Bil Jax Cougar Lift Electric Hydraulic Platform Xlt 1571Dc Users Manual

2015-02-02

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AERIAL WORK PLATFORMS

Model XLT-1571DC
Operation and
Maintenance Manual

Electric Hydraulic Lift Platform

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B33-01-0014-04

NIN

TELESCOPIC PERSONNEL LIFT
This equipment is designed and manufactured in compliance with the duties, responsibilities, and standards set forth for manufacturers in the ANSI 92.3 standard
in effect at the time of manufacture.
This equipment will meet or exceed applicable OSHA codes and ANSI A92.3 standards when used in accordance with sections 5, 6, 7, 8, 9 & 10 of ANSI A92.3 and all
other manufacturer’s recommendations.
It is the responsibility of the user of this equipment to follow all applicable ANSI,
OSHA, Federal, State, and local codes and regulations that govern the safe operation of this equipment.

Table of Contents
1

Safety ............................................................................................................... 1-1
1-1
Introduction ........................................................................................ 1-1
1-2
Before Operation ............................................................................... 1-3
1-3
During Operation................................................................................ 1-4
1-4
Maintenance Safety ........................................................................... 1-6
1-5
Damaged Equipment Policy ............................................................. 1-7

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

Operation ........................................................................................................ 3-1
3-1
Operator Controls.............................................................................. 3-1
3-2
Normal Operating Procedure............................................................ 3-2
3-3
Emergency Lowering Procedure ...................................................... 3-3

Maintenance.................................................................................................... 4-1
4-1
Scheduled Service Checks................................................................ 4-1
4-2
Lubrication ......................................................................................... 4-3
4-3
Hydraulic System .............................................................................. 4-5
4-4
Electrical System............................................................................. 4-11
4-5
Lift Chains And Slide Blocks ....................................................... 4-12
4-6
Troubleshooting ............................................................................... 4-15

Replacement Decals ........................................................................................ 5-1

Parts List ......................................................................................................... 6-1
6-1
Top Mast Parts List ......................................................................... 6-2
6-2
Center Mast Parts List ..................................................................... 6-4
6-3
Lower Mast Parts List ..................................................................... 6-6
6-4
Battery Compartment Parts List ...................................................... 6-9
6-5
Hydraulic Pump Compartment Parts List ..................................... 6-11
6-6
Upper Base Parts List.................................................................... 6-13
6-7
Base Mast Parts List ...................................................................... 6-15
6-8
Lower Base Parts List.................................................................... 6-17
6-9
Platform Parts List.......................................................................... 6-19
6-10
Hydraulic Unit Parts List............................................................... 6-22
6-11
Hydraulic Fittings And Hoses Diagram............................................ 6-24
6-12
Hydraulic Fittings And Hoses Schematic ..................................... 6-26
6-13
Electrical Diagram........................................................................... 6-27

ANSI Reprint ................................................................................................. 7-1

List of Illustrations
Figure 3-1.
Figure 3-2.
Figure 3-3.
Figure 4-1.
Figure 4-2.
Figure 4-3.
Figure 4-4.
Figure 4-5.
Figure 4-6.
Figure 4-7.
Figure 4-8.
Figure 4-9.
Figure 5-1.
Figure 5-2.
Figure 5-3.
Figure 6-1.
Figure 6-2.
Figure 6-3.
Figure 6-4.
Figure 6-5.
Figure 6-6.
Figure 6-7.
Figure 6-8.
Figure 6-9.
Figure 6-10.
Figure 6-11.
Figure 6-12.
Figure 6-13.
Figure 6-14.

Lower Control Box ................................................................................. 3-1
Upper Control Box.................................................................................. 3-2
Emergency Lowering Valve.................................................................... 3-3
Lift Chain Lubrication............................................................................. 4-3
Caster Lubrication................................................................................... 4-4
Pressure Relief Valve Adjustment .......................................................... 4-6
Flow Restrictor Valve ............................................................................. 4-7
Raise Valve Operation Check ................................................................. 4-8
Hydraulic Cylinder Exploded View...................................................... 4-10
Chain Elongation Inspection ................................................................. 4-12
Lift Chain Adjustment........................................................................... 4-13
Slide Block Adjustment ........................................................................ 4-14
Replacement Decals................................................................................ 5-2
Decal Locations, Side View.................................................................... 5-3
Decal Locations, Front View .................................................................. 5-4
Top Mast Exploded View ....................................................................... 6-2
Center Mast Exploded View ................................................................... 6-4
Lower Mast Exploded View ................................................................... 6-7
Battery Compartment Exploded View .................................................... 6-9
Hydraulic Pump Compartment Exploded View.................................... 6-11
Upper Base Exploded View.................................................................. 6-13
Base Mast Exploded View.................................................................... 6-15
Lower Base Exploded View.................................................................. 6-17
Platform Exploded View....................................................................... 6-19
Hydraulic Unit Assembly...................................................................... 6-22
Hydraulic Fittings and Hoses Diagram ................................................. 6-24
Hydraulic Fittings and Hoses Schematic............................................... 6-26
Electrical Diagram ................................................................................ 6-27
Electrical Layout Diagram .................................................................... 6-28

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
Specifications.......................................................................................... 2-2
Daily/Weekly Service Checks ................................................................ 4-1
Monthly Service Checks ......................................................................... 4-2
Troubleshooting Chart .......................................................................... 4-15
Replacement Decals................................................................................ 5-1
Top Mast Parts List ................................................................................ 6-3
Center Mast Parts List ............................................................................ 6-5
Lower Mast Parts List............................................................................. 6-8
Battery Compartment Parts List............................................................ 6-10
Hydraulic Pump Compartment Parts List ............................................. 6-12
Upper Base Parts List ........................................................................... 6-14
Base Mast Parts List ............................................................................. 6-16
Lower Base Parts List........................................................................... 6-18
Platform Parts List ................................................................................ 6-21
Hydraulic Unit Parts List ...................................................................... 6-23
Hydraulic Fittings and Hoses Parts List................................................ 6-25
Minimum Safe Approach Distance (M.S.A.D.) to energized
(exposed or insulated) power lines and parts.................................... 7-11

iii

Safety

1-1

INTRODUCTION
Familiarity and proper training are required for the safe operation of mechanical equipment. Equipment operated improperly or by untrained personnel can be dangerous. Read
the operating instructions in this manual and become familiar with the location and proper
use of all controls. Inexperienced operators should receive instruction from someone familiar with the equipment before being allowed to operate the machine. The use of intelligence and common sense in the operation of mechanical equipment is the best practice in
any safety policy. Be professional and always observe the safety procedures set forth in
this manual.
All OSHA, ANSI, state and local codes and regulations pertaining to this equipment
should be obtained, read, and thoroughly understood before attempting to operate this
equipment. Persons under the influence of drugs, alcohol, or prescription medication
should not be on or near this equipment. Common sense should be implemented at all
times during the use of this equipment. Do not operate this equipment in areas where
equipment or user may come in contact with live power source.
The information contained herein is not to be considered as legal advice and is intended
for informational purposes only. This information is offered to alert 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 419.445.9675 before
operating.

1-1

XLT-1571DC

Safety Notes
This manual contains DANGERS, WARNINGS, CAUTIONS, and NOTES that must be
followed to prevent the possibility of improper service, damage to the equipment, or personal injury.

DANGER
Dangers warn of equipment operation near electrical power lines that could lead
to personal injury or death.

WARNING
Warnings describe conditions or practices that could lead to personal injury or
death.

CAUTION
Cautions provide information important to prevent errors that could damage machine or components.

NOTE:

1-2

Notes contain additional information important to a procedure.

1 — SAFETY

1-2

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

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

1-3

XLT-1571DC

1-3

DURING OPERATION
Ensure the following general safety precautions are followed during the operation of the
Cougar Lift.

DANGER
This machine is not insulated for use near electrical power lines and DOES NOT
provide protection from contact with or close proximity to any electrically charged
conductor. Operator must maintain safe clearances at all times (10 feet minimum)
and always allow for platform movement such as wind induced sway. Always contact the power company before performing work near power lines. Assume every
line is hot. Remember, power lines can be blown by the wind.
Refer to Table 1-1 for minimum safe approach distances between machine and electrical
power lines.
Table 1-1. Minimum Safe Approach Distances
Voltage Range
(Phase to Phase)

Minimum Safe Approach Distance
(Feet)

0 to 300V

1-4

(Meters)
Avoid Contact

Over 300V to 50KV

3.05

Over 50KV to 200KV

4.60

Over 200KV to 350KV

6.10

Over 350KV to 500KV

7.62

Over 500KV to 750KV

10.67

Over 750KV to 1000KV

13.72

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

1 — SAFETY

•

NEVER allow electrode contact with any part of the platform if welding is being
performed by a worker from the platform.

•

NEVER use without the floor pads fully based on the floor.

•

NEVER override or by-pass manufacturer's safety devices.

•

NEVER release floor locks or move unit with a person or materials on board.

•

NEVER stand or sit on guard rails. Work only within the platform guard rail area
and do not lean out over guard rails to perform work.

•

NEVER attempt to increase working height with boxes, ladders, or other means.

•

NEVER operate this equipment when exposed to high winds, thunderstorms, ice,
or any other weather conditions that would compromise the safety of the
operator.

•

NEVER climb up or down masts.

•

NEVER allow ropes, electric cords, hoses, etc. to become entangled in the
equipment when the platform is being raised or lowered.

•

NEVER exceed manufacturer's platform load limits and make sure all materials
are evenly distributed over the entire platform.

•

NEVER exceed platform load ratings by transferring loads to platform at elevated heights.

•

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

1-5

XLT-1571DC

1-4

MAINTENANCE SAFETY
Ensure the following general safety precautions are observed when maintenance is performed on the Cougar Lift.
•

ALWAYS perform maintenance procedures according to manufacturer's requirements. NEVER short change maintenance procedures.

