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

1. REPLACE CHAIN IF 20 PITCHES MEASURES OVER 12 75 1 32 385 CM Figure 4 7 Chain Elongation Inspection NOTE Itis recommended that chains be replaced every four years unless dam age or wear requires replacement at a lesser interval 4 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 4 8 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 4 8 Lift Chain Adjustment 4 13 XLT 1571AC 4 14 Slide Block Adjustment Annually check for wear on the slide blocks and replace or retighten as necessary If the lift exhibits excessive mast sway it is probable that the slide blocks
2. 6 18 Figure 6 10 Hydraulic Unit Assembly seen 6 20 Figure 6 11 Hydraulic Fittings and Hoses Diagram eee 6 22 Figure 6 12 Hydraulic Fittings and Hoses Schematic esses 6 24 Figure 6 13 Electrical 6 25 Figure 6 14 Electrical Layout Diagram eerte 6 26 List of Tables Table 1 1 Table 2 1 Table 4 1 Table 4 2 Table 4 3 Table 5 1 Table 6 1 Table 6 2 Table 6 3 Table 6 4 Table 6 5 Table 6 6 Table 6 7 Table 6 8 Table 6 9 Table 6 10 Table 6 11 Table 7 1 Minimum Safe Approach Distances 1 4 Sp CIfICatlOnS i totem te teme ehe edere en 2 2 Daily Weekly Service Checks eene 4 1 Monthly Service Checks essere 4 2 Troubleshooting Chart eese ener 4 15 Replacement Decals ote re erred ete tette 5 1 M st Parts Dist ee Ricette rere ede 6 3 Genter Mast Parts 6 5 Lower Mast Parts Last eie een ete een 6 7 Battery Compartment Parts List essere 6 9 Hydraulic Pump Compartment Parts List eese 6 11 Upper Base Parts iei tee etes 6 13 Base Mast Parts 6 15 Lower Base Parts Rr PEE 6 17 Platform Parts List uude reet ceo nn eerie ded 6 19 Hydraulic Unit
3. 8 lift is now ready for operation While depressing the ON pushbutton select the desired function UP or DOWN on the position selector switch The platform will raise or lower respectively The EMERGENCY STOP pushbutton deactivates the control circuit NOTE Should the platform continue to rise after the UP switch is released press the ON pushbutton and select the DOWN position at the same time and the platform should stop or lower EMERGENCY LOWERING PROCEDURE The Cougar Lift is equipped with a manual lowering valve in case of emergency situa tions to lower the platform The emergency lowering valve is located on the hydraulic block manifold in the hydraulic pump compartment The valve may be accessed through the opening on the base door To lower the platform turn the red knob on the valve counterclockwise Refer to Figure 3 3 uto Y LOST ERO LOWERING VALVE RED KNOB Figure 3 3 Emergency Lowering Valve 3 3 XLT 1571AC 4 1 Maintenance SCHEDULED SERVICE CHECKS Daily Weekly Service Checks Perform the following daily weekly service checks as listed in Table 4 1 Table 4 1 Daily Weekly Service Checks Daily Service Check before use Ensure Operation Manual is located in manual tube v Check chain assemblies for split leaves loose pins excessive wear or elongation Check and retighten all nuts and bolts Y Check cage attachment to the
4. b um amp 7 B02 15 0061 Magnet Plumbing B02 15 0121 Filter B02 15 0125 Cover Suction 11 B02 15 0126 Screw Taptite M6 x 1 0 12 mm Torx N Z gt 13 14 15 16 17 18 19 20 21 22 23 24 B02 15 0197 Valve Check Cartridge B02 15 0170 Bolt 5 16 18 x 1 00 B02 15 0171 AC Motor B02 15 0382 Bolt M6 x 1 0 B02 15 0383 Washer Lock B02 15 0199 Bolt 12 24 x 0 50 Hex B02 15 0206 Tank Horizontal Mount Plastic with Drain B02 15 0201 Breather Cap with Check Valve B02 15 0127 Spring Relief B01 09 0041 Plug Connector Hirschmann B02 15 0174 Wiring Assembly B02 15 0175 Adaptor 25 B02 15 0176 Strain Relief 26 B02 15 0361 Coil Solenoid 115VAC 27 B02 15 0073 O Ring 28 B02 15 0203 Head End 29 B02 15 0146 Pump Assembly 1 2 30 B02 15 0030 Cap Assembly Relief 31 B01 10 0148 Timer Delay 32 B05 01 0034 18 2 Wire 33 B02 15 0204 Plug 1 16 NPT Flush 34 B02 15 0205 Tube Return 3 8 90 35 B02 15 0059 Elbow Nylon B02 15 0357 Valve Cartridge NC B02 15 0351 Valve Body 2 Way NO B02 15 0026 Screw Valve Adjustment ON 6 21 XLT 1571AC 6 11 HYDRAULIC FITTINGS AND HOSES DIAGRAM PP Figure 6 11 Hydraulic Fittings and Hoses Diagram 6 22 6 PARTS LIST Table 6 11 Hydraulic Fittings and Hoses Parts List Item No 1 Part No Description B02 03 0018 Cylinder Hydraulic Lift 1 5 in Diameter B02 02 0002 Fitting 4JIC 4NPT 90 2501 4 B02 04 0002 Valve
5. heel 1 4 Upper Control E Stop ON Down NC o oul Light 6 PARTS LIST Lower Lift Option E R2 Wheel Valve R2 6 Mast Switch ooo Foot Switches Q R3 NO Terminal Connections for Black Box Terminal No Wire Color From Terminal No Wire Color From 1 BLK Mast Down Limit Switch 11 RED Level Sensor BLK Upper Control Box WHT Left Foot Limit Switch 2 BLK Lower Control Box 12 WHT Mast Down Limit Switch BLK Right Foot Limit Switch ORG BLK STR Lower Control Box 3 WHT Hydraulic Pump Motor 13 WHT Upper Control Box YEL Lower Control Box BRN BLK STR Lower Control Box 14 RED Hydraulic Manifold 15 GRN Upper Control Box RED BLK STR Lower Control Box YEL BLK STR Lower Control Box 16 7 17 WHT Level Sensor RED Lower Control Box 8 BLK Hydraulic Pump Motor 18 9 BLK Hydraulic Manifold 19 GRN Hydraulic Manifold WHT Hydraulic Manifold BLK Level Sensor 10 RED Upper Control Box 20 BRN Lower Control Box BLU Lower Control Box BLK Base Ground GRN Hydraulic Pump Motor Figure 6 13 Electrical Diagram 6 25 XLT 1571AC 1571 1071 AC Electric LayOut B01 03 0039 Foot Switches B01 01 0113 Plug Lead t i i i 8 i 2 s 3 115 8 2 T i 53 18 D 28 T10 H 8 ot aah 55 5 i B01 10 0139 Switc
6. ON PUSHBUTTON Figure 3 2 Upper Control Box 3 2 NORMAL OPERATING PROCEDURE Perform the following procedures to operate the Cougar Lift 1 Read and follow all safety precautions contained in Section 1 and all responsi bilities outlined in the ANSI A92 3 reprint contained in Section 7 of this man ual 2 Position the lift at the work area Make sure the lift is on a firm and level surface and that there are no potential hazards such as overhead obstructions or electri cally charged conductors Do not operate the lift if such hazards exist 3 Check the lift for damaged or worn parts and repair or replace as necessary 4 Check to be sure that the platform is properly attached to the lift 5 Raise the casters located under the platform by depressing the WHEEL UP BASE SET pushbutton located on the lower control box Raising the casters allows the base to set firmly on the two foot pads 6 Thelift should be level and positioned on the two foot pads with the WHEEL UP BASE SET pushbutton lit green Ensure that the platform s upward path of travel is free from obstructions Reposition the lift if necessary NOTE Thelift is equipped with a level sensor that will prevent the lift from rais ing if the lift is at a slope greater than 1 degree The green WHEEL UP BASE SET pushbutton will no longer illuminate until the lift is re leveled 7 Enter the platform Ensure that both side midrails are positioned properly 3
7. Figure 6 4 Rear Compartment Exploded View 6 8 Table 6 4 Battery Compartment Parts List Description Base Weldment Screw Threadcut 10 24 x 1 2 in Receptacle Flush Mount Screw 8 32 x 3 4 in Box Black TomCat Washer Flat 10 0090 0181 Nut Lock 8 32 Cover with screws 0090 0125 Bolt Carriage 1 4 20 x 1 1 4 in 0090 0206 Washer Lock 1 4 in 0090 0159 Nut 1 4 20 B44 00 0002 Board B37 00 0002 Lock Assy Utility 6 PARTS LIST Qty ele te 6 9 XLT 1571AC 6 5 HYDRAULIC PUMP COMPARTMENT PARTS LIST Refer to Table 6 5 for the parts list for the hydraulic pump compartment Figure 6 5 Hydraulic Pump Compartment Exploded View 6 PARTS LIST Table 6 5 Hydraulic Pump Compartment Parts List 1 B11 01 0087 Base Weldment 1 2 B05 00 0006 Tape Foam Adhesive 2 ft 3 4 Bolt 1 4 20 x 3 4 5 Washer Flat 1 4 in Bracket Hydraulic Valve 0090 0014 Bolt 1 4 20 x 2 1 2 in 2 0440047 Valve Combination 9 802 05 0011 Pump Hydraulic Bolt 3 8 16 x 3 4 in 0090 0210 Washer Lock Washer Flat Cover with 2 screws ur um 22 0090 0183 Nut Lock 1 4 20 4 Ese si 61 t2 r2 t2 t2 t2 0o XLT 1571AC 6 6 UPPER BASE PARTS LIST Refer to Table 6 6 for the parts list for the upper base Figure 6 6 Upp
8. The raise valve is a normally open N O valve in the hydraulic system Perform the fol lowing procedures to check the operation of the raise valve 1 Disconnect the black and yellow wires from the solenoid to the valve at the wire connector Figure 4 5 2 the upper control box select UP on the direction selector switch while de pressing the ON pushbutton This should cause the motor to run without the plat form raising 3 If the platform raises the raise valve must be cleaned or replaced 4 Reconnect the wires at the connector between the solenoid and the raise valve upon determining that the valve is functioning properly WIRE CONNECTOR RT Figure 4 5 Raise Valve Operation Check 4 8 4 Hydraulic Cylinder Repair AY CAUTION Removing the hydraulic cylinder from the Cougar Lift requires major disassem bly of the unit Contact Bil Jax before removing the hydraulic cylinder from the unit for assistance Hydraulic Cylinder Removal It is recommended that Bil Jax be contacted for assistance before removing the hydraulic cylinder 1 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 2 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
