JLG 15MVL, 20MVL, 15MSP, 20MSP Operation And Safety Manual
ANSI
Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Model(s)
15/20MVL
15/20MSP
3121230
June 29, 2018 - Rev L
WARNING
Operating, servicing and maintaining this vehicle or equipment
can expose you to chemicals including engine exhaust, carbon
monoxide, phthalates, and lead, which are known to the State of
California to cause cancer and birth defects or other
reproductive harm. To minimize exposure, avoid breathing
exhaust, do not idle the engine except as necessary, service your
vehicle or equipment in a well-ventilated area and wear gloves
or wash your hands frequently when servicing. For more
information go to www.P65Warnings.ca.gov.
FOREWORD
FOREWORD
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.
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.
Other Publications Available:
Service Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3121231
Illustrated Parts Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3121232
3121230 – JLG Lift – a
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
This is the Safety Alert Symbol. It is used to alert you to the potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death
INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT
AVOIDED,
WILL HAVE A RED BACKGROUND.
IN DICATES A POTENTIA LIT Y HA Z ARDOUS S ITUATI O N. IF NOT
AVOIDED,
WILL HAVE AN ORANGE BACKGROUND.
b – JLG Lift – 3121230
WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL
COULD RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL
IN DICATES A POTENTIA LIT Y HA Z ARDOUS S ITUATI O N. IF NOT
AVOIDED,
ALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVE A
YELLOW BACKGROUND.
INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES
DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY.
MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED
JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY
RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS
PRODUCT.
JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE
OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES,
INC. TO ENSURE THAT THE CURRENT OWNER RECORDS ARE UPDATED
AND ACCURATE.
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.
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
For :
• Accident Reporting
• Product Safety Publications
• Current Owner
Updates
• Questions Regarding
Product Safety
Contact :
Product Safety and Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
or Your Local JLG Office
(See addresses on inside of manual cover)
In USA:
Toll Free: 877-JLG-SAFE (877-554-7233)
Outside USA:
Phone: 240-420-2661
E-mail: ProductSafety@JLG.com
• Standards and Regulations Compliance Information
• Questions Regarding Special Product Applications
• Questions Regarding
Product Modifications
3121230 – JLG Lift – c
REVISION LOG
REVISION LOG
Original Issue A - November 29, 2005
Revised B - April 19, 2006
Revised C - October 4, 2006
Revised D - April 2, 2007
Revised E - November 6, 2007
Revised F - May 12, 2009
Revised G - December 22, 2009
Revised H - November 24, 2010
Revised I - February 24, 2012
Revised J - December 5, 2013
Revised K - December 20, 2013
Revised L - June 29, 2018 - Revised Covers, Prop 65
d – JLG Lift – 3121230
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
FOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL
WORDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B
Contact : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
In USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Outside USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
REVISION LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D
SECTION - 1 - SAFETY PRECAUTIONS
1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Operator Training And Knowledge . . . . . . . . . . . 1-1
Workplace Inspection. . . . . . . . . . . . . . . . . . . . . . . . 1-2
Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Trip and Fall Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Electrocution Hazards. . . . . . . . . . . . . . . . . . . . . . . . 1-4
Tipping Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Crushing And Collision Hazard . . . . . . . . . . . . . . . 1-7
3121230 – JLG Lift – i
1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . . . . 1-8
SECTION - 2 - PREPARATION AND INSPECTION
2.1 PERSONNEL TRAINING. . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 PREPARATION, INSPECTION, AND MAINTENANCE 2-
2
