WERNERCO BoSS X Series Maintenance Manual Download Page 30 | Manualshive

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BoSS X-Series

Maintenance Manual

Section 10 - Hydraulic schematic

CYLINDER

MOUNTED ON

CYLINDER

AUTOMATIC HOSE BURST

SAFETY CHECK VALVE

EMERGENCY

RELEASE

VALVE

SOLENOID

RETURN

VALVE

EMERGENCY

RELEASE

VALVE

FILTER

SOLENOID

RETURN

VALVE

NON RETURN VALVE

MOTOR

PUMP

FILTER

RESERVOIR

POWER PACK

RELIEF VALVE

1

3
2

PRESSURE RELAY

BoSS X Series_Maintanence Manual Rev B 0519.indd 28

16/05/2019 14:59

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Summary of Contents for BoSS X Series

Page 1: ...MAINTENANCE MANUAL EN 280 IP24 X SERIES The ultimate push around scissor lifts EN 280 IP24 BoSS X Series_Maintanence Manual Rev B 0519 indd 1 16 05 2019 14 57 ...

Page 2: ...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 BoS...

Page 3: ...inations 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...

Page 4: ... 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 w...

Page 5: ...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 pr...

Page 6: ...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 re...

Page 7: ...oSS 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 ...

Page 8: ...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 t...

Page 9: ...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...

Page 10: ... 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 ...

Page 11: ... 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 BoSS X Series_Maintanence Manual Rev B 0519 indd 9 16 05 2019 14 59 ...

Page 12: ... 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 BoSS X Series_Maintanence Manual Rev B 0519 indd 10 16 05 2019 14 59 ...

Page 13: ...ption 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 BoSS X Series_Maintanence Manual Rev B 0519 indd 11 16 05 2019 14 59 ...

Page 14: ...12 BoSS X Series Maintenance Manual Guardrail Assembly 7 8 1 2 6 5 4 3 9 BoSS X3X X3 X2 guardrail assembly BoSS X Series_Maintanence Manual Rev B 0519 indd 12 16 05 2019 14 59 ...

Page 15: ... 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 gu...

Page 16: ...witch 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 BoSS X Series_Maintanence Manual Rev B 0519 indd 14 16 05 2019 14 59 ...

Page 17: ...0131 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 B...

Page 18: ... 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 BoSS X Series_Maintanence Manual Rev B 0519 indd 16 16 05 2019 14 59 ...

Page 19: ...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 val...

Page 20: ...e 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 6 7 3 BoSS X Series_Maintanence Manual Rev B 0519 indd 18 16 05 2019 14 59 ...

Page 21: ...roof cover 1 10 81910035 Tilt sensor calibration point cover 1 11 81910034 Terminal block cover 1 12 81905015 Steel protector for height limit switch 1 13 81910018 Height limit switch 1 14 81801005 Fixed castor brake assembly 1 15 81905041 Machine plate stamped with details 1 16 81905025 Winching eye 1 17 83905009 Blanking plate 1 18 81090141 Hydraulic hose nylon fixing 2 19 81905024 Drawer runner...

Page 22: ...05022 Chassis back plate assembly 1 12 81905038 Waterproof cover 1 13 81905031 Left fixed castor 1 14 81905024 Drawer runner 2 15 81910018 Height limit switch 1 16 81905015 Steel protector for height limit switch 1 17 81090141 Hydraulic hose nylon fixing 1 18 81905041 Machine plate stamped with details 1 19 81905025 Winching eye 1 20 82911020 81911020 X2 X3 emergency solenoid valve release handle ...

Page 23: ...bosspoweredaccess com 21 BoSS X3X X3 X2 chassis drawer assembly 1 4 3 2 5 6 7 8 9 21 22 11 13 14 15 16 17 18 19 20 23 10 12 24 25 26 BoSS X Series_Maintanence Manual Rev B 0519 indd 21 16 05 2019 14 59 ...

Page 24: ...eal kit 1 25 81040181 Star head drawer closer bolt 1 26 81987777 100A fuse pull strap 1 BoSS X2 chassis drawer assembly Item ref Part no Description Qty 1 81910043 Terminal block cover 1 2 81801009 Relay assembly 16A 1 3 81801010 Relay assembly 5A 2 4 81801011 Timer relay assembly 1 5 82910003 Battery 80A 1 6 81907014 Battery fixing plate 1 7 82910002 Power pack 0 8kW 1 8 81801012 Pressure sensor ...