9. 2 Grease all caster axles and swivel raceways at the 2 grease fittings on each caster semiannually with wheel bearing grease Refer to Figure 4 2 Figure 4 2 Caster Lubrication NOTE The plastic slide blocks in the mast are made of a bearing material which has a high degree of lubricity and need only be kept clean However precautions should be taken to ensure that the paths along which the blocks move are kept clean and lightly lubricated with a dry type silicon lubricant 4 3 4 MAINTENANCE HYDRAULIC SYSTEM Hydraulic system maintenance varies by the amount of use and the environment in which the lift is used Constant attention to keep the oil clean and the reservoir properly filled will help prevent possible damage to the system Hydraulic System Inspection Check all hydraulic hoses and fittings for leaks and damage daily Tighten or replace as necessary to prevent hydraulic oil loss Refer to the hydraulic schematic diagram in Sec tion 6 for general reference Fluid Check and Replacement The reservoir should be filled to within 1 2 inch of the top with the platform in its lowest position The lift is shipped from the factory with Energol HLP HD46 BP Oil a high grade non foaming hydraulic oil designed for temperatures as low as 20 F 29 C Use Dextron Automatic Transmission Fluid Type A for temperatures as low as 40 F 40 C If either oil is not available a good grade SAE 10W hydraulic oil may be used whe
10. 5 1 XLT 1571AC Operation Instructions for Stockpickers Read and follow safety precautions and all responsibilities sections set forth in the operators manual 2 Position the lift at the work area Make sure the lift is on a firm and level surface and that there are no potential hazards such as overhead obstructions or electri cally charged conductors DO NOT use the lift where such hazards exist 3 Check the lift for damaged or worn parts and repair or replace as necessary 4 Check to be sure that the cage is properly attached to the lift 5 Depress the WHEEL UP button located on the lower control box which will raise the caster located under the cage allowing the base to sit firmly on the two foot pads 6 Once the lift is level and sitting firmly on the two leveling pads and the green WHEEL UP button is lit check again to be sure that the platforms path of travel is free from obstructions and reposition the lift as necessary DO NOT use the lift if not operating properly BO6 00 0306 SERIAL NO 1571 Stand clear when PLATFORM 14 n 10 in lowering lift onto the POWER SOURCE Tavoc foot pads as required WAS for proper operation OTHER Contact with foot pads will cause serious il iax crushing injury 4r bil jax 125 TAYLOR PARKWAY ARCHBOLD 43502 U S A 800 527 5333 PATENT 4 484 663 BO6 00 0228 Again check to see that the lift is positi
11. sese 3 2 3 3 Emergency Lowering Procedure esee 3 3 4 Maintenance eese ee eere ee esee ense enean tna tn tne 4 1 4 1 Scheduled Service Checks 4 1 4 2 L bric tion name Hte RED eR bte 4 3 4 3 Hydrauhc System ter duet 4 5 4 4 Electrical System iiie DEC Pere n 4 11 4 5 Lift Chains And Slide Blocks see 4 12 4 6 Troubleshooting edet d he pre teer 4 15 5 Replacement Decals e 5 1 jr 6 1 6 1 Top Mast Parts eere rette ePi 6 2 6 2 Center Mast Parts ee cot 6 4 6 3 Lower Mast Parts 5 ope ose 6 6 6 4 Rear Compartment Parts List eese 6 8 6 5 Hydraulic Pump Compartment Parts List 6 10 6 6 Upper Base Parts List Ute e 6 12 6 7 Base Mast Parts Last prices ioanen eb 6 14 6 8 Lower Base Last iiis oe erigi 6 16 6 9 Platform Parts eed ees 6 18 6 10 Hydraulic Unit Parts List 6 20 6 11 Hydraulic Fittings And Hoses Diagram esee 6 22 6 12 Hydraulic Fittings And Hoses 6 24 6 13 Electrical ut dtu n eR ds 6 25 7 ANSI odd m M 7 1 List of Illustrations Figure 3 1 Lower Control Box 3 1 Figure 3 2 Upper Control 3
12. Flow Control 1 25 in B02 02 0041 Fitting 4NPT 4NPT 90 B02 01 0110 Hose Hydraulic 22 in 4M3K W 2 4 AFJX B02 05 0011 Pump Hydraulic Standard AC B02 02 0072 Fitting 4JIC 6ORM 90 6801 4 6 B02 01 0113 Hose Hydraulic 80 in 4M3K W 2 4 AFJX B02 01 0124 Hose Hydraulic 15 in 4M3K W 2 4 4FJX B02 03 0010 Cylinder Hydraulic Wheel B02 04 0047 Manifold Block Hydraulic B02 02 0163 Fitting 4JIC 60RM Nip B02 04 0047 Valve Combination for Stockpickers and Tom Cats B02 14 0036 Valve Needle Emergency Down B02 14 0038 Valve Cartridge NC Lift Cylinder B01 08 0002 Coil 12v Lift B02 14 0037 Valve Cartridge NC Wheel Cylinder B01 08 0011 Coil 12v Wheel B02 14 0039 Disc Orifice B02 02 0194 Plug SAE4 7 10 11 12 13 14 u i 6 23 XLT 1571AC 6 12 HYDRAULIC FITTINGS AND HOSES SCHEMATIC FLOW CONTROL VALVE LIFT CYLINDER WHEEL CYLINDER EMERGENCY LOWERING HYD PUMP MOTOR UNIT PRESET PRESSURE ES RELIEF VI NORMALLY CLOSED SOLENOID VALVE V2 NORMALLY OPEN SOLENOID VALVE V3 RAISE LOWER SOLENOID VALVE V4 WHEEL RAISE LOWER SOLENOID VALVE Figure 6 12 Hydraulic Fittings and Hoses Schematic 6 24 6 13 110v Flush Mt Recp AC Switcher Board ELECTRICAL DIAGRAM 1571 1071 Schematic Lower Control Nin E Stop Wheel Up Dow Wheel t
13. 0018 Complete Hydraulic Cylinder Assembly Includes all items O Figure 4 6 Hydraulic Cylinder Exploded View 4 4 4 MAINTENANCE ELECTRICAL SYSTEM Regular maintenance is necessary to keep the electrical system in proper working order Check daily all electrical wires for cuts broken wires potential short circuits and any other damage XLT 1571AC 4 12 4 5 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 4 7 5 8 IN 1 5875 CM PITCH rna ra ra ra ra ra ra Imm E7 GT g 7 y co um nm co lt 20 PITCHES 12 5 IN 31 75 CM
14. 2 Figure 3 3 Emergency Lowering 3 3 Figure 4 1 Lift Chain 0 4 3 Figure 4 2 Caster Lubrication 4 4 4 Figure 4 3 Pressure Relief Valve Adjustment eee 4 6 Figure 4 4 Flow Restrictor Valve cccescesssessseesceeecesceeeceeeeseceeeceaecenecaeecaeeeneenneees 4 7 Figure 4 5 Raise Valve Operation Check esee 4 8 Figure 4 6 Hydraulic Cylinder Exploded View eese 4 10 Figure 4 7 Chain Elongation Inspection eee 4 12 Figure 4 8 Lift Chain Adjustment sese eren enne 4 13 Figure 4 9 Slide Block Adjustment sese 4 14 Figure 5 1 Replacement Decals desorienteret sorie siressa ori 5 2 Figure 5 2 Locations Side 5 3 Figure 5 3 Locations Front 1 5 4 Figure 6 1 Mast Exploded View sese 6 2 Figure 6 2 Center Mast Exploded View 6 4 Figure 6 3 Lower Mast Exploded View eese 6 6 Figure 6 4 Rear Compartment Exploded View 6 8 Figure 6 5 Hydraulic Pump Compartment Exploded 6 10 Figure 6 6 Upper Base Exploded View eese 6 12 Figure 6 7 Base Mast Exploded View 6 14 Figure 6 8 Lower Base Exploded View 6 16 Figure 6 9 Platform Exploded 1
15. B02 03 0018 Cylinder Hydraulic Lift 1 5 in Diameter 18 0090 0654 Clamp U bolt 5 16 18 x 2 1 2 x 2 5 8 19 0090 0185 Nut Lock 5 16 18 20 0090 0344 Screw Threadcut 10 24 x 1 2 21 B29 00 0049 Retainer Tube 22 B00 00 0007 Tube Plastic 23 0090 0043 Bolt 3 8 16 x 1 1 4 24 0090 0219 Washer Lock 3 8 25 0090 0162 Nut Hex 3 8 16 26 B00 00 0008 0090 0498 Pin Cotter 1 6 mm Plug Plastic Washer Flat 3 16 in Chain Assy includes items 9 10 11 and 12 N I NOTE It is recommended that chain parts be purchased as an assembly 6 15 XLT 1571AC 6 8 LOWER BASE PARTS LIST Refer to Table 6 8 for the parts list for the lower base Figure 6 8 Lower Base Exploded View Table 6 8 Lower Base Parts List Item No Description Screw Threadcut 10 24 x 1 2 in Screw Threadcut 10 24 x 1 2 in Clamp Cable Cable Assembly Mast Switch Switch Limit Mast 0090 0770 Pin Cotter Washer Flat 3 4 in Spring 10 B04 07 0032 Clamp Cable DG 6 11 B01 01 0122 Cable Assembly Foot Switch B11 01 0085 Foot Inner B23 02 0034 Foot Pad B01 03 0039 Foot Switch Assembly Htem No m 0090 0183 Nut Lock 1 4 20 0090 0049 Bolt 3 8 16 x 2 1 4 in Cylinder Hydraulic Wheel Bolt 3 8 16 x 3 1 2 in Nut Lock 3 8 16 Arm Weldment Hydraulic Cylinder Caster Rigid 6 in Bolt 3 8 16 x 1 in Washer Lock 3 8 in Nut
16. Hex 3 8 16 Nut Lock 1 4 20 B04 07 0035 Clamp Cable DG 14 0090 0463 Bolt 1 2 13 x 4 in 0090 0192 Nut Lock 1 2 13 Sensor Level Bolt 1 4 20 x 3 4 Caster 8 in Plug Level Sensor 0090 0188 Nut Lock 3 8 16 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 28 29 30 3l 32 33 6 PARTS LIST FP 6 17 XLT 1571AC 6 9 PLATFORM PARTS LIST Refer to Table 6 9 for the parts list for the platform NC NIRSRACE REX Figure 6 9 Platform Exploded View Table 6 9 Platform Parts List Description Platform Weldment Bolt 3 8 16 x 2 3 4 in Washer Lock 3 8 in 6 B01 03 009 Switch Limit 7 1 10 0002 Alarm Audible 9 0090 0802 Screw 10 24 x 7 8 in Nut Lock 10 24 11 B17 00 0058 Support Platform Bolt 3 8 16 x 2 in Bolt 3 8 16 x 1 in Tube Foam 13 1 2 in Tube Split 8 1 2 in TyRap Tape Strip 43 in Cap Manual Tube 6 PARTS LIST 6 19 XLT 1571AC 6 10 HYDRAULIC UNIT PARTS LIST AC UNIT Figure 6 10 Hydraulic Unit Assembly 6 PARTS LIST Table 6 10 Hydraulic Unit Parts List Item No Part No Description B02 15 0088 Bolt 5 16 24 x 2 75 Torx B02 15 0119 Coupler 9T 20 40 B02 02 0087 Plug 46 ORM B02 15 0128 Ball Steel B02 15 0091 Seal Shaft B02 15 0006 Washer 1
17. 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 500 165 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 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
