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Bil-Jax Cougar Lift Hydraulic Lift Platform Personal Lift User Manual

1. REPLACE CHAIN IF 20 PITCHES MEASURES OVER 12 75 32 385 CM Figure 3 4 Chain Elongation Inspection NOTE Itis recommended that chains be replaced every four years unless dam age or wear requires replacement at a lesser interval 3 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 After the platform is completely lowered remove the plexiglass cover from the base Chains should be tight to the touch with no loose play Check all four lift chains for snugness If a chain is loose tighten the lock nut below the clevis retainer Refer to Figure 3 5 Adjust any loose chain until it just becomes snug Do not overtighten any chain so that the platform is raised from its resting position 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 Figure 3 5 Lift Chain Adjustment 3 9 XLT 1071AIR 3 10 Slide Block Adjustment Annually check for wear on the slide blocks and replace or retighten as necessary If the lift exhibits excessive mast s
2. 2 779 mov ceps 5 PARTS LIST XLT 1071AIR 5 10 AIR REG LUBE VALVE ASSEMBLY PUG UN Prosiuew LLOO LO LLS RSS 9219 90 208 ISd 00 91195 95944 PISM 8000 00 608 uo usndyg 1200 00 608 O06W2 L dN8 W LdN8 eur l 13 9020 NETS es m 9 asn Assy eqn1 Dey 11 JUMA v qr 4 ebd Y 6000 00 609 0100 00 609 3000 00 60 1200 00 609 06 WldNz uo usndp 2000 00 608 Figure 5 10 Air Reg Lube Valve Assembly Drawing 5 20 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 appl
3. 3 1 Monthly Service 220 00000401000 3 2 Replacement Decals esses sees eene 4 1 Top Mast Parts ASt eie eee vo eo iere er ete 5 3 Lower Mast P tts Iust ise eite etri 5 6 Upper Base Parts 1456 tete resins 5 7 Platform Parts Past eere PET Eten eh 5 10 Air Pump Unit Parts eee peteret 5 11 Pneumatic Plumbing Parts List esee 5 13 Control Boxes Parts List enne 5 17 Minimum Safe Approach Distance M S A D to energized exposed or insulated power lines and 5 6 11 1 1 Safety INTRODUCTION Familiarity and proper training are required for the safe operation of mechanical equip ment 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 fa miliar with the equipment before being allowed to operate the machine The use of intelli gence 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 ope
4. 4 2 must be used at all times dur 1 EET 06 00 0034 B06 00 0173 06 00 0192 ing operation Failure to wear Full Body Harness and Lanyard may allow operator to fall from platform resulting in serious injury or death 06 00 0339 FAILURE TO COMPLY WITH THE FOLLOWING SAFETY INSTRUCTIONS OR ANY OTHER IM Batt SERIAL NO TUTI PROPER USE OF THIS EQUIPMENT WILL RESULT IN SERIOUS INJURY OR DEATH attery MAX PLATFORM 14 n 10 BEFORE USE DO NOT exert horizontal torce to the platform while performing work Charger POWER SOURCE DO NOT use in area where there are cranes or other moving vehicles gt Operator must read and understand owners manual and decals on ovat machine before operating It is your responsibility to comply with all warnings and instructions Survey the job site for all potential hazards Perkin Work outside the guard ril area Inspect unit for damaged parts DO NOT operate until all damaged parts DO NOT use withoutentry place 1 1 5V bil jax aparts stayclearatallmoving parts andkeep allperson have beenreplacedandallmaintenencehes been performed as utlinedin 125 TAYLOR PARKWAY owners manual nel hie raising end lowering piston 06 00 0296 ARCHBOLD 43502 U S A DO NOT allow ropes lecti cords hoses et
5. 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 6 5 XLT 1071AIR 6 6 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
6. 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
7. 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
8. from the unit After maintenance has been performed on the hydraulic cylinder follow the re moval 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 3 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 Reinstall the hydraulic cylinder into the unit and reconnect the hydraulic hose Refill hydraulic fluid reservoir 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
9. 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 th
