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OPERATORS & SAFETY

Models

10VP15VP

20VP

3120848

February 7, 2000

AUSTRALIAN OFFICE

JLG INDUSTRIES, INC.P.O. Box 5119

11 Bolwar ra Road

Port Macquarie, Australia

Telephone: 065 811111

Fax: 065 81 012 2

EUROPEAN OFFICE

JLG INDUSTRIES (EUROPE)Kilmart ing Place,

Tannochside Park

Uddingston, Scotland , G71 5PH

Telephone: 01698 81100 5

Main Fax: 01698 811055

Parts Fax: 01698 811 455

WORLD HEADQUARTERS

JLG INDUSTRIES, INC.1 JLG Drive

McConnellsburg, PA.

17233-9533

USA

Telephone: (717) 48 5-5161

Fax: (717 ) 485-6417


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FOREWORD

The purpos e of this ma nua l is to provide use rs with the ope rating proce dures es se ntia l for the promotion of

proper machine operation for its intended purpose. It is important to over-stress proper machine usage. All

information in this manual should be READ an d UNDERSTOOD before any attempt is made to operate themachine. YOUR OPERATING MANUAL IS YOUR MOST IMPORTANT TOOL - Keep it with the machine

REMEMBER ANY EQUIPMENT IS ONLY AS SAFE AS THE OPERATOR. BECAUSE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION ANDOPERATION, PROPER SAFETY PRACTICES ARE THE RESPONSIBILITY OF THE USER AND HIS OPERATING PERSONNEL.

ALL INSTRUCTIONS IN THIS MANUAL ARE BASED ON THE USE OF THE MACHINE UNDER PROPEROPERATING CONDITIONS, WITH NO DEVIATIONS FROM THE ORIGINAL DESIGN. ALTERATION AND/OR MODIFICATION OF THE MACHINE IS STRICTLY FORBIDDEN, WITHOUT WRITTEN APPROVALFROM JLG INDUSTRIES, PER OSHA REGULATIONS.

THIS "SAFETY ALERT SYMBOL" IS USED TO CALL ATTENTION TO POTENTIAL HAZARDSWHICH MAY LEAD TO SERIOUS INJ URY OR DEATH IF IGNORED.

S a fety of personnel and proper use of the ma chine a re of prima ry conce rn, DANGER, WARNING, CAUTIONIMPORTANT, INSTRUCTIONS an d NOTE are inserted throughout this manual to emphasize these areas.They a re defined a s follow s:

JLG INDUSTRIES, INC. M AY HAVE ISSUED SAFETY RELATED BULLETINS FOR YOUR JLG PRODUCT. CONTACT JLG INDUS-

TRIES, INC. OR THE LOCAL AUTHORIZED JLG DISTRIBUTOR FOR INFORMATION CONCERNING SAFETY RELATED BULLE-

TINS WHICH M AY HAVE BEEN ISSUED FOR YOUR JLG PRODUCT. ALL ITEMS REQUIRED BY THE SAFETY RELATED

BULLETINS MUST BE COMPLETED ON THE AFFECTED JLG PRODUCT.

Due to the c ontinuous p roduct improvements, J LG Industries, Inc. rese rves the right to m ake s pec ifica tion c hang es without

prior notifica tion. Co ntac t J LG Indus tries, Inc. for upda ted informa tion.

DANGER INDI CATES AN IM MI NENTLY HAZARDOUS SITUA-

TION WHICH, IF NOT AVOIDED WILL RESULT IN SERIOUS

INJURY OR DEATH.

CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUA-

TION WHI CH, IF NOT AVOIDED, M AY RESULT IN M INOR OR

MODERATE INJURY. IT MAY ALSO BE USED TO ALERT

AGAINST UNSAFE PRACTICES.

Also in this Ma nual "Notes: " a re use d to provide infor-

ma tion o f spec ia l interest.

WARNING INDICATES A POTENTIALLY HAZARDOUS SITU-

ATION WHICH, IF NOT AVOIDED COULD RESULT IN SERI-

OUS INJURY OR DEATH.

IMPORTANT OR INSTRUCTIONS PROCEDURES ESSENTIAL

FOR SAFE OPERATION AND WHICH, IF NOT FOLLOWED

MAY RESULT IN A MALFUNCTION OR DAMAGE TO THE

MACHINE.


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INTRODUCTION - M AINTENANCE SAFETY PRECAUTIONS

3120848 – JLG L ift – a

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A. GENERAL

This s ec t ion conta ins the g enera l s a fe ty preca ut ions

which must be observed during maintenance of the aerial

platform. It is of utmost importance that maintenance per-

sonnel pay strict attention to these warnings and precau-

tions to a void poss ible injury to thems elves or others or

da mag e to the eq uipment. A maintenance program must

be e stab lished by a q ualified pe rson and m ust be followe d

to ensure that the ma chine is s afe to ope rate.

MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEASTAS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLA-

TION.

The sp ec ific preca utions to b e ob se rved d uring m ac hine

ma intenance are inserted a t the a ppropria te point in the

ma nual. These prec autions are, for the mos t part , those

that apply when s ervicing hyd raulic a nd large r machine

component parts.

Your sa fety, a nd that of others, is the first cons ide ration

when engaging in the maintenance of equipment. Always

be consc ious o f component weight and never attempt to

move heavy parts without the aid of a mechanical device.

Do no t allow he avy ob jects to rest in a n unstab le po sition.

When raising a portion o f the e q uipment, ens ure that a de-q uate s upport is provided .

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON-

TROL OVER THE FIELD INSPECTION AND MAINTENANCE,SAFETY IN THIS AREA IS THE RESPONSIBILITY OF THE OWNER/OPERATOR.

B. HYDRAULIC SYSTEM SAFETY

1. It should be particularly noted that the mac hines

hydraulic systems operate at extremely high andpotentially d ang erous pressures. Every e ffort should

be ma de to relieve a ny sys tem pressure prior to dis-

co nnecting or remo ving any portion o f the s ystem.

2. Relieve system press ure by a ctivating the lift DOWN

control with the platform completely lowered to

direct any line pressure back into the return line to

the reservoir. Pressure feed lines to system compo-

nents can then be disconnected with minimal fluid

loss.

C. MAINTENANCE

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED INTHIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION.

• REMOVE ALL RINGS , WATCHES , AND J EWELRY

WHEN PERFORMING ANY MAINTENANCE.

• DO NOT WEAR LONG HAIR UNRESTRAINED, OR

LOOS E FITTING C LOTHING AND NECKTIES WHICH

ARE AP TTO BEC OME CAUG HT ON OR ENTANGLED

IN EQUIP MENT.

• OBS ERVE AND OBEY ALL DANGER, WARNING, CAU

TION AND OTHER INS TRU C TIONS ON MACHINE

AND IN SERVICE MANUAL.

• KEEP S TANDING S URFACES AND HAND HOLDS

FREE OF O IL, G REASE, WATER, ETC.

• NEVER WORK UNDER AN ELEVATED P LATFORM

UNTIL P LATFORM HAS B EE N S AFELY RES TRAINED

FRO M ANY MOVEMENT BY B LOC KING OR OVER

HEAD SLING.

• BEFO RE MAKING ADJ US TMENTS , LUBRICATING OR

P ERFO RMING ANY OTHER MAINTENANCE , S HUT

OFF ALL POWER CONTROLS .

• BATTERY SHOULD ALWAYS BE DISC ONNECTED

DURING REP LACE MENT OF ELEC TRICAL CO MPO

NENTS .

• KEEP ALL SUP PORT EQUIPMENT AND ATTACH

MENTS S TOWED IN THEIR P ROP ER P LACE .

• US E ONLY AP P ROVED, NONFLAMMABLE CLEANING

S OLVENTS .


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INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

b – JLG Lift – 3120848

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EFFECTIVITY PAGE

3120848 – JLG L ift – c

EFFECTIVITY CHANGES

S eptem be r 15, 1997 - Da te of Issue

J a nua ry 20, 2000 - Revise d

February 7, 2000 – Revise d – Pa ge s Affected ; Se ction-2, Pa ge 2-7, Ta ble 2-1.

(removed lube check requirement for drive wheel gear box)


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EFFECTIVITY PAGE

d – JLG Lift – 3120848

This Page Left Intentionally Blank


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3120848 – JLG Lift –

TABLE OF CONTENTS

SUBJ ECT - SECTION, PARAGRAPH PAGE NO.

SECTION INTRODUCTION - - MAINTENANCE SAFETY PRECAUTIONS

A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a

B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a

C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a

SECTION 1 - SAFETY PRECAUTIONS

1.1 G eneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 Electrocution Haza rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.3 Transporting Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.4 Pre-Operational Sa fety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.5 Operating S afety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

SECTION 2 - PREPARATION AND INSPECTION

2.1 G eneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.2 Preparat ion For Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.3 Delivery And Freq uent Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12.4 Daily Walk-around Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

2.5 Daily Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

2.6 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2.7 Bat tery Charging &Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

SECTION 3 - USER RESPONSIBILITIES & MACHINE CONTROLS

3.1 G eneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.2 Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.3 Operating C haracteristics And Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3.4 Controls And Indica tors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3.5 J lg P ot-Hole Protection Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

SECTION 4 - MACHINE OPERATION

4.1 Machine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14.2 G eneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.3 Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4.4 Quick-chang e Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4.5 Transpo rting, Lifting And Tie Down P rocedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

SECTION 5 - OPTIONAL EQUIPMENT

5.1 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.2 Extendible Platform Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

SECTION 6 - EMERGENCY PROCEDURES

6.1 Ge neral Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.2 Emerge ncy Controls And Their Loca tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.3 Emergency Operat ion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.4 Incident Notifica tion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

SECTION 7 - INSPECTION AND REPAIR LOG


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ii – JLG Lift – 3120848

TABLE OF CONTENTS (Continued)

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

2-1. Daily Walk-Around Inspec tion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

2-2. Ba ttery Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2-3. Charger Assembly and Po wer Cord S torag e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52-4. Battery Charger Front Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-5. Lubrica tion Cha rt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