18. OF THIS EQUIPMENT WILL RESULT IN INJURY OR DEATH Risk of Electric Shock DO NOT expose charger to rain power wash detergents or spray DO NOT use frayed or damaged electric cords when charging During charging explosive oxyhydrogen gas is generated DO NOT smoke or allow open fire sparks or embers near battery when charging 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 not cover the plates add only enough distilled or demineral ized water to completely cover the plates Keep terminals and terminal connections clean Consult Operation and Maintenance Manual for additional information on battery maintenance 16 00 0094 BO6 00 0034 Operation Instructions for Battery Charger Since batteries are the power source for the machine proper battery care cannot be overemphasized Recharge batteries after each work shift When the machine is not being used batteries should be charged at least once a week The normal charging time should be 10 to 12 hours If batteries are extremely low charging time may be as long as 24 hours Charge batteries as follows Connect an extension from 110 AC 60 Hz outlet to the flush mount receptacle The extension cord to be used should be as short
19. before at tempting to operate equipment ALWAYS inspect the equipment for damaged or worn parts Check for cracked welds hydraulic leaks damaged wiring loose wire connectors damaged cast ers and damaged floor pads Also check for any improper operation NEVER operate equipment if damaged in any way Improperly operating equipment must be repaired before using ALWAYS wear proper clothing for the job Wear protective equipment as re quired by federal state or local regulations ALWAYS locate read and follow all directions and warnings displayed on the equipment ALWAYS inspect the equipment for any DO NOT USE tags placed on the equipment by maintenance personnel NEVER use any equipment tagged in this way until repairs are made and all tags are removed by authorized maintenance personnel ALWAYS make sure the platform and shoes are free of mud grease or other foreign material This will reduce the possibility of slipping NEVER allow improperly trained personnel to operate this equipment Only trained and authorized personnel shall be allowed to operate this equipment NEVER operate this equipment if you are under the influence of alcohol or drugs or if you feel ill dizzy or unsteady in any way Operators must be physi cally 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 e
20. 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 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 lo
21. mast sections at all times BO06 00 0009 STAY CLEAR WHILE RAISING OR LOWERING BO6 00 0225 5 REPLACEMENT DECALS 0146 0170 0339 OR OSS9BLT 0173 0192 9 S 0291 8 0170 o M ees 0167 oun BASE ON ALL SIDES 0306 Figure 5 2 Decal Locations Side View 5 3 XLT 1571AC 0349 INSIDE 0286 0003 e foe INSIDE 0289 0167 n AROUND INSIDE ASE ON ALL SIDES Figure 5 3 Decal Locations Front View 5 4 Parts List XLT 1571AC TOP MAST PARTS LIST 6 1 Refer to Table 6 1 for the parts list for the top mast 14 Figure 6 1 Top Mast Exploded View 6 2 6 PARTS LIST Table 6 1 Top Mast Parts List Item No 1 Part No Description B16 01 0024 Top Mast Weldment 0090 0014 Screw 1 4 20 x 2 1 4 in B01 09 0026 Grommet Plastic B29 00 0076 Bracket Outreach 0090 0181 Nut Lock 8 32 0090 0813 Screw 8 32 x 3 4 in B01 02 0059 Box Control Upper B40 00 0003 Cable 3 16 in B40 01 0008 Chain Lift B04 07 0078 Pin Clevis 11 B04 07 0087 Clevis Lower 12 0090 0389 Screw Adjustment 1 2 20 x 1 2 in 13 0090 0403 Screw 10 x 1 in 14 B31 00 0001 Slide Block Plastic 15 0090 0206 Washer Lock 1 4 in 16 0090 0159 Nut Hex 1 4 20 17 B01 09 0029 Bushing Strain Relief 18 B05 01
22. 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 4 9 1 Loosen do not remove the slotted hex head screw securing the slide block to be adjusted 2 Using an allen wrench turn the set screws in clockwise This will push the block in against the next mast Do not overtighten Tighten the slotted hex head screw to secure the slide block in position 3 Check all slide blocks and make adjustments as necessary 4 After all adjustments are made fully extend the lift If the platform can be low ered without stopping then the blocks are properly adjusted SLIDE BLOCKS SET P SCREWS IZ e SLOTTED HEX SCREW Figure 4 9 Slide Block Adjustment NOTE The plastic slide blocks in the mast are made of a bearing material which has a high degree of lubricity and need only be kept clean However precautions should be taken to ensure that the paths along which the blocks move are kept clean and lightly lubricated with a dry type silicon lubricant 4 4 6 TROUBLESHOOTING Table 4 3 Troubleshooting Chart Problem Cause Correction 1 Green WHEEL UP BASE SET button will not light Base not firmly set on fo
23. not lit c Motor start relay is not activating Check voltage at white wire on motor start relay If voltage replace defec tive motor start relay If no voltage check for loose or broken wire Re pair or replace wire d Motor start relay is activating but Check hydraulic gear pump for sei motor does not run zure If seized replace pump If not check motor Motor may need re placement e Low voltage Check incoming power line 5 Hydraulic cylinderleaks at a Loose gland nut Tighten gland nut gland nut b Defective seals Replace seals in hydraulic cylinder Refer to Hydraulic Cylinder Repair in section 4 3 NOTE Smart start solenoid will not engage if voltage is low 4 16 Replacement Decals Refer to Table 5 1 and Figures 5 1 5 2 and 5 3 for descriptions and locations of decals on the Cougar Lift Table 5 1 Replacement Decals Description of Decal B06 00 0003 Bil Jax ID Number Not available as replacement part B06 00 0009 Warning Moving telescopic masts will create B06 00 0034 Danger During charging explosive oxyhydrogen gas B06 00 0138 Warning Maintenance decal 1 B06 00 0289 Check level with cage fully down 1 B06 00 0295 Danger Failure To Comply With The Following 1 Warning Stand clear when lowering lift onto the foot pads B06 00 0350 Operation Instructions for Stockpickers B06 00 0455 Bil Jax Vertical transfer type decal
24. 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 v Check to see that all decals are present Y Z 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 Check that all functions at lower and upper control boxes are operating properly Weekly lt lt lt lt 4 1 XLT 1571AC Monthly Service Checks Perform the following monthly service checks as listed in Table 4 2 Table 4 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 Replace hydraulic oil Check slide blocks for wear o o o r i Check for mast sway _ Reise itera ddd lt lt lt 4 2 4 4 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 4 1 a 3 ARLIN Figure 4 1 Lift Chain Lubrication XLT 1571AC
25. shall assume the responsibilities of users as specified in Section 7 and the operating personnel shall assume the responsibilities of operators as specified in Section 8 of this standard 5 8 Assistance to Owners and Users If a dealer is unable to answer an owner s or user s question relating to rated capacity intended use maintenance repair inspection or operation of the aerial platform the dealer shall obtain the proper information from the manufacturer and provide that information to the owner or user 7 1 XLT 1571AC 7 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 5 11 Manufacturer s Safety Bulletins The dealer shall comply with safety related bulletins as received from the manufacturer 6 Responsibilities of Owners 6 1 Basic Principles Sound principles of safety training inspection maintenance application and operation consistent with all data available regarding the parameters of intended use and expected environment shall be applied in the performance of the responsibilities of ow
26. the cylinder to the base 3 Remove the plexiglass cover from the base 4 Remove the mounting bolt washer and nut securing the top of the hydraulic cylinder to the lower mast 5 Disconnect the two lift chains from the base mast 6 Using a crane with at least one ton of lifting capacity lift the lower mast section high enough to remove the clamp securing the cylinder to the base and remove the cylinder from the unit 7 After maintenance has been performed on the hydraulic cylinder follow the 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 4 6 It is recommended that whenever the hydraulic cylinder is disassembled all seals be replaced order seal repair kit B02 13 0097 1 Remove gland nut 3 Figure 4 6 with gland nut seal 4 rod wiper 2 and o ring 5 from the cylinder jacket 1 2 Remove piston rod 6 and wear ring 7 Inspect piston rod 6 for any scratches or pits Pits that go into the base metal are unacceptable Scratches that catch the fingernail but are not through the base metal or less than 1 2 inch long and are around the rod are acceptable providing they are not sharp enough to cut the seal The rod surface should not have any of the chrome worn through Re place the cylinder if any of these conditions are not met 3 Clean inside the cylinde