2.3 PRE-START INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 DAILY WALK-AROUND INSPECTION . . . . . . . . . . . . . 2-5
2.5 FUNCTION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
SECTION - 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 MACHINE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3 MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4 BATTERY CHARGING. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Battery - Low Voltage Warning Indicators . . . . . 3-3
To Charge Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Battery Charging Status Indicators. . . . . . . . . . . . 3-4
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
3.5 GROUND CONTROL STATION - OPERATION . . . . . 3-7
Main Power Selector Switch . . . . . . . . . . . . . . . . . . 3-7
Emergency Stop/Shut Down Button . . . . . . . . . . 3-7
Brake Release Button . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Platform Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Platform Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Manual Descent Control Valve . . . . . . . . . . . . . . . . 3-9
Machine Status LCD Display . . . . . . . . . . . . . . . . 3-10
LCD Display Fault Conditions . . . . . . . . . . . . . . . 3-11
3.6 PLATFORM CONTROL CONSOLE OPERATION . . . 3-15
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Platform On/Off Key Switch. . . . . . . . . . . . . . . . . 3-16
Platform Emergency Stop Button . . . . . . . . . . . 3-17
Platform Control Display Panel . . . . . . . . . . . . . 3-17
Drive/Lift Mode Selector Switch . . . . . . . . . . . . 3-19
Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Joystick Function Enable Lever . . . . . . . . . . . . . 3-19
Multifunction Joystick Control . . . . . . . . . . . . . . 3-20
Drive Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Lift Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Drive Speed Setting Controls . . . . . . . . . . . . . . . 3-23
3.7 PARKING MACHINE. . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
3.8 PLATFORM CONFIGURATIONS . . . . . . . . . . . . . . . . .3-24
StockPicking Platform Operation . . . . . . . . . . . 3-28
ii – JLG Lift – 3121230
3.9 FALL PROTECTION - LANYARD ATTACHMENT . . 3-30
3.10 QUICK-CHANGE PLATFORM MOUNTING. . . . . . . 3-31
Platform Removal (see illustration following) 3-31
Platform Installation . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.11 TRANSPORTING, LIFTING AND
TIE DOWN PROCEDURES . . . . . . . . . . . . . . . . . . . . . . 3-32
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Truck Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Machine Tie-Down . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Crane Hook Accessory (Option). . . . . . . . . . . . . 3-33
Fork-Lift Truck Transport. . . . . . . . . . . . . . . . . . . . 3-34
3.12 PROGAMMABLE SECURITY LOCK (PSL™)
(MVL/MSP - OPTION). . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
PSL™ Box and Ground Control Locations . . . . 3-36
Machine Power Up using the PSL™ . . . . . . . . . . 3-37
Machine Power Down . . . . . . . . . . . . . . . . . . . . . . 3-37
Changing the Operator’s Code . . . . . . . . . . . . . . 3-37
3.13 OBSTRUCTION SENSING SYSTEM -
(MSP OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
System Description . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
OSS Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . 3-39
3.14 RUG CARRIER ACCESSORY
(MSP - OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
Pre-Start Inspection. . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Hanging a Rug using the Rug Carrier
Accessory Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Removing a Rug using Rug Carrier
Accessory Arms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
3.15 STOCK-PICKER HANGER ACCESSORY . . . . . . . . . . 3-45
Pre-Start Inspection. . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Loading and Transporting an Item
using the Hanger Accessory. . . . . . . . . . . . . . . . . 3-45
SECTION - 4 - EMERGENCY PROCEDURES
4.1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 EMERGENCY OPERATION. . . . . . . . . . . . . . . . . . . . . . . 4-1
Operator Unable to Control Machine . . . . . . . . . 4-1
Platform Caught Overhead. . . . . . . . . . . . . . . . . . . 4-1
4.3 INCIDENT NOTIFICATION. . . . . . . . . . . . . . . . . . . . . . . 4-1
SECTION - 5 - GENERAL SPECIFICATIONS AND OPERATOR
MAINTENANCE
5.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 5-2
