03365 Platform Weldment – 4’ 1
2 A-03359 Platform Floor 1
3 0096-0102 Cap Screw, M8 x 25 26
4 0096-0040 Hex Nut, Self-Locking, M8 26
5 A-03361 Upper Control Box Mount 1
6 0096-0016 Cap Screw, M10 x 25 4
7 0096-0041 Hex Nut, Self-Locking, M10 4
8 A-00466 Control Box Latch 1
9 A-00463 Midrail End 4
10 0096-0115 Slotted Head Cap Screw, M6 x 20 2
11 A-00464 Midrail 1
12 0096-0052 Cap Screw, M6 x 40 2
13 0096-0039 Hex Nut, Self-Locking, M6 6
14 A-00468 Manual Storage Mount Plate 1
15 0096-0017 Cap Screw, M10 x 30 2
16 A-00475 Manual Storage Box 1
17 0096-0001 Cap Screw, M6 x 16 4
18 A-00474 Cord Wrap Bracket 1
19 A-00071 Platform Pin 1
20 0090-0147 Cotter Pin – 1/8 x 1 1/4 2
21 A-00028 Pin – Platform to End Weldment 1
22 A-00779 Upper Control Box – 4WD Articulating 1
23 A-00462 Spool 7
24 0096-0003 Flat Head Cap Screw, M6 x 40 7

75
76
17 20 13 25
12
18
11

19
15 20

17
16
10

17 17
17
14
24
17
24

19

2 21 8 9
19 19
PUMP ASSEMBLY (A-03254)

20 4
6

1
5 21 22
17 17 7

23

17
19
 PUMP ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 B02-15-0496 Manifold, Valve Housing 1
2 B02-14-0108 Valve, Cartridge (Telescope) 2
3 B02-15-0472 Manual Pump, Extend/Retract/Rotate 1
4 B02-14-0089 Valve, Cartridge (Outrigger Check) 1
5 B02-14-0109 Valve, Cartridge (Outrigger) 2
6 B02-14-0091 Valve, Check 1
7 B02-14-0110 Valve, Check 1
8 B02-14-0094 Valve, Proportional 1
9 B02-14-0095 Coil Sterling, Proportional Valve 1
10 B02-14-0111 Valve, Relief 1
11 B02-14-0097 Valve, Relief 1
12 B02-14-0098 Valve, Shuttle 1
13 B02-14-0099 Valve, Cartridge (Rotator) 1
14 B02-14-0100 Valve, Counterbalance 2
15 B02-14-0101 Valve, Cartridge (Basket Compensate) 1
16 B02-14-0114 Valve, Flow Control (Rotator) 1
17 B02-02-0245 Fitting, Plug, #2 ORB 11
18 B02-02-0246 Fitting, Hex Plug 1
19 B02-02-0248 Fitting, Plug, #4 ORB 5
20 B02-14-0112 Coil, 20 VDC, #8 5
21 B02-14-0113 Coil, 20 VDC, #10 4
22 B02-15-0497 Stud, #1/4-20 x 5/8 4
23 B02-15-0498 Expansion Plug 1
24 B02-02-0235 Fitting, Plug, #6 ORB 2
25 B02-15-0478 Seal Ring 1

77
78
5
18 12

20

19

14
15

15
22
17
PUMP ASSEMBLY, CONTINUED

8
3 2
9 7
4
21

16

11

13 10
 PUMP ASSEMBLY PARTS LIST, CONTINUED

Item No. Part No. Description Qty.

1 B02-15-0513 Reservoir 1
2 B02-15-0470 Pump Assembly, 2.09CCM 1
3 B02-15-0471 Motor, Pump, 24 V DC 1
4 B02-15-0500 Coupling, .875 x 2.795 1
5 B02-15-0501 Filter, Hydraulic 1
6 B02-15-0476 Sight Glass 1
7 B02-15-0477 Socket Head Cap Screw, M8 x 85 2
8 B02-02-0247 Fitting, Plug, M14 x 1.5 x 5.8 1
9 B02-15-0478 Seal Ring 1
10 B02-15-0485 Clamp, Band, #10-16 2
11 B02-15-0480 Filter, Suction, Pump 1
12 B02-15-0504 Allen Nut, 1/4-20 4
13 B02-02-0255 Fitting, M18 x HB-90 MxHB-90 1
14 B02-15-0503 O-Ring, 110.72 x 3.53 NBR 70D 1
15 B02-02-0279 Fitting, JIC-8 x Push On FsxPO 2
16 B02-15-0505 Hose, Black, 1/2 x 6” 1
17 B02-02-0280 Fitting JIC-8 x #6 90 MxM 1
18 B02-15-0506 Cap Screw, #5/16-18 x 1 1/4 2
19 B02-02-0283 Fitting, JIC-8 x G 3/4 MxM 1
20 B02-02-0281 Fitting, Plug, #12 ORB 2
21 B02-02-0282 Fitting, 3/8 NPT x 1/2 MxHB 1
22 B02-15-0507 Hose, Black, 1/2 x 15” 1
B02-02-0276 Fitting, Plug, #8 ORB (Under Reservoir) 1

79
 BOOM AND ROTATION HYDRAULIC LINES (A-03269)

12
13
0237
Slave RET
Basket Level EXT
0237

Jib
10 Master 11
Basket Level 0259
EXT 0259

RET
Telescopic
23 21
0259
RET

EXT
0260
17 22

16 0258 20
19 0259
9 0259
0258 15 RET RET
5 6
EXT
Lower Lift EXT
Upper Lift
0258 14 18
0258
EXT 0259 0259

7 8

3 4

0242
0196
0262
TP1 Top Port
PRA
45 Bottom
SMA 2 Port

PRB 0259
45 0262
SMB
1
ECA
45
Rotation
BCB BCA
Kinematics
45 45 Slew Drive
ECB
45

24
Outrigger Ret 0241

ORB 45
ORA
45
Outrigger EXT

80
 BOOM AND ROTATION HYDRAULIC LINES PARTS LISTS
Item No. Part No. Description
1 B02-01-0281 #4 x 36” Hydraulic Hose
2 B02-01-0280 #4 x 36” Hydraulic Hose
3 B02-01-0313 #4 x 204” Hydraulic Hose
4 B02-01-0314 #4 x 204” Hydraulic Hose
5 B02-01-0315 #6 x 237” Hydraulic Hose
6 B02-01-0316 #6 x 237” Hydraulic Hose
7 B02-01-0289 #6 x 20” Hydraulic Hose
8 B02-01-0290 #4 x 20” Hydraulic Hose
9 B02-01-0291 #4 x 15” Hydraulic Hose
10 B02-01-0320 #4 x 310” Hydraulic Hose
11 B02-01-0321 #4 x 310” Hydraulic Hose
12 B02-01-0234 #4 x 16” Hydraulic Hose
13 B02-01-0235 #4 x 16” Hydraulic Hose
14 B02-01-0294 #6 x 20” Hydraulic Hose
15 B02-01-0295 #4 x 20” Hydraulic Hose
16 B02-01-0322 #6 x 183” Hydraulic Hose
17 B02-01-0323 #4 x 183” Hydraulic Hose
18 B02-01-0298 #6 x 20” Hydraulic Hose
19 B02-01-0299 #4 x 20” Hydraulic Hose
20 B02-01-0324 #6 x 316” Hydraulic Hose
21 B02-01-0301 #6 x 54” Hydraulic Hose
22 B02-01-0346 #4 x 316” Hydraulic Hose
23 B02-01-0343 #4 x 54” Hydraulic Hose
24 B02-01-0282 #3 x 20” Hydraulic Hose

FITTINGS
Part No. Description Qty.
B02-02-0259 #6 MORFS - #6 MORB, STR 11
B02-02-0264 #6 MORFS - # 6 MORB, 45º 8
B02-02-0260 #6 MORFS - #6 MORB, 90º 1
B02-02-0237 #4 MORFS - #6 MORB, STR 2
B02-02-0262 #6 MORFS - #10 MORB, 45º 2
B02-02-0258 #6 MORFS, Tee 5
B02-02-0270 #6 MORFS - #6 MORFS - #6 MORB, Tee 1
B02-02-0196 #4 MORB - #2 MNPT, STR 1
B02-02-0241 #2 NPTFM Coupling 1
B02-02-0242 #2 QD Plug 1

81
 OUTRIGGER HYDRAULIC LINES (A-03182)

EX

ET
T

R
RE

T
10
T

10

EX
1 RET 4
6 2 1

2 8

1 7

2
2 9 EXT 9
3
5 RE
T

10 1 T
EX

10 EX
ET

T
R

OUTRIGGER HYDRAULIC LINES PARTS LIST

Item No. Part No. Description Qty.

1 B02-01-0213 #4 x 28” Hydraulic Hose 4
2 B02-01-0214 #4 x 28” Hydraulic Hose 4
3 B02-01-0215 #6 x 56” Hydraulic Hose 1
4 B02-01-0216 #6 x 56” Hydraulic Hose 1
5 B02-01-0219 #6 x 28” Hydraulic Hose 1
6 B02-01-0220 #6 x 28” Hydraulic Hose 1
7 B02-01-0327 #6 x 46” Hydraulic Hose 1
8 B02-01-0328 #6 x 46” Hydraulic Hose 1
9 B02-02-0258 Fitting, Tee, #6 MORFS 6
10 B02-02-0259 Fitting, #6 MORFS - #6 MORB 8

82
 Oil Filter

5 5
#8MORFS-#12MORB STR
FF6400-8-12
13
12
OIL #4MORFS-#4MORB 90
COOLER FF6801-4-4
FF6400-4-4
#4MORFS-#4MORB 90 B1
FF6801-4-4 FF6801-6-6
S1A M2A M3A M1A M4A

1A
TB
Driver P1A FF6400-4-4
90 FF6400-4-6
FF6400-6-6 FF6400-6-6 FF6400-6-6
#12ORBM-#10ORBFM STR FF6400-6-6 FF6400-6-6
6410-12-10
TA

2A
#10MORFS-#10MOBR-#10MORFS Tee P2B
FF6804-10-10-10 STR FF6400-6-6 FF6400-6-6 FF6400-6-6 FF6400-6-6
#10MORFS-#10FMORFS 90 FF6801-L-6-6 FF6400-8-8
FF6500-10-10 S1B M2B M3B M1B M4B
7
P2A FF6400-4-6
90L

P1B
6 90
1
FF6801-6-6

6-14 Metric
2 90
9
8 P Aux
#8MORFS Tee
FF2603-8-8-8 T Pump
22
2B 4A
8-18 Metric
16 90

3B
4 14 18 20
4B (2) #4MORFS-#4MORB 45
(2)#10MORB-#6FMORB 15 17 (2)#10MORB-#6FMORB FF6802-4-4
19 21
6410-L-10-6 6410-L-10-6
(2)#6MORFS-#6MORB 90 (2)#6MORFS-#6MORB 90 B1
FF6801-6-6 FF6801-6-6
10 Top Top Brake

Control MANUAL
3
Pump BRAKE
Side RELEASE
Side 23

Front Front
Bottom Bottom #4MORFS Tee
FF2603-4-4-4
24

24
TP3 Front
#6MORFS-#6MORB STR
TP2 Front 15

1B
FF6400-6-6
7 Pump
A 19
Control Side
6 SMA
A Side 14
Rear
Dual Rear 18 Rear
#10MORFS-#12ORB 90 SMB
Pump FF6801-10-12 Rear
5GPM (2) #6MORFS-#10MORB STR
(2) #6MORFS-#10MORB STR FF6400-6-10
FF6400-6-10 (2) #4MORFS-#4MORB 90
10MORB Plug (2) #4MORFS-#4MORB 90 FF6801-4-4
(2) #8MORFS-#10MORB 45 6408-H-10 FF6801-4-4
FF6802-8-10
#4MORFS Tee
FF2603-4-4-4

