Operators and Safety Manual

Transcription

1 Operators and Safety Manual Model 15VPSP June 14, 2001 ANSI

2 JLG Lift

3 FOREWORD - GENERAL This manual is a very important tool! Keep it with the machine at all times. The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose. It is important to stress proper machine usage at all times. All information in this manual must be read and understood before any attempt is made to operate the machine. Because the manufacturer has no direct control over machine operation and application, proper safety practices are the responsibility of the owners, users, operators, lessors, and lessees. All instructions in this manual are based upon the use of the machine under proper operating conditions, with no deviations from the original design. Any alteration or modification of the machine is strictly forbidden without written approval from JLG Industries, Inc. Note: Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.

4 FOREWORD SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS This is the Safety Alert Symbol. It is used to alert you to a potential personal injury hazard. Obey all safety messages that follow this symbol to avoid possible injury or death. The Safety Alert Symbol will be used with the appropriate Safety Signal Word of DANGER, WARNING, or CAUTION to call attention to a potential hazard and designate a level of hazard seriousness. The Safety Signal Words are inserted throughout this manual in Black/White. On the machine, the Safety Signal Words will have either a Red, Orange, or Yellow background as part of a safety sign or decal. The DANGER, WARNING, and CAUTION Safety Signal Words definitions and associated colors are as follows: Indicates an imminently hazardous situation which, if not avoided, will result in serious injury or death. This signal word is used in the most extreme cases. When installed on the machine, this Signal Word will have a Red background as part of a decal. Indicates a potentially hazardous situation which, if not avoided, could result in serious injury or death. When installed on the machine, this Signal Word will have an Orange background as part of a decal. Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. When installed on the machine, this Signal Word will have a Yellow background as part of a decal. The IMPORTANT Safety Signal Word may also appear in this manual or on the machine. This Safety Signal Word typically will not appear with the Safety Alert Symbol, but contains important information that must be followed for safe and proper operation. The IMPORTANT Safety Signal Word definition and associated color is as follows: IMPORTANT Indicates procedures essential for safe operation and which, if not followed, may result in a machine malfunction or damage. When installed on the machine, this Signal Word will have a Green background as part of a decal.

5 All safety-related bulletins must be accomplished on this product. JLG Industries, Inc. may have issued safetyrelated bulletins for this JLG product. Contact JLG Industries, Inc. or the local authorized JLG dealer for information regarding safety-related bulletins which may have been issued for this product. IMPORTANT For the purpose of receiving safety-related bulletins, it is important that the current owner of this unit ensures JLG Industries, Inc. has updated ownership information. Contact JLG Industries, Inc. to ensure that the current owner records are updated and accurate. IMPORTANT JLG Industries, Inc. must be notified immediately in all instances where JLG products have been involved in an accident involving bodily injury or death of personnel or when substantial damage has occurred to personal property or the JLG product. FOR: Accident Reporting Product Safety Publications Current Owner Updates Questions Regarding Product Safety Standards and Regulations Compliance Information Questions Regarding Special Product Applications Questions Regarding Product Modifications CONTACT: Product Safety and Reliability Department JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA TOLL FREE: 877-JLG-SAFE ( ) ProductSafety@JLG.com

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7 EFFECTIVITY PAGE EFFECTIVITY CHANGES Issued - February 28, 2000 April 20, 2000 Revised Added Proposition 65 to front of manual. November 15, 2000 Revised Pages Affected: Section 4 - Pages 4-2 & 4-3. February 26, 2001 Revised Pages Affected; Section 5 - All Pages. June 14, 2001 Revised Pages Affected; Section 3 - Page 3-2. Section 4 - Page 4-3. Section 5 - Pages 5-1, 5-5 and added JLG Lift a

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9 TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION SECTION SECTION SECTION SECTION SECTION SECTION Effectivity Changes 1 - SAFETY PRECAUTIONS 1.1 General Pre-Operation Operation Towing, Lifting, And Hauling Maintenance PREPARATION AND INSPECTION 2.1 General Preparation For Use Delivery And Frequent Inspection Daily Walk-Around Inspection Daily Functional Check Torque Requirements Battery Charging & Maintenance USER RESPONSIBILITIES & MACHINE CONTROLS 3.1 General Personnel Training Operating Characteristics And Limitations Controls And Indicators Jlg Pot-Hole Protection Device MACHINE OPERATION 4.1 Machine Description General Machine Operation Transporting, Lifting And Tie Down Procedures OPTIONAL EQUIPMENT 5.1 Optional Equipment Obstruction Sensing System (OSS) Rug Carrier Accessory Progammable Security Lock (PSL ) EMERGENCY PROCEDURES 6.1 General Information Emergency Controls And Their Location Emergency Operation Incident Notification INSPECTION AND REPAIR LOG a JLG Lift i

10 TABLE OF CONTENTS (Continued) LIST OF FIGURES FIGURE NO. TITLE PAGE NO Daily Walk-Around Inspection Battery Fluid Level Charger Assembly and Power Cord Storage Battery Charger Front Panel Lubrication Chart Torque Chart Ground Controls Platform Controller Brake Release Handle JLGs Pot-Hole-Protection Device - PHP Bar Operation Decal Locations (Front View) Decal From Figure Decal Locations (Rear View) Decal Locations (Top View) Decal Locations (Right/Left View) Platform Operating Configurations Forklift Truck Lifting Pockets and Machine Tie Down Bar Locations Transducer Sensor Array Location. (Underside of Platform) Horn Button on Platform Control Daily Check of Operation - Transducer Arrays Positioning Rug Hanger Arms Placing Carpet Roll on Hanger Arms Removing Rug From Display Arm PSL Switch & Ground Control Station Locations - At Rear of Machine PSL Switch Controls & Indicators Ground Control Selector Switch LIST OF TABLES TABLE NO. TITLE PAGE NO. 1-1 Minimum Safe Approach Distance (to energized power lines or parts) Lubrication Intervals for Various Components Machine Interlock Switch Operating Conditions Maximum Rated Platform Load Capacity Machine Gross Weights Inspection and Repair Log ii JLG Lift

11 SECTION 1 - SAFETY PRECAUTIONS SECTION 1. SAFETY PRECAUTIONS 1.1 GENERAL This section outlines the necessary precautions for proper and safe machine usage and maintenance. In order to promote proper machine usage, it is mandatory that a daily routine is established based on the content of this manual. A maintenance program, using the information provided in this manual and the Service and Maintenance Manual, must also be established by a qualified person and must be followed to ensure that the machine is safe to operate. The owner/user/operator/lessor/lessee of the machine should not accept operating responsibility until this manual has been read, training is accomplished, and operation of the machine has been completed under the supervision of an experienced and qualified operator. The owner/user/operator/lessor/lessee must be familiar with Sections 6, 7, 8, 9, 10 of ANSI A These sections contain the responsibilities of the owner, user, operator, lessor, and lessee concerning safety, training, inspection, maintenance, application, and operation. If there are any questions with regard to safety, training, inspection, maintenance, application, and operation, please contact JLG Industries, Inc. ( JLG ). FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROP- ERTY DAMAGE, PERSONAL INJURY OR DEATH. 1.2 PRE-OPERATION Operator Training And Knowledge The Operators and Safety Manual must be read and understood in its entirety before operating the machine. For clarification, questions, or additional information regarding any portions of this manual, contact JLG Industries, Inc. An operator must not accept operating responsibilities until adequate training has been given by competent and authorized persons. Allow only those authorized and qualified personnel to operate the machine who have demonstrated that they understand the safe and proper operation and maintenance of the unit. Read, understand, and obey all DANGERS, WARN- INGS, CAUTIONS, and operating instructions on the machine and in this manual. Ensure that the machine is to be used in a manner which is within the scope of its intended application as determined by JLG. All operating personnel must be familiar with the emergency controls and emergency operation of the machine as specified in this manual. Read, understand, and obey all applicable employer, local, and governmental regulations as they pertain to your utilization and application of the machine. Before operation, the operator must be familiar with the machine capabilities and operating specifications as specified in Section 4. Workplace Inspection Precautions to avoid all hazards in the work area must be taken by the user before operation of the machine. Do not operate or raise the platform from a position on trucks, trailers, railway cars, floating vessels, scaffolds or other equipment unless the application is approved in writing by JLG JLG Lift 1-1