Page 25: ...tem ref Part no Description Qty 1 81100021 Motor contactor 1 2 81100091 One way solenoid emergency release valve 1 3 81801018 O ring 1 4 81801019 Pump 1 BoSS X3X X3 X2 power pack assembly BoSS X Series_Maintanence Manual Rev B 0519 indd 23 16 05 2019 14 59 ...

Page 26: ...t guardrail assembly 1 4 81250081 Top bar assembly 1 5 81250211 Sliding bar gate fixings 1 6 81250221 Star head bolts 2 7 81250091 Drop bar gate assembly 1 8 81250071 Toeboard assembly 1 9 81250231 Guardrail fixings 1 BoSS X3X X3 X2 Confined Space Guardrail assembly accessory available to purchase separately BoSS X Series_Maintanence Manual Rev B 0519 indd 24 16 05 2019 14 59 ...

Page 27: ...bosspoweredaccess com 25 Section 7 Electrical schematic 13 BoSS X Series_Maintanence Manual Rev B 0519 indd 25 16 05 2019 14 59 ...

Page 28: ...26 BoSS X Series Maintenance Manual Section 8 Wiring diagram Handset Controller BoSS X Series_Maintanence Manual Rev B 0519 indd 26 16 05 2019 14 59 ...

Page 29: ... sensor below 7 Place a calibrated inclinometer on top of the chassis The inclinometer needs to be able to read both the lateral and longitudinal angles ie x and y in degrees to an accuracy of 2 decimal places 8 Using 2 jacks one under the side of the chassis which needs to be raised and one under the end which needs to be raised level the chassis so that the lateral and longitudinal reading on th...

Page 30: ...AUTOMATIC HOSE BURST SAFETY CHECK VALVE EMERGENCY RELEASE VALVE SOLENOID RETURN VALVE EMERGENCY RELEASE VALVE FILTER SOLENOID RETURN VALVE NON RETURN VALVE MOTOR PUMP FILTER RESERVOIR POWER PACK RELIEF VALVE 1 3 2 PRESSURE RELAY BoSS X Series_Maintanence Manual Rev B 0519 indd 28 16 05 2019 14 59 ...

Page 31: ...9 Add an additional 48kg of calibrated weights to the platform 10 Press the UP button on the handset controller and ensure the platform cannot raise and that the red OVERLOAD LED on top of the handset controller is flashing see Figure 2 opposite If the platform can still raise then slightly adjust the pressure sensor see Figure 1 above Repeat this process until the platform cannot raise and the re...

Page 32: ...r OVERLOAD Fork LiFting Point Pass transit straPs through here MaxiMuM WheeL Load 450kg InstructIons for use MAXIMUM SAFE WORKING LOAD 240KG ONE PERSON PLUS TOOLS AND MATERIALS ATTENTION PRESS THE EMERGENCY STOP BUTTON ON THE HANDSETAND REMOVE THE KEY PRIOR TO CHARGING POWER SUPPLY 110 OR 240 VOLTS SELECT THE APPROPRIATE CABLE FROM THE CHARGING CABLES AND GUARDRAIL TOOL BOX MOUNTED ON THE GUARDRAI...

Page 33: ... ram Check both emergency descent solenoid valves one on the power pack and the other on the hydraulic cylinder Replace as necessary Oil leakage in hydraulic circuit Check the hydualic circuit for leaks and repair Oil leakage from hydrailic cylinder ram Faulty sealing Replace all seals with the appropriate seal kit Oil leaking from hydraulic hose or joint Insufficient tightening of connectors or s...

Page 34: ...ollows STEP 1 Turn the finger screw on the valve on the hydraulic cylinder anticlockwise until it will not turn any further as shown in Figure 1 opposite STEP 2 Turn the finger screw on the power pack emergency descent valve anticlockwise until it will not turn any further as shown in Figure 2 opposite The platform will now lower safely WARNINGS 1 ALWAYS ensure that someone at ground level ie othe...

Page 35: ...amination i within an interval of 6 months under regulation 9 3 a i ii within an interval of 12 months under regulation 9 3 a ii iii in accordance with an examination scheme under regulation 9 3 a iii or iv after the occurrence of exceptional circumstances under regulation 9 3 a iv b if such be the case that the lifting equipment would be safe to operate 8 In relation to every thorough examination...

Page 36: ...r BoSS X Series machines or any other products and services please contact Werner UK Sales Distribution Ltd Blackwater Trading Estate The Causeway Maldon Essex CM9 4LJ United Kingdom uk customercare wernerco com bosspoweredaccess com BoSS X Series_Maintanence Manual Rev B 0519 indd 34 16 05 2019 14 59 ...

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