Bil-Jax Cougar XLT-1571AC lift platform Operation and Maintenance Manual
Below you will find brief information for lift platform Cougar XLT-1571AC. The Cougar Lift is designed and manufactured for use as a warehouse stocking and order picking machine. Its unique guard rail design permits the operator to ride on the platform with the load, while transferring it from group level to its overhead storage location. The maximum platform load is limited to 500 lbs. Platform elevation is accomplished by means of a 1-1/2 inch displacement type hydraulic cylinder. The lower telescoping section is pushed vertically upward by the cylinder while the upper sections are raised by a mechanical motion advantage accomplished through two sets of chains and sheaves.
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AERIAL WORK PLATFORMS
Model XLT-1571AC
Operation and
Maintenance Manual
Electric Hydraulic Lift Platform
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DANGER
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WARNING
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B33-01-0062
TELESCOPIC PERSONNEL LIFT
This equipment is designed and manufactured in compliance with the duties, responsibilities, and standards set forth for manufacturers in the ANSI 92.3 standard in effect at the time of manufacture.
This equipment will meet or exceed applicable OSHA codes and ANSI A92.3 standards when used in accordance with sections 5, 6, 7, 8, 9 & 10 of ANSI A92.3 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 that govern the safe operation of this equipment.
Table of Contents
Maintenance Safety............................................................................1-6
Damaged Equipment Policy .............................................................1-6
Normal Operating Procedure ............................................................3-2
Emergency Lowering Procedure ......................................................3-3
4-1 Scheduled Service Checks ................................................................4-1
4-5 Lift Chains And Slide Blocks .......................................................4-12
Top Mast Parts List..........................................................................6-2
Center Mast Parts List......................................................................6-4
Lower Mast Parts List......................................................................6-6
Hydraulic Pump Compartment Parts List .....................................6-10
Upper Base Parts List ....................................................................6-12
Base Mast Parts List ......................................................................6-14
Lower Base Parts List ....................................................................6-16
Platform Parts List ..........................................................................6-18
6-10 Hydraulic Unit Parts List ...............................................................6-20
6-11 Hydraulic Fittings And Hoses Diagram............................................6-22
6-12 Hydraulic Fittings And Hoses Schematic .....................................6-24
i
ii
List of Illustrations
Figure 6-5. Hydraulic Pump Compartment Exploded View ................................... 6-10
List of Tables
Table 6-5. Hydraulic Pump Compartment Parts List .............................................6-11
Table 7-1. Minimum Safe Approach Distance (M.S.A.D.) to energized
(exposed or insulated) power lines and parts....................................7-11
iii
iv
1
Safety
1-1 INTRODUCTION
Familiarity and proper training are required for the safe operation of mechanical equ ipment. Equipment operated improperly or by untrained personnel can be dangerous. Read the operating instructions in this manual and become familiar with the location and proper use of all controls. Inexperienced operators should receive instruction from so meone familiar with the equipment before being allowed to operate the machine. The use of intelligence and common sense in the operation of mechanical equipment is the best practice in any safety policy. Be professional and always observe the safety procedure s set forth in this manual.
All OSHA, ANSI, state and local codes and regulations pertaining to this equipment should be obtained, read, and thoroughly understood before attempting to operate this equipment. Persons under the influence of drugs, alcohol, or prescription medication should not be on or near this equipment. Common sense should b e implemented at all times during the use of this equipment. Do not operate 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 intended for informational purposes only. This information is offered to alert Bil-Jax customers 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
Bil-Jax equipment only.
For any questions concerning the safe use of this equipment, call 800-537-0540 before operating.
1-1
XLT-1571AC
Safety Notes
This manual contains DANGERS, WARNINGS, CAUTIONS, and NOTES that must be followed to prevent the possibility of improper service, damage to the equipment, or personal injury.
DANGER
Dangers warn of equipment operation near electrical power lines that could lead to personal injury or death.
WARNING
Warnings describe conditions or practices that could lead to personal injury or death.
CAUTION
Cautions provide information important to prevent errors that could damage machine or components.
NOTE:
Notes contain additional information important to a procedure.
1-2
1 — SAFETY
1-2 BEFORE OPERATION
Ensure the following general safety precautions are followed before operating the Cougar
Lift.
• ALWAYS survey the usage area 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 operating area.
• ALWAYS read, understand, and follow the procedures in this manual before attempting to operate equipment.
• ALWAYS inspect the equipment for damaged or worn parts. Check for cracked welds, hydraulic leaks, damaged wiring, loose wire connectors, damaged casters, and damaged floor pads. Also check for any improper operation. NEVER operate equipment if damaged in any way. Improperly operating equipment must be repaired before using.
• ALWAYS wear proper clothing for the job. Wear protective equipment as required by federal, state, or local regulations.
• ALWAYS locate, read, and follow all directions and warnings displayed on the equipment.
• ALWAYS inspect the equipment for any “DO NOT USE” tags placed on the equipment by maintenance personnel. NEVER use any equipment tagged in this way until repairs are made and all tags are removed by authorized maintenance personnel.
• ALWAYS make sure the platform and shoes are free of mud, grease, or other foreign material. This will reduce the possibility of slipping.
• NEVER allow improperly trained personnel to operate this equipment. Only trained and authorized personnel shall be allowed to operate this equipment.
• NEVER 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.
• NEVER modify, alter, or change the equipment in any way that would affect its original design or operation in any way.
• NEVER operate this equipment in ways for which it is not intended.
1-3
XLT-1571AC
1-4
Ensure the following general safety precautions are followed during the operation of the
Cougar Lift.
DANGER
This machine is not insulated for use near electrical power lines and DOES NOT provide protection from contact with or close proximity to any electrically charged conductor. Operator must maintain safe clearances at all times (10 feet minimum) and always allow for platform movement such as wind induced sway.
Always contact the power company before performing work near power lines. Assume every line is hot. Remember, power lines can be blown by the wind.
Refer to Table 1-1 for minimum safe approach distances between machine and electrical power lines.
Voltage Range
(Phase to Phase)
0 to 300V
Over 300V to 50KV
Over 50KV to 200KV
Over 200KV to 350KV
Over 350KV to 500KV
Over 500KV to 750KV
Over 750KV to 1000KV
Table 1-1. Minimum Safe Approach Distances
Minimum Safe Approach Distance
(Feet) (Meters)
Avoid Contact
10
15
20
25
3.05
4.60
6.10
7.62
35
45
10.67
13.72
• ALWAYS position lift far enough away from power sources to ensure that no part of the lift can accidentally reach into an unsafe area.
• ALWAYS operate only on a firm and level surface. NEVER use on surfaces that do not support the weight of the equipment and its rated load capacity.
• ALWAYS keep yourself and all personnel away from potential pinch or shear points.
• ALWAYS report any misuse of equipment to the proper authorities. Horseplay is prohibited.
• ALWAYS maintain good footing on the platform. NEVER wear slippery soled shoes.
• ALWAYS make certain all personnel are clear and there are no obstructions before repositioning platform.
• ALWAYS cordon off area around the base to keep personnel and other equipment away from it while in use.
• ALWAYS stay clear of wires, cables, and other overhead obstructions.
• ALWAYS disconnect power at the batteries when not in use to guard against unauthorized use.
1 — SAFETY
• NEVER allow electrode contact with any part of the platform if welding is being performed by a worker from the platform.
• NEVER use without the floor pads fully based on the floor.
• NEVER override or by-pass manufacturer's safety devices.
• NEVER release floor locks or move unit with a person or materials on board.
• NEVER stand or sit on guardrails. Work only within the platform guardrail area and do not lean out over guardrails to perform work.
• NEVER attempt to increase working height with boxes, ladders, or other means.
• NEVER operate this equipment when exposed to high winds, thunderstorms, ice, or any other weather conditions that would compromise the safety of the operator.
• NEVER climb up or down masts.
• NEVER allow ropes, electric cords, hoses, etc. to become entangled in the equipment when the platform is being raised or lowered.
• NEVER exceed manufacturer's platform load limits and make sure all materials are evenly distributed over the entire platform.
• NEVER exceed platform load ratings by transferring loads to platform at elevated heights.
• NEVER use guardrails to carry materials and never allow overhang of materials when raising or lowering platform.
1-5
XLT-1571AC
1-6
1-4 MAINTENANCE SAFETY
Ensure the following general safety precautions are observed when maintenance is performed on the Cougar Lift.
• ALWAYS perform maintenance procedures according to manufacturer's requirements. NEVER short change maintenance procedures.
• ALWAYS check hydraulic system. Make sure all lines, connectors, and fittings are tight and in good condition.
• ALWAYS 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.
• ALWAYS locate and protect against possible pinch points prior to performing maintenance and repairs.
• ALWAYS use only factory approved parts to repair or maintain this equipment.
If this equipment is rebuilt, retesting is required in accordance with factory instructions.
• NEVER add unauthorized fluids to the hydraulic system or battery. Check manufacturers specifications.
• NEVER exceed the manufacturer's recommended relief valve settings.
• NEVER attempt repairs you do not understand. Consult manufacturer if you have any questions regarding proper maintenance, specifications, or repair.