Machine Specifications . . . . . . . . . . . . . . . . . . . . . . 5-2
Machine Wheel Loads and PSI - Per Wheel . . . . 5-4
Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . 5-6
3121230 – JLG Lift – iii
5.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 5-9
5.4 GROUND CONTROL STATION -
5.5 DRIVE MOTOR BRUSH WEAR -
5.6 SUPPLEMENTAL INFORMATION. . . . . . . . . . . . . . . . 5-21
SECTION - 6 - INSPECTION AND REPAIR LOG
Platform Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Machine Component Weights . . . . . . . . . . . . . . . . 5-8
Serial Number Locations . . . . . . . . . . . . . . . . . . . . . 5-8
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
PROGRAMMING5-14
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Programming Levels . . . . . . . . . . . . . . . . . . . . . . . 5-14
Operator Programming Mode . . . . . . . . . . . . . . 5-14
Activating Programming Mode . . . . . . . . . . . . . 5-17
Entering Password . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Programming Mode Selection . . . . . . . . . . . . . . 5-18
Selecting Programmable Item to Adjust . . . . 5-19
Adjusting Programmable Setting . . . . . . . . . . . 5-19
WARNING INDICATION . . . . . . . . . . . . . . . . . . . . . . . . 5-20
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
LIST OF FIGURES
2-1. Daily Walk-Around Inspection for
MVL/MSP Machines.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-2. Pot-Hole-Protection Bars Lowered. . . . . . . . . . . . . . 2-7
3-1. Ground Control Station. (Machine Rear View) . . . 3-8
3-2. Platform Control Console. . . . . . . . . . . . . . . . . . . . . . 3-15
3-3. Platform Control Display Panel. . . . . . . . . . . . . . . . . 3-17
3-4. Machine Operating Specifications . . . . . . . . . . . . . 3-21
3-5. Crane Hook Accessory. . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3-6. Forklift Truck Lifting Pockets and
Machine Tie Down Loop Locations. . . . . . . . . . . . . 3-35
3-7. PSL™ Switch & Ground Control Station
Locations - At Rear of Machine. . . . . . . . . . . . . . . . . 3-36
3-8. PSL™ Switch Controls & Indicators.. . . . . . . . . . . . . 3-36
3-9. OSS Transducer Sensor Array Location. . . . . . . . .3-39
3-10. OSS - Pre-Start Inspection of Operation. . . . . . . . . 3-40
3-11. MVL Series Decal Installation Chart -
(See Table 3-4 for Installation) . . . . . . . . . . . . . . . . . 3-47
3-12. MSP Decal Installation Chart -
(See Table 3-5. for Installation) . . . . . . . . . . . . . . . . . 3-50
5-1. Wheel Lug Nut Tightening Sequence . . . . . . . . . . 5-10
5-2. Location of Lubrication Points (See Table 5-5) . . 5-12
iv – JLG Lift – 3121230
Minimum Approach Distances (M.A.D.) . . . . . . . . . . . . . . . 1-5
Inspection and Maintenance Table . . . . . . . . . . . . . . . . . . . 2-3
Battery Low Voltage Warning Indicators.. . . . . . . . . . . . . . 3-3
LCD Display - Operation Fault Conditions . . . . . . . . . . . . 3-12
Max. Capacity with Side Entry Platform
w/Folding Material Tray Installed . . . . . . . . . . . . . . . . . . . . 3-26
MVL Series Decal Installation Chart. . . . . . . . . . . . . . . . . . . 3-48
MSP Decal Installation Chart. . . . . . . . . . . . . . . . . . . . . . . . . 3-51
15MVL/MSP - Machine Maximum
Wheel Loads (Lb.) and (PSI) - Per Wheel.. . . . . . . . . . . . . . . 5-4
20MVL/MSP - Machine Maximum
Wheel Loads (Lb.) and (PSI) - Per Wheel.. . . . . . . . . . . . . . . 5-5
Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Lubrication Intervals for Various Components. . . . . . . . 5-13
Ground Control Module Setting Range and
Default Factory Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Inspection and Repair Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
LIST OF TABLES
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. For proper machine use,
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.
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, PROPERTY DAMAGE, PERSONAL
INJURY OR DEATH.
3121230 – JLG Lift – 1-1
1.2 PRE-OPERATION
Operator Training And Knowledge
• Read and understand this manual before operating the
machine.
• Do not operate this machine until complete training is performed by authorized persons.
• Only authorized and qualified personnel can operate the
machine.
• Read, understand, and obey all DANGERS, WARNINGS, CAUTIONS, and operating instructions on the machine and in
this manual.
• Use the machine in a manner which is within the scope of
its intended application set by JLG.
