BOSSCO X-SERIES User manual

X-SERIES
The ultimate push around scissor lifts
USER GUIDE
EN 280 IP24
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1BoSS X-Series User guide
1.1 Introduction
1.2 Characteristics and description
1.3 Intended use
1.4 Selection and minimum attributes of operators
1.5 Modications
1.6 Terminology
Contents
Section 1 - Description
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Section 2 – Specification
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2.1 Technical data
2.2 Operating site
2.2.1 Ground conditions
2.2.2 Ground atness
2.2.3 Overhead obstructions
2.2.4 Segregation from other site vehicle movements
2.3 Noise and vibration
2.4 Limitations
Section 3 – Safety rules
Section 4 – Operating instructions
4.1 Daily checks
4.2 Manoeuvring the platform
4.3 Engaging the brakes
4.4 Battery isolation switch
4.5 Entering and leaving the work platform
4.6 Handset controller
4.7 Emergency stop
4.8 Emergency lowering
4.9 Battery charging
Section 5 – Transport, handling and storage
5.1 Storage
5.2 Loading and unloading
5.3 Lifting
5.4 Preparation for transport
6.1 Machine labelling
6.2 Maintenance record
6.3 Repairs record
6.4 Examination / tests record
6.5 Daily checks – operator checklist
Section 6 – Maintenance and repair record
7.1 Conned Space Guardrail
7.2 Bumpers - Front and side impact protection
7.3 Heavy-Duty All-Weather Covers
Section 7 – BoSS X-Series accessories
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Section 8 – Variations on earlier BoSS X-Series
machines
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1.1 Introduction
This user guide provides information on the safe operation of the
BoSS X-Series single person push around scissor lifts namely the
BoSS X2 (now discontinued), BoSS X3 and BoSS X3X. This user
guide does not apply to BoSS X3 machines with serial numbers
between YMG11001 and 11300. Operators should read and
understand all the information contained within this user guide before
operating a BoSS X-Series machine.
Additional copies of this user guide may also be obtained from the
manufacturer; please see the contact details on the back cover. The
instructions are also available to download from the manufacturer’s
website at www.bosspoweredaccess.com.
The information contained in this user guide is based on the latest
product information at the time of publication. The manufacturer
operates a policy of continuous product improvement. We reserve
the right to make product changes at any time without notice.
Section 1 - Description
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3BoSS X-Series User guide
1.2 Characteristics and description
The BoSS X-Series is a range of manually propelled scissor lifts.
Each machine includes the following features as standard:
Automaticbrakingonxedcastors
Foot operated click-on brakes on swivel castors
Tilt sensor
Platform overload sensor with LED indicator on handset controller
Pressure loss valve
Safety cut-out on descent (preprogrammed to 3 seconds)
Audible alarm on descent
Self-closing gate with locking latch and transit gate lock
Gate incorporates end toeboard removing trip hazard
Slip-resistant deck incorporating lanyard point
Safety and usage instructions mounted on the guardrail
Platform mounted handset controller with emergency stop
Secondary emergency stop button mounted on the chassis
Battery charge level indicator
Battery charger with charging indicator
Non-powered emergency platform lowering mechanism
Fail-safe props for deployment during maintenance
Anti-static strip
Rigid,robustboxsectionscissors
Machinestthroughstandarddoorwaysandintosmallpassenger
lifts
Winching eye
Heavy duty power pack, battery charger and battery
Serviceable components in slide out drawer
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1.2 Characteristics and description
Guardrailmountedtoolbox(withtooltray)forstorageofcharging
cables and guardrail tools
Wide forklift pockets for lifting, hoisting and strapping during
transit
Heavy-duty castors with cast aluminium hubs and non-marking
tyres
Maintenance Manual
EC Declaration of Conformity
6monthsLOLERcertication(UKonly)
3-year parts warranty
The following BoSS X-Series machine accessories are also
available:
ConnedSpaceGuardrail
Bumpers - Front and side impact protection
Heavy-Duty All-Weather Covers
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5BoSS X-Series User guide
BoSS X-Series machines have been designed to comply with the
safety requirements of the European Machinery, Low Voltage and
Electromagnetic Compatibility Directives and in accordance with
the European Standard EN 280 Mobile Elevating Work Platforms
– Design calculations – Stability criteria – Construction – Safety –
Examinationsandtests.