10. on the aerial platform 8 7 Workplace Inspection Before the aerial platform is used and during use the operator shall check the area in which the aerial platform is to be used for possible hazards such as but not limited to 1 Drop offs or holes 2 Bumps and floor obstructions 3 Debris 4 Overhead obstructions and high voltage conductors 5 Hazardous locations 6 Inadequate surface and support to withstand all load forces imposed by the aerial platform in all operating configurations 7 Wind and weather conditions 8 Other possible unsafe conditions 8 8 During Operation The aerial platform shall be used in accordance with this standard The operator shall ensure the following before each elevation of the platform 1 That the aerial platform is operated on a surface within the limits specified by the manufacturer 2 That the outriggers stabilizers extendable axles or other stability enhancing means are used as required by the manufacturer 3 That the guardrails are installed and access gates or openings are closed per manufacturer s instructions 4 That the load and its distribution on the platform and any platform extensions are in accordance with the manufacturer s rated capacity for that specific configuration 5 That there is adequate clearance from overhead obstructions 6 That the minimum safe approach distances MSAD to energized power lines and parts as listed in Table One are maintained See Figure 2 for examples of s
11. 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 f
12. 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 ANSI REPRINT 77 Before Operation Before authorizing 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
13. 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 6 ANSI REPRINT 8 2 Manuals The operator shall be aware that the operating safety manuals including the manual that defines the responsibilities of dealers owners lessors lessees users and operators are stored on the aerial platform and the location where they are stored The operator shall be familiar with the manuals stored on the aerial platform and consult them when questions arise with respect to the aerial platform 8 3 Prestart Inspection 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
14. to Table 5 4 for the parts list for the platform Q E f SS Sk SSS SS LSS SSS AFNA 77 WITH Ul ZH Uf Gh SY Figure 5 4 Platform Exploded View XLT 1071AIR Table 5 4 Platform Parts List 0090 0802 Screw 10 24 x 7 8 in Not Used on Air Unit T E i gt 5 T 5 10 5 PARTS LIST 5 5 AIR PUMP UNIT PARTS LIST Refer to Table 5 5 for the parts list for the air pump unit A W SS ENDHEAD MC E ELMAR T ay Noy 7 000000 x ME X Figure 5 5 Air Pump Unit Drawing XLT 1071AIR Table 5 5 Air Pump Unit B02 05 0026 PB 1020 Parts List gt 8 gt gt 5 PARTS LIST 5 6 PNEUMATIC PLUMBING PARTS LIST Refer to Table 5 6 for the parts list for the pneumatic plumbing 2I IN
15. what constitutes structural damage please call the Workforce Service De partment at 419 445 9675 Damage Repair Notice There may be occasions when a Workforce lift is involved in an incident resulting in non structural damage When this occurs and repairs are made by the owner or area distribu tor please notify Workforce of these non maintenance repairs and request a repair form to be filled out and returned to Workforce 1 7 XLT 1071AIR 1 8 2 1 Introduction 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 Ibs 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 el
16. 0KV 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 e ALWAYS position lift far enough away from power sources to ensure that part of the lift can accidentally reach into an unsafe area e ALWAYS operate only on firm and level surface NEVER use on surfaces that do not support the weight of the equipment and its rated load capacity e ALWAYS keep yourself and all personnel away from potential pinch or shear points e ALWAYS report any misuse of equipment to the proper authorities Horseplay is prohibited e ALWAYS maintain good footing on the platform NEVER wear slippery soled shoes e ALWAYS make certain all personnel are clear and there are no obstructions be fore repositioning platform e 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 e ALWAYS disconnect power at the batteries when not in use to guard against un authorized use 1 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 plat
17. All emergency and safety devices 7 Lubrication of all moving parts inspection of filter element s hydraulic oil engine oil and coolant as specified by the manufacturer 8 Visual inspection of structural components and other critical components such as fasteners pins shafts and locking devices 9 Placards warnings and control markings 10 Items specified by the manufacturer 11 Correction of all malfunctions and problems identified and further inspection if necessary 6 5 Annual Inspection The owner of an aerial platform shall cause an annual inspection to be performed on the aerial platform no later than 13 months from the date of the prior annual inspection The inspection shall be made by a person qualified as a mechanic on the specific make and model of the aerial platform The inspection shall include all items specified by the manufacturer for an annual inspection 6 ANSI REPRINT 6 6 Maintenance Safety Precautions Before adjustments and repairs are started 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
