Bil-Jax XLT-1071AIR User Manual

®

AERIAL WORK PLATFORMS

Model XLT-1071AIR

Operation and

Maintenance Manual

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Hydraulic Lift Platform

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XLT 1

0 7 1

WARNING

WARNING

®

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.

It is the responsibility of the user of this equipment to follow all applicable ANSI, OSHA, Federal, State, and local codes and regulations that govern the safe operation of this equipment.

Table of Contents

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	1-6
	1-5 .............................................................	Damaged Equipment Policy	1-7

2	Introduction ....................................................................................................		2-1
	2-1	General Description...........................................................................	2-1
	2-2	Specifications .....................................................................................	2-2
	2-3	Warranty.............................................................................................	2-2

3	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
4	Replacement Decals........................................................................................					4-1
5	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
6	ANSI Reprint .................................................................................................					6-1

i

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

ii

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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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. 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 obtained, read, and thoroughly understood before attempting to operate this equipment. Persons under the influence of drugs, alcohol, or prescription medication should not be on or near this equipment. Common sense should 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.

1-1

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 procedure.

1-2

1 — SAFETY

1-2 BEFORE OPERATION

Ensure the following general safety precautions are followed before operating the Cougar Lift.

•ALWAYS survey the usage area for potential hazards such as untampered earth fills, unlevel surfaces, overhead obstructions, and electrically charged conductors or wires. Be aware of any potential hazards and always consider what could happen. Watch for moving vehicles in the operating area.

•ALWAYS read, understand, and follow the procedures in this manual before attempting to operate equipment.

•ALWAYS inspect the equipment for damaged or worn parts. Check for cracked welds, hydraulic leaks, damaged wiring, loose wire connectors, damaged casters, and damaged floor pads. Also check for any improper operation. NEVER operate equipment if damaged in any way. Improperly operating equipment must be repaired before using.

•ALWAYS wear proper clothing for the job. Wear protective equipment as required by federal, state, or local regulations.

•ALWAYS locate, read, and follow all directions and warnings displayed on the equipment.

•ALWAYS inspect the equipment for any “DO NOT USE” tags placed on the equipment by maintenance personnel. NEVER use any equipment tagged in this way until repairs are made and all tags are removed by authorized maintenance personnel.

•ALWAYS make sure the platform and shoes are free of mud, grease, or other foreign material. This will reduce the possibility of slipping.

•NEVER allow improperly trained personnel to operate this equipment. Only trained and authorized personnel shall be allowed to operate this equipment.

•NEVER operate this equipment if you are under the influence of alcohol or drugs or if you feel ill, dizzy, or unsteady in any way. Operators must be physically fit, thoroughly trained, and not easily excitable.

•NEVER modify, alter, or change the equipment in any way that would affect its original design or operation in any way.

•NEVER operate this equipment in ways for which it is not intended.

1-3

XLT-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	Minimum Safe Approach Distance
	(Feet)		(Meters)
(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

•ALWAYS position lift far enough away from power sources to ensure that no part of the lift can accidentally reach into an unsafe area.

•ALWAYS operate only on a firm and level surface. NEVER use on surfaces that do not support the weight of the equipment and its rated load capacity.

•ALWAYS keep yourself and all personnel away from potential pinch or shear points.

•ALWAYS report any misuse of equipment to the proper authorities. Horseplay is prohibited.

•ALWAYS maintain good footing on the platform. NEVER wear slippery soled shoes.

•ALWAYS make certain all personnel are clear and there are no obstructions before repositioning platform.

•ALWAYS cordon off area around the base to keep personnel and other equipment away from it while in use.

•ALWAYS stay clear of wires, cables, and other overhead obstructions.

•ALWAYS disconnect power at the batteries when not in use to guard against unauthorized use.

1-4

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 elevated heights.

•NEVER use guard rails to carry materials and never allow overhang of materials when raising or lowering platform.

1-5

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 requirements. NEVER short change maintenance procedures.

•ALWAYS check hydraulic system. Make sure all lines, connectors, and fittings are tight and in good condition.

•ALWAYS keep all mechanisms properly adjusted and lubricated according to maintenance schedule and manufacturers specifications.

•ALWAYS perform a function check of operating controls before each use and after repairs have been made.

•ALWAYS locate and protect against possible pinch points prior to performing maintenance and repairs.

•ALWAYS use only factory approved parts to repair or maintain this equipment. If this equipment is rebuilt, retesting is required in accordance with factory instructions.

•NEVER add unauthorized fluids to the hydraulic system or battery. Check manufacturers specifications.

•NEVER exceed the manufacturer's recommended relief valve settings.

•NEVER attempt repairs you do not understand. Consult manufacturer if you have any questions regarding proper maintenance, specifications, or repair.

1-6

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

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. 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.

2-1

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 properly in normal use.

This warranty does not apply if the lift and/or its component parts have been altered, changed, or repaired without the consent of Bil-Jax or by anyone other than Bil-Jax or its factory trained personnel, nor if the lift and/or its components have been subjected to misuse, negligence, accident or any conditions deemed other than those considered as occurring during normal use.

Components not manufactured by Bil-Jax are covered by their respective 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.

2-2

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

	Daily
Service Check	before use	Weekly
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.

3-1

XLT-1071AIR

Monthly Service Checks

Perform the following monthly service checks as listed in Table 3-2.

Table 3-2. Monthly Service Checks

	Every	Every	Every	Every
Service Check	month	6 months	12 months	48 months
Check hydraulic raise valve
operation.
Check operation of manual
emergency lowering valve.
Lubricate caster swivels and
axles.
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.

3-2

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

3-3