Operation and Safety Manual Keep this manual with the machine at all times.
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 and operating 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 changes without prior notification. Contact JLG Industries, Inc. for updated information.
SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS This is the Safety Alert Symbol. It is used to alert you to the potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death CAUTION DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACKGROUND. INDICATES A POTENTIALITY HAZARDOUS SITUATION.
SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS For: THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT. • Accident Reporting • Product Safety Publications • Current Owner Updates • Questions Regarding Product Safety NOTICE JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE.
SECTION - REVISION LOG REVISION LOG Original Issue of Manual . . . . . . . . . . . . . . . . . February 5, 2009 Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE FOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B Contact:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C In USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C Outside USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - 4 - MACHINE OPERATION 4.1 4.2 4.3 4.4 4.5 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATING CHARACTERISTICS AND LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SET-UP AND OPERATION . . . . . . . . . . . . . . . . . . . . . . Platform Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT LIST OF FIGURES 2-1. 3-1. 3-2. 3-3. 3-4. 3-5. 3121153 PAGE LIST OF TABLES Daily Walk-Around inspection . . . . . . . . . . . . . . . . Ground Control Station. . . . . . . . . . . . . . . . . . . . . . Manual Descent Valve Location. . . . . . . . . . . . . . . Platform Control Station. . . . . . . . . . . . . . . . . . . . . Platform Control Footswitch . . . . . . . . . . . . . . . . . . 15BD/19BD - Decal Installation . .
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SECTION 1 - SAFETY PRECAUTIONS SECTION 1. SAFETY PRECAUTIONS 1.1 GENERAL 1.2 This section outlines the necessary precautions for proper and safe machine usage and maintenance. For proper machine use, it is mandatory that a daily routine is established based on the content of this manual.
SECTION 1 - SAFETY PRECAUTIONS • All operating personnel must be familiar with the emergency controls and emergency operation of the machine as specified in this manual. • Do not operate this machine until it has been serviced and maintained according to requirements specified in the Service and Maintenance Manual. • Read, understand, and obey all applicable employer, local, and governmental regulations as they pertain to operation of the machine. • Ensure all safety devices are operating properly.
SECTION 1 - SAFETY PRECAUTIONS 1.3 OPERATION • Never exceed the maximum platform capacity. Distribute loads evenly in the platform. General • Never attempt to use the machine as a crane. • Always ensure the machine is properly attached to a solid, firm and level floor surface. • Do not increase the platform size with unauthorized deck extensions or attachments. • Do not use the machine for any purpose other than positioning personnel, their tools and equipment.
SECTION 1 - SAFETY PRECAUTIONS • Use extreme caution when entering or leaving platform. Ensure that the mast assembly is fully lowered. Face the machine when entering or leaving the platform. Always maintain “three point contact” with the machine, using two hands and one foot or two feet and one hand at all times during entry and exit. • Before operating the machine, make sure all railing and gates are fastened in their proper position. • Keep both feet firmly positioned on the platform floor at all times.
SECTION 1 - SAFETY PRECAUTIONS Electrocution Hazards Table 1-1. Minimum Approach Distances (M.A.D.) • This machine is not insulated and does not provide protection from contact or proximity to electrical current.
SECTION 1 - SAFETY PRECAUTIONS made by a qualified person in accordance with the employer, local, or governmental requirements for work practices near energized equipment DANGER DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE. Crushing And Collision Hazards • Personal protection equipment must be worn by all operating and ground personnel.
SECTION 1 - SAFETY PRECAUTIONS • Exercise extreme caution at all times to prevent obstacles from striking or interfering with operating controls and person in the platform. 1.4 • Ensure that operators of other overhead and floor level machines are aware of the aerial work platform’s presence. Disconnect power to overhead cranes. • Warn personnel not to work, stand, or walk under a raised platform. Position barricades on floor as necessary.
