Bil-Jax XLT 1001 DC lift platform Operation and Maintenance Manual
Below you will find brief information for lift platform XLT 1001. This manual will help you understand the operation and maintenance of the Bil-Jax Cougar Lift XLT 1001, a telescopic lift platform that can be used to raise personnel and tools to heights up to 10-10 inches. The platform is powered by a 12-volt battery and has a maximum load capacity of 400 pounds. The manual includes instructions on how to operate the lift, how to perform routine maintenance tasks, and how to troubleshoot common problems. The manual is intended for use by authorized personnel who have been trained in the safe operation of this equipment.
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Нах; pi une NET РО ААМ ИО pre > cree COUGAR LIFT ELECTRIC HYDRAULIC LIFT PLATFORM eration and Maintenance Manual For Model XLT-1001 DC Y AA TT | hea) ps — 125 Taylor Parkway * Archbold, OH 43502 B33-01-0013-01 Ph 800-537-0540 » Fax 419-445-0367 TELESCOPIC PERSONNEL LIFTS This equipment is designed and manufactured in compliance with the duties, re- sponsibilities, and standards set forth for manufacturers in ANSI A92.3-1980. This equipment will meet or exceed applicable OSHA codes and ANSI A92.3-1980 standards when used in accordance with section 13 of ANSI A92.3-1980 and all other manufacturer's recommendations. It is the responsibility of the user of this equipment to follow all applicable ANSI, OSHA, Federal, State and local codes and regulations which govern the safe opera- tion of this equipment. SERVICE CHECK LIST FOR XLT COUGAR LIFTS MODEL: SERIAL NO. DEALER ADDRESS: CUSTOMER ADDRESS: PHONE: PHONE: SUGGESTED SERVICE PERIOD" DATE Check chain assemblies for split leaves, loose pins, excessive wear, or elongation. D Check battery electrolyte level. (DC Only) D Check outrigger lock pins and cage D lock pins. Check and retighten all nuts and bolts. D Check to see that the cage entrance midrail D slides freely. Check to be sure guide blocks and their path of movement are clean and lightly D lubricated with a silicone lubricant. Check for wear on chain sheaves, including where it rotates around the sheave axle. W Lubricate chains with 4OW oil. W Adiust chains as described on page 14 of manual. W Check casters for wear on axies and swivel raceways also be sure that wheels are not WwW cracked or excessively worn. Check adjustment of normally open (N.O.) M valve, Lubricate caster swivels and axles. 6 Lubricate outrigger jack. 6 Check operation of manual emergency 6 lowering valve. Check to see that all decals are present and legible (see pages 18-19) and maintenance 6 manual 1s on machine. Replace hydraulic oll. 12 Check mast sway. 12 Load test with 300% or 400€. 12 Check for wear on outrigger jack threaded 12 rod. Replace all chains. 48 Page 3 of 52 This page intentionally left blank. Page 4 of 52 TABLE OF CONTENTS Specifications and Warranty .....................e..... 2er ie EEE 7 Operation Instructions..............=..=..e.e..eeíeerren eee ene De 8 Description of Operation ...............e.eeerrrerrerererrerre e er er ee 9 General Safety INStructions .....................-—.erereerieeeren nee e A 10-13 Maintenance: Inspection ....................00000meen nee RR 14-15 Lubrication ................. e. reee ree e ea EEE 15 Hydraulics ...............e.ereeenerrer rene e 15-16 Electrical.................e.eercoccreceeo en De DD II RR O IDA 16-17 Annual Maintenance ….…….……rereneenenenenntnmnnnnsnnnnnnnnnnnnnn 17 Replacement Decals ….....…..rcrrrerrerrcrcraserreerassesanea sacs amas a TERR IAE 18-19 General Assembly Photograph and Parts List ...................eeeeeeveceoo 20-21 Short Outrigger Assembly .....................erieciiere ene E RE EEGGG 23 Hydraulic System Schematic and Parts List …........……erressenmencerianess 24 Hydraulic Cylinder Assembly and Parts L]Ast …....…...errerrensenserenrers 25 Hydraulic Unit Parts Breakdown and Parts List.................e......... 26-27 Electrical System.............. simi re reee rceneeeceereee. 28 DC-Wiring Diagram for Junction BOX ................merveserrieerieneceren ene 29 DC Wiring Diagram and Parts List.….….…...….…....nnennsmennnn 30-31 Control Assembly ................e....1ese0cereerricerieeee ccoo eee reee Dee s 32 Outrigger Indicator Box WIiring...............-e==...ereerereerereec eee IIA 33 Damaged Equipment Policy ............... 2.2... A 34 ANSI A92.3 Reprint Section 5 - Responsibilities of Dealers............... e... 35-36 Section 6 - Responsibilities of Owners ........................e. 36-37 Section 7 - Responsibilities of Users... 37-40 Section 8 - Responsibilities of Operators 40-42 Section 9 - Responsibilities of Lessors...............—....e..... 42-43 Section 10 - Responsibilities of Lessees ..................eerieereceees 43 Electrical Safe Approach Distance ...............e..e0-. e... 44 Material Safety Data Sheets ….….…..…..…rrenenenenmsnnennnnnnnnnnnn 45-52 Page 5 of 52 This page intentionally left blank. Page 6 of 52 COUGAR LIFT ELECTRIC HYDRAULIC LIFT PLATFORM Model No. XLT-1001-(DC) (AC) Serial No, Manufactured By: Mailing Address: Bil-Jax, Inc. Bil-Jax, Inc. 125 Taylor Parkway 125 Taylor Parkway Archbold, OH 43502 U.S.A. Archbold, OH 43502 U.S.A. Phone (419) 445-8915 SPECIFICATIONS: Rated Platform Load: 400# Total Including Operator (1 Person + Tools Not To Exceed 400 lbs.) 181 kg Total Including Operator (1 Person + Tools Not To Exceed 181 kg) Extended Platform Height: 10-10" (3.3m) Retracted Platform Height: 1-3" (4 m) Platform Dimensions: 26" x 38" (.66x .97 m) Extended Outrigger Base Area: 3-7" x 4-0° (1 Imx 1.2 m) Ready Retracted Dimensions: 2'-6"w x 4-8"] x 6-7"h (76 x 1.42 x 2m ) Folded Shipping Dimensions: 2"-6"w x 4-8"1 x 6-7"h (76 x 1.42 x 2 m) Gross Shipping Weight: 555# (252 kg) Full Extension Time: 8 Seconds Empty, 13 Seconds Loaded Complete Retraction Time: 16 Seconds Platform Extension Rate: 1.25 feet (.38 m)/Sec. Empty, .77 feet (.23 m)/Sec. Loaded . Hydraulic System Pressure: 1000 PSI Empty, 2400 PSI Loaded Power Source: DC - 12 Volt Deep Cycle Battery AC - 110 Volt Motor on Pump. NOTE: AC UNITS ARE TO BE OPERATED WITH NO MORE THAN OR NO LIGHTER THAN 100' OF 14-3 WIRE. WARRANTY: Bil-Jax, Inc. warrants its telescopic stockpicker lifts for one year from the date of delivery against all defects of material and workmanship, provided the unit is operated and maintained in compliance with Bil-Jax's operating and maintenance instructions. Bil-Jax will, at its option, repair and replace any unit or components part which fails to function properly in normal use. This warranty does not apply if the lift and/or its component parts have been altered, changed or repaired without the consent of Bil-Jax or by anyone other than Bil-Jax or its factory trained personnel, nor if the lift and/or its components have been subjected to misuse, negligence, accident or any conditions deemed other than those considered as occurring during normal use. Components not manufactured by Bil-Jax are covered by their respective manufacturers warranties. A list of those components and their warranteis is available upon written request to Bil-Jax, Inc, Bil-Jax, Inc. shall not, in any event, be liable for the cost of any special, indirect or consequential damages to anyone, product or thing. This warranty is in lieu of ali other warranties expressed or implied. We neither assume nor authorize any representative or other person to assume for us any other liability in connection with the sale, rental or use of this product. Page 7 of 52 1) 2) 3) 4) 5) 6) 7) $) 7) OPERATION INSTRUCTIONS FOR GROUND ENTRY MODEL XLT-1001 Read and follow safety precautions and all responsibilities sections as set forth in the operators manual. Position