3A
11 11

ORB
Banjo
Bolt

83
TRAILER HYDRAULIC LINES – 4WD (A-01075)
 TRAILER HYDRAULIC LINES PARTS LISTS
Item No. Part No. Description
1 B02-01-0402 #10 x 28” Hydraulic Hose
2 B02-01-0401 #8 x 154” Hydraulic Hose
3 B02-01-0398 #8 x 16” Hydraulic Hose
4 B02-01-0400 #8 x 24” Hydraulic Hose
5 B02-01-0399 #8 x 18” Hydraulic Hose
6 B02-01-0386 #6 x 30” Hydraulic Hose
7 B02-01-0387 #6 x 30” Hydraulic Hose
8 B02-01-0397 #6 x 166” Hydraulic Hose
9 B02-01-0396 #6 x 150” Hydraulic Hose
10 B02-01-0385 #4 x 118” Hydraulic Hose
11 B02-01-0379 #4 x 16” Hydraulic Hose
12 B02-01-0382 #4 x 30” Hydraulic Hose
13 B02-01-0383 #4 x 40” Hydraulic Hose
14 B02-01-0393 #6 x 138” Hydraulic Hose
15 B02-01-0392 #6 x 138” Hydraulic Hose
16 B02-01-0388 #6 x 38” Hydraulic Hose
17 B02-01-0389 #6 x 38” Hydraulic Hose
18 B02-01-0395 #6 x 138” Hydraulic Hose
19 B02-01-0394 #6 x 138” Hydraulic Hose
20 B02-01-0390 #6 x 62” Hydraulic Hose
21 B02-01-0391 #6 x 62” Hydraulic Hose
22 B02-01-0380 #4 x 21” Hydraulic Hose
23 B02-01-0384 #4 x 105” Hydraulic Hose
24 B02-01-0381 #4 x 25” Hydraulic Hose

84
 FITTINGS
Part No. Description Qty.
B02-02-0259 #6 MORFS - #6 MORB, STR 10
B02-02-0293 #8 MORFS - #8 MORB, STR 1
B02-02-0260 #6 MORFS - #6 MORB, 90º 6
B02-02-0287 #4 MORFS - #4 MORB, STR 2
B02-02-0288 #4 MORFS - #4 MORB, 90º 6
B02-02-0289 #4 MORFS, Tee 2
B02-02-0294 #6 MORFS - #6 MORB, 90ºL 1
B02-02-0295 #12 MORB - #10 FMORB 1
B02-02-0296 #10 MORFS - #10 MORB - #10 MORFS, Tee 1
B02-02-0297 #10 MORFS - #10 FMORFS, 90º 1
B02-02-0298 #8 MORFS - #12 MORB, STR 1
B02-02-0299 #8 MORFS - #10 MORB, 45º 2
B02-02-0300 #10 MORFS - #12 MORB, 90º 1
B02-02-0303 #10 MORB Plug 1
B02-02-0304 #10 MORB - #6 FMORB 4
B02-02-0305 #6 MORFS - #10 MORB, STR 4
B02-02-0237 #4 MORFS - #6 MORB, STR 2
B02-02-0307 #8 MORFS, Tee 1
B02-02-0308 #4 MORB Plug 1
B02-02-0309 #8MORFS - #12 MORB, 90º 2

85
 MANIFOLD ASSEMBLY – 4WD (A-01033)

86
 MANIFOLD ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 B02-15-0516 Valve, Cartridge, NC 2
2 B02-14-0111 Relief Valve, 3000 psi 1
3 B02-14-0118 Relief Valve, 600 psi 1
4 B02-14-0092 Check Valve 8
5 B02-15-0092 Proportional Valve 1
6 B02-14-0119 Valve, Directional – Steering, 4WD 1
7 B02-14-0098 Shuttle Valve 1
8 B02-15-0518 Cartridge Valve, NO 1
9 B02-14-0120 Orifice, Brake 1
10 B02-14-0121 Cartridge Valve, NO 2
11 B02-14-0122 Valve, Directional – Drive, 4WD 2
12 B02-14-0123 Flow Control Valve 1
13 B02-14-0112 Coil – 20v DC – Deutsch Connector 11
14 B02-15-0524 Coil – Proportional – 20v DC – Deutsch Conn. 1

87
 WIRE HARNESSES - ANSI
Upper
Control
Box

Platform Plug B F D

E A C

Motor Motor
Wh Bla Re
Cntl Cntl
B+ B- Blu Or Gr

3 6 8
1 2 4 7 9

P4 & P5 J4
Connector Platform Connector

P3 P1 P2
Turntable Connector Analog Connector Lift/Engine Connector
36 24 23 16 35 24

12 1 8 1 12 1

11 5 1 31 7 13 23 10 17 35 32
24 3 4 26 15 16 23 8 22 1 20 12 3 21 20 8 14 9 34 18 32
1 2 27 13 14 22 15 23 16

+ - X Y + -
Jib
R B O Br Cyl
C17 Prop
Coil
C8
Strobe Sec PLT
Cyl DN
C16 C14

PLT Chk
Level Prim UP Valve
Sensor Cyl C13 C6A
C5 Boom
Rot OR
CCW RET EXT
C9 C12 C6
Rot Boom OR
CW EXT RET
C10 C11 C7

Motor Motor Pump

Controller Controller
Main Aux
LF
3 1 3 1
LF LR RF RR **NO Speed Enable Speed Enable Oil
Press
AC
Switch
C1 C3 C2 C4 B- M- B+ B- M- B+ Switch
LR

**NO
# # NO # # NO
RF 10 25 27 24 9 26

Front
**NO D
Jib
Boom A 2 E2 1 E1
Throttle Fuel
Switches
Switches Aux Sol Switch
RR
Pump
Boom # NC # NC NO
Down
** 200
Amp Motor
Fuses Choke Engine
Relay NC Sol Stop
2 D 1 E1
A 2E
34 33 11 10 9 8 7 6
Main
Engine
Pump Start
Fan
C26 C25 C24 C23 C22 C21 C20
Motor
12 Engine
L N
Run
35

C31 C30 C29 C28 C27

Engine Engine Stop
IEC Recp. Start
21 20 19 18 17

Start Engine Spark

Drive
Manifold
Fuel Start Sol

**Switch is forced Closed

when outrigger is loaded Fan Fuel Sol

#
Switch is forced open
M
AC when Boom is lifted Fan
GFCI Plug AC Switch ##
Plug Switch is forced Closed
when Boom is Stowed

Generator

88
WIRE HARNESSES – CE

89
 MANIFOLD WIRE HARNESS (A-00785)

Deutsch Term.
0462-201-16141
Orange C20 1 Deutsch
DT06-2S
2
Label Wires Wires White C21 1
2 Pin Plug
Connected W2S Wedge
Both Ends Wire Color 2
& Sealed Green C22 1
2
Red C23 1
2
12020786 A C20 Orange
Blue C24 1
6 Pin Male Conn B C21 White
2
1208089040 C C22 Green White/B C25 1
Male Term
D C23 Red 2
12015323 9"
Green Wire Seal E C24 Blue Orange/B C27 1
F C25 White/B 2
Blue/B C28 1
12010717 Label Label GND 1 9" 2
3 Pin Male Conn A GND Black A-00785 A-00785 3" Black Green/W C29 1
12089040 C26(+) Red/B
B Rev- Rev- 2
Male Term 3"
C C26(-) Green/B Red/W C30 1
12015323 Black/W
Green Wire Seal 156" (13')(+/- 2") 16 Cond 18ga Wire GND 2 2
Blue/W C31 1
A C27 Orange/B SOOW or Equivalent 2
12020926 B Blue/B
C28 Wires Red/B C26 + 1
6 Pin FM Conn
C C29 Green/W Green/B C26 - 2
12089188 Connected
FM Term D C30 Red/W
& Sealed
12015323 E C31 Blue/W
Green Wire Seal F Black/W
GND
Stripe wire
to 12"
Stripe wire
to 4"

GAS ENGINE WIRE HARNESS (A-01034)

12020829
3 Pin Female Conn Wire
12089188 Wire Color Label
Label
Female Term Color
12015323 Delphi
Green Wire Seal Weather Pack
R/BL Oil Press Sw (+) A
C Or/BL Or/BL Oil Press Sw 12015792
Oil Press Sw B
2 Pin Female Conn
B Oil Press Sw (+) R/BL
12089188
A Gen Switch Wh/Bl Female Term
Wh/Bl Gen Switch B 12015323
Green Green Wire Seal
GND A
C Engine Run Red
B GND Green Delphi
A Choke Black Weather Pack
12020827 120" (10') 5" 12010973
3 Pin Male Conn 2 Pin Male Conn
12089040 18ga-10 Cond Wire 12089040
Male Term Male Term
12015323 SOOW or Equivalent Black Choke A
12015323
Green Wire Seal Orange Throttle B Green Wire Seal

A-01034 A-01034
Green Splice &
12020829 Rev- Rev- 1" Heat Sealed
3 Pin Female Conn Delphi
Label Both
12089188
Ends 5" Weather Pack
Female Term
12015323 12020830
Red Engine Run A
Green Wire Seal 4 Pin Male Conn
White Engine Start B 12089040
C Throttle Orange Blue Engine Stop C Male Term
B Engine Start White Green GND D 12015323
Green Wire Seal
A Engine Stop Blue
Strip Wires 6"
Strip Wires 3"

90
 CHOKE /THROTTLE SOLENOID WIRE HARNESS (A-01042)

1"
A-01042
Rev- Label

Weather Pack Put Wires

FM Term
in 16"
12089188
Cable Seal Split
12015323 tubing
FM Housing
Heat Seal
12015792
Both
ends
B B

A W
20" 18ga TXL
Or Equivalent

ENGINE RELAYS WIRE HARNESS (A-01044)

Solder inline &

Heat Shrink
A-01044
Rev- Label
Resistor
2.2k-Ohm
.5Watt
Wire
Color Wire
Length
10" Split Engine
¼” Female Spade Engine Run Red 10" 4" ¼” Male Spade
Tube Wrap Run

Tape At ¼” Female Spade

Delphi Weather Pack
Each End Male Term 12089040
Green Seal 12015323
FAN 4" Red Fuel F 87 15" Green Fuel Sw ¼” Female Spade
¼” Female Spade Ign K 87a Black 15" Ign Coil ¼” Male Spade
¼” Female Spade Starter S 87 Yellow 20" Starter ¼” Female Spade
F 30 6"
¼” Female S 30 6"
12v + Orange 18" + 12V 5/16" Ring Term
Spade C 30 8"
T 30 8"
All wires 18 ga
Heat
TXL or Equivalent Labels
Shrink
Wire Color All Measurements
are +/- 0.250 In
3"
3"
3"

B G R
8"
6"

91
 ATC FUSE HOLDER (A-01049)

ATC Fuse Holder

Waytek # 46278
or Equivalent

5/16" Ring
¼” Female Spade Ins Term

4"- 6" Leads 4"- 6" Leads

12 ga Wire 12 ga Wire

START/STOP/RUN WIRE HARNESS (A-01098)

2"
A-01098
Label
Rev -

10" Split Tube Wrap

& Heat Shrink
Each End
Tape Both Sides Wire Label
7" Delphi Weather Pack
of Drop Out
12020832
4 Pin Female Conn ¼” Male Spade
12089188 Engine Run
Insulated
Female Term
12015323 Wire Start S 86
Green Wire Seal Color Length
6" Stop K 86
18" A Red 24"
4" Fuel F 86
B White 26"
C Blue 20" 8" GND 85
D Green 20" 6" GND 85
12015792 4" GND 85
Delphi Weather Pack 2 Pin Female Conn 6" GND 85
12089188
8" GND 85
Female Term
12015323
Green Wire Seal
A Choke Black 28" Choke C 86 ¼” Female Spade Insulated
B Throttle Orange 28" Throttle T 86

A Choke Yellow 28" Choke C 87

B 15" Black

A Throttle Orange/Bl 28" Throttle T 87

B 15" Black

12010973
2 Pin Male Housing Frame
9" Black Black 11" K 30
12089040 Gnd
Male Terminal ¼” Ring
12015323 Terminal
5"
Green Wire Seal Delphi Weather Pack

Delphi Weather Pack All wires 12010973 Fan

2 Pin Male Housing
TXL or Equivalent 12089040 A – Leave
All Measurements Splice & Heat Male Terminal Open
A
B

are +/- 0.250 In Shrink Seal 12015323

Green Wire Seal

92
 GENERATOR SWITCHER BOX ASSEMBLY (A-03040)

Box-A-01015

B01-06-0056
B01-01-0180
30 Amp Relay
B01-10-0354 DPST – NO
20 Amp Circuit Breaker Allied Electronics
W/.250 Male Spade Terminal 20 #850-0345
Allied Electronics Amp
Or Equivilant
#886-0036
Or Equivilant

Ground
Stud

Bl
Y/
Br
g
B W G B W G B W
Cord Grip
Heyco #3231
Or Equivilant

W A
B01-01-0181 B01-01-0179
B B
B01-01-0178

Delphi Weather Pack

2 Pin Male Housing 12010973
B W G Male Terminal 12089040
Green Seal 12015323

Delphi Weather Pack

3 Pin Male Housing 12015793
Male Terminal 12010293
C
A

Gray Seal 12010293

WIRE ASSEMBLY – FAN (A-03041)

B
A
A-3041
Label Rev.