SECTION 1 - SAFETY PRECAUTIONS
• 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 operation
of the machine.
Workplace Inspection
• The operator is to take safety measures to avoid all hazards
in the work area prior to machine operation.
• Do not operate or raise the platform while on trucks, trailers, railway cars, floating vessels, scaffolds or other equipment unless approved in writing by JLG.
• This machine can be operated in temperatures of 0° F to
104° F (-20° C to 40° C). Consult JLG for operation outside
this range.
Machine Inspection
• Before machine operation, perform inspections and functional checks. Refer to Section 2 of this manual for detailed
instructions.
• Do not operate this machine until it has been serviced and
maintained according to requirements specified in the 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 PLATFORM SHALL BE
MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER
• Do not operate any machine on which the safety or instruction placards or decals are missing or illegible.
• Avoid any build up of debris on platform floor. Keep mud,
oil, grease, and other slippery substances from footwear
and platform floor.
1-2 – JLG Lift – 3121230
SECTION 1 - SAFETY PRECAUTIONS
1.3 OPERATION
General
• The JLG MVL/MSP Model Lifts are electric self-propelled
machines with an aerial work platform mounted to an elevating aluminum mast mechanism. The personnel lift’s
intended purpose is to provide personnel access to areas
above ground level.
The MSP model lift is intended for stock picking purposes in
retail stores or warehouses to allow placing and removing
of stock from storage or display areas.
• Do not use the machine for any purpose other than positioning personnel, their tools and equipment, or for hand
stock picking.
• Never operate a machine that is not working properly. If a
malfunction occurs, shut down the machine.
• 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.
• Fully lower mast assembly and shut off all power before
leaving machine.
• When performing welding operations at elevation, precautions must be taken to protect all machine components
from contact with weld splatter or molten metal.
• Battery fluid is highly corrosive. Avoid contact with skin and
clothing at all times.
• Charge batteries on in a well ventilated area.
Trip and Fall Hazard
• JLG Industries, Inc. recommends that the operator in the
platform wear approved fall protection attached to an
authorized lanyard anchorage point. Reference “StockPicking Platform Operation” on page 28 for fall protection
requirements applicable to stockpicker platforms operated
with the rails in the open position. For further information
regarding fall protection requirements on JLG products,
contact JLG Industries, Inc.
3121230 – JLG Lift – 1-3
SECTION 1 - SAFETY PRECAUTIONS
• Before operating the machine, make sure all railing and
gates are fastened in their proper position.
• Keep both feet firmly positioned on the platform floor at all
times. Never use ladders, boxes, steps, planks, or similar
items on platform to provide additional reach.
• Never use the mast assembly to enter 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.
1-4 – JLG Lift – 3121230
SECTION 1 - SAFETY PRECAUTIONS
Electrocution Hazards
• This machine is not insulated and does not provide protection from contact or proximity to electrical current.
• Maintain distance from electrical lines, apparatus, or any
energized (exposed or insulated) parts according to the
Minimum Approach Distance (MAD) as shown in Table 1-1.
• Allow for machine movement and electrical line swaying.
Table 1-1. Minimum Approach Distances (M.A.D.)
Voltage Range
(Phase to Phase)
0 to 50 KV 10 (3)
Over 50KV to 200 KV 15 (5)
Over 200 KV to 350 KV 20 (6)
Over 350 KV to 500 KV 25 (8)
Over 500 KV to 750 KV 35 (11)
Over 750 KV to 1000 KV 45 (14)
NOTE: This requirement shall apply except where employer, local or govern-
mental regulations are more stringent.
• 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.
• The minimum approach distance may be reduced if insulating barriers are installed to prevent contact, and the barriers are rated for the voltage of the line being guarded.
These barriers shall not be part of (or attached to) the
machine. The minimum approach distance shall be reduced
to a distance within the designed working dimensions of
the insulating barrier. This determination shall be made by
MINIMUM APPROACH DISTANCE
in Feet (Meters)
3121230 – JLG Lift – 1-5
SECTION 1 - SAFETY PRECAUTIONS
a qualified person in accordance with the employer, local,
or governmental requirements for work practices near
energized equipment
DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE
(MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED
UNLESS KNOWN OTHERWISE.
