Youngman BOSS X Series User manual

MAINTENANCE
MANUAL
Edition December 2011
The ultimate range of push
around micro powered
access platforms
EN 280 IP24

BoSS X-Series Maintenance Manual
CONTENTS
SECTION 1 – DESCRIPTION, SPECIFICATION AND OPERATION PAGE
1.1 Introduction 1
1.2 Intended use 1
1.3 Modifications 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 control unit 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 – MACHINE LABELLING 29
SECTION 12 – STORAGE 30
SECTION 13 – TROUBLESHOOTING 30
SECTION 14 – DISPOSAL 30
SECTION 15 – MODIFICATIONS TO LATER BOSS X-SERIES MACHINES (REFER TO
SERIAL NUMBERS AT START OF THIS SECTION)
31
APPENDIX – Example of report of thorough examination – LOLER 6 monthly inspection
(UK only)
37

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1.1 INTRODUCTION
This Maintenance Manual provides the necessary
information to enable maintenance to be undertaken
on BoSS X-Series single person push around
micro 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 YMG 11001 and 11300.
Additional copies of this Maintenance Manual may
be obtained from Youngman Group Ltd., please
see contact details in Section 1.3 on this page.
The manual is also available to download from our
website at youngmangroup.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 maintenance, cleaning, painting, fit
out work etc. at varying heights above ground level.
WARNING
The user must obtain the guidance and written approval of
Youngman Group Ltd in the event of any special working
methods or conditions which are outside those specied
in this section.
1.3 MODIFICATIONS
No modifications shall be made to any BoSS X-Series
machine unless Youngman Group Ltd. has given full
written approval. If in doubt please contact us for advice:
Youngman Group Ltd.
The Causeway
Maldon
Essex
CM9 4LJ
United Kingdom
t+44 (0) 1621 745900
f+44 (0) 1621 859845
[e-mail]
SECTION 1 – DESCRIPTION, SPECIFICATION AND OPERATION

2
BoSS X-Series Maintenance Manual
1.4 TERMINOLOGY
1Charging cables and guardrail tools tray
2Forklift access, hoisting and transit strap points
3Battery charging connection point
4Battery charging indicator
5Battery charge level indicator
6Base unit emergency stop
7Smooth roll castors with non marking tyres
8Step up to platform
9
Fixed castors with auto braking applied as the
platform is raised
10 Swivel castors with click on brakes
11 Emergency lowering release valve
12 Guardrails
13 Work platform
14 Scissor assembly
15 Hydraulic ram
16 Pressure loss valve
17 Fail-safe props
18 Chassis
19 Winching eye
20 Handset control unit
21 Instructions for Use storage tube
22 Access gate
23 Slip resistant deck incorporating lanyard point
10
7
1
2
3 4
11
8
9
65
13
12
16
20
14
18
22
15
21
17
19
23
BoSS X-Series Maintenance Manual

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1.5 TECHNICAL DATA
* Including 3 seconds for intermediate stop
on descent
BoSS X3X BoSS X3 BoSS X2
Rated load, manual forces and weight:
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 1.25o1.5o1.5o
Maximum allowable wind speed 0m/s
Maximum load per wheel 450kg
Machine weight 370kg 349kg 313kg
Maximum point loading 17.43kg/cm² 16.83kg/cm² 15.8kg/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 delay on descent height 1.87m 1.85m 1.4m
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
Motor 1.2kW 1.2kW 0.8kW
Battery (deep cycle/sealed gel) 12V/100Ah 12V/100Ah 12V/80Ah
Battery charger Automatic multi voltage 110 and 240v
Hydraulics:
Maximum hydrauilic pressure 225 bar
Working pressure 150 bar
Hydraulic fluid reservoir 2 litres
Performance:
Maximum number of lifts and descents on one
charge:
with 80kg platform load >325 >430 >565
with 240kg platform load >215 >225 >250
Ascent times:
with 80kg platform load 15 seconds 12 seconds 10 seconds
with 240kg platform load 18 seconds 15 seconds 12 seconds
Descent times*:
with 80kg platform load 21 seconds 17 seconds 15 seconds
with 240kg platform load 21 seconds 18 seconds 15 seconds

