Workforce XLT 1601E Electric Hydraulic Lift Platform Operation and Maintenance Manual

 © ~~ COUGAR LIFT
Electric Hydraulic Lift Platform
OPERATION AND MAINTENANCE
MANUAL FOR MODEL XLT-1601E
7 workforce
bil-jax inc.
A Member of the plettac Group
| AERIAL WORK PLATFORMS
| 125 TAYLOR PARKWAY
| ARCHBOLD, OH 43502 U.S.A.
ORDER PARTS FROM YOUR NEAREST AUTHORIZED DEALER:
Page 1 of 54
B33-01-0012-01
я
— TELESCOPIC PERSONNEL LIFTS
This equipment is designed and manufactured in compliance with the duties, responsibilities |
and standards set forth for manufacturers in the ANSI A92.3 standard in effect at the time of
manufacture. |
This equipment will meet or exceed applicable OSHA codes and ANSI A92.3 standards when
used inaccordance with sections 5, 6,7, 8,9, and 10 of ANSI A92.3 and all other manufacturer's
recommendations.
It 1s 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 operation of this
equipment.
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О
Aa me a A
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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,
Replace all chains. |
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 reti ghten 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 ны
where it rotates around the sheave axle. _
Lubricate chains with 40W oil. W
Adjust chains as described on page 14 of |
manual. | W
Check casters for wear on axles and swivel
raceways also be sure that wheels are not W
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 is on machine.
Replace hydraulic oil. 12
Check mast sway. 12
Load test with 300# or 400#. 12
Check for wear on outrigger jack threaded 12
rod.
BB
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O
TABLE OF CONTENTS
Specifications and Warranty ...................er merce annernana recaen. cesse .. 7
Operation Instructions ........ N cecccrrencen se 8
Description of Operation ......................... ee en earn eee 9
General Safety Instructions .........................ire EEE 10-13
Maintenance: Inspection .....................e..e eee 14-15
LUDTICAtION ………...…...…...…rcerecsrsearereenerrrsncrrsecrencerencrr 15
Hydraulics ............ A reece 15-16
Electrical een зенеееееееенененнннеее. 16-17
Annual Maintenance ................ er ——————— eee 17
Replacement Decals ............................... eeiaioneneanennananeeacarenenea enana. 18-19
General Assembly Photograph and Parts List ................. nenrearerenene 20-21
Hydraulic System. .............. AD eee 22
Hydraulic Cylinder Assembly and Parts List …… careresserases ee, 23:
— Hydraulic Unit Assembly and Parts List ............2e.e......c..... ere 24-25
Electrical System... anaversorseterscensecceneranra cena nedonase nacre canne .. 26
Control Assembly & Pump Wiring Diagram ce... vevoncrcesencenennencensenrsecness 27
AC Wiring Diagram essences eonenacannanenen nneenanenooencanenereneees 28
Damaged Equipment Policy . pananenecioneoonecine neon eee eee ene nono eee 30
ANSI A92.3 Reprint
Section 5 - Responsibilities of Dealers conraceceuee DE 31-32
Section 6 - Responsibilities of Owners ............. SA 32-33
Section 7 - Responsibilities of Users............... nonenennaconens 33-36
Section 8 - Responsibilities of Operators ....................... 36-38
Section 9 - Responsibilities of Lessors...................—..... 38-39
Section 10 - Responsibilities of Lessees .......2.............r........ 39
Electrical Safe Approach Distance ............. eer neenecneos 40
Material Safety Data Sheets............... eee eee e eee 41-48
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COUGAR LIFT ELECTRIC HYDRAULIC LIFT PLATFORM
Model No. XLT-1601E-(DC) (AC) Serial No.
Manufactured By: | Mailing Address:
Workforce Products, Inc. Workforce Products, Inc.
125 Taylor Parkway 125 Taylor Parkway
Archbold, Ohio 43502 | Archbold, Ohio 43502
U.S.A.
Telephone: (419) 445-9675
SPECIFICATIONS:
Rated Platform Load: 400# Total Including Operator (1 Person + Tools Not To Exceed 400 Ibs.)
