Document Outline

• Model
  • 15VPSP
  • 3120796
    • June 14, 2001
  • OPERATORS & SAFETY
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• FOREWORD - GENERAL
• FOREWORD
• SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
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• Effectivity Changes
  • LIST OF FIGURES
  • LIST OF TABLES
• Section 1. safety precautions
  • 1.1 GENERAL
    • This section outlines the necessary precautions for proper and safe machine usage and maintenance...
    • The owner/user/operator/lessor/lessee of the machine should not accept operating responsibility u...
    • The owner/user/operator/lessor/lessee must be familiar with Sections 6, 7, 8, 9, 10 of ANSI A92.6...
    • If there are any questions with regard to safety, training, inspection, maintenance, application,...
  • 1.2 PRE-OPERATION
    • Operator Training And Knowledge
      • The Operators and Safety Manual must be read and understood in its entirety before operating the ...
    • Workplace Inspection
    • Machine Inspection
  • 1.3 OPERATION
    • General
    • Trip And Fall Hazards
    • Electrocution Hazards
      • Table 1-1. Minimum Safe Approach Distance (to energized power lines or parts)
    • Tipping Hazards
    • Crushing And Collision Hazards
  • 1.4 Towing, Lifting, And Hauling
  • 1.5 Maintenance
    • General
      • This section contains general safety precautions which must be observed during maintenance of thi...
    • Maintenance Hazards
    • Battery Hazards
• Section 2. preparation and inspection
  • 2.1 general
    • This section provides the necessary information needed by those personnel that are responsible to...
  • 2.2 preparation for use
    • Before a new machine is put into operation it must be carefully inspected for any evidence of dam...
    • All preparation necessary to place the machine in operation readiness status are the responsibili...
    • It should be assured that the items appearing in the Delivery and Frequent Inspection and Functio...
  • 2.3 DELIVERY AND FREQUENT INSPECTION
    • The following check list provides a systematic inspection to assist in detecting defective, damag...
    • Platform Assembly
      • Properly secured; no visible damage; free of dirt and debris. Platform gate functions properly.
    • Mast
      • No visible damage, abrasions and/or distortions; no binding; mast sections free of dirt or other ...
    • Mast Chains
      • No visible damage; proper chain tension; evidence of proper lubrication. Chain sheaves, sheave pi...
    • Platform Controller/(Power) Cable(s)
      • No visible damage; cable properly tensioned and seated in control cable sheaves; control cable sh...
    • Lift Cylinder (check w/mast extended)
      • No rust, nicks, scratches or foreign material on piston rod. No leakage.
    • Frame
      • No visible damage; loose or missing hardware (top and underside).
    • Drive Wheels and Front Casters
      • Casters free rolling; no loose or missing parts; no visible damage. Drive wheel hub retainer secu...
    • Hydraulic Oil Supply
      • Check the hydraulic oil level of the hydraulic fluid reservoir located in the lower access hole o...
      • If fluid level is low, see Service Manual, Section 1 - Specifications; Sub-Section 1-5. “Lubricat...
    • Controls - (Platform and Ground)
      • Controls operable; no visible damage; placards secure and legible.
    • Batteries
      • Proper electrolyte level; cable connections tight; no visible damage; no corrosion at battery cab...
    • Pump Motor/Hydraulic Pump/Valves andLines
      • No leakage; units secure.
    • Placards
      • No visible damage; placards secure and legible, daily walk-around inspection
      • It is the user/operator’s responsibility to inspect the machine before the start of each work day...
  • 2.4 Daily Walk-Around Inspection
    • Begin the “Walk-Around Inspection” at item one listed following. Continue around machine checking...
    • 1. Drive and Caster Wheels - Properly secured and lubricated. Check for any visible damage or deb...
    • 2. Base Frame - No visible damage; drive wheel motor components properly secured; JLG’s Pot-Hole-...
    • 3. Battery/Battery Charger - Proper battery electrolyte level, cables secure, no damage or corros...