2-6. Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

3-1. Ground Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3-2. Platform Co ntroller. (OLD STYLE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3-3. Platform Co ntroller. (NEW S TYLE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3-4. Brake Relea se Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

3-5. J LGs Pot-Hole-Protection Device - PHP B ar Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

3-6. Deca l Loca tions (Front View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

3-7. Deca l Loca tions (Rear View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

3-8. Deca l Loca tions (Top View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

3-9. Deca l Loca tions (Rig ht/Left View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

3-10. Wheel Loa d De ca ls (10/15/20VP ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

4-1. Quick-Chang e Platform Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-44-2. Forklift Truck Lifting P oc kets a nd Machine Tie Dow n Ba r Loca tions. . . . . . . . . . . . . . . . . . . . . . .4-5

5-1. Extendible Platform. (Platform shown extended) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1 Minimum Safe Approa ch Distance (to energized powe r lines or parts) . . . . . . . . . . . . . . . . . . . .1-1

2-1 Lubrication Intervals for Various Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

4-1 Maximum Rated Loa d Ca pacity (for all platforms except Extendible). . . . . . . . . . . . . . . . . . . . . .4-2

4-2 Maximum Rated Loa d Ca pacity (for Extendible Platform*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4-3 Mac hine Interlock Switch Operating C onditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4-4 Mac hine Gross Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-67-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1


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3120848 – JLG L ift – 1-1

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL

This sec tion presc ribe s the proper and sa fe pra ctice s formajor areas of machine usage which have been divided

into three b a sic ca teg ories : Trans porting , Pre-Ope ration

and Operation. In order to promote proper usag e of the

mac hine, i t is ma nda tory that a da ily routine b e es tab-

lished based on instruction given in this section. A mainte-

nance prog ram must a lso b e es tablished by a q ualif ied

person a nd must b e followed to ensure that the ma chine

is safe to operate.

The use r/ope rator of the ma chine sh ould not a cc ept ope r-

ating res pons ibility until this ma nual ha s be en READ a nd

UNDERSTOOD, and ope rating instructions of the mac hine

under the s upervis ion of an experience d and qua lif ied

operator, has been completed. If there is a question on

app lica t ion and /or ope ra t ion , J LG Indus t r ies P rod uctS afety a nd Reliab ility personnel should be cons ulted.

MODIFICATION OF THE MACHINE WITHOUT APPROVAL OF JLG

INDUSTRIES, OR CERTIFICATION BY A NATIONALLY RECOG-NIZED TESTING LAB TO BE IN CONFORMITY WITH APPLICABLEREGULATIONS AND TO BE AT LEAST AS SAFE AS BEFORE MOD-

IFICATION, IS PROHIBITED.

1.2 ELECTROCUTION HAZARD

Minimum sa fe ap proac h d is ta nce s (M.S .A.D.) to ene r-

gized (exposed or insulated) powe r lines and parts.

DO NOT MANEUVER MACHINE OR PERSONNEL TO DISTANCELESS THAN M.S.A.D (SEE TABLE 1-1.). ASSUME ALL ELECTRI-CAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWNOTHERWISE.

THIS MACHINE DOES NOT PROVIDE PROTECTION FROMCON-TACT WITH OR PROXIMITY TO AN ELECTRICALLY CHARGED

CONDUCTOR. MAINTAIN A CLEARANCE OF AT LEAST 3M(10FT.) BETWEEN ANY PART OF THE MACHINE AND ANY ELECTRI-CAL LINE OR APPARATUS CARRYING UP TO 50,000 VOLTS. 0.3M

(1 FT.) ADDITIONAL CLEARANCE IS REQUIRED FOR EVERY ADDITIONAL 30,000 VOLTS OR LESS. ALLOWFOR PLATFORM

SWAY, ROCK OR SAG AND ELECTRICAL LINE SWAYING, (SEEFOLLOWING TABLE).

.

1.3 TRANSPORTING MACHINE

Before trans porting (hauling) the ma chine the use r/ope ra

tor must be familia r with the prope r proced ures for trans

por ting the ma chine (see Sect ion 4-5) , a s wel l a s the

weight and size of the ma chine.

The use r/ope rator s hould b e familia r with the surrounding

work area and surface before transporting the machine

The wo rk area must be a firm surface ca pa ble of support

ing the combined weight of the transport vehicle and the

machine.

NOTE: Remember that the key to safe and proper usage is

common sense and its careful application.

ALWAYS RELEASE THE DRIVE MOTOR BRAKES ON THEMACHINE WHEN MANUALLY PUSHING, PULLING, OR WHEN

TRANSPORTING MACHINE BY FORK-LIFT TRUCK. THIS WILLALLOWTHE REAR DRIVE WHEELS, GEAR BOX DRIVE SHAFT

AND GEARS TO ROTATE FREELY PREVENTING ANY DAMAGE TOTHE DRIVE SYSTEM.

IF MACHINE IS PLACED ON A TRANSPORT VEHICLE, REENGAGE THE BRAKES IN COMBINATION WITH PROPERMACHINE TIE DOWN, TO RESTRAIN MACHINE FROMANY MOVEMENT DURING TRANSPORT.

ALWAYS REMEMBER TO RE-ENGAGE THE BRAKE SYSTEMBEFORE OPERATING MACHINE.

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED INTHIS SECTION AND ON MACHINE COULD RESULT IN MACHINEDAMAGE, PERSONAL INJURY OR DEATH AND IS A SAFETY VIOLATION.

Table 1-1. Minimum Safe Approach Distance(to energized power lines or parts)

VOLTAGE RANGE(PHASE TO PHASE)

MINIMUMSAFE DISTANCEMeter [Feet]

0 -300V Avoid Contact

Over 300V to 50KV 3 m [10 f t.]

Over 50KV to 200KV 4.6 m [ 15 f t.]

Over 200KV to 350KV 6 m [ 20 f t.]

Over 350KV to 500KV 7.6 m [25 f t.]

Over 500KV to 750KV 10.6 m [35 f t.]

Over 750KV to 1000KV 13.7 m [45 f t.]


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1-2 – JLG Lift – 3120848

1.4 PRE-OPERATIONAL SAFETY

• READ YOUR MANUAL. UNDERS TAND WHAT YOU’VE

READ - THEN B EG IN OP ERATIONS.

• ALLOW ONLY THOS E AUTHORIZED AND QUALIFIED

P ERS ONNEL TO OP ERATE MACHINE WHO HAVE

DEMONSTRATED THAT THEY UNDERS TAND S AFE

AND P ROP ER OP ERATION AND MAINTENANCE O F

THE UNIT.

• AN OPERATOR MUST NOT ACCEP T OPERATING

RES P ONS IBILITIES UNTIL ADEQUATE TRAINING HAS

BE EN GIVEN BY COMPETENT AND AUTHORIZED

PERSONS.

• BEFORE OP ERATION CHECK WORK AREA FOR

OVERHEAD ELECTRIC LINES . (S EE ELECTROC UTION

HAZARD, S EC TION 1-2.)

• S TUDY THE WORK AREA FOR AREAS TO AVOID

S UCH AS ; S URFACE EDG ES THATD ROP-OFF, HOLES

OR D IPS IN SURFACE , OR ANY UNLEVEL AREAS

WHICH COULD CAUS E THE UNITTO TIP OVER.

• ALSO B EFORE O P ERATION CHECK WORK AREA FOR

MACHINE TRAFFIC S UC H AS FORKLIFTS , C RANES ,

AND OTHER CONS TRUC TION EQUIPMENT.

• ENSURE THAT OP ERATORS OF OTHER OVERHEAD

AND FLOO R LEVEL MACHINES ARE AWARE OF THE

AERIAL P LATFORMS P RES ENCE. DISC ONNECTP OWER TO OVERHEAD CRANES . B ARRICADE FLOOR

AREA IF NECES S ARY.

• P RECAUTIONS TO AVOID ALL KNOWN HAZARDS IN

THE WORK AREA MUS T BE TAKEN BY THE OP ERA-

TOR AND HIS S UP ERVISO R BEFORE S TARTING THE

WORK.

• DO NOT OP ERATE THIS MACHINE UNLESS IT HAS

BEEN S ERVICED AND MAINTAINED ACC ORD ING TO

THE MANUFACTURERS S P EC IFICATIONS AND

SCHEDULE.

• ENSURE DAILY INSP ECTION AND FUNCTION CHEC K

IS P ERFORMED P RIOR TO P LACING MACHINE INTO

OP ERATION. HAVE AUTHORIZED P ERS ONNEL TAKE

ANY NEC ES S ARY CORRECTIVE ACTION BE FORE

P LACING MACHINE INTO OP ERATION.

• NEVER DIS ABLE OR MODIFY ANY S AFETY DEVICE.

ANY MODIFIC ATION OF THE MACHINE IS A SAFETY

VIOLATION.

• DO NOT OP ERATE MACHINE WHEN EXP OS ED TO

HIG H WIND, RAIN OR S NOW.

• NEVER OP ERATE OR RAISE P LATFORM WHEN

MACHINE IS ON A TRUC K OR OTHER VEHIC LE.

• AP P ROVED HEAD G EAR (I.E . HARD HAT, ETC.) MUST

BE WORN WHEN REQUIRED BY ALL OP ERATING AND

G ROUND PERS ONNEL.

• READ AND OBE Y ALL DANGER, WARNING S , CAU-

TIONS AND OP ERATING INSTRUC TIONS ON

MACHINE AND IN THIS MANUAL.

• BE FAMILIAR WITH LOC ATION AND OP ERATION OF

G ROUND C ONTROLS AND EMERGENCY CONTROLS .

LIFT MACHINE AT DESIGNATEDLIFTING POINTS ONLY


11/48


3120848 – JLG L ift – 1-3

1.5 OPERATING SAFETY

FAILURE TO OBSERVE THE FOLLOWING TIPPING HAZARDINSTRUCTIONS COULD CAUSE THE UNIT TO TIP OVER OR BEHARD TO CONTROL WHEN BEING MOVED, WHICH COULD

RESULT IN SERIOUS INJURY OR DEATH DUE TO BEING PINNEDOR CRUSHED BY THE UNIT.

