Summit 3522a manual

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BOOM PERSONNEL LIFT This equipment is desi gne d and manufactured in compliance with the dutie s, responsibilities and standards set forth for manufacturers in the ANSI 92.2 standard at the time of manufacture. This equipment will meet or exceed appl icabl e OSHA and ANSI codes and standard s when operated in accordance with sections 7, 8, 9 and 10[...]

1 TABLE OF CONTENTS Table of Contents 1 Illustrations 2 Tables 2 1 Safety 3 Before Operation 4 During Operation 4 Maintenance Safety 5 Damaged Equipment Policy 7 Reporting Safety Defects 8 2 General Introduction 9 Specifications 11 Warranty 12 3 Operations 13 Ground Control Station 14 Platform Control Station 16 Normal Operating Procedure 18 Manual[...]

2 LIST OF ILLUSTRATIONS Figure 2-1 Bil-Jax Model 3522A 9 Figure 2-2 Boom Lift Control Panel 10 Figure 2-3 Range of Motion 10 Figure 3-1 Ground Control Station 14 Figure 3-2 Platform Control Station 16 Figure 3-3 Outrigger Controls 18 Figure 3-4 Boom Travel Latch 18 Figure 3-5 Hand Pump and Control s for Man ual Op eration 20 Figure 3-6 Manual Lower[...]

1 SAFETY Familiarity with all equipment and prope r training are required for the safe operation of any mechanical device. Attempting to operate any mechanical equipment imp rope rly or wit hout training creates a situation that is potentially hazardous. Prior to operation, read the instructio ns and safety precautions included in th is manual and [...]

BIL-JAX 3522A BEFORE OPERATION DURING OPERATION Ensure the following general safety pre c aution s are followed before operating the Bil-Jax Model 3522A Articulating Boom Lift: ALWAYS survey the usage area for potential hazards, such as untampe d earth fills, unlevel surfaces, overhead obstructions an d ele ctrically charged conductors or wire s. M[...]

1 — SAFETY 5 ALWAYS stay clear of wires, cables and other overhead obstructions. ALWAYS engage the boom tr avel latches before towing the trailer. NEVER allow electrode contact with any part of the machine while welding from the platform. NEVER use without the outriggers fully extended and firmly based. NEVER override or bypass the manufacturer&a[...]

BIL-JAX 3522A 6 NEVER adjust, repair, replace or bypass any hydraulic or electrical control or safety device. These include, but are not limited to, hydraulic load control and flow control valves, solenoid valve s and limit switches. Contact the Bil-Jax Service Department at 800-537-0540 if these compone nts require maintenance. NEVER attempt repai[...]

1 — SAFETY 7 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 an d test ed to comply with current applicable federal OSHA and ANSI codes and regulations. Damage Policy There may be occasions when a Bil-Ja x lift is involved in an in cid [...]

BIL-JAX 3522A 8 Bil-Jax, Inc. 125 Taylor Parkway Archbold, Ohio 43502 800-537-0540 REPORTING SAFETY DEFECTS If you believe that your vehicle has a def ect that could cau se a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Bil-Jax, Inc. If the NH[...]

2 GENERAL INTRODUCTION The Bil-Jax 3522A Articulating Boom Lift (Figure 2-1) is a Summit Series™ Trailer-Mounted Boom, desi gne d and manufactured to position personnel with their tools and equi pment at overhead work locations. The work platform load cap acity is rated at 500 pounds. During all boom operations, four extended outriggers sup port [...]

BIL-JAX 3522A The hydraulic power unit uses a 24 Volt, one horsepower DC motor to drive the hydraulic pump. The DC motor is powered by four 6 Volt DC, 245 Amp-hour deep charg e batteries conne cted in series. A 25 Amp, automatic onbo ard b attery charger is provided with sta ndard models for recharging the batteries at the end of each work period. [...]