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BoSS X-Series Maintenance Manual
1.6 ENGAGING THE BRAKES
The BoSS X-Series machine is fitted with two braking
systems:
Fixed castors – these brakes are applied
automatically as the platform rises
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 provided with a key
operated switch which 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 below making sure 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 battery is fully charged
the segment at the far right hand side of the display will
be illuminated red, as shown in figure 1 opposite.
When the second segment from the left is illuminated, as
shown in figure 2 below, it is time to put the
BoSS X-Series machine on charge
Figure 1 Figure 2
BoSS X-Series machines are fitted with low battery
protection. If the battery level falls below 20% 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 the steps below:
a. Depress the emergency stop button on the
handset control unit and remove the key.
b. Remove the cover from the charging connection
point as shown in figure 1 below.
Figure 1 Figure 2
c. Connect either the mains or 110V transformer
charging cable to the BoSS X-Series machine
charging connection point, as shown in
figure 2 above. These cables are to be found in the
charging cable and guardrail tools tray under the
step up to the platform.
d. Connect the charging cable to a suitable power
supply (110V transformer or mains)
e. Whilst the battery is charging to 80% of capacity
the second light will be flashing as shown in
figure 1 on the following page and when the
charging of the remaining 20% is underway the
third light will begin flashing as indicated in
figure 2 on the following page.

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Figure 1 Figure 2
f. When the battery is fully charged all four
lights will illuminate after approximately
10 hours.
WARNING
BoSS X-Series machines must be charged where the
ambient temperature is between 0 and 50ºC.
1.9 HANDSET CONTROL UNIT
The handset control unit houses the platform raise and
lower controls.
Pressing the ‘UP’ button raises the platform.
Pressing the ‘DOWN’ button lowers the platform
To avoid crushing or shearing hazards, an intermediate
stop feature on lowering is fitted to activate when the
platform reaches a base of work platform height from
ground level of:
BoSS X3X – 1.87m
BoSS X3 – 1.85m
BoSS X2 – 1.4m
This is a safety mechanism
that reminds the operator
to look around the machine
to determine whether any
persons are adjacent to the
machine. After a time delay
and when the operator is sure
it is safe to do so, the ‘DOWN’
button can be depressed a
second time to continue the
descent.
BoSS X-Series machines
are fitted with an overload
sensor system. If the
platform load is exceeded
the platform will not raise
and the red LED indicator
on top of the handset will
illuminate as shown on the
right.
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.
1.Turn the finger screw on the pressure loss
valve anticlockwise until it will not turn any further as
shown in figure 1.
2.Then, turn the emergency valve on the base
unit anticlockwise until the platform begins to
descend, as shown in figure 2. If you need to stop the
descent simply turn this valve clockwise again.
Figure 1 Figure 2
WARNING
Always ensure someone other than the operator is
trained to perform this rescue.

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BoSS X-Series Maintenance Manual
SECTION 2 – SAFETY DURING
MAINTENANCE
When carrying out 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:
i. verify that the BoSS X-Series
machine is operating as it is
intended to in accordance with
the Instructions for Use;
ii. identify defects or weaknesses
which could compromise the use
of the BoSS X-Series machine;
iii. specify the appropriate time
scales 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 the correct function of all
safety devices;
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 split pin retainers
Inspect platform
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
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 hydraulic oil level
Check operation of descent alarm
Check operation of tilt sensor and alarm
Check electrical connectors
Grease scissor nipples
Grease platform and chassis roller nipples
Grease castor nipples
Check all castor nuts are fully tightened
Check integrity and tightness of all visible fixings eg screws, nuts
and bolts
Replace hydraulic oil
Prior to the first use of a BoSS X-Series machine all
daily/pre-use checks should be undertaken.
If the BoSS X-Series machine has been out of
service for any length of time the six 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 Youngman 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
youngmangroup.com or by calling
[phone].
You will need to provide our parts distributor with:
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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BoSS 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.
WARNING
Ensure the platform is fully lowered when checking
the oil level.
Do not overfill the hydraulic oil reservoir and take
care not to spill the oil on any of the surrounding
machine components.
The hydraulic oil is changed as follows:
1. Ensure the platform is fully lowered.
2. Lift the machine with a forklift using the lateral
forklift points and secure with safety props.
3. Slide out the component drawer of the
machine.
4. Remove the red and black oil reservoir cap
from the top of the reservoir.
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 can hold a minimum of 2
litres.
Dispose of the oil at an approved disposal
facility.
7. Replace M10 bolt and refill reservoir until the
aluminium plate at the opening to the reservoir
is just covered.
8. Replace the reservoir cap.
VG 46 Hydraulic Oil
Appearance Amber coloured oil
Relative density at 15 oC0.87-0.89
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 daily 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
plate just inside the reservoir, see figure 1 opposite,
and the cap replaced.
Figure 1