12 SECTION 1 - SAFETY PRECAUTIONS Before operation, check work area for overhead hazards such as electric lines, bridge cranes, and other potential overhead obstructions. Check floor surfaces for holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards. Check the work area for hazardous locations. Do not operate the machine in hazardous environments unless approved for that purpose by JLG. Ensure that the ground conditions are adequate to support the maximum tire load indicated on the tire load decals located on the chassis adjacent to each wheel. Do not operate the machine when wind conditions exceed 30 mph (12.5 m/s). This machine can be operated in nominal ambient temperatures of 0 F to 104 F (-20 C to 40 C). Consult JLG to optimize operation outside of this temperature range. Machine Inspection Do not operate this machine until the inspections and functional checks have been performed as specified in Section 2 of this manual. Do not operate this machine until it has been serviced and maintained according to the maintenance and inspection requirements as specified in the machine s Service and Maintenance Manual. Ensure all safety devices are operating properly. Modification of these devices is a safety violation. MODIFICATION OR ALTERATION OF AN AERIAL WORK PLAT- FORM SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMIS- SION FROM THE MANUFACTURER Do not operate any machine on which the safety or instruction placards or decals are missing or illegible. Check the machine for modifications to original components. Ensure that any modifications have been approved by JLG. Avoid accumulation of debris on platform deck. Keep mud, oil, grease, and other slippery substances from footwear and platform deck. 1.3 OPERATION General Do not use the machine for any purpose other than positioning personnel, their tools and equipment, or for hand stock picking. Before operation, the user must be familiar with the machine capabilities and operating characteristics of all functions. Never operate a malfunctioning machine. If a malfunction occurs, shut down the machine. Remove the unit from service and notify the proper authorities. Do not remove, modify, or disable any safety devices. Never slam a control switch or lever through neutral to an opposite direction. Always return switch to neutral and stop before moving the switch to the next function. Operate controls with slow and even pressure. Do not allow personnel to tamper with or operate the machine from the ground with personnel in the platform, except in an emergency. Do not carry materials directly on platform railing unless approved by JLG. Always ensure that power tools are properly stowed and never left hanging by their cord from the platform work area. Do not assist a stuck or disabled machine by pushing or pulling except by pulling at the chassis tie-down bars. Fully lower mast assembly and shut off all power before leaving machine. Trip And Fall Hazards JLG Industries, Inc. recommends that the operator in the platform wear a full body harness with a lanyard attached to an authorized lanyard anchorage point while operating this machine. For further information regarding fall protection requirements on JLG products, contact JLG Industries, Inc. Prior to operation, ensure all gates are fastened and secured in their proper position. Identify the designated lanyard anchorage point(s) at the platform and securely attach the lanyard. 1-2 JLG Lift

13 SECTION 1 - SAFETY PRECAUTIONS Electrocution Hazards This machine is not insulated and does not provide protection from contact with an electrically charged conductor. Keep both feet firmly positioned on the platform floor at all times. Never position ladders, boxes, steps, planks, or similar items on unit to provide additional reach for any purpose. Never use the mast assembly to gain access to or leave the platform. Use extreme caution when entering or leaving platform. Ensure that the mast assembly is fully lowered. Face the machine when entering or leaving the platform. Always maintain three point contact with the machine, using two hands and one foot or two feet and one hand at all times during entry and exit. Platform-to-structure transfers at elevated positions are discouraged. Where transfer is necessary, enter/exit through the gate only with the platform within 1 foot (0.3m) of a safe and secure structure. 100% tie-off is also required in this situation utilizing two lanyards. One lanyard must be attached to the platform with the second lanyard attached to the structure. The lanyard connected to the platform must not be disconnected until such time the transfer to the structure is safe and complete. Keep oil, mud, and slippery substances cleaned from footwear and the platform floor. Maintain safe clearance from electrical lines, apparatus, or any energized (exposed or insulated) parts in accordance with the Minimum Safe Approach Distance (MSAD) as specified in Table 1-1. Allow for machine movement and electrical line swaying. Table 1-1.Minimum Safe Approach Distance (to energized power lines or parts) VOLTAGE RANGE (PHASE TO PHASE) MINIMUM SAFE DISTANCE - Feet [m] 0-300V Avoid Contact Over 300V to 50KV 10 ft. [3 m] Over 50KV to 200KV 15 ft. [4.6 m] Over 200KV to 350KV 20 ft. [6 m] Over 350KV to 500KV 25 ft. [7.6 m] Over 500KV to 750KV 35 ft. [10.6 m] Over 750KV to 1000KV 45 ft. [13.7 m] Maintain a clearance of at least 10 ft (3m) between any part of the machine and its occupants, their tools, and their equipment from any electrical line or apparatus carrying up to 50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less. DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIB- ITED ZONE (MSAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE JLG Lift 1-3

14 SECTION 1 - SAFETY PRECAUTIONS Tipping Hazards Ensure that the ground conditions are adequate to support the maximum tire load indicated on the tire load decals located on the chassis adjacent to each wheel. Do not travel on unsupported surfaces. The user should be familiar with the driving surface before driving. Do not exceed the allowable sideslope and grade while driving. Never attempt to use the machine as a crane. Do not tie-off machine to any adjacent structure. Never attach wire, cable, or any similar items to platform. Do not operate the machine when wind conditions exceed 30 mph (12.5 m/s). Do not cover the platform sides or carry large surfacearea items in the platform when operating outdoors. The addition of such items increases the exposed wind area of the machine. Do not increase the platform size with unauthorized deck extensions or attachments. If mast assembly or platform is caught so that one or more wheels are off the ground, the operator must be removed before attempting to free the machine. Use cranes, forklift trucks, or other appropriate equipment to stabilize machine and remove personnel. Crushing And Collision Hazards Approved head gear must be worn by all operating and ground personnel. Keep hands and limbs out of the mast assembly during operation. Watch for obstructions around machine and overhead when driving. Check clearances above, on sides, and bottom of platform when lifting or lowering platform. Do not elevate platform or drive with platform elevated while on a slope (of more than 1.5 ), or on an uneven or soft surface. Ensure machine is positioned on a firm, level and uniformly supported surface before elevating platform or driving with the platform in the elevated position. Before driving on floors, bridges, trucks, and other surfaces, check allowable capacity of the surfaces. Never exceed the maximum work load as specified on the platform. Distribute loads evenly on platform floor. Keep all loads within the confines of the platform, unless authorized by JLG. Keep the chassis of the machine a minimum of 2 ft. (0.6m) from holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards at the ground level. During operation, keep all body parts inside platform railing. Always post a lookout when driving in areas where vision is obstructed. Keep non-operating personnel at least 6 ft. (1.8m) away from machine during all driving operations. Under all travel conditions, the operator must limit travel speed according to conditions of ground surface, congestion, visibility, slope, location of personnel, and other factors causing hazards of collision or injury to personnel. Be aware of stopping distances in all drive speeds. 1-4 JLG Lift

15 SECTION 1 - SAFETY PRECAUTIONS Reduce drive speed in restricted or close quarters or when driving in reverse. Exercise extreme caution at all times to prevent obstacles from striking or interfering with operating controls and persons in the platform. Ensure that operators of other overhead and floor level machines are aware of the aerial work platform s presence. Disconnect power to overhead cranes. Barricade floor area if necessary. Avoid operating over ground personnel. Warn personnel not to work, stand, or walk under a raised platform. Position barricades on floor as necessary. 1.4 TOWING, LIFTING, AND HAULING Never allow personnel in platform while towing, lifting, or hauling. This machine should not be towed, except in the event of emergency, malfunction, power failure, or loading/ unloading. Refer to Section 4 for emergency towing procedures. Ensure platform is fully retracted and completely empty of tools prior to towing, lifting or hauling. When lifting machine with a forklift, position forks only at designated areas of the machine. Lift with a forklift of adequate capacity. (Refer to Section 4 for lifting information.) 1.5 MAINTENANCE General This section contains general safety precautions which must be observed during maintenance of this machine. Additional precautions to be observed during machine maintenance are inserted at the appropriate points in this manual and in the Service and Maintenance Manual. It is of utmost importance that maintenance personnel pay strict attention to these precautions to avoid possible injury to personnel or damage to the machine or property. A maintenance program must be establif ensure that the machine is safe. Maintenance Hazards Shut off power to all controls and ensure that all operating systems are secured from inadvertent motion prior to performing any adjustments or repairs. Never work under an elevated platform until it has been fully lowered to the full down position, if possible, or otherwise supported and restrained from movement with appropriate safety props, blocking, or overhead supports. Always relieve hydraulic pressure from all hydraulic circuits before loosening or removing hydraulic components. Always disconnect batteries when servicing electrical components or when performing welding on the machine. Ensure replacement parts or components are identical or equivalent to original parts or components. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. Ensure adequate support is provided when raising components of the machine. Remove all rings, watches, and jewelry when performing any maintenance. Do not wear loose fitting clothing or long hair unrestrained which may become caught or entangled in equipment. Use only clean approved non-flammable cleaning solvents. Never alter, remove, or substitute any items such as counterweights, tires, batteries, platforms or other items that may reduce or affect the overall weight or stability of the machine. Reference the Service and Maintenance Manual for the weights of critical stability items. MODIFICATION OR ALTERATION OF AN AERIAL WORK PLAT- FORM SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMIS- SION FROM THE MANUFACTURER JLG Lift 1-5

