JLG DVSP Operator Manual

Download

Operation and Safety Manual

Keep this manual with the machine at all times.

Model(s)

DVL &

DVSP

Series

P/N - 3121135

September 27, 2005

FOREWORD

This manual is a ve ry important too l! 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 int ended purpose. Due to continuous pro du ct imp ro v em en ts , JLG Industries, Inc. re se rv es th e right to make specification changes

without prior notification. Contact JLG Industries, Inc. for updated information.

Other Publications Available:

Service and Maintenance Manual .......................................................3121136

Illustrated Parts Manual (ANSI/CSA) ...................................................3121137

Illustrated Parts Manual (CE)...............................................................3121839

3121135 – JLG Lift – a

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

This is the Safety Alert Symbol. It is used to alert yo u to the potential personal injury hazards. Obey all safety messages that follow this symbol to avoid poss ibl e injury or death

INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL DECAL WILL HAVE A RED BACKGROUND.

INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD DECAL WILL HAVE AN ORANGE BACKGROUND.

RESULT IN SERIOUS INJURY OR DEATH. THIS

INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY ALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVE A YELLOW BACKGROUND.

RESULT IN MINOR OR MODERATE INJURY. IT MAY

IMPORTANT

INDICATES PROCEDURES ESSENTIAL FOR SAFE OPERATION. THIS DECAL WILL HAVE A GREEN BACKGROUND.

b – JLG Lif t – 3121135

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

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.

IMPORTANT

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.

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 PRO DUCT.

FOR :

•Accident Reporting

•Product Safety Publications

•Current Owner Updates

•Questions Regarding Product Safety

•Standards and Regulatio ns Compliance Information

•Questions Rega rd in g Special Product Applica t io ns

•Questions Regarding Product Modifications

CONTACT :

Product Safety and Reliability Department JLG Industries , Inc. 1 JLG Drive McConnellsburg, PA 17233

or Your Local JLG Office (See addresses on back cover of manual)

In USA: Toll Free: 877-JLG-SAFE

877-554-7233

Outside USA:

717-485-5161

E-mail: ProductSafety@JLG . com

3121135 – JLG Lift – c

REVISION LOG

October 1, 2001 – Original Issue of Manual November 19, 2001 – Manual Revised December 13, 2001 – Manual Revised February 22, 2002 – Manual Revised October 29, 2002 – Manual Revised January 22, 2003 – Manual Revised February 18, 2003 – Manual Revised August 9, 2004 – Manual Revised May 6, 2005 - Manual Revised July 25, 2005 – Manual Revised September 27, 2005 – Manual Revised

REVISION LOG

d – JLG Lif t – 3121135

TABLE OF CONTENTS

SUBJECT - SECTION, PARAGRAPH PAGE NO.

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a

SAFETY ALERT SYMBOL S AN D SAFETY SIGNAL WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b

REVISION LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . d

SECTION 1 - SAFETY PRECAUTIONS

1.1 GENER AL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 PRE-OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Operator Training And Knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Workplace Inspec t i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.3 OPERA TION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Trip and Fall Hazar d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Electrocutio n Ha z ard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Tipping Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Crushing And Collision Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

SECTION 2 - PREPA RATION AND INS PECTION

2.1 PERSONNEL TRAI NIN G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Operator Training. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Training Supervis ion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Operator Respon s ibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 1

2.2 PREPARATION, IN S PECTION, AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

2.3 PRE-START INSP ECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

2.4 DAILY WALK-AROUND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

2.5 FUNCTION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

SECTION 3- MACHINE CONTROLS, INDICATORS AND OPERATION

3.1 GENER AL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3.2 MACHINE DESCRI P TION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3.3 MACHINE OPERATIO N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Getting Start e d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3.4 BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Battery Low Voltage Warning Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

To Charge Batter ie s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Battery Chargi ng Status Indicat ors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3.5 GROUND CONTROL STATION - OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Main Power Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Emergency Stop/Shut Down Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Master Disconnec t Switch - (EE Option Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Brake Release But t on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Platform Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Platform Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Manual Descent Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Machine Status LCD Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

LCD Display Fault Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

3121135 – JLG Lift – i

TABLE OF CONTENTS

3.6 GROUND CO N TROL STATION - PROGRAMMING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Programming Lev e l s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Operator Programming Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Activating Programming Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Entering Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Programming Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Selecting Progr ammable Item to Adju s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

Adjusting Progr ammable Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

3.7 PLATFORM CONTROL CONSOLE OPERATION -

(MACHINES SERIAL NUMBER - 0130007616 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . .3- 11

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Platform On/Off Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

Platform Eme rgency Stop/Shu t Down Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

Platform Control Display Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

Drive/Lift Mode Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3- 13

Joystick Function Enable Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

Multifunction Joystick Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

Drive Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

Lift Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Drive Speed Setting Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

3.8 PLATFORM CONTROL CONSOLE OPERATION -

(MACHINES BEFORE SERIAL NUMBER - 0130007616) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

At Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

Emergency Sto p/Shut-Down But t on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

Battery Charg e /Fault Code LED Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

Driving Machi ne. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

Adjusting Maxi mum Drive Speed Cont r ol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 -17

Elevating/Lowering the Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

3.9 PARKI N G M ACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

3.10 PROGAMMABLE SECURITY LOCK (PSL™) (DVL/DVSP - OPTION) . . . . . . . . . . . . . . . . . . . . . .3-18

PSL™ Box and Ground Control Locati ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

Machine Power Up u s ing the PSL™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

Machine Power Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

Changing the Operator’s Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

3.11 PLATFORM CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

StockPicking Platform Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

3.12 FA L L PRO TECTION - LANYARD ATTACHMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3- 2 1

3.13 QUICK-CHANGE PLA T FO RM MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

Platform Rem ov al. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

Platform Inst al l ation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

3.14 OBSTRUCTION SENSIN G SY STEM (DVSP - OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3- 2 2

System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

OSS Pre-Start Ins pe ction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

3.15 TRANSPORTING, LIFTING AND TIE DOWN PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

Truck Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

Machine Tie-D own. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

Crane Hook Acce s sory (DVL Option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

Fork-Lift Truck Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

3.16 RUG CA R RIER ACCESSORY (DVSP - OPTION). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3- 2 5

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

ii – JLG Lift – 3121135

Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Hanging a Rug using the Rug Carrier Accessory Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Removing a Rug using Rug Carrier Accessory Arm s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

3.17 STOCK-PICKER HANGER ACCESSORY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

Loading and Transporting an Item using the Hanger Accessory. . . . . . . . . . . . . . . . . . . . .3-27

SECTION 4 - EMERGENCY PROCEDURES

4.1 GENERAL INFORMATI O N. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.2 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Operator Unabl e to C ont rol Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Platform Caught Overhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.3 INCIDENT NOTIFICA TION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

SECTION 5- GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

5.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.2 GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Electrical Spec ifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Platform Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Machine Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Serial Number Lo c at i ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5.3 OPERATOR MAINTE N AN CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

TABLE OF CONTENTS

SECTION 6 - INSPECTION AND REPAI R LOG

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

2-1. Daily Walk-Around Inspection for DVL/DVSP Machines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

3-1. Battery Charger Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3-2. Ground Control Stat ion. (Machine Rear View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

3-3. Platform Control Console (Machines Serial Number - 0130007616 to Present) . . . . . . . . . . . . . .3-11

3-4. Platform Control Display Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

3-5. Platform Control Console (Machines Before Serial Number - 0130007616) . . . . . . . . . . . . . . . . .3-15

3-6. PSL™ Switch & Groun d Control Station Locations - At Rear of Machi ne .. . . . . . . . . . . . . . . . . . .3-18

3-7. PSL™ Switch Controls & Indicators.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

3-8. OSS Transducer Sens or Array Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

3-9. OSS - Pre-Start Inspection of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

3-10. Crane Hook Accessory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

3-11. Forklift Truck Lifting Pockets and Machine Tie Down Bar Locations. . . . . . . . . . . . . . . . . . . . . . .3-24

3-12. DVL Series Decal Ins t all at ion Chart - (See Table 3-5 for Specification ). . . . . . . . . . . . . . . . . . . . .3-28

3-13. DVSP Decal Instal la t ion Chart - (See Table 3-6. for Specificatio n) . . . . . . . . . . . . . . . . . . . . . . . .3-30

3121135 – JLG Lift – iii

TABLE OF CONTENTS

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1 Minimum Safe Approach Distance (M .S.A.D.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

2-1 Inspect ion and Maintenance Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

3-1 DVL And DVSP - Mac hi ne Operating Spe cifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3-2 Battery Low Voltage Warning Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3-3 LCD Display - Ope r ating Fault Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

3-4 DVL/DVSP Ground Control Station - Level 3 - Programmable Settings and Factory Presets. . . .3-8

3-5 DVL Series - Dec a l Installation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29

3-6 DVSP Decal Installation Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

5-1 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

5-2 Lubrication Int e rvals for Variou s Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

6-1 Inspection an d Re pair Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

iv – JLG Lift – 3121135

SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL

This section outlines the necessary precautions for proper and safe machine usage and mainten ance. 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 t his manual has been read, training is accomplished, and operation of the machine has been completed under the supervision of an e xperienced and qu al ified 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 SAF ETY PRECAUTI ONS LISTED IN THIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

1.2 PRE-OPERATION

Operator Training And Knowledge

•Read and understand this manual before operating the machine.

• Do not operate this ma chine until complete training is performed by aut horized persons.

• Only authorized and qualified personnel can operate the machine.

•Read, understand, and obey all DANGERS, WARNINGS, CAUTIONS, and operatin g instruc tions on th e machine and in t hi s m an ual.

•Use the machine in a manner which is within the scope of its intended application set by JLG.

•All operating personnel must be familiar with the emergency controls and emergency operation of the machine as specified in this man ual.

• 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 inst r uctions.

•Do not operate this machine until it has been serviced and maintained according to requirements specified in the Service and Maintenance Manual.

3121135 – JLG Lift – 1-1

SECTION 1 - SAFETY PRECAUTIONS

•Ensure all safety devices are operating properly . Modifi cation of these devices is a safety violation.

MODIFICATIO N OR ALTE RATION OF AN AERI AL WORK PL ATFORM SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER

• Do not operate any machine on which the safety or instruction pl acards or decals are missing or ille gible.

• Avoid any build up of debris on platform floor. Keep mud, oil, grease, and other slippery substances fro m footwear and platform fl oor.

1.3 OPERATION

General

• Do not use the machine for any purpose other than positioning personnel, their tools and equipment, or for hand stock pick i ng.

•Never operate a machine that is not working properly. If a malfunction occurs , s hut 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 a full body harness with a lanyard attached to an authorized lanyard anchorage point. For further informa tion regard ing fall pr otection requ irements on JLG products, contact JLG Industries, Inc.

•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.

•Platform-to-s tructure 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.

1-2 – JLG Lift – 3121135

SECTION 1 - SAFETY PRECAUTIONS

Electrocution Hazard

Table 1-1. Minimum Safe Approach Distance (M.S.A.D.)

VOLTAGE RANGE

(PHASE TO PHASE)

0-50KV 10 (3)

Over 50KV to 200KV 15 (5) Over 200KV to 350KV 20 (6) Over 350KV to 500KV 25 (8) Over 500KV to 750KV 35 (11)

Over 750KV to 1000KV 45 (14)

NOTE: This Minim um Safe Approach D istance shall apply

except where employer , local, or governmental 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 f rom any el ectrical line or ap paratu s carrying up to 50,000 volts. One foot (0.3m) additional clearance is required for every additional 30,000 volts or less.