Driving Safety

• READ YOUR MANUAL, UNDERS TAND WHAT YOU’VE

READ - THEN B EG IN OPERATIONS .

• WATCH FOR OBS TRUC TIONS AROUND MACHINE

AND OVERHEAD WHEN MOVING.

• CHECK TRAVEL PATH FOR PERS ONS, HOLES ,

BUMPS , DROP-OFFS, OB S TRUCTIONS , DEBRIS, ANDCOVERINGS WHICH MAY CONC EAL HOLES AND

OTHER HAZARDS , AS TIP P ING COULD OC CUR.

• BEFORE MOVING MACHINE ON FLOORS AND OTHER

S URFACES , C HEC K ALLOWABLE CAPACITY OF S UR-

FACES.

• DO NOT OP ERATE MACHINE ON S OFT FOOTING

THATWILL ALLOW THE WHEELS TO S ETTLE INTO OR

BREAK THROUG H S URFACE, AS TIPP ING WILL

OCCUR.

• NEVER P OS ITION THE UNITS IDEWAYS ON A S LOP E.

• US E C AUTION AND CHEC K CLEARANCES WHEN

MOVING MACHINE IN RES TRICTED OR CLOSE QUAR

TERS .

• ALWAYS US E AN AS S ISTANT WHEN MOVING

MACHINE IN AREAS WHERE VISION IS

OB S TRUC TED.

General Operating Safety

• KEEP NON-OP ERATING P ERS ONNEL ATLEAS T1.8 M

(6 FEET) AWAY FROM MACHINE DURING OP ERA

TIONS .

• DO NOT OP ERATE ANY MACHINE ON WHICH DAN

G ER, WARNING, C AUTION OR INS TRUC TION P LAC

ARDS OR DEC ALS ARE MISS ING OR ILLEGIBLE.

• NEVER EXCEED MANUFACTURERS RATED P LAT

FORM CAPACITY - REFER TO C APACITY DEC AL ON

MACHINE.

• NEVER OP ERATE A MALFUNCTIONING MACHINE. IF

A MALFUNCTION OC CURS , S HUT DOWN THE

MACHINE, RED TAG IT, AND NOTIFY PROP ER

AUTHORITIES .

ALWAYS LOOK IN DIRECTION OF TRAVEL

NEVER OPERATE ON SOFTOR UNEVEN SURFACES


12/48


1-4 – JLG Lift – 3120848

• ALL P ERS ONNEL MUST S TAND CLEAR WHEN P LAT-

FORM IS BEING RAISED OR LOWERED. B E S URE TO

WATCH FO R OVERHEAD AND OTHER OB S TRUC-

TIONS .• CHEC K CLEARANCES ABOVE, ON S IDES AND BOT-

TOM OF P LATFORM WHEN RAISING AND LOWERING

P LATFORM.

• NEVER US E THE MAS T TO G AIN ACC ES S TO OR

LEAVE P LATFORM.

• DO NOT ATTACH OVERHANG ING LOADS TO THE

P LATFORM OR INC REAS E THE P LATFORM S IZE WITH

UNAUTHORIZED DECK EXTENS IONS OR ATTACH-

MENTS .

• DO NOT TIE OFF MACHINE TO ANY ADJ ACENT

S TRUCTURE. NEVER ATTACH WIRE, C ABLE OR ANY

S IMILAR ITEMS TO P LATFORM.• TRANSFERS BETWEEN A STRUC TURE AND THE

AERIAL P LATFORM EXP OS E OP ERATING P ERS ON-

NEL TO FALL POTENTIALS. THIS P RACTICE S HOULD

BE DISCOURAGED WHEREVER POSSIBLE. WHERE

TRANSFER MUS T BE ACC OMPLIS HED TO P ERFORM

THE J OB , AN AP P ROVED FALL PROTEC TION DEVICE

AND TWO S AFETY LANYARDS WILL BE US ED. ONE

LANYARD S HOULD BE ATTACHED TO THE AERIAL

P LATFORM. THE OTHER TO THE S TRUCTURE. THE

S AFETY LANYARD THAT IS ATTACHED TO THE

AERIAL P LATFORM S HOULD NOT BE D ISC ON-

NEC TED UNTIL SUC H TIME AS THE TRANSFER TO

THE S TRUC TURE IS C OMP LETE. WHEN RE-ENTER-

ING THE P LATFORM THIS P ROC EDURE MUS T BEP ERFORMED IN REVERS E. TO AVOID FALLING - US E

EXTREME C AUTION WHEN ENTERING OR LEAVING

P LATFORM ABOVE GROUND. ENTER OR EXIT THRU

G ATE ONLY. P LATFORM FLOOR MUS T BE WITHIN 31

CM (1 FT.) OF ADJACENT - SAFE AND S EC URE -

S TRUCTURE. ALLOW FOR ANY VERTICAL MOVE-

MENT OF P LATFORM (UP OR DOWN) WHEN ENTER-

ING OR LEAVING P LATFORM.

• NO HORS EP LAY IS P ERMITTED IN P LATFORM.

• DO NOT ALLOW P ERS ONNEL TO TAMPER WITH,

S ERVICE, OR OP ERATE THIS MACHINE FROM THE

G ROUND WITH P ERS ONNEL IN PLATFORM EXCEP T

IN AN EMERG ENC Y.• DURING OP ERATION KEEP ALL BODY PARTS INS IDE

P LATFORM RAILINGS .

• NEVER P OS ITION LADDERS , S TEP S , OR S IMILAR

ITEMS ON UNIT TO P ROVIDE ADDITIONAL REACH

FOR ANY PURPOSE.

ALWAYS STAND ON PLATFORM FLOOR

NOT ON BOXES, PLANKS OR RAILINGS

KEEP EVERYONE CLEAR OF A

WORKING PLATFORM


13/48


3120848 – JLG L ift – 2-1

SECTION 2. PREPARATION AND INSPECTION

2.1 GENERAL

This sec tion provide s the nec ess ary information need edby those personnel tha t a re respons ible to p lace the

machine in operation readiness, and lists checks that are

performed prior to use of the machine. It is important that

the in format ion c onta ined in th is s ec t ion b e rea d a nd

understood before any a t tempt is made to operate the

mac hine. Ensure that all the neces sa ry inspections have

been completed successfully before placing the machine

into s ervice. Thes e proced ures w ill aid in o bta ining ma xi-

mum s ervice life and sa fe operation.

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON-TROL OVER THE FIELD INSPECTION AND MAINTENANCE, THIS

IS THE RESPONSIBILITY OF THE OWNER/OPERATOR.

2.2 PREPARATION FOR USE

Before a new ma chine is put into o perat ion i t must be

carefully inspected for any evidence of damage resulting

from s hipment a nd inspec ted pe riod ica lly therea fter, as

outlined in Section 2-3, Delivery and Frequent Inspection.

The unit sho uld be thoroug hly chec ked for hydraulic lea ks

during initial start-up and run. A check of all components

should be ma de to as sure their security.

All preparation necessary to place the machine in opera-

t ion read iness s ta tus a re the respo nsibility of mana g e-

ment personnel . P repara t ion requires good common

sense , (i.e. lift wo rks smoo thly) coupled with a series of

visua l inspe ctions. The m and atory req uirements a re g iven

in Section 2-4, Daily Walk Around Inspection.

It should be as sured that the items a ppea ring in the Deliv-

ery and Freq uent Inspec t ion a nd Funct iona l Check a re

co mplied with prior to putting the ma chine into se rvice .

2.3 DELIVERY AND FREQUENT INSPECTION

The follow ing che ck list provide s a sys tema tic inspe ctionto as sist in detec ting d efective, da mag ed , or improperly

insta lled parts . The c hec k lis t d enotes the i tems to b e

inspe cted and co nditions to examine. Frequent inspection

shall be performed every three (3) months or 150 hours

or more often when required by environment, severity

and freq uency of usag e.

Platform Assembly

Proper ly se cured; no v is ib le d am ag e; f ree o f d irt and

debris. Platform gate functions properly.

Mast

No visible d am ag e, a bras ions a nd/or distortions; no b ind-ing ; ma st se ctions free of dirt or other foreign ma teria l

Se quenc ing c ab les properly secured; no visible da mag e

proper cab le tension.

Mast Chains

No v is ible da mag e; proper cha in tens ion ; ev idence o

proper lubrica tion. C hain shea ves, s hea ve pins a nd rollers

properly secured; no visible damage.

Platform Controller/(Power) Cable(s)

No visible da mag e; ca ble properly tensioned and sea ted

in control cab le s heaves; c ontrol cable shea ves not da m

ag ed a nd rotating freely.

Lift Cylinder (check w/mast extended)

No rust, nicks, sc ra tches or foreign m aterial on piston rod

No leakag e. Evidence of proper lubrica tion.

Frame

No vis ible d ama ge ; loose o r missing ha rdware (top and

underside) .

Drive Wheels and Front Casters

Casters free rolling; no loose or missing parts; no visible

damage. Drive wheel hub snap rings secure; no damage

to whee l tread; electric d rive motors se cure; no loose omiss ing wires .

Hydraulic Oil Supply

Che ck the hy dra ulic oil level of the hyd raulic fluid res ervoi

located in the lower access hole on the rear cover. Main

tain a n o il level to the “Fill To Line” indica tor on the s ide o

reservoir.


14/48


2-2 – JLG Lift – 3120848

If fluid level is low, se e S ervice Ma nua l, Se ction 1 - Spe cifi-

ca tion s; S ub -S ec tion 1-5. “Lubrica tion ”; Ta ble 1-1. “Rec -

ommended Hydraulic Oils” for use in machine.

Controls - (Platform and Ground)

Controls operable; no visible d ama ge; plac ards secureand leg ible.

