Operation and Safety Manual - JLG Industries Vertical Mast... · Operation and Safety Manual ... 19BD Vertical Lift P/N - 3121153 May 3, 2011. NOTES: SECTION - FOREWORD 3121153

Operation and Safety Manual

ANSI

Keep this manual with the machine at all times.

Model(s)15BD19BDVertical Lift

P/N - 3121153May 3, 2011

NOTES:

SECTION - FOREWORD

FOREWORD

This manual is a very important tool! Keep it with the machine at all times.

The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions andoperating procedures essential for the safe and proper machine operation for its intended purpose.

Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changeswithout prior notification. Contact JLG Industries, Inc. for updated information.

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SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

DANGERINDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOTAVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECALWILL HAVE A RED BACKGROUND.

INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOTAVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THISDECAL WILL HAVE AN ORANGE BACKGROUND.

CAUTIONINDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOTAVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAYALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVEA YELLOW BACKGROUND.

NOTICEINDICATES INFORMATION OR A COMPANY POLICY THAT RELATESDIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PRO-TECTION OF PROPERTY.

This is the Safety Alert Symbol. It is used to alert you to the potential personalinjury hazards. Obey all safety messages that follow this symbol to avoid possibleinjury or death

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SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE-TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZEDJLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETYRELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THISPRODUCT.

NOTICEJLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THEOWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES,INC. TO ENSURE THAT THE CURRENT OWNER RECORDS AREUPDATED AND ACCURATE.

NOTICEJLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALLINSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN ANACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL ORWHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONALPROPERTY OR THE JLG PRODUCT.

Contact:Product Safety and Reliability DepartmentJLG Industries, Inc.13224 Fountainhead PlazaHagerstown, MD 21742

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

In USA:Toll Free: 877-JLG-SAFE (877-554-7233)

Outside USA:Phone: 240-420-2661E-mail: [email protected]

For:• Accident Reporting

• Product Safety Publica-tions

• Current Owner Updates

• Questions Regarding Product Safety

• Standards and Regulations Compliance Information

• Questions Regarding Spe-cial Product Applications

• Questions Regarding Prod-uct Modifications

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SECTION - REVISION LOG

REVISION LOG

Original Issue of Manual . . . . . . . . . . . . . . . . . February 5, 2009Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . .May 3, 2011

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TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

FOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B

Contact:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CIn USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .COutside USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C

REVISION LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D

SECTION - 1 - SAFETY PRECAUTIONS

1.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.2 PRE-OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Operator Training And Knowledge. . . . . . . . . . . . . . 1-1Workplace Inspection . . . . . . . . . . . . . . . . . . . . . . . . 1-2Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . . . . 1-3Electrocution Hazards. . . . . . . . . . . . . . . . . . . . . . . . 1-5Crushing And Collision Hazards. . . . . . . . . . . . . . . . 1-6

1.4 LIFTING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

SECTION - 2 - USER RESPONSIBILITIES, MACHINEPREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING. . . . . . . . . . . . . . . . . . . . . . . . 2-1Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 PREPARATION, INSPECTION, AND MAINTENANCE . 2-2Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.3 WALK-AROUND INSPECTION . . . . . . . . . . . . . . . . . . . 2-5General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.4 FUNCTION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

SECTION - 3 - MACHINE CONTROLS AND INDICATORS

3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . 3-1

Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . 3-1Manual Descent Valve Location . . . . . . . . . . . . . . . . 3-2Platform Control Station . . . . . . . . . . . . . . . . . . . . . . 3-318 Ft. Height Limiter - (19BD ONLY - OPTION) . . . . 3-4Platform Gate Interlock - (OPTION). . . . . . . . . . . . . . 3-4Platform Gate Lock - (OPTION) -S/N-0130016195 to Present . . . . . . . . . . . . . . . . . . . 3-4Platform Foot Control Switches - (OPTION) . . . . . . . 3-5

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TABLE OF CONTENTS


SECTION - 4 - MACHINE OPERATION

4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14.2 OPERATING CHARACTERISTICS AND

LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.3 SET-UP AND OPERATION . . . . . . . . . . . . . . . . . . . . . . 4-2Platform Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Platform Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.4 PLATFORM CONFIGURATIONS . . . . . . . . . . . . . . . . . 4-34.5 MACHINE SHUT DOWN. . . . . . . . . . . . . . . . . . . . . . . . 4-4

SECTION - 5 - OPTIONAL EQUIPMENT

5.1 OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . 5-128" x 26" Front Entry Gullwing Platform . . . . . . . . . . 5-1Tool/Bottle Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Platform Foot Control Switch . . . . . . . . . . . . . . . . . . 5-1Tube Carrier (PVC) . . . . . . . . . . . . . . . . . . . . . . . . . . 5-118 Ft. Height Limiter - (19BD ONLY - OPTION) . . . . 5-1Platform Gate Interlock - (OPTION). . . . . . . . . . . . . . 5-1Platform Gate Lock - (OPTION) -S/N-0130016195 to Present . . . . . . . . . . . . . . . . . . . 5-2

SECTION - 6 - EMERGENCY PROCEDURES

6.1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . 6-16.2 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . 6-1

Operator Unable to Control Machine. . . . . . . . . . . . . 6-1Platform Caught Overhead . . . . . . . . . . . . . . . . . . . . 6-1