18. ERATE horde THIS EQUIPMENT WITHIN 10 and the green ur tn athe lover conl ox ory FEET OF HIGH VOLTAGE LINES 06 00 0009 OF 50 000 VOLTS LESS 06 00 0291 For safe clearance of lines in excess of 50 000 volts see owners manual This machine is NOT insulated Do not use within 10 ft of power lines or other electrically charged sources This machine DOES NOT provide STAY CLEAR protection for personnel from contact with or close proximity to any live WHI LE RAISING electrical power source and should be considered energized by all personnel coming in contact with machine OR LOWERING 06 00 0146 B06 00 0146 B06 00 0225 Figure 4 1 Replacement Decals 4 2 4 REPLACEMENT DECALS 0146 0170 0339 OR 0339BLT 0173 Ww R 0192 0 X i 0105 T7 LA 0291 e 0170 9 pees 0167 ROUND cree BASE ALL SIDES Figure 4 2 Decal Locations Side View 4 3 XLT 1071AIR 0296 0034 a 0003 CN Foe INSIDE 0167 Geen atl SIDES INSIDE BASE ON ALL SIDES Figure 4 3 Decal Locations Front View 4 4 5 Parts List XLT 1071AIR 5 1 MAST PARTS LIST Refer to Table 5 1 for the parts list for the top mast Figure 5 1 Top Mas
19. Lubrication 3 3 3 3 Hydraulic 3 6 3 4 Lift Chains And Slide 3 8 4 Replacement Decals 5 5 0 ecco oer e sociae ease sa testo sana ara ravenna rand 4 1 5 Parts List C 5 1 5 1 Top Mast Parts List eee ete 5 2 5 2 Lower Mast emp 5 4 5 3 Upper 5 7 5 4 Platform Parts Tea Sts ini eerte eite eere 5 9 5 5 Air Pump Unit Parts List 5 10 5 6 Pneumatic Plumbing Parts List see 5 12 5 7 Pneumatic Schematic 5 14 5 8 Hydraulic Schematic 5 15 5 9 Control Boxes Parts 1150 5 16 5 10 Air Reg Lube Valve Assembly Drawing 5 18 6 ANSI Cove ett 6 1 List of Illustrations Figure 3 1 Lift Chain 3 3 Figure 3 2 Caster Lubrication societe ee eee tte bestehen 3 4 Figure 3 3 Hydraulic Cylinder Exploded 3 7 Figure 3 4 Chain Elongation 2 04 3 8 Figure 3 5 Lift Chain Adjustment sess 3 9 Fig
20. 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 3 XLT 1071AIR 3 6 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 hy draulic cylinder 1 Be sure cylinder is completely retracted and pressure is released from the sys tem Place a pan underneath the hydraulic cylinder to catch the hydraulic oil Disconnect the hydraulic hose from the bottom of the cylinder and drain the hy draulic oil Remove the two bolts washers and nuts securing the bottom of the cylinder to the base Remove the plexiglass cover from the base Remove the mounting bolt washer and nut securing the top of the hydraulic inder to the lower mast Disconnect the two lift chains from the base mast Using a crane with at least one ton of lifting capacity lift the lower mast section high enough to remove the clamp securing the cylinder to the base and remove the cylinder
21. VEOAH eOLOWS LINN H3MOd 5 O H 110 2 E u3 110 831713 1071 NMOG 3015 AINSVYSWS 440 7 Figure 5 6 Pneumatic Plumbing Diagram 5 13 XLT 1071AIR Table 5 6 Pneumatic Plumbing Parts List gt b _ b b b a B02 05 0026 Air Driven Hydraulic Pump Unit w Mounting Bolts 77 71 779 meos 5 14 5 PARTS LIST 5 7 PNEUMATIC SCHEMATIC 3010 IV 0 9 H32N3 IIS 330 0 YOLVNLIV 5 15 XLT 1071AIR Figure 5 7 Pneumatic Schematic Diagram 5 8 HYDRAULIC SCHEMATIC B02 03 0018 Lift Cylinder B02 13 0097 Seal Kit B02 01 0001 15 Hose Assembly B02 05 0026 Air Pump Unit gt 02 04 0002 i i Flow Control 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 Upper Control Box Lower Control Box Figure 5 9 Control Boxes Exploded Views 5 17 XLT 1071AIR 5 18 Table 5 7 Control Boxes Parts List 2 mme Jai Ji 4 Ja meas air swish Pus Buon 5 J gt 7
22. WORKFORCE Model XLT 1071AIR AERIAL WORK PLATFORMS Operation and Maintenance Manual COUGAR LIFT Hydraulic Lift P latform bil B33 01 0087 A Member of the plettac Group TELESCOPIC PERSONNEL LIFT This equipment is designed and manufactured in compliance with the duties re sponsibilities 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 stan dards when used in accordance with sections 5 6 7 8 9 amp 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 opera tion of this equipment Table of Contents 1 1 1 1 1 Introduction reote 1 1 1 2 Before Operation oit erre 1 3 1 3 During Operation 1 4 1 4 Maintenance 5 1 6 1 5 Damaged Equipment 1 7 2 Jntrod ction c 2 1 2 1 General 2 1 2 2 Specifications Die nee 2 2 2 3 dro i er eer ert ente e e eerie 2 2 3 3 1 3 1 Scheduled Service 3 1 3 2
