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®
Model XLT-1071AIR
AERIAL WORK PLATFORMS
AERIAL WORK PLATFORMS
AERIAL WORK PLATFORMSAERIAL WORK PLATFORMS
Hydraulic Lift Platform
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Operation and
Maintenance Manual
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B33-01-0087
XLT
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A Member of the plettac Group
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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.
Page 3
Table of Contents
1111 Safety ............................................................................................................... 1-1
1-1 Introduction........................................................................................ 1-1
1-2 Before Operation............................................................................... 1-3
1-3 During Operation................................................................................ 1-4
1-4 Maintenance Safety........................................................................... 1-6
1-5 Damaged Equipment Policy............................................................. 1-7
2222 Introduction .................................................................................................... 2-1
2-1 General Description........................................................................... 2-1
2-2 Specifications..................................................................................... 2-2
2-3 Warranty............................................................................................. 2-2
3333 Maintenance.................................................................................................... 3-1
3-1 Scheduled Service Checks................................................................ 3-1
3-2 Lubrication......................................................................................... 3-3
3-3 Hydraulic System.............................................................................. 3-6
3-4 Lift Chains And Slide Blocks......................................................... 3-8
4444 Replacement Decals........................................................................................ 4-1
5555 Parts List ......................................................................................................... 5-1
5-1 Top Mast Parts List......................................................................... 5-2
5-2 Lower Mast Parts List ..................................................................... 5-4
5-3 Upper Base Parts List...................................................................... 5-7
5-4 Platform Parts List............................................................................ 5-9
5-5 Air Pump Unit Parts List.............................................................. 5-10
5-6 Pneumatic Plumbing Parts List...................................................... 5-12
5-7 Pneumatic Schematic Diagram....................................................... 5-14
5-8 Hydraulic Schematic Diagram........................................................ 5-15
5-9 Control Boxes Parts List................................................................5-16
5-10 Air-Reg-Lube-Valve Assembly Drawing....................................... 5-18
6666 ANSI Reprint................................................................................................. 6-1
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List of Illustrations
Figure 3-1. Lift Chain Lubrication.............................................................................3-3
Figure 3-2. Caster Lubrication...................................................................................3-4
Figure 3-3. Hydraulic Cylinder Exploded View........................................................3-7
Figure 3-4. Chain Elongation Inspection................................................................... 3-8
Figure 3-5. Lift Chain Adjustment.............................................................................3-9
Figure 3-6. Slide Block Adjustment........................................................................3-10
Figure 4-1. Replacement Decals................................................................................ 4-2
Figure 4-2. Decal Locations, Side View.................................................................... 4-3
Figure 4-3. Decal Locations, Front View.................................................................. 4-4
Figure 5-1. Top Mast Exploded View.......................................................................5-2
Figure 5-2. Lower Mast Exploded View................................................................... 5-5
Figure 5-3. Upper Base Exploded View.................................................................... 5-7
Figure 5-4. Platform Exploded View.........................................................................5-9
Figure 5-5. Air Pump Unit Drawing........................................................................ 5-10
Figure 5-6. Pneumatic Plumbing Diagram...............................................................5-12
Figure 5-7. Pneumatic Schematic Diagram .............................................................5-14
Figure 5-8. Hydraulic Schematic Diagram..............................................................5-15
Figure 5-9. Control Boxes Exploded Views............................................................5-16
Figure 5-10. Air-Reg-Lube-Valve Assembly Drawing.............................................. 5-18
Figure 6-1. Minimum Safe Approach Distance Diagram........................................ 6-10
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List of Tables
Table 1-1. Minimum Safe Approach Distances....................................................... 1-4
Table 2-1. Specifications.......................................................................................... 2-2
Table 3-1. Daily/Weekly Service Checks ................................................................ 3-1
Table 3-2. Monthly Service Checks......................................................................... 3-2
Table 4-1. Replacement Decals................................................................................ 4-1
Table 5-1. Top Mast Parts List ................................................................................ 5-3
Table 5-2. Lower Mast Parts List............................................................................. 5-6
Table 5-3. Upper Base Parts List............................................................................. 5-7
Table 5-4. Platform Parts List................................................................................ 5-10
Table 5-5. Air Pump Unit Parts List ...................................................................... 5-11
Table 5-6. Pneumatic Plumbing Parts List............................................................. 5-13
Table 5-7. Control Boxes Parts List....................................................................... 5-17
Table 6-1. Minimum Safe Approach Distance (M.S.A.D.) to energized
(exposed or insulated) power lines and parts.................................... 6-11
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11
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. 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 procedures set forth in
this manual.
