WERNERCO BoSS X Series User manual

MAINTENANCE MANUAL
EN 280 IP24
X-SERIES
The ultimate push around scissor lifts
EN 280 IP24
EN 280 IP24
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BoSS X-Series Maintenance Manual
Contents
Section 1 - Description, specification & operation Page
1.1 Introduction....................................................................1
1.2 Intended use ...................................................................1
1.3 Modications...................................................................1
1.4 Terminology ...................................................................2
1.5 Technical data ..................................................................3
1.6 Engaging the brakes ............................................................4
1.7 Battery isolation switch ..........................................................4
1.8 Battery charging ................................................................4
1.9 Handset controller ..............................................................5
1.10 Emergency lowering ............................................................5
Section 2 – Safety during maintenance .....................................................6
Section 3 – Service engineer attributes .....................................................6
Section 4 – Competent person for thorough examination attributes ..........................6
Section 5 – Periodical maintenance and checks .............................................7
Section 6 – Exploded drawings and parts list ...............................................9
Section 7 – Electrical schematic ...........................................................25
Section 8 – Wiring diagram ...............................................................26
Section 9 – Tilt sensor ....................................................................27
Section 10 – Hydraulic schematic..........................................................28
Section 11 - Overload calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Section 12 – Machine labelling ............................................................30
Section 13 – Storage ......................................................................31
Section 14 – Troubleshooting..............................................................31
Section 15 – Disposal .....................................................................31
Section 16 – Variations on earlier BoSS X-Series machines .................................32
Appendix – UK only - Schedule 1 – Information to be contained in a report
of a thorough examination (The Lifting Operations and Lifting
Equipment Regulations 1998 - Regulation 10 (1)) ...............................33
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1.1 Introduction
This Manual provides the necessary information to
enable maintenance to be undertaken on BoSS X-Series
single person push around scissor lifts. Maintenance
engineers should read and understand all the
information contained in this manual before carrying out
work on any BoSS X-Series machine.
This Manual does not apply to BoSS X3 machines with
serial numbers between YMG11001 and 11300.
Additional copies of this Maintenance Manual may
be obtained from the manufacturer; please see contact
details in Section 1.3 on this page. The manual is also
available to download from the manufacturers' website at
www.bosspoweredaccess.com
1.2 Intended use
BoSS X-Series machines have been designed to comply
with the safety requirements of the European Machinery,
Low Voltage and Electromagnetic Compatibilty Directives
and in accordance with the European Standard EN 280
Mobile Elevating Work Platforms – Design calculations –
Stability criteria – Construction – Safety – Examinations
and tests.
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 weight of
the machine and its maximum safe working load.
Typical applications include building and construction,
particularly fit and strip out, shop fitting, painting and
decorating, general maintenance and 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 conditions which are outside those specified
in this section.
1.3 Modifications
No modifications shall be made to any BoSS X-Series
machine unless the manufacturer has given full written
approval. If in doubt, please contact the manufacturer for
advice:
Werner UK Sales & Distribution Ltd.
Blackwater Trading Estate
The Causeway
Maldon
Essex
CM9 4LJ
United Kingdom
t+44 (0) 1621 745900
f+44 (0) 1621 859845
e [e-mail]
Section 1 - Description, specification and operation
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2BoSS X-Series Maintenance Manual
1.4 Terminology
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
3 4 6 7
8
910
2
5
11
13
16
12
14
15
17
18
19
24
1
20 21
22
23
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)
24
25
25
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1.5 Technical data
Rated load, manual forces and weight: BoSS X3X BoSS X3 BoSS X2
(Discontinued)
Safe working load 240kg
equivalent to 1 person (80kg) plus 160kg tools & materials
Maximum allowable manual force 200N (interior use only)
Maximum allowable chassis inclination 1.25˚ 1.5˚ 1.5˚
Maximum allowable wind speed 0m/s
Maximum load per wheel 450kg
Machine weight 370kg 349kg 313kg
Maximum point loading (fully loaded) 17.43kg/cm216.83kg/cm215.8kg/cm2
Dimensions:
Maximum platform height 3.2m 2.55m 2.01m
Minimum platform height 0.695m 0.695m 0.6m
Maximum safe working height 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 Automatic multi voltage (110 & 240V)
Hydraulics:
Maximum hydraulic pressure 225 bar
Working pressure 150 bar
Hydraulic fluid reservoir 2 litres
Performance:
Maximum lifts/descents on one charge >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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4BoSS X-Series Maintenance Manual
1.6 Engaging the brakes
The BoSS X-Series machine is fitted with two braking
systems:
On the two fixed castors – these brakes are applied
automatically 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. To release, push the foot
under the lever and flick upwards. The swivel castors
MUST be locked whenever the machine is stationary
whether or not it is in use.