181 kg Total Including Operator (1 Person + Tools Not To Exceed 181 kg)
Extended Platform Height: 16-0" (4.9m) |
Retracted Platform Height: 6'-6" (2m)
Platform Dimensions: 26" x 26" (.66m x .66m)
Extended Outrigger Base Area: 5-4" x 4'-8" (1.63m x 1.42m)
Ready Retracted Dimensions: 2'-6"W x 4'-8"L x 9'-11"H (.76m x 1.42m x 3.02m)
Folded Shipping Dimensions: 2'-6"W x 4'-8"L x 6'-7"H (.76m x 1.42m x 2m)
Gross Shipping Weight: 580# (263kg) — a
Full Extension Time: 11 Seconds Empty, 15 Seconds Loaded
Complete Retraction Time: 14 Seconds a ВЕ
Platform Extension Rate: .86 Feet / Sec. Empty, .63 Feet / Sec. Loaded
Hydraulic System Pressure: 900 PSI Empty, 2000 PSI Loaded
Power Source: DC - 12 Volt Deep Cycle Battery |
© AC - 110/220 Volt 50/60 HZ Motor on Pump
WARRANTY:
WORKFORCE PRODUCTS COMPANY warrants its Telescopic 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
WORKFORCE'S operating and maintenance instructions. WORKFORCE 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 WORKFORCE or by anyone other than WORKFORCE 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 WORKFORCE, are covered by their respective manufacturers warranties.
A list of those components and their warranties is available upon written request to WORKFORCE PRODUCTS.
WORKFORCE PRODUCTS 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.
Page 7 of 54
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5)
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9)
OPERATION INSTRUCTIONS
FOR LADDER ENTRY MODEL XLT-1601E
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 repair or replace as necessary. Next remove the
control box from the guard rail.
Swing out and stabilize each outrigger (4 total) making sure that they lock into position and that the
lift is level. On lifts with outriggers that must be telescoped out, swing out each outrigger as described
above, remove the "L" shaped pin located near the jack and extend the telescoping tube until it stops.
Reinsert the "L" shaped pin, screw the jack down to the ground, and make sure the lift is level.
Position the cage in its upright working position and make sure both lock pins are fully engaged with
the safety arm stand positioned behind the left lock pin.
Raise the empty platform to the height at which-you. intend to work. : Check again to be:sure.that the Ce ©
platform's path of travel is free from obstructions and reposition the lift as necessary. DO NOT use
if lift is not operating properly. - .
Reattach the control cord assembly to the platform guard rail.
Again check to see that all outriggers are properly set (step 4). Enter the cage and make sure the cage
entrance midrail drops into its proper position.
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. 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.
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DESCRIPTION OF OPERATION
The Model No. XLT-1601E DC 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 one person and tools not
to exceed 400#. The electric pump motor is powered by a 12 volt wet cell battery; a 6 amp automatic
battery charger is for recharging the battery at the end of each day. The AC powered version is provided
with a pigtail that can be plugged into any 20 amp 110 volt standard outlet.
Elevating the platform is performed by means of a 1" diameter hydraulic displacement type 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
asetof chains and sheaves. Consequently, the platform is raised two inches foreach 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 nonadjustable restrictor valve controls and fixes the rate of platform
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 platformi 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 until the platform be gins
to descend. : |
Read carefully the following General Safety Instructions before using the Cougar Lift.
Page 9 of 54
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. - i
* 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. |
o 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.
e 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 54
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!
VOLTAGE RANGE MINIMUM SAFE APPROACH DISTANCE
(Phase to Phase) (Feet) (Meters)
0 to 300V | AVOID CONTACT
Over 300V to 50KV 10 3.05
“Over 50KV to 200KV a. 15 | 4.60
Over 200KV to 350KV 20 | | 6.10
Over 350KV to 500KV | 25 7.62
Over 500KV to 750KV | 35 10.67
Over 750KV to 1000KV 45 | 13.72
Position liftfar enough away from power sources to ensure that no part of the lift can acciden tly reach
into an unsafe area.
DO NOT use without all outriggers fully extended, locked, and stabilized.
DO NOT override or F by-pass manufacturer's safety devices.
Operate only on a firm and level surface, DO NOT use on surfaces which will not support the w wei eight
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 54
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.
DONOT exceed manufacturer's platform load limits and make sure all tools and equipment areevenly
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.
DONOT 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 fittin gs 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 54
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,
o 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 or eyes. 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.
о РО NOT short across battery posts to check for current. DON OT break a live circuit at battery.
O * 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 use 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 МОТ ТО ВЕ CONSIDERED AS LEGAL ADVICE AND IS IN-
TENDED FOR INFORMATIONAL PURPOSES ONLY. This informationi 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.