1-5 DAMAGED EQUIPMENT POLICY
Safety Statement
At Bil-Jax, we are dedicated to the safety of all users of our products. Therefore, all
Bil-Jax lifts are designed, manufactured and tested to comply with current applicable
Federal OSHA and ANSI codes and regulations.
Damage Policy
There may be occasions when a Bil-Jax lift is involved in an incident that results in structural damage to the lift. This can seriously compromise the ability of the lift to perform in a safe manner. Therefore, whenever a Bil-Jax lift is damaged structurally or when there is the possibility of structural damage (this damage may be internal and is not always visible to the naked eye), Bil-Jax requires that the lift be returned to our facility at 125 Taylor Parkway, Archbold, Ohio, for reconditioning. If you have any questions concerning what constitutes structural damage, please call the Bil-Jax Service Department at
800-537-0540.
Damage Repair Notice
There may be occasions when a Bil-Jax lift is involved in an incident resulting in nonstructural damage. When this occurs and repairs are made by the owner or area distributor, please notify Bil-Jax of these non-maintenance repairs and request a repair form to be filled out and returned to Bil-Jax.
2
Introduction
2-1 GENERAL DESCRIPTION
The model XLT-1571 Cougar Lift is designed and manufactured for use as a warehouse stocking and order picking machine. Its unique guard rail design per mits the operator to ride on the platform with the load, while transferring it from group level to its overhead storage location. The maximum platform load is limited to 500 lbs.
Platform elevation is accomplished by means of a 1-1/2 inch displacement type hydraul ic cylinder. The lower telescoping section is pushed vertically upward by the cylinder whil e the upper sections are raised by a mechanical motion advantage accomplished through two sets of chains and sheaves. The platform is raised three inches for each one inch of cylinder extension. Platform elevation and descent is controlled by pushbuttons on the upper control box located on the platform.
Safety of operation is assured by proper inspection and maintenance procedures as set forth in this manual. The possibility of platform free-fall is eliminated by proper maintenance and replacement of the chains, sheaves and sheave pins, a properly installed flow restrictor valve, and a clean mast. The non-adjustable restrictor valve controls and fixes the rate of platform descent whether empty or fully l oaded to approximately 0.6 feet per second. A hydraulic hose failure will result in the same rate of descent, eliminating freefall, when the restrictor valve is installed properly.
Emergency lowering of the platform is accomplished by means of a manual control valve located on the hydraulic manifold block assembly, next to the pump/motor unit.
The Cougar Lift features a displacement type of cylinder that will not rust or c orrode during storage since the cylinder rod is immersed in oil. It is important that the cylinder rod be kept clean and undamaged for the protection of the cylinder head packing.
The floor lock safety switch prevents the unit from raising until the two floor pads have been properly engaged and helps to make the Cougar Lift a safe, dependable machine.
Carefully read all the safety instructions contained in Section 1 of this manual before operating the Cougar Lift.
2-1
XLT-1571AC
2-2
2-2 SPECIFICATIONS
Cougar Lift Electric Hydraulic Lift Platform
Model Number XLT-1571AC Serial Number ________________
Manufactured by: Bil-Jax, Inc.
125 Taylor Parkway
Archbold, Ohio 43502
800-537-0540
Table 2-1. Specifications
Rated Platform Load
Extended Platform Height
Retracted Platform Height
Platform Dimensions
500 lbs (227 kg) total including operator [1 person + materials not to exceed 500 lbs (227 kg)]
14 ft-10 in. (4.5 m)
18-1/2 in. (0.47 m)
29 in. w x 50 in. l x 42 in. h
(0.74 m x 1.27 m x 1.07 m)
Base Dimensions
Retracted Dimensions
Gross Shipping Weight
Full Extension Time
Complete Retraction Time
Platform Extension Rate
30-1/2 in. w x 71 in. l x 77 in. h
(0.77 m x 1.8 m x 1.95 m)
30-1/2 in. w x 73-1/2 in. l x 77 in. h
(0.77 m x 1.87 m x 1.95 m)
1025 lbs (465 kg)
20 seconds empty, 32 seconds loaded
22 seconds empty, 22 seconds loaded
0.66 ft (0.3 m)/sec. empty
0.42 ft (0.19 m)/sec. loaded
Hydraulic System Pressure 1200 psi empty, 2100 psi loaded
Power Source 110VAC, 60 Hz
2-3 WARRANTY
Bil-Jax warrants its telescopic lifts for three years 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 or replace any unit or component 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 warranties is available upon written request to Bil-Jax.
Bil-Jax shall not in any event be liable for the cost of any special, indirect or consequential damages to anyone, product, or thing. This warranty is in lieu of all 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.
3
Operation
3-1 OPERATOR CONTROLS
The operator controls for the Cougar Lift are contained on the upper and lower control boxes.
Lower Control Box
The lower control box is located on the front of the base platform and contains 3 pushbutton controls,
EMERGENCY STOP
,
WHEEL DOWN
/
BASE ROLLS
, and
WHEEL UP
/
BASE
SET
. The controls on the lower control box are used to set the unit in proper position before the platform can be raised. Refer to Figure 3-1.
EMERGENCY
STOP
BUTTON
WHEEL DOWN
BASE ROLLS
BUTTON
WHEEL UP
BASE SET
BUTTON
Figure 3-1. Lower Control Box
3-1
XLT-1571AC
3-2
Upper Control Box
The upper control box is located on the back of the top mast and is accessible from the platform. The upper control box contains 3 controls,
UP
/
DOWN selector switch,
EMERGENCY STOP
pushbutton, and
ON pushbutton. The controls on the upper control box are used to raise and lower the unit. Refer to Figure 3-2.
EMERGENCY
STOP
PUSHBUTTON
UP/DOWN
SELECTOR
SWITCH
ON
PUSHBUTTON
Figure 3-2. Upper Control Box
3-2 NORMAL OPERATING PROCEDURE
Perform the following procedures to operate the Cougar Lift.
1. Read and follow all safety precautions contained in Section 1 and all responsibilities outlined in the ANSI A92.3 reprint contained in Section 7 of this manual.
2. 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 operate the lift if such hazards exist.
3. Check the lift for damaged or worn parts and repair or replace as necessary.
4. Check to be sure that the platform is properly attached to the lift.
5. Raise the casters located under the platform by depressing the
WHEEL UP
/
BASE
SET pushbutton located on the lower control box. Raising the casters allows the base to set firmly on the two foot pads.
6. The lift should be level and positioned on the two foot pads with the
WHEEL
UP
/
BASE SET pushbutton lit green. Ensure that the platform's upward path of travel is free from obstructions. Reposition the lift if necessary.
NOTE:
The lift is equipped with a level sensor that will prevent the lift from raising if the lift is at a slope greater than 1 degree. The green
WHEEL
UP
/
BASE SET
pushbutton will no longer illuminate until the lift is releveled.
7. Enter the platform. Ensure that both side midrails are positioned properly.
3 — OPERATION
8. The lift is now ready for operation. While depressing the
ON
pushbutton, select the desired function,
UP
or
DOWN
on the position selector switch. The platform will raise or lower respectively. The
EMERGENCY STOP
pushbutton deactivates the control circuit.
NOTE:
Should the platform continue to rise after the
UP
switch is released, press the
ON
pushbutton and select the
DOWN
position at the same time and the platform should stop or lower.
3-3 EMERGENCY LOWERING PROCEDURE
The Cougar Lift is equipped with a manual lowering valve in case of emergency situations to lower the platform. The emergency lowering valve is located on the hydraulic block manifold in the hydraulic pump compartment. The valve may be accessed through the opening on the base door. To lower the platform, turn the red knob on the valve counterclockwise. Refer to Figure 3-3.
EMERGENCY
LOWERING
VALVE
RED KNOB
Figure 3-3. Emergency Lowering Valve
3-3
XLT-1571AC
3-4
4
Maintenance
4-1 SCHEDULED SERVICE C HECKS
Daily/Weekly Service Checks
Perform the following daily/weekly service checks as listed in Table 4 -1.
Table 4-1. Daily /Weekly Service Chec ks
Service Check
Ensure Operation Manual is located in manual tube.
Check chain assemblies for split leaves, loose pins, excessive wear, or elongation.
Check and retighten all nuts and bolts.
Check cage attachment to the platform is secure and that th e cage side midrails slide freely.
Check to be sure slide blocks and their path are clean and lightly lubricated with a silicone lubrican t.
Check level sensor.
Check to see that all decals are present.
Check that all functions at lower and upper control bo xes are operating properly.
Check for wear on chain sheaves, sheave axles, and bearings.
Lubricate chains with 40W oil.
Check casters for wear on axles and swivel raceways.
Check surface of casters for cracks or excessive wear.
D aily before use Weekly
4-1
XLT-1571AC
Monthly Service Checks
Perform the following monthly service checks as listed in Table 4-2.
Service Check
Table 4-2. Monthly Service Checks
Every month
Every
6 months
Check hydraulic raise valve operation.
Check operation of manual emergency lowering valve.