6.3 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . . . . 6-1

SECTION - 7 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

7.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17.2 GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 7-2

Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . 7-2Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . 7-2

7.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . 7-3Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

SECTION - 8 - INSPECTION AND REPAIR LOG

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TABLE OF CONTENTS


LIST OF FIGURES

2-1. Daily Walk-Around inspection . . . . . . . . . . . . . . . . 2-63-1. Ground Control Station. . . . . . . . . . . . . . . . . . . . . . 3-23-2. Manual Descent Valve Location. . . . . . . . . . . . . . . 3-23-3. Platform Control Station. . . . . . . . . . . . . . . . . . . . . 3-33-4. Platform Control Footswitch. . . . . . . . . . . . . . . . . . 3-53-5. 15BD/19BD - Decal Installation . . . . . . . . . . . . . . . 3-6

LIST OF TABLES

1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . 1-52-1 Inspection and Maintenance Table. . . . . . . . . . . . . 2-33-1 15BD - Decal Installation . . . . . . . . . . . . . . . . . . . . . 3-77-1 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . 7-37-1 15BD Lubrication Points . . . . . . . . . . . . . . . . . . . . . 7-47-2 Lubrication Intervals for Various Components . . . . 7-58-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . 8-1

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TABLE OF CONTENTS

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iv – JLG Lift – 3121153

SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERALThis section outlines the necessary precautions for proper andsafe machine usage and maintenance. For proper machine use, itis mandatory that a daily routine is established based on the con-tent of this manual. A maintenance program, using the informa-tion provided in this manual and the Service and MaintenanceManual, must also be established by a qualified person and mustbe followed to ensure that the machine is safe to operate.

The owner/user/operator/lessor/lessee of the machine should notaccept operating responsibility until this manual has been read,training is accomplished, and operation of the machine has beencompleted under the supervision of an experienced and qualifiedoperator.

If there are any questions with regard to safety, training, inspec-tion, maintenance, application, and operation, please contact JLGIndustries, Inc. (“JLG”).

FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED INTHIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTYDAMAGE, PERSONAL INJURY OR DEATH.

1.2 PRE-OPERATION

Operator Training And Knowledge

• Read and understand this manual before operating themachine.

• Do not operate this machine until complete training is per-formed by authorized persons.

• Only authorized and qualified personnel can operate themachine.

• Read, understand, and obey all DANGERS, WARNINGS,CAUTIONS, and operating instructions on the machineand in this manual.

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

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• All operating personnel must be familiar with the emer-gency controls and emergency operation of the machineas specified in this manual.

• Read, understand, and obey all applicable employer,local, and governmental regulations as they pertain tooperation of the machine.

Workplace Inspection

• The operator is to take safety measures to avoid all haz-ards in the work area prior to machine operation.

• Do not operate or raise the platform unless the machine isproperly secured to a suitable floor surface.

• This machine can be operated in temperatures of 0° F to104° F (-20° C to 40° C). Consult JLG for operation out-side this range.

• Do not operate the machine in hazardous environmentsunless approved for the purpose by JLG.

Machine Inspection

• Before machine operation, perform inspections and func-tional checks. Refer to Section 2 of this manual fordetailed instructions.

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

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

MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORMSHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THEMANUFACTURER

• Do not operate any machine on which the safety orinstruction placards or decals are missing or illegible.

• Avoid any build up of debris on platform floor. Keep mud,oil, grease, and other slippery substances from footwearand platform floor.

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1.3 OPERATION

General

• Always ensure the machine is properly attached to a solid,firm and level floor surface.

• Do not use the machine for any purpose other than posi-tioning personnel, their tools and equipment.

• Never operate a machine that is not working properly. If amalfunction occurs, shut down the machine.

• Do not allow personnel to tamper with or operate themachine from the ground with personnel in the platform,except in an emergency.

• Do not carry materials directly on platform railing unlessapproved by JLG.

• Always ensure that power tools are properly stowed andnever left hanging by their cord from the platform workarea.

• Fully lower mast assembly and shut off all power beforeleaving machine.

• When performing welding operations at elevation, precau-tions must be taken to protect all machine componentsfrom contact with weld splatter or molten metal.

• Never exceed the maximum platform capacity. Distributeloads evenly in the platform.

• Never attempt to use the machine as a crane.

• Do not increase the platform size with unauthorized deckextensions or attachments.

• If mast assembly or platform is caught while elevated, theoperator must be removed before attempting to free themachine. Use cranes, forklift trucks, or other appropriateequipment to stabilize machine prior to removing person-nel.

Trip and Fall Hazards

• JLG Industries, Inc. recommends that the operator in theplatform use an approved fall restraint device with a lan-yard attached to the authorized lanyard anchorage point.For further information regarding fall protection require-ments on JLG products, contact JLG Industries, Inc.

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• Before operating the machine, make sure all railing andgates are fastened in their proper position.

• Keep both feet firmly positioned on the platform floor at alltimes. Never use ladders, boxes, steps, planks, or similaritems on platform to provide additional reach.

• Never use the mast assembly to enter or leave the plat-form.

• Use extreme caution when entering or leaving platform.Ensure that the mast assembly is fully lowered. Face themachine when entering or leaving the platform. Alwaysmaintain “three point contact” with the machine, using twohands and one foot or two feet and one hand at all timesduring entry and exit.