•

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

•

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

•

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

•

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

•

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

•

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

•

NEVER exceed the manufacturer's recommended relief valve settings.

•

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

Battery Maintenance
Ensure the following general safety precautions are followed when battery maintenance is
being performed on the Cougar Lift.

1-6

•

ALWAYS check battery acid level daily. Check battery test indicator for proper
state of charge on maintenance free batteries before using lift.

•

ALWAYS wear safety glasses when working near battery.

•

ALWAYS avoid contact with battery acid. Battery acid causes serious burns.
Avoid contact with skin or eyes. If accidental contact occurs, flush with water
and consult a physician immediately.

•

ALWAYS disconnect ground cable first when removing battery.

•

ALWAYS connect ground cable last when installing battery.

•

ALWAYS charge batteries in open, well ventilated areas.

•

NEVER smoke when servicing battery.

•

NEVER allow batteries to overcharge and boil.

•

NEVER short across battery posts to check for current. NEVER break a live circuit at battery.

•

NEVER jump start other vehicles using lift battery.

1 — SAFETY

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 structural 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 visible
to the naked eye), Bil-Jax requires that the lift be returned to our facility at 125 Taylor
Parkway, Archbold, Ohio, for reconditioning. If you have any questions concerning what
constitutes structural damage, please call the Bil-Jax Service Department at
419.445.9675.

Damage Repair Notice
There may be occasions when a Bil-Jax lift is involved in an incident resulting in nonstructural damage. When this occurs and repairs are made by the owner or area distributor, please notify Bil-Jax of these non-maintenance repairs and request a repair form to be
filled out and returned to Bil-Jax.

1-7

XLT-1571DC

1-8

Introduction

2-1

GENERAL DESCRIPTION
The model XLT-1571 Cougar Lift is designed and manufactured for use as a warehouse
stocking and order picking machine. Its unique guard rail design permits the operator to
ride on the platform with the load, while transferring it from group level to its overhead
storage location. The maximum platform load is limited to 500 lbs. The electric pump
motor is powered by a 12VDC battery. A 20 amp automatic battery charger is included
for recharging the battery at the end of each work period.
Platform elevation is accomplished by means of a 1-1/2 inch displacement type hydraulic
cylinder. The lower telescoping section is pushed vertically upward by the cylinder while
the upper sections are raised by a mechanical motion advantage accomplished through
two sets of chains and sheaves. The platform is raised three inches for each one inch of
cylinder extension. Platform elevation and descent is controlled by pushbuttons on the
upper control box located on the platform.
Safety of operation is assured by proper inspection and maintenance procedures as set
forth in this manual. The possibility of platform free-fall is eliminated by proper maintenance and replacement of the chains, sheaves and sheave pins, a properly installed flow
restrictor valve, and a clean mast. The non-adjustable restrictor valve controls and fixes
the rate of platform descent whether empty or fully loaded to approximately 0.6 feet per
second. A hydraulic hose failure will result in the same rate of descent, eliminating freefall, when the restrictor valve is installed properly.
Emergency lowering of the platform is accomplished by means of a manual control valve
located on the hydraulic manifold block assembly, next to the pump/motor unit.
The Cougar Lift features a displacement type of cylinder that will not rust or corrode during storage since the cylinder rod is immersed in oil. It is important that the cylinder rod
be kept clean and undamaged for the protection of the cylinder head packing.
The floor lock safety switch prevents the unit from raising until the two floor pads have
been properly engaged and helps to make the Cougar Lift a safe, dependable machine.
Carefully read all the safety instructions contained in Section 1 of this manual before operating the Cougar Lift.

2-1

XLT-1571DC

2-2

SPECIFICATIONS
Cougar Lift Electric Hydraulic Lift Platform
Model Number XLT-1571
Manufactured by:

Serial Number ________________

Bil-Jax, Inc.
125 Taylor Parkway
Archbold, Ohio 43502
419.445.9675
Table 2-1. Specifications

Rated Platform Load

500 lbs (227 kg) total including operator [1 person +
materials not to exceed 500 lbs (227 kg)]

Extended Platform Height

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. l x 42 in. h
(0.74 m x 1.27 m x 1.07 m)

Base Dimensions

30-1/2 in. w x 71 in. l x 77 in. h
(0.77 m x 1.8 m x 1.95 m)

Retracted Dimensions

30-1/2 in. w x 73-1/2 in. l x 77 in. h
(0.77 m x 1.87 m x 1.95 m)

Gross Shipping Weight

1025 lbs (465 kg)

Full Extension Time

20 seconds empty, 32 seconds loaded

Complete Retraction Time

22 seconds empty, 22 seconds loaded

Platform Extension Rate

0.66 ft (0.3 m)/sec. empty
0.42 ft (0.19 m)/sec. loaded

Hydraulic System Pressure

1200 psi empty, 2100 psi loaded

Power Source
DC - 12 volt deep cycle battery
* Home Depot units are equipped with a 12’ Stockpicker™ Lift Option, B03-00-0137.
This option limits extended platform height 12 feet.

2-3

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 assume nor authorize any representative or
other person to assume for us any other liability in connection with the sale, rental, or use
of this product.

2-2

Operation

3-1

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 before the
platform can be raised. Refer to Figure 3-1.

EMERGENCY
STOP
BUTTON

WHEEL DOWN
BASE ROLLS
BUTTON

WHEEL UP
BASE SET
BUTTON

Figure 3-1. Lower Control Box

3-1

XLT-1571DC

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.

EMERGENCY
STOP
PUSHBUTTON
UP/DOWN
SELECTOR
SWITCH

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 responsibilities outlined in the ANSI A92.3 reprint contained in Section 7 of this manual.

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 electrically charged conductors. Do not operate the lift if such hazards exist.

Check the lift for damaged or worn parts and repair or replace as necessary.

Check to be sure that the platform is properly attached to the lift.

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.

The lift 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:

7.
3-2

The lift is equipped with a level sensor that will prevent the lift from raising 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 releveled.
Enter the platform. Ensure that both side midrails are positioned properly.

3 — OPERATION

NOTE:

3-3

The 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.
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 situations 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.

EMERGENCY
LOWERING
VALVE
RED KNOB

Figure 3-3. Emergency Lowering Valve

3-3

XLT-1571DC

3-4

Maintenance

4-1

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
Service Check

Daily
before use

Ensure Operation Manual is located in manual tube.

Check chain assemblies for split leaves, loose pins,
excessive wear, or elongation.

Check battery electrolyte level.

Check and retighten all nuts and bolts.

Check cage attachment to the platform is secure and that the
cage side midrails slide freely.

Check to be sure slide blocks and their path are clean and
lightly lubricated with a silicone lubricant.

Check level sensor.

Check to see that all decals are present.

Check that all functions at lower and upper control boxes are
operating properly.

Weekly

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.

4-1

XLT-1571DC

Monthly Service Checks
Perform the following monthly service checks as listed in Table 4-2.
Table 4-2. Monthly Service Checks
Service Check
Check hydraulic raise valve
operation.

Clean battery terminals.

Check operation of manual
emergency lowering valve.

Every
6 months

Lubricate caster swivels and
axles.

Check battery cables and wiring
for loose connections and
damaged wires.

Every
12 months

Replace hydraulic oil.

Check slide blocks for wear.

Check for mast sway.

Load test with 500 pounds.

Replace lift chains.

4-2

Every
month

Every
48 months

4 — MAINTENANCE

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.

LIFT
CHAINS

Figure 4-1. Lift Chain Lubrication

4-3

XLT-1571DC

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:

4-4

The plastic slide blocks in the mast are made of a bearing material which
has a high degree of lubricity and need only be kept clean. However,
precautions should be taken to ensure that the paths along which the
blocks move are kept clean and lightly lubricated with a dry type silicon
lubricant.

4 — MAINTENANCE

4-3

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 Section 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 where 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 cylinder. Perform the following procedure to bleed air from the system.
1.

Fill the reservoir with the proper hydraulic fluid.

Fully extend the lift.

Lower the unit to allow the oil with entrapped air to return to the reservoir, being
careful not to overflow it.

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-1571DC

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.

Install a 4000 psi gauge into the main pressure port in the pump unit.

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.

While depressing the WHEEL DOWN/BASE ROLLS pushbutton on the lower control
box, adjust the screw until maximum pressure of 2100 psi is obtained.

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.

If a gauge is unavailable, place 500 pounds on the platform and adjust the pressure 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 — MAINTENANCE

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 cylinder
port. If marked with the word “IN”, the end of the valve marked “IN” must be toward the
hydraulic cylinder port. Only a 1/4 inch NPT hydraulic elbow should be connected 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.

FLOW
RESTRICTOR
VALVE

¼ INCH NPT
HYDRAULIC
ELBOW

HYDRAULIC
CYLINDER

HYDRAULIC
CYLINDER
PORT

Figure 4-4. Flow Restrictor Valve

4-7

XLT-1571DC

Raise Valve Operation Check
The raise valve is a normally open (N.O.) valve in the hydraulic system. Perform the following 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.

On the upper control box, select UP on the direction selector switch while depressing the ON pushbutton. This should cause the motor to run without the platform raising.

If the platform raises, the raise valve must be cleaned or replaced.

Reconnect the wires at the connector between the solenoid and the raise valve
upon determining that the valve is functioning properly.
WIRE
CONNECTOR

RAISE
VALVE

Figure 4-5. Raise Valve Operation Check

4-8

4 — MAINTENANCE

Hydraulic Cylinder Repair

CAUTION
Removing the hydraulic cylinder from the Cougar Lift requires major disassembly
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.

Be sure cylinder is completely retracted and pressure is released from the system. Place a pan underneath the hydraulic cylinder to catch the hydraulic oil.

Disconnect the hydraulic hose from the bottom of the cylinder and drain the hydraulic oil. Remove the two bolts, washers, and nuts securing the bottom of the
cylinder to the base.

Remove the plexiglass cover from the base.