    • 4. Motor/Pump/Reservoir Unit - Properly secured, no visible damage, no evidence of hydraulic leak...
    • 5. Ground Controls - Properly secured, no loose or missing parts, no visible damage; key switch o...
    • 6. Mast Assembly - Mast sections properly secured, no visible damage to mast sections, no loose o...
    • 7. Manual Brake Release Control - Handle secure and undamaged; cables attached properly; control ...
    • 8. Platform Assembly - Secure to mast; All railings securely attached; no loose or missing parts,...
    • 9. Platform Controls - Platform up/down, lift function enable and horn switch pads on faceplate n...
    • In addition to the Daily Walk-Around Inspection, be sure to include the following as part of the ...
    • Batteries Charged
      • Start each day with fully charged batteries. (See Section 2- 7. “Battery Charging & Maintenance”)
    • Overall Cleanliness
      • Keep oil, grease, water, etc. wiped from standing surfaces and hand holds.
    • Placards
      • Keep all information and operating placards clean and unobstructed. Cover areas where placards ar...
    • Operation and Safety and ANSI Responsibilities Manual
      • Ensure a copy of manual is enclosed in the manual storage box.
    • Lubrication
      • For those parts pointed out in the Walk-Around Inspection requiring lubrication, refer to the Lub...
      • Hydraulic oils must have anti-wear qualities at least to API Service Classification GL-3, and suf...
      • For cold weather applications, i.e. when temperatures remain consistently below +20˚F (–7˚C) JLG ...
  • 2.5 daily functional check
    • Once the Walk-Around Inspection is complete, a functional check of all systems should be performe...
    • Set-up machine for operation, according to instructions in Section 4-3, “Machine Operation”.
    • Ground Controls Function Check
      • 1. With key switch turned to GRND position (clockwise), operate the platform up and down switch (...
      • 2. With platform completely lowered, check hydraulic oil level in hydraulic fluid reservoir. If n...
      • 3. Depress EMERGENCY STOP (red) button (next to key switch), all machine operations will be disab...
      • 4. Operate the MANUAL BRAKE RELEASE CONTROL (Over-center handle mounted on the right side of the ...
      • 5. Set key switch to PLAT (platform operation, all the way counterclockwise) and continue with th...
    • Platform Controls Function Check
      • 1. Check that the PLATFORM CONTROLLER box is properly mounted (facing forward) and secure on the ...
      • 2. RESET the EMERGENCY STOP (red) button on the platform controller, if necessary.
      • 3. On the platform controller box, check the BATTERY STATUS INDICATOR LED’s for charge status of ...
      • 4. Depress and HOLD the JOYSTICK DRIVE BUTTON (located on top of the joystick knob) and slowly mo...
      • 5. While driving the machine forward (platform down), rotate the SPEED CONTROL knob from maximum ...
      • 6. Depress and HOLD the LIFT ENABLE pad switch, and operate the platform UP and DOWN pad switches...
      • 7. With the platform elevated check the JLG Automatic Pot-Hole-Protection system, if operating pr...
      • 8. With the platform still elevated approximately 2 ft., drive machine and check if SPEED CUT-BAC...
      • 9. Depress the EMERGENCY STOP (red) button on the Platform Controller box, all machine operations...
    • Tilt Sensor (1.5˚) and Drive Brakes
      • 1. With the platform lowered, drive the machine onto a grade within the allowable grade and slope...
      • If all machine functions are operating properly, machine is ready for operation.
  • 2.6 torque requirements
    • The Torque Chart, Figure 2-6., consists of standard torque values based on bolt diameter and grad...
  • 2.7 battery charging & maintenance
    • VPSP Models are equipped with 24 volt, 10 amp output battery chargers (U.S.A. - 120 Volt AC input...
    • Battery Maintenance and Safety Practices
      • (Refer to Figure 2-2.)
      • As with any wet cell battery, check the electrolyte level of the batteries often, adding only dis...
    • Battery Charger Operation
      • (Refer to Figure 2-3 & 2-4.)