The minimum safe approach distance may be reduced if insulating barriers are installed to prevent contact, and if 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 safe approach distance shall be reduced to a distance within the designed working dimensions of the insulating barrier. This determination shall be made by a qualified person in accordance with employer, local, or governmental requirements for work practices near energized equipment.

MINIMUM SAFE APPROACH

DISTANCE - Feet (m)

Tipping Hazard

•The user should be familiar with the surface before driving. Do not exceed the allo wable sidesl ope and grade while driving.

•Do not elevate platform or d rive with platform elevated while on a slope, o r 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, conce al ed holes, and othe r pot e ntial 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 attem pting t o free th e machi ne. Use cranes, forklift trucks, or other appropri ate eq uipment to stabilize ma chine and remove pe r s onnel.

3121135 – JLG Lift – 1-3

SECTION 1 - SAFETY PRECAUTIONS

Crushing And Collision Hazard

•Personal protection equipment must be worn by all operating an d 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.

•Keep non-operating personnel at least 6 ft. (1.8m) away from machine dur ing all driving operations.

• Limit travel speed according to conditions of ground surface, congestion, visibility, slope, location of personnel, and other factors ca using ha zards 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 revers e .

•Exercise extreme caution at all times to prevent obstacles from striki ng or interfe ring w ith op erating contr ols and persons in the pl atform.

• Ensu re that ope rators of o ther overh ead and flo or level machines are awar e of the aerial work platfor m’s pr esence. 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 no t assist a stuck or disabled machine by pus hing or pulling except by pulling at the chassis tie-down bars.

•When lifting machine with a forklift, positio n forks on ly at designated areas of the machine. Lift with a forklift of adequate capa city.

•Refer to the Machine Operation section of this manual for lifting informatio n.

1-4 – JLG Lift – 3121135

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 maint ained 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 tha t 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 o r Dis tr ibuto r wil l provi de q ualif ied

people for training assistance with the first unit(s) delivered and fro m th at ti me forward as requested by the user or his/her personnel.

3121135 – 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 in creased as nece ssary when th e machine is used in a harsh or hostile environment, if the machine is used with increased fre quency, or if the machine is used in a severe manner.

Table 2-1. Inspection and Maintenance Table

TYPE FREQUENCY

Pre-Start Inspection

Pre-Delivery Inspection

(See Note)

Frequent Inspection

Annual Machine Inspection

Preventative Maintenance

Before using each day; or whenever there’s an Operator change.

Before each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG

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.

IMPORTANT

JLG INDUSTRIES, INC. RECOGNIZES A QUALIFIED JLG MECHANIC AS A PERSON WH O HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL.

PRIMARY

RESPONSIBILITY

User or Operator User or Operator Operator and Safety Manual

Owner, Dealer, or User Qualified JLG

SERVICE

QUALIFICATION

Mechanic

REFERENCE

Service and Maintenance Manual and applicable JLG inspection form

Service and Maintenance Manual

NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.

2-2 – JLG Lift – 3121135

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 Installa- tions" 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 Ma nual of Responsibilities (Domestic only) is enclosed in the weather resistant storage conta i ner.

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 bef ore add ing. DO NOT OVERFILL.

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 th e conditions lis ted in the f ollowing 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.

IMPORTANT

DO NOT OVERLOOK VISUAL INSP ECTION OF THE BASE FRAME UNDERSIDE. CHECK THIS AREA FOR OBJECTS OR DEBRIS WHICH COULD CAUSE EXTENSIVE MACHINE DAMAGE.

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.

FILL TO LINE on Hydraulic Reservoir indicates the proper level for hydraulic oil.

7. Funct ion Che ck – Check all machine controls for operation. (See Section 2.5)

If optional equipment is installed on this machine refer to Section 3 for specific Pre-Start Inspection and Operation instructions.

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 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 - Battery cables; no corrosion.

6. Platform Assembly and Gate - Quick-Change platform mounting and mounting pins; DVSP - platform fasteners; platform railings; entry bar or gate in proper working or der.

7. Platform Control Console - Platform control; plac- ards 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 rotating freely.

3121135 – JLG Lift – 2-3

SECTION 2 - PREPARATION AND INSPECTION

Figure 2-1. Daily Walk-Around Inspection for DVL/DVSP Machines.

1. Drive and Caster Wheels 4. Motor/Pump/Reservoir Unit 7. Platform Control Console

2. Base Frame 5. Batteries (Open Cover Doors) 8. Ground Control Station

3. Manual Descent Control Valve 6. Platform Assembly 9. Mast Assembly

2-4 – JLG Lift – 3121135

SECTION 2 - PREPARATION AND INSPECTION

2.5 FUNCTION CHECK

Once the “Walk-Around” Inspection is c omplete , perfor m a function check of all systems in an area free o f o verhead 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 MAINT ENANCE PERS ONNEL. DO NO T 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.

NOTE: Ensure Pot-Hole-Protection device is fully engaged

(both bars down) when the platform is elevated .

b. Ensure that all machine functions are disabled

when the Emergency Stop Button is activated.

c. Check Manual Descent Control valve is operat-

ing properly.

2. From the platform control console:

a. Ensure that the control console is properly

mounted and secure.

b. Raise and lo wer p l atfo rm 2 ft. to 3 ft. (.61m to .92

m) several times. Check for smooth elevation and lowering of pl atform.

c. Operate all functions and check all limit and cut-

out switches.

d. Ensure that all machine functions are disabled

when the Emergency Stop Button is activated.

3. With platform in the transport (stowed) positio n:

a. Drive the machine on a grade, not to exceed the

rated grade ability, and stop to ensure the brakes hold.

b. Check the 1.5 degree tilt sensor alarm to ensure

proper operation.

3121135 – JLG Lift – 2-5

SECTION 2 - PREPARATION AND INSPECTION

This page intentionally left blank.

2-6 – JLG Lift – 3121135

SECTION 3 - MAC HINE CONTROLS, INDICATORS AND OPERATION

SECTION 3. MACHINE CONTROLS, INDICATORS AND OPERATION

Table 3-1. DVL And DVSP - Machine Operating Specifications

15DVL 20DVL 15DVSP 20DVSP

Maximum Occupants: 1 Maximum W ork Load (Capacity) :

(DVL-Std. Platform / DVSP - Stockpicker Platform)

Maximum T r avel Grade (Gradeabilit y):

(Platform STOWED ONL Y)

Maximum T ravel Grade (Side Slope):

(Platform STOWED ONL Y)

500 lb.

(230 kg)

350 lb.

(160 kg)

20%

5°

500 lb.

(230 kg)

400 lb.

(180 kg)

Machine Height (Platform Stowed) 78 in. (198cm) Maximum Vertical Platform Height: 15 ft. (4.57 m) 19.5 ft. (5.94 m) 15 ft. (4.57 m) 19.5 ft. (5.94 m) Maximum Wheel Load (Per Wheel): 800 lb. (360 kg) Maximum Drive Speeds (Operator Variabl e): 0.5 - 2 mph (0.8 - 3.2 kph)

Max. Platform Speeds (w/Max. Load): Plat-

20 sec. 22.5 sec. 20 sec. 22.5 sec.

form Up:

Platform Down: 15 - 21 sec. 21 - 26 sec. 15 - 21 sec. 21 - 26 sec.

Gross Machine Weight (Standard Equipment/Platform Empty):

2,105 lb. (955 kg)

2,105 lb.

(955 kg)

2,150 lb. (975 kg)

2,150 lb.

(975kg)

3121135 – JLG Lift – 3-1

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

3.1 GENERAL

IMPORTANT

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 oper ation.

3.2 MACHINE DESCRIPTION

The JLG DVL and DVSP 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 DVSP model lift is intended for stock picking pur poses in retail store s or wa rehouses.

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 hazar dous to an operator working in the platform.

The continuous A-Weighted sound pressure level at the work platform is less than 70db (A).

3.4 BATTERY CHARGING

DVL and DVSP machines are equipped with an AC voltage input/DC voltage output battery charger. The charger automatically terminates charging when the batteries reach full capaci ty.

NOTE: The machine’s platform drive function is disabled

when the battery charger is plugged into an AC receptacle.

Figure 3-1. Battery Charger Location.

1. Battery Charger

NOTE: Machines built to the UL-EE electrical specification

(option) include additional controls and design features. These controls are labeled as (EE Only).

3.3 MACHINE OPERATION

Getting Started

The following control conditions must be met before the machine can be operated from either the G round or Platform Controls.

• The batteries contain enough voltage to operate the machine.

• The Main Power Selector Switch on the Gound Control Station must be se t for eith er Grou nd C ontrol Mode or Platform Control Mode.

• Both Emergency Stop Switches, one on the Ground Control Station the other on the Platform Contr ol 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.

Battery Charger Fron t Panel

1. 120V/5 Amp Breaker 3. 240V/5 Amp Breaker

2. AC Input Voltage Selector

3-2 – JLG Lift – 3121135

SECTION 3 - MAC HINE CONTROLS, INDICATORS AND OPERATION

Battery Low Voltage Warning Indicators

The Platform Control Console and Ground Control Station indicate battery low voltage at three (3) Warning Levels.

Table 3-2. Battery Low Voltage Warning Indicators.

IMPORTANT: The 3 Levels of Battery Low Voltage Warning indication will only activate on Ground Control Modules with version 29 or later Ground Control Module software (implemented 8/2004). However, machines with earlier versions of software must follow the same LED/BAR indicator guidelines and battery charging cycles to maximize battery life.

WARNING

LEVEL

LEVEL-1 • 3 LEDs/BARS Flashing with

PLATFORM CONTROL LED GROUND CONTROL LCD

INDICATOR LOCATION

RESULT

an audible beep.

• Machine will Operate - No

ACTION REQUIRED TO

CLEAR FAULT

Charge b atteries to a level o f four (4) LEDs/BARS or more before

operating. Control Functions Locked Out.

LEVEL-2 • 2 LEDs/BARS Flashing with

an audible beep.

• Platform Lift-UP Function is Locked Out.

LEVEL-3 • 1 LED/BAR Flashing with an

audible beep.

•Drive and Platform Lift-UP Functions Locked Out.

Charge batteries for a minimum of four (4) continuous hours or eight (8) LEDs/BARS lit before operatin g. (a)

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 be fore operating the machine. When drain ed to Warning Level 2 or 3, batteries must be charged until 8 ba rs are lit on the ground station LCD display to clear the fault code.

To Charge Batteries

1. Park machine in a well ventilated area near an AC voltage electrical outlet.

2. Check the AC voltage selector switch on front of the battery charger is set to correct local AC voltage.

NOTE: The batteries on DVL/DVSP machines require

approximately five (5) hours to fully charge when drained to LOW BATTERY VOLTAGE warning on the Ground Control Module LCD display.

Battery Charging Status Indicators

The battery charging status indica tors are located just above the Charger AC input receptacle on the center cover section at the rear of the machine. (See Figure 3-2.)

When first plugged in, the charger runs through a selfdiagnostic test, lighting the LEDs in sequence, then charging will begin.

CHARGE COMPLETE

GREEN (TOP) LED ON 100% Complete

3. Plug a h eavy duty

AC extensio n cord into the Charger AC Input Receptacle on the center rear cover of the machine.

CHARGING

AMBER (MIDDLE) LED ON Charge Incomplete

CHARGING PROBLEM

RED (BOTTOM) LED ON

Consult Troubleshooting Section of the Serv ice Manual.

