Youngman BoSS X3X-SP User manual

Picture of
machine being
used in situ. at full
height.
The ultimate self propelled micro scissor lift
INSTRUCTIONS
FOR USE
Edition April 2011
EN 280 IP54

BoSS X3X-SP Instructions for Use
Contents
SECTION 1 - DESCRIPTION PAGE
1.1 Introduction 1
1.2 Characteristics and description 2
1.3 Intended use 3
1.4 Selection and minimum attributes of
operators
4
1.5 Modifications 5
1.6 Terminology 6
SECTION 2 - SPECIFICATION
2.1 Technical data 10
2.2 Operating site 12
2.2.1 Ground conditions 12
2.2.2 Ground flatness 12
2.2.3 Overhead obstructions 12
2.2.4 Segregation from other site vehicle
movements
12
2.3 Noise and vibrations 13
2.4 Limitations 13
SECTION 3 - SAFETY RULES 14
SECTION 4 - OPERATING INSTRUCTIONS
4.1 Daily checks 16
4.2 Disengaging the drive wheel brakes 17
4.3 Battery isolation switch 19
4.4 Entering and leaving the work
platform
19
4.5 Handset control unit 20
4.6 Base unit control panel 22
4.7 Emergency lowering 23
4.8 Battery charging 24
4.9 Driving and manoeuvering the
platform
26
4.10 Extending the work platform 27
SECTION 5 - TRANSPORT, HANDLING AND
STORAGE
5.1 Storage 28
5.2 Loading and unloading 29
5.3 Lifting 31
5.4 Preparation for transport 31
SECTION 6 - MAINTENANCE AND REPAIR
RECORD
6.1 Machine labelling 32
6.2 Maintenance record 38
6.3 Repairs record 38
6.4 Examination/tests record 38
6.5 Daily checks – Operator checklist 40
SECTION 7 BOSS X3X-SP ACCESSORIES
7.1 Confined Space Guardrail 42
7.2 Heavy Duty All Weather Cover 42

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1.1 INTRODUCTION
These Instructions for Use provide information
on the safe operation of the BoSS X3X-SP single
person, self propelled micro scissor lift. Operators
should read and understand all the information
contained within this manual before operating the
BoSS X3X-SP.
Additional copies of these instructions may also
be obtained from Youngman Group Ltd, please
see contact details on the back cover. The
Instructions are also available to download from
our website at youngmangroup.com.
The information contained in these instructions
is based on the latest product information at
the time of publication. As Youngman Group
Ltd. operate a policy of continuous product
improvement we reserve the right to make
product changes at any time without obligation

2 BoSS X3X-SP Instructions for Use
1.2 CHARACTERISTICS AND DESCRIPTION
The BoSS X3X-SP is a self propelled, micro
scissor lift.
• Safe working height of 5.14 metres (Platform
height – 3.14 metres)
• Drivable at full height (13.5 metres/minute)
• 76 centimetres wide – ts through personnel
doorways and into passenger lifts
• For indoor and outdoor use – wind rating with
non extended platform
• 1.65 metres platform length (including 0.4
metre extension)
• Weight of 495 kilograms facilitating lifting on a
standard tail lift
• Straight line driving with swivel castor lock
feature
• Highly manoeuvrable – turns within its own
footprint of only 1.27 metres
• 350 lifts and descents, 16.1 kilometres driving
or mix of two on a single charge
• Pothole protection activation on platform ascent
• Ramp loading – up to 35% (19.2°)
• Forklift loading via longitudinal fork lifting points
• Low battery protection system
• Electromagnetic brakes on drive motors with
backup powered & manual release systems
• Tilt sensor, overload and pressure loss
protection as standard
• Safety cut out on descent (3 seconds)
• Audible alarm and ashing light on ascent,
descent and drive
• Self closing gate with built in toeboard, locking
latch and transit gate lock
• Slip resistant deck incorporating lanyard point
• Safety and usage instructions mounted on
guardrail
• Multi function handset controller with locking or
lift off feature
• Base unit LED display and diagnostic centre,
emergency stop, key switch, raise and lower
buttons, charging point and indicator light
• Emergency descent (backup power and
manual systems)
• Two slide out drawers for easy maintenance
access
• Fail safe props for deployment during
maintenance
• Anti static strip
• Rigid and robust box section scissors
• Heavy duty drive wheels, swivel castors, power
pack, battery charger and batteries
• Guardrail mounted tool box for storage of
charging cables and guardrail tools
• Maintenance manual
• EC Declaration of Conformity
• 6 months LOLER certication (UK only)
• 12 months parts warranty
The following optional equipment is also available:
• Heavy Duty All Weather Protective Cover
• Conned Space Guardrail

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1.3 INTENDED USE
The BoSS X3X-SP has 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 – Examinations and
tests.
The BoSS X3X-SP is intended to lift one person,
plus essential tools and materials, to enable work
to be undertaken at height. The BoSS X3X-SP is
designed for indoor and outdoor use (outdoor
only with platform closed) 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 and strip 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 specified in this section.