the lift at the work area. Make sure the lift is on a firm and level surface and that there are no potential hazards such as overhead obstructions or electrically charged conductors. DO NOT use the lift where such hazards exist. Check the machine for damage or worn parts and plug the control box into the lower receptacle. Check to be sure that the cage is properly attached to the lift. (There should be (2) u-bolts holding the midrail to the mast and two (2) hex bolts through the floor of the platform and fastened to the mast.) Then swing out or extend and stabilize all outriggers making sure that they lock into position and that the lift is level. (When the outriggers are properly positioned, the 2 outrigger indicator lamps located in the outrigger indicator box mounted on the base of the lift will light.) Raise the empty platform to the height at which you intend to work. Check again to be sure that the platform's path of travel is free from obstructions and reposition the lift as necessary. Remove the control cord assembly from the base receptacle and plug it into the platform receptacle. Again check to see that all outriggers are properly set (step 5). Enter the cage and make sure the cage entrance midrail drops into its proper position. The lift will not raise unless the green lamps are lit indicating that the outriggers are properly set. The machine is now ready for operation. Depress the "on" push button and while holding it down, turn the selector switch to the desired function, "up" or "down". The platform will raise or lower respectively. The emergency stop deactivates the control circuit only. NERO Should the platform continue to raise after the "up" switch is released, push the "on" switch, select "down" and the platform should stop or lower. Page 8 of 52 DESCRIPTION OF OPERATION The Mode! No. XLT-1001 Cougar Lift is designed and manufactured for use as an elevating work platform to raise personnel, along with their tools and necessary materials to job sites situated directly above the platform area. The maximum platform load is limited to 400# or | person + tools (not to exceed 400#). The electric pump motor is powered by a 95 amp hour, 12 volt, wet cell battery. A 15 amp automatic battery charger is included for recharging the battery at the end of each day. Elevating the platform is performed by means of a 1-1/2" diameter displacement type hydraulic cylinder operated at the touch of a button. The lower telescoping section is pushed vertically upwards by the cylinder while the upper sections are raised by mechanical motion advantage accomplished through four sets of chains and sheaves. Consequently, the platform is raised two inches for each one inch of cylinder extension, Platform descent is also commanded by means of a push button. Safe use of this equipment is assured by proper operation, inspection, and maintenance procedures as set forth in this Manual. Dependability is also ensured by proper maintenance and replacement of the chains, sheaves, and sheave pins and the properly installed flow restrictor valve. (See the Maintenance sections of this Manual.) This non-adjustable flow restrictor valve controls and fixes the rate of platform descent whether empty or fully loaded to approximately .9 feet per second. A hydraulic hose failure will result in the same rate of descent and not in free fall when the restrictor valve is installed properly. Precautions should also be taken to ensure that the paths along which the slide blocks move are kept clean and lightly lubricated with a dry type silicone lubricant. Emergency lowering of the platform is accomplished by means of a manual control valve located on the side of the electric pump unit. To lower the platform, pull the lever forward or towards the side of the machine until the platform begins to descend. Read carefully the following General Safety Instructions before using the Cougar Lift. Page 9 of 52 VERTICAL TELESCOPIC LIFT SAFETY INSTRUCTIONS INTRODUCTION The operation of any work platform is subject to certain hazards which cannot be protected against by mechanical means, but only by the diligent exercise of intelligence and common sense. Safety for yourself and your fellow workers is YOUR RESPONSIBILITY, since any piece of equipment is only as safe as the PERSON USING IT makes it. You are the only part of the machine which can think. Be a PROFESSIONAL and follow these safety rules exactly. BEFORE USE Survey the jobsite for potential hazards such as untampered earth fills, unlevel surfaces, overhead obstructions, and electrically charged conductors or wires. Be aware of any potential hazards and always consider what could happen. Watch for moving vehicles in the area of use. Read and understand the manufacturer's operating manual. Make sure you have a complete understanding of all operating and safety instructions provided. Only trained and authorized personnel shall be allowed to operate this equipment. Inspect the equipment for damaged or worn parts. Also check for cracked welds, hydraulic leaks, damaged wiring, loose wire connectors, or damaged casters and outriggers. Also check for any improper operation. DO NOT use if damaged in any way. Improperly operating equipment must be repaired before using. DO NOT operate this equipment if you are under the influence of alcohol or drugs or if you feel ill, dizzy, or unsteady in any way. Operators must be physically fit, thoroughly trained, and not easily excitable. Wear proper clothing for the job. Wear personnel protective equipment as required by federal, state, or local regulations. Locate, read, and follow all directions and warnings displayed on the equipment. Inspect the equipment for any "DO NOT USE" tags placed on the equipment by maintenance personnel. DO NOT use any equipment tagged in this way until repairs are made and all tags removed by authorized maintenance personnel. Make sure the platform and your shoes are free of mud, grease, or other foreign material. This will reduce the possibility of slipping. DO NOT modify, alter, or change the equipment in any way that would affect its original design or operation in any way. DO NOT use this equipment in ways for which it is not intended. Page 10 of 52 DURING USE ! DANGER ! This machine is not insulated for use near electrical power lines and DOES NOT provide protection from contact with or close proximity to any electrically charged conductor. User must maintain safe clearances at all times (minimum of 10 feet) and always allow for platform movement such as wind induced sway. Always contact the power company before performing work near power lines. Assume every line is hot. Remember, power lines can be blown by the wind! YOLTAGE RANGE MINIMUM SAFE APPROACH DISTANCE (Phase to Phase) (Feet) (Meters) 0 to 300V AVOID CONTACT Over 300V to SOKY 10 3.05 Over SOKV to 200KV 15 4.60 Over 200KY to 350K Y 20 6.10 Over 350KV to 500KV 25 7.62 Over 500KV to 750K Y 35 10.67 Over 750KV to 1000KV 45 13.72 Position lift farenough away from power sources to ensure that no part of the lift can accidently reach into an unsafe area. DO NOT use without all outriggers fully extended, locked, and stabilized. DO NOT override or by-pass manufacturer's safety devices. Operate only on a firm and level surface, DO NOT use on surfaces which will not support the weight of the equipment or the force exerted on the outriggers during use of the lift. DO NOT use without entry chain/bar in place. DO NOT release outriggers or move unit with a person or materials on board. DO NOT stand or sit on guard rails. Work only within the platform guard rail area and do not lean out over guard rails to perform work. DO NOT attempt to increase working height with boxes, ladders, or