Remove the mounting bolt, washer, and nut securing the top of the hydraulic cylinder to the lower mast.

Disconnect the two lift chains from the base mast.

Using a crane with at least one ton of lifting capacity, lift the lower mast section
high enough to remove the clamp securing the cylinder to the base, and remove
the cylinder from the unit.

After maintenance has been performed on the hydraulic cylinder, follow the removal procedure in reverse to reinstall the cylinder in the unit.

Hydraulic Cylinder Repair Procedure
Perform the following procedure to repair and maintain the hydraulic lift cylinder. Refer
to Figure 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).

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. Replace
the cylinder if any of these conditions are not met.

Clean inside the cylinder 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 cylinder if any of these conditions are not met.

Install wear ring (7) into the grooves at the bottom of the piston rod (6). Lubricate assembly with hydraulic fluid and place back into cylinder jacket (1).

Lubricate rod wiper (2), gland nut seal (4), and o-ring (5) with hydraulic fluid.

4-9

XLT-1571DC

Twist gland nut seal (4) into a “C” 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 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 oring (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
3
4
5

1.
2.
3.
4.
5.
6.
7.

Cylinder Jacket
Rod Wiper
Gland Nut (B02-13-0096)
Seal, Gland Nut
O-Ring
Piston Rod
Wear Ring

B02-13-0097 Seal Repair Kit
(Includes items 2, 4, 5, & 7)
B02-03-0018 Complete
Hydraulic Cylinder Assembly
(Includes all items)

Figure 4-6. Hydraulic Cylinder Exploded View

4-10

4 — MAINTENANCE

4-4

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.

Battery Care and Charging
The electric system is designed to provide power for a normal work shift. However, the
charge life of the battery pack depends on machine usage. Plan your work to prevent unnecessary use of electrical power.
Since the power source for the machine is a battery, proper battery care is important. Recharge the battery after each work shift. When the machine is not being used, batteries
should be charged at least once a week. Normal battery charging time should be 10 to 12
hours. If the battery is extremely low, charging time may be as long as 24 hours.
Clean battery terminals monthly. Remove the cables from the battery, clean the battery
posts and cable ends to shiny metal, and replace. Always connect the insulated cable from
the starter solenoid to the positive post. Lubricate the outside of the connections with petroleum jelly or grease.
Battery Charging Procedure
1.

Connect an extension cord from a 110V AC 60 Hz outlet to the flush mount receptacle on the side of the Cougar Lift. The extension cord should be kept as
short and as large as possible to reduce voltage drop.

When there is power to the battery charger, a red “ON-CHARGING” LED on
the charger will be lit and the ammeter will display the rate of charge.

Once the battery voltage reaches a predetermined level programmed in the electronic control, the yellow “80% CHARGE” LED will illuminate.

3-1/2 hours after the yellow “80% CHARGE” LED is lit, the charge will be
completed and the charger will automatically shut off. All LED’s will be unlit.

NOTE:

If the battery voltage does not reach the 80% level within 14 hours, the
charger will shut off and the red “CHECK BATTERY” LED will illuminate. This is to avoid prolonged charging of a defective battery that will
not properly recharge.

CAUTION
Before making or breaking connections between charger and battery, always remove the power cord from the 110 volt AC outlet. Always check the battery electrolyte level and add water after charging the battery. For more information, refer
to the instructions supplied with the battery charger.
5.

Unplug the extension cord from the flush mount receptacle on the side of the
Cougar Lift.

4-11

XLT-1571DC

4-5

LIFT CHAINS AND SLIDE BLOCKS
WARNING
Do not operate a unit on which any chain assembly is damaged or in need of replacement. Operating a unit with a damaged chain can cause severe injury or
death to personnel and damage to equipment.
Inspect all lift chains daily. Inspect for signs of wear, split leaves, loose pins, clevis damage, and elongation. Replace any chain which is damaged in any way. Chain assemblies
may be ordered from your dealer or direct from the factory. Do not operate a unit on
which any chain assembly is damaged and in need of replacement.

Chain Elongation Inspection
One pitch of chain should measure 5/8 in. (1,5875 cm). Measure 20 pitches of chain. The
ideal measurement for 20 pitches of chain should be 12.5 in. (31,75 cm). Replace the
chain if 20 pitches measure over 12.75 in. (32,385 cm). Refer to Figure 4-7.
5/8 IN. (1,5875 CM) PITCH

20 PITCHES = 12.5 IN. (31,75 CM)
REPLACE CHAIN IF 20 PITCHES MEASURES
OVER 12.75 IN (32,385 CM)

Figure 4-7. Chain Elongation Inspection

NOTE:

4-12

It is recommended that chains be replaced every four years unless damage or wear requires replacement at a lesser interval.

4 — MAINTENANCE

Lift Chain Adjustment
1.

Raise the platform to the maximum extended height and then lower it while
someone checks to see that all sheaves are turning and checks for chain damage
or wear.

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.

LIFT
CHAINS

CLEVIS

LOCK
NUT

Figure 4-8. Lift Chain Adjustment

4-13

XLT-1571DC

Slide Block Adjustment
Annually check for wear on the slide blocks and replace or retighten as necessary. If the
lift exhibits excessive mast sway, it is probable that the slide blocks need adjustment. The
slide blocks should be adjusted so that there is no air gap between the slide block and the
mast the slide block is moving against. There are 12 slide blocks, 6 upper and 6 lower.
The adjustment procedure is the same for all slide blocks. Three upper slide blocks are
shown in Figure 4-9.
1.

Loosen, do not remove, the slotted hex head screw securing the slide block to be
adjusted.

Using an allen wrench, turn the set screws in (clockwise). This will push the
block in against the next mast. Do not overtighten. Tighten the slotted hex head
screw to secure the slide block in position.

Check all slide blocks and make adjustments as necessary.

After all adjustments are made, fully extend the lift. If the platform can be lowered without stopping then the blocks are properly adjusted.
SLIDE
BLOCKS

SET
SCREWS

SLOTTED
HEX SCREW

Figure 4-9. Slide Block Adjustment

NOTE:

4-14

4 — MAINTENANCE

4-6

TROUBLESHOOTING
Table 4-3. Troubleshooting Chart

Problem
1.

Green WHEEL UP/BASE SET
button will not light.

When UP switch is selected,
motor runs but unit will not
lift a load.

Masts have excessive sway
when fully extended.

Cause

Correction

Base not firmly set on foot pads.

Depress WHEEL UP/BASE SET button
raising front casters. This allows lift to
firmly set on foot pads.

*Low voltage.

Recharge battery or replace if damaged.

Burned out bulb.

Replace bulb.

Lift is out of level.

Level lift with two adjusting foot pads
or relocate lift to level surface.

Broken or loose wire.

Repair or replace wire.

Two parts of battery connector plug
not mated together.

Mate battery connector plug parts
together.

More than 500 lbs. on platform.

Ensure load is 500 lbs. or less.

N.O. (Normally Open) valve is not
being energized.

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.

Emergency lowering valve is open.

Close emergency lowering valve.

Mast sections are dirty.

Clean and lubricate masts with dry
silicone.

Plastic slide blocks are out of adjustment.

Refer to Slide Block Adjustment in
section 4-5.

*NOTE: Smart start solenoid will not engage if battery charge drops below 9 volts.

4-15

XLT-1571DC

Table 4-3. Troubleshooting Chart, Continued
Problem
4.

Pump/motor will not run
when UP is selected.

Cause
a.

EMERGENCY STOP button

Correction
is activated

Turn EMERGENCY STOP button counterclockwise to de-activate.

(pushed in).
b.

Green WHEEL UP/BASE SET button is
not lit.

Refer to Problem 1.

Motor start relay is not activating.

Check voltage at white wire on motor
start relay. If voltage, replace defective motor start relay. If no voltage,
check for loose or broken wire. Repair
or replace wire.

Motor start relay is activating, but
motor does not run.

Check hydraulic gear pump for seizure. If seized, replace pump. If not,
check motor. Motor may need replacement.

*Low voltage.

Recharge or replace the battery.

When two parts of battery
connector plug are mated together, the motor runs without UP switch being selected.

Short in electrical system.

Repair or replace any loose or broken
wires.

Motor start relay is stuck in “on”
position.

Replace defective motor start relay.

Hydraulic cylinder leaks at
gland nut.

Loose gland nut.

Tighten gland nut.

Defective seals.

Replace seals in hydraulic cylinder.
Refer to Hydraulic Cylinder Repair, in
section 4-3.

*NOTE: Smart start solenoid will not engage if battery charge drops below 9 volts.

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
Decal No.

Description of Decal

Qty

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...

B06-00-0106

XLT-1571 (Transfer type decal)

B06-00-0138

Warning...(Maintenance decal)

B06-00-0146

Danger...(High voltage line warning)

B06-00-0167

Striped Safety Tape - On all four sides (per roll only)

B06-00-0170

Maximum Capacity...500 lb. Or...

B06-00-0173

Safety Belt Lanyard Attachment Point

B06-00-0175

Caution...This machine designed and manufactured...

B06-00-0192

Operation And Service Manual Inside

B06-00-0225

Warning...Stay clear when raising or lowering

B06-00-0228

Serial Number Tag (Not available as replacement part)

B06-00-0289

Check level with cage fully down

B06-00-0291

Warning...Level machine before use

B06-00-0295

Danger...Failure To Comply With The Following...

B06-00-0296

Battery Charger Receptacle

B06-00-0306

Warning...Stand clear when lowering lift onto the foot pads...

B06-00-0339

Warning...Full Body Harness and Lanyard...

B06-00-0339BLT Warning...Body Belt and Lanyard...