1.7 Battery isolation switch
The BoSS X-Series machine
is fitted with a key operated
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.
1.8 Battery charging
A battery charge level indicator is fitted to the BoSS
X-Series machine. When the machine is fully charged all
segments on the indicator will be illuminated red, as shown
in Figure 1 below. When only the first segment, on the left
of the indicator is illuminated red and flashing, as shown in
Figure 2 below, it is time to put the machine on charge.
BoSS X-Series machines are fitted with a low battery
protection system. If the battery level falls below 10%,
then the platform will not raise but can still descend. The
BoSS X-Series machine is fitted with an integral battery
charger. To charge the battery, follow these steps:
STEP 1 Depress the emergency stop button on the
handset controller and remove the key.
STEP 2 Turn the cover to expose the battery charging
cable connection point, as shown in Figure 1 below.
STEP 3 Connect either the mains power or 110V
transformer charging cable to the BoSS X-Series
machine battery charging cable connection point, as
shown in Figure 2 above. Both of these cables can be
found in the tool box which is mounted on the platform
guardrail.
STEP 4 Plug the other end of the charging cable into
either a mains 240V or transformer 110V power supply.
STEP 5 While the battery is charging to 80% of its
capacity the second LED from the left on the indicator
will be flashing green as shown in Figure 1 below. When
the charging of the final 20% is underway the third LED
from the left will be flashing green as shown in Figure 2
below.
STEP 6 When the battery is fully charged, all four lights
will illuminate, after approximately ten hours.
WARNING
BoSS X-Series machines must be charged where the
ambient temperature is between 0 and 45ºC.
Figure 1 Figure 2
Figure 1 Figure 2
Figure 1 Figure 2
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1.9 Handset controller
The handset controller
includes the platform raise
and lower controls. Pressing
the ‘UP’ button raises the
platform. 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.
BoSS X-Series machines are fitted with a platform
overload sensor. If the platform load is exceeded the
platform will not ascend and the red LED indicator on top
of the handset will illuminate.
1.10 Emergency lowering
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 Turn the finger screw on the emergency descent
valve 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.
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.
Figure 1
Figure 2
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6BoSS X-Series Maintenance Manual
Section 2 – Safety during
maintenance
When undertaking maintenance on a BoSS X-Series
machine with the platform elevated, always ensure that
the maintenance props are deployed as shown in the
picture below.
Section 3 – Service
engineer attributes
The BoSS X-Series service engineer should:
a. be physically fit and competent to carry out the
work being undertaken;
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;
f. be able to identify equipment;
g. be able to demonstrate an understanding
of and apply the information contained in this
Maintenance Manual;
h. be able to demonstrate that they can diagnose,
rectify and record faults;
i. be able to demonstrate an understanding
and knowledge of how to carry out inspections
(other than thorough examinations) and can
make recommendations for the continued use
of the equipment;
j. be able to demonstrate an understanding of
and apply company procedures;
k. be able to demonstrate that they can operate
the equipment safely;
l. be able to demonstrate that they can carry out
functional checks and setting procedures;
m. be able to demonstrate knowledge of how to
record all maintenance work carried out;
n. be able to demonstrate the required knowledge
and expertise of the BoSS X-Series machines
for service and maintenance purposes;
o. be undergoing a form of Continuous
Professional Development.