other means. DO NOT use this equipment when exposed to high winds, thunderstorms, ice, or any other weather condition that would compromise the safety of the operator. DO NOT climb up or down masts. DO NOT allow ropes, electric cords, hoses, etc. to become entangled in the equipment when the platform is being raised or lowered. DO NOT use the work platform as a "dead man" in performing work operations which produce excessive horizontal force. Keep yourself and all personnel away from potential pinch or shear points. Page 11 of 52 Horseplay is prohibited—Report any misuse of equipment to the proper authorities. Always maintain good footing on the platform—do not wear slippery soled shoes. DO NOT exceed manufacturer's platform load limits and make sure all tools and equipment are evenly distributed over the entire platform. Always make certain all personnel are clear and there are no obstructions before repositioning platform. If welding is performed by a worker from the platform, do not allow electrode contact with any part of the platform. DO NOT exceed platform load ratings by transferring loads to platform at elevated heights. Cordon off area around the base to keep personnel and other equipment away from it while in use. DO NOT use guard rails to carry materials and do not allow overhang of materials when elevating platform. Stay clear of wires, cables, and other overhead obstructions. Always disconnect power at Master Power Switch and remove key (CAT) or disconnect power at knife switch and lock cover (Cougar) when not in use to guard against unauthorized use. MAINTENANCE SAFETY Maintenance shall be performed according to manufacturers requirements—Do Not short change maintenance. DO NOT add incorrect fluids to the hydraulic system or battery. Check manufacturers specifications. Pressurized hydraulic oil can cause injury. Check to make sure all lines, connectors, and fittings are tight and in good condition. Do not exceed the manufacturer's recommended relief valve settings. DO NOT attempt repairs you do not understand—consult manufacturer if you have any questions regarding proper maintenance, specifications, or repair. Keep all mechanisms properly adjusted and lubricated according to maintenance schedule and manufacturers specifications. Always perform a function check of operating controls before each use and after repairs have been made. Page 12 of 52 + Locate and protect against possible pinch points prior to performing maintenance and repairs. * Use only factory approved parts to reapir or maintain this equipment. If this equipment is rebuild, retesting is required in accordance with factory instructions. BATTERY MAINTENANCE - (Only on battery powered machines) * Check battery acid level daily —check battery test indicator for proper state of charge on maintenance free batteries before using lift. * Always wear safety glasses when working near battery. DO NOT smoke when servicing battery. + Contact with battery acid causes serious burns. Avoid contact with skin oreyes. If accidental contact occurs, flush with water and consult a physician immediately. * Hydrogen and oxygen gases are produced during normal battery operation. This gas mixture can explode. DO NOT allow flames or sparks near batteries. * DO NOT allow batteries to overcharge and boil. * DO NOT short across battery posts to check for current. DO NOT break a live circuit at battery. * DO NOT charge batteries except in open, well ventilated areas. * When removing battery, always disconnect ground cable first. * When installing battery always connect ground cable last. * DO NOT jump start other vehicles using lift battery. Note: All OSHA, ANSI, state and local codes and regulations pertaining to this equipment should be obtained, read, and thoroughly understood before attempting to use this equipment. Persons under the influence of drugs, alcohol, or prescription medication should not be on or near this equipment. Common sense should be implemented at all times during the usc of this equipment. DO NOT USE THIS EQUIPMENT IN AREAS WHERE EQUIPMENT OR USER MAY COME IN CONTACT WITH LIVE POWER SOURCE. THE INFORMATION CONTAINED HEREIN IS NOT TO BE CONSIDERED AS LEGAL ADVICE AND IS IN- TENDED FOR INFORMATIONAL PURPOSES ONLY. This information is offered so as to alert customers of Workforce Products, Inc. to procedures that may be of concern to them, This information is not intended to be all inclusive and is to be followed in the use of Workforce equipment only, For any questions concerning the safe use of this equipment, call 419/445-9675 before using. Page 13 of 52 MAINTENANCE INSPECTION: It is extremely important that a complete inspection is made each day to insure the operator's safety. 1. Inspect daily, tightening if loose, and replacing if worn or damaged, all fasteners, pins, etc. including but not limited to the following: a) Chains and locknuts per 42 below. b) Cylinder mounting bolts and locknuts. ¢) Chain sheaves, sheave pin and cotter key. d) Platform fastening bolts and locknuts. e) Plastic slide blocks and mounting screws. f) Outrigger and cage lock pins (Replace bent pins—Do Not attempt to straighten.) 2. Inspect all chains for damage daily. Look for signs of wear, split leaves, loose pins, clevis damage, elongation, etc. Replace any chain which is damaged in any way or which has elongated more than 3%. The chain assemblies may be ordered from your dealer or the factory direct. Do not use a unit on which any chain assembly is in need of replacement. We recommend that chains be replaced every four years unless damage or wear requires replacement at a lesser interval. ELONGATION INSPECTION FOR AL-544 LEAF CHAIN бр Er lm ey той EFF A EE FL ESS | PITCHES = 12,5" IF MEASURES t2.75" TO 12,875“ REPLACEI Adjust the lift chains weekly as follows: Extend all outriggers and base all four leveling screws. Raise the platform to the maximum extended height and then lower it while someone checks to see that all sheaves are turning and checks for chain damage or wear as described above, After completely lowering the platform, remove the large mast cover. Adjust the chains until they are just snug against the retainer. Do not over tighten the chains so as to raise the platform from its resting position. Make sure that the hex locknuts are turned onto the threaded clevis ends with at least 1/8" of the end extending through the nut. Replace any locknut which does not stay in position during use. Replace mast cover. 3. Inspect all mast sections daily to make sure that they are free of dirt or other foreign material which would in any way restrict the free movement of the glide blocks. 4. Be sure that all decals are completely readable and the maintenance/operation manual is attached to the lift. Page 14 of 52 MAINTENANCE (cont.) 5. Annually check for wear on slide blocks and replace or retighten as necessary. The blocks should be adjusted so that air gap between the guide blocks and the mast is removed. This is accomplished by first backing out the slotted hex head screws and using an allen wrench turn the set screws in (clockwise). This will push the block in against the next mast. [DO NOT OVER TIGHTEN. | After adjustments are made, extend the outriggers and fully extend the lift from the ground, without load in the platform. If the platform: a) lowers without stopping and (b) within the time period shown on Page 7 of this Manual and (c) air gap between the guide blocks and the mast is removed, then the blocks are properly adjusted. NOTE: If at any time there appears to be excessive mast sway, it may indicate that the blocks may need to be adjusted as described above. 