B06-00-0286

Emergency Lowering

B06-00-0349

Operation Instructions for Battery Charger

B06-00-0350

Operation Instructions for Stockpickers

B06-00-0455

Bil-Jax (Vertical transfer type decal)

5-1

XLT-1571DC

B06-00-0306
B06-00-0228

B06-00-0170
B06-00-0034
B06-00-0350

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

B06-00-0339BLT

B06-00-0339
B06-00-0349
B06-00-0295

B06-00-0173

B06-00-0175
B06-00-0106

B06-00-0138

B06-00-0455

B06-00-0286
B06-00-0296

B06-00-0289

B06-00-0009
B06-00-0291

CCFO

B06-00-0146

B06-00-0192
Figure 5-1. Replacement Decals

5-2

STAY CLEAR
WHILE RAISING
OR LOWERING

B06-00-0225

5 — REPLACEMENT DECALS

0009

ING
RN
WA

R
GE

N
DA

0173

R
WA

NIN

0146
0170
0339 OR 0339BLT
0173

0455

0192

XL
T

0106

1
5
7
1

A
W
R
N
IN
G

0291
0170

WA
RN
ING

0225

0167

0306

COMPLETE
(AROUND
BASE ON ALL SIDES )

Figure 5-2. Decal Locations, Side View

5-3

XLT-1571DC

0009
0228

ING
RN
WA

0295

N
DA

0455

UT
CA

0138
R
WA

NIN

0175

ION

0350

(

XL
T

0106

0296

1
5
7
1

0286

DA
N

0034

0003

CHARGER
)
(ON INSIDE

0167

COMPLETE
(AROUND
BASE ON ALL SIDES)

(

0289

)

ON RESERVOIR
INSIDE

Figure 5-3. Decal Locations, Front View

5-4

0349

)

INSIDE
DOOR

Parts List

6-1

XLT-1571DC

6-1

TOP MAST PARTS LIST
Refer to Table 6-1 for the parts list for the top mast.

6
22

24 23
16

26
ON

21 28

WN
DO

Y
NC
GE
ER P
EM STO

25
28
17

8
18

14
12
19

11
Figure 6-1. Top Mast Exploded View

6-2

6 — PARTS LIST

Table 6-1. Top Mast Parts List
Item No.

Part No.

Description

Qty

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

B04-07-0087

Clevis, Lower

0090-0389

Screw, Adjustment, 1/2-20 x 1/2 in.

0090-0403

Screw, #10 x 1 in.

B31-00-0001

Slide Block, Plastic

0090-0206

Washer, Lock, 1/4 in.

0090-0159

Nut, Hex, 1/4-20

B01-09-0029

Bushing, Strain Relief

B05-01-0034

Cable, SJO, 18-2

0090-0860

Pin, Cotter

B19-00-0001

Box Only, 3-Position

B01-02-0005

Contact, NO

B01-02-0006

Contact, NC

B00-00-0015

Plate, ON

B00-00-0017

Plate, Stop, Emergency

B00-00-0016

Plate, Up/Down

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

80 in.

*NOTE: It is recommended that chain parts be purchased as an assembly.

6-3

XLT-1571DC

6-2

CENTER MAST PARTS LIST
Refer to Table 6-2 for the parts list for the center mast.
2
3

4
5

8
6
7

15
13 6

20
3

13
7
15

14
15

4
16

18
13
13

Figure 6-2. Center Mast Exploded View
6-4

6 — PARTS LIST

Table 6-2. Center Mast Parts List
Item No.

Part No.

Description

Qty

B16-01-0020

Center Mast Weldment

0090-0770

Pin, Cotter 3/16 x 1-1/2 in.

B36-01-0002

Sheave Axle

0090-0425

Washer, 5/8 in.

B26-00-0009

Chain Sheave Assembly

0090-0389

Screw, Adjustment, 1/2-20 x 1/2 in.

0090-0403

Screw, #10 x 1 in.

B31-00-0001

Slide Block, Plastic

B40-00-0003

Cable, 3/16 in.

B40-01-0008

Chain, Lift

B40-07-0078

Pin, Clevis

B04-07-0087

Clevis, Lower

0090-0042

Bolt, 3/8-16 x 1 in.

B29-00-0033

Mast Stop

0090-0210

Washer, Lock, 3/8 in.

0090-0162

Nut, 3/8-16

0090-0860

Pin, Cotter

0064-0363

Actuator, Limit Switch

B29-00-0078

Bracket, Weldment

0090-0147

Pin, Cotter

B24-01-0008

Mounting Bracket

B26-00-0001

Sheave, Cable

B03-00-0009

Chain Assy, includes items 10, 11, 12, and 17

*NOTE: It is recommended that chain parts be purchased as an assembly.

6-5

XLT-1571DC

6-3

LOWER MAST PARTS LIST
Refer to Table 6-3 for the parts list for the lower mast.

6-6

6 — PARTS LIST

5
2

4
6
7
12

3
13
14

8
15

9
11
10
1

9
10

19
19 22

21
18

4
23

20
17

4
18

Figure 6-3. Lower Mast Exploded View
6-7

XLT-1571DC

Table 6-3. Lower Mast Parts List
Item No.

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

B31-00-0001

Slide Block, Plastic

B40-01-0008

Chain, Lift

0090-0860

Pin, Cotter

B04-07-0078

Pin, Clevis

B04-07-0088

Clevis, Upper

0090-0192

Nut, Lock, 1/2-13

0090-0042

Bolt, 3/8-16 x 1 in.

0090-0210

Washer, Lock, 3/8 in.

0090-0162

Nut, 3/8-16

B24-01-0008

Mounting Bracket

B29-00-0033

Mast Stop

B29-00-0078

Bracket, Weldment

B26-00-0001

Sheave, Cable

0090-0147

Pin, Cotter

B03-00-0009

Chain Assy, includes items 12, 13, 14, and 15

*NOTE: It is recommended that chain parts be purchased as an assembly.

6-8

Qty

6 — PARTS LIST

6-4

BATTERY COMPARTMENT PARTS LIST
Refer to Table 6-4 for the parts list for the battery compartment.
10

1
12

19
20

24 17
18
13

25
26

14
15

18
17

TO START SOLENOID

2
22

5
4

Figure 6-4. Battery Compartment Exploded View

6-9

XLT-1571DC

Table 6-4. Battery Compartment Parts List
Item No.

6-10

Part No.

Description

Qty

B11-01-0076

Base Weldment

0090-0344

Screw, Threadcut, 10-24 x 1/2 in.

B01-10-0003

Receptacle, Flush Mount

0090-0813

Screw, 8-32 x 3/4 in.

B19-00-0022

Box, Black, TomCat

0090-0415

Washer, Flat, #10

0090-0181

Nut, Lock, 8-32

B18-00-0026

Cover, (with screws)

(part of 8)

Screw

B00-00-0048

Strap, Rubber

B01-01-0115

Cable, Battery, 16 in., Black

B01-04-0008

Battery, 12 Volt

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

0090-0669

Bolt, Eye, 5/16-18 x 2 in.

0090-0160

Nut, 5/16-18

0090-0420

Washer, 5/16

B01-01-0116

Cable, Battery, 16 in., Red

B01-09-0031

Plug, Connector

B44-00-0002

Board, Battery

B37-00-0006

Lock Assy., Utility

B01-01-0038

Cable, Battery, 22 in., Black

B01-01-0036

Cable, Battery, 33 in., Red

0090-0210

Washer, Lock, 3/8 in.

0090-0126

Nut, Hex, 3/8-16

6 — PARTS LIST

6-5

HYDRAULIC PUMP COMPARTMENT PARTS LIST
Refer to Table 6-5 for the parts list for the hydraulic pump compartment.

2
3

8
7

6
11
6
16

15
14

8
10

Figure 6-5. Hydraulic Pump Compartment Exploded View

6-11

XLT-1571DC

Table 6-5. Hydraulic Pump Compartment Parts List
Item No.

6-12

Part No.

Description

Qty

B11-01-0076

Base Weldment

B04-07-0093

Rod, Hold Down, Weldment

B07-06-5119

Strap, Hold Down

B01-05-0039

Charger, Battery

B05-00-0006

Tape, Foam Adhesive

0090-0183

Nut, Lock, 1/4-20

0090-0005

Bolt, 1/4-20 x 3/4

0090-0419

Washer, Flat, 1/4 in.

B29-00-0116

Bracket, Hydraulic Valve

0090-0014

Bolt, 1/4-20 x 2-1/2 in.

B02-04-0047

Valve, Combination

B02-05-0024

Pump, Hydraulic

0090-0040

Bolt, 3/8-16 x 3/4 in.

0090-0210

Washer, Lock

0090-0422

Washer, Flat

B18-00-0026

Cover, (with 2 screws)

2 ft.

6 — PARTS LIST

6-6

UPPER BASE PARTS LIST
Refer to Table 6-6 for the parts list for the upper base.

2
3

2
ER
NG
DA

ION
UT
CA
ING
RN
WA

6
10
6
7

12
23
13

12
15 16

17
22

Y
NC
GE
ER P
EM STO

N
OW
L D LS
EE OL
WHSE R
BA

P
LU
EE ET
WHSE S
BA

19
20
18
19
Figure 6-6. Upper Base Exploded View
6-13

XLT-1571DC

Table 6-6. Upper Base Parts List
Item No.

6-14

Part No.

Description

Qty

B11-01-0076

Base Weldment

0090-0344

Screw, Threadcut, 10-24 x 1/2 in.

B07-01-2003

Edge, Top Cover

B05-00-0006

Tape, Foam Adhesive

B18-00-0108

Plexiglass, 1/8 in.

B24-01-009

Frame, Aluminum

B01-02-0058

Box, Control, Lower

0090-0813

Screw, 8-32 x 3/4 in.

