® AERIAL WORK PLATFORMS Model XLT-1071AIR Operation and Maintenance Manual R Hydraulic Lift Platform ING RN WA ER NG DA RN WA ING W O R K F O R C E XL T 1 0 7 1 G IN N AR W WA RN ING ® B33-01-0087 A Member of the plettac Group
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.
Table of Contents 1 Safety ............................................................................................................... 1-1 1-1 Introduction ........................................................................................ 1-1 1-2 Before Operation ............................................................................... 1-3 1-3 During Operation................................................................................ 1-4 1-4 Maintenance Safety .........................
List of Illustrations Figure 3-1. Figure 3-2. Figure 3-3. Figure 3-4. Figure 3-5. Figure 3-6. Figure 4-1. Figure 4-2. Figure 4-3. Figure 5-1. Figure 5-2. Figure 5-3. Figure 5-4. Figure 5-5. Figure 5-6. Figure 5-7. Figure 5-8. Figure 5-9. Figure 5-10. Figure 6-1. ii Lift Chain Lubrication............................................................................. 3-3 Caster Lubrication................................................................................... 3-4 Hydraulic Cylinder Exploded View..
List of Tables Table 1-1. Table 2-1. Table 3-1. Table 3-2. Table 4-1. Table 5-1. Table 5-2. Table 5-3. Table 5-4. Table 5-5. Table 5-6. Table 5-7. Table 6-1. Minimum Safe Approach Distances ....................................................... 1-4 Specifications.......................................................................................... 2-2 Daily/Weekly Service Checks ................................................................ 3-1 Monthly Service Checks ................................
iv
1 Safety 1-1 INTRODUCTION Familiarity and proper training are required for the safe operation of mechanical equipment. 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 someone familiar with the equipment before being allowed to operate the machine.
XLT-1071AIR 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.
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.
XLT-1071AIR 1-3 DURING OPERATION 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.
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 guard rails. Work only within the platform guard rail area and do not lean out over guard rails to perform work.
XLT-1071AIR 1-4 MAINTENANCE SAFETY Ensure the following general safety precautions are observed when maintenance is performed on the Cougar Lift. 1-6 • 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.
1 — SAFETY 1-5 DAMAGED EQUIPMENT POLICY Safety Statement At Workforce, we are dedicated to the safety of all users of our products. Therefore, 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 that results in structural damage to the lift. This can seriously compromise the ability of the lift to perform in a safe manner.
XLT-1071AIR 1-8
2 Introduction 2-1 GENERAL DESCRIPTION The model XLT-1071 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.
XLT-1071AIR 2-2 SPECIFICATIONS Cougar Lift Hydraulic Lift Platform Model Number XLT-1071AIR Manufactured by: Serial Number ________________ bil-jax, Inc. WORKFORCE AERIAL WORK PLATFORMS 125 Taylor Parkway Archbold, Ohio 43502 419.445.8915 Table 2-1. Specifications 2-3 Rated Platform Load 500 lbs (227 kg) total including operator [1 person + materials not to exceed 500 lbs (227 kg)] Extended Platform Height 10 ft-6 in. (3.2 m) Retracted Platform Height 18-1/2 in. (0.
3 Maintenance 3-1 SCHEDULED SERVICE CHECKS Daily/Weekly Service Checks Perform the following daily/weekly service checks as listed in Table 3-1. Table 3-1. Daily/Weekly Service Checks Service Check Daily before use 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 the cage side midrails slide freely.
XLT-1071AIR Monthly Service Checks Perform the following monthly service checks as listed in Table 3-2. Table 3-2. Monthly Service Checks Service Check Check hydraulic raise valve operation. Check operation of manual emergency lowering valve. Every 6 months Lubricate caster swivels and axles. Check battery cables and wiring for loose connections and damaged wires. Every 12 months Replace hydraulic oil. Check slide blocks for wear. Check for mast sway.
3 — MAINTENANCE 3-2 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 3-1. LIFT CHAINS LIFT CHAINS Figure 3-1.
XLT-1071AIR 2. Grease all caster axles and swivel raceways at the 2 grease fittings on each caster semiannually with wheel bearing grease. Refer to Figure 3-2. Figure 3-2. Caster Lubrication NOTE: 3-4 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.
3 — MAINTENANCE 3-5
XLT-1071AIR 3-3 HYDRAULIC SYSTEM Hydraulic Cylinder Repair CAUTION Removing the hydraulic cylinder from the Cougar Lift requires major disassembly of the unit. Contact Workforce before removing the hydraulic cylinder from the unit for assistance. Hydraulic Cylinder Removal It is recommended that Workforce be contacted for assistance before removing the hydraulic cylinder. 1. Be sure cylinder is completely retracted and pressure is released from the system.