6. Check for wear on the outrigger jack screw and nut. If the vertical movement between the jack threads and the nut threads is .025" or greater, replace both the jack and the nut. 7. Check casters to see that there is not excessive wear on the axle, axle bearings or swivel raceways and that the wheels are not cracked or excessively worn. LUBRICATION: Minor Lubrication will make the operation of the Cougar Lift more efficient and extend its useful life. 1. Oil all chains by brush or other effective means with 40W oil weekly. 2. Grease caster axles and swivel raceways semi-annually. 3. Lightly oil or apply a thin coat of grease to the outrigger screw jacks each week. IMPORTANT: The plastic slide blocks in the mast are made of a bearing material which has a high degree of lubricity and need only be kept clean. However, precautions should also be taken to be sure that the paths along which the blocks move are kept clean and lightly lubricated with a dry type silicon lubricant. HYDRAULICS: It is important to maintain the hydraulic system as necessitated by amount of use and the environment in which the lift is used. Constant attention to keeping the oil clean will help prevent possible damage to the system. 1. Check the hose assembly and fittings for leakage or damage each day. Tighten or replace when necessary to prevent hydraulic oil loss. 2. The reservoir should be filled to within 1/2" of the top with the platform in its lowest position. Use Dextron Automatic Transmission Fluid Type A for temperatures as low as -40°F. If not available, a good grade SAE 10W Hydraulic Oil may be used where the minimum climatic temperature is above 32°F. SAE SW Hydraulic Oil may be used where temperatures are as low as O”, Do not mix different hydraulic oils. Page 15 of 52 MAINTENANCE (cont.) . Delayed response or sporadic action may indicate a presence of air in the cylinder. To bleed air from the system, base all four levelers. Remove the reservoir breather cap, and with the reservoir full of fluid, fully extend the unit. Lower the unit to allow the oil with entrapped air to return to the reservoir being careful as to not overflow it. Let the unit set while the air escapes the fluid and then repeat if necessary. Each time the platform is lowered, refill the reservoir to prevent pump- ing more air into the cylinder. . Clean the reservoir sump strainer and replace the hydraulic oil at least once a year or whenever it should become contaminated. . If the platform will not stay up, it may be necessary to clean the power unit ball check valve or solenoid valve. This can be done by simply holding down both the "up" and the "down" switch simultaneously for approximately 10-15 seconds. It may be necessary to repeat this procedure several times. If this does not remedy the situation, contact your Distributor or Workforce Prod- ucts for additional information. . To reset the pressure relief valve, install a 3,000 PSI gage into the 3/8" NPT pressure port on the pump (use port furthest from emergency down valve). Remove the hex cover from the relief valve screw and adjust the screw until the maximum pressure obtained is 2,400 PSI when the cylinder tops out. If no gage is available, place 400 on the platform and adjust the screw so that the load can just be lifted without bypassing oil. CAUTION: Do not adjust the pressure relief valve higher than 2,400 PSI since possible over- loading could occur. . Should it ever be necessary to remove the flow restrictor valve, it is of utmost importance that it be properly reinstalled. The valve will be marked in one of two ways: either with an arrow or with the word IN. The end of the valve marked IN must be towards the cylinder port, or on the valve with an arrow the arrow must point away from the cylinder port, Only a 1/4" NPT hydraulic elbow should be connected between the cylinder port and the end of the flow regulator, Improper installation will permit widely varying rates of descent and would result in near free fall in case of a hose failure. ELECTRICAL: The electrical system is relatively simple, but regular maintenance is neces- sary to keep it working properly. 1. Check all electrical wires for cuts, broken wires, potential short circuits, etc., each day. 2. Charge the batteries daily or after each period of usage. Time for a complete charge on a totally discharged battery is 8-12 hours. The charger will shut off automatically when the batteries have reached full charge. Page 16 of 52 MAINTENANCE (cont.) CAUTION: Before making or breaking connections between charger and battery, always remove the power cord from the 110 volt AC outlet. Always check the battery electrolyte level and add water after charging the battery. For more information, refer to the instructions supplied with the battery charger. 3. Clean battery terminals monthly. Remove the cables from the battery, clean the battery posts and cable ends to shiny metal, and replace. Always connect the insulated cable from the starter sole- noid to the positive post. Lube the outside of the connections with petroleum jelly or grease. 4. Procedure for checking adjustment of N.O. valve; A.) Disconnect the jumper wire running from the start solenoid to the N.O. valve. B.) Once the jumper wire 1s disconnected, activate the "up” function, causing the motor to run, NOTE: The platform should not raise, but if the platform begins to raise, the N.O. valve must be cleaned or 15} 132 8 PORT 3/8" NPTE PRESSURE RETURN 35 33 Fo = = = = = “= = < m replaced. N B02-15-0113 . . (9— \ C.) Re-connect the jumper wire upon determining that the N.O RELIED valve is operating properly. - N ANNUAL MAINTENANCE À thorough inspection must be made at least once each year or after approximately each 500 hours of operation. Complete checks should be made of all items listed in the Maintenance Section of this Manual, and necessary adjustments and repairs should be made. In addition to this annual inspection and service, we recommend that all lift chains be replaced every four years. Page 17 of 52 REPLACEMENT DECALS - ORDER AS NEEDED : Moving telescopde masts will create 4°} pinch points. Keep fingers, hands, YT | ams andfeet clear of ali telescopic mast sections at all times. 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"Eat Esad ted y RATA EXA Ap dad - Paga dagatactitiza dr a Эх wt igen Era sta ls ad ut ce ER " DONNA art A tea a Sacha na E Er ar Fa ENS CES ropes, crete El В ETRE, after crat:da] ATA UA ph $ ap ESE EII TA Foros nf mh] HE PESE pie BIL-JAX === ARE, ESTOS B06-00-0104 LIT. 4 ao wu ZH тн Mage, Pau et LAA FESTA B06-00-0 3 5 : AWARD : т, er IR a SERALNO 1001-0105 MAX PLATFORMAT 10FF. 10H E Lore Ne FARLRE TO cou LY WITH TEL ECC LOG MANTENANCE RECGUTREMENTS POWER SOURCE 18 COCLLD RESULT El SERES WILEY CR DEATH + Feli completa mahtanante screfd2 attired n es E MovAC УЗ бои В AE ar Ca ss ee adan a sees, {astenets hrs, re 028333 parts daly OTHER IT IS UNLAWFUL TO OPERATE ser a ion Rare cone x THIS EQUIPMENT WITHIN 10 Core cern sts Uca BIL-jAX + Ea blce k Aris must ba +20 cas — ex Y 44 ents, md other 175 TAYLOR PARIONAY FEET OF HIGH VOLTAGE LINES gn mata | о ARCHBOLD. OH 43602 U SA OF 50,000 VOLTS OR LESS. DES Pr DE МЫ аське у ао pay PATENT #4 494 663 Forse claarared fingida dices of SG ADO 15 15, 166 Cuférs ал SEE RAL MLE LEE Fi Mach E Hot иене Do nctusewnthis 10fE of power hess BO6- 00- 0 | 38 B06 00 0233 of Cher eects 2ty charged sarees This maschine DO EST prova - - role tion for personne fron contact wat or chose procimuty to ang he decid pont source and should he copudersd en&qzed ty #l Farscnned comand in cent act seth machine FEF tax ne 5005 INCE a B06-00-0146 о SHE OPERATION INSTRUCTIONS RA CNW NBN e FOR GROUND ENTRY MODELS à Bana ratio ua won acer on nus ео оны влага Ada ra aa tectalhazerdseuch 7 all decals on this machine as well as the complete owner's manual, E 1 15 OvésFoad electrical DO NOT vse the UN whare Such nazerds ен i + Ba sure cage 15 securely fastened lo lift by means of 2 U-boits at costae china For mage of wor pars snd eps of epace 1s rece ssary. Rost lug a control hos to e Ir midrait and 2 hex bolts through the floor of Iha platform. 