40" Loom
Tape each End &
Middle
Label Wire
Weather Pack Weather Pack
FM Term
Wires Color FM Term
12089188 B GND B 12089188
Black A-03041
Cable Seal Cable Seal
12015323 A Relay Red Rev. A 12015323
FM Housing FM Housing
12015792 12015792
36"

All wires 18 ga
TXL or Equivalent
All Measurements
are +/- 0.250 In
B
A

93
 IEC CORD MALE – ANSI (A-03042)

18"

A-03042
Rev
SO cable or Label
Equivalent

North America
Minimum Requirements 120V Male Plug
IEC 90 Degree Plug
Interpower Current 15 AMP
IEC 60320 C19
Mold 012 Voltage 120/240VAC

GENERATOR 110V WIRE HARNESS (A-03043)

12-3 SO
Or Equivilant .0625" 3" B
2"
A B 36" (+/- 2") B 3" B
3" W
B W W 2"
3" W
W B

C W B
G

1/2” Grommet OD
Delphi Weather Pack
12010717
3 Pin Male Housing
12124582
Male Terminal 12/14ga
12010293
Seal 12/14ga

OIL SWITCH ASSEMBLY (A-03044A)

Delphi Weather Pack

B00-00-0170 12010973 (B01-09-0109)
Wire Casing 2 Pin Male Housing
A-03044 PVC 12089040 (B01-09-0110)
OIL PRESSURE SWITCH 4WD
16" Tape Male Terminal
TRANSDUCER DIRECT #TDPS211A8FW 12015323 (B01-09-0093)
Green Seal

R A

B
B

Wires should be 17-18" Long

94
 CORD ASSEMBLY 110V GENERATOR (B01-01-0178)

24"
¼” Female Spade

B
A

B W G B01-01-0178

W
B ¼” Female Spade
Rev
C

G
14-3 #10 Ring Terminal
SO or Equivalent
Delphi Weather Pack
12015793 4"
3 Pin Female Housing
12124580 Label
Female Terminal 12/14ga
12010293
Seal 12/14ga

CORD ASSEMBLY GENERATOR SWITCH (B01-01-0179)

28"

¼” Female Spade
A W B01-01-0179
B B Rev
¼” Female Spade
18-2
Delphi Weather Pack SO or Equivalent
12010973 4"
2 Pin Male Housing Label
12089040
Male Terminal
12015323
Green Seal

CORD ASSEMBLY SWITCH JUMPER (B01-01-0180)

B01-01-0180
¼” Female Spade Rev
¼” Female Spade

14ga Black

TXL or Equivalent
Label
All Measurements
are +/- 0.250 In

CORD ASSEMBLY 110V AC PLUG – FM (B01-01-0181)

12"

¼” Female Spade
B

B01-01-0181
W

¼” Female Spade
Rev
G

14-3
SO or Equivalent
4"
North America
110V Female Plug

95
 SWITCHER BOX ASSEMBLY – CE MODELS (A-03040CE)
Box-A-01015

B01-01-0180
B01-06-0056
30 Amp Relay
B01-10-0354 20
DPST – NO
20 Amp Circuit Breaker Amp Allied Electronics
W/.250 Male Spade Terminal #850-0345
Allied Electronics Or Equivilant
#886-0036 20
Amp
Or Equivilant

Bl
Y/
Br
g
B W G G W B B W
Cord Grip
Heyco #3231
Or Equivilant
B01-09-0005
Blue Wire Nut

W A
B01-01-0181CE B01-01-0179
B B
B01-01-0178

Delphi Weather Pack

2 Pin Male Housing 12010973
B W G Male Terminal 12089040
Green Seal 12015323

Delphi Weather Pack

3 Pin Male Housing 12015793
Male Terminal 12010293
C
A

Gray Seal 12010293

220V GENERATOR WIRE HARNESS – CE (A-03043CE)

14-3 SO
Or Equivilant .0625"
2"
A 24" (+/- 2")
B W G

Green 2" 2" G G Y W

B
White 4" W B G R
C
Black 4" Generator
Wire Colors
Delphi Weather Pack
12015793
1/2” Grommet OD
3 Pin Female Housing
12124580
Female Terminal 12/14ga
12010293
Seal 12/14ga

CORD ASSEMBLY 220V AC PLUG – CE (B01-01-0181)

12"

¼” Female Spade
B

B01-01-0181CE
W

¼” Female Spade
Rev
G

14-3
SO or Equivalent
4"

InterPower
# 88010390
16A Socket or
Equiliviant

96
 Pin 15 12" 18ga Jib Rot CW A Delphi Weather Pack A Delphi
B 12020829 3 Pin FM Housing 12020827 3 Pin Male Break wires out of loom
Pin 16 12" 18ga Jib Rot CCW B
12089188 FM Term 12010300 Cavity Plug In groups as shown
Pin 22 12" 18ga GND C 12015323 Green Seal C Tape both side of loom
AMP Where wires exit
Pin 5 12" 18ga Jib Pos A
770520-1 -Label all wires at plug end
B
Pin 12 12" 18ga Jib Neg B

770520-1
Pin 3 12" 18ga Sec Boom Pos A
Sec Boom Neg
B
6" 18ga B
B B
770520-1 A B A
Pin 11 3" B B 3" 6" 18ga Prim Boom Neg B B B B B
A A 9" 18ga W
54" SJO W
Pin 1 3" Prim Boom Pos A A A
770520-1 Pin 7 60" 18ga Rotate CW 2
0462-201-16141 40"
A 12" 1
770520-1 0462-201-16141
Pin 8 60" 18ga Rotate CCW 2
Delphi Weather Pack 0462-201-16141
770520-1 12" 1 Engine
12010973 2 Pin M Housing Pin 23 48" 18ga GND Option
12089040 M Term 770520-1 0462-201-16141 Outrigger Ret Pos
Pin 13 60" 18ga Platform Level UP 2 Wires Outrigger Ext Pos
12015323 Green Seal 0462-201-16141 10" Split Prop Valve Pos
12" 1
B 770520-1 0462-201-16141 Loom Prop Valve Neg
Pin 14 60" 18ga Platform Level DN 2
Delphi Weather Pack 0462-201-16141 Extend Sol Pos
12015792 2 Pin FM Housing 12" 1 Retract Sol Pos
12089188 FM Term 770520-1 0462-201-16141
Pin 9 48" 18ga Boom Extend 2
12015323 Green Seal 0462-201-16141
12" 1
770520-1 0462-201-16141
Pin 10 48" 18ga Boom Retract 2
770520-1 0462-201-16141 50" Split
Pin 34 36" 18ga GND 12" 1 Prim Sec &
Jib Loom
Jib Boom
770520-1 0462-201-16141 Rotate
Pin 17 48" 18ga Outrigger Retract 2 wires
Amp 10" Split
0462-201-16141 10" Split
Housing 12" 1 Loom
0462-201-16141 Loom
776164-2 12" 2
770520-1 0462-201-16141 Rotate CW Pos
White Pin 35 36" 18ga GND 12" 1
0462-201-16141 Rotate CCW Pos
770520-1 12" 2 Plat Level Up
Pin 18 36" 18ga Outrigger Extend 0462-201-16141 Plat Level DN
12" 1

24
1
770520-1 Deutsch 0462-201-16141 Socket
Pin 32 60" 18ga Prop Valve Pos ¼” Female Spade Ins Deutsch Prim
DT06-2S Boom
770520-1 2 Pin Plug
Pin 33 60" 18ga Prop Valve Neg ¼” Female Spade Ins 18-2
W2S Wedge
770520-1
Pin 26 12" 18ga Engine Stop A Delphi Weather Pack A Delphi
770520-1 12020827 3Pin Male Housing 12020829 3 Pin FM
Pin 25 12" 18ga Engine Start B B
770520-1 12089040 Male Term 12010300 Cavity Plug
Pin 24 12" 18ga Throttle C 12015323 Green Seal C

35
12
770520-1 A Delphi
Pin 27 12" 18ga Choke A Delphi Weather Pack
12020829 3 Pin FM Housing 12020827 3 Pin Male
B B B
6" 18ga Ground 12089188 FM Term 12010300 Cavity Plug
B 6" 18ga Engine Run 12015323 Green Seal C
A C
All individual wires 770520-1
Pin 20 12" 18ga Gen Switch A Delphi Weather Pack A Delphi
TXL or Equivalent 770520-1
All Measurements are Oil Press Sw (+) 12020827 3Pin Male Housing 12020829 3 Pin FM
Pin 31 12" 18ga B B
+/- 0.250 In 770520-1 12089040 Male Term 12010300 Cavity Plug
Pin 21 12" 18ga Oil Press Sw C 12015323 Green Seal C

97
PUMP AND CYLINDER WIRE HARNESS (A-03716)
98
(180")

Pin 27 B Strip 4" R B Boom

Strip 3" A Weather Pack Weather Pack
Pin 24 R Strip 4" G NC Switch FM Term
18-4 Boom Down Switches Male Term
G 4" 12089188
B B Boom 12124582
W 4" Cable Seal Cable Seal
W A NC Switch
12015323 12015323
(88") FM Housing
G B Jib Male Housing
W 4" Strip 3" A 12010973 12015792
R NC Switch
4" 18ga BL G 4" Boom Down Switches
Pin 26 18-3 B B Jib
R 4"
Amp FM Conn 4" W A N0 Switch
770520-1
B
Splice group of
(184")
Label B B B
wires together 18-2 Driver’s Front LF Switch A
A-03039 and seal
Pin 13 W W
(184") Weather Pack
Rev- B B Male Term 1"
18-2 Pass. Front RF Switch B
Pin 14 W W A 12124582
Amp Housing (170") Cable Seal
12015323 10" 10"
776164-1 B B B
18-2 Driver’s Rear LR Switch Male Housing Split Split
Black Pin 15 W W A
12010973 Loom Loom
(170")
B B B
18-2 Pass. Rear RR Switch

1
W A

24
Pin 16 W
130"
B B B 36"
18-2 Driver’s Front LF Coil A
Pin 1 W W Nylon
130" Weather Pack Sleeve
Splice group of B B B FM Term

35
12
18-2 Pass. Front RF Coil A
wires together Pin 2 W W 12089188
and seal 108" Cable Seal
B 12015323
Insert all contacts into B B
Pin 3 W 18-2 Driver’s Rear LR Coil A FM Housing
W
Designated Locations of 108" 12015792
B B B
AMP Housing 18-2 Pass. Rear RR Coil W A
Pin 4 W
18ga x 12" (+/- .25")
Pin 23 Strobe Neg Strobe Neg B Delphi
Pin 22 Strobe Pos Strobe Pos A Weather Pack
Amp FM Conn 18ga x 12" (+/- .25") Label each wire
770520-1 TXL or Equivalent Both ends 12020926
Wire Color
Pin 6 Orange C20 A 6 Pin FM Conn
Pin 7 C21 B 12089188
White
FM Term
Pin 8 Green C22 C 12015323
Pin 9 Red C23 D Green Wire Seal
All single wires
Pin 10 Blue C24 E
18ga x 12" (+/- .25") 12015793
TXL or Equivalent Pin 11 White/B C25 F
3 Pin FM Conn
Pin 12 Black GND A 12089188 Outrigger Coil
All jacketed wires Pin 33 Red/B C26(+) B FM Term & Switches
18 ga (+/- .25") Pin 34 Green/B C26(-) C 12015323
SJO or Equivalent Green Wire Seal
Pin 17 Orange/B C27 A A
Pin 18 Blue/B C28 B B 12020786
Pin 19 C29 C C 6 Pin Male Conn
Amp FM Conn Green/W 12020926
1208089040
770520-1 Pin 20 Red/W C30 D D 6 Pin FM Conn
Male Term
E 12010330
Pin 21 Blue/W C31 E 12015323
Cavity Plug
Pin 35 Black/W GND F F Green Wire Seal
OUTRIGGER COIL & SWITCHES WIRE HARNESS (A-03039)
 ANALOG HARNESS (A-00715)
Amp
770680

Individual Label
A-00715
AMP 770520-1
Wire Labels Rev
1"
Pin Pump Speed Signal
¼” FM Spade
1 3' (36") 18 ga Green Insulated

Pin Motor Cntrl Enab ¼” FM Spade

16 Insulated
3' (36") 18 ga Yellow 15" Loom

Amp Pin Ground Weather Pack

Housing 9 12" 18 ga Black
B 12010973 2 Pin Housing
770680-1 Pin Engine Run + 12089040 Male Terminal
A 12015323 Wire Seal
Black 10 12" 18 ga Red
10" Loom
Engine
Run
18" 18ga Red A
Label
16

¼” FM Spade
1

B
Insulated
18" 18ga Black ¼” FM Spade B C
Splice & Heat Insulated D
Shrink Seal A
Level
23

Sensor
Pin Level Sensor +24 Label
A 32" Loom
8 10" 18 ga Red
8"
Motor 8" Loom
Pin Level Sensor GND
All wires A Control
15 B
10" 18 ga Black Weather Pack
TXL or Equivalent 8" Label
B 12020830 4 Pos housing
All Measurements Pin Level Sensor X Mates With 12020832
are +/- 0.250 In 22
C C 12089040 Male Terminal
18" 18 ga Orange 12015323 Wire Seal Pump Speed Signal
D Motor Cntrl Enab

Pin Level Sensor Y Start

D Contactor
23 18" 18 ga Brown
Label

POWER HARNESS (A-00718)

AMP
1-66740-1
Or 12ga Red
66740-6 32"
Batt Pos
Pin 1 5/16" Ring Terminal

AMP 3 Pin Housing AMP Cable Clamp

206037-2 206070-1

AMP
1-66740-1 12ga
Or Black
66740-6
32"
AMP

Batt Neg
A-00718 Pin 2 5/16" Ring Terminal
Rev.