Lubricate caster swivels and axles.
Replace hydraulic oil.
Check slide blocks for wear.
Check for mast sway.
Load test with 500 pounds.
Replace lift chains.
Every
12 months
Every
48 months
4-2
4 — MAINTENANCE
4-2 LUBRICATION
Lubrication makes operation of the Cougar Lift more efficient and extends the life of the unit. Perform the following lubrication procedures.
1. Oil lift chains with clean 40W oil weekly or as needed. Refer to Figure 4-1.
LIFT
CHAINS
LIFT
CHAINS
Figure 4-1. Lift Chain Lubrication
4-3
XLT-1571AC
2. Grease all caster axles and swivel raceways at the 2 grease fittings on each caster semiannually with wheel bearing grease. Refer to Figure 4-2.
Figure 4-2. Caster Lubrication
NOTE:
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 be taken to ensure that the paths along which the blocks move are kept clean and lightly lubricated with a dry type silicon lubricant.
4-4
4 — MAINTENANCE
4-3 HYDRAULIC SYSTEM
Hydraulic system maintenance varies by the amount of use and the environment in which the lift is used. Constant attention to keep the oil clean and the reservoir properly filled will help prevent possible damage to the system.
Hydraulic System Inspection
Check all hydraulic hoses and fittings for leaks and damage daily. Tighten or replace as necessary to prevent hydraulic oil loss. Refer to the hydraulic schematic diagram in Section 6 for general reference.
Fluid Check and Replacement
The reservoir should be filled to within 1/2 inch of the top with the platform in its lowest position. The lift is shipped from the factory with Energol HLP-HD46 (BP Oil), a high grade, non-foaming hydraulic oil designed for temperatures as low as -20
°F/-29°C. Use
Dextron Automatic Transmission Fluid Type A for temperatures as low as -40
°F/-40°C.
If either oil is not available, a good grade SAE 10W hydraulic oil may be used where the minimum climatic temperature is above 32
°F/0°C. SAE 5W hydraulic oil may be used where temperatures are as low as 0
°F/-18°C. Do not mix different hydraulic oils. Clean the reservoir sump strainer and replace the hydraulic oil at least once a year or whenever it becomes contaminated.
Hydraulic System Air Bleeding Procedure
Delayed response or sporadic action in the unit may indicate a presence of air in the cylinder. Perform the following procedure to bleed air from the system.
1. Fill the reservoir with the proper hydraulic fluid.
2. Fully extend the lift.
3. Lower the unit to allow the oil with entrapped air to return to the reservoir, being careful not to overflow it.
4. 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 pumping more air into the cylinder.
4-5
XLT-1571AC
Pressure Relief Valve Reset
Perform the following procedure to reset the pressure relief valve. Refer to Figure 4-3.
1. Disconnect the hydraulic hose from the main pressure port.
2. Install a 4000 psi gauge into the main pressure port in the pump unit.
CAUTION
Do not adjust the pressure relief valve higher than 2100 psi. Overloading may occur at pressures greater than 2100 psi.
3. Remove the hex cover from the pressure relief valve.
4. While depressing the
WHEEL DOWN
/
BASE ROLLS
pushbutton on the lower control box, adjust the screw until maximum pressure of 2100 psi is obtained.
5. After adjusting the pressure relief valve, replace the hex cover, remove the 4000 psi gauge, and reconnect the hydraulic hose to the main pressure port.
6. If a gauge is unavailable, place 500 pounds on the platform and adjust the pressure relief valve screw so that the load can just be lifted without bypassing oil through the pressure relief valve.
MAIN
PRESSURE
PORT
4-6
HEX COVER FOR
PRESSURE
RELIEF VALVE
Figure 4-3. Pressure Relief Valve Adjustment
4 — MAINTENANCE
Flow Restrictor Valve Replacement
If the flow restrictor valve Figure 4-4 needs to be removed or replaced, it is important that it be properly reinstalled. The valve will be marked either with an arrow or with the word “IN”. If marked with an arrow, the arrow must point away from the hydraulic cylinder port. If marked with the word “IN”, the end of the valve marked “IN” must be toward the hydraulic cylinder port. Only a 1/4 inch NPT hydraulic elbow should be connected between the hydraulic cylinder port and the end of the flow restrictor valve.
Improper installation of the flow restrictor valve or the use of the wrong size elbow will permit widely varying rates of descent and may result in near free-fall in case of hose failure.
FLOW
RESTRICTOR
VALVE
¼ INCH NPT
HYDRAULIC
ELBOW
HYDRAULIC
CYLINDER
PORT
Figure 4-4. Flow Restrictor Valve
HYDRAULIC
CYLINDER
4-7
XLT-1571AC
Raise Valve Operation Check
The raise valve is a normally open (N.O.) valve in the hydraulic system. Perform the following procedures to check the operation of the raise valve.
1. Disconnect the black and yellow wires from the solenoid, to the valve at the wire connector, Figure 4-5.
2. On the upper control box, select
UP
on the direction selector switch while depressing the
ON
pushbutton. This should cause the motor to run without the platform raising.
3. If the platform raises, the raise valve must be cleaned or replaced.
4. Reconnect the wires at the connector between the solenoid and the raise valve upon determining that the valve is functioning properly.
WIRE
CONNECTOR
RAISE
VALVE
Figure 4-5. Raise Valve Operation Check
4-8
4 — MAINTENANCE
Hydraulic Cylinder Repair
CAUTION
Removing the hydraulic cylinder from the Cougar Lift requires major disassembly of the unit. Contact Bil-Jax before removing the hydraulic cylinder from the unit for assistance.
Hydraulic Cylinder Removal
It is recommended that Bil-Jax be contacted for assistance before removing the hydraulic cylinder.
1. Be sure cylinder is completely retracted and pressure is released from the system. Place a pan underneath the hydraulic cylinder to catch the hydraulic oil.
2. Disconnect the hydraulic hose from the bottom of the cylinder and drain the hydraulic oil. Remove the two bolts, washers, and nuts securing the bottom of the cylinder to the base.
3. Remove the plexiglass cover from the base.
4. Remove the mounting bolt, washer, and nut securing the top of the hydraulic cylinder to the lower mast.
5. Disconnect the two lift chains from the base mast.
6. Using a crane with at least one ton of lifting capacity, lift the lower mast section high enough to remove the clamp securing the cylinder to the base, and remove the cylinder from the unit.
7. After maintenance has been performed on the hydraulic cylinder, follow the removal procedure in reverse to reinstall the cylinder in the unit.
Hydraulic Cylinder Repair Procedure
Perform the following procedure to repair and maintain the hydraulic lift cylinder. Refer to Figure 4-6. It is recommended that whenever the hydraulic cylinder is disassembled, all seals be replaced; order seal repair kit B02-13-0097.
1. Remove gland nut (3, Figure 4-6) with gland nut seal (4), rod wiper (2), and o-ring (5) from the cylinder jacket (1).
2. Remove piston rod (6) and wear ring (7). Inspect piston rod (6) for any scratches or pits. Pits that go into the base metal are unacceptable. Scratches that catch the fingernail, but are not through the base metal or less than 1/2 inch long and are around the rod are acceptable providing they are not sharp enough to cut the seal. The rod surface should not have any of the chrome worn through. Replace the cylinder if any of these conditions are not met.
3. Clean inside the cylinder jacket (1) and inspect for any scratches or pits. Pits that are deep enough to catch the fingernail are unacceptable. Scratches that catch the fingernail, but are less than 1/2 inch long and are around the tube are acceptable providing they are not sharp enough to cut the seal. Replace the cylinder if any of these conditions are not met.
4. Install wear ring (7) into the grooves at the bottom of the piston rod (6). Lubricate assembly with hydraulic fluid and place back into cylinder jacket (1).
5. Lubricate rod wiper (2), gland nut seal (4), and o-ring (5) with hydraulic fluid.
6. Twist gland nut seal (4) into a “C” shape and insert it with lip side down into the groove inside the gland nut (3). Place o-ring (5) over the threads of the gland
4-9
XLT-1571AC
nut (3) and install in groove. Install rod wiper (2) into the top of the gland nut
(3).
7. Place gland nut (3) complete with a new gland nut seal (4), rod wiper (2), and oring (5) onto the cylinder and tighten down.
8. Reinstall the hydraulic cylinder into the unit and reconnect the hydraulic hose.
Refill hydraulic fluid reservoir.
9. Pressurize the cylinder and extend one full stroke to fill it with hydraulic fluid and remove any trapped air.
2
3
4
5
1. Cylinder Jacket
2. Rod Wiper
3. Gland Nut (B02-13-0096)
4. Seal, Gland Nut
5. O-Ring
6. Piston Rod
7. Wear Ring
B02-13-0097 Seal Repair Kit
(Includes items 2, 4, 5, & 7)
B02-03-0018 Complete
Hydraulic Cylinder Assembly
(Includes all items)
6
1
7
Figure 4-6. Hydraulic Cylinder Exploded View
4-10
4 — MAINTENANCE
4-4 ELECTRICAL SYSTEM
Regular maintenance is necessary to keep the electrical system in proper working order.