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Electrocution Hazards

• This machine is not insulated and does not provide pro-tection from contact or proximity to electrical current.

• Maintain distance from electrical lines, apparatus, or anyenergized (exposed or insulated) parts according to theMinimum Approach Distance (MAD) as shown in Table 1-1.

• Allow for machine movement and electrical line swaying.

• Maintain a clearance of at least 10 ft. (3m) between anypart of the machine and its occupants, their tools, andtheir equipment from any electrical line or apparatus car-rying up to 50,000 volts. One foot additional clearance isrequired for every additional 30,000 volts or less.

• The minimum approach distance may be reduced if insu-lating barriers are installed to prevent contact, and thebarriers are rated for the voltage of the line being guarded.These barriers shall not be part of (or attached to) themachine. The minimum approach distance shall bereduced to a distance within the designed working dimen-sions of the insulating barrier. This determination shall be

Table 1-1. Minimum Approach Distances (M.A.D.)

Voltage Range(Phase to Phase)

MINIMUM APPROACH DISTANCEin Feet (Meters)

0 to 50 KV 10 (3)

Over 50KV to 200 KV 15 (5)

Over 200 KV to 350 KV 20 (6)

Over 350 KV to 500 KV 25 (8)

Over 500 KV to 750 KV 35 (11)

Over 750 KV to 1000 KV 45 (14)

NOTE: This requirement shall apply except where employer,local or governmental regulations are more stringent.

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made by a qualified person in accordance with theemployer, local, or governmental requirements for workpractices near energized equipment

DANGERDO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITEDZONE (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING AREENERGIZED UNLESS KNOWN OTHERWISE.

Crushing And Collision Hazards

• Personal protection equipment must be worn by all oper-ating and ground personnel.

• Check work area clearances above, on sides, and bottomwhile lifting or lowering the platform.

• During platform operation, keep all body parts inside plat-form railing.

• Keep non-operating personnel at least 6 ft. (1.8m) awaywhile operating machine.

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• Exercise extreme caution at all times to prevent obstaclesfrom striking or interfering with operating controls and per-son in the platform.

• Ensure that operators of other overhead and floor levelmachines are aware of the aerial work platform’s pres-ence. Disconnect power to overhead cranes.

• Warn personnel not to work, stand, or walk under a raisedplatform. Position barricades on floor as necessary.

1.4 LIFTING MACHINE

• When lifting machine with a forklift, position forks only atdesignated areas of the machine. Lift with a forklift of ade-quate capacity.

• Ensure machine is secure on the forks before transport-ing. Keep machine as low to the ground as possible.

• Refer to the Machine Operation section of this manual forlifting information.

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NOTES:

1-8 – JLG Lift – 3121153

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.1 Personnel TrainingThe aerial platform is a personnel handling device; so it is neces-sary that it be operated and maintained only by trained personnel.

Persons under the influence of drugs or alcohol or who are subjectto seizures, dizziness or loss of physical control must not operatethis machine.

Operator TrainingOperator training must cover:

1. Use and limitations of the controls in the platform and at the ground, emergency controls and safety systems.

2. Control labels, instructions, and warnings on the machine.

3. Rules of the employer and government regulations.

4. Use of approved fall protection device.

5. Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential mal-function.

6. The safest means to operate the machine around over-head obstructions and other moving equipment.

7. Means to avoid the hazards of unprotected electrical conductors.

8. Specific job requirements or machine application.

Training SupervisionTraining must be done under the supervision of a qualified personin an open area free of obstructions until the trainee has devel-oped the ability to safely control and operate the machine.

Operator ResponsibilityThe operator must be instructed that he/she has the responsibilityand authority to shut down the machine in case of a malfunction orother unsafe condition of either the machine or the job site.

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2.2 Preparation, Inspection, and MaintenanceThe following table covers the periodic machine inspections andmaintenance recommended by JLG Industries, Inc. Consult localregulations for further requirements for aerial work platforms. Thefrequency of inspections and maintenance must be increased asnecessary when the machine is used in a harsh or hostile environ-ment; if the machine is used with increased frequency; or if themachine is used in a severe manner.

NOTICEJLG INDUSTRIES, INC. RECOGNIZES A FACTORY TRAINED SERVICETECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETEDTHE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PROD-UCT MODEL.

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Table 2-1. Inspection and Maintenance Table

TYPE FREQUENCYPRIMARY

RESPONSIBILITYSERVICE

QUALIFICATIONREFERENCE

Pre-Start Inspection Before using each day; or whenever there’s an Operator change.

User or Operator User or Operator Operator and Safety Manual

Pre-Delivery Inspection(See Note)

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

Service and Maintenance Manual and applicable JLG inspection form

Frequent Inspection In service for 3 months, whichever comes first; or;Out of service for a period of more than 3 months; orPurchased used.

Owner, Dealer, or User Qualified JLG Mechanic


Annual Machine Inspection Annually, no later than 13 months from the date of prior inspection.

Owner, Dealer, or User Factory TrainedService Technician (Recommended)


Preventative Maintenance At intervals as specified in the Service and Main-tenance Manual.

