Haulotte SUMMIT Series Parts And Service Manual
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Haulotte SUMMIT Series Parts And Service Manual

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  • Page 1 Click Here To View Item at www.GapPower.com...
  • Page 2 PARTS AND SERVICE MANUAL B33-01-0094-03...
  • Page 3 Haulotte Group | BilJax Service Department. Copyright © Haulotte Group | BilJax, Inc. 2009. All Rights Reserved. “Haulotte Group | BilJax” is a registered trademark and “A Step Above” and “Summit Series” are trademarks of Haulotte Group | BilJax, Inc.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Table of Contents Illustrations Tables 1 Safety Legend: Safety Advisories Before Operation During Operation Maintenance Safety Damaged Equipment Policy 2 Specifications Range of Motion Specifications Warranty 3 Equipment Maintenance Daily Service Checks Weekly Service Checks Monthly Service Checks Annual Service Checks Structural Inspection Battery Recharge...

  • Page 5: Illustrations

    LIST OF ILLUSTRATIONS Figure 2-1 Range of Motion Figure 3-1 Outrigger Position Switch Figure 3-2 Hydraulic Reservoir Figure 3-3 Wheel Nut Tightening Sequence Figure 3-4 Slew Ring Position Measurement Figure 3-5 Battery Charger Faceplate Figure 4-1 Lift Cylinder Replacement Figure 4-2 Outrigger Cylinder Replacement Figure 5-1 Decal Locations...

  • Page 6: Safety

    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.

  • Page 7: Legend: Safety Advisories

    HAULOTTE GROUP | BILJAX 3522A 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.

  • Page 8: Before Operation

    ALWAYS wear a safety harness and energy- absorbing lanyard, such as the safety harness and Minimum Safe Approach Distance Voltage Range lanyard provided by Haulotte Group | BilJax. (Feet) (Meters) (Phase to Phase) ALWAYS inspect platform floor and outrigger...
  • Page 9 NEVER exceed the load limits set by the trailer tongue and/or tow vehicle. manufacturer. Use only the Material Lifting Hook, supplied as an option and manufactured by Haulotte ALWAYS disengage boom travel latches before Group | BilJax, when lifting materials. Safely stow all raising boom sections and reengage boom travel tools and equipment.

  • Page 10: Maintenance Safety

    If NEVER charge batteries near flammable materials. the motor becomes wet, consult an authorized Haulotte Group | BilJax service technician for proper NEVER allow batteries to overcharge and boil. drying instructions. NEVER short across battery posts to check for NEVER add unauthorized fluids to the hydraulic current.

  • Page 11: Damaged Equipment Policy

    Safety Statement At Haulotte Group | BilJax, we are dedicated to the safety of all users of our products. All Haulotte Group | BilJax lifts are designed, manufactured and tested to comply with current applicable federal OSHA and ANSI codes and regulations.

  • Page 12: Specifications

    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 Haulotte Group | BilJax representative or to the Haulotte Group | BilJax Service Department.

  • Page 13: Range Of Motion

    HAULOTTE GROUP | BILJAX 3522A RANGE OF MOTION Figure 2-1. Range of Motion...

  • Page 14: Specifications

    2 — SPECIFICATIONS SPECIFICATIONS SERIAL NUMBER____________________________ Working Height 41 ft 9 in Towing Brake Hydraulic Surge 12.9 m Rated Towing Speed 65 mph Maximum Platform Height 35 ft 9 in 105 km/h 10.9 m Tire Size ST 205/75 R14C Maximum Horizontal Outreach Control System 24V DC From Centerline...

  • Page 15: Warranty

    Haulotte Group | BilJax’s maximum liability under this warranty is limited to the amount paid to Haulotte Group | BilJax for the product. This warranty is in lieu of all other warranties expressed or implied. Haulotte Group | BilJax 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.

  • Page 16: Equipment Maintenance

    This manual contains a list of recommended maintenance procedures to be performed daily, weekly, monthly and annually. It is the practice of Haulotte Group | BilJax, Inc. to issue Service and/or Safety Bulletins, which may include updates to the information contained in this manual.