All OSHA, ANSI, state and local codes and regulations pertaining to this equipment
should be ob tained, read, a nd 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 be 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 Workforce 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
Workforce equipment only.
For any questions concerning the safe use of this equipment, call 419.445.9675 before
operating.
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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.
CAUTION
Cautions provide information important to prevent errors that could damage machine or components.
NOTE: Notes contain additional information important to a pro cedure.
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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 o perating area.
• ALWAYS read, understand, and follow the procedures in this manual before at-
tempting 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 re-
quired 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 no t 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.
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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. 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.
Table 1-1. Minimum Safe Approach Distances
Voltage Range
(Phase to Phase)
0 to 300V 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 13.72
Minimum Safe Approach Distance
(Feet) (Meters)
• 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 be-
fore repositioning platform.
• ALWAYS cordon off area around the base to keep personnel and other equip-
ment 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 un-
authorized use.
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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.
• 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 ele-
vated heights.
• NEVER use guard rails to c arry materials and never al low overhang of materials
when raising or lower ing platform.
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XLT-1071AIR
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 re-
quirements. 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 unauthorize d fluids to the hydraulic system or battery. Check manu-
facturers 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, specific ations, or repa ir.
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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. 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, Archbold, Ohio, for reconditioning. If you have any questions
concerning what constitutes structural damage, please call the Workforce Service Department at 419.445.9675.
Damage Repair Notice
There may be occasions when a Workforce lift is involved in an incident resulting in nonstructural damage. When this occurs and repairs are made by the owner or area distributor, please notify Workforce of these non-maintenance repairs and request a repair form
to be filled out and returned to Workforce.
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XLT-1071AIR
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2
2
22
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. 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. 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 loaded 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 corrode 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.
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XLT-1071AIR
2-2 SPECIFICATIONS
Cougar Lift Hydraulic Lift Platform
Model Number XLT-1071AIR Serial Number ________________
Manufactured by: bil-jax, Inc.
WORKFORCE AERIAL WORK PLATFORMS
125 Taylor Parkway
Archbold, Ohio 43502
419.445.8915
Table 2-1. Specifications
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. (0.47 m)
Platform Dimensions 29 in. w x 50 in. l x 42 in. h
(0.74 m x 1.27 m x 1.07 m)
Base Dimensions 30-1/2 in. w x 71 in. l x 77 in. h
(0.77 m x 1.8 m x 1.95 m)
Retracted Dimensions 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)
Gross Shipping Weight 1025 lbs (465 kg)
Full Extension Time 20 seconds empty, 32 seconds loaded
Complete Retraction Time 22 seconds empty, 22 seconds loaded
Platform Extension Rate 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 Air – 150 CFM Minimum Supply
2-3 WARRANTY
Bil-Jax 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 Bil-Jax’s operating and maintenance instructions; structural components are
warranted for three years. Bil-Jax will, at its option, repair or replace any unit or component part which fails to function prop erly 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 manufacturer’s
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.
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3
3
33
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
Daily
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 the
cage side midrails slide freely.
Check to be sure slide blocks and their path are clean and
lightly lubricated with a silicone lubricant.
Check level sensor.
Check to see that all decals are present.
Check that all functions at lower and upper control boxes 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.
before use Weekly
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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.
Lubricate caster swivels and
axles.
Every
month
Every
6 months
Every
12 months
Check battery cables and wiring
for loose connections and
damaged wires.
Replace hydraulic oil.
Check slide blocks for wear.
Check for mast sway.
Load test with 500 pounds.
Replace lift chains.
Every
48 months
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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. Lift Chain Lubrication
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XLT-1071AIR
2. Grease all caster axles and swivel raceways at the 2 grease fittings on each caster
semiannually with wheel bearing greas e. Refer to Figure 3-2 .
Figure 3-2. 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.
3-4
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3 — MAINTENANCE
3-5
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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. 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 t he 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 3-3.
1. Remove gland nut (4, Figure 3-7), washer (2), and rod packing rings (3) from the
cylinder jacket (1).