Batteries

P roper electrolyte level; ca ble co nnec tions tigh t; no visible

damage; no corrosion at battery cable connections.

Pump Motor/Hydraulic Pump/ValvesandLines

No lea kage ; units se cure.

Placards

No visible da mag e; placa rds se cure and legible.

2.4 DAILY WALK-AROUND INSPECTION

It is the use r/op era tor’s res po ns ibi li ty to insp ec t the

machine before the start of each work day. It is recom-

mende d that ea ch use r/ope rator inspe ct the mac hine

before operation, even if the mach ine ha s a lready b een

put into s ervice unde r a nothe r use r/op erato r. This Da ily

Wa lk-Around Inspe ction is the preferred method of ins pec -

tion.

GENERAL

Be g in the “Wa lk-Around Ins pe ction” a t item one lis ted fo l-lowing. Continue around machine checking each item in

se q uen ce fo r the c on dition s liste d in the “Wa lk-Around

Inspe ction C hec k list”.

TO AVOID INJURY DO NOT OPERATE MACHINE UNTIL ALL MAL-FUNCTIONS HAVE BEEN CORRECTED. USE OF A MALFUNC-TIONING MACHINE IS A SAFETY VIOLATION.TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS“OFF” DURING “WALK-AROUND INSPECTION”.

NOTE: Do not overlook visual inspection of the base frame

underside. Check this area for objects or debris

which could cause extensive machine damage.

1. Drive and Caster Wheels - Properly secured and

lubricated. Check for any visible damage or debris,

stuck to or around w heels.

2. Base Frame - No visible da ma ge ; d rive whee l motor

compo nents properly s ecured; J LG ’s P ot-Hole-Pro-

tection System components secure; no loose wires

or cables dangling below the base; bubble level in

place a nd functioning properly.

3. Battery/Battery Charger - Prope r ba ttery electrolyte

level, ca bles sec ure, no da mag e or corros ion.

4. Motor/Pump/Reservoir Unit - Properly secured, no

visible damage, no evidence of hydraulic leaks.

Hydraulic oil level should be filled level with the full

line, (“Fill To Line”) on the side o f the hyd raulic rese r-voir. Also check that reservoir cap is properly

secured.

5. Ground Controls - Properly secured, no loose ormissing parts, no visible damage; key switch opera-

ble, no visible da mag e; placa rds secure and leg ible;

emergency stop switch, no visible damage and

properly set for operation.

6. Mast Assembly - Mast sections properly secured,no visible damage to mast sections, no loose or

missing parts, slide pads properly secured. Mast

cha ins properly sec ured a nd lubrica ted. Se q uencing

cables properly secured and undamaged. Platform

control and power cab les (on side of mast) , no visi-

ble damage; cables properly tensioned and seated

in sheaves; cable sheaves not damaged and rotat-

ing freely. Eleva tion/S pe ed Limit switch (top inside of

mast section 1) s ecure a nd working properly.

7. Manual Brake Release Control - Handle secure

and undamaged; cables attached properly; control

in working order.

8. Platform Assembly - Secure to mast; All railingssec urely attached ; no loose o r miss ing pa rts, no vis-

ible damage; sliding entry bar in proper working

orde r. Platform ga te wo rking properly, no visible sig n

of dama ge (if so equipp ed) .

9. Platform Controls - P latform up /do wn , functionenable and horn buttons on faceplate working prop-

erly, no loose or missing parts, no visible damage.

Joystick control secure and working properly. Plac-

ards secure and legible, emergency shut-off button

set for operation. Control markings legible; Opera-

tors manual enclosed in manual storage box.

In a dd ition to the Da ily Wa lk-Around Inspec tion, be sure to

include the following as part of the daily inspection:

Batteries Charged

S tart ea ch d ay with fully cha rged ba tteries. (See Section 2-

7. “Battery Charging & Maintenance”)

Overall Cleanliness

Keep oil, g rease , wa ter, etc. wiped from stand ing s urface s

and ha nd holds .

Placards

Keep a ll informat ion and operat ing plac ards clean a nd

unobstructed. Cover areas where placards are present


15/48


3120848 – JLG L ift – 2-3

when us ing the mac hine for spraying pa int or any ma terial

which could co ver these surfa ces and reduce leg ibility.

Operation and Safety Manual

Ensure a copy o f manual is e nclose d in the ma nual stor-

ag e box.

Lubrication

For those pa rts pointed out in the Wa lk-Around Insp ec tion

req uiring lubrication, refer to the Lubrica tion Cha rt, Figure

2-4., for s pec ific time interval req uireme nts.

2.5 DAILY FUNCTIONAL CHECK

TO AVOID INJURY DO NOT OPERATE A MACHINE UNTIL ALLMALFUNCTIONS HAVE BEEN CORRECTED. USE OF A MALFUNC

TIONING MACHINE IS A SAFETY VIOLATION.

Once the Wa lk-Around Inspe ction is c omp lete, a Func

t iona l Check of a l l sys tems s hould be p erformed in an

area free of overhead and ground level obstructions. Per

form a Functiona l Check in ac corda nce with the following

procedures:

Set-up machine for operation, according to instructions in

Se ction 4-3, “Machine Opera tion” .

Ground Controls

1. With key switch turned to GRND position (clockwise) , operate the platform up and down switch

(located in lower access hole with hydraulic fluid res

ervoir) . Raise a nd lowe r pla tform .5m to 1m ( 2 ft. to 3

Figure 2-1. Daily Walk-Around Inspection.

1

1

2

3

4

5

6

7

8

9

Daily Walk-Around

Inspection Items

1. Drive and Castor Wheels2. Base Frame

3. Battery/Battery Charger

4.Motor/Pump/Reservoir Unit

5. Ground Controls

6. Mast Assembly

7. Manual Brake ReleaseControl

8. PlatformAssembly

9. PlatformControls


16/48


2-4 – JLG Lift – 3120848

ft.) several times. Check for smooth elevation and

lowering o f pla tform.

2. With platform completely lowered, check hydraulic

oil level in hyd raulic fluid res ervoir. If nece ss a ry, a dd

hyd raulic fluid to prop er level (full line) . NEVER US E

HYDRAULIC BRAKE FLUID, refer to the LubricationChart (Table 2-1) for specific requirements.

3. Depres s EMERG ENCY S TOP (red) button (next to key switch) , all machine operations will be disabled

if functioning properly. If ok, reset EMERGENCY

S TOP for operation.

4. Set key switch to PLAT (platform ope ration, all the way co untercloc kwise) and continue with the follow-

ing steps.

Platform Controls

SEE SECTION-3 FOR INFORMATION ABOUT MACHINE CON-

TROLS AND SECTION-4 FOR PROPER OPERATION OF MACHINE.

1. Enter platform and check the MANUAL BRAKERELEASE CONTROL (Over-center handle mounted

on side o f mast) , is set properly for normal operation

(brakes engaged ) .

2. Ch ec k tha t the P LATFORM CO NTROLLER b ox isproperly mounted (facing forward) and secure on

the platform’s rail.

3. On the P LATFORM CONTROLLER bo x, chec k theBATTERY S TATUS INDICATOR LED’s for cha rge

status of ba tteries.

4. Che ck for proper o peration o f the FUNCTION

ENABLE pa d, a nd tha t the J OYSTICK CONTROL

moves freely.

5. Activate the J OYS TICK and slow ly move it in a lldirections, if operating properly the machine will

mo ve in the d irec tion the J OYS TICK is pointed .

6. While d riving the ma chine forward rotate the SP EED

CO NTROL knob from ma ximum to minimum (clock-

wise to co unterclockwise) checking for proper oper-

ation. If operating properly, speed should vary from

.8 to 3.2 kph (1/2 mph to a maximum of 2 mph) .

7. Activate the platform UP and DOWN buttons (up arrow and d own arrow) to raise and lower platform

.5m to 1m (2 ft. to 3 ft.) several times. Check for

smooth elevation and lowering of platform.

8. With the p la tform e leva ted che ck the J LG Automa tic

Pot-Hole-Protection system, if operating properly,

the PHP bars on each side of the machine base will

be automatically engaged (lowered) with the plat-

form raised.

9. With the platform still elevated approximately .5m (2 ft.) , drive machine and check if speed cut-back is

operating properly, machine should drive at low

speed only (appro x. .8 kph (1/2 mph ) .

10. Depress the EMERGENCY STOP (red) button on the

Platform Controller box, all machine operations willbe disabled if functioning properly. RESET the

EMERG ENCY S TOP.

Tilt Sensor (1.5°) and Drive Brakes

1. With the platform lowered, drive the machine onto agrade within the allowable grade and slope limits of

the machine (maximum g rade of 15% or 8.5°, maxi-

mum s ide slope o f 5°) . S top the mac hine pa rt of the

wa y up the grad e, che ck if the drive brakes ho ld the

ma chine in place . Also while o n the g rade (of greater

than 1.5°) , a ttempt to raise the platform. The tilt se n-

sor (1.5°) must prevent the platform from elevating

and will so und a beeping a larm a t the platform con-

troller bo x.

If all machine functions a re ope rating properly, ma chine is

ready for operation.

2.6 TORQUE REQUIREMENTS

The Torque Cha rt, Figure 2-5., co nsists o f sta nda rd torque

values b as ed o n bolt diame ter and grad e, it also spe cifies

dry and wet torque va lues in acco rdance with recom-

mend ed s hop prac tices . This cha rt is provided a s a n aid

to the user/ope rator in the event he/she notices a co ndi-

tion that req uires p rompt a ttention d uring the wa lk-a round

insp ec tion or during ope ration until the prope r service per-

so nnel ca n be notified. Utilizing this Torq ue C ha rt in co n-

junction with the P reventive Maintena nce an d Inspe ction

S ched ule ta ble in the S ervice Ma nual, will enhanc e the

sa fety, relia bility, a nd p erforma nce of the ma chine.