3 — MAINTENANCE 6. Replace gland nut (4) complete with a new rod wiper (5), if worn. Thread down gland nut until it makes contact with rod packing rings (3). 7. Reinstall the hydraulic cylinder into the unit and reconnect the hydraulic hose. Refill hydraulic fluid reservoir. 8. Stoke the cylinder to allow rod packing rings (3) and wear ring (7) to seat and align, then tighten gland nut (4) an additional 1-1/2 to 2 turns, making sure that the air has been bled from the cylinder.
XLT-1071AIR 3-4 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.
3 — 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 3-5.
XLT-1071AIR 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 3-6. 1.
4 Replacement Decals Refer to Table 4-1, and Figures 4-1, 4-2, and 4-3 for descriptions and locations of decals on the Cougar Lift. Table 4-1. Replacement Decals Decal No. Description of Decal Qty B06-00-0003 Workforce ID Number (Not available as replacement part) 1 B06-00-0009 Warning...Moving telescopic masts will create... 2 B06-00-0034 Danger...During charging, explosive oxyhydrogen gas...
XLT-1071AIR B06-00-0170 B06-00-0289 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 injury or death.
4 — REPLACEMENT DECALS 0009 ING RN WA ER NG DA 0173 RN WA ING 0146 0170 0339 OR 0339BLT 0173 W O R K F O R C E 0137 0192 XL T 0105 1 0 7 1 A W R N IN G 0291 0170 0225 0167 COMPLETE (AROUND BASE ON ALL SIDES ) Figure 4-2.
XLT-1071AIR 0009 0228 ING RN WA 0295 W O R K F O R C E 0137 0138 R GE N DA CA RN WA IO UT 0175 N ING XL T 1 0 7 1 0105 0296 DA NG ER 0034 0003 CHARGER ) (ON INSIDE 0167 COMPLETE (AROUND BASE ON ALL SIDES) ( 0289 ) ON RESERVOIR INSIDE Figure 4-3.
5 Parts List 5-1
XLT-1071AIR 5-1 TOP MAST PARTS LIST Refer to Table 5-1 for the parts list for the top mast. 2 3 1 4 15 5 16 7 3 6 17 8 18 9 14 12 19 10 13 11 Figure 5-1.
5 — PARTS LIST Table 5-1. Top Mast Parts List Item No. Part No. Description Qty 1 B16-01-0025 Top Mast Weldment 1 2 0090-0014 Screw, 1/4-20 x 2-1/4 in. 2 3 B01-09-0026 Grommet, Plastic 3 4 B29-00-0160 Bracket, Outreach 1 5 0090-0181 Nut, Lock, 8-32 3 6 0090-0813 Screw, 8-32 x 3/4 in. – **Not Used on Air Unit** 3 7 B01-02-0059 Box, Control, Upper – **Not Used on Air Unit** 1 8 B40-00-0003 Cable, 3/16 in.
XLT-1071AIR 5-2 LOWER MAST PARTS LIST Refer to Table 5-2 for the parts list for the lower mast.
5 — PARTS LIST 4 5 2 4 6 7 12 3 13 14 8 15 9 11 10 1 16 11 17 9 10 17 19 19 22 21 18 24 3 18 4 23 20 17 4 18 19 Figure 5-2.
XLT-1071AIR Table 5-2. Lower Mast Parts List Item No. Part No. Description 1 B16-01-0021 Lower Mast Weldment 1 2 0090-0770 Pin, Cotter 3/16 x 1-1/2 in. 2 3 B36-01-0002 Sheave Axle 3 4 0090-0425 Washer, Flat, 5/8 in. 6 5 B26-00-0009 Chain Sheave Assembly 2 6 0090-0188 Nut, Lock, 3/8-16 1 7 0090-0422 Washer, Flat, 3/8 1 8 B40-00-0003 Cable 1 9 0090-0389 Screw, Adjustment, 1/2-20 x 1/2 in.
5 — PARTS LIST 5-3 UPPER BASE PARTS LIST Refer to Table 5-3 for the parts list for the upper base. 2 3 1 4 5 12 4 11 2 O R LIG 13 PE ER NG DA ION UT CA 6 ING RN WA 6 10 14 6 7 8 9 15 Figure 5-3. Upper Base Exploded View Table 5-3.