23. afe 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 6 7 XLT 1071AIR 8 10 Warnings and Instructions The operator and other personnel on the platform shall comply with the requirements in 8 10 1 through 8 10 17 8 10 1 Personnel Footing Personnel shall maintain a firm footing on the platform floor while working thereon Use of planks ladders or any other devices on the aerial platform for achieving additional height or reach shall be prohibited 8 10 2 Other Moving Equipment 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 operatio
24. c to become entangled in Never Take Chances DO this machine if you the lift while platform is being raised or lowered are under the influence of drugs or alcohol or if you PATENT 4 484 663 DO NOT modify lift or bypass safety devices feel dizzy ill or unsteady in any way DO NOT move lift with person or material on Operate on firm and level surface only oard Cordon off area around base to keep personnel and 06 00 0228 DURING USE OWNERS AND OPERATORS ARE RESPONSIBLE FOR DO NOT use where lift can come into contact with INSPECTION MAINTENANCE TRAINING AND OPERATION AS REQUIRED BY THE OWNERS MANUAL AND THE ANSI 2 3 STANDARD overhead obstructions such as electric wires cables MANUAL AND THE ropes overhangs ete DO NOT use boxes ladders scaffolding for lifts WORKFORCE planking or other means to increase working height Ifyou have not been provided with safety literature G bil jax DO NOT use exposed to wind rain snow or ice or for questions concerning the safe use of this call 419 Member otta petos DONOT exceed rated load capacity of platform oM X L 06 00 0295 06 00 0295 1 0 This machine is designed and manufactured compli 7 FAILURE TO COMPLY 1 WITH THE FOLLOWING MAINTENANCE REQUIREMENTS ance with the ANSI 92 3 standar
25. cals 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 _ __ extras sopas _ 1 3 2 3 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 lift chains with clean 40W oil weekly or as needed Refer to Figure 3 1 LIFT CHAINS Figure 3 1 Lift Chain Lubrication 3 3 XLT 1071AIR 2 Grease all caster axles and swivel raceways at the 2 grease fittings on each caster semiannually with wheel bearing grease Refer to Figure 3 2 Figure 3 2 Caster Lubrication NOTE
26. d in force on the date of COULD RESULT IN SERIOUS INJURY OR DEATH manufacture Dealers owners users operators lessors and lessees are responsible for inspection maintenance Follow complete maintenance schedule outlined in Owner s Manual ini i and Section 6 of the 5 standard reprinted in the Owner s Manual training and operation as required by 192 and ine owners Inspect all chain assemblies fasteners pins and related parts daily manual 06 00 0105 for wear damage proper tightness and function Replace according Alterations modifications or changes to this machine to Owner s Manual recommendations without the written authorization of Workforce Products SiDe motoversihter Inc as well as any unauthorized adjustment of valves Slide block paths must be kept clean free of dirt grease and other disabli b nd of safety devi the foreign material isabling or by passing of safety devices or the improper DO NOT use grease oil or any similar lubricant on masts or slide use of this machine shall exempt Workforce Products Inc blocks For additional lubrication use dry silicone only from any liability for any resulting injuries or damage ome B06 00 0137 B06 00 0138 B06 00 0175 Moving telescopic masts will create Level machine before use pinch points Keep fingers hands arms and feet clear of all telescopic IT IS UNLAWFUL TO OP
27. e aerial platform the owner shall obtain the proper information from the dealer or manufacturer and provide that information to user or operator 6 12 Record Retention The owner shall retain the following records for at least 3 years 1 Name and address of the purchaser of each aerial platform by serial number and date of delivery 2 Records of the person s trained upon each delivery of an aerial platform 3 Written records of the frequent and annual inspections performed by the owner The record shall include deficiencies found corrective action and identification of the person s performing the inspection and repairs 4 Records of the predelivery preparation performed prior to each delivery 6 13 Modifications The owner shall not modify or concur in modifications or alteration to the aerial platform without the modifications being approved and certified in writing by the manufacturer 6 14 Manufacturer s Safety Bulletins The owner shall comply with safety related bulletins as received from the manufacturer or dealer 7 Responsibilities of Users 7 1 Basic Principles The information in this standard must be supplemented by good job management safety control and the application of sound principles of safety training inspection maintenance application and operation consistent with all data available regarding the parameters of intended use and expected environment Since the user has direct control over the application and ope