B34-00-0005

Trim, Rubber

B01-09-0027

Grommet, Plastic

0090-0181

Nut, Lock, 8-32

B19-00-0001

Box Only, 3-Position

B01-02-0029

Socket, Light, Contact with

B01-10-0042

Light Bulb, 12v

B00-00-0091

Plate, Wheel Down

B00-00-0092

Plate, Wheel Up

B01-02-0028

Button, Push, Lighted

B01-02-0003

Button, Push, Flush

B01-02-0004

Button, Stop, Emergency

B00-00-0017

Plate, Stop, Emergency

B01-02-0005

Contact, NO

B01-02-0006

Contact, NC

B01-10-0001

Receptacle, Female, 3-Wire

B04-07-0012

Nut, Elec. Drive, 1/2”

32 in.

6 — PARTS LIST

6-7

BASE MAST PARTS LIST
Refer to Table 6-7 for the parts list for the base mast.

9
1

11
12

3
19

7
4

17
18
21

23
20
25
21

27
8
Figure 6-7. Base Mast Exploded View
6-15

XLT-1571DC

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

Cable

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

0090-0860

Pin, Cotter, 1.6 mm

B04-07-0078

Pin, Clevis

B04-07-0088

Clevis, Upper

0090-0192

Nut, Lock, 1/2-13

0090-0071

Bolt, 1/2-13 X 2-1/2 in.

0090-0212

Washer, Lock, 1/2 in.

0090-0166

Nut, Hex, 1/2-13

B02-03-0018

Cylinder, Hydraulic Lift, 1.5 in. Diameter

0090-0654

Clamp, U-bolt, 5/16-18 x 2-1/2 x 2-5/8

0090-0185

Nut, Lock, 5/16-18

0090-0344

Screw, Threadcut, 10-24 x 1/2

B29-00-0049

Retainer, Tube

B00-00-0007

Tube, Plastic

0090-0043

Bolt, 3/8-16 x 1-1/4

0090-0219

Washer, Lock, 3/8

0090-0162

Nut, Hex, 3/8-16

B00-00-0008

Plug, Plastic

0090-0498

Washer, Flat, 3/16 in.

B03-00-0009

Chain Assy, includes items 9, 10, 11, and 12

*NOTE: It is recommended that chain parts be purchased as an assembly.

6-16

Qty

6 — PARTS LIST

6-8

LOWER BASE PARTS LIST
Refer to Table 6-8 for the parts list for the lower base.

2
1
4
5

26
27

7
28

8
3
10

31
25

15
17

12
25
24
19

21
20

22
23

Figure 6-8. Lower Base Exploded View

6-17

XLT-1571DC

Table 6-8. Lower Base Parts List
Item No.

6-18

Part No.

Description

Qty

0090-0344

Screw, Threadcut, 10-24 x 1/2 in.

B18-00-0107

Cover

0090-0344

Screw, Threadcut, 10-24 x 1/2 in.

B04-07-0015

Clamp, Cable

B01-01-0123

Cable Assembly, Mast Switch

B01-03-0040

Switch, Limit, Mast

0090-0770

Pin, Cotter

0090-0195

Washer, Flat, 3/4 in.

B39-00-0027

Spring

B04-07-0032

Clamp, Cable, DG-6

B01-01-0122

Cable Assembly, Foot Switch

B11-01-0085

Foot, Inner

B23-02-0034

Foot, Pad

B01-03-0039

Foot Switch Assembly

0090-0183

Nut, Lock, 1/4-20

0090-0049

Bolt, 3/8-16 x 2-1/4 in.

0090-0188

Nut, Lock, 3/8-16

B02-03-0010

Cylinder, Hydraulic Wheel

0090-0054

Bolt, 3/8-16 x 3-1/2 in.

0090-0188

Nut, Lock, 3/8-16

B11-01-0073

Arm Weldment, Hydraulic Cylinder

B08-01-0019

Caster, Rigid, 6 in.

0090-0042

Bolt, 3/8-16 x 1 in.

0090-0210

Washer, Lock, 3/8 in.

0090-0162

Nut, Hex, 3/8-16

0090-0183

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

B01-10-0135

Sensor, Level

0090-0005

Bolt, 1/4-20 x 3/4

B08-01-0002

Caster, 8 in.

B01-01-0113

Plug, Level Sensor

6 — PARTS LIST

6-9

PLATFORM PARTS LIST
Refer to Table 6-9 for the parts list for the platform.
12

1
22
19, 20
18

21
2

15
17

3
16

10
8
9

5
14
13

Figure 6-9. Platform Exploded View

6-19

XLT-1571DC

6-20

6 — PARTS LIST

Table 6-9. Platform Parts List
Item No.

Part No.

Description

Qty

B17-00-0057

Platform Weldment

0090-0051

Bolt, 3/8-16 x 2-3/4 in.

0090-0210

Washer, Lock, 3/8 in.

0090-0162

Nut, 3/8-16

0068-061

Pin, Snap

B01-03-009

Switch, Limit

B01-10-0002

Alarm, Audible

B01-10-0004

Light

0090-0802

Screw, 10-24 x 7/8 in.

0090-0182

Nut, Lock, 10-24

B17-00-0058

Support, Platform

0090-0048

Bolt, 3/8-16 x 2 in.

B40-00-0019

Chain

0090-0552

Ring, Key

B01-03-0002

Cover

0090-0042

Bolt, 3/8-16 x 1 in.

B01-09-0030

TyRap

B05-00-0001

Tube, Foam, 13-1/2 in.

B00-00-0086

Tube, Split, 8-1/2 in.

B01-09-0030

TyRap

B06-00-0167

Tape, Strip, 43 in.

B00-00-0014

Cap, Manual Tube

6-21

XLT-1571DC

6-10 HYDRAULIC UNIT PARTS LIST

Figure 6-10. Hydraulic Unit Assembly

6-22

6 — PARTS LIST

Table 6-10. Hydraulic Unit Parts List
Item No.

Part No.

Description

Qty

B02-15-0088

Bolt, 5/16-24 x 2.75 Torx

B02-15-0119

Coupler, 9T-20-40

B02-15-0365

Plug, Drain, 9/16 SAE

B02-15-0128

Ball, Steel

B02-15-0091

Seal, Shaft

B02-15-0093

Washer

B02-15-0061

Magnet, Plumbing

B02-15-0121

Filter

B02-15-0122

Motor, DC - 12V

B02-15-0123

Screw, Taptite, 1/4-20 x 0.25 Hex

B02-15-0125

Cover, Suction

B02-15-0126

Screw, Taptite, M6 x 1.0, 12 mm Torx

B02-15-0197

Valve, Check, Cartridge

B02-15-0170

Bolt, 5/16-18 x 1.00

B02-15-0199

Bolt, 12-24 x 0.50 Hex

B02-15-0348

Wiring Assembly, 2 Pin

B02-15-0346

Wiring Assembly, 4 Pin

B02-15-0206

Tank, Horizontal Mount, Plastic with Drain

B02-15-0201

Breather Cap, with Check Valve

B02-15-0127

Spring, Relief

B02-15-0345

Solenoid, Smart Start

B02-15-0349

Coil, Solenoid, 12VDC

B02-15-0114

Pin, 1/8 x 1/4

B02-15-0073

O-Ring

B02-15-0203

Head, End

B02-15-0078

Pump Assembly, 1.6 GPM

B02-15-0030

Cap Assembly, Relief

B02-15-0204

Plug, 1/16 NPT Flush

B02-15-0205

Tube, Return, 3/8, 90°

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

6-23

XLT-1571DC

6-11 HYDRAULIC FITTINGS AND HOSES DIAGRAM
17
18

15
16
14

B
G
L

11
B
G

A
W

5
9

7
2

4
6
Figure 6-11. Hydraulic Fittings and Hoses Diagram

6-24

6 — PARTS LIST

Table 6-11. Hydraulic Fittings and Hoses Parts List
Item No.

Part No.

Description

Qty

B02-03-0018

Cylinder, Hydraulic Lift, 1.5 in. Diameter

B02-02-0002

Fitting, 4JIC-4NPT 90°, 2501-4

B02-04-0002

Valve, Flow Control, 1.25 in.

B02-02-0041

Fitting, 4NPT-4NPT 90°

B02-01-0110

Hose, Hydraulic, 22 in., 4M3K W/2 4-4FJX

B02-05-0024

Pump, Hydraulic, Standard DC

B02-02-0072

Fitting, 4JIC-6ORM 90°, 6801-4-6

B02-01-0113

Hose, Hydraulic, 80 in., 4M3K W/2 4-4FJX

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-6ORM 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, SAE 4

6-25

XLT-1571DC

6-12 HYDRAULIC FITTINGS AND HOSES SCHEMATIC

Figure 6-12. Hydraulic Fittings and Hoses Schematic

6-26

6 — PARTS LIST

6-13 ELECTRICAL DIAGRAM
1571/1071 Schematic
Lower Lift
Option

Lower
Control

110v
Flush Mt
Recp.

Charger

T
13

T6
E-Stop Wheel Up

T12

B R

T4
Wheel
Down
T
17

E-Stop ON

Upper
Control

R1 R2

T15
T7

E-Stop

Beeper

Start
Sol

T
13

Light

T8
T5

Wheel
Valve

Motor
T
Mast 12
Switch

Down
Valve Pump

Lift
Valve

T
15

E-Stop ON Down

T10

T
15

Wheel
Set

T13

Battery

Down

Level
Sensor

Foot Switches
R3

NO
Valve
T17 R2

R W
B

Terminal Connections for Black Box
Terminal No.

Wire Color

From

Terminal No.