Owner, Dealer, or User Qualified JLG Mechanic

Service and Maintenance Manual

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

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Pre-Start InspectionThe Pre-Start Inspection should include each of the following:

1. Cleanliness – Check all surfaces for oil leakage or for-eign objects. Report any leakage to the proper mainte-nance personnel.

2. Decals and Placards – Check all for cleanliness and legibility. Make sure none of the decals and placards are missing. Make sure all illegible decals and placards are cleaned or replaced.

3. Operators and Safety Manuals – Make sure a copy of the Operator and Safety Manual, EMI Safety Manual (Domestic only), and ANSI Manual of Responsibilities (Domestic only) is enclosed in the weather resistant storage container.

4. “Walk-Around” Inspection – Refer to Figure 2-1. and Section 2.3.

5. Hydraulic Oil – Check the hydraulic oil level. Ensure hydraulic oil is added as required.

6. Function Check – Once the “Walk-Around” Inspection is complete, perform a function check of all systems in an area free of overhead and ground level obstructions. Refer to Machine Operation section for more specific instructions on the operation of each function.

IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THEMACHINE IMMEDIATELY! REPORT THE PROBLEM TO THE PROPER MAIN-TENANCE PERSONNEL. DO NOT OPERATE THE MACHINE UNTIL IT ISDECLARED SAFE FOR OPERATION.

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2.3 WALK-AROUND INSPECTION(See Figure 2-1.)

GeneralBegin the Walk-Around Inspection at item 1 below. Continuearound machine checking each item in this check list.

CAUTIONTO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS OFF DUR-ING WALK-AROUND INSPECTION.

INSPECTION NOTE: On each item, make sure there are no looseor missing parts, that they are securely fastened and thatno visible damage exists in addition to any other criteriamentioned.

1. Base Frame - Properly secured to work surface. See Inspection Note.

2. Manual Descent Control Valve - No evidence of hydraulic leaks.

3. Motor/Pump/Reservoir Power Unit - No evidence of hydraulic leaks. Check that hydraulic reservoir fluid level is filled to the "Fill to Line" mark on the side of the reser-voir.

4. Ground Controls - Key switch operable; emergency stop switch properly set for operation.

5. Mast Assembly - Inspect mast chains and sequence cables as per inspection note. Control and power cables properly tensioned and seated in control cable sheaves; control cable sheaves rotate freely.

6. AC Voltage Junction Box - Secure to support, access door secure and closed.

7. Platform Controls - Inspect UP/DOWN and Function Enable buttons as per inspection note. Emergency Stop switch functions properly. Operation & Safety Manual in manual storage box.

8. Platform Control Foot Switches (optional) - Inspect UP and DOWN foot pedals. Ensure foot switch enclo-sure is properly secured to the platform floor.

9. Platform Assembly - Secure to mast; Properly secured to mounting brackets; entry gate(s) closing properly.

10. Hourmeter - Hourmeter secure and legible.

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1. Base Frame2. Manual Descent Control Valve3. Motor/Pump/Reservoir Power Unit4. Ground Controls5. Mast Assembly6. AC Junction Box Assembly7. Platform Controls8. Platform Control Foot Switches (option)9. Platform Assembly

10. Hourmeter

Figure 2-1. Daily Walk-Around inspection.(Shown with Standard Platform)

12

3

4

5

6

7

8

9

10

8

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2.4 FUNCTION CHECKThe function check of all systems should be performed in an areafree of overhead and ground level obstructions. Perform a functioncheck as follows:

1. Set-up machine for operation, according to operating instructions in Section 4.

2. Enter platform, raise and lower platform 2 ft. to 3 ft. (.61m to .92 m) several times. Check for smooth eleva-tion and lowering of platform.

3. With the aid of an assistant in the platform, test the man-ual decent valve. Elevate the platform approximately 12 inches, then activate the manual decent function, pull and hold the red knob until the platform is completely lowered.

4. Ensure that all machine functions are disabled when the Emergency Stop Switch is pressed.

5. With platform completely lowered, check hydraulic oil level in reservoir at ground control station. Maintain an oil level to the "Fill to Line" indicator on the side of the reservoir. NEVER USE HYDRAULIC BRAKE FLUID.

6. If equipped with the optional platform gate interlocks, verify the lift function does not operate with either gate open.

NOTE: To verify if the machine is equipped with the optional gateinterlocks, look for a wire harness to exit the platform mid-rail through a small hole in the midrail near the mastheader.

7. Machines equipped with the optional platform foot switch controls, check proper operation for elevating and lowering of the platform.

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NOTES:

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1 GENERAL

NOTICETHE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINEAPPLICATION AND OPERATION. THE USER AND OPERATOR ARERESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES.

This section provides the necessary information needed to under-stand control functions.

3.2 CONTROLS AND INDICATORS

Ground Control Station (See Figure 3-1.)

1. POWER ON/OFF Key Switch

A key switch located on the ground control station con-trols power to all functions on the machine. The machinewill not operate without the key inserted and turned to theON position. When left unattended, removing the key willprevent unauthorized operaton.

2. EMERGENCY STOP SWITCH

A two position mushroom shaped switch furnishes powerto the platform and ground controls when RESET (ON).

When pushed in (OFF), power is shut off to the platformand ground controls.

3. HYDRAULIC RESERVOIR/CIRCUIT BREAKER/FUSE (located inside the ground control station housing)

The hydraulic oil level can be checked through an accesshole in the side of the cover.