27. 0034 Cable SJO 18 2 19 0090 0860 Pin Cotter 20 B19 00 0001 Box Only 3 Position 21 B01 02 0005 Contact NO 22 B01 02 0006 Contact NC 23 B00 00 0015 Plate ON 24 B00 00 0017 Plate Stop Emergency 25 B00 00 0016 Plate Up Down 26 B01 02 0003 Button Push Flush B01 02 0004 Button Stop Emergency B01 02 0025 Switch Selector B03 00 0009 Chain Assy includes items 9 10 11 and 19 28 NOTE It is recommended that chain parts be purchased as an assembly 6 3 XLT 1571AC 6 2 CENTER MAST PARTS LIST Refer to Table 6 2 for the parts list for the center mast wo Ae gt 6 gt d Figure 6 2 Center Mast Exploded View 6 4 6 PARTS LIST Table 6 2 Center Mast Parts List Description Center Mast Weldment Pin Cotter 3 16 x 1 1 2 in Sheave Axle Washer 5 8 in Chain Sheave Assembly 6 0090 0389 Screw Adjustment 1 2 20 x 1 2 in 0090 0403 Screw 10 x 1 in 1 00 0001 Slide Block Plastic B40 00 0003 Cable 3 16 in 11 B04 07 0078 Pin Clevis Clevis Lower Bolt 3 8 16 x 1 in Washer Lock 3 8 in Actuator Limit Switch Bracket Weldment Pin Cotter Mounting Bracket Sheave Cable Chain Assy includes items 10 11 12 and 17 NOTE It is recommended that chain parts be purchased as an assembly Qty 1 2 3 6 2 8 4 4 1
28. 2 2 2 7 1 7 7 1 1 1 1 1 1 1 6 5 XLT 1571AC 6 3 LOWER MAST PARTS LIST Refer to Table 6 3 for the parts list for the lower mast 2 4 N E AS S Y k E ely Figure 6 3 Lower Mast Exploded View 6 PARTS LIST Table 6 3 Lower Mast Parts List Item No 1 Part No Description B16 01 0021 Lower Mast Weldment 0090 0770 Pin Cotter 3 16 x 1 1 2 in B36 01 0002 Sheave Axle 0090 0425 Washer Flat 5 8 in B26 00 0009 Chain Sheave Assembly 0090 0188 Nut Lock 3 8 16 0090 0422 Washer Flat 3 8 B40 00 0003 Cable 0090 0389 Screw Adjustment 1 2 20 x 1 2 in 0090 0403 Screw 10 x 1 11 B31 00 0001 Slide Block Plastic 12 B40 01 0008 Chain Lift 13 0090 0860 Pin Cotter 14 04 07 0078 Pin Clevis 15 B04 07 0088 Clevis Upper 16 0090 0192 Nut Lock 1 2 13 17 0090 0042 Bolt 3 8 16 x 1 in 18 0090 0210 Washer Lock 3 8 in 19 0090 0162 Nut 3 8 16 20 B24 01 0008 Mounting Bracket 21 B29 00 0033 Mast Stop 22 B29 00 0078 Bracket Weldment 23 B26 00 0001 Sheave Cable 24 0090 0147 Pin Cotter B03 00 0009 Chain Assy includes items 12 13 14 and 15 No NOTE It is recommended that chain parts be purchased as an assembly 6 7 XLT 1571AC 6 4 REAR COMPARTMENT PARTS LIST Refer to Table 6 4 for the parts list for the rear compartment 1
29. 6 21 Hydraulic Fittings and Hoses Parts List esee 6 23 Minimum Safe Approach Distance M S A D to energized exposed or insulated power lines and 7 11 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 some one 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 pur
30. Batteries shall be charged in a well ventilated area free of flame sparks or other hazards that may cause fire or explosion 8 10 11 Platform Positioning The aerial platform shall not be positioned against another object to steady the platform 8 10 12 Misuse as a Crane The aerial platform shall not be used as a crane 8 10 13 Operating Areas The aerial platform shall not be operated from a position on trucks trailers railway cars floating vessels scaffolds or similar equipment unless the application is approved in writing by the manufacturer 8 10 14 Travel Conditions Under all travel conditions the operator shall limit travel speed according to conditions of ground surface congestion visibility slope location of personnel and other factors causing hazards of collision or injury to personnel 8 10 15 Unauthorized Use Means shall be used to protect against use by unauthorized person s 8 10 16 Misuse as a Jack The platform of the aerial platform shall not be used to jack the wheels off the ground unless the machine is designed for that purpose by the manufacturer 8 10 17 Snagged Platform If the platform or elevating assembly becomes caught snagged or otherwise prevented from normal motion by adjacent structure or other obstacles such that control reversal does not free the platform all personnel shall be removed from the platform before attempts are made to free the platform using ground controls 8 11 Assistance to Oper
31. 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 qualified person on the contents of the manufacturer s owner s operating instructions and safety rules 3 Understood by reading or by having a qualified person explain all decals warnings and instructions displayed on the aerial platform 8 7 Workplace Inspection Before the aerial platform is used and during use the operator shall check the area in which the aerial platform is to be used for possible hazards such as but not limited to 1 Drop offs or holes 2 Bumps and floor obstructions 3 Debris 4 Overhead 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
32. Model XLT 1571AC Operation and Maintenance Manual BIL JAX AERIAL WORK PLATFORMS COUGAR LIFT Electric Hydraulic Lift Platform ADe mwa 17 HAAN j B33 01 0062 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 Inttodu cti n 1 1 1 2 Before Operation tbe epe deep 1 3 1 3 During Operation ER eoe ette pendet 1 4 1 4 Maintenance Safety rond teret ere adeps 1 6 1 5 Damaged Equipment Policy eee 1 6 2 iani uU pem 2 1 2 1 General Description inposita upper 2 1 2 2 Specifications t sone i etie etti eric 2 2 2 3 p PS 2 2 3 Oper DIDI 3 1 3 1 Operator Controls 4 2 n rmt te e n e etes 3 1 3 2 Normal Operating Procedure
33. ads are transferred to the platform at any height 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 5 XLT 1571AC 7 6 7 11 8 Fueling The engine shall be shut down while fuel tanks are being filled Fueling shall be done in a well ventilated area free of flame sparks or other hazards that may cause fire or explosion 7 11 9 Battery Charging Batteries shall be charged in a well ventilated area free of flame sparks or other hazards that may cause fire or explosion 7 11 10 Platform Positioning The aerial platform shall not be positioned against another object to steady the platform 7 11 11 Misuse as a Crane The aerial platform shall not be used as a crane 7 11 12 Operating Areas The aerial platform shall not be operated from a position on trucks trailers railway cars floating vessels scaffolds or similar equipment unless the application is approved in writing by the manufacturer 7 11 13 Travel Conditions Under all travel conditions the operator shall limit travel speed according to conditions of ground surface congestion visibility slope locations of personnel and other factors causing hazards of collision or injury to personnel 7 11 14 Unauthorized Use Means shall be used to protect against use by unauthorized person s 7 12 Operation of the Aerial Platform If a user is also the operator of an aerial plat
34. and large possible A small long cord will decrease the output of the charger due to the voltage drop in the line this will increase the charge back time If there is power in the line the on charging red LED light will indicate charge current is flowing and the ammeter will show the rate of charge C the battery voltage reaches a predetermined level programmed in the electronic control the 80 Charge yellow LED will tum on D 3 4 2 hours after the yellow light goes on the charge will be completed and the charger will automatically shut off At this time all the LED s will tum off NOTE If the battery does not reach the 80 level in 14 hours the charger will shut off and the check battery red LED light will tum on This is to avoid prolonged charging of a defective battery that will not properly charge OFF 06 00 0349 B06 00 0349 XLT 7 B06 00 0106 B L J A X BO6 00 0455 BO6 00 0289 Level machine before use Failure to level this machine could result in serious injury or death If unit becomes out of level machine will not lift and the green up button at the lower control box will not illuminate BO6 00 0291 OPERATION AND SERVICE MANUAL INSIDE core 06 00 0182 B06 00 0192 Figure 5 1 Replacement Decals Moving telescopic masts will create pinch points Keep fingers hands arms and feet clear of all telescopic
35. ator If an operator encounters any suspected malfunction of the aerial platform or any hazard or potentially unsafe condition relating to capacity the operator shall cease operation of the aerial platform and request further information as to safe operation from management or from the owner dealer or manufacturer before further operation of the aerial platform 8 12 Modifications An operator shall not modify or concur in modification of an aerial platform without the specific written approval of the manufacturer of the aerial platform 9 Responsibilities of Lessors 7 ANSI REPRINT 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 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 le
36. autions shall be taken as applicable 1 All controls in the off position and all operating features secured from inadvertent motion by brakes blocks or other means 2 Powerplant stopped and starting means rendered inoperative 3 Platform lowered to the full down position if possible or otherwise secured by blocking or cribbing to prevent dropping 4 Hydraulic oil pressure relieved from all hydraulic circuits before loosening or removing hydraulic components 5 Safety props or latches installed where applicable as described by the manufacturer 6 7 Replacement Parts When parts or components are replaced they shall be identical or equivalent to original aerial platform parts or components 6 8 Maintenance Training The owners shall train their maintenance personnel in inspection and maintenance of the aerial platform in accordance with 6 3 6 4 6 5 6 6 6 7 and 6 9 of this standard and with the manufacturer s recommendations 6 9 Operator Training An owner who directs or authorizes an individual to operate an aerial platform shall ensure that the individual has been trained in accordance with the manufacturer s operating manual and requirements listed in Section 8 of this standard before operating the aerial platform Manufacturer s operating instruction and required training on the proper use and operation of the aerial platform shall be provided upon each delivery by sale lease or rental 6 10 Operation When an owner operate