O) For any questions concerning the safe use of this equipment, call 419/445-9675 before using.
Page 13 of 54
MAINTENANCE
INSPECTION: Itis 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 #2 below.
b) Cylinder mounting bolts and locknuts.
c) 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, NOTE] 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
20 PITCHES = 12.5”
IF MEASURES 12.75” TO 12.875” REPLACEI
Adjustthe 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 O
the lift.
Page 14 of 54
@
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 onthe outrigger jack screw and nut. If the vertical movement between the jack threads
and the nut threads is .063" or greater, replace both the jack and the nut.
7. Check casters to see that there i 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 o more
| efficient and extend its useful life. a es
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:
TTT
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: Itis 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 5W Hydraulic Oil may be used where temperatures are as
low as 0°F. Do not mix different hydraulic oils.
Page 15 of 54
MAINTENANCE (cont.)
3. 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 i is lowered, refill the r reservoir to prevent pump- |
ing more air into the cylinder. - | | ВЕ
4. Clean the reservoir sump strainer and replace the hydraulic oil at least once a year or whenever it
should become contaminated.
5. 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 the "on" switch, selecting "raise", while
simultaneously holding the emergency valve open 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 Products for additional information.
6. 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 2,000: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: Don not ot adjust. the pressure relief valve higher than 2, 000 PSI s since possible o over-
loading could occur. Зо
7. 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 54 -
()
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CAUTION:
MAINTENANCE (cont.)
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 the operation of Normally Open (N.O.) raise valve:
A.) Disconnect the jumper wire
running from the start solenoid RELEASE - 3/8" NPTE
to the N.O. valve. JAE | PP PORE 7 POE = м En
| | VALVE
B.) Once the jumper wire is | 5
disconnected, activate the "up" | сои | SWAYNG,
function, causing the motor to _ | SOL. CART. VALVE
run. NOTE: The platform \ Ре
should not raise, but if the IY N 68 N tea
platform begins to raise, the N N ©
М.О. valve must be cleaned or | NN B02-15-0113
replaced. ee a
| BELIEF
C.) Re-connect the jumper wire - YN EE
upon determining that the N.O 2) (196:
valve is properly adjusted. —
ANNUAL MAINTENANCE
A 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 54
| i
REPLACEMENT DECALS - ORDER AS NEEDED
MAXIMUM CAPACITY )
| 400LBS. OR puse Los.
B06-00-0002
EMERGENCY CONTROL VALVE]
B06-00-0006
FALURE TOCOMPLY WITH THE FOLLOWINGS STAUSTICNE
| 716 ro OR ANT OTHER MPROPER USE OR MANTENANGE OF THIS
+ | Prt tectic Smock }
00 НОТ крова charger bo rain, wash detergents of
spey + DO ROT uce beyodos denaped slectle conte when
charging. @
A e
+ During charging. sxpbaive cxylydrogen gus i generated.
DO NOT emola сё асом open Pire, sparks, oF embers naar
bariey pen charging.
» Connect Input cord only lo properly grounded three wire
vi paca vote end icf
* Shares west salty goggies and ace shiekd when working
OF Gf TW hati.
Check battery fach day, if acid dows
cove [he plates, add only srough distitied of demineral
B06-00-0005 | ==
= Coreuh Operation and Mairieniroe Manual tor adollonal
Irdormation on batlery malmenance.
dema
B06-00-0034
Moving telescopic masts will create
pinch points. Keep fingers, hands,
arms and feet clear of all telescopic
mast sections at all times.
e Ps e e
FAILURE TO COMPLY WITH THE FOLLOWING SAFETY INSTRUCTIONS OR ANY OTHER
IMPROPER USE OF THIS EQUIPMENT WILL RESULT IN SERIQUS INJURY OR DEATH.
О DO OT mar arizona ras e e pleito a
BEFORE USE « DONOT
* Oparvier Miel reid uf Mtleriand venere mérval and of decals an * DONOT wei
Machina heists apery Eg. 14 your respamabdity be somply with al * DO NOT vend or alt wn querd тор
warnings ard bnsiructene. + DO NOT hi mel ever quand redle ar
* a NT ñam pt be partorm werk sviclds he
pe мана ; rail a,
ha $ DG HOT wi whan
MONQ TADOS
FAILURE TO COMPLY
WITH THE FOLLOWING MAINTENANCE REQUIREMENTS
be mataro manual md jf,
МЕНА Sas 00 HOT vu is machine A von ar under ir + DO NOT wast wither sviry char auf Ebay la places
and Section 6 of he ANSI standard reprinted In the Owner's Manual. parserral ed ¿Qur aquipmend ery
+ Inspectall chain assembiios, fasteners, pins, and related parts daily » fm cio mo ita
ki wear, damage, proper tightnass, and function. Replace sccording et mr bass ponitord behind fi tech pin.