17/48


3120848 – JLG L ift – 2-5

2.7 BATTERY CHARGING & MAINTENANCE

VP Mod els a re eq uipped with 24 volt, 10 amp o utput bat-

tery chargers ( Europe - 240V AC inpu t/50 Hz, U.K. On ly -

120/240V AC input/50Hz, Australia - 250V AC inp ut/50 Hz) .

The b attery cha rger includes a microproces sor c ontrolledautoma tic c harge sens ing c ircuit which ca n determine ce ll

vo lt ag e a nd reg ula te cha rg er ou tput a s required . The

cha rger automa tica lly terminates cha rging when a full bat-

tery cha rge is ac heived. Also a built-in interloc k device

prohibits driving the ma chine w hile the b attery cha rger is

plugged in.

Battery Maintenance and Safety Practices

(Refer to Figure 2-2.)

ENSURE THAT BATTERY ACID DOES NOT COME INTO CONTACT

WITH SKIN OR CLOTHING. WEAR PROTECTIVE CLOTHING ANDEYEWEAR WHEN WORKING WITH BATTERIES. NEUTRALIZE ANY BATTERY ACID SPILLS WITH BAKING SODA AND WATER.

BATTERY ACID RELEASES AN EXPLOSIVE GAS WHILE CHARG-ING, ALLOWNO OPEN FLAMES, SPARKS OR LIGHTED TOBACCOPRODUCTS IN THE AREA WHILE CHARGING BATTERIES.CHARGE BATTERIES ONLY IN A WELL VENTILATED AREA.

ADD ONLY DISTILLED WATER TO BATTERIES. WHEN ADDINGDISTILLED WATER TO THE BATTERIES, A NON-METALLIC CON-

TAINER AND/OR FUNNEL MUST BE USED.

As with a ny w et ce ll ba ttery, che ck the e lec trolyte level of

the ba t ter ies o f ten , adding only d is t i l led wa ter whenrequired. When fully charged, battery fluid level should be

1/8" b elow vent tube s. (See Figure 2-2.) .

• DO NOTfill to bottom of vent tubes.

• DO NOT allow fluid level to go b elow the top of the

pla tes when cha rging o r operating.

Battery Charger Operation

(Refer to Figure 2 -3 & 2-4.)

1. Position machine in well ventilated area near an ACelec trica l outlet an d s et the G round Co ntrol-P LAT/

OFF/G RND key s witch to the OFF po sition .

2. Open the left battery cover and unwrap the batterycharger AC power cable from under the cover.

3. Connect the battery charger AC power cable to aproperly g rounded recepta cle, use a suitable exten-

sion cord, if necess ary.

4. When po wered o n, the cha rger runs through a self-

diag nos tic che ck which ligh ts a ll five (5) ligh ts o n the

face of the cha rger three (3) times , then ea ch ligh t in

sequence, then all five (5) lights three (3) times

ag ain on the front pa nel of the b attery charger.

5. When ready to charge, the CHARGER ON light andthe INCOMPLETE lig ht on the fron t pa nel of the

charger will light up, the charger will then begin to

cha rge the ba tteries.

NOTE: If the ABNORMAL CYCLE light comes on and stays

on at any time during the charge cycle, see sub-sec

tion following about the ABNORMAL CYCLE indica

tor light.

Figure 2-2. Battery Fluid Level.

Figure 2-3. Charger Assembly and

Power Cord Storage.

1/8 "

BATTERY

FILLER CAPFLUID LEVEL OF FULLY

CHARGED B ATTERY

VENT TUBE

PLATES

KEY

SWITCH

CORD

STORAGE

AREA

BATTERY

CHARGER


18/48


2-6 – JLG Lift – 3120848

6. When the b a ttery cell voltag e rea che s 2.37 V/ce ll the

80%CHARGE lig ht on the front pa nel of the cha rg er

will light up. The c ha rge r then c ontinues to mon itor

the increas e in charge until it sees no increase , and

then terminates the c harging proces s.

7. The C HARG E CO MPLETE lig ht will c om e o n whe nthe cha rging proce ss is finished .

8. Unplug the charger AC power cord and wraparound s torage lugs under the left battery cover.

Abnormal Cycle Indicator Light

If the ABNORMAL CYCLE indicator light should come on

during the normal cha rging cyc le o f the ba tteries, it could

indicate any of the following cond itions;

• The AC input to the cha rger was interupted, i.e. loca l

pow e r fa i lu re o r c ha rg e r c a b l e wa s unp lug g e d o r

bumped and power was interupted intermittently.

• A de a d ce ll or cells in either ba ttery wo uld prevent thecha rger from sensing eno ugh voltag e to co mplete the

battery charge.

• One or more of the batteries terminal connections loos e

resulting in an intermittent incomplete circuit. Figure 2-4. Battery Charger Front Panel.


19/48


3120848 – JLG L ift – 2-7

Figure 2-5. Lubrication Chart.

2

1

3

4, 5

6

Table 2-1.Lubrication Intervals for Various Components

ITEM COMPONTENTNO/TYPE

LUBE POINTSLUBE/METHOD

INTERVAL HOURS

COMMENTS3

MONTHS150 Hrs.

6

MONTHS300 Hrs.

1

YEAR600 Hrs.

2

YEARS1200 Hrs.

1 Hydraulic Oil Fill To Line onReservoir5 Qt. Reservoir

HO - Check Hyd. Oil LevelHO - Change Hyd. Oil

Check hydraulic oil every 10 hrs.Change hydraulic oil every 1200hrs.

2 Drive WheelBearings

4 - Grease Fittings MPG- Pressure Gun

3 Drive WheelGear Box

2 - Gear Box Gear OilChange only when serviced -requires 176cc’s to fill.

4 Caster Axles 2 - Grease Fitting MPG - Pressure Gun

5 Swivel Raceways 2 - Front Casters MPG - Pressure Gun

6 Mast Chains * 2 - Per Section Chain Lube - Brush orSpray

*Applies Only to Mast Sections with Chains.

Key to Lubricants: MPG - Multipurpose Grease HO - Hydraulic Oil - See Table 7-1. in Service Manual.

Notes: 1. Be certain to lubricate like items on each side of the machine.2. Recommended lubricating intervals are based on normal use. If machine is subjected to severe operating conditions,

such as a high number of cycles, location, corrosive/dirty environment, etc., user must adjust lubricating requirements accordingly.3. Prior to checking hydraulic oil level, operate machine through one complete cycle of lift function (full up and down). Failure to do so will

result in incorrect oil level reading on the hydraulic reservoir.


20/48


2-8 – JLG Lift – 3120848

Figure 2-6. Torque Chart.


21/48

SECTION 3 - USER RESPONSIBI LITIES & MACHINE CONTROLS

3120848 – JLG L ift – 3-1

SECTION 3. USER RESPONSIBILITIES & MACHINE CONTROLS

3.1 GENERAL

SINCE THE MANUFACTURER HAS NO DIRECT CONTROL OVER

MACHINE APPLICATION AND OPERATION, CONFORMANCE WITHGOOD SAFETY PRACTICES IN THESE AREAS IS THE RESPONSI-BILITY OF THE USER AND HIS OPERATING PERSONNEL.

This sec tion provide s the nec ess ary information need ed

to understand control functions. Included in this section

are the o perating cha racteristics a nd limitations, a nd func-

tions a nd purpose s o f controls a nd indicators. It is impor-

t an t tha t the user/ope ra tor rea d a nd und ers t an d the

proper proce dures b efore operating the ma chine. These

proce dures will aid in ob taining optimum service life a nd

safe operation.

3.2 PERSONNEL TRAINING

The a eria l lift is a perso nnel ha ndling d evice; the refore, it

is essential that it be operated and maintained only by

authorized personnel who have demonstrated that they

understand the proper use and maintenance of the

machine. It is important that all personnel who are

as signed to a nd respons ible for the operation and ma inte-

nance of the machine undergo a thorough training pro-

gram and check out period in order to become familiar

with the characteristics prior to operating the machine.

Persons under the influence of drugs or alcohol or whoare subject to seizures, dizziness or loss of physical con-

trol must not be permitted to ope rate the ma chine.

Operator Training

Ope rator training mus t include instruction in the following

1. Use and limitations of the platform controls, groundcontrols and emergency controls.

2. Knowledg e a nd understanding of this ma nual and othe control markings, instructions and warnings on

the machine itself.

3. Knowledge and understanding of all safety workrules of the employer and Federal, State and Loca

Statutes, including training in the recognition and

avoidance of potential hazards in the work place

with particular a ttention to the wo rk to be performed

4. Proper use of all required personnel safety equip

ment.

5. Sufficient knowledg e of the me cha nica l ope ration o

the machine to recognize a malfunction or potentia

malfunction.

6. The sa fest means to ope rate near overhea d ob structions, other moving equipment, obstacles, depres

sions, holes, drop-offs, etc. on the supporting

surface.

7. Mea ns to avoid the haz ards o f unprotected electrica

conductors.

8. Any other requirements of a specific job or machine

application.

Training Supervision

Training must b e d one unde r the s upervision of a q ua lified

operator or supervisor in an open a rea free of ob structions

until the trainee ha s developed the a bility to s afely co ntro

an ae rial lift in c ong es ted w ork loc ations.

Operator Responsibility

The o perator must be instructed tha t he ha s the respo nsi

bility and authority to shut dow n the ma chine in ca se of a

malfunction or other unsafe condition of either the

machine or the job site and to request further information

from his supe rviso r or JLG Distributor be fore proc ee ding .

NOTE: Manufacturer or Distributor will provide qualified per

sons for training assistance with first machine(s)

delivered and thereafter as requested by user or his

personnel.


22/48

SECTION 3 - USER RESPONSIB ILITIES & MACHINE CONTROLS

3-2 – JLG Lift – 3120848

3.3 OPERATING CHARACTERISTICS ANDLIMITATIONS

General

A thorough knowledge of the operating characteristicsand limitations of the machine is always the first require-

ment for any user, regardless of user’s experience with

simila r types o f eq uipment.

