JLG DVSP Operator Manual

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

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