Section 4 – Competent
person for thorough
examination attributes
The competent person carrying out a thorough
inspection of a BoSS X-Series machine should:
a. be physically fit;
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;
f. comply with EN 45004;
g. be capable of detecting defects or weaknesses
in the BoSS X-Series machine for the purpose
of the thorough examination;
h. have sufficient knowledge and experience to
assess the importance of defects or
weaknesses in the BoSS X-Series machine and
identifying what actions need to be taken in
order to rectify them. In particular they should
be able to:
iverify that the BoSS X-Series machine is
operating as it is intended to in accordance
with the User Guide;
ii. identify defects or weaknesses which could
compromise the use of the BoSS X-Series
machine;
iii. specify the appropriate timescales within
which identified defects or weaknesses need
to be rectified;
iv. establish that defects identified in the previous
report of thorough examination have received
attention;
v. assess that all safety devices are functioning
correctly;
vi. check that warning notices are correctly fixed
and legible, and where necessary specify any
limitations to the use of the BoSS X-Series
machine;
vii. carry out any testing required as part of the
thorough examination;
viii. report on the findings of the thorough
examination.
Maintenance props
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Section 5 - Periodical maintenance and checks
The following checks should be undertaken at the intervals shown:
Daily/pre-use Monthly 6-monthly Annually
Inspect structure
Check condition of castellated scissor nuts and locking pins
Check latching of gate and transit gate lock
Inspect platform including harness lanyard point
Check condition of castors including tyres
Check castor brake function - auto braking on fixed castors and manually
applied brakes on swivel castors
Inspect hydraulic circuit for oil leaks
Check condition of hydraulic hose
Check condition of electrical cables
Check battery charge level and battery charging
Check platform raise & lower functions including descent delay
Inspect platform full height cut off and descent delay switches
Inspect all safety labelling and machine plate
Check handset emergency stop
Check base unit emergency stop
Check emergency lowering function
Check operation of descent alarm
Check operation of tilt sensor and alarm
Check all castor nuts are fully tightened
Check hydraulic oil level
Check electrical connectors
Grease scissor nipples
Grease platform and chassis roller nipples
Check integrity and tightness of all visible fixings eg screws, nuts and
bolts etc.
Replace hydraulic oil
Prior to the first use of a BoSS X-Series machine all
daily/pre-use checks must be undertaken.
If the BoSS X-Series machine has been out of service
for any length of time the 6-monthly checks referred to in
the table above should be undertaken by an authorised,
competent and suitably trained person.
The Lifting Operations and Lifting Equipment Regulations
1998 (LOLER) require that lifting equipment for lifting
persons must be THOROUGHLY EXAMINED every six
months (UK only).
Following any maintenance of a BoSS X-Series machine,
a full test of the functionality should be undertaken to
ensure the correct operation of the machine.
It is essential that only Werner UK Sales & Distribution
Ltd. approved replacement parts are used when
maintaining and servicing the BoSS X-Series machine.
Failure to do so may result in an unsafe machine. Details
on how to order replacement parts can be found by
visiting www.bosspoweredaccess.com.
Please provide the following information when requesting
replacement parts:
Name of model ie BoSS X2, X3 or X3X
Serial number to be found on the machine plate
attached to the chassis of the machine
Year of construction
Date of purchase of machine
Part number from this Maintenance Manual
Description from this Maintenance Manual
Quantity required
Company invoice address
Delivery address and contact number at this address
Desired method of shipment
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8BoSS X-Series Maintenance Manual
Lubrication
The recommended lubricant for use with the BoSS
X-Series machines is standard machine grease and the
lubrication points are shown in the pictures below
Scissors
Scissor rollers
Hydraulic oil
The hydraulic oil used to top up the reservoir of
the BoSS X-Series machine or when a complete oil
change is required should be a VG 46 fully inhibited
hydraulic oil manufactured in accordance with DIN
51524 Part 2.
VG 46 Hydraulic Oil
Appearance Amber coloured oil
Relative density at 15 oC 0.87-0.89
Kinematic viscosity at 40 oC 41.4-50.6 cSt
Flash point - open cup (oC) >180
Pour point (oC) -12
The hydraulic oil level
should be checked
6-monthly and topped
up as required.