BoSS X-Series machines are intended to lift one person (plus
essential tools and materials) to enable work to be undertaken at
height. BoSS X-Series machines are designed for indoor use only
and must be used on level ground which is able to support the
weightofthemachineanditsmaximumsafeworkingload.Typical
applicationsincludebuildingandconstruction,particularlytandstrip
out,shoptting,paintinganddecorating,generalmaintenanceand
cleaning at varying heights above ground level.
WARNING
The user must obtain the guidance and written approval of the
manufacturer in the event of any special working methods or
conditionswhichareoutsidethosespeciedinthissection.
1.4 Selection and minimum attributes of
operators
Personnel operating a BoSS X-Series machine should have either
been selected, trained and authorised to do so, or be undergoing
formal training under supervision. ISO 18878 gives details of the
requirements for the training of MEWP operators. Records of training
andexperienceofpersonnelshouldbeconsultedtoassistinthe
selection of suitable personnel.
Personnelshouldbeinstructednottoworkundertheinuenceof
alcohol,drugsorotherimpairmenttoefciency.Personnelshould
also be assessed as to their physical ability to undertake the
appointed tasks. The BoSS X-Series machine operator should:
1.3 Intended use
a. be physically t.
b. appear to be comfortable working at height when taken up in
the work platform of a MEWP.
c. have a responsible attitude.
d. demonstrate an ability to learn.
e. be able to communicate clearly with other personnel on site.
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f. be able to demonstrate understanding of relevant health and
safety regulations.
g. be able to demonstrate understanding of accident prevention
and control.
h. be able to demonstrate that they can work safely at height.
i. be able to demonstrate understanding of the need for
plus correct use and maintenance of personal protective
equipment.
j. operate the BoSS X-Series machine safely and manoeuvre the
machine as required, to correctly position and carry out the
tasks in a correct and proper manner.
k. be able to identify and avoid foreseeable hazards plus
recognise unsafe practices and developing situations.
l. carry out daily pre-use checks.
WARNING
Operation of the BoSS X-Series machine by untrained or inadequately
trained operators may result in serious injury or death.
A course for the category Push Around Vertical (PAV) is offered by
IPAF-approvedtrainingcentresintheUK.
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1.4 Continued
In addition to the Operator of the BoSS X-Series machine the Site
Surveyor and Planner plus the machine Demonstrator should be
competenttofulltheserolesasspeciedintheSafeUseofMEWP’s
– Code of Practice sections 7.2.6 and 7.2.7 respectively.
When planning the job the Site Surveyor and Planner should work
through the following stages
a. Identify the task to be undertaken.
b. Select an appropriate MEWP.
c. Identify the hazards associated with the task.
d. Carry out a risk assessment.
e. Identify control measures.
f. Develop the method to be used.
g. Record the planning in a Method Statement (including any
contingency activities for personnel rescue).
h. Communicate the plan to all persons involved.
i. Review the plan before the job starts and incorporate any
changing circumstances.
1.5 Modifications
NomodicationsshallbemadetoanyBoSSX-Seriesmachine
unless the manufacturer has given full written approval. If in doubt,
please contact the manufacturer for advice:
WernerUKSales&DistributionLtd.