37. autions shall be taken to comply with local ordinances or safety standards established for the workplace Warnings such as but not limited to flags roped off areas flashing lights and barricades shall be used 8 10 3 Reporting Problems or Malfunctions The operator shall immediately report to a supervisor any problems or malfunctions that become evident during operation Any problems or malfunctions that affect the safety of operation shall be repaired prior to continued use of the aerial platform 8 10 4 Reporting Potential Hazardous Locations The operator shall immediately report to a supervisor any potential hazardous locations environment that become evident during operation 8 10 5 Altering Safety Devices Altering or disabling of interlocks or other safety devices shall be prohibited 8 10 6 Entanglement Care shall be taken to prevent rope electric cords hoses etc from becoming entangled in the aerial platform 8 10 7 Capacity Limitation Aerial platform rated capacities shall not be exceeded when loads are transferred to the platform at any heights 8 10 8 Work Area The operator shall ensure that the area surrounding the aerial platform is clear of personnel and equipment before lowering the platform 8 10 9 Fueling The engine shall be shut down while fuel tanks are being filled Fueling shall be done in a well ventilated area free of flame sparks or other hazards that may cause fire or explosion 8 10 10 Battery Charging
38. 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 e ALWAYS stay clear of wires cables and other overhead obstructions e ALWAYS disconnect power at the batteries when not in use to guard against unauthorized use 1 NEVER allow electrode contact with any part of the platform if welding is be ing 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 guardrails Work only within the platform guardrail area and do not lean out over guardrails 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 rai
39. 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 7 ANSI REPRINT 7 7 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 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 impose
40. closed per manufacturer s instructions 4 That the load and its distribution on the platform and any platform extensions are in accordance with the manufacturer s rated capacity for that specific configuration 5 That there is adequate clearance from overhead obstructions 6 That the minimum safe approach distances MSAD to energized power lines and parts as listed in Table One are maintained See Figure 2 for examples of safe operating procedures 7 That he or she and all other personnel on the platform are wearing fall protection devices and other safety gear as required at all times see 4 9 5 8 9 Determination of Hazardous Locations It shall be the responsibility of the user to determine the hazard classification of any particular atmosphere or location according to ANSI NFPA 505 8 9 1 Hazardous Location Operating Requirements Aerial platforms operated in hazardous locations shall be approved and of the type required by ANSI NFPA 505 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 7 7 XLT 1571AC 7 8 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 prec
41. d by the aerial platform in all operating configurations 7 Wind and weather conditions 8 Other possible unsafe conditions 9 Presence of unauthorized persons 7 9 During Operation The aerial platform shall be used in accordance with this standard The user shall direct the operator to ensure the following before each elevation of the platform 1 That the aerial platform is operated on a surface within the limits specified by the manufacturer 2 That the outriggers stabilizers extendable axles or other stabilizing methods are used as required by the manufacturer 3 That guardrails are installed and access gates or openings are closed per manufacturer s instructions 4 That the load and its distribution on the platform and any platform extension are in accordance with the manufacturer s rated capacity for that specific configuration 5 That there is adequate clearance from overhead obstructions 6 That the minimum safe approach distances MSAD to energized power lines and parts as listed in Table One are maintained See Figure 2 for examples of safe operating procedures 7 That the precautions defined in 7 3 3 7 6 7 7 7 8 7 9 7 10 and 7 11 of this standard are followed during operation of the aerial platform 7 10 Determination of Hazardous Locations It shall be the responsibility of the user to determine the hazard classification of any particular atmosphere or location according to ANSI NFPA 505 1987 Aerial platforms operated in
42. e severity of the operating environment Aerial platforms that are not in proper operating condition shall be immediately removed from service until repaired Repairs shall be made by a qualified person and the repairs shall be in conformance with the manufacturer s recommendations 7 3 1 Frequent Inspection An inspection as outlined in 6 4 of this standard shall be conducted 7 3 2 Annual Inspection An inspection as outlined in 6 5 of this standard shall be conducted 7 3 3 Prestart Inspection Before use each day 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 pos
43. epairs you do not understand Consult manufacturer if you have any questions regarding proper maintenance specifications or repair 1 5 DAMAGED EQUIPMENT POLICY Safety Statement At Bil Jax we are dedicated to the safety of all users of our products Therefore all Bil Jax 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 Bil Jax lift is involved in an incident that results in struc tural damage to the lift This can seriously compromise the ability of the lift to perform in a safe manner Therefore whenever a Bil Jax lift is damaged structurally or when there is the possibility of structural damage this damage may be internal and is not always visi ble to the naked eye Bil Jax requires that the lift be returned to our facility at 125 Tay lor Parkway Archbold Ohio for reconditioning If you have any questions concerning what constitutes structural damage please call the Bil Jax Service Department at 800 537 0540 Damage Repair Notice There may be occasions when a Bil Jax 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 Bil Jax of these non maintenance repairs and request a repair form to be filled out and returned to Bil Jax 1 6 2 1 Introduction GENERAL DESCRIPTION The model XLT 1571 Cougar
44. er 7 Responsibilities of Users 7 1 Basic Principles The information in this standard must be supplemented by good job management safety control and the application of sound principles of safety training inspection maintenance application and operation consistent with all data available regarding the parameters of intended use and expected environment Since the user has direct control over the application and operation of aerial platforms conformance with good safety practices in this area is the responsibility of the user and the operating personnel including the operator Decisions on the use and operation of the aerial platform must always be made with due consideration for the fact that the machine will be carrying personnel whose safety is dependent on those decisions XLT 1571AC 7 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 th
45. er Base Exploded View 6 12 Table 6 6 Upper Base Parts List Description Base Weldment Screw Threadcut 10 24 x 1 2 in Edge Top Cover Tape Foam Adhesive Plexiglass 1 8 6 824 01 0009 Frame Aluminum 7 B01 02 0058 Box Control Lower 0090 0813 Screw 8 32 x 3 4 in 9 B3400 0005 Trim Rubber Grommet Plastic 0090 0181 Nut Lock 8 32 Box Only 3 Position Socket Light Contact with Light Bulb 12v Plate Wheel Down Plate Wheel Up Button Push Lighted Button Stop Emergency Plate Stop Emergency Contact NO Contact NC Receptacle Female 3 Wire Nut Elec Drive 1 2 Button Push Flush 2 cr 3 6 PARTS LIST 6 13 XLT 1571AC 6 7 MAST PARTS LIST Refer to Table 6 7 for the parts list for the base mast Figure 6 7 Base Mast Exploded View 6 PARTS LIST Table 6 7 Base Mast Parts List Item No Part No Description 0090 0188 Nut Lock 3 8 16 0090 0422 Washer Flat 3 8 in B40 00 0003 0090 0389 Screw Adjustment 1 2 20 x 1 2 in 0090 0403 Screw 10 x 1 in B31 00 0001 Slide Block Plastic B01 01 0046 Cord Retractable 0090 0684 Rivet Pop 3 16 x 1 2 in B40 01 0008 Chain Lift 10 0090 0860 11 B04 07 0078 Pin Clevis 12 B04 07 0088 Clevis Upper 13 0090 0192 Nut Lock 1 2 13 14 0090 0071 Bolt 1 2 13 X 2 1 2 in 15 0090 0212 Washer Lock 1 2 in 16 0090 0166 Nut Hex 1 2 13 17