4 BoSS X3X-SP Instructions for Use
1.4 SELECTION AND MINIMUM ATTRIBUTES
OF OPERATORS
Personnel operating the BoSS X3X-SP 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 and experience of personnel
should be consulted to assist in the selection of
suitable personnel.
Personnel should be instructed not to work under
the influence of alcohol, drugs or other impairment
to efficiency. Personnel should also be assessed
as to their physical ability to undertake the
appointed tasks.
The BoSS X3X-SP operator 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. 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 (Youngman offer a Work at
Height Regulations training course called
the Knowledge. For more information
please call +44 (0) 1621 745900)
i. be able to demonstrate understanding
of the need for and correct use and
maintenance of personal protective
equipment;
j. operate the BoSS X3X-SP 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 and recognise unsafe practices/
developing situations;
l. carry out daily pre-use checks.
WARNING
Operation of the BoSS X3X-SP by untrained
or inadequately trained operators may result in
serious injury or death.
We recommend that all operators are trained
to use a Type 3a MEWP at an IPAF approved
training centre.

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In addition to the Operator of the BoSS X3X-SP
the Site Surveyor and Planner and machine
Demonstrator should be competent to fulfil these
roles as specified in the Safe Use of MEWP’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
No modifications shall be made to a BoSS X3X-SP
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
esales@youngmangroup.com
1.4 SELECTION AND MINIMUM ATTRIBUTES
OF OPERATORS

6 BoSS X3X-SP Instructions for Use
1.6 TERMINOLOGY
1
Guardrails
Work platform
Scissor assembly
Hydraulic ram
Pressure loss valve
Fail safe maintenance props (x2)
Chassis
2
3
4
5
6
7
2
1
3
4
5
6
7

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1.6 TERMINOLOGY
8
10 9
Deck extension
Motion warning light
Fork lifting point
8
9
10

8 BoSS X3X-SP Instructions for Use
12
15
16
11
Main safety and operation label
Instructions for Use tube
Handset controller
Tool box
Slip resistant deck incorporating lanyard
point
Access gate
Emergency descent handle - stage 2 of
manual operation
Emergency descent button - single stage
using backup power
Step up to platform
Hoisting, winching and tie down point (x4)
11
12
13
14
15
16
17
18
19
20
14
20
13
17 18
19
1.6 TERMINOLOGY

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24 32
31
21 30 2923 25
22 27
Drive wheel (x2)
Drawer release handle (x2)
LCD display and diagnostic centre
Base unit emergency stop
Control position selector key switch
Raise and lower buttons
Charging indicator light
Charging socket
Swivel castor (x2)
Pothole protection bar (x2)
Handset controller connector
Deck release tab for cleaning
21
22
23
24
25
26
27
28
29
30
31
32
Deck extension release pedal
Emergency descent valve - stage 1 of
manual operation
33
34
34
33
28
26
1.6 TERMINOLOGY