Tipping Hazard
• The user should be familiar with the surface before driving.
Do not exceed the allowable sideslope and grade while
driving.
1-6 – JLG Lift – 3121230
SECTION 1 - SAFETY PRECAUTIONS
• Do not elevate platform or drive with platform elevated
while on a slope, or on an uneven or soft surface.
• Before driving on floors, bridges, trucks, and other surfaces,
check allowable capacity of the surfaces.
• Never exceed the maximum platform capacity. Distribute
loads evenly on platform floor.
• 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.
• Never attempt to use the machine as a crane. Do not tie-off
machine to any adjacent structure.
• Do not increase the platform size with unauthorized deck
extensions or attachments, increasing the area exposed to
wind will decrease stability.
• 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 Hazard
• Personal protection equipment must be worn by all operating and ground personnel.
• Check work area clearances above, on sides, and bottom of
platform while driving and lifting or lowering platform.
• During operation, keep all body parts inside platform railing.
• Always post a lookout when driving in areas where vision is
obstructed.
3121230 – JLG Lift – 1-7
SECTION 1 - SAFETY PRECAUTIONS
• Keep non-operating personnel at least 6 ft. (1.8m) away
from machine during all driving operations.
• 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.
• Do not drive at high speeds 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.
• 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 the Emergency Procedures Section of this
manual for emergency towing procedures.
• Ensure platform is fully retracted and completely empty of
tools prior to towing, lifting or hauling.
• Do not assist a stuck or disabled machine by pushing or
pulling except by pulling at the chassis tie-down bars.
• When lifting machine with a forklift, position forks only at
designated areas of the machine. Lift with a forklift of adequate capacity.
• Refer to the Machine Operation section of this manual for
lifting information.
1-8 – JLG Lift – 3121230
SECTION 2 - PREPARATION AND INSPECTION
SECTION 2. PREPARATION AND INSPECTION
2.1 PERSONNEL TRAINING
The aerial platform is a personnel handling device; so it is necessary that it be operated and maintained only by trained personnel.
Persons under the influence of drugs or alcohol or who are subject to seizures, dizziness or loss of physical control must not
operate this machine.
Operator Training
Operator training must cover:
1. Use and limitations of the controls in the platform and
at the ground, emergency controls and safety systems.
2. Control labels, instructions, and warnings on the
machine.
3. Rules of the employer and government regulations.
4. Use of approved fall protection device.
5. Enough knowledge of the mechanical operation of
the machine to recognize a malfunction.
6. The safest means to operate the machine where overhead obstructions, other moving equipment, and
obstacles, depressions, holes, drop-offs are present.
7. Means to avoid the hazards of unprotected electrical
conductors.
8. Specific job requirements or machine application.
Training Supervision
Training must be done under the supervision of a qualified person in an open area free of obstructions until the trainee has
developed the ability to safely control and operate the machine.
Operator Responsibility
The operator must be instructed that he/she 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.
NOTE: The Manufacturer or Distributor will provide qualified peo-
ple for training assistance with the first unit(s) delivered
and from that time forward as requested by the user or
his/her personnel.
3121230 – JLG Lift – 2-1
SECTION 2 - PREPARATION AND INSPECTION
2.2 PREPARATION, INSPECTION, AND MAINTENANCE
The following table covers the periodic machine inspections
and maintenance recommended by JLG Industries, Inc. Consult
local regulations for further requirements for aerial work platforms. The frequency of inspections and maintenance must be
increased as necessary when the machine is used in a harsh or
hostile environment, if the machine is used with increased frequency, or if the machine is used in a severe manner.
2-2 – JLG Lift – 3121230
SECTION 2 - PREPARATION AND INSPECTION
NOTICE
Table 2-1. Inspection and Maintenance Table
TYPE FREQUENCY
Pre-Star t
Inspection
Pre-Delivery
Inspection
(See Note)
Frequent
Inspection
Annual Machine
Inspection
Preventative
Maintenance
NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.