Check daily all electrical wires for cuts, broken wires, potential short circuits, and any other damage.
4-11
XLT-1571AC
4-5 LIFT CHAINS AND SLIDE BLOCKS
WARNING
Do not operate a unit on which any chain assembly is damaged or in need of replacement. Operating a unit with a damaged chain can cause severe injury or death to personnel and damage to equipment.
Inspect all lift chains daily. Inspect for signs of wear, split leaves, loose pins, clevis damage, and elongation. Replace any chain which is damaged in any way. Chain assemblies may be ordered from your dealer or direct from the factory. Do not operate a unit on which any chain assembly is damaged and in need of replacement.
Chain Elongation Inspection
One pitch of chain should measure 5/8 in. (1,5875 cm). Measure 20 pitches of chain. The ideal measurement for 20 pitches of chain should be 12.5 in. (31,75 cm). Replace the chain if 20 pitches measure over 12.75 in. (32,385 cm). Refer to Figure 4-7.
5/8 IN. (1,5875 CM) PITCH
20 PITCHES = 12.5 IN. (31,75 CM)
REPLACE CHAIN IF 20 PITCHES MEASURES
OVER 12.75 IN (32,385 CM)
Figure 4-7. Chain Elongation Inspection
NOTE: It is recommended that chains be replaced every four years unless damage or wear requires replacement at a lesser interval.
4-12
4 — MAINTENANCE
Lift Chain Adjustment
1. 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.
2. After the platform is completely lowered, remove the plexiglass cover from the base.
3. Chains should be tight to the touch with no loose play. Check all four lift chains for snugness. If a chain is loose, tighten the lock nut below the clevis retainer.
Refer to Figure 4-8. Adjust any loose chain until it just becomes snug. Do not overtighten any chain so that the platform is raised from its resting position.
4. Make sure the lock nuts are turned onto the threaded clevis ends with at least
1/8 in. of the clevis end extending through the nut. Replace any lock nut which does not stay in position during use. Replace the plexiglass cover.
LIFT
CHAINS
CLEVIS
LIFT
CHAINS
CLEVIS
LOCK
NUT
Figure 4-8. Lift Chain Adjustment
LOCK
NUT
4-13
XLT-1571AC
Slide Block Adjustment
Annually check for wear on the slide blocks and replace or retighten as necessary. If the lift exhibits excessive mast sway, it is probable that the slide blocks need adjustment. The slide blocks should be adjusted so that there is no air gap between the slide block and the mast the slide block is moving against. There are 12 slide blocks, 6 upper and 6 lower.
The adjustment procedure is the same for all slide blocks. Three upper slide blocks are shown in Figure 4-9.
1. Loosen, do not remove, the slotted hex head screw securing the slide block to be adjusted.
2. Using an allen wrench, turn the set screws in (clockwise). This will push the block in against the next mast. Do not overtighten. Tighten the slotted hex head screw to secure the slide block in position.
3. Check all slide blocks and make adjustments as necessary.
4. After all adjustments are made, fully extend the lift. If the platform can be lowered without stopping then the blocks are properly adjusted.
SLIDE
BLOCKS
SET
SCREWS
SLOTTED
HEX SCREW
Figure 4-9. Slide Block Adjustment
NOTE:
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 be taken to ensure that the paths along which the blocks move are kept clean and lightly lubricated with a dry type silicon lubricant.
4-14
4 — MAINTENANCE
4-6 TROUBLESHOOTING
Table 4-3. Troubleshooting Chart
Problem Cause Correction
WHEEL UP
/
BASE SET button will not light. a. Base not firmly set on footpads.
WHEEL UP
/
BASE SET button raising front casters. This allows lift to firmly set on footpads. b. Check incoming power line. c. Burned out bulb. d. Lift is out of level. e. Broken or loose wire.
UP switch is selected, motor runs but unit will not lift a load.
3. Masts have excessive sway when fully extended. a. More than 500 lbs. on platform. b. N.O. (Normally Open) valve is not being energized. c. Emergency lowering valve is open. d. Mast sections are dirty. a. Plastic slide blocks are out of adjustment. d. Level lift with two adjusting foot pads or relocate lift to level surface. e. Repair or replace wire. a. Ensure load is 500 lbs. or less. b. Check voltage at N.O. valve. If no voltage, check for loose or broken wire. If voltage, ensure at least 9 volts for start solenoid operation. Check battery and start solenoid. Repair or replace as needed. c. Close emergency lowering valve. d. Clean and lubricate masts with dry silicone. a. Refer to Slide Block Adjustment in section 4-5.
*NOTE: Smart start solenoid will not engage if voltage is low.
4-15
XLT-1571AC
Table 4-3. Troubleshooting Chart, Continued
Problem Cause Correction
4. Pump/motor will not run when
UP is selected. a.
EMERGENCY STOP
(pushed in). button is activated
EMERGENCY STOP button counterclockwise to de-activate. not lit.
WHEEL UP
/
BASE SET button is c. Motor start relay is not activating. d. Motor start relay is activating, but motor does not run. b. Refer to Problem 1. c. Check voltage at white wire on motor start relay. If voltage, replace defective motor start relay. If no voltage, check for loose or broken wire. Repair or replace wire. d. Check hydraulic gear pump for seizure. If seized, replace pump. If not, check motor. Motor may need replacement.
5. Hydraulic cylinder leaks at gland nut. a. Loose gland nut. e. Check incoming power line. a. Tighten gland nut. b. Replace seals in hydraulic cylinder.
Refer to Hydraulic Cylinder Repair, in section 4-3.
*NOTE: Smart start solenoid will not engage if voltage is low.
4-16
5
Replacement Decals
Refer to Table 5-1, and Figures 5-1, 5-2, and 5-3 for descriptions and locations of decals on the Cougar Lift.
Table 5-1. Replacement Decals
Decal No.
B06-00-0003
B06-00-0167
B06-00-0170
B06-00-0173
Description of Decal
Bil-Jax ID Number (Not available as replacement part)
Striped Safety Tape - On all four sides (per roll only)
Maximum Capacity...500 lb. Or...
Safety Belt Lanyard Attachment Point
B06-00-0192 Operation And Service Manual Inside
B06-00-0228 Serial Number Tag (Not available as replacement part)
B06-00-0289 Check level with cage fully down
B06-00-0291 Warning...Level machine before use
B06-00-0295 Danger...Failure To Comply With The Following...
B06-00-0306 Warning...Stand clear when lowering lift onto the foot pads... 2
1
B06-00-0339BLT Warning...Body Belt and Lanyard... 1
B06-00-0349 Operation Instructions for Battery Charger
B06-00-0350 Operation Instructions for Stockpickers
1
1
2
1
1
1
2
1
1
2
1
1
1
4
2
Qty
1
2
1
2
1
5-1
XLT-1571AC
B06-00-0350
B06-00-0306
B06-00-0228
B06-00-0170
Fall protection equipment must be used at all times during operation.
Failure to wear fall protection equipment may allow operator to fall from platform resulting in serious
UTT/ATT
B06-00-0339BLT
B06-00-0339BLT
B06-00-0034
B06-00-0339
B06-00-0349
B06-00-0295
5-2
B06-00-0138
B06-00-0146
B06-00-0173
B06-00-0286
B06-00-0175
B06-00-0106
B06-00-0455
B06-00-0289
B06-00-0291
B06-00-0192
Figure 5-1. Replacement Decals
B06-00-0009
STAY CLEAR
WHILE RAISING
OR LOWERING
CCFO
B06-00-0225
B06-00-0225
0173
0455
0106
XL
T
1
5
7
1
5 — REPLACEMENT DECALS
0009
WA
RN
ING
DANGER
WARNING
0146
0170
0339 OR 0339BLT
0173
0192
WA
RNIN
G
0291
0170
WA
RNIN
G
0225
0306
Figure 5-2. Decal Locations, Side View
0167
(
AROUND COMPLETE
BASE ON ALL SIDES
)
5-3
XLT-1571AC
0228
0009
WARNING
0295
0455
0138
0350
DANGER
CA
UTIO
N
WARNING
0175
0106
XL
T
1
5
7
1
DANGER
0034
(
0349
INSIDE
DOOR
0286
)
(
0003
ON CHARGER
INSIDE
)
(
0167
AROUND COMPLETE
BASE ON ALL SIDES
)
(
0289
ON RESERVOIR
INSIDE
)
Figure 5-3. Decal Locations, Front View
5-4
6
Parts List
6-1
XLT-1571AC
3
5
4
2
6-1 TOP MAST PARTS LIST
Refer to Table 6-1 for the parts list for the top mast.
1
20
6
22
21
15
27
26
16
20
24 23
26
ON
7
UP
0
21
28
3
25
28
27
17
8
18
9
19
10
11
6-2
12
13
14
Figure 6-1. Top Mast Exploded View
6 — PARTS LIST
Item No.
1
2
5
6
7
8
12
13
14
15
16
17
18
20
24
26
27
Part No.