Blackwater Trading Estate
The Causeway
Maldon
Essex
CM9 4LJ
UnitedKingdom
t +44 (0) 1621 745900
f +44 (0) 1621 859845
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1.6 Terminology
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Guardrail mounted tool box (with tool tray)
Forklift pockets for lifting, hoisting and
strapping during transit
Battery charging cable connection point
Battery charging indicator
Battery charge level indicator
Chassis mounted emergency stop
Heavy-duty castors with cast aluminium
hubs and non-marking tyres
Step up to platform
Fixed castors with automatic braking
applied on platform ascent
Swivel castors with click on brakes
Emergency lowering release valve (stage
1 of 2 of emergency descent procedure)
Guardrails
Work platform
Scissor assembly
Hydraulic cylinder
Pressure loss valve
Fail-safe props
Chassis
Winching eye
Handset controller
User guide storage tube
Self-closing gate with locking latch and
transit gate lock
Slip-resistant deck incorporating lanyard
point
Anti-static strip
Emergency lowering pull handle (stage 2
of 2 of emergency descent procedure)
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9BoSS X-Series User guide
Section 2 - Specification
Rated load, manual forces and weight: BoSS X3X BoSS X3 BoSS X2
(Discontinued)
Safe working load 240kg
Equivalent to 1person(80kg)plus160kgtools&materials
Maximumallowablemanualforce 200N (interior use only)
Maximumallowablechassisinclination 1.25˚ 1.5˚ 1.5˚
Maximumallowablewindspeed 0m/s
Maximumloadperwheel 450kg
Machine weight 370kg 349kg 313kg
Maximumpointloading(fullyloaded) 17.43kg/cm216.83kg/cm215.8kg/cm2
Dimensions:
Maximumplatformheight 3.2m 2.55m 2.01m
Minimum platform height 0.695m 0.695m 0.6m
Maximumsafeworkingheight 5.2m 4.55m 4.01m
Platform width 0.57m
Platform length 1.25m 1.05m 1.05m
Platform guardrail height 1.1m
Toeboard height 0.15m
Overall width 0.76m 0.7m 0.7m
Stowed height 1.8m 1.8m 1.7m
Stowed length 1.41m 1.21m 1.21m
Ground clearance 0.05m
Electrical:
Voltage 12V DC
Power pack motor 1.2kW DC 1.2kW DC 0.8kW DC
Battery 12V/100Ah 12V/100Ah 12V/80Ah
Battery charger Automaticmultivoltage(110&240V)
Hydraulics:
Maximumhydraulicpressure 225 bar
Working pressure 150 bar
Hydraulicuidreservoir 2 litres
2.1 Technical data
Performance:
Maximumlifts/descentsononecharge >215 (240kg load) >225 (240kg load) >250 (240kg load)
Ascent time 18 seconds
(240kg load)
15 seconds
(240kg load)
12 seconds
(240kg load)
Descent time (including 3 second delay) 21 seconds
(240kg load)
18 seconds
(240kg load)
15 seconds
(240kg load)
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2.2 Operating site
When a BoSS X-Series machine is delivered to site ensure that
the machine will be able to reach the work area; these are not
rough terrain machines and should not be pushed across unstable
orunevengroundasthiscouldcausesignicantdamagetothe
machines. It is good practice to walk the route from the machine
parking place to the workplace.
A visual inspection of the operating area should be made before
setting up the machine paying particular attention to the following
issues:
2.2.1 Ground conditions
Ensure that the ground on which the BoSS X-Series machine is to
operate is capable of supporting the weight of the machine (including
themaximumratedloadof240kg).Beawareofspecicoorareas
such as manhole covers which may not be designed to withstand the
followingmaximumpointloadingexertedbythecastorwheels:
BoSS X3X – 17.43kg/cm2
BoSS X3 – 16.83kg/cm2
BoSS X2 – 15.8kg/cm2
2.2.2 Ground flatness
IdeallytheBoSSX-Seriesmachineshouldbeoperatedonaat
surface resulting in a 0 degree chassis inclination. However, the
BoSS X-Series machine can be safely operated where the ground
isslightlyunevenresultinginthefollowingmaximumlateraland
longitudinal inclinations:
BoSS X3X – 1.250
BoSS X3 – 1.50
BoSS X2 – 1.50
TheBoSSX-Seriesmachinesarettedwithatiltsensorandwill
notraiseifthisangleisexceeded.Allfourcastorwheelsmustbein
contact with the ground at all times.