NOTE: Check hydraulic oil only when platform is completely low-ered and after cycling platform up/down a few times.

NOTE: A replaceable 5 Amp fuse for the DC Voltage circuit and areset type circuit breaker for the AC Voltage circuit islocated in the AC Junction Box on BD Models.

4. HOURMETER

The machine hourmeter registers pump operation timeduring the platform LIFT UP cycle only. The hourmeter islocated on the back of the Ground Control Station on thepump mounting bracket.

3121153 – JLG Lift – 3-1


Manual Descent Valve Location(See Figure 3-2.)

Located at the rear and bottom of the base frame. ThisPULL TO RELEASE - spring loaded return valve (REDKnob), allows for lowering of the platform in an emergencyor power failure.

Figure 3-1. Ground Control Station.

1. Power ON/OFF Key Switch2. Emergency Stop Switch

3. Hydraulic Reservoir/Circuit Breaker/Fuse

4. Hourmeter

2

3

1

4

Figure 3-2. Manual Descent Valve Location.

1. Manual Descent Valve 2. Rear of Base Frame Assembly

21

3-2 – JLG Lift – 3121153


Platform Control Station (See Figure 3-3.)

1. EMERGENCY STOP SWITCH

A two position mushroom shaped switch furnishes powerto the platform controls when pulled out (ON). Whenpushed in (OFF), power is shut off to the platform.

2. PLATFORM UP Button (WHITE)

When depressed simultaneously with ENABLE (GREEN)button raises the platform.

3. FUNCTION ENABLE Button.

This (GREEN) button must be depressed simultaneouslywith either the UP or DOWN platform function buttons inorder to raise or lower the platform.

4. PLATFORM DOWN Button (WHITE).

When depressed simultaneously with ENABLE (GREEN)button lowers the platform.

Figure 3-3. Platform Control Station.

1. Emergency Stop Switch - (RED)

2. Platform UP - (WHITE)

3. Function Enable - (GREEN)4. Platform DOWN - (WHITE)

3121153 – JLG Lift – 3-3


18 Ft. Height Limiter - (19BD ONLY - OPTION)19BD machines may be equipped with an 18 ft. height lim-iter option. This option prevents the platform from elevat-ing beyond a height of 18 ft. Otherwise the platform willoperate normally.

Platform Gate Interlock - (OPTION)If equipped, the optional platform gate interlock will pre-vent the platform lift function from operating when eithergate is open.


Platform Gate Lock - (OPTION) - S/N-0130016195 to Present

If equipped, the optional platform gate lock will prevent theplatform lift function from operating if the platform gatesare not closed and the lock slide bar is not engaged.

Once the slide bar is engaged and gates locked, the slidebar will only disengage when the platform is fully lowered.

3-4 – JLG Lift – 3121153


Platform Foot Control Switches - (OPTION) (See Figure 3-4.)

1. FOOTSWITCH Operation Decal.

Shows which pedal controls platform lift up and lift down.

2. PLATFORM DOWN Pedal.

When depressed simultaneously with FUNCTIONENABLE button located on the platform control station,LOWERS the platform.

3. PLATFORM UP Pedal.

When depressed simultaneously with FUNCTIONENABLE button located on the platform control station,RAISES the platform.

Figure 3-4. Platform Control Footswitch

1. Footswitch Operation Decal 2. Platform DOWN Pedal3. Platform UP Pedal

2

1

3

3121153 – JLG Lift – 3-5


Figure 3-5. 15BD/19BD - Decal Installation

1

3

3

3

3

2

4

5

6

15

7

7

8

9

1010

11

12

13

14

3-6 – JLG Lift – 3121153


Table 3-1. 15BD/19BD - Decal Installation

ITEM # PART NUMBER DESCRIPTION

0272159 DECAL INSTALLATION

1 1700584 Decal - Patent

2 1702631 Decal - Bar Code

3 1703073 Decal - Fork Pockets

4 1705633 Decal - Function Controls

5 1703781 Decal - Electrical Hazard

6 1705635 Decal - Maximum Capacity

7 1705634 Decal - Crushing Hazard

8 1703788 Decal - Manual

9 1705220 Decal - Warning

10 1703072 Decal - No Fork-Lifting Here

11 1705636 Decal - Manual Descent

12 1001111596 Nameplate - Serial Number

13 1702120 Decal - Extension Cord Wire Size

14 1702569 Decal - Electrical Voltage

15 1703166 Decal - Footswitch Operation (optional)

3121153 – JLG Lift – 3-7


NOTES:

3-8 – JLG Lift – 3121153

SECTION 4 - MACHINE OPERATION

SECTION 4. MACHINE OPERATION

4.1 DESCRIPTIONThis machine is a stationary base frame - bolt down version ofJLG’s manually propelled AM-AC model vertical lift. It features awork platform mounted to an elevating aluminum mast mecha-nism. The personnel lift’s intended purpose is to provide person-nel (with their tools and supplies) access to areas above groundlevel.

The main power is turned on/off at the ground control station, anemergency stop switch is located directly next to the main powerkey switch.

The primary operator control station is located in the platform.From this control station, the operator can raise and lower the plat-form. An emergency stop switch is located here also.

