Operators and Safety Manual Model 15VPSP 3120796 June 14, 2001 ANSI
– JLG Lift –
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.
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.
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.
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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 5-6.
EFFECTIVITY PAGE This Page Left Intentionally Blank b – JLG Lift – 3120796
TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. Effectivity Changes a SECTION 1 - SAFETY PRECAUTIONS 1.1 1.2 1.3 1.4 1.5 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Pre-Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS (Continued) LIST OF FIGURES FIGURE NO. 2-1. 2-2. 2-3. 2-4. 2-5. 2-6. 3-1. 3-2. 3-3. 3-4. 3-5. 3-6. 3-7. 3-8. 3-9. 4-1. 4-2. 5-1. 5-2. 5-3. 5-4. 5-5. 5-6. 5-7. 5-8. 5-9. TITLE PAGE NO. Daily Walk-Around Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 Battery Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 - SAFETY PRECAUTIONS SECTION 1. SAFETY PRECAUTIONS 1.1 GENERAL 1.2 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.
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.
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.
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.
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.
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.
SECTION 2 - PREPARATION AND INSPECTION SECTION 2. PREPARATION AND INSPECTION 2.1 GENERAL 2.3 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.
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. 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.
SECTION 2 - PREPARATION AND INSPECTION 7 8 9 6 4 3 2 5 1 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.
SECTION 2 - PREPARATION AND INSPECTION 1m) several times. Check for smooth elevation and lowering of platform. 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. 2.
SECTION 2 - PREPARATION AND INSPECTION 2.7 BATTERY CHARGING & MAINTENANCE BATTERY FILLER CAP VPSP Models are equipped with 24 volt, 10 amp output battery chargers (U.S.A. - 120 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.
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.
SECTION 2 - PREPARATION AND INSPECTION 6 1 2 5 3 4 Figure 2-5. Lubrication Chart. Table 2-1. Lubrication Intervals for Various Components INTERVAL HOURS ITEM 1 COMPONENT Hydraulic Oil NO/TYPE LUBE POINTS Fill To Line on Reservoir 5 Qt. Reservoir LUBE/METHOD 3 MONTHS 150 Hrs. 6 MONTHS 300 Hrs. 1 2 YEAR YEARS 600 Hrs. 1200 Hrs. HO - Check Hyd. Oil Level HO - Change Hyd.
SECTION 2 - PREPARATION AND INSPECTION Figure 2-6. Torque Chart.
SECTION 3 - USER RESPONSIBILITIES & MACHINE CONTROLS SECTION 3. USER RESPONSIBILITIES & MACHINE CONTROLS 3.1 Operator Training GENERAL Operator training must include instruction in the following: IMPORTANT 1. Use and limitations of the platform controls, ground controls and emergency controls. SINCE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION, CONFORMANCE WITH GOOD SAFETY PRACTICES IN THESE AREAS IS THE RESPONSIBILITY OF THE USER AND HIS OPERATING PERSONNEL. 2.
SECTION 3 - USER RESPONSIBILITIES & MACHINE CONTROLS 3.3 OPERATING CHARACTERISTICS AND LIMITATIONS 3.4 CONTROLS AND INDICATORS Ground Controls General (See Figure 3-1.) 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.
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 LIFT ENABLE PAD SWITCH (See Figure 3-2.) BATTERY VOLTAGE/ FAULT CODE INDICATOR The platform controller contains all the controls necessary to operate the lift from the platform.
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. 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. 4.
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.
SECTION 3 - USER RESPONSIBILITIES & MACHINE CONTROLS Figure 3-5.
20796 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. ● ● ● – JLG Lift – MOLDED PLATFORM/ MATERIAL TRAY 100 LBS 45 kg Do not replace items (i.e. batteries, wheels, counterweight, etc.
SECTION 3 - USER RESPONSIBILITIES & MACHINE CONTROLS Figure 3-7.
SECTION 3 - USER RESPONSIBILITIES & MACHINE CONTROLS Figure 3-8.
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. 1703708 P/N-1703708 BRAKE FREE WHEELING 1703636 P/N-1703636 P/N-1703072 MAX 484 kg 1090 lbs 1704539 P/N-1704539 Figure 3-9.
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.
SECTION 4 - MACHINE OPERATION 15VPSP OPERATING SPECIFICATIONS Maximum Occupants: . . . . . . . . . . . . . . . . . . . . . . . . . . 1 person Maximum Work Load (Capacity): Total platform capacity: . . . . . . . . . . . . . . . . . . . . . . . . 500 lb. (230 kg) Maximum allowed on rear of platform: . . . . . . . . . . . . . 250 lb. (115 kg) Maximum allowed on front of platform: . . . . . . . . . . . . . 250 lb. (115 kg) Maximum Travel Grade (Gradeability): . . . . . . . . . . . . .