2.2.3 Overheard obstructions
Ensure that adequate clearance is available above and around the
platform before deployment and elevation. Pay particular attention to
the presence of live electrical cables.
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11 BoSS X-Series User guide
2.2.4 Segregation from other site vehicle movements
Every worksite should be subject to a risk assessment and where
vehicle movements are likely to occur close to the BoSS X-Series
machine, measures should be taken to segregate the machine from
other vehicles. This might include the use of cones, barriers, signage
and rerouting measures.
2.3 Noise and vibration
ThemaximumnoiselevelemittedbyaBoSSX-Seriesmachineis
75.8dB(A).HandandarmvibrationexperiencedonaBoSSX-Series
machinedoesnotexceed2.31m/s2.
2.4 Limitations
The BoSS X-Series machine is limited to indoor operation and
must not be used outdoors. Please consult the manufacturer if you
are unsure about any application for which the machine is being
considered.
The machine has been tested for Electromagnetic Compatibility
(EMC). However, operation near to high powered radio transmission
apparatus (e.g. radar, antennae) or within strong electrical and/or
magneticeldsmayaffectsomeofthefeaturesofthismachine.
WARNING
This machine has not been designed for operation in a hazardous
environmentwhereammableorexplosivegasesorparticulates
are present. Advice should be sought from the person in charge of
the site regarding the need to select MEWP’s that are designed for
use in the hazardous environment and the use of suitable personal
protectiveequipment.Expertadvicemayneedtobesought.
This machine is not electrically insulated and must never be used for
live line working. Death or serious injury can result from contact with
(or inadequate clearance from) electrical conductors.
The risk assessment carried out as part of the planning process when
considering the use of a BoSS X-Series machine should take account
of the particular hazards of lone working. Of particular concern is
the rescue of the occupant from the platform in the case of machine
malfunction, work platform entanglement or a medical emergency.
GuidanceonloneworkingisgivenintheHSEleaetINDG73.
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Section 3 - Safety rules
These safety rules should be adhered to in every way.
NEVER exceedthe240kgSafeWorkingLoadoftheplatform.
NEVER use the BoSS X-Series machine as a crane.
NEVER attempt to increase the reach or working height of the BoSS
X-Series machine by use of additional equipment eg. ladders.
NEVER usetheBoSSX-Seriesmachineintemperaturesexceeding45ºCor
below-15ºC.
NEVER manoeuvre the BoSS X-Series machine on an inclined surface
otherwise it may become uncontrollable.
NEVER release the brakes or manoeuvre the BoSS X-Series machine whilst
in an elevated position, as this may cause instability.
NEVER manoeuvre the BoSS X-Series machine with a person or materials
on the platform.
NEVER attempt to get on or off the work platform of the BoSS X-Series
machine when elevated.
NEVER applyexternalsideloadstotheplatformorscissorstructure.
NEVER allow persons at ground level to operate the controls whilst the
platform is occupied (unless in an emergency situation).
NEVER operate the BoSS X-Series machine outdoors.
NEVER use the BoSS X-Series machine as a jack, prop or tie to support
other structures or machines etc.
NEVER interfere with, wedge or attempt to override hydraulic, electrical or
mechanical safety devices.
NEVER open the drawer in the chassis. The drawer must only be opened by
an authorised, trained and competent maintenance engineer.
NEVER allow works overhead of the BoSS X-Series machine to be carried
out which are outside the control of the operator.
NEVER use the BoSS X-Series machine as an electrical earth when welding
structures alongside it.
NEVER use the guardrails to carry materials.
NEVER attempt to overreach.
NEVER stand in front of, or behind the BoSS X-Series machine whilst it is
being winched.
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Section 3 - Safety rules
ALWAYS ensure that there are no obstructions/persons that may be struck by
the platform before and during raising and lowering of the platform.
ALWAYS carrytoolsandmaterialswithintheconnesoftheguardrailsofthe
work platform.
ALWAYS undertake the daily checks recommended in this user guide prior to
the operation of the machine.