      • 1. Position machine in well ventilated area near an AC electrical outlet and set the Ground Contr...
      • 2. Open the left battery cover and unwrap the battery charger AC power cable from under the cover.
      • 3. Connect the battery charger AC power cable to a properly grounded receptacle, use a suitable e...
      • 4. When powered on, the charger runs through a self- diagnostic check which lights all five (5) l...
      • 5. When ready to charge, the CHARGER ON light and the INCOMPLETE light on the front panel of the ...
      • 6. When the battery cell voltage reaches 2.37 V/cell the 80% CHARGE light on the front panel of t...
      • 7. The CHARGE COMPLETE light will come on when the charging process is finished.
      • 8. Unplug the charger AC power cord and wrap around storage lugs under the left battery cover.
    • Abnormal Cycle Indicator Light
      • If the ABNORMAL CYCLE indicator light should come on during the normal charging cycle of the batt...
      • Table 2-1. Lubrication Intervals for Various Components
        • HO - Hydraulic Oil - Hydraulic oils must have anti-wear qualities at least to API Service Classif...
        • For cold weather applications, i.e. when temperatures remain consistently below +20˚F (–7˚C) JLG ...
        • Gear Oil - Good Quality Worm Gear Oil - SAE 90 - AGMA#5 - EP Compounded
• Section 3. user responsibilities & machine controls
  • 3.1 general
    • This section provides the necessary information needed to understand control functions. Included ...
  • 3.2 personnel training
    • The aerial lift is a personnel handling device; therefore, it is essential that it be operated an...
    • In addition, personnel operating the machine should be familiar with Sections 6, 7, 8, 9, 10 of A...
    • Persons under the influence of drugs or alcohol or who are subject to seizures, dizziness or loss...
    • Operator Training
      • Operator training must include instruction in the following:
      • 1. Use and limitations of the platform controls, ground controls and emergency controls.
      • 2. Knowledge and understanding of this manual and of the control markings, instructions and warni...
      • 3. Knowledge and understanding of all safety work rules of the employer and Federal, State and Lo...
      • 4. Proper use of all required personnel safety equipment.
      • 5. Sufficient knowledge of the mechanical operation of the machine to recognize a malfunction or ...
      • 6. The safest means to operate near overhead obstructions, other moving equipment, obstacles, dep...
      • 7. Means to avoid the hazards of unprotected electrical conductors.
      • 8. Any other requirements of a specific job or machine application.
    • Training Supervision
      • Training must be done under the supervision of a qualified operator or supervisor in an open area...
    • Operator Responsibility
      • The operator must be instructed that he has the responsibility and authority to shut down the mac...
  • 3.3 operating characteristics and limitations
    • General
      • A thorough knowledge of the operating characteristics and limitations of the machine is always th...
    • Placards
      • (See Figure 3-5., 3-6., 3-7., 3-8., & 3-9.)
      • Important points to remember during operation are provided at the control stations by DANGER, WAR...
    • Capacities
      • Raising the platform above the stowed position is based on the following criteria:
    • Stability
      • This machine, as originally manufactured by JLG and when operated within its rated capacity on a ...
  • 3.4 controls and indicators
    • Ground Controls
      • (See Figure 3-1.)
      • 1. POWER PLAT/OFF/GROUND KEY SWITCH
      • 2. PLATFORM UP/DOWN (GROUND CONTROL)
      • 3. EMERGENCY STOP BUTTON
      • 4. EMERGENCY/MANUAL DESCENT KNOB
      • 5. HYDRAULIC OIL RESERVOIR
    • Platform Controller
      • (See Figure 3-2.)
      • The platform controller contains all the controls necessary to operate the lift from the platform.
      • The following is a description of each function.
      • 1. BATTERY VOLTAGE / FAULT CODE LED INDICATORS
      • 2. LIFT ENABLE PAD SWITCH
      • 3. PLATFORM UP PAD SWITCH (Up Arrow)
      • 4. PLATFORM DOWN PAD SWITCH (Down Arrow)
      • 5. EMERGENCY STOP/SHUT-OFF BUTTON
      • 6. JOYSTICK DRIVE/STEER CONTROL and DRIVE ENABLE BUTTON
      • 7. VARIABLE SPEED CONTROL
      • 8. WARNING HORN SWITCH
    • Brake Release Control
      • (See Figure 3-3.)