3121135 – JLG Lift – 3-3

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

3.5 GROUND CONTROL STATION OPERATION

(See Figure 3-2.)

NOTE: If equipped with optional Programmable Security

Lock (PSL) see Section 3.10 for additional instructions.

Main Power Selector Switch

Set the Main Power Selector Switch to Ground Control Mode at the Ground Control Station

Emergency Stop/Shut Down Button

POWER OFF

PUSH IN To Engage Emergency Stop

Brake Release Button

PUSH and RELEASE TO DISENGAGE Brakes

PUSH and RELE A S E AGAIN TO ENGAGE Brakes

NOTE: The brakes only DISENGAGE (electrically) when the

joystick control is moved off center during driving or are manually DISENGAGED (electrically) using the the Brake Release Button. If the machine’s batteries are completely depleted of electrical charge the brakes cannot be released manually.

CAUTION

DO NOT MANUALLY DISENGAGE T HE BRAKES UNLESS MACHINE IS SETTING ON A LEVEL SURFACE OR MACHINE IS FULLY RESTRAINED.

Platform Up

PUSH IN TO ELEVATE Platform

RELEASE TO STOP ELEVATING

POWER ON

TURN CLOCKWISE and RELEASE To Reset Emergency Stop

Master Disconnect Switch - (EE Option Only)

POWER ON

Lever is pointing

xxxxxxx

straight out towards left side of machine.

POWER OFF

Lever is TURNED COUNTERCLOCKWISE towards decal.

Platform Down

PUSH IN TO LOWER Platform

RELEASE TO STOP LOWERING

Manual Descent Control Valve

PUSH-IN TO LOWER Platform

RELEASE TO STOP Platform Descent

3-4 – JLG Lift – 3121135

SECTION 3 - MAC HINE CONTROLS, INDICATORS AND OPERATION

xxxxxxx

FILL TO LINE

Figure 3-2. Ground Control Station. (Machine Rear View)

1. Machine Status LCD Display 5. Platform Up 9. Hydraulic Oil Reservoir

2. Main Power Selector Switch 6. Platform Down 10. Manual Descent Control Valve

3. Emergency Stop 7. Battery Char ging Status Indicators 11. Master Power Disconnect Switch (UL - EE Only)

4. Brake Release 8. Charger A/C Input Receptacle

3121135 – JLG Lift – 3-5

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

Machine Status LCD Display

At power-up and during operation the LCD display on the Ground Control Module displays the current machine operating status. The following illustration explains the symbol indication s.

00000.0

In the LCD Display Symbols illustration item (2), the Function Display or Function Disabled Indicators will vary as shown followi ng:

DRIVE Disabled

LIFT UP Disabled

LIFT DOWN Disabled

Both LIFT UP and LIFT DOWN Disabled

Drive Speed Cut-Back (Turtle) Mode Engaged (When Platform is Elevated)

LCD Display Symbols

1. Battery Charge Indicator (BCI)

2. Function Display or Function Disabled Indicators

3. Hour Meter Display

4. Fault Code Indicator

5. Fault Text Message Display (a)

Note: (a) When an Fault Code is indicate d the LC D sc reen will

alternate between the text and symbol display modes.

Battery Charger (AC) Plugged In

LCD Display Fault Conditions

Table 3-3, LCD Display - Operating Fault Conditions show common LCD display Fault i ndications wh ich may occur during operation and are usually caused by either an erro r in machine operation or a work area condition. These fault conditions can usually be corr ected by the ope rator and do not require a qualified mechanic to repair.

IMPORTANT

AFTER A FAULT CONDITION IS CORRECTED THE MACHINE POWER MAY NEED TO BE RECYCLED TO RESET THE GROUND CONTROL STATION.

3-6 – JLG Lift – 3121135

SECTION 3 - MAC HINE CONTROLS, INDICATORS AND OPERATION

Table 3-3. LCD Display - Operating Fa ult Conditions

PLATFORM FAULT CODE

CONSOLE

LED FAULT

CODE

LCD SYMBOL SCREEN LCD TEXT SCREEN

——

00000.0

—— NONE

00000.0

——

00000.0

——

00000.0

02 2

00000.0

03 2

00000.0

04 3

00000.0

13 6

00000.0

17 7

00000.0

32 7

00000.0

33 2

00000.0

34 —

35 —

FAULT DESCRIPTION/ MACHINE CONDITION

Brakes Released (DRIVE Disabled)

Charger AC Plugged In DRIVE Disabled

Obstruction Sensor System (Platform Elevated) LIFT DOWN Disabled

Programmable Security Lock Password

Left PHP Bar UP (Platform Elevated)

DRIVE and Lift UP Disabled Right PHP Bar UP

(Platform Elevated)

DRIVE and Lift UP Disabled Tilt Condition

(Platform Elevated)

DRIVE and Lift UP Disabled Traction Module

Over T emperature

(DRIVE Disabled) Ground Control Module

Over T emperature

(Machine Stopped) Pump Motor Over Current

(LIFT UP Disabled)

Both PHP Bars UP DRIVE and Lift UP Disabled

Aux. #1 - Platform Gate Open or No Pressure on the Platform Enable switch.

Aux. #1 - Platform Enable switch depressed during Machine Power-up.

LOOK FOR THIS

T o Engage Brakes - Press Brake Release Button on Ground Contr ol Station

Unplug Charger AC Power Cord

Obstruction Under Platform or Sensor Defective

Enter Code on PSL Ke ypad to Powe r-Up Machi ne

Lower Platform and Ch eck the Left Pot Hole Protection Bar

Lower the Platform and Check the Right P ot Hole Protection Bar

Lower the Platform and Drive off the Tilt Condition

Allow Dri ve System T ract ion Module to Cool Before Operating

Allow Ground Control Module to Cool Before Operating

Platform Load Over Capacity

Check for Object Blocking Both the Left and Right PHP Bars

Close Platform G ate or Depress Platform Enable switch during machine operation.

Do Not Press on P latform Enable switch during Machine P ower -Up.

NOTE: The fault conditi ons sh own above are fault cond itions whic h the O perato r may be able t o resol ve. Should a fault

occur and be displayed on the LCD screen which cannot be corrected at the Operator’s level, the problem must be referred to a quali fied m echan ic. A comp le te tab le o f Fault Codes is listed in the TroubleSh ooting Sectio n of the Service and Maintenance Manual.

3121135 – JLG Lift – 3-7

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

3.6 GROUND CONTROL STATION PROGRAMMING

General

The DVL/DVSP mach ine Ground Control Stat ion allows on-board prog r amming of various co mponent and cont rol function personality settings.

Programming may be required under circumstances such as:

• Optional equipment has been added to the machine in the field and a function must be enabled before operation.

• Customizing the machine to fit a specific application, such as changing the LCD display language.

Programming Levels

There is one (1) password protected programming level available to the Operator:

• Level-3: Operator’s Settings -

Level-3 Password: 33271

Operator Programming Mode

In the Operator Level Programming Mode the following items are shown on the main menu (See Table 3-4 f o r S et- ting Range and Default Factory Setting):

•Tilt Sensor

•Program

•Tilt Sensor

Allows viewing current tilt sensor individual X and Y direction degree reading.

•Program

Allows programm ing of the items shown in Table 3-4, the following is a brief explanation of each programming item.

NOTE: There are two produc tion modules available at this

time, one for North/South American and European languages, and one for Asian languages. All programmable items between these modules are identical with the excepti on of lang uage selection.

• Back To Main - When selected, will return to main level menu.

• Set Language - Selects the language that text on the LCD screen will be displ aye d.

• Set Sleep Time - Allows setting the length of time the machine will remain powered up without control input before po we r ing itself down.

• Set Polarity of Keypad Code - Turns on or off the Programmable Security Lock switch circuit, if equipped.

• Enable Detection of Horn Open Circuit - Enables horn electrical circuit to be turned on (YES) or off (NO) if machine is equipped with a horn.

Table 3-4. DVL/DVSP Ground Control Station - Level 3 - Programmable Settings and Factory Presets.

Level-3: Operator Progr ammable Setti ngs On LCD Disp lay: YES =

LEVEL PROGRAMMABLE ITEM

3 Back to Main — Return to Main Menu 3 Set Language

NOTE: There are two production modules available at this

time, one for Nor th/South Americ an and European Languages, and one for Asian Languages.

3 Set Sleep Time 5 MINS 0 - 60 MINS 3 Set Polari ty of the Keyp ad Code L OW HIGH/L OW 3 Enable Detection of Horn Open Circuit NO (a) YES/NO 3 Enable Detection of Beacon Open Circuit NO (a) YES/NO 3 Forward Alarm Disable NO YES/NO 3 OSS Diagnostics NO YES/NO

Notes: (a) DVSP Models this feature is standard equipment and preset to YES at factory.

FACTORY

PRESET

1 1 - English 6 - Italian

2 - German 7 - Swedish 3 - Dutch 8 - Brazilian Portuguese 4 - French 9 - Finnish 5 - Spanish

2 1 - English 3 - Japanese

2 - Chinese

NO =

SETTING RANGE

HIGH = LOW =

↑ ↓

3-8 – JLG Lift – 3121135

SECTION 3 - MAC HINE CONTROLS, INDICATORS AND OPERATION

• Enable Detection of Beacon Open Circuit - Enables mast/base beacon strobe electrica l circuits to be turned on (YES) or off (NO) if machine is equipped with either or both beacon strobes.

• Forward A larm Disable - When turned on (YES) will disable the alarm wh e n dr iving forward.

• OSS Diagnostics - When turned on (YES) will cause the controller LCD to continuously display the Obstruction Sensing System (OSS) Diagnostics until

turned back off (NO)...... .the machine wil l function

normally, but only the OSS Diagnostics screen will display until this setting is re-set to the off (NO) position.

Activating Programming Mode

NOTE: If machine does not power up, check that both the

Ground Control Station - Emergency Stop Button, and the Platform Control Console - Emergency Stop Button, are in the RESET position. Also if machine is equipped with the (PSL) Programmable Security Lock option, see Section 3.5 of this Operators Manual for additional machine power-up steps.

Entering Password

00000

1. The Brake Release button (1) moves the box from left

to right to select which digit to change.

2. Platform UP button (2) increases the numerical digit.

3. Platform DOWN button (3) decreases the numerical

digit.

4. Change all five digits (4) to match password level, then press the Brake Release button (1) again.

1. W ith machine power OFF, press and hold the Brake

Release Button (1) on the Ground Control Station.

2. While holding the Brake Release Button in, power machine up by turning the Main Power Selector Switch (2), to either the Ground Control or Platform Control Mode.

3. Release the Brake Release Button (1) after machine is powered up. The LCD display should now display five zeros, one wit h a box around . Continue to n ext step Entering Password.

Programming Mode Selection

1. Use Platform UP/DOWN buttons (1) to move the

selection box (2) up or down to select item to program.

2. Press the Brake Release button (3) to enter selected mode then move on to Selecting Programmable Item to Adjust.

3121135 – JLG Lift – 3-9

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

Selecting Programmable Item to Adjust Adjusting Programmable Setting

1. Use the Platform UP/DOWN buttons (1) to scroll

through the list of programmable items available to your programming level.

2. Once a programmable item to be adjusted is selected, press the Brake Release button (2) to enter that settings’ adjustment mode.

1. Adjust the programmable setting using the Platform

UP/DOWN buttons (1), see Table 3-4 for range of settings for that item.