4} Check to be suo That tha cage [à property stachad fo the ER. {Thesg should be ta (2} ros hiking the mick a 10 the 3 mas ari чо Пя Bon eu e ce of 4 Ter and tnd to e ma 8} + Extend, lock and stabilize outriggers béforé using. Maké sure lit is 5) Then swing cut oe axterd and stabilize 8% oulriggers mabing sure that they lock into positide snd that the iF ix level {when level. thé guar 5 Me iones he d eutrigger háxater la # located nthe oud 1 Inehieator ton mounted on tha sar of the En ars propery pos e viana * Keep hands and feet Inside the cage and clear of telescoping 6} Rlalsa the empty platform to the height et which jou [rend to work. Check again to be sure that tha platon petit of travel sections during operation. 4 rea fro tha 14 33 necessary. DO HOT v4 1d UT Es not operating pr "| Remove tha control card artembiy from the bass recaptecie and plug it into th platform recaptacia * Do notlean outover quardralis or attemplto perforr work outside S Again check to чей На одни же property set [ep 5) Enter Ma cage and mate sure tu cage emrance midras tha guard rail area. op Frodo de proper position The BE will not tales (ode 4 Hh green Lamp arg El cicaling that he autriggers aa property * Malntaln a 107 minimursa distance from energized power Hines. Y he Machina 15 nea ready for eper For Depress the “on” push bustos and while holding & dow, fur th saléctos vaitci ls FET Bla e 204 E ACES thé desired function, “up” or -doen”. The placer vell resa or lower respectively. The amargency stop desctivales iho \. = — — у control cirouit aly. ee platform coming to false after the MP" FATECH Le reed sed, polí th “on” gwitch, = $efect “down pnd the platen should sop of ower EP fe Pah E B06-00-0 | 83 B06-00-0174 OPERATING INSTRUCTIONS uy IANA RA 1) Connect input plug to receptacia with same number and size as ouvager minita ty nsnded 6 OPERATION AND SERVICE ® pins as plug controls wiloparate. When eachoutrigger is MANUAL INSIDE к 2) Charger turns on after à short delay fait electrical cireuts pape. correspanding Maicator COFG 5 Betas, Inc 2004 80-00-0192 and battery vosge testgood Mandor intal charge rate for B06-00-0 i 3 7 Preper torna on Far gear dschamed battery, depress start 1 e e i B06-00-0 i 92 swith und! chamer continues operaton aer release я ru 2) Intial charge rate wil vary from 8 to 12 amps depending on #7 Еее battery dischargé and condon #} Charge raté tapers te 1 to 4 amps for the last fes hours of charge d alt cetis tést good Charger tums off as battery reaches maximum charge 5) After chamer ums 0% dsconrect input plug from recep i tacle В = Keep Fl ventiaton openings free from obstructions For best battery fife, follow dejaded instructons in cmiers manual 1 » Level machine before use. M + Failure to level this machine could "= tran om e I. result in serious injury or death! BO6- 00- 0267 06-00-0775 | О о | LFC 06-00-0186 Page 18 of 52 XLT-1001 DECAL PLACEMENT Instruction 0009 > Panel em NN 0135 7 =) oy ie 1 —otos otis / Nerf] IE —— 0009 0146 m Sn À N 0135 0138 = CT \ | \ ES \ 0146 0175 / / 0192 = т 0175 {on manual | Al tube) E \ 0138 0174 E de Y Ш \ 0174 воза — io —malo=———— 0034 teeboard) 0279 (on black — ho A = —— 0006 DECAL NO. DESCRIPTION OF DECAL NO. DECALS/PIECE B06-00-0002 MAXIMUM CAPACITY. . 400 LBS. OR | OCCUPANT 3 B06-00-0003 WORKFORCE, INC. NO. XXXX (WORKFORCE SERIAL NO. DECAL) 2 B06-00-0005 PULL TO LOWER i B06-00-0006 EMERGENCY CONTROL VALVE I BO6-00-0009 WARNING .. . MOVING TELESCOPIC MASTS WILL CREATE... 2 B06-00-0034 DANGER. . DURING CHARGING, OXYHYDROGEN GAS. .. 1 B06-00-0104 XLT-1001 (TRANSFER TYPE DECAL) 1 B06-00-0135 DANGER... MAIN WARNING DECAL FOR COUGARS & CATS i B06-00-0137 WORKFORCE (VERTICAL TRANSFER TYPE DECAL) i B06-00-0138 WARNING... (MAINENTANCE DECAL FOR COUGARS £ CATS) i B06-00-0139 DANGER . .. BEFORE USING: EXTEND, LOCK & STABILIZE... 2 B06-00-0146 DANGER . .. (ELECTRICITY WARNING FOR ALL LIFTS) 1 B06-00-0174 WARNING. . OPERATION INSTRUCTIONS-GROUND ENTRY 2 B06-00-0175 CAUTION . .. THIS MACHINE DESIGNED... 92.3 1 B06-00-0183 WARNING .. . (WARNING DECAL FOR GROUND ENTRY - IN CAGE) 1 B06-00-0189 WARNING... LEVEL MACHINE BEFORE USE... l B06-00-0192 OPERATION & SERVICE MANUAL 1 B06-00-0233 SERIAL NUMBER TAG - XLT-1001 1 B06-00-0267 OPERATING INSTRUCTIONS - CHARGER ] B06-00-0279 1 WARNING. . .ALL OUTRIGGERS MUST BE FULLY EXTENDED Page 19 of 52 GENERAL ASSEMBLY XLT-1001 ITEM # PART # DESCRIPTION QTY. 1 B11-01-0040 Base Weldment 1 la B44-00-0008 Plywood for Pump Deck } Ib B44-00-0009 Plywood for Baitery & Charger ] lc B31-00-0001 Plastic Slide Block 2 ld B04-07-0026 #10 x 1" Screw 2 le B30-00-0013 Rubber Bumpers 4 2 B18-00-0007 Equipment Housing Cover 1 2a B 18-00-0032 Equipment Housing Door 1 2b B37-00-0001 Camlock & Keys 2 3 B18-00-0088 Mast Cover 1 3a B04-04-0005 #10-24 x 1/2" screw 8 4 B16-01-0031 First Mast Section 1 4a B26-00-0002 Sheave 2 4b B36-01-0002 Sheave Axle 2 4с B31-00-0001 Plastic Slide Block 2 4d B04-07-0026 #10 x 1" Screw 2 de B04-07-0011 Cotter Pin 2 5 B17-00-0061 Platform Brace 1 За В 16-91-0016 Platform Mast Sectiion 1 Sb B31-00-0001 Plastic Slide Block 4 Sc B04-07-0026 #10 X 1" Screw 8 5d 3/8"-16 x 1" Hex Bolt w/Lockwasher & Nut 2 6 B03-00-0009 Chain Assembly 2 6a 3/8"-16 Locknut 2 7 B17-00-0062 Platform 1 7a B44-00-0019 Plywood J 7b 3/8"-16 x 1-1/2" Carriage Bolt w/lL.ockwasher & Nut 4 8 B17-00-0063 Cage 1 ба 3/8"-16 X 1-3/4" Hex Bolt w/l.ocknut 6 9 B29-00-0087 Electrical Outreach Bracket 1 Oa 1/4"-20 x 3/4" Hex Bolt w/Lockwasher & Nut 2 10 B03-00-0074 Outrigger Right 1 10a B03-00-0075 Outrigger Left 1 10b 1/2"-13 x 5" Grade 5 Hex Bolt w/Locknut 2 11 B03-00-0004 Outrigger Pin Assembly 2 12 B08-01-0002 8" Swivel Caster 2 12a B08-01-0001 8" Locking Swivel Caster 2 12b 3/8"-16 x 1" Hex Bolt w/Lockwasher & Nut 16 13 B04-07-0027 1/2"-20 x 1/2" Set Screw 10 i4 See Hydraulic System (Pages 22-25) 15 See Electrical System (Pages 26-31) Page 20 of 52 GENERAL ASSEMBLY 1001 PHOTO i qi te о о ol E Sn $ é E E 0 HE SR Ee ETE Page 21 of 52 This page intentionally left blank. Page 22 of 52 SHORT OUTRIGGER ASSEMBLY ITEM # PART # DESCRIPTION OTY, B04-04-2111 6-32 Machine Screw 4 B23-01-0053 Right Outrigger Weldment B23-01-0054 Left Outrigger Weldment 1 2 2 3 B01-03-0013 Limit Switch 2 4 B04-04-2611 6-32 Lock Nut 4 5 B04-05-3509 3/8" - 16 Hex Bolt Î 6 B46-00-0010 Plastic Knob i 7 B04-02-3002 3/8" Lock Nut i 8 B46-00-0009 Outrigger Handle i 9 Wire | 10 B04-04-0005 Self Thread Screw | il B23-02-0014 Outrigger Screw 1 12 B04-06-0007 Bronze Washer 1 13 B23-02-0011 Rubber Floor Pad 1 14 B04-06-0017 3/8" Flat Washer 1 15 B18-00-0081 Left Switch Cover 15 B18-00-0082 Right Switch Cover 16 B04-05-3511 3/8" - 16 Hex Bolt Î Page 23 of 52 ITEM # 1 S1-SOLENGID Se -SOLENOID TT TTR TS mT Te mm Mm mr ren mn жит но ные —— =] —s TEESE TEES PD PU "РН —] — _ —] — —— —]o— de ai ad A PEE PEU DDD UD ну — — — — PART # B02-05-0002 B02-02-0040 B02-01-0001 B02-02-0042 B02-04-0001 B02-02-0041 B02-03-0001 мн ны не — оне Ок kl Sl aH — _—— WE — | HYDRAULIC SYSTEM VALVE (RAISING) 4 VALVE (LOWERING) — — —u — — 3 PRESET RELIEF MOTOR, PUMP, VALVE HYDRAULIC UNIT DESCRIPTION Motor-Pump Hydraulic Unit (Breakdown pages 29 & 30) 3/8"-16 x 3/4" Hex Bolt w/ Flat Washer & Lockwasher 3/8" NPT to 1/4" NPTS Street Elbow 1/4" Flared End Hose Assembly x 15" 1/4" NPT to 1/4" NPTS Street Elbow *Flow Regulator 1/4" NPT Double Male Elbow 1" Diameter Displacement Cylinder 3/8"-16 x 1" Hex Bolt, Lockwasher, & Hex Nut 