Placards

(See Figures 3-6, 3-7, 3-8 & 3-9.)

Important points to remember during operation are pro-

vide d a t the co ntrol sta tions by DANG ER, WARNING,

CAUTION, IMP ORTANTa nd INS TRUC TION pla ca rds . This

information is place d a t various loca tions on the mac hine

for the express purpose o f alerting personne l of potentia l

haza rds co nstituted b y the ope rating cha racteristics and

load limitations of the machine. See the Foreword at thestart of this manual for a definition of the seriousness of

each of the above placard types. See decal location fig-

ures in this s ection for deca ls w hich app ly to this ma chine.

Capacities

Raising the platform above the stowed position is based

on the following criteria:

• The mac hine is pos itioned on a smoo th, firm level sur-

face.

• The loa d is within manufacturer’s rated ca pac ity.

• All machine s ystems a re functioning p roperly.

Stability

This ma chine, as origina lly ma nufactured b y J LG , and

when o perated w ithin its rated ca pac ity on a smoo th, firm

and level supporting surface, (check b ubble level indica-

tor on base frame) , provides a stable aerial platform for all

platform po sitions .

3.4 CONTROLS AND INDICATORS

Ground Controls

(See Figure 3-1.)

NOTE: When the machine is not being used or when charg-

ing the battery, be sure the POWER PLAT/OFF/

GRND KEY SWITCH is positioned to OFF to prevent

draining the batteries. For information on battery

charging see SECTION 2-7, Battery Charging.

1. POWER PLAT/OFF/GROUND KEY SWITCH

A key ope ra ted po wer P LAT/OFF/G ROUND s witch

located in the upper access hole of the rear cover

(on back of machine) , co ntrols po wer to a ll functions

on the ma chine. The ma chine platform controls will

not operate without the key inserted and turned to

the PLAT (platform) position. When the key switch is

set to the GRND (ground) position this allows use ofthe platfo rm UP /DOWN switch loca ted n ext to the

hydraulic oil reservoir (lower access hole) . When left

unattended, removing the key will prevent unautho-

rized mac hine us e.

2. PLATFORM UP/DOWN (GROUND CONTROL)

The g round o perated platform control switch is

located next to the hydraulic reservoir in the lower

a cce ss hole of the rea r cover. This three po sition

tog gle s witch w ill raise (lift up) and lower (lift dow n) ,

the platform from the ground control position when

the P LAT/OFF/G RND key s witch is s et to the G RND

(ground) po sition.

3. EMERGENCY STOP BUTTON

An EMERG ENCY S TOP (red button) is mounted on

both the ground control station and the platform

controller. When either button is depressed, all

ma ch ine func tions w ill sto p. To re-ac tiva te powe r to

the machine, turn button to RESET the emergency

stop b utton.

4. EMERGENCY/MANUAL DESCENT KNOB

This (RED knu rled) knob, located on the electric/

hydraulic pump-motor unit in the lower access hole

of the rear cover provides for lowering of the plat-

form in the event of an emergency or power failure.

Turn knob (counterclockwise) to ope n the valve and

low er the platform. This valve must b e c los ed

(turned all the way cloc kwise) for normal operation

of the machine. (Refer to Section 6 for Emergency

Descent operating proced ures.)

5. HYDRAULIC OIL RESERVOIR

The hyd raulic oil rese rvoir is ho use d inside the low er

a cce ss hole in the rear cover. Che ck the hydraulic oil

level visually by observing the oil level in the reser-


23/48


3120848 – JLG L ift – 3-3

voir a s c omp a red to the FILL TO LINE indica tor on

the side o f the rese rvoir. Hydraulic o il can b e a dd ed

if necessary through the OIL FILL CAP on top of the

reservoir. DO NOTOVERFILL.

NOTE: Always check hydraulic oil level with oil at operating

temperature and with the platform completely low-

ered.

Platform Controller(See Figure 3-2. & 3-3.)

The platform con troller conta ins a ll the co ntrols ne ce ss a ry

to op erate the lift from the p la tform.

The follow ing is a d es cription of ea ch function.

1. BATTERY VOLTAGE / FAULT CODE LED INDICA-TORS.

The LED strip (green when lit) running between the

pad buttons on the controller pad indicates the bat-

tery voltag e level when the ma chine is po wered-up.

The g rad ua ted LED strip indicate s b a tteries at FULL

CHARGE (25 volts) whe n lit all the w ay to the to p (F),and a LOW CHARGE (18 volts) at bottom (E) when

one or two LEDs are illuminated.

NOTE: When voltage drops below 16.5 volts an error code

is indicated, and the batteries will require a recharge.

This LED strip a lso a cts a s a fault co de indicato r to

help diagnose problems with the machines’ electri-

cal system. (See Service M anual Troublesho oting,

for information about reading fault codes) .

2. FUNCTION ENABLE SWITCH (OLD STYLE) (Fig. 3-2

This s witch must be pres se d b efore a ny of the plat

form or joystick drive functions can be operated

Once activated, the operator has approximately

three seconds to activate any of the control func

tions.

Figure 3-1. Ground Controls.

Figure 3-2. Platform Controller. (OLD STYLE)


24/48


3-4 – JLG Lift – 3120848

2. LIFT ENABLE SWITCH (NEW STYLE) (Fig. 3-3.)

The LIFT ENABLE switch mus t be press ed and

HELD be fore UP /DOWN LIFTo f the pla tform is ope r-

ational.

3. PLATFORM UP SWITCH (Up Arrow)

When pres sed and HELD this switch raises the plat-

form to a higher level, when released the upward

movement is stopped.

4. PLATFORM DOWN SWITCH (Down Arrow)

When pressed and HELD this switch lowers the plat-

form from a raised position, when released, the

downwa rd mo vement is s topped.

5. EMERGENCY STOP/SHUT-OFF BUTTON

An EMERG ENCY STOP (RED) button is provided in

order to immediately stop machine functions from

the platform in the event of an emergency. When

button is d epresse d, a ll ma chine functions will stop.To re-activate po we r to the ma chine, turn button

clockwise to RESETthe emergency stop.

6. JOYSTICK DRIVE/STEER CONTROL(OLD STYLE)

This is a “Po int & Go ™” control which moves the

platform in the d irection which the stick is moved . It

is a fully proportional control, the further from the

center position the joystick is moved, the faster the

ma chine tra vels. To a ctivate the c ontrol depress the

FUNCTION ENABLE switch a nd mo ve the joys tick

within three (3) se con ds .

7. JOYSTICK DRIVE/STEER CONTROL and DRIVEENABLE BUTTON (NEW STYLE)

This is a “P oint & G o™ ” c ontrol which moves thema chine in the direction which the stick is moved . It

is a fully proportional control, the further from the

center position the joystick is moved, the faster the

ma chine travels. To a ctivate the co ntrol PRES S a nd

HOLD the DRIVE ENABLE BUTTON on the top of

the joystick.

8. VARIABLE SPEED CONTROL

The variab le s peed control knob ca n be used to

speed up or slow d own d rive speed of the ma chine.

Adjust speed knob while driving machine with joy-

stick controller, clockwise increases speed, counter-

clockwise decreases speed.

Drive speed is automatically cut from 3.2 kph to .8

kph (2 mph to 1/2 mph) when the platform is in an

elevated p os ition. The s pee d c ontrol knob wo rks

with the platform in this position, but to a lesser

degree.

9. WARNING HORN PAD

If machine is equipped with (optional) mounted

horn, this pa d when press ed so unds the horn.

Brake Release Control

(See Figure 3-4.)

Standard equipment on all VP Series lifts is a braking sys-tem integrated into the electric m otor d rive s ystem . The

braking system is spring engaged and released electri-

cally while the machine is being driven with the joystick

controller. When the lift is at rest or the power is turned off,

the brakes are automatically engaged.

If the lift must be moved around manually such as

described in the following examples; the batteries

become depleted and the machine needs to be moved

from an a isleway, or ma chine is be ing winched onto a roll-

ba ck truck bed , etc. To relea se the b rakes, a brake relea se

control has been provided to enga ge/disenga ge the brake

system.

FOLLOWALL APPLICABLE SAFETY PRECAUTIONS WHEN MAN-UALLY MOVING MACHINE AROUND(SEE SECTION 1-3) .

The b rake releas e c ontrol lever is loca ted o n the right s ide

of the mast (bubble level side) . To disenga ge o r engag e

the brakes, check the brake decal located just above the

hand le a sse mbly to s ee w hich direction the hand le need s

to be pointed, (the brakes a re ENG AG ED (normal driving

position) when the handle is in the up (vertical) position,

Figure 3-3. Platform Controller. (NEW STYLE)


25/48


26/48


27/48


3120848 – JLG L ift – 3-7

Figure 3-7. Decal Locations (Rear View)


28/48


3-8 – JLG Lift – 3120848

Figure 3-8. Decal Locations (Top View)


29/48


3120848 – JLG L ift – 3-9

Figure 3-9. Decal Locations (Right/Left View)

P/N-1703072 WHEEL LOAD DECALS

SEE FIGURE 3-10.

P/N-1703636

P/N-1703708

BRAKE

1703636

FREE

WHEELING

BRAKE HANDLE MUST

BE IN “FREE-WHEELING“

POSITION & GROUND

STATION KEY

SWITCH MUST BE

IN “OFF” POSITION

BEFORE TOWING OR

WINCHING MACHINE

TOW OR WINCH

SLOWLY:

2 MPH MAX.

1703708


30/48


3-10 – JLG Lift – 3120848

Figure 3-10. Wheel Load Decals (10/15/20VP)

1703501

MAX180 kg396 lbs

1703502

MAX260 kg573 lbs

1703503

MAX375 kg

826 lbs

P/N-1703501

P/N-1703502

P/N-1703503

10VP

15VP

20VP


31/48


3120848 – JLG L ift – 4-1

SECTION 4. MACHINE OPERATION

4.1 MACHINE DESCRIPTION

The J LG VP S eries mod el line o f lifts a re a n elec tric se lf-propelled ma chine, with a n a erial wo rk platform mounted

to a n elevating aluminum ma st mec hanism. The ma st is

ra ised and lowered by a hydrau lic c y linder ex tending

betwee n ma st se ction-1 and -2, the remaining ma st sec -

t ions are proport ionally extended and retracted using

steel cha ins o r cab les. Hydraulic press ure is s upplied to

the lift cylinder by an electrically powered hydraulic pump.