2. Once parameter is set for the programmable item, press the Brake Release button (2), this will enter the parameter and return you to the Programmable Settings Menu.

TO EXIT Programming Mode after adjusting programmable settings, power machine down w ith either the Main Power Selector Switch or Emergency Stop Button.

3-10 – JLG Lift – 3121135

SECTION 3 - MAC HINE CONTROLS, INDICATORS AND OPERATION

3.7 PLATFORM CONTROL CONSOLE OPERATION - (MACHINES SERIAL NUMBER 0130007616 TO PRESENT)

1. On/Off Key Switch -

(See page 3-12)

2. Emergency Stop/Shut D own Button (See page 3-12)

3. Functio n Enable Lever - (on front of joystick) (See page 3-13)

4. Multifunction Joystick Control (See page 3-13)

5. Drive Speed Setting Selector Switch (See page 3-14)

6. Platform Control Display Panel (See page 3-12)

7. Horn Button - (See page 3-13)

8. Drive/Lift Mode Selector Switch -

(See page 3-13)

Figure 3-3. Platform Control Console -

(Machines Serial Number - 0130007616 to Present)

General

The following conditions must be met before the machine can be operated from the platform control console:

• Ground Control Station - Main Power Selector Switch must be set to PLATFORM CONTROL MODE.

• Ground Control Station - Emergency Stop/Shut Down Button must be in the RESET position (POWER ON).

NOTE: See Section 3.5 on page 3-4, for Ground Control

Station operation.

• Platform Console - On/Off Key Switch must be set to the ON position.

• Platform Console - Emergency Stop/Shut Down Button must be in the RESET po sition (POWER ON).

• If equipped with the OPTIONAL - PSL (Programmable Security Lock) it must be set to the ON position.

NOTE: See Section 3.10 on page 3-18, for locati on a nd PSL

instructions.

NOTE: SLEEP MODE - During operation if no control func-

tions have been activated for 10 minutes (default programmable setting), the ground control module will power the machine down to conserve battery power. Cycle power back on using either the main power selector switch (key) or the emergency stop/ power down button either on the platform controller or on the ground control station.

3121135 – JLG Lift – 3-11

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

Platform On/Off Key Switch

Set the ON/OFF Key Switch to th e OFF posi tion to pow er machine down.

NOTE: If necessary, when machine is not in use, remove

key from platform key switch to disabl e machi ne from unauthorized use.

NOTE: During operation the operator in the platform can

prevent unauthorized control of the machine (from the Ground Control Station) by either switching the On/Off Key to the OFF position, or activating the Emergency Stop Button on the platform control console.

At the Platform Control Cons ole Set the On/Off Key Switch to th e ON position (2) to operate machine.

1. OFF Position

2. ON Position

Platform Control Display Panel

Figure 3-4. Platform Control Display Panel.

1. Battery Charge/Flash Code LEDS

2. Drive Mode Indicator

3. Lift Mode Indicator

4. Drive Speed Setting

Indicator

Platform Emergency Stop/Shut Down Button

NOTE: The Platform and Ground Control Station Emer-

gency Stop/Shut Down Buttons must both be in the RESET position to operate machine.

POWER OFF

PUSH IN TO ENGAGE Emergency Stop

POWER ON

TURN CLOCKW ISE and RELEASE to RESET Emergency Stop

1. Battery Charge/Flash Code Indicator LEDS On normal pow er-up and operation this series of ten

(10) LEDs visually indicates the amount of charge remaining in the batteries.

The number of LEDs lit will change depending on the level of charge in the batteries.

• (+) All Three (3) GREEN LEDs lit up indicate maxi-

mum battery charge.

• Four (4) YELLOW LEDs indicate a two thirds to one

third battery charge remaining.

• (–) Three (3) RED LED’s lit indicate minimum battery

charge remaining. The mach ine will continue to operate at this charge level but will begin to indicate low battery voltage warning indicators.

NOTE: For more information on Battery Warning Level Indi-

cators See “Battery Low Voltage Warning Indicators” on page 3-3.

This set of ten (10) LEDs will also indicate a flash (fault) code if operating problems are detected by the Ground Control Station.

NOTE: LED Flash (Fault) Code indications that can be cor-

rected by the operator are shown on Table 3-3 on page 3-7, this section of the manual.

3-12 – JLG Lift – 3121135

SECTION 3 - MAC HINE CONTROLS, INDICATORS AND OPERATION

2. Drive Mode Indicator When the Drive/Lift Mode Selector Switch is set to

DRIVE MODE the round LED indicator on that portion of the display panel will light up indicating the DRIVE Mode active.

3. Lift Mode Indicator When the Drive/Lift Mode Selector Switch is set to LIFT

MODE the round LED indicator on that portion of the display panel will light up indicating the LIFT Mode active.

4. Drive Speed Setting Indicator The five (5) GREEN LEDs on the top of this indicator

display the drive speed setting with the TURTLE (on the left) representing the MINIMUM speed setting and the RABBIT (on the right) representing the MAXIMUM speed setting.

Drive/Lift Mode Selector Switch

1 2

1. LIFT Mode

2. DRIVE Mode

Horn Button

When the machine is powered on, pressing this button will sound the Horn.

Joystick Function Enable Lever

The Function Enable lever on the front of the joystick control, must be engaged and held in during any joystick operation.

PUSH the rocker switch to se lect mode of operation. Whichever mode is selected the appropriate LED indicat or on the display panel below will light up showing which mode has been activated for joystick operation.

IMPORTANT:

The selected mode will only remain active for 5 seconds if the function is not op erated.

Multifunctio n Joystick Contro l

The joystick will operate the following machine functions:

•Drive

•Platform Lift Up and Down

NOTE: Use the Drive/Lift Mode Selector Switch to select

which function the joystick will operate. The selected operating mode will only remain active for 5 seconds if the function is not operated. Remember to press and hold the joystick function enable lever to operate any joystick functions.

WARNING

WHEN DRIVING WITH PLATFORM LOWERED, DO NOT ATTEMPT TO DRIVE MACHINE UP A RAMP (GRA DE) OF GREA TER THAN FIFTEEN PER CENT (15%).

DRIVING WITH PLATFORM ELEVATED IS RESTRICTED TO A SMOOTH, FIRM AND LEVEL SURFACE WITHIN 1.5 DEGREES OF LEVEL IN AN Y DI RE CT ION .

3121135 – JLG Lift – 3-13

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

Drive Mode

WARNING

1. Activate the Drive Mode using the Drive/ Lift Mode Selector switch.

Within 5 seconds of activation - ENGAGE and HOLD the JOYSTICK ENABLE LEVER then move the joystick in the desired direction of travel. Drive power is applied proportionally the further the joystick is moved off center .

THE GROUND CON TROL STATION CONTAINS A 1.5 DEGREE TILT ALARM, IF THE TILT ALARM HAS BEEN AC TIVATED, THE PLATFORM WILL NOT ELEVATE. ALSO IF THE TILT ALARM HAS BEEN ACTIVATED WHEN THE PLATFORM IS ELEVATED, T HE DRIVE AND LIFT UP FUNCTIONS WILL BE DISABLED UNTIL THE PLATFORM IS COMPLETELY LOWERED, THEN DRIVEN OFF T HE TILT CONDITION.

Drive Speed Setting Controls

NOTE: When the platform is elevated the maximum drive

speed is automatically cut-back to 1/4th the speed when the platform is fully lowered. The Ground Control Module-LCD screen will display a turtle when in this mode, See page 3-6 - Ground Control - LCD Status Display in this section of the manual.

Lift Mode

1. Activate the Lift Mode using the Drive/Lift Mode Selector switch.

2. Platform LIFT DOWN Direction

3. Platform LIFT UP Direction

Within 5 seconds of activation - ENGAGE and HOL D the JOYSTICK EN ABLE LEVER then move the joystick in the direction of LIFT (3) OR LOWER (2).

Drive Speed Setting Selector Switch

1. Selector Switch (on top of joystick)

Each PRESS on this side of the switch will DECREASE maximum drive speed. (FEWER LEDs Lit up on the

Drive Speed Indicator .)

Each PRESS on this side of the switch will INC REA S E maximum drive speed. (MORE LEDs Lit up on the Drive Speed Indicator.)

3-14 – JLG Lift – 3121135

SECTION 3 - MAC HINE CONTROLS, INDICATORS AND OPERATION

3.8 PLATFORM CONTROL CONS OLE OPERATION - (MACHINES BEFORE SERIAL NUMBER -

0130007616)

Figure 3-5. Platform Control Console -

(Machines Before Serial Number - 0130007616

1. Battery Charge/Fault Code (LEDs) 4. Increase Max. Drive Speed 7. Platform Function (Enable)

2. Max. Drive Speed Setting (LEDs) 5. Horn 8. Joystick with Enable Button

3. Decrease Max. Drive Speed 6. Drive Function (Enable) 9. Emergency Stop

At Ground Control Station Emergency Stop/Shut-Down Button

Set the Main Power Selector Switch to Platform Control Mode at the Ground Control Station. (See Figure 3-2.)

3121135 – JLG Lift – 3-15

POWER OFF

PUSH IN TO ENGAGE Emergency Stop

POWER ON

TURN CLOCKW ISE and RELEASE TO RESET Emergency Stop

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

Battery Charge/Fault Code LED Indicator

–+

On normal power-up and operation this series of LEDs visually indicates the amount of charge left in the batteries.

• (+) GREEN LEDs lit indicate maximum charge.

• (–) RED LED’s lit indicate minimum charge remaining.

• The number of LEDs lit will change depending on the level of charge in the batteries.

If battery voltage falls below 16.8 volts a fault condition will occur and the machine will stop operating. The batteries will need recharged.

NOTE: LED Fault Code indications are in Table 3-3, LCD

Display - Operating Fault Conditions, this section of the manual.

Driving Machine

WARNING

WHEN DRIVING WITH PLATFORM LOWERED, DO NOT ATTEMPT TO DRIVE MACHINE UP A RAMP (GRA DE) OF GREA TER THAN TWENTY PER CENT(20%), AS TIPPING COULD OCCUR.

POINT G

1. Enter the platform.

POINT & GO

The Joystick can be moved in any direction off center.

Drive Power is applied proportionally the further the Joystick is moved off center.

2. PRESS and RELEASE the Drive Function Button. The flashing LED indicates the function is active. The function remains active 3 to 4 seconds.

3. While the Drive Function is active. PRESS and HOLD the enable button on top the joystick

POINT G

4. Move the joystick in the desired direction of travel. TO STOP the machine return the joystick back to center.

3-16 – JLG Lift – 3121135

SECTION 3 - MAC HINE CONTROLS, INDICATORS AND OPERATION

Adjusting Maximum Drive Speed Co ntrol

NOTE: When the platform is elevated the maximum drive

speed is cut-back to 1/4th the speed when the platform is fully lowered. The Ground Control ModuleLCD screen will display a turtle when in this mode, see Machine LCD Status Display in this section of the manual.

Maximum Drive Speed Indicator

1. Each Press of this button will

reduce the Maximum Drive Speed allowed. (LESS LEDs Lit.)

2. Each Press of this button will increase the Maximum Drive Speed allowed. (MORE LEDs Lit.)

Indicates current Maximum Dr i ve Speed Setting. Slow to Fast.

1. Drive the machine to the area where overhead work is to be performed and position the machine into it’s approximate work position .

2. PRESS and RELEASE the Platform Function Button. The flashing LED indicates the function is active and will remain active 3 to 4 seconds.