2. Remove cylinder rod (6) and wear ring (7). Inspect piston rod (6) and wear ring
(7) for gouges, scratches, and wear. Replace if necessary. Wear ring is installed
in the grooves at the bottom of the piston rod.
3. Clean inside the cylinder jacket (1).
4. Place piston rod (6) and wear ring (7) back into cylinder jacket (1) and insert
washer (2).
5. Grease rod packing rings (3) on the inside and outside diameters. Reinstall one
rod packing ring at a time, making sure each rod packing ring lies flat on the ring
prior to it.
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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. The distance between the top of the
threaded collar and the bottom of the large section on the gland nut should be
1/4 in. (0.635 cm) to 5/16 in. (0.794 cm). Do not over tighten the gland nut.
5
1. Cylinder Jacket
2. Washer
3. Rod Packing Rings
4
4. Gland Nut
5. Rod Wiper
3
6. Piston Rod
7. Wear Ring
2
6
1
7
Figure 3-3. Hydraulic Cylinder Exploded View
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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. 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 3-4.
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 3-4. Chain Elongation Inspection
NOTE: It is recommended that chains be replaced every four years unless dam-
age or wear requires replacement at a lesser interval.
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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 cha in is loose, tighten the lock nut below the clevis r etainer.
Refer to Figure 3-5. 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.
LOCK
NUT
LIFT
CHAINS
CLEVIS
LIFT
CHAINS
CLEVIS
Figure 3-5. Lift Chain Adjustment
LOCK
NUT
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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. 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 t he next mast. Do not overti ghten. Tighten the slott ed 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
SLOTTED
SET
SCREWS
Figure 3-6. 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.
HEX SCREW
3-10
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4
4
44
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... 1
B06-00-0105 XLT-1071 (Transfer type decal) 2
B06-00-0137 Workforce (Vertical transfer type decal) 2
B06-00-0138 Warning...(Maintenance decal) 1
B06-00-0146 Danger...(High voltage line warning) 1
B06-00-0167 Striped Safety Tape - On all four sides (per roll only) 4
B06-00-0170 Maximum Capacity...500 lb. Or... 2
B06-00-0173 Safety Belt Lanyard Attachment Point 2
B06-00-0175 Caution...This machine designed and manufactured... 1
B06-00-0192 Operation And Service Manual Inside 1
B06-00-0225 Warning...Stay clear when raising or lowering 2
B06-00-0228 Serial Number Tag (Not available as replacement part) 1
B06-00-0289 Check level with cage fully down 1
B06-00-0291 Warning...Level machine before use 1
B06-00-0295 Danger...Failure To Comply With The Following... 1
B06-00-0296 Battery Charger Receptacle 1
B06-00-0339 Warning...Full Body Harness and Lanyard... 1
4-1
Page 28
XLT-1071AIR
Fall protection equipment must
be used at all times during
operation. Failure to wear fall
protection equipment may allow
B06-00-0170
B06-00-0289
operator to fall from platform
resulting in serious injury or
death.
UTT/ATT
B06-00-0339BLT
B06-00-0339BLT
B06-00-0173
B06-00-0295
B06-00-0192
B06-00-0034
B06-00-0339
0
B06-00-0296
B06-00-0228
0
B06-00-0105
B06-00-0137
B06-00-0138
B06-00-0175
B06-00-0009
B06-00-0291
STAY CLEAR
WHILE RAISING
B06-00-0146
OR LOWERING
CCFO
B06-00-0225
B06-00-0225
Figure 4-1. Replacement Decals
4-2
Page 29
4 — REPLACEMENT DECALS
0009
0146
G
0105
0173
0137
XLT
IN
N
R
ER
WA
G
DAN
R
WA
W
O
R
K
F
O
R
C
E
1
0
7
1
0170
0339 OR 0339BLT
G
N
I
N
0173
0192
WARNING
0291
0170
0225
Figure 4-2. Decal Locations, Side View
0167
AROUND COMPLETE
()
BASE ON ALL SIDES
4-3
Page 30
XLT-1071AIR
0009
0228
WARNING
0137
0138
0105
0296
0034
W
O
R
K
F
O
R
C
E
XLT
1
0
7
1
DANGER
DANGER
AU
C
G
IN
WARN
N
TIO
ON CHARGER
(
0003
INSIDE
0295
0175
)
0289
AROUND COMPLETE
(
BASE ON ALL SIDES
0167
)
ON RESERVOIR
(
INSIDE
)
Figure 4-3. Decal Locations, Front View
4-4
Page 31
5
5
55
Parts List
5-1
Page 32
XLT-1071AIR
5-1 TOP MAST PARTS LIST
Refer to Table 5-1 for the parts list for the top mast.