16 SECTION 1 - SAFETY PRECAUTIONS Battery Hazards Always disconnect batteries when servicing electrical components or when performing welding on the machine. Do not allow smoking, open flame, or sparks near battery during charging or servicing. Do not contact tools or other metal objects across the battery terminals. Always wear hand, eye, and face protection when servicing batteries. Ensure that battery acid does not come in contact with skin or clothing. BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH CLEAN WATER AND SEEK MEDICAL ATTENTION. Charge batteries only in a well ventilated area. Avoid overfilling the battery fluid level. Add distilled water to batteries only after the batteries are fully charged. 1-6 JLG Lift

17 SECTION 2 - PREPARATION AND INSPECTION SECTION 2. PREPARATION AND INSPECTION 2.1 GENERAL This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness, and lists checks that are performed prior to use of the machine. It is important that the information contained in this section be read and understood before any attempt is made to operate the machine. Ensure that all the necessary inspections have been completed successfully before placing the machine into service. These procedures will aid in obtaining maximum service life and safe operation. IMPORTANT SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON- TROL OVER THE FIELD INSPECTION AND MAINTENANCE, THIS IS THE RESPONSIBILITY OF THE OWNER/OPERATOR. 2.2 PREPARATION FOR USE Before a new machine is put into operation it must be carefully inspected for any evidence of damage resulting from shipment and inspected periodically thereafter, as outlined in Section 2-3, Delivery and Frequent Inspection. The unit should be thoroughly checked for hydraulic leaks during initial start-up and run. A check of all components should be made to assure their security. All preparation necessary to place the machine in operation readiness status are the responsibility of management personnel. Preparation requires good common sense, (i.e. lift works smoothly) coupled with a series of visual inspections. The mandatory requirements are given in Section 2-4, Daily Walk Around Inspection. It should be assured that the items appearing in the Delivery and Frequent Inspection and Functional Check are complied with prior to putting the machine into service. 2.3 DELIVERY AND FREQUENT INSPECTION The following check list provides a systematic inspection to assist in detecting defective, damaged, or improperly installed parts. The check list denotes the items to be inspected and conditions to examine. Frequent inspection shall be performed every three (3) months or 150 hours, or more often when required by environment, severity, and frequency of usage. Platform Assembly Properly secured; no visible damage; free of dirt and debris. Platform gate functions properly. Mast No visible damage, abrasions and/or distortions; no binding; mast sections free of dirt or other foreign material. Sequencing cables properly secured; no visible damage; proper cable tension. Mast Chains No visible damage; proper chain tension; evidence of proper lubrication. Chain sheaves, sheave pins and rollers properly secured; no visible damage. Platform Controller/(Power) Cable(s) No visible damage; cable properly tensioned and seated in control cable sheaves; control cable sheaves not damaged and rotating freely. Lift Cylinder (check w/mast extended) No rust, nicks, scratches or foreign material on piston rod. No leakage. Frame No visible damage; loose or missing hardware (top and underside). Drive Wheels and Front Casters Casters free rolling; no loose or missing parts; no visible damage. Drive wheel hub retainer secure; no damage to wheel tread; electric drive motors secure; no loose or missing wires. Hydraulic Oil Supply Check the hydraulic oil level of the hydraulic fluid reservoir located in the lower access hole on the rear cover. Maintain an oil level to the Fill To Line indicator on the side of reservoir JLG Lift 2-1

18 SECTION 2 - PREPARATION AND INSPECTION If fluid level is low, see Service Manual, Section 1 - Specifications; Sub-Section 1-5. Lubrication ; Table 1-1. Recommended Hydraulic Oils for use in machine. Controls - (Platform and Ground) Controls operable; no visible damage; placards secure and legible. Batteries Proper electrolyte level; cable connections tight; no visible damage; no corrosion at battery cable connections. Pump Motor/Hydraulic Pump/Valves andlines No leakage; units secure. Placards No visible damage; placards secure and legible, daily walk-around inspection It is the user/operator s responsibility to inspect the machine before the start of each work day. It is recommended that each user/operator inspect the machine before operation, even if the machine has already been put into service under another user/operator. This Daily Walk-Around Inspection is the preferred method of inspection. 2.4 DAILY WALK-AROUND INSPECTION Begin the Walk-Around Inspection at item one listed following. Continue around machine checking each item in sequence for the conditions listed in the Walk-Around Inspection Check list. TO AVOID INJURY DO NOT OPERATE MACHINE UNTIL ALL MAL- FUNCTIONS HAVE BEEN CORRECTED. USE OF A MALFUNC- TIONING MACHINE IS A SAFETY VIOLATION. TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS OFF DURING WALK-AROUND INSPECTION. NOTE: Do not overlook visual inspection of the base frame underside. Check this area for objects or debris which could cause extensive machine damage. 1. Drive and Caster Wheels - Properly secured and lubricated. Check for any visible damage or debris, stuck to or around wheels. 2. Base Frame - No visible damage; drive wheel motor components properly secured; JLG s Pot-Hole-Protection System components secure; no loose wires or cables dangling below the base; amber warning beacon secure and undamaged. 3. Battery/Battery Charger - Proper battery electrolyte level, cables secure, no damage or corrosion. 4. Motor/Pump/Reservoir Unit - Properly secured, no visible damage, no evidence of hydraulic leaks. Hydraulic oil level should be filled level with the full line, ( Fill To Line ) on the side of the hydraulic reservoir. Also check that reservoir cap is properly secured. 5. Ground Controls - Properly secured, no loose or missing parts, no visible damage; key switch operable, no visible damage; placards secure and legible; emergency stop switch, no visible damage and properly set for operation. 6. Mast Assembly - Mast sections properly secured, no visible damage to mast sections, no loose or missing parts, slide pads properly secured. Mast chains properly secured and lubricated. Sequencing cables properly secured and undamaged. Platform control and power cables (on side of mast), no visible damage; power cables properly tensioned and seated in sheaves; cable sheaves not damaged and rotating freely. Elevation/Speed Limit switch (top inside of mast section 1) secure and working properly. 7. Manual Brake Release Control - Handle secure and undamaged; cables attached properly; control in working order. 8. Platform Assembly - Secure to mast; All railings securely attached; no loose or missing parts, no visible damage; sliding entry bar in proper working order. Platform gate working properly, no visible sign of damage (if so equipped). 9. Platform Controls - Platform up/down, lift function enable and horn switch pads on faceplate no loose or missing parts, no visible damage. Joystick control secure and working properly. Placards secure and legible, emergency shut-off button set for operation. Control markings legible; Operators manual enclosed in manual storage box. In addition to the Daily Walk-Around Inspection, be sure to include the following as part of the daily inspection: Batteries Charged Start each day with fully charged batteries. (See Section 2-7. Battery Charging & Maintenance ) Overall Cleanliness Keep oil, grease, water, etc. wiped from standing surfaces and hand holds. Placards Keep all information and operating placards clean and unobstructed. Cover areas where placards are present 2-2 JLG Lift

19 SECTION 2 - PREPARATION AND INSPECTION Daily Walk-Around Inspection Items 1. Drive and Castor Wheels 4. Battery/Battery Charger 7. Mast Assembly 2. Base Frame 5. Ground Controls 8. Platform Controls 3. Motor/Pump/Reservoir Unit 6. Manual Brake Release Control 9. Platform Assembly Figure 2-1. Daily Walk-Around Inspection. when using the machine for spraying paint or any material which could cover these surfaces and reduce legibility. Operation and Safety and ANSI Responsibilities Manual Ensure a copy of manual is enclosed in the manual storage box. Lubrication For those parts pointed out in the Walk-Around Inspection requiring lubrication, refer to the Lubrication Chart, Figure 2-4., for specific time interval requirements. Hydraulic oils must have anti-wear qualities at least to API Service Classification GL-3, and sufficient chemical stability for mobile hydraulic system service. JLG Industries, recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity of 10W-30 and a viscosity index of 152. For cold weather applications, i.e. when temperatures remain consistently below +20 F ( 7 C) JLG recommends using Mobil DTE 13 hydraulic oil. 2.5 DAILY FUNCTIONAL CHECK TO AVOID INJURY DO NOT OPERATE A MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED. USE OF A MALFUNC- TIONING MACHINE IS A SAFETY VIOLATION. Once the Walk-Around Inspection is complete, a functional check of all systems should be performed in an area free of overhead and ground level obstructions. Perform a functional check in accordance with the following procedures: Set-up machine for operation, according to instructions in Section 4-3, Machine Operation. Ground Controls Function Check 1. With key switch turned to GRND position (clockwise), operate the platform up and down switch (located in lower access hole with hydraulic fluid reservoir). Raise and lower platform 2 ft. to 3 ft. (.5m to JLG Lift 2-3