COULD RESULT IN SERIOUS INJURY OR DEATH md tomng platera.
0 0 7 $ Dron fem wd toe mts + decir da, h whe, ba e had e
; = M + hoch and stabilise eras 4 mula platform de bring оный et temer.
= Follow complate maintenance schedula outlined In Ownar's Manual B 6 0 013 * mo. = : PE Y
to Ovners Manual recommondatons, DURING USE rT a dr rl A
+ Do not overtighien slide blocks, + DOMOT FE ERS oY AZ boa MANUAL A H Mist 22 5ТАМПАНО
+ Skde block paths mus| bo kepl clean — rea of dirt, grease, and other | . РОО че посто ramp die 20s hy mr f
foreign matertal, Turk ithe, planing, or sliver maura bs Soro ent heat PCT POT {
i. creas working hight A WORKFORCE" Dr e eee
» DO NOT use groasa, oil, or amy similar lubricant on masts or slide « DO NOT uel it вороной М mind cul ных PRODUCTS SAT URL oF TH ECUPUENT,
blocks. For additional lubrication, use dry silicone от. . , arme cas es pene
| eran wos. ot 34
XL] B06-00-0135
B06-00-0138
BEFORE BOARDING PLATFORM:
d 1) Position support bar behind left lock pin.
N 2) Lock pins must extend through cage .
tabs and be fully engaged in the locked
position,
BEFORE USING: EXTEND, LOCK, STABILIZE
… OUTRIGGERS; AND LEVEL MACHINE. 6
This machine is designed and manufactured in compli-
ance with the ANSI-92.3 standard in force orr the‘date of COTE ETE
THIS EQUIPMENT WITHIN 10 | De
SS FEET OF HIGH VOLTAGE LINES | and lessees are responsible for inspection, maintenance, Dar
| manufacture. Dealers, owners, users, operators, lessors, AE TOUT
O YT 18 UNLAWFUL TO OPERATE
training, and operation as required by A92.3 and the owners
OF 50,000 VOLTS OR LESS. | ; manual. : '
For safe clearance of lines In excess of 50,000 volls, ses owners manual. | Alterations, modifications, or changes to this machine
This machine is NOT Insulated. Do hot use within 10 ft. of power lines | without the written authorization of Workforce Products,
or other electrically charged sources. This machine DOES NOT provide BO 6 00 01 49 Inc. as well as any unauthorized adjustment of valves, -
protection for personnel from. contact with or close proximity to any. "e y > disabling or by-passing of safety devices or the improper |- --- -—-
personnel coming In contact with machine. ya: use of this machine shall exempt Workforce Products, Inc.
IES from any liability for any resulting injuries or damage.
B06-00-0146 Ne sas
B06-00-0175
¥
E
i
e * Do not operate this machine unless you have resd and understood м FT
all decals on this machine as well as the completa owners manual. A outriggers must be full „extended
Be ‘ ui upport ba 1 and in proper contact w surface
tioned behind ler look pin. y locked with cage в ' before li fi controls will operate. When
each outri rigger is deployed correctly,
send y piertermencas + Extand, lock and stabilize outriggers befors using. Make sure liftis corresponding Indicator bulb will light.
gaie sénat > P i 99 nd Tred + biol dope Inta Na prog vel
en me menor th hoiding Ku molestar un но Моб, * Keep hands and fest inside the cage and de not lean out over guard © @
poe emm to "im Масео рабо "ура? rk oh, фойе down" and the platform sh JE e Ë rails or attempt to perform work outside the guard rail area.
B06- 00- 00182 + Maintain a 10' minimum distance from snergled power lines.
RET o BOS-00-0184
Mes
B06-00-0184 |
o
SERIAL NO: 1601E-0101 oo : 7 N
MAX. PLATFORM HT. _16 _fi_0 in | © Q
POWER SOURCE: 2V DC * Level machine before use.
110V AC * Failure to level this machine could ma poca
result in serious injury or death!