10 BoSS X3X-SP Instructions for Use
2.1 TECHNICAL DATA
*Including 3 seconds for the intermediate stop on descent
Measurments: Metric Imperial
Rated load, manual forces and weight:
Safe working load 150kg
(inc on platform extension)
331lbs
(inc on platform extension)
equivalent to (1 person (80kg) plus 70kg
tools & materials)
(1 person (176lbs) plus
154lbs tools & materials)
Maximum allowable manual force 200N
Maximum allowable chassis inclination 1.5°
Maximum allowable wind speed 12.5m/s
(with platform closed)
28mph
(with platform closed)
Maximum load per wheel 420kg (based on drive
wheels – swivel castor
rating is 500kg)
926lbs (based on drive
wheels – swivel castor
rating is 1102lbs)
Machine weight 495kg 1091lbs
Maximum point loading 14.83kg/cm²211psi
Dimensions:
Maximum platform height 3.14m 10’4”
Minimum platform height 0.63m 2’1”
Maximum safe working height 5.14m 16’10”
Platform delay on descent height 1.86m 4’7”
Platform width 0.7m 2’4”
Platform length 1.25m-1.65m 4’1”-5’5”
Platform guardrail height 1.1m 3’7”
Toeboard height 0.15m 6”
Overall width 0.76m 2’6”
Stowed height 1.74m (0.89m with
guardrails removed)
5’9” ( 2’11” with guardrails
removed)
Stowed length (with step deployed) 1.39m 4’7”
Ground clearance Platform lowered
0.045-0.09m
Platform raised 0.01m
Platform lowered 2”- 4”
Platform raised 0.4”
Electrical:
Voltage 24V DC
Power pack motor 1.2kW DC
Drive wheel motors 24V/2800rpm/0.5kW
Batteries (deep cycle/sealed gel) 2 x 12V/100Ah
Battery charger 100-120V/200-240V (automatic switching)
Hydraulics:
Maximum hydraulic pressure 255 bar
Working pressure 150 bar
Hydraulic uid reservoir 1.5 litres 0.33 gallons
Performance:
Maximum number of lifts and descents on one charge: 350 (150kg load) 211 psi
Ascent time 19 seconds (150kg load)
Descent time 21 seconds (150kg load)
Maximum driving speed (platform lowered) 65m/minute 2.42mph
Maximum driving speed (platform raised) 13.5m/minute 0.5mph

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Measurments: Metric Imperial
Rated load, manual forces and weight:
Safe working load 150kg
(inc on platform extension)
331lbs
(inc on platform extension)
equivalent to (1 person (80kg) plus 70kg
tools & materials)
(1 person (176lbs) plus
154lbs tools & materials)
Maximum allowable manual force 200N
Maximum allowable chassis inclination 1.5°
Maximum allowable wind speed 12.5m/s
(with platform closed)
28mph
(with platform closed)
Maximum load per wheel 420kg (based on drive
wheels – swivel castor
rating is 500kg)
926lbs (based on drive
wheels – swivel castor
rating is 1102lbs)
Machine weight 495kg 1091lbs
Maximum point loading 14.83kg/cm²211psi
Dimensions:
Maximum platform height 3.14m 10’4”
Minimum platform height 0.63m 2’1”
Maximum safe working height 5.14m 16’10”
Platform delay on descent height 1.86m 4’7”
Platform width 0.7m 2’4”
Platform length 1.25m-1.65m 4’1”-5’5”
Platform guardrail height 1.1m 3’7”
Toeboard height 0.15m 6”
Overall width 0.76m 2’6”
Stowed height 1.74m (0.89m with
guardrails removed)
5’9” ( 2’11” with guardrails
removed)
Stowed length (with step deployed) 1.39m 4’7”
Ground clearance Platform lowered
0.045-0.09m
Platform raised 0.01m
Platform lowered 2”- 4”
Platform raised 0.4”
Electrical:
Voltage 24V DC
Power pack motor 1.2kW DC
Drive wheel motors 24V/2800rpm/0.5kW
Batteries (deep cycle/sealed gel) 2 x 12V/100Ah
Battery charger 100-120V/200-240V (automatic switching)
Hydraulics:
Maximum hydraulic pressure 255 bar
Working pressure 150 bar
Hydraulic uid reservoir 1.5 litres 0.33 gallons
Performance:
Maximum number of lifts and descents on one charge: 350 (150kg load) 211 psi
Ascent time 19 seconds (150kg load)
Descent time 21 seconds (150kg load)
Maximum driving speed (platform lowered) 65m/minute 2.42mph
Maximum driving speed (platform raised) 13.5m/minute 0.5mph
2.1 TECHNICAL DATA