20 SECTION 2 - PREPARATION AND INSPECTION 1m) several times. Check for smooth elevation and lowering of platform. 2. With platform completely lowered, check hydraulic oil level in hydraulic fluid reservoir. If necessary, add hydraulic fluid to proper level (full line). NEVER USE HYDRAULIC BRAKE FLUID, refer to the Lubrication Chart (Figure 2-4) for specific requirements. 3. Depress EMERGENCY STOP (red) button (next to key switch), all machine operations will be disabled if functioning properly. If ok, reset EMERGENCY STOP for normal operation. 4. Operate the MANUAL BRAKE RELEASE CONTROL (Over-center handle mounted on the right side of the mast). When the handle is in the vertical position it is set for normal operation, brakes ENGAGED. When the handle is pulled DOWN to a horizontal position, the brakes are DISENGAGED. 5. Set key switch to PLAT (platform operation, all the way counterclockwise) and continue with the following steps. Platform Controls Function Check IMPORTANT SEE SECTION-3 FOR INFORMATION ABOUT MACHINE CON- TROLS AND SECTION-4 FOR PROPER OPERATION OF MACHINE. NOTE: Check that the MANUAL BRAKE RELEASE CON- TROL (Over-center handle mounted on side of mast), is set for normal operation (brakes engaged) before entering platform. 1. Check that the PLATFORM CONTROLLER box is properly mounted (facing forward) and secure on the platform s rail. 2. RESET the EMERGENCY STOP (red) button on the platform controller, if necessary. 3. On the platform controller box, check the BATTERY STATUS INDICATOR LED s for charge status of batteries. 4. Depress and HOLD the JOYSTICK DRIVE BUTTON (located on top of the joystick knob) and slowly move the JOYSTICK in all directions. If operating properly the machine will move in the direction the JOYSTICK is pointed. 5. While driving the machine forward (platform down), rotate the SPEED CONTROL knob from maximum to minimum (clockwise to counterclockwise) checking operation. If operating properly, speed will vary from 2 mph to 1/2 mph. 6. Depress and HOLD the LIFT ENABLE pad switch, and operate the platform UP and DOWN pad switches (up arrow and down arrows) to raise and lower platform 2 ft. to 3 ft. (.5m to 1m) several times. If operating properly the platform will elevate/lower until either button is released. Check for smooth elevation and lowering of platform. NOTE: A short delay between lift motor starting and platform movement is normal. 7. With the platform elevated check the JLG Automatic Pot-Hole-Protection system, if operating properly, the PHP bars on each side of the machine base will be automatically engaged (lowered) when the platform is raised approximately 2 ft. (.5 m). 8. With the platform still elevated approximately 2 ft., drive machine and check if SPEED CUT-BACK is operating properly. The machine should drive at one fourth (1/4) the speed of when the platform was lowered. 9. Depress the EMERGENCY STOP (red) button on the Platform Controller box, all machine operations will be disabled if functioning properly. RESET the EMERGENCY STOP. Tilt Sensor (1.5 ) and Drive Brakes 1. With the platform lowered, drive the machine onto a grade within the allowable grade and slope limits of the machine (maximum grade of 15% or 8.5, maximum side slope of 5 ). Stop the machine part of the way up the grade, check if the drive brakes hold the machine in place. Also while on the grade (of greater than 1.5 ), attempt to raise the platform. The tilt sensor (1.5 ) must prevent the platform from elevating and will sound a beeping alarm at the platform controller box. If all machine functions are operating properly, machine is ready for operation. 2.6 TORQUE REQUIREMENTS The Torque Chart, Figure 2-6., consists of standard torque values based on bolt diameter and grade, it also specifies dry and wet torque values in accordance with recommended shop practices. This chart is provided as an aid to the user/operator in the event he/she notices a condition that requires prompt attention during the walk-around inspection or during operation until the proper service personnel can be notified. Utilizing this Torque Chart in conjunction with the Preventive Maintenance and Inspection Schedule table in the Service Manual, will enhance the safety, reliability, and performance of the machine. 2-4 JLG Lift

21 SECTION 2 - PREPARATION AND INSPECTION 2.7 BATTERY CHARGING & MAINTENANCE VPSP Models are equipped with 24 volt, 10 amp output battery chargers (U.S.A Volt AC input/60hz). The battery charger includes a microprocessor controlled automatic charge sensing circuit which can determine cell voltage and regulate charger output as required. The charger automatically terminates charging when a full battery charge is acheived. Also a built-in interlock device prohibits driving the machine while the battery charger is plugged in. BATTERY FILLER CAP 1/8 " PLATES VENT TUBE FLUID LEVEL OF FULLY CHARGED BATTERY Battery Maintenance and Safety Practices (Refer to Figure 2-2.) ENSURE THAT BATTERY ACID DOES NOT COME INTO CONTACT WITH SKIN OR CLOTHING. WEAR PROTECTIVE CLOTHING AND EYEWEAR WHEN WORKING WITH BATTERIES. NEUTRALIZE ANY BATTERY ACID SPILLS WITH BAKING SODA AND WATER. Figure 2-2. Battery Fluid Level. BATTERY ACID RELEASES AN EXPLOSIVE GAS WHILE CHARG- ING, ALLOW NO OPEN FLAMES, SPARKS OR LIGHTED TOBACCO PRODUCTS IN THE AREA WHILE CHARGING BATTERIES. CHARGE BATTERIES ONLY IN A WELL VENTILATED AREA. ADD ONLY DISTILLED WATER TO BATTERIES. WHEN ADDING DISTILLED WATER TO THE BATTERIES, A NON-METALLIC CON- TAINER AND/OR FUNNEL MUST BE USED. As with any wet cell battery, check the electrolyte level of the batteries often, adding only distilled water when required. When fully charged, battery fluid level should be 1/8" below vent tubes. (See Figure 2-2.). DO NOT fill to bottom of vent tubes. DO NOT allow fluid level to go below the top of the plates when charging or operating. CORD STORAGE AREA KEY SWITCH BATTERY CHARGER Battery Charger Operation (Refer to Figure 2-3 & 2-4.) 1. Position machine in well ventilated area near an AC electrical outlet and set the Ground Control-PLAT/ OFF/GRND key switch to the OFF position. 2. Open the left battery cover and unwrap the battery charger AC power cable from under the cover. 3. Connect the battery charger AC power cable to a properly grounded receptacle, use a suitable extension cord, if necessary. 4. When powered on, the charger runs through a selfdiagnostic check which lights all five (5) lights on the face of the charger three (3) times, then each light in Figure 2-3. Charger Assembly and Power Cord Storage. sequence, then all five (5) lights three (3) times again on the front panel of the battery charger. 5. When ready to charge, the CHARGER ON light and the INCOMPLETE light on the front panel of the charger will light up, the charger will then begin to charge the batteries. NOTE: If the ABNORMAL CYCLE light comes on and stays on at any time during the charge cycle, see sub-section following about the ABNORMAL CYCLE indicator light JLG Lift 2-5

22 SECTION 2 - PREPARATION AND INSPECTION 6. When the battery cell voltage reaches 2.37 V/cell the 80% CHARGE light on the front panel of the charger will light up. The charger then continues to monitor the increase in charge until it sees no increase, and then terminates the charging process. 7. The CHARGE COMPLETE light will come on when the charging process is finished. 8. Unplug the charger AC power cord and wrap around storage lugs under the left battery cover. Abnormal Cycle Indicator Light If the ABNORMAL CYCLE indicator light should come on during the normal charging cycle of the batteries, it could indicate any of the following conditions; The AC input to the charger was interupted, i.e. local power failure or charger cable was unplugged or bumped and power was interupted intermittently. A dead cell or cells in either battery would prevent the charger from sensing enough voltage to complete the battery charge. One or more of the batteries terminal connections loose resulting in an intermittent incomplete circuit. Figure 2-4. Battery Charger Front Panel. 2-6 JLG Lift