SECTION 1 - SAFETY PRECAUTIONS 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 Training 7. Means to avoid the hazards of unprotected electrical conductors. The aerial platform is a personnel handling device; so it is necessary that it be operated and maintained only by trained personnel.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.2 Preparation, Inspection, and Maintenance The following table covers the periodic machine inspections and maintenance recommended by JLG Industries, Inc. Consult local regulations for further requirements for aerial work platforms.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Table 2-1. Inspection and Maintenance Table TYPE PRIMARY RESPONSIBILITY FREQUENCY SERVICE QUALIFICATION REFERENCE 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.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Pre-Start Inspection 4. “Walk-Around” Inspection – Refer to Figure 2-1. and Section 2.3. The Pre-Start Inspection should include each of the following: 1. Cleanliness – Check all surfaces for oil leakage or foreign objects. Report any leakage to the proper maintenance personnel. 2. Decals and Placards – Check all for cleanliness and legibility. Make sure none of the decals and placards are missing.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.3 WALK-AROUND INSPECTION 4. Ground Controls - Key switch operable; emergency stop switch properly set for operation. (See Figure 2-1.) General Begin the Walk-Around Inspection at item 1 below. Continue around machine checking each item in this check list. 5. Mast Assembly - Inspect mast chains and sequence cables as per inspection note.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 5 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 6 4 7 9 3 Base Frame Manual Descent Control Valve Motor/Pump/Reservoir Power Unit Ground Controls Mast Assembly AC Junction Box Assembly Platform Controls Platform Control Foot Switches (option) Platform Assembly Hourmeter 8 8 2 1 Figure 2-1. Daily Walk-Around inspection.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.4 FUNCTION CHECK 4. Ensure that all machine functions are disabled when the Emergency Stop Switch is pressed. The function check of all systems should be performed in an area free of overhead and ground level obstructions. Perform a function check as follows: 5. With platform completely lowered, check hydraulic oil level in reservoir at ground control station.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION NOTES: 2-8 – JLG Lift – 3121153
SECTION 3 - MACHINE CONTROLS AND INDICATORS SECTION 3. MACHINE CONTROLS AND INDICATORS 3.1 GENERAL When pushed in (OFF), power is shut off to the platform and ground controls. NOTICE 3. HYDRAULIC RESERVOIR/CIRCUIT BREAKER/FUSE (located inside the ground control station housing) THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION. THE USER AND OPERATOR ARE RESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES.
SECTION 3 - MACHINE CONTROLS AND INDICATORS Manual Descent Valve Location 4 (See Figure 3-2.) Located at the rear and bottom of the base frame. This PULL TO RELEASE - spring loaded return valve (RED Knob), allows for lowering of the platform in an emergency or power failure. 1 2 3 1 Figure 3-1. Ground Control Station. 1. Power ON/OFF Key Switch 2. Emergency Stop Switch 3-2 3. Hydraulic Reservoir/Circuit Breaker/Fuse 4. Hourmeter 2 Figure 3-2. Manual Descent Valve Location. 1.
SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Control Station (See Figure 3-3.) 1. EMERGENCY STOP SWITCH A two position mushroom shaped switch furnishes power to the platform controls when pulled out (ON). When pushed 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.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 18 Ft. Height Limiter - (19BD ONLY - OPTION) 19BD machines may be equipped with an 18 ft. height limiter option. This option prevents the platform from elevating beyond a height of 18 ft. Otherwise the platform will operate normally. Platform Gate Lock - (OPTION) - S/N-0130016195 to Present If equipped, the optional platform gate lock will prevent the platform lift function from operating if the platform gates are not closed and the lock slide bar is not engaged.
SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Foot Control Switches - (OPTION) (See Figure 3-4.) 1. FOOTSWITCH Operation Decal. Shows which pedal controls platform lift up and lift down. 1 2. PLATFORM DOWN Pedal. When depressed simultaneously with FUNCTION ENABLE button located on the platform control station, LOWERS the platform. 3. PLATFORM UP Pedal. When depressed simultaneously with FUNCTION ENABLE button located on the platform control station, RAISES the platform. 2 3 Figure 3-4.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 13 4 14 6 12 5 9 8 15 3 7 3 2 1 10 10 11 3 7 3 Figure 3-5.
SECTION 3 - MACHINE CONTROLS AND INDICATORS Table 3-1.
SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTES: 3-8 – JLG Lift – 3121153
SECTION 4 - MACHINE OPERATION SECTION 4. MACHINE OPERATION 4.1 DESCRIPTION This machine is a stationary base frame - bolt down version of JLG’s manually propelled AM-AC model vertical lift. It features a work platform mounted to an elevating aluminum mast mechanism. The personnel lift’s intended purpose is to provide personnel (with their tools and supplies) access to areas above ground level.
SECTION 4 - MACHINE OPERATION 4.3 SET-UP AND OPERATION The platform maximum rated load capacity is shown on a placard located on the platform control panel. DO NOT ATTEMPT TO RAISE THE PLATFORM UNTIL THE MACHINE IS PROPERLY SECURED TO THE WORK AREA MOUNTING SURFACE. Platform Operation 1. Enter platform and close the entry gate(s). NOTE: To set-up the machine for operation the operator must: 1. Turn key switch to the ON position at the ground control station. 2.