12 BoSS X3X-SP Instructions for Use
2.2 OPERATING SITE
When a BoSS X3X-SP is delivered to site ensure
that the machine will be able to reach the work
area; this is not rough terrain machine and should
not be transported across unstable or uneven
ground as this could cause significant damage to
the machine. It is good practice to walk the route
from the machines parking place to the workplace.
A visual inspection of the operating area should
be made before using the machine paying
particular attention to the following issues:
2.2.1 GROUND CONDITIONS
Ensure that the ground on which the
BoSS X3X-SP is to operate is capable of
supporting the weight of the machine (including
the maximum rated load of 150kg). Be aware of
specific floor areas such as manhole covers which
may not be designed to withstand the maximum
point loading of 14.83kg/cm2exerted by the
wheels.
2.2.2 GROUND FLATNESS
Ideally the BoSS X3X-SP should be operated
on at surfaces resulting in a 0 degree chassis
inclination. However, the BoSS X3X-SP can be
safely operated where the ground is slightly
uneven resulting in a 1.5˚ maximum lateral
and longitudinal inclination. The BoSS X3X-SP
operating system is fitted with a tilt sensor and will
not raise or drive if this angle is exceeded.
All four wheels must be in contact with the ground
at all times.
2.2.3 OVERHEAD OBSTRUCTIONS
Ensure that adequate clearance is available
above and all round the platform before
deployment and elevation and pay particular
attention to the presence of live electrical cables.
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 X3X-SP, measures
should be taken to segregate the machine from
other vehicles. This might include the use of
cones, barriers, signage and re-routing measures.
WARNING
When the machine is being
operated in an area where there
are other vehicle movements
the operator should wear a
harness and the lanyard should
be clipped into the lanyard point
on the floor of the platform as
shown.

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2.3 NOISE AND VIBRATION
The maximum noise level emitted by a
BoSS X3X-SP is 84.6dB(A).
Hand and arm vibration experienced on the
BoSS X3X-SP does not exceed 6.37m/s2.
2.4 LIMITATIONS
The BoSS X3X-SP can be used indoors or
outdoors, BUT IF USED OUTDOORS THE
PLATFORM MUST BE CLOSED IE. NOT
EXTENDED.
Please consult Youngman direct 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 (eg radar, antennae)
or within strong electrical and/or magnetic
fields may affect some of the features of this
machine.
WARNING
This machine has not been designed for
operation in a hazardous environment where
flammable or explosive gases or particulates
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 protective equipment. Expert advice
may need to be sought.
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 X3X-SP 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. Guidance on lone working is
given in the HSE leaflet INDG 73 [20].

14 BoSS X3X-SP Instructions for Use
3 SAFETY RULES3 SAFETY RULES
These safety rules should be adhered to in every
w a y.
NEVER exceed the 150kg rated capacity (Safe
Working Load or SWL) of the platform
NEVER use the BoSS X3X-SP as a crane
NEVER attempt to increase the reach or working
height of the BoSS X3X-SP by use of
additional equipment eg ladders
NEVER use the BoSS X3X-SP in temperatures
exceeding 50˚C or below -20˚C
NEVER attempt to get on or off the work platform
of the BoSS X3X-SP when elevated
NEVER apply external side loads to the platform or
scissor structure
NEVER allow persons at ground level to operate
the controls whilst the platform is occupied
(unless in an emergency situation)
NEVER operate the BoSS X3X-SP outdoors with the
platform extended
NEVER drive or raise the platform with the
component access drawers open
NEVER use the BoSS X3X-SP 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 remove the platform guardrails when
the machine is in use
NEVER allow works overhead of the
BoSS X3X-SP to be carried out which are
outside the control of the operator
NEVER use the BoSS X3X-SP as an electrical earth
when welding structures alongside it
NEVER use the guardrails to carry materials
NEVER forklift the machine from either side or
from the drive wheel end – use the fork
lifting points at the swivel castor end of the
machine
NEVER stand behind or in front of the machine
during ramp loading
NEVER make any addition to the BoSS X3X-SP
which would increase its wind load eg
notice boards
NEVER use the BoSS X3X-SP without the
removable guardrails in place
NEVER allow anyone to stand near the machine
as the platform is being raised. This
particularly applies to each side of the
machine where there is a foot trap hazard
caused by the deployment of the pothole
protection bars as the platform rises
NEVER attempt to overreach

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3 SAFETY RULES
ALWAYS check that there are no obstructions
or persons that may be struck by the
platform before and during the raising,
lowering and driving of the platform
ALWAYS carry tools and materials within
the confines of the guardrails of
the work platform
ALWAYS undertake the daily checks
recommended in this handbook
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 X3X-SP is positioned
on adequate ground to support the
weight of the machine and its rated
load.
ALWAYS keep the BoSS X3X-SP clear of live
electric conductors
ALWAYS keep the BoSS X3X-SP away from
contact with xed objects (buildings etc)
or moving objects (vehicles, cranes etc)
ALWAYS ensure hands are within the confines
of the guardrails when elevating or
lowering 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
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
(eg cordon off areas to prevent persons
and other vehicles entering the danger
area)
ALWAYS ensure the horn sounds when the power
is switched on
ALWAYS ensure the batteries are charged
before use
ALWAYS read and understand these Instructions
for Use before using the machine
ALWAYS use fail-safe props if working under the
work platform
ALWAYS thread the hoisting straps inside
the guardrails when hoisting the
machine
ALWAYS lock the swivel castors before ramp
loading
ALWAYS check that the LOLER certification
of the machine is in date before use (UK
ONLY)