46. ete Retraction Time 20 seconds empty 32 seconds loaded 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 110VAC 60 Hz WARRANTY Bil Jax warrants its telescopic lifts for three years 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 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 manufacturers 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 as
47. form the user shall have the responsibilities of operators specified in Section 8 of this standard as well as responsibilities of users as specified in Section 7 of this standard 7 13 Assistance to Operator If a user is unable to answer any operator s questions relating to rated capacity intended use maintenance condition or safety of operation of the aerial platform the user shall obtain the proper information from the dealer owner or manufacturer and provide that information to the operator before use of the aerial platform in the application of concern 7 14 Shutdown of Aerial Platform The user shall authorize and direct the operating personnel to cease operation of the aerial platform in case of any suspected malfunctions of the aerial platform or any hazard or potentially unsafe condition that may be encountered and to request further information as to safe operation from the owner dealer or manufacturer before further operation of the aerial platform 7 15 Record Retention The user shall retain the following records for at least 3 years 1 Records of the operator s trained on each model of an aerial platform 2 Written records 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 acc
48. ft while platform is being raised or lowered DO NOT modify lift or bypass safety devices DO NOT move lift with a person or material on board DO NOT climb up or down masts Plug in charger at end of each day BEFORE USE Operator must read and understand owners manual and all decals on machine before operating It is your responsibility to comply with all warnings and instructions Survey the job site for all potential hazards Inspect unit for damaged parts DO NOT operate until all damaged parts have been replaced andall maintenance has been performedas outlined in owners manual Never Take Chances DO NOT use this machine if you under the influence of drugs or alcohol or if you feel dizzy Il or unsteady in any way Operate on firm and level surface only Cordon off area around base to keep personnel and other equipment away from unit while in use DURING USE DO NOT use wh OWNERS AND OPERATORS ARE RESPONSIBLE FOR INSPECTION MAINTENANCE TRAINING AND OPERATION AS REQUIRED BY THE OWNERS MANUAL AND THE ANSI 92 3 STANDARD can come into contact with overhead obstructions such as electric wires cables ropes overhangs etc DO use boxes ladders scaffolding fork li planking or other means to increase working height DO NOT use lift if exposed to wind rain snow or ice DO NOT exceed rated load capacity of platform IN EFFECT AT DATE OF MANUFACTURE WORKFORCE Ifyou have not bee
49. her Board 1801 06 015 12v Relay Figure 6 14 Electrical Layout Diagram 6 26 ANSI Reprint The following sections are reprinted from the ANSI A92 3 1990 code in effect at the time of manufacture Permission to reprint has been granted by the Scaffold Industry Association 5 Responsibilities of Dealers 5 1 Basic Principles Sound principles of safety training inspection maintenance applications and operation consistent with all data available regarding the parameters intended use and expected environment shall be applied in the training of operators in maintenance application and operation of the aerial platform with due consideration of the knowledge that the unit will be carrying personnel 5 2 Manuals Dealers shall keep and maintain copy ies of the operating and maintenance manual s required in 4 17 Copy ies of operating manual s shall be provided upon each rental or lease delivery Copy ies of operating and maintenance manual s shall be provided upon each sale delivery The operating manual s shall be stored in the location required by 4 18 These manual s are considered an integral part of the aerial platform and are vital to communicate necessary safety information to users and operators 5 3 Predelivery Preparation Aerial platforms shall be inspected serviced and adjusted to manufacturer s requirements prior to each delivery by sale lease or rental 5 4 Maintenance Safety Precaut
50. ions Before adjustments and repairs are started on an aerial platform the following precautions shall be taken as applicable 1 AII controls in the off position and all operating features secured from inadvertent motion by brakes blocks or other means 2 Powerplant stopped and starting means rendered inoperative 3 Platform lowered to the full down position if possible or otherwise secured by blocking or cribbing to prevent dropping 4 Hydraulic oil pressure relieved from all hydraulic circuits before loosening or removing hydraulic components 5 Safety props or latches installed where applicable as described by the manufacturer 5 5 Replacement Parts When parts or components are replaced they shall be identical or equivalent to original aerial platform parts or components 5 6 Training Whenever a dealer directs or authorizes an individual to operate an aerial platform the dealer shall ensure that the individual has been trained under the direction of a qualified person in accordance with the manufacturer s operating and maintenance manual and requirements listed in Section 8 before operating the aerial platform 5 6 1 Training on Delivery Manufacturer s operating 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
51. ise with respect to the aerial platform 8 3 Prestart Inspection Before use each day or at the beginning of each shift the aerial platform shall be given a visual inspection and functional test including but not limited to the following 1 Operating and emergency controls 2 Safety devices 3 Personal protective devices including fall protection 4 Air hydraulic and fuel system leaks 5 Cables and wiring harness 6 Loose or missing parts 7 Tires and wheels 8 Placards warnings and control markings 9 Outriggers stabilizers and other structures 10 Guardrail system 11 Items specified by the manufacturer 8 4 Problems or Malfunctions Any problems or malfunctions that affect the safety of operations shall be repaired prior to the use of the aerial platform 8 5 Training The operator shall have been trained either on the same model of aerial platform or one having operating characteristics and controls consistent with the one to be used during actual work site operation The operator trainee shall operate the aerial platform in an area free of obstructions under the direction of the qualified person for a time sufficient to determine that the trainee displays proficiency in knowledge and actual operation of the aerial platform Only properly trained and authorized personnel shall be permitted to operate the aerial platform 8 6 Before Operation Before being authorized to operate the aerial platform the operator shall have 1
52. n provided with safety literature ortor any questions concerning the safe use of this equipment call 419 BO6 00 0295 SAFETY HARNESS LANYARD ATTACHMENT POINT BO6 00 0173 FAILURE TO COMPLY WITH THE FOLLOWING MAINTENANCE REQUIREMENTS COULD RESULT IN SERIOUS INJURY OR DEATH Follow complete maintenance schedule outlined in Owner s Manual and Section 6 of the ANSI standard reprinted in the Owner s Manual Inspect all chain assemblies fasteners pins and related parts daily for wear damage proper tightness and function Replace according to Owner s Manual recommendations Do not overtighten slide blocks Slide block paths must be kept clean free of dirt grease and other foreign material DO NOT use grease oil or any similar lubricant on masts or slide blocks For additional lubrication use dry silicone only 06 00 0138 BO6 00 0138 EMERGENCY LOWERING TURN RED KNOB COUNTER CLOCKWISE TO LOWER 2a 118 06 00 0286 IS UNLAWFUL OPERATE THIS EQUIPMENT WITHIN 10 FEET OF HIGH VOLTAGE LINES OF 50 000 VOLTS OR LESS 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 protection for personnel from contact with or close proximity to any live electrical power
53. ners with due consideration of knowledge that the unit will be carrying personnel 6 2 Manuals Owners shall keep and maintain copy ies of the operating and maintenance manual s required in 4 17 of this standard Copy ies of operating manual s shall be provided upon each rental or lease delivery Copy ies of operating and maintenance manuals s shall be provided upon each sale delivery The operating manual s shall be stored in the location required in 4 18 of this standard These manual s are considered an integral part of the aerial platform and are vital to communicate necessary safety information to users and operators 6 3 Maintenance The owner of an aerial platform shall arrange that the maintenance specified in this standard is properly performed on a timely basis The owner shall establish a preventive maintenance program in accordance with the manufacturer s recommendations and based on the environment and severity of use of the aerial platform The owner shall arrange that frequent and annual inspections are performed 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 pe