1/2" x 1-5/16" Flat Head Rivet 5/16" x 1-3/4" x 2-1/4" U-Bolt, Lockwasher & Nuts 1/8" x 1" Cotter Pin * Flow Regulator must be installed with end marked IN towards cylinder port, or on the valve with an arrow, the arrow must point away from the cylinder port with only a 1/4" NPT Hydraulic 90° elbow between the cylinder and the restrictor valve. Page 24 of 52 Cylinder Jacket Washer Rod Packing Gland Nut Rod Wiper Piston Rod Wear Ring B02-13-0002 Seal Repair Kit REPAIRING HYDRAULIC CYLINDER Be sure cylinder is completely retracted and pressure is released from the system. Disconnect hose line, drain oil, and remove cylinder from the unit. Remove gland nut, washer, and rod packing from the tube cylinder jacket. Clean internal tube and inspect piston rod for gouges, scraiches, or wear, and replace if necessary. Place piston rod back into cylinder Jacket and insert washer. Grease the rod packing on the inside and outside diameters. Reinstall one ring at a time making sure each ring lies flat on the ring prior to it, Replace the gland nut complete with a new rod wiper if worn. Thread it down until it makes contact with the rings. Reinstall the cylinder into the unit and reconnect the hose line. Stoke the cylinder to allow rod packing rings to seat and align, then tighten gland nut an additional 1-1/2 to 2 turns making sure that the air has been bled from the cylinder. The distance between the top of the threaded collar and the bottom of the large section on the gland nut should be 5/16" to 1/4’. DO NOT OVER TIGHTEN GLAND NUT. Page 25 of 52 HYDRAULIC UNIT PARTS BREAKDOWN n- #10-32 SWITCH #10-32 SWITCH 3/8 M.P.Y, FILLE COM, {RAISE} CONN. (LOWER) 7 BAEATHEA POAT 5/16-24 12v D.C. POWER CONNECTION / MANUAL OYERRIDE HAROLE (1) J ST ERMINAL (OPPOSITE SIDE) 3/8-16 x 58 DP. MIG. HOLES (2) SOLENCIO RELEASE VALYE ASSEMBLY 8 CHECK 17 2-WAY H.O. SPOOL TYPE SOL, CAAT. VALVE W/ (2) 1/4* SPADE TERMINALS x A Ar am Page 26 of 52 1001 POWER UNIT PARTS LIST (ITEM # | PART# DESCRIPTION QTY. i B02-15-0003 Adjusting Screw 1 2 B02-15-0088 Bolt 5/16-24 x 2.75 2 3 B02-15-0043 8-32 x .50 Screw 6 4 B02-15-0114 1/8 x 1/4 Pin 1 6 B02-15-0006 O-Ring 1 8 B02-15-0106 Solenoid Bracket Cover ] 9 B02-15-0090 Screw 5/16-18 x 1 1 11 B02-15-0115 Manual Release Rod 1 12 B02-15-0116 Endhead 1 13 B02-15-0078 Pump Assembly 1 14 BO2-15-0117 Reservior | 15 B02-15-0013 Spring & Ball (Check) 1 16 B02-15-0014 Spring & Ball Assembly (Relief) 1 17 B02-15-0015 Check Cap Assembiy 1 18 B02-15-0118 Release Valve Assembly 1 19 B02-15-0030 Relief Cap Assembly 1 20 B02-15-0091 Seal Shaft ] 21 B02-15-0018 Release Stem Assembly 1 22 B02-15-0113 12VDC N.O. Spool Cart. Valve 1 23 BO1-15-0124 Electric Terminal Strap 1 24 B02-15-0020 Solenoid Assembly 1 25 B02-15-0093 Washer 1 26 B02-15-0022 Solenoid Mounting Bracket Assembiy i 27 B02-15-0126 Screw M6-1 x 12mm 2 29 B02-15-0059 Nylon Ell 1 30 B02-15-0125 Cover Suction 1 31 B02-15-0026 Adjusting Screw 1 32 B02-15-0027 Spring Retainer 1 33 B02-15-0028 Seal Ring 1 34 B02-15-0119 Coupling 1 35 B02-15-0052 Breather Plastic 3/§NPT 1 36 B02-15-0046 O-Ring 2 37 B02-15-0120 ~ Solenoid Start DC12 1 38 B02-15-0097 Plumbing Plug 3/8 NPT 2 40 B02-15-0061 Plumbing Magnet 1 42 B02-15-0121 Filter 1 43 B02-15-0122 Motor DC 12V i « 44 B02-15-0123 Screw 1/4-20 x .25 2 y Page 27 of 52 ELECTRICAL SYSTEM MASTER 12V DC POWER + | - SWITCH "= EMEREENCY ON SWITCH UP 1 1 R1 R2 «To — 5% 9 0—DIHH— 6 Cl - MOTOR START CONTACTOR Ri-R2 CONTROL RELAYS DOWN Si - RAISE VALVE | S2 - LOWERING VALVE LT NN 63 * LOWER CONTROL RECEPTICAL @ | я P| Pa A x = © Da A JL oo æ NU El Ci | ® PART# DESCRIPTION QTY. B04-07-0003 Battery Hold Down Rod 2 B29-00-0001 Battery Hold Down Strap ] 1/4" S.À.E. Flatwasher 2 1/4"-20 Hex Lockut B01-05-0022 15 Amp Battery Charger - 12 Volt 1 B04-07-0028 #10 x 1/2" Hex Slotted Head Screw 4 B03-00-0014 2-1/4" Dia, Electrical Tube Assembly 1 Page 28 of 52 WIRING DIAGRAM FOR JUNCTION BOX ON DC LIFTS X0S AI IE NES 7-81 3LIHA азы IN | / asus f ММ / | SN - №3289 - ЛОУ 8 A — NN nn N NE / dnd OL > SS = | — Cao A 7 319YLIYLEY me ZA NU Zz X XIV 16 Во | | \ ve JLIHA 289 à MOVIE — 1 > > Г TX III .Ld 938 Page 29 of 52 DC - WIRING DIAGRAM I£ IIVd MIBIA CE94Y E LS HIMO ES 351Y4 15 HILTMS LYLE Tx OLE E e IE Page 30 of 52 3a Sa 5b Sc Sd Je sa 8b SC 10 11 12 13 14 15 18 19 19a 19b 19c 19d 19e 19f 19g 19h 191 19; 20 21 PART # B01-10-0001 B04-07-0012 B01-10-0047 BO1-10-0049 B01-09-0005 B01-09-0042 B01-09-0029 B01-01-0002 В00-00-0007 B00-00-0008 B04-08-0002 B29-00-0049 B04-04-0005 B01-09-0003 B18-00-0026 B01-03-0019 B04-04-2105 B04-01-2002 B04-06-1002 B01-10-0064 B01-09-0027 B01-01-0068 B01-02-0001 B01-04-0002 B01-01-0069 B01-01-0070 B01-01-0073 B19-00-0018 B 19-00-0017 B04-04-2103 B04-01-2002 BO1-06-0015 B01-09-0029 B0i-10-0101 B04-04-4105 B04-01-4002 B04-06-1004 B04-07-0038 B01-01-0074 B01-01-0005 DC - WIRING PARTS LIST DESCRIPTION 3 Conductor Receptacle Drive Lock Nut Unilet Box Unilet Cover 10-24 x 3/4" Bolts w/Lockwashers & Nuts Wire Nut Wire Nuts Threaded Cord Grip 16/3 Retractile Cord Plastic Tube Plastic Plug for Tube Pop Rivets Mounting Brackets for Tube 10-24 x 1/2" Self Threading Screw Cord Grips Handy Box Cover Switch Bolts #6 x 3/4" 46 Locknuts #6 Flat Washers Diode Cord Grips 18-4 x 66" w/Wire Ends Battery Disconnect Battery 12v DC 27 DCM 18-2 Wire Assembly 60" Long 18-2 Wire Assembly 88" Long 18-4 Wire 25" Long Black Box Lid w/Mtg. Screws Bolts #6 x 1/2" #6 Lock Nuts 12v DC Relays Cord Grips Green Indicator Lights Boits #10 x 3/4 #10 Locknuts #10 Flat Washers Plastic Locknut for 19e 18-2 Wire 30" Long 22" Battery Lead Page 31 of 52 QTY. a EA EAN EDO 00 = mu pk ek pb a A A RRA Be Re BRD ВО BD E A AAN a IN CONTROL ASSEMBLY PRPPP е A 1/0 ITEM # OS =~] ON UA La Wd Бо — Nad jt bred fe — La QB) = OND PART # B 19-00-0001 BO1-02-0003 В01-02-0004 BO1-02-0025 B00-00-0015 B00-00-0017 B00-00-0016 B01-02-0006 В01-02-0005 BO1-09-0003 BO1-01-0003 B01-01-0042 BO1-01-0043 B01-01-0042 DESCRIPTION 3 Switch Box w/Cover Push Button "Emergency Stop” Button Selector Switch "On" Plate "Emergency Stop” Plate "Up-O-Down" Plate Contact Block N.C. Contact Block N.O, Strain Relief Bushing Control Cord 16 Ga. x 2 3/4" Wire 16 Ga. x 3 3/4" Wire 16 Ga. x 2 3/4" Wire Page 32 of 52 = E fk mk jt pp DL deen ees ek ный het bed fe arm, OUTRIGGER INDICATOR BOX WIRING GREEN — RED FROM LIGHT и ALL WHITE / FROM LIGHTS Bo" Ps Page 33 of 32 DAMAGED EQUIPMENT POLICY SAFETY STATEMENT: At Workforce, we are dedicated to the safety of all users of our products. There- fore, all Workforce 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 Workforce lift is involved in an incident which results in structural damage to the lift. This can seriously compromise the ability of the lift to perform in a safe manner. Therefore, whenever a Workforce lift 1s dam- aged structurally or when there is the possibility of structural damage (this damage may be internal and is not always visible to the naked eye), Workforce requires that the lift be returned to our facility at 595 E. Lugbill Rd. for reconditioning. If you have any questions concerning what constitutes structural damage, please call the Workforce Service Department at 419-445-9675. DAMAGE REPAIR NOTICE: There may be occasions when a Workforce lift is involved in an incident resulting in non-structural damage. When this occurs and repairs are made by the owner or area distributor, please notify Workforce of these non-maintenance repairs and request a repair form to be filled out and returned to Workforce. Page 34 of 52 The following sections are reprinted from the ANSI A92.3-1990 code in effect at the time of manufacture. Permission to reprint has been granted by the Scaffold Industry Association. 