Fill Strain Relief with RTV then put on

cable clamp and wipe off excess
Bundle wires in 28" of loom.
Tape both ends if split loom is used

110 VAC TOWER-PLATFORM HARNESS (A-03722)

Delphi Weather Pack
3 Pin Male Housing
12020827
Male Terminal
12089040
Green cable seal
12015323
49'
A Red
14-3 SDN or Equivalent
B Black

C Blue

A-03722
Rev

99
 SECONDARY CYLINDER WIRE (A-03724)

Delphi Weather Pack

Delphi Weather Pack 2 Pin Male Housing
2 Pin Female Housing 12010973
12025792 Male Terminal
Female Terminal 12124582
12089188 Green Wire Seal
Green Wire Seal 12015323
Label Both
12015323 ends
20'
A W 18-2 SJO or Equivalent W A
Sec Cyl Wire Sec Cyl Wire
B B B B

JIB WIRE (A-03725)

Delphi Weather Pack

Delphi Weather Pack 2 Pin Male Housing
2 Pin Female Housing 12010973
12025792 Male Terminal
Female Terminal 12124582
12089188 Green Wire Seal
Green Wire Seal 12015323
12015323 Label Both ends
50'6"
A W 18-2 SJO or Equivalent W A
JIB Wire JIB Wire
B B B B

PLATFORM-GROUND COMMUNICATION CABLE (A-03714)

Amp
ITT CA3101F18-12SF80 Connector Kit 66100-7 or
66101-2 Amp AMP
Pins Part of Kit FM 207008-2 206708-1
53' Terminal Strain Relief Plug
Orange
Pin A 18/6 Cable Orange
Pin 7
White
Pin B For Cable Track White
Pin 3
Green Green
Pin C Pin 9
Red Red
Pin D Pin 8
Blue Blue
Pin E Pin 4
Black Black
Pin F Pin 6

Jacket of cable must A-03714

be in strain relief Rev
Jacket of cable must
be in strain relief
Fill Strain Relief with
Black RTV and wipe
off excess

100
 WATER LINE TO PLATFORM (OPTION A-03701)

Part No. Description

B09-00-0044 #6 x 142” W/1-6-6FMP, 1-6-6MP 3000 PSI Pressure Washer Hose
B09-00-0045 #6 x 516” W/2-6-6MPSW 3000 PSI Pressure Washer Hose
B09-00-0041 #6 x 78” W/1-6-6FMP, 1-6-6MP 3000 PSI Pressure Washer Hose
B09-00-0032 Fitting, QD E Series FM-#6FMNPT
B09-00-0033 Fitting, QD E Series M-#6FMNPT

AIR LINE TO PLATFORM (OPTION A-03700)

Part No. Description

B09-00-0046 #6 x 142” W/1-6-6FMPSW, 1-6-6MP 300 PSI Air Hose
B09-00-0047 #6 x 516” W/2-6-6MP 300 PSI Air Hose
B09-00-0036 #6 x 78” W/1-6-6FMPSW, 1-6-6MP 300 PSI Air Hose
B02-02-0108 Fitting, #6FMNPT-#4FMNPT STR
B09-00-0025 Fitting, Univ QD FM-#4MNPT
B09-00-0026 Fitting, QD IND Series M-#4MNPT
B09-00-0027 Fitting,QD ARO Series M-#4MNPT
B09-00-0028 Fitting, Univ QD FM-#6FMNPT
B09-00-0029 Fitting, QD DF Series M-#6FMNPT
B09-00-0030 Fitting, QD J Series M-#6FMNPT

101
 LOAD SENSE ASSEMBLY (OPTION A-01846)

5 8 4 1

4
3

11
10

17

18
9
6

19

15

16 13 14 12

102
 LOAD SENSE ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-01977 Platform Mount Weldment – LS 1
2 A-00982 Load Sense Weldment 1
3 0096-0055 Cap Screw, M12 x 190 1
4 0096-0042 Hex Nut, Self-Locking, M12 3
5 A-00988-1 Load Cell 1
6 0096-0089 Cap Screw, M12 x 65 2
7 A-00990A Load Sense Spacer A 1
8 A-00990B Load Sense Spacer B 2
9 0096-0069 Cap Screw, M10 x 75 1
10 0096-0041 Hex Nut, Self-Locking, M10 1
11 A-00033 Bearing 4
12 A-00994 LS Roller Bar 1
13 A-00995 LS Roller 2
14 0096-0046 Washer, Flat, M12 4
15 0090-0147 Cotter Pin 2
16 0096-0009 Cap Screw, M8 x 10 2
17 A-00038 Ramp 4
18 0096-0003 Flat Head Cap Screw, M6 x 20 8
19 0096-0039 Hex Nut, Self-Locking, M6 8

20 A-00992 Load Sense Interface (Not Pictured) 1

21 0096-0085 Cap Screw, M6 x 60 3
22 0096-0039 Hex Nut, Self-Locking, M6 3

103
 MATERIAL LIFT HOOK ASSEMBLY (OPTION A-01846)

MATERIAL LIFT HOOK PARTS LIST

Item No. Part No. Description Qty.

1 A-00480 Material Lift Weldment 1
2 A-00155 Lift Hook Storage Bracket 1
3 A-01156 Bracket Clamp 1
4 A-00028 Pin 1
5 A-00485 Lift Hook Assembly 1
6 A-00037 Ramp, Short 4
7 0096-0003 Flat Head Cap Screw, M6 x 20 4
8 0096-0039 Hex Nut, Self-Locking, M6 4
9 0096-0016 Cap Screw, M10 x 25 2
10 0096-0041 Hex Nut, Self-Locking, M10 2
11 0096-0029 Cap Screw, M12 x 220 1
12 0096-0042 Hex Nut, Self-Locking, M12 1
A-01976 Load Sense Module (Not Pictured) 1

104
 BATTERY LAYOUT

- + - +
3 3

+ - + -
2

1
10
+ + 4
- - D4

Motor 0-5V Enable

D5
5 Controller 3 1

6 M-
B- B+
E2 D1
A2 E1
D6 D2
200 AMP Drive
Fuse
D1 Motor
D3
Pump
Contactor
24VDC 100AMP 8
B01-06-0058
200 AMP
Fuse 9

B+ M- B-
1 3
11
Enable 0-5V
7

E2 D1
A2 E1

Main
Pump
Motor
Contactor
24VDC 100AMP
B01-06-0058

Item No. Kit No. A-00272

1 30” 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 22” Black, 2 Gauge, 5/16 Ring – Lug
5 24” Red, 2 Gauge, 5/16 Ring – Lug
6 48” Black, 2 Gauge, 5/16 Ring – Lug
7 22” Red, 2 Gauge, 5/16 Ring – Lug
8 48” Red, 2 Gauge, 5/16 Ring – 5/16 Ring
9 45” Black, 2 Gauge, 5/16 Ring – 5/16 Ring
10 19” Black, 2 Gauge, 5/16 Ring – 5/16 Ring
11 13” Red, 2 Gauge, 5/16 Ring – 5/16 Ring
Item No. Kit No. A-00934
D1 6” Red, 2 Gauge, 5/16 Ring – 5/16 Ring
D2 30” Red, 2 Gauge, 5/16 Ring – 5/16 Ring
D3 13” Black, 2 Gauge, 5/16 Ring – 5/16 Ring
D4 40” Red, 2 Gauge, 5/16 Ring – 5/16 Ring
D5 40” Black, 2 Gauge, 5/16 Ring – 5/16 Ring
D6 20” Red, 2 Gauge, 5/16 Ring – 5/16 Ring

105
 MANUAL PLATFORM ROTATE ASSEMBLY (OPTION A-00300)

106
 MANUAL PLATFORM ROTATE ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-00301 Platform Mount A Weldment 1
2 A-00308 Platform Mount Weldment 1
3 A-00315 Gearbox – Platform Rotate 1
4 A-00330 Bearing – .75” ID 2
5 A-00329 Pin – 0.75 x 10.25 DB 1
6 A-00017 Pin Retainer – 0.75 2
7 0096-0014 Cap Screw, M10 x 20 6
8 0096-0041 Hex Nut, Self-Locking, M10 2
9 0096-0019 Cap Screw, M12 x 25 2
10 0096-0042 Hex Nut, Self-Locking, M12 2
11 A-00071 Pin, Platform 1
12 0090-0147 Cotter Pin 2
13 0096-0103 Cap Screw, M8 x 140 2
14 0096-0040 Hex Nut, Self-Locking, M8 2

107
 ORDERING REPLACEMENT PARTS
To order replacement parts, contact the Bil-Jax Service Department by phone at
800-537-0540, by fax at 419-446-8202 or by email at techsupport@biljax.com.
For swift service, always have the part number available, as well as the
equipment model and serial number. When ordering parts by fax or email, always
provide the above information.
See Page 12 for Equipment Warranty information.

QUICK REFERENCE
Equipment Model: Bil-Jax 45XA Articulating Boom Lift

Serial Number: ______________________________________________

NOTES

108
 APPENDIX:ERROR CODES
The error codes listed below may not be applicable to all machines and
configurations.

Error Message Error Explanation & What To Check &

Displayed Possible Causes Corrective Action To Clear Error
The Machine has gone into DOWN ONLY mode. 1. Check outrigger and level LED indicators and if
required re-level machine
This is a self clearing error. When error condition is 2. Reduce boom load
removed, error is cleared. 3. Reduce boom load

NOTE: This error will not be displayed when boom is

001 MACHINE IS IN down or if so equipped, when the Load Sense Module
DOWN ONLY MODE has detected an overloaded condition.

Possible causes include:

1. Machine went out of level during use
2. Load sense has detected an overload condition
3. Moment sense has detected an overload
condition
The Lower Control has lost communication with the 1. Correctly configure Lower Control
Platform Control. 2. Replace Boom Cable
3. Replace Upper Control
This is a latched error. To clear this error, first the error 4. Replace Lower Control
condition must be removed and second the power
must be cycled off then back on.

002 LOSS OF NOTE: During this error condition, the Platform Control
PLATFORM "Engine On" LED will blink a “2 blink” error code and
COMMUNICATION the Lower Control “Power” LED will blink a “2 blink”
error code.

Possible causes include:

1. Lower control incorrectly configured
2. Faulty Boom Cable
3. Faulty Upper Control
4. Faulty Lower Control
The Lower Control has lost communication with the 1. Correctly configure Lower Control
Drive Control. 2. Replace Boom Cable
3. Replace Upper Control
This is a latched error. To clear this error, first the error 4. Replace Lower Control
condition must be removed and second the power
must be cycled off then back on.