Wire Color

From

BLK
BLK

Mast Down Limit Switch
Upper Control Box

RED
WHT

Level Sensor
Left Foot Limit Switch

BLK
BLK

Lower Control Box
Right Foot Limit Switch

WHT
ORG/BLK STR

Mast Down Limit Switch
Lower Control Box

WHT

Hydraulic Pump Motor

WHT
YEL

Upper Control Box
Lower Control Box

BRN/BLK STR

Lower Control Box

RED

Hydraulic Manifold

GRN
RED/BLK STR

Upper Control Box
Lower Control Box

YEL/BLK STR

Lower Control Box

16
WHT
RED

Level Sensor
Lower Control Box

BLK

Hydraulic Pump Motor

BLK

Hydraulic Manifold

GRN
WHT
BLK

Hydraulic Manifold
Hydraulic Manifold
Level Sensor

RED
BLU
GRN

Upper Control Box
Lower Control Box
Hydraulic Pump Motor

BRN
BLK

Lower Control Box
Base Ground

Figure 6-13. Electrical Diagram

6-27

XLT-1571DC
B R

1571/1071
Layout
Upper
Control
Box

N N N N N N
O O C C O O

B01-03-0039
Foot Switches

W G

B01-01-0122
Plug Wire
96"

80"
18-2
B

C N0 NC

Level
Sensor

Light

W B
T
T1
11

10"

Lift

B01-03-0040
Mast Switch
Wheel

B01-01-0123
Plug Wire
60"

Beeper

#1 #4

T1 T4

T
17
N
C

N N
C O
T
10
#
10

N
0

X
1

N
O

X
2

N
C

T
12

#6 Gr/Y

T
13

T
15

Batt

T
3

T
8

B01-01-0113
Plug Lead

T
10

Lift
Wheel
3' 18-4

Pump
Plug

T
3

2'
18Ga
Black

B W

(-)

T
1

B W G

T
13

T
10

T
15

T1
T4
T6
T10
T12
T13
T15
T17

T1
T11

Pump
Unit
B02-05-0024

Rect Cord

(-)

W B G

T11
T17

(-)

Handy Box
30" 18-4

4/5/00 Added wire
for NO Valve

Figure 6-14. Electrical Layout Diagram

6-28

Lift
Pump GRD
Plug Stud Wheel

T
17

Foot
Level
Lower Control Box Switch Sensor

(-)

GRD
Stud
(-)
2' 12Ga
Black

Charger

T
11

Female
Recp

(-)

Mast SW Handy
Box

GRD
Stud

4' 12Cond wire
B05-01-0037
Lower
Control
Box
B
3Cond

T1
T12
T1
T10
T13
T15
T3
T8
T10

(-)
T5
T9

(-)
(-)

UP
DN

T
12

ANSI Reprint

The following sections are reprinted from the ANSI A92.3-1990 code in effect at the
time of manufacture. Permission to reprint has been granted by the Scaffold
Industry Association.
5. Responsibilities of Dealers
5.1 Basic Principles. Sound principles of safety, training, inspection, maintenance,
applications, and operation consistent with all data available regarding the parameters
intended use and expected environment shall be applied in the training of operators, in
maintenance, application, and operation of the aerial platform with due consideration of
the knowledge that the unit will be carrying personnel.
5.2 Manuals. Dealers shall keep and maintain copy(ies) of the operating and
maintenance manual(s) required in 4.17. Copy(ies) of operating manual(s) shall be
provided upon each rental or lease delivery. Copy(ies) of operating and maintenance
manual(s) shall be provided upon each sale delivery. The operating manual(s) shall be
stored in the location required by 4.18. These manual(s) are considered an integral part
of the aerial platform and are vital to communicate necessary safety information to users
and operators.
5.3 Predelivery Preparation. Aerial platforms shall be inspected, serviced, and
adjusted to manufacturer's requirements prior to each delivery by sale, lease, or rental.
5.4 Maintenance Safety Precautions. Before adjustments and repairs are started on an
aerial platform, the following precautions shall be taken as applicable: (1) All controls in
the "off" position and all operating features secured from inadvertent motion by brakes,
blocks, or other means. (2) Powerplant stopped and starting means rendered inoperative
(3) Platform lowered to the full down position, if possible, or otherwise secured by
blocking or cribbing to prevent dropping (4) Hydraulic oil pressure relieved from all
hydraulic circuits before loosening or removing hydraulic components (5) Safety props
or latches installed where applicable as described by the manufacturer.
5.5 Replacement Parts. When parts or components are replaced, they shall be identical
or equivalent to original aerial platform parts or components
5.6 Training. Whenever a dealer directs or authorizes an individual to operate an aerial
platform, the dealer shall ensure that the individual has been trained under the direction of
a qualified person in accordance with the manufacturer's operating and maintenance
manual and requirements listed in Section 8 before operating the aerial platform.
5.6.1 Training on Delivery. Manufacturer's operating instruction and required
training on the proper use and operation of the aerial platform shall be provided upon
each delivery, by sale, lease, or rental.
5.7 Operation. When a dealer operates an aerial platform in sales demonstrations or for
other beneficial use, the dealer shall assume the responsibilities of users as specified in
Section 7 and the operating personnel shall assume the responsibilities of operators as
specified in Section 8 of this standard.
5.8 Assistance to Owners and Users. If a dealer is unable to answer an owner's or
user's question relating to rated capacity, intended use, maintenance, repair, inspection,
or operation of the aerial platform, the dealer shall obtain the proper information from the
manufacturer and provide that information to the owner or user.

7-1

XLT-1571DC

5.9 Record Retention. Dealer(s) shall retain the following records for at least 3 years:
(1) Name and address of the purchaser of each aerial platform by serial number and the
date of delivery (2) Records of the person(s) trained upon each delivery of an aerial
platform (3) Records of the predelivery preparation performed prior to each delivery.
5.10 Modifications. Modifications or alterations of aerial platforms shall be made only
with prior written permission of the manufacturer.
5.11 Manufacturer's Safety Bulletins. The dealer shall comply with safety-related
bulletins as received from the manufacturer.
6. Responsibilities of Owners
6.1 Basic Principles. Sound principles of safety, training, inspection, maintenance,
application, and operation consistent with all data available regarding the parameters of
intended use and expected environment shall be applied in the performance of the
responsibilities of owners with due consideration of knowledge that the unit will be
carrying personnel.
6.2 Manuals. Owners shall keep and maintain copy(ies) of the operating and
maintenance manual(s) required in 4.17 of this standard. Copy(ies) of operating
manual(s) shall be provided upon each rental or lease delivery. Copy(ies) of operating
and maintenance manuals(s) shall be provided upon each sale delivery. The operating
manual(s) shall be stored in the location required in 4.18 of this standard. These
manual(s) are considered an integral part of the aerial platform and are vital to
communicate necessary safety information to users and operators.
6.3 Maintenance. The owner of an aerial platform shall arrange that the maintenance
specified in this standard is properly performed on a timely basis. The owner shall
establish a preventive maintenance program in accordance with the manufacturer's
recommendations and based on the environment and severity of use of the aerial platform.
The owner shall arrange that frequent and annual inspections are performed. All
malfunctions and problems noted shall be corrected before the aerial platform is returned
to service.
6.4 Frequent Inspection. The owner of an aerial platform shall cause a frequent
inspection to be performed on an aerial platform: (1) That has been in service for 3
months or 150 hours, whichever comes first (2) That has been out of service for a period
longer than 3 months.
The inspection shall be made by a person qualified as a mechanic on the specific make
and model of the aerial platform. The inspection shall include all items specified by the
manufacturer for a frequent inspection and shall include, but not be limited to, the
following: (3) All functions and their controls for speed(s), smoothness, and limits of
motion (4) Emergency lowering means (5) All chain and cable mechanisms for
adjustment and worn or damaged parts (6) All emergency and safety devices (7)
Lubrication of all moving parts, inspection of filter element(s), hydraulic oil, engine oil,
and coolant, as specified by the manufacturer (8) Visual inspection of structural
components and other critical components, such as fasteners, pins, shafts, and locking
devices (9) Placards, warnings, and control markings (10) Items specified by the
manufacturer (11) Correction of all malfunctions and problems identified and further
inspection, if necessary.
6.5 Annual Inspection. The owner of an aerial platform shall cause an annual
inspection to be performed on the aerial platform no later than 13 months from the date of
the prior 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.

7-2

7 — ANSI REPRINT

6.6 Maintenance Safety Precautions. Before adjustments and repairs are started on an
aerial platform, the following precautions shall be taken as applicable: (1) All controls in
the "off" position and all operating features secured from inadvertent motion by brakes,
blocks, or other means (2) Powerplant stopped and starting means rendered inoperative
(3) Platform lowered to the full down position, if possible, or otherwise secured by
blocking or cribbing to prevent dropping (4) Hydraulic oil pressure relieved from all
hydraulic circuits before loosening or removing hydraulic components (5) Safety props
or latches installed where applicable as described by the manufacturer.
6.7 Replacement Parts. When parts or components are replaced, they shall be identical
or equivalent to original aerial platform parts or components.
6.8 Maintenance Training. The owners shall train their maintenance personnel in
inspection and maintenance of the aerial platform in accordance with 6.3, 6.4, 6.5, 6.6,
6.7 and 6.9 of this standard, and with the manufacturer's recommendations.
6.9 Operator Training. An owner who directs or authorizes an individual to operate an
aerial platform shall ensure that the individual has been trained in accordance with the
manufacturer's operating manual, and requirements listed in Section 8 of this standard
before operating the aerial platform.
Manufacturer's operating instruction and required training on the proper use and operation
of the aerial platform shall be provided upon each delivery, by sale, lease, or rental.
6.10 Operation. When an owner operates an aerial platform, the owner shall have the
responsibilities of users as specified in Section 7 of this standard, and the operating
personnel shall have responsibilities of operators as specified in Section 8 of this
standard.
6.11 Assistance to Users and Operators. If an owner is unable to answer a user's or
operator's questions related to rated capacity, intended use, maintenance, repair,
inspection, or operation of the aerial platform, the owner shall obtain the proper
information from the dealer or manufacturer and provide that information to user or
operator.
6.12 Record Retention. The owner shall retain the following records for at least 3
years: (1) Name and address of the purchaser of each aerial platform by serial number
and date of delivery (2) Records of the person(s) trained upon each delivery of an aerial
platform (3) Written records of the frequent and annual inspections performed by the
owner. The record shall include deficiencies found, corrective action, and identification
of the person(s) performing the inspection and repairs (4) Records of the predelivery
preparation performed prior to each delivery.
6.13 Modifications. The owner shall not modify or concur in modifications or alteration
to the aerial platform without the modifications being approved and certified in writing by
the manufacturer.
6.14 Manufacturer's Safety Bulletins. The owner shall comply with safety-related
bulletins as received from the manufacturer or dealer.
7. Responsibilities of Users.
7.1 Basic Principles. The information in this standard must be supplemented by good
job management, safety control, and the application of sound principles of safety,
training, inspection, maintenance, application, and operation consistent with all data
available regarding the parameters of intended use and expected environment. Since the
user has direct control over the application and 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.