54. omplished on the aerial platform including the date of any such repair a description of the work accomplished and the identification of the person s performing the repair 7 16 Modifications A user shall not modify or concur in modification of an aerial platform without the specific written approval of the manufacturer of the aerial platform 7 17 Manufacturer s Safety Bulletins The user shall comply with safety related bulletins as received from the manufacturer dealer or owner 8 Responsibilities of Operators 8 1 Basic Principles The information in this standard shall be supplemented by good judgment safety control and caution in evaluating each situation Since the operator is in direct control of the aerial platform conformance with good safety practices in this area is the responsibility of the operator The operator shall make decisions on the use and operation of the aerial platform with due consideration for the fact that his or her own safety as well as the safety of other personnel on the platform is dependent on those decisions 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 7 ANSI REPRINT operator shall be familiar with the manuals stored the aerial platform and consult them when questions ar
55. oned properly on the two foot pads and the WHEEL UP button is lit Enter the cage and make sure the cage entrance MAXIMUM CAPACITY midrail drops into its proper position 8 The lift is now ready for operation While holding the ON button select the de sired function UP or DOWN The platform will raise or lower respectively The T 500LBS 1 OCCUPANT PLUS 320 LBS emergency stop deactivates the control circuit only NOTE lift is equipped with a Level Sensor that will prevent the lift from rais ing only if the lift is at a slope greater than 1 degree The green WHEEL UP button will no longer light until the lift is leveled If the lift become out of level while operating lower the platforms and properly level the lift OFF 06 00 0350 B06 00 0350 A DANGER FAILURE TO COMPLY WITH THE FOLLOWING SAFETY INSTRUCTIONS OR ANY OTHER IM PROPER USE OF THIS EQUIPMENT WILL RESULT IN SERIOUS INJURY OR DEATH DO NOT exert horizontal force to the platform while performing work DO NOT use in an area where there are cranes or other moving vehicles DO NOT stand or sit on guard railing DO NOT lean out over guard rails or attempt to perform work outside the guard rail area DO NOT use without entry bar in place Stay clear of all moving parts and keepall person clear while raising and lowering platform DO NOT allow ropes electric cords hoses etc to become entangled in the li
56. otpads Low voltage Burned out bulb Lift is out of level Broken or loose wire Depress WHEEL UP BASE SET button raising front casters This allows lift to firmly set on footpads Check incoming power line Replace bulb Level lift with two adjusting foot pads or relocate lift to level surface Repair or replace wire 2 When UP switch is selected motor runs but unit will not lift a load More than 500 165 on platform N O Normally Open valve is not being energized Emergency lowering valve is open Mast sections are dirty Ensure load is 500 Ibs or less Check voltage at N O valve If no voltage check for loose or broken wire If voltage ensure at least 9 volts for start solenoid operation Check battery and start solenoid Repair or replace as needed Close emergency lowering valve Clean and lubricate masts with dry silicone 3 Masts have excessive sway when fully extended Plastic slide blocks are out of adjust ment Refer to Slide Block Adjustment in section 4 5 NOTE Smart start solenoid will not engage if voltage is low 4 15 XLT 1571AC Table 4 3 Troubleshooting Chart Continued Problem Cause Correction 4 Pump motor will not run a EMERGENCY STOP button is activated Turn EMERGENCY STOP button coun when UP is selected pushed in terclockwise to de activate b Green WHEEL UP BASE SET button is Refer to Problem 1
57. poses only This information is offered to alert Bil Jax 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 Bil Jax equipment only For any questions concerning the safe use of this equipment call 800 537 0540 before operating 1 1 XLT 1571AC 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 AX WARNING Warnings describe conditions or practices that could lead to personal injury or death 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 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 conduc tors 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
58. pressure of 2100 psi is obtained 5 After adjusting the pressure relief valve replace the hex cover remove the 4000 psi gauge and reconnect the hydraulic hose to the main pressure port 6 Ifa gauge is unavailable place 500 pounds on the platform and adjust the pres sure relief valve screw so that the load can just be lifted without bypassing oil through the pressure relief valve MAIN PRESSURE PORT HEX COVER FOR PRESSURE RELIEF VALVE Figure 4 3 Pressure Relief Valve Adjustment 4 6 4 Flow Restrictor Valve Replacement If the flow restrictor valve Figure 4 4 needs to be removed or replaced it is important that it be properly reinstalled The valve will be marked either with an arrow or with the word IN If marked with an arrow the arrow must point away from the hydraulic cyl inder port If marked with the word IN the end of the valve marked IN must be to ward the hydraulic cylinder port Only a 1 4 inch NPT hydraulic elbow should be con nected between the hydraulic cylinder port and the end of the flow restrictor valve Improper installation of the flow restrictor valve or the use of the wrong size elbow will permit widely varying rates of descent and may result in near free fall in case of hose failure INCH HYDRAULIC Ei ELBOW HYDRAULIC CYLINDER PORT Figure 4 4 Flow Restrictor Valve 4 7 XLT 1571AC Raise Valve Operation Check
59. quipment in ways for which it is not intended 1 3 XLT 1571AC 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 contact the power company before performing work near power lines As sume 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 50KV 10 3 05 Over 50KV 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 1000KV 45 13 72 e ALWAYS position lift far enough away from power sources to ensure that no part of the lift can accidentally reach into an unsafe area e 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 e ALWAYS keep yourself and all personnel
60. r jacket 1 and inspect for any scratches or pits Pits that are deep enough to catch the fingernail are unacceptable Scratches that catch the fingernail but are less than 1 2 inch long and are around the tube are acceptable providing they are not sharp enough to cut the seal Replace the cyl inder if any of these conditions are not met 4 Install wear ring 7 into the grooves at the bottom of the piston rod 6 Lubri cate assembly with hydraulic fluid and place back into cylinder jacket 1 5 Lubricate rod wiper 2 gland nut seal 4 and o ring 5 with hydraulic fluid 6 Twist gland nut seal 4 into a shape and insert it with lip side down into the groove inside the gland nut 3 Place o ring 5 over the threads of the gland 4 9 XLT 1571AC 4 10 nut 3 and install in groove Install rod wiper 2 into the top of the gland nut 3 Place gland nut 3 complete with a new gland nut seal 4 rod wiper 2 and o ring 5 onto the cylinder and tighten down Reinstall the hydraulic cylinder into the unit and reconnect the hydraulic hose Refill hydraulic fluid reservoir Pressurize the cylinder and extend one full stroke to fill it with hydraulic fluid and remove any trapped air 2 1 Cylinder Jacket 2 Rod Wiper 3 Gland Nut B02 13 0096 3 NJ 4 Seal Gland Nut 5 O Ring 4 6 Piston Rod 7 Wear Ring 5s O B02 13 0097 Seal Repair Includes items 2 4 5 amp 7 B02 03
61. re the minimum climatic temperature is above 32 F 0 C SAE 5W hydraulic oil may be used where temperatures are as low as 0 F 18 C Do not mix different hydraulic oils Clean the reservoir sump strainer and replace the hydraulic oil at least once a year or whenever it becomes contaminated Hydraulic System Air Bleeding Procedure Delayed response or sporadic action in the unit may indicate a presence of air in the cyl inder Perform the following procedure to bleed air from the system 1 the reservoir with the proper hydraulic fluid 2 Fully extend the lift 3 Lower the unit to allow the oil with entrapped air to return to the reservoir be ing careful not to overflow it 4 Let the unit set while the air escapes the fluid and then repeat if necessary Each time the platform is lowered refill the reservoir to prevent pumping more air into the cylinder 4 5 XLT 1571AC Pressure Relief Valve Reset Perform the following procedure to reset the pressure relief valve Refer to Figure 4 3 1 Disconnect the hydraulic hose from the main pressure port 2 Install a 4000 psi gauge into the main pressure port in the pump unit AN CAUTION Do not adjust the pressure relief valve higher than 2100 psi Overloading may occur at pressures greater than 2100 psi 3 Remove the hex cover from the pressure relief valve 4 While depressing the WHEEL DOWN BASE ROLLS pushbutton on the lower control box adjust the screw until maximum