SECTION 4 - MACHINE OPERATION 4.4 Platform Configurations ENSURE AREA BENEATH PLATFORM IS FREE OF PERSONNEL AND OBSTRUCTIONS PRIOR TO LOWERING PLATFORM. 2 1 3. To lower platform, depress FUNCTION ENABLE button and platform DOWN button on control panel simultaneously. 3 STANDARD PLATFORM Model 15BD and 19BD 1. Side Swinging Entry Gate 2. Platform Control Station 3121153 – JLG Lift – Max. Capacity 350 lb. (160kg) 3.
SECTION 4 - MACHINE OPERATION 4.5 Machine Shut down 1. Ensure that platform is fully lowered, push in the emergency 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. 3 1 2. If necessary, remove the key from the key switch at the ground control station to disable the machine from unauthorized use. 2 GULL-WING - FRONT ENTRY PLATFORM - OPTION Model Max. Capacity 15BD and 19BD 350 lb. (160kg) 1.
SECTION 5 - OPTIONAL EQUIPMENT SECTION 5. OPTIONAL EQUIPMENT 5.1 OPTIONAL EQUIPMENT The following optional equipment is available for 15BD model machines: 28" x 26" Front Entry Gullwing Platform The 28" (71cm) long by 26" (66cm) wide platform features a gull wing gate opening. Tool/Bottle Tray Platform attachment to hold hand tools or other small items placed in the tray. in diameter and are approx.
SECTION 5 - OPTIONAL EQUIPMENT Platform Gate Lock - (OPTION) - S/N-0130016195 to Present If equipped, the optional platform gate lock will prevent the platform lift function from operating if the platform gates are not closed and the lock slide bar is not engaged. Once the slide bar is engaged and gates locked, the slide bar will only disengage when the platform is fully lowered.
SECTION 6 - EMERGENCY PROCEDURES SECTION 6. EMERGENCY PROCEDURES 6.1 GENERAL INFORMATION Platform Caught Overhead This section explains the steps to be taken in case of an emergency situation while operating the machine. 6.2 EMERGENCY OPERATION 6.3 Operator Unable to Control Machine IF THE PLATFORM OPERATOR IS PINNED, TRAPPED OR UNABLE TO OPERATE OR CONTROL THE MACHINE, USE THE FOLLOWING INSTRUCTIONS AS A GUIDELINE. DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION PROPERLY 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 Introduction Other Publications Available Specific to this Machine: This section of the manual provides additional necessary information to the operator for proper operation and maintenance of this machine.
SECTION 7 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 7.2 General Specifications Machine Specifications SPECIFICATION SPECIFICATION 15BD System Voltage: 19BD Maximum Occupants: (Persons) Machine Base Mounting Footprint: 1 Maximum Work Load (Platform Capacity): 77.22 in. (1.96 m) Machine Stowed Width: 77.81 in. (1.97 m) 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.
SECTION 7 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 7.3 Operator Maintenance Lubrication Hydraulic Oil (HO) Table 7-1. - Lubrication Specifications 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 KEY SPECIFICATIONS MPG - Multipurpose Grease having a minimum dripping point of 350° F.
SECTION 7 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 2 1 Table 1-1. 15BD Lubrication Points (See Table 7-2.
SECTION 7 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Table 7-2. Lubrication Intervals for Various Components ITEM COMPONENT INTERVAL HOURS (b) NO/TYPE (a) LUBE POINTS LUBE/METHOD 3 MONTHS or 5 Hm.Hrs. 1 Hydraulic Oil Fill To Line on Reservoir 5 Qt. (4.3 L) Reservoir HO-Check Hyd. Oil Level HO-Change Hyd. Oil 2 Mast Chains 2 - Per Section Chain Lube - Brush or Spray Key to Lubricants: (See Table 7-1) 6 MONTHS or 10 Hm.Hrs. 1 YEAR or 20 Hm.Hrs. 2 YEARS or COMMENTS 40 Hm.Hrs.
SECTION 7 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE NOTES: 7-6 – JLG Lift – 3121153
SECTION 8 - INSPECTION AND REPAIR LOG SECTION 8. INSPECTION AND REPAIR LOG Machine Serial Number: _________________________ Table 8-1.
SECTION 8 - INSPECTION AND REPAIR LOG Machine Serial Number: _________________________ Table 8-1.
Title:____________________________________________________________________ Name: ___________________________________________________________________ Who in your organization should we notify? Country: _________________________ Telephone: (_______) ____________________ _________________________________________________________________________ Address: _________________________________________________________________ Current Owner: ____________________________________________________________ Date of Tra
JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 3121153 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil +61 2 65 811111 +55 19 3295 1025 +55 19 3295 0407 +44 (0)161 654 1000 +61 2 65 810122 JLG Deutschland GmbH Max-Planck-Str.