JLG INDUSTRIES, INC. RECOGNIZES A QUALIFIED JLG MECHANIC AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG
PRODUCT MODEL.
Before using each day; or
whenever there’s an Operator change.
Before each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Man-
In service for 3 months or 150 hours, whichever
comes first; or;
Out of service for a period of more than 3 months; or
Purchased used.
Annually, no later than 13 months from the date of
prior inspection.
At intervals as specified in the Service and Maintenance Manual.
PRIMARY
RESPONSIBILITY
User or Operator User or Operator Operator and Safety Manual
Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Man-
Owner, Dealer, or User Qualified JLG Mechanic
(Recommended)
Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Man-
SERVICE
QUALIFICATION
REFERENCE
ual and applicable JLG inspection form
ual and applicable JLG inspection form
Service and Maintenance Manual and applicable JLG inspection form
ual
3121230 – JLG Lift – 2-3
SECTION 2 - PREPARATION AND INSPECTION
2.3 PRE-START INSPECTION
The Pre-Start Inspection should include each of the following:
1. Cleanliness – Check all surfaces for leakage (oil, fuel,
or battery fluid) or foreign objects. Report any leakage
to the proper maintenance personnel.
2. Decals and Placards – Check all for cleanliness and
legibility. Make sure no decals or placards are missing.
Make sure all illegible decals and placards are cleaned
or replaced. (Reference "Decal Installations" in Section
3).
3. Operators and Safety Manuals – Make sure a copy of
the Operator and Safety Manual, EMI Safety Manual
(Domestic only), and ANSI Manual of Responsibilities
(Domestic only) is enclosed in the weather resistant
storage container.
4. Daily Walk-Around Inspection – (See Section 2.4)
5. Battery – Charge as required.
6. Hydraulic Oil – Check the hydraulic oil level.
NOTE: Check Service Manual for instructions and hydraulic oil
specification before adding. DO NOT OVERFILL.
FILL TO LINE
on Hydraulic
Reservoir
indicates the
proper level for
hydraulic oil.
7. Function Check – Check all machine controls for
operation per Section 2.5, Function Check.
If optional equipment is installed on this machine refer to Section 3 for specific Pre-Start Inspection and Operation instructions.
2-4 – JLG Lift – 3121230
SECTION 2 - PREPARATION AND INSPECTION
2.4 DAILY WALK-AROUND INSPECTION
Begin the “Walk-Around Inspection” at item one (1) as noted on
the diagram. Continue around machine check each item in
sequence for the conditions listed in the following check list.
TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS “OFF” DURING
“WALK-AROUND INSPECTION”.
DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED.
DO NOT OVERLOOK VISUAL INSPECTION OF THE BASE FRAME UNDERSIDE.
CHECK THIS AREA FOR OBJECTS OR DEBRIS WHICH COULD CAUSE EXTENSIVE
MACHINE DAMAGE.
INSPECTION NOTE: On all components, make sure there are no
loose or missing parts, that they are securely fastened, and that no
visible damage, leaks or excessive wear exists in addition to any
other criteria mentioned.
1. Drive and Caster Wheels - Check for any debris stuck
to or around wheels.
2. Base Frame - Check pot-hole-protection system components; check for loose wires or cables dangling
below the base.
3. Manual Descent Control Valve - See inspection note
above.
4. Motor/Pump/Reservoir Unit - No evidence of
hydraulic leaks. Hydraulic oil level should be filled level
with the full line.
5. Batteries - Charge if necessary.
6. Platform Assembly and Gate - Quick-Change plat-
form mounting and mounting pins; platform railings;
entry bar or gate in proper working order; MSP - platform fasteners.
7. Platform Control Console - Platform control; placards
secure and legible; emergency stop switch reset for
operation; Control markings legible.
8. Ground Control Station - Main Power Selector Switch
operable; placards secure and legible; emergency stop
switch operates properly.
9. Mast Assembly - Mast sections; slide pads; mast
chains; sequencing cables; platform control and
power cables (on side of mast); power cables properly
tensioned and seated in sheaves; cable sheaves rotat-
ing freely.