2 — GENERAL I NTRODUCTION SPECIFICATIONS Boom Lift Work Platform Model Number: 3522A Serial Number__________ ____ ________ Manufactured by: Bil-Jax, Inc. 125 Taylor Parkway Archbold, Ohio 43502 800-537-0540 11 Feature Model 3522A Working Height 43 ft 2 in (13.3 m) Maximum Platform Height 37 ft 2 in (11.3 m) Maximum Horizont al Outreach From Cente[...]

BIL-JAX 3522A 12 WARRANTY Bil-Jax, Inc. warrants this product for one year, beginning on the date of delivery, to be free from defects of material and workm anship provided the unit is operated and maintained in compliance with the guidelines established in the Operations and Maintenance Manual s. Major structural co mpo nents, including trailer to[...]

13 3 OPERATION The Model 3522A Articulating Boom Lift is equippe d wi th multiple operator control stations. Equipment po wer and outrigger controls are located at ground level. Boom lift and rotation controls are located a t ground level and on the work platform. Before attempting boom lift operation, Operator s should:  Obtain, read and obey a[...]

BIL-JAX 3522A GROUND CONTROL STATION The ground control station is used to operate outrigg ers and control boom motion. To access the ground c ont rol station, op en the control panel access cover found o n the turntable. Turn the key switch to the ground controls setting. Figure 3-1. Ground Control Station. The ground control station includes the [...]

3 — OPERATION 15 Display Panel The DISPLAY PANEL is a lighted text window that displays the present operating status or a n existing error condition when the key switch is on. Emergency Stop Button When pushed in, the emergency STOP button disconnects electri cal po wer to the ground and platform control stations. The emergency STOP pushbutton sh[...]

BIL-JAX 3522A PLATFORM CONTROL STATION The platform control station is used to control boom motion. To access the platform control station, turn the key sw itch at the ground control station to the platform controls setting and enter the work cage. Figure 3-2. Platform Control Station The platform control station includes the following controls and[...]

3 — OPERATION 17 Speed Buttons The SPEED buttons along the lower rig ht side of the control panel must be pressed a nd hel d while selecting boom function s. Four speeds are available to control the positioning of the boom lift. Boom Rotation CW/CCW Button s Pressing and holding a desired SPEED button and the BOOM ROTATION CW or CCW button at the[...]

BIL-JAX 3522A NORMAL OPERATING PROCEDURE Perform the following proc edures to operate the Bil- Jax Model 3522A Articulating Boom Lift.  Read and obey all safety precautions and operating instructions, as well as all applicable portions of ANSI A92.2, reprinted in Section 6.  Position the boom lift at the work area. Make sure the boom lift is [...]

3 — OPERATION 19  Use the ground control panel to operate the boom lift functions. Raise, lower, extend and rotate the booms by pressing and holding the desired SPEED and function buttons at the sam e time. Become familiar with the location and function of all controls. Learn to smoothly start and stop all boom motions.  Fully lower both bo[...]

BIL-JAX 3522A MANUAL BOOM OPERATION Manual retraction, rotation and loweri ng functions allow the Model 3522A Articulating Boom Lift to be moved and lowered during hydrauli c po wer interruption or failure. In each instance, refer to Figure 3-5. The following procedure s for man ual retraction, rotation and lowering requi re a pe rson on the ground[...]

3 — OPERATION Manual Lowering Each Manual Lowering Valve (Figure 3-6) is equipped with a plunger, found at the base of the lift cylinders and on the back side of the jib boom (Figure 3-7). Use the plungers to lowe r the platform in case of a complete electrical power failure, a load shift, or other emergency situation. To lower the work platform,[...]

BIL-JAX 3522A BATTERY RECHARGE Recharge boom lift batteries after e ach 8-hour work shift or as needed. When boom lift is not in use, batteries should be rech arged at lea st once per week. Under normal circu mstances, battery recharge should take approximately 10-12 hours. However, a full recharge may take up to 24 hou rs, if the battery charge is[...]

3 — OPERATION BOOM LIFT TRANSPORT The boom lift trailer includes a single axle, two-in ch ball hitch, hydraulic surge brakes, me ch anical parking brake, breakaway safety cable, safety chains, brake lights and side marker lig hts. Prope r boom transport requires the proper atta chment and inspection of these compo nents before towing. Refer to Fi[...]