Following removal
of the cap to the
hydraulic reservoir, the
oil as specified above
should be poured from
a small jug or through
a funnel into the
reservoir until the oil covers the aluminium cylinder just
inside the reservoir, see Figure 1, and the cap replaced.
WARNING
Ensure the platform is fully lowered when checking the
hydraulic oil level.
Do not overfill the hydraulic oil reservoir and take
care not to spill the oil on any of the surrounding
components.
The hydraulic oil is changed as follows:
1. Ensure the platform is fully lowered.
2. Slide out the component drawer of the machine.
3. Remove the red and black hydraulic oil reservoir
cap from the top of the reservoir.
4. Lift the machine with a forklift using the lateral
forklift pockets and secure with safety props.
5. Look under the drawer where you will see an M10
Allen bolt as shown below.
6. Undo the bolt and let the oil drain into an open top
container which must be able to hold a minimum of
2 litres.
Dispose of the oil at an approved disposal facility.
7. Replace the M10 Allen bolt and tighten.
8. Lower the machine and ensure the ground is level.
9. Refill the reservoir until the aluminium cylinder at the
opening to the reservoir is just covered.
10. Replace the reservoir cap.
Figure 1
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Section 6 – Exploded drawings and parts list
BoSS X3X assembly
BoSS X3X Assembly
4
2
3
5
1
Item ref. Part no. Description Qty.
1 83901000 Guardrail assembly 1
2 81908000 Handset controller assembly 1
3 83902000 Aluminium platform and steel runners 1
4 81902014 Handle screw with locking nut 4
5 83904000 Cylinder assembly X3X 1
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10 BoSS X-Series Maintenance Manual
BoSS X3 Assembly
1
2
3
4
5
5
Item ref. Part no. Description Qty.
1 81901001 Guardrail assembly 1
2 81908000 Handset controller assembly 1
3 81902001 Platform assembly 1
4 81902014 Handle screw with locking nut 4
5 81904000 Cylinder assembly X3 1
BoSS X3 assembly
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BoSS X2 Assembly
12
3
4
5
Item ref. Part no. Description Qty.
1 82901001 Guardrail assembly 1
2 81908000 Handset controller assembly 1
3 82902001 Platform assembly 1
4 81902014 Handle screw with locking nut 4
5 82904000 Cylinder assembly X2 1
BoSS X2 assembly
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12 BoSS X-Series Maintenance Manual
Guardrail Assembly
7
8
1
2
6
5
4
3
9
BoSS X3X/X3/X2 guardrail assembly
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BoSS X3X/X3/X2 guardrail assembly continued
X3X guardrail assembly
Item ref. Part no. Description Qty.
1 83801020 Right guardrail & gate assembly 1
2 83901003 Left guardrail assembly 1
3 83901007 Back guardrail assembly 1
4 81020071 Instruction tube cap 1
5 81801017 Gate hinge fixing kit 1
6 83901024 Gate toeboard with label 1
7 81020101 Gate latch 1
8 81122061 Transit gate lock 1
9 81200501 X-Series tool box 1
X3 guardrail assembly
Item ref. Part no. Description Qty.
1 81801020 Right guardrail & gate assembly 1
2 81901005 Left guardrail assembly 1
3 81901007 Back guardrail assembly 1
4 81020071 Instruction tube cap 1
5 81801017 Gate hinge fixing kit 1
6 81901024 Gate toeboard with label 1
7 81020101 Gate latch 1
8 81122061 Transit gate lock 1
9 81200501 X-Series tool box 1
X2 guardrail assembly
Item ref. Part no. Description Qty.