3
4
5
8
2
1
15
16
7
3
6
17
19
11
18
9
14
12
10
Figure 5-1. Top Mast Exploded View
13
5-2
Page 33
5 — PARTS LIST
Table 5-1. Top Mast Par ts 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**
7 B01-02-0059 Box, Control, Upper – **Not Used on Air
Unit**
8 B40-00-0003 Cable, 3/16 in. 1
9 B40-01-0008 Chain, Lift 2
10 B04-07-0078 Pin, Clevis 2
11 B04-07-0087 Clevis, Lower 2
12 0090-0389 Screw, Adjustment, 1/2-20 x 1/2 in. 4
13 0090-0403 Screw, #10 x 1 in. 2
14 B31-00-0001 Slide Block, Plastic 2
15 0090-0206 Washer, Lock, 1/4 in. 2
16 0090-0159 Nut, Hex, 1/4-20 2
17 B01-09-0029 Bushing, Strain Relief – **Not Used on Air
Unit**
18 B05-01-0034 Cable, SJO, 18-2 – **Not Used on Air Unit** 80 in.
19 0090-0860 Pin, Cotter 2
* B03-00-0009 Chain Assy, includes items 9, 10, 11, and 19 1
3
1
2
*NOTE: It is recommended that chain parts be purchased as an assembly.
5-3
Page 34
XLT-1071AIR
5-2 LOWER MAST PARTS LIST
Refer to Table 5-2 for the parts list for the lower mast.
5-4
Page 35
5 — PARTS LIST
4
5
4
2
6
7
12
3
13
9
10
11
16
8
14
15
1
11
9
10
17
17
21
18
19
19
22
24
3
18
4
23
20
17
18
4
19
Figure 5-2. Lower Mast Exploded View
5-5
Page 36
XLT-1071AIR
Table 5-2. Lower Mast Parts List
Item No. Part No. Description Qty
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. 8
10 0090-0403 Screw, #10 x 1 4
11 B31-00-0001 Slide Block, Plastic 4
12 B40-01-0008 Chain, Lift 2
13 0090-0860 Pin, Cotter 2
14 B04-07-0078 Pin, Clevis 2
15 B04-07-0088 Clevis, Upper 2
16 0090-0192 Nut, Lock, 1/2-13 2
17 0090-0042 Bolt, 3/8-16 x 1 in. 6
18 0090-0210 Washer, Lock, 3/8 in. 6
19 0090-0162 Nut, 3/8-16 6
20 B24-01-0008 Mounting Bracket 1
21 B29-00-0033 Mast Stop 1
22 B29-00-0078 Bracket, Weldment 1
23 B26-00-0001 Sheave, Cable 1
24 0090-0147 Pin, Cotter 1
* B03-00-0009 Chain Assy, includes items 12, 13, 14, and 15 1
*NOTE: It is recommended that chain parts be purchased as an assembly.
5-6
Page 37
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
4
5
12
11
10
PELIGRO
DANGER
CAUTION
WARNING
2
13
6
6
14
6
7
8
9
15
Figure 5-3. Upper Base Exploded View
Table 5-3. Upper Base Parts List
5-7
Page 38
XLT-1071AIR
Item No. 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 32 in.