28. eneral safety precautions are followed before operating the Cougar Lift e 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 hap pen Watch for moving vehicles in the operating area e ALWAYS read understand and follow the procedures in this manual before at tempting to operate equipment e 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 oper ate equipment if damaged in any way Improperly operating equipment must be repaired before using e ALWAYS wear proper clothing for the job Wear protective equipment as re quired by federal state or local regulations e ALWAYS locate read and follow all directions and warnings displayed on the equipment e 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 e ALWAYS make sure the platform and shoes are free of mud grease or other foreign material This will reduce the possibility of slipping e NEVER allow improperly trained personnel to operate this
29. equipment Only trained and authorized personnel shall be allowed to operate this equipment e 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 physi cally fit thoroughly trained and not easily excitable e NEVER modify alter or change the equipment in any way that would affect its original design or operation in any way e NEVER operate this equipment in ways for which it is not intended 1 3 XLT 1071AIR 1 4 1 3 DURING OPERATION Ensure the following general safety precautions are followed during the operation of the Cougar Lift N 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 con tact 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 Phase to Phase Feet Meters 0 to 300V Avoid Contact Over 300V to 50 10 3 05 Over 50KV to 200KV 15 4 60 Over 20
30. form 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 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 per formed on the Cougar Lift e ALWAYS perform maintenance procedures according to manufacturer s re quirements NEVER short change maintenance procedures e ALWAYS check hydraulic system Make sure all lines connectors and fittings are tight and in good condition e ALWAYS keep all mechanisms properly adjusted and lubricated according to maintenance schedule and manufacturers specifications e ALWAYS perform a function check of operating controls before each use and after repairs have been made e ALWAYS
31. ications 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 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 pre
32. iminated by proper mainte nance 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 free fall 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 dur ing 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 erating the Cougar Lift 2 1 XLT 1071AIR 2 2 2 3 SPECIFICATIONS Cougar Lift Hydraulic Lift Platform Model Number XLT 1071 AIR Manufactured by Serial Number bil jax Inc WORKFORCE AERIAL WORK PLATFORMS 125 Taylor Parkway Archbold Ohio 43502 419 445 8915 Table 2 1 Specifications Rated Pla
33. information from the manufacturer and provide that information to the owner or user 6 1 XLT 1071AIR 6 2 5 9 Record Retention Dealer s shall retain the following records for at least 3 years 1 Name and address of the purchaser of each aerial platform by serial number and the date of delivery 2 Records of the person s trained upon each delivery of an aerial platform 3 Records of the predelivery preparation performed prior to each delivery 5 10 Modifications Modifications or alterations of aerial platforms shall be made only with prior written permission of the manufacturer 511 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 5 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
34. ing 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 6 9 XLT 1071AIR BUS BARS M S A D Minimum Safe Approach Distance See Table 6 1 DENOTES PROHIBITED ZONE DANGER Do not allow machine personnel or conductive materials inside prohibited zone Maintain M S A D from all energized lines and parts as well as those shown Assume all electrical parts and wires are energized unles