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25 4 OPERATOR SERVICE Performing the appropriate daily, weekly and monthly service checks and scheduled maintenance proce dures w ill extend the life of the boom lift and will help ensure the safety of personnel ope rating the equipment. Additional annual and semi-ann ual main tenance and repair proce du res can be found in the Bil-Jax Model 3522A [...]

BIL-JAX 3522A DAILY SERVICE CHECKS The following Maintenance Proce dures should be performed daily before operation. Verify that all decals are correctly applied and in plain view.  Refer to Section 5 for decal locations. Verify that all controls and indicators at groun d and platform control stations operate properly.  Lower outriggers to le[...]

4 — OPERATOR SERVICE WEEKLY SERVICE CHECKS Perform the following service che cks at least once each week: Check Battery electroly te level.  If battery charge 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 elect[...]

BIL-JAX 3522A 28 TROUBLESHOOTING Refer to Table 4-1 for basic troubl eshooting operations. Additional information can be found in the Bil-Jax Model 3522A Parts and Service Manual. Contact the Bil-Jax Service Department with any question s or before attempting any advanced troubleshooting operation s. Table 4-1. Troubleshooting Steps PROBLEM CAUSE S[...]

4 — OPERATOR SERVICE 29 ERROR CODE DEFINITIONS The DISPLAY PANEL located on the ground control panel indicates the present operating status of the boom lift. If an erro r condition is detected by the control processor during start-up o r ope ration, the app ropriate error code will be displayed on this panel. Refer to Table 4-2 for a co mpre hens[...]

BIL-JAX 3522A 30 ERROR MESSAGE DEFINIT ION OF ERROR COMMENTS 031 OPEN CIRCUIT JIB DOWN A load of less than 70mA detected when jib down circuit was energized Check for faulty jib down solenoi d coil and wiring. 032 SHORTED CIRCUIT JIB DOWN Excessive load detected when jib down circuit was energized. Check for faulty jib down solenoi d coil and wirin[...]

4 — OPERATOR SERVICE 31 ERROR MESSAGE DEFINIT ION OF ERROR COMMENTS 056 SHORTED CIRCUIT RF OUTRIGGER Excessive load detected in right front outrigg er circuit on power-up. Check for faulty solenoid coil/wiring at outrigger. 057 OPEN CIRCUIT LR OUTRIGGER A load of less than 70mA detected in left rear outrigger circuit on po wer-up. Check for fault[...]

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33 5 REPLACEMENT DECALS Refer to Table 5-1 and Fig ure 5 -1 for descriptions and locations of decals on the Bil-Jax Model 3522A Articulating Boom Lift. Table 5-1. Replacement Decal Des criptions Decal No. Decal De scription Qty 0202-0523 Made in USA 1 B06-00-0034 DANGER: Elec tric Shock 1 B06-00-0037 Lubricate Semi-Annually 1 B06-00-0062 NOTI CE: A[...]

BIL-JAX 3522A Figure 5-1. Decal Locations 34[...]

35 6 ANSI REPRINT The following sections a re rep rinted from the ANSI A92.2-2001 code in effect at the time of manufacture and govern the safe u se of the Bil-Jax Model 3522A Articulating Boom Lift. Permission to reprint this material has be en gra nted by the Scaffold Industry Association. 7. Re sponsibilities of Dealers and Installers 7.1 Genera[...]

BIL-JAX 3522A 36 locking devices. Any suspected items shall be carefully examined or tested and a determination made by a qualified person as to whether they constitute a safety hazard. All unsafe items shall be replaced or repaired before use. 8.2.4 Periodic Inspection or Tes t. An inspection of the mobile unit shall be performed at the intervals [...]

6 — ANSI REPRINT 37 8.12 Training, Retraining, and Familiarization of Oper ators. 8.12.1 Owner as a Renter or Lessor. When an o wner functions as a renter or lessor he shall have the same responsibilities as specified under Section 11 of this standard. 8.12.2 General Training . Only personnel who have received general instructions regarding the i[...]