62. rson 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 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 7 ANSI REPRINT 6 6 Maintenance Safety Precautions Before adjustments and repairs are started on aerial platform the following prec
63. s an aerial platform the owner shall have the responsibilities of users as specified in Section 7 of this standard and the operating personnel shall have responsibilities of operators as specified in Section 8 of this standard 6 11 Assistance to Users and Operators If an owner is unable to answer a user s or operator s questions related to rated capacity intended use maintenance repair inspection or operation of the aerial platform the owner shall obtain the proper information from the dealer or manufacturer and provide that information to user or operator 6 12 Record Retention The owner shall retain the following records for at least 3 years 1 Name and address of the purchaser of each aerial platform by serial number and date of delivery 2 Records of the person s trained upon each delivery of an aerial platform 3 Written records of the frequent and annual inspections performed by the owner The record shall include deficiencies found corrective action and identification of the person s performing the inspection and repairs 4 Records of the predelivery preparation performed prior to each delivery 6 13 Modifications The owner shall not modify or concur in modifications 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 deal
64. sed 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 guardrails to carry materials and never allow overhang of materials when raising or lowering platform 1 5 XLT 1571AC 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 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 manufacturers specifications e NEVER exceed the manufacturer s recommended relief valve settings e NEVER attempt r
65. sibilities of operators as specified in Section 8 of this standard 7 9 XLT 1571AC BUS BARS BUS BARS M S A D Minimum Safe Approach Distance See Table 7 1 DANGER DENOTES PROHIBITED ZONE Do not allow machine personnel or conductive materials inside prohibited zone Maintain M S A D from all energized lines and parts as well as those shown Assume all electrical parts and wires are energized unless known otherwise CAUTION Diagrams shown are only for purposes of illustrating M S A D work positions not all work positions 7 10 Table 7 1 Minimum Safe Approach Distance M S A D to energized exposed or insulated power lines and parts 7 ANSI REPRINT Minimum Safe Approach Distance Voltage Range Phase to Phase Feet Meters 0 to 300V Avoid Contact Over 300V to SOKV 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 XLT 1571AC IL JAX A STEP ABOVE 9 125 Taylor Parkway Archbold 43502 419 445 8915 800 537 0540 419 445 0367
66. sible or otherwise secured by blocking or cribbing to prevent dropping 4 Hydraulic oil pressure relieved from all hydraulic circuits before loosening or removing hydraulic components 5 Safety props or latches installed where applicable as described by the manufacturer 6 Precautions specified by the manufacturer 7 4 Replacement Parts When parts or components are replaced they shall be identical or equivalent to original aerial platform parts or components 7 5 Maintenance Training The user shall train the maintenance personnel in inspection and maintenance of the aerial platform in accordance with 7 3 7 4 and 7 6 of this standard and with the manufacturer s recommendations 7 6 Operator Training Whenever a user directs or authorizes an individual to operate an aerial platform the user shall ensure that the individual has been trained in accordance with the manufacturer s operation and maintenance manual the user s work instructions and the requirements listed in Section 8 of this standard before operating the aerial platform 7 6 1 Model Training The user shall be responsible for the operator being trained on the model of the aerial platform to be operated Such training shall be in an area free of obstructions under the direction of a qualified person for a time sufficient to determine that the trainee displays proficiency in knowledge and actual operation of the aerial platform Only properly trained and authorized personnel shall
67. source and should be considered energized by all personnel coming in contact with machine BO6 00 01 46 06 00 0125 BO6 00 0170 Fall protection equipment must be used at all times during operation Failure to wear fall protection equipment may allow operator to fall from platform resulting in serious UTT ATT BO6 00 03398LT Full Body Harness and Lanyard must be used at all times dur ing operation Failure to wear Full Body Harness and Lanyard may allow operator to fall from platform resulting in serious injury or death BO6 00 0339 This machine is designed and manufactured in compli ance with the ANSI 92 3 standard in force on the date of manufacture Dealers owners users operators lessors and lessees are responsible for inspection maintenance ing and operation as required by A92 3 and the owners trai manual Alterations modifications or changes to this machine n of Workforce Products Inc as well as any unauthorized adjustment of valves disabling or by passing of safety devices or the improper use of this machine shall exempt Workforce Products Inc from any liability for any resulting injuries or damage without the written authorizai REC 06 00 0175 BO6 00 0175 CHECK LEVEL WITH CAGE FULLY DOWN MAX MIN A DANGER FAILURE TO COMPLY WITH THE FOLLOWING INSTRUCTIONS OR ANY OTHER IMPROPER USE OR MAINTENANCE
68. ssor shall have responsibilities of owners as specified in Section 6 of this standard 9 2 3 Lessor as a User When a lessor uses the aerial platform as a user the lessor shall have the responsibilities of operators as specified in Section 8 of this standard 10 Responsibilities of Lessees 10 1 Basic Principles Sound principles of safety training inspection maintenance application and operation consistent with all data available regarding the parameters of intended use and expected environment shall be applied in the performance of responsibilities of lessees with due consideration of the knowledge that the aerial platform carries personnel 10 2 Lessee A lessee is a person s or entity to whom an aerial platform is provided by lease rental loan or other arrangement A lessee may also be a user or operator 10 2 1 Lessee as a Dealer When a lessee uses the aerial platform as a dealer the lessee shall have the responsibilities of dealers as specified in Section 5 of this standard 10 2 2 Lessee as an Owner When a lessee uses the aerial platform as an owner the lessee shall have the responsibilities of owners as specified in Section 6 of this standard 10 2 3 Lessee as a User When a lessee uses the aerial platform as a user the lessee shall have the responsibilities of users as specified in Section 7 of this standard 10 2 4 Lessee as an Operator When a lessee uses the aerial platform as an operator the lessee shall have the respon
69. sume 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 3 1 Operation OPERATOR CONTROLS The operator controls for the Cougar Lift are contained on the upper and lower control boxes Lower Control Box The lower control box is located on the front of the base platform and contains 3 pushbutton controls EMERGENCY STOP WHEEL DOWN BASE ROLLS and WHEEL UP BASE SET The controls on the lower control box are used to set the unit in proper position be fore the platform can be raised Refer to Figure 3 1 WHEEL DOWN WHEEL UP BASE ROLLS BASE SET BUTTON BUTTON Figure 3 1 Lower Control Box 3 1 XLT 1571AC 3 2 Upper Control Box The upper control box is located on the back of the top mast and is accessible from the platform The upper control box contains 3 controls UP DOWN selector switch EMERGENCY STOP pushbutton and ON pushbutton The controls on the upper control box are used to raise and lower the unit Refer to Figure 3 2 protection hor personnel From CoL amm OF pruweey vs emm power sote and show s Dt toc yderrd emerged dy per sores Cortact et mac hune ee MAXIMUM CAPACITY 500185 OR UP DOWN SELECTOR aa SWITCH ing operation to n Fu Pares and Lanyard gun sios opecator tal fom paccm eto n Mem wey cr
70. 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 op erating the Cougar Lift 2 1 XLT 1571AC 2 2 2 2 2 3 SPECIFICATIONS Cougar Lift Electric Hydraulic Lift Platform Model Number XLT 1571 AC Bil Jax Inc Manufactured by Serial Number 125 Taylor Parkway Archbold Ohio 43502 800 537 0540 Table 2 1 Specifications Rated Platform Load 500 Ibs 227 kg total including operator 1 person materials not to exceed 500 Ibs 227 kg Extended Platform Height 14 ft 10 in 4 5 m Retracted Platform Height 18 1 2 in 0 47 m Platform Dimensions 29 in w x 50 in 1x 42 in h 0 74 m x 1 27 m x 1 07 m Base Dimensions 30 1 2 in w x 71 in 1x 77 in h 0 77 m x 1 8 mx 1 95 m Retracted Dimensions 30 1 2 in w x 73 1 2 in 1 x 77 in h 0 77 m x 1 87 m x 1 95 m Gross Shipping Weight 1025 Ibs 465 kg Full Extension Time Compl

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

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