OTHER æ posais) | B06-00-0269
WORKFORCE‘ E
PRODUCTS, I: B06-00-0189 C
125 TAYLOR PARKWAY
ARCHBOLD, OH 43502 USA. OPERATION AND SERVICE
PATENT# 4,484,663
o - MANUAL INSIDE
COFC B06-00-0192
B06-00-00236 B06-00-0192
Page 18 of 54
XLT-1601E DECAL PLACEMENT
0192 0002 a 9184 + 0192
e | 1 a ml 0182 0002 —
— — PA
—— == — — 0140
A — —|
| pe 0009
| omo 0140— TI
Nooo 00027 IL OPS
| 1 150137 EC |S | 0146
a Cotes or] =) pm
0138-71
| 0175— Aa
0034 > = 0034
0139 0139 7
0236 / , a 00 E.
0) 0005 / 0139 Won charger) =
0006 0% EE
DECAL NO. DESCRIPTION OF DECAL — |NO.DECALS/PIECE | +
B06-00-0002 | MAXIMUM CAPACITY ...400LBS. OR 1 OCCUPANT — 2
B06-00-0003 | WORKFORCE, INC. NO. XXXX (WORKEORCE SERIAL NO. DECAL) |. 2
B06-00-0005 | PULL TO LOWER a o 1
B06-00-0006 | EMERGENCY CONTROL VALVE 1
B06-00-0009 | WARNING... MOVING TELESCOPIC MASTS WILL CREATE... 1
B06-00-0034 | DANGER. ..DURING CHARGING, OXYHYDROGEN GAS... 1
B06-00-0058 | SAFETY STAIR TREADS 6
| B06-00-0135 | DANGER... MAIN WARNING DECAL FOR COUGARSAND CATS 1
[ B06-00-0137 | WORKFORCE (VERTICAL TRANSFER TYPE DECAL) 1
| B06-00-0138 | WARNING ...(MAINENTANCE DECAL FOR COUGARS & CATS) 1
B06-00-0139 | DANGER...BEFORE USING: EXTEND,LOCK & STABILIZE. .. 4
B06-00-0140 | DANGER... BEFORE BOARDING PLATFORM ... 2
B06-00-0146 | DANGER... (ELECTRICITY WARNING FOR ALL LIFTS) 1
B06-00-0149 | XLT-1601E (TRANSFER)
B06-00-0175 | CAUTION... THIS MACHINE DESIGNED. . . 92.3 1
| B06-00-0182 | WARNING ...OPERATION INSTRUCTIONS - LADDER ENTRY 2
B06-00-0184 | WARNING ...(WARNING DECAL FOR LADDER ENTRY - IN CAGE) 1
С | B06-00-0189 | WARNING... LEVEL MACHINE BEFORE USE. .. 1
| B06-00-0192 | OPERATION & SERVICE MANUAL INSIDE 1
B06-00-0236 | WORKFORCE SERIAL NUMBER TAG (WITH PATENT NO.) 1
B06-00-0269 | ALL OUTRIGGERS MUST BE FULLY EXTENDED. . . 1
Page 19 of 54
GENERAL ASSEMBLY - XLT-1601E
FAL AT Lh Xa
SR NE OP
RNE
mado los. oad PP"
TH
Page 20 of 54
ITEM NO.
1
la
2
2a
2b
2c
2d
2e
3
3a
3b
4
4a
4b
4c
4d
4e
>
6
ba
7
7a
8
ба
8b
SC
9
Oa
9b
10
10a
10b
10c
11
lla
11b
12
13
14
15
16
17
GENERAL ASSEMBLY - XLT-1601F
PART NO.
B17-00-0001
B17-00-0052
B44-00-0018
B36-00-0001
B39-00-0001
B04-07-0006
B16-01-0022
B31-00-0001
B16-01-0023
B26-00-0002
B36-01-0002
B31-00-0001
B04-07-0011
B18-00-0080
B18-00-0002
B37-00-0003
B23-01-0023
B23-01-0024
B03-00-0004
B08-01-0007
B08-01-0008
B23-01-0025
B23-01-0026
B03-00-0004
B11-01-0020
B06-00-0058
B44-00-0017
B23-01-0035
B40-01-0004
B04-07-0027
B17-00-0002
QTY.