1 82801020 Right guardrail & gate assembly 1
2 81901005 Left guardrail assembly 1
3 82901007 Back guardrail assembly 1
4 81020071 Instruction tube cap 1
5 81801017 Gate hinge fixing kit 1
6 82901024 Gate toeboard with label 1
7 81020101 Gate latch 1
8 81122061 Transit gate lock 1
9 81200501 X-Series tool box 1
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14 BoSS X-Series Maintenance Manual
Handset Controller Assembly
1
1
2
2
3
4
6
7
8
5
9
Item ref. Part no. Description Qty.
1 81130041 Normally open switch 2
2 81130171 Normally closed switch 2
3 81130081 Up button 1
4 81130091 Down button 1
5 81130101 Emergency stop 1
6 81801016 Key 1
7 81020121 Curly cable assembly 1
8 81801002 Overload light assembly 1
9 81911018 Overload label 1
BoSS X3X/X3/X2 handset controller assembly
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BoSS X3X & BoSS X3 Scissors Assembly
1
2
3
4
5
7
6
8
X3X scissor assembly
Item
ref. Part no. Description Qty.
1 81070091 Scissor bush 24
2 81070111 Platform roller 2
3 81200151 Scissor black end cap 16
4 81903041 Maintenance prop assembly 2
5 81903039 Chassis roller 2
6 81070131 Caps for maintenance props 2
7 81903037 Scissor pads 8
8 83905013 X3X scissor cable 1
X3 scissor assembly
Item
ref. Part no. Description Qty.
1 81070091 Scissor bush 24
2 81070111 Platform roller 2
3 81200151 Scissor black end cap 16
4 81903041 Maintenance prop assembly 2
5 81903039 Chassis roller 2
6 81070131 Caps for maintenance props 2
7 81903037 Scissor pads 8
8 81910028 X3 scissor cable 1
BoSS X3X/X3 scissor assembly
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16 BoSS X-Series Maintenance Manual
BoSS X2 Scissors Assembly
1
2
3
7
4
5
6
8
Item ref. Part no. Description Qty.
1 81070091 Scissor bush 24
2 81070111 Platform roller 2
3 81200151 Scissor black end cap 16
4 81903041 Maintenance prop assembly 2
5 81903039 Chassis roller 2
6 81070131 Caps for maintenance props 2
7 81903037 Scissor pads 8
8 82905003 X2 scissor cable 1
BoSS X2 scissor assembly
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4
5
4
8
1
2
67
3
X3X hydraulic cylinder assembly
Item
ref. Part no. Description Qty.
1 81904026 Pressure loss valve cover 1
2 81904006 Pressure loss valve 1
3 81801003 Pressure loss valve o-rings 1
4 81070091 Bush 4
5 81801004 Seal kit 1
6 83904002 X3X hydraulic hose 1
7 81904031 Pressure loss valve seal kit 1
8 81100093 Two-way solenoid cartridge valve -
handle type 1
X3 hydraulic cylinder assembly
Item
ref. Part no. Description Qty.
1 81904026 Pressure loss valve cover 1
2 81904006 Pressure loss valve 1
3 81801003 Pressure loss valve o-rings 1
4 81070091 Bush 4
5 81801004 Seal kit 1
6 81904014 X3 hydraulic hose 1
7 81904031 Pressure loss valve seal kit 1
8 81100093 Two-way solenoid cartridge valve -
handle type 1
BoSS X3X/X3 hydraulic cylinder assembly
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18 BoSS X-Series Maintenance Manual
Item ref. Part no. Description Qty.
1 82904026 Pressure loss valve cover 1
2 81904006 Pressure loss valve 1
3 81801003 Pressure loss valve o-rings 1
4 81070091 Bush 4
5 81801004 Seal kit 1
6 82904014 X2 hydraulic hose 1
7 81904031 Pressure loss valve seal kit 1
8 81100093 Two-way solenoid cartridge valve - handle type 1
BoSS X2 hydraulic cylinder assembly
4
5
4
8
1
2
67
3
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