3121230 – JLG Lift – 2-5
SECTION 2 - PREPARATION AND INSPECTION
1. Drive and Caster Wheels
2. Base Frame
3. Manual Descent Control Valve
4. Motor/Pump/Reservoir Unit
5. Batteries - (Inside Cover)
6. Platform Assembly
7. Platform Control Console
8. Ground Control Station
9. Mast Assembly
Figure 2-1. Daily Walk-Around Inspection for MVL/MSP Machines.
2-6 – JLG Lift – 3121230
SECTION 2 - PREPARATION AND INSPECTION
2.5 FUNCTION CHECK
Once the “Walk-Around” Inspection is complete, perform a
function check of all systems in an area free of overhead and
ground level obstructions. Refer to Section 3 for more specific
operating instructions.
IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE MACHINE
IMMEDIATELY! REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL. DO NOT OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR
OPERATION.
Perform a Function Check as follows:
1. From the ground controls with no load in the platform:
a. Operate ground control functions, platform lift up and
lift down.
b. Ensure Pot-Hole-Protection device is fully engaged
(bars down on sides) when the platform is elevated (See
Figure 2-2.).
c. Ensure that all machine functions are disabled when
the Emergency Stop Button is activated.
d. Check Manual Descent Control valve is operating prop-
erly.
Figure 2-2. Pot-Hole-Protection Bars Lowered.
2. From the platform control console:
a. Ensure that the control console is properly mounted
and secure.
b. Raise and lower platform 2 ft. to 3 ft. (.61m to .92 m) sev-
eral times. Check for smooth elevation and lowering of
platform.
c. Operate all functions, check all limit, cut-out, and
enable switches are functioning properly:
• Machine Brakes - Drive the machine on a grade,
(do not exceed the rated gradeability), and stop
to ensure the brakes hold.
• Tilt Warning Limit - With the platform completely
lowered, drive the machine onto a surface with a tilt
of more than 1.5° in any direction (do not exceed
rated gradeability). The machine will indicate a tilt
3121230 – JLG Lift – 2-7
SECTION 2 - PREPARATION AND INSPECTION
condition if any attempt is made to elevate the platform.
• Drive Speed Reduction Limit - When platform is
elevated more than 1.5 to 2 ft. (.5m) drive speed is
cut to 1/4 of platform lowered drive speed.
• Platform Joystick Enable Trigger - The machine
will not operate (drive or lift) unless this switch is
pressed and held during drive or lift operation.
d. Ensure all machine functions are disabled when the
Emergency Stop Button is activated (pressed in).
2-8 – JLG Lift – 3121230
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
SECTION 3. MACHINE CONTROLS, INDICATORS AND OPERATION
3.1 GENERAL
THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION. THE USER AND OPERATOR ARE RESPONSIBLE FOR
CONFORMING WITH GOOD SAFETY PRACTICES.
This section provides the necessary information needed to
understand control function and operation.
3121230 – JLG Lift – 3-1
3.2 MACHINE DESCRIPTION
The JLG MVL/MSP Model Lifts are electric self-propelled
machines with an aerial work platform mounted to an elevating
aluminum mast mechanism. The personnel lift’s intended purpose is to provide personnel access to areas above ground level.
The MSP model lift is intended for stock picking purposes in
retail stores or warehouses to allow placing and removing of
stock from storage or display areas.
The primary control station is located in the platform. From the
Platform Control Console the operator can drive the machine
and raise or lower the platform.
The controls of the programmable Ground Control Station are
to be used during machine power-up, machine maintenance or
in case of emergency should the operator in the platform be
unable to lower the platform.
Vibrations emitted by these machines are not hazardous to an
operator working in the platform.
The continuous A-Weighted sound pressure level at the work
platform is less than 70db (A).
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
3.3 MACHINE OPERATION
Getting Started
The following control conditions must be met before the
machine can be operated from either the Ground or Platform
Controls.
• The batteries contain enough voltage to operate the
machine.
• The Main Power Selector Switch on the Ground Control Station must be set for either Ground Control Mode or Platform Control Mode.