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**
8 0090-0813 Screw, 8-32 x 3/4 in. – **Not Used on Air
Unit**
9 B34-00-0005 Trim, Rubber 1
10 B01-09-0027 Grommet, Plastic 1
11 0090-0181 Nut, Lock, 8-32 2
12 B29-00-0161 Bracket, Air Line Tube 1
13 B00-00-0143 Tube, Air Line Container 1
14 B11-01-0141 Retainer, Air Line 1
15 B08-00-0018 Floor Lock 1
1
2
5-8
Page 39
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
23
15
6
3
16
4
Figure 5-4. Platform Exploded View
17
7
24
10
8
9
11
14
5
14
13
5-9
Page 40
XLT-1071AIR
Table 5-4. Platform Parts List
Item No. 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. – **Not Used on Air
Unit**
10 0090-0182 Nut, Lock, 10-24 – **Not Used on Air Unit** 3
11 B17-00-0066 Support, Platform 1
12 0090-0048 Bolt, 3/8-16 x 2 in. 2
13 B40-00-0019 Chain 2
14 0090-0552 Ring, Key 4
15 B01-03-0002 Cover – **Not Used on Air Unit** 1
16 0090-0042 Bolt, 3/8-16 x 1 in. 2
17 B01-09-0030 TyRap – **Not Used on Air Unit** 1
18 B05-00-0001 Tube, Foam, 13-1/2 in. 2
19 B00-00-0086 Tube, Split, 8-1/2 in. 4
20 B01-09-0030 TyRap 12
21 B06-00-0167 Tape, Strip, 43 in. 2
22 B00-00-0014 Cap, Manual Tube 2
23 B08-01-0002 Caster, Rear, Swivel 2
24 B08-01-0001 Caster, Front, Swivel Lock 2
3
5-10
Page 41
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. Air Pump Unit Drawing
5-11
Page 42
XLT-1071AIR
Table 5-5. Air Pump Unit (B02-05-0026, PB-1020) Parts List
Item No. Part No. Description 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-2.0 1
10 B02-15-0379 V6 SQ Flange 1
11 B02-15-0380 Valve, Manual Release 1
12 B02-15-0128 Steel Ball 1
13 B02-15-0091 Shaft Seal 1
14 B02-15-0093 Washer 3
15 B02-15-0061 Magnet 1
16 B02-15-0121 Filter 1
17 B02-15-0125 Suction Cover 1
18 B02-15-0126 Screw Taptite 2
19 B02-15-0365 Drain Plug 1
20 B02-15-0381 Coupling, SAE-Tang Short 1
21 B02-15-0170 Bolt, 5/16-18 x 1” 1
22 B02-15-0359 Bolt, M8 x 75mm 2
23 B02-15-0382 Bolt, M6 x 1.0 x 35mm 4
24 B02-15-0383 ¼” Lockwasher Hi Collar 4
25 B02-15-0199 Bolt, 12-24 x 1/2 4
26 B02-15-0201 Breather Cap 1
27 B02-15-0127 Spring Relief 1
28 B02-15-0384 Spring 1
29 B02-15-0073 O-Ring 1
30 Packaging Plug
31 B02-15-0030 Relief Cap Assembly 1
32 B02-02-0087 6 ORM Plug 1
33 B02-15-0204 Plug 1/16 NPT Flush 2
34 B02-15-0059 Nylon Elbow 1
35 B02-15-0026 Relief Screw 1
36 Packaging Plug
5-12
Page 43
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. Pneumatic Plumbing Diagram
5-13
Page 44
XLT-1071AIR
Table 5-6. Pneumatic Plumbing Parts List
Item No. Part No. Description Qty
1 B19-00-0011 Upper Control Box w/o Switches 1
1a B09-00-0015 On/Off Switch 1
1b B09-00-0016 Emergency Stop 1
1c B09-00-0001 Up/Down Toggle Switch 1
2 B09-00-0004 3 Strand Retractile Tubing 1
2a B00-00-0013 Plastic Pipe 1
2b B29-00-0046 Top Mounting Bracket w/Screws 1
2c B29-00-0045 Bottom Mounting Bracket w/Screws 1
2d Outreach Bracket 1
3 B09-00-0005 Filter/Oiler/Regulator w/Oiler 1
3a B02-02-0101 Pipe Nip 1
3b B09-00-0006 Quick Connect 1
4 B09-00-0007 Manifold 1
4a B09-00-0008 Straight Tube Fitting 1
4b B11-00-0011 Mounting Stand For Manifold w/Fasteners 1
5 B09-00-0009 Main Valve 1
5a B09-00-0010 Exhaust Muffler 1
5b B09-00-0002
5c B02-02-0102
90° Tube Fitting
90° Swivel Elbow Fitting
1
1
5d B02-02-0101 Pipe Nip 1
6 B02-05-0026 Air Driven Hydraulic Pump Unit w/Mounting
1
Bolts
6a B09-00-0011 Silencer 1
6b B02-02-0103
90° Swivel Elbow Fitting
1
6c B02-01-0058 Hose (Valve to Motor) 1
7 B09-00-0012 Bulkhead Adapter 2
8 B09-00-0013 Plastic Tubing 1
9 B09-00-0014 Plastic Tubing 1
5-14
Page 45
5 — PARTS LIST
5-7 PNEUMATIC SCHEMATIC
5-15
Page 46
XLT-1071AIR
Figure 5-7. Pneumatic Schematic Diagram
5-8 HYDRAULIC SCHEMATIC
5-16
Page 47
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. Control Boxes Exploded Views
5-17
Page 48
XLT-1071AIR
Table 5-7. Control Boxes Parts List
Item No. Part No. Description Qty
1 B09-00-0002 4 Push On-2NPT 90 13
2 B19-00-0020 Upper Control Box 1
3 B19-00-0021 Lower Control Box 1
4 B09-00-0001 Air Switch Toggle 1
5 B09-00-0015 Air Switch Push Button 3
6 B09-00-0016 Air Switch E-Stop 2
7 B09-00-0022 Tee 4-Pushon 1
8 B02-02-0197 2 NPT Plug 2
9 B05-00-0003 Clear Plastic Tube ¼”
5-18
Page 49
5 — PARTS LIST
5-19
Page 50
XLT-1071AIR
5-10 AIR-REG-LUBE-VALVE ASSEMBLY
Figure 5-10. Air-Reg-Lube-Valve Assembly Drawing
5-20
Page 51
6
6
66
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. Sound principles of safety, training, inspection, maintenance,
applications, and operation consistent with all data available regarding the parameters
intended use and expected environment shall be applied in the training of operators, in