A platform manual descent valve is located inside the base frameat the rear of the machine. This valve will lower the platform to theground in an emergency or if a power failure should occur and theoperator in the platform is unable to do so.

4.2 OPERATING CHARACTERISTICS ANDLIMITATIONS

Capacities

MACHINE BASE FRAME MUST BE PROPERLY SECURED TO IT’S WORKAREA MOUNTING SURFACE USING A MINIMUM OF 1/2" (19MM) DIAME-TER GRADE 5 FASTENERS (OR EQUIVALENT) AND WIDE FLATWASHERSBEFORE ATTEMPTING TO OPERATE LIFT.

NOTE: Refer to Service and Maintenance Manual for bolt downspecifications.

The platform can be raised above the stowed position if:

• The machine is properly and securely mounted to a firmand level surface.

• Load is within manufacturer’s maximum rated capacity.

• All machine functions are operating properly.

3121153 – JLG Lift – 4-1


4.3 SET-UP AND OPERATION

DO NOT ATTEMPT TO RAISE THE PLATFORM UNTIL THE MACHINE ISPROPERLY SECURED TO THE WORK AREA MOUNTING SURFACE.

To set-up the machine for operation the operator must:

1. Turn key switch to the ON position at the ground control station.

2. Ensure both emergency stop switches, (one at platform controls and one at ground controls), are in the RESET (pulled out) position for operation.

3. Ensure manual decent control valve (red knob) located on the rear base frame is closed (spring loaded - default position).

Platform Loading

JLG INDUSTRIES, INC. RECOMMENDS THE OPERATOR IN THE PLATFORMUSE AN APPROVED FALL RESTRAINT DEVICE WITH A LANYARDATTACHED TO AN AUTHORIZED LANYARD ANCHORAGE POINT.

The platform maximum rated load capacity is shown on a placardlocated on the platform control panel.

Platform Operation

1. Enter platform and close the entry gate(s).

NOTE: Machines equipped with optional entry gate interlocks,the platform controls will not lift or lower without bothgates completely closed. To verify if the machine isequipped with the optional gate interlocks, look for a wireharness to exit the platform midrail through a small hole inthe midrail near the mast header.

2. To raise the platform, depress the FUNCTION ENABLE button and platform UP button simultaneously. Upon reaching desired elevation level, release the UP and FUNCTION ENABLE buttons.

NOTE: Machines equipped with the optional platform foot controlswitches, the footswitch is equipped with two pedals, onelabeled UP and one labeled DOWN. These pedals workthe same as the UP/DOWN buttons on the platform con-trol station. The FUNCTION ENABLE button must bedepressed before either foot pedal will raise or lower theplatform.

4-2 – JLG Lift – 3121153


ENSURE AREA BENEATH PLATFORM IS FREE OF PERSONNEL ANDOBSTRUCTIONS PRIOR TO LOWERING PLATFORM.

3. To lower platform, depress FUNCTION ENABLE button and platform DOWN button on control panel simulta-neously.

4.4 Platform Configurations

STANDARD PLATFORMModel Max. Capacity

15BD and 19BD 350 lb. (160kg)1. Side Swinging Entry Gate 3. Lanyard Attach Point - 2. Platform Control Station (round bar in corner of mid rail)

12

3

3121153 – JLG Lift – 4-3


4.5 Machine Shut down

1. Ensure that platform is fully lowered, push in the emer-gency stop at the platform controls. Exit the platform and push in the emergency stop at the ground control station. Turn the key switch to the OFF position.

2. If necessary, remove the key from the key switch at the ground control station to disable the machine from unauthorized use.

GULL-WING - FRONT ENTRY PLATFORM - OPTIONModel Max. Capacity

15BD and 19BD 350 lb. (160kg)1. Front Gull-Wing Entry Gate 3. Lanyard Attach Point - (mounted2. Entry Gate Latch on side of mast assembly)

1

3

2

4-4 – JLG Lift – 3121153

SECTION 5 - OPTIONAL EQUIPMENT

SECTION 5. OPTIONAL EQUIPMENT

5.1 OPTIONAL EQUIPMENTThe following optional equipment is available for 15BD modelmachines:

28" x 26" Front Entry Gullwing Platform

The 28" (71cm) long by 26" (66cm) wide platform features a gullwing gate opening.

Tool/Bottle Tray

Platform attachment to hold hand tools or other small itemsplaced in the tray.

Platform Foot Control Switch

This is a dual footswitch operated control that is mounted on thefloor of the platform. These switches in conjunction with thefunction enable switch (GREEN) on the platform control panel,allows control of the UP (raising) and Down (lowering) of theplatform.

Tube Carrier (PVC)

These carriers are mounted to the right side of the mast assem-bly, just behind the platform rail. They are approximately 3.5 in

in diameter and are approx. 45 inches in length and allow forstorage of materials that may be required while working in theplatform.

18 Ft. Height Limiter - (19BD ONLY - OPTION)

The platform limiter switch when installed on the 19BD modellift, limits the platform to a maximum height of 18 ft. This can beuseful when platform height must be limited due to ceilingheight, or a specific work height is required.

Platform Gate Interlock - (OPTION)If equipped, the optional platform gate interlock will pre-vent the platform lift function from operating with eithergate open.