      • Standard equipment on all VPSP model lifts is a braking system integrated into the electric motor...
      • If the lift must be moved around manually such as described in the following examples; the batter...
      • The brake release control lever is located on the right side of the mast. To disengage or engage ...
  • 3.5 JLG Pot-Hole Protection device
    • (See Figure 3-4.)
    • VPSP model lifts are equipped with JLG’s Pot-Hole-Protection system (PHP). The PHP system consist...
    • When the machine is driven in areas where obstacles are higher than three quarters (3/4) inch off...
• Section 4. machine operation
  • 4.1 machine description
    • The JLG VPSP model lifts are an electric self-propelled machine, with an aerial work platform mou...
    • The JLG VPSP lift has a primary controller in the platform. From the platform control the operato...
    • Instructions and warnings are posted adjacent to both platform and ground operator control statio...
    • The JLG VP personnel lift is designed to provide efficient and safe operation when maintained and...
    • Any evidence of lack of maintenance, malfunction, excessive wear, damage or modification to the m...
    • The JLG VPSP personnel lift is not intended to be used to lift material other than hand-picked st...
    • The total platform capacity of the VPSP personnel lift must be uniformly distributed in the platf...
  • 4.2 general
    • This section provides the necessary information needed to operate the machine. Included in this s...
  • 15VPSP OPERATING SPECIFICATIONS
    • 4.3 machine operation
      • The following sequence of basic procedures must be followed to safely operate the machine.
      • 1. At the ground control station, set power PLAT/OFF/ GRND key switch to the PLAT position to ope...
      • 2. Check that the EMERGENCY STOP button on the GROUND and PLATFORM control are in the RESET posit...
      • 3. Check the LED strip on the platform controller for current battery charge level before operati...
      • 4. Inspect work area before operating lift.
    • Interlock Switch Operating Conditions
      • Table 4-1. shown, lists machine response to various interlock switch positions.
    • Driving
      • 1. Enter platform and close the front platform gate if the platform is configured as a closed pla...
      • 2. Attach your fall protection harness to the lanyard attachment on the top platform rail at the ...
      • 3. Check the floor and overhead area in the direction of travel for obstacles to avoid.
      • 4. Press and HOLD the DRIVE ENABLE button on the JOYSTICK then gently point the JOYSTICK in the d...
      • Table 4-1. Machine Interlock Switch Operating Conditions.
    • mast retracted
    • bars raised
    • (not tilted)
    • engaged
    • mast retracted
    • bars raised
    • (not tilted)
    • disengaged
    • mast extended
    • bars lowered
    • (not tilted)
    • engaged
    • mast extended
    • bars lowered
    • (tilt)
    • engaged
    • mast retracted
    • bars raised
    • (tilt)
    • engaged
    • mast retracted
    • bars raised
    • (tilt)
    • disengaged
    • mast retracted
    • bars raised/battery charger plugged-in
    • (not tilted)
    • engaged
      • 5. To stop, either release the JOYSTICK (quick stop), or slowly move the JOYSTICK back to the neu...
      • Platform Loading
        • The platform maximum rated load capacity is displayed on the platform capacity decal located on t...
        • Maximum rated load capacity for all platforms is as follows:
        • Table 4-2. Maximum Rated Platform Load Capacity
    • 15VPSP
    • 500 lb. (227 Kg)
      • Elevating Platform
        • 1. Drive the machine to the area where overhead work is to be performed and position the machine ...
        • 2. To raise the platform, at the platform control, PRESS and HOLD the LIFT ENABLE pad switch and ...
        • 3. If necessary, reposition (drive) lift using platform controller joystick to bring work object ...
      • Lowering Platform
        • 1. To lower platform, PRESS and HOLD the LIFT ENABLE switch and platform DOWN switch (down arrow)...