3. While the Platform Function is active. PRESS and HOLD the Enable Button on top the Joystick

4. Push the Joystick FORWARD from center TO ELEVATE the Platform.

TO STOP platform movement return the joystick back to center.

Pull the Joystick BACK from center TO LOWER the Platform.

Elevating/Lowering the Platform

WARNING

IF THE TILT ALARM HAS B EEN ACTIVATED, THE PLATFORM WILL NOT ELEVATE. ALSO IF THE TILT ALARM HAS BEEN ACTIVATED WHEN THE PLATFORM IS E LEVATED, THE DRIVE FUNCTION WILL BE DISABLED UNTIL THE PLATFORM IS COMPLETELY LOWERED.

NOTE: For DVSP Models equipped with the optional

Obstruction Sensing System, see Section 3.14 for additional platform operation instructions.

5. If necessary, reposition (drive) lift using platform con- troller joystick to bring work object within reach.

3.9 PARKING MACHINE

1. Drive machine to a well-protected and well-ventilated area.

2. Ensure the platform is fully lowered, turn the main power selector switch to the OFF position (centered).

NOTE: If required, charge batter ies in preparation for next

work d ay.

3121135 – JLG Lift – 3-17

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

3.10PROGAMMABLE SECURITY LOCK

™

(PSL

The optional Programmable Security Lock switch can be programmed with a four (4) digit operators code to allow only those persons wit h the c ode to power-up and ope rate the machine.

PSL™ Box and Ground Control Locations

Figure 3-6. PSL

Note: (a) Machines with bolt on (fixed) covers, the PSL

) (DVL/DVSP - OPT ION)

™

Switch & Ground Control Station

Locations - At Rear of Machine.

1. PSL Switch (Inside Right Cover) (a)

2. Ground Control Station

Switch is mounted on outside of right cover.

Machine Power Up using the PSL™

NOTE: When entering code on the key pad, a short beep

indicates a properly depressed key, a long beep indicates an error in depressing key. If an error occurs,

you must restart the code entry process again.

1. Enter the four digit code on the PSL key pad. The ACCEPT - AMBER LED indicator will be lit if the code is correct.

2. Press the keypad ON button. The ON - GREEN LED indicator will light and power will be supplied to the Ground Control Station.

3. At the ground control station, turn the main power selector switch from OFF to either Platform Control Mode or Ground Cont r ol Mode.

4. The machine will now operate normally.

Machine Power D own

1. At the Ground Control Station set the main power selector switch to the OFF position.

2. Press the OFF button on the PSL keypad. No LEDs on the PSL box will be lit.

Changing the Operator’s Code

The PSL Operators Code can b e c hanged by a supervisor should the need occur. A separate permanent Supervisor’s Code matched to the serial number of the PSL box is included on a sheet in the PSL user manual supplied with the machine.

1. Enter the Supervisor’s code on the key pad. The PROGRAM - RED LED will be lit if correct code is entered.

NOTE: ON or OFF cannot be one of the four digits of the

new Operator’s code.

2. Enter a new four (4) digit Operator’s code on the keypad. The ACCEPT - AMBER LED will light up if the new Operator’s code is accep t ed.

3. Press the OFF button on the keypad to activate the new Operator’s code .

NOTE: The new Oper ator’s code will remain in the PSL e v en

when power is removed from the equipment, or until the Supervisor changes the Operator’s code.

PSL

™

123 456

Figure 3-7. PSL

1. ON (Green LED) 4. Key Pad

2. ACCEPT (Amber LED) 5. OFF Swi tc h

3. PROGRAM (Red LED) 6. ON Switch

789

™

Switch Controls & Indicators.

1 2 3

3-18 – JLG Lift – 3121135

SECTION 3 - MAC HINE CONTROLS, INDICATORS AND OPERATION

3.11PLATFORM CONFIGURATIONS

STANDARD PLA TFORM (DVL)

Model Max. Capacity

20DVL 350 lb. (160kg) 15DVL 500 lb. (230kg)

1. Sliding Side Ent ry Gate 3. Lanyard Attach Point -

2. Platform Control Co nsole (Left side of mast)

EXTENDIBLE PLATFORM (GULL-WING ENTRY - NON CE)

Model Max. Capacity

20DVL 350 lb. (160kg)

15DVL/15DVSP 500 lb. (230 kg)

1. Gullwing Entry Gate 4. Exte ns ion S lid e/L oc k Ha nd le

2. Entry Gate L atch 5. Platform Con trol Console

3. Lanyard Attac h Point (on mast) 6. Sliding Extendible Section

MOLDED PLA TFORM (OPTION) - SHOWN w/MATERIAL TRA Y

Model

20DVL 350 lb. (160kg) 100 lb. (45kg)

15DVL/15DVSP 500 lb. (230kg) 150 lb. (70kg)

1. Swing Up Side Entry Gate 3. Lanyard Attac h Point - (on m ast)

2. Entry Gate L atch 4. Platform Control Console

Platform & T ray

Combined Max. Capacity

Material T ray

Max. Capacity

EXTENDIBLE PLA TFORM (SLIDING BAR ENTRY - CE ONL Y)

Model Max. Capacity

20DVL 350 lb. (160kg)

15DVL/15DVSP 500 lb. (230 kg)

1. Sliding Bar Entry Gate 4. Pla tform Control Console

2. Lanyard Attach Point (on ma st) 5. Sliding Extendible Sec tion

3. Extension Slide/Lock Hand le

3121135 – JLG Lift – 3-19

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

StockPicking Platform Operation

The stockpicking platform is available in two (2) versions.

• Fixed side-rail version

• Folding side-rail version

NON-CE UNITS:

THE OPERATOR MUST WEAR A FULL BODY HARNESS WITH A LANYARD (MAX. 6 FT. (1M) ATTACHED TO THE AUTHORIZED LANYARD POINT OR A BODY BELT EQUIPPED WITH A L ANYARD SHORT ENOUGH TO PREVENT A FALL FROM THE PLAT FORM.

WHILE OPERATING THE MACHINE IN THE OPEN RAIL CONFIGURATION, ALWAYS OPERATE THE MACHINE FROM THE REAR OF THE PLATFORM WITH THE MID-GATE CLOSED AND THE PLATFORM CONTROL CONSOLE ATTACHED TO THE FIXED PORTION OF THE GUARDRAIL.

STOCKPICKER PLATFORM

(WITH FOLDING SIDE-RAILS) (DVSP)

Model Max. Capa city

15DVSP 500 lb. (230 kg) 20DVSP 400 lb. (180 kg)

1. Primary Entrance/Exit Gate 4. Platform Control Console

2. Primary Entrance Latch 5. Mid-Gate

3. Lanyard Attach Point - 6. Gate Release/Lock Pins (on side of mast) 7. Secondary Exit Gate

CAUTION

THE STOCKPICKER PLATFORM ALLOWS THE MACHINE TO BE OPERATED IN AN OPEN RAIL CONFIGURATION (SEE ILLUSTRATION).

CE SPECIFICATION MACHINES:

THE OPERATOR MUST WEAR A FULL BODY HARNESS EQUIPPED WITH A LANYARD SHORT ENOU GH TO PREVENT A FALL FROM TH E PLATFORM. THE LANYA RD MUST BE ATTACHED TO THE AUTHROIZED LANYARD POINT. ALSO, JLG RECOMMENDS THAT C E SPECIFICATIO N MACHINES E QUIPPED WITH THE STOCKPICKER PLATFORM ARE ONLY TO BE USED FOR STOCKPICKING APPLICATIONS.

STOCKPICKER PLATFORM

(OPEN RAIL CONFIGURATION) (DVSP)

1. Platform Mid-Gate (enter rear of platform and close mid-gate

when driving with front rails open).

2. Open Rail Configuration work area. (See previou s Caution about fall protection requirements).

3. Platform Control Console attached to fixed side-rail in the rear of the platform .

3-20 – JLG Lift – 3121135

SECTION 3 - MAC HINE CONTROLS, INDICATORS AND OPERATION

3.12FALL PROTECTION - LANYARD ATTACHMENT

CAUTION

JLG INDUSTRIES, INC. RECOMMENDS THE OPERATOR IN THE PLATFORM WEAR A FULL BODY HARNESS WITH A LANYARD ATTACHED TO AN AUTHORIZED LANYARD ANCHORAGE POINT.

3.13QUICK-CHANGE PLATFORM MOUNTING

DVL Model Lifts are equipped with quick-change platform mounts which allow quick removal and installation of currently available quick-change platforms.

NOTE: DVSP Models require the installation of the Quick-

Change mount kit to use Quick-Change Platforms.

The main lanyard attach point for all DVL/DVSP machines is located on the lower left side of the mast platform header, just behind the operators platform.

CAUTION

AFTER ENTERING THE PLATFOR M, BEFORE BEGINNING OPE RATION ALWAYS CLOSE THE PLATFORM ENTRY GATE(S).

1. Upper Platform Mount 3. Lower Platform Mount

2. Upper Mount Attach Pins 4. Lower Mount Pins

Platform Removal

1. Remove the platform control console from the platform and lay aside.

2. Remove both upper and lower mount attach pins securing the platform support rails to the mast mounting channels.

3. Swing and lift the platform out of the mounts and lay aside.

Platform Installation

1. Set platform in upper and lower mou nts .

2. Install attach pins in upper and lower mounts.

3. Attach platform control console to platform rail.

WARNING

ENSURE ALL PINS AND FASTENERS ARE IN STALLED AND SECURE PRIOR TO OPERATION.

3121135 – JLG Lift – 3-21

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

3.14OBSTRUCTION SENSING SYSTEM

(DVSP -

OPTION)

System Description

The Obstruction Sensing System (OSS) is designed to detect the presence of obstructions within a predetermined detection zone beneath the platform, when lowering the platform from an elevated position.

NOTE: The OSS only operates normally when the Ground

Control Module - Power Selector Switch is set to PLATFORM CONTROL MODE. When the Power Selector Switch is set to GROUND CONTROL MODE the OSS will detect an obstruction but will not stop platform downward movement or sound the horn. However, the OSS Control Module LED will flash if a sensor detects the presence of an object.

Operation

NOTE: See Figure 3-9. for the location of the OSS Elec-

tronic module.

When the machine is powered on a RED LED located on the OSS electronics module will illuminate. During platform lowering, if no obstructions have enter ed the detection zone beneath the platform, the platform will lower normally.

If an obstruction is detected within the detection zone beneath the platform, the platform will;

•Stop Lowering

• The RED LED on the electronics module will flash

• The horn will sound three short blasts

If an obstruction is detected, have the obstruction cleared by someone on the ground or carefully drive the lift until clear of the obstruction. Reset the OS S by pr essing the horn button on t he platform co ntrol once and continue machine operation. Should the OSS falsely detect an obstruction, the system can be overridden by pressing and holding the horn b utton whil e oper ating t he plat form lowering controls.

WARNING

ALWAYS CHECK THE AREA UNDER THE PLATFORM IS CLEAR OF OBSTRUCTIONS BEFORE LOWERING THE PLATFORM.

Figure 3-8. OSS Transducer Sensor Array Location.

1. Transducer Arrays #1 through #6

2. Underside of DVSP Platform

OSS Pre-Start Inspection

(See Figure 3-9.)