7-3

XLT-1571DC

7.2 Manuals. Users shall keep and maintain copy(ies) of the operating and maintenance
manual(s) required in 4.17 of this standard. The operating manual(s) shall be stored in
the location required in 4.18 of this standard. These manuals are considered an integral
part of the aerial platform and are vital to communication of necessary safety information
to users and operators.
7.3 Inspection and Maintenance. Users shall inspect and maintain the aerial platform
as required to ensure proper operation. The frequency of inspection and maintenance
shall be determined by the manufacturer's recommendation and be compatible with
operating conditions and the severity of the operating environment. Aerial platforms that
are not in proper operating condition shall be immediately removed from service until
repaired. Repairs shall be made by a qualified person and the repairs shall be in
conformance with the manufacturer's recommendations.
7.3.1 Frequent Inspection. An inspection as outlined in 6.4 of this standard shall
be conducted.
7.3.2 Annual Inspection. An inspection as outlined in 6.5 of this standard shall be
conducted.
7.3.3 Prestart Inspection. Before use each day or at the beginning of each shift, the
aerial platform shall be given a visual inspection and function test including but not
limited to the following: (1) Operating and emergency controls (2) Safety devices
(3) Personal protective devices, including fall protection (4) Air, hydraulic and fuel
system leaks (5) Cables and wiring harness (6) Loose or missing parts (7) Tires
and wheels (8) Placards, warnings, and control markings (9) Outriggers,
stabilizers, and other structures (10) Guardrail system (11) Items specified by the
manufacturer.
7.3.4 Maintenance Safety Precautions. Before adjustments and repairs are started
on an aerial platform, the following precautions shall be taken as applicable: (1) All
controls in the "off" position and all operating features secured from inadvertent
motion by brakes, blocks, or other means (2) Powerplant stopped and starting
means rendered inoperative (3) Platform lowered to the full down position, if
possible, or otherwise secured by blocking or cribbing to prevent dropping (4)
Hydraulic oil pressure relieved from all hydraulic circuits before loosening or
removing hydraulic components (5) Safety props or latches installed where
applicable as described by the manufacturer (6) Precautions specified by the
manufacturer.
7.4 Replacement Parts. When parts or components are replaced, they shall be identical
or equivalent to original aerial platform parts or components.
7.5 Maintenance Training. The user shall train the maintenance personnel in
inspection and maintenance of the aerial platform in accordance with 7.3, 7.4, and 7.6 of
this standard and with the manufacturer's recommendations.
7.6 Operator Training. Whenever a user directs or authorizes an individual to operate
an aerial platform, the user shall ensure that the individual has been trained in accordance
with the manufacturer's operation and maintenance manual, the user's work instructions,
and the requirements listed in Section 8 of this standard before operating the aerial
platform.
7.6.1 Model Training. The user shall be responsible for the operator being trained
on the model of the aerial platform to be operated. Such training shall be in an area
free of obstructions, under the direction of a qualified person for a time sufficient to
determine that the trainee displays proficiency in knowledge and actual operation of
the aerial platform. Only properly trained and authorized personnel shall be
permitted to operate the aerial platform.
7.6.2 Trainees Training Record. A record of the trainee's aerial platform
instruction shall be maintained by the user for at least 3 years.

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7 — ANSI REPRINT

7.7 Before Operation. Before authorizing an operator to operate an aerial platform, the
user shall ensure that the operator has: (1) Been instructed by a qualified person in the
intended purpose and function of each control (2) Read and understood the
manufacturer's operating instructions and user's safety rules, or been trained by a qualified
person on the contents of the manufacturer's operating instructions and user's safety rules
(3) Understood by reading or by having a qualified person explain all decals, warnings,
and instructions displayed on the aerial platform (4) Determine that the purpose for
which the aerial platform is to be used is within the scope of the intended applications
defined by the manufacturer (5) Been provided with approved fall protection devices
and other safety gear for all personnel on the platform (see 4.9.5).
7.8 Work Place Inspection. Before the aerial platform is used and during use, the user
shall check the area in which the aerial platform is to be used for possible hazards such as,
but not limited to: (1) Drop-offs or holes (2) Bumps and floor obstructions (3) Debris
(4) Overhead obstructions and high voltage conductors (5) Hazardous locations (6)
Inadequate surface and support to withstand all load forces imposed by the aerial platform
in all operating configurations (7) Wind and weather conditions (8) Other possible
unsafe conditions (9) Presence of unauthorized persons.
7.9 During Operation. The aerial platform shall be used in accordance with this
standard. The user shall direct the operator to ensure the following before each elevation
of the platform: (1) That the aerial platform is operated on a surface within the limits
specified by the manufacturer (2) That the outriggers, stabilizers, extendable axles, or
other stabilizing methods are used as required by the manufacturer (3) That guardrails
are installed and access gates or openings are closed per manufacturer's instructions (4)
That the load and its distribution on the platform and any platform extension are in
accordance with the manufacturer's rated capacity for that specific configuration (5) That
there is adequate clearance from overhead obstructions (6) That the minimum safe
approach distances (MSAD) to energized power lines and parts, as listed in Table One
are maintained. See Figure 2 for examples of safe operating procedures (7) That the
precautions defined in 7.3.3, 7.6, 7.7, 7.8, 7.9, 7.10 and 7.11 of this standard are followed
during operation of the aerial platform.
7.10 Determination of Hazardous Locations. It shall be the responsibility of the user
to determine the hazard classification of any particular atmosphere or location according
to ANSI/NFPA 505-1987. Aerial platforms operated in hazardous locations shall be
approved in accordance with, and of the type required, by ANSI/NFPA 505-1987.
7.11 Warnings and Instruction. The user shall direct his 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 loads are transferred to the platform at any height.

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XLT-1571DC

7.11.7 Work Area. The operator shall ensure that the area surrounding the aerial
platform is clear of personnel and equipment before lowering the platform.
7.11.8 Fueling. The engine shall be shut down while fuel tanks are being filled.
Fueling shall be done in a well-ventilated area free of flame, sparks, or other hazards
that may cause fire or explosion.
7.11.9 Battery Charging. Batteries shall be charged in a well-ventilated area free
of flame, sparks, or other hazards that may cause fire or explosion.
7.11.10 Platform Positioning. The aerial platform shall not be positioned against
another object to steady the platform.
7.11.11 Misuse as a Crane. The aerial platform shall not be used as a crane.
7.11.12 Operating Areas. The aerial platform shall not be operated from a position
on trucks, trailers, railway cars, floating vessels, scaffolds, or similar equipment,
unless the application is approved in writing by the manufacturer.
7.11.13 Travel Conditions. Under all travel conditions, the operator shall limit
travel speed according to conditions of ground surface, congestion, visibility, slope,
locations of personnel, and other factors causing hazards of collision or injury to
personnel.
7.11.14 Unauthorized Use. Means shall be used to protect against use by
unauthorized person(s).
7.12 Operation of the Aerial Platform. If a user is also the operator of an aerial
platform, the user shall have the responsibilities of operators specified in Section 8 of this
standard as well as responsibilities of users as specified in Section 7 of this standard.
7.13 Assistance to Operator. If a user is unable to answer any operator's questions
relating to rated capacity, intended use, maintenance, condition, or safety of operation of
the aerial platform, the user shall obtain the proper information from the dealer, owner, or
manufacturer and provide that information to the operator before use of the aerial
platform in the application of concern.
7.14 Shutdown of Aerial Platform. The user shall authorize and direct the operating
personnel to cease operation of the aerial platform in case of any suspected malfunctions
of the aerial platform, or any hazard or potentially unsafe condition that may be
encountered, and to request further information as to safe operation from the owner,
dealer, or manufacturer before further operation of the aerial platform.
7.15 Record Retention. The user shall retain the following records for at least 3 years:
(1) Records of the operator(s) trained on each model of an aerial platform (2) Written
records of the frequent and annual inspections shall be kept by the user when performing
the inspections. The records shall include the date of inspection, any deficiencies found,
the corrective action recommended and identification of the person(s) performing the
inspection (3) Written records of all repairs accomplished on the aerial platform,
including the date of any such repair, a description of the work accomplished, and the
identification of the person(s) performing the repair.
7.16 Modifications. A user shall not modify or concur in modification of an aerial
platform without the specific written approval of the manufacturer of the aerial platform.
7.17 Manufacturer's Safety Bulletins. The user shall comply with safety-related
bulletins as received from the manufacturer, dealer, or owner.
8. Responsibilities of Operators
8.1 Basic Principles. The information in this standard shall be supplemented by good
judgment, safety control, and caution in evaluating each situation. Since the operator is
in direct control of the aerial platform, conformance with good safety practices in this
area is the responsibility of the operator. The operator shall make decisions on the use
and operation of the aerial platform with due consideration for the fact that his or her own
safety as well as the safety of other personnel on the platform is dependent on those
decisions.