  • Page 17: Daily Service Checks

    HAULOTTE GROUP | BILJAX 3522A 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 a fully lowered, stowed position.

  • Page 18: Figure 3-2 Hydraulic Reservoir

    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.

  • Page 19: Weekly Service Checks

    HAULOTTE GROUP | BILJAX 3522A 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 battery charge is low, add enough water to bring the electrolyte level to the top of the plates.

  • Page 20: Monthly Service Checks

    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.

  • Page 21: Annual Service Checks

    HAULOTTE GROUP | BILJAX 3522A 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 distance between the slew ring gear and the Drain hydraulic reservoir, clean and replace oil.

  • Page 22: Structural Inspection

    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.

  • Page 23: Battery Recharge

    HAULOTTE GROUP | BILJAX 3522A BATTERY RECHARGE Recharge boom lift batteries after each 8-hour work The CHARGING indicator LED remains lit shift or as needed. When boom lift is not in use, continuously during the first stage of the charge batteries should be recharged at least once per cycle.

  • Page 24: Troubleshooting

    TROUBLESHOOTING Refer to Table 3-2 for basic troubleshooting operations. Additional information can be found in the Haulotte Group | BilJax Model 3522A Operator’s Manual. Contact the Haulotte Group | BilJax Service Department with any questions or before attempting any advanced troubleshooting operations.

  • Page 25: Error Code Definitions

    HAULOTTE GROUP | BILJAX 3522A ERROR CODE DEFINITIONS The 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.
  • Page 26 3 — EQUIPMENT MAINTENANCE 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...
  • Page 27 HAULOTTE GROUP | BILJAX 3522A 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...

  • Page 28: Cylinder Replacement

    Perform all maintenance procedures only in an area that is well-lit and well-ventilated. Haulotte Group | BilJax, 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.

  • Page 29: Lift Cylinder Replacement

    HAULOTTE GROUP | BILJAX 3522A LIFT CYLINDER REPLACEMENT Use the following procedure to remove and replace At the base of the cylinder, unbolt and remove retainer plate from each side of the pivot pin. faulty or damaged hydraulic cylinders on the boom...

  • Page 30: Outrigger Cylinder Replacement

    4 — CYLINDER REPLACEMENT OUTRIGGER CYLINDER REPLACEMENT Unplug the cylinder valve solenoid. Use the following procedure to remove and replace faulty or damaged hydraulic cylinders on the Place absorbent cloths below the cylinder ports and outriggers: detach hydraulic hoses from the cylinder. Elevate hoses to prevent leakage.
  • Page 31 HAULOTTE GROUP | BILJAX 3522A...

  • Page 32: Replacement Decals

    REPLACEMENT DECALS WARNING 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. Promptly replace all decals that are no longer legible.

  • Page 33: Table 5-1 Replacement Decal Descriptions

    B06-00-0496 B06-00-0062 NOTICE: AC Power Capacity 200 lbs. B06-00-0068 NOTICE: Hydraulic System Oil B06-00-0503 NOTICE: Handle Applications Haulotte Group | BilJax Logo, 6” B06-00-0504 NOTICE: Emergency Hand Pump B06-00-0161B Black Transfer DANGER: Before Use/Main B06-00-0505 NOTICE: Fall Protection Instruction/Hazards (ground)

  • Page 34: Figure 5-1 Decal Locations

    5 — REPLACEMENT DECALS Figure 5-1. Decal Locations...
  • Page 35 HAULOTTE GROUP | BILJAX 3522A...