35. ll protection equipment be used at all times durin 4 operation Failure to wear fall A DANGER FAILURE TO COMPLY WITH THE FOLLOWING INSTRUCTIONS OR ANY OTHER IMPROPER USE OR MAINTENANCE OF THIS EQUIPMENT WILL RESULT IN INJURY OR DEATH protection equipment may all Risk of Electric Shock MN operator to fall from platfor 1 OCCUPANT 500 LBS OR piys320LBs 06 00 0170 o DO NOT expose charger to rain power wash detergents or resulting in serious injury spray DO NOT use frayed or damaged electric cords when 06 00 0289 charging UTT ATT 806 00 0339BLT During charging explosive oxyhydrogen gas is generated DO NOT smoke or allow open fire sparks or embers near battery when charging B 0 6 0 0 03 3 9 B LT Connect input cord only to properly grounded three wire outlet with specified voltage and frequency Always wear safety goggles and face shield when working on or near battery Check battery acid level at the start of each day If acid does SAFETY not cover the plates add only enough distilled or demineral HARNESS ized water to completely cover the plates LANYARD OPERATION AND SERVICE Keep terminals and terminal connections clean MANUAL INSIDE Consult Operation and Maint for additional POINT core mao Full Body Harness and Lanyard iniornation on battery
36. locate and protect against possible pinch points prior to performing maintenance and repairs e ALWAYS use only factory approved parts to repair or maintain this equipment If this equipment is rebuilt retesting is required in accordance with factory in structions e NEVER add unauthorized fluids to the hydraulic system or battery Check manu facturers specifications e NEVER exceed the manufacturer s recommended relief valve settings e NEVER attempt repairs you do not understand Consult manufacturer if you have any questions regarding proper maintenance specifications or repair 1 6 1 5 1 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 per form 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 facil ity at 125 Taylor Parkway Archbold Ohio for reconditioning If you have any questions concerning
37. n 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 floati
38. ng vessels scaffolds or similar equipment unless the application is approved in writing by the manufacturer 8 10 14 Travel Conditions Under all travel conditions the operator shall limit travel speed according to conditions of ground surface congestion visibility slope location of personnel and other factors causing hazards of collision or injury to personnel 8 10 15 Unauthorized Use Means shall be used to protect against use by unauthorized person s 8 10 16 Misuse as a Jack The platform of the aerial platform shall not be used to jack the wheels off the ground unless the machine is designed for that purpose by the manufacturer 8 10 17 Snagged Platform If the platform or elevating assembly becomes caught snagged or otherwise prevented from normal motion by adjacent structure or other obstacles such that control reversal does not free the platform all personnel shall be removed from the platform before attempts are made to free the platform using ground controls 8 11 Assistance to Operator If an operator encounters any suspected malfunction of the aerial platform or any hazard or potentially unsafe condition relating to capacity the operator shall cease operation of the aerial platform and request further information as to safe operation from management or from the owner dealer or manufacturer before further operation of the aerial platform 8 12 Modifications An operator shall not modify or concur in modification of an ae
39. 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
40. rate 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 1 2 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 per sonal injury N 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 ma chine or components NOTE Notes contain additional information important to a procedure 1 1 2 BEFORE OPERATION Ensure the following g
41. ration 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 XLT 1071AIR 6 4 7 2 Manuals Users shall keep and maintain copy ies of the operating and maintenance manual s required in 4 17 of this standard The operating manual s shall be stored in the location required in 4 18 of this standard These manuals are considered an integral part of the aerial platform and are vital to communication of necessary safety information to users and operators 7 3 Inspection and Maintenance Users shall inspect and maintain the aerial platform as required to ensure proper operation The frequency of inspection and maintenance shall be determined by the manufacturer s recommendation and be compatible with operating conditions and the severity of the operating environment Aerial platforms that are not in proper operating condition shall be immediately removed from service until repaired Repairs shall be made by a qualified person and the repairs shall be in conformance with the manufacturer s recommendations 7 3 1 Frequent Inspection An inspection as outlined in 6 4 of this standard shall be conducted 7 3 2 Annual Inspection An inspection as