0090-0181
0090-0813
Table 6-1. Top Mast Parts List
Description
B16-01-0024 Top Mast Weldment
0090-0014 Screw, 1/4-20 x 2-1/4 in.
B01-02-0059 Box, Control, Upper
B40-00-0003 Cable, 3/16 in.
0090-0389
0090-0403
0090-0159
B19-00-0001
B00-00-0017
B01-02-0003
B01-02-0004
Nut, Lock, 8-32
Screw, 8-32 x 3/4 in.
Screw, Adjustment, 1/2-20 x 1/2 in.
Screw, #10 x 1 in.
B31-00-0001 Slide Block, Plastic
0090-0206 Washer, Lock, 1/4 in.
Nut, Hex, 1/4-20
B01-09-0029 Bushing, Strain Relief
B05-01-0034 Cable, SJO, 18-2
Box Only, 3-Position
Plate, Stop, Emergency
Button, Push, Flush
Button, Stop, Emergency
* B03-00-0009 Chain Assy, includes items 9, 10, 11, and 19
*NOTE: It is recommended that chain parts be purchased as an assembly.
2
2
2
2
2
80 in.
2
1
4
2
1
1
Qty
1
2
3
1
3
3
1
1
2
2
2
4
1
1
1
1
1
6-3
XLT-1571AC
6-2 CENTER MAST PARTS LIST
Refer to Table 6-2 for the parts list for the center mast.
2
4
5
4
3
1
8
6
7
6-4
9
10
16
8
17
11
12
13
13
15
6 16
19
20
3
7
15
14
15
16
21
13
18
13
15
16
4
22
4
Figure 6-2. Center Mast Exploded View
6 — PARTS LIST
Item No.
1
2
4
5
6
7
8
9
13
15
18
0090-0425
0090-0389
0090-0403
0090-0042
0090-0210
0064-0363
Table 6-2. Center Mast Parts List
Part No.
B26-00-0009
Description
B16-01-0020 Center Mast Weldment
0090-0770 Pin, Cotter 3/16 x 1-1/2 in.
Washer, 5/8 in.
Chain Sheave Assembly
Screw, Adjustment, 1/2-20 x 1/2 in.
Screw, #10 x 1 in.
B31-00-0001 Slide Block, Plastic
B40-00-0003 Cable, 3/16 in.
Bolt, 3/8-16 x 1 in.
Washer, Lock, 3/8 in.
Actuator, Limit Switch
* B03-00-0009 Chain Assy, includes items 10, 11, 12, and 17
*NOTE: It is recommended that chain parts be purchased as an assembly.
7
1
7
7
1
1
1
1
1
1
1
Qty
1
2
3
6
2
8
4
4
1
2
2
2
6-5
XLT-1571AC
6-3 LOWER MAST PARTS LIST
Refer to Table 6-3 for the parts list for the lower mast.
4
5
4
2
6
7
3
8
9
10
11
16
1
15
12
13
14
6-6
11
9
10
17
17
19
19
22
24
21
18
18
3
4
20
17
18
Figure 6-3. Lower Mast Exploded View
4
19
23
6 — PARTS LIST
Item No.
1
2
4
5
6
7
9
10
11
16
17
18
Part No.
0090-0425
0090-0188
0090-0422
0090-0389
0090-0403
Table 6-3. Lower Mast Parts List
Description
B16-01-0021 Lower Mast Weldment
0090-0770 Pin, Cotter 3/16 x 1-1/2 in.
Washer, Flat, 5/8 in.
B26-00-0009 Chain Sheave Assembly
Nut, Lock, 3/8-16
Washer, Flat, 3/8
B31-00-0001 Slide Block, Plastic
0090-0192
0090-0042
0090-0210
Screw, Adjustment, 1/2-20 x 1/2 in.
Screw, #10 x 1
Nut, Lock, 1/2-13
Bolt, 3/8-16 x 1 in.
Washer, Lock, 3/8 in.
* B03-00-0009 Chain Assy, includes items 12, 13, 14, and 15
*NOTE: It is recommended that chain parts be purchased as an assembly.
2
6
6
2
2
2
6
1
1
1
1
1
1
Qty
1
2
3
6
2
1
1
1
8
4
4
2
6-7
XLT-1571AC
6-4 REAR COMPARTMENT PARTS LIST
Refer to Table 6-4 for the parts list for the rear compartment.
1
6-8
10
11
12
8
9
2
3
14
4
5
7
6
Figure 6-4. Rear Compartment Exploded View
14
13
Item No.
2
Table 6-4. Battery Compartment Parts List
Part No.
0090-0344
Description
Screw, Threadcut, 10-24 x 1/2 in.
7
8
9
4
5
6
10
11
0090-0813 Screw, 8-32 x 3/4 in.
B19-00-0022 Box, Black, TomCat
0090-0415 Washer, Flat, #10
0090-0181 Nut, Lock, 8-32
B18-00-0026 Cover, (with screws)
(part of 8) Screw
0090-0125
0090-0206
Bolt, Carriage, 1/4-20 x 1-1/4 in.
Washer, Lock, 1/4 in.
6 — PARTS LIST
Qty
1
2
1
4
1
4
4
1
2
1
1
1
1
1
6-9
XLT-1571AC
6-5 HYDRAULIC PUMP COMPARTMENT PARTS LIST
Refer to Table 6-5 for the parts list for the hydraulic pump compartment.
6-10
1
2
3
3
6
5
4
8
13
2
12
11
10
13
Figure 6-5. Hydraulic Pump Compartment Exploded View
9
5
7
Item No.
Table 6-5. Hydraulic Pump Compartment Parts List
Part No. Description
6 — PARTS LIST
2
3
4
5
6
7
10
13
B05-00-0006 Tape, Foam Adhesive
0090-0183
0090-0005
0090-0419
B29-00-0116
0090-0014
0090-0040
Nut, Lock, 1/4-20
Bolt, 1/4-20 x 3/4
Washer, Flat, 1/4 in.
Bracket, Hydraulic Valve
Bolt, 1/4-20 x 2-1/2 in.
Bolt, 3/8-16 x 3/4 in.
Qty
1
2 ft.
6
2
4
1
2
1
1
2
2
2
1 B18-00-0026 Cover, (with 2 screws)
6-11
XLT-1571AC
11
6-6 UPPER BASE PARTS LIST
Refer to Table 6-6 for the parts list for the upper base.
1
2
3
4
5
4
10
DANGER
CA
UTI
ON
WARNI
NG
6
2
6
6
7
6-12
9
12
23
24
8
22
21
19
18
13
14
17
12
15 16
17
EE
L D
OWN
OLLS
WH
BASE R
L U
P
WH
EE
BASE SET
20
19
18
Figure 6-6. Upper Base Exploded View
16
17
18
19
20
11
12
13
14
15
Item No.
2
3
4
5
Part No.
Table 6-6. Upper Base Parts List
Description
0090-0344 Screw, Threadcut, 10-24 x 1/2 in.
B07-01-2003 Edge, Top Cover
B05-00-0006 Tape, Foam Adhesive
B18-00-0108 Plexiglass, 1/8 in.
7
8
B01-02-0058 Box, Control, Lower
0090-0813 Screw, 8-32 x 3/4 in.
23
24
0090-0181
B19-00-0001
B01-02-0004
B00-00-0017
B01-10-0001 Receptacle, Female, 3-Wire
B04-07-0012 Nut, Elec. Drive, 1/2”
Nut, Lock, 8-32
Box Only, 3-Position
B01-02-0029 Socket, Light, Contact with
B01-10-0042 Light Bulb, 12v
B00-00-0091 Plate, Wheel Down
B00-00-0092 Plate, Wheel Up
B01-02-0028 Button, Push, Lighted
B01-02-0003 Button, Push, Flush
Button, Stop, Emergency
Plate, Stop, Emergency
6 — PARTS LIST
1
1
1
1
1
1
1
1
1
1
1
1
Qty
1
8
1
32 in.
1
3
1
2
1
1
2
1
6-13
XLT-1571AC
1
2
3
4
5
6-7 BASE MAST PARTS LIST
Refer to Table 6-7 for the parts list for the base mast.
6
19
13
9
10
11
12
14
7
15
16
17
18
21
20
22
6-14
23
26
21
27
Figure 6-7. Base Mast Exploded View
20
8
25
24
6 — PARTS LIST
Item No.
1
2
4
5
6
8
10
13
14
15
16
17
18
19
20
23
24
25
Part No.
0090-0188
0090-0422
0090-0389
0090-0403
Table 6-7. Base Mast Parts List
Description
Nut, Lock, 3/8-16
Washer, Flat, 3/8 in.
Screw, Adjustment, 1/2-20 x 1/2 in.
Screw, #10 x 1 in.
B31-00-0001 Slide Block, Plastic
0090-0684
0090-0860
0090-0192
0090-0071
0090-0212
0090-0166
0090-0185
0090-0344
0090-0043
0090-0219
0090-0162
Rivet, Pop, 3/16 x 1/2 in.
Pin, Cotter, 1.6 mm
Nut, Lock, 1/2-13
Bolt, 1/2-13 X 2-1/2 in.
Washer, Lock, 1/2 in.