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SECTION 6 – EXPLODED DRAWINGS AND PARTS LIST
BoSS X3X Assembly
Item Ref Part No. Description Qty.
1 83901000 Guardrail assembly 1
2 81908000 Handset controller assembly 1
3 83902000 Aluminium platform and steel runner 1
4 81902014 Handle screw with locking nut 4
5 83904000 Cylinder assembly X3X 1
4
2
1
3
5

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BoSS X-Series Maintenance Manual
BoSS X3 Assembly
1
2
3
4
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

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BoSS X2 Assembly
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
12
3
4
5

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BoSS X-Series Maintenance Manual
BoSS X3X/X3/X2 Guardrail Assembly
7
8
1
2
3
4
6
5

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Item Ref Part No. Description Qty.
1 82801001 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 xing kit 1
6 82901024 Gate toeboard with label 1
7 81020101 Gate latch 1
8 81122061 Transit gate lock 1
X2 Guardrail Assembly
X3 Guardrail Assembly
Item Ref Part No. Description Qty.
1 81801001 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 xing kit 1
6 81901024 Gate toeboard with label 1
7 81020101 Gate latch 1
8 81122061 Transit gate lock 1
BoSS X3X/X3/X2 Guardrail Assembly continued
X3X Guardrail Assembly
Item Ref Part No. Description Qty.
1 83801001 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 xing kit 1
6 83901024 Gate toeboard with label 1
7 81020101 Gate latch 1
8 81122061 Transit gate lock 1

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BoSS X-Series Maintenance Manual
BoSS X3X/X3/X2 Handset Controller Assembly
Item Ref Part No. Description Qty.
1 81130041 Normally open switch 2
2 81130171 Normally closed switch 2
3 81130051 Main body 1
4 81130181 Front plate & back plate 1
5 81130081 Up button 1
6 81130091 Down button 1
7 81130101 Emergency stop 1
8 81801016 Key 1
9 81130131 Waterproof cover 1
10 81020121 Curly cable assembly 1
11 81801002 Overload light assembly 1
12 81911018 Overload label 1
1
1
2
2
3
4
4
5
6
8
9
10
11
7
12

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BoSS X3X/X3 Scissor Assembly
1
2
3
4
5
7
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 Base roller 2
6 81070131 Caps for maintenance props 2
7 81903037 Scissor pads 8
8 83905013 X3X scissor cable 1
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 Base roller 2
6 81070131 Caps for maintenance props 2
7 81903037 Scissor pads 8
8 81910028 X3 scissor cable 1
X3 Scissor Assembly

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BoSS X-Series Maintenance Manual
BoSS X2 Scissor 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 8
4 81903041 Maintenance prop assembly 2
5 81903039 Base roller 2
6 81070131 Caps for maintenance props 2
7 81903037 Scissor pads 4
8 82905003 X2 scissor cable 1

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BoSS X3X/X3 Hydraulic Cylinder Assembly
BoSS X3X/X3 Hydraulic Cylinder Assembly
1
2
3
4
5
4
6
7
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
X3X Hydraulic Cylinder Assembly
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

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BoSS X-Series Maintenance Manual
BoSS X2 Hydraulic Cylinder Assembly
BoSS X2 Hydraulic Cylinder Assembly
1
2
4
3
5
4
6
7
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 82904014 X2 hydraulic hose 1
7 81904031 Pressure loss valve seal kit 1