NOTE: During this error condition, the Platform Control

003 LOSS OF DRIVE
"Engine On" LED will blink a “2 blink” error code and
COMMUNICATION
the Lower Control “Power” LED will blink a “2 blink”
error code.

Possible causes include:

1. Lower Control incorrectly configured
2. Faulty Boom Cable
3. Faulty Upper Control
4. Faulty Lower Control
The Lower Control has lost communication with the 1. Replace cable between PC and Lower Control
PC. 2. Disconnect PC or run PC’s program
3. Replace PC
This is a self clearing error. When error condition is 4. Replace Lower Control
removed, error is cleared.

004 LOSS OF PC NOTE: During this error condition, the Lower Control
COMMUNICATION “Power” LED will blink a “4 blink” error code.

Possible causes include:

1. Faulty cable between PC and Lower Control
2. PC’s program is not running
3. Faulty PC
4. Faulty Lower Control

109
 Error Message Error Explanation & What To Check &
Displayed Possible Causes Corrective Action To Clear Error
The Platform Control has detected a stuck or pressed 1. Free stuck or pressed key on Platform Control
key on power up. 2. Replace Platform Control

This is a latched error. To clear this error, first the error

condition must be removed and second the power must
005 PLATFORM be cycled off then back on.
CONTROL
HAS STUCK KEY NOTE: During this error condition, the Platform Control
"Engine On" LED will blink a “1 blink” error code.

Possible causes include:

1. Platform Control has a stuck key
2. Faulty Platform Control
The Drive Control has detected a stuck or pressed key 1. Free stuck or pressed key on Drive Control
on power up. 2. Replace Drive Control

This is a latched error. To clear this error, first the error

condition must be removed and second the power must
be cycled off then back on.
006 DRIVE CONTROL
HAS STUCK KEY
NOTE: During this error condition, the Drive Control
"Engine On" LED will blink a “1 blink” error code.

Possible causes include:

1. Drive Control has a stuck key
2. Faulty Drive Control
The Drive Control has detected a stuck joystick on 1. Free or replace stuck joystick on Drive Control
power up. 2. Replace Drive Control

This is a latched error. To clear this error, first the error

condition must be removed and second the power must
be cycled off then back on.
007 DRIVE CONTROL
HAS STUCK JOYSTICK
NOTE: During this error condition, the Drive Control
"Engine On" LED will blink a “2 blink” error code.

Possible causes include:

1. Drive Control has a stuck joystick
2. Faulty Drive Control
The Lower Control has detected a stuck or pressed key 1. Free stuck or pressed key on Lower Control
on power up. 2. Replace Lower Control

This is a latched error. To clear this error, first the error

condition must be removed and second the power must
be cycled off then back on.
008 GROUND CONTROL
HAS STUCK KEY
NOTE: During this error condition, the Lower Control
"Power" LED will blink a “1 blink” error code.

Possible causes include:

1. Lower Control has a stuck key
2. Faulty Lower Control
The Lower Control has detected the boom is up without 1. Check and repair boom and outrigger limit
all four outriggers on the ground. switches
2. Repair or replace boom and outrigger limit switch
This is a self clearing error. When error condition is wiring
removed, error is cleared. 3. Replace Lower Control
009 BOOM UP WITHOUT
OUTRIGGERS ON
NOTE: Alarm will sound during this error condition.
GROUND
Possible causes include:
1. Faulty boom down or outrigger limit switches
2. Faulty boom down or outrigger limit switch wiring
3. Faulty Lower Control

110
 Error Message Error Explanation & What To Check &
Displayed Possible Causes Corrective Action To Clear Error
The Lower Control has detected a rapidly changing 1. Check Level Sensor
output from the level sensor. 2. Repair or replace Level Sensor wiring
3. Replace Lower Control
This is a self clearing error. When error condition is
010 LEVEL SENSOR removed, error is cleared. NOTE: With machine powered and level, Level Sensor
HAS ERRATIC OUTPUT should have a steady approximately 24 volt supply
Possible causes include: voltage and a steady approximately 2.50 volt output on
1. Faulty Level Sensor both X and Y outputs with respect to the Level Sensor
2. Faulty Level Sensor wiring ground connection.
3. Faulty Lower Control
An attempt was made to drive machine without 1. Engage trailer brake
engaging the trailer brake. 2. Check and repair trailer brake switch
3. Repair or replace trailer brake switch wiring
This is a self clearing error. When error condition is 4. Replace Lower Control
removed, error is cleared.

011 TRYING TO DRIVE NOTE: This error only occurs on machines equipped
W/ TRAILER BRAKE OFF with the Drive & Set option.

Possible causes include:

1. Trailer brake not engaged
2. Faulty trailer brake switch
3. Faulty trailer brake switch wiring
4. Faulty Lower Control
The Lower Control has detected the angle sensor 1. Check angle sensor
output is out of range. 2. Repair or replace angle sensor wiring
3. Correctly configure Lower Control
This is a self clearing error. When error condition is 4. Replace Lower Control
removed, error is cleared.

012 ANGLE SENSOR IS NOTE: This error only occurs on machines equipped
DISCONNECTED OR BAD with the Moment Sense option.

Possible causes include:

1. Faulty angle sensor
2. Faulty angle sensor wiring
3. Lower Control incorrectly configured
4. Faulty Lower Control
The Lower Control has detected the pressure sensor 1. Check pressure sensor
output is out of range. 2. Repair or replace pressure sensor wiring
3. Correctly configure Lower Control
This is a self clearing error. When error condition is 4. Replace Lower Control
removed, error is cleared.
013 PRESSURE SENSOR
NOTE: This error only occurs on machines equipped
IS DISCONNECTED OR
with the Moment Sense option.
BAD
Possible causes include:
1. Faulty pressure sensor
2. Faulty pressure sensor wiring
3. Lower Control incorrectly configured
4. Faulty Lower Control
The Lower Control has detected the engine had low oil 1. Check engine oil level
pressure while running. 2. Check oil pressure sensor
3. Repair or replace oil pressure sensor wiring
This is a latched error. To clear this error, first the error 4. Correctly configure Lower Control
condition must be removed and second the power must 5. Replace Lower Control
be cycled off then back on.

014 CHECK ENGINE NOTE: This error only occurs on machines equipped
LOW OIL PRESSURE with the X-Boom option.

Possible causes include:

1. Engine oil low
2. Faulty oil pressure sensor
3. Faulty oil pressure sensor wiring
4. Lower Control incorrectly configured
5. Faulty Lower Control

111
 Error Message Error Explanation & What To Check &
Displayed Possible Causes Corrective Action To Clear Error
The Lower Control has detected the machine has all 1. Check outrigger and level LED indicators and if
four outriggers on the ground but is not level. required re-level machine
2. Check level sensor
This is a self clearing error. When error condition is 3. Repair or replace level sensor wiring
removed, error is cleared. 4. Replace Lower Control
015 MACHINE IS
NOT LEVEL
Possible causes include:
1. Machine has gone out of level with use
2. Faulty level sensor
3. Faulty level sensor wiring
4. Faulty Lower Control
The Lower Control has detected the Boom must be 1. Check that boom is raised before trying to rotate
raised before the requested function can be performed. boom
2. Check that boom is raised before trying to extend
This is a self clearing error. When error condition is boom
removed, error is cleared. 3. Check that boom is raised before trying to retract
boom
016 LIFT BOOM Possible causes include: 4. Check and repair boom down limit switch
1. Trying to rotate boom while boom is down 5. Repair or replace boom down limit switch wiring
2. Trying to extend boom while boom is down 6. Replace Lower Control
3. Trying to retract boom while boom is down
4. Faulty boom down limit switch
5. Faulty boom down limit switch wiring
6. Faulty Lower Control
The Lower Control has detected the boom must be 1. Check that boom is down before trying to auto
lowered before the requested function can be level machine
performed. 2. Check that boom is down before trying to extend
outriggers
This is a self clearing error. When error condition is 3. Check that boom is down before trying to retract
removed, error is cleared. outriggers
4. Check and repair boom down limit switch
017 STOW BOOM
Possible causes include: 5. Repair or replace boom down limit switch wiring
1. Trying to auto level machine while boom is raised 6. Replace Lower Control
2. Trying to extend outriggers while boom is raised
3. Trying to retract outriggers while boom is raised
4. Faulty boom down limit switch
5. Faulty boom down limit switch wiring
6. Faulty Lower Control
The Lower Control has lost communication with the 1. Correctly configure Lower Control
Load Sense Module. 2. Replace Boom Cable
3. Replace Load Sense Module
This is a latched error. To clear this error, first the error 4. Replace Lower Control
condition must be removed and second the power must
be cycled off then back on.

NOTE: During this error condition, the Load Sense

Module “Status” LED will blink a red “2 blink” error code
018 LOSS OF LOAD
and the Lower Control “Power” LED will blink a “5 blink”
SENSE
error code.
COMMUNICATION
NOTE: This error only occurs on machines equipped
with the Load Sense option.

Possible causes include:

1. Lower control incorrectly configured
2. Faulty Boom Cable
3. Faulty Load Sense Module
4. Faulty Lower Control

112
Error Message Error Explanation & What To Check &
Displayed Possible Causes Corrective Action To Clear Error
The Load Sense Module has detected an overloaded 1. Reduce weight in basket or on hook
boom condition which caused the Lower Control to 2. Correctly configure Lower Control
disable all boom functions. 3. Replace Load Cell
4. Repair or replace Load Cell wiring
This is a self clearing error. When error condition is 5. Replace Load Sense Module
removed, error is cleared. 6. Replace Lower Control

NOTE: This error only occurs on machines equipped

019 BOOM FUNCTION
with the Load Sense option.
DISABLED
Possible causes include:
1. Too much weight in basket or on hook
2. Lower Control incorrectly configured
3. Faulty Load Cell
4. Faulty Load Cell wiring
5. Faulty Load Sense Module
6. Faulty Lower Control
The Load Sense Module has detected a loss of 1. Replace Load Cell
connection to the Load Cell. 2. Repair or replace Load Cell wiring
3. Replace Load Sense Module
This is a self clearing error. When error condition is
removed, error is cleared.
30 LOSS OF LOAD
NOTE: This error only occurs on machines equipped
CELL CONNECTION
with the Load Sense option.

Possible causes include:

1. Faulty Load Cell
2. Faulty Load Cell wiring
3. Faulty Load Sense Module
The Lower Control has detected an open circuit on the 1. Repair or replace Primary Up solenoid wiring
Primary Up solenoid output when it was energized 2. Replace Primary Up solenoid
during startup self diagnostics. 3. Replace Lower Control

NOTE: A load of less than 70mA will be detected as an

021 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
PRIMARY UP
Possible causes include:
1. Faulty Primary Up solenoid wiring
2. Faulty Primary Up solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Primary Up solenoid wiring
the Primary Up solenoid output when it was energized 2. Replace Primary Up solenoid
during startup self diagnostics. 3. Replace Lower Control
022 SHORTED CIRCUIT
PRIMARY UP Possible causes include:
1. Faulty Primary Up solenoid wiring
2. Faulty Primary Up solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace Primary Down solenoid wiring
Primary Down solenoid output when it was energized 2. Replace Primary Down solenoid
during startup self diagnostics. 3. Replace Lower Control

NOTE: A load of less than 70mA will be detected as an

023 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
PRIMARY DOWN
Possible causes include:
1. Faulty Primary Down solenoid wiring
2. Faulty Primary Down solenoid
3. Faulty Lower Control

113
 Error Message Error Explanation & What To Check &
Displayed Possible Causes Corrective Action To Clear Error
The Lower Control has detected excessive current on 1. Repair or replace Primary Down solenoid wiring
the Primary Down solenoid output when it was 2. Replace Primary Down solenoid
energized during startup self diagnostics. 3. Replace Lower Control
024 SHORTED CIRCUIT
PRIMARY DOWN Possible causes include:
1. Faulty Primary Down solenoid wiring
2. Faulty Primary Down solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace Secondary Up solenoid wiring
Secondary Up solenoid output when it was energized 2. Replace Secondary Up solenoid
during startup self diagnostics. 3. Replace Lower Control