Nut, Hex, 1/2-13
B02-03-0018 Cylinder, Hydraulic Lift, 1.5 in. Diameter
0090-0654 Clamp, U-bolt, 5/16-18 x 2-1/2 x 2-5/8
Nut, Lock, 5/16-18
Screw, Threadcut, 10-24 x 1/2
Bolt, 3/8-16 x 1-1/4
Washer, Lock, 3/8
Nut, Hex, 3/8-16
27
*
0090-0498
B03-00-0009
Washer, Flat, 3/16 in.
Chain Assy, includes items 9, 10, 11, and 12
*NOTE: It is recommended that chain parts be purchased as an assembly.
1
1
1
2
1
1
2
2
2
1
2
2
2
1
2
1
Qty
1
1
1
4
2
2
1
2
2
2
2
2
6-15
XLT-1571AC
6-8 LOWER BASE PARTS LIST
Refer to Table 6-8 for the parts list for the lower base.
2
1
5
4
6-16
32
33
24
25
3
6
29
27
26
30
31
15
28
10
11
14
3
10
17
16
9
8
7
12
24
25
21
19
20
22
23
Figure 6-8. Lower Base Exploded View
18
13
Item No.
1
3
5
6
8
10
11
Part No.
0090-0344
0090-0344
0090-0195
Table 6-8. Lower Base Parts List
Description
Screw, Threadcut, 10-24 x 1/2 in.
Screw, Threadcut, 10-24 x 1/2 in.
B01-01-0123 Cable Assembly, Mast Switch
B01-03-0040 Switch, Limit, Mast
Washer, Flat, 3/4 in.
B04-07-0032 Clamp, Cable, DG-6
B01-01-0122 Cable Assembly, Foot Switch
19
20
21
22
23
24
14
15
16
17
18
25
26
27
28
29
B01-03-0039 Foot Switch Assembly
0090-0183 Nut, Lock, 1/4-20
0090-0049
0090-0188
Bolt, 3/8-16 x 2-1/4 in.
Nut, Lock, 3/8-16
B02-03-0010 Cylinder, Hydraulic Wheel
0090-0054
0090-0188
Bolt, 3/8-16 x 3-1/2 in.
Nut, Lock, 3/8-16
B11-01-0073 Arm Weldment, Hydraulic Cylinder
B08-01-0019 Caster, Rigid, 6 in.
0090-0042 Bolt, 3/8-16 x 1 in.
0090-0210 Washer, Lock, 3/8 in.
0090-0162
0090-0183
Nut, Hex, 3/8-16
Nut, Lock, 1/4-20
B04-07-0035 Clamp, Cable, DG-14
0090-0463
0090-0192
Bolt, 1/2-13 x 4 in.
Nut, Lock, 1/2-13
31
32
33
0090-0005 Bolt, 1/4-20 x 3/4
B08-01-0002 Caster, 8 in.
B01-01-0113 Plug, Level Sensor
6 — PARTS LIST
2
8
16
1
1
1
1
1
1
2
1
2
Qty
4
1
6
2
1
1
2
2
2
3
1
2
2
2
1
16
3
3
2
2
1
6-17
XLT-1571AC
6-9 PLATFORM PARTS LIST
Refer to Table 6-9 for the parts list for the platform.
12
1
22
19, 20
18
21
2
16
4
15
6
17
7
3
10
8
9
11
14
13
14
5
6-18
Figure 6-9. Platform Exploded View
Item No.
2
3
Part No.
0090-0051
0090-0210
Table 6-9. Platform Parts List
Description
Bolt, 3/8-16 x 2-3/4 in.
Washer, Lock, 3/8 in.
9
10
12
16
18
19
21
22
0090-0802
0090-0182
0090-0048
0090-0042
Screw, 10-24 x 7/8 in.
Nut, Lock, 10-24
Bolt, 3/8-16 x 2 in.
Bolt, 3/8-16 x 1 in.
B05-00-0001 Tube, Foam, 13-1/2 in.
B00-00-0086 Tube, Split, 8-1/2 in.
B06-00-0167 Tape, Strip, 43 in.
B00-00-0014 Cap, Manual Tube
6 — PARTS LIST
2
4
1
2
1
2
4
12
2
2
Qty
1
4
8
8
2
1
1
1
3
3
1
2
6-19
XLT-1571AC
6-10 HYDRAULIC UNIT PARTS LIST
6-20
Figure 6-10. Hydraulic Unit Assembly
6 — PARTS LIST
Item No.
1
3
5
Table 6-10. Hydraulic Unit Parts List
Part No. Description
B02-15-0088 Bolt, 5/16-24 x 2.75 Torx
B02-02-0087
B02-15-0091
7 NA
Plug, #6 ORM
Seal, Shaft
16
18
19
20
11 B02-15-0126 Screw, Taptite, M6 x 1.0, 12 mm Torx
12 NA
13
14
B02-15-0197 Valve, Check, Cartridge
B02-15-0170 Bolt, 5/16-18 x 1.00
22
B02-15-0382 Bolt, M6 x 1.0
B02-15-0199 Bolt, 12-24 x 0.50 Hex
B02-15-0206 Tank, Horizontal Mount, Plastic with Drain
B02-15-0201 Breather Cap, with Check Valve
B01-09-0041 Plug Connector Hirschmann
26
29
30
33
36
37
38
B02-15-0361
B02-15-0146
B02-15-0030
Coil, Solenoid, 115VAC
Pump Assembly, 1.2
Cap Assembly, Relief
B02-15-0204 Plug, 1/16 NPT Flush
34 B02-15-0205
°
B02-15-0357 Valve, Cartridge NC
B02-15-0351 Valve Body, 2 Way NO
B02-15-0026 Screw, Valve Adjustment
1
1
1
4
4
4
1
1
1
2
1
1
2
1
1
1
1
1
12
″
1
1
2
1
2
2
Qty
2
1
1
1
1
1
1
1
1
3
6-21
3
2
4
XLT-1571AC
6-11 HYDRAULIC FITTINGS AND HOSES DIAGRAM
17
18
16
15
14
20
13
G
L
A
W
B
19
1
G
L
A
W
B
11
12
5
9
7
P
T
7
2
2
5
8
10
8
6
Figure 6-11. Hydraulic Fittings and Hoses Diagram
6-22
6 — PARTS LIST
Table 6-11. Hydraulic Fittings and Hoses Parts List
Item No. Part No. Description
1 B02-03-0018 Cylinder, Hydraulic Lift, 1.5 in. Diameter
2 B02-02-0002
°, 2501-4
3 B02-04-0002 Valve, Flow Control, 1.25 in.
4 B02-02-0041
°
5 B02-01-0110 Hose, Hydraulic, 22 in., 4M3K W/2 4-4FJX
14
15
16
17
18
8
9
6 B02-05-0011 Pump, Hydraulic, Standard AC
7 B02-02-0072
°, 6801-4-6
10
11
B02-01-0113
B02-01-0124
B02-03-0010
B02-04-0047
Hose, Hydraulic, 80 in., 4M3K W/2 4-4FJX
Hose, Hydraulic, 15 in., 4M3K W/2 4-4FJX
Cylinder, Hydraulic Wheel
Manifold Block, Hydraulic
12
13
B02-02-0163 Fitting, 4JIC-6ORM Nip
B02-04-0047 Valve, Combination (for Stockpickers and
Tom Cats)
B02-14-0036 Valve, Needle, Emergency Down
B02-14-0038
B01-08-0002
B02-14-0037
B01-08-0011
Valve, Cartridge, NC, Lift Cylinder
Coil, 12v, Lift
Valve, Cartridge, NC, Wheel Cylinder
Coil, 12v, Wheel
20 B02-02-0194 Plug, SAE 4
Qty
1
3
1
1
1
2
2
5
1
2
1
1
1
1
1
1
1
1
1
3
6-23
XLT-1571AC
6-12 HYDRAULIC FITTINGS AND HOSES SCHEMATIC
6-24
Figure 6-12. Hydraulic Fittings and Hoses Schematic
6 — PARTS LIST
6-13 ELECTRICAL DIAGRAM
1571/1071 Schematic
110v
Flush Mt
Recp.
AC
Switcher
Board
Lower
Control
T2
T6
E-Stop Wheel Up
T12
Wheel
Down
T
17
T4
Wheel
Set
Lower Lift
Option
UP
E-Stop ON Down
T
13
T
15
T13
R1 R2
Terminal No. Wire Color
1 BLK
BLK
2 BLK
BLK
3 WHT
4 BRN/BLK STR
5 RED
6 YEL/BLK STR
7
8 BLK
9 BLK
10 RED
BLU
GRN
W
Motor
Start
Sol
T10
E-Stop
Upper
Control
ON UP
E-Stop ON Down
R2
T4
T
13
T
15
T1
Mast
Switch
T
12
R2
Foot Switches
R3
T3
Level
Sensor
T17 R2
R W
B
T15
R 3
T7
Beeper
NC
Light
T9
Lift
Valve
T6
NO
Valve
T5
T8
Down
ValvePump
Wheel
Valve
Terminal Connections for Black Box
From Terminal No.