16 BoSS X3X-SP Instructions for Use
4.1 DAILY CHECKS
It is essential to carry out daily checks on the
BoSS X3X-SP to ensure its safe condition of use
including the following as a minimum:
• Hydraulic oil leaks by visual inspection of the
floor around the base unit, by feeling
underneath the drawer which houses the
power pack and by examination of the ram and
pressure loss valve and sensor
• Loose electrical ttings and sensors by visual
inspection
• Chafed hydraulic hose or electrical cables by
visual inspection
• Condition of drive wheel and swivel castor tyres
and wheels by visual inspection
• Structure – guardrails, platform, scissors and
chassis (eg damage, cracks, corrosion,
abrasions, welds, connections)
• Visual inspection of the tab locking nuts and
washers on the scissor assembly
• Obscured, dirty or damaged instruction
labelling and plates
• Emergency stop function activated on the
handset controller
• Emergency stop function activated on the base
unit
• Emergency lowering of platform – both backup
power and manual systems (see page 23)
• Raise and lower functions including descent
delay and deployment of pothole protection
bars at each side of the base unit (the raise
and lower functions can be tested by
unclipping and removing the handset controller
from its holder on the work platform and using
the controls whilst at ground level)
• With the base unit key selector in the platform
position try to push the machine to ensure drive
wheel brakes are engaged
• Switch on power and:
- Ensure that the horn sounds to confirm
operation
- Check that the battery is fully charged using
either the battery level indicator on the front
of the handset controller or by checking the
base unit LCD display
If the above pre-use checks reveal malfunctions
or damage on the machine, then it must not be
used until the problem is rectified. If in doubt seek
further assistance by contacting Youngman.
If instruction labels or plates are no longer legible
or missing contact Youngman for replacements.
The Daily Checks page in Section 6.5 of these
Instructions for Use may be photocopied or are
available to download from our website at
youngmangroup.com to provide an aide memoir
for operators when undertaking these important
checks.
WARNING
Before operating the BoSS X3X-SP, you must
ensure that you have been adequately trained in
its use and have read and fully understood these
Instructions for Use, paying particular attention to
the Safety Rules in Section 3.

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4.2 DISENGAGING THE DRIVE WHEEL
BRAKES
In the case of an operating system or power
failure and in order to move the BoSS X3X-SP
clear of the work area or to facilitate loading the
machine onto a tail lift, the electromagnetic brakes
of the drive wheels can be disengaged.
Firstly, open the drawer by pressing the button on
the drawer lock and then rotating the bar
anticlockwise as shown below.
The drawer is equipped with a handle on the base
at each side to facilitate drawer opening as shown
below.
There is a brake release switch which uses the
machines backup power supply mounted on top
of the battery retainer plate in the drawer
(see figure 1).
Remove the switch and the extension cable from
their retaining clips and standing at the swivel
castor end of the machine press the red button
(see figure 2) and the brakes will release. The
machine can then be pushed manually and
steered using the swivel castors.
Always ensure that you release the button to
engage the brakes after moving the machine.
Figure 1 Figure 2

In exceptional circumstances and in the case of a
failure of the powered brake release system each
drive wheel brake can be manually disengaged by
removing the protective cover using the two
release bolts (see figure 1) and turning the wing
nuts clockwise (see figure 2).
Always ensure that you engage the brakes by
turning the wing nut on each drive wheel
anticlockwise until the brakes engage.
WARNING
The BoSS X3X-SP weighs 495 kilograms and may
require more than one person to push it when the
drive wheel brakes are disengaged.
Never attempt to move the platform on a gradient
with the drive wheel brakes disengaged without
assistance.
Always carry out a risk assessment.
Figure 1
Figure 2
18 BoSS X3X-SP Instructions for Use
4.2 DISENGAGING THE DRIVE WHEEL
BRAKES
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