From ground controls, raise platform approximately 5'-6'. The RED LED on the electronic module will b e illuminated when power is applied. If an obst ructi on , such as a pad of paper is placed under any of the transducer sensor arrays, the RED LED will flash and remain flashing while the obstruction is present and stop flashing 3 seco nds after the obstru ction is remov ed. Chec k th e oper ation of each transducer sens o r array by placing an object individually under each sensor array (within approximately 6"-12") and checking if the RED LED starts to "flash", and stops flashing 3 seconds after the obstruction is removed. Also, inspect the transducer arrays and electronic module for physical damage, loose wires, loose mount ing hardware, etc.

3-22 – JLG Lift – 3121135

SECTION 3 - MAC HINE CONTROLS, INDICATORS AND OPERATION

3.15TRANSPORTING, LIFTING AND TIE DOWN PROCEDURES

General

All DVL Series and DVSP 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 payloa d capacity capable of supporting the full weight of the machine (Check

machine gro ss w eigh ts in the O per ating Spec Cha rt at the beginning of this Section).

• Moved with a fork-lift truck using the fork-lift pockets in the base frame.

Figure 3-9. OSS - Pre-Start Inspection of Operation.

1. Electronic Module LED Indicator (a)

2. Detection Zone

3. Place a pad of paper or similar size object, 6 to

12 in. (15 to 30cm) individually beneath each transducer to check detection.

Notes: (a) The LED Indicator will flash when an object is

detected at each sen s o r. Remove ob je c t an d allow the LED to stop flashing before testing next sensor.

Truck Transport

CAUTION

DO NOT TRANSPORT THE MACHINE IN A HORIZONTAL POSITION DUE TO LEAKAGE OF BATTERY ACID FROM THE BATTERIES OR HYDRAULIC FLUID FROM THE HYDRAULIC RESE RVOIR.

The machine may be winched onto a tilted roll-back truck bed (see important note following) which has been rolled back to ground level. Disengage the brakes and always winch (pull) from the mast (rear) end of the machine, using the rear tie-down loop attached to the base frame.

IMPORTANT

DO NOT ATTEMPT TO DRIVE MACHINE ONTO, OFF OF, OR PUSH MACHINE ONTO A TILTED ROLL-BACK TRUCK BED. THE DVL AND DVSP MACHINES POWER MODULE COULD SUSTAIN SERIOUS DAMAGE WHEN THE UNIT IS PUSHED, OR TOWED AT SPEEDS GREATER THAN 2 MPH.

WHEN TOWING OR WINCHING, THE MACHINE’S BRAKES MUST BE DISENGAGED.

RE-ENGAGE THE BRAKES O NCE MACHIN E IS IN PLAC E WITH TRUCK BED LEVEL AND READY FOR TIE DOWN.

TIE DOWN LOOPS ARE PROVIDED ON BOTH ENDS OF THE BASE FRAME TO SECURE MACHINE TO BED OF TRANSPORT VEHICLE.

3121135 – JLG Lift – 3-23

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

Machine Tie-Down

With machine in position to be tied dow n 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 WHEEL COMPONENTS.

1. Secure machine with an adequate chain attached through the tie down loops located at the front and rear of machine. (See Figure 3-11.)

2. The chain should be securely tightened with a force of approximately 100 lb. applied two feet from the pivot handle.

Crane Hook Accessory (DVL Option)

NOTE: Lifting devise must be capable of handling the gross

weight of the machine, see the Operating Spec ifications table at the beginning of this Section.

1 2

Figure 3-10. Crane Hook Accessory

1. Crane Hook Attachment 2. Back of Mast

Fork-Lift Truck Transport

All DVL and DVSP Model Lifts a re equipped w ith wide fork lift pockets running throug h the bas e frame. (See Fig ure 3-

11.) This allows the machine to be either transported around a work area or lifted onto a higher level usi ng a standard fork-lift truck.

NOTE: Fork-lift trucks must be capable of handling the

gross weight of the machine, see the Operating Specifications table at the beginning of this Section.

Figure 3-11. Forklift Truck Lifting Pockets and Machine Tie Down Bar Locations.

1. Rear Tie-Down Loop 2. Fork Lift Pockets 3. Fr ont Tie-Down Loop

3-24 – JLG Lift – 3121135

SECTION 3 - MAC HINE CONTROLS, INDICATORS AND OPERATION

3.16RUG CARRIER ACCESSORY (DVSP - OPTION)

NOTE: The Rug Carrier accessory is available only on the

JLG DVSP model and is not authorized for use with any other JLG lift. The Rug Carrier Accessory is intended for use in hanging and removal of rugs in hanging display racks only. Use for any other purpose is not authorized by JLG.

General

The Rug Carrier Accessory consists of two pivoting arms mounted to the DVSP platform left side rails. The pivoting arms are locked in the plane of the platform side rail when not in use (the stowed position). The arms are locked into position at approximately 90 degrees to the left side platform side rails when in use (the carry position). The pivoting arms’ position can be changed by lifting ea ch arm to release the lock, rotating the arm, and lowering each arm back into a locked position.

Pre-Start Inspection

Prior to use of the Rug Carrier accessory, check the following;

• Carrier arm mounting is secure to the platform railing, no missing or damaged fasteners.

• The arm lock pins ar e in place and working properly.

Hanging a Rug using the Rug Carrier Accessory Arms

The following is a description for use of the Rug Carrier accessory in hanging rugs on horizontal pivoting arm display racks.

1. Select the intended location in the display for mounting the rug. Open the display rack to provide adequate space for the DVSP lift and rug.

Positioning Rug Carr ier Arms

1. Carry Position 3. Lift Arm Up, Swing

2. Stowed Position and Lock into Position

8. After adequately attaching the rug to the display arm, lower the platform, stow the Rug Carrier Accessory arms.

9. As required reposition and elevate the DVSP to completely attach the rug.

2. With the Rug Carrier Accessory arms stowed, drive the

DVSP into position prior to loading the rug.

3. Swing and lock Rug Carrier Accessory arms into the carry position.

4. Load the rolled rug with the finished side facing the platform. As required, use an assistant to load the rug onto the Rug Carrier Accessory arms.

5. Make sure that the rug is centered over its length on the Rug Carrier Accessory .

6. Elevate the platform to the required height for mounting the rug onto the display arm.

7. Properly attach the rug to the display arm. Never climb onto the platform rails for any reason.

Positioning Carpet Roll On Rug Carrier

1. Center Carpet on Arms 3. Platform Front

2. Rest on Arms Here (a)

Note: (a) Maximum Capacity of Arms - 150 lb. (68kg)

3121135 – JLG Lift – 3-25

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

Removing a Rug using Rug Carrier Accessory Arms

This section describes the use of the Rug Carrier accessory in removing a rug from a horizontal pivoting arm display rack.

1. Select the intended location in the display for removal of the rug. Open the display rack to provide adequate space for the DVSP lift and rug.

2. With the Rug Carrier Accessory arms stowed, drive the DVSP into position prior to loading the rug.

3. Swing and lock the Rug Carrier Accessory arms into the carry position.

4. Elevate the platform a few feet. Start to roll the rug onto the Rug Carrier Accessory arms.

5. Be certain the rug is centered over its length on the

Rug Carrier Accessory.

6. While elevating to the required height for removing the rug from the display arm, continue to roll the rug until it is completely rolled up on the carrier arms.

7. Properly remove the rug from the display arm. Never climb onto the platform rails for any reason.

8. After adequately removing the rug from the display arm, lower the platform.

9. Remove the rug from the Rug Carrier Accessory. If required, use an assistant to unload the rug from the Rug Carrier Accessory Arms.

10. Replace the Rug Hanger Accessory arms to the stowed position for normal operation.

CAUTION

THE RUG CARRIER ACCESSORY ARMS MUST BE LOCKED IN THE STOWED POSITION WHEN NOT I N USE.

EXTREME CAUTION MUST BE EXERCISED AT ALL TIMES W HILE THE RUG CARRIER ACCESSORY IS IN USE (DRIVING, RAISING AND LOWERING) TO PREVEN T OBSTACLES AND P ERSONNEL FROM STRIKING THE LOAD.

Removing Rug From Display Arm.

1. Roll Rug onto Rug Carrier while Elevating Platform

2. Rug Carrier in Carry Position

WHEN DRIVING WITH A RUG WITHIN THE RUG CARRIER ACCE SSORY, THE RUG MUST BE PROPERL Y SECURED TO PR EVENT INADVERTENT MOTION OR MOVEMENT OF THE RUG AND MUS T NOT EXCEED THE RATED CAPACITY OF THE RUG CARRIER ACCESSORY.

NEVER OVERLOAD THE RUG CARRIER ACCESSORY. MAXIMUM CAPACITY OF THE RUG CARRIER ACCESSORY IS 150 LBS.

THE COMBINED WEIGHT OF PERSONNEL, MATERIALS, EQUIPMENT PLUS ANY LOAD ON THE RUG CARRIER ACCESSORY MUST NOT EXCEED THE MAXIMUM CAPACITY OF THE PLATFORM.

NEVER USE A RUG CARRIER ACCESSORY THAT HAS DAMAGE OR LOOSE MOUNTINGS. IM MEDIATELY RE PORT ANY DAMAGE TO APPROPRIATE PERSONNEL. DISCONTINUE USE OF THE RUG CARRIER ACCESSORY UNTIL ALL DISCREPANCIES HAVE BEEN CORRECTED.

3-26 – JLG Lift – 3121135

SECTION 3 - MAC HINE CONTROLS, INDICATORS AND OPERATION

3.17STOCK-PICKER HANGER ACCESSORY

NOTE: The stock-picker hanger accessory is available only

on the JLG DVSP model and is not authorized for use with any o the r J LG l ift. This hanger accessory is intended for use in placin g or retrievin g stock items such as bicycles, ladders, etc., on racks or shelves above ground level. Use for any other purpose is not authorized by JLG.

The hanger accessory is a pivoting arm mounted to the DVSP platfo rm rail. Th e hanger acce ssory can be mounted to eithe r side of the pl atform in divi dually, or two can be mounted, one on each side of the platform. Each individual hanger has a maximum load capacity of 100 lb. (45kg).

The hanger arm can be pivoted out of the way parallel with the platform side rails when not in use, (the stowed position). The hanger arm is pinned into position at 90 degrees to the platform side rails when in use, (the carry position).

Pre-Start Inspection

Prior to use of the hanger accessory, check the following;

• Hanger arm mounting is secure to the platform railing, no missing or damaged fasteners.

• The hanger arm lock pin is in place and secure.

CAUTION

THE COMBINED WEIGHT OF PERSONNEL, MATERIALS, EQUIPMENT PLUS ANY LOAD ON THE HANGER ARM ACCESSORY MUST NOT EXCEED THE MAXIMU M LOAD CAPACITY OF THE PLATFORM.

AND PREVENTING THE PLATFORM FROM LOWERING. IF NECESSARY, R EPOSITION THE OBJECT OUT OF THE OSS DETECT ION ZONE.

4. Be aware of clearance above, below, and around the object when driving and lifting or lowering the platform.

Stock Picker Hanger - Carry Position

1. Mounting Bracket 4. Lock Pin (Carry Position)

2. Hanger Arm (Carry Position) 5. Hanger Arm Strap

3. Capacity Decal (a)

Notes: (a) Maximum load capac i ty of hanger is 100 lb. (45kg).

Loading and Transporting an Item using the

Hanger Accessory

Use the following steps as a guide when loading and transporting an object with the hanger accessory arm.

1. Keep the hanger arm in the stowed position when not in use.

2. When ready to use, pull the lock pin from the stowed position hole and swing the hanger arm into the carry position. Place pin in the carry position hole locking the hanger arm in place.