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7 — ANSI REPRINT

8.2 Manuals. The operator shall be aware that the operating safety manuals, including
the manual that defines the responsibilities of dealers, owners, lessors, lessees, users, and
operators are stored on the aerial platform and the location where they are stored. The
operator shall be familiar with the manuals stored on the aerial platform and consult them
when questions arise with respect to the aerial platform.
8.3 Prestart Inspection. Before use each day or at the beginning of each shift, the aerial
platform shall be given a visual inspection and functional test including but not limited to
the following: (1) Operating and emergency controls (2) Safety devices (3) Personal
protective devices, including fall protection (4) Air, hydraulic, and fuel system leaks (5)
Cables and wiring harness (6) Loose or missing parts (7) Tires and wheels (8) Placards,
warnings, and control markings (9) Outriggers, stabilizers, and other structures (10)
Guardrail system (11) Items specified by the manufacturer.
8.4 Problems or Malfunctions. Any problems or malfunctions that affect the safety of
operations shall be repaired prior to the use of the aerial platform.
8.5 Training. The operator shall have been trained either on the same model of aerial
platform or one having operating characteristics and controls consistent with the one to be
used during actual work site operation. The operator trainee shall operate the aerial
platform in an area free of obstructions under the direction of the qualified person for a
time sufficient to determine that the trainee displays proficiency in knowledge and actual
operation of the aerial platform. Only properly trained and authorized personnel shall be
permitted to operate the aerial platform.
8.6 Before Operation. Before being authorized to operate the aerial platform, the
operator shall have: (1) Been instructed by a qualified person in the intended purpose and
function of each of the controls (2) Read and understood the manufacturer's/owner's
operating instructions and safety rules, or been trained by a qualified person on the
contents of the manufacturer's/owner's operating instructions and safety rules (3)
Understood by reading or by having a qualified person explain all decals, warnings, and
instructions displayed on the aerial platform.
8.7 Workplace Inspection. Before the aerial platform is used and during use, the
operator shall check the area in which the aerial platform is to be used for possible
hazards such as, but not limited to: (1) Drop-offs or holes (2) Bumps and floor
obstructions (3) Debris (4) Overhead obstructions and high voltage conductors (5)
Hazardous locations (6) Inadequate surface and support to withstand all load forces
imposed by the aerial platform in all operating configurations (7) Wind and weather
conditions (8) Other possible unsafe conditions.
8.8 During Operation. The aerial platform shall be used in accordance with this
standard. The operator shall ensure the following before each elevation of the platform:
(1) That the aerial platform is operated on a surface within the limits specified by the
manufacturer (2) That the outriggers, stabilizers, extendable axles, or other stability
enhancing means are used as required by the manufacturer (3) That the guardrails are
installed and access gates or openings are closed per manufacturer's instructions (4) That
the load and its distribution on the platform and any platform extensions are in
accordance with the manufacturer's rated capacity for that specific configuration (5) That
there is adequate clearance from overhead obstructions (6) That the minimum safe
approach distances (MSAD) to energized power lines and parts, as listed in Table One,
are maintained. See Figure 2 for examples of safe operating procedures (7) That he or
she and all other personnel on the platform are wearing fall protection devices and other
safety gear as required at all times (see 4.9.5).
8.9 Determination of Hazardous Locations. It shall be the responsibility of the user to
determine the hazard classification of any particular atmosphere or location according to
ANSI/NFPA 505.
8.9.1 Hazardous Location Operating Requirements. Aerial platforms operated in
hazardous locations shall be approved and of the type required by ANSI/NFPA 505.
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XLT-1571DC

8.10 Warnings and Instructions. The operator and other personnel on the platform
shall comply with the requirements in 8.10.1 through 8.10.17.
8.10.1 Personnel Footing. Personnel shall maintain a firm footing on the platform
floor while working thereon. Use of planks, ladders, or any other devices on the
aerial platform for achieving additional height or reach shall be prohibited.
8.10.2 Other Moving Equipment. When other moving equipment or vehicles are
present, special precautions shall be taken to comply with local ordinances or safety
standards established for the workplace. Warnings such as, but not limited to, flags,
roped off areas, flashing lights, and barricades shall be used.
8.10.3 Reporting Problems or Malfunctions. The operator shall immediately
report to a supervisor any problems or malfunctions that become evident during
operation. Any problems or malfunctions that affect the safety of operation shall be
repaired prior to continued use of the aerial platform.
8.10.4 Reporting Potential Hazardous Locations. The operator shall immediately
report to a supervisor any potential hazardous locations (environment) that become
evident during operation.
8.10.5 Altering Safety Devices. Altering or disabling of interlocks or other safety
devices shall be prohibited.
8.10.6 Entanglement. Care shall be taken to prevent rope, electric cords, hoses,
etc., from becoming entangled in the aerial platform.
8.10.7 Capacity Limitation. Aerial-platform rated capacities shall not be exceeded
when loads are transferred to the platform at any heights
8.10.8 Work Area. The operator shall ensure that the area surrounding the aerial
platform is clear of personnel and equipment before lowering the platform.
8.10.9 Fueling. The engine shall be shut down while fuel tanks are being filled.
Fueling shall be done in a well-ventilated area free of flame, sparks, or other hazards
that may cause fire or explosion.
8.10.10 Battery Charging. Batteries shall be charged in a well-ventilated area free
of flame, sparks, or other hazards that may cause fire or explosion.
8.10.11 Platform Positioning. The aerial platform shall not be positioned against
another object to steady the platform.
8.10.12 Misuse as a Crane. The aerial platform shall not be used as a crane.
8.10.13 Operating Areas. The aerial platform shall not be operated from a position
on trucks, trailers, railway cars, floating vessels, scaffolds, or similar equipment,
unless the application is approved in writing by the manufacturer.
8.10.14 Travel Conditions. Under all travel conditions, the operator shall limit
travel speed according to conditions of ground surface, congestion, visibility, slope,
location of personnel, and other factors causing hazards of collision or injury to
personnel.
8.10.15 Unauthorized Use. Means shall be used to protect against use by
unauthorized person(s).
8.10.16 Misuse as a Jack. The platform of the aerial platform shall not be used to
jack the wheels off the ground unless the machine is designed for that purpose by the
manufacturer.
8.10.17 Snagged Platform. If the platform or elevating assembly becomes caught,
snagged, or otherwise prevented from normal motion by adjacent structure or other
obstacles such that control reversal does not free the platform, all personnel shall be
removed from the platform before attempts are made to free the platform using
ground controls.
8.11 Assistance to Operator. If an operator encounters any suspected malfunction of
the aerial platform, or any hazard or potentially unsafe condition relating to capacity, the
operator shall cease operation of the aerial platform and request further information as to
safe operation from management, or from the owner, dealer, or manufacturer, before
further operation of the aerial platform.
8.12 Modifications. An operator shall not modify or concur in modification of an aerial
platform without the specific written approval of the manufacturer of the aerial platform.
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7 — ANSI REPRINT

9. Responsibilities of Lessors
9.1 Basic Principles. Sound principles of safety, training, inspection, maintenance,
application, and operation consistent with all data available regarding the parameters of
intended use and expected environment shall be applied in the performance of
responsibilities of lessors with due consideration of the knowledge that the unit shall be
carrying personnel.
9.2 Lessor. A lessor is a person(s) or entity who leases, rents, loans, or otherwise
provides an aerial platform to another party for the beneficial use of that party (the user).
A lessor may also be a dealer, owner, lessee, user, or operator.
9.2.1 Lessor as a Dealer. When a lessor uses the aerial platform as a dealer, the
lessor shall have the responsibilities of dealers as specified in Section 5 of this
standard.
9.2.2 Lessor as an Owner. When a lessor uses the aerial platform as an owner, the
lessor shall have responsibilities of owners as specified in Section 6 of this standard.
9.2.3 Lessor as a User. When a lessor uses the aerial platform as a user, the lessor
shall have the responsibilities of operators as specified in Section 8 of this standard.
10. Responsibilities of Lessees
10.1 Basic Principles. Sound principles of safety, training, inspection, maintenance,
application, and operation consistent with all data available regarding the parameters of
intended use, and expected environment, shall be applied in the performance of
responsibilities of lessees with due consideration of the knowledge that the aerial platform
carries personnel.
10.2 Lessee. A lessee is a person(s) or entity to whom an aerial platform is provided by
lease, rental, loan, or other arrangement. A lessee may also be a user or operator.
10.2.1 Lessee as a Dealer. When a lessee uses the aerial platform as a dealer, the
lessee shall have the responsibilities of dealers as specified in Section 5 of this
standard.
10.2.2 Lessee as an Owner. When a lessee uses the aerial platform as an owner, the
lessee shall have the responsibilities of owners as specified in Section 6 of this
standard.
10.2.3 Lessee as a User. When a lessee uses the aerial platform as a user, the lessee
shall have the responsibilities of users as specified in Section 7 of this standard.
10.2.4 Lessee as an Operator. When a lessee uses the aerial platform as an
operator, the lessee shall have the responsibilities of operators as specified in Section
8 of this standard.

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XLT-1571DC

M.S.A.D. = Minimum Safe Approach Distance (See Table 7-1).

DENOTES PROHIBITED ZONE

• Do not allow machine, personnel, or conductive materials inside prohibited zone.
• Maintain M.S.A.D. from all energized lines and parts as well as those shown.
• Assume all electrical parts and wires are energized unless known otherwise.

Diagrams shown are only for purposes of illustrating M.S.A.D. work positions, not
all work positions.

7-10

7 — ANSI REPRINT

Table 7-1. Minimum Safe Approach Distance (M.S.A.D.) to energized
(exposed or insulated) power lines and parts.
Voltage Range
(Phase to Phase)

Minimum Safe Approach Distance
(Feet)

0 to 300V

(Meters)
Avoid Contact

Over 300V to 50KV

3.05

Over 50KV to 200KV

4.60

Over 200KV to 350KV

6.10

Over 350KV to 500KV

7.62

Over 500KV to 750KV

10.67

Over 750KV to 1000KV

13.72

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XLT-1571DC

7-12

125 Taylor Parkway
Archbold, OH 43502
Phone (419) 445-9675
(800) 527-5333
Fax
(419) 445-0367

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Bil Jax Cougar Lift Electric Hydraulic Platform Xlt 1571Dc Users Manual

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