  • Page 36: Ansi Reprint

    ANSI REPRINT The following sections are reprinted from the ANSI A92.2-2009 code in effect at the time of manufacture and govern the safe use of the Haulotte Group | BilJax Model 3522A Articulating Boom Lift. Permission to reprint this material has been granted by the Scaffold...
  • Page 37 HAULOTTE GROUP | BILJAX 3522A Control functions and operation clearly marked. may be relied upon when performed frequently, (3) Check visual and audible safety devices for proper however the unit shall undergo an ac voltage test operation. at least every three years in accordance with (4) Visually inspect fiberglass and insulating components Table 2 criteria;...
  • Page 38 6 — ANSI REPRINT 8.4.1 Maintenance Training. The owner shall train their The purpose of placards and decals. maintenance personnel in inspection and maintenance of Workplace inspection. the aerial device in accordance with the manufacturer’s Applicable safety rules and regulations, such as Part 4, recommendations and Section 8 of this standard.
  • Page 39 HAULOTTE GROUP | BILJAX 3522A (12) Proper use of personal fall protection equipment. Fall 10.7 Alterations. Altering or disabling the function of safety protection systems criteria and practices are covered in devices, guards or interlocks, if so equipped, is prohibited.
  • Page 40 6 — ANSI REPRINT 10.11 Mobile Operation. Before engaging in mobile operation 11.1 General Responsibilities. Each lessor or lessee shall the operator shall determine that the aerial device is comply with the requirements of the applicable section or specifically designed for mobile operation. sections below.

  • Page 41: Figure 6-1 Minimum Safe Approach Distances

    HAULOTTE GROUP | BILJAX 3522A (12) Electrical hazards and Minimum Approach Responsibilities of Brokers Distance to energized conductors and apparatus. See 12.1 Broker Involved In a Sale. A broker involved in a sale Appendix F. shall: 11.4.2 Familiarization. When operators are directed to operate an...