3. Load the object onto the hanger arm and use the hanger arm strap to secure the object during transport.

IMPORTANT

DVSP MACHINE’S EQUIPPED WITH THE OBSTRUCTION SENSING SYSTEM (OSS) OPT ION – OBJECTS PLACE D ON THE HANGER ACCESSORY AND EXTENDING BELOW THE BASE OF THE PLATFORM MAY CAUSE AN OSS DETECTION - SOUNDING THE HORN

1. Hanger Arm (Stowe d Position)3. Hanger Arm (Carry Position)

2. Lock Pin (Stowed Position)

3121135 – JLG Lift – 3-27

Stock Picker Hanger - Stowed Position

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

Figure 3-12. DVL Series Dec al Installation Chart - (See Table 3-5 for Specification)

3-28 – JLG Lift – 3121135

SECTION 3 - MAC HINE CONTROLS, INDICATORS AND OPERATION

Table 3-5. DVL Series - Decal Installation Chart (See Figure 3-12.)

ANSI

1700584 1700584 1 700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700 584

1701504 1701504 1 701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701 504

1702631 1702631 1 702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702 631

1703072 1703072 1 703072 1703072 1703072 1703072 1703072 1703072 1703072 1703072 1703072 1703072 1703 072

1703681 1703681 1 703681 1703681 1703681 1703681 1703681 1703681 1703681 1703681 1703681 1703681 1703 681

1703687 1703687 1 703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703 687

1703788 1703788 1 703788 1703788 1703788 1703788 1703788 1703788 1703788 1703788 1703788 1703788 1703 788

1703814 1703814 1 703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703 814

1703817 1703817 1 703817 1703817 1703817 1703817 1703817 1703817 1703817 1703817 1703817 1703817 1703 817

1705016 1705016 1 705016 1705016 1705016 1705016 1705016 1705016 1705016 1705016 1705016 1705016 1705 016

15DVL -

1705191

20DVL -

1705017

ANSI

(LAT)

15DVL -

1705191

20DVL -

1705017

ANSI

(BRZ)

15DVL -

1705191

20DVL -

1705017

ANSI

(JPN)

15DVL -

1705191

20DVL -

1705017

ANSI (CHI)

15DVL -

1705191

20DVL -

1705017

CSA

(FRE)

15DVL -

1705191

20DVL -

1705017

CE (ENG/ (AUS)

15DVL -

1705191

20DVL -

1705017

(GER)CE(FRE)CE(SPA)CE(ITA)CE(DUT)CE(SWE)

15DVL -

1705191

20DVL -

1705017

15DVL -

1705191

20DVL -

1705017

15DVL -

1705191

20DVL -

1705017

15DVL -

1705191

20DVL -

1705017

15DVL -

1705191

20DVL -

1705017

15DVL -

1705191

20DVL -

1705017

1705048 1705048 1 705048 1705048 1705048 1705048 1705048 1705048 1705048 1705048 1705048 1705048 1705 048

1705059 1705059 1 705059 1705059 1705059 1705059 1705059 1705059 1705059 1705059 1705059 1705059 1705 059

1705060 1705060 1 705060 1705060 1705060 1705060 1705060 1705060 1705060 1705060 1705060 1705060 1705 060

1705064 1705064 1 705064 1705064 1705064 1705064 1705064 1705064 1705064 1705064 1705064 1705064 1705 064

1703786 1704032 1 704024 1705099 1704081 1704039 1705099 1705099 1705099 1705099 1705099 1705099 1705 099

1702153 — — — — — — — — — — — —

1703684 1703685 1 703686 1703723 1703751 1703719 1703684 1703718 1703719 1703685 1703721 1703722 1705 100

1705046 1705104 1 705105 1705118 1705106 1705107 1705049 1705113 1705114 1705112 1705115 1705116 1705 117

1703785 1704031 1 704023 1704089 1704079 1704797 1703785 1704071 1704042 1704031 1704063 1704055 1705 102

1703779 — — — — — — — — — — — —

3252797 1702797 1 702797 1702798 1702797 1702797 3252798 3252798 3252798 3252798 3252798 3252798 3252 798

3121135 – JLG Lift – 3-29

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

2425

17 8

Figure 3-13. DVSP Decal Installation Chart - (See Table 3-6. for Specification)

3-30 – JLG Lift – 3121135

SECTION 3 - MAC HINE CONTROLS, INDICATORS AND OPERATION

Table 3-6. DVSP Decal Installation Char t (See Figure 3-13.)

ANSI

1700584 170058 4 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584

1701504 170150 4 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504

1702631 170263 1 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631

1703072 170307 2 1703072 1703072 1703072 1703072 1703072 1703072 1703072 1703072 1703072 1703072 1703072 1703072

1703681 170368 1 1703681 1703681 1703681 1703681 1703681 1703681 1703681 1703681 1703681 1703681 1703681 1703681

1703687 170368 7 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687

1703788 170378 8 1703788 1703788 1703788 1703788 1703788 1703788 1703788 1703788 1703788 1703788 1703788 1703788

1703814 170381 4 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814

1703817 170381 7 1703817 1703817 1703817 1703817 1703817 1703817 1703817 1703817 1703817 1703817 1703817 1703817

1705016 170501 6 1705016 1705016 1705016 1705016 1705016 1705016 1705016 1705016 1705016 1705016 1705016 1705016

15DVSP -

1705018

20DVSP -

1705703

ANSI (LAT)

15DVSP -

1705018

20DVSP -

1705703

ANSI

(BRZ)

15DVSP -

1705018

20DVSP -

1705703

ANSI

(JPN)

15DVSP -

1705018

20DVSP -

1705703

ANSI (CHI)

15DVSP -

1705018

20DVSP -

170570

CSA

(FRE)

15DVSP -

1705018

20DVSP -

170570

CE (ENG/ (AUS)

15DVSP -

1705018

20DVSP -

170570

(GER)CE(FRE)CE(SPA)CE(ITA)CE(DUT)CE(SWE)CE(FIN)

15DVSP -

1705018

20DVSP -

170570

15DVSP -

1705018

20DVSP -

170570

15DVSP -

1705018

20DVSP -

170570

15DVSP -

1705018

20DVSP -

170570

15DVSP -

1705018

20DVSP -

170570

15DVSP -

1705018

20DVSP -

170570

15DVSP -

1705018

20DVSP -

170570

1705048 170504 8 1705048 1705048 1705048 1705048 1705048 1705048 1705048 1705048 1705048 1705048 1705048 1705048

1705059 170505 9 1705059 1705059 1705059 1705059 1705059 1705059 1705059 1705059 1705059 1705059 1705059 1705059

1705060 170506 0 1705060 1705060 1705060 1705060 1705060 1705060 1705060 1705060 1705060 1705060 1705060 1705060

1705064 170506 4 1705064 1705064 1705064 1705064 1705064 1705064 1705064 1705064 1705064 1705064 1705064 1705064

1703786 170403 2 1704024 1705099 1704081 1704039 1705099 1705099 1705099 1705099 1705099 1705099 1705099 1705099

1702153 — ————————————

1703684 170368 5 1703686 1703723 1703751 1703719 1703684 1703718 1703719 1703685 1703721 1703722 1705101 1705100

15DVSP -

1705047

20DVSP -

1705702

1703785 170403 1 1704023 1704089 1704079 1704797 1703785 1704071 1704042 1704031 1704063 1704055 1705103 1705102

1703779 — ————————————

3252797 170279 7 1702797 1702797 1702797 1702797 3252798 3252798 3252798 3252798 3252798 3252798 3252798 3252798

4420051 442005 1 4420051 4420051 4420051 4420051 4420051 4420051 4420051 4420051 4420051 4420051 4420051 4420051

24 25

1704366 170514 1 1705142 1704777 1704910 1704804 1704980 1705146 1705147 1705494 1705148 1705149 1705151 1705150

1704469 170515 3 1705154 1705164 1705155 1705156 1704469 1705158 1705159 1705157 1705160 1705161 1705163 1705162

15DVSP -

1705108

— — — 1705140 — 1704804 1704981 1705134 1705135 1705133 1705136 1705137 1705139 1705138

15DVSP -

1705109

15DVSP -

1705127

15DVSP -

1705110

15DVSP -

1705111

15DVSP -

1705050

15DVSP -

1705121

15DVSP -

1705122

15DVSP -

1705120

15DVSP -

1705123

15DVSP -

1705124

15DVSP -

1705126

15DVSP -

1705125

3121135 – JLG Lift – 3-31

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

This page intentionally left blank.

3-32 – JLG Lift – 3121135

SECTION 4 - EMERGENCY PROCEDURES

SECTION 4. EMERG ENCY PR OCEDU RES

4.1 GENERAL INFORMATION

This section explains the steps to be taken in case of an emergency situation during operation.

4.2 EMERGENCY OPERATION

Operator Unable to Control Machine

IF THE PLATFORM OPERATOR IS PINNED, TRAPPED OR UNABLE TO OPERATE OR CONTROL THE MACHINE:

1. Other personnel should operate the machine from ground controls only as required.

2. Only qualif ied personnel in the platform may use the platform controls. DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION PROPERLY.

3. Cranes, forklift trucks or other equipment can be used to remove the platform occupant and stabilize motion of the machine.

Platform Caught Overhe ad

If the platform becomes jamm ed or snagged in ov erhead structures or equipment, rescue the platform occupant prior to freeing the machine.

4.3 INCIDENT NOTIFICATION

JLG Industries, Inc. must be notified immediately of any incident involving a JLG product. Even if no injury or property damage is evident, the factory should be contacted by telephone and provided with all necessary details.

JLG Phone:

U.S.A.:

877-JLG-SAFE (554-7233)

(8am till 4:45pm EST)

EURO:

(44) 1 698 811005

AUSTRALIA:

E-mail: prod uctsafety@jlg.com Failure to not ify t he manu fac tur er of an inci den t in volvi ng a

JLG Industries product within 48 hours of such an occurrence may void any warranty consideration on that particular machine.

FOLLOWING ANY ACCIDENT, THORO UGHLY INSPECT THE MACHINE AND TEST ALL FUNCTIONS FIRST FRO M THE GROUND CONTROL STATION, THEN FROM THE PLATFORM CONTROL CONSOLE. DO NOT LIFT ABOVE 10 FT. (3 M) UNTIL YOU ARE SURE THAT ALL DAMAGE H AS BEEN REP AIRED, IF REQ UIRED, AND THAT ALL CONTROLS ARE OPERATING CORRECTLY.

(61) 2 65 811111

IMPORTANT

3121135 – JLG Lift – 4-1

SECTION 4 - EMERGENCY PROCEDURES

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4-2 – JLG Lift – 3121135

SECTION 5 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

SECTION 5. GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

5.1 INTRODUCTION

This section of the manual provides additional necessary information to the operator for proper operation and maintenance of this machine.

The maintenance portion of this section is intended as information to assist the machine operator to perform dail y maintenance tasks only, and does not replace the more thorough Preventive Maintenance and Inspection Schedule included in the Service and Maintenance Manual.