BIL-JAX 3522A 38 10.4 Brakes. The vehicle parking brake(s) shall be set at all times that the boom is elevated exc ept when the aerial device is being used in accordance with 9.5. 10.5 Loading. Any loading which includes a horizontal load shall be avoided unless the mobile unit is designed for that application. 10.6 Observations. Observations dur i[...]

6 — ANSI REPRINT Elevating and Rotating Aerial De vices. These manuals shall be stored on the mobile unit. 11.4 Training. The renter or lessor shall offer training or training materials that aid the renting entity or lessee in the operation, inspection, testing and maintenance of the aerial device. This training shall be offered initially and sub[...]

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41 7 MATERIAL SAFETY DATA The following Material Safety Data Sheets describe t he co rrect procedures for the safe handling of ch em ical components within the Model 3522A Articulating Boom Lift, as well as any potential health and safety hazards related to these chemicals. Material Sa fety Data Sheets are included here in ac co rdance with applica[...]

BIL-JAX 3522A 42 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 [...]

7 — MATER IAL SA FETY DATA 43 MATERIAL SAFETY DATA SHEET DEXRON III/MERCON AUTOMATIC TRAN SMISSION FLUID (HYDRAULIC OI L) SECTION I -- GENERAL INFORMATION TRADE NAME: CITGO TRANSGARD™ ATF, DE XRON III/MERCON EMERGENCY TELEPHONE NUMBERS: 918.495.4700 (medical); 800.424.9300 (chemical) CHEMICAL FAMILY: AUTOMATIC TRANSMISSION FLUID, LUBRICATING OI[...]

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45 8 EQUIPMENT OPTIONS The Bil-Jax Model 3522A may be equipped with one or more optional components de si gned for t he convenience and safety of operators when using the equipm ent to accompli sh specific tasks. Always use only those components manufactu red a nd/or authorized by Bil-Jax, Inc. Never make any adjustments or modifications or otherwi[...]

BIL-JAX 3522A MATERIAL LIFTING HOOK If the boom lift is equipped with a material lifting hook, observe the following procedure for mate rial lift operation:  Remove platform controls from the work platform by releasing the latch on the ba ck of the platform control box.  Disconnect platform control box from the load sense module located on th[...]

8 — EQUIPMENT OPTIONS HORIZONTAL JIB ROTATOR The optional jib rotator allows the jib boo m and wo rk platform to be rotated clockwise or countercl ockwise around a vertical axis. Boom lifts equipped with jib rotator option will have additional control s on the ground and platform co ntrol panels (Figure 8-3). 47 Figure 8-3. Ground Controls w ith [...]

BIL-JAX 3522A COMBINATION HITCH Observe the following procedure to change the hitch coupler on lifts equippe d wi th an optional combination hitch:  Choose the desired hitch coupler from among the following: 2-inch ball hitch, 2 5 / 16 -inch ball hitch, 2 ½-inch Pintle Ring, or Clevis hitch.  Insert the hitch coupler into the hitch bra cket [...]

8 — EQUIPMENT OPTIONS REPLACEMENT DECALS Refer to Table 8-1 and Fig ure 8 -7 to Figure 8-8 for a descriptions and location s of replaceme nt decals for optional components. Ref er to Section 5 for a comprehensive list of standard d ecals o n the Bil-Jax Model 3522A Articulating Boom Lift. All decals related to optional equipment have a quantity o[...]

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BIL-JAX MODEL 3522A QUICK START GUIDE Obtain, read and obey all Safety Guidelines:  In this manual  Attached to the boom lift  Indicated by federal, state and local regu lati ons Position the boom lift in work area Unhitch from the tow vehicl e and di sengage all boom travel lat ches Turn Key Switch to ground control statio n for outrigger[...]

125 Taylor Park way Archbold, OH 43502 Phone (419) 445-8915 (800) 537-0540 Fax (419) 445-0367 Distributed by : http:// www. biljax .com[...]