23 SECTION 2 - PREPARATION AND INSPECTION ITEM COMPONENT NO/TYPE LUBE POINTS 1 Hydraulic Oil Fill To Line on Reservoir 5 Qt. Reservoir 2 Drive Wheel Bearings Figure 2-5. Lubrication Chart. Table 2-1. Lubrication Intervals for Various Components LUBE/METHOD HO - Check Hyd. Oil Level HO - Change Hyd. Oil 3 MONTHS 150 Hrs. 4 - Grease Fittings MPG- Pressure Gun 3 Drive Wheel 2 - Gear Box Gear Oil Gear Box 4 Caster Axles 2 - Grease Fitting MPG - Pressure Gun 5 Swivel Raceways 2 - Front Casters MPG - Pressure Gun INTERVAL HOURS 6 MONTHS 300 Hrs. 1 YEAR 600 Hrs. 2 COMMENTS YEARS 1200 Hrs. Check hydraulic oil every 10 hrs. Change hydraulic oil every 1200 hrs. Change only when serviced - requires 6 oz. (175cc s) to fill. 6 Mast Chains * 2 - Per Section Chain Lube - Brush or Inspect, lubricate if dry or rusting. Spray * Applies Only to Mast Sections with Chains. Key to Lubricants: MPG - Multipurpose Grease HO - Hydraulic Oil - Hydraulic oils must have anti-wear qualities at least to API Service Classification GL-3, and sufficient chemical stability for mobile hydraulic system service. JLG Industries, recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity of 10W-30 and a viscosity index of 152. For cold weather applications, i.e. when temperatures remain consistently below +20 F ( 7 C) JLG recommends using Mobil DTE 13 hydraulic oil. Gear Oil - Good Quality Worm Gear Oil - SAE 90 - AGMA#5 - EP Compounded Notes: 1. Be certain to lubricate like items on each side of the machine. 2. Recommended lubricating intervals are based on normal use. If machine is subjected to severe operating conditions, such as a high number of cycles, location, corrosive/dirty environment, etc., user must adjust lubricating requirements accordingly. 3. Prior to checking hydraulic oil level, operate machine through one complete cycle of lift function (full up and down). Failure to do so will result in incorrect oil level reading on the hydraulic reservoir JLG Lift 2-7

24 SECTION 2 - PREPARATION AND INSPECTION Figure 2-6. Torque Chart. 2-8 JLG Lift

25 SECTION 3 - USER RESPONSIBILITIES & MACHINE CONTROLS SECTION 3. USER RESPONSIBILITIES & MACHINE CONTROLS 3.1 GENERAL IMPORTANT SINCE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION, CONFORMANCE WITH GOOD SAFETY PRACTICES IN THESE AREAS IS THE RESPONSI- BILITY OF THE USER AND HIS OPERATING PERSONNEL. This section provides the necessary information needed to understand control functions. Included in this section are the operating characteristics and limitations, and functions and purposes of controls and indicators. It is important that the user/operator read and understand the proper procedures before operating the machine. These procedures will aid in obtaining optimum service life and safe operation. 3.2 PERSONNEL TRAINING The aerial lift is a personnel handling device; therefore, it is essential that it be operated and maintained only by authorized personnel who have demonstrated that they understand the proper use and maintenance of the machine. It is important that all personnel who are assigned to and responsible for the operation and maintenance of the machine undergo a thorough training program and check out period in order to become familiar with the characteristics prior to operating the machine. In addition, personnel operating the machine should be familiar with Sections 6, 7, 8, 9, 10 of ANSI standard A , Responsibilities. This standard contains sections outlining the responsibilities of the owners, users, operators, lessors and lessees concerning safety, training, inspection, maintenance, application and operation. Persons under the influence of drugs or alcohol or who are subject to seizures, dizziness or loss of physical control must not be permitted to operate the machine. Operator Training Operator training must include instruction in the following: 1. Use and limitations of the platform controls, ground controls and emergency controls. 2. Knowledge and understanding of this manual and of the control markings, instructions and warnings on the machine itself. 3. Knowledge and understanding of all safety work rules of the employer and Federal, State and Local Statutes, including training in the recognition and avoidance of potential hazards in the work place; with particular attention to the work to be performed. 4. Proper use of all required personnel safety equipment. 5. Sufficient knowledge of the mechanical operation of the machine to recognize a malfunction or potential malfunction. 6. The safest means to operate near overhead obstructions, other moving equipment, obstacles, depressions, holes, drop-offs, etc. on the supporting surface. 7. Means to avoid the hazards of unprotected electrical conductors. 8. Any other requirements of a specific job or machine application. Training Supervision Training must be done under the supervision of a qualified operator or supervisor in an open area free of obstructions until the trainee has developed the ability to safely control an aerial lift in congested work locations. Operator Responsibility The operator must be instructed that he has the responsibility and authority to shut down the machine in case of a malfunction or other unsafe condition of either the machine or the job site and to request further information from his supervisor or JLG Distributor before proceeding. NOTE: Manufacturer or Distributor will provide qualified training materials via video tape for training purposes JLG Lift 3-1

26 SECTION 3 - USER RESPONSIBILITIES & MACHINE CONTROLS 3.3 OPERATING CHARACTERISTICS AND LIMITATIONS General A thorough knowledge of the operating characteristics and limitations of the machine is always the first requirement for any user, regardless of user s experience with similar types of equipment. Placards (See Figure 3-5., 3-6., 3-7., 3-8., & 3-9.) Important points to remember during operation are provided at the control stations by DANGER, WARNING, CAUTION, IMPORTANT and INSTRUCTION placards. This information is placed at various locations on the machine for the express purpose of alerting personnel of potential hazards constituted by the operating characteristics and load limitations of the machine. See the Foreword at the start of this manual for a definition of the seriousness of each of the above placard types. See decal location figures in this section for decals which apply to this machine. Capacities Raising the platform above the stowed position is based on the following criteria: The machine is positioned on a smooth, firm level surface. The load is within manufacturer s rated capacity. All machine systems are functioning properly. Stability This machine, as originally manufactured by JLG and when operated within its rated capacity on a smooth, firm and level supporting surface, provides a stable aerial platform for all platform positions. 3.4 CONTROLS AND INDICATORS Ground Controls (See Figure 3-1.) NOTE: When the machine is not being used or when charging the battery, set the POWER PLAT/OFF/ GRND KEY SWITCH to OFF to prevent draining the batteries. For information on battery charging see SEC- TION 2-7, Battery Charging. 1. POWER PLAT/OFF/GROUND KEY SWITCH A key operated power PLAT/OFF/GROUND switch located in the upper access hole of the rear cover (on back of machine), controls power to all functions on the machine. When left unattended, removing the key will prevent unauthorized machine use. If machine is equipped with optional Programmable Security Lock see Section 5 for details on use. 2. PLATFORM UP/DOWN (GROUND CONTROL) The ground operated platform control switch is located next to the hydraulic reservoir in the lower access hole of the rear cover. This three position toggle switch will raise (lift up) and lower (lift down), the platform from the ground control position when the PLAT/OFF/GRND key switch is set to the GRND (ground) position. 3. EMERGENCY STOP BUTTON An EMERGENCY STOP (red button) is mounted on both the ground control station and the platform controller. When either button is depressed, all machine functions will stop. To re-activate power to the machine, turn button clockwise to RESET the emergency stop button. 4. EMERGENCY/MANUAL DESCENT KNOB This (RED knurled) knob, located on the electric/ hydraulic pump-motor unit in the lower access hole of the rear cover provides for lowering of the platform in the event of an emergency or power failure. Turn knob (counterclockwise) to open the valve and lower the platform. This valve must be closed (turned all the way clockwise) for normal operation of the machine. (Refer to Section 6 for Emergency Descent operating procedures.) 5. HYDRAULIC OIL RESERVOIR The hydraulic oil reservoir is housed inside the lower access hole in the rear cover. Check the hydraulic oil level visually by observing the oil level in the reservoir as compared to the FILL TO LINE indicator on the side of the reservoir. Hydraulic oil can be added if necessary through the OIL FILL CAP on top of the reservoir. DO NOT OVERFILL. 3-2 JLG Lift

27 SECTION 3 - USER RESPONSIBILITIES & MACHINE CONTROLS Figure 3-1. Ground Controls. NOTE: Always check hydraulic oil level with oil at operating temperature and with the platform completely lowered. NOTE: A short delay between lift motor starting and platform movement is normal. Platform Controller (See Figure 3-2.) The platform controller contains all the controls necessary to operate the lift from the platform. The following is a description of each function. 1. BATTERY VOLTAGE / FAULT CODE LED INDICA- TORS The LED strip (green when lit) running between the pad switches on the controller indicates the battery voltage level when the machine is powered-up. The graduated LED strip indicates batteries at FULL CHARGE (25 volts) when lit all the way to the top (F), and a LOW CHARGE (18 volts) at bottom (E) when one or two LEDs are illuminated. LIFT ENABLE PAD SWITCH WARNING HORN (OPTION) DOWN (PLATFORM) BATTERY VOLTAGE/ FAULT CODE INDICATOR UP (PLATFORM) DRIVE ENABLE SWITCH JOYSTICK DRIVE/STEER NOTE: When voltage drops below 16.5 volts an error code is indicated, and the batteries will require a recharge. This LED strip also acts as a fault code indicator to help diagnose problems with the machines electrical system. (See Service Manual Troubleshooting, for information about reading fault codes). 2. LIFT ENABLE PAD SWITCH The LIFT ENABLE pad switch must be pressed and HELD before UP/DOWN LIFT of the platform is operational. EMERGENCY STOP SHUT-OFF BUTTON Figure 3-2. Platform Controller. VARIABLE SPEED CONTROL JLG Lift 3-3