5. Responsibilities of Dealers 5.1 Basic Principles. Sound principles of safety, training, inspection, maintenance, applications, and operation consistent with all data available regarding the parameters intended use and expected environment shall be applied in the training of operators, in maintenance, application, and operation of the aerial platform with due consideration of the knowledge that the unit will be carrying personnel. 5.2 Manuals. Dealers shall keep and maintain copy(ies) of the operating and maintenance manual(s) required in 4.17. Copy(ies) of operating manual(s) shall be provided upon each rental or lease delivery. Copy(ies) of operating and maintenance manual(s) shall be provided upon each sale delivery. The operating manual(s) shall be stored in the location required by 4.18. These manual(s) are considered an integral part of the aerial platform and are vital to communicate necessary safety information to users and operators. 5.3 Predelivery Preparation, Aerial platforms shall be inspected, serviced, and adjusted to manufacturer's requirements prior to each delivery by sale, lease, or rental. 5.4 Maintenance Safety Precautions. Before adjustments and repairs are started on an aerial platform, the following precautions shall be taken as applicable: (1) All controls in the "off" position and all operating features secured from inadvertent motion by brakes, blocks, or other means. (2) Powerplant stopped and starting means rendered inoperative (3) Platform lowered to the full down position, if possible, or otherwise secured by blocking or cribbing to prevent dropping (4) Hydraulic oil pressure relieved from all hydraulic circuits before loosening or removing hydraulic components (5) Safety props or latches installed where applicable as described by the manufacturer. 5.5 Replacement Parts. When parts or components are replaced, they shall be identical or equivalent to original aerial platform parts or components. 5.6 Training. Whenever a dealer directs or authorizes an individual to operate an aerial platform, the dealer shall ensure that the individual has been trained under the direction of a qualified person in accordance with the manufacturer's operating and maintenance manual and requirements listed in Section 8 before operating the aerial platform, 5.6.1 Training on Delivery. Manufacturer's operating instruction and required training on the proper use and operation of the aerial platform shall be provided upon each delivery, by sale, lease, or rental. 5.7 Operation. When a dealer operates an aerial platform in sales demonstrations or for other beneficial use, the dealer shall assume the responsibilities of users as specified in Section 7 and the operating personnel shail assume the responsibilities of operators as specified in Section 8 of this standard. 5.8 Assistance to Owners and Users. If a dealer is unable to answer an owner's or user's question relating to rated capacity, intended use, maintenance, repair, inspection, or operation of the aerial platform, the dealer shall obtain the proper information from the manufacturer and provide that information to the owner or user. 5,9 Record Retention. Dealer(s) shall retain the following records for at least 3 years: (1) Name and address of the purchaser of each aerial platform by serial number and the date of delivery (2) Records of the person(s) trained upon each delivery of an aerial platform (3) Records of the predelivery preparation performed prior to each delivery. 5.10 Modifications. Modifications or alterations of aerial platforms shall be made only with prior written permission of the manufacturer. Page 35 of 52 5.11 Manufacturer's Safety Bulletins. The dealer shall comply with safety-related bulletins as received from the manufacturer. 6. Responsibilities of Owners 6.1 Basic Principles. Sound principles of safety, training, inspection, maintenance, application, and operation consistent with all data available regarding the parameters of intended use and expected environment shall be applied in the performance of the responsibilities of owners with due consideration of knowledge that the unit will be carrying personnel. 6.2 Manuals. Owners shall keep and maintain copy(ies) of the operating and maintenance manual(s) required in 4.17 of this standard. Copy(ies) of operating manual(s) shall be provided upon each rental or lease delivery. Copy(ies) of operating and maintenance manuals(s) shall be provided upon each sale delivery. The operating manual(s) shall be stored in the location required in 4.18 of this standard. These manual(s) are considered an integral part of the aerial platform and are vital to communicate necessary safety information to users and operators. 6.3 Maintenance. The owner of an aerial platform shall arrange that the maintenance specified in this standard is properly performed on a timely basis. The owner shall establish a preventive maintenance program in accordance with the manufacturer's recommendations and based on the environment and severity of use of the acrial platform. The owner shall arrange that frequent and annual inspections are performed. All malfunctions and problems noted shall be corrected before the aerial platform is returned to service. 6.4 Frequent Inspection. The owner of an aerial platform shall cause a frequent inspection to be performed on an aerial platform: (1) That has been in service for 3 months or 150 hours, whichever comes first (2) That has been out of service for a period longer than 3 months. The inspection shall be made by a person qualified as a mechanic on the specific make and model of the aerial platform. The inspection shall include all items specified by the manufacturer for a frequent inspection and shall include, but not be limited to, the following: (3) All functions and their controls for speed(s), smoothness, and limits of motion (4) Emergency lowering means (5) All chain and cable mechanisms for adjustment and worn or damaged parts (6) All emergency and safety devices (7) Lubrication of all moving parts, inspection of filter element(s), hydraulic oil, engine oil, and coolant, as specified by the manufacturer (8) Visual inspection of structural components and other critical components, such as fasteners, pins, shafts, and locking devices (9) Placards, warnings, and control markings (10) Items specified by the manufacturer (11) Correction of all malfunctions and problems identified and further inspection, if necessary. 6.5 Annual Inspection. The owner of an aerial platform shall cause an annual inspection to be performed on the aerial platform no later than 13 months from the date of the prior annual inspection. The inspection shall be made by a person qualified as a mechanic on the specific make and model of the aerial platform. The inspection shall include all items specified by the manufactarer for an annual inspection. 6.6 Maintenance Safety Precautions. Before adjustments and repairs are started on an aerial platform, the following precautions shall be taken as applicable: (1) All controls in the "off" position and all operating features secured from inadvertent motion by brakes, blocks, or other means (2) Powerplant stopped and starting means rendered inoperative (3) Platform lowered to the full down position, if possible, or otherwise secured by blocking or cribbing to prevent dropping (4) Hydraulic oil pressure relieved from all hydraulic circuits before loosening or removing hydraulic components (5) Safety props or latches installed where applicable as described by the manufacturer, 6.7 Replacement Parts. When parts or components are replaced, they shall be identical or equivalent to original aerial platform parts or components. Page 36 of 52 6.8 Maintenance Training, The owners shall train their maintenance personnel in inspection and maintenance of the aerial platform in accordance with 6.3, 6.4, 6.5, 6.6, 6.7 and 6.9 of this standard, and with the manufacturer's recommendations. 