XLT-1071AIR Item No. 5-8 Part No. Description Qty 1 B11-01-0093 Base Weldment 1 2 0090-0344 Screw, Threadcut, 10-24 x 1/2 in. 8 3 B07-01-2003 Edge, Top Cover 1 4 B05-00-0006 Tape, Foam Adhesive 5 B18-00-0108 Plexiglass, 1/8 in. 1 6 B24-01-009 Frame, Aluminum 3 7 B01-02-0058 Box, Control, Lower – **Not Used on Air Unit** 1 8 0090-0813 Screw, 8-32 x 3/4 in.
5 — PARTS LIST 5-4 PLATFORM PARTS LIST Refer to Table 5-4 for the parts list for the platform. 12 1 22 19, 20 18 21 2 15 17 6 7 5 14 13 11 3 16 14 10 8 9 4 23 24 Figure 5-4.
XLT-1071AIR Table 5-4. Platform Parts List Item No. 5-10 Part No. Description Qty 1 B17-00-0087 Platform Weldment 1 2 0090-0051 Bolt, 3/8-16 x 2-3/4 in. 4 3 0090-0210 Washer, Lock, 3/8 in. 8 4 0090-0162 Nut, 3/8-16 8 5 0068-061 Pin, Snap 2 6 B01-03-0009 Switch, Limit – **Not Used on Air Unit** 1 7 B01-10-0002 Alarm, Audible – **Not Used on Air Unit** 1 8 B01-10-0004 Light – **Not Used on Air Unit** 1 9 0090-0802 Screw, 10-24 x 7/8 in.
5 — PARTS LIST 5-5 AIR PUMP UNIT PARTS LIST Refer to Table 5-5 for the parts list for the air pump unit. Figure 5-5.
XLT-1071AIR Table 5-5. Air Pump Unit (B02-05-0026, PB-1020) Parts List Item No. Part No. Qty 2 B02-15-0197 Cartridge Check Valve 1 3 B09-00-0011 Silencer 1 4 B02-15-0375 Valve Spacer 1 5 B02-15-0376 Cylinder Air Release 1 6 B02-15-0206 Tank 1 7 B02-15-0377 Decal, Manual Lowering 1 8 B02-15-0378 End Head 1 9 B02-15-0159 Pump Assembly, PS-2.
5 — PARTS LIST 5-6 PNEUMATIC PLUMBING PARTS LIST Refer to Table 5-6 for the parts list for the pneumatic plumbing. Figure 5-6.
XLT-1071AIR Table 5-6. Pneumatic Plumbing Parts List Item No. Part No.
5 — PARTS LIST 5-7 PNEUMATIC SCHEMATIC 5-15
XLT-1071AIR Figure 5-7.
5 — PARTS LIST Figure 5-8. Hydraulic Schematic Diagram 5-9 CONTROL BOXES PARTS LIST Refer to Table 5-7 for the parts list for the control boxes. Figure 5-9.
XLT-1071AIR Table 5-7. Control Boxes Parts List Item No. 5-18 Part No.
5 — PARTS LIST 5-19
XLT-1071AIR 5-10 AIR-REG-LUBE-VALVE ASSEMBLY Figure 5-10.
6 ANSI Reprint The following sections are reprinted from the ANSI A92.3-1990 code in effect at the time of manufacture. Permission to reprint has been granted by the Scaffold Industry Association. 5. Responsibilities of Dealers 5.1 Basic Principles.
XLT-1071AIR 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.
6 — ANSI REPRINT 6.6 Maintenance Safety Precautions.
XLT-1071AIR 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.
6 — ANSI REPRINT 7.7 Before Operation.
XLT-1071AIR 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. 7.11.8 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.
6 — ANSI REPRINT 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 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.
XLT-1071AIR 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. 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.
6 — ANSI REPRINT 9. Responsibilities of Lessors 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.
XLT-1071AIR M.S.A.D. = Minimum Safe Approach Distance (See Table 6-1). 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.
6 — ANSI REPRINT Table 6-1. Minimum Safe Approach Distance (M.S.A.D.) to energized (exposed or insulated) power lines and parts. Voltage Range (Phase to Phase) Minimum Safe Approach Distance (Feet) 0 to 300V (Meters) Avoid Contact Over 300V to 50KV 10 3.05 Over 50KV to 200KV 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.
XLT-1071AIR 6-12
® 125 Taylor Parkway Archbold, OH 43502 Phone (419) 445-9675 (800) 527-5333 Fax (419) 445-0367