28 SECTION 3 - USER RESPONSIBILITIES & MACHINE CONTROLS 3. PLATFORM UP PAD SWITCH (Up Arrow) When pressed in conjunction with the lift enable pad this switch raises the platform to a higher level, when released the upward movement is stopped. 4. PLATFORM DOWN PAD SWITCH (Down Arrow) When pressed in conjunction with the lift enable pad this switch lowers the platform from a raised position, when released, the downward movement is stopped. 5. EMERGENCY STOP/SHUT-OFF BUTTON An EMERGENCY STOP (RED) button is provided in order to immediately stop machine functions from the platform in the event of an emergency. When button is depressed, all machine functions will stop. To re-activate power to the machine, turn button clockwise to RESET the emergency stop. 6. JOYSTICK DRIVE/STEER CONTROL and DRIVE ENABLE BUTTON This is a Point & Go control which moves the machine in the direction which the stick is moved. It is a fully proportional control, the further from the center position the joystick is moved, the faster the machine travels. To activate the control depress and HOLD the DRIVE ENABLE BUTTON on the top of the joystick, then move the joystick in the direction of travel desired. 7. VARIABLE SPEED CONTROL The variable speed control knob can be used to increase or decrease the maximum drive speed of the machine. Clockwise rotation of the knob increases speed, counterclockwise decreases speed. When the platform is elevated drive speed is automatically cut to one fourth of when the platform was in the lowered position. 8. WARNING HORN SWITCH If machine is equipped with (optional) mounted horn, this switch when pressed sounds the horn. Brake Release Control (See Figure 3-3.) Standard equipment on all VPSP model lifts is a braking system integrated into the electric motor drive system. The braking system is spring engaged and released electrically while the machine is being driven with the joystick controller. When the lift is at rest or the power is turned off, the brakes are automatically engaged. If the lift must be moved around manually such as described in the following examples; the batteries become depleted and the machine needs to be moved from an aisleway, or machine is being winched onto a rollback truck bed, etc, the brakes can be manually disengaged. To release the brakes, a brake release control has been provided to engage/disengage the brake system. AFTER THE MACHINE HAS BEEN MANUALLY MOVED AND BEFORE DRIVING MACHINE, ALWAYS RE-ENGAGE THE BRAKE SYSTEM. IMPORTANT WHEN PUSHED OR PULLED MANUALLY, THE MACHINE S BRAKES MUST BE DISENGAGED AND THE EMERGENCY STOP BUTTON SET TO THE OFF POSITION, (DEPRESSED) AND THE KEY SWITCH SET TO THE OFF POSITION. DO NOT ATTEMPT TO TOW OR WINCH THE MACHINE AT A SPEED GREATER THAN (2) MPH, OR DAMAGE COULD OCCUR TO THE MACHINE S ELEC- TRONIC CONTROLLER BOX - (DUE TO HIGH VOLTAGE BEING GENERATED BY THE DRIVE MOTORS FEEDING BACK INTO THE CONTROLLER BOX). The brake release control lever is located on the right side of the mast. To disengage or engage the brakes, check the brake decal located just above the handle assembly to see which direction the handle needs to be pointed. The brakes are ENGAGED (normal driving position) when the handle is in the up (vertical) position. The brakes are DIS- ENGAGED when the handle is pulled down in a horizontal position, (machine can be moved manually when the handle is pulled down in a horizontal position). Figure 3-3. Brake Release Handle. 3-4 JLG Lift

29 SECTION 3 - USER RESPONSIBILITIES & MACHINE CONTROLS 3.5 JLG POT-HOLE PROTECTION DEVICE (See Figure 3-4.) VPSP model lifts are equipped with JLG s Pot-Hole-Protection system (PHP). The PHP system consists of hinged steel bars extending from the bottom edge of both sides of the base frame. The steel bars are cable operated by a spring loaded actuator mounted on the base frame directly under the mast assembly. The PHP bars are automatically ENGAGED (lowered) when the platform is raised more than (approximately) six (6) inches. The bars have a ground clearance of approximately three quarters (3/4) inch when ENGAGED (lowered), and are designed to support the weight of the machine should one of its wheels drop into a hole or crack. As the machine drops onto the PHP bar, the bar will limit the amount of tilt the machine will incur and reduce the likelihood of the machine tipping over. If this condition should occur, the operator must then fully lower and exit the platform, then safely remove the machine from the situation. When the machine is driven in areas where obstacles are higher than three quarters (3/4) inch off the work surface (door sills, thick carpeting, etc.) the platform must be completely lowered to allow the PHP bars to DISENGAGE (retract), allowing sufficient clearance of the machine s base frame. Figure 3-4. JLGs Pot-Hole-Protection Device - PHP Bar Operation JLG Lift 3-5

30 SECTION 3 - USER RESPONSIBILITIES & MACHINE CONTROLS Figure 3-5. Decal Locations (Front View) 3-6 JLG Lift

31 SECTION 3 - USER RESPONSIBILITIES & MACHINE CONTROLS ELECTROCUTION HAZARD DANGER This machine is not electrically insulated. Maintain a clearance of at least 10 ft. between any part of machine or load and any electrical line or apparatus charged up to 50,000 volts. One foot additional clearance is required for each additional 30,000 volts or less. Allowances must be made for operator error, machine deflection and electrical line swaying. Death or serious injury will occur from contact or being too close to electrical lines. IMPORTANT FREE-WHEELING INSTRUCTIONS Brake control handle is located on side of mast. Brake handle must be in drive position before continuing operation. Brake handle must be in free-wheeling position before towing or manually moving machine. Manufactured by: JLG Industries Inc JLG-LIFT THIS MACHINE MUST NOT BE USED UNTIL IT IS INSPECTED AND OPERATING PROPERLY: Do not operate this machine unless you have been properly trained as described in the JLG Operation and Safety Manual and authorized to operate this machine. Your training includes reading and understanding the JLG safety and operation manuals for this model, watching and understanding the JLG operation and safety video for this model, and knowing your employers work rules and applicable governmental regulations Follow the Instructions in the Operating Manual and Sections 6, 7, and 8 of ANSI A92.6 Self-Propelled Elevating Aerial Platforms for daily, frequent, and annual inspections. These may be obtained from your authorized JLG Industries, Inc. equipment dealer or JLG Industries, Inc. Do not replace items (i.e. batteries, wheels, counterweight, etc.) with items of different weight or specification because this will affect stability of machine. Do not modify or change machine without written approval from manufacturer. Operate this machine with extreme caution. STOP all operation if malfunction occurs. Improper use of this machine could cause death or serious injury. WARNING FALLING HAZARD Keep both feet on platform floor. Do not climb, sit or stand on platform guard rails. Do not use planks, ladders or similar items in platform to get added reach. All guard rails must be securely locked before operation. Fall protection must be worn at all times, if platform rails are configured in any open configuration. Falling from platform could cause death or serious injury. TIP-OVER HAZARD Do not exceed platform rated capacity or rated number of people. Do not expose platform to high winds or horizontal forces. Machine must be on smooth, firm and level surface before elevating platform. Do not drive near drop offs, holes or other hazards. Make sure operating surface will support the machine. Death or serious injury could occur from a tip-over. CRUSHING HAZARD Always look in the direction of movement. Keep clear of obstructions. Keep all body parts inside the platform during operation. Failure to follow instructions could result in death or serious injury. FORWARD LIFT ENABLE F UP 100 LBS 45 kg BATTERY CHARGE/ FAULT INDICATOR HORN E LIFT DOWN EXTENSION PLATFORM FORWARD DRIVE/ STEER DRIVE/STEER ENABLE STOP EMERGENCY CONTROL SPEED MOLDED PLATFORM/ MATERIAL TRAY LOW HIGH R Figure 3-6. Decal From Figure JLG Lift 3-7