3121153 – JLG Lift – 5-1

SECTION 5 - OPTIONAL EQUIPMENT

Platform Gate Lock - (OPTION) - S/N-0130016195 to Present

If equipped, the optional platform gate lock will prevent theplatform lift function from operating if the platform gatesare not closed and the lock slide bar is not engaged.

Once the slide bar is engaged and gates locked, the slidebar will only disengage when the platform is fully lowered.

5-2 – JLG Lift – 3121153

SECTION 6 - EMERGENCY PROCEDURES

SECTION 6. EMERGENCY PROCEDURES

6.1 GENERAL INFORMATION This section explains the steps to be taken in case of an emer-gency situation while operating the machine.

6.2 EMERGENCY OPERATION

Operator Unable to Control MachineIF THE PLATFORM OPERATOR IS PINNED, TRAPPED ORUNABLE TO OPERATE OR CONTROL THE MACHINE, USE THEFOLLOWING INSTRUCTIONS AS A GUIDELINE. DO NOT CON-TINUE OPERATION IF CONTROLS DO NOT FUNCTION PROP-ERLY

1. If the operator is unable to lower the platform from the platform controls, other personnel should operate the emergency descent control valve located at the rear of the machines base frame, “Manual Descent Valve Loca-tion” on page 3-2, to lower the platform.

2. If necessary, rescue equipment can be used to remove the platform occupant and stabilize motion of the machine.

Platform Caught OverheadIf the platform becomes jammed or snagged in overhead struc-tures or equipment, rescue the platform occupant prior to freeingthe machine.

6.3 INCIDENT NOTIFICATIONJLG Industries, Inc. must be notified immediately of any incidentinvolving a JLG product. Even if no injury or property damage isevident, the factory should be contacted by telephone and pro-vided with all necessary details.

JLG Phone: USA: 877-JLG-SAFE (554-7233) (8am till 4:45pm EST)

Email (USA): [email protected]

Failure to notify the Manufacturer of an incident involving a JLGIndustries product within 48 hours of such an occurrence mayvoid any warranty consideration on that particular machine.

NOTICEFOLLOWING ANY INCIDENT, THOROUGHLY INSPECT THE MACHINEAND TEST ALL FUNCTIONS. DO NOT ELEVATE PLATFORM UNTIL YOUARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED, IF REQUIRED,AND THAT ALL CONTROLS ARE OPERATING CORRECTLY.

3121153 – JLG Lift – 6-1

SECTION 6 - EMERGENCY PROCEDURES

NOTES:

6-2 – JLG Lift – 3121153

SECTION 7 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

SECTION 7. GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

7.1 IntroductionThis section of the manual provides additional necessary informa-tion to the operator for proper operation and maintenance of thismachine.

The maintenance portion of this section is intended as informationto assist the machine operator to perform daily maintenance tasksonly, and does not replace the more thorough Preventive Mainte-nance and Inspection Schedule included in the Service and Main-tenance Manual.

Other Publications Available Specific to this Machine:

Service and Maintenance Manual

ANSI. . . .. . . . . . . .. . . . . .. . . . . .. . . . . .. . . . . 3121154

Illustrated Parts Manual

ANSI. . . .. . . . . . . .. . . . . .. . . . . .. . . . . .. . . . . 3121155

3121153 – JLG Lift – 7-1


7.2 General Specifications

Machine Specifications

Serial Number LocationsFor machine identification, a serial number plate is affixed to themachine. The plate is located on the back of the mast, just abovethe mast support bracket.

SPECIFICATION 15BD 19BD

Maximum Occupants: (Persons) 1

Maximum Work Load(Platform Capacity):

350 lb. (160 kg)

Machine Stowed Height: 77.22 in. (1.96 m) 77.81 in. (1.97 m)

Machine Stowed Width: 29.75 in. (75.5 cm)

Maximum Vertical Platform Height(Ground to Platform Floor - Platform Fully Extended):

15.25 ft. (4.65 m) 18.75 ft. (5.72 m)

Maximum Step-in Platform Height(Ground to Platform Floor - Platform Fully Lowered):

12.75 in. ( cm) 13.37 in. ( cm)

Working Height: 21 ft. (6.4 m) 24.75 ft. (7.54 m)

Standard Platform Size: 27 in. x 23 in.(68.5 cm x 58.5 cm)

Platform Speed (seconds) Lift Up: 20 22

(w/max. rated load) Lift Down: 32 - 40 18 - 25

Machine Weight (Platform Empty ): 725 lb. (329 kg) 830 lb. (376 kg)

SPECIFICATION 15BD 19BD

System Voltage: 12V DC/120 Volts-60Hz AC

Machine Base Mounting Footprint: 18 in. x 33 in.(45.72 cm x 83.82 cm)0.75 Dia. Holes

20 in. x 24 in.(50.8 cm x 60.96 cm)0.75 Dia. Holes

7-2 – JLG Lift – 3121153


7.3 Operator Maintenance

LubricationHydraulic Oil (HO)

Hydraulic oils must have anti-wear qualities at least to API ServiceClassification GL-3, and sufficient chemical stability for mobilehydraulic system service. JLG Industries, recommends Mobilfluid424 hydraulic oil, which has an SAE viscosity of 10W-30 and a vis-cosity index of 152.

For cold weather applications, i.e. when temperatures remain con-sistently below +20°F (–7°C) JLG recommends using Mobil DTE13 hydraulic oil.