Mast Down Limit Switch
Upper Control Box
Lower Control Box
Right Foot Limit Switch
Hydraulic Pump Motor
Wire Color
11 RED
13
WHT
12 WHT
ORG/BLK STR
Lower Control Box 14
WHT
YEL
Lower Control Box
15 GRN
RED/BLK STR
16
17 WHT
RED
Hydraulic Pump Motor
Upper Control Box
Lower Control Box
Hydraulic Pump Motor
18
19 GRN
WHT
BLK
20 BRN
BLK
Figure 6-13. Electrical Diagram
From
Level Sensor
Left Foot Limit Switch
Mast Down Limit Switch
Lower Control Box
Upper Control Box
Lower Control Box
Upper Control Box
Lower Control Box
Level Sensor
Lower Control Box
Hydraulic Manifold
Hydraulic Manifold
Level Sensor
Lower Control Box
Base Ground
6-25
XLT-1571AC
6-26
Figure 6-14. Electrical Layout Diagram
7
ANSI Reprint
The following sections are reprinted from the ANSI A92.3-1990 code in effect at the time of manufacture. Permissi on 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 conside ration 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 locat ion 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 brak es, blocks, or other means. (2) Powerplant stopped and starting means rendered inoperativ e
(3) Platform lowered to the full down position, if possible, or otherwise secured by blocking or cribbing to prevent dropping (4) Hydraulic oil pressure reli eved 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 aeria l platform, the dealer shall ensure that the individual has been trained under the dire ction of a qualified person in accordance with the manufacturer's operating and maintenance man ual 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 f or other beneficial use, the dealer shall ass ume the responsibilities of users as specified in
Section 7 and the operating personnel shall 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, maintenan ce, 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.
7-1
XLT-1571AC
7-2
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.
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 aerial 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 manufacturer for an annual inspection.
7 — ANSI REPRINT
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.
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 shall be provided upon each delivery, by sale, lease, or rental.
6.10 Operation. When an owner operates an aerial platform, the owner shall 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 user'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.
7-3
XLT-1571AC
7-4
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 repairs shall be in conformance with the manufacturer's recommendations.
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.
7.3.4 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 (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 — ANSI REPRINT
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) Determine that the purpose for which the aerial platform is to be used is within the scope of the intended applications defined by the manufacturer (5) Been provided with approved fall protection devices and other safety gear for all personnel on the platform (see 4.9.5).
7.8 Work Place Inspection. Before the aerial platform is used and during use, the user shall check the area in which the aerial platform is to be used for possible hazards such as, but not limited to: (1) Drop-offs or holes (2) Bumps and floor obstructions (3)
Debris (4) Overhead obstructions and high voltage conductors (5) Hazardous locations
(6) Inadequate surface and support to withstand all load forces imposed by the aerial platform in all operating configurations (7) Wind and weather conditions (8) Other possible unsafe conditions (9) Presence of unauthorized persons.
7.9 During Operation. The aerial platform shall be used in accordance with this standard. The user shall direct the operator to ensure the following before each elevation of the platform: (1) That the aerial platform is operated on a surface within the limits specified by the manufacturer (2) That the outriggers, stabilizers, extendable axles, or other stabilizing methods are used as required by the manufacturer (3) That guardrails are installed and access gates or openings are closed per manufacturer's instructions (4)
That the load and its distribution on the platform and any platform extension are in accordance with the manufacturer's rated capacity for that specific configuration (5)
That there is adequate clearance from overhead obstructions (6) That the minimum safe approach distances (MSAD) to energized power lines and parts, as listed in Table One are maintained. See Figure 2 for examples of safe operating procedures (7) That the precautions defined in 7.3.3, 7.6, 7.7, 7.8, 7.9, 7.10 and 7.11 of this standard are followed during operation of the aerial platform.
7.10 Determination of Hazardous Locations. It shall be the responsibility of the user to determine the hazard classification of any particular atmosphere or location according to ANSI/NFPA 505-1987. Aerial platforms operated in hazardous locations shall be approved in accordance with, and of the type required, by ANSI/NFPA 505-1987.
7.11 Warnings and Instruction. The user shall direct his operating personnel and supervise the work to ensure operation in compliance with the requirements in 7.11.1 through 7.11.14.
7.11.1 Personnel Footing. Personnel shall maintain a firm footing on the platform floor while working thereon. Use of planks, ladders, or any other device on the aerial platform for achieving additional height or reach shall be prohibited.
7.11.2 Other Moving Equipment. When other moving equipment or vehicles are present, special precautions shall be taken to comply with local ordinances or safety standards established for the workplace. Warnings such as, but not limited to, flags, roped-off areas, flashing lights, and barricades shall be used.
7.11.3 Reporting Problems or Malfunctions. The operator shall immediately report to the supervisor any problems or malfunctions that become evident during operation. Any problems or malfunctions that affect the safety or operations shall be repaired prior to continued use of the aerial platform.
7.11.4 Altering Safety Devices. Altering or disabling of interlocks or other safety devices shall be prohibited.
7.11.5 Entanglement. Care shall be taken to prevent rope, electric cords, hoses, etc., from becoming entangled in the aerial platform.
7.11.6 Capacity Limitation. Aerial platform rated capacities shall not be exceeded when loads are transferred to the platform at any height.
7.11.7 Work Area. The operator shall ensure that the area surrounding the aerial platform is clear of personnel and equipment before lowering the platform.
7-5
XLT-1571AC
7-6
7.11.8 Fueling. The engine shall be shut down while fuel tanks are being filled.
Fueling shall be done in a well-ventilated area free of flame, sparks, or other hazards that may cause fire or explosion.
7.11.9 Battery Charging. Batteries shall be charged in a well-ventilated area free of flame, sparks, or other hazards that may cause fire or explosion.
7.11.10 Platform Positioning. The aerial platform shall not be positioned against another object to steady the platform.
7.11.11 Misuse as a Crane. The aerial platform shall not be used as a crane.
7.11.12 Operating Areas. The aerial platform shall not be operated from a position on trucks, trailers, railway cars, floating vessels, scaffolds, or similar equipment, unless the application is approved in writing by the manufacturer.
7.11.13 Travel Conditions. Under all travel conditions, the operator shall limit travel speed according to conditions of ground surface, congestion, visibility, slope, locations of personnel, and other factors causing hazards of collision or injury to personnel.
7.11.14 Unauthorized Use. Means shall be used to protect against use by unauthorized person(s).
7.12 Operation of the Aerial Platform. If a user is also the operator of an aerial platform, the user shall have the responsibilities of operators specified in Section 8 of this standard as well as responsibilities of users as specified in Section 7 of this standard.
7.13 Assistance to Operator. If a user is unable to answer any operator's questions relating to rated capacity, intended use, maintenance, condition, or safety of operation of the aerial platform, the user shall obtain the proper information from the dealer, owner, or manufacturer and provide that information to the operator before use of the aerial platform in the application of concern.
7.14 Shutdown of Aerial Platform. The user shall authorize and direct the operating personnel to cease operation of the aerial platform in case of any suspected malfunctions of the aerial platform, or any hazard or potentially unsafe condition that may be encountered, and to request further information as to safe operation from the owner, dealer, or manufacturer before further operation of the aerial platform.
7.15 Record Retention. The user shall retain the following records for at least 3 years:
(1) Records of the operator(s) trained on each model of an aerial platform (2) Written records of the frequent and annual inspections shall be kept by the user when performing the inspections. The records shall include the date of inspection, any deficiencies found, the corrective action recommended and identification of the person(s) performing the inspection (3) Written records of all repairs accomplished on the aerial platform, including the date of any such repair, a description of the work accomplished, and the identification of the person(s) performing the repair.
7.16 Modifications. A user shall not modify or concur in modification of an aerial platform without the specific written approval of the manufacturer of the aerial platform.
7.17 Manufacturer's Safety Bulletins. The user shall comply with safety-related bulletins as received from the manufacturer, dealer, or owner.
8. Responsibilities of Operators
8.1 Basic Principles. The information in this standard shall be supplemented by good judgment, safety control, and caution in evaluating each situation. Since the operator is in direct control of the aerial platform, conformance with good safety practices in this area is the responsibility of the operator. The operator shall make decisions on the use and operation of the aerial platform with due consideration for the fact that his or her own safety as well as the safety of other personnel on the platform is dependent on those decisions.
8.2 Manuals. The operator shall be aware that the operating safety manuals, including the manual that defines the responsibilities of dealers, owners, lessors, lessees, users, and operators are stored on the aerial platform and the location where they are stored. The
7 — ANSI REPRINT
operator shall be familiar with the manuals stored on the aerial platform and consult them when questions arise with respect to the aerial platform.
8.3 Prestart Inspection. Before use each day or at the beginning of each shift, the aerial platform shall be given a visual inspection and functional 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.
8.4 Problems or Malfunctions. Any problems or malfunctions that affect the safety of operations shall be repaired prior to the use of the aerial platform.