32 SECTION 3 - USER RESPONSIBILITIES & MACHINE CONTROLS Figure 3-7. Decal Locations (Rear View) 3-8 JLG Lift

33 SECTION 3 - USER RESPONSIBILITIES & MACHINE CONTROLS Figure 3-8. Decal Locations (Top View) JLG Lift 3-9

34 SECTION 3 - USER RESPONSIBILITIES & MACHINE CONTROLS BRAKE HANDLE MUST BE IN FREE-WHEELING POSITION & GROUND STATION KEY SWITCH MUST BE IN OFF POSITION BEFORE TOWING OR WINCHING MACHINE TOW OR WINCH SLOWLY: 2 MPH MAX P/N BRAKE FREE WHEELING P/N P/N MAX 484 kg 1090 lbs P/N Figure 3-9. Decal Locations (Right/Left View) 3-10 JLG Lift

35 SECTION 4 - MACHINE OPERATION SECTION 4. MACHINE OPERATION 4.1 MACHINE DESCRIPTION The JLG VPSP model lifts are an electric self-propelled machine, with an aerial work platform mounted to an elevating aluminum mast mechanism. The mast is raised and lowered by a hydraulic cylinder extending between mast section-1 and -2, the remaining mast sections are proportionally extended and retracted using steel chains or cables. Hydraulic pressure is supplied to the lift cylinder by an electrically powered hydraulic pump. All VP Series models feature a steel base frame with swivel caster wheels mounted on the front and fixed drive wheels on the rear of the machine. The personnel lift s intended purpose is to provide personnel access to areas above ground level. The JLG VPSP lift has a primary controller in the platform. From the platform control the operator can drive the unit and raise or lower the platform. Ground controls are also provided, these controls consist of a keyed power on/off/ grnd switch, an emergency stop button, an emergency/ manual decent valve and a platform up/down control switch. Instructions and warnings are posted adjacent to both platform and ground operator control stations and at other places on the machine. It is extremely important that the user/operator know what instructions and warnings are placed on the machine and in the manual. And that these instructions and warning be reviewed periodically. The JLG VP personnel lift is designed to provide efficient and safe operation when maintained and operated in accordance with instructions and warnings on the machine, in the Operating, Safety and Maintenance Manual, ANSI Responsibilities Manual and by obeying all job site and government rules and regulations. As with any type of machine, the operator is very important to efficient and safe operation. It is absolutely necessary that the JLG VP lift be regularly maintained in accordance with this manual. Any evidence of lack of maintenance, malfunction, excessive wear, damage or modification to the machine must be reported immediately to its owner, the job site supervisor, or safety manager and that the machine be taken out of service until all discrepancies are corrected. The JLG VPSP personnel lift is not intended to be used to lift material other than hand-picked stock or supplies. Supplies or tools which extend outside the platform are prohibited except for JLG approved receptacles. The personnel lift must not be used as a forklift, crane, or support for overhead structure. The total platform capacity of the VPSP personnel lift must be uniformly distributed in the platform. This means that the total combined weight of personnel, tools and supplies loaded into the platform must not exceed the platform capacity figures. 4.2 GENERAL This section provides the necessary information needed to operate the machine. Included in this section are procedures for driving the machine, raising, lowering and loading the platform, and also transporting the machine. It is important that the user read and understand the proper procedures before operating the machine. Although some of the more important operating safety precautions will be listed in the following paragraph sections, IT IS EXTREMELY IMPORTANT ALL SAFETY PRECAUTIONS IN SECTION 1 - "SAFETY PRECAUTIONS", BE READ AND UNDERSTOOD BEFORE OPERATING MACHINE. If a Daily Walk-Around Inspection, (see Section 2-4.) has not been performed, do so before starting set-up and operation. The operator must also be familiar with all lift controls as described in Section 3 - "User/Operator Responsibilities and Machine Controls" JLG Lift 4-1

36 SECTION 4 - MACHINE OPERATION 15VPSP OPERATING SPECIFICATIONS Maximum Occupants: person Maximum Work Load (Capacity): Total platform capacity: lb. (230 kg) Maximum allowed on rear of platform: lb. (115 kg) Maximum allowed on front of platform: lb. (115 kg) Maximum Travel Grade (Gradeability): % (Platform stowed ONLY) Maximum Travel Grade (Side Slope): (Platform stowed ONLY) Maximum Vertical Platform Height: ft. (4.57 m) Maximum Horizontal Platform Reach: in. (115.5 cm) (Fixed length of platform) Turning Radius (inside): in. (0 cm) Maximum Wheel Load: Reference decal on chassis adjacent to each wheel Maximum Drive Speeds: Platform Raised: mph (reduced automatically with limit switch) Platform Stowed: mph Maximum Platform Speeds: Platform Up: seconds (w/max. rated load) Platform Down: seconds (w/max. rated load) Gross Machine Weight (platform empty): ,190 lb. (994 kg) (See serial number plate for actual weight) 4-2 JLG Lift

37 SECTION 4 - MACHINE OPERATION 4.3 MACHINE OPERATION The following sequence of basic procedures must be followed to safely operate the machine. 1. At the ground control station, set power PLAT/OFF/ GRND key switch to the PLAT position to operate from platform control, or GRND to operate from ground controls. Note if equipped with optional Programmable Security Lock see Section 5 for instructions then return here to continue. 2. Check that the EMERGENCY STOP button on the GROUND and PLATFORM control are in the RESET position for operation. Also check that Emergency/ Manual Decent Control valve is closed (lower access opening in rear cover). 3. Check the LED strip on the platform controller for current battery charge level before operating lift to be certain charge is sufficient to complete your work task. If the battery charger is plugged into an AC outlet, drive functions on the machine will be locked out. NOTE: If LED S are flashing a fault code on the platform control box at machine power-up, depress the EMERGENCY STOP button and RESET it to clear any false fault codes. If the fault continues after RESET, see Section-3, Troubleshooting of the Service and Maintenance Manual for information on reading fault codes. WORK AREA MUST BE A SMOOTH, FIRM AND LEVEL SURFACE FREE OF HOLES, LARGE CRACKS OR DEBRIS ON SURFACE. THE WORK SURFACE MUST BE CAPABLE OF SUPPORTING THE WEIGHT OF THE MACHINE PLUS THE PLATFORM S MAXIMUM RATED LOAD CAPACITY. ALWAYS CHECK THE BUBBLE LEVEL INDICATOR ON BASE FRAME TO BE SURE MACHINE IS LEVEL BEFORE RAISING PLATFORM. Interlock Switch Operating Conditions Table 4-1. shown, lists machine response to various interlock switch positions. Driving WHEN DRIVING WITH PLATFORM LOWERED, DO NOT ATTEMPT TO DRIVE MACHINE UP A RAMP (GRADE) OF GREATER THAN TEN (10%) PERCENT, AS TIPPING COULD OCCUR. NEVER ATTEMPT TO DRIVE ONTO A GRADE WITH THE PLATFORM ELEVATED. 1. Enter platform and close the front platform gate if the platform is configured as a closed platform. If platform is configured as open, enter rear of platform and close the mid platform gate before driving. (See Figure 4-1.) FALL PROTECTION EQUIPMENT MUST BE WORN AND ATTACHED TO THE LANYARD ATTACHMENT AT ALL TIMES WHILE OPERATING THIS MACHINE. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DEATH OR SERIOUS INJURY. 2. Attach your fall protection harness to the lanyard attachment on the top platform rail at the rear of the platform. 3. Check the floor and overhead area in the direction of travel for obstacles to avoid. 4. Press and HOLD the DRIVE ENABLE button on the JOYSTICK then gently point the JOYSTICK in the direction of travel. If necessary, adjust the VARIABLE SPEED CONTROL knob on the controller (round knurled knob) while driving. 4. Inspect work area before operating lift. Elevation/ Speed Switch Table 4-1. Machine Interlock Switch Operating Conditions. Drive Cutout (PHP System) Tilt Status Brake Status Controller Response mast retracted bars raised (not tilted) engaged Full Drive and Lift mast retracted bars raised (not tilted) disengaged Drive and Lift disabled mast extended bars lowered (not tilted) engaged Drive 25% max. mast extended bars lowered (tilt) engaged Drive and Lift disabled mast retracted bars raised (tilt) engaged Lift disabled mast retracted bars raised (tilt) disengaged Drive and Lift disabled mast retracted bars raised/battery charger plugged-in (not tilted) engaged Drive disabled JLG Lift 4-3