B00 ANN EN YOR e a
нон ВЮ юн DEN DNS DR MH
но
10
DESCRIPTION
Cage Assembly
3/8"-16 x 2" Hex Bolt w/Locknut
Platform
Plywood
3/8"-16 x 1-1/2" Carriage Bolt w/Lockwasher & Nut
Cage Support Pin
Support Pin Spring
1/8" x 3/4" Roll Pin
Top Mast Section
Plastic Slide Block
#10 x 1" Screw
Middle Mast Section
Sheave
Sheave Axle
Plastic Slide Blocks
#10 x 1" Screw
Cotter Pin
See Hydraulic System Page
Mast Cover
#10-24 x 1/2" Screws
Equipment Housing Cover
Padlock
Outrigger - Right
Outrigger - Left
Lock Pin Assembly
1/2"-13 x 5" Grade 5 Hex Bolt w/Locknut
8" Locking Swivel Caster
8" Swivel Caster
3/8"-16 x 1" Hex Bolt w/Lockwasher & Nut
Outrigger - Right
Outrigger - Left
Lock Pin Assembly
1/2"-13 x 5" Grade 5 Hex Bolt w/Locknut
Base Weldment
Safety Tread
_ Power Unit Plywood
See Electrical System Page
See Hydraulic System Page
See Hydraulic System Page
Chain Assembly w/Locknut
1/2"-20 x 1/2" Set Screws
Cage Safety Support
Page 21 of 54
SHORT OUTRIGGER ASSEMBLY
ITEM # PART # DESCRIPTION
1 B04-04-2111 6-32 Machine Screw
2 B23-01-0053 Right Outrigger Weldment
2 B23-01-0054 Left Outrigger Weldment
3 B01-03-0019 Limit Switch
4 B04-04-2611 6-32 Lock Nut
5 B04-05-3509 3/8" - 16 Hex Bolt
6 B46-00-0010 . “Plastic Knob |
7 B04-02-3002 3/8" Lock Nut
8 B46-00-0009 Outrigger Handle
9 Wire
10 B04-04-0005 Self Thread Screw
11 B23-02-0014 Outrigger Screw
12 B04-06-0007 Bronze Washer
13 B23-02-0011 Rubber Floor Pad
14 B04-06-0017 3/8" Flat Washer
15 В 18-00-0081 Left Switch Cover
15 B18-00-0082 Right Switch Cover
16 B04-00-3511 3/8" - 16 Hex Bolt
Page 22 of 54
ITEM #
1
№ 69 —3 С\ Сл А 52 5
PART #
B04-04-2111
B23-01-0056
B23-01-0055
B01-03-0019
B04-04-2611
B04-05-3509
B04-05-3511
B46-00-0010
B04-02-3002
B46-00-0009
B23-02-0014
B04-06-0007
B23-02-0011
B04-06-0017
B18-00-0078
B18-00-0075
B04-04-0005
Page 23 of 54
DESCRIPTION
6-32 Machine Screw
Left Outrigger Weldment
Right Outrigger Weldment
Limit Switch
6-32 Lock Nut
3/8" - 16 Hex Bolt
3/8" - 16 Hex Bolt
Plastic Knob
3/8" Lock Nut
Outrigger Handle
Wire
Outrigger Screw
Bronze Washer
Rubber Floor Pad
3/8" Flat Washer
Left Switch Cover
Right Switch Cover
Self Thread Screw
QTY.
AC WIRING DIAGRAM FOR MAIN CONTROL BOX
Page 24 of 54
1.0 AMP -
FUSE
+ |
[
ill
L1ÍLAIL3
—A]]
MS1
ho T1
Es
[T1|TE|T3
TO | |
MOTOR | B o
1357 1H —— | |
| LG | | L —
E (-) AC
|| BRI
| N
LOWERING AC (+)
VALVEL ,. |. 7
W ]
B.