NOTE: A load of less than 70mA will be detected as an

025 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
SECONDARY UP
Possible causes include:
1. Faulty Secondary Up solenoid wiring
2. Faulty Secondary Up solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Secondary Up solenoid wiring
the Secondary Up solenoid output when it was 2. Replace Secondary Up solenoid
energized during startup self diagnostics. 3. Replace Lower Control
026 SHORTED CIRCUIT
SECONDARY UP Possible causes include:
1. Faulty Secondary Up solenoid wiring
2. Faulty Secondary Up solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace Secondary Down solenoid
Secondary Down solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Secondary Down solenoid
3. Replace Lower Control
NOTE: A load of less than 70mA will be detected as an
027 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
SECONDARY DOWN
Possible causes include:
1. Faulty Secondary Down solenoid wiring
2. Faulty Secondary Down solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Secondary Down solenoid
the Secondary Down solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Secondary Down solenoid
028 SHORTED CIRCUIT 3. Replace Lower Control
SECONDARY DOWN Possible causes include:
1. Faulty Secondary Down solenoid wiring
2. Faulty Secondary Down solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace Jib Up solenoid wiring
Jib Up solenoid output when it was energized during 2. Replace Jib Up solenoid
startup self diagnostics. 3. Replace Lower Control

NOTE: A load of less than 70mA will be detected as an

029 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
JIB UP
Possible causes include:
1. Faulty Jib Up solenoid wiring
2. Faulty Jib Up solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Jib Up solenoid wiring
the Jib Up solenoid output when it was energized 2. Replace Jib Up solenoid
during startup self diagnostics. 3. Replace Lower Control
030 SHORTED CIRCUIT
JIB UP Possible causes include:
1. Faulty Jib Up solenoid wiring
2. Faulty Jib Up solenoid
3. Faulty Lower Control

114
Error Message Error Explanation & What To Check &
Displayed Possible Causes Corrective Action To Clear Error
The Lower Control has detected an open circuit on the 1. Repair or replace Jib Down solenoid wiring
Jib Down solenoid output when it was energized during 2. Replace Jib Down solenoid
startup self diagnostics. 3. Replace Lower Control

NOTE: A load of less than 70mA will be detected as an

031 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
JIB DOWN
Possible causes include:
1. Faulty Jib Down solenoid wiring
2. Faulty Jib Down solenoid
3. Fault Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Jib Down solenoid wiring
the Jib Down solenoid output when it was energized 2. Replace Jib Down solenoid
during startup self diagnostics. 3. Replace Lower Control
032 SHORTED CIRCUIT
JIB DOWN Possible causes include:
1. Faulty Jib Down solenoid wiring
2. Faulty Jib Down solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace Extend boom solenoid wiring
Extend boom solenoid output when it was energized 2. Replace Extend solenoid
during startup self diagnostics. 3. Replace Lower Control

NOTE: A load of less than 70mA will be detected as an

033 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
EXTEND
Possible causes include:
1. Faulty Extend boom solenoid wiring
2. Faulty Extend boom solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Extend boom solenoid wiring
the Extend boom solenoid output when it was 2. Replace Extend solenoid
energized during startup self diagnostics. 3. Replace Lower Control
034 SHORTED CIRCUIT
EXTEND Possible causes include:
1. Faulty Extend boom solenoid wiring
2. Faulty Extend boom solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace Retract boom solenoid wiring
Retract boom solenoid output when it was energized 2. Replace Retract boom solenoid
during startup self diagnostics. 3. Replace Lower Control

NOTE: A load of less than 70mA will be detected as an

035 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
RETRACT
Possible causes include:
1. Faulty Retract boom solenoid wiring
2. Faulty Retract boom solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Retract boom solenoid wiring
the Retract boom solenoid output when it was 2. Replace Retract boom solenoid
energized during startup self diagnostics. 3. Replace Lower Control
036 SHORTED CIRCUIT
RETRACT Possible causes include:
1. Faulty Retract boom solenoid wiring
2. Faulty Retract boom solenoid
3. Faulty Lower Control

115
 Error Message Error Explanation & What To Check &
Displayed Possible Causes Corrective Action To Clear Error
The Lower Control has detected an open circuit on the 1. Repair or replace Platform Level Up solenoid
Platform Level Up solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Platform Level Up solenoid
3. Replace Lower Control
NOTE: A load of less than 70mA will be detected as an
037 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
PLATFORM LEVEL UP
Possible causes include:
1. Faulty Platform Level Up solenoid wiring
2. Faulty Platform Level Up solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Platform Level Up solenoid
the Platform Level Up solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Platform Level Up solenoid
038 SHORTED CIRCUIT 3. Replace Lower Control
PLATFORM LEVEL UP Possible causes include:
1. Faulty Platform Level Up solenoid wiring
2. Faulty Platform Level Up solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace Platform Level Down solenoid
Platform Level Down solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Platform Level Down solenoid
3. Replace Lower Control
039 OPEN CIRCUIT NOTE: A load of less than 70mA will be detected as an
PLATFORM LEVEL open circuit. The typical load is approximately 800mA.
DOWN
Possible causes include:
1. Faulty Platform Level Down solenoid wiring
2. Faulty Platform Level Down solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Platform Level Down solenoid
the Platform Level Down solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Platform Level Down solenoid
040 SHORTED CIRCUIT
3. Replace Lower Control
PLATFORM LEVEL
Possible causes include:
DOWN
1. Faulty Platform Level Down solenoid wiring
2. Faulty Platform Level Down solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace Platform CW solenoid wiring
Platform CW solenoid output when it was energized 2. Replace Platform CW solenoid
during startup self diagnostics. 3. Replace Lower Control

NOTE: A load of less than 70mA will be detected as an

041 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
PLATFORM CW
Possible causes include:
1. Faulty Platform CW solenoid wiring
2. Faulty Platform CW solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Platform CW solenoid wiring
the Platform CW solenoid output when it was energized 2. Replace Platform CW solenoid
during startup self diagnostics. 3. Replace Lower Control
042 SHORTED CIRCUIT
PLATFORM CW Possible causes include:
1. Faulty Platform CW solenoid wiring
2. Faulty Platform CW solenoid
3. Faulty Lower Control

116
Error Message Error Explanation & What To Check &
Displayed Possible Causes Corrective Action To Clear Error
The Lower Control has detected an open circuit on the 1. Repair or replace Platform CCW solenoid wiring
Platform CCW solenoid output when it was energized 2. Replace Platform CCW solenoid
during startup self diagnostics. 3. Replace Lower Control

NOTE: A load of less than 70mA will be detected as an

043 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
PLATFORM CCW
Possible causes include:
1. Faulty Platform CCW solenoid wiring
2. Faulty Platform CCW solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Platform CCW solenoid wiring
the Platform CW solenoid output when it was energized 2. Replace Platform CCW solenoid
during startup self diagnostics. 3. Replace Lower Control
044 SHORTED CIRCUIT
PLATFORM CCW Possible causes include:
1. Faulty Platform CCW solenoid wiring
2. Faulty Platform CCW solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace Turntable CW solenoid wiring
Turntable CW solenoid output when it was energized 2. Replace Turntable CW solenoid
during startup self diagnostics. 3. Replace Lower Control

NOTE: A load of less than 70mA will be detected as an

045 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
TURNTABLE CW
Possible causes include:
1. Faulty Turntable CW solenoid wiring
2. Faulty Turntable CW solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Turntable CW solenoid wiring
the Turntable CW solenoid output when it was 2. Replace Turntable CW solenoid
energized during startup self diagnostics. 3. Replace Lower Control
046 SHORTED CIRCUIT
TURNTABLE CW Possible causes include:
1. Faulty Turntable CW solenoid wiring
2. Faulty Turntable CW solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace Turntable CCW solenoid wiring
Turntable CCW solenoid output when it was energized 2. Replace Turntable CCW solenoid
during startup self diagnostics. 3. Replace Lower Control

NOTE: A load of less than 70mA will be detected as an

047 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
TURNTABLE CCW
Possible causes include:
1. Faulty Turntable CCW solenoid wiring
2. Faulty Turntable CCW solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Turntable CCW solenoid wiring
the Turntable CCW solenoid output when it was 2. Replace Turntable CCW solenoid
energized during startup self diagnostics. 3. Replace Lower Control
048 SHORTED CIRCUIT
TURNTABLE CCW Possible causes include:
1. Faulty Turntable CCW solenoid wiring
2. Faulty Turntable CCW solenoid
3. Faulty Lower Control

117
 Error Message Error Explanation & What To Check &
Displayed Possible Causes Corrective Action To Clear Error
The Lower Control has detected an open circuit on the 1. Repair or replace Outrigger Retract solenoid
Outrigger Retract solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Outrigger Retract solenoid
3. Replace Lower Control
NOTE: A load of less than 70mA will be detected as an
049 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
OUTRIGGER RETRACT
Possible causes include:
1. Faulty Outrigger Retract solenoid wiring
2. Faulty Outrigger Retract solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Outrigger Retract solenoid
the Outrigger Retract solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Outrigger Retract solenoid
050 SHORTED CIRCUIT 3. Replace Lower Control
OUTRIGGER RETRACT Possible causes include:
1. Faulty Outrigger Retract solenoid wiring
2. Faulty Outrigger Retract solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace Outrigger Extend solenoid
Outrigger Extend solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Outrigger Extend solenoid
3. Replace Lower Control
NOTE: A load of less than 70mA will be detected as an
051 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
OUTRIGGER EXTEND
Possible causes include:
1. Faulty Outrigger Extend solenoid wiring
2. Faulty Outrigger Extend solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Outrigger Extend solenoid
the Outrigger Extend solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Outrigger Extend solenoid
052 SHORTED CIRCUIT 3. Replace Lower Control
OUTRIGGER EXTEND Possible causes include:
1. Faulty Outrigger Extend solenoid wiring
2. Faulty Outrigger Extend solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace LF Outrigger solenoid wiring
LF Outrigger solenoid output when it was energized 2. Replace LF Outrigger solenoid
during startup self diagnostics. 3. Replace Lower Control

NOTE: A load of less than 70mA will be detected as an

053 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
LF OUTRIGGER
Possible causes include:
1. Faulty LF Outrigger solenoid wiring
2. Faulty LF Outrigger solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace LF Outrigger solenoid wiring
the LF Outrigger solenoid output when it was energized 2. Replace LF Outrigger solenoid
during startup self diagnostics. 3. Replace Lower Control
054 SHORTED CIRCUIT
LF OUTRIGGER Possible causes include:
1. Faulty LF Outrigger solenoid wiring
2. Faulty LF Outrigger solenoid
3. Faulty Lower Control

118
Error Message Error Explanation & What To Check &
Displayed Possible Causes Corrective Action To Clear Error
The Lower Control has detected an open circuit on the 1. Repair or replace RF Outrigger solenoid wiring
RF Outrigger solenoid output when it was energized 2. Replace RF Outrigger solenoid
during startup self diagnostics. 3. Replace Lower Control

NOTE: A load of less than 70mA will be detected as an

055 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
RF OUTRIGGER
Possible causes include:
1. Faulty RF Outrigger solenoid wiring
2. Faulty RF Outrigger solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace RF Outrigger solenoid wiring
the RF Outrigger solenoid output when it was 2. Replace RF Outrigger solenoid
energized during startup self diagnostics. 3. Replace Lower Control
056 SHORTED CIRCUIT
RF OUTRIGGER Possible causes include:
1. Faulty RF Outrigger solenoid wiring
2. Faulty RF Outrigger solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace LR Outrigger solenoid wiring
LR Outrigger solenoid output when it was energized 2. Replace LR Outrigger solenoid
during startup self diagnostics. 3. Replace Lower Control

NOTE: A load of less than 70mA will be detected as an

057 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
LR OUTRIGGER
Possible causes include:
1. Faulty LR Outrigger solenoid wiring
2. Faulty LR Outrigger solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace LR Outrigger solenoid wiring
the LR Outrigger solenoid output when it was energized 2. Replace LR Outrigger solenoid
during startup self diagnostics. 3. Replace Lower Control
058 SHORTED CIRCUIT
LR OUTRIGGER Possible causes include:
1. Faulty LR Outrigger solenoid wiring
2. Faulty LR Outrigger solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace RR Outrigger solenoid wiring
RR Outrigger solenoid output when it was energized 2. Replace RR Outrigger solenoid
during startup self diagnostics. 3. Replace Lower Control

NOTE: A load of less than 70mA will be detected as an

059 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
RR OUTRIGGER
Possible causes include:
1. Faulty RR Outrigger solenoid wiring
2. Faulty RR Outrigger solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace RR Outrigger solenoid wiring
the RR Outrigger solenoid output when it was 2. Replace RR Outrigger solenoid
energized during startup self diagnostics. 3. Replace Lower Control
060 SHORTED CIRCUIT
RR OUTRIGGER Possible causes include:
1. Faulty RR Outrigger solenoid wiring
2. Faulty RR Outrigger solenoid
3. Faulty Lower Control

119
 Error Message Error Explanation & What To Check &
Displayed Possible Causes Corrective Action To Clear Error
The Lower Control has detected an open circuit on the 1. Repair or replace Engine Throttle relay wiring
Engine Throttle relay output when it was energized 2. Replace Engine Throttle relay
during startup self diagnostics. 3. Replace Lower Control

NOTE: A load of less than 70mA will be detected as an

061 OPEN CIRCUIT open circuit. This load is less than 70mA and this error
ENGINE THROTTLE is suppressed to avoid false errors.