42. rial platform without the specific written approval of the manufacturer of the aerial platform 6 8 6 ANSI REPRINT 9 Responsibilities of Lessors 9 1 Basic Principles Sound principles of safety training inspection maintenance application and operation consistent with all data available regarding the parameters of intended use and expected environment shall be applied in the performance of responsibilities of lessors with due consideration of the knowledge that the unit shall be carrying personnel 9 2 Lessor 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 regard
43. rom the dealer owner or manufacturer and provide that information to the operator before use of the aerial platform in the application of concern 7 14 Shutdown of Aerial Platform The user shall authorize and direct the operating personnel to cease operation of the aerial platform in case of any suspected malfunctions of the aerial platform or any hazard or potentially unsafe condition that may be encountered and to request further information as to safe operation from the owner dealer or manufacturer before further operation of the aerial platform 7 15 Record Retention The user shall retain the following records for at least 3 years 1 Records of the operator s trained on each model of an aerial platform 2 Written records of the frequent and annual inspections shall be kept by the user when performing the inspections The records shall include the date of inspection any deficiencies found the corrective action recommended and identification of the person s performing the inspection 3 Written records of all repairs accomplished on the aerial platform including the date of any such repair a description of the work accomplished and the identification of the person s performing the repair 7 16 Modifications A user shall not modify or concur in modification of an aerial platform without the specific written approval of the manufacturer of the aerial platform 7 17 Manufacturer s Safety Bulletins The user shall comply with safety
44. s known otherwise N CAUTION Diagrams shown are only for purposes of illustrating M S A D work positions not all work positions 6 10 Table 6 1 Minimum Safe Approach Distance M S A D to energized 6 ANSI REPRINT exposed or insulated power lines and parts Minimum Safe Approach Distance Voltage Range Phase to Phase Feet Meters 0 to 300V Avoid Contact Over 300V to 50 10 3 05 Over 5 to 200KV 15 4 60 Over 200KV to 350KV 20 6 10 Over 350KV to 500 25 7 62 Over 500KV to 750KV 35 10 67 Over 750KV to 1000 45 13 72 XLT 1071AIR bil 125 Taylor Parkway Archbold OH 43502 Phone 419 445 9675 800 527 5333 419 445 0367
45. specified by the manufacturer 2 That the outriggers stabilizers extendable axles or other stabilizing methods are used as required by the manufacturer 3 That guardrails are installed and access gates or openings are closed per manufacturer s instructions 4 That the load and its distribution on the platform and any platform extension are in accordance with the manufacturer s rated capacity for that specific configuration 5 That there is adequate clearance from overhead obstructions 6 That the minimum safe approach distances MSAD to energized power lines and parts as listed in Table One are maintained See Figure 2 for examples of safe operating procedures 7 That the precautions defined in 7 3 3 7 6 7 7 7 8 7 9 7 10 and 7 11 of this standard are followed during operation of the aerial platform 7 10 Determination of Hazardous Locations It shall be the responsibility of the user to determine the hazard classification of any particular atmosphere or location according to ANSI NFPA 505 1987 Aerial platforms operated in hazardous locations shall be approved in accordance with and of the type required by ANSI NFPA 505 1987 7 11 Warnings and Instruction The user shall direct his operating personnel and supervise the work to ensure operation in compliance with the requirements in 7 11 1 through 7 11 14 7 11 1 Personnel Footing Personnel shall maintain a firm footing on the platform floor while working thereon Use of planks ladders
46. 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 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 functions and their controls for speed s smoothness and limits of motion 4 Emergency lowering means 5 chain and cable mechanisms for adjustment and worn or damaged parts 6