6.9 Operator Training. An owner who directs or authorizes an individual to operate an aerial platform shall ensure that the individual has been trained in accordance with the manufacturer's operating manual, and requirements listed in Section 8 of this standard before operating the aerial platform. Manufacturer's operating instruction and required training on the proper use and operation of the aerial platform shail be provided upon each delivery, by sale, lease, or rental. 6.10 Operation. When an owner operates an aerial platform, the owner shail have the responsibilities of users as specified in Section 7 of this standard, and the operating personnel shall have responsibilities of operators as specified in Section 8 of this standard. 6.11 Assistance to Users and Operators. If an owner is unable to answer a uset’s or operator's questions related to rated capacity, intended use, maintenance, repair, inspection, or operation of the aerial platform, the owner shall obtain the proper information from the dealer or manufacturer and provide that information to user or operator. 6.12 Record Retention. The owner shall retain the following records for at least 3 years: (1) Name and address of the purchaser of each aerial platform by serial number and date of delivery (2) Records of the person(s) trained upon each delivery of an aerial platform (3) Written records of the frequent and annual inspections performed by the owner. The record shall include deficiencies found, corrective action, and identification of the person(s) performing the inspection and repairs (4) Records of the predelivery preparation performed prior to each delivery. 6.13 Modifications. The owner shall not modify or concur in modifications or alteration to the aerial platform without the modifications being approved and certified in writing by the manufacturer. 6.14 Manufacturer's Safety Bulletins, The owner shall comply with safety-related bulletins as received from the manufacturer or dealer. 7. Responsibilities of Users. 7.1 Basic Principles. The information in this standard must be supplemented by good job management, safety control, and the application of sound principles of safety, training, inspection, maintenance, application, and operation consistent with all data available regarding the parameters of intended use and expected environment. Since the user has direct control over the application and operation of aerial platforms, conformance with good safety practices in this area is the responsibility of the user and the operating personnel, including the operator. Decisions on the use and operation of the aerial platform must always be made with due consideration for the fact that the machine will be carrying personnel whose safety is dependent on those decisions. 7.2 Manuals. Users shall keep and maintain copy(ies) of the operating and maintenance manual(s) required in 4.17 of this standard. The operating manual(s) shall be stored in the location required in 4.18 of this standard. These manuals are considered an integral part of the aerial platform and are vital to communication of necessary safety information to users and operators. 7.3 Inspection and Maintenance. Users shall inspect and maintain the aerial platform as required to ensure proper operation. The frequency of inspection and maintenance shall be determined by the manufacturer's recommendation and be compatible with operating conditions and the severity of the operating environment, Aerial platforms that are not in proper operating condition shall be immediately removed from service until repaired. Repairs shall be made by a qualified person and the reapirs shall be in conformance with the manufacturer's recommendations. Page 37 of 52 7.3.1 Frequent Inspection. An inspection as outlined in 6.4 of this standard shall be conducted. 7.3.2 Annual Inspection. An inspection as outlined in 6.5 of this standard shall be conducted. 7.3.3 Prestart Inspection. Before use each day or at the beginning of each shift, the aerial platform shall be given a visual inspection and function test including but not limited to the following: (1) Operating and emergency controls (2) Safety devices (3) Personal protective devices, including fall protection (4) Air, hydraulic and fuel system leaks (5) Cables and wiring harness (6) Loose or missing parts (7) Tires and wheels (8) Placards, warnings, and control markings (9) Outriggers, stabilizers, and other structures (10) Guardrail system (11) Items specified by the manufacturer, 7,34 Maintenance Safety Precautions. Before adjustments and repairs are started on an aerial platform, the following precautions shall be taken as applicable: (1) All controls in the "off" position and all operating features secured from inadvertent motion by brakes, blocks, or other means (2) Powerplant stopped and starting means rendered inoperative (3) Platform lowered to the full down position, if possible, or otherwise secured by blocking or cribbing to prevent dropping (4) Hydraulic oil pressure relieved from all hydraulic circuits before loosening or removing hydraulic components (5) Safety props or latches installed where applicable as described by the manufacturer (6) Precautions specified by the manufacturer. 7.4 Replacement Parts. When parts or components are replaced, they shall be identical or equivalent to original aerial platform parts or components. 7.5 Maintenance Training. The user shall train the maintenance personnel in inspection and maintenance of the aerial platform in accordance with 7.3, 7.4, and 7.6 of this standard and with the manufacturer's recommendations. 7.6 Operator Training, Whenever a user directs or authorizes an individual to operate an aerial platform, the user shall ensure that the individual has been trained in accordance with the manufacturer's operation and maintenance manual, the user's work instructions, and the requirements listed in Section 8 of this standard before operating the aerial platform. 7.6.1 Model Training. The user shall be responsible for the operator being trained on the model of the aerial platform to be operated. Such training shall be in an area free of obstructions, under the direction of a qualified person for a time sufficient to determine that the trainee displays proficiency in knowledge and actual operation of the aerial platform. Only properly trained and authorized personnel shall be permitted to operate the aerial platform. 7.6.2 Trainees Training Record. A record of the trainee's aerial platform instruction shall be maintained by the user for at least 3 years. 7.7 Before Operation. Before authorizing an operator to operate an aerial platform, the user shall ensure that the operator has: (1) Been instructed by a qualified person in the intended purpose and function of each control (2) Read and understood the manufacturer's operating instructions and user's safety rules, or been trained by a qualified person on the contents of the manufacturer's operating instructions and user's safety rules (3) Understood by reading or by having a qualified person explain all decals, warnings, and instructions displayed on the aerial platform (4) Determin">

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Key features
- Telescopic design
- 10'10'' maximum height
- 400 lbs. capacity
- 12-volt battery power
- Outriggers for stability
- Flow restrictor valve for controlled descent
Frequently asked questions
The XLT 1001 DC can reach a maximum height of 10'10''.
The XLT 1001 DC has a maximum capacity of 400 lbs.
The XLT 1001 DC is powered by a 12-volt battery.