Possible causes include:

1. Faulty Engine Throttle relay wiring
2. Faulty Engine Throttle relay
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Engine Throttle relay wiring
the Engine Throttle relay output when it was energized 2. Replace Engine Throttle relay
during startup self diagnostics. 3. Replace Lower Control
062 SHORTED CIRCUIT
ENGINE THROTTLE Possible causes include:
1. Faulty Engine Throttle relay wiring
2. Faulty Engine Throttle relay
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace Engine Starter relay wiring
Engine Starter relay output when it was energized 2. Replace Engine Starter relay
during startup self diagnostics. 3. Replace Lower Control

NOTE: A load of less than 70mA will be detected as an

063 OPEN CIRCUIT open circuit. This load is less than 70mA and this error
ENGINE STARTER is suppressed to avoid false errors.

Possible causes include:

1. Faulty Engine Starter relay wiring
2. Faulty Engine Starter relay
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Engine Starter relay wiring
the Engine Starter relay output when it was energized 2. Replace Engine Starter relay
during startup self diagnostics. 3. Replace Lower Control
064 SHORTED CIRCUIT
ENGINE STARTER Possible causes include:
1. Faulty Engine Starter relay wiring
2. Faulty Engine Starter relay
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace Engine Choke relay wiring
Engine Choke relay output when it was energized 2. Replace Engine Choke relay
during startup self diagnostics. 3. Replace Lower Control

NOTE: A load of less than 70mA will be detected as an

065 OPEN CIRCUIT open circuit. This load is less than 70mA and this error
ENGINE CHOKE is suppressed to avoid false errors.

Possible causes include:

1. Faulty Engine Choke relay wiring
2. Faulty Engine Choke relay
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Engine Choke relay wiring
the Engine Choke relay output when it was energized 2. Replace Engine Choke relay
during startup self diagnostics. 3. Replace Lower Control
066 SHORTED CIRCUIT
ENGINE CHOKE Possible causes include:
1. Faulty Engine Choke relay wiring
2. Faulty Engine Choke relay
3. Faulty Lower Control

120
Error Message Error Explanation & What To Check &
Displayed Possible Causes Corrective Action To Clear Error
The Lower Control has detected an open circuit on the 1. Repair or replace Engine Stop relay wiring
Engine Stop relay output when it was energized during 2. Replace Engine Stop relay
startup self diagnostics. 3. Replace Lower Control

NOTE: A load of less than 70mA will be detected as an

067 OPEN CIRCUIT open circuit. This load is less than 70mA and this error
ENGINE STOP is suppressed to avoid false errors.

Possible causes include:

1. Faulty Engine Stop relay wiring
2. Faulty Engine Stop relay
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Engine Stop relay wiring
the Engine Stop relay output when it was energized 2. Replace Engine Stop relay
during startup self diagnostics. 3. Replace Lower Control
068 SHORTED CIRCUIT
ENGINE STOP Possible causes include:
1. Faulty Engine Stop relay wiring
2. Faulty Engine Stop relay
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace Proportional valve solenoid
Proportional valve solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Proportional valve solenoid
3. Replace Lower Control
NOTE: A load of less than 70mA will be detected as an
069 OPEN CIRCUIT open circuit. The typical load is approximately 800mA
PROPORTIONAL at 100%.

Possible causes include:

1. Faulty Proportional valve solenoid wiring
2. Faulty Proportional valve solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Proportional valve solenoid
the Proportional valve solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Proportional valve solenoid
070 SHORTED CIRCUIT 3. Replace Lower Control
PROPORTIONAL Possible causes include:
1. Faulty Proportional valve solenoid wiring
2. Faulty Proportional valve solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace Motor Control Enable wiring
Motor Control Enable output when it was energized 2. Replace Motor Control
during startup self diagnostics. 3. Replace Lower Control

NOTE: A load of less than 70mA will be detected as an

071 OPEN CIRCUIT
open circuit. This load is less than 70mA and this error
MOTOR CONTROL
is suppressed to avoid false errors.
ENABLE
Possible causes include:
1. Faulty Motor Control Enable wiring
2. Faulty Motor Control
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Motor Control Enable wiring
the Motor Control Enable output when it was energized 2. Replace Motor Control
during startup self diagnostics. 3. Replace Lower Control
072 SHORTED CIRCUIT
MOTOR CONTROL
Possible causes include:
ENABLE
1. Faulty Motor Control Enable wiring
2. Faulty Motor Control
3. Faulty Lower Control

121
 Error Message Error Explanation & What To Check &
Displayed Possible Causes Corrective Action To Clear Error
The Lower Control has detected an open circuit on the 1. Replace Lower Control
Spare solenoid output when it was energized during
startup self diagnostics.

073 OPEN CIRCUIT NOTE: A load of less than 70mA will be detected as an
SPARE OUTPUT open circuit. This output is not used and this error is
suppressed to avoid false errors.

Possible causes include:

1. Faulty Lower Control
The Lower Control has detected excessive current on 1. Replace Lower Control
the Motor Control Enable output when it was energized
during startup self diagnostics.
074 SHORTED CIRCUIT
NOTE: This output is not used and this error is
SPARE OUTPUT
suppressed to avoid false errors.

Possible causes include:

1. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace AC Switch wiring
AC Switch output when it was energized during startup 2. Replace AC Switch
self diagnostics. 3. Replace Lower Control

NOTE: A load of less than 70mA will be detected as an

075 OPEN CIRCUIT open circuit. This load is less than 70mA and this error
AC SWITCH is suppressed to avoid false errors.

Possible causes include:

1. Faulty AC Switch wiring
2. Faulty AC Switch
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace AC Switch wiring
the AC Switch output when it was energized during 2. Replace AC Switch
startup self diagnostics. 3. Replace Lower Control
076 SHORTED CIRCUIT
AC SWITCH Possible causes include:
1. Faulty AC Switch wiring
2. Faulty AC Switch
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace Strobe wiring
Strobe output when it was energized during startup self 2. Replace Strobe
diagnostics. 3. Replace Lower Control

NOTE: A load of less than 70mA will be detected as an

077 OPEN CIRCUIT open circuit. This load is less than 70mA and this error
STROBE is suppressed to avoid false errors.

Possible causes include:

1. Faulty Strobe wiring
2. Faulty Strobe
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Strobe wiring
the Strobe output when it was energized during startup 2. Replace Strobe
self diagnostics. 3. Replace Lower Control
078 SHORTED CIRCUIT
STROBE Possible causes include:
1. Faulty Strobe wiring
2. Faulty Strobe
3. Faulty Lower Control

122
Error Message Error Explanation & What To Check &
Displayed Possible Causes Corrective Action To Clear Error
The Lower Control has detected an open circuit on the 1. Repair or replace Drive PWM valve solenoid
Drive PWM valve solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Drive PWM valve
3. Replace Lower Control
NOTE: A load of less than 70mA will be detected as an
079 OPEN CIRCUIT open circuit. The typical load is approximately 800mA
DRIVE PWM at 100%.

Possible causes include:

1. Faulty Drive PWM valve solenoid wiring
2. Faulty Drive PWM valve solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Drive PWM valve solenoid
the Drive PWM valve solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Drive PWM valve
080 SHORTED CIRCUIT 3. Replace Lower Control
DRIVE PWM Possible causes include:
1. Faulty Drive PWM valve solenoid wiring
2. Faulty Drive PWM valve solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace Drive Enable solenoid wiring
Drive Enable solenoid output when it was energized 2. Replace Drive Enable solenoid
during startup self diagnostics. 3. Replace Lower Control

NOTE: A load of less than 70mA will be detected as an

081 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
DRIVE ENABLE
Possible causes include:
1. Faulty Drive Enable solenoid wiring
2. Faulty Drive Enable solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Drive Enable solenoid wiring
the Drive Enable solenoid output when it was energized 2. Replace Drive Enable solenoid
during startup self diagnostics. 3. Replace Lower Control
082 SHORTED CIRCUIT
DRIVE ENABLE Possible causes include:
1. Faulty Drive Enable solenoid wiring
2. Faulty Drive Enable solenoid
3. Faulty Lower Control

123
 Error Message Error Explanation & What To Check &
Displayed Possible Causes Corrective Action To Clear Error
The Lower Control has detected an open circuit on the 1. Repair or replace Drive Engage solenoid wiring
Drive Engage solenoid output when it was energized 2. Replace Drive Engage solenoid
during startup self diagnostics. 3. Replace Lower Control

NOTE: A load of less than 70mA will be detected as an

083 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
DRIVE ENGAGE
Possible causes include:
1. Faulty Drive Engage solenoid wiring
2. Faulty Drive Engage solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Drive Engage solenoid wiring
the Drive Enable solenoid output when it was energized 2. Replace Drive Engage solenoid
during startup self diagnostics. 3. Replace Lower Control
084 SHORTED CIRCUIT
DRIVE ENGAGE Possible causes include:
1. Faulty Drive Engage solenoid wiring
2. Faulty Drive Engage solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace Left Wheel Forward solenoid
Left Wheel Forward solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Left Wheel Forward solenoid
3. Replace Lower Control
NOTE: A load of less than 70mA will be detected as an
085 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
LEFT WHEEL FORWARD
Possible causes include:
1. Faulty Left Wheel Forward solenoid wiring
2. Faulty Left Wheel Forward solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Left Wheel Forward solenoid
the Left Wheel Forward solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Left Wheel Forward solenoid
086 SHORTED CIRCUIT 3. Replace Lower Control
LEFT WHEEL FORWARD Possible causes include:
1. Faulty Left Wheel Forward solenoid wiring
2. Faulty Left Wheel Forward solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace Left Wheel Reverse solenoid
Left Wheel Reverse solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Left Wheel Reverse solenoid
3. Replace Lower Control
NOTE: A load of less than 70mA will be detected as an
087 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
LEFT WHEEL REVERSE
Possible causes include:
1. Faulty Left Wheel Reverse solenoid wiring
2. Faulty Left Wheel Reverse solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Left Wheel Reverse solenoid
the Left Wheel Reverse solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Left Wheel Reverse solenoid
088 SHORTED CIRCUIT 3. Replace Lower Control
LEFT WHEEL REVERSE Possible causes include:
1. Faulty Left Wheel Reverse solenoid wiring
2. Faulty Left Wheel Reverse solenoid
3. Faulty Lower Control

124
 Error Message Error Explanation & What To Check &
Displayed Possible Causes Corrective Action To Clear Error
The Lower Control has detected an open circuit on the 1. Repair or replace Right Wheel Forward solenoid
Right Wheel Forward solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Right Wheel Forward solenoid
3. Replace Lower Control
089 OPEN CIRCUIT NOTE: A load of less than 70mA will be detected as an
RIGHT WHEEL open circuit. The typical load is approximately 800mA.
FORWARD
Possible causes include:
1. Faulty Right Wheel Forward solenoid wiring
2. Faulty Right Wheel Forward solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Right Wheel Forward solenoid
the Right Wheel Forward solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Right Wheel Forward solenoid
090 SHORTED CIRCUIT
3. Replace Lower Control
RIGHT WHEEL
Possible causes include:
FORWARD
1. Faulty Right Wheel Forward solenoid wiring
2. Faulty Right Wheel Forward solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace Right Wheel Reverse solenoid
Right Wheel Reverse solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Right Wheel Reverse solenoid
3. Replace Lower Control
NOTE: A load of less than 70mA will be detected as an
091 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
RIGHT WHEEL REVERSE
Possible causes include:
1. Faulty Right Wheel Reverse solenoid wiring
2. Faulty Right Wheel Reverse solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Right Wheel Reverse solenoid
the Right Wheel Reverse solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Right Wheel Reverse solenoid
092 SHORTED CIRCUIT 3. Replace Lower Control
RIGHT WHEEL REVERSE Possible causes include:
1. Faulty Right Wheel Reverse solenoid wiring
2. Faulty Right Wheel Reverse solenoid
3. Faulty Lower Control