      • Parking Machine
        • 1. Drive machine to a well-protected and well-ventilated area.
        • 2. Ensure the platform is fully lowered, turn power PLAT/OFF/GRND switch to the OFF position (cen...
        • 3. Park machine with brakes engaged. (Brake over- center handle up, drive position).
        • 4. If necessary, remove key from POWER PLAT/OFF/ GRND key switch to disable machine from unauthor...
        • 4.4 TRANSPORTING, LIFTING AND TIE DOWN PROCEDURES
      • General
        • All VP Series model personnel lifts may be transported to a work site using the following methods:
      • Driving to Work Area
        • The VPSP machines are capable of being driven to a work area, if the surrounding travel surface p...
      • Truck Transport
        • The machine may be winched onto a tilted roll-back truck bed (see important note following) which...
      • Machine Tie-Down
        • With machine in position to be tied down and brakes engaged, use the following guidelines for res...
        • 1. Secure machine with an adequate chain attached through the tie down bars at the front and back...
        • 2. The chain should be securely tightened with a force of approximately 100 lb. applied two feet ...
      • Fork-lift Truck Transport
        • As standard equipment, all VPSP model lifts are equipped with 7-1/2 in. wide fork-lift pockets ru...
        • Table 4-3. Machine Gross Weights
    • 15VPSP
    • 2,190 lb. (994 kg)
• Section 5. optional equipment
  • 5.1 Optional Equipment
    • The VPSP Series models are available with the following optional equipment:
    • Lifting Hook
      • The optional lifting hook is mounted at the top rear of the first mast section. The hook is used ...
    • Horn
      • The horn is activated by the horn pad on the platform controller box. It can be used at the descr...
    • Obstruction Sensing System
      • The Obstruction Sensing System (OSS) is designed to detect the presence of obstructions directly ...
    • Rug Carrier Accessory
      • The Rug Carrier Accessory consists of two pivoting arms mounted to the 15VPSP platform left side ...
      • See Section 5.3, Rug Carrier Accessory for complete detailed description and operation.
    • Programmable Security Lock (Keyless)
      • This keyless PSLtm Programmable Security Lock switch features a numbered keypad where a four (4) ...
      • See Section 5.4, Progammable Security Lock (PSL™) for complete detailed description and operation.
  • 5.2 Obstruction Sensing System (OSS)
    • System Description
      • The Obstruction Sensing System (OSS) is designed to detect the presence of obstructions under the...
    • Operation
      • When power is applied to the OSS, the red LED on the electronics module will illuminate. If no ob...
      • If an obstruction is detected within the detection zone beneath the platform, the platform will;
      • If an obstruction is detected, have the obstruction cleared by someone on the ground or carefully...
    • Daily Inspection
      • (See Figure 5-3.)
      • From ground controls, raise platform approximately 5'-6'. The red LED on the electronic module wi...
  • 5.3 Rug Carrier Accessory
    • General (See Figure 5-4. & Figure 5-5.)
      • The Rug Carrier Accessory consists of two pivoting arms mounted to the 15VPSP platform left side ...
    • Hanging a Rug using the Rug Carrier Accessory Arms
      • This section describes the use of the Rug Carrier accessory in hanging rugs on horizontal pivotin...
      • 1. Select the intended location in the display for mounting the rug. Open the display rack to pro...
      • 2. With the Rug Carrier Accessory arms stowed, drive the 15VPSP into position prior to loading th...
      • 3. Swing and lock Rug Carrier Accessory arms into the carry position. (See Figure 5-4.)
      • 4. Load the rolled rug with the finished side facing the platform. As required, use an assistant ...
      • 5. Make sure that the rug is centered over its length on the Rug Carrier Accessory.
      • 6. Elevate the platform to the required height for mounting the rug onto the display arm.
      • 7. Properly attach the rug to the display arm. Never climb onto the platform rails for any reason.
      • 8. After adequately attaching the rug to the display arm, lower the platform, stow the Rug Carrie...