Other Publications Available Specific to this Machine:

Service and Maintenance Manual

GLOBAL ...................................................................3121136

Illustrated Parts Manual

ANSI .........................................................................3121137

CE ............................................................................3121839

5.2 GENERAL SPECIFICATIONS Machine Specifications

SPECIFICATION 15DVL 20DVL 15DVSP 20DVSP

Gross Machine Weight (Platform Empty):

Machine Height (Platform Stowed): Maximum Ground Bearing Pressure: (per wheel) 800 lb. (360 kg) Maximum Operating Incline: 1.5° Maximum Travel Grade (Gradeability):

(Platform STOWED ONL Y)

Maximum T ravel Grade (Sid e Slope):

(Platform STOWED ONL Y)

Maximum Drive Speeds (Operato r Variable): 0.5 - 2 mph (0.8 - 3.2 kph) Machine Base - Overall : (Width x Length) 29.25 in.- W x 52 in.- L (74cm) x (132cm) Maximum Wind Speed: 0 mph (0kph) - Machine rated for indoor use only Maximum Horizo ntal Manual Side Force:

(Platform fully extended with Maximum load)

Maximum Hydraulic System Pressure:

(Recommended initial setting)

Hydraulic System Capacity: 5 qts. U.S. (4.7 L) Hydraulic Reservoir Capacity: 1 Gallon (3.78 L)

2,105 lb. (955 kg)

2600 PSI

(180 Bars)

2,105 lb.

(955 kg)

78 in. (198cm)

45 Pound Force (200 Newtons)

1800 PSI

(124 Bars)

2,150 lb.

(975 kg)

20%

5°

2600PSI

(180 Bars)

2,150 lb.

(975kg)

2800 PSI

(193 Bars)

3121135 – JLG Lift – 5-1

SECTION 5 - GENERAL SPEC IFICATIONS AND OPERATOR MAINTENANCE

Electrical Specifications

SPECIFICATION 15DVL 20DVL 15DVSP 20DVSP

System Voltage: 24 Volts DC Battery Specifications: Battery Type: AGM (VRLA) (Sealed)

Voltage: 12 Volts DC

Amp Hour (AH) Rating: 100 Amp Hr . @ 20 Hr.

Battery Charger (DC Models) Input: 120/240 Volts AC - 50/60 Hz - Voltage Selectable

Output: 24 volt, 20 Amp Output - with 2 Amp Finish

Platform Data

SPECIFICATION 15DVL 20DVL 15DVSP 20DVSP

Occupants: (Persons allowed in Platform) 1 Maximum Work Load (Capacity): Standard:

500 lb.

(230 kg)

350 lb.

(160 kg)

——

Platform Heig ht - Mast Fully E xtended -

(Ground to Platform Floor):

Platform Cycle Performance: Lift Up: (in seconds) (w/max. rated load) Lift Down:

Machine Component Weights

SPECIFICATION 15DVL 20DVL 15DVSP 20DVSP

Platform Weight : Standard Platform: 55 lb. (25 kg) (Quick-Change Platforms) Molded Platform: 70 lb. (32 kg) Battery: (per battery) 65.7 lb. (29.8 Kg)

Serial Number Locations

Stockpicker:

Extendible:

Molded:

——

500 lb.

(230 kg)

500 lb.

(230 kg)

15 ft.

(4.57 m)

20 sec. 22.5 sec. 20 sec. 22.5 sec.

15 - 21 sec. 21 - 26 sec. 15 - 21 sec. 21 - 26 sec.

350 lb.

(160 kg)

350 lb.

(160 kg)

19.5 ft.

(5.94 m)

500 lb.

(230 kg)

500 lb.

(230 kg)

500 lb.

(230 kg)

15 ft.

(4.57 m)

400 lb.

(180 kg)

350 lb.

(160 kg)

350 lb.

(160 kg)

19.5 ft.

(5.94 m)

For machine identification, a serial num ber plate is affixed to the machine. The plate is located on the back of the mast, just above the mast support bracket.

5-2 – JLG Lift – 3121135

SECTION 5 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

5.3 OPERATOR MAINTENANCE Lubrication

Hydraulic Oil (HO)

Hydraulic oils must have anti-we ar qualities at least t o API Service Cl assification 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.

Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparab le viscosities. If use of hyd raulic oil other tha n Mobilfluid 424 is desired , contact JLG Industries for proper recommendations.

EPGL - Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 or MIL -Spec MIL -L-2105.

HYDRAULIC SYSTEM OPERATING TEMPERATURE RANGE SAE VISCOSITYGRADE

+0° F to +180° F (-18° C to -83° C) 10W

+0° F to +210° F (-18° C to +99° C) 10W-20, 10W-30

+50° F to +210° F (+10° C to +99° C) 20W-20

Table 5-1. - Lubrication Specifications

KEY SPECIFICATIONS MPG - Multipurpose Grease having a minimum dripping point of 350° F . Excellent water resistance and adhesive

qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.)

HO - Hydraulic Oil. ISO- Vg grade 32, 46.

CL - Chain Lube. Use a good quali ty chain lubrican t

NOTE: Refer to Lubrication Chart, Table 5-2 for specific lubrication locations on machine.

3121135 – JLG Lift – 5-3

SECTION 5 - GENERAL SPEC IFICATIONS AND OPERATOR MAINTENANCE

Table 5-2.Lubrication Intervals for Various Components

ITEM COMPONENT

1Hydraulic Oil

Drive Wheel

Gear Box

NO/TYPE

LUBE POINTS

Fill T o Line on Reservoir 5 Qt. Rese rvoir

2 - Gear Boxe s Gear Oil

(a)

LUBE/METHOD

HO - Check Hyd. Oil Level HO - Change Hyd. Oil

3 Caster Axles 2 - Grease Fittings MPG - Pr essure Gun 4 Swivel Raceways 2 - Front Casters MPG - Pressure Gun

5Mast Chains

2 - Per M ast Section

CL - Brush or Spra y

INTERVAL

MONTHS6MONTHS1YEAR2YEARS

✔ ✔

✔

(b)

COMMENTS

Check fluid level every day.

✔

Change hydraulic oil every 2 years.

Change only when serviced requires 6 oz. (175 cc’s) to fill.

Inspect, lubricate if dry or rusting.

Key to Lubr icants: MPG - Multipurpose Grease

HO - Hydraulic Oil - ISO- Vg grade 32, 46. GEAR OIL - Good Quality Worm Gear Oil - SAE 90 - AGMA# 5 - EP Compounded CL - Chain Lube. Use a good quality chain lubricant

Notes: (a) Be certain to lubricate like items on each side of the machine.

(b) 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.

(c) 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.

(c)

5-4 – JLG Lift – 3121135

SECTION 6 - INSPECTION AND REPAIR LOG

SECTION 6. INSPECTION AND REPAIR LOG

Machine Serial Number:

Table 6-1. Inspection and Repair Log

Date Comments

3121135 – JLG Lift – 6-1

SECTION 6 - INSPECTION AND REPAIR LOG

Table 6-1. Inspection and Repair Log

Date Comments

6-2 – JLG Lift – 3121135

Corporate Office

JLG Industries, Inc.

1 JLG Drive

McConnellsburg PA. 17233-9533

USA

Phone: (717) 485-5161

Fax: (717) 485-6417

JLG Worldwide Locations

JLG Industries (Au stralia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia Phone: (61) 2 65 811111 Fax: (61) 2 65 810122

JLG Latino Americana Ltda . Rua Eng. Carlos Stev enson, 80-Suite 71 13092-310 Campinas-SP Brazil Phone: (55) 19 3295 0407 Fax: (55) 19 3295 1025

JLG Industries (Europe) Kilmartin Place, Tannochside Park Uddingston G71 5PH Scotland Phone: (44) 1 698 811005 Fax: (44) 1 698 811055

JLG Industries (UK) Unit 12, Southside Bredbury Park Industrial Estate Bredbury Stockport SK6 2sP England Phone: (44) 870 200 7700 Fax: (44) 870 200 7711

JLG Europe B.V. Jupiterstraat 234 2132 HJ Foofddorp The Netherlands Phone: (31) 23 565 5665 Fax: (31) 23 557 2493

JLG Industries (Pty) Ltd. Unit 1, 24 Industrial Complex Herman Street Meadowdale Germiston South Afri ca Phone: (27) 11 453 1334 Fax: (27) 11 453 1342

JLG Deutschland GmbH Max Planck Strasse 21 D-27721 Ritterhude/lhlpohl Bei Bremen Germany Phone: (49) 421 693 500 Fax: (49) 421 693 5035

JLG Industries (Norge AS) Sofeimy rveien 12 N-1412 Sofienyr Norway Phone: (47) 6682 2000 Fax: (47) 6682 2001

Plataformas Elevadoras JLG Iberica, S.L. Trapadella, 2 P.I. Castellbisbal Sur 08755Castellbisbal Spain Phone: (34) 93 77 24700 Fax: (34) 93 77 11762

JLG Industries (Italia) Via Po. 22 20010 Pregnana Milanese - MI Italy Phone: (39) 02 9359 5210 Fax: (39) 02 93 59 5845

JLG Polska UI. Krolewska 00-060 Warsa wa Poland Phone: (48) 91 4320 245 Fax: (48) 91 4358 200

JLG Industries (Sweden) Enkopingsvagen 150 Box 704 SE - 175 27 Jarfa lla Sweden Phone: (46) 8 506 59500 Fax: (46) 8 506 59534

JLG DVSP Operator Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FOREWORD

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

REVISION LOG

TABLE OF CONTENTS

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL

1.2 PRE-OPERATION

Operator Training And Knowledge

Workplace Inspection

Machine Inspection

1.3 OPERATION

General

Trip and Fall Hazard

Electrocution Hazard

Tipping Hazard

Crushing And Collision Hazard

1.4 TOWING, LIFTING, AND HAULING

SECTION 2. PREPARATION AND INSPECTION

2.1 PERSONNEL TRAINING

Operator Training

Training Supervision

Operator Responsibility

2.2 PREPARATION, INSPECTION, AND MAINTENANCE

2.3 PRE-START INSPECTION

2.4 DAILY WALK-AROUND INSPECTION

2.5 FUNCTION CHECK

SECTION 3. MACHINE CONTROLS, INDICATORS AND OPERATION

3.1 GENERAL

3.2 MACHINE DESCRIPTION

3.4 BATTERY CHARGING

3.3 MACHINE OPERATION

Getting Started

Battery Low Voltage Warning Indicators

To Charge Batteries

Battery Charging Status Indicators

Main Power Selector Switch

Emergency Stop/Shut Down Button

Brake Release Button

Platform Up

Master Disconnect Switch - (EE Option Only)

Platform Down

Manual Descent Control Valve

Machine Status LCD Display

LCD Display Fault Conditions

General

Programming Levels

Operator Programming Mode

Activating Programming Mode

Entering Password

Programming Mode Selection

Selecting Programmable Item to Adjust Adjusting Programmable Setting

General

Platform On/Off Key Switch

Platform Control Display Panel

Platform Emergency Stop/Shut Down Button

Drive/Lift Mode Selector Switch

Horn Button

Joystick Function Enable Lever

Multifunctio n Joystick Contro l

Drive Mode

Drive Speed Setting Controls

Lift Mode

At Ground Control Station Emergency Stop/Shut-Down Button

Battery Charge/Fault Code LED Indicator

Driving Machine

Adjusting Maximum Drive Speed Co ntrol

Elevating/Lowering the Platform

3.9 PARKING MACHINE

PSL™ Box and Ground Control Locations

Machine Power Up using the PSL™

Machine Power D own

Changing the Operator’s Code

3.11PLATFORM CONFIGURATIONS

StockPicking Platform Operation

3.12FALL PROTECTION - LANYARD ATTACHMENT

3.13QUICK-CHANGE PLATFORM MOUNTING