• Both Emergency Stop Switches, one on the Ground Control
Station the other on the Platform Control Console must be
in the RESET position.
• If equipped, the On/Off Key Switch on the Platform Console
must be set to the ON position.
3.4 BATTERY CHARGING
This machine is equipped with an AC voltage input/DC voltage
output battery charger. The charger automatically terminates
charging when the batteries reach full capacity.
NOTE: The platform drive function is disabled when the battery
charger is plugged into an AC receptacle.
LEAD ACID BATTERIES MAY GENERATE EXPLOSIVE HYDROGEN GAS DURING
NORMAL OPERATION. KEEP SPARKS, FLAMES, AND SMOKING MATERIALS
AWAY FROM BATTERIES. PROVIDE ADEQUATE VENTILATION DURING CHARGING. NEVER CHARGE A FROZEN BATTERY. STUDY ALL BATTERY MANUFACTURERS’ SPECIFIC PRECAUTIONS SUCH AS RECOMMENDED RATES OF CHARGE
AND REMOVING OR NOT REMOVING CELL CAPS WHILE CHARGING.
3-2 – JLG Lift – 3121230
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
Battery - Low Voltage Warning Indicators
The MVL/MSP Platform Control Console and Ground Control Station indicate battery low voltage at three (3) Warning Levels.
Table 3-1. Battery Low Voltage Warning Indicators.
WARNING
LEVEL
PLATFORM CONTROL LED GROUND CONTROL LCD
LEVEL-1
LEVEL-2
LEVEL-3
NOTE: (a) To maximize battery life, it is recommended that the factory supplied batteries be charged continuously for a minimum of 4 hours or until 8 bars are lit on the ground station LCD Display
before operating the machine. When drained to Warning Level 2 or 3, batteries must be charged until 8 bars are lit on the ground station LCD display to clear the fault code.
INDICATOR LOCATION
RESULT ACTION REQUIRED TO CLEAR FAULT
• 3 LEDs/BARS Flashing with an audible
beep.
• Machine will Operate - No Control
Functions Locked Out.
• 2 LEDs/BARS Flashing with an audible
beep.
• Platform Lift-UP Function is Locked
Out.
• 1 LED/BAR Flashing with an audible
beep.
• Drive and Platform Lift-UP Functions
Locked Out.
Charge batteries to a level of four (4)
LEDs/BARS or more before operating.
Charge batteries for a minimum of four
(4) continuous hours or eight (8) LEDs/
BARS lit before operating. (a)
Charge batteries for a minimum of four
(4) continuous hours or eight (8) LEDs/
BARS lit before operating. (a)
3121230 – JLG Lift – 3-3
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
To Charge Batteries
1. Park machine in a well ventilated area near an AC voltage electrical outlet.
2. Always use a
grounded AC outlet.
Connect charger to
an outlet that has
been properly
installed and
grounded in accordance with all local
codes and ordinances. A grounded
outlet is required to
reduce risk of electric shock – do not
use ground adapters or modify plug.
When using an
extension cord,
avoid excessive voltage drops by using a
grounded 3-wire 12
AWG cord.
Battery Charging Status Indicators
The battery charging status indicators are located just above the
Charger AC input receptacle on the center cover section at the
rear of the machine. (See Figure 3-1. on page 3-8)
1. When plugged in the charger will automatically turn
on and run through a short LED indicator self-test (all
LED’s will flash in an up-down sequence for two seconds).
2. The YELLOW ‘CHARGING’ LED will turn on and a trickle
current will be applied until a minimum voltage is
reached.
CHARGING
YELLOW (MIDDLE) LED ON
Charge Incomplete
Once a minimum battery voltage of 2 volts per cell is
detected, the charger will enter the bulk charging constant-current stage and the YELLOW ‘CHARGING’ LED
will remain on. The length of charge time will vary by
how large and how depleted the battery pack is, the
input voltage (the higher, the better), and ambient
temperatures (the lower, the better). If the input AC
voltage is low (below 104VAC), then the charging
3-4 – JLG Lift – 3121230
Loading...