      • 9. As required reposition and elevate the 15VPSP to completely attach the rug.
    • Removing a Rug using Rug Carrier Accessory Arms
      • This section describes the use of the Rug Carrier accessory in removing rugs from horizontal pivo...
      • 1. Select the intended location in the display for removal of the rug. Open the display rack to p...
      • 2. With the Rug Carrier Accessory arms stowed, drive the 15VPSP into position prior to loading th...
      • 3. Swing and lock Rug Carrier Accessory arms into the carry position as shown in Figure 5-4.
      • 4. Elevate the platform a few feet. Start to roll the rug up onto the Rug Carrier Accessory arms ...
      • 5. Make sure that the rug is centered over its length on the Rug Carrier Accessory as shown in Fi...
      • 6. While elevating to the required height for removing the rug from the display arm, continue to ...
      • 7. Properly remove the rug from the display arm. Never climb onto the platform rails for any reason.
      • 8. After adequately removing the rug from the display arm, lower the platform.
      • 9. Remove the rug from the Rug Carrier Accessory. As required, use an assistant to unload the rug...
      • 10. Stow the Rug Hanger Accessory arms.
  • 5.4 Progammable Security Lock (PSL™)
    • The optional keyless Programmable Security Lock switch can be programmed with a four (4) digit op...
    • PSL™ Box and Ground Control Locations
    • Machine Power Up using the PSL™
      • 1. At the ground control station, turn the keyless three position selector switch from OFF to eit...
      • 2. Enter the four digit code on the PSL key pad. The AMBER - ACCEPT led will be lit if the code i...
      • 3. Then press the ON button on the keypad. The GREEN - ON led will light and the machine will pow...
      • 4. The machine will now operate normally.
    • Machine Power Down
      • 1. Set the ground control selector switch to the OFF position.
      • 2. Press the OFF button on the PSL keypad. No led’s on the PSL box will be lit.
    • Changing the Operator’s Code
      • As an added security feature the PSL operators code can be changed by a supervisor should the nee...
      • 1. Enter the Supervisor’s code on the key pad. The RED - PROGRAM led will be lit if correct.
      • 2. Enter a new four (4) digit Operator’s code on the keypad. The AMBER - ACCEPT led will light up...
      • 3. Press the OFF button on the keypad to activate the new Operator’s code.
• Section 6. emergency procedures
  • 6.1 general information
    • This section provides information on procedures to be followed, and systems and controls to be us...
  • 6.2 emergency controls and their location
    • Platform Emergency Stop Switch
      • This (RED) button is located on the platform joystick controller box and, when depressed, will im...
    • Ground Emergency Stop Switch
      • The ground emergency stop switch (RED) button is located inside the rear cover (upper access hole...
    • Manual Descent Knob
      • The manual descent knob is used in the event of either a total power failure, or if the operator ...
  • 6.3 emergency operation
    • Use of Ground Controls
      • Ground personnel must be thoroughly familiar with the machine operating characteristics and the g...
    • Operator Unable to Control Machine
      • 1. Operate the machine from the ground controls ONLY with the assistance of other personnel and e...
      • 2. DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION NORMALLY.
      • 3. Cranes, forklift trucks or other equipment which may be available are to be used to help remov...
      • continued next page
    • Platform Caught Overhead
      • If the platform becomes jammed or snagged in overhead structures or equipment, do not continue op...
    • Post-Incident Inspection
      • Following any incident, thoroughly inspect the machine and test all functions. Do not lift platfo...
  • 6.4 INCIDENT NOTIFICATION
    • It is imperative that JLG Industries, Inc. be notified immediately of any incident involving a JL...
    • JLG Phone: 877-JLG-SAFE (554-7233) (8am till 4:45pm EST)
    • Email: [email protected]
    • It should be noted that failure to notify the Manufacturer of an incident involving a JLG Industr...
      • Machine Serial Number:
• Section 7. INSPECTION AND REPAIR LOG
  • Table 7-1. Inspection and Repair Log