All VP S eries mod els feature a steel ba se fram e w ith swivel

ca ster wheels mo unted on the front and fixed d rive whee ls

on the rea r of the ma chine. The perso nnel lift’s intended

purpose is to provide personnel (with their tools and sup -

plies) a ccess to areas a bove ground level.

The J LG VP lift has a prima ry co ntroller in the p la tform.From the platform controller the o perator c a n d rive the

unit and raise or lowe r the platform. Ground c ontrols a re

also provided , these c ontrols cons ist of a keyed pow er on/

off/grnd s witch, an eme rgenc y stop button, a n emer-

ge ncy/manua l decent va lve a nd a platform up/dow n co n-

trol switch.

Instruct ions a nd wa rnings are pos ted ad jac ent to both

platform and g round operator control stations and at other

places on the ma chine. It is e xtremely important tha t the

user/ope rator know w ha t instructions an d w arnings a re

plac ed o n the mac hine a nd in the ma nual. And that these

instructions a nd w a rning be review ed period ica lly.

The J LG VP perso nne l lift is d es igned to provide e fficient

and sa fe opera t ion when ma inta ined a nd opera ted in

a c c o r d a n c e w it h in s t ru c t io n s a n d w a r nin g s o n t h e

mac hine, in the Operating, S a fety a nd Maintena nce Man-

ual, and b y ob eying all job site a nd g overnment rules and

regulations . As with a ny type o f mac hine, the o perator is

very important to efficient and safe operation. It is abso-

lutely nec es sa ry that the J LG VP lift be regularly ma in-

tained in a cco rdance with this manua l.

Any evidence of lack of maintenance, malfunction, exces

sive we ar, da mag e or mod ifica tion to the ma chine must be

reported immed ia tely to its o wne r, the job site supe rviso ror safety manager and that the machine be taken out o

se rvice until a ll disc repan cies a re corrected.

The J LG VP perso nnel lift is n ot intended to b e us ed to lif

ma terial other than supplies which perso nnel in the plat

form require to do their job. Supplies or tools which

extend o utside the platform are prohibited exce pt for J LG

a pproved rece ptac les . The perso nnel lift must not be us ed

a s a forklift, cra ne, o r support for overhead structure.

The tota l pla tform c a pa city o f mo de ls 10VP, 15VP, 20VP

must b e uniformly d istributed in the center o f the platform

This me a ns tha t the total combined w eight of personne l

tools a nd s upplies loa ded into the pla t form must noexceed the platform capacity figures.

4.2 GENERAL

This s ection provide s the nec es sa ry information nee de d

to ope rate the ma chine. Included in this sec tion are proce

dures for driving the ma chine, raising, lowe ring and loa d

ing the platform, a nd a lso tra nspo rting the ma chine. It is

important that the user read a nd understand the proper

procedures b efore o perating the ma chine. Although s ome

of the more important operating safety precautions will be

lis t e d i n t h e f o llo w in g p a r a g r a p h s e c t i o n s , IT IS

EXTREMELY IMPO RTANTALL S AFETY P RECAUTIONS IN

S EC TION 1 - S AFETY PR EC AUTIONS B E RE AD AND

UNDERS TOOD B EFO RE OP ERATING MAC HINE. If a

“Da ily Wa lk-Around Inspe ction” , (see Section 2-4.) has no

been performed, do so before starting set-up and opera

tion . The o pera tor mus t also be fam ilia r with a ll lift con trol

a s des cribe d in S ection 3 - User/Opera tor Resp ons ibilities

and Mac hine C ontrols.


32/48


4-2 – JLG Lift – 3120848

4.3 MACHINE OPERATION

The follow ing s eq uence o f ba sic proced ures must be fol-

lowed to safely operate the machine.

1. At the g round co ntrol sta tion , se t pow er P LAT/OFF/

G RND key s witch to the PLAT pos ition to o peratefrom platform controller, or GRND to operate from

ground c ontrols.

NOTE: Chec k that the Emergenc y Stop button on g round

and p latform c ontroller are in the reset position for

operation. Also check that Emergency/Manual

Decent Control valve is closed (low er access ho le in

rear cover).

If LED’S are flashing a fault code o n the platform

controller box at mach ine power-up, see Section-3,

“Troublesho oting” of the Service and Maintenance

Manual for information on reading fault cod es.

2. Check LED strip on the platform controller for cur-rent battery charge level before operating lift to be

certain charge is sufficient to complete your work

task. If the battery charger is plugged into an AC

outlet, drive functions on the machine will be locked

out.

WORK AREA MUST BE A SMOOTH, FIRMAND LEVEL SURFACE

FREE OF HOLES, LARGE CRACKS OR DEBRIS ON SURFACE.THE WORK SURFACE MUST BE CAPABLE OF SUPPORTING THEWEIGHT OF THE MACHINE PLUS THE PLATFORM’S MAXIMUMRATED LOAD CAPACITY. ALWAYS CHECK THE BUBBLE LEVELINDICATOR ON BASE FRAME TO BE SURE MACHINE IS LEVEL

BEFORE RAISING PLATFORM.

3. Inspect work area before operating lift.

Platform Loading

The platform maximum rated loa d c ap ac ity is d isplaye d

on a dec al loca ted o n the platform. The ma ximum rated

load capacity includes the combined weight of the opera-

tor and any materials, tools, etc. placed in the platform

with the ope rator.

Ma ximum rated loa d ca pa city for a l l pla t forms (Except

Extendible) is a s follows :

* Extendible Pla tform a vaila ble o nly for 20VP.

Interlock Switch Operating Conditions

Ta ble 4-3. sho wn, lists m a chine res pon se to various inter-

lock switch positions.

Table 4-1. Maximum Rated Load Capacity(for all platforms excep t Extendible)

ModelMax. Capacity(CE - Euro)

10VP 160 kg (350 lb.)

15VP 160 kg (350 lb.)

20VP 160 kg (350 lb.)

Table 4-2. Maximum Rated Load Capacity(for Extendible Platform* )

ModelMax. Capacity(CE - Euro)

10VP Not Available*

15VP Not Available*

20VP 160/120 kg (350/265 lb.)

Table 4-3.Machine Interlock Switch Operating Conditions.

Elevation/SpeedSwitch

Drive Cutout(PHP System)

Tilt Status Brake Status Controller Response

mast retracted bars raised (not tilted) engaged Full Drive and Lift

mast retracted bars raised (not tilted) disengaged Drive and Lift disabledmast extended bars lowered (not tilted) engaged Drive 25%maximum

mast extended bars lowered (not tilted) engaged Drive disabled

mast retracted bars raised (tilt) engaged Lift disabled

mast retracted bars raised (tilt) disengaged Drive and Lift disabled

mast retractedbars raised/battery charger

plugged-in(not tilted) engaged Drive disabled


33/48


3120848 – JLG L ift – 4-3

Driving

WHEN DRIVING WITH PLATFORM LOWERED, DO NOT ATTEMPT

TO DRIVE MACHINE UP A RAM P (GRADE) OF GREATER THAN FIF-

TEEN 15% PERCENT (8-1/2° DEGREES), OR SIDE SLOPEGREATER THAN ( 5° DEGREES), AS TI PPING COULD OCCUR.

NEVER ATTEMPT TO DRIVE ONTO A GRADE WITH THE PL ATFORM

ELEVATED.

1. Enter the platform and c lose the ga te.

2. Chec k the floor a nd o verhea d a rea in the d irec tion oftravel for ob stac les to a void.

OLD STYLE CONTROLLER

3. On the platform co ntroller the FUNCTION ENABLE

switch must be pressed and released before any

other platform function will operate. You must acti-

vate the desired function within three (3) seconds

a fter pres sing the FUNC TION ENABLE sw itch .

4. P ress an d relea se the FUNCTION ENABLE switchthen g ently point the J OYS TICK in the d irec tion o f

trave l. If nece ss a ry, a djust the S P EED CO NTROL on

the platform controller (round knurled knob ) while

driving.

5. To s top, e ither relea se the J OYSTICK (quick stop) , o rslow ly move the J OYSTICK ba ck to the neutral (cen-

ter) position (preferred) , to bring lift to a smooth

stop.

NEW STYLE CONTROLLER

3. On the joystick control the DRIVE ENABLE button

located on the top of joystick must be pressed and

HELD down before driving the machine with the joy-

stick co ntrol.

4. Press and HOLD the DRIVE ENABLE button theng ently po int the J OYS TICK in the direction of travel.

If necessary, adjust the VARIABLE SPEED CON-

TROL kno b o n the c on troller (round knurled knob)

while driving.

5. To s top, e ither relea se the J OYSTICK (quick stop) , o r

slow ly move the J OYSTICK ba ck to the neutral (cen-

ter) position (preferred) , to bring lift to a smooth

stop.

Elevating Platform

DO NOT ATTEMPT TO RAISE THE PLATFORMUNLESS ALL FOUR

WHEELS OF THE MACHINE ARE RESTING ON A FIRMAND LEVELSURFACE.

ALWAYS CHECK THE BUBBLE LEVEL OR TILT INDICATOR ON

BASE THE FRAME TO BE SURE MACHINE IS ON A LEVEL SURFACE BEFORE RAISING PLATFORM.

ALSO, OBSERVE SURFACE AREA AROUND MACHINE IFMACHINE IS TO BE MOVED (DRIVEN) WHILE PLATFORMIS ELE

VATED.

DO NOT ATTEMPT TO DRIVE ONTO A GRADE WITH THE PLATFORMELEVATED.