ALWAYS ensure that all instructions, warning and safe working load labelling
and plates are clean and legible.
ALWAYS ensure the BoSS X-Series machine is positioned on adequate
ground to support the weight of the machine and its rated load.
ALWAYS keep the BoSS X-Series machine clear of live electric conductors.
ALWAYS keeptheBoSSX-Seriesmachineawayfromcontactwithxed
objects (e.g. ceilings etc.) or moving objects (e.g. vehicles, cranes
etc.)
ALWAYS ensurehandsarewithintheconnesoftheguardrailswhenelevating
the work platform.
ALWAYS ensure the access gate is closed and latched once the operator has
entered the work platform.
ALWAYS ensure that another responsible person on site knows how to use the
emergency controls (i.e. the chassis mounted emergency stop and
the two stage emergency lowering procedure).
ALWAYS ensure the weight is evenly distributed within the platform.
ALWAYS ensure the safety of persons that may enter the area around the
platform and keep other vehicles clear of the work area (cordon off to
prevent persons and other vehicles entering the danger area).
ALWAYS lock the swivel castors when the machine is stationary whether or not
it is in use.
ALWAYS ensure the tilt sensor alarm sounds when the power is switched on.
ALWAYS ensure that the battery is charged before use.
ALWAYS read and understand this user guide before using the machine.
ALWAYS deploy both fail-safe props if working under the work platform.
ALWAYS thread the hoisting straps inside the guardrails when hoisting the
machine.
ALWAYS checkthattheLOLERcerticationofthemachineisindatebefore
use(UKONLY).
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4.1 Daily checks
It is essential to carry out daily checks on the BoSS X-Series machine
to ensure its safe condition of use including the following as a
minimum:
Hydraulicoilleaksbyvisualinspectionoftheooraroundthe
chassis and by feeling underneath the chassis drawer outer casing.
Visiblelooseelectricalttingsandswitchesbyvisualinspection.
Visible chafed hydraulic hose or electrical cables by visual
inspection.
Condition of castors, tyres and brakes by visual inspection.
Structure – guardrails, platform, scissors and chassis (e.g. cracks,
corrosion,abrasions,crackedwelds,loosexings,generaldamage
etc).
Visual inspection of castellated scissor nuts and locking pins.
Obscured, dirty or damaged instruction labelling and plates.
Emergency stop function activated on the handset.
Emergency stop function activated on the chassis.
Emergency lowering of the platform (see page 19).
Raise and lower functions including the 3 second descent delay
(the raise and lower functions can be tested by removing the
handset controller from its mount on the work platform and using
the controls whilst at ground level).
Without the swivel castor brakes applied and on a level surface,
raisetheplatformuntiltheautoxedcastorbrakesareengaged.
Then push the machine from the left and right side of the gate end
of the machine to ensure the brakes are functioning.
Switch on the power and ensure that the tilt sensor alarm sounds
toconrmoperation.Alsocheckthatthebatteryisfullycharged.
If the above daily pre-use checks reveal malfunctions or damage on the
machine,thenitmustnotbeuseduntiltheproblemisrectiedbyan
accredited maintenance engineer. If in doubt, seek further assistance by
contacting the manufacturer. If instruction labels or plates are no longer
legible or missing, contact the manufacturer for replacements. The Daily
Checks page in Section 6.5 of this user guide may be photocopied or are
available to download from our website at bosspoweredaccess.com to
provide an aide memoire for operators when undertaking these essential
checks.
WARNING
Before operating the BoSS X-Series machine, you must ensure that
you have been adequately trained in its use and have read and fully
understood this user guide, paying particular attention to the Safety Rules
in Section 3.
Section 4 – Operating instructions
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15 BoSS X-Series User guide
4.2 Manoeuvring the platform
Manoeuvre the platform into position using both hands on the
platform guardrail uprights as shown below. Take care to avoid
trapping hands or feet whilst manoeuvring the platform.
WARNING
Never manoeuvre the BoSS X-Series machine whilst it is elevated or
with a person, tools or materials on the platform.