maintenance, application, and operation of the aerial platform with due consideration of
the knowledge that the unit will be carrying personnel.
5.2 Manuals. Dealers shall keep and maintain copy(ies) of the operating and
maintenance manual(s) required in 4.17. Copy(ies) of operating manual(s) shall be
provided upon each rental or lease delivery. Copy(ies) of operating and maintenance
manual(s) shall be provided upon each sale delivery. The operating manual(s) shall be
stored in the location required by 4.18. These manual(s) are considered an integral part
of the aerial platform and are vital to communicate necessary safety information to users
and operators.
5.3 Predelivery Preparation. Aerial platforms shall be inspected, serviced, and
adjusted to manufacturer's requirements prior to each delivery by sale, lease, or rental.
5.4 Maintenance Safety Precautions. Before adjustments and repairs are started on an
aerial platform, the following precautions shall be taken as applicable: (1) All controls in
the "off" position and all operating features secured from inadvertent motion by brakes,
blocks, or other means. (2) Powerplant stopped and starting means rendered inoperative
(3) Platform lowered to the full down position, if possible, or otherwise secured by
blocking or cribbing to prevent dropping (4) Hydraulic oil pressure relieved from all
hydraulic circuits before loosening or removing hydraulic components (5) Safety props
or latches installed where applicable as described by the manufacturer.
5.5 Replacement Parts. When parts or components are replaced, they shall be identical
or equivalent to original aerial platform parts or components
5.6 Training. Whenever a dealer directs or authorizes an individual to operate an aerial
platform, the dealer shall ensure that the individual has been trained under the direction of
a qualified person in accordance with the manufacturer's operating and maintenance
manual and requirements listed in Section 8 before operating the aerial platform.
5.6.1 Training on Delivery. Manufacturer's operating inst ruction and required
training on the proper use and operation of the aerial platform shall be provided upon
each delivery, by sale, lease, or rental.
5.7 Operation. When a dealer operates an aerial platform in sales demonstrations or for
other beneficial use, the dealer shall assume the responsibilities of users as specified in
Section 7 and the operating personnel 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.
6-1
Page 52
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.
5.11 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 annua l 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.
6-2
Page 53
6 — 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 freq uent 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.
6-3
Page 54
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 Maint e nance. 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.
6-4
Page 55
6 — 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 opera t ing 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.
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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. 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 o f t he 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.
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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. 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 obs tructions 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.
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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. 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 contr ols.
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.
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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. 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.
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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 w e ll a s tho se sho wn.
• 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.
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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) (Meters)
0 to 300V 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 13.72
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®
125 Taylor Parkway
Archbold, OH 43502
Phone (419) 445-9675
(800) 527-5333
Fax (419) 445-0367
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