18-2|
- JB
e |
| \ _ 612-3
G 110V
POWER
SL —
JB
NW RIB WIG
TO HANDY
BOX
18-3 18-4 TO OUTRIGGERS
SWITCHES
AC ELECTRICAL SCHEMATIC
+ | 110V MSI (—)
E-STOP | В N—
RI R2 R3 RA
A > ie
y DN | |
1
x
1.0 AMP FUSE
X
BR1-BRIDGE RECTIFIER
M-MOTOR
MS1-MOTOR START RELAY(110V)
S1-DOWN VALVE
T1- TRANSFORMER
%-UPPER CONTROL RECEPTACLE W-
R1-R4-0OUTRIGGER CONTROL RELAYS
+ | |
a |
бо оо RD) —
OUTRIGGER SWITCHES > >
N.C.-POSITION Fo RA
N.O.-LOAD SENSOR NZ
NS Nu 7
6 боб ©
> | > T
oo R3
a Su
—
WIRING DIAGRAM FOR JUNCTION BOX FOR AC LIFTS
RECEPTACLE
WHITE +
\_ BLACK
18-3 3
RETACTABLE MAIN
CORD BOX
BLACK
GREEN
GREEN
Page 25 of 54
899999
"CONTROL ASSEMBLY
UP/DOWN
EMERGENCY ON
STOP
9)
ITEM #
Jk
OWI A U Yo
pi pt med pad
Fa LD VD —
PART #
B19-00-0001
B01-02-0003
B01-02-0004
B01-02-0025
B00-00-0015
B00-00-0017
B00-00-0016
B01-02-0006
B01-02-0005
B01-09-0003
B01-01-0003
B01-01-0042
B01-01-0043
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 26 of 54
QTY.
jp md ped fad 2) = ко = | == = = = ei
ELECTRICAL SYSTEM
| | MASTER
O Lev Bt SWITCH
LOL so
EMERGENCY ON SWITCH UP |
1 | 'R1 R2 R3 R4
<—alo——s 6—— > AHHH HE
—x | x
C1 - MOTOR START CONTACTOR
R1-R4 CONTROL RELAYS DOWN
S1 - RAISE VALVE уе | —
S2 -'LOWERI L
X LOWER CONTROL RECEPTICAL 77 | 7
LI
| к
- N
4 о = RD
: Ny
E = @
— 9 —
O7
1 A | LU
; | NU vn ;
| 4 == a
| | >
RY
C1 Spf?
| I (М
|| UD
PARTE DESCRIPTION QTY.
B04-07-0003 — Battery Hold Down Rod 2
B29-00-0001 Battery Hold Down Strap 1
1/4" S.A.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
1
B03-00-0014 2-1/4" Dia. Electrical Tube Assembly
Page 27 of 54
DC - WIRING DIAGRAM
43aMOT 25
3SIVY IS
HILIMS
M a =
es “re | J
0g 5d 7
- MOTA pasiejua 998
Page 28 of 54
O ITEM #
1
la
2
2a
2b
3
3a
4
5
5a
5b
5c
5d
Se
6
7
8.
8a
8b
8c
9
10
11
О т
14
15
17
18
19
19a
19b
19c
19d
19e
19f
195
19h
191
19]
20
21
5
16 .
PART #
B01-10-0001
B04-07-0012
B01-10-0047
B01-10-0049
B01-09-0005
B01-09-0042
B01-09-0029
B01-01-0002
B00-00-0007
B00-00-0008
B04-08-0002
B29-00-0049
' В04-04-0005
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
B01-01-0071
B01-01-0072
B01-01-0073
B19-00-0018
B19-00-0017
B04-04-2103
B04-01-2002
B01-06-0015
B01-09-0029
B01-10-0101
B04-04-4105
` В04-01-4002
`В04-06-1004
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"
#6 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
18-2 Wire 42" Long
18-2 Wire 72" 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
Bolts #10 x 3/4
#10 Locknuts
#10 Flat Washers
Plastic Locknut for 19e
18-2 Wire 30" Long
22" Battery Lead
Page 29 of 54
INR BB DBR 0000 ыы на ны а а ed he AND SS E 00 ANOS NN o a AAN Ao N
OTY.
OUTRIGGER INDICATOR BOX WIRING
Yar ALL WHITE
FROM LIGHTS
RED —\
LIGHT
wo
GREENz=—=z===
BLACK
RED
YHITE
3
Page 30 of 54
WIRING DIAGRAM FOR JUNCTION BOX ON DC LIFTS
X08 X5V18 Woyd v-gl
3LIHA — 7 03
ANN | yA NE3U9
N [|
(— XO) N
H-N33#9
Pe + 9218
| N J
er > a / 7013
7
азы —/ 7
зана | » | + 3LIHA
№389 —/\\_ ; J)
vie | |
3TVLd303Y -
Page 31 of 54
———
NE
|
|
|
;
|
—— | — —
| Ba
oe 1 |_ _Hose Line __ __, Cylinder
HYDRAULIC SYSTEM
ITEM # PART #
1 B02-05-0002
B02-02-0040
2 B02-01-0001
B02-02-0042
3 B02-04-0001
B02-02-0041
4 B02-03-0001
ne
| e ly
VL PRESET RELIEF
~ S1-Solenoid Valve (Raising)
S2-Solenoid Valve (Lowering)
= —— — — 0
DESCRIPTION
Motor-Pump Hydraulic Unit
3/8"-16 x 1" Hex Bolt, Lockwasher & Hex Nut
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 - A8-2100-.90
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 32 of 54
A
— —F]— — —" --— —
QTY.