38 SECTION 4 - MACHINE OPERATION 5. To stop, either release the JOYSTICK (quick stop), or slowly move the JOYSTICK back to the neutral (center) position (preferred), to bring the lift to a smooth stop. Platform Loading The platform maximum rated load capacity is displayed on the platform capacity decal located on the billboard at the rear of the platform. (See Section-3, Figure 3-5.) The maximum rated load capacity includes the combined weight of the operator and any materials, tools or stock placed in the platform with the operator. Distribute weight evenly across the platform floor. Maximum rated load capacity for all platforms is as follows: Table 4-2. Maximum Rated Platform Load Capacity Model 15VPSP Max. Capacity 500 lb. (227 Kg) ATTACH POINT PLATFORM CONTROL BOX GATE RELEASE/ LATCH Elevating Platform GATE RELEASE/ LATCH GATE RELEASE/ LATCH DO NOT ATTEMPT TO RAISE THE PLATFORM UNLESS ALL FOUR WHEELS OF THE MACHINE ARE RESTING ON A FIRM AND LEVEL SURFACE. THE PLATFORM WILL NOT ELEVATE IF THE TILT ALARM HAS BEEN ACTIVATED. OBSERVE SURFACE AREA AROUND MACHINE IF IT IS TO BE DRIVEN WHILE PLATFORM IS ELEVATED. DO NOT ATTEMPT TO DRIVE ONTO A GRADE OR SIDE SLOPE WITH THE PLATFORM ELEVATED. 1. Drive the machine to the area where overhead work is to be performed and position the machine into it s approximate work position. NOTE: A short delay between lift motor starting and platform movement is normal. 2. To raise the platform, at the platform control, PRESS and HOLD the LIFT ENABLE pad switch and the PLATFORM UP (up arrow) switch simultaneously. Upon reaching desired elevation level, release the PLATFORM UP (arrow) and the LIFT ENABLE switch. PLATFORM CLOSED MID PLATFORM GATE ENTER REAR OF PLATFORM AND CLOSE THIS GATE WHEN DRIVING WITH PLATFORM OPEN NOTE: When platform is elevated, drive speed is automatically decreased to one fourth (1/4) of when platform was lowered. 3. If necessary, reposition (drive) lift using platform controller joystick to bring work object within reach. PLATFORM OPEN Figure 4-1. Platform Operating Configurations. 4-4 JLG Lift

39 SECTION 4 - MACHINE OPERATION Lowering Platform ENSURE AREA BENEATH PLATFORM IS FREE OF PERSONNEL AND OBSTRUCTIONS PRIOR TO LOWERING PLATFORM. 1. To lower platform, PRESS and HOLD the LIFT ENABLE switch and platform DOWN switch (down arrow) on the platform control pad. Upon reaching desired lower level release the DOWN (down arrow) switch and the LIFT ENABLE switch. Parking Machine 1. Drive machine to a well-protected and well-ventilated area. 2. Ensure the platform is fully lowered, turn power PLAT/OFF/GRND switch to the OFF position (centered). 3. Park machine with brakes engaged. (Brake overcenter handle up, drive position). 4. If necessary, remove key from POWER PLAT/OFF/ GRND key switch to disable machine from unauthorized use. NOTE: If required, plug in AC battery charger so machine batteries will be charged in preparation for next work day in accordance with Section 2-7, Battery Charging. 4.4 TRANSPORTING, LIFTING AND TIE DOWN PROCEDURES General All VP Series model personnel lifts may be transported to a work site using the following methods: Driving the machine around on its base wheels if travel surface area permits. Loaded, IN AN UPRIGHT POSITION ONLY onto a heavy-duty vehicle with the payload capacity capable of supporting the full weight of the machine (see machine weights in the following sub-section Fork-lift Truck Transport ). Moved with a fork-lift truck using the fork-lift pockets in the base frame. IMPORTANT THE VP SERIES CONTROLLER COULD SUSTAIN SERIOUS DAMAGE WHEN THE UNIT IS PUSHED, OR TOWED WHILE NOT UNDER POWER, FOR EXAMPLE PUSHING OR TOWING WITH OTHER MACHINERY, AT SPEEDS OF 4 MPH. DO NOT ATTEMPT TO PUSH OR TOW THE MACHINE AT SPEEDS GREATER THAN 2 MPH. ALWAYS BE CERTAIN THE MACHINES BRAKES ARE DISENGAGED AND THE EMERGENCY STOP BUTTON IS SET TO THE OFF POSITION, WHEN PUSHING, WINCHING OR TOWING. Driving to Work Area The VPSP machines are capable of being driven to a work area, if the surrounding travel surface permits. Follow the driving and safety instructions as noted in this Section 4-3., Machine Operation - Driving. Truck Transport DO NOT TRANSPORT THE MACHINE IN A HORIZONTAL POSITION DUE TO LEAKAGE OF BATTERY ACID FROM THE BATTERIES OR HYDRAULIC FLUID FROM THE HYDRAULIC RESERVOIR. The machine may be winched onto a tilted roll-back truck bed (see important note following) which has been rolled back to ground level. Always winch (pull) from the mast (rear) end of the machine, using the rear tie-down bar located in the base frame (See Figure 4-2.). IMPORTANT DO NOT ATTEMPT TO DRIVE MACHINE ONTO, OFF OF, OR PUSH MACHINE ONTO A TILTED ROLL-BACK TRUCK BED. WHEN TOWING OR WINCHING, THE MACHINE S BRAKES MUST BE DISENGAGED (SEE SECTION 3-4. CONTROLS AND INDICA- TOR, SUB-SECTION BRAKE RELEASE CONTROL ), AND THE EMERGENCY STOP BUTTON SET TO THE OFF POSITION, (DEPRESSED). DO NOT ATTEMPT TO TOW OR WINCH THE MACHINE AT A SPEED GREATER THAN (2) MPH, OR DAMAGE COULD OCCUR TO THE MACHINES ELECTRONIC CONTROLLER BOX, (DUE TO HIGH VOLTAGE BEING GENERATED BY THE DRIVE MOTORS FEEDING BACK INTO THE CONTROLLER BOX). RE-ENGAGE THE BRAKES ONCE MACHINE IS IN PLACE WITH TRUCK BED LEVEL AND READY FOR TIE DOWN. TIE DOWN BARS ARE PROVIDED ON BOTH ENDS OF THE BASE FRAME TO SECURE MACHINE TO BED OF TRANSPORT VEHICLE. Machine Tie-Down With machine in position to be tied down and brakes engaged, use the following guidelines for restraining the machine during transport. IMPORTANT USE OF EXCESSIVE FORCE WHEN SECURING MACHINE (DRIVE WHEEL LOAD), CAN CAUSE DAMAGE TO THE MACHINES DRIVE JLG Lift 4-5

40 SECTION 4 - MACHINE OPERATION COMPONENTS, I.E. AXLES, AXLE BEARINGS, TORQUE LIMITING CLUTCH, OR DRIVE GEARS. 1. Secure machine with an adequate chain attached through the tie down bars at the front and back of machine. (See Figure 4-2.) 2. The chain should be securely tightened with a force of approximately 100 lb. applied two feet from the pivot handle. (i.e.. the chain is properly tightened when a 200 lb. load placed on the chain (a 200 lb. man standing on the chain), just flexes the chain). Fork-lift Truck Transport IMPORTANT ALWAYS RELEASE THE DRIVE MOTOR BRAKES AND SET THE EMER- GENCY STOP BUTTON TO THE OFF POSITION, (DEPRESSED) ON THE MACHINE WHEN MANUALLY PUSHING, PULLING, OR WHEN TRANSPORTING MACHINE BY FORK-LIFT TRUCK. THIS WILL ALLOW THE DRIVE MOTORS AND GEARS TO ROTATE WITH LEAST RESISTANCE SHOULD THE DRIVE WHEELS COME IN CONTACT WITH ANY SURFACE. IF CONTACT OF THE REAR DRIVE WHEELS DOES OCCUR WHILE FORKLIFT TRUCKING, AT SPEEDS GREATER THAN 2 MPH, DAMAGE COULD OCCUR TO THE MACHINES ELEC- TRONIC CONTROLLER BOX, (DUE TO HIGH VOLTAGE BEING GENER- ATED BY THE DRIVE MOTORS FEEDING BACK INTO THE CONTROLLER BOX). ALWAYS REMEMBER TO RE-ENGAGE THE BRAKE SYSTEM BEFORE MACHINE OPERATION. As standard equipment, all VPSP model lifts are equipped with 7-1/2 in. wide fork-lift pockets running through the base frame. This allows the machine to be either transported around a work area or lifted onto a higher level using a standard fork-lift truck. NOTE: Fork-lift trucks must be capable of handling the following weights: Table 4-3. Machine Gross Weights Model 15VPSP ANSI SPEC (United States) 2,190 lb. (994 kg) Figure 4-2. Forklift Truck Lifting Pockets and Machine Tie Down Bar Locations. 4-6 JLG Lift