8.5 Training. The operator shall have been trained either on the same model of aerial platform or one having operating characteristics and controls consistent with the one to be used during actual work site operation. The operator trainee shall operate the aerial platform in an area free of obstructions under the direction of the 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.
8.6 Before Operation. Before being authorized to operate the aerial platform, the operator shall have: (1) Been instructed by a qualified person in the intended purpose and function of each of the controls (2) Read and understood the manufacturer's/owner's operating instructions and safety rules, or been trained by a qualified person on the contents of the manufacturer's/owner's operating instructions and safety rules (3)
Understood by reading or by having a qualified person explain all decals, warnings, and instructions displayed on the aerial platform.
8.7 Workplace Inspection. Before the aerial platform is used and during use, the operator shall check the area in which the aerial platform is to be used for possible hazards such as, but not limited to: (1) Drop-offs or holes (2) Bumps and floor obstructions (3) Debris (4) Overhead obstructions and high voltage conductors (5)
Hazardous locations (6) Inadequate surface and support to withstand all load forces imposed by the aerial platform in all operating configurations (7) Wind and weather conditions (8) Other possible unsafe conditions.
8.8 During Operation. The aerial platform shall be used in accordance with this standard. The operator shall ensure the following before each elevation of the platform:
(1) That the aerial platform is operated on a surface within the limits specified by the manufacturer (2) That the outriggers, stabilizers, extendable axles, or other stability enhancing means are used as required by the manufacturer (3) That the guardrails are installed and access gates or openings are closed per manufacturer's instructions (4) That the load and its distribution on the platform and any platform extensions are in accordance with the manufacturer's rated capacity for that specific configuration (5) That there is adequate clearance from overhead obstructions (6) That the minimum safe approach distances (MSAD) to energized power lines and parts, as listed in Table One, are maintained. See Figure 2 for examples of safe operating procedures (7) That he or she and all other personnel on the platform are wearing fall protection devices and other safety gear as required at all times (see 4.9.5).
8.9 Determination of Hazardous Locations. It shall be the responsibility of the user to determine the hazard classification of any particular atmosphere or location according to
ANSI/NFPA 505.
8.9.1 Hazardous Location Operating Requirements. Aerial platforms operated in hazardous locations shall be approved and of the type required by ANSI/NFPA
505.
8.10 Warnings and Instructions. The operator and other personnel on the platform shall comply with the requirements in 8.10.1 through 8.10.17.
7-7
XLT-1571AC
7-8
8.10.1 Personnel Footing. Personnel shall maintain a firm footing on the platform floor while working thereon. Use of planks, ladders, or any other devices on the aerial platform for achieving additional height or reach shall be prohibited.
8.10.2 Other Moving Equipment. When other moving equipment or vehicles are present, special precautions shall be taken to comply with local ordinances or safety standards established for the workplace. Warnings such as, but not limited to, flags, roped off areas, flashing lights, and barricades shall be used.
8.10.3 Reporting Problems or Malfunctions. The operator shall immediately report to a supervisor any problems or malfunctions that become evident during operation. Any problems or malfunctions that affect the safety of operation shall be repaired prior to continued use of the aerial platform.
8.10.4 Reporting Potential Hazardous Locations. The operator shall immediately report to a supervisor any potential hazardous locations (environment) that become evident during operation.
8.10.5 Altering Safety Devices. Altering or disabling of interlocks or other safety devices shall be prohibited.
8.10.6 Entanglement. Care shall be taken to prevent rope, electric cords, hoses, etc., from becoming entangled in the aerial platform.
8.10.7 Capacity Limitation. Aerial-platform rated capacities shall not be exceeded when loads are transferred to the platform at any heights
8.10.8 Work Area. The operator shall ensure that the area surrounding the aerial platform is clear of personnel and equipment before lowering the platform.
8.10.9 Fueling. The engine shall be shut down while fuel tanks are being filled.
Fueling shall be done in a well-ventilated area free of flame, sparks, or other hazards that may cause fire or explosion.
8.10.10 Battery Charging. Batteries shall be charged in a well-ventilated area free of flame, sparks, or other hazards that may cause fire or explosion.
8.10.11 Platform Positioning. The aerial platform shall not be positioned against another object to steady the platform.
8.10.12 Misuse as a Crane. The aerial platform shall not be used as a crane.
8.10.13 Operating Areas. The aerial platform shall not be operated from a position on trucks, trailers, railway cars, floating vessels, scaffolds, or similar equipment, unless the application is approved in writing by the manufacturer.
8.10.14 Travel Conditions. Under all travel conditions, the operator shall limit travel speed according to conditions of ground surface, congestion, visibility, slope, location of personnel, and other factors causing hazards of collision or injury to personnel.
8.10.15 Unauthorized Use. Means shall be used to protect against use by unauthorized person(s).
8.10.16 Misuse as a Jack. The platform of the aerial platform shall not be used to jack the wheels off the ground unless the machine is designed for that purpose by the manufacturer.
8.10.17 Snagged Platform. If the platform or elevating assembly becomes caught, snagged, or otherwise prevented from normal motion by adjacent structure or other obstacles such that control reversal does not free the platform, all personnel shall be removed from the platform before attempts are made to free the platform using ground controls.
8.11 Assistance to Operator. If an operator encounters any suspected malfunction of the aerial platform, or any hazard or potentially unsafe condition relating to capacity, the operator shall cease operation of the aerial platform and request further information as to safe operation from management, or from the owner, dealer, or manufacturer, before further operation of the aerial platform.
8.12 Modifications. An operator shall not modify or concur in modification of an aerial platform without the specific written approval of the manufacturer of the aerial platform.
9. Responsibilities of Lessors
7 — ANSI REPRINT
9.1 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 responsibilities of lessors with due consideration of the knowledge that the unit shall be carrying personnel.
9.2 Lessor. A lessor is a person(s) or entity who leases, rents, loans, or otherwise provides an aerial platform to another party for the beneficial use of that party (the user).
A lessor may also be a dealer, owner, lessee, user, or operator.
9.2.1 Lessor as a Dealer. When a lessor uses the aerial platform as a dealer, the lessor shall have the responsibilities of dealers as specified in Section 5 of this standard.
9.2.2 Lessor as an Owner. When a lessor uses the aerial platform as an owner, the lessor shall have responsibilities of owners as specified in Section 6 of this standard.
9.2.3 Lessor as a User. When a lessor uses the aerial platform as a user, the lessor shall have the responsibilities of operators as specified in Section 8 of this standard.
10. Responsibilities of Lessees
10.1 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 responsibilities of lessees with due consideration of the knowledge that the aerial platform carries personnel.
10.2 Lessee. A lessee is a person(s) or entity to whom an aerial platform is provided by lease, rental, loan, or other arrangement. A lessee may also be a user or operator.
10.2.1 Lessee as a Dealer. When a lessee uses the aerial platform as a dealer, the lessee shall have the responsibilities of dealers as specified in Section 5 of this standard.
10.2.2 Lessee as an Owner. When a lessee uses the aerial platform as an owner, the lessee shall have the responsibilities of owners as specified in Section 6 of this standard.
10.2.3 Lessee as a User. When a lessee uses the aerial platform as a user, the lessee shall have the responsibilities of users as specified in Section 7 of this standard.
10.2.4 Lessee as an Operator. When a lessee uses the aerial platform as an operator, the lessee shall have the responsibilities of operators as specified in Section
8 of this standard.
7-9
XLT-1571AC
7-10
M.S.A.D. = Minimum Safe Approach Distance (See Table 7-1).
DENOTES PROHIBITED ZONE
• Do not allow machine, personnel, or conductive materials inside prohibited zone.
• Maintain M.S.A.D. from all energized lines and parts as well as those shown.
• Assume all electrical parts and wires are energized unless known otherwise.
Diagrams shown are only for purposes of illustrating M.S.A.D. work positions, not all work positions.
7 — ANSI REPRINT
Table 7-1. Minimum Safe Approach Distance (M.S.A.D.) to energized
(exposed or insulated) power lines and parts.
Voltage Range
(Phase to Phase)
0 to 300V
Over 300V to 50KV
Over 50KV to 200KV
Over 200KV to 350KV
Over 350KV to 500KV
Over 500KV to 750KV
Over 750KV to 1000KV
Minimum Safe Approach Distance
(Feet) (Meters)
Avoid Contact
10 3.05
15
20
25
35
45
4.60
6.10
7.62
10.67
13.72
7-11
XLT-1571AC
7-12
125 Taylor Parkway
Archbold, OH 43502

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Key features
- Maximum platform load of 500 lbs
- Extended platform height of 14 ft-10 in.
- Retracted platform height of 18-1/2 in.
- Platform dimensions of 29 in. w x 50 in. l x 42 in. h
- Base dimensions of 30-1/2 in. w x 71 in. l x 77 in. h
- Full extension time of 20 seconds empty, 32 seconds loaded
- Complete retraction time of 22 seconds empty, 22 seconds loaded
- Platform extension rate of 0.66 ft/sec empty, 0.42 ft/sec loaded
- Hydraulic system pressure of 1200 psi empty, 2100 psi loaded
- Power source of 110VAC, 60 Hz