O
Cylinder Jacket
2 SA-150-W Washer —_
3 SA-150-P Rod Packing . ..
4 SA-150-6N Gland Nut —
5 SA-150-WR Rod Wiper
6 Piston Rod
7 Wear Ring
8
B02-13-0002 Seal Repair Kit
(Incl. SA-150-W,
SA-150-P, SA-1 50-WR)
REPAIRING HYDRAULIC CYLINDER
Be sure cylinder i 15 completely retracted and pressure is released from he 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, scratches, 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 rin gatatime
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 33 of 54
HYDRAULIC UNIT PARTS BREAKDOWN
9 10-32 SWITCH #10-32 SWITCH 3/8 N.P.T. FILLER-
CONN. (RAISE) CONN. (LOWER) BREATHER PORT
5/ 16-24 12v.0.C. — .
POWER CONNECTION
/ MANUAL OVERAIDE HANOLE (1
E MI
o o — de wk НН — ча
[en Damme ОО
TERMINAL (OPPOSITE SIDE)
3/8-15 x .50 DP.
MTS. HOLES (2) | ai
'SOLENOIO RELEASE
VALVE ASSEMBLY
8 18
_'2-WAY N.0. SPOOL TYPE
SOL. CART, VALVE M/ (2)
4/4" SPADE TERMINALS
== wm ow ww wy
Page 34 of 54
O
=
5
POWER UNIT PARTS LIST
(ITEM # PART # DESCRIPTION QTY. ^
1 В02-15-0003 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 1
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 B02-15-0117 Reservior 1
15 B02-15-0013 Spring & Ball (Check) 1
16 B02-15-0014 Spring & Ball Assembly (Relief) 1
17 B02-15-0015 Check Cap Assembly 1
18 B02-15-0118 Release Valve Assembly 1
19 B02-15-0030 Relief Cap Assembly 1
20 B02-15-0091 — Seal Shaft a 1
21 ‘B02-15-0018 Release Stem Assembly 1
22 B02-15-0113 12 VDC N.O. Spool Cartridge Valve 1
23 B01-15-0124 Electric Terminal Strap 1
24 B02-15-0020 Solenoid Assembly 1
25 B02-15-0093 Washer o 1
26 B02-15-0022 Solenoid Mounting Bracket Assembly 1
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/SNPT 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 1
\ 44 B02-15-0123 Screw 1/4-20 x .25 2
Page 35 of 54
WORKFORCE PRODUCTS, INC.
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 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), Workforce
requires that the lift be returned to our facility at 125 Taylor Parkway for recondi-
tioning. If you have any questions concerning what constitutes structural damage,
please call the Workforce Service Department at 419-445-9675.
. - sE ea
aus
DAMAGE REPAIR NOTICE: ~ … e. . . . Co seas
There may be occasions when a Workforce lift is involved in an incident =» но:
о - | “ * . | - . ` ERY
resulting in non-structural damage. When this occurs-and repairs are made by the vu
. owner or area distributor, please notify Workforce of these non-maintenance O
repairs and request a repair form to be filled out and returned to Workforce. Е TA
Page 36 of 54
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.
S. 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
inthe 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 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 listedi in Section 8 before operating the aerial
platform.
5.6.1 Training on Delivery. Manufacturer's operating instruction and required training on n 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 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, 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.
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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 15 returned to service. .. skh
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6.4 Frequent Inspection. The owner of 2 an aerial platform shall cause a 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 shallbe 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.
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.
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6.5 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 ofthe predelivery preparation performed priortoe each delivery.
6.13 Modifications. The owner shall not modify o 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’ $ Safety Bulletins. The owner shall comply with safety-related bulletins as réceived 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 repairs shall be in conformance with the manufacturer's recommendations.
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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 manufacturers
recommendations. a
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7.6 Operator Training. Whenever a.user directs or authorizes an individual to oper">