47. t Exploded View 5 PARTS LIST Table 5 1 Mast Parts List 772 0090 0813 Screw 8 32 x 3 4 in Not Used on Air Unit 01 02 0059 Box Control Upper Not Used Air Unit T gt B01 09 0029 Bushing Strain Relief Not Used Air Unit 8 B05 01 0034 Cable SJO 18 2 Not Used Air Unit 80 in B03 00 0009 Chain Assy includes items 9 10 11 and 19 NOTE It is recommended that chain parts be purchased as an assembly 5 3 XLT 1071AIR 5 2 LOWER MAST PARTS LIST Refer to Table 5 2 for the parts list for the lower mast 5 4 5 PARTS LIST Figure 5 2 Lower Mast Exploded View 5 5 XLT 1071AIR Table 5 2 Lower Mast Parts List 3 ewe Pin coeno 7 7 gt gt gt 5 T NOTE It is recommended that chain parts be purchased as an assembly 5 6 5 PARTS LIST 5 3 UPPER BASE PARTS LIST Refer to Table 5 3 for the parts list for the upper base Figure 5 3 Upper Base Exploded View Table 5 3 Upper Base Parts List 5 7 XLT 1071AIR 6 meoree 7 01 02 0058 Box Control Lower Not Used Unit 0090 0813 Screw 8 32 x 3 4 in Not Used Air Unit Tein Ratner 5 8 5 PARTS LIST 5 4 PLATFORM PARTS LIST Refer
48. tform Load 500 Ibs 227 kg total including operator 1 person materials not to exceed 500 Ibs 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 wx 50 in 1 x 42 in h 0 74 m x 1 27 mx 1 07 m Base Dimensions 30 1 2 in w x 71 in 77 in h 0 77 mx 1 8 mx 1 95 m Retracted Dimensions 30 1 2 in w x 73 1 2 x 77 in h 0 77 mx 1 87 mx 1 95 m Gross Shipping Weight 1025 Ibs 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 WARRANTY Bil Jax warrants its telescopic lifts for one year from the date of delivery against all de fects of material and workmanship provided the unit is operated and maintained in com pliance 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 compo nent 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
49. 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 oc curring during normal use Components not manufactured by Bil Jax are covered by their respective manufacturer s warranties list of those components and their warranties is available upon written re quest to Bil Jax Bil Jax shall not in any event be liable for the cost of any special indirect or consequen tial 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 per son to assume for us any other liability in connection with the sale rental or use of this product 2 2 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 Y 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 de
50. 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 Cylinder Jacket Washer Rod Packing Rings Gland Nut Rod Wiper Piston Rod Wear Ring gt 0 9 E N oc _ Figure 3 3 Hydraulic Cylinder Exploded View 3 7 XLT 1071AIR 3 8 3 4 LIFT CHAINS AND SLIDE BLOCKS WARNING Do not operate a unit on which any chain assembly is damaged or in need of re placement 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 dam age 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 ra ra p rn A 21 rH cH lt 20 PITCHES 12 5 IN 31 75
51. ure 3 6 Slide Block 3 10 Figure 4 1 Replacement Decals ee pede tee 4 2 Figure 4 2 Decal Locations Side 4 3 Figure 4 3 Decal Locations Front View esee 4 4 Figure 5 1 Mast Exploded View seen 5 2 Figure 5 2 Lower Mast Exploded View essere 5 5 Figure 5 3 Upper Base Exploded 5 7 Figure 5 4 Platform Exploded View eese eene 5 9 Figure 5 5 Air Pump Unit 5 10 Figure 5 6 Pneumatic Plumbing Diagram esee 5 12 Figure 5 7 Pneumatic Schematic Diagram 5 14 Figure 5 8 Hydraulic Schematic 5 15 Figure 5 9 Control Boxes Exploded Views esee 5 16 Figure 5 10 Air Reg Lube Valve Assembly Drawing 5 18 Figure 6 1 Minimum Safe Approach Distance Diagram 6 10 List of Tables Table 1 1 Table 2 1 Table 3 1 Table 3 2 Table 4 1 Table 5 1 Table 5 2 Table 5 3 Table 5 4 Table 5 5 Table 5 6 Table 5 7 Table 6 1 Minimum Safe Approach Distances 1 4 Specifications 22 Daily Weekly Service Checks 2
52. vent 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 instruction and required training on the proper use and operation of the aerial platform shall be provided upon each delivery by sale lease or rental 5 7 Operation When a dealer operates an aerial platform in sales demonstrations or 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
53. way 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 NOTE Loosen do not remove the slotted hex head screw securing the slide block to be adjusted Using an allen wrench turn the set screws in clockwise This will push the block in against the next mast Do not overtighten Tighten the slotted hex head screw to secure the slide block in position Check all slide blocks and make adjustments as necessary After all adjustments are made fully extend the lift If the platform can be low ered without stopping then the blocks are properly adjusted SLIDE BLOCKS Figure 3 6 Slide Block Adjustment 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 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 4 1 XLT 1071AIR CHECK LEVEL MAXIMUM CAPACITY bee ue Fa

Bil-Jax Cougar Lift Hydraulic Lift Platform Personal Lift User Manual

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