1. Drive the machine to the area where overhead work

is to be performed and position the machine into it’s

approximate work position. (Use optional laser posi

tioning p ointer if equipped ) .

2. Check the tilt indicator or the bubble level indicatoron base frame of machine, the bubble inside the

level indicator must be inside the small center ring

before attempting to raise the platform.


3. To ra ise the platform, PRES S an d RELEASE the

FUNCTION ENABLE s witch o n the platform c on trol

ler, then within three (3) seconds PRESS the plat

form UP (up arrow) switch on the controller panel

Upon reaching desired elevation level release the

UP (arrow) switch.


3. To ra ise the platform, P RES S a nd HOLD the LIFTENABLE switch on the platform controller then the

platform UP (up arrow) switch on the controlle

panel. Upon reaching desired elevation level release

the UP (arrow) s witch a nd the LIFTENABLE sw itch.NOTE: Maximum drive speed is automatically decreased to

0.8 kph (one half (1/2) mph) maximum when platform

is elevated.

4. If necessary, reposition (drive) machine using plat

form co ntroller J OYS TICK to bring w ork ob jec t into

reach.

Lowering Platform

ENSURE AREA BENEATH PLATFORMIS FREE OF PERSONNELAND OBSTRUCTIONS PRIOR TO LOWERING PLATFORM.


1. To low er pla tform, p res s the FUNC TION ENABLEswitch and platform DOWN switch (down arrow) on

the platform controller pa nel. Upon reac hing d es ired

lower level release the DOWN (down arrow) switch.


1. To low er platform, PRES S a nd HOLD the LIFTENABLE switch and platform DOWN switch (down


34/48


4-4 – JLG Lift – 3120848

arrow) o n the platform c ontroller pa nel. Upon rea ch-

ing desired lower level release the DOWN (down

arrow) sw itch a nd the LIFTENABLE sw itch.

Parking Machine

1. Drive machine to a well-protected and well-venti-lated a rea.

2. Ensure the platform is fully lowered, turn powerP LAT/OFF/G RND key switc h to the OFF po s ition

(centered) .

3. Pa rk machine with brakes enga ged .(Brake over-center handle up, drive position) .

4. If nece ss a ry, rem ove key from P OWER P LAT/OFF/G RND key switch to disab le ma chine from unautho-

rized use.

NOTE: If required , plug in AC battery charger so mach ine

batteries will be charged in preparation for next work day in acco rdance w ith Section 2-7, “Battery Charg-

ing”.

4.4 QUICK-CHANGE PLATFORM

(See Figure 4-1.)

PLEASE NOTE THAT THE OPTIONAL EXTENDIBLE PLATFORMISONLY AVAILABLE FOR THE 20VP AND CAN ONLY BE MOUNTED ONTHAT MODEL.

This des ign VP mo de l is eq uippe d with quick-cha ng e plat-form mounts w hich w ill allow q uick remova l and insta lla-

tion o f the c urrently ava ila ble q uick-cha ng e pla tforms. The

fo llowing proced ures de sc r ibe p la t form remova l and

installation:

Platform Removal

1. Remove the platform (joystick) controller and

bracket by turning the bracket clamp screw knob

counterclockwise to loosen the clamp screw secur-

ing the controller bracket to the platform rail.

Remove controller and bracket from platform and

lay a side.

2. Remove both pins securing the lower platform sup-port rail to the ma st mo unting cha nnel.

3. Remove both pins from the upper platform supportrail to m as t mounting crad le.

4. Using either suitable lifting equipment, capable oflifting the we ig ht of the mo unted p latform, or anothe r

person, swing the lower platform support rail for-

ward, away from the mast to clear the lower channel

mount, then lift the upper platform support rail up

and out of the top crad le mo unt. Move platform clear

of the machine and carefully set the platform on its

ba se o ut of the wa y.

Platform Installation

1. Using either suitable lifting equipment, capable oflifting the weight of the unmounted platform or

another person, lift the platform and set the plat-

form’s upper support rail into the mast upper plat-

form cradle mount.

2. Swing the platform lower support rail into the mastlower platform channel mount.

3. Secure the platform support rails with the two (2)upper platform cradle mount pins, and the two (2)

low er platform cha nnel mount pins.

4. Install the platform (joystick) controller and bracketa t it’s prope r pos ition on the platform rail while p rop-

erly routing the controller cable inside the platform

rails.

The platform is no w rea dy for ope ration.

.

Figure 4-1. Quick-Change Platform Mount.

PLATFORM

UPPER MOUNT

PLATFORM

LOWER MOUNT

UPPER

MOUNT PINS

LOWER

MOUNT PINS


35/48


36/48


4-6 – JLG Lift – 3120848

DO NOT ATTEMPT TO DRIVE MACHINE ONTO, OFF OF, OR PUSHMACHINE ONTO A TILTED ROLL-BACK TRUCK BED.

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

DISENGAGED(SEE SECTION 3-4. CONTROLS AND INDICATOR,SUB-SECTION “BRAKE RELEASE CONTROL”) , AND THE EMER-GENCY STOP BUTTON SET TO THE OFF POSITION,(DEPRESSED) .

DO NOT ATTEMPT TO TOWOR WINCH THE MACHINE AT A SPEEDGREATER THAN 3.2 KPH(2 MPH) , OR DAMAGE COULD OCCUR TOTHE MACHINES ELECTRONIC CONTROLLER BOX,(DUE TO HIGH VOLTAGE BEING GENERATED BY THE DRIVE MOTORS FEEDING

BACK INTO THE CONTROLLER BOX) .

RE-ENGAGE THE BRAKES ONCE MACHINE IS IN PLACE WITHTRUCK BED LEVEL AND READY FOR TIE DOWN.

TIE DOWN BARS ARE PROVIDED ON BOTH ENDS OF THE BASEFRAME TO SECURE MACHINE TO BED OF TRANSPORT VEHICLE.

Machine Tie-Down

With machine in posit ion to be t ied down and brakes

engaged, use the following guidelines for restraining the

ma chine during trans port.

USE OF EXCESSIVE FORCE WHEN SECURING MACHINE (DRIVEWHEEL LOAD), CAN CAUSE DAMAGE TO THE MACHINES DRIVE

COMPONENTS, I.E. AXLES, AXLE BEARINGS, TORQUE LIMITINGCLUTCH, OR DRIVE GEARS.

1. Secure machine with an adaquate chain attached

through the tie down bars at the front and back of

machine. (See Figure 4-2.)

2. The c hain should b e sec urely tig htened with a forceof approximately 45.5 kg (100 lb.) applied two feet

from the pivot handle. (i.e.. the chain is p roperly

tightened when a 91 kg (200 lb.) load placed on the

chain (a 91 kg (200 lb.) man standing o n the chain,

just flexes the chain) .

Fork-lift Truck Transport

ALWAYS RELEASE THE DRIVE MOTOR BRAKES AND SET THEEMERGENCY STOP BUTTON TO THE OFF POSITION,(DEPRESSED)

ON THE MACHINE WHEN MANUALLY PUSHING, PULLING, ORWHEN TRANSPORTING MACHINE BY FORK-LIFT TRUCK. THIS WILLALLOWTHE DRIVE MOTORS AND GEARS TO ROTATE WITH LEAST

RESISTANCE SHOULD THE DRIVE WHEELS COME IN CONTACTWITH ANY SURFACE. IF CONTACT OF THE REAR DRIVE WHEELSDOES OCCUR WHILE FORKLIFT TRUCKING, AT SPEEDS GREATER

THAN 3.2 KPH (2 MPH), DAMAGE COULD OCCUR TO THEMACHINES ELECTRONIC CONTROLLER BOX,(DUE TO HIGH VOLT-

AGE BEING GENERATED BY THE DRIVE MOTORS FEEDING BACK

INTO THE CONTROLLER BOX) .

ALWAYS REMEMBER TO RE-ENGAGE THE BRAKE SYSTEMBEFORE MACHINE OPERATION.

As s t and a rd eq uipment , a ll VP se r ies l if t mod els a re

equipped with 19 cm (7-1/2 in.) wide fork-lift pockets run-

ning throug h the ba se frame . This a llow s the ma chine to

be either transported around a work area or lifted onto a

highe r level using a sta nda rd fork-lift truck.

NOTE: Fork-lift trucks must be c apable o f handling the fol-

lowing weights:

Table 4-4. Machine Gross Weights

ModelCE SPEC

(Europe/UK)

10VP 422 kg (930 lb.)

15VP 615 kg (1355 lbs .)

20VP 940 kg (2072 lbs .)


37/48

SECTION 5 - OPTIONAL EQUIPMENT

3120848 – JLG L ift – 5-1

SECTION 5. OPTIONAL EQUIPMENT

5.1 OPTIONAL EQUIPMENT

The VP S eries mod els a re a vaila ble w ith the follow ingoptiona l eq uipment:

26" x 28" Quick-Change Platform

The 66 x 71 cm (26" long by 28" wide) platform features a

gull wing ga te and is a ttac hed to the ma st using the q uick

chang e mount.

25" x 22" Quick-Change Platform

The 63 x 56 cm (25" long by 22" wide) platform features a

gull wing ga te and is a ttac hed to the ma st using the q uick

chang e mount.

26" x 50" Quick-Change - ExtendiblePlatform(See Section 5-2, Extendib le Platform Operation)

PLEASE NOTE THAT THE OPTIONAL EXTENDIBLE PLATFORMISONLY AVAILABLE FOR THE 20VP AND CAN ONLY BE MOUNTEDON THAT MODEL.

The 66 x 127cm (26" long x 50" wide) extendible platform

features a g ull wing ga te and is a ttac hed to the ma st using

the quick change mount.

25" x 26" Step-in Molded Platformw/Swing-up Gate

This fixed mo unt 63 x 66cm (25" long x 26" wide ) platform

is a lso ava ilab le, the pla t form features a tough mo lded

shell base and s ides mounted to a welded s teel frame.

This step-in platf

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