Aside from JLG recommendations, it is not advisable to mix oils ofdifferent brands or types, as they may not contain the samerequired additives or be of comparable viscosities. If use ofhydraulic oil other than Mobilfluid 424 is desired, contact JLGIndustries for proper recommendations.

NOTE: Refer to Lubrication Chart, Table 7-2. for specific lubrica-tion locations on machine.

HYDRAULIC SYSTEM OPERATING TEMPERATURE RANGE

SAE VISCOSITYGRADE

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

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

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

Table 7-1. - Lubrication Specifications

KEY SPECIFICATIONS

MPG - Multipurpose Grease having a minimum dripping point of 350° F. Excellent water resistance and adhesive qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.)

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

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

CL - Chain Lube. Use a good quality chain lubricant

3121153 – JLG Lift – 7-3


Table 1-1. 15BD Lubrication Points (See Table 7-2. on page 7-5)

1

2

7-4 – JLG Lift – 3121153


Table 7-2. Lubrication Intervals for Various Components

ITEM COMPONENT NO/TYPE (a)

LUBE POINTSLUBE/METHOD

INTERVAL HOURS (b)

COMMENTS3MONTHS

or5 Hm.Hrs.

6MONTHS

or10 Hm.Hrs.

1YEAR

or20 Hm.Hrs.

2YEARS

or40 Hm.Hrs.

1 Hydraulic Oil Fill To Lineon Reservoir5 Qt. (4.3 L)Reservoir

HO-Check Hyd.Oil Level

HO-Change Hyd. Oil

Check hydraulic oil level daily.(c)

Change oil after every 40 Hourmeter Hrs. of operation.

2 Mast Chains 2 - Per Section Chain Lube - Brush or Spray

Key to Lubricants: MPG - Multipurpose Grease(See Table 7-1) HO - Hydraulic Oil

Notes: a. Be certain to lubricate like items on each side of the machine.b. Recommended lubricating intervals are calculated on hourmeter hours (Hm.Hrs.= pump run cycle - lift up - only).

Recommended lubricating intervals are based on normal use. If machine is subjected to severe operating conditions, such as a highnumber of cycles, location, corrosive/dirty environment, etc., user must adjust lubricating requirements accordingly.

c. Prior to checking hydraulic oil level, operate machine through one complete cycle of lift function (full up and down). Ensure platform isfully lowered, failure to do so will result in incorrect oil level reading on the hydraulic reservoir.

3121153 – JLG Lift – 7-5


NOTES:

7-6 – JLG Lift – 3121153

SECTION 8 - INSPECTION AND REPAIR LOG

SECTION 8. INSPECTION AND REPAIR LOG

Machine Serial Number: _________________________

Table 8-1. Inspection and Repair Log

Date Comments

3121153 – JLG Lift – 8-1

SECTION 8 - INSPECTION AND REPAIR LOG

Machine Serial Number: _________________________

Table 8-1. Inspection and Repair Log

Date Comments

8-2 – JLG Lift – 3121153

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JLG Industries, Inc.

1 JLG Drive

McConnellsburg PA. 17233-9533

USA

(717) 485-5161

(717) 485-6417

JLG Worldwide LocationsJLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 2444Australia

+61 2 65 811111

+61 2 65 810122

JLG Latino Americana Ltda.Rua Eng. Carlos Stevenson,80-Suite 7113092-310 Campinas-SPBrazil

+55 19 3295 0407

+55 19 3295 1025

JLG Industries (UK) LtdBentley HouseBentley AvenueMiddletonGreater ManchesterM24 2GP - England

+44 (0)161 654 1000

+44 (0)161 654 1001

JLG France SASZ.I. de Baulieu47400 FauilletFrance

+33 (0)5 53 88 31 70

+33 (0)5 53 88 31 79

JLG Deutschland GmbHMax-Planck-Str. 21D - 27721 Ritterhude - IhlpohlGermany

+49 (0)421 69 350 20

+49 (0)421 69 350 45

JLG Equipment Services Ltd.Rm 1107 Landmark North39 Lung Sum AvenueSheung Shui N. T.Hong Kong

(852) 2639 5783

(852) 2639 5797

JLG Industries (Italia) s.r.l.Via Po. 2220010 Pregnana Milanese - MIItaly

+39 029 359 5210

+39 029 359 5845

Oshkosh - JLG Singapore T. E. P. Ltd.29 Tuas Ave 4Jurong Industrial Estate639379Singapore

+65-6591-9030

+65-6591-9031

JLG PolskaUI. Krolewska00-060 WarsawaPoland

+48 (0)914 320 245

+48 (0)914 358 200

Plataformas Elevadoras JLG Iberica, S.L.Trapadella, 2P.I. Castellbisbal Sur08755 Castellbisbal, BarcelonaSpain

+34 93 772 4700

+34 93 771 1762

JLG Sverige ABEnkopingsvagen 150Box 704SE - 176 27 JarfallaSweden

+46 (0)850 659 500

+46 (0)850 659 534

www.jlg.com

3121153

Documents

Operation and Safety Manual - JLG Industries Vertical Mast... · Operation and Safety Manual ... 19BD Vertical Lift P/N - 3121153 May 3, 2011. NOTES: SECTION - FOREWORD 3121153