SECTION 4 - MACHINE OPERATION 4.3 Interlock Switch Operating Conditions MACHINE OPERATION Table 4-1. shown, lists machine response to various interlock switch positions. 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.
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. ATTACH POINT PLATFORM CONTROL BOX 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.
SECTION 4 - MACHINE OPERATION 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. 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.
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).
SECTION 5 - OPTIONAL EQUIPMENT SECTION 5. OPTIONAL EQUIPMENT 5.1 Rug Carrier Accessory OPTIONAL EQUIPMENT The VPSP Series models are available with the following optional equipment: Lifting Hook The optional lifting hook is mounted at the top rear of the first mast section. The hook is used to lift the machine up or down to another level. Horn The horn is activated by the horn pad on the platform controller box.
SECTION 5 - OPTIONAL EQUIPMENT 5.2 OBSTRUCTION SENSING SYSTEM (OSS) System Description When power is applied to the OSS, the red LED on the electronics module will illuminate. If no obstructions are located within the detection zone beneath the platform, the lift will operate normally.
SECTION 5 - OPTIONAL EQUIPMENT Daily Inspection 5.3 RUG CARRIER ACCESSORY (See Figure 5-3.) From ground controls, raise platform approximately 5’-6’. The red LED on the electronic module will be illuminated when power is applied. If an obstruction, such as a pad of paper is placed under one of the transducer sensor arrays, the LED will flash and remain flashing while the obstruction is present and stop flashing 3 seconds after the obstruction is removed.
SECTION 5 - OPTIONAL EQUIPMENT Hanging a Rug using the Rug Carrier Accessory Arms This section describes the use of the Rug Carrier accessory in hanging rugs on horizontal pivoting arm display racks. CENTER CARPET ROLL FRONT TO REAR ON ARMS 1. Select the intended location in the display for mounting the rug. Open the display rack to provide adequate space for the 15VPSP lift and rug. 2. With the Rug Carrier Accessory arms stowed, drive the 15VPSP into position prior to loading the rug. 3.
SECTION 5 - OPTIONAL EQUIPMENT 9. Remove the rug from the Rug Carrier Accessory. As required, use an assistant to unload the rug from the Rug Carrier Accessory Arms. 5.4 PROGAMMABLE SECURITY LOCK (PSL™) The optional keyless Programmable Security Lock switch can be programmed with a four (4) digit operators code to allow only those persons with the code to start and operate the machine. 10. Stow the Rug Hanger Accessory arms.
SECTION 5 - OPTIONAL EQUIPMENT Machine Power Up using the PSL™ Machine Power Down 1. Set the ground control selector switch to the OFF position. 1. At the ground control station, turn the keyless three position selector switch from OFF to either PLAT for platform operation, or GRND for ground control operation. 2. Press the OFF button on the PSL keypad. No led’s on the PSL box will be lit.
SECTION 6 - EMERGENCY PROCEDURES SECTION 6. EMERGENCY PROCEDURES 6.1 GENERAL INFORMATION 6.3 This section provides information on procedures to be followed, and systems and controls to be used in the event an emergency situation is encountered during machine operation. Prior to operation of the machine and periodically thereafter, the entire operating manual, including this section, should be reviewed by all personnel whose responsibilities include any work or contact with the machine. 6.
SECTION 6 - EMERGENCY PROCEDURES Platform Caught Overhead 6.4 If the platform becomes jammed or snagged in overhead structures or equipment, do not continue operation of the machine from either the platform or the ground until the operator and all personnel are safely moved to a secure location. Only then should an attempt be made to free the platform using any necessary equipment and personnel.
SECTION 7 - INSPECTION AND REPAIR LOG SECTION 7. INSPECTION AND REPAIR LOG Machine Serial Number: Table 7-1.
SECTION 7 - INSPECTION AND REPAIR LOG Table 7-1.
JLG Industries, Inc. TRANSFER OF OWNERSHIP To: JLG, Gradall, Lull and Sky Trak product owner: If you now own, but ARE NOT the original purchaser of the product covered by this manual, we would like to know who you are. For the purpose of receiving safety-related bulletins, it is very important to keep JLG Industries, Inc. updated with the current ownership of all JLG products. JLG maintains owner information for each JLG product and uses this information in cases where owner notification is necessary.