125
 Error Message Error Explanation & What To Check &
Displayed Possible Causes Corrective Action To Clear Error
The Lower Control has detected an open circuit on the 1. Repair or replace Drive Dump (C21) solenoid
Drive Dump (C21) solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Drive Dump (C21) solenoid
3. Replace Lower Control
NOTE: A load of less than 70mA will be detected as an
083 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
DRIVE DUMP (C21)
Possible causes include:
1. Faulty Drive Dump (C21) solenoid wiring
2. Faulty Drive Dump (C21) solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Drive Dump (C21) solenoid
the Drive Dump (C21) solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Drive Dump (C21) solenoid
084 SHORTED CIRCUIT 3. Replace Lower Control
DRIVE DUMP (C21) Possible causes include:
1. Faulty Drive Dump (C21) solenoid wiring
2. Faulty Drive Dump (C21) solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace Turn Left (C22) solenoid wiring
Turn Left (C22) solenoid output when it was energized 2. Replace Turn Left (C22) solenoid
during startup self diagnostics. 3. Replace Lower Control

NOTE: A load of less than 70mA will be detected as an

085 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
TURN LEFT (C22)
Possible causes include:
1. Faulty Turn Left (C22) solenoid wiring
2. Faulty Turn Left (C22) solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Turn Left (C22) solenoid wiring
the Turn Left (C22) solenoid output when it was 2. Replace Turn Left (C22) solenoid
energized during startup self diagnostics. 3. Replace Lower Control
086 SHORTED CIRCUIT
TURN LEFT (C22) Possible causes include:
1. Faulty Turn Left (C22) solenoid wiring
2. Faulty Turn Left (C22) solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace Turn Right (C23) solenoid
Turn Right (C23) solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Turn Right (C23) solenoid
3. Replace Lower Control
NOTE: A load of less than 70mA will be detected as an
087 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
TURN RIGHT (C23)
Possible causes include:
1. Faulty Turn Right (C23) solenoid wiring
2. Faulty Turn Right (C23) solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Turn Right (C23) solenoid
the Turn Right (C23) solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Turn Right (C23) solenoid
088 SHORTED CIRCUIT 3. Replace Lower Control
TURN RIGHT (C23) Possible causes include:
1. Faulty Turn Right (C23) solenoid wiring
2. Faulty Turn Right (C23) solenoid
3. Faulty Lower Control

126
Error Message Error Explanation & What To Check &
Displayed Possible Causes Corrective Action To Clear Error
The Lower Control has detected an open circuit on the 1. Repair or replace Forward 1 (C24) solenoid wiring
Forward 1 (C24) solenoid output when it was energized 2. Replace Forward 1 (C24) solenoid
during startup self diagnostics. 3. Replace Lower Control

NOTE: A load of less than 70mA will be detected as an

089 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
FORWARD 1 (C24)
Possible causes include:
1. Faulty Forward 1 (C24) solenoid wiring
2. Faulty Forward 1 (C24) solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Forward 1 (C24) solenoid wiring
the Forward 1 (C24) solenoid output when it was 2. Replace Forward 1 (C24) solenoid
energized during startup self diagnostics. 3. Replace Lower Control
090 SHORTED CIRCUIT
FORWARD 1 (C24) Possible causes include:
1. Faulty Forward 1 (C24) solenoid wiring
2. Faulty Forward 1 (C24) solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace Reverse 1 (C25) solenoid
Reverse 1 (C25) solenoid output when it was energized wiring
during startup self diagnostics. 2. Replace Reverse 1 (C25) solenoid
3. Replace Lower Control
NOTE: A load of less than 70mA will be detected as an
091 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
REVERSE 1 (C25)
Possible causes include:
1. Faulty Reverse 1 (C25) solenoid wiring
2. Faulty Reverse 1 (C25) solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Reverse 1 (C25) solenoid
the Reverse 1 (C24) solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Reverse 1 (C25) solenoid
092 SHORTED CIRCUIT 3. Replace Lower Control
REVERSE 1 (C25) Possible causes include:
1. Faulty Reverse 1 (C25) solenoid wiring
2. Faulty Reverse 1 (C25) solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace Forward 2 (C27) solenoid wiring
Forward 2 (C27) solenoid output when it was energized 2. Replace Forward 2 (C27) solenoid
during startup self diagnostics. 3. Replace Lower Control

NOTE: A load of less than 70mA will be detected as an

093 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
FORWARD 2 (C27)
Possible causes include:
1. Faulty Forward 2 (C27) solenoid wiring
2. Faulty Forward 2 (C27) solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Forward 2 (C27) solenoid wiring
the Forward 2 (C27) solenoid output when it was 2. Replace Forward 2 (C27) solenoid
energized during startup self diagnostics. 3. Replace Lower Control
094 SHORTED CIRCUIT
FORWARD 2 (C27) Possible causes include:
1. Faulty Forward 2 (C27) solenoid wiring
2. Faulty Forward 2 (C27) solenoid
3. Faulty Lower Control

127
 Error Message Error Explanation & What To Check &
Displayed Possible Causes Corrective Action To Clear Error
The Lower Control has detected an open circuit on the 1. Repair or replace Reverse 2 (C28) solenoid
Reverse 2 (C28) solenoid output when it was energized wiring
during startup self diagnostics. 2. Replace Reverse 2 (C28) solenoid
3. Replace Lower Control
NOTE: A load of less than 70mA will be detected as an
095 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
REVERSE 2 (C28)
Possible causes include:
1. Faulty Reverse 2 (C28) solenoid wiring
2. Faulty Reverse 2 (C28) solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Reverse 2 (C28) solenoid
the Reverse 2 (C28) solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Reverse 2 (C28) solenoid
096 SHORTED CIRCUIT 3. Replace Lower Control
REVERSE 2 (C28) Possible causes include:
1. Faulty Reverse 2 (C28) solenoid wiring
2. Faulty Reverse 2 (C28) solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace Torque H/L (C29) solenoid
Torque H/L (C29) solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Torque H/L (C29) solenoid
3. Replace Lower Control
NOTE: A load of less than 70mA will be detected as an
097 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
TORQUE H/L (C29)
Possible causes include:
1. Faulty Torque H/L (C29) solenoid wiring
2. Faulty Torque H/L (C29) solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Torque H/L (C29) solenoid
the Torque H/L (C29) solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Torque H/L (C29) solenoid
098 SHORTED CIRCUIT 3. Replace Lower Control
TORQUE H/L (C29) Possible causes include:
1. Faulty Torque H/L (C29) solenoid wiring
2. Faulty Torque H/L (C29) solenoid
3. Faulty Lower Control
The Lower Control has detected an open circuit on the 1. Repair or replace Torque H/L (C30) solenoid
Torque H/L (C30) solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Torque H/L (C30) solenoid
3. Replace Lower Control
NOTE: A load of less than 70mA will be detected as an
099 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
TORQUE H/L (C30)
Possible causes include:
1. Faulty Torque H/L (C30) solenoid wiring
2. Faulty Torque H/L (C30) solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Torque H/L (C30) solenoid
the Torque H/L (C30) solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Torque H/L (C30) solenoid
100 SHORTED CIRCUIT 3. Replace Lower Control
TORQUE H/L (C30) Possible causes include:
1. Faulty Torque H/L (C30) solenoid wiring
2. Faulty Torque H/L (C30) solenoid
3. Faulty Lower Control

128
Error Message Error Explanation & What To Check &
Displayed Possible Causes Corrective Action To Clear Error
The Lower Control has detected an open circuit on the 1. Repair or replace Torque H/L (C31) solenoid
Torque H/L (C31) solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Torque H/L (C31) solenoid
3. Replace Lower Control
NOTE: A load of less than 70mA will be detected as an
101 OPEN CIRCUIT
open circuit. The typical load is approximately 800mA.
TORQUE H/L (C31)
Possible causes include:
1. Faulty Torque H/L (C31) solenoid wiring
2. Faulty Torque H/L (C31) solenoid
3. Faulty Lower Control
The Lower Control has detected excessive current on 1. Repair or replace Torque H/L (C31) solenoid
the Torque H/L (C31) solenoid output when it was wiring
energized during startup self diagnostics. 2. Replace Torque H/L (C31) solenoid
102 SHORTED CIRCUIT 3. Replace Lower Control
TORQUE H/L (C31) Possible causes include:
1. Faulty Torque H/L (C31) solenoid wiring
2. Faulty Torque H/L (C31) solenoid
3. Faulty Lower Control

129
 Error Message Error Explanation & What To Check &
Displayed Possible Causes Corrective Action To Clear Error
The Lower Control has detected the boom has reached 1. Reduce weight in basket or on hook
or exceeded 95% of maximum outreach setting. 2. Retract boom
3. Raise boom
NOTE: This error only occurs on machines equipped 4. Correctly configure Lower Control
with the Moment Sense option. 5. Replace Lower Control
103 OUTREACH
NEAR MAXIMUM Possible causes include:
1. Too much weight on boom
2. Boom extended too far for weight on boom
3. Boom lowered too far for weight on boom
4. Lower Control incorrectly configured
5. Faulty Lower Control
The Lower Control has detected the boom has reached 1. Reduce weight in basket or on hook
the maximum outreach setting. 2. Retract boom
3. Raise boom
NOTE: This error only occurs on machines equipped 4. Correctly configure Lower Control
with the Moment Sense option. 5. Replace Lower Control
104 OUTREACH
AT MAXIMUM Possible causes include:
1. Too much weight on boom
2. Boom extended too far for weight on boom
3. Boom lowered too far for weight on boom
4. Lower Control incorrectly configured
5. Faulty Lower Control
The Lower Control has detected the primary boom 1. Reduce weight in basket or on hook
cylinder has reached or exceeded the maximum 2. Retract boom
pressure setting. 3. Raise boom
4. Correctly configure Lower Control
NOTE: This error only occurs on machines equipped 5. Replace Lower Control
with the Moment Sense option.
105 OVER MAXIMUM
CYLINDER PRESSURE
Possible causes include:
1. Too much weight on boom
2. Boom extended too far for weight on boom
3. Boom lowered too far for weight on boom
4. Lower Control incorrectly configured
5. Faulty Lower Control
The Primary boom cylinder pressure safety switch has 1. Check angle sensor
detected the primary cylinder has reached or exceeded 2. Repair or replace angle sensor wiring
the maximum pressure setting and disabled all boom 3. Check pressure sensor
functions. 4. Repair or replace pressure wiring
5. Check and repair Primary boom cylinder pressure
If this error occurs one or more of the three sensors switch
responsible for determining the moment are not reading 6. Repair or replace Primary boom cylinder pressure
correctly. The angle sensor, the pressure sensor and switch wiring
the pressure switch must be examined to determine 7. Correctly configure Lower Control
which sensor or sensors have failed. 8. Replace Lower Control
106 OUTREACH
NOTE: This error only occurs on machines equipped
SENSING FAULT
with the Moment Sense option.

Possible causes include:

1. Faulty angle sensor
2. Faulty angle sensor wiring
3. Faulty pressure sensor
4. Faulty pressure sensor wiring
5. Faulty Primary cylinder pressure switch
6. Faulty Primary cylinder pressure switch wiring
7. Lower Control incorrectly configured
8. Faulty Lower Control

130
 Lower Control “Blink” Error Codes
The “Power” led blinks to indicate the following error conditions:
1 Blink = Stuck key on Lower Control
2 Blinks = Loss of communication with Platform Control
3 Blinks = Loss of communication with Drive Control
4 Blinks = Loss of communication with PC
5 Blinks = Loss of communication with Load Sense Module

Upper Control “Blink” Error Codes

The “Engine” led blinks to indicate the following error conditions:
1 Blink = Stuck key on Upper Control
2 Blinks = Loss of communication with Lower Control
3 Blinks = Stuck Joystick

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