Moving the machine up or down a slight gradient:
ALWAYS ensure that no person or obstacle is in front of the
machine going down a slight gradient or behind the machine going
up a slight gradient
DO NOT attempt to move the machine up or down a steep gradient
ALWAYS undertake a risk assessment
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4.3 Engaging the brakes
TheBoSSX-Seriesmachineisttedwithtwobrakingsystems:
Onthetwoxedcastors–thesebrakesareappliedautomatically
as the platform rises.
On the two swivel castors – these brakes are engaged by the use
of a foot pushing down on the lever as shown in the picture below.
Torelease,pushthefootundertheleverandickupwards.
The swivel castors MUST be locked whenever the machine is
stationary whether or not it is in use.
4.4 Battery isolation switch
The BoSS X-Series machine
isttedwithakeyoperated
switch on the handset
controller. This switch is used
to isolate the battery, and
therefore the electrical system,
preventing unauthorised
use. To enable the electrical
system, insert the key and turn
clockwise, as shown in the
image on the right, ensuring
the red emergency stop button
is fully released.
Ensure that when the machine
is not in use, the emergency
stop button is depressed and
the key removed.
New image using current BoSS X3X
at photo shoot
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17 BoSS X-Series User guide
4.5 Entering and leaving the work platform
Alwaysusethreepointsofcontactwhenenteringandexitingthe
platform (e.g. the use of two hands and one foot as shown in the
pictures below). Always use the step up to the platform on the chassis
of the machine.
On entering the platform, ensure that the gate is closed behind you,
as shown below.
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4.6 Handset controller
The handset controller includes the platform
raise and lower controls.
Pressingthe‘UP’buttonraisestheplatform.
Pressing the ‘DOWN’ button lowers the
platform.
Part way through the descent of the platform, a 3-second stop is
triggered to alert the operator to look down and around all 4 sides
of the platform to ensure that there are no people or obstacles
preventing the continued descent of the platform, thus averting any
risk of crushing or shearing.
Once the operator is sure that it is safe to continue the descent, the
‘DOWN’ button can be depressed a second time to continue the
lowering of the platform.
BoSSX-Seriesmachinesarettedwithaplatformoverloadsensor.
Iftheplatformloadisexceededtheplatformwillnotascendandthe
red LED indicator on top of the handset will illuminate.
4.7 Emergency stop
An emergency stop button is provided on the handset controller.
Once depressed this isolates the power to the raise and lower
functions.
To restore the power, twist the emergency stop button key clockwise
to release the button as shown below.
There is also an
emergency stop
button on the
chassis. Push in
to activate and
twist clockwise to
release.
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19 BoSS X-Series User guide
In the unlikely event of a power failure of the BoSS X-Series machine
the platform can be lowered manually by use of the following
procedure:
STEP 1 Turnthengerscrewontheemergencydescentvalve
anticlockwise until it will not turn any further, as shown in Figure 1 below.
STEP 2 Pull the red handle under the step up to the platform towards
you until the platform has fully lowered, as shown in Figure 2 below.
If for any reason, you need to stop the emergency descent at any
time, release the handle and the platform will stop descending.
To continue the descent pull the red handle again.
Figure 1 Figure 2
WARNING
Always ensure that someone at ground level i.e. other than the
operator, is trained to perform this procedure.
In the unlikely event that the motor will not stop running, even after
both emergency stop buttons have been depressed, open the drawer
in the chassis and using the red strap remove the 100A fuse and close
the drawer before undertaking the emergency lowering procedure
above. DO NOT reuse the machine until it has been inspected, and if
necessary repaired, by a competent engineer.
4.8 Emergency lowering
AbatterychargelevelindicatoristtedtotheBoSSX-Seriesmachine.
When the machine is fully charged all segments on the indicator will
beilluminatedred,asshowninFigure1below.Whenonlytherst
segment,ontheleftoftheindicatorisilluminatedredandashing,as
shown in Figure 2 below, it is time to put the machine on charge.
4.9 Battery charging
Figure 1 Figure 2
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