  • Page 42: Appendix: Replacement Parts

    REPLACEMENT PARTS APPENDIX: Use only parts manufactured and/or authorized by Haulotte Group | BilJax, Inc. when replacing damaged components. See page 88 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.
  • Page 43 OUTRIGGER ASSEMBLY...
  • Page 44 OUTRIGGER ASSEMBLY PARTS LIST Item No. Part No. Description Qty. A-01120 Outrigger Weldment A-00046 Grommet, 1.5 x 1.25 x 1.75 A-00031 Bearing A-00058 Pin, 1.0 x 5.25 (Front Outriggers Only) A-00018 Pin Retainer (Front Outriggers) Pin Retainer (Rear Outriggers) 0096-0016 Cap Screw, M10 x 25 (Front Outriggers) Cap Screw, M10 x 25 (Rear Outriggers) 0096-0041...
  • Page 45 TOWING ASSEMBLY...
  • Page 46 TOWING ASSEMBLY PARTS LIST Item No. Part No. Description Qty. B03-00-0017 Safety Chain Assembly 0096-0025 Cap Screw, M12 x 120 0096-0046 Washer, Flat, M12 0096-0042 Hex Nut, Self-Locking, M12 A-02177 Brake Bracket A-00192 Brake Lever 0096-0010 Cap Screw, M8 x 20 0096-0040 Hex Nut, Self-Locking, M8 A-01154...
  • Page 47 FRONT REST ASSEMBLY...
  • Page 48 FRONT REST ASSEMBLY PARTS LIST Item No. Part No. Description Qty. A-01145 Front Rest Weldment 0096-0024 Cap Screw, M12 x 100 0096-0042 Hex Nut, Self-Locking, M12 A-00157 Front Rest Pad 0096-0017 Cap Screw, M10 x 30 0096-0041 Hex Nut, Self-Locking, M10 A-00159 Boom Latch 0096-0016...
  • Page 49 BRAKE AND AXLE ASSEMBLY...
  • Page 50 BRAKE AND AXLE ASSEMBLY PARTS LIST Item No. Part No. Description Qty. A-01171 Axle Mount Weldment A-00143 Fender A-00184 Equalizer Bracket A-00151-1 Fender Mount – Left A-00151-2 Fender Mount – Right 0096-0014 Cap Screw, M10 x 20 0096-0041 Hex Nut, Self-Locking, M10 0096-0016 Cap Screw, M10 x 25 0096-0010...
  • Page 51 SLEW RING ASSEMBLY...
  • Page 52 SLEW RING ASSEMBLY PARTS LIST Item No. Part No. Description Qty. A-01189 Slew Assembly and Adapter Slew Ring Slew Ring Drive A-01149 Base Ring Adapter 0090-0461 Cap Screw, 1/2-13 x 2 0090-0212 Lock Washer, 1/2 0096-0033 Flat Head Cap Screw, M16 x 35 0096-0054 Flat Head Cap Screw, M16 x 50 0090-0643...
  • Page 53 LIMIT SWITCH ASSEMBLY...
  • Page 54 LIMIT SWITCH ASSEMBLY PARTS LIST Item No. Part No. Description Qty. A-01190L Switch Plate – Left A-01190R Switch Plate – Right 0096-0016 Cap Screw, M10 x 25 B01-03-0078 Limit Switch NO B01-03-0079 Limit Switch NC A-01191 Switch Cam Weldment A-01195 Switch Cam Top Slide 0096-0012 Flat Head Cap Screw, M8 x 25...
  • Page 55 CONTROL COMPARTMENT ASSEMBLY...
  • Page 56 CONTROL COMPARTMENT ASSEMBLY PARTS LIST Item No. Part No. Description Qty. A-00712 Lower Control Box A-00233 Lower Control Mount A-00290 Cover Stop Bracket 0096-0016 Cap Screw, M10 x 25 0096-0041 Hex Nut, Self-Locking, M10 A-00259 Level Sensor 0096-0002 Cap Screw, M6 x 20 0096-0039 Hex Nut, Self-Locking, M6 A-00287...
  • Page 57 PUMP COMPARTMENT ASSEMBLY...
  • Page 58 PUMP COMPARTMENT PARTS LIST Item No. Part No. Description Qty. A-00268 Tire Iron/Jack Handle B04-07-0033 Clamp 0096-0001 Cap Screw, M6 x 16 0096-0039 Hex Nut, Self-Locking, M6 A-00290 Cover Stop Bracket 0096-0002 Cap Screw, M6 x 20 0096-0014 Cap Screw, M10 x 20...
  • Page 59 BATTERY COMPARTMENT ASSEMBLY...
  • Page 60 BATTERY COMPARTMENT ASSEMBLY PARTS LIST Item No. Part No. Description Qty. A-00215 Battery Box Weldment – Left A-00220 Battery Box Weldment – Right A-00278 Battery Hinge Pin 0096-0050 Washer, Flat, M16 0090-0147 Cotter Pin A-00271 Battery Clamp 0096-0010 Cap Screw, M8 x 20 0096-0040 Hex Nut, Self-Locking, M8 A-01219...
  • Page 61 COVER ASSEMBLY...
  • Page 62 COVER ASSEMBLY PARTS LIST Item No. Part No. Description Qty. A-01240 Cover – Left A-01239 Cover – Right A-01230 Cover Brace A-00252 Hinge 0096-0002 Cap Screw, M6 x 20 0096-0039 Hex Nut, Self-Locking, M6 0090-1080 Pop Rivet A-00284 Controls Cover – Left Side w/Hinge A-00292 Cover Latch Assembly...
  • Page 63 LOWER BOOM ASSEMBLY...
  • Page 64 LOWER BOOM ASSEMBLY PARTS LIST Item No. Part No. Description Qty. A-01300 Lower Boom Weldment A-01314 Lower Link Weldment A-01551 Lift Cylinder A-00159 Boom Latch 0096-0016 Cap Screw, M10 x 25 0096-0041 Hex Nut, Self-Locking, M10 A-00157 Rest Pad 0096-0017 Cap Screw, M10 x 30 A-00021 Pin, 1.25 x 8.5...
  • Page 65 TRIANGLE WELDMENT ASSEMBLY...
  • Page 66 TRIANGLE WELDMENT ASSEMBLY PARTS LIST Item No. Part No. Description Qty. A-01320 Triangle Weldment A-01552 Master Cylinder A-01555 Lift Cylinder – Upper A-00021 Pin, 1.25 x 8.5 A-00019 Pin Retainer, 1.25 0096-0016 Cap Screw, M10 x 25 0096-0041 Hex Nut, Self-Locking, M10 A-00018 Pin Retainer, 1.0 A-00049...
  • Page 67 UPPER BOOM ASSEMBLY...
  • Page 68 UPPER BOOM ASSEMBLY PARTS LIST Item No. Part No. Description Qty. A-01502 Upper Boom Weldment A-01510 Telescopic Boom Tube A-01550 Extension Cylinder A-00535 Slider 0096-0017 Cap Screw, M10 x 30 0096-0041 Hex Nut, Self-Locking, M10 0096-0033 Flat Head Cap Screw, M16 x 35 A-00533 Wear Pad A-00534...
  • Page 69 JIB BOOM ASSEMBLY...
  • Page 70 JIB ASSEMBLY PARTS LIST Item No. Part No. Description Qty. A-00657 Jib Link Weldment A-00651 End Pivot Weldment A-00660 Jib Cylinder A-01553 Slave Cylinder A-00662 Jib End Weldment A-01979 Bulkhead – Left 0096-0016 Cap Screw, M10 x 25 0096-0041 Hex Nut, Self-Locking, M10 0096-0091 Flat Head Cap Screw, M10 x 25 A-00054...
  • Page 71 PLATFORM ASSEMBLY...
  • Page 72 PLATFORM ASSEMBLY PARTS LIST Item No. Part No. Description Qty. A-00450 Platform Weldment A-00713 Platform Control Box A-00461 Upper Control Box Mount 0096-0016 Cap Screw, M10 x 25 0096-00041 Hex Nut, Self-Locking, M10 A-00466 Control Box Latch 0090-1088 Rivet A-00462 Spool 0096-0003 Flat Head Cap Screw, M6 x 20...
  • Page 73 PUMP ASSEMBLY (A-01254)
  • Page 74 PUMP ASSEMBLY PARTS LIST Item No. Part No. Description Qty. B02-15-0496 Manifold, Valve Housing B02-14-0108 Valve, Cartridge (Telescope) B02-15-0472 Manual Pump, Extend/Retract/Rotate B02-14-0089 Valve, Cartridge (Outrigger Check) B02-14-0109 Valve, Cartridge (Outrigger) B02-14-0091 Valve, Check B02-14-0110 Valve, Check B02-14-0094 Valve, Proportional B02-14-0095 Coil Sterling, Proportional Valve B02-14-0111...
  • Page 75 PUMP ASSEMBLY, CONTINUED...
  • Page 76 PUMP ASSEMBLY PARTS LIST, CONTINUED Item No. Part No. Description Qty. B02-15-0499 Reservoir B02-15-0470 Pump Assembly, 2.09CCM B02-15-0471 Motor, Pump, 24 V DC B02-15-0500 Coupling, .875 x 2.795 B02-15-0501 Filter, Hydraulic B02-15-0476 Sight Glass B02-15-0477 Socket Head Cap Screw, M8 x 85 B02-02-0247 Fitting, Plug, M14 x 1.5 x 5.8 B02-15-0478...
  • Page 77 BOOM AND ROTATION HYDRAULIC LINES...
  • Page 78 BOOM AND ROTATION HYDRAULIC LINES PARTS LISTS Item No. Part No. Description B02-01-0283 #4 x 32” Hydraulic Hose B02-01-0284 #4 x 32” Hydraulic Hose B02-01-0285 #4 x 168” Hydraulic Hose B02-01-0286 #4 x 168” Hydraulic Hose B02-01-0287 #6 x 204” Hydraulic Hose B02-01-0288 #6 x 204”...
  • Page 79 OUTRIGGER HYDRAULIC LINES OUTRIGGER HYDRAULIC LINES PARTS LIST Item No. Part No. Description Qty. B02-01-0325 #4 x 24” Hydraulic Hose B02-01-0326 #4 x 24” Hydraulic Hose B02-01-0327 #6 x 46” Hydraulic Hose B02-01-0328 #6 x 46” Hydraulic Hose B02-01-0219 #6 x 28” Hydraulic Hose B02-01-0220 #6 x 28”...
  • Page 80 WATER LINE TO PLATFORM (OPTION A-01701) Part No. Description B09-00-0039 #6 x 126” W/1-6-6FMP, 1-6-6MP 3000 PSI Pressure Washer Hose B09-00-0040 #6 x 420” 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...
  • Page 81 WIRE HARNESSES...
  • Page 82 WIRE HARNESSES AND KITS – ANSI Part No. Description A-01153 Light Kit – Trailer A-01182 Hose Kit – Trailer (See Page 76) A-01187 Brake Cable (Hydraulic Surge) A-01246 Tail Light Kit – Cage A-01269 Hose Kit – Boom (See Page 74-75) A-01272 Battery Cable Kit A-01714...
  • Page 83 MANUAL PLATFORM ROTATE ASSEMBLY (OPTION A-00300)
  • Page 84 MANUAL PLATFORM ROTATE ASSEMBLY PARTS LIST Item No. Part No. Description Qty. A-00301 Platform Mount A Weldment A-00308 Platform Mount Weldment A-00315 Gearbox – Platform Rotate A-00330 Bearing – .75” ID A-00329 Pin – 0.75 x 10.25 DB A-00017 Pin Retainer – 0.75 0096-0014 Cap Screw, M10 x 20 0096-0041...
  • Page 85 MATERIAL LIFT HOOK ASSEMBLY (OPTION A-01846)
  • Page 86 MATERIAL LIFT ASSEMBLY PARTS LIST Item No. Part No. Description Qty. A-01977 Platform Mount Weldment – LS A-00982 Load Sense Weldment 0096-0055 Cap Screw, M12 x 190 0096-0042 Hex Nut, Self-Locking, M12 A-00988-1 Load Cell 0096-0089 Cap Screw, M12 x 65 A-00990A Load Sense Spacer A A-00990B...
  • Page 87 MATERIAL LIFT ASSEMBLY, CONTINUED MATERIAL LIFT HOOK PARTS LIST Item No. Part No. Description Qty. A-00480 Material Lift Weldment A-00155 Lift Hook Storage Bracket A-01156 Bracket Clamp A-00028 A-00485 Lift Hook Assembly A-00037 Ramp, Short 0096-0003 Flat Head Cap Screw, M6 x 20 0096-0039 Hex Nut, Self-Locking, M6 0096-0016...
  • Page 88 BATTERY LAYOUT 3522A BATTERY LAYOUT (Kit A-01272) Item No. Description 30” Red, 2 Gauge, 5/16” Ring – Lug 37” Black, 2 Gauge, 5/16” Ring – 5/16” Ring 8” Black, 2 Gauge, 5/16” Ring – 5/16” Ring (Qty. 2) 15” Black, 2 Gauge, 5/16” Ring – Lug 24”...
  • Page 89 DRIVE AND SET ASSEMBLY...
  • Page 90 DRIVE AND SET ASSEMBLY PARTS LIST Item No. Part No. Description Qty. A-00901L Drive & Set Weldment – Left A-00901R Drive & Set Weldment – Right (Not Pictured) A-00906 Drive & Set Cylinder A-00907-1 Drive & Set Fender Mount – Left A-00907-2 Drive &...

  • Page 91: Ordering Replacement Parts

    ORDERING REPLACEMENT PARTS To order replacement parts, contact the Haulotte Group | BilJax 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.

  • Page 92: Appendix: Error Codes

    ERROR CODES APPENDIX: 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. Check outrigger and level LED indicators and if required re-level machine This is a self clearing error.
  • Page 93 Error Message Error Explanation & What To Check & Displayed Possible Causes Corrective Action To Clear Error The Platform Control has detected a stuck or pressed Free stuck or pressed key on Platform Control key on power up. Replace Platform Control This is a latched error.
  • Page 94 Error Message Error Explanation & What To Check & Displayed Possible Causes Corrective Action To Clear Error The Lower Control has detected a rapidly changing Check Level Sensor output from the level sensor. Repair or replace Level Sensor wiring Replace Lower Control This is a self clearing error.
  • Page 95 Error Message Error Explanation & What To Check & Displayed Possible Causes Corrective Action To Clear Error The Lower Control has detected the machine has all Check outrigger and level LED indicators and if four outriggers on the ground but is not level. required re-level machine Check level sensor This is a self clearing error.
  • Page 96 Error Message Error Explanation & What To Check & Displayed Possible Causes Corrective Action To Clear Error The Load Sense Module has detected an overloaded Reduce weight in basket or on hook boom condition which caused the Lower Control to Correctly configure Lower Control disable all boom functions.
  • Page 97 Error Message Error Explanation & What To Check & Displayed Possible Causes Corrective Action To Clear Error The Lower Control has detected excessive current on Repair or replace Primary Down solenoid wiring the Primary Down solenoid output when it was Replace Primary Down solenoid energized during startup self diagnostics.
  • Page 98 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 Repair or replace Jib Down solenoid wiring Jib Down solenoid output when it was energized during Replace Jib Down solenoid startup self diagnostics.
  • Page 99 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 Repair or replace Platform Level Up solenoid Platform Level Up solenoid output when it was wiring energized during startup self diagnostics.
  • Page 100 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 Repair or replace Platform CCW solenoid wiring Platform CCW solenoid output when it was energized Replace Platform CCW solenoid during startup self diagnostics.
  • Page 101 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 Repair or replace Outrigger Retract solenoid Outrigger Retract solenoid output when it was wiring energized during startup self diagnostics.
  • Page 102 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 Repair or replace RF Outrigger solenoid wiring RF Outrigger solenoid output when it was energized Replace RF Outrigger solenoid during startup self diagnostics.
  • Page 103 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 Repair or replace Engine Throttle relay wiring Engine Throttle relay output when it was energized Replace Engine Throttle relay during startup self diagnostics.
  • Page 104 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 Repair or replace Engine Stop relay wiring Engine Stop relay output when it was energized during Replace Engine Stop relay startup self diagnostics.
  • Page 105 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 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...
  • Page 106 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 Repair or replace Drive PWM valve solenoid Drive PWM valve solenoid output when it was wiring energized during startup self diagnostics.
  • Page 107 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 Repair or replace Drive Engage solenoid wiring Drive Engage solenoid output when it was energized Replace Drive Engage solenoid during startup self diagnostics.
  • Page 108 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 Repair or replace Right Wheel Forward solenoid Right Wheel Forward solenoid output when it was wiring energized during startup self diagnostics.
  • Page 109 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 Repair or replace Drive Dump (C21) solenoid Drive Dump (C21) solenoid output when it was wiring energized during startup self diagnostics.
  • Page 110 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 Repair or replace Forward 1 (C24) solenoid wiring Forward 1 (C24) solenoid output when it was energized Replace Forward 1 (C24) solenoid during startup self diagnostics.
  • Page 111 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 Repair or replace Reverse 2 (C28) solenoid Reverse 2 (C28) solenoid output when it was energized wiring during startup self diagnostics.
  • Page 112 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 Repair or replace Torque H/L (C31) solenoid Torque H/L (C31) solenoid output when it was wiring energized during startup self diagnostics.
  • Page 113 Error Message Error Explanation & What To Check & Displayed Possible Causes Corrective Action To Clear Error The Lower Control has detected the boom has reached Reduce weight in basket or on hook or exceeded 95% of maximum outreach setting. Retract boom Raise boom NOTE: This error only occurs on machines equipped...
  • Page 114 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”...
  • Page 116 HAULOTTE GROUP | BILJAX 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 regulations Position the boom lift in work area Unhitch from the tow vehicle and disengage all boom travel latches...
  • Page 117 Distributed by: 125 Taylor Parkway Archbold, OH 43502 Phone (419